Deutz WP6C/WP4C Series Marine Diesel Engines Operation and ... · Deutz WP6C/WP4C Series Marine Diesel Engine Use and Maintenance Manual 1 WP6/WP4 series diesel engines model meaning

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


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


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



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


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


2

Tab

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3

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.


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.


5

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.


6

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


7

3.3 Installation of external connection systems for diesel engine

The exhaust pipeline of diesel engine should avoid excessive bends. Expansion joint should be mounted around the middle of the pipeline. In addition, additive support should be mounted for pipeline. The inner diameter of exhaust pipeline should not be less than 83mm and the exhaust back pressure 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 satisfy that the diesel engine works for 8h at rated load. The fuel tank should be positioned where the fuel filler is not lower than inlet of fuel delivery pump. The inner diameter of fuel pipeline should not be less than 12mm.


8

4 Operation and maintenance of diesel engine

4.1 Preparations before operation

4.1.1 Unseal

When the diesel engine package is opened, first, the user should check the diesel engine and accessories according to the factory packing list, check whether the diesel engine surface is damaged, whether the connecting pieces are not loosened, etc., and then carries out the following operations:

(1) Scrub the rustproof layer, the anticorrosive agent, etc. of the exposed parts.

(2) Drain the oil-sealed oil of the fuel filter and the fuel system parts (starting without draining the oil-sealed oil of the fuel system is permitted, but only when the oil-sealed oil of the fuel system is consumed and the normal diesel fuel is available, the loaded operation of engine is permitted.)

(3) Check whether the 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 environment.

4.1.2 Add the oil

(1) The oil should meet the specified requirements; otherwise, it may lead to insufficient oil pressure, even wear and starting difficulty. The oil must be very clean. Weichai Power special oil (Shell) CD/15W-40 is recommended (refer to 2.1).

(2) Tighten the oil drain plug.

(3) Open the oil filler cap (refer to figure 4-1) and add the oil through the filter screen.

(4). Place the diesel engine on the flat ground, and pull out the dipstick to check the oil level. Add oil to the upper limit of the dipstick when necessary.

(5) Tighten the oil filler cap. Note: Check the oil level every time before starting the diesel engine.

Figure 4-1 Engine oil filler


9

4.1.3 Add the fuel

(1) The diesel fuel should meet the related regulations (refer to 2.2).

(2) Pay attention to the cleanliness of the diesel fuel, and store the diesel fuel still for above 72h before adding. Add the diesel fuel into the fuel tank through the internal filter screen.

Note: Check the diesel fuel level every time before starting the diesel engine.

4.1.4 Air bleeding of fuel system (Refer to figure 4-2)

(1) Unscrew the fuel screw 1 at the outlet of fuel delivery pump for half a turn. Operate the hand pump 2 of the fuel delivery pump 3 until the diesel fuel emits out and then tighten the fuel screw.

(2) Unscrew the air bleed screw 4 on the fuel filter 5. Operate the hand pump of the fuel delivery pump until the diesel fuel emits out and then tighten the air bleed screw.

(3) Unscrew the air bleed screw 6 on the fuel injection pump 7. Operate the hand pump of the fuel delivery pump until the diesel fuel emits out and then tighten the air bleed screw.

(4) Continue to operate the hand pump, check the fuel line for leakage, and then tighten the hand pump.

4.1.5 Add the coolant

The coolant is prepared from softened 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 as soon as possible. Add softened cleaning water as much as possible and try to avoid frequent changing of coolant. The coolant drained from the water tank can be reused after being filtered by fabric and fine screen.

Check the coolant level every time before starting the diesel engine.

4.1.6 Battery charging

Please refer to the battery instruction manual.

Note: The gases generated during charging are explosive. No smoking is allowed around the battery, and the battery must be kept away from any naked flame and spark. There is strong corrosive acid in the battery, please flush with a large amount of fresh water if the acid is splashed into the eyes or on the skin.

Operation sequence for charging:

(1) Open the seal cover.

(2) Add the battery sulfuric acid from the filler to the marked position.

(3) Fasten the seal cap.

(4) Apply antirust grease on the battery electrodes.

(5) Connect the terminal and the electrodes, Connect the positive electrode firstly.

Figure 4-2 Air bleeding of fuel system


10

(6) It is not allowed to place any metal object on the battery.

(7) Check the sulfuric acid level every day after the use of battery. Add distilled water if needed.

4.2 Operation precautions

4.2.1 Operation precautions

Prior to starting the diesel engine, check the levels of oil, cooling water and fuel and the connections of pipelines (refer to 4.1).Rotate the crankshaft for several turns and confirm that there is no clamping or binding phenomenon.

When starting the diesel engine, if it is not started in 15s, wait for 2min and then restart it.

After starting the diesel engine, run it at idle speed for 2~3min and the oil pressure should be higher than 120kPa, if not, stop it immediately for check; if the cooling water temperature is not higher than 60 , do not run the diesel engine suddenly in high speed and with large load, because ℃

this will affect the wear resistance and the reliability of the engine.

Check the diesel engine for “three leakages” every time after 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 the cable connecting the battery anode. Different from the DC generator, it is not allowed to check the alternator voltage by grounding temporarily.

4.2.2 Precautions for starting and operation in cold environment

(1) If long-acting antifreeze is not added in the cooling water of the diesel engine, during use in cold days, the cooling water must be drained out after shutdown to avoid frosting the diesel engine. Open the special drain valve (Refer to figure 4-3) at lower position of the cylinder block of injection pump side, the cooling water in the diesel engine can be drained out.

Figure 4-3 Drain valve

(2) Before the cold seasons begin, check electrolyte level, viscosity and unit voltage of the battery. If the engine is in an environment with very low temperature for a long time, take the battery down and store it in a warm room.


11

4.3 Maintenance of diesel engine

Maintenance schedule of diesel engine

No repetitive operation is needed after maintenance according to the following time:

Operation item Running time h

Retighten the connecting bolts and the cylinder head bolts

30

Check the belt and the tightness 30 125

Change the oil and replace the oil filter element

30 125

Check the valve clearance 30 125

Repeat the maintenance operation according to the following time:

Operation item Running time h

250 500 1000

Clean the air filter element 1) ×

Check and tighten the V-belt ×

Check the raw water pump impeller 2) ×

Check the 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 for standby state and emergency state

Seal the diesel engine up if it is not used for weeks (for example, in winter).

Time Maintenance requirements

Every month Trial run with load

6 months After operating for 6 months, if the operation time does not reach 500h, carry out all maintenance operations required in this period.

After12 months After operating for 12 months, if the operation time does not reach 1000h, carry out all maintenance operations required in this period.


12

Overhaul

The operation reliability of the diesel engine will be affected by wear and corrosion. To avoid abnormal operation of the diesel engine, we recommend that complete overhaul be carried out according to the following table. Carry out the first overhaul after 2000h’s or 2 years’ (in the case of not reaching to 2000h) operation of the diesel engine.

Items Operation time

Check the nozzle 2000

Check the compression pressure 2000

Check the bearing 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 mechanism 10000

Check the transmission gear 10000

Overhaul the fuel injection pump thoroughly 10000

Replace the oil pump 10000

Replace the water pump 10000

Replace the crankshaft oil seal 10000

Replace the shock absorber 10000

The above checks and repairs require professional skills and should be carried out by professionals.


13

5. Common fault analysis and troubleshooting

5.1 The diesel engine cannot start

S/N Cause Troubleshooting

1 Use

(1) Air starter: The air pressure in the starting air bottle is insufficient or is not in optimal starting position.

Always keep the pressure in the air bottle above 2MPa; prior to starting, barring the engine and make one of the cylinders at an angle about 15° behind the top dead center.

(2) Electric starter: The battery is low in capacity.

Check the specific gravity of battery electrolyte (which should be 1.28-1.30) and keep the battery warm in winter or cold regions or use the insulation (low-temperature) battery.

(3) The service handle is not in the service position.

Tighten the service handle to the service position.

(4) The diesel engine is loaded. Unloading

(5) The oil viscosity is high and the 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 selected diesel fuel is improper.

Select according to regions and seasons.

2 Fuel system

(1) There is leakage from the fuel pipe joint.

Check and tighten the joint.

(2) The fuel pipe is blocked. Check and clean or blow free the fuel pipe.

(3) The diesel filter is blocked. Remove, clean or replace the filter element.

(4) The spray of the fuel injector is not good.

Adjust and repair the fuel injector. Replace the needle valve coupled parts when necessary.

(5) The fuel supply advance angle is incorrect.

Adjust as required.

(6) The fuel injection pump or the fuel injector is damaged.

Overhaul or replace

3 Others

(1) There is leakage from the

inlet/exhaust valve. Overhaul and readjust the valve clearance.


14


(2) There is air leakage from the cylinder.

Check the cylinder head gaskets and tighten the cylinder head nuts.

(3) The valve spring is broken. Replace it.

(4) There is gas leakage from the piston rings.

Replace the piston ring.

(5) The piston is stuck in the cylinder.

Remove and repair.

(6) There is gathered water in the cylinder.

Remove the cylinder head, drain the water, and find out the cause.

(7) The timing of air distribution plate of the air starter is wrong.

Remove and reinstall.

5.2 The diesel engine cannot output specified power


1 Use

(1) The speed is low. Adjust to the rated speed.

(2) The elevation or ambient temperature of operation regions is too high.

Correct according to the environmental conditions, refer to annex “Power correction table”.

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 or overhaul the fuel injection pump.

(3) The fuel injection pump is worn, the fuel supply is insufficient.

Unscrew the limit screw of the fuel pump control rack, increase the fuel capacity or replace a new plunger and barrel assembly.

(4) The diesel fuel filter is clogged, the fuel pressure of the fuel delivery pump is insufficient, the check valve of the fuel delivery pump is broken or worn, or the spring is broken.

Check and clean or adjust and replace

(5) The diesel fuel selected is improper. Select the specified grade according to regions and seasons (ambient temperature).

(6) The fuel supply advance angle is incorrect. Check and adjust

3 Air distribution system


15


(1) The air filter, the supercharger compressor or the intercooler is unclean.

Remove and clean.

(2) The external exhaust pipe does not meet the requirements or the exhaust back pressure is too high.

Design and install the external exhaust pipe as required.

(3) There is leakage from the inlet/exhaust valve. Check and grind repair.

(4) The inlet/exhaust timing is incorrect. Check and adjust.

(5) There is air leakage from the air inlet valve or the start valve on the air starter cylinder head.

Remove and grind repair.

4 Others

(1) The compression pressure is insufficient (the compression ratio is incorrect or the piston rings are excessively worn)

Check, adjust or replace the piston rings.

(2) The piston and the cylinder liner are scuffed or other worn parts are faulted.

Remove the cylinder head, check the internal surface of the cylinder 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


1 Off-white smoke

(1) The diesel engine is too cold. Adjust to rated speed.

(2) There is water leakage in the cylinder. Remove the exhaust pipe or the cylinder head and check

(3) Incomplete combustion. Check the fuel injector or the compression pressure in the cylinder.

2 Taupe smoke

(1) The diesel engine load is too high. Lower the load

(2) There is too much fuel pumped out from some sub-pump.

Adjust according the method described in chapter 4.

(3) The fuel injector is faulted (if the fuel drops from the fuel nozzle, the exhaust will smoke intermittently).

Check the fuel injector or repair or replace the injection nozzle.

(4) The fuel supply advance angle is insufficient (there is black smoke or flame in the exhaust).

Adjust the fuel supply advance angle as required.

3 Sky-blue smoke


16


(1) In the case of cold state, the engine oil enters the combustion chamber.

Rise the inlet water temperature.

(2) The running time of the new engine is not long. Increase the running-in time.

(3) The piston rings are worn. Overhaul

5.4 Abnormal noise or vibration during diesel engine running


1 Premature fuel injection or uneven fuel delivery causes the clear, rhythmic and metallic knocking noise, especially at start or low speed.

Adjust the fuel supply advance angle or adjust the uniformity of fuel amount.

2 The clearances of the intake valves or exhaust valves are excessive, making rhythmic and slight knocking noise.

Adjust valve clearance

3 Increase load before diesel engine is preheated. The clearance between the piston and cylinder liner is excessive, making knocking noise.

Unloading for idle warning of diesel engine.

4 The wear of piston, piston rings and cylinder liner are excessive, making knocking noise.

Replace the related parts

5 The wear between each journal 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 impacts the top of piston.

Adjust valve clearance or timing

8 Individual cylinder does not work and diesel engine vibration is aggravated.

Check the fuel system and solve the failure.

9 The valve is fractured (the valve lock clip is damaged, valve drops or the piston fractures, causing sudden or strong knocking noise)

Immediately stop the engine for inspection.

10 Air leaks from the cylinder head gasket, making howling.

Check the cylinder head nuts for tightness or replace the cylinder head gasket.

11 Wear of each gear is excessive, making knocking noise.

Check and then replace it

12 The fixing bolts attaching to diesel engine is loose or damaged, aggravating vibration.

Tighten or replace the bolts

13 Diesel engine is not coaxial to the connected work device, aggravating the vibration.

Check and adjust it

14 Uneven foundation causes the deformation of common base plate.

Check and adjust it


17

5.5 Unstable diesel engine operation


1 The clearance increases due to inflexible movement of governor flyweight movement or wear factors.

Check for the existence of stuck phenomenon. Repair or replace accordingly.

2 The buffering clamp spring of the speed governor loses its elasticity or is fractured and results in control rack vibration and unstable speed.

Check or replace

3 The diesel engine speed is too low and the engine runs at the intermediate speed. The land engine double-speed governor fails to operate automatically.

Accelerate to the rated speed.

4 The diesel engine load changes frequently. Check the condition of load output.

5 Some of cylinder ignites interruptedly. Therefore, these cylinders explode fiercely due to excessive accumulated fuel and 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 pump water or water supply is insufficient


1 There is air in the water pump or water absorption pipe.

Fill some water to bleed air from it.

2 The water pipe is clogged or frozen (in cold season).

Remove clogging or fill the cooling system with hot water or fill with antifreeze in advance.

3 The water pump sealing device or sealing gasket is damaged and there is air leakage.

Overhaul or replace.

4 The water pump belt is too loose. Check and adjust.

5 There is excessive water scale in the diesel engine water pump.

Remove water scale.

6 The water pump suction height is excessive.

Install the water pump according to relevant specifications.


18

5.7 Oil pressure is too low


1 The lubrication oil is in poor quality (the specific phenomenon is the oil pressure drops gradually with diesel engine running).

Select proper lubrication oil according to relevant specifications.

2 The diesel engine is overheated and the oil gets thinner.

Troubleshoot according to items in Section 5.8 of this chapter.

3 The oil filter is clogged. Clean

4 There are loose pipe joints and oil leakage in the oil line or there is air in the pipeline.

Check and tighten.

5 There is diesel fuel mixed in the oil. Change and find out the cause.

6 The spring for the pressure adjusting valve of the oil 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


1 There is no sufficient coolant. Troubleshoot according to items in Section 5.6 of this chapter.

2 The water inlet temperature is too high.

Reduce the water inlet temperature.

3 The oil pressure is too low. Troubleshoot according to items in Section 5.7 of this chapter

4 The diesel engine is overloaded. Reduce its load and find out the cause.

5 Fuel injection is too late. Check and adjust.

6 There is air leakage at the piston ring.

Check and replace

7 The bearing fit is too tight. Check and properly grind.

8 The ambient temperature is too high. Implement power correction and reduce the load effect.


1

II. User Service Guide (Warranty Card)

Weichai Power Product Warranty Card (for User)

Item Content Item Content

Model Customer Name

Order Number Post Code

Serial Number Address

Date of Purchase Office Tel.

Distributor Home Tel.

Dear customer,

Welcome to use Weichai products and thank you to select Weichai products!

For proper usage and maintenance of your diesel engine, please read the Operation and Maintenance Manual of Diesel Engine carefully and keep strict compliance with relevant specifications in operations. In the case of 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 Dong Street, Kuiwen District, Weifang, Shandong

Post Code: 261001

Website: http://www.weichai.com

Main Engine Sales Tel.: 0536-8232488/ 8233371

Spare Parts Sales Tel.: 0536-2297313/ 2297319

Service Hotline:

400 Free Service Hotline: 400-6183066

800 Free Service Hotline: 800-8603066

Customer Service Center Hotline: 0536-8235369 (Fax)

Customer Service Center Complaint Phone: 0536-2297322

24-Hour Service Hotline


2

Maintenance Registration Form (Filled 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


3

Warranty Instructions

1. Service Commitment:

Our company provides maintenance service within the service area of maintenance service units. Once an user message arrives and corresponding service demand is confirmed, maintenance men from the maintenance service center would arrive the service site within 3 hours for local urban areas, 24 hours for general areas and 48 hours for remote areas (when force majeure is excluded).

2. Further Hints:

� Diesel engine operators should carefully read this Operation and Maintenance Manual and be familiar with structure of the diesel engine, strictly follow technical operations and maintenance regulations specified in the manual and pay attention to cautions and warning signs.

� This diesel engine has passed factory test according to relevant test specifications. A lead seal limit has been applied to the throttle and it is prohibited to remove the lead seal at will for a larger throttle opening. Otherwise, Weichai Power would be exempted from the liability of warranty.

� Bolts of the diesel engine possess various strict tightening torque requirements and times of usage so that users are not allowed to loose main bearing bolts or connecting rod bolts at will. For detailed requirements, please refer to the Operation and Maintenance Manual.

� In the case of a new engine, customers should implement 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 operate without an air filter. To prevent unfiltered air from getting into air cylinders, you should clean the air filter element more frequently or shorten its replacement interval in the case of severe operation environment so as to avoid faults like premature wears of the diesel engine.

� When filling the diesel engine with fuel and oil, it is necessary to select that with specified grade and adopt special clean containers. During filling, they should be filtered by the filter screen. Moreover, fuel should be precipitated by more than 72 hours.

3. “Three Guarantees” Service Principles and Rules:

(1) Three Guarantees Service Principles

� For product damages due to their manufacturing and assembling in the case of normal use and proper maintenance, these Weichai engines or products equipped with Weichai engines are included in “Three guarantees” scope during the “Three guarantees” period.

� The diesel engine and parts should be repaired firstly of all. If it is confirmed that they are not repairable, replace them with corresponding parts: If it meets the conditions for the whole engine replacement specified by Weichai Power Co., Ltd. , the replacement should be submit to the person in charge for approval.


4

(2) Three Guarantee Period

� For end engine products manufactured by Weichai, their Three guarantees service and warranty period starts from the actual date of sales and Weichai sales invoices and warranty cards or sales invoices from distributors can be taken as the evidence (The Three guarantee period for marine main engine starts from the actual testing and adjusting date of the engine).

� For that of matching engines for the other products, the agreement between two parties prevails; If there are specific specifications for the engine three guarantees issued by the main engine manufacturer, these specifications prevail．The attached warranty card is regarded as the evidence for the executive standard. If there is no specific standard for the three guarantees service of the engine or detailed contents are unknown, Weichai standards prevail. Three guarantees service and the start date would depend on the actual sales date of the matching products and relevant sales invoice and warranty card are taken as the evidence.

� For original quality problems in spare parts purchased from Weichai, the three guarantee period for assembly parts is 3 months, for basic parts, it is 1 year. In the case of wear parts, rubber parts, piston rings, oil seals, bearing bushes, bolts, fuel injector couplings etc are not included in the scope of three guarantees after their installation. If there are quality problems of basic parts in the three guarantee period, the three guarantees service will be billed according to work hours after the site confirmation from the dispatched man in the 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 engine faults due to improper usage, maintenance and matching; Damages occur during loading and unloading of transport after purchasing; Operating conditions exceed the scope specified in the product manual; improper matching and overspeed and overload application etc; Running-in and maintenance which are not implemented according to product manual; Application of oil/fuel, antifreeze and filters etc which are in poor quality and do not comply with relevant specifications.

� Faults due to modification, adjustment and disassembling of parts which are not allowed to be modified, adjusted and disassembled.

� Oil, antifreeze, filtering elements, hoses, belts and fuel injector couplings etc which are applied to normal use, consumption and maintenance.

� Absence of three guarantees evidences like warranty card and relevant invoice etc and the user fails to prove the purchased product is still in the valid three guarantee period. The product specification and model on the evidence or invoice do not comply with those included in the three guarantees or such specification and model have been altered.

� The user fails to remain the original status after fault occurrence but implements troubleshooting at will and it is impossible to implement technical appraisals for the detection of fault causes.

� Faults caused by misoperation.

� Damages result from force majeure like wars and natural disasters etc.

� Diesel engine damages due to traffic accidents.


5

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

S/N Product Model

Term of Three Guarantees

Remarks

I. Complete diesel engine

The date of actual sales prevails and the sales invoice, warranty card or time counter are take as evidences;

1 Marine diesel engine, diesel engine for generating set and diesel engine for other power equipments

1 year

II. Diesel engine components

1 Basic parts

Engine body, crankshaft, engine seat and connecting rod

2 years (with original faults in manufacturing like air blisters etc)

2 Important parts

Cylinder head, flywheel, flywheel housing, timing gear chamber, connecting rod bolt, piston, piston ring, piston pin, connecting rod bearing shell, main bearing shell, camshaft bearing bush, camshaft, cylinder liner, valve, valve spring, valve seat, valve guide pipe, valve cover, tappet, push rod, rocker arm and shaft, various gears and gear shafts, tension pulley, ring gear, oil pump, intake and exhaust manifold, oil sump, front and rear brackets, belt pulley and flange, water tank, high-pressure fuel pump, fuel injector body, fuel pump holder, coupling, air compressor, various cover plates and base plates, water pump, oil radiator, fan bracket, silicone oil clutch, 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, suction filter, dipstick pipe fitting, cooling oil nozzle etc.

It is the same with the term of the complete diesel engine three guarantees.

3 Common parts

Front oil seal and other oil seals, supercharger, intake manifold gasket, exhaust manifold gasket, supercharger gasket, valve cover gasket, rubber hose, fuel injector return pipe, fuel delivery pump, dipstick, fan, waterproof and oil-proof rubber gaskets, bowl plug.

6 months or 750 hours

Electrical parts

Starter, generator, instrument, various sensors, electronic speed controller, throttle pedal, harness, solenoid valve and flame preheater.

6 months or 750 hours

4 Wear parts

Belt, fan shroud, fuel spray nozzle, plunger coupled parts, other gaskets, various braided hose, clamps, time counter.

1 month

Remarks: 1. If the time counter of marine or power generating engine is damaged, you can calculate the three guarantee period on the basis of 15h/day;

2. The start date of warranty period should begin from the testing and adjusting date for the new engine. However, the time interval between the testing and adjusting date and date of purchase should not exceed 1 year.


6

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License Plate Number

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Customer Name Engine Number

Detailed Address Date of Mandatory Maintenance

Mileage of Mandatory

Maintenance

Purchase Entity Date of Purchase

Identifier: Service Station Official Seal:

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 the Customer Satisfaction Questionnaire in this manual will be returned to the administrative area office by the service station.



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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 in this manual will be returned to the administrative area office by the service station.



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WEIFANG WEICHAI DEUTZ DIESEL ENGINE CO.,LTD.

Address: 121, Beigong Street, Weifang, Shandong 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.

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