WP12WP13四气门国Ⅳ国V欧五系列车用柴油机使用保养说明书 EN

612640820053
Operation and Maintenance Manual of WP12/WP13

China IV/V and Euro V Four-valve Diesel Engine for
Vehicles
Weichai Power Co., Ltd.

Operation and Maintenance Manual of WP12/WP13 China IV/V and Euro V Four-valve Diesel Engine for Vehicles
WP12/WP13 China IV/V and Euro V Diesel Engine

Foreword
This series is the high-speed engine independently developed by Weichai Power Co., Ltd. The series has
compact structure, high reliability, strong power, and good economy performance, as well as fast start, easy
operation and maintenance.
Basic information and operation/maintenance methods are introduced in this manual. Make sure that you
have known the structure of the engine well and have mastered operation and maintenance methods before
usage.
With the increasing variants and continuous improvements of the series engine, this Manual will be subject
to change without notice. Weichai Power Co., Ltd. is authorized to carry out the after-sales service of this
product, and users can access latest product information through the website of www.weichai.com
Dear users:
Thank you for choosing Weichai products!
To use and maintain the engine properly, please read this operation and maintenance manual carefully and
operate in strict accordance with relevant provisions.
Service commitments:
If the engine has any fault, please contact Weichai call center 400-6183066 as soon as possible. We promise
that the special maintenance service center will arrive at the fault site within 3 h for the center-located city,
within 24 h for the general region and within 48 h for the remote area, and provide fast, high-quality and
considerate service according to Weichai service requirements.
To ensure the effective and normal running of your engine, please read the following content carefully
before use.
 Before operation, please carefully read this Manual,

strictly observe the operation and maintenance
regulations specified in this Manual, and pay attention to
warning instructions and warning signs. Please pay
attention to the following issues because the engine
warranty will be invalidated if the operation is performed
not in accordance with the requirements of this Manual!
 As the engine has been tested in strict accordance with Please refer to this Manual
the test specifications upon 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, cotton yarn) away
from the turbocharger when the engine is running, so as
to avoid personal injury or engine damage. Do not
disassemble the rotor component.
Do not touch the high-speed rotating part with hand
 Do not loosen or remove the main bearing bolt or the

connecting rod bolt of the engine without permission as
they are subject to strict torque and rotation
requirements.
Tightenin
g torque requirement
 Always fill the engine with the oil or fuel of grade specified
in this Manual, and filtered by a special filter; for the fuel,
subject it to a precipitation more than 72 h. Prior to start,
always check that the coolant and oil levels are
satisfactory, and if not, please fill the engine with fuel or
oil of grade specified in this Manual at an authorized
gasoline station.
 Before running a new engine, subject it to running-in for Please refer to the relevant chapter(s) in this Manual
50 h.
 Never run the engine without an air filter.
 After starting a cold engine, accelerate it slowly rather

than abruptly, and do not run it at an idle speed for a long
time.
 Regularly check the coolant, and never change the engine

coolant with water or coolant with poor quality. At a low
temperature, please select the coolant of the correct
grade in accordance with the requirements of this Manual.
 The engine has been sealed by oil before delivery to avoid

rust. The engine’s oil-sealing period is one year, and the
engine should be checked and necessary measures should
be taken when this valid period expires. Please refer to the relevant chapter(s) in this Manual
 Please have the diesel engine disassembled and repaired

at the Weichai Power designated service station in case of
a fault. Do not use the spare parts not specified by
Weichai Power for maintenance; otherwise, Weichai will
not assume any responsibility for damage to the engine
therefrom.
 Always have the components of the electrical system

maintained by Weichai professional technicians.
 Please turn off the power and remove ECU plugs while
performing welding to protect the ECU.
Authentic Weichai spare parts
 Replace emission-related key parts (such as turbocharger,
fuel injection pump, injector, ECU, exhaust gas
after-treatment system and EGR system) with parts of the
same model and type as original ones; otherwise, Weichai
will not be responsible for any consequences.
 Weichai has the right to refuse to provide warranty

services if the diesel oil, urea, air filter element were
bought through informal channels or air filter
maintenance were not maintained in a correct way.
"GB17691-2018 Heavy-duty Diesel Vehicle Pollutant Emission Limits and Measurement Methods (China VI)"
stipulates that not using correctly urea is illegal and the user "should retain the proof of use of materials and
reagents that meet the standard requirements during the warranty period (eg, gas station receipt, reagent sales
voucher for authentic stores within one year)."
In order to protect your legal rights, please be sure to use diesel, engine oil, urea (reagent) and coolant as
specified in this Notice. In order to avoid follow-up disputes, please purchase the above products through regular
channels such as Weichai Special Maintenance Service Center and regular gas station, and promptly request and
properly keep the invoices for diesel, engine oil, urea (reagent), coolant and other oil materials for future
reference. .
If one of the following conditions occurs within the warranty period, we will not be responsible for the warranty
of engine emission related parts:
1. The user cannot provide proof of the continuous use of compliant oils and reagents during the warranty
period, or the materials provided by the user proves to be false and invalid, or the proof of such materials is
obviously not matched with the mileage and time of use. ;
2. It is determined by our company that the malfunction or damage of these parts is caused by improper use or
maintenance by the user.
Please read this Manual before use

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
danger.
However, the warning information in this Manual does not cover all possible conditions!
Before applying a procedure or method not recommended in this Manual, make sure that the operation
will never cause any danger to you, others or the equipment.
This warning sign indicates a potential hazard which can lead to serious
injury even death or great property loss, if the occurrence cannot be avoided.
This warning sign indicates a potential hazard which, if not being

avoided, can lead to slight injury or property loss. It can also be used for
WARNING
hazardous operation warning.
The considerations in this Manual can indicate how to properly
operate and install the engine manufactured by the company. However,
the potential hazards cannot be eliminated by simply reading the
CAUTION
manual. The considerations will not be beneficial to the correct use
unless the implication is properly understood.
Please pay attention to followings before maintenance and repair:
1. Avoid repeated exposure to the used oil for a long time.
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 cut and injury, take first-aid measures as soon as possible.
7. Before working, always apply some protective cream which will make it easier to remove the oil in case
that the skin is contaminated with mineral oil.
8. Use soap and hot water, or liquid soap and nail brush to wash hands for the convenience of removing all
oil stains. If the grease secreted by skin is washed off, the product containing lanum can substitute the grease
secreted by skin to moisturize the skin.
9. Do not clean the skin with any gasoline, kerosene, fuel, thinner or solvent.
10. Upon detection of skin irritation, please seek medical attention immediately.
11. Remove oil from the parts before transportation, if available.
12. Please use goggles or face guard masks when your eyes might be exposed to danger. Eye flush fluid must
be readily available.
13. When maintaining the engine, please don’t spill oil or other liquids on the ground. In case of accidental
leakage of hydrocarbons or other liquids, all necessary measures should be taken to isolate the area to keep the
environment clean and protect people from harm.
14. The handling, storage and recovery of hydrocarbon, ethylene, glycol and petroleum must comply with
the safety and environmental standards of the local country.
Contents
Chapter I Structure and Performance Parameters of the Engine ...................................................................................1
1.1 Outline drawing of engine ......................................................................................................................................... 1
1.2 Designation of engine model ..................................................................................................................................... 3
1.3 Main performance parameters ..................................................................................................................................4
Chapter II Installation and Operation ............................................................................................................................ 7
2.1 Unpacking .................................................................................................................................................................. 7
2.2 Hoisting ...................................................................................................................................................................... 7
2.3 Installation ................................................................................................................................................................. 8

2.3.1 Engine ................................................................................................................................................................. 8
2.3.2 Cooling system ....................................................................................................................................................8
2.3.3 Exhaust system ................................................................................................................................................... 8
2.3.4 Intake system ...................................................................................................................................................... 8
2.3 Preparations before start ...........................................................................................................................................8
2.4 Start ............................................................................................................................................................................9
2.5 Running ...................................................................................................................................................................... 9
2.6 Stop .......................................................................................................................................................................... 10
Chapter III Maintenance ..............................................................................................................................................13
3.1 Fuel, lubricating oil, coolant, and auxiliary materials ..............................................................................................13

3.1.1 Fuel ................................................................................................................................................................... 13
3.1.2 Lubricating oil ................................................................................................................................................... 13
3.1.3 Coolant ..............................................................................................................................................................14
3.1.4 Urea solution .................................................................................................................................................... 15
3.1.5 Auxiliary materials ............................................................................................................................................ 17
3.2 Daily maintenance ................................................................................................................................................... 19

3.2.1 Daily maintenance ............................................................................................................................................ 19
3.2.2 Daily inspection ................................................................................................................................................ 20
3.3 Regular maintenance interval and specification ..................................................................................................... 21

3.3.1 Regular maintenance interval and specification .............................................................................................. 21
3.4 Description of maintenance of all levels .................................................................................................................. 27

3.4.1 Oil change ......................................................................................................................................................... 27
3.4.2 Replacement of oil filter or oil filter element ...................................................................................................28
3.4.3 Replacement of fuel filter and filter element ...................................................................................................28
3.4.4 Check and adjustment of valve clearance ........................................................................................................ 28
3.4.5 Check of air seal ................................................................................................................................................30
3.4.6 Check of air filter element ................................................................................................................................ 30
3.4.7 Maintenance of after-treatment parts .............................................................................................................31
3.4.8 Air bleeding of low pressure pipeline ...............................................................................................................32
3.4.9 Maintenance of oil-gas separator .....................................................................................................................32
3.5 Cleaning, protection and handling ...........................................................................................................................33

3.5.1 Cleaning and protection ................................................................................................................................... 33
3.5.2 Protection during storage .................................................................................................................................33
3.5.3 Oil sealing ......................................................................................................................................................... 33
3.5.4 Handling ............................................................................................................................................................33
Chapter Ⅳ Typical Faults and Troubleshooting ..................................................................................................... 33
4.1 Overview .................................................................................................................................................................. 33

4.1.1 Overview ...........................................................................................................................................................33
4.2 Fault diagnostic methods .........................................................................................................................................34

4.2.1 Traditional fault diagnostic methods ................................................................................................................34
4.2.2 On-board diagnostics (OBD) general description and indicator lights explanation ......................................... 35
4.3 Typical troubleshooting ............................................................................................................................................38

4.3.1 Startup failure ................................................................................................................................................... 38
4.3.2 Stop shortly after startup ................................................................................................................................. 39
4.3.3 Insufficient power .............................................................................................................................................40
4.3.4 Low oil pressure ................................................................................................................................................42
4.3.5 The temperature of coolant is too high ............................................................................................................43
4.3.6 Too much noise .................................................................................................................................................44
4.3.7 Starter motor does not work ............................................................................................................................46
4.3.8 Starter motor is powerless ............................................................................................................................... 47
4.3.9 Excessive fuel consumption ..............................................................................................................................48
4.3.10 Exhaust black smoke .......................................................................................................................................49
4.3.11 Exhaust white/blue smoke ............................................................................................................................. 51
4.3.12 Turbocharger intake port and intake pipe are enriched with oil ....................................................................53
4.3.13 Unstable engine speed ................................................................................................................................... 53
4.3.14 Fast wear of parts ........................................................................................................................................... 54
4.3.15 Alternator does not generate at all ................................................................................................................ 56
4.3.16 Undercharged alternator ................................................................................................................................57
4.3.17 Unstable charging current .............................................................................................................................. 58
4.3.18 Overcharged alternator .................................................................................................................................. 59
4.3.19 Abnormal sound from the alternator .............................................................................................................60
Chapter I Structure and Performance Parameters of

the Engine
1.1 Outline drawing of engine
Fig. 1-1 Outline Drawing 1 of Engine (Intake Side)
No. Name No. Name No. Name No. Name
Common rail
1 ECU 2 Alternator 3 Intake pipe 4
pipe
5 Fuel injection pump 6 Fuel filter assembly 7 starter
1
Fig. 1-2 Outline Drawing 2 of Engine (Exhaust Manifold Side)
No. Name No. Name No. Name No. Name
Oil cooler
1 Air compressor 2 Turbocharger 3 Oil-gas separator 4 cover
5 Oil filter
2
Fig. 1-3 Outline Drawing 3 of Engine (Fan End)
1.2 Designation of engine model
Variant
Emission standard
Power
Application
Product series number
3
1.3 Main performance parameters
Fig. 1-4 Engine Nameplate
Please refer to the engine nameplate for information like engine model, power, speed, delivery number, net
weight, etc.
Other parameters are as shown in Tab. 1-1.
Tab 1-1 Main Specifications of Engine
Item Specification
Four-stroke, water-cooling, electronic control, high pressure
Type
common rail, direct injection, turbocharged and intercooled
Number of cylinders 6
126×155(WP12)
Cylinder bore × stroke (mm × mm)
127×165(WP13)
11.596(WP12)
Displacement (L)
12.54(WP13)
394~338(WP12)
Power range (kW)
353~405(WP13)
Oil-fuel consumption rate (%) ＜0.1%
Rotation (viewed from free end) Clockwise
4
Tab. 1-1 Main Specifications of Engine (Continued)
Item Specification
Starting method Electric start
Allowed longitudinal inclination: 10 forwards/10 backwards
Allowed long-term inclination angle (°) Allowed transverse inclination: 45 at exhaust manifold side/15
at intake manifold side
5
Chapter II Installation and Operation
2.1 Unpacking
After unpacking the engine, please check it and its accessories against the Packing List, and check the
appearance and fastening condition of connectors. Carry out following work afterwards:
1. Wipe the anti-rust coating and corrosion inhibitor off the exposed parts;
2. Fill the oil pan with appropriate grade of lubricating oil as specified. Please see the requirements for
adding of lubricating oil specified in relevant section.
3. The special coolant for Weichai Power engines is available in three kinds of freezing points: -25°C, -35°C
and -40°C. Please select the coolant with appropriate freezing point according to the local ambient temperature.
Generally, the freezing point of the selected coolant should be 10°C below the ambient temperature.
4. Depending on the agreement between the manufacturer and the user, if the engine has been filled with
coolant before delivery, check the behavior of coolant after unpacking. AccepTab. coolant has the freezing
resistance such that it will not freeze at the temperature of -30 °C or -35, the pH value of 7～8 (neutral), and the
total hardness of 5～15°d [9～15°f (hardness)). If the coolant cannot meet the above requirements, drain it off,
and fill the engine with coolant containing antifreeze. For details of selection of special coolant for Weichai Power,
see relevant sections of this Manual.
2.2 Hoisting
When hoisting the engine, keep the crankshaft centerline horizontal. Never hoist an inclined engine or hoist
the engine by one side. Hoist and lower the engine slowly.
Right Wrong
Fig. 2-1 Hoisting
7
2.3 Installation
2.3.1 Engine
When installing the engine, make sure that the crankshaft centerline is coaxial with the input shaft of drive
gears (gearbox, transmission or generator etc.), and that the crankshaft is not subject to additional axial force
produced due to installation.
2.3.2 Cooling system

The diesel internal cooling circuit has been connected before delivery. Corrosion-resistant cooling water
pipeline is chosen and the length of pipeline and the number of elbows are minimized to the least. The inner
diameter of water pipe shall not be less than that of the joint of the connecting parts, in order to reduce
waterway resistance and improve pump efficiency.
2.3.3 Exhaust system

The external exhaust pipe is made of steel and should be firmly fixed on the engine to avoid excessive
vibration. Besides, its weight should not be applied onto the diesel expansion tube. To ensure an optimum
performance, the exhaust back pressure should not exceed 35 kPa after the set-up of exhaust system. The
surface temperature of the exhaust pipe might reach a high degree due to the operation of diesel engine, so
the exhaust pipe should be away from flammable objects. To prevent scald accidents, please install heat
insulation on the surface of the exhaust pipe.
2.3.4 Intake system

To ensure enough fresh air for the diesel engine, the intake of which should be placed in a place with little
dust, rain and splash water and a place that is cool and ventilated. Elbows of the intake pipe should be
minimized to the least and adopt a large arc transition. A protective cover should be added to the air filter at
the inlet to prevent water and dirt from entering the diesel engine.
2.3 Preparations before start

1. Check the coolant level
Add engine coolant timely in case the coolant level is low.
When opening the filler cap with a pressure relief valve and a ventilation button, if the engine is in a hot
state, always press down the ventilation button first. Do not add too much coolant when the engine is hot.
Otherwise, the parts will be damaged due to the great temperature change. Start the engine, and when the
engine is running at the speed of 1000 r/min, continue to add the coolant until the level reaches the specified
position and stable, and finally close the filler cap.
2. Check the fuel level
If the engine has been installed on the vehicle, turn on the power switch and check the fuel level through
the fuel gauge or check the fuel tank directly. If the engine comes standard with fuel system protector, as
shown in Figure 2-2. It improves the low temperature starting performance of the diesel engine so that the
diesel engine can be started normally in the low temperature of -35℃. The fuel pumping will start when the
ignition switch is turned on, and will stop automatically when the air in the low-pressure circuit is emptied
effectively. The fuel heating will start when the diesel temperature is lower than 7 ℃ , and will stop
8
automatically when the diesel temperature is higher than 24℃.
3. Check the oil level

The oil level should be between the H and L marks on the oil dipstick. Fill oil from the oil filler if necessary.
4. Check the parts and wiring connections
Check if the engine accessories are connected reliably, and eliminate any abnormalities.
Check if the starting system circuit is connected normally, and the battery is fully charged. After that, open
the fuel tank valve, unscrew the bleed screw on the primary fuel filter, and operate the hand pump on the
primary fuel filter to exhaust the fuel system.
Check whether the pipeline connection of the SCR system is reliable. Leakage of urea solution is not
allowed.
5. Check the urea solution level of urea solution tank
In general, the urea solution consumption accounts for about 3%~5% (volume ratio) of the fuel
consumption. Check that the urea solution level is between 30% and 80% as appropriate, and add urea solution
if necessary; do not add too much urea solution lest urea solution overflows.
2.4 Start
When start conditions are available, turn the electric key to start the engine. If the engine can’t be started
within (5~10) s, wait for 1 min before the next start attempt. If three successive starting attempts fail, do not
start the engine until the fault has been identified and eliminated. After the engine is started, notice the
instruments, and check that the oil pressure gauge works normally. Do not run a cold engine at high speed,
instead, run it at an idle speed for a period of time not longer than 30 s. After that, check the oil pressure and
water temperature.
In a cold environment, start the engine with the starting aid. Activate the electronic heating flange by a relay
to ensure successful start at low temperature (such as -30°C).
2.5 Running
1. After the engine is started, run it at an idle speed for 3 min, and then accelerate it to (1,000~1,200) r/min.
9
Increase the engine load and speed gradually, and avoid abrupt loading or unloading as much as possible.
2. Within the running-in period of first 50h, it is recommended to run under medium load. The engine
should not be used for a long time at low speed. The whole machine is not designed to operate at low speed and
under low load conditions, otherwise it is prone to oil expelling.
3. It is allowed to run the engine continuously at rated power and speed during normal operation,; however,
when the engine is to be stopped after unloading, it is required to run it at idle speed for1~2 min.
4. The parameters of engine during normal operation are as shown in Tab. 2-1.
Tab. 2-1 Parameters of Engine
Parameter Normal range

Pressure of main lubricating oil passage Rated condition: 350 kPa~580 kPa
Oil temperature of oil pan 85~105℃
Coolant outlet temperature ≤95℃
Turbine downstream exhaust gas temperature ≤600℃
Intercooled intake air temperature (55±5)℃
5. Check the exhaust color to identify the operation quality and load of the fuel injector. If the smoke color is
improper, stop the engine for inspection. Check the engine for water, gas and oil leakage, if any, stop it for
troubleshooting.
6. Precautions for running in a cold environment:
1) Fuel: select appropriate grade of diesel according to the outdoor temperature in winter.
2) Lubricating oil: select appropriate grade of lubricating oil according to different seasons.
3) Coolant: add anti-freeze into the cooling system, and determine the antifreeze grade and mixture ratio
according to the ambient temperature.

4) Start: apply the starting aid in winter when necessary. After the engine is started, do not run it under a
load or at a high speed until the oil pressure and water temperature are normal.
5) The electrolyte level, viscosity and unit voltage of the battery must be checked before the cold season
coming. If the diesel engine is at a very low temperature and will not be used for a long time, the battery should
be removed and stored in a warmer room.
2.6 Stop
Before shutting down the diesel engine, unload it, reduce its speed gradually, and run it at an idle
speed for a few minutes. In case of f exceeding speed, the engine can be stopped by cutting off the
pipeline of the high-pressure fuel pump and blocking the air filter intake.
After engine shutdown, disconnect the electric key to prevent the battery current from flowing
back into the excitation coil of the silicon rectifier alternator to avoid battery discharge.
When the ambient temperature is lower than 0°C, if the engine will be out of service for a long time,
turn on the water release switch and drain all the coolant to prevent frost cracking. The coolant doesn’t
10
need to be drained if antifreeze is added.
CAUTION
1. For models equipped with Weichai WCBS in-cylinder brake system, when the in-cylinder brake system is
used, the operating speed of the engine must not exceed 2100 rpm. However, for models that do not have a
WCBS in-cylinder brake system (with WEVB exhaust brake), the operating speed of the engine must not exceed
2300 rpm when using exhaust brakes.
2. The overspeed alarm will ring when the engine’s speed reaches 2450r/mi
11
Chapter III Maintenance
3.1 Fuel, lubricating oil, coolant, and auxiliary materials
3.1.1 Fuel
The fuel should be consistent with GB19147 and selected based on the local ambient temperature in
accordance with the provisions of this standard as follows:
—5# automobile diesel: to be used in area where risk rate is 10% and min. temperature is above 8℃;
—0# automobile diesel: to be used in area where risk rate is 10% and min. temperature is above 4℃;
—-10# automobile diesel: to be used in area where risk rate is 10% and min. temperature is above -5℃;
—-50# automobile diesel: to be used in area where risk rate is 10% and min. temperature is above -44℃.
3.1.2 Lubricating oil

The criteria for engine lubricating oil selection are presented in Tab. 3-1.
Tab. 3-1 Selection Criteria of Special Lubricating Oil for Weichai Power Engines
Category Grade Packing specification

Engine CI-4 4 L, 18 L, 170 kg
For the temperature and viscosity of engine lubricating oil, refer to Tab. 3-2. Viscosity selection based on
ambient temperature
Tab. 3-2 Oil Viscosity and Applicable Ambient Temperature
Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature range, ℃ temperature range, ℃
0W -35~-15 10W-50 -25~50
0W-20 -35~20 15W-30 -20~30
0W-30 -35~30 15W-40 -20~40
0W-40 -35~40 15W-50 -20~50
5W -30~-10 20W-30 -15~30
5W-20 -30~20 20W-40 -15~40
5W-30 -30~30 20W-50 -15~50
5W-40 -30~40 20 -10~20
13
Tab. 3-2 Oil Viscosity and Applicable Ambient Temperature (Continued)
Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature range, ℃ temperature range, ℃
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 requirements of engine
lubricating oil are detailed in GB11122.
CAUTION
1. Before starting the engine, always check the oil level in oil pan.
2. Never check the oil level when the engine is running.
3. Never mix engine oil from other manufacturers with the special oil for Weichai Power engines.
The filling amount of engine lubricating oil is shown in Tab. 3-3.
Tab. 3-3 Filling Amount of Engine Lubricating Oil
Quantity of filter(s)
Diesel engine
Model Oiling amount (L)
Fuel filter
Oil filter Primary Secondary
fuel filter fuel filter
WP12WP13 25~28 2 1 1
Note:
1) The oiling amount given herein is for reference only. Please check the oil dipstick for actual oiling amount.
2) Weichai fuel system protector or water separator, if installed on the vehicle, should be replaced together with the diesel fuel filter.
3) The number of filters given herein is for reference only. For the actual number, the actual model shall prevail.
3.1.3 Coolant
The special coolant for Weichai Power engines is available in three kinds of freezing points: -25°C, -35°C and
-40°C. Please select the coolant with appropriate freezing point according to the local ambient temperature.
Generally, the freezing point of the selected coolant should be 10°C below the ambient temperature. The coolant
for heavy-duty engine is as shown in Tab. 3-4.
Tab. 3-4 Selection Criteria of Coolant
Category Grade Packing specification
HEC-II-25
Coolant for heavy-duty engine 4 kg, 10 kg
HEC-II-35
HEC-II-40
14
CAUTION
1. Always check the coolant on a regular basis, and change it in time as appropriate to avoid damage from
corrosion.
2. Never change the engine coolant with water or coolant with poor quality.
3.1.4 Urea solution

Urea solution quality
The urea solution quality and performance should conform to the provisions of GB 29518. The requirements
for concentration and composition of urea solution are presented in Tab. 3-5.
Note!
 Substandard urea solution poses the risk of clogging the urea solution pump and nozzle, and may
contain the metal impurities that are prone to causing permanent poisoning of SCR catalyst and
reducing the efficiency of SCR catalytic converter thereafter;
 Urea solution should be added through a specified channel or by a designated unit.
 It is strictly forbidden to replace urea solution with any fluid during normal use.
Tab. 3-5 Compositions of urea solution
Composition Unit Lower limit Upper limit

Weight percentage of urea % 31.8 33.2
Density at 20℃ kg/m3 1087 1093
Refractive index at 20°C - 1.3814 1.3843

Weight percentage of ammonia % - 0.2
bases
Weight percentage of biuret % - 0.3
Acetaldehyde mg/kg - 5
Insoluble substances mg/kg - 20
Phosphorus (phosphorus tetroxide) 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
15
Aluminum mg/kg - 0.5
Magnesium mg/kg - 0.5
Sodium mg/kg - 0.5
Potassium mg/kg - 0.5
Storage of urea solution
The urea solution for vehicle should be stored in an enclosed light-resistant container at the ambient
temperature of 5°C-25°C, with the shelf life shown in Tab. 3-6.
Tab. 3-6 Shelf Life of urea solution for Vehicles
Shelf life of urea solution for vehicle

Ambient storage temperature °C Minimum shelf life (month)
≤10 36
a 18
≤25
≤30 12
≤35 6
≥35 b
Note: The shelf life in the table is specified by giving major consideration to the ambient storage temperature and initial alkalinity of urea
solution besides the difference in evaporation between ventilated and non-ventilated storage containers.
a Avoid transporting or storing urea solution at a temperature above 25°C for a prolonged period of time, so as to prevent decomposition
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 made of recommended materials in
accordance with GB 29518 such as austenitic alloys and additive-free teflon, polyethylene and polypropylene
should be used. In case of storage below 5°C, a proper space should be reserved in the storage containers as the
volume of urea solution in the solidification state will be increased by 7% compared to that in the liquid state.
For the engine filled with urea solution, the effectiveness of urea solution should be noted. The relationship
between the shelf life of urea solution and the ambient temperature during the inventory period of engine is
shown in Tab. 3-6. If the inventory period exceeds the shelf life, it is required to drain away urea solution through
the drain valve at the bottom of the urea solution tank and fill the tank with acceptable urea solution before the
delivery of engine. When the ambient temperature is greater than 35°C, it is necessary to check if urea solution
in the urea solution tank is still up to standard before delivery of the vehicle, and if not, replace it with acceptable
urea solution.
CAUTION
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. If urea solution is poured directly into the urea solution
tank, it may splash, causing environmental pollution. It is recommended to use special filling equipment.
16
2. Urea solution is corrosive to the skin, and if it contacts the skin or eyes accidentally when filling, wash
it 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.
3.1.5 Auxiliary materials

The auxiliary materials for the engine are shown in Tab. 3-7.
Tab. 3-7 Auxiliary Materials for the Engine
No. Name Color Purpose and application

To be applied to smooth metal surfaces to prevent
1 Molykote Pulver Black
blocking, e.g. external surface of cylinder liner
To be applied for lubrication before the pressure of
2 Molykote G-N-U.plus Dark grey
lubricating oil builds up, e.g. intake valve stem
The reference for sealant application of engine is given in Tab. 3-8.
Tab. 3-8 Reference for Sealant Application of Engine
Designation Main purpose Examples of application position Supplements

Camshaft timing gear bolts
Camshaft thrust plate fastening bolt
Flywheel housing bolt
To be applied to the Intermediate idler bolt
thread for locking Front end cap bolt
Weichai special and prevention of Oil filter seat bolt
As an option, the
sealant 242 looseness due to Oil cooler bolt
DriLoc204
vibration, with Plug for oil cooler regulator
thread-locking
medium strength. Air compressor shaft end thread
adhesive can be
Suction filter bolt
sued for
Bolts for oil pump return pipe fixing devices
pre-application.
Bolts for sensors and harness fixing devices
Applied onto the
external threads for
Weichai special
locking and sealing Auxiliary bolt of cylinder head
sealant 262
and to prevent
looseness
For the top surface
Weichai special
sealing of the Push rod tube - cylinder head None
sealant 270
cylinder head
17
Weichai special
For fastening Bowl plug for oil hole None
sealant 271
Weichai special For sealing between

core and hole Other bowl plugs None
sealant 277
Tab. 3-8 Reference for Sealant Application of Engine（continued）
Designation Main purpose Examples of application position Supplements

Joint surface of cylinder block and
crankcase
Front face of the block and front

cover
Rear face of the block and connecting

plate of flywheel housing
Water pump rear cover - front end of

Weichai Applied on shining the block
special sealant metal surface for None
5188(update sealing Flywheel housing connecting plate -
version of 510) flywheel housing
Joint surface of cylinder block and oil

cooler cover
Joint surface of cylinder block and oil

filler cap
Joint surface of crankshaft gear and

crankshaft rear end
18
3.2 Daily maintenance
3.2.1 Daily maintenance

1. Check the coolant level, and if the coolant is
not enough, open the filler cap for topping up.
CAUTION
Always press down the exhaust button before

opening the filler cap, so as to avoid scalding by hot
coolant when the engine is hot.
Fig. 3-1 Coolant Filler Cap
2. When the oil level is below the L mark or above

the H mark, never start the engine.
At this time, fill oil through the oil filler.
CAUTION
Always check the oil level at least 5 min after

shutting down the engine, enabling the oil to return
to the oil pan.
3. Check the fuel level, and add fuel timely.

Fig. 3-2 Marks of Oil Dipstick
4. Check the urea solution level.
The liquid level of the urea tank should be kept

between 30% and 80% of the total volume of the urea
tank.
CAUTION
The volume of urea that you add into tank one time should not be less than 5L. For tank of which the volume is
less than 10L, the one-time adding should not be less than 3.5L.
When the urea level is lower than 10%, alarm system is active, driver alarm lights flash. At this time, urea
should be added in time. If not, engine power would be limited later.
When adding urea, please note:
1) Cap of urea tank and urea tank top area should be clean and cap is important to prevent urea from being
polluted by dust, which cannot be lost.
19
Cleaning the tank surface

2) When it is not convenient to add urea, use the pipe or other tools to help you. After finishing, wash the tools
with water and then package them well in plastic bags.
Adding urea with the help of pipe

3) The sealing film on the urea tank should be removed thoroughly. Seal the tank well during storage.
Removing the sealing film of urea tank
3.2.2 Daily inspection

1. Check the level of coolant, oil and fuel; and
check if there is sufficient grease at greasing positions.
2. Check for leakage of fuel/oil, water and air.
3. Check if external parts and attachments are

properly connected and tightened.
20
Fig. 3-3 Check of connection
4. Check the fan and belts for overtension or

undertension.
5. Check if the exhaust temperature, color, sound

and vibration are normal, and if the engine speed
is stable.
6. Check if the turbocharger’s oil inlet and outlet

pipes are free from blockage or leakage.
7. Check that the exhaust manifold is not leaking

and the intake manifold is unblocked.
Fig. 3-4 Check of fan
3.3 Regular maintenance interval and specification
3.3.1 Regular maintenance interval and specification
Tab. 3-9 Maintenance interval and specification
Highway vehicle under Construction vehicle

Application Agitator truck
standard load (tractor/truck) (dumper)
Maintenance First Regular First Regular First Regular
type maintenance maintenance maintenance maintenance maintenance maintenance
Maintenance 3000-6000 60000km/6 2000-3000 10000km/2 3000-6000 30000km/6

cycle km/3 month months km/3 month months km/3 month months
Change the
● ● ● ● ● ●
oil
Replace the
oil filter or
● ● ● ● ● ●
oil filter
element
Change fuel
water ● ● ●
separator
Check and
adjust the
● ● ● ● ● ●
valve
clearance
Check the
water pump
(lubricate it ● ● ●
with grease
cup)
21
Tab. 3-9 Maintenance interval and specification(continued)
Highway vehicle under

Construction vehicle
Application standard load Agitator truck
(dumper)
(tractor/truck)
First Regular
First Regular First Regular
Maintenance type maintenan maintenan
maintenance maintenance maintenance maintenance
ce ce
Replace the fuel
● ● ●
filter element
Check the coolant
● ● ● ● ● ●
level and add some
Replace the coolant Once a year
Tighten the pipe

clamp of the cooling ● ● ●
pipeline
Tighten the intake

manifold, hose and ● ● ● ● ● ●
flange connector
Check the service
light or indicator of ● ● ●
the air filter
Clean the dust
collector of the air
filter (except for ● ● ●
automatic
de-dusting type)
Clean the main filter

element of the air When the indicator light is on
filter
Replace the main Refer to the relevant

Refer to the relevant Refer to the relevant
filter element of the provisions of the
provisions of the manual provisions of the manual
air filter manual
Compress air filter Refer to the relevant provisions of the manual
22
Replace the
safety filter element After cleaning the main filter element for 5 times
of the air filter
23
Operation and Maintenance Manual of WP3N Series Four-valve China V Vehicle Diesel Engine
Tab. 3-9 Maintenance interval and specification(continued)
Highway vehicle under

Application Construction vehicle (dumper) Agitator truck
standard load (tractor/truck)
Maintenance First Regular First Regular First Regular
type maintenance maintenance maintenance maintenance maintenance maintenance
Check and
tighten the ● ● ● ● ● ●
V-belt
Check the
bearing
clearance of Every 240,000km Every 80,000km Every 150,000km
the
turbocharger
Urea pump
and nozzle ● ● ●
washing
Change the
filter of urea ● ● ●
pump
Urea nozzle
When urea nozzle is removed
gasket
Clean urea
solution tank
● ● ●
and its filter
element
Clean urea
tank sensor ● ● ●
filter
Clean urea
pump inlet ● ● ●
pipe filter
Note 1: ● indicates the item requiring maintenance
Note 2: The diesel engine that is withdrawn out of service for more than half a year shall be subject to corresponding maintenance such as
re-preservation.
Note 3: Engines should be filled with oil to the MAX mark every 15,000 km.
Note 4: Weichai will provide maintenance recommendations upon request from the user.
Note 5: For bus or coach regular maintenance: replace oil & oil filter every 60,000km or 6 months. For optional configuration, the oil & oil
filters that need to be replaced every 100,000 km/12months are also available. The first maintenance handled by service station is
implemented according to every 60,000km/6months.
Note 6: if one aspect of fuel, urea, and working condition could not be fulfilled, halve the replace interval of oil. If two aspects can not be
fulfilled, oil change interval should be one quarter of original requirement.
24
Tab 3-10 Maintenance interval and specification
Harbor tractor, wide

Application Bus/School bus Passenger car
body dumper
First Regular First
Maintenance First Regular Maintenance
maintenance maintenance maintenanc
type maintenance maintenance type
e
2,000km/20 5,000km/50
Maintenance 3,000-6,000k 15,000km/6 3,000-6,000k 30,000km/6
0h 0h
cycle m/3 months months m/3 months months
Change the
● ● ● ● ● ●
oil
Replace the oil

filter or oil filter ● ● ● ● ● ●
element
Replace water ●
fuel separator ● ●
filter
Check and adjust
the valve ● ● ● ● ● ●
clearance
Check the water
pump (lubricate it ● ● ●
by grease cup)
Replace the fuel

● ● ●
filter element
Check the coolant

level and add ● ● ● ● ● ●
some
Replace the Once a year

coolant
Tighten the pipe

clamp of the ● ● ●
cooling pipeline
Tighten the intake
manifold, hose
● ● ● ● ● ●
and flange
connector
Check the service
light or indicator ● ● ●
of the air filter
25
Harbor tractor, wide

Application Bus/School bus Passenger car
body dumper
First Regular First
Maintenance First Regular Maintenance
maintenance maintenance maintenanc
type maintenance maintenance type
e
Clean the
dust collector of
the air filter
● ● ●
(except for
automatic
de-dusting type)
Clean the Clean the main filter element of the air filter
main filter
element of the air
filter
Replace the main
filter element of After cleaning the main filter element for 5 times
the air filter
Check and tighten

● ● ● ● ● ●
the V-belt
Check the bearing

clearance of the Every 80,000km Every 150,000km Every 240,000km
turbocharger
Rinse urea pump

● ● ●
and urea nozzle
Replace gasket of
Every time when disassembling urea nozzle
urea nozzle
Clean urea
solution tank and ● ● ●
its filter element
Clean urea pump

● ● ●
inlet pipe filter
Clean urea tank

● ● ●
sensor filter
Note 1: ● indicates the item requiring maintenance

Note 2: The diesel engine that is withdrawn out of service for more than half a year shall be subject to corresponding maintenance such as
re-preservation.
Note 3: Engines should be filled with oil to the MAX mark every 15,000 km.
Note 4: Weichai will provide maintenance recommendations upon request from the user.
Note 5: For bus or coach regular maintenance: replace oil & oil filter every 60,000km or 6 months. For optional configuration, the oil & oil
filters that need to be replaced every 100,000 km/12months are also available. The first maintenance handled by service station is
implemented according to every 60,000km/6months.
Note 6: if one aspect of fuel, urea, and working condition could not be fulfilled, halve the replace interval of oil. If two aspects can not be
26
fulfilled, oil change interval should be one quarter of original requirement.
Tab 3-11 Maintenance interval and specification (auto crane, railcar)
Maintenance interval Maintenance specification

Check fuel level, engine oil level, coolant level and belt, drain water from the fuel
Daily
water separator, and maintain the air filter element
Check air filter element, air filter alarm and intake manifold (for any wear, looseness
Weekly
or leakage)
First maintenance
Check the valve clearance, change oil, and replace oil filter.
100-200 hours
Every 250 hours or 3 Replace air filter element (shorten the maintenance interval depending on working
months conditions), and check dust collector, alternator and starter fan wire harness.
Regular maintenance
Every 500 hours or 6 Replace oil, oil filter and fuel filter, grease coolant pump and fan bracket
months
Every 1000 hours or 1 check valve clearance.
year
3.4 Description of maintenance of all levels
3.4.1 Oil change

1. Unscrew the drain plug at the bottom of oil pan
to drain out oil, and then screw on the drain plug
again.
Drain plug
Fig. 3-5 Drain Plug
27
2. Open the filler cap to fill oil through the filler;

check the oil dipstick, and when the required level is Oil filler cap
reached, refit the filler cap.
Fig. 3-6 Oil filler cap
3.4.2 Replacement of oil filter or oil filter element

1. Use special tools to remove the filter element. Please pay attention to the oil inside it in case of
environment pollution caused by oil leakage and do not discard the replaced oil filter casually.
2. Wipe the sealing surface of the joint surface with a clean rag to ensure that the sealing surface is free of
impurities so as not to affect the seal.
3. Spread a layer of oil film to the new seal ring and fill the filter with oil, then lightly tighten the rubber ring
to the sealing surface, after which tighten it with a special wrench for 3/4–1 turn is also necessary. .
4. Start the engine to check for damage and oil leakage.
Unqualified diesel or oil filter will cause early wear of the bushing at the crankshaft and other parts,
which will increase the risk of excessive emissions!
3.4.3 Replacement of fuel filter and filter element

Procedures:
1. Remove the old fuel filter element.
2. Lubricate the seal.
3. Screw the filter by hand until the seal fits the connection.
4. Continue to screw the filter by hand until it is installed
firmly (by about 3/4 circles).
5. Discharge the air until no bubbles appear. Fuel filter
6. Carry out a leakage test. Fig. 3-7 Fuel filter
3.4.4 Check and adjustment of valve clearance

Check and adjustment sequence of valve clearance:
1. Turn the engine to the top dead center of cylinder1 (the flywheel housing observation window
scale line is aligned with the flywheel groove).
2. Adjust the intake valve clearance of cylinder1, cylinder2 and cylinder4; the intake valve clearance is
0.4mm (see Fig. 3–11 Intake valve clearance adjustment methods).
3. Adjust the brake clearance and exhaust valve clearance
28
of cylinder3(first adjust the brake clearance, then the

exhaust valve clearance). The brake clearance is 2.05mm,
and the exhaust valve clearance is 3.0mm. For more details,
see Fig. 3 –12 Exhaust clearance adjustment method.
Fig.3-8 Flywheel tick
4. Facing the flywheel end, turn the engine counterclockwise

until the flywheel housing observation window tick mark align
with “mark line 16” on the flywheel. Then adjust the cylinder6’s
brake clearance and exhaust valve clearance (first adjust the
brake clearance, then the exhaust valve clearance). The
brake clearance is 2.05mm, and the exhaust valve clearance
is 3.0mm. For more details, see Fig.3–12 Exhaust clearance
adjustment method.
Fig.3-9 Flywheel tick

until the flywheel housing observation window tick mark align
with “mark line 25” on the flywheel. Then adjust cylinder2’s
brake clearance and exhaust valve clearance (first adjust the
brake clearance, then the exhaust valve clearance). The
brake clearance is 2.05mm, and the exhaust valve clearance
is 3.0mm. For more details, see Fig.3–12 Exhaust clearance
adjustment method.
until the flywheel housing observation window tick mark align Fig.3-10 Flywheel tick
with “mark line 34” on the flywheel.
7. Adjust the intake valve clearance of cylinder3, cylinder5
and cylinder6; the intake valve clearance is 0.4mm (see Fig.
3–11 Intake valve clearance adjustment methods).
8. Adjust cylinder4’s brake clearance and exhaust valve clearance (first adjust the brake clearance, then
the exhaust valve clearance). The brake clearance is 2.05mm, and the exhaust valve clearance is 3.0mm. For
more details, see Fig. 3 –12 Exhaust clearance adjustment method.
9. Facing the flywheel end, turn the engine counterclockwise until the flywheel housing observation
window tick mark align with “mark line 16” on the flywheel. Then adjust cylinder1’s brake clearance and
exhaust valve clearance (first adjust the brake clearance, then the exhaust valve clearance). The brake
clearance is 2.05mm, and the exhaust valve clearance is 3.0mm. For more details, see Fig.3–12 Exhaust
clearance adjustment method.
10. Facing the flywheel end, turn the engine counterclockwise until the flywheel housing observation
29
window tick mark align with “mark line 25” on the flywheel. Then adjust the cylinder5’s brake clearance and
exhaust valve clearance (first adjust the brake clearance, then the exhaust valve clearance). The brake
clearance is 2.05mm, and the exhaust valve clearance is 3.0mm. For more details, see Fig.3–12 Exhaust gap
adjustment method.
Valve clearance adjustment method
1. Turn the engine to the corresponding location.
2. Intake valve clearance adjustment: insert the Adjustment screw
Nut
feeler gauge between the intake valve bridge and the
Foot support
intake rocker arm; adjust the valve clearance to 0.4 mm
and tightening torque to (45 ± 5) N.m.
3. Brake clearance adjustment: insert the feeler
gauge between the exhaust valve bridge and the
smaller piston of the exhaust rocker arm; adjust the
push rod side screw, adjust the brake clearance to
2.05mm, and tightening torque to (45 ± 5) N.m.
Fig. 3-11 Intake valve clearance adjustment
Exhaust clearance
4. Exhaust valve clearance adjustment: Insert the

Brake clearance
feeler gauge between the exhaust valve bridge and the
foot support; adjust the valve side screw, adjust the
exhaust valve clearance to 3.0mm, and the tightening
torque to (45±5) N•m.
Fig. 3-12 Exhaust clearance adjustment method
3.4.5 Check of air seal

Check if the intake hose is cracked due to aging, and if the hoop gets loosened. When necessary, tighten or
replace related parts to ensure the tightness of intake system.
3.4.6 Check of air filter element

The max permissible intake resistance of the engine is 6 kPa, and it shall be checked when the engine runs
at rated speed and full load. When this max permissible intake resistance is reached, clean or replace the air filter
element as specified by the manufacturer.
CAUTION
30
Never run the engine without an air filter; otherwise, dust and foreign matters may enter the engine to
cause premature engine wear!
Remove the air filter element from the filter,

and tap its end face to shake off the dust, or blow
its end face with compressed air from inside to
outside.
Fig. 3-13 Compressed air back blowing
CAUTION
Unqualified air filter elements can cause abnormal blockage for DPF, resulting in serious failures such as
excessive emissions and DPF damage!
3.4.7 Maintenance of after-treatment parts

Check of urea solution pump filter element
During maintenance, remove the urea solution pump filter element, and clean it with water before refitting.
Do not beat or knock the filter element with force.
CAUTION
Check the situation of urea solution nozzle each time the urea solution nozzle is replaced or removed and
refitted. The nozzle gasket, if damaged or deformed, should be replaced!
Clean urea solution tank and its filter element
When doing maintenance, check the cleanliness of the urea tank and filter element and clean it/them if
necessary.
CAUTION
After the engine is shut off (only T15 powers off), the SCR system will automatically enter the inverted
suction state, and the urea solution in the urea pump and the urea pipeline will be sucked back into the urea
box. This stage will last for 2 minutes. During this period, it is forbidden to turn off the main switch of the
vehicle power supply.
Urea tank maintenance
Regularly clean the urea tank every 60,000 km or 6 months to avoid the blockage and wear of the urea
pump caused by particulate impurities in the tank.
31
The urea tank sensor is an intelligent sensor that measures the liquid level and urea concentration and
corresponds to the data in the engine ECU. If the unmatched urea tank is replaced, it may cause OBD failure and
result in engine torque limit. If you need to replace it, please be sure to choose a same type urea tank produced
by the original manufacturer.
3.4.8 Air bleeding of low pressure pipeline

Air bleeding shall be carried out on the high pressure common rail fuel system after component
replacement, or when the fuel tank is empty, air enters the low pressure fuel circuit, or the vehicle is used for the
first time. The following operational procedures should be followed for air bleeding:
1. Check all the joints of the pipeline, especially the joints at the inlet and outlet of the fuel tank, whether
they are loose or leaking. Tighten them if phenomena above occur.
2. Bleed the air in the primary filter: loosen the fuel inlet connector (or the opposite fuel inlet plug) on the
primary filter; press the pump of fuel filter with water separator until bubble-free fuel continuously flows out;
tighten the screw.
3. Bleed the air in the secondary filter: loosen the fuel inlet connector (or the opposite fuel inlet plug); press
the pump of fuel filter with water separator; see gas get out of the inlet until bubble-free fuel continuously flows
out; tighten the connector.
4. Bleed the air in the pipeline: loosen the high pressure fuel pump return joint; continue to press the hand
pump until bubble-free fuel continuously flows out; tighten the joint.
5. Continue to press the manual fuel pump until more fuel continuously enters the high pressure fuel pump.
6. Start the engine after air bleeding. Keep the engine running at a high speed for more than 5 minutes (You
can press the throttle hard in neutral or low gear to reach a high speed) and bleed the left air completely.
3.4.9 Maintenance of oil-gas separator

1. Open the top cover of the oil-gas separator and take out the filter element.
2. Check the adhesive on both ends of the filter element. Replace the filter if there is any crack.
3. Clean the surface of the filter element with light diesel or gasoline.
4. Check the filter element and seal ring at the upper cover. Replace the seal if it has deteriorated or
hardened.
5. Press the filter element into the housing and tighten the top cover.
Top cover
Seal ring
Filter element
Fig. 3-14 Oil-gas32separator

3.5 Cleaning, protection and handling
NOTICE！
Weichai engine seal period can be maintained for one year, if over the one year seal period, the engine shall be
protected against rust according to the storage protection instructions in this section.
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;
2. Empty the fuel tank, and then fill it with anti-rust oil mixture;
3. Empty the water tank and then fill it with coolant containing anti-rust agent;
4. Start the engine, and run it at an idle speed for (15~25) min;
5. Drain off the oil, fuel and coolant;
6. Preserve other parts of the engine.
3.5.2 Protection during storage

Block inlets and outlets of fuel, oil, air and coolant by caps or plastic cloth; seal up the whole engine with
VCI film.
3.5.3 Oil sealing

The seal period of the diesel engine is 1 year, and the engine outside this period should be sealed again as
follows:
1. The engine should be sealed in a clean environment. The engine block and its parts should be thoroughly
cleaned and free of corrosion, oil stain and dust before sealing.
2. The engine can be sealed by immersion, spraying, coating or filling method as appropriate.
3. Sealed parts: turbocharger air inlet/air outlet, air compressor inlet, and intake manifold port.
3.5.4 Handling
Pack the engine for handling where appropriate.
Chapter Ⅳ Typical Faults and Troubleshooting
4.1 Overview
4.1.1 Overview
Engines of this series are designed and manufactured under a strict quality assurance system, and have
33
been subject to specified tests before delivery. Moreover, engine is the precise machinery whose lasting good
performance is related closely to a proper maintenance. The premature failure of engine is generally resulted
from:
1. Operation against regulations, improper management and misuse;
2. Failure to inspect and maintain the engine as specified, and more serious, replacement of maintenance
with repair;
3. Use of defective spare parts, or even counterfeit and shoddy parts due to their cheap price, which will
dramatically shorten the service life of engine;
4. Use of fuel and lubricating oil with improper grade or poor quality.
CAUTION
1. The engine troubleshooting is a complicated work. Thus, do not disassemble or remove the engine at
discretion before determining its basic fault cause; otherwise, the fault will not be eliminated, and even more
serious fault may occur due to improper refitting.
2. Key components of the engine such as the high pressure fuel pump and turbocharger should be
maintained and inspected by special apparatus and based on certain experience. Therefore, users having no
relevant experience and equipment are not allowed to remove or adjust the engine at random.
4.2 Fault diagnostic methods
4.2.1 Traditional fault diagnostic methods

1. Observation: Determine the fault by observing
the symptom of diesel engine, such as smoke.
Fig. 4-1 Observation

2. Listening: Determine the fault location,
symptom and severity by listening to the abnormal
noise of diesel engine.
3. Comparison: Replace a certain assembly or
component to determine whether it is faulty.
Fig. 4-2 Listening
34
4.2.2 On-board diagnostics (OBD) general description and indicator lights explanation
4.2.2.1 General description
1) General description of Weichai NOx controlling system
It contains 3 main parts.
 Driver alarm system
It contains the following subsystem that indicator lights, symbols, alarm of voice and output information from
vehicle monitoring system. When system detects that there is relevant failures, it sends the alarm system to
driver in time to let him pay attention on the maintenance.
Driver alarm system is integrated on the dash board of your vehicle, which may be different from vehicle
manufacturers.
 Basic limitation system for driving performance
Engine torque will be limited. The trigger situation listed as bellow.
 Severe limitation system for driving performance
Failure mode Alarm system activated Basic limitation activated Severe limitation
activated
Urea not proper Instant 10h later after 20h later after
malfunction detected malfunction detected
Urea consumption not Instant 10h later after 20h later after
proper malfunction detected malfunction detected
Urea injection Instant 10h later after 20h later after
malfunction malfunction detected malfunction detected
EGR valve malfunction Instant 36h later after 100h later after
malfunction detected malfunction detected
Monitoring Instant 36h later after 100h later after
system/after-treatment malfunction detected malfunction detected
type A malfunction
Urea level of tank ≤10% 2.5%< level ≤10% ≤2.5%
Basic and severe limitations aren’t applicable to the vehicles for emergency, military, firefighting, etc. The
limitation only could be removed by weichai or its OEM.
2) When the limitation disappears
When all the triggers of limitation don’t exist any longer, for instance urea is added enough again or malfunction
is solved.
4.2.2.2 Explanation of light status of EU VI engines
No. Indicator light Status Explanation Illustrator
1 MIL light According to law Emission system
malfunction
2 Driver alarm light Continuously Other malfunction

yellow
3 Yellow glisten Urea level low
4 Continuously red Torque limitation to
75%
5 Red glisten Vehicle velocity
35
limited to 20km/h
6 DPF regeneration Continuously Regeneration is on
indicator light yellow
7 Yellow glisten Vehicle stopped to
do regeneration
8 Continuously red Regeneration in
service station
9 DPF regeneration Continuously red DPF regeneration
light not allowed light not allowed
briefly
10 SVS light Continuously on Engine
malfunction(except
emission system)
Note: Information maybe different due to vehicle design.
4.2.2.3 MIL & SVS lights Check
1) MIL light indicates the after-treatment malfunctions. MIL lights mainly contain 3 stages which are self-check,
display of ready status, malfunction indicator.
When T15 is on and engine isn’t started, MIL will run the above stages successively.
MIL light self-check: being on 5s -> being off 10s
MIL light is ready: if ready, the MIL light is on for 5s, if not, light glisten for five times then being off for 5s.
MIL malfunction indicator: there are 3 kinds of malfunction for after-treatment system, containing A/B/C kind.
If there is no malfunction of after-treatment system:
Ready status stage finishing, MIL flash once every 5s, no malfunction. After engine is started, MIL is off
automatically.
Type C malfunction:
Ready status stage finishing, MIL flash twice every 5s, and it means it is type C malfunction and doesn’t affect
driving. After engine is started, MIL is off automatically.
Type B malfunction:
Ready status stage finishing, Mil flash three times every 5s, and it means it is type B malfunction. After engine is
started, MIL light is on for 15s then off.
Type A malfunction:
Ready status stage finishing, Mil light is on continuously and it stands for type A malfunction. After engine is
started, MIL light is on continuously.
OBD SVS light

2) The SVS light is used to indicate the engine system fault. When powered on, it will perform self-check, go on a
36
while and then go off.

 In case it stays on after power-on, check for existence of DTC; if there is no DTC, check for circuit fault.
 If the SVS lamp does not come on during the self-diagnosis after power-on, this may be caused by the circuit
fault or bulb damage.
This DTC list enables the maintenance technician to, according to the DTC, find out the engine fault name and its
related description and P-Code (the code that can be viewed on the vehicle by connecting the engine to the
vehicle), fault-related components, fault cause, solutions, etc., so as to quickly determine the cause of the engine
fault.
Table 4-1 OBD Method

Step Inspection location Inspection method
1 Preliminarily identify the fault Preliminarily judge the fault orientation (mechanics, electrics, and components)
orientation and location according to the symptom and response of the vehicle; do not replace any
component blindly;
2 Read DTCs (P code and flash DTCs indicate inactive fault and active fault respectively, and the inactive fault has no
code) impact on the vehicle performance. The location of fault that affects the vehicle
performance can be determined by reading-recording-clearing-reading-recording
(analysis).
3 Do troubleshooting as per DTCs Check the engine step by step and case by case, and do not replace any component
before identifying the fault location. Most of DTCs indicate the faulty portion only
rather than the faulty component or sensor. Be sure to comprehensively identify the
fault location by taking the actual working process of engine into consideration
during troubleshooting. Scope of troubleshooting for engine-related DTCs is
classified as follows:
DTCs of fuel system: Fuel tank, filter, pipeline and joint, high-pressure fuel pump and
rail, and fuel injector;
DTCs of air system: Air filter, pipeline, turbocharger, charge air pressure and
temperature sensor, inter-cooler, etc.;
Preliminary check of electrics: Harness, connector, sensor, actuator, etc.
4 Do troubleshooting without DTC In case no DTC can be read, check if the communication harness between scan tool
and ECU are normal; if no DTC is accessible, do analysis and judgment based on
experience and data stream.
37
4.3 Typical troubleshooting
4.3.1 Startup failure

Steps Checking points Troubleshooting
Inlet filter screen or hose of fuel injection pump is

Step 1 …………… …………… Remove dirt and check the cleanliness of the fuel.
blocked
Bleed air from the fuel system; check joint tightness and
Step 2 …………… Air enters the fuel system ……………
repair it.
Check the plunger; repair the fuel outlet valve or replace

Step 3 …………… Fuel injection pump malfunctions. ……………
the damaged parts.
Step 4
…………… Fuel injector malfunctions. …………... Check the atomization of injector.
…………… …………… Check and adjust it.

Step 5 Valve train or fuel pipe is damaged, and leaks
Step 6
…………… The high pressure fuel pipe is damaged, and leaks …………… Repair or replace it.
…………… Check the tightness of valve, cylinder gasket, the wear

Step 7 Insufficient cylinder compression pressure ……………
of piston ring, repair or replace it.
38
Step 8 …………… ……………

The ambient temperature is too low. Use starting aids
4.3.2 Stop shortly after startup

…………… Remove the filter, remove internal contaminants and

Step 1 The fuel filter is blocked. ……………
moisture, and replace the filter if necessary.
Check the tightness of the fuel pipe and joints, and tighten
Step 2 …………… Air enters the fuel system ……………
the bleeder screws to repel the trapped air.
Step 3 …………… The fuel injection pump does not work. …………… The fuel injection pump does not work.
Step 4 …………… Poor fuel quality and contains excessive water …………… Clean the filter and replace the fuel.
Step 5 …………… Regulated idle speed is too low …………… Readjust
39
4.3.3 Insufficient power

…………… Check the air filter, intake manifold, clean or replace the
Step 1 Blockage of air intake (air filter blockage) ……………
filter element
…………… …………… Check the valve timing, check whether the exhaust pipe is
Step 2 Exhaust back pressure is too high.
blocked, adjust or repair it if necessary.
Step 3 …………… Pressure of turbocharger system is insufficient …………… Check the tightness of pipe connection and troubleshoot
the leakage fault
1) If the compressor o turbine runner is blocked, clean or

replace it.
Step 4 …………… Turbocharger malfunctions. …………… 2) If the floating bearing fails to work, replace it.
3) If there is carbon/sludge deposit on the turbine or the
back of the compressor, remove it.
Step 5 …………… Intercooler is damaged and leaks …………… Replace or repair it.
Check the tightness of the fuel pipe and the joints,

…………… ……………
Step 6 Fuel pipeline is blocked or leaks check the contamination of the filter, repair the fuel
pipe or remove the smudge, replace the fuel element
40
Clean the fuel tank, filtering part and fuel pipe,

Step 7 …………… ……………
Fuel of poor quality replace the fuel.
Step 8 …………… Fuel injection pump wears too much …………… Repair or replace it.
…………… …………… Check the injection pressure and carbon deposit on

Step 9 Poor atomization of injector nozzle
the injector nozzle, adjust or repair it.
Incorrect valve timing or fuel supply timing

Step 10 …………… …………… Check and adjust it/them.
Check the regulated high speed, and adjust it.

Step 11 …………… Regulated high speed is too low ……………
Step 12 …………… Oil level in the oil pan is too high …………… Check the dipstick and release excessive oil.
Check the compression pressure when warming up

Step 13 …………… Cylinder gasket leaks ……………
the vehicle and replace the damaged cylinder gasket.
gasket.
…………… The piston ring is worn and broken, and the bearing
Step 14 …………… Replace worn parts or overhaul the engine
bush clearance is too large.
41
Step 15 …………… Cylinder liner or piston is worn or piston scratches …………… Replace worn parts or overhaul the engine.
4.3.4 Low oil pressure

…………… Check whether there’s any leaky point, and add some
Step 1 The oil pan contains insufficient oil ……………
oil
Step 2 …………… The pressure regulating valve of main oil passage is …………… Check, clean and repair the valve.
faulty
Whether the suction, oil pipeline or joint gasket is Check and clean the air compressor’s flow path,
Step 3 …………… ……………
blocked or broken remove the fouling, and remove carbon deposits on
the exhaust passage.
…………… Change the oil according to the regulations and select

Step 4 Oil grade does not meet the requirements. ……………
the appropriate brand of engine oil.
Step 5 …………… Leakage of oil pump inlet pipe …………… Repair or replace the oil pipe and the joint.
…………… The temperature of coolant and oil are too high

Step 6 …………… Check and repair the cooling system.
42
Step 7 …………… The oil filter is under excessive resistance …………… Replace it with a new filter element.
Step 8 …………… Blockage of oil cooler …………… Check and clean it up.
Step 9 …………… Blockage of main oil passage …………… Check and clean it up.
The bearing bush clearance is too large, or the bearing ……………

Step 10 …………… Check and replace it.
bush is damaged.
…………… Check the working hours of the engine and overhaul

Step 11 Parts are worn out and need to be overhauled. ……………
it.
4.3.5 The temperature of coolant is too high

Step 1 …………… The water tank contains insufficient coolant …………… Check if the water tank is leaky, and add coolant if
necessary
Step 2 …………… Blockage of water tank …………… Check the water tank, clean or repair it.
43
Step 3 …………… Slack of pump belt …………… Adjust the tension according to the regulations.
Step 4 …………… Damage of pump gasket and wear of pump impeller. …………… Check and repair or replace it.
Step 5 ……… Failure of thermostat ……… Replace it.

…… ……
Step 6 ……… ……… Check the water pipe, joint and gasket, and replace
Water pipe is damaged and air enters the pipe.
…… …… the damaged parts
Step 7 …………… Check the oil level and leaky points of the oil pan,
The oil pan contains insufficient oil ……………
repair the damaged part and add oil
4.3.6 Too much noise

Step 1 …………… Fuel of poor quality …………… Replace the fuel.
Step 2 …………… The temperature of coolant is too low …………… Check the thermostat and replace if necessary.
44
Step 3 …………… Incorrect valve timing or fuel supply timing …………… Check, repair and adjust
Check, repair and adjust

Step 4 …………… Poor atomization of fuel injector nozzle ……………
Step 5 …………… The injection pump injects too much fuel …………… Check and adjust it (by fuel pump manufacturer).
Check for damage and the situation of connecting

Step 6 …………… The damper wears ……………
bolts, then replace damaged parts.
Step 7 …………… The valve leaks or is improperly adjusted …………… Remove and check the valve, then adjust it.
Step 8 …………… …………… Check and replace the damaged parts.

The gear backlash is excessive or the teeth are broken
…………… ……………
Step 9 The cylinder liner or piston is worn or scratching Check, repair or replace it.
45
Step 10 ……… ……
The push rod is bent or broken Replace it.
…… ………
Step 11 …………… Piston ring is broken or worn. …………… Check or replace damaged parts.
4.3.7 Starter motor does not work

Step 1 …………… Insufficient battery charging …………… Check, charge or replace the battery.
Step 2 …………… Poor contact of the cable …………… Clean the line and tighten the terminal.
Step 3 …………… Fuse melts …………… Change the fuse.
Step 4 …………… Poor contact of the brush …………… Clean the brush surface or replace the brush.
…………… Repair the motor or replace the assembly.

Step 5 …………… Starter motor is short- circuited.
46
4.3.8 Starter motor is powerless

Step 1 …………… Insufficient battery charging …………… Charge or replace the battery.
Step 2 …………… Wear of bearing bush …………… Replace the assembly.
Step 3 …………… Poor contact of the brush …………… Clean the brush surface or replace the brush.
Clean the oil stain and polish the assembly with sand
Step 4 …………… The commutator is dirty or burned ……………
paper or replace it.
Step 5 …………… Desoldering of the wire end …………… Resolder.
Step 6 …………… Poor contact in the switch …………… Check the switch and fix it.
Adjust the working torque of the clutch or replace the

Step 7 …………… The worn clutch slips. ……………
assembly.
47
4.3.9 Excessive fuel consumption

Step 1 …………… Blockage of the intake pipe …………… Check and clean the air filter and intake line.
Step 2 …………… Exhaust back pressure is too high. …………… Check and clean the exhaust pipe and brake valve.
Step 3 …………… Fuel of poor quality …………… Replace the fuel as required.
Step 4 …………… Blockage of fuel pipeline …………… Check and fix it.
Step 5 …………… The fuel pipeline leaks …………… Check and fix it.
Step 6 …………… Poor atomization of the fuel injector …………… Check, adjust or repair it.
48
…………… …………… Adjust the valve clearance and the fuel supply
Step 7 Incorrect valve timing or fuel supply timing
advance angle as required.
Step 8 …………… Leakage of cylinder gasket …………… Check the compression pressure.
The bearing bush clearance is too large and the engine

Step 9 …………… …………… Check and overhaul it.
needs to be overhauled.
Step 10 …………… Piston expanding …………… Replace the cylinder liner, piston and piston ring.
Step 11 …………… ……………

The pressure of turbocharging system is insufficient Check and troubleshoot the leakage of the pipe and
the joints.
Step 12 …………… Turbocharger malfunctions. …………… Check and replace it.
Step 13 …………… Damage or leakage of intercooler …………… Fix or replace it.
49
4.3.10 Exhaust black smoke

Step 1 …………… Blockage of intake pipe or high exhaust back pressure …………… Clean it.
Clean it.
Step 2 …………… Fuel of poor quality …………… Clean and replace it.
Incorrect valve timing or fuel supply timing

Step 3 …………… …………… Adjust as required.
Step 4 …………… Poor atomization of injector nozzle …………… Check, repair or replace it.
Step 7 …………… Turbocharger malfunctions …………… Check and replace the assembly.
Step 8 …………… Damage and leakage of intercooler …………… Fix or replace it.
Step 9 …………… Smoke detector works abnormally. …………… Readjust it (by the fuel pump manufacturer).
50
4.3.11 Exhaust white/blue smoke

Step 1 …………… Fuel of poor quality and contains excessive water …………… Replace the fuel.
Step 2 …………… …………… Check the operating temperature of the thermostat

The temperature of coolant is too low.
and replace it if necessary.
Step 3 …………… Incorrect valve timing or fuel supply timing …………… Check and adjust it.
Step 4 …………… Poor atomization of injector nozzle …………… Check and repair it.
…………… Low compression pressure, incomplete combustion and …………… Check and repair the piston ring, cylinder liner and
Step 5
piston expanding cylinder gasket.
Step 6 …………… Piston ring and cylinder liner does not run in well. …………… Continue to run them in.
51
Step 7 …………… Piston ring’s opening is not staggered. …………… Adjust and reassemble it.
Step 8 …………… Failure of piston oil ring …………… Replace it.
…………… The matching clearance between piston and cylinder ……………

Step 9 Repair or replace it.
liner is too large.
Step 10 …………… Wear of turbocharger seal ring …………… Check and replace it.
Step 11 …………… Wear of turbocharger thrust bearing …………… Check and replace it.
Step 12 …………. Blockage of turbocharger oil return pipe …………… Clean or repair it.
..
52
4.3.12 Turbocharger intake port and intake pipe are enriched with oil
Step 1 …………. Failure of turbocharger sealing. …………… Repair or replace the turbocharger.
..
Step 2 …………. Failure of oil-gas separator …………… Replace it.

..
Too much oil in the oil pan

Step 3 …………. …………… Release some oil.
..
4.3.13 Unstable engine speed

Step 1 …………. Fuel of poor quality, and contains water or wax …………… Change the fuel.
..
…………. …………… Check the tightness of the fuel pipe and joint, bleed
Step 2 Air enters the fuel suction pipe.
.. the air
The governor weight and speed regulating spring work

Step 3 …………. ………….. Check and adjust it (by fuel pump manufacturer).
abnormally
..
53
Step 4 …………… Uneven fuel supply …………… Check and adjust it (by fuel pump manufacturer).
Step 5 …………… Unstable atomization of injector nozzle. …………… Check and repair it.
Clean the flow passage of air compressor, and remove

Step 6 …………… Turbocharger surging …………… the carbon deposits on the exhaust passage
Step 7 …………… Damage of turbocharger bearing …………… Replace it.
4.3.14 Fast wear of parts

Step 1 …………… Air filter element is unqualified or damaged. …………… Check and replace it.
…………… …………… Check intake manifold, gasket, connecting pipe sleeve,

Step 2 Intake system is short-circuited.
then repair or replace it.
54
Step 3 …………… The oil pan contains insufficient oil …………… Check the oil level and leaky point, repair and add oil
Step 4 …………… Blockage of the oil passage …………… Clean the oil passage.
Step 5 …………… The oil is of unspecified grade …………… Change the oil as required.
Step 6 …………… Piston ring is broken or worn. …………… Replace the damaged parts
Remove the piston and cylinder liner, repair or replace

Step 7 …………… The cylinder liner or piston is worn or scratches ……………
them.
Step 8 …………… …………… Replace it as required.

Oil filter element has not been replaced in time.
Step 9 …………… The parts are worn out and need overhaul. …………… Check the mileage and overhaul it.
55
Step 10 …………… The crankshaft is not concentric with the driven shaft. …………… Check and repair the mounting bracket.
…………… The quality of the oil used does not meet the ……………
Step 11 Use the oil of specified grade.
requirements.
4.3.15 Alternator does not generate at all

The wiring is open-circuited or short-circuited, and joints Check the alternator and ammeter wiring, then repair
Step 1 …………… ……………
are loose. it.
Rotor and stator coil are open-circuited, short-circuited ……………

Step 2 …………… Repair or replace the assembly.
or grounded.
Step 3 …………… Rectifier damage …………… Replace the assembly.
Step 4 …………… The stigma paper is damaged and the wire is broken. …………… Repair it.
Step 5 …………… Regulator adjustment voltage is too low. …………… Repair it.
56
Step 6 …………… Regulator contact melts. …………… Repair or replace the assembly.
4.3.16 Undercharged alternator

The wiring is open-circuited or short-circuited, and joints ……………

Step 1 …………… Repair it.
are loose.
Rotor and stator coil are open-circuited, short-circuited

Step 2 …………… …………… Repair or replace the assembly.
or grounded.
Step 3 …………… Alternator belt is slack …………… Check and adjust the belt.
Step 4 …………… Damage of alternator rectifier and poor battery contact …………… Repair it.
Step 5 …………… Regulated voltage is too low. …………… Adjust it.
Step 6 …………… Disconnection of regulator field coil or resistor wiring. …………… Repair or replace it.
57
Step 7 …………… Too little battery electrolyte or old battery …………… Add electrolyte or replace the battery.
4.3.17 Unstable charging current

St Check points Check methods
Step 1 ………….. Rotor and stator coil are to be open-circuited or …………… Repair or replace it.
short-circuited.
Step 2 .…………. Poor contact of the brush …………… Repair it.
Step 3 …………… Loose or poor contact of terminal studs …………… Repair it.
…
Step 4 ………….. Damage of voltage regulator …………… Repair it.

…
Step 5 ………….. Improper voltage adjustment …………… Check and adjust it.
…
58
4.3.18 Overcharged alternator

Step 1 …………… Interior of the battery is short-circuited. …………… Repair or replace it.
Step 2 …………… Voltage of the regulator is too high. …………… Repair and adjust it.
Step 3 …………… The voltage regulator is improperly grounded. …………… Repair it.
…………… Failure or contamination of regulator contact, ……………

Step 4 Repair or replace it/them.
disconnection of voltage coil or resistance wiring
59
4.3.19 Abnormal sound from the alternator

Step 1 Improper installation of the alternator Repair it.

……… ……
Step 2 Damage of the bearing Replace it.

……… ……
Step 3 The rotating part has run into the fixed part. Repair or replace it.
……… ……
Step 4 Rectifier is short-circuited. Replace it.

……… ……
Step 5 Stator coil is short-circuited. Repair or replace it.

……… ……
60
Contact Us
Address: 197A, East Fushou Street, High-Tech Zone, Weifang, Shandong
Postcode: 261061
Website: http://www. weichai.com
Free service or complaint hotline: 400-6183066
Customer service hotline: 0536-8235369 (Fax)
61
Quality Standard
XK06-002-00156

Address: 197A, East Fushou Street, High-Tech Zone, Weifang, Shandong
Postcode: 261061
Phone: 0536-8197777
Fax: 0536-8231074
E-mail: weichai@weichai.com
Website: http://www.weichai.com
Service hotline: 400 618 3066
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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WP12WP13四气门国Ⅳ国V欧五系列车用柴油机使用保养说明书 EN

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612640820053

Operation and Maintenance Manual of WP12/WP13

Weichai Power Co., Ltd.

WP12/WP13 China IV/V and Euro V Diesel Engine

Thank you for choosing Weichai products!

 Before operation, please carefully read this Manual,

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

Do not touch the high-speed rotating part with hand

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

 Never run the engine without an air filter.

 After starting a cold engine, accelerate it slowly rather

 Regularly check the coolant, and never change the engine

 The engine has been sealed by oil before delivery to avoid

 Please have the diesel engine disassembled and repaired

 Always have the components of the electrical system

 Weichai has the right to refuse to provide warranty

Please read this Manual before use

This warning sign indicates a potential hazard which, if not being

Please pay attention to followings before maintenance and repair:

1. Avoid repeated exposure to the used oil for a long time.

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.

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

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

1.1 Outline drawing of engine ......................................................................................................................................... 1

1.2 Designation of engine model ..................................................................................................................................... 3

1.3 Main performance parameters ..................................................................................................................................4

Chapter II Installation and Operation ............................................................................................................................ 7

2.1 Unpacking .................................................................................................................................................................. 7

2.2 Hoisting ...................................................................................................................................................................... 7

2.3 Installation ................................................................................................................................................................. 8

2.3 Preparations before start ...........................................................................................................................................8

2.4 Start ............................................................................................................................................................................9

2.5 Running ...................................................................................................................................................................... 9

2.6 Stop .......................................................................................................................................................................... 10

Chapter III Maintenance ..............................................................................................................................................13

3.1 Fuel, lubricating oil, coolant, and auxiliary materials ..............................................................................................13

3.2 Daily maintenance ................................................................................................................................................... 19

3.3 Regular maintenance interval and specification ..................................................................................................... 21

3.4 Description of maintenance of all levels .................................................................................................................. 27

3.5 Cleaning, protection and handling ...........................................................................................................................33

Chapter Ⅳ Typical Faults and Troubleshooting ..................................................................................................... 33

4.1 Overview .................................................................................................................................................................. 33

4.2 Fault diagnostic methods .........................................................................................................................................34

4.3 Typical troubleshooting ............................................................................................................................................38

Chapter I Structure and Performance Parameters of

1.1 Outline drawing of engine

Fig. 1-1 Outline Drawing 1 of Engine (Intake Side)

No. Name No. Name No. Name No. Name

5 Fuel injection pump 6 Fuel filter assembly 7 starter

Fig. 1-2 Outline Drawing 2 of Engine (Exhaust Manifold Side)

No. Name No. Name No. Name No. Name

Fig. 1-3 Outline Drawing 3 of Engine (Fan End)

1.2 Designation of engine model

Product series number

1.3 Main performance parameters

Fig. 1-4 Engine Nameplate

Other parameters are as shown in Tab. 1-1.

Tab 1-1 Main Specifications of Engine

Chapter II Installation and Operation

Fig. 2-1 Hoisting