WEICHAI WP13GTA Assembly/Disassembly Manual Download

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Assembly & Disassembly Manual

Gas Engine

Model: WP13GTA

WEICHAI AMERICA CORP.

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

Summary of Contents for WP13GTA

Page 1: ...Assembly Disassembly Manual Gas Engine Model WP13GTA WEICHAI AMERICA CORP Document Courtesy of Fly Parts Guy Co www FlyPartsGuy com Document Courtesy of Fly Parts Guy Co www FlyPartsGuy com...

Page 2: ...provider that you choose However your engine warranty does not cover damage or failure caused by improper maintenance or repairs Owner s Manual Maintenance Records Storage Use Store this Owner s Manu...

Page 3: ...and Disassembly 16 3 2 Disassembly and assembly of cylinder head cover 23 3 3 Oil and gas separator dismantling and assembly 24 3 4 Lifting Lugs Assembly and Disassembly 26 4 Crank rod mechanism 28 4...

Page 4: ...8 Lubrication system 64 8 1 Lubrication system dismantling and assembly 64 8 2 Oil filter dismantling and assembly 65 8 3 Oil pump disassembly and assembly 66 8 4 Oil filter oil filter seat disassembl...

Page 5: ...Weichai America Corp 4 11 APPENDIX A 82 Document Courtesy of Fly Parts Guy Co www FlyPartsGuy com Document Courtesy of Fly Parts Guy Co www FlyPartsGuy com...

Page 6: ...y result in serious injury or death Note Before proceeding with any maintenance or repair operation place a sign clearly stating Maintenance in Progress Do Not Use on the engine starter switch Take th...

Page 7: ...n 12 Gasket 13 Pressure temperature sensor 14 Gasket 15 Hex head plug 16 Knock sensor 17 Gasket 18 Hex head plug 19 Gasket 20 Hex flange bolts 21 Oil dip tube plug Fig 2 1 Exploded view of engine bloc...

Page 8: ...here are cracks and clean cylinder liner the use of special tooling into the cylinder bore press the outer surface of the front cylinder coating molybdenum powder cylinder liner protruding amount 0 05...

Page 9: ...on 2 Preparation before disassembly Remove gearbox and clutch remove flywheel flywheel housing gear housing and oil pan 2 2 3 Dismantling 1 Disassemble the internal thread cylinder pin 2 Remove camsha...

Page 10: ...4 Assembly The main bearing bolts are symmetrically fastened in the order shown in Figure 2 3 first tighten by pneumatic wrench next tighten to the torque of 80Nm then tighten to 140Nm after this tigh...

Page 11: ...opposite of the front cover removal procedure 2 3 5 Service Key point 1 After the front cover is removed it should be placed in a clean environment Before assembly it is necessary to check whether the...

Page 12: ...draulic pump cover 15 O ring rubber seal 16 Hex head bolt 17 Speed sensor 18 Hexagon head Screw 19 flywheel shell connector plate 20 hex head bolt 21 Hex flange bolts to increase the series 22 Hex soc...

Page 13: ...y and the flywheel housing bolts are reusable twice 2 During installation a uniform sealant should be applied on the joint surface of the cylinder block and the flywheel housing and the application of...

Page 14: ...opposite of the disassembly sequence 2 5 5 Service Key point 1 Hollow bolt tightening torque 20 30 N m 2 Before assembly check if the dowel pin is defective and replace if necessary Align the locatin...

Page 15: ...ve thrust plate 2 6 4 Assembling 1 Assemble the crankshaft 2 Fit thrust plate no ears 3 Fit thrust plate 2 6 5 Service Key point Thrust piece to be used in pairs Assembly the first crankshaft into the...

Page 16: ...e the flywheel housing 4 Remove the rear oil seal 2 7 4 Assembling 1 Assemble the front cover 2 Assemble the front oil seal 3 Assembled flywheel housing 4 Assemble the rear oil seal 2 7 5 Service Key...

Page 17: ...1 valve gland 2 shoulder nut 3 cylinder head bolt 4 ignition coil bushing plate 5 ring clamping block 6 Ignition coil bushing 7 clamping block 8 bolt 9 cylinder head sub assembly 10 cylinder head gas...

Page 18: ...the cylinder for subsequent analysis of the problem 6 Remove the cylinder head gasket if the removal of multiple cylinder head gasket need to indicate the cylinder head cylinder serial number for sub...

Page 19: ...the cylinder head gasket on each hole and the cylinder on the hole alignment check the cylinder head gasket assembly is correct 3 Assembly valve stem gland 1 Valve stem gland only allowed to use once...

Page 20: ...ing block 1 Wipe the clamping block 2 Clamp block in the support surface coated with clean oil according to the disassembly position in turn mounted on the cylinder head oiled to the right amount to p...

Page 21: ...by 120 5 Then make marks on the bolts 7 Tighten the nuts of auxiliary bolts in the specified sequence by another 120 5 8 Tighten the main bolts in the specified sequence by another 120 5 9 Tightening...

Page 22: ...e the new lubricant into the tubing If the oil leakage appears in the hollow bolt you need to replace the hollow bolts combination ferrules tighten and then check for oil leakage 4 Before disassembly...

Page 23: ...let and outlet channels remove the surface area of carbon and viscose and check the surface condition 7 Check the diameter of the valve guide tube valve guide tube valve inner diameter of the contact...

Page 24: ...bolts 3 2 2 Exploded view of cylinder head cover 1 plus oil cap 2 ring 3 hex flange bolts 4 hexagonal head cap screws 5 cover 6 O rubber seal 7 cylinder head cover 8 cylinder head cover gasket Figure...

Page 25: ...nd the filler cap onto the cylinder head cover in turn 3 2 5 Cylinder head cover inspection and maintenance Key Point 1 Assembly Cylinder head cover shims should only be used once when replacement new...

Page 26: ...s separator dismantling map 3 3 3 Oil and gas separator removal steps 1 Disassemble the inlet pipe 17 the outlet pipe 20 the pre oil separator 15 of the oil gas separator the clamp of the inlet pipe 1...

Page 27: ...eliminate the impurities in the oil separator Clean up and clear If you do this the pre splitter is still not clear and you will need to replace the new pre splitter 3 You can check whether the oil se...

Page 28: ...ly Procedure Loosen and remove the lifting lugs 3 4 3 Lifting Lugs Assembly Procedure Check the lifting lugs and standoffs for any damaged threads Replace either if damage is found Tighten the lugs af...

Page 29: ...g assembly 5 Oil pump gear 6 Shock absorbers bolts 7 Gasket 8 Torsional vibration damper 9 Crankshaft pulley 10 Hex head bolt 11 Crankshaft 12 cylinder block 13 Piston rod combination group 14 Cranksh...

Page 30: ...there is crush 3 Check pulleys bolts for damage 4 1 5 Installation The reverse order of disassembly 4 1 6 Service Key point Key Point Assembly Apply a clean lubricant to the bolt threads and to the su...

Page 31: ...g gear 6 and the flywheel coupling plate 8 to the flywheel 7 and tighten the connecting bolt 9 diagonally 2 Insert the cylindrical pin 2 at the rear end of the crankshaft 1 install the crankshaft rear...

Page 32: ...aration before disassembly 1 Equipment conditions no special tooling to be prepared to mark the marker 2 Disassembly Preparation Remove the front and rear pulley and flywheel combination group remove...

Page 33: ...bearing wear 2 Check whether there is bearing metal flaking positioning lip damage and lateral cracks 4 4 Crankshaft removal and installation 4 4 1 Exploded view Figure 4 5 Exploded view 4 4 2 Prepar...

Page 34: ...llation 1 Hang the crankshaft 4 on the support Avoid knock bumps 2 Insert a cylindrical pin in the rear pin hole of the crankshaft 4 3 The oil pump gear is hot mounted on the crankshaft and supplied t...

Page 35: ...mined the friction pair be cleaned 8 Insert the top thrust plate 2 noting that the thrust plate groove faces outward toward the crankshaft Thrust piece before loading with the bearing cap surface coat...

Page 36: ...nce qualified axial clearance 0 052 0 255 mm 4 5 Piston rod group disassembly and assembly 4 5 1 Exploded view 1 Piston 2 Piston pin 3 Link body 4 Link cover 5 Connecting rod bolt 6 Trapezoidal barrel...

Page 37: ...sembly in the same manner The piston connecting rod bolts connecting rod cover number respectively in order 5 Use the retaining ring pliers carefully remove the retaining rings on both sides of the pi...

Page 38: ...tion 3 The installed piston rod components arranged in order according to the cylinder number and then the piston ring installation clamp oil ring the second gas ring the first gas ring in turn into t...

Page 39: ...e connecting rod bolt Hand Tighten Tighten first and then symmetrically with a torque of 115N m with a final rotation of 90 5 The same method to install the remaining cylinder Automatic wrench tighten...

Page 40: ...de wear is abnormal check the connecting rod bending 7 Check the bearing rod wear the alloy layer whether tile peeling slippage and so on 5 Valve train 5 1 Disassembly and assembly of Valve train 5 1...

Page 41: ...1 Remove the rocker arm and rocker arm see rocker and rocker arm disassembly steps 2 Remove the exhaust valve see the valve removal step 3 Demolition tappet and putter see tappet and putter removal s...

Page 42: ...out on the assembly bench After the disassembly of the flywheel housing is completed remove the camshaft and camshaft timing gears 5 2 3 Dismantling 1 Turn the crankshaft to check whether the camshaft...

Page 43: ...nto the camshaft hole camshaft installation is complete remove the camshaft guide tool and camshaft sleeve Be careful to injure the camshaft bushing when penetrating the camshaft 3 Install the camshaf...

Page 44: ...alve bridge 3 Cylindrical pin 4 Rocker arm assembly 5 Rocker arm assembly 6 Hex head bolt 7 Rocker bracket Figure 5 3 Exploded view 5 3 2 Preparation before disassembly 1 Equipment conditions torque w...

Page 45: ...hole on the lower side of the rocker arm bracket with the locating pin on the plane on the cylinder head and fully seat the rocker arm ball pin in the hole of the valve push rod 5 Tighten the rocker s...

Page 46: ...t diameter with the calculation of clearance 6 Check the rocker shaft combination group is worn rocker arm holder is intact without cracks no wear Point 2 Assembly Install the rocker arm assembly 4 wi...

Page 47: ...valve tappet 2 the outer surface of the cylinder and the bottom clean oil oil evenly 3 Use the tappet installation tool to install the tappet to the tappet hole the tappet and the tappet hole may not...

Page 48: ...sembly 1 Equipment conditions valve spring compressor or valve top pliers or other valve spring tool depress 2 Preparation before disassembly Rocker arm shaft removal is complete remove the cylinder h...

Page 49: ...e rod sealing sleeve internal spring is intact 5 Valve spring 5 6 loading valve spring seat depress the valve spring 5 the valve lock clip 4 7 After the valve lock clip is loaded the rubber hammer is...

Page 50: ...timing gear fuel pump gear 5 6 3 Dismantling 1 Loosen the hex head bolt 1 and remove the two hexagon head bolts 1 below the bottom 2 Remove the remaining hexagon head bolt 1 from the intermediate gea...

Page 51: ...bearing surface is crushed Point 3 Check whether each tooth flaking tooth surface broken teeth Point 4 There is abnormal wear between the middle gear shaft and middle gear bushing Whether each oil ho...

Page 52: ...utions 1 The air filter cartridge must be regularly cleaned and inspected When cleaning the air filter element gently tap the end face of the filter element on the flat plate and blow it back out of t...

Page 53: ...Disassembly steps In contrast to the assembly procedure recommended tightening torques for intake pipe bolts are 23 N m 6 2 4 Installation 1 Secure the temperature and pressure transducer 8 to the mi...

Page 54: ...use regardless of whether the gasket is defective or not as long as the disassembly are required to replace the new gasket 3 Check the temperature of the pressure sensor burnout short circuit etc if y...

Page 55: ...ort on the pump with the clamp 15 and the coolant connection hose 4 and tighten with a wrench 5 Fit the fitting 9 through the gasket 10 to the exhaust pipe and tighten with a wrench 6 3 4 Maintenance...

Page 56: ...t 11 double pipe joint 12 connecting nut 13 supercharger return pipe gasket 14 supercharger back Oil pipe assembly 15 support block 16 coolant connection hose 17 clamp 18 hexagonal flange bolt 19 supe...

Page 57: ...through the double pipe joint 11 Tighten the wrench 6 Assemble the supercharger return pipe assembly 14 to the supercharger with a hexagon socket head cap screw tighten with a wrench and the other end...

Page 58: ...ioned by the manufacturer for disassembly 6 5 Mixed intake system with the disassembly and assembly of the group 6 5 1 Exploded view 1 7 25 hexagon socket head cap screws 2 wave spring washers 3 mixed...

Page 59: ...bolt 23 Use a wrench to tighten and then use a wrench to fasten the other end 8 Connect the intake bypass valve balancing pipe to the corresponding pipe joint on the intake pipe through the clamp 9 an...

Page 60: ...stat cover 3 Seal 4 Fan tray 5 Fan drive shaft 6 Fan 7 Belt 8 Heater connector 9 Pump 10 Heater connector 11 Seal Figure 7 1 Exploded view 7 1 2 Preparation before disassembly 1 Equipment conditions S...

Page 61: ...omponents 3 Requires no sealing surface sealing 7 2 Fan dismantling and assembly 7 2 1 Exploded view 1 Fan bracket 2 Fan drive shaft 3 Hex flange bolt 4 Nut 5 Fan 6 Hex head bolt Figure 7 2 Exploded v...

Page 62: ...ck the drive shaft failure and replace the drive shaft 7 3 Pump disassembly and assembly 7 3 1 Exploded view 1 Hose connector 2 Hex flange bolts 3 Temperature sensor 4 Thermostat cover 5 Hex flange bo...

Page 63: ...3 5 Maintenance points Check whether the pump is running flexible seals are damaged if necessary to replace the new pieces 7 4 Thermostat dismantling and assembly 7 4 1 Exploded view 1 Hex flange bol...

Page 64: ...and then placed in 2 O ring fitted thermostat cover and tightened 7 4 5 Maintenance points Check thermostat and seal for damage if damaged you need to replace the new one Document Courtesy of Fly Par...

Page 65: ...eparation before disassembly 1 Equipment conditions Socket wrench 2 Disassembly Preparation None 8 1 3 Dismantling 1 Remove the oil sump and dipstick drain the oil plug and see the body group disassem...

Page 66: ...ation before disassembly 1 Equipment conditions Socket wrench 2 Disassembly Preparation Remove the oil pan 8 2 3 Dismantling Loosen the two hexagonal bolts on the strainer and remove the strainer and...

Page 67: ...ure 8 3 Exploded view 8 3 2 Preparation before disassembly 1 Equipment conditions Socket wrench 2 Disassembly Preparation Remove the oil pan oil filter 8 3 3 Dismantling 1 Loosen and remove the hex he...

Page 68: ...ne 8 4 3 Dismantling Remove the oil filter with a special tooling loosen the 4 bolts that fit the oil filter seat and remove the oil filter seat 8 4 4 Installation 1 Grind oil filter seat and the body...

Page 69: ...er check the oil cooler cover seal and the oil cooler cover to ensure that no defects and damages are created and used 2 Clean the oil cooler cover and the fuselage joint surface install the oil coole...

Page 70: ...n 1 Before installing the oil cooler check the oil cooler seal and the oil cooler to ensure that no defects and damage are created and used 2 Clean the oil cooler and fuselage junction install the oil...

Page 71: ...pport block 4 Remove the oil pan and gasket 5 Remove the magnetic plug and the composite gasket 8 7 4 Installation The installation steps are the opposite of the dismantling steps 8 7 5 Maintenance po...

Page 72: ...erica Corp 71 tightening torque is 22N m 29N m Figure 8 8 tighten the oil pan fastening bolts Document Courtesy of Fly Parts Guy Co www FlyPartsGuy com Document Courtesy of Fly Parts Guy Co www FlyPar...

Page 73: ...Figure 9 1 Exploded view 9 1 2 Dismantling 1 Remove the starter 2 Remove the ring gear 9 1 3 Installation The starting system assembly procedure is the opposite of the starting system disassembly pro...

Page 74: ...before disassembly Equipment conditions Spark plug special wrench sleeve 10 1 3 Dismantling 1 Remove the ignition coil mounting screw 2 Pull out the ignition coil along the axis the ignition coil cann...

Page 75: ...mm the gap between each cylinder should be the same if necessary replace Note If the spark plug gap is too large first plug into the gap gently wrench with a small wrench corner of the side electrode...

Page 76: ...pump mounting flange bolts the signal generator and fuel pump flange overall removal 2 Remove the timing gear fixing nut and separate the timing gear from the signal generator 3 Remove the signal gen...

Page 77: ...hat the TDC scale line alignment with the speed sensor centerline Figure 10 4 Slotted signal generator tooth plate diagram 6 Install the cover and tighten the hexagon socket head cap screws M6 tighten...

Page 78: ...Figure 10 5 Exploded view 10 3 2 Preparation before disassembly Equipment conditions pneumatic wrench sleeve 10 3 3 Dismantling 1 Then disassemble the hexagon socket head cap screws on the ECU 2 Remo...

Page 79: ...pad 6 tee adapter 7 clamp 8 bolt 9 gasket 10 Nut 11 LPG electromagnetic shut off valve 12 LPG evaporator 13 Water pipe joint 14 Clamp 15 Pipe joint 16 Nut 17 Bolt 18 Gas pipe 19 Clamp 20 Hexagon socke...

Page 80: ...air connections on the LPG evaporator 10 4 4 Installation The assembly procedure is the opposite of the disassembly procedure 10 4 5 Maintenance points 1 After disassembly and installation you need to...

Page 81: ...33 hex Flange bolt 34 hexagonal flange nut 35 hexagonal flange bolt Figure 10 7 NG Exploded view 10 5 2 Preparation before disassembly 1 Equipment conditions pneumatic wrench sleeve 2 Preparation bef...

Page 82: ...remove the mixer bracket 12 Remove the fixing bolt between the transition bracket and the flywheel housing and remove the transition bracket 10 5 4 Installation The assembly procedure is the opposite...

Page 83: ...4 8 Piston ring s gap in cold state The first top ring 0 35 0 5 The second ring 0 5 0 7 Oil ring 0 2 0 7 9 Piston ring end face gap in cold state The first top ring 0 11 0 16 The second ring 0 06 0 1...

Page 84: ...ichai America Corp 3100 Golf Road Rolling Meadows IL 60008 http www WeichaiAmerica com Document Courtesy of Fly Parts Guy Co www FlyPartsGuy com Document Courtesy of Fly Parts Guy Co www FlyPartsGuy c...

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