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 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Special Notice  The operator of the diesel engine must carefully read the product service manual of the diesel engine, strictly abide by the technical operation and maintenance specifications specified in the product service manual, and notice the warning instructions and signs.
Page 3 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators non-filtered air into the cylinders. 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. ...
Page 4 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Foreword This series diesel engine features compact structure, high operation reliability, excellent power and economy performances, rapid start, simple operations, convenient maintenances, and advanced emission performance. This service manual is prepared for the extensive users to rapidly understand and correctly use the 4M11 China-II stationary generator series diesel engine.
Page 5: Table Of Contents
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Table of Contents Chapter I General Information ··································································································· 1 1.1 Exterior View of Diesel Engine ······················································································ 1 1.2 Model Meaning of Diesel Engine ···················································································· 3 1.3 Main Specification of Diesel Engine ················································································ 3 1.4 Unsealing of Diesel Engine ···························································································...
Page 6 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 3.2.5 Diesel Engine Overheating ············································································· 25 3.2.6 Abnormal Exhaust Gas Color of Diesel Engine ····················································· 26 3.2.7 Diesel Automatic Parking ··············································································· 27 3.2.8 Abnormal Sound during Running of Diesel Engine ················································· 27 Chapter IV Disassembly and Assembly of Engine ··········································································...
Page 7 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.4.3 Disassembly, Inspection, Repair, and Assembly of Crankshaft ···································· 61 4.4.4 Disassembly, Inspection, Repair, and Assembly of Flywheel and Ring Gear ··················· 63 4.4.5 Disassembly, Inspection, Repair, and Assembly of Torsional Damper, Belt Pulley and Hub · 64 4.4.6 Disassembly, Inspection, Repair, and Assembly of Crankshaft Bearing Shell ··················...
Page 8 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.9.1 Disassembly and Assembly of Lubrication System ················································· 97 4.9.2 Disassembly, Inspection, Repair, and Assembly of Oil Pump ····································· 98 4.9.3 Disassembly, Inspection, Repair, and Assembly of Engine Oil Filter ···························· 99 4.9.4 Disassembly, Inspection, Repair, and Assembly of Oil Cooler ···································...
Page 9: Chapter I General Information
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 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 1 ...
Page 10 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure 1-3 Flywheel End of 4M11Diesel Engine Figure 1-4 Fan End of 4M11Diesel Engine 2 ...
Page 11: Model Meaning Of Diesel Engine
1.2 Model Meaning of Diesel Engine 1.3 Main Specification of Diesel Engine Table 1-1 Main Specification of 4M11 Diesel Engine Item Unit Model Engine type 4M11G Four-stroke, water-cooling, in-line, direct-injection, wet-type Engine type — sleeve, high-speed diesel engine Intake type —...
Page 12: Unsealing Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators starter Cold starting-with auxiliary starter ℃ Noise at 1m reach dB(A) ≤115 Lifetime 500,000 1.4 Unsealing of Diesel Engine After the diesel engine is unpacked, the user shall firstly count the diesel engine and its accessories as per the delivery packing list, check the exterior of diesel engine for presence of damage and the connectors for presence of looseness, and then fulfill the following works: (1) Wipe the anti-rusting layer and anticorrosive agent on the exposed parts.
Page 13: Assembly Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators True False Figure 1- 1Hoisting Diagram of Diesel Engine Every diesel engine is fitted with two special cylinder head bolts for hoisting of diesel engine. The end face of the hexagon head of these bolts has a M14 screw and a lifting eye is assembled on this screw.
Page 14: Start Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators and check fuel level from the fuel gauge or check the fuel tank. (3) Check the engine oil level The engine oil level shall be between upper and lower markings of the oil dipstick. If necessary, add engine oil through the engine oil filler port.
Page 15 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators diesel engine may not run for more than 20 minutes at the speed 105% the rated speed or the output 110% the rated output. After the unloading, idle the diesel engine for (1~2) min before stop.
Page 16: Stop Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators electrolyte and unit voltage of the battery. If the diesel engine is not to be used for a long time and is under extremely low temperature, disassemble the battery and store in a warm indoor place.
Page 17: Chapter Ii Maintenance Guide
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Chapter II Maintenance Guide 2.1 Fuel Oil, Lubricating Oil, Coolant, and Auxiliary Materials for Diesel Engine 2.1.1 Fuel Oil Summer: 0# diesel (GB 252) Winter: generally -10# diesel fuel shall be used; however, -20# diesel fuel shall be used if ambient temperature is lower than -15ºC.
Page 18: Coolant
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 20W-50 -15-45 Note: 1) Before starting the diesel engine, ensure to check the engine oil level within oil pan. 2) Do not check the oil level while the diesel engine is running. 3) Never mix special engine oil of Weichai Power with engine oils of other manufacturers.
Page 19: Auxiliary Materials
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators HEC-Ⅱ-40 Note: 1) Make sure to periodically check the coolant and, to prevent the corrosion and damage, timely replace depending on actual situation. 2) It’s prohibited to use water or low quality coolant as the engine coolant. 2.1.4 Auxiliary Materials Table 2-5 Auxiliary Materials Name...
Page 20: Routine Maintenance
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Preventing looseness, Loctite 271 Cup plug, oil drain hole fixing sealing between Loctite 277 Other cup plug element and bore Loctite 270 Sealing cylinder head top Push rod -cylinder head Loctite 518 It’s applied onto shining Plates connecting engine body...
Page 21 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators Figure 2 2-1 Bleeding B Button otice: Make sure to che eck the cool ant level be efore startin ng the diesel l engine eac ch time.
Page 22 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Check the fuel level indication from the instrument panel. Add fuel if necessary. The diesel used shall meet the specification. Keep clean the diesel. It's better to place the diesel under stationary state for more than 72 hours before adding into diesel engine.
Page 23: Contents Of Maintenance At Each Level
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 2.3 Conte ents of Ma aintenance e at Each L Level  Replac ce engine oi Place horiz zontally the e diesel eng gine, place a container r for collec ction of oil...
Page 24 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Engine oil filter Figure 2-7 Engine Oil Filter  Check and adjust the clearances of intake and exhaust valves. Check and adjust the clearances of intake and exhaust valves as per following procedure: ①Under the cold status of diesel engine, turn the engine (along the rotation direction of engine) to the compression top dead center of 1st, 4th cylinder.
Page 25 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators Figur re 2-9 Adjust Valve Cleara ance eck the clea rance betwe een rocker a and valve s tem head b y feeler gau uge 1 as per r Table 3.
Page 26 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4th c cylinder haust Intake Intake an nd exhaust n-adjustabl compres ssion stroke alve valve lves  Replac ce the fuel f filter, see Fi igure 2-11.
Page 27 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure 2-12 Air Filter The resistance of the air filter shall not be too high. The maximum permissible resistance shall not exceed 3kPa under non-contaminated state and shall be 5kPa under contaminated state.
Page 28: Maintenance For Long-Term Storage
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure2-13 Cleaning Element Notice: Do not blow through the filter paper Do not clean the filter paper by water or oil Do not pat or beat the filter element strongly Ensure to replace the damaged filter element and seal ring.
Page 29 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ⑦Apply protective oil to all machined parts 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: Chapter Iii Typical Faults And Solutions
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators Chapter r III Typi ical Fault s and Sol lutions M11 series diesel engi ne is design ned and man nufactured u under strict quality sys tem and each d...
Page 31: Diesel Engine General Fault And Troubleshooting
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators  Comparison method: For some assemblies or parts, the replacement method is adopted to determine the presence of malfunction. Note: 1. Judging the malfunction cause of diesel engine is a really precise work. Before the cause is basically identified, do not disassemble the diesel engine casually, or it will not only eliminate the malfunction, but also lead to more serious malfunction due to improper assembly after disassembly.
Page 32: Unstable Running Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators the leaks (if any). Starting system fault Insufficient voltage of battery Charging and overhaul to battery Poor contact of electric circuit connectors Check the circuit No rotation or weak rotation of starter motor Overhaul starter motor Incomplete meshing between starter motor Rotate the flywheel ring gear for an angle.
Page 33: Abnormal Oil Pressure Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Low fuel quality or water content in fuel Check fuel , and replace if necessary Insufficient compression pressure of cylinder Excessive wear of piston rings and cylinder Check and replace piston rings and when necessary sleeves replace cylinder sleeves and pistons.
Page 34: Abnormal Exhaust Gas Color Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Check the oil dipstick and add/drain engine oil as per Insufficient or excessive oil specification. Internal blockage of oil cooler Clean or replace engine oil cooler Coolant temperature too high Insufficient coolant volume Replace oil pump Insufficient displacement of water...
Page 35: Diesel Automatic Parking
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators pump and fuel injectors. Late fuel supply timing and serious Adjust fuel supply advance angle after-combustion Incorrect valve clearance or poor sealing Check valve clearance and valve airtightness. status of valve Blockage of air filter Clean air filter element Poor fuel quality...
Page 36 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators end bearing and clear metallic knocking sound (especially at low guarantee specified clearance. and high speeds) Excessive clearance between connecting rod and bearing, with Replace bearing dumb impact sound Excessive clearance of main bearing (similar to knocking sound of Replace main bearing connecting rod bearing)
Page 37: Chapter Iv Disassembly And Assembly Of Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Chapter IV Disassembly and Assembly of Engine 4.1 Overview During disassembly and assembly of engine, please follow operating instructions in this manual strictly and pay attention to operation steps containing danger and safety marks, so as to ensure personal safety and avoid accidents.
Page 38: Safety Sign
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators decide to use a procedure or a method that is outside the range recommended in this manual, please make sure that such operation will not bring harm to yourself, any other person or the equipment.
Page 39: Used Tools
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.1.3 Used Tools Table 4-2Used Tools Figure Meaning 2.5mm hexagonal wrench 5mm hexagonal wrench 8 mm sleeve Flat screwdriver Professional tool 10mm flat-end hexagon wrench Should any method or tool used is not recommended in this manual, the user must first ensure personal safety, and avoid jeopardizing the life of the user or other personnel, as well as guarantee that the use, maintenance or repairing method will not cause damage risks or jeopardize personal safety.
Page 40: Environmental Protection Measures
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators naturally secreted grease to help moisturize the skin. Do not clean the skin by gasoline, kerosene, fuel, thinner, or solvent. (10) Upon detection of skin irritation, please immediately seek for medical treatment. (11) If possible, deoil the parts before the handling of parts.
Page 41 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Notice: Stop the engine during maintenance or service. 33 ...
Page 42: Cylinder Head Group
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.2 Cylinder Head Group 4.2.1 Disassembly and Assembly of Cylinder Head 4.2.1.1 Exploded View for Assembly of Cylinder Head Group Cylinder head cover bolt Combination sealing washer Cylinder head cover Cylinder head cover gasket...
Page 43 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 5) Disassemble the lifting ring. 6) Disassemble the cylinder head cover and the cylinder head cover gasket. 7) Disassemble the fuel injector. For details , see the instructions for disassembly of fuel system;...
Page 44: Disassembly, Inspection, Repair, And Assembly Of Cylinder Head Group
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.2.2 Disassembly, Inspection, Repair, and Assembly of Cylinder Head Group 4.2.2.1 Exploded View for Assembly of Cylinder Head Cover Cylinder head cover bolt Combination sealing washer Cylinder head cover Cylinder head cover gasket Figure 4-2 Exploded View for Assembly of Cylinder Head Cover...
Page 45: Disassembly, Inspection, Repair, And Assembly Of Cylinder Head
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 2) Spray clean engine oil to the contact area between rocker and valve, the contact area between rocker and tappet, and the center between above two contacts. 3) Place the cylinder head cover gasket; 4) Place the cylinder head cover;...
Page 46 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators head, tak ke it out and d place it ba ack to the cy ylinder bloc ) Disassem mble the cy ylinder head d and plac e it on a p paper board d, in order...
Page 47 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators range, the cylinde er head shal ll be replace ed to ensure e the reliabi ility of dies sel engine o operation. If the va alve sink do oes not exce eed the perm...
Page 48 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 3) Assemble the cylinder head onto the cylinder block. 4) Loose cylinder head bolt; 5) Tighten the cylinder head bolts to 30N.m, rotate the bolts for 120°±4°, and then rotate further for 120°±4°.
Page 49: Disassembly, Inspection, Repair, And Assembly Of Oil-Gas Separator
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.2.4 Disassembly, Inspection, Repair, and Assembly of Oil-gas Separator 4.2.4.1 Exploded View for Assembly of Oil-gas Separator Oil-gas Crankshaft Clamp Hexagon bolt Hexagon nut; Spring Spring Flat Oil link hose Spring Pipe Flat...
Page 50: Disassembly, Inspection, Repair, And Assembly Of Lifting Ring
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.2.5 Disassembly, Inspection, Repair, and Assembly of Lifting Ring 4.2.5.1 Exploded View for Assembly of Lifting Ring 1- Lifting ring 2- Cylinder head bolt Figure 4-8 Exploded View for Assembly 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.
Page 51: Engine Block Group
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.3 Engine Block Group 4.3.1 Disassembly, Inspection, Repair, and Assembly of Engine Body Combination Group 4.3.1.1 Exploded View for Assembly of Engine Body Combination Group Figure 4-9 Exploded View for Assembly of Engine Body Combination Group Name Name Name...
Page 52 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators O-shap ped seal ring Hexagon hea ad screw plug O-shap ped seal ring Stud d bolt up plug Cylinder head bolt ad plate Cylinder head bolt Weld ded elbow...
Page 53 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 2nd cylinder - 3rd cylinder -4th cylinder - 1st cylinder (4) Control range of tightening torque for cylinder head bolts: M14－12.9： (230～300) N·m M14－10.9： (190～285) N·m Point 2: Assembly Assemble the grease-applied seal ring to the welded elbow, insert the welded elbow into corresponding hole of cylinder block, and fix it by fixing plate, hexagon socket bolts, and spring washers.
Page 54: Disassembly, Inspection, Repair, And Assembly Of Body Components
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.3.1.4 En ngine Bod dy Combin nation Gro oup Assem mbly Proc edures Assembly of f engine bod dy combina ation group i is in the rev verse order o of disassem mbly.
Page 55 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators step and rotate the bolts for 90º±4º for the 2nd step. Figure 4-12 Tightening of Main Bearing Bolts Point 2: Assembly Assemble the thrust bearing cap to the rear end of cylinder block and assemble non-thrust bearing caps for other places.
Page 56: Disassembly, Inspection, Repair, And Assembly Of Front Wall Cover
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.3.3 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Front Wa all Cover 4.3.3.1 Ex xploded V View for A Assembly o of Front W Wall Cover...
Page 57 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 2) App ply the seal ant by a rol ller uniform mly to the ju unction surf face of fron nt wall cap, with hout broken n line or sur face.
Page 58: Disassembly, Inspection, Repair, And Assembly Of Flywheel Cover
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.3.4 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Flywhee el Cover 4.3.4.1 Ex xploded V View for A Assembly o of Flywhe eel Cover Sens...
Page 59 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure 4-18 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: Disassembly, Inspection, Repair, And Assembly Of Oil Pan
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.3.5 Disassembly, Inspection, Repair, and Assembly of Oil Pan 4.3.5.1 Exploded View for Assembly of Oil Pan 1 - Combination washer 2 - Combination seal washer 3 - Magnetic plug 4 - Hexagon head plug 5 - Screw plug 6 - Square head plug Figure 4-19 Assembling Explosive View of Oil Sump 4.3.5.2 Oil Pan DisassemblyProcedures...
Page 61: Disassembly, Inspection, Repair, And Assembly Of Piston Nozzle
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 3) Insert t the bolts an nd washers and tighten n the bolts b by pneumati ic wrench to 20~35 5N.m. 4.3.5.4 O Oil Pan Ass sembly Pr rocedures The assembl...
Page 62: Disassembly, Inspection, Repair, And Assembly Of Thrust Halfring
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.3.7 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Thrust H Halfring 4.3.7.1 Ex xploded V View for A Assembly o of Thrust H Halfring Thrust...
Page 63: Disassembly, Inspection, Repair, And Assembly Of Front And Rear Oil Seal
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.3.8 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Front an d Rear Oi il Seal 4.3.8.1 Ex xploded V View for A Assembly o of Front an...
Page 64 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Blot Corrugated gasket Figure 4-23 Tightening Sequence of Bolts Point 2: Check Check and ensure that the inner sealing surface of the seal ring is free of damage, the oil seal rubber is free of damage, and the rear oil seal cap is clean, without clear scratch on machined surfaces.
Page 65: Crank Connecting Rod Mechanism
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.4 Crank k Connect ting Rod M Mechanism 4.4.1 D Disassembl ly and Ass sembly of f Crank Co onnecting Rod Mech hanism 4.4.1.1 Ex xploded V View of Cr rank Conn...
Page 66: Disassembly, Inspection, Repair, And Assembly Of Piston Connecting Rod Group
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.4.2 Disassembly, Inspection, Repair, and Assembly of Piston Connecting Rod Group 4.4.2.1 Exploded View for Assembly of Piston Connecting Rod Piston connecting rod group Crankshaft Engine block Piston connecting rod group ...
Page 67 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators tightening torque of connecting rod bolts. 2. Tilt the engine, turn the piston to be disassembled to the bottom dead center, and disassemble the connecting rod bolts and connecting rod cap. 3.
Page 68 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators umbers, and d use a pair r of piston r ring pliers to mount th he oil ring, 2nd and 1s st gas rings nto the pisto on ring gro oove in seq...
Page 69: Disassembly, Inspection, Repair, And Assembly Of Crankshaft
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.4.3 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Cranksh 4.4.3.1 Ex xploded V View for A Assembly o of Cranksh haft Syste Cranksha aft timing...
Page 70 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 2.2 After the upper bearing is assembled, it shall be aligned to the oil hole and oil groove on the cylinder body, and the bearing deviating from the oil hole by 1/5-1/4 shall not be assembled;...
Page 71: Disassembly, Inspection, Repair, And Assembly Of Flywheel And Ring Gear
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators Figure 4- -29 Tightenin ng Sequence o of Main Bear ring Bolts 4.4.4 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Flywhee el and Ring g Gear...
Page 72: Disassembly, Inspection, Repair, And Assembly Of Torsional Damper, Belt Pulley And Hub
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators parallel p pin to the en After ins serting the f flywheel gui ide bar in th he threaded hole of the e crankshaft t, mount the flywheel l parts and p...
Page 73: Disassembly, Inspection, Repair, And Assembly Of Crankshaft Bearing Shell
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.4.5.4 Torsional Damper and Pulley Assembly Procedures After the assembly of timing gear, assemble the wheel hub, torsion damper, and pulley in turn. 1. Fix the wheel hub onto the crankshaft by hexagon socket cylindrical head screws. Hexagon socket cylindrical head screw: M16-12.9 (4 pieces);...
Page 74: Disassembly, Inspection, Repair, And Assembly Of Secondary Balance Mechanism
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators is directly assembled. During assembly, pay attention that the lips should be aligned, and applied with a small amount of oil. 4.4.7 Disassembly, Inspection, Repair, and Assembly of Secondary Balance Mechanism 4.4.7.1 Exploded View for Assembly of Secondary Balance Mechanism Adjusting gasket...
Page 75 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure 4-34 Diagram for Markings of Engine Double-Stage Balance Mechanism Rotate the double-stage 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: Valve Mechanism
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure 4-36 Diagram for Markings of Engine Double-Stage Balance Mechanism 4. Withdraw the locating bar and insert the bolt. Note: Differentiate the bolt length and ensure there is no plain washer or spring washer. 5.
Page 77: Disassembly And Assembly Of Valve Mechanism
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.5.1 D Disassembl ly and Ass sembly of f Valve Me echanism 4.5.1.1 Ex xploded v view for A Assembly o of Valve M Mechanism Hexagon b bolt...
Page 78: Disassembly, Inspection, Repair, And Assembly Of Camshaft And Timing Gear
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4) Ass semble the i intake and e exhaust valv ves. For de etails, see 4. .5.5.4 valve es assembly proc cedures; 5) Ass semble the r rocker arm a and rocker...
Page 79 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.5.2.4 Camshaft and timing gear Assembly Procedures With the camshaft, timing gear and air compressor drive geardisassembled, check them for excessive wear or deviation from parameter specifications. If any, repair the camshaft, timing gear and air compressor drive gear, or replace them with new ones.
Page 80 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators Fuel inject tion pump Air compressor drive g gear Camshaf ft timing gear Air compr ressor gear Interm mediate gear Engine oil l pump gear Crankshaft gear Figure 4-3 9 Diagram fo...
Page 81: Disassembly, Inspection, Repair, And Assembly Of Rocker Arm And Rocker Arm Shaft
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.5.3 D Disassembl ly, Inspect tion, Repa air, and A Assembly of Rocke er Arm an nd Rocker Shaft 4.5.3.1 Ex xploded V View for A Assembly o of Rocker r Arm and...
Page 82 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ⑤ Measure the rocker arm hole diameter and rocker arm shaft diameter, and calculate the fitting clearance. 4.5.3.4 Rocker Arm and Rocker Arm Shaft Assembly Procedures ① Check and ensure that the parts assembled are clean without knocking damage, scratch, or rust. ②...
Page 83: Disassembly, Inspection, Repair, And Assembly Of Tappet And Push Rod
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.5.4 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Tappet a and Push R 4.5.4.1 Ex xploded V View for A Assembly o of Tappet and Push...
Page 84: Disassembly, Inspection, Repair, And Assembly Of Valve
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ⑤ Apply clean lubricating oil to the push rods. Ensure that the push rod ends are sufficiently lubricated. ⑥ Assemble the push rods and lightly insert the push rods into the tappets through the cylinder head.
Page 85: Disassembly, Inspection, Repair, And Assembly Of Intermediate Gear
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ① Apply some molybdenum disulfide paste on the intake and exhaust valve stems evenly, and assemble the intake and exhaust valves into the cylinder head, ensuring that the intake and exhaust valves slide in the guide, without blockage;...
Page 86: Intake And Exhaust System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ③ Screw one M8 bolt into the intermediate gear shaft to pull out the shaft. Take cautions to prevent the falloff of intermediate gear and disassemble the intermediate gear along with idler shaft.
Page 87: Disassembly And Assembly Of Intake And Exhaust System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.6.1 Disassembly and Assembly of Intake and Exhaust System 4.6.1.1 Exploded View for Assembly of Intake and Exhaust System 1— Intake pipe 2 - Exhaust pipe 3 - Turbocharger oil inlet subassembly 4 - Turbocharger 5 - Turbocharger oil return pipe subassembly Figure 4-44 Exploded View for Assembly of Intake and Exhaust System 4.6.1.2 Intake and Exhaust System Disassembly Procedures...
Page 88: Disassembly, Inspection, Repair, And Assembly Of Intake Pipe
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators section 4.6.2 “Disassembly, inspection, repair, and assembly of intake pipe”. 4.6.1.3 Intake and Exhaust System Assembly Procedures The assembly procedures are in the reverse order of the disassembly procedures. 4.6.2 Disassembly, Inspection, Repair, and Assembly of Intake Pipe 4.6.2.1 Exploded View for Assembly of Intake Pipe 1- Hexagon head screw plug...
Page 89: Disassembly, Inspection, Repair, And Assembly Of Exhaust Pipe
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators required to replace the pipe with a new one. ②Check the gasket of intake pipe for deformation, tear and absence. If necessary, replace it with a new one. 4.6.2.4 Intake Pipe Assembly Procedures Assembly Procedures are in the reverse order of disassembly.
Page 90: Disassembly, Inspection, Repair, And Assembly Of Turbocharger System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ③Loosen the lock nut, take out the turbocharger gasket, and take out the stud. 4.6.3.3 Inspection and Maintenance of Exhaust Pipe ① Check whether the exhaust pipe is cracked or damaged, and the flange is deformed, and if any, it is required to replace the use exhaust pipe with a new one.
Page 91 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators that the bearing is worn abnormally or collision or jamming between the rotating part and the stationary part occurs, it is required to analyze cause and carry out troubleshooting. 2.
Page 92 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Figure 4-49 Diagram for Measurement of Radial Play Daily Maintenance: 1. Check whether the connecting pipe between the turbocharger and the engine is loosened or not, and if any, eliminate the problem. 2.
Page 93 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators the oil inlet pipe subassembly. Rotate the turbocharger impeller to determine whether it rotates 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;...
Page 94: Fuel System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.7 Fuel System 4.7.1 Disassembly and Assembly of Fuel System 4.7.1.1 Exploded View for Assembly of Fuel System High-pressure fuel pipe Fuel injector Fuel injector return pipe Filter Low-pressure fuel pipe Fuel injection pump Figure 4-50 Exploded View for Assembly of Fuel System...
Page 95: Disassembly, Inspection, Repair, And Assembly Of Injection Pump
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.7.1.3 Fuel system Assembly Procedures The assembly procedures are in the reverse order of the disassembly procedures. 4.7.2 Disassembly, Inspection, Repair, and Assembly of Injection Pump 4.7.2.1 Exploded View for Assembly of Fuel Injection Pump Fuel injection pump gear Pressure plate Blot...
Page 96 Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators e the air pip pe of smokin ng limiter f for presence e of crackin g and conn ectors on tw wo ends for ③Observe presen nce of air le...
Page 97: Disassembly, Inspection, Repair, And Assembly Of High-Pressure Oil Pipe
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators Chec k two hole for co oncentricity Figu ure 4-54 Chec cking of Con ncentricity for r Two Holes o of Fuel Inject tion Pump As sho own in Figu ure 4-47, tig...
Page 98: Disassembly, Inspection, Repair, And Assembly Of Fuel Injector
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ② Disassemble the connecting nuts between high pressure fuel pipe and various cylinders of fuel injection pump in turn. 4.7.3.3 Inspection and Maintenance of High-pressure Oil Pipe ① Observe the external surface of high pressure fuel pipe for presence of cracking and leakage. If yes, replace high pressure fuel pipe and feed back as per corresponding procedure.
Page 99: Disassembly, Inspection, Repair, And Assembly Of Engine Oil Filter
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators deposit and other impurities, in order to ensure the sealing performance. Never incorrectly assemble every fuel injector, seal washer, and adjustment shim thereon during assembly, in order to ensure that the protrusions of fuel injector lower cone and tip meet the specification. ②Check the external surface of fuel injector return pipe for presence of damage and leakage.
Page 100: Disassembly, Inspection, Repair, And Assembly Of Low-Pressure Oil Pipe
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators manual pump on strainer to bleed air from the filter. 4.7.5.4 Fuel Filter Assembly Procedures The assembly procedures are in the reverse order of the disassembly procedures. However, during replacement of filter element, it’s necessary to fill clean diesel to new filter element, and keep clean the filter seat base and apply lubricating oil to rubber gasket.
Page 101 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 1— Thermostat 2 - Coolant connecting hose 3 - Thermostat cover 4 - Water pump pulley 5 - Intermediate pad 6 - Water pump7- Belt 8- Fan Figure 4-59 Exploded View for Assembly of Cooling System Heater Heater Pressure limiting valve cover...
Page 102: Disassembly, Inspection, Repair, And Assembly Of Water Pump
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ⑤Disassemble the thermostat. For details, see 4.8.3.2 Thermostat Disassembly Procedures. Disassemble the inlet pipe . ⑥Disassemble the air compressor and hydraulic pump. ⑦Disassemble the water pump and water pipe joint. For details, see 4.8.2.2 Water pump Disassembly Procedures..
Page 103: Disassembly, Inspection, Repair, And Assembly Of Thermostat
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators ③Disassemble the hexagon head bolts and spring washers from the water pump and disassemble the water pump. ④Disassemble the washers and intermediate pads of water pump. 4.8.2.3 Inspection and Maintenance of Water Pump ①Check whether the water pump gasket is broken or has other damages, and replace the defective gasket if any.
Page 104: Disassembly, Inspection, Repair, And Assembly Of Fan
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.8.3.3 Inspection and Maintenance of Thermostat ①Check the clamps for failure. If any, replace them. ②Check the coolant hoses for cracks. If any, replace them . ③Check the thermostat for breakage. If any, replace it. 4.8.3.4 Thermostat Assembly Procedures Assembly is in the reverse order of disassembly.
Page 105: Lubrication System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.9 Lubrication System 4.9.1 Disassembly and Assembly of Lubrication System 4.9.1.1 Exploded View for Assembly of Lubrication System 1 - Engine oil filter 2 - Engine oil cooler 3 - Engine oil filter seat 4 - Oil sump 5 - Engine oil pump Figure 4-64 Exploded View for Assembly of Lubrication System 4.9.1.2 Lubrication System Disassembly Procedures ①Disassemble the oil pan.
Page 106: Disassembly, Inspection, Repair, And Assembly Of Oil Pump
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.9.1.4 Lu ubrication n System D Diagram Engine Oil pump Filter holder oil filter tion Safety valve Oil cooler Conne ecti Main beari Turb bocharger Rock Tapp...
Page 107: Disassembly, Inspection, Repair, And Assembly Of Engine Oil Filter
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators pump, as shown in Figure 4-58. 4.9.2.3 Inspection and Maintenance of Oil Pump ① Check the engine oil pump for cracks. Check whether the inner cavity of the pump is smooth. If necessary, disassemble the pump.
Page 108: Disassembly, Inspection, Repair, And Assembly Of Oil Cooler
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators use defect or damage. ②Tighten the filter as per the specification indicated on filter cover. 4.9.4 Disassembly, Inspection, Repair, and Assembly of Oil Cooler 4.9.4.1 Exploded View for Assembly of Oil Cooler Water return pipe of engine oil cooler Water inlet pipe of engine oil cooler...
Page 109: Disassembly, Inspection, Repair, And Assembly Of Main Oil-Way Pressure Control Valve
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.9.5 D Disassembl ly, Inspec ction, Rep pair, and A Assembly y of Main n Oil-way y Pressure Contr rol Valve 4.9.5.1 D Disassembl ly and Ass sembly of f Main Oil...
Page 110: Disassembly, Inspection, Repair, And Assembly Of Oil Suction Filter
Maintenance M Manual of 4M1 1 Series Diesel l Engine For La and Power Gene erators 4.9.6 D Disassembl ly, Inspect tion, Repa air, and As ssembly of f Oil Sucti ion Filter 4.9.6.1 Ex xploded V View for A Assembly o of Oil Suc ction Filter...
Page 111: Starting System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.10 Starting System 4.10.1 Disassembly, Inspection, Repair, and Assembly of Starter 4.10.1.1 Exploded View of Starter Starter Figure 4-71 Exploded View of Starter 4.10.1.2 Starting System Disassembly Procedures ①Disassemble the hexagon bolts and spring washers. ②Hold the starter motor securely by two hands and take it out along the rotation axis of starter motor gear.
Page 112: Vehicles Accessories System
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 4.11 Vehicles Accessories System 4.11.1 Disassembly, Inspection, Repair, and Assembly of Alternator 4.11.1.1 Exploded View for Assembly of Alternator Alternator Alternator bracket Figure 4-72 Exploded View for Assembly of Alternator 4.11.1.2 Starter Disassembly Procedures ①Disassemble the alternator mounting bracket and connecting bolts and nuts of tension bolts...
Page 113 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators 打开车辆电源开关将测试灯连接在发电机的B+和E Turn on the power switch of the vehicle and connect the test lamp to the terminal B+ and E (negative) of the alternator. （负极）端说明发电机的B+端没有电压，同蓄否 It indicates that there is no voltage at terminal B+ 测试灯是否亮...
Page 114 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators exciting terminal is within indicator lamp or loose connection in circuit. Adjust 1~3V. the indicator lamp power or check the circuit connectors and connection points. If the alternator indicator lamp terminal voltage is zero, it indicate the presence of short-circuit to ground at the excitation circuit alternator terminal.
Page 115 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators voltage. The alternator regulator, rectifier bridge, stator, or internal connection may be malfunctioned and need repair or replacement. b) Low charging voltage Malfunction 2: Low charging voltage Vehicle symptom Fault Detection Solution Understand...
Page 116 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Check for presence of high Grind the wire lugs with oxidized surfaces temperature due to looseness, and the housing surface for assembly of oxidation, or loose connection at grounding bolt and reassemble. the joint between wire and bolt of Retighten any loose nut and wire lug and charging system.
Page 117 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Observe the battery surfaces for cleanliness and dryness and check whether the wiring terminals and clamps are in good fit. Replace as soon as possible in event of any damage. Check the phase output voltage of alternator If there is high difference between phase terminal (This voltage shall be approximately one half...
Page 118 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Speed-dependent squealing within This is the noise generated by the vibration alternator of stator iron core. If necessary, replace stator subassembly. 110 ...
Page 119: Appendix A Fit Clearances For Main Parts Of Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Appendix A Fit Clearances for Main Parts of Diesel Engine (Reference value) Item Theoretical value (mm) Main bearing clearance 0.08～0.11 Connecting rod bearing clearance 0.07～0.10 Crankshaft endplay 0.04～0.25 Axial clearance of connecting rod plane 0.30～0.50 Clearance between connecting rod small 0.03～0.08...
Page 120: Appendix B Wear Evaluation References For Main Friction Pairs In Diesel Engine
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Appendix B Wear Evaluation References for Main Friction Pairs in Diesel Engine (Reference value) Wear limit Clearance limit Closed gap of the 1st piston ring 1.70 Height of the 1st piston ring 0.10 Closed gap of the 2nd piston ring 1.50...
Page 121 Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Thickness of thrust bearing 0.40 Intake valve sink 0.04*d Intake valve seat 0.75 Intake valve seat 0.75 Exhaust valve sink 0.04*d Exhaust valve seat 0.85 Exhaust valve seat 0.85 Inside diameter of intake valve guide 0.06...
Page 122: Appendix C Tightening Torques For Main Bolts
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Appendix C Tightening Torques for Main Bolts Bolt Control value Inspection value Bolt name specification (N.m) (N.m) Fastening bolt for intake and exhaust pipes 45～50 45～60 Flywheel bolt M16-10.9 285～295 285～340...
Page 123: Appendix D Recommended Torques For Other Standard Bolts
Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators Appendix D Recommended Torques for Other Standard Bolts Friction 0.125(galvanization) 0.14(shining) coefficient Strength grade 10.9 12.9 10.9 12.9 Bolt specification Recommended torque N·m 13.0 16.0 14.0 1100 600 1000 1200 1400 1650 890 1050 1500 1800...

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