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Operation and Maintenance Manual for WP13 Series Diesel Engines

Operation and Maintenance Manual for WP13

Series Diesel Engines

Weichai Power Co., Ltd.

Summary of Contents for WP13 Series

Page 1: ...Operation and Maintenance Manual for WP13 Series Diesel Engines I Operation and Maintenance Manual for WP13 Series Diesel Engines Weichai Power Co Ltd...

Page 2: ...permitted Otherwise our company s warranty will become invalid The diesel engine main bearing bolts and connecting rod bolts have their torques and rotation angles subject to strict requirements so a...

Page 3: ...temperature may be lower than 0 but no antifreeze additive is used the water in the water tank and the diesel engine should be drained 6 Never have the diesel engine working if there is no air filter...

Page 4: ...mance operation inspection maintenance and relevant contents of WP13 series diesel engines With the continuous development of production and technology the structure of the engine will be improved so...

Page 5: ...dditive of the Engine Cooling System 5 3 5 Auxiliary Materials 6 Chapter IV Use and Operation of Diesel Engine 7 4 1 Unsealing of the Diesel Engine 7 4 2 Lifting of the Diesel Engine 8 4 3 Installatio...

Page 6: ...Operation and Maintenance Manual for WP13 Series Diesel Engines VI...

Page 7: ...and rated speed of 353 405 kW and 2100r min respectively therein WP13 480 has its rated speed of 1900r min 1 2 Main Structural Characteristics of the Diesel Engine One cylinder one head reliable work...

Page 8: ......

Page 9: ...ement L 12 54 Cold valve clearance mm Intake valve 0 4 Exhaust valve 0 6 Valve timing Valve clearance intake 0 4 mm exhaust 0 6 mm Intake valve opening 20 before the TDC Top Dead Center Intake valve c...

Page 10: ...ing oil in order to achieve safe and reliable operation of your diesel engine please use such grades of lubricating oils 15W 40CF 4 or 20W 40CF 4 Therein 15W 40CF 4 and 20W 40CF 4 can be applicable wi...

Page 11: ...reezing temperature as required 30 C Calculation method Find out the point of the total coolant of 40L on the abscissa draw a line through the point and find out its intersections 1 and 2 with the abo...

Page 12: ...Pulver fine molybdenum powder Black Coated on smooth metal surfaces to prevent occlusion For example coated on the cylinder liner surface etc 2 Molykotte G u plus Molybdenum disulfide MoS2 oiling age...

Page 13: ...accessories according to the delivery packing list and check whether the engine has any visual damage check whether there is any connector loose and then complete the following work Wipe off the anti...

Page 14: ...Starting Check the coolant level If the engine has been installed on a vehicle or a bench the coolant level can be seen through the glass window on the expansion tank at any time and if there is insu...

Page 15: ...or a few minutes then increase its speed up to 1000 1200 r min and then have it partially loaded Only when the water and engine oil temperature is higher than 60 and 50 respectively can you have it wo...

Page 16: ...y low temperature the battery should be removed and stored in a warm room Parking when parking in a cold climate you should first remove its load then let it idling for 1 2 minutes and then stop it un...

Page 17: ...oil dipstick absolutely never start the diesel engine Check the oil level after the diesel engine has been stopped for at least 5 minutes so that the oil has sufficient time to flow back into the oil...

Page 18: ...check whether the fan has any blade damaged and whether the connecting bolts are tightened Figure 5 5 Check the belt The belt can be tensioned automatically through the belt tensioner and users can c...

Page 19: ...lter element as shown in Figure 5 10 To replace the oil filter you should follow the steps below A Remove the old oil filter B Fill the new filter with clean oil C Coat the rubber pad with engine oil...

Page 20: ...udge whether Cylinder 1 or Cylinder 6 is at its compression stroke the cylinder in its compression stroke has clearances between its intake and exhaust valves and the rocker arm as shown in Figure 5 1...

Page 21: ...in the cold state 0 6mm Figure 5 13 D After Cylinder 1 or Cylinder 6 has been checked turn the crankshaft forward 360 to have Cylinder 6 or Cylinder 1 at its working stroke then check and adjust the r...

Page 22: ...he nut J Check the valve clearance again and if necessary adjust it again Replace the fuel filter element as shown in Figure 5 15 Follow the steps below to replace the fuel filter element A Remove the...

Page 23: ...oil drain plug Figure 5 17 Drain the Water in the Water Collector Replace the water collector Steps as shown in figure 5 18 A Turn off the engine B Drain the water in the water collector C If possibl...

Page 24: ...intake system as shown in Figure 5 19 Check whether the air intake hose is aging or cracked and whether the hoop becomes loose When necessary tighten or replace relevant parts to ensure sealing perfor...

Page 25: ...it from the inside outward Figure 5 21 Note Never blow the filter paper broken never use water or oil to clean the filter paper and never beat or tap the filter element by force 5 3 Maintenance of the...

Page 26: ...0000 kilometers 200 hours working A First mandatory maintenance replace the engine oil and oil filter but do not replace the fuel strainer and fine filter elements B Routine maintenance Replace the en...

Page 27: ...ntenance The accessories ill manufactured and especially fake and shoddy products bought for sake of the lower price will greatly shorten the service life of the diesel engine The fuel or lubricating...

Page 28: ...rking switch is designed as an inching type able to reset automatically Check whether this switch is normal If this switch cannot reset automatically as designed you should check whether this switch i...

Page 29: ...ir completely exhausted then it can be judged that the high pressure fuel way suffers from air invasion and you should also exhaust the air in the high pressure fuel way Exhaust method loosen the high...

Page 30: ...gine speed Rated fuel rail pressure Actual fuel rail pressure Voltage of accumulator tube pressure sensor If not normal first check whether the connectors are fastened reliably and if there is no prob...

Page 31: ...on At this time the interface for test conditions will appear After the operator has confirmed that the conditions are satisfied click Next to start the test Function test is finished Proportioning un...

Page 32: ...s Operating Manual 26 Flow measurement unit connector Fuel injector wiring Crankshaft speed sensor Camshaft speed sensor Rail pressure sensor Oil pressure sensor Water temperature sensor Intake pressu...

Page 33: ...ith the relevant technical documents to ensure synchronization of the signals 6 2 2 Difficult to Start Reason and Troubleshooting of the difficulty in engine starting The diesel engine hasn t been wor...

Page 34: ...rrosion Note The ECU may not report any error The wiring faults are as follows due to vibration abrasion and other relevant reasons if the wire harness is disconnected or directly lowered on the cylin...

Page 35: ...this error appears one sensor generally has its signal invalid Read out the flash code by means of the flash code indicator and refer to the table for flash codes to find out the specific reasons wit...

Page 36: ...e and pressure water temperature and rail pressure sensors to see whether the connectors are installed firmly Note When the fault 1 3 4 5 or 6 appears the diesel engine will enter its limp home mode 6...

Page 37: ...sensor will have input of speed signals in time of parking check the speedometer and speed sensor signals and wiring The fuel is poor in quality with water or wax clean the fuel system and replace the...

Page 38: ...of the dry intake air not equal to the atmospheric pressure respectively this correction table is only applicable to the temperature of 10 40 and the pressure of 80 110 Pa The experiment should need...

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