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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1 front cover 2 Pin 3 Hex flange bolts
Figure 2-4 Exploded view of front cover
2.3.2 Preparation before disassembly
1. Equipment conditions: Socket wrench
2. Preparation before disassembly: Remove the front attachment
2.3.3 Dismantling
1. Remove the front cover fastening bolt;
2. Remove the front cover;
3. Remove the front cover seal.
2.3.4 Assembling
The front cover assembly procedure is the opposite of the front cover removal procedure.
2.3.5 Service Key point
1. After the front cover is removed, it should be placed in a clean environment. Before assembly,
it is necessary to check whether the inside of the front cover has greater dirt to ensure the
front cover is tidy.
2. Before assembling the front cover, apply the sealant on the bonding surface of the body, and
the glue line should be continuous.
3. Check the seal for damage, if damaged need to be replaced with new parts. When assembled,
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the seal must be pressed fully into the front cover groove.
2.4 Assembly and disassembly of flywheel housing
2.4.1 Exploded view of flywheel housing
1. Flywheel shell 2. Hexagon flange bolts to increase the series 3. Hex flange bolts to increase the
series 4. Cylindrical pins 5. Studs 6. Spring washers 7. Hexagon nut 1 8. Observation hole cover
9 Hexagon head bolt 10. Gasket 11. Hex head screw 12. Washer 13. Hexagon socket head cap 14.
Hydraulic pump cover 15. O-ring rubber seal 16. Hex head bolt 17. Speed sensor 18. Hexagon
head Screw 19. flywheel shell connector plate 20. hex head bolt 21. Hex flange bolts to increase
the series 22. Hex socket head cap screws 23. Hex flange bolts
Figure 2-5 Exploded view of flywheel housing
2.4.2 Preparation before disassembly
1. Equipment conditions: Socket wrench
2. Preparation before disassembly: Remove transmission and clutch, remove flywheel
2.4.3 Dismantling
1. Remove the hydraulic pump cover fastening bolt and remove the hydraulic cover;
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2. Remove the observation hole cover fastening bolt, remove the observation hole cover;
3. Remove the flywheel housing stud along the outside;
4. Remove the flywheel housing fastening bolt according to the diagonal loosening sequence;
5. Remove the flywheel housing, cylinder pin and rear oil seal.
2.4.4 Assembling
The flywheel housing assembly step is the opposite of the flywheel housing removal step.
2.4.5 Service Key point
1. The flywheel housing bolts are pre-glued, symmetrically tightened, oiled on the bolt flange
before assembly, and the flywheel housing bolts are reusable twice.
2. During installation, a uniform sealant should be applied on the joint surface of the cylinder
block and the flywheel housing, and the application of glue should be continuous and
uniform. Hoisting the flywheel shell to prevent knock bumps.
3. Flywheel housing bolt in the thread and pressure surface with lubricating oil, into the threaded
hole diagonal bolt. Tightening torque is 110N.m~140N.m
2.5 Assembly and disassembly of piston nozzle
2.5.1 Exploded view of piston nozzle
1. Hollow bolt 2. Nozzle body 3. Piston nozzle 4. Cylindrical pin
Figure 2-6 Piston cooling nozzle disassembly
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2.5.2 Preparation before disassembly
1. Equipment conditions: Socket wrench
2. Preparation before disassembly: Remove the crankcase, crankshaft and other components.
2.5.3 Dismantling
1. Remove the hollow bolt；
2. Remove the nozzle assembly；
3. Remove the cylinder pin.
2.5.4 Assembling
The order of assembly is the opposite of the disassembly sequence.
2.5.5 Service Key point
1. Hollow bolt tightening torque (20 ~ 30) N · m.
2. Before assembly, check if the dowel pin is defective and replace if necessary. Align the
locating pin with the body pin hole and tap the nozzle body with a copper hammer so that the
locating pin is completely inserted into the body pin hole.
2.6 Assembly and disassembly of thrust plates
2.6.1 Exploded view
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1. Cylinder block 2. Crankcase 3. Upper thrust plate 4. Lower thrust plate
Figure 2-7 Thrust piece dismantling map
2.6.2 Preparation before disassembly
1. Equipment conditions: Socket wrench
2. Preparation before disassembly: Remove the crankcase, crankshaft and other components.
2.6.3 Dismantling
1. Remove the crankcase；
2. Remove the crankshaft；
3. Remove thrust plate.
2.6.4 Assembling
1. Assemble the crankshaft；
2. Fit thrust plate (no ears)；
3. Fit thrust plate.
2.6.5 Service Key point
Thrust piece to be used in pairs. Assembly, the first crankshaft into the body, the installation of
thrust washer (no ears), the thrust washer coated grease, attached to the crankcase, together with
the crankcase assembly. Throttle washer side points to crank arm side.
2.7 Assembly and disassembly of oil seal
2.7.1 Exploded view
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1. Body combination group 2. Front cover 3. Flywheel housing 4. Rear oil seal 5. Front oil seal
Figure 2-8 Oil seal dismantling map
2.7.2 Preparation before disassembly
1. Equipment conditions: Socket wrench
2. Preparation before disassembly: Remove the crankcase, flywheel housing
2.7.3 Dismantling
1. Remove the front cover；
2. Remove the front oil seal；
3. Remove the flywheel housing；
4. Remove the rear oil seal.
2.7.4 Assembling
1. Assemble the front cover；
2. Assemble the front oil seal；
3. Assembled flywheel housing；
4. Assemble the rear oil seal；
2.7.5 Service Key point
1. Oil seal is no longer used after disassembly；
2. Oil seal assembly before cleaning holes and oil seals, do not allow dirt. Oil seal assembly
using special tools, the oil seal into the smooth. Before assembly, oil seals and press tools
need to be lubricated.
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3Cylinder Head Group
3.1 Cylinder Heads Assembly and Disassembly
3.1.1 Preparation before disassembly
1. Equipment conditions: Socket wrench
2. Preparation before disassembly: Remove the cylinder head cover, intake pipe, exhaust pipe.
3.1.2 Exploded view
1-valve gland; 2-shoulder nut; 3-cylinder head bolt; 4-ignition coil bushing plate; 5-ring clamping block;
6-Ignition coil bushing；7-clamping block 8-bolt 9-cylinder head sub-assembly 10-cylinder head gasket
11-bolt
Figure 3-1 Exploded view of cylinder head
3.1.3 Cylinder Heads Disassembly Procedure
1. Loosen and remove the eyebolts on both ends of the engine；
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2. Loosen the cylinder head bolt and nut, and remove the clamping block, clamping block has
three structures: one is mounted between the two cylinder head cylindrical clamping block,
mounted on a bolt; the second Kinds for the assembly of the engine at both ends, only
mounted on a cylinder head clamping block, mounted on the two bolts above, you can install
the rings block; the third is installed on both ends of the engine, only installed in a cylinder
Cover the clamping block, mounted on a bolt；
3. Loosen the cylinder head main bolt and remove the main bolt and place it in place；
4. Remove the ignition coil bushing, release the ignition coil bushing mounting plate bolts,
remove the ignition coil bushing, remove the O-ring；
5. 1) Remove the cylinder head and place the removed cylinder head on the board to avoid
wearing the combustion chamber upper surface and other sealing surfaces. If you need to
remove more than one-cylinder head cylinder head number marked on the cylinder for
subsequent analysis of the problem;
6. Remove the cylinder head gasket, if the removal of multiple cylinder head gasket need to
indicate the cylinder head cylinder serial number for subsequent analysis of the problem；
7. If the cylinder head bolt needs to be replaced or needs to be checked, remove the cylinder
head bolt；
8. Demolition of rocker seat, into the exhaust valve and other gas institutions；
9. To check or replace the valve stem gland, remove the valve stem gland, use a special tool to
remove the valve stem gland, or clamp the outer sidewall of the valve stem gland with a pair
of pliers, and rotate to extract the lower valve stem Gland, valve stem gland removed after
dismantling cannot be used repeatedly.
3.1.4 Cylinder Heads Assembly Procedure
1. Assemble cylinder head bolt.
1) Cylinder head bolt allows the use of 3 times, after 3 times, please replace the new parts;
2) Installed in the first row of the oil cooler cap assembly side of the cylinder head bolt
screwed into the end (short thread end) coated with anaerobic thread locking agent 262.
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3) Clean the threaded hole on the cylinder body;
4) Tighten the bolts, tightening torque: (20+10) N ·m.
2. Assemble cylinder head gasket
Figure 3-2 Cylinder head gasket
1) Cylinder head gasket can only be used once, in case of repair, you must replace the new
parts;
2) Wipe cylinder liner wall, and coated with clean oil, clean the plane body, and then put the
cylinder head gasket in accordance with the corresponding pin hole;
3) Check the cylinder head gasket on each hole and the cylinder on the hole alignment,
check the cylinder head gasket assembly is correct.
3. Assembly valve stem gland
1) Valve stem gland only allowed to use once, in case of repair must be replaced by new
parts;
2) Check the valve stem seal sleeve without defects, the valve stem seal sleeve spring is
intact;
3) In the valve guide to install valve stem seal sleeve;
4) In the valve stem seal sleeve lip lubricants;
5) Valve stem seal sleeve assembly tools and rubber hammer smashed valve stem gland.
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Figure 3-3 Valve stems gland and its installation and installation
4. Assemble the cylinder head
1) Carefully clean the cylinder head, to ensure that no dust, debris, sand and other dirt, and
then wipe the cylinder head plane;
2) Check the cylinder head airway, waterways no foreign body, check the cylinder without
foreign matter, cylinder head gasket and cylinder head plane cleaning;
3) Cylinder head bolt fastening before the cylinder head with pin - surface positioning;
4) Assembly cylinder head.
5. Assemble the clamping block
1) Wipe the clamping block;
2) Clamp block in the support surface coated with clean oil, according to the disassembly
position in turn mounted on the cylinder head, oiled to the right amount to prevent the flow
of lubricant into the gap between the cylinder head;
3) Clamp clamping folder to allow the direction of the groove and cylinder head gap between
the same direction;
4) Hand cylinder head bolt nut screwed into the cylinder head bolt.
6. Assemble cylinder head bolts
1) cylinder head bolts allow 3 times;
Installation
direction
Valve stem gland
installation tools
Valve stem gland
Valve guide
Cylinder head
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