Ford wsg-1068 Operator's Handbook Manual

OPERATOR HANDBOOK

WSG

1068

Gasoline

LIQUEFIED PETROLEUM GAS (LPG)

NATURAL GAS (NG) ENGINES

Part #: 1080050

EDI Revision F

March , 2011

W

ARNING:

FORD WSG-1068 ENGINES
Gasoline

LIQUEFIED PETROLEUM GAS (LPG)
NATURAL GAS (NG)

Reproduction in any manner, in whole or in part, is prohibited without the
express permission in writing from

Engine 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.

CONTENTS

HEALTH & SAFETY .......................................................................................................... 4

General Guidelines: ................................................................................................ 4

Important Safety Notice........................................................................................... 4

Notes, Cautions, and Warnings .............................................................................. 5

FORWARD ........................................................................................................................ 6

ENGINE IDENTIFICATION................................................................................................ 6

U.S.A. Engine Identification Decal .......................................................................... 7

Non-Certified Engine Decal..................................................................................... 7

Federal Emissions Warranty Statement.................................................................. 8

California Emission Control Warranty Statement.................................................... 8

What Is Covered? .................................................................................................. 10

European Service Identification Plate .................................................................... 11

PARTS AND SERVICE..................................................................................................... 12

SERVICE LITERATURE................................................................................................... 12

WARRANTY REGISTRATION ......................................................................................... 12

BEFORE OPERATING THE ENGINE.............................................................................. .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) ............................................................. 16

Charge Indicator Light (Where Fitted).................................................................... 16

Safety Switch Override Button (Where Fitted) ....................................................... 16

Ignition or Isolation Switch ..................................................................................... 16

Fuel Select Switch (Where Fitted).......................................................................... 16

STARTING THE ENGINE.................................................................................................. 17

Initial Start-up ......................................................................................................... 17

To Start From cold ................................................................................................. 17

To Re-start When Warm ........................................................................................ 17

CONTENTS

STOPPING THE ENGINE ................................................................................................ 18

Normal Conditions.................................................................................................. 18

Abnormal Conditions.............................................................................................. 18

RUNNING-IN PROCEDURE ............................................................................................ 18

FUEL RECOMMENDATION............................................................................................. 19

LUBRICATION AND MAINTENANCE.............................................................................. 19

RECOMMENDED MAINTENANCE SCHEDULES........................................................... 20

RECOMMENDED MAINTENANCE OPERATIONS ........................................................ 21

Recommended Lubricants .................................................................................... 21

Used Engine Oils .................................................................................................. 22

Change Engine Oil ............................................................................................... 22

Check Engine Oil 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

ENGINE SYSTEM CHECK.............................................................................................. 34

SPECIFICATIONS .......................................................................................................... 38

TIGHTENING TORQUES................................................................................................ 39

CONVERSION TABLE ....................................................................................... ............40

FORD POWER PRODUCTS SERVICE ......................................................................... 41

HEALTH & SAFETY

WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE
CAREFULLY OBSERVED.

Carrying out certain operations and handling some substances can be dangerous or harmful to the
operator if the correct safety precautions are not observed. Some such precautions are
recommended at the appropriate points in this book.

While it is important that these recommended safety precautions are observed, care near
machinery is always necessary, and no list can be exhaustive. ALWAYS BE ON YOUR GUARD!

General Guidelines:

The following recommendations are for general guidance:

1. Always wear correctly fitting protective clothing which should be laundered
regularly. Loose or baggy clothing can be extremely dangerous when working on running q
engines or machinery. Clothing which becomes impregnated with oil or other substances
can constitute a health hazard due to prolonged contact with the skin even through
underclothing.

2. So far as practicable, work on or close to engines or machinery only when they are stopped.

If this is not practicable, remember to keep tools, test equipment and all parts of the body
well away from the moving parts of the engine or equipment—fans, drive belts and pulleys
are particularly dangerous. The electric cooling fan used on some installations is actuated
automatically when the coolant reaches a specified temperature. For this reason, care
should 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 if taken internally or splashed into the

eyes. In the event of accidentally swallowing gasoline (petrol), oil, diesel fuel, antifreeze,
battery acid etc., DO NOT ENCOURAGE VOMITING AND OBTAIN QUALIFIED MEDICAL
ASSISTANCE IMMEDIATELY.

Wear protective goggles when handling liquids which are harmful to the eyes these include
ammonia and battery acid. If any of these substances are splashed in the eyes, wash out
thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.

Important Safety Notice

Appropriate service methods and proper repair procedures are essential for the safe, reliable
operation of all industrial engines as well as the personal safety of the individual doing the work.
This operator handbook provides general directions for accomplishing service and repair work with
tested, effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing equipment,
as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all
such variations and provide advice or
the instructions

cautions as to each. Accordingly, anyone who departs from

provided in this Manual must first establish that neither personal safety nor equipment integrity are
compromised by the choice of methods, tools or parts.

Notes, Cautions, and Warnings

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS.
Each one is there for a specific purpose. NOTES gives you added information that will help you to
complete a particular procedure. CAUTIONS are given to prevent you from making an error that
could damage the equipment. WARNINGS remind you to be especially careful in those areas
where carelessness can cause personal injury. The following list contains some general
WARNINGS that you should follow when you work on the equipment.

GENERAL WARNINGS:

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the

equipment.

• Be sure that the ignition switch is always in the OFF position, unless otherwise

required by the procedure.

• Set the parking brake (if equipped) when working on the 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 yourself and your clothing away from moving parts when the engine is
running, especially the fan belts.

• To prevent serious burns, avoid contact with hot metal parts such as the
radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the equipment.

• To reduce the risk of injury, always remove rings, watches, loose hanging

jewelry, and loose clothing before beginning to work on the equipment. Tie long
hair securely behind the head.

• Keep hands and other objects clear of the radiator fan blades. Electric cooling
fans can start to operate at any time by an increase in underhood temperatures,
even though the ignition is in the OFF position. Therefore, care should be taken
to ensure that the electric cooling fan is completely disconnected when working
under the hood.

FORWARD

This book contains operating and maintenance instructions for the engine(s) listed on the title
page.

The life of your engine unit and the delivery of the high performance built into it will depend on the
care it receives throughout its life. It is the operator’s responsibility to ensure that the engine is
correctly operated and that the maintenance operations outlined in this book are carried out
regularly after the specified hours of operation have been reached. We consider it to be in your
interests to enlist the aid of an authorized Ford Power Products Distributor not only when repairs
are required but also for regular maintenance. Distributors are listed at the back of this handbook.

Regular maintenance will result in minimal operating costs.
Engines manufactured by Ford Motor Company are available through Ford Power

Products Distributors. When in need of parts or service, contact your local Authorized Distributor.
In overseas territories, in the event of difficulties, communicate directly with the supervising Ford
affiliated Company in your area whose address appears at the end of 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 procedures outlined in this book still apply to
your engine

ENGINE IDENTIFICATION

Because Engine Distributors has such a wide range of industrial gasoline and diesel engines ­manufactured both in the U.S. and overseas - it is important that you have as complete
identification of the engine as possible in order to provide the correct replacement parts. Review
the list of distributors for a distributor in your area. You can obtain a standard parts listing
describing the parts. It remains a distributor function to identify the part number.

The key to identifying the engine is the identification decal mounted on the engine rocker cover.
That decal provides not only the engine serial number, but also the exact model or type,
configuration code and customer name. The combination of that data permits you to isolate the
precise engine, build level and customer so you can determine the correct replacement parts.

EDI Engine Identification Decal

An identification Decal is affixed to the valve cover of the engine. The decal contains the engine serial number which
identifies this unit from all others. Use all numbers when seeking information or ordering replacement parts for this
engine.

For handy reference, transfer the data recorded on this decal to a safe place.

Your Warranty Rights and Obligations

The California Air Resources Board, U.S. EPA and Engine Distributors, Inc. are pleased to explain the
emission control system warranty on your new 2010 and subsequent model year emission certified engine
(or brand equipment). New off-road large spark-ignition (LSI) engines must be designed, built and equipped
to meet stringent Federal and State anti-smog standards. Engine Distributors, Inc. warrants that the
emission control system on your engine for the periods of time listed below provided there has been no
abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, regulator or fuel-injection system,
ignition 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 is two years or 2000 hours. This includes the base
engine and ancillary parts such as the starter and alternator.

The new 2010 model year off-road large spark-ignition engines are warranted for three years or 2500 hours
of service, whichever occurs first from the date the equipment is delivered to the first retail purchaser or
when the equipment is first placed in service. If any emission-related part on the engine is defective, the
part will be repaired or replaced by an authorized Engine Distributors, Inc. dealer. This is your General
Emissions Warranty.

For five years or 3500 hours of service (whichever occurs first) if any emission-related part specially noted
with coverage for five years or 3500 hours is defective, the part will be repaired or replaced by and
authorized Engine Distributors, Inc. dealer. This is your High Priced Parts Emission Warranty.

Owner’s Warranty Responsibilities

As the off-road LSI engine owner, you are responsible for the performance of the required maintenance
listed in your owner’s manual. Engine Distributors, Inc. recommends that you retain all records covering
maintenance on your off-road engine, but Engine Distributors, Inc. cannot deny warranty solely for the lack
of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the off-road large spark-ignition engine owner, you should however be aware that Engine Distributors,
Inc. may deny you warranty coverage if your off-road large spark-ignition engine or a part has failed due to
abuse, neglect, improper maintenance or unapproved modifications.

Depending on the model of engine you have purchased, your engine may be designed to operate on LPG,
Gasoline, and/or Natural Gas fuels. Use of any other fuel may result in your engine no longer operating in
compliance with applicable emissions requirements.

You are responsible for initiating the warranty process. Engine Distributors suggests that you present your
off-road large spark-ignition engine to an Engine Distributors, Inc. dealer as soon as a problem exists. The
warranty repairs 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 [phone].

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 of one of the components listed below results in failure of another part, both will be covered by this
warranty. For detailed information concerning specific components covered by these emission control
systems warranties, ask your dealer.

General Emissions Warranty Parts List – 3 years or 2,500 hours, whichever comes first

• Fuel Metering System

o Fuel injection system.
o Air/fuel ratio feedback and control system.
o Carburetor system (internal parts and/or pressure regulator or fuel mixer or injection system).

• Air Induction System

o Air intake system.

• Catalyst or Thermal Reactor System

• Positive Crankcase Ventilation (PCV) System.

o PCV Valve.
o Oil Filler Cap.

• Ignition Control System

o Ignition module(s).
o Spark Plugs

• Miscellaneous items Used in Above Systems

o Vacuum, temperature, and time sensitive valves and switches.
o Sensors used for electronic controls.
o Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices,

and mounting hardware.

o Pulleys, belts and idlers.

• Emission Related Components (Only Covered if Your Engine was Sold in California)

o Air Induction System
o Fuel System
o Ignition System
o Exhaust Gas Recirculation Systems
o After Treatment Devices
o Crankcase Ventilation Valves
o Sensors
o Electronic Control Units
o Fuel Tank
o Fuel Cap
o Fuel Line
o Fuel 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:

• Press Regulator

• Catalytic Muffler

• Engine Control Module (ECM).

• Intake Manifold

• Exhaust Manifold

• Harness

• Throttle

SERVICE LITERATURE

A service manual can be purchased from your EDI distributor. This publication will provide the
necessary servicing and overhaul information for your Ford Power Products engine.

• WSG1068 SERVICE MANUAL - EDI

• WSG1068 PARTS LIST - EDI

BEFORE OPERATING THE ENGINE

1. Before operating a new engine it should be thoroughly inspected to ensure that during

transit and installation it has not suffered damage likely to affect its subsequent operation.
Controls and instruments should be studied carefully in order that their functions are
thoroughly understood.

2. Check that the radiator (where applicable) is full and top off as necessary -- Refer to

“Cooling System” on page 28 for recommended coolant mixtures.

3. In the case of marine/industrial engines, 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 charged and, if necessary, top up with distilled water.
NOTE: Ensure that ALL wiring ground connections are properly made to a clean point on the

chassis/frame.

6. The engine must be started in accordance with the starting instructions -- Refer
to “STARTING THE ENGINE” on page 17.

OPERATING CONTROLS
Ignition or Isolation Switch

An ignition or isolation switch is usually fitted which connects the engine starter motor and other
electrical equipment to the battery. The switch can be moved to any of the four positions shown by
rotating the key. These positions are:

1. Auxiliary Circuits - When moved to this position the auxiliary electrical equipment such as
radios and heater fans, can be operated without also connecting the starting circuit with the
battery.

2. Off - When set to this position, the switch disconnects the auxiliary electrical equipment and
the starting circuit from the battery. The key can be removed from the switch when it is in
this position; this will help to prevent unauthorized operation of the engine.

3. Run - This switch position connects the auxiliary circuits as described previously, and the
alternator is given initial excitation via the battery.

4. Start - In this position, the starter solenoid is energized and the starter motor cranks the
engine. The switch, when released, automatically returns to the RUN position.

Safety Switch (where fitted)

A low oil pressure/high water temperature safety switch may be fitted. This automatically shuts off
the ignition when the oil pressure drops below a pre-set value, or when the water temperature rises
above a pre-set value. A button on the instrument panel is used to override the safety switch when
starting the engine. The safety switch override 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 towards the engine engages the clutch and moving the lever away from
the engine disengages the clutch.

When moving the handle to engage the clutch and pick up the load, do so in a smooth manner.
Moving the clutch handle too slowly will cause slippage and wear, while moving it too fast will
cause quick engagement and possible damage to the power take-off, engine or driven equipment.
The normal force required to engage the clutch is 55 lbf (245 N) for the over-centre type and 25 lbf
(110 N) for the spring loaded type.

Throttle Control (where fitted)

The throttle control adjusts engine speed. Initial engine speed adjustment is obtained by pressing
the throttle control release button while pulling the throttle knob out to increase the engine speed or
pushing it in to decrease the engine speed. A final fine speed adjustment is obtained by turning the
throttle control counterclockwise to increase engine speed or clockwise to decrease engine speed.

INSTRUMENTS

Your Ford Powered Equipment will have been fitted with instruments selected by the manufacturer.
The types of instruments most likely to be encountered are detailed here. A typical instrument
panel is shown below.

Ammeter (Where Fitted)

This instrument registers the charging current which is being passed to the battery from the
alternator. It also registers a discharge equivalent to the amount of current being used by the
electrical equipment when the alternator is not charging.

Battery Condition Indicator (Where Fitted)

This is sometimes fitted instead of an ammeter and measures the battery voltage thus indicating
the state of charge of the battery.

Tachometer (Where Fitted)

The tachometer indicates the actual engine running speed 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 lubricating system pressure in bar (kgf/cm2 or Ibf/in2) and
should be frequently observed to ensure that the system is functioning correctly.

Temperature Gauge (Where Fitted)

The temperature gauge enables a close check to be kept on the coolant temperatures.

Malfunction Indicator Light (Where Fitted)

Used on all industrial engines. This light will illuminate whenever there is an engine malfunction
such as low oil pressure, high engine temperature, fuel injection system fault. The engine can be
programmed to shut down in the event of a malfunction.