WEICHAI WP10GTA User manual

Assembly & Disassembly Manual
Gas Engine
Model: WP10GTA
WEICHAI AMERICA CORP.
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Purpose
This manual is intended to inform customers on how to assemble and disassemble the Weichai
America 10 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 should be sure to follow proper warranty procedures. (See Weichai America Corp Warranty
Procedure Manual)
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Table of Contents
1Disassembly & 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
2Engine Block Group.............................................................................................................6
2.1 Disassembly and Assembly of Engine Block Group..........................................................6
2.2 Reassembly, Disassembly and Assembly of Cylinder Block.............................................9
2.3 Disassembly and Assembly of Gear Chamber................................................................11
2.4 Disassembly and Assembly of Front-end Cover .............................................................14
2.5 Disassembly and Assembly of Piston Nozzle..................................................................15
2.6 Disassembly and Assembly of Thrust Plate....................................................................16
2.7 Disassembly and Assembly of Front and Rear Oil Seals ................................................18
2.8 Disassembly and Assembly of Flywheel Housing ...........................................................19
2.9 Disassembly and Assembly of Cylinder Head.................................................................22
2.10 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
3Crank-Connecting Rod Mechanism ...................................................................................34
3.1 Disassembly and assembly of crankshaft.......................................................................34
3.2 Disassembly and assembly of piston & connecting rod group.........................................37
3.3 Disassembly and assembly of crankshaft bearing...........................................................41
3.4 Disassembly and assembly of flywheel and ring gear.....................................................42
3.5 Disassembly and assembly of vibration damper and crankshaft pulley...........................44
4Valve train..........................................................................................................................45
4.1 Disassembly and assembly of valve train .......................................................................45
4.2 Disassembly and assembly of camshaft and camshaft timing gear.................................47
4.3 Disassembly and assembly of rocker arm and rocker shaft ............................................50
4.4 Disassembly and assembly of tappet and push rod........................................................52
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4.5 Disassembly and assembly of valve ...............................................................................54
4.6 Disassembly and assembly of intermediate gear............................................................57
5Intake/exhaust system.......................................................................................................59
5.1 Disassembly and assembly of intermediate gear............................................................59
5.2 Disassembly and Assembly of Turbocharger System.....................................................60
5.3 Disassembly and assembly of exhaust manifold.............................................................62
5.4 Disassembly and Assembly of Mix Air Intake Pipe..........................................................64
5.5 Disassembly and assembly of intake manifold................................................................66
6Ignition System..................................................................................................................68
6.1 Ignition System Assembly and Disassembly...................................................................68
6.2 Engine Control Unit (ECU) Assembly and Disassembly..................................................70
6.3 Signal Generator Assembly and Disassembly ................................................................71
7Fuel System.......................................................................................................................73
7.1 LPG Intake System Assembly and Disassembly.............................................................73
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
8Cooling System..................................................................................................................77
8.1 Cooling System Disassembly and Assembly ..................................................................77
8.2 Radiator Disassembly and Assembly..............................................................................78
8.3 Fan and Hub Disassembly and Assembly.......................................................................79
8.4 Water Pump and Water Pump Disassembly and Assembly............................................80
8.5 Water Pump Disassembly and Assembly .......................................................................82
8.6 Disassembly and Assembly of Thermostat .....................................................................83
9Lubrication System ............................................................................................................86
9.1 Disassembly and Assembly of Lubrication system..........................................................86
9.2 Disassembly and Assembly of Oil Sump.........................................................................88
9.3 Disassembly and assembly of oil strainer .......................................................................90
9.4 Disassembly and assembly of oil pump intermediate gear assembly..............................91
9.5 Disassembly and assembly of oil pump..........................................................................92
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9.6 Disassembly and assembly of main oil passage pressure limiting valve .........................94
9.7 Disassembly and assembly of oil filter ............................................................................95
9.8 Disassembly and Assembly of Oil Cooler Cover.............................................................96
9.9 Disassembly and Assembly 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 Engine Accessory System Assembly and Disassembly......................................102
11.2 Alternator Assembly and Disassembly................................................................103
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1Disassembly & Assembly of Engine
1.1 Safety Precautions
Please strictly comply with instructions in this manual to safely and properly disassemble and
assemble the engine.
1.2 Environmental Protection Measures
Please comply with relevant laws and regulations on environmental protection when handling oil
and hydrocarbon waste. For further instructions please contact your local officials.
1.3 Notes for Disassembly and Assembly of Engine
Failure in complying with safety regulations and basic safety practices causes the majority of
engine-related accidents. Proper training is required for all engine operators and maintenance
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 is clean and suitable for safe operation.
•Remove any rings, necklaces, watches, or other jewelry and wear appropriate close-fit work
clothes before entering the maintenance site.
•Wear relevant protective devices (goggles, gloves, shoes, masks, work clothes, helmet, etc.)
that are in good condition prior to entering the maintenance site.
•Do not use any defective, worn, broken, or inappropriate tools.
NOTICE: THE ENGINE MUST BE COMPLETELY SHUT DOWN PRIOR TO
MAINTENANCE.
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2Engine Block Group
2.1 Disassembly and Assembly of Engine Block Group
2.1.1 Explosive View of Engine Block Group
Fig. 1 Exploded view of engine block assembly
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Fig. 2 Exploded view of engine block assembly
Fig. 2- 1 Exploded view of engine block assembly
No. name No. name No. name
1 Spring pin 7 washer 13 Hexagon bolt
2 Rivet 8 Hexagon socket
head bolt
14 Knock sensor
3 O-ring 9 Cylinder liner 15 Seal washer
4 Hexagon head plug 10 Main oil passage
rear screw plug
16 Hexagon plug
5 Cylindrical pin 11 Seal washer 17 Hexagon plug
6 Oil press sensor 12 Rivet
2.1.2 Pre-assembly Preparation
1. Equipment condition: 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
1. Remove main oil passage screw plug;
2. Remove cylinder liner;
3. Unscrew the crankcase fastening bolts;
4. Unscrew the main bearing bolt;
5. Remove sealing ring.
2.1.4 Assembling Steps of Engine Block Group
The assembly should be conducted in the reverse order of disassembly.
2.1.5 Inspection and repair of engine block group
Key point 1:
Assembly
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Tightening
torque 22Nm~29Nm Grade 8.8
Tightening
torque 29Nm~35Nm Grade 10.9
Key point 2:
Assembly
Tighten the main bearing bolts in a symmetric way according to the sequence shown in the figure
below. Before assembly, apply clean lubricating oil to the bearing surface of crankcase and the
threads of main bearing bolts. The main bearing bolts can be used repeatedly 6 times, the length
of the bolt extension is less than 172 mm.
ⅠⅡⅢⅣⅤⅥⅦ
1
23
4
5
67
8
9
1011
12
13
14
Fig. 2-2 Tighten order of main bearing bolts
Tightening
torque 265Nm±25Nm
Key point 3:
Assembly
Tighten the cylinder head auxiliary bolts according to the sequence shown in the figure below,
and these bolts can be reused at most 2 times.
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Ⅵ Ⅴ Ⅳ Ⅲ Ⅱ Ⅰ
16
17
18
10
11
12
3
4
5
2
1
6
9
8
7
15
14
13
21
20
19
Fig. 2-3 Cylinder Head Auxiliary Bolts Tightening Order
Key point 4:
Assembly
Before assembly, inspect the cylinder liner carefully for cracks and other defects, then clean and
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 View of Preassembly of Cylinder Block
Figure 2-4 Explosive View of Preassembly of Cylinder Block
No. name No. name No. name
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1 Cylinder block 5 Bowl plug 9 Bowl plug
2 Crankcase 6 Bowl plug 10 Camshaft bush
3 Bowl plug 7 Bowl plug 11 Cylindrical pin with
internal thread
4 Bowl plug 8 Bowl plug 12 Main bearing bolt
2.2.2 Pre-assembly Preparation
1. Equipment condition: socket wrench, copper hammer
2. Preparation: disassemble the transmission and clutch; disassemble the flywheel, flywheel
housing, gear housing and oil pan.
2.2.3 Disassembling Steps of Preassembly of Cylinder Block
1. Disassemble the camshaft bushing;
2. Disassemble the main bearing bolts and crankcase fastening bolts;
3. 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 disassembly.
2.2.5 Overhaul of Preassembly of Cylinder Block
Key point 1:
For disassembling, use special tooling to disassemble the camshaft bushing. In the process of
disassembly, take care to protect other bushings.
Key point 2:
Before assembly, carefully check if there is scratch on internal surface of camshaft bushing, and
replace it when necessary. The camshaft bushing oil hole should be aligned with the camshaft
bottom hole oil hole of engine block.
Key point 3:
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Before assembly, clean the upper plane of crankcase and it is necessary to apply sealants onto the
upper plane of crankcase.
Key point 4:
If replace the bowl, clean the bottom hole and bowl surface before assembly,
Apply sealant to the joint face 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 greater than 0.5mm.
2.3 Disassembly and Assembly of Gear Chamber
2.3.1 Explosive View of Gear Chamber
Figure 2-5 Explosive View of Gear Chamber
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No. name No. name No. name
1 Seal ring 4 Hexagon bolt 7 Hexagon bolt
2 O-ring 5 O-ring 8 Hexagon plug screw
3 Cylinder pin 6 Hexagon plug
screw
9 Timing gear
chamber
2.3.2 Pre-assembly Preparation
1. Equipment condition: socket wrench
2. Preparation: disassemble the accessory of the gear chamber
2.3.3 Disassembling Steps of Gear Chamber
1. Disassemble 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 chamber should be assembled in the reverse order of disassembly.
2.3.5 Overhaul of Gear Chamber
Key point 1:
Symmetrically and crosswise tighten up the gear chamber fastening bolts in the order shown in
the figure below.
Tightening torque 44～58N.m
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Figure 2-6 Schematic Diagram of Fastening Order of Gear Chamber Fastening Bolts
Key point 2:
Before assembly of the seal ring, observe if there is scratch or other defects on the seal ring; if
there is, timely replace it with a seal ring. For assembling, apply oil onto the seal ring, completely
press it into groove, and avoid scratching the seal ring by groove.
Key point 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 chamber, put it in a clean environment.
Key point 4:
First, after installing the intermediate gear shaft into the intermediate gear, put the intermediate
gear into the gear chamber; apply sealant at water inlet and outlet ports of cylinder block and
press in seal rings.
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2.4 Disassembly and Assembly of Front-end Cover
2.4.1 Explosive View of Front-end Cover
Figure 2-7 Explosive View of Front-end Cover
No. name No. name No. name
1 Seal ring 3 Hexagon bolt 5 Hexagon bolt
2 O-ring 4 O-ring 6 Hexagon plug screw
2.4.2 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 cover fastening bolt;
2. Disassemble the front-end cover;
3. Disassemble the front-end cover gasket.
2.4.4 Assembling Steps of Front-end Cover
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The assembly should be conducted in the reverse order of disassembly.
2.4.5 Overhaul of Front-end Cover
1. After disassembling the front end cover, put it in a clean environment, before assembly, check
if there is relatively big dirt inside the front end cover to ensure the cleanliness of front end
cover.
2. Before assembly of front end 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 one.
For assembling, press the gasket completely into the front end cover groove.
2.5 Disassembly and Assembly of Piston Nozzle
2.5.1 Explosive View of Piston Nozzle
Figure 2-8 Explosive View of Piston Nozzle
No. name No. name No. name
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1 Piston nozzle
assembly 3 Elastic cylinder pin 5
2 Nozzle 4 Hollow bolt 6
2.4.2 Pre-assembly Preparation
1. Equipment condition: socket wrench
2. Preparation: disassemble the crankshaft and crankcase.
2.4.3 Disassembling Steps of Piston Nozzle
1. Disassemble the hollow bolt;
2. Disassemble the nozzle assembly;
3. Disassemble the elastic cylinder pin.
2.4.4 Assembling Steps of Piston Nozzle
The piston cooling nozzle should be assembled in the 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 pin is defective, and replace it when necessary. Align the
positioning cylinder pin with cylinder pin hole of engine block, use a copper hammer to knock
lightly the nozzle body to make the cylinder pin completely enter into engine block cylinder pin
hole.
2.6 Disassembly and Assembly of Thrust Plate
2.6.1 Explosive View of Thrust Plate
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Figure 2-9 Explosive View of Thrust Plate
No. name No. name
1 Upper thrust plate 2 Lower thrust plate
2.6.2 Pre-assembly Preparation
1. Equipment condition: socket wrench
2. Preparation: disassemble the crankshaft and crankcase.
2.6.3 Disassembling Steps of Thrust Plate
1. Disassemble the crankcase;
2. Disassemble the 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 Thrust Plate
The thrust plates should be used in pairs. For assembling, first install crankshaft into the engine
block, install the upper thrust plate (no ear), apply lubricating grease onto the lower thrust plate,
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attach it to the crankcase and assemble it together with crankcase. The oil groove side of thrust
plate should be outward.
2.7 Disassembly and Assembly of Front and Rear Oil Seals
2.7.1 Explosive View of Front and Rear Oil Seals
Figure 2-10 Explosive View of Front and Rear Oil Seals
No. name No. name
1 Rear oil seal 2 Front oil seal
2.7.2 Pre-assembly Preparation
1. Equipment condition: socket wrench
2. Preparation: 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. Disassemble the rear oil seal.
2.7.4 Assembling Steps of Front and Rear Oil Seals
The front and rear oil seals should be assembled in the reverse order of disassembly.
2.7.5 Overhaul of Front and Rear Oil Seals
1. Before assembly of oil seals, the installation hole and oil seals should be cleaned, free of dirt.
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For assembling oil seals, use special tooling to steadily press into the oil seals. Before
assembly, the lubricant 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 Housing
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