This document provides installation instructions for certified WEICHAI WP10GTA engines. It describes the emission control system components, including the closed crankcase ventilation, fuel system, sensors, engine management system, and three-way catalytic converter. The instructions stress the importance of following the documentation to maintain EPA certification and avoid penalties.
Adpower Offer Generating sets in IVECO Motors Range @ DubaiAdpower FZCO
Adpower gives you a generator specification of IVECO generating sets. Engine IVECO/FPT model N45 TM2A with 1500RPM engine speed and 100kva, 80kw prime rating in 50HZ. If you want this generating sets in affordable price contact us today. Email me – sales@adpower.ae
Adpower here for supply FPT/IVECO generator in Dubai. About our product , IVECO IA-160 engine model - N67 TM3A model with include 50HZ 160kva, 128kw, 6th cylinder, engine speed 1500RMP and comfort with light weight. For more information please visit our website - www.adpower.ae
Diesel Generators and Diesel Generating Set Company UAE, DubaiAdpower FZCO
The diesel electrical generator will be the combination of the diesel motor having an power electrical generator (often an alternator) to generate electrical power. Diesel-powered bringing in sets are widely-used in spots with out connection to an electric grid, or perhaps because urgent situation power-supply when the grid does not work out.
Adpower Offer Generating sets in IVECO Motors Range @ DubaiAdpower FZCO
Adpower gives you a generator specification of IVECO generating sets. Engine IVECO/FPT model N45 TM2A with 1500RPM engine speed and 100kva, 80kw prime rating in 50HZ. If you want this generating sets in affordable price contact us today. Email me – sales@adpower.ae
Adpower here for supply FPT/IVECO generator in Dubai. About our product , IVECO IA-160 engine model - N67 TM3A model with include 50HZ 160kva, 128kw, 6th cylinder, engine speed 1500RMP and comfort with light weight. For more information please visit our website - www.adpower.ae
Diesel Generators and Diesel Generating Set Company UAE, DubaiAdpower FZCO
The diesel electrical generator will be the combination of the diesel motor having an power electrical generator (often an alternator) to generate electrical power. Diesel-powered bringing in sets are widely-used in spots with out connection to an electric grid, or perhaps because urgent situation power-supply when the grid does not work out.
China Wind Turbine Control Systems Industry, 2011 ( Deep Research Report )ReportsnReports
2011 Deep Research Report on China Wind Turbine Control Systems Industry was published by QYResearch Wind Energy Research Center on May 2011. It was a professional and depth research report on China Wind Power Control Systems Industry.
Power Generator | IVECO and FPT Generating set - DubaiAdpower FZCO
Adpower is one of the most important providers of Diesel Generators and IVECO Generators in UAE. FTP Generator sets Supply an excellent solution for emergency standby power supply and we have all types of Spare Part related to generator. Please visit for more details: https://www.adpower.ae/
EFI Swap | Automotive Wiring Products Manual for 2006 – Current GEN IV LSX/Vo...PSI Conversion
Instructional Manual for Swap Wiring Harness-LSX
Automotive Wiring Products Manual for 2006 – Current GEN IV LSX/Vortec 4.8, 5.3, 6.0, 6.2, 7.0 Drive by Wire (58X) Electronic Fuel Injection Wiring Harness w/4L60E or 4L80E Automatic Transmission
www.psiconversion.com
This harness is designed to be a complete wiring harness for the fuel injection system on General Motors 2006 and newer LSX and Vortec fuel injected engines using a 58X crank sensor and the 4L60E/4L80E transmission with factory installed Drive By Wire throttle Body.
Manual: 2005 and Newer - LS2 LS3 Drive By EFI Wiring Harness PSI Conversion
Specifically designed for complete wiring
harness for the fuel injection system on General Motors 2005 and newer- LS2/LS3 Gen IV fuel
injected engines with Drive By Cable Throttle Body and 4L60E or 4L80E transmission. If using a
58x Engine (LS3, etc) then a Lingenfelter Crank Signal Converter box (available through PSI) is
required so the 411 PCM (Red/Blue Connectors) can be utilized. The factory E38 or E67 controller
does not have the ability to operate a cable throttle body. If using a 24x LS2 no converter box is
required, however a 411 PCM (Red/Blue Connectors) is required.
This harness is constructed with GM Delphi Connectors and Terminals with GXL/TXL (600 volt
polyethylene cross-linked) wire which is professionally assembled and 100% quality inspected prior
to shipping. This harness includes all wiring that is needed by the PCM to run and control the fuel
injection system and transmission.
China Wind Turbine Control Systems Industry, 2011 ( Deep Research Report )ReportsnReports
2011 Deep Research Report on China Wind Turbine Control Systems Industry was published by QYResearch Wind Energy Research Center on May 2011. It was a professional and depth research report on China Wind Power Control Systems Industry.
Power Generator | IVECO and FPT Generating set - DubaiAdpower FZCO
Adpower is one of the most important providers of Diesel Generators and IVECO Generators in UAE. FTP Generator sets Supply an excellent solution for emergency standby power supply and we have all types of Spare Part related to generator. Please visit for more details: https://www.adpower.ae/
EFI Swap | Automotive Wiring Products Manual for 2006 – Current GEN IV LSX/Vo...PSI Conversion
Instructional Manual for Swap Wiring Harness-LSX
Automotive Wiring Products Manual for 2006 – Current GEN IV LSX/Vortec 4.8, 5.3, 6.0, 6.2, 7.0 Drive by Wire (58X) Electronic Fuel Injection Wiring Harness w/4L60E or 4L80E Automatic Transmission
www.psiconversion.com
This harness is designed to be a complete wiring harness for the fuel injection system on General Motors 2006 and newer LSX and Vortec fuel injected engines using a 58X crank sensor and the 4L60E/4L80E transmission with factory installed Drive By Wire throttle Body.
Manual: 2005 and Newer - LS2 LS3 Drive By EFI Wiring Harness PSI Conversion
Specifically designed for complete wiring
harness for the fuel injection system on General Motors 2005 and newer- LS2/LS3 Gen IV fuel
injected engines with Drive By Cable Throttle Body and 4L60E or 4L80E transmission. If using a
58x Engine (LS3, etc) then a Lingenfelter Crank Signal Converter box (available through PSI) is
required so the 411 PCM (Red/Blue Connectors) can be utilized. The factory E38 or E67 controller
does not have the ability to operate a cable throttle body. If using a 24x LS2 no converter box is
required, however a 411 PCM (Red/Blue Connectors) is required.
This harness is constructed with GM Delphi Connectors and Terminals with GXL/TXL (600 volt
polyethylene cross-linked) wire which is professionally assembled and 100% quality inspected prior
to shipping. This harness includes all wiring that is needed by the PCM to run and control the fuel
injection system and transmission.
2005- Current LS2/LS3 Drive by Cable | Electronic Fuel Injection | Wiring Har...PSI Conversion
2005- Current LS2/LS3 Drive by Cable Manual
Electronic Fuel Injection | Wiring Harness
Automotive Wire Harnesses Manual and Instructions
www.psiconversion.com
#EFI #conversion #swap #LS2 #LS3
This harness is designed to be a complete wiring harness for the fuel injection system on General Motors 2005 and newer LS2/LS3 Gen IV fuel injected engines with Drive By Cable Throttle Body and 4L60E or 4L80E transmission. If using a 58x Engine (LS3, etc) then a Lingenfelter Crank Signal Converter box (available through PSI) is required so the 411 PCM (Red/Blue Connectors) can be utilized. The factory E38 or E67 controller does not have the ability to operate a cable throttle body. If using a 24x LS2 no converter box is required, however a 411 PCM (Red/Blue Connectors) is required.
This harness is constructed with GM Delphi Connectors and Terminals with GXL/TXL (600 volt polyethylene cross-linked) wire which is professionally assembled and 100% quality inspected prior to shipping. This harness includes all wiring that is needed by the PCM to run and control the fuel injection system and transmission.
EFI CONVERSION KITS- Manual attached - psiconversion.com
Shop ONLINE @ http://secure.ultracart.com/catalog/PSI/
This harness is designed to be a complete wiring harness for the fuel injection system on General Motors 05-07 LS2 24x fuel injected engines with Drive By Wire Throttle Body and 4L60E or 4L80E transmission.
This harness is constructed with GM Delphi Connectors and Terminals with GXL/TXL (600 volt polyethylene cross-linked) wire which is professionally assembled and 100% quality inspected prior to shipping. This harness includes all wiring that is needed by the PCM to run and control the fuel injection system and transmission.
Your #1 Resource for:
efi conversions
lt1 wiring
ls2 swap kit
lt1 tuning
ls1 harness rework
ls2 drive by wire
efi wiring harness
vortec conversion
t56 wiring
ls1 wiring harness modification
What Does the Active Steering Malfunction Warning Mean for Your BMWTanner Motors
Discover the reasons why your BMW’s Active Steering malfunction warning might come on. From electrical glitches to mechanical failures and software anomalies, addressing these promptly with professional inspection and maintenance ensures continued safety and performance on the road, maintaining the integrity of your driving experience.
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
Why Isn't Your BMW X5's Comfort Access Functioning Properly Find Out Here
10 ta application - flypartsguy.com - 4.2017
1. WP10GTA INSTALLATION AND
APPLICATION MANUAL
EMISSION-RELATED INSTALLATION INSTRUCTIONS
FOR WP10GTA ENGINE
NG, LPG & VPG
3100 GOLF ROAD, ROLLING MEADOWS, IL
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
2. 1
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 .................................................................................................... 15
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
OIL LEVEL GAUGE INSTALLATION .......................................................................................... 22
ACRONYM DEFINITION .......................................................................................................... 24
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
3. 1
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
4. 2
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
5. 3
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: WP10GTA 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 WP10GTA 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
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
6. 4
proper valve and sensor arrangement the fuel supply transition can be made while in operation, under
full load, and automatically.
NG/VPG is WP10GTA standard configuration. With added on option, WP10GTA 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:
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
7. 5
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
8. 6
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
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
9. 7
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
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
10. 8
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)
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
11. 9
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
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
12. 10
ELECTRICAL SYSTEM
WIRE HARNESS DIAGRAM
Figure 8: Wire Harness Diagram
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
13. 11
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
14. 12
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
15. 13
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
16. 14
Figure 12: Closed Crankcase Ventilation System
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
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
17. 15
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.
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
18. 16
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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
19. 17
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.
-
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).
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
20. 18
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.
Underfloor installation of the sensor remote from the engine requires an additional check of the
following points:
- Positioning of the sensor with respect to stone impact hazard.
- Positioning and fixing of cable and connector with respect to mechanical damage, cable bending
stress and thermal stress.
The sensor cable must be routed so that it is free of bends, mechanical tension, and chafing points
considering the movement of the exhaust system in relation to the vehicle body. The cable and
connector should not be subjected to excessive temperatures that could cause damage.
Additional instructions for the installation downstream the catalytic converter
- Between catalyst and sensor location absolute gas tightness of the exhaust system must be ensured.
- When the sensor is installed in the exhaust pipe there should be no detachable connections
between catalytic converter and sensor (e.g. flange, clamp-screw joint).
- In order to protect the active sensor ceramic against condensation water from the exhaust gas side
the sensor heater voltage must be power controlled after cold start of the engine. During the
condensation water phase, the ceramic temperature should be kept at approx. 302degF ~572degF
(150°C-300°C). The corresponding control parameter must be determined according to application.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
21. 19
- 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 should be 15.7 inches (400 mm).
CATALYTIC CONVERTER
A very important component in a low emission engine is the catalytic converter. Weichai engines use a
TWC converter. For this type of catalytic converter to work properly, the following two criterion must be
met:
- The air-to-fuel ratio must oscillate between rich and lean.
- The catalyst substrate (also known as a “brick,” located inside the converter shell) must be kept hot.
Strict compliance with these provisions, conditions, and operating limits for catalytic converters must be
maintained. If these parameters cannot be met or are not known, additional engineering and validation
are required.
Operation
- The continuous operating exhaust gas temperature must be between 1112degF (600°C) and
1562degF (850°C).
- The product installer shall take necessary precautions to accommodate shell skin temperatures up
to 1202degF (650°C).
- System backpressure must remain with +/- 5% of nominal conditions.
- Engine misfires and exhaust stream containments are not permissible.
Vibration
- Vibration isolation must be provided between the engine and the TWC.
- Vibration isolation must be provided between the product and the chassis.
- Vibration acceleration loads shall not exceed 10g.
Installation
- Product shall not support mounting loads from adjacent components.
- Product must be mounted within +/- 10°of horizontal. Any other orientation must be approved by
the WEICHAI.
- Product must be supported at a minimum of two mounting locations.
- Installer shall ensure mounting hardware, such as fasteners, is sufficient for the application.
- WEICHAI recommends use of graphite gaskets for flanged joints.
- Heat shields 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 measurement is made along the length of the exhaust pipe and must take all bends and
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
22. 20
curves into consideration. The max distance allowed downstream of the exhaust manifold flange is
36inches (914mm). Figure 18 depicts an example of catalytic converter setup.
Figure 18: Catalytic Convertor Orientation
Figure 19 depicts an example catalytic mounting options
Figure 19: Catalytic Convertor Mounting Options
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
23. 21
FLYWHEEL
The Weichai engines come with SAE 1 standard flywheel housing and flywheel SAE 11.5 adapter. The
flywheel adapter will be used depending on the customer requirement and as shown in Figure 20.
Contact Weichai representative for assistance of the connector/adaptor installation.
Figure 20: Flywheel and Flywheel Housing
ADJUSTABLE PARAMETERS
This engine has been certified by the US EPA to operate on pipeline quality commercial Natural Gas fuel
as well as commercial LPG/propane.
The Fuel System is non-adjustable and it can compensate for changes within commercial fuels at
different locations in the US. Customers can use a fuel switch (PG Switch in Figure 21) to switch
between NG and LPG operation. The default setting is for NG, the other position “PG” is for fuels with
LPG/VPG (short Engine Interface Pin G & R).
Figure 21 Fuel Switch for Different Fuels
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
24. 22
WARNING: ADJUSTMENTS MADE TO THE FUEL DELIVERY SYSTEM WILL INFLUENCE THE TAILPIPE
EXHAUST EMISSIONS. IT IS THE OWNER/OPERATOR’S RESPONSIBILITY TO TEST THE SPECIFIC FUEL TYPE
AT EACH SITE OF INSTALLATION AND DETERMINE THE CORRECT 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
the operation of the Integrated Electronic Pressure Regulator (EPR) and Shut-Off Valve. The Shut-Off
Valve solenoid prevents fuel flow unless the engine is cranking or running.
At Key ON, the DEPR valve receives a two (2) second prime pulse from the ECM, allowing time
for the fuel to flow through the fuel filter and fuel lines to the IEPR.
The fuel is then to the mixer. Engine cranking generates vacuum which provided lift for the mixer air
valve and is commonly referred to as air valve vacuum. Once in the mixer, the fuel is combined with air
and is drawn into the engine for combustion.
OIL LEVEL GAUGE INSTALLATION
The WP06GNA and WP06GTA Wecichai engine comes equipped with the capability of using an oil level
gauge. If a gauge was purchased through Weichai America Corporation, the connector on the wiring
harness and the connector on the gauge should be a match. If the gauge was not supplied by Weichai
America Corporation, please contact our service department and the right connector can be purchased.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
25. 23
Figure 22: Oil Feed to Oil Level Gauge
To install the gauge, remove the M20x1.5 plug from the oil pan shown in
Figure 21, and install a M20x1.5 to ¾” barbed hose fitting. Use ¾” 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 one Oil Balance Line Block, four
M6x1.0x35 bolts, two gaskets, one 1/8” NPT to 3/8” barbed fitting, one oil fill neck assembly and 3/8”
hose at the desired length. Remove the oil cap, sandwich the Oil Balance Line Block with provided
gaskets, place the oil fill neck assembly on top of the gasket and thread provided bolts into the four
holes. Ensure the fill neck is pointing at the 6 o’clock position so that oil poured into the filler neck will
M20x1.5 to 3/4” Barbed
3/4” Hose rated for Oil
3/4” NPT to 3/4” Barbed
3/8” NPT to 3/8” Barbed
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
26. 24
drain into the engine and not on the ground. Torque bolts to 9 Nm. See
Figure 13 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.
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
27. 25
Figure 13: Balance Line
ACRONYM DEFINITION
ABBREVIATION DEFINITION
DEPR Direct acting Electronic Pressure Regulator
DSR Dual Stage Regulator
DST Diagnostic 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
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com
Document Courtesy of Fly Parts Guy Co.
www.FlyPartsGuy.com