WEICHAI WP4GNA Installation And Application Manual
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WEICHAI WP4GNA Installation And Application Manual

WEICHAI WP4GNA Installation And Application Manual

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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

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  • Page 1 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...

  • Page 2: Table Of Contents

    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 ..................11 ELECTRICAL SYSTEM ....................... 12 INTAKE AIR SYSTEM ....................... 13 CLOSED CRANKCASE VENTILATION..................

  • Page 3: Installation Of Certified Engines

    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.

  • Page 4: 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.

  • Page 5: System Overview

    Natural Gas (NG) to Propane (LPG/VPG) fuel is a software command from the operator console or a switch input into the 4G ECM. The Weichai WP04GNA engine is capable of operating in bi-fuel mode starting from VPG/LPG and switching to NG after the NG pressure develops from operation. With the proper valve and sensor arrangement the fuel supply transition can be made while in operation, under full load, and automatically.
  • Page 6 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.
  • Page 7 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.
  • Page 8 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.
  • Page 9 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.

  • Page 10: Engine Mounting Suspension

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM ENGINE MOUNTING SUSPENSION Maximum inclination angles Maximum inclination angles at which the engine will operate satisfactorily: Transverse inclination, intake 10 deg Transverse inclination, exhaust 10 deg Longitudinal inclination, front 5 deg...

  • Page 11: Electrical System

    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...

  • Page 12: Intake Air System

    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.

  • Page 13: Closed Crankcase Ventilation

    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.

  • Page 14: Natural Gas/Wellhead Gas Fuel System

    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.

  • Page 15: Vpg Single Fuel System

    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.

  • Page 16: Pre-Catalyst Oxygen Sensor

    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).
  • Page 17 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.

  • Page 18: Catalytic Converter

    Minimum distance between sensor and exhaust outlet should be 15.7 inches (400 mm). CATALYTIC CONVERTER A very important component in a low emission engine is the catalytic converter. Weichai Engines use a TWC converter. For this type of catalytic converter to work properly, the following two criteria must be met: The air-to-fuel ratio must oscillate between rich and lean.
  • Page 19 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).

  • Page 20: Flywheel

    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.

  • Page 21: Adjustable Parameters

    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.

  • Page 22: Oil Level Gauge Installation

    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.

  • Page 23: Abbreviation Definition

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM 1/8” NPT to 3/8” Barbed 4x M6x1.0x35 Gasket Oil Filler Neck Assembly Gasket Oil Balance Line Block Figure 11: Balance Line ABBREVIATION DEFINITION ABBREVIATION DEFINITION DEPR Direct acting Electronic Pressure Regulator...

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