WEICHAI WP6GTA Assembly/Disassembly Manual
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WEICHAI WP6GTA Assembly/Disassembly Manual

WEICHAI WP6GTA Assembly/Disassembly Manual

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Assembly & Disassembly Manual
Gas Engine
Model: WP6GTA
WEICHAI AMERICA CORP.

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Summary of Contents for WEICHAI WP6GTA

  • Page 1 Assembly & Disassembly Manual Gas Engine Model: WP6GTA 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 6 Liters turbocharged 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 America Corp. Table of 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 assembly ......................6 2.1 Disassembly and assembly of engine block assembly ............6 2.2 Steps to Assemble and disassemble Engine Block Module ..........
  • Page 4 Weichai America Corp. 4.3 Intermediate Gear Assembly and Disassembly ............... 43 4.4 Tappet and Pushrod Assembly and Disassembly ............44 4.5 Assembly and disassembly of valve................46 4.6 Rocker and Rocker Shaft Assembly and Disassembly ............ 47 Intake and Exhaust System ....................50 5.1 Intake and Exhaust System Assembly and Disassembly ..........
  • Page 5 Weichai America Corp. Starting System ....................80 10.1 Starting System Assembly and Disassembly ............80 Engine Accessory System ..................81 11.1 Engine Accessory System Assembly and Disassembly ........81 11.2 Alternator Assembly and Disassembly ..............82...

  • Page 6: Disassembly & Assembly Of Engine

    Weichai America Corp. 1 Disassembly & Assembly of Engine Safety Precautions Please strictly comply with instructions in this manual to safely and properly disassemble and assemble the engine. Environmental Protection Measures Please comply with relevant laws and regulations on environmental protection when handling oil and hydrocarbon waste.

  • Page 7: Engine Block Assembly

    Weichai America Corp. 2 Engine block assembly Disassembly and assembly of engine block assembly 2.1.1 Exploded view of engine block assembly Fig. 2- 1 Exploded view of engine block assembly name name name Engine block Rivet Plug shaft Rivet Cup plug...
  • Page 8 Weichai America Corp. O seal ring Stud Seal plug Cup plug Stud Rivet washer 2.1.2 Steps to disassemble engine block 1. Remove cylinder head bolt (key point 1) 2. Remove oil dipstick assembly. 3. Remove oil pipe plus screw and swivel nut 4.

  • Page 9: Steps To Assemble And Disassemble Engine Block Module

    Weichai America Corp. Disassembling: 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 10 Weichai America Corp. Fig. 2-2 Exploded view of engine block 2.2.2 step to disassemble Engine Block Module 1. Remove main bearing bolts (key point 1); 2. Remove main bearing caps (key point 2); 2.2.3 Steps to assemble engine block module.

  • Page 11: Gear Housing Assembly And Disassembly

    Weichai America Corp. Key point 2 Installation: Install the thrust bearing cap on the rear end of cylinder block, and install non-thrust bearing caps to other positions. Pay attention to distinguishing two ends of the bearing cap for a proper positioning, and if the bearing cap is reversed, the main bearing bolt cannot be mounted.
  • Page 12 Weichai America Corp. 3. Remove the front oil seal (key point 2). 2.3.3 Gear Housing Assembly Procedure Reverse the Disassembly Procedure to assemble the Gear Housing. 2.3.4 Gear Housing Inspection and Maintenance Key Point 1: Inspection: Check the gear housing to ensure that it is clean and without any damage or burrs on the fitting surface.
  • Page 13 Weichai America Corp. Fig. 2-6 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 the cover and engine block can fit together closely.

  • Page 14: Assembly And Disassembly Of Piston Nozzle

    Weichai America Corp. Fig.2- 8 Tighten order of gear housing bolt Key Point 2: Assembling: Oil seals and seal rings should be checked before assembling. Ensure there 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 on the seal.
  • Page 15 Weichai America Corp. Fig. 2-9 Exploded view of piston nozzle 2.4.2 Steps to disassemble piston nozzle. 1. Remove the hexagon bolt (key point 1) 2. Remove the piston nozzle (key point 2) 2.4.3 Steps to assemble piston nozzle Assembling steps are contrary to disassembling ones.

  • Page 16: Assembly And Disassembly Of Thrust Plates

    Weichai America Corp. Inspection: Check O-shape seal ring for damage; make sure the nozzle is clean and free of burr. Assembly and disassembly of thrust plates. 2.5.1 Exploded view of thrust plates. Fig. 2-10 Exploded view of thrust plates 2.5.2 Steps to disassemble thrust plates 1.
  • Page 17 Weichai America Corp. Fig. 2-11 exploded view of front oil seal and rear oil seal 2.6.2 Steps to disassemble front and rear oil seal 1. Remove gear housing plate 2. Remove engine front oil seal 3. Remove engine rear oil seal cover (Key point 1) 4.

  • Page 18: Assembly And Disassembly Of Flywheel Housing

    Weichai America Corp. (3) Apply oil on surface of crankshaft flange, assemble rear oil seal and tighten bolt. Bolt tightening sequence is: 1-2-6-7-3-4-5-8-9-10。 Fig. 2-12 tightening sequence of rear oil seal cover bolt Key point 2: Inspection: Oil seals and seal rings should be checked before assembling, make sure there is no damage.
  • Page 19 Weichai America Corp. Fig. 2-13 Exploded view of flywheel housing name name name connector bolt Speed sensor bolt Inspect window bolt Flywheel housing bolt plug 2.7.2 Steps to disassemble flywheel housing 1. Remove fixing bolts of flywheel housing (Key point 1).
  • Page 20 Weichai America Corp. 2.7.4 Inspection and maintenance of flywheel housing. Key point 1: Assembling Check whether flywheel is cleaned up. Debut the corresponding fitting surface on engine block with 240# fine oil stone and clean the surface with ethyl alcohol. Apply sealant on fitting surfaces of flywheel housing and engine block.

  • Page 21: Assembly And Disassembly Of Oil Sump

    Weichai America Corp. Assembly and disassembly of oil sump. 4.2.8.1 Exploded view of oil sump. bolt seat washer plug seat oil pan seat seal magnetic washer plug Fig. 2-15 Exploded view of oil sump 2.8.2 Steps to disassemble oil sump.

  • Page 22: Cylinder Heads Assembly And Disassembly

    Weichai America Corp. Assembling (1) Apply sealant on fitting surface of engine block and partially apply sealant on oil sump, place sealing gasket on the fitting surface. (2) Lift and place oil sump, be careful and avoid crashing the fitting surface.
  • Page 23 Weichai America Corp. 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. Put the removed cylinder head on cardboard to prevent damage to the upper surface of the combustion chamber and other sealing surfaces.
  • Page 24 Weichai America Corp. Fig. 2-17 Individual Cylinder Head Tightening Order 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. 3. Install the valve oil seal. Key point 2:...
  • Page 25 Weichai America Corp. Fig. 2-18 A Depth Micrometer Reference Table 2-3 for valve recession requirements. If valve recession exceeds the allowed range, the cylinder cover must be replaced to ensure engine reliability. If valve recession doesn’t exceed allowed range, disassemble the valve and check the sealing surface between the valve and valve seat for wear and abnormal damage.

  • Page 26: Cylinder Head Cover Assembly And Disassembly

    Weichai America Corp. 4. 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 27: Lifting Lugs Assembly And Disassembly

    Weichai America Corp. 2. Clean the upper 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. 2.10.4 Cylinder Head Cover Inspection and Maintenance...

  • Page 28: Ccv Breather System Assembly And Disassembly

    Weichai America Corp. 2.11.2 Lifting Lugs Disassembly Procedure Loosen and remove the lifting lugs. 2.11.3 Lifting Lugs Assembly Procedure Check the lifting lugs and standoffs for any damaged threads. Replace either if damage is found. Tighten the lugs after installing them.
  • Page 29 Weichai America Corp. hose clamp Support block clamp clamp Air exhaust pipe of Oil return pipe Hexagon bolt oil-gas separator clamp washer clamp CCV Breather Bypass Port clamp clamp O-ring bolt hose Bracket Joint pipe clamp Breather Bracket Air intake pipe of oil-gas separator 2.12.2 CCV Breather System Disassembly Procedure...

  • Page 30: Ccv Breather Assembly And Disassembly

    Weichai America Corp. (2) Check for any oil leakages in the system. Check for proper air flow by blowing air into the CCV breather. If resistance is high, clean the breather element. If the problem persists, replace the breather element.

  • Page 31: Crank-Rod Mechanism

    Weichai America Corp. 3 Crank-rod mechanism Assembly and disassembly of crank-rod mechanism. 3.1.1 Exploded view of crank-rod mechanism. Fig. 3-1 Exploded view of crank-rod mechanism 3.1.2 Steps to disassemble crank-rod mechanism 1. Check before disassembling. Check connecting rod axial backlash, check tightening torque of connecting rod bolts;...
  • Page 32 Weichai America Corp. Fig. 3-2 Exploded view of crankshaft system 3.2.2 Steps to disassemble crankshaft system 1. Put the engine crankcase upward, and then remove main bearing bolts and place them orderly; 2. Take down crankshaft and flywheel, remove front and rear thrust plates and flywheel bearing.
  • Page 33 Weichai America Corp. prevent crashing the crankshaft in this process. 7. Clean up upper thrust plate and press it into cylinder body. Then side with oil groove should face outward (face to crankshaft). 8. Check and make sure the oil seal is flat and free of distortion, and then place it into seal groove on cylinder undersurface with dedicated tool.

  • Page 34: Assembly And Disassembly Of Crankshaft Bearing Shell

    Weichai America Corp. 4. Check whether there is failure like thread damage on main bearing bolts 5. Check crankshaft flange bolt holes for crack. 6. Check wear condition of crankshaft journal, check bend and distortion condition of crankshaft. Assembly and disassembly of crankshaft bearing shell 3.3.1 Exploded view of crankshaft bearing shell...

  • Page 35: Assembly And Disassembly Of Flywheel And Ring Gear

    Weichai America Corp. 3.3.4 Inspection and maintenance of crankshaft bearing shell 1. Clean the bearing shells and check their wear condition 2. Check and ensure there is no peeling, locating lip damage and transverse crack on the shell. Assembly and disassembly of flywheel and ring gear 3.4.1 Exploded view of flywheel and ring gear...

  • Page 36: Assembly And Disassembly Of Piston-Rod Assembly

    Weichai America Corp. Bolt specification M16-12.9 (×6); Tightening torque: 285~295Nm; Test value: 285~340Nm. 3.4.4 Inspection and maintenance of flywheel and ring gear 1. Check whether there is failure like thread damage on flywheel bolts. 2. Check flywheel surface for conquassation.
  • Page 37 Weichai America Corp. Fig. 3-7 Exploded view of piston-rod assembly 3.5.2 Steps to disassemble piston-rod assembly 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 38 Weichai America Corp. 1. Install one circlip into piston circlip groove with internal circlip plier, and rotate the circlip to ensure it is properly fitted. The end with corner angle should face inward, 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 the other side of the piston.

  • Page 39: Assembly And Disassembly Of Torsional Vibration Damper Crankshaft Belt Pulley And Hub38

    Weichai America Corp. 6. Rotate the flywheel with external force until cylinder 1, 6 get to BDC, install thrust plates of cylinder 1 and 6, and screw on connecting rod bolts. Rod parting surface should face left side of cylinder block (i.e. engine oil cooler side). The numbered pistons should not be mixed, install each piston to the corresponding cylinder;...
  • Page 40 Weichai America Corp. crankshaft timing crankshaft torsional vibration damper gear crankshaft belt pulley fastening bolt hub fastening bolt Fig. 3-9 Exploded view of Torsional vibration damper Crankshaft belt pulley and Hub 3.6.2 Steps to disassemble torsional vibration damper and crankshaft belt pulley loosen the bolt of crankshaft belt pulley, remove the crankshaft belt pulley and torsional vibration damper in turn.

  • Page 41: Valve Train

    Weichai America Corp. 4 Valve train Disassembly and assembly of valve train 4.1.1 Exploded view of valve train Fig. 4-1 Exploded view of valve train 4.1.2 Disassembling steps of valve train 1. Remove the rocker arm and the rocker arm shaft;...
  • Page 42 Weichai America Corp. Fig. 4-2 Exploded view of camshaft 4.2.2 Steps to disassemble camshaft Disassembling steps are contrary to assembling ones. 4.2.3 Steps to assemble camshaft 1. After disassembling, examine camshaft and timing gear, and part with wear or large parameter deviation should be repaired or replaced.
  • Page 43 Weichai America Corp. required range after deburring, then the camshaft should be replaced. Fig. 4-3 Crankshaft gear and camshaft meshing diagram 6. After correctly installed the gears, mark 0 tick position of camshaft timing gear and crankshaft timing gear with a marking pen.

  • Page 44: Intermediate Gear Assembly And Disassembly

    Weichai America Corp. Intermediate Gear Assembly and Disassembly 4.3.1 Intermediate Gear Exploded View Fig. 4-4 Exploded view of intermediate gear name name name Intermediate gear washer Front end cover shaft shaft Intermediate gear bolt 4.3.2 Intermediate Gear Disassembly Procedure 1. Locate the four M10 bolts to be removed.

  • Page 45: Tappet And Pushrod Assembly And Disassembly

    Weichai America Corp. Fig. 4-5 install direction of intermediate gear 3. Put the intermediate gear module in the front cover. Install the pin-shaft. 4. Insert the four M10 bolts after installing the washer. Torque the bolts to 65~70 Nm. 5. Rotate the gear by hand after tightening the bolts. Check the clearance and ensure the gear turns smoothly.
  • Page 46 Weichai America Corp. Fig. 4-6 Exploded view of tappet and pushrod 4.4.2 Tappet and Pushrod Disassembly Procedure 1. After removing rockers and rocker shafts, pull the pushrods out vertically. 2. After removing camshaft, directly take out valve tappet, place them orderly;...

  • Page 47: Assembly And Disassembly Of Valve

    Weichai America Corp. 2. Ensure that the oil channels of valve tappet and pushrod are smooth. 3. Ensure that the pushrod is not crooked. Check wear condition on the outside surface. 4. Ensure that the two ends of the pushrod are not worn.

  • Page 48: Rocker And Rocker Shaft Assembly And Disassembly

    Weichai America Corp. 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 cartridge is in good condition before assembling. 2. Install valve inner and outer spring;...
  • Page 49 Weichai America Corp. Fig. 4-8 Exploded view of rocker and rocker shaft 4.6.2 Rocker and Rocker Shaft Disassembly Procedure 1. Rotate the crankshaft to ensure that the rocker moves smoothly. 2. Measure each valve clearance, and check any changes in valve clearance.
  • Page 50 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 51: Intake And Exhaust System

    Weichai America Corp. 5 Intake and Exhaust System Intake and Exhaust System Assembly and Disassembly 5.1.1 Intake and Exhaust System Exploded View turbocharger group intake pipe group exhaust pipe group Fig. 5-1 Exploded view of intake and exhaust system 5.1.2 Intake and Exhaust System Disassembly Procedure 1.

  • Page 52: Intake Manifold Assembly And Disassembly

    Weichai America Corp. to prevent the O-ring from falling out. 5. Remove the bolts bolting the intake elbow to the intake manifold. Remove the intake elbow and intake elbow gasket. 6. Remove the nuts bolting the exhaust elbow to the exhaust manifold. Remove the exhaust pipe and gasket.

  • Page 53: Exhaust Manifold Assembly And Disassembly

    Weichai America Corp. Air intake joint pipe Hexagon nut Mix air pipe joint Intake elbow pipe 5.2.2 Intake Manifold Disassembly Procedure 1. loosen the fastening bolt of the mix air joint pipe and the joint block, remove the mixer joint pipe and the gasket.
  • Page 54 Weichai America Corp. Fig. 5-3 Exploded view of exhaust manifold name name name Hexagon nut heat shield Ring Heat insulating cover of stud exhaust pipe Exhaust pipe Exhaust pipe gasket 9 Sleeve 5.3.2 Exhaust Manifold Disassembly Procedure CAUTION: All parts of the exhaust manifold and exhaust elbow will be extremely hot after engine operation.

  • Page 55: Disassembly And Assembly Of Turbocharger System

    Weichai America Corp. Reverse the Disassembly Procedure to assemble the exhaust pipe. Note the following during assembly: 1. Apply molybdenum disulfide to exhaust manifold bolts before use. 2. Torque the exhaust manifold attachment bolts to the recommended tightening torque of 65~80Nm.
  • Page 56 Weichai America Corp. 5.4.2 Disassembling steps of turbocharger system Disassemble the turbocharger system with the reverse order of assembly. 5.4.3 Assembling steps for turbocharger system 1. Install the turbocharger gasket to the exhaust manifold flange. 2. Install the gasket on the exhaust manifold flange to install the turbocharger assembly, and loosely install the style 2 all-metal hexagon lock nuts and tighten them.
  • Page 57 Weichai America Corp. Fig. 5-5 Measuring of axial end play 3. Check radial play of compressor impeller Press down or hold the compressor impeller by hand in the radial direction, and use the feeler gauge to measure the min/max clearances between the compressor impeller and compressor casing as shown in figure5-6.
  • Page 58 Weichai America Corp. Fig. 5-6 Measuring of radial play Daily maintenance: 1. Check the pipeline connecting of turbocharger and engine for looseness; if any, eliminate it. 2. Check the turbocharger for air and oil leakage; if any, eliminate it. 3. Check the turbocharger tightening screw for looseness; if any, eliminate it.

  • Page 59: Ignition System

    Weichai America Corp. 6 Ignition System Ignition System Assembly and Disassembly 6.1.1 Ignition System Exploded View Fig. 6-1 Exploded view of ignition system name name name bolt sparking plug ignition coil seat washer bolt ignition coil washer 6.1.2 Ignition System Disassembly Steps...

  • Page 60: Signal Generator Assembly And Disassembly

    Weichai America Corp. 2. Remove the ignition coil. 3. Dismount the sparking plug with the wrench for the sparking plug. 4. Remove the ignition coil seat. 6.1.3 Ignition System Assembly Steps 1. Check the clearance of the sparking plug with a feeler, the clearance is 0.35mm.
  • Page 61 Weichai America Corp. Fig. 6-2 Exploded view of signal generator name name name Signal generator timing gear washer speed sensor clamp plate stud Hexagon bolt hexagon bolt...
  • Page 62 Weichai America Corp. Fig. 6-3 Exploded view of signal generator name name name inner hexagon clamp plate screw washer washer Signal generator cover shield gear disc 6.2.2 Signal Generator Disassembly Procedure 1. Open the cover of the gear housing (the back of the signal generator (4)) 2.

  • Page 63: Engine Control Unit (Ecu) Assembly And Disassembly

    Weichai America Corp. 2. Check that the locknuts of the signal generator fluted disc are tightened and that the ignition angle of the signal generator is correct. 3. Change the O-ring and the washer after dismounting. 4. Check for damage to the speed sensor, tooth disc, or housing Engine Control Unit (ECU) Assembly and Disassembly 6.3.1 ECU Exploded View...
  • Page 64 Weichai America Corp. 6.3.4 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 plastic portion of the ECU connection for damage. Replace the ECU if there is any...

  • Page 65: Fuel System

    Weichai America Corp. 7 Fuel System Fuel System Assembly and Disassembly 7.1.1 fuel system interface diagram inlet bypass valve interface air filter joint pipe turbocharger inlet pipe water outlet interface water return joint pipe LPG joint pipe oil-gas separator joint pipe...
  • Page 66 Weichai America Corp. Fig. 7-2 Exploded view of LPG supply system name name name bolt cushion O-ring bolt cushion gas tube cushion joint bolt pipe clamp solenoid valve bolt pipe clamp bracket water joint gas joint joint O-ring bolt plug...

  • Page 67: Mix Air Intake System Assembly And Disassembly

    Weichai America Corp. 2. Remove the nut (13) 3. Remove the bolt (8) 4. Remove the water pipe of the LPG evaporator (20). 5. Remove the LPG evaporator and the bracket. 6. Change the spare parts which need be changed.
  • Page 68 Weichai America Corp. Fig. 7-3 Mix Intake System Exploded View name name name clamp bracket Inlet elbow hose air intake joint clamp clamp mixer bolt bracket bolt hose mix intake pipe bolt joint air intake joint pipe bracket gasket 7.2.2 Mix Air Intake System Disassembly Procedure 1.

  • Page 69: Ng Gas Supply And Gas Flow Control Valve (Epr Valve) Assembly And Disassembly

    Weichai America Corp. 5. Remove the air intake joint pipe (5) 6. Dismount the bolt (17) 7. Take the inlet elbow (15) 8. Disassemble the air return pipe of the oil-gas separator, remove the air intake joint pipe (6). 9. Remove the EPR valve, remove the mixer (10) 10.
  • Page 70 Weichai America Corp. bolt cross pipe bolt bolt bolt bolt bracket O-ring bracket EPR valve bolt electromagnetic bolt valve 7.3.2 NG Gas Supply And Gas Flow Control Valve (EPR Valve) Disassembly Procedure 1. Remove the bolt (2) 2. Remove the bolt (5) 3.

  • Page 71: Cooling System

    Weichai America Corp. 8 Cooling System Cooling System Disassembly and Assembly 8.1.1 Cooling System Exploded View The cooling system ensures that the engine can operate at the proper operating temperature. Forced circulation cooling is most effective at keeping the engine within the normal operating temperature range.

  • Page 72: Water Pump Assembly And Disassembly

    Weichai America Corp. 5. Remove the thermostat. 6. Remove the water pump. 7. Remove the middle cushion block of water pump. 8.1.3 Cooling System Assembly Procedure Reverse the Disassembly Procedure to assemble the Cooling System. Water Pump Assembly and Disassembly 8.2.1 Water Pump Exploded View...

  • Page 73: Thermostat Disassembly And Assembly

    Weichai America Corp. 8.2.3 Water Pump Assembly Procedure Reverse the Disassembly Procedure to assemble the Water Pump. 8.2.4 Water Pump Inspection and Maintenance 1. Check the water pump gasket for any cracks or damage. Replace it if necessary. 2. Check the bolts and studs for any damage to the threads. Replace any if necessary.
  • Page 74 Weichai America Corp. 4.8.3.4 Thermostat Inspection and Maintenance 1. Check the clamps to ensure good condition. Replace any if necessary. 2. Check the coolant rubber hoses for cracks or damage. Replace them if necessary. 3. Check the thermostat for fracturing or damage. Replace it if necessary.

  • Page 75: Lubrication System

    Weichai America Corp. damage. Replace components if necessary. 2. Reverse the Disassembly Procedure to assemble the Fan. 8.4.4 Inspection and Maintenance of Fan Check the fan, flange, and water pump pulley for any cracks or damage. Replace if necessary. 9 Lubrication System Disassembly and Assembly of Lubricating System 9.1.1 Exploded View of Lubricating System...

  • Page 76: Disassembly And Assembly Of Engine Oil Pump

    Weichai America Corp. 3. Remove engine oil pump. 4. Remove the cooling module of engine oil filter. 9.1.3 Steps to Assemble Lubricating System Assembling steps are contrary to disassembling ones. Disassembly and Assembly of Engine Oil Pump 9.2.1 Exploded View of Engine Oil Pump Fig.

  • Page 77: Disassembly And Assembly Of Engine Oil Filter

    Weichai America Corp. Disassembly and Assembly of Engine Oil Filter 9.3.1 Exploded View of Engine Oil Filter Fig. 9-3 Exploded view of engine oil filter 9.3.2 Steps to Disassemble Engine Oil Filter Remove the filter with dedicated tool, as shown in Fig..

  • Page 78: Disassembly And Assembly Of Main Oil Gallery Pressure Limiting Valve

    Weichai America Corp. Fig. 9-4 Exploded view of engine oil cooler 9.4.2 Steps to Disassemble Engine Oil Cooler Loose the connecting bolts and take down the cooler, as shown in Fig.. 9.4.3 Steps to Assemble Engine Oil Cooler 1. Check the cooler before assembling, make sure there is no manufacturing defect and damage.

  • Page 79: Disassembly And Assembly Of Deputy Oil Pressure Limiting Valve

    Weichai America Corp. Fig. 9-5 Exploded View of Main Oil Gallery Pressure Limiting Valve 9.5.2 Steps to Disassemble Main Oil Gallery Pressure Limiting Valve Screw off main oil gallery pressure limiting valve, as shown in Fig. 9.5.3 Steps to Assemble Main Oil Gallery Pressure Limiting Valve 1.

  • Page 80: Disassembly And Assembly Of Engine Oil Strainer

    Weichai America Corp. Fig. 9-6 Exploded view of deputy oil pressure limiting valve 9.6.2 Steps to Disassemble Deputy Oil Pressure Limiting Valve Screw off and take down deputy oil pressure limiting valve. 9.6.3 Steps to Assemble Deputy Oil Pressure Limiting Valve 1.

  • Page 81: Starting System

    Weichai America Corp. Fig. 9-7 Exploded view of engine oil strainer 9.7.2 Steps to Disassemble Engine Oil 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.

  • Page 82: Engine Accessory System

    Weichai America Corp. motor’s main components are the DC motor, one-way clutch, reduction gear train, electromagnetic switches, and the starter relay. See the dismantled starting system in Fig.10-1. Fig. 10-1 Exploded view of starting system 10.1.2 Starting System Disassembly Procedure 1.

  • Page 83: Alternator Assembly And Disassembly

    Weichai America Corp. fasten bracket bolt alternator belt Fig. 11-1 Exploded view of engine accessory system 11.1.2 Engine Accessory System Disassembly Refer to the Engine Accessory System Exploded View for disassembly details. 1. Remove the alternator pulley belt, bolts, and alternator. See Alternator Assembly and Disassembly for details.
  • Page 84 Weichai America Corp. alternator Hexagon bolt tighten bolt lock nut bolt bracket bolt Fig. 11-2 Exploded view of generator 11.2.2 Alternator Disassembly Procedure 1. Remove the alternator lock nut to loosen the belt if it has not already been removed. Remove the belt from the alternator pulley.
  • Page 85 Weichai America Corp. When providing warranty service for user, check the alternator on vehicle for malfunction. Tool: test lamp, the process is as shown in figure 11-3. Turn on the power switch of the vehicle, and connect the test lamp to the terminal B+ and E (negative pole) of the...
  • Page 86 Weichai America Corp. Vehicle fault Fault testing Troubleshooting a. Test for voltage a. If the terminal voltage of alternator indicator lamp is too low, it indicates that the power of excitation circuit indicator is of alternator too small or there is poor connection of circuit. Adjust the...
  • Page 87 Weichai America Corp. speed and does at b. Low idle speed high speed. of engine b) Low charging voltage Failure2: Low charging voltage Vehicle fault Fault testing Troubleshooting Check if alternator Test the voltage at alternator terminal B+ and which should be output power and (27.8~28.4) V.
  • Page 88 Weichai America Corp. firmly, and whether it Notice: Check if the reinstalled or re-tightened parts are still very hot is oxidized, virtual after engine runs with heavy load for (3~5) min. connected and overheated. g. Test the phase When the phase output voltage (W/R/AC) is greatly different from...
  • Page 89 Weichai America Corp. d) Unstable charging voltage Failure4: Unstable charging voltage Vehicle fault Fault testing Troubleshooting When engine a. Alternator and related belt is loose, belt Tension alternator and related belt. runs normally, slippage. voltmeter b. The joints of charging circuit get loose Inspect all connections of charging circuit.
  • Page 90 Weichai America Corp. 3100 Golf Road Rolling Meadows, IL 60008 http://www.WeichaiAmerica.com/...

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