WEICHAI WP4GNA User manual

Weichai America Corp.
Revision: August 2019 1
Operation and Maintenance Manual
Gas Engine
Model: WP04
WEICHAI AMERICA CORP.
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Revision: August 2019 2
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.
Maintenance Providers
Maintenance and repair services may be performed by you or any qualified 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 Weichai America Corp.
Operation and maintenance manual revision: August 2019
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Table of Contents
Description of the Illustration Marks ........................................................................................... 5
Engine Introduction and Performance Parameters..................................................................... 6
1. Introduction of Engine Model ........................................................................................... 6
2. Engine Main Performance Parameters ............................................................................ 6
3. WP04 Gas Engine Data................................................................................................... 7
U.S. EPA Legal Requirements................................................................................................... 8
Emission Related Installation Instructions.................................................................................. 8
Personal Safety.......................................................................................................................... 9
Fuel Information........................................................................................................................10
Oil and Coolant Information.......................................................................................................10
New Engine Break-in Procedures .............................................................................................11
Engine Loading.........................................................................................................................11
Rating Definition for Power Generation.....................................................................................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 Oil Pressure.........................................................................................................19
4. Check Overall Operating Condition.................................................................................19
5. Change Oil and Oil Filter.................................................................................................19
6. Engine Valve Lash Inspection/Adjustment........................................................................21
8. Check Air Filter.................................................................................................................23
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9. Replace Engine Breather Filter.........................................................................................24
10. Inspect Belts, Pipes, Clamps and Hoses ........................................................................24
11. Inspect Ignition System...................................................................................................24
12. Check Coolant 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
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Description of the Illustration Marks
Dismounting (assembly parts) Oil Coating
Fitting (assembly parts) Special Tools
Marking (do before disassembling,
adjust when assemble)
Pay attention to assembly
direction
Filling –full charge (such as
lubricating oil, cooling 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
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Engine Introduction and Performance Parameters
1. Introduction 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
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See engine nameplate to find engine model, series number, rated power, rated speed and
weight.
More data as following table:
3. WP04 Gas Engine Data
Item Unit Content
Engine type WP04 naturally aspirated
Number of cylinders 4
Displacement L 4.5
Cylinder bore * stroke mm 105 * 130
Compression ratio 9.75:1
Idle speed rpm 900
Fire order 1-3-4-2
Rotation CCW viewed on flywheel
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
Note: Oil Viscosity should be determined based on Ambient Temperature Operations.
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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. It is illegal to operate this engine in a variable-speed
(foot pedal speed control) application.
A maintenance plan and log provided within this manual are for you to record your engine
maintenance. Update the log each time you service your engine.
NOTE
The repair shop or person of the owner’s choosing may maintain, replace, or repair emissions
control devices and systems. The emissions warranty is not conditioned on the engine being
serviced by a Weichai 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 engine is only for constant-speed operation. Do not install the engine in variable-speed
applications.
NOTE
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.
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Personal Safety
WARNING
Improper operation of this machine could result in death or serious injury. Before operating
any equipment, ensure every operator:
•Is instructed on safe operation and use of all equipment
•Fully understands all manuals and safety measures for all equipment before use
•Practices safety precautions for all equipment during operation
•Reads and fully understands all decals on equipment
•Clear the immediate area of all non-
essential personnel before operating
WARNING
CALIFORNIA PROPOSITION 65
Engine exhaust from this production contains chemicals known to the State of California 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 additions to previously sold equipment.
NOTE
All data given in this manual is subject to production variations. Operating and service
messages displayed on the electronic operating panel may vary from what is shown in the
Operator’s Manual. Please adhere to the instructions displayed on the Electronic Operation
Panel.
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Fuel Information
Natural Gas
Your engine is certified to run on "pipeline-quality natural gas". Pipeline quality natural gas is
supplied by a natural gas utility through a pipeline. It must be composed of at least 70% methane
by volume or have a heating value of 950-1100 BTU per standard cubic foot (HHV). Maximum
allowable H2S is 55ppm.
Liquid Propane Gas (LPG)
HD5 grade propane which consists of minimum of 90% propane, maximum of 5% propylene,
and maximum 5% of other gases (is o-butane, butane, methane, etc.) Maximum allowable H2S
is 55ppm.
Wellhead Gas (Non-Emergency Only)
Your WP04 naturally aspirated engine is certified to run on "wellhead-quality natural gas". It must
have a heating value of 700-2362 BTU (a fuel switch should be used if above 1800BTU) per
standard cubic 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
Lubricant
SAE Viscosity
grade
Ambient temperature (°F) Ambient temperature (°C)
0W-20 -31 to 68 -35 to 20
5W-30 -22 to 86 -30 to 30
10W-30 -12 to 86 -25 to 30
15W-40 -4 to 104 -20 to 40
20W-50 5 to 113 -15 to 45
API No. CI-4 or above are also recommended.
Engine Coolants
Weichai America Corp. recommends using a 50/50 mixture of fully formulated Ethylene Glycol
or fully formulated Propylene Glycol coolant and distilled water. Follow recommended coolant
maintenance practices by coolant supplier.
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New Engine Break-in Procedures
The way any heavy-duty industrial natural gas engine is operated during the first 4 hours of
service, will have a major impact on how well that engine will perform, how much oil it will
consume and how long it will last. 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. The main purpose of break-in is to seat the compression rings to the cylinder 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 engines are designed to operate continuously at industry accepted high ratings and to
provide optimum service life. It is not recommended to operate a natural gas engine continuously
at low load levels. A general rule used for most low emission natural gas engines is to operate at
60% load or above.
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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. No overload capability is available for this rating.
2. Prime Power (PRP) is defined as being the maximum power which the generating set is
capable of delivering continuously whilst supplying a variable electrical load when operated for
an unlimited number of hours per year. The permissible average power output over 250 hours of
operation shall not exceed 70%, the total time at full load over a year of operation shall not
exceed 500h. It is allowed to overload 10% for 1 hour during 12 hours of operation but 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 power output over
24 hours of operation shall not exceed 80% of the ESP. The permissible time at full load shall
be less than 25 hours per year.
See operating conditions as following table:
Continuous Power
(COP) Prime Power (PRP) Standby Power (ESP)
Annual working time Unlimited Unlimited ≤200 hours
Mean engine load
factor 100% ≤70% per 250 hours ≤80% per 24 hours
Time at full load Unlimited ≤500 hours per year ≤25 hours per year
Overload capacity No 1 h per 12 hours
(10% overload)
≤25hours per year No
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Engine Hoist
While lifting, the centerline of the crankshaft of the engine must be kept level; no tilt or single-
point lifting. Lift and lower slowly (See Illustration 1)
Illustration 2- Engine Installation Diagram
Extreme Operating Conditions
1. Engine Speed
This engine is designed to operate at constant speed (1000 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 is 180°F to 200°F (82°C to 93°C)
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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.
1. Pre-Start Engine Check
•Verify engine oil level is correct
•Verify engine coolant level is correct
•Inspect engine for leaks or a frayed belt or any condition or appearance out of the
ordinary
•Verify all belts and moving parts are clear of obstructions
•Verify the “Check Engine” light is on with the key in the “ON” position and the engine not
running (if applicable)
2. Engine Starting
With the controls in the idle position, start engine. To prevent damage to the starter, do not
engage the starter motor for more than fifteen (15) seconds. Wait two (2) minutes between each
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 load. Verify the “Warning” light is not illuminated during engine operation. Inspect for
fuel, coolant, and oil leaks with engine operating. If leaks are found, shut down engine and repair
leaks before operating engine.
4. Engine Shut-Down
If engine has been running under load and reached operating temperature, run engine for five (5)
minutes at idle without a load to allow engine to cool before engine shut down. The engine may
run one to five seconds while the fuel is depleted from the engine’s fuel system.
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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.
NOTE
Valve lash adjustments will be accomplished every 500 hours (1000, 1500, etc.) engine
operating 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 shor
tening engine life.
NOTE
Always dispose of all chemicals and filters in accordance with Federal, State and Local laws
and regulations.
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Maintenance Intervals –Emergency
Preventative Maintenance Schedule –Emergency
Event
Number Maintenance Event Weekly Interval Every
Two
Years
The first
50 hours 6 months 250 hrs or 1 year
1 Check Engine Oil Level X X
2 Check Engine Coolant Level X X
3 Check Oil Pressure X X
4 Check Overall Operating Condition
(hose/clamp/pipe/belt/harness/connector) X X
5 Change Oil and Oil Filter * (Sample)#X
6 Valve Lash (Inspect/Adjust) X
7 Spark Plugs (Check/Adjust/Replace) X
8 Check Air Filter * (Inspect/Replace) X
9 Replace Breather Filter X
10 Belts**, Pipes, Clamps and 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 to replace Belt every 3 months.
WARNING
Before servicing engine, ensure the engine has stopped and all high voltage disconnect
switches
are in the open (disconnected) position.
CAUTION
Failure to follow these procedures could cause engine damage or decreased engine life.
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Maintenance Intervals–Non-emergency
Preventative Maintenance Schedule –Non-Emergency
Event
Number Maintenance Event Weekly Interval
(Hours) Interval
The first
50hours 500 1500 6 months
1 Check Engine Oil Level X X
2 Check Engine Coolant Level X X
3 Check Oil Pressure X X
4 Check Overall Operating Condition
(hose/clamp/pipe/belt/harness/connector) X X
5 Change Oil and Oil Filter * (Sample)#X
6 Valve Lash (Inspect/Adjust)## X
7 Spark Plugs (Check/Adjust/Replace) X
8 Check Air Filter (Inspect/Replace) X
9 Replace Breather Filter X
10 Belts**, Pipes, Clamps and 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 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.
## Valve lash inspection/ adjustment should be implemented at least once a month.
WARNING
Before servicing engine, ensure the engine has stopped and all high voltage disconnect
switches are in the open
(disconnected) position.
CAUTION
Failure to follow these procedures could cause engine damage or decreased engine life.
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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.
C. Ensure oil level is between high and low marks.
Illustration 3
D. If the oil level is below the low mark, add additional oil as necessary.
E. Install dipstick.
2. Check Coolant Level
Caution: 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. Test pressurized cap (replace if necessary or reinstall).
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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.
B. Ensure oil pressure is in the range of the table below both at idle and rated speed
and operating temperature.
Oil Pressure
Idle PSI KPa
Min 17 120
Rated Speed
Min 43 300
Max 80 550
Table 3
4. Check Overall Operating Condition
A. Inspect hoses, pipes and clamps for loose connections or leaks.
B. Check the belt for fraying or damage.
C. Look for fluid leaks under and around the engine.
D. Inspect ignition wires 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 Gas Engines Oil (NGEO); CI-4 or above.
NOTE: For continuous operation in extreme temperatures or in excessively dusty, dirty
environments, rely on oil analysis to determine maintenance intervals.
NOTE: For best results, change engine oil while engine is still warm from operation.
A. Remove the oil pan drain plug and drain oil completely.
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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.
D. Reinstall drain plug and tighten securely.
E. Remove the old filters by the filter wrench. Wipe filter base clean. Then apply a
thin coat of motor oil to o- ring on new oil filter(s).
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 wait five (5) minutes. Check engine oil level and adjust to
proper level if necessary.
Drain plug
Oil refill
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