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.
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.
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.
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:..........................................................
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 WP 7 . 270 E6 1 transmutation type emission level E6 stands for Euro Ⅵ emission rated power (horsepower) space, no meaning displacement Weichai Power company Diesel Base Parameter the Parameter of WP7 Euro Ⅵ diesel engine Model Unit WP7.270E61 Type 6 cylinder Inline Intake Bore × Journey TDI mm ×mm 108×136 displace L 7.
Operation & Maintenance Manual and User Service Guide Tools and equipments: 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
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.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine Table 1-1 Selection of oil grade Ambient tempera ture Multigrade oil 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 rustproofing and antifreezing. 1.3.2 For the long-lasting antifreeze formulation, please refer to the instruction of antifreeze.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine Items Urea content Density at 20℃ Refracting index at 20℃ Alkalinity as NH3 Biuret Aldehyde Insolubles Phosphate (PO4) Calcium Iron Copper Zinc Chromium Nickel Aluminium Magnesium Sodium Potassium Unit % by weight kg/m³ % % mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg Min limit 31.8 1,087 1.3814 - Max limit 33.2 1,093 1.3843 0.2 0.3 5 20 0.5 0.5 0.5 0.2 0.2 0.2 0.2 0.5 0.5 0.5 0.5 1.
Operation & Maintenance Manual for WP7 Euro Ⅵ 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 Special oil Common oil class IV Most oils adopt domestic class I base oil, a few adopt class II base oil Base oil Adopt the imported hydrocracking basic oil. Additive Mainly adopt the imported high-quality Domestic additive composite additive.
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 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 GL-5 85W/90 80W/90 4L, 18L Diesel engine oil Gear oil of heavy-duty vehicles 1.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 1.9 How to select proper viscosity SAE Viscosity grade Applicable ambient temperature (℃) 5W/30 -30~35 10W/30 -25~35 15W/40 -20~40 20W/50 -15~50 85W/90 -15~49 80W/90 -25~49 85W/140 (viscosity higher than 85W/90) -15~49 Lubricating oil Gear oil 1.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 2 Regular inspection and maintenance of diesel engine Table 2-1 Working conditions of matched vehicles (WG I) (WG II) Working under severe conditions (extremely cold or hot; dusty; short distance transport; working on construction site and city buses, municipal construction vehicles, snow sweeper vehicles or fire trucks) or annual mileage is less than 20,000 km or annual working hours is less than 600h (WG III) Annual mileage is less
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine Table 2-3 Oil changing interval according to vehicle maintenance specifications (WG I) Item Working condition Annual mileage less than 20,000 km 1st inspection P Having traveled for 1,000-2,000km (WG II) Annual mileage less than 60,000 km Having traveled 1,500-2,000 km (WG III) Annual mileage longer than 60,000 km Having traveled 1,500-2,000 km Every 5000km Every 10,000 km Every 15,000 km WD1 Every 10,000 km Every 20,000 km E
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine Table 2-4 Oil changing intervals determined by oil working condition (changes with the oil consumption) Normal oil working condition (at normal oil consumption) Ambient air temperature: -10℃ to +30℃ Sulfur content of fuel: less than 0.5% (by weight) Severe oil working condition (at normal oil consumption) Tropical or frigid zone (temperature is always A higher than +30℃ or lower than -10℃) B Sulfur content of fuel: 0.5%-1.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine Table 2-5 Maintenance specification of the engine Item 1st inspection Regular inspection Level 1 maintenance Level 2 maintenance Level 3 maintenance Level 4 maintenance Change oil (at least once per year) ● ● ● ● ● ● Replace the oil filter element Inspect and adjust the valve clearance Each time when changing diesel engine oil ● ● ● ● Replace filter element of the fine fuel filter ● ● ● ● Wash coarse fuel filter or
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 1st inspection Item Regular inspection Inspect maintenance indicating light or indicator of air filter Wash the dust cup of air filter (excluding the auto dustremoval type) ● Level 1 maintenance Level 2 maintenance Level 3 maintenance Level 4 maintenance ● ● ● ● ● ● ● ● Wash the air filter main element When the indicator is on Replace the air filter main element Please refer to related regulations in the vehicle instruc
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3 Common failures and Troubleshooting 3.1 The engine fails in starting Causes 1. Fuel pipe is blocked Troubleshooting Check and remove the blockage and check if the fuel is clean Release the air and check air tightness of joints 2. There is air in the fuel system 3. High pressure fuel pipe is damaged Repair it or replace it with a new one and fuel leaks out 4. The ambient temperature is too low Use auxiliary start device 5.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.4 High fuel consumption Causes Troubleshooting 1. Air inlet pipe is blocked (air filter is blocked) Check the air filter and air inlet pipe to ensure smooth air-inlet 2 Check the exhaust pipe and braking valve to ensure smooth exhausting Exhaust back pressure is high 3. Poor fuel quality Replace the fuel as specified 4. Fuel pipe is blocked Check and remove the blockage 5.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.6 White or blue smoke emission Troubleshooting Causes 1. Poor quality fuel that contains too Change the fuel much water Check working temperature of the 2. Coolant water has low temperature thermostat or replace it when necessary 3. Wrong valve timing or injection Check and adjust timing 4. Injector nozzle poor atomization 5. Low compression pressure, incomplete combustion or cylinder scuffing 6.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.7 Unstable speed Causes Troubleshooting 1. Poor quality fuel, containing too Clean the fuel system and replace the fuel much water or wax 2. Air comes into the fuel suction pipe Check the tightness of fuel pipes and the joints; release the air 3. Governor weight and spring do not Check and repair (by specialized operator) work normally 4. Uneven fuel supply Check and adjust (by specialized operator) 5.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.9 High temperature of cooling water Causes Troubleshooting 1. Low water level in water tank Check if there is any leakage and add water 2. The water tank is blocked Check the water tank to clean or repair 3. The water pump belt is loose Tighten the belt as specified 4. Water pump gasket is damaged and Check and repair or replace the pump impeller is worn 5. The thermostat failure Replace 6.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.11 Loud noise Causes Troubleshooting 1. Poor fuel quality Replace the fuel 2. Cooling water has low temperature Check the thermostat or replace it if necessary 3. Wrong valve timing or injection timing Adjust 4. Injector nozzle has poor atomization Check and repair 5. Injection pump injects too much oil Check and operator) 6.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.12 The starter motor does not work Causes Troubleshooting 1. The battery is not fully charged Examine, charge or replace the battery 2. Wires are nor well connected Well connect the wires 3. Fuse is burnt Replace the fuse 4. Electric brush has poor contact Clean the bush surface or replace the bush 5. The motor itself is short circuited Repair the motor or replace the assembly 3.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.15 Unstable generator charging current Troubleshooting Causes 1. The stator or rotor coil is about to open or Repair or replace. short circuit 2. Poor contact of brush Repair 3. The terminal is loosened with poor contact Repair 4. The voltage adjuster is damaged Repair 5. The voltage is improperly adjusted Check and adjust. 3.16 Overcharged generator Causes 1. Internal short circuit of battery Repair or replace 2.
Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engine 3.19 Abnormal indication of the urea solution level Troubleshooting Causes 1. Liquid lever sensor of urea solution-tank is Check and replace failure 3.20 Urea-crystal appear at the nozzle position on the exhaust pipe Causes Troubleshooting 1. Wrong urea solution nozzle mounting size Check and adjust 2.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide II. User Service Guide (warranty card) Weichai Power Product Warranty Card (Kept by user) Item Content Item Model User’s name Order No. Zip code Number: Address Purchasing date Office phone Distributor Home phone Content Respected users: Thank you for using Weichai products, and we appreciate your trust! In order to correctly use and maintain the diesel engine, please carefully read this manual and closely follow the specifications.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Service Registration Form (filled by the service staff) Item Content Item Model User’s name Order No.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Warranty Explanations 1. Service commitment In the service area of our service centers, after receiving the calls for help from the users and confirmed that the service is needed, service personnel of Weichai will arrive at the service site within 3h (cities), 24h (general areas) and 48h (remote areas) (force majeure excluded). 2.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide approval of the leader. (2) Three guarantee period ● For the Weichai’s end products, the three-guarantee service and warranty start from the purchasing date and take the Weichai invoice and warranty card or dealer’s invoice as the basis (the warranty period of marine engine starts from the commissioning date). ● For the engines matching with vehicles, the three-guarantees service and warranty should be implemented in accordance with the agreement.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide “Three guarantees” period. The product model and type on the “Three guarantees” certificate or invoice are not consistent to that claimed to be guaranteed by “Three guarantees”, or the “Three guarantees” certificate or invoice is modified. ● The original state of damage is not kept causing that the reason of fault cannot be identified. ● Failures caused by improper operation. ● Damage caused by force majeure, such as war or natural disaster etc.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide “Three guarantees” period for diesel engine of Weichai Power S/N Product model Three guarantees period Remarks I. Diesel engine 1 Diesel engine for road vehicle 1 year or 60,000km 2 Diesel engine for engineering vehicle 3 Diesel engine for bus Natural gas engine for bus 6 months or 30,000km 1 year or 100,000 km 4 1 year or 100,000 km II.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Weichai international marketing service network Weichai International Marketing Service Network Area CIS Office (country) Russia Mongolia Kazakhstan Tajikistan Uzbekistan Azerbaijan Singapore Indonesia Philippines APAC Malaysia Laos Thailand Myanmar Vietnam South Asia India Bangladesh Pakistan Office (city) No.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Weichai International Marketing Service Network Area Middle East Europe and North Africa Office (country) Office (city) Iran Tehran United Arab Emirates Dubai Saudi Arabia Riyadh Algeria Algiers Libya Turkey Istanbul Kenya Mombasa East Africa Tanzania Ethiopia the Sudan South Africa South Africa West Africa Angola Nigeria 59 60 Service in charge Luan Song Weihua Wang Dong Chen Yun Wang Sui Zhen Shi Hongbo Yu Chunbo Huo Chunlei Meng
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide The European Union representative office office address: Societe international des Moteurs Baudouin CS50001 FR-13711 Cassis France Linkman: Zhang Guoping (Paul. Zhang) Mobile(in China): 008618953658085 Email: zhanggp@weichai.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Diesel engine mandatory maintenance card Manufacturer User’s name Diesel engine No.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Diesel engine mandatory maintenance card Manufacturer User’s name Diesel engine No.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Diesel engine mandatory maintenance card Manufacturer User’s name Diesel engine No.
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide Customer Satisfaction Questionnaire Item Diesel engine product quality Evaluation factor Excellent Good Acceptable Bad Not acceptable Appearance Performance Reliability Engine completeness Diesel engine delivery quality Attached spare parts and tools Attached documents engine Delivery time Diesel engine service quality Service promptness Service quality Service attitude Customer cancellation Return of products Others Additional transportatio