WEICHAI WP13GTA User manual

Assembly & Disassembly Manual
Gas Engine
Model: WP13GTA
WEICHAI AMERICA CORP.
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Purpose
This manual is intended to inform customers on how to assemble and disassemble the Weichai
America 13 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 assembly........................................................................................................6
2.1 Disassembly and assembly of engine block assembly......................................................6
2.2 Steps to Assemble and disassemble Engine Block Module ..............................................7
2.3 Front cover disassembly and assembly............................................................................9
2.4 Assembly and disassembly of flywheel housing..............................................................11
2.5 Assembly and disassembly of piston nozzle...................................................................12
2.6 Assembly and disassembly of thrust plates.....................................................................13
2.7 Assembly and disassembly of oil seal.............................................................................14
3Cylinder Head Group.........................................................................................................16
3.1 Cylinder Heads Assembly and Disassembly...................................................................16
3.2 Disassembly and assembly of cylinder head cover.........................................................23
3.3 Oil and gas separator dismantling and assembly............................................................24
3.4 Lifting Lugs Assembly and Disassembly.........................................................................26
4Crank-rod mechanism........................................................................................................28
4.1 Shock absorber, crankshaft pulley disassembly and installation.....................................28
4.2 Flywheel, flywheel gear ring, flywheel connection plate removal and installation............29
4.3 Crankshaft bearing disassembly and assembly ..............................................................31
4.4 Crankshaft removal and installation................................................................................32
4.5 Piston rod group disassembly and assembly..................................................................35
5Valve train..........................................................................................................................39
5.1 Disassembly and assembly of Valve train.......................................................................39
5.2 Camshaft disassembly and assembly.............................................................................41
5.3 Rocker and rocker shaft removal and installation............................................................43
5.4 Tappet and putter removal and installation .....................................................................45
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5.5 Valve removal and installation........................................................................................47
5.6 Intermediate gear disassembly and assembly ................................................................49
6Intake and Exhaust System ...............................................................................................50
6.1 Air filter combination group dismantling and assembly....................................................50
6.2 Intake pipe combination group disassembly and assembly.............................................52
6.3 Exhaust pipe disassembly and assembly........................................................................53
6.4 Turbocharger dismantling and assembly ........................................................................55
6.5 Mixed intake system with the disassembly and assembly of the group...........................57
7Cooling system..................................................................................................................59
7.1 Cooling system disassembly and assembly....................................................................59
7.2 Fan dismantling and assembly........................................................................................60
7.3 Pump disassembly and assembly...................................................................................61
7.4 Thermostat dismantling and assembly............................................................................62
8Lubrication system.............................................................................................................64
8.1 Lubrication system dismantling and assembly................................................................64
8.2 Oil filter dismantling and assembly..................................................................................65
8.3 Oil pump disassembly and assembly..............................................................................66
8.4 Oil filter, oil filter seat disassembly and assembly ...........................................................67
8.5 Oil cooler cap disassembly and assembly.......................................................................68
8.6 Oil cooler disassembly and assembly.............................................................................69
8.7 Oil pan disassembly and assembly.................................................................................70
9Start the system.................................................................................................................72
9.1 Startup system disassembly and assembly.....................................................................72
10 Gas system ..........................................................................................................73
10.1 Ignition system disassembly and assembly ..........................................................73
10.2 Signal generator disassembly and assembly........................................................75
10.3 Electronic control module disassembly and assembly ..........................................77
10.4 LPG supply system dismantling and assembly.....................................................78
10.5 NG gas supply system dismantling and assembly ................................................79
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11 APPENDIX A........................................................................................................82
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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 assembly
2.1 Disassembly and assembly of engine block assembly
2.1.1 Exploded view of engine block assembly
1. Engine block 2. Cylinder liner 3. Pin 4. Gasket 5. Hex head bolt 6. Hexagon socket head cap
screws 7. Hex head bolt 8. Hex head bolt 9. O seal ring 10. O seal ring 11. Pin 12. Gasket 13.
Pressure temperature sensor 14. Gasket 15. Hex head plug 16. Knock sensor 17. Gasket 18. Hex
head plug 19. Gasket 20. Hex flange bolts 21. Oil dip tube plug
Fig. 2- 1 Exploded view of engine block assembly
2.1.2 Preparation before disassembly
1. Equipment conditions: Socket wrench, copper hammer and so on
2. Preparation before disassembly: Remove gearbox and clutch, remove flywheel, flywheel
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housing, gear housing and oil pan
2.1.3 Dismantling
1. Remove the crankcase around the bolt;
2. Remove the main bearing bolts;
3. Remove the seal；
4. Remove the main oil duct plug；
5. Remove cylinder liner.
2.1.4 Assembling
Assembling steps are contrary to disassembling ones.
2.1.5 Service Key point
1. Assembling: Crankcase around the tight bolt tightening torque were：8.8 bolts, tightening
torque of 22N · m ~ 29N · m; 10.9 bolts, tightening torque 29N · m ~ 35N · m;
2. Assembling: cylinder liner should be carefully checked before assembly, To see if there are
cracks and clean cylinder liner, the use of special tooling into the cylinder bore, press the
outer surface of the front cylinder coating molybdenum powder, cylinder liner protruding
amount（0.05~0.10）mm.
3. Check the body of the processing surface, the processing surface should be no glitches, oil,
bump and so on, with Whetstone, sandpaper towels, etc. removed；
4. Check the body of the oil, waterways, cavities and other places without iron, burrs, flash, etc.,
with air gun, iron brush to remove clean;
5. Requires no sealing surface sealing.
2.2 Steps to Assemble and disassemble Engine Block Module
2.2.1 Exploded View of Engine Block Module
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1.Cylinder block 2. Internal thread cylindrical pin 3. Camshaft bushings 4. Rear camshaft bushing
5. Main bearing bolts 6. Crankcase 7. Bowl plug 8. Bowl plug
Fig. 2- 2 Exploded View of Engine Block Module
2.2.2 Preparation before disassembly
1. Equipment conditions: Socket wrench, copper hammer and so on
2. Preparation before disassembly: Remove gearbox and clutch, remove flywheel, flywheel
housing, gear housing and oil pan
2.2.3 Dismantling
1. Disassemble the internal thread cylinder pin;
2. Remove camshaft bushings;
3. Remove the main bearing bolts and crankcase bolts;
4. Remove the crankcase;
2.2.4 Assembling
Cylinder pre-assembly and assembly steps and cylinder block pre-assembly and disassembly
steps.
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2.2.5 Service Key point
1. Disassembly: Use special tools to disassemble the camshaft bushing, pay attention to protect
the other bushing during disassembly;
2. Assembly: Before assembly, carefully check the inner surface of the camshaft bush for
scratches, replace if necessary. Camshaft bushing oil hole alignment body camshaft bottom
hole oil hole.
3. Assembly: clean the crankcase before assembly plane, the crankcase on the plane to be coated
sealant;
4. Assembly: The main bearing bolts are symmetrically fastened in the order shown in Figure 2-3,
first tighten by pneumatic wrench, next tighten to the torque of 80Nm, then tighten to 140Nm,
after this tighten bolts in the specified sequence by 90°, last tighten by 60° to finish assembly.
Before assembly in the crankcase bearing surface and the main bearing bolt threaded parts
brushing clean lubricant;
ⅠⅡⅢⅣⅤⅥⅦ
1
23
4
5
67
8
9
1011
12
13
14
Figure 2-3 Main bearing bolt tightening order
2.3 Front cover disassembly and assembly
2.3.1 Exploded view of front cover
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