WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM WP04GNA INSTALLATION AND APPLICATION MANUAL EMISSION-RELATED INSTALLATION INSTRUCTIONS FOR WP04GNA ENGINE NON-COMMERCIAL FUELS, NG, LPG & VPG Non-Emergency 3100 GOLF ROAD, ROLLING MEADOWS, IL WEICHAI EMISSION-RELATED INSTALLATION INSTRUCTIONS GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Contents INSTALLATION OF CERTIFIED ENGINES .................................................................................... 4 NOTICE OF IMPORTANT REQUIREMENTS OF CERTIFIED ENGINES.......................................... 5 SYSTEM OVERVIEW .................................................................................................................. 6 ENGINE MOUNTING SUSPENSION .........................................................
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM INSTALLATION OF CERTIFIED ENGINES Thank you for your recent purchase of an EPA certified WEICHAI Nonroad and Stationary Industrial Engine. These instructions are intended to provide the installer of the engine all the information that is necessary to properly install the engine and related components into the equipment chassis.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM NOTICE OF IMPORTANT REQUIREMENTS OF CERTIFIED ENGINES Important Notice- The required Emissions Control Information label has been placed on this certified engine during the WEICHAI assembly process. If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40 CFR 1068.105.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM SYSTEM OVERVIEW STOICHIOMETRIC, RICH BURN CONTROL The 4G engine control module is the backbone of the EControls control system. Proven in a multitude of applications around the world, the 4G based engine control system delivers reliable operation and optimal engine operation no matter the environment.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM TELEMATICS SUPPORT Hardware and software capability exist in the full authority 4G control system to send and receive CAN communication files in a structured message format. The input and output file structure and variable content need to be defined by the customer and implemented by WEICHAI. There will be an engineering change associated with setting up the file structures and debugging the communications with the telematics module.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Figure 2 Direct Acting Electronic Pressure Regulator - It is a continuous fuel flow device. This allows the most homogeneous mixture of air and fuel to the engine yielding optimum combustion with minimum emissions and maximum fuel economy. It operates on low pressure fuel from 6 to 20 inches of water of inlet pressure, no pressure intensification system required.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Figure 3 E330 Mixer MIXER: E330 A relatively constant pressure drop mixer is used to draw fuel when coupled with EPR. The basic principle of the product is to introduce air and fuel into engine. It also aids in introducing turbulence into the air and fuel assisting in making it a homogeneous mixture.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM HEAVY-DUTY DUAL STAGE REGULATOR: The heavy-duty dual stage regulator vaporizes liquid propane to gaseous form and also regulates the fuel pressure to meet the fuel pressure requirement as is shown in Figure 4. Figure 4 Heavy-Duty Dual Stage Regulator The HD DSR is a two stage fully mechanical regulator that is available in LPG configurations.
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WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM ELECTRICAL SYSTEM WIRE HARNESS DIAGRAM Figure 6 Wire Harness Diagram CONTROL PANEL: Optional: PV380 AND REALATED HARNESS, Murphy MPC10, MPC20, and additional panel options are available. Contact Weichai for details. Figure 7 PV380 & Related Harness BATTERY SETUP WEICHAI EMISSION-RELATED INSTALLATION INSTRUCTIONS GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM One 12V battery is used to provide 12V to the control system. The battery needs to be setup according to the steps below: - Engine Electrical System is 12-volt DC Negative Ground - The Engine Battery should be 650CCA or Greater. Never disconnect the battery when running. The batteries should be attached to the engine at all times. - Connect positive (+) red wire to positive (+) terminal on battery.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Figure 9 Intake Air System CLOSED CRANKCASE VENTILATION Weichai engine uses a closed crankcase system as shown in Figure 10. The breather separates the crankcase oil/gas mixture and lets the oil return to the sump and sends the gas into the intake system. Figure 10 Closed Crankcase Ventilation System WEICHAI EMISSION-RELATED INSTALLATION INSTRUCTIONS GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM NATURAL GAS/WELLHEAD GAS FUEL SYSTEM The fuel first passes the fuel shut-off valve when the engine starts cranking. Then it goes through the DEPR and comes into the mixer to be mixed with the air from the air filter as shown in Figure 11. Figure 11 Natural Gas/Wellhead Gas Fuel System LPG & NG DUAL FUEL SYSTEM When the engine operates with LPG, the NG shutoff valve will be closed.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM VPG SINGLE FUEL SYSTEM For single VPG fuel application, the same shut-off valve as NG is used to turn on or off the fuel, but the shut-off valve needs to be connected with the secondary fuel connector from the harness as Secondary Lock-off (LPG) only. COOLING SYSTEM Figure 13 shows the configuration of the cooling system.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM PRE-CATALYST OXYGEN SENSOR Apply an adequate amount of anti-seize compound to the threads of the oxygen sensor and install the sensor in the O2 sensor port located on the exhaust manifold elbow pipe. Tighten the sensor to the specified torque 29.5ft-lb ~44ft-lb (40Nm~60Nm). Anti-seize on thread only, don’t put on the sensor.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM - - Attempt to achieve rapid heating-up of the exhaust pipes in the area in front of the sensor. The exhaust pipe in front of the sensor should not contain any pockets, projections, protruding or edges etc. to avoid accumulation of condensation water. A downside slope of the pipe is recommended. The use of a sensor type with double protection tube can give a better protection of the sensor ceramic against condensation water drops.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM The sensor must not be exposed to strong mechanical shocks (e.g. while the sensor is installed). Otherwise the sensor element may crack without visible damage at the sensor housing. For physical reasons the sensor needs ambient air at its reference gas side. Replacement of the air volume inside the sensor must be guaranteed by a sufficient air permeability of the wires and the connectors between sensor and ECU.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Operation - The continuous operating exhaust gas temperature must be between 1112 deg F (600°C) and 1562 deg F (850°C). - The Product installer shall take necessary precautions to accommodate shell skin temperatures - up to 1202 deg F (650°C). - System backpressure must remain with +/- 5% of nominal conditions. - Engine misfires and exhaust stream containments are not permissible.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Figure 17 depicts an example of catalytic mounting options. Figure 17 CATALYTIC CONVERTER MOUNTING OPTIONS FLYWHEEL All the Weichai engines come with SAE 1 standard flywheel with SAE 3 adapters. The adapter will be used depending on the customer requirement and the adapters are as shown in below picture. Contract Weichai representative for assistance of the connector/adaptor installation.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM ADJUSTABLE PARAMETERS This engine has been certified by the US EPA to operate on pipeline quality commercial Natural Gas fuel as well as commercial LPG/propane. The Fuel System is non-adjustable and it can compensate for changes within commercial fuels at different locations in the US. Customers can use a fuel switch (PG Switch in Figure 19) to switch between NG and LPG operation.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM OIL LEVEL GAUGE INSTALLATION The WP04GNA Weichai engine comes equipped with the capability of using an oil level gauge. If a gauge was purchased through Weichai America Corporation, the connector on the wiring harness and the connector on the gauge should be a match. If the gauge was not supplied by Weichai America Corporation, please contact our service department and the right connector can be purchased.
WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM 1/8” NPT to 3/8” Barbed 4x M6x1.
