WEICHAI WP12 User manual

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, specications 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 Modications 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 Specication.............................................................3
2.1 Main Specication ...........................................................3
2.2 Specication for Sub-Assemblies and Accessories .........4
2.3 Overall Dimensions Of WP12 Marine Diesel Engine ......5
2.4 Engine Model Identication ..............................................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
Specications 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 classication 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 modications or conversions
• Non-compliance with the safety instructions
• Skipping of routine checks and inspection
• Operation, maintenance and repair by unqualied personnel
1.2 Correct use
Every engine is designed and built to suit a desired application. WP12 Weichai-
Marine diesel engine is specically 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 Modications or conversions
Any modication on engine may impair its performance and shorten its life.
Unauthorized modications 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 modications 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 Rectied, 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

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 WP12C400-18 400 295 1800
3 WP12C450-21 450 330 2100
Table 2.3

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 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, ywheel etc.
2. Drain preservation oil from the engine sump.
3. Inject sufcient lubricant to turbocharger lubrication line to ensure proper
lubrication during startup.
The preservation period of diesel engine is six months. When
the storage/ idle duration exceeds six months, conduct
inspection and adopt necessary supplementary measures as
per company recommendations.
3.2 Engine installation procedure
WP12 series marine diesel engine is assembled with SAE-I ywheel and ywheel
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. Dimensions from diesel engine-mounting bracket plane to
crankshaft centerline will be varying for different engine models. Fabricate / select
the correct base-frame according to the engine model (Refer gure 2.1 & 2.2).
It is advised to couple the diesel engine with gear box by using suitable elastic
coupling. After coupling the engine with gear box, no axial force is allowed to act
on the diesel engine crankshaft; otherwise it will lead to failure and damages of
engine’s major sub-assemblies.
Figure 3.1 Figure 3.2

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 and bends should be minimized. Using of sharp bend
(elbows) in the system will create air ow restriction; use large arc bends instead.
The inlet air lter should be provided with an additional protective cover to prevent
ingress of water and dirt into system during rainy season. To take advantage of
air ow during boat movement; opening of the air inlet entry should be preferably
faced towards the front end of the boat.
3.4 Installation of exhaust system
The external exhaust duct should be fabricated with steel pipe. Using of sharp bend
(elbows) in the system will create restriction in exhaust gas outlet; this will develop
excessive back pressure in the system, resulting in poor engine performance. The
complete exhaust ducting should be properly supported and xed to the hull of
the boat. Pay attention to expansion bellow while installing the ducting; ducting
weight should not be exerted on the expansion bellow. After installing the system,
make sure the back pressure is within the limit. Maximum allowable back pressure
in the exhaust system is 6KPa. Exhaust system surface temperature is relatively
high during operation of engine. Avoid installing the exhaust pipe near ammable
objects, so as to prevent any re accidents or injury to the working personnel.
It is advised to provide adequate heat insulation to the external exhaust system
surface. Opening of the exhaust gas outlet should preferably facing rear end of the
boat. The exhaust outlet face should be minimum 1.5 Meters higher than the air
inlet opening. Refer schematic diagram of gure 3.3.
Figure 3.3

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 modication 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. User can install the pump on
either side of the engine according to the design of the engine room. Ensure that
the pump drive pulley and engine output pulley is aligned properly.
Fabricate the system pipe line only with anti-corrosive material. Reduce the length
of the system pipelines and number of elbows to minimize the resistance of water
ow. Dimension of the connecting lines (suction and delivery) should be same as
per the pump design.
Before priming/commissioning, make sure that the sea water
supply line is completely ushed and clean so that the system
is free from any metal obstacles or burrs.
3.6 Installation of diesel engine front end output
The front end output pulley of diesel engine can be used to drive small-sized
machinery, such as sea water pump, hydraulic steering pump and power take-off
etc. These units should be symmetrically arranged on two sides of the diesel engine
so as to avoid the diesel engine crankshaft from being subject to unidirectional
tension force. If it is necessary to drive large-sized machinery such as net-hauling
machine, then, an elastic coupling must be used for connection. Refer gure 3.4
The installation should be conducted according to the requirements on aligning
accuracy of different couplings as specied by the international standard. In service,
its coaxial accuracy should be periodically checked to ensure the alignment of the
coupling; otherwise it will lead to damage of parts and components of diesel engine.
ELASTIC COUPLING
Figure 3.4

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. Properly
connect the terminals without changing the polarity. Refer gure 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.
The key features of the electrical system are as below:
• Engine control - start and stop control from main and remote panel.
• Important parameter display on main and remote panel.
• Engine Safety – alarm with display and stopping the engine if crossing the safe
operational limits.
Properly mount the main engine control panel on the engine and remote panel in
the wheelhouse dashboard. Connect the wire harness plug in sockets from the
engine to the monitor. Establish the connection between the main and remote
monitors. Conrm all the functions (start, stop, display and safety) are working
properly from main and remote panel.
B -VE
B +VE
Figure 3.5 Figure 3.6 Figure 3.7

11
ELECTRICAL SYSTEM DRAWING FOR WP12 MARINE DIESEL ENGINE
MonitorWater 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
Regulator
30 50
B+ B-
D+
W
W
W
V
U
G
31
D2 D3 D4 D5 D6
Starter
Pin D1
Starter
Pin D2
Starter
Pin D6
Generator
Pin D3
Generator
Pin D5
Alarm
Pin D4
-
+
Starter Motor

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 experience and careless operation
may cause fatal accident. However, if the operator has mastered the operating
technique and understood the power limit in advance, and is carefully operating,
then the personal injury caused by accident can be completely avoided.
4.2 General instructions
Proper attention and care of engine will ensure optimum performance, long life and
more economical operations.
• Follow daily maintenance as per the guidelines.
• Ensure all meter and gauges are in operational conditions.
• Running the engine on idle speed must be limited to 3~4 minutes. Idling the
engine for longer periods will cause carbon to clog injector spray holes and
piston rings.
• Do not operate the engine with low engine body temperature for longer period.
If the engine temperature becomes too low (≤60˚C), raw fuel will dilute with the
lubricant. Fuel mixed lubricant could not provide proper lubrication between the
moving components. It is also harmful for the internal sub-assemblies.
4.3 Preparation for rst start
To avoid personal injury or machine damage, clear the loose
material away from the engine vicinity before starting
When preparing to start a new or overhauled engine, perform all the operations
listed below. Failure to follow these instructions may result in serious engine
damage. The operator must be familiar with all the instruments, gauges, and
controls which are needed to operate the engine. Understand the locations and
function of the following: Oil pressure indicator, low oil pressure warning indicator,
coolant temperature indicator, high coolant temperature warning indicator etc.
Closely monitor the overall engine performance and if any abnormal sign like
excessive blow by, overheat, excessive consumption of fuel or lube oil, abnormal
vibration or noise, change in exhaust gas color etc. is noticed, turn off the engine
immediately and rectify the cause of trouble. Engine damage may be avoided by a
quick response to early indications of troubles.
System-wise checks
Carry out a system-wise check to avoid any mistakes or points left out before
the rst start of the engine.
CAUTION

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
lter mounting) is closed properly. Refer gure 4.1
Figure 4.1
2. The coolant can be lled from the heat exchanger. Remove the cap provided
on the top (gure 4.2) and slowly ll the cooling system with recommended
coolant (gure 4.3). Slowly lling the coolant will help the air to escape without
trapping in the system.
For more details about coolant specication, refer section VI.
Figure 4.2 Figure 4.3

14
4.3.2 Lubrication system
Sump Capacity - 30 Liters
1. Check and drain out the preservation oil from the sump. After draining, x the
drain plug properly.
2. Engine oil can be lled from the lling port provided near the Fuel Injection
Pump. Refer gure 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.
For more details about lube oil specication, refer section VI

15
4.3.3 Checking the oil level
Make sure the boat is on oat or kept on a level surface. A dipstick is provided on
the crank case near to the oil lter assembly (gure 4.8). Check the oil level using
the oil dipstick. Safe oil level range is marked on the dipstick bottom (gure 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. (gure 4.10)
If necessary, top up the oil through the oil lling port. Do not overll.
DIPSTICK
Figure 4.8
Oil dipstick
H
HH
OK
LLL
OK
OK
Figure 4.9 Figure 4.10
Immediately clean up any oil spillage to avoid personal injury
4.3.4 After an extended storage
If an engine is non-operational for an extended period of time (shing off season for
example) may accumulate water in the oil pan and internal surfaces of the engine
through normal condensation of high humid air. Water mixed lube oil cannot provide
adequate bearing protection at engine startup and operation. For this reason, the
company recommends replacing the engine oil with lters after extended storage.
The lubricating oil lm on the rotating parts and bearings of an engine (which has
been in storage for six months or more), may be insufcient when the engine is
started for the rst time
CAUTION