WEICHAI WP13GTA User guide

WP13GTA INSTALLATION AND
APPLICATION MANUAL
EMISSION-RELATED INSTALLATION INSTRUCTIONS
FOR WP13GTA ENGINE
NG, LPG & VPG
3100 GOLF ROAD, ROLLING MEADOWS, IL
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Contents
INSTALLATION OF CERTIFIED ENGINES.................................................................................... 1
NOTICE OF IMPORTANT REQUIREMENTS OF CERTIFIED ENGINES.......................................... 2
SYSTEM OVERVIEW.................................................................................................................. 3
ENGINE MOUNTING SUSPENSION........................................................................................... 9
ELECTRICAL SYSTEM............................................................................................................... 10
INTAKE AIR SYSTEM ............................................................................................................... 12
CLOSED CRANKCASE VENTILATION........................................................................................ 13
NATURAL GAS FUEL SYSTEM.................................................................................................. 14
LPG & NG BI-FUEL SYSTEM .................................................................................................... 14
VPG SINGLE FUEL SYSTEM ..................................................................................................... 15
COOLING SYSTEM .................................................................................................................. 15
PRE-CATALYST OXYGEN SENSOR ........................................................................................... 16
POST-CATALYST OXYGEN SENSOR ......................................................................................... 17
CATALYTIC CONVERTER ......................................................................................................... 19
FLYWHEEL .............................................................................................................................. 21
ADJUSTABLE PARAMETERS.................................................................................................... 21
FUEL SYSTEM DIAGNOSTIC .................................................................................................... 22
ACRONYM DEFINITION .......................................................................................................... 23
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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 give the installer of the engine all the information that is necessary to
properly install the engine and related components into the equipment chassis. The United States
Environmental Protection Agency (EPA) requires that the manufacturer of the engine provide
installation instructions to the equipment manufacturers as defined in the Code of Federal Regulations
(40CFR 1048.130).
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment
violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean
Air Act.
This engine is certified to be used in mobile and stationary constant speed only equipment
applications. Do not install 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 Manufacturer (OEM), it will meet or exceed the Emission Standards
for Large Spark Ignited (LSI) engines established by the US Environmental Protection Agency (EPA). This
engine has been certified to exhaust emission standards in 40 CFR Part 1048 and 40 CFR Part 60 JJJJ
including appropriate deterioration factors, over the regulated useful lifetime of seven years or 5000
hours, whichever occurs first.
Emission compliance throughout the useful lifetime requires proper engine maintenance. Please refer to
the maintenance schedule in the service manual for details.
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NOTICE OF IMPORTANT REQUIREMENTS OF CERTIFIED ENGINES
Important Notice- The required Emission 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. Contact Weichai to request a
duplicate label (Dial 1-855-922-9001).
Important Notice- This engine uses a crankcase recirculation system that routes all crankcase gasses
back to the engine intake air system. The EPA requires every certified industrial engine to have a closed
crankcase and no crankcase emissions may be vented to the atmosphere as described 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 in order to prevent dilution of the exhaust sample
with ambient air during the exhaust emissions test.
Important Notice- EPA requires that WEICHAI warranty all emission-related components as defined in
40 CFR Part 1048.120. Please refer to the Emission Related Warranty Statement included with the sale
of all new engines for further details. Warranty for non-critical emission components will be as defined
in the individual purchase agreement.
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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. The 4G engine control system for highly regulated
emission countries enables operation at the stoichiometric air / fuel ratio with Rich Burn and a 3 Way
Catalyst. Stoichiometric engine operation ensures that there is the precise amount of air delivered to
completely burn all the fuel. The stoichiometric Air Fuel Ratio (AFR) for natural gas is 17.2:1 and for
propane 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: WP13GTA Schematic
Bi-FUEL
The 4G Engine Controls System has full engine software control authority, therefore switching from
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 WP13GTA 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
6
0
E480
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proper valve and sensor arrangement the fuel supply transition can be made while in operation, under
full load, and automatically.
NG/VPG is WP13GTA standard configuration. With added on option, WP13GTA can also support LPG,
manual or automatic switching.
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. Equipment and technical support is available from Weichai.
Diagnostic Messages
The 4G engine control system contains a highly configurable diagnostic list that can be tailored to each
application’s specific needs using the calibration spreadsheet. With each available P-code listed along
with the short-name description. Note that not all DTCs necessarily apply to every 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 lean burn or stoichiometric combustion control, continuous
fuel injection control or standard digital injectors, ignition control electronic boost control for
turbochargers –VGT or wastegate, drive-by-wire throttle control, oxygen sensor based closed-loop
air/fuel ratio control (wide band (UEGOs) or switching (HEGOs)), adaptive spark and fuel control, EGR
control, transmission / engine coordination, speed control/governing (idle, max speed, all-speed, cruise
control) and vehicle network interface systems (CAN, J1708, J1850, Ford SCP).
DEPR: Direct Acting Electronic Pressure Regulator
Our fuel control device is referred to as a Direct Acting Electronic Pressure Regulator or D-EPR shown in
Figure 2. Its benefits to our customers and the end customer are:
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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.
- It does not wear in the case or dry fuels (NG) and it does not stick or clog due to heavy hydrocarbons
or waxes found in LPG.
- It is fast and accurate, providing precise air/flow ratio control during transients (or load acceptance).
The DEPR is a single-stage microprocessor based electromechanical fuel 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 engine either
rich or lean. When the DEPR receives an output pressure command from the ECM, the valve is internally
driven to attain targeted fuel pressure, the DEPR then closes the loop internally using a built in fuel
pressure sensor to maintain target fuel pressure/fuel flow rate, until another external command from
the ECM is received.
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Figure 3: E480 Mixer
MIXER: E480
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. The mixer also acts to increase or
decrease the fuel entering the engine 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 resolution and repeatability, eliminates idle adjustment
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HEAVY-DUTY DUAL STAGE REGULATOR (DSR)
The heavy-duty dual stage regulator vaporizes liquid propane to gaseous form and also regulates the
fuel pressure to meet the fuel pressure requirement.
Figure 4: Heavy Duty Dual Stage Regulator
The HD DSR is a two stage fully mechanical regulator that is available in LPG configurations. The DSR is
normally open with a positive outlet pressure and must be used with fuel lock-off upstream to prevent
fuel flow when the engine is not cranking or running. The HD DSR is connected to the DEPR, by a low
pressure flexible hose. It also has a reference 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
TURBOCHARGER
The turbocharger provides the air-fuel mixture at the optimal pressure level to the engine in order to
generate the right power. Along with turbocharger, a by-pass valve controls the boost level required for
the rated speed and engine load. The turbocharger not only provides the boost pressure for higher
power output but also acts as a secondary mixer for air-fuel mixture.
Figure 5: Turbocharger
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BOOST RECIRCULATION VALVE (BRV)
The Boost Recirculation Valve is a piston-actuated high flow pressure recirculation valve system. It is
designed to reduce or eliminate intake system pressure spikes between the throttle plate and the
turbocharger, which in turn minimizes wear and fatigue on turbocharger components. This is a
normally-closed valve which is actuated by differences in throttle inlet pressure (TIP), compressor inlet
pressure (CIP) and manifold absolute pressure (MAP). The MAP connection is the reference pressure
used to actuate the BRV.
Key features of the BRV are:
- Reduces/eliminates turbocharger compressor stall/surge
- Increase turbocharger life
- Flow is bi-directional through the MAP reference
Figure 6: Boost Recirculation Valve (BRV)
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ENGINE MOUNTING SUSPENSION
Maximum inclination angles
Maximum inclination angles at which the engine will operate satisfactorily:
- Transverse inclination, intake 10deg
- Transverse inclination, exhaust 10deg
- Longitudinal inclination, front 5deg
- Longitudinal inclination, back 5deg
Engine General Dimension
Figure 7: Engine General Dimensions and layout
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ELECTRICAL SYSTEM
WIRE HARNESS DIAGRAM
Figure 8: Wire Harness Diagram
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CONTROL PANEL:
Optional: PV380 AND REALATED HARNESS, Murphy MPC10, MPC20, and additional panel options are
available. Contact Weichai for details.
Figure 9: PV380 and Related Harness
BATTERY SETUP
The battery needs to be setup according to the steps below:
- 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.
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CANBUS J1939 INTERFACE CONNECTING WITH ZTR TELEMATICS
Figure 10: CANBUS J1939 Interface Connection with ZTR Telematics
INTAKE AIR SYSTEM
The intake system should be sealed between the mixer inlet and the filter. Proper clamps should 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.
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Figure 11: Intake Air System
CLOSED CRANKCASE VENTILATION
Weichai engine uses a closed crankcase system as shown in Figure 12. 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 12: Closed Crankcase Ventilation System
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NATURAL GAS FUEL SYSTEM
The fuel first passes the fuel shut off 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 13.
Figure 13: Natural Gas Fuel System
LPG & NG BI-FUEL SYSTEM
When the engine operates with LPG, the NG shutoff valve will be closed. The LPG first enters the LPG
shutoff valve and then goes to LPG evaporator to turn the LPG to vapor and later enters the DEPR and
further mixes with the air in the mixer as shown in Figure 14.
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Figure 14: LPG & NG Bi-fuel system
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 15 shows the configuration of the cooling system. Please refer to Figure 7 for the 2D dimensions
of the cooling system installed with the engine and skid.
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Figure 15: Cooling System
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.
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Figure 16: UEGO Sensor Installation
POST-CATALYST OXYGEN SENSOR
The sensor installation point must be sufficiently tested by the customer for functionality and durability.
There shall be no possibility of exhaust leaks upstream of the sensor as exhaust pulsations can draw in
ambient air leading to erroneous measurements.
Installation in the exhaust line must be at a point guaranteeing representative exhaust gas composition
while also satisfying the specified temperature limits. The active sensor ceramic element heats up
quickly. This means that the sensor installation location must be selected to minimize exhaust-side
stressing with condensation water in order to prevent ceramic element 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, 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. In this case make sure, that the front hole of the double
protection tube does not point against exhaust gas stream.
-
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System measures:
- Never switch on sensor heating before engine starting.
- Delayed switch-on or power control of the sensor heater (e.g. as a function of engine and ambient
temperature), so that the max. allowed ceramic temperature is not exceeded when there is
condensation water present.
Installation angle should be inclined at least 10°towards horizontal (electrical connection upwards), thus
preventing the collection of liquids between sensor housing and sensor element during the cold start
phase. Other installation angles must be inspected and tested individually.
Avoid inadmissible heating up of the sensor cable grommet, particularly when the engine has been
switched off after running under max. load conditions. The use of cleaning/greasing fluids or
evaporating solids at the sensor plug connection is not permitted. Assemble with high temperature
resistant grease on the screw-in thread. Tightening 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 17: TWC and Post HEGO Sensor Installation
There is to be no possibility of the sensor protection tube contacting the opposite side of the exhaust
pipe. A waterproof electrical connector’s version is required.
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. The breathability should be higher than 1 ml/minute at a test
pressure of 100mbar.
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