Weichai Engine WP10

Contents
Chapter I Maintenance for Landking WP10 Euro III Diesel

Engines
1.1Regular Inspection for Landking Euro III Diesel Engines …………………….1
1.1.1 Cooling System ……………………………………………………………...1
1.1.2 Lubricating System ………………………………………………………….3
1.1.3 Fuel Supply System ………………………………………………………....6
1.1.4 Electrical System …………………………………………………….……..13
1.1.5 Mechanical Transmission System ………………………………….……17
1.2 Maintenance for Landking Euro III Diesel Engines …………………………19
1.2.1 Truck …………………………………………………………………….……19
1.2.2 Bus ……………………………………………………………………………20
1.2.3 Construction Machinery ……………………………………………………21
1.3 Attention Points for Operating Landking Euro III Diesel Engines …………24
1.3.1 Accelerator Pedal Operation of Euro Ⅲ Diesel Engines ……………...…24
1.3.2 Time Selection for Shifting the Gear ………………………………………24
1.3.3 Economical Speed of Diesel Engines …………………………………...25
1.3.4 Usage of WEVB ……………………………………………………………...26
1.4. The Way of Maintenance for Landking WP10 Diesel Engines ………….28
1.4.1 Replace Oil and Oil Filter ………………………………………………….28
1.4.2 Check and Adjust the Valve Clearance ………………………………….31
1.4.3 Replace Fuel Filter Element ………………………………………………..37
1.4.4 Check Air Filter Element …………………………………………………..38
Chapter II The key Process of Disassembling and Assembling
WP10 Diesel Engine
2.1 The Assembly of Cooling Nozzle, Camshaft and Cylinder Liner …………41
2.1.1Installing Spray ……………………………………………………………..41
2.1.2Installing Camshaft …………………………………………………………42
2.1.3Installing Cylinder Liners …………………………………………………..43
2.2 The Pre-assembly and Assembly of Camshaft …………………………….44
2.3 The Assembly of Cylinder Block …………………………………………….46
2.4The Pre-assembly and Assembly of Connecting Rod and Piston …………48
2.5The Assembly of Timing Gear Housing ……………………………………...52
2.6The Assembly of Flywheel Housing and Flywheel ………………………..54
2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear ……………..56
2.8 The Assembly of High Pressure Fuel Pump ………………………………58
2.9 Tightening Torque and Tightening Method of Main Bolts of Diesel Engine ……59
Chapter III Landking Euro III High Pressure Common Rail
Diesel Engines—Failure Diagnosis and Case Analysis
3.1 Introduction of High Pressure Common Rail System …………………….61
3.2 Failure Diagnosis and Case Analysis ………………………………………..68
3.2.1 Failure Type1: Diesel Engine Cannot Be Started ……………………….68
3.2.1.1 Description of the Case That Diesel Engine Cannot Be Started (1)…72
3.2.1.3 Description of the Case That Diesel Engine Cannot BeStarted (3) …74
3.2.2 Failure Type 2: The Diesel Engine Starts with Difficulty … … … … … … 77
3.2.2.1Case Description (1) ………………………………………………...…….79
3.2.2.2 Case Description (2) ………………………………………………...……80
3.2.3 Failure Type 3: After the Engine’s Started, It Is Flameout Automatically …81
3.2.4 Failure Type 4: The Engine Exhausts Black Smoke …………………….89
3.2.5 Failure Type 5: Insufficient Power …………………………………………93
3.2.6 Failure Type 6: Limp-home ………………………………………………..99
3.2.6.1 Case Description (1) ………………………………………………...…100
3.2.6.5. Case Description (5) ……………………………………………...…104
3.2.7 Idle Speed Is Not Stable …………………………………………………105
3.2.8 The Engine Is Always at 1000r/min ……………………………………..106
3.2.9 Other Failures ……………………………………………………………..108
3.2.9.1Description of the Case That Accelerator Works Now and Then When
Driving …………………………………………………………………………….108
3.2.9.2 Description of the Case That Vibration at Idle Speed Is Huge (1) …109
3.2.9.3 Description of the Case That Vibration at Idle Speed Is Huge (2) …110
3.3 Parts Failure Analysis ……………………………………………………….111
3.3.1 Injector ……………………………………………………………………...112
3.3.1.1 Table about Analysis of Injector Fault …………………………………113
3.3.1.2 Analysis about Injector Fault …………………………………………..114
3.3.2 High Pressure Fuel Pump ………………………………………………...116
3.3.2.1 Table for Analysis of High Pressure Fuel Pump ……………………..116
3.3.2.2 Analysis about High Pressure Fuel Pump ……………………………117
3.3.3 Common Rail Pipe ………………………………………………………..118
3.3.3.1 Table about Analysis of Common Rail Pipe Fault …………………...118
3.3.3.2 Analysis about Fault of Common Rail Pipe ………………………….119
3.3.4 ECU ……………………………………………………………………….119
3.3.4.1 Table about Analysis of ECU Fault ……………………………………..120
3.3.4.2 Analysis about ECU Fault ………………………………………………120
3.3.5 Sensor and Wiring Harness …………………………………………….122
3.3.5.1 Table of Function of Sensor ………………………………………….122
3.3.5.2 Analysis Table for Fault of Sensor and Wiring Harness ……………..123
3.3.5.3 Analysis about Sensor and Wiring Harness Fault ……………………123
3.3.5.4 Guide for Sensor Inspection ……………………………………………124
3.3.6 Accelerator Pedal …………………………………………………………129
3.3.6.1 Table about Accelerator Pedal Fault ………………………………….130
3.3.6.2 Analysis about Accelerator Pedal Fault ……………………………...131
Chapter I Maintenance for Landking WP10
Euro III Diesel Engines
1.1 Regular Inspection for Landking

Euro III Diesel Engines
1.1.1 Cooling System
● Before starting the engine

should check coolant level,
check whether the cooling
system is leaking or not.
● Check whether water
temperature is at the required
range or not when the engine is running.
● When water temperature is too
high, please check:
①the tension of water pump belt
②the tension of fan belt
③thermostat
Diagram of water temperature in cab
1
Use liquid coolant when ambient temperature is below 4℃ !
Recommendation
Long-acting liquid coolant
Brand -25 -35 -45
Applied temperature -25℃ above -35℃ above -45℃ above
Learning and thinking：
2
1.1.2 Lubricating System
● Check the height of oil level before drive every day.

● How to check it?
The vehicle is parking on the plain road, before start or stop for 15
minutes till the engine cools, pull out oil dipstick to check oil level: When
the level is below the lower limit of oil dipstick or above the upper limit, it’s
forbidden to start the engine.
● Before replace oil, firstly, loosen the whorl plug at the bottom of oil
pan. After used oil is drained out, tighten the plug. Then open the oil filling
cap to fill CF-4 oil up to the limit required, and then tighten the cap.
upper limit
lower limit
Learning and Thinking:
3
The position of oil filling inlet
Oil filling inlet of 1st

cylinder rocker arm
cover
WP6/WP10/WP12 series
WP12 series
● Recommend CF-4 oil to be used in Landking Euro Ⅲ diesel

engines. High quality oil is allowed to replace low quality oil. The
specification of common oil is as follows:
Viscosity
0W-30 5W-30 10W-30 15W-40 20W-50
grade
Applied
-40～30℃ -30～35℃ -25～35℃ -20～40℃ -15～50℃
temperature
Please use right oil according to

ambient temperature, otherwise, engine
trouble can occur.
Notice: WP10 diesel engine must use
CF 15W/40 oil.
4
Common sense: performances of different brands of oil at the
temperature of -35°C
0W-30 5W-30 10W-30 10W-40 15W-40
Learning and thinking:
5
1.1.3 Fuel Supply System
Landking
Euro Ⅲ diesel
engines apply
high pressure
CR made by
Bosch, and
parts of the
main systems
as the right
Figure:
6
Common rail
High pressure
fuel pump
Fuel injector
ECU
Fuel filter
7
Deflating Air from Fuel Supply System
● Mixed air-fuel in the low pressure fuel passage could possibly be

caused by new engines, old engines not used for a long time, or fuel
tank empty, pipe leakage, which can result in difficult starting. Therefore,
deflating air by hand before start is necessary as the following way:
① Make sure enough fuel

in the tank before deflate air.
② loosen deflating bolt
(refer to the right Figure ).
③ Press hand pump until
no air bubble spraying out from
the deflating bolt.
④ Tighten deflating bolt,
then start the engine.
Don’t overexert loosening or

tightening deflating bolt, so as to
avoid damaging.
8
Special attentions
● Don’t forcibly start engine by the starter before deflate air from
the low pressure fuel passage, otherwise, the electric system could be
damaged, and the starter even could be burnt out.
● Fuel must be filled in when fuel pointer reaches the red warning
line, otherwise, air could easily penetrate into the fuel passage.
9
Drain Water from Fuel Pre-filter
● If there’s water in the fuel supply

system, high pressure fuel pump and
fuel injector could be easily damaged
or invalidated.
● Please periodically inspect
whether there’s water in the filter cup
of pre-filter or not, so as to drain water
Drain water from water collector
in time
● The method to drain water :
● Open drain plug (2) at the
bottom of water collector (1) to drain
off water;
● Tighten the drain plug again.
Lightly loosen or tighten the plastic

plug, so as to prevent it from damaging
10
Special attentions
● Because of fuel quality differences in different places,

about two-hour driving later, please inspect the water level of water
collector after refill fuel.
Fuel Selection
There’s no more special requirements about fuel quality for

Landking Euro III diesel engines than that for mechanical
pump diesel engines. Please try your best to avoid using low
quality fuel !
Special attention:
● Recommend using qualified fuel to guarantee the quality of

fuel filled.
11
Common sense
● Fuel brand doesn’t mean the ambient temperature the fuel can
fit, but the freezing point at which the fuel can’t flow under certain
temperature.
12
1.1.4 Electrical System
● Landking Euro III diesel engines are with ECU, sensors and
electrically controlled fuel injectors, etc. Too high voltage or current can
damage electrical system. Generators of Landking Euro III series diesel
engines, with rated voltage of 28v have transistor regulators (breakdown
diode). Therefore, please pay attention to the following aspects when
electrically weld whole vehicle:
Cut off electricity supply before weld;
Special generators for Landking Euro III engines must be used.
● Close the control switch of battery,

and cut off negative electrode of
battery jar.
● Pull out the wiring harness
connecter connecting with ECU.
Pull out the collector as the

following steps:
※ Push aside the locking
slice of collector, and press it
into its bottom.
※ Pull out the collector.
13
Don’t shake to avoid ECU stitch bending.
Identify positive and negative electrode of electricity supply
when connect ECU with electricity supply to avoid ECU
burning out.
● Welding operation
● Plug into the wiring harness collector connecting with ECU.
Plug into the collector in the following steps:

※ Gently and properly put the collector in the ECU
groove, and press it into its bottom
※ Shut down the locking slice.
14
Notice: Not allowed to
frequently pull out and
plug the ECU collector, thereby
avoiding influencing message
connecting of ECU.
15
● Connect negative electrode of battery jar, open the control switch of
battery.
When pull out or plug ECU,

pay attention to:
※ Cut off electricity supply
for ECU before pull out or plug
ECU. Don’t touch ECU stitch by
hand.
※ Don’t forcibly draw
electrical wire of whole vehicle
or electric wiring harness.
Hold the disconnection
locking buckle when need to
disconnect connectors. Don’t
draw the electrical wire against
damaging.
16
1.1.5 Mechanical Transmission System
● Inspect mechanical
transmission system of external
diesel engines before running,
such as intensity and wearing of
the belt.
● Belt can be automatically
tightened through tension pulley.
Press belt by hand to check
tension of the belt.
17
Fan bracket
Adding grease inlet
18
1.2 Maintenance for Landking Euro III Diesel Engines
● Proper maintenance can effectively prolong service life of diesel

engines, decrease trouble rate and reduce cost.
※ Maintenance contents :
Replace fuel filter element and oil filter element;
Clean and check air filter element. Replace it every 5 times of
cleaning.
※ Maintenance interval:
Maintenance should be done in time at Landking Euro Ⅲ service
stations according to the following requirements:
1.2.1 Truck
● Maintenance for highway trucks according to the following standard:
load ≤rated load ＞rated load
New vehicle run 3000 km or for 50 hrs (of the two

1stmaintenance
situations, choose the first achieved one)
Every 10,000 km or 500 Every 10,000 km or 500

periodical hrs (of the two situations, hrs (of the two situations,
maintenance choose the first achieved choose the first achieved
one) one)
19
● Maintenance for non-highway truck (including cement mixing
vehicle) according to the following standard:
load ≤rated load ＞rated load
New vehicle run for 50 hrs or 3,000 km (of the two

1stmaintenance
Every 300 hrs or 2,0000 Every 200 hrs or 1,0000

periodical km (of the two situations, km (of the two situations,
maintenance choose the first achieved choose the first achieved
one) one)
1.2.2 Bus
● Maintenance for bus (city bus, dedicated bus for workers )according
to the following standard:
New vehicle run 50 hrs or 3,000 km (of the two

1st maintenance
Periodical Every 300 hrs or 10,000 km (of the two

maintenance situations, choose the first achieved one)
20
● Maintenance for passenger bus, sight seeing bus according to the
following standard:
New vehicles run 3,000 km or 30 hrs (of the

1stmaintenance
two situations, choose the first achieved one)
Periodical Every 10,000 km or 300 hrs (of the two

1.2.3 Construction Machinery
● Maintenance for loader, excavating machine, road roller and crane,

etc according to the following standard:
New vehicle run for 50 hrs or 3,000 km (of the

1st Maintenance
two situations, choose the first achieved one)
Periodical Every 200 hrs or 10,000 km (of the two

Special attention:
● Please properly shorten periodical maintenance interval or mileage

under severe work condition.
21
● Operators of diesel engines must carefully read Operation
and Maintenance Manual, and well understand the structure
of diesel engines, strictly comply with the operation and
maintenance stipulated in the Operation and Maintenance
manual.
● Based on the maintenance requirements stipulated in the
manual, please periodically inspect diesel engines and replace
oil in accordance with work condition.
22
● Maintenance Guide for Landking Euro Ⅲ Diesel Engines
● Maintenance on mechanical system of Landking Euro Ⅲ
Diesel Engines is similar with that of Euro II.
● For the trouble on electronically controlled system of
Landking Euro Ⅲ Diesel Engines, users may go to Weichai
Euro Ⅲ maintenance station nearby. Don’t dismantle or
repair fuel supply system and electronically controlled system
privately, so as to avoid unnecessary loss.
Special attention:
● When repair or replace components of diesel engines, pay attention to :

Landking Euro III series diesel engines have high performance;
therefore, maintenance should be done in accordance with Maintenance
Manual and Parts Catalogue of Weichai Power Landking Euro III
series diesel engines. Please purchase special fittings to ensure the
performance, reliability and service life of diesel engines.
23
1.3 Attention Points for Operating Landking Euro III Diesel
Engines
1.3.1 Accelerator Pedal Operation of Euro III Diesel Engines
● Landking Euro Ⅲ
diesel engines adopt electro-
accelerator pedal with
electro-structure sensor
inside. Recommend that
users placidly accelerate or
decelerate speed when drive
to ensure more effective fuel-
saving.
1.3.2 Time Selection for Shifting the Gear
● Operating points of diesel engines influence fuel economy, but gear

selection when drive also has a great impact on fuel saving. Generally,
high gear saves fuel.
A. Shift the first gear to start.

B. Before shift high gear, the
speed of diesel engines should be
accelerated to about 1200 r/min.
C. In order to avoid high
speed, but low gear, should
positively shift high gear to make
diesel engines run at the range
of economical speed if work
condition permitted.
24
Special attention:
● For mechanical gear-box, whole vehicle matched with Landking

Euro III diesel engines stop injecting fuel when sliding with shifting the
gear, which is more fuel-saving than that when sliding with neutral gear.
1.3.3 Economical Speed of Diesel Engines
Diesel engine series Economical speed
WP6 1200-1800
WP10, WP10N 1100-1600
WP12, WP12N 1100-1600
25
1.3.4 Usage of WEVB
● Recommend to use WEVB when run downward the long slope (

Weichai patent of safety brake system for engines)
● WEVB is controlled by electronically controlled unit. When WEVB
works, the diesel engine doesn’t inject fuel to save fuel.
WEVB can’t work when the

speed of diesel engines is
less than 800 r/min.
● Four Special Attentions for Landking Euro III Diesel

Engine Service of Weichai Power
● Forcible Maintenance Suggestion--- Forcible Maintenance should

be done by Euro III maintenance station of Weichai Power in accordance
with relevant requirements;
● Maintenance Suggestion---Maintenance should be done by Euro III
maintenance station of Weichai Power;
● Fittings Suggestion--- Use special fittings provided by Euro III
maintenance station of Weichai Power;
26
● Oil Suggestion--- Use special oil for Landking Euro III diesel
engines provided by exclusive agency of fittings.
27
1.4. The Way of Maintenance for Landking WP10 Diesel Engines
1.4.1 Replace Oil and Oil Filter
● 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: 32 mm open-ended wrench

● Remove the whorl plug，prepare a container to collect 24 L of oil．
Note：Hot oil can injure people.
28
※ Tool: The special wrench
for filter.
※ Clean the end surrounding
of the filter，and remove it.
※ Install the new oil filter
Note ： Adjust the seal ring and

smear some lubricating oil on it
while fitting the oil filter.
※ Tool:32mm open-
ended wrench
※ Check and clean the
screw thread and seal
ring ， and then install
the whorl plug.
※ Fill the clean oil up
to the upper limit, the
capacity of the oil sump
is 24L．
29
Note：STEYR engine must use CF-4
15W/40 oil．
※ Run the engine at

idling speed and check
the filter to find whether it
leaks or not．
※ 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．
30
1.4.2 Check and Adjust the Valve Clearance
● Tool：13 mm sleeve wrench

● Disassemble 6 cylinder head
covers．
● To o l ： 3 2 m m w r e n c h f o r
turning the crankshaft
● Turn 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 1st cylinder (the intake
and exhaust valve of 1 cylinder are
closed)．
● Tool：Clearance gauge
● The clearance of intake
valve is 0.30mm
● The clearance of exhaust valve
is 0.40mm
● The clearance for WEVB
system is 0.25mm.
Note: When check the clearance of valve，the engine should be at

the cool condition-its temperature is less than 60℃ .When the clearance
gauge glides between the top of valve rod and rocker arm and can
be felt retarded and sticky, the measuring result is proper
31
● After WEVB system is used, the adjustment method of
exhaust valve clearance is as follows (see Fig. 2 for part serial
numbers)
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
32
● The cylinder piston to be adjusted is located on the top
dead center of the compression travel.
● As shown in Fig. 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 0.4 mm.
Tighten check nut.
Fig. 2 Total Valve Clearance of Fig. 3 End Valve Clearance of

Cold-State Exhaust Valve 0.4 mm Cold-State Exhaust Valve 0.25mm
33
● Then as shown in Fig. 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.
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.
34
● Tools：6# screwdriver
and 14mm double offset ring
wrench
● The piston of 1st
cylinder is at TDC of the
compression stroke．
● Check and adjust
the valve clearance as step Step A
A (I-air intake Valve E-air
Exhaust valve)
● Adjust the clearance
by gauge and tighten the
fixing nut of rocker arm，
re-check the clearance till it
meets the requirement．
● Turn the crankshaft
360° by the spanner；it can
also be turned 360° after
marking on the vibration
damper.
● Adjust the valve
clearance as step B
● Loosen the fixing
nut of rocker arm，adjust
the clearance by gauge then
tighten the nut again Step B
35
● Tool: 13mm sleeve
wrench
● Install the gasket
and cylinder head cover.
● The tightening
torque of bolt is 23N•m
(recommended).
36
1.4.3 Replace Fuel Filter Element
● Replace fuel filter

element in the following steps:
● A. Dismantle the old
fuel filter element. Remove
the water collector installed on
coarse filter if reused.
● B. Lubricate the seal lips.
● C. Turn the filter by hand
until the seal is closed with
interface.
● D. Continue to turn the
filter with hands until the filter is
installed solidly (about ¾ turns).
● H. Retighten when
necessary
● E. Deflate until there is
no bubble.
● F. Start Engine.
● G. Conduct leakage test.
● H. Retighten when
necessary
37
1.4.4 Check Air Filter Element
● The maximum air intake

resistance of the engine should
be 7kPa and inspection should
be done at the rated speed and
full load. When the resistance
reaches the maximum limit
allowed，the air filter element
should be cleaned or replaced
as per the maintenance guide
from the manufacture.
● Caution:
Don't blow off the air filtering paper
Don't clean the air filtering paper by water and oil
Don't beat the core forcibly．
38
● Note：It is not allowed to use the engine without air
filter, otherwise the dust and impurity will cause early wearing
of the engine.
● 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．
39
Chapter II The key Process of Disassembling
and Assembling WP10 Diesel Engine
2.1. The Assembly of Cooling Nozzle, Camshaft and Cylinder

Liner
2.1.1 Installing Spray
Assembling process:
● Polish bottom of the cylinder block，blow branch oil passage hole

and main and sub-passage of oil by compressed air, and clear the bottom
of cylinder block.
● Install the cooling nozzles into the engine block by hollow bolts and
matching seal rings, and then tighten them.
Notice ：
● Check the cooling nozzles to make sure that they don’t have
impurities or dust.
● Adjust the position of cooling nozzle when tighten the hollow bolts
to make sure that the spring cylindrical pin can be driven into pin hole
when necessary by copper stick.
● Check whether the cooling nozzles (and the surface of the cylinder
block) are hurt and have impurities.
41
2.1.2 Installing Camshaft
● Clean the camshaft hole and smear lubricant used for cleaning.
● Cleaning the camshaft, inspecting whether the camshaft is hurt and
then installing it through camshaft hole.

● Install camshaft thrusts, and then tighten hexagonal bolts.
● Smear cleaning lubricant on the thrusts and turn camshaft by
hand to ensure that the camshaft can be turned smoothly and has no
resistance. In the end, check the clearance of camshaft by hand.
Notice：
● The camshaft bush must be checked whether it is hurt or not, and it
isn’t allowed to use after repairing.

● Smear clean lubricant on the special tool of camshaft before
installing the camshaft into camshaft hole in the cylinder block.

● Please be careful to avoid hurting camshaft bush when installing
the camshaft into the camshaft hole.

● Coat the thread with thread locket
42
2.1.3 Installing Cylinder Liners
● Clean cylinder holes and inner and outer surfaces of cylinder liner.
● Coat outer surface of cylinder liner with 0# Molybdenum disulfide
Lube and install part of the cylinder liner into cylinder hole.
● Press cylinder liner into cylinder hole by cylinder liner pressing
machine.
● Cylinder liner is 0.05~0.10mm higher than top surface of cylinder
block.
● Check cylindrical and oval degree in cylinder hole
43
2.2 Pre-assembly and Assembly of Crankshaft
Assembling processes:
● The flange needs heating up to 290℃ and its color turns to yellow.
The gear of crankshaft needs heating up to 180℃. (Heating temperature
is recommended in order to prevail in the assembly).
※ Notice: It isn’t allowed to assemble when the heating color of
flange and gear is purple.
● Remove burr of flat key and grooving and then drive into flat key,
gear of crankshaft and flange. The cylindrical pin should be driven into the
end of crankshaft.
● Put rivets into oblique oil holes of crankshaft, and then rivet them
by special tools.
44
● Cleaning the bottom surface of the cylinder block by cleaner 755 or
industrial alcohol.
● Install main bearing shells and thrusts, and than smear oil.
● Lifting the crankshaft parts, with compressed air blowing holes of
oil passage wipe main shaft neck and connecting rod journal with a towel,
and then gently fall into the cylinder body. After that Install thrust.
※ Notice:
Check carefully whether crankshaft is scratched, and remove it when
necessary.
Oil groove of thrust should be towards crankshaft.
● Coat 510 sealant on the engine block surface (the connecting
surface of crankcase), and sealant line should be continuous
45
2.3 The Assembly of Cylinder Block
● Insert oriented stick into holes of main bearing bolt as this figure
position, lift crankcase and then turn it 180°, at last fall it into cylinder
block gently along oriented stick.
※ Notice:
The matching NO. of crankcase and cylinder block should be
unanimous.
Orientational pin should
be inserted in the right place.
Prevent sleeve and seal
ring falling during lifting.
● Knock the bottom of
crankcase gently to make
sure that the connecting surface of crankcase and cylinder block can be
inserted into cylindrical pin and locked.

※ Notice: Please pay attention to the rule of “middle first, and then
both sides” when driving into cylindrical pin.
46
● Install crankshaft rear oil seal coated with sealant on the crankshaft.
※ Notice: Coat outer circle of rear oil seal with sealant. The line of
sealant should be continuous.
● Press oil seal into cylinder block by oil seal pressing tool.
※ Notice: Smear cleaning lubricant on the oil seal pressing tool.
● Take off the oriented stick, and then tighten main and auxiliary bolts
of cylinder block.
47
2.4 The Pre-assembly and Assembly of Connecting Rod and Piston
● 6 pistons within the same weight group are placed in the assembly
stage. The weight group of piston is marked 10 g per group, which is
G1, G2, G3, G4, and G5. The pistons within the same weight group are
installed in the same engine.
● Heat the piston up to 60-80 ℃
● The pre-assembly and assembly of piston and connecting rod:
insert small head of connecting rod into inner lumen of piston so that
small head hole of connecting rod and hole of piston pin are matched
together, and then install piston pin and piston pin ring
※ Notice:
Direction of firebox and connecting rod.
Coat cleaning lubricant before installing small head of connecting rod
and piston pin.
● Install spiral spring oil ring, conical ring and double ladder ring of
piston ring.
※ Notice:
Piston assembling sequence and mark. Small surface of conical ring
is up and “TOP” surface of double ladder ring is up.
48
● The weight group of connecting rod is marked 29g per group, which
is C, D, E, F, G, H, J, K, and L. The matching NO. of connecting rod body
and connecting rod cap of every connecting rod must be unanimous.
● Remove connecting rod bolts and check whether the thread of
connecting rod is damaged. Replace and check whether the matching
NO. is right or not when necessary.
● Check whether the connecting rod shell is damaged before
installing. Replace (do not repair) it when necessary.
● Clean inner surface of cylinder liner, crankshaft arm, piston and
connecting rod and then coat clean lubricant.
● Turn crankshaft to ensure the crank arm in the right position.
※ Notice:
Check whether piston ring can be turned flexibly in the groove.
There is 30°±5° between the opening of the 1st ring and axis of
piston pin and there is 120° among 3 rings of a piston.
49
The parts of piston and connecting rod must be within the same
weight group in an engine.
Check whether connecting rod shell is hurt. Do not repair and reuse if
it is hurt.
Install parts of the piston and connecting rod as the sequence and
tighten connecting rod bolts.
※ Notice:
The separating surface of the connecting rod shell cover should be
towards oil cooler.
The No. of piston must match
with the No. of cylinder.
The connecting rod cover
must match with connecting
rod body and can not be
interchanged.
Please be careful to avoid
the connecting rod body to hurt
crankshaft arm when assembling.
Coat clean lubricant on the
supporting surface and thread
before tightening connecting rod bolts.
Coat clean lubricant on the inner and outer surface of special tool
which is used to install piston.
Tighten connecting rod and piston as techniques requirement. Firstly
turn crankshaft 120° and then tighten connecting rod bolts of cylinder 1
and 6; turn crankshaft 120° again, and then tighten connecting rod bolts of
cylinder 2 and 5; at last turn crankshaft 120° for the 3rd time, and tighten
connecting rod bolts of cylinder 3 and 4.
50
※ Notice:
Bolts per cylinder should be tightened alternately by hand. The torque
is 120 Nm for the 1st time, turn bolts 90°±5° for the 2nd time. Replace
those bolts that can not reach required torque range.
Turn crankshaft flexibly.
51
2.5 The Assembly of the Timing Gear Housing
● Check whether every combining surface of timing gear housing is
hurt and remove grease after polishing and cleaning.
● Drive springy cylindrical pin into side, coat thread locking agents
on thread parts of the double-headed thud, tighten it and clean excessive
sealant.
● Tighten hexagonal bolts with seal gaskets Install refueling tube
gasket and then refueling tube. Insert hexagonal bolts with springy
gaskets and then tighten them.
● Polish, clean, remove grease and coat sealing glue on the
combining surface of cylinder block and timing gear housing.
● Install medium gear shaft into middle gear, and then put them into
timing gear housing.
● Install timing gear housing parts. Drive intermediate gear shaft into
gear housing, insert hexagonal bolts with gaskets and tighten them. The
level of the cover to the left groove.
52
※ Smear general lithium grease on the shaft.
※ Tightening torque: 60±5Nm.
※ Turn bolts 90°, and the torque range is 100~125Nm. Replace
those bolts than not reach required torque range.
● Install intermediate gear parts of oil pump, and then drive into
intermediate gear shaft of oil pump.
※ Notice :
The convexity of intermediate gear parts of oil pump should be
towards inside.
Check whether the intermediate gear shaft of oil pump can be turned
flexibly after installing.
● Install hexagonal bolts in the intermediate gear shaft of oil pump
and tighten them. Tightening torque: 59+5 Nm (smear glue). Tighten all
the M10 bolts.
● Check the clearance of gear.
53
2.6 The Assembly of Fly Wheel Housing and Fly Wheel
The assembly of fly wheel housing:
● Polish, clean, remove grease and coat sealing glue on the surface
of cylinder block and fly wheel housing.
● Lift fly wheel housing and pre-assemble fly wheel housing bolts.
Notice:
※ Cylindrical pin of end back of cylinder block must match with
orientational hole which is below
fly wheel housing.
※ Coat clean lubricant on
thread of bolts and supporting
block.
※ Tighten bolts in twice by
hand, the 1st time: 40+20N•m,
and the make a mark between
bolts and fly wheel housing; the 2nd time: 110~140 Nm. Replace those
bolts that can not reach required torque range.
※ Tightening sequence as the sequence in above figure.
※ Special notice: The fly wheel bolts of 4,5,6,7,8,9 are M12X60, the
bolts of 1, 2, 3, 10, 11, 12, 13 are M12X70.
54
The assembly of fly wheel:
● Fix tooth ring of fly wheel in the fly wheel by accessory bolts.
● Drive centripetal ball bearing into fly wheel axle hole and then
install springy ring.

Notice:
※ Clean outer round before drive into bearing, and coat Automobile
Lithium Grease on the inner hole of fly wheel.

● Install fly wheel and tooth ring of fly wheel in the crankshaft.
Notice:
※ Coat antirust oil on the inner surface of the fly wheel.
● Insert fly wheel bolts
and tighten them.

Notice:
※ Coat lubricant on
thread of bolts and supporting

block before inserting bolts.
※ Tighten bolts by hand.
Firstly pre- tighten these bolts

symmetrically with a torque
of 60~80Nm, and then turn
them 90°±5°symmetrically
in twice. The torque range is
230~280Nm. Replace those
bolts that can not reach
required torque range.
55
2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear
● Install front oil seal parts.
● Turn the engine block to the top dead center of cylinder 1 and 6.
● Turn engine block as rotary direction of crankshaft. The rotary
direction is contra rotation when you stand towards the side of timing gear
housing.
● Install the camshaft timing gear. The scale and mark of camshaft
timing gear and OT scale and the mark on timing gear housing should be
aligned.
● Tighten hexagonal bolts, and then make a mark between any bolt
and gear housing.
Notice:
※ Tighten symmetrically with a torque of 35Nm and then coat thread
with thread sealant.
※ Use hands to inspect the clearance of gears. (The control range of
clearance of gears is 0.034~0.265mm, and recommended inner control
range is 0.10~0.25mm.
56
● Hit a pin into the front of the timing gear house.
● Install camshaft gear cover gasket and camshaft gear cover.
● Tighten inner hexagonal cylindrical head screws and matching
saddle-shaped spring gaskets. Tighten (1) hexagonal nuts and matching
spring gaskets.
57
2.8 The Assembly of High Pressure Fuel Pump
Please check
after installing
● Keep marks of the high pressure fuel pump gear and fuel
pump flange in the same direction.

● Install fuel pump into gear house.
● Check whether the installing of step 2 is right or not
through gear house viewing hole.

● If right, please tightening fuel pump nuts and viewing hole
nuts.
58
2.9 Tightening Torque and Tightening Method of Main Bolts of
Diesel Engine
Tightening Torque(N Time of

Name
m)+Turning Angle Reuse
Main bearing bolts 250+30

M18 0
Connecting rod bolts 120+(90 ° +/-5 °)at the

0
M14*1.5 same time reach 170-250N.m
Cylinder head
200+10+2*(90°+/-5°)at the
Main bolt for cylinder head
same time reach 260-380N.m 3
M16
0
90+10+2*(90°+/-5°)at the
Auxiliary nuts of cylinder
head M12
0
60+20+2*(90°+/-5°)at the
Bolt for fly wheel
M14*1.5
0
40+20+(120°+/-5°)at the
Bolt for flywheel housing
M12
0
Bolt for oil pump idler gear 60+5
shaft M10 0
Bolt for camshaft gear

32-36
M8
Bolt for timing idling gear 60+5N.m (at the same time
M10 reach 100-125N.m)
Bolt for pressing crankshaft

60+10
belt pulley M10
Bolt for injector press plate

25
M8
Pressing bolt for press
plate of iron plate injector 15
M8
Bolt for air exhaust pipe
50-70 2
M10
Bolt for rocker-arm seat

100+10
M12
Press nut for air compressor 200+20

gear M18*1.5 0
59
Press nut for fuel pump gear
450-500
M24*1.5
Fixing bolt for tension pulley

195
M16
Fixing bolt for fuel pump
coupling bearing cover 25
M8
Tension bolt for angel
130+20 / 150+15
adjusting plate M12 /
0 0
M14*1.5
Connecting bolt for coupling
springy connecting piece 74 / 110
M10 /M12
Torque requirement: tightening bolts as techniques requirement.

8.8 level：M6, M8, M10, M12, M14, M16, M18
Nm：9∽12；22∽30；45∽59；78∽104；124∽165；195∽257；
264∽354；
10.9 level：M6, M8, M10, M12, M14, M16, M18
N m ： 1 3 ∽ 1 6 ； 3 0 ∽ 3 6 ； 6 5 ∽ 7 8 ； 11 0 ∽ 1 3 0 ； 1 8 0 ∽ 2 1 0 ；
280∽330；380∽450；
60
Chapter III Landking Euro III High Pressure
Common Rail Diesel Engines—Failure
Diagnosis and Case Analysis
3.1 Introduction of High Pressure Common Rail System
Weichai Power Landking Euro III Diesel Engines

● Initiatively applying advanced Germany BOSCH electronically
controlled high pressure common rail system
● BOSCH high pressure common rail system has features of high
reliability, economy, safety, comfort and highly intelligentizing.
● Can meet the requirement of Euro Ⅳ, Ⅴ emission standard
● Landking Euro III series diesel engines are developed in
accordance with Europe R&D process, adopting internationally advanced
casting, machining, assembling equipment and process. Fittings
purchasing adopts global supply chain mode. The engines fully verified
are put into the market, which ensure the excellent quality.
● 100,000 market shares of Weichai Power Landking Euro III diesel
engines enjoy high popularity among customers.
61
Landking Euro III electronically controlled high pressure common rail
picture
Injector
High pressure fuel
ECU
Weichai Power Landking Euro III diesel engines：

● Much higher reliability--- Failure rate is 63% less than that of
mechanical pump engine
● Much more economical--- Fuel consumption per 100km is less
5-10% than that of mechanical pump vehicle at the same condition
● Much lower maintenance cost--- 10L engine is less 1650RMB/Year
than mechanical pump engine, and 12L engine is less 828RMB/Year
(calculating by 180,000km/Year)
● Much better suitability of oil – Compared with mechanical pump
engines, it has more powerful ability to filter impurity and water. There’s
no special requirement about oil brand. The period of “Three Guarantees”
for fuel system is much longer.
● Low vibration and noise----much higher reliability
62
speed-up
performance 400 km-driving
model noise (db) vibration
compared fatigue
with WD615
WD615 115 100%
Improving by
WP10 97 63%
10%
Improving by
WP12 96 50%
35%
● Low fuel consumption

Weichai makes good use of the control function of electronically
controlled high pressure common rail system to develop a series of new
fuel-saving technology, and push out exclusive fuel-saving technology
products:
※ WP multi-power fuel-saving switch
※ Fuel-saving 1+1 (fuel-saving constant temperature fan + fuel-
saving fuel-cut technology)
※ Personalization power
Super truck power, standard truck power, dedicated mixer lorry
power, dedicated crane power, dedicated bus power, dedicated city bus
power, etc.
63
● Much lower maintenance cost
※ Maintenance interval of Euro II diesel engines is 10,000km, while
that of Landking, Euro III diesel engines is 30.000km.

※ WP10 VS. WD615
Take the common standard load highway transportation vehicle

as an example, WP10 can save 1650RMB maintenance expenses
compared with WD 615 (calculating by 180,000km/year)
Maintenance
Quota WP10 WD615 Note
item (set/unit)
fuel coarse filter

core＋fine filter
core+trustworthy 3 334 26
dewater filter
core （piece）（1）The
maintenance
interval of WP10
oil filter core is 30000km,
2 40 40
（piece）
but oil filter
core should be
oil（L） 24 534 355 replaced once
every 10000km
（2）The
maintenance
maintenance 908＋ interval of WD615
expenses of 421×3
80＝ is 10000km
30,000 km =1263
988 （3）WP10
（RMB）
applies Landking
Euro III CH-4
special oil
total
maintenance
expenses 5928 7578
for one year
（RMB）
● Much lower maintenance cost

Take the common standard load highway transportation vehicle as
an example, WP12 can save 828RMB maintenance expenses compared
with WD12 (calculating by 180,000km/year)
64
WP12 VS.WD12
Maintenance item
Quota WP12 WD12 Note
(set/unit)
fuel coarse filter
core＋fine filter
core+trustworthy 3 334 26
dewater filter core
（piece）（1）The
maintenance
interval of
oil filter core
2 82 40 WP12is 30000
（piece）
km, but oil filter
core should be
replaced once
oil（L） 36 770 430
every 10000 km
（2）The
maintenance maintenance
1186＋ interval of WD12
expenses of 496×3
164＝ is 10000 km
30,000 km =1488
1350 （3）WP12
（RMB）
applies Landking
Euro III CH-4
special oil
total maintenance
expenses for one 8100 8928
year（RMB）
65
● Much better suitability of oil
Fuel coarse, fine filter core Trustworthy dewater filter
● Intensifier filter with high efficiency

● Landking Euro III engine is equipped with high efficiency fuel
filter which has a better ability to filter impurity in fuel to effectively
protect fuel system.
● Trustworthy dewater filter

※ It can dewater more than 95% water in diesel.
※ It has the high-efficiency function of fuel-water separation, and
users can use it at ease.
※ It is assembled on the obvious position of vehicle frame to facilitate
drivers’ venting air and pumping fuel.
66
※ It has high-volume transparent water cup with good low-
temperature resistance performance, which is convenient for drivers to
observe water level so as to drain off water in time.
※ It is equipped with hand pump, and the vehicle has hand pump
double insurance.
Special attention:
※ Please often observe the water level of “trustworthy dewater filter”
and drain off water in time.
※ Pay attention that replacing interval of “trustworthy dewater filter”
filter core should be same as that of fuel coarse and fine filter cores.
※ Pay attention that “trustworthy dewater filter” filter core can be
replaced by Landking EuroIII fuel coarse filter core, but it can’t substitute
for Landking EuroIII fuel coarse filter core.
Trustworthy
dewater filter
67
3.2 Failure Diagnosis and Case Analysis
● When diesel engine is failure, removal method of “easy first

and difficult later” one by one should be applied.
● Don’t rashly replace any fitting before find out problems.
● Don’t rashly get rid of blinking code before find out problems.
Please note that do record blinking code.
3.2.1 Failure Type 1: Diesel Engine Cannot Be Started
Failure removal procedures:

● Read blink code according
to blink light to make sure failure.
Turn to next step if the failure can’t
WP-VDS10
be confirmed.
● Two ways to read blink code:
Read through failure iagnosis
equipment; or read through blink code
light . Actuator—fault light
Read blink code:

● The blink code light gives a blink code every time when the
diagnosis switch sends a pulse signal. When the diagnosis switch is
through, the blink code light is on.
● ECU err memory can save 10 errs at most, on and off 0.5 s1s.
● Every blink code consists of three digits, and the time interval
between each digit is 1 second. For instance: 321
68
The method to get rid of blink code by hand:
● Press down the failure diagnosis switch before T15 is through, then
turn on the key switch (T15 is through), and keep the diagnosis switch on
for 4-8 seconds, then release.
● If some blink code can not be deleted, that is the current failure.
● Get rid of hardware failure first, then clear ECU failure memory.
● If the blink code can not be deleted, should inform professional
people to take care of it asap.
Special attention:
After the failure is removed, please clear the blink code by

equipment or by hand.
Air exhaust pipe is folded
Failure diagnosis
switch
Blink code light
69
Ignition key switch Starter
● Inspect if the shift is in neutral position, and the switch

of neutral shift is normal or not; inspect if the auxiliary flameout
switch (it is under the vehicle) is normal. Turn to the next step if it
still can not be started.
● Inspect whether the whole vehicle start line and battery jar
are normal or not. Turn to the next step if it still can not be started.
● Diagnose whether the starter works normally or not. If the
problem still can’t be solved, should further inspect if the diesel
engine rotates freely or not, valve timing right or not. Turn to the
next step if it still can’t be started.
● Inspect if the low pressure fuel passage is entering air,
leakages air, or blocked. Turn to the next step if it still can’t be
started.
Neutral shift switch
Stop motion
switch
70
● Contact people from
special repair station to use
professional equipment to
inspect as follows:
※ Failure diagnosis
equipment used to inspect if the
flywheel signal panel and fuel Camshaft speed sensor
pump camshaft signal panel are

synchronous (the synchronous
signal of data stream is 48). Turn
to the next step if it still can’t be
started.
※ Failure diagnosis
equipment used to further
inspect if the rail pressure built
is normal. If the rail pressure is
abnormal, it’s probably caused
by injector, common rail, high
pressure fuel pump and ECU,
and reference to Parts Failure
Analysis
Crankshaft rotary
transducer
71
3.2.1.1 Description of the Case That Diesel Engine Cannot Be Started (1)
● The whole vehicle doesn’t have blink code. Start line, starter
and battery jar are all normal, but the start can’t start the diesel
engine. Therefore, the start system can be diagnosed that no
failure.
● Further inspect low and high pressure fuel passage, and
remove air, then it can be started. But after 5-minute flameout, the
difficulty in starting appears again. Inspect the fuel passage and
find that there’s still air, therefore, air leakage in the low pressure
fuel passage is confirmed.
● Through careful inspection for parts in the low pressure fuel
passage, it’s found that there’s damage in the thread of fuel inlet of
fuel coarse filter, and air enters the fuel passage, which results in
the diesel engine can’t be stated.
Case
Improper assembling or frequently disassembling and assembling

result in that low pressure passage seal is not tight
Remed
Replace fuel coarse filter or low pressure passage

parts to make sure good seal
There’s damage in
the thread of fuel
inlet of fuel coarse
filter, and fine crack
in fuel inlet
Fuel return Air deflation

Hand hollow bolt bolt
pump
72
● When start, starter doesn’t respond, and no blink code.

Auxiliary flameout switch and neutral shift switch are normal;
● Inspect starter connecting wire and battery jar, and they are normal;
● Inspect when battery jar is connecting with starter, and the
starter works normally;
● Further inspect if the battery jar gets through the four wires of
ECU. After measuring voltage, the four wires proved are power-on
with 24v, which meets the requirement. T15 switch is inspected to
be in normal voltage, and the whole vehicle K wire is also normal;
● It’s found that there’s scorch track between whole vehicle
wiring harness plug connector and ECU stitch when dismantle
whole vehicle wiring harness plug. After inspection, it’s found that 11
stitches (1.37, 1.51) have been burnt out. There’s no voltage output
from ECU, hereby, it’s confirmed that ECU has been damaged.
Case
ECU plug connector looses contact or seals fails resulting in water

leakage or overtension, which leads to burning down (the vehicle
was once welding frame, but ECU plug was not plucked when
welding, which caused burning down)
Remed
Replace ECU
Damaged ECU plug

1.70 stitch was connector: One of whole
burnt out vehicle plug stitches broke,
and the other thick stitches rust.
73
● The starter can work normally, but the engine can’t be

started.
● After inspection, it’s found that there’s paraffin deposit in the
low pressure fuel passage, which caused no fluidity of fuel resulting
in blocking fuel passage and filter core.
● Inquiry that the customer fills up -10＃fuel when get the
vehicle in Beijing, but it can’t be started next day after stopped in
Liaoning. Because the temperature of Liaoning is much lower than
that of Beijing, and -35＃fuel should be filled up in Liaoning.
Case
They don’t choose different brand fuel according to different

temperature, and paraffin deposit leads to fuel pipe blocking.
The required fuel should be replaced in time according to actual
status when the vehicle is running trans-regionally with large
temperature difference
Remed
Dredge fuel passage, and replace with
74
● The motor works normally when the engine starts. The

engine rotates normally, but can’t be started, and no blink code.
● Inspect if the fuel voltage of low pressure fuel passage is
normal, fuel outlet from high pressure fuel pump is normal---proves
that fuel delivery is sufficient.
● Loose fuel return pipe of each injector and observe fuel
return delivery. After contrast observing, all the injectors don’t return
fuel except the injector of the third cylinder returns a lot of fuel---
proves that the injector of the third cylinder is damaged, and back
to normal after replaced.
Case
Poor quality fuel with high water content can cause injector
needle-valve wore and tightless sealing. If the injector leakages
too much, the engine can’t be started.
Remed
Replace injector, and add trustworthy dewater filter
Damaged injector
The left is the original fuel used

The right is normal fuel
75
● The starting system and low pressure fuel passage are

normal, and no blink code. The above methods can’t remove the
failure.
● Failure diagnosis used to inspect that rail pressure can’t
reach the starting pressure of 160bar Inspect that CR pressure
limiting valve doesn’t leakage, and injectors are normal.
● Cut off fuel outlet pipe of high pressure fuel pump, and start
the engine through starter. It’s found that two fuel outlets of high
pressure fuel pump can deliver fuel, but the high fuel pillar is 4.5
cm, the low is mere 2cm. Contrast through eyeballing to find that
the fuel pump can’t supply sufficient fuel (the engine speed is 200-
250r/min, and the normal fuel pillar should be 4-5cm).
Case
Poor quality diesel with high water content leads to damage of

high pressure fuel pump plunger
Remed
Replace high pressure fuel pump, and add

trustworthy dewater filter
HP fuel pump
plunger is damaged
Fuel brand
76
3.2.2 Failure Type 2: The Diesel Engine Starts with Difficulty
Failure removal procedures:

1st step: If it is caused by plateau or
paramos
2nd step: Read the blink code, and
Plateau, high
confirm the failure. Turn to the next step
and cold
if there’s no blink code.
3rd step: Inspect that if the starter
is normal, electricity of the battery jar is
sufficient. Turn to the next step if it still
can’t be started smoothly.
4th step: Inspect whether low
pressure fuel passage is normal or not.
Turn to the next step if it still can’t be Blink
code
started smoothly.
5th step: Further inspect whether
the engine rotates normally or not, valve
timing normal or not. Turn to the next
step if it still can’t be started smoothly.
Starter
6th step: Inspect whether crankshaft
rotary transducer and camshaft speed
sensor and their plugs are damaged,
firmed, clean or not. Turn to the next
step if it still can’t be started smoothly.
7th step: Contact special repair
station people, and use professional
equipment to inspect as follows:
● Use failure diagnosis equipment
to check if flywheel signal panel and
fuel pump camshaft signal panel are
synchronous (the synchronous signal of WP-VDS100 Failure
diagnosis scanner
data stream is 48). Turn to the next step
if it still can’t be started.
to further inspect whether rail pressure is
built normally. If not, it’s probably caused by
injector, CR, HP fuel pump and ECU, Please
refer to Common Parts Failure Analysis
77
Diesel engine is equipped with two speed sensors, one is on the
flywheel and the other is on the outboard of HP fuel pump. Their functions
are crankshaft position sensor and cylinder judging sensor respectively.
The injection timing of electronically controlled engine is decided by
the two sensors. If one lost signal, the engine starts with difficulty. If the
engine can’t be started, the two signals lost.
Crankshaft rotary
Camshaft speed sensor
78
3.2.2.1 Case Description (1)
● No problems are found out after inspection as the above

procedures.
● Use failure diagnosis to inspect the synchronous signal
displaying 48, but responding time is relatively long (exceeds 3
seconds). Inspect crankshaft rotary transducer and find that the
sensor surface and flywheel signal hole are very dirty. Clean them,
then install again, the failure is removed.
Case
Impurity caused that the sensor can’t identify the position of the
signal hole on the flywheel very timely and precisel
Remed
Clean away impurity to ensure sensors right

identification
Damaged
sensor
79
● The diesel engine starts with difficulty, and it makes the great
sound “Kaka” one moment when it’s going to start. After starting,
the speed can only reach 1500 r/min; the engine is in the status of
Limp-home, and the blink code light is on.
● Read the blink code of 112– the failure is crankshaft rotary
transducer. After inspection, it’s Found that crankshaft rotary
transducer plug looses. After reinstalled, the failure is removed.
Case
The plug looses contact (other possible reasons: forgot to

connect the sensor or the sensor fails)
Remed
Reconnect the sensor (or replace with a new sensor)
Not
Not installed
installed
80
3.2.3 Failure Type 3: After the Engine’s Started, It Is Flameout Automatically
Inspection Steps:
Inspection Steps:
1st step: Read blink code and Fault
confirm the failure. Turn to the next step diagnosis
if can’t confirm it.

2nd step: Firstly inspect if low
pressure fuel passage leakages air or
blocked (including fuel return pipe), check
Oil return
if air intake and exhaust is normal. Turn to hollow
bolt
the next step if the problem can’t be solved.
3rd step: Inspect if wires, sensors
and plug is damaged. Turn to the next
step if the problem can’t be solved. Hand
4th step: Contact special repair pump
station people, and use professional

to check if flywheel signal panel and
fuel pump camshaft signal panel are
synchronous (the synchronous signal of
data stream is 48). Turn to the next step
if the problem still can’t be solved.
Air deflating
● Use failure diagnosis equipment bolt
to further inspect whether rail pressure is

built normally. If not, it’s probably caused
by injector, CR, HP fuel pump and ECU,
Please refer to Parts Failure Analysis
WP-VDS100 Failure
diagnosis scanner
81
● After engine flameout, it can’t be started, no blink code.

● Inspect that no fuel in the fuel tank; refill fuel and deflate air
from low pressure fuel passage, it still can’t be started.
● Inspect HP fuel passage, and loose the two HP fuel pipe
tie-ins at the end of fuel pump, then rotate by starter and found
that no fuel is drained out. It’s confirmed that there’s air in HP fuel
pump. Again, the starter used to help deflate air until fuel is drained
out from the tie-in, then reconnect them, the starting is back to be
normal.
Case
Because of inadequate fuel in the tank, air bubble caused by fuel

return are sucked into the fuel passage, which leads to air and
fuel existing in low pressure fuel passage and HP pump.
Remed
Fill up enough diesel, and remove the failure

according to the case description
82
● The engine works for a while, then flameout, stops for a

while, then back to be normal, but a moment later, flameout again.
● Read the blink code displaying242--- water temperature is
too high.
● Inspect that water passage is normal, but failure diagnosis
used to inspect and find that water temperature rapidly increase
to about 107℃ after starting, but the water temperature actually
measured is only 65 ℃ . Hereby, it’s confirmed that water
temperature sensor is damaged, which leads to wrong water
temperature signal ECU got, then the engine enters to self-
protection mode and flameout when load.
Case
When the sensor is damaged, it sends a wrong signal to ECU. ECU

judges wrongly to make the engine enter self-protection mode.
Remed
Replace water temperature sensor
83
Water temperature sensor
84
● The engine starts normally, but the speed is up and down

automatically, then flameout. The blink code light is on.
● Read blink code displaying 324—the speed signal has some
problems. The customer reflects that the speed sensor was touched
when fix the mileage counter.
● After replace the vehicle speed sensor, trial-run is normal.
The failure is removed.
Case
The vehicle speed sensor is damaged
Remed
Replace sensor and shield vehicle speed signal
85
● After the engine starting for 1-2 seconds, it’s flameout

automatically. At the same time, the engine is dithering, and the
speed rapidly increases to 540 r/min, then decrease immediately.
● Inspect low pressure fuel passage and HP fuel passage and
find that no leakage or fuel return pipe squeezed.
● Dismantle the fuel return pipe of injectors and PRV, then start
the vehicle and find that there’s fuel sprays out from the fuel return
pipe of CR when the engine has explosion sound.
● Connect the failure diagnosis and find that rail pressure
rise to 440bar then down to 280bar, then fluctuate between 280-
320bar. Hereby, it’s confirmed that pressure limiting valve of CR is
damaged.
Case
Pressure limiting valve of CR fails
Remed
Replace CR
86
● The engine is flameout suddenly when running, can’t be

started again, no response even if open ignition switch.
● Inspect the power supply is normal, and the wire has
electricity, but the diagnosis equipment connected can’t be
communicated.
● Use multimeter to measure 1.04 stitch with no voltage.
Hereby, it’s confirmed that ECU is damaged.
Case
The plug looses contact, sealing parts fails leading to water

leakage or over-high voltage, which cause ECU damaged.
Remed
Replace ECU
Rail pressure
Rail
pressure
Pressure limiting valve Fuel inlet
87
● The engine’s flameout suddenly when running, but still can

be started again. However, the flameout still exists, and no blink
code.
● Inspect the key switch is normal (If the key switch is short
circuit or open circuit, which probably cause the above problem.
● Inspect ECU power wire is normal (If the power is open
circuit, which probably cause the above problem.)
● Inspect the auxiliary flameout switch (under-vehicle flameout
switch) and find wire insulate rubber wore out, which cause that
ECU receives flameout signal.
Case
Since the wire is not fixed, when it’s wore out, it causes
signal’s short circuit, and the wrong
Remed
Reconnect the wire, and remove the failure
Sensor wire harness
Oil pressure Camshaft

sensor speed sensor
Water
temperature Crankshaft
sensor rotary
transducer
Air intake
pressure
sensor Rail pressure
sensor
88
3.2.4 Failure Type 4: The Engine Exhausts Black Smoke
Failure removal steps:
1st step: Inspect if air filter and air intake and exhaust pipe,
valve clearance are normal. Turn to the next step if normal
2nd step: Inspect if turbocharger is working normally. Turn to
the next step if normally
3rd step: Inspect if diesel quality is normal. Turn to the next
step if normal.
4th step: Contact special repair station people, and use
professional equipment to inspect as follows:
● Use failure diagnosis equipment to check if flywheel signal
panel and fuel pump camshaft signal panel are synchronous (the
synchronous signal of data stream is 48). Turn to the next step if it’s
still black smoking.
● Use failure diagnosis equipment to further inspect whether
rail pressure is built normally. If not, it’s probably caused by injector,
CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis
89
● The engine’s flameout suddenly when running, then the

driver stops the vehicle immediately. Afterwards, it’s difficult to start
again, and black smoking when start.
● Conduct inspection according to the above 3 steps, and all
are normal.
● Use failure diagnosis to inspect: the rail pressure can only
reach 160bar when start.
● Inspect that low pressure fuel passage. CR and HP fuel
pump are normal. Inspect injectors and find that the second cylinder
fuel returning is abnormal. Hereby, it’s confirmed that the injector
fails.
Case
Injector needle valve is seriously damaged, and fuel

atomization is poor.
Remed
Replace injector
Injector
binding post
90
● The engine exhausts black smoke, but inspect that air filter,
air passage and turbocharger work normally.
● Inspect low pressure fuel passage and fuel quality, and find
there’s water in diesel. Dismantle injectors and find incrustation on
the head. Hereby, it’s confirmed that water in the diesel leads to the
six injector needle valves rusting and stuck.
Case
Unqualified fuel, fuel mixing water, and no trustworthy

dewater filter lead to Injector needle valve rusting and
stuck, poor fuel atomization.
Remed
Replace with qualified diesel and injectors, add

trustworthy dewater filter
Injectors rust
91
3.2.4.3 Case Description(3)
● The engine exhausts black smoke when heavily load, but

no black smoke when no-load, and no blink code. After stop the
vehicle, inspect air filter, air passage and turbocharger are normal.
● Inspect fuel passage and fuel quality with no problems.
● Use failure diagnosis to monitor air intake pressure, speed,
rail pressure and fuel delivery: when speed-up with heavy load, the
air intake pressure can reach 1.5kg (absolute pressure), but rapidly
decrease to 0.6kg, and speed also decreases with black smoke.
Hereby, it’s confirmed that air passage has some problem. After
careful inspection, it’s found a piece of rubber tube behind the air
filter becomes soft and sucked to be squeezed when speed-up,
which cause inadequate air-intake.
Case
The rubber tube is so soft that sucked to squeezed

when speed-up, which results in inadequate air-intake.
Remed
Replace air-intake tube
92
3.2.5 Failure Type 5: Insufficient Power
Inspection steps
1st step; For the vehicle equipped with multi-power fuel-saving

switch, inspect if the power shift is on the right position.
2nd step: Read blink code, and turn to the next step if no blink code.
3rd step: Inspect if low pressure fuel passage and fuel quality is
normal. Turn to the next step if normal.
4th step: Inspect if air filter, air-intake passage and turbocharger work
normally. Turn to the next step if normally.
5th step: Inspect if valve clearance is normal. Turn to the next step if
normal.
6th step: Inspect if each sensor plug, accelerator pedal plug and
whole vehicle wire harness connect well. Turn to the next step if normal.
7th step: Contact special repair station people, and use professional
● Use failure diagnosis equipment to check if flywheel signal panel
and fuel pump camshaft signal panel are synchronous (the synchronous
signal of data stream is 48). Turn to the next step if still Insufficient power.
● Use failure diagnosis equipment to further inspect whether rail
pressure is built normally. If not, it’s probably caused by injector, CR, HP
fuel pump and ECU, Please refer to Parts Failure Analysis
● For the vehicle equipped with multi-power fuel-saving switch,
inspect if the power shift fails.
93
● When the speed reaches 1500r/min in the process of driving,

it appears unsteady speed, and the whole vehicle dithering. The
speed can’t be increased even if keep stepping on accelerator. It
shows insufficient power with blink code light on.
● Read blink code displaying 114---crankshaft rotary transducer
signal is abnormal.
● Use failure diagnosis to inspect and find that step
on accelerator to speed-up when the vehicle stays still; the
synchronous signal’s bouncing when the speed exceeds 1500r/
min, can’t keep at 48.The crankshaft rotary transducer wire harness
inspected is normal. Hereby, it’s confirmed that the crankshaft
rotary transducer fails.
Case
When the engine runs at high speed, crankshaft rotary

transducer signal is not stable.
Remed
Replace crankshaft rotary transducer
Crankshaft rotary transducer
94
● nsufficient power, no blink code.

● Inspect multi-power fuel-saving switch and find no change
about power when change shift. It’s confirmed that the switch fails.
Case
Multi-power fuel-saving switch fails
Remed
Replace multi-power fuel-saving switch
95
● The power is insufficient with heavy load, and the speed can
only increase to 1500r/min.
● Read blink code displaying 253—fuel supply in the low
pressure passage is difficult.
● Inspect fuel tank, fuel pipe and filter core and find that filter
doesn’t mix with water the fuel tank is not blocked, but the low
pressure fuel pipe is curved.
Case
Too small inside diameter of fuel pipe (required id ≥Φ12mm)

or curved pipe caused unsmooth fuel supply
Remed
Restore the curved place
Normal Tucked position
96
● Insufficient power, no blink code.

● Fuel passage and quality are inspected to be normal.
● Inspect air filter and air-intake pipe and find the lower end of
intercooler splits for about 15cm opening
Case
Air-intake pipe leakages air
Remed
Replace intercooler
Intercooler splits
97
● Fuel can’t fill up when the engine runs for a while, but the
speed is not restricted.
● The blink code is 143– the third cylinder injector wire harness
is open circuit.
● After replace injector wire harness, it’s normal.
Case
The nut at the wire harness binding post is not screwed down
or the injector wire is open circuit.
Remed
Firstly screw down the nut, if it doesn’t work, replace injector

wire harness to solve the problem.
98
3.2.6 Failure Type 6: Limp-home
1st step: Read the blink code.

2nd step: To confirm the failure according to blink code. Turn to
the next step if can’t remove the failure.
3rd step: Inspect if the low pressure fuel passage is seriously
blocked, fuel meets the requirement of ambient temperature. Turn
to the next step if can’t remove the failure.
4th step: Contact special repair station people, and use
● Use failure diagnosis equipment to check if flywheel signal
panel and fuel pump camshaft signal panel are synchronous (the
synchronous signal of data stream is 48). Turn to the next step if
the problem still can’t be solved.
● Use failure diagnosis equipment to further inspect whether
rail pressure is built normally. If not, it’s probably caused by injector,
CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis
99
1. The max speed can only reach 1500r/min after the engine
starts, and the blink code light is on.
2. The blink code is 134– CR pressure limiting valve opens
3. After starting, step on accelerator for the first time, and it
can reach rated speed. In the first seconds, the actual rail pressure
value exceeds setting value. Hereby, it’s confirmed that the fuel
return passage is not smooth. Through inspection, it’s found that
the fuel return pipe of fuel tank is blocked.
Case
The blocked fuel return passage leads to unsmooth fuel

return, which cause rail pressure exceeding the setting value.
Remed
Clean fuel return passage
100
● It appears the max speed of 1500r/min when running, and

the blink code light is on.
● The blink code is 134– CR pressure limiting valve is open.
● Inspect fuel passage: low pressure fuel passage is normal,
but fuel color is abnormal.
● Use failure diagnosis to monitor rail pressure: it rapidly
increases to 1800bar, then decreases to 760bar. Hereby, it’s
confirmed that CR pressure limiting valve is normal, but metering
unit is damaged.
Case
Poor quality fuel leads to metering unit valve stuck
Remed
Replace metering unit or HP fuel pump, clean fuel

passage and replace fuel.
● Metering unit failure
Metering unit
※ Removal method: check and repair wire, to judge metering unit

failure or rail pressure sensor failure.
101
● The max speed is 1500r/min after starting, and the blink code
light is on.
● The blink code of 231– The voltage of air-intake pressure
sensor exceeds upper limit value. The blink code of 233– The
voltage of air-intake temperature exceeds upper limit value.
● Through inspection, it’s found that the wire harness plug of
air-intake pressure temperature looses.
Case
The wire harness plug of air-intake pressure temperature looses or

the air-intake pressure sensor is damaged.
Remed
Reinstall the plug
● Air-intake pressure sensor
102
● The blink code light is on now and then when running. The
max. speed can reach 1500r/min, and the blink code light is on.
● The blink code is 254—fuel feeding resistance is too huge.
● Inspect low pressure fuel passage and find that fuel passage
from fuel tank to fuel coarse filter is curved.
Case analysis
Curved fuel passage leads to unsmooth fuel feeding.
Remedy
Clean or replace low pressure fuel pipe
103
1. The max. speed can reach 1500r/min, and the blink code light
is on.
2. The blink code is 134– CR pressure limiting valve opens.
3. Inspect low pressure fuel passage
4. Inspect HP fuel passage
Method 1: Inspect fuel return of injector, and find that 6th cylinder
fuel return is abnormal; after replacing the 6th cylinder injector, it’s
normal.
Method 2: Use failure diagnosis to test HP: when the speed is
2200r/min, the actual rail pressure can’t reach the setting value of
1300bar, 400bar less. That proves that there’s leakage in HP system.
After fuel-cut test, it’s found the 6th cylinder injector works badly
Case analysis
Injector failure
Remedy
Replace injector
104
3.2.7 Idle Speed Is Not Stable
● 1st step: Read the blink code and confirm the failure. Turn to the
next step if can’t confirm.
● 2nd step: Inspect if low pressure fuel passage is normal. Turn to
the next step if can’t remove the failure.
● 3rd step: Inspect if each sensor plug and wire harness are normal.
Turn to the next step if can’t remove the failure.
● 4th step: Contact special repair station people, and use
● Use failure diagnosis equipment to inspect if vehicle speed sensor
is normal. Turn to the next step if can’t remove the failure.
● Use failure diagnosis equipment to further inspect whether rail
pressure is built normally. If not, it’s probably caused by injector, CR, HP
fuel pump and ECU, Please refer to Parts Failure Analysis
105
Case description
● The idle speed is not stable after starting, no blink code.

● Inspect that low pressure fuel passage, sensor plug and
wire harness is normal.
● Use failure diagnosis to read vehicle speed signal: when
the vehicle is at idle state, the speed signal exists, and fluctuates
between 0—7km/h
Case analysis
Unstable vehicle speed sensor signal caused unstable idle speed.
Remedy
Replace with qualified vehicle speed sensor. If the vehicle doesn’t

use sensor, the speed signal can be shielded.
3.2.8 The Engine Is Always at 1000r/min
1st step: Read the blink code and confirm the failure.
2nd step: Remove the failure according to blink code.
3rd step: Inspect if electric accelerator pedal plug looses, wrongly
connected or short circuit.
4th step: Inspect if the electric accelerator pedal fails.
106
Case description
● The speed is always at 1000r/min after starting; the

accelerator pedal doesn’t work; the blink code light is on.
● The blink code is 221--- the accelerator pedal signal is
abnormal.
● Inspect that the electric accelerator pedal plug is normal
● Use failure diagnosis to inspect accelerator pedal voltage:
it’s not the twice voltage. Inspect that the wire connecting is
normal. Hereby, it’s confirmed that it’s the accelerator pedal
sensor failure.
Case analysis
The accelerator pedal sensor failure leads to wrong signal
Remedy
Replace accelerator pedal
※ The electric accelerator pedal wire looses or wrongly connecting.

Re-plug or inspect if the accelerator wire is right, then reconnect.
※ The electric accelerator plug connector leakages water: dry it, and
then restart.
Note: Replace the accelerator

with the same model
107
3.2.9 Other Failures
3.2.9.1. Description of the Case That Accelerator Works Now and Then
When Driving
● The accelerator pedal fails when the engine works for a

while, back to normal after stop for a while, then fails again. The
water temperature rapidly increases to about 107℃ after starting.
● After inspection, it’s found that the water pump pulley
looses resulting in too high water temperature, and the engine
enters overheat protection mode.
Case analysis
The unique intelligent protection function of the electronically

controlled diesel engine is that the accelerator fails when water
temperature is too high. When the temperature is down, the
accelerator’s back to normal.
Remedy
Tighten belt (remove the sensor failure)
Note: After installing the belt, pull out the pin of belt tensioner with
pliers to realize automatic tension.
Belt looses
108
3.2.9.2. Description of the Case That Vibration at Idle Speed Is Huge (1)
● The vehicle is equipped with WP10.300N series engine,

Fast RTO 11509F gear box rear axle ratio: 4.42, original idle
speed of the engine: 550rpm
● When the engine is at idle speed, it takes place resonance
vibration with gear box and the operator cabin.
Case analysis
The speed of 550rpm is the resonance vibration point of this engine
Remedy
The idle speed is adjusted to 620rpm, and then the

problem is solved
109
3.2.9.3 Description of the Case That Vibration at Idle Speed Is Huge (2)
● When the vehicle speed is about 60km/h, and the engine

speed is about 1300r/min, the vehicle is seriously dithering.
● The engine doesn’t dither after stop the vehicle.
Case analysis
The engine and whole vehicle transmission system is resonance

vibration when driving
Remedy
Replace vehicle transmission shaft
110
3.3 Parts Failure Analysis
Main parts in common rail system
Main parts in common rail system
111
3.3.1 Injector
Fault: insufficient power, black smoke exhaust, difficult to start and

limp-home fault
Injector working principle picture
112
3.3.1.1 Table about Analysis of Injector Fault
No. Fault type Cause Remedy Remarks
Carbon Clean replace

Atomization of deposit injector if fault
1
injector is bad heavily on cannot be
fuel head removed
Needle
Injectors don’t valve is Replace
2
inject fuel locked in injector
closed state
Needle
valve is
locked
at usual
position
Fuel head of Replace
3 or needle
injector drip fuel injector
valve of
injector is
worn and its
sealing isn’t
tight
Fuel return
Fuel return
plunger
amount per
taper is Replace
4 injector is great or
worn and its injector
it is very different
sealing isn’t
from other ones
tight
Inexact
orientation
Pay
Injector Bronze lead to
Replace attention to
cover or washer distort or
5 bronze cover orientation
is distorted or tighten with
or washer when
damaged big strength
installing
when
installing
Screw cap of
connection pole
Screw cap
is loose, which
and wiring Fasten screw
causes wiring
6 harness cap and wiring
harness of injector
cannot harness
is loose or worn
fasten firmly
and cylinder head
is short circuit
Turnoff or
big electric
Electromagnetism current Resistance
Replace
7 valve of injector is is burnt of injector is
injector
damaged because 0.9 ohm
of other
causes
113
3.3.1.2 Analysis about Injector Fault
Fault: insufficient power, block smoke exhaust, difficult to start and

limp-home fault
● Atomization of injector is bad
cause: carbon deposit heavily on fuel
head （right picture）
Remedy: clean, replace injector if the
fault cannot be removed.
● Injector doesn’t inject fuel
Cause: injector is locked in closed state
Remedy: replace injector
● Flow fuel on fuel head of injector

Cause: needle valve is locked in usual position or needle valve of
injector is worn
● Fuel return amount in every injector is big or there is big different

from other injectors
Cause: fuel return plunger taper is worn
114
● Bronze cover or washer of injector is distorted and damaged

Cause: distortion because of inexact orientation or tighten with great
strength when installing them
Remedy: replace bronze cover or washer
● Screw cap of connection pole is loose, which causes wiring
harness of injector is loose or worn and cylinder head is short circuit
Cause: screw cap and wiring harness is not fastened
Remedy: fasten screw cap and wiring harness.
● Electromagnetism valve of injector is damaged

Cause: turnoff or big electric current is burnt because of other
causes.
My note:
115
3.3.2 High Pressure Fuel Pump
3.3.2.1 Table for Analysis of High Pressure Fuel Pump
There is air
Fuel outlet pipe Remove air or
in plunger or There are 2 rotation
of high pressure replace high
1 gear pump, direction in gear
fuel pump can pressure fuel
or plunger is pump, do not confuse
supply fuel pump
worn
Connection of
Pull out and
Bnc connector
insert bnc
Flow metering plugs of wiring Resistance of flow
connector
2 unit is often harness is metering unit is
plugs again or
open bad, and flow 2.6～3.15ohm
replace flow
metering unit
metering unit
is damaged
Connection of
Bnc connector Pull out and
3 flow metering
plugs is loose insert again
unit is bad
Timing of timing Timing of gear

Re-adjust as
gear of high is wrong when
4 requirement of
pressure fuel installing fuel
technics
pump is wrong pump
116
3.3.2.2 Analysis about High Pressure Fuel Pump
Fault: can not be started, difficult to start and limp-home
● Fuel outlet pipe of High pressure fuel pump cannot supply fuel
Cause: there is air in cavity of plunger or gear pump or plunger worn
Remedy: remove air or replace high pressure pump
● Flow metering unit is often
open.
Cause: contact of bnc connector
plugs of wiring harness is bad, and
flow metering unit is damaged.
Remedy: pull out and insert
bnc connector plugs or replace flow
metering unit.
● Connection of bnc connector
plugs of flow metering unit is bad
Cause: bnc connector plugs is
loose
Remedy: pull out and insert again
● The timing of timing gear of high pressure fuel pump is wrong
Cause: timing of gear is wrong when installing fuel pump.
Remedy: re-adjust as requirement of techniques
117
3.3.3 Common Rail Pipe
3.3.3.1 Table about Analysis of Common Rail Pipe Fault
Sealing of
pressure released
valve is bad or
spring of pressure Replace
Pressure released valve pressure
Rail pressure
released in invalid, which released
1 cannot be set up
valve leaks cause fuel valve or
abnormally
abnormally releases from common
pressure released rail pipe
valve when rail
pressure doesn’t
reach 1600bar
Pull out
and
Instable and
insert bnc
Connection of bnc illogical rail
Fault connector
connector plugs pressure: signal
of Rail plugs
2 is bad, and rail voltage of rail
pressure again or
pressure sensor is sensor is about
sensor replace
damaged 1V at idling
rail
speed
pressure
sensor
118
3.3.3.2 Analysis about Fault of Common Rail Pipe
※ Fault: difficult to start and fault of limp-home

Pressure released valve leaks abnormally
Cause: Sealing of pressure released valve is bad or spring of
pressure released valve in invalid, which cause fuel releases from
pressure released valve when rail pressure doesn’t reach 1600bar
Remedy: replace pressure released valve or common-rail pipe.
※ Fault of Rail pressure sensor
Cause: Connection of bnc connector plugs is bad, and rail pressure
sensor is damaged
Remedy: pull out and insert bnc connector plugs again or replace rail
pressure sensor
3.3.4 ECU
119
3.3.4.1 Table about Analysis of ECU Fault
Communication
between
diagnostic and
ECU is failure
ECU is Replace
1 and blink code
burnt ECU
light and cold
started light
cannot self-
check
There is
K line has not wrong with Check
2 Usually 24V
voltage 1.89 stitch 1.89 line
line
Wrong
operation
when pull
ECU stitch is Replace
3 out and
folded ECU
insert bnc
connector
plugs
Turnoff
or didn’t Caution reliability
ECU is hit by big pull out Replace of ECU line, and
4
electric current ECU bnc ECU protect ECU when
connector jointing
plugs
Flow into Clean Add sealing ring

ECU stitch is Conductive liquid or on wiring harness,
5
turnoff electricity replace and caution
liquid ECU waterproof
3.3.4.2 Analysis about ECU Fault
Fault: engine cannot be started, flameout
※ Communication between
diagnostic and ECU is failure ， electric
blink code light and cold started light
cannot self-check.
120
Cause: ECU is burnt.
Remedy: replace ECU
※ K line has no voltage (usually about 23.5 )
Cause: 1.89 stitch line is wrong.
Remedy: check 1.89 line
※ ECU stitch is folded
Cause: there is wrong operation when pull out and insert ECU bnc
connector plugs.
Remedy: replace ECU
※ ECU is hit by big electric current
Cause: line turnoff or did not pull out ECU bnc connector plugs
Remedy: replace ECU (caution that reliability of ECU line, and protect
ECU when jointing)
※ ECU stitch turnoff
Cause: be flowed into conductive electricity liquid
Remedy: clean liquid or replace ECU (add sealing ring on wiring
harness and pay attention to be waterproof)
121
3.3.5 Sensor and Wiring Harness
Oil temperature and Air intake temperature Crankshaft

pressure sensor and pressure sensor
speed sensor
Water
temperature
sensor
Rail pressure
sensor
Camshaft
speed sensor
3.3.5.1 Table of Function of Sensor
System responses
No. Sensor Function
when it fails
It is one of the key sensors PRV opens, the

Rail pressure in common rail system, and temperature of return
1
sensor it provides the pressure in oil rises, and it runs
common rail pipe limp-home.
It provides the coolant

Water
temperature and is relevant
2 temperature It runs limp-home.
to the function of air-intake
sensor
heating and heat protection.
Oil
It provides the parameters
temperature
3 of oil pressure and Oil pressure alarms
and pressure
temperature.
sensor
Air-intake Diesel engine

It provides the signals of
temperature discharges black
4 crankshaft position and
and pressure smoke, white smoke,
rotating speed.
sensor and runs limp-home.
It provides the signals of It is difficult to start

Crankshaft
5 crankshaft position and and discharges
speed sensor
rotating speed. smoke.
It provides the signals of

Camshaft It is difficult to start
6 piston working position and
speed sensor and runs limp home.
camshaft rotating speed.
122
3.3.5.2 Analysis Table for Fault of Sensor and Wiring Harness
No. Fault type Cause Remedy Remark
bnc connector
Sensor
plugs or sensor Replace a new
1 hardware is
shell is damaged sensor
damaged
when installing
Electric Because of
feature of electro circuit, Replace a new
2
sensor is Sensor is sensor
wrong damaged.
Insert part Insert untightly or

Pull out and
of wiring damage
insert again or
3 harness bnc connector
replace wiring
is bad or plugs when
harness
damaged operating
Turnoff and Connection

Protect or
short circuit rubber worn of
4 replace wiring
of wiring Wiring harness
harness
harness broken
3.3.5.3 Analysis about Sensor and Wiring Harness Fault
※ Sensor hardness damaged

Cause: bnc connector plugs or
sensor shell damaged when installing
Remedy: Replace a new sensor.
※ Wrong electric feature of sensor
Cause: because of electro circuit,
sensor is damaged
Remedy: replace a new sensor
※ Insert part of wiring harness is
bad or damaged
123
Cause: Insert untightly or
damage
bnc connector plugs when
operating.
Remedy: insert and pull out
again or replace wiring harness
※ Turnoff and short circuit of
wiring harness
Cause: connection rubber
worn or wiring harness broken.
Remedy: protect or replace wiring harness
3.3.5.4 Guide for Sensor Inspection
Assembly Item Standard numeral value
Camshaft Resistance 770-950 ohm

speed between 2
sensor stitches of
(installed sensor
on the
flywheel)
2.23-
2.19 wave
shape(idling
speed)
124
Camshaft Voltage 3.2-4.9 V

speed between
sensor 2.09 and
(installed ground line
on （idling
flywheel) speed）
Resistance 770-950 ohm
between 2
stitches of
sensor
2.09-2.10
wave shape
（idling
speed）
Resistance 2.60-3.15 ohm（environmental temperature

of flow 20 ℃）
metering unit
Data flow 1380～1420mA

(electric
Flow metering current in
unit (installed idling speed)
up and left side
of high pressure
pump)
125
Standard numeral
Assembly Item
value
Rail pressure sensor 2.14－2.12 voltage
0.5V
(installed near right side) (T15)
2.14－2.12 voltage
1.2～1.5V
(idling speed)
Rail pressure (idling

340～450bar
speed)
Changed range
0.5～4.5V (0bar
(voltage of rail ～1800bar)
pressure sensor)
Water Resistance
temperature feature from
sensor（ 2.15 to 2.16
installed on in different
the water water
outlet pipe） temperature
(right picture)
，Rnom is
standard
numeral
value
126
Air inlet Resistance

temperature feature
and from 2.36-
pressure 2.25 in
sensor different
(installed on temperature
air intake (right
pipe) picture)
nominal is
standard
numeral
value，
Air inlet Voltage from 0.5～0.8 V

pressure 2.34 to 2.25
sensor （idling
speed）
Voltage from
2.34 to 2.25
127
Oil Resistance
temperature feature of
sensor 2.28－2.24
in different
temperature
(right picture)
，nominal
is standard
value
Oil pressure Voltage of

sensor 2.27－2.24
Air intake Voltage of 23～29 V

heating 1.55－1.59
relay
128
3.3.6 Accelerator Pedal
129
3.3.6.1 Table about Accelerator Pedal Fault
No. Fault type Cause Remedy Remark
Inserting
Pull out
part of
1 Insert untightly and insert
accelerator
again
is not good
Turnoff Connection
and short rubber worn or
2 Protection
circuit of wiring harness
accelerator broken
That pedal
Opening of APP1：0.75-
output voltage
accelerator Replace 3.84V
3 cannot reach
pedal is pedal APP2：0.375-
quirement of
abnormal 1.92V
EUC
Double
Replace
voltage
Pedal cannot pedal after Signal1 is
relationship
4 reach the remove double signal
of
requirement cause of 2(voltage)
ccelerator
line
is failure
130
3.3.6.2 Analysis about Accelerator Pedal Fault
Fault: engine runs at speed of 1,000r/min always, and idling speed is high
● Accelerator parts contacts bad

※ Cause: insert untightly.
※ Remedy: pull out and insert again
● Turnoff and short circuit of accelerator connection
※ Cause: connection rubber worn or wiring harness broken
※ Remedy: protection
● Opening of accelerator pedal is abnormal
※ Cause: that pedal output voltage cannot reach requirement of ECU.
※ Remedy: replace pedal.
● Double voltage relationship of accelerator signal is failure.
※ Cause: pedal cannot reach the requirement.
※ Remedy: remove line problem and remove pedal.
131

Weichai Engine WP10

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Contents

Chapter I Maintenance for Landking WP10 Euro III Diesel

1.1 Regular Inspection for Landking

● Before starting the engine

Diagram of water temperature in cab

Brand -25 -35 -45

Applied temperature -25℃ above -35℃ above -45℃ above

Learning and thinking：

● Check the height of oil level before drive every day.

Learning and Thinking:

Oil filling inlet of 1st

● Recommend CF-4 oil to be used in Landking Euro Ⅲ diesel

Please use right oil according to

0W-30 5W-30 10W-30 10W-40 15W-40

Learning and thinking:

Learning and thinking:

● Mixed air-fuel in the low pressure fuel passage could possibly be

① Make sure enough fuel

Don’t overexert loosening or

● If there’s water in the fuel supply

Lightly loosen or tighten the plastic

Learning and thinking:

● Because of fuel quality differences in different places,

There’s no more special requirements about fuel quality for

● Recommend using qualified fuel to guarantee the quality of

Learning and thinking:

Learning and thinking:

Cut off electricity supply before weld;

Special generators for Landking Euro III engines must be used.

● Close the control switch of battery,

Pull out the collector as the

● Plug into the wiring harness collector connecting with ECU.

Plug into the collector in the following steps:

Learning and thinking:

When pull out or plug ECU,

Learning and thinking:

Learning and thinking:

Learning and thinking:

● Proper maintenance can effectively prolong service life of diesel

● Maintenance for highway trucks according to the following standard:

load ≤rated load ＞rated load

New vehicle run 3000 km or for 50 hrs (of the two

Every 10,000 km or 500 Every 10,000 km or 500

load ≤rated load ＞rated load

New vehicle run for 50 hrs or 3,000 km (of the two

Every 300 hrs or 2,0000 Every 200 hrs or 1,0000

New vehicle run 50 hrs or 3,000 km (of the two

Periodical Every 300 hrs or 10,000 km (of the two

Learning and thinking:

New vehicles run 3,000 km or 30 hrs (of the

Periodical Every 10,000 km or 300 hrs (of the two

1.2.3 Construction Machinery

● Maintenance for loader, excavating machine, road roller and crane,

New vehicle run for 50 hrs or 3,000 km (of the

Periodical Every 200 hrs or 10,000 km (of the two

● Please properly shorten periodical maintenance interval or mileage

Learning and thinking:

Learning and thinking:

● When repair or replace components of diesel engines, pay attention to :

Learning and thinking:

1.3.1 Accelerator Pedal Operation of Euro III Diesel Engines

● Operating points of diesel engines influence fuel economy, but gear

A. Shift the first gear to start.