WEICHAI WP06 G NA Operation And Maintenance Manual Download

Page: 1 / 33

Weichai America Corp.

Revision: August 2019 1

Operation and Maintenance Manual

Gas Engine

Model: WP04

WEICHAI AMERICA CORP.

WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM

GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM

Summary of Contents for WP06 G NA

Page 1: ...evision August 2019 1 Operation and Maintenance Manual Gas Engine Model WP04 WEICHAI AMERICA CORP WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 2: ...ed engine service provider that you choose However your engine warranty does not cover damage or failure caused by improper maintenance or repairs Owner s Manual Maintenance Log Storage Use Store this Owner s Manual and Maintenance Log in a safe visible place by your engine The maintenance log must be updated whenever your engine is serviced Note This manual may be updated from time to time by Wei...

Page 3: ...ration 12 Engine Hoist 13 Extreme Operating Conditions 13 1 Engine Speed 13 2 Over Temperature 13 Engine Operation 14 1 Pre Start Engine Check 14 2 Engine Starting 14 3 Performance 14 4 Engine Shut Down 14 Service Intervals 15 Maintenance Intervals Emergency 16 Maintenance Intervals Non emergency 17 WP04 Gas Engine Maintenance Procedures 18 1 Check Engine Oil 18 2 Check Coolant Level 18 3 Check Oi...

Page 4: ...nt Conditioner 24 13 Inspect Water Pump 24 14 Test and or Replace Batteries 24 Maintenance for Long Term Storage 25 Engine Fastener Torque Specifications 26 Engine Service Schedule Log 29 Engine Identification 30 PM INSPECTION Performed by 31 WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 5: ...oling water etc Deflating Draining off lubricating oil or cooling water Unloosing such as unloose clamping equipment Loose proof fixed Coat fluid sealant Clamping such as reinforcing clamp equipment Accident preventing marks for dangerous occasion Inspecting adjusting such as tightening torque dimension pressure and clearance Replacement during re assembly Inspecting WEICHAI PSI SERVICE MANUALS AV...

Page 6: ...on of Engine Model WP04 G TA NA NA Natural aspirated TA Turbocharged G Gas engine WPxx Engine series 2 Engine Main Performance Parameters Illustration 1 Engine nameplate nameplate WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 7: ...wheel Oil pressure Idle speed KPA 120 Rated speed KPA 300 550 Oil temperature range under rated condition 85 105 Oil capacity L 9 12 Engine coolant capacity L Engine 5 3L engine and radiator 16 3L Intake valve lash cold mm 0 2 Exhaust valve lash cold mm 0 3 Spark plug gap mm 0 3 0 35 Allow to tilt Front back 5 5 Right left 5 5 Weight kg 560 Size with radiator and air filter L W H mm 1433 774 1097 ...

Page 8: ...chai America dealer or service establishment Emission Related Installation Instructions WARNING Failure to follow these instructions or installing a certified engine in a Non Road equipment violates Federal Law 40 CFR 1068 105 b subject to fines or other penalties as described in the Clean Air Act NOTE To perform emission sampling add a 20 centimeter extension to the exhaust pipe WARNING This engi...

Page 9: ...rnia to cause cancer birth defects and other reproductive harm CAUTION 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 a...

Page 10: ...foot LHV Maximum allowable H2S is 55ppm 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 Relation between oil viscosity and ambient temperature L...

Page 11: ...linder walls It is recommended that during the first 4 hours of service 1 Operate at one half to three quarters load Do not operate at maximum rated load for more than five 5 minutes at a time 2 Do not run the engine unloaded for long periods as this will cause cylinder walls to Glaze before the piston rings seat properly and result in excessive lubricating oil consumption Engine Loading The gas e...

Page 12: ...ut total time at overload shall be less than 25 hours per year 3 Emergency Standby Power ESP is defined as the maximum power available during a variable electrical power sequence under the stated operating conditions for which a generating set is capable of delivering in the event of a utility power outage or under test conditions for up to 200 hours of operation per year The permissible average p...

Page 13: ...00 to 2200 RPM and should not exceed 2400 RPM for any length of time If engine is operated at excessive RPM fuel and ignition systems will shut down until engine RPM decreases to the recommended operating RPMs 2 Over Temperature CAUTION To prevent engine damage shut down engine immediately if the coolant reaches operating temperature above 230 F 110 C Normal operating temperature for this engine i...

Page 14: ...h start attempt to allow the starter motor to cool If oil pressure reading does not indicate normal oil pressure 120kPa within fifteen seconds of engine start immediately shut down the engine to avoid damage to the engine Service the engine prior to attempting to start engine again 3 Performance For monthly engine system check idle the engine for at least one 1 minute before applying operating loa...

Page 15: ...ng time on non emergency NOTE The oil change interval is based on normal operating conditions Continuous operation during excessive hot or cold climate constant operation with high loads frequent starts and stops poor quality lubricants and fuel contaminants would require more frequent oil change intervals to prevent shortening engine life NOTE Always dispose of all chemicals and filters in accord...

Page 16: ...nd Hoses Inspect Replace X X 11 Check Ignition System Plug Wires Coils X 12 Check Coolant Condition Sample X 13 Inspect Water Pump X 14 Test Batteries Alternator X 15 Replace Coolant X Table 1 Service may be required more frequently in dirty or extreme conditions recommend sampling fluids Actual oil life and change interval is determined through engine oil sampling and analysis It is recommended t...

Page 17: ... System Plug Wires Coils X 12 Check Coolant Condition Sample X 13 Inspect Water Pump X 14 Test Batteries Alternator X 15 Replace Coolant Every 2 Years Table 2 Service may be required more frequently in dirty or extreme conditions recommend sampling fluids Actual oil life and change interval is determined through engine oil sampling and analysis It is recommended to replace Belt every 3 months Valv...

Page 18: ...Never remove radiator or top tank cap when coolant is hot Burns and physical harm may occur Illustration 4 A When coolant is room temperature or below remove pressurized cap and inspect top tank or radiator for fluid level B If engine has a sight gauge or plastic top tank a visual level check is adequate C If coolant level is low determine reason for low fluid and top off with specified coolant D ...

Page 19: ...s and system for routing and connections E Inspect the engine harness for corrosion abrasions cuts or shorts F Look around engine for any debris or loose materials that might become a hazard G Assure battery voltage is 12v each and terminal connections are clean and tight 5 Change Oil and Oil Filter Materials Materials QYT Oil 9 12L see dipstick Oil filter 1 Table 4 NOTE Recommended oil is Natural...

Page 20: ... F Install oil filter Tighten filter until the rubber gasket contacts base Tighten additional 3 4 to 1 turn to seal G Using the recommended grade of oil fill crankcase with specified quantity H Fill the grease cup of the signal generator with lithium grease NLGI Gr 2 I Operate engine for five 5 minutes Check for leaks at filter base and oil pan drain plug during operation J Shut down engine and wa...

Page 21: ...roke and the timing pointer on the front cover is in line with the TDC mark on the crankshaft damper Some engines may have a permanent groove mark on the flywheel for TDC Illustration 5 Illustration 6 C Using Illustration 9 adjust the four 4 valves corresponding with cylinder 1 TDC Insert the correct feeler gauge between the rocker arm and valve stem tip Loosen the locknut and turn the valve adjus...

Page 22: ...r gauge G Tighten the locknut once the valve is adjusted properly Remove the feeler gauge A very slight resistance should be felt when removing the feeler gauge NOTE Ensure valve cover is completely seated and not resting on bolts or washers adjacent to the valve cover H Install gasket onto the valve cover and align the cover and gasket onto the cylinder head Tighten the valve cover mounting bolts...

Page 23: ...tions Over tightened can cause damage and removal of spark plug difficult Under tightened could cause the spark plug to overheat resulting in pre ignition and possible engine damage A Install new spark plug Torque to 18 20 ft lbs 25 28N m B Apply spark plug boot dielectric grease to inside of boot C Reconnect the spark plug wire or COP to the spark plug in the proper order 8 Check Air Filter A Ins...

Page 24: ...of coolant and measure the levels of coolant additives with a test strip applies to conventional coolants only B Replace coolant or additive package if necessary or every two years Ensure 50 50 mixture C Remove thermostat replace with new as needed or every two years during coolant change flush D Run engine until thermostat opens and allow engine to cool to inspect coolant level E Reinstall radiat...

Page 25: ...ducts Operate engine at high idle no load until it reaches operating temperature in order to coat all surfaces with preservative oil solution If engine is not runnable crank for a maximum of 30 seconds with two minute rests between cranking until all surfaces are coated If unable to crank engine bar engine over several times and use a spray to put preserving oil solution into the cylinders through...

Page 26: ...N m Rocker seat M10 8 8 40 45 N m Spark plug M14x1 25 25 28 N m UEGO sensor M18x1 5 40 5 N m Water temperature sensor M14x1 5 25 5 N m Values of superscript and subscript are permissible tolerance ranges The angle value is the further turned angle after reaching the specific torque The number before the angle is the number of time to turn the angle There are corresponding requirements on the stren...

Page 27: ...der head covers Illustration 14 Tighten order of cylinder head bolt Tightening Process is as follows a After lubricating bolt and thread part tighten the bolts to 30N m follow the order in Illustration 14 b Turn the bolt to 120 4 follow the order in Illustration 14 c Turn the bolt to 120 4 again and meanwhile the torque reaches to 230 to 300N m follow the order in Illustration 14 WEICHAI PSI SERVI...

Page 28: ... M24 560 660 930 1100 600 710 1000 1200 M27 830 980 1400 1650 890 1050 1500 1800 M30 1100 1350 1850 2250 1200 1450 2000 2400 M8x1 21 25 35 42 23 27 38 45 M10x1 25 41 49 66 82 44 52 73 88 M12x1 25 74 88 125 150 80 95 135 155 M12x1 5 70 83 115 140 76 90 125 150 M14x1 5 115 140 195 235 125 150 210 250 M16x1 5 175 210 295 350 190 225 315 380 M18x1 5 255 305 425 510 275 325 460 550 M20x1 5 360 425 600 ...

Page 29: ...al hr Service Date Start Time Complete Time Hour Meter Comments Initial 50 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

Page 30: ...dentification Engine Part Number Engine Serial Number Engine Application Purchased From In Service Date Engine Hours at Delivery WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

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Page 32: ..._______________________ ________________________________________________________________________ ________________________________________________________________________ 11 ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 12 _____...

Page 33: ... August 2019 33 Weichai America Corp 3100 Golf Road Rolling Meadows IL 60008 http www WeichaiAmerica com WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM ...

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