WeICHAI WP10 E40 REPAIR MANUAL
WeICHAI WP10 E40 REPAIR MANUAL
WeICHAI WP10 E40 REPAIR MANUAL
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
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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1.7 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)
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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)
15W/40 -20~40
20W/50 -15~50
85W/90 -15~49
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◆ 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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Correct Wrong
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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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Figure 3-1
Expansion
water tank
Figure 3-2
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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
◆ 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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Figure 3-7
Figure 3-8
Attention: The waste oil shall be placed in designated location and container to ease the
recycling.
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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.
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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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.
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 3-12
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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.
⑥ If the water collector is reused on a new spin-on filter, check for presence of damage.
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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.
⑤ Fully drain the engine oil, fuel, coolant and urea solvent.
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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.
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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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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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◆ 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 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)
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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Figure 4-6
Figure 4-7
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◆ 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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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
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
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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Figure 4-10
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Figure 4-11
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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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”.
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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
40
User Service Guide for WP10 Series National IV Vehicle Diesel Engine
WEICHAI
● 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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User Service Guide for WP10 Series National IV Vehicle Diesel Engine
WEICHAI
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.
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
Russia An pengfei 0074953152825 0079267519073 [email protected] 117519,г.Москва ул.кировоградская , дом 32,Апартотель ЭРИДАН кв.15-С1
Southeast
Vietnam Xue hua
Asia
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
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.
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.
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.
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.
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.
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.
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
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.
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.
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
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