WEICHAI WP10 User manual

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.

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
WP10 Series Four-valve Diesel Engine (China IV, V)

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
Special Notice
●Before operating the diesel engine, please always read this Operation and Maintenance Manual carefully, and
follow the technical operation and maintenance practices therein strictly.
●As the diesel engine has been tested strictly according to the related test specification, it is prohibited to
increase the engine power by changing the ECU data without permission, otherwise, the warranty service
commitments of Weichai will be invalid.
●The ECU, common-rail fuel pump and injector are of precision components, it is prohibited to disassemble at
will; otherwise, the warranty service commitments of Weichai will be invalid.
●The turbochargerotor shaft is of precision and high speed rotation component, it is prohibited to disassemble
or impact with hard objects; otherwise, the warranty service commitments of Weichai will be invalid.
●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.
●The diesel engine should use the oil and fuel specified in this Operation and Maintenance Manualand they
should be filtered with special clean filters in filling (the fuel should also be deposited for 72h before being
added). Check the coolant and oil level every time before starting the engine.
●It is prohibited to run the diesel engine without air filter to avoid the unfiltered air from entering the cylinders
directly.
●For the new diesel engine, 50h test run shall be performed before normal using.
●After the engine is started in cold state, please run it at idle speed for a while (do not run it at idle speed for a
long time) and then increase the engine speed slowly. After running under heavy load, do not stop the engine
immediately (except in special cases), you should run the engine at low speed for 5~10 minutes before
stopping.
●Please check the coolant periodically and replace it if necessary. It is prohibited to use cold water or
low-grade coolant.
●Inspection and repair of the electrical system components of diesel engine should be carried out by
professional technicians.
●Inspection and repair of the electronic control system components of diesel engine should be carried out by
professional technicians of Weichai Service Station.
●In general, the oil seal period of diesel engine is one year, please check and take necessary measures if
exceeded.
●The key components (such as turbocharger, injection pump, injector, ECU, exhaust after-treatment system
and EGR system) related to engine emission should be replaced with that of the same model of same
manufacturer. Otherwise, Weichai will not bear any responsibility for the diesel engine damage caused due to
not using the specified spare parts.

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. The engine is quick to start, simple to operate and easy to
maintain.
This manual covers the basic information for the use and maintenance of the diesel engine. To gain optimum
performance and properly maintain the engine, please understand the diesel engine structure in detail,and learn to
master the maintenance and use methods.
With the continual launch of new products in this series, notification of changes will be made via our website;
please visithttp://www.weichai.comfor the latest product information.
June 2017

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

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
Contents
1. Product overview.......................................................................................................................................... 1
1.1 Power and speed of the diesel engine......................................................................................................... 1
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.......................................................................................... 2
2.2 Main performance parameters of the diesel engine.................................................................................... 3
3. Fuel, Lubricating Oil, Coolant, Diesel Exhaust Fluid and Auxiliary Material of the Diesel Engine............ 5
3.1 Fuel............................................................................................................................................................. 5
3.2 Lubricating oil............................................................................................................................................ 5
3.3 Lubrication of tensioner.............................................................................................................................. 6
3.4 Diesel engine coolant.................................................................................................................................. 6
3.5 Diesel Exhaust Fluid................................................................................................................................... 7
3.6 Auxiliary materials ..................................................................................................................................... 7
4. Use and Operation of the Diesel Engine....................................................................................................... 9
4.1 Diesel engine unsealing.............................................................................................................................. 9
4.2 Hoisting of diesel engine.......................................................................................................................... 10
4.3 Installation of the diesel engine................................................................................................................ 10
4.4 Preparations for Diesel Engine Starting.................................................................................................... 10
4.5 Diesel Engine Starting...............................................................................................................................11
4.6 Diesel Engine Running..............................................................................................................................11
5. Regular Inspection and Technical Maintenance of the Diesel Engine........................................................ 13
5.1 Routine Maintenance of the Diesel Engine.............................................................................................. 13
5.2 Periodic maintenance items...................................................................................................................... 16
5.3 Maintenance of Diesel Engine for Long-term Storage............................................................................. 26
5.4 Regular inspection and maintenance of diesel engine.............................................................................. 27
6. Common Faults and Troubleshooting......................................................................................................... 29
6.1 Fault Diagnostic Method.......................................................................................................................... 29
6.2 Common Faults and Troubleshooting....................................................................................................... 30
Appendix: Power correction factor................................................................................................................. 42
Contact Us...................................................................................................................................................... 43

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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
●One cylinder one head, reliable in working and convenient in dismantling.
●Left side arranged common rail system is adopted (viewed from the free end of the diesel engine) foreasy
vehicle lay out.
●Framemain bearing structure,high strength cylinder block, ensuring the high reliability and long service life of
the whole engine.
●Middle or rear arranged turbocharger, with small change of overall dimensions of various models.
●Front designed gear train, with impact structure and lower noise
●All series of products are of inline six-cylinder structure with good interchangeability, convenient for vehicle
matching.
●Equipped with high pressure common rail system and SCR after-treatment system.
1.3 Meaning of the diesel engine model
WP10.XXE4(5)X
Rated speed
Emission level
Rated power, Ps
Displacement, L
POWER
WEICHAI

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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
Engine type
Liquid cooled, 4-stroke, DI, turbocharged and
inter-cooled, with EVB
Bore/stroke (mm)
126/130
Displacement (L)
9.726
Compression ratio
17:1
Firing order
1-5-3-6-2-4
Fuel system
Electronic controlled high pressure common rail
Catalytic converter
Urea-SCR system
Cold state valve clearance (mm)
Intake valve: 0.4; exhaust valve: 0.6; EVB
system: 0.4
Valve timing
(valve clearance: intake 0.4, exhaust 0.6)
Intake valve open: 20° before TDC;
Intake valve close: 34° after BDC;
Exhaust valve open: 49° before BDC;
Exhaust valve close: 21° after TDC

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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Thermostat opening temperature (°C)
83
Starting type
Electric starter
Lubricating mode
Pressure lubrication
Oil capacity (L)
24
Cooling mode
Water cooling forced circulation
Oil pressure (kPa)
350~550
Oil pressure at idling speed (kPa)
≥100
Permissible longitudinal
inclination (°)
Front/rear
Long time: 10/10
Short time: 30/30
Permissible sidewise
inclination (°)
Exhaust manifold
side/injection pump side
Long time: 45/5
Short time: 45/30
Crankshaft rotation (view from free end)
Clockwise
2.2 Main performance parameters of the diesel engine
Table 2-2 Main performance parameters
Unit
WP10 diesel engine(China IV, V)
Engine model
WP10.240
WP10.270
WP10.300
WP10.336
Engine type
-
Liquid cooled, 4-stroke, DI, turbocharged and inter-cooled,
with EVB and SCR
Displacement
L
9.726
Bore × stroke
mm
126×130
Number of cylinders
-
6
Valves per cylinder
4
Fuel injection equipment
Electronic controlled high pressure common rail
Rated power
kW
175
199
221
247
Rated speed
r/min
1900
Max torque
Nm
1150
1270
1390
1500
Speed at max torque
r/min
1200~1500
Emission level
-
China IV/V
Fuel consumption at rated power
g/kWh
≤210
Min fuel consumption at full load
g/kWh
195

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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Cold starting (without starting aid)
°C
-10
White smoke emission
Opacity
≤15% after idling for 20s
Cold starting (with starting aid)
°C
-30
Noise at 1m away from the engine
dB(A)
<104
B10 lifetime
km
800,000

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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3. Fuel, Lubricating Oil, Coolant, Diesel Exhaust Fluid and Auxiliary Material of the Diesel
Engine
3.1 Fuel
In summer: 0# diesel fuel (GB252) should be used.
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.
Table3-1 Specification for Weichai Power special oil selection
Type
Product class
Packaging
capacity
Applicable engine models
Oil for
diesel
engine
CI-4
10w/30
15w/40
20w/50
4L,18L,170kg
China IV series diesel engines: WP4,
WP5, WP6, WP7, WP10, WP12,
WP13,etc.
For Viscosity selection for Weichai Power special oilrefers to table 3-2.
Table 3-2 Relation table between viscosity and applicable ambient temperature
SAE Viscosity grade
Applicable ambient temperature (℃)
0W-20
-35-20
5W-30
-30-30
10W-30
-25-30
15W-40
-20-40
20W-50
-15-50
Attention:
1)Before starting the diesel engine, check the oil level in the oil sump firstly.
2)Don't inspect the oil level when the diesel engine is running.
3)Oils with different manufacturers or different grades are not allowed for mixing with Weichai Power special
oil.
Table13-3Oil filling capacity and filter element number for all series of Weichai engines

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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Engine
series
Oil
filling
capacity
(L)
Filter numbers
Diesel engine
Gas engine
Oil filter
Fuel filter
Oil filter
Gas filter
Coarse filter
Fine filter
WP10
22~26
2
1
1
2
1
Note:
1) The oil filling capacity in this table is only for reference, for the actual filling, take the oil
dipstick as the standard.
2) If fuel system protector or fuel filter with water separator is equipped, its element should be
replaced together with the fuel filter.
3.3 Lubrication of tensioner
The tensioner shall be lubricated with general lithium base grease for automobile (Refer to national standard
GB/T5671-1995).
3.4Diesel engine coolant
The diesel engine cooling system shall be filled with pure coolant. The function of coolant is to prevent freezing
under cold weather and to prevent boiling under high temperature. Furthermore, the coolant contains
rust-inhibiting and anticorrosion additives, which can offer special protection to the water tank and engine cooling
chamber, and avoid cylinder liner cavitation and cooling system corrosion.
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.
Table 3-4Weichai Power special coolants for heavy-duty engine
Type
Designation
Packing
Heavy-duty
engine coolant
HEC-II-25
HEC-II-35
HEC-II-40
4kg, 10kg
Notice:1) Check the coolant regularly to prevent corrosion damage. Replace the coolant if necessary.
2) Never use water or low-grade coolant.

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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. So, the quality and the performance of DEF shall meet the requirements specified in standard ISO 22241.
See table 3-5 for details.
Table 3-5DEF specifications as perISO 22241
Items
Unit
Minimum
Maximum
Urea content
% by weight
31.8
33.2
Density at 20°C
kg/m³
1,087
1,093
Refracting index at 20°C
-
1.3814
1.3843
Alkalinity as NH3
%
-
0.2
Biuret
%
-
0.3
Aldehyde
mg/kg
-
5
Insolubles
mg/kg
-
20
Phosphate (PO4)
mg/kg
-
0.5
Calcium
mg/kg
-
0.5
Iron
mg/kg
-
0.5
Copper
mg/kg
-
0.2
Zinc
mg/kg
-
0.2
Chromium
mg/kg
-
0.2
Nickel
mg/kg
-
0.2
Aluminium
mg/kg
-
0.5
Magnesium
mg/kg
-
0.5
Sodium
mg/kg
-
0.5
Potassium
mg/kg
-
0.5
3.6 Auxiliary materials
Table 3-6 Auxiliary materials and applications

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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No.
Name
Color
Function and application
1
Molykote Pulver
(fine molybdenum powder)
Black
Applied on flat and smooth metal surfaces to prevent seizing
For instance: Applied onto outer surface of cylinder liner
2
Molykote G-N plus
(Molybdenum disulfide, oil
solution)
Dark grey
Achieve lubrication function before lubricating oil pressure is
built up
For instance: Applied onto intake valve stem
Table 3-7Application of sealant for diesel engine
Grade
Major application
Application part
Supplements
Loctite 242
Applied onto the threads to
prevent looseness due to
vibration, with moderate
strength.
Flywheel housing bolt
Camshaft thrust plate bolt
Camshaft timing gear bolt
Intermediate idler gear bolt
Front end cover bolt
Oil filter head bolt
Oil cooler bolt
Screw plug of engine oil cooler regulator
valve
Bolt of oil pump return pipe fixing device
Air compressor shaft end thread
Strainer bolt
Bolt of sensor and harness fixing device
Alternatively,
DriLoc204
thread-locking
adhesive can be
used for
pre-coating
Loctite262
Applied onto the external
threads for locking, sealing,
preventing vibration from
causing looseness
Cylinder head secondary bolt
Loctite271
Locking and tightening
Bowl-shape plug for oil hole
Loctite277
For sealing between core and
hole
Other bowl-shape plugs
Loctite270
For sealing of cylinder head top
surface
Push rod tube - cylinder head

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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Loctite518
(upgraded
product based
on 510)
Applied on shining metal
surface for sealing
Mating faces of cylinder block and crankcase
Cylinder block front end face and the front
end cover
Connecting plate between cylinder block rear
end face and flywheel housing
Mating faces of oil filter seat and crankcase
Water pump rear cover and cylinder block
front end face
Flywheel housing connecting plate and
flywheel housing
Mating face between cylinder block and
engine oil cooler
Mating face between cylinder block and oil
filler port cover plate
4. Use and Operation of the Diesel Engine
4.1 Diesel engine unsealing
After opening the engine packing case, please check the engine appearance for damage and loose connection
before carrying out the following operations:
1) Wipe away the rust proof coat or anti-corrosion agent on the surfaces of exposed components.
2) Drain the sealing oil from the fuel filter and fuel system components (it is allowed to run the engine with load
only when the sealing oil is used up and the normal diesel fuel has been supplied).
Notice: The oil seal is only effective for one year, and when the time is up, please get your engine inspected and
take necessary remedies.
3) Rotate the flywheel and spray solvent into the intake pipe until the oil sealing oil in the cylinder is completely
removed.
4) Spray solvent into the turbocharger intake/exhaust ports until the oil sealing oil is completely removed.
5) Add lubricating oil of specified grade to the oil pan as required.If the oil containing running-in accelerant is
filled in the oil pan before delivery, it is suggested that the oil should be drained off after running for2,000km (or
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
(hardness)], the coolant can be used. Otherwise, drain the coolant and add new coolant which contains antifreeze
additives.

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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).
Figure 4-1Diesel enginehoisting
4.3 Installation of the diesel engine
When installing, it should be ensure that the centerline of diesel engine crankshaft is concentric with the axis of
input shaft of driving device (gear box, alternator etc.) and elastic coupling should be used to ensure that there is
noadditional axial foron the crankshaft caused by the installation.
4.4 Preparations for Diesel Engine Starting
1) Check coolant level
Check the coolant level through the glass window of expansion tank, and add coolant from the filler port if
necessary. When the engine is still hot, beforeopen the filler cap with relief valve and bleed button, please always
press down the bleed button first to release the hot air. It is prohibited to add a large amount of coolant when the
engine is relative hot; otherwise, the related parts of diesel engine may get damaged due to sudden excessive
temperature change. The coolant (water) should be added via the filler port until it overflows.
Start the engine, and when the engine is running (at 1000 r/min), continue to add coolant till the liquid level is
stable, and then close the filler cap.
2) Check fuel level
If the engine has been installed on the vehicle, please turn on the power supply switch, and check fuel level
through the fuel meter or check the fuel tank directly.
3) Check engine oil level
The engine oil level shall be locatedat between the upper and lower markings of the oil dipstick. If necessary, add
engine oil from the filler port.
4) Check liquid level in DEF tank
Correct
Wrong

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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.
Figure 4-2 Urea Level Identification on Urea Tank
4) Check all accessories of the diesel engine for reliable connections.
5) Check the starting system for normal wiring and check and ensure that the battery is chargedsufficiently.Then
open the fuel tank valve, loosen the bleeding screw onprimary fuel filter, and operate the manual pump on the fuel
filter toremove the air inside the fuel system.
4.5 Diesel Engine Starting
1) Turn the power switch, ignition key to the starting position, andmove the gear lever to the neutral gear position
before starting the engine.
2) Depress the clutch pedal and throttle pedal, and turn the ignition key to start the engine.Ifthe engine fails to be
started within 5~10 seconds for the first attempt, start it again one minute later. If the engine still fails to be started
after three attempts, stop the attempt and find out and solve the malfunction before retry.After the engine is started,
check the readings of meters. The engine oil pressure meter shall immediately indicate a pressure. For the cold
engine, you should run it at idle speed for a while (no more than 10 minutes).
3) It is recommended to use the starting aid in case of engine startup at lower temperature. Under the action of
relay, the electronic heating flange begins to work and then heats the incoming air, allowing a smooth startup of
the engine at -30°C.
4.6 Diesel Engine Running
1) After the engine is started, run it at idle speed for a few minutes and then increase the speed to (1,000~1,200)
r/min and add part load.Only when the water outlet temperature is higher than 60°C and the oil temperature is
higher than 50°C, can you operate the engine with fullload. It is recommended to increase the load and speed
gradually, and avoid sudden loading or unloading as possible.
2) In the running-in period (about 60h or 3,000km) of diesel engine, the engine can only be run with load below

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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. But if the running
speed is 105% or 110% of the rated speed, it can be allowed to run for 20 minutes only. After the diesel engine is
unloaded, it is required to run the engine at idle speed for (1~2) minutes before shutdown.
5) Check the following parameters in operation:
a. Oil pressure in main oil passage:(350~550) kPa;
b. Oil temperature in oil pan: ≤110°C;
c. Coolant outlet temperature: (80+5) °C, no more than 95°C;
d. Exhaust temperature after turbine: <600°C;
e. Intake temperature after intercooler: (50~55) °C.
6) Check the color of exhaust gas to estimate the working performance of fuel injector and the operating load; if
the color is abnormal (i.e., serious black or white smoke), stop the engine for troubleshooting.
Notice: Check the diesel engine for water, air and oil/fuel leakages during operation; and if any, stop the
engine for troubleshooting.
7) The operator should acknowledge the following features of the engine:
a. The fuel consumption is relatively low at max torque, and increases along with the rotation speed rise.
b. The torque reaches its peak value within the medium speed range (1,200 - 1,500 r/min);
c. The engine power increases along with the speed, and reaches its rated value at rated speed.
8) Precautions for engine running under cold environments:
a. Fuel: Choose the diesel fuel of proper grade according to the ambient temperature in winter.
b. Lubricating oil: Choose the lubricating oil with proper viscosity based on the season.
c. Coolant: The cooling system should be filled with coolant (containing antifreezing additives) of proper grade
according to the ambient temperature.
d. Startup: Use starting aid when necessary in winter. After starting the engine, the running speed and load of
diesel engine can be increased only after the oil pressure and water temperature become normal.
e. Battery: Before the cold season comes, make sure to check the electrolyte level, viscosity and unit voltage of
the battery; and if the diesel engine is not used for a long time and the ambient temperature is very low, it is
recommended to remove the battery and keep it in a warm room.
f. Shutdown: To stop the engine in cold weathers, unload the engine first, and run it at idle speed for (1~2)
minutes, and wait for a while until the water temperature and oil temperature lower down; the coolant with

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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.
5. Regular Inspection and Technical Maintenance of the Diesel Engine
5.1Routine Maintenance of the Diesel Engine
a. Check the liquid level and temperature of coolant
Check the coolant level through the sight hole on the expansion tank, and if it is insufficient, open the filler port
cap to add coolant. As shown in figure 5-1 and 5-2.
Notice: Before opening the filler cap, press down the air bleeding button to avoid personalby the hot coolant
while the engine is hot.
Figure5-1Coolant filler port cover

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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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.
When checking the oil level, stop the engine and wait for at least 5 minutes, enabling the oil to flow back to the oil
pan. The oil capacity difference between the upper mark and lower mark is about 3L.As shown in figure 5-3.
Figure 5-3 Oil dipstick
c. Check fuel level
d. Check for leakages
Check the external surface of diesel engine for water, air/gas and oil/fuel leakage.
Oil dipstick
Expansion
tank