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- WP12
- Operating Instructions Manual
WEICHAI WP12 Operating Instructions Manual
Summary of WP12
Page 1
Part no: 100000154 operating instructions for wp12 marine diesel engine.
Page 2: Foreword
Foreword this manual contains installation and operating information of wp12 series weichai marine diesel engine. Content of this manual is intended to explain about safety, installation guidelines, operation and maintenance instructions, specifications for fuel, lube oil & coolant. Information prov...
Page 3: Contents
Contents section - i safety regulations ....................................................................1 1.1 general instructions .........................................................1 1.2 correct use .......................................................................1 1.3 modifications...
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Section – iv operating instructions ..............................................................12 4.1 safety precautions for operation of diesel engine ............12 4.2 general instructions .........................................................12 4.3 preparation for first start ................
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5.6 disposal of used oil or fuel ...............................................28 5.7 periodic maintenance instructions ...................................29 5.7.1 check air filter ........................................................29 5.7.2 cleaning air filter ....................................
Page 6: Section - I
1 section - i safety regulations 1.1 general instructions wp12 series weichai marine diesel engine has been designed and assembled by the company, meeting all applicable safety regulations of international standards. In addition to the instructions in this manual, applicable industrial safety regula...
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1.6 safety regulations for startup and operation 1.6.1 before installing or operating the engine, the operator should carefully read and understand the content of this manual to get familiar with the engine structure, correct operation and maintenance procedures. 1.6.2 this diesel engine is a high s...
Page 8: Section - II
3 section - ii technical specification 2.1 main specification sr.No. Description specifications 1 type 4stroke double, direct injection, in-line, forced circulation water cooled 2 number of cylinders 6 3 bore/stroke (mm) 126/155 4 displacement (litres) 11.596 5 oil to fuel consumption rate (g/kw-h) ...
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4 2.2 specification for sub-assemblies and accessories sr.No. Description of sub assembly related parameter specification 1 fuel filter type double filtering area ≥ 3400cm 2 2 engine oil pump assembly type gear-type rated speed 1900 rpm safety valve opening pressure 1200±150 3 engine oil filter type...
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5 2.3 overall dimensions of wp12 marine diesel engine (all dimensions are in mm) outside diameter se a water outlet figure 2.1 heat exchanger sea water outlet air-cooler sea water inlet fuel oil filter fuel oil pump figure 2.2.
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6 2.4 engine model identification wd 12 c xxx xx engine speed x100 (rpm) rated power (hp) application code total displacement volume (ltrs) water cooled diesel engine 2.5 engine model and power range sr.No engine model power rating rated speed hp kw rpm 1 wp12c350-15 350 258 1500 2 wp12c400-18 400 2...
Page 12: Section – III
7 section – iii installation guidelines for engines and accessories 3.1 de-preservation of new engine after the engine packing crate is unpacked, carry out the pre-commissioning inspection (pci). Make sure engine and the sub parts supplied are as per the purchase order, free from defects and all mat...
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8 3.3 installation of air inlet system correct design and installation of the air intake system will be one of the key parameter to achieve optimum engine performance. Opening of air inlet system should be arranged outside the engine room to ensure fresh air availability to the engine. Sharp curves ...
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9 3.5 installation of cooling system 3.5.1 fresh water cooling system the diesel engine internal cooling system (freshwater system) is a closed circuit that is assembled in the factory. No additional installation or modification is required. 3.5.2 sea water system the sea water pump sub assembly is ...
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10 3.7 installation of electrical and engine control system the electrical system is operating on 24v dc supply. Select the battery and connecting cables according to the engine power range. Identify the positive (+) and negative (-) terminals of battery, starter motor and charging alternator. Prope...
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11 electrical system drawing for wp12 marine diesel engine monitor water temp, sensor engine speed sensor 24v battery battery + - oil temp, sensor oil pressure sensor generator schematic diagram generator generator schematic diagram engine wiring diagram generator starter d1 50 30 31 m d+ b+ d+ df r...
Page 17: Section – IV
12 section – iv operating instructions 4.1 safety precautions for operation of diesel engine before the engine is started, the operator must understand the operating method; master the working principle of diesel engine and understand its power limit. During starting and running of engine, lack of e...
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13 4.3.1 cooling system capacity: 40 liters 1. Make sure the main drain valve of the fresh water cooling system (above the oil filter mounting) is closed properly. Refer figure 4.1 figure 4.1 2. The coolant can be filled from the heat exchanger. Remove the cap provided on the top (figure 4.2) and sl...
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14 4.3.2 lubrication system sump capacity - 30 liters 1. Check and drain out the preservation oil from the sump. After draining, fix the drain plug properly. 2. Engine oil can be filled from the filling port provided near the fuel injection pump. Refer figure 4.4,4.5 & 4.6 figure 4.4 figure 4.5 figu...
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15 4.3.3 checking the oil level make sure the boat is on float or kept on a level surface. A dipstick is provided on the crank case near to the oil filter assembly (figure 4.8). Check the oil level using the oil dipstick. Safe oil level range is marked on the dipstick bottom (figure 4.9). If the oil...
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16 4.3.4.1 pre-lubricating the engine to ensure immediate flow of oil to all bearing surfaces at initial engine startup, prepare the engines as follows: 1. Charge the engine lubrication system with lubricating oil using a commercially available pressure pre-lubricator. 2. Manually lubricate the turb...
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17 properly check the fuel system for loose connections and leaking joints. Loose connection or damaged sealing will cause air to enter into the system 4.3.5.(a) priming the fuel system operate the hand priming pump (lift pump) provided on the fip several times till the low pressure system get press...
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18 4.3.7.(a) normal starting switch on the main power supply button provided on the engine control monitor. (figure 4.15) observe and ensure all the parameters on the monitor display are normal. The battery voltage should not be less than 24v. Ensure the fuel throttle lever is on the minimum positio...
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19 before stopping the engine, gradually reduce the load, then gradually reduce the engine speed to 600~1000 r/min. To stop the engine from the main control panel, press the emergency stop button provided on the display monitor.(refer figure 4.18) figure 4.18 and to stop the engine from the remote m...
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20 4.4 regular operation practice the daily inspection and maintenance for trouble free, safe and reliable engine performance (refer table 4.1) daily inspection and maintenance before start up ► ensure oil level is correct. ► ensure coolant level is correct. ► ensure sufficient fuel level in the fue...
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21 4.4.1 engine starting • before starting the engine confirm the fuel throttling and gear box engaging lever is in neutral position (refer figure 4.20). • do not touch the throttle or throttle lever while starting the engine. Engine should start and stabilize in the specified idle speed without any...
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22 fit and clearance values o f major sub-assemblies sr.No. Description of location theoretical value (in mm) 1 clearance of main bearing 0.095 ~ 0.171 2 clearance of connecting rod bearing 0.059 ~ 0.135 3 crankshaft axial clearance 0.052 ~ 0.255 4 crankshaft axial clearance crankshaft axial clearan...
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23 during operation, coolant level must be between the low and high marks of the tank level. If there is no coolant in emergencies, slowly add coolant with temperature not too lower from the coolant filler, until the coolant becomes over-flown. Start engine and continue to add coolant with engine ru...
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24 in normal operation of the engine, it is allowed to operate continuously at described rated speed and power. However, the permissible over-speed is 103% of the rated speed and over-load is 110% of the rated power. Duration for the above permissible over-speed/load is 1 hour within every 12 hours....
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25 parameters to monitor during regular operation sr.No parameter unit value remark 1 oil pressure in main oil passage kpa 350~550 rated speed and power 2 oil pressure in main oil passage kpa ≥100 idle speed 3 oil temperature in oil sump °c 85~115 4 engine oil temperature at normal operation °c 75~1...
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26 4. Starting: in winter, use the auxiliary starter if required. It is allowed to run the engine at higher speed and apply load after attaining the normal oil pressure and water temperature. Battery: before beginning of winter season, check the electrolyte level, specific gravity and cell voltage. ...
Page 32: Section - V
27 section - v periodic maintenance weichai engines are designed for high reliability and long life. The engines are built to withstand marine operational environment. Preventive maintenance is the cost effective and economical way to reduce the operational cost of a diesel engine. If the preventive...
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28 5.4 reliability of parts prior to replacing any parts and components, customer must make sure that the new parts and components to be installed are made by the original engine manufacturer or authorized cooperative production factories, and use necessary measuring instruments to check and make su...
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29 periodic maintenance chart maintenance description first inspection periodical inspection scheduled maintenance interval first 50 hours every 300 hours level 1 level 2 level 3 level 4 every 600 hours every 1500 hours every 3000 hours every 6000 hours engine oil replace replace replace replace rep...
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30 5.7.2 cleaning air filter always use clean and dry air to clean the air filter element. The air pressure should not exceed 600 kpa. To make cleaning process more efficient, always direct the compressed air from inside to outside the element. Don’t clean the air filter with diesel or water. (refer...
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31 5.7.4 replacement of oil filter use the filter wrench to loosen the filter and remove it by hand refer figure 5.2 & 5.3. Use a suitable tray under the filter location to collect oil spillage before removing the filter. Figure 5.2 figure 5.3 let the oil drain completely from the filter housing ref...
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32 run the engine for a short time, during running check and ensure no leakage from the filter sealing and from the oil drain plug refer figure 5.7 ok figure 5.7 stop the engine; check the tightness of filter for reliability, if necessary. Measure the oil level with the help of the oil dipstick. To ...
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33 5.7.7 air bleeding from fuel system after every filter change and maintenance of engine fuel system, or air entered into the system, check the whole fuel system and bleed out the air from the system. (refer figure for 5.10 & 5.11 for main air bleeding points in the fuel system) figure 5.10 figure...
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34 5.7.9 arrangement of cylinder head and valve wp12 series marine diesel engine is designed with individual head assembly for each cylin- der. Each cylinder head is designed with two valves; one for inlet and the other for exhaust. The valve arrangement from the front end is as per figure 5.15 (i- ...
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35 open the inspection window on the flywheel and match the ot mark to the pointer (refer figure 5.19). 0 figure 5.19 check and confirm compression tdc of the 1st cylinder. Adjust the clearance in the following order. (refer figure 5.20 & 5.21) cyl. No 1 2 3 4 5 6 step- 1 i e i - - e i - - e - - fig...
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36 figure 5.22 cyl. No 1 2 3 4 5 6 step- 2 - - - e i - - e i - i e once the adjustment is completed, refit the rocker cover. Pay attention to the cover gasket for damages. If any damage is noticed, replace it with the new one. 5.8 maintenance recommendation the major maintenance is depends on main f...
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37 recommended maintenance schedule sr. No related system or subassembly sr. No description maintenance interval (hours) abbreviations: a- adjust, c- clean, i-inspection, m- monitor, r- replace, s-service, cal- calibrate, ms- major service 50 hrs. 300 hrs. 600 hrs. 1500 hrs. 3000 hrs. 6000 hrs. 1200...
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38 5 jacket cooling system 1 coolant c&t c&t c&t c&t c&t r r 2 coolant water pump i s&i 3 water jacket i c&i 4 thermostat m r r r 5 heat exchanger m m m m c&i c&i c&i 6 crank case water jacket c&i c&i 7 dummey for water jacket m c r 8 hoses and clamps m m m m r r r 9 fuel tank c&i c&i c&i 10 flexibl...
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39 8 moving element 7 conrod big end bearing i r 8 conrod i i 9 crank case - cam shaft - crank shaft - gear train 1 main bearings & thrust bearings r 2 cam bush bearing r 3 bearings related to gear train r 4 oil seals r r 5 tappet i i 6 cam shaft i 7 crank sahft i 8 cam & idle gear i 9 roller bearin...
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40 tightening table and torque values for main fasteners descriptions specifications (size – grade) requirements allowable times to reuse main bearing bolt m18x169 - 10.9 140n.M+210° 2 crankcase secondary bolt m8x 25 - 8.8 m8x210 - 8.8 8n.M+30 2 cylinder head main bolt m14x185 - 10.9 60n.M+2×120° 3 ...
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41 1 2 4 5 9 8 6 3 7 10 14 11 main bearing bolts tightening sequence cylinder head main bolts tightening sequence cylinder head auxiliary bolts tightening sequence.
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42 list of sealants and thread locking compounds used for engine maintenance sr. No description color usage and application 1 molykotte pulver black apply it to smooth metal surface to prevent seizing for example: apply it on the outer surface of cylinder sleeve. 2 molykotte g.U. Plus dark grey take...
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43 trouble shooting guide for wp12 marine diesel engine d e t s u j d a e b o t s d e e n r o t c e j n i l e u f d e r o c s r o n r o w s i n o t s i p r o e v e e ls r e d n il y c t c e r r o c n i s i g n i m it e v l a v d n a n o it c e j n i l e u f e s o o l s i tl o b g n it n u o m s tr a...
Page 49: Section - VI
44 section - vi specifications for lubricant, coolant and fuel 6.1 lubricant 6.1.1 the functioning of lubricating oil in a diesel engine the lubricating oil used in the engine must be multifunctional. It must perform the primary functions of: 1. Lubrication: basic function is to reduce friction and ...
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45 4. Contamination due to dirt entering the engine through the atmospheric air and bad fuel. 5. Other additive depletion due to reaction which will affect the performance of oil. The engine oil becomes inefficient after the recommend hours. Hence, it is necessary to replace. 6.1.5 oil performance c...
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46 multi graded oils are generally produced by adding viscosity index improver additives to retard the thinning effects that the low viscosity base oil will experience at engine operating temperatures. Multi graded oils that meet the requirements of the api classifications, are recommended for use i...
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47 hence, we strongly recommend the use of sae 15w40 lube oil with api, ch4 or ci4+ classification for all engines to get the various advantages and opti-mum performance from the engine. This oil should have a minimum tbn of 10.5 to counteract the higher sulphur content of high speed diesel availabl...
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48 specification for automotive diesel fuel (bv iv) (is 1460-2005 with amendment 2 march, 2010) sr. No parameter specification std.Method typical analysis 1 acidity, inorganic, mg koh/g nil is 1448, p:2 nil 2 acidity, total, mg koh/gm to report is 1448, p:2 0.05 3 ash, percent by mass, max 0.01 is 1...
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49 specification for automotive diesel fuel (bv iii) (is 1460-2005 with amendment 2 march, 2010) sr. No parameter specification std.Method typical analysis 1 acidity, inorganic, mg koh/g nil is 1448, p:2 nil 2 acidity, total, mg koh/gm to report is 1448, p:2 0.05 3 ash, percent by mass, max 0.01 is ...
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50 6.5 coolant an engine coolant is a heat transfer fluid which flows through or around an engine to prevent its overheating, transferring the heat produced by the engine to radiator /heat exchanger that dissipate it. An operating engine typically converts only one third of the energy derived throug...
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51 premixed ready to use antifreeze engine coolant is recommended to use as is condition, as a first fill as well as for top up of the cooling system. Refer table 6.6 to select the best suitable coolant solution general specification for coolant parameter standard jfl318 jfl-336 jfl-336 1. Glycol co...
Page 57: (A Weichai Power Company)
Shandong heavy industry india pvt. Ltd. (a weichai power company) survey no 280/281, village mann, taluka mulshi, hinjewadi phase-ii, pune, maharashtra, india - 411057.