Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Operation and Maintenance Manual for WP10 Series

Four-valve Diesel Engine (China IV, V)

Weichai Power Co., Ltd.

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

WP10 Series Four-valve Diesel Engine (China IV, V)

Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Special Notice
● Before operating the diesel engine, please always read this Operation and Maintenance Manual carefully, and
follow the technical operation and maintenance practices therein strictly.
● As the diesel engine has been tested strictly according to the related test specification, it is prohibited to
increase the engine power by changing the ECU data without permission, otherwise, the warranty service
commitments of Weichai will be invalid.
● The ECU, common-rail fuel pump and injector are of precision components, it is prohibited to disassemble at
will; otherwise, the warranty service commitments of Weichai will be invalid.
● The turbochargerotor shaft is of precision and high speed rotation component, it is prohibited to disassemble
or impact with hard objects; otherwise, the warranty service commitments of Weichai will be invalid.
● For the important bolts of diesel engine (such as main bearing bolt and connecting rod bolt), there are strict
requirements on tightening torque and rotating angle, it is prohibited to unscrew or dismantle at will. The
connecting rod bolt can be used only one time. Otherwise, the warranty service commitments of Weichai will
be invalid.
● The diesel engine should use the oil and fuel specified in this Operation and Maintenance Manualand they
should be filtered with special clean filters in filling (the fuel should also be deposited for 72h before being
added). Check the coolant and oil level every time before starting the engine.
● It is prohibited to run the diesel engine without air filter to avoid the unfiltered air from entering the cylinders
directly.
● For the new diesel engine, 50h test run shall be performed before normal using.
● After the engine is started in cold state, please run it at idle speed for a while (do not run it at idle speed for a
long time) and then increase the engine speed slowly. After running under heavy load, do not stop the engine
immediately (except in special cases), you should run the engine at low speed for 5~10 minutes before
stopping.
● Please check the coolant periodically and replace it if necessary. It is prohibited to use cold water or
low-grade coolant.
● Inspection and repair of the electrical system components of diesel engine should be carried out by
professional technicians.
● Inspection and repair of the electronic control system components of diesel engine should be carried out by
professional technicians of Weichai Service Station.
● In general, the oil seal period of diesel engine is one year, please check and take necessary measures if
exceeded.
● The key components (such as turbocharger, injection pump, injector, ECU, exhaust after-treatment system
and EGR system) related to engine emission should be replaced with that of the same model of same
manufacturer. Otherwise, Weichai will not bear any responsibility for the diesel engine damage caused due to
not using the specified spare parts.
Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Foreword
This seriesdiesel engine is of high-speeddiesel engine developed and manufactureby Weichai Power Co., Ltd.This

series has a compact structure, reliable operation, excellent performance, low fuel consumption and meets the

requirements of international emission standards. The engine is quick to start, simple to operate and easy to

maintain.

This manual covers the basic information for the use and maintenance of the diesel engine. To gain optimum

performance and properly maintain the engine, please understand the diesel engine structure in detail,and learn to

master the maintenance and use methods.

With the continual launch of new products in this series, notification of changes will be made via our website;

please visithttp://www.weichai.comfor the latest product information.

June 2017
Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Contents
1. Product overview .......................................................................................................................................... 1
1.1 Power and speed of the diesel engine ......................................................................................................... 1
1.2 Main structural features of the diesel engine .............................................................................................. 1
1.3 Meaning of the diesel engine model ........................................................................................................... 1
1.4 Outline drawings of WP10 series China IV/V diesel engine ...................................................................... 2
2. Technology and performance parameters of the diesel engine ..................................................................... 2
2.1 Main technical parameters of the diesel engine .......................................................................................... 2
2.2 Main performance parameters of the diesel engine .................................................................................... 3
3. Fuel, Lubricating Oil, Coolant, Diesel Exhaust Fluid and Auxiliary Material of the Diesel Engine............ 5
3.1 Fuel ............................................................................................................................................................. 5
3.2 Lubricating oil ............................................................................................................................................ 5
3.3 Lubrication of tensioner.............................................................................................................................. 6
3.4 Diesel engine coolant.................................................................................................................................. 6
3.5 Diesel Exhaust Fluid ................................................................................................................................... 7
3.6 Auxiliary materials ..................................................................................................................................... 7
4. Use and Operation of the Diesel Engine....................................................................................................... 9
4.1 Diesel engine unsealing .............................................................................................................................. 9
4.2 Hoisting of diesel engine .......................................................................................................................... 10
4.3 Installation of the diesel engine ................................................................................................................ 10
4.4 Preparations for Diesel Engine Starting.................................................................................................... 10
4.5 Diesel Engine Starting ...............................................................................................................................11
4.6 Diesel Engine Running ..............................................................................................................................11
5. Regular Inspection and Technical Maintenance of the Diesel Engine........................................................ 13
5.1 Routine Maintenance of the Diesel Engine .............................................................................................. 13
5.2 Periodic maintenance items ...................................................................................................................... 16
5.3 Maintenance of Diesel Engine for Long-term Storage ............................................................................. 26
5.4 Regular inspection and maintenance of diesel engine .............................................................................. 27
6. Common Faults and Troubleshooting......................................................................................................... 29
6.1 Fault Diagnostic Method .......................................................................................................................... 29
6.2 Common Faults and Troubleshooting....................................................................................................... 30
Appendix: Power correction factor ................................................................................................................. 42
Contact Us ...................................................................................................................................................... 43
Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

1.Product overview

1.1 Power and speed of the diesel engine

The power range of WP10 series diesel engine (China IV, V) is 175-247kW, the rated speed is 1900r/min.

1.2 Main structural features of the diesel engine

● One cylinder one head, reliable in working and convenient in dismantling.

● Left side arranged common rail system is adopted (viewed from the free end of the diesel engine) foreasy
vehicle lay out.

● Framemain bearing structure,high strength cylinder block, ensuring the high reliability and long service life of
the whole engine.

● Middle or rear arranged turbocharger, with small change of overall dimensions of various models.

● Front designed gear train, with impact structure and lower noise

● All series of products are of inline six-cylinder structure with good interchangeability, convenient for vehicle
matching.

● Equipped with high pressure common rail system and SCR after-treatment system.

1.3 Meaning of the diesel engine model

WP10.XXE4(5)X

Rated speed

Emission level

Rated power, Ps

Displacement, L

POWER

WEICHAI

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

1.4 Outline drawings of WP10 series China IV/V diesel engine

2. Technology and performance parameters of the diesel engine

2.1 Main technical parameters of the diesel engine

Table 2-1 Main technical parameters

Engine type Liquid cooled, 4-stroke, DI, turbocharged and
inter-cooled, with EVB
Bore/stroke (mm) 126/130
Displacement (L) 9.726
Compression ratio 17:1
Firing order 1-5-3-6-2-4
Fuel system Electronic controlled high pressure common rail
Catalytic converter Urea-SCR system
Cold state valve clearance (mm) Intake valve: 0.4; exhaust valve: 0.6; EVB
system: 0.4
Valve timing Intake valve open: 20° before TDC;
(valve clearance: intake 0.4, exhaust 0.6) Intake valve close: 34° after BDC;
Exhaust valve open: 49° before BDC;
Exhaust valve close: 21° after TDC
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Thermostat opening temperature (°C) 83

Starting type Electric starter
Lubricating mode Pressure lubrication
Oil capacity (L) 24
Cooling mode Water cooling forced circulation
Oil pressure (kPa) 350~550
Oil pressure at idling speed (kPa) ≥100
Permissible longitudinal Front/rear Long time: 10/10 Short time: 30/30
inclination (°)
Permissible sidewise Exhaust manifold Long time: 45/5 Short time: 45/30
inclination (°) side/injection pump side
Crankshaft rotation (view from free end) Clockwise

2.2 Main performance parameters of the diesel engine

Table 2-2 Main performance parameters

Unit WP10 diesel engine(China IV, V)

Engine model WP10.240 WP10.270 WP10.300 WP10.336

Engine type - Liquid cooled, 4-stroke, DI, turbocharged and inter-cooled,

with EVB and SCR

Displacement L 9.726

Bore × stroke mm 126×130

Number of cylinders - 6

Valves per cylinder 4

Fuel injection equipment Electronic controlled high pressure common rail

Rated power kW 175 199 221 247

Rated speed r/min 1900

Max torque Nm 1150 1270 1390 1500

Speed at max torque r/min 1200~1500

Emission level - China IV/V

Fuel consumption at rated power g/kWh ≤210

Min fuel consumption at full load g/kWh 195

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Cold starting (without starting aid) °C -10

White smoke emission Opacity ≤15% after idling for 20s

Cold starting (with starting aid) °C -30

Noise at 1m away from the engine dB(A) <104

B10 lifetime km 800,000

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

3. Fuel, Lubricating Oil, Coolant, Diesel Exhaust Fluid and Auxiliary Material of the Diesel

Engine

3.1 Fuel

In summer: 0# diesel fuel (GB252) should be used.

In winter: Select the fuel of proper gradeaccording to the ambient temperature.

3.2 Lubricating oil

For Weichai Power China IV Series and China V series Diesel Engines, grade CI-4 should be used. Special oil
for Weichai Power should be usedrefers to table 3-1.

Table3-1 Specification for Weichai Power special oil selection

Packaging
Type Product class Applicable engine models
capacity

Oil for 10w/30 China IV series diesel engines: WP4,

diesel CI-4 15w/40 4L,18L,170kg WP5, WP6, WP7, WP10, WP12,
engine 20w/50 WP13,etc.

For Viscosity selection for Weichai Power special oilrefers to table 3-2.

Table 3-2 Relation table between viscosity and applicable ambient temperature

SAE Viscosity grade Applicable ambient temperature (℃)

0W-20 -35-20
5W-30 -30-30
10W-30 -25-30
15W-40 -20-40
20W-50 -15-50

Attention:

1) Before starting the diesel engine, check the oil level in the oil sump firstly.

2) Don't inspect the oil level when the diesel engine is running.

3) Oils with different manufacturers or different grades are not allowed for mixing with Weichai Power special
oil.

Table13-3Oil filling capacity and filter element number for all series of Weichai engines

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Filter numbers

Oil
Diesel engine Gas engine
Engine filling
series capacity
Fuel filter
(L)
Oil filter Oil filter Gas filter
Coarse filter Fine filter

WP10 22~26 2 1 1 2 1

Note:

1) The oil filling capacity in this table is only for reference, for the actual filling, take the oil
dipstick as the standard.

2) If fuel system protector or fuel filter with water separator is equipped, its element should be
replaced together with the fuel filter.

3.3 Lubrication of tensioner

The tensioner shall be lubricated with general lithium base grease for automobile (Refer to national standard
GB/T5671-1995).

3.4Diesel engine coolant

The diesel engine cooling system shall be filled with pure coolant. The function of coolant is to prevent freezing
under cold weather and to prevent boiling under high temperature. Furthermore, the coolant contains
rust-inhibiting and anticorrosion additives, which can offer special protection to the water tank and engine cooling
chamber, and avoid cylinder liner cavitation and cooling system corrosion.

The Weichai Power special coolants with freezing points of -25°C, -35°C and -40°C are available. Please choose
the coolant based on the local ambient temperatures in such manner that the freezing point of coolant should be
10°C lower than the local air temperature.

Table 3-4Weichai Power special coolants for heavy-duty engine

Type Designation Packing

HEC-II-25
Heavy-duty
HEC-II-35 4kg, 10kg
engine coolant
HEC-II-40

Notice:1) Check the coolant regularly to prevent corrosion damage. Replace the coolant if necessary.

2) Never use water or low-grade coolant.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

3.5 Diesel Exhaust Fluid

The substandard diesel exhaust fluid(DEF) will easily lead to poisoning failure of SCR catalyst orlower reduction
efficiency(For instance, the out-of-limit of phosphorus, sodium, potassium and calcium contents in the DEF will
easily lead to poisoning of catalyst and if the concentration of DEFis unqualified, it will easily lead to excessive
leakage of NH3 or lower reduction efficiency of NOx) and excessive emission and malfunction indicator lamp
warning. So, the quality and the performance of DEF shall meet the requirements specified in standard ISO 22241.
See table 3-5 for details.

Table 3-5DEF specifications as perISO 22241

Items Unit Minimum Maximum

Urea content % by weight 31.8 33.2

Density at 20°C kg/m³ 1,087 1,093

Refracting index at 20°C - 1.3814 1.3843

Alkalinity as NH3 % - 0.2

Biuret % - 0.3

Aldehyde mg/kg - 5

Insolubles 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

Aluminium mg/kg - 0.5

Magnesium mg/kg - 0.5

Sodium mg/kg - 0.5

Potassium mg/kg - 0.5

3.6 Auxiliary materials

Table 3-6 Auxiliary materials and applications

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

No. Name Color Function and application

Molykote Pulver Applied on flat and smooth metal surfaces to prevent seizing
1 Black
(fine molybdenum powder) For instance: Applied onto outer surface of cylinder liner

Molykote G-N plus Achieve lubrication function before lubricating oil pressure is
2 (Molybdenum disulfide, oil Dark grey built up
solution) For instance: Applied onto intake valve stem

Table 3-7Application of sealant for diesel engine

Grade Major application Application part Supplements

Flywheel housing bolt
Camshaft thrust plate bolt
Camshaft timing gear bolt
Intermediate idler gear bolt
Front end cover bolt
Applied onto the threads to
Oil filter head bolt
prevent looseness due to Alternatively,
Loctite 242 Oil cooler bolt
vibration, with moderate DriLoc204
Screw plug of engine oil cooler regulator
strength. thread-locking
valve
adhesive can be
Bolt of oil pump return pipe fixing device
used for
Air compressor shaft end thread
pre-coating
Strainer bolt
Bolt of sensor and harness fixing device
Applied onto the external
threads for locking, sealing,
Loctite262 Cylinder head secondary bolt
preventing vibration from
causing looseness
Loctite271 Locking and tightening Bowl-shape plug for oil hole
For sealing between core and
Loctite277 Other bowl-shape plugs
hole
For sealing of cylinder head top
Loctite270 Push rod tube - cylinder head
surface

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Mating faces of cylinder block and crankcase

Cylinder block front end face and the front
end cover
Connecting plate between cylinder block rear
end face and flywheel housing
Loctite518 Mating faces of oil filter seat and crankcase
(upgraded Applied on shining metal Water pump rear cover and cylinder block
product based surface for sealing front end face
on 510) Flywheel housing connecting plate and
flywheel housing
Mating face between cylinder block and
engine oil cooler
Mating face between cylinder block and oil
filler port cover plate

4. Use and Operation of the Diesel Engine

4.1 Diesel engine unsealing

After opening the engine packing case, please check the engine appearance for damage and loose connection
before carrying out the following operations:

1) Wipe away the rust proof coat or anti-corrosion agent on the surfaces of exposed components.

2) Drain the sealing oil from the fuel filter and fuel system components (it is allowed to run the engine with load
only when the sealing oil is used up and the normal diesel fuel has been supplied).

Notice: The oil seal is only effective for one year, and when the time is up, please get your engine inspected and
take necessary remedies.

3) Rotate the flywheel and spray solvent into the intake pipe until the oil sealing oil in the cylinder is completely
removed.

4) Spray solvent into the turbocharger intake/exhaust ports until the oil sealing oil is completely removed.

5) Add lubricating oil of specified grade to the oil pan as required.If the oil containing running-in accelerant is
filled in the oil pan before delivery, it is suggested that the oil should be drained off after running for2,000km (or
50h) and then fill with new oil.

6) Base on the agreement between Weichai and user, if the coolant is already filled according to the user’s
requirement before delivery, please check the coolant performance when unpacking. If the antifreezing capability
is suitable for -30°C or -35°C, the PH value is 7~8 (neutral), the total hardness number is 5-15°d [9-15°f
(hardness)], the coolant can be used. Otherwise, drain the coolant and add new coolant which contains antifreeze
additives.
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

4.2 Hoisting of diesel engine

When hoisting the engine, keep the engine crankshaft centerline in horizontal state, and never hoist the engine
obliquely or at one side (as shown in figure 4-1).

Correct Wrong

Figure 4-1Diesel enginehoisting

4.3 Installation of the diesel engine

When installing, it should be ensure that the centerline of diesel engine crankshaft is concentric with the axis of
input shaft of driving device (gear box, alternator etc.) and elastic coupling should be used to ensure that there is
noadditional axial foron the crankshaft caused by the installation.

4.4 Preparations for Diesel Engine Starting

1) Check coolant level

Check the coolant level through the glass window of expansion tank, and add coolant from the filler port if
necessary. When the engine is still hot, beforeopen the filler cap with relief valve and bleed button, please always
press down the bleed button first to release the hot air. It is prohibited to add a large amount of coolant when the
engine is relative hot; otherwise, the related parts of diesel engine may get damaged due to sudden excessive
temperature change. The coolant (water) should be added via the filler port until it overflows.

Start the engine, and when the engine is running (at 1000 r/min), continue to add coolant till the liquid level is
stable, and then close the filler cap.

2) Check fuel level

If the engine has been installed on the vehicle, please turn on the power supply switch, and check fuel level
through the fuel meter or check the fuel tank directly.

3) Check engine oil level

The engine oil level shall be locatedat between the upper and lower markings of the oil dipstick. If necessary, add
engine oil from the filler port.

4) Check liquid level in DEF tank

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Generally, the DEF consumption accounts for 3~5% of the fuel consumption (by volume). Check the liquid level
of DEFfrequently based on the use condition. Please maintain the liquid level at 30~80% of full level and timely
add if necessary.

Figure 4-2 Urea Level Identification on Urea Tank

4) Check all accessories of the diesel engine for reliable connections.

5) Check the starting system for normal wiring and check and ensure that the battery is chargedsufficiently.Then
open the fuel tank valve, loosen the bleeding screw onprimary fuel filter, and operate the manual pump on the fuel
filter toremove the air inside the fuel system.

4.5 Diesel Engine Starting

1) Turn the power switch, ignition key to the starting position, andmove the gear lever to the neutral gear position
before starting the engine.

2) Depress the clutch pedal and throttle pedal, and turn the ignition key to start the engine.Ifthe engine fails to be
started within 5~10 seconds for the first attempt, start it again one minute later. If the engine still fails to be started
after three attempts, stop the attempt and find out and solve the malfunction before retry.After the engine is started,
check the readings of meters. The engine oil pressure meter shall immediately indicate a pressure. For the cold
engine, you should run it at idle speed for a while (no more than 10 minutes).

3) It is recommended to use the starting aid in case of engine startup at lower temperature. Under the action of
relay, the electronic heating flange begins to work and then heats the incoming air, allowing a smooth startup of
the engine at -30°C.

4.6 Diesel Engine Running

1) After the engine is started, run it at idle speed for a few minutes and then increase the speed to (1,000~1,200)
r/min and add part load.Only when the water outlet temperature is higher than 60°C and the oil temperature is
higher than 50°C, can you operate the engine with fullload. It is recommended to increase the load and speed
gradually, and avoid sudden loading or unloading as possible.

2) In the running-in period (about 60h or 3,000km) of diesel engine, the engine can only be run with load below
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

the moderate.

3) Speed down timely when driving on a slope road. Long term work under large torque condition, small load and
low rotating speed are not recommend, for which may lead to excessive oil consumption.

4) In normal use, you can run the diesel engine continuously at rated power and rated speed. But if the running
speed is 105% or 110% of the rated speed, it can be allowed to run for 20 minutes only. After the diesel engine is
unloaded, it is required to run the engine at idle speed for (1~2) minutes before shutdown.

5) Check the following parameters in operation:

a. Oil pressure in main oil passage:(350~550) kPa;

b. Oil temperature in oil pan: ≤110°C;

c. Coolant outlet temperature: (80+5) °C, no more than 95°C;

d. Exhaust temperature after turbine: <600°C;

e. Intake temperature after intercooler: (50~55) °C.

6) Check the color of exhaust gas to estimate the working performance of fuel injector and the operating load; if
the color is abnormal (i.e., serious black or white smoke), stop the engine for troubleshooting.

Notice: Check the diesel engine for water, air and oil/fuel leakages during operation; and if any, stop the
engine for troubleshooting.

7) The operator should acknowledge the following features of the engine:

a. The fuel consumption is relatively low at max torque, and increases along with the rotation speed rise.

b. The torque reaches its peak value within the medium speed range (1,200 - 1,500 r/min);

c. The engine power increases along with the speed, and reaches its rated value at rated speed.

8) Precautions for engine running under cold environments:

a. Fuel: Choose the diesel fuel of proper grade according to the ambient temperature in winter.

b. Lubricating oil: Choose the lubricating oil with proper viscosity based on the season.

c. Coolant: The cooling system should be filled with coolant (containing antifreezing additives) of proper grade
according to the ambient temperature.

d. Startup: Use starting aid when necessary in winter. After starting the engine, the running speed and load of
diesel engine can be increased only after the oil pressure and water temperature become normal.

e. Battery: Before the cold season comes, make sure to check the electrolyte level, viscosity and unit voltage of
the battery; and if the diesel engine is not used for a long time and the ambient temperature is very low, it is
recommended to remove the battery and keep it in a warm room.

f. Shutdown: To stop the engine in cold weathers, unload the engine first, and run it at idle speed for (1~2)
minutes, and wait for a while until the water temperature and oil temperature lower down; the coolant with

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

antifreeze should not be drained out after shutdown. However, if the coolant contains no antifreeze additive, make
sure to drain off the coolant from the engine block, oil cooler cover, radiator and water pipes to prevent the engine
from being frost cracked.

5. Regular Inspection and Technical Maintenance of the Diesel Engine

5.1Routine Maintenance of the Diesel Engine

a. Check the liquid level and temperature of coolant

Check the coolant level through the sight hole on the expansion tank, and if it is insufficient, open the filler port
cap to add coolant. As shown in figure 5-1 and 5-2.

Notice: Before opening the filler cap, press down the air bleeding button to avoid personalby the hot coolant
while the engine is hot.

Figure5-1Coolant filler port cover

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Expansion
tank

Figure 5-2 Expansion tank

b.Check the oil level

Check the oil level with oil dipstick.When the oil level is below the lower mark or above the upper mark, it is not
allowed to start the diesel engine.

When checking the oil level, stop the engine and wait for at least 5 minutes, enabling the oil to flow back to the oil
pan. The oil capacity difference between the upper mark and lower mark is about 3L.As shown in figure 5-3.

Oil dipstick

Figure 5-3 Oil dipstick

c. Check fuel level

d. Check for leakages

Check the external surface of diesel engine for water, air/gas and oil/fuel leakage.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Figure 5-4 Diesel engine

e. Check the liquid level in DEF tank

The liquid level should be maintained in between 30% to 80% of total urea tank volume.

f. Check the fan

Visually check fan blade fordeformation and damage and check the connecting bolts for tightness (Figure 5-5).

Figure 5-5

g. Check the belt

The belt is automatically tensioned by the tensioner. Check the tension of belt by pressing the belt with hand.

h. Check the exhaust color

The normal color of exhaust gas is light grey. Do troubleshooting if the color has changed. See figure 5-6.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Figure 5-6

h. Check the running sound of diesel engine.

i. Check the speed and vibration of diesel engine.

5.2 Periodic maintenance items

 Replace the engine oil

Place anoil recycling container under the engine, unscrew the drain plug at the bottom of oil pan (figure5-7), drain
off the oil completely, and then screw in the drain plug again.

Openthe oil filler cap, add fresh new oil through the filler port, the oil should be filtered by a strainer when filling;
check the oil level through the scale mark of oil dipstick, tighten the filler port cap finally. See figure 5-8

Oil filler port

Drain plug

Figure5-7 Figure 5-8

Notice:Set the vessel containing waste oil in specified placefor recycling.

 Replace the oil filter or filter element (figure 5-9)

a. Remove the old oil filter;

b. Fill the new filter with clean oil;

c. Apply lubricating oil on the sealing gasket before installing the new oil filter;

d. After the sealing gasket touches the filter seat, tighten 3/4 to 1 more turns to seal tight;
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

e. Start the engine to check for oil leakage.

Oil filter

Figure 5-9

 Check and adjust intake/exhaust valve clearance

Check and adjust intake/exhaust valve clearance as follows:

a. With the diesel engine in cold state, turn the flywheel with a bar (along with the running direction of diesel
engine crankshaft) to make the pistons of No. 1 cylinder and No. 6 cylinder to TDC, when the notch groove on
flywheel should be aligned with the pointer on the inspection window cover plate.

b. Remove the valve rocker arm cover from the cylinder head, and determine if the No. 1 cylinder or No. 6
cylinder is in the compression stroke (as indicated by the existence of clearance between the intake/exhaust valve
and the rocker arm under the compression stroke).

c. Use a feeler gauge to check the clearance between the upper plane of valve bridge and rocker arm. For WP10
diesel engine, the intake valve clearance and exhaust valve clearance should be 0.4mm and 0.6mm respectively.
Please rotate the adjusting screw on the rocker arm to achieve proper valve clearance. See figure 5-10.

Adjusting screw

Figure 5-10 Cold state valve clearance: intake valve, 0.4mm; exhaust valve, 0.6mm

d. After the checking of the No. 1 or No. 6 cylinder, turn the flywheel by another 360°, ensuring that the No. 6
cylinder or No. 1 cylinder is in working stroke, and then adjust the remaining valves (see table 5-1).
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Table 5-1Adjustment of valve clearances

No. 1 cylinder No. 2 No. 3 No. 4 No. 5 No. 6 cylinder

cylinder cylinder cylinder cylinder

No. 1 cylinder, Intake/exhaust Intake Exhaust Intake Exhaust Non-adjustable

compression stroke valves valve valve valve valve

No. 6 cylinder, Non-adjustable Exhaust Intake Exhaust Intake Intake/exhaust

compression stroke valve valve valve valve valve

Adjustment of exhaust valve with EVB:

Figure 5-11 Adjustment of exhaust valve and EVB clearances

With the piston at TDC of compression stroke;

Loose nut 1;

Adjust the screw 1 till the clearance between the screw and the valve bridge is “0”;

Loose nut 2;

Adjust the screw 2 and set a feeler gauge (0.6mm) in between the screw 2 and the valve bridge;

Adjust the screw 2 to make the feeler gauge being clamped by the small piston;

Adjust the valve clearance 0.6mm, turn the adjusting screw till the feeler gauge being clamped and then lock the
nut;

Adjust the screw 1 and set a feeler gauge (0.4mm) in between the valve bridge and the screw 1;

Adjust the screw 1 to make the feeler gauge being clamped by the small piston and then lock the nut;

Check the valve clearance and make adjustment if necessary.

 Replace the fuel filter element (figure 5-12)

Replace the fuel filter element as follows:

a. Remove the used fuel filter element, if the water collector installed on the primary filter can be reused, please

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

remove the collector.

b. Apply lubricating oil to the sealing port.

c. Screw the fuel filter with hands until the sealing port comes into contact with the mating port.

d. Continue to screw the new fuel filter until it is securely installed (about 3/4 turn).

e. Remove the air in the fuel system.

f. Conduct the leakage test.

Fuel filter

Figure 5-12

Notice: After replacing the primary spin-on filter or reinstalling fuel pipe, remove the air in the primary filter (see

figure 5-13).
① Stop the engine.
② Dismantle the bleeding screw on the primary fuel filter.
③ Pumping fuel with hand pump until only fuel comes out.
④ Retighten the bleeding screw.

Figure 5-13 Air removal from the primary fuel filter

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Drain off the water inwater collector of filter (figure 5-14):

(Notice: Drain the water timely when the water collector is full or the spin-on filter is replaced)

① Open the drain plug 2 at the bottom of water collector 1 to drain the water out.

② Retighten the drain plug.

Figure 5-14

Steps for replacing water collector (see figure 5-15):

a. Stop the engine.

b. Drain off the water from water collector.

c. Remove the water collector.

d. Apply lubricating oil to the seal ring of new collector.

e. Install the water collector by hand and tighten up with tool.

f. Check the water collector for damage before it is being used in a new filter.

g. Install the water collector with a torque wrench (tightening torque: 20Nm).

Figure 5-15

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

 Check the intake system (figure 5-16)

Check the intake hose for cracks due to aging, and check the clamp for loosening. When necessary, tighten or
replace the related parts to ensure the tightness of intake system.

Intake manifold

Figure 5-16 Intake system

 Check the air filter element

Figure 5-17 Air filter element checking

The maximum allowable intake resistance of the diesel engine is 7kPa. Please check the maximum intake
resistance only when the diesel engine is running at rated speed and full load. If the intake resistance reaches the
maximum permissible limit, please clean or replace the filter element timely as per the manufacturer’s
instructions.

Notice: It’s absolutely prohibited to run the engine without the air filter; otherwise, dust and foreign matters may
get into the cylinder of diesel engine to cause early wear of diesel engine.

Dismantle the filter element from the air filter, and tap the end face of filter element or blow with compressed air
(from inside out) to remove the dust.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Figure 5-18 Filter element cleaning

Notice: 1) Do not damage the filter paper;2) Do not clean the filter paper with water or oil; 3) Do not knock the
filter element forcibly.

● Check urea dosing pump filter element

At the time of maintenance, it’s necessary to remove the filter element of urea dosing pump and thoroughly clean
with water before installation. Do not slap or knock the filter element forcibly.

● Check the urea nozzle gasket

At each replacement or disassembly of urea nozzle, it’s necessary to check the urea nozzle gasket. In event of
damage or deformation, replace the gasket.

● Clean the urea tank and urea tank filter element

At the time of maintenance, it’s necessary to check the cleanliness of urea tank and filter element and clean them
if necessary.

 Maintenance of urea dosing pump

The urea dosing pump filter element of the DeNOx 2.2 system or DeNOx6-5 system shall be replaced every 3
years or 100,000 km. For the harsh application environments, the DEF will be seriously polluted, so the filter
element shall be replaced according to the actual situation. Before replacement, clean the outer surface of the urea
dosing pump, and prevent the filter element area from being polluted in the installation. The filter cover shall be
tightened with the torque of (20+5) Nm. The replacement of the filter element of DeNOx 2.2 or DeNOx6-5 is
shown in table 5-2 and table 5-3 respectively.

Table 5-2

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

1 Unscrew the filter cover with the wrench of 27mm

(DIN3124/ISO2725-1)

2 Remove the balancing unit

3 Check the color of the filter element: if it is gray, use the gray
end of special tool; if it is black, use the black end. Stretch the
proper end of tool into the filter element until you hear a clicking
sound, indicating that the tool has been installed in place.

4 Draw out the filter element (use the slot of special tool and other
tools if necessary).

5 Clean the outer surface of the filter element cover with water.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

6 Lubricate the O-rings at both ends and install the HCF filter
element. (it is recommended to use MobilVelocite No.6, other
lubricating oil may lead to O-ring failure)

7 Tighten the filter cover with the torque of 20+5Nm, and the size
of wrench is 27mm (DIN3124/ISO2715-1).

When fixing the urea dosing pump harness, the distance between the first fixing point and the connector shall be
less than 200mm, and the fixing point and the fixed part shall be on the same vibration source.

Table 5-3

1 Unscrew the filter cover with the wrench of 27mm

(DIN3124/ISO2725-1)

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

2 Remove the balancing unit.

3 Stretch the proper end of tool into the filter element and rotate
the tool clockwise until you hear a clicking sound, indicating that
the tool has been installed in place.

4 Draw out the filter element (use the slot of special tool and other
tools if necessary).

5 Clean the outer surface of the filter element chamber threads

with water.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

6 Lubricate the O-rings at both ends and install the HCF filter
element. (it is recommended to use MobilVelocite No.6, other
lubricating oil may cause the O-ring failure)

7 Tighten the filter cover with the torque of 20+5Nm, and the size
of wrench is 27mm (DIN3124/ISO2715-1).

When fixing the urea dosing pump harness, the distance between the first fixing point and the connector shall be
less than 200mm, and the fixing point and the fixed part shall be on the same vibration source.

5.3 Maintenance of Diesel Engine for Long-term Storage

5.3.1 Clean the diesel engine

5.3.2 Protection of diesel engine before storage

1) After warm up of the diesel engine, discharge the engine oil, clean the oil filter, and add rust resisting oil to the
oil pan.

2) Drain the diesel fuel out of the fuel system, and fill it with anti-rust oil to protect the fuel line.

3) Discharge the cooling water from cooling system, and fill the cooling system with cooling water containing rust
inhibitor.

4) Start the engine and run it at idle speed for (15~25) minutes.

5) Discharge all the engine oil, fuel, coolant and DEF.

6) Take protective measures for other positions.

5.3.3 Protection during storage

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Use cap or plastic cloth to seal oil, air and water inlets and outlets; use VCI film to cover the whole diesel engine.

Note: Outer packing is needed for transportation.

5.4 Regular inspection and maintenance of diesel engine

Table 5-4 Using conditions of matched vehicles

(WG I) (WG II)

Working under severe conditions (extremely cold or hot;

dusty; short distance transport; working on construction site
Various commercial vehicles that annual mileage is
and city buses, municipal engineering vehicles, snow
more than 20,000 km.
sweeper vehicles or fire trucks) or annual mileage is less
than 20,000 km or annual working timeis less than 600h.

Table 5-5 Maintenance interval

Using
conditions Mileage (time) WG I WG II
Items
First mandatory
3,000km (or 50h) A A
maintenance
10,000km (or 200h) B C
Routine maintenance 30,000 km (or400h) B
For WG II using conditions, it should replace the oil filter element in the Weichai
designated service center every 10,000km (or 200h).

Note: “A” - First mandatory maintenance: replace the oil, oil filter element;
“B” - Routine maintenance: Replace the oil, oil filter element, primary and secondary fuel filter elements;
“C” – Replace the oil filter element only.

Table 5-6 Specification of diesel engine maintenance

Maintenance items First mandatory maintenance Routine maintenance

Every time when changing the
Replace oil filter or filter element ●
oil
Check and adjust the valve clearance ● ●
Check coolant amount and add if necessary ● ●
Tighten the clamps for cooling system pipeline ●
Tighten air intake pipe, hose and flange fitting ● ●
Check the maintenance indicating light or
●
indicator of air filter
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Clean the dust cup of air filter (excluding the auto

●
dust-removal type)
Clean the air filter main element When the indicator is lit
Replace the air filter main element Please refer to the related regulations in the instruction manual
Replace the air filter safety element After the main element has been cleaned for 5 times
Check and tighten the belt ● ●
Check turbocharger bearing clearance Every 160,000km
Check and adjust clutch stroke ● ●
Check urea dosing pump filter element ● ●
Check urea spray nozzle gasket Every time when mounting the spray nozzle after disassembly
Clean urea tank and its filter element ● ●
Note: The symbol “●” indicates that maintenance is required.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

6.Common Faults and Troubleshooting

WP10 series China IV/V diesel engines are designed and manufactured under strict quality management system
and each delivered diesel engine has passed the specified tests. As the diesel engine is of precision machinery, and
the long-term guarantee of its functionality is closely related to the normal maintenances. The causes leading to
earlier failure of diesel engine are generally as follows:

(1) Operation against the regulations, and improper management and use;

(2) Failure to fulfill maintenance as required, or even repair instead of maintenance;

(3) Poorly manufactured parts, especially the counterfeit products procured due to temptation of cheap prices,
which will greatly shorten the service life of diesel engine;

(4) Inappropriate or unqualified fuel and oil are used.

6.1Fault Diagnostic Method

Generally, the common diagnostic methods for diesel engine faults are as follows:

(1) Observation method: Judge the fault situation by observing its features such as exhaust smoke color of diesel
engine (figure 6-1).

(2) Listening diagnosis method: Judge the location, feature and extent of fault by listening the abnormal noise of
diesel engine (figure 6-2).

Figure 6-1 Figure 6-2

(3) Cylinder deactivation method: Generally, cut off the fuel supply to the suspect malfunctioned cylinder, and
compare the working condition of the diesel engine before and after stopping fuel supply to narrow down the
scope for further determination of the fault location or causes.

(4) Comparison method: Replace a certain assembly or component to determine whether there is failure.

Notice:

(1) The cause of diesel engine fault shall be determined carefully. Before the causes are basically found, do not
disassemble the diesel engine at will. Or it will not only eliminate the fault, but also lead to more serious fault due
to improper assembly after disassembly.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

(2) Inspection and maintenance on critical components (such as injection pump, ECU, common rail and
turbocharger) shall be performed by Weichai designated service stations.

6.2Common Faults and Troubleshooting

6.2.1Failure in diesel engine starting

(1) The starter motor does not work

The starter motor of WP10 series China IV/V diesel engines are controlled by ECU. Under normal working
conditions, the ECU produces anoutput current to drive the starter relay. When the relay is activated, the battery
drives the starter motor to start the engine. In case of start failure, you should mainly check the neutral gear.

Factors to be checked: correlation between neutral gear switch, starter relay, battery and off-vehicle shutdown
switch and related parts.

◆ Check whether the gear shift is at neutral position.

Before starting, check whether the gear shift is at neutral gear position.

◆ Check the position of off-vehicle shutdown switch (which should be at OFF position).

The off-vehicle shutdown switch is of inching switch and capable of automatic reset. Check this switch for normal
functioning.

If the switch cannot reset automatically, check whether it is at ON position.

◆ Check the neutral switch and its wiring to ensure they are under sound conditions, and try to perform
emergency starting (press down and hold the ignition switch for more than 5s).

For the engine of which the starter motor is controlled with ECU, when starting, the ECU determines whether the
gear shift is placed at neutral position based on the signal from the neutral switch. When the neutral switch or its
wiring is damaged, no neutral position signal will be received by ECU, and the starter motor will not work.

◆ Check whether the battery voltage is too low to drive the starter motor.

Normally, the battery voltage is 24V. If the voltage is too low, the starter motor cannot be driven to work. Actual
“battery voltage” can be measured with voltage range of the or with the fault diagnostic device.

◆ Check whether the starter relay and its wiring are under sound conditions.

Check the surface of the wiring terminals for excessive oxide, and check the wiring terminal bolt for looseness or
fracture.

◆ Check whether the starter motor has been burnt.

Check with whether the starter relay is functioning properly.

◆ Check whether the ignition switch and starting switch are damaged.

Turn the ignition key to “ON” position, and check whether the panel lamp becomes on;

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Turn the ignition key to starting position, and check whether the starter motoris working (with other causes having
been excluded).

Starter
motor

Ignition key switch

(2) Common rail pressure build up failure (the starter motor can properly function, but the engine cannot be
started)

Air releasing
screw
Hand pump Hollow bolt for
fuel return

◆Check if the fuel level in the fuel tank is too low.

Special attention must be paid to this cause although it tends to be overlooked.

◆ Check if the hand pump is functioning properly.

Operate the hand pump with hand to check the working condition.

◆ Check whether there is air in the low pressure fuel line, and remove the air if any (Leakage of the low pressure
fuel line is sometimes not noticeable, so careful inspection is required).

Air removal method: it is mainly to remove the air in the primary fuel filter. Loosen the bleed screw on the
primary fuel filter, and manually operate the hand pump on the primary filter until fuel flows out continually from
the bleed screw.

If the diesel engine still fails to be started after the air in low pressure fuel line is removed, there mightbe air in
high pressure fuel line. Remove the air in the high pressure fuel line.

Air removal method: loosen the high pressure fuel line of a cylinder, and drive the diesel engine to run with the
starter motor until fuel flows out continually from the high pressure fuel line. (It is recommended not to frequently
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

dismantle the high pressure fuel line joint.)

◆ Check whether there is leakage in the high pressure fuel line.

The leakage of high pressure fuel line is quite easy to be noticed. Check whether the joint nut of the high pressure
fuel line is loose, and tighten it if necessary.

◆ Check if the fuel line and the fuel filter are blocked. It is recommended to replace the fuel filter element
timely.

Inspection method: loosen the bolt at outlet of secondary fuel filter, drive the diesel engine to run with the starter
motor. If only a small amount of fuel flows out, it means that the filter element is blocked, please replace the filter
element.

◆ Check if the initial voltage value of the common rail pressure sensor is around 500mV, or check if thecommon
rail pressure is set to be 30-50MPa.

Measuring method:

Enter the operating interface of the fault diagnosis instrument, select “actual value”, and click “next”.

Then all “actual values” will be displayed, and among them, select “accumulator pressure sensor voltage” and
“rated fuel rail pressure”.

If any abnormal condition occurs, first check the connector, and if it is OK, then the common rail pressure sensor
may be damaged.
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

If no testing equipment is available, disconnect the connector of the common rail pressure sensor, and try to start
the engine (the engine will come into “Limp Home” mode after starting).

◆ Check the flow metering unit, disconnect the connector of the flow metering unit, and try starting again.

① First, visually check the hardware for noticeable damage and check the connector for reliable connection;

② Perform Meter-unit test with fault diagnosis apparatus.

Go to operating interface of fault diagnosis apparatus, select “functional test” and click “next”;

Next

Go to sub-interface of functional test, select “Meter-unit test”, and click “next”;

Next

At this time, the test condition interface appears, and the operator will confirm that the conditions are OK, click
“next”, and start the test;

At the end of test, it will display if the flow metering unit is normal.

(3) Poor connection of injector harness, sensor harness or vehicle harness connector, or the harness is open circuit
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

or short circuit

◆ Check the installation of the connector, and check circuit continuity with the multimeter (“wiring inspection
tester” is recommended) according to pin definition on the circuit diagram.

Wiring inspection
tester
Circuit connection diagram of engine manufacturer

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Weichai EDC17 vehicle wiring harness connection diagram

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

(4) Crankshaft and camshaft signals lost

The diesel engine is provided with two speed sensors, which are mounted on the outsides of flywheel housing and
high pressure fuel pump respectively, and they serve as crankshaft position sensor and cylinder identification
sensor respectively. The fuel injection timing of electronic control engine depends onthese sensors. Both signals
will be lost when the diesel engine fails to start.

◆ Possible causes for loss of both signals

(1) The sensor is damaged, or the harness is short-circuited or open-circuited;

(2) The sensor is not fastened, causing too large or too small clearance (1±0.5mm in general) between the
sensor and the sensing tooth.

Troubleshooting: check the sensor and harness for damage and reliable connection.

◆ To ensure signal synchronization, the reassembly of high pressure fuel pump and flywheel must be
performed in strict accordance with related process documents.

Camshaft speed sensor

Crankshaft speed sensor

6.2.2The engine is hard to start

Causes and troubleshooting:

◆ The diesel engine has not been running for a long time: Insert the fuel return pipe to below the fuel level.
◆ There is air in the low pressure fuel line: Remove the air.
◆ Too weak crankshaft speed and camshaft speed signals, and too long synchronization judgment time: Find
the causes and make adjustment.
◆ Too low ambient temperature and failure of pre-heating device: Check the heating flange wiring, or replace
the pre-heating device.
◆ Poor diesel fuel or oil quality: Replace as required.
◆ Starter or flywheel gear with teeth collision: Replace the starter motor and flywheel ring gear.
◆ Piston ring or cylinder liner worn or valve seal not tight: Replace piston ring, cylinder liner, or valve seat

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

andvalve.
◆ EVB butterfly valve is stuck at close state, causing the exhaust to be blocked: Replace the butterfly valve

6.2.3 Engine power is insufficient

Limp home: A running mode of engine under malfunctioned state. The engine malfunction is detected, but the
ECU will not stop the engine immediately. Instead, it will restrain the engine power in such manner that the
engine speed can only be increased to 1,500r/min, so that the driver can drive the vehicle to the 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 injector due to excessive dirt in the fuel
or water ingress corrosion (Caution: ECU may not report this fault).

Wiring fault: the harness is disconnected or directly contact with the cylinder head and shorted to ground due to
vibration, wearing and other causes. ECU will report this fault.

Injector wiring terminal

(2) Water, engine oil and inlet air temperatures are too high

When the temperature of water, engine oil or inlet air is too high, ECU will enable the overheat protection
function to limit the power of diesel engine.

Prior to troubleshooting, first eliminate distortion of response from the sensor and instrument.

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

◆ Causes and remedies for excessively high water temperature

① The water level in the tank is too low: Check for leakage, and add water if necessary;
② Fan rotate at low speed or does not rotate: Check the fan drive unit;
③ Water tank is blocked: Check the water tank, and clean or repair if necessary;
④ Water pump belt is loose: Adjust the tension as required;
⑤ Water pump gasket is damaged and water pump impeller is worn: Check, repair or replace;
⑥ Thermostat fault: Replace;
⑦ Water pipe seal damaged: Check the water pipe, joint, gasket, etc., and replace any damaged part.

◆ Causes for excessively high engine oil temperature and troubleshooting

① Low oil level in oil pan: Check the oil level and oil leakage, repair and add oil;
② Water temperature is high: Check the cause for high water temperatures, and eliminate it;
③ Oil cooler blocked: Check and clean.

◆ Causes for excessively high intake temperature and troubleshooting

Check the heattransferperformanceof intercooler.

(3) Synchronization signal fault

When this fault occurs, generally it is that the signal of one sensor is failure.

Read the flash code with flash code light, find the specific cause against the flash code table, and eliminate it.

(4) Flow metering unit fault

The flow metering unit is the actuator to control the common rail pressure, and it is mounted on the high pressure
fuel pump. In case of metering unit failure, the high pressure fuel pump will supply fuel to the common rail pipe
at the 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 fault to the rail pressure sensor.

Flow metering unit

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

◆ Troubleshooting: Inspect and repair the wiring, and determine if the fault occurs to the flow metering unit or
common rail pressure sensor, and inform the office for troubleshooting.

(5) Abnormal fluctuation of common rail pressure due to leakage in fuel line

In the vehicle running, the speed will appear unstable.

◆ Troubleshooting:

First, cut off the power for one minute and then restart. If the fault still exists, check and repair the sealing of the
fuel line.

(6) Sensor fault

ECU will estimate the inlet air volume through the intake pressure sensor (mounted on the intake manifold), and
heat load of the engine is estimated with water temperature sensor (mounted on water pump), and the fuel
pressure in the common rail is tested with the rail pressure sensor (mounted on the common rail pipe).

Rail pressure sensor

Water temperature
sensor

Intake pressure sensor

◆ Troubleshooting

Check the intake temperature and pressure sensors, water temperature sensor and rail pressure sensor, and ensure
that the connectors are connected firmly.

Caution: In event of fault 1, 3, 4, 5 or 6, the diesel engine will enter the “Limp Home” mode.
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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

6.2.4 Engine always running at speed of 1,000r/min

Theaccelerator isfailure at this time: the ECU will judge the load through the signal coming from the pedal
potentiometer, and when the pedal malfunctions, the ECU will control the diesel engine to automatically return to
the idling speed (1,000r/min) for safety.

◆ Electronic throttle pedal wire loosed or wrong connected

Check and reconnect the throttle wiring.

◆ There is water in connector of electronic throttle pedal

Drying the connector and then start the engine again.

Notice: Replace the throttle pedal with same model.

6.2.5 Unstable idle speed of engine

◆ Causes and troubleshooting for unstable idling speed of engine:

① Malfunction of fuel injector: Check the fuel injectors and harnesses of all cylinders.

② For the complete vehicle equipped with speed sensor, there is speed signal input when parking: Check the
speedometer and speed sensor signal and wiring.

③ Poor fuel quality, containing water or wax: Clean fuel system and replace fuel filter.

④ There is air in low pressure fuel pipeline: Check air-tightness of fuel pipes and connectors and remove the
air.

⑤ Unstable atomization of fuel injector nozzle: Check and repair.

Notice: It’s a normal function of ECU that the idling speed will increase due to low water temperature.

If there is additional load (for instance, the air conditioner is turned on), the idling speed will increase by
about 100r/min.

6.2.6 Malfunction of SCR exhaust after treatment system

◆ Normal DEF injection cannot be achieved

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

If the SCR system does not work when the engine is working normally, please check whether theconnectors
ofDEF pump, spray nozzle and sensor areinstalled reliably. Check whether the DEF connecting pipes and joints
are bent, loose or broken.

Check the fluid level in the urea tank and add timely. If the DEF is poor in quality containing excessive impurities,
please check the cleanliness of the urea tank and clean the tank if necessary. Check the contamination state of the
DEF pump filter element and clean or replace the filter element if necessary. Check the contamination state near
the spray nozzle holes. If the nozzle hole is blocked, clean or replace the spray nozzle.

If the engine is working in cold weather conditions, it is normal that the DEF cannot be sprayed normally because
the DEF has not yet been unfrozen. If it cannot be unfrozen for a long time, there may be a malfunction in the
heating function and you should contact the local service station for troubleshooting.

◆ Exhaust backpressure of engine increased

In the event of serious black smoke or increased fuel consumption during running of the engine,please check for
urea crystals or stones in the exhaust pipe. If theenvironment temperature istoo low or the DEF spray nozzle is
poor atomization, it will probably lead to obviousurea crystallization on the inner wall of pipe. Heatpreservation
measures for the exhaust pipe should be performed as required. Please check the blockage of spray nozzle and
check the catalyst carrier in the SCR tank for damage and timely contact the service station for troubleshooting.

41
 Appendix: Power correction factor
Temperature

Air pressure
Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

1. The temperature in this table is that of intake air, and the air pressure (not equal to atmospheric pressure) is that of dry intake air.
2. This table only suitable for the temperature range of 10-40°C, and air pressure range of 80-110kPa. In order to make actual air inlet status
meets the above conditions, the engine test should be carried out in proper time by adopting suitable measures.
3. Pe0=ad*Pe (Pe0 is corrected power, Pe is measured power, ad is correction factor)

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Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)

Contact Us

Weichai Power Co., Ltd.

Address: 197A, Fushou East Street, High-tech Development Zone, Weifang, Shandong, China

Zip code: 261205

Website: http://www.weichai.com

Engine sales line: 0536-8232488; 0536-8233371

Spare part sales line: 0536-2297313; 0536-2297319

400 free service hotline: 400-6183066

800 free service hotline: 800-8603066

Aftersales Service Center: 0536-8235369 (Fax)

AftersalesService Center complaint line: 0536-2297322

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