WEICHAI WP10, Operation And Maintenance Manual

Page 1: ...ration and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine 1 Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine ...

Page 2: ... use for power generation the other application fields are not covered by this manual This manual describes the operation and maintenance inspection essentials and service guide of industrial power WP10 series diesel engines and can be used as reference In order for the industrial power WP10 series diesel engines to better service and give full play to its effectiveness the users are expected to c...

Page 3: ... and closely abide by the technical operation and maintenance procedures specified in this manual 4 At any time of starting the diesel engine please check whether the coolant and oil is filled up 5 For the new diesel engine 50h running in is needed with maximum load not more than 80 of the rated load and average load not more than 60 6 The starting time of the engine should not last for more than ...

Page 4: ...for more than 72h 11 Do not simultaneously use the diethyl ether assisted starting equipment and flame preheater or glow plug 12 The inspection of electrical system should be done by the personnel mastering the electrical knowledge 13 The valid duration of oil sealing of diesel engine is one year If they expire please take necessary supplement measures 14 Feedback of engine quality information Our...

Page 5: ...l engines 8 2 Diesel engine installation and connection 12 3 Precautions and operational requirements for diesel engine 16 4 Maintenance specifications for industrial engines 20 5 Maintenance specifications for main accessories of diesel engine 24 6 Common failure analysis and troubleshooting 36 Ⅱ User Service Guide 43 Weichai Power Product Warranty Card 43 Service Registration Form 44 Repairs ins...

Page 6: ...Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine 6 Ⅰ Operation and maintenance for industrial power WP10 series land diesel engines Schematic for WP10 series land diesel engine ...

Page 7: ...Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine 7 Schematic for WP10 series marine diesel engine Dry or water jacket exhaust manifold ...

Page 8: ...l viscosity Refer to table 1 1 for selection of oil viscosity Table 1 1 The relation between oil viscosity and ambient temperature Lubricating oil SAE Viscosity grade Ambient temperature 5W 30 30 35 10W 30 25 35 15W 40 20 40 20W 50 15 50 Notice Before starting of diesel engine thoroughly check the oil level in the oil sump Do not check engine oil level with engine running It is not allowed to mix ...

Page 9: ...ure the diesel fuel may precipitate the waxy material leading to poor mobility of diesel fuel In such case the fuel system will be clogged causing failure of diesel engine Therefore if the ambient temperature is less than 0 please use the diesel fuel suitable for winter According to the GB252 diesel fuel standard if the ambient temperature is 5 or more please choose the 10 diesel fuel If the ambie...

Page 10: ...3 10 26 4 73 6 1 0340 20 36 2 63 8 1 0506 30 45 6 54 4 1 0627 40 52 3 47 7 1 0713 50 58 0 42 0 1 0780 60 63 1 36 9 1 0833 1 3 3 Correct use of coolant a Do not overhasty fill the coolant Otherwise the gas in the engine can not be drained It is better to keep the filling speed at 13 5L min b Do not fill the radiator up for the first time Start engine to let its temperature rise then check the coola...

Page 11: ...stion It is recommended to use the Weichai Power heavy load engine coolant which is sold at all the service stations of Weichai at the unified national sale price 1 4 Disposal of used oil fuel coolant Use the special container to collect the waste As the oil fuel and coolant is toxic neither drink nor touch them ...

Page 12: ...mounted is greatly different from the information provided by the factory please ask for professional 2 3 WP10 series diesel engine unpacking and hoisting During unpacking the diesel engine do not damage the parts of diesel engine After unpacking check whether the exposed port seals of oil fuel coolant pipes are in intact It is prohibited that the foreign material gets into the pipes Refer the pac...

Page 13: ...The diesel engine models are different so are the lengths from the engine frame to the center line of crankshaft 2 4 3 WP10 series auxiliary marine diesel engine can be installed together with the SAE I flywheel housing and marine gearbox Elastic coupling is permissible for connecting the engine with the machine After the couplings are connected the crankshaft is not allowed to be subjected to axi...

Page 14: ...peration the intake inlet should be arranged at the well ventilated position Intake pipe of diesel engine should not be very long reduce the quantity of elbows and adopt the large arc transition The inside diameter of intake pipe should not be less than 120mm and the inside wall should be free of welding slag During installation avoid any foreign material from getting into the intake pipe and ensu...

Page 15: ...any fire and scald etc heat insulation measures should be taken around the surface of exhaust pipe If some diesel engines installed together and share the same extended exhaust pipe some problems will emerge condensed water developed by the exhaust will enter the inoperative diesel engine which can easily damage to the parts of diesel engine Therefore each diesel engine should possess its own inde...

Page 16: ...te and whether the coolant oil temperature sensors are supplied In addition any part provided by the user should be installed Note Do not start the diesel engine until it is correctly installed and connected If diesel engine runs in enclosed room ventilation must be conducted to ensure the exhaust is drained to the outside 3 1 2 Filling oil a Oil filling should meet the requirements If not oil pre...

Page 17: ...t screw on the fuel filter Repeat pressing down the hand pump until the diesel emerges then tighten the vent screw c Loosen the vent screw on the fuel injection pump Repeat pressing down the hand pump until the diesel emerges then tighten the vent screw d Continue to pump the hand pump to check whether the fuel pipe leaks then tighten the hand pump 3 1 5 Filling coolant Coolant is formulated by th...

Page 18: ... is not started within 5s immediately release the start button and waiting after 1min for the second startup If the engine could not be started for 3 consecutive times please stop start up at once troubleshoot for starting again 3 2 4 After the diesel engine is successfully started idle running for 2 3min and the oil pressure should not be less than 100kPa Otherwise find out the cause If the coola...

Page 19: ...If abnormal conditions were appeared during the engine is running stop the engine imminently After engine is stopped in emergency case barring the crankshaft for a few circles then check whether for abnormal In addition as the engine is still hot shortly after stop scuffing of cylinder or piston seize should be prevented 3 5 Operational environment If the ambient temperature is higher than 15 the ...

Page 20: ... 1000h Level 4 maintenance WD4 Diesel engine running interval 3000h 4 1 2 Daily maintenance for diesel engine 4 1 2 1 With diesel engine running always note that the oil temperature oil pressure and coolant temperature at outlet and check for three leakage oil gas and water In case of any abnormal find out the cause for troubleshooting 4 1 2 2 After the diesel engine is stopped check the fuel fres...

Page 21: ...t Clean the intercooler element Clean the fan and radiator Replace or clean air cleaner element Check and tighten the belt Check the fuel injection pump at the service station Note means items needed to be maintained Note The maintenance intervals are based on the diesel engine working for 1500h every year If the diesel engine works for 500h or less every year its maintenance intervals should be 1...

Page 22: ...vel 4 maintenance WD4 Engine running interval 3000h 4 2 2 Maintenance for gas engines Items Maintenance content Maintenance mileage Daily inspection Oil level coolant level drive belt for wear cooling fan for damage gas supply system for leakage hot water filled in gas supply system for cycle normal electrical system for reliability air cleaner for looseness Refer to the routine inspection and mai...

Page 23: ...prolonging its service life 4 2 4 Maintenance Instruction After the Weichai industrial engines are installed user is expected to notify the Weichai special service center for commissioning In case of any failure happening within three guaranty period timely notify the Weichai special service center Weichai will bear no responsibility in case of failures caused by using special spare parts or oil n...

Page 24: ... only could reduce the engine performance but also could greatly shorten the service life of fuel injection pump and engine a Use the high quality fuel Generally 0 light diesel fuel is used for summer and 10 or higher grade light diesel fuel for winter b The fuel to be filled should be clean without any foreign material and moisture Therefore fuel to be filled should be sedimentated for 72h or mor...

Page 25: ...ine requirements to adjust the fuel injection advance angle Namely the piston of 1st cylinder should be at optimal injection position before TDC Loosen the high pressure fuel pipe of 1st cylinder connected to the fuel injection pump and bolts attached to the fuel injection pump flange and couplings As you crank the pump or camshaft observe where engine flywheel scale is when the fuel is just the f...

Page 26: ... to dismantle or impact it Failing to do so will cause the factory s guarantee invalid 5 3 Use and maintenance of air compressor The air compressor mounted on WP10 series diesel engine is of single cylinder reciprocating type crank and connecting rod which is driven by the belt or gear a The lubricant of air compressor flows from the main oil passage to lubricating the bearing in the air compresso...

Page 27: ...ce of starter a Starter as short time working part should work for 15s at most every time In addition the starting interval should be more than 30s b In winter if ambient temperature is less than 5 preheat the engine before startup c Release the starting switch the moment the engine is started separating the drive gear of starter from the gear ring of flywheel d Do not power the starter until the ...

Page 28: ...tion environment Working temperature of generator is 40 93 Therefore its installation should be kept away from any heat source distance of 400mm at least or effective insulation plate should be installed which should be approved by the generator factory or supplier e The wire of generator should be rational and wiring should be correct and reliable Each terminal of generator should be correctly co...

Page 29: ...he consecutive rotation of gear could continuously provide the each lubricating system with oil a Pressure limiting valve is mounted on the oil pump which functions to prevent the oil pump and lubricating system from having too high pressure and accordingly ensure each part works safely The pressure limiting valve also functions as bypass valve When the oil pressure exceeds the pre set value this ...

Page 30: ...leaner element c For the filter with multi stage filtration the strainer must be installed d During installation do not sharply bend the venting pipe and check it for leakage e Water is prohibited to enter the air cleaner f For the air cleaner with safety element it is prohibited to remove the safety element during maintenance of air cleaner g Generally the main paper element of air cleaner should...

Page 31: ...water b Generally filter element should be maintained once every 200 300h and shortened if the fuel quality is poor During maintenance timely replace any damaged filter element c Before maintenance block the two holes on the main element to prevent any dirt from getting in The filter element should be cleaned in clean kerosene and diesel fuel by a soft brush After that use clean kerosene and diese...

Page 32: ...each quarter by smoothing the pipeline removing the dirt and replacing the zinc slab c Before reinstalling the air cooler already cleaned hydraulic test should be conduct As a result there should be no leakage after it is pressed with pressure of 0 4Mpa for 30min 5 12 Use and Maintenance of electronic governor The electronic governor of WP10 series diesel engine consists of speed controller electr...

Page 33: ...lectromagnetic interference In addition sufficient space should be reserved for installation maintenance and thermal dissipation The housing of rpm controller should be properly grounded In addition speed sensor and speed trimmer potentiometer should be connected to the controller by shield cable of which shielding layer should be grounded at one point of controller 5 12 4 The governor has the wor...

Page 34: ...maged cable Cable should be clamped to prevent against rubbing with engine In addition the layout of cable should be kept away from the high temperature parts such as supercharger and exhaust pipe b Check whether the executor is reliably installed c Check whether the executor connector sensor connector and cable screws are contaminated with oil or loosened if so timely clean or tighten them d Chec...

Page 35: ...ection device should be independent and can t be replaced by the electromagnetic executor d Each time of starting engine please ensure the idling rating speed switch is at idling position e The potentiometers of controller have already well set at delivery and should not be adjusted by the non professional f With engine not running it is not allowed to adjust specially increase the rated speed of ...

Page 36: ...the diesel engine 5 Oil viscosity is high thus the flowability is poor Refer to the ambient temperature to select proper oil or heat oil 6 There is air in the fuel system Degassing of the system 7 Water is mixed in the diesel Check the fuel tank and then open the plug at the bottom of diesel filter for draining water 8 The vent screw of fuel injector is not tightened unable to inject fuel Clockwis...

Page 37: ...ne can not output stipulated power S N Causes Troubleshooting 1 Operation 1 Rotating speed is low Adjust to rated speed 2 The local altitude or ambient temperature is too high Refer to GB standard Power Correction Table for correcting the output power 2 Fuel system 1 Fuel injector failed nozzle is clogged atomization is poor fuel injection pressure is not insufficient the height of nozzle protrudi...

Page 38: ...xhaust system is too high Refer to the specifications and design to arrange the exhaust pipeline 3 Intake valves and exhaust valves are leaked Check and grind them 4 Timing of inlet valves and outlet valves is wrong Check and adjust it 5 For the air starter the inflation valve or starting valve on the cylinder head are leaked Dismantle and then grind them 4 Others 1 The compression pressure is ins...

Page 39: ...aust system Adjust the advance angle of fuel injection 3 Blue smoke 1 With engine still at low temperature oil blows into the combustion chamber Increase the coolant temperature at the inlet of engine 2 The engine is new Prolong the running in time 3 Piston rings wear Repair 6 4 Abnormal noise or vibration during diesel engine running S N Cause Troubleshooting 1 Premature fuel injection or uneven ...

Page 40: ... Check the cylinder head nuts for tightness or replace the cylinder liner 11 Wear of each gear is excessive making knocking noise Check or replace it 12 The fixing bolts attaching to diesel engine is loose or damaged causing vibration aggravating Tighten or replace the bolts 13 Diesel engine is not coaxial to the connected work device aggravating the vibration Check and adjust it 14 Uneven foundat...

Page 41: ...eplace it 4 Water pump belt is too loose Check and adjust it 5 Water pump has too much scale Remove the scale 6 Water pump has excessive suction head Refer to the specifications to install the water pump 6 7 Too low oil pressure S N Cause Troubleshooting 1 Oil quality is poor because as the diesel engine is running the oil pressure gradually drops Refer to the specifications to select the oil 2 Di...

Page 42: ...2 Inlet temperature of coolant is very high Decrease the coolant inlet temperature 3 Oil pressure is too low Refer to the section 6 7 in this chapter 4 Diesel engine is overloaded Reduce load and find out the cause 5 Fuel injection delays Check and adjust it 6 Piston rings leak Check or replace it 7 Matching of bearings too tight Inspection and grind them 8 Ambient temperature is too high Correct ...

Page 43: ...ine please carefully read this manual and closely follow the specifications In case of any failure please timely contact with the Weichai Power Maintenance and Service Center or Customer Service Center and we will delivery effective service on time Service Registration Form should be filled by the Maintenance and Service Center during service and then saved by the user Weichai Power Co Ltd Address...

Page 44: ...00 8603066 Customer Service Center 0536 8235369 fax Customer Service Center Complaint 0536 2297322 Service Registration Form filled by the service staff Name Content Name Content Model Name Order No Zip code Number Address Purchasing date Office phone Dealer Home phone Service Center Name Date Maintenance items Replaced parts Quantity Signed by the service staff Signed by user ...

Page 45: ...or repair Customer Service Center 800 and 400 hotlines are available for 24h providing quick and effective high quality service Oversea Centers and Authorized Service Centers are on duty for 24h wherever you are Namely where there is Weichai product there is Weichai service 2 Oversea Repair User could call for Weichai Power International Service Department Hotline 0536 8197520 or send a fax 0536 8...

Page 46: ... guaranty warranty for the retail products From the purchasing date on the invoice the Three guaranty will last for one year or 1500h whichever comes first 2 3 If the engine after being delivered is stored for one year or more before starting it notify the Industry Power Sale Company of Weichai for arranging the Weichai Authorized Service Center for paid maintenance Otherwise Three guaranty warran...

Page 47: ...1 Radiator with fan 22 Camshaft bushing 23 Pulley crankshaft 24 High pressure fuel pipe 25 Valve 26 Metallic coolant pipe 27 Warning device for fuel leaking 28 Valve spring 29 Intermediate gear shaft 30 Rotation axle oil pump 31 Valve spring seat 32 Fuel injector excluding nozzle 33 Gear ring of flywheel 34 Valve port 35 High pressure fuel pump support 36 Bolts on connecting rod 37 Valve guide 38 ...

Page 48: ... pump 6 Fuel return pipe of fuel injection pump 7 Fuel atomizer air starter 8 Fuel supply pump 9 Gaskets of intake pipe and exhaust pipe 10 Hand oil pump 11 Gaskets of supercharger 12 Expansion joint 13 Dipstick 14 Fan 15 Bushing of fuel injector 16 Thermostat 17 Gaskets of oil sump 18 Bowl type plug 19 All kinds of O rings 20 All kinds of mechanical instruments 21 All kinds of bolts and crews 22 ...

Page 49: ...months or 1500h from the delivery date whichever comes first 1 Electronic throttle 2 Exhaust control valve 3 Ignition module 4 Fuel metering valve 5 Heat exchanger 6 Gas thermostat 7 ECU 8 Signal generator assembly 9 Mixer assembly 10 Throttle pipe 11 Fuel injection pipe 12 Support 13 Joint pipe 14 Intake elbow 15 Air pipe joint 16 Pad 17 Cover plate 18 All kinds of metallic fuel pipes 19 All kind...

Page 50: ... Engine 50 1 Solenoid valve 2 All kinds of sensors 3 Ignition coil 4 Relay 5 Harness 6 Ignition cable The following parts as wear parts are out of Three guaranty 1 Spark plug 2 Fuel filter assembly Note If the timer is fault the Three guaranty period should be calculated referring to 10h each day ...

Page 51: ...by Three guaranty Gaskets all except for cylinder head gaskets Filter elements air cleaner fuel filter oil filter Rubber waterproof ring of cylinder liner sealing rubber ring sealing gasket of oil sump Sensor coolant temperature sensor oil pressure sensor Mate parts matching parts of nozzle injection pump plunger and barrel Fasteners clamp and clip Bolts purchased separately connecting rod cylinde...

Page 52: ...mp 26 Telematics 27 Common rail tube 28 Valve 29 Injection pump 30 High pressure fuel pipe 31 Valve spring 32 Fuel injector body 33 Cooling nozzle 34 Valve spring seat 35 Shock absorber 36 Dipstick assembly 37 Valve port 38 Strainer 39 Fuel filter body 40 Valve guide 41 Air compressor 42 Oil filter seat 43 Valve cover housing 44 All kinds of gaskets and covers 45 Flywheel 46 Tappet 47 Cylinder gas...

Page 53: ...al range of this Manual mismatching overloading overspeeding improper running in and maintenance or use of inferior oil fuel antifreeze and Three filter etc 2 2 Failures caused by modifying adjusting or removing any parts unallowable in this Manual 2 3 Oil antifreeze filter element hose belt and fuel injector mate parts which is normally used consumed or maintained 2 4 Lack of Warranty Card invoic...