WEICHAI WP4GNA Assembly/Disassembly Manual
  1. Manuals
  2. Brands
  3. WEICHAI Manuals
  4. Engine
  5. WP4GNA
  6. Assembly/disassembly manual
WEICHAI WP4GNA Assembly/Disassembly Manual

WEICHAI WP4GNA Assembly/Disassembly Manual

Hide thumbs Also See for WP4GNA:
Table of Contents

Advertisement

Quick Links

WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM
Assembly & Disassembly Manual
Gas Engine
Model: WP4GNA
WEICHAI AMERICA CORP.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the WP4GNA and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for WEICHAI WP4GNA

Summary of Contents for WEICHAI WP4GNA

  • Page 1 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Assembly & Disassembly Manual Gas Engine Model: WP4GNA WEICHAI AMERICA CORP.
  • Page 2 Weichai America Corp. Purpose This manual is intended to inform customers on how to assemble and disassemble the Weichai America 4 Liters naturally aspirated engine. This document will be provided to customer so they can incorporate this information into their manuals and service documents.

  • Page 3: Table Of Contents

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Contents 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 Engine block group ......................
  • Page 4 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4.1 Exploded view of timing mechanism ................45 4.2 camshaft assembly and disassembly ................46 4.3 Intermediate gear assembly and disassembly ..............48 4.4 Push rod and tappet assembly and disassembly ............50 4.5 valve assembly and disassembly ..................
  • Page 5 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.2 Oil pump assembly and disassembly ................77 9.3 Oil filter, oil cooler assembly and disassembly ..............78 9.4 Pressure-limiting valve of main oil gallery assembly and disassembly ......79 9.5 Oil strainer assembly and disassembly ................

  • Page 6: Disassembly & Assembly Of Engine

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1 Disassembly & 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.

  • Page 7: Engine Block Group

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2 Engine block group Engine block group assembly and disassembly 2.1.1 Engine block group exploded view Pos. Name Pos. Name Pos. Name Engine block Fixing plate stud Cylinder liner...
  • Page 8 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Camshaft bushing Screw Cylinder head bolt Plug O-ring Sleeve Screw Plug Ball Plug Seal ring Shaft O-ring Washer O-ring Spring Freeze Plug Hex Plug Lifting Bolt 2.1.2 Steps to disassemble engine block group...
  • Page 9 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2) The tightening sequence of cylinder head is: 2-3-4-1 3) The torque range of cylinder head bolt should be: M14－12.9: (230～300) N·m M14－10.9: (190～285) N·m Key point 2: Inspection: 1) Measure the protrusion of cylinder sleeve (0.05mm~0.10mm is qualified).

  • Page 10: Engine Block Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Use dedicated tool to disassemble the camshaft sleeve, and try to protect other sleeves during disassembling. Inspection: Before 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.
  • Page 11 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Pos. Name Pos. Name Pos. Name Engine block Bolt of main bearing Cap of main bearing Cap of thrust main bearing Bolt of main bearing 2.2.2 step to disassemble Engine Block 1) Remove main bearing bolts (key point 1);...
  • Page 12 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Key point 2: Installation Install the thrust bearing cap on rear end of engine block, and the others are non-thrust bearing caps. Take the cap two ends as locating basis when assembling; the main bearing bolts cannot be screwed on...

  • Page 13: Gear Housing Group Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Gear housing group assembly and disassembly 2.3.1 Exploded view of gear housing group Pos. Name Pos. Name Pos. Name plug Bolt Intermediate gear O-ring Front seal shaft Front cover plate...
  • Page 14 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Inspection: Check the gear housing to ensure that it is clean and without any damage or burrs on the fitting surface. Check the O-Rings to ensure that they are in good condition. Replace the O-Rings if necessary.
  • Page 15 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Gear Housing installation 4) Place the bolts with gaskets in their corresponding holes. Tighten them with a pneumatic impact wrench and an open-end wrench. Fig. Tighten sequence of gear housing bolts...

  • Page 16: Piston Nozzle Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. The removed oil seal can not be reused; replace it with a new one. Piston nozzle assembly and disassembly 2.4.1 Exploded view of piston nozzle Pos. Name Pos.

  • Page 17: Thrust Plate Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Key point 2: inspection Check O-shape seal ring for damage; make sure the nozzle is clean and free of burr. Thrust plate assembly and disassembly 2.5.1 Exploded view of thrust plate Pos.

  • Page 18: Front & Rear Oil Seal Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Thrust plate should be used in pairs and the side with oil groove should be outward during assembling. Put the anti-misloading lug in corresponding groove of thrust bearing cap.
  • Page 19 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.6.4 Front & rear oil seal inspection and repair Key point 1: Inspection: Check whether the junction surface between rear oil seal cover and engine body is cleaning or knocking wound.

  • Page 20: Flywheel Housing Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Assembly: Apply sealant on the rear oil seal outer ring first, and then press-in the seal slowly with dedicated tool. NOTICE: Do not damage the seal during assembling, and seal outer ring should be parallel and level to oil seal cap plane.
  • Page 21 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.7.2 Steps to disassemble flywheel housing 1) Remove fixing bolts of flywheel housing adapter and take out the adapter. 2) Remove speed sensor 3) Remove fixing bolts of monitoring window cap on flywheel housing, take out the cap;...

  • Page 22: Oil Pan Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. Tighten sequence of flywheel housing bolt NOTICE: For the strengthening bolts listed above, the thread and bearing surface of each bolt should be applied with lubricating oil before assembling.
  • Page 23 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Pos. Name Pos. Name Pos. Name Seal washer Plug Bolt Washer Plug Bolt Magnetic plug Pipe connector Oil pan 2.8.2 Steps to disassembly oil pan 1) Remove oil drain bolt...

  • Page 24: Cylinder Head Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.8.4 oil pan inspection and repair Key point 1 Before the disassembling, all engine oil should be drained out. Put an engine oil container under drain screw plug of oil sump, screw off the plug with a plug wrench to drain oil out.
  • Page 25 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.9.2 Steps to disassemble cylinder head 1) Loosen the cylinder head bolts and remove them. 2) Pull the cylinder head up vertically to take it down. If the cylinder head gasket is attached on the removed cylinder head, remove it and place it back on engine block.
  • Page 26 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. Tighten sequence of cylinder head bolts 2) The cylinder head bolt will stretch and deform between 0.2~0.6mm after tightening. The bolt can’t be reuse if the length over 160.5mm.
  • Page 27 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Valve Recession: Valve recession is the vertical distance between valve undersurface and cylinder cover undersurface. Any difference between the measured and required values 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 below: Reference Table below for valve recession requirements.

  • Page 28: Valve Cover Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Cylinder head gasket: If there is air leakage, water leakage or oil leakage in cylinder head gasket, then the gasket should be checked and replaced; Check the gasket for visible damage and analyze the cause, cylinder cover gaskets are disposable, and should be replaced during maintenance.

  • Page 29: Lifting Lug Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.10.2 Steps to disassemble valve cover 1) Loosen the valve cover bolts. Remove the bolts and the washers. 2) Pull the covers up vertically to remove them. Remove all gaskets.

  • Page 30: Ccv System Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Pos. Name Pos. Name Pos. Name Lifting lug 2.11.2 Steps to disassemble lifting lug Loosen and remove the lifting lugs. 2.11.3 Steps to assembly lifting lug Check the lifting lugs and standoffs for any damaged threads. Replace either if damage is found.
  • Page 31 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Pos. Name Pos. Name Pos. Name Clamp Clamp Air intake pipe CCV breather Hose, air Bracket Bolt Clamp Bracket Pipe Hose, air 2.12.2 Steps to disassemble CCV system 1) Loosen the clamps on the air outlet.

  • Page 32: Ccv Breather Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.13 CCV breather assembly and disassembly 2.13.1 Exploded view of CCV breather Fig. Exploded view of CCV breather Fig. Schematic diagram of disassembly 2.13.2 Steps to disassemble CCV Breather Open the top cover of the breather by tool or hand.

  • Page 33: Crank-Rod Mechanism

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3 Crank-rod mechanism Crank-rod mechanism assembly and disassembly 3.1.1 Exploded view of Crank-rod mechanism Pos. Name Pos. Name Pos. Name Piston-rod Bolt Crankshaft assembly Engine block Bolt Flywheel gear...

  • Page 34: Crankshaft Group Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. caution to avoid jamming cylinder block with connecting rod tip. Remover other pistons in the same way, number and place them orderly. 2) Screw off fastening bolts of torque vibration damper and fastening bolts of hub, take down crankshaft pulley, torque vibration damper and hub.
  • Page 35 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2) Take down crankshaft and flywheel, remove front and rear thrust plates and flywheel bearing. Remove oil seals; place the crankshaft on bracket (for long time storage, the crankshaft should be placed vertical);...

  • Page 36: Main Bearing Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10) Apply clean lubricating oil on crankcase bolt bearing surface and main bearing bolt thread. Place main bearing bolts and pre-tighten them according to the order shown in Figure below.

  • Page 37: Balance Mechanism Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3.3.2 Steps to disassemble crankshaft bearing shell Push the shells out with hand, and mark the removed shells (should be corresponded with holes on engine block and crankcase).
  • Page 38 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2) Install 3 adjusting shims on each locating sleeve. 3) Rotate crankshaft until the 2 gear teeth with “0” marked arrive at the location which is marked by red circle on following figure, then mark these two gear teeth’s crest and flank by marking pen.
  • Page 39 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5) Install balance mechanism, insure that the gear teeth with “0” marked on crankshaft gear and balance mechanism gear engage. 6) Install bolts, pay attention on distinguish bolt’s length, do not install bolts in wrong location, and note that there is no washer.

  • Page 40: Flywheel And Gear Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. flywheel and gear assembly and disassembly 3.5.1 Exploded view of flywheel Pos. Name Pos. Name Pos. Name Bolt Washer Flywheel Flywheel adapter Bolt 3.5.2 Steps to disassemble flywheel Reverse assembly procedure to disassemble flywheel and gear.

  • Page 41: Piston-Rod Group Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Flywheel bolts: Bolt specification M16-12.9 (×6); Tightening torque: 285~295Nm; Test value: 285~340Nm. 3.5.4 inspection and maintenance of flywheel and gear 1) Check whether there is failure like thread damage on flywheel bolts.
  • Page 42 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3.6.2 Steps to disassemble piston-rod group 1) Check before disassembling. Check connecting rod axial backlash, check tightening torque of connecting rod bolts; 2) Tilt and lay the engine on its side, rotate the flywheel until the to-be removed piston is in BDC, and then remove connecting rod bolts and cap;...
  • Page 43 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4) Clean up cylinder inner wall, crankshaft connecting lever and piston-rod assembly, and apply clean lubricating oil on each motion pair. 5) Adjust opening direction of each ring: The opening direction of first compression ring should be 30°...

  • Page 44: Damper, Crankshaft Pulley And Hub Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3.6.4 Inspection and maintenance of piston-rod group 1) Check whether there is crack on combustor throat fillet and piston pin boss; Check piston skirt and piston head for cylinder scoring phenomenon; Check wear condition of piston pin hole.
  • Page 45 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Connecting plate washer 3.7.2 Steps to disassemble damper, crankshaft pulley. Remove pulley bolts, take pulley/ connecting plate and damper down. 3.7.3 Steps to assemble damper and crankshaft pulley.

  • Page 46: Timing Mechanism

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4 Timing mechanism Exploded view of timing mechanism Pos. Name Pos. Name Pos. Name Bolt Engine block Push rod Rocker seat Plate Intake valve clip Bolt Cylinder head...

  • Page 47: Camshaft Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. camshaft assembly and disassembly 4.2.1 Exploded view of camshaft Pos. Name Pos. Name Pos. Name Camshaft Flange Plate Camshaft gear Bolt Engine block Bolt Bolt 4.2.2 Steps to disassemble camshaft Rotate the camshaft, check whether the camshaft and timing gear are flexible and moving without clamping stagnation.
  • Page 48 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1) Check camshaft for blur and bump damage, and make sure there is no rust, scratch and scrap iron. 2) Apply clean engine oil on camshaft hole and tappet hole inner surface. Install camshaft, do not damage camshaft surface and engine block hole during the push-in process of camshaft and the push-in strength should be equally, the end with thread should be on gear housing side.

  • Page 49: Intermediate Gear Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6) After correctly installed the gears, mark 0 tick position of camshaft timing gear and crankshaft timing gear with a marking pen. 7) After adjusting the holes, install camshaft bolts (cleaned and applied with KB277 sealant) through flanges holes;...
  • Page 50 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Shaft Bolt Intermediate shaft Intermediate Washer gear 4.3.2 Steps to remove intermediate gear 1) Remove four M10 bolts and the washer. 2) Insert a M8 bolt into the pin-shaft. Pull the pin-shaft out along this bolt. Take care to ensure that the intermediate gear does not slide off and get damaged.

  • Page 51: Push Rod And Tappet Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Push rod and tappet assembly and disassembly 4.4.1 Exploded view of tappet and push rod Pos. Name Pos. Name Pos. Name Camshaft Tappet Push rod 4.4.2 Steps to disassemble tappet and push rod 1) After removing rockers and rocker shafts, pull the pushrods out vertically.

  • Page 52: Valve Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5) Apply clean lubricating oil on the pushrod and ensure that the round head is applied with sufficient oil. 6) Install the pushrod by putting the pushrod into the valve tappet through the cylinder cover.
  • Page 53 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Valve seal Cylinder Upper valve head seat 4.5.2 Steps to disassemble valves 1) Depress valve springs with vale spring compressor or valve overhead plier or other tools, take out valve lock clamp, upper valve spring seat and lower valve spring seat and valve springs orderly;...

  • Page 54: Rocker Arm And Shaft Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Rocker arm and shaft assembly and disassembly 4.6.1 Exploded view of rocker arm and shaft Pos. Name Pos. Name Pos. Name Bolt Adjust bolt Washer Cylinder head Rocker arm seat...
  • Page 55 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4) Loose-fit rocker seat on cylinder cover with hexagon bolts; 5) Install valve pushrod, refer to assembly of valve pushrod for details; 6) Pre-tighten rocker seat, align rocker adjusting screw socket head to valve pushrod round head, tighten the hexagon bolts to 40~45Nm.

  • Page 56: Air Intake And Exhaust System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5 Air intake and exhaust system Air intake and exhaust system assembly and disassembly 5.1.1 Exploded view of air intake and exhaust system Pos. Name Pos. Name Pos.
  • Page 57 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Pos. Name Pos. Name Pos. Name Mixing air intake pipe Bolt throttle Clamp Washer Gasket Hose Washer Mixer Flange Bolt Screw plug Bolt Air intake temperature and pressure sensor...

  • Page 58: Air Intake Manifold Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4) Loosen the bolts fixing throttle and adapter, remove adapter. 5) Loosen the bolts fixing throttle and air intake elbow, remove throttle and gasket. 6) Loosen the bolts fixing air intake elbow and air intake manifold, remove intake elbow and gasket.

  • Page 59: Exhaust Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5.2.2 Steps to disassemble air intake manifold 1) Remove nuts to take air intake manifold and gasket down. 2) Loosen clamps to take hose down. 5.2.3 Steps to assemble air intake manifold Reverse disassembly procedure to assemble air intake manifold, the torque of intake manifold bolt is 23N·m.
  • Page 60 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Gasket Bolt Exhaust manifold Gasket Stud 5.3.2 Steps to disassemble exhaust manifold 1) Remove nuts to take exhaust tail pipe and gaskets down. 2) Remove bolts to take exhaust manifold and gasket down.

  • Page 61: Exhaust Tail Pipe Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Exhaust tail pipe assembly and disassembly 5.4.1 Exploded view of exhaust tail pipe Pos. Name Pos. Name Pos. Name Bolt Protective cover Washer Expansion joint O2 sensor Gasket Heat shield 5.4.2 Steps to disassemble exhaust tail pipe...
  • Page 62 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5.4.3 Steps to assemble exhaust tail pipe Reverse disassembly procedure to assemble exhaust manifold. Note: the recommended tightening torque of exhaust manifold bolt is 65N·m～80N·m and do not reuse this bolt more than twice.

  • Page 63: Ignition System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6 Ignition system Ignition system assembly and disassembly 6.1.1 Exploded view of ignition system Pos. Name Pos. Name Pos. Name Bolt Bolt Spark plug washer washer Ignition coil Coil seat 6.1.2 Steps to disassemble ignition coil...

  • Page 64: Signal Generator Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Signal generator assembly and disassembly 6.2.1 Exploded view of signal generator Pos. Name Pos. Name Pos. Name Gear Washer Filling plate washer stud Toothed disc Signal generator Bolt...
  • Page 65 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6.2.2 Steps to disassemble signal generator 1) Remove cover plate on the gear housing. 2) Remove nut #9, take gear out. 3) Remove nut #1 and take signal generator down.

  • Page 66: Ecm Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ECM assembly and disassembly 6.3.1 Exploded view of ECM Pos. Name Pos. Name Pos. Name Support block Washer ECM bracket Bolt Bolt 6.3.2 Steps to disassemble ECM 1) Remove bolt #6;...

  • Page 67: Fuel System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7 Fuel system Fuel system assembly and disassembly 7.1.1 Exploded view of fuel system Pos. Name Pos. Name Pos. Name Bracket T-junction Pipe connector LPG evaporator Pipe connector...

  • Page 68: Lpg System Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. LPG system assembly and disassembly 7.2.1 Exploded view of LPG system Pos. Name Pos. Name Pos. Name LPG evaporator Bolt Bolt Pipe connector Shock pad Bolt Pipe connector...

  • Page 69: Ng Shut-Off Valve Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4) Remove fitting bolts and shock pads to remove LPG evaporator from its bracket. 5) Remove shut-off valve from LPG evaporator. 6) Remove all connectors and plugs on the evaporator.

  • Page 70: Epr Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2) Remove the bolts and nuts bolting the NG bracket to the NG shut-off valve. Remove the NG shut-off valve. 7.3.3 Steps to assemble NG shut-off valve Reverse disassembly procedure to assemble NG shut-off valve.

  • Page 71: Mixer Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Mixer assembly and disassembly 7.5.1 Exploded view of Mixer Part Name Part Name Part Name Screws Diaphragm Spring Mixer Cover Ring Adjustment Screw Spring Air Fuel Regulator Gasket...
  • Page 72 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7.5.2 Steps to disassemble mixer 1) Remove the screws on the mixer cover. Remove the mixer cover. 2) Remove the diaphragm spring. 3) Remove the diaphragm assembly. 7.5.3 Steps to assemble mixer Reverse the Disassembly Procedure to assemble the Mixer.

  • Page 73: Cooling System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 8 Cooling system Cooling system assembly and disassembly 8.1.1 Exploded view of cooling system The cooling system ensures that the engine can operate at the proper operating temperature.

  • Page 74: Fan Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fan assembly and disassembly 8.2.1 Exploded view of fan Part Name Part Name Part Name Flange Washer Bolt 8.2.2 Steps to disassemble fan 1) Loosen 4 fixing bolts on the fan and take fan down.

  • Page 75: Water Pump Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Water pump assembly and disassembly 8.3.3 Exploded view of water pump Part Name Part Name Part Name Water pump Belt pulley Flange Belt 8.3.2 Steps to disassemble water pump 1) Remove water pump pulley 2) Remove thermostat connecting hose and clamps;...

  • Page 76: Thermostat Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3) Check water pump and middle cushion block for cracks. Replace them if necessary. Thermostat assembly and disassembly 8.4.1 Exploded view of thermostat Part Name Part Name Part Name...

  • Page 77: Lubricating System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9 Lubricating system Exploded view of lubricating system Part Name Part Name Part Name Oil pump Oil pan Oil filter Oil strainer Oil cooler...

  • Page 78: Oil Pump Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Oil pump assembly and disassembly 9.2.1 Exploded view of oil pump 9.2.2 Steps to disassemble oil pump Remove the two hexagon bolts and self-locking nut, take down engine oil pump, as shown in Fig.

  • Page 79: Oil Filter, Oil Cooler Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Oil filter, oil cooler assembly and disassembly 9.3.1 Exploded view of oil filter and cooler Part Name Part Name Part Name Gasket O-ring Bolt Oil filter seat Connecting...

  • Page 80: Pressure-Limiting Valve Of Main Oil Gallery Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3) Loose clamps on the water outlet pipe; 4) Remove water inlet pipe; 5) Remove the bolts fitting the oil cooler and take oil cooler down. 9.3.3 Steps to assemble oil filter and cooler 1) Check oil filter’s O-ring and oil cooler for manufacturing defect and damage before installing...

  • Page 81: Oil Strainer Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.4.2 Steps to disassemble pressure-limiting valve Loose the nut to take pressure-limiting valve down. 9.4.3 Steps to assemble pressure-limiting valve 1) Check the valve before assembling, make sure there is no manufacturing defect and damage.
  • Page 82 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. O-ring Oil pipe Washer 9.5.2 Steps to disassemble oil strainer Screw off two hexagon flange bolts and the hexagon nuts on the bended plate, take down the oil strainer.

  • Page 83: Starting System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10 Starting system 10.1 Exploded view of starting system The starter is the core component of the starting system. The starter converts battery power to electromagnetic torque. The ring gear mechanism drives the starting engine rotation. The starter motor’s main components are the DC motor, one-way clutch, reduction gear train, electromagnetic switches, and the starter relay.
  • Page 84 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10.1.3 Inspection and maintenance 1) Check the starter motor gear for damage, replace it if necessary. 2) Check the starter wiring to ensure that it is correct, tight, and secure.

  • Page 85: Alternator

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11 Alternator 11.1 Alternator assembly and disassembly 11.1.1 Exploded view of alternator Part Name Part Name Part Name Bracket Alternator Bolt Belt 11.2 Exploded view of alternator...
  • Page 86 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Part Name Part Name Part Name Alternator Bracket Bolt Locknut Bolt Washer Bolt Washer Bolt 11.2.1 Steps to disassemble alternator 1) Remove the alternator lock nut to loosen the belt, then remove the belt from the alternator pulley.
  • Page 87 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. APPENDIX A Appendix A: Torsional Torque and Tightening Method for Main Bolts and Nuts Bolts Specification Tightening Inspect value Bolts torque(N·m) (N·m) Intake manifold bolt 45～50 40～60 Exhaust manifold bolt 45～50...
  • Page 88 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. APPENDIX B Appendix B: Tolerance Clearance for Main Parts of Gas Engine (Reference value) Items Theoretical value (mm) Main bearing clearance 0.05～0.11 Connecting rod bearing clearance 0.045～0.09 Crankshaft axial clearance 0.04～0.25...
  • Page 89 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. APPENDIX C Appendix C: The Evaluation Criteria for Main Friction Wear of Gas Engine (Reference value) Wear Parts life Clearance limit (hours) limit (mm) (mm) Closed clearance of the first (top) ring 1.70...
  • Page 90 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3100 Golf Road Rolling Meadows, IL 60008 http://www.WeichaiAmerica.com/...

Table of Contents

Save PDF