WEICHAI WP10GTA Assembly/Disassembly Manual
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WEICHAI WP10GTA Assembly/Disassembly Manual

WEICHAI WP10GTA Assembly/Disassembly Manual

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WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM
Assembly & Disassembly Manual
Gas Engine
Model: WP10GTA
WEICHAI AMERICA CORP.

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Summary of Contents for WEICHAI WP10GTA

  • Page 1 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Assembly & Disassembly Manual Gas Engine Model: WP10GTA 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 10 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 & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM 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 Group ......................
  • Page 4 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4.5 Disassembly and assembly of valve ................54 4.6 Disassembly and assembly of intermediate gear ............57 Intake/exhaust system ....................... 59 5.1 Disassembly and assembly of intermediate gear ............59 5.2 Disassembly and Assembly of Turbocharger System .............
  • Page 5 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.6 Disassembly and assembly of main oil passage pressure limiting valve ......94 9.7 Disassembly and assembly of oil filter ................95 9.8 Disassembly and Assembly of Oil Cooler Cover ............. 96 9.9 Disassembly and Assembly of Oil Cooler ...............

  • Page 6: Disassembly & Assembly Of Engine

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM 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 Group

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2 Engine Block Group Disassembly and Assembly of Engine Block Group 2.1.1 Explosive View of Engine Block Group Fig. 1 Exploded view of engine block assembly...
  • Page 8 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 2 Exploded view of engine block assembly Fig. 2- 1 Exploded view of engine block assembly name name name Spring pin washer Hexagon bolt Hexagon socket Knock sensor...
  • Page 9 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Tightening Grade 22Nm~29Nm torque Tightening Grade 29Nm~35Nm torque 10.9 Key point 2: Assembly Tighten the main bearing bolts in a symmetric way according to the sequence shown in the figure below.

  • Page 10: Reassembly, Disassembly And Assembly Of Cylinder Block

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Ⅵ Ⅴ Ⅳ Ⅲ Ⅱ Ⅰ Fig. 2-3 Cylinder Head Auxiliary Bolts Tightening Order Key point 4: Assembly Before assembly, inspect the cylinder liner carefully for cracks and other defects, then clean and press it into the cylinder bore with special tool after applying molybdenum powder to the outside surface of cylinder liner.
  • Page 11 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Cylinder block Bowl plug Bowl plug Crankcase Bowl plug Camshaft bush Cylindrical pin with Bowl plug Bowl plug internal thread Bowl plug Bowl plug Main bearing bolt 2.2.2 Pre-assembly Preparation 1.

  • Page 12: Disassembly And Assembly Of Gear Chamber

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Before assembly, clean the upper plane of crankcase and it is necessary to apply sealants onto the upper plane of crankcase. Key point 4: If replace the bowl, clean the bottom hole and bowl surface before assembly, Apply sealant to the joint face of the bowl and engine body.
  • Page 13 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. name name name Seal ring Hexagon bolt Hexagon bolt O-ring O-ring Hexagon plug screw Hexagon plug Timing gear Cylinder pin screw chamber 2.3.2 Pre-assembly Preparation 1. Equipment condition: socket wrench 2.
  • Page 14 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 2-6 Schematic Diagram of Fastening Order of Gear Chamber Fastening Bolts Key point 2: Before assembly of the seal ring, observe if there is scratch or other defects on the seal ring; if there is, timely replace it with a seal ring.

  • Page 15: Disassembly And Assembly Of Front-End Cover

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Disassembly and Assembly of Front-end Cover 2.4.1 Explosive View of Front-end Cover Figure 2-7 Explosive View of Front-end Cover name name name Seal ring Hexagon bolt Hexagon bolt...

  • Page 16: Disassembly And Assembly Of Piston Nozzle

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. The assembly should be conducted in the reverse order of disassembly. 2.4.5 Overhaul of Front-end Cover 1. After disassembling the front end cover, put it in a clean environment, before assembly, check if there is relatively big dirt inside the front end cover to ensure the cleanliness of front end cover.

  • Page 17: Disassembly And Assembly Of Thrust Plate

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Piston nozzle Elastic cylinder pin assembly Nozzle Hollow bolt 2.4.2 Pre-assembly Preparation 1. Equipment condition: socket wrench 2. Preparation: disassemble the crankshaft and crankcase. 2.4.3 Disassembling Steps of Piston Nozzle 1.
  • Page 18 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 2-9 Explosive View of Thrust Plate name name Upper thrust plate Lower thrust plate 2.6.2 Pre-assembly Preparation 1. Equipment condition: socket wrench 2. Preparation: disassemble the crankshaft and crankcase.

  • Page 19: Disassembly And Assembly Of Front And Rear Oil Seals

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. attach it to the crankcase and assemble it together with crankcase. The oil groove side of thrust plate should be outward. Disassembly and Assembly of Front and Rear Oil Seals 2.7.1 Explosive View of Front and Rear Oil Seals...

  • Page 20: Disassembly And Assembly Of Flywheel Housing

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. For assembling oil seals, use special tooling to steadily press into the oil seals. Before assembly, the lubricant should be applied to oil seals and pressing tooling. 2. The oil seal should not be reused after disassembly.
  • Page 21 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 2-11: Explosive View of Flywheel Housing name name name Observation hole Flywheel housing Speed sensor cover plate Flywheel housing Hexagon bolt Hexagon plug bolt Flywheel Housing Flywheel...
  • Page 22 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Disassemble the flywheel housing bolts; 2. Disassemble the flywheel housing hexagon bolts and inspection port cover plate; 3. Disassemble the flywheel housing. 2.8.4 Assembling Steps of Flywheel Housing 1.

  • Page 23: Disassembly And Assembly Of Cylinder Head

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Disassembly and Assembly of Cylinder Head 2.9.1 Explosive View of Cylinder Head Figure 2-13 Explosive View of Cylinder Head name name name Ignition winding Cylinder head O seal ring...
  • Page 24 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Loosen cylinder head auxiliary bolt nuts, and take down the clamping block; 3. Loosen cylinder head main bolts; place them on the appropriate place. 4. loosen the install bolt of the Ignition winding clamp plate, remove the Ignition winding bush and remove the O seal ring;...
  • Page 25 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 4) Tighten the bolts to (76~102) Name. 2. Assemble cylinder head gasket Fig. 2-14 Cylinder head gasket 1) The cylinder head gasket can only be used for once and must be replaced with a new one when repairing;...
  • Page 26 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Install tool Valve Valve Stem Seal Guide cylinder head Fig. 2-15 Assembly of valve stem sealing sleeve 4. Assemble cylinder head 1) Clean the cylinder head carefully and ensure it is free of dust, chip, sand and other dirt; after that, clean the cylinder head lower surface;...
  • Page 27 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1) It is allowed that the cylinder head main bolt can be reused for three times; 2) Align the cylinder heads in turn, and apply a proper amount of clean lubricating oil to cylinder head main bolt thread, flange bearing surface and flanged nut before installing them to cylinder head.
  • Page 28 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Apply some sealant on the O- ring, put it in the groove of the cylinder head O seal ring. Assemble the ignition winding clamp plate, fasten the bolt in a symmetric way. Tighten the bolt to 15 Nm firstly, then tighten the bolt to (20-25) Nm.
  • Page 29 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Table 2-3 Required valve sinkage Required valve sinkage (mm) Intake valve -0.2~0.2 Exhaust valve -0.22~0.22 4. Check the inside of cylinder head intake and exhaust passages for water leakage after removing valve train;...

  • Page 30: Disassembly And Assembly Of Cylinder Head Cover

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2.10 Disassembly and Assembly of Cylinder Head Cover 2.10.1 Explosive View of Cylinder Head Cover Figure 2-19 Explosive View of Cylinder Head Cover name name name Hexagon bolt...

  • Page 31: Disassembly, Overhaul And Assembly Of Hoisting Rings Of Engine

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Check the new cylinder head cover gasket for manufacturing and operational defects as well as other damages before installing. 2. Clean the cylinder head upper surface, and then correctly install the cylinder head gaskets in turn.

  • Page 32: Disassembly And Assembly Of Oil-Gas Separator

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 2-20 Explosive View of Hoisting Rings of Engine name name Engine Hanger Hexagon bolt Plate Bracket of oil-gas Bracket separator 2.11.2 Disassembling Steps of Hoisting Rings of Engine Loosen the engine Hanger Plate, bracket of oil-gas separator and the hexagon bolt, remove them.
  • Page 33 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 2-21 Explosive View of Oil-air Separator name name name Air intake pipe of Oil-gas separator Pipe oil-gas separator Joint Hollow screw Pipe clamp Oil return pipe of...
  • Page 34 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5. If further disassembly is required, the oil-gas separator assembly can be removed as shown in figure 2-21. 2.12.3 Assembly steps of oil-gas separator The oil-air separator should be assembled in the reverse order of disassembly. It is required to ensure correct positions of all rubber tube and connectors according to Figure 2-21.

  • Page 35: Crank-Connecting Rod Mechanism

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3 Crank-Connecting Rod Mechanism Disassembly and assembly of crankshaft 3.1.1 Exploded view of crankshaft assembly Figure 3-1 Explosive View of Crank-Connecting Rod Mechanism name name name Main bearing bolt...
  • Page 36 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. connecting rod Main bearing shell Engine block 3.1.2 Pre-assembly Preparation 1. Equipment condition: socket wrench, torque wrench, open spanner, hole ring pliers 2. Preparation: attach the engine body to the rotating bracket, disassemble the cylinder head, oil pan and other peripheral parts.
  • Page 37 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7. Clean the upper thrust washer, and press it into the cylinder block, always with the oil groove of upper thrust washer outwards (towards the crankshaft). 8. With the oil seal flat/not distorted, place the oil seal into the seal ring groove on the lower plane of cylinder block with a special tool.

  • Page 38: Disassembly And Assembly Of Piston & Connecting Rod Group

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6. Check the wear of main journal and bending and distortion condition of crankshaft Disassembly and assembly of piston & connecting rod group 3.2.1 Exploded view of piston & connecting rod group Fig 3-3 Exploded view of piston &...
  • Page 39 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3.2.3 Disassembly steps of piston & connecting rod assembly 1. Inspections before disassembling. Check the axial clearance of connecting rod and the tightening torque of connecting rod bolts.
  • Page 40 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 30° Fig 3-4 Exploded view of Circlip 2. Insert the small end of connecting rod into the piston cavity, align the connecting rod small end with the piston pin hole and install the piston pin; finally, install the piston pin circlip on the other side.
  • Page 41 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ring into the piston ring grooves in sequence, ensuring that the piston ring face with "TOP" upwards, and the ring could be moved flexibly in the ring groove.

  • Page 42: Disassembly And Assembly Of Crankshaft Bearing

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7. Tighten the connecting rod bolts as follows: pretighten first, and next tighten diagonally with a torque of 120 Nm, and finally turn them by 90°±5° to a torque of 170Nm~250 Nm. Complete the installation for the other cylinders following the same method.

  • Page 43: Disassembly And Assembly Of Flywheel And Ring Gear

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Main bearing upper Main bearing lower Crankshaft shell shell 3.3.2 Pre-assembly Preparation 1. Equipment condition: marker pen 2. Preparation: disassemble the pulley and flywheel group, remove the crankcase and crankshaft.
  • Page 44 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig 3-8 Exploded view of flywheel and ring gear name name name Crankshaft Flywheel ring gear Bolt Locating pin Flywheel Flywheel bolt 3.4.2 Disassembly steps of flywheel and ring gear Disassemble the flywheel and ring gear with the reverse order of assembly.

  • Page 45: Disassembly And Assembly Of Vibration Damper And Crankshaft Pulley

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Hand tightening specifications: After adding lubricating oil to flywheel bolt thread and bearing surface, put the bolts into thread holes, and tighten them diagonally with a torque of 6020 0Nm.

  • Page 46: Valve Train

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Bolt vibration damper 3.5.2 Pre-assembly Preparation 1. Equipment condition: socket wrench, air wrench. 2. Preparation: remove the belt. 3.5.3 Disassembly steps of vibration damper and crankshaft pulley Remove the pulley bolts, take down the pulley and vibration damper.
  • Page 47 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 4-1 Exploded view of valve train name name name Gear housing Cylinder head Valve bridge Hexagon bolt Tappet Timing gear Push rod Rocker arm set Hexagon bolt...

  • Page 48: Disassembly And Assembly Of Camshaft And Camshaft Timing Gear

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Remove the rocker arm and the rocker shaft, and see section “Disassembly steps of rocker arm and rocker shaft” for details; 2. Remove the intake/exhaust valve, and see section “Disassembly steps of valve” for details;...
  • Page 49 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig.4-2 Exploded view of camshaft and timing gear assembly name name name Hexagon bolt Thrust plate Engine block Camshaft timing Camshaft gear Hexagon bolt Gear housing 4.2.2 Pre-assembly Preparation 1.
  • Page 50 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Check the backlash of timing gear; 4. On the engine assembly and disassembly work bench, rotate the crankshaft to locate the camshaft timing gear at the TDC of the 1# cylinder. Unscrew the hexagon head bolts of camshaft timing gear, and remove the timing gear and the locating pin;...

  • Page 51: Disassembly And Assembly Of Rocker Arm And Rocker Shaft

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2) Check whether the bolt is bent and deformed. Check the timing gear for teeth collision or serious wear on teeth surface. Key point 2: Assembly 1) If any impact damage is found on the camshaft hole, it is not allowed to repair it for reuse.
  • Page 52 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. name name name Cylinder head Rocker arm set Rocker arm bracket Valve bridge Rocker arm shaft Cylinder pin Hexagon bolt 4.3.2 Pre-assembly Preparation 1. Equipment condition: torque wrench, oil can, oil, small wrench 2.

  • Page 53: Disassembly And Assembly Of Tappet And Push Rod

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Turn the flywheel for 360° to make the 6# cylinder at the compression TDC; 4. Adjust the intake valve clearance of 6#, 5# and 3# cylinders and exhaust valve clearance of 6#, 4# and 2# cylinders clearance.
  • Page 54 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 4-4 Exploded view of tappet and push rod name name Engine block Cylinder head Tappet Push rod 4.4.2 Pre-assembly Preparation 1. Equipment condition: oil can, oil 2. Preparation: remove the rocker arm assembly before remove the push rod; remove the cylinder head before remove the tappet.

  • Page 55: Disassembly And Assembly Of Valve

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Apply clean lubricating oil to the valve tappet; 3. Place the valve tappet into the tappet hole; 4. After the cylinder head is assembled (see assembly steps of cylinder head), blow the push rod clean with compressed air, and then check if the oil hole is smooth;...
  • Page 56 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 4-5 Exploded view of valve name name name Valve spring top Valve spring Intake valve seat Cylinder head Valve collet Exhaust valve 4.5.2 Pre-assembly Preparation 1. Equipment condition: valve spring compressor, valve overhead clamp or other equivalent tools.
  • Page 57 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Apply molybdenum disulfide grease on the intake/exhaust valve stem uniformly, and then install the intake/exhaust valve to the cylinder head, and make sure that the intake/exhaust valve can slide in the guide pipe without being blocked;...

  • Page 58: Disassembly And Assembly Of Intermediate Gear

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Disassembly and assembly of intermediate gear 4.6.1 Exploded view of intermediate gear Fig. 4-6 Exploded view of intermediate gear name name name Intermediate gear Intermediate gear Intermediate gear...
  • Page 59 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Check the mark for mounting bolts of intermediate gear, and make sure the bolts have not rotated. Remove four M10 hexagon head bolts of the intermediate gear bolts and remove the flange spacer.

  • Page 60: Intake/Exhaust System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5 Intake/exhaust system Disassembly and assembly of intermediate gear 5.1.1 Exploded view of air filter group Fig 5-1 Exploded view of air filter group name name name Hexagon bolt...

  • Page 61: Disassembly And Assembly Of Turbocharger System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Hexagon bolt Plug 5.1.2 Pre-assembly Preparation 1. Equipment condition: air wrench, sleeve 2. Preparation: remove the peripheral parts on the air filter. 5.1.3 Disassembly steps of air filter group Disassemble the air filter group with the reverse order of assembly.
  • Page 62 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 5-2 Explosive View of Turbocharger system name name name Stud Rubber clamp Gasket Turbocharger Turbocharger oil Clamp gasket return pipe bolt Hexagon nut Clamp Clamp Turbocharger oil...

  • Page 63: Disassembly And Assembly Of Exhaust Manifold

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Seal ring Retaining washer Hollow bolt Washer 5.2.2 Pre-assembly Preparation Equipment condition: wrench, sleeve 5.2.3 Disassembling Steps of Turbocharger System 1. Loosen the hexagon bolt of the pipe clamp, take away hexagon bolt.
  • Page 64 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 5-3 Explosive View of Air Exhaust Manifold name name name Exhaust manifold Stud Pipe joint Exhaust manifold Seal ring Hexagon bolt gasket 5.3.2 Pre-assembly Preparation 1. Equipment condition: air wrench, sleeve 2.

  • Page 65: Disassembly And Assembly Of Mix Air Intake Pipe

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Check if there is indication of air leakage at the position of exhaust pipe flange. If there is, it is necessary to replace it with a new exhaust pipe gasket.
  • Page 66 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Pressure and Inner hexagon Hexagon bolt temperature screw sensor O-ring Washer Hexagon bolt Washer Pipe Hexagon bolt Wave spiral washer Pipe joint Hexagon bolt Inner hexagon Decompression Hexagon bolt...

  • Page 67: Disassembly And Assembly Of Intake Manifold

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Check is there burn out, short circuit or any other damage on the pressure temperature sensor, if there is, it is necessary to replace it. 4. Check if there is indication of air leakage at the position of exhaust pipe flange, if there is, it is necessary to replace it.
  • Page 68 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5.5.2 Pre-assembly Preparation 1. Equipment condition: air wrench, sleeve 2. Preparation: remove the peripheral parts of the exhaust manifold. 5.5.3 Disassembly steps of intake manifold Disassemble the intake manifold with the reverse order of assembly.

  • Page 69: 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 Ignition System Exploded View Fig. 6-1 Exploded view of ignition system name name Inner hexagon bolt Ignition coil Washer Ignition plug 6.1.2 Ignition System Disassembly Steps...
  • Page 70 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 6-2 Exploded view of ignition plug wrench 6.1.3 Ignition System Assembly Steps 1. Tighten the ignition plug with the ignition plug wrench, tighten torque (25-28) nm 2. Assemble the Ignition coil, 3.

  • Page 71: Engine Control Unit (Ecu) Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Control Unit (ECU) Assembly and Disassembly 6.2.1 Engine Control Unit Exploded View Fig. 6-3 Exploded view of Engine Control Unit name name name Hexagon bolt Hexagon bolt...

  • Page 72: Signal Generator Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Signal Generator Assembly and Disassembly 6.3.1 Signal Generator Exploded View Fig. 6-4 Exploded view of signal generator name name name Hexagon bolt Hexagon bolt Timing gear Cover Speed sensor...
  • Page 73 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 6-5 Exploded view of signal generator mark 6.3.3 Signal Generator Assembly Procedure 1. Assemble the timing gear onto the signal generator, fasten with M22 hexagon bolts, the fasten torque is (290-310) Nm.

  • Page 74: Fuel System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5. Check the clearance between the speed sensor and the fluted disc of the signal generator, it’s (0.5-0.15) mm. 7 Fuel System LPG Intake System Assembly and Disassembly 7.1.1 LPG Intake System Exploded View...

  • Page 75: Mix Air Intake System Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Outlet water pipe Plate washer Water pipe joint joint Clamp Three-way joint Cushion Bolt Inner hexagon bolt Gas joint Spring washer Spring washer 7.1.2 Signal Generator Disassembly Procedure 1.
  • Page 76 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 7-2 Mix Intake System Exploded View name name name clamp Hexagon bolt Hexagon bolt hose mixer Intake elbow hose bracket hose Clamp washer clamp mix intake joint...

  • Page 77: Ng Gas Supply And Gas Flow Control Valve (Epr Valve) Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6. Disassemble the fasten bolt of the mixer bracket, remove the mixer bracket. 7.2.3 Mix Air Intake System Assembly Procedure Reverse the disassembly procedure to assemble the mix air intake system.

  • Page 78: Cooling System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Check the balance tube of the LPG evaporator.. 4. Inspect the inlet pressure of the NG, the right pressure is 2.5kpa. 5. Inspect the joint of the gas path, make there is no leakage.

  • Page 79: Radiator Disassembly And Assembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Disassemble the tensioning pulley. 3. Disassemble the belts. 4. Disassemble the alternator, alternator support, crankshaft pulley and absorber. 5. Disassemble the alternator and alternator support. 6. Disassemble the thermostat. For more details, see Disassembling Instructions for Thermostat.

  • Page 80: Fan And Hub Disassembly And Assembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Clamp Water inlet pipe Water outlet pipe Hose Water outlet pipe 8.2.2 Pre-assembly Preparation Equipment condition: air wrench, sleeve wrench, open end wrench 8.2.3 Disassembling Steps of the radiator 1.

  • Page 81: Water Pump And Water Pump Disassembly And Assembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 8-3 Exploded view of the fan and hub name name name Hexagon bolt Hexagon self-lock Hexagon self-lock Hexagon bolt bolt bolt 8.3.2 Pre-assembly Preparation 1. Equipment condition: air wrench, sleeve wrench, open end wrench 2.
  • Page 82 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 8-4 Exploded view of the water pump and water pipe name name name Water pump Hexagon bolt Hexagon bolt Hexagon head Washer Hexagon bolt screw plug Water inlet pipe Pipe joint 8.4.2 Pre-assembly Preparation...

  • Page 83: Water Pump Disassembly And Assembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Check if there is blockage or crack or any other kind of damage of pipe connector and pipe connector subassembly. Replace if necessary. 2. Check if there is fracture or any other kind of damage of pipe connector gasket and water pump gasket.

  • Page 84: Disassembly And Assembly Of Thermostat

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Preparation: remove the belts, remove the alternator 8.5.3 Disassembling Steps 1. Remove the hexagon bolt 5, remove water pump 4 and water pump gasket 6; 2. Remove the stud 7 and stud 8.
  • Page 85 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 8-6 Exploded view of the thermostat name name name Water outlet pipe Water pipe washer Thermostat cover Water pipe washer Blocking cover Hexagon bolt Hexagon bolt Pipe joint...
  • Page 86 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5. Remove the hexagon bolt 3, separate the thermostat 10 and water pipe 4. 8.6.4 Assembling Steps of the thermostat 1. Before assembly, first, check the clamp, rubber tube clamp, rubber tube, thermostat, thermostat head, and make sure there is no defect or damage on manufacturing or use.

  • Page 87: Lubrication System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9 Lubrication System Disassembly and Assembly of Lubrication system Fig. 9-1 Schematic Diagram of Lubrication System 9.1.1 Explosive View of Lubrication System...
  • Page 88 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 9-2 Exploded view of lubrication system name name name Oil pump Dipstick Bypass valve Oil pan Oil filter Oil filling pipe Oil strainer Oil cooler cover Main oil passage...

  • Page 89: Disassembly And Assembly Of Oil Sump

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5. Disassemble the oil pump. 6. Disassemble the main oil gallery relief valve. 7. Disassemble the oil filter 8. Loosen the hollow bolts used for water intaking of air compressor on oil cooler cover and hexagon bolts used for fastening dipstick subassembly and disassemble the oil cooler cover, as shown in Figure 9-7.
  • Page 90 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.2.3 Disassembling Steps of Oil Sump 1. Turn the engine, sending the oil sump stand upwards (Key point 1); 2. Disassemble the oil sump fastening bolts (Key point 2);...

  • Page 91: Disassembly And Assembly Of Oil Strainer

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 9-4 Schematic Diagram of Fastening Order of Oil Sump Fastening Bolts Disassembly and assembly of oil strainer 9.3.1 Exploded view of oil strainer assembly Fig. 9-5 Exploded view of oil strainer assembly...

  • Page 92: Disassembly And Assembly Of Oil Pump Intermediate Gear Assembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.3.4 Inspection & repair of oil strainer Check the oil strainer, oil suction pipe and gasket for damage such as cracks, and replace them if necessary. 9.3.5 Assembly steps of oil strainer Assemble the oil strainer with the reverse order of disassembly.

  • Page 93: Disassembly And Assembly Of Oil Pump

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.4.3 Disassembly steps of oil pump intermediate gear assembly 1. Remove the hexagon head bolt. 2. Remove the intermediate gear shaft with special tools, and then remove the oil pump intermediate gear assembly.
  • Page 94 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 9-7 Exploded view of oil pump assembly name name Hexagon flange bolt Oil pump Hexagon flange bolt Oil pump gasket 9.5.2 Pre-assembly Preparation 1. Equipment condition: sleeve wrench, copper hammer 2.

  • Page 95: Disassembly And Assembly Of Main Oil Passage Pressure Limiting Valve

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. If there is oil leakage of oil pump gasket, check the failure of oil pump gasket, and replace the oil pump gaskets. 9.5.5 Assembling Steps of Oil Pump 1.

  • Page 96: Disassembly And Assembly Of Oil Filter

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.6.4 Assembly steps of relief valve of main oil passage 1. Before assembling, check the pressure limiting valve, and ensure that there is no defect and damage due to manufacturing and use.

  • Page 97: Disassembly And Assembly Of Oil Cooler Cover

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.7.2 Pre-assembly Preparation 1. Equipment condition: sleeve wrench, copper hammer 2. Preparation: no. 9.7.3 Disassembly steps of oil filter Loosen the oil filter bolts, remove the oil filter assembly and oil filter gasket.
  • Page 98 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Figure 9-10 Explosive View of Oil Cooler Cover name name name Oil cooler cover Hexagon flange Spring washer gasket bolt Hexagon flange Oil cooler cover Support block bolt...

  • Page 99: Disassembly And Assembly Of Oil Cooler

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Before installing oil cooler cover gasket, first, check the oil cooler cover gasket and oil cooler cover, and make sure there is no manufacturing or use defect and damage.

  • Page 100: Disassembly And Assembly Of Oil Cooler Bypass Valve

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1. Equipment condition: sleeve wrench, copper hammer 2. Preparation: remove the oil cooler cover, prepare drip pan. 9.9.3 Disassembling Steps of Oil Cooler Loosen the four bolts on oil cooler, and remove oil cooler and seal ring.
  • Page 101 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. name name Hexagon bolt Safety valve spring Composite washer Safety valve 9.10.2 Pre-assembly Preparation 1. Equipment condition: sleeve wrench, copper hammer 2. Preparation: no. 9.10.3 Disassembling Steps of Oil Cooler Bypass Valve Loosen and remove the hexagon plug screws, and then remove composite washer, safety valve spring and safety valve in order.

  • Page 102: Start-Up System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10 Start-up System 10.1 Disassembly and Assembly of Start-up System 10.1.1 Explosive View of Start-up System The starter is the core component of the starting system. The starter converts battery power to electromagnetic torque.

  • Page 103: Engine Accessory System

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Reverse the Disassembly Procedure to assemble the Starting System 10.1.4 Inspection and Maintenance of Starting System 1. Pay attention to the wiring terminals and wiring harness in maintenance, don’t collide and pull the terminal and harness.

  • Page 104: Alternator Assembly And Disassembly

    WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.1.2 Engine Accessory System Disassembly 1. Swing the tension wheel clockwise, remove the belt tension and remove the belt. 2. Remove the alternator, See alternator disassembly for details.
  • Page 105 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.2.3 Alternator Disassembly Procedure 1. Remove the belt, remove the hexagon bolt and hexagon flange bolt, remove the plate. 2. Remove the alternator. 11.2.4 Alternator Assembly Procedure Reverse the Disassembly Procedure to assemble the Alternator.
  • Page 106 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Turn on the power switch of the vehicle, and connect the test lamp to the terminal B+ and E (negative pole) of the alternator It indicates that there is no voltage at wiring...
  • Page 107 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. connection point. engine is working to earth, it should b. When the terminal voltage of alternator indicator lamp is be (1~3) V zero, short circuit point may exist at alternator end of excitation circuit, please test the circuit.
  • Page 108 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 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 (27.8~28.4) output power and V.
  • Page 109 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. should be about half of the output voltage at B+). h. Inspect battery for After charging for 10 min, the charging current should drop to about10A, normal charging.
  • Page 110 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 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 111 WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3100 Golf Road Rolling Meadows, IL 60008 http://www.WeichaiAmerica.com/...

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