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Assembly & Disassembly Manual

Gas Engine

Model: WP10GTA

WEICHAI AMERICA CORP.

WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM

GET YOUR WEICHAI & AFTERMARKET SERVICE PARTS AT FLYPARTSGUY.COM

Содержание WP10GTA

Страница 1: ...Assembly Disassembly Manual Gas Engine Model WP10GTA WEICHAI AMERICA CORP WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM...

Страница 2: ...ider 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 an...

Страница 3: ...10 Disassembly and Assembly of Cylinder Head Cover 29 2 11 Disassembly Overhaul and Assembly of Hoisting Rings of Engine 30 2 12 Disassembly and Assembly of Oil gas Separator 31 3 Crank Connecting Ro...

Страница 4: ...3 7 2 Mix air Intake System Assembly and Disassembly 74 7 3 NG Gas Supply And Gas Flow Control Valve EPR Valve Assembly And Disassembly 76 8 Cooling System 77 8 1 Cooling System Disassembly and Assemb...

Страница 5: ...sembly of Oil Cooler 98 9 10 Disassembly and Assembly of Oil Cooler Bypass Valve 99 10 Start up System 101 10 1 Disassembly and Assembly of Start up System 101 11 Engine Accessory System 102 11 1 Engi...

Страница 6: ...ult 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 fol...

Страница 7: ...embly and Assembly of Engine Block Group 2 1 1 Explosive View of Engine Block Group Fig 1 Exploded view of engine block assembly WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOU...

Страница 8: ...tion socket wrench copper hammer 2 Preparation disassemble the transmission and clutch disassemble the flywheel flywheel housing gear housing and oil pan 2 1 3 Disassembly steps of engine block group...

Страница 9: ...f main bearing bolts The main bearing bolts can be used repeatedly 6 times the length of the bolt extension is less than 172 mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Fig 2 2 Tighten order of main bearing b...

Страница 10: ...nd press it into the cylinder bore with special tool after applying molybdenum powder to the outside surface of cylinder liner 2 2 Reassembly Disassembly and Assembly of Cylinder Block 2 2 1 Explosive...

Страница 11: ...Disassemble the crankcase 4 Disassemble the cylinder pin with internal threads 2 2 4 Assembling Steps of Preassembly of Cylinder Block The assembly should be conducted in the reverse order of disasse...

Страница 12: ...e of the bowl and engine body Press into the bowl plug with special tool when assembling press the depth down to 0 1 mm under pressure and the height difference of the end face of the bowl is not grea...

Страница 13: ...mble the gear chamber fastening bolt 2 Disassemble the screw plug and composite washer 3 Disassemble the gear chamber 4 Disassemble the seal ring 2 3 4 Assembling Steps of Gear Chamber The gear chambe...

Страница 14: ...3 For disassembling the gear chamber first dismantle the gear chamber fastening bolts and then disassemble the intermediate gear shaft and oil pump intermediate gear shaft After disassembly of gear c...

Страница 15: ...4 2 Pre assembly Preparation 1 Equipment condition socket wrench 2 Preparation disassemble the accessory of the gear chamber 2 4 3 Disassembling Steps of Front end Cover 1 Disassemble the front end c...

Страница 16: ...cover apply the sealant at junction surface of engine block and the thread of sealant should be continuous 3 Check if the gasket is damaged if it is damaged it is necessary to replace it with a new o...

Страница 17: ...e reverse order of disassembly 2 4 5 Overhaul of Piston Nozzle Key point 1 Assembly Tightening torque of hollow bolt Tightening torque 20 30N m Key point 2 Assembly Check if the positioning cylinder p...

Страница 18: ...crankshaft 3 Disassemble the thrust plate 2 6 4 Assembling Steps of Thrust Plate 1 Assemble the crankshaft 2 Assemble the upper thrust plate no ear 3 Assemble the lower thrust plate 2 6 5 Overhaul of...

Страница 19: ...ation disassemble the crankcase and flywheel housing 2 7 3 Disassembling Steps of Front and Rear Oil Seals 1 Disassemble the gear chamber 2 Disassemble front oil seal 3 Disassemble the crankcase 4 Dis...

Страница 20: ...ricant should be applied to oil seals and pressing tooling 2 The oil seal should not be reused after disassembly 2 8 Disassembly and Assembly of Flywheel Housing 2 8 1 Explosive View of Flywheel Housi...

Страница 21: ...Coupling Ring 4 Starter 10 Cylinder pin 16 washer 5 stud 11 Observation hole cover plate 17 Hexagon bolt 6 nut 12 Hexagon bolt 2 8 2 Pre assembly Preparation 1 Equipment condition socket wrench coppe...

Страница 22: ...housing and fasten the bolt 2 8 5 Inspection and repair of flywheel housing 1 Symmetrically tighten up the flywheel housing bolts in the order shown in the figure below Before assembly apply oil to th...

Страница 23: ...ing 5 Ignition winding clamp plate 9 Cylinder head gasket 2 Clump block 6 Ignition winding bush 10 Secondary Blots 3 Valve stem seal 7 Shoulder nut 4 Cylinder head main bolt 8 Cylinder head 2 9 2 Disa...

Страница 24: ...ead auxiliary bolts 8 Remove valve train including rocker arm support intake valve exhaust valve etc refer to Disassembly of valve mechanism 9 If the valve stem sealing sleeve were needed to be replac...

Страница 25: ...on cylinder head gasket are aligned with those on cylinder block and whether the cylinder head gasket is assembled properly 3 Assemble valve stem sealing sleeve 1 All valve stem sealing sleeve can on...

Страница 26: ...the cylinder head 5 Assemble clamping block 1 Clean the clamping block 2 Apply clean lubricating oil to the bearing surface of clamping block before assemble the clamps to cylinder heads in turn and n...

Страница 27: ...n bolts to 200Nm in turn with torque wrench and make marks on the bolts 7 Rotate the auxiliary bolt nuts by 90 in turn with torque wrench and mark the new positions of the nuts 8 Rotate the main bolts...

Страница 28: ...by using a depth micrometer i e the vertical distance between valve bottom surface and cylinder head bottom surface and the difference between the measured sinkage and the required sinkage can reflec...

Страница 29: ...e affected and thus reducing the operational reliability of diesel engine The valve guide inside diameter can be measured with inside micrometer as shown in figure 4 18 Permissible inside diameter is...

Страница 30: ...Wave spiral washer 3 Cover 6 Cylinder head cover gasket 2 10 2 Disassembling Steps of Cylinder Head Cover 1 Loosen the install bolt remove the O ring and the cover 2 Loosen the bolt of the cylinder h...

Страница 31: ...e replaced when repairing Key point 2 Inspection 1 Check if there is crack large wearing and any other damage of cylinder head cover itself If there is crack it is necessary to replace it with a new c...

Страница 32: ...hexagon bolt remove them 2 11 3 Assembling Steps of Hoisting Rings of Engine Remove and check front and rear lifting eyes and clamping blocks for crack heavy deformation and other failures and check t...

Страница 33: ...steps of oil gas separator 1 Unscrew the two fastening bolts from the oil gas separator intake pipe joint on cylinder block 2 Unscrew the bolt fixing the oil gas separator to front lifting eye 3 Remo...

Страница 34: ...n and repair of oil gas separator 1 Check each component surface for damage crack rubber hose hardening and other failures if any of the aforesaid problems is found please renew the corresponding part...

Страница 35: ...ve View of Crank Connecting Rod Mechanism No name No name No name 1 Main bearing bolt 6 Absorber 11 Flywheel bolt 2 Crankcase 7 Crankshaft pulley 12 Flywheel 3 Connecting Rod Cover 8 Bolt 13 Flywheel...

Страница 36: ...on cylinder block 2 Press the upper bearing into the bottom hole of the cylinder block and wipe away the foreign matters scraped from the bearing port 1 The upper bearing should be checked for scratch...

Страница 37: ...2 Fig 3 2 Tightening sequence of main bearing bolts 11 Tighten the main bearing bolts by using low torque pneumatic wrench for the first time then tighten to 80Nm for the second time and 250Nm 280Nm...

Страница 38: ...n 5 Connecting rod bolt 9 Circlip 2 Piston pin 6 Taper sided ring 10 Connecting rod bushing 3 Connecting rod body 7 Conical ring 11 Connecting Rod Upper Shell 4 Connecting rod cover 8 Oil ring 12 Conn...

Страница 39: ...carefully push out the piston pin and remove the connecting rod body Number the piston pins and connecting rods respectively and place them in order 6 Use a piston ring pliers to remove the 1st ring 2...

Страница 40: ...on with that of the inlet hole of piston cooling oil duct and the connecting rod small end hole and piston pin should be applied with appropriate clean lubricating oil before assembling Fig 3 5 Explod...

Страница 41: ...away from both openings of the 1st ring and 2nd ring as shown in fig 5 5 Fig 3 6 Schematic diagram for included angles between piston rings 6 Crank the engine to bring the No 1 cylinder and No 6 cylin...

Страница 42: ...ring are excessively worn 3 Check if the oil ring is rotated flexibly in the piston oil groove 4 Check if the outer perimeter of the piston ring is excessively worn 5 Check the large end bottom hole...

Страница 43: ...not to be replaced with new ones install them into the engine block upper half and crankcase lower half with the reverse order disassembly always with upper half and lower half clearly distinguished...

Страница 44: ...eel and ring gear 1 Bolt the flywheel ring gear together with the flywheel 2 Knock a straight pin into the rear end of crankshaft always into position 3 Insert a guide bar into the crankshaft threaded...

Страница 45: ...nally with a torque of 60Nm Afterwards turn angle of 160 5 and the torque reaches 230Nm 300Nm If the prescribed torque couldn t reach replace the bolt with new one The bolt could be used for twice 3 4...

Страница 46: ...alled install the vibration damper and pulley in sequence and tighten them onto the crankshaft flange with pulley bolt 3 5 5 Inspection and repair of torsional damper and crankshaft pulley 1 Check the...

Страница 47: ...h rod 17 Rocker arm set 4 Hexagon bolt 11 Valve spring 18 Rocker arm shaft 5 Thrust plate 12 Exhaust valve 19 Hexagon bolt 6 Camshaft 13 Valve spring top retainer 20 Rocker arm bracket 7 Intake valve...

Страница 48: ...details 4 1 3 Assembly steps of valve mechanism 1 Install the camshaft and the camshaft timing gear and see section Assembly steps of camshaft and camshaft timing gear for details 2 Install the tappe...

Страница 49: ...ywheel housing remove the camshaft and timing gear 4 2 3 Disassembly steps of camshaft and camshaft timing gear 1 Rotate the camshaft and check if the camshaft and timing gear are flexible without bei...

Страница 50: ...for reuse 2 Insert the camshaft guide and camshaft sliding sleeve into the camshaft hole wipe the camshaft and check for impact damage after this insert the camshaft through the camshaft hole and when...

Страница 51: ...to repair it for reuse 2 Be careful not to scratch the camshaft bush when inserting the camshaft 3 Apply sealant to the thread of the bolt thread 4 3 Disassembly and assembly of rocker arm and rocker...

Страница 52: ...rocker shaft 1 Install the cylinder pin into the hole below rocker arm shaft the pin should be fully in without crack 2 Assemble the bracket and rocker arm set apply little oil on the rocker arm shaf...

Страница 53: ...on 1 Clean the rocker arm and observe its surface for cracks or other defects 2 Check the rocker arm inner bore for wear and scratches and measure its diameter 3 Check the ball pin and the arc surface...

Страница 54: ...1 Upon removal of rocker arm and rockshaft take out push rods and place them in order 2 After the cylinder heads are removed see disassembly steps of cylinder head take out tappets and place them in o...

Страница 55: ...Clean the valve tappet and push rod 2 Check if the oil passage of valve tappet and push rod is smooth 3 Check the push rod for bending and the external surface for wear 4 Check the ball head and socke...

Страница 56: ...emble the cylinder head from engine block 4 5 3 Disassembly steps of valve 1 Use a valve spring compressor valve overhead clamp or other equivalent tools to press the valve spring and remove the valve...

Страница 57: ...l sleeve is intact before installation 4 Install the inner valve spring and outer valve spring ensuring that they are reverse in spiral direction 5 Install the valve spring upper seat press the valve...

Страница 58: ...2 Pre assembly Preparation 1 Equipment condition valve spring compressor valve overhead clamp or other equivalent tools 2 Preparation remove the compressor 4 6 3 Disassembly steps of intermediate gear...

Страница 59: ...rmediate gear assembly intermediate gear bush keeping the face with V on the intermediate gear outward i e V is not to be overlapped by the intermediate gear shaft locate the intermediate gear assembl...

Страница 60: ...5 1 Exploded view of air filter group No name No name No name 1 Hexagon bolt 5 Air filter bracket 9 Joint 2 Spring washer 6 Clamp 10 Differential pressure transducer 3 Flat washer 7 Intake joint pipe...

Страница 61: ...filter group 1 Assemble the air filter bracket onto the air filter tighten the hexagon bolt with wrench 2 Assemble the air filter and air filter bracket onto the flywheel housing with the spring washe...

Страница 62: ...pipe bolt 3 Hexagon nut 12 Clamp 21 Clamp 4 Block 13 Hexagon bolt 22 Turbocharger oil pipe 5 Seal washer 14 Turbocharger 23 Pipe joint nut 6 Turbocharger water pipe 15 Turbocharger water pipe 24 Clamp...

Страница 63: ...nd turbocharger oil return pipe 4 Loosen the hollow bolt of the turbocharger exhaust gas pipe and oil cooler in turn remove the seal washer and water pipe of the turbocharger 5 Loosen the hexagon bolt...

Страница 64: ...exhaust manifold 1 Loosen the hexagon bolt of the exhaust manifold 2 Remove the exhaust manifold stud and exhaust manifold gasket 5 3 4 Assembly steps of exhaust manifold Assemble the exhaust manifold...

Страница 65: ...on exhaust pipe seal ring If there is it is necessary to replace it 5 All the bolts and nuts of the gas exhaust system are made of heat resistant steel they are can t changed to ordinary ones 5 4 Dis...

Страница 66: ...4 Loosen the hexagon bolt of the decompression valve remove the decompression valve gasket and hexagon bolt 5 Loosen the inner hexagon screw of the throttle remove the mix air gasket throttle 6 Loose...

Страница 67: ...ly of intake manifold 5 5 1 Exploded view of intake manifold Fig 5 5 Exploded view of intake manifold No name No name No name 1 Hexagon bolt 6 Plate washer 11 Joint 2 Hexagon bolt 7 Spring washer 12 I...

Страница 68: ...agon bolt 2 Assemble the pressure temperature sensor into the mix air intake pipe with hexagon 3 Assemble the gasket and mix air joint pipe onto the intake manifold 5 5 5 Inspection and repair of inta...

Страница 69: ...name 1 Inner hexagon bolt 3 Ignition coil 2 Washer 4 Ignition plug 6 1 2 Ignition System Disassembly Steps 1 Remove the install bolt of the ignition coil 2 Remove the ignition coil 3 Dismount the spa...

Страница 70: ...te Adjust the clearance of the sparking plug if it is not right If the clearance of the sparking plug is large place the feeler in the gap first then tap the electrode with a small wrench If the clear...

Страница 71: ...he Harness ECU Connection from the ECU 3 Remove the ECU bolts Remove the ECU from the bracket 6 2 3 ECU Assembly Procedure Reverse the disassembly procedure to assemble the ECU 6 2 4 Inspection and Ma...

Страница 72: ...r piston should be in its compression stroke check the mark of the signal generator gear and the mark of the signal generator housing are right or not 2 Remove the fastening bolt of the signal generat...

Страница 73: ...is 39 46 Nm 5 Adjust the crankshaft to TDC the first cylinder piston should be in its compression stroke Tighten the connecting bolts between the pump gear and signal generator 6 Assemble the cover f...

Страница 74: ...view of LPG supply system No name No name No name 1 Inner hexagon bolt 12 LPG EPR bracket 23 Plate washer 2 Spring washer 13 Bolt 24 Cover 3 Plate washer 14 Cushion 25 Clamp 4 nut 15 Support block 26...

Страница 75: ...ons between the LPG evaporator and the LPG bracket Fully remove the LPG evaporator assembly from the LPG bracket 4 According to the chart replace the parts which is needed repaired 5 Remove the hex ni...

Страница 76: ...Disassemble the clamp between the mix air intake joint pipe and turbocharger remove the hose 2 Disassemble the clamp between the mix air intake joint pipe and intake elbow remove the mix air intake jo...

Страница 77: ...Gas Supply And Gas Flow Control Valve EPR Valve Disassembly Procedure 1 Disassemble the connect bolt between the EPR valve and the gas pipe remove the EPR valve 2 Disassemble the bolt of the electroma...

Страница 78: ...s any change the gas pipe 8 Cooling System 8 1 Cooling System Disassembly and Assembly 8 1 1 Cooling System Exploded View Fig 8 1 Exploded view of cooling system No name No name No name 1 Radiator 4 A...

Страница 79: ...ydraulic pump 8 Disassemble the water pump water pipe connector and water pump For more details see Disassembling Instructions for water pump 8 1 3 Assembling Steps of Cooling System The assembly shou...

Страница 80: ...pe remove the water pipe 5 and water pipe 6 8 2 4 Assembling Steps of the radiator The assembly should be conducted in the reverse order of disassembly 8 2 5 Inspection and Maintenance of Radiator 1 C...

Страница 81: ...and bolt 6 remove the hub 3 8 3 4 Assembling Steps of the radiator The assembly should be conducted in the reverse order of disassembly 8 3 5 Inspection and Maintenance of Fan 1 Before assembly first...

Страница 82: ...per hammer 2 Preparation remove the belts remove the alternator 8 4 3 Disassembling Steps 1 Remove the two hexagon bolts 7 2 Remove the hexagon bolt 4 and bolt 5 remove the water inlet pipe 3 and wash...

Страница 83: ...y 4 Check if there is fracture or any other kind of damage of water pump Replace if necessary 8 5 Water Pump Disassembly and Assembly 8 5 1 Water Pump Exploded View Fig 8 5 Exploded view of the water...

Страница 84: ...efect or damage on manufacturing or use 2 Clean the inner chamber on gear chamber connecting with the water pump 3 The assembly should be conducted in the reverse order of disassembly 4 Check if there...

Страница 85: ...king cover 8 6 2 Pre assembly Preparation 1 Equipment condition air wrench sleeve wrench open end wrench rubber hammer 2 Preparation remove the belts remove all the water joint hose of the thermostat...

Страница 86: ...the reverse order of disassembly Parameter table of thermostat opening temperature 8 6 5 Inspection and Maintenance 1 Check if there is failure or any other damage of the four clamps If there is it is...

Страница 87: ...mbly and Assembly of Lubrication system Fig 9 1 Schematic Diagram of Lubrication System 9 1 1 Explosive View of Lubrication System WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET Y...

Страница 88: ...ostat 1 Disassemble the oil sump For more details see Disassembling Instructions for Engine Block Combination 2 Disassemble the strainer 3 Disassemble the crankshaft pulley absorber and hexagon plug s...

Страница 89: ...1 3 Assembling Steps of Lubrication System The assembly should be conducted in the reverse order of disassembly 9 2 Disassembly and Assembly of Oil Sump 9 2 1 Explosive View of Oil Sump Fig 9 3 Explo...

Страница 90: ...9 2 4 Overhaul of Oil Sump Key point 1 Disassembly Before disassembly of oil sump presently drain up the oil Put the vessel containing oil under the oil sump oil draining screw plug and use a screw p...

Страница 91: ...g washer 11 Clamp 4 Strainer 8 Flat washer 9 3 2 Pre assembly Preparation 1 Equipment condition sleeve wrench open end wrench copper hammer 2 Preparation remove the oil pan 9 3 3 Disassembly steps of...

Страница 92: ...iate gear assembly 9 4 1 Exploded view of oil pump intermediate gear assembly Fig 9 6 Exploded view of oil pump intermediate gear assembly No name No name 1 Hexagon head bolt 3 Intermediate gear shaft...

Страница 93: ...is no defect and damage due to manufacturing and use 2 Clean the mating surfaces of crankcase and oil pump intermediate gear assembly and the oil pump intermediate gear assembly 3 Install the sealing...

Страница 94: ...pan remove the oil strainer 9 5 3 Disassembling Steps of Oil Pump Loosen the hexagon flange face toothed bolts on the oil pump and remove the oil pump and oil pump gasket 9 5 4 Overhaul of Oil Pump 1...

Страница 95: ...l the two hexagon flange face toothed bolts and tighten them up 9 6 Disassembly and assembly of main oil passage pressure limiting valve 9 6 1 Exploded view of main oil passage relief valve assembly F...

Страница 96: ...pection repair of pressure limiting valve for main oil passage 1 Check the elasticity of pressure limiting valve for main oil passage and replace it if necessary 2 Check the pressure limiting valve fo...

Страница 97: ...cturing or use 2 Clean the mating surfaces of oil filter assembly and engine block 3 Install the oil filter seat gasket and the oil filter assembly 4 Install the wave spring washer and bolt and tighte...

Страница 98: ...1 Equipment condition sleeve wrench copper hammer 2 Preparation open the water drain valve drain the water 9 8 3 Disassembling Steps of Oil Cooler Cover Before disassemble first drain the coolant in t...

Страница 99: ...n oil cooler cover itself If there is crack it is necessary to replace the oil cooler cover 2 Check oil cooler cover gasket If there is water leakage it is necessary to check the failure of oil cooler...

Страница 100: ...n the junction surface of oil cooler and engine block 3 Install the seal rings and oil cooler 4 Install the waveform elastic washer and bolts and tighten them up 9 9 5 Overhaul of Oil Cooler Check if...

Страница 101: ...h a new safety valve spring 2 Check if there is crack or any other problem with safety valve hexagon plug screw and composite gasket If there is replace it with a new one 9 10 5 Assembling Steps of Oi...

Страница 102: ...d the starter relay Fig 10 1 Exploded view of starting system No name No name 1 Flywheel housing 3 Hexagon flange bolt 2 Stud 4 Starter 10 1 2 Pre assembly Preparation 1 Equipment condition ordinary o...

Страница 103: ...od condition or not if it is necessary replace it No short circuit between the 30 end and the shell 11 Engine Accessory System 11 1 Engine Accessory System Assembly and Disassembly 11 1 1 Engine Acces...

Страница 104: ...y 11 2 1 Alternator Exploded View Alternator parts include the alternator alternator bracket tension bolts corresponding attachment bolts washers Fig 11 2 Exploded view of generator No name No name No...

Страница 105: ...Check whether the insulation washer and cover are in good condition or not if it is necessary replace it No short circuit between the positive battery and the shell otherwise the alternator is strictl...

Страница 106: ...or test circuit connector and Turn on the power switch of 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 termi...

Страница 107: ...ernator output voltage is 27 28 5 V vehicle excitation circuit has failed and requires to be reconditioned b With normal brightness the indicator lamp does not go out after starting engine and alterna...

Страница 108: ...ltages at alternator and battery terminals a In case of voltage difference more than 1V big voltage drop due to thin wire under heavy load working condition please replace the wire If the current is l...

Страница 109: ...b In case of short circuit reconnect the wires c Check whether battery is working normally a Check if the charging current value changes greatly drops from 50A to less than 10A in a short period of t...

Страница 110: ...normal 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 engin...

Страница 111: ...America Corp 3100 Golf Road Rolling Meadows IL 60008 http www WeichaiAmerica com WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTS...

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