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WEICHAI WP10 Series Operation & Maintenance Manual
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WEICHAI WP10 Series Operation & Maintenance Manual

WEICHAI WP10 Series Operation & Maintenance Manual

National iv vehicle diesel engine
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Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine
User Service Guide for WP10 Series National IV Vehicle Diesel Engine
WEICHAI
Operation & Maintenance Manual and User's Service Guide
for WP10 Series National IV Vehicle Diesel Engine

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Summary of Contents for WEICHAI WP10 Series

  • Page 1 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI Operation & Maintenance Manual and User’s Service Guide for WP10 Series National IV Vehicle Diesel Engine...
  • Page 2 The diesel engine covered by this manual is the basic model of WP10 series National IV diesel engine. Following the continual development and improvement of the WP10 series product, we hope that you can timely pay attention to all technical information released by our company.
  • Page 3 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI Special Instructions ● Before operation, the operator of the diesel engine must carefully read the Operation and Maintenance Manual of the Diesel Engine and strictly abide by the operation and maintenance practices specified in the operation and maintenance manual.
  • Page 4 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI Contents Operation and Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine ......................1 Fuel, Lubricating Oil, Coolant, Urea Solution, and Auxiliary Materials for Diesel Engine ............................
  • Page 5 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI I. Operation and Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine Fuel, Lubricating Oil, Coolant, Urea Solution, and Auxiliary Materials for Diesel Engine Fuel: Summer: 0# diesel (GB252)
  • Page 6 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Antifreeze Additive for Engine Cooling System The glycol antifreeze additive is adopted. It’s allowed to substitute with home-made long-acting antifreeze additive, provided that the quality of such additive is reliable. Please refer to the relevant instructions for the specific operation methods.
  • Page 7 1.6.3 Professional protection prolongs engine life Through a great number of performance and durability tests in response to the Weichai engine, the professional compound for lubricating oil of high horsepower and high load engine is developed to provide professional protection for Weichai engine and effectively prolong the service life of engine (by 30%~40% against common engine oil).
  • Page 8 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Differences between Weichai Power Special Oils and Common Engine Oils Item Special engine oil Common engine oils Mainly the imported class Ⅲ hydrocracking base oil is Mostly the home-made class I or Base oil a little class II base oil is adopted.
  • Page 9 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Corresponding Table between Weichai Power Special Oils and Engine Models Standard number Type Recommended main applicable models of special oil WP-E1 Medium speed diesel engine unit (CD) National I and National II diesel engines;...
  • Page 10 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Table 3 Reference Table for Application of Sealant for Diesel Engine Additional Trademark Main Applications List of locations for application of sealant description Flywheel housing bolt Camshaft thrust plate bolt...
  • Page 11 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Uses and Operations of Diesel Engine Unsealing of Diesel Engine After the diesel engine is unpacked, the user shall firstly count the diesel engine and its accessories...
  • Page 12 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Hoisting of Diesel Engine During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to hoist in tilted or at one side. Hoist up and down slowly (Refer to Figure 2-1).
  • Page 13 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Checking of fuel level ◆ If the engine is installed on the vehicle, turn on the power switch and check the fuel level from the fuel gauge or check the fuel tank.
  • Page 14 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Start of Diesel Engine ◆ Place the power switch and electric key on the vehicle to position START, place the gearshift lever to neutral gear, and begin to start the engine.
  • Page 15 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Intake temperature after inter-cooler: 50~55ºC. Check the color of exhaust gas to judge the working quality and application load of the fuel injector. If the color of exhaust gas is really bad, stop the engine for checking.
  • Page 16 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI 3 Periodical Checking and Technical Maintenance of Diesel Engine Daily Maintenance Check the coolant level, engine oil level, and fuel level, check the lubricating grease application points for sufficient lubricating grease, check for leakage of oil, water and gas, check the...
  • Page 17 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Check engine oil level ◆ It’s prohibited to start the diesel engine when the oil level is below lower marking of oil dipstick or is above upper marking of oil dipstick.
  • Page 18 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Figure 3-4 ◆ Check the urea solvent level The urea solvent level shall be maintained at 30~80% of total capacity of urea tank. ◆ Check the fan Visually check the blades of fan for presence of damage and check connecting bolts for fastening.
  • Page 19 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI The belt is automatically tensioned by belt tensioner. Check the tension of belt by pushing the belt with hand. Figure -3-6 ◆ Check exhaust gas for normal color The normal color of exhaust gas is light grey.
  • Page 20 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Oil drainage plug Figure 3-7 Engine oil filler port Figure 3-8 Attention: The waste oil shall be placed in designated location and container to ease the recycling.
  • Page 21 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Replace engine oil filter or filter element. See Figure 3-9: ◆ At the replacement of engine oil filter, operate as per the following procedure: ① Remove used engine oil filter.
  • Page 22 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI ⑥ Conduct the leakage test. Fuel filter Figure 3-10 Attention: At the replacement of strainer or at the reinstallation of fuel delivery pipe, it’s necessary to bleed the air from the strainer.
  • Page 23 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Figure 3-11 Air bleeding of strainer Drain the water from the water collector: Attention: When the water collector is full or the spin-on filter is replaced, it’s necessary to drain the water collected.
  • Page 24 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Replace the water collector: Procedure (As shown in Figure 3-13) ① Stop the engine. ② Drain water from the water collector. ③ If possible, remove the screw 1 of water collector with hand. If the screw 1 is too tight, use the remover tool attached in the new water collector.
  • Page 25 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Check urea pump filter element ◆ At the time of maintenance, it’s necessary to remove the filter element of urea pump and thoroughly clean with clean water before installation. Do not slap or knock the filter element with high force.
  • Page 26 30000km (400h) Routine maintenance For class WG II vehicles, replace the engine oil filter element at the Weichai’s designated service center at interval of 10,000km (200h) A – Initial mandatory maintenance: Replace oil and oil filter element and do not replace fuel strainer and fuel fine filter elements.
  • Page 27 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Table 3-3 Maintenance Specification of Diesel Engine Maintenance item of Routine Level 1 Level 2 Level 3 Level 4 checki diesel engine checking maintenance maintenance maintenance maintenance Replacement of oil (at ●...
  • Page 28 WEICHAI 4 Analysis and Troubleshooting of Common Malfunctions WP10 series National IV diesel engine is designed and manufactured under strict quality assurance system and each delivered diesel engine passed the specified tests. In addition, the diesel engine is a kind of precision machinery and the long-term guarantee of its functionality is closely related to the normal maintenance.
  • Page 29 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Figure 4-2 ◆ Cylinder interruption method: Interrupt the working of certain cylinder to judge whether the malfunction occurs in such cylinder. Generally, the cylinder interruption method is to cut off...
  • Page 30 4.2.1 Start failure of diesel engine (1) No working of starter The starter of WP10 series National IV diesel engine is controlled by ECU. During normal working, the ECU outputs a current to drive the starter relay and, after the relay is actuated, the battery drives the start of the starter.
  • Page 31 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Turn the ignition key to position ON and observe whether the instrument lamps light up. Turn the ignition key to position START and observe whether the starter acts (Provided that all...
  • Page 32 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI (2) Establishment failure of rail pressure (The starter can work normally, but can’t start) Air bleeding bolt Figure 4-5 ◆ Check the fuel tank for low fuel level. This cause can be easily ignored and shall be paid with attention.
  • Page 33 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Checking method: Loosen the outlet bolt of filter, drive the running of diesel engine with starter, and observe for spray-out or flow-out of diesel. If only a small amount of diesel flows out, it can be determined that the filter element is blocked.
  • Page 34 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Camshaft speed sensor Figure 4-6 Crankshaft speed sensor Figure 4-7...
  • Page 35 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI 4.2.2 Difficult start Cause and troubleshooting for difficult start of engine: ◆ The diesel engine is not running for a long time: The fuel return pipe shall reach beneath the fuel level.
  • Page 36 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Fuel injector wiring Figure 4-8 (2) Over-high water temperature, oil temperature or intake temperature When the water temperature, oil temperature or intake temperature is over-high, the ECU will activate the overheating protection function to restrain the engine power.
  • Page 37 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI ⑦ Damage of water pipe seals or ingress of air: Check water pipes, connectors and gaskets and replace damaged parts Causes and troubleshooting for over-high engine oil temperature ◆...
  • Page 38 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI (5) Abnormal fluctuation of rail pressure due to leakage of fuel pipeline During the traveling of the vehicle, the vehicle speed will be unstable and the vehicle will have symptom of forward jumping.
  • Page 39 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI Rail pressure sensor Figure 4-11 Intake pressure & temperature sensor Figure 4-12...
  • Page 40 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI ◆ Troubleshooting Check the intake temperature and pressure sensors, water temperature sensor and rail pressure sensor and check the connectors for secure connection. Attention: In event of malfunction 1, 3, 4, 5 or 6, the diesel engine will enter the “Limping Home”...
  • Page 41 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine WEICHAI ③ Poor fuel quality, with water or waxy content: Clean fuel system and replace fuel filter ④ Air ingress in low pressure fuel pipeline: Check air-tightness of fuel pipes and connectors and bleed the air ⑤...
  • Page 42 Weichai Service Center or Customer Service Center of Weichai Power. We will provide you with timely and effective repair services. Some items of the “Maintenance Registration Form” are to be filled by the Service Center. Please properly preserve the “Maintenance Registration Form”.
  • Page 43 User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI Maintenance Registration Form (To be filled by maintenance personnel) Name Description Name Description Model User Name Ordering number Postal code Address Purchase date Office tel. Dealer Residence tel.
  • Page 44 ● While adding fuel and engine oil into the diesel engine, make sure to select the specified trademarks. Make sure to use Weichai special oil and special clean container. The oil shall be filtered by filter screen during refilling. 3. “Warranty” Service Principle and Rule (1) Warranty service principle ●...
  • Page 45 Weichai or the sales invoice of the dealer (For the marine main unit, the warranty period shall start from the actual adjustment test date of the engine).
  • Page 46 User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI Rule of Warranty Period for Weichai Power Diesel Engine Product Model Warranty period Remarks I. Complete diesel engine Diesel engine for road vehicles 1 year or 60,000km Diesel engine for engineering vehicles 0.5 year or 30,000km...
  • Page 47 User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI Weichai International Marketing Service Network Sales Service Area Office Local TEL Mobile E-mail Address in charge in charge Russia An pengfei 0074953152825 0079267519073 weichairussia@yahoo.com.cn 117519，г.Москва ул.кировоградская , дом 32,Апартотель ЭРИДАН кв.15-С1...
  • Page 48 Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled and the card with missing item will be considered void. Supervision Tel. of Weichai Power: 400-6183066 800-8603066 At completion of mandatory maintenance, the service station shall summarize the offices within responsible region along with the Customer Satisfaction Survey attached in this manual.
  • Page 49 Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled and the card with missing item will be considered void. Supervision Tel. of Weichai Power: 400-6183066 800-8603066 At completion of mandatory maintenance, the service station shall summarize the offices within responsible region along with the Customer Satisfaction Survey attached in this manual.
  • Page 50 Tip: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled and the card with missing item will be considered void. Supervision Tel. of Weichai Power: 400-6183066 800-8603066 At completion of mandatory maintenance, the service station shall summarize the offices within responsible region along with the Customer Satisfaction Survey attached in this manual.
  • Page 51 Other opinion of customer Customer seal Date Customer Service Center of Weichai Power Co., Ltd. Address: No. 26, Minsheng Street, Kuiwen District, Weifang, Shandong, China Postal Code: 261001 Tel.: 400-6183066 (for mobile and landline) and 800-8603066 (for landline) Fax: 0536-8235369...