Operation and Maintenance Manual forWP10 Series Four-valve Diesel Engine (China IV, V)
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6.Common Faults and Troubleshooting
WP10 series China IV/V diesel engines are designed and manufactured under strict quality management system
and each delivered diesel engine has passed the specified tests. As the diesel engine is of precision machinery, and
the long-term guarantee of its functionality is closely related to the normal maintenances. The causes leading to
earlier failure of diesel engine are generally as follows:
(1) Operation against the regulations, and improper management and use;
(2) Failure to fulfill maintenance as required, or even repair instead of maintenance;
(3) Poorly manufactured parts, especially the counterfeit products procured due to temptation of cheap prices,
which will greatly shorten the service life of diesel engine;
(4) Inappropriate or unqualified fuel and oil are used.
6.1Fault Diagnostic Method
Generally, the common diagnostic methods for diesel engine faults are as follows:
(1) Observation method: Judge the fault situation by observing its features such as exhaust smoke color of diesel
engine (figure 6-1).
(2) Listening diagnosis method: Judge the location, feature and extent of fault by listening the abnormal noise of
diesel engine (figure 6-2).
Figure 6-1 Figure 6-2
(3) Cylinder deactivation method: Generally, cut off the fuel supply to the suspect malfunctioned cylinder, and
compare the working condition of the diesel engine before and after stopping fuel supply to narrow down the
scope for further determination of the fault location or causes.
(4) Comparison method: Replace a certain assembly or component to determine whether there is failure.
Notice:
(1) The cause of diesel engine fault shall be determined carefully. Before the causes are basically found, do not
disassemble the diesel engine at will. Or it will not only eliminate the fault, but also lead to more serious fault due
to improper assembly after disassembly.
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