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Deutz WP6C/WP4C Series Marine Diesel EnginesOperation and Maintenance Manual andUser Service Guide13060345

Deutz WP6C/WP4C Series Marine Diesel Engine Operation and Maintenance ManualDeutz WP6C/WP4C Series Marine Diesel Engine User Service GuideImportantIn order to ensure your safety and give full play of high performance of diesel engine, pleasecarefully read this manual before operating the diesel engine and closely abide by theoperation and maintenance procedures specified in this manual.In order to protect your lawful rights and interests, never dismantle the lead sealing for thefuel amount from the fuel pump without permission.The guarantee from the factory will be invalid for adjusting the fuel injection pump ordismantling the lead sealing.Because the fuel injection pump is sophisticated component, users are not allowed todismantle it. Failure to do so will cause the factory's guarantee invalid.Because the rotor shaft of supercharger is sophisticated high-speed rotating part, users are notallowed to dismantle it or let it be impacted. Failure to do so will cause the factory’sguarantee invalid.Because of the strict torque and turn angle requirements for the main bearing bolts andconnecting rod bolts of diesel engine, users are not allowed to loosen and dismantle them.Failure to do so will cause the factory’s guarantee invalid.At any time of starting the diesel engine, please check whether the coolant and oil is fullyfilled.As the connecting rod bolts are disposable, never reuse them.

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance ManualDeutz WP6C/WP4C Series Marine Diesel Engine User Service GuidePrecautions1.Before delivery of the engine, the delivery test is already and strictly done based on testspecifications. As the throttle openness is already limited by lead sealing, never randomlydismantle the lead sealing to increase the throttle. Otherwise, our factory will not perform theThree-guarantee. Users are hoped to pay attention to this.2.The operator should carefully read this Operation and Maintenance Manual, be familiar withthe structure of this diesel engine and closely abide by the technical operation andmaintenance procedures specified in this manual.3.Before using the new diesel engine, please perform the trial operation for 50h.4.After the diesel engine is cold started, please slowly increase the rotating speed and neveridle for long time. After engine running with load, do not immediately stop it. It is necessaryto idle for 5-10 min at low speed.5.After engine is stopped, if the ambient temperature is lower than 0 , yet the antifreezeadditive is not applied, please completely drain the water in water tank and diesel engine.6.The diesel engine is prohibited to work without air cleaner which could prevent unfiltered airfrom entering the cylinders.7.Please select the specified fuel and oil grades which will be filled into the diesel engine (it issuggested to use Weichai Power special oil sold at all service stations of Weichai). Use thespecial clean container. The fuel and oil should be filtered through the strainer before beingadded. Precipitate the fuel for 72h or more.8.The inspection of electrical system should be done by the personnel mastering the electricalknowledge.9.The valid duration of oil sealing for the diesel engine is one year. If the valid duration isbeyond one year, please take necessary supplement measures.10. The power calibration and revision of diesel engine should be based on theCB/T3254.1-1994.

Deutz WP6C/WP4C Series Marine Diesel Engine Operation and Maintenance ManualDeutz WP6C/WP4C Series Marine Diesel Engine User Service GuidePrefaceWP6/WP4 series marine diesel engines are manufactured by Weifang Weichai Deutz DieselEngine Co. Ltd - the joint venture of Weichai Power Co. Ltd and Deutz AG. This series dieselengines are classified into supercharge type and supercharge and intercooled type based on theaspiration methods. There are two kinds of cylinder types: 4-cylinder and 6-cylinder. These seriesdiesel engines are of four stroke, water cooling, in-line, DI combustion chamber and high speedengines, featuring by compact structure, reliability operation, excellent power performance andeconomy indexes, advanced emission indicators, quick start, easy operation and convenientmaintenance etc. These series diesel engines are the ideal propulsion power for small vessels usedfor inland water transportation, fishery and high-speed ships.This manual mainly covers the main technical parameters, performance indicators, structuralfeatures and operation and maintenance precautions for WP6/WP4 series marine main andauxiliary engines. Before using this engine, please closely follow all requirements specified in thismanual. This could ensure the operation reliability and prolong the useful life of diesel engine.Before servicing, disassembling and installing the diesel engine, please carefully read the DeutzWP6/WP4 Series Marine Diesel Engine Parts Catalogue to master the basic structures of allsystems of the diesel engine.What this manual describes is the basic models of WP6/WP4 series marine diesel engines. As toother model information which is not listed into basic model, users could consult according to thecontact phone, fax etc on the “User Feedback Card”. As the products continuously develop, thestructure will also change. Partial content in this manual may be slightly different from the actualproducts. This manual will be subject to be revised without notice. Access the www.weichai.comfor updated product information and hope users timely pay close attention to all the issuedtechnical information. If you feel the content important, please timely contact with the technicaldepartment or sale department of Weichai Power Co. Ltd to avoid unnecessary trouble during thenormal use and maintenance.Welcome comments and suggestions for product improvement from users. Please send the “UserFeedback Card” annexed at the end of this manual to the Sales Company or ApplicationEngineering Department of Weichai Power Co. Ltd.Mar.2010

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance ManualDeutz WP6C/WP4C Series Marine Diesel Engine User Service GuideContentsI. Deutz WP6C/WP4C Series Marine Diesel Engine Use and MaintenanceManualWP6/WP4 series diesel engines model meaning . 1WP6/WP4 series marine diesel engine structural features: . 11 Main performance and technical parameters for WP6C/WP4C series marine diesel engines. 22 Fuel, oil and coolant used for diesel engines . 32.1 Oil . 32.2 Fuel . 32.3 Coolant . 43 Diesel engine installation and connection. 63.1 Diesel engine hoisting . 63.2 Diesel engine installation . 63.3 Installation of external connection systems for diesel engine . 74 Operation and maintenance of diesel engine . 84.1 Preparations before operation . 84.2 Operation precautions . 104.3 Maintenance of diesel engine . 115. Common fault analysis and troubleshooting . 13II. User Service Guide (Warranty Card) . 1Weichai Power Product Warranty Card (for User) . 1Maintenance Registration Form (Filled by Maintenance Personnel) . 2Warranty Instructions . 3Regulations about Term of Three Guarantees Service for Weichai Power Marine or PowerGenerating Diesel Engine . 5Customer Satisfaction Questionnaire . 6Engine Mandatory Maintenance Card

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance ManualWP6/WP4 series diesel engines model meaningThe symbols of all models from the WP6/WP4 series diesel engines are shown as follows:Rotating speed code (see table 1)DashPower code (expressed in HP)Application feature symbol (C- marine main engine; CDmarine auxiliary engine)Total displacement LWeichai PowerTable 1Rotating speedRotating speed 518212325WP6/WP4 series marine diesel engine structural features:One head for one cylinder, reliable operation and convenient disassembly.With the high body rigid, preassembled camshaft sleeve should increase the engine reliability.Compact engine layout, special and flat oil sump, convenient for matching with the ship.1

MainperformanceandtechnicalparametersforWP6C/WP4C seriesmarinedieselenginesTable 11Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual2

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual2 Fuel, oil and coolant used for diesel engines2.1 OilQuality grade: Oil should be classed according to its quality and features. Generally apply theAPI or GB for classification.Oil allowable to be used: CD grade or betterViscosityOil viscosity greatly depends on the temperature. Please refer to the fig.2-1 (ambienttemperature ) to select proper oil. The ambient temperature should not exceed the temperaturelimit for long time to keep the wear within the lowest limit.Ambienttemperature.Multi-grade oilSingle-grade oilFig.2-1 Selection of oil gradeSuggestion:1.Use the multi-grade oil to avoid changing oil as the season changes. Therefore the fuelconsumption rate can be decreased.2.If the ambient temperature is -15 or more, use the CF-4 grade 15W/40 oil. If the ambienttemperature is -15 or less, use the 5W/20 oil.It is recommended to use the Weichai Power special (Shell) 15W-40 oil, which is mixed by theimported quality basic oil and selected additive. This oil is sold at all service stations of Weichai atthe unified national sale price.Caution:1.Do not check the lubricant level during engine running.2.It is not allowed to mix the different grades of oil.2.2 FuelThis diesel engine uses the light diesel as the fuel;Quality gradeSulfur content in the fuel of specified grade should not be higher than 0.5%.Apply the following grades of diesel fuel based on the ambient temperature.3

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance ManualIf the ambient temperature is higher than 5 , it is recommended to use the 0# diesel (GB 252-94)At low temperature, the diesel fuel may precipitate the waxy material which causing poorflowability of diesel fuel. In such case, the fuel system will be clogged, causing failures of dieselengine. Therefore when the ambient temperature is less than 0 , please use the winter diesel fuel.According to the GB252 diesel fuel standard, if the ambient temperature is -5 or more, pleasechoose the -10# diesel fuel. If the ambient temperature is -14 or more, please choose the -20#diesel fuel. If the ambient temperature is -29 or more, please choose the -35# diesel fuel. If theambient temperature is -44 or more, please choose the -50# diesel fuel.2.3 CoolantThe coolant of diesel engine should be soft water added by the anticorrosive agent andlong-lasting antifreeze.Long-lasting antifreezeLong-lasting antifreeze is of resistance to corrosion and freeze. Please refer to antifreeze relatedmanual for the proportion of long-lasting antifreeze. See the table 2-1 for the domestic long-lastingantifreeze.Table 2-1 Domestic long-lasting 41.082Boiling point 104.5 1108.5 1110.0 1Freezing point -18 1-36 1-45 1-10-26-35ItemsGlycol content %Specific gravity (15.6 )Proper min. temperature Caution1.Periodically check the antifreeze concentration if temperature is below 0 .Theconcentration of antifreeze should be inspected every 1000h yet at least once foreach quarter. The antifreeze should be changed every two years to avoidcorrosion.2.As to the regions where the temperature is always higher than 0 , use thewater anti-rust and anti-scale treated as the coolant. Never use the untreatedwater as the coolant.Anti-corrosive agentIf the ambient temperature is higher than 5 (in summer or autumn or regions with highertemperature), the anti-corrosive agent should be added into the coolant (NL emulsified anti-rustagent or LQS comprehensive protective agent). Please refer to related manual for the proportion ofa

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual Deutz WP6C/WP4C Series Marine Diesel Engine User Service Guide Precautions 1. Before delivery of the engine, the delivery test is already and strictly done based on test specifications. As the throttle openness is already limited by lead sealing, never randomly dismantle the lead sealing to increase the throttle. Otherwise .