01 Engine System LG956L

LG956L Training material
Chapter 3 Engine System
Chapter 3 Engine System
Section 1 overview of engine

1 Model meaning
2.Characteristic of engine
Section 2 Crank-link mechanism
1.Engine block group
2.Crankshaft flywheel group
3.Piston rod group
Section 3 Valve mechanism
1.Overview
2.Main composition of valve
mechanism
Section 4 Fuel supply system
1.Overview
2.Fuel injection pump
3.Regulator
4.Fuel delivery pump
5.Fuel injection
6.
7.Fuel filter
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1
Section5 Lubrication system

1.Function
2.Method of lubrication
3.Main spare part
Section 6 Cooling system
1.Function of cooling system
2.Main spare part of cooling system
Section 7 Air intake and exhaust system
1.Function of air intake and exhaust system
2.Working principle of air intake and exhaust system
3.Parts of air intake and exhaust system
Section 8 Common failures
1.Start unsuccessfully engine
2.Underpower of engine
3.Exhaust black smoke
4.Exhaust white and blue smoke
5.Low lubricating oil pressure
6.High lubricating oil pressure
7.High lubricating oil consumption
8.High coolant temperature
RELIABILITY IN ACTION
Section 1 Overview
1
Introduction of the meaning
LG956L is equiped with Weichai
engine which is in-line, four-
WD10G220E23
stroke, water-cooled, turbocharged

six-cylinder diesel engine, the
engien model number is
Water Diesel
10
Displacement Code
(Displacement is 10L.)
Construction machinery
220
Power(220ps)
E2
State three emission

standard
Variant code
WD
WD10G220E23, the meanings of

the words and numbers see the
right table.
2
Section 1 Overview
2Characteristics of the Weichai
engineWD10G220E23
1High reliability, long life
Using the tunnel structure, the
crankcase and the seven main bearing
cap are forged as one piece by
high-quality alloy steel, nitrided
crankshaft and connecting rod, and
strength bolts with flexible design, to
ensure the high reliability of the engine
moving parts. Reasonable design of the
high power function of the camshaft
profile can make the engine distribution
system has higher reliability and lower
mechanical vibration noise.
Characteristics of the use of construction
machinery are fully considered,
3
Section 1 Overview
2
Powerful engine
large torque reserve
Using the imported Ps3000, Ps7100 fuel
injection pump with low inertia porous injector,
through fuel supply characteristics correcting
and efficiency turbocharger proper matching can
achieve a good dynamic and make the torque
reserves reach more than 20%, to provide strong
horsepower for all kinds of engineering
machinery.
3
Good economy
Three new structures of piston rings, best
matching cylinder clearance, equiped with new
type of combustion chamber and the best swirl
ratio, overlapping curve is honed on the cylinder
plate form to aviod leakage, ensure a more
perfect geometry of cylinder bore, and reduce
the consumption of fuel and oil, the lowest fuel
consumption of the turbocharged engine reaches
194g/kW.h, , oil consumption less than
0.5g/kW.h.
4
Section 1 Overview
4
Powerful engine
High
torque reserve
The exhaust can meet the Euro II
emission standard, which are well suited
for working in limited space such as
tunnels, warehouse, cabins, etc.
5
Good ability to adopt the
plateau
The new type of turbocharger has a
function of air intake reflow, which can
broaden the scope of the diesel engine
high effiency workspace, compensate for
the power loss in plateau, and can
provide good adaptability in plateau.
6
Good low temperature start
The cold starting device is added to
ensure the engine can start smoothly at 40 .
5
Section 2 Crank and connecting rod mechanism

Crank and connecting rod
mechanism
Piston rod assembly
1
Basic components
The crank and connecting rod

mechanism mainly consists of
three parts: the body assembly,
crankshaft flywheel assembly,
piston and connecting rod
Engine body assembly
assembly.
Crankshaft flywheel assembly
6

Crank and connecting rod
mechanism
2
Main function
The crank and connecting rod
mechanism is the main parts of the
reciprocating piston engine to transfer
the heat energy into mechanical energy,
which function is to transfer the pressure
on the piston crown acted by the gas to
the rotational torque of the crankshaft,
and output to the external.
Most of the power is tranmitted to the
outside through the flywheel, another
portion is through the gear and idler gear
of the front end of the crankshaft to drive
other mechanisms and systems of itself,
primarily to withstand high temperature,
high pressure, chemical corrosion and
the impact of inertia force.
7

1
The cylinder block assembly
It is mainly composed of the cylinder
block, cylinder liner, cylinder head,
cylinder gasket, oil sump, engine mounts
and other mechanical components.
1
Cylinder block
Function The cylinder block is a
basic installation for each mechanisms
and systems, which is used to maintain
the precise positional relationship
between each moving parts of the
General form
General type
engine. The cylinder block is usually

forged together with crankcase as one
piece, so called cylinder-crankcase.
characteristic
Application
General
The lower surface of the cylinder block

and the axis of the crankshaft are on the
same plane, the stiffness is small
Cars, small trucks
Gantry
The lower surface of the cylinder block

is below the axis of the crankshaft, the
stiffness is larger
Medium and heavy trucks
Tunnel
Main bearings are not separated

(equipped with modular crankshafts),
the stiffness and weight are the largest
large mechanical
loadload of diesel engine
different position of the installation
the oil pan, the cylinder block is usually

divided into three types: general
crankcase, crankcase and gantry tunnel
Tunnel form
FORM
Structure According to the
planes between the cylinder block and
Gantry form
crankcase.
8

1
Cylinder block
The structural style of the
LG956L Weichai engine
The cylinder block of the Weichai
WD10G220E23 engine is the tunnel
structure, the main bearing cover and the
crankcase forged toghther in one
piece,the crankcase and the cylinder
block are separated by the centerline of
the crankshaft, the upper part is the
cylinder block, the lower part is the
crankcase, the crankcase and the seven
main bearings together form a integrated
framework with good stiffness.
This tunnel structure not only has a
good stiffness, and can use the sliding
bearings to reduce the noise and improve
the service life.
9

1) Cylinder block
Precautions for the installtion of
the Cylinder block and crankcase
The WD10G220E23 engine has no
gasket between the crankcase and
cylinder, the bottom of the cylinder
block should be coated smoothly with
510 sealant, which will lower the oil
pressure, the sealant does not need too
much, and installation should be
implemented immediately after the
coating finished.
Notice: The cylinder block and
crankcase are required to be installed in
pairs, which are not interchangeable.
When one of the parts is damaged, both
parts should be replaced, optional
installation is not allowed.
10
2
Cylinder liner
Function
The main function of the cylinder liner
is to guide the piston direction and seal
the gas inside the cylinder.
Classification of cylinder
sleeve
There are two types of cylinder liners:
Dry cylinder liner and wet cylinder liner,
Wet cylinder liner
the dry cylinder liner is not directly in

contact with the cooling liquid, but the
Form
Characteristic
Advantage
Aisadvantage
Demand
Wet
cylinder
sleeve
The outer surface

is in direct contact
with the cooling
Cooling effect,
casting
convenient,
easy
disassembly
Poor rigidity,
easy
leakage(water
and gas)
With upper and

lower positioning
belt and lower
bearing seal tape
Dry
cylinder
sleeve
The outer surface

is not in direct
contact with the
cooling water
wet cylinder is just the opposite.

Weichai WD10G220E23 diesel engine
uses the thin-walled dry cylinder liner.
Dry cylinder liner
Contrary to the above
With upper and

lower positioning
belt
11

2
Cylinder sleeve
Precautions for the installtion of
Weichai WD10G220E23 diesel engine
cylinder liner
Use alcohol or Loctite 755 to wash the
grease off the cylinder hole and the
cylinder liner external surface before
installation, then apply a thin layer of
molybdenum disulfide powder on the
surface of the cylinder liner external
surface, and finally, use hands or tools to
pressure the cylinder liner into the
cylinder block.
Check the cylinder liner is 0.020.07mm above the upper surface of the
cylinder block after the cylinder liner
pressed into the cylnder block.
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12

Cylinder head
3
Cylinder head
Function
The main function of the
cylinder head is to seal the upper
part of the cylinder, and form a
combustion chamber with piston
Integral-type
crown and cylinder wall.

Type of cylinder head
The cylinder head has common
types of integral-type, single-
Double-cylinder
split type
form
characteristic
application
integral
Poor rigidity, easily deformed by

heat or pressure, which will
influence the seal, the whole block
must be replaced when damaged.
old-fashioned
engine
cylinder split type and double

cylinder split type.
Single-cylinder
split type
one cylinder per

block
split
two cylinder per

block
easy to be made or repaired, good

rigidity
wide application
three cylinder
per block
13

3
Cylinder block
The cylinder head of Weichai
WD10G220E23 engine adopts the
structure with one cylinder and one
cover, good manufacture technics,
and easily disassembled and
transported.
Each cylinder is fixed by four
M16 bolt, and two adjacent
cylinder head simultaneously
pressed together by three M12 stud
with a clamping block, which
increases the engine rigidity.
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14

2
The piston and connecting rod
assembly
The Piston and connecting rod
assembly is mainly composed of piston,
piston ring, connecting rod, piston pin and
other mechanical components.
1-piston
2-Spiral spring-loaded oil ringoil ring
3-cone ringCompression ring
4-ladder ringCompression ring
5-connecting rod sleeve
6-connecting rod
7-connecting rod cover
8-connecting rod bolt
9-connecting rod bush
1011connecting rod bush
12-retaining ring
15

1
Piston
Function of piston
The main function of the piston is
designed to withstand the pressure from
buring air, and transmit the force through the
piston pin to the connecting rod to push the
crankshaft rotate. The piston head forms a
combustion chamber with cylinder head and
cylinder wall.
Structure of piston
The basic structure of the piston can be
divided into three parts: the crown, the head
and the skirt.
The piston head forms a combustion
chamber with cylinder head and cylinder
block, bear force generated by the air
1
top
2
head
3
skirt
4
land
5
ring groove
6
pin boss
7
reinforcing rib 8
Snap ring groove 9
Oil discharge hole and Oil discharge groove
pressure in the cylinder, and transmit the

force through the piston pin to the
connecting rod to push the crankshaft rotate.
16

The piston head is the upper part
above the piston ring groove,
which function is as follows:
A: Withstand the air force and transmit it
to the connecting rod.
B: Working together with the piston
rings to realize the cylinder cealing.
C: Transmit the heat absorbed from the
piston head to the cylinder wall by
passing throught the piston ring.
The piston skirt is the lower part of the
engine from the oil ring groove down to
the bottom, which function is to guide
the piston reciprocated in the cylinder
1
top
2
head
3
skirt
4
land
5
ring groove
6
pin boss
7
reinforcing rib 8
Snap ring groove 9
Oil discharge hole and Oil discharge groove
and withstand side pressure.
17
The structure and characteristics of the

Weichai WD10G220E23 engine piston
AThe piston is made of aluminum alloy, the
specific weight is small, and the thermal
conductivity is very good.
B
The top of the piston has a S - shaped
combustion chamber, and a pit which can avoid

the valve, in additional, combustion chamber and
avoid the valve pit, while the product code is on
the piston top.
C: Piston top shore (also known as fire shore)
processes a thin annular groove, called back slot,
which has the function of collecting dirt and
proventing occlusion, and can improve the
running state between the top of the piston and
the cylinder.
DThe piston can be grouped by weight, the

difference between each group is not more than
10g, the marks of these groups are G1
G3
G2
G4G5. When replacing the piston, the
weight of the pistons on the same machine

should be the same.
E
Engine oil should be applied before the
piston installation, the opening of the piston rings

should be staggered 120
and angle between
the opening of the first ring and the edge of the

18
piston pin hole should not less than 30

(2) Piston ring
Classification
Piston ring is a resilient split ring,
which can be divided into compression
Compression ring
ring and oil ring.
Function of compression ring

The first and second rings are called
compression ring, which function is to
ensure the seal between the cylinder and
the piston, prevent the gas leakage, and
transmit most of the heat absorbed from
Oil ring
the piston crown to the cylinder wall.
Function of oil ring

The third ring is oil ring, which
function is to distribute oil, scrape oil,
reduce the friction resistance and assist
the sealing.
19

(2) Piston
Sealing principle of
Gas ring has a slot, and is flexible, which
outer diameter is greater than the cylinder
diameter in free state, when installed into the
cylinder together with the piston, the outer
surface set close to the cylinder wall to form
the first sealing surface, the sealed gas can
not get throught the space between gas ring
and the cylinder, but enter the space between
ring and ring groove, on one hand, it can
press the ring to the surface of the groove to
form the second sealing surface, on the other
hand, the pressure acting on the back of the
ring can greatly enhance the sealing effect of
the first sealing surface.The gas ring sealing
First sealing face
second sealing face
effect is generally related to the number of

the gas ring, WeiChai diesel engine has 2 gas
rings.
20

(2) Piston ring
Type of the compression ring section

Rectangular ring Simple technical process,
good thermal conductivity, but the oil pumping
phenomenon is easy to occur, which will cause
the carbon deposition.
Twist ring
The torque M is generated by the
left-right asymmetry, which can make the edge

of the rings to contact with the upper and lower
Rectangular ring
Taper face ring
surface of the groove, prevent oil pumping, and
Twist ring
increase seal.
Taper face ring
Scrap the oil downward,
and
float on the oil film when slide upward,which

can reduce the mechanical wear, but the cone
angle is hard to be made.
Keystone ring
The ring side clearance is
changed according to the changes of the direction
Twist ring
Keystone ring
Barrell face ring
of the side pressure, which can squeeze the

carbon deposition out of the ring groove, but the
technical process of the upper and lower surfaces
are more complicated.
Barrell face ring
Good contact can increase
sealing, but the convex surface is hard to be

made.
21

(2) Piston ring
Compression ring pump oil
piston
Function
Good for cylinder
piston
lubrication.
Harm
Large lubricating oil
Cylinder
Cylinder
consumption, easy to form carbon

deposition in the ring groove,
which will caused ring stuck in the
groove and lose the sealing effect,
scratch the cylinder wall, and even
break the ring.
Measure
Reduce the ring
quality, change the shape of the
ring section, and use the
combination oil ring.
22

(2) Piston ring
Oil ring
FunctionThe main function of the engine oil
ring is is to distribute oil, scrape oil, and play an
assistant role to sealing the gas, which can be
divided into two types, common oil ring and
combination oil ring.
A: General oil ring
The general oil ring is also called integral oil
ring, with a groove machined in the middle of the
outer cylindrical surface of the ring, and a hold
General oil ring
or a slot drilled in the groove, when the piston

moves downward, the excess oil will be scraped
off the cylinder wall and flow back to the
crankcase through the small hole or slot.
B
combination oil ring
The combination oil ring is composed of a

pair of upper and lower side rail rings and a
Combination oil ring
Combination oil ring
middle dilator, the side rail ring is made of

chrome-plated steel, the perimeter of the dilator
is slightly larger than the internal circumference
Function of oil
scraper ring
of the cylinder, which can tightly press the side

rail ring against the cylinder wall, and the
scraping effect is obvious.
23

2piston ring
The structure and characteristics of Weichai

WD10G220E23 engine piston rings
First ring
The surface of the double sided
trapezoid tubbish ring is treated by means of

phosphating treatment, with a notch and an
installation marking "TOP"on the upper part; The
work surface is sprayed with molybdenum layer,
which will help to increase the effect of wearing
resistance and anti galling.
Cone ring, the cone angle of the

torus is 90 5 ', the surface is treated by
Second ring
means of oxidation treatment, the work surface is

sprayed with chromium layer, and the upper part
of the ring has a installation marking "TOP"
Third ring
The internal expanding circle
combined oil ring is made of cast iron, has 12

blades, double-edged surface chrome plated,
lined with spiral springs, which has the
characteristics of small abrasion, good oil seal
and scraping effect, stable performance, durable
and so on.
24

3
piston pin
Function
Connecting the piston and connecting rod,

transfering the force between the two parts.
Structure
Hollow cylinder.
Material
Alloy surface carburization (surface hardness

increased)
Assembly
Connecting rod head
Full floatingThe pin rotates freely and wear

evenly in the pin hole and connecting rod
Snap
bushing, the inner of both ends of the pin seat has
ring
Connecting rod sleeve

Piston pin
clip rings.
Half floatingThe the floats in the pin seat,
Piston pin seat
which is connected with the small end of the

connecting rod by bolts.
Notice
90
Heat the aluminum pistons in the 70
water or oil before installing the pin into
the piston to ensure the combination between the

pin and the pin seat hole in the cold state is a
Full floating assembly
Half floating assembly
transition fit .
25

4
Connecting rod
Composition
T h e c o n n e c t i n g r o d i s c o mp o s e d o f
Connecting rod
small end
connecting rod small end, shaft, connecting rod

big end, screw and connecting rod cap,etc.
Function
Connect the piston with the crankshaft,
transfer the force from piston to crankshaft, and
Connecting rod
transfer the reciprocating movement of the piston
shank
into the rotary movement of the crankshaft.
Classification
Generally, the engine connecting rod can be
divided into two types, the equal type and the
oblique fractional type.
Connecting rod
Weichai WD10G220E23 engine adopts the
large end
oblique fractional rod.
Inclined cut
26

4
Connecting rod
Connecting rod of weichai
engine(WD10G220E23)
A: Weichai WD10G220E23 engine connecting
rod big end is the oblique incision type,split by
45
oblique, using the 60teeth to locate the
combined surface, with characteristics of

positioning accuracy, combined tightly, etc.
B
The weight of the connecting rod is divided
into 9 groups which are respectively marked by

C, D, E, F, G, H, J, K, I, the quality of each level
is no more than 29g, when replacing the
connecting rod, make sure the marked letter is
the same, otherwise it will cause the diesel
engine to produce abnormal vibration.
C The connecting rod and connecting rod cover

must be processed as a whole set, marked the
same number, and are not interchangeable.
The connecting rod bolts can only be used
once.
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27

5
Bearing shell
A tile form of sliding bearing is
mounted in the connecting rod big end
hole to reduce friction and the wear of
connecting rod journal of the crankshaft,
which is called connecting rod bearing.
The bearing shell is divided into
upper and lower shell, which is currently
use the thin-walled rigid bearing, with
wear-resistant alloy layer casted on the
internal surface.
Function of the connecting rod
bearing shell
Bearing, heat conduction, protecting the

big end connecting rod and reduce the
wear.
1-steel backing
2-oil groove
3-locating tang
4-antiwear alloy layer
28

3
Crankshaft flywheel
assembly
Mainly consists of crankshaft,
flywheel and other accessories.
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29

1
Crankshaft
Composition
The crankshaft is composed of main
journal, connecting rod shaft neck,
crank, counterbalance, front-end and
back-end, etc.
A connecting rod shaft neck and a
crankshaft constitute a crank.
Function
The crankshaft interacts closely with
Main journal
the connecting rod to change the gas
crankshaft
Connecting rod
journal
pressure into rotation power, transfer the

force to the transmission mechanism,
and drive the valve mechanism and other
auxiliary devices.
collar
30

2
Flywheel
Function: Depending on the flywheel
inertia to keep the engine running
balance, and help engine to overcome
short time overloading.
Material: High strength, wear-resistant

material (Grey cast iron)
1
flywheel 3
bush
4
bolt
5 support7 gear ring
8 flange
31

3
Absorber
In the process of engine working, each
cylinder has its own working stroke, the
magnitude and direction of the force transfered
from the connecting rod to the crank pin are
changed periodically, the exciting force caused
by the periodic variation acts on the crankshaft to
cause the the instantaneous angular velocity of
the crank is also changed periodically. But the
flywheel fixed on the crankshaft has a big rotary
inertia, which can be regarded to do uniform
rotation, so at one moment the crank speed is
faster than the flywheel and the next the crank
speed is slower than the flywheel, which can
form a torsional oscillation against the flywheel,
such is the crankshaft torsional vibration. When
the ratio of the excitation frequency to the
natural frequency of the crankshaft is an integer,
1
Absorber
Absorber
2
Pulley
3
Bolt
the crankshaft will produce resonance.
Reduce the vibration, avoid
Function
resonance
Principle
Friction in the damper gradually
consumes the energy of the crankshaft torsional

vibration to gradually reduce the amplitude.
32

4
Six cylinder engine crank layout
Principle
1.The firing interval should be uniform

to ensure that the engine is running
smoothly.
2.The two continuous working cylinders
1-6
should be as far as possibleTo reduce

the load of the main journal, and avoid
the overlap of the air influences the air
intake.
5-2
3-4
33

5Firing order of six-stroke engine
The four stroke inline six cylinder
engine firing angle is 720/6=120 , six
Crank
corner
cranks are respectively arranged on the
0~60
three planes, the firing order is 1-5-3-6-
60~120
2-4.
T h e c y l i n d e r o f t h e We i c h a i
WD10G220E23 engine, near the fan, is
the first cylinder.
Cylinder
1
Cylinder
2
Cylinder
3
Cylinder
4
Cylinder
5
Cylinder
6
exhaust
intake
power
compre
ssion
intake
power
compre
ssion
120~180
intake
180~240
240~300
power
exhaust
power
300~360
360~420
420~480
intake
exhaust
power
exhaust
660~72
0
compre
ssion
power
540~600
compre
ssion
compres
sion
intake
compre
ssion
480~540
600~660
exhaust
intake
exhaust
exhaus
t
intake
power
compr
ession
34

1
Overview
The function of valve mechanism is to control
7
the air inlet and outlet, which regularly controls
the opening and closing of the intake and exhaust
valve, supply mixture fresh air to the cylinder
and timely draw used air out according to the

requirement of the cylinder working order and
working process. In addition, when the inlet and
outlet valve closed, it can ensure the cylinder

seal.
When the engine works, the camshaft is
driven by the crankshaft through the timing gear,
the cams push the tappet and rod and pass the
action to the rocker arm which rotate around an
axis to overcome the spring force to push the

valve moves down and be opened. When the
camshaft continue to rotate and cross the
3
maximum pushing process, the valves will return
to the original position and be closed.
1-pushrod
2-tappet
3-camshaft
4-valve
5-valve spring 6-locking plate 7-rocher arm
35

2
Main composition of valve mechanism
The valve mechanism is maily composed of

Valve assemb ly and valve tr ansmissio n
assembly.
1
Valve group
Valve spring retainer
The valve assembly includes valves, valve

seats, valve guides, valve springs, locking plate
and retainer.
Locking plate
(1) Valve
The function of the valve is to control the
opening and closing of the inlet and outlet valve,
Snap ring
resist high temperature, high pressure and
impact, require the valve to have the following
characteristic: sufficient stiffness, strength, wear
resistance, high temperature resistance, corrosion
resistance, impact resistance.
(2) Valve guide
It's function is to guide the valve, ensure the
valves do straight reciprocating motion. In
adition, it has the function of heat transfer, pass
heat from the valve head to the rod shaft, and
spread out through the cylinder head.
Valve spring
Valve cone angle
valve
36

3
valve seat
The valve seat interacts closely with the valve
head sealing conical surface to seal the cylinder,
Valve spring retainer
and the heat from the valve head can be

transmitted to the outside through the valve seat.
4
valve spring
Locking plate
The function of the valve spring is to ensure

the valve's return, prevent the transmission parts
detachment during movement. When the valve
Snap ring
closed, the valve spring should ensure the seal

between valve and valve seat. when the valve
opened, it should ensure the valve can't be
separated from the cam by the inertial force
created during the movement. The valve spring is
a cylindrical spiral spring, one end is supported
on the cylinder head and the other end is pressed
against the spring seat which is at the end of the
valve rod, the spring seat is fixed to the end of
the valve rod with a locking plate.
Valve spring
Valve cone angle
valve
37

2
Valve transmission assembly
The valve transmission assembly transfers
movement between camshaft and valve, which
includes camshaft, tappet, push rod, rocker arm,
valve clearance adjusting screw and other
components.
1
Camshaft
The camshaft controls the opening and
Cam shape
Air intake (exhaust) cam angle
closing of the valve, each intake valve and

exhaust valve respectively has corresponding
Push rod
intake cam and exhaust cam, the valve opening

and closing time and height can be influenced by
the rotation of the cam, the cam arrangement
influences the opening and closing time of the
valve and working order.
The cam has two types, the inlet cam and
outlet cam, the number of cams is the same as the
number of inlet and outlet valves. For each
SixSix-stroke
engine camshaft
Rocker arm
working cycle, the crankshaf will turn two
tappet
cycles, and the camshaft will turn one cycle.

360/60=60
The angle between the same name valves for

each cylinder is 360/60=60
38

2
Tappet
The function of the cam tappet is to
transmit the thrust from the cam to the
push rod, and bear the lateral force
exerted by the rotation of the camshaft.
3
Pushrod
The function of the push rod is
to
Cam shape
Air intake (exhaust) cam angle
transmit the thrust from the camshaft to

the rocker arm, which is the most easily
Push rod
flexible parts of the gas distribution
mechanism
4
rocker arm and seat
The function is to transmit the thrust
from the tappet and push rod to the
rocker arm to push the rocker arm swing
to open and close the valve.
SixSix-stroke
engine camshaft
Rocker arm
tappet
39

3
valve clearance
definition
Valve clearance means the clearance
between the end of the valve rod and
rocker arm or tappet when the valve is
completely closed under the cold
condition.
function
The function is to compensate for the

amount of expansion after the valve is
heated. Different models have different
size of valve clearance, the exhaust valve
clearance is larger than the inlet valve
clearance in common cold state.
40

valve clearance
Valve clearance is too large or too small
3
will cause certain harms:

If the valve clearance is too large, which will
cause the the open of the inlet and exhaust valve
delayed, the exhaust time shortened , the valve
opening height reduced, and the normal gas
distribution phase changed , result in insufficient
air intake and incompletely air exhaust, parts of
the gas distribution mechanism impact increased
and wear accelerated. If the valve clearance is
too small, when the parts heated and expanded,
WD10G220E23 engine intake and exhaust valve clearance

cool state
state
Intake valve
Exhaust valve
0.3mm
0.4mm
which will push the valve open, cause the valve

can not be tightly closed to prevent the gas to be
released, reduce the engine power, result in
serious carbon deposition or burn, and even the
valve strike the piston.
The Weichai WD10G220E23 engine air intake
valve clearance(cold machine) is 0.3mm and the
exhaust valve clearance is 0.40mm
41

3
valve clearance
adjustment and inspection of valve
clearance
1Using the 13mm socket wrench to
remove the 6 cylinder head cover.
2Use the 32mm Crank Wrench to

slowly rotate the diesel engine, adjust the
tick mark on the flywheel house point to
the OT mark and the piston of the first
cylinder point to the compression top
dead center(The inlet and exhaust valves
of the first cylinder are closed.)
The first cylinder is from the fan end.
42

3
Valve clearance
Adjustment and inspection of valve
clearance
5
Take the intake and exhaust valve
clearance
with
feeler
Intake valve clearance: 0.3mm

Exhaust valve clearance:0.4mm
Notice: When measuring the valve clearance,
the accurate value is taken under the
condition that the diesel engine should be in
a cold state(lower 60 ), and there should be

a obstacles sticky feeling as the feeler slides
between the valve lifter and the rocker.
6
When adjusting the valve clearance,
first unscrew loosen the locknut and the

adjusting bolt, and then place the required
thickness feeler between the rocker arm and
the valve, tighten the adjusting bolts, and
then tighten the lock nut.
43

3
valve clearance
adjustment and inspection of valve
clearance
7
Rotate the engine until the first cylinder
to the compression top dead center, adjust

the clearance of the intake and exhaust valve
of the first cylinder, the intake valve of the
second cylinder, the exhaust valve of the
third cylinder, the intake valve of the fourth
cylinder, the exhaust valve of the fifth
cylinder, the sixth cylinder should not be
adjusted. See right picture(I means the air
intake, E means the air exhaust).
8
Keep on rotating the engine until the
sixth cylinder to the compression top dead

center, then adjust the other valve clearance
which have not been adjusted in the seventh
adjusting step.
44

4
valve phase
1Intake valve early opening and late

closing
Enlarge the valve opening height at the
beginning of the air intake stroke, reduce the air
intake resistance, and increase the air intake
quantity.
Intake valve late closing
Delaying the intake time, and increasing the air

intake q uantity und er the effect o f the
atmospheric pressure and the gas inertia force.
Exhaust valve open early
The cylinder can exhaust the gas by itself with

the help of the high pressure in the cylinder,
which can reduce the exhaust resistance,and
ensure the gas discharged cleanly.
Exhaust valve close late
Extending the air exhaust time, and ensure the

air completely discharged the pressure and
inertia force of the exhaust air.
45

4
valve phase
Valve phase
2
valve overlap
As the inlet valve opens early, the exhaust
Compression
process
valve closes late, the inlet valve opened before

the upper dead point, while the exhaust valve
closed after the upper dead point, which
Working process
inevitably cause the phenomenon of two valves

opened at the same time, in this case the valve
angle will be overlapped, when two valves
opened at the same time, the corresponding crank
angle is called the valve overlap angle.
3 Ai r
a c t ua l i ntake and exhaust valve
opening, closing and duration time.
Exhaust process
Intake process
The actual air intake and duration time:

At the end of the air exhaust stroke, the piston
reaches the upper dead point, when the
crankshaft turned to a position where the angle
between the crankshaft and the upper dead point
is a, the inlet valve begin to open, and will be
closed until the piston accross the bottom dead
point.
46

4
valve phase
3
Air actual intake and exhaust
Valve phase
valve opening, closing and duration

time.
Compression
process
The actual time and duration of the air

intake.
Working process
The duration of the entire intake
process is equivalent to the crank
rotation angle: 180 + + .
: Intake advance angle, generally =
10-30
: Intake lag angle generally=40Exhaust process
Intake process
80
Weichai WD10G220E23 engine:
Exhaust advance angle =34 39
Exhaust lag angle =61 67
47
valve phase
3Intake and exhaust valve opening
4
Valve phase
Compression
process
and closing time and duration.

The actual time and duration of the air
intake.
When the working process is closing to the
Working process
end, and the piston angle before the bottom

dead point is , the exhaust valve opens.
When the piston passes the up dead point,
and the after angle is , the exhaust valve is
closed. The crankshaft rotates 180
+ +
during the whole process.

:exhaust advance angle
80
:Intake lag angle
generally =40-
Exhaust process
Intake process
generally: =10-30
Weichai WD10G220E23 engine:
81
Intake lag angle =26 34
exhaust advance angle =76
48
High pressure pipe
Oil injector
1.overview
(1) composition of fuel supply system
The fuel supply system consists of injection
pump, fuel supply pump, fuel filter, injector,
high pressure oil pipe, low pressure oil pipe
and other accessories.
2function of fuel supply system

The main function of the fuel supply
system is to continuously feed the engine
with filtrated clean fuel, and inject certain
amount of diesel into combustion chamber as
certain pressure and
quality according to
different engine performance requirements,

which will mix and burn with the air rapidly
.
Fuel supply system consists of fuel
injection pump, fuel delivery pump, fuel

filter, fuel injector, high pressure oil pipe,
low pressure oil pipe and accessories.
High pressure
pump
Low
pressure
pipe
Fuel filter
49

1.overview
3working process of fuel supply system

The engine rotation is transfered from the
coupling or drive gear to the injection pump

camshaft through the advance device. The
camshaft rotation drives the fule delievery pump
suck oil from the fuel tank, the filter clean oil
will be delivered to the plunger through fuel
channel in the fuel injection pump, the plunger
will move upward through the cam shaft rotation,
the piston, the fuel pressure will increased to a
high pressure, and the fuel oil will flow into the
injector nozzle through the high pressure oil pipe
and the injector.
When the pressure of the fuel oil delivered to
the injector nozzle reaches above the specified
starting injection pressure of the injector, the oil
will be sprayed into the engine combustion
chamber in the form of mist.
The overflowed or left fuel oil of the fuel
injector and fuel injection pump will flow back to
the fuel tank through their respective fuel pipe.
50

Injection pump
2.Oil injection pump
1function of injection pump
high pressure fuel pump
The main function of the fuel injection pump is

to supply certain amount of high pressure fuel to
the injector in regulation time
while at the same
time accomplishing the engine rotary speed

control.
2basic demand of injection pump

The fuel pressure should ensure
the
requirement o f t h e injection pressure and

atomization quality.
The fuel supply should meet the exact
amount of fuel required by the diesel engine.
Ensure the diesel engine working order and
accurate fuel supply within the given time.
The amount of fuel supply and fuel injection
timing could be adjusted to ensure each cylinder

oil supply evenly.
The fuel supply regulation should ensure the
diesel fuel burned completely.
The beginning and ending of the oil supply
oil return pipe
connector
Injector assembly
must act quickly, the oil cut off must act swiftly
to avoide oil drip.
51

(3)working principle of injection pump
oil intake process
The plunger will move downward under
the force of spring after the cam convex
portion turned over the highest position
which will creat vacuum in the plunger
upper space (called the pump oil chamber),
when the hole on the plunger sleeve
opened by the plunger upper end, the
diesel fuel in the oil channel of the pump
upper space will enter the the pump oil
chamber through the oil inlet, when the
plunger moves to the bottom dead center,
the oil inlet progress ended.
52
3working principle of injection pump

oil supply process
When the camshaft turned to the cam convex
portion and lift up the roller body, the plunger
will move upward under the force of the spring,
the diesel oil will be compressed, and part of the
fuel will return to the upper oil chamber of the
injection pump through the oil hole. When the
plunger upper end cover the upper edge of the
inlet hold on the sleeve, the pump oil chamber
will become a sealed oil chamber at the top of
the plunger, the p lunger continues to move
upward, the pressure in the pump oil chamber
will rapidly increased, when the pump oil
pressure > the spring force of the oil outlet valve
+ the residual pressure of the high pressure pipe,
the oil outlet valve will be pushed open, the high
pressure oil will enter the high pressure pipe
through the oil outlet valve, and sprayed into the
combustion chamber through the injector.
53
3working principle of injection pump

oil return process
The plunger supply oil upward, when the
plunger moves to a position where the chute
connected to the oil return hole on the sleeve, the
low pressure oil channel of the pump oil chamber
will be connected with
the mid level outlet, radial hole and the chute, the
oil pressure will be lowered, the oil outlet valve
will rapidly closed under the spring force, and
the oil supply will be stopped. Then the plunger
will still move upward, when the cam convex
portion turned over the highest position the

plunger will move downward under the spring
force, and the next cycle is begin.
54

3.governor
1
working principle
The fuel injection volume can be
changed by the governor by controlling
the movement of the governor rake.
When the engine load increased and
the rotation speed decreased, the
governor will automatically increase the
amount of fuel injection to prevent
engine power off.
When the engine load decreased and
the rotation speed increased, the
governor will automatically reduce the
amount of fuel injection to prevent the
engine speed is too high.
Right picture shows the basic structure
1pull-rod2speed adjusting bolt3guide rod4floating lever5

high speed limit screw6control handle7idle screw
8shift yoke rod9idle spring10stroke adjusting screw
11speed adjusting sleeve12flyweight13roller14camshaft15
adjusting speed spring16adjusting gear17connecting rod18start
spring19 speed adjusting rod20-speed stabilizing spring
of the RAD type speed governor.
55

4.Fuel delivery pump
1structure
The fuel delivery pump is installed on one

side of the oil injection pump and is droven
by the eccentric cam of the injection pump
camshaft.
2function
The function of the delivery pump is to
send the fuel from the fuel tank to the low
pressure oil chamber of the oil injection
pump by passing through the oil filter.
The fuel delievery pump is equipped with a
manual pump, which is used to exclude the
air in the low pressure oil channel, and
ensure the channel full of diesel oil, so that
the engine can easily be started.
The screw in the air filter inlet channel is
equipped with a strainer to filter the
impurities in the fuel.
56

4. Fuel delivery pump
3working principle
The eccentric gear pushes the piston move
downward through the push rod, volume of the
working chamber under the pistion decreased,
the inlet valve closed, the outlet valve opened,
and the volumn of the pressure chamber above
the piston increases, which causes the generation
of a vacuum, and the diesel can flow into the
pressure chamber along the direction of the
arrow by passing through the outlet valve.
Eccentric gear turns away, the piston moves
upward under the force of the spring, negative
pressure created in the working chamber beneath
the piston, the outlet valve closed, and the inlet
valve openned, oil flows into the working
chamber, the volume of pressure chamber B
decreased by the upward movement of the
piston, the pressure of the diesel in the chamber
increased, oil flowed to the outside, which
pressure controlled by the spring pretightening
Working principle map of oil delivery pump

force.
57

4. Fuel delivery pump
3
working principle
When the oil input of the fuel delivery
pump is greater than the output, the
pressure of the oil pipeline and the
pressure chamber B will increased to be
greater than or equal to the spring
pretightening force. At this time, the
piston can not return to the upper dead
point, the piston stroke will be
decreased, and the amount of the oil
supply will also be increased
accordingly, such as to achieve the
automatic adjustment of the oil volume
and oil pressure.
Working principle map of oil delivery pump
58

5.Oil injector
1
working principle
The fuel outlet is closed by the injector
nozzle needle under the pressure of the
Outlet
valve
Injector unit
injector spring. When the injection

pressure reaches the injector spray
pressure, the needle will be jached up,
and the fuel will be sprayed out in the
form of mist.
Rotating the regulating screw, the
spring pressure will be changed, that is
the adjustment of the fuel injection
pressure.
59

5.Oil injector
2
Function and requirement
The function of the fuel injection pump
Overflow pipe
unit
Return oil tank
Pressure adjusting
valve
is to spray the high pressure fuel oil from

the fuel injection pump, under a certain
Injector unit
spring
pressure, in the form of mist.

Vaporific injecting text
Requirement:
Uniform atomization
Rapid injection
No post-drop phenomenon
The shape and direction of the oil
beam suit the form of the combustion
chamber.
Push rod
Connect oiloilinjector pump
Injector unit
body(nozzle)
60

6.Fuel water-separator
The fuel water-separator contains electric
Electric
pump
pump, water filtration, electronic controllers and

other three parts.
Main function of the fuel water-separator
1
To solve problems, such as engine start
Oil inlet
M16X1.5
failure, engine power off and lack of motivation

in cold regions caused by fuel wax.
2
To solve the problem of high rate of starter
failure caused by the using of starter to discharge

gas.
3
Electronic
controller
To solve users' complain about the artificial
air exhaust when doing filter maintanance, or

when there were air in the pipe.
4
To solve engine start failures caused by big
Oil outlet
M16X1.5
temperature changes in some places, sharp

temperature decrease and Cross-regional
operation.
Water filter
61

6.Fuel water-separator
Working principle of electric pump
1
Pump oil and discharge gas: Open the electric
pump by the electronic controller of the electric

oil pump filter, a vacuum negative pressure is
formed by the high-speed rotation of the inner
roller, which will make the fuel oil flow in the
24V oil pumping
heating power
low pressure oil pipe, so that the air will be

discharged from the fuel pipe.
2
Turn
t h e i gnition switch to the ON
position,the fuel water-separator will begin to

pump oil, and will be automatically stopped in 10
input
Negative
earth
Union DJ431DJ431-4C
24VDC power
minutes, if need to pump oil again, turn off the

ignition switch, restart it again, the new cycle
will begin.
When the environment temperature is below

7, and the ignition switch turned to the ON
30A fuse
position, the fuel water-separator begins to start
T15
switch
heating, and will be automatically stopped when

the tempreture reaches 24
62

7.Fuel filter
Fuel filter is a two-stage series, the
primary filter is felt filter, the fine filter is
paper filter, both of them are mounted on the
same filter seat, with a "" mark casted on
the surface to indicate the flow direction of
the fuel oil.
The function of the filter is to remove
harmful particles and water from the engine
fuel gas system to protect the pump nozzle,
cylinder liner, piston rings, etc., reduce wear
and avoid jam.
Fuel oil filtered in the fuel water-seperator,
then into the fuel filter to further filtration,
and finally into the fuel supply pump of the
high-pressure pump.
63

5.Oil injector
3injector style
Currently the fuel injectors adopted by the
Filter
needle
Inlet port
diesel engine are all closed injector, which

has two kinds, hole type and shaft needle
type.
Outlet port
adjusting
washer
The injector of the Weichai

WD10G220E23 engine is the closed hole
type, the opening pressure is 225+5bar, the
nozzle is thin-walled heat-resistant steel
Pressure
adjusting
spring
sleeve, with a insulation sheath in the nozzle

head, the purpose of this design is to reduce
block
Injector
body
Spring seat
the direct contact between the nozzle and the

gas, so as to reduce the temperature of the
nozzle head, and improve the working
Needlevalve part
reliability and service life of the nozzle.
Tensioning
cap
64
Section 5 Lubrication system
Function
The function of lubrication system is to

delivery certain amount of lubricating oil to the
surface of the parts with relative motion,
realizing the liquid friction, reducing the friction
resistance and mechanical wear, and cleaning
and cooling the surface of the parts. Summarized
as follows:
lubricating parts surface, reducing
Lubrication
wear and engine power consumption.
Cleaning the friction surface, removing
Wash
abrasive dust and other foreign matters.

cooling
Engine oil can take away heat
generated by friction when cycles in the

Lubricating system.
sealing
Forming a film of oil between parts to
1- pressure limiting valve;2-oil strainer;3-engine oil pump;4-radiator;
improve sealing, prevent leakage of gas and oil.
5- pressure limiting valve;6-crankshaft;7-connecting rod small end;
antirust
8-camshaft;9-rocker arm shaft;10-tappet;11-injector pump
Forming a film of oil on the surface of
parts to prevent the corrosion and rust.
12-air compressor;13-supercharger;14-main oil passage;

15- pressure limiting valve;16-engine oil filter;17-filter by-pass valve
65

2
lubrication method
1
Pressure lubrication
Using the oil
pump to continuously send certain pressure
of lubricating oil to the friction surface,
which is called pressure lubrication, such as
crankshaft bearings, connecting rod bearings
and camshaft bearings, etc.
2 Splash lubrication T he wa y of
using oil droplets or oil mist flied up by
engine parts to lubricate friction surface is
called the splash lubrication, such as cylinder
wall, piston pin, valve cam tappet surface,
etc.
3
Composition lubrication
Lubrication of two or more than two kinds.
1- pressure limiting valve;2-oil strainer;3-engine oil pump;4-radiator;
4
Grease lubrication
Such as
5- pressure limiting valve;6-crankshaft;7-connecting rod small end;
lubrication in water pump.
8-camshaft;9-rocker arm shaft;10-tappet;11-injector pump

12-air compressor;13-supercharger;14-main oil passage;
15- pressure limiting valve;16-engine oil filter;17-filter by-pass valve
66

3
Main parts
The lubrication system is mainly
composed of oil strainer, oil pump, oil
filter, main oil pressure limiting valve,
oil radiator and oil pan and other
components.
Engine oil
pump
Oil
pan
Engine oil
cooler
Engine oil
filter
67

3
main spare part
1
oil strainer
Oil strainer installed in the oil pan for
coarse filter, as shown in the right
picture.
1-oil strainer
2-gasket
3-washer
4-bolt
68
main spare part

2engine pump
When the gear oil pump works, the driving

gear drives the driven gear to rotate in
counterclockwise direction, the engine oil
fully filled between the alveolar will flow
from the oil inlet chamber to the oil outlet
chamber along the wall of the pump housing,
on the side of the oil inlet chamber, because
Drive gear
Pump body
Pump cover
of the vaccum generated by the gear

disengaging and the oil continuously being
brought out, the oil in the oil pan will enter
the oil inlet chamber through the oil strainer
under the atmospheric pressure, but on the
other side of the oil outlet chamber, because
of the pressure effect generated by the gear
engaging and oil continuously being brought
in, the oil will be pumped out at a certain
pressure.
Driving
gear shaft
Drive
n gear
Driving spring
gear
Pressure limiting valve
69

3.Engine filter
When the engine works, metal wear debris,
dust in the air and carbon particles generated by
incomplete combustion of the fuel oil will go into
spring
the engine oil, and the engine itself will generate
By-pass
valve
gelatinous precipitates due to thermal oxidation,

if such dirty oil were directly delivered to the
surface
of
the
moving
part,
mechanical
impurities in the engine will become abrasive
lever
which will accelerate the parts wear and cause

the oil duct obstruction, piston ring, engine
valves and other components cementation.
Filter
insert
Therefore, oil filter is designed in the lubricating

system to filter the engine oil and extend the
service life of the machine.
pressing
spring
The oil flow direction shown by the arrows in

the right picture, there is a bypass valve on the
upper cover, when the filter insert is blocked, the
bypass valve will be openned by the pressure of
Paper filter
the engine oil, the lubricating oil will flow

directly into the main oil channel without passing
through the valve insert, thus guarantees the
engine oil supply could not be interrupted.
70

4.Enging cooler
The engine oil cooler placed in the engine oil
Oil outlet port
cooling channel, using the coolant temperature to

control the temperature of the lubricating oil, the
lubricating oil could be cooled by the coolant
Water
inlet port
insert
Water
inlet port
when the its temperature is high, when the engine

starts, heat will be absorbed from the coolant to
cover
quickly raise the temperature of lubricating oil.
insert
The Weichai WD10G220E23 uses the plate-fin

radiator, which is installed in the coolant channel
Water outlet
port
on the right side of the engine, with good cooling
by-pass valve
Oil outlet port
capacity, and ensure the engine oil works in a

suitable temperature range.
Engine cooler
The engine oil cooler has a safety valve, with an

opening pressure of 0.6Mpa to ensure the engine
is lubricated as usual, the pressure can prevent
the safety valve openned and the engine oil flow
directly into the main channel without by passing
Oil outlet port

Oil inlet port
through the oil cooler when the engine oil cooler

blocked.
71

5.Crankshaft case ventilation
When the engine works, part of the
combustible gas mixture and the exhaust
gas leaks into he crankcase through the
Air filter
piston rings, which will be condensed

into droplets to dilute the lubricating oil.
Meanwhile, high temperature of the
exhaust gas and the acidic substances or
water vapor in the exhaust gas will erode
parts, and make the oil performance
deterioration. In addition, since the
mixture gas and the exhaust gas enters
the crankcase, the pressure in the
Air inlet
pipe
crankcase will be inceased, temperature

will be raised, and engine oil will easily
leak outward from the oil seals, gaskets,
Natural
ventilation
etc.
72

5.Crankshaft case ventilation
T h e c r a n k c a s e o f t h e We i c h a i
WD10G220E23 engine uses natural
ventilation, the crankcase is connected to
the air through oil and gas separator.
The function of the oil and gas
separator is to ensure crankcase pressure
and environmental pressure balanced,
and separate the high temperature oil in
the crankcase, the separated liquid
engine oil will flow back to the oil pan,
which will reduce oil consumption.
73

3.Engine oil filter
The Weichai WD10G220E23 engine
oil filter is a rotary type paper filter,
good filtering effect, strong filtering
pass-ability, and an opening pressure of
250 17.5kPa bypass valve to prevent
the pressure limiting valve openned
when the filter blocked.
The engine oil filter should be changed
according to the using condition and
maintenance requirements, can not be
washed and reused.
1-assembly seat
2-washer
34-bolt
5-engine oil filter
74

Cooling water line
1
Cooling system function
The function of the cooling system is to
timely distribute heat absorbed by the
heated parts to ensure the engine
Radiator
cap
Radiator
Water temperature
indication
working in the most suitable temperature

Water temperature
sensor
conditions.
Shutter
According to the cooling mode, It can

be divided into two types, the air-cooled,
water-cooled.
The Weichai WD10G220E23 engine
Water
pump
Divide water
pipe
Fan
using the forced closed pressure

circulating water cooling.
It consists of the radiator, water
Drain
plug
pump,fan, cooling water jacket and a

thermostat device.
75

3
main spare part of cooling system
1
radiator
Radiator is also called water tank,
which is composed of upper water
chamber, radiator core and the lower
water chamber, etc.
Its main function is to increase the heat
dissipation area, accelerate the water
cooling.
The coolant temperature can be reduced
by 10-15 after passing through the
radiator, a fan installed behind the
radiator to take away the heat released
from the radiator by coordination with
the radiator.
76

2
Water pump
The coolant is pumped into the right side water

chamber of the engine by the water pump, first
cool the oil cooler, then entering the water
channel inside the engine to cool the cylinder,
Pump shaft
next entering the cylinder head water chamber

through the string holes on the cylinder block and
Pump impeller
cylinder head to cool the gas valve, injector and

cylinder head, finally flow back to the water
outlet pipe which end connect with the
Water outlet
pipe
thermostat.
Water inlet
pipe
77
Thermostat in the small

circulation
Thermostat in the large

circulation
3.Thermostat
The engine thermostat contains a thermal
element( wax which could expand when
heated and contract when cooled ) which can
be moved up and down according to the
different remperature.
When the coolant temperature is low, the
wax will contract, which will close the
mouth of the channel leading to the radiator,
and open the channel leading to the water
to radiator
to radiator
Thermostat
Spring
Thermostat
Spring
valve
valve
Plunger
Plunger
Open the entrance

to radiator
pump(small circulation).
When the coolant temperature rises to a
certain extent, the was will expand, which
will open the mouth of the channel leading to
the radiator, and close the channel leading to
the water pump(large circulation).
From
engine
Hot
sensing
body
From
engine
Hot
sensing
body
Open the entrance

to pump
To pump
Cooling water in low

temperature
Cooling water in
high temperature
To pump
78

3.Thermostat
Thermostat of the Weichai
WD10G220E23 engine, as shown in the
right picture.
Valve seat
Small
spring
Valve
Vice
valve
Support
&205
79
Large
spring
Shell

4.Cooling water circulation
The cooling water cycle is divided into small
circulation and circulation which are two kinds
of circulation state of the coolant circulation.
When the temperature is below 71
, the
cooling ability will be weak, which will lead the

coolant temperature rise rapidly, so as to ensure
all parts of the engine rapidly hot or avoid the
engine to be too cold, at this time, the circuit is
short, and the flow is small, which is called samll
circulation, the flow path: thermostat - pumps - water - oil radiator thermostat.
When the temperature is higher than 82
, the
cooling ability will be strong, which will lead the

coolant temperature decrease so as not to get too
high, at this time, the cooling circuit is long, and
flow is large, so called large circulation.The path:
thermostat - water pump-engine oil radiatorwater sleeve-thermostate.
When the temperature is between 71-82
, the
Large
spring
cycle enter mixed circulation, namely, the small

circulation and large circulation are carried on at
the same time.
80

1
Function
The intake and exhaust system draws air into
Valve seat
the cylinder, mix and burn it with the fuel oil,

and then discharg the exhaust gas to the outside.
The fresh air enters the turbocharger inlet after
passing through the air cleaner, the pressure and
air density will be incr eased,
and the
temperature will rised.

The fresh air enters the turbocharger inlet after
passing through the air cleaner, the pressure will
be increased, and the air density and temperature
will be increased accordingly.
The cooled air will be burned in the cylinder
after passing through the valve, changed into
exhaust gas and discharged outside the cylinder
through the compression stroke. The exhaust air
will enter the turbocharger through the exhaust
pipe, and will be discharged outside from the
outlet of the turbocharger after pushing the
1-air filter
2-intercooler
3-piston
4-turbocharger
turbine rotate at high speed.

Exhaust gas from the turbocharger will be
discharged into the atmosphere after passing
5-air line connecting pipe
6-silencer
through the silencer and carbon removal.
81

3
Spare part
1.Air filter
Function
The cleaned air will enter the
combustion chamber after filtered from dust and

impurities to reduce the wear between the piston
and cylinder liner, the piston group and valve
group.
Principle
After entering the air cleaner, the air
will rotate between the air cleaner housing and

air filter insert under the action of the shroud,
larger particles and dust in the air will be thrown
to the air cleaner housing due to the centrifugal
force, and will fall along the housing into the
bottom cover and dust collecting bag, the
centrifuged and purified air will pass through the
paper filter and the felt security filter to filter out
fine dust, and at last enter the turbocharger inlet
pipe through the central channel of the safety
filter.
If the filter is dirty, when the engine works, the
degree of the vacuum will be increased, and the
indicator of the filter will turn red to warn that
the air cleaner needs to be cleaned or replaced.
82

3
Spare part
2.Turbocharger
Principle Using the engine exhaust
pressure waves to drive the turbine,
Engine
Air outlet line
Turbocharger
bring the compressor impeller on the

other side to blow air.
Function: Supply additional air to the
Air inlet port
engine, so that it can burn more fuel, and

generate more power.
Air outlet line
83

3
Spare part
2.Turbocharger
Structure
The turbocharger is mainly composed

two parts , the compressor and t h e
turbine.
The compressor in mainly includes
single stage centrifugal compressor,
diffuser and the compressor casing.
The turbine section: including turbine
shell, single-stage radial turbine.
84

3
Spare part
Air outlet
2.Turbocharger
outlet connection
Rear cover
Air compressor casing, impeller casing

and the middle connection are the main
fasteners, the impeller casing and the
middle connection connected with each
other by bolts and cover plate, the
Air compressor casing
compressor casing and the middle

connector connected with each other by
the rear plate of the
, bolts and cover
Inlet connection
plate.
Air compressor casing could be
installed in different directions around
the axle.
Air inlet
Air compressor
impeller
85

3
Spare part
2.Turbocharger
Double flowing way
Heat
shield
Turbocharger rotor bearing is the inner

supporting type, with floating bearing
Air
outlet
locating in the middle connector between

the two impeller, axle force of the rotor
depends on the end surface of the thrust
bearing to support.
Thrust bearing
and seat
Floating bearing
Exhaust
flange
Turbine and shaft

Connection flange
Air inlet
86

3
Spare part
2.Turbocharger
Turbine shaft and turbine are welded
together as a whole part, impeller is
installed on the turbine shaft with
clearance coordinate, and be compressed
by nut.
Rotor working rotation speed is from
tens of thousand to more than two
hundred rotation per minute.
Purpose of the moving balance
lengthen the bearing life.
reduce vibration
reduce noise
reduce power lose
reduce rotor load
Rotor
87

3
Spare part
2.Turbocharger
Lubrication of the turbocharger
Oil inlet
The turbocharger adopts pressure

lubricaiton, the lubricating oil flows into
the oil inlet through the main oil channel
on the fuselage, enter the lubrication
system, and then return back to the oil
pan through the oil outlet.
Function of the lubrication system.
Cool heat generated from the
turbocharger working.
Supply lubricating oil to the bearing
system.
Provide film support for the rotor
moving balance.
Oil outlet
88

3
Spare part
3.Intercooler
Function: Cool the heated air from the
turbocharger, increase the air density,
improve engine gas charging efficiency.
Generally speaking, the temperature of
the air will be increased more than
1 0 0 a ft er p as s i n g t h rou gh t h e
turbocharger, the air will expand after
being heated, which is not good for the
air inlet, but the temperature could be
reduced by passing through the charge
air cooler.
Classification: air-air charge air
cooler, water-air charge air cooler.
Notice: LG956L engine doesn't have a
charge air cooler.
89

3
Spare part
4.Silencer
Change the flow direction of the
exhaust air to consume the energy of the
exhaust air by ways of , and balance air
flow pressure fluctuation to get the
needed attenuation character, so as to
reduce the noise.
90
Section 8. Common malfunction

1. Engine does not start
91
Serial
number
1
Cause of malfunction
Repairing method
Starter motor speed is too low
Check the starting system, cranking speed shall not be less than 110 r/min.
Air in fuel supply system
1. Check fuel pipe connector for loose. Release bleed screw on the fuel
filter, and use hand pump to pump fuel, until the overflow of fuel without
air bubbles.
2.Release high pressure fuel pipe connection on injector, and use hand
pump to pump fuel, until the overflow of fuel without air bubbles.
Fuel line blocked
Check fuel supply lines for unobstructed.
Fuel filter blocked
Replace the spin-on filter element of fuel filter assembly.
The delivery pump can not feed Check the fuel inlet lines for leaks and fuel delivery pump for
fuel or feed intermittently
malfunction.
Fuel injection less, no injection

or injection pressure low
1. Check the injector spray condition;

2. whether the injection pump plunger and the outlet valve is worn or
stuck, whether the plunger spring and outlet valve spring is broken.
Starting system circuit wiring

error or poor contact
Check the wiring is correct and reliable.
The battery power insufficient
Charge the battery.
Starter motor carbon brushes

and commutator contact poor
Repair or replace the electric brush; clean the commutator surface by

abrasive paper and blow it clean.
10
Low compression pressure low

due to piston ring excessive
wear or valve leaks
Check valve clearance, valve spring, valve guides and sealing of valve
seat, it is necessary to grinding valve seats if the sealing is poor.
11
Fuel shut-off solenoid

connector may be loose or dirty, Tighten, clean or replace.
corroded
12
Fuel injection timing is not

assembled correctly
Check and adjust.

2. Engine lacks of power
Serial
number
Repairing method
Air intake blocked
Check the air filter and air intake, clean or replace

the air filter element.
Exhaust back pressure is too

high
Check valve timing, adjust if necessary; clean

exhaust pipes.
Fuel lines leaking or blocked
Check sealing conditions of fuel lines and

fittings,check fuel filter for blocked, replace spinon filter element, check injection pump sealing.
Fuel injection pump plunger

excessive wear
Check and replace the plunger and barrel assembly.
Fuel injector poor atomization
Check fuel injection pressure,clean up the carbon

deposit, adjust and repair.
Fuel injection advance angle is

Check and adjust.
smaller or larger than normal
The air phase is error
Cylinder head gasket air leaks
Valve sealing poor

Piston rings is worn
excessively
10
92
Check and adjust valve timing and valve clearance.

Tighten the cylinder head bolts in sequence in
accordance with specified torque or replace
cylinder head gasket.
Grind or replace to regrind.
Replace piston rings.

3. Exhaust black smoke
Serial
number
93
Repairing method
Air intake blocked
Check the air filter and air intake pipes and clean-up.
Poor fuel quality
Use fuel up to specification
Fuel injector poor atomization Check, repair, or replace.
Valve clearance is excessive
Adjust valve clearance in accordance with the

standard

4. Exhaust white smoke, blue
smoke
Serial
number
1
2
3
4
94
Poor fuel quality, with excessive
water in fuel
Compression pressure is low,
incomplete combustion
Air supply or fuel feed timing is
not correct
Compression pressure is low,
incomplete combustion
Repairing method
Replace fuel up to specification.
Check piston ring and cylinder head gasket and
replace it.
The specialized staff to check and adjust.
Check piston ring and cylinder head gasket and
replace it.

5. Oil pressure is too low
Serial
number
1
2
3
4
5
6
95
Oil thin, or use improper oil
The oil pump rotor is worn or assembly
clearance is too large
Oil filter pressure regulator valve failure
The pump inlet pipe cracks
The pump inlet pipe mounting bolts loose
Shaft bearing clearance is too large
Repairing method
Select appropriate oil according to
specification
Replace the pump
Repair
Repair, replace
tighten to specified torque
Check and replace

6. Oil pressure is too high
Serial
number
96
Repairing method
Temperature is too low, the oil

viscosity is large
Choose specified type of oil, it is required to run at

slow speed after start, check wheel the oil
temperature is normal
Pressure relief valve blocked
Check, clean

7. Excessive oil consumption
Serial
number
1
2
3
4
97
External oil line leaks
Diesel engine is overload
The type of oil is improperly
The piston is stuck or excessively worn
Cylinder bore is worn excessively
Valve guide is worn, valve stem

sealing failure
Repairing method
Check and repair
Reduce the load
Use as required
Check, repair, and replace if necessary
Cylinder boring for increased piston or
installing the repair-using cylinder liner
Check and replace

8. High coolant temperature
Serial
number
1
2
3
4
5
6
98
Insufficient cooling water, the
water flow is too small
Whether the belt is too loose
Water pump leakage
Thermostat is failure or
damaged
Water temperature sensor is
damaged, the water temperature
sensor failure
The cylinder head gasket is
blow-out
Repairing method
Check whether the cooling water is sufficient and
add if necessary
Adjust
Repair in time
Check and replace
Check whether the actual temperature is identical
to the gauge indicating value; if not, replace the
temperature sensor or the temperature gauge
Check and replace
THE END
99

01 Engine System LG956L

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01 Engine System LG956L

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LG956L Training material

Chapter 3 Engine System

Chapter 3 Engine System

Section 1 overview of engine

Section5 Lubrication system

stroke, water-cooled, turbocharged

State three emission

WD10G220E23, the meanings of

Section 2 Crank and connecting rod mechanism

Crank and connecting rod

Piston rod assembly

The crank and connecting rod

Crankshaft flywheel assembly

Section 2 Crank and connecting rod mechanism

Section 2 Crank and connecting rod mechanism

engine. The cylinder block is usually

The lower surface of the cylinder block

Cars, small trucks

The lower surface of the cylinder block

Medium and heavy trucks

Main bearings are not separated

different position of the installation

the oil pan, the cylinder block is usually

Structure According to the

planes between the cylinder block and

Section 2 Crank and connecting rod mechanism

Section 2 Crank and connecting rod mechanism

Section 2 Crank and connecting rod mechanism

the dry cylinder liner is not directly in

The outer surface

With upper and

The outer surface

wet cylinder is just the opposite.

Dry cylinder liner

Contrary to the above

With upper and

Section 2 Crank and connecting rod mechanism

Section 2 Crank and connecting rod mechanism

crown and cylinder wall.

Poor rigidity, easily deformed by

cylinder split type and double

one cylinder per

two cylinder per

easy to be made or repaired, good

Section 2 Crank and connecting rod mechanism

Section 2 Crank and connecting rod mechanism

Section 2 Crank and connecting rod mechanism

pressure in the cylinder, and transmit the

Section 2 Crank and connecting rod mechanism

and withstand side pressure.

Section 2 Crank and connecting rod mechanism

The structure and characteristics of the

The top of the piston has a S - shaped

combustion chamber, and a pit which can avoid

DThe piston can be grouped by weight, the

G4G5. When replacing the piston, the

weight of the pistons on the same machine

Engine oil should be applied before the

piston installation, the opening of the piston rings

and angle between

the opening of the first ring and the edge of the

Section 2 Crank and connecting rod mechanism

ring and oil ring.