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WP10NA INSTALLATION AND

APPLICATION MANUAL

EMISSION-RELATED INSTALLATION INSTRUCTIONS

FOR WP10GNA ENGINE

NG, LPG & VPG

3100 GOLF ROAD, ROLLING MEADOWS, IL

WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM

GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM

Summary of Contents for WP10NA

Page 1: ...ANUAL EMISSION RELATED INSTALLATION INSTRUCTIONS FOR WP10GNA ENGINE NG LPG VPG 3100 GOLF ROAD ROLLING MEADOWS IL WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 2: ... NATURAL GAS FUEL SYSTEM 13 LPG NG BI FUEL SYSTEM 14 VPG SINGLE FUEL SYSTEM 14 COOLING SYSTEM 14 PRE CATALYST OXYGEN SENSOR 15 POST CATALYST OXYGEN SENSOR 16 CATALYTIC CONVERTER 18 FLYWHEEL 20 ADJUSTABLE PARAMETERS 21 FUEL SYSTEM DIAGNOSTIC 21 OIL LEVEL GAUGE INSTALLATION 22 ACRONYM DEFINITION 23 WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE P...

Page 3: ...stall this engine for use in any variable speed applications This industrial engine comes fully equipped and certified with a complete emission control system which includes the fuel system sensors and actuators a fully integrated engine management system and an exhaust aftertreatment system including a three way catalyst When this industrial engine is correctly installed by an Original Equipment ...

Page 4: ...scribed in the Code of Federal Regulations 40 CFR 1048 115 Please refer to the Intake Air System section included in these instructions for details Important Notice To meet EPA exhaust emission field testing requirements it is important that the OEM design the exhaust system so that a 20 centimeter extension can be temporarily installed on the equipment s exhaust outlet The extension is required i...

Page 5: ...opane is 15 5 1 With rich burn there is slightly less air delivered relative to fuel resulting in slightly less fuel efficiency more power and a cooler combustion process Figure 1 shows the required 4G engine control system configurations for Propane VPG Natural Gas NG and Bi Fuel VPG and NG with the TWC Figure 1 WP10GNA Schematic Bi FUEL The 4G Engine Controls System has full engine software cont...

Page 6: ...application ECM Engine Control Module 4G 120 pin The ECM is full authority by this we mean it includes the ignition and air fuel ratio control contains all the I O to interface the engine with the application and has a complete set of diagnostics By implementing all functions in one box the overall system complexity is reduced as is the total system cost Some of features included in the ECMs are l...

Page 7: ...pressure regulator that incorporates a high speed actuator It communicates with the Engine Control Module ECM over a Controller Area Network CAN link receiving fuel pressure commands and broadcasting DEPR operating parameters back to the ECM The DEPR can regulate fuel pressure between 17 inches of water column above the Mixer air inlet pressure providing sufficient control authority to stall an en...

Page 8: ... proportional to the amount of air flowing in the engine on a volumetric basis E480 MIXER provide the following benefits to the market Superior fuel air phi ratio accuracy Reduced part to part fuel air ratio repeatability Extended diaphragm life through material selection and design Performance over the 40C to 125C temperature range Eliminate LPG fuel contamination issues Superior low flow resolut...

Page 9: ...ce port that is connected to the fuel air mixer for turbo charged applications Key features of the HD Dual Stage Regulator are Full mechanical pressure regulation Can be engine or chassis mounted vibration requirements are defined on the installation drawing Flows 250 kW at the rate inlet pressure 1725 kPa inlet regulated down to a 3 5 kPa outlet pressure ENGINE MOUNTING SUSPENSION Maximum inclina...

Page 10: ...8 Figure 5 Engine General Dimensions and layout WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 11: ...9 ELECTRICAL SYSTEM WIRE HARNESS DIAGRAM Figure 6 Wire Harness Diagram WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 12: ...low Engine Electrical System is 24 volt DC Negative Ground Engine Battery should be 650CCA or Greater Never disconnect battery when running The battery should be attached to the engine at all times Connect positive red wire to positive terminal on the battery Connect negative black wire to negative terminal on the battery WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEI...

Page 13: ...d be used to ensure unfiltered air is not drawn into the system Use piping with minimum diameter equal to mixer inlet When in an enclosure it can sometimes be necessary to use an externally mounted filter It can be beneficial to engine life and performance to draw in air from the coolest location possible WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET ...

Page 14: ...ankcase 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 WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 15: ...when the engine starts cranking Then it goes through the DEPRs and comes into the mixers to be mixed with the air from the air filter as shown in Figure 11 Figure 11 Natural Gas Fuel System WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 16: ...EL 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 Please refer to Figure 5 for the 2D dimensions of the cooling system installed with the engine ...

Page 17: ...or 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 GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 18: ...ent cracking This is helped by locating the sensor on the outlet of the catalyst assembly Design measures Locate sensor as close to the catalytic converter outlet as possible without exceeding maximum allowed temperature range 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 projection...

Page 19: ...ng torque 29 5ft lb 44ft lb 40Nm 60Nm Material characteristics and strength of the thread must be appropriate Recommended material for the thread boss in the exhaust pipe is temperature resistant stainless ferritic steel e g X 5 CrNi 18 9 DIN 17440 1 4301 or 1 4303 or SAE 30304 or SAE 30305 US standard The sensor s protection tube must protrude completely into the exhaust gas flow Figure 15 TWC an...

Page 20: ...egF 150 C 300 C The corresponding control parameter must be determined according to application The sensor should be mounted as close to the outlet of the catalytic converter as possible without exceeding sensor maximum temperatures The sensor should be mounted as far from the exhaust pipe outlet as possible to avoid dilution from ambient air Minimum distance between sensor and exhaust outlet shou...

Page 21: ... must be reviewed by the manufacturer Product cannot be used in corrosive environments i e salt water Mounting the catalytic converter in the proper location will control the substrate temperature To quickly heat up the catalyst and to ensure an effective operating temperature the center of the substrate must be located a minimum of 30 inches 762mm downstream of the exhaust manifold flange This me...

Page 22: ...g and flywheel SAE 3 adapter The flywheel adapter will be used depending on the customer requirement and as shown in Figure 18 Contact Weichai representative for assistance of the connector adaptor installation Figure 18 Flywheel and Flywheel Housing WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 23: ...T FUEL SYSTEM SETTINGS Fuel Pressure Fuel Pressure need to be checked for the first start as in the Table 1 Table 1 EPR inlet pressure specification Maximum EPR Rated Pressure kPa 6 9 Maximum Running pressure to Electronic Pressure Regulator EPR kPa 2 7 FUEL SYSTEM DIAGNOSTIC FUEL SYSTEM DESCRIPTION The Engine Control Module ECM receives information from various engine sensors in order to control ...

Page 24: ...connector can be purchased Figure 20 Oil Feed to Oil Level Gauge To install the gauge remove the M20x1 5 plug from the oil pan shown in Figure 20 and install a M20x1 5 to barbed hose fitting Use hose rated for oil to connect the gauge to the fitting If the gauge must be balanced according to the owner s manual an Oil Balance Line Kit can be purchased from our service department The kit includes on...

Page 25: ...ill drain into the engine and not on the ground Torque bolts to 9 Nm See Figure 12 for reference When running the balance line from the oil level gauge to the Oil Balance Line Block ensure there are no peaks or valleys The line must gradually increase from the gauge to the block Set the center of the gauge 4 from the bottom of the engine feet for the correct level during operation WEICHAI PSI SERV...

Page 26: ...gnostic Service Tool ECM Engine Control Module LPG Liquid Propane Gas NG Natural Gas TWC Three Way Catalyst VPG Vapor Propane Gas Oil Filler Neck Assembly Gasket 4x M6x1 0x35 Gasket Oil Balance Line Block 1 8 NPT to 3 8 Barbed WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

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