Hướng dẫn sữa chữa WP10 E30 Maintenance and repair manual1.1.Designation of diesel types of the WP10 series1.2.Features of the operation of the new diesel engine1.3.Recommended timing of the first oil change1.4 Initial check before starting a new engine1.5 Check before start1.6 Starting the diesel1.7.Diesel operation1.8 Points to pay attention to when starting and running the engine in cold conditions.2.Diesel service2.1 Daily maintenance2.2 Periodic maintenance2.2.1. Diesel maintenance intervals2.2.2. Production operations during diesel maintenance2.3.Form of the maintenance report3. Diesel maintenance operations3.1 Daily maintenance3.2 Contents of periodic maintenance3.2.1 Draining the engine oil and removing the oil filter3.2.2 Installing a new oil filter3.2.3 Filling engine oil3.2.4 Checking and adjusting valve clearances3.2.4.1 Exhaust valve drive lever3.2.4.2 Adjustment of clearances in the exhaust valve drive3.2.4.3 Adjusting the intake valve clearance3.2.5 Checking the Vbelt tension3.2.6 Checking the engine cooling system3.2.7 Changing the fuel filter3.2.8 Checking the intake system3.2.9 Checking and maintaining the air filter3.3 Diesel maintenance after long storage3.4. Preservation4. Schemes of the main diesel systems4.1 Engine lubrication system4.1.1 Lubrication of moving parts.4.1.2 Lubrication of the valve drive mechanism4.1.3 Lubrication of the turbocharger4.2 Cooling system4.3 Intake and exhaust systems4.4 Fuel system WP104.4.1 Electronic fuel management system4.4.2 High pressure fuel pump (TNVD)4.4.3 Diesel fuel prefilter5. Moments and methods of tightening threaded connections5.1 Bolts for fastening the crankshaft support bearing plate (main bearing5.2. Bolts of fastening of heads of the block of cylinders5.3 Connecting rod bolt5.4.Flywheel mounting bolts5.5.Flywheel housing fastening bolts
DIESEL ENGINE WP-10 Ecological class EURO-III MANAGEMENT FOR MAINTENANCE AND REPAIR WP10 series diesel service manual Table of contents Foreword Operational description of diesel WP-10 1.1.Designation of diesel types of the WP-10 series 1.2.Features of the operation of the new diesel engine 1.3.Recommended timing of the first oil change 1.4 Initial check before starting a new engine 1.5 Check before start 1.6 Starting the diesel 1.7.Diesel operation 1.8 Points to pay attention to when starting and running the engine in cold conditions 2.Diesel service 2.1 Daily maintenance 2.2 Periodic maintenance 2.2.1 Diesel maintenance intervals 2.2.2 Production operations during diesel maintenance 2.3.Form of the maintenance report Diesel maintenance operations 3.1 Daily maintenance 3.2 Contents of periodic maintenance 3.2.1 Draining the engine oil and removing the oil filter 3.2.2 Installing a new oil filter 3.2.3 Filling engine oil 3.2.4 Checking and adjusting valve clearances 3.2.4.1 Exhaust valve drive lever 3.2.4.2 Adjustment of clearances in the exhaust valve drive 3.2.4.3 Adjusting the intake valve clearance 3.2.5 Checking the V-belt tension 3.2.6 Checking the engine cooling system 3.2.7 Changing the fuel filter 3.2.8 Checking the intake system 3.2.9 Checking and maintaining the air filter 3.3 Diesel maintenance after long storage 3.4 Preservation Schemes of the main diesel systems 4.1 Engine lubrication system 4.1.1 Lubrication of moving parts 4.1.2 Lubrication of the valve drive mechanism 4.1.3 Lubrication of the turbocharger 4.2 Cooling system 4.3 Intake and exhaust systems 4.4 Fuel system WP-10 4.4.1 Electronic fuel management system 4.4.2 High pressure fuel pump (TNVD) 4.4.3 Diesel fuel pre-filter Moments and methods of tightening threaded connections 5.1 Bolts for fastening the crankshaft support bearing plate (main bearing 5.2 Bolts of fastening of heads of the block of cylinders 5.3 Connecting rod bolt 5.4.Flywheel mounting bolts 5.5.Flywheel housing fastening bolts WP10 series diesel service manual 5.6 Bolt of intermediate gear shaft 5.7 Bolt of the parasitic gear shaft of the oil pump 5.8 Bolt lever cushion 5.9.Nuts for high-pressure fuel lines 5.10.Nut for fastening the driving gear of the injection pump 5.11 Camshaft hexagon bolts 5.12 Bolts for connecting the pulley of the vibration isolator of the crankshaft 5.13.Injector fastening bolts 5.14.Exhaust manifold bolt 6.Engine fuel, lubricating oil, coolant and auxiliary materials for diesel 6.1 Diesel fuel 6.2 Lubricating engine oil 6.2.1 Type of engine oil 6.2.2 Using higher quality engine oil 6.2.3 Selection of engine oil by viscosity 6.2.4 Oil level in the engine crankcase 6.3 Lithium grease for water pump 6.4 Coolant 6.5 Auxiliary materials 6.5.1 Sealants 6.5.2 Molybdenum powder 6.5.3 Use of auxiliary materials Electrical part 7.1.Electronic control unit ECU 7.2.Power generator WP-10 7.3.Starter WP-10 7.4 Engine oil pressure sensor 7.5 Coolant temperature sensor Adjustment and replacement of main parts and assemblies 8.1 Cooling system 8.2 Lubrication system 8.3 Replacing the oil pump 8.4 Replacing the nozzle 8.5 Inlet system Typical failures and their elimination 9.1 Diesel does not start 9.1.1.Starter does not work 9.1.2 Lack of fuel in the high pressure system 9.1.3 Injector harness connectors 9.1.4 Loss of crankshaft and camshaft signal 9.2 Difficulties in starting a diesel engine 9.3 Engine does not develop full power 9.3.1 Nozzle damage 9.3.2 Temperature of coolant, engine oil, inlet too high 9.3.3 Cause and remedy for high coolant temperature 9.3.4 Causes of high engine oil temperature and remedy 9.3.5 Cause of too high inlet temperature and remedy 9.3.6 Synchronization error signal 9.3.7.Failure of the measuring block of fuel consumption 9.3.8 Leakage in the fuel line 9.3.9 Failure of the intake pressure sensor WP10 series diesel service manual 9.3.10 Failure of the pressure sensor in the common fuel supply pipe 9.4 The engine runs at a constant speed of 1000 rpm 9.5 Engine idling 10.Points of attention 11.Explanation of graphic marks WP10 series diesel service manual Section Operational description of the WP10 diesel Engine model XX YYY Power P Cylinder displacement W WEICHAI 1.1 Designation of diesel types of WP10 series 1.2 Features of the operation of the new diesel engine When running in a new diesel engine, it is necessary to limit the diesel load to no more than 75% of the rated load within the first 60 hours of operation or 3,000 kilometers 1.3 Recommended timing for first oil change Within 1,500-2,000 km After running in during initial operation, it is necessary to change the engine oil in the engine, otherwise, damage to diesel parts may occur Proper maintenance of the engine ensures its efficiency and long service life 1.4 Initial check before starting a new engine Every day, check the serviceability of the oil pressure gauge, thermometer, alarm control lamp and other instruments to ensure normal operation When opening the diesel package, first, according to the documentation, clarify the indicators of the diesel engine and on-board units Carefully inspect the outer surface of the diesel engine for damage Remove the anti-corrosion coating of the diesel engine and the anti-corrosion compound of the external parts, etc Drain the storage oil from the oil filter and fuel supply lines Turn the handwheel to inject the solvent into the inlet tube until completely removed conservation oil in the cylinders Inject solvent into the blower outlet until the preservative oil is completely removed Check the quantity and properties of the coolant filled at the factory If the anti-icing capacity satisfies the value of pH 7-8 (chemically neutral environment, freezing point -5-15°C), this coolant can be used If not suitable, then the coolant must be drained and filled with new coolant or antifreeze, approximately 40 liters 1.5 Check before launch Check coolant level Check fuel level Check engine oil level 1.6 Diesel start Turn on power supplies, electronic key to the start position Set the shift lever to neutral position Depress the clutch and gas pedals, turn on the electronic key to start the engine If a If the engine does not start within 15 seconds, repeat the above operation after minutes After starting the engine, the engine oil pressure gauge should show pressure immediately Under low temperature conditions, it is possible to facilitate the start of a diesel engine by using an auxiliary device for starting - an electronic heating flange Successful implementation of the launch is possible at a temperature of -25°C 1.7 Diesel operation After starting, the diesel engine should idle for 2-3 minutes In this case, the engine oil pressure must be above 100 atm Gradually increase the rotation speed to 1000~1200 rpm After working at full load, before stopping, the diesel engine should idle for 3-5 minutes Check the oil pressure gauge and coolant thermometer frequently WP10 series diesel service manual If the pressure and temperature not meet the requirement, the diesel must be stopped immediately Attention! When the coolant temperature is below 60ºC or above 100ºC, continuous operation will damage the engine Attention! Before a complete stop, the engine should run at idle and after 1-2 minutes will stop 1.8 Points to pay attention to when starting and running the engine in cold weather Engine fuel must match the outdoor temperature, select the appropriate brand of diesel fuel Engine oil must be suitable for the ambient temperature of the seasons An oil of the appropriate viscosity must be selected Fill the cooling system with antifreeze for the appropriate outdoor temperature An auxiliary starter can be used to start the engine in winter if necessary Before the start of the frosty season, be sure to check the level, viscosity and density of the electrolyte in the batteries If the diesel engine is stale and is at a very low temperature, it is necessary to remove the battery and put it in a warm room for charging Section Diesel maintenance 2.1 Daily service Check: oil level on the oil gauge dipstick; coolant level; fuel level; fan for no damage; drive V-belt for cracks, scratches; condition of fastening of units;coolant and oil for leakage; operating condition of the battery charge control lamp; the presence of oil in the cavity of the water pump;oil pressure and coolant temperature; exhaust temperature, sounds and vibrations of a running diesel engine 2.2 Periodic maintenance Attention! Fill out a service protocol 2.2.1 Diesel maintenance intervals The frequency of maintenance during normal operation of a diesel engine should not exceed 400 hours of operation or 15,000 km of vehicle run In case of local operation: cold climate (temperature - 10ºC), hot climate (temperature above + 30ºC), high dust content in the air, short distance transportation, urban operation, off-road operation, sulfur content in the fuel used is 0.05-0.2% (sulfur content of 0.2-0.5% should be referred to as ultraharsh conditions) - service intervals should be shortened And vice versa, when operating a diesel engine in gentle conditions (for example, a truck tractor with long runs), a reasonable increase in intervals is permissible WP10 series diesel service manual 2.2.2 Production operations for diesel maintenance Scheduled diesel maintenance includes the following operations: - computer diagnostics of engine operation parameters - changing the engine oil (at least once a year) - replacement of oil filters (every oil change) - replacement of fuel filters - cleaning (purging) the air cleaning filter (when receiving a signal from the control lamp) replacing the air cleaning filter (see section 3.2.9 of this manual) - checking and adjusting valve clearances (see section 3.2.4) - check the coolant level (top up if necessary) - coolant replacement (every years) - checking the tension of the drive belts (see section 3.2.5) - checking the condition of the engine mounts - checking the tightening of the engine mounting bolts - check the play of the turbocharger bearings WP10 series diesel service manual 2.3 Maintenance protocol form Diesel number Diesel type _ Date Mileage or working hours Actual distance Maintenance content Executor service Note Section Diesel Maintenance Operations - Oil dipstick 3.1 Daily Maintenance Every day, preventive maintenance is performed to know the working condition of the diesel Before starting the diesel engine, the engine oil level, the coolant level and the presence of diesel fuel are checked Check: Leakage of working fluids and oils; The condition of the main units and any anomaly in the operation of the diesel engine Check the position of the engine oil level mark on the dipstick When the oil level is below the lower scale of the oil gauge or above the upper scale, diesel engine is prohibited Checking the oil level is carried out no earlier than minutes after stopping the diesel engine so that the engine oil can glass into the oil pan The difference in the oil gauge from low to high is equivalent to topping up - liters of oil WP10 series diesel service manual 10 Checking the coolant level Inspect the coolant level through the glass hole, if the coolant liquid is not enough, it is necessary to open the filler cap and add coolant Attention !: When opening the filler cap, the overpressure release button must be pressed to prevent hot coolant from spilling onto a person Check fuel level Check the condition of the motor fan: - check the plastic fan for the absence of deformation, the condition of the rivets of the iron fan - for the absence of misalignment of the blades, to ensure further reliable operation of the fan Check the condition of the V-belt for cracks and wear If necessary (delamination, cracks), it must be replaced 10 WP10 series diesel service manual 11 Check the color of the exhaust gases The color of the normal exhaust is light grey When changing color, you need to find out cause and eliminate Check the sound of a running diesel engine for the absence of extraneous knocks, squeaks, etc Check motor shaft speed and vibration 3.2 Contents of periodic maintenance In addition to performing daily maintenance, the following verification activities are added 3.2.1 Draining the engine oil and removing the oil filter During the operation of a diesel engine, engine oil becomes contaminated with the products of combustion of fuel Fuel consumption depends on the content of contaminants in the oil Attention :The frequency of replacing engine oil during normal operation of a diesel engine is, in any case, no more than 400 hours (15,000 km of run) Attention Drain the oil when the engine is warm A 32 mm open-end wrench is used to open the drain hole Before draining the oil, prepare a container to collect 24 liters of oil Attention Hot engine oil can injure a person 11 WP10 series diesel service manual 42 16 mm socket wrench Install the new oil pump, its gasket, and tighten the hex bolts (one in the hex plug) Install the oil pump idler gear (note projection inward) Install the oil pump intermediate gear shaft bolt 42 WP10 series diesel service manual 43 16mm socket wrench Install the intermediate gear shaft bolt and tighten Tightening torque 60+5 N m Install vibration isolator and pulley 16mm socket wrench Install pulley bolts and tighten Tightening torque 60+5N m 16 mm open end wrench Install the V-belt with a moderate tightening, tighten the locknut 43 WP10 series diesel service manual 44 8.4 Nozzle replacement 17mm open end wrench Clean the end of the injector, disconnect the high pressure fuel pipe fitting Disconnect fuel return pipe Hexagon 6mm Disconnect the clamp mounting bolts, remove the injector clamp and mounting bracket Remove nozzle Clean the nozzle seat Replace Copper Atomizer O-Ring Prepare a new nozzle Check: the nozzle must be wearing a rubber sealing ring 44 WP10 series diesel service manual 45 Install a new injector into the hole in the cylinder block After installing the nozzle, check the rubber ring for squeezing Attention After installing the injector, check the rubber ring for squeezing Install the injector clamp The injector mounting bolts must be tightened evenly Tightening torque -10-12 Nm Tighten the fuel supply pipe fitting (high pressure) Install return tube 8.5 intake system Turbocharger replacement mm screwdriver Loosen the rubber inlet hose clamp and the compressor outlet hose clamp 45 WP10 series diesel service manual 46 Loosen the clamp on the blower hose mm internal hex wrench 16 mm open end wrench Remove the self-locking flange nut connecting the exhaust pipe and supercharger Take off supercharger Replace blower with a new one Attention If you not immediately replace the turbine supercharger, then close all inlets and outlets to prevent any objects from falling into the cylinders mm internal hex wrench Replace the inlet pipe gasket with a new one and tighten the inlet pipe bolt Attention When installing the intake pipe gasket, be sure to align the oil holes in the gasket and supercharger flange Pour in clean engine oil while rotating the turbine wheel so that the engine oil flows into the bearing chamber Section Typical failures and their elimination 9.1 Diesel does not start 9.1.1 Starter not working In WP10 series engines, the starter is controlled by the ECU During normal operation, the ECU provides a signal to start by energizing the battery relay and actuating the starter In order to ensure the safe start of the engine, a neutral sensor is installed in the gearbox If the transmission is in a position other than neutral when the engine is started, the starter circuit is not completed and the engine cannot be started If the starter does not start, we recommend that you perform the following checks in sequence Check that the gearbox is in neutral 46 WP10 series diesel service manual 47 Inspect the neutral switch and its circuit Use a standby engine start mode if the starter starts to work there is a problem in the neutral sensor circuit Check battery voltage Reduced voltage prevents starting or reduces starter torque In general, the battery voltage is 24 V The voltage drop at the starter can be checked with a tester or the actual “battery voltage” value can be shown with a fault diagnosis tool Check the starter relay for operation Remove oxide from wire terminal surfaces Check tightening of bolts and nuts terminals for loosening and breaking Check the starter for burning of the connection points of the electrical circuit and the movable contact group Check the operation of the starter relay with a tester Check ignition switch and ground switch Turn the ignition key to the ON position, the lamp on the instrument panel should light up Turn the ignition key further to the start position, check the inclusion of the starter in the working condition 9.1.2 Lack of fuel in the high pressure system (starter runs fine but engine does not start) Check the fuel level in the tank Check the fuel supply with the manual priming pump Check the tightness of the low pressure fuel supply pipes Reestablish tightness and release air (sometimes a fuel leak from the low pressure line is not visible, you need to check everything carefully) A method for releasing air from a fuel pre-filter Clean and loosen the outlet bolt on the fuel prefilter Press the manual fuel priming pump with your hands Pump until fuel appears without air bubbles at the location of the loosened exhaust bolt If the diesel does not start after bleeding the air from the low pressure fuel line, check for air in the high pressure fuel line and bleed it Release method Loosen the high pressure fuel line union nut from the cylinder injector Crank the engine with the starter until a continuous flow of fuel from the high pressure fuel line (it is not recommended to frequently remove the high pressure fuel line fitting!) Check the high pressure fuel line for leaks This case is generally more visible, check the tightness of the fuel line union nut high pressure, if the fastening is loose, then tighten the nut 47 WP10 series diesel service manual 48 Check for uninterrupted fuel supply Check the diesel filter for clogging and replace the diesel fuel filter element in a timely manner Release method Release the outlet bolt of the fine filter, the starter cranks the diesel, while checking for diesel fuel leakage from the filter If little diesel fuel flows out, then it can be assumed that the filter is clogged with dirt or wax The dirty filter element needs to be replaced Check the value of the initial voltage of the pressure sensor of the common fuel supply pipe within the limit of about 500 mV, which corresponds to the pressure in the common fuel supply pipe of 30-50 MPa Measurement method A device for diagnosing damage is used On the control panel of the fault diagnosis instrument, select “actual value”, click the “next” button In this case, the entire “actual value” will select “battery voltage sensor voltage”, “nominal pressure of the common fuel supply pipe” - engine rotation speed - nominal pressure of the common fuel supply pipe - actual pressure of the common fuel supply pipe - indication of the battery voltage sensor If the gauge shows low pressure, check the line connectors for possible leaks If no leaks are found, the common supply pipe pressure sensor may be broken If there is no test equipment, you can unscrew the connector of the pressure sensor of the common supply pipe, try starting the engine again (after starting, enter the “waddle home” module) Check the operation of the flow meter for safety, unscrew the connector of the flow meter, try starting again First, check the absence of visible hardware damage, the connection of the connector for reliability 48 WP10 series diesel service manual 49 Switch on the damage diagnosis device to measure the Meter-unit Enter the control panel of the damage diagnosis device, select “function measurement” Click the “Next” button >> Next Enter the function measurement subpanel, select “dosing unit measurement” Click the “Next” button >> Next This will bring up the measurement condition panel, the operator will confirm that the condition is met, click the “next” button to start measuring 49 WP10 series diesel service manual 50 At the end of the measurement, check the indication of the fuel consumption measuring block for compliance with the normal operation mode 9.1.3 Injector harness connectors The sensor harness, the harness of the whole machine is not correctly inserted or the harnesses are turned off or short-circuited.Check the wiring status of the connectors, using a tester (it is better to turn on the “circuit tester”), check the circuit on and off according to the definition of the circuit indicator inlet pressure sensor, water temperature sensor, oil pressure sensor, 50 WP10 series diesel service manual 51 camshaft speed sensor, crankshaft speed sensor, common supply pipe pressure sensor, * installation of the nozzle, ** fuel consumption measuring block connector 9.1.4 Loss of crankshaft and camshaft signal The diesel engine has speed sensors installed in the flywheel housing and on the outside of the high pressure fuel pump Their function is to determine the timing of fuel injection at the injector The electronic control of the engine depends on the operation of these two sensors The diesel engine will not start if these two signals are completely absent Possible reasons for the complete loss of both signals - the sensors are faulty, the harnesses are switched off or switched on for a short circuit - the sensors are poorly fixed, because of this reason the gap between the sensors and the inductive flywheel teeth, too large and the signal generated by them will be too small in voltage amplitude (generally ± 0.5 mm) Remedy - check the sensors for damage, harnesses for safe inclusion, sensors for no release, etc Strictly, according to the relevant technological documentation, install the high pressure fuel pump and flywheel after removing them to ensure signal synchronization 9.2 Difficulty starting a diesel Causes of difficult starting of the engine and ways to eliminate them Diesel has not worked for a long time The swing tube must be below the diesel level There is air in the low pressure fuel line Air release required Signals from the crankshaft and camshaft position sensors are too weak Timing detection time is relatively long, find out the specific cause and adjust again Due to too low ambient temperature, the heating equipment loses its performance, it does not heat up enough Check heating flange connection and/or replace defective heating equipment The quality of diesel fuel and engine oil does not correspond to the operating conditions of the engine Replace them with new ones that correspond to the air temperature The starter drive and flywheel ring gears strike Replace starter and flywheel or ring Piston rings and cylinder liner worn or valves leaking Replace piston rings, cylinder liner or valve seat, lap valves or replace The outlet thrust butterfly sticks in the closed position, because of this, the outlet does not circulate the working mixture Replace butterfly 9.3 The engine does not develop full power The engine is running under reduced load Engine damage can be detected by checking the ECU The engine should not be stopped immediately Limit the engine power and speed to 1500 rpm and get to the engine service and repair point 51 WP10 series diesel service manual 52 9.3.1 Nozzle damage In general, mechanical or joint damage may occur Mechanical damage when the locking needle sticks, as there is a lot of dirt in diesel fuel or corrosion from water, the stop needle is stuck in the nozzle and does not work Attention The ECU may show connector damage Harnesses are off or right on the cylinder head short to ground due to vibration or wear (ECU may show corresponding error) Injector terminal short 52 9.3.2 Coolant, engine oil, intake temperatures are too high (engine overheating) If the temperature of the coolant, engine oil, intake air is too high, the ECU will activate the overheat protection function and limit the engine power Before the failure is eliminated, first of all, eliminate the distortion of signals reflected by sensors and devices 9.3.3 Cause and remedy for high coolant temperature The engine coolant level is too low Check for possible leaks, add coolant The fan rotates too slowly or does not rotate Check drive pulleys and fan belts Water radiator, engine jacket, tank clogged with dirt Check, clean and fix The water pump belt is loose Tighten, according to the rule, adjust the belt tension The water pump gasket and water pump vanes are worn Check and fix or replace Thermostat failure Replace thermostat Hermetic parts of the plumbing are worn out Check plumbing Replace fitting, gasket and worn parts 9.3.4 Causes of high engine oil temperature and how to eliminate it The oil level in the oil pan is low or there is not enough oil Check oil level and oil leaks, correct and refill The coolant temperature is high Find out the causes of high coolant temperature and eliminate them The engine oil cooler is inoperative Check and clean 9.3.5 Cause of too high intake temperature and remedy Check intercooler airflow capability 9.3.6 Synchronization error signal Such a malfunction may occur when the signal of one of the sensors (crankshaft or camshaft) loses its strength (See the digital error code on the malfunction indicator in the cab of the car, see the error code interpretation to identify the causes of the malfunction) The method of elimination is the same as 9.1.4 9.3.7 Failure of the measuring block of fuel consumption The flow measuring unit, mounted on the high pressure fuel pump, is the actuator for controlling the pressure in the common supply pipe After a request from the unit appears, the highpressure fuel pump increases the fuel supply to the common supply pipe to the maximum, while the decompression valve on the common supply pipe generally opens, sounds “ka, ka” in the diesel a similar phenomenon is also present in the sensor of the common supply pipe Remedy Check circuit for failure of flowmeter or common supply pipe pressure sensor Notify the office for a decision 9.3.8 Leak in the fuel line Causes a change in pressure in the common high pressure pipe On the go, the speed of the machine is not stable, the machine does not consistently respond to management changes Remedy Switch off first, restart the engine after one minute If the question still remains, then check the tightness of the fuel pipe and repair 9.3.9 Intake pressure sensor failure The ECU will calculate the air flow using the intake pressure sensor (mounted on the intake pipe), the coolant temperature sensor detects the engine heat load (mounted on the water pipe), sensor common supply pipe pressure checks the fuel pressure of the common supply pipe (installed on the common fuel supply pipe) 53 9.3.10 Failure of the pressure sensor in the fuel rail Remedy: Check intake pressure sensor, coolant temperature sensor, sensor pressure in the fuel rail, check the connector for reliability 9.4 The engine runs at a constant speed of 1000 rpm The engine does not respond to the position of the accelerator pedal The ECU control unit determines the load according to the signal set by the pedal potentiometer, when the pedal fails, considering safety, the ECU controls the diesel so that the diesel speed automatically returns to 1000 rpm The electronic accelerator pedal assembly is loose or incorrectly installed Repair or check accelerator installation for correct installation The connector of the electronic accelerator is filled with water Dry the connector, restart Attention :When replacing the accelerator, it is necessary to install an accelerator of the same type 9.5 Engine idling The reason for the decrease in engine power and how to eliminate it The injectors are working in an unspecified order Check cylinder injectors and harnesses When the machine stops, the sensor stores the speed indicator Check the speedometer and speed sensor signal and installation The presence of water and wax in the fuel Clean the fuel system, replace the fuel filter Air entering the low pressure fuel line Check tightness connections of the fuel line and fitting, remove air Unstable fuel atomization conditions by the injector Check and fix Attention An increase in idle speed due to low water temperature is a normal function of the electronic control unit (ECU) Under other loads (for example, turn on the air conditioner), idling naturally exceeds 100 rpm 54 Special Reminder Before operating the diesel engine, the personnel carefully carefully study the instructions for use and maintenance of the diesel engine, strictly observe the rules for its operation and maintenance specified in the operation and maintenance instructions It is forbidden to arbitrarily change and adjust ECU data in order to protect your legal right When adjusting and changing the ECU data, the company’s warranty will be void The user must not dismantle the ECU pressure pump of the common supply pipe and injector, which are precision units, otherwise the company’s warranty will be void The blower rotor is a high-speed rotation unit, when the machine is running, it is forbidden to place any objects (hands, tools, cotton yarn, etc.) near the turbine inlet to prevent them from entering the turbine Diesel main bearing and connecting rod bolt have strict torque and angle requirement, user must not loosen and dismantle them, otherwise the company’s warranty will be void Before each start of the diesel engine, it is necessary to check that the coolant and engine oil are completely filled The connecting rod bolt is a one-time use bolt and cannot be reused 10 Points of attention When this diesel engine is released, it is adjusted in accordance with the test standards, you can not adjust the electronic control system (ECU) at will increase the power of diesel, otherwise our company will not fulfill the three guarantees, we ask consumers to pay Attention to this Upon receipt of a new machine, it is necessary to carry out a break-in within 50 hours After starting the diesel engine, you can slowly increase its rotation speed, you can not suddenly rotate it at a high speed, and you can not idle for a long time After driving with a heavy load, you can not immediately stop the car (except in special cases) After running at low speed without load, the engine should run for to 10 minutes, after which you can stop the machine When the ambient temperature is less than 0º , after stopping the machine, when the machine is not filled with antifreeze, it is necessary to release the coolant from the water tank and diesel engine It is forbidden to work without an air filter to prevent air from entering the pneumatic cylinder without filtering To facilitate starting, the diesel engine can be filled with heated hot lubricating oil and fuel of the appropriate grade Hot fuel cools down after 72 hours It is necessary to determine that the amount of coolant and engine oil filling corresponds to the requirement Inspection and repair of electrical system units may only be carried out by specially trained personnel at our company’s service and repair units of the electronic control system When a diesel engine leaves the company, conservation is carried out to avoid corrosion The total period of diesel conservation is year If the period is more than year, it is necessary to check and take additional measures to protect against corrosion 10 Feedback about the quality of the engine Our company provides quality assurance and compiles an archive of WP-10 series diesel products When using the product, the consumer fills in the card upon request and sends it to our company The card creates a connection with the consumer 11 When servicing, the user must carry out work according to the requirements in the parts book and service manual for WP10 series diesel When purchasing appropriate parts and spare parts, it is necessary to use products specified and approved by the factory in order to ensure their quality, reliability and service life 55 11 Deciphering graphic symbols Dismantle (block) lubricate Collect (block) Special tool e.g S K……KUKKO…… TS……W Mark before disassembly, mark, when reassembling, turn Attention to adjust Reverse Attention to build direction Fill-fill (e.g water, etc.) grease, cooling Release (e.g grease, cooling water, etc.) (Protection against loosening, peeling off) Lubricate with liquid sealant Accident prevention (marking dangerous places) Must be replaced with every assembly Air outlet Loosen (for example: release the clamp) Clamp (for example: clamp a jig) Check-adjust (tightening size, pressure, gap, etc.) torque, check 56