Operation and Maintenance Manual and User Service Guide: Deutz WP6C/WP4C Series Marine Diesel Engines

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
WP6/WP4 series diesel engines model meaning
The symbols of all models from the WP6/WP4 series diesel engines are shown as follows:
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
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.
1
2
Tab
le 11 Main
performa
nce and
technical
parameter
s for
WP6C/W
P4C series
marine
diesel
engines
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
Multi-grade oil Single-grade oil
temperature.
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.
3
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
JFL-318 JFL-336 JFL-345
Items
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.
4
Table 2-2 Coolant composition
Water quality min max

PH 6.5 8.5
Chloride ion content mg/dm3 - 100
3
Carbonate content mg/dm - 100
Total negative ion content mg/dm3 - 150
Only if the coolant meets the water-quality
Total hardness when using the composition, can it be mixed with the
3 12
long-lasting antifreeze, mg/dm3 antifreeze or anti-corrosion agent.
Carbonate hardness mg/dm3 3 -
Total hardness when using the
anti-corrosive agent (take note of the 0 10
instruction of supplier) mg／dm3
Note: Because inner galvanized tube is not suitable to use anti-corrosive agent, this tube is not
used as the coolant pipe.
5
3 Diesel engine installation and connection
3.1 Diesel engine hoisting

Incorrect hoisting will cause damage to diesel engine.
Fig. A
Correct Wrong
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.
6
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.
7
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
8
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
Figure 4-2 Air bleeding of fuel system
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.
9
(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.
10
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
30
head bolts
Check the belt and the tightness 30 125
Change the oil and replace the oil filter
30 125
element
Check the valve clearance 30 125
Repeat the maintenance operation according to the following time:
Running time h
Operation item
250 500 1000
1)
Clean the air filter element ×
Check and tighten the V-belt ×
2)
Check the raw water pump impeller ×
2)
Check the zinc anode ×
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
After operating for 6 months, if the operation time does not reach 500h, carry
6 months
out all maintenance operations required in this period.
After operating for 12 months, if the operation time does not reach 1000h,
After12 months
carry out all maintenance operations required in this period.
11
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
10000
exhaust pipe and check the corrosion
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.
12
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 Always keep the pressure in the air bottle above
in the starting air bottle is 2MPa; prior to starting, barring the engine and make
insufficient or is not in one of the cylinders at an angle about 15° behind the
optimal starting position. top dead center.
Check the specific gravity of battery electrolyte
(2) Electric starter: The battery is (which should be 1.28-1.30) and keep the battery
low in capacity. warm in winter or cold regions or use the insulation
(low-temperature) battery.
(3) The service handle is not in
Tighten the service handle to the service position.
the service position.
(4) The diesel engine is loaded. Unloading
(5) The oil viscosity is high and Select the oil according to ambient temperature or heat
the liquidity is poor. the oil.
(6) There is air in the fuel
Bleed the air in the system.
system.
(7) There is water in the diesel Check the fuel tank; unscrew the plug at the lower part
fuel. of the diesel filter, and discharge the water.
(8) The bleed screw of the fuel
injector is not tightened, and Tighten it clockwise.
there is no fuel injection.
(9) The selected diesel fuel is
Select according to regions and seasons.
improper.
2 Fuel system
(1) There is leakage from the
Check and tighten the joint.
fuel pipe 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 Adjust and repair the fuel injector. Replace the needle
is not good. valve coupled parts when necessary.
(5) The fuel supply advance
Adjust as required.
angle is incorrect.
(6) The fuel injection pump or
Overhaul or replace
the fuel injector is damaged.
3 Others
(1) There is leakage from the
Overhaul and readjust the valve clearance.
inlet/exhaust valve.
13

(2) There is air leakage from the Check the cylinder head gaskets and tighten the
cylinder. cylinder head nuts.
(3) The valve spring is broken. Replace it.
(4) There is gas leakage from the
Replace the piston ring.
piston rings.
(5) The piston is stuck in the
Remove and repair.
cylinder.
(6) There is gathered water in Remove the cylinder head, drain the water, and find
the cylinder. out the cause.
(7) The timing of air distribution
plate of the air starter is Remove and reinstall.
wrong.
5.2 The diesel engine cannot output specified power

1 Use
(1) The speed is low. Adjust to the rated speed.
Correct according to the
(2) The elevation or ambient temperature of
environmental conditions, refer to
operation regions is too high.
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
Adjust or overhaul the fuel injector as
injection pressure is insufficient, or the height
required.
of the injection nozzle stretching out of the
cylinder head is incorrect).
(2) The fuel supply of the fuel injection pump is
Adjust the fuel capacity or overhaul
uneven or one or two sub-pumps are
the fuel injection pump.
inoperative.
Unscrew the limit screw of the fuel
(3) The fuel injection pump is worn, the fuel pump control rack, increase the fuel
supply is insufficient. 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 Check and clean or adjust and replace
delivery pump is broken or worn, or the
spring is broken.
Select the specified grade according
(5) The diesel fuel selected is improper. to regions and seasons (ambient
temperature).
(6) The fuel supply advance angle is incorrect. Check and adjust
3 Air distribution system
14

(1) The air filter, the supercharger compressor or
Remove and clean.
the intercooler is unclean.
(2) The external exhaust pipe does not meet the
Design and install the external
requirements or the exhaust back pressure is
exhaust pipe as required.
too high.
(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
Remove and grind repair.
the start valve on the air starter cylinder head.
4 Others
(1) The compression pressure is insufficient (the
Check, adjust or replace the piston
compression ratio is incorrect or the piston
rings.
rings are excessively worn)
Remove the cylinder head, check the
(2) The piston and the cylinder liner are scuffed internal surface of the cylinder liner
or other worn parts are faulted. or other worn parts, and repair or
replace timely.
Check the belt tightness and all parts
(3) The diesel engine is not sufficiently cooled
of the cooling system, or remove the
and is too hot.
water scales.
(4) The bearings are not well lubricated or are too Overhaul the lubrication system or
hot. clean it.
5.3 Exhaust smoke

1 Off-white smoke
(1) The diesel engine is too cold. Adjust to rated speed.
Remove the exhaust pipe or the
(2) There is water leakage in the cylinder.
cylinder head and check
Check the fuel injector or the
(3) Incomplete combustion. 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 Adjust according the method
sub-pump. described in chapter 4.
(3) The fuel injector is faulted (if the fuel drops
Check the fuel injector or repair or
from the fuel nozzle, the exhaust will smoke
replace the injection nozzle.
intermittently).
(4) The fuel supply advance angle is insufficient Adjust the fuel supply advance
(there is black smoke or flame in the exhaust). angle as required.
3 Sky-blue smoke
15

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

Premature fuel injection or uneven fuel delivery Adjust the fuel supply advance
1 causes the clear, rhythmic and metallic knocking angle or adjust the uniformity of
noise, especially at start or low speed. fuel amount.
The clearances of the intake valves or exhaust valves
2 are excessive, making rhythmic and slight knocking Adjust valve clearance
noise.
Increase load before diesel engine is preheated. The
Unloading for idle warning of
3 clearance between the piston and cylinder liner is
diesel engine.
excessive, making knocking noise.
The wear of piston, piston rings and cylinder liner are
4 Replace the related parts
excessive, making knocking noise.
The wear between each journal and bearing bush of
5 crankshaft is excessive, making knocking noise along Repair or replace it
the overall length of diesel engine.
Compression ratio is too high, causing rough The compression ratio should be
6
operation and large vibration. adjusted to specification.
The clearances of the intake valves or exhaust valves
are small, or the exhaust or intake timing is not
7 Adjust valve clearance or timing
correct, causing that the valve impacts the top of
piston.
Individual cylinder does not work and diesel engine Check the fuel system and solve
8
vibration is aggravated. the failure.
The valve is fractured (the valve lock clip is damaged,
Immediately stop the engine for
9 valve drops or the piston fractures, causing sudden or
inspection.
strong knocking noise)
Check the cylinder head nuts for
Air leaks from the cylinder head gasket, making
10 tightness or replace the cylinder
howling.
head gasket.
Wear of each gear is excessive, making knocking
11 Check and then replace it
noise.
The fixing bolts attaching to diesel engine is loose or
12 Tighten or replace the bolts
damaged, aggravating vibration.
Diesel engine is not coaxial to the connected work
13 Check and adjust it
device, aggravating the vibration.
Uneven foundation causes the deformation of
14 Check and adjust it
common base plate.
16
5.5 Unstable diesel engine operation

Check for the existence of stuck
The clearance increases due to inflexible movement of
1 phenomenon. Repair or replace
governor flyweight movement or wear factors.
accordingly.
The buffering clamp spring of the speed governor loses
2 its elasticity or is fractured and results in control rack Check or replace
vibration and unstable speed.
The diesel engine speed is too low and the engine runs
3 at the intermediate speed. The land engine Accelerate to the rated speed.
double-speed governor fails to operate automatically.
Check the condition of load
4 The diesel engine load changes frequently.
output.
Some of cylinder ignites interruptedly. Therefore, these
5 cylinders explode fiercely due to excessive Check the fuel system.
accumulated fuel and this leads to cylinder knocking.
Injection volume and injection time for injection
6 Check and adjust
pumps are different.
7 There is air in the fuel system. Check and carry out air bleeding
Check the fuel and carry out
8 There is moisture in the fuel system.
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

There is air in the water pump or water
1 Fill some water to bleed air from it.
absorption pipe.
Remove clogging or fill the cooling system
The water pipe is clogged or frozen (in
2 with hot water or fill with antifreeze in
cold season).
advance.
The water pump sealing device or sealing
3 gasket is damaged and there is air Overhaul or replace.
leakage.
4 The water pump belt is too loose. Check and adjust.
There is excessive water scale in the
5 Remove water scale.
diesel engine water pump.
The water pump suction height is Install the water pump according to relevant
6
excessive. specifications.
17
5.7 Oil pressure is too low

The lubrication oil is in poor quality (the specific Select proper lubrication oil
1 phenomenon is the oil pressure drops gradually with according to relevant
diesel engine running). specifications.
The diesel engine is overheated and the oil gets Troubleshoot according to items
2
thinner. in Section 5.8 of this chapter.
3 The oil filter is clogged. Clean
There are loose pipe joints and oil leakage in the oil
4 Check and tighten.
line or there is air in the pipeline.
5 There is diesel fuel mixed in the oil. Change and find out the cause.
The spring for the pressure adjusting valve of the oil
6 Replace
pump gets fractured.
Oil pressure in the oil sump is too low or the oil pump Add some oil or reinstall the oil
7
suction height is excessive. pump and oil tank.
The clearance between the connecting rod bearing and
8 Check and replace
the main bearing is too large.
5.8 Diesel engine is overheated

Troubleshoot according to items in Section 5.6 of
1 There is no sufficient coolant.
this chapter.
The water inlet temperature is too
2 Reduce the water inlet temperature.
high.
Troubleshoot according to items in Section 5.7 of
3 The oil pressure is too low.
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.
There is air leakage at the piston
6 Check and replace
ring.
7 The bearing fit is too tight. Check and properly grind.
Implement power correction and reduce the load
8 The ambient temperature is too high.
effect.
18
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
24-Hour Service Hotline
800 Free Service Hotline: 800-8603066
Customer Service Center Hotline: 0536-8235369 (Fax)
Customer Service Center Complaint Phone: 0536-2297322
1
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 Signature of
Warranty Replaced Signature of
Maintenance Date Quantity Maintenance
Item Spare Part Customer
Service Center Man
2
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.
3
(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.
4
Regulations about Term of Three Guarantees Service for Weichai

Power Marine or Power Generating Diesel Engine
S/N Term of Three

Product Model Remarks
Guarantees
I. Complete diesel engine
1 Marine diesel engine, diesel engine for generating set and 1 year
diesel engine for other power equipments
II. Diesel engine components
1 Basic Engine body, crankshaft, engine seat and 2 years (with
parts connecting rod original faults in
manufacturing like
air blisters etc)
2 Important Cylinder head, flywheel, flywheel housing, It is the same with
parts timing gear chamber, connecting rod bolt, piston, the term of the
piston ring, piston pin, connecting rod bearing complete diesel
shell, main bearing shell, camshaft bearing bush, engine three
camshaft, cylinder liner, valve, valve spring, guarantees.
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 The date of actual
pump holder, coupling, air compressor, various sales prevails and
cover plates and base plates, water pump, oil the sales invoice,
radiator, fan bracket, silicone oil clutch, pressure warranty card or
limiting valve, shock absorber, crankshaft balance time counter are
mechanism, rear oil seal and seat, various metal take as evidences;
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.
3 Common Front oil seal and other oil seals, supercharger, 6 months or 750
parts intake manifold gasket, exhaust manifold gasket, hours
supercharger gasket, valve cover gasket, rubber
hose, fuel injector return pipe, fuel delivery
pump, dipstick, fan, waterproof and oil-proof
rubber gaskets, bowl plug.
Electrical Starter, generator, instrument, various sensors, 6 months or 750
parts electronic speed controller, throttle pedal, harness, hours
solenoid valve and flame preheater.
4 Wear Belt, fan shroud, fuel spray nozzle, plunger 1 month
parts coupled parts, other gaskets, various braided hose,
clamps, time counter.
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.
5
6
No
te: Custom
Ple er
ase Satisfac
tic tion
k Questio
wit
nnaire
h
“√”
in
cor
res
po
ndi
ng
col
um
ns.
7
8
License Plate
Manufacturer
The first copy

Number
Customer Name Engine Number
Date of Mandatory Maintenance
Detailed Address Mileage of Mandatory
Maintenance
Counterfoil
Purchase Entity Date of Purchase
Identifier: Customer Signature:
Label of Weichai Power Special
Valid Documentation:
Oil:
Service Station Official Seal: Customer Tel.:
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.

License Plate
Manufacturer
The first copy

Number
Maintenance
Counterfoil
Identifier: Customer Signature: Label of Weichai Power Special
Valid Documentation: Oil:
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.

License Plate
Manufacturer
The first copy
Number
Maintenance
Counterfoil

1
License Plate
The second copy

Manufacturer
Number
Maintenance
For Weichai

License Plate
The second copy

Manufacturer
Number
Maintenance
For Weichai

License Plate
The second copy
Manufacturer
Number
Maintenance
For Weichai

2
The third copy

License Plate
Manufacturer
Number
For service station

Maintenance
The third copy

License Plate
Manufacturer
Number
For service station

Maintenance
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.

The third copy
License Plate
Manufacturer
Number
For service station
Maintenance
3
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.

Operation and Maintenance Manual and User Service Guide: Deutz WP6C/WP4C Series Marine Diesel Engines

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation and Maintenance Manual and User Service Guide: Deutz WP6C/WP4C Series Marine Diesel Engines

Uploaded by

Copyright:

Available Formats

Deutz WP6C/WP4C Series Marine Diesel Engines

Operation and Maintenance Manual and

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

II. User Service Guide (Warranty Card) ................................................................... 1

WP6/WP4 series diesel engines model meaning

Rotating speed code (see table 1)

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

WP6/WP4 series marine diesel engine structural features:

2 Fuel, oil and coolant used for diesel engines

Fig.2-1 Selection of oil grade

1. Do not check the lubricant level during engine running.

1. Periodically check the antifreeze concentration if temperature is below 0℃.The

Table 2-2 Coolant composition

Water quality min max

3 Diesel engine installation and connection

3.1 Diesel engine hoisting

3.3 Installation of external connection systems for diesel engine

4 Operation and maintenance of diesel engine

4.1 Preparations before operation

Figure 4-1 Engine oil filler

4.1.3 Add the fuel

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

Figure 4-3 Drain valve

4.3 Maintenance of diesel engine

Operation item Running time h

Repeat the maintenance operation according to the following time:

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.

Maintenance instructions for standby state and emergency state

Time Maintenance requirements

Items Operation time

5. Common fault analysis and troubleshooting

5.1 The diesel engine cannot start

S/N Cause Troubleshooting

S/N Cause Troubleshooting

5.2 The diesel engine cannot output specified power

S/N Cause Troubleshooting

S/N Cause Troubleshooting

5.3 Exhaust smoke

S/N Cause Troubleshooting

S/N Cause Troubleshooting

5.4 Abnormal noise or vibration during diesel engine running

S/N Cause Troubleshooting

5.5 Unstable diesel engine operation

S/N Cause Troubleshooting

S/N Cause Troubleshooting

5.7 Oil pressure is too low

S/N Cause Troubleshooting

5.8 Diesel engine is overheated

S/N Cause Troubleshooting

II. User Service Guide (Warranty Card)

Weichai Power Product Warranty Card (for User)

Item Content Item Content

Weichai Power Co., Ltd.

Maintenance Registration Form (Filled by Maintenance Personnel)

Item Content Item Content

(2) Three Guarantee Period

Regulations about Term of Three Guarantees Service for Weichai

S/N Term of Three

The first copy

Engine Mandatory Maintenance Card

The first copy