WEICHAI WP7 Euro VI Installation guide

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 ⅥVehicle Diesel Engines..1
1 Fuel, lubricating oil, antifreeze and auxiliary material for the diesel engines
..........................................................................................................1
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
2Regular inspection and maintenance of diesel engine...............................7
3Common 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 ......................................................................... 29
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
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
TDI
Bore ×Journey
mm ×mm
108×136
displace
L
7.47
Rated power/ speed
kW/r/min
199/2100
BSFC @rated speed
g/kW∙h
205
Max torque/speed
n∙m/r/min
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
weight
kg
700±20
Life of B10
km
800,000
Period of oil change
km
20,000

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
1
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 Ⅵseries 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
2
Table 1-1 Selection of oil grade
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.
Item Grade
JFL-318
JFL-336
JFL-345
Glycol content %
33
50
56
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
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)
Ambient
tempera
ture
Multi-
grade oil

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
3
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.
1.5.2 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
sediments in the turbocharger.
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

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
4
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
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

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
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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
1.8 Corresponding table between the Weichai Power special oil and engine
models
Type
Special oil
grade
Applicable engine models
High-
speed
diesel
engines
and high-
power
medium-
speed
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 Ⅵdiesel 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.

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
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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
1.10 Auxiliary materials
The applicable positions are shown in the following table:
Table 1-4 Auxiliary materials for WP7 Euro Ⅵdiesel engines
S/N
Name
Color
Usage and Application
1
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.
2
Loctite 242
Blue
Coated on the threads and outside surface of
bearings to prevent against any potential looseness
due to vibration, with medium strength.
3
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.
4
Loctite 275
Green
Coated on the pipeline and connection portion
5
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.
6
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.
7
(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.

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
7
2 Regular inspection and maintenance of diesel engine
Table 2-1 Working conditions of matched vehicles
(WG I)
(WG II)
(WG III)
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
Annual mileage is less
than 60,000 km; short
or medium distance
transport (goods
transport)
Annual mileage is longer
than 60,000 km; long
distance transport
Table 2-2 Intervals for 1st inspection, regular inspection and maintenance
Working
condition
Item
(WG I)
(WG II)
(WG III)
1st inspection
Having traveled
1,000-1,500km or
having worked for
30-50h
Having traveled
1,500-2,000 km
Having traveled
1,500-2,000 km
Regular
inspection
Every5,000km or
every150h
Every 10,000 km
Every 15,000 km
Grade 1
maintenance
Every 10,000 km
or every300h
Every 20,000 km
Every 30,000 km
Grade 2
maintenance
Every 20,000 km
or every 600h
Every 40,000 km
Every 60,000 km
Grade 3
maintenance
Every 40,000 km
or every1,200h
Every 80,000 km
Every 120,000 km
Grade 4
maintenance
Every 80,000 km
or every2,400h
Every 160,000 km
Every 240,000 km

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
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Table 2-3 Oil changing interval according to vehicle maintenance specifications
Working
condition
Item
(WG I)
(WG II)
(WG III)
Annual mileage less
than 20,000 km
Annual mileage
less than 60,000
km
Annual mileage
longer than 60,000
km
1st inspection
Having traveled for
1,000-2,000km
Having traveled
1,500-2,000 km
Having traveled
1,500-2,000 km
P
Every 5000km
Every 10,000 km
Every 15,000 km
WD1
Every 10,000 km
Every 20,000 km
Every 30,000 km
WD2
Every 20,000 km
Every 40,000 km
Every 60,000 km
WD3
Every 40,000 km
Every 80,000 km
Every 120,000 km
WD4
Every 80,000 km
Every 160,000 km
Every 240,000 km

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
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Table 2-4 Oil changing intervals determined by oil working condition (changes with
the oil consumption)
Normal oil working condition (at normal oil
consumption)
Severe oil working condition
(at normal oil consumption)
Ambient air temperature: -10℃to +30℃
Sulfur content of fuel: less than 0.5%
(by weight)
A
Tropical or frigid zone
(temperature is always
higher than +30℃or
lower than -10℃)
B
Sulfur content of fuel:
0.5%-1.0%
C
Sulfur content of fuel:
1.0%-1.5%
Oil working condition
Working condition
Normal condition
WG I
WG II
WG III
Every 5,000 km
Every 10,000 km
Every 15,000 km
Severe condition A
WG I
WG II
WG III
Every 5,000 km
Every 5,000 km
Every 5,000 km
Severe condition B
WG I
WG II
WG III
Every 5,000 km
Every 5,000 km
Every 10,000 km
Severe condition C
WG I
WG II
WG III
Every 5,000 km
Every 5,000 km
Every 5,000 km
Severe condition A+B
WG I
WG II
WG III
Every 5,000 km
Every 5,000 km
Every 5,000 km
Severe condition A+C
WG I
WG II
WG III
Every 2,500 km
Every 2,500 km
Every 2,500 km

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
10
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
Each time when changing diesel engine oil
Inspect and
adjust the
valve
clearance
●
●
●
●
●
Replace filter
element of
the fine fuel
filter
●
●
●
●
Wash
coarse fuel
filter or
replace the
element
●
●
●
●
Inspect
coolant
amount and
add to
required
amount
●
●
●
●
●
●
Change the
coolant
Once a year
Tighten clips
on cooling
pipe
●
Tighten air
inlet pipe,
hose and
flange
connections
●
●
●
●
●

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
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Item
1st
inspection
Regular
inspection
Level 1
maintenance
Level 2
maintenance
Level 3
maintenance
Level 4
maintenance
Inspect
maintenance
indicating
light or
indicator of
air filter
●
●
●
●
Wash the dust
cup of air
filter
(excluding
the auto dust-
removal type)
●
●
●
●
●
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 instruction manual
Replace the
air filter
safety
element
After the main element has been washed for 5 times
Inspect and
tighten the
belt
●
●
●
●
●
●
Inspect the
clearance of
turbocharger
bearings
●
Note: ●indicates that maintenance is required.
Engine shut down and stored for more than 6 months shall be maintained as
required. Suggestion or advice will be given based on the user’s requirements.

Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
12
3 Common failures and Troubleshooting
3.1 The engine fails in starting
Causes
Troubleshooting
1. Fuel pipe is blocked
Check and remove the blockage and check if the
fuel is clean
2. There is air in the fuel system
Release the air and check air tightness of joints
3. High pressure fuel pipe is damaged
and fuel leaks out
Repair it or replace it with a new one
4. The ambient temperature is too low
Use auxiliary start device
5. There is few fuel or no fuel left in
the tank
Check and refuel
3.2 The engine stops soon after starting
Causes
Troubleshooting
1. Fuel filter is blocked
Disassemble the filter to clean and dry the inside;
or replace it if necessary
2. There is air in the fuel system
Check the tightness of fuel pipes and the joints;
check if the bleed screw is tightened; release the
air
3. Fuel is of poor quality, containing
too much water
Wash the filter and use high quality fuel
3.3 Engine Power is insufficient
Causes
Troubleshooting
1. Air inlet pipe is blocked (air filter
is blocked)
Check and clean the air filter and air inlet pipe or
replace the element
2. Exhaust back pressure is high
Check if the exhaust pipe is blocked
3. The pressure of turbocharging
system is insufficient
Check and remove any leakage with the exhaust
pipe
4. Fuel pipe leaks or is blocked
Check the tightness of fuel pipes and the joints;
check the fuel pipes and check ifthe filter is dirty;
Repair or remove any blockage; replace the filter
element
5. Poor fuel quality
Wash the fuel tank, filter parts and fuel pipes;
replace the fuel
6. High oil level
Release the extra lubricating oil