Operation Manual For WP10CD Series Marine Diesel Gen-Set

Operation & Maintenance Manual for WP10CD Series Marine Diesel Gen-set
Operation & Maintenance Manual for

WP10CD Series Marine Diesel Gen-set
Weichai Heavy Machinery Co., Ltd.

Foreword
Weichai Heavy Machinery Co., Ltd. is China’s appointed manufacturer of
various types of stationary gen-set and marine gen-set.
The manual provides instructions on the installation, operation, maintenance and

trouble shooting of marine gen-set according to the characteristics of WP10CD Series
marine diesel gen-set for user’s safe and reliable operation. Please refer to the
Operation Manuals for diesel engine, power alternator and various special parts in
instrument boxes when using this manual, and operate, service and maintain it in
accordance with corresponding requirements.
Along with technical development and product improvement, changes will be

made on this manual accordingly. This manual is subject to revisions and changes
from time to time.
Contents
CHAPTER I CODE REPRESENTING METHOD ................................................. - 5 -
CHAPTER II WORKING CONDITIONS ............................................................... - 5 -
I. RELIABLE WORKING CONDITIONS .............................................................. - 5 -
II. WORKING CONDITIONS FOR GEN-SET TO OUTPUT RATED POWER ... - 2 -
CHAPTER III TECHNICAL SPECIFICATIONS AND MAIN PARAMETERS ... - 2 -
I. MAIN TECHNICAL SPECIFICATIONS ............................................................. - 2 -
II. MAIN ELECTRICAL PERFORMANCE INDICATORS................................... - 2 -
III. GEN-SET PROTECTION PARAMETERS ....................................................... - 3 -
IV．OVERALL DIMENSIONS OF GEN-SET ...................................................... - 4 -
V. GEN-SET OUTLINE DRAWING ....................................................................... - 4 -
CHAPTER IV OVERVIEW OF MAIN STRUCTURES ......................................... - 6 -
I． DIESEL ENGINE .............................................................................................. - 6 -
II. AC ALTERNATOR .............................................................................................. - 7 -
III. INSTRUMENT BOX ......................................................................................... - 8 -
IV. SOLID BASE FRAME ....................................................................................... - 8 -
CHAPTER V STORAGE AND INSTALLATION .................................................. - 8 -
I. STORAGE ............................................................................................................. - 8 -
II. UNPACKING ACCEPTANCE ............................................................................ - 8 -
III. LIFTING & HANDLING ........................................................................... - 9 -
IV. INSTALLATION ................................................................................................ - 9 -
1. Installation of gen-set external pipes .................................................................... - 9 -
2. Installation of vent-pipe ...................................................................................... - 10 -
3. Installation of fuel pipes...................................................................................... - 11 -
4. Installation of cooling pipes ................................................................................ - 12 -
5．Installation of starting system ........................................................................... - 13 -
6. Other requirements.............................................................................................. - 13 -
CHAPTER VI GEN-SET ELECTRICAL SYSTEM ............................................. - 14 -
I. INSTRUMENT BOX .......................................................................................... - 14 -
1. Local ordinary instrument box ............................................................................ - 14 -
2. Local self-starting instrument box ...................................................................... - 18 -
3. New style local ordinary instrument box ............................................................ - 22 -

4. New style local self-starting instrument box ...................................................... - 26 -
5. Onboard instrument ............................................................................................ - 31 -
6. Accelerator servo mechanism ............................................................................. - 34 -
II. ALTERNATOR .................................................................................................. - 36 -
CHAPTER VII OPERATION................................................................................. - 37 -
I. PREPARATION .................................................................................................. - 37 -
II. COMMISSIONING ........................................................................................... - 37 -
CHAPTER VIII PARALLEL OPERATION .......................................................... - 39 -
I. CONDITIONS FOR PARALLEL OPERATION ................................................ - 39 -
II. METHODS......................................................................................................... - 39 -
III. LOAD TRANSFER IN PARALLEL ................................................................ - 40 -
IV． DISCONNECTION OF PARALLEL GEN-SET ......................................... - 41 -
CHAPTER IX PRECAUTIONS............................................................................. - 41 -
CHAPTER X ANALYSIS OF COMMON FAULTS AND TROUBLESHOOTING ... -
42 -
CHAPTER XI RULES FOR SAFE OPERATION ................................................. - 43 -
CHAPTER XII SERVICING AND MAINTENANCE .......................................... - 43 -
ANNEX I: LIST OF TOOLS DELIVERED WITH GEN-SET (EX-FACTORY
STANDARD CONFIGURATION) ........................................................................ - 46 -
ANNEX II: LIST OF SPARE PARTS DELIVERED WITH GEN-SET
(EX-FACTORY STANDARD CONFIGURATION) ............................................. - 47 -
Chapter I Code Representing Method
CCF × ×
Factory design code, represented in capital letters

ranging from A to Z
Code of navigation zone applicable to gen-set , W for

unlimited navigation zone and Y for limited navigation zone
Gen-set classification code, J for basic type, Z for
automatic type and Z for emergency type
Gen-set rated power code representing in kW
Current classification code, J for AC and Z for DC
Marine diesel gen-set code
Chapter II Working Conditions
I. Reliable working conditions

Gen-set can operate reliably under following conditions:
Table 2-1 Working Conditions
1 Ambient temperature 45C

Outboard water 32C (Outboard water temperature of gen-set in limited navigating zone
2
temperature and under corresponding conditions shall be 25C.)
3 Relative air humidity 60%
4 Absolute atmosphere 100kPa
5 Transverse inclination 15°(22.5° for emergency gen-set and inland vessel)
Longitudinal
6 7.5° (10° for emergency gen-set and inland vessel)
inclination
7 Rolling 22.5°
8 Pitching 10°
9 Able to bear the vibration and shock generated during normal sailing.
10 Having salt fog, mould, oil mist, condensing fog, damp air.
II. Working conditions for gen-set to output rated power

Gen-set should be able to continuously output rated power under following
working conditions:
a For gen-set in unlimited navigating zone: ambient temperature 45C, primary

cooling water temperature 32C, relative humidity 60%;
b For gen-set in limited navigating zone and under corresponding conditions:

ambient temperature 40C, primary cooling water temperature 25℃, relative humidity
60%.
Chapter III Technical Specifications and Main Parameters
I. Main technical specifications

Table 3-1 Main technical specifications
Serial No. Items Contents

1 Mode of gen-set CCFJ150J-W* CCFJ180J-W* CCFJ200J-W*
2 Diesel engine mode WP10CD200E200 WP10CD238E200 WP10CD264E200
3 Rated power(kW) 150 180 200
4 Rated voltage (V) 400/230
5 Rated frequency (Hz) 50Hz

6 Rated current (A) 271 325 361
7 Rated power factor 0.8 (lagging)

8 Rated speed (r/min) 1500r/min
9 Starting mode Electric motor
10 Speed regulating mode Electric speed regulation/mechanical speed regulation
11 Exciting mode Brushless self-excitation
Voltage regulating
12 Automatic
mode
13 Wiring mode Three-phase four-wire Y-connection
14 Cooling method Opening type bi-circulating water cooling
II. Main electrical performance indicators

Table 3-2 Main electrical performance indicators
Serial Items Electrical indicators
-2-
No.
Steady-state voltage regulation
1 ±2.5% (for emergency gen-set ±3.5%)
factor
Transient voltage regulation
2 -15% transient voltage regulation factor +20%
factor
3 Voltage stabilization time 1.5s
4 Voltage fluctuation ratio ±1%
5 No-load voltage setting range ≥±5% rated voltage
Steady-state speed regulation Electronic speed regulation 3%/(mechanical speed
6
factor regulation 5%)
Transient speed regulation
7 ±10%
factor
8 Stabilization time 5S
9 Speed fluctuation ratio ±0.5%
110% rated load operating for 1 hour is allowed by gen-set continuously running for each
10
12 hours
Two gen-sets can maintain long-term stable parallel operation. It can maintain stable
operation and steadily transfer active power and reactive power when the load varies
11 within 20%-100% of total rated power against rated power factors; the active power
sharing unbalance is not greater than 15% of alternator’s rated power and reactive power
sharing unbalance is greater than 10% of alternator’s rated reactive power.
III. Gen-set protection parameters

Table 3-3 Gen-set protection parameters
Serial
Alarm description Alarm value Remarks
No.
110% rated
1 Speed is high Alarming
speed
2 Oil pressure is low 0.12±0.02Mpa Alarming
3 Water temperature is high 95+3C Alarming
4 Oil temperature is high 102+3C Alarming
5 Speed is too high 115% rated speed Alarming and shutdown
6 Oil pressure is too low 0.08±0.02Mpa Alarming and shutdown
7 Storage battery voltage is low <19V Alarming
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Alarming, and fuel leakage alarm

8 Fuel leakage alarm (optional)
apparatus required
IV．Overall dimensions of gen-set

Table 3-4 Overall dimensions of gen-set
Gen-set Model L*W*H (mm) Weight (kg)

CCFJ150J-WE 2375X1082X1572 2490
CCFJ150J-WI 2375X1082X1572 1963
CCFJ150J-W* CCFJ150J-WU 2375X1082X1572 2011
CCFJ150J-WQ 2375X1082X1572 1906
CCFJ150J-WY 2375X1082X1572 2032
CCFJ180J-WE 2542X1082X1572 2491
CCFJ180J-WI 2542X1082X1572 2059
CCFJ180J-WQ 2542X1082X1572 1968
CCFJ180J-WY 2542X1082X1572 2081

CCFJ200J-WE 2542X1082X1572 2491
CCFJ200J-WI 2542X1082X1572 2059
CCFJ200J-WQ 2542X1082X1572 2033
CCFJ200J-WY 2542X1082X1572 2081
Note: “*”in “W*” represents the alternator to be used for the diesel gen-set. “*”
can be replaced by E, I, U, Q, Y, among which, E represents LD alternator, I
represents Marathon alternator, U represents Stanford alternator, Q represents Kangfu
alternator (formerly known as Sanbo alternator) and Y represents Wuxi Siemens
alternator.
V. Gen-set outline drawing

Outline drawing examples of CCFJ150J-W*/ CCFJ180J-W*/ CCFJ200J-W* marine
diesel gen-set (standard configuration: equipped with ordinary instrument box) are as
shown in Figure 3-1, Figure 3-2, Figure 3-3, Figure3-4 and Figure 3-5 (relevant
drawings of other configurations can also be provided according to customer’s
requirements):
-4-
E engine oil filler
Fuel oil return

opening
①Belt
Figure 3-1 Front view Figure 3-2 Left view
Intercooler cooling water inlet
Intercooler cooling
water outlet
Figure 3-3 Rear view Figure 3-4 Right view
List of unit parts

1.Belt pulley
2.Heat exchanger water outlet
3.Heat exchanger water inlet
4.Intercooler water outlet
5.Intercooler water inlet
6.Fuel oil inlet (dewater safety
filter)
7.Fuel oil return opening
8.Fresh water filler
A． M20×1.5 (engine oil
discharge outlet)
C. Common base frame
D. Magnetic plug screw
E. Engine oil filter
Figure 3-5 Top view

-5-
Chapter IV Overview of main structures
I． Diesel engine
Diesel engine is the power source of gen-set and this unit adopts Weichai
WP10CD series alternator (please refer to Operation and Maintenance Manual for
WP10CD Series Gas Alternator for detailed structure principles). Main technical
specifications of the diesel engine are shown in Table 4-1:
Table 4-1 Main technical specifications of diesel engine
Serial Model
WP10CD200E200 WP10CD238E200 WP10CD264E200
No. Items
In-line, four-stroke, water cooling, direct injection,
1 Model
pressurization, intercooling
2 Number of cylinders 6
Cylinder diameter/stroke
3 126/130
mm/mm
Rotation of crankshaft
4 (towards the end of Anticlockwise
flywheel)
5 Declared speed r/min 1500
6 Declared power kW 182 216 240
Piston total displacement
7 9.726
L
8 Compression ratio 17:1
9 Start-up mode Electrical starting/pneumatic starting
Electric motor starting
10 5.4
power kW
Starting battery capacity
11 150*2
Ah
12 Starting cable mm2 70(mm2)
Fuel consumption under
13 200±5%
rated conditions g/kW.h
14 Fuel type Domestic 0# or -10# light diesel oil (GB252)
15 Fuel system Mechanical/electrical pump
16 Engine oil grade CF or above
Maximum oil volume of
17 23
oil pan L
-6-
Inlet air flow under rated

18 835 876 1076
condition kg/h
Exhaust back pressure
19 6
kPa
Exhaust flow under rated
20 869 917 1121
conditions
Exhaust temperature
21 ≤750
before turbine C
Exhaust temperature after
22 ≤550
turbine C
(standard configuration)
23 sea water pump flow 316
L/min
(standard configuration)
24 15
sea water pump lift
Note: this table mainly describes relevant parameters of WP10CD Series

1500r/min marine diesel engine. For this series, 1800r/min diesel engine can be used
for 150kW/60Hz~200kW/60Hz and below gen-set if required by the customer.
II. AC alternator
Alternator is a kind of equipment which is able to convert mechanical energy
into electric energy. Please refer to alternator manual for detailed structure principles.
Main technical specifications are shown in Table 4-2:
Table 4-2 Main technical specifications
Serial
Item Value Remarks
No.
1 Rated voltage V 400
2 Rated frequency 50
Rated power factor
3 0.8 (legging)
cosφ
4 Rated current A I=1.804P
5 Insulation grade F/H
6 Protection level IP23
7 Exciting mode Brushless self-excitation
8 Outgoing line Three-phase Y-connection
9 Bearing type Rolling bearing
-7-
10 Radio interference level Level N

11 Anti-condensation heater 220V
In the left (seeing from diesel engine to
12 Stuffing box outlet direction
alternator)
Steady-state short circuit
13 3-5times rated current, duration 5s
current
14 Over-current features 1.5 times rated current, last for 2 min
15 Cooling method Self-ventilation
Note: alternators operating at other voltage levels and with 1800r/min speed
(corresponding rated frequency 60 Hz) may be selected as required by the customer.
III. Instrument box

Please refer to “Instrument box” in “Chapter VI Electric System of Gen-set” for
detailed structure functions.
IV. Solid base frame

The common chassisshall be made from bent steel plate.
Chapter V Storage and Installation

I. Storage
Storage yard shall be well ventilated with no acid gas, alkaline gas and other
corrosive gases and protected from the sun and rain. The factory guarantees that
gen-set can be stored for half a year after delivery, in case of more than half a year,
proper treatment measures shall be taken, such as alternator winding insulation
measurement, moisture removal as the case may be.
II. Unpacking acceptance

Unpacking method: remove connections between packing case housing and the
bottom of packing case and use lifting tools to open the case. Note: a person shall be
assigned to support the packing case housing with hand during lifting to protect
exposed parts of gen-set from being damaged by packing case housing. Generally,
gen-set shall undergo unpacking acceptance after arriving in delivery destination.
Acceptance method and personnel shall be in accordance with contract specifications.
As the basis of acceptance, “packing list” shall be put in same document pocket with
other documents to be provided with the unit.
Basic acceptance items are:
Appearance inspection: check whether exposed parts are damaged by visual

-8-
inspection or whether there is collision, deformation and other abnormal phenomena

and make records;
 Check accompanying documents according to the list of accompanying

documents and make records;
 Check the spare parts according to the “list of accompanying spare parts” and
make records;
 Check accompanying tools according to the “list of accompanying tools” and

make records.
 In case that gen-set has any damages in appearance and accompanying spare
parts, attachment, documents and tools are inconsistent with the list. The
consigner and carrier shall be informed within 24 hours by fax or telephone
after acceptance for claims.
III. Lifting & handling

Steel wire rope shall have enough strength, and carrying capacity of lifting tools
shall meet safety specifications. Each steel wire rope shall be in the same length to
avoid tilting during lifting.
Steel wire rope shall be attached onto the lifting position of gen-set packing case
base.
When bare machine is lifted, steel wire rope shall be attached onto the lifting
position of the common chassisof the generating unit. Contact between steel wire rope
and other gen-set components shall be prohibited, if not, separate them with a board.
Cover lifting shall be stopped if contact parts are small or non-bearing parts, and try
again after changing the length of rope or adding support to change force bearing
point. Please contact us for any questions.
IV. Installation
1. Installation of gen‐set external pipes
Installation of various gen-set pipes shall abide by following rules:
 External pipes and gen-set shall be connected by flexible hose.
 Sharp turn shall be avoided on the pipe line, and bend & tee shall be avoided
in most cases.
 For the convenience of maintenance, valves shall be installed in proper

position.
-9-
 Pipes shall be reliably secured on the support. Measures should be taken to

relieve stress generated by expansion and contraction of pipelines.
 After the completion of gen-set installation, oil supply and water supply can
only be allowed after pipes are totally cleaned. Test run shall be carried out
for checking whether various pipes meet relevant requirements, pipeline
pressure drop is too large, pump drive capability is enough and cooling water
flow meets operating requirements. Otherwise, pipes in larger size shall be
used.
2. Installation of vent‐pipe
(1) Installation of vent-pipe shall abide by following rules:
a. Vent-pipe dead-weight shall be reliably supported, and it is strictly prohibited

to use supercharger to bear vent-pipe weight. Generally, fixed support shall be located
1m away from expansion joint to prevent stress generated by vent-pipe gravity,
thermal expansion or transversal displacement from being transferred to supercharger.
Diesel supercharger shall be provided with precise bearing and impeller and has high
speed. In case that supercharger exhaust flange bears too much bending moment,
supercharger shaft will be deformed and normal operation of supercharger is disturbed
with noise which finally leads to the damage of supercharger.
b. External vent-pipe shall be made from steel tube without too many turns and
shall be fixed tightly on ship body with no vibrations. Its weight shall not be applied
on diesel expansion pipe. Exhaust back pressure of diesel engine shall be not greater
than 6kPa after the completion of exhaust system installation. Otherwise, diesel
engine performance will be affected. As diesel vent-pipe surface temperature is high
during operation, vent-pipe shall be kept away from flammable objects to avoid
worker scald. Thermal insulation apparatus shall be mounted on the surface of
external exhaust pipes.
c. Exhaust silencer shall be installed on the end of vent-pipe to reduce influence

of exhaust noise.
d. There is vapor generated in the process of diesel oil burning, therefore,

condensate water drain valve shall be installed on vent-pipe to discharge condensate
water in vent-pipe. Condensate water drain valve shall be located as low as possible
on the pipe close to diesel engine.
(2) Diffuser pipe and vent-pipe diameter
The size of the bellow expansion joint provided by the manufacturer is not
- 10 -
exactly the same as the diameter of vent-pipe. Sometimes, a 500-800mm long diffuser
pipe with increasing diameter is needed, which is also used as a connector to reduce
airflow resistance. Diffuser pipe can be made from 3-5mm sheet steel.
(3) Exhaust silencer
Exhaust noise is generated when diesel combustion emission is discharged from

exhaust valve to vent-pipe, which always causes exhaust gas vibration and pressure
wave. Pressure wave is the mixture of many waves of different lengths and
amplitudes. These wave lengths (frequency) and amplitudes (loudness) are all within
the recognizable range of human ear.
Exhaust silencer can consume and absorb the energy of pressure wave to reduce
pressure wave amplitude of exhaust gas discharged from exhaust silencer. Most diesel
exhaust silencer reduces acoustics energy by reflecting the pressure wave. Generally,
increase of silencer dimension will improve noise reduction effect. If there is
limitation on silencer dimension, increase of silencer decay degree will result in
increase of exhaust resistance. Therefore, proper silencer shall be selected according
to the resistance of exhaust system.
Exhaust silencer is not covered in standard supply scope. The user can purchase
in the market or order from us.
3. Installation of fuel pipes
Installation of fuel pipes shall abide by following rules:
a. Volume of fuel tank for everyday use can keep gen-set continuously running
for at least 8h.
b. Oil tank shall be made aluminum sheet, phosphatization steel plate, and
reinforced plastic plate instead of galvanized steel plate.
c. Contact between oil return pipe and high temperature components (such as
vent-pipe, turbocharger, exhaust gas return pipe) of diesel engine shall be avoided
during installation. Throttling area is not allowed in oil return pipe. Return pipe shall
not contact with sharp edges, be bended with sharp corners or distorted. Improper
installation of return pipe will lead to fuel leakage on alternator. Fuel return pipe shall
be connected to fuel tank with returned oil flowing along with the tank wall to reduce
eddying flow. The return oil of WP10CD series diesel engine is internal return oil
passed through cylinder head (Figure 5-1). Oil injector mounting hole in cylinder
head can ensure that return oil can be fully sealed.
- 11 -
Injector oil O-ring sealing

return hole oil return
Seal ring
Internal oil return through

cylinder head
Figure 5-1 Oil return method
d. Diesel engine inlet and outlet fuel pipe shall be equipped with stop valve for
the convenience of maintenance.
4. Installation of cooling pipes
Proper installation of cooling system plays an important part in diesel engine

service life and performance. Please read the operating principles and installation
precautions of cooling system to ensure the design and installation of gen-set external
pipes meet following requirements:
(1) Diameter of inlet and outlet pipes shall meet relevant requirements of
gen-set. Large diameter pipes shall be used when too many lengthy pipelines are
required. Excessive resistance of pipeline system will lead to insufficient flow of
cooling water; therefore, the diesel engine is lack of sufficient cooling water which
causes abnormal operation of the diesel engine. Elbows and tees shall be minimized.
(2) Pump suction pipe shall be as short as possible to guarantee that pump water
inlet pressure is greater than atmospheric pressure (i.e. positive pressure). Negative
pressure will cause pump gas etching and insufficient cooling water flow which cause
abnormal operation of pump.
(3) Pipeline system must be equipped with exhaust apparatus to discharge air in
pipeline.
(4) Purchase a new pump when the lift of the pump supplied with the unit can
not satisfy pipeline lift requirement.
(5) Preservative must be added to cooling water in closed cooling system. Filter
screen shall be mounted on water suction pipe mouth in open type cooling system to
- 12 -
protect intercooler and oil/water cooler from being blocked by dirts.
Box-type fresh water Fresh water filler

heat exchanger
Diesel engine effluent

Thermostat
Small circulation
Sea water inlet
Sea water outlet
Diesel engine
Intercooler
Fresh water
pump
Diesel engine intake
Figure 5-2 Circulating cooling system diagram
5．Installation of starting system
Sectional area of cables (multi-core copper flexible cable) between starting engine
and the battery shall be not less than 70mm² and the length shall not exceed 1.5m. Our
standard marine diesel gen-sets are all equipped with starting battery cable.
6. Other requirements
a. A 1m maintenance space shall be reserved around gen-set.
b. Foundation of gen-set shall be firm and has no deformation during installation

and operation of gen-set. During installation, level gauge shall be used to measure the
levelness of foundation installation surface which should be leveled up with flat
gasket to ensure that the gen-set can be placed horizontally. Gen-set shall be fixed
with foundation bolt and its classis undersurface shall be in good contact with the
ground during installation, in case of gaps, use thin iron sheet to level them up to
guarantee the concentricity of diesel engine and alternator axial lead.
c. Diesel vent-pipe shall extend outboard to facilitate ventilation, and vent-pipe
- 13 -
bending angle shall be not less than 90° without too many bends. Inner diameter of
external vent-pipe shall not be less that the inner diameter stipulated in Diesel Engine
Operation and Maintenance Manual. Vent-pipe shall not be too long and satisfy fire
protection requirements. Vent-pipe and the diesel engine shall be in flexible
connection instead of rigid coupling. Water drain valve shall be installed at the lowest
position of vent-pipe in order to guarantee the smooth discharge of condensate water
in vent-pipe. For other requirements, follow the Diesel Engine Operation and
Maintenance Manual.
d. The cabin shall be equipped with intake channel and exhaust channel. There
shall be no obstacles obviously hindering the airflow.
e. If ambient environment of gen-set in the winter is lower than 0C, anti-freezing

solution shall be added into gen-set cooling system.
f. Fuel tank separate from gen-set shall be 0.5m above the ground.
g. Sectional area of gen-set major loop connecting cable shall meet relevant
current requirements.
h. Gen-set must be equipped with ground lead and reliably grounded.
Chapter VI Gen-set electrical system
I. Instrument box
Please refer to Operation Manual for Diesel Engine Monitoring and Control
Instrument delivered with gen-set for main operation and maintenance instructions for
instrument box. Brief introduction to several common instrument boxes is hereunder
provided. We can also produce special instrument boxes according to customer’s
special requirements.
1. Local ordinary instrument box
Local ordinary instrument box of WP10CD Series marine diesel gen-set is a

microcomputer-controlled full-automatic electronic measurement and control system
for the diesel engine and alternator which precisely detects and displays diesel engine
speed, oil pressure, water temperature, oil temperature, pressure and other parameters,
and monitors all detected parameters to send out audible alarm, visual alarm, remote
alarm and other signals in real time. In addition, it is provided with starting and
stopping functions. So it will send out shutdown signal when the parameter exceeds
- 14 -
shutdown limit. Meanwhile, remote displayer or diesel engine remote display

instrument can also be used to realize remote monitoring and control of diesel
operating parameters. There are several indicators on instrument box which can
display the operating status and functional status of gen-set in real time. Instrument
box is characterized by advanced design, high measurement precision, reliable
operation, small size, digital display, precise and clear display, and easy installation.
Figure 6-1 Standard ordinary local instrument panel
6-1 Local ordinary instrument panel
(1) Operating function
Table 6-1 Local ordinary instrument function
Serial
Name Function description
No.
1 Power switch Turn on this switch to power on the instrument box.
Local/remote
2 Selection of diesel control position.
control
Instrument box will send out signals to start the diesel engine by
3 Starting
pressing this button.
When the switch is in “rated” position, diesel engine runs in high speed;
4 Idling/rated
When the switch is in “idling” position, diesel engine runs in low speed.
Instrument box will send out shutdown signal to shutdown the diesel
5 Shutdown
engine forcefully by pressing this button.
- 15 -
When diesel engine shutdown and emergency shutdown functions are

used, this button has self-locking function. Press this button to close fuel
Emergency
6 magnetic valve and shut down the diesel engine forcefully. Press this
shutdown
button again after the diesel engine is completely stopped to open fuel
magnetic valve for next starting.
Speed fine
7 Diesel speed fine adjustment
adjustment
Press this button when there is no rotation, various channels of
instrument box will simulate external changing conditions to carry out
self-inspection items one by one. Instrument box will send out audible
8 Self-inspection
and visual alarm signal when alarm setting value is reached, and
instrument box will send out automatic stopping signal when stopping
setting value is reached.
Press this button when there is alarm signal, and the audible alarm will
9 Silencer
be turned off and alarm light keeps shining and stop blinking.
Press this button, and speed display window shows the accumulative
10 Timekeeping
running time of diesel engine. Speed will be displayed after 5 sec.
11 Reset Press this button to reset instrument box
Please refer to accompanying document Operation Manual for Diesel Engine

Monitoring and Control Instrument for more function descriptions and usage
information.
(2) Local ordinary instrument box alarm protection function
Table 6-2 Local ordinary instrument box alarm protection function
Serial
No.
110% rated
1 Speed is high Audible and visual alarm
speed
0.12±
2 Oil pressure is low Audible and visual alarm
0.02Mpa
Water temperature is
3 95+3C Audible and visual alarm
high
Oil temperature is
4 102+3C Audible and visual alarm
high
115% rated
5 Speed is too high Audible and visual alarm and shutdown
speed
6 Oil pressure is too 0.080.02Mpa Audible and visual alarm and shutdown
- 16 -
low
7 Battery voltage is low <19V Audible and visual alarm
Fuel leakage alarm Audible and visual alarm; fuel leakage alarm
8
(optional) apparatus is required
(3) Local ordinary instrument wiring diagram
Microcomputer self-starting controller

Alarm Alarm when Alarm Battery Stop Stop when
Alarm
when oil undervolta Fuel Stop when when oil water Stop Successful Rated
when speed when oil water speed is
pressure temperatur indication starting speed
pressure is temperature temperatur ge leakage high
is high low is high e is high is low e is high
Relay board
Alarm Alarm Alarm when Alarm Battery Fuel Stop when Stop Stop when Stop Successful Rated
when oil
when speed when oil water undervolta leakage speed is when oil water
indication starting speed
pressure is temperature temperatur high temperatur
is high low is high e is high ge pressure
is low e is high
Shunt passive alarm contact, contact to central control

room
Figure 6-2 a) Local ordinary instrument wiring diagram
Wiring diagram
Control position signal output
Remote starting
Diesel operation signal output
Remote high/low speed control
Remote emergency
Comprehensive alarm output
Remote shutdown
Fuel leakage alarm input
Outage magnetic valve
pneumatic starting
Double output during
Power supply-
Power supply+
Onboard alternator
Excitation voltage
Starting motor
- 17 -
Figure 6-2 b) Local ordinary instrument wiring diagram
2. Local self‐starting instrument box
Local self-starting instrument box (hereinafter referred to as instrument box) of

WP10CD Series marine diesel gen-set is a microcomputer-controlled full-automatic
electronic measurement and control system. The whole system has functions of
distribution panel loss of power status monitoring, automatic starting of diesel engine,
automatic monitoring and measurement of working conditions, output of diesel
alternator automatic switching on and tripping signals, automatic stop, limit protection
and other basic monitoring and control functions. Control of speed-up and
speed-down, preheating of cooling water and lubricating oil and electronic speed
regulating control can also be configured for the diesel engine on the basis of basic
functional configuration. Meanwhile, remote display or diesel remote display
instrument can also be configured to perform remote monitoring and control of diesel
operating parameters. There are various indicators on instrument box which displays
gen-set operating status and functional status in real time. In addition, many ways are
available for the communication between instrument box and cabin distribution panel
to realize remote control of the operation, remote monitoring and measurement,
remote RS485 communication so as to form a highly automatic marine diesel
generating station.
Figure 6-3 shows standard local self-starting instrument box operation panel
Figure 6-3 Self-starting instrument panel

- 18 -
(1) Operation function
Table 6-3 lists the operation functions of local self-starting instrument
Table 6-3 Operation functions of local self-starting instrument
Serial
No.
1 Power switch Turn on this switch to power on the instrument box.
Local operation can be performed when the switch is in
“manual” position.
Manual/
Gen-set is in standby status when the switch is in “automatic”
2 automatic
position to automatically supply power for startup or stop
switching
power supply for shutdown according to instructions from
switch panel.
Self-starting instrument box will send out signals to start the
3 Starting
diesel engine by pressing this button.
When the switch is in “rated” position, diesel engine runs in
high speed;
4 Idling/rated
When the switch is on “idling” position, diesel engine runs in
low speed.
5 Shutdown Press this button to stop the diesel engine forcefully.
Operator can manually shut down the diesel engine in
emergency cases by pressing this button. Actuator can be
Emergency controlled manually to cut down the fuel pipe by this button
6
shutdown so as to shut down the diesel engine and open the main switch
of gen-set forcefully.
Speed up/speed
7 Diesel engine speed fine adjustment
down
Voltage fine
8 Alternator voltage fine adjustment
adjustment
When gen-set is in standby status, open this switch and the
heater works after being charged. When diesel engine is
9 Heating switch
started or in operation, the heater will be automatically
switched off and stop work.
Press this button when there is no rotation, self-starting
10 Self-inspection instrument box will simulate external changing conditions to
carry out self-inspection items one by one. Audible and visual
- 19 -
alarm signal will be sent out when alarm setting value is

reached and automatic stopping signal will be sent out when
stopping setting value is reached.
Instrument box can send out audile and visual alarm signals
when diesel engine working condition is out of limit or the
diesel engine fails to start for three times, and relevant alarm
indicators on the panel twinkles; meanwhile digital display
11 Silencer
window corresponding to digital displayer twinkles. Press
“Silencer” button, and audible alarm will be turned off and
alarm light keeps shining and stop blinking until the operation
returns to normal conditions.
Press this button, and speed display window shows the
12 Timekeeping accumulative running time of diesel engine. Speed will be
displayed after 5 sec.
In case that diesel engine fails to start for three times and
stops because limit protection is triggered, it represents that
the diesel engine is faulty and needs to be repaired. In case
13 Reset that gen-set is to be started after troubleshooting, press “reset”
button to notify the instrument box that the fault is
eliminated. At this time, controller will cancel alarm signal
and put gen-set into operation again.

information.
(2) Alarm protection function
Table 6-4 Self-starting instrument alarm function
Serial Alarm description Alarm value Remarks

No.
1 Speed is high 110% rated Audible and visual alarm
speed
2 Oil pressure is low 0.12 ± Audible and visual alarm
0.02Mpa
3 Water temperature is 95+3C Audible and visual alarm
high
4 Oil temperature is 102+3C Audible and visual alarm
high
- 20 -
5 Speed is high 115% rated Audible and visual alarm and shutdown
speed
6 Oil pressure is low 0.08 ± Audible and visual alarm and shutdown
0.02Mpa
7 Battery voltage is ＜19V Audible and visual alarm
low
8 Starting fails three Audible and visual alarm
times
9 Fuel leakage alarm Audible and visual alarm, and fuel leakage
(optional) alarm apparatus is required
(3) Local self-starting instrument box wiring diagram

Microcomputer self-starting controller
Alarm when Alarm when Alarm when Alarm when
Water Oil water oil Fuel Failure Battery
Oil speed is high oil pressure is temperature
Speed temperature temperature pressure low is high
temperature
is high leakage starting undervoltage
Remote control 10-core aviation plug
Remote control 5-core aviation plug
Water Oil Oil

Speed
temperature temperature
sensor
sensor sensor
pressure
sensor Relay board
Alarm Alarm Alarm Alarm when Alarm when

Fuel Failure Battery
when oil when oil water oil
when speed temperature
pressure is pressure is temperature is leakage starting undervoltage
is high is high
low low high
Figure 6-4 a) local self-starting instrument box wiring diagram
- 21 -
Figure 6-4 b) local self-starting instrument box wiring diagram
Figure 6-4 c) local self-starting instrument box wiring diagram
3. New style local ordinary instrument box
On the basis of original WP10CD marine diesel gen-set local ordinary

instrument panel, our company has launched new style local ordinary instrument box
by optimizing instrument box components and parts, its functions and redesigning
appearance. New instrument box has more beautiful appearance, firm installation,
reasonable functional design, beautiful wiring layout and convenient plug connectors.
Instrument box is a microcomputer-controlled full-automatic electronic measurement
and control system of diesel engine and gen-set which precisely detects and displays
- 22 -
diesel engine speed, oil pressure, water temperature, oil temperature, water pressure
and other parameters and monitors all detected parameters according to user’s settings
and sends out audible alarm, visual alarm, remote alarm and other signals. If there is a
stop setting, it will send out shutdown signal when the parameter exceeds shutdown
value. Meanwhile, remote displayer or diesel engine remote control display
instrument can also be provided to realize remote monitoring and control of diesel
engine operating parameters. There are several indicators on instrument box which
can display the operating status and functional status of gen-set in real time. Diesel
engine instrument box also has diesel engine running time accumulation function. It
can also provide extended alarms, diesel engine operating parameter and computer
data communication functions according to user’s special requirements.
Figure 6-5 standard new style ordinary local instrument panel
Figure 6-5 New style local ordinary instrument panel
- 23 -
Table 6-5 New style local ordinary instrument function
Serial
No.
1 Power switch Turn on this switch to power on instrument box.
Local/ remote
2 Selection of diesel engine control position.
control
Instrument box will send out signals to start the diesel engine by
3 Starting
When the switch is in “rated” position, diesel engine runs in high
speed;
4 Idling/rated
When the switch is in “idling” position, diesel engine runs in low
speed.
Instrument box will send out shutdown signal to shutdown the diesel
5 Shutdown
engine forcefully by pressing this button.
When diesel shutdown and emergency shutdown functions are used,
this button has self-locking function. Press this button to close fuel
Emergency
6 magnetic valve and close the diesel engine forcefully. Press this button
shutdown
again after the diesel is completely stopped to open fuel magnetic
valve for next starting.
Speed fine
7 Diesel speed fine adjustment
adjustment
instrument box will simulate external changing conditions to carry out
self-inspection items one by one. Instrument box will send out audible
8 Self-inspection
and visual alarm signal when alarm setting value is reached and
instrument box will send out automatic stopping signal when stopping
9 Silencer
Press this button, and speed display window displays the diesel
10 Timekeeping
accumulative running time. Speed will be displayed after 5 sec.
11 reset Press this button to reset the instrument box.

information.
(2)New style local ordinary instrument box alarm protection function

- 24 -
Table 6-6 new style local ordinary instrument alarm protection function
Serial
Alarm descriptions Alarm value Remarks
No.
110% rated
1 Speed is high Audible and visual alarming
speed
0.12 ±
2 Oil pressure is low Audible and visual alarming
0.02Mpa
3 95+3℃ Audible and visual alarming
high
Oil temperature is
high
115% rated
5 Speed is too high Audible and visual alarming and shutdown
speed
Oil pressure is too 0.08 ±
6 Audible and visual alarming and shutdown
low 0.02Mpa
Storage battery
7 <19V Audible and visual alarming
voltage is low
8 Water pressure is low 0.01MPa Audible and visual alarming
Fuel leakage alarm Audible and visual alarm, and fuel leakage
9
(optional) alarm apparatus is required
Main power source
10 Audible and visual alarming
fails
Auxiliary power
source fails
(3) New style local ordinary instrument wiring diagram
- 25 -
Figure 6-6 a) New style local ordinary instrument wiring diagram
Figure 6-6 b) New style local ordinary instrument wiring diagram
4. New style local self‐starting instrument box
On the basis of original WP10CD marine diesel gen-set local ordinary

instrument panel, our company has launched new style local ordinary instrument box
by optimizing instrument box components and parts, its functions and redesigning
appearance. New instrument box has more beautiful appearance, firm installation,
reasonable functional design, beautiful wiring layout and convenient plug connectors.
- 26 -
Marine diesel alternator new style local self-starting instrument box (hereinafter
referred to as instrument box) is a full-automatic alternator working condition
electronic monitoring and control system, which is controlled by a control system
consisting of GEC16W monitoring display module and GEC8000-K1 safety
protection module. GEC16W monitoring display module has a large LCD which has
CAN communication interface and displays alternator speed, oil pressure, water
temperature, oil temperature and other parameters. Meanwhile, it can also detect
battery voltage, alternator accumulative operating time and other parameters; monitor
and display all detected parameters in real time. When there is alarm signal detected
in control box, it will send out audible and visual alarm signals; when fault shutdown
signal is detected (for example over-speed shutdown), control box will output
shutdown control signal automatically to stop the alternator. Control box system can
be used to perform automatic starting and automatic shutdown operations. Meanwhile,
remote displayer or diesel engine remote control display instrument can be used to
perform remote monitoring and control of diesel engine remote display instrument.
Figure 6-7 shows the new style local self-starting instrument box operation panel
- 27 -
Figure 6-7 new style local self-starting instrument panel
Table 6-7 shows the operation functions of new style local self-starting
instrument
Table 6-7 Operation functions of new style local self-starting instrument
Serial
No.
1 Power switch Open this switch to power on the instrument.
Local/remote/automatic Selection of “remote”, “local” and “automatic”

2
control control mode
Alternator oil/water heater control switch. Such

3 Heating switch change-over switch shall be in “off” position during
normal condition; change-over switch shall be in
- 28 -
“on” position when oil water heater indicator light is

on.
When the switch is in “rated” position, diesel engine
runs in high speed;
4 Idling/rated
When the switch is in “idling” position, diesel engine
runs in low speed.
Starting of standby
This button can be used for emergency start when
5 device
GEC 16W module fails.
This button shall be used by operator for the

emergency stopping of diesel engine. Actuator is
6 Emergency shutdown manually controlled by using of this button for
disconnecting fuel pipe, stopping diesel engine and
open the main switch of gen-set forcefully.
Used to control the starting of alternator under local
7 Starting
mode.
Used to control the stop of alternator under local
8 Shutdown
mode.
To change displayed content (parameters of
alternator) on the main page, select parameter
9 Scrolling up/down
number on the parameter selection page, and set the
digitals on the parameter editing page.
To switch to parameter selection setting page from
the main page, return to the main page from
10 Page switching parameter selection setting page, and return to
parameter selection setting page under parameter
modification status.
To enter into corresponding submenu from parameter
11 Confirmation selection setting page, and write the modified
parameter under parameter modification status.
Press the two buttons when alternator stops running,
and the system will enter self-check procedure and
displays user’s predefined alternator parameters
Self-check in double
12 successively, such as number of flywheel tooth, rated
MODE combination
speed, over-speed alarm value, etc. The system will
return to initial state automatically after completion
of self-check procedure.
Instrument box can send out audile and visual alarm
signals when diesel engine working condition is out
of limit or the diesel engine fails to start for three
13 Silencer
times, and relevant alarm indicators on the panel
twinkles; meanwhile digital display window
corresponding to digital displayer twinkles. Press
- 29 -
“Silencer” button, and audible alarm will be turned

off and alarm light keeps shining and stop blinking
until the operation returns to normal conditions.
In case that diesel engine fails to start for three times
and stops because limit protection is triggered, it
represents that the diesel engine is faulty and needs
to be repaired. In case that gen-set is to be started
14 Reset
after troubleshooting, press “reset” button to notify
the instrument box that the fault is eliminated. At this
time, controller will cancel alarm signal and put
gen-set into operation again.

information.
(2) Alarm protection function
Table 6-8 New style self-starting instrument alarm function
Serial
No.
110% rated
1 Speed is high Audible and visual alarming
speed
0.12±
2 Oil pressure is low Audible and visual alarming
0.02Mpa
high
4 Oil temperature is high 102+3℃ Audible and visual alarming
115% rated
5 Speed is too high Audible and visual alarm and shutdown
speed
0.08±
6 Oil pressure is too low Audible and visual alarming and shutdown
0.02Mpa
Storage battery voltage is
7 <19V Audible and visual alarming
low
Starting fails for three
times
Fuel leakage alarm Audible and visual alarming, and fuel
9
(optional) leakage alarm apparatus is required
Water level/oil level is Audible and visual alarm, and level switch
10
low (optional) is required
- 30 -
(3) New style local self-starting instrument box wiring diagram
Figure 6-8 a）new style local self-starting instrument box wiring diagram
Figure 6-8 b) new style local self-starting instrument box wiring diagram
5. Onboard instrument
Diesel engine monitoring and control instrument (hereinafter referred to as

monitoring and control instrument) shall be mounted on diesel engine body, so it is
called onboard instrument and is a microcomputer-controlled full-automatic electronic
measurement and control system of diesel engine and alternator which precisely
detects and displays diesel engine speed, oil pressure, water temperature, oil
temperature, pressure and other parameters, monitors all detected parameters and
sends out audible alarm, visual alarm, remote control alarm and other signals in real
time according to user’s settings. If there is a stop setting, it will send out shutdown
signal when the parameter exceeds shutdown value. Meanwhile, remote displayer or
remote control display instrument can also be used to realize remote monitoring and
control of diesel engine operating parameters. Compared with local instrument,
onboard instrument is simpler in structures and functions.
- 31 -
Figure 6-9 onboard instrument panels
6-9 onboard instrument panel
(1) Operating function
Table 6-9 onboard instrument function
Serial
No.
1 Power switch Turn on this switch to power on the onboard instrument.
When “local/remote” control change-over switch is in “remote”
position, the monitoring and control instrument shall be in remote
Local/ remote control state; therefore, remote control instrument can be used to start
2
control the diesel engine remotely. When “local/remote” change-over switch
is in “local” position, monitoring and control instrument shall be in
local status; therefore, the diesel engine can be controlled locally.
Onboard instrument will send out signals to start the diesel engine by
3 Starting
Onboard instrument will send out shutdown signal to shut down the
4 Shutdown
diesel engine forcefully by pressing this button.
onboard instrument will simulate external changing conditions to carry
5 Self-inspection
out self-inspection items one by one. Onboard instrument will send out
audible and visual alarm signal when alarm setting value is reached
- 32 -
and instrument will send out automatic stopping signal when stopping
6 Silencer
Press this button, speed display window displays the diesel
7 Timekeeping
accumulative running time. Speed will be displayed after 5 sec.
8 Reset Press this button to reset onboard instrument.

information.
(2) Onboard instrument alarm protection function
Table 6-10 Onboard instrument alarm protection function
Serial
No.
1 Speed is high 110% Rated speed Alarming
2 Oil pressure is low 0.12±0.02Mpa Alarming
3 Water temperature is high 95+3℃ Alarming
4 Oil temperature is high 102+3℃ Alarming
5 Speed is too high 115% rated speed Alarming and shutdown
6 Oil pressure is too low 0.08±0.02Mpa Alarming and shutdown
Storage battery voltage is Alarming
7 <19V
low
Audible and visual alarming, and
8 Fuel leakage alarm (optional) fuel leakage alarm apparatus is
required
(3) Onboard instrument wiring diagram
- 33 -
Power
supply-
Power
supply+
Battery
charging+
Excitation+
Starting+
Shutdown+
Shutdown-
Alarm+
Comprehensive
alarm
Fuel leakage
(input)
Fuel leakage
(input)
Figure 6-10 Onboard instrument wiring diagram
6. Accelerator servo mechanism
A set of accelerator servo mechanism shall be equipped for mechanically regulated

marine diesel gen-set to control diesel engine speed. Generally, WP10CD Series
marine diesel gen-set adopts A-300B6 type servo mechanism. Hereinafter provide a
simple introduction of such servo mechanism.
(1) Main technical data
Voltage: DC 24V Power: 40W
(2) Motor wiring diagram
- 34 -
(3) Typical application wiring diagram (reference)
High speed limit

switch
Low speed limit

switch
Notes:
KMA1, KMA2, KMA3 adopts Schneider
CJX2-Z/25A auxiliary equipment
Contact 2-open, 1-close A-300B3 type servo
mechanism
Buttons SA1, SA2, SA3 adopts LA18.
Indicator AD11
(4) Precautions
1）Hand wheel shall rotate in clockwise direction from left to right during
electric or manual operation.
2）Hand wheel shall be pulled back during manual operation and make spindle
nose turn right by 60.
3）Hand wheel shall be pulled back during electric operation and make spindle
- 35 -
nose turn left by 60.
Please refer to Operation Manual for Servo Mechanism for more information about
the operation of servo mechanism.
II. Alternator
1. WP10CD Series marine diesel gen-set adopts five kinds of alternators:
Marathon alternator, Stanford alternator, Siemens alternator, Kangfu alternator
(formerly known as Sanbo alternator) and Landian alternator. WP10CD Series
marine diesel gen-set is mainly configured with above-mentioned five alternators.
Please refer to relevant alternator operation manual supplied with the unit for
relevant alternator descriptions and wiring principles.
2.Special configuration for marine alternator
Working environment of marine gen-set is very bad. Moisture on water surface,

salt fog on the sea, oil mist in the cabin and large day and night temperature difference
has a bad influence on alternator insulating material. Therefore, following special
configurations are added to marine alternator.
(1) Air filter
Some dust, oil mist can be removed by installing air filter on alternator air inlet
to prevent moist air during shutdown.
(2) Anti-condensation heater
220V electric heater shall be mounted on the end of alternator stator winding.
Electric heater shall heat alternator winding to remove moist air and prevent water
condensation on the winding.
(3) Winding temperature sensor, alarm and protection
Alternator’s external circuit or improper operation will lead to the sharp rise of
winding temperature which will exceed the alternator’s temperature rise limit. In
order to prevent motor winding damage, temperature sensor shall be embedded on
motor winding. Temperature sensors are divided into two kinds: one is PTC
thermistor, the other is PT100, which together with detection, alarm and trip circuit,
can provide protection for the alternator.
- 36 -
Chapter VII Operation
I. Preparation
1.Clean the dust and other dirt on gen-set surface.
2.Check whether various fasteners and connectors are loose and various
revolving components are flexible.
3.Check whether all electrical connection parts are in good contact and correct
wiring.
4.Add corresponding fuel into fuel tank to remove the air left in fuel system
according to fuel specifications stipulated in Diesel Engine Operation and
Maintenance Manual.
5.Check whether diesel lubricating oil meets requirements according to

lubricating oil specifications stipulated in Diesel Engine Operation and
Maintenance Manual. In case of replenishment, lubricating oil in corresponding
grade shall be added.
6.Check whether the stored cooling water meets requirements.
7.Check whether battery voltage is within specified ranges (generally it is

23-28V)
8.Check the status of following switches:
(1) Gen-set power distribution system air isolation switch shall be in normal
tripping position;
(2) Starting switch shall be in off position;
(3) Electron speed regulator “rated/idling” switch shall be in idling position.
II. Commissioning
1.Gen-set starting
1）Press “start” button to start the gen-set (pay attention to readings of

various instruments)
2）Observe whether various parts are in normal operation (engine oil

pressure shall be greater than 0.15Mpa)
- 37 -
3) Gen-set shall be in idling status (generally 600-750 r/min), idling engine

heating shall last for 5-10 min;
2.Engine heating
The diesel engine shall operate for 5-10min in idling status after the starting of
gen-set meanwhile observing diesel oil pressure, oil temperature, cooling water
temperature and diesel operating conditions, in case of abnormalities, shut down the
unit for inspection.
3.Acceleration and voltage buildup
High/low speed switch of electronic speed regulator mounted on gen-set shall be

switched to high speed position when diesel engine speed reaches rated speed, the
diesel engine will accelerate the speed automatically. Regulate speed fine adjustment
potentiometer to make diesel engine speed reach rated speed; at this time, alternator
voltage shall be built up.
Regulate voltage setting resistor to make it reach rated value; then turn the voltage
change-over switch mounted on onboard detection device to check whether
three-phase voltage is in balance, no current value is shown, and alternator indicator
light turns on.
4.Test run
1)During normal operation of the unit, connect the load and observe
whether various parts are in reliable operation and indicating device is in
normal operation;
2)About 25% rated load shall be connected during test run, and check
whether various parameter indicators and whether any abnormal noise
arising from alternators or diesel engine;
3)Load shall be added gradually under normal operation and the load for
first test run shall be not greater than 80% rated load.
4)Observe the water temperature, oil temperature, oil pressure and other
diesel engine parameters and voltage, current and other electrical
parameters.
5)Record various parameters during operation.
- 38 -
Notes: sharp increase and decrease of load shall be prohibited during initial
operation.
5.Shutdown
Reduce the load gradually, turn off main switch and open load disconnector. The
diesel engine will operate at the speed reduced to idling value for 2~5 min; then the
alternator will be stopped and various switches shall be turned off to separate these
units. Then the commissioning is finished.
Chapter VIII Parallel operation
Parallel operation of gen-set can increase power supply reliability and stability,
in addition, number of parallel gen-sets shall be determined according to load level in
places subject to large load fluctuation for economic operation.
I. Conditions for parallel operation

Gen-set shall meet following conditions during parallel operation:
(1) Voltage of gen-set to be connected shall be the same as that of operating unit;
(2) Frequency of gen-set to be connected shall be the same as that of operating

unit;
(3) Phase position of gen-set to be connected shall be the same as that of

operating unit;
(4) Phase sequence of gen-set to be connected shall be the same as that of

operating unit;
II. Methods
Common parallel connection methods include light extinction method, light
rotation method and synchronizing device method. Currently, the most commonly
used method is synchronizing device method. And synchronizing device method can
be divided into quasi-synchronizing parallel method and automatic self synchronizing
parallel method. Hereinafter provide the introduction of quasi-synchronizing parallel
method.
On implementation model, quasi-synchronizing parallel operation is divided into

manual quasi-synchronizing parallel method and automatic quasi-synchronizing
- 39 -
parallel method. Hereinafter provide the introduction of manual quasi-synchronizing

parallel method.
Gen-set to be connected in parallel shall be involved in synchronizing operation

after meeting the four parallel conditions stipulated in this Chapter. Operating steps
are as follows:
(1) Check whether phase sequences of two parallel gen-sets are consistent with
each other before parallel operation and use phase sequence indicating device to
check alternator stator winding leading-out terminal marks.
(2) Start the gen-set and adjust the speed and voltage of two gen-sets into rated
value, meanwhile, their phase sequences shall be consistent (the adjustment of
gen-set steady-state speed regulation factor and steady-state voltage regulation
factor shall be completed before delivery). One gen-set shall be switched on
firstly (it can operate without load or be used to supply power);
(3) Regulate regulating resistor of gen-set to be connected to make the voltage be

consistent with that of the already connected unit;
(4) Manual quasi-synchronizing operation: observe the rotation of synchronizing

indicating finger, then make corresponding regulation upon frequency of gen-set
to be connected until synchronizing indicating finger reaches synchronizing
balance line in clockwise rotation and send out switch-on order immediately to
make put gen-set into parallel operation. After parallel operation, regulate the
speed of one gen-set to achieve power sharing balance. All input signals of
combined type synchronoscope shall be turned off after parallel operation to take
the synchronoscope out of service.
III. Load transfer in parallel

Load transfer shall be done after units are put into parallel operation. There are
load transfer method, one is active load transfer between two gen-sets which is
achieved by regulating accelerator to change diesel engine oil supply. Active load
increases along with oil supply; the other is transfer of reactive load, which can be
accomplished by using regulating differential resistor and voltage regulation resistor
on regulation panel to regulate reactive power between two gen-sets.
- 40 -
IV． Disconnection of parallel gen-set

When load of two gen-sets in parallel operation is less than the 50% of rated load
and one unit needs to be disconnected, all the load (or most part) of the unit to be
disconnected shall be transferred to the other unit by adjusting speed before turning
off load switch to disconnect the unit.
Chapter IX Precautions
1.Personnel who are unfamiliar with gen-set operating specification are

prohibited to operate on the unit.
2.Gen-set output current shall not exceed the rated current stipulated on
alternator nameplate. Please refer to power correction method stipulated in diesel
engine Operation Manual to correct gen-set output power when gen-set working
condition does not conform to working conditions stipulated in this manual.
3.During initial operation, maximum power of the unit shall not exceed 90% of
rated power which help extend service life. When gen-set is started in emergency
status, initial load shall not exceed 50% of rated power.
4.Check water temperature, engine oil pressure changes regularly to meet

specifications stipulated in diesel engine operation and maintenance manual.
5.Check battery voltage regularly to ensure it is in good condition.
6.During operation of gen-set, pay attention to cooling water level in box cooler
and replenish if necessary.
7.Repair it in a timely manner in case that there is oil leakage, water leakage and
air leakage in various pipes.
8.Do not use silicon rectifier to replace battery
9.Water in cooling system shall be discharged or anti-freezing agent shall be

added when gen-set ambient temperature is low with possibility of freezing to
prevent frost crack of unit body and water drainage shall be done after the unit
has stopped for half an hour.
10.During operation of gen-set, loading process shall be stable to avoid gen-set

from being damaged by impact load.
- 41 -
11.Gen-set shall be in horizontal position during lifting.
12.As gen-set can be exposed in moisture air, salt mist, oil mist and mould
environment, the user shall start it up regularly to guarantee that gen-set is in
good working condition to prevent gen-set from being corroded or damaged.
13.Pay attention to keep gen-set clean and make it in good working conditions.
14.Gen-set is heavy equipment. For the sake of human body and equipment safety,
it shall be operated with care. Operation against rules and drunk operation are
prohibited.
15.In case that there are any failures and factory assistance is required, the user
should provide the detailed information for quick solution.
Chapter X Analysis of common faults and troubleshooting
1.Analysis of common faults
Table 10-1 Analysis of common faults
Fault phenomena Analysis of causes Troubleshooting methods
Check battery wiring, capacity and

Battery fault
voltage.
Cannot be started
Check whether fuel oil circuit is blocked
Fuel circuit is blocked.
and discharge air in fuel oil circuit.
Electronic speed regulator Check electronic speed regulator.
Excitation circuit is open. Check the wiring of excitation circuit.
AC, DC transformation system

Refer to alternator Operation Manual.
No voltage is damaged.
Fuse is damaged. Replace fuse.
Excitation circuit is in bad

Check the wiring of excitation circuit.
Alternator voltage contact.
is unstable. Rectifier diode has poor
Replace diode.
performance.
Alternator speed is Electron speed regulator does Refer to electronic speed regulator
unstable. not work in optimum status Operation Manual.
- 42 -
2.See Operation Manual for Three-phase Synchronous Alternator for

synchronous alternator fault and troubleshooting methods.
3.See Operation Manual for Diesel Engine Monitoring and Control Instrument
for gen-set instrument box fault troubleshooting methods.
4.See Operation Manual for Electronic Speed Regulator for electronic speed
regulator fault and troubleshooting methods.
Chapter XI Rules for Safe Operation
1.Operator shall be familiar with gen-set operations, operation method and

positions of all control mechanisms, manual valves and stop mechanism.
2.Open flame is forbidden in cabin with fuel oil and lubricating oil to avoid fire.
3.Proper fire fighting equipments shall be equipped in cabin or in nearby places.
4.Whole gen-set must be earthed reliably and meet applicable neutral earthing
requirements.
5.The equipment, barriers and dangerous goods not to be used for the unit shall
not be placed on the unit and the ground shall be dry and clean without oil
contamination.
6.As there are noises generated during gen-set operation, it is recommended that
worker in noise environment shall wear proper safety devices, such as ear
protector.
7.All power supply lines must be disconnected before any maintenance,

especially DC power supply circuit. Set a “during maintenance” warning plate
and assign another person to ensure the safety, especially for maintenance
performed in narrow area.
Chapter XII Servicing and Maintenance
1.Please read relevant chapters of this Operation Manual carefully before

maintenance and servicing.
2.Generally, gen-set shall be inspected once a week. Operate for a short time with
load (best of all) to confirm that gen-set is in good status; meanwhile make
- 43 -
records on relevant conditions and parameters.
3.Basic maintenance specifications are as follows:
（1）Check the conditions of air filter, fuel filter elements, clean them in time and
replace them if necessary.
（2）Check cooling water or anti-freezing solution and replenish it in time.
（3）Check whether there is lubricating oil, fuel and cooling water leakage.
（4）Check whether oil in pump body is within specified limit and replenish it in
time.
（5）Check the battery voltage and specific gravity of electrolyte.
（6）Check the conditions of various indicating devices and various switches on

instrument box.
（7）Check whether electric connection and mechanical joint is loose and fasten it if
necessary.
4.Routine inspection items
（1）Diesel maintenance
The purpose of correct maintenance is to guarantee the normal and reliable

operation of diesel engine and is an important step to extend diesel engine service life.
The user shall maintain the diesel engine regularly according to technical maintenance
items stipulated in this Chapter.
1）Maintenance frequency of WP10CD Series diesel engine
First inspection (P) after diesel engine runs for 30-50 hours
Level I maintenance (WD1) after diesel engine runs for each 250 hours
Level II maintenance (WD2) after diesel engine runs for each 500 hours
Level III (WD3) after diesel engine runs for each 1000 hours
Level IV (WD4) after diesel engine runs for each 4000 hours
Note: Above-mentioned frequency shall be calculated assuming that the unit

operate for 1500 hours annually, in case that diesel engine working time annually does
- 44 -
not exceed 500 hours, diesel engine maintenance frequency shall be 0.5 times
above-mentioned maintenance frequency; in case that diesel working time annually
exceeds 1500 hours, the maintenance frequency shall be 1.5 times above-mentioned
frequency.
Note: Lubricating oil of CE grade or lower is not allowed for WP10CD Series diesel
engine. Replace oil filter element during oil replacement.
3）Operations to be done during diesel engine inspection and maintenance
Table 12-1 Operations during diesel engine maintenance

First Routine
Item WD1 WD2 WD3 WD4
inspection inspection
Replace diesel engine oil ▲ ▲ ▲ ▲ ▲ ▲
Check whether water pump leaks. ▲ ▲ ▲ ▲ ▲
Replace oil filter ▲ When replacing alternator oil
Check and regulate air valve gap. ▲ ▲ ▲ ▲ ▲
Replace fuel oil filter. ▲ ▲ ▲ ▲
Clean fuel oil pump coarse strainer. ▲ ▲ ▲ ▲
Check the capacity of cooling
▲ ▲ ▲ ▲ ▲ ▲
liquid and replenish if necessary.
Fasten cooling pipe clamp. ▲
Fasten air inlet pipe and flexible
▲ ▲ ▲ ▲ ▲
pipe.
Clean air filter element. ▲ ▲ ▲
Check and fasten triangle belt. ▲ ▲ ▲ ▲ ▲ ▲
Check fuel oil injection pump in
▲
special workshop.
Regulate idling speed. ▲
(2) Gen-set routine inspection items
Note: “1” in Table 12-2 represents inspection after operation for each 12 h or
once a week; “2” represents inspection after operation for each 100h or once a month;
“3” represents inspection after operation for each 200h or once a year.
Table 12-12 Inspection items during diesel engine-gen-set maintenance
Parts Inspection item Frequency
Check battery electrolyte level. 1

Starting
part Use hydrometer to check the charging status. 2
- 45 -
Clean battery terminals and oil it again. 3
Use dry compressed air to purge the porthole and internals. 2
Replace bearing lubricating grease (if necessary). 3
Check whether inner coupling bolt is loose. 2
Alternator Check whether there is barrier in ventilation area. 1
Check the conditions of alternator outgoing line insulation. 1
Check the working condition of air isolation switch. 3
Check whether alternator terminals are loose. 1
Check and fasten all bolts and nuts. 3
Check the status of damper. 3

Gen-set
Clean whole gen-set. 3
Operate gen-set for 1h at 50% load (optimal condition) and record the
1
starting time of gen-set.
Annex I: List of Tools Delivered with Gen-set (Ex-factory Standard

Configuration)
Serial No. Name Parts name Quantity

1 615GJ01 Tool box
2 615GJ010100 Angle Adjusting Driver 1
3 615GJ010200 Anlasser Disassembling Wrench 1
4 615GJ010300 Feeler 1
5 XB-A Filter wrench 1
6 615GJ0101 1/2 Dr Extension 280mm 1
7 615GJ0102 1/2 Dr Extension 120mm 1
8 615GJ0103 1/2 Dr Power Ratchet Wrench 1
9 615GJ0104 1/2 Dr Socket Set (12mm) 1
10 615GJ0105 1/2 Dr Socket Set (13mm] 1
- 46 -

18 615GJ0114 Combination wrench(12mm) 1
29 615GJ0126 1/2 Dr Speeder Wrench 1
30 615GJ0127 Hex Wrench (5mm) 1
31 615GJ0128 Inner hex wrench(6mm) 1
34 615GJ0132 Intenal Snap Ring Ptier 1
35 615GJ0133 External Snap Ring Ptier 1
36 615GJ0134 Magnetisn Probing Pen 1
37 615GJ0135 Oil Draim Plug Driver 1
Annex II: List of Spare Parts Delivered with Gen-set (Ex-factory Standard
Configuration)
Serial Part Number

Name Quantity Remarks
No.
1 61000070005 Screw oil filter 2
2 612600080934 Fuel filter element 2
- 47 -
3 612600020654 Polyrib belt 1
WD615/618 Marine standard

4 P00000110167 1
equipped
- 48 -

Operation Manual For WP10CD Series Marine Diesel Gen-Set

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Operation Manual For WP10CD Series Marine Diesel Gen-Set

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Operation & Maintenance Manual for WP10CD Series Marine Diesel Gen-set

Operation & Maintenance Manual for

Weichai Heavy Machinery Co., Ltd.

The manual provides instructions on the installation, operation, maintenance and

Along with technical development and product improvement, changes will be

3. New style local ordinary instrument box ............................................................ - 22 -

Chapter I Code Representing Method

Factory design code, represented in capital letters

Code of navigation zone applicable to gen-set , W for

Gen-set rated power code representing in kW

Current classification code, J for AC and Z for DC

Marine diesel gen-set code

Chapter II Working Conditions

I. Reliable working conditions

Table 2-1 Working Conditions

1 Ambient temperature 45C

II. Working conditions for gen-set to output rated power

a For gen-set in unlimited navigating zone: ambient temperature 45C, primary

b For gen-set in limited navigating zone and under corresponding conditions:

Chapter III Technical Specifications and Main Parameters

I. Main technical specifications

Serial No. Items Contents

2 Diesel engine mode WP10CD200E200 WP10CD238E200 WP10CD264E200

3 Rated power(kW) 150 180 200

4 Rated voltage (V) 400/230

5 Rated frequency (Hz) 50Hz

7 Rated power factor 0.8 (lagging)

II. Main electrical performance indicators

Serial Items Electrical indicators

III. Gen-set protection parameters

Alarming, and fuel leakage alarm

IV．Overall dimensions of gen-set

Gen-set Model L*W*H (mm) Weight (kg)

CCFJ150J-WI 2375X1082X1572 1963

CCFJ150J-W* CCFJ150J-WU 2375X1082X1572 2011

CCFJ150J-WQ 2375X1082X1572 1906

CCFJ150J-WY 2375X1082X1572 2032

CCFJ180J-WE 2542X1082X1572 2491

CCFJ180J-WI 2542X1082X1572 2059

CCFJ180J-W* CCFJ180J-WU 2542X1082X1572 2011

CCFJ180J-WQ 2542X1082X1572 1968

CCFJ180J-WY 2542X1082X1572 2081

V. Gen-set outline drawing

E engine oil filler

Fuel oil return

Figure 3-1 Front view Figure 3-2 Left view

Intercooler cooling water inlet

Figure 3-3 Rear view Figure 3-4 Right view

List of unit parts

Figure 3-5 Top view

Chapter IV Overview of main structures

Table 4-1 Main technical specifications of diesel engine

Inlet air flow under rated

Note: this table mainly describes relevant parameters of WP10CD Series

Table 4-2 Main technical specifications

10 Radio interference level Level N

III. Instrument box

IV. Solid base frame

Chapter V Storage and Installation

II. Unpacking acceptance

Basic acceptance items are:

Appearance inspection: check whether exposed parts are damaged by visual

inspection or whether there is collision, deformation and other abnormal phenomena

Gen-set Model LWH (mm) Weight (kg)