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Summary of Contents for WEICHAI WP12
- Page 1 PART NO: 100000154 OPERATING INSTRUCTIONS FOR WP12 MARINE DIESEL ENGINE...
- Page 2 /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 &...
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Page 3: Table Of Contents
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... - Page 4 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...
- Page 5 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...
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Page 6: Safety Regulations
Operation, maintenance and repair by unqualified personnel 1.2 Correct use Every engine is designed and built to suit a desired application. WP12 Weichai- Marine diesel engine is specifically 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. -
Page 7: Safety Regulations For Startup And Operation
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. -
Page 8: Technical Specification
SECTION - II TECHNICAL SPECIFICATION 2.1 MAIN SPECIFICATION SR.NO. DESCRIPTION SPECIFICATIONS 4stroke double, direct Type injection, in-line, forced circulation water cooled Number of cylinders Bore/stroke (mm) 126/155 Displacement (Litres) 11.596 Oil to fuel consumption rate (g/kw-h) ≤0.3 Idling speed (r/min) 600±50 Turbocharged and Intake method... -
Page 9: Specification For Sub-Assemblies And Accessories
2.2 SPECIFICATION FOR SUB-ASSEMBLIES AND ACCESSORIES DESCRIPTION RELATED SR.NO. SPECIFICATION OF SUB ASSEMBLY PARAMETER Type Double Fuel filter Filtering Area ≥ 3400cm Type Gear-type Engine oil pump Rated speed 1900 RPM Assembly Safety valve opening 1200±150 pressure Type Rotary Filtering Area ≥... -
Page 10: Overall Dimensions Of Wp12 Marine Diesel Engine
2.3 OVERALL DIMENSIONS OF WP12 MARINE DIESEL ENGINE (all dimensions are in mm) Figure 2.1 Figure 2.2... -
Page 11: Engine Model Identification
2.4 ENGINE MODEL IDENTIFICATION Engine Speed X100 (RPM) Rated Power (HP) Application Code Total Displacement Volume (Ltrs) Water cooled Diesel Engine 2.5 ENGINE MODEL AND POWER RANGE Power Rating Rated Speed SR.NO Engine Model WP12C350-15 1500 WP12C400-18 1800 WP12C450-21 2100 Table 2.3... -
Page 12: Installation Guidelines For Engines And Accessories
3.2 Engine installation procedure WP12 series marine diesel engine is assembled with SAE-I flywheel and flywheel housing. Select the gear box and coupling accordingly. When installing the engine, ensure the axial and radial alignment of engine crankshaft is linearly arranged with the gear box input shaft. -
Page 13: Installation Of Air Inlet System
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. -
Page 14: Installation Of Cooling System
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. -
Page 15: Installation Of Electrical And Engine Control System
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. - Page 16 ELECTRICAL SYSTEM DRAWING FOR WP12 MARINE DIESEL ENGINE Monitor Water Temp, Sensor Engine Speed Sensor Starter Motor Battery Oil Temp, Sensor Generator Oil Pressure Sensor Generator Schematic Diagram Engine Wiring Diagram Starter Starter Generator Alarm Generator Starter Pin D1 Pin D2...
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Page 17: Operating Instructions
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. -
Page 18: Cooling System
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). -
Page 19: Lubrication 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. -
Page 20: Checking The Oil 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. -
Page 21: Fuel System
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. -
Page 22: A) Priming The Fuel System
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). -
Page 23: A) Normal Starting
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. -
Page 24: Running In Period
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. -
Page 25: Regular Operation
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. ►... -
Page 26: Engine Starting
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. •... -
Page 27: Monitoring The Engine Coolant
FIT AND CLEARANCE VALUES O F MAJOR SUB-ASSEMBLIES THEORETICAL SR.NO. DESCRIPTION OF LOCATION VALUE (IN MM) Clearance of main bearing 0.095 ~ 0.171 Clearance of connecting rod bearing 0.059 ~ 0.135 Crankshaft axial clearance 0.052 ~ 0.255 Crankshaft axial Crankshaft axial clearance clearance Clearance between connecting rod small end 0.045 ~ 0.061... -
Page 28: Monitoring The Exhaust Gas
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. - Page 29 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.
- Page 30 PARAMETERS TO MONITOR DURING REGULAR OPERATION SR.NO PARAMETER UNIT VALUE REMARK Oil pressure in main oil Rated speed 350~550 passage and power Oil pressure in main oil ≥100 Idle speed passage Oil temperature in oil sump °C 85~115 Engine oil temperature at °C 75~105 normal operation...
- Page 31 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.
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Page 32: Periodic Maintenance
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. -
Page 33: Reliability Of Parts
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. -
Page 34: Periodic Maintenance Instructions
1. Above maintenance interval is applicable only when the maintenance procedure is followed from the first Inspection onwards and used the Weichai recommended products. 2. It is suggested to operate the engine at operating temperature once in a week for minimum 5 minutes 3. -
Page 35: Cleaning Air Filter
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. -
Page 36: Replacement Of Oil Filter
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. -
Page 37: Cleaning Of Oil Gas Separator
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 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. -
Page 38: Air Bleeding From Fuel System
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... -
Page 39: Arrangement Of Cylinder Head And Valve
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- Inlet & E- Exhaust) Figure 5.15... - Page 40 Open the inspection window on the flywheel and match the OT mark to the pointer (Refer figure 5.19). 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.
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Page 41: Maintenance Recommendation
Figure 5.22 CYL. NO STEP- 2 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. -
Page 42: Recommended Maintenance Schedule
RECOMMENDED MAINTENANCE SCHEDULE MAINTENANCE INTERVAL (HOURS) ABBREVIATIONS: A- ADJUST, C- CLEAN, RELATED I-INSPECTION, M- MONITOR, R- REPLACE, S-SERVICE, SYSTEM OR DESCRIPTION CAL- CALIBRATE, MS- MAJOR SERVICE SUBASSEMBLY 1500 3000 6000 12000 Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. LUBE OIL STRAINER PUMP S&I... - Page 43 COOLANT C&T C&T C&T C&T C&T COOLANT WATER S&I PUMP WATER JACKET C&I THERMOSTAT HEAT EXCHANGER C&I C&I C&I CRANK CASE WATER JACKET C&I C&I JACKET COOLING SYSTEM DUMMEY FOR WATER JACKET HOSES AND CLAMPS FUEL TANK C&I C&I C&I FLEXIBLE HOSES AND CLAMP FUEL WATER...
- Page 44 CONROD BIG END MOVING BEARING ELEMENT CONROD MAIN BEARINGS & THRUST BEARINGS CAM BUSH BEARING BEARINGS RELATED TO GEAR TRAIN CRANK CASE OIL SEALS - CAM SHAFT - CRANK TAPPET SHAFT - GEAR CAM SHAFT TRAIN CRANK SAHFT CAM & IDLE GEAR ROLLER BEARING FASTNERS FAN BELT...
- Page 45 TIGHTENING TABLE AND TORQUE VALUES FOR MAIN FASTENERS ALLOWABLE SPECIFICATIONS DESCRIPTIONS REQUIREMENTS TIMES (SIZE – GRADE) TO REUSE Main bearing bolt M18X169 - 10.9 140N.m+210° Crankcase secondary bolt M8X 25 - 8.8 8N.m+30 M8X210 - 8.8 Cylinder head main bolt M14X185 - 10.9 60N.m+2×120°...
- Page 46 Main bearing bolts tightening sequence Cylinder head main Bolts tightening sequence Cylinder head auxiliary bolts tightening sequence...
- Page 47 LIST OF SEALANTS AND THREAD LOCKING COMPOUNDS USED FOR ENGINE MAINTENANCE DESCRIPTION COLOR USAGE AND APPLICATION Apply it to smooth metal surface to prevent Molykotte Black seizing For example: apply it on the outer Pulver surface of cylinder sleeve. Take the lubricating function before the Molykotte G.u.
- Page 48 TROUBLE SHOOTING GUIDE FOR WP12 MARINE DIESEL ENGINE PROBABLE REASONFAILURE ▲ ▲ ▲ ▲ i f f / r i ▲ ▲ ▲ ▲ ▲ . r i ▲ ▲ ▲ manifold ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲...
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Page 49: Specifications For Lubricant, Coolant And Fuel
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. -
Page 50: Oil Performance Classification System
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. -
Page 51: Engine Oil Recommendations For Weichai Engines
(above 85W/90) Table 6.2 6.2 Engine oil recommendations for Weichai engines Quality of lubricating oil is one of the key drive factors to decide the performance, durability and total cost of operating of diesel engine. Hence, we have always been recommending the best available/suitable engine oil to be used in our engine. -
Page 52: Grease Recommendations
Weichai will not be responsible for problems occurring on engines due to poor quality of oil. 6.4 Fuel oil recommendations Weichai diesel engines will operate both BV-IV and BV-III standard diesel. The basic specification for diesel is as Table 6.3 & Table 6.4:... - Page 53 SPECIFICATION FOR AUTOMOTIVE DIESEL FUEL (BV IV) (IS 1460-2005 with Amendment 2 March, 2010) Typical SR. NO PARAMETER SPECIFICATION STD.METHOD Analysis Acidity, inorganic, mg KOH/g IS 1448, P:2 Acidity, total, mg KOH/gm To report IS 1448, P:2 0.05 IS 1448, P:4 Ash, percent by mass, Max 0.01 <0.01...
- Page 54 SPECIFICATION FOR AUTOMOTIVE DIESEL FUEL (BV III) (IS 1460-2005 with Amendment 2 March, 2010) Typical SR. NO PARAMETER SPECIFICATION STD.METHOD Analysis Acidity, inorganic, mg KOH/g IS 1448, P:2 Acidity, total, mg KOH/gm To report IS 1448, P:2 0.05 Ash, percent by mass, Max 0.01 IS 1448, P:4/ISO 6245 <0.01...
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Page 55: Coolant
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. - Page 56 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...
- Page 57 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...
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Need wp12 fasteners tour question chart
The fasteners torque specification chart for WEICHAI WP12 is as follows:
Fuel (WP12) Torque Requirements:
- Fuel tank pulling belt fixing nut (M10): 45±5 N.m
- Fuel tank pulling belt fixing nut (M12): 81±8 N.m
- Fuel tank pulling belt fixing nut (M16): 202±20 N.m
- Fuel tank inlet/outlet fuel pipe: 46±6 N.m
- Oil-water separator seat fixing bolt (M10): 45±5 N.m
- Oil-water separator seat fixing bolt (M12): 81±8 N.m
- Inlet and outlet fuel pipes link bolt: 46±6 N.m
Additional torque specifications for other components are also available in the document.
This answer is automatically generated