WP10series Manual PDF

WP10系列柴油机维修保养手册
Maintenance Manual for WP10 series Diesel Engine
1. 柴油机使用说明
Usage Instruction
1.1 WP10系列柴油机型号含义
Signification of WP10 Series Diesel Engine Type Code
W P XX YYY
机型号(MODEL)
排量(DISPLACEMENT)
动力(POWER)
潍柴(WEICHAI)
1.2 新柴油机使用须知
Operating notice for new diesel engine
◆新柴油机在使用的最初 60 小时（或 3000 公里）内应限制柴油机的负荷不应超过标定负荷
的 75% 。
Within the first 60 hours (or 3,000 km), the load of new diesel engine shall not exceed 75% of the
rated load.
◆新机经初期使用磨合后，需要更换机油，否则可能造成柴油机零件的过度磨损或损坏。正确
地维护保养将使您的柴油机有更好的性能、更经济的运转及更长的寿命。
The lubricating oil should be replaced after the primary running period，otherwise the engine parts
possibly be over worn or damaged．Proper protection and maintenance will—ensure your engine with
better performance，more economical and longer service 1ife．
◆首次换油期的规定
Provision of the first oil replacement period
对于年行驶里程不到 2 万公里的汽车，首次换油期：1000 ～ 1500 公里；
For the vehicle with running mileage less than 20,000 km per year, the first oil replacement period is
1,000~1500 km;
对于年行驶里程超过 2 万公里的汽车，首次换油期：1500 ～ 2000 公里。
For the vehicle with running mileage more than 20,000 km per year, the first oil
replacement period is 1,500~2000 km;
--
◆每日检查油压表、温度表、报警指示灯和其它仪表，确保它们正常使用。
Check the oil pressure gauge，temperature meter, alarm indicator light and other instrument every
day．
◆按说明书中要求进行日常维护和保养
Keep daily maintenance as per this manual．
1.3 柴油机的启封工作
Package opening of engine
当您打开您的柴油机包装箱之后，首先按文件清点柴油机及随机附件，检查柴油机外表有无
损伤，然后进行下述工作：
When opening the packing of engine，you should firstly check the surface of engine and the amount
of accessories as per packing list，then proceed on as following：
◆擦拭外露件的防锈层，防蚀剂等；
Clean the anticorrosive coating and preservative of outer parts．
◆放出燃油滤清器及燃油系统零件内部油封油 ( 也允许燃油系统的油封油不经放出而启动，
但必须等燃油系统油封油消耗完正常柴油已供应到才允许发动机满负荷运行 )。
Drain off the seal diesel oil from fuel filters and fuel supply system(the engine is also allowed to be
started before seal diesel oil draining，but not allowed to be operated at full load until the seal diesel oil
of fuel supply system has been used up and the usual fuel has been provided).
◆转动飞轮并向进气管内喷溶剂到驱尽气缸内油封油为止。
Turn the flywheel and inject solvent to air intake manifold till the seal oil of cylinder has been
drained off.
◆向增压器排气口喷溶剂，直到驱尽油封油为止。
Inject solvent to the air outlet of turbocharger till the seal oil has been drained off．
◆根据厂方与用户的协约，对油底壳内未注油的应按规定注油。
As per the agreement between Weichai and the customer，the engines supplied with empty oil
sumps should be filled with oil．
◆ 按厂方与用户的协议，出厂据用户需要，已加注满冷却液的应检查冷却液的性能，如果防
冻能力满足 -30℃ ~-35℃时，其 pH 值为 7-8( 中性 )，总硬度值为 5-15° d[9-27°f( 硬度 )] 则可
以使用这些冷却液，如不合乎要求，则应放出，重新加注含防冻剂的冷却液，发动机加约 40 升冷
却液。
As per the agreement between Weichai and the customer,and as per customer’s requirement
--
before delivery,coolant performance"should be checked if the engine has been filled up with coolant.
The coolant could be remained to use if its antifreezing performance could meet-30℃ or-35℃ and pH
is 7-8(1itmusless),and its total rigidity number is 5-15°d [9-27°f(rigidity)] , otherwise it should be
drained off and replaced by new coolant containing antifreeze.The volume of coolant filled to engine is
approximately 40 liter.
1.4 起动前的检查
Inspection before starting
◆ 检查冷却液面
Inspect the coolant level．
◆检查燃油液面
Inspect the fuel level．
◆检查发动机机油液面
Inspect the lubricating oil level．
1.5 柴油机的起动
Starting
◆将电源开关、电钥匙处于起动位置
Put the power switch and starting key at the starting position.
◆变速杆处于空档位置
Put the gearlever at empty gear-matching position．
◆踩下离合器踏板和油门踏板，转动电钥匙起动柴油机，若发动机在 15 秒内起动不了，则待
约 2 分钟后再重复上述操作。发动机起动后，机油压力表应立即显示压力。
Press down clutch pedal and accelerator pedal, turn the electric key to start the engine. If the engine
can not be started within 15 seconds, repeat the second starting process after two minute. Upon starting,
notice the readings of all instruments. The engine oil pressure gage shall display pressure immediately.
◆ 低温条件下起动柴油机应使用辅助起动装置，通过继电器使电子加热法兰工作，从而实
现 -25℃环境下顺利起动。
Use auxiliary starting device during starting at low temperature. By using relay, enable the electronic
heating flange to operate, so as to realize smooth starting at -25℃ environment.
1.6 柴油机的运转
Running of Diesel Engine
◆柴油机起动后，应先以怠速运行 2-3 分钟 , 机油压力应高于 100kPa，然后将转速提高到
--
1000~1200r/min，依次使柴油机在低转速空载运转加热，然后进入部分负荷运转，当冷却水出水温
度达到 60℃后，才允许提高到最高转速和投入满负荷运行。
After running at idle speed for 2~3min,oil pressure should be higher than 100kPa. Then speed up to
1000~1200r/min, preheat the diesel engine by no-load running at low speed, and then operate with part
load. The engine is allowed to run at the highest speed and with full load when temperature of the outlet
coolant rises to 60℃ .
◆柴油机在 60h 磨合期以内，只宜在中等负荷以下工作。
Diesel engine in the 60h-running-in period shall run with medium load.
◆ 柴油机在低于最大扭矩的转速下，全油门持续运转不超过 1 min。
When the engine running at the speed lower than the speed of the biggest torque，it is not allowed to
continue running on full load over l min．
◆柴油机全负荷运转后，停车前要怠速运转 3-5 min。
After running on full load，the engine should run in idling speed for 3-5 minutes before stopped．
◆经常注视油压表及冷却液温度表：
Often watch and check the oil pressure gauge and coolant temperature meter．
◆若压力和温度不符合规定要求时应该将柴油机停车。
Stop the engine if the pressure and temperature cannot meet the standard requirement．
注意：在冷却液温度低于60℃或高于100℃时连续运转将有损于发动机。
Note：Diesel engine can not continue to run when the coolant temperature is lower than 60℃
or higher than 100℃，because this would damage the engine．
注意：发动机在停止之前以怠速运转1-2min后再停车。
Note：The engine should run in idling speed for 1-2 minutes before stopped．
◆ 在寒冷环境下运转注意事项；
Precautions for running in cold environment:
1、燃料油：按冬季室外温度不同，选用不同牌号的柴油。
Fuel: In accordance with different outdoor temperature, select diesel fuel of different brands.
2、润滑油：按季节选择不同粘度的润滑油。
Oil: According to the season, select the oils of different viscosity.
3、冷却液：冷却系统加入防冻添加剂，随室外温度不同，选用不同的牌号和不同数量。
Coolant: Add anti-freeze additive into cooling system. According to the different outdoor
temperature, select different brand and quantity of coolant.
--
4、起动：冬季必要时可采用辅助起动器。柴油机起动后待油压水温正常后方能加负荷高速运
转。
Starting: In winter, use auxiliary starting device when necessary. After starting, the diesel engine
can not be loaded and operate at high speed when the oil pressure of and water temperature of are normal.
5、蓄电池在寒冷季节开始之前，一定检查电解液液位、粘度和单位电压，如果柴油机长期不
用并处于很低的温度下，应把蓄电池取下，储存于较温暖的室内。
Prior to starting in cold season, users should inspect the electrolyte level, viscosity and unit voltage
of battery. If the diesel engine is stored in cold environment for a long time, remove the battery and store
it in a warm room.
6、停车：若环境温度低于 0℃而且未使用防冻添加剂时，应将水箱和柴油机内的水放净。
Stopping: If the environmental temperature is lower than 0 ℃ and the anti-freeze additive is not
used, drain all the water from the water tank and the diesel engine.
--
2. 柴油机维护保养指南
Guide For Maintenance Of Diesel Engine
2.1 日常维护
Daily Maintenance
◆检查；
Inspection；
◆机油液面是否在油尺的刻线范围；
Check the oil level；
◆冷却液液面；
Check the coolant level；
◆燃油液面；
Check the fuel level；
◆风扇有无破损；
Check whether the fan is damaged；
◆传动三角皮带有无裂纹、擦伤；
Check whether the V-belt is cracked or scratched；
◆附件紧固情况是否良好；
Check whether the accessories are fixed well;
◆水油有无泄漏 ;
Check whether the water or oil is leaking;
◆充电指示灯是否正常 ;
Check whether the charging indicator light is in order;
◆水泵油腔内润滑脂是否充足 ;
Inspect sufficient grease;
◆机油压力，水温是否正常 ;
Inspect toil pressure and water temperature are normal condition；
◆柴油机排气温度、声音、振动是否正常 ;
Inspect that exhaust temperature, sound and vibration are normal condition；
◆转速是否平稳。
Inspect rotary speed is stable.
--
2.2 定期保养并做好保养记录
Periodic maintenance and Records
定期保养参照下表进行，若柴油机在多尘环境或在频繁停车情况下工作，须根据情况相应缩
短保养周期。
Regular maintenance can be conduct on as per the following table．If the operating condition is
heavy dust content or the engine running on started-stopped frequently，the regular maintenance period
should be shortened accordingly．
2.2.1 维护保养周期
Oil replacement period during vehicle maintenance

表 2-1 汽车配套三类使用条件
Three categories of operating conditions with vehicle
(WGⅠ) (WGⅡ) (WGⅢ)
使用条件恶劣（气候严寒年行驶里程不足 6× 年行驶里程超过 6×
4 4
或酷热，含尘量高，短距离运 10 km 的汽车，短中距离运输 10 km 的汽车，远距离运输
输，在工地使用以及公共汽（用于送货） Annual running mileage of
车，市政工程车，扫雪车，消 Annual running mileage of the vehicle more than 6×104km
防车）或汽车年行驶里程不足 the vehicle less than 6×104km, for long distance transportation.
4
2×10 km 或年工作时间不足 for short- or medium-distance
600h transportation (for goods).
Under severe operating
condition (e.g. cold or hot
weather, high dust content,
short-distance transportation,
service in construction site and
bus, municipal engineering
vehicle, snow sweeper, fire
bridge vehicle), annual running
mileage of the vehicle less than
2×10 4km or annual operated
time less than 600h.
--
表 2-2 保养周期
使用条件
Operating
condition (WGⅠ) (WGⅡ) (WGⅢ)
项目
Item
行驶1000～1500km时
行驶30～50h 行驶1500～2000km时行驶1500～2000km时
第1次检查
Running Running Running
The first inspection
1,000~1,500km or 1,500~2,000km 1,500~2,000km
30~50h
每隔5000km
例行检查每隔150h 每隔1x104km 每隔1.5x104km
Periodical inspection Every 5,000km or Every 1×104 km Every 1.5×104 km
150h
每隔1x104km
1级保养每隔300h 每隔2x104km 每隔3x104km
Level 1 maintenance Every 1×104 km or Every 2×104 km Every 3×104 km
300h
每隔2x104km
600h
每隔4x104km
1,200h
每隔8x104km
2,400h
--
表2-3 汽车保养制度的机油换油期
(WGⅠ) (WGⅡ) (WGⅢ)

使用条件
Operating
年行驶里程年行驶里程年行驶里程
condition 4 4
不到2x10 km 不到6x10 km 超过2x104km
项目
Annual running mileage Annual running mileage Annual running mileage
Item 4 4
<2×10 km < 6×10 km > 6×104 km
第1次检查行驶1000～1500km时行驶1500～2000km时行驶1500～2000km时

The first inspection Running 1000~1500km Running 1500~2000km Running 1500~2000km
例行检查 P 每隔500km 每隔1x104km 每隔1.5x104km

Periodical inspection Every 500km Every 1×104 km Every 1.5×104 km
1级保养 WD1 每隔1x104km 每隔2x104km 每隔3x104km

Level 1 maintenance Every 1×104 km Every 2×104 km Every 3×104 km



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2.2.2 柴油机保养项目
Diesel engine maintenance project
第一次
例行检查 1级保养 2级保养 3级保养 4级保养
柴油机保养项目检查
Periodical Level 1 Level 2 Level 3 Level 4
Maintenance items The first
inspection maintenance maintenance maintenance maintenance
inspection
更换机油(每年至少1次)
● ● ● ● ● ●
Replace oil (once a year at least)
更换机油滤清器或滤芯每次更换机油时
●
Replace oil filter or filter element When replacing oil every time
检查调整气门间隙
● ● ● ● ●
Inspect and adjust valve clearance
更换燃油滤清器芯
● ● ● ●
Replace fuel filter element
检查冷却液容量并加足
● ● ● ● ● ●
Inspect coolant capacity and fill
紧固冷却管路管夹
●
Fasten cooling pipe clamp
紧固进气管路、软管和凸缘连接件
Fasten connecting parts of air inlet pipe, ● ● ● ● ●
hose and flange
检查空滤器保养指示灯或指示器
Inspect air filter maintenance light or ● ● ● ●
indicator
清洗空滤器的集尘杯(不包自动排尘式)
Clean dust pocket of air filter r(except ● ● ● ● ●
auto dust exhaust style)
清洗空滤器主滤芯当指示灯亮时
Clean air filter main element When indicator light comes on
更换空滤器主滤芯参看说明书有关规定
Replace air filter main element Refer to the relevant provisions in the manual
更换空滤器安全滤芯清洗5次主滤芯以后
Replace air filter safety element After 5 times of cleaning of main filter element
检查、紧固三角皮带
● ● ● ● ● ●
Inspect and fasten V belt
检查增压器轴承间隙
●
Inspect supercharger bearing clearance
检查、调整离合器行程
● ● ● ● ● ●
Inspect and adjust clutch travel
注：●需要保养标记
Note: ● requiring maintenance required.
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2.3 维护保养记录
Maintenance Record
柴油机编号柴油机型号
Engine number Engine model
用户名称设备名称
User name Equipment name
公里小时
或间隔时间实际里程保养内容
日期保养者备注
Running Actual Maintenance
Date Operator Remark
Kilometers／hours Kilometers contents
or interval hours
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3. 柴油机保养内容
Maintenance Contents of Diesel Engine
3.1 日常保养
Daily Maintenance
预防性保养从每天做起，了解柴
油机工作状况。
Preventive maintenance should be
done everyday in order to understand the
engine's condition．
起动柴油机以前需检查机油液
面、冷却液液面和柴油液面。
Before starting the engine should
check the oil level ， coolant level and
fuel level. ．
检查：
Inspect：
·泄漏
Leakage
·易损件
Fast wearing parts
·柴油机上出现的任何异常
Any unconventionality
-15-
● 检查机油油面高度
Inspect the oil level height
当油面低于油尺的下刻线或高于油尺的上刻线时，决不允许开动柴油机。
When the oil level is lower than the lower limit or higher than the upper limit，it is not allowed to
start the engine．
在柴油机停车后检查油面，至少等 5 分钟后进行，使机油有充分时间流回油底壳。
After the engine stopped， inspect the oil level at least 5 minutes later in order to ensure the oil
can flow back to the oil sump．
油尺低位至高位的油量差为 3 升。
The oil volume tolerance between the lower limit and the upper limit is 3 liters．
-16-
● 冷却液液面
Inspect the coolant level
玻璃视孔观察冷却液面，冷却液
不够时，可打开加水口盖加入冷却液。
Inspect the coolant level through
the vitreous view hole，if the coolant is
not sufficient，open the inlet cover and
fill into the coolant.
注意：打开加水口盖时，必须先
按下排气按钮，以免发动机热状态时
热冷却液会伤人。
Note:When opening the inlet cover，
must press down the exhaust button
firstly to prevent hot coolant from
injuring people.
检查燃油液面。
Check the fuel level.
-17-
● 检查风扇
Inspect the fan
检查塑料风扇是否变形，铁风扇
铆钉是否松动，叶片是否弯曲，确保
风扇工作可靠。
Check whether the plastic fan is
distorted.For steel fan，check whether
the rivet loosened and the vane is
curved to ensure reliable running
● 检查三角皮带
Inspect the V-belts
用肉眼检查三角皮带，有无裂纹
或擦伤，必要时应更换。
Inspect the V-belts with your eyes
to find if there is any crack or scratch on
the V-belts．Replace them if necessary
-18-
● 检查排气颜色是否正常。
Inspect exhaust gas for normal
color. Attached diagram:
正常排气颜色为淡灰色。颜色出
现变化应检查原因并排除。
The normal color is light grey. If
the color changes, find the reason and
remove it.
● 检查声音是否正常。
Inspect for normal sound.
● 检查转速、振动是否正常。
Inspect for normal speed and
vibration.
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3.2 各级保养的保养内容
Maintenance Content of
Different Levels
除完成每日保养外，增加下列检
查项目：
The following contents will be
added except daily maintenance items：
机油和机油滤清器的更换
Replacement of the oil and oil filter
柴油机使用后机油将变脏，污染
物含量与燃油机油耗总量成正比。
The oil will be polluted after
using，the pollution contents is of
accordance with the consumption of
fuel and oil．
注意：正常使用的柴油机更换机
油的周期无论如何不可超过 250h(1
万公里 )。
Note:The replacement
period of oil under proper using
condition cannot beyond 250h
(10,000Kilometers)
-20-
更换机油和机油滤清器，以清除
悬浮在机油中的杂质。
Replace the oil and oil filter to
clean the impurities containing in oil.
注意：应在机油是热的时候放油
Note: The oil should be drained
off when it is hot．

32mm 开口扳手
Tool:32mm open-ended wrench
拆下放油螺塞，准备收集 24L 机
油。
Remove the whorl plug，prepare a
container to collect 24L of oil．
注意：热机油会伤人
Note：Hot oil can injure people.
-21-
滤清器专用扳手
Tool:The special wrench for filter.
清洁滤清器头部四周，拆下滤清
器。
Clean the end surrounding of the
filter，and remove it.
装上新的机油滤清器
Install the new oil filter
注意：安装机油滤清器时 , 密封
圈要校正，且要在密封圈上涂上润滑
油。
Note：Adjust the seal ring and
smear some lubricating oil on it while
fitting the oil filter.
-22-
32mm 开口扳手
Tool:32mm open-ended
wrench
检查和清洁放油螺塞螺纹及密封
表面，并装上放油螺塞。
Check and clean the screw thread
and seal ring，and then install the whorl
plug.
将清洁的机油注入柴油机到油尺
的上刻度线，油底壳容量为 24L。
Fill the clean oil up to the upper
limit，the capacity of the oil sump iS
24L．
注意：斯太尔柴油机必须使用
CF-4 级 15 W/40 牌号机油。
Note：STEYR engine must use
CF-4 15W/40 oil．
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发动机怠速运转，检查滤清
器和放油螺塞处是否漏油。
Run th e engine at idling speed
and check the filter to find whether
it leaks or not．
停车后约 5min 让机油自上部

零件流人油底壳，再检查油面高
度，必要时补充机油至油尺的上
刻线。
Stop the engine and make the
oil run into the sump from the upper
parts 5 minutes later，then check
the oil level，fill oil up to the upper
limit if necessary．
-24-
检查调整气门间隙
Check and adjust the valve
clearance
13mm 套筒扳手
Tool：13mm sleeve wrench
拆下 6 个气缸盖罩
Disassemble 6 cylinder head
covers．
32mm 盘车扳手
Tool：32mm wrench for
turning the crankshaft
用盘车扳手慢慢转动柴油机 ,
使飞轮壳上刻线对准飞轮上的刻
槽，此时使第一缸活塞处于压缩
行程的上止点位置 ( 一缸进排气
阀处于关闭状态 )
Tum the flywheel until its
scale and the mark on its housing
are aligned,push the piston to the
position of TDC of compression
stroke of 1 st cylinder(the intake
and exhaust valve of 1 cylinder are
closed)．
-25-
塞尺
Tool：Clearance guage
进气门间隙 0.30mm
The clearance of intake valve is
0.30mm
排气门间隙 0.40mm
The clearance of exhaust valve is
0.40mm
其中，带 WEVB 系统的间隙
0.25mm。
The clearance for WEVB system is
0.25mm.
注意：检测气门间隙时，柴油机
应为冷态——低于 60℃，塞尺在气门
杆顶和摇臂间滑动时，有阻滞发粘感
觉时，所测间隙值为准确值。
Note:When check the clearance
of valve，the engine should be at
the cool condition-its temperature is
less than 60℃ .When the clearance
guage glides between the top of
valve rod and rocker arm and can
be felt retarded and sticky，the
measuring result is proper．
-26-
采用 WEVB 系统后，排气门间隙的调整方法 ( 零件序号参见图 7-1)：
After WEVB system is used, the adjustment method of exhaust valve clearance is as follows (see
Fig. 7-1 for part serial numbers)
1、所要调整的气缸的活塞位于压缩行程上止点；
The cylinder piston to be adjusted is located on the top dead center of the compression travel.
2、如图 7-2 所示 , 在序号 2 调节螺栓总成松开 , 不压紧排气门摇臂封油平面的情况下 , 先通
过调整推杆端序号 10 气门间隙调整螺钉 , 将总气门间隙调整为 0.4mm, 将防松螺母拧紧。
As shown in Fig. 7-2, loosen No. 2 adjusting bolt assembly. In case that the oil seal plane of exhaust
valve rocker arm is not pressed, first by using No. 10 valve clearance adjusting screw at the push rod end,
adjust the total valve clearance to 0.4mm. Tighten check nut.
注意：调整过程中应转动气门间隙调整螺钉直到将塞规夹住 , 从而保证使序号 5 气门摇臂活
塞压到底，与排气门摇臂中的活塞安装孔底部平面之间无间隙；
Caution: During adjustment, turn the valve clearance adjusting screw until the clearance
gauge is clamped so that No. 5 valve rocker arm piston is pressed to its bottom. There is not
clearance between No.5 valve rocker arm piston and the piston installation hole bottom plane in
exhaust valve rocker arm.

3、然后如图 7-3 所示，在序号 5 气门摇臂活塞与排气门杆端或气门杆帽之间再放入 0.25mm
的塞规，通过调整序号 2 调节螺栓总成，将气门端间隙调整为 0.25mm, 将防松螺母拧紧。
Then as shown in Fig. 7-3, insert the clearance gauge between No. 5 valve rocker arm piston and
the exhaust valve rod end or valve rod cap. By turning No.2 regulating bolt, adjust the valve clearance to
0.25mm. Tighten check nut.
注意：调整过程中应转动序号 2 调节螺栓总成直到将塞规夹住，从而保证使序号 5 气门摇臂
活塞压到底，与排气门摇臂中的活塞安装孔底部平面之间无间隙。
Caution: During adjustment, turn No. 2 regulating bolt until clearance gauge is clamped so
that No. 5 valve rocker arm piston is pressed to its bottom. There is not clearance between No.5
valve rocker arm piston and the piston installation hole bottom plane in exhaust valve rocker
arm.
-27-
图7-1
1.气门间隙调整螺母 2.调节螺栓总成 3.排气门摇臂总成 4.钢球
5.气门摇臂活塞 6.摇臂活塞弹簧 7.滚针 8.球阀弹簧
9.气门摇臂座总成 10.气门间隙调整螺钉 11.六角头螺栓 12.支撑臂
1. Valve clearance adjusting nut 2. Regulating bolt assembly 3. Exhaust valve rocker arm assembly 4. Steel ball
5. Valve rocker arm piston 6. Rocker arm piston spring 7. Needle 8. Ball valve spring
9. Valve rocker arm seat assembly 10. Valve clearance adjusting screw 11. Hexagonal bolt 12. Support arm
图7-2 冷态排气门总气门间隙0.4mm 图7-3 冷态排气门端气门间隙0.25mm

Fig. 7-2 Total Valve Clearance of Cold-State Exhaust Valve 0.4mm Fig. 7-3 End Valve Clearance of Cold-State Exhaust Valve 0.25mm
-28-
6# 螺丝刀、14mm 梅花扳手
Tools：6#screwdriver and 14mm
double offset ring wrench
第一缸活塞位于压缩行程上止点
位置。
The piston of 1st cylinder is at TDC
of the compression stroke．
如步骤 A 所示检查或调整气门
间隙 (I 表示进气，E 表示排气 )。
Check and adjust the valve
clearance as step A(I-air intake Valve
E-air exhaust valve)
用塞尺调整好间隙后拧紧摇臂锁
紧螺母，并复查气门间隙，直到达到
要求为止。
Adjust the clearance by guage and
tighten the fixing nut of rocker arm，
re-check the clearance till it meets the
requirement．
-29-
用盘车扳手再转动曲轴 360° ,
也可以在减震器上做标记后转动
360°。
Turn the crankshaft 360°by the
spanner;it can also be turned 360°after
marking on the vibration damper
按步骤 B 所示调整气门间隙。
Adjust the valve clearance as
step B.
同样松动摇臂锁紧螺母，用塞尺
调整好后重新拧紧摇臂锁紧螺母。
Loosen the fixing nut of rocker
arm，adjust the c|earance by guage then
tighten the nut again.
-30-
13mm 套筒扳手
Tool:13mm sleeve wrench
安装气缸盖罩垫片和气缸盖罩。
Install the gasket and cylinder head
cover.
螺栓拧紧力矩 23N·m( 推荐数
值 )。
The tightening torque of bolt is
23N·m(recommended).
检查三角皮带涨紧力
Check the tension of V-belts

在三角皮带的最大跨距上测量其
挠度：一般要求在强有力的大拇指压
力下，皮带挠度不大于 l0 mm。
Measure the flexibility of the V—
belt at the middle of its biggest span，
generally the requirement result should
be less than l0mm under strong press by
your thumb．
-31-
16mm 开口扳手
16mm open-ended wrench
如果挠度大于 l0mm，说明三角
皮带松动，需松开涨紧轮涨紧螺母，
重新涨紧皮带，然后拧紧涨紧螺母。
If the flexibility is more than
l0mm，it means the V-belt has been
loosen．the nut for tension pulley needs
to be relaxed，strain the V-belt again
and tighten the nut．
检查冷却管路橡胶管是否老化有
裂缝、软管卡箍是否松动，必要时紧
固或更换零件，确保其密封性。
Check whether the rubber pipes
of cooling system is aging or cracked，
the steel wire hoop is loosening．If it is
necessary，tighten or replace the parts
to ensure good sealing pertormance.
-32-
更换燃油滤清器芯
Replace fuel filter element
更换燃油滤清器芯时按以下步骤
操作 :
Replace fuel filter element in the
following steps:
A. 卸下旧的燃油滤清器芯；如
果安装在粗滤器上的集水器皿还可以
再用，请将集水器皿取下。
Dismantle the old fuel filter
element. Remove the water collector
installed on coarse filter if reused.
B. 润滑封口。
Lubricate the seal lips.
C. 用手拧上滤清器直至封口与
接口结合。
Turn the filter by hand until the
seal is closed with interface.
D. 继续用手拧滤清器直至滤清
器牢固安装（大约 3/4 圈）, 不要使用
工具。
Continue to turn the filter with
hands until the filter is installed solidly
(about 3/4 turns),
-33-
E. 排气直至无气泡出现。
Deflate until there is no bubble.
F. 启动发动机。
Start Engine.
-34-
G. 进行泄漏实验。
Conduct leakage test.
H. 必要时重新拧紧。
Retighten when necessary.
检查进气系统
Check the air intake system

检查进气胶管是否老化有裂缝、
环箍是否松动，必要时紧固或更换零
件，确保进气系统密封性。
Check whether the air intake
rubber pipes are aging or cracked，the
steel wire hoop is loosening．If it is
necessary tighten or replace the parts to
ensure good sealing performance．
-35-
检查空气滤清器滤芯
Check the air filter element
柴油机最大允许进气阻力为
7kPa，柴油机必须在标定转速和全负
荷运转时检查最大进气阻力，当进气
阻力达到最大允许极限时，应按制造
厂的规定清洁或更换滤芯。
The maximum air intake resistance

1.纸质主滤芯：Paper filtering element
of the engine should be less than 7kpa，
2.毛毡安全滤芯：Blanketry safety filtering element
it should check while the engine running
at rated speed and full load. When the
resistance reaches the maximum limit or
the indicator light glows，the air filter
element should be cleaned or replaced
as per the maintenance guide from the
manufacture.
注意：决不允许在没有空滤器时
使用发动机。否则灰尘和杂质进入柴
油机会导致发动机早期磨损。
Note：lt is not allowed to
use the engine without air filter，
otherwise the dust and impurity will
cause early wearing of the engine.
-36-
从空滤器中拆下空滤芯，轻拍端
面使灰尘落下，也可用压缩空气反吹 High pressure air pipe
( 由内向外吹 )。
Remove the filter core from the
air filter element and beat the side of
the element lightly to make dust fall
down,or blow the element backward
(blow back from inside to outside)by
compressed air．
注意：
Nole：
·不得吹破滤纸
Don't blow off the air filtering paper
·不得用水和油清洗滤纸
Don't clean the air filtering paper by
water and oil
·不得用力拍打或敲打滤芯
Don't beat the core forcibly．
-37-
3.3 柴油机长期存放时的维护保养
Maintenance during long-term storage
● 为防止锈蚀 , 柴油机出公司时进行油封 , 一般柴油机的油封期为一年 , 凡超过一年的应进
行检查并采取必要的补充措施。
In order to prevent rust and corrosion, the diesel engine is oil sealed before ex-work. Usually, the
oil seal period for the diesel engine is one year. Whenever the oil seal period exceeds one year, check and
take necessary supplementary measures.
● 油封：首先向柴油机加入机油和带防锈剂的冷却液，开机并空转 15-25 分钟，在停机前 2
分钟向空气压缩机进口喷射油封油，停车后拆除中冷器与发动机的连接管路，以起动机带动发动
机转动，向发动机进气管、涡轮增压器等内腔喷油封油。向所有的裸露表面和轴伸出端涂油封油。
Preservation: First fill the diesel engine with sealing oil and coolant with anti-rust agent, start the
engine and run at idling speed for 15~25min. Spray sealing oil to air compressor intake 2min before
stopping of the engine. After stop, remove the pipeline connecting intercooler and engine, so that the
starter drives the engine to rotate. The sealing oil is sprayed into the cavities of intake pipe, turbo-
supercharger, etc. Apply sealing oil on all the exposed surfaces and the extended shaft ends.
● 存放期间的防护：用盖子或用塑料布捆扎封堵各油、气、水的进出口；用气象防锈膜封存
整台柴油机。
Protection in storage period:Block all the oil, air and water inlets and outlets with cap or banded
plastic cloth; and seal up the whole diesel engine with weather rust proof film.
● 如果需要运输则应该外加包装。
Add external package if transportation is needed.
-38-
4. 柴油机几大系统示意图
The Main System Flow Chart of Engine
·润滑系统
Lubricating system
·冷却系统
Cooling system
·进排气系统
Intake and exhaust system
·燃油系统
Fuel supplying system
了解 WP10 柴油机的各大系统流程，将为您使用维护保养及故障排除提供帮助。
To understand the main system flow chart of the engine will give help to you for operating and
maintaining the engine．
4.1 润滑系统
Lubricating system
1．集滤器
Strainer
2．机油泵
Oil pump
3．机油滤清器
Oil filter
4．机油冷却器
Oil cooler
5．主油道
Main oil passage
6．机油泵安全阀
Safety valve of oil pump
7．安全阀
Safety valve
8．主油道限压阀
Oil release valve for main
oil passage
9．机油滤清器旁通阀
Bypass valve of oil filter
-39-
各大运动零件的润滑
Lubricating for main moving parts
1．机油冷却器来油
The oil flowing from the oil cooler
2．主油道
Main oil passage
3．通往主轴颈
Oil to the main crankshaft journal
4．连杆轴颈
Connecting rod journal
5．曲轴主轴颈处
The main journal of crankshaft
6．通往连杆轴承
Oil to connecting rod beating
7．主油道通向主轴承的斜油道
The branch oil passage passing to
main Dearing
8．付油道
Sub-passage of oil
9．冷却活塞喷油
Oil injection nozzle to Cool piston
10．凸轮轴轴承
Camshaft beating
11．付油道来油润滑共轨喷油泵
Lubricating fuel injection pump
through the oil from sub-passage
-40-
摇臂机构的润滑
Lubricating for rocker arm system
1．主油道斜油孔来油
Oil flowing from the oil branch
passage
2．挺柱油孔
Tappet oil hole
3．挺杆油孔
Push rod oil hole
4．摇臂螺钉油孔
Oil hole of rocker arm bolt
5．摇臂油孔
Oil hole of rocker arm
增压器的润滑
Lubricating turbocharger
1．主油道来油
Oil from the main oil passage
2．增压器进油口
Oil inlet of turbocharger
3．增压器回油口
The oil outlet of turbocharger
-41-
4.2 冷却系统
Cooling system
1．水泵进水口
Water pump inlet
2．水泵
Water pump
3．机油冷却器水腔
Water channel of oil cooler
4．气缸体水套
Water jacket of cylinder block
1．气缸体水套
Water jacket of cylinder block
2．来自缸体水套之水
Cooling water flowing from water
jacket of cylinder block
3．气缸垫
Cylinder head gasket
4．流经气缸盖水腔
Cooling water passing through the
water passage of cylinder head
5．出水口
Cooling water outlet
-42-
1．机体流出冷却液
Coolant flowing from cylinder block
2．调节器
Thermostat
3．旁通阀
Bypass valve
4．流入水泵的冷却液
Coolant flowing into water pump
5．旁通阀关闭
Bypass valve closed
6．冷却液流入散热器
Coolant flowing into the radiator
-43-
4.3 进排气系统
Intake and exhaust system
1．经过滤清器滤清的空气进
入增压器
The fresh air passing through the air
filter flows into turbocharger
2．流经中冷器的增压空气
( 增压非中冷机无中冷器 )
The turbocharged air passing through
intercooler(There is no intercooler for
turbocharged but not inter-cooled engine)
3．中冷器(我厂不配带中冷
器)
Intercooler(The engine supplied
without intercooler when delivering out of
our company)
4．进气管
Intake manifold
5．进气门
Intake valve
1．排气门
Exhaust Valve
2．排气管
Exhaust manifold
3.排气进入增压器涡轮
Exhausting gas flowing into the turbo
of turbocharger
4．增压器排气出口
Exhaust outlet of turbocharger
-44-
4.4 燃油系统
Fuel System
WP10 系列欧Ⅲ柴油机采用了 Bosch 公司的高压共轨系统 , 使发动机能够满足最高 1600bar 的
喷油压力，实现燃油量与正时的灵活控制，达到低排放与低油耗。
WP10 Series Euro III diesel engine applies high pressure common rail system made by Bosch
Company, which enables engine to meet the max. fuel injection pressure of 1,600bar, to realize the
flexible control of fuel quantity and timing; resulting in low emission and low fuel consumption.
共轨式电控燃油喷射技术是一种全新的技术，因为它集成了计算机控制技术、现代传感检测
技术以及先进的喷油结构于一身。它不仅能达到较高的喷射压力、实现喷射压力和喷油量的控制，
而且能实现预喷射和后喷，从而优化喷油特性形状，降低柴油机噪声和大大减少废气的排放量。
The common-rail electronically-controlled fuel injection technology is a brand-new one, for it
combines computer control technology, modern sensing and detecting technology and advanced fuel
injection structure. It can not only reach comparatively high injection pressure, and realize the control
of fuel injection pressure and quantity, but can also conduct pre-injection and post-injection, so as to
optimize the characteristic shape of fuel injection, decrease the noise of diesel engine and reduce emission
greatly.
共轨系统对燃油油路要求较高，低压油路（油箱→粗滤→精滤，回油）、高压油路（高压油泵→
共轨管→高压油管→喷油器）都要保证密闭。
The rail system has higher standard on fuel lines. The low pressure fuel line (fuel tank → coarse
filter → fine filter, scavenge) and high pressure oil line (high pressure fuel pump → rail pipe → high
pressure fuel pipe → fuel injector) all need to be sealed.
-45-
WP10系列欧Ⅲ柴油机电控共轨系统
WP10 series Euro Ⅲdiesel engine with electroni cally controlled common rail system
High pressure fuel outlet
Diesel intake (from filter)

Diesel outlet (to tank)
Fuel metering valve
Overflow valve
Camshaft
Oil inlet(optional)
Diesel outlet (to filter)
Initial oil filler valve cover
Camshaft phase sensor:DG6

Gear pump ZP5
Diesel intake (from tank)
WP10系列欧Ⅲ柴油机高压油泵
High pressure fuel pump of WP10 Series Euro III diesel engine
-46-
4.1.2 柴油粗滤器组件
Fuel coarse filter assembly
柴油粗滤器功能
Function of fuel coarse filter
粗滤系统是安装在油箱油路的下游，它会将流过它的水和微小颗粒从柴油中分离出来（利用
它的多层介质构造）。分离出来的水会被收集到位于过滤器底部的集水器皿之中。然后通过放水塞
流出。如果在粗滤器顶部安装了电加热器，那么当油流过粗滤器的时候，它将会被 350W 的加热器
加热。
The coarse filter system is installed in the downstream of fuel tank line. It is used to separate the
water and minor granules passing it from the fuel (with its multilayer medium structure). The separated
water is collected in a water collector at the bottom of filter, and then flows out through drain plug.
Provided an electric heater is installed on the top of coarse filter, the fuel, when passing the coarse filter,
is heated by 350W heater.
柴油滤清器组件
Diesel fuel filter assembly
1.进油口 Fuel inlet 2.过滤器盖 Filter cap 3.手泵 Hand pump 4.放气螺丝 Deflating screw
5.安装用法兰 Flange for installation 6.加热器 Heater 7.出油口 Fuel outlet 8.旋压过滤器 Spinning filter
9.集水器 Water collector 10.排水螺丝 Drain screw 11.出油口 Fuel outlet
-47-
注意：当更换旋压粗滤器或对输油管进行重装时，那么需要给粗滤器进行排气。
Caution: When replacing spinning coarse filter or re-installing fuel delivery pipe, deflate the
coarse filter first.
粗滤器排气步骤：
Deflate the coarse filter in following steps:
1、停止发动机
Stop the engine.
2、卸下放气螺丝
Remove the deflating screw.
3、使用手泵打气直到有油从放气螺丝中冒出
Pump with hand pump until there is fuel belching out from deflating screw.
4、重新上紧放气螺丝
Tighten deflating screw again.
粗滤器排气
Deflating of coarse filter
-48-
注意：当集水器满了或旋压过滤器已经替换,则需要将收集到的水放出
Caution: When water collector is full or the spinning filter has been replaced, drain the collected
water from the water collector.
集水器放水步骤：
Drain water from water collector in the following steps:
1．打开集水器 (1) 底部的放油塞 (2) 让水排净；
Open drain plug (1) at the bottom of water collector, (2) to drain off the water;
2．重新上紧放油塞。
Tighten the drain plug again.
集水器放水
Water drain from water collector
-49-
5. 柴油机强力螺栓的拧紧力矩和拧紧方法
Tightening Torque And Tightening Method
of High Strength Bolts
1. 主轴承螺栓：
Main-Bearing Bolt
14根M18 22套筒扳手
Total nos.: 14 pcs M 1 8 bolts，Tool：
22mm sleeve wrench
分两次拧紧(拧紧顺序按上图所示) 第一
次：80N·m 第二次：250+25N·m
Tighten bolts in twice(tightening
sequence see the figure above)
The first time：80N·m
The second time：250+25N·m
2. 气缸盖螺栓：
Cylinder Head Bolt：
24根M1 6的主螺栓，22套筒扳手
Total nos：24 pcs M16 main bolts，
7根M 12副螺栓的螺母，17套筒扳手
T ota l nos：7 pc s nut s of M 12
auxiliary bolt，Tool：17mm sleeve wrench
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按下列顺序拧紧：
Following such tightening sequence：
第一步：气缸盖安装好后须找正，即排气口侧应在一个平面内：所有螺栓按 30N·m 预紧。
Step 1：Align cylinder head after assembly，i．e．the exhaust port side of cylinder heads should be
in the same plane．All the bolts should be tightened beforehand，and the torque is 30N·m．
第二步：24 根主螺栓用 200N-m 力矩按上图所示主螺栓次序拧紧。
Step 2：Tighten 24 pcs main bolts as the sequence in above figure，and the torque is 200N·m
第三步：7 根副螺栓螺母用 100N·m 力矩按上图所示副螺栓次序拧紧。
Step 3：Tighten 7 pcs auxiliary bolts as the sequence in above figure．and the torque is 100N·m
第四步：主螺栓按上图次序旋转 90°
Step 4：Turn the main bolts 90° as the sequence in above figure．
第五步：副螺栓螺母按上图次序旋转 90°
Step 5：Turn the auxiliary bolts 90° as the sequence in above figure．
第六步：主螺栓按上图次序再次旋转 90°扭矩达到 240-340 N·m。
Step 6：Turn the main bolts 90 ° as the sequence in above figure again，and the torque range is
240-340 N·m．
第七步：将副螺栓螺母按上图次序再次旋转 90°，扭矩同时达到 120-160N·m。
Step 7：Turn the auxiliary bolts 90 ° as the sequence in above figure again．the torque range is
120 ～ 160 N·m．
对达不到最终扭矩要求的螺栓应更换，主螺栓允许重复使用 3 次，副螺栓允许重复使用 2 次。
Replace those bolts that cannot reach required torque range．The main bolt is allowed to be reused
for 3 times．and the auxiliary bolt is allowed to be reused for 2 times．
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3. 连杆螺栓：
Connecting rod Bolt：Connecting rod Bolt：
两根M14x1.5 19mm套筒扳手
Total nos．：2 pcs M14x1.5 for each connecting rod Tool：19 mm sleeve wrench
第一步：先拧靠，再用120N·m的力矩对称扭紧。
Step 1: Tighten tightly，then tighten these bolts symmetrically with a torque of 120N·m.
第二步：旋扭90°±5°，扭矩须在170-250 N·m范围内
Step 2：Turn these bolts 90°±5°．and the torque range is 170-250 N·m．
对达不到扭矩要求的螺栓应更换
Replace those bolts that can not reach required torque range．
注意：经过拆卸后的连杆螺栓不得再使用。
Note：The connecting rod bolts that have been used should not be reused．
4. 飞轮螺栓：
Flywheel Bolt：
9根M14X1.5 22套筒扳手
Total nos．：9 pcs M14×1.5 Tool：22mm sleeve wrench
第一步：60N·m力矩对称扭紧
Step 1：Tighten these bolts symmetrically with a torque of 60N·m．
第二步：转180°±5°，扭矩同时达到230-280 N·m
Step 2：Turn these bolts 180°±5°，and the torque range is 230-280 N·m．
对达不到扭矩要求的螺栓应更换
注意：飞轮螺栓只许使用2次。
Note：The flywheel bolt is only allowed to be reused for 2 times．
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5. 飞轮壳螺栓：
Bolt for Flywheel Housing
13根M12螺栓套筒扳手
Total nos．：1 3 pcs M12 bolts Tool：box wrench
第一步：40N·m力矩拧紧
Step 1：Tighten these bolts with a torque of 40 N·m．
第二步：分别旋转120°±50°，同时达到110～140N·m
Step 2：Turn these bolts 120°±5°respectively，and the torque range is110 ～ 140 N·m．
不在扭矩范围内的螺栓应更换
飞轮壳螺栓允许重复使用2次。
The flywheel housing bolt is allowed to be reused for 2 times．
注意：以上几种强力螺栓拧入前均要在螺纹及支撑面上涂润滑油。
Note：Smear th read and bearing surface of high strength bolts described above with
lubricating oil before tightening．
6. 中间齿轮轴螺栓：
Bolt for Intermediate Gear Shaft
4根M10 套筒扳手
Total nos．：4 pcs M10 bolts Tool sleeve wrench
第一步：60N·m力矩对称拧紧
Step 1：Tighten these bolts symmetrically with a torque of 60N·m．
第二步：分别旋转90°，扭矩达到100-125 N·m
Step 2：Turn these bolts 90°，and the torque range is 100-125 N·m．
达不到扭矩要求的螺栓应更换
螺栓拧入前螺纹部位涂乐泰密封胶242。
Smear the thread with LOCTITE 242 THREADLOCKER before tightening．
中间齿轮轴螺栓允许重复使用 3 次。
The bolt of intermediate gear shaft is allowed to be reused for three times.
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7．机油泵惰轮轴螺栓：
Bolt/Oil Pump Idler Gear Shaft
M10 16mm套筒扳手
T0tal nos．：1 piece M10 bolt
一次拧紧到60 +5N·m
Tighten the bolt with a torque of 60+5
N·m．
拧人前螺纹部位涂乐泰密封胶242。
Coat the thread with LOCTITE 242
THREADLOCKER before tightening．
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8．摇臂座螺栓：
Bolt ／ Rocker-Arm Support
12根M12
Total nos．：12 pcs M12 bolts
18mm套筒扳手
一次拧紧到100N·m
Tighten these bolts with a torque of
100N·m
9．高压油管紧固螺母拧紧力矩喷
油器端20-25N·m，轨端、油泵端
25-35N·m：
Tighten the high pressure pipe
nuts to the torque of 20~25N·m for
the injector side, and 25~35N·m for
the rail end and fuel pump end.
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10．共轨喷油泵驱动齿轮紧固螺
母:
Tight Nut/Injection Pump Driving
Gear
M24x1.5．
Total nos．: 1 piece M24x1.5 nut
36mm 套筒扳手
一次拧紧到300N·m
Tighten the nut with a torque of
300N·m．
拧人前螺纹部位涂乐泰密封胶
242。
Coat the thread with LOCTlTE 242
THREADLOCKER before tightening.
11．凸轮轴齿轮螺栓：
Bolts Camshaft Gear
4 根 M8
Total nos．：4 pcs M8 bolts
13mm 套筒扳手
对称拧紧到 35N·m
Tighten these bolts symmetrically
with a torque of 35N·m．
拧入前螺纹部位涂乐泰密封胶 242。
Coat the thread with
LOCTITE 242
THREADLOCKER
before tightening．
-57-
12．减振器皮带轮与曲轴连接螺
栓：
Bolt ／ Attaching Damper
Pulley and Crankshaft
8 根 M10
Total nos：8 pcs M10 bolts
16mm 套筒扳手
对称拧紧到 60+5N·m
with a torque of 60+5 N·m．
13．喷油器紧固螺栓M8(2根)：
对称拧紧并注意侧螺一致10-12
N·m injector bolts M8 (2 pieces):
Symmetrically tighten them to a torque of
10-12mm with same side clearance.
-58-
14．排气管螺栓：
Bolts/Exhaust manifold
12 根 M10
Total nos．：12 pcs M 10 bolts
对称拧紧到 (65 ~ 80)N·m
with a torque of(65 ~ 80)N·m．
注意：螺栓拧入前在螺纹部位及螺
纹支撑面上涂二硫化钼油剂。
Note：Coat the thread and bearing
surface with Molybdenum disulfide
Lube before tightening．
排气管螺栓允许重复使用 2 次。
The exhaust pipe bolt is allowed to be
reused for twice.
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6. 柴油机所用的燃料油、润滑油、冷却液和辅助材料
Fuel，Lbricant，Coolant and Auxiliary Materials
6.1 燃料油
Fuel：
夏季 0 号柴油 GB252 冬季 -10 号柴油 GB252
In Summer No.0 Diesel Fuel GB252 In Winter No.-10 Diesel Fuel GB252
当冬季温度为 -20℃，选用 -20 号柴油 ; 冬季温度低于 -30℃，采用 -35 号柴油。
In winter，when the temperature is - 20℃，you should use No.-20 Diesel Fuel. If the temperature
is below-30℃，you should use No.-35 Diesel Fuel．
6.2 润滑油：
Lubricant：
6.2.1 选用 CF-4 级机油。
Select CF-4 oil.
6.2.2 允许以高品位的机油代替较低品位的。
It is allowed to replace low-grade oil with high-grade oil．
6.2.3 发动机润滑油的粘度可参照下图选用。
Please reference the following chart to choose viscosity of lubricant．
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6.2.4 油面处于油标尺上限位置时，机油容量约24升，油标尺上下刻度问的落差约3升；根据用户
协约，出厂时油底壳内，可以是充油，也可以是不充油的。当充油时，该油内含有特种磨合(防
蚀)剂，用户可在运行2000公里(或50小时)时将机油全部放出，更换新机油。
The approximate volume of the oil sump is 24 litres when the oil level stays at the upper limit of
oil dipstick．The fall between upper and lower limit of oil dipstick is about 3 litres.According to the
agreement between Weichai and customers，the engine could be supplied with or without the oil in the
sump of the engine．If the engine was supplied with the oil in the sump，some special anticorrosive agent
was contained．The customer can replace it with new oil after running 2000km (or 50hs)．
6.3 润滑脂：水泵油杯注入锂基脂，符合 GB/T5671 的要求。
Grease：Fill the grease cup of the water pump with lithium grease that meets the
requirements of GB/T5671.
6.4 冷却液：冷却系统加入防冻液约40升，此液体具有防锈防冻的能力。(配比请参阅防
冻液使用说明)
Coolant：Fill the cooling system with 40 litres anti-freeze coolant which can prevent rust
and frostbite．(Please reference the Operating Instruction Manual of Coolant for mixture ratio)
6.5 辅助材料：
Auxiliary Materials：
6.5.1 本机在装修过程中，可使用乐泰510、242、271、277、262等规格的密封胶和粘接剂。
LOCTITE 510、242、271、277、262 sealing glue and cohesive material can be used during the
process of mounting and repairing．
6.5.2 细钼粉
Fine molybdenum powder．
6.5.3 各种辅助材料的使用部位见下表。
Please reference the following table for detailed application of auxiliary materials．
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WP10 系列柴油机所用的辅助材料表
Auxiliary Materials List of WP10 Series Diesel Engine
序号名称颜色用途与应用
Serial No． Name Color Function and Application
涂在平滑的金属表面防止咬合
细钼粉 Apply to smooth surface of metal to prevent
Fine 黑色 biting.
1
Molybdenum Black 例如：涂在气缸套外表面
Powder eg,Apply to exterior surface of cylinder
liner.
零件处在较高温度下防粘着
To prevent adhesion of parts under higher
二硫化钼油剂
深灰色 temperature.
2 Molybdenum
Dark Grey 例：增压器排气口螺栓等
disulfide Lube
eg，Apply to the bolts of exhaust outlet of
turbocharger.
涂在螺纹部位固持、密封
乐泰242
兰色 Apply to thread to seal．
3 Loctite 242
Blue 例：各种螺栓、螺纹部位
glue
eg，Apply to bolts and thread．
涂在螺纹部位锁紧密封、高力度
乐泰262 Apply to thread to lock and seal．
红色
4 Loctite 262 例：气缸盖副螺栓
Red
glue eg，Apply to auxiliary bolts of cylinder
head.
涂在金属表面起密封作用
乐泰510 Apply to surface of metal to seal．
红色
5 Loctite510 例：气缸体与曲轴箱结合面
Red
glue eg，Apply to bond surface of cylinder
block and crankcase．
涂在金属表面起密封作用
乐泰271
红色 Apply to surface of metal to seal．
6 Loctite 271
Red 例：油道碗形塞
glue
eg，Apply to oil channel plug．
芯子与孔之间的密封
乐泰277 Sealing of plug and hole．
红色
7 Loctite 277 例：机身水腔碗形塞
Red
glue eg，Apply to the water reservoir plug of
cylinder block．
锂基脂无色水泵润滑脂
8
Lithium Grease Achromaic Color Grease for Water Pump
-63-
本章注意：为确保您所购的柴油机的正常使用，必须按本说明中规定，使用正确牌号的燃油、
机油。
Note：To ensure the proper operation of our diesel engines，please use the correct brand
fueI and oil as this manuaI described．
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7. 电气部分
Electric System
电气系统包括发电机、起动机、电子控制单元（ECU）、电加热法兰、水温表传感器 ( 另有
Bosch 生产的水温传感器与 ECU 直接相连 )、机油压力传感器、进气温度压力传感器 ( 另有 Bosch
生产的机油压力表与 ECU 直接相连 )、转速传感器及继电器等。
The electric system is composed of generator, starter, electronic control unit (ECU), water
temperature gauge sensor (additionally a water temperature sensor produced by BOSCH is directly
connected with EW), oil pressure sensor (additionally an oil pressure and temperature sensor produced by
BOSCH is directly connected with EW), intake air temperature and pressure sensor, speed sensor, relay,
etc.)
7.1 ECU
ECU
采用 BOSCH 的电子控制单元（图 7-1），具有稳定的系统处理能力；多层次的系统保护和纠
错措施，提高发动机的可靠性和安全性；采用 CAN 和 K 总线可以实现与整车电控单元的自由通信，
更人性化地实现整车故障诊断和报警处理。
BOSCH ECU (Figure 7-1) has the stable system processing ability; and multi-layer system
protecting and correcting measures, so as improve the reliability and safety of the engine. The CAN and
K bus can communicate with the whole vehicle ECU freely, and realize the fault diagnosis and alarm
treatment of the whole vehicle much more humanly.
图7-1 ECU外形图
Fig 7-1 External view of ECU
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7.2 发电机
Generator
WP10 系列柴油机的发电机额定电压为 28V，带有晶体管调节器。发电机在汽车上与蓄电池并
联工作，工作时发电机自激磁。发电机电路图见图 7-2。
The generator of WP10 Series diesel engine is of 28V rated voltage and with transistor regulator.
On the vehicle, the generator operates in parallel with battery and is self-excited during operation. The
generator circuit diagram is as shown in Figure 7-2.
图7-2 发电机原理图
Fig 7-2 Schematic diagram of generator
发电机在安装、接线时要注意：
During generator installation and wring, pay attention to:
◆必须充分冷却
Cool fully.
◆必须防尘、防溅、防油
Prevent dust, splashing and oil.
◆检查电机皮带的涨紧
Inspect the tension of generator belt.
◆只能与电压调节器和蓄电池连接运行
Operate only when connected with voltage regulator and battery.
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7.3 起动机
Starter
WP10 系列柴油机起动机为电磁控制、齿轮传动、以摩擦片式单向器传递扭矩的直流起动机，
功率 5.4kW。起动机电路图见图 7-3。
The starter of WP10 Series diesel engine is a electromagnetically controlled, gear-driven, direct
current starter, which transmits torque by friction plate type isolator. Its power is 5.4kW. The circuit
diagram of starter is as shown in Figure 7-3.
图7-3 起动机电路图
Fig 7-3 Circuit diagram of starter
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为了保证起动机无故障运行，应注意：
In order to guarantee the fault-free operation of starter, pay attention to:
◆对喷溅水、道路泥浆、机油加以防护，必要时要装防护板
Protect it from splashing water, roadway mud and oil, and install baffle if necessary
◆防高温，起动机壳体的许用温度不大于 100℃
Protect it from high temperature. The permissible temperature for starter housing is not more than
100℃
◆如果驾驶员监控不到起动过程（例如发动机安装在尾部的商用车），为保护起动机和防止打
齿，必须安装起动继电器，起动继电器电流容量应大于 80A，在柴油机开始正常运转后立即切断起
动机电路；起动继电器的轴线应与地面平行，且垂直于车辆运行方向，以防由于振动和冲击等原
因而使起动机意外啮合。
If the driver can not monitor the starting process (for example, for the commercial vehicle, whose
starter is mounted at the afterbody), in order to protect the starter and avoid gear damage, mount a
starting relay. The current capacity of starting relay shall be more than 80A. Once the diesel engine
operates normally, cut off the circuit of starter immediately. The axis of starting relay shall be paralleled
with the ground, and vertical to the driving direction of vehicle, in order to prevent starter from accident
engagement due to vibration and shock.
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7.4 机油压力传感器
Oil pressure sensor
机油压力感应塞的工作温度为 -25 ～ 100℃，测量范围 0 ～ 500kPa，报警压力为 45 ～ 75kPa（当
压力降低时触点闭合），报警器通断功率最大 5W，额定电压 6 ～ 24V，感应塞的接口尺寸见图 7-4。
For oil pressure sensing plug, the working temperature of is -25~100℃ ; the measuring range
0~550kPa; the alarm pressure 25~40kPa (contact is closed when the pressure decreases); max. switching
power for alarm device 5W; and the rated voltage 6~24V. The interface dimension of sensing plug is as
shown in Figure 7-4.
Piece-shaped plug 4.8 x 0.8 Hex nut M4DIN934 B4 Spring washer DIN 128 Housing zinc-plated Wrench opening width(24)
As per DIN 46244
Piece-shaped plug A6.3 x 0.8
As per DIN 46244
Max 40 Max 44.5
Max 79.5
图7-4 机油压力感应塞接口图
Fig 7-4 Interface graph of oil pressure sensing plug
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7.5水温表传感器
Water temperature sensor
水温表传感器的工作温度为 -25 ～ 120℃，分为普通和带报警两种结构，带报警的传感器报
警温度 96±3℃。水温表传感器允许外力扭矩 19.6N·m，额定电压 6 ～ 24V，水温表传感器的接
口尺寸见图 7-5。
The water temperature sensor operates at temperature of -25~120℃ , and is constructed in two
styles, ordinary and alarm. The alarm temperature of the alarm sensor is 96±3℃ . The permitted external
force torque of water temperature sensor is 19.6N·m, and its rated voltage is 6~24V. The interface
dimension of water temperature sensor is as shown in Figure 7-5.
Alarm plug 4.8 x 0.8 as per D46247
as per D46248
Sensor flat plug 4.8 x 0.8

Black insulation part
图7-5水温表传感器接口图
Fig 7-5 Interface graph of water temperature sensor
-70-
8．主要零部件的调整与更换
Adjustment and Replacement of Main Components
8.1 冷却系统
Cooling System
更换三角皮带
Replace the V-belts
16mm 开口扳手
松开发电机拉紧螺栓螺母，拿下发
电机皮带。
Loosen the tightening nut of the
generator to remove generator belt．
换上三角皮带，涨紧合适后重新拉
紧螺栓螺母。
Replace the V-belts，tighten the nuts
of tension bolts again．
-71-
更换水泵
Replace Water Pump
16mm 开口扳手
Tool：16mm open-ended wrench
松开发电机拉紧螺栓。
Loosen the tightening bolts of
generator .
6# 螺丝刀
Tool：6#Screwdriver
松开水管接头处橡胶软管卡箍。
Loosen the rubber hose clamp of
water pipe joint．
-72-
13mm 套筒扳手
松开水管接头螺栓，并拆下水管接
头。
Loosen the bolt of water pipe joint to
remove water pipe joint.
13mm 开口扳手
拆下水泵与齿轮室连接的 6 个六角
螺母。
Loosen the 6 hexagon nuts attaching
water pump and gear case.
拆下水泵。
Remove water pump.
-73-
擦净水泵密封平面。
Clean the seal surface of water pump．
13mm 开口扳手
Tool：13 mm open-ended wrench
换上新的水泵总成，拧紧 6 个六角
螺母 ( 注意水管接头内侧有一螺母 )。
Install the new water pump assembly，
tighten 6 hexagon nuts.(There is a nut in
the inner side of water pipe joint)
注意 : 水泵内腔内装入约 120cm3
汽车通用锂基润滑脂。需定期从小油杯
处补充。
Note：Fill the Iumen of water
pump with 120cm 3 general Iithium
grease．Refill lithium grease Witll
grease cup periodically．
-74-
13mm 开口扳手
安装水管接头，并拧紧水管接头上
两 M8 螺栓，并安装好橡胶软管。
Install the water pipe joint， tighten
two M8 bolts of water pipe joint，then i
nstall the rubber hose．
16mm 开口扳手，铁棒
Tool：16mm open-ended wrench and
pontil
安装三角皮带，调好涨紧度拧紧发
电机拉紧螺栓。
Install the V-belt and adjust the
tensity，tighten top nuts of tightening bolts.
-75-
8.2 润滑系统
Lubricating System
更换机油冷却器芯
Replace the oil cooler core
13mm 套筒扳手
松开机油冷却器盖上的一圈 M8 螺
栓，并拆下机油冷却器盖。( 拆卸前要放
掉发动机内的冷却液 )
Loosen all of the M8 bolts on the oil
cooler cover to remove oil cooler cover．
(Discharge coolant before demounting the
oil cooler cove)
清理机油冷却器盖和机身密封结合
面并更换新的机油冷却器盖垫片。
Clean the oil cooler cover and seal
surface of the cylinder block,replace with
new gasket of oil cooler cover
-76-
13mm 套筒扳手
松开机油冷却器芯 4 根 M8 螺栓。
Loosen the 4 pcs M8 bolts of oil
cooler element
拆下机油冷却器芯，并清理干净机
身上机油冷却器芯法兰结合面。
Remove element of oil cooler and
clean the bonding surface of flange of oil
cooler element．
-77-
更换机油冷却器芯密封垫圈。
Replace the sealing gasket of oil
cooler flange.
13mm 套筒扳手
安装新的机油冷却器芯，并拧紧 M8
六角螺栓。
Install the new oil cooler element and
tighten the M8 hexagon bolts．
注：螺栓拧紧前须在螺纹部位涂乐
泰 242 密封胶。
Note：Coat the thread with
LOCTITE 242 THREADLOCKER
before tightening．
-78-
3mm 套筒扳手
安装机油冷却器盖，并拧紧外围所
有 M8 六角头螺栓。
Install the oil cooler cover and tighten
all the peripheral M8 hex head bolts．
更换主油道限压阀
Replace the release valve of main
oil channel
13mm 套筒扳手
松开油底壳外围 M8 六角头螺栓。
Loosen all peripheral M8 hex head
bolts of oil pan．
-79-
拆下油底壳托块，并拿下油底壳。
Remove retainer，then remove oil
pan.
27mm 开口扳手
拆下主油道限压阀。
Remove the release valve of main oil
channel．
拆下主油道限压阀时应搬动阀体六
方的外螺纹端部分。
When removing the release valve
of oil channel,move the male end of
hexagonal part on valve body．
-80-
27mm 开口扳手
安装新的限压阀，拧入前需在螺纹
部位涂乐泰 242 密封胶。
Install new release valve，
coat the thread with LOCTITE 242
THREADLOCKER before tightening.
安装新的限压阀时应搬动阀体六方
的外螺纹端部分。
When installing new release valve，
move the male end of hexagonal part on
valve body．
13mm 开口扳手
安装油底壳，拧紧 M8 六角头螺栓。
Install oil pan and tighten the M8 hex
head bolts．
注意：压好油底壳密封垫圈
Note：Make sure packing washer
of oil pan was pressed well.
-81-
更换机油泵
Replace Oil Pump
13mm 套筒扳手 16mm 开口扳手
Tool：13mm sleeve wrench and
16mm open-ended wrench
拆下油底壳，拆机油集滤器。
Remove oil pan and suction pipe。
10mm 开口扳手
松开吸油管固定压板 ( 双级机油
泵 )。
Loosen the mounting plate of oil
suction pipe(two-stage oil pump).
-82-
16mm 开口扳手 ( 双级机油泵 )

Tool：16mm open-ended
wrench(two-stage oil pump)
松开吸油管 M10 六角螺栓，并拆下
吸油管。
Loosen the M10 hex head bolts of oil
suction pipe to remove oil suction pipe．
16mm 开口扳手，16mm 套筒扳手

Tool：16mm open-ended wrench and
16mm sleeve wrench
松开涨紧轮六角螺母和曲轴皮带轮
螺栓。
Loosen the hex head bolts of tension
pulley and the bolts of crankshaft pulley．
-83-
拆下皮带轮和减振器，减振器和曲
轴为过渡配合，必要时可以轻击减震器。
Remove the pulley and damper，the
damper and crankshaft is transition fit，
the damper can be knocked slightly if it is
necessary for removing．
22mm 开口扳手
拆下齿轮室处六角螺塞。
Remove the hex head plug screws of
gear case．
-84-
16mm 套筒扳手
拆下机油泵中间齿轮轴螺栓。
Remove the bolts of intermediate gear
shaft of oil pump．
用专用工具拆下机油泵中间齿轮
轴。
Remove intermediate gear shaft of oil
pump with special tool．
-85-
拆下机油泵中间齿轮。
Remove intermediate gear of oil
pump.
16mm 套筒扳手
拆下六角螺塞处六角头螺栓和另外
一个六角头螺栓。
Remove the hex head bolts from the
hex plug and another hex head bolt.
拆下机油泵。
Remove oil pump．
-86-
清理曲轴箱与机油泵结合面处。
Clean the seal Surface between
crankcase and oil pump.
16mm 套筒扳手
Tool:16mm sleeve wrench
安装新的机油泵和机油泵垫片，并
拧紧六角螺栓 ( 一个在六角螺塞处 )。
Install new oil pump and gasket，
tighten the hex head bolts(one of them is in
the hex head plug).
安装机油泵中间齿轮 ( 注：凸面朝
里 )。
Install intermediate gear of oil
pump(Note：convex towards inside).
-87-
安装机油泵中间齿轮轴。
Install intermediate gear shaft of oil
pump．
16mm 套筒扳手
安装中间齿轮轴螺栓，并拧紧。
Install the bolts of intermediate gear
shaft and tighten them．
拧紧力矩：60+5N·m
Tightening torque：60+5N·m
安装减振器和皮带轮。
Install damper and pulley．
-88-
16mm 套筒扳手
安装皮带轮螺栓，并拧紧。
Install the bolts of pulley and tighten
them．
拧紧力矩：60+5N·m
Tightening torque：60+5N·m
16mm 开口扳手
装好三角皮带涨紧适度后拧紧涨紧
六角锁紧螺母。
Install the V-belt pulley and adjust
the tensity，then tighten the hex head lock
nuts．
-89-
更换喷油器
Replace injector
17mm 开口扳手
清理喷油器四周并拆下高压油管与
喷油器连接接头。
Clean all round of the injector，
remove the joint attaching high pressure
fuel pipe and injector．
拆下喷油器回油管。
Remove fuel return pipe of the
injector．
-90-
13mm 开口扳手
松开紧固压板螺栓，拿下喷油器压
紧块和喷油器垫块。
Loosen bolts of mounting plate and
then remove injector mounting blocks and
padding blocks.
拆下喷油器。
Remove injectors．
-91-
清洁喷油器座孔。
Clean seat hole of injector．
更换新的铜质密封垫圈。
Replace with new copper washer．
-92-
更换新的喷油器然后装上新的橡胶
密封圈。
Replace with new injector and install
new rubber seal ring．
将新的喷油器装入喷油器座孔。
Install new injector into the seat hole．
注意：装好喷油器后胶圈不得有压
挤现象。
Note：It is not allowed to appear
any mark of pressing rubber cushion
after mounting injector．
-93-
安装喷油器固定板。
Install the mounting plate of injector．
安装喷油器。
Install bolts.
紧固螺栓对称拧紧并注意侧隙一
致，拧紧力矩 10 ～ 12N·m。
Install fuel injector bolts and tighten
them symmetrically. Pay attention to the
uniformity of the side clearance. Tightening
torque: 10 ～ 12N·m.
拧紧喷油器与高压油管连接接头及
安装好回油管。
Tighten the joint attaching injector
and high pressure fuel pipe，install fuel
return pipe．
-94-
8.4 进气系统
Air Intake System
更换涡轮增压器
Replace Turbocharger
6mm 螺丝刀
Tool：6mm screwdriver
松开压气进气管处的橡胶软管卡箍
和压气机出气管软管卡箍。
Loosen rubber hose clamps from the
inlet and outlet of compressor.
6mm 螺丝刀
Tool：6mm screwdriver
松开增压器回油管软管卡箍。
Loosen hose clamp from turbocharger
oil retum pipe．
-95-
6mm 内六角扳手
Tool：6mm inner hexagon wrench
拆下增压器进油管内六角螺栓，抬
起进油管法兰。
Remove inner head bolts from
turbocharger oil inlet sucker,raise flange of
sucker．
16mm 开口扳手
拆开排气管和增压器连接法兰自锁
螺母，拿下增压器。
Remove the self-locking nuts from
exhaust manifold to remove turbocharger．
-96-
更换新的增压器
Replace with new turbocharger
注意：如果涡轮增压器不是立即更
换．则应盖好各进出气口。以防止任何
物品掉入气缸里。
Note：If the turbocharger is not
replaced immediately，the intake and
exhaust manifolds should be covered
to prevent anything falling into cylinder.
6mm 内六角扳手
Tool：6mm inner hexagon wrench
更换新的进油管垫片，并拧紧进油
管螺栓。
Replace with new gasket for oil return
pipe，tighten bolts of oil return pipe．
注意：安装进油管垫片时，一定对
正垫片油孔和增压器法兰处油孔。且加
入干净的机油并转动涡轮叶轮．使机油
流入轴承室。
Note：Make sure to adjust the
gasket oil hole and turbocharger flange
oil hole，add some clean oil and rotate
turbo impeller to Iet oil flow into bearing
case．
-97-
9. 常见故障及排除
Common Troubles and Remedy
9.1 柴油机不能起动
Diesel engine can not start
9.1.1 起动机不工作
Starter is inoperative
WP10 系列起动机由 ECU 控制，正常工作时，ECU 输出一个电流驱动起动继电器，继电器接
通后电瓶带动起动机起动。出现故障时主要是对空档的检查。
WP10 Series starter is controlled by ECU. Under normal condition, ECU outputs a current to drive
the starting relay. When the relay is closed, battery drives the starter to start. When there is fault, mainly
inspect the neutral position.
检查时有几个要素：空档开关、起动继电器、电瓶、车下停车开关的关联。
Factors for inspection: neutral position switch, starting relay, battery, and conjunction of shut-down
switch under vehicle.
◆检查是否挂在空档位置
Inspect whether gear shift is at neutral position.
起车前，首先检查档位手柄是否挂在空档位置
Before starting, inspect whether the gear shaft handle is at neutral position.
◆检查车下停车开关的位置（应处于断开状态）
Inspect the position of shut-down switch under vehicle (in shut-down state).
车下停车开关做成点动式，并且能自动复位，检查此开关是否正常
The shut-down switch under vehicle is inching style, and can be reset automatically. Inspect this
switch for normal condition.
若此开关不是自动复位式，应检查此开关是否在接通状态
If this switch is not the automatic resetting style, inspect whether this switch is at ON position.
◆检查空档开关及接线是否完好，试着使用紧急起动（点火开关持续按下 5 秒以上）
Inspect neutral position switch and its wiring for condition, and try to use the emergency starting
(press the ignition switch for more than 5 seconds continuously)
-99-
起动机受 ECU 控制的发动机，起动时 ECU 先根据空档开关传来的信号判定是否挂在空档位

置。当空档开关损坏或接线连接不良时，ECU 接收不到空档信号，起动机是不工作的。
The engine of which the starter is controlled by ECU, during starting, the ECU judges whether the
gear shift is at neutral position with help of the signal transmitted from neutral position switch. When the
neutral position switch is damaged or wiring bad, the ECU can not receive any neutral position signal,
and then the starter does not operate.
◆检查电瓶电压是否过低，导致不能带动起动机
Inspect whether battery voltage is too low to drive the starter.
一般电瓶电压为 24V，太低则不能带动起动机工作，可以用万用表的电压档进行检查或用故
障诊断仪读取实际值“电池电压”。
Normally the battery voltage is 24V. If it is too low, the starter can not be driven to work. By using
multimeter at voltage range or with the fault diagnostic apparatus, measure the actual value of “battery
voltage”.
◆起动机继电器及接线是否完好
Inspect whether the starter relay and its wiring are good.
检查接线柱表面氧化物是否太多，接线柱表面螺栓是否松动或断裂
Inspect the terminal surface for deposit oxide, and for loose or cracked bolt.
◆检查起动机是否已烧坏
Inspect whether the starter has been burnt out.
用万用表检查起动机继电器是否正常
Inspect with multimeter whether the starter relay is normal.
◆点火开关及起动开关是否已坏
Inspect whether ignition switch and starting switch are damaged.
将点火钥匙旋至 ON 档，看仪表盘灯是否亮
Turn ignition key to ON position, and check that panel light comes on.
将点火钥匙旋至起动档，检查起动机是否有动作（此时是在其它原因排除的前提下）
Turn ignition key to starting position, and check that the starter operates (at this time, the other
reasons have been excluded)
Starter
Ignition key switch
-100-
9.1.2 轨压无法建立（起动机能正常工作，但无法起动）
Rail pressure can not be established (the starter can work normally but can not be started)
Deflating bolt
Oil return hollow bolt
Hand pump
◆检查油箱油位是否过低
Inspect whether the fuel level in fuel tank is too low.
此原因比较容易忽略，要引起注意
Pay attention to this reason that is easy to be neglected.
◆检查手油泵是否工作正常
Inspect whether hand pump operates normally.
用手压动手油泵看是否正常
Press hand pump with hand, and check whether it is normal.
◆检查低压油路是否有气，并排空气 ( 有时低压油路泄漏不明显，需要仔细检查 )
Inspect whether there is air in low pressure line, and exhaust the air (sometimes, the leakage of low
pressure line is not obvious, so inspect carefully).
排气方法：主要排粗滤里面的空气。松开粗滤上的放气螺栓，用手压动粗滤器上的手压泵，直
至放气螺栓处持续出油为止。
Deflating method: Mainly deflate the air in coarse filter. Loosen the deflating bolt on coarse filter.
Manually press the hand pump on coarse filter until fuel flows out continually at the deflating bolt.
低压油路空气排净后仍不能起动柴油机，则判断高压油路有空气，也需要排出高压油路的空
气。
If the diesel engine still can not be started after the air in low pressure line is deflated, it may be
judged that there is air in high pressure line. Deflate the air in the high pressure line.
-101-
排气方法：松开某缸高压油管，用起动机带动柴油机运转直至高压油管持续出油为止！（不
建议经常拆卸高压油管接头！）
Deflating method: Loosen high pressure pipe of a certain cylinder, and drive the diesel engine to
run with starter until the fuel flows out continually from high pressure pipe. (To disassemble the high
pressure pipe joint frequently is not recommended.)
◆检查高压油路有无泄漏
Inspect whether there is leakage in high pressure fuel line.
这种情况一般较为明显，检查高压油管接头螺帽是否有松动，若是，拧紧。
Usually, this case is very obvious. Inspect whether the joint nut of high pressure fuel pipe is loose,
and if any, tighten it.
◆检查油路是否通畅，检查柴油滤清器是否堵塞，建议及时更换柴油滤芯。
Inspect whether the fuel line is through, and whether fuel filter is blocked. It is recommended to
replace fuel filter element in time.
检查方法：松开精滤出口螺栓，用起动机带动柴油机运转，看是否有柴油喷出或流出，若只有
少量柴油流出，则可以判定滤芯堵塞，此时需要更换滤芯。
Inspection method: Loosen the outlet bolt of fine filter, drive the diesel engine to operate with
starter, and check whether fuel is jetted or flows out. If only a few fuel flows out, then it means the filter
element is blocked, and the filter element needs to be replaced.
◆检查轨压传感器初始电压值是否在 500mV 左右，或设定轨压是否为 30-50Mpa。测量方法
为：
Inspect whether the initial voltage value of rail pressure sensor is about 500mV, or the set rail
pressure is 30-50MPa or not. The measuring method is:
进入故障诊断仪操作界面，选中“实际值”, 点击下一步
Enter into the fault diagnostic apparatus operating interface, select“Actual value”, and click“Next”.
Select required function

Click >> to continue
Identification
Fault storage
Omit the fault memory in fault storage
Executing element
Function test
-102-
此时会出现所有的“实际值”选中“蓄压管压力传感器电压”
“额定油轨压力”
At this time, select “Accumulation pipe pressure sensor voltage” and “Rated fuel rail pressure”
in the displayed “Actual values:
engine speed
rated rail pressure
real rail pressure
accumulation pipe sensor voltage
若不正常首先检查接插件是否牢靠，若没有问题，则可能是轨压传感器坏了
If not normal, inspect whether the connector is reliable or not. If it is out of question, the rail
pressure sensor may be damaged.
若无检查设备，可以拔掉轨压传感器接插件尝试再起动（起车后会进入“跛行回家”模式）
If there is no inspection equipment, disconnect the connector of rail pressure sensor, and try to
restart (After starting, it comes into “limp-home” mode)
◆检查流量计量单元是否完好，拔掉流量计量单元接插件尝试再起动
Inspect whether the flow metering unit is good, disconnect the connector of flow metering unit, and
try to restart
①首先观察是否有明显的硬件损伤、插接件连接是否牢靠
First, visually check hardware for obvious damage, and connector for reliable connection.
②连接故障诊断仪进行 Meter-unit 测试
Connect the fault diagnostic apparatus, and carry out the Meter-unit test.
-103-
进入故障诊断仪操作界面，选中“功能测试”，点击下一步
Enter into the fault diagnostic apparatus operating interface, select“Function test”, and click“Next”.
下一步
Next
进入功能测试子界面，选中“配量单元测试”，点击下一步；
Enter into the function test sub-interface, select “Meter-unit test”, and click “Next”.
下一步
Next
-104-
此时会出现测试条件界面，操作者确认条件符合，点击下一步，开始测试；
At this time, it will display the test condition interface, if operator confirms that the condition is
fitted, click Next, and start the test;
测试结束后，显示油量计量单元是否正常。
Upon completion of test, it displays whether the flow metering unit is normal.
9.1.3喷油器线束、传感器线束、整车线束接插件未插好或者线束断路或短路
Connectors of injector wiring harness, sensor wiring harness and vehicle wiring harness
badly connected, or wiring harness short-circuited or open circuited
◆检查接插件的安装，用万用表 ( 最好接“线路检查仪”) 按照线路图的指针定义检查线路的
通断。
Inspect installation of connector, and inspect circuit continuity with multimeter (it is better to
connect “Circuit Checker”) as per circuit diagram.
Circuit checker
-105-
Water temperature sensor Oil pressure sensor Camshaft speed sensor
Crankshaft speed sensor
Rail pressure sensor

Air inlet pressure sensor
Injector wiring
Flow metering unit connector
-106-
9.1.4 曲轴信号和凸轮轴信号丧失
Crankshaft and camshaft signal lost
柴油机上安装两个转速传感器，分别在飞轮壳和高压油泵外侧。功能分别为：曲轴位置传感
器和判缸传感器。电控发动机的喷油正时取决于这两个传感器。出现柴油机不能起动的情况，两个
信号全部丢失。
There are two speed sensors on the diesel engine, on the outside of flywheel housing and high
pressure fuel pump respectively. They may be functionally divided into tow type: crankshaft position
sensor and cylinder judging sensor. The fuel injection timing of electronically controlled starter is
determined by the two sensors. When the diesel engine can not start, both of the signals are missing.
◆两信号全部丢失可能的原因
Possible cause for loss of both signals
⑴ 传感器损坏，线束短路或断路
Sensor is damaged, and wiring harness is short-circuited or open-circuited.
⑵ 传感器固定不牢，造成传感器与感应齿之间间隙过大或过小 ( 一般为 1±0.5mm)
Sensor is not fixed reliably, resulting in too large or too small clearance between sensor and sensing
tooth (usually 1±0.5mm).
排除方法：检查传感器是否损坏，线束是否连接良好，传感器是否松动等
Remedy: Inspect sensor for damage; wiring harness for connection; and sensor for looseness.
◆拆装高压油泵及飞轮后的安装应严格按照相关工艺文件执行，以确保信号同步
Reinstall the dismounted high pressure fuel pump and flywheel strictly in accordance with relevant
workmanship document so as to ensure signal synchronization.
Camshaft speed sensor
Crankshaft speed sensor
-107-
9.2 起动困难
Difficult to start
发动机起动困难的原因及排除方法：
Cause and remedy for difficult engine starter:
◆柴油机较长时间没有运转：回油管要伸在柴油液面下
Diesel engine has not operated for a long time: Extend the return pipe to under fuel level.
◆低压管路有少量空气：排气
There is a little air in low pressure line: Deflating
◆曲轴转速信号、凸轮轴信号太弱，同步判断时间较长：查找具体原因，重新调整
The crankshaft speed signal and camshaft signal are too weak, and the synchronous judging time is
relatively long: Find the specific reasons, and adjust again.
◆环境温度太低，预热装置失效：检查加热法兰接线是否正常或更换预热装置
The ambient temperature is too low, and pre-heating device fails: Inspect heating flange wiring for
condition, or replace pre-heating device.
◆柴油、机油品质太差未达标：更换标准油品
The quality of fuel and engine oil is too bad to meet the standard: Replace with standard product.
◆起动机或飞轮齿圈打齿：更换起动机及飞轮齿圈
The starter or flywheel gear ring is tooth hit: Replace the starter or flywheel gear ring.
◆活塞环、缸套磨损或气门密封不严：更换活塞环、缸套或气门座、气门
The piston ring or cylinder liner is worn, or valve seal is not tight: Replace piston ring, cylinder
liner, valve seat or valve.
◆排气制动蝶阀卡死在关闭状态，导致排气不畅：更换蝶阀
The deflating brake butterfly valve is jammed at closed position, resulting in difficult exhaust:
Replace the butterfly valve.
-108-
9.3 发动机功率不足
Engine power is inadequate
跛行回家：发动机带故障运行的一种模式。ECU 检测到发动机出现了故障，但不会立即停车，
而是会限制发动机的功率，使发动机转速只能增加到 1500 转，司机能将车开到就近的维修站进行
维修。
Limp-home: This a kind of mode in which engine runs with fault. When ECU detects fault in
engine, it does not shut down the engine immediately, but limits engine power, and increases engine
speed to 1,500r/min only. The driver can drive the vehicle to the nearby maintenance station for
maintenance and repair.
9.3.1 喷油器出现故障
Injector defective
喷油器出现故障，一般分为机械故障和接线故障
The faults in injector can usually be divided into mechanical fault and wiring fault.
机械故障为：针阀卡死，由于柴油中污物较多或进水腐蚀，针阀卡死在喷油器内，不能动作。
（注意：ECU 可能不报错！）
Mechanical fault: Needle valve is seized due to excessive dirt in fuel or water corrosion. The needle
valve is seized in the injector, and can not move.(Caution: ECU may not report this fault!)
接线故障为：线束由于振动、磨损等原因，连接断开或直接搭在缸盖上与地短接。ECU 会报
错。
Wiring fault: Wire is broken or bonded directly on cylinder head and shorted to ground. ECU reports
this fault.
Injector terminal
-109-
9.3.2 水温、机油温、进气温度过高
Temperature of water, oil and inlet air is too high
水温、机油温、进气温度过高时，ECU 会进入过热保护功能，限制发动机功率。
When temperature of water, oil and inlet air is too high, ECU enters into overheat protection
function, and limits the engine power
在排除故障之前，首先要排除传感器及仪表的反映失真情况。
Before removal of the trouble, eliminate the distortion of sensor and instrument first.
◆造成水温高的原因及排除方法
Cause and remedy for too high water temperature
① 水箱水面过低：检查有无漏水处，加水
The water level in water tank is too low: Inspect for water leakage, and fill water.
② 风扇转速过慢或不转：检查风扇传动部件
The fan rotates at very low speed or fails to rotate: Inspect fan driving components.
③ 水箱堵塞：检查水箱，清理或修复
The water tank is blocked: Inspect the water tank, and clean or repair.
④ 水泵皮带松弛：按规定调整涨紧力
The water pump belt is loose: Adjust the tension force as per the regulations.
⑤ 水泵垫片损坏，水泵叶轮磨损：检查并修复或更换
The water pump gasket is damaged, and the water pump impeller is worn: Inspect and repair or
replace.
⑥ 节温器故障：更换
The thermostat is defective: Replace.
⑦ 水管密封件损坏，漏入空气：检查水管、接头、垫片等，更换损坏件
The water pipe seal is damaged, and air penetrates: Inspect the water pipe, joint, gasket, etc., and
replace the damaged part.
◆机油温度过高的原因及排除方法
Cause and remedy for too high oil temperature
① 油底壳油面低或缺油：检查油面及漏油处，修复并加油
The sump is at low oil level or lack of oil: Inspect oil level and find oil leaking point, repair and fill
oil.
② 水温高：检查上述造成水温高的原因并排除之
The water temperature is high: Find the reason for high water temperature, and remove it.
③ 机油冷却器流通不畅：检查并清理
The circulating of oil cooler is bad: Inspect and clean.
-110-
◆进气温度过高的原因及排除方法
Cause for too high inlet air temperature
检查中冷器的散热能力
Inspect the heat-sinking capability of intercooler.
9.3.3 同步信号出错
Synchronous signal faulty
出现该问题时，一般是一个传感器的信号失效。
If this fault takes place, usually signal of one sensor is in failure.
通过闪码灯读出闪码，查看闪码表查找具体原因，排除方法同 9.1.4
Read the flash code from the flash code light, and check the flash code table to find the specific
reason, and remove the trouble as per Para. 9.1.4.
9.3.4 流量计量单元故障
Flow metering unit defective
流量计量单元是控制轨压的执行机构，安装在高压油泵上，它出现问题以后，高压油泵会以最
大的能力向共轨管供油，此时共轨管上的泄压阀一般会打开，柴油机会有“咔咔”的噪音。轨压传
感器出现问题也会有类似的现象。
The flow metering unit is the actuator to control rail pressure, and is mounted on the high pressure
fuel pump. When it has fault, the high pressure fuel pump will take all the efforts to supply fuel to rail
pipe. Usually, the relief valve on rail pipe is open at that time, and there is Click noise from the engine. If
the rail pressure sensor has fault, similar phenomenon will take place.
Flow metering unit
◆排除方法：检修线路，确认是流量计量单元或轨压传感器故障，通知办事处处理
Remedy: Examine and repair the circuit, and confirm that there is fault in flow metering unit or
rail pressure sensor, and inform the office for handling.
-111-
9.3.5 燃油管路泄漏引起轨压异常波动
Abnormal fluctuation of rail pressure due to leakage of fuel line
在车运行过程中，会出现车速不稳，车有向前一窜一窜的现象出现。
The vehicle runs at unstable speed move forward with sudden leaps
◆排除方法：
Remedy:
首先断电一分钟重新起动，若问题仍然存在则检查燃油管路密封性并排除
First, turn off the power for one minute and restart. If the fault still exists, inspect the sealing of fuel
line and remove it.
9.3.6 传感器故障
Sensor is defective
进气压力传感器是 ECU 用来估算进气量的传感器（安装在进气管上），水温传感器是用来判
断发动机热负荷的传感器（安装在出水管上），轨压传感器是用来检测共轨管的燃油压力（安装在
共轨管上）。
Air inlet pressure sensor is the sensor (mounted on air inlet pipe) used by ECU to estimate inlet air
volume. Water temperature sensor is the sensor (mounted on the water pump) used to judge the thermo
load of engine. Rail pressure sensor is the sensor (mounted on the rail pipe) used to detect the fuel
pressure of rail pipe.
Rail pressure sensor
-112-
◆排除方法
Remedy
检查进气压力、水温、轨压传感器，看接插件是否牢靠
Inspect the sensors of air inlet temperature and pressure, water temperature and rail pressure, and
check that connector is reliable.
9.4 发动机始终运行在1000转
Engine runs at speed of 1,000r/min always
此时油门失效：ECU 通过踏板电位计给出的信号来判断负荷，当踏板出故障时，出于安全考
虑，ECU 会控制柴油机自动回到 1000 转。
At this time, the accelerator fails: The ECU judges the load from the signal given by pedal
potentiometer. If there is fault in pedal, for the sake of safety, ECU controls the diesel engine to return to
the idling 1,000r/min automatically.
◆电子油门踏线松脱或接错
The pedal wire of electronic accelerator is loose or connected wrongly
重新插或检查油门接线是否正确，重新接线
Pull out and insert again or inspect the wiring, and connect the wire again.
◆电子油门接插件进水
There is water penetration in connector of electronic accelerator
用工具把接插件吹干再起动
Blow the connector dry with tool first, then start.
注意：更换油门时，需要同一型号的油门
Caution: The accelerator should be replaced with that of the same type.
-113-
9.5 发动机怠速游车
Engine idle hunting
◆发动机游车的原因及排除方法：
Cause and remedy for engine hunting
① 喷油器工作不正常：检查各缸喷油器及线束；
The injector does not operates properly: Inspect the injector and wiring harness of each cylinder.
② 具有车速传感器的整车，停车时有车速信号输入：检查车速表及车速传感器信号及接线；
For the complete vehicle with speed sensor, there is still the input speed signal during parking:
Inspect the speedometer, the speed sensor signal and the wiring.
③ 燃油质量差含水或蜡质：清洗燃油系统，更换燃油滤清器；
The fuel is of bad quality, and contains water or waxiness: Clean the fuel system, and replace the
fuel filter.
④ 燃油低压油路漏入空气：检查油管及接头密封性，排除空气；
The air leaks into low pressure fuel line: Inspect the sealing of fuel pipe and joint, and deflate the
air.
⑤ 喷油嘴雾化不稳定：检查并修复。
The atomization of oil nozzle is not stable: Inspect and repair.
注：由于水温低引起的怠速上升是 ECU 正常的功能。有其他负载时（如打开空调），怠速会自
然提升 100 转。
Note: Idle speed increase due to low water temperature is normal function of ECU. When
there is the other load (for example, air conditioning on), the idling speed increases by 100r/min
automatically.
-114-
! 特别提示
Special Attention
· 柴油机的操作人员在操作之前，必须认真阅读柴油机的使用保养说明书，
严格遵守使用保养说明书规定的操作与保养规程；
Prior to the operation, the operator shall read the Diesel Engine Operation and
Maintenance Manual carefully, and comply with the operation and maintenance
procedure thereof strictly.
· 为使您的合法权益得到保护，严禁私自更改调整 ECU 数据。
In order to protect legitimate right and interest of user, it is forbidden to change
and adjust the ECU data privately.
· ECU 数据调整更改时公司的保证就失效。
Once the ECU data are changed or adjusted, the guarantee of our company ceases
to be in effect.
· ECU 共轨喷油泵和喷油器为精密部件，用户不得拆解，否则公司保证失效。
ECU common-rail fuel injection pump and fuel injector are precision units which
can not be disassembled by user, or the guarantee ceases to be in effect.
· 增压器转子为高速旋转部件，在机器运转时，严禁任何可移动物件 ( 例如
手、工具、棉纱等 ) 接近涡轮增压器的进口，以免对人身或机器造成损害；对转子
组件除涡轮增压器专业维修人员或经潍柴特许的专业维修站点，不得拆卸。
The rotator of turbocharger is a high speed rotating component. It is prohibited any
moving objects (such as hands, tools, cotton yarn) to approach the inlet of turbocharger
for prevention of the people from injury or of machine from damage. No one other than
the professional maintenance personnel on turbocharger or professional maintenance
station authorized by Weichai is entitled to dismantle the rotator assembly;
· 柴油机主轴承和连杆螺栓有严格的扭矩和转角要求，用户不得松动和拆
卸，否则公司保证失效。
There are strict demands on torque and turned angle for main bearing bolts and
connecting rod，loosening and dismantling is forbidden，or the guarantee cease to be in
effect．
· 柴油机每次开车前，必须检查冷却液是否加满，机油是否加足。
Before starting the diesel engine，check whether the coolant is full and whether
the lub-oil is enough．
· 连杆螺栓为一次性使用螺栓，不得重复使用。
Connecting rod bolts can be used only once time．

注意事项
Points for Attention
1. 本柴油机出公司时已按试验规范严格进行出公司试验，不得随意调整
ECU 数据，加大柴油机功率。否则我公司将不实行三包，敬请用户注意；
Precedence to the delivery, the diesel engine has been tested strictly under the
test specification, the ECU data can not be adjusted and its power can not be increased
at will. Or we are not liable to undertake the guarantee of repair, replacement and
refund, the users shall note this.
2. 用户在使用新机时，应进行 50 小时试运转；
Before using a new engine,50 hours test running should be done;
3. 柴油机冷车起动后应徐徐提高转速，不应猛然使其高速运转，也不宜长期
空转；大负荷运转后，不应立即停车（特殊情况除外），应低速空载运转 5 ～ 10 分
钟后停车；
Provided the diesel engine is started from the cold state, its rotary speed shall
be increased gradually, rather than making it operate at high speed suddenly or idle
for a long time. At the end of running with heavy load, do not shut down the engine
immediately (other than under particular circumstance), but run at low speed for 5 to 10
minute, then shut it down.
4. 停车后，如果运转环境有可能低于 0℃，而且机器中未使用防冻添加剂的
冷却液时，应将水箱和柴油机中的冷却液放净；
After shutdown, if the ambient temperature for operation is possibly lower than 0℃
and coolant with antifreeze additive is not used, then, water in water tank and the diesel
engine should be released;

5. 禁止柴油机在无空气滤清器的情况下工作，防止空气未经过滤就进入气
缸；
Do not allow the diesel engine to operate without air filter for the sake of
avoiding the air from entering into the cylinder directly without filtering.
6. 向柴油机添加的机油或燃油，其牌号必须符合使用保养说明书的规定，并
经专用的清洁滤清器过滤，燃油要经过 72 小时以上沉淀；在每次开车前，必须
确认冷却液和机油的加入量是否符合要求；
The brands of engine oil or fuel added to the diesel engine shall comply with the
provision of Operation and Maintenance Manual, and be filtered by the special filters.
The fuel needs more than 72 hours sediment. Prior to each starting, users shall ensure
whether the quantity of the added coolant and engine oil are in accordance with the
requirements or not.
7. 电气系统各部件的检修必须由电气专业技术人员进行；
The inspection and repair of all the components in electric system shall be done
by professional electric technical personnel;
8. 电控系统各部件的检修必须由我公司维修站专业人员进行；
The inspection and repair of all components in electronic control system shall be
done by professional personnel in our maintenance station;
9. 为防止锈蚀，柴油机出公司时进行油封，一般柴油机的油封期为一年，凡
超过一年的应进行检查并采取必要的补充措施。
For the sake of preventing corrosion, the diesel engine is oil sealed before delivery
from our company. Generally the oil seal period is one year. If the oil seal period
exceeds one year, inspection and necessary actions should be taken.

10. 发动机质量信息反馈
Feedback of engine quality information
我公司对 WP10 系列柴油机产品实行质量跟踪建档，用户在使用产品时请按
卡片要求填写寄回我公司。凭卡建立用户联系关系。
The manufacturer has established quality files for WP10 series diesel engine.
Please fill in the card and post it to us，we will contact with user according to the
card．
11. 在维修、更换发动机零配件时须知：
Notice to repairing and replacing parts:
斯太尔 WP10 系列柴油机产品 , 是高性能的柴油机 , 用户在维修时请按斯太

尔 WP10 系列柴油机零件图册和维修手册的诸项要求进行工作 , 但购买有关零配
件 , 必须采用主机厂鉴定认可的产品 , 以确保其性能 , 可靠性和寿命。
WP10 series diesel engine is of high performance product. Maintenance
should be done in accordance with WP10 series diesel engine parts catalogue and
specifications of maintenance manual. Purchased parts must have ap-proved by us
in order to ensure performance，reliability and service life．

前言
WP10 系列柴油机的前身是采用国外引进技术在中国制造的 WD615 系列高
速柴油机，可供重型载重汽车、大型客车使用，本机使用可靠、动力性，经济性技
术指标优良，起动迅速，操作简单和维修方便。特别是排放指标先进，达到国Ⅲ
排放标准，为使广大用户更快了解和正确使用 WP10 系列柴油机，特编制此以图
片为主的维修保养手册。
随着产品不断发展，其结构还会有所改进，如果您发现您的柴油机与本手册
所述内容不符时，请访问潍柴网站 http://www.weichai.com 或向本公司技术中心
查询。
本公司欢迎用户对产品提出进一步改进的意见和建议。
2007年4月
FOREWORD
The predecessor of WP10 Series Diesel Engine was the WD615 Series high-
speed diesel engine made in China by adopting foreign technologies. This engine can
be used on heavy-duty truck and large bus. This engine is characterized by reliable
power, fine economical and technical performance, quick starting, simple operation
and easy maintenance, especially by the advanced emission index, which reaches the
State- Ⅲ emission standard. In order to help customers understand and operate WP10
series diesel engines well and correctly. We especially provide this maintenance
manual.
With continuous development, the engine structure will be improved
accordingly. So if there are any differences between your engines and this manual,
please do not hesitate to visit WEICHAI Website: http://www.weicai.com, or enquire
our Research and Development Department.
April，2007
目录
TABLE OF CONTENTS
标记说明
Description of Illustration Marks
第一章柴油机使用说明 ---------------------------------1
Chapter 1 Operation Description
第二章柴油机维护保养指南 -----------------------------7
Chapter 2 Guide for Maintenance
第三章柴油机保养内容 ---------------------------------15
Chapter 3 Maintenance Contents
第四章柴油机几大系统示意图 ---------------------------39
Chapter 4 Schematic Diagram of Main Systems
第五章柴油机强力螺栓的扭紧力矩和扭紧方法 ---------------51
Chapter 5 Tightening Torque and Tightening Method of Rigid Bolts
第六章柴油机所用的燃料油、润滑油、冷却液和辅助材料 -------61
Chapter 6 Fuel, Oil, Coolant and Auxiliary Materials
第七章电气部分 --------------------------------------65
Chapter 7 Electrical System
第八章主要零部件的调整与更换 --------------------------71
Chapter 8 Adjustment and Replacement of Main Parts and Components
第九章柴油机典型故障及处理 ----------------------------99
Chapter 9 Typical Troubles and Remedy
图示标记说明
Description Of The Illustration Marks
拆卸(组合件)
涂润滑油
Dismounting (assembly
Oil coating
parts)
专用工具，如S K……，
装配(组合件) KUKKO,……，TS……W
Fitting (assembly parts) Special tools, such as K--- ---,
KUKKO, --- ---, TS--- ---W
打记号（分解前打上，重新
装配时注意对正）
注意装配方向
Marking (do before
Pay attention to assembly direction
disassemble, adjust when
assemble)
注入－充满（如润滑油，冷
却水等）
放气
Filling- full charge (such as
Deflating
lubricating oil, cooling water
etc.)
排出（例如润滑油、冷却
松开（例如：夹紧装置的松开）
水等）
Unloosing (such as: unloose clamping
Draining off (lubricating oil
equipment)
or cooling water)
（防松－粘固）涂液态密
夹紧（例如：夹紧装置的紧固）
封剂
Clamping (such as: reinforcing clamp
(loose-proof-fixed) Coat
equipment)
fluid sealant
检测－调整（例如：拧紧力矩，尺
防止人身事故（危险场合
寸，压力，间隙等）
标记）
Inspecting-adjusting (such as:
Accident preventing (marks
tightening torque, dimension pressure
for dangerous occasion)
and clearance)
每次装配都要更换
检查
Replacement when re-
Inspecting
assembly

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WP10系列柴油机维修保养手册

Maintenance Manual for WP10 series Diesel Engine

should be shortened accordingly．

Oil replacement period during vehicle maintenance

(WGⅠ) (WGⅡ) (WGⅢ)

(WGⅠ) (WGⅡ) (WGⅢ)

第1次检查 行驶1000～1500km时 行驶1500～2000km时 行驶1500～2000km时

例行检查 P 每隔500km 每隔1x104km 每隔1.5x104km

1级保养 WD1 每隔1x104km 每隔2x104km 每隔3x104km

2级保养 WD2 每隔2x104km 每隔4x104km 每隔6x104km

3级保养 WD3 每隔4x104km 每隔8x104km 每隔12x104km

4级保养 WD4 每隔8x104km 每隔16x104km 每隔24x104km

Preventive maintenance should be

done everyday in order to understand the

Before starting the engine should

check the oil level ， coolant level and

fuel level. ．

Fast wearing parts

Inspect the oil level height

start the engine．

can flow back to the oil sump．

Inspect the coolant level

Inspect the coolant level through

the vitreous view hole，if the coolant is

not sufficient，open the inlet cover and

fill into the coolant.

Note:When opening the inlet cover，

must press down the exhaust button

firstly to prevent hot coolant from

Check the fuel level.

Inspect the fan

Check whether the plastic fan is

distorted.For steel fan，check whether

the rivet loosened and the vane is

curved to ensure reliable running

Inspect the V-belts

the V-belts．Replace them if necessary

Inspect exhaust gas for normal

color. Attached diagram:

The normal color is light grey. If

the color changes, find the reason and

Inspect for normal sound.

Inspect for normal speed and

The following contents will be

added except daily maintenance items：

Replacement of the oil and oil filter

The oil will be polluted after

using，the pollution contents is of

accordance with the consumption of

fuel and oil．

period of oil under proper using

condition cannot beyond 250h

Replace the oil and oil filter to

clean the impurities containing in oil.

Note: The oil should be drained

off when it is hot．

Tool:32mm open-ended wrench

Remove the whorl plug，prepare a

container to collect 24L of oil．

Note：Hot oil can injure people.

Tool:The special wrench for filter.

Clean the end surrounding of the

filter，and remove it.

第1次检查行驶1000～1500km时行驶1500～2000km时行驶1500～2000km时