Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine

User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI

Operation & Maintenance Manual and User’s Service Guide

for WP10 Series National IV Vehicle Diesel Engine
 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine
User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI

Foreword
WP10 series National IV diesel engine is a high speed diesel engine developed with the adoption
of brand new design concept. This series diesel engine features compact structure, reliable uses,
excellent technical indexes (power performance, economy and emission), fast startup, simple
operations, and easy maintenance and is an ideal power unit for heavy-duty trucks and large-sized
luxury buses.
This manual provides an overview of the structural characteristics and operation and maintenance
precautions for WP10 series National IV diesel engine. While the user is using this diesel engine,
the truly fulfillment as per the requirements specified in this manual will surely prolong the
service life of diesel engine greatly.
The diesel engine covered by this manual is the basic model of WP10 series National IV diesel
engine. Following the continual development and improvement of the WP10 series product, we
hope that you can timely pay attention to all technical information released by our company. This
manual is subject to change without notice. Please access Weichai website at http://cn.weichai-
group.com for the latest product information.
You are welcome to put forward proposals and suggestions for further improvement to our
products.

August, 2010
 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine
User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI

Special Instructions
● Before operation, the operator of the diesel engine must carefully read the Operation and
Maintenance Manual of the Diesel Engine and strictly abide by the operation and
maintenance practices specified in the operation and maintenance manual.
● This diesel engine is tested strictly as per the test specification before delivery. Do not
adjust the ECU data at will to increase the power of diesel engine, otherwise our warranty
commitment will be voided.
● The ECU, common rail fuel pump, and fuel injector are of precision parts. Do not
disassemble these parts by self, otherwise our warranty commitment will be voided.
● The strict torque and angle requirements are specified for the main bearing bolts and
connecting rod bolts of the diesel engine. Please do not loosen or disassemble any bolt by
self. The connecting rod bolts are of one-time bolts and can’t be reused, otherwise our
warranty commitment will be voided.
● The grades of the engine oil or fuel added into the diesel engine must conform to the
requirements specified in the operation and maintenance manual and the engine oil or fuel
added must be filtered by the special clean filter. The fuel shall be deposited for at least 72h.
Before driving the vehicle each time, make sure that the filling amounts of the coolant and
engine oil conform to the requirements.
● It’s prohibited to run the diesel engine without air cleaner, in order to prevent the ingress of
non-filtered air into the cylinders.
● While using a new engine, the user shall fulfill the 50h run-in.
● After the cold start of the diesel engine, slowly increase the engine speed, instead of running
at high speed suddenly or long-term idling. After the running under heavy load, run the
engine at low speed for 5~10min before stopping, instead of stopping the engine suddenly
(except special cases).
● After the engine is stopped, if the temperature of working environment is probably below 0º
and the coolant without antifreeze additive is used, fully drain the coolant from the water
tank and diesel engine.
● The checking and repair for all parts of the electric system must be fulfilled by the
professional electric technicians.
● The checking and repair for all parts of electronic control system must be fulfilled by the
professionals of our service station.
● The diesel engine is oil sealed before delivery to prevent rusting. Generally, the oil sealing
period for diesel engine is one year. If the oil sealing time is more than one year, conduct
checking and take necessary supplemental measures.
 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine
User Service Guide for WP10 Series National IV Vehicle Diesel Engine WEICHAI

Contents
I. Operation and Maintenance Manual for WP10 Series National IV Vehicle
Diesel Engine ........................................................................................................ 1
1. Fuel, Lubricating Oil, Coolant, Urea Solution, and Auxiliary Materials for Diesel Engine
........................................................................................................................................... 1
1.1 Fuel: ...................................................................................................................... 1
1.2 Lubricating Oil for Diesel Engine ......................................................................... 1
1.3 Lubrication of Water Pump ................................................................................... 1
1.4 Antifreeze Additive for Engine Cooling System ................................................... 2
1.5 Urea Solution ........................................................................................................ 2
1.6 Characteristics of Weichai Power Special Oil ....................................................... 3
1.7 Differences between Weichai Power Special Oils and Common Engine Oils ...... 4
1.8 Some Common Products of Weichai Power Special Oils ..................................... 4
1.9 Corresponding Table between Weichai Power Special Oils and Engine Models .. 5
1.10 How to correctly choose appropriate viscosity ..................................................... 5
1.11 Auxiliary Materials ............................................................................................... 5
2. Uses and Operations of Diesel Engine .............................................................................. 7
3 Periodical Checking and Technical Maintenance of Diesel Engine................................ 12
4 Analysis and Troubleshooting of Common Malfunctions .............................................. 24
II. User Service Guide (Warranty Card) ............................................................. 38
Warranty Card for Weichai Power Products (To be preserved by user) ............................... 38
Maintenance Registration Form (To be filled by maintenance personnel) ........................... 39
Warranty Instruction ............................................................................................................... 40
Rule of Warranty Period for Weichai Power Diesel Engine ................................................. 42
Weichai International Marketing Service Network ................................. 错误！未定义书签。
Engine Mandatory Maintenance Card ................................................................................... 44
Customer Satisfaction Survey ................................................................................................ 47
 Operation & Maintenance Manual for WP10 Series National IV Vehicle Diesel Engine
WEICHAI

I. Operation and Maintenance Manual for WP10 Series

National IV Vehicle Diesel Engine
1. Fuel, Lubricating Oil, Coolant, Urea Solution, and Auxiliary Materials for
Diesel Engine
1.1 Fuel:
Summer: 0# diesel (GB252)
Winter: Generally, appropriate grade of diesel fuel shall be selected depending on the actual
environment temperature
Attention: The fuel in use must conform to the requirements in Appendix C of national standard
GB 17691-2005 (Revised in June, 2008).
1.2 Lubricating Oil for Diesel Engine
The capacity of lubricating oil depends on the marking of the oil dipstick (The oil capacities vary
depending on different models).
Choice of lubricating oil: To ensure safe and reliable running of your diesel engine, please choose
grade 15W/40 CF-4 or 20W/40 CF-4 lubricating oil. The 15W/40CF-4 oil can be used under the
temperature range of -15℃~+30℃, the 20W/40CF-4 oil can be used under the temperature range
of -10℃~+30℃ (The Weichai Power special oil is recommended), the 5W/20CF-4 shall be
adopted for the temperature below -15ºC.
Table 1 Table for Choice of Lubricating Oil Grades

Environment
Environment Multiple grades of oil temperature
temperature

Attention: It’s disallowed to use grade CE, CD, CC, CB, or CA lubricating oil for WP10
series National IV diesel engine. The engine oil filter element shall be replaced at each
replacement of engine oil.
1.3 Lubrication of Water Pump
The water pump shall be lubricated by general lithium-based lubricating grease for vehicles (Refer
to standard GB/T5671-1995).

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1.4 Antifreeze Additive for Engine Cooling System

The glycol antifreeze additive is adopted. It’s allowed to substitute with home-made long-acting
antifreeze additive, provided that the quality of such additive is reliable. Please refer to the
relevant instructions for the specific operation methods. Two home-made long-acting antifreeze
additives that are available recently are recommended as below:
JFL－336# long-acting antifreeze additive

FD－30# long-acting antifreeze additive

It shall be noted that the long-active antifreeze additive in use shall be periodically replaced as per
the relevant requirements.
1.5 Urea Solution
The inappropriate urea solution will easily lead to poisoning failure of SCR catalyst or insufficient
reduction rate (For instance, the out-of-tolerance of phosphor, sodium, potassium, and calcium
contents in the urea solution will easily lead to poisoning of catalyst and the out-of-tolerance of
urea solution concentration will easily lead to excessive leakage of NH3 or insufficient reduction
rate of NOx) and out-of-tolerance of emission and warning of malfunction indicator lamp.
Therefore, the quality and the performance of urea solution in use shall meet the requirements
specified in standard ISO 22241.
Table 2 Contents of Urea (Refer to standard ISO 22241)
Content Unit Minimum Maximum
Urea mass percentage % 31.8 33.2
Density at 20℃ kg/m3 1087 1093

Refraction rate at 20℃ - 1.3814 1.3843

Ammonia soda mass percentage % - 0.2

Biuret mass percentage % - 0.3
Acetaldehyde mg/kg - 5
Insoluble substance mg/kg - 20
Phosphorus (Phosphorus tetroxide) mg/kg - 0.5
Calcium mg/kg - 0.5
Ferrum mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
Nickel mg/kg - 0.2
Aluminum mg/kg - 0.5
Magnesium mg/kg - 0.5
Sodium mg/kg - 0.5
Potassium mg/kg - 0.5

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1.6 Characteristics of Weichai Power Special Oil

1.6.1 High configuration guarantees high quality
The imported fine hydrocracking base oil and imported composite additive are mainly selected to
guarantee the high quality of lubricating oil.
1.6.2 Under normal working conditions, the oil replacement interval can be prolonged by
3,500~7,000km (The oil replacement interval can be prolonged to 10,000km for CH-4). The
excellent high temperature oxidation resistance and outstanding retentivity of base number (TBN)
effectively prolong the oil replacement interval of engine.
1.6.3 Professional protection prolongs engine life
Through a great number of performance and durability tests in response to the Weichai engine, the
professional compound for lubricating oil of high horsepower and high load engine is developed
to provide professional protection for Weichai engine and effectively prolong the service life of
engine (by 30%~40% against common engine oil).
1.6.4 Better performance requirements
It features better wear resistance, base number retentivity, rusting protection, oxidation resistance,
fuel consumption control, and shear stability and reduces the formation of deposits in the
turbocharger.
1.6.5 Energy-saving
With “low viscosity + multi-polarization + friction improving agent”, the energy-saving
compound features high viscosity index of oil, good oil film strength and elasticity, and stable
running, low resistance and low fuel consumption of the engine.
1.6.6 Low contents of ash, sulfur and phosphorous and better environment-friendly
The maximum ash content of 1.0% prolongs the service life of diesel particle filter (DPF). The
maximum sulfur content of 0.4% prevents the failure of oxidation catalyst (DOC) and reduces the
particulate matters. The maximum phosphorous content of 0.12% prevents the failure of DOC and
the failure of NOx control system. The volatility can be controlled at 13%.

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1.7 Differences between Weichai Power Special Oils and Common Engine Oils
Item Special engine oil Common engine oils
Mainly the imported class Ⅲ hydrocracking base oil is Mostly the home-made class I or
Base oil
adopted a little class II base oil is adopted.
Mainly the imported quality composite additives are
Additives Home-made additives
adopted
The targeted professional compound features good
lubrication performance, strong cleanliness, and
effectively improved fuel economy (saving fuel by Only the general lubrication
Performance
3~8%) and provides professional caring for the engine performance can be met.
under harsh working conditions (heavy load or heavy
dust).
Oil replacement During normal use, the oil replacement period can be
Conventional value
period prolonged by 3,500~7,000km (by 10,000km for CH-4)

1.8 Some Common Products of Weichai Power Special Oils

Type Grade Specification Package capacity
15W/40
WP-E1 (CD) 20W/50 4L，18L，200L
10W/30
15W/40
WP-E2 (CF-4) 20W/50 4L，18L，200L
Diesel engine oil 10W/30
5W/30
15W/40
WP-E3 (CH-4) 4L，18L，200L
20W/50
10W/30

WP-E4 (CI-4) 15W/40 4L，18L

85W/90
Heavy-load vehicle gear oil GL-5 4L，18L
80W/90

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1.9 Corresponding Table between Weichai Power Special Oils and Engine Models
Standard number
Type Recommended main applicable models
of special oil
WP-E1
Medium speed diesel engine unit
(CD)

WP-E2 National I and National II diesel engines; construction machinery (50

High speed engine and 30 loaders); WD618/WD12 series and WD615/WD10 series;
and high (CF-4) 226B and medium speed engine; heavy-duty trucks of 15t and above.
horsepower
medium speed WP-E3 National III diesel engine; Landking Engine series; ultra-heavy duty
diesel engine truck; bus; WP4/WP6 (165~270HP), WP10 (240~375HP), WP12
(CH-4) (336~460HP), WD10, WD12, and WP5/WP7 (160~300HP).
WP-E4
National IV series (including ultra-heavy duty truck)
(CI-4)
Compressed natural gas engine and bus and alternator unit fitted with
Gas engine CNG
compressed natural gas engine

1.10 How to correctly choose appropriate viscosity

Applicable environment
SAE viscosity grade
temperature (ºC)
5W/30 -30～35
Lubricating oil 10W/30 -25～35

15W/40 -20～40

20W/50 -15～50

85W/90 -15～49

Gear oil 80W/90 -25～49

85W/140 (higher viscosity than 85W/90) -15～49

1.11 Auxiliary Materials

No. Name Color Applications
Applied on smooth metal surfaces to prevent seizure
Molykotte Pulver
1 Black For instance: Applied onto outer surfaces of cylinder
(Fine molybdenum powder)
liner
Molykotte G.u.plus Achieve lubrication function before establishment of
2 Dark grey lubricating oil pressure
(Molybdenum disulfide oiling
agent) For instance: Applied onto intake valve stem.

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Table 3 Reference Table for Application of Sealant for Diesel Engine

Additional
Trademark Main Applications List of locations for application of sealant
description
Flywheel housing bolt
Camshaft thrust plate bolt
Camshaft timing gear bolt
Intermediate idler bolt
Front end cap bolts
It’s applied onto the
threads to prevent being Engine oil filter seat bolt
Loctite 242 Alternatively, the
vibrated to looseness, Engine oil cooler bolt
with moderate strength. DriLoc204 thread
Screw plug of engine oil cooler regulator valve pre-application
sealant can be pre-
Bolt of oil pump return pipe fixing device applied.
Air compressor shaft end thread
Strainer bolt
Bolt of sensor and harness fixing device
It’s applied onto the
external threads to lock,
Loctite 262 Cylinder head auxiliary bolt
seal, and prevent being
vibrated to looseness
Loctite 271 Locking and tightening Bowl plug for oil port
For sealing between
Loctite 277 Other bowl plugs
element and bore
For sealing top surface of
Loctite 270 Push rod tube – Cylinder head
cylinder head
Mating face between cylinder block and
crankcase
Between front end face of engine block and
front end cap and between rear end face and
flywheel housing connecting plate
Mating face between engine oil filter seat and
Loctite 518 crankcase
It’s applied onto shining
(Updated
metal surfaces for sealing Water pump rear cap – Engine block front end
product of
purpose. face
510)
Flywheel housing connecting plate – Flywheel
housing
Mating face between cylinder block and engine
oil cooler
Mating face between cylinder block and engine
oil filler port cover

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2. Uses and Operations of Diesel Engine

2.1 Unsealing of Diesel Engine
After the diesel engine is unpacked, the user shall firstly count the diesel engine and its accessories
as per the delivery packing list, check the exterior of diesel engine for presence of damage and the
connectors for presence of looseness, and then conduct the following works:
◆ Wipe the anti-rusting layer and anticorrosive agent on the exposed parts.

◆ Drain the oil sealing oil from the inside of fuel filter and the parts of fuel system (It’s
allowed to start the engine without draining the oil sealing oil from the fuel system.
However, it’s permitted to run the engine under loaded condition only when the oil sealing
oil in the fuel system is used up and the diesel fuel is supplied to the engine normally).
Attention: Generally, the oil sealing period for diesel engine is one year. If the oil sealing
time is more than one year, conduct checking and take necessary supplemental measures.
◆ Rotate the flywheel and spray solvent into the intake pipe, till the oil sealing oil in the
cylinder is completely removed.
◆ Spray solvent to the intake and exhaust ports of the turbocharger, till the oil sealing oil is
completely removed.
◆ As agreed between the manufacturer and the user, the oil sump not filled with oil shall be
added with oil as specified. For the oil sump filled with engine oil containing run-in
accelerator at the time of delivery, it’s recommended to drain oil and replace with new oil
after the initial 2,000km mileage (or 50 running hours).
◆ If the coolant is filled fully before delivery as agreed between manufacturer and user to meet
the user’s demands, check the performance of coolant at the time of unsealing. If the
antifreeze capability meets -30ºC or -35ºC, with PH value at 7~8 (neutral) and total hardness
at 5~15ºD [9~15ºf (hardness)], the coolant can be used. If disqualified, drain the coolant and
refill the coolant with antifreeze additive.

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2.2 Hoisting of Diesel Engine

During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to hoist in
tilted or at one side. Hoist up and down slowly (Refer to Figure 2-1).

Correct Wrong

Figure 2-1 Hoisting Diagram of Diesel Engine

2.3 Installation of Diesel engine
For supply installation, ensure that the crankshaft centerline of the diesel engine is coaxial with the
axis of input shaft of drive unit (gearbox, transmission, or alternator) and ensure that the
crankshaft is free of additional axial force due to installation.
2.4 Preparations before Start
◆ Checking of Coolant Level
If the engine is installed on the vehicle or on the stand, the coolant level is visible from the glass
sight hole on the expansion water tank at all times. If the coolant is insufficient, add coolant
through the filler port cap. While opening the filler port cap with pressure relief valve and air
bleeding button, if the engine is under hot state, make sure to push down the air bleeding button to
open the cap. It’s prohibited to add a great amount of coolant while the engine is under hot state,
as the high thermal change will damage the parts. If there is not coolant under special cases, it’s
allowed to slowly add cool water with not very low temperature. Add the coolant through the filter
port, till the coolant overflows. Start the engine. While the engine is running (1,000r/min),
continue to add the coolant, till the coolant level is stable, and finally install the filler port cap.

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◆ Checking of fuel level

If the engine is installed on the vehicle, turn on the power switch and check the fuel level from the
fuel gauge or check the fuel tank.
◆ Checking of engine oil level
The engine oil level shall be between upper and lower markings of the oil dipstick. If necessary,
add engine oil through the engine oil filler port.
◆ Checking of urea level in urea tank
Generally, the urea consumption accounts for 3~5% of the fuel consumption (by volume). Check
the level of urea solvent depending on the working condition. Maintain the level at 30~80% and
timely add if insufficient. Do not add excessive urea, or it will lead to overflow of urea.

Figure 2-2 Urea Level Marking in Urea Tank

◆ Checking of diesel engine accessories
Check various accessories of diesel engine for reliable connections and resolve any abnormal
phenomenon. Check the starter system for normal wiring and check whether the battery is
sufficiently charged. Then, open the fuel tank valve, loosen the air bleeding bolt on the fuel
strainer, and use manual pump on the fuel strainer to bleed the air from the fuel system. Check the
SCR system for reliable pipeline connections. No leakage of urea solvent is allowed.

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2.5 Start of Diesel Engine

◆ Place the power switch and electric key on the vehicle to position START, place the gearshift
lever to neutral gear, and begin to start the engine.
◆ Turn the electric key to start the diesel engine. If the engine fails to start in 5~10s, wait for
1min before retry. If the engine can’t be started by three consecutive attempts, stop the
attempt and find out and resolve the malfunction before retry. After the start of engine,
observe the readings of various instruments. The engine oil pressure gauge shall indicate the
pressure immediately. Pay attention not to run the cold engine at high speed. Firstly, idle run
the engine for a while. However, do not idle run the engine for a long period.
◆ The auxiliary starter shall be used to start the diesel engine under cold temperature. By means
of the electric heating flange via relay, the engine can start successfully under -30ºC
environment.
2.6 Running of Diesel Engine
◆ After the diesel engine is started, idle run for several minutes and then increase the speed to
1,000~1,200r/min and apply partial load. It’s permitted to run the engine under full load only
when the water outlet temperature is higher than 60ºC and the engine oil temperature is
higher than 50ºC. The load and speed shall be increased gradually. Avoid the haste
acceleration and haste application of load as far as possible.
◆ Within the 60h run-in period (or the initial 3,000km mileage) of the diesel engine, it’s
preferable to run the engine under moderate load and without trailer.
◆ Timely decelerate the engine while driving on slopes. It’s not preferable to run the engine for
a long period under high torque condition. In addition, it’s not preferable to run the engine
under extremely low load or speed, or it will easily lead to malfunctions such as oily smoke.
◆ During normal use of the diesel engine, it’s permitted to continually run the engine at rated
power and rated speed. However, if running the engine at 105% of rated speed and 110% of
rated power, it’s permitted to run the engine for up to 20min. Once unloaded, please idle run
the diesel engine for 1~2min before stopping the engine.
◆ Parameters and checking locations to be real-time observed in using:
Pressure of main lubricating oil passage: 350~500kPa;
Oil temperature of in oil sump: <110℃.
Coolant outlet temperature: 80+5º, no more than 105ºC.
Exhaust temperature after turbine: <600℃;

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Intake temperature after inter-cooler: 50~55ºC.

Check the color of exhaust gas to judge the working quality and application load of the fuel
injector. If the color of exhaust gas is really bad, stop the engine for checking.
Pay attention to observe the diesel engine for presence of water, air and fuel leakages. If any, stop
the engine for troubleshooting.
◆ The operator shall understand the following characteristics of diesel engine:

① The fuel consumption is really low when the torque output is at maximum value and
increases along with the increasing of speed.
② The torque reaches the best value at the moderate speed range of the engine
(1,200~1,600r/min).
③ The power output of the engine increases along with the increasing of the speed and
reaches rated power at the rated speed.
◆ Precautions for running under cold environments:

① Fuel: Choose diesel fuel of different grades depending on the outdoors temperature in
winter.
② Lubricating oil: Choose lubricating oil of different viscosities depending on the seasons.

③ Coolant: Add antifreeze additive into the cooling system and choose antifreeze of
different trademarks and quantities depending on different outdoors temperatures.
④ Start: The auxiliary starter can be adopted if necessary in winter. After the start of the
diesel engine, wait for the oil pressure and water temperature are normal before running
at high speed under loaded condition.
⑤ Before the approach of the cold season, make sure to check the electrolyte level and
viscosity and unit voltage of the battery. If the diesel engine is not to be used for a long
time and is under extremely low temperature, remove the battery and store in a warmer
indoors place.
⑥ Stop: To stop the engine under cold weathers, unload the engine, idle run the engine for
1~2min, and wait for the water temperature and oil temperature to cool down before
stop. Please be noted that it’s disallowed to drain the coolant containing antifreeze
additive. If the coolant contains no antifreeze additive, make sure to open the water
drainage valves or water plugs on the engine block, engine oil cooler cap, radiator, and
water inlet pipe to fully drain the coolant, in order to prevent the frozen cracking of the
engine.

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3 Periodical Checking and Technical Maintenance of Diesel Engine

3.1 Daily Maintenance
Check the coolant level, engine oil level, and fuel level, check the lubricating grease application
points for sufficient lubricating grease, check for leakage of oil, water and gas, check the
peripheral parts and accessories for good connections and fastening, check the fan and belts for
presence of over-tightness and looseness, check the oil pressure and coolant temperature of the
diesel engine, check the temperature, color of exhaust gas, the sound and vibration of the engine
for normality, and check the engine for stable speed.
◆ Check the coolant level and temperature
Observe the coolant level via glass sight hole. If the coolant is insufficient, open the filler port cap
and add coolant.
Attention: While opening the filler port cap, make sure to push down the air bleeding button,
in order to prevent the coolant from causing personal injuries under hot state of engine.

Figure 3-1
Expansion
water tank

Figure 3-2

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◆ Check engine oil level

It’s prohibited to start the diesel engine when the oil level is below lower marking of oil dipstick
or is above upper marking of oil dipstick.
After the diesel engine is stopped, wait for at least 5min before checking the oil level, in order to
enable the engine oil to have sufficient time to flow back to oil sump.
The oil amount difference between lower marking and upper marking of oil dipstick is 3L.

Figure 3-3
◆ Check fuel level
Check for leakages: The entire engine shall be free of leakage of water, gas or oil.

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Figure 3-4
◆ Check the urea solvent level
The urea solvent level shall be maintained at 30~80% of total capacity of urea tank.
◆ Check the fan
Visually check the blades of fan for presence of damage and check connecting bolts for fastening.

Figure 3-5
◆ Check belt

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

Figure -3-6
◆ Check exhaust gas for normal color
The normal color of exhaust gas is light grey. In event of change in color, check cause and resolve,
as shown in Figure 3-6.
◆ Check for normal sound

◆ Check for normal speed and normal vibration

5.2 Items for various levels of maintenance
In addition to the daily maintenance items, fulfill the following items:
◆ Replace the diesel engine oil.

◆ Screw off the oil drainage plug from the bottom of oil sump to fully drain the engine oil and
then screw on the oil drainage plug, as shown in Figure 3-7.
◆ Open the oil filler cap (as shown in Figure 3-8), add engine oil through engine oil filler port,
observe the level of oil dipstick till the required oil level is reached, and then install the oil
filler cap.

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Oil drainage plug

Figure 3-7

Engine oil filler port

Figure 3-8
Attention: The waste oil shall be placed in designated location and container to ease the
recycling.

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◆ Replace engine oil filter or filter element. See Figure 3-9:

At the replacement of engine oil filter, operate as per the following procedure:
① Remove used engine oil filter.

② Fill the new filter completely with clean engine oil.

③ Before installing new engine oil filter, apply engine oil onto the rubber gasket.

④ After the rubber gasket comes into contact with the base, tighten for 3/4~1 turn to seal.

⑤ Start the diesel engine and check for presence of oil leakage.

Engine oil filter

Figure 3-9
◆ Replace the fuel filter element. See Figure 3-10.
At the replacement of fuel filter, operate as per the following procedure:
① Remove the used fuel filter element. The water collector installed on the strainer can be
reused. Please take out the water collector.
② Lubricate the sealing port.

③ Screw on the filter with hand, till the sealing port comes into contact with the connecting
port.
④ Continue to screw on the filter with hand, till the filter is securely installed (for
approximate 3/4 turn).
⑤ Bleed the air, till there is no presence of air bubble.

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⑥ Conduct the leakage test.

Fuel filter

Figure 3-10

Attention: At the replacement of strainer or at the reinstallation of fuel delivery pipe, it’s
necessary to bleed the air from the strainer.
Procedure: (As shown in Figure 3-11).
① Stop the engine.

② Remove the air bleeding screw.

③ Pump up fuel filter with the manual pump, till only the fuel overflows from the air
bleeding screw.
④ Retighten the air bleeding screw.

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Figure 3-11 Air bleeding of strainer

Drain the water from the water collector:

Attention: When the water collector is full or the spin-on filter is replaced, it’s necessary to drain
the water collected.
Procedure (As shown in Figure 3-12)
②
Open the fuel drainage plug 2 on the bottom of water collector 1 to fully
drain the water.
② Retighten the fuel drainage plug.

Figure 3-12

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Replace the water collector:

Procedure (As shown in Figure 3-13)
① Stop the engine.

② Drain water from the water collector.

③ If possible, remove the screw 1 of water collector with hand. If the screw 1 is too tight,
use the remover tool attached in the new water collector.
④ Lubricate the seal ring 2 of new water collector with several drops of oil.

⑤ Install the screw with hand and tighten with tool.

⑥ If the water collector is reused on a new spin-on filter, check for presence of damage.

⑦ Install with torque wrench and tighten to 20N.m.

Figure 3-13 Replacement of water collector

◆ Check the air intake system
Check the intake hose for presence of aging or cracking and check the hoop for presence of
looseness. When necessary, tighten or replace parts to ensure air-tightness of intake system.

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◆ Check urea pump filter element

At the time of maintenance, it’s necessary to remove the filter element of urea pump and
thoroughly clean with clean water before installation. Do not slap or knock the filter element with
high force.
◆ Check the urea nozzle gasket
At each replacement or disassembly/installation of urea nozzle, it’s necessary to check the status
of urea nozzle gasket. In event of damage or deformation, replace the urea nozzle gasket.
◆ Clean the urea tank and urea tank filter element
At the time of maintenance, it’s necessary to check the cleanliness of urea tank and filter element
and when necessary clean.
3.3 Maintenance for long-term storage of diesel engine
◆ Clean the diesel engine.

◆ Take protective measures:

① After the engine warm-up, drain the engine oil, clean engine oil filter, and add anti-
rusting oil.
② Drain the fuel and refill anti-rusting oil mixture.

③ Drain the water and add coolant with anti-rusting agent.

④ Start the engine and idle run for 15~25min.

⑤ Fully drain the engine oil, fuel, coolant and urea solvent.

⑥ Take protective measures for other portions.

◆ Protection during storage:

Plug with caps or wrap with plastic film all inlets and outlets of oil, gas and water and seal up the
entire diesel engine with weather anti-rusting film.
◆ If the transport is required, the outer package shall be supplemented.

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3.4 Fulfill the maintenances and complete maintenance records

Table 3-1 Operation Conditions for Two Classes of Vehicles
(Class WG I) (Class WG II)
Harsh working conditions (cold or hot weathers, heavy dust, short-
All kinds of commercial vehicles with
distance transport, operation in working sites, and bus, municipal
more than 2×104km yearly driving
engineering vehicle, snow sweeper, and fire truck) or no more than
mileage
2×104km yearly driving mileage or no more than 600h working hours

Table 3-2 Maintenance Period

Working condition
Driving mileage (time) WG I WG II
Item
Initial mandatory
3000km (50h) A A
maintenance
10000km (200h) B C
30000km (400h) B
Routine maintenance
For class WG II vehicles, replace the engine oil filter element at the Weichai’s
designated service center at interval of 10,000km (200h)

A – Initial mandatory maintenance: Replace oil and oil filter element and do not replace fuel strainer and fuel fine
filter elements.

B – Routine maintenance: Replace engine oil, engine oil filter element, fuel strainer and fuel fine filter elements.

C – Only replace oil filter element.

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Table 3-3 Maintenance Specification of Diesel Engine

1st
Maintenance item of Routine Level 1 Level 2 Level 3 Level 4
checki
diesel engine checking maintenance maintenance maintenance maintenance
ng
Replacement of oil (at
● ● ● ● ● ●
least once a year)
Replacement of oil filter
● At each replacement of diesel engine oil
element
Checking and adjustment
● ● ● ● ●
of valve clearance.
Replacement of fuel filter
● ● ● ●
element.
Cleaning of fuel strainer
or replacement of filter ● ● ● ●
element
Checking of coolant
● ● ● ● ● ●
amount and refilling
Replacement of coolant Replace once a year
Fastening of cooling
●
pipeline clamps
Fastening of intake
pipeline, hose and flange ● ● ● ● ●
connector
Checking of air cleaner
maintenance indicating ● ● ● ●
lamp or indicator
Cleaning of air cleaner
dust collector (except
● ● ● ● ●
automatic dust discharge
type)
Cleaning of air cleaner
When the indicator lamp lights up
main filter element
Replacement of air
cleaner main filter Refer to relevant regulations of vehicle manual
element
Replacement of air
cleaner safety filter After main filter element is cleaned for 5 times
element
Checking and fastening
● ● ● ● ● ●
of belt
Checking of turbocharger
●
bearing clearance
Urea pump filter element ● ● ● ●
Urea nozzle gasket At each disassembly of urea nozzle
Cleaning of urea tank and
● ● ● ●
urea tank filter element

Note: ● denotes necessity of maintenance.

The relevant maintenance must be conducted for the diesel engine that is stored for more than half
year, such as oil resealing.
Weichai will provide maintenance recommendations upon request of the user.

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4 Analysis and Troubleshooting of Common Malfunctions

WP10 series National IV diesel engine is designed and manufactured under strict quality
assurance system and each delivered diesel engine passed the specified tests. In addition, the
diesel engine is a kind of precision machinery and the long-term guarantee of its functionality is
closely related to the normal maintenance. The causes leading to earlier failure of diesel engine are
generally as below:
◆ Operations against rules or improper management and operations.

◆ Failure to fulfill maintenance as specified or even repair works instead.

◆ Poorly manufactured parts, especially the counterfeit products procured due to

temptation of cheap prices, which will greatly shorten the service life of diesel engine.
Inappropriate grade of fuel or lubricating oil or disqualified fuel or lubricating oil
4.1 Diagnosis method
The common diagnosis methods for malfunctions of diesel engine are generally as below:
◆ Observation method: Judge the malfunction situation by observing the malfunction symptom,
such as exhaust smoke of diesel engine.
◆ Listening diagnosis method: Judge the characteristic and extent of the malfunction portion by
listening as per the abnormal sound of diesel engine.

Figure 4-1

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Figure 4-2
◆ Cylinder interruption method: Interrupt the working of certain cylinder to judge whether the
malfunction occurs in such cylinder. Generally, the cylinder interruption method is to cut off
the fuel supply to the suspiciously malfunctioned cylinder and compare the status changes of
the engine before and after the interruption of cylinder, in order to narrow the scope for
further detection of the malfunction portion or cause.
◆ Comparison method: For some assemblies or parts, the replacement method is adopted to
determine the presence of malfunction.
Attention:
① Judging the malfunction formation cause of diesel engine is a really careful work.
Before the cause is basically identified, do not disassemble the diesel engine casually, or
it will not only eliminate the malfunction, but also lead to more serious malfunction due
to improper assembly after disassembly.
② For critical parts such as high pressure fuel pump, ECU, rail supply pipe, and
turbocharger, please have them checked and repaired by Weichai’s designated service
station.

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4.2 Common Malfunctions and Troubleshooting

4.2.1 Start failure of diesel engine
(1) No working of starter
The starter of WP10 series National IV diesel engine is controlled by ECU. During normal
working, the ECU outputs a current to drive the starter relay and, after the relay is actuated, the
battery drives the start of the starter. In event of malfunction, mainly check the neutral gear.
There are several elements during the checking: Relevance of neutral gear switch, starter relay,
battery and underframe stop switch.
◆ Check whether it is shifted at neutral gear
Before the start, firstly check whether the gearshift lever is shifted at neutral gear.

◆ Check the position of underframe stop switch (which shall be under OFF state)
The underframe stop switch is of inching type and is capable of automatic reset. Check this switch
for normal functioning.
If this switch is other than automatic reset type, check whether this switch is at ON state.

◆ Check the neutral gear switch and wiring for intactness. Try to use the emergency start (Push
down and hold the ignition switch for more than 5s).
For the engine with starter controlled by ECU, at the time of start, the ECU will firstly judge
whether it’s at neutral gear as per the signal transmitted from neutral gear switch. If the neutral
gear switch is damaged or the wiring is poorly connected, the ECU fails to receive neutral gear
signal and the starter can’t work.

◆ Check whether the battery voltage is too low to drive the starter
Generally the battery voltage is 24V. The under-low voltage can’t drive the working of starter.
Use the voltage measurement of multimeter to check or read the actual “battery voltage” by
malfunction diagnostic unit.

◆ Check starter relay and wiring for intactness

Check surfaces of wiring terminals for presence of excessive oxide and check the bolts on surfaces
of wiring posts for looseness and breakage.

◆ Check the starter for burnout

Use a multimeter to check the starter relay for normal working.

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

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Turn the ignition key to position ON and observe whether the instrument lamps light up.
Turn the ignition key to position START and observe whether the starter acts (Provided that all
other causes are excluded)

Ignition key switch

Figure 4-3

Starter
motor

Figure 4-4

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(2) Establishment failure of rail pressure (The starter can work normally, but can’t start)

Air bleeding
bolt

Figure 4-5
◆ Check the fuel tank for low fuel level. This cause can be easily ignored and shall be paid with
attention.
◆ Check the manual fuel pump for normal working and push the manual fuel pump with hand
to check for normality.
◆ Check the low pressure fuel line for presence of air and bleed the air (Sometime the leakage
of low pressure fuel line is not obvious and shall be carefully checked)
Air bleeding method: Mainly bleed the air from the strainer. Loosen the air bleeding bolt on the
strainer and push the manual pump on the strainer with hand, till the fuel flows out continually at
the air bleeding bolt.
If the diesel engine can’t be started after the air in the low pressure fuel line is completely bled, it
can be judged that there is air in the high pressure fuel line and it’s necessary to bleed the air from
high pressure fuel line.
Air bleeding method: Loosen high pressure fuel pipe for certain cylinder and drive the working of
diesel engine with starter, till the fuel flows out continually from the high pressure fuel pipe (It’s
recommended not to disassemble the high pressure fuel pipe connector frequently!)
◆ Check the high pressure fuel line for presence of leakage
This symptom is relatively obvious. Check the nut of high pressure fuel pipe connector for
presence of looseness. If yes, tighten the nut.
◆ Check the fuel line for blockage and check the diesel filter for presence of blockage. It’s
recommended to timely replace the diesel filter element.

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Checking method: Loosen the outlet bolt of filter, drive the running of diesel engine with starter,
and observe for spray-out or flow-out of diesel. If only a small amount of diesel flows out, it can
be determined that the filter element is blocked. In such case, it’s necessary to replace the filter
element.
◆ Check whether the initial voltage of the rail pressure sensor is at approximate 500mV or the
rail pressure setting is at 30~50MPa.
(3) Improper connection of engine harness or vehicle harness or open-circuit or short-
circuit of harness
◆ Check the installations of connectors and use a multimeter (preferable “circuit diagnostic
unit”) to check the continuity of circuit as per the pin definition of the circuit diagram.
(4) Loss of crankshaft signal and camshaft signal
Two speed sensors are installed on the diesel engine, on the outer sides of flywheel housing and
high pressure fuel pump respectively. The functions are crankshaft position sensor and cylinder
judgment sensor respectively. The fuel injection timing of the electronically controlled engine
depends on these two sensors. In event of start failure of diesel engine, both the signals are lost
completely.
◆ Possible cause for loss of both signals
(1) Damage of sensor or short-circuit or open-circuit of harness
(2) Insecure fixing of sensor, leading to over-high or under-low gap between sensor and inductive
tooth (generally 1±0.5mm)
Troubleshooting: Check the sensor for presence of damage, check the harness for good connection,
and check the sensor for looseness.
◆ After the disassembly of high pressure fuel pump and flywheel, the reinstallation shall be
conducted strictly as per the relevant process documentation, in order to ensure signal
synchronization.

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Camshaft speed sensor

Figure 4-6

Crankshaft speed sensor

Figure 4-7

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4.2.2 Difficult start

Cause and troubleshooting for difficult start of engine:

◆ The diesel engine is not running for a long time: The fuel return pipe shall reach beneath the
fuel level.
◆ There is a small amount of air in low pressure pipeline: Bleed the air.

◆ The crankshaft speed signal and the camshaft signal are weak and the synchronization
judgment time is long: Find out specific cause and readjust.
◆ The environment temperature is too low or the preheater is failed: Check the heating flange
for normal wiring or replace preheater.
◆ Poor or disqualified fuel or oil: Replace with quality fuel or oil.

◆ Broken teeth of starter or flywheel gear ring: Replace starter and flywheel gear ring.

◆ Wear of piston ring and cylinder liner or poor sealing of valve: Replace piston ring, cylinder
liner or valve seat and valve
◆ Blockage of exhaust brake butterfly valve at OFF state, leading to choked exhaust: Replace
the butterfly valve.
4.2.3 Low engine power
Limping home: One running mode of engine under malfunctioned state. Upon detection of engine
malfunction, the ECU will not stop the engine immediately. Instead, it will restrain the engine
power in such manner that the engine speed can only accelerate to 1,500r/min so that the driver
can drive the vehicle to the nearest service station for repair.
(1) Malfunction of fuel injector
The malfunction of fuel injector is generally composed of mechanical malfunction and wiring
malfunction.
The mechanical malfunction is the blockage of needle valve. Due to excessive dirt in the diesel
fuel or corrosion from air ingress, the needle valve is blocked within the fuel injector against
actions (Attention: The ECU may not report error!).
Wiring malfunction is the disconnection of harness or short-circuit of harness to ground due to
direct grounding of the cylinder head, arising from the causes such as vibration and wear. In such
case, the ECU will report error.

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Fuel injector wiring

Figure 4-8
(2) Over-high water temperature, oil temperature or intake temperature
When the water temperature, oil temperature or intake temperature is over-high, the ECU will
activate the overheating protection function to restrain the engine power.
Before solving the malfunction, firstly the distorted feedback of sensors and instruments shall be
excluded.
◆ Causes and troubleshooting for over-high water temperature

① Low level in water tank: Check for leakage and add water

② Slow speed or no rotation of fan: Check the drive parts of fan

③ Blockage of water tank: Check water tank and clean or repair

④ Loose water pump belt: Adjust the tension as specified

⑤ Damage of water pump gasket or wear of water pump impeller: Check and repair or
replace
⑥ Thermostat malfunction: Replace

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⑦ Damage of water pipe seals or ingress of air: Check water pipes, connectors and gaskets
and replace damaged parts
◆ Causes and troubleshooting for over-high engine oil temperature

① Low level or oil shortage in oil sump: Check oil level and leakage, repair and add oil

② High water temperature: Check and resolve the above-mentioned causes leading to over-
high water temperature
③ Blocked flow of oil cooler: Check and clean

◆ Causes and troubleshooting for over-high intake temperature

Check the heat radiation capability of inter-cooler.
(3) Signal synchronization error
In event of this problem, generally the signal of one sensor is failed.
Read the flash code by flash code lamp and find out and resolve the specific cause with reference
to the flash code table.
(4) Malfunction of flow metering unit
The flow metering unit is the actuator for control of rail pressure and is installed on the high
pressure fuel pump. When it's malfunctioned, the high pressure fuel pump will supply fuel to the
common rail pipe at its maximum capacity. In such case, the pressure relief valve on the common
rail pipe generally opens and there is a “click” noise in the diesel engine. There is a similar
symptom when the rail pressure sensor is malfunctioned.

Flow metering unit

Figure 4-9
◆ Troubleshooting: Check the circuit, determine the malfunction of flow metering unit or rail
pressure sensor, and notify the office for handling.

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(5) Abnormal fluctuation of rail pressure due to leakage of fuel pipeline

During the traveling of the vehicle, the vehicle speed will be unstable and the vehicle will have
symptom of forward jumping.
◆ Troubleshooting:
Restart after 1min power cutoff. If the problem still exists, check the air-tightness of fuel pipeline
and resolve.
(6) Sensor malfunction
The intake pressure sensor is the sensor used by ECU to estimate the air intake flow (installed on
the intake pipe). The water temperature sensor is the sensor used to judge the thermal load of the
engine (installed on the water outlet pipe). The rail pressure sensor is used to check the fuel
pressure of common rail tube (installed on the common rail tube).

Water temperature sensor

Figure 4-10

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Rail pressure sensor

Figure 4-11

Intake pressure &

temperature sensor

Figure 4-12

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◆ Troubleshooting
Check the intake temperature and pressure sensors, water temperature sensor and rail pressure
sensor and check the connectors for secure connection.
Attention: In event of malfunction 1, 3, 4, 5 or 6, the diesel engine will enter the “Limping
Home” mode.
4.2.4 Constant running of engine at 1,000r/min
In such case, the throttle is failed. The ECU judges the load as per the signal from the pedal
potentiometer. In event of malfunction of pedal, for safety consideration, the ECU will control the
diesel engine to automatically drop to 1,000r/min idling.
◆ Loose electronic throttle pedal wire or error connection
Reconnect or check throttle for correct wiring and reconnect the wiring.
◆ Water ingress in connector of electronic throttle pedal
Use a tool to blow the connector and then start the engine.

Attention: At the replacement of throttle pedal, keep the same model of pedal.
4.2.5 Swing during idling of engine
◆ Causes and troubleshooting for rough idling of engine:

① Abnormal working of fuel injector: Check fuel injectors and harnesses for all cylinders.

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

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③ Poor fuel quality, with water or waxy content: Clean fuel system and replace fuel filter

④ Air ingress in low pressure fuel pipeline: Check air-tightness of fuel pipes and
connectors and bleed the air
⑤ Unstable atomization of fuel injector nozzle: Check and repair.
Attention: It’s a normal function of ECU that the idling speed is increased due to low water
temperature. If other load is available (for instance, the air conditioner is turned on), the
idling speed will be increased naturally!
4.2.6 Malfunction of SCR
◆ Failure for normal injection of urea
If the SCR system is not working during normal running of the engine, check the connectors at
SCR urea pump, urea nozzle and urea sensor for reliable connections and check the urea
connection pipelines and connectors for presence of bending, looseness or breakage.
Check the urea level in urea tank. If the urea is insufficient, add the urea timely. In event of poor
quality of urea solvent, with excessive impurities, check the cleanliness in the urea tank and clean
the urea tank depending on actual condition. Check the contamination state of the urea pump filter
element and clean the filter element of urea pump depending on actual condition. In event of
serious contamination, replace the filter element. Check the contamination in the vicinity of the
urea nozzle port. If the urea nozzle port is blocked, clean or replace the urea nozzle.
When the engine is running under cold weathers, it’s normal if the urea solvent can’t be normally
sprayed as the unfreezing of urea is not completed. If the unfreezing can’t be completed after a
long period, the heating function is probably malfunctioned and it’s necessary to contact the
service station.
◆ Increased exhaust backpressure of engine
In event of serious black smoke or increased fuel consumption during running of the engine, check
the inside of exhaust pipe for serious crystallization or stone of urea. The low environment
temperature and poor atomization of urea sprayed by the urea nozzle will probably lead to clear
crystallization of urea on the inner walls of pipeline. Depending on the actual condition, take the
heat preservation measures for the walls of exhaust pipe or check the blockage of urea nozzle.
Check catalyst carrier within the SCR tank for presence of falloff or breakage and timely contact
the service station.

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II. User Service Guide (Warranty Card)

Warranty Card for Weichai Power Products (To be preserved by user)
Name Description Name Description
Model User Name
Ordering number Postal code
Number Address
Purchase date Office tel.
Dealer Residence tel.

Distinguished user:
Welcome to using Weichai product and thanks for your favor to Weichai product!
To use and maintain the diesel engine correctly, please carefully read the operation and
maintenance manual of diesel engine and operate strictly as per the relevant regulations. In event
of malfunction of diesel engine, please contact Weichai Service Center or Customer Service
Center of Weichai Power. We will provide you with timely and effective repair services.
Some items of the “Maintenance Registration Form” are to be filled by the Service Center. Please
properly preserve the “Maintenance Registration Form”.

Weichai Power Co., Ltd.

Address: No. 26, Minsheng East Street, Kuiwen District, Weifang, Shandong, China
Postal Code: 261001
Website: http://www.weichai.com
Sales hotline for engines: 0536-8232488 8233371
Sales hotline for parts: 0536-2297313 2297319
Service hotline:
400 toll-free service hotline: 400-6183066
24-hour service hotline
800 toll-free service hotline: 800-8603066
Customer Service Center Hotline: 0536-8235369 (fax)
Customer Service Center Complaint Hotline: 0536-2297322

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Maintenance Registration Form (To be filled by maintenance personnel)

Name Description Name Description
Model User Name
Ordering number Postal code
No. Address
Purchase date Office tel.
Dealer Residence tel.

Seal of
Name of service Maintenance Replacement
Date Quantity maintenance Seal of user
center items parts
personnel

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Warranty Instruction
1. Service Commitment
Within the responsible service region, upon receipt of the user’s information, the service unit of
our company will arrive at the service site within 3 hours for the city in which the service unit is
located, within 24h for general areas, and 48h for remote areas once the service need is confirmed
(except the force majeure factors).
2. Special Instructions
● The operator of the diesel engine must carefully read the operation and maintenance manual,
understand the structure of diesel engine, strictly abide by the technical operation and
maintenance practices specified in the manual, and pay attention to the warning instructions
and warning signs.
● This diesel engine passed our company’s tests strictly as per the test specification before
delivery and it's absolutely prohibited to change the ECU data without consent, otherwise
Weichai will not provide warranty services.
● There are strict torque requirements and service times for various bolts of the diesel engine.
Do not loosen the main bearing bolts or connecting rod bolts at will. Refer to the operation
and maintenance manual for the specific requirements.
● Please fulfill the 50h run-in while using a new engine.
● After the cold start of the diesel engine, slowly increase the engine speed. Do not run at high
speed suddenly or idle run for a long time.
● It’s prohibited to run the diesel engine without the air cleaner, in order to prevent the ingress
of non-filtered air into the cylinders. Under harsh working environment, increase the cleaning
or replacement times of the air cleaner filter element, in order to prevent malfunctions (such
as earlier wear) of diesel engine.
● While adding fuel and engine oil into the diesel engine, make sure to select the specified
trademarks. Make sure to use Weichai special oil and special clean container. The oil shall be
filtered by filter screen during refilling.
3. “Warranty” Service Principle and Rule
(1) Warranty service principle
● After the user purchases Weichai product or vehicle equipped with Weichai product, under
normal operation and maintenance conditions, Weichai product is warranty covered within
warranty period against all damages due to assembly or manufacture causes of the product.
● For the diesel engine and its parts, the repair is the priority method. Those determined as non-
repairable shall be replaced. For the replacement of entire engine, the conditions of Weichai
Power Co., Ltd. for replacement of entire engine must be met and the request shall be
submitted to the responsible leader for approval.
(2) Warranty Period

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● For the end-products manufactured by Weichai, the warranty service and warranty period
shall start from the actual purchase date and shall be based on the sales invoice and warranty
card of Weichai or the sales invoice of the dealer (For the marine main unit, the warranty
period shall start from the actual adjustment test date of the engine).
● The warranty for the products supplied to the vehicle manufacturers shall be as agreed by
both parties. If the vehicle manufacturer has explicit rules on the warranty of engine, the rule
of the vehicle manufacturer shall be followed, with the criterion as per the vehicle attached
warranty card. If there is no explicit criterion or contents on the warranty service of the engine,
the criterion of Weichai shall be followed. The warranty service and warranty period shall
start from the actual purchase date of the vehicle and shall be based on the sales invoice and
warranty card.
● If the parts purchased from Weichai are attributed to the original quality cause, the warranty
period is 3 months for assemblies and 1 year for basic parts. No warranty is provided for the
wearing parts, rubber parts, piston rings, oil seals, bushings, bolts and fuel injector couplings
once they are assembled on the engine. In event of quality issues of basic parts within
warranty period, upon the site confirmation of the service personnel from externally station
center with the presence of effective photos, the labor cost will be calculated for the warranty
service. The warranty period for the spare parts is based on the date of sales invoice of the
central warehouse or the authorized service center. For the assembly quality issues, Weichai
will not provide warranty service and the warranty service shall be provided by the assembly
unit.
4. Rule for exclusion of warranty
● The malfunctions of diesel engine due to improper use, maintenance or matching. Such as the
damage due to loading and unloading during self transportation, the application conditions out
of the scope specified in the operation manual of the product, improper matching, over-speed
and over-load use, the failure for fulfillment of run-in or maintenance as specified in
operation manual, and the use of disqualified or poor oils, antifreeze and water, oil and air
filters.
● The malfunctions of the portions and parts due to self modification, adjustment and assembly
and disassembly, which are disallowed for self adjustment or assembly and disassembly as
specified in the operation manual.
● The oil, antifreeze, filter element, hose, belt and fuel injector coupling replaced during normal
use, consumption and maintenance.
● There is warranty evidences (warranty card and invoice) and the coverage of warranty period
for the product purchased can’t be proved. The product specification and model on the
warranty evidence or invoice are not consistent with the product requested for warranty
service or there is a trace of modification on the warranty evidence or invoice.
● The failure to maintain the original statue in event of malfunction and the self handing, which
leads to impossible technical authentication of the malfunction cause.
● The malfunction arising from misoperation.
● The damages arising from force majeure, such as war and natural disaster.
● The diesel engine is damaged on the vehicle after traffic accident.

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Rule of Warranty Period for Weichai Power Diesel Engine

No. Product Model Warranty period Remarks

I. Complete diesel engine

1 Diesel engine for road vehicles 1 year or 60,000km

2 Diesel engine for engineering vehicles 0.5 year or 30,000km

3 Diesel engine for buses 1 year or 100,000km

4 Gas engine for buses 1 year or 100,000km

II. Diesel engine parts

2 years or 200,000km
(attributed to original
1 Basic parts Cylinder block, crankshaft, engine base and connecting rod
manufacture defect, such
as sand inclusion)

Cylinder head, flywheel, flywheel housing, connecting rod bolt, Follow the warranty
piston, piston ring, piston pin, connecting rod bushing, main period of above complete Based on the
shaft bushing, camshaft bushing, camshaft, cylinder liner, valve, diesel engine. actual sales date
valve spring, valve seat, valve guide tube, valve cover, tappet, and the sales
tapper rod, rocker arm and rockshaft, various gears and gear invoice,
shafts, tensioner, gear ring, oil pump, intake and exhaust warranty card,
manifolds, oil sump, pulley, high pressure fuel pump, fuel or timer.
Important injector body, air compressor, various cover plates and pads,
2
parts water pump, oil radiator, silicone oil clutch, pressure limiting
valve, shock absorber, crankshaft balancer, various metal oil
pipes, water pipes and pipe connectors, steering pump,
thermostat, fuel-water separator, cylinder gasket, ECU, common Warranty period
rail tube, air cleaner body, diesel filter body, oil filter body, or mileage
muffler, distribution disc, starter valve, inter-cooler, thermal (hour),
exchange, air reservoir, thrust plate, strainer, oil dipstick whichever
subassembly, cooling oil nozzle, SCR tank and urea tank. comes first.

Front oil seals and other oil seals, turbocharger, intake manifold 6 months or 30,000km for
gasket, exhaust manifold gasket, turbocharger gasket, valve road vehicles. 3 months or
General
3 cover gasket, rubber hose, fuel injector return pipe, fuel delivery 15,000km for engineering
parts
pump, oil dipstick, fan, water-proof and oil-proof rubber rings, vehicles. 6 months or
and cup plug. 50,000km for buses.

6 months or 30,000km for

Starter, alternator, instruments, various sensors, electric road vehicles. 3 months or
Electric
4 regulators, throttle pedal, harness, solenoid valve and flame 15,000km for engineering
units
preheater. vehicles. 6 months or
50,000km for buses.

5,000km or within
Wearing Belt, shroud, fuel injector nozzle, plunger coupling, other mandatory maintenance
5
parts gaskets, various braided hoses, clamps and timer. period. 1 month or
10,000km for buses.

Note: 1. If the engine odometer of the road vehicle is damaged, the warranty period will be calculated based on 325km a day.
2. If the engine odometer of the engineering vehicle is damaged, the warranty period will be calculated based on 300km a day.
3. If the engine odometer of the bus is damaged, the warranty period will be calculated based on 400km a day for touring buses
and 200km a day for public buses.
4. The road vehicles include trucks, truck-mounted cranes, and mixer trucks and the engineering vehicles include dump trucks.
5. If the vehicle manufacturer has explicit rules, such rules shall be followed.

42
 User Service Guide for WP10 Series National IV Vehicle Diesel Engine
WEICHAI

Weichai International Marketing Service Network

Sales Service
Area Office Local TEL Mobile E-mail Address
in charge in charge

Russia An pengfei 0074953152825 0079267519073 [email protected] 117519，г.Москва ул.кировоградская , дом 32,Апартотель ЭРИДАН кв.15-С1

Commonwealt Mongolia Liu weijun 00976-99602398 [email protected]

h of indenpent Tutubalin
States Республика Казахстан , г.Алматы, ул.Бузурбава 23
Kazakstan Shan hongwu 0077011725466 [email protected]

Azərbaycan,Baki,Nəsimi,2-ci Mikrorayon,Rəşid Məmmədov,ev 0025,mən

Azerbaijan Zhang lei 00994-773301769 [email protected]
0099

Singapore Zhang jingping

Indonesia Zhang jingping

Dai liancheng 0065-67794869 0065 9623 4801 [email protected] WESTECH BUILDING No 237, PANDAN LOOP,#05-11 SINGAPORE 128424
Philippines Wang hongshan

Southeast
Vietnam Xue hua
Asia

Hong kong Zhang jingping Liu haitao 0085293364201 [email protected]

235/1,Seri-onnut Village,Onnut Soi 70/1,Sukhumvit 77 Road,Khet

Thailand Zhuo laixian Zhang yunjian 0066-27212357 0066-867001639 [email protected]
Pravate,Bangkok 10250 Thailand
ROOM NO.14-08, 17 FLOOR, BLOCK (D),
Burma Liu sen wang jiaquan 0095-1-541348 0095-9-5008728 [email protected]
PEARL CONDO, BAHAN TOWNSHIP,

Bangladesh Liu jingrui zhang yong [email protected]

South Asia
No.201,Pentagon-3,Magarpatta City,Hadapsar,Pune-
India Li jian Pan shankao 0091-20-30262800 0091-7387006182 [email protected]
411013,Maharashtra,India
United Arab
Chen yun 0097142381447 00971509420629 [email protected] Flat No.705,Jscome Tower-11,Al Qusais-1,Al Qusais,Dubai,UAE.
Emirates

Middle east Iran Sun lifeng Zhong lei 00982122344130 00971506753806 [email protected] No.1,Floor-7,Block-11,Atisaz,EXP,Chamran,Tehran,Iran

[email protected] Villa No.17, Dana compound, Naseem Dist. Khurais Road Exit 30, Riyadh,
Saudi Arabia Sui zhen 00966-56-2108200
[email protected] Kindom of Saudi Arabia

Italy [email protected]
Europe Hao feng
France [email protected]

[email protected] 。
Algeria Huo chunlei 00213551883843 Cite Krim Belkacem ilot 17 n 14-Dar El Beida-Alger-Algerie
North Africa Gao donghai
Egypt Zhou jingwei 00201125846195 [email protected] ‫ اﻟﻌﺮﺑﻴﺔ ﻣﺼﺮ ﺟﻤﻬﻮرﻳﺔ‬-‫ اﻟﻘﺎهﺮة‬-‫ ﻧﺼﺮ ﻣﺪﻳﻨﺔ‬-40 ‫اﻟﺴﺒﻊ اﻟﺤﻲ ﺣﻨﻴﻔﺔ اﺑﻲ اﻻﻣﺎم ﺷﺎرع‬

No.601 lakeside apartment, kiambu lane road kizingo mombasa

Kenya Cao lei 00254-705978578 [email protected]
P.O.Box:99206 Mombasa

East Africa Ethiopia Gao jingui Hu xiaoqun 00251-924909463 [email protected] P.O.BOX 1947 .Debre Zeit，Ethiopia TOMMY INTERNATIONNAL HOTEL

00249
Sundan Wang zimao 00249 922868539 [email protected] ‫ أ اﻟﻌﻤﺎرة اﻟﺴﻜﻨﻲ ﻧﺼﺮ ﻣﺠﻤﻊ‬15 ‫ ﻃﺎﺑﻖ‬1 ‫ ﻏﺮﻓﺔ‬02 ‫اﻟﺴﻮدان اﻟﻌﺎﺻﻤﺔ اﻟﺨﺮﻃﻮم ﻓﻲ‬.
155255168

South Africa Wan kuishao 0027717282045 [email protected] 11 Glenrosa, 30 Arterial Road, Bedfordview, Johannesburg, South Africa.
South Africa Wan kuishao
Angola Fu yongsheng 00244924771275 [email protected]

West Africa Nigeria Wang ge Wang changcong 00234-8155777771 [email protected] No22,citrus close，Alfred garden estate Oregun Ikeja，Lagos State.

Venezuela Xia jianning 00233-541164989 [email protected]

South America Cuba Wang lu Huang jinggui 0053-07-2033597 [email protected] Calle21#8214e/82y84PlayaHabanaCuba.

Brazil Song zhiping 005511976427085 [email protected] rua pires da mota 647,aclimacao,sao paulo,brazil

North America America Liu haifeng +1(847)718-0602 [email protected] 3100 Golf Rd,Rolling Meadows, IL,US

43
 Engine Mandatory Maintenance Card
License plate number Manufacturer
User name Engine number
Mandatory maintenance date

Sheet 1 Stub
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special engine oil
Valid certificate: label:
Seal of service station: Customer tel.:

Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.

Supervision Tel. of Weichai Power: 400-6183066 800-8603066

At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

Engine Mandatory Maintenance Card

License plate number Manufacturer
User name Engine number

Sheet 1 Stub
Mandatory maintenance date
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:

Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.

Supervision Tel. of Weichai Power: 400-6183066 800-8603066

At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

Engine Mandatory Maintenance Card

License plate number Manufacturer
User name Engine number
Detailed address Mandatory maintenance date
Sheet 1 Stub

Mandatory maintenance mileage

Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:

Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.

Supervision Tel. of Weichai Power: 400-6183066 800-8603066

At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

44
 Engine Mandatory Maintenance Card
License plate number Manufacturer
User name Engine number

Sheet 2 For Weichai

Mandatory maintenance date
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:

Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.
Supervision Tel. of Weichai Power: 400-6183066 800-8603066
At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

Engine Mandatory Maintenance Card

License plate number Manufacturer
User name Engine number

Sheet 2 For Weichai

Mandatory maintenance date
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:

Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.
Supervision Tel. of Weichai Power: 400-6183066 800-8603066
At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

Engine Mandatory Maintenance Card

License plate number Manufacturer
User name Engine number
Sheet 2 For Weichai

Mandatory maintenance date

Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:

Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.
Supervision Tel. of Weichai Power: 400-6183066 800-8603066
At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

45
 Engine Mandatory Maintenance Card
License plate number Manufacturer

Sheet 3 For Service Station

User name Engine number
Mandatory maintenance date
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:
Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.
Supervision Tel. of Weichai Power: 400-6183066 800-8603066
At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

Engine Mandatory Maintenance Card

License plate number Manufacturer

Sheet 3 For Service Station

User name Engine number
Mandatory maintenance date
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:
Tip: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.
Supervision Tel. of Weichai Power: 400-6183066 800-8603066
At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

Engine Mandatory Maintenance Card

License plate number Manufacturer
Sheet 3 For Service Station

User name Engine number

Mandatory maintenance date
Detailed address
Mandatory maintenance mileage
Purchaser Purchase date
Audited by: User signature: Weichai Power special oil label:
Valid certificate:
Seal of service station: Customer tel.:
Tips: This mandatory card is in triple sheets and must be signed by customer for approval. All items shall be filled
and the card with missing item will be considered void.
Supervision Tel. of Weichai Power: 400-6183066 800-8603066
At completion of mandatory maintenance, the service station shall summarize the offices within responsible region
along with the Customer Satisfaction Survey attached in this manual.

46
 Customer Satisfaction Survey
Item Evaluation element Very satisfied Satisfied Moderate Dissatisfied Very dissatisfied
Appearance
Engine
Performance
Article quality
Reliability
Engine integrity
Engine Attached spare parts and tools
Delivery quality Attached documentation
Delivery time
Service timeliness
Engine
Maintenance quality
Service quality
Service attitude
Customer interruption
Return
Others
Additional freight
Other opinion of customer
Customer seal
Date
Customer Service Center of Weichai Power Co., Ltd.
Address: No. 26, Minsheng Street, Kuiwen District, Weifang, Shandong, China Postal Code: 261001
Tel.: 400-6183066 (for mobile and landline) and 800-8603066 (for landline) Fax: 0536-8235369

Note: Please mark “√” in corresponding column.