WEICHAI WP10 Bedienungsanleitung

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

Operation and Maintenance Manual andUser Service Guide for

Industrial Power WP10 Series Diesel Engine

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

PREFACE

Industrial power covers six industries: land generation power, marine

generation power, emergency marine generation power, pump power, air

compressor power and fixation power for other purposes.

On the basis of Weichai WD615 series diesel engines, the industrial power

WP10 series diesel engines, as special power, are independently researched

and developed by our company for meeting stricter emission requirements.

This series of diesel engines are featured by compact structure, reliable

operation, advanced economic technical index, quick startup, easy operation

and convenient maintenance etc. This series of diesel engines are not limited

to use for power generation, the other application fields are not covered by

this manual.

This manual describes the operation and maintenance, inspection essentials

and service guide of industrial power WP10 series diesel engines, and can be

used as reference.

In order for the industrial power WP10 series diesel engines to better service

and give full play to its effectiveness, the users are expected to carefully read

and learn the diesel engine structure, maintenance and operation methods.

The diesel engine useful life can be greatly prolonged if the users can follow

this manual for maintenance.

As the industrial power WP10 series diesel engines have increasingly models

and been improved, users are expected to timely pay attention to the

technical information issued by our company. This manual will be subjected

to modify without any prior notification. To obtain more information, users

(or sellers) should log in the website: www.weichai.com.

June, 2013

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

Notice

1. Before delivery, this series of diesel engines have already been tested,

strictly following the test codes. Therefore, never dismantle the lead

sealing on the throttle to raise its openness; never dismantle or impact

the rotor of turbocharger which belongs to the sophisticated parts;

never loosen or remove the main bearings of diesel engine and bolts

attached to the connecting rod which have strict requirements for

torque and turning angles. Otherwise, our factory will not perform the

“Three-guarantee”. Hope the user pay attention to it.

2. As the bolts for connecting rod are disposable, never reuse them.

3. The operator should carefully read this Operation and Maintenance

Manual, be familiar with the structure of the diesel engine and closely

abide by the technical operation and maintenance procedures specified

in this manual.

4. At any time of starting the diesel engine, please check whether the

coolant and oil is filled up.

5. For the new diesel engine, 50h running-in is needed, with maximum

load not more than 80% of the rated load and average load not more

than 60%.

6. The starting time of the engine should not last for more than 30s. If the

engine can’t be started within 30s, wait for 1-2min for startup again.

7. After the diesel engine is cold started, please slowly increase the

rotating speed and never idle running for long time. After engine

running with heavy load, do not immediately stop it. It is necessary to

idle running for 5-10 min at low speed.

8. After engine is stopped, if the ambient temperature is less than 0℃,

moreover the antifreeze additive is not applied, please completely

drain the water in radiator and diesel engine.

9. The diesel engine is prohibited to work without air cleaner which could

prevent the air not to be filtrated from entering the cylinder.

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

10. Please select the specified fuel and oil grades which will be filled into

the diesel engine (it is suggested to use the Weichai special oil sold at

all service stations of Weichai). Use the special clean container. The

fuel and oil should be filtrated through the strainer before being added.

Let the fuel precipitate for more than 72h.

11. Do not simultaneously use the diethyl-ether-assisted starting

equipment and flame preheater or glow plug.

12. The inspection of electrical system should be done by the personnel

mastering the electrical knowledge.

13. The valid duration of oil sealing of diesel engine is one year. If they

expire, please take necessary supplement measures.

14. Feedback of engine quality information:

Our company perform the quality-trace filing for industrial power WP10

series diesels engine, therefore users are expected to fill the card and then

send it back to our company. Keep relation with our user by this card.

June, 2013

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

CONTENTS

Ⅰ. Operation and maintenance for industrial power WP10 series land diesel engines....6

Schematic for WP10 series land diesel engines. ...............................................................6

Schematic for WP10 series marine diesel engines............................................................7

1. Fuel, lubricating oil and coolant used for diesel engines ..............................................8

2. Diesel engine installation and connection...................................................................12

3. Precautions and operational requirements for diesel engine.......................................16

4. Maintenance specifications for industrial engines ......................................................20

5. Maintenance specifications for main accessories of diesel engine..............................24

6. Common failure analysis and troubleshooting............................................................36

Ⅱ. User Service Guide....................................................................................................43

Weichai Power Product Warranty Card ..........................................................................43

Service Registration Form ..............................................................................................44

Repairs instruction ..........................................................................................................45

Diesel engine “Three-guaranty” warranty specification .................................................46

Weichai industrial engine spare parts “Three-guaranty” warranty specification ............51

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

Ⅰ. Operation and maintenance for industrial power WP10

series land diesel engines

Schematic for WP10 series land diesel engine

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

Schematic for WP10 series marine diesel engine

Dry or water

jacket exhaust

manifold

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

1 Fuel, lubricating oil and coolant used for diesel engines

1.1 Oil

1.1.1 Quality grade

Refer to the quality and feature to divide the oil into API and GB standards.

Oil allowed to be used:

API grade: CF-4 and CH-4

GB grade: CF-4 and CH-4

It is allowed to use the oil with higher quality grade to take place of one with

lower quality grade.

1.1.2 Oil viscosity

Refer to table 1-1 for selection of oil viscosity.

Table 1-1 The relation between oil viscosity and ambient temperature

Lubricating

oil

SAE Viscosity grade

Ambient temperature (℃)

5W/30

30-35

10W/30

25-35

15W/40

20-40

20W/50

15-50

Notice: Before starting of diesel engine, thoroughly check the oil

level in the oil sump.

Do not check engine oil level with engine running.

It is not allowed to mix the different grades of oil.

Suggestion:

It is recommended to use the Weichai special oil, which is mixed by the

imported quality basic oil and selected additive. This oil is sold at all the

service stations of Weichai at the unified national sale price.

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

1.2. Fuel

1.2.1 The diesel engine uses the light diesel as the fuel;

1.2.2 Quality grade

Sulfur content in the fuel with specified grade should not be higher than 1%.

It is allowed to use the following diesel fuels:

-GB252 0 ，－10 ，－20 ，－35 ，－50

-DIN 51601

-NATO CODES F54，F57，F76

-BS 2869：A1，A2 ( for A2, pay attention to the sulfur content)

-ASTM D975-81：1-D，2-D

-W-F-800C：DF-A，DF-1，DF-2

●Apply the following grades of diesel fuel based on the ambient

temperature.

If the ambient temperature is higher than 5℃, it is recommended to use the

0# diesel fuel (GB 252-94) .

At low temperature, the diesel fuel may precipitate the waxy material,

leading to poor mobility of diesel fuel. In such case, the fuel system will be

clogged, causing failure of diesel engine. Therefore, if the ambient

temperature is less than 0℃, please use the diesel fuel suitable for winter.

According to the GB252 diesel fuel standard, if the ambient temperature is

－5℃or more, please choose the －10# diesel fuel. If the ambient

temperature is －14℃or more, please choose the －20# diesel fuel. If the

ambient temperature is －29℃or more, please choose the －35# diesel fuel.

If the ambient temperature is －44℃or more, please choose the －50# diesel

fuel.

1.3 Coolant

1.3.1 Coolant must be filled in the cooling system of diesel engine

The coolant for the industrial power engine, which is glycol type, should have the

features like antifreezing, anticorrosion and scale proofing, as well as high boiling

point.

Operation and Maintenance Manual and User Service Guide for Industrial Power WP10 Series Diesel Engine

Coolant classification

Coolants are classified into two grades according to the engine loads:

a. Coolant for light engine load

b. Coolant for heavy engine load

1.3.2 Correct selection of coolant

Coolant selection is dependent on the ambient temperature. Generally, the

antifreeze selection standard is to be lower than ambient temperature by 10℃.

Never use water as the coolant.

Relation between the freezing point of coolant and mass fraction of glycol

Freezing point

of coolant /℃

Mass fraction of

glycol

(％)

Mass fraction of

water

(％)

Density/(kg.m-

10

26.4

73.6

1.0340

20

36.2

63.8

1.0506

30

45.6

54.4

1.0627

40

52.3

47.7

1.0713

50

58.0

42.0

1.0780

60

63.1

36.9

1.0833

1.3.3 Correct use of coolant

a. Do not overhasty fill the coolant. Otherwise, the gas in the engine can

not be drained. It is better to keep the filling speed at 13.5L/min.

b. Do not fill the radiator up for the first time. Start engine to let its

temperature rise, then check the coolant level again. If needed, refill

again.

c. The concentration of antifreeze should be inspected every 1000h. The

antifreeze should be changed every two years to avoid corrosion.

d. Each time of maintenance or starting engine, check for coolant level and

leakage.

e. Avoid continuously running diesel engine with coolant lower than

60℃or higher than 100℃. If the coolant temperature is lower than

60℃or higher than 100℃, find out the cause and resolve it.

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