weichai wp7 Maintenance Manual

Operation & Maintenance Manual and User Service Guide

WP7 Euro Ⅵ Vehicle Diesel Engine

Operation & Maintenance Manual and User

Service Guide

610800820289

Operation & Maintenance Manual and User Service Guide

Foreword

WP7 Euro Ⅵ vehicle diesel engines are developed based on a new design concept and meet the Euro Ⅵ 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 Ⅵ 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 Ⅵ diesel engine, special Euro Ⅵ 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.

Operation & Maintenance Manual and User Service Guide

CONTENTS

WP7 Euro Ⅵ diesel engine outside view 6

The meaning of diesel engine model 7

Diesel Base Parameter 7

Tools and equipments: 8

I. Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engines 1

1 Fuel, lubricating oil, antifreeze and auxiliary material for the diesel engines

1.1 Fuel 1

1.2 Lubricating oil 1

1.3 Antifreeze 2

1.4 Urea Solution 2

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

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

3 Common failures and Troubleshooting 12 II. User Service Guide (warranty card) 21 Weichai Power Product Warranty Card (Kept by user) 21

Service Registration Form (filled by the service staff) 22

Warranty Explanations 23

“Three guarantees” period for diesel engine of Weichai Power 26

Weichai international marketing service network 27

The European Union representative office 28

Diesel engine mandatory maintenance card 30

Customer Satisfaction Questionnaire 33

Operation & Maintenance Manual and User Service Guide

WP7 Euro Ⅵ diesel engine outside view

Operation & Maintenance Manual and User Service Guide

The meaning of diesel engine model

Model

Unit

WP7.270E61

Type

6 cylinder Inline

Intake

TDI

WP 7 . 270 E6 1

transmutation type

emission level

rated power (horsepower)

displacement Weichai Power company

Diesel Base Parameter

the Parameter of WP7 Euro Ⅵ diesel engine

E6 stands for Euro Ⅵ emission

space, no meaning

Operation & Maintenance Manual and User Service Guide

Bore × Journey

mm ×mm

108×136

displaceL7.47

Rated power/ speed

kW/r/min

199/2100

BSFC @rated speed

g/kW·h

205

Max torque/speed

n·m/r/mi

1050/1200~1700

Max speed

r/min

2500±50

Idle speed

r/min

700±50

Fire order

1-5-3-6-2-4

Noise

dB(A)

≤118

weightkg700±20

Life of B10km800,000

Period of oil change

20,000

torque wrench

sleeve wrench

adjusted wrench

depth gauge micrometer

piston ring plier

dial indicator

screwdriver

copper hammer

orientation sleeve

pressure oil spot

filler gauge

diameter gauge micrometer

Tools and equipments:

Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engine

I. Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engines

1 Fuel, 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 Ⅵ 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.

1.2.3 If 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.

Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engine

Table 1-1 Selection of oil grade

Item Grade

JFL-318

JFL-336

JFL-345

Glycol content %

335056

Specific gravity

(15.6℃)

1.05

1.074

1.082

Boiling point ℃

104.5±1

108.5±1

110.0±1

Freezing point ℃

-18±1

-36±1

-45±1

Applicable lowest

temperature ℃

-10

-26

-35

Due to the flat viscosity curve, the multi-grade oil has excellent lubricating characteristics at lower and higher temperatures.

1.3 Antifreeze

1.3.1 The cooling system should be filled with long-lasting antifreeze fro

rust-proofing and antifreezing.

1.3.2 For 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.

1.4 Urea Solution Product Properties for urea solution as per the revised ISO22241 standard. See Table

1-3 for details.

Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engine

Table 1-3 Requirements on Urea solution (Refer to ISO22241)

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 NH

%-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.

1.5.2 At 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.

1.5.3 Professional 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).

1.5.4 Better performance

It features of better wear resistance, TBN retention, anti-rust performance, antioxidation, better fuel consumption control, shear stability and can reduce

Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engine

sediments in the turbocharger.

Item

Special oil

Common oil

Base oil

Adopt the imported class IV hydrocracking basic oil.

Most oils adopt domestic class I base oil, a few adopt class II base oil

Additive

Mainly adopt the imported high-quality composite additive.

Domestic additive

Performance

With targeted professional formulation, the special oil features good lubricating and cleaning performance, and effectively improves the fuel economy (saving fuel by 3~8%) and provides professional protection for the diesel engine even in severe working conditions such as heavy load and dusty environment (heavy load or heavy dust)

Only meet the common lubricating requirements

Oil change interval

At normal use, it can be extended by 3,500~7,000km (for CH-4, 10000km can be extended).

Normal interval

1.5.5 Energy-saving

“Low viscosity + Multi-grade + Friction modifiers”, energy-saving formula, high oil viscosity index, high oil-film strength and elasticity, thus the engine can run stably with low resistance and low fuel consumption.

1.6 Difference between the Weichai Power special oil and common oils

Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engine

1.7 Some Common Products of Weichai Power Special Oils

Type

Oil grade

Viscosity grade

Package capacity

Diesel engine oil

WP-E1(CD)

15W/40 20W/50 10W/30

4L, 18L, 200L

WP-E2(CF-4)

15W/40 20W/50 10W/30

4L, 18L, 200L

WP-E3(CH-4)

5W/30 15W/40 20W/50 10W/30

4L, 18L, 200L

WP-E4(CI-4)

15W/40

4L, 18L

Gear oil of heavy-duty

vehicles

GL-5

85W/90 80W/90

4L, 18L

Type

Special

oil grade

Applicable engine models

High-speed

diesel engines

and

high-power

medium-spee

d diesel engines

WP-E1

(CD)

Medium-speed diesel engine sets

WP-E2

(CF-4)

China I and China II diesel engine; construction machineries such as 50 and 30 loaders; WD618/WD12 series, WD615/WD10 series; 226B and medium-speed engine; 15T or more heavy-duty trucks

WP-E3 (CH-4)

Euro Ⅵ diesel engines; Landing engine series; extra-large heavy-duty trucks and buses; WP4/WP6(165~270HP), WP10(240~375HP), WP12(336~460HP), WD10, WD12 and WP5/WP7(160~300HP)

Natural gas

engine

CNG

Compressed natural gas engine; Coach, generator sets and others equipped with compressed natural gas diesel engines.

1.8 Corresponding table between the Weichai Power special oil and engine models

Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engine

1.9 How to select proper viscosity

Lubricating

oil

SAE Viscosity grade

Applicable ambient

temperature (℃)

5W/30

-30~35

10W/30

-25~35

15W/40

-20~40

20W/50

-15~50

Gear oil

85W/90

-15~49

80W/90

-25~49

85W/140 (viscosity higher than 85W/90)

-15~49

S/N

Name

Color

Usage and Application

Molybdenum

disulfide, oil

solution

Dark

gray

Acting as a lubricant before the lubricating oil pressure is built up. For example: coated on the intake valve stem etc.

Loctite 242

Blue

Coated on the threads and outside surface of bearings to prevent against any potential looseness due to vibration, with medium strength.

Loctite 262

Red

Coated on the outside surface of threads, playing the role of locking, sealing and resistance to looseness due to shock, with high strength.

Loctite 275

Green

Coated on the pipeline and connection portion

Loctite 510

Red

(Orange

)

Coated on the shiny metal surface to function as sealing. For example: the joint faces of the cylinder block and flywheel housing.

Loctite 277

Red

Suitable for sealing the space between core and hole and applied to the oil chamber and oil passage, such as the cylindrical surface of bowl-plug.

(Loctite 648)

Green

Coated on the shining metal surface to function as fixing, such as the inside hole of tensioning bearing and outside surface of the shaft etc.

1.10 Auxiliary materials

The applicable positions are shown in the following table:

Table 1-4 Auxiliary materials for WP7 Euro Ⅵ diesel engines

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