WEICHAI WP12 Manuel utilisateur
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, specications 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.
The technician who is operating any Weichai marine diesel engine must understand
the safe operating procedure, routine inspection and maintenance practices.
Repairing of the engine must be carried out by trained professional and this service
is available in all our authorized service centers.
As a policy of continuous improvement, Weichai Power Company Ltd reserves
the right to change /modify/ upgrade the content of this manual at any time without
prior notice.
WP12 series marine diesel engine is the upgraded version of TD226B series. It
has distinguishing features like improved reliability, improved emission qualities,
quick starting, improved maintenance interval and low operating cost. Weichai
engines are popular for the best in class fuel economy, low noise & vibrations and
comparatively low engine room temperature. WP12 series marine diesel engines
are the ideal propulsion power for small & medium type shing boats, for inland
water transportation vessels and high-speed ships.
CONTENTS
SECTION - I
Safety Regulations....................................................................1
1.1 General Instructions .........................................................1
1.2 Correct use.......................................................................1
1.3 Modications or conversions............................................1
1.4 Spare parts.......................................................................1
1.5 Reworking of components................................................1
1.6 Safety regulations for startup and operation ....................2
SECTION - II
Technical Specication.............................................................3
2.1 Main Specication ...........................................................3
2.2 Specication for Sub-Assemblies and Accessories .........4
2.3 Overall Dimensions Of WP12 Marine Diesel Engine ......5
2.4 Engine Model Identication ..............................................6
2.5 Engine Model and Power Range .....................................6
SECTION – III
Installation Guidelines For Engines And Accessories ..........7
3.1 De-preservation of new engine ........................................7
3.2 Engine installation procedure...........................................7
3.3 Installation of air inlet system ...........................................8
3.4 Installation of exhaust system ..........................................8
3.5 Installation of cooling system ...........................................9
3.5.1 Fresh water cooling system....................................9
3.5.2 Sea water system...................................................9
3.6 Installation of diesel engine front end output....................9
3.7 Installation of electrical and engine control system..........10
SECTION – IV
Operating Instructions..............................................................12
4.1 Safety precautions for operation of diesel engine ............12
4.2 General instructions .........................................................12
4.3 Preparation for rst start...................................................12
4.3.1 Cooling system.......................................................13
4.3.2 Lubrication system .................................................14
4.3.3 Checking the oil level .............................................15
4.3.4 After an extended storage ......................................15
4.3.5 Fuel system ............................................................16
4.3.5.(a) Priming the fuel system.....................................17
4.3.6 Electrical system ...................................................17
4.3.7 Engine starting, operating and stopping.................17
4.3.7.(a) Normal starting..................................................18
4.3.8 Running in period ...................................................19
4.4 Regular operation.............................................................20
4.4.1 Engine starting .......................................................21
4.4.2 Engine warm up .....................................................21
4.4.3 Monitoring the engine oil ........................................21
4.4.4 Monitoring the engine coolant ................................22
4.4.5 Monitoring the exhaust gas ....................................23
4.4.6 Engine shutdown....................................................23
SECTION - V
Periodic Maintenance ...............................................................27
5.1 Safety precautions ...........................................................27
5.2 Importance of periodic maintenance ................................27
5.3 Replacement of parts and components ...........................27
5.4 Reliability of parts.............................................................28
5.5 Safe use of oil and fuel in a diesel engine........................28
5.6 Disposal of used oil or fuel ...............................................28
5.7 Periodic Maintenance instructions ...................................29
5.7.1 Check air lter ........................................................29
5.7.2 Cleaning air lter ....................................................30
5.7.3 Replacement of engine oil......................................30
5.7.4 Replacement of oil lter..........................................31
5.7.5 Cleaning of oil gas separator..................................32
5.7.6 Replacement of fuel lter........................................32
5.7.7 Air bleeding from fuel system .................................33
5.7.8 Adjustments and replacement of V-Belt .................33
5.7.9 Arrangement of cylinder head and valve ................34
5.7.10 Adjustment of valve clearance..............................34
5.8 Maintenance recommendation.........................................36
SECTION - VI
Specications for Lubricant, Coolant and Fuel......................44
6.1 Lubricant ..........................................................................44
6.1.1 The functioning of lubricating oil in a diesel engine44
6.1.2 Engine oil consist of ...............................................44
6.1.3 Why oil to be drained?............................................44
6.1.4 How engine oil performance getting deteriorated...44
6.1.5 Oil performance classication system ....................45
6.1.6 SAE viscosity recommendations ............................45
6.2 Engine oil recommendations for Weichai engines ...........46
6.3 Grease Recommendations ..............................................47
6.4 Fuel oil recommendations ................................................47
6.5 Coolant.............................................................................50
6.6 A good coolant should have following properties .............50
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 regulations
regarding accident prevention and environmental protection must be followed by
the operator of this engine.
The engine may nevertheless present a risk of injury or damage in the following
cases:
• Incorrect use
• Unauthorized modications or conversions
• Non-compliance with the safety instructions
• Skipping of routine checks and inspection
• Operation, maintenance and repair by unqualied personnel
1.2 Correct use
Every engine is designed and built to suit a desired application. WP12 Weichai-
Marine diesel engine is specically designed for the use of marine propulsion.
Any other use is being considered as improper use. The engine manufacturer
accepts no-liability whatsoever for resultant damage or injury. In such cases, the
responsibility will be borne by the user only.
Correct use also includes periodically monitoring engine operating parameters,
carryout routine inspection and maintenance as per recommendation by the
company.
1.3 Modications or conversions
Any modication on engine may impair its performance and shorten its life.
Unauthorized modications on the engine are also a risk to human and machine
safety. The company will accept no liability or warranty claims for any damage
caused by unauthorized modications or conversions.
1.4 Spare parts
Only Weichai genuine spare parts must be used to replace components or
assemblies. The company accepts no liability whatsoever for damage or injury
resulting from the use of other spare parts and the warranty shall be void in such
case.
1.5 Reworking of components
Any repair or overhaul of the engine must be carried out by the company authorized
service center. The company accepts no liability whatsoever for damage or injury
resulting from the repair by un-authorized person.
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.
1.6.3 Tampering with the fuel injection and electronic system could affect
engine power output and threat to engine safety. Any attempt, to tamper
with will void the warranty and the company will not be
responsible for any injury due to alteration.
1.6.4 If the engine is new or overhauled in major parts (in either case), follow
the 60 hours of running in procedure.
1.6.5 Select the lubricating oil, coolant and fuel as recommended in section-VI.
1.6.6 Always use recommended lubricant and coolant. The company
recommends to use premixed coolant for better protection of
engine cooling system. Never use sea water or riverwater in
engine internal cooling system.
1.6.7 Gradually speed up the engine after starting from the cold state. Do not
raise the speed suddenly or let the engine run with no load for a long time.
1.6.8 Never operate the engine without air lters. Inducting un-ltered air to
the combustion system will shorten engine life and adversely affect the
engine performance.
1.6.9 Any service or repair related to the electrical system must be carried out
by a trained electrical/electronic professional.
1.6.10 Prevention of harms caused by engine emission:
It is absolutely prohibited to operate the engine in a closed room without
proper ventilation, because exhaust gas from engine emission is toxic,
which is harmful to the human health.
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) ≤0.3
6 Idling speed (r/min) 600±50
7 Intake method Turbocharged and
Intercooled
8 Starting method Electric motor start
9 Cooling method Water cooled forced
Circulation
10 Lubricating method Pressurized lubrication
11 Oil sump capacity (Liters) 30
12 Oil pressure (kPa) (at rated working
condition) 350-550
13 Oil pressure in idling speed (kPa) >100
14 Exhaust temperature after turbine (°C) ≤550
15 Direction of Crankshaft rotation
(face to output end) Counter clockwise
16 Valve clearance (cold state) (mm) Intake valve : 0.40
Exhaust valve: 0.60
17 Firing order 1-5-3-6-2-4
18 Outline dimension See outline drawing
Table 2.1
4
2.2 SPECIFICATION FOR SUB-ASSEMBLIES AND ACCESSORIES
SR.NO. DESCRIPTION
OF SUB ASSEMBLY
RELATED
PARAMETER SPECIFICATION
1Fuel lter
Type Double
Filtering Area ≥ 3400cm2
2Engine oil pump
Assembly
Type Gear-type
Rated speed 1900 RPM
Safety valve opening
pressure 1200±150
3Engine oil lter
Type Rotary
Filtering Area ≥ 5046Cm2
Maximum pressure
bearing strength
1.5 MPa
(3-4 minute)
4 Water pump Type
Centrifugal
(scroll-case & gear
cell integrated)
Pressure 117.6 kPa
5 Starter
Type DC
Power 7.5kW
Range 24V
6 Thermostat Type Wax
Temperature 760c – 880c
7 Generator
Type Rectied, regulated
and integral
Power 980W
Range 28V
8 Vibration damper
Type Silicone oil
External Dimension ɸ 280 mm
9 Heat exchanger Type
Flat tube
corrugated ribbon,
water-cooled
10 Intercooler Type
Flat tube
corrugated ribbon,
water-cooled
Table 2.2
5
2.3 OVERALL DIMENSIONS OF WP12 MARINE DIESEL ENGINE
(all dimensions are in mm)
Outside diamete
r
se a water outle
t
Figure 2.1
hea t exchanger
sea water outlet
air-cooler
sea water inlet
fuel oil filter
fuel oil pump
Figure 2.2
Table des matières
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