Operation and Maintenance Manual for WP2.1C/WP3.9C Marine
Contents
1. Possible Causes Suggested Remedies 1 Engine detonating with clear knocking Ponts 4 Readjust injection timing noise in cylinder 2 Delayed combustion Backfire 1 Sail e osha dye tes eadjust injection timing exhaust pipe 22 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 3 Clearance between piston and cylinde liner too big causing thudding noise Thel f sere i Check and repair Replace piston and liner if necessary noise disappears after fuel delivery to thel ylinder being cut off for 3 to 5 seconds 4 Clearance between crankshaft and mai bearing too big causing low heavy pounding Check and repair Replace main bearing or thrust plate noise periodically 5 Clearance between crankpin and bearingiCheck and repair oo big causing dull pounding noise eplace connecting rod bearing 6 Clearance between piston pin and omnecting rod bushing too big causing sharp Check and repair Replace bushing knocking noise 7 Valve clearance too big causing IReadjust valve clearance hattering noise 8 Piston striking valve causing clear metal A a f IReadjust valve clearance and valve timing noise 6 7 Black Exhaust Possible Causes Suggested Remedies 1 Engine overloaded Reduce load 2 Fuel delivery not even or too much Adjust injection pump and governor 3 Injection pressure too low causing Readjust no2. There is a graphite coated gasket between the cylinder block and cylinder head Check to see that the holes in the gasket line up respectively with the holes for the locating sleeves and the holes for the circulation of water and oil in the cylinder block Place an O ring seal 6 318 in the oil hole of the gasket 3 3 Valve System Both camshaft gear part 1 in Fig 4 and injection pump gear part3 in 2 driven by the crankshaft gear part 6 in Fig 4 via an idle gear part 2 in F _ ae gears have dot marks on them In assembly all the marks should be correctly placed to ensure correct valve timing and injection timing see Fig 5 The valves are opened and closed in certain timing events They are driven by the camshaft through tappets push rods and rocker arms Z 5 4 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 1 Camshaft timing gear 2 Idle gear 3 Injection pump gear 4 Oil pump gear 5 Oil pump driving gear 6 Crankshaft timing Fig 5 The valves are opened and closed in certain timing events They are driven by the camshaft through tappets push rods and rocker arms 3 4 Crank connecting Rod Mechanism The crank connecting rod mechanism is composed of the piston connecting rod assembly and crankshaft flywheel assembly The piston connecting rod assembly consists of the piston compression rings oil scraper ring piston pin connecting rod connecting rod bearings and connectin
3. Lowidlespeed i 800 850 Firing order 1 3 4 2 Lubricating method Combination of pressure and splash Cooling method Pressurized water cooling Dry weight 1084 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Model WP3 9C53E1 WP3 9C61E1 Type Water cooled vertical in line four stroke Apiration Natural aspiration No of cylinder BorexStroke mm 4 102x118 Total displacement L 3 86 Compression ratio 17 5 1 Mean effective pressure kPa 590 7 590 7 Mean piston speed m s 7 87 7 87 Rated output kW 38 38 Rated Speed r min 2000 2000 Fuel consumption at rated power g kW h lt 235 Oil consumption lt 0 5 Speed droop lt 5 Lowidlespeed r min 750 800 Firing order 1 3 4 2 Lubricating method Combination of pressure and splash Cooling method Pressurized water cooling Starting method Electric Dry weight kg 440 L mm 1084 Overall dimensions W mm 718 H mm 890 Dimension to flywheel housing end Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 1 2 Specifications of Main Components Model WP2 1C27E201 WP2 1C35E201 Type In line plunger type Designation 4Q366 BH4Q75R8 Injection pump Governor TQA Mechanical centrifugal type Fuel supply pump Single acting piston pump KBAL P028 Injector E TERTA CDSLA 153 P 777 Nozzle diameter 5x 0 22 Nozzle opening p
4. The cylinder head assembly is composed mainly of cylinder head fuel injectors valve mechanism intake and exhaust manifolds front cover plate rear cover plate thermostat and water temperature sensor The inlet and exhaust valve guides are of the same design The valve guide and valve seat insert are press fitted into the cylinder head The valves are not interchangeable because they and their seats have been lapped in pairs to form continuous regular and bright seating lines No leakage is allowed in the seat line of the valve The normal valve seating line width is 1 0 1 4mm If it gets too wide to ensure tight sealing reshape it by means of a special reamer Each valve is marked with a cylinder number because they are not interchangeable in assembly The standard valve recession i e the specified distance from the valve head to the cylinder head surface is 0 4 0 1mm see Fig 1 If the valve recession is too small ream the valve insert to enlarge it if it is too large replace the valve and valve seat Fig 1 The cylinder head is mounted on the cylinder block with 18 bolts They should be evenly tightened in 2 3 steps The tightening of the bolts in each step should Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel be done in the order as shown in Fig 2 When dismounting the cylinder head slacken the bolts in the reverse order The operation procedure should be followed to prevent leakage and cyl
5. seal 7 Cylinder head gasket 17 V belt 8 Upper main bearing 18 Oil filter cartridge 9 Lower main bearing 19 Fuel filter cartridge 10 Piston 20 Nozzle needle body pair 26
6. Operation and Maintenance Manual for WP2 1C WP3 9C Marine Diesel WEICHAI POWER YANGZHOU DIESEL ENGINE CO LTD Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Contents Section I Main Specifications and Engine Data eeeesessesseeeseeeseeeeeeseeeseeeseesseeeseesseseeesaeesseesseeeeeeseeeeeeeaees 1 I Specifications of the Engines irirangi an enir Eea EN EENE INTENEK RESEN aint ae 1 1 2 Specifications of Main Component c ccssesgecsncvecessgensgecsncvsseeonevsaccoacuegeeeacvdaceaeceaevegscaacveiecancvndecaneeedssneenas sais 3 1 3 Main Engine DatascicsunninanaiiinihenisinbaneunGnundneiblnundninunianaiabn aun ninindah 5 Section I Operation of the Engine cccccessssssseceesesssseeseeecseeseescseeeecaesacseesecaesecsesacseceesaesaeeaeeeeesaeeaeeeeeesaesaeeaeereas 6 2 1 Fuel Lubricating Oil and Cooling Water ecssesessecsseceseceeceseceseeeaeeeseceaeceneceaecsaeaeceaesaeceaecaesaeceaeeaeeeaeeaes 6 22 Runne 108 the PoE Cs exc ies 5 Sees vtec cd caud secwiee sdeceyes She c ies egeceses suecwdeaet Hecasdsuecwies Soecases fudcwietstecaset sleceere eedety 7 2 3 Preparations Tor Stam intn Bess ccc scs es ceca ce es a ae ars ce Sekt aD Dae Soe ae eae ek oes 7 2A Starling MEENE MO raoin on acs tanavacasddavacachcavapavadasadesdcabapghausddasads bacesapesad cua cas eeayesed snafebidanopeniheuz udeanaetenics 8 Section II Engine Assembly and Disassembly ccceccsssssssceseeseeeseeceecseeseeeeeceeesaeeaeseeeceeea
7. ce manual of the injection pump The TQA type governor is a centrifugal and variable speed governor The maximum speed setting screw is used to set the maximum speed of the engine and the idle speed setting screw is for low idle setting The speed setting screws have been properly adjusted in the factory and are not allowed to be readjusted by customers The P type injector has a nozzle with 5 holes of dia 0 22mm It is mounted with one clamping plate and one tightening bolt The injector nozzle tip protrusion is 3 3 0 1mm Special shims are used for adjusting the protrusion The nozzle needle and valve seat are finely matched to each other and should not be interchanged Keep the injector parts absolutely clean during maintenance operation 3 6 Lubricating System The lubricating system consists of the oil pump oil pump strainer oil filter and oil pipeline The lubrication of the engine is of the splash and pressure combined type Some bearings such as the main bearing connecting rod bearing camshaft bearing and rocker arm bearing are pressure lubricated while other friction surface such as the cylinder liner piston piston pin valves and gears are lubricated by splashed oil The lubricating oil drawn by the oil pump flows into the oil filter Filtered oil flows through the main oil gallery in the cylinder block to lubricate the crankshaft main bearings camshaft bushings and rocker arm bushings and oil through the oil hole fro
8. cing isscicsciesleecte icceastedetcactyicesactzsctcastesctensbescerysesuezsctetstesctepctesctepsleesedbatebctepsteiss chstebacdaesastaatenstvasenvivests 22 6 6 Abnormal NoisGierennimieeneiiniii iene detec deere dete dee totes E E E heb eentees 22 6 7 Black EXWQuUsts A tase ayes E lasses aye deena dees teresa deat regs E sins Adee 23 6 8 Coolant Temperature Too Highs csc decscceses Access E abt Reese N 23 6 9 Low Lubricating Oil Pressures icccccccsascuectucieeceuceuegucieuesveeeeuecgntieueseneieuneneegnereueeseeeuecantieueseneeeueenereeeeeeereeeenee 24 6 10 Excessive Oil Consumption ie spaccnvctas destedes spatenss n E betas E EE E SE E S EA 24 6 11 Deterioration of Lubricating Oil ssraseisrnio aE ie Heese ieee Mec eee eed 25 6 12 Trouble Shooting in Electrical System sccsscsssvsssesossssssnsoeesecssesnasecosevstsensonsssseacesevsnsereentvseevsnseveonteenes 25 Appendix Spare parts of Diesel Engine WP2 1 2 5CD ccccccscccssscesssccsssecsssecessecesseeeesseceseeseseceesenseeesseessues 26 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Section I Main Specifications and Engine Data 1 1 Specifications of the Engines Model WP2 1C27E1 WP2 1C35E1 Water cooled vertical in line four stroke Type No of cylinder BorexStroke mm 4 85x92 Total displacement Mean effective pressure Mean piston speed Rated Speed Fuel consumption at rated power g kW h Oil consumption Speed droop
9. d in the following procedures A Drain lubricating oil cooling water and fuel oil from the engine when it is hot B Dismount intake and exhaust manifolds Through the inlet and exhaust ports in the cylinder head pour 200 grammes dehydrated lubricating oil into each cylinder Rotate the crankshaft to apply the oil to the piston piston rings cylinder liner and valve seats C Cover the openings on the engine to prevent foreign objects and moisture from entering them D Smear rust resisting oil on the unpainted surface of the engine E Store the engine in a clean dry place with good ventilation The engine should not be stored near chemicals F Repeat the procedures from A to E for every six months during the engine storage Section VI Trouble shooting 6 1 Failure to Start Possible Causes Suggested Remedies 1 Fuel tank empty or fuel tank cock no pen efill fuel tank Open cock 20 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 2 Fuel pipeline or fuel filter clogged IDismount fuel pipeline or fuel filter Clean or replace them oth Bleed fuel system 3 Air within fuel system f ighten all fuel pipe connections 4 Defective injection pump or incorrectCheck fuel feed pump and injection pump Adjust injectio injection timing iming 5 No injection or poor characteristics offClean and lap nozzle needle and body in pair Readjust spray nozzle openi
10. er temperature is over 30 C Then start the engine in the procedure described above It is not allowed to run the starting motor continuously for more than ten seconds If the engine fails to start up wait for two minutes before making another attempt It is necessary to check over the engine if it fails to start up for three times in succession After starting up let the engine run at about 800 r min for several minutes Do not load the engine until the lubricating oil pressure is in the normal range Running at rated speed and full load is not allowed until the outlet cooling water temperature reaches 60 C During operation pay close attention to the indications of meters especially that for lubricating oil pressure Before stopping the engine reduce the load and speed gradually Stop the engine by pulling the engine stop lever after the engine has been run at idle speed for several minutes In case of engine running away choke the intake pipe to stop the engine If the ambient temperature falls below 0 C and the engine is not to be run for a long time drain the cooling water from the engine and radiator to prevent frost 8 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel fracture of the engine Section II Engine Assembly and Disassembly 3 1 Cylinder Head The monolithic cylinder head is made of high strength cast iron The fuel injectors and valve train parts are mounted on the cylinder head
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12. fuel filter cartridge E Complete all the procedures mentioned above F Check the seat lines of valves Relap valves and readjust valve clearances if necessary G Check the fuel delivery advance angle Readjust it if necessary H Check the nozzle opening pressure and spray pattern Readjust the injection pressure I Check the tightening torque of main bearing bolts and connecting rod bolts J Check the leakage from the weep hole of the water pump Replace the water seal if the leaking rate is too high K Clear the silencer of carbon deposits L Check all cable connections in the electric system Clean and tighten the connections if dark burned spots are found 19 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 5 4 Maintenance at the Completion of Every 1000 Working Hours A Complete all the procedures mentioned above B Replace air filter cartridge C Clear the cooling system of scale D Clean the fuel tank and fuel pipeline E Check for technical conditions and performance of the engine to see if it needs some repairing Dismount and inspect relevant parts Clear away carbon deposits from cylinder head piston piston rings and cylinder liner Check to see if the piston rings cylinder liner crank pin bearing or main journal bearing are subject to premature wearing 5 5 Engine Preservation If the engine is to be kept in store for a long period of time it should be treated beforehan
13. fuel pipelines Fuel from the fuel tank flows through the strainer into the feed pump and then pass through the fuel filter to the injection pump The fuel at high pressure from the injection pump is delivered to the fuel injector and sprayed into the combustion chamber The superfluous fuel from the injection pump and injectors flows back to the fuel tank see Fig 7 Fig 7 1 Fuel return pipe 2 Fuel injection pipe 3 Fuel fine 4 Fuel tank 5 fuel rough filter 6 Filter 13 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel The fuel feed pump is of single acting and plunger type It is mounted on one side of the injection pump and driven by a cam on the camshaft of the pump A primer pump is attached on the feed pump to bleed air from the fuel pipeline before starting the engine When it is not in use lock the primer pump handle by pressing and turning the nut on the top of it to prevent leakage of fuel Fuel should be kept absolutely clean to ensure a long service life of the parts in the fuel supply system Replace the cartridge with a new one if it is clogged The fuel injection pump is the BQ or PL series injection pumps The injection pump has been adjusted and sealed in the factory It should not be readjusted by customers except when absolutely necessary All the service operations should be carried out by qualified servicemen on an injection pump tester according to the instructions in the servi
14. g rod bolts The crankshaft flywheel assembly consists of the crankshaft flywheel crankshaft timing gear and crankshaft pulley Two compression rings and one oil scraper ring are fitted into the piston The first compression ring is a keystone type ring When the rings are fitted into their grooves their gaps should be apart from each other around the circumference of the piston Furthermore the oil scraper ring should be so placed that its gap is 90 degrees apart from the pinhole centre around the circumference The second compression ring should have its top surface marked with STD in the area near the gap upward in assembly When checking the ring gap place the ring into a cylinder liner and measure it with a feeler gauge If the gap is too small correct it by fine filing if too large replace the ring with a new one When assembling the piston and connecting rod heat the piston in hot oil to the temperature of 100 to 120 degrees centigrade and then push the piston pin through them The connecting rod and cap are machined and marked in couples They are not interchangeable Two connecting rod bolts should be tightened step by step in turn to reach the specified torque Before placing the piston and connecting rod assembly into the liner smear them with a little clean oil Make sure the intake valve pocket the larger one of the two pockets on the piston is on the left side of the exhaust valve pocket viewed from the inject
15. i f _ Reduce load to lower oil temperature or refill with suitable emperature and low viscosity of lubricating l il il 8 Too big clearance between oil pump eplace rotors or housing cover of oil pump rotors and housing cover 6 10 Excessive Oil Consumption Possible Causes Suggested Remedies 1 Worn piston ring or oil scraper ring Seer ss at ash oil scraper ring in kerosene or replace defective ring stuck in ring groove due to carbon deposits 2 Oil return holes plugged due to carbo re Clean oil return holes in piston deposits 3 Oil level too high Oil into the i nso or f Check with dipstick and drain oil to correct level ombustion chamber 4 Leakage in lubricating system ighten connectors and replace sealing washers and gaskets 24 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 6 11 Deterioration of Lubricating Oil Possible Causes Suggested Remedies 1 Piston ring worm or stuck in groove causing combustion gasor fuel to leak into theClean or replace piston ring oil sump 2 Water leaking into oil due to faulty eplace gasket ylinder gasket 3 Water leaking into oil due to crack i eplace cylinder head ylinder head 6 12 Trouble Shooting in Electrical System Symptoms and causes Suggested Remedies Faulty generator no recharging of battery o current too weak 1 Loose connections o
16. inder head deformation Fig 2 Fig 3 When mounting the fuel injector into the cylinder head make sure that the protrusion of the injector tip from the cylinder head reaches the specified value see Fig 3 It can be adjusted with shims 3 2 Cylinder Block On the front there are the gear case gear case cover oil pump timing gears water pump and fan assembly On the left side of the cylinder block mounted the injection pump lubricating oil filter and oil cooler There is an inspection window on gear case for timing the injection pump in service Before dismounting the injection pump remove the inspection window covers and turn the crankshaft less than two revolutions so as to align the mark on injection pump gear with the points in the inspection windows respectively you can make a mark on the injection pump gear also The crankshaft should not be turned before mounting the injection pump again When mounting make sure that the mark on the injection pump gear is aligned with the point in the inspection window On the right side are mounted the generator starting motor The flywheel housing is attached to the rear of the cylinder block Through the inspection window on the top of the flywheel housing marks can be seen on the rim of the flywheel indicating the TDC and the beginning of fuel delivery to the first cylinder Both flywheel and flywheel housing have the SAE standard dimensions The main bearing covers and the cyli
17. injection starting the pressure should be within the range as specified in Section I Main Engine Data The fuel spray should be uniform and the puffing sound of injection should be short and clear The opening pressure of the P type injector can be adjusted by choosing from different adjusting shims of the thickness in the range from 1 0 mm to 2 0mm The gauge step is 0 01mm Most of the injector manufactures use the shims of the thickness from 1 7mm to 1 9mm Before reassembling the injector clean the nozzle valve and the adjusting shim Care must be taken not to scratch the matching faces After attaining the specified pressure remount the lock nut and check for the opening pressure again 4 4 Adjustment of Lubricating Oil Pressure Pay frequent attention to the lubricating oil pressure The normal oil pressure ranges from 200 kPa to 500 kPa The adjustment of lubricating oil pressure should be carried out after the engine gets warm when the lubricating oil temperature is around 80 C Dismount the sealing nut from the adjusting screw on the oil filter Turn the adjusting screw to adjust oil pressure Screw in or out the adjusting screw to increase or decrease the oil pressure After adjustment put on the sealing washer and then tighten the sealing nut 17 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 4 5 Adjustment of injection pump The injection pump has been adjusted and sealed in the factory It sho
18. ion pump side of the engine in assembly When moving the piston and connecting rod through the cylinder liner be careful not to bruise the liner surface 12 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel The difference in weight between the piston connecting assemblies for the same engine should be less than 10 grammes This requirement can be met through selection The crankshaft is made of ductile nodular cast iron There are five main journals and four crankpins on the crankshaft An oil hole in each journal leading to the neighboring crankpin is employed to supply lubricating oil to the crankpin bearing On the front end of the crankshaft there are the timing gear and oil pump driving gear both driven with a flat key On the front and rear of the crankshaft there are oil seals to prevent oil leakage When installing the flywheel tighten the flywheel bolts evenly in the order shown in Fig 6 to reach the specified torque in 2 3 steps The crankshaft and flywheel are dynamically balanced as an assembly The same figure is marked side by side on the crankshaft flange end and the flywheel as an indication of the pairing relation and mounting position Be sure to assemble the flywheel with the crankshaft in the correct position as indicated with the figure mark 3 5 Fuel Supply System The fuel supply system consists of the fuel tank rough filter feed pump fine filter injection pump governor injectors and
19. ions The maintenance work schedule is as follows 1 Shift maintenance 2 Maintenance at the completion of 125 working hours 3 Maintenance at the completion of 500 working hours 4 Maintenance at the completion of 1000 working hours 5 1 Shift Maintenance A Check the oil level in oil sump and injection pump Refill to the specified level if necessary 18 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel B Check the water level in the radiator Refill if necessary C Check the fuel level in fuel tank Refill if necessary D Check the tightness of mounting bolts of the engine and installing bolts of components Tighten them if necessary E Check the leakages of air oil and water Repair if necessary F Eliminate all faults and abnormal conditions found in operation G Clean the engine and accessories of oil sludge and dust H Clean the air filter and air duct every day in dusty environment 5 2 Maintenance at the Completion of Every 125 Working Hours A Complete all the procedures mentioned above B Check the tension of the fan belt Adjust it if necessary 5 3 Maintenance at the Completion of Every 500 Working Hours A Clean away dust from the paper cartridge and dust chamber of the air cleaner B Check the valve clearances and make adjustments if necessary C At the completion of every 250 working hours replace oil filter cartridge D At the completion of every 250 working hours replace
20. le after the engine being reassembled or running for 500 hours The procedure for checking and adjusting is as follows 16 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Remove the high pressure fuel pipe for the first cylinder join a pipe to a thin glass tube and connect it with the first cylinder delivery valve holder of the injection pump Set the speed control lever to the maximum delivery position and bleed off the air in the fuel system Turn the crankshaft till there are no air bubbles in the fuel flowing out of the glass tube Then turn the crankshaft slowly and watch attentively for the rise of the fuel level in the glass tube Stop turning the crankshaft at the beginning of the rise of fuel level which implies the beginning of the fuel delivery to the first cylinder Check to see if the mark of fuel delivery to the first cylinder on the flywheel aligns with the timing pointer inside the flywheel housing If it does not readjust in the following procedure Slacken the bolts which fasten the injection pump onto the connecting flange Turning the injection pump with its top towards the cylinder block results in the increase in the fuel delivery advance angle and vice versa 4 3 Adjustment of Nozzle Opening Pressure Dismount the fuel injector from the cylinder head and mount it on the injector tester for checking and adjusting Actuate the pump handle and watch the indication of pressure At the time of
21. load without going through the running in period may cause excessive wear resulting in a reduction of service life or even damages to the cylinder piston and bearings After the replacement of any of the important parts such as the piston piston ring cylinder liner crankshaft main bearing and connecting rod bearing the engine should be run at low speed and under light load for 10 to 15 hours before normal service If anything abnormal occurs during the running in period stop the engine to check for the cause and make corrections After running in proceed to the following operations Drain off the oil in the oil pan immediately after stopping the engine Clean oil pan and strainer with diesel oil Replace the oil filter cartridge Check and adjust valve clearance Check and retighten all the external securing bolts and nuts Check and eliminate any abnormality Lubricating maintenance 2 3 Preparations for Starting 2 3 1 Check the tightness and security of the mounting of engine parts and accessories including the injection pump fuel filter lubricating oil filter generator electric starter water pump fan pulleys etc Check the freedom of movement of the fuel injection pump control levers 2 3 2 Fill the engine with clean fuel oil lubricating oil and cooling water as specified in Section 2 2 Check the oil level in the oil sump Oil level in the oil sump should be near to the upper mark on the dipstick but not ab
22. m the crankshaft journal to the crank pin to lubricate the connecting rod bearing 14 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel The lubricating oil filter cartridge is a spin on canister In case the cartridge is seriously clogged the bypass valve will open allowing unfiltered oil to flow directly to the main oil gallery in the cylinder block Be sure to follow the instructions described in Chapter V during maintenance operation of the oil filter Replace the filter cartridge if necessary The pressure adjusting valve serves to adjust the oil pressure in the main oil gallery and keep it within the range from 200kPa to 500kPa 3 7 Cooling System The engine has a pressure type cooling system It consists of the radiator fan water pump and thermostat When the engine cooling water temperature is below 73 C the thermostat is closed and the cooling water is stopped from going to the radiator It goes from the thermostat housing back to the water pump So the engine will be warmed up in a short while As the water temperature gets higher above 80 C the thermostat opens gradually and lets the cooling water into the radiator The cooling water from the radiator goes through the tube and back into the water pump The water pump is of the centrifugal type Its maintenance free bearings need no greasing When water continuously leaks out from the weep hole in the bottom of the pump housing due to exces
23. n impurities and then filtered with a silk cloth Lub oil The lubricating oil for the engine should be chosen from the products specified in the China National Standard GB11122 according to ambient temperatures Proper grades of lubricating oil for different ambient temperatures are shown in the table below Lub oil Specifications CF grade 10W SW 30 10W 30 15W 30 15W 40 20W 40 20W 20 30 40 Ambient 90 5 25 25 20 20 10 25 10 35 10 30 10 10 5 30 gt 25 Check the oil level with the dipstick at least 5 mins after refilling or stopping the engine Coolant Coolant for diesel engines should be clean soft water such as water from rain snow or clean rivers In case of hard water such as water from wells and fountains it should be softened beforehand There are two methods of doing it 1 To boil up the hard water 2 To add caustic soda into hard water 20 grams of caustic soda for 30 liters of hard water Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 2 2 Running in of the Engine A new engine or an overhauled one should not be run under rated conditions before it has gone through 50 hours of running in under part load Only 2 hours of running in of the new engines is carried out on the test bench They should be run about 20 hours under half or lighter load before normal service at rated conditions Operating an engine under heavy
24. n generator and battery Check and tighten all connections Clean contacting surfaces lor corroded contacts land improve insulation 2 V belt slip IReadjust belt tension 3 Generator out of order Check and repair a CN voltage regulator C Resistor of regulator burnt out of regulator burnt out 1 Battery terminals incorrectly connected Reconnect cables 2 Cutout relay out of order current reversed att low engine speed ID Starting motor will not run 1 Loose connection of cables Clean off dirt Tighten connections 2 Battery not fully charged Check and recharge it 3 Bad contact of brushes Clean and polish with fine sandpaper 4 Short circuit within starting motor Check and repair E Starting motor will run idle but unable to crank the engine up Symptoms and Causes Suggested Remedies 1 Bad contact of brush Clean and polish with fine sandpaper 2 Badcontactofcableconnectionand switch Clean off dirt Tighten all connections 3 Weak battery Check and recharge it 25 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Appendix I Spare parts of Diesel Engine WP2 1 2 5CD No Part Name No Part Name 1 Valve spring outer 11 First compression ring 2 Valve spring inner 12 Second compression ring 3 Intake valve 13 Oil scraper ring assembly 4 Exhaust valve 14 Connecting rod bearing 5 Valve collet 15 Front oil seal 6 Cylinder liner 16 Rear oil
25. nder block are machined in couple The main bearing covers are marked with sequence numbers and orientational arrow marks They are not interchangeable and should be installed with the arrow marks pointing to the front side fan and gear side of the engine When tightening the main 10 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel bearing cover bolts tighten the middle ones first and then the ones on both sides symmetrically to complete one operation step The specified torque should be reached gradually in 2 3 steps The two halves of main bearings are different The upper one has an oil groove and an oil hole It should be placed in the bearing saddle of the cylinder block On both sides of the fifth main bearing cover are installed two thrust bearings to control the endwise movement of the crankshaft The thrust bearings should be placed with the grooved face outward The cylinder liner is of the dry type After the liners are pressed into the cylinder block the top surface of each cylinder liner collar should be 0 04 0 12 mm higher above the surface of the cylinder block see Fig 4 For the same cylinder block the difference in the height between one cylinder liner and another should be less than 0 05 mm If this dimensional tolerance is exceeded replace the wrong cylinder liners with selected ones When pressing in a liner be sure to apply the force evenly and perpendicularly on its top 0 06 0 10mm
26. ng pressure 6 Ambient temperature too low and engine oo cold Heat cooling water 7 Insufficient compression pressure i See item 6 3 hereafter ylinders 8 Starting motor runs at low speed or will See item 6 12 hereafter not run 6 2 Lack of Power Possible Causes Suggested Remedies 1 Insufficient compression pressure in See item 6 3 below cylinders 2 Wrong grade of fuel or fuel ontaminated with water se proper fuel Clean fuel tank and refill 3 Clogged air cleaner Cleanaircleanercartridge Replace cartridgeif necessary 4 Choked exhaust silencer Clear away carbon deposits or dirt from silencer 5 Air within fuel system leed fuel system Tighten all fuel pipeline connections ts nspect camshaft and marks on gears Check valve 6 Incorrect valve timing learances 7 Incorrect fuel delivery advance angle Check marks on gears Readjust fuel delivery advance angle 8 Low injection pressure or poor spray eadjust nozzle opening pressure haracteristics 9 Uneven distribution of fuel eadjust uniformity of fuel delivery from fuel injection among cylinders ump to cylinders 10 Engine unable to reach the rated speed eset speed control lever 6 3 Insufficient Compression Pressure in Cylinder Possible Causes Suggested Remedies 1 Valve clearance too small or no Readjust valve clearance clearance 2 Carbon deposi
27. ove it 2 3 3 Check for the leakage of oil and water Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 2 3 4 Turn the crankshaft for several revolutions to check whether the movable parts move smoothly without interference 2 3 5 Check the battery and wiring in the electric system 2 3 6 Bleed the fuel supply system in the following procedure 1 Slacken the venting screw on the fuel filter Actuate the handle of the prime pump to bleed the fuel filter and pipes And then retighten the venting screw 2 Slacken the venting screw on the injection pump Bleed the fuel injection pump by actuating the handle of prime pump until no air bubbles can be found in the outflowing fuel Retighten the venting screw 3 Slacken the union nuts connecting the injectors and high pressure fuel pipes Turn the speed control lever of the governor to its halfway position Crank the engine by means of the starting motor until fuel flows out from the joints Then retighten the union nuts 2 4 Starting the Engine Before starting check to see that the prime pump handle resists hand operation and that a puffing sound of injector can be heard when engine is cranked If not bleed the fuel system again Turn the speed control lever halfway and set the starting switch to the start position to start the engine In cold weather open the drain cock on the cylinder block and refill the cooling system with hot water until drain wat
28. ressure MPa 20 20 5 Type Lub oil pump ated speed r min centrifugation Cooling water pump ated speed r min 1800 Flow rate L min 45 Type Spin on paper cartridge Fuel filter Designation CX0708 Type paper cartridge Air filter Designation K2007 Type Spin on Full flow Lub oil filter Designation JX0708 Type Wax element type Thermostat Designation 155B Designation QD138Y Voltage V 12 Starting motor 5 Designation JFWZ13 Generator Voltage V 4 Poweroutput W 350 2 1 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Model WP3 9C53E1 WP3 9C61E1 Injection pump Injector Nozzle opening pressure MPa Type Type Designation In line plunger type KBAL P028 P Type Porous type 24 25 Type Spin on paper cartridge Fuel filter Designation CX0710T Type Spin on Full flow Lub oil filter Designation JX0814ZC Type Gear type Lub oil pump Rated speed r min 1900 Flow rate L min 15 Type centrifugation Rated speed 1 min 3000 Cooling water 7 Flow rate L min 200 pump Voltage V 12 Power supply kW 3 8 Designation JFWZ13 Generator Voltage V 14 Poweroutput W 350 Designation 2DRS 10 24 105A 10 12 105 Glow pulug Voltage V 24 12 continuous working lt 30 lt 30 Type Wax element type Thermostat Designation JWQ 1039 76K Lub oil Type Disk stack type cooler De
29. signation 28Z2 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 1 3 Main Engine Data Model WP2 1C27E1 WP2 1C35El1 rated conditions KPa 200 400 low idle speed kPa Lub oil pressure yb oil temperature C Cooling water temperature Exhaust temperature C Cylinder head bolts Tightening torque specifications N m Flywheel bolts Main bearing cover bolts 120 135 Connecting rod bolts 60 70 Crankshaft pulley clamping Intake valves open Before valve Intake valves close After iming crankshaft angle degrees Exhaust valves open Before Exhaust valves close After Valve clearances on id Exhaust valves mm Intake valves mm 0 20 0 25 0 25 0 30 Fuel delivery advance angle Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Section I Operation of the Engine 2 1 Fuel Lubricating Oil and Cooling Water Fuel The fuel for the engines is the light diesel oil grades10 0 10 20 and 35 specified in the China National Standard GB 252 The fuel for different working conditions should be chosen according to the fuel specifications below Fuel Specifications Grade of fuel 10 0 10 20 35 Cetane value 50 50 50 48 43 Pour point C 10 0 10 20 35 Lowest ambient temperature C 18 8 2 12 23 Before using diesel oil should be stored for at least 48 hours to settle dow
30. sion stroke both intake and exhaust valves of the first cylinder are closed In this position check the clearances of intake valve and exhaust valve of the first cylinder the intake valve of the second cylinder and the exhaust valve of the third cylinder i e the clearances of the first second third and sixth valves counted from the front with a feeler gauge To adjust the valve clearances slacken the lock nut with a wrench and hold it screw in or out the adjusting screw with a screwdriver until the feeler gauge inserted between the rocker head and the top surface of the valve stem feels neither too loose nor too tight Then tighten the lock nut and check the clearance again Readjust if necessary till it is properly set After the adjustment of the clearances of the above mentioned four valves rotate the crankshaft a complete turn to place the piston of the forth cylinder at its top dead center on the compression stroke In this position check the clearances of intake valve and exhaust valve of the fourth cylinder the intake valve of the third cylinder and the exhaust valve of the second cylinder i e the clearances of the fourth fifth seventh and eighth valves counted from the front Adjust the clearances of these valves in the same way as described above 4 2 Adjustment of Fuel Injection Timing In order to maintain fuel economy and power characteristics of the engine it is necessary to check and adjust the fuel delivery advance ang
31. sive wear of the water seal dismount the impeller from the shaft and replace the water seal see Fig 8 1 Radiator 2 Thermostat 3 Fan 4 Water pump Fig 8 3 8 Electrical System The electrical system consists of the starting motor and a generator with a silicon rectifier Be sure to have the negative pole of the generator connected to the ground The electrical system voltage is 12V and the generator power output is 350W 15 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel Power supply of the starting motor is 3 8kW Section IV Adjustment of the Engine 4 1 Adjustment of Valve Clearances It is essential to adjust the valve clearances in operating an engine The valve clearances on cold engines are 0 20mm for inlet valves and 0 25mm for exhaust valves Apart from the adjustment of valve clearances after reassembling the engine it is necessary to check and adjust the valve clearances periodically because of the possible loosening of adjusting screws and wear of parts in the valve system The inspection interval is recommended to be 250 running hours The adjustment should be carried out on a cold engine The procedure is as follows Remove the cylinder head cover Turn the crankshaft until the mark of the top dead center of the first cylinder on the crankshaft pulley aligns with the pointer of the timing indicator When the piston of the first cylinder is at its top dead center on the compres
32. ts on valve and seat Clear away carbon deposits and relap valve and valve seat orn valve and seat eam valve seat if necessary 21 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 3 Piston ring worn or lack of tension eplace piston ring 4 Piston ring stuck due to carbon deposits Clean piston and rings in kerosene 5 Cylinder liner and piston worn Leakage in cylinder head gasket face etighten cylinder head bolts or replace the gasket Gas leakage in injector mounting bore Check copper washer Reset injector Broken valve spring eplace valve spring Valve stuck in valve guide Clean valveinkerosene Replace ifitiswormout or deformed 6 4 Engine Stalls Possible Causes Suggested Remedies 1 No fuel in tank Refill fuel tank i Bleed fuel system Drain water from fuel tank Replacq 2 Air and water in fuel system f cartridge of fuel filter 3 Clogged fuel filter Clean or replace cartridge 4 Choked air cleaner Replace air cleaner cartridge 5 Piston stuck in cylinder Repair or replace piston and cylinder liner 6 5 Engine Racing Possible Causes Suggested Remedies E TT Stop the engine Dismount injection pump and governor Repair or replace governor 2 es nuechon pampconme Stop the engine Repair injection pump rod 3 Clip ring disconnected from control Stop the engine and check Reinstall clip ring aanl 6 6 Abnormal Noise
33. uld not be readjusted by customers except when absolutely necessary All the service operations should be carried out by qualified servicemen on an injection pump tester according to the instructions in the service manual of the injection pump 4 6 Adjustment of V belt Tension Though very easy to adjust the tension of V belt has great influence on the rotational speed of the generator and water pump and hence the operation of the engine It is recommended to adjust it periodically When engine is not running press on the middle of a straight section of the belt with a force of 30 40 N The sag of V belt should be within the range of 10 15 mm If not qualified loosen the adjusting bolt on the adjusting bracket to move the generator to adjust the belt to a proper tension Excessive tension will shorten the service life of the belt and cause the premature wear of bearings in the generator and water pump due to the heavy load resulted from excessive belt tension Insufficient belt tension however will lead to the belt creep and fracture resulting in the engine overheating Section V Technical Maintenance Regular maintenance of the engine is essential to efficient and trouble free operation good mileage between major repairs and long service life General procedures of different assignments of technical maintenance stipulated below should be followed in principle Customers can make some alterations according to particular service condit
34. ustment Of m echon PUMP erinin ia aE NT EN ea EE sete REREN EE RSEN EEE eee EREN scot 18 4 6 Adjustment of V belt TensiOniacaiasnintdaaiacnidacadacnndansiacnuiiiacnsiacnaiaiaiiacnaiamsiascnids 18 Section V Technical Maintenance ccssscesceseeseseeseeececseeseesceecsesaeeaceaceeesesaesesaeaeeesaesaeeaeseeeesaesaeeeeeeseesaeeaeeesensaeees 18 Quill Shut Maintenance 2 22 4 82sicee E ee NE aici clea ei eiNe E 18 5 2 Maintenance at the Completion of Every 125 Working Hours eeeceesceeseeeseeeeeeeeeeeseeeseeeseeseeeeeeeeeeeeaees 19 5 3 Maintenance at the Completion of Every 500 Working Hours eeesceesceeseeeseeeeeeeeeeeeeeseesseeeeeeeeeeeeeaeeaees 19 5 4 Maintenance at the Completion of Every 1000 Working Hours ec cecesessceeseeeseeeseeeeeeeseeeseeeeeeeeeeeeeeeees 20 33 EM SIN Proen AU OMe cazc fees cactstetest ast ctseeanteates a Aree ees e tv Aree hat ee Ar aie iaree ide 20 Section VI Troubleshooting ca s 0savssssnesiessazaensanagidiceneeassnan stags iseasutelavaredsachdsbavasensvagentassacexteseageds cata sadeean ayebheatesgoans 20 6 1 Failure to Start cranio NE ENEAN NEN ENE ANTENE ENEN RNE ai gates aiden heen 20 6 2 Lack Of POWers siccsscceiccuctyscecietyscepieseteictascieieigi E EE AEA OEEO EOE E TONE OO ETETA 21 6 3 Insufficient Compression Pressure in Cylinder 0 eee eeeesceesceeseeeseeeeeeseeeseesaeesseeeaeesaeeeaesseesaeeeseeeeeeaeeeeeeaees 21 6 4 Enoine Stalls E T eve E eee a Ree eee ea eel eres de ete ee 22 6 5 Popme Ra
35. zzle opening pressure poor spray characteristics 4 Fuel injection timing too late Readjust injection timing 5 Air cleaner choked Clear away dust from cartridge or replace cartridge 6 Wrong grade of fuel or bad fuel Drain tank and refill with proper fuel 6 8 Coolant Temperature Too High Possible Causes Suggested Remedies 1 Cooling water flow reduction due to loose V belt Adjust belt tension or replace V belt 3 Cooling water insufficient Refill radiator 23 Operation and Maintenance Manual for WP2 1C WP3 9C Series Marine Diesel 4 Cooling water flow reduction due to lowCheck clearance between water pump impeller and housing ater pump efficiency eplace impeller if necessary 5 Defective water pump impeller eplace impeller 6 Cooling water circulation obstructed Clean cooling system 7 Defective thermostat IReplace thermostat 8 Defective water thermometer Replace thermometer 9 Insufficient lubrication Inspectlubricatingsystemandcleanoil gallery 6 9 Low Lubricating Oil Pressure Possible Causes Suggested Remedies Check oil level Refill to the specified level 1 Insufficient oil in oil sump Defectivelowoilpressurealarm Clogged oil gallery Clogged oil strainer alve 6 Excessive bearing clearances due to wea of main bearing and crankpin bearing 7 Engine overheated causing hig
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