Deutz WP6C Series, WP4C Series Operation And Maintenance Manual

Deutz WP6C/WP4C Series Marine Diesel Engines

Operation and Maintenance Manual and

User Service Guide

13060345

Deutz WP6C/WP4C Series Marine Diesel Engine Operation and Maintenance Manual

Deutz WP6C/WP4C Series Marine Diesel Engine User Service Guide

Important

 In order to ensure your safety and give full play of high performance of diesel engine, please

carefully read this manual before operating the diesel engine and closely abide by the
operation and maintenance procedures specified in this manual.

 In order to protect your lawful rights and interests, never dismantle the lead sealing for the

fuel amount from the fuel pump without permission.

 The guarantee from the factory will be invalid for adjusting the fuel 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
guarantee invalid.

 Because of the strict torque and turn angle requirements for the main bearing bolts and

connecting 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 fully

filled.

 As the connecting rod bolts are disposable, never reuse them.

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, our factory will not perform the
Three-guarantee. Users are hoped to pay attention to this.

2. The operator should carefully read this Operation and Maintenance Manual, be familiar with
the structure of this diesel engine and closely abide by the technical operation and
maintenance 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 never
idle for long 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 entering the cylinders.

7. Please select the specified fuel and oil grades which will be filled into the diesel engine (it is
suggested to use Weichai Power special oil sold at all service stations of Weichai). Use the
special clean container. The fuel and oil should be filtered through the strainer before being
added. Precipitate the fuel for 72h or more.

8. The inspection of electrical system should be done by the personnel mastering the electrical
knowledge.

9. The valid duration of oil sealing for the diesel engine is one year. If the valid duration is
beyond one year, please take necessary supplement measures.

10. The power calibration and revision of diesel engine should be based on the
CB/T3254.1-1994.

Deutz WP6C/WP4C Series Marine Diesel Engine Operation and Maintenance Manual

Deutz WP6C/WP4C Series Marine Diesel Engine User Service Guide

Preface

WP6/WP4 series marine diesel engines are manufactured by Weifang Weichai Deutz Diesel
Engine Co. Ltd - the joint venture of Weichai Power Co. Ltd and Deutz AG. This series diesel
engines are classified into supercharge type and supercharge and intercooled type based on the
aspiration methods. There are two kinds of cylinder types: 4-cylinder and 6-cylinder. These series
diesel engines are of four stroke, water cooling, in-line, DI combustion chamber and high speed
engines, featuring by compact structure, reliability operation, excellent power performance and
economy indexes, advanced emission indicators, quick start, easy operation and convenient
maintenance etc. These series diesel engines are the ideal propulsion power for small vessels used
for inland water transportation, fishery and high-speed ships.

This manual mainly covers the main technical parameters, performance indicators, structural
features and operation and maintenance precautions for WP6/WP4 series marine main and
auxiliary engines. Before using this engine, please 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 models of WP6/WP4 series marine diesel engines. As to
other model information which is not listed into basic model, users could consult according to the
contact phone, fax etc on the “User Feedback Card”. As the products continuously develop, the
structure will also change. Partial content in this manual may be slightly different from the actual
products. This manual will be subject to be revised without notice. Access the www.weichai.com
for updated product information and hope users timely pay close attention to all the issued
technical information. If you feel the content important, please timely contact with the technical
department or sale department of Weichai Power Co. Ltd to avoid unnecessary trouble during the
normal use and maintenance.

Welcome comments and suggestions for product improvement from users. Please send the “User
Feedback Card” annexed at the end of this manual to the Sales Company or Application
Engineering Department of Weichai Power Co. Ltd.

Mar.2010

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual

Deutz WP6C/WP4C Series Marine Diesel Engine User Service Guide

Contents

I. Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance
Manual





WP6/WP4 series diesel engines model meaning ........................................................................... 1

WP6/WP4 series marine diesel engine structural features: ............................................................ 1

1 Main performance and technical parameters for WP6C/WP4C series marine diesel engines

.......................................................................................................................................................... 2

2 Fuel, oil and coolant used for diesel engines .............................................................................. 3

2.1 Oil ............................................................................................................................................... 3

2.2 Fuel ............................................................................................................................................. 3

2.3 Coolant ........................................................................................................................................ 4

3 Diesel engine 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 Power Product Warranty Card (for User) ............................................................................ 1

Maintenance Registration Form (Filled by Maintenance Personnel) ................................................ 2

Warranty Instructions ........................................................................................................................ 3

Regulations about Term of Three Guarantees Service for Weichai Power Marine or Power

Generating Diesel Engine ................................................................................................................. 5

Customer Satisfaction Questionnaire ................................................................................................ 6

Engine Mandatory Maintenance Card

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual

1

WP6/WP4 series diesel engines model meaning

The symbols of all models from the WP6/WP4 series diesel engines are shown as follows:

Table 1
Rotating speed 1500r/min 1800r/min 2100r/min 2300r/min 2500r/min

Rotating speed code 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 feature symbol (C- marine main engine; CD

-

marine auxiliary engine)
Total displacement L

Weichai Power

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

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual

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2 Fuel, oil and coolant used for diesel engines

2.1 Oil

 Quality grade: Oil should be classed according to its quality and features. Generally apply the

API or GB for classification.

Oil allowable to be used: CD grade or better
 Viscosity
Oil viscosity greatly depends on the temperature. Please refer to the fig.2-1 (ambient

temperature ) to select proper oil.℃ The ambient temperature should not exceed the temperature
limit for long time to keep the wear within the lowest limit.

Ambient

temperature.

Multi-grade oil Single-grade oil

Fig.2-1 Selection of oil grade

 Suggestion:

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. This oil is sold at all service stations of Weichai at
the 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 Fuel

This diesel engine uses the light diesel as the fuel;
 Quality grade
Sulfur 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.

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual

4

If 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 poor

flowability of diesel fuel. In such case, the fuel system will be clogged, causing failures of diesel
engine. 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, please ℃
choose 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 the
ambient temperature is -44 or more, please choose the ℃ -50# diesel fuel.

2.3 Coolant

The coolant of diesel engine should be soft water added by the anticorrosive agent and
long-lasting antifreeze.

 Long-lasting antifreeze
Long-lasting antifreeze is of resistance to corrosion and freeze. Please 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. Periodically check the antifreeze concentration if temperature is below 0 .The ℃

℃℃

℃

concentration of antifreeze should be inspected every 1000h yet at least once for
each quarter. The antifreeze should be changed every two years to avoid
corrosion.

2. As to the regions where the temperature is always higher than 0℃℃℃℃, use the
water anti-rust and anti-scale treated as the coolant. Never use the untreated
water as the coolant.

 Anti-corrosive agent
If the ambient temperature is higher than 5℃ (in summer or autumn or regions with higher

temperature), the anti-corrosive agent should be added into the coolant (NL emulsified anti-rust
agent or LQS comprehensive protective agent). Please refer to related manual for the proportion of
anti-corrosion agent and soft water.

 Coolant
For the composition of coolant, see the table 2-2.

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual

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Table 2-2 Coolant composition

Water quality min max
PH 6.5 8.5

Only if the coolant meets the water-quality
composition, can it be mixed with the
antifreeze or anti-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 tube is not
used as the coolant pipe.

Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual

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3 Diesel engine installation and connection

3.1 Diesel engine hoisting

Incorrect hoisting will cause damage to diesel engine.

Fig. A

Fig. B

2 special cylinder-head bolts have been installed on each diesel engine, which are used for hoisting
diesel engine. A M14 threaded rod is mounted on the six-square end face of the two bolts, which is
used to mount the special slings (see fig. A) and lifting eyes. When using the special slings, screw
the suspender with M14 threaded hole onto two cylinder head bolts, adjust the center of gravity
and then it is good 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 are not at the same line. Therefore, this could cause damage to the bolts and
even fracture during hoisting, leading to damage to diesel engine.

3.2 Diesel engine installation

Apply the elastic coupler and ensure the crankshaft center line is concentric to the axis of the input
shaft of gearing equipments (gearbox, transmission). There should be no additive axial force on
the crankshaft caused by installation.

Correct

Wrong