WP9H、WP10H、WP10 5H发动机保养说明书-英文

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Operation and Maintenance Manual of
WP9H/WP10H Series Euro IV/V Vehicle Diesel
Engine
王明王明
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王训伟宋安泽
王明
亮 Weichai于千钧 Power Co., 王明Ltd.
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“1004878471 - WP9HWP10H欧Ⅳ欧V系列车用柴油机使用保养说明书-EN, B”ECN_495982
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Operation and Maintenance Manual of WP9H/WP10H Series Euro IV/V Vehicle Diesel Engines
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WP9H/WP10H Series Euro IV/V Vehicle Diesel Engine (truck)
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Foreword
WP9H/WP10H Euro IV/V series diesel engines are developed independently by Weichai Power Co., Ltd.,
and it boasts many advantages such as compact structure, outstanding performances including reliable
王明 strong power and good economy, as well as fast start,
王easy
明亮operation and maintenance.
running, 亮
2023 (应用工 2023 (应用工
/ /11/
程中 basic information and operation and maintenance
11/mainly
This Manual 13 1 includes 心 ) 13 1 程中心 of the engine.
methods
3 :
To make the engine serve13:you ( w angplease
41 better,
3 : 13:4 )in(wdetails,
ming thoroughly understand the engine structure angm and
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l i 1 iang
master the maintenance and operation methods.ang01 01)
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With the increasing variants and continuous improvement of the series engine, all changes with this
manual will be made without further notice. Please access http://www.weichai.com to obtain the latest
product information. Weichai Power Co., Ltd. is authorized to carry out the after-sales service of this
product.
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Dear users:
Thank you for your trust in our company and choosing our products!
To use and maintain the engine properly, please read this manual carefully and operate in strict
王
accordance
明亮
with relevant provisions. 王明亮
(应用 (
2 0 2 /11/ 工程中
Service3commitment: 2 0 23/1 应用工程
13 1 心)( 1/13 中
3 : w
13:4occur, aplease
n 13:1 心)(wan
If any engine failure should 1 gmincontact with Weichai call center at 3:41 as soon
400-6183066 gminas
glia glia
ng0arrive
possible. We promise that the service personal will 1) at the site to provide fast, high quality and ng01
)
attentive service according to the related requirements within 3 hours for the city that our authorized
service center is located in, within 24 hours for the general area, and within 48 hours for the remote area.
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 specified operation and
maintenance regulations, and pay attention to
王warning
明 instructions and warning signs. 王明
亮亮
2023 (应用工 2023 (应用工
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13 1 程中心)(
Failure the中instructions in this manual will
13 1 心 ) (
3:1commitmentsw 3:13
affect the warranty 3:41 angmin for the engine!
glia :41 wangming
ng01 lian
 As the engine has been tested in strict accordance ) g01)
Please refer to this Manual
with the test specifications before delivery, it is not
allowed to adjust the fuel injection pump or ECU
randomly.
 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 turbocharger when the
王engine
明
is running, so as to avoid personal injury or
王明
亮(应亮
20engine
2
damage. Do not disassemble the rotor
用 2023 (应用工
3 / 11/1 工程中
component.
心 Do/not
11touch 程中 rotating part with hands
/13 the high-speed
3 13
:13: )(wangm 13:1 心)(wan
41the main bearing
ingl bolt or the 3:41 gmin
 Do not loosen or remove
iang glia
01)
connecting rod bolt of the engine without permission
ng01)
as they are subject to strict torque and rotation
requirements.
Tightening torque requirement

王训伟宋安泽
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 The grades of oil and fuel used for the engine must
meet the requirements of this manual and must be
filtered through special clean filter. The fuel should
also be deposited for more than 72h before filling.
王Before
明亮
engine starting, be sure that the coolant and oil 王明
( 亮
23 1 应用工程
20are added as required. Please fill the engine with fuel 2023 (应用工
and / oil 1specified
/13 in this 中 Manual at an authorized filling /11/
13 1 程中心)(
13:1 心)(wan 3:13 wang
station. 3:41 gmin :41chapter m ng
glia Please refer to the relevant in thisiManual
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 Before running a new engine, 50h test running ng0shall ang0
1) 1)
be performed.
 It is prohibited to run the diesel engine without air
filter.
 After starting a cold engine, increase the engine
speed slowly rather than abruptly, and do not run it at
idle speed for a long time.
 Regularly check the coolant, and never replace the
engine coolant with water or coolant with poor quality.
王Please
明亮 select the coolant with correct grade in 王明
( with the requirements of this Manual. 亮
23/1 应用
20accordance 工程 2023 (应用工
/11/
 To prevent1/13corrosion, 中心 engine has been oil sealed
13:1 the )( 13 程中心)(
Please refer to1the
3:relevant
3
before delivery. Generally :41 thewaoil
ngseal
mingvalid period is 1
waningthis Manual
13:4 chapter ming
lian lian
one year, and the engine should be checked g01and
) g 01)
necessary measures should be taken when this valid
period expires.
 In case of engine fault, please have the diesel engine
disassembled and repaired at the Weichai Power
designated service station by using the specified
spare parts; otherwise, Weichai will not assume any
responsibility for the diesel engine damage arising
therefrom.
 王Always
明亮 have the components of the electrical system 王明
( by Weichai professional technicians. 亮
23/1 应用
20maintained 2023 (应用工
1/13 工operations,
程中 /11/
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 Before welding 13:1 心)(cut wanoffg the power supply, 3:13
3 : 4 1 ming :41 wangming
unplug the ECU connector. lian li ang0
 The emission-related key components (such g01)as 1)
turbocharger, fuel injection pump, injector, ECU,
Weichai special spare parts
exhaust gas after-treatment system and EGR system)
should be replaced with parts of the same
manufacturer and model as original ones; otherwise,
Weichai will not be responsible for any consequences.
王训伟宋安泽
亮亮
/11/ 许太法 /11/
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3林世龙 w 3:13
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Please read this Manual before operation
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Safety warning
This is a “safety warning sign” in the industry to emphasize the importance of the following information.
Make sure that you understand the consequence of dangerous conditions and the way to avoid such
王明 danger. 王
亮(应the warning information in this Manual does not cover all明亮(应conditions!
202However,
3 用工 202possible
3 用工
/ 11applying 中心 or method not the recommended in/1this
/13 a程procedure 1/1Manual, 程
3 13 中心)(w
Before make sure that the
13: cause any
operation will never
13:4 )(danger
wa to you, others or the equipment. :
13:4 a
1 ngmi 1 ngmi
ngsign
liaindicates ngli
This warning ng01 a potential hazard, which, if not being avoided, ang0
may lead to serious injury ) death or great property damage.
even 1)
This warning sign indicates a potential hazard, which, if not being avoided,
may lead to slight injury or property damage. It is also used for warning
WARNING hazardous operation.
The caution signs in this Manual indicate how to properly operate and install
the engine. However, the potential hazards cannot be eliminated by simply
reading the text content in the caution sign. The information contained will
CAUTION
not be helpful to the correct use unless the implication is properly
understood.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /1
13 1 程
Please pay attention to 中心 )
followings
(wanbefore maintenance and repair:1/13 1
程中
心)(
3:13 3
:41 gmin
g
: 1 3 :41 wangming
liaanlong time.
1. Avoid repeated exposure to the used oil for lian
g01) g01)
2. Wear the protective clothing and water-proof gloves properly, if available.
3. Do not place the oily rag in the pocket.
4. Avoid contaminating clothes especially underwear with oil.
5. Wash work clothes frequently, and throw away the oil-impregnated clothes and shoes that cannot
be cleaned up.
6. In case of injury, take first-aid measures as soon as possible.

王明王明
7. 亮(working,
应亮(应 it easier to remove the oil in
20Before 用工 always apply some protective cream which will
2023 make
2 3 / 11/the
case that 程is 中 /11/ 用工程中
13 skin
13:1
contaminated with mineral oil.
心 )(wa 13 1 心)(
3 n gmihot 3 : 1 3 wang
:41 soap and ngwater, :41 the ming
8. Wash your hands by using lian or liquid soap and nail brush to remove lian
oil stains.
g01the
If the naturally secreted grease is washed off, ) product containing lanolin can be used to g01)
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;
11. Remove oil from the parts before transportation, if available.
12. Please wear goggles

王训伟or face mask 宋安泽
whenever your eyes are endangered. Eye washings must be
readily available;
13.20 亮(maintenance
During 应用 other亮liquid
of the engine, do not splash oil or20 (应用 on the floor. In the event of
23/1 工于千钧
程中许太法 23/1 工程
1 /13 1 /13 中
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gm20200321
ingl 3:41 gmin
iang
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accidental leakage of hydrocarbon or other liquid, please take all necessary measures to separate
this area to keep clean the environment and guard personnel against injuries;
14. The handling, storage and recovery of hydride, ethylene, glycol and petroleum must comply with the
safety and environmental standards of the local country.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
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1) 1)
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王训伟宋安泽
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Table of Contents
王明I Engine Structure and Performance Parameters ...............................................................................
Chapter 王明 1
亮 ( 亮 (
023/ 应用工...............................................................................................................................................
1.12Outline drawings 2023 应用工
/11/
程中 model ......................................................................................................................
程
1
11/1of the engine 心)( 13 1 中心)( 2
1.2 Instruction 3 13 w 3 w
: 13:4 angm : 13:4 angm 3
1.3 Main performance parameters 1 .......................................................................................................................
ingl
i 1 ingl
ang0
Chapter II Installation and Operation ...................................................................................................................
1) 5 iang01
)
2.1 Unsealing ........................................................................................................................................................... 5
2.2 Hoisting .............................................................................................................................................................. 5
2.3 Installation ......................................................................................................................................................... 5
2.4 Preparations for engine starting ..................................................................................................................... 5
2.5 Engine starting .................................................................................................................................................. 6
2.6 Engine running.................................................................................................................................................. 7
2.7 Engine stopping ................................................................................................................................................ 8
Chapter III Maintenance......................................................................................................................................... 9
3.1王Fuel,
明亮王明
lubricating oil, coolant and auxiliary materials.................................................................................... 9
( 应用亮 (
20Fuel
3.1.1
工程 2023 应用工
23/1................................................................................................................................................................. 9
1 中 / 1 1 程中
/13oil.................................................................................................................................................
/13
3.1.2 Lubricating 13:1 心)(wan 13:1 心)(wan 9
3 :41 gmin 3 :41 gmin10
3.1.3 Coolant .........................................................................................................................................................
glia gli
n g01)
3.1.4 Urea solution................................................................................................................................................ 10 ang01)
3.1.5 Auxiliary materials ....................................................................................................................................... 12
3.2 Daily maintenance .......................................................................................................................................... 13
3.2.1 Daily check ................................................................................................................................................... 13
3.2.2 Daily maintenance ...................................................................................................................................... 13
3.3 Maintenance items ......................................................................................................................................... 14
3.3.1 Oil change .................................................................................................................................................... 14
3.3.2 Replacement of oil filter or filter element ................................................................................................. 14
3.3.3 Check and adjust Replace the fuel filter and filter element .................................................................. 15
王Check
3.3.4 王明
明亮 the sealing of intake system.......................................................................................................... 15
( 应亮(应
2 23/1 the 用
3.3.50Check air工 2 023/ 用
11/1 工程中心
filter element ........................................................................................................................ 15
1 / 1 程中
3 1of3urea dosing 心 3 13
3.3.6 Maintenance
:13: )(wpump angm :13: )(wangm 15
...........................................................................................................
3.3.7 Maintenance of compressed 4 glia 41
1 air filterin....................................................................................................... in16 glia
n g 0 1) ng01
3.4 Regular maintenance interval and specification ........................................................................................ 20 )
3.4.1 Regular maintenance interval and specification ..................................................................................... 20
3.5 Cleaning, protection and handling ............................................................................................................... 22
3.5.1 Cleaning and protection ............................................................................................................................. 22
3.5.2 Protection during storage........................................................................................................................... 22
3.5.3 Oil sealing..................................................................................................................................................... 22
3.5.4 Oil sealing..................................................................................................................................................... 23
4.1 Overview ..........................................................................................................................................................
王训伟宋安泽 24
4.1.1 Overview....................................................................................................................................................... 24
4.2王明亮
Fault 于千钧王明
亮(应
diagnostic methods .............................................................................................................................. 24
2 0 ( 应用 2 0 用
2 3/1
4.2.1 Traditional 工于千钧
fault 程
diagnostic methods许太法 2 3/1 工程
......................................................................................................... 24
中 1/13 1/13 中
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gmin
20200321 3:41 gmin
glia glia
ng01 ng01
) )
4.3 Common faults and troubleshooting methods ........................................................................................... 25

4.3.1 Engine cannot be started ........................................................................................................................... 25
4.3.2 Engine is hard to start ................................................................................................................................ 27
4.3.3 Engine power is insufficient ....................................................................................................................... 27
王Unstable
4.3.4 idling speed of engine................................................................................................................
王明 30
明亮亮
4.3.5
023/ ( 2 023/ (
应用 after-treatment system failure ...........................................................................................
2 SCR exhaust 应用 30
11/1 工程中心 11/1 工程中心
3 13 3 13
:13: )(wangm :13: )(wangm
41 ingl 41 ing lian
iang g01)
01)
王明王明
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王明王明
亮亮
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/11/ /11/
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3:13 3:13
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1) 1)
王训伟宋安泽
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/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
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:13:
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ingl :41 wangming
iang ang0 li
1) 0 1)
Chapter I Engine Structure and Performance

王明
亮( Parameters王明
亮(
2023 应 2023 应
/11/ 用工程中 /11/ 用工程中
13 1 13 1
3:13 心)(wang 3:13 心)(wang
: ming :41 ming
1.1 Outline drawings 41 li ang0 li ang0
1) 1)
Take the truck engine structure as an example:
王明王明
亮亮
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/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
1-Alternator; 2-ECU; 3-Oil-gas separator; 4-Injection pump; 5-Air compressor
Fig. 1-1 Outline drawing of the engine (fuel pump side)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王训伟
1-Starter motor; 2-Turbocharger;宋安泽
3-Water pump; 4-Oil cooling/filtering module; 5-Water pump
王明 Fig. 1-2 Outline 于千钧王明

亮亮(应
drawing of the engine (turbocharger side)
2023 (应用工于千钧 2 0 2 3/11 用工程中
/11/ 许太法
13 1 程中心)( /13
13:1 心)(wan
3林世龙
:13: wang 20200321 3:41 gmin
41 ming glia
lian ng01
g01) )
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 1-3 Outline drawing of the engine (the fan end)

王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3the 3:13
1.2 Instruction of :41 wamodel
:13engine ngmi
ngli :41 wangming
ang0 li ang0
1) 1)
Product variant code
Emission level code
王明王明Power code
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
:41 wangming Application code :41 wangming
li ang0 li ang0
1) 1)
Product series number
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
1.3 Main performance parameters
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( Fig. 1-4 Engine Nameplate 13 1 程中心)(
3:13 w 3:13
:41 angming :41 wangming
lianfor engine model, power, speed, factory number,
Please refer to the engine nameplate information lian
g01) g01)
weight, etc.
Other parameters are as shown in Table 1-1.
Table 1-1 Main Parameters of the Engine
Item Technical parameters

Engine model WP9H WP10H
Type 4-stroke, water cooling, electronic controlled high pressure common rail, DI,
turbocharged and intercooled
王明 Number of cylinders 王明
亮(应 6
亮 6
202Cylinder 用工 mm
3/11 bore×stroke, 2023 (应用工
/13 程中心) /11/
13 1 程中心9.5)(
116×139 116×150
13:1 L
3:41 (wangmin 3:13
:41 wangming
Piston displacement, 8.8
Power range, hp gli an290~350 375~400 li ang0
g01) 1)
Minimum fuel consumption, g/(kW·h) ≤185 ≤192
Oil/fuel consumption rate, % ≤0.1 ≤0.1
Crankshaft rotation (viewed from free end) Clockwise Clockwise
Starting mode Electric starter Electric starter
Allowed long term tilt angle Longitudinal inclination (front/rear): 17°/ 17°
Transverse inclination (exhaust manifold side/intake manifold side): 15°/ 30°
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
Chapter II Installation and Operation

2.1 Unsealing
王明
Open the package of the engine, check the engine and its 王accessories against the packing list, and
明亮
亮 ( 应用appearance and fastening condition of the fittings, (应carry
2 the engine
check
023/ 2 then
023/用 out the following work:
3 13 coating and
) 3 13
1. Wipe the anti-rust :13: (wangm anti-corrosion agent off the exposed parts; :13: )(wangm
41 ingl 41 ingl
iang oil as specified. Please see the requirements for iang01
2. 01)
Fill the oil pan with appropriate grade of lubricating
)
adding of lubricating oil specified in relevant section.
3. The special coolant for Weichai Power engines are available in three freezing points: -25°C, -35°C
and -40°C. Please choose the special coolant with appropriate freezing point according to the local
ambient temperature. Generally, the freezing point of the selected coolant should be 10°C below the
ambient temperature.
4. Depending on the agreement between the manufacturer and the users, if the engine has been filled
with coolant before delivery, it is recommended to check the performance of coolant. If the
王antifreezing
明亮王明
performance is suitable for -30°C or -35°C environment temperature, the PH value is
( 亮
应 the total hardness number is 5-15°d [9-15°f2(hardness)], (
27~8
/11/ 用工程中
023(neutral), 023/ 应用 thus the coolant can be used.
工程
Otherwise,1drain
1 1 中
/13 antifreeze.
3 13off the 心
coolant,
) (wan 13:1 心)(For
and fill the engine with coolant containing
w
details of
: 1 3 gminPower, please see relevant sections of this
:41 for Weichai 3 :4Manual.a n gmin
selection of special coolant
glia 1 glia
ng01 ng01
2.2 Hoisting ) )
When hoisting the engine, keep the crankshaft centerline horizontal. Tilt or single side lifting is strictly
prohibited. Hoist and lower the engine slowly (see Figure 2-1).
王明王明
亮亮(应
2023 (应用工 Yes 202No
3/11 用工程中
/11/ 程
13 1 中心)( /13
13:1 心)(wan
3:13
:41 wangming 3:41 gmin
gli
li ang0 ang0
1) 1)
Fig. 2-1 Hoisting of the engine
2.3 Installation
Install the engine such that the crankshaft centerline is coaxial with the input shaft of drive gear (gearbox,
transmission or generator etc.), and the crankshaft is not subject to any additional axial force produced
due to installation. 王训伟宋安泽
2.4王
Preparations for engine starting
于千钧王明
明亮亮
2Check (应用
023/ the 2023 (应用工
工于千钧
程许太法 /11/
11/1coolant 13 1 程中心)(
1. level
3 13 中心)(w 3:13
:13:
林世龙 41 angm20200321
ingl :41 wangming
iang
ang0 li
1) 0 1)
Check the coolant level before starting the engine and add coolant from the filler port timely.
When the engine is still hot, before open the filler cap with pressure relief valve and venting button,
please always press down the bleeding button first to release the hot air. It is prohibited to add a
large amount of coolant when the engine is hot. Start the engine, and run it at 1,000 r/min, continue
王to明王
亮coolant until the liquid level is stable, and finally close明the
add 亮filler cap
2023 (应用工 2023 (应用工
/ 程中 /11/
2. Check1the
1/1fuel
3 1level 心 ) (wan 13 1 程中心)(
3:13 gmithe 3:13 wang
:41 and check nglfuel :4check
1 ming
Turn on the power switch, iang
level indicated by the fuel gauge, or the fuel li
01) protector, as shown in figure 2-2, the engine ang01)
tank directly. If the engine is equipped with fuel system
can be started normally under -35°C ambient temperature. When the ignition switch is turned to the
“ON” position, it begins to supply fuel and stops automatically when the air in the low pressure fuel
line is removed. When the fuel temperature is below 7°C, it begins heating, and stops automatically
when the temperature is higher than 24°C.
Electric pump
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程Fuel
中 filter/water separator 13 1 程中心)(
3:13 心 )( 3:13
lian li ang0
g01) 1)
Heater
Fig. 2-2 Fuel system protector
3. Check the oil level

王明王明
亮
oil (level
应 should be between the H and L marks on the oil 亮 (应用Add oil from the filler port if
20The
2 用工 2023 dipstick.
3 / 11/1 程 / 11/1 工程中心
necessary.
3 13 中心)(w 3 13
:13: angm :13: )(wangm
4. Check the components and 4 ingl
1 wiring connections 41 ingl
iang iang
01) 01)
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. After that,
open the fuel tank valve, unscrew the bleed screw on the fuel primary filter, and operate the hand
pump on the fuel primary filter to remove the air from the fuel system.
2.5 Engine starting

When start conditions 王训伟are available, turn the electric key to start the engine. If the engine cannot be
宋安泽
started within (5~10) s, wait for 1 min before the next start attempt. If three successive starting attempts
fail,王
do明亮start
not the engine until the fault于千钧王明eliminated. After the engine is started,
has been identified and 亮(应
2 02the ( 应用工于千钧 20gauge 用normally.
check 3/1instrument 程
readings, and check许太法
that the oil pressure 2 3 /1 works 工程 Do not run a cold
1/13
中 1/13 中
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gmin
20200321 3:41 gmin
glia glia
ng01 ng01
) )
engine at high speed, instead, run it at the 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 heating flange
through a relay to ensure successful start at low temperatures (such as -30°C).
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
2.6 Engine running
li angspeed li ang0
1. After the engine is started, run it at the idle 01) for 3 min, and then increase the speed to 1)
(1,000~1,200) r/min. The engine load and speed should be increased gradually, and avoid loading or
unloading suddenly as much as possible.
2. Within the running-in period of first 50 h (or initial 3,000 km), it is recommended to run under medium
load.
3. Do not keep running the engine at a large torque for a long time, or do not run it under low speed
with light load.
4. In normal use, the diesel engine is allowed to be operated continuously at rated power and rated
王明亮After being unloaded, run the engine at idle speed王 for明
speed. ( 应亮(minutes before stopping.
(3~5)
2023 2023 应用工
/11/ 用工程中 /1
5. 13 1 of engine
The parameters 心 during
) (wan normal operation are as shown in1/ 13 12-1.程中心)(
Table
3:13 3:13
:41 gmin
g :41 wangming
liEngine
Table 2-1 ang0 parameters lian
1) g01)
Parameter Normal range
Oil pressure in main oil passage Idle speed condition: 100 kPa~320 kPa
Rated condition: 370 kPa~580 kPa
Oil temperature in main oil passage <107℃
Coolant outlet temperature (90±5)℃
Exhaust temperature after turbine ≤550℃
Intake temperature after intercooling (45±5) ℃
王明王明
6. 2Check
亮(应exhaust 亮(and
应用
023/ the 20injector
用工 color to identify the operation of the fuel 2 3
the engine load. In the event
工程
1 1
of heavy / 程中心 / 1 1 中心 water leakage,
/13the engine
13 1or white
black smoke, stop the engine for inspection. Check
) (wan 13:1 for )(wa
3:13 3 ngmi
:41 if any,gmstop
gas leakage and oil leakage, in it for troubleshooting.
glia : 4 1 n glia
ng01 ng01
7. Precautions for operation in a cold environment: ) )
1) Fuel: choose appropriate grade of diesel fuel according to the outdoor temperature in winter.
2) Lubricating oil: choose appropriate grade of lubricating oil according to different seasons.
3) Coolant: add anti-freeze additives into the cooling system, and choose the grade of antifreeze
according to the ambient temperature.
4) 王训伟
Start: apply 宋安泽
the auxiliary starting device in winter when necessary. After the engine is started,
it can only be loaded and put into high-speed operation after oil pressure and water
亮temperature
(应 get normal. 亮(应
2023 2023
/11/ 用工于千钧许太法 /11/ 用工程中
13 1 程中心)( 13 1
3林世龙
:13: w 3:13 心)(wang
41 angm20200321
ingl lian
:41 ming
iang g01)
1) 0
2.7 Engine stopping

When the engine is to be stopped, remove the load gradually and run the engine at the speed of
(600~1,000) r/min for a few minutes. Switch off the instrument power supply after the engine is stopped.
When the diesel engine is to be stopped immediately in case of an emergency, you can press down the
王button 王明
明亮 or cut off the fuel pipe of injection pump or block the
stop 亮of air filter directly.
inlet
2023 (应用工 2023 (应用工
/11/for Jacobs /11/
13 1 程中 13 1 程中心)(
3:13 心)(wang
Instructions in-cylinder braking system:
3:13
:41 ming :41 wangming
1. Operation lian lian
g01) g01)
1) Before using the Jacobs in-cylinder braking system, ensure that the engine oil temperature is
higher than 85°C;
2) The working speed of the in-cylinder braking system is the engine speed (1,000~2,300) rpm,
when the speed is lower than 1,000 rpm, the braking will be released automatically;
3) Preconditions for activating the Jacobs in-cylinder braking system
The clutch pedal is released;
王明The transmission is in gear (not neutral position); 王明

亮亮
2023 (应用工 2023 (应用工
/11main
/13 程中心) /11/
13 1 程中心)(
The switch of braking system is closed.
13:1 ( w angm (fuel supply stopped), the braking 3:13 wang
2. 3:41 is released
Once the throttle pedal ingl :41 will
system ming
activate
i a n lian
automatically; when the throttle pedal or clutch g01pedal
) is pressed down, the braking system will g01)
release automatically. In an emergency, press down the main brake pedal (foot brake of the truck),
the braking power will be superimposed, achieving better braking effect.
3. How to increase the braking effect
1) Under the same condition, the higher the engine speed, the better the braking effect. And the
braking power can be increased through down shift.
2) The recommended engine braking speed is (1,900~2,300) rpm.
4. 王明 instruction
Safety 王明
亮亮
2023 (应用工 2023 (应用工
/ 程 /11/conditions
1) Do1not
1/1use
3 1the 中心 in-cylinder braking system in overspeed
Jacobs
) ( 13 1 程(>2,500
中心 rpm) to avoid
)(wa
3 :
that the speed is13 w angand 3 : 1 3 ngmi
:4of
out
1
control m the engine is damaged.
ingl : 4 1 ngli
iang a
2) It is recommended that the Jacobs in-cylinder 0 1)braking system should not be used on wet or ng01)
slippery road surfaces.
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
Chapter III Maintenance

3.1 Fuel, lubricating oil, coolant and auxiliary materials
王 Fuel
3.1.1
明亮王明
( 应亮(应
2
The 0 23/used 用工be consistent with GB19147 and selected 20based
2 3 用工
fuel 11/1should 程中 /11on
/
the 程ambient
local
中心
temperature:
3 13 心 ) 1 3 1
(wan where the lowest temperature with risk3rate ) (wan C;
:13:used in gmin :13of
:410% gmin
5# automobile diesel fuel: 41 areas glia 1 is 8° glia
ng01 ng01
) temperature with risk rate of 10% is 4°C;
0# automobile diesel fuel: used in areas where the lowest )
-10# automobile diesel fuel: used in areas where the lowest temperature with risk rate of 10% is -5°C;
-50# automobile diesel fuel: used in areas where the lowest temperature with risk rate of 10% is -44°C.
3.1.2 Lubricating oil

王明亮 criteria for engine lubricating oil is presented in Table
明亮王
2023 应用工 (
The selection (
3-1.
2023 应用工
/11/ Table 程 /11/ Power Engines
13 1 3-1中心 )
Selection 13 1 程中心)(
Criteria of Special Lubricating Oil for Weichai
(wan
3:13 3:13
:41 gmin
g :41 wangming
Category liaGrade
ng01 Packing specification lian
) g01)
Diesel engine CI-4 4 L, 18 L, 170 kg
For the temperature and viscosity of engine lubricating oil, refer to Table 3-2.
Table 3-2 Oil Viscosity and Applicable Ambient Temperature
Viscosity grade Applicable ambient Viscosity grade Applicable ambient

temperature, °C temperature, °C
0W -35 ~ -15 10W-50 -25 ~ 50
0W-20 -35 ~ 20 15W-30 -20 ~ 30
王明 0W-30 王明亮
亮(应 -35 ~ 30 15W-40 -20 ~ 40
2023 0W-40
/11/ 工程中用 023/ (应用工程
215W-50
1 心
-35 ~ 40 11/1 中心-20 ~ 50
3 1 3:13 ) ( -30 ~ -10 3 1 3:13 -15)(~ 30
5W 20W-30
5W-20 -30 ~ 20 li ang0 20W-40 -15 ~ 40 li ang0
5W-30 -30 ~ 30
1) 20W-50 -15 ~ 50
1)
5W-40 -30 ~ 40 20 -10 ~ 20
5W-50 -30 ~ 50 30 -5 ~ 30
10W-30 -25 ~ 30 40 5 ~ 40
10W-40 -25 ~ 40 50 15 ~ 50
Note: For the viscosity grade of the oil in the table, the smaller the number before W, the better the low temperature performance
of the oil; the larger the number after W, the greater the viscosity of the oil. The viscosity and temperature performance
王训伟宋安泽
requirements of engine lubricating oil are detailed in GB11122.
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
CAUTION
1. Before starting the engine, always check the oil level in oil pan;
2. Do not check the oil level while the diesel engine is running;
王明王明
亮(应 to mix Weichai Power special oil with other oils.
3. It2is prohibited 亮(应
用 2
023/
11/1 工程中 0 2 3 /11/ 用工程中
心 13 1
3 of13engine lubricating
The filling volume :13: )(wangoil is shown in Table 3-3. 3:13 心)(wang
41 ming :41 ming
lian of Engine Lubricating Oil lian
Table 3-3 Filling Volumeg01) g01)
Quantity of filter(s)
Filling volume
Engine Model Diesel engine
(L) Fuel filter
Oil filter
Fuel primary filter Fuel secondary filter
WP9H/WP10H 30 1 1 1
Note:
1) The oil filling volume given herein is for reference only. The actual filling volume should base on the oil dipstick.
2) If Weichai fuel system protector or fuel filter/water separator is equipped, the filter should be replaced together with fuel filter.
王明
3) The number of filters given herein is for reference only.王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3.1.3 Coolant
3:13 w angmengines are available in three freezing 3points:
:13: -25°C,wa-35°
ngmCiand
:41 Power
The special coolant for Weichai ingl 41 ngli
i ang0 ang0
1)
-40°C. Please choose the special coolant with appropriate freezing point according to the local ambient 1)
temperature. Generally, the freezing point of the selected coolant should be 10°C below the ambient
temperature. The coolant for heavy-duty engine is as shown in Table 3-4.
Table 3-4 Selection Criteria of Coolant
Category Grade Packing specification

HEC-II-25
Coolant for heavy-duty engine HEC-II-35 4 kg, 10 kg
HEC-II-40
王明王明
亮亮
2023 (应CAUTION 2023 (应用工
/11/ 用工程中 /11/
13 1 心 ) ( 13 1 程中心)(
3 :
1. Please check and replace w angmregularly to avoid corrosion damage. 3:13:4 wangm
13:4the coolant
1 ingl 1 ingl
iawith
ng0water iang
2. It is not allowed to change the engine coolant 1) or poor quality coolant. 01)
3.1.4 Urea solution
Urea solution quality
The urea solution quality and performance should conform to the provisions of ISO 22241. The
requirements for concentration and composition of urea solution are presented in Table 3-5.
Substandard urea solution poses the risk of clogging the urea dosing pump and spray nozzle, and may
王训伟 that are prone
contain the metal impurities 宋安泽 to causing permanent poisoning of SCR catalyst and
reducing the efficiency of SCR catalytic converter thereafter. The urea solution should be added through
王明 channel. It is strictly forbidden于千钧王明with any fluid during normal use.
亮(
a specified
应 to replace urea solution 亮( 应
2023 2023
/11/ 用工于千钧许太法 /11/ 用工程中
13 1 程中心)( 13 1
3林世龙
:13: w 3:13 心)(wang
41 angm20200321
ingl :41 ming
li
iang ang0
1) 0 1)
Table 3-5 Compositions of urea solution (refer to ISO 22241)
Composition Unit Minimum Maximum

Urea content % (m/m) 31.8 33.2
3
Density at 20℃ kg/m 1,087 1,093
王明 index at 20°C 王明亮
亮(
202-3 (应用工
Refractive - 1.3814 1.3843
23/1 应
20Alkalinity 用工程 /11/
1/as1NH 13 1 程中心)(
% (m/m) 0.2
3
3
中心
1 3:13 ) ( 3:13
Biuret
:41 wa%n(m/m)
gmin -
:41 0.3wangming
Aldehydes mg/kg gl iang - 5 li ang0
01) 1)
Insoluble matter mg/kg - 20
Phosphate (PO4) mg/kg - 0.5
Calcium mg/kg - 0.5
Iron mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
Nickel mg/kg - 0.2
王明Aluminium mg/kg 王明 - 0.5

亮(应亮(应
2023Magnesium用工 202-3
/11/ 用工程中
mg/kg 0.5
/11/ 程中
Sodium13 13 1
13:1 心)(wamg/kg
ngmi
-
3:13 心)(0.5wang
Potassium
3 :41 mg/kg ngli - :41 0.5 ming
ang0 li ang0
1) 1)
Storage of urea solution
The urea solution for vehicle should be stored in an enclosed container at the ambient temperature of
5°C-25°C, without direct sunlight, with the shelf life shown in Table 3-6.
Table 3-6 Shelf Life of urea solution for Vehicle
Shelf life of urea solution for vehicle

Ambient temperature °C Minimum shelf life (month)
≤10 36
王明王明
亮 ≤25 a
亮
2023 (应用工 ≤30 2023 (应用工
18
/11/ /11/
13 1 程中心)( 13 1 程中心)(
12
3:1≤35
3:41 wangmin 63:1
3:41 wangmin
≥ 35 gli ang0 b gli ang0
1)
Note: The shelf life in the table is specified by giving major consideration to the ambient temperature and initial alkalinity of urea
1)
solution besides the difference in evaporation between ventilated and non-ventilated storage containers.
Note a: Avoid transporting or storing the urea solution for long hours at temperature above 25°C, avoiding decomposition;
Note b: Check whether each batch of urea solution is up to standard before use.
The materials of the urea solution storage containers should be properly compatible with urea solution
for vehicle, without chemical reactions or impurity migration. Containers should be made of the
recommended materials 王训伟 in ISO22241-3 宋安泽
such as austenitic alloys and additive-free teflon, polyethylene
and polypropylene without additives. In case of storage below 5°C, a proper space should be reserved in
the王明亮 containers as the volume of 于千钧
storage urea solution in the 王明亮 state will be increased by 7%
solidification
2 0 ( 应用 2 0 (应用
2
compared 3/1to that in工于千钧
程
the liquid state. 许太法 2 3 / 1 工程
中1/13 1/13 中
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gmin
20200321 3:41 gmin
glia glia
ng01 ng01
) )
Please pay attention to the effectiveness of urea solution in the vehicle. The relationship between the
shelf life of urea solution and the ambient temperature during the inventory period of the vehicle is shown
in Table 3-6. If the inventory period exceeds the shelf life, it is required to drain away the urea solution
through the drain valve at the bottom of urea solution tank and fill the tank with acceptable urea solution
王明delivery. When the ambient temperature is higher than
before 王明 35°C, it is necessary to check if urea
亮 ( 亮of (应
2023in the应urea
solution 用工 solution tank is still up to standard before 2
delivery
0 2 3
the用vehicle, and if not, replace it
工
/ 程中
11/1 urea solution. / 1 1 /13 程中心
with acceptable 3 13:1 心 ) 13:1 )
3:41 (wangmin 3:41 (wangmin
glia glia
CAUTION ng01 ng01
) )
1. Urea solution should be stored in the tightly closed container, which should be placed in the cool
and dry storage room, far away from strong oxidizers. It is recommended to use special filling
equipment to avoid splashing and causing environmental pollution.
2. Urea solution is corrosive to the skin, and if it contacts the skin or eyes accidentally when filling,
wash with water as soon as possible; if the pain continues, please seek medical help. If it is
swallowed accidentally, never induce vomiting but immediately seek medical treatment.
王明
3.1.5 Auxiliary materials 王明
亮亮(应
2023 (应用工 2
/11/materials程for中the engine are shown in Table 3-7. 023/11/ 用工程中
The auxiliary
13 1 13 1
3:13 心)(wang 3:13 心)(wang
:41 Table 3-7
miAuxiliary
ngli Materials for the Engine :41 ming
ang0 lian
1 ) g01)
No. Name Color Purpose and application
To be applied to smooth metal surfaces to prevent seizing,
1 Molykote Pulver Black
e.g. external surface of cylinder liner
To be applied for lubrication before the pressure of
2 Molykote G-N plus Dark grey
lubricating oil builds up, e.g. intake valve stem
The sealant application of engine is given in Table 3-8.
Table 3-8 Sealant Application of Engine
王明亮
Designation Main purpose Examples of王明亮 position
application Comments
2023 (应用工 2 0 2 3/11
(应用
工
/11/
13 1 程中心)( /13 程中心)
Camshaft timing gear bolt
13:1
3:13
:41 wangmiBolt 3:41 (wangmin
Camshaft thrust plate bolt
ngfor
lian
retainer plate of oil pump intermediate gear glia
g 0 1) gear bolt ng01
Oil pump intermediate )
To be applied to the Air compressor shaft end threads As an option,
thread for locking and High pressure fuel pump flange bolt DriLoc204
Weichai special prevention of Clamp nut for high pressure fuel pump gear thread-locking
sealant 242 looseness due to Cylinder head cover baffle bolt adhesive can
vibration. It has Oil dipstick tube bolt be used for
medium strength. Stud bolt for starter motor pre-coating.
王训伟宋安泽
Stud bolt for fan bracket
Oil dipstick hole plug
王明于千钧王明 fixing device Front cover
亮亮
Bolts for sensor and wire harness
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
bolt
3林世龙 wang 20200321 3:13
:13:
lian lian
g01) g01)
Suction strainer support bolt

Fastening bolt for air compressor
Cup plug for engine body water cavity
Cup plug for cylinder head
王明王cover
Cup plug for cylinder head
明亮
(pre-separation of oil and
亮 ( For sealing between
2Weichai
023/special应用 cup plug or connector gas separator)
工 2023 (应用工
1/13 程中心
sealant1277
/11/ head cover 程中 None
13and )
Pre-separated oil return pipe of cylinder1 3 1 心
(U-pipe)
)
3:41 (wangmiPipe
:1hole
ngjoint connecting the water pipe
3:13 (
:41 wangming
l an
Warmericonnector
lian
g01) g01)
Water pipe joint
Weichai special Apply to shiny metal
Joint faces of front end cover and engine body None
sealant 5910 surface for sealing
Weichai special Apply to shiny metal
Joint faces of flywheel housing and engine body None
sealant 510 surface for sealing
Water inlet/outlet pipe of air compressor
Weichai special
Filling and sealing Exhaust connector of air compressor None
sealant 567
Air compressor water pipe joint
王明亮
Weichai special Bottom plane of front end王明亮
cover or engine body
2silicone ( 应
023/sealant 用工程
Filling and sealing
2 023/or(engine
应用body None
11/1
Bottom plane of flywheel housing
11/1 工程
3 13 中心)(w 3 13 中心)(w
:13: angm :13:
3.2 Daily maintenance 41 ingl 41 angmingl
iang iang
01) 01)
3.2.1 Daily check
1. Check the coolant level, oil level and fuel level

and check and add grease when necessary.
2. Check for oil, water or air leakage.
3. Check if the external parts and accessories

are connected and fastened securely.
王明王明
亮(应亮
20Check
23/1the 用工 2023 (应用工
4.
1/1fan 程belt;
and /11Checking
/13 of程connections
3 13 中心)(w Fig. 3-1 中
13:1 心)(wan
5.
:13temperature,
Check if the exhaust :41 angcolor,
ming 3:41 gmin
li gli
engine sound and vibration are normal, andaifng01 ang0
1)
)
the engine speed is stable;
6. Check the oil return pipe of turbocharger for

blockage and leakage;
7. Check the exhaust pipe for leakage and

blockage.
王训伟
3.2.2 Daily maintenance 宋安泽
Fig. 3-2 Checking of engine fan
1. 王明亮the coolant level, and open the于千钧
Check filler cap 王明
( 亮
2to02add 应用when
3 coolant 工 necessary. 2023 (应用工
/11/ 于千钧许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang
ang0 li
1) 0 1)
CAUTION
Caution: Before opening the filler cap, make

sure to press the vent button to prevent
王明 injury due to hot coolant when the 王明
personal亮(应亮
202engine
3/1 is用hot.
工程 2023 (应用工
/11/
13 1 程中心)(
diesel
1/13 中
13:1 心)(wan 3:13 wang
3:41 gmin : cap ming
glia Fig. 3-3 Coolant filler 4 1 li
ng01 ang0
) 1)
2. When the oil level is below the L mark or above
the H mark, never start the engine. Oil dipstick
At this time, add oil through the oil filler.
CAUTION
Always check the oil level at least 5 min after

engine shutdown, enabling the oil to return to
王 pan.
the oil明
王明Fig. 3-4 Marks of Oil Dipstick
亮( 亮
2023 应 2023 (应用工
/11/ 用工程中 /11/
Check the 1 13 1 程中心)(
3. fuel
3:13and心add
3 1level, )(wfuel timely.
3:13
:41 a n gmin
gli :41 wangming
4. Check the urea solution level. ang0 li ang0
1) 1)
The liquid level of the urea tank shall be kept at 30% ~ 80% of the total volume of the urea tank.
3.3 Maintenance items

3.3.1 Oil change
1. Unscrew the drain plug at the bottom of oil pan,

and drain the old oil completely, and then screw on
the drain plug.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/ Oil drain
13 1 程中心)( 13 1 程plug 中
3:13 3:13 心)(wang
:41 wangming Fig. 3-5 Oil drainage:plug
41 ming
li ang0 li ang0
1) 1)
2. Open the oil filler cap and add oil from the oil
filler port. At the same time, check the oil level
through oil dipstick, and then install the oil filler cap
until the specified oil level is reached.
Oil filler cap
王训伟宋安泽 Fig. 3-6 Oil filler cap
王Replacement of oil filter or filter element

3.3.2
明亮于千钧王明
(应用亮
2 0 23/1the 工于千钧 2023 (应用工
of程oil cooling/filtering许太法 /11/
13 1 程中心)(
1. Remove
1/1head
3 13 中心)(w
module
3:13
:13:
林世龙 41 angm20200321 ingl :41 wangming
iang
ang0 li
01) 1)
Use the socket wrench to loosen the bolts on the upper part of oil cooling/filter module and remove the
top part of the module. At this time, the paper filter element can be clearly seen. The top of the module is
equipped with a rotor filter. When the engine is working, only small part of the oil enters the rotor filter, so
the replacement cycle of the filter is relatively longer.
王明 and replace the filter element. 王明
亮
2. Remove 亮
2023 (应用工 2023 (应用工
/ /13 filter程
11new /1module.
中 let it fall naturally to the bottom of the 1/13 程中心
13:1 心)(wan
3. Install the element,
13:1 )(wa
3:41 g m ingl is designed at the lower end of the filter 1elementngand
3 : 4 minthe
glia
Note: Special guiding and positioning structureiang
0 1) in the module, the filter element will locate ng01)
internal of the module. After the filter element is placed
naturally to inside the module along the base pipe. In addition, do not press the filter element forcibly
after the filter element is loaded.
4. Replace the base pipe
When installing the base pipe, align the two notches at the lower part of base pipe with the two bulges of
the base, push the base pipe into place until it cannot be rotated.
3.3.3 Check and adjust valve clearance

王
Please明
王明亮
亮( local Weichai service center for valve clearance adjustment.
contact (
2023 应用工 2023 应用工
/1 程中 intake system /11/
3.3.4 Check1/ 13sealing
the 13:1 of心 ) 13 1 程中心)(
3:41 (wangmin 3:13
:41 wangming
gl
Check the intake hose for aging or cracking and iacheck lian
ng01the pipe clamp hoops for loosening. When g01)
necessary, tighten or replace the related parts to ensure)air tightness of intake system.
3.3.5 Check the air filter element
The maximum allowable intake resistance of the engine is 6kPa, and it must be checked only when the
engine is running at rated speed and full load. If the intake resistance reaches the maximum allowable
limit, please clean or replace the filtering element timely according to the manufacturer’s instructions.
CAUTION
王明王明
Caution:亮 absolutely prohibited to run the engine without air亮
2023 It’s(应用工 (应用
2023 filter; otherwise, dust and foreign
/
matters will 1 the程cylinders,
11/enter 中心
/
causing early wear of the engine.11/1 工程中心
3 13 3 13
41from the airifilter,
Remove the filtering element nglitap 41 ingl
an i ang0
the end face gently to remove the dust, or blow the g01 1)
High pressure air pipe
)
filtering element with compressed air (from inside
out), as shown in figure 3-13.
Fig. 3-13 Clean with compressed air (from inside out)
王训伟
3.3.6 Maintenance of 宋安泽
urea dosing pump
王明 of filter element of urea dosing于千钧王明
亮
Checking pump 亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
Remove the filter element of urea dosing pump and clean with water before reassembling. Do not knock
or flap the filter element forcibly.
CAUTION
王明王明
亮(应亮(应the damaged or deformed
202disassembling
When 用工and assembling the urea nozzle, check 2and replace
3 / 11/1 程中 0 2 3 /11/ 用工程中
spray nozzle. 3 13:1心 ) 13 心 13:1 )
glia
Cleaning of urea solution tank and its filter element glia
ng01 ng01
) )
During maintenance, check the urea solution tank and filter element, and clean them if necessary.
CAUTION
The maintenance of post-processed parts needs to be carried out by using special maintenance tools at
Weichai service station. Urea pump and urea nozzle are cleaned by Weichai special urea injection
system testing and cleaning tools!
3.3.7 Maintenance of compressed air filter

王明亮王明亮removal every 5,000 km (or, when
2023 (应用工 2023 (应用工
After the compressed air filter is installed, please perform dirt (dust)
/11and perform
necessary);
/13 程中 maintenance of compressed air filter every/1 1
30,000
/13 km. 程中
13:1 心)(wan 13:1 心)(wan
3 :41operations,
! Before carrying the following 3:4and
gminthe air pressure in the compressed air filter gmin
1 its connected
glia glia
n g01) ng01
pipes must be fully released. )
Dirt (dust) removal methods:
1. Turn the drainage valve handle clockwise, open the drainage valve by moving the valve stem
upward, thus the dirt will be drained from the valve stem drainage hole.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
Drainage valve handle
li ang0 li ang0
1) 1)
Fig. 3-14 Opening of drain valve
2. After the dirt is discharged completely, turn the drainage valve spanner counterclockwise and tighten
it to (1.8±0.3) Nm.
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
Tightening torque for drain valve:
/11/ (1.8±0.3) Nm /11
13 1 程中心)( /13 程中心)
13:1
3:13
:41 wangming 3:41 (wangmin
li ang0 glia
1) ng01
)
Fig. 3-15 Tightening of drainage valve
Maintenance methods:
1. Remove the air pipe connecting the vehicle and compressed air filter.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li
Remove outlet pipe ang0
Remove inlet pipe 1) 1)
Fig. 3-16 Removal of connecting air pipe
2. Unscrew the bolts connecting the compressed air filter and vehicle and remove the compressed air
filter.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
Unscrew the bolts connecting 1) 1)
the vehicle
Fig. 3-17 Connecting bolt

王训伟宋安泽
3. Fix the filter seat on the bench vice and remove the filtering tank by using a spanner, take down the
王明亮and put it into waste container.于千钧王明
O-ring 亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang lian
1) 0 g01)
Remove the O-ring
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 3-18 Removal of filtering tank
4. Unscrew the end cover counterclockwise, remove the filter element and put it into the waste
container.
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 3-19 Removal of filter element
5. Clean the inner wall of filter seat, inner wall and external threads of filtering tank, O-ring groove, air
inlet/outlet pipe joint, inner wall of filter seat air passage and outer surface of end cover. Remove the
impurities attached on the parts by using compressed air at first, then clean the parts with detergent
or clean water and wipe them clean.
Clean the inner wall of air passage

王明王明
亮the(应亮
202Clean
3/11 用工程中
inner wall of air passage
2023 (应用工
/13 /11Clean
/13the inner程wall中of心
joint
13:1 心)(wan 13:1 )
3:41 gmin 3:41 (wangmin
gli ang0 gli ang0
Clean the inner wall of joint 1) 1)
Clean the inner wall of filter seat
Fig. 3-20 Cleaning of filter seat
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
Clean the external threads of
filtering tank and O-ring groove Clean the inner wall of filtering tank
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 3-21 Cleaning of filtering tank
6. Fix the clean filter seat on the bench vice, place the new filter element into filter seat and tighten the
end cover with the torque of (1.3±0.3) N.m.
Tightening torque:
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 3-22 Screwing of filter element
7. Install a new O-ring into the ring groove, then install the filtering tank onto filter seat and tighten it
with the torque of (20~25) N.m.
Tightening torque:
Install the O-ring into the
groove of filtering tank
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 3-23 Tightening of filtering tank
8. During the replacement of the filter element, please keep the operating environment clean and
prevent foreign matter from entering the compressed air filter.
9. Install and fix the王训伟宋安泽

clean compressed air filter onto the vehicle and connect the air pipes.
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
3.4 Regular maintenance interval and specification

3.4.1 Regular maintenance interval and specification
Table 3-9 Maintenance interval and specification
王明王明
亮 High speed and standard load
亮(应
2023 (应用工
Application road vehicle (towing vehicles,
Engineering vehicles
2023truck) 用工 Agitating lorries
/11/ 程 (common dump / 1 1 /13 程中心)
13 1 中心)( trucks)
13:First
3:First
13:4 w angm
Regular First Regular
ingl maintenance maintenance maintenance 13:4 (waRegular
ngmi
maintenance1 1 maintenance
ngli
Maintenance type
maintenance iang ang0
Maintenance 5,000 km or 1 60,000 km or 6 0
5,000 1 ) or 1 10,000 km or 2 5,000 km or 1 30,000 km or 6
km 1)
interval month months month months month months
Change the oil ● ● ● ● ● ●
Replace the
centrifugal filter ● ● ●
element
Replace the oil
filter or filter ● ● ● ● ● ●
element
Check and adjust
the valve ● ● ● ● ● ●
王明 clearance 王明
亮亮
2023 (应用工
Clean or replace
2023 ● (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
the filter element of ● ●
3:13 3:13
oil-gas separator
Check the water
●
li ● ang0 ● ● ●
li ● ang0
pump (lubricated
wiht grease)
1) 1)
Replace the fuel
● ● ● ●
filter element
Check and add the
● ● ● ● ● ●
coolant
Tighten the coolant
● ● ●
pipe clamp
Tighten the intake
piped, hose and ● ● ● ● ● ●
flange connector
Check the service
王明王明 ●
亮
reminder indicator ● 亮 ●
2023 (应用工 2023 (应用工
/11/
of air filter
/11/
13 1 程中心)(
Clean the dust cup 13 1 程中心)(
3:13 3:13
of air filter :41 wangming :41 wangming
(automatic ● li ang0 ● ● li ang0
de-dusting type 1) 1)
excepted)
Clean the main
When the indicator lamp comes When the indicator lamp comes
filter element of air When the indicator lamp comes on
on on
filter
Replace the main
Refer to relevant requirements in Refer to relevant requirements Refer to relevant requirements
filter element of air
the manual in the manual in the manual
filter
Replace the safety
After cleaning the main filter After cleaning the main filter After cleaning the main filter
filter element of air 王训伟
element for 5 times
宋安泽 element for 5 times element for 5 times
filter
王明
Check and tension 于千钧王明 ●
亮 ● ● ● 亮(应 ● ●
2023 (应用工于千钧
the V-belt 2 0 2 用
/11/ 中心240,000 km 许太法 /11/ 工程中
Every 80,0003km
13 1 程Every
Check the
13 1 Every 150,000 km
)
:13: (wangm20200321
3林世龙 3:13 心)(wang
41 ingl :41 ming
iang lian
01) g01)
clearance of
turbocharger
bearing
Check and adjust
the travel of clutch ● ● ● ● ● ●
pedal
王明王明
亮亮
2023 (应用工 2023 (应用工
Clean the urea
● ● ●
/11/
dosing pump and
/11/
urea nozzles13 1 程中心)( 13 1 程中心)(
3:13 3:13
Replace the filter :41 wangming :41 wangming
element of urea li ● ang0 ● li ● ang0
dosing pump 1) 1)
Check and replace
urea dosing pump ● ● ●
filter element
Clean or replace
the filter screen of
● ● ●
the urea tank
sensor
Check and replace When the urea nozzle is removed When the urea nozzle is When the urea nozzle is
urea nozzle gasket each time removed each time removed each time
Clean urea
王明
solution tank and ● 王明 ● ●
亮亮
2023 (应用工
filter element 2023 (应用工
/11/ /11/
13 1 程中心)(
Note 1: “●” indicates the item requiring maintenance.
13 1 程中心)(
3:13 3:13
Note 2: Diesel engine that is out of service for more than half a year shall be subject to corresponding maintenance.
li
Note 3: Add oil to the upper scale mark of oil dipstick every 15,000 km.
ang0 li ang0
1)
Note 4: Weichai will provide maintenance recommendations upon request from the user. 1)
Note 5: For passenger coaches and tourist buses, the regular maintenance interval of oil/oil filter (standard) is 60,000 km/6
months; the regular maintenance interval of oil/oil filter (optional) is 100,000 km/12 months. The first maintenance is performed
based on the standard oil/oil filter.
Table 3-10 Maintenance interval and specification
Application Bus, school bus Passenger coach, tourist bus

Regular Regular
Maintenance type First maintenance First maintenance
maintenance maintenance
3,000~5,000 km or 1 60,000 km or 12 3,000~5,000 km or 1 60,000 km or 6
Maintenance interval
month months month months
王明Change the oil ● ● 王明 ● ●
亮 centrifugal filter 亮
023/the(应
2Replace 用 2023 (应用工
1/13 工程中心
1element ● /11/
13 1 程中心)(
●
Replace the oil filter1or 13:4 )(wang●mi

3:filter 3:13
:41 wan●gming
1 ngli ● ●
li
element
ang0 ang0
Check and adjust the valve
●
1) ● ● ●
1)
clearance
Clean or replace the filter element
● ● ● ●
of oil-gas separator
Check the water pump (lubricated
● ●
with grease)
Replace the fuel filter element ● ● ● ●
Check and add the coolant ● ● ● ●
Tighten the coolant pipe clamp ● ●
Tighten the intake piped, 王训伟hose and 宋安泽
● ● ● ●
flange connector
王明于千钧
Check the service reminder 王明
亮 ● 亮 ●
2023 (应用工
indicator of air filter 2023 (应用工
/11/ 于千钧
许太法 /11/
13 1 程中心)(
Clean the dust cup of air filter ●
13 1 程中心)( ●
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
(automatic de-dusting type

excepted)
Clean the main filter element of air
When the indicator lamp comes on When the indicator lamp comes on
filter
Replace the main filter element of Refer to relevant requirements in the Refer to relevant requirements in the
air filter manual manual
王明王明
亮亮
2023 (应用工 2023 (应用工
Replace the safety filter element of After cleaning the main filter element for 5 After cleaning the main filter element for 5
/11/
air filter times
/11/ times
13 1 程中心)(
Check and tension the V-belt ● ● 13 1 程中心)( ● ●
3:13 3:13
:41 wangming
Check the clearance of :41 wangming
turbocharger bearing li Every 180,000 km
ang0 li
Every 240,000 km
ang0
Clean the urea dosing pump and 1) 1)
● ●
urea nozzles
Replace the filter element of urea
● ●
dosing pump
Check and replace urea dosing
● ●
pump filter element
Clean or replace the filter screen of
● ●
the urea tank sensor
Check and replace urea nozzle When the urea nozzle is removed each
When the urea nozzle is removed each time
gasket time
Clean urea solution tank and filter
● ●
王明王明
element
亮亮
2023 (应用工
Note 1: “●” indicates the item requiring maintenance. 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
Note 2: Diesel engine that is out of service for more than half a year shall be subject to corresponding maintenance.
3:13 3:13
:41 wangming
Note 3: Add oil to the upper scale mark of oil dipstick every 15,000 km.
:41 wangming
li
Note 4: Weichai will provide maintenance recommendations upon request from the user.
ang0 li ang0
1)
Note 5: For passenger coaches and tourist buses, the regular maintenance interval of oil/oil filter (standard) is 60,000 km/6 1)
months; the regular maintenance interval of oil/oil filter (optional) is 100,000 km/12 months. The first maintenance is performed
based on the standard oil/oil filter.
3.5 Cleaning, protection and handling

3.5.1 Cleaning and protection
1. Warm up the engine, drain the engine oil away, clean the oil filter, and fill the engine with
anti-rust oil;
王明王明
亮(应 the fuel system, and fill it with anti-rust oil mixture; 亮
202.23 Empty 2023 (应用工
/11/ 用工程中 /11/ 程中
3. Empty13 the1cooling
3:13 心 ) (wan
system and then fill it with coolant containing 1rust
3 1inhibitor;
3 心)(
:41 gmin
g
: 1 3 :41 wangming
lianfor (15~25) min; lian
4. Start the engine, and run it at idle speed g01) g01)
5. Drain off the oil, fuel and coolant completely;
6. Protect the other parts of the engine.
3.5.2 Protection during storage
Block off the inlets and outlets of fuel, oil, air and coolant with caps or plastic cloth; cover and seal up the
whole engine with VCI film.
王训伟宋安泽
3.5.3 Oil sealing
亮(应亮period
(应用should be resealed as
20 the
Generally
23/1 seal valid period is one year, and engine out2of0 such
oil用
工于千钧许太法 23/1 工程
1 /13 程中 1 /13 中
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gm20200321
ingl 3:41 gmin
iang
ang0 gli
1) 01)
follows:
1. The oil seal operation should be carried out in clean environment, and the diesel engine and related
components should clean without rust, oil stain and dust.
王accordance with specific requirements, dipping, spraying,王coating or filling methods can be used.
2. In
明亮明亮
2 0 (应用 2 0 (应用
2 工
3/1positions: 2 3 / 11/1 工程
3. Oil seal
1/13 程中心 inlet/outlet port of turbocharger, inlet port of air compressor and intake pipe port.
3 13 中心)(w
13:1 )(wa :13:
3.5.4 Oil sealing 3:41 ngmi
ngli 41 angmingl
ang0 iang
1)
External packing should be provided in the event of transport. 01)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
Chapter 4 Typical Faults and Troubleshooting
4.1王Overview 王明
明亮亮
2 ( 应 2023 (应用工
4.1.102 3/11 用工程中 /11/
13 1 程中心)(
Overview
/13
13:1 心)(wan 3:13 wang and
3:designed
Engines of this series are 41 gminmanufactured under strict quality management
and :41 system, ming
glia
ng01Moreover, the engine is a precision machinery, itsliang01
have been passed the specified tests before delivery.
) )
lasting good performance is related closely to proper maintenance. The premature failure of engine is
generally resulted from:
1. Improper operation, management and use;;
2. Failure to inspect and maintain the engine as specified, or even, replace maintenance with repair;
3. Use of defective spare parts, or even counterfeit and shoddy parts, which will dramatically shorten
the service life of engine;
4. Use of fuel and lubricating oil with improper grade or poor quality.
王明王明
亮 CAUTION 亮
2023 (应用工 2023 (应用工
/11/ 程中 /11/
1. The engine13troubleshooting 13 1 程or中remove
13:1 心)(iswaancomplicated work. Thus, do not disassemble 心)( the engine
3
3
parts at discretion before
: 1 3
gmin its fault causes basically; otherwise, the
:41 determining glia :41faultwwill
angnot
minbe
glia
n g01due ng01
eliminated, and even more serious fault may occur ) to improper reassembling. )
2. Key components of the engine such as high pressure fuel pump and turbocharger should be
maintained and inspected by the experienced personnel with dedicated instruments. Therefore,
users having no relevant experience and equipment are not allowed to disassemble or adjust the
engine at random.
4.2 Fault diagnostic methods

4.2.1 Traditional fault diagnostic methods
1. 王明亮
Observation: Determine the fault by observing 王明
( 亮
2the 应 2023 (应用工
/11/ 用of
023symptom 工程 diesel engine, such as the /11/
1 中心
3 13smoke. )( 13 1 程中心)(
color of exhaust
wang 3:13
:13:
lian li ang0
g01) 1)
Fig. 4-1 Observation method

2. Listening: Determine the fault location and
severity by listening to the abnormal noise of
diesel engine.
3. Comparison: Replace a certain assembly or
component to determine
王训伟 whether it is宋安泽faulty.
亮亮应
2023 (应用工于千钧 2023 Fig.(4-2
/11/ 许太法 /11/ 用工 method
13 1 程中心)( 13 1 程中心)(
Listening
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
4.3 Common faults and troubleshooting methods

4.3.1 Engine cannot be started
1. The starter motor doesn’t work
The starter motor of the engine is controlled by ECU. When the starter is in normal operation, the ECU
王明 an output current to drive the starter relay. When the 王明
produces 亮(应亮is(应
relay activated, the battery drives the
2 0 2 用
3/11 to start工the 2 0 2 3/mainly 用工 the neutral gear.
/13 程中心) 程中
starter motor engine. In case of start failure, you should 11/1 check
13:1neutral gear( 3 parts
1 3 心)(
Factors to be checked:
3:41 angminw switch, starter relay, battery and related wang stop
:1of3:the off-vehicle
glia 4 1 ming
switch.
ng01 lian
a. Check the shift lever position ) g01)
Before starting, check if the shift lever is at neutral gear position. For the starter motor that is
controlled by ECU, when starting the engine, the ECU will determine whether the gear shift lever is
switched to neutral position based on the signal from the neutral switch. When the neutral switch or
its wiring is damaged, ECU cannot receive the neutral gear signal, and the starter motor will not
work.
b. Check whether the starter relay and its wiring are in good conditions
Check the surface of the wiring terminals for oxide, and check the wiring terminal bolt for looseness
or fracture.
王王明 motor.
明亮whether the battery voltage is too low to drive the starter 亮
2023 (应用工 2023 (应用工
c. Check
d. Check /1the
1/13 程中心
position of off-vehicle stop switch (which should be /1“OFF”
at 程中
1/13position).
) 心
e. Check whether the1 3:1starter (
3:41 angminw
motor has been burnt 1 3 :13: )(wangm
glrelay 41 ingl
Check with multimeter whether the starter iangis functioning properly. iang
01) 01)
f. Check whether the ignition switch and starting switch are damaged.
Turn the ignition key to “ON” position, and check whether the dashboard light is on;
Turn the ignition key to the “Starting” position, and check whether the starter motor is working (with
other causes having been excluded).
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 4-3 Starter motor

2. Common rail pressure build up failure (starter motor works properly, but the engine cannot be
started)
a. Check if the fuel level in the fuel tank is low, and if the hand fuel pump is functioning properly.
b. Check and remove

王训伟 the air in the low
宋安泽 pressure fuel pipe (Leakage of low pressure fuel pipe is
sometimes not noticeable, so careful inspection is required).
王Air明于千钧王明pipe joint on high pressure fuel pump,
亮(应of low pressure fuel pipe: Loosen the low pressure
removal 亮应
2operate 用工于千钧 2023 (from
023/ the hand
11/1 程中
pump on fuel filter 许太法
until fuel flows out /11/ 用
continually 工pipe
the 程中 joint.
心 1
3 13 )
:13: (wangm20200321
3 1 3:13 心)(wang
林世龙 41 ingl :41 ming
iang lian
01) g01)
If the diesel engine still fails to be started after the air in low pressure fuel pipe is removed, there may
be air in high pressure fuel pipe. Loosen the high pressure fuel pipe of one cylinder and drive the
diesel engine with starter motor until fuel flows out continually from the high pressure fuel pipe. (It is
recommended not to frequently dismantle the high pressure fuel line joint.)
c. 王 Check for leakage of high pressure fuel line. 王明
明亮亮(Check
2The
023/ ( 应
leakage of
用工 high pressure fuel line is quite easy to be2noticed.
0 应用 and tighten the joint nut of
11/1 fuel程 2 3 / 工
high pressure 3 13 中心)(w
line. 1 1 /13 程中心)
:13and angfilter 13:1 (wan
d. Check if the fuel line :41the fuel ngli 3:4timely.
mi are blocked. Replace the fuel filter element 1 gmi ngli
ang0 ang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/joint 程中
13 1 程中Fig. 心 )4-4 Hand fuel pump and low pressure fuel pipe
(wan 13 1 心)(
3:13 3
:41 gmin
g
: 1 3 :41 wangming
3. Poor connection of injector harness, sensor liharness
ang0 and vehicle harness connector, or wire harnessliang0
is open circuit or short circuit
1) 1)
Check the installation of connector, and check make-and break of circuit with the multimeter (“wiring
inspection tester” is recommended) according to the pins definition of the circuit diagram.
4. Crankshaft and camshaft signals lost
Two speed sensors are installed respectively on the flywheel housing and the oil pump of diesel
engine, and they serve as crankshaft position sensor and cylinder identification sensor. The fuel
injection timing of electronic-controlled engine depends on these sensors. When the diesel engine
fails to start, the two signals may be lost.
◆王明 causes of loss of both signals

Possible 王明
亮(应亮
20Sensor 2023 (应用工
用工or short circuit or open circuit of wire harness;
23/1 damage,
1/13 程中心 /11/
13 1 程中心)(
a.
1 3 : ) ( w 3 3 0.5mmwin
b. The sensor is not 1fixed
3:41properly, ming too large or too small clearance:1(1±
angcausing :41 angeneral)
gmin
glia
lian
between the sensor and the detection tooth. ng01
g01) )
Troubleshooting: check the sensor and wire harness for damage and reliable connection.
◆ The reassembly of high pressure fuel pump and flywheel must be performed in strict accordance with
related maintenance documents to ensure signal synchronization.
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 4-5 camshaft position sensor
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
Fig. 4-6 Crankshaft position sensor
4.3.2 Engine is hard to start

Causes and troubleshooting:
◆ The engine does not work for a long time: Fuel return pipe should be extended to below the fuel
liquid level.
◆ There is air in the low pressure fuel line: Remove the air.
王明王明
◆ 2Too
亮(应亮long
(应synchronization
023/weak 用工
crankshaft speed and camshaft speed signals, 202too
and
3 用工 judgment time:
Find the causes 程中adjustment.
11/1 and make / 1 1 /13 程中
3 13 心 13:1 心)(wan
:13: )(wangm 3:41flange wiring,
gminor
41 and failure
◆ Too low ambient temperature inglof pre-heating device: Check the heating glia
replace the pre-heating device.
i a n g01) ng01
)
◆ Poor diesel fuel or lubricating oil quality: Replace as required.
◆ Teeth collision appears at starter motor gear or flywheel ring gear: Replace the starter motor and
flywheel ring gear.
◆ Piston ring or cylinder liner wear or valve seal failure: Replace the piston ring, cylinder liner, or valve
seat and valve.
4.3.3 Engine power is insufficient

王训伟宋安泽
Limp home: An operation mode of engine with fault. The ECU detected an engine malfunction, but the
王will
明亮于千钧王明the engine power in such manner that
ECU not stop the engine immediately.
( 应
Instead, it will restrain 亮(应
2 023 speed
the engine 用can
工 only be increased to 1,500 r/min, so that 2023the driver
用can
工 drive the vehicle to the
/11/ 于千钧许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
nearest service station for repair.

1. Fuel injector fault
In general, fuel injector fault includes mechanical fault and wiring fault.
Mechanical fault: needle valve is stuck. The needle valve is seized in the fuel injector due to excessive
dirt王
in 明
the亮王this
fuel or water corrosion (Caution: ECU may not report 明亮 fault!).
2023 (应用工 2023 (应用工
/ 11the
Wiring fault: 程中 is disconnected or directly contact with
/13wire harness /1the
1/1cylinder程head
中心due to vibration,
心 ) 3 1fault.
1 3:1leading
wear and other causes, (
towshort
3:41 angmin circuit to ground. ECU will report this 3 : 13:4 )(wangmi
glia 1 ngli
ng01 ang0
Wiring terminal of injector ) 1)
王明王明
亮 Fig. 4-7 Injector wiring terminal 亮
2023 (应用工 2023 (应用工
/ 1/13 程lubricating /11/
2. Water 1 temperature, 中
13:1 心)(wan
oil temperature and air intake temperature 13 1are程high
中心
)(wa
3 : 1
3
When the water temperature, gmioil
:41lubricating ngli
temperature and air intake temperature 3 : 4
are1 high, nECU
gminwill
glia
enable the overheat protection function to limit theanengine
g01) power. ng01
)
Prior to troubleshooting, it is needed to eliminate the response distortion of the sensor and instrument.
◆ Causes of excessive high water temperature and troubleshooting method
a. The water level in the tank is low: Check for leakage and add water;
b. The fan rotates at low speed or does not rotate: Check the drive part of fan;
c. Water tank is blocked: Check and clean or repair the water tank;
d. Water pump belt is slack: Adjust the tension as required;
王e. Water pump gasket is damaged and water pump impeller

明亮王is明worn: Check, repair or replace;
( 亮
23/1 应用
2f.0Thermostat 工 2023 (应用工
failure:
1/13 程中心
Replace; /11/
1 ) ( 13 1 程中心)(
3:damaged: w 3:13 the damaged
g. Water pipe seal 13:4
1
angm
Check the water
ingl
pipe, joint and gasket, and replace
:41 wangmpart.
ingl
iang and troubleshooting method
◆ Causes of excessive high lubricating oil temperature iang
01) 01)
a. Low oil level in oil pan: Check the oil level and oil leakage, repair and add oil;
b. Water temperature is high: Check the causes of high water temperature for troubleshooting;
c. Oil cooler is blocked: Check and clean.
◆ Cause of high intake temperature and troubleshooting method
Check the heat transfer performance of intercooler.
3. Synchronization 王训伟
signal error 宋安泽
王明
When signal failure of one 王
this fault occurs, it is generally the 于千钧明
sensor.
亮(应亮(应
202the 用 through the flash code 2023code table
Read 1 code工于千钧
3/flash
1/13 中程许太法lamp, check the flash
中 /1 用to 工find
程 the specific causes.
1/13
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gmin
20200321 3:41 gmin
glia glia
ng01 ng01
) )
4. Flow metering unit malfunction

The flow metering unit is the actuator to control the common rail pressure. It is installed on the high
pressure fuel pump. In case of the metering unit failure, the high pressure fuel pump will supply fuel to
the common rail with its maximum capacity. At this time, the pressure relief valve on the common rail
pipe will open, and the diesel engine gives out clicking noise. The same occurs in case of malfunction of
rail王明 sensor.
pressure 王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11metering
13 1 程中心)( Flow /13 unit程中
13:1 心)(wan
3:13 wang 3:41 gmin
:41 connector
High pressure ming g
l iang lian
01) g01)
Flange
Fuel return connector
Shaft
Gear pump High pressure cylinder cover
王明王明
亮亮
2023 (应用工 2023 (应用工
Fuel inlet connector
/11/ /11/
13 1 程中心)( Fig. 4-8 Flow metering unit 13 1 程中心)(
3:13 w 3:13
:41 angming :41 wangming
Troubleshooting method: Check and repair lthe ianwiring, and determine if the fault occurs to the flowliang
metering unit or common rail pressure sensor, and g 01) the service center for troubleshooting.
inform 01)
5. Abnormal fluctuation of common rail pressure due to leakage in fuel line
In the process of vehicle operation, the engine speed is unstable.
Troubleshooting method: First, cut off the power supply of the vehicle for one minute and then restart. If
the fault still exists, check and repair the sealing of the fuel line.
6. Sensor fault
The ECU uses the intake air temperature and pressure sensor to estimate the air intake flow (mounted
on the intake manifold), the water temperature sensor is used to determine the engine thermal load
王明 on the water pump), and the rail pressure sensor王
(mounted is 明
used to detect the fuel pressure of the
亮 ( 应用(installed on the common rail). 亮(应
2
common
023/ rail pipe 2 用
023/
3 13 3 13
41 ingl 41 ing lian
iaunit
Fuel metering ng01)Rail pressure sensor g01)
王训伟宋安泽
Fig. 4-9 Air intake temperature/pressure sensor and water temperature sensor
亮亮应 water temperature sensor
2023 (应用
Troubleshooting 2023 (sensor,
method: Check the intake temperature and pressure
工于千钧用工
and rail /11 sensor,
pressure
/13 程中 and ensure 许太法
that the
/13 connectors are /11 firmly.
connected 程中
13:1 心)(wan 13:1 心)(wan
林世龙3:41 gmin
20200321 3:41 gmin
glia glia
ng01 ng01
) )
CAUTION
In the event of fault 1, 3, 4, 5 and 6, the diesel engine will enter the “Limp Home” mode.
4.3.4 Unstable idling speed of engine

王明王明
亮亮(应
202 and(troubleshooting
应用 202
/11/ 用工程中
Causes for unstable idling speed of engine:
3/11 工程 3
/ 1 中
1. Malfunction of3fuel 心
13injector: )(wa the fuel injectors and wire harnesses13of all 心)(
13cylinders.
:13: Check
41 n gmin
g
: 1 3 :41 wangming
2. For the engine equipped with speed sensor, lithere
ang0is speed signal input when the engine is stopped:liang0
1)
Check the tachometer and speed sensor signal and wiring. 1)
3. Poor fuel quality, containing water or waxes: Clean fuel system and replace fuel filter.
4. There is air in the low pressure fuel line: Check the air-tightness of fuel pipes and connectors and
remove the air.
5. Unstable atomization of fuel spray nozzle: Check and repair.
CAUTION
It’s王
a normal function of ECU that the idling speed will increase
王due to low water temperature.
明亮明亮
(应用 load (for instance, the air conditioner is turned
2023is additional 2023 on),(应
If there
/ 1/13 程中心工 /11/the用idling
工 speed will increase by
about 100 1r/min.
13:1 ) 13 程中心 13:1 )
glifailure
4.3.5 SCR exhaust after-treatment system
ang0 glia
1) ng01
1. The urea solution cannot be sprayed normally
)
The SCR system does not work when the engine is running normally. Check that the connectors of the
SCR urea pump, urea nozzle and urea sensor are reliable and check if the urea connection pipes and
joints are bent, loose or broken.
Check the liquid level of urea solution in the urea tank and add urea solution timely. If poor quality urea
solution is used, check and clean the urea tank. Check and clean the urea pump filter element. Replace
the urea pump filter element if it is contaminated seriously. Check for contamination of urea nozzle, and
clean or replace the urea nozzle when necessary.
If the engine is running in cold weather, it is normal for the urea solution not to be sprayed normally
王明 the urea solution has not been thawed completely. If王the 明unfreezing
because 亮( 亮(应 cannot be completed for a
long 23 the应
20time,
/11/ heating
程中
2023the repair
用工 function may be faulty. Please contact with /11/ 用service
工 station.
13 backpressure
13:1 心)(increased 13 1 程中心)(
3:41 wangmin 3:13
:41 wangming
2. Engine exhaust
gli
If serious black smoke and high fuel consumptionang0occurred when the engine was running, please li ang0
1) 1)
check for urea crystals or stones in the exhaust pipe. Low environment temperature and poor
atomization of urea solution from spray nozzle may lead to obvious urea crystallization on the inner
wall of pipe. Thus, it is necessary to take the insulation measures for exhaust pipe or check the
blockage of urea nozzle. Check the catalyst carrier in the SCR tank for damage and timely contact the
repair service station for troubleshooting.
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
Contact Us
王明Power Co., Ltd.

Weichai 王明
亮(应 East Fushou Street, High-Tech Development Zone, 亮(应 Shandong, Euro
2023 197A,
Address: 用工 2023 Weifang,
/ 11/1 程中 /11/ 用工程中
心 13 1
3 13 3:13 心)(wang
Zip code: 261061
:13: )(wangm :41 ming
41
Website: http://www.weichai.com ingl lian
iang g01)
Free service or complaints hotline: 400-6183066 01)
Free service or complaints hotline: 800-8603066 (only for landline calls)
Customer service hotline: 0536-8235369 (Fax)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 liang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 liang0
1) 1)
王训伟宋安泽
亮亮
/11/ 许太法 /11/
13 1 程中心)( 13 1 程中心)(
3林世龙 w 3:13
:13:
41 angm20200321
ingl :41 wangming
iang ang0 li
1) 0 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
1) 1)
XK06-002-00156
王明王明
亮亮
2023 (应用工 2023 (应用工
/11/ /11/
13 1 程中心)( 13 1 程中心)(
3:13 3:13
li ang0 li ang0
Weichai Power Co., Ltd. 1) 1)
Address: 197A, East Fushou Street, High-Tech Development Zone, Weifang, Shandong, Euro
Zip code: 261061
Tel: 0536-8197777
Fax: 0536-8231074
E-mail: weichai@weichai.com
Website: http://www.weichai.com
王训伟
Service hotline: 400-6183066 宋安泽
亮亮
This document is for reference only. Product parameters or pictures are subject to change without prior notice. The actual product shall prevail.

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WP9H、WP10H、WP10 5H发动机保养说明书-英文

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WP9H、WP10H、WP10 5H发动机保养说明书-英文

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王明 王明

 Before operation, please carefully read this manual,

 For the engine with a turbocharger, the rotor shaft of

Tightening torque requirement

Please read this Manual before operation

3. Do not place the oily rag in the pocket.

4. Avoid contaminating clothes especially underwear with oil.

6. In case of injury, take first-aid measures as soon as possible.

11. Remove oil from the parts before transportation, if available.

12. Please wear goggles

4.3 Common faults and troubleshooting methods ........................................................................................... 25

Chapter I Engine Structure and Performance

1-Alternator; 2-ECU; 3-Oil-gas separator; 4-Injection pump; 5-Air compressor

Fig. 1-1 Outline drawing of the engine (fuel pump side)

王明 Fig. 1-2 Outline 于千钧 王明

Fig. 1-3 Outline drawing of the engine (the fan end)

Product variant code

Emission level code

1.3 Main performance parameters

Other parameters are as shown in Table 1-1.

Table 1-1 Main Parameters of the Engine

Item Technical parameters

Chapter II Installation and Operation

Fig. 2-1 Hoisting of the engine

Fig. 2-2 Fuel system protector

3. Check the oil level

2.5 Engine starting

2.7 Engine stopping

3) Preconditions for activating the Jacobs in-cylinder braking system

The clutch pedal is released;

王明The transmission is in gear (not neutral position); 王明

3. How to increase the braking effect

2) The recommended engine braking speed is (1,900~2,300) rpm.

Chapter III Maintenance

3.1.2 Lubricating oil

Table 3-2 Oil Viscosity and Applicable Ambient Temperature

Viscosity grade Applicable ambient Viscosity grade Applicable ambient

Table 3-4 Selection Criteria of Coolant

Category Grade Packing specification

Urea solution quality

Table 3-5 Compositions of urea solution (refer to ISO 22241)

Composition Unit Minimum Maximum

王明Aluminium mg/kg 王明 - 0.5

Table 3-6 Shelf Life of urea solution for Vehicle

Shelf life of urea solution for vehicle

The sealant application of engine is given in Table 3-8.

Table 3-8 Sealant Application of Engine

Suction strainer support bolt

1. Check the coolant level, oil level and fuel level

2. Check for oil, water or air leakage.

3. Check if the external parts and accessories

6. Check the oil return pipe of turbocharger for

7. Check the exhaust pipe for leakage and

Caution: Before opening the filler cap, make

At this time, add oil through the oil filler.

Always check the oil level at least 5 min after

3.3 Maintenance items

1. Unscrew the drain plug at the bottom of oil pan,

Oil filler cap

王训伟 宋安泽 Fig. 3-6 Oil filler cap

王Replacement of oil filter or filter element

4. Replace the base pipe

3.3.3 Check and adjust valve clearance

王明王明

王明 Fig. 1-2 Outline 于千钧王明

王训伟宋安泽 Fig. 3-6 Oil filler cap

9. Install and fix the王训伟宋安泽

◆王明 causes of loss of both signals