Maintenance for Landking

WP10 E III Di l E i WP10 Euro III Diesel Engines

Respected customers:
Thank you for using Landking Euro III diesel engines of WeiChai Power Thank you for using Landking Euro III diesel engines of WeiChai Power.
Landking series diesel engines, developed by European R&D center of
WeiChai Power integrating the most advanced technology of internal
combustion engines, are mature products with world-class technology.
Friendly tips fromWeiChai Power: Friendly tips from WeiChai Power:
In order to improve your operation efficiency and reduce cost, please
read the manual carefully for proper use and maintenance. Special
fittings and oil should be adopted.
WeiChai Power
Contents
Regular inspection for Landking Euro III diesel Regular inspection for Landking Euro III diesel
engines
1 Cooling System 1. Cooling System
2. Lubricating System
3 Fuel System 3. Fuel System
4. Electrical System
5. Mechanical Transmission System
Maintenance for Landking Euro III Diesel
Engines
Attention Points for Operating Landking Euro III Attention Points for Operating Landking Euro III
Diesel Engines
The Way of Maintenance for Landking WP10 The Way of Maintenance for Landking WP10
Diesel Engines
Regular inspection for Landking Euro III diesel
engines
1. Cooling system
Before starting the engine should check
coolant level, check whether the cooling
. system is leaking or not.
Check whether water temperature is at the
required range or not when the engine is
running.
The normal water
When water temperature is too high,
please check:
the tension of water pump belt
temperature under the
sea-level of 3000
meters is 80~95
the tension of water pump belt
the tension of fan belt
thermostat
diagram of water temperature in cab diagram of water temperature in cab
Must use liquid coolant when ambient temperature
is below 4!
Recommendation
Long-acting liquid coolant
B d
-25 -35 -45
Brand
-25 -35 -45
above-25 above -35 above-45
Applied
temperature
above-25 above -35 above-45
2. Lubricating system
1Check the height of oil level before drive every day.
2How to check? The vehicle is parking on the plain road, before
start or stop for 15 minutes till the engine cools, pull out oil dipstick to
check oil level: When the level is below the lower limit of oil dipstick or
above the upper limit, its forbidden to start the engine.
Before replace oil, firstly, loosen the whorl plug at the bottom of oil pan.
After used oil is drained out tighten the plug Then open the oil filling cap After used oil is drained out, tighten the plug. Then open the oil filling cap
to fill CF-4 oil up to the limit required, then tighten the cap.
upper limit
lower limit
The position of oil filling inlet
oil filling inlet of 1st
li d k cylinder rocker arm
cover
WP6/WP10/WP12 series WP12 series
Recommend CF-4 oil to be used in Landking Eurodiesel engines. High
quality oil is allowed to replace low quality oil. The specification of common oil is
as follows:
Viscosity grade
0W-30 5W-30 10W-30 15W-40 20W-50
Applied
temperature
-40
30
-30
35
-2535 -2040 -1550
Please use right oil according to ambient temperature,
otherwise, engine trouble can occur.
Notice: WP10 diesel engine must use CF 15W/40 oil.
Common sense: performances of different brands of oil at the
temperature of -35C
0W-30
5W-30
10W-30 10W-40 15W-40
3. Fuel supply system
Landking Euro
diesel engines
apply high
pressure CR made
by Bosh and parts by Bosh, and parts
of the main
systems as the
right Figure:
common rail
high pressure
fuel pump
fuel injector
ECU
fuel filter
3.1Deflating Air from Fuel Supply System
Mixed air-fuel in the low pressure fuel passage could possibly be
caused by new engines, old engines not used for a long time, or fuel
tank empty pipe leakage which can result in difficult starting tank empty, pipe leakage, which can result in difficult starting.
Therefore, deflating air by hand before start is necessary as the
following way:
3.1Deflating Air From Fuel Supply System
1.Make sure enough fuel in the tank before 1.Make sure enough fuel in the tank before
deflate air.
2.loosen deflating bolt (refer to the right 2.loosen deflating bolt (refer to the right
Figure ).
3.Press hand pump until no air bubble 3.Press hand pump until no air bubble
spraying out from the deflating bolt.
4.Tighten deflating bolt then start the engine 4.Tighten deflating bolt, then start the engine.
Dont overexert loosening or tightening deflating bolt, so
as to avoid damaging.
Special Attentions: Special Attentions:
1.Dont forcibly start engine by the starter before deflate air from the low pressure fuel
passage, otherwise, the electric system could be damaged, and the starter even
could be burnt out.
2.Fuel must be filled in when fuel pointer reaches the red warning line, 2. p g ,
otherwise, air could easily penetrate into the fuel passage.
3.2Drain Water from Fuel Pre-filter
If theres water in the fuel supply system, high pressure fuel pump and fuel
injector could be easily damaged or invalidated. injector could be easily damaged or invalidated.
Pl i di ll i t h th th Please periodically inspect whether theres
water in the filter cup of pre-filter or not,
so as to drain water in time
drain water from water
collector collector
3.2Drain Water from Fuel Pre-filter
The method to drain water :
1. Open drain plug (2) at the bottom of water collector (1) to drain off water;
2. Tighten the drain plug again 2. Tighten the drain plug again.
Lightly loosen or tighten the plastic
plug so as to prevent it fromdamaging plug, so as to prevent it from damaging.
Special Attention:
Because of fuel quality differences in different places,
b t t h d i i l t l i t th t
drain water from
about two-hour driving later, please inspect the water
level of water collector after refill fuel.
drain water from
water collector
3.3 Fuel Selection
Theres no more special requirements about fuel quality for
Landking Euro III diesel engines than that for
mechanical pump diesel engines. Please try your best
to avoid using low quality fuel ! g q y
Special Attention:
Recommend using qualified fuel to guarantee
p
Recommend using qualified fuel to guarantee
the quality of fuel filled.
Common sense
40 30 20 10 0 10 20 30 40
8 5#
ambient temp.
4
0#
-5
-10#
-5
-20#
35#
10#
-14
-29
-35#
-50#
-29
-45
Fuel brand doesnt mean the ambient temperature the fuel can fit, but the freezing
point at which the fuel cant flow under certain temperature.
4. Electrical System
Landking Euro III diesel engines are with ECU, sensors and electrically controlled fuel
injectors, etc. Too high voltage or current can damage electrical system. Generators of
Landking Euro III series diesel engines, with rated voltage of 28v,have transistor
regulators (breakdown diode) Therefore please pay attention to the following aspects regulators (breakdown diode). Therefore, please pay attention to the following aspects
when electrically weld whole vehicle:
Cut off electricity supply before weld;
Special generators for Landking Euro III engines must be used. Special generators for Landking Euro III engines must be used.
1Close the control switch of battery, and cut
off negative electrode of battery jar.
2 Pull out the wiring harness connecter connecting
with ECU.
Pull out the collector as the following g
steps:
push aside the locking slice of
collector, and press it into its bottom. p
pull out the collector.
Dont shake to avoid ECU stitch bending.
Identify positive and negative electrode of electricity supply when connect
ECU with electricity supply to avoid ECU burning out.
3Welding operation
4Plug into the wiring harness collector connecting
with ECU with ECU.
plug into the collector in the following steps:
Gently and properly put the collector in the ECU groove and Gently and properly put the collector in the ECU groove, and
press it into its bottom;
Shut down the locking slice.
Notice: Not allowed to frequently pull out and plug the ECU
collector, thereby avoiding influencing message connecting of
ECU ECU.
5Connect negative electrode of battery jar, open the
control switch of battery.
When pull out or plug ECU, pay attention to :
Must cut off electricity supply for ECU
before pull out or plug ECU. Dont touch ECU
stitch by hand. stitch by hand.
Dont forcibl dra electrical ire of hole Dont forcibly draw electrical wire of whole
vehicle or electric wiring harness. Hold the
disconnection locking buckle when need to
disconnect connectors Dont drawthe disconnect connectors. Dont draw the
electrical wire against damaging.
5. Mechanical transmission
system
Inspect mechanical transmission system of
external diesel engines before running external diesel engines before running,
such as tensity and wearing of the belt.
Belt can be automatically tightened through
tension pulley. Press belt by hand to check
tension of the belt.
fan bracket fan bracket
adding grease inlet
Maintenance for Diesel Engines g
P i ff i l l i lif f di l i Proper maintenance can effectively prolong service life of diesel engines,
decrease trouble rate and reduce cost.
Maintenance contents : Maintenance contents :
Replace fuel filter element and oil filter element;
Clean and check air filter element. Replace it every 5 times of cleaning.
Maintenance interval: Maintenance interval:
Maintenance should be done in time at Landking Euro service stations
accordingto the following requirements: according to the following requirements:
1 Truck 1. Truck
Maintenance for highway trucks according to the following
standard: standard:
l d t d l d t d l d load rated load rated load
1
st
maintenance
New vehicle run 3000 km or for 50hrs
periodical
maintenance
Every 40000km or
500hrs
Every 30000km or
500hrs
maintenance
500hrs 500hrs
Maintenance for non-highway truck (including cement mixing vehicle) according to the
following standard:
load
rated load rated load
1
st
maintenance
New vehicle run for 50hrs or 3000kms
periodical
maintenance
Every 300hrs or
20000km
Every 200hrs or 15000km
maintenance 20000km
2. Bus 2. Bus
Maintenance for bus (city bus, dedicated bus for workers )according to the
followingstandard: following standard:
1st
i t
New vehicle run 50hrs or 3000km
maintenance
New vehicle run 50hrs or 3000km
i di l periodical
maintenance
Every 300hrs or 20000km
Maintenance for passenger bus, sight seeing bus according to the
followingstandard: following standard:
1st
i t
New vehicles run 3000km or 30hrs
maintenance
New vehicles run 3000km or 30hrs
periodical
maintenance
Every 30000km or 300hrs
maintenance
3. Construction Machinery 3. Construction Machinery
Maintenance for loader, excavating machine, road roller and crane, etc
according to the following standard:
1st
maintenance
New vehicle run for 50hrs or 3000km
periodical
maintenance
Every 200hrs or 10000km
Special attention: Please properly shorten periodical
maintenance interval or mileage under severe work condition.
Operators of diesel engines must carefully read Operation and
Maintenance Manual, and well understand the structure of diesel Maintenance Manual, and well understand the structure of diesel
engines, strictly comply with the operation and maintenance
stipulated in the Operation and Maintenance manual.
Based on the maintenance requirements stipulated in the manual,
please periodically inspect diesel engines and replace oil in
accordance with work condition.
Maintenance Guide for Landking Euro Diesel Engines
Maintenance on mechanical system of Landking Euro Diesel Engines is
i il ith th t f E II similar with that of Euro II.
For the trouble on electronically controlled system of Landking Euro Diesel
Engines users may go to Wei Chai Euro maintenance station nearby Dont Engines, users may go to Wei Chai Euro maintenance station nearby. Dont
dismantle or repair fuel supply system and electronically controlled system
privately, so as to avoid unnecessary loss.
Special attention:
When repair or replace components of diesel engines, pay attention
to :
Landking Euro III series diesel engines have high performance, therefore,
maintenance should be done in accordance with Maintenance Manual and Parts
C t l f W i Ch i P L dki E III i di l i Pl Catalogue of Wei Chai Power Landking Euro III series diesel engines. Please
purchase special fittings to ensure the performance, reliability and service life
of diesel engines of diesel engines.
Attention points for operating diesel engines
1. Accelerator Pedal Operation of EuroDiesel Engines
L dki E di l i d t l t l t d l ith l t Landking Euro diesel engines adopt electro-accelerator pedal with electro-
structure sensor inside. Recommend that users placidly accelerate or decelerate
d h d i t ff ti f l i speed when drive to ensure more effective fuel-saving.
2. Time selection for shifting the gear
Operating points of diesel engines influence fuel economy, but gear selection when
drive also has a great impact on fuel saving. Generally, high gear saves fuel. g p g y, g g
AShift the first gear to start.
BBefore shift high gear, the speed of diesel engines should be accelerated
to about 1200 r/min.
2. Time selection for shifting the gear
CIn order to avoid high speed, but low gear, should positively shift high gear to
make diesel engines run at the range of economical speed if work condition make diesel engines run at the range of economical speed if work condition
permitted.
Special Attention: For mechanical gear-box, whole vehicle matched with Special Attention: For mechanical gear box, whole vehicle matched with
Landking Euro III diesel engines stop injecting fuel when sliding with shifting the
gear, which is more fuel-saving than that when sliding with neutral gear.
3. Economical Speed of Diesel Engines
diesel engine
economical speed
diesel engine
series
economical speed
WP6
1200-1800
WP10WP10N
1100-1600
WP12WP12N
1100 1600
WP12WP12N
1100-1600
4.Usage of WEVB
Recommend to use WEVB when run downward the
long slope ( WeiChai patent of safety brake system long slope ( WeiChai patent of safety brake system
for engines)
WEVB is controlled by electronically controlled unit.
When WEVB works, the diesel engine doesnt inject
fuel to save fuel.
WEVB cant work when the speed of diesel engines is less
than 800 r/min.
Four Special Attentions for Landking Euro III Diesel Engine Service of
Wei Chai Power
Forcible Maintenance Suggestion--- Forcible Maintenance should be done by Euro
III maintenance station of WeiChai Power in accordance with relevant requirements;
Maintenance Suggestion---Maintenance should be done by Euro III
maintenance station of WeiChai Power;
Fittings Suggestion--- Use special fittings provided byEuro III maintenance Fittings Suggestion--- Use special fittings provided byEuro III maintenance
station of Wei Chai Power;
Oil Suggestion--- Use special oil for Landking Euro III diesel engines provided by
exclusive agency of fittings.
The way of maintenance for Landking
WP10 di l i WP10 diesel engines
49
1Replace Oil and Oil Filter
Replace the oil and oil filter to clean the impurities containing in oil.
Note: The oil should be drained off when it is hot
Tool:32mm open-ended wrench
Remove the whorl plugprepare a container to collect 24L of oil
NoteHot oil can injure people.
50
1Replace Oil and Oil Filter
Tool: The special wrench for filter.
Clean the end surrounding of the filterand remove it Clean the end surrounding of the filterand remove it.
Install the ne oil filter Install the new oil filter
NoteAdjust the seal ring and
smear some lubricating oil on it while
fitting the oil filter.
51
1Replace Oil and Oil Filter
Tool:32mm open-ended wrench
Check and clean the screwthread Check and clean the screw thread
and seal ringand then install the whorl plug.
Fill th l il t th Fill the clean oil up to the upper
limitthe capacity of the oil sump is 24L
NoteSTEYR engine must use CF-4 15W/40 oil
52
1Replace Oil and Oil Filter
Run the engine at idling speed
and check the filter to find whether and check the filter to find whether
it leaks or not
Stop the engine and make the
oil run into the sump from the upper
parts 5 minutes laterthen check
the oil levelfill oil up to the upper
limit if necessary limit if necessary
53
2 Check and adjust the valve clearance
Check and adjust the valve clearance
Tool13mmsleeve wrench Tool13mm sleeve wrench
Disassemble 6 cylinder head covers
Tool 3 2 mm wrench for turning the crankshaft
T th fl h l til it l d th k it Turn the flywheel until its scale and the mark on its
housing are aligned, push the piston to the position
of TDC of compression stroke of 1st cylinder p y
(the intake and exhaust valve of 1 cylinder are closed)
54
2Check and adjust the valve clearance
ToolClearance gauge
The clearance of intake valve is0 30mm The clearance of intake valve is0.30mm
The clearance of exhaust valve is 0.40mm
The clearance for WEVB system is0.25mm.
Note: When check the clearance of valvethe engine should be at the cool
condition-its temperature is less than 60.When the clearance guage glides condition its temperature is less than 60.When the clearance guage glides
between the top of valve rod and rocker arm and can be felt retarded and
stickythe measuring result is proper
55
2Check and adjust the valve clearance
After WEVB system is used, the adjustment method of exhaust valve clearance is
as follows (see Fig. 2 for part serial numbers) ( g p )
1. Valve clearance adjusting nut 2. Regulating bolt assembly 3. Exhaust valve
rocker arm assembly 4. Steel ball 5. Valve rocker arm piston 6. Rocker arm
i t i 7 N dl 8 B ll l i 9 V l k t bl piston spring 7. Needle 8. Ball valve spring 9. Valve rocker arm seat assembly
10. Valve clearance adjusting screw 11. Hexagonal bolt 12. Support arm
56
2Check and adjust the valve clearance
1The cylinder piston to be adjusted is located on the top dead center of the
compression travel. p
2As shown in Fig. 2, loosen No. 2 adjusting bolt assembly. In case that the oil
seal plane of exhaust valve rocker armis not pressed first by using No 10 valve seal plane of exhaust valve rocker arm is not pressed, first by using No. 10 valve
clearance
adjusting screw at the push rod end, adjust the total valve clearance to 0.4mm. Tighten
h k t check nut.
57
2Check and adjust the valve clearance
Fig. 2 Total Valve Clearance of Cold-State Fig. 3 End Valve Clearance of
Cold-State Exhaust Valve 0.4mm Exhaust Valve 0.25mm
58
2Check and adjust the valve clearance
3Then as shown in Fig. 3, insert the clearance gauge between No. 5 valve
rocker arm rocker arm
piston and the exhaust valve rod end or valve rod cap. By turning No.2 regulating
bolt, adjust the valve clearance to 0.25mm. Tighten check nut.
C ti D i dj t t t N 2 l ti b lt til l i Caution: During adjustment, turn No. 2 regulating bolt until clearance gauge is
clamped so that No. 5 valve rocker arm piston is pressed to its bottom. There is not
clearance between No.5 valve rocker arm piston and the piston installation hole
bottom plane in exhaust valve rocker arm.
59
2Check and adjust the valve clearance
Tools6#screwdriver and14mm double offset ring wrench
The piston of 1st cylinder is at TDC of the compression stroke The piston of 1st cylinder is at TDC of the compression stroke
Check and adjust the valve clearance as step A(I-air intake Valve E-air Exhaust valve)
Adjust the clearance by gauge and tighten the fixing nut of rocker armre-check
th l till it t th i t the clearance till it meets the requirement
Step A
60
2Check and adjust the valve clearance
Turn the crankshaft 360by
the spannerit can also be turned the spannerit can also be turned
360after marking on the vibration damper.
Adj t th l l t B Adjust the valve clearance as step B
Loosen the fixing nut of rocker g
armadjust the clearance by gauge
then tighten the nut again .
61
2Check and adjust the valve clearance
Tool:13mm sleeve wrench
Install the gasket and cylinder head cover Install the gasket and cylinder head cover.
The tightening torque of bolt is
23Nm(recommended).
R l f l filt l t Replace fuel filter element
Replace fuel filter element in the following steps:
Dismantle the old fuel filter element. Remove
the water collector installed on coarse filter if reused.
62
3Replace fuel filter element
Lubricate the seal lips.
Turn the filter by hand until the Turn the filter by hand until the
seal is closed with interface.
Continue to turn the filter with hands until the filter is installed solidly (about
turns),
63
3Replace fuel filter element
E. Deflate until there is no bubble.
F. Start Engine.
G. Conduct leakage test.
H. Retighten when necessary H. Retighten when necessary
64
4 Check the air filter element
Check the air filter element
The maximumair intake resistance of the engine The maximum air intake resistance of the engine
should be 7kPa and inspection should be done at the
rated speed and full load. When the resistance reaches
th i li it ll d th i filt l t h ld the maximum limit allowedthe air filter element should
be cleaned or replaced as per the maintenance guide from
the manufacture.
65
4 Check the air filter element
Caution
Don't blow off the air filtering paper
Don't clean the air filteringpaper by water and oil
D 't b t th f ibl Don't beat the core forcibly
66
4Check the air filter element
Notelt is not allowed to use the engine without air filter otherwise the dust Notelt is not allowed to use the engine without air filterotherwise the dust
and impurity will cause early wearing of the engine.
R th filt f th i filt l t d b t th id f th l t Remove the filter core from the air filter element and beat the side of the element
lightly to make dust fall down, or blow the element backward (blow back from
inside to outside) by compressed air
67