SDLG WP6 User manual

Service Manual for WP6Mechanical Pump Series Engine
Service Manual for WP6 Diesel Engine

Service Manual for WP6 Diesel Engine
Special Tips
Operators must carefully read Diesel Engine Instruction Manual, all technical operations and
maintenance regulations specified in the manual must be strictly complied with, and also pay
attention to warning instructions and labels;
Each diesel engine has passed strict and specified pre-delivery test, accelerator throttle has been
lead sealed, do not casually remove the lead seal to increase throttle;
Turbocharger rotor is high-speed rotating component, it is strictly prohibited to approach the
intake port of turbocharger with any removable object (such as hand, tools, gauze, etc.) when
the engine is running, in order to avoid human body damage or machine damage; For rotor
module, it can only be disassembled by qualified maintenance personnel in professional
maintenance site authorized by Weichai Power;
Various bolts like diesel engine main bearing bolts and connecting rod bolts have strict torque
requirements and limiting use times, users are not allowed to loosen or remove the bolts
casually; connecting rod bolts are disposable bolts, do not reuse them;
The added engine oil or diesel oil, whose brand must complied with requirements specified in
operation and maintenance manual, moreover, all oil must be filtered with specialized clean
filter, fuel must be subsided for more than 72 hours; Before operating the machine each time,
check and make sure coolant level and engine oil level meet the requirements;
Test run a new machine for 50 hours (run-in period) before putting it into operation, replace
engine oil and engine oil filter element after run-in period;
Increase the engine rotating speed slowly after cold starting, neither increase the speed abruptly
or long-term idling is proper; After heavy load running, do not stop the engine immediately
(peculiar circumstance exception), you should run it at low speed for 5~10 minutes before
shutting down;
After parking, if the ambient temperature is likely to be lower than 0oC and there is unused
coolant in the machine, please be sure to drain the coolant in water tank and diesel engine out;
It is forbidden to run the diesel engine without an air filter to prevent unfiltered air entering into
cylinders. Air filter should be enlarged or replaced more frequently when operating in severe
conditions, in order to prevent engine failure, such as premature wear;
Overhaul of electrical components must be carried out by electrical professionals.

Service Manual for WP6 Diesel Engine
Preface
WP6 mechanical pump series diesel engine has the features of compact structure, reliable
service, excellent dynamic property and economic efficiency, rapid start, easy operation and
convenient maintenance. WP can achieve advanced emissions target, definitely an ideal engine for
automobile, construction machinery, agricultural machinery, building machinery and main and
auxiliary equipment of generator set. To help the vast consumers quickly learn and correctly use
WP6 engine, we provide you this service manual.
This manual briefly introduced the technical parameters, structural features, operation and
maintenance methods, and overhaul tips of WP6 mechanical pump series diesel engine, for users to
refer to; provided service technologies of diesel engine to help serviceman profoundly understand
disassembly and assembly methods of the engine, also laid a solid technical foundation for
serviceman to do troubleshooting. Please carefully read this manual to make the best use of it. With
development of product, some structures may be improved, so there might be a slight difference
between technical specifications and graphic descriptions in this manual and the real machine in use,
users should pay attention to the differences despite our company will continuously do the
complements in the successive versions.
SDLG
Technology Department
June 2014

Service Manual for WP6 Diesel Engine
CONTENTS
1Usage Instructions for Diesel Engine.....................................................................1
11 External View of Diesel Engine.............................................................................1
12 Diesel Engine Model Composition and Significance ............................................ 3
13 Diesel Engine Main Technical Parameters ............................................................4
14 Unseal of Diesel engine..........................................................................................5
15 Lifting of Diesel Engine.........................................................................................6
16 Installation of Engine..............................................................................................6
17 Preparation before Starting Engine ........................................................................7
18 Start the Engine ......................................................................................................7
19 Run the Engine .......................................................................................................8
2Maintenance Guidelines for Diesel Engine..........................................................10
21 Fuel Oil, Engine oil, Coolant and Auxiliary Materials........................................10
211 Fuel Oil.........................................................................................................10
212 Engine Oil.....................................................................................................10
213 Lubrication of Tensioning Wheel.................................................................11
214 Antifreeze Additive in Engine Cooling System...........................................11
215 Auxiliary Materials.......................................................................................12
22 Daily Maintenance................................................................................................13
221 Check Coolant Level and Temperature........................................................13
222 Check Engine Oil Level ...............................................................................14
223 Check Fuel Level..........................................................................................15
224 Check “Three Leakages”..............................................................................15
225 Check Fan.....................................................................................................15
226 Check Belt ....................................................................................................15
227 Check Whether Exhaust Gas Color is Normal.............................................15
228 Check Whether Running Sound is Normal..................................................16
229 Check Whether Rotating Speed and Vibration are Normal.........................16
23 Periodic Maintenance...........................................................................................16
24 Maintenance for Long-Term Storage...................................................................21
241 Cleaning........................................................................................................21
242 Protection......................................................................................................21

Service Manual for WP6 Diesel Engine
3Disassembly & Assembly of Diesel Engine.........................................................22
31 Overview...............................................................................................................22
311 Danger Signs.................................................................................................22
312 Safety Signs..................................................................................................23
313 Recommended Tools....................................................................................24
314 Notes for Health Protection..........................................................................24
315 Environmental Protection Measures.............................................................25
316 Notes for Disassembly and Assembly of Engine.........................................25
32 Cylinder Cover Assembly ....................................................................................26
321 Disassembly and Assembly of Cylinder Cover Assembly...........................26
322 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover
Shield............................................................................................................28
323 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover..30
324 Disassembly, Inspection, Maintenance and Assembly of Water Outlet Pipe..
...................................................................................................................34
325 Disassembly, Inspection, Maintenance and Assembly of Oil-Gas Separator..
...................................................................................................................36
326 Disassembly, Inspection, Maintenance and Assembly of Lifting Eyes.......37
33 Engine Block Assembly .......................................................................................39
331 Disassembly, Inspection, Maintenance and Assembly of Engine Block
Assembly ......................................................................................................39
332 Disassembly, Inspection, Maintenance and Assembly of Engine Block
Module..........................................................................................................43
333 Disassembly, Inspection, Maintenance and Assembly of Engine Front Cover
...................................................................................................................45
334 Disassembly, Inspection, Maintenance and Assembly of Flywheel Housing .
...................................................................................................................48
335 Disassembly, Inspection, Maintenance and Assembly of Oil Sump............50
336 Disassembly, Inspection, Maintenance and Assembly of Piston Nozzle.....51
337 Disassembly, Inspection, Maintenance and Assembly of Thrust Plates......52
338 Disassembly, Inspection, Maintenance and Assembly of Front and Rear Oil
Seals..............................................................................................................53
34 Crank-Rod Mechanism.........................................................................................55
341 Disassembly and Assembly of Crank-Rod Mechanism...............................55
342 Disassembly, Inspection, Maintenance and Assembly of Piston-Rod
Assembly ......................................................................................................56
343 Disassembly, Inspection, Maintenance and Assembly of Crankshaft .........59

Service Manual for WP6 Diesel Engine
344 Disassembly, Inspection, Maintenance and Assembly of Flywheel and Ring
Gear...............................................................................................................61
345 Disassembly, Inspection, Maintenance and Assembly of Torque Vibration
Damper, Crankshaft Pulley and Hub............................................................62
346 Disassembly, Inspection, Maintenance and Assembly of Crankshaft Bearing
Shell..............................................................................................................63
35 Valve Mechanism.................................................................................................64
351 Disassembly and Assembly of Valve Mechanism.......................................64
352 Disassembly, Inspection, Maintenance and Assembly of Camshaft ...........65
353 Disassembly, Inspection, Maintenance and Assembly of Rocker and Rocker
Shaft..............................................................................................................67
354 Disassembly, Inspection, Maintenance and Assembly of Valve Tappet and
Pushrod.........................................................................................................69
355 Disassembly, Inspection, Maintenance and Assembly of Valve .................70
36 Intake and Exhaust System...................................................................................72
361 Disassembly and Assembly of Intake and Exhaust System.........................72
362 Disassembly, Inspection, Maintenance and Assembly of Intake Pipe.........73
363 Disassembly, Inspection, Maintenance and Assembly of Exhaust Pipe......74
364 Disassembly, Inspection, Maintenance and Assembly of Turbocharger
System ..........................................................................................................75
37 Fuel System ..........................................................................................................78
371 Disassembly and Assembly of Fuel System ................................................78
372 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump
...................................................................................................................79
373 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel
Pipe...............................................................................................................80
374 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector ......81
375 Disassembly, Inspection, Maintenance and Assembly of Fuel Filters ........81
376 Disassembly, Inspection, Maintenance and Assembly of Low Pressure Fuel
Pipe...............................................................................................................82
38 Cooling System.....................................................................................................84
381 Disassembly and Assembly of Cooling System...........................................84
382 Disassembly, Inspection, Maintenance and Assembly of Fan.....................86
383 Disassembly, Inspection, Maintenance and Assembly of Water Pump.......87
384 Disassembly, Inspection, Maintenance and Assembly of Thermostat.........88
39 Lubricating System...............................................................................................89
391 Disassembly and Assembly of Lubricating System.....................................89

Service Manual for WP6 Diesel Engine
392 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump...
...................................................................................................................90
393 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Filter....
...................................................................................................................91
394 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler..
...................................................................................................................92
395 Disassembly, Inspection, Maintenance and Assembly of Main Oil Gallery
Pressure Limiting Valve...............................................................................93
396 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Strainer
...................................................................................................................94
310 Starting System...................................................................................................95
3101Disassembly, Inspection, Maintenance and Assembly of Starting System.95
311 Engine Accessory System ..................................................................................96
3111 Disassembly and Assembly of Engine Accessory System.........................96
3112 Disassembly, Inspection, Maintenance and Assembly of Generator.........97
3113 Disassembly, Inspection, Maintenance and Assembly of Air Compressor ...
....................................................................................................................103

Service Manual for WP6 Diesel Engine
1
1Usage Instructions for Diesel Engine
11 External View of Diesel Engine
Fig. 1-1 WP6 mechanical pump series diesel engine (View 1)

Service Manual for WP6 Diesel Engine
2
Fig. 1-2 WP6 mechanical pump series diesel engine (View 2)

Service Manual for WP6 Diesel Engine
3
Fig. 1-3 WP6 mechanical pump series diesel engine (View 3)
12 Diesel Engine Model Composition and Significance
WP6 G XXXE2 XX
Variant code
Emission standard
Power code
Use code
Product series code
Fig. 1-4 Diesel Engine Model Composition and Significance

Service Manual for WP6 Diesel Engine
4
13 Diesel Engine Main Technical Parameters
Table 1-1 Main Technical Parameters of first-generation WP6 mechanical pump series diesel
engine
Items
Unit
Type
Engine model
WP6 mechanical pump series diesel engine
125
140
160
175
Engine type
—
4-stroke, water-cooling, in-line, direct injection,
wet-type cylinder sleeve, high speed diesel engine
Intake pattern
—
Turbocharged
Displacement
L
6.75
Cylinder diameter×Stroke
mm
105×130
Number of cylinders
—
6
Number of air valves for each
cylinder
—
2
Compression ratio
—
18:1
Ignition order
—
1-5-3-6-2-4
Fuel injection equipment
—
Mechanical pump
Rated power
kW
92
105
118
129
Rated speed
r/min
2200
2200
2000
2200
Maximum torque
Nm
540
560
640
680
Speed at maximum torque
r/min
1300~1600
Emission standard
—
China stage II
Fuel consumption at rated power
g/kilom
≤250
Minimum fuel consumption under
full load
g/kilom
≤215
Cold start—without aid
oC
-10
Cold start—with aid
oC
-30
Noise at 1m
dB
＜117
B10 service life
km
500,000

Service Manual for WP6 Diesel Engine
5
14 Unseal of Diesel engine
After opened the engine packing container, the user should firstly check the engine and its
accessories according to the packing list, check whether engine appearance is damaged and whether
connections are loose, and then perform the following work:
(1) Wipe up the antirust coat and anticorrosive agent on exposed surface of the engine.
(2) Drain seal fuel in fuel filter and parts of fuel system out (It’s also allowed to start the engine
without draining seal fuel in fuel system, but only can the engine be loaded after all seal fuel
are consumed and normal diesel fuel is supplied in place). The users also need to pay
attention to that storage life for diesel engine before unpacking is one year, for new diesel
engine that has been stored for more than one year should be inspected and taken
additional measures:
Rotate the flywheel and spray solvent into engine intake tube, until all seal fuel in cylinders
is expelled.
Spray solvent into turbocharger intake and exhaust vent, until all seal fuel there is expelled.
According to the service agreement with customer, we are obliged to add specified engine
oil to engine without oil in oil sump; while for engine that has been filled with engine oil
(with running-in accelerant) before being delivered, we suggest you replace the engine oil
after run-in period (2000km or 50h).
According to the service agreement with customer, for engine that has been filled with
coolant before delivery under customer’s requirements, the coolant performance should be
checked after unpacking, if the coolant is subjected to -30oC or -35oC, its PH should be 7~8
(neutral) and hardness value should be 5~15°d[9~15°f (hardness)], otherwise, drain the old
coolant and out and refill coolant with antifreeze additive.
(3) Check whether water blockage and grease blockage are unobstructed, check whether water
temperature sensor and oil temperature sensor are in readiness.
NOTICE: Never start an engine before it is correctly installed and properly connected. When
running the engine in enclosed environment, maintain good ventilation to ensure exhaust gas
emissions into the atmosphere.

Service Manual for WP6 Diesel Engine
6
15 Lifting of Diesel Engine
Keep the center line of engine crankshaft horizontal during lifting, tilting or unilateral lifting is
strictly forbidden. Keep the lifting-up and putting-down process slowly, incorrect lifting may
damage the engine.
Correct Wrong
Fig. 1-5 Lifting of diesel engine
Each engine is installed with two special bolts on cylinder cover for lifting. On hexagonal
head of the bolt, a M14 threaded rod is connected and lifting eye is installed on the rod. We suggest
you apply lifting appliance as shown in left-hand chart of Fig. 1-5, and keep the center line of
engine crankshaft horizontal during lifting. It is inadvisable to lift the engine triangularly with
only one rope (as shown in right-hand chart of Fig. 1-5); because at this point lifting rope and
lifting bolts, lifting eyes are not aligned, it may damage, break the bolt, even damage the
engine. The users should pay special attention to this.
16 Installation of Engine
Flexible coupling should be adopted and ensure the center line of engine crankshaft and input
shaft axis of transmission (transmission box, gearbox or generator) are coaxial. And make sure
crankshaft is no subjected to additional axial force caused by assembly.

Service Manual for WP6 Diesel Engine
7
17 Preparation before Starting Engine
(1) Check coolant level
If the engine is already installed on a vehicle or platform, you can check the coolant level
through the glass window on expansion water tank at any time, if the coolant is insufficient,
open the filler cap to add coolant. When open a filler cap with pressure relief valve and exhaust
button, be sure to press down exhaust button in advance if the engine is in hot state. Avoid
filling plenty of coolant when the engine is hot, otherwise some parts may be damaged due to
sharp temperature reduction. In an extraordinary situation, if there is no coolant in the engine, it
is allowed to add not too cold water slowly until the water overflows. Start the engine, run the
engine at 1000r/min and keep adding coolant until level gets stable, finally close the filler cap.
(2) Check fuel level
If the engine is already installed on a vehicle, turn on power switch, check the fuel level gauge
on instrument panel or check the fuel tank.
(3) Check engine oil level
Engine oil level should between the bottom scale and top scale on oil dipstick, add engine oil
through oil filling port if necessary.
(4) Check whether all accessories are reliably connected to the engine and eliminate abnormal
phenomenon. Check whether start-up system wirings are normal, whether storage battery is
fully charged. And then open fuel tank valve, loosen the air bleeding screw on fuel coarse filter,
deflate the fuel system by using the hand pump on fuel coarse filter.
18 Start the Engine
Adjust diesel engine throttle to suitable position, appropriately increase the throttle when
environment temperature is lower than 5oC, and then press the start button to start the engine. To
prevent damaging the engine, continuous starting time should not exceed 15s, if failed to start the
engine in the first 15s, then restart it 2min later. But if failed three times in a row, you should stop
trying, find out the cause and eliminate it.
After the engine is started, pay attention to all readings of gauges on instrument panel and keep
the engine run idly, at this point engine oil pressure should not lower than 120kPa, idling time
should not be too long.
Use starting aid to start the engine in cold weather. By controlling the relay to put heating
equipment into work, the engine can be successfully started in -30oC environment.

Service Manual for WP6 Diesel Engine
8
19 Run the Engine
After the engine is started, firstly let it run idly for 2~3min, engine oil pressure should higher
than 120kPa. Do not suddenly run the engine in heavy load and high speed if coolant temperature is
lower than 60oC, otherwise it may affect abrasion resistance and reliability of the engine. The load
and speed should be increased gradually, try not to load or unload abruptly.
In run-in period (3000km), the engine is only suitable for moderate duty work and under.
It is allowed to run the engine in rated power and rated speed for normal use, but only no more
than 20min is allowed for overload running (105% rated speed or 110% rated power). Only idling
for 1~2min after unloading can the engine be shut down.
Parameters and check points that should always be noticed during normal use:
(1) Engine oil pressure (300~600kPa) (Idling≥120kPa);
(2) Engine oil temperature (80~105oC);
(3) Coolant outlet temperature (80~90oC);
(4) Turbine rear exhaust temperature≤550oC;
(5) Diesel fuel inlet temperature (40~45oC);
(6) Check the exhaust gas color to determine working quality of injector and load condition, if the
color is serious bad, stop the engine for inspection.
NOTICE: When the engine is in operation, check it for water leakage, air leakage and oil
leakage, and stop the engine immediately for troubleshooting.
Following diesel engine features should be fully aware by operator:
(1) The engine consumes less fuel when output torque is large, and fuel consumption rises as
engine speed increases.
(2) Output torque reaches the best value at intermediate speed range (1200~1600r/min).
(3) Engine output power increases as rotating speed gets faster, and reaches rated power at rated
speed.
NOTICE: To avoid damaging the diesel engine, cable to engine regulator and battery positive
mustn’t be disconnected. Unlike DC generator, it is strictly forbidden to check the voltage of
AC generator by transient grounding.
Notes for running the engine in cold environment:
(1) Fuel oil: Choose different brands of diesel fuel based on ambient temperature.
(2) Engine oil: Choose engine oil of different viscosity according to season.
(3) Coolant: Antifreeze additive is required for cooling system, choose different brands and

Service Manual for WP6 Diesel Engine
9
different proportion based on ambient temperature.
(4) Starting: Use starting aid to start the engine in winter. Load and speed up the engine only after
oil pressure and water temperature get normal.
(5) Storage battery: Be sure to check electrolyte level, viscosity and unit voltage before winter
comes. If the engine needs to be stored in cold weather for long term, be sure to take down the
battery and put it in warm environment.
(6) Stop: For shutting down the engine in cold weather, you should firstly unload it and run it idly
for 1~2min, stop the engine after all temperature drops down. Notice that coolant with
antifreeze additive mustn’t be drained out after stop. For coolant without antifreeze additive, it
must be drained out to prevent frost cracking the engine, open the water drain valve or cap on
engine block, engine oil cooler, radiator and water inlet pipe to drain the coolant out.

Service Manual for WP6 Diesel Engine
10
2Maintenance Guidelines for Diesel Engine
21 Fuel Oil, Engine oil, Coolant and Auxiliary Materials
211 Fuel Oil
Summer: 0# diesel fuel (GB252)
Winter: -10# diesel fuel is generally used, choose -20# diesel fuel if ambient temperature lower than
-15oC, and choose -35# diesel fuel if ambient temperature lower than -30oC.
The chosen fuel should meet requirements in appendix C.6 of GB17691-2005 (Revised in June
2008).
212 Engine Oil
Diesel engine oil capacity: 16L, engine oil capacity is subjected to the marks on oil dipstick (there
might slight differences between different models).
Selection of engine oil: To ensure safety and reliable operation of your diesel engine, please choose
CD grade engine oil. (Weichai dedicated engine oil is recommended, and only choose Weichai
dedicated engine oil for the first replacement). As shown in Fig. 2-1.
Ambient
temperature Multi-grade oil Ambient
temperature
Fig. 2-1 Engine oil brand selection chart
NOTICE: It is allowed to replace low-grade engine oil brand with high-grade one. Replace the
filter along with the engine oil replacement.