Operation & Maintenance Manual and User Service Guide
WP7 Euro Vehicle Diesel Engine
Operation & Maintenance Manual and User
Service Guide
610800820289
Operation & Maintenance Manual and User Service Guide
Foreword
WP7 Euro vehicle diesel engines are developed based on a new design concept and meet the Euro emission standard. WP7 diesel engines feature compact structure, reliable operation, high economy indexes and power performance, quick startup, easy operation and convenient maintenance and are the ideal power for the middle/heavy-duty trucks and middle/large buses.
This manual, as reference, describes methods of operation and maintenance, inspection essentials and service guide for WP7 diesel engines.
To make best use of WP7 diesel engines, users are expected to carefully read and learn the diesel engine structure, maintenance and operation methods. The diesel engine service life can be significantly prolonged if the users can follow this manual during maintenance.
With the increasing numbers and improving of the variants of WP7 vehicle diesel engines, users are expected to timely pay attention to the technical information released by Weichai. Any revision will not be notified in advance. For more information about new products, please visit http://en.weichai.com.
March. 2014
Operation & Maintenance Manual and User Service Guide
Special instructions
1)It is very dangerous to increase the power by modifying the ECU data. Any change of ECU data without permit will lead to invalid “Three guarantees” and so on, and all losses and the legal responsibilities arising therefore would be borne by the users.
2)Common-rail fuel pump, turbocharger, urea solution injection system and other components, as the precision parts, should not be impacted or dismantled without permission; otherwise the "Three guarantees" will be invalid.
3)Please use Weichai designated fuel strainer and fine filter; otherwise any damage to the common-rail system will not be covered by the “Three guarantees”.
4)For Euro Diesel Engine, in order to make sure the normal operation of the SCR processor, please add urea solution produced by formal manufactures timely. It is forbidden to use urea solution mixed privately or other solutions, otherwise, all losses and the legal responsibilities arising therefrom would be borne by the users.
5)Please go to the formal fuel station to refill the stipulated fuel, otherwise any damage to the fuel system due to fuel quality will not be covered by the “Three guarantees”.
6)For Euro diesel engine, special Euro diesel fuel should be used, otherwise any problems arising therefrom, such as the emissions exceeded the limits of standard, should be borne by the users.
7)Any service such as repair or maintenance should be done at the designated service station and spare parts specified by Weichai Power should be used; otherwise, any damage to the diesel engines should be borne by the users.
8)The product norm follows Q/WCG 100.
Operation & Maintenance Manual and User Service Guide
Notice
1.Before the first use, the engine should go through a 50h trial run. For more information, refer to the running-in requirements.
2.After the cold start, the engine should slowly increase the speed. Don’t let the engine run at idle speed for a long time or suddenly speed up. After running with heavy load, do not immediately stop. It is necessary to idle for 5-10 min at low speed.
3.It is prohibited to work without air filters which could prevent air from entering the cylinder without being filtrated. The air filter should be regularly maintained or replaced, otherwise power reduction, parts wearing and other problems would happen.
4.Please select specified grades of fuel and oil and use the special and clean containers. The fuel and oil should be filtrated with the strainer before being added.
5.If the diesel engine fails to start within 15s, repeat after at least 2 min.
6.It is prohibited to fill the diesel engine with water rather than antifreeze, which could greatly reduce the engine life and leads to damage of the after-treatment system and other parts.
7.Before the start, please ensure the antifreeze, urea solution and oil are at the proper levels.
8.The strainer of urea solution tank must be cleaned regularly, otherwise the OBD system will giving alarm.
9.When the vehicle is parked for a long time and the ambient temperature is lower than the freezing point of antifreeze, it is necessary to drain the water out through the discharge valve of the air compressor.
10.It is not allowed to reuse the cylinder head gasket and all kinds of asbestos or metal coated sheet gaskets.
11.Feedback of engine quality information
Our company performs the quality-trace filing for WP7 diesel engines, therefore users are expected to fill the card and send it back to our company for further service based on the card.
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Operation & Maintenance Manual and User Service Guide |
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CONTENTS |
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WP7 Euro diesel engine outside view ........................................................................... |
6 |
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The meaning of diesel engine model .................................................................................... |
7 |
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Diesel Base Parameter.......................................................................................................... |
7 |
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Tools and equipments:.......................................................................................................... |
8 |
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I. Operation & Maintenance Manual for WP7 Euro Vehicle Diesel Engines.. |
1 |
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1 Fuel, lubricating oil, antifreeze and auxiliary material for the diesel engines |
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1 |
1.1 ............................................................................................................................ |
Fuel |
1 |
1.2 ........................................................................................................... |
Lubricating oil |
1 |
1.3 .................................................................................................................. |
Antifreeze |
2 |
1.4 Urea ..................................................................................................................Solution |
2 |
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1.5 ....................................................................... |
Features of Weichai Power special oil |
3 |
1.6 ....................... |
Difference between the Weichai Power special oil and common oils |
4 |
1.7 Some ..............................................Common Products of Weichai Power Special Oils |
5 |
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1.8 ..... |
Corresponding table between the Weichai Power special oil and engine models |
5 |
1.9 ................................................................................... |
How to select proper viscosity |
6 |
1.10 .................................................................................................... |
Auxiliary materials |
6 |
2 Regular ...............................inspection and maintenance of diesel engine |
7 |
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3 Common .................................................failures and Troubleshooting |
12 |
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II. User Service ..............................................................Guide (warranty card) |
21 |
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Weichai .......................................Power Product Warranty Card (Kept by user) |
21 |
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Service ..................................Registration Form (filled by the service staff) |
22 |
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Warranty .............................................................................Explanations |
23 |
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“Three .....................guarantees” period for diesel engine of Weichai Power |
26 |
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Weichai .........................................international marketing service network |
27 |
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The .........................................................................European Union representative office |
29 |
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Diesel .................................................engine mandatory maintenance card |
30 |
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Customer ..........................................................Satisfaction Questionnaire |
33 |
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Operation & Maintenance Manual and User Service Guide
WP7 Euro diesel engine outside view
Operation & Maintenance Manual and User Service Guide
The meaning of diesel engine model
WP 7 . 270 E6 1
transmutation type
emission level
E6 stands for Euro emission rated power (horsepower) space, no meaning displacement
Weichai Power company
Diesel Base Parameter
the Parameter of WP7 Euro diesel engine
Model |
Unit |
WP7.270E61 |
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Type |
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6 cylinder Inline |
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Intake |
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TDI |
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Bore × Journey |
mm ×mm |
108×136 |
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displace |
L |
7.47 |
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Rated power/ speed |
kW/r/min |
199/2100 |
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BSFC @rated speed |
g/kW∙h |
205 |
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Max torque/speed |
n∙m/r/min |
1050/1200~1700 |
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Max speed |
r/min |
2500±50 |
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Idle speed |
r/min |
700±50 |
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Fire order |
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1-5-3-6-2-4 |
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Noise |
dB(A) |
≤118 |
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weight |
kg |
700±20 |
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Life of B10 |
km |
800,000 |
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Period of oil change |
km |
20,000 |
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Operation & Maintenance Manual and User Service Guide
Tools and equipments:
torque wrench |
sleeve wrench |
adjusted wrench |
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depth gauge micrometer |
piston ring plier |
dial indicator |
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screwdriver |
copper hammer |
orientation sleeve |
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pressure oil spot |
filler gauge |
diameter gauge micrometer |
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Operation & Maintenance Manual for WP7 Euro
Vehicle Diesel Engine
I.Operation & Maintenance Manual for WP7 Euro
Vehicle Diesel Engines
1Fuel, lubricating oil, antifreeze and auxiliary material for the diesel engines
1.1 Fuel
Summer: use the #0 diesel fuel.
Winter: use the #-10 diesel fuel under general conditions, use the #-20 diesel fuel when the atmospheric temperature is below -15 and #-35 diesel fuel when below -30 .
The fuel to be filled should meet the standard in appendix C.6 of national standard GB 17691-2005.
1.2 Lubricating oil
1.2.1 For WP7 Euro series diesel engines, use oil with higher grade than CI-4 or CJ-4.
1.2.2. It is allowed to use the oil of higher grade instead of oil of lower grade.
1.2.3If the ambient temperature is -15 or higher, use the 15W/40 oil; if the ambient temperature is -15 or lower, use the 5W/20 oil.
(Weichai Power special oil should be used, see sections from 1.5 to1.8) Before the startup of diesel engine, check the oil level in the oil sump.
1. Do not check the oil level during operation.
2. It is not allowed to mix the oils of different grades.
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Operation & Maintenance Manual for WP7 Euro
Vehicle Diesel Engine
Table 1-1 Selection of oil grade
Ambient |
Multi- |
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Due to the flat viscosity curve, the multi-grade oil has excellent lubricating characteristics at lower and higher temperatures.
1.3 Antifreeze
1.3.1The cooling system should be filled with long-lasting antifreeze fro rustproofing and antifreezing.
1.3.2For the long-lasting antifreeze formulation, please refer to the instruction of antifreeze. Some domestic long-lasting antifreezes are shown in Table 1-2.
Table 1-2 Domestic long-lasting antifreeze.
Item |
Grade |
JFL-318 |
JFL-336 |
JFL-345 |
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Glycol content % |
33 |
50 |
56 |
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Specific gravity |
1.05 |
1.074 |
1.082 |
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(15.6 ) |
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Boiling point |
104.5±1 |
108.5±1 |
110.0±1 |
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Freezing point |
-18±1 |
-36±1 |
-45±1 |
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Applicable lowest |
-10 |
-26 |
-35 |
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temperature |
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1.4 Urea Solution
Product Properties for urea solution as per the revised ISO22241 standard. See Table 1-3 for details.
Table 1-3 Requirements on Urea solution (Refer to ISO22241)
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Operation & Maintenance Manual for WP7 Euro
Vehicle Diesel Engine
Items |
Unit |
Min limit |
Max limit |
Urea content |
% by weight |
31.8 |
33.2 |
Density at 20 |
kg/m³ |
1,087 |
1,093 |
Refracting index at 20 |
- |
1.3814 |
1.3843 |
Alkalinity as NH3 |
% |
- |
0.2 |
Biuret |
% |
- |
0.3 |
Aldehyde |
mg/kg |
- |
5 |
Insolubles |
mg/kg |
- |
20 |
Phosphate (PO4) |
mg/kg |
- |
0.5 |
Calcium |
mg/kg |
- |
0.5 |
Iron |
mg/kg |
- |
0.5 |
Copper |
mg/kg |
- |
0.2 |
Zinc |
mg/kg |
- |
0.2 |
Chromium |
mg/kg |
- |
0.2 |
Nickel |
mg/kg |
- |
0.2 |
Aluminium |
mg/kg |
- |
0.5 |
Magnesium |
mg/kg |
- |
0.5 |
Sodium |
mg/kg |
- |
0.5 |
Potassium |
mg/kg |
- |
0.5 |
1.5 Features of Weichai Power special oil 1.5.1 High-qualified lubricating oil
Adopt fine imported hydrocracking base oil and composite additives to ensure the high quality of lubricating oil.
1.5.2At normal use, the oil-change interval can be increased by 3,500~7,000km (10,000km for CH-4); excellent oxidation resistance at high temperature and excellent TBN retention will also prolong the engine life.
1.5.3Professional protection to extend the engine life
Through a lot of performance and durability tests on Weichai diesel engines, a professional oil formula suitable for high power and high load engines is worked out. The special oil can provide the Weichai engine with special protection and can significantly prolong their service life (by 30~40% in contrast with others).
1.5.4Better performance
It features of better wear resistance, TBN retention, anti-rust performance, antioxidation, better fuel consumption control, shear stability and can reduce sediments in the turbocharger.
1.5.5Energy-saving
“Low viscosity + Multi-grade + Friction modifiers”, energy-saving formula, high oil viscosity index, high oil-film strength and elasticity, thus the engine
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Operation & Maintenance Manual for WP7 Euro
Vehicle Diesel Engine
can run stably with low resistance and low fuel consumption. 1.6 Difference between the Weichai Power special oil and common oils
Item |
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Special oil |
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Common oil |
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Adopt the imported class IV |
Most oils adopt domestic |
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Base oil |
class I base oil, a few |
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hydrocracking basic oil. |
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adopt class II base oil |
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Additive |
Mainly adopt the imported high-quality |
Domestic additive |
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composite additive. |
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With targeted professional formulation, |
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the special oil features good lubricating |
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and |
cleaning |
performance, |
and |
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effectively improves the fuel economy |
Only meet the common |
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Performance |
(saving fuel by 3~8%) and provides |
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professional protection for the diesel |
lubricating requirements |
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engine even in severe working |
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conditions such as heavy load and dusty |
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environment (heavy load or heavy dust) |
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Oil change |
At normal use, it can be extended by |
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3,500~7,000km |
(for CH-4, 10000km |
Normal interval |
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interval |
can be extended). |
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4
Operation & Maintenance Manual for WP7 Euro
Vehicle Diesel Engine
1.7 Some Common Products of Weichai Power Special Oils
Type |
Oil grade |
Viscosity grade |
Package capacity |
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15W/40 |
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WP-E1(CD) |
20W/50 |
4L, 18L, 200L |
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10W/30 |
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15W/40 |
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WP-E2(CF-4) |
20W/50 |
4L, 18L, 200L |
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Diesel engine oil |
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10W/30 |
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5W/30 |
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WP-E3(CH-4) |
15W/40 |
4L, 18L, 200L |
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20W/50 |
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10W/30 |
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WP-E4(CI-4) |
15W/40 |
4L, 18L |
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Gear oil of heavy-duty |
GL-5 |
85W/90 |
4L, 18L |
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vehicles |
80W/90 |
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1.8Corresponding table between the Weichai Power special oil and engine models
Type |
Special oil |
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Applicable engine models |
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grade |
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WP-E1 |
Medium-speed diesel engine sets |
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High- |
(CD) |
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speed |
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China |
I and China |
II diesel engine; |
construction |
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diesel |
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WP-E2 |
machineries such as 50 and 30 loaders; WD618/WD12 |
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engines |
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(CF-4) |
series, |
WD615/WD10 |
series; 226B and medium-speed |
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and high- |
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engine; 15T or more heavy-duty trucks |
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power |
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Euro diesel engines; Landing engine series; extra- |
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medium- |
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speed |
WP-E3 |
large heavy-duty trucks and buses; |
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diesel |
WP4/WP6(165~270HP), WP10(240~375HP), |
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(CH-4) |
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engines |
WP12(336~460HP), WD10, WD12 and |
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WP5/WP7(160~300HP) |
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Natural |
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Compressed natural gas engine; Coach, generator sets and |
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CNG |
others |
equipped with |
compressed natural |
gas diesel |
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gas engine |
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engines. |
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