WP12四气门国二系列车用保养说明书英文

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Operation and Maintenance Manual of WP12

Four-Valve China II/Euro II Diesel Engine for
Vehicles
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Weichai Power Co., Ltd.
白克勤谭利明
国际郭祥军闫玉国际
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“1008754865 - WP12四气门国二系列车用柴油机使用保养说明书(英文), A”
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白克勤谭利明
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Operation and Maintenance Manual of WP12 Four-Valve China
II/Euro II Diesel Engine for Vehicles
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WP12 Four-Valve China II/Euro II Diesel Engine for Vehicles

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白克勤谭利明
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白克勤谭利明
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Foreword
The series engine is a high-speed engine independently developed by Weichai Power Co., Ltd. It
boasts many advantages such as compact structure, outstanding performances including reliable running,
strong power and good economic efficiency, as well as fast start, easy operation and maintenance.
The main contents of this Manual include basic information and operation and maintenance
国际服 of the series engine. To make the engine serve you 国 in a际
methods 服务way, you are recommended to
better
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2understand (gjengine 2 0 2 2/06and(operation
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06/0 fw)
structure in details, and master the maintenance
/ 0 )
1 16 1 16 to change without
:31:variants of the series engine, this Manual will be subject
With the increasing :31:
26latest product information through the website of http://www.
notice. Users can access the 26Weichai.com.
Weichai Power Co., Ltd. is authorized to carry out the after-sales service of this product.
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白克勤谭利明
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白克勤谭利明
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Dear users:
Welcome to use Weichai products! Thank you for choosing Weichai products!
To use and maintain the engine properly, please read this Operation and Maintenance Manual
carefully and operate in strict accordance with relevant provisions.
国际国际
服务服
2022Service (commitments: 2022 务(gjfw
/06/ gjfw) /06/
01 1 as)soon as possible. We
01 1has any fault, please contact Weichai call center 400-6183066
If the engine 6:31 6:31
promise that the special : 26
maintenance service center will arrive at the fault site within 3:h2for
6 the center-
located city, within 24 h for the general region and within 48 h for the remote area, and provide fast, high-
quality and considerate service according to Weichai service requirements.
To ensure the effective and normal running of your engine, please read the following content
carefully before use.
♦ Before operation, please carefully read this Manual,

strictly observe the operation and maintenance regulations
specified in this Manual, and pay attention to warning
instructions and warning signs. Please pay attention to the
following issues because the engine warranty will be
国invalidated if the operation is performed not in accordance
际服国际
务( 服
2with the requirements
022/ g of this Manual! 2022 务(gjfw
06/0 jfw) /06/
Please01
)
♦ 1 1engine
As the
6:31has been tested in strict accordance refer
16to:3this Manual.
:2upon
with the test specifications 6 delivery, it is not allowed to 1:26
adjust the fuel pump without permission.
♦ For the engine with a turbocharger, the rotor
shaft of the turbocharger is a precise high-speed rotating
part. Please keep any objects (such as hand, tool, and cotton
yarn) away from the inlet of the turbocharger when the
engine is running, so as to avoid personal injury or engine
damage. Do not disassemble the rotor group.
Do not touch high-speed rotating parts with

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♦ Do not loosen or remove the main bearing bolt or the

connecting rod bolt of the engine without permission as
they are subject to strict torque and rotation requirements. Tightening torque requirement
♦ Always fill the engine with the oil or fuel of grade

specified in this Manual, and filtered by a special filter; for
the fuel, subject it to a precipitation more than 72 h. Prior to
start, always check 白克勤 that the coolant 谭利明
and oil levels are
satisfactory, and if not, please fill the engine with fuel or oil
国
of grade specified 郭祥军
际服 authorized gasoline 国
in this Manual at an 闫玉
际服
station.
20 务 (g 20 refer务
Please (grelevant chapter in this Manual
to the
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6/01 fw闫玉王国强 6/01 fw)
16:3 16:3
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♦ Before running a new engine, subject it to

running-in for 50 h.
♦ Never run the engine without an air filter.
♦ After starting a cold engine, accelerate it slowly
rather than abruptly, and do not run it at an idle speed for a
国
long
际time. 国际
服服
2022♦ 务 ( gjfwcheck the coolant, and never change the 2022/ 务(gjfw
/06Regularly
/01 with)water or coolant of poor quality. At a 06/0 )
engine coolant 16:3 1 16
1:select :31:
low temperature, please 26 the coolant of the correct 26
grade in accordance with the requirements of this Manual.
♦ The engine has been preserved before delivery for
avoiding rust. The engine preservation period is one year,
and the engine should be checked and necessary measures Please refer to the relevant chapter in this
should be taken when this valid period expires. Manual
♦ Please have the diesel engine disassembled and

repaired at the Weichai Power designated service station in
case of a fault. Do not use the spare parts not specified by
Weichai Power for maintenance; otherwise, Weichai will not
assume any responsibility for damage to the engine
国国际
际服服
务
therefrom.
2022 (gjf 2022 务(gjfw
/ w ) /06/
06/0 have the
♦ Always 1 16 components of the electrical system 01 1 )
:
maintained by Weichai3professional
1:26 6:31
technicians. :26
♦ The user is not allowed to disassemble the fuel
injection pump and injector as they are precision Authentic Weichai spare parts
components.
♦ Valve clearance adjustment shall be carried out in a
professional Weichai Service Station, and it is strictly
forbidden for users to adjust the valve clearance without
permission. All engine problems caused by user's
unauthorized adjustment shall be the responsibility of the
user himself.
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！ Please read this Manual before operation
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Please pay attention to followings before maintenance and repair:

1. Avoid repeated exposure to used oil for a long time.
2. Wear protective clothing and water-proof gloves properly, if available.
3. Do not place the oily rag in the pocket.
国际4. Avoid contaminating clothes especially underwear with
国oil.
际服
服
5./06Wash /06/
/01 work) clothes frequently, and throw away the oil-impregnated )
01 1 clothes and shoes that
1 6 :
cannot be cleaned up.31: 6 : 31:2
26 6
6. In case of cut and injury, please take first-aid measures as soon as possible.
7. Before working, always apply some protective creams, which will make it easier to remove oil in
case that the skin is contaminated with mineral oil.
8. Use soap and hot water, or liquid soap and nail brush to wash hands for the convenience of
removing all oil stains. If the grease secreted by skin is washed off, the product containing lanum can
substitute the grease secreted by skin to moisturize the skin.
9. Do not clean the skin with any gasoline, kerosene, fuel, thinner or solvent.
10. Upon detection of skin irritation, please seek medical attention immediately.
国际11. Remove oil from the parts before transportation, if possible.
国际
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202212. 务 ( gjfuse
w 202might
2 (gjf to danger. Eye flush
/06Please ) / 0 /01 w)
goggles or face guard masks when your eyes be exposed
/0readily
1 16 available. 6
fluid must be
:31: 16:3
26 1:26
13. During engine maintenance, do not splash oil or other liquid on the floor. In the event of
accidental leakage of hydrocarbon or other liquid, please take all necessary measures to separate this
area to keep the environment clean and guard personnel against injuries.
14. The handling, storage and recovery of hydrocarbon, ethylene, glycol or petroleum must comply
with the safety and environmental standards of the local country.
白克勤谭利明
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Contents
Chapter 1 Structure and Performance Parameters.........................................................................1
1.1 Outline drawing .............................................................................................................................. 1
1.2 Designation of model ..................................................................................................................... 3
国1.3
际国际
Main parameters ............................................................................................................................ 4
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022/ 2务
2Chapter w )
2022 务(gjfw
(gjf and Operation....................................................................................................
/06/
01 1 )
Installation
06/0 6
1 16 6:31
2.1 Unpacking:.......................................................................................................................................
31:2 :26 6
6
2.2 Hoisting ........................................................................................................................................... 7
2.3 Installation ...................................................................................................................................... 7
2.4 Preparations before start ............................................................................................................... 7
2.5 Start ................................................................................................................................................ 8
2.6 Running ........................................................................................................................................... 8
2.7 Shutdown........................................................................................................................................ 9
Chapter 3 Maintenance .............................................................................................................. 11
3.1 Fuel, lubricating oil, coolant, and auxiliary materials ................................................................... 11
3.1.1 Fuel ........................................................................................................................................... 11
国际3.1.2 Lubricating oil ...........................................................................................................................
国际 11
服服务
20223.1.3务(Coolant 2 (
/06/ gjfw).....................................................................................................................................
022/
06/0 jfw)
g 12
0 1 16 materials ....................................................................................................................
3.1.4 Auxiliary 1 16 12
:31: :31:
3.2 Daily maintenance 26........................................................................................................................
26 13
3.2.1 Daily inspection ........................................................................................................................ 13
3.2.2 Daily maintenance .................................................................................................................... 14
3.3 Regular maintenance interval and specification .......................................................................... 14
3.3.1 Regular maintenance interval and specification ...................................................................... 14
3.4 Cleaning, protection and handling ............................................................................................... 16
3.4.1 Cleaning and protection ........................................................................................................... 16
3.4.2 Protection during storage ......................................................................................................... 16
3.4.3 Oil seal ...................................................................................................................................... 16
3.4.4 Handling ................................................................................................................................... 16
国3.5
际服国际
Description of maintenance at all levels ...................................................................................... 16
务服务
20223.5.1 (Oilgjchange 2022 (
................................................................................................................................. 16
/06/ gjfw)
fw) of oil filter or filter element.................................................................................
/06/ Replacement
3.5.2 01 1 01 1 16
6
3.5.3 Replacement: 31:of 6 : 31:2
26fuel filter and its element ...............................................................................
6 17
3.5.4 Checking air seal ....................................................................................................................... 19
3.5.5 Checking air filter element........................................................................................................ 19
3.5.6 Maintenance of oil-gas separator ............................................................................................ 20
Chapter 4 Typical Faults and Troubleshooting ............................................................................. 21
4.1 Overview ....................................................................................................................................... 21
4.1.1 Overview ................................................................................................................................... 21
4.2 Diagnostic method........................................................................................................................ 21
4.2.1 Traditional
白克勤 fault diagnostic methods 谭利明 ....................................................................................... 21
4.3 Typical faults and troubleshooting ............................................................................................... 21
国际4.3.1 Engine郭祥军闫玉国际
start failure ................................................................................................................... 21
服服务
20224.3.2务(Engine
gjfw闫玉 flameout soon after start 2 022/ ( gjfw
.............................................................................................. 22
/ 06/0 ) 王国强 06/0 )
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4.3.3 Underpower .............................................................................................................................. 22

4.3.4 Excessive fuel consumption ...................................................................................................... 23
4.3.5 Unstable rotating speed ........................................................................................................... 24
4.3.6 Low oil pressure ........................................................................................................................ 25
4.3.7 High cooling water temperature .............................................................................................. 25
国际4.3.8 Fast wearing of parts................................................................................................................
国际 26
服服
20224.3.9务(Excessive 2022 务(gjfw
gjfw noise.......................................................................................................................... 27
/ 06/0 Starter
4.3.10 /
) failure .......................................................................................................................
06/0 ) 27
1 16 1 16
4.3.11 :
Starter3underpower
1:26 : 31:2
.............................................................................................................. 28
4.3.12
6
Thorough alternator failure.................................................................................................. 28
4.3.13 Insufficient charging of alternator ....................................................................................... 29
4.3.14 Unstable charging current.................................................................................................... 29
4.3.15 Excessive charging of alternator .......................................................................................... 30
4.3.16 Abnormal noise of alternator ............................................................................................... 30
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白克勤谭利明
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Chapter 1 Structure and Performance Parameters

1.1 Outline drawing
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Fig. 1-1 Engine outline drawing 1 (intake side)
S/N Item S/N Item S/N Item S/N Item

Intake Fuel pump
1 Fuel filter 2 Alternator 3 4
manifold assembly
5 Starter
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国际国际
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2022 务(gjfw Engine outline drawing 2 2 022/ side) (g
06/0 jfw)
Fig. 1-2 (exhaust
/06/
01 1 ) 1 16 S/N
S/N 6:31
Item S/N Item S/N Item :31 Item
:26 :26
Air Oil-gas Oil cooler
1 2 Turbocharger 3 4
compressor separator cover
5 Oil filter
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国际国际
服服务
2022 务(gjfw Fig. 1-3
(g
Engine outline drawing 3 (fan end)
2022
/06/
01 1 ) of model
/ 06/0 jfw)
1.2 Designation
6:31 1 16
:26 :31:
26
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白克勤谭利明
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1.3 Main parameters
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Fig. 1-4 Engine nameplate
Please refer to the engine nameplate for engine model, power, speed, delivery number, net mass, etc.
See Tab. 1–1 for other performance parameters.
Tab. 1-1 Main engine parameters
Item Technical parameter

Engine type In-line, water cooled, four stroke, direct injection
Number of cylinders 6
国际 Cylinder bore × stroke (mm × mm) 国际 126×155

服务服务 11.596
2022 ( Displacement (L) 2022 (gjf
/06/ gjfPower
w) range (kW) /06/ 294~316w
01 1 01 1 )
6:consumption
31:2 rate (%) ≤0.2 6:31
Oil-fuel
6 :26
Rotation (viewed from free end) Clockwise (viewed in front of the free end)
Tab. 1–1 Main engine parameters (continued)
Item Technical parameter

Starting method Electric starting
Permissible trim: 10 forward/10 backward for a long time

and 30 forward/30 backward for a short time.
Allowed long-term inclination angle (°)
Permissible heeling: exhaust pipe side 45/intake pipe side 15
白克勤谭利明 for a long time; 45 forward/30 backward for a short time.
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白克勤谭利明
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Chapter 2 Installation and Operation

2.1 Unpacking
After unpacking the engine, please check it and its accessories against the Packing List, and check the
appearance and fastening condition of connectors; carry out following work afterwards:
国际1. Wipe the anti-rust coating and corrosion inhibitor, etc. 国off
际the
服服exposed parts.
2./06Fill
/01the oil) pan with appropriate grade of lubricating/0oil6/as01specified.
) Please see the
requirements for 1adding
6:31of lubricating oil specified in relevant section. 16:3
1:26
:26
3. The special coolant for Weichai Power engines is available in three kinds of freezing points: -
25°C, -35°C and -40°C. Please select the coolant with appropriate freezing point according to the local
ambient temperature. Generally, the freezing point of the selected coolant shall be 10°C below the
ambient temperature.
4. Depending on the agreement between the manufacturer and the user, if the engine has been
filled with coolant before delivery, check the behavior of coolant after unpacking. Acceptable coolant has
the freezing resistance such that it will not freeze at the temperature of -30 °C or -35 °C, the pH value of
7~8 (neutral), and the total hardness of 5°d~15°d [9°f~15°f (hardness)). If the coolant cannot meet the
above requirements, drain it off, and fill the engine with coolant containing antifreeze additive. For details
of selection of special coolant for Weichai Power, see relevant sections of this Manual.
国际For any engine, vehicle that would be stored for more than国际12 months, when start it for the first
服务服
2time:
022/ ( gjfw 2022 务(gjfw
06/0 ) /06/ )
1 the
16:engine 01Check
1
1. Check
31:2and carry out maintenance according to Tab. 2–1 6 :before
31:2start.
6 Tab. 2-1 Check before start
6
S/N Part name Check items Maintenance method
Whether there is water or rust in
1 Fuel Replace directly in case of water or rust
the fuel tank of the vehicle
Replace the gas in the gas cylinder of the
2 Gas
vehicle
Replace directly
3 Oil Whether the oil turns white
(If it turns white, check the engine thoroughly.)
4 Coolant Replace directly
5 Fuel filter element Replace directly
国际 6 Oil filter element 国际 Replace directly
服服
20272 务(gjfTurbocharger 务 ( jf in case of sticking
2022 Replace
/06/ gdirectly
Rotate the impeller to check for
/06/ w w
01 1 ) sticking
01 1 )
6:31 6:31
:26 Tab. 2-1 Check before start (continued) :26
S/N Part name Check items Maintenance method
Replace the gas pipe of gas engine directly in
Connecting hose, rubber Whether there is corrosion or
8 case of corrosion or leakage
hose and gas pipe of engine leakage at the joint
Replace directly
9 Start preheating device Whether the terminal is rusted Remove the rust
10 Alternator and starter Whether the terminal is rusted Remove the rust
Whether there is corrosion or
11 Plastic fan Replace directly
leakage
12 白克勤
Belt 谭利明 Replace directly
In case of other problems, please deal with them according to the situation on
国际 13 Others
郭祥军闫玉国际 site.
服务服
2022 (gjf 闫玉
w 2022 务(gjfw
/ 王国强 /06/are stuck;)
) for 3 ~ 5 turns to check whether the rotating parts
06/0manually
2. Crank
1 16 01 1
:31: 6:31
6 谭磊 26 20211023 :26
3. Use the starter to drive the crankshaft to rotate and repeat it for 3 ~ 5 cycles (the working time
of the starter shall not exceed 12 seconds each time, and the interval between two starts shall not be less
than 60 seconds);
4. Start and check the vehicle according to the steps specified in "maintenance for storage
vehicles or units every six months" in the above section.
国
2.2际Hoisting 国际
服服
/06/hoisting )the engine, keep the crankshaft centerline horizontal.
/ Never hoist an inclined engine
01 1 by one side. Hoist and lower the engine slowly. 06/01 1 )
When
or hoist the engine6:31 6:31
:26 :26
国际国际
服服
/06/ Fig. 2-1 Hoisting
/06/
01 1 ) 01 1 )
6:31
2.3 Installation 6:31
:26 :26
Install the engine such that the crankshaft centerline is coaxial with the input shaft of drive gears
(gearbox, transmission or generator etc.), and the crankshaft is not subject to additional axial force
produced due to installation.
2.4 Preparations before start

1. Checking the coolant level
Add engine coolant in time when it is insufficient.
To open the filler cap with pressure relief valve and ventilation button, if the engine is in a hot state,
the ventilation button must be pressed first. Never add a large amount of coolant to the engine when it is
国国际
hot; otherwise the parts may be damaged due to the violent temperature
际服 change. Start the engine, and
务服add
务
2022
add the (gjf
coolant with the engine running at 1000 r/ min. 2022
Continue to (gjcoolant
the
f
to the designated
/
position0until w /
) level is stable. At last, cover the filler cap. 06/
6/ the coolant w )
01 1 01 1
6:31 6:31
2. Checking the :2level
fuel 6 :26
If the engine has already been installed on a vehicle, turn on the power switch, check the fuel level
from the fuel gauge or check the fuel tank. The engine is equipped with a fuel system protector as
standard configuration, as shown in Fig. 2-2, which can improve the low-temperature starting
performance of the engine and ensure it start normally in a low-temperature environment of -35°C. Fuel
pumping starts when the ignition switch is turned to ON, and stops automatically after the air in the low-
pressure circuit is bled effectively. Heating starts when the diesel temperature is lower than 7°C, and
stops automatically when the diesel temperature is higher than 24°C.
白克勤谭利明
服服
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01 1 ) 01 1 )
6谭磊
:31: 6:31
26 20211023 :26 7
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
Fig. 2-2 Fuel system protector
3. Checking the oil level

The oil level shall be between the H and L marks on the oil dipstick. Fill oil from the oil filler if
necessary.
4. Checking the parts and wire connections
Check if the engine accessories are connected reliably, and eliminate any abnormalities.
Check if the starting system circuit is connected normally, and the battery is fully charged. Then open
国the际国际
fuel tank valve, loosen the bleed screw on the primary fuel filter, and exhaust the air in the fuel
服务服务
2system ( gjfw 2 (
022/ 0 2 /06/ gjfw)
with the hand pump on the primary fuel filter.
06/0 ) 2
1 16 01 1
2.5 Start :31: 6:31
26 :26
When start conditions are available, turn the electric key to start the engine. If the engine cannot be
started within (5~10) s, wait for 1 min before the next start attempt. If three successive start attempts fail,
do not start the engine until the fault has been identified and eliminated. After the engine is started, pay
attention to the instrument readings, and check and make sure that the oil pressure gauge works
normally. Do not run a cold engine at a high speed. Instead, run it at an idle speed for a period of time not
longer than 30 s. After that, check the oil pressure and water temperature.
In a cold environment, start the engine with the starting aid. Activate the electronic heater by a relay
to ensure successful start at low temperature (such as -30°C).
2.6 Running 白克勤谭利明
国际1. After the郭祥军 engine is started, 闫玉国际

run it at an idle speed for 3 min, and then accelerate it to
服务服务
2(1000~1200)( gjfw闫玉 2 ( abrupt loading or unloading
022/ 0 /06/ gjfw)
r/min. Increase the engine load and speed gradually,
2 and avoid
06/0 ) 王国强 2
1 16 01 1
:31: 6:31
8 谭磊 26 20211023 :26
as much as possible.
2. Within the running-in period of the first 50 h, it is recommended that the engine run under
medium load. The engine shall not run at low speed and low load for a long time; otherwise, it may lead
to faults like oil expelling.
3. It is allowed to run the engine continuously at rated power and speed during normal use. Prior
国
to stop,
际服国unloading.
diesel engine should run at idle speed for 1 ~ 2 min after
际服
20224. 务 (gjfparameters during normal operation are as shown
2 0 务(2-2.
g
Engine
/06/
01 1
w) 06/0 jfw)
22in/Tab.
6:31 1 16
:26
Tab. 2-2 Main engine parameters :31:
26
Parameter Normal range
(130~250) kPa (idle point)
Pressure of main lubricating oil passage
(350~550) kPa (rated point)
Main oil passage oil temperature (85~105)°C
Coolant outlet temperature (83~95)°C
Turbine downstream exhaust gas temperature ≤600°C
Intercooled intake air temperature (50~55)°C
5. Check the exhaust color to identify the operation quality and load of the fuel injector. If the
smoke color is improper, stop the engine for inspection. Check the engine for water, gas and oil leakage, if
any, stop it for troubleshooting.
国际国
服 Precautions for engine running in a cold environment: 际服务
20226. 务 (gjf 2022 (
/06/ w) /06/ gjfw)
01 Select 01 1
16:3diesel of appropriate grade according to the outdoor temperature
1) Fuel:
1:26 6:31 in winter.
:26
2) Lubricating oil: Select lubricating oil of appropriate viscosity according to different seasons.
3) Coolant: add anti-freeze into the cooling system, and determine the antifreeze grade and
mixture ratio according to the ambient temperature.
4) Start: Apply the starting aid in winter when necessary. After the diesel engine is started, do not
run it under a load or at a high speed until the oil pressure and water temperature are normal.
5) Before the cold season, check the electrolyte level, viscosity and unit voltage of battery. If the
diesel engine would not be used for a long time and would be kept at an extremely low temperature,
remove the battery and store it in a warm room.
2.7 Shutdown
国际国际
服务 stop the diesel engine, the load should be removed 服
2022Before (gjf
w 2022 and务the
(gjrotating
f w
speed should be
/ 06reduced,
gradually /01 and /
) the engine should be stopped after running at0idle
6/0speed ) several minutes. In
for
16:other 1 cut
1 6
case of runaway and 31:2 faults, the pipes of high-pressure fuel pump can be :3and
off
1:2the intake port
6 to force the diesel engine to stop.
of the air filter can be blocked 6
After stop, the electric key should be disconnected to prevent the battery current from flowing
backward into the excitation coil of the silicon rectifier alternator and avoid the battery discharging.
If the engine will rest for a long time under an atmospheric temperature below 0°C, turn on the
water drain switch and drain all coolant to prevent block cracking due to freeze. If anti-freezing solution is
added to the water, it should not be drained.
白克勤谭利明
服服
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01 1 ) 01 1 )
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:31: 6:31
26 20211023 :26 9
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
白克勤谭利明
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
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:31: 6:31
10 26 20211023 :26
Chapter 3 Maintenance
3.1 Fuel, lubricating oil, coolant, and auxiliary materials
3.1.1 Fuel
Summer: 0# diesel oil (GB252)
国际国际
服务 -10 # light diesel is generally used, but -20 # diesel 服务 be used when the operating
2022Winter:(gjf 2022should (
/ w ) of diesel engine is lower than -15℃.
06/0temperature /06/ gjfw)
environment
1 16 01 1
:31: 6:31
26
When the ambient temperature :26
is lower than -30℃, -35# diesel should be selected.
3.1.2 Lubricating oil

The criteria for engine lubricating oil selection are presented in Tab. 3-1.
Tab. 3-1 Selection criteria of special lubricating oil for Weichai Power engines
Category Grade Packing specification

Diesel engine CF-4 or above 4 L, 18 L, 170 kg
For the temperature and viscosity of engine lubricating oil, refer to Tab. 3-2.
Tab. 3-2 Oil viscosity and applicable ambient temperature
国际国际
服务 grade 服
2 grade务(g
Operating temperature Operating temperature
(
2022 Viscosity
/06/ gjfw) 022/
Viscosity
range, °C j
06/0 fw) range, °C
01 1 1 16
0W 6:31 -35~-15 10W-50
:31: -25~50
0W-20 :26 -35~20 15W-30 2-20~30
6
0W-30 -35~30 15W-40 -20~40
0W-40 -35~40 15W-50 -20~50
5W -30~-10 20W-30 -15~30
5W-20 -30~20 20W-40 -15~40
5W-30 -30~30 20W-50 -15~50
5W-40 -30~40 20 -10~20
5W-50 -30~50 30 -5~30
10W-30 -25~30 40 5~40
Tab. 3-2 Oil viscosity and applicable ambient temperature (continued)

国际国际
服务服
( grade
2022 Viscosity Operating temperature
202 grade务(gj Operating temperature
/06/ gjfw) f
Viscosity
2/06
/01 w)
range, °C range, °C
01 1 16:3
10W-40 6:31 -25~40 50
1:215~50
:2
Note: For the viscosity grade of oil6in the table, the lower the number before W, the better the low temperature
6
performance of oil; the higher the number after W, the greater the viscosity of oil; the viscosity and temperature
performance requirements of engine lubricating oil are detailed in GB11122.
1. Before starting the engine, always check the oil level in the oil pan.
2. Never check the oil level when the engine is running.
3.
白克勤谭利明
Never mix oil from other manufacturers with the special oil for Weichai Power engine.
国际The filling amount
郭祥军闫玉
of engine lubricating oil is shown in Tab.国际服
3-3.
服
2022 务(gjfw闫玉 2 0 务(g
/06/
01 1 )
王国强 2 2 / 06/0 jfw)
6谭磊 1 16
:31: :31:
26 20211023 26 11
Tab. 3-3 Filling amount of engine lubricating oil
Quantity of filter(s)
Diesel engine
Model Oiling amount (L)
Diesel filter
Oil filter
Primary filter Secondary filter
国际 WP12 25~28 2 国际 1 1
服务服务
2Note:
022/ ( gjfw 2 022/ ( g fw
The0oil
6/filling
01 amount ) given herein is for reference only. Please check the 06/0forjthe )
1)
1 6
oil dipstick
1 16actual filling amount.
: :31: with the diesel
31:2 or water separator, if installed on the vehicle, shall be replaced together
2) Weichai fuel system protector
fuel filter. 6 26
3) The number of filters given herein is for reference only. For the actual number, the actual model shall be taken as
reference.
3.1.3 Coolant
The special coolant for Weichai Power engines is available in three kinds of freezing points: -25°C, -
35°C and -40°C. Please select the coolant with appropriate freezing point according to the local ambient
temperature. Generally, the freezing point of the selected coolant shall be 10°C below the ambient
temperature. The coolant for engine is as shown in Tab. 3-4.
Tab. 3-4 Selection criteria of engine coolant
国际 Category Grade 国际 Packing specification

服务服务
2022 (gjf 2022 (
/06/ gjfw) 4 kg, 10 kg
HEC-Ⅱ-25
/ w
0 6 01 1 ) engine
/heavy-duty
Coolant for HEC-Ⅱ-35 01 1
6:31 6:31
:26 HEC-Ⅱ-40 :26
1. Be sure to check the coolant on a regular basis, and change it in time as appropriate to avoid
damage from corrosion.
2. Never change the engine coolant with water or coolant of poor quality.
3.1.4 Auxiliary materials

The auxiliary materials for the engine are shown in Tab. 3-5.
国际国际服
服
Tab. 3-5 Auxiliary materials for engine
/
S/N 06/01 ) Item Color
/06Purpose
/01 and )application
16:3 16:3
1 :26 To be applied to smooth metal1surfaces
:26 to prevent
1 Molykote Pulver Black blocking
E.g. external surface of cylinder liner
To be applied for lubrication before the pressure of
2 Molykote G-N-U. plus Dark grey lubricating oil builds up
E.g. intake valve stem
The reference for sealant application of engine is given in Tab. 3-6.

Tab. 3-6 Reference for sealant application of engine
Grade Main purpose Examples of application position Comments

白克勤谭利明 Flywheel housing bolt
To be applied onto the As an option,
国际
Weichai special 郭祥军
thread for locking and 闫玉国际
Camshaft thrust plate bolt DriLoc204 thread-
服242务 prevention of looseness due 服务
Camshaft timing gear bolt locking adhesive
2022 (gjfto闫玉 20 2 (gj
/ 06/0 wvibration,
) with medium 王国强 Intermediate2idler 6/01 fw)
/0bolt can be used for
1 16 16:3
谭磊:31: 1:
12 26 20211023 26
strength. Front end cover bolt pre-application.
Oil filter seat bolt
Oil cooler bolt
Screw plug for oil cooler regulating valve
Oil pump return pipe fixing device bolt
Air compressor shaft end thread
国际国filter bolt
Suction
际服
服务
2Weichai
022/ special(gjf To be applied onto the
w) for locking, sealing, 2022 务(gjfw
0 6 /06bolt/01 )
262 /01
thread Cylinder head auxiliary None
1 6:prevention
and 31:2 of looseness 16:3
6 1:26
Weichai special
For locking and tightening Bowl plug for oil holes None
271
Weichai special For sealing between core
Other bowl plugs None
277 and hole
Weichai special For sealing the top surface
Push rod tube - cylinder head None
270 of the cylinder head
Combination surface of cylinder block and crankcase,
front of engine block and front end cover.
Weichai special To be applied to smooth
Joint surface of cylinder block and oil filler pipe None
510 metal surfaces for sealing
Joint surface of crankshaft gear and crankshaft rear
end
Loctite 5188 To be applied to smooth Joint surface of cylinder block and oil cooler cover
国际sealant Water pump rear cover国际服 None
服 metal surfaces for sealing - front end of cylinder block
2022 务(gjfTo w)be applied to smooth 202housing 务(g
jfw)plate
2/06connecting
/0sealant
Silicone 6/01 metal
Rear end face and flywheel
/01 housing None
16:3surfaces for sealing 16:3
Flywheel housing connecting plate - flywheel
1:26 1:26
3.2 Daily maintenance
3.2.1 Daily inspection
1. Check the level of coolant, oil and fuel. Check if there is sufficient grease at greasing positions.
2. Check for leakage of fuel/oil, coolant and air;
3. Check if external parts and accessories

国际
are properly connected and tightened; 国际
服服
/06/ /06/
01 1 ) 01 1 )connections
6:31 Fig. 3-1 6:31
Checking
: 26 :26
4. Check the fan and belts for overtension or
undertension;
5. Check if the exhaust temperature, color,
sound and vibration are normal, and if the engine
speed is stable;
6. Check if the turbocharger oil inlet and
return pipes are free from blockage or leakage;
7. Check and 白克勤谭利明
make sure that the exhaust Fig. 3-2 Checking fan
manifold is not leaking and the intake manifold is
国际
unblocked. 郭祥军闫玉国际
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
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:31: 6:31
26 20211023 :26 13
3.2.2 Daily maintenance
1. Check the coolant level, and if the coolant

is not sufficient, open the filler cap for topping up.
国际国际
服务 press down the ventilation button 服
2022Always (gj 2022 务(gjfw
6/01 fthe
before/0opening w) filler cap, so as to avoid /06/
01 1 )
1 6:31when the engine is hot.
scalding by hot coolant Fig. 3-3 6:filler
Coolant 31:cap
:26 26
2. When the oil level is below the L mark or
above the H mark, never start the engine.
In such cases, fill oil through the oil filler.
Always check the oil level at least 5 min after

engine shutdown, enabling the oil to return to the Fig. 3-4 Marks of oil dipstick
oil pan.
国际3. Check the fuel level, and add fuel timely. 国际

服服
20224. 务 (gjfthat the whole engine should be 2022 务(gjfw
/06Check w) /06/
/0leakage,
free of water 1 16 air leakage and oil leakage. 01 1 )
:31: 6:31
5. Check the fan. 26
:26
Visually check fan blades for damage, and
check whether connecting bolts are properly
tightened.
Fig. 3-5 Checking fan
6. Check the belt.

The belt should be tensioned by the belt
tensioner, and the user checks the tension of the
belt by pressing the belt by hand.
国际7. Check whether the exhaust color is 国际

服服
022/ 务(gjfw)
2normal. 2022 务(gjfw
/06/
0 /0
The 6exhaust
1 16color of the diesel engine in 01 1 )
normal operation is :light
31:gray. 6:31
26 Color change should :26
be checked and eliminated.
Fig. 3-6 Check the belt
8. Check whether the sound is normal.
9. Check whether the rotating speed and
vibration are normal.
3.3 Regular maintenance interval and specification

3.3.1 Regular maintenance interval and specification
白克勤谭利明
Tab. 3-7 Three types of service conditions for automobile accessories
国际 (WGI)郭祥军闫玉国际
服 (WGII) 服 (WGIII)
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
14 26 20211023 :26
Bad service conditions (severe cold or

hot climate, high dust content, short-
distance transportation, use on
construction site, buses, municipal Vehicles with annual mileage less than Vehicles with annual mileage more than
4 4
engineering vehicles, snow sweepers 6x10 km for short and medium distance 6x10 km for long distance
and fire engines) or the annual mileage transportation (for delivery). transportation.
4
of automobiles is less than 2x10 km or
国
the annual working hours are less than
际服国际
务 600h. 服务
2022 ( 2022 (gjf
/06/ gjfw)Tab. 3-8 / 0 6 w)
/01period
01 1 First inspection, routine inspection and maintenance
16:3
6:31 1:
Condition for use
:26 (WGⅠ) (WGⅡ) 2(WGⅢ)
6
After driving 1000～1500km;
First inspection After driving 1500～2000km After driving 1500～2000km
after driving 30～50h
Routine inspection (P) Every 5000km; every 150h Every 1×104km Every 1.5×104km
Level 1 maintenance (WD1) Every 1×104km; every 300h Every 2×104km Every 3×104km
Tab. 3-9 Regular maintenance interval and specification
Level 3
国际 First Routine 国1际 Level 2 maintenanc
Level Level 4
服 Work item maintenance服
2022 务(gjfw maintenance inspection
202 务 (gj
maintenance
2/06 f e
maintenance
/06/
0of1diesel)and oil (at /01 w)
Replacement
1 6 :31: ● ● ● ● 16:3 ● ●
least once a year) 26 1: 26
Replacement of oil filter or oil filter
● Every time diesel and oil is changed
element
Checking and adjusting the valve
● ● ● ● ●
clearance.
Checking and adjusting fuel injector
● ●
opening pressure
Replacement of fuel filter element ● ● ● ●
Cleaning the primary fuel filter or
● ● ● ●
replace the filter element
Checking and topping up coolant ● ● ● ● ● ●
Replacement of coolant Refer to relevant regulations in the Manual
国Tightening
际服 of cooling pipe clamp 国际
务(g ● 服
20Tightening
22/0 intake jmanifold,
fw) hose 2022 务(gjfw
/06/ ●
6 / 0 1 connector
and flange 16:3
● ● 01 1 ) ● ●
1:the26air 6:31
Checking service indicator of :26
● ● ● ●
filter
Cleaning of dust collector of the air
filter (except for automatic de- ● ● ● ● ●
dusting type)
Cleaning of main filter element of air
When the indicator comes on
filter
Replacement of main filter element
Refer to relevant regulations in the Manual
of air filter
Replacement of safety filter element
After cleaning the main filter element for 5 times
of air filter
白克勤谭利明
Check and tightening of belt ● ● ● ● ● ●
国Checking 郭祥军
际服 turbocharger 闫玉国际
bearing
服
2022 务clearance 2022 务(gjfw
●
(gjf 闫玉
/06/ w 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
26 20211023 :26 15
Checking and adjusting the fuel

● ●
injection pump on the test bench
Checking and adjusting clutch stroke
● ● ● ● ● ●
and wire rope condition
Adjusting idle speed ●
国3.4际Cleaning, protection and handling 国际

服务服
23.4.1 ( gjfw and protection
022/ Cleaning 2022 务(gjfw
) /06/
06/0
1 16 01 1 )
: 31engine, 6:31with anti-rust oil.
1. Warm up the :26 drain the oil away, clean the oil filter, and fill the engine :26
2. Empty the fuel tank, and then fill in the tank with anti-rust oil mixture.
3. Empty the radiator and then fill in it with coolant containing anti-rust agent.
4. Start the engine, and run it at idle speed for (15~25) min;
5. Drain off oil, fuel, and coolant.
6. Preserve other parts of the engine.
3.4.2 Protection during storage

Block inlets and outlets of fuel, oil, gas and coolant by caps or plastic cloth; seal up the whole engine
国
with VCI
际服 film. 国际服
022/ 务
23.4.3 ( g j 2 0 务(g
Oil
06/0 sealf w ) 2 2 / 06/0 jfw)
1 16 1 16
The seal period :of31the
:2diesel :3shall
engine is 1 year, and the engine outside this period 1:2be
as follows:
6 6 sealed again
1. The engine shall be sealed in a clean environment. The engine and parts shall be thoroughly
cleaned without corrosion, oil stain and dust before oil sealing.
2. The engine can be sealed by immersion, spraying, coating or filling method as appropriate.
3. Sealed parts: turbocharger air inlet/outlet, air compressor inlet, and intake manifold orifice.
3.4.4 Handling
Pack the engine for handling where appropriate.
国3.5 Description of maintenance at all levels 国际

际服服
022/ 务
23.5.1 Oil(gchange 2022 务(gjfw
06/0 jfw) /06/
01 1 )
1 16 6:31
:31: :26
26
1. Unscrew the drain plug at the bottom of
oil pan to drain out oil, and then screw the drain
plug back.
2. Open the oil filler cap to fill oil through
the oil filler. Observe the scale mark of the oil
dipstick till the required level is reached. Then, refit
the oil filler cap.
白克勤谭利明 Fig. 3-7 Oil drain plug and oil filler
3.5.2 服 Replacement of oil filter or filter element 服
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
16 26 20211023 :26
1. Remove the old oil filter;

2. Fill the new filter with clean oil;
3. Apply oil to the rubber pad before installing the new oil filter;
4. After the rubber pad touches the base, tighten it for 3/4 ~ 1 turn for sealing.
国际5. Start the diesel engine to check for oil leakage. 国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:2oil6 filter element may bring about early wear of crankshaft
Unqualified diesel or :26 and lead
bushing,
to excessive emission.
3.5.3 Replacement of fuel filter and its element

Replacement of fuel filter element
Replace the fuel filter element by the following steps:
1. Remove the old fuel filter element. If the water cup installed on the primary fuel filter can be
reused, remove the water cup.
2. Lubricate the seal.
国际3. Screw on the filter by hand until the seal properly fits国 the connector.
际服
服
20224. 务 (gjf to screw the filter until it is installed firmly (by
Continue
w) 2 0 2about
务 g
2/063/4(turns).
jfw)
/06/ /
0 1 air
16until 0 1 16
5. Bleed :31no bubbles appear.
:26 :31:
26
6. Carry out a leakage test.
Exhaust from primary fuel filter
To replace the spinning primary fuel filter or re-install the fuel delivery pipe, it is necessary to
exhaust the primary fuel filter.
Exhaust the primary fuel filter by the following steps:
1. Shut down the engine.
国际2. Remove the bleed bolt. 国际

服服务
20223. 务 ( ghand
jfwpump (gbolt.
2022the bleed jf
/06Use
/01 )
to pump air until only fuel flows out from
/ 0 6 /01 w)
16:the
4. Re-tighten 31:bleed bolt. See Fig. 3-8. 16:3
26 1:26
白克勤谭利明
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
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:31: 6:31
26 20211023 :26 17
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
Fig. 3-8 Exhaust from primary fuel filter
Discharging from water cup
When the water cup is full or the spinning filter is replaced, the water collected needs to be
国际服国际
服
discharged.
/ ) in water cup by the following steps: /06/
06/0 the water
1 16
Discharge 01 1 )
:31: 6:31
:2as6shown in Fig.
26plug at the bottom of the water cup to discharge the water,
1. Open the oil drain
3-9.
2. Re-tighten the oil drain plug.
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
Fig. 3-9 Draining water from cup
Replacement of water cup

白克勤
Replace the water 谭利明
cup by the following steps:
国际1. Shut the 郭祥军

engine down. 闫玉国际
服务服
(gjf 闫玉
20222. Discharge
w the water from the cup. 2022 务(gjfw
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
18 26 20211023 :26
3. If possible, remove the water cup by hand, as shown in Fig. 3-10. If it is too tight, use the
installer and remover in the new water cup kit.
4. Lubricate the sealing ring of the new water cup with a few drops of oil.
5. Install the water cup by hand and tighten it with tools.
6. If the water cup is reused on a new spinning filter, check whether it is damaged.
国际国
服 Install with a torque wrench with a torque of 20 N·m. 际服务
20227. 务 (gjf 2022 (
/06/ w) /06/ gjfw)
01 1 01 1
6:31 6:31
:26 :26
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
Fig. 3-10 Replacement of water cup
3.5.4 Checking air seal

Check whether the intake hose is cracked due to aging and whether the clamp gets loosened. Fasten
or replace parts if necessary to ensure the tightness of the air intake system.
3.5.5 Checking air filter element

国际国际
服 max permissible intake resistance of the engine is 6 kPa, and服务 be checked when the engine
2022The 务 (gjf
w
(gjf
2022 it shall w) is reached, clean or
/ 6/01speed)and full load. When this max. permissible intake
runs at 0rated /06/resistance
1
replace the air filter6element
0 1 1
:31: as specified by the manufacturer. 6:31
26 :26
Never run the engine without an air filter; otherwise, dust and foreign matters may enter the
engine to cause premature engine wear!
Remove the air filter element from the filter,

and tap its end face to shake off the dust, or blow its
白克勤air from inside谭利明
end face with compressed to outside.
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
26 20211023 :26 19
Fig. 3-11 Blowback with compressed air
Non-conforming air filter elements may result in serious faults such as abnormal blockage during
DPF after-treatment, excessive emission and DPF damage!
国际国际
服务服
23.5.6
022/ (
Maintenance
gjfw of oil-gas separator 2022 务(gjfw
) /06
06/0
1. Open1 the
16upper 01 1 )
cover of oil-gas separator and take out the filter/element.
:31: 6:31
26 :26
2. Check the adhesive on both ends of the filter element. If there is any crack, please replace the
filter element.
3. Clean the dirt on the filter element surface in light diesel or gasoline.
4. Check the sealing ring of the filter element and the upper cover. If the sealing ring has aged and
hardened, replace it.
5. Press the filter element into the housing and screw on the upper cover.
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
Fig. 3-12 Oil-gas separator
白克勤谭利明
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
20 26 20211023 :26
Chapter 4 Typical Faults and Troubleshooting

4.1 Overview
4.1.1 Overview
Engines of this series are designed and manufactured under a strict quality assurance system, and
国际been 国际engine is a precise machinery whose
have 服务subject to specified tests before delivery. Moreover, the 服务
2lasting ( gjfw
022/good performance 2022 The (gjf failure of engine is
/01 w)
is related closely to proper maintenance. / premature
0 6 )
/01 from:
generally resulted
0 6
16:3 16:3
1:26 1:26
1. Operation against regulations; improper management and misuse;
2. Failure to maintain the engine as specified, and more serious, replacement of maintenance with
repair;
3. Use of defective spare parts, or even counterfeit and shoddy parts due to their cheap price,
which will dramatically shorten the engine service life;
4. Use of fuel and lubricating oil with improper grade or poor quality.
1. The engine troubleshooting is a complicated work. Thus, do not disassemble or remove the
国际 at discretion before determining its basic fault cause; otherwise,
engine 国际 the fault will not be eliminated,
服务
and even more serious fault may occur due to improper refitting. 服务
2022 ( 2022 (
/06/ gjfw) /06/ gjfw)
2. Key 01components 01 and
16:3 of the engine such as the high-pressure fuel pump 16:turbocharger shall be
maintained and inspected 31:Therefore,
1:26by special apparatus and based on certain experience. 26 users
having no relevant experience and equipment are not allowed to remove or adjust the engine without
permission.
4.2 Diagnostic method

4.2.1 Traditional fault diagnostic methods
1. Observation: Determine the fault by

observing the symptom of diesel engine, like smoke.
国际国际Fig. 4-1 Observation

服服
/0 / /06/
01 1 )Determine the fault location,
2. 6Listening: 01 1 )
6:3by
1:listening 6:31
symptom and severity 26 to the abnormal :26
noise of diesel engine.
3. Comparison: Replace a certain assembly
or component to determine whether it is faulty. Fig. 4-2 Listening
4.3 Typical faults and troubleshooting

4.3.1 Engine start failure
Step Check points Check methods
白克勤谭利明
Fuel passages such as
fuel inlet filter screen or Check and remove the dirt and check the cleanliness of
国际Step 1 ... 郭祥军
hose of fuel supply 闫玉
...
fuel. 国际
服务服
2022 (gjf 闫玉pump are blocked. 王国强
w 2022 务(gjfw
/06/ /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
26 20211023 : 26 21
There is air in the fuel Bleed air. Check the tightness of the joint, and repair if
Step 2 ... ...
system. necessary.
Check the plunger and fuel outlet valve, and repair or

Step 3 ... The fuel pump is faulty. ...
replace damaged parts.
国际国际
服务服务
2/406 (gj...fw) The
202Step fuel injector is
2/06 (gofjthe
202atomization f fuel injector.
/01 w)
... Check the
/01 faulty.
16:3 16:3
1:26 1:26
... The valve train or fuel
Step 5 supply pipe is damaged ... Check and adjust.
and leaks.
The high-pressure fuel

Step 6 ... pipe is damaged and ... Repair and replace.
leaky.
The cylinder
Check the valve sealing, cylinder gasket sealing, and
Step 7 ... compression pressure is ...
piston ring for wear, and repair or replace them.
insufficient.
国际国际
服 8 务( ...
服
2 assist务equipment
The temperature is too
202Step g j ...
022/
Add starting (g or measures.
2/06
/01 w)
f low.
06/0 jfw)
1 16
4.3.2 Engine1flameout
6:31
:26 soon after start :31:
26
... Disassemble the filter, remove internal contaminates
Step 1 The fuel filter is blocked. ... and moisture, and replace the filter element if
necessary.
... Check the tightness of fuel pipes and joints, and check
There is air entering the
Step 2 ... whether the air bleed screws are tightened. Bleed the
fuel system.
air in the pipes.
The fuel supply pump

Step 3 ... ... The fuel supply pump does not work
does not work
国际国际
服服
2022 务(gj...fw The fuel is of poor quality 2022 务(gjfw
/
Step 406/01 ) and contains too much / 6/replace the) fuel.
Clean the filter0and
16:3moisture.
... 01 1
1:26 6:31
:26
Step 5 ... The idle speed is too low. ... Readjust.
4.3.3 Underpower
The air intake (air filter) Check the air filter and intake pipe. Clean or replace
Step 1 ... ...
is blocked. the filter element.
The exhaust back Check the valve timing and check whether the exhaust
Step 2 ... ...
白克勤
pressure is too high.谭利明 pipe is blocked. Make adjustment and fix the problem.
服3 务 ... The booster system is ... 服务leakage at pipeline joint.
202Step (
2/06 gjfw闫玉
Check 2
and eliminate
022/ (
g
06/0 jfw)
underpressure.
王国强
/01 ) 1 16
16:3 :31:
22 谭磊1:26 20211023 26
1) Blockage of compressor and turbine

passages—clean or replace.
The turbocharger does 2) Failure of floating bearing—replace.
Step 4 ... ...
not function properly. 3) Carbon deposit and oil sludge at the
clearance on the back of turbine and compressor—
clean.
国际国际
服服
2022 务(gjfw The intercooler is 2022 务(gjfw
/05 6/ ... ) /06/
Step 01 1 damaged and leaky ... Replace or repair. 01 1 )
6:31 6:31
:26 :26
Check the tightness of fuel pipes and pipe joints, the
The fuel pipeline is leaky filter contamination and fuel pipe. Repair or remove
...
or blocked. the contamination or blockage, and replace the filter
Step 6 ... element.
The fuel is of poor Clean the fuel tank, filter parts and fuel pipes, and
Step 7 ... ...
quality. replace the fuel.
The fuel pump is

Step 8 ... ... Repair or replace.
excessively worn.
国际 The atomization of the Check 国the 际

injection pressure and carbon deposit on the
服9 服 repair.
2022 务(gjfw fuel injector is not good. nozzle;2adjust and务
Step ... ...
022/ (g
/06/
01 1 ) 06/0 jfw)
6:31The timing of air 1 16
:26 :31:
Step 10 ... distribution or fuel ... Check and adjust.
26
supply is incorrect.
... High-speed regulation of

the speed regulation
Step 11 ... Check the speed regulation characteristics and adjust.
characteristics is
excessively low.
The oil level in the oil pan

Step 12 ... ... Check the dipstick and drain the excess oil.
is too high.
The cylinder gasket is Check the compression pressure and replace the
国Step
际服 13 ...
leaky.
... 国cylinder
damaged 际服 gasket during warming-up.
/06/ /06/
01 ...1 ) The piston ring is worn 01 1 )
6:31 6: 1
:2broken,
and 6 and the Replace worn parts, or carry out 3 :26 of the
overhaul
Step 14 ...
bearing bush clearance is engine.
too large.
The cylinder liner or

Replace worn parts, or carry out overhaul of the
Step 15 ... piston is worn or ...
engine.
scratches the cylinder.
4.3.4 Excessive fuel consumption

...白克勤谭利明
The intake pipe is
Step 1 ... Check the air filter and intake pipeline, and clean.
blocked.
服务服
202Step (
2/06 gjfw闫玉
2 ... The exhaust back ... Check 2 02exhaust务
the
2/06 (gj and brake valve, and clean.
pipeline
f
/01 ) 王国强
/01 w)
16:3 16:3
谭磊1:26 20211023 1: 26 23
pressure is too high.
The fuel is of poor

Step 3 ... ... Replace the fuel as required.
quality.
The fuel pipeline is

Step 4 ... ... Check and repair.
国际 blocked. 国际
服务服
2022 ( 2022 务(gjfw
/06/ gjfw) The fuel pipeline is /06/
01 1... 01 1 )
Step 5 6:31leaky. ... Check and repair. 6:31
:26 :26
The atomization of the
Step 6 ... ... Check, and adjust or repair.
fuel injector is poor.
Step 7 ... The timing of air

Adjust the valve clearance and fuel supply advance
distribution or fuel ...
angle according to regulations.
supply is incorrect.
The cylinder gasket is

Step 8 ... ... Check the compression pressure.
leaky.
国际Step 9 ... The clearance of bearing 国际

服务 bush is too large, and 服务(g
2022 ( Check 2
/06/ gjfw) the engine requires 0 overhaul.
22/0 j
... and
f
01 1 overhaul. 6 /01 w)
6:31 16:3
:26 1: 26
The piston expands and
Step 10 ... ... Replace the cylinder liner, piston and piston ring.
is stuck in the cylinder.
The booster system is

Step 11 ... ... Check and eliminate leakage at pipeline joints.
underpressure.
The turbocharger does

Step 12 ... ... Check and replace.
not function properly.
The intercooler is
Step 13 ... ... Replace or repair.
damaged or leaky.
国际国际
服 Unstable rotating speed 服
022/ 务
24.3.5 (g 2022 务(gjfw
06/0 jfw) /06/ )
01 methods
Step 1 16 16:3
:31: Check points Check
1 :26
The2fuel
6 is of poor
Step 1 ... quality and contains ... Replace the fuel.
moisture or wax.
Air enters the fuel Check the tightness of fuel pipes and joints, and bleed
Step 2 ... ...
suction pipe. the air.
... The governor weight

and speed regulating
Step 3 ... Check and adjust (by fuel pump manufacturer).
spring are not working
properly
白克勤谭利明
国Step
际服 4 ... 郭祥军闫玉...
Fuel supply is uneven. Check 国
and际
adjust (by fuel pump manufacturer).
服
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
24 26 20211023 : 26
The atomization of fuel

Step 5 ... ... Check and repair.
injector is unstable.
... Check and clean the compressor passage, eliminate

The turbocharger
Step 6 ... blockage, and remove the carbon deposit in the
vibrates.
exhaust gas passage.
国际国际
服务服务
22/70 (gj...fw) bearing is damaged. 2/06 (gjfw)
The turbocharger
20Step ... 202
Replacement
6/01 /01
16:3 16:3
4.3.6 1:26
Low oil pressure 1: 26
The oil level of oil pan is
Check the oil level and whether there is oil leakage, and
Step 1 ... too low or the pan is ...
add oil.
short of oil.
... The pressure regulating

Step 2 valve of the main oil ... Check the valve, clean and repair it.
passage is faulty
Is the suction filter, oil Check and clean the compressor passage, eliminate
Step 3 ... pipeline and joint gasket ... blockage, and remove the carbon deposit in the
国际国gas际passage.
服 blocked or broken. exhaust
服
/06/ /06/
01 ...1 ) The oil grade is not in 01 1 )
6:31conformity with 6:31 and select oil of
Replace oil according to regulations,
Step 4 :26 ...
appropriate grade. :26
regulations.
The inlet pipe of the oil Check the oil pipes and joints, and repair or replace
Step 5 ... ...
pump is leaky. them.
The water temperature

of the cooling system is
Check the operation of the cooling system, and correct
Step 6 ... too high, and the oil ...
it if necessary.
temperature is also too
high.
The resistance of oil

国Step
际服 7 ... ... 国the际filter element with a new one.
Replace
filter is excessive. 服
/06/ /06/
01 ...1 ) The oil cooler is blocked. 01 1 )
Step 8 6:31 ... Check and clean. 6:31
:26 : 26
The main oil passage is
Step 9 ... ... Check and clean.
blocked.
The bearing bush

clearance is too large, or
Step 10 ... ... Check and replace.
the bearing bush is
damaged.
The part is excessively

Check the working condition of the engine, and
Step 11 ... 白克勤谭利明
worn and needs to be ...
overhaul it.
overhauled.
服务服
24.3.7
022/
High
( g cooling water temperature 2022 务(gjfw
06/0 jfw闫玉 ) 王国强 /06/
01 1 )
1 16 6:31
:31:
谭磊 :26
26 20211023
25

The water level in the
Step 1 ... ... Check for leaks and add water.
water tank is too low.
Step 2 ... The water tank is blocked. ... Check the water tank, and clean or repair it.
国际国际
服 3 务
The water pump belt is
服务
202Step ( ...
2/06 gjfw) slack.
... Adjust the tension
2022 according to regulations.
(g
/01 / 06/0 jfw)
16 1 16
... :31 :2water :31:
26
Step 4 The
6 pump gasket is
damaged and the water ... Check, and repair or replace.
pump impeller is worn.
Step 5 ... The thermostat is faulty. ... Replace.
... The water pipe is

Check water pipes, joints, gaskets, etc., and replace the
Step 6 damaged, and air enters ...
damaged parts.
the pipe.
The oil level of the oil pan

Check the oil level and oil leakage. Repair the damaged
Step 7 ... is too low or the pan is ...
part and add oil.
国际 short of oil.
国际
服服
022/ 务
24.3.8 (gjwearing
f 2022 务(gjfw
06Fast
/01 w)
of parts /06/
01 1 )
16:3 6:31
Step 1:26Check points Check methods
:26
The air filter element is
Check and replace the filter element with one of
Step 1 ... of unacceptable quality ...
acceptable quality.
or is damaged.
The intake system is Check the intake pipe, gasket and connecting pipe
Step 2 ... ...
short circuited. sleeve, and repair or replace as necessary.
The oil level of oil pan is

Check the oil level and oil leakage. Repair the damaged
Step 3 ... too low or the pan is ...
part and add oil.
short of oil.
The oil passage is

国际Step 4 ... ... 国oil
Clean the 际passage.
服 blocked. 服
/06/ /06/
01 1 ) The oil grade is not in 01 1 )
6:31 6:31
Step 5 ... :26 with
conformity ... Change the oil as required. : 26
regulations.
Piston rings are broken

Step 6 ... ... Replace damaged parts.
or worn.
The cylinder liner or

Disassemble and check the piston and cylinder liner.
Step 7 ... piston is worn or ...
Repair or replace as necessary.
白克勤
The oil filter element谭利明
Step 8 ... was not replaced in ... Replace as required.
国际郭祥军
time. 闫玉国际
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31 6:31
26 :26 20211023 :26
The part is excessively

Step 9 ... worn and needs to be ... Check the mileage and schedule overhaul.
overhauled.
The crankshaft is not

Step 10 ... concentric with the ... Check the mounting bracket and repair it.
driven shaft
国际国际
服服
2022 务(gjfw The quality of oil used 2022 务(gjfw
/06 ) /06/
Step 11 /01 ...1 01 1to)standards.
6:31does not meet the ... Use oil of grade conforming
6:31
:26
requirements :26
4.3.9 Excessive noise
The fuel is of poor
Step 1 ... ... Replace the fuel.
quality.
The cooling water

Step 2 ... ... Check the thermostat and replace it if necessary.
temperature is too low.
The timing of air

Step 3 ... distribution or fuel ... Check, repair and adjust.
国际国际
服 supply is incorrect.
服
/06/ /06/
01 1 ) The atomization of the 01 )
Step 4 ... 6:3 ... Check, repair and adjust. 16:3
1fuel
:2injector
6 is not good. 1 :26
The fuel quantity of fuel Check and adjust (adjusted by fuel pump
Step 5 ... ...
pump is too large. manufacturer).
... Check for damage and check the connecting bolts.

Step 6 The damper is worn. ...
Replace the damaged parts.
The valve is leaky or Disassemble and check the valve, and make adjustment
Step 7 ... ...
improperly adjusted. accordingly.
The gear clearance is too

国Step
际服 8 ... large or the gear tooth is ... Check 国
and际
replace the damaged parts.
服
2022 务(gjfw broken. 2022 务(gjfw
/06/ /06/
01 1 ) 01 1 )
... 6:31 :2cylinder liner or
6:31
:
Step 9
The
piston6is worn or ... Check, and repair or replace.
26
The push rod is bent or

Step 10 ... ... Replace.
broken.
Piston rings are broken

Step 11 ... ... Check or replace the damaged parts.
or worn.
4.3.10 Starter failure

白克勤谭利明
国Step
际服郭祥军
The battery is 闫玉国际服
2022 务(gjfw闫玉undercharged. 2022 务(gjfw
1 ... ... Check, charge or replace the battery.
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
26 20211023 : 26 27
The connecting
Step 2 ... wires are poorly ... Ravel out the wires and tighten the terminal.
connected.
Step 3 ... The fuse is blown. ... Replace the fuse.

国际国际
服务服务
22/40 (gj...fw) The
20Step brush is of 20brush (gj
22/0surface
6/01 poor contact.
... Clean the
6/01or freplace
w) the brush.
16:3 16:3
1:26 1:26
The starter motor
Step 5 ... ... Check and repair the motor, or replace the assembly.
is short-circuited.
4.3.11 Starter underpower

The battery is
Step 1 ... ... Charge or replace the battery.
undercharged.
The bearing
Step 2 ... ... Replace the assembly.
bushing is worn.
国际国际服surface or replace the brush.

Step服
The brush is of
2022 务(gjfw poor contact. 务
3 ... ... Clean the brush
2022 (g
/06/
01 1 )
/ 06/0 jfw)
6:31The commutator 1 16
:26 Remove the oil stains and grind:the
31surface
:26 with sand
Step 4 ... ...
is dirty or singed. paper, or replace the assembly.
Welding failure
Step 5 ... occurs at the end ... Re-weld.
of wire.
The switch is of
Step 6 ... ... Check the switch and repair it.
poor contact.
The worn clutch Adjust the clutch operating torque, or replace the
Step 7 ... ...
slips. assembly.
国际服 Thorough alternator failure 国际
4.3.12 服
/ ) /06/Check methods
Step 06/01 Check points
16:3 The connecting wire is 01 1 )
1:26 6:31
:26 and fix
Check the wiring of alternator and ammeter,
Step 1 ... open or short circuited. ...
the problems found.
The joint is loose.
Rotor and stator coils

Step 2 ... Open circuit, short ... Repair or replace the assembly.
circuit or ground
The rectifying tube is

Step 3 ... ... Replace the assembly.
damaged.
白克勤谭利明
The terminal paper
国Step
际服 4
insulation is damaged,
... 郭祥军闫玉... Repair.国际
务服
2022 务(gjfw
and the wire is
2022 (gjf 闫玉disconnected.
/06/ w 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
28 26 20211023 : 26
The regulator has an

Step 5 ... excessively low ... Repair.
regulating voltage.
The regulator contacts

Step 6 ... ... Repair or replace the assembly.
国际 are melted.
国际
服服
022/ 务
24.3.13 (gjf 2022 务(gjfw
06Insufficient
/01 w)
charging of alternator /06/
01 1 )
16:3 6:31
Step 1:26Check points Check methods
:26
The connecting wire is
Step 1 ... open or short circuited. ... Repair it.
The joint is loose.
The rotor and stator

Step 2 ... coils are open, short- ... Repair or replace the assembly.
circuited or grounded.
The alternator belt is

Step 3 ... ... Check and adjust the belt tension.
slack.
国际 The rectifying tube of

国际
服 4 务服
022/ 务(gjfw)
alternator is damaged,
22/0 (gjfw) and the battery has
20Step ... ... Repair.2
6/01 06/0
16:3
poor contact. 1 16
1:26 :31 :26
The regulator voltage is
Step 5 ... adjusted to an excessive ... Adjust.
low.
The regulator field coil

Step 6 ... or the resistor wire is ... Repair or replace.
disconnected.
The battery contains

Step 7 ... insufficient electrolyte ... Add electrolyte or replace the battery.
or is obsolete.
国际服 Unstable charging current

4.3.14 国际
服
/06/ /06/Check methods
Step
01 1 ) Check points
01 1 )
6:31The stator or rotor coil is 6:31
Step 1 ...
:26to be open or
about ... Repair or replace.
:26
short circuited.
The brush is of poor

Step 2 ... ... Repair.
contact.
... The terminal is loose

Step 3 ... Repair.
and is in poor contact.
The voltage regulator is

Step 4 ... 白克勤
damaged. 谭利明
... Repair.
服 5 务(gj...
服
0 adjust.务(gj
The voltage regulation is
20Step
22/0 ... Check 2
22/0
and
6/01 fw闫玉
) improper. 王国强 6 f
/01 w)
16:3 16:3
谭磊1:26 20211023 1: 26 29
4.3.15 Excessive charging of alternator

The battery is internally
short circuited.
国际Step 2
The regulator voltage is
Repair国
and际
服务 ... ... adjust.
服
2022 务(gjfw
too high.
2022 (gjf
/06/ w /06/
01 1 ) The regulator is 01 1 )
6:31 6:31
Step 3 ... :26 grounded.
improperly
... Repair. : 26
... The regulator contact is

inoperative or dirty, and
Step 4 the voltage coil or ... Repair or replace.
resistor wire is
disconnected.
4.3.16 Abnormal noise of alternator

The alternator is
Step 1 ... ... Repair.
improperly installed.
国际国际
服务服务
22/20 (gj...fw) The bearing is damaged.
20Step ... 20the22bearing.
Replace (
/06/ gjfw)
6/01 01 1
16:3 6:31
... 1The
:2rotating
6 part has :26
Step 3 ... Repair or replace.
touched the fixed part.
The rectifier is short

Step 4 ... ... Replace.
circuited.
The stator coil is short

circuited.
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
白克勤谭利明
服服
/06/ 王国强 /06/
01 1 ) 01 1 )
6谭磊
:31: 6:31
30 26 20211023 :26
Contact Us
国Weichai
际服Power Co., Ltd. 国际
务服
2Address: (
022/ 197A,gEast
j f w 2022 务 (gjf
) /01 w)
/06China
06/0 Fushou Street, High-Tech Zone, Weifang, Shandong,
1 16 16:3
Postcode: 261061 :31: 1:26
26
Website: http://www. weichai.com
Free service or complaint hotline: 400-6183066
Customer service hotline: 0536-8235369 (Fax)
国际国际
服服
/06/ /06/
01 1 ) 01 1 )
6:31 6:31
:26 :26
Service Butler
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Weichai Power Co., Ltd.

Address: Building A, No. 197, East Fushou Street, High-Tech Industry Development Zone, Weifang,
Shandong, China
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服 261061 服
022/ 务
2Postcode: (g 2022 务(gjfw
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1 16
Tel.: 0536-8197777 6:31
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Fax: 0536-8231074
E-mail: weichai@weichai.com
Website: http://www.weichai.com
Service hotline: 400-6183066
白克勤谭利明
This document is for
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郭祥军闫玉parameters or pictures
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The actual product shall prevail.
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WP12四气门国二系列车用保养说明书英文

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WP12四气门国二系列车用保养说明书英文

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国际 国际

Operation and Maintenance Manual of WP12

WP12 Four-Valve China II/Euro II Diesel Engine for Vehicles

♦ Before operation, please carefully read this Manual,

Do not touch high-speed rotating parts with

♦ Do not loosen or remove the main bearing bolt or the

♦ Always fill the engine with the oil or fuel of grade

♦ Before running a new engine, subject it to

♦ Please have the diesel engine disassembled and

！ Please read this Manual before operation

Please pay attention to followings before maintenance and repair:

4.3.3 Underpower .............................................................................................................................. 22

Chapter 1 Structure and Performance Parameters

S/N Item S/N Item S/N Item S/N Item

1.3 Main parameters

Item Technical parameter

国际 Cylinder bore × stroke (mm × mm) 国际 126×155

Tab. 1–1 Main engine parameters (continued)

Item Technical parameter

Permissible trim: 10 forward/10 backward for a long time

Chapter 2 Installation and Operation

2.4 Preparations before start

Fig. 2-2 Fuel system protector

3. Checking the oil level

2.6 Running 白克勤 谭利明

国际1. After the郭祥军 engine is started, 闫玉 国际

3.1.2 Lubricating oil

Category Grade Packing specification

Tab. 3-2 Oil viscosity and applicable ambient temperature (continued)

Tab. 3-3 Filling amount of engine lubricating oil

国际 Category Grade 国际 Packing specification

3.1.4 Auxiliary materials

The reference for sealant application of engine is given in Tab. 3-6.

Grade Main purpose Examples of application position Comments

3. Check if external parts and accessories

3.2.2 Daily maintenance

1. Check the coolant level, and if the coolant

Always check the oil level at least 5 min after

国际3. Check the fuel level, and add fuel timely. 国际

6. Check the belt.

国际7. Check whether the exhaust color is 国际

3.3 Regular maintenance interval and specification

Bad service conditions (severe cold or

Tab. 3-9 Regular maintenance interval and specification

Checking and adjusting the fuel

国3.4际Cleaning, protection and handling 国际

3.4.2 Protection during storage

国3.5 Description of maintenance at all levels 国际

1. Remove the old oil filter;

3.5.3 Replacement of fuel filter and its element

国际2. Remove the bleed bolt. 国际

Fig. 3-8 Exhaust from primary fuel filter

Discharging from water cup

Fig. 3-9 Draining water from cup

Replacement of water cup

国际1. Shut the 郭祥军

Fig. 3-10 Replacement of water cup

3.5.4 Checking air seal

3.5.5 Checking air filter element

Remove the air filter element from the filter,

Fig. 3-11 Blowback with compressed air

Chapter 4 Typical Faults and Troubleshooting

4.2 Diagnostic method

1. Observation: Determine the fault by

国际国际

2.6 Running 白克勤谭利明

国际1. After the郭祥军 engine is started, 闫玉国际

国际国际Fig. 4-1 Observation

国际国际服surface or replace the brush.

国际服 Unstable charging current