Service Manual For WP6 Diesel Engine
Service Manual for WP6 Mechanical Pump Series EngineService Manual for WP6 Diesel Engine
Service Manual for WP6 Diesel EngineSpecial Tips Operators must carefully read Diesel Engine Instruction Manual, all technical operations andmaintenance regulations specified in the manual must be strictly complied with, and also payattention to warning instructions and labels; Each diesel engine has passed strict and specified pre-delivery test, accelerator throttle has beenlead sealed, do not casually remove the lead seal to increase throttle; Turbocharger rotor is high-speed rotating component, it is strictly prohibited to approach theintake port of turbocharger with any removable object (such as hand, tools, gauze, etc.) whenthe engine is running, in order to avoid human body damage or machine damage; For rotormodule, it can only be disassembled by qualified maintenance personnel in professionalmaintenance site authorized by Weichai Power; Various bolts like diesel engine main bearing bolts and connecting rod bolts have strict torquerequirements and limiting use times, users are not allowed to loosen or remove the boltscasually; connecting rod bolts are disposable bolts, do not reuse them; The added engine oil or diesel oil, whose brand must complied with requirements specified inoperation and maintenance manual, moreover, all oil must be filtered with specialized cleanfilter, 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, replaceengine oil and engine oil filter element after run-in period; Increase the engine rotating speed slowly after cold starting, neither increase the speed abruptlyor 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 beforeshutting down; After parking, if the ambient temperature is likely to be lower than 0oC and there is unusedcoolant 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 intocylinders. Air filter should be enlarged or replaced more frequently when operating in severeconditions, 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 EnginePrefaceWP6 mechanical pump series diesel engine has the features of compact structure, reliableservice, excellent dynamic property and economic efficiency, rapid start, easy operation andconvenient maintenance. WP can achieve advanced emissions target, definitely an ideal engine forautomobile, construction machinery, agricultural machinery, building machinery and main andauxiliary equipment of generator set. To help the vast consumers quickly learn and correctly useWP6 engine, we provide you this service manual.This manual briefly introduced the technical parameters, structural features, operation andmaintenance methods, and overhaul tips of WP6 mechanical pump series diesel engine, for users torefer to; provided service technologies of diesel engine to help serviceman profoundly understanddisassembly and assembly methods of the engine, also laid a solid technical foundation forserviceman to do troubleshooting. Please carefully read this manual to make the best use of it. Withdevelopment of product, some structures may be improved, so there might be a slight differencebetween 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 thecomplements in the successive versions.SDLGTechnology DepartmentJune 2014
Service Manual for WP6 Diesel EngineCONTENTS1 Usage Instructions for Diesel Engine . 111 External View of Diesel Engine . 112 Diesel Engine Model Composition and Significance . 313 Diesel Engine Main Technical Parameters . 414 Unseal of Diesel engine . 515 Lifting of Diesel Engine . 616 Installation of Engine. 617 Preparation before Starting Engine . 718 Start the Engine . 719 Run the Engine . 82 Maintenance Guidelines for Diesel Engine . 1021 Fuel Oil, Engine oil, Coolant and Auxiliary Materials . 10211 Fuel Oil . 10212 Engine Oil . 10213 Lubrication of Tensioning Wheel. 11214 Antifreeze Additive in Engine Cooling System . 11215 Auxiliary Materials . 1222 Daily Maintenance . 13221 Check Coolant Level and Temperature . 13222 Check Engine Oil Level . 14223 Check Fuel Level . 15224 Check “Three Leakages” . 15225 Check Fan . 15226 Check Belt . 15227 Check Whether Exhaust Gas Color is Normal . 15228 Check Whether Running Sound is Normal . 16229 Check Whether Rotating Speed and Vibration are Normal . 1623 Periodic Maintenance . 1624 Maintenance for Long-Term Storage . 21241 Cleaning . 21242 Protection . 21
Service Manual for WP6 Diesel Engine3 Disassembly & Assembly of Diesel Engine . 2231 Overview. 22311 Danger Signs . 22312 Safety Signs . 23313 Recommended Tools . 24314 Notes for Health Protection . 24315 Environmental Protection Measures. 25316 Notes for Disassembly and Assembly of Engine . 2532 Cylinder Cover Assembly . 26321 Disassembly and Assembly of Cylinder Cover Assembly . 26322 Disassembly, Inspection, Maintenance and Assembly of Cylinder CoverShield . 28323 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover . 30324 Disassembly, Inspection, Maintenance and Assembly of Water Outlet Pipe . 34325 Disassembly, Inspection, Maintenance and Assembly of Oil-Gas Separator . 36326 Disassembly, Inspection, Maintenance and Assembly of Lifting Eyes . 3733 Engine Block Assembly . 39331 Disassembly, Inspection, Maintenance and Assembly of Engine BlockAssembly . 39332 Disassembly, Inspection, Maintenance and Assembly of Engine BlockModule . 43333 Disassembly, Inspection, Maintenance and Assembly of Engine Front Cover. 45334 Disassembly, Inspection, Maintenance and Assembly of Flywheel Housing . 48335 Disassembly, Inspection, Maintenance and Assembly of Oil Sump. 50336 Disassembly, Inspection, Maintenance and Assembly of Piston Nozzle . 51337 Disassembly, Inspection, Maintenance and Assembly of Thrust Plates . 52338 Disassembly, Inspection, Maintenance and Assembly of Front and Rear OilSeals . 5334 Crank-Rod Mechanism . 55341 Disassembly and Assembly of Crank-Rod Mechanism . 55342 Disassembly, Inspection, Maintenance and Assembly of Piston-RodAssembly . 56343 Disassembly, Inspection, Maintenance and Assembly of Crankshaft . 59
Service Manual for WP6 Diesel Engine344 Disassembly, Inspection, Maintenance and Assembly of Flywheel and RingGear. 61345 Disassembly, Inspection, Maintenance and Assembly of Torque VibrationDamper, Crankshaft Pulley and Hub . 62346 Disassembly, Inspection, Maintenance and Assembly of Crankshaft BearingShell . 6335 Valve Mechanism . 64351 Disassembly and Assembly of Valve Mechanism . 64352 Disassembly, Inspection, Maintenance and Assembly of Camshaft . 65353 Disassembly, Inspection, Maintenance and Assembly of Rocker and RockerShaft . 67354 Disassembly, Inspection, Maintenance and Assembly of Valve Tappet andPushrod . 69355 Disassembly, Inspection, Maintenance and Assembly of Valve . 7036 Intake and Exhaust System . 72361 Disassembly and Assembly of Intake and Exhaust System . 72362 Disassembly, Inspection, Maintenance and Assembly of Intake Pipe . 73363 Disassembly, Inspection, Maintenance and Assembly of Exhaust Pipe . 74364 Disassembly, Inspection, Maintenance and Assembly of TurbochargerSystem . 7537 Fuel System . 78371 Disassembly and Assembly of Fuel System . 78372 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump. 79373 Disassembly, Inspection, Maintenance and Assembly of High Pressure FuelPipe . 80374 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector . 81375 Disassembly, Inspection, Maintenance and Assembly of Fuel Filters . 81376 Disassembly, Inspection, Maintenance and Assembly of Low Pressure FuelPipe . 8238 Cooling System. 84381 Disassembly and Assembly of Cooling System . 84382 Disassembly, Inspection, Maintenance and Assembly of Fan . 86383 Disassembly, Inspection, Maintenance and Assembly of Water Pump . 87384 Disassembly, Inspection, Maintenance and Assembly of Thermostat. 8839 Lubricating System . 89391 Disassembly and Assembly of Lubricating System . 89
Service Manual for WP6 Diesel Engine392 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump . 90393 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Filter . 91394 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler . 92395 Disassembly, Inspection, Maintenance and Assembly of Main Oil GalleryPressure Limiting Valve . 93396 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Strainer. 94310 Starting System . 953101Disassembly, Inspection, Maintenance and Assembly of Starting System. 95311 Engine Accessory System . 963111 Disassembly and Assembly of Engine Accessory System . 963112 Disassembly, Inspection, Maintenance and Assembly of Generator . 973113 Disassembly, Inspection, Maintenance and Assembly of Air Compressor . 103
Service Manual for WP6 Diesel Engine1 Usage Instructions for Diesel Engine11 External View of Diesel EngineFig. 1-1 WP6 mechanical pump series diesel engine (View 1)1
Service Manual for WP6 Diesel EngineFig. 1-2 WP6 mechanical pump series diesel engine (View 2)2
Service Manual for WP6 Diesel EngineFig. 1-3 WP6 mechanical pump series diesel engine (View 3)12 Diesel Engine Model Composition and SignificanceWP6 G XXX E2 XXVariant codeEmission standardPower codeUse codeProduct series codeFig. 1-4 Diesel Engine Model Composition and Significance3
Service Manual for WP6 Diesel Engine13 Diesel Engine Main Technical ParametersTable 1-1 Main Technical Parameters of first-generation WP6 mechanical pump series dieselengineItemsUnitTypeWP6 mechanical pump series diesel engineEngine model125140160175Engine type—4-stroke, water-cooling, in-line, direct injection,wet-type cylinder sleeve, high speed diesel engineIntake pattern—TurbochargedDisplacementL6.75Cylinder diameter Strokemm105 130Number of cylinders—6Number of air valves for eachcylinder—2Compression ratio—18:1Ignition order—1-5-3-6-2-4Fuel injection equipment—Mechanical pumpRated powerkW92105118129Rated speedr/min2200220020002200Maximum torqueNm540560640680Speed at maximum torquer/min1300 1600Emission standard—China stage IIFuel consumption at rated powerg/kilom 250Minimum fuel consumption underfull loadg/kilom 215Cold start—without aido-10Cold start—with aido-30Noise at 1mdB 117B10 service lifekm500,000CC4
Service Manual for WP6 Diesel Engine14 Unseal of Diesel engineAfter opened the engine packing container, the user should firstly check the engine and itsaccessories according to the packing list, check whether engine appearance is damaged and whetherconnections 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 enginewithout draining seal fuel in fuel system, but only can the engine be loaded after all seal fuelare consumed and normal diesel fuel is supplied in place). The users also need to payattention to that storage life for diesel engine before unpacking is one year, for new dieselengine that has been stored for more than one year should be inspected and takenadditional measures: Rotate the flywheel and spray solvent into engine intake tube, until all seal fuel in cylindersis 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 engineoil 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 oilafter run-in period (2000km or 50h). According to the service agreement with customer, for engine that has been filled withcoolant before delivery under customer’s requirements, the coolant performance should bechecked 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 oldcoolant and out and refill coolant with antifreeze additive.(3) Check whether water blockage and grease blockage are unobstructed, check whether watertemperature sensor and oil temperature sensor are in readiness.NOTICE: Never start an engine before it is correctly installed and properly connected. Whenrunning the engine in enclosed environment, maintain good ventilation to ensure exhaust gasemissions into the atmosphere.5
Service Manual for WP6 Diesel Engine15 Lifting of Diesel EngineKeep the center line of engine cr
Service Manual for WP6 Diesel Engine Preface WP6 mechanical pump series diesel engine has the features of compact structure, reliable
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