PART NO: 100000154 OPERATING INSTRUCTIONS FOR WP12 MARINE DIESEL ENGINE
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 provided in this manual is limited to regular operations and maintenance. Hence cannot be considered for major overhaul or repair.
CONTENTS SECTION - I Safety Regulations.....................................................................1 1.1 General Instructions..........................................................1 1.2 Correct use........................................................................1 1.3 Modifications or conversions.............................................1 1.4 Spare parts........................................................................1 1.5 Reworking of components..................................
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....................................................12 4.3.1 Cooling system........................................................13 4.3.2 Lubrication system..................................................14 4.3.
.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.....................................................30 5.7.3 Replacement of engine oil.......................................30 5.7.4 Replacement of oil filter...........................................31 5.7.
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 regulations regarding accident prevention and environmental protection must be followed by the operator of this engine.
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 speed rotating machinery. When the engine is in operation, do not touch any moving parts. 1.6.
SECTION - II TECHNICAL SPECIFICATION 2.1 MAIN SPECIFICATION SR.NO. DESCRIPTION 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) ≤0.
2.2 SPECIFICATION FOR SUB-ASSEMBLIES AND ACCESSORIES SR.NO. DESCRIPTION OF SUB ASSEMBLY 1 Fuel filter 2 3 4 5 6 7 Engine oil pump Assembly Engine oil filter Water pump Starter Thermostat Generator RELATED PARAMETER SPECIFICATION Type Double Filtering Area ≥ 3400cm2 Type Gear-type Rated speed 1900 RPM Safety valve opening pressure 1200±150 Type Rotary Filtering Area ≥ 5046Cm2 Maximum pressure bearing strength 1.
2.3 OVERALL DIMENSIONS OF WP12 MARINE DIESEL ENGINE (all dimensions are in mm) se a water outlet Outside diameter Figure 2.1 hea t exchanger air-cooler sea water outlet sea water inlet fuel oil filter fuel oil pump Figure 2.
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 1 Power Rating Rated Speed HP KW RPM WP12C350-15 350 258 1500 2 WP12C400-18 400 295 1800 3 WP12C450-21 450 330 2100 Table 2.
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 material supplied are as per the packing list. 1. Wipe off the anti-rust coat, anti-corrosion agent, from the exposed parts such as turbocharger, flywheel etc. 2. Drain preservation oil from the engine sump. 3.
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 and bends should be minimized. Using of sharp bend (elbows) in the system will create air flow restriction; use large arc bends instead.
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 supplied with this engine in a separate box. It is a centrifugal type, pulley driven pump. The input drive can be availed from the front end pulley of the engine through a B-type V-belt.
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. Properly connect the terminals without changing the polarity. Refer figure 3.5, 3.6& 3.7. A set of engine control panel (main and remote) with necessary wire harness is provided along with the engine.
ELECTRICAL SYSTEM DRAWING FOR WP12 MARINE DIESEL ENGINE Monitor Water Temp, Sensor Engine Speed Sensor Starter Motor 24V Battery + - Oil Temp, Sensor Generator Oil Pressure Sensor Engine Wiring Diagram Generator Schematic Diagram D+ W B+ Starter Pin D1 Starter Pin D2 D1 D2 Generator Pin D3 D3 Alarm Pin D4 D4 Generator Starter Pin D5 Pin D6 D5 D6 DF W U G Regulator V Battery + 30 50 31 D+ - Generator Schematic Diagram 50 30 M 31 11 W B+ BD+ Generator Starter
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 experience and careless operation may cause fatal accident.
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 slowly fill the cooling system with recommended coolant (figure 4.3). Slowly filling the coolant will help the air to escape without trapping in the system.
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 Figure 4.6 Figure 4.7 3. Fill up the engine oil to the correct level.
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 level is in between the high level and low level area, then the oil is at the proper level for engine operation. (figure 4.10) If necessary, top up the oil through the oil filling port. Do not overfill.
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 turbocharger bearings and spin the shaft by hand two to three times. (figure 4.11, 4.12 & 4.13) Figure 4.11 Figure 4.12 Figure 4.
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 pressurized (figure 4.14). Remove trapped air from the system stage by stage. Refer section 5.7.7 for details about air bleeding from the fuel system.
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 position. Press the start button (figure 4.16 &4.17). If the engine cannot be started in 5~10 seconds, repeat the above procedure after 1 minute.
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 monitor, push the stop button (Refer Fig. 4.19) Figure 4.19 After stopping the engine, turn off the power supply to the control panel.
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 fuel tank. ► Drain out water and impurities from fuel water separator and filter respectively ► Ensure the belt tightness is sufficient, and that there is no crack, peel off etc.
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 aid. • If engine has stopped by pressing emergency button, release the button before restart. • If the engine is stopped by shutting main fuel supply valve, open the fuel valve before the starting attempt.
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 clearance 5 Clearance between connecting rod small end bush and piston pin 0.045 ~ 0.061 6 Clearance between piston pin seat and piston pin 0.005 ~ 0.
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 running at 1000 r/min, till it is full and the level becomes stable. Finally cover the filler cap. 4.4.
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. Do not check oil or coolant level while engine is running CAUTION OK OK Mixture of different grade or brands of engine oil is strictly prohibited.
PARAMETERS TO MONITOR DURING REGULAR OPERATION SR.
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. If the diesel engine is not used for a long time and ambient temperature is very low, then remove the battery and store it in a warm room.
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 maintenance is carried out as per quality and schedule, downtime and costly breakdowns can be eliminated. The maintenance schedule is defined by the actual operating environment of the engine.
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 sure they meet the relevant technical specifications. Non-genuine spare part components may lead to physical damage of the components, functional safety of the engine, human injury or severe equipment damage. 5.
PERIODIC MAINTENANCE CHART Maintenance Description Engine oil First Inspection Periodical Inspection First 50 Hours Every 300 Hours Replace Scheduled maintenance interval Replace Oil filter Level 1 Level 2 Level 3 Level 4 Every 600 Hours Every 1500 Hours Every 3000 Hours Every 6000 Hours Replace Replace Replace Replace Replace it on every oil change Fuel filter Replace Fuel water separator Replace Replace Replace Replace Replace Replace Replace Replace Coolant Check & top
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 figure 5.1). compresed air (<600 kPa) Figure 5.1 5.7.3 Replacement of engine oil Generally, the oil and oil filter are required to be replaced at the same time.
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 refer figure 5.4. Wipe the sealing surface with a clean cloth, and apply fresh oil to the seal ring, then position the filter on the housing by hand and tighten it with the help of filter wrench refer figure 5.5& 5.
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 get correct oil level, always check it 5 to 10 minutes after stopping the engine 5.7.
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 5.11 5.7.8 Adjustments and replacement of V-Belt Two B type V belts used to drive the fresh water pump and the charging alternator. Refer Fig. 5.
5.7.9 Arrangement of cylinder head and valve WP12 series marine diesel engine is designed with individual head assembly for each cylinder. 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- Inlet & E- Exhaust) I E 1 I E 2 I E 3 I E 4 I E 5 I E 6 Figure 5.15 5.7.10 Adjustment of valve clearance Correct valve clearance is one of the main factors to balance power adjustment of engine.
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 STEP- 1 1 I 2 E I Figure 5.20 3 - - 4 E I 5 - - 6 E Figure 5.21 Rotate the engine 360° - match the OT mark to the pointer. Adjust the clearance in the following order. (Refer figure 5.22).
Figure 5.22 CYL. NO STEP- 2 1 - 2 - - 3 E I 4 - - 5 E I 6 - 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 factors like routine inspection and maintenance, quality of fuel, lubricant and coolant, atmosphere etc. Considering the ideal situation, periodic maintenance chart is prepared (refer table 5.1).
RECOMMENDED MAINTENANCE SCHEDULE MAINTENANCE INTERVAL (HOURS) SR. NO 1 2 3 4 37 RELATED SYSTEM OR SUBASSEMBLY LUBE OIL SYSTEM FUEL SYSTEM AIR INTAKE SYSTEM EXHAUST SYSTEM SR. NO DESCRIPTION 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. 12000 Hrs.
5 6 7 8 JACKET COOLING SYSTEM CYLINDER HEAD VALVE TRAIN MOVING ELEMENT 1 COOLANT 2 C&T R R COOLANT WATER PUMP I S&I 3 WATER JACKET I C&I 4 THERMOSTAT 5 HEAT EXCHANGER 6 CRANK CASE WATER JACKET 7 DUMMEY FOR WATER JACKET 8 HOSES AND CLAMPS 9 FUEL TANK 10 FLEXIBLE HOSES AND CLAMP 11 FUEL WATER SEPARATOR 12 GASKETS & SEALS 1 INTAKE VALVE AND EXHAUST VALVE I I R 2 VALVE SEAT I I R 3 VALVE GUIDE I I R 4 COLLETS I I R 5 SEALS R R R 6 SPRING SET I I
8 9 10 MOVING ELEMENT CRANK CASE - CAM SHAFT - CRANK SHAFT - GEAR TRAIN OTHERS SUB ASSEMBLIES 7 CONROD BIG END BEARING I R 8 CONROD I I 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 BEARING R 10 FASTNERS I 1 FAN BELT 2 BELT TENSIONOR PULLEY 3 FLEXIBLE HOSES AND CLAMP 4 SET OF O RINGS AND GASKETS 5 STARTER MOTOR M M M
TIGHTENING TABLE AND TORQUE VALUES FOR MAIN FASTENERS DESCRIPTIONS SPECIFICATIONS (SIZE – GRADE) REQUIREMENTS Main bearing bolt M18X169 - 10.9 140N.m+210° Crankcase secondary bolt M8X 25 - 8.8 M8X210 - 8.8 8N.m+30 Cylinder head main bolt M14X185 - 10.9 60N.m+2×120° Cylinder head secondary bolt M12×1.5X195 - 8.8 20+10N.m Seal with Loctite 262 Sealant Cylinder head secondary nut 25N.m+2×120° Crankshaft pulley bolt M12×1.5X75 - 10.9 45N.
11 10 3 2 5 8 14 7 6 1 4 9 Main bearing bolts tightening sequence Cylinder head main Bolts tightening sequence Cylinder head auxiliary bolts tightening sequence 41
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 the lubricating function before the lubricating oil pressure is established, For example: apply on inlet valve rod.
▲ ▲ ▲ H i g h ex h au st b ack p ressu re ▲ ▲ ▲ L o w d esn se ai r.
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 minimize the wear and tear.
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 classification system Following are the organizations designing and approving oil classification and specification standards.
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 in engines. It is recommended to use the multi graded lubricating oil with the viscosity grade as table 6.2.
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 available in India. CAUTION Beware of the spurious oils in the market. Bad oil quality is detrimental to engine performance.
SPECIFICATION FOR AUTOMOTIVE DIESEL FUEL (BV IV) (IS 1460-2005 with Amendment 2 March, 2010) SR. NO PARAMETER SPECIFICATION STD.METHOD Typical Analysis Nil IS 1448, P:2 Nil To report IS 1448, P:2 0.05 1 Acidity, inorganic, mg KOH/g 2 Acidity, total, mg KOH/gm 3 Ash, percent by mass, Max 0.01 IS 1448, P:4 /ISO 6245 <0.01 4 Carbon residue (Ramsbottom) on 10% residue, % by mass, max 0.30 IS 1448, P:8 /ISO 10370 0.
SPECIFICATION FOR AUTOMOTIVE DIESEL FUEL (BV III) (IS 1460-2005 with Amendment 2 March, 2010) SR. NO PARAMETER SPECIFICATION STD.METHOD Typical Analysis Nil IS 1448, P:2 NiL To report IS 1448, P:2 0.05 1 Acidity, inorganic, mg KOH/g 2 Acidity, total, mg KOH/gm 3 Ash, percent by mass, Max 0.01 IS 1448, P:4/ISO 6245 <0.01 4 Carbon residue (Ramsbottom) on 10% residue, % by mass, max 0.30 IS 1448, P:8/ISO 10370 0.
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 through the combustion of fuel into work. The other two thirds is converted into heat, of which one third goes out with the exhaust and remaining one third is removed by engine coolant.
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 1. Glycol content % 2. Specific weight(15.6°C) 3. Boiling Point(°C) 4. Freezing Point(°C) 5. Minimum temperature for application(°C) JFL318 JFL-336 JFL-336 33 50 56 1.05 1.074 1.082 104.5±1 108.5±1 110.
Shandong Heavy Industry India Pvt. Ltd.
