Ford wsg-1068, Operator'S Handbook Manual

Page 1: ...OPERATOR HANDBOOK WSG 1068 Gasoline LIQUEFIED PETROLEUM GAS LPG NATURAL GAS NG ENGINES Part 1080050 EDI Revision F March 2011 W ...

Page 2: ...ARNING ...

Page 3: ...ne Distributors Incorporated Engine Distributors policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects the right to change prices specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as a final description of any individual engine ...

Page 4: ...NE 13 OPERATING CONTROLS 13 Ignition or Isolation Switch 13 Safety Switch where fitted 14 Power Take off where fitted 14 Throttle Control where fitted 14 INSTRUMENTS 15 Ammeter Where Fitted 15 Battery Condition Indicator Where Fitted 15 Tachometer Where Fitted 15 Hourmeter Where Fitted 15 Oil Pressure Gauge Where Fitted 15 Temperature Gauge Where Fitted 16 Malfunction Indicator Light Where Fitted ...

Page 5: ... Level 23 Renew Engine Oil Filter 23 Ignition System 24 Renew Spark Plugs 24 Electronic Actuator 26 Check Condition of Ancillary Drive Belts 26 Check Engine Coolant Level 26 Renew Air Cleaner Element 27 Renew PCV Valve 27 GENERAL MAINTENANCE INFORMATION 28 Cooling System 28 Draining Flushing and Filling the Cooling System 30 Engine Lubrication System 30 Electrical System 31 Generator 32 Storage 33...

Page 6: ...hould be taken to ensure that the ignition isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate 3 Avoid contact with exhaust pipes exhaust manifolds and silencers when an engine is or has recently been running these can be very hot and can cause severe burns 4 Many liquids used in engines or vehicles are harmful...

Page 7: ...e equipment If you have an automatic transmission set it in PARK REVERSE engine off or NEUTRAL engine on unless instructed otherwise for a specific operation Place wood blocks 4 x 4 or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent equipment movement Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide Keep yours...

Page 8: ...this book Where the terms Right or Left occur in this publication they refer to the respective sides of the engine when viewed from the rear or flywheel end Pistons and valves are numbered from the front or timing cover end of the engine commencing at No 1 You may find that your engine assembly includes optional equipment not specifically covered in the following text Nevertheless the maintenance ...

Page 9: ...tion system engine computer unit ECM catalytic converter and air induction system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable condition exists Engine Distributors Inc will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage Standard warranty for any non emissions related part...

Page 10: ...airs should be completed by the dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact Engine Distributors Inc at 800 220 2700 What is Covered Below is a list of the systems that affect emissions on your engine Emission control components on these systems are covered by the emissions warranties as applicable If failure o...

Page 11: ...el Line Fittings o Clamps o Pressure Relief Valves o Control Valves o Control Solenoids o Electronic Controls o Vacuum Control Diaphragms o Control Cables o Control Linkages o Purge Valves o Vapor Hoses o Liquid Vapor Separator o Carbon Canister o Canister Mounting Brackets o Carburetor Purge Port Connector High Priced Emissions Warranty Parts List 5 years or 3 500 hours whichever comes first Pres...

Page 12: ...gines ensure that there is coolant in the degas expansion tank where applicable CAUTION Under no circumstances may the engine be started without liquid in the cooling system 4 Check the engine oil level and top up or fill as necessary Refer to Check Engine Oil Level on page 23 For the correct type and grade of oil Refer to Recommended Lubricants on page 21 5 Ensure that the battery is fully charge...

Page 13: ... button must be depressed to start the engine NOTE With EDI GCP safety shut down incorporated oil pressure below 6 psi and or coolant temperature goes above 250 F will shut down ignition system Corrective action must be taken and key recycled to restart Power Take off where fitted The power take off control handle allows engagement and disengagement of the power take off clutch Moving the lever to...

Page 14: ...ed in crankshaft revolutions per minute Hourmeter Where Fitted This instrument records the number of hours of operation which the engine has completed at the rated rpm It is frequently combined with the tachometer and is used to determine when an engine service operation is required If no hourmeter is fitted a log should be kept Oil Pressure Gauge Where Fitted The oil pressure gauge registers the ...

Page 15: ...rt the engine Once the engine has started the charge indicator light should cease glowing Safety Switch Override Button Where Fitted This must be depressed when starting the engine as the safety switch operates when the oil pressure falls due to the engine stopping Refer to Safety Switch where fitted on page 14 Ignition or Isolation Switch Refer to Ignition or Isolation Switch on page 13 Fuel Sele...

Page 16: ...ires NOTE Where a safety switch is fitted the override button must be depressed while the engine is being cranked 3 Set the throttle to give a fast idle speed until normal operating temperature is reached where fitted CAUTION If the engine stalls or falters in starting wait 3 4 seconds before re engaging starter This will prevent possible damage to the starter or engine The starter should not oper...

Page 17: ...wly until the radiator is full WARNING TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT ENGINE COVER THE RADIATOR CAP IN A THICK CLOTH AND TURN IT SLOWLY COUNTERCLOCKWISE TO THE FIRST STOP AFTER THE PRESSURE HAS BEEN COMPLETELY RELEASED PRESS THE CAP DOWNWARD AND FINISH REMOVING THE CAP The above instructions also apply to engines that stop due to operation of the low oil pressure high water tempe...

Page 18: ...ill give Detailed instructions regarding this maintenance are given in the following pages Your Authorized EDI Distributor listed in the back section of this manual will be pleased to carry out this regular maintenance for you The various maintenance operations are listed Refer to RECOMMENDED MAINTENANCE SCHEDULES on page 20 When carrying out any of the following maintenance operations any fault o...

Page 19: ... to renew the filter element more frequently PCV Valve inspection and Spark Plug replacement are recommended at the interval s described Spark plug cleaning replacement at these intervals will ensure maximum engine performance fuel economy and emissions Failure to complete recommended maintenance does not disqualify your engine from any emissions related warranty coverage s ...

Page 20: ...he front of the container or API specification SH or SJ NOTE Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current API classification should be used API classifications are broken into two categories gasoline and diesel engines API s classification is designated by a two letter sy...

Page 21: ...engine to normal operating temperature 2 Make sure that the equipment is standing level and that the engine is stopped 3 Obtain a sufficiently large draining pan to accommodate the engine oil Refer to Service Oil fill capacity including filter on page 38 4 Remove the oil filler cap from the rocker cover remove the drain plug from the oil pan and drain the oil into the draining pan NOTE Modern high...

Page 22: ...armful abrasive and sludgy particles without clogging up or blocking the flow of the oil to vital engine parts This filter is especially designed for use in engines built by Ford to give successful operation with the recommended oil filter change intervals Contact your nearest EDI Distributor Dealer listed in the back section to obtain the correct filter Before commencing place a drain pan beneath...

Page 23: ...CESS OF 30 000 VOLTS PLEASE USE CAUTION CAUTION Do not pull directly on the lead as this could cause the wire connection inside the boot to become separated NOTE To remove spark plugs you must first remove coils 1 Disconnect the ignition coil wire connectors 2 Remove the hold down screw then the coil NOTE For fuel rail clearance rotate coils 45 clockwise and lift out 3 After loosening each spark p...

Page 24: ... the specified torque value listed under specification of this manual NOTE Do not over tighten spark plugs as the gap may change considerably due to the distortion of the plug outer shell 6 Coat the inside of each spark plug boot with silicone dielectric compound D7AZ 1 9A33 1 A USA or equivalent using a small nscrewdriver blade 7 Install the plug coils and tighten hold down bolt to 5 7 Nm 44 62 i...

Page 25: ...E FIRST STOP AFTER THE PRESSURE HAS BEEN COMPLETELY RELEASED PRESS DOWNWARD AND FINISH REMOVING CAP FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND OR PERSONAL INJURY CAUTION Do not add coolant to an engine that has become overheated until the engine cools Adding coolant to an extremely hot engine can result in a cracked block or cylinder head 1 Allo...

Page 26: ...under severe dust conditions to prevent engine damage 1 Release the air cleaner lid retaining hardware 2 Lift the air cleaner lid clear of the air cleaner body then remove the air cleaner element and discard it 3 Wipe the inside of the air cleaner body and lid clean using a lint free rag 4 Insert the new element ensuring that it fits properly and install air cleaner lid Renew PCV Valve 1 Detach th...

Page 27: ... REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO AT LEAST 40 C 110 F 1 Wrap a thick cloth around the pressure relief cap a...

Page 28: ...e concentration A reading of 1040 represents a 25 antifreeze concentration A reading of 1000 represents plain water WARNING ANTIFREEZE CONTAINS MONO ETHYLENE GLYCOL AND OTHER CONSTITUENTS WHICH ARE TOXIC IF TAKEN INTERNALLY AND CAN BE ABSORBED IN TOXIC AMOUNTS ON REPEATED OR PROLONGED SKIN CONTACT PERSONS USING ANTIFREEZE ARE RECOMMENDED TO ADHERE TO THE FOLLOWING PRECAUTIONS ANTIFREEZE MUST NEVER...

Page 29: ...rain cock or replace the bottom radiator hose Recover all old antifreeze and dispose of properly Contact your local municipal government for the proper disposal 5 Fill the system with the correct coolant mixture via the expansion degas tank filler neck Fill the system slowly to avoid air locks up to the maximum mark on the degas tank 6 Run engine and check hose connections for leaks Check and if n...

Page 30: ...ectric current to keep the battery fully charged under normal operating conditions The generator requires no lubrication or maintenance WARNING IT IS ESSENTIAL THAT THE WIRING CONNECTIONS TO THE GENERATOR ARE NOT REMOVED WHILE THE ENGINE IS RUNNING AS THIS WILL RESULT IN DAMAGE TO THE REGULATOR OR PERSONAL INJURY Fuse Amps Circuits protected 1 10 Battery Voltage to EPR 2 5 Ignition Voltage to GCP ...

Page 31: ... crankcase completely and refill with recommended engine oil SAE 10 or equivalent Run engine and treat upper cylinders by spraying fogging agent into the air intake for about two minutes Open throttle for short burst of speed shut off engine and allow it to come to a stop while continuing to spray into air intake Check coolant protection Disconnect and remove battery Clean exterior surface of engi...

Page 32: ...ndicator or illuminate the MIL light NOTE EDI engines are used in many different applications and equipment When performing any system diagnosis be aware of any OEM inputs or equipment monitoring devices that may have an effect on the engine s performance or any of the engine s operating systems Engine Performance No Load ...

Page 33: ...Engine Performance While Under Load ...

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Page 35: ...Engine Concerns ...

Page 36: ...SPECIFICATIONS ...

Page 37: ...TIGHTENING TORQUES ...

Page 38: ...CONVERSION TABLE ...

Page 39: ...EDI Distributors Europe ...

Page 40: ...New Zealand North America Canada ...

Page 41: ...North America United States ...

Page 42: ...North America United States Continued ...

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