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Weichai America Corp.       

 

 

Revision: August 2019                                                              2 
 

Table of Contents 

1

 

Disassembly & Assembly of Engine ..................................................................................... 5

 

1.1

 

Safety Precautions ............................................................................................................ 5

 

1.2

 

Environmental Protection Measures ................................................................................. 5

 

1.3

 

Notes for Disassembly and Assembly of Engine ............................................................... 5

 

2

 

Fuel System ......................................................................................................................... 6

 

2.1

 

Fuel System Assembly and Disassembly ......................................................................... 6

 

2.2

 

LPG Intake System Assembly and Disassembly ............................................................... 7

 

2.3

 

NG Shut-Off Valve Assembly and Disassembly ................................................................ 8

 

2.4

 

Electronic Pressure Regulator (EPR) Assembly and Disassembly .................................... 9

 

2.5

 

Mixer Assembly and Disassembly .................................................................................... 9

 

3

 

Intake and Exhaust System ............................................................................................... 12

 

3.1

 

Intake and Exhaust System Assembly and Disassembly ................................................ 12

 

3.2

 

Intake Manifold Assembly and Disassembly ................................................................... 14

 

3.3

 

Exhaust Manifold Assembly and Disassembly ................................................................ 14

 

3.4

 

Ignition System Assembly and Disassembly ................................................................... 16

 

3.5

 

Signal Generator Assembly and Disassembly ................................................................ 17

 

3.6

 

Engine Control Unit (ECU) Assembly and Disassembly .................................................. 19

 

4

 

Starting System ................................................................................................................. 19

 

4.1

 

Starting System Assembly and Disassembly .................................................................. 19

 

5

 

Engine Accessory System ................................................................................................. 21

 

5.1

 

Engine Accessory System Assembly and Disassembly .................................................. 21

 

5.2

 

Alternator Assembly and Disassembly ............................................................................ 21

 

6

 

Closed Crankcase Ventilation (CCV) Breather System Assembly and Disassembly .......... 23

 

6.1

 

CCV Breather System Assembly and Disassembly ........................................................ 23

 

6.2

 

CCV Breather Assembly and Disassembly ..................................................................... 24

 

7

 

Cooling System .................................................................................................................. 26

 

7.1

 

Cooling System Disassembly and Assembly .................................................................. 26

 

WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM

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Содержание WP6GNA

Страница 1: ...Assembly Disassembly Manual Gas Engine Model WP6GNA WEICHAI AMERICA CORP WEICHAI PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY COM GET YOUR WEICHAI AFTERMARKET SERVICE PARTS AT FLYPARTSGUY COM...

Страница 2: ...gine 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...

Страница 3: ...y and Disassembly 14 3 3 Exhaust Manifold Assembly and Disassembly 14 3 4 Ignition System Assembly and Disassembly 16 3 5 Signal Generator Assembly and Disassembly 17 3 6 Engine Control Unit ECU Assem...

Страница 4: ...lve 44 10 Oil Lubrication System 47 10 1 Assembly and disassembly of oil sump 47 10 2 Disassembly and Assembly of Engine Oil Strainer 48 10 3 Disassembly and Assembly of Lubricating System 49 10 4 Ass...

Страница 5: ...ankshaft bearing shell 68 11 8 Assembly and disassembly of thrust plates 69 11 9 Assembly and disassembly of camshaft 70 12 Engine block assembly 72 12 1 Disassembly and assembly of engine block assem...

Страница 6: ...al 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 Ta...

Страница 7: ...ure 1 Remove ECU 2 Remove the LPG intake system 3 Remove the NG intake system 4 Remove the electronic pressure regulating system 2 1 3 Fuel System Assembly Procedure Reverse the Disassembly Procedure...

Страница 8: ...r from the water inlet and outlet hoses 4 Remove the connecting bolts and isolator cushions between the LPG evaporator and the LPG bracket Fully remove the LPG evaporator assembly from the LPG bracket...

Страница 9: ...d nuts bolting the NG bracket to the NG shut off valve Remove the NG shut off valve 3 Remove the O ring from the groove in the NG shut off valve 2 3 3 NG Shut Off Valve Assembly Procedure Replace the...

Страница 10: ...t to the EPR 2 Remove the hex bolts and washers bolting the EPR to the mixer Remove the EPR 2 4 3 EPR Assembly Procedure Reverse the Disassembly Procedure 2 4 2 to assemble the EPR 2 4 4 EPR Inspectio...

Страница 11: ...ulator Valve 13 Gasket 4 Screws 9 Diaphragm Assembly 5 Board 10 Mixer body 2 5 2 Mixer Diaphragm Disassembly Procedure 1 Remove the screws on the mixer cover Remove the mixer cover 2 Remove the diaphr...

Страница 12: ...a biogas diaphragm to increase the flow of gas To replace the mixer diaphragm according to maintenance specifications 1 Remove the old mixer diaphragm 2 Check the diaphragm for deformation tears and...

Страница 13: ...t System Assembly and Disassembly 3 1 1 Intake and Exhaust System Exploded View Fig 3 1 Exploded view of intake and exhaust system Fig 3 2 Exploded view of intake elbow WEICHAI PSI SERVICE MANUALS AVA...

Страница 14: ...val hold the throttle and throttle adapter together with bolt holes still aligned to prevent the O ring from falling out 5 Remove the bolts bolting the intake elbow to the intake manifold Remove the i...

Страница 15: ...kets 3 2 3 Intake Manifold Assembly Reverse the Disassembly Procedure 3 2 2 to assemble the intake pipe Recommended tightening torque for the nuts bolting the intake pipe to the engine block is 23Nm 3...

Страница 16: ...e the nuts bolting the exhaust elbow to the exhaust manifold Remove the exhaust elbow and gasket 5 Remove the nuts bolting the exhaust manifold to the engine block Remove the exhaust manifold 3 3 3 Ex...

Страница 17: ...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 deficienc...

Страница 18: ...Disassembly 3 5 for details 3 4 3 Ignition System Assembly Steps Reverse the Disassembly Procedure 3 4 2 to assemble the Ignition System 3 4 4 Ignition System Inspection and Maintenance Inspection and...

Страница 19: ...between signal generator and engine block 3 Adjust the fluted signal generator disc until its TDC mark points at the center of the speed sensor and the predetermined ignition angle is reached 4 Tight...

Страница 20: ...cedure 3 6 2 to assemble the ECU 3 6 4 Inspection 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...

Страница 21: ...Remove the three hex bolts between the starter and the flywheel housing 3 Hold the starter motor firmly and pull it out from the flywheel housing Caution The starter motor is heavy so maintain a very...

Страница 22: ...ils 1 Remove the alternator pulley belt bolts and alternator See Alternator Assembly and Disassembly 5 2 for details 2 Remove the alternator bracket and bolts 5 1 3 Engine Accessory System Assembly Re...

Страница 23: ...tery cable from the alternator 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...

Страница 24: ...o Name No Name No Name No Name 1 Clamp 11 Bracket 21 Bypass Port 31 Bolt 2 Rubber Hose 12 CCV Breather 22 O Ring 32 Washer 3 Formed Hose 13 Hex Bolt 23 Bracket 33 Clamp 4 Formed Hose 14 Breather Brack...

Страница 25: ...ngine block Remove the bypass port bolt washer and O ring 6 1 3 CCV Breather System Assembly Procedure 1 Install the bypass port with a new O ring Each O ring can only be used once 2 Install the breat...

Страница 26: ...e breather filter element 6 2 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 6 2 4 CCV Breather Inspection...

Страница 27: ...e normal operating temperature range The cooling system primarily consists of the water pump fan expansion water tank water tank and thermostat Fig 7 1 Exploded view of cooling system 7 1 2 Cooling Sy...

Страница 28: ...fan 2 Loosen the bolts connection the flange to the spacer block Remove the bolts washers flange and spacer block 7 2 3 Fan Assembly Procedure 1 Prior to assembly check the fan flange and fastening bo...

Страница 29: ...at and water pump Remove the hose and thermostat 7 3 3 Thermostat Assembly Procedure Reverse the Disassembly Procedure 7 3 2 to assemble the Thermostat 7 3 4 Thermostat Inspection and Maintenance 1 Ch...

Страница 30: ...middle cushion block 7 4 3 Water Pump Assembly Procedure Reverse the Disassembly Procedure 7 4 2 to assemble the Water Pump 7 4 4 Water Pump Inspection and Maintenance 1 Check the water pump gasket f...

Страница 31: ...bolts Remove the hub from the crankshaft 8 1 3 Torque Vibration Damper and Crankshaft Pulley Assembly Procedure Install the hub torque vibration damper and crankshaft pulley as follows 1 Fasten the hu...

Страница 32: ...eck the torque vibration damper and hub for damage Replace either if necessary 3 Check the hub fastening bolts and damper fastening bolts for damaged Replace any if necessary 8 2 Gear Housing Assembly...

Страница 33: ...r section 8 2 4 8 2 3 Gear Housing Assembly Procedure Reverse the Disassembly Procedure 8 2 2 to assemble the Gear Housing 8 2 4 Gear Housing Inspection and Maintenance Key Point 1 Inspection Check th...

Страница 34: ...ant is evenly distributed and continuous Fig 8 4 Sealing surface of Gear Housing 3 Place the gear housing with alignment pins in the pin holes Knock the cover edge gently with a nylon rod such that th...

Страница 35: ...e is 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...

Страница 36: ...the contact surface of the intermediate gear and intermediate shaft 3 Put the intermediate gear module in the front cover Install the pin shaft 4 Insert the four M10 bolts after installing the washer...

Страница 37: ...Lifting Lugs Disassembly Procedure Loosen and remove the lifting lugs 9 1 3 Lifting Lugs Assembly Procedure Check the lifting lugs and standoffs for any damaged threads Replace either if damage is fou...

Страница 38: ...surface of the cylinder head Install cylinder head cover gaskets 3 Clean and install cylinder head cover 4 Install the bolts and fasten The required torque is 10 15Nm 9 2 4 Cylinder Head Cover Inspec...

Страница 39: ...cker and the other butterfly spring washer Mark the items to prevent improper assembly 9 3 3 Rocker and Rocker Shaft Assembly Procedure Check whether all to be assembled pars are clean free of bump da...

Страница 40: ...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 finishe...

Страница 41: ...t 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...

Страница 42: ...g 9 5 Exploded view of cylinder heads 9 5 2 Cylinder Heads Disassembly Procedure 1 Loosen the cylinder head bolts and remove them 2 Pull the cylinder head up vertically to take it down If the cylinder...

Страница 43: ...reused 4 Assemble the cylinder head to the engine block 5 Thread the cylinder head bolts into the cylinder head 6 Tighten the cylinder head bolts See Key Point 1 in 9 5 4 9 5 4 Inspection and maintena...

Страница 44: ...of valve recession can reflect the degree of wear on the valve and valve seat A depth micrometer can be used to measure valve recession as shown in Figure 9 7 below Fig 9 7 A Depth Micrometer Referen...

Страница 45: ...er Both allowed ranges for clearance between intake valve rod and its guide pipe exhaust valve rod and its guide pipe are 0 03 0 06mm If clearance exceeds allowed range the cylinder cover must be repl...

Страница 46: ...m on intake and exhaust valve rod and then install intake and exhaust valve into cylinder cover ensure the valve can slide smoothly in valve guide pipe NOTICE Check and ensure spring in valve rod seal...

Страница 47: ...hether valve rod and its end faces are worn Check whether valve conical surface is worn or damaged Check valve conical surface and retainer end faces for carbon deposit WEICHAI PSI SERVICE MANUALS AVA...

Страница 48: ...ination gasket and magnetic screw plug assembly 10 1 3 Steps to assemble oil sump Assembling steps are contrary to disassembling ones 10 1 4 Inspection and maintenance of oil sump Key point 1 Disassem...

Страница 49: ...l Strainer Screw off two hexagon flange bolts and the 2 type hexagon nuts on the bended plate take down the oil strainer as shown in Fig 10 2 10 2 3 Steps to Assemble Engine Oil Strainer Check the str...

Страница 50: ...mbly of oil sump for details Remove gearbox refer to disassembly of gearbox for details Remove engine oil pump Remove the cooling module of engine oil filter 10 3 3 Steps to Assemble Lubricating Syste...

Страница 51: ...sassembling ones 10 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 i...

Страница 52: ...nd 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 10 5 4 Inspection and Main...

Страница 53: ...ling 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 10 6 4 Inspection and Maintenance of Engine...

Страница 54: ...ngine oil cooler and filter seat Install engine oil cooler and the connecting thread sleeve tighten it 10 7 4 Inspection and Maintenance of Engine Oil Cooler Check the engine oil cooler for crack dama...

Страница 55: ...d damage Clean up the pressure limiting valve and pressure limiting valve fitting hole on the module Install the valve and tighten it 10 8 4 Inspection and Maintenance of Main Oil Gallery Pressure Lim...

Страница 56: ...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 10 9 4 Inspection and Maintenance of Deputy Oil Pressure Lim...

Страница 57: ...ing key point 2 11 1 3 Steps to assemble flywheel housing Assembling steps are contrary to disassembling ones 11 1 4 Inspection and maintenance of flywheel housing Key point 1 Assembling Check whether...

Страница 58: ...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 NOTICE For the strengthening bolts listed above the thread and bearing surface...

Страница 59: ...ing flywheel guide rod into crankshaft threaded hole install flywheel and pre tighten the bolts diagonally Apply lubricating oil on bolt thread and bearing surface Flywheel bolts Bolt specification M1...

Страница 60: ...e 2 Remove engine front oil seal 3 Remove engine rear oil seal cover Key point 1 4 Remove engine rear oil seal key point 2 11 3 3 Steps to assemble front and rear oil seal Assembling steps are contrar...

Страница 61: ...y point 2 Inspection Oil seals and seal rings should be checked before assembling make sure there is no damage Check whether rear oil seal cover is clean and whether its finished surface is free of ob...

Страница 62: ...iston 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...

Страница 63: ...iew of piston rod assembly 11 5 2 Steps to disassemble piston rod assembly 1 Check before disassembling Check connecting rod axial backlash check tightening torque of connecting rod bolts WEICHAI PSI...

Страница 64: ...ward and its opening should be upward 2 Insert small end of connecting rod into piston inner cavity and align it to piston pin holes and then install piston pin finally install the other circlip to th...

Страница 65: ...ould not be mixed install each piston to the corresponding cylinder connecting rod cap and connecting rod should be used in pairs apply clean lubricating oil on connecting rod bolts before assembling...

Страница 66: ...connecting rod small end oil hole Check alloy layer of connecting rod shell for abnormal wear and peeling phenomenon Check wear condition of connecting rod side faces check crooking condition of conne...

Страница 67: ...1 5 1 4 of oil hole is strictly forbidden The assembled upper bearing shell should be closely fit with cylinder bottom holes Apply clean lubricating oil on inner surface of upper bearing shell Clean u...

Страница 68: ...ance of crankshaft system Check whether there is crack on fillet area of crankshaft main journal and neck of crankshaft Check the joint part of crankshaft and main bearing for crack check and dredge t...

Страница 69: ...no shell is replaced then install the two shells into engine block upper and crankcase lower respectively pay attention to the mark shells should be installed into corresponding holes on engine block...

Страница 70: ...nkshaft steps Remove thrust plates key point 1 11 8 3 Steps to assemble thrust plates Assembling thrust plate steps are contrary to disassembling ones 11 8 4 Inspection and maintenance of thrust plate...

Страница 71: ...r replaced Check camshaft for blur and bump damage and make sure there is no rust scratch and scrap iron Apply clean engine oil on camshaft hole and tappet hole inner surface Install camshaft do not d...

Страница 72: ...Fig 11 14 Crankshaft gear and camshaft meshing diagram After correctly installed the gears mark 0 tick position of camshaft timing gear and crankshaft timing gear with a marking pen After adjusting th...

Страница 73: ...seizure and abrasion Check whether timing gear and hexagon bolts are distorted 12 Engine block assembly 12 1 Disassembly and assembly of engine block assembly 12 1 1 Exploded view of engine block asse...

Страница 74: ...pe plus screw and swivel nut 4 Remove cylinder liner key point 2 5 Remove camshaft bushing 12 1 3 Steps to assemble engine block assembly Assembling steps are contrary to disassembling ones 12 1 4 Ins...

Страница 75: ...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...

Страница 76: ...fore assembling grease on sleeve back bush surface and fitting hole inner surface must be wiped out and make sure there is no burr overlap and scrap iron Assembling Apply oil on engine block hole put...

Страница 77: ...s 12 2 4 Inspect and repair engine block module Key point 1 Inspection Check and clean engine block Including but not limited to Assembly environment must be clean check engine block finished surfaces...

Страница 78: ...h bolt to 70Nm and tighten the bolts for further 90 4 Fig 12 3 Tighten order of main bearing bolt Key point 2 Assembling Install the thrust bearing cap on rear end of engine block and the others are n...

Страница 79: ...Fastening Nut of Injection Pump Driving Gear M10 10 9 65 70 65 80 Nuts of Injection Pump Shaft M14 1 5 85 100 85 110 M18 1 5 100 110 100 120 Hexagon bolts and stud of flywheel M12 12 9 140 145 140 170...

Страница 80: ...te The first top ring The second ring 0 06 0 095 Oil ring 0 05 0 085 10 Plane values of valve bottom recess cylinder head 1 0 1 45 11 Plane values of cylinder liner top above the engine body 0 05 0 10...

Страница 81: ...tip 2 00 The outer diameter of the cam base circle 0 05 The outside diameter of crankshaft journal 0 12 0 15 The diameter of connecting rod bearing bore 0 10 The outer diameter of the crankshaft main...

Страница 82: ...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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