Baudoulin 4M11G User manual

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

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
The delivery test was completed for the diesel engine as per the test specification strictly and
the throttle was already limited by lead seal at the time of delivery. It’s prohibited to
disassemble the lead seal to increase the fuel volume.
The turbocharger rotor is a high-speed rotating part. When the machine runs, no moveable
items (like hand, tool, and cotton yarn) are allowed to approach the inlet of turbocharger, so as
to avoid causing damages to personnel or machine; the rotor assembly shall not be
disassembled except for that it is done by professional maintenance personnel or professional
maintenance stations licensed by Weichai;
The strict torque and angle requirements are specified for the main bearing 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 vehicle, check that the coolant and oil levels meet the
requirements.
When the user uses a new machine, 50-hour trial running is needed to the machine. After the
run-in period, it is required to replace the engine oil and engine oil filter element.
After the cold start of the diesel engine, slowly increase the engine speed, instead of running at
high speed suddenly or long-term idling (not more than 3min). After the running under heavy
load, run the engine at low speed for 5~10min before stopping the engine, instead of stopping
the engine suddenly (except special cases);
After the engine is stopped, if the temperature of working environment is probably below 0℃
and the coolant without antifreeze additive is used, fully drain the coolant from the water tank
and diesel engine.
It’s prohibited to run the diesel engine without the air filter, in order to prevent the supply of

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
The checking and repair for all parts of the electric system must be fulfilled by the professional
electric technicians.

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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. The main application scope of this manual 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 will be subject to improvement and the contents contained in this manual
may become obsolete. For latest product information, the user (or dealer) may access Weichai
website at http://www.weichai.com. Your suggestions and opinions for further improvement of
product are really welcomed.
October, 2015

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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 ···························································································4
1.5 Hoisting of Diesel Engine·····························································································4
1.6 Assembly of Diesel Engine ···························································································5
1.7 Pre-start Preparations of Diesel Engine ·············································································5
1.8 Start of Diesel Engine ·································································································6
1.9 Running of Diesel Engine·····························································································6
1.10 Stop of Diesel 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
3.1 Diagnostic Method ··································································································· 22
3.2 Diesel Engine General Fault and Troubleshooting ······························································ 23
3.2.1 Start Failure or Difficult Start of Diesel Engine ····················································· 23
3.2.2 Unstable Running of Diesel Engine ··································································· 24
3.2.3 Low Power of Diesel Engine ··········································································· 24
3.2.4 Abnormal Oil Pressure of Diesel Engine ····························································· 25

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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 ·········································································· 29
4.1 Overview ·············································································································· 29
4.1.1 Danger Sign ······························································································· 29
4.1.2 Safety Sign ································································································ 30
4.1.3 Used Tools································································································· 31
4.1.4 Precautions for Health Protection······································································ 31
4.1.5 Environmental Protection Measures··································································· 32
4.1.6 Precautions on Disassembly and Assembly of Engine·············································· 32
4.2 Cylinder Head Group ································································································ 34
4.2.1 Disassembly and Assembly of Cylinder Head ······················································· 34
4.2.2 Disassembly, Inspection, Repair, and Assembly of Cylinder Head Group······················· 36
4.2.3 Disassembly, Inspection, Repair, and Assembly of Cylinder Head ······························· 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
4.3.4 Disassembly, Inspection, Repair, and Assembly of Flywheel Cover ····························· 50
4.3.5 Disassembly, Inspection, Repair, and Assembly of Oil Pan········································ 52
4.3.6 Disassembly, Inspection, Repair, and Assembly of Piston Nozzle ································ 53
4.3.7 Disassembly, Inspection, Repair, and Assembly of Thrust Halfring ······························ 54
4.3.8 Disassembly, Inspection, Repair, and Assembly of Front and Rear Oil Seal ···················· 55
4.4 Crank Connecting Rod Mechanism················································································ 57
4.4.1 Disassembly and Assembly of Crank Connecting Rod Mechanism ······························ 57
4.4.2 Disassembly, Inspection, Repair, and Assembly of Piston Connecting Rod Group ············ 58

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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 ·················· 65
4.4.7 Disassembly, Inspection, Repair, and Assembly of Secondary Balance Mechanism··········· 66
4.5 Valve Mechanism ···································································································· 68
4.5.1 Disassembly and Assembly of Valve Mechanism ··················································· 69
4.5.2 Disassembly, Inspection, Repair, and Assembly of Camshaft and Timing Gear ················ 70
4.5.3 Disassembly, Inspection, Repair, and Assembly of Rocker Arm and Rocker Arm Shaft ······ 73
4.5.4 Disassembly, Inspection, Repair, and Assembly of Tappet and Push Rod ······················· 75
4.5.5 Disassembly, Inspection, Repair, and Assembly of Valve ·········································· 76
4.5.6 Disassembly, Inspection, 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 Assembly of Fuel System ·························································· 86
4.7.2 Disassembly, Inspection, Repair, and Assembly of Injection Pump ······························ 87
4.7.3 Disassembly, Inspection, Repair, and Assembly of High-pressure Oil Pipe ····················· 89
4.7.4 Disassembly, Inspection, Repair, and Assembly of Fuel Injector ································· 90
4.7.5 Disassembly, Inspection, Repair, and Assembly of Engine Oil Filter ···························· 91
4.7.6 Disassembly, Inspection, Repair, and Assembly of Low-pressure Oil Pipe ····················· 92
4.8 Cooling System······································································································· 92
4.8.1 Disassembly and Assembly of Cooling System ····················································· 92
4.8.2 Disassembly, Inspection, Repair, and Assembly of Water Pump ·································· 94
4.8.3 Disassembly, Inspection, Repair, and Assembly of Thermostat ··································· 95
4.8.4 Disassembly, Inspection, Repair, and Assembly of Fan ············································ 96
4.9 Lubrication System ·································································································· 97

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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 ···································100
4.9.5 Disassembly, Inspection, Repair, and Assembly of Main Oil-way Pressure 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 Main Friction Pairs in Diesel Engine ··································112
Appendix C Tightening Torques for Main Bolts············································································114
Appendix D Recommended Torques for Other Standard Bolts···························································115
Appendix E Assembling Torques for Hollow Bolts ················································· 错误！未定义书签。

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

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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Figure 1-3 Flywheel End of 4M11Diesel Engine
Figure 1-4 Fan End of 4M11Diesel Engine

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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
Engine type —
Four-stroke, water-cooling, 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 consumption under
full-load condition
g/(kW·h) ≤215
Cold starting-without auxiliary ℃-10

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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starter
Cold starting-with auxiliary starter ℃-30
Noise at 1m reach dB(A) ≤115
B10Lifetime km 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.
(2) Drain the sealing oil from the inside of fuel filter and the parts of fuel system (It’s
allowed to start the engine without draining the sealing oil from the fuel system. However, it’s
permitted to run the engine under loaded condition 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 temperature sensors, and ensure that all parts to be self-provided are
completely fitted.
Notice: Do not start the diesel engine before it’s correctly assembled and connected to the
final position. When the diesel engine is running in an enclosed environment, keep well ventilated
to ensure that the exhaust gas is drained to the open air.
1.5 Hoisting of Diesel Engine
During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to
hoist in tilted or unidirectional manner. Hoist up and down slowly. The incorrect hoisting will
damage the diesel engine during hoisting.

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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a) b)
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. During the hoisting, it’s recommended to use the slings shown in
figure a) of Figure 1-4. Keep the crankshaft of diesel engine level during the hoisting. If the
slings are not on one same line with the cylinder head bolts or lifting eyes, the cylinder head
bolts will be damaged or even broken during hoisting to damage the diesel engine. Therefore,
it must be especially cautioned by the user.
1.6 Assembly of Diesel Engine
Adopt the flexible connections and ensure that the crankshaft centerline 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 filler port cap. The filler cap is equipped with a
pressure relief valve and a bleeding button. Before opening the filler cap, press the bleeding
button to open the cap in the case of a hot engine. If the diesel engine remains hot, do not add
a great deal of coolant. Dramatic temperature change could cause damage to the parts. Start
the engine. While the engine is running (1,000 r/min), continue to add the coolant to specified
location, till the coolant level is stable, and finally assemble the filler port cap.
(2) Check the fuel level
With the engine assembly on the complete machine, turn on the power supply switch,
True False

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
(4) Check all accessories of diesel engine for reliable connections and solve any
abnormal phenomenon. Check the starter system for normal wiring and check and
ensure that the battery is sufficiently charged. Open the valve fuel tank. Loosen the
bleeding screw of the fuel coarse filter. By operating the manual pump, bleed air
from the fuel coarse filter.
1.8 Start of Diesel Engine
Adjust the throttle of the diesel engine to an appropriate position. If the environmental temperature is
≤5ºC, the opening extent of the throttle can be increased appropriately. Press the starter button to start the
engine. To prevent the damage of starter motor, do not run the starter motor continuously
for >15s. 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 time.
The auxiliary starter shall be used to start the diesel engine under cold temperature. By
running the electric heating device via intake, the engine can start successfully under -30ºC
environment.
1.9 Running of Diesel Engine
After the start of diesel engine, idle the engine for (2~3) min. The engine oil pressure
shall be higher than 120kPa. When the coolant temperature is less than 60ºC, do not run the
engine immediately at high speed under heavy-load, otherwise the wear resistance and
reliability of the engine will be impaired. Apply load and increase the speed gradually. Avoid
the sudden loading and unloading whenever possible.
In the run-in period (3000km), the diesel engine is better to run under a moderate load.
Normally the diesel engine can continuously run with rated output and rated speed. The

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
Parameters and checking locations to be observed at all times during operations are as
below:
(1) Engine oil pressure (300～600) KPa (Idle speeds ≥120kPa);
(2) Engine oil temperature (85~105)℃;
(3) Outlet temperature of coolant (80~90)℃;
(4) Exhaust temperature after turbine ≤550℃
(5) Diesel inlet temperature : 35～41 ℃
(6) Check the exhaust fume color, to estimate the performances of the injectors and the
load of the engine. If the color of exhaust gas is black, stop and check the engine.
Note: During the diesel engine operation, check the engine for presence of water, air, and
fuel leakages. If any, stop the engine for troubleshooting.
The operator shall understand the following characteristics of diesel engine:
The 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
voltage checking.
Notice the following items while the diesel engine is running in cold regions:
(1) Fuel: Choose diesel of different trademarks depending on the environmental temperature
in winter.
(2) Lubricating oil: Choose lubricating oil of different viscosities depending on the seasons.
(3) Coolant: Add antifreeze additive into the cooling system and choose the coolant of
different trademarks and quantities depending on the ambient temperature.
(4) Start: The auxiliary starter can be adopted if necessary in winter. After the start of the
diesel engine, wait for the oil pressure and water temperature to turn normal before
running at high speed under loaded condition.
(5) Before the approach of the cold season, make sure to check the level and viscosity of

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
(6) Stop: To stop the engine under cold weathers, unload the engine, idle the engine for
(1~2) min, and wait for all the temperature to cool down before stop. Please be noted
that it’s disallowed to drain the coolant containing antifreeze additive after the stop of
the engine. If the coolant contains no antifreeze additive, make sure to open the water
drainage valves or water plugs on the engine block, oil cooler cover, radiator, and
water inlet pipe to fully drain the coolant, in order to prevent the frozen cracking of the
engine.
1.10 Stop of Diesel Engine
Avoid the stop of engine under full load. Before stopping the engine, reduce the load and
speed and run the engine under idling or low-load condition for 3~5min. This is intended to
cool 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 running of the diesel engine. If the diesel
engine is stopped suddenly, the turbocharger temperature will increase remarkably to cause
overheating, which will lead to seizure of bearings or failure of oil seals.
Rotate the key switch to position “OFF” or press the stop button to stop the engine, till
the flywheel stops rotation or the speed indication on the instrument panel is zero.
If the diesel engine circulating coolant is not added with antifreeze, ensure to drain the
coolant after stop in cold days, in order to prevent the frozen damage of diesel engine. The
water drainage valve is located beneath the engine oil cooler. Rotate the water drainage valve
switch to drain the water from diesel engine. In addition, disassemble the water drainage plug
from the radiator to drain the coolant from the radiator.

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
-35# diesel fuel shall be used if ambient temperature is lower than -30ºC.
The fuel used must conform to the requirements in section D.1 of Appendix D to
national standard GB20891-2007.
2.1.2 Lubricating Oil
The capacity of diesel engine lubricating 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
20W-50
4L, 18L,
170kg
National II diesel engine: WD615,
WD10, WD618, WD12, WP6 non-road
Stage-II series, etc.
Choose the viscosity of Weichai special engine oil based on the temperature, with reference to Table
2-2.
Table 2- 2 Relationship Table between Viscosity and Environmental Temperature
SAE viscosity grade
Applicable environmental
temperature (ºC)
0W-20 -35-20
5W-30 -30-30
10W-30 -25-30
15W-40 -20-40

Maintenance Manual of 4M11 Series Diesel Engine For Land Power Generators
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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.
For the added volumes of engine oil and numbers of filters of Weichai Power engines. See Table 2-3.
Table 2- 3 Added Volumes of Engine Oil and Numbers of Filters of Weichai Power Engines
Model
Added
volume of
engine oil
(L)
Number of filters
Diesel engine
Engine oil
filter
Diesel filter
Coarse 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 special coolant includes -25ºC, -35ºC, and
-40ºC. Please choose Weichai special coolant of different freezing points based on the local
environmental temperature in such manner that the freezing point is less than local air
temperature by approximately 10ºC, with reference to Table 2-4.
Table 2- 4Weichai Special Heavy-duty Engine Coolant
Variety Product category
Packing
specification
Heavy-duty
engine coolant
HEC-Ⅱ-25
HEC-Ⅱ-35
4kg，10kg

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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
SN. Name Color Purpose and location
1 MolykotePulver Black
Applied on flat and smooth metal surfaces to prevent seize
For example, applied onto outer surfaces of cylinder liners
2 Molykote G-N plus Dark grey
Lubrication before the lubricating oil pressure builds up.
For example, applied 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
Engine oil filter base bolt
Oil cooler bolt
Screw plug, control valve, engine
oil cooler,
Bolt, fuel return pipe fixing device,
fuel pump,
Air compressor shaft end thread
Suction filter bolt
Bolts of sensor and harness fixing
device
Alternatively, the thread
pre-application sealant
DriLoc204 can be
pre-applied.
Loctite 262
Applied onto outer threads
for locking, sealing,
preventing vibration from
causing looseness
Auxiliary bolt, cylinder head

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Loctite 271 Preventing looseness,
fixing Cup plug, oil drain hole
Loctite 277 For sealing between
element and bore Other cup plug
Loctite 270 Sealing cylinder head top Push rod -cylinder head
Loctite 518
(modified from
Loctite 510)
It’s applied onto shining
metal surfaces for sealing
purpose.
Plates connecting engine body
front end face to front end cover,
and connecting engine body rear
end face to flywheel cover
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 coolant level through glass sight hole. If the coolant is insufficient, open the
filler port cap and add coolant.
Note: While opening the filler port cap, make sure to push down the air bleeding button,
in order to prevent the coolant from causing personal injuries under hot state of engine.