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Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators

Maintenance

Manual

4M11

Series

Diesel

Engine

For

Land

Power

Generators

Summary of Contents for 4M11G

Page 1: ...Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ...

Page 2: ...bolts and connecting rod bolts of the diesel engine Please do not loosen or disassemble any bolt by self The connecting rod bolts are of one time bolts and can t be reused The oil and fuel added to the diesel engine must be of the designations specified in this service manual Dedicated clean filters must be used for the addition Before addition the fuel shall settle for 72 hours Before driving the...

Page 3: ...linders Under severe working environment increase the cleaning or replacement frequency of the air filter element in order to prevent malfunctions such as earlier wear of diesel engine The checking and repair for all parts of the electric system must be fulfilled by the professional electric technicians ...

Page 4: ...includes the engines for stationary generators pumps air compressors and marine emergency applications This manual briefly describes the technical parameters structural characteristics operation and maintenance methods and service essentials of 4M11 China II stationary generator series diesel engine for the user s reference Following the continuous development of the product the product structure ...

Page 5: ...Engine 8 Chapter II Maintenance Guide 9 2 1 Fuel Oil Lubricating Oil Coolant and Auxiliary Materials for Diesel Engine 9 2 1 1 Fuel Oil 9 2 1 2 Lubricating Oil 9 2 1 3 Coolant 10 2 1 4 Auxiliary Materials 11 2 2 Routine Maintenance 12 2 3 Contents of Maintenance at Each Level 15 2 4 Maintenance for Long term Storage 20 2 4 1 Clean 20 2 4 2 Protection 20 Chapter III Typical Faults and Solutions 22 ...

Page 6: ...ad 37 4 2 4 Disassembly Inspection Repair and Assembly of Oil gas Separator 41 4 2 5 Disassembly Inspection Repair and Assembly of Lifting Ring 42 4 3 Engine Block Group 43 4 3 1 Disassembly Inspection Repair and Assembly of Engine Body Combination Group 43 4 3 2 Disassembly Inspection Repair and Assembly of Body Components 46 4 3 3 Disassembly Inspection Repair and Assembly of Front Wall Cover 48...

Page 7: ...ion Repair and Assembly of Intermediate Gear 77 4 6 Intake and Exhaust System 78 4 6 1 Disassembly and Assembly of Intake and Exhaust System 79 4 6 2 Disassembly Inspection Repair and Assembly of Intake Pipe 80 4 6 3 Disassembly Inspection Repair and Assembly of Exhaust Pipe 81 4 6 4 Disassembly Inspection Repair and Assembly of Turbocharger System 82 4 7 Fuel System 86 4 7 1 Disassembly and Assem...

Page 8: ...ssure Control Valve 101 4 9 6 Disassembly Inspection Repair and Assembly of Oil Suction Filter 102 4 10 Starting System 103 4 10 1 Disassembly Inspection Repair and Assembly of Starter 103 4 11 Vehicles Accessories System 104 4 11 1 Disassembly Inspection Repair and Assembly of Alternator 104 Appendix A Fit Clearances for Main Parts of Diesel Engine 111 Appendix B Wear Evaluation References for Ma...

Page 9: ... 4M11 Series Diesel Engine For Land Power Generators 1 Chapter I General Information 1 1 Exterior View of Diesel Engine Figure 1 1 Exterior View of 4M11 Diesel Engine Figure 1 2 Intake and Exhaust Side of 4M11 Diesel Engine ...

Page 10: ...Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 2 Figure 1 3 Flywheel End of 4M11Diesel Engine Figure 1 4 Fan End of 4M11Diesel Engine ...

Page 11: ... in line direct injection wet type sleeve high speed diesel engine Intake type Turbochargerd Turbochargerd and inner cooling Displacement L 4 5 Bore Stroke mm mm 105 130 Number of cylinders 4 Valve number of per cylinder 2 Compression ratio 18 1 Ignition Sequence 1 3 4 2 Fuel injector Mechanical pump Emission level Non road stage II Fuel consumption at rated power g kW h 250 Minimum fuel consumpti...

Page 12: ...ndition only when the sealing oil in the fuel system is used up and the diesel is supplied to the engine But the user should pay attention that the oil sealing period for diesel engine is one year At the expiration of one year conduct checking and take necessary supplemental measures 3 Check the water plug and oil plug for presence of blockage check for completeness of water temperature and oil te...

Page 13: ...erline of the diesel engine is coaxial with the axis of input shaft of drive unit gearbox transmission or alternator and ensure that the crankshaft is free of additional axial force due to assembly 1 7 Pre start Preparations of Diesel Engine 1 Check the coolant level If the engine is already assembled on a machine observe the coolant level If the coolant is insufficient add coolant through the fil...

Page 14: ...If the diesel engine fails to start in 15s wait for 2min before retry If the engine can t be started by three consecutive attempts stop the attempt and find out and solve the malfunction before retry After the start of diesel engine observe the readings of the instruments and keep the engine idling In such case the engine oil pressure shall be no less than 120kPa Do not idle the engine for a long ...

Page 15: ...e power output of the engine increases along with the increasing of the speed and reaches rated value at the rated speed Notice To prevent damaging the diesel engine it s prohibited to disconnect the cable to the diesel engine voltage regulator or to the positive terminal of battery while the engine is running Differing from DC generator it s prohibited to temporarily ground an alternator for volt...

Page 16: ...ol down the piston cylinder sleeves bushings shaft sleeve and turbocharger for a sufficient time in order to prevent the cylinder scuffing and bushing scratch This is especially important for a turbocharged diesel engine The bearings and oil seals in the turbocharger are subject to the influence of the high temperature exhaust gas This heat is carried away by the circulating engine oil during the ...

Page 17: ...ng is 9 8L depending on the marking of the oil dipstick The oil capacities vary depending on different models For Weichai Power non road phase II series diesel engines CF 4 grade engine oil shall be used For details refer to Table 2 1 Table 2 1 Selection Specification of Weichai Special Engine Oil Variety Product category Packing specification Applicable model Diesel engine oil CF 4 10W 30 15W 40 ...

Page 18: ...filter Fine filter 4M11 9 12 1 1 1 Remark 1 The added volumes listed in the table are only for reference Actual added volumes shall be decided with the oil dipstick 2 If the vehicle is equipped a highly cold resistant filter or moisture removing filter as developed by Weichai Power they shall also be replaced when the fuel is replaced 2 1 3 Coolant The freezing point specification for Weichai spec...

Page 19: ...pplied onto the intake valve stem Table 2 6 Reference Table for Sealant Application of Diesel Engine Mark Main use List of locations for application of sealant Supplement Loctite 242 It s applied onto the threads to prevent being vibrated to looseness with moderate strength Flywheel cover bolt Camshaft thrust halfring bolt Camshaft timing gear bolt Intermediate idler bolt Front end cover bolt Engi...

Page 20: ...ver Interface between water pump rear cover and engine body front end face Interface between flywheel cover and its connecting plate Interface between cylinder block and engine oil cooler cover Interface between cylinder block and engine oil filler cap cover Loctite KB5910 Junction surface between oil sump and engine block 2 2 Routine Maintenance Check the coolant level and temperature Observe the...

Page 21: ...Figure 2 eck the cool ngine oil le engine whe f oil dipstick is stopped l to flow int Description f ne oil level b and Power Gene 13 2 1 Bleeding B ant level be vel is with en the oil le k wait for at to the oil pa for Markings before star erators Button efore startin hin the mar evel is below least 5min an sufficient of Engine Oi rting the die ng the diesel rkings of t w lower ma and then ch tly ...

Page 22: ...leakage Check the fan Visually check the fan blades for presence of damage check the plastic fan for presence of deformation check the steel fan rivets for presence of looseness check the blades for presence of bending and check the connecting bolts for secure fastening in order to ensure the reliable functioning of fan Check the belt The belt is tensioned automatically by belt tensioner Check the...

Page 23: ... gine place on the botto en the oil fil il dipstick ti ort lement see e oil filter o by special o tely with cle of new oil f mes into co d check for p and Power Gene 15 Level a container om of oil su ller cap add ill the requi Figure 2 7 operate as pe oil filter wre ean engine o filter before ontact with t presence of erators r for collec ump to fully d oil throug ired level is er the follow ench ...

Page 24: ...the rotation direction of engine to the compression top dead center of 1st 4th cylinder In such case the groove on the flywheel is aligned with marking OT on the flywheel housing as shown in Figure 2 8 Figure 2 8 Flywheel Marking Disassemble the valve rocker cover from the cylinder head and judge whether the 1st or 4th cylinder is at compression stroke there is a gap between exhaust valve and rock...

Page 25: ...le 2 7 Table 2 7 Val st cylinder ke and exhau valves djusting bolt and Power Gene 17 re 2 9 Adjust and valve s o valves pe respectively the clearanc gure 2 9 an igure 2 10 Ad 4th cylinde then check lve Adjustmen 2 cyl ust In va erators Valve Cleara tem head b er cylinder y If the cle ce by adjustm nd tighten th djusting Bolt er turn the e k and adjus nt Sequence 2nd linder c ntake alve ance y feel...

Page 26: ...ip fuel system ghtness of a tem ntake hose f hen necess er element l Engine For La n adjustabl igure 2 11 lter operate peline by special f il to the sea hand peline m assembled f for presence ary tighten Figure 2 12 and Power Gene 18 e Exh va e as per the fuel filter w al ring befor fuel filter Figure 2 11 F e of aging o n or replac 2 gives the d erators haust alve following p wrench to dis re ass...

Page 27: ...ted speed under full load When the intake resistance reaches the maximum permissible limit clean or replace the filter element as per the manufacturer s instructions Notice It s absolutely prohibited to run the engine without the air filter otherwise the ingress of dusts and impurities into the diesel engine will lead to earlier wear of engine Disassemble the filter element from the air filter and...

Page 28: ... the entire fuel line If the diesel engine is not filled with cooling emulsion after the drainage of coolant add cooling emulsion and anti rust oil for protection of cooling chamber Before sealed storage start the engine with above mentioned emulsion as per the start procedure and idle for 15 25min Disassemble the end cover plate of the intake pipe and spray anti rust oil into the intake pipe by p...

Page 29: ... and easy rusting parts of the diesel engine Seal for storage after above procedure is completed To prevent the ingress of moisture and impurities into the diesel engine seal all openings of diesel engine including intake port exhaust port and coolant pipes by caps and properly cover the diesel engine by plastic jacket ...

Page 30: ...r Ge ly malfunct e interruptio n location or and Power Gene 22 ical Fault ned and man specified te ng term guar leading to er managem ecified or ev ecially the ly shorten th ubricating o for malfun malfunction ngine See F ge the char nd of diesel rrupt the wo enerally the tioned cylin on of cylind r cause erators s and Sol nufactured u ests In addi rantee of its failure of di ment and ope ven repa...

Page 31: ...ine General Fault and Troubleshooting 3 2 1 Start Failure or Difficult Start of Diesel Engine SN Cause Troubleshooting 1 Malfunction in fuel system 1 1 Non opened switch or no fuel of fuel tank Open switch or add sufficient fuel 1 2 Air content in fuel system Check pipeline connectors for looseness and bleed air form fuel line 1 3 No fuel supply of fuel delivery pump Check fuel delivery pump and r...

Page 32: ...linders of fuel injection pump Check and repair fuel injection pump and adjust on fuel pump test stand to ensure consistent fuel supply volume for all cylinders 4 Poor working performance of individual fuel injector Check fuel injector with poor working performance and clean or replace 5 Unstable working of speed regulator Check speed regulator and solve malfunction 6 Low fuel quality or water con...

Page 33: ...use 3 2 4 Abnormal Oil Pressure of Diesel Engine SN Cause Troubleshooting 1 Low oil level in oil sump Add to specified level 2 Failure of engine oil pressure gauge Overhaul or replace 3 Blockage of engine oil strainer and filter Clean replace engine oil filter element 4 Excessive wear of crankshaft main bearing and connecting rod bearing Overhaul or replace 5 Incorrect engine oil trademark and wat...

Page 34: ...Failure non opened of thermostat Check the cause and replace 3 2 6 Abnormal Exhaust Gas Color of Diesel Engine SN Cause Troubleshooting 1 White Exhaust Gas 1 1 Poor atomization of fuel injector Check injection pressure and state of fuel injector 1 2 Water in diesel Clean diesel tank and filter and replace diesel 1 3 Insufficient compression pressure of cylinder Check valves cylinder gasket and pis...

Page 35: ...tem Bleed air and check pipeline airtightness 2 2 Blockage of fuel system Clean and replace fuel filter element 2 3 Seizure of fuel injection pump rack or plunger Overhaul fuel injection pump 2 4 Blockage of intake pipe or air filter Check and clean air filter 2 5 Diesel runs out Add diesel 3 2 8 Abnormal Sound during Running of Diesel Engine SN Cause Troubleshooting 1 Rhythmic clear sound within ...

Page 36: ... rod and bearing with dumb impact sound Replace bearing 7 Excessive clearance of main bearing similar to knocking sound of connecting rod bearing Replace main bearing 8 Impact between piston and valve and metallic knocking sound near cylinder at low speed Check valve timing 9 Excessive gear clearance and knocking sound in gear chamber at sudden reduction of speed Check and adjust gear clearance an...

Page 37: ... you know what potential risks are and how to ward off such risks In case of any behaviors in violation of the warning information it may result in damage to property personal injury and even death Some common danger signs are usually used for ordinary warnings Warning information in this manual is classified into different types slight injury serious injury and death according to severity of poss...

Page 38: ... this manual cannot give warning instructions for all kinds of potential danger If the procedures taken by you are not recommended ones please ensure the same procedures are safe to operate and do not result in any damage to property Figur Meaning Wear hand protections Wear ear protections Wear eye protections Wear head protections Wear foot protections Wear protective masks Wear overalls Avoid na...

Page 39: ... 2 If possible please wear the protective clothing and water proof gloves 3 Never place any oil immersed rag into your pocket 4 Guard your clothing especially the underwear against the oil contamination 5 Wash your working clothing frequently Throw away oil immersed clothing and shoes that can t be cleaned 6 In event of cuts or injuries please immediately take the emergency treatment 7 Make sure t...

Page 40: ... and Assembly of Engine Most accidents in connection with use maintenance and service of engine are resulted from failure to observe safety rules and basic precautions So you should know risks you face and take corresponding preventive measures to avoid occurrence of accidents Operation maintenance and repair of the engine shall be performed by personnel who have received required trainings and ha...

Page 41: ...Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 33 Notice Stop the engine during maintenance or service ...

Page 42: ...sassembling instructions of intake and exhaust system for details 2 Disassemble the fuel return pipe of fuel injector and the high pressure fuel pipe For details see the instructions for disassembly of fuel system 3 Disassemble the exhaust pipe For details see the instructions for disassembly of intake and exhaust system 4 Disassemble the intake pipe For details see the instructions for disassembl...

Page 43: ...and push rod For details see the instructions for disassembly of valve mechanism 9 Disassemble the cylinder head assembly and the cylinder head gasket 10 Disassemble the inner and outer springs of valves spring upper and lower seats of intake and exhaust valves valve collets and valves For details see the instructions for disassembly of valve mechanism 11 Disassemble the valve stem seal 4 2 1 3 Cy...

Page 44: ...ce of Cylinder Head 1 Observe the cylinder head cover for presence of cracking Upon detection of cracking replace with new cylinder head cover 2 In the case of oil leakage from the cylinder head cover gasket check for cylinder head gasket failure and replace the cylinder head cover gasket 3 The cylinder head cover gaskets can be used only once Replace with new ones in event of repair 4 2 2 4 Cylin...

Page 45: ...for Assembly of Cylinder Head Figure 4 3 Exploded View for Assembly of Cylinder Head 4 2 3 2 Cylinder Head DisassemblyProcedures 1 Disassemble the cylinder head cover Refer to disassembling instructions of cylinder head cover for details 2 Disassembly the fuel injector For details see the instructions for disassembly of fuel system 3 Loosen the cylinder head bolts in reverse sequence of the assemb...

Page 46: ...nd urface condi ion d crack of the vertical etween mea It is possib Figure 4 sinks refer and Power Gene 38 ack to the cy d and plac ombustion nder heads roblem anal d gasket If ylinder num haust valve m for detail al f Cylinder head check malities in an the surfa exhaust por itions the cylinde distance b asured and ble to use de 4 4 Depth Mi r to Table 4 erators ylinder bloc e it on a p chamber an...

Page 47: ... Proc take and exh der head gas and Power Gene 39 ed to ensure missible va alve seat rin ealing surfa equired Valve quired Valv 1 1 and valve g guide is the stem and va guiding eff meter of th e Measure r clearance value is ou y of diesel e 4 5InsideMic l leakage at to the cyli head gaske rubber lips pring for in ling sleeve a edures haust valve sket It s pro erators e the reliabi alue disasse ng ...

Page 48: ...e further for 120 4 6 The tightening sequence for the cylinder head bolts of each cylinder is shown in figure below The tightening sequence for the cylinders is 2nd 3rd 4th and 1st cylinders Notice Each bolt is stretched by 0 2 0 6 mm during every tightening process The maximum allowable length is 160 5mm for the bolts after repeated use Any bolt in excess of this length must be replaced with new ...

Page 49: ...ator and O ring 4 2 4 3 Inspection and Maintenance of Oil gas Separator 1 Check all rubber hoses for presence of aging Upon detection of serious aging or cracking the replacement is probably required 2 Check the external surfaces of the ventilator and the oil gas separator for presence of cracking Upon detection of deep cracking that already or probably leads to leakage the replacement is required...

Page 50: ...mbly of Lifting Ring 4 2 5 2 Lifting Ring DisassemblyProcedures After disassembling the covering part of lifting eye bolts loosen and disassemble the lifting eye bolts 4 2 5 3 Inspection and Maintenance of Lifting Ring Check the external surface of lifting eye bolts and the threaded holes for presence of cracking If any replace with new ones 4 2 5 4 Lifting Ring Assembly Procedures The assembly pr...

Page 51: ...of Engine Body Combination Group SN Name SN Name SN Name 1 Engine block components 15 Spring washer 29 Cylinder head bolt 2 Cylinder liner 16 Stud bolt 30 Flexible parallel pin 3 Camshaft bushing 17 Hex socket head cap screw 31 Parallel pin 4 Camshaft bushing 18 O shaped seal ring 32 Parallel pin 5 Camshaft bushing 19 Screw 33 Shaft 6 Plug 20 Steel ball 34 Spring washer 7 Sleeve 21 Combination sea...

Page 52: ...the fo hten to 30N for 120º 4º further for 1 ing sequenc ing Sequenc l Engine For La 24 25 26 27 28 nation Gro cylinder hea lbow Point ery passage liners point bushings p r of Cylind the suppor per the follo by four axis m to tighten following m m 20º 4º ce for the c Figure 4 ce for Cylin and Power Gene 44 Hexagon hea Stud Cylinder Cylinder Cylinder oup Disas ad point 1 t 2 plug and w t 3 point 4 ...

Page 53: ...embling wipe clean and apply clean lubricating oil or grease Assembling Erect the cylinder sleeves on the cylinder block assemble seal rings to corresponding positions between cylinder block and cylinder sleeves place the cylinder sleeves vertically into the cylinder bores and knock the cylinder sleeves in place by a nylon bar Point 4 Disassembly Using a special tool disassemble the camshaft bushi...

Page 54: ...ring bo n bearing ca tenance of e block inc d surfaces o ng damage ng Unless bolts of mai per the seq and Power Gene 46 oup Assem ation group i air and As ponents or Assembly ody Comp olts point 1 ap point 2 f Engine B luding but of the cylind scratch an otherwise s in bearing c uence show Main bearing bolt erators mbly Proc is in the rev ssembly of of Engine Bl onents 1 Block Com not limited der ...

Page 55: ...s Point 2 Assembly Assemble the thrust bearing cap to the rear end of cylinder block and assemble non thrust bearing caps for other places Orient by two ends during assembly The main bearing bolts can t be assembled in event of reverse orientation 4 3 2 4 Engine Block Components Assembly Procedures Assembly of engine block combination is in the reverse order of disassembly ...

Page 56: ...O ring ator ar ate gear shaft ng subassemb Hexagon bolt Spri l Engine For La tion Repa Assembly o Exploded Vi dures of F tilator w plug nt wall cap ial seal ring tenance of cleanliness rs and check ocating pin Figure 4 14 Shaft ft bly t ing washer and Power Gene 48 air and As of Front W iew for Assem Front Wall Point 1 g Point 2 f Front Wa of front w k seal ring f to correspon Knock in of erators ...

Page 57: ...le sembly Pr res of front Knocking side edges and Power Gene 49 ller uniform face tion of Sealan the front w fit the fron Knocking of F ding threade nch and ope eals and sea rt While as wly press in distributed and must rocedures wall cover of s erators mly to the ju nt for Front W wall cap and nt wall cap w Front Wall Ca ed holes at en end wren al rings to en ssembling ti the oil seal to the peri...

Page 58: ... o 7 Exploded V assemblyP wheel cover ywheel cov wheel cover tenance of using for th y 240 fine ywheel hou bolts and 17 e bolts s respective ure and tigh and Power Gene 50 air and As of Flywhe View for Asse Procedures fixing bolts ver observa point 2 f Flywhee horough cle oilstone wi using and c 7mm and 19 ely Tighten hten the M erators ssembly of eel Cover embly of Flyw s s point 1 ation wind el ...

Page 59: ... Tightening Sequence of Bolts Notice For above mentioned high strength bolts apply lubricating oil to the threads and support surface before assembly 4 3 4 4 Flywheel Cover Assembly Procedures The assembly procedures of flywheel cover are in the reverse order of the disassembly procedures ...

Page 60: ... oil pan and sealing gasket 4 Disassemble the magnetic plug and combination washers 4 3 5 3 Inspection and Maintenance of Oil Pan Point 1 Disassembly Using a special tool disassemble the camshaft bushing While doing so be careful not to cause damage to other bushings Place the container containing oil beneath the drain plug of the oil pan and use a screw plug wrench to loosen the drain plug to emp...

Page 61: ... Engine For La nd washers rocedures es are in the tion Repa Assembly o 7 Exploded V semblyPro agon bolt p zle assembl tenance of fuel injecto re plate to th resence of d an without b mbly Proce nozzle is in and Power Gene 53 and tighten e reverse ord air and As of Piston N View for Asse ocedures point 1 ly point2 f Piston N or subassem he recessed damage and burrs edures n the reverse erators n th...

Page 62: ...e f the thrust h l Engine For La tion Repa Assembly o 1 Exploded V assemblyP n bearing cap nkshaft see st halfrings tenance of be used in p ace the erro embly Pro halfrings is and Power Gene 54 air and As of Thrust H View for Asse Procedures p see sectio section 4 4 point 1 f Thrust H air During r proof lug ocedures in the rever erators ssembly of Halfring embly of Thru s on 4 3 2 4 Halfrings asse...

Page 63: ...se he rear oil se tenance of the junctio hout damage junction su the junction rankshaft fla ating pin to ear oil seal c nch Tighte and Power Gene 55 air and As of Front an for Assembly semblyPro l cover see seal see sec eal cover p eal point 2 f Front an on surfaces e urfaces betw n surface of ange the end by a cap insert t ning Sequen erators ssembly of nd Rear O y of Front and ocedures e section...

Page 64: ... is clean without clear scratch on machined surfaces Assembly Apply sealant to the perimeter of the rear oil seal radial seal ring and press it into the rear oil seal cap by special tooling Notice Ensure that the seal ring is free of damage and the outer end of seal ring is level with the oil seal cap plane after assembling 4 3 8 4 Front and Rear Oil Seal Assembly Procedures Assembly of the front ...

Page 65: ...ble the rem exagon sock er and whe heel bolts od Mecha he reverse o gear ub Main bearing Main bearing bolt and Power Gene 57 m f Crank Co necting Ro w of Crank C anism Disa y Check a bolt put th center and the top dead ct the big en maining pis ket cylindric eel hub and disasse anism Asse order of the Conne rod ca Pi co erators onnecting od Mechan Connecting Ro assembly P axial backla he slant sid...

Page 66: ...and Connecting Rod Subassembly 4 4 2 2 Piston Connecting Rod Group Disassembly Procedures 1 Inspection before disassembly Check the axial play of connecting rod shaft and check the Piston connecting rod group Piston connecting rod group Crankshaft Engine block Piston pin Piston pin retainer Connecting rod shank Elastic locating pin Connecting rod caps Connecting rod bolts The 1st compression ring ...

Page 67: ...n rings for excessive wear Check the upper and lower sides of piston rings for excessive wear 3 Check the outer surface of piston pin for excessive wear 4 Check the connecting rod big end pre formed hole connecting rod shank and connecting rod small end lubricating oil hole for cracks Check the connecting rod bearing shells for excessive wear or peeling off of alloy layer Check the flanks of conne...

Page 68: ...ibly ylinder cran ting oil at in f rings the f the centerlin r that its ope l ring is asse of the first r dicular bise ston Ring Ga ntil the pis tom dead c Slightly tigh ft of cylind arked on the he connectin nk Before screw them hem by 58 and connec Oil rin erators to mount th e TOP e in the ring nkshaft cran ndividual ki first ring is ne of the p ening end i embled in su ing and the ctor of the ...

Page 69: ...earin front and re and distortio y Procedur aring base h gs into the materials scr g shell is pr nd if collide aft timing al Hub and Power Gene 61 air and As of Cranksh ew for Assem dures ng cap upwa uence d flywheel e oil seal t too long th be put by ca f Cranksha al of cranksh tion part o nd other abn ng journal an lings ont and rear ng bolts are ar end of cr on of cranks res holes of the main b...

Page 70: ...oove of the upper thrust halfring should be outward toward the crankshaft 6 Press in the lower main bushing assemble the main bearing cap and assemble the lower thrust plate with the oil groove facing towards the crankshaft end 7 Ensure that the oil seal is level without distortion or deformation and place the oil seal levelly into the seal ring groove of the cylinder block lower plane by special ...

Page 71: ...o 4 30 Explode Ring Disas are in the r tenance of flywheel is surface for flywheel ge Gear Assem ar ring to th el pin to th Crankshaft and Power Gene 63 ng Sequence o air and As of Flywhe ed View for A ssembly Pr everse orde f Flywhee subject to th damage ar ring is da mbly Proc he flywheel u he rear end o erators of Main Bear ssembly of eel Assembly of F rocedures er of the asse el and Gea hread ...

Page 72: ...ey D socket cylin ulley bolts tenance of damper for pulley or hu bolts and he Con lt ew kshaft pulley and Power Gene 64 ide bar in th the flywhee and pressur M16 12 9 l pection valu pair and A of Torsion sembly of Tor Disassemb ndrical head and then ta f Torsiona r deformatio ub is damag exagon sock nnecting plate Torsional da Cranksha erators he threaded el bolts in a re bearing s evel 6 piec ue ...

Page 73: ...Crankshaft Bearing Shell Disassembly Procedures Push out the bearing shell from its side by hand and mark the bearing shell dismantled corresponding to saddle bores of the engine block and main bearing cap 4 4 6 3 Inspection and Maintenance of Crankshaft Bearing Shell 1 Clean the bearing shell and check wear condition of the bearing shell 2 Check whether the bearing shell is subject to metal peeli...

Page 74: ...e Mechanism Figure 4 33 Exploded View for Assembly of Secondary Balance Mechanism 4 4 7 2 Secondary Balance Mechanism Assembly Procedures 1 Assemble two locating sleeves by special tool 2 Place 3 adjustment shims on each side and insert the locating bar 3 Turn the crankshaft to rotate two zero point markings of balance mechanism ring gear to the red marking shown in Figure 4 26 and mark the addend...

Page 75: ...age balance mechanism and mark the addendum and flank of 1st tooth at zero point position by a white marker pen as shown in Figure 4 27 Figure 4 35 Diagram for Markings of Engine Double Stage Balance Mechanism Place the double stage balance mechanism as shown in Figure 4 28 and keep the zero point of crankshaft ring gear engaged with zero point of balance mechanism gear ...

Page 76: ...ar backlash is 0 3mm or 0 4mm disassemble the double stage balance mechanism and adjust by adjusting the number of adjustment shims or finally replace the double stage balance mechanism The maximum number of adjustment shims is 5 pieces and the pre tightening setting of the pneumatic wrench shall be level 2 6 After the proper adjustment of gear backlash tighten four bolts by a torque wrench and th...

Page 77: ...shaft camshaft tim tappet and edures Rocker and Power Gene 69 f Valve Me of Valve M iew for Assem y Procedu arm and roc m shaft disas and exhau nd push rod ft and cam ming gear di diate gear Procedures ate gear F and camsh ming gear as push rod F C Se erators echanism Mechanism mbly of Valve ures cker arm s ssembly pro ust valves For detail mshaft timin isassembly p For detail s For details haft t...

Page 78: ...d a worn Camshaft Engine block and Power Gene 70 exhaust valv and rocker mbly proced air and As of Camsha ed View for A sassembly er the cams mshaft g gear and a and disasse at the top for presenc gear hexag or drive gea ge bolt of c and prevent f Camshaf act with the ning hexago air compres Hex hea Hex hea F H C Air com Sector plat erators ves For de arm shaft F dures ssembly of aft Assembly of C...

Page 79: ...lock bores and place the threaded end of camshaft on the front wall cap side Assemble the sector plate tighten the bolts to 35 10 N m and then apply the seal paint Assemble the cylinder block front end of the camshaft assemble the gasket flange washers and hexagon head screws and measure the axial play of camshaft The axial play shall be 0 1 0 29mm If the axial play of the camshaft is too small ch...

Page 80: ...l inject mediate gear Camshaf l pump gear and Power Gene 72 or Alignment non symme the bolts th bolts of ca t between ca by a torque s After the zero points tion pump ft timing gear erators of Gear Train etric holes hrough flan amshaft tim amshaft tim e wrench Ti required tig of all gears Crankshaft gear A n Markings apply seala nge hole an ming gear by ming gear an ightening to ghtening to s for ...

Page 81: ...e dual valves e rotation o ly take out washer in s tenance of erve the app m hole is w nt screws a resence of o and Power Gene 73 air and A of Rocker Assembly of R Shaft Disa er the rocke and check f rocker or the rocker turn and f Rocker A pearances o worn or abrad and the arc obstruction Rocker arm erators Assembly r Arm and Rocker Arm a assemblyP er arm is tur change in c large chan r seat shaf...

Page 82: ...the clearances of intake and exhaust valves Turn the crankshaft in such manner that the phase pointer is aligned with the zero point of phase plate and observe the engagement between zero points of crankshaft timing gear and camshaft gear In such case adjust the rockers 1 2 3 6 counted from front end to adjust the clearances of intake valves Insert a 0 2mm feeler gauge and tighten the nuts by a to...

Page 83: ... cker arm sh haft take o tenance of pets e tappets an ding and ex ush rods for es and unde the tappets Assembly nd push rod y Before ass ole is unobst on the out ppet bores li pet bores w ng procedur oosely onto head and Power Gene 75 air and As of Tappet w for Assemb mbly Proc aft have be out tappets f Tappet a d push rods cessive wea r excessive w ersides of th for excessi y Procedur have a pro ...

Page 84: ...press squarely the valve springs Disassemble the valve collets Disassemble the upper retainers for the valve springs and the inner and outer valve springs Disassemble the valve from the valve seat 4 5 5 3 Inspection and Maintenance of Valve Check whether the valve stem and valve stem end surface are worn Check whether the valve cone is worn or damaged Check the valve cones and arc surfaces for pre...

Page 85: ...alve spring in place Assemble the valve collet After assembly of the valve collets tap the intake and exhaust valves using a rubber hammer so that the valve collets come in close contact with the upper retainers for the valve springs If the valve collets fail to come in contact with the upper retainers for the valve springs identify then disassemble the causes 4 5 6 Disassembly Inspection Repair a...

Page 86: ... abnormal wear between intermediate gear shaft and intermediate gear bushing and between shaft and intermediate gear shaft Check whether the oil holes are clogged by contaminants or foreign matters 4 5 6 4 Intermediate Gear Assembly Procedures Assemble the front wall cap subassembly onto the cylinder block as per specification Assemble the intermediate gear subassembly Assemble the intermediate ge...

Page 87: ... and connecting hose Loosen the connecting bolts of muffler pipeline and take out the muffler and its pipeline Loosen the clamp of air circuit connecting hose and take out the outlet connecting pipe of turbocharger compressor Loosen the inlet and outlet oil pipes fixing bolts of the turbocharger Disassemble the inlet and outlet oil pipes and their gasket Loosen the turbocharger fastening bolts and...

Page 88: ...ug 2 Intake pipe subassembly 3 Clamp 4 Air pipeline connecting hose 5 Intake Pipe gasket Figure 4 45 Exploded View for Assembly of Intake Pipe 4 6 2 2 Intake Pipe DisassemblyProcedures Disassemble the intake connecting pipe Disassemble the thermostat cover built in thermostat and coolant connecting hose Loosen the intake pipe bolts in sequence and disassemble the intake pipe and its gasket Take ou...

Page 89: ... disassembly The bolts should be tightened to the torque of 23N m 4 6 3 Disassembly Inspection Repair and Assembly of Exhaust Pipe 4 6 3 1 Exploded View for Assembly of Exhaust Pipe 1 Exhaust pipe gasket 2 Exhaust pipe 3 Lock nut 4 Gasket 5 Stud bolt Figure 4 46 Exploded View for Assembly of Exhaust Pipe 4 6 3 2 Exhaust Pipe Disassembly Procedures Loosen the hexagon head bolts and take out the exh...

Page 90: ...y procedures Please pay attention when assembling The exhaust pipe bolt is applied with anti seize sealant molybdenum disulfide and tightened to a torque within 465 N m 50 N m and can be re used twice at most 4 6 4 Disassembly Inspection Repair and Assembly of Turbocharger System 4 6 4 1 Exploded View for Assembly of Turbocharger System 1 Turbocharger oil inlet pipe subassembly 2 Turbocharger 3 Tu...

Page 91: ... 0 118mm and in case of exceeding this range it indicates that the thrust bearing plate or thrust halfring and bearing body are worn and it is required to analyze cause and eliminate the problem Figure 4 48 Diagram for Measurement of Axial Play 3 Check the radial clearance of air compressor impeller Press the air compressor impeller by hand in axial direction and use a plug gauge to measure the mi...

Page 92: ...edures 1 Loosely assemble one end of pre assembled turbocharger oil inlet pipe to the main oil passage of cylinder block Adjust the position of the oil inlet pipe for easy connection to the turbocharger 2 Assemble the turbocharger gasket onto the exhaust pipe flange 3 Mount the return pipe of the turbocharger and stud bolt onto the turbocharger assembly and apply 0 molybdenum disulfide and clean l...

Page 93: ...es freely without jamming 7 Assemble the return pipe and pipe clamp of the turbocharger and tighten them Note that the two pipe clamps shall be in the same direction and adjust the position of return oil pipe 8 Assemble and tighten the gasket and clamps and assemble the guard caps on two ends 9 9 All gaskets can be used only once Replace with new ones in event of repair ...

Page 94: ...procedure of low pressure fuel pipe for details Disassemble the air pipe of smoke limiter Disassemble the high pressure fuel pipe subassembly Disassemble the filter subassembly Disassemble the fuel injector subassembly Refer to 4 7 4 2 disassembling procedure of fuel injectors for details Disassemble the upper cover plate of front wall cap Refer to 4 3 3 2 disassembling procedure of front wall cap...

Page 95: ...l injector fuel return pipe Disassemble the connecting nuts between fuel injection pump and high pressure fuel pipe in turn Disassemble the connecting hollow bolts between fuel injection pump and lubricating oil pipe Disassemble the upper cover plate of front wall cap Refer to disassembling instructions of front wall cap for details Disassemble the fuel injection pump bolts and disassemble the fue...

Page 96: ...in the ob 4 53 Adjustme Alignmen and Power Gene 88 for presence on of cracki tors on two nce of oil le based on th y Procedur reverse ord rkings of Fue Fuel Suppl op dead cent rve the mar 46 adjust large flange ange screw el injector o l injection p bservation p ent of Fuel Pu nt plate erators e of crackin ing replace o ends repla eakage If an he leakage lo res der of the di el Injection Pu ly Adv...

Page 97: ... o xploded View Pipe Disas nuts betwe and Power Gene 89 ncentricity for stening bolt ump gear is ng torque 6 Control of Fa kshaft to zer ervation por disassemble Verify wheth air and As of High pr for Assembly ssemblyPr een high pre Chec for co Flange diagram erators r Two Holes o ts of fuel inj free of rota 60 5N m astening Bolts ro point the rt 45 drip the advanc her the gear ssembly of ressure ...

Page 98: ... notice to keep the high pressure fuel pipe clean and intact 4 7 4 Disassembly Inspection Repair and Assembly of Fuel Injector 4 7 4 1 Exploded View for Assembly of Fuel Injector Figure 4 57 Exploded View for Assembly of Fuel Injector 4 7 4 2 Fuel Injector DisassemblyProcedures Disassemble the connecting hollow bolts between fuel injectors of various cylinders and fuel injector fuel return pipe Di...

Page 99: ...r 4 7 5 2 Fuel filter Disassembly Procedures Disassemble the connecting hollow bolts between fuel filter and low pressure fuel pipe Disassemble the connecting bolts between fuel filter and fixing bracket Disassemble and separate the fuel filter element and seat 4 7 5 3 Inspection and maintenance of Fuel filter Check the appearance of fuel filter for intactness Check the junction surface between fu...

Page 100: ...rackets of low pressure fuel pipe from the cylinder head and cylinder block Disassemble the connecting hollow bolts between low pressure fuel pipe and fuel injection pump Disassemble the connecting hollow bolts between low pressure fuel pipe and fuel fine filter or strainer 4 7 6 3 Inspection and Maintenance of Low pressure Oil Pipe Check the external surfaces of low pressure fuel pipe for presenc...

Page 101: ...te Diagram of 4M11 Series Diesel Engine 4 8 1 2 Cooling System Disassembly Procedures As shown in figure Disassemble the fan connecting plate For details see 4 8 4 2 Fan Disassembly Procedures Disassemble the tensioner Disassemble the belt Disassemble the alternator alternator bracket crankshaft pulley and vibration damper Heater Heater Pressure limiting valve cover Expansion tank Thermostat Water...

Page 102: ...3 Cooling System Assembly Procedures The assembly procedures are in the reverse order of the disassembly procedures 4 8 2 Disassembly Inspection Repair and Assembly of Water Pump 4 8 2 1Exploded View for Assembly of Water Pump 1 Thermostat 2 Coolant connecting hose 3 Thermostat cover 4 Water pump pulley 5 Intermediate pad 6 Water pump 7 Belt 8 Fan Figure 4 61 Exploded View for Assembly of Water Pu...

Page 103: ...new one Observe the water pump and intermediate pads for presence of damages such as cracking If yes replace with new one 4 8 2 4Water Pump Assembly Procedures Assembly Procedures are in the reverse order of Disassembly 4 8 3 Disassembly Inspection Repair and Assembly of Thermostat 4 8 3 1 Exploded View for Assembly of Thermostat Figure 4 62 Exploded View for Assembly of Thermostat 4 8 3 2 Thermos...

Page 104: ... for Assembly of Fan 4 8 4 2 Fan DisassemblyProcedures As shown in Figure 4 55 Disassemble the connecting bolts and type 2 full metal hexagon lock nuts between fan and fan hub assembly and disassemble the fan Disassemble the studs and type 2 full metal hexagon lock nuts between fan hub assembly and crankshaft pulley and disassemble the fan hub assembly Disassemble the pulley 4 8 4 3 Inspection and...

Page 105: ...oded View for Assembly of Lubrication System 4 9 1 2 Lubrication System Disassembly Procedures Disassemble the oil pan For details see the engine body group disassembly for details Disassemble the crankshaft pulley shock absorber and hexagon screw plug on gear chamber Disassemble the oil pump Disassemble the engine oil suction filter Disassemble the engine oil filter Disassemble the oil cooler 4 9...

Page 106: ...on Conne ng b i Pus d Piston Intermediat e gear bearing and Power Gene 98 Lubrication Sy air and As of Oil Pum ed View for A ures nuts from e Oil pump Safety valve ecti rod Tapp t sh d Seconda fuel line Piston cooling nozzle r erators ystem Diagra ssembly of mp Assembly of O engine oil p Filter holder Main beari Turb Cam Fue inje Press limit ary Seco balan mech am f Oil Pump Oil Pump pump and t En...

Page 107: ...ine oil pump and crankcase Assemble the engine oil pump Assemble the two hexagon head flanged bolts and lock nut and then tighten them 4 9 3 Disassembly Inspection Repair and Assembly of Engine Oil Filter 4 9 3 1 Exploded View for Assembly of Engine Oil Filter Figure 4 67 Exploded View for Assembly of Engine Oil Filter 4 9 3 2 Engine Oil Filter DisassemblyProcedures Unscrew the engine oil filter b...

Page 108: ... pipe of engine oil cooler and take out the engine oil cooler as shown in Figure 4 60 4 9 4 3 Inspection and Maintenance of Oil Cooler Check the engine oil cooler for cracks If any replace it with a new one 4 9 4 4 Oil Cooler Assembly Procedures Before assembly check the engine oil cooler for defects in manufacturing or application and damage They shall be in good conditions Clean the mating faces...

Page 109: ...t essure contr ure Contro at main oil p ding damage passage pre e pressure c Steel ball Spring Screw bination sealin her Cap nut and Power Gene 101 pair and A f Main Oil embly of Ma ntrol Valv e pressure c f Main Oi rol valve sp rol valve for ol Valve A passage pre e essure contr control valv ng erators Assembly way Pres ain Oil way P ve Disassem control valv l way Pre pring for fai r cracks If As...

Page 110: ...or La tion Repa Assembly o 0 Exploded Vi sassembly e angle plate er as shown tenance of acks If any sembly Pr il suction f od condition suction filte emble and ti Angle plate ock nut xagon nut rugated gasket and Power Gene 102 air and As of Oil Suc iew for Assem y Procedur e of main be n in Figure f Oil Sucti y replace it w rocedures filter for de ns er and engi ighten two h Gasket O erators ssemb...

Page 111: ...rting System Disassembly Procedures Disassemble the hexagon bolts and spring washers Hold the starter motor securely by two hands and take it out along the rotation axis of starter motor gear 4 10 1 3 Inspection and Maintenance of Starter Check the gear teeth of the starter for damage If any replace the starter 4 10 1 4 Starting System Assembly Procedures The assembly procedures are in the reverse...

Page 112: ... connecting bolts and nuts of tension bolts and take out the nuts tension bolts and tension bolt pads Disassemble the other fastening bolt of alternator rotate the alternator body to take out the front belt of alternator and take out the fastening bolt and alternator 4 11 1 3 Inspection and Maintenance of Alternator Procedure for judgment of alternator malfunction During the warranty service for t...

Page 113: ...harging indicator lamp fails to turn off during idling of engine and turns off during high speed running of engine Low power of indicator lamp or loose parallel excitation resistor Low idling speed of engine Use recommended 2 6W lamp bulb or repair circuit Adjust idling speed of the engine Check whether the voltage to ground of the alternator If the alternator indicator lamp terminal voltage is re...

Page 114: ... zero check whether both the positive and negative wires between alternator and battery are under continuity status If the B voltage to ground is significantly below the battery voltage check the connecting points of positive and negative wires between alternator and battery for presence of looseness or check the battery for damage Recommended measurement method Jumper connect one 2W indicator lam...

Page 115: ...igher than 1600RPM When the alternator is working under high power load condition for instance the air conditioner is switched on the alternator speed shall be 2000rpm or the voltage shall be approximately 27V Check the drive belt quality and tension for alternator and related gear system Check the quality of belts for alternator and relevant pulley systems and replace any burnt ruptured distorted...

Page 116: ...l drop to approximately 10A after 10min charging If the charging current is at 30 90A constantly the battery is damaged and needs repair or replacement c High charging voltage Malfunction 3 High charging voltage Vehicle symptom Fault Detection Solution The voltmeter indicates high voltage Check voltmeter for damage The measurement of alternator B terminal voltage generally shall be at 27 28 4V If ...

Page 117: ... the pointer fluctuates and the reading can t be read or the charging indicator lamp turns off occasionally Loose belt or belt run out for alternator or related pulley systems Tension belts for alternator and related pulley systems Looseness or poor contact at connections of charging circuit Check and tighten connections of charging circuit Contamination of collector ring excessive wear of electri...

Page 118: ...nual of 4M11 Series Diesel Engine For Land Power Generators 110 it Speed dependent squealing within alternator This is the noise generated by the vibration of stator iron core If necessary replace stator subassembly ...

Page 119: ... End clearance of piston ring in cold state 1st ring 2nd ring 0 06 0 095 Oil ring 0 05 0 085 10 Valve bottom sink in cylinder head 1 0 1 45 11 Protrusion of cylinder liner top above engine body top 0 05 0 10 12 Camshaft axial clearance 0 10 0 29 13 Camshaft bearing clearance 0 04 0 08 14 Clearance between tappet and value tappet hole 0 006 0 035 15 Gap between piston top and cylinder head bottom s...

Page 120: ...de diameter of piston skirt 0 25 0 60 Inside diameter of cylinder liner 0 50 Outside diameter of piston pin 0 04 0 10 Inside diameter of piston pin hole 0 08 Inside diameter of bushing at connecting rod small end 0 08 Outside diameter of main journal of camshaft 0 06 0 10 Inside diameter of camshaft bushing 0 06 Height of cam nose relative to basic circle 2 00 Outside diameter of basic circle of c...

Page 121: ...alve seat 0 75 Exhaust valve sink 0 04 d 1 Exhaust valve seat 0 85 Exhaust valve seat 0 85 Inside diameter of intake valve guide 0 06 0 1 Outside diameter of intake valve stem 0 06 Inside diameter of exhaust valve guide 0 06 0 1 Outside diameter of exhaust valve stem 0 06 Inside diameter of bushing of rocker arm shaft 0 10 0 12 Outside diameter of rocker arm shaft 0 05 ...

Page 122: ...4 1 5 85 100 85 110 M18 1 5 100 110 100 120 Hexagon bolt and stud for flywheel housing M12 12 9 140 145 140 170 M10 12 9 80 85 80 95 Fastening bolt for oil sump Cylindrical head bolt for cast carrying oil sump M8 8 8 20 25 20 35 M8 10 9 30 35 30 45 Fastening bolt for double stage balance mechanism M8 8 8 20 25 20 35 Fastening bolt for engine oil pump Stud with lock nut M8 12 9 30 40 30 50 M8 8 8 2...

Page 123: ... 330 180 210 295 355 M18 225 270 390 455 245 290 405 485 M20 325 385 540 650 345 410 580 690 M22 435 510 720 870 465 550 780 930 M24 560 660 930 1100 600 710 1000 1200 M27 830 980 1400 1650 890 1050 1500 1800 M30 1100 1350 1850 2250 1200 1450 2000 2400 M8 1 21 25 35 42 23 27 38 45 M10 1 25 41 49 66 82 44 52 73 88 M12 1 25 74 88 125 150 80 95 135 155 M12 1 5 70 83 115 140 76 90 125 150 M14 1 5 115 ...

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Baudoulin 4M11G, Maintenance Manual

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