WP10 Gas Engine Key point of maintenance and assembly

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WP10 Gas EngineKey point of maintenance and assembly

Aug 2018

Document Courtesy of Fly Parts Guy Co.www.FlyPartsGuy.com

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CONTENTS

1. Maintenance

2. Key point of assembly


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1.Maintenance—Specification of fuel, lubricating oil and coolant

•Natural Gas: at least 70% methane by volume or have a heating value of 950-1100 BTUs per standard cubic foot

•LPG: minimum of 90% propane, maximum of 5% propylene, and maximum 5% of other gases

Fuel

•Recommends using a straight weight or multi-weight low ash content oil specifically formulated for Natural Gas Engines.

•Specific weight depends on operating temperatures: (10W-30 : -25 to 30℃), (15W-40 : -20 to 40℃), (20W-50 : -15 to 45℃)

•API No. CH-4 or above are also recommended.

Oil

•recommends using a 50/50 mixture of fully formulated Ethylene Glycol or fully formulated Propylene Glycol coolant and distilled water

Coolant


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1.Maintenance—Maintenance schedule

Non-emergency


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1.Maintenance—Maintenance schedule

Emergency


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1.Maintenance—Daily check

1.Check engine oil level

2.Check coolant level

Caution : Never remove radiator

or top tank cap when coolant is

hot!

3. Check operation conditions

❖ Check hoses, clamps, pipes for loose

connection or leak.

❖ Check connectors for loose connection.

❖ Check harness for cut, short, corrosion

or abrasions.

❖ Check belt for loose or fraying.

❖ Assure battery voltage is ≥12v each.

4. Check oil pressure

Oil Pressure

Idle PSI KPa

Min 19 ≥130

Rated Speed

Min 50 350

Max 84 580


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1.Maintenance—Replace lubricating oil and oil filter element

Engine model Oil refill volume Material details

WP1027~30L (7.1~7.9 Gal) Recheck dipstick

2 filter elements and 2 O-rings

Replace oil filter element:

1. Drain oil completely.

2. Remove oil filters by the filter wrench and

remove O-rings.

3. Install new filter and O-ring by hand.(Apply a

thin coat of motor oil to o- ring before

installing)

4. Tighten filter until the rubber gasket contacts

base. Tighten additional 3/4 to 1 turn to seal..

5. Fill new oil and run engine for 5 minutes,

check for leaks.


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1.Maintenance—Adjust valve lash

1.The first piston is on the “TDC” of compression stroke

Valve lash (cold)

intake 0.5mm

exhaust 0.8mm

Fan side

#1@TDC(COMPRESSION STROKE)

INT EXH INT EXH INT EXH Flywheel side1 1 2 3 4 5

2.The number six piston is on the “TDC” of compression stroke

Fan side

EXH INT EXH INT INT EXH #6@TDC(COMPRESSION STROKE)

Flywheel side2 3 4 5 6 6

TDC mark


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CONTENTS

1. Maintenance

2. Key point of assembly


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2. Key point of assembly—Gear timing

1.Rotate the crankshaft to the TDC of first and sixth cylinder.

2.Rotate the camshaft and install the timing gear when the scale mark in timing

gear and “OT” scale mark in gear housing are aligning.

NOTE: Camshaft timing fastening bolts: Apply tighten

glue and tight to 45~45Nm.

1.Crankshaft gear 2.Intermediate gear

3.Camshaft gear 5.Signal generator gear

6.Oil pump intermediate gear

7.Oil pump gearDocument Courtesy of Fly Parts Guy Co.www.FlyPartsGuy.com

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2. Key point of assembly—Intermediate gear

“V” mark

Install intermediate gear:

1. The “V” mark should face to front (out side).

2. Bolts: Apply tighten glue and tight to (60±5)Nm, turn 90°, reach to

100~120Nm at the same time.


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2. Key point of assembly—Signal generator

1. Rotate the crankshaft to “OT” mark, make sure the first piston is on the top

dead center of compression stroke.

2. Install the signal generator and adjust angle of the fluted disc until its TDC mark

points at the center of the phase sensor and the predetermined ignition angle is

reached.

3. Tighten the locknut (80～100N·m) on the signal generator fluted disc.

Note: the correct value of the gap between the fluted disc and sensor is 0.8~1.5mm

1th piston@ TDC of

compression stroke

TDC mark points at the

center of phase sensor.Fluted disc


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2. Key point of assembly—Connecting rod and piston

Key points:

1. The connecting rod oblique split are back to the piston notch.

2. The piston notch and oil nozzle should be in the same direction when install

the connect rod and piston combinations.

3. The torque of connecting rod bolt is :120N·m + (90±5°), (Reach 170 to

250N·m at the same time)

NOTE: 1.The connecting rod bolts can’t be re-used.

2. The opening mouth of piston rings should not overlap.

Adjust the angle of piston

rings to make sure the

opening not overlap.

1.The oblique split

are back to the

piston notch.

2. The piston notch

should be in the

same direction with

oil nozzle

Piston

notch


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2. Key point of assembly—Main bearing bolt

Main bearing bolts:

The first time 80Nm, the second time 250Nm. Required sequence of

tightening as below

Note: the oil groove on the thrust plate should face to crankshaft.


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2. Key point of assembly—Cylinder head bolts

Cylinder head bolts and nuts:1. Align the cylinder head with the cylinder block. Apply a proper amount of clean lubricating oil to the

threads and pressure-bearing surfaces of shoulders of the main bolts of cylinder head and the

shouldered nuts. Install the main bolts to the cylinder head. Install the clamping blocks and nuts to

the auxiliary bolts of cylinder head.

2. Tighten the main bolts and nuts of auxiliary bolts of cylinder head to the torque of (30~50) Nm.

3. Tap the clamping blocks so that they descend in place.

4. Tighten the nuts of auxiliary bolts in the sequence to the torque of 100N·m.

5. Tighten the main bolts in the sequence to the torque of 200N·m.

6. Tighten the nuts of auxiliary bolts in the sequence by 90º. Then make marks on the nuts.

7. Tighten the main bolts in the sequence by 90º. Then make marks on the bolts.

8. Tighten the nuts of auxiliary bolts in the sequence by another 90º to the torque of (120~160) Nm.

9. Tighten the main bolts in the sequence by another 90º to the torque of (240~340) Nm.

10. The cylinder head bolts and nuts shall be tightened according to the order given by Illustration

below, in which, those numbering 1-21 are nuts of auxiliary bolt, while those numbering 22-45 are

main bolts of cylinder head


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2. Key point of assembly—Flywheel housing

Flywheel housing bolts:

1. Apply the lubricating oil on the contact surface and thread of bolts.

2. Tighten torque: 100~140Nm and tighten sequence as below.


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2. Key point of assembly—

Engine Fastener Torque Specifications

Fastener’s Name Bolt SpecificationTightening torque (N·m) + further turned

angle (°)

Permissible times of

repeat used

Main bearing M18-10.9The first time 80N·m, the second time

250~280N·m (See illustration13)2

Connecting rod M14x1.5-12.9120N·m + (90±5°), (Reach 170 to 250N·m at

the same time)0

Cylinder head M16-12.9

200N·m +2x (90±5°), required sequence of

tightening (See illustration14), (Reach 240 to

340N.m at the same time)

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Flywheel M14x1.560N·m +2x(90±5°), (Reach 230 to 280N·m at

the same time)2

Flywheel housing 110 to 140N·m 2

Camshaft gear M8-12.9 40 to 45N·m

Exhaust manifold M10 50 to 70N·m 2

Intake manifold M10 45+5N.m -

Damper M10-10.9 65 to 70N·m -

Spark-plug M14x1.25 (25 to 28) N·m -

UEGO sensor M18x1.5 40N.m±5N·m -

Water temperature

sensorM14x1.5 25N.m±5N·m -


18Document Courtesy of Fly Parts Guy Co.www.FlyPartsGuy.com

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WP10 Gas Engine Key point of maintenance and assembly