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WEICHAI WP6GTA, Assembly/Disassembly Manual

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WEICHAI WP6GTA Assembly/Disassembly Manual Download Page 2

Weichai America Corp.       

 

1 

 

Purpose

 

 

This manual is intended to inform customers on how to assemble and disassemble the Weichai America 
6 Liters turbocharged engine. This document will be provided to customer so they can incorporate this 
information into their manuals and service documents. 

 

Maintenance Providers

 

 

Maintenance and repair services may be performed by you or any qualified engine service 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  Manual  and  Maintenance  Records  in  a  safe,  visible  place  by  your  engine.  The 
maintenance log must be updated whenever your engine is serviced. If repairs are being done under 
warranty be sure to follow proper warranty procedures. (see Weichai America Corp Warranty Procedure 
Manual) 

 

 

Summary of Contents for WP6GTA

Page 1: ...Assembly Disassembly Manual Gas Engine Model WP6GTA WEICHAI AMERICA CORP ...

Page 2: ...rvices may be performed by you or any qualified engine service 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 Manual and Maintenance Records in a safe visible place by your engine The maintenance log must be updated whenever your engine is serviced If ...

Page 3: ...7 2 8 Assembly and disassembly of oil sump 20 2 9 Cylinder Heads Assembly and Disassembly 21 2 10 Cylinder Head Cover Assembly and Disassembly 25 2 11 Lifting Lugs Assembly and Disassembly 26 2 12 CCV Breather System Assembly and Disassembly 27 2 13 CCV Breather Assembly and Disassembly 29 3 Crank rod mechanism 30 3 1 Assembly and disassembly of crank rod mechanism 30 3 2 Assembly and disassembly ...

Page 4: ...sembly and Disassembly 62 7 Fuel System 64 7 1 Fuel System Assembly and Disassembly 64 7 2 Mix air Intake System Assembly and Disassembly 66 7 3 NG Gas Supply And Gas Flow Control Valve EPR Valve Assembly And Disassembly 68 8 Cooling System 70 8 1 Cooling System Disassembly and Assembly 70 8 2 Water Pump Assembly and Disassembly 71 8 3 Thermostat Disassembly and Assembly 72 9 Lubrication System 74...

Page 5: ...rica Corp 4 10 Starting System 80 10 1 Starting System Assembly and Disassembly 80 11 Engine Accessory System 81 11 1 Engine Accessory System Assembly and Disassembly 81 11 2 Alternator Assembly and Disassembly 82 ...

Page 6: ...e personnel Any violation of instructions in this manual may 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 the following precautions before using a lockout tool and beginning maintenance or repair Ensure the maintenance site and surrounding area are ...

Page 7: ...ploded view of engine block assembly Fig 2 1 Exploded view of engine block assembly No name No name No name 1 Engine block 11 Rivet 21 Plug 2 Pin 12 shaft 22 Rivet 3 Cup plug 13 Camshaft bushing 23 Stud 4 Camshaft bushing 14 Camshaft bushing 24 Cup plug 5 Cylinder liner 15 Pin 25 Dipstick 6 O seal ring 16 Plug ...

Page 8: ... assembly Key point 1 Inspection 1 Measure the protrusion of cylinder sleeve 0 05mm 0 10mm is qualified Note that protrusion of cylinder sleeve is average value of X direction and Y direction and the measurement should be done without seal rings Cylinder sleeve for the same engine should be uniform 2 No corrosion scratch and crash damage is allowed for fitting surface and friction surface wipe the...

Page 9: ...p iron Assembling Apply oil on engine block hole put camshaft sleeve into the dedicated tool and guide it into engine block in the meantime align oil gallery holes on the sleeve and engine block Key point 3 Assembly Install the greased seal ring to the welded elbow insert the elbow into the corresponding hole and fix it on the engine block by using a fixing plate hexagon socket bolts and spring wa...

Page 10: ...not limited to Assembly environment must be clean check engine block finished surfaces for crash damage scratch and rust do not bump and scratch the parts during assembling and besides special requirements sharp corner and edge on parts must be smoothed Assembling For 6 cylinder engine 14 M14 10 9 main bearing bolts are used to fix the bearings As shown in Fig 2 3 start with middle bearings do the...

Page 11: ...ring cap for a proper positioning and if the bearing cap is reversed the main bearing bolt cannot be mounted 2 3 Gear Housing Assembly and Disassembly 2 3 1 Gear Housing Exploded View Fig 2 4 Exploded view of Gear Housing No name No name No name 1 Front end cover 4 washer 7 bolt 2 bolt 5 bolt 3 bolt 6 bolt 2 3 2 Gear Housing Disassembly Procedure 1 Remove the intermediate gear 2 Remove the front c...

Page 12: ... the gear housing to ensure that it is clean and without any damage or burrs on the fitting surface Check the O Rings to ensure that they are in good condition Replace the O Rings if necessary Assembling 1 Knock the locating pins into place as shown in the figure below Fig 2 5 Locating pin installation for Gear Housing 2 Apply sealant on the sealing surface of the Gear Housing Ensure that the seal...

Page 13: ...ignment pins in the pin holes Knock the cover edge gently with a nylon rod such that the cover and engine block can fit together closely Fig 2 7 Gear Housing installation 4 Place the bolts with gaskets in their corresponding holes Tighten them with a pneumatic impact wrench and an open end wrench ...

Page 14: ... no damage or dirt For a tight seal apply some clean engine oil on the shaft first and then press the seal in slowly with the dedicated tool ensuring that the pressing force is evenly distributed on the seal Disassembling The removed oil seal cannot be reused replace it with a new one 2 4 Assembly and disassembly of piston nozzle 2 4 1 Exploded view of piston nozzle ...

Page 15: ...e piston nozzle key point 2 2 4 3 Steps to assemble piston nozzle Assembling steps are contrary to disassembling ones 2 4 4 Inspection and maintenance of piston nozzle Key point 1 Assembling 1 Compress nozzle module tightly with bolt with spring washer and pressing plate 2 Place the pressing plate in nozzle end face groove 3 Bolts tightening Key point 2 ...

Page 16: ...efer to disassemble engine block module steps 2 Remove crankshaft refer to disassemble crankshaft steps 3 Remove thrust plates key point 1 2 5 3 Inspection and maintenance of thrust plates Key point 1 Assembling Thrust plate should be used in pairs and the side with oil groove should be outward during assembling Put the anti miss loading lug in corresponding groove of thrust bearing cap 2 6 Assemb...

Page 17: ...ar oil seal key point 2 2 6 3 Steps to assemble front and rear oil seal Assembling steps are contrary to disassembling ones 2 6 4 Inspection and maintenance of engine front and rear oil seal Key point 1 Inspection Check whether the junction surface between rear oil seal cover and engine body is cleaning or knocking wound Assembling 1 Clean the junction surface and install 2 pins into engine body 2...

Page 18: ...ked before assembling make sure there is no damage Check whether rear oil seal cover is clean and whether its finished surface is free of obvious scratch Assembling Apply sealant on the rear oil seal outer ring first and then press in the seal slowly with dedicated tool NOTICE Do not damage the seal during assembling and seal outer ring should be parallel and level to oil seal cap plane 2 7 Assemb...

Page 19: ...wheel housing 6 bolt 9 plug 2 7 2 Steps to disassemble flywheel housing 1 Remove fixing bolts of flywheel housing Key point 1 2 Remove speed sensor 3 Remove fixing bolts of monitoring window cap on flywheel housing take down the cap 4 Remove flywheel housing key point 2 2 7 3 Steps to assemble flywheel housing Assembling steps are contrary to disassembling ones ...

Page 20: ...s and tools M10 10 9 hexagon bolts 12 M12 10 9 hexagon bolts 6 17mm and 19mm socket spanner Step 1 Preassemble the bolts Step 2 Follow the sequence of arrow to tighten the M10 bolts tighten torque for M10 bolts is 80 85Nm And then tighten the M12 bolts according to the marked order 1 2 3 4 5 6 tighten torque for M12 bolts is 140 145Nm Fig 2 14 tightening sequence of flywheel housing NOTICE For the...

Page 21: ...4 Remove the combination gasket and magnetic screw plug assembly 2 8 3 Steps to assemble oil sump Assembling steps are contrary to disassembling ones 2 8 4 Inspection and maintenance of oil sump Key point 1 Disassembling Before the disassembling all engine oil should be drained out Put an engine oil container under drain screw plug of oil sump screw off the plug with a plug wrench to drain oil out...

Page 22: ... fitting surface 3 Place bolts and gaskets and tighten the bolts with pneumatic impact wrench to 20 35 5Nm 2 9 Cylinder Heads Assembly and Disassembly 2 9 1 Cylinder Heads Exploded View Fig 2 16 Exploded view of cylinder heads No name No name No name 1 Cylinder head gasket 3 Seal washer of valve stem 2 Cylinder head 4 Cylinder head bolt 2 9 2 Cylinder Heads Disassembly Procedure 1 Loosen the cylin...

Page 23: ... reference 4 Remove the intake and exhaust valve module Refer to disassembly of valve mechanism for details 5 Remove the valve seal Valve seals can t be reused 2 9 3 Cylinder Heads Assembly Procedure 1 Insert the seal valve into the valve guide pipe 2 Install the intake valve and exhaust valve onto the cylinder head 3 Install new cylinder head gaskets Cylinder head gaskets can not be reused 4 Asse...

Page 24: ...e and exhaust passages Remove the carbon deposits and mucilage glue and check the surface condition 1 Appearance Inspection Check the cylinder cover for any discoloration or cracks If any cracks are discovered a leak test should be done 2 Valve Recession Valve recession is the vertical distance between valve undersurface and cylinder cover undersurface Any difference between the measured and requi...

Page 25: ...od and valve guide pipe Internal surface of valve guide pipe is the contacting surface between valve rod and valve guide pipe if clearance between valve rod and valve guide pipe exceeds allowed value due to abrasion then the guide effect will at state which may affect reliability of the engine The inner diameter of guide pipe can be measured with an inside micrometer as shown in Fig 2 19 Outer dia...

Page 26: ...bly and Disassembly 2 10 1 Cylinder Head Cover Exploded View Fig 2 20 Exploded view of cylinder head cover No name No name 1 bolt 3 Cylinder head cover 2 washer 4 Cylinder head cover gasket 2 10 2 Cylinder Head Cover Disassembly Procedure 1 Loosen the cylinder head cover bolts Remove the bolts and the washers 2 Pull the covers up vertically to remove them Remove all gaskets 2 10 3 Cylinder Head Co...

Page 27: ... Maintenance Key point 1 Assembling Cylinder head cover gaskets are disposable and should be replaced during maintenance Key point 2 Inspection 1 Check the covers for any cracks or other damage Replace if damaged 2 If there is leakage through the cylinder head cover gaskets then all gaskets should be checked and replaced 2 11 Lifting Lugs Assembly and Disassembly 2 11 1 Lifting Lugs Exploded View ...

Page 28: ... Procedure Check the lifting lugs and standoffs for any damaged threads Replace either if damage is found Tighten the lugs after installing them 2 12 CCV Breather System Assembly and Disassembly 2 12 1 CCV Breather System Exploded View Fig 2 22 Exploded view of CCV breather system No name No name No name 1 Clamp 11 clamp 21 bolt ...

Page 29: ... the clamps on the air inlet Remove all air inlet formed and rubber hoses 4 Loosen the bolts fixing the breather to the breather bracket Remove the breather completely 5 Loosen the bolts fixing the breather bracket to the engine block Remove the breather bracket 6 Remove the bypass port from the engine block Remove the bypass port bolt washer and O ring 2 12 3 CCV Breather System Assembly Procedur...

Page 30: ...Breather Exploded View Fig 2 23 Exploded view of CCV breather Fig 2 24Schematic diagram of disassembly 2 13 2 CCV Breather Disassembly Open the top cover of the breather by tool or hand Remove the breather filter element 2 13 3 CCV Breather Assembly 1 Clean the inside of the breather Insert a new breather filter element 2 Screw the top cover back onto the breather 4 2 13 4 CCV Breather Inspection ...

Page 31: ...g rod bolts and cap Rotate the flywheel until the to be removed piston is in TDC knock the piston out with wooden hammer proceed with caution to avoid jamming cylinder block with connecting rod tip Remover other pistons in the same way number and place them orderly 2 Screw off fastening bolts of torque vibration damper and fastening bolts of hub take down crankshaft pulley torque vibration damper ...

Page 32: ...d clean up scraped foreign matters The bearing shell should be strictly inspected for bump damage before assembling and shell with bump damage should not be reused even if repaired The assembled upper bearing shell should be aligned to oil hole and oil groove on cylinder body misalignment exceeds 1 5 1 4 of oil hole is strictly forbidden The assembled upper bearing shell should be closely fit with...

Page 33: ... bearing surface and main bearing bolt thread Place main bearing bolts and pre tighten them according to the order shown in Figure below Firstly pre tighten to 70Nm and then tighten each bolt for another 90 4 Assembly of crank shaft is finished Fig 3 3 Tighten order of main bearing bolts 3 2 4 Inspection and maintenance of crankshaft system 1 Check whether there is crack on fillet area of cranksha...

Page 34: ...disassemble crankshaft bearing shell Push the shells out with hand and mark the removed shells should be corresponded with holes on engine block and crankcase 3 3 3 Steps to assemble crankshaft bearing shell 1 Clean up main bearing shells and the fitting holes 2 If no shell is replaced then install the two shells into engine block upper and crankcase lower respectively pay attention to the mark sh...

Page 35: ...f flywheel and ring gear Fig 3 5 Exploded view of flywheel and ring gear 3 4 2 Steps to disassemble flywheel and ring gear Disassembling steps are contrary to assembling ones 3 4 3 Steps to assemble flywheel and ring gear 1 Fix the flywheel ring gear on flywheel with bolts 2 Knock the pin into crankshaft rear end fully 3 After inserting flywheel guide rod into crankshaft threaded hole install flyw...

Page 36: ...ance of flywheel and ring gear 1 Check whether there is failure like thread damage on flywheel bolts 2 Check flywheel surface for conquassation 3 Check whether flywheel ring gear is damaged 3 5 Assembly and disassembly of piston rod assembly 3 5 1 Exploded view of piston rod assembly Fig 3 6 Schematic diagram of piston rod assembly ...

Page 37: ...the flywheel until the to be removed piston is in TDC knock the piston out with wooden hammer proceed with caution to avoid jamming cylinder block with connecting rod tip 4 Remover other pistons in the same way number and place them orderly 5 Remove circlip on two sides of piston with internal circlip plier and push piston pin out take down the connecting rod body Number the piston pins connecting...

Page 38: ...linder number order and then install oil ring second compression ring and first compression ring into piston ring grooves orderly with piston ring plier The face with mark TOP should be upward and the ring should be flexible in ring groove 4 Clean up cylinder inner wall crankshaft connecting lever and piston rod assembly and apply clean lubricating oil on each motion pair 5 Adjust opening directio...

Page 39: ...embly 1 Check whether there is crack on combustor throat fillet and piston pin boss Check piston skirt and piston head for cylinder scoring phenomenon Check wear condition of piston pin hole 2 Check wear condition of piston ring outer edge Check wear condition of piston ring upper and lower end face 3 Check wear condition of piston pin external surface 4 Check whether there is crack on connecting ...

Page 40: ...ication M16 12 9 4 Tightening torque 300 310Nm Test value 300 360Nm 2 Fix the crankshaft belt pulley and torsional vibration damper on the crankshaft hub with the torsional vibration damper fastening bolts Torsional vibration damper fastening bolts Bolt specification M10 10 9 6 Tightening torque 65 70Nm Test value 65 80Nm 3 6 4 Inspection and maintenance of crankshaft system 1 Check whether there ...

Page 41: ...ve train 1 Remove the rocker arm and the rocker arm shaft 2 Remove the intake exhaust valve 3 Remove the tappet and the push rod 4 Remove the camshaft and the camshaft timing gear 5 Remove the intermediate gear 4 1 3 Assembling steps of valve mechanism Assemble the valve train with the reverse order of disassembly 4 2 Assembly and disassembly of camshaft 4 2 1 Exploded view of camshaft ...

Page 42: ...gine oil on camshaft hole and tappet hole inner surface Install camshaft do not damage camshaft surface and engine block hole during the push in process of camshaft and the push in strength should be equally the end with thread should be on gear housing side 4 Install sector plate tightening torque of bolts should be 35 10Nm seal up the bolts with lacquer 5 Install gaskets flange washers and hexag...

Page 43: ...ming gear fixing bolts with pneumatic impact wrench and pre tighten connecting bolts between camshaft timing gear and fuel injection pump driven gear Tighten the bolts with torque spanner tightening torque for M10 bolts 85 90Nm tightening torque for M8 bolts 55 60 5Nm seal up the bolts with lacquer after tightening Rotate crankshaft to check whether 0 tick of each gear is normally engaged 4 2 4 In...

Page 44: ...the four M10 bolts to be removed 2 Remove four bolts and the washer 3 Insert a M8 bolt into the pin shaft Pull the pin shaft out along this bolt Take care to ensure that the intermediate gear does not slide off and get damaged 4 3 3 Intermediate Gear Assembly Procedure 1 Assemble the front cover according to the front cover assembly procedure 4 3 2 2 Assemble the intermediate gear Apply oil on the...

Page 45: ...s Check the clearance and ensure the gear turns smoothly 4 3 4 Intermediate Gear Inspection and Maintenance 1 Check the bolts to ensure that they are threaded and tightened properly 2 Check the tooth of the gear for any damage or sapling 3 Check the intermediate shaft and the interface between the intermediate shaft and the bushing or pin shaft for any wear Check the oil passage for any blockage 4...

Page 46: ...ean lubricating oil evenly onto the engine block tappet fitting hole and valve tappet fitting surface 3 Install the valve tappet into the engine block tappet fitting hole The tappet should rotate freely in the hole Install the camshaft refer to camshaft assembly 11 9 3 for details 4 Loosely fit the rocker seat onto the cylinder cover Check to ensure that the pushrod is clean and the welding area i...

Page 47: ...t worn 4 5 Assembly and disassembly of valve 4 5 1 Exploded view of valve Fig 4 7 Exploded view of valve 4 5 2 Steps to disassemble valve 1 Depress valve springs with vale spring compressor or valve overhead plier or other tools take out valve lock clamp upper valve spring seat and lower valve spring seat and valve springs orderly 2 Take valve out of valve seat 4 5 3 Steps to assemble valve 1 A va...

Page 48: ...stall valve lock clamp 4 Knock the valve with rubber hammer to settle the lock clamp if the valve lock clamp or upper valve spring seat cannot be settled please find out the cause and eliminate it 4 5 4 Inspection and maintenance of valve 1 Check whether valve rod and its end faces are worn 2 Check whether valve conical surface is worn or damaged 3 Check valve conical surface and retainer end face...

Page 49: ...clip butterfly spring washer rocker and the other butterfly spring washer Mark the items to prevent improper assembly 4 6 3 Rocker and Rocker Shaft Assembly Procedure 1 Check whether all to be assembled pars are clean free of bump damage scratch and rust 2 Install rocker adjusting screw and lock nut the screw should be fully screwed in while the lock nut only needs to be screwed in for 2 3 thread ...

Page 50: ...of intake valve is finished Exhaust valve adjustment firstly fill in a 0 3mm plug gauge and tighten the nuts with torque spanner to 20 5Nm pull out the gauge make sure the gauge can be easily pulled out and check the clearance with a 0 35mm plug gauge make sure the gauge cannot get through adjusting of exhaust valve is finished 2 Further rotate crankshaft until phase pointer points at 0 tick on ph...

Page 51: ...ose 2 Remove the hex bolts bolting the air filter to the air filter bracket Remove the air filter 3 Remove the socket head bolts bolting the throttle adapter to the mixer Remove the mixer Note If the EPR has not been removed remove the hex bolts bolting the EPR to the mixer 4 Remove the nut and bolt bolting the intake elbow to the throttle and throttle adapter Remove the throttle adapter and throt...

Page 52: ...Remove the bolts bolting the intake manifold to the engine block Remove the intake manifold cover plates and gaskets See details in Intake Manifold Assembly and Disassembly 5 1 3 Intake and Exhaust System Assembly Procedure Reverse the Disassembly Procedure to assemble the Intake and Exhaust System 5 2 Intake Manifold Assembly and Disassembly 5 2 1 Intake Manifold Exploded View Fig 5 2 Exploded vi...

Page 53: ... 4 Remove the air intake elbow and the gasket 5 loosen the fastening bolt remove the air intake pipe 6 Remove the air intake pipe cover 5 2 3 Intake Manifold Assembly Reverse the Disassembly Procedure to assemble the intake pipe Recommended tightening torque for the nuts bolting the intake pipe to the engine block is 23Nm 5 2 4 Intake Manifold Inspection and Maintenance 1 Check the intake manifold...

Page 54: ...of the exhaust manifold and exhaust elbow will be extremely hot after engine operation 1 Remove the heat shield bolts and the heat shield 2 Untie the exhaust elbow insulation ties Remove the exhaust elbow insulation with the ties 3 Remove the nuts bolting the exhaust elbow to the exhaust manifold Remove the exhaust elbow and gasket 4 Remove the nuts bolting the exhaust manifold to the engine block...

Page 55: ...n twice 5 3 4 Exhaust Manifold Inspection and Maintenance 1 Check for cracks in the exhaust manifold and deformations in the exhaust elbow flange Replace the exhaust manifold and exhaust elbow if necessary 2 Check the exhaust elbow flange for any air leakage Replace the exhaust elbow gasket if necessary 3 Check exhaust elbow gasket for any deformation tearing or deficiencies Replace it if necessar...

Page 56: ... maintenance of turbocharger system 1 Check the running of rotor Turn the air compressor stator with hand if it rotates for more than one turn it indicates that it is normal if it stops rotating soon it indicates that the bearing is worn abnormally or there is interference between the moving part and the fixed part or the moving part is blocked in this case you shall find out the causes and elimin...

Page 57: ...peller by hand in the radial direction and use the feeler gauge to measure the min max clearances between the compressor impeller and compressor casing as shown in figure5 6 The value shall be in the range of 0 4 0 8mm if this value is exceeded check the bearing and eliminate the failures Note Measurement shall be carried out at cold state ...

Page 58: ...ine connecting of turbocharger and engine for looseness if any eliminate it 2 Check the turbocharger for air and oil leakage if any eliminate it 3 Check the turbocharger tightening screw for looseness if any eliminate it 4 Check the air filter if excessive dust is found clean it without delay ...

Page 59: ...ssembly 6 1 1 Ignition System Exploded View Fig 6 1 Exploded view of ignition system No name No name No name 1 bolt 4 sparking plug 7 ignition coil seat 2 washer 5 bolt 3 ignition coil 6 washer 6 1 2 Ignition System Disassembly Steps 1 Remove the install bolt of the ignition coil ...

Page 60: ...all raise the gap with a small vise then place the feeler in the gap then tap the electrode with a small wrench When adjusting the clearance ensure that the side electrode is parallel to the center electrode 3 Tighten the sparking plug with the sparking plug wrench after adjusting clearance 4 Place the ignition coil and tighten the bolt of the ignition coil 6 1 4 Ignition System Inspection and Mai...

Page 61: ...eichai America Corp 60 Fig 6 2 Exploded view of signal generator No name No name No name 1 nut 4 Signal generator 7 timing gear 2 washer 5 speed sensor 8 clamp plate 3 stud 6 Hexagon bolt 9 hexagon bolt ...

Page 62: ...stud 3 into the gear house 3 Make sure that the O ring in the gear house is good 4 Install the signal generator 4 into the gear house tighten the nut 1 5 Install the timing gear 7 into the signal generator 4 tighten the screw 9 6 2 4 Signal Generator Disc Adjust Procedure 1 Adjust the crankshaft to TDC the first cylinder piston should be in its compression stroke Tighten the connecting bolts betwe...

Page 63: ...6 3 Engine Control Unit ECU Assembly and Disassembly 6 3 1 ECU Exploded View Fig 6 4 Exploded view of ECU No name No name No name 1 inner hexagon screw 3 nut 5 clamp plate 2 washer 4 washer 6 nut 6 3 2 ECU Disassembly Procedure 1 Remove the fuse box bolts Remove the fuse box from the bracket 2 Remove the Harness ECU Connection from the ECU 3 Remove the ECU bolts Remove the ECU from the bracket 6 3...

Page 64: ...n and Maintenance of ECU 1 Check to see if any ECU connection pins are corroded bent broken missing or damaged Replace the pins if necessary 2 Check the plastic portion of the ECU connection for damage Replace the ECU if there is any damage ...

Page 65: ...nterface diagram Fig 7 1 fuel system interface diagram 7 1 2 LPG Intake System Exploded View air filter joint pipe inlet bypass valve interface turbocharger inlet pipe oil gas separator joint pipe NG joint pipe water return joint pipe LPG joint pipe mixer air inlet joint pipe water outlet interface ...

Page 66: ... bolt 22 cushion 3 gas tube 13 nut 23 cushion 4 nut 14 joint 24 bolt 5 pipe clamp 15 solenoid valve 25 bolt 6 pipe clamp bracket 16 water joint 26 gas joint 7 nut 17 joint 27 O ring 8 bolt 18 plug 28 bolt 9 holder 19 bolt 29 hose 10 cushion 20 LPG EPR 30 clamp 7 1 3 LPG Intake System Disassembly Procedure 1 Remove the clamp 30 ...

Page 67: ... LPG evaporator and the bracket 6 Change the spare parts which need be changed 7 Remove the bolt 1 8 Remove the gas pipe 3 7 1 4 LPG Intake System Assembly Procedure Reverse the disassembly procedure to assemble the LPG supply system 7 2 Mix air Intake System Assembly and Disassembly 7 2 1 Mix air Intake System Exploded View ...

Page 68: ...lbow 2 hose 9 air intake joint 16 clamp 3 clamp 10 mixer 17 bolt 4 bracket 11 bolt 18 hose 5 mix intake pipe 12 bolt 19 joint 6 air intake joint pipe 13 bracket 7 gasket 14 nut 7 2 2 Mix Air Intake System Disassembly Procedure 1 Remove the clamp 1 2 Remove the clamp 3 3 Remove the clamp 16 4 Remove the hose 2 hose 18 ...

Page 69: ...he mixer 10 10 Remove the bolt 11 bolt 12 11 Remove the bracket 8 bracket 13 7 2 3 Mix Air Intake System Assembly Procedure Reverse the disassembly procedure to assemble the mix air intake system 7 3 NG Gas Supply And Gas Flow Control Valve EPR Valve Assembly And Disassembly 7 3 1 NG Gas Supply And Gas Flow Control Valve EPR Valve Exploded View Fig 7 4 Exploded view of NG gas supply and gas flow c...

Page 70: ...bolt 11 9 Remove the electromagnetic valve 10 10 Remove the bolt 12 11 Take the bracket 13 7 3 3 NG Gas Supply And Gas Flow Control Valve EPR Valve Assembly Procedure Reverse the disassembly procedure to assemble the NG gas supply and gas flow control valve EPR valve 7 3 4 Fuel System Inspection and Maintenance 1 Change the gasket and O ring after disassembling 2 Check the joint and clamp make sur...

Page 71: ... within the normal operating temperature range The cooling system primarily consists of the water pump fan expansion water tank water tank and thermostat Fig 8 1 Exploded view of cooling system No name No name No name 1 radiator 4 Water pump 7 Intermediate plate 2 fan 5 Thermostat 3 Fan bracket 6 Water input pipe 8 1 2 Cooling System Disassembly Procedure 1 Remove the water tank 2 Remove the fan 3...

Page 72: ... Assembly and Disassembly 8 2 1 Water Pump Exploded View Fig 8 2 Exploded view of water pump No name No name No name 1 Hexagon bolt 3 Water pump washer 5 Intermediate plate 2 Water pump 4 Hexagon bolt 6 Water pump washer 8 2 2 Water Pump Disassembly Procedure 1 Remove the water pump pulley 2 Remove thermostat connecting hose and clamps 3 Remove the hexagon bolts on the pump 4 Remove water pump gas...

Page 73: ...and middle cushion block for cracks Replace them if necessary 8 3 Thermostat Disassembly and Assembly 8 3 1 Thermostat Exploded View Fig 8 3 Exploded view of thermostat 8 3 2 Thermostat Disassembly Procedure 1 Loosen the clamps around the hose connecting the water pipe and thermostat Remove the hose 2 Loosen the clamps around the hose connecting the thermostat and water pump Remove the hose and th...

Page 74: ...f necessary 4 8 4 Fan Assembly and Disassembly 4 8 4 1 Fan Exploded View Fig 8 4 Exploded view of fan 8 4 2 Fan Disassembly Procedure 1 Loosen the six fixing bolts on the fan Remove the bolts washers and fan 2 Loosen the bolts connection the flange to the spacer block Remove the bolts washers flange and spacer block 8 4 3 Fan Assembly Procedure 1 Prior to assembly check the fan flange and fastenin...

Page 75: ...racks or damage Replace if necessary 9 Lubrication System 9 1 Disassembly and Assembly of Lubricating System 9 1 1 Exploded View of Lubricating System Fig 9 1 Exploded view of lubricating system 9 1 2 Steps to Disassemble Lubricating System 1 Remove oil sump refer to disassembly of oil sump for details 2 Remove gearbox refer to disassembly of gearbox for details oil pan oil pump oil strainer oil c...

Page 76: ...d self locking nut take down engine oil pump as shown in Fig 9 2 3 Steps to Assemble Engine Oil Pump 1 Check the pump before assembling make sure there is no manufacturing defect and damage 2 Clean up the fitting surface between oil pump and engine block 3 Install engine oil pump 4 Install and tighten the two toothed hexagon bolts and self locking nut 9 2 4 Inspection and Maintenance of Engine Oil...

Page 77: ...s to Assemble Engine Oil Filter 1 Check the O shape seal ring of engine oil filter before assembling make sure there is no manufacturing defect and damage replace the O ring if necessary 2 Tighten the filter according to the requirements on filter cap 9 3 4 Inspection and Maintenance of Engine Oil Filter Check the engine oil filter assembly for damage replace it if necessary 9 4 Disassembly and As...

Page 78: ...nd damage 2 Clean up the fitting surface between engine oil cooler and filter seat 3 Install engine oil cooler and the connecting thread sleeve tighten it 9 4 4 Inspection and Maintenance of Engine Oil Cooler Check the engine oil cooler for crack damage replace it if necessary Check whether the oil cooler bypass valve has sluggish phenomenon replace it if necessary 9 5 Disassembly and Assembly of ...

Page 79: ...ng make sure there is no manufacturing defect and damage 2 Clean up the pressure limiting valve and pressure limiting valve fitting hole on the module 3 Install the valve and tighten it 9 5 4 Inspection and Maintenance of Main Oil Gallery Pressure Limiting Valve 1 Check service condition of the valve spring replace the spring if necessary 2 Check the valve for crack damage replace it if necessary ...

Page 80: ...embling make sure there is no manufacturing defect and damage 2 Clean up the pressure limiting valve and pressure limiting valve fitting hole on the module 3 Install the valve and tighten it 9 6 4 Inspection and Maintenance of Deputy Oil Pressure Limiting Valve 1 Check service condition of the valve spring replace the spring if necessary 2 Check the valve for crack damage replace it if necessary 9...

Page 81: ...at the same time 2 Clean up the oil supply hole of oil pump and the strainer inner cavity 3 Install the strainer 4 Assemble and tighten the two hexagon flange bolts and the 2 type hexagon nuts 9 7 4 Inspection and Maintenance of Engine Oil Strainer Check the strainer for crack damage replace it if necessary 10 Starting System 10 1 Starting System Assembly and Disassembly 10 1 1 Starting System Exp...

Page 82: ...r motor firmly and pull it out from the flywheel housing Caution The starter motor is heavy so maintain a very firm grip before pulling 10 1 3 Starting System Assembly Procedure Reverse the Disassembly Procedure to assemble the Starting System 10 1 4 Inspection and Maintenance of Starting System 1 Check the starter motor gear for damage replace it if necessary 2 Check the starter wiring to ensure ...

Page 83: ...Alternator Assembly and Disassembly for details 2 Remove the alternator bracket and bolts 11 1 3 Engine Accessory System Assembly Reverse the Disassembly Procedure to assemble the Engine Accessory System 11 2 Alternator Assembly and Disassembly 11 2 1 Alternator Exploded View Alternator parts include the alternator alternator bracket tension bolts corresponding attachment bolts washers and nuts as...

Page 84: ...ternator 3 Remove all bolts bolting the alternator to the bracket Remove the alternator from its bracket 4 Remove the four hex bolts bolting the alternator bracket to the engine block Remove the alternator bracket from the engine block 11 2 3 Alternator Assembly Procedure Reverse the Disassembly Procedure to assemble the Alternator 11 2 4 Fault diagnosis and maintenance of alternator 1 Fault diagn...

Page 85: ... the vehicle and connect the test lamp to the terminal B and E negative pole of the alternator Is the test lamp ON Connect the wire from terminal E to terminal D of the alternator Is the test lamp light ON Start the engine Is the test lamp light ON The alternator is trouble free Alternator malfunction It indicates that the internal electric circuit of wiring terminal D of the alternator is malfunc...

Page 86: ... to battery for looseness or battery damage Recommended testing method bridge a 2W indicator lamp between alternator output B and excitation terminal D L and check its working condition Troubleshooting a With normal brightness the indicator lamp goes out after starting engine and alternator output voltage is 27 28 5 V vehicle excitation circuit has failed and requires to be reconditioned b With no...

Page 87: ...formed or if it have fall into pulley groove bottom replace it timely b Retighten alternator and related belts Notice If the system is drove by dual belt then two belts shall be replaced simultaneously d Check alternator pulley Tighten if it is loose e Check whether the lead is used properly and test the voltages at alternator and battery terminals a In case of voltage difference more than 1V big ...

Page 88: ...r voltmeter calibration value error and repair or replacement is required b Check the charging system wires and joints and check if the terminal stud is loosened virtual connected and overheated and if the wire is shorted to alternator housing a In case of poor contact retighten loosened connection and reinsert connector into place b In case of short circuit reconnect the wires c Check whether bat...

Page 89: ...electric brush and its spring d Regulator damaged Replace the regulator e Abnormal noise from alternator Failure 5 Abnormal noise from alternator Vehicle fault Fault testing Troubleshooting Alternator sounds abnormally during its running a Deformed alternator mounting bracket or getting too close with external engine body Improve the mounting bracket strength and adjust mounting condition b Altern...

Page 90: ...Weichai America Corp 3100 Golf Road Rolling Meadows IL 60008 http www WeichaiAmerica com ...

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