WEICHAI WP13 Series User manual

Operation and Maintenance Manual for WP13 Series Diesel Engines
I
Operation and Maintenance Manual for WP13
Series Diesel Engines
Weichai Power Co., Ltd.

Operation and Maintenance Manual for WP13 Series Diesel Engines
II
Special Notes
◆The fuel injection pump and injectors are precision components, so no
adjustment or disassembly shall be available for any user. Otherwise, our
company’s warranty will become invalid.
◆The supercharger rotor shaft is a precision high-speed rotating part, so no
dismantling or collision is permitted. Otherwise, our company’s warranty will
become invalid.
◆The diesel engine main bearing bolts and connecting rod bolts have their torques
and rotation angles subject to strict requirements, so any user shall not be
permitted to unscrew or remove any bolt. Otherwise, our company’s warranty
will become invalid.
◆Every time the diesel engine is started, you must check whether it has been filled
with enough coolant and engine oil.
◆The connecting rod bolts shall never be used for a second time.
Please read this Manual carefully
before operating the diesel engine

Operation and Maintenance Manual for WP13 Series Diesel Engines
III
Precautions
1. This diesel engine has been strictly tested in accordance with the test
specifications before delivery, so never adjust the ECU data or increase the
power of the diesel engine arbitrarily. Otherwise, our company will not
implement the three guarantees. Please take care!
2. The diesel engine operators must read this Operating and Maintenance Manual
carefully, familiarize them with the engine structure and strictly follow the
technical operation and maintenance procedures as provided in the Manual.
3. Any new engine should have a running-in period of 50 hours.
4. The diesel engine can only be accelerated slowly after cold start, but never be
forced to work at its high speed in a sudden or idle for long. After heavy load
operation, never stop it immediately but let it idling for 5-10 minutes in advance.
5. After shutdown, if the ambient temperature may be lower than 0 but no ℃
antifreeze additive is used, the water in the water tank and the diesel engine
should be drained.
6. Never have the diesel engine working if there is no air filter to prevent air into
the cylinder before filtered.
7. When refueling or oiling the diesel engine, you must use the grades as provided
in this Manual by means of dedicated clean container with the fuel or oil filtered
in advance. The fuel shall be precipitated for more than 72 hours.
8. The electrical system shall have its parts overhauled by anyone familiar with
electrical knowledge.
9. In order to prevent rust, our company’s diesel engine have been oil sealed before
delivery and sealing effective period should generally be one year, once longer
than one year, any engine should be checked, and additional measures should be
taken when necessary.
10. The diesel engine should not be kept idling for long (generally no more than 10
minutes).
11. Please use the oil filters, diesel filters and air filters produced by the
manufacturers as provided by our company. Otherwise, our company will not
implement the three guarantees.

Operation and Maintenance Manual for WP13 Series Diesel Engines
IV
Introduction
The WP13 series diesel engines are of high-speed diesel engines developed on the
basis of WP12 Landking diesel engines in accordance with National III / IV / V
emission requirements and designed according to the relevant national standards. The
engines feature reliable operation, excellent economic and technical indicators, low
emission, fast start-up, simple operation and convenient repair, being the ideal power
of heavy-duty vehicles.
This Manual has detailed the structure, performance, operation, inspection,
maintenance and relevant contents of WP13 series diesel engines. With the
continuous development of production and technology, the structure of the engine
will be improved, so this Manual may have its contents different from later
improvement. Hope you can pay attention to it.
We sincerely hope that the repairmen and relevant personnel should read this Manual
carefully before operation and maintenance of this diesel engine, and strictly
implement various provisions in the Manual to ensure correct and reasonable use and
prolong the engine service life.
If any problem is found during operation, please contact the after-sales service
department of our company as soon as possible to get timely and thoughtful services.
October, 2012

Operation and Maintenance Manual for WP13 Series Diesel Engines
V
Contents
Chapter I Product Technical Survey.................................................................................................1
1.1 Diesel Engine Power and Speed ............................................................................................1
1.2 Main Structural Characteristics of the Diesel Engine............................................................1
1.3 Meanings of WP13 Series Diesel Engine Models.................................................................1
Chapter II Technical and Performance Parameters of Diesel Engines.............................................3
2.1 Main Technical Parameters of WP13 Series Diesel Engines ................................................3
Chapter III Fuel, Lubricating Oil, Coolant and Auxiliary Materials for Diesel Engine...................4
3.1 Fuel.........................................................................................................................................4
3.2 Engine Lubricating Oil...........................................................................................................4
3.3 Lubrication of Tension Gear..................................................................................................4
3.4 Antifreeze additive of the Engine Cooling System................................................................5
3.5 Auxiliary Materials................................................................................................................6
Chapter IV Use and Operation of Diesel Engine..............................................................................7
4.1 Unsealing of the Diesel Engine..............................................................................................7
4.2 Lifting of the Diesel Engine...................................................................................................8
4.3 Installation of the Diesel Engine............................................................................................8
4.4 Preparation before Starting ....................................................................................................8
4.5 Starting of the Diesel Engine.................................................................................................9
4.6 Operation of the Diesel Engine..............................................................................................9
Chapter V Regular Inspection and Maintenance of the Diesel Engine...........................................10
5.1 Daily Maintenance and Services..........................................................................................10
5.2 Maintenance Contents for Different Levels of Maintenance...............................................13
5.3 Maintenance of the Diesel Engine Kept in Storage for Long..............................................19
5.4 Complete Regular Maintenance and Keep Detailed Records..............................................20
Chapter VI Analysis and Troubleshooting of the Common Troubles............................................21
6.1 Diagnostic Methods .............................................................................................................21
6.2 Common Faults and Troubleshooting..................................................................................22

Operation and Maintenance Manual for WP13 Series Diesel Engines
VI

Operation and Maintenance Manual for WP13 Series Diesel Engines
1
Product implementation standards:
Q/WCG134 WD10 Series Diesel Engines (for filing)
Q/WCG131 WP10 Series Diesel Engines (for filing)
GJBZ768A-1998 Guide for Fault Tree Analysis
GJB/Z3-1988 After-sales Technical Services for Military Products
GJB1443-1992 Quality Management Requirements for Product Packaging, Loading and Unloading,
Transport and Storage A.1
GJB/Z1391-2006 Guide for Analysis of Fault Mode Effects and Danger
GJB1107-1991 Maintainability Specifications for Military Vehicles
Chapter I Product Technical Survey
1.1 Diesel Engine Power and Speed
The WP13 engine has its power range and rated speed of 353 - 405 kW and 2100r/min respectively
(therein, WP13.480 has its rated speed of 1900r/min).
1.2 Main Structural Characteristics of the Diesel Engine
●One cylinder one head, reliable work and convenient disassembly
●Right-mounted common rail system (seen from the free end), convenient for arrangement of
the complete vehicle
●Frame main bearing structure, high overall rigidity, conducive to the reliability and service life
of the complete engine
●Mid-set supercharger, fewer dimensional changes of all types of the engine series
●Rear-set gear transmission, featuring a compact structure and low noise
●Inline six cylinders of the whole series, featuring a high degree of universality and convenient
for complete vehicle matching
1.3 Meanings of WP13 Series Diesel Engine Models
Variant number
Emission level
Engine model
Displacement
Power
Weichai
X

WP13 Diesel Engine Series Operating Manual
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Chapter II Technical and Performance Parameters of Diesel Engines
2.1 Main Technical Parameters of WP13 Series Diesel Engines
Table 2-1 Main Technical Parameters of WP13 Series Diesel Engines
Model WP13.480 WP13.500 WP13.530 WP13.550
Type Inline, water-cooling, four-stroke, direct-injection,
turbocharged and intercooled
Fuel system High-pressure common rail
Number of cylinders × bore × stroke mm×mm 6×127×165
Direction of rotation Clockwise (towards the free end)
Firing order 1-5-3-6-2-4
Rated power – speed kW-r/min 353-1900 368-2100 390-2100 405-2100
Maximum torque Nm 2110 2100 2220 2300
Speed at the maximum torque r/min 1100-1400 1200-1500
Piston total displacement L 12.54
Cold valve clearance mm Intake valve 0.4
Exhaust valve 0.6
Valve timing
(Valve clearance:
intake 0.4 mm, exhaust 0.6 mm)
Intake valve opening 20° before the TDC (Top Dead Center)
Intake valve closing 34° after the BDC (Bottom Dead
Center)
Exhaust valve opening 49° before the BDC (Bottom Dead
Center)
Exhaust valve closing 21° after the TDC (Top Dead Center)
Lubrication mode Pressure lubrication
Startup mode Electric starting
Engine oil capacity L 28 (trucks) /25 (buses)
Cooling mode Water-cooling forced circulation
Overall dimensions mm 1556×817×1094
Complete engine mass kg 1000
Cold start - without an auxiliary starting
device ℃-10
Cold start - with an auxiliary starting device ℃-30
Emission level National III / IV / V
Allowable longitudinal
inclination (°) Front / rear Long term 10/10 Short term 30/30
Allowable transverse
inclination (°)
Exhaust manifold side /
fuel injection pump
side Long term 45/15 Short term 45/30

WP13 Diesel Engine Series Operating Manual
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Chapter III Fuel, Lubricating Oil, Coolant and Auxiliary Materials
for Diesel Engine
3.1 Fuel
Summer: 0# diesel fuel (GB252)
Winter: -10# light diesel fuel for general use (GB252), but when the air temperature is below -20°C,
-20# diesel fuel should be used; when the outdoor temperature is below -30°C, -35# diesel fuel
should be used.
3.2 Engine Lubricating Oil
Lubricating oil capacity of diesel engine: 28L for trucks (reference value), 25L for buses (reference
value), subject to the oil dipstick mark (with the oil capacity slightly different for different models).
Selection of lubricating oil: in order to achieve safe and reliable operation of your diesel engine,
please use such grades of lubricating oils 15W/40CF-4 or 20W/40CF-4. Therein, 15W/40CF-4 and
20W/40CF-4 can be applicable within the range of -15°C to +30°C and -10°C to +30°C
respectively (Weichai special oil is recommended), but 5W/20CF-4 lubricating oil should be used
when lower than -15℃.
A
mbient
temperature
Multistage oil
A
mbient
temperature
Figure 3-1 Table for Grade Options of Lubricating Oil
Attention: The WP13 series diesel engines shall never use any lubricating oil below level CF,
and once the engine oil is replaced, you should replace the oil filter element at the same time!
3.3 Lubrication of Tension Gear
For the lubrication of tension gear , lithium base grease common for automobiles should be used
(see the GB5671 standard).