Weichai WP12 Marine Diesel Engine Manual (EN)

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. 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 fishing boats, for inland water transportation vessels and high-speed ships.

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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................................................1 1.6 Safety regulations for startup and operation.....................2 SECTION - II Technical Specification.............................................................3 2.1 Main Specification ............................................................3 2.2 Specification for Sub-Assemblies and Accessories..........4 2.3 Overall Dimensions Of WP12 Marine Diesel Engine .......5 2.4 Engine Model Identification...............................................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

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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...................................................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

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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.....................................................30 5.7.3 Replacement of engine oil......................................30 5.7.4 Replacement of oil filter..........................................31 5.7.5 Cleaning of oil gas separator..................................32 5.7.6 Replacement of fuel filter........................................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 Specifications for Lubricant, Coolant and Fuel......................44 6.1 Lubricant...........................................................................44 6.1.1 The functioning of lubricating oil in a diesel engine.44 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 classification 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

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