Deutz WP4C Series, Operation And Maintenance Manual

Page 1: ...Deutz WP6C WP4C Series Marine Diesel Engines Operation and Maintenance Manual and User Service Guide 13060345 ...

Page 2: ...uel injection pump or dismantling the lead sealing Because the fuel injection pump is sophisticated component users are not allowed to dismantle 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 not allowed to dismantle it or let it be impacted Failure to do so will cause the factory s guarante...

Page 3: ...time After engine running with load do not immediately stop it It is necessary to idle for 5 10 min at low speed 5 After engine is stopped if the ambient temperature is lower than 0 yet the antifreeze additive 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 air from enterin...

Page 4: ...closely follow all requirements specified in this manual 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 Deutz WP6 WP4 Series Marine Diesel Engine Parts Catalogue to master the basic structures of all systems of the diesel engine What this manual describes is the basic...

Page 5: ...installation and connection 6 3 1 Diesel engine hoisting 6 3 2 Diesel engine installation 6 3 3 Installation of external connection systems for diesel engine 7 4 Operation and maintenance of diesel engine 8 4 1 Preparations before operation 8 4 2 Operation precautions 10 4 3 Maintenance of diesel engine 11 5 Common fault analysis and troubleshooting 13 II User Service Guide Warranty Card 1 Weichai...

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Page 7: ... 15 18 21 23 25 WP6 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 Rotating speed code see table 1 Dash Power code expressed in HP Application f...

Page 8: ...Deutz WP6C WP4C Series Marine Diesel Engine Use and Maintenance Manual 2 Tab le 1 1 Main performa nce and technical parameter s for WP6C W P4C series marine diesel engines ...

Page 9: ...stion 1 Use the multi grade oil to avoid changing oil as the season changes Therefore the fuel consumption rate can be decreased 2 If the ambient temperature is 15 or more use the CF 4 grade 15W 40 oil If the ambient temperature 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 the imported quality basic oil and selected additive ...

Page 10: ...ease refer to antifreeze related manual for the proportion of long lasting antifreeze See the table 2 1 for the domestic long lasting antifreeze Table 2 1 Domestic long lasting antifreeze Grade Items JFL 318 JFL 336 JFL 345 Glycol content 33 50 56 Specific gravity 15 6 1 05 1 074 1 082 Boiling point 104 5 1 108 5 1 110 0 1 Freezing point 18 1 36 1 45 1 Proper min temperature 10 26 35 Caution 1 Per...

Page 11: ...i corrosion agent Chloride ion content mg dm3 100 Carbonate content mg dm3 100 Total negative ion content mg dm3 150 Total hardness when using the long lasting antifreeze mg dm3 3 12 Carbonate hardness mg dm3 3 Total hardness when using the anti corrosive agent take note of the instruction of supplier mg dm3 0 10 Note Because inner galvanized tube is not suitable to use anti corrosive agent this t...

Page 12: ...ood for hoisting If the engine is hoisted through the lifting eyes attaching to the cylinder head bolts the slings as shown in fig B is recommended When hoisting the engine its crankshaft should be at horizontal level and two slings should at parallel status Do not use one sling which will lift the engine in the way of triangle If you use one sling the sling cylinder head bolts and lifting eyes ar...

Page 13: ...essure should not be less than 6kPa Rain cover should be mounted onto the outdoor outlet of exhaust pipe In order to smoothly drain the condensed water from the exhaust pipe water drain valve should be installed at the lowest place of the exhaust pipe Waterproof cap should be installed onto the outdoor inlet to prevent the rain water from entering the intake system The capacity of fuel tank should...

Page 14: ...water plug and the oil plug are plugged whether the water temperature and oil temperature sensors are complete and make sure that all necessary parts are available Note Do not start before the diesel engine is correctly installed and connected to the final position Ensure the ventilation and make sure that the exhaust gas is emitted to the atmosphere when the diesel engine runs in enclosed environ...

Page 15: ...tened cleaning water and anticorrosion agent or antifreeze strictly conform to the regulations of additive manufacturer during preparation refer to 2 3 Add the coolant from the water filler of the radiator or the heat exchanger and bleed the air from the cooling circulation system Note Frequent water adding and changing will generate scales in the system Repair the leakages of the cooling system a...

Page 16: ...ter operation If the diesel engine runs with load prior to shutdown decrease the load lower the speed and run it at idle speed for 4 5min to avoid full load shutdown Check the oil level of the diesel engine carry out the check 5min later after shutdown Note To avoid damaging the diesel engine during operation it is not allowed to remove the cable connecting the diesel engine pressure regulator and...

Page 17: ...zinc anode 2 Change the oil and replace the oil filter element Check the valve clearance Replace the diesel filter element Clean the crankcase ventilation device 3 1 Replace earlier if there is more dust Clean the wet air filter at least in 200h s operation 2 Only for marine engines only 3 Only for conditions when the crankcase ventilation device is not guided to air inlet Maintenance instructions...

Page 18: ...g clearance of water pump 5000 Check the supercharger 5000 Check the fuel injection pump 5000 Check the cylinder head 5000 Check the cylinder liner 5000 Clean the water cavity of the water cooling exhaust pipe and check the corrosion 10000 Check the connecting rod and the main bearing 10000 Check the piston 10000 Check the crankshaft 10000 Check the camshaft 10000 Check the secondary balance mecha...

Page 19: ...liquidity is poor Select the oil according to ambient temperature or heat the oil 6 There is air in the fuel system Bleed the air in the system 7 There is water in the diesel fuel Check the fuel tank unscrew the plug at the lower part of the diesel filter and discharge the water 8 The bleed screw of the fuel injector is not tightened and there is no fuel injection Tighten it clockwise 9 The select...

Page 20: ...ble 2 Fuel system 1 The fuel injector is faulted the injection hole is clogged the spray is not good the fuel injection pressure is insufficient or the height of the injection nozzle stretching out of the cylinder head is incorrect Adjust or overhaul the fuel injector as required 2 The fuel supply of the fuel injection pump is uneven or one or two sub pumps are inoperative Adjust the fuel capacity...

Page 21: ...der liner or other worn parts and repair or replace timely 3 The diesel engine is not sufficiently cooled and is too hot Check the belt tightness and all parts of the cooling system or remove the water scales 4 The bearings are not well lubricated or are too hot Overhaul the lubrication system or clean it 5 3 Exhaust smoke S N Cause Troubleshooting 1 Off white smoke 1 The diesel engine is too cold...

Page 22: ...l and bearing bush of crankshaft is excessive making knocking noise along the overall length of diesel engine Repair or replace it 6 Compression ratio is too high causing rough operation and large vibration The compression ratio should be adjusted to specification 7 The clearances of the intake valves or exhaust valves are small or the exhaust or intake timing is not correct causing that the valve...

Page 23: ...d this leads to cylinder knocking Check the fuel system 6 Injection volume and injection time for injection pumps are different Check and adjust 7 There is air in the fuel system Check and carry out air bleeding 8 There is moisture in the fuel system Check the fuel and carry out water drainage 9 There is left and right movement of timing gear Check all gears for fastening 5 6 Water pump does not p...

Page 24: ...pump gets fractured Replace 7 Oil pressure in the oil sump is too low or the oil pump suction height is excessive Add some oil or reinstall the oil pump and oil tank 8 The clearance between the connecting rod bearing and the main bearing is too large Check and replace 5 8 Diesel engine is overheated S N Cause Troubleshooting 1 There is no sufficient coolant Troubleshoot according to items in Secti...

Page 25: ... diesel engine faults please contact with Weichai Maintenance Service Center or Weichai Power Co Ltd Customer Service Center as soon as possible We will provide you with timely and effective maintenance service Maintenance Registration Form should be filled by the Maintenance Service Center during maintenance and customers should keep this form properly Weichai Power Co Ltd Address 26 Minsheng Don...

Page 26: ...ed by Maintenance Personnel Item Content Item Content Model Customer Name Order Number Post Code Serial Number Address Date of Purchase Office Tel Distributor Home Tel Name of Maintenance Service Center Date Warranty Item Replaced Spare Part Quantity Signature of Maintenance Man Signature of Customer ...

Page 27: ...nt 50h trial run for the engine After cold start of the diesel engine please increase the engine speed slowly Neither let the engine run at a high speed suddenly nor let it idle for a long time After stopping if the ambient temperature is lower than 0 and antifreeze additive is not used you should completely drain water from the water tank and the diesel engine The diesel engine is prohibited to o...

Page 28: ...he center service and preservation of effective photographs For three guarantee period of spare parts the sales invoice date of center warehouse or special service center prevails Assembling quality problems are not included in the scope of Weichai s three guarantees but it should be the assembling entity which undertakes the three guarantees 4 Regulations about Non Three Guarantee Items Diesel en...

Page 29: ...pressure limiting valve shock absorber crankshaft balance mechanism rear oil seal and seat various metal oil pipes water pipes and pipe joints steering pump thermostat oil gas separator cylinder gasket ECU common rail pipe high pressure fuel pipe air filter body diesel fuel filter body oil filter body muffler distribution plate starting valve intercooler heat exchanger air bottle thrust washer suc...

Page 30: ...Deutz WP6C WP4C Series Marine Diesel Engine User Service Guide 6 No te Ple ase tic k wit h in cor res po ndi ng col um ns Custom er Satisfac tion Questio nnaire ...

Page 31: ...Deutz WP6C WP4C Series Marine Diesel Engine User Service Guide 7 ...

Page 32: ...Deutz WP6C WP4C Series Marine Diesel Engine User Service Guide 8 ...

Page 33: ...omer Signature Valid Documentation Customer Tel Label of Weichai Power Special Oil Prompt This Mandatory Maintenance Card is in triple and all of them should be signed by the customer and it would be invalid in the case of any missed out item Weichai Power Service Hotline 400 6183066 800 8603066 After the completion of mandatory maintenance this card and the Customer Satisfaction Questionnaire in ...

Page 34: ...omer Signature Valid Documentation Customer Tel Label of Weichai Power Special Oil Prompt This Mandatory Maintenance Card is in triple and all of them should be signed by the customer and it would be invalid in the case of any missed out item Weichai Power Service Hotline 400 6183066 800 8603066 After the completion of mandatory maintenance this card and the Customer Satisfaction Questionnaire in ...

Page 35: ...Customer Signature Valid Documentation Customer Tel Label of Weichai Power Special Oil Prompt This Mandatory Maintenance Card is in triple and all of them should be signed by the customer and it would be invalid in the case of any missed out item Weichai Power Service Hotline 400 6183066 800 8603066 After the completion of mandatory maintenance this card and theCustomer Satisfaction Questionnaire ...

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Page 37: ...ng Tel 86 0536 8679536 Fax 86 0536 8679526 Post Code 261009 Part Number 13060345 Design Version Number ppbsj sjzl 201040 Amended in March 2009 This material is provided as reference only In the case of any product parameter changes the actual product prevails without any further notice ...