WEICHAI WP4GNA Operation And Maintenance Manual
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- Installation and application manual (23 pages) ,
- Assembly/disassembly manual (90 pages)
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Summary of Contents for WEICHAI WP4GNA
- Page 1 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Operation and Maintenance Manual Gas Engine Model: WP04 WEICHAI AMERICA CORP. Revision: August 2019...
- Page 2 Weichai America Corp. Purpose This manual is intended to inform customers on how to operate, install and maintain the Weichai America WP04 series gas engines. This document will be provided to customer so they can incorporate this information into their manuals and service documents.
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Page 3: Table Of Contents
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Table of Contents Description of the Illustration Marks ................... 5 Engine Introduction and Performance Parameters ..............6 1. Introduction of Engine Model ................... 6 2. - Page 4 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9. Replace Engine Breather Filter ..................24 10. Inspect Belts, Pipes, Clamps and Hoses ................24 11. Inspect Ignition System ....................24 12.
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Page 5: Description Of The Illustration Marks
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Description of the Illustration Marks Dismounting (assembly parts) Oil Coating Fitting (assembly parts) Special Tools Marking (do before disassembling,... -
Page 6: Engine Introduction And Performance Parameters
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Introduction and Performance Parameters 1. Introduction of Engine Model WP04 TA/NA NA: Natural aspirated TA: Turbocharged G: Gas engine WPxx: Engine series 2. -
Page 7: Wp04 Gas Engine Data
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. See engine nameplate to find engine model, series number, rated power, rated speed and weight. More data as following table: 3. -
Page 8: Epa Legal Requirements
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. U.S. EPA Legal Requirements This engine has been certified by the U.S. Environmental Protection Agency (EPA) as a Non- road and stationary constant-speed engine. -
Page 9: Personal Safety
Failure to follow these instructions could cause damage or decrease the life of equipment. Weichai America Corp. is continually striving to improve its products and therefore reserves the right to make improvements and changes when it becomes practical and/ or possible to do so, without incurring any obligation to make changes or additions to previously sold equipment. -
Page 10: Fuel Information
Oil and Coolant Information Natural Gas Engine Oil Weichai America Corp. recommends using a straight weight or multi-weight low ash content oil specifically formulated for Natural Gas Engines. Specific weight depends on operating temperatures. Consult your oil supplier for specific product recommendations. -
Page 11: New Engine Break-In Procedures
The engines moving parts are closely fitted for long service, and even though all Weichai America WP04 Gas Engines are run before they leave the factory, an additional period may be required before uniform oil films are established between all mating parts. -
Page 12: Rating Definition For Power Generation
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Rating Definition for Power Generation 1. Continuous Power (COP) is defined as being the maximum power which the generating set is capable of delivering continuously whilst supplying a constant electrical load when operated for an unlimited number of hours per year. -
Page 13: Engine Hoist
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Hoist While lifting, the centerline of the crankshaft of the engine must be kept level; no tilt or single- point lifting. -
Page 14: Engine Operation
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Operation WARNING The use of starting fluids could create an extremely hazardous condition and is not authorized with this engine. The use of starting fluid could cause severe injury and/or damage to equipment. -
Page 15: Service Intervals
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Service Intervals NOTE Non-critical emission-related maintenance is not necessary to keep the emission-related warranty valid. CAUTION Failure to follow these scheduled maintenance intervals could cause engine damage or decreased engine life. -
Page 16: Maintenance Intervals - Emergency
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Maintenance Intervals – Emergency Preventative Maintenance Schedule – Emergency Interval Every Event Maintenance Event Weekly The first 250 hrs or... -
Page 17: Maintenance Intervals- Non-Emergency
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Maintenance Intervals– Non-emergency Preventative Maintenance Schedule – Non-Emergency Interval Interval (Hours) Event Maintenance Event Weekly Number The first 1500... -
Page 18: Wp04 Gas Engine Maintenance Procedures
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. WP04 Gas Engine Maintenance Procedures 1. Check Engine Oil A. Ensure engine is level. B. Pull dipstick after the engine stop running at least 5 minutes. -
Page 19: Check Oil Pressure
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Check Oil Pressure A. When engine is running and at normal operating temperature, check oil pressure gauge. i. Some engines will have an analog gauge and others will have an electronic gauge from the ECU. - Page 20 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Drain plug B. Inspect drain plug washer (replace if necessary) and clean plug seating surface. C. Inspect magnetic plug for iron and ferrous material. If this exists, consider an oil analysis to determine source of debris.
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Page 21: Engine Valve Lash Inspection/Adjustment
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6. Engine Valve Lash Inspection/Adjustment NOTE: Required every 500 hours (1000, 1500, etc.) on non-emergency. NOTE Confirm that #1 piston is on the compression stroke by turning both pushrods by hand to verify that both valves are closed. - Page 22 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Illustration 7 Illustration 8 E. Rotate the crankshaft (360°) until the number 4 piston is on the compression stroke and the timing pointer on the front cover is in line with the “TDC”...
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Page 23: Check Air Filter
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. With #4 piston at “TDC” adjust these valves to: WP04GNA Exhaust 0.3mm/0.012” / Intake 0.2mm/0.008”; #4@TDC Illustration 10 7.Inspect Spark Plugs Inspect high tension leads from coils for shorts, cracking and damage. -
Page 24: Replace Engine Breather Filter
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9. Replace Engine Breather Filter Unscrew breather housing top counter-clockwise. Pull top of filter element up and remove filter. -
Page 25: Maintenance For Long-Term Storage
Weichai America Corp. Maintenance for Long-Term Storage Weichai America Corp. runs all completed engines prior to shipping to customers. Your engine was hot tested and calibrated using fully formulated coolant in the cooling system and Mobil Pegasus 805 40W Natural Gas Engine Oil prior to being drained and shipped to you. Your engine can be stored Six (6) to twelve (12) months depending on humidity control in storage without any further service. -
Page 26: Engine Fastener Torque Specifications
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Fastener Torque Specifications Tightening torque (N ) + further Permissible times ·m Fastener’s Name Bolt Specification turned angle (°) of repeat used 70N·m + (90±4°), required sequence of... - Page 27 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Illustration 13 Torque Head Bolts NOTE: Cylinder head bolts are allowed to be reused and torqued only three (3) times.
- Page 28 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 0.125 (Galvanized) 0.14 (Bright) Strength 10.9 12.9 10.9 12.9 Class Bolt Specs Recommended Torque (N · m ) 13.0 16.0...
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Page 29: Engine Service Schedule Log
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Service Schedule Log Service Service Start Complete Hour Comments Initial Interval (hr.) Date Time Time Meter 1000 1500... -
Page 30: Engine Identification
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Identification Engine Part Number: Engine Serial Number: Engine Application: Purchased From: In-Service Date: Engine Hours at Delivery: Revision: August 2019... -
Page 31: Pm Inspection Performed By
GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. PM INSPECTION Performed by: ______________________________________________________ UNIT #______________ DATE: __________________HOURS: ________________ WORK ORDER#_________________ PM TYPE: ____ hr. _________ mo/yr Codes:... - Page 32 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 7. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 8. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 9. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 10. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 11.
- Page 33 GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Weichai America Corp. 3100 Golf Road Rolling Meadows, IL 60008 http://www.WeichaiAmerica.com/ Revision: August 2019...
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