WEICHAI WP10 Series Operation And Maintenance Manual
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WEICHAI WP10 Series Operation And Maintenance Manual

Four-valve diesel engine
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
Operation and Maintenance Manual for WP10 Series
Four-valve Diesel Engine (China IV, V)
Weichai Power Co., Ltd.

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  • Page 1 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Operation and Maintenance Manual for WP10 Series Four-valve Diesel Engine (China IV, V) Weichai Power Co., Ltd.
  • Page 2 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) WP10 Series Four-valve Diesel Engine (China IV, V)
  • Page 3 For the important bolts of diesel engine (such as main bearing bolt and connecting rod bolt), there are strict requirements on tightening torque and rotating angle, it is prohibited to unscrew or dismantle at will. The connecting rod bolt can be used only one time. Otherwise, the warranty service commitments of Weichai will be invalid.
  • Page 4 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Foreword This seriesdiesel engine is of high-speeddiesel engine developed and manufactureby Weichai Power Co., Ltd.This series has a compact structure, reliable operation, excellent performance, low fuel consumption and meets the requirements of international emission standards.
  • Page 5 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

  • Page 6: Table Of Contents

    1.2 Main structural features of the diesel engine ....................1 1.3 Meaning of the diesel engine model ......................1 1.4 Outline drawings of WP10 series China IV/V diesel engine ..............2 2. Technology and performance parameters of the diesel engine ..............2 2.1 Main technical parameters of the diesel engine ..................

  • Page 7: Product Overview

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) 1.Product overview 1.1 Power and speed of the diesel engine The power range of WP10 series diesel engine (China IV, V) is 175-247kW, the rated speed is 1900r/min. 1.2 Main structural features of the diesel engine ●...

  • Page 8: Outline Drawings Of Wp10 Series China Iv/V Diesel Engine

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) 1.4 Outline drawings of WP10 series China IV/V diesel engine 2. Technology and performance parameters of the diesel engine 2.1 Main technical parameters of the diesel engine Table 2-1 Main technical parameters...

  • Page 9: Main Performance Parameters Of The Diesel Engine

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Thermostat opening temperature (°C) Starting type Electric starter Lubricating mode Pressure lubrication Oil capacity (L) Cooling mode Water cooling forced circulation Oil pressure (kPa) 350~550 ≥100 Oil pressure at idling speed (kPa) Permissible longitudinal Front/rear Long time: 10/10...
  • Page 10 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Cold starting (without starting aid) °C ≤15% after idling for 20s White smoke emission Opacity Cold starting (with starting aid) °C Noise at 1m away from the engine dB(A) <104 lifetime...

  • Page 11: Fuel, Lubricating Oil, Coolant, Diesel Exhaust Fluid And Auxiliary Material Of The Diesel Engine

    In winter: Select the fuel of proper gradeaccording to the ambient temperature. 3.2 Lubricating oil For Weichai Power China IV Series and China V series Diesel Engines, grade CI-4 should be used. Special oil for Weichai Power should be usedrefers to table 3-1.

  • Page 12: Lubrication Of Tensioner

    The 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 10°C lower than the local air temperature.

  • Page 13: Diesel Exhaust Fluid

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) 3.5 Diesel Exhaust Fluid The substandard diesel exhaust fluid(DEF) will easily lead to poisoning failure of SCR catalyst orlower reduction efficiency(For instance, the out-of-limit of phosphorus, sodium, potassium and calcium contents in the DEF will easily lead to poisoning of catalyst and if the concentration of DEFis unqualified, it will easily lead to excessive leakage of NH3 or lower reduction efficiency of NOx) and excessive emission and malfunction indicator lamp warning.
  • Page 14 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Name Color Function and application Molykote Pulver Applied on flat and smooth metal surfaces to prevent seizing Black (fine molybdenum powder) For instance: Applied onto outer surface of cylinder liner Molykote G-N plus Achieve lubrication function before lubricating oil pressure is built up...

  • Page 15: Use And Operation Of The Diesel Engine

    50h) and then fill with new oil. 6) Base on the agreement between Weichai and user, if the coolant is already filled according to the user’s requirement before delivery, please check the coolant performance when unpacking. If the antifreezing capability is suitable for -30°C or -35°C, the PH value is 7~8 (neutral), the total hardness number is 5-15°d [9-15°f...

  • Page 16: Hoisting Of Diesel Engine

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) 4.2 Hoisting of diesel engine When hoisting the engine, keep the engine crankshaft centerline in horizontal state, and never hoist the engine obliquely or at one side (as shown in figure 4-1). Correct Wrong Figure 4-1Diesel enginehoisting...

  • Page 17: Diesel Engine Starting

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Generally, the DEF consumption accounts for 3~5% of the fuel consumption (by volume). Check the liquid level of DEFfrequently based on the use condition. Please maintain the liquid level at 30~80% of full level and timely add if necessary.
  • Page 18 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) the moderate. 3) Speed down timely when driving on a slope road. Long term work under large torque condition, small load and low rotating speed are not recommend, for which may lead to excessive oil consumption. 4) In normal use, you can run the diesel engine continuously at rated power and rated speed.

  • Page 19: Regular Inspection And Technical Maintenance Of The Diesel Engine

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) antifreeze should not be drained out after shutdown. However, if the coolant contains no antifreeze additive, make sure to drain off the coolant from the engine block, oil cooler cover, radiator and water pipes to prevent the engine from being frost cracked.
  • Page 20 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Expansion tank Figure 5-2 Expansion tank b.Check the oil level Check the oil level with oil dipstick.When the oil level is below the lower mark or above the upper mark, it is not allowed to start the diesel engine.
  • Page 21 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Figure 5-4 Diesel engine e. Check the liquid level in DEF tank The liquid level should be maintained in between 30% to 80% of total urea tank volume. f.

  • Page 22: Periodic Maintenance Items

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Figure 5-6 h. Check the running sound of diesel engine. i. Check the speed and vibration of diesel engine. 5.2 Periodic maintenance items  Replace the engine oil Place anoil recycling container under the engine, unscrew the drain plug at the bottom of oil pan (figure5-7), drain off the oil completely, and then screw in the drain plug again.
  • Page 23 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) e. Start the engine to check for oil leakage. Oil filter Figure 5-9  Check and adjust intake/exhaust valve clearance Check and adjust intake/exhaust valve clearance as follows: a.
  • Page 24 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Table 5-1Adjustment of valve clearances No. 1 cylinder No. 2 No. 3 No. 4 No. 5 No. 6 cylinder cylinder cylinder cylinder cylinder No. 1 cylinder, Intake/exhaust Intake Exhaust Intake Exhaust...
  • Page 25 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) remove the collector. b. Apply lubricating oil to the sealing port. c. Screw the fuel filter with hands until the sealing port comes into contact with the mating port. d.
  • Page 26 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Drain off the water inwater collector of filter (figure 5-14): (Notice: Drain the water timely when the water collector is full or the spin-on filter is replaced) ① Open the drain plug 2 at the bottom of water collector 1 to drain the water out. ②...
  • Page 27 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)  Check the intake system (figure 5-16) 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. Intake manifold Figure 5-16 Intake system ...
  • Page 28 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Figure 5-18 Filter element cleaning Notice: 1) Do not damage the filter paper;2) Do not clean the filter paper with water or oil; 3) Do not knock the filter element forcibly.
  • Page 29 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Unscrew the filter cover with the wrench of 27mm (DIN3124/ISO2725-1) Remove the balancing unit Check the color of the filter element: if it is gray, use the gray end of special tool;...
  • Page 30 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Lubricate the O-rings at both ends and install the HCF filter element. (it is recommended to use MobilVelocite No.6, other lubricating oil may lead to O-ring failure) Tighten the filter cover with the torque of 20+5Nm, and the size of wrench is 27mm (DIN3124/ISO2715-1).
  • Page 31 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Remove the balancing unit. Stretch the proper end of tool into the filter element and rotate the tool clockwise until you hear a clicking sound, indicating that the tool has been installed in place. Draw out the filter element (use the slot of special tool and other tools if necessary).

  • Page 32: Maintenance Of Diesel Engine For Long-Term Storage

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Lubricate the O-rings at both ends and install the HCF filter element. (it is recommended to use MobilVelocite No.6, other lubricating oil may cause the O-ring failure) Tighten the filter cover with the torque of 20+5Nm, and the size of wrench is 27mm (DIN3124/ISO2715-1).

  • Page 33: Regular Inspection And Maintenance Of Diesel Engine

    Routine maintenance 30,000 km (or400h) For WG II using conditions, it should replace the oil filter element in the Weichai designated service center every 10,000km (or 200h). Note: “A” - First mandatory maintenance : replace the oil, oil filter element;...
  • Page 34 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Clean the dust cup of air filter (excluding the auto ● dust-removal type) Clean the air filter main element When the indicator is lit Replace the air filter main element Please refer to the related regulations in the instruction manual Replace the air filter safety element After the main element has been cleaned for 5 times...

  • Page 35: Common Faults And Troubleshooting

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) 6.Common Faults and Troubleshooting WP10 series China IV/V diesel engines are designed and manufactured under strict quality management system and each delivered diesel engine has passed the specified tests. As the diesel engine is of precision machinery, and the long-term guarantee of its functionality is closely related to the normal maintenances.

  • Page 36: Common Faults And Troubleshooting

    (1) The starter motor does not work The starter motor of WP10 series China IV/V diesel engines are controlled by ECU. Under normal working conditions, the ECU produces anoutput current to drive the starter relay. When the relay is activated, the battery drives the starter motor to start the engine.
  • Page 37 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Turn the ignition key to starting position, and check whether the starter motoris working (with other causes having been excluded). Starter motor Ignition key switch (2) Common rail pressure build up failure (the starter motor can properly function, but the engine cannot be started) Air releasing screw...
  • Page 38 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) dismantle the high pressure fuel line joint.) ◆ Check whether there is leakage in the high pressure fuel line. The leakage of high pressure fuel line is quite easy to be noticed. Check whether the joint nut of the high pressure fuel line is loose, and tighten it if necessary.
  • Page 39 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) If no testing equipment is available, disconnect the connector of the common rail pressure sensor, and try to start the engine (the engine will come into “Limp Home” mode after starting). ◆...
  • Page 40 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) or short circuit ◆ Check the installation of the connector, and check circuit continuity with the multimeter (“wiring inspection tester” is recommended) according to pin definition on the circuit diagram. Wiring inspection tester...
  • Page 41 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Weichai EDC17 vehicle wiring harness connection diagram...
  • Page 42 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) (4) Crankshaft and camshaft signals lost The diesel engine is provided with two speed sensors, which are mounted on the outsides of flywheel housing and high pressure fuel pump respectively, and they serve as crankshaft position sensor and cylinder identification sensor respectively.
  • Page 43 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) andvalve. ◆ EVB butterfly valve is stuck at close state, causing the exhaust to be blocked: Replace the butterfly valve 6.2.3 Engine power is insufficient Limp home: A running mode of engine under malfunctioned state. The engine malfunction is detected, but the ECU will not stop the engine immediately.
  • Page 44 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) ◆ Causes and remedies for excessively high water temperature ① The water level in the tank is too low: Check for leakage, and add water if necessary; ② Fan rotate at low speed or does not rotate: Check the fan drive unit; ③...
  • Page 45 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) ◆ Troubleshooting: Inspect and repair the wiring, and determine if the fault occurs to the flow metering unit or common rail pressure sensor, and inform the office for troubleshooting. (5) Abnormal fluctuation of common rail pressure due to leakage in fuel line In the vehicle running, the speed will appear unstable.
  • Page 46 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) 6.2.4 Engine always running at speed of 1,000r/min Theaccelerator isfailure at this time: the ECU will judge the load through the signal coming from the pedal potentiometer, and when the pedal malfunctions, the ECU will control the diesel engine to automatically return to the idling speed (1,000r/min) for safety.
  • Page 47 Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) If the SCR system does not work when the engine is working normally, please check whether theconnectors ofDEF pump, spray nozzle and sensor areinstalled reliably. Check whether the DEF connecting pipes and joints are bent, loose or broken.

  • Page 48: Appendix: Power Correction Factor

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Air pressure...

  • Page 49: Contact Us

    Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V) Contact Us Weichai Power Co., Ltd. Address: 197A, Fushou East Street, High-tech Development Zone, Weifang, Shandong, China Zip code: 261205 Website: http://www.weichai.com Engine sales line: 0536-8232488; 0536-8233371 Spare part sales line: 0536-2297313;...

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