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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Weichai (Weifang) Medium Diesel Engine Co., Ltd.



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Outside view of WP6 non-road Stage II diesel engine for power generation



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Special Notes ●



Please always read the Maintenance Manual of the diesel engine carefully, follow the technical operation and maintenance practices therein strictly, and pay attention to the warning signs and warning labels.



●



The diesel engine has been tested strictly under the test specification and gotten its throttle lead sealed before delivery, it is prohibited to remove the lead seal to increase the fuel supply without permission.



●



The turbocharger rotor is of high-speed rotating part, please keep any movable objects (such as hands, tools, cotton yarns) away from the turbocharger inlet when the machine is working to avoid personal injury or machine damage; the rotor assembly of turbocharger can only bed is mantled by professional maintenance personnel or the authorized Weichai service station.



●



There are strict torque and service life for the main bearing bolts and connecting rod bolts, it is prohibited to unscrew or remove them without permission; do not reuse the connecting rod bolts as they are disposable.



●



The diesel engine should be filled with oil and fuel specified in this Maintenance Manual and they should be filtered with special filter in filling (the fuel should also be deposited for 72h before filling); prior to each starting, be sure that the amounts of coolant and oil are as specified.



●



For a new engine, do a trial running for 50h, and replace oil and oil filter element after running-in period.



●



If the engine is started in cold state, increase the engine speed slowly instead of running at high speed suddenly, and do not run it at idle speed for a long time (no more than 3 min). After run heavy load, run the engine at low speed for 5~10 min before stopping, instead of stop the engine immediately (except special cases);



●



After the engine is stopped, if the ambient temperature is probably lower than 0°Cand the coolant without antifreeze additive is used, fully drain the coolant from the water tank and diesel engine.



●



It’s prohibited to run the diesel engine without the air filter, in order to prevent the unfiltered air from entering the cylinder directly. If the working environment is poor, replace the air filter element more frequently, avoiding early wear or other failures of diesel engine.



●



Only have the components of electrical system inspected by professional technicians.



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Foreword This diesel engine is developed by Weichai Power Co., Ltd. and manufactured by Weichai (Weifang) Medium Diesel Engine Co., Ltd. This diesel engine features compact structure, reliable operation, excellent power performance and economic performance, rapid starting, easy operation/maintenance and advanced emission indicators meeting the international advanced emission standards. This manual mainly includes the operation precautions, maintenance and service methods, common check and adjustment, and diagnosis and troubleshooting of common faults of WP6 series diesel engine. It should be noted that determining of diesel engine faults requires special carefulness and certain knowledge and experience, do not disassemble the diesel engine before the fault causes are found out. Or else, the fault may not be eliminated, or even become more serious due to improper reassembling, particularly the key parts such as electronic control system and turbocharger, for which special instrument or equipment shall be used in checking and maintaining. Users inexperienced or having no special equipment shall not disassemble or adjust the diesel engine randomly. With the development and improvement of products, the contents of this maintenance manual may be lagged and will be updated. All changes will be made without further notice. Forthe latest product information, please visit the Weichai website http://www.weichai.com. Suggestions and opinions on further product improvement from you are welcome.



September2016



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Contents Chapter I Instructions for Use of the Diesel Engine .................................................................................................. 1 1.1 Outline drawing of the diesel engine ........................................................................................................ 1 1.2 Meaning of diesel engine model ............................................................................................................... 4 1.3 Basic parameters of the diesel engine ....................................................................................................... 4 1.4 Unsealing of the diesel engine .................................................................................................................. 4 1.5 Hoisting of the diesel engine..................................................................................................................... 5 1.6 Installation of the diesel engine ................................................................................................................ 6 1.7 Preparations before starting of the diesel engine ...................................................................................... 6 1.8 Starting of the diesel engine ...................................................................................................................... 6 1.9 Running of the diesel engine..................................................................................................................... 7 1.10 Stopping of the Diesel Engine ................................................................................................................ 8 Chapter II Maintenance Guide of the Diesel Engine ................................................................................................. 9 2.1 Fuel, lubricating oil, coolant and auxiliary materials ................................................................................ 9 2.1.1 Fuel.............................................................................................................................................. 9 2.1.2 Lubricating oil ............................................................................................................................. 9 2.1.3 Coolant ...................................................................................................................................... 10 2.1.4 Auxiliary materials .................................................................................................................... 11 2.2 Daily maintenance items of the diesel engine ......................................................................................... 13 2.3 Periodic maintenance of the diesel engine .............................................................................................. 15 2.4 Maintenance of diesel engine for long-term storage ............................................................................... 20 2.4.1 Cleaning .................................................................................................................................... 20 2.4.2 Protection of diesel engine before preservation ........................................................................ 20 2.4.3Oil sealing .................................................................................................................................. 20 Chapter III Common Failures and Troubleshooting ................................................................................................ 22 3.1 Diagnostic Method .................................................................................................................................. 22 3.2 Malfunction causes and troubleshooting................................................................................................. 23 3.2.1 Diesel engine cannot be started or it is difficult to start ............................................................ 23 3.2.2 Diesel engine runs unstably....................................................................................................... 24 3.2.3 Insufficient engine power .......................................................................................................... 25 3.2.4 Oil pressure of diesel engine is abnormal ................................................................................. 25 3.2.5 Diesel engine temperature is too high ....................................................................................... 26 3.2.6 Diesel engine smoke color is abnormal ..................................................................................... 26 3.2.7 Diesel engine stopped automatically ......................................................................................... 28 3.2.8 Abnormal noise during running of diesel engine ...................................................................... 28 Chapter IV Disassembly and Assembly of the Diesel Engine................................................................................. 30 4.1 Overview................................................................................................................................................. 30



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.1.1 Dangersigns ............................................................................................................................... 30 4.1.2Safety signs ................................................................................................................................ 31 4.1.3Tools used .................................................................................................................................. 32 4.1.4 Health care consideration .......................................................................................................... 32 4.1.5 Environmental protection measures .......................................................................................... 33 4.1.6 Considerations for disassembly and assembly of diesel engine ................................................ 33 4.2 Cylinder block group .............................................................................................................................. 34 4.2.1 Disassembly and assembly of cylinder block group ................................................................. 34 4.2.2 Disassembly and assembly of cylinder block............................................................................ 37 4.2.3 Disassembly and assembly of front end cover .......................................................................... 38 4.2.4 Disassembly and assembly of flywheel housing ....................................................................... 42 4.2.5 Disassembly and assembly of oil pan........................................................................................ 43 4.2.6 Disassembly and assembly of piston cooling nozzle ................................................................ 44 4.2.7 Disassembly and assembly of thrust washer ............................................................................. 45 4.2.8 Disassembly and assembly of front/rear oil seals...................................................................... 46 4.2.9 Disassembly and assembly of cylinder head group ................................................................... 47 4.2.10 Disassembly and assembly of cylinder head cover ................................................................. 49 4.2.11 Disassembly and assembly of cylinder head ........................................................................... 50 4.2.12 Disassembly and assembly of oil-gas separator ...................................................................... 53 4.2.13 Disassembly and assembly of lifting eye ................................................................................ 54 4.3 Crank and connecting rod mechanism .................................................................................................... 55 4.3.1 Disassembly and assembly of crank and connecting rod mechanism ....................................... 55 4.3.2 Disassembly and assembly of piston and connecting rod group ............................................... 55 4.3.3 Disassembly and assembly of crankshaft and flywheel group .................................................. 58 4.3.4 Disassembly and assembly of flywheel and ring gear............................................................... 60 4.3.5 Disassembly and assembly of torsional vibration damper, pulley and hub............................... 61 4.3.6 Disassembly and assembly of crankshaft bearing ..................................................................... 62 4.4 Valve train............................................................................................................................................... 63 4.4.1Disassembly and assembly of valve train................................................................................... 63 4.4.2 Disassembly and assembly of camshaft .................................................................................... 63 4.4.3 Disassembly and assembly of rocker arm and rocker shaft....................................................... 65 4.4.4 Disassembly and assembly of tappet and push rod ................................................................... 67 4.4.5Disassembly and assembly of valve ........................................................................................... 68 4.5 Intake/exhaust system ............................................................................................................................. 69 4.5.1Disassembly and assembly of intake/exhaust system ................................................................ 69 4.5.2 Disassembly and assembly of intake manifold ......................................................................... 70 4.5.3 Disassembly and assembly of exhaust manifold ....................................................................... 71



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.5.4 Disassembly and assembly of turbocharging system ................................................................ 72 4.6 Fuel system ............................................................................................................................................. 74 4.6.1 Disassembly and assembly of fuel system ................................................................................ 74 4.6.2 Disassembly and assembly of injection pump .......................................................................... 75 4.6.3 Disassembly and assembly of high pressure fuel pipe .............................................................. 77 4.6.4 Disassembly and assembly of injector ...................................................................................... 78 4.6.5 Disassembly and assembly of fuel filter.................................................................................... 78 4.6.6 Disassembly and assembly of low pressure fuel pipe ............................................................... 80 4.7 Cooling system ....................................................................................................................................... 80 4.7.1 Disassembly and assembly of cooling system .......................................................................... 80 4.7.2 Disassembly and assembly of fan ............................................................................................. 82 4.7.3 Disassembly and assembly of water pump................................................................................ 82 4.7.4 Disassembly and assembly of thermostat .................................................................................. 83 4.7.5 Disassembly and assembly of water outlet pipe ........................................................................ 84 4.8 Lubricating system .................................................................................................................................. 86 4.8.1 Disassembly and assembly of lubricating system ..................................................................... 86 4.8.2 Disassembly and assembly of oil pump .................................................................................... 86 4.8.3 Disassembly and assembly of oil filter...................................................................................... 87 4.8.4 Disassembly and assembly of oil cooler ................................................................................... 88 4.8.5 Disassembly and assembly of pressure limiting valve of main oil passage .............................. 89 4.8.6 Disassembly and assembly of oil suction strainer ..................................................................... 90 4.9 Starting system ........................................................................................................................................ 90 4.9.1 Disassembly and assembly of starting system .......................................................................... 91 Appendix A: Fit clearances of main parts of the engine ............................................................................... 92 Appendix B: Evaluation benchmark for wear of main friction pairs ............................................................ 93 



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Chapter I Instructions for Use of the Diesel Engine 1.1 Outline drawing of the diesel engine



Figure 1-1 Outline drawing of WP6 Stage II diesel engine for power generation



1



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 1-2 Outline drawing of WP6 Stage II diesel engine for power generation



2



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 1-3 Outline drawing of WP6 Stage II diesel engine for power generation



3



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



1.2 Meaning of diesel engine model



1.3 Basic parameters of the diesel engine Table 1-1Performance parameters of WP6stage II land diesel engine for power generation Items



Unit



Model



Engine model



Engine type



WP6 non-road Stage II, power generation



132E



132E



152E



158E



180E



200



201



200



201



201



—



4-stroke, water-cooled, in-line, DI, wet cylinder liner, high-speed diesel engine



—



Turbocharged



Displacement



L



6.75



Bore × stroke



mm×mm



105×130



—



6



—



2



—



18:1



—



1-5-3-6-2-4



—



Mechanical pump



Aspiration method



Number of cylinder Number of valve per cylinder Compression ratio firing order Fuel injection device Rated power



kW



120



120



138



144



180



Rated speed



r/min



1500



1800



1500



1800



1800



1.4 Unsealing of the diesel engine 4



Maintenance e Manual of WP6 Stage II La and Diesel Engine for Powe er Generation



After openning the enginne packing caase, please firrst check the engine and itts accessoriess according to o the packingg list, and chheck the enggine appearannce for dam mage and loose connections before caarrying out th he followingg operations:: 1) Wipe aw way the rust proof p coat or anti-corrosion a n agent on th he surfaces off exposed com mponents; 2) Dischargge the sealingg oil from thee fuel filter annd fuel system m componennts (it is allow wed to run thee engine withh load only when w the sealling oil is used up and the normal dieseel fuel has beeen supplied). Notice: Thhe oil seal is only o effectivee for one yearr, and when the t time is upp, please get yyour engine inspected andd take necesssary remediess. 3) Rotate thhe flywheel and a spray sollvent into the intake pipe until u the oil sealing oil in tthe cylinder is i completelyy removed. 4) Spray soolvent into the turbochargeer intake/exhaaust ports unttil the oil sealling oil is com mpletely removed. 5) Base onn the agreemeent between Weichai W and user, the oil pan shall be filled with ooil in accordaance with thee requiremennt; if oil contaaining runninng-in acceleraant is filled in n the oil pan before b deliveery, it is suggeested that thee oil should be b drained offf after runninng for 50h and then fill with new oil. 6) Base onn the agreem ment between Weichai and user, if thee coolant is already filledd according to the user’ss requiremennt before deelivery, pleasse check thee coolant peerformance when w unpackking. If the anti-freezingg capability is suitable foor -30°C or -35°C, the PH value is 7~8 7 (neutral),, the total haardness numb ber is 5-15°dd [9-15°f (haardness)], thee coolant can be used. Othherwise, drain the coolantt and add new w coolant wh hich containss antifreeze additives. a 7) Check thhe water plugg and oil plugg for blockagee, check the water w temperaature and oil ttemperature sensors. s Notice: Do not start thee diesel engin ne until it is installed and d connected into position n. Keep good d ventilation n ke sure that the t exhaust into i the atmoosphere. if the enginee runs in encclosed enviroonment, mak



1.5 Hoistin ng of the diiesel enginee When hoistiing up and down d of the diesel d enginee, it should be b slow and keep the enggine crankshaaft centerlinee horizontal, and a never hoiist it obliquelyy or from onee side (as sho own in figure 1-4).



Wrong



Correcct



5



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



a)



b)



Figure 1-4Hoisting of the diesel engine



1.6 Installation of the diesel engine When installing, it should be ensure that the crankshaft axis is coaxial with that of input shaft of driving gears (gearbox, transmission or generator etc.) and



should be used ensuring that the crankshaft isnot affected by the



additional force originated from the installation.



1.7 Preparations before starting of the diesel engine 1) Check coolant level If the engine is still hot when the filler cap with relief valve and bleed button is to be opened, always press down the bleed button first. It is prohibited to add a large amount of coolant when the engine is relative hot; otherwise, related parts may get damaged due to sudden excessive temperature change. If there is no proper coolant under some abnormal cases, it is permissible to add relatively warm water. The coolant (water) should be added via the filler port until it overflows. Start the engine, and when the engine is running (at 1000 r/min), continue to add coolant till the level is stable, and then cover the filler cap. 2) Check fuel level With the engine installation completed, turn on the power supply switch, and check fuel level from the fuel gauge or check the fuel tank. 3) Check engine oil level The engine oil level of oil pan shall be in between the upper and lower markings of oil dipstick. If necessary, add engine oil from the filler port. 4) Check all accessories of diesel engine for reliable connections and solve any abnormal phenomenon. Check the starting system for normal wiring and check and ensure that the battery is sufficiently charged. Open the valve of fuel tank. Loosen the bleeding screw of the primary fuel filter. By operating the manual pump on the injection pump, remove the air inside the fuel system.



1.8 Starting of the diesel engine When the starting conditions are met, press the starting button to start the diesel engine. To avoid the starter motor from being damaged, do not start the engine continuously for more than 15 seconds; if the engine fails to be started within 15 seconds for the first attempt, start it again 2 minutes later. If the engine still fails to be started after three attempts, stop the attempt and find out and solve the malfunction before retry. 6



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



After the engine is started, check the readings of instruments, and keep the engine running at idle speed, when the engine oil pressure should not be lower than 120kPa. Do not run the engine at idle speed for a long time. It is recommended to use the starting aid in case of engine startup at lower temperature. Under the action of relay, the electronic flange is put into service and then heats the incoming air, allowing a smooth startup of the engine at -30°C.



1.9 Running of the diesel engine After the engine is started, run it at idle speed for (2~3) min until the engine oil pressure is higher than 120kPa. When the coolant temperature is lower than 60°C, do not run the engine at higher speed with higher load suddenly, to avoid affecting the wear resistance and reliability of the engine. It is recommended to increase the load and speed gradually, and avoid sudden loading or unloading as possible. It is recommended to run the engine with medium load during the running-in period (50h). In normal use, the diesel engine is allowed to run continuously at rated power and rated speed, but it may not run for more than 20 min at the speed 105% the rated speed and power 110% of rated power. After the diesel engine is unloaded, it is required to run the engine at idle speed for (1~2) min before shutdown. Check the parameters and related components in operation: 1) Oil pressure: (300~600)kPa(≥120kPa at idle speed); 2) Oil temperature: (85~105)°C; 3) Coolant outlet temperature: (80~90)°C; 4) Exhaust temperature after turbine: ≤550°C; 5) Fuel inlet temperature: (40~45)°C; 6) Check the color of exhaust gas to estimate the operating load and the working performance of fuel injector; if the color is abnormal (i.e., black smoke), stop the engine for troubleshooting. Notice: Check the diesel engine for water, air and oil/fuel operation; and if any, stop the engine for troubleshooting. The operator should acknowledge the following features of the engine: 1) The engine power increases along with the speed, and reaches its rated value at rated speed. Notice: To avoid damage of the diesel engine, do not disconnect the cables of voltage regulator and the battery positive electrode when the engine is running. Different with the DC generator, it is prohibited voltage of alternator by temporary grounding. Precautions for running under cold environments: 1) Fuel: Choose the diesel fuel of proper grade depending to the ambient temperature in winter; 7



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



2) Lubricating oil: Choose the lubricating oil of different viscosities based on the season; 3) Coolant: Add anti-freeze into the cooling system, and determine the antifreeze grade and mixture ratio according to the ambient temperature. 4) Startup: Use starting aid when necessary in winter. After starting the engine, the running speed and load of diesel engine can be increased only after the oil pressure and water temperature become normal. 5) Battery: Before the cold season comes, make sure to check the electrolyte level, viscosity and unit voltage of the battery; and if the diesel engine is to be withdrawn out of service for a long time and the ambient temperature is very low, it is recommended to remove the battery and keep it in a warm room; 6) Shutdown: To stop the engine in cold weathers, unload the engine first, and run it at idle speed for (1~2) minutes, and wait for a while until the water temperature and oil temperature lower down; the coolant with antifreeze should not be drained out after shutdown. However, if the coolant contains no antifreeze additive, make sure to open the drain valves or drain plugs on the engine block, oil cooler cover, radiator and water inlet pipe to fully drain the coolant, to prevent the engine from being frost cracked.



1.10 Stopping of the Diesel Engine It should be avoided to stop the engine at full load. Before stopping the engine, reduce the load and lower the speed and then run the engine for 3~5min at idling or low-load working condition. This is intended to cool down the piston, cylinder liner, bearing bushing, shaft sleeve and turbocharger sufficiently, in order to prevent cylinder scuffing and bearing bushing damage. It is important especially for a turbocharged diesel engine. The bearings and oil seals of the turbocharger are subject to the influence of the high temperature exhaust gas. During the running of the diesel engine, B the heat is carried away by the circulating oil. If the diesel engine is stopped suddenly, the turbocharger temperature will increase remarkably to cause overheating, which will lead to seizure of bearings or failure of oil seals. Turn the key switch to position “OFF” or press the stop button to stop the running engine, till the flywheel stops rotation or the speed indication on the instrument panel is zero. If the cooling water of diesel engine contains no antifreeze additives, make sure to drain the cooling water after stopping in cold weather to prevent the diesel engine from being damaged due to freezing. The water drainage valve is located at the bottom of oil cooler. Turn the drainage valve switch to drain the water from diesel engine. At the same time, remove the water drainage plug of radiator to drain the cooling water inside.



8



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Chapter II Maintenance Guide of the Diesel Engine 2.1 Fuel, lubricating oil, coolant and auxiliary materials 2.1.1 Fuel Summer: 0# diesel fuel (GB252) Winter: generally -10# diesel fuel shall be used; however, -20# diesel fuel shall be used if ambient temperature is lower than -15ºC, -35# diesel fuel shall be used if ambient temperature is lower than -30ºC. The fuels used must conform to the requirements specified in section D.1 of Appendix D to the national standard GB20891-2014. 2.1.2 Lubricating oil Oil capacity: 16L, based on the markings of oil dipstick. See table 2-1 for details. Table 2-1 Engine oil special for Weichai Power engine and applicable engine model Type



Product category



Packing



10W-30 CF-4



15W-40



4L, 18L, 170kg



20W-50



CH-4



CJ-4



15W-40



4L, 18L, 170kg WP10, WP12 and WP13 series diesel engines



15W-40



China IV WP4, WP5, WP6, WP7, 4L, 18L, 170kg WP10, WP12 and WP13 series diesel



20W-50 10W-30



engines China V WP4, WP5, WP6, WP7,



15W-40



4L, 18L, 170kg WP10, WP12 and WP13 series diesel



20W-50 Engine oils special for gas engine



WD12 and WP6 series diesel engines China III WP4, WP5, WP6, WP7,



10W-30 CI-4



China II WD615, WD10, WD618,



10W-30 20W-50



Diesel engine oil



Applicable engine models



10W-30 15W-40



engines 4L, 18L ,170kg Natural gas engines



For Weichai Power special oil, please select the oil viscosity according to the ambient temperatures with reference to Table 2-2. Table 2-2 Oil viscosity and applicable temperature SAE viscosity grade



Ambient temperature (ºC)



0W-20



-35-20



5W-30



-30-30 9



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



10W-30



-25-30



15W-40



-20-40



20W-50



-15-45



Note: 1)



Check the oil level in the oil pan before starting the diesel engine.



2)



Do not check the oil level while the diesel engine is running.



3)



It is not allowed to mix the Weichai Power special engine oil with other oils.



For the oil filling volume and the number of filters of Weichai engines, see Table 2-3. Table 2-3 Oil Filling Volume and Number of Filters of Weichai Engines Number of filters Engine



Oil filling



model



volume (L)



Diesel engine



Gas engine



Diesel fuel filter Oil filter



Primary



Secondary Oil filter



filter



filter



Natural gas filter



WP4



9~12



1



1



1



1



1



WP5



13~16



1



1



1



1



1



WP6



16~24



1



1



1



1



1



WP7



20~24



1



1



1



1



1



WP10



22~26



2



1



1



2



1



WP12



25~28



2



1



1



2



1



WP13



25~28



2



1



1



2



1



Remark: 1)



The oil filling volumes listed in the table are for reference only. The actual filling based on the markings of oil dipstick.



2)



If Weichai fuel system protector or fuel filter with water separator is equipped, their filter elements shall be replaced when replacing the diesel



2.1.3 Coolant Weichai Power special coolants with freezing points of -25°C, -35°C and -40°C are available. Please choose the coolant based on the local ambient temperatures in such manner that the freezing point of coolant should be lower than the local air temperature of about 10°C. See Table 2-4. 10



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Table2-4Special Coolant for Weichai Power Heavy-Duty Engine Type



Designation



Packing



HEC-II-25



Heavy-duty



HEC-II-35



engine coolant



4kg，10kg



HEC-II-40 Notice: 1) Check the coolant regularly to prevent corrosion damage. Replace the coolant if necessary. 2) Never use water or low-grade coolant.



2.1.4 Auxiliary materials Table 2-5 Auxiliary materials No.



Name



Color



Molykote Pulver 1



Applied on flat and smooth metal surfaces to prevent Black



(fine molybdenum powder)



seizing For instance: Applied onto outer surface of cylinder liner



Molykote G-N plus 2



Function and application



(Molybdenum disulfide,



Achieve lubrication function before lubricating oil Dark grey



oil solution)



pressure is built up For instance: Applied onto intake valve stem



Table 2-6Application of sealant for diesel engine Grade



Major application



Application part



Supplements



Flywheel housing bolt Camshaft thrust plate bolt Applied onto the threads Weichai special



to prevent looseness due



sealant 242



to vibration, with moderate strength.



Camshaft timing gear bolt Intermediate idler gear bolt



Alternatively, DriLoc204



Front end cover bolt



thread-locking adhesive can



Oil filter head bolt Oil cooler bolt Weichai special



Applied onto the external threads for



Cylinder head auxiliary bolt 11



be used for pre-coating



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



sealant 262



locking, sealing, preventing vibration from causing looseness



Weichai special sealant 271



Locking and tightening



Weichai special



For sealing between core



sealant 277



and hole



Weichai special



For sealing of cylinder



sealant 270



head top surface



Bowl-shape plug for oil hole



Other bowl-shape plugs



Push rod tube - cylinder head Mating faces of cylinder block and crankcase Cylinder block front end face and the front end cover



Weichai special sealant 518



Applied on shining



(updated product metal surface for sealing based on 510)



Connecting plate between the rear end face and flywheel housing Mating faces of oil filter seat and crankcase Water pump rear cover and cylinder block front end face



12



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



2.2 Daily maintenance items of the diesel engine 2.2.1 Check the liquid level and temperature of coolant Check the coolant level through the sight hole, and if it is insufficient, open the filler port cap to add coolant. Notice: Before opening the filler cap, push down the air bleeding button to avoid personal injuries by the hot coolant while the engine is hot.



Figure 2-1Checking of coolant level and temperature Notice: Always check the coolant level before starting the diesel engine each time. 2.2.2 Check oil level Check the oil level with oil dipstick. When the oil level is below the lower marking or above the upper marking, it is not allowed to start the diesel engine (figure 2-2). When checking the oil level, stop the engine and wait for at least 5 minutes, enabling the oil to flow back to the oil pan.



13



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Oil dipstick



Figure 2-2 Oil dipstick Notice: Always check the oil level before starting the engine each time.



2.2.3 Check for presence of air, water and oil/fuel leakage Check the external surface of diesel engine for water, air and oil/fuel leakage. 2.2.4Check the fan Visually check if the fan blade is damaged, if the plastic fan is deformed, if the iron fan rivet is loosened, if the blade is bent and if the connecting bolt is tightened to ensure the fan works reliably. 2.2.5 Check the belt The belt is automatically tensioned by the ten. Check the tension of belt by pushing the belt with hand. Visually check the V-belt for cracks or scratches, and replace it if necessary. 2.2.6 Check the exhaust color The normal color of exhaust gas is light grey. Do troubleshooting if the color has changed (figure 2-3).



Figure 2-3 Exhaust color checking 2.2.7 Check the running sound of diesel engine. 14



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



2.2.8 Check the speed and vibration of diesel engine.



2.3 Periodic maintenance of the diesel engine 2.3.1 Replace the engine oil Place the diesel engine on a flat place, set anoil recycling container under the engine, unscrew the drain plug at the bottom of oil pan (figure 2-5), drain off the oil completely, then screw in the drain plug again. Openthe oil filler cap, add fresh new oil through the filler port(figure 2-4), the oil should be filtered by a strainer when filling; check the oil level through the scale mark of oil dipstick, tighten the filler port cap finally.



Figure 2-4 Oil filler



Figure 2-5 Oil drain plug



2.3.2Replace the oil filter Replace the oil filter as follows: 1) Remove the used oil filter with a special spanner(figure 2-6); 2) Fill the new filter with clean oil; 3) Apply lubricating oil to the sealing ring of new oil filter, and tighten the oil filter with hands; 4) After the sealing ring coming into contact with the base, tighten the filter by 3/4~1 more circles for proper tightness; 5) Start the diesel engine and check for oil leakage.



15



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Oil filter



Figure 2-6 Oil filter 2.3.3 Check and adjust intake/exhaust valve clearance Check and adjust intake/exhaust valve clearance as follows: ①With the diesel engine in cold state, turn the flywheel with a bar (along with the running direction of diesel engine crankshaft) to make the pistons of No. 1 cylinder and No. 6 cylinder to TDC, when the notch groove on flywheel should be aligned with the OT groove line on the flywheel housing, as shown in Figure 2-7.



Flywheel notch groove



OT groove line is aligned with flywheel notch groove



Figure 2-7 Flywheel notch groove ② Remove the valve rocker arm cover from the cylinder head, and determine if the No. 1 cylinder or No. 6 cylinder is in the compression stroke (as indicated by the existence of clearance between the intake/exhaust valve and the rocker arm under the compression stroke).



16



Maintenance e Manual of WP6 Stage II La and Diesel Engine for Powe er Generation



F Figure 2-8 Addjustment of valve v clearancce ③Use a feeeler gauge to adjust the cllearance betw ween the rock ker arm and the t valve stem head as peer Table 2-7.. ForWP6nonn-road Stage II I land diesell engine for power p generaation, the intaake valve cleearance and exhaust e valvee clearance shhould be 0.2m mm and 0.3m mm respectiveely. If the cleaarance is too large or too small, pleasee regulate thee adjusting boolt on the rockker arm to achhieve the propper valve clearance. As shhown in Figurre 2-9.



Adju usting bolt



Figure 2-9 Adjustin ng screw ④After the checking of the No. 1 orr No. 6 cylindder, turn the flywheel by another 360°°, ensuring th hat the No. 6 cylinder or No. N 1 cylindeer is at TDC of o working strroke, and then n adjust the remaining r vallves (see tablee 2-7). Table 2-7Staate of each cyylinder when the No. 1 and d No. 6 cylindders are in woorking strokee No. 1 cylinder



Noo. 2



o. 3 No



Noo. 4



Noo. 5



cyliinder



cyliinder



cyliinder



cyliinder



No. 6 cylinder



No. 1 cylindder,



Intake/exhauust



Intakke



Exhaaust



Intakke



Exhaaust



compressionn stroke



valves



valvee



valvee



valvee



valvee



No. 6 cylindder,



Non-adjustaable



Exhaaust



ke Intak



Exhaaust



Intakke



ke/exhaust Intak



valvee



valvee



valvee



valvee



valvee



compressionn stroke



Non--adjustable



2.3.4Replacee the fuel filter Replace the fuel filter eleement as folloows: w collectorr installed onn the primary filter can bee ① Remove the used fueel filter elemeent (figure 2--10), if the water 17



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



reused, please remove the collector. ② Lubricate the sealing port. ③Screw the fuel filter with hands until the sealing port comes into contact with the mating port. ④ Continue to screw the new fuel filter until it is securely installed (about 3/4 turn). ⑤ Remove the air in the fuel system. ⑥Conduct the leakage test.



Fuel filter  Figure 2-10 Fuel filter 2.3.5Check intake system Check the intake hose for cracks due to aging, and check the clamp for loosening. When necessary, tighten or replace the related parts to ensure the tightness of intake system. 2.3.6Check the air filter element



18



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 2-11 Air filter The maximum permissible intake resistance of the diesel engine is6kPa. Check the maximum intake resistance only when the diesel engine is running at rated speed under full load. If the intake resistance reaches the maximum permissible limit, please clean or replace the filter element as per the manufacturer’s instructions. Notice: It’s absolutely prohibited to run the engine without the air filter; otherwise, dust and foreign matters may get into the diesel engine to cause early wear of diesel engine. Disassemble the filter element from the air filter, and tap the end face of filter element or blow with compressed air (from inside out) to remove the dust, as shown in figure2-12.



High pressure air pipe



Figure 2-12Filter element cleaning Notice: Do not damage the filter paper; Do not clean the filter paper with water or oil; Do not tap or knock the filter element forcibly; Be sure to replace the damaged filter element and seal ring.



19



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



2.4Maintenance of diesel engine for long-term storage 2.4.1 Cleaning Remove the dust with appropriate methods, and clean the parts and positions to be protected with protective agent (such as lubricating oil line, fuel system and turbocharger) thoroughly. 2.4.2 Protection of diesel engine before preservation ①After warm up of the diesel engine, discharge the engine oil, clean the oil filter, and fill the oil tank or oil pan with rust resisting oil. ②Drain the diesel fuel out of the fuel system, and fill it with anti-rust oil to protect the fuel line. ③If the diesel engine is not filled with cooling emulsion, drain out the cooling water, and fill the cooling system with cooling water emulsion and rust resisting oil. Before sealing preservation, start the engine according to the startup procedure and run it at idle speed for 15-25 minutes. ④Remove the cover plate at the short side of intake pipe, sprayrust resisting oil into the intake pipe using a pressure nozzle, at the same time, turn the crankshaft with hand to open the air valve and let the rust resisting oil coming into the combustion chamber. After the sealing preservation is completed, do not turn the crankshaft any more to prevent the oil film attached to the cylinder wall from being scraped. ⑤Open all drain valves and discharge or pump out the rust resisting oil from the engine base, and drain out the cooling water emulsion from the cooling system ⑥Remove the rocker arm cover, and spray rust resisting oil to the valve spring and rocker arm. ⑦Apply protective oil to all machined surface of parts of diesel engine. Notice: To avoid moisture and foreign matters coming into the diesel engine, it is recommended to cover the inlet and outlet ports of intake pipe, exhaust pipe and cooling water pipe, and cover the diesel engine with a plastic hood in the process of transport and storage. 2.4.3Oil sealing Generally, the validity period of oil sealing is one year for the diesel engine in storage. If the storage time exceeds one year, oil sealing process shall be performed again as follows: 1) The oil sealing process shall be performed in a clean environment. Before doing so, remove rust, oil stain and dust from the engine and components. 2) Subject to actual requirements, oil sealing process may be dipping in, spraying, coating or filling with rust resisting oil. 3) Locations and requirements: (a) Intake and exhaust systems: Make the diesel engine running by using a starter motor or a driving device and spray JB-1 calibration fluid to the intake pipe port for at least 15 seconds by using air spray gun. 20



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



(b) Turbocharger: Under stationary state or make the diesel engine running by using a driving device, spray JB-1 calibration fluid to the inlet/outlet port of turbocharger for at least 5 seconds by using air spray gun.



21



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Chapter III Common Failures and Troubleshooting WP6 non-road Stage II land diesel engine for power generation is designed and manufactured under strict quality management system and each delivered diesel engine has passed the specified tests. As the diesel engine is a kind of 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) Operation against the regulations, and improper management and use; (2) Failure to fulfill maintenance as required, 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 or unqualified fuel and oil are used.



3.1 Diagnostic Method Generally, the common diagnostic methods for malfunctions of diesel engine are as follows: (1) Observation method: Judge the malfunction situation by observing malfunction features such as exhaust smoke color of diesel engine (figure 3-1). (2) Listening diagnosis method: Judge the location, feature and extent of malfunction by listening the abnormal noise of diesel engine (figure 3-2).



Figure 3-1



Figure 3-2



(3) Cylinder deactivation method: Generally, cut off the fuel supply to the suspect malfunctioned cylinder, and compare the working conditionof the diesel engine before and after stopping fuel supply to narrow down the scope for further determination of the malfunction location or cause. (4)Comparison method: Replace a certain assembly or component to determine whether there is failure. Notice: (1) The causeof diesel engine malfunction shall be determined carefully.Before the cause is basically found, do 22



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



not disassemble the diesel engine at will. Orit will not only eliminate the malfunction, but also lead to more serious malfunction due to improper assembly after removal. (2) Inspection and maintenance on critical componentssuch as high-pressure fuel pump and turbocharger shall be performed by experienced personnel using special instrument or equipment. Users without experience shall not disassemble or adjust them randomly.



3.2Malfunction causes and troubleshooting 3.2.1 Diesel engine cannot be startedor it is difficult to start S/N 1



Malfunction causes



Troubleshooting



Fuel system malfunction



1-1



Fuel tank valve is not opened or there is no fuel



1-2



There is air in fuel system



1-3



Fuel delivery pump fails to supply fuel



1-4



Fuel injector atomizes poorly



Adjust or check the fuel injector



1-5



Incorrect fuel supply advance angle



Check and adjust fuel supply advance angle



1-6



Fuel pipe or fuel filter is blocked



Check and clean



2 2-1



Open the valve or add enough fuel Check pipe joint for looseness, and remove the air in fuel pipe Check fuel delivery pump, and replace the pump if necessary



Cylinder compression pressure is insufficient Piston ring and cylinder liner are worn Check the clearance and sealing of valve , and excessively



2-2



The valve leaks air



2-3



Cylinder gasket leaks air



grind the valve if necessary Check the clearance and sealing of valve, and grind the valve if necessary Check the cylinder gasket, and eliminate the leakage failure



3



Starting system malfunction



3-1



Battery is lack of electricity



Charging the battery or check and repair



3-2



Poor contact of electrical circuit



Check the circuit



3-3



Starter motor do not run or powerless



Check and repair the starter motor



3-4



Starter motor gear cannot engage properly with flywheel ring gear



Turn the flywheel ring gear by a certain angle,if theengine still cannot get started, check the starter motor.



23



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



3.2.2Diesel engine runs unstably S/N



Malfunction causes



1



There is air in the fuel system



2



Fuel system is blocked



3



Troubleshooting Check the connection of pipe joint, and remove the air in fuel pipe Clean or replace the diesel filter



Uneven fuel supply of the cylinders of injection pump



Check and repair the injection pump, and adjust the fuel supply of each cylinder of the pump on the test bed Check and determine the injector in poor working



4



A certain injector malfunction



5



Speed governor works unstably



Check the speed governor, and eliminate the failure



6



Fuel quality is poor or there is water in fuel



Check the fuel and renew it if necessary



condition, and clean or replace it



24



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



3.2.3 Insufficient engine power S/N 1 1-1



1-2



1-3



Malfunction causes



Troubleshooting



Fuel system malfunction Fuel system is blocked or air enters the fuel



Clean or replace the diesel filter, and remove the air



system



in fuel system



Poor fuel atomization of fuel injector, fuel



Check and correct the fuel injector, and replace it if



injection pressure is insufficient



necessary



Fuel injection pump supplies insufficient or



Check or replace



uneven fuel



1-4



Fuel supply advance angle is inappropriate



Check and adjust the fuel supply advance angle



1-5



Fuel quality is poor or there is water in fuel



Check the fuel and renew it if necessary



2 2-1



Cylinder compression pressure is insufficient Piston



ring



and



cylinder



liner



is



worn Check and replace piston ring, and replace cylinder



excessively



liner and piston if necessary



2-2



Air valve leaks air



2-3



Cylinder gasket leaks air



Check the clearance and sealing of valve, and grind the valve if necessary Check the cylinder gasket for air leakage, and eliminate the failure



3



Air filter is blocked



Clean or replace the filter element



4



Exhaust passage or muffler is blocked



Check and clean exhaust passage and muffler



5



Exhaust pipe is not smooth



Find out the failure cause, and eliminate the failure



3.2.4 Oil pressure of diesel engine is abnormal S/N



Malfunction causes



Troubleshooting



1



The oil level in oil pan is excessively low



Fill in engine oil to the specified level



2



Oil pressure gauge malfunction



Repair or replace



3



Suction oil filter and filter are blocked



Clean and replace filter element



4 5



Crankshaft main bearing and connecting rod bearing are worn excessively Oil grade is incorrect, there is water in the oil 25



Repair or replace Check the oil grade, find out the failure cause, and



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



renew the oil 6



Oil pump driving/driven gears are worn



Replace the oil pump



7



Relief valvemalfunction



Check and replace



8



Oil pipeline is blocked or leaks oil



Check and repair



3.2.5Diesel engine temperatureis too high S/N



Malfunction causes



Troubleshooting



1



Diesel engine runs overloaded for a long time



2



Poor combustion



3



Oil temperature is too high



3-1



Insufficient or too much oil



3-2



Oil cooler is blocked



4



Check the fuel injection and fuel supply advance angle



Check the oil dipstick, and add or reduce the oil volume as required Clean or replace the oil cooler



High coolant temperature



4-1



Cooling water is insufficient



4-2



Insufficient water pump flow



4-3



Fan speed is low



4-4



Reduce the load



Replace the water pump Check the clearance of water pump impeller, and replace it if necessary Adjust the tension of fan belt



There is too much limescale in the cooling system



4-5



Bad heat dissipation of radiator



4-6



Thermostat malfunction



Remove the limescale Remove the dirt from radiator fin, and improve the water tank ventilation Find out the failure cause, and replace it



3.2.6Diesel engine smoke color is abnormal S/N 1 1-1



Malfunction causes



Troubleshooting



White exhaust smoke Poor fuel atomization of fuel injector



Check the injection pressure and atomization



26



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Clean the diesel tank and filter, and renew the diesel



1-2



There is water in diesel fuel



1-3



Cylinder compression pressure is insufficient



2



fuel Check the valve, cylinder gasket and piston ring for air leakage, and eliminate the failure



Blue exhaust smoke



2-1



Oil level ofoil pan is too high



Drain off excessive oil



2-2



Piston ring is worn out or lack of elasticity



Check and replace the piston ring



2-3



Valve seal failure



3



seal



Black exhaust smoke



3-1



Diesel engine is overloaded



3-2



Poor fuel injection or atomization



3-3



Check the valve seal, and replace the valve stem



Adjust to the specified load Repair or replace the outlet valve of injection pump and fuel injector



Fuel delivery is too late, causing serious post combustion



Adjust thefuel supply advance angle



3-4



Incorrect valve clearance or poor valve seal



Check the clearance and sealing of valve



3-5



Air filter is blocked



Clean the air filter element



3-6



Poor fuel quality



Replace with quality fuel



27



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



3.2.7Diesel engine stopped automatically S/N 1



Malfunction causes



Troubleshooting



Crankshaft cannot rotate after engine stopped



1-1



Crankshaft and bearing liner get stuck



Repair orreplace the related parts



1-2



Piston and cylinder liner get stuck



Repair and replace the piston, piston ring and cylinder liner



2



Crankshaft can rotate easily after engine stopped



2-1



There is air in the fuel system



Remove the air, and check the sealing of pipeline



2-2



Fuel system is blocked



Clean and replace the fuel filter element



2-3



Fuel injection pump rack or plunger gets stuck



Repair the injection pump



2-4



Air intake pipe or air filter are blocked



Check and clean the air filter



2-5



Diesel fuel is used up



Add diesel fuel



3.2.8 Abnormal noise during running of diesel engine S/N 1



2



Malfunction causes



Troubleshooting



Fuel injection is too early, there is rhythmic clear sound in the cylinder Fuel injection is too late, there is deep and unclear knocking sound in the cylinder



Check and adjust the fuel injection time



Check and adjustthe fuel injection time



The clearance between valve and rocker arm is 3



too large, there is metallic knocking sound of



Check and adjustthe valve clearance



the valve mechanism 4



The clearance between piston and cylinder is



Check the cylinder clearance, replace piston or



too large



cylinder liner



The clearance between piston pin and small end bearing of connection rod and there is loud 5



metal knocking sound, which is particularly



Replace the connecting rod bushing



noticeable when diesel engine runs at low and high speeds 6



The clearance of connecting rod bearing is too Replace the bearing 28



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



large, there is dull metal knocking sound The clearance of main bearing is too large, 7



there is as similar noise as that for connecting



Replace the main bearing



rod bearing Piston comes in contact with the valve,, a 8



metallic knocking sound can be heard near the cylinder when the diesel engine runs at low



Check the valve timing



speed The clearance of gear is too large, impactsound 9



can be heard at the gear chamber when the diesel engine speed is reduced suddenly



29



Check and adjust the gear clearance, and replace the gear if necessary



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Chapter IV Disassembly and Assemblyof the Diesel Engine 4.1 Overview During disassembly and assemblyof the diesel engine, please follow the instructions in this manual strictly and pay attention to the operation steps containing danger and safety signs to ensure personal safety and avoid accidents. In this manual, the following signs is used to emphasize certain information. Undoubtedly, it requires more than just the safety instructions to avoid all hazards. The only way to avoid the accident is to follow the specific operation instructions strictly and learn to use common senses concerned. 4.1.1 Dangersigns This is a world-recognized warning sign. In the manual, this sign is used to emphasize the importance of the following information. Please make sure that you understand the consequence of hazardous conditions and how to avoid such dangers. In case of any behaviors in violation of the warning information, it may result in damage to property, personal injury and even death. The common danger signs are usually used to indicate general warning.Warning information in this manual is classified into different types (slight injury, serious injury and death) according to severity of possible consequences.



WARNING



This warning sign indicates a potential danger, which, if not warded off, may lead to serious injury even death or major property loss.



PRECAUTION



This warning sign indicates a potential danger, which, if not warded off, may lead to slight injury or property loss. It is also be used to warn against dangerous operation warning.



The cautions in this manual are provided to explain how to correctly operate and safely use the engine of our company.. However, simply reading through this document will not prevent risks from happening. Theconsiderations will not be beneficial to the correct use unless the information contained is properly understood. The warning information provided herein may not cover all possible conditions! If theprocedures or methodsused beyond those recommended in this manual, make sure that such operation will never cause any danger to you, to 30



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



others or to the equipment. 4.1.2Safety signs Table 4-1Safety signs Figure



Definition Wear hand protection Wear ear protection Wear eye protection Wear head protection Wear foot protection Wear a protective mask Wear overalls Avoid naked flames No smoking Do not use mobile phone Danger: battery acid Danger: live cables, electrical shockhazard



Highly flammable product



Keep away from hanging loads



Keep an extinguisher nearby



Many potential dangersmay occur unexpectedly without any signs when the engine is in running. Therefore, this 31



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



manual cannot give warning instructions for all kinds of potential danger. To apply a procedure beyond the special recommendations, make sure that the procedureis safe and do not result in any damage to property.



4.1.3Tools used Table 4-2Tools Figure



Definition 2.5mm hexagonal wrench



5mm hexagonal wrench



8mm socket



Flat screwdriver



Special tool



10mm flathexagonal wrench To use a method or tool beyond those recommended in this manual, the user shall always ensure the personal safety, avoid danger to the life of user or others, meanwhile, make sure that the use, maintenance or repair method will not result in damage risk or safety hazard. 4.1.4 Health care consideration The following “Precautions for health protection” are specified to reduce the risk of engine maintenance staffs suffering from any contamination. (1) Avoid repeated exposure to used oil for a long time; (2) Wear the protective clothing and water-proof gloves properly, if available; (3) Do not place the oil-soaked rag in the pocket; (4) Avoid contaminating clothes especially underwear with oil; (5) Wash working clothes frequently, and throw away the oil-impregnated clothes and shoes that cannot be cleaned up; (6) In case of cut and injury, take first-aid measures as soon as possible; (7) Before working, always apply some protective cream which will make it easier to remove the oil in case that 32



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



the skin is contaminated with mineral oil; (8) Use soap and hot water, or liquid soap and nail brush to wash hands for the convenience of removing all oil stains. If the grease secreted by skin is washed off, the lanolin-containing products can be used to moisturize the skin; (9) Do not clean the skin with any gasoline, kerosene, fuel, thinner or solvent; (10) If your skin is discomfort, seek for medical care immediately; (11) Remove the oil on the parts before transportation, if possible; (12) If the eyes are under threaten, wear goggles or protective mask. Always prepare eyes wash liquid within reach; (13) To repair the engine, do not splash oil or other liquid on the floor. If hydrocarbon or other liquid leaks unexpectedly, take all essential measures to isolate the area to keep the environment clean and to protect the personnel from injury; (14) The hydrocarbon, ethylene, glycol or petroleum shall be transferred, stored and recycled under the safety and environment standard in the local country. 4.1.5 Environmental protection measures For used oil and hydrocarbon handling, refer to the relevant environmental protection regulations. Consult the local officials for details. 4.1.6 Considerations fordisassembly and assembly of diesel engine (1) Most accidents in connection with the use, maintenance and repair of diesel engine are resulted from failure to observe the safety rules and basic precautions. So, you shall be aware of the danger lying ahead and take the corresponding measures to avoid the accident. Only the well-trained personnel with required skills and appropriate tools can operate, maintain and repair the diesel engine. (2) The violation of instructions in the manual can lead to serious accident, and even endanger life. We cannot foresee all potential dangers, meanwhile, the rules and instructions specified in this manual are not meant to be comprehensive. (3) Before continuing the maintenance or repair, place “DO NOT USE” sign board or similar signs on the starter switch. (4) Take necessary precautions before using barring rod; (5) Make sure that the maintenancesite and the surroundings are suitable for safe operation; (6) Make sure that the maintenance workshop or area around the engine is clean and tidy; (7) Before working, remember to remove the ring, necklace and watch, and wear well-fitted working clothes; (8) Before working, please check whether the corresponding protective equipment (goggles, gloves, shoes, mask, working cloth, helmet etc.) are within the effective service life; 33



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



(9) Do not use the faulty or improper tools. (10) Before the maintenance or repair, please stop the engine.



4.2Cylinder block group 4.2.1 Disassembly and assembly of cylinder block group 4.2.1.1 Exploded view of cylinder block group The cylinder block group consists mainly of the cylinder block assembly, cylinder liner, camshaft bushing and bowl plug. See figure4-1 and table 4-1 for details.



Figure 4-1 Exploded view of cylinder block group Table 4-1 Part No. and name No.



Name



No.



Name



No.



Name



1



Cylinder liner



12



Thrust main bearing



23



Pipe fitting



2



O-ring



13



Main bearing bolt



24



Stud



3



O-ring



14



Main bearing cover



25



Straight pin



4



Corehole plug



15



Cylinderblock



26



Blanking cover



5



Camshaft bush



16



Corehole plug



27



Liner tube



6



Blind rivet



17



Hexagonplug screw



28



Ball



7



Blanking cover



18



Gasket



29



Restoring spring



8



Camshaft bush



19



Clip plate



30



Threaded rod



9



Camshaft bush



20



Spring washer



31



Gasket



10



Stud



21



Screw



32



Cap nut



34



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation 11



Main bearing bolt



22



O-ring



4.2.1.2 Disassembling steps of cylinder block group ① Unscrew the cylinder head bolts (key point 1); ② Remove the welded elbow (key point 2); ③Remove the screw plug and washer of vertical oil duct; ④Remove the cylinder liner (key point 3); ⑤ Remove the camshaft bushing (key point 4); ⑥Remove the relief valve between main and secondary oil passages (key point 5). 4.2.1.3 Inspection and repair of cylinder block group Key point 1: Assembling: Apply lubricating oil to the bearing face and threads of cylinder head bolt, and tighten the bolts as specified below: (1) Use a four-axis tightening machine to tighten the bolts on the assembling line as follows: a. Tighten to 15Nm; b. Tighten to 60 Nm; c. Turn an angle of 230°±4°. (2) If the four-axis tightening machine is unavailable, tighten with a torque wrench as follows: a. Tighten to 30Nm; b. Turn an angle of 120°±4°; c. Turn an angle of120°±4° again. The tightening sequence of cylinder head bolts for each cylinder is shown in figure 4-2.



35



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 4-2 (3) The tightening sequence of cylinder head bolts is: 3rd cylinder –4th cylinder – 5th cylinder – 2nd cylinder– 1st cylinder – 6th cylinder (4) The tightening torque of cylinder head bolts should be: M14-12.9: (230~300)Nm; M14-10.9:(190~285)Nm. Key point 2: Assembling: Install the greased seal ring to the welded elbow, insert the elbow into the corresponding hole, and fix it on the cylinder block by using a fixing plate,hexagon socket bolts and spring washers. Key point 3: Inspection: 1) Check the protrusion height of cylinder liner (it should be 0.05mm-0.10mm); Notice: The protrusion heightof cylinder liner is the average ofthe protrusion measurements in the directions of X and Y without seal rings on cylinder block and cylinder liner; the grouping mark for cylinder liners of the same cylinder block should be the same. 2) Check that the mating face and friction surface are free of dust, scratches and impact damages, and before assembling, apply clean lubricating oil or grease. Assembling:Place the cylinder liner on the cylinder block vertically, install the seal rings ofcylinder block and cylinder liner into position, put the cylinder liners into corresponding bore holes vertically, and knock them in place with a nylon bar. Key point 4: Disassembling:Remove the camshaft bushing by using special tooling, and be careful not to damage other bushings; 36



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Inspection: Before assembling the bushing, always clear the grease on thebacks ofbushing andbearing and the mating bottom hole surface; ensure that the bushing, bearing and bottom hole are free of burrs, flashings and iron chips etc. Assembling: Apply lubricating oil to the port/hole of cylinder block, install the camshaft bushing into the special tooling, and guide it into the cylinder block,align the camshaft bushing oil duct hole with cylinder block oil passage hole. Key point 5: Assembling:Install the threaded rod with a special tool, and install steel ball, spring and acorn nut with washer, and tighten them with an open-end wrench. 4.2.1.4 Assembling steps of cylinder block group Assemble the cylinder block group with the reverse order of disassembly.



4.2.2 Disassembly and assembly of cylinder block 4.2.2.1 Exploded view of cylinder block assembly The cylinder block assembly consists mainly of cylinder block, main bearing cap, main bearing bolt and thrust bearing cap (see figure 4-3).



Cylinder block



Thrust bearing cap Main bearing cap



Main bearing bolt



Main bearing bolt



Figure 4-3 Exploded view of cylinder block assembly 4.2.2.2 Disassembling steps of cylinder block assembly ① Remove the main bearing bolts (key point 1); ②Remove the main bearing caps (key point 2). 4.2.2.3 Inspection and repair of cylinder block assembly 37



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Key point 1: Inspection: Check and clean the cylinder block, including but not limited to: the assembly site must be clean; checking that the machined surface of cylinder block from the cylinder block line is free of impact damages, scratches and rust stains; prevent the parts from beingimpact damaged and scratched in assembling; chamfering the sharp angles and edges unless otherwise specified. Installation: For the 6-cylinder engine, a total 14 main bearing bolts (M14-10.9) are used.When tightening, tighten the bolts of the middle bearing firstly, and then that of the adjacent bearings, at last, tighten the bolts of main bearings at two ends (figure 4-4).The bolts should be tightenedin two times, that is, tighten them with a torque of 70Nm first, and then turn them by angle of 90°±4°.



Figure 4-4 Tightening order of main bearing bolts Key point 2: Installation: Install the thrust bearing cap onthe rear end of cylinder block, and install non-thrust bearing caps to other positions. Pay attention to distinguishing two ends of the bearing cap for a proper positioning, and if the bearing cap is reversed, the main bearing bolt cannot be mounted. 4.2.2.4 Assembling steps of cylinder block assembly Assemble the cylinder block assemblywith the reverse order of disassembly.



4.2.3 Disassembly and assembly of front end cover 4.2.3.1 Exploded view of front end cover The front end cover assembly consists mainly of the front end cover, sealing ring, bolt and washer (figure 4-5).



38



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 4-5 Exploded view of front end cover 4.2.3.2 Disassembling steps of front end cover ①Remove the breather; ②Remove the cover plate; ③Unscrew the screw plug; ④Remove the front end cover (key point 1); ⑤Remove the radial seal ring (key point 2). 4.2.3.3 Inspection and repair of front end cover Key point 1: Inspection: Check the front wall cover for cleanness, check the mating face fordamage and burrs, and check the seal ring for damage. Assembling: 1) Knock the locating pin into position as shown in figure 4-6.



39



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 4-6 Position of locating pin 2) Use a roller to apply sealant to the mating face of front end cover uniformly (figure 4-7).



Figure4-7 3)



Align the pin holes, set the front end cover onto position, and knock the side of front end cover gently by using a nylon rod,to make the front end cover contacting with the cylinder block completely (figure 4-8).



Knockingthe sides



Figure4-8 4) Insert the bolts into the corresponding thread holes, install the matched washers and tighten the bolts with pneumatic wrench or open-end wrench. Tightening order of bolts is shown in figure4-9.



40



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure 4-9 Tightening order of bolts is shown Note: For the M8 bolt and M10, the pneumatic wrench is set to thesecond and the thirdgears respectively. Tighten the bolts of No. 3, 7, 10 and 18 in order first, then tighten the other bolts in sequence. For No. 5 bolt with copper washer, screw on with pneumatic wrench and then tighten it with open-ended spanner. Bolt sizes: M8*45: No. 1, 2, 19, 20 and 21 bolts; M10*90: No. 4bolt; M8*75: No. 5, 7, 8, 9 and 10bolts; If No. 9 and No. 10 bolts are for alternator bracket, the bolt size should be M8*90; M8*25: No. 11 and 15bolts; M8*35: No. 16 and 17 bolts.



Key point 2: Assembling: Before assembling, check the oil seals and seal rings are for damage and check the mating face for dirt. If the oil seal or seal ring is relative tight, it is recommended to apply clean oil to the shaft, and use a special tool to press it in slowly with the force uniformly applied to the sides of oil seal or seal ring. Disassembling: After the removal of oil seal, replace it with a new one. 41



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.2.3.4 Assembling steps of front end cover Assemble the front end cover with the reverse order of disassembly.



4.2.4 Disassembly and assembly of flywheel housing 4.2.4.1 Exploded view of flywheel housing The flywheel assembly consists mainly of flywheel, inspection window, gasket and bolt. See figure4-10. Hexagon head bolt Inspection window cover



Spring washer Gasket



Hexagon head bolt Hexagon head bolt Radial seal ring



Flywheel housing



Figure4-10 Exploded view of flywheel housing 4.2.4.2 Disassembling steps of flywheel housing ① Unscrew the fixing bolts of flywheel housing (key point 1); ②Unscrew the fixing bolt ofinspection window on flywheel housing and remove the inspection window cover; ③ Remove the flywheel housing (key point 2); 4.2.4.3 Inspection and repair of flywheel housing Key point 1: Assembling: Check the flywheel housing for cleanness. Remove the burs on corresponding mating face of cylinder block with a 240# fine oil stone, clean the surface with ethyl alcohol, and apply sealant to the mating face of flywheel and the cylinder block. Step 1: Preinstall the bolts. 42



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Step 2: Tighten the bolts. For M10 bolts, tighten them with the torque of (80~85) Nm according to the direction as indicated by the arrowin figure 4-11; for M12 bolts, tighten them with the torque of (140~145) Nmin sequence of 1-2-3-4-5-6.



Figure4-11 Notice: Thethreads and bearing face of strengthening bolts above should be applied with lubricating oil before mounting. 4.2.4.4 Assembling steps of flywheel housing Assemble the flywheel housing with the reverse order of disassembly.



4.2.5 Disassembly and assembly of oil pan 4.2.5.1 Exploded view of oil pan The oil pan assembly consists mainly of oil pan, magnetic screw plug, gasket and bolt. See figure4-12.



Oil pan



Figure4-12 Exploded view of oil pan 43



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.2.5.2 Disassembling steps of oil pan 1) Place the diesel engine withoil pan upwards (key point 1); 2) Unscrew the fixing bolts of oil pan (key point 2); 3) Remove the oil pan and gasket; 4) Remove the magnetic screw plug and washer. 4.2.5.3 Inspection and repair of oil pan Key point 1: Disassembling: Drain the oil inside before removing the oil pan. For this purpose, place an appropriate container under the drain plug of oil pan, and unscrew the drain plug by using a plug wrench to drain the oil. Key point 2: Assembling: 1) Apply sealant to cylinder block mating face along the threaded hole inner side (for stamped oil pan, coated with sealant partially, and set a gasket on the mating face); 2) Align the oil pan with the cylinder block mating face gently to avoid damaging the contacting face; 3) Set the bolt and gasket, and use a pneumatic wrench to tighten the bolts with a torque of (20-35) Nm. 4.2.5.4 Assembling steps of oil pan Assemble the oil panwith the reverse order of disassembly.



4.2.6 Disassembly and assembly of piston cooling nozzle 4.3.6.1 Exploded view of piston cooling nozzle Piston cooling nozzle assembly consists mainly of nozzle assembly, bolt and gasket. See figure4-13.



44



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Gasket Spring washer Hexagon head bolt



Seal ring



Nozzle assembly



Figure4-13 Exploded view of piston cooling nozzle 4.2.6.2 Disassembling steps of piston cooling nozzle ①Unscrew the hexagon head bolts (key point 1); ②Remove the nozzle assembly (key point 2). 4.2.6.3 Inspection and repair of piston cooling nozzle Key point 1: Assembling: ①Clamp the nozzle assembly with bolts and clamp plate; ②Place the clamp plate on the concave plane of spray nozzle end face; ③Tighten the bolt with TOKU pneumatic wrench at second gear. Key point 2: Inspection: Check the O-ring for damage, and check the cylinder block nozzle hole for cleanness without burrs. 4.2.6.4 Assembling steps of piston nozzle Assemble the piston nozzle with the reverse order of disassembly.



4.2.7 Disassembly and assembly of thrust washer 4.2.7.1 Exploded view of thrust washer 45



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



The position of thrust washer is shown in figure4-14.



Thrust washer



Figure4-14 Exploded view of thrust washer 4.2.7.2 Disassembling steps of thrust washer ①Remove the main bearing cap; ②Remove the crankshaft; ③Remove the thrust washer (key point 1). 4.2.7.3 Inspection and repair of thrust washer Key point 1: Assembling: Thrust washers should be used in pair. To assemble the thrust washer, the side with oil grooveshould outwards, and place the "lug" into the thrust bearing cap correspondinglyto avoid wrong installation. 4.2.7.4 Assembling steps of thrust washer Assemble the thrust washer with the reverse order ofdisassembly.



4.2.8Disassembly and assembly of front/rear oil seals 4.2.8.1 Exploded view of front/rear oil seals The mounting positions of front/rear oil seals are shown in figure4-15.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-15 Exploded view of front/rear oil seals 4.2.8.2 Disassembling steps of front/rear oil seals 1) Remove the front end cover; 2) Remove the front oil seal; 3) Remove the rear oil seal (key point 1). 4.2.8.3 Inspection and repair of front/rear oil seals Key point 1: Inspection: Check the seal ring and the oil seal for damage; and check the rear oil seal cover for cleanness and visible scratches on machining face. Assembling: Apply sealant to the outer side of rear oil seal (radial seal ring), and press it into the rear oil seal cover with a special tooling. Notice: The seal ring should be such assembled that its outer end face is flush with the oil seal cover plane without any damage. 4.2.8.4 Assembling steps of front/rear oil seals Assemble the front/rear oil sealswith the reverse order of disassembly. 4.2.9 Disassembly and assembly of cylinder head group 4.2.9.1 Exploded view of cylinder head group The cylinder head group consists mainly of cylinder head, gasket, cylinder head cover and bolt. See figure 4-16.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-16 Exploded view of cylinder head group 4.2.9.2 Disassembling steps of cylinder head group 1)Remove the air filter. Refer to disassembling instructions of intake/exhaust system for details; 2)Remove turbocharger and connecting pipeline. Refer to disassembling instructions of intake/exhaust system for details; 3) Remove fuel return pipe of fuel injector and highpressure fuel pipe. Refer to disassembling instructions of fuel system for details; 4) Remove the thermostat and water outlet pipe; 5) Remove the exhaust manifold. Refer to disassembling instructions of intake/exhaust system for details; 6) Remove the intake manifold. Refer to disassembling instructions of intake/exhaust system for details; 7) Remove the cylinder head cover and its gasket; 8) Remove the fuel injector. Refer to disassembling instructions of fuel system for details; 9) Remove the rocker arm assembly and push rod. Refer to disassembling instructions of valve train for details; 10) Remove the lubricating oil pipe of cylinder head; 11) Remove the cylinder head assembly and cylinder head gasket; 12) Remove the valve inner/outer springs, intake/exhaust valve spring upper/lower seat, valve collet and valve etc. Refer to disassembling instructions of valve train for details; 13) Remove the valve stem seal. 4.2.9.3 Assembling steps of cylinder head group Assemble the cylinder head group with the reverse order of disassembly.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.2.10Disassembly and assembly of cylinder head cover 4.2.10.1 Exploded view of cylinder head cover The cylinder head cover group consists mainly of cylinder head cover, gasket, bolt and washer. See figure4-17.



Lifting eye



Cylinder head cover



Figure4-17 Exploded view of cylinder head cover 4.2.10.2 Disassembling steps of cylinder head cover 1) Loosen the bolts of cylinder head cover in order; 2) Take out the cylinder head cover and its gasket upward vertically. 4.2.10.3 Inspection and repair of cylinder head cover 1) Check the cylinder head cover for damage (such as cracks). In case of any crack, replace it with a new one; 2) If the leakage occurs to the gasket of cylinder head cover, check the gasket for failure and replace it with a new one; 3) The gasket of cylinder head cover can be used onceonly. Always replace it with a new one when it is returned for repair. 4.2.10.4 Assembling steps of cylinder head cover 1) Before assembling, check the gasket of cylinder head cover and the surface of cylinder head for defect and damage; 2) Apply clean oil at the connecting places of rocker arm and valve, the connecting place of rocker arm and tappet and at the middle of the two places; 49



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



3) Set the gasket of cylinder head cover with the graphite layer upwards; 4) Set the cylinder head cover; 5) Adjust the gasket to the middle of cylinder head cover so that their U-grooves are aligned with each other and there is gasket appearing around the cylinder head cover; 6) Tighten the bolts of cylinder head cover with a torque of (10~15) Nm. During the tightening, note to prevent the gasket of cylinder head cover deviating from the original position. 4.2.11Disassembly and assembly of cylinder head 4.2.11.1 Exploded view of cylinder head The cylinder head assembly consists mainly of cylinder head and the main parts of valve train. See figure4-18.



Cylinder head cover Cylinder head cover gasket Rocker bracket assembly Pipe connector Cylinder head bolt Cylinder head Bowl plug Exhaust valve Intake valve Cylinder head gasket Valve stem seal



Figure4-18 Exploded view of cylinder head



4.2.11.2 Disassembling steps of cylinder head 1) Disassemble the cylinder head cover; 2) Disassemble the fuel injector. Refer to disassembling instructions of fuel system for details; 3) Loose the bolts of cylinder head with the reverse order of assembly (refer to the figure for assembling steps of cylinder head); 50



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4) Take out the cylinder head upward vertically. Before removing, always make sure that the fuel injector has been taken down. During removing, do not shake the cylinder head preventing residual coolant flows out. If the gasket is attached to the cylinder head, take it out and place it back onto the cylinder block; 5) Disassemble the cylinder head and place it on the paper board preventing the upper surfaceand other sealing surface of combustion chamber being worn. To disassemble several cylinders, mark the cylinder number on the cylinder head for the convenience of problem analysis; 6) Remove the cylinder head gasket. To disassemble several cylinders, mark the cylinder number on the cylinder head gasket for the convenience of problem analysis; 7) Disassemble the intake/exhaust valve assembly. Refer to disassembling instructions of valve train for details; 8) Disassemble the valve stem seal. 4.2.11.3 Inspection and repair of cylinder head Before disassembling the cylinder head, check the cylinder head for water/oil/air leakage and other abnormal symptoms for the convenience of locating the failure and analyze the problem accurately. Clean the cylinder head (take care to clean the surface of combustion chamber, valve seat, intake/exhaust valve, air inlet/outlet port), remove the carbon deposit from the surface, and check for surface condition. 1) Appearance inspection Carefully check the cylinder head for discoloration and crack. If any crack is found, conduct dye penetrant inspection. 2) Valve sinkage checking The valve sinkage is the vertical distance between the valve bottom and the base plane of cylinder head. The difference between the measured value and required value of valve sinkage indicates the wear of valve and valve seat. A depth micrometer can be used to measure the valve sinkage as shown in Figure4-19.



Figure4-19 Depth micrometer For the required value of valve sinkage, please refer to Table 4-2. If the sinkage exceeds the permissible range, replace the cylinder head to ensure the reliability of diesel engine. If the valve sinkage does not exceed the permissible valve, remove the valve, check the sealing surface of valve and valve seat ring for obvious wear and abnormal damage. 51



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Table 4-2 Required valve sinkage Required valve sinkage (mm) Intake valve



1.0~1.45



Exhaust valve



1.0~1.45



3) Clearance between valve stem and valve guide The inside diameter of valve guide is the contact surface of valve guide and valve. If the clearance between valve guide and valve stem exceeds the permissible value, it willaffect guiding of valve and the reliability of diesel engine. Use aninside micrometer to measure the inside diameter of valve guide as shown in figure4-20, and use an outside micrometer to measure the outside diameter of valve guide. The permissible clearance range between the intake/exhaust valve stem and the corresponding valve guide is (0.03-0.06) mm. If the clearance exceeds the specified, replace the cylinder head to make sure the reliability of diesel engine.



Figure4-20 Inside micrometer 4) Cylinder head gasket If water/oil/air leakage occurs to the cylinder head gasket, check and replace the gasket. Check the gasket of cylinder head for visible damage and analyze the cause. No matter whether the gasket of cylinder head is failure or not, please replace with new one as long as it is removed. 4.2.11.4 Assembling steps of cylinder head 1) Pre-assemble the intake/exhaust valve assembly; 2) Assemble the cylinder headgasket (thickness: 1.4mm); 3) Assemble the cylinder head to the cylinder block; 4) Install the cylinder head boltswithout tightening; 5) Tighten the bolts of cylinder head to 30Nm, rotate them by an angle of 120°±4°, and rotate themby another angle of 120°±4°; 6) Tighten the bolts of cylinder heads from the 1st cylinder to 6th cylinder. For the bolts of each cylinder, the tightening order is shown in figure4-21.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-21 tightening order  4.2.12Disassembly and assembly ofoil-gas separator 4.2.12.1 Exploded view of oil-gas separator The oil-gas separator consists mainly of oil-gas separator assembly, connecting rubber hose, bolt and washer. See figure4-22.



Bracket



Connecting rubber hose Clamp Oil-gas separator assembly Spring Hose Clamp O-ring



Breather Gasket Bolt



Figure4-22 Exploded view of oil-gas separator 4.2.12.2 Disassembling steps of oil-gas separator 1)



Loosen the clamps;



2)



Removethe connecting rubber hose;



3)



Remove the hexagon head bolt fixing the oil-gas separator; 53



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4)



Remove the oil-gas separator and bracket, and take out the spring;



5)



Remove the hose connecting oil-gas separator and breather;



6)



Loosen the bolts, and disassemble the breather and O-ring.



4.2.12.3 Inspection and repair of oil-gas separator 1) Check the rubber hose for aging. Replace any seriously aged and cracked hose; 2) Check the outer surfaces of breather and oil-gas separator for cracks. In case of deep crack or the crack has led to or is likely to lead to leakage, replace them timely; 3) Check the joints for oil leakage. Tighten the corresponding joint if necessary. 4.2.12.4 Assembling steps of oil-gas separator Assemble the oil-gas separator with the reverse order of disassembly. 4.2.13Disassembly and assembly of lifting eye 4.2.13.1 Exploded view of lifting eye The position of lifting eye on the engine is shown in figure4-23.



Lifting eye bolt



Figure4-23 Exploded view of lifting eye 4.2.13.2 Disassembling steps of lifting eye After the parts covering the lifting eye screw are removed, remove the lifting eye screw. 4.2.13.3 Inspection and repair of lifting eye Check the outer surface of lifting eye screw and inner threaded hole for crack. In case of any crack, replace it with a new one. 4.2.13.4 Assembling steps of lifting eye 54



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Assemble the lifting eye with the reverse order of disassembly.



4.3 Crank and connecting rod mechanism 4.3.1 Disassembly and assembly of crank and connecting rod mechanism 4.3.1.1 Exploded view of crank and connecting rod mechanism The crank and connecting rod mechanism is divided to crankshaft and flywheel group and piston and connecting rod group. See figure4-24. Piston and connecting rod assembly Flywheel ring gear Crankshaft timing gear Crankshaft pulley



Flywheel Crankshaft



Vibration damper Hub



Vibration damper bolt Flywheel bolt Hub bolt Mainbearing



Figure4-24 Exploded view of crank and connecting rod mechanism 4.3.1.2 Disassembling steps of crank and connecting rod mechanism (1)Checking before disassembling: Check the axial clearance of connecting rod and the tightening torque of connecting rod bolts. Place the engine obliquely, rotate the flywheel to make the pistonto be removed to BDC, and remove the connecting rod cap and bolt; make the piston to TDC, knock out the piston with a wood hammer carefully, preventing the cylinder block from being blocked by connecting rod big end. Remove the remaining pistons following the same method, and place them in order. (2) Unscrew the vibration damper bolt, hub bolt, and remove the crankshaft pulley, torsional vibration damper and hub etc. (3) Unscrew the flywheel bolt, and remove the flywheel assembly, bearing and other related parts. 4.3.1.3 Assembling steps of crank and connecting rod mechanism Assemble the crank and connecting rod mechanism with the reverse order ofdisassembly.



4.3.2 Disassembly and assembly of piston and connecting rod group 4.3.2.1 Exploded view of piston and connecting rod group (figure4-25)



55



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Piston and connecting rod assembly



Cylinder block assembly



Piston and connecting rod assembly



Crankshaft



Figure4-25 Assembling position of piston and connecting rod group



The piston and connecting rod group consists mainly of piston, piston ring, piston pin, pin circlip, connecting rod body, connecting rod cap, connecting rod bush, connecting rod bearing and connecting rod bolt. See figure4-26. 1st compression ring



2nd compression ring



Piston pin Piston pin circlip



Oil ring



Piston Connecting rod body Elastic locating pin Connecting rod bush Connect rod cap Connecting rod bearing (upper half) Connecting rod bearing (lower half)



Connecting rod bolt



Figure4-26 Exploded view of piston and connecting rod assembly 4.3.2.2 Disassembling steps of piston and connecting rod assembly (1) Inspections before disassembling. Check the axial clearance of connecting rod and the tightening torque of 56



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



connecting rod bolt. (2) Place the engine tilted on its position, rotate the flywheel to make the pistonto be removed to BDC, and remove the connecting rod cap and bolt. (3)Makethe piston to TDC, knock out the piston with a wood hammer carefully, preventing the cylinder block from being blocked. (4) Remove the remaining pistons following the same method, and place them in order. (5) Use internal circlip pliers to remove the circlips at both sides of piston pin carefully, push out the piston pin and remove the connecting rod body. Number the piston pins and connecting rod bodies respectively, and place them in order. (6) Use a piston ring pliers to remove the 1st compression ring, 2nd compression ring and the oil control ring, and mark them respectively. 4.3.2.3 Inspection and repair of piston and connecting rod assembly (1) Check the rounded corner at the throat of piston combustion chamber and the piston pin seat for cracks; check the skirt and head of piston for cylinder scuffing; check the piston pin hole for excessive wear. (2) Check the outer perimeter and the upper and lower end faces of the piston ring for excessive wear. (3) Check if the outer perimeter of the piston ring is excessively worn. (4) Check the large end bottom hole, body and small end oil hole of connecting rod for cracks; check the alloy layer of connecting rod bush for abnormal wear or spalling; check the connecting rod sides for abnormal wear, and check the connecting rod body for bending. (5) Check the connecting rod bearing for wear, and the alloy layer for discoloring and metal spalling etc. 4.3.2.4 Assembling steps of piston and connecting rod (1) Use internal circlip pliers to install one circlip into the piston circlip groovewith the edged face inwards, and rotate the circlip for secure installation. The opening of piston ring circlip should be upwards. (2) Insert the small end of connecting rod into the piston cavity, align the connecting rod small end withthe piston pin hole and install the piston pin; finally, install the piston pin circlip on the other side. Pay attention to that the oblique cut of connecting rod should be in the same direction with the inlet hole of piston cooling oil duct, and the connecting rod small end hole and piston pin should be applied with appropriate clean lubricating oil before assembling. (3) Arrange the installed piston and connecting rod assemblies in order by the cylinder number, and use a piston ring pliers to install the oil control ring, 2nd compression ring and 1st compression ring into the piston ring grooves in sequence, ensuring that the side with "TOP"of piston ring upwards, and the ring can move flexibly in the ring groove. (4) Wipe the cylinder inner wall, crank arm and piston and connecting rod assembly, and apply clean lubricating oil to the moving pair parts. (5) Adjust the opening orientation of rings: the opening of 1st compression ring should be 30° away from the piston pin centerline, the opening of 2nd compression ring should be 120° away from that of the 1st compression 57



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



ring, and the opening of oil controlring should be 120° away from both openings of the 1st ring and 2nd ring, as shown in figure4-27.



2nd compression ring



1st compression ring



Horizontaldirecti on of iston pin



Oil control ring



Figure4-27 Schematic diagram for included angles between piston rings (6)Rotate the crankshaft to make the pistons ofNo. 1 cylinder and No. 6 cylinder near the BDC, install the piston and connecting rod assembly of No. 1 cylinder and No. 6 cylinder, and install the connecting rod bolt without tightening, always with the parting surface of connecting rod towards the left side of cylinder block (i.e. the side of oil cooler). Pay attention to that the piston number should be identical to the cylinder number, the connecting rod cap should be used in pairs with the connecting rod body, and the connecting rod bolt should be applied with clean lubricating oil before installation. (7) Tighten the connecting rod bolts as follows: Screw on the bolts, and tighten them diagonally with a torque of 30Nm, rotate them by an angle of 58°~65° to a torque of (85~135) Nm finally. Complete the installation for remaining cylinders following the same method. 4.3.3 Disassembly and assembly of crankshaft and flywheel group 4.3.3.1 Exploded view of crankshaft and flywheel The crankshaft and flywheel group consists mainly of crankshaft, main bearing, timing gear, vibration damper, flywheel, ring gear. See figure4-28. Flywheel ring gear Crankshaft timing gear Vibration damper



Flywheel



Crankshaft



Crankshaft pulley Hub Vibration damper bolt



Flywheel bolt Hub bolt



Mainbearing



Figure4-28 Exploded view of crankshaft and flywheel group



58



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.3.3.2 Disassembling steps of crankshaft and flywheel group (1) With the cylinder block cap upwards, remove the main bearing bolts, and place them in order. (2) Remove the crankshaft, flywheel and then the front/rear thrust washers and the bearing at flywheel end. Take out the oil seals; place the crankshaft on the carrier frame (the crankshaft should be vertically placed in case of long-time placement). (3)Place the removed parts as required. 4.3.3.3 Inspection and repair of crankshaft and flywheel group (1) Check rounded corners of the main bearing journal and connecting rod journal, the contacting part ofcrankshaft and bearing shell and the oil duct for cracks or other abnormalities. (2) Check the main bearing journal and connecting rod journal for wear, visible linear traces, metal spalling and cracks. (3) Check the wear condition of front/rear oil seals. (4) Check the main bearing bolts for thread damage or other failures. (5) Check the threaded holes of crankshaft flange end for cracks. (6) Check the main journal for wear and check the crankshaft forbending and distortion conditions. 4.3.3.4 Assembling steps of crankshaft and flywheel group (1)Clean the main bearing bottom hole of cylinder block. (2) Press the upper bearing shell into the main bearing bottom hole of cylinder block, and wipe away the foreign matters scraped at bearing port. a.The upper bearing shell should be checked for scratches strictly before installing, and the damaged bearing should not be reused. b.The upper bearing shell should be aligned with the oil hole and oil groove on the cylinder block after installation, and any deviation above 1/5-1/4 of the oil hole diameter is not allowed; the upper bearing shell should fit well with the main bearing bottom hole of the cylinder block. (3) Apply appropriate clean lubricating oil to the inside of main bearing shell. (4) Remove the oil on the lower surface of cylinder block. (5) Apply sealant evenly on the lower surface of cylinder block with rubber roller. (6) Lift the crankshaft, clean the oil duct hole with compressed air, clean the main bearing journal and connecting rod journal with a towel, and place it into the cylinder block gently, preventing the crankshaft from being damaged. (7)Clean the upper thrust plate and press in cylinder block with the oil groove towards outside (with the oil groove towards the crankshaft). 59



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



(8) With the oil seal flat without distortion, place the oil seal flatly into the seal ring groove on the lower plane of cylinder block with special tooling. (9)Installthe lower main bearing shell and lower thrust plate into the crankcase (with the oil groove facing crankshaft), install the crankshaft. (10) Apply clean lubricating oil to the thread bearing face of crankshaft bolt and the threads of main bearing bolt, install the main bearing bolts without tightening, and then tighten all main bearing bolts in the sequence as shown in Figure4-29. The bolts should be tightenedin twice, that is, tighten them with a torque of 70Nm first, and then rotate them by angle of 90°±4°, thus the assembling of crankshaft is completed.



Figure4-29 Tightening sequence of main bearing bolts



4.3.4 Disassembly and assembly of flywheel and ring gear 4.3.4.1 Exploded view of flywheeland ring gear The flywheel and ring gear group consists mainly of flywheel, ring gear, locating pin and flywheel bolt. See figure4-30. Flywheel



Flywheel ring gear Crankshaft



Flywheel bolt



Locating pin



Figure4-30 Exploded view of flywheel and ring gear 4.3.4.2 Disassembling steps of flywheel and ring gear 60



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Disassemble the flywheel and ring gear with the reverse order ofassembly. 4.3.4.3 Inspection and repair of flywheel and ring gear (1) Check the flywheel bolts for thread damage or other failures. (2) Check the flywheel surface for crushing damage. (3) Check the flywheel ring gear for damage. 4.3.4.4 Assembling steps of flywheel and ring gear (1)Bolt the flywheel ring gear together with the flywheel. (2) Knock a straight pin into the rear end of crankshaft completely. (3) Insert a guide bar into the crankshaft threaded hole, install the flywheel, and tighten the flywheel bolts diagonally. ① Apply lubricating oil to the threads and bearing face of flywheel bolts. ② Flywheel bolt specification: M16-12.9 (6 PCS); tightening torque: (285~295) Nm; check value: (285~340) Nm.



4.3.5 Disassembly and assembly of torsional vibration damper, pulley and hub 4.3.5.1 Exploded view of torsional vibration damper, pulley and hub The torsional vibration damper, pulley and hub group consists mainly of torsional vibration damper, crankshaft pulley, hub and bolt. See figure4-31. Crankshaft timing gear Crankshaft



Torsional vibration damper Hub



Crankshaft pulley



Torsional vibration damper bolt



Hub bolt



Figure4-31 Exploded view of torsional vibration damper, pulley and hub 4.3.5.2 Disassembling steps of torsional vibration damper, pulley and hub Remove the pulley bolts, take down the pulley and vibration damper. 4.3.5.3 Inspection and repair of torsional vibration damper, pulley and hub 61



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



(1) Check damper for impactdamage and deformation etc. (2) Check the pulley and hub for damage and crushing damage. (3) Check the hub bolt and vibration damper bolt for damage. 4.3.5.4 Assembling steps of torsional vibration damper, pulley and hub With timing gear properly installed, install the hub, torsional vibration damper and pulley in sequence； (1) Tighten the hub onto the crankshaft with hub bolts (bolt specification: M16-12.9 (4 PCS); tightening torque: (300~310) Nm, check value: (300~360) Nm). (2) Tighten the pulley and torsional vibration damper onto the hub with vibration damper bolts (bolt specification: M10-10.9 (6 PCS); tightening torque: 65-70 Nm, check value: 65-80 Nm).



4.3.6 Disassembly and assembly of crankshaft bearing 4.3.6.1 Exploded view of crankshaft bearing The crankshaft bearing group consists mainly of main bearing upper half and lower half. See figure4-32.



Main bearing lower half



Crankshaft



Main bearing upper half



Figure4-32 Exploded view of crankshaft bearing 4.3.6.2 Disassembling steps of crankshaft bearing shell Push out the bearing shellfrom side with hands, and make marks on the removed bearing shells according to the seat holes of cylinder block and crankcase. 4.3.6.3 Inspection and repair of crankshaft bearing shell (1) Clean the bearing shell and check for wear condition. (2) Check the bearing shell for metal spalling, locating lip damage and transvers cracks. 4.3.6.4 Assembling steps of crankshaft bearing shell (1) Clean the main bearing shell and mounting bottom hole. (2) If the bearing shell is not to be replaced, refitit into the cylinder block (upper bearing) and crankcase (lower 62



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



bearing) with the reverse order of disassembly (Notice: The upper bearing has oil groove); if the bearing shell is to be replaced, install the new bearing directly. When installing, apply small amount of lubricating oil to the bearingand align the lips of bearing shells.



4.4 Valve train 4.4.1Disassembly and assembly of valve train 3.4.1.1 Exploded view of valve train The valve train is divided to valve group and valve driving group. The valve group consists mainly of valve, valve guide, valve seat and valve spring. The valve driving group consists mainly of camshaft, timing gear, tappet, push rod, rocker, rocker shaft. See figure 4-33 for details.



Rocker bracket



Hexagon bolt



Butterfly spring washer



Valve collet



Hexagon nut



Shaft elastic retainer ring Valve internal spring



Rocker arm



Valve external spring



Adjusting screw



Valve spring lower seat



Valve spring upper seat



Camshaft



Valve stem seal Cylinder head



Injection pump gear Camshaft timing gear



Valve



Hexagon sockethead cap screw



Valve tappet



Flange Hex flange bolt Hex flange bolt



Cylinder block



Sector plate



Figure4-33 Exploded view of valve train 4.4.1.2Disassembling steps of valve train 1) Remove the rocker arm and the rocker arm shaft; 2) Remove the intake/exhaust valve; 3) Remove the tappet and the push rod; 4) Remove the camshaft and the camshaft timing gear. 4.4.1.3 Assembling steps of valve mechanism Assemble the valve trainwith the reverse order ofdisassembly. 4.4.2 Disassemblyand assembly of camshaft 4.4.2.1Exploded view of camshaft 63



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Injection pump gear Camshaft



Camshaft timing gear



Hexagon socket head cap screw Flange Hex flange bolt



Hex flange bolt Cylinder block



Sector plate



Figure4-34 Exploded view of camshaft and timing gear 4.4.2.2Disassembling steps of camshaft Assemble the camshaftwith the reverse order ofdisassembly. 4.4.2.3 Inspection and repair of camshaft and timing gear ①Check the cam surface contacting to the valve tappet for wear and check the main journal for seizure and wear; ②Check the timing gear fastening hexagon head bolt for deformation, check the camshaft timing gear and the injection pump gear for teeth collision damage or the teeth surface for serious wear. 4.4.2.4 Assembling steps of camshaft After disassembling the camshaft, check the camshaft, timing gear and injection pump gear; if there is any wear or large deviation of part size, repair the related part, or replace with new ones. ①Check the parts for burrs, impact damages and ensure that the surface has no rust, scratches and impurities such as iron chips. ②Apply a proper amount of clean oil to the camshaft holes and the valve tappet holes, then install the valve tappet and camshaft.During installation, avoid damages to the camshaft surface and the cylinder block holes, and ensure that the camshaft end with threads is located at the front end cover side. ③Install the sector plate and tighten the bolts to (35±10)Nm, and then perform paint sealing; ④ Install the camshaft at the front end of the cylinder block,then install the shim, flange, washer, hexagon head bolt and measure the axial clearance of the camshaft which shall be 0.1-0.29mm; if the clearance is too small, check if there is burrs in between the camshaft and the sector plate; and if the axial clearance above is still not meet the requirements after deburring, replace the camshaft. ⑤ Rotate the crankshaft to make the “0” point on the timing gear nearest to the camshaft; place the injection pump gear on the camshaft, and then install the camshaft timing gear to the camshaft and ensure that the “0” 64



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



pointson the camshaft gear and the crankshaft timing gear mesh with each other; ⑥After alignment of gear mesh points and self-inspection,if it is OK, identify the position of “0” points of camshaft timing gear and crankshaft timing gear with a marker. ⑦Adjust and align the asymmetric holes, and install the clean camshaft gear bolt applied with sealant KB277 into the flange hole and tighten the camshaft timing gear bolt by using a pneumatic wrench, and then tighten the bolt connecting the camshaft timing gear and the injection pump gear. Tightening torque of the gear connecting bolts: (85-90) Nm for the M10 bolt and (55-60) Nm for the M8 bolt. Thenperform paint sealing after tightening. Turn the crankshaft to check if the “0” points on gears mesh with each other. 4.4.3 Disassemblyand assembly of rocker arm and rocker shaft 4.4.3.1Exploded view of rocker arm and rocker shaft The rocker arm and rocker shaft group consists mainly of rocker arm, rocker arm support, adjusting screw and bolt. Hexagon head bolt



Rocker arm support



Hexagon nut



Butterfly spring washer



Rocker arm



Shaft spring washer



Adjusting screw



Cylinder head



Figure4-35 Exploded view of rocker arm and rocker shaft 4.4.3.2 Disassembling steps of rocker arm and rocker shaft 65



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



①Rotate the crankshaft and check the rocker arm for flexible rotation. ②Measure the valve clearance and check change of clearances. ③If the rocker arm cannot rotate flexibly or the valve clearance changes excessively, unscrew the hexagon head screw, then remove the rocker arm support, shaft elastic retainer ring, butterfly spring washer, rocker arm and butterfly spring washer.And then mark them with the cylinder numbers. 4.4.3.3 Inspection and repair of rocker arm and rocker shaft ①Clean the rocker arm and check the surface for cracks or other defects. ②Check the rocker arm inner hole for wear and scratches and measure its diameter. ③Check the rocker arm adjusting screw and arc surface at the other side of the rocker arm for wear. ④Check all oil passages for blockage. ⑤Measure the diameter of rocker arm hole and rocker shaft, and calculate the fitting clearance. 4.4.3.4 Assembling steps of rocker arm and rocker arm shaft ①Check all parts for cleanness without impact damages, scratches or rust; ②Install the rocker arm adjusting screw and nut, tighten the screw completely and the tighten the lock nut for 2-3 pitches; ③Apply a proper amount of lubricating oil on the rocker arm support and rocker arm hole,and install the butterfly spring washer, rocker arm assembly, butterfly spring washer and shaft elastic retainer ring in order to the rocker arm support; ④Use the hexagon bolt to install the rocker arm support to the cylinder head; ⑤Install the valve push rod; ⑥Install the rocker arm support, align the rocker arm adjusting screw socket head with the valve push rod ball end, and finally tighten the hexagon head bolt to (40~45) Nm; Inspection and adjustment of intake/exhaust valve clearance ①Turn the crankshaft till the phase pointer aligns with the “0” point of the phase plate, and check and ensure that the crankshaft timing gear “0” point meshes with camshaft gear “0” point; in this case, adjust the valve clearances of No. 1, 2, 3, 6, 7 and 10 rocker armsin the order. To adjust the intake valve: insert a 0.2mm feeler gauge, and use a torque wrench to tighten the nut to (20-25) Nm. And the plug gauge should be able to pullout with hand at this time. Andthen use a 0.25mm feeler gauge to check the clearance; it is acceptable only when the gauge cannot pass through the clearance. To adjust the exhaust valve: insert a 0.3mm feeler gauge, and then use a torque wrench to tighten the nut to (20±5) Nm. And the plug gauge should be able to pullout with hand at this time. And then use a 0.35mm feeler gauge to check the clearance; it is acceptable only when the gauge cannot pass through the 66



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



clearance. ②Turn the crankshaft till the phase pointer aligns with the “0” point of the phase plate, and observe and ensure that the crankshaft timing gear “0” point meshes with the 180°point of the “0” pointof camshaft gear. In this case, adjust the valve clearance of No. 4, 5, 8, 9, 11 and 12 rocker armsin the order in the same way withabove. 4.4.4Disassembly and assembly of tappet and push rod 4.4.4.1Exploded view of tappet and push rod The position of tappet and push rod on the engine is shown in figure4-36.



Cylinder head Push rod



Cylinder block



Tappet



Figure4-36 Exploded view of tappet and push rod 4.4.4.2 Disassembling steps ofvalve tappet and push rod; ①Remove the rocker arm and rocker shaft, take out the push rods and place them in order; ②After removal of camshaft, take out the valve tappets and place them in order. 4.4.4.3 Inspection and repair of valve tappet and push rod ①Clean the valve tappet and push rod; ②Check the oil passages of valve tappet and push rod for blockage; ③Check the push rod for bending and the external surface for wear condition; ④Check the ball end and concave end of the push rod for wear; ⑤Check the valve tappet surface and bottom surface for wear; ⑥Check the internal concave end of the valve tappet for wear. 4.4.4.4 Assembling steps of valve tappet and push rod 67



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



①Check if there is any defect occurs in the valve tappet and push rod; if any, replace with new ones.Before installing the valve tappet, clean it with compressed air, and then check the oil hole for blocking. ②Apply clean lubricating oil to the cylinder block tappet hole and valve tappet outer side evenly; ③Slightly place the tappet into the tappet hole from the lower side of cylinder block; the tappet should able to freely rotate in the tappet hole with even resistance. Install the camshaft. ④Install the rocker arm support to the cylinder head and check the push rod for cleanness and check the welding state. ⑤Apply clean lubricating oil to the push rod, and ensure that the ball end is sufficiently lubricated; ⑥Install the push rod onto the tappet. 4.4.5Disassembly and assembly of valve 4.4.5.1Exploded view of valve The valve group consists mainly of intake/exhaust valve, inner/out valve spring, valve seat, valve collet and valve stem. See figure4-37 for details.



Valve collet



Valve spring upper seat



Internal valve spring



External valve spring



Valve stem sealing sleeve



Valve spring lower seat



Cylinder head



Intake valve



Exhaust valve



Figure4-37 Exploded view of valve



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.4.5.2Disassembling steps of valve ① Compress the valve springs with valve spring compressor, valve spring pliers or other tools, take out the valve collets and remove upper valve spring seat and internal and external valve springs. ② Remove the valves from valve seats. 4.4.5.3 Inspection and repair of valve ① Check the valve rod and its end surface for abrasion. ② Check the valve cone for abrasion or damage. ③ Check the valve cone for carbon deposit. ④ Check the end surface of valve disc for carbon deposit or sintering. 4.4.5.4 Assembling steps of valve The valve shall be replaced in case of abrasion, carbon deposit or severe sintering etc. ① Apply molybdenum disulfide evenly on the rods of intake and exhaust valves, install the intake and exhaust valves in cylinder head to make sure that the intake and exhaust valves can move smoothly in the valve guide. ②Install the intake valve lower seat, preinstall the protector to the intake/exhaust valve stem, and then install the valve stem seal sleeve; Notice: Check if thespring inside the valve stem seal sleeve is intact before installation. ③Install the internal/external valve spring; ④Install the valve spring upper seat, press down the valve spring and install the valve collet; ⑤After assembling the valve collets, tap the intake and exhaust valves with rubber hammer to make sure correct installation. For valve collet or upper valve spring seat which is not installed in place, find out the causes and install again. .



4.5 Intake/exhaust system 4.5.1Disassembly and assembly of intake/exhaust system 4.5.1.1Exploded view of intake/exhaust system The intake/exhaust system consists mainly of intake manifold, exhaust manifold, turbocharger and air filter. See figure 4-38.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Intake manifold



Exhaust manifold



Turbocharger



Figure4-38 Exploded view of intake/exhaust system 4.5.1.2Disassembling steps of intake/exhaust system ①Unscrew the air filter mounting bolts and the rubber hose clamp, remove the air filter and connecting pipe; ②Loosen the connecting rubber hose clamp to remove the outlet connecting pipe of turbocharger compressor; ③Unscrew the turbocharger inlet/return oil pipe bolts to remove the turbochargerinlet/return oil pipe andgasket; ④Unscrew the exhaust tail tube bolts and turbocharger bolts to remove the turbocharger; ⑤Remove the heat shield bolts and the heat shield, and unscrew the exhaust manifold bolts to remove the exhaust manifold and gasket; ⑥Unscrew the intake manifold bolts to remove the intake manifold andgasket. 4.5.1.3 Assembling steps of intake/exhaust system Assemble the intake/exhaust system with the reverse order ofdisassembly. 4.5.2 Disassembly and assembly of intake manifold 4.5.2.1Exploded view of intake manifold The intake manifold group consists mainly of intake manifold, gasket and bolt. See figure4-39.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-39 Exploded view of intake manifold 4.5.2.2 Disassembling steps of intake manifold ①Unscrew the intake manifold bolts and remove the intake manifold and gasket. 4.5.2.3 Inspection and repair of intake manifold ①Check the intake manifold body for welding defects; if any, replace it with a new one. ②Check the intake manifold gasket for deformation, damage, missing or other defects; if any, replace it. 4.5.2.4 Assembling steps for intake manifold Assemble the intake manifoldwith the reverse order ofdisassemblywith bolt tightening torque of (45-50) Nm. 4.5.3 Disassembly and assembly of exhaust manifold 4.5.3.1Exploded view of exhaust manifold The exhaust manifold group consists mainly of exhaust manifold, exhaust connection tube and gasket. See figure4-40. Lock nut Stud Exhaust connection tube



Exhaust manifold Exhaust manifold gasket



Figure4-40 Exploded view of exhaust manifold 4.5.3.2Disassembling steps of exhaust manifold 71



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



①Unscrew the nuts and remove the exhaust connecting tube; ②Unscrew the exhaust manifold bolts and remove the exhaust manifold and gaskets. 4.5.3.3 Inspection and repair of exhaust manifold ①Check the exhaust manifold body for crack or other damages, check the flange for deformation; Replace it if necessary; ②Check the exhaust manifold flange for leakage; Replace the exhaust manifold gasket if necessary; ③Check the exhaust manifold gasket for deformation, damage, missing or other defects; replace it if necessary. 4.5.3.4 Assembling steps of exhaust manifold Assemble the exhaust manifoldwith the reverse order ofdisassembly. ① Apply anti-seize agent (molybdenum disulfide) to the exhaust manifold bolts; the tightening torque of bolt shall be (45~50) Nm; and the exhaust manifold bolt can only be used for twice at most. 4.5.4 Disassembly and assembly of turbocharging system 4.5.4.1Exploded view of turbocharging system The turbocharging system consists mainly of turbocharger, gasket, stud and nut. See figure4-41.



Figure4-41 Exploded view of turbocharging system 4.5.4.2Disassembling steps of turbocharging system Disassemble the turbocharging systemwith the reverse order ofassembly. 4.5.4.3 Inspection and repair of turbocharging system a. Check the running of rotor Turn the air compressor stator with hand; if it rotates for more than one turn, it indicates that it is normal; if it 72



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



stops rotating soon, it indicates that the bearing is worn abnormally or there is interference between the moving part and the fixed part or the moving part is blocked; in this case, you shall find out the causes and eliminate them. b. Check the axial play of rotor Place the measuring head of the dial indicator against the air compressor end, push and pull the rotating shaft with hand in the axial direction, and measure and record the difference value as shown in the figure 4-42. The rotor axial play shall be in the range of (0.088~0.118) mm; if it goes out of this range, it indicates that the thrust bearing plate or the thrust plate and bearing body are worn; in this case, you shall find out the causes and eliminate them.



Figure4-42 Measuring of axial play c. Check radial play of compressor impeller Press down or hold the compressor impeller by hand in the radial direction, and use the feeler gauge to measure the min/max clearancesbetween the compressor impeller and compressor casing as shown in figure4-43. The value shall be in the range of 0.4~0.8mm; if this value is exceeded, check the bearing and eliminate the failures. Note: Measurement shall be carried out at cold state.



Figure4-43 Measuring of radialplay



Daily maintenance: a. Check the pipeline connecting of turbocharger and engine for looseness; if any, eliminate it. b. Check the turbocharger for air and oil leakage; if any, eliminate it. 73



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



c. Check the turbocharger tightening screw for looseness; if any, eliminate it. d. Check the air filter; if excessive dust is found, clean it without delay. 4.5.4.4 Assembling steps for turbocharging system a. Install one end of the pre-installed turbocharger intake pipe to the cylinder block main oil passage. Pay attention to adjusting the position of intake pipe for connecting the turbocharger. b. Install the turbocharger gasket to the exhaust manifold flange. c. Install the turbocharger oil return pipe and stud to the turbocharger assembly, and apply 0# molybdenum disulfide and clean lubricating oil onto the stud. The tightening torque of oil return pipe bolt shall be 22-29 Nm. d. Install the gasket on the exhaust manifold flange to install the turbocharger assembly, and loosely install the style 2 all-metal hexagon lock nut and tighten it. e. Apply a proper amount of clean lubricating oil to the turbocharger intake port, and wipe the excessive lubricating oil. f. Install the turbocharger oil inlet pipe with gasket, screw on the bolts with washer and then tighten them with torque of 22-29 Nm. Check that the impeller of turbocharger shall be flexible without being blocked when rotating it. g. Install the turbocharger return hose and hose clamp and tighten them. Note that the two clamps shall be located in the same direction and the return pipe shall be aligned. h. Install the gasket, stud and connect the muffler. i. All the gaskets can only be used for once and shall be replaced when repairing.



4.6 Fuel system 4.6.1 Disassembly and assembly of fuel system 4.6.1.1 Exploded view of fuel system The fuel system consists mainly of primary fuel filter, fuel filter, high/low pressure fuel pipe, injection pump, injector and fuel return pipe. See figure 4-44 for details.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Injector



High pressure fuel pipe



Fuel return pipe of injection pump Fuel filter Low pressure fuel pipe



Injection pump



Figure 4-44 Exploded view of fuel system



4.6.1.2Disassembling steps of fuel system ①Remove the pipeline and wire of fuel system connecting the vehicle; ②Remove the low pressure fuel pip; ③Remove the air pipe of smoke limiter; ④Remove intake/exhaust manifold assembly; ⑤Remove the high pressure fuel pipe assembly; ⑥Remove the filter assembly; ⑦Remove the injector assembly; ⑧Remove the upper cover plate of front end cover; ⑨Remove the injection pump assembly. 4.6.1.3 Assembling steps for fuel system Assemble the fuel systemwith the reverse order ofdisassembly. 4.6.2 Disassembly and assembly of injection pump 4.6.2.1Exploded view of injection pump The position of injection pump on the engine is shown in figure4-45.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Injection pump



Injection pump gear



Oil pipe of injection pump



Figure 4-45 Exploded view of injection pump 4.6.2.2 Disassembling steps of injection pump ①Remove the pipeline and wire connecting the injection pump and the vehicle; ②Remove the hollow bolt connecting the low pressure fuel pipe and the injection pump; ③Remove the hollow bolt connecting theair pipe of smoke limiter and the injection pump; ④Remove the hollow bolt connecting the injector return pipe and the injection pump; ⑤Remove the nuts connecting injection pump and high pressure fuel pipes; ⑥Remove the hollow bolt connecting the lubricating oil pipe and the injection pump; ⑦Remove the upper cover plate of front end cover; ⑧Remove the injection pump camshaft nut and then remove the injection pump gear; ⑨Remove the mounting nut of injection pump and front end cover to remove the injection pump. 4.6.2.3 Inspection and repair of injection pump ①Check the injection pump for cracks or leakage; if any, replace it and give feedback to the manufacturer through corresponding processes. ②Check the injection pump lead seal for damage; if any, replace the injection pump and adjust the fuel amount on the test rigof fuel pump. ③Check the smoke limiter air pipe for cracks and the joints at two end for air leakage; if any crack occurs, replace the smoke limiter air pipe, and if air leakage occurs, replace the hollow bolt gaskets at both ends. ④Check the lubricating oil pipe for leakage; if any,replace the lubricating oil pipe or the hollow bolt gaskets at both ends. 76



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.6.2.4 Assembling steps of injection pump Assemble the injection pump with the reverse order ofdisassembly.Notice: When assembling the injection pump gear, the groove mark on the injection pump gear should align with that of front wall cover.Rotate the engine crankshaft tomake the injection pump to the position with correct fuel supply advance angle, then tighten the bolts of injection pump and front end cover. 4.6.3 Disassembly and assembly of high pressure fuel pipe 4.6.3.1Exploded view of high pressure fuel pipe



1-high pressure fuel pipe assembly Figure 4-46 Exploded view of high pressure fuel pipe



4.6.3.2 Disassembling steps of high pressure fuel pipe ①Remove intake/exhaust manifold assembly; ②Remove fixing bracket of high pressure fuel pipe on cylinder head; ③Remove the nuts connecting high pressure fuel pipes and injectors. ④Remove the nuts connecting high pressure fuel pipes and injection pump cylinders. 4.6.3.3 Inspection and repair of high pressure fuel pipe ①Check the high pressure fuel pipe for cracks or leakage; if any, replace it and give feedback to the manufacturer through the corresponding processes. ②Check the joint conical surfaces at both ends of high pressure fuel pipe for defects. 4.6.3.4 Assembling steps of high pressure fuel pipe Assemble the high pressure fuel pipe with the reverse order ofdisassembly.The high pressure fuel pipe shall be clean and in good conditions. 77



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.6.4 Disassembly and assembly of injector 4.6.4.1Exploded view of injector



1-bolt; 2-spherical washer; 3-injector clamp; 4-injector; 5-gasket; 6-hollow bolt Figure 4-47 Exploded view of injector 4.6.4.2 Disassembling steps of injector ①Remove the hollow bolts connecting the injector return pipes and the injectors. ②Remove the injector hold-down bolt and the injector pressure plate. ③Remove the injector using special tool. 4.6.4.3 Inspection and repair of injector ①Check the copper seal washer for excessive deformation or other damages; if any, replace it, and clean the injector seat bore surface to clear the carbon deposit for ensuring sealing. Notice: Install the injector, seal washer and adjusting shim correctly to ensure that the injection nozzle body lower cone and the nozzle protrusion of sharp end meet the requirements. ②Check the fuel return pipe of injectorfor damage or fuel leakage; if any, replace it. 4.6.4.4 Assembling steps of injector Assemble the injector with the reverse order ofdisassembly.



4.6.5 Disassembly and assembly of fuel filter 4.6.5.1Exploded view of fuel filter



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



1-fuel filter bracket; 2-spring washer; 3-screw; 4-fuel filter; 5-fuel pipe; 6-sprign washer; 7-bolt; 8-spring washer; 9-bolt; 10, 11-pipe clamp; 12-fuel pipe Figure 4-48 Exploded view of fuel filter



4.6.5.2 Disassembling steps of fuel filter ①Remove the hollow bolts connecting the low pressure pipe and the primary/secondaryfuel filter. ②Remove the connecting bolts of primary/fine fuel filter and fixing bracket. ③Disassemble the fuel filter element and the filter seat. 4.6.5.3 Inspection and repair of fuel filter ①Check the fuel filter for damage. ②Check the fuel filter and the filter seat for leakage; if any, replace the related parts. ③Check the fuel filter for blockage; if any, replace the filter element. When replacing the filter element, remove the old element first, fill clean diesel fuel to the new element and apply lubricating oil to the rubber gasket of the filter seat; install the filter and tighten it for 3/4 to 1 more turns to seal tightly after the rubber gasket contacting the seat,; and finally, remove the bleed screw on filter seat and operate the hand pump on the injection pump to remove the air inside. 4.6.5.4 Assembling steps of fuel filter Assemble the fuel filter with the reverse order ofdisassembly.When replacing the filter element, fill clean diesel fuel to the new element and apply lubricating oil to the rubber gasket of the filter seat; install the filter and tighten it for 3/4 to 1 more turns to seal tightly after the rubber gasket contacting the seat,; and finally, remove the bleed screw on filter seat and operate the hand pump on the injection pump to remove the air inside.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.6.6 Disassembly and assembly of low pressure fuel pipe 4.6.6.1Exploded view of low pressure fuel pipe See figure4-48 for details. 4.6.6.2 Disassembling steps of low pressure fuel pipe ①Remove thebracketsof low pressure fuel pipe installed on the cylinder head and the cylinder block. ②Remove the hollow bolt connecting the low pressure fuel pipe and the injection pump. ②Remove the hollow bolt connecting the low pressure fuel pipe and fuel secondary filter or primary filter. 4.6.6.3 Inspection and repair of low pressure fuel pipe ①Check the low pressure fuel pipe for leakage; if any, replace it and give feedback to the manufacturer through the corresponding processes. ②Check the jointsat two ends of low pressure fuel pipe for oil leakage; if any, replace the hollow bolt gasket. 4.6.6.4 Assembling steps of low pressure fuel pipe Assemble the low pressure fuel pipe with the reverse order ofdisassembly.



4.7 Cooling system 4.7.1Disassemblyandassembly of cooling system 4.7.1.1 Exploded view of cooling system assembly The function of cooling system is to ensure the continuous work of diesel engine under appropriate temperature, and it is composed of water pump, fan, water tank and thermostat. See figure4-49.



Thermostat



Intermediate spacer block



Rubber hose



Water pump gasket



Fan



Water pump Water pump pulley



Adapting flange



80



Rubber hose



Gasket



Water inlet pipe



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-49 Exploded view of cooling system assembly The cooling line of the cooling system is shown in figure4-50. For the long circulation circuit (working at high ambient temperature), the water will flow through the radiator, and then flow back to water pump. For the short circulation circuit (working at low ambient temperature), the water will flow back to the water pump without flowing through the radiator. When the ambient temperature is lower in winter, a part of water will flow through the warming system and then flows back to the water pump.



Air heater



Air heater



Relief valve cap Expansion tank



Water outlet pipe



Cylinder head



Oil cooler



Air compressor



Radiator



Fan



Therm ostat



Water pump



Diesel cylinder block



Figure4-50Cooling system loop 4.7.1.2 Disassembling steps of cooling system As shown in figure 4-49: ①Remove the fan and adapting flange. ②Remove the tensioner. ③Remove the belt. ④Remove the alternator and its bracket, crankshaft pulley and vibration damper. ⑤Remove the thermostat, remove the water inlet pipe. ⑥Remove the water pipe fitting and water pump. ⑦Remove the intermediate spacer block of water pump. 4.7.1.3 Assembling steps of cooling system Assemble the cooling system with the reverse order ofdisassembly. 81



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.7.2Disassembly and assembly of fan 4.7.2.1 Exploded view of fan assembly The fan group consists mainly of fan, fan clutch and bolt and washer. See figure4-51. Hexagon socket cap Spring washer screw



Hexagon socket cap screw



Adapting flange



Spring washer Fan



Water pump pulley



Figure4-51 Exploded view of fan assembly 4.7.2.2 Disassembling steps of fan As shown in figure4-51: 1) Remove the bolt and washer connecting the fan and adapting flange and remove the fan. 2) Remove the screw and washer connecting the adapting flange and pulley. 3) Remove the adapting flange. 4) Remove the pulley. 4.7.2.3 Inspection and repair of fan Check the fan, adapting flange and pulley for damages such as cracks, and replace them if necessary. 4.7.2.4 Assembling steps of fan Assemble the fan with the reverse order of disassembly.



4.7.3Disassembly and assembly of water pump 4.7.3.1 Exploded view of water pump assembly The water pump group consists mainly of water pump, gasket, pulley, intermediate spacer block and bolt and washer. As shown infigure4-52.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Gasket Intermediate spacer block Gasket Water pump



Water pump pulley Hexagon bolt Spring washer



Hexagon bolt



Figure4-52 Exploded view of water pump assembly



4.7.3.2 Disassembling steps of water pump As shown in figure4-52: ①Remove the water pump pulley. ②Remove the connecting rubber hose and clamps connecting the water inlet pipe and thermostat; ③Remove hexagonal bolt and spring washer from water pump, remove the water pump. ④Remove water pump gasket and intermediate spacer block. 4.7.3.3 Inspection and repair of water pump ①Check the water pump gasket for damage, and replace it if necessary. ②Check the bolts and studs for threads damage, and replace them if necessary. ③Check the water pump and intermediate spacer block for damages, and replace them if necessary. 4.7.3.4 Assembling steps of water pump Assemble the water pump with the reverse order of disassembly.



4.7.4Disassembly and assembly of thermostat 4.7.4.1 Exploded view of thermostat assembly The thermostat group consists mainly of thermostat and connecting rubber hoses. As shown infigure4-53.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-53 Exploded view of thermostat assembly 4.7.4.2 Disassembling steps of thermostat As shown in figure4-53: ①Remove the clamp and hose connecting the cooling water pipe and thermostat. ②Remove the clampand hoseconnecting the water pump and thermostat. ③Remove thermostat. ④ Remove the coolant rubber hoses. 4.7.4.3 Inspection and repair of thermostat ①Check the clamp for damage, and replace it if necessary. ②Check the coolant connecting rubber hose for damage, and replace it if necessary. ③Check the thermostat for damage, and replace it if necessary. 4.7.4.4 Assembling steps of thermostat Assemble the thermostatwith the reverse order ofdisassembly.



4.7.5 Disassembly and assembly of water outlet pipe 4.7.5.1 Exploded view of water outlet pipe The water outlet pipe group consists mainly of water outlet pipe (cooling water pipe assembly), union joint assembly and connecting rubber hose. As shown in figure4-54.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-54Exploded view of water outlet pipe assembly 4.7.5.2 Disassembling steps of water outlet pipe ① Remove the clamp. ② Remove the external thermostat. ③ Remove the rubber hoses. ④Remove the water outlet pipe. ⑤Do not damage the welding portion of water pipe when disassembling. 4.7.5.3 Inspection and repair of water outlet pipe Check water outlet pipe for leakage before disassembling, and check the pipe body for cracks and corrosion. Replace the whole pipe even if onlyone union joint is damaged and find out the reason. 4.7.5.4Assembling steps of water outlet pipe (1) Assemble the union joints oncylinder head. (2) Place the clamps at corresponding positions. (3) Install the water outlet pipe. (4) Connect the thermostat inlet and the outlet of water outlet pipe with rubber hose of coolant without tightening the clamp. (5)Connect the inlet of water pump and the outlet of thermostat with rubber hose of small circulation circuit without tightening the clamp. (6) Check the rubber hose for bend and distortion. (7) Tighten the clamps to fix the rubber hoses with the clamp heads at the same direction. 85



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.8 Lubricating system 4.8.1 Disassembly and assembly of lubricating system 4.8.1.1 Exploded view of lubricating system assembly The lubricating system assembly consists mainly of oil suction strainer, oil filter, oil pump, oil cooler and pressurelimiting valve of main oil passage. As shown in figure 4-55.



Oil pump



Suction strainer



Oil filter



Figure4-55 Exploded view of lubricating system assembly 4.8.1.2 Disassembling steps of lubricating system (1) Remove the oil pan, and see engine block group removal instruction for details. (2) Remove the crankshaft pulley, vibration damper and screw plug on the gear chamber. (3) Remove the oil pump. (4) Remove the pressure limiting valve of main oil passage. (5) Remove the oil filter. (6) Remove the oil cooler. 4.8.1.3 Assembling steps of lubricating system Assemble the lubricating system with the reverse order of disassembly. 4.8.2 Disassembly and assembly of oil pump 4.8.2.1 Exploded view of oil pump assembly The oil pump group consists mainly of oil pump and bolts related. As shown in figure 4-56.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Figure4-56 Exploded view of oil pump assembly 4.8.2.2 Disassembling steps of oil pump Unscrew the two bolts and self-locking nuts, and remove the oil pump. 4.8.2.3 Inspection and repair of oil pump ①Checkthe oil pump for damages and check the inner cavity for smoothness, and replace the oil pump if necessary. ② Check the rotation of oil pump shaft, and replace it if necessary. 4.8.2.4 Assembling steps of oil pump ①Before assembling, check the oil pump for manufacturing defects andusagedamage. ②Clean the mating surfaces of oil pump and engine block. ③Install the oil pump. ④Install and tighten the two hex flange bolts and self-locking nuts. 4.8.3 Disassembly and assembly of oil filter 4.8.3.1 Exploded view of oil filter assembly The position of oil filter on the engine is as shown in figure4-57.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Oil filter



Figure4-57 Exploded view of oil filter assembly 4.8.3.2 Disassembling steps of oil filter Remove the oil filter with special wrench. 4.8.3.3 Check and repair of oil filter ①Check the oil filter subassembly for damage, and replace it if necessary. 4.8.3.4 Assembling steps of oil filter ①Before assembling, checkthe O-ring of oil filter and confirm that there is no manufacturingdefect or usage damage. ②Tighten the oil filter according to the requirements specified.



4.8.4 Disassembly and assembly of oil cooler 4.8.4.1 Exploded view of oil cooler assembly The oil cooler group consists mainly of oil cooler, water inlet/outlet pipe, connecting rubber hose and clamps. As shown infigure4-58.



Oil cooler



Figure4-58 Exploded view of oil cooler assembly 88



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.8.4.2 Disassembling steps of oil cooler Unscrew the connecting screw thread of oil cooler, loosen the clamp and rubber hose connecting the water inlet/return pipe of oil cooler, and remove the oil cooler. 4.8.4.3 Inspection and repair of oil cooler Check the oil cooler for damage, and replace it if necessary. 4.8.4.4 Assembling steps of oil cooler ①Before assembling, check oil cooler and confirm that there is nomanufacturing defect or usage damage. ②Clean the mating surfaces of oil cooler and filter seat. ③Install the oil cooler, mount and tighten the connecting screw thread, connect the water inlet/outlet pipe of oil cooler, and then tighten the clamp.



4.8.5 Disassembly and assembly of pressure limiting valve of main oil passage 4.8.5.1 Exploded view of pressure limiting valve of main oil passage The pressure limiting valve of main oil passage consists mainly of cap nut, threaded rod, steel ball and sealing washer. As shown infigure4-59.



Steel ball Spring Threaded rod Sealing washer Cap nut



Figure4-59 Exploded view of pressure limiting valve assemblyof main oil passage 4.8.5.2 Disassembling steps of pressure limiting valve of main oil passage Unscrew and remove pressure limiting valve of main oil passage. 4.8.5.3 Inspection and repair of pressure limiting valve of main oil passage ①Check the pressure limiting valve spring for elasticity, and replace it if necessary. ②Check the pressure limiting valve for damages, and replace it if necessary. 89



Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.8.5.4 Assembling steps of pressure limiting valve of main oil passage ①Before assembling, check the pressure limiting valve and confirm that there is no defects or damages. ②Clean the pressure limiting valve and valve hole on the cylinder block. ③Install and tighten the pressure limiting valve. 4.8.6 Disassembly and assembly of oilsuction strainer 4.8.6.1 Exploded view of oil suction strainer assembly The oil suction strainer assembly consists mainly of suction strainer, bolt, washer and nut. As shown infigure4-60.



Figure4-60 Exploded view of oil suction strainer assembly 4.8.6.2 Disassembling steps of oil strainer Unscrew the type I hexagon nut of angle plate on main bearing cap, unscrew the two self-locking nuts and remove the oil suction strainer. 4.8.6.3 Inspection and repair of oil suction strainer Check the oil suction strainer for damages, and replace it if necessary. 4.8.6.4 Assembling steps of oil suction strainer ①Before assembling, confirm that the oil suction strainer has no defectsor damages. ②Clean the mating surfaces of the oil strainer and oil pump, clean the inner cavityof oil strainer. ③Install the angle plate. ④Install the oil suction strainer, mount the two hexagon bolts and self-locking nuts, and then tighten them.



4.9 Starting system



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



4.9.1 Disassembly and assembly of starting system 4.9.1.1 Exploded view of starting system The starting system consists mainly of starter, bolt and washer. As shown infigure4-61.



1-flywheel ring gear; 2-spring washer; 3-bolt; 4-starter Figure4-61 Exploded view of starting system 4.9.1.2 Disassembling steps of starting system ①Remove the hexagon bolts and spring washers; ② Hold the starter with hands, and remove it along the rotation axis of starter gear. 4.9.1.3 Inspection and repair of starting system Check the starter gear for damages and replace it if necessary. 4.9.1.4 Assembling steps of starting system Assemble the starting system with the reverse order of disassembly.



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Maintenance Manual of WP6 Stage II Land Diesel Engine for Power Generation



Appendix A: Fit clearances of main parts of the engine



S/N



Items



Theoretical value (mm)



1



Main bearing clearance



0.08~0.11



2



Connecting rod bearing clearance



0.075~0.10



3



Crankshaft axial clearance



0.04~0.25



4



Axial clearance of connecting rod plane



0.30~0.50



5



Camshaft axial clearance



0.1~0.29



6



Valve clearance, intake/exhaust (at cold state)



92



0.2~0.3/0.3~0.4



Maintenance Manual for WP4 Mechanical Pump Series Diesel Engine



Appendix B:Evaluation benchmark for wear of main friction pairs



Wear limit



Clearance limit



mm



mm



First ring end clearance



1.70



-



First ring height



0.10



-



Second ring end clearance



1.50



-



Second ring height



0.10



-



Oil control ring end clearance



1.50



-



Oil control ring height



0.15



-



Outer diameter of piston skirt



0.25



Inner diameter of cylinder liner



0.50



Outer diameter of piston pin



0.04



Inner diameter of piston pin hole



0.08



Inner diameter of small end bushing of connecting rod



0.08



Outer diameter of camshaft main journal



0.06



Inner diameter of camshaft bush



0.06



Height of cam tip



2.00



-



Outer diameter of cam base circle



0.05



-



Outer diameter of crankshaftconnecting rod journal



0.12



Inner diameter of connecting rod bearing



0.10



Outer diameter of crankshaft main journal



0.08



Inner diameter of main bearing



0.10



Thickness of thrust bearing



0.40



Items



0.60



0.10



0.10



0.15



0.15 -



0.04*d(1)



Intake valvesinkage Intake valve seal ring



0.75



Intake valve seat ring



0.75



Exhaust valvesinkage



0.04*d(1)



Exhaust valve seal ring



0.85



Exhaust valve seat ring



0.85



Inner diameter ofintake valve guide



0.06 93



0.1



Maintenance Manual for WP4 Mechanical Pump Series Diesel Engine



Outer diameter of intake valve stem



0.06



Inner diameter of exhaust valve guide



0.06



Outer diameter of exhaust valve stem



0.06



Inner diameter of rocker shaft bush



0.10



Outer diameter of rocker shaft



0.05



 



94



0.1



0.12