D11 Technical Specifications

3
2021
D series Technical Document

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VMAN ENGINE
TO USERS AND OPERATORS
D series engine is an ideal power for generator sets and industrial use with advantages of economical fuel
consumption, large output, low emission and high reliability.
In order to be instructive, this manual mainly describes technical speci cations, basic structure, uses,
maintenance and troubleshooting of D series diesel engines and the replacement and adjustment of main
components. Following symbols are used to indicate the type of operations to be performed.
The diesel engine will improve continuously, so the content described herein may not be the same product
you purchase. Any questions, please inquire our sales department. Please specify the diesel engine model,
order number and produce date so that we can serve you more ef ciently. The manual will also be revised
and reprinted according to the diesel engine improvement.
Users should use fuel, lubricant and coolant properly according to this manual.
Users should use and maintain diesel engines according to this manual and keep maintenance records
regularly.
This manual should be delivered to new users along with diesel engine.
If you have any question or suggestion regarding this manual, please contact us.
Thank you.
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VMAN ENGINE Technical Documentation
1. SAFETY PROCEDURES& DIESEL ENGINE SPECIFICATIONS
1.1 Safety Procedures

1.1.1 Abstract
- In order to avoid errors and malfunctions during operation and maintenance, only professional workers
having a full knowledge of safety notes and warnings are allowed to operate.
- This abstract is a compilation of the most important procedures, which can be broken down into main
sections containing the information necessary for preventing injury to persons and damages to property and
pollution. In addition, diesel engine related local regulations are to be observed.
IMPORTANT: If despite all precautions, an accident occurs, especially for corrosive acid, fuel, sharp iron
llings, hot oil and anti-freeze uid sputtering into eyes, shall go to doctor immediately.
During start-up and running, any person or tool are not allowed to contact rotating parts!
During running or just stopped, skin and eyes are not allowed to touch extremely hot and corrosive
material like oil, coolant and waste gas!
During running or just stopped, fuel, engine oil, etc. must not be put close to ame, or on the diesel
engine surface.
For safe and stable operation, people authorized to operate and repair must have received special
training and abide by the procedures of this manual!
1.1.2 Operation cautions

- Before start up a new diesel engine, carefully read the instruction and clarify the model, speci cation as
well as maintenance and tool use requirements.
- Before start up an engine, carefully check the status of fuel, engine oil, coolant, battery charging, electric
parts and fuel injection control system, make sure everything is normal.
- When engine running normally, pay attention to working environment, make sure operating under a safe
circumstance. Frequent transit overspeed and overloaded operation are forbidden. Troubleshooting or
special tools shall be applied as per fault degree after engine stopped. Engine shall stop gradually after
Do not touch oil drain plug or oil lters with bare hands in case of scaldings.
Electrolyte is toxic and corrosive and battery gas is explosive, wherefore battery repair shall be performed
by professional and authorized people only.
Health precautions: Avoid prolonged or repeated skin contact with used engine oil. Protect your skin by
suitable hand creams or wearing protective gloves. Clean skin which has been in contact with engine oil
timely. After washing apply a fatty skin cream to the skin.Change oil-soaked clothing and shoes. Do not
put oily rags into your pockets.
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Technical Documentation VMAN ENGINE
1.2 Diesel engine speci cations

1.2.1 D11 series
RATINGS DEFINITION
The power ratings of Emergency Standby and Prime are in accordance with the standard
of IS08528. Fuel Stop power in accordance with the standard of ISO3046.
Electric power (kW) should be estimated by considering generator ef ciency, cooling fan
power loss and power derating due to altitude and temperature.
STANDBY POWER RATING is applicable for supplying emergency power for the duration
of the utility power outage. No overload capability is available for this rating. A standby
rated engine should be sized for a maximum of a 70% average load factor and 200 hours
of operation per year, this includes less than 25 hours per year at the Standby Power
rating.
PRIME POWER RATING is available for an unlimited of hours per year in variable load
application. Variable load should not exceed a 70% average the Prime Power rating during
any operating period hours., The Total operating time at 100% Prime Power shall not
exceed 500 hours per year.
10% overload capability is available for a period of 1 hour within a 12 hours period of
operation. Total operating time at the 10% overload power shall not exceed 25 hours per
year,
CONTINUOUS POWER RATING is the power that the engine can continue to use under
the prescribed speed and the speci c environment condition in the normal maintenance
period stipulated in the manufacturing plant. And continuous power applicable for
supplying utility power at a constant 100% for an unlimited number of hours per year. No
overload capability is available for this rating.
Ratings  
1500rpm / 50Hz 1800rpm / 60Hz
(kW/PS)
D11 D11A D11A1 D11A2 D11B D11B1 D11B2
Prime 320/435 285/388 265/360 240/326 342/465 318/432 288/392
Standby 360/490 314//427 292/397 264/359 390/530 340/462 317/431
Continuous 249/338 217/295 201/273 182/247 260/353 242/329 219/297
GENERAL ENGINE DATA

Engine Model D11 D11A D11A1 D11A2 D11B D11B1 D11B2
Engine Type 4-Cycle, V-type, 6-Cylinder, Turbo charged & inter-cooled (air to air)
Speed 1500 rpm 1800 rpm
Bore x stroke 128 x 142 mm
Displacement 10.964 L
Compression ratio 14.6 : 1 15.5 : 1 14.6 : 1 15.5 : 1
Rotation {Looking at flywheel} Counter clockwise {CCW}
Firing order 1-4-2-5-3-6
Injection timing 18˚±1˚ BTDC @ 1500 rpm 20˚±1˚ BTDC @ 1800 rpm
Dry weight {W/O cooling system} 904 kg
Dimension {L x W x H} 1251*1389*1288 mm
Flywheel housing SAE 1
Flywheel 14{PCD:438.15mm/17.25inch}
Number of teeth on flywheel 160
Piston speed 200 m/s 240 m/s
ENGINE MOUNTING
Max.Bending Moment at Rear Face to Block 1325 N.m
AIR INDUCTION SYSTEM

Maximum Intake Air Restriction
- With Clean Filter Element (m³/h) 2119 1820 1675 1507 2365 2042 1857
- With Dirty Filter Element (m³/h) 6103 5242 4824 4340 6811 5881 5348
Max.static pressure after radiator (Pa) 955 Pa
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Technical
VMAN ENGINEDocumentation
COOLING SYSTEM
Water circulation by centrifugal pump on engine
Cooling method Fresh water forced circulation
Coolant capacity 19 L
Coolant flow rate 320 liters / min @1800 rpm, 390 liters / min @1500 rpm
Pressure Cap 49 kPa
Max.Permissible Temperature 90 °C
Max.Coolant warning Temperature 95 °C
Max.Coolant Shutdown Temperature 105 °C
Thermostat Open Temperature 71 °C
Max.external coolant system restriction Not available
Two radiator options are provided, based on allowable maximum Air temperature On radiator inlet ( Air On 40 °C) Air On 50 °C
- ATB (Ambient Temperature before Boiling ) of generator set varies depending on the engine room ventilation design, even if the same radiator applied. Adequate selection of radiator
options by means of the cooling test is highly recommended, and generator set makers are responsible for the selection.
LUBRICATION SYSTEM
Force-feed lubrication by gear pump, lubricating oil cooling water circuit of engine
Lub.Method Fully forced pressure feed type
Oil lter Full flow, cartridge type
Lube oil speci cation CF-4
Idle Speed : Min 160 kPa
Lube oil pressure
Governed Speed: Min 200 kPa
Maximum oil temperature 110 °C
Max.Permissible Oil Temperature 90 °C
Oil Consumption (as % of fuel consumption) ≤0.5
Oil capacity 25 L
FUEL SYSTEM
In-line pump with integrated, electromagnetic actuator
Governor Electric type (Original GAC from USA)
Speed drop G2 Class (ISO 8528)
Feed pump Mechanical type in pump
Injection nozzle Multi hole type
Opening pressure 28 MPa
Fuel lter Full flow, Cartridge type with water drain valve
Maximum fuel inlet restriction 30 kPa
Maximum fuel return restriction 60 kPa
Fuel feed pump Capacity 630 liters / hr
Fuel Diesel fuel
Fuel Consumption of generator set
Standby power- 100% load (l/h) 89 77 70 63 101 85 79
Prime Power - 100% load (l/h) 78 68 63 57 87 79 71
- 75% load (l/h) 58 51 47 42 64 59 51
- 50% load (l/h) 39 34 33 30 44 40 36
- 25% load (l/h) 24 21 19 18 25 23 21
Continous power - 100% load (l/h) 59 52 41 43 66 60 54
Lowest Fuel Consumption Ratio(g/kW.h) 198 195 193 192 204 202 197
ELECTRICAL SYSTEM
Charging Alternator Voltage 28V
Charging Alternator Capacity 45A
Voltage regulator Built-in type IC regulator
Starting motor 7kW
Battery Voltage 24V
Battery Capacity 2 *200 Ah ( recommended )
Starting aid (Option) Block heater ( Min. Temperature for Unaided Cold Start -10°C )
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Technical Documentation
VMAN ENGINE
VALVE SYSTEM
Type Overhead valve type
Number of valve Intake 1, exhaust 1 per cylinder
Valve lashes at cold Intake 0.3 mm, Exhaust 0.4 mm
Valve timing
Opening Close
- Intake valve 24 deg.BTDC 36 deg.ABDC
- Exhaust valve 63 deg.BBDC 27 deg.ATDC
Engine Data with Dry Exhaust Manifold (Standby Power)

Cooling Water Circulation 320 L/min (1500 rpm) 390L/min (1800 rpm)
Heat Rejection to Exhaust (kW) 278 242 219 197 314 266 246
Heat Rejection to Coolant (kW) 121 106 95 86 137 116 107
Heat Rejection to Intercooler (kW) 81 70 64 57 91 77 71
Radiated Heat to Ambient (kW) 37 32 21 18 60 41 35
Engine Data with Dry Exhaust Manifold (Prime Power)

D11 (V6) Series diesel engine drawing
Water Temperature
Sensor NPTF 3/8
1620
151
255
414
Oil Pressure
151
Sensor NPT 1/8-27
1410 1585
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Technical
VMAN ENGINEDocumentation Technical Documentation
1.2.2 D15 series

RATINGS DEFINITION
The power ratings of Emergency Standby and Prime are in accordance with the
standard of IS08528. Fuel Stop power in accordance with the standard of ISO3046.
Electric power (kW) should be estimated by considering generator ef ciency, cooling
fan power loss and power derating due to altitude and temperature.
STANDBY POWER RATING is applicable for supplying emergency power for the
duration of the utility power outage. No overload capability is available for this rating.
A standby rated engine should be sized for a maximum of a 70% average load factor
and 200 hours of operation per year, this includes less than 25 hours per year at the
Standby Power rating.
PRIME POWER RATING is available for an unlimited of hours per year in variable
load application. Variable load should not exceed a 70% average the Prime Power
rating during any operating period hours., The Total operating time at 100% Prime
Power shall not exceed 500 hours per year.
operation. Total operating time at the 10% overload power shall not exceed 25 hours
per year,
CONTINUOUS POWER RATING is the power that the engine can continue to use
under the prescribed speed and the speci c environment condition in the normal
maintenance period stipulated in the manufacturing plant. And continuous power
applicable for supplying utility power at a constant 100% for an unlimited number of
hours per year. No overload capability is available for this rating.
Ratings
1500rpm / 50Hz 1800rpm / 60Hz
(kW/PS)
D15 D15A D15A1 D15A2 D15B D15B1 D15B2
Prime 450/612 405/551 365/496 330/450 440/599 405/551 370/503
Standby 500/680 445/605 415/565 363/494 500/680 460/626 405/551
Continous 346/470 308/418 277/376 251/341 334/454 308/418 281/382
GENERAL ENGINE DATA

Speed 1500 rpm 1800rpm
Bore x stroke 128 * 142 mm
Firing order 1-5-7-2-6-3-4-8
Flywheel 14{PCD:438.15mm/17.25inch}
Number or teeth on flywheel 160
ENGINE MOUNTING
INTAKE & EXHAUST SYSTEM

Max.Intake Restriction (kPa) 5
Max.Exhaust Back Pressure (kPa) <10
Combustion Air Consumption (m³/h) 3047 2699 2418 2137 3077 2749 2396
Max.Exhaust Temp.(After Turbo°C) 520 510 493 440 530 500 465
Exhaust Gas Flow (m³/h) 7447 6512 5709 4695 7615 6548 5449
Cooling fan air flow (m³/h/min) 713 713 675 675 810 810 810
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VMAN ENGINE

- With Clean Filter Element (m³/h) 3047 2697 2418 2137 3077 2749 2396
- With Dirty Filter Element (m³/h) 8775 7767 6964 6155 8862 7917 6900
Max.static pressure after radiator (Pa) 1126 Pa @1500rpm 955 Pa @1800rpm
COOLING SYSTEM
Coolant capacity Engine only : Approx.23 lit, With Radiator (*Air On 43°C ：Approx 114 lit )
Coolant flow rate 660 liters/min @1800rpm； 590 liters/min @1500 rpm
Pressure Cap 49 kPa
Coolant Capacity for Engine 20 L
LUBRICATION SYSTEM
Lube oil pressure
Oil capacity 27 L
FUEL SYSTEM
Fuel Diesel fuel
Standby power- 100% load (l/h) 127 113 102 88 131 115 102
Prime Power - 100% load (l/h) 113 101 89 80 114 100 91
- 75% load (l/h) 84 75 65 59 83 74 68
- 50% load (l/h) 57 51 46 41 57 50 45
- 25% load (l/h) 31 27 25 23 33 29 27
Continous power - 100% load (l/h) 86 77 67 61 86 76 69
Lowest Fuel Consumption Ratio(g/kW.h) 205 204 196 198 207 201 199
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Technical
ELECTRICAL SYSTEM
Starting motor 7kW
Battery Voltage 24V
Battery Capacity 2 * 200 Ah ( recommended )
VALVE SYSTEM
Valve timing
Opening Close


Water Temperature
Sensor NPT 3/8
1605
255
413
153
Oil Pressure
Sensor NPT 1/8-27
1410 1751
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VMAN ENGINE
1.2.3 D22 series

RATINGS DEFINITION
The power ratings of Emergency Standby and Prime are in accordance with the standard of
IS08528. Fuel Stop power in accordance with the standard of ISO3046.
Electric power (kW) should be estimated by considering generator ef ciency, cooling fan power
loss and power derating due to altitude and temperature.
STANDBY POWER RATING is applicable for supplying emergency power for the duration of the
utility power outage. No overload capability is available for this rating. A standby rated engine
should be sized for a maximum of a 70% average load factor and 200 hours of operation per year,
this includes less than 25 hours per year at the Standby Power rating.
PRIME POWER RATING is available for an unlimited of hours per year in variable load
application. Variable load should not exceed a 70% average the Prime Power rating during any
operating period hours., The Total operating time at 100% Prime Power shall not exceed 500 hours
per year.
10% overload capability is available for a period of 1 hour within a 12 hours period of operation.
Total operating time at the 10% overload power shall not exceed 25 hours per year,
CONTINUOUS POWER RATING is the power that the engine can continue to use under the
prescribed speed and the speci c environment condition in the normal maintenance period
stipulated in the manufacturing plant. And continuous power applicable for supplying utility
power at a constant 100% for an unlimited number of hours per year. No overload capability is
available for this rating.
Ratings
1500rpm / 50Hz 1800rpm / 60Hz
(kW/PS)
D22Z D22 D22A D22A2 D22A3 D22.1 D22.2 D22B D22B1 D22B2 D22B3
Prime 660/897 630/857 555/755 515/700 455/619 756/1028 718/976 671/912 620/843 565/768 525/714
Standby 735/1000 700/952 606/824 565/768 505/687 832/1131 790/1075 739/1005 682/927 627/853 577/785
Continous 508/690 479/651 422/573 391/531 346/470 575/781 546/742 510/693 471/640 429/583 399/542
GENERAL ENGINE DATA

Engine Model D22Z D22 D22A D22A2 D22A3 D22.1 D22.2 D22B D22B1 D22B2 D22B3
Compression ratio 14.6 : 15.5 : 1 14.6 : 15.5 : 1
Firing order 1-12-5-8-3-10-6-7-2-11-4-9
Flywheel housing SAE 1 or SAE 0
Flywheel 14{PCD:438.15mm/17.25inch} or 18{PCD:543mm/31.38inch}
ENGINE MOUNTING

Combustion Air Consumption (m³/h) 4480 4204 3477 3309 2958 5710 4838 4504 4096 3728 3396
Max.Exhaust Temp.(After Turbo°C) 550 550 540 513 502 550 545 540 525 510 480
Exhaust Gas Flow (m³/h) 11361 10662 8712 8015 7064 13112 12197 11284 10072 8996 7882
Cooling fan air flow (m³/min) 863 863 750 720 720 1100 950 950 950 950 950
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Technical

- With Clean Filter Element (m³/h) 4480 4204 3477 3309 2958 5170 4838 4504 4096 3728 3396
- With Dirty Filter Element (m³/h) 12902 12108 10014 9530 8519 14890 13933 12972 11796 10737 9780
COOLING SYSTEM
Coolant flow rate 660 liters/min @1800rpm； 590 liters/min @1500rpm
Pressure Cap 49 kPa
LUBRICATION SYSTEM
Lube oil pressure
Oil capacity 57 L
FUEL SYSTEM
Maximum fuel return restriction 60kPa
Fuel Diesel fuel
Standby power- 100% load (l/h) 185 176 152 138 121 219 207 193 175 158 145
Prime Power - 100% load (l/h) 167 157 133 124 109 197 186 174 158 140 130
- 75% load (l/h) 123 116 98 92 82 145 137 128 116 105 97
- 50% load (l/h) 83 79 66 63 56 104 98 91 83 74 68
- 25% load (l/h) 47 44 39 38 34 62 59 55 48 43 40
Continous power - 100% load (l/h) 127 120 101 94 83 150 142 132 120 107 99
Lowest Fuel Consumption Ratio(g/kW.h) 205 202 193 197 197 209 206 205 202 200 198
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VMAN ENGINE
ELECTRICAL SYSTEM
Starting motor 9kW
Battery Voltage 24V
VALVE SYSTEM
Valve timing
Opening Close

Cooling Water Circulation 590 L/min @ 1500 rpm 660 L/min @ 1800 rpm
Heat Rejection to Exhaust (kW) 578 551 475 431 378 684 646 604 548 493 452
Heat Rejection to Coolant (kW) 252 240 207 188 165 298 282 263 239 215 197
Heat Rejection to Intercooler (kW) 168 160 138 125 110 199 188 175 159 143 131
Radiated Heat to Ambient (kW) 92 88 76 69 60 109 103 97 88 79 72

Cooling Water Circulation 590 L/min @1500rpm 660 L/min @1800rpm
Heat Rejection to Exhaust (kW) 526 496 435 393 341 621 587 549 498 444 411
Heat Rejection to Coolant (kW) 229 216 189 171 149 271 256 239 217 194 179
Heat Rejection to Intercooler (kW) 153 144 126 114 99 180 170 159 145 129 119
Radiated Heat to Ambient (kW) 84 79 69 63 54 99 94 88 80 71 66
Water Temperature
Sensor NPTF 3/8

1803
255
159
512
153
Oil Pressure
Sensor NPTF 1/8-27
1391 2093±5
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1.2.4 D30 series RATINGS DEFINITION

The power ratings of Emergency Standby and Prime are in accordance with the
standard of IS08528. Fuel Stop power in accordance with the standard of ISO3046.
Electric power (kW) should be estimated by considering generator ef ciency, cooling
fan power loss and power derating due to altitude and temperature.
STANDBY POWER RATING is applicable for supplying emergency power for the
duration of the utility power outage. No overload capability is available for this rating.
A standby rated engine should be sized for a maximum of a 70% average load factor
and 200 hours of operation per year, this includes less than 25 hours per year at the
Standby Power rating.
PRIME POWER RATING is available for an unlimited of hours per year in variable
load application. Variable load should not exceed a 70% average the Prime Power
rating during any operating period hours., The Total operating time at 100% Prime
Power shall not exceed 500 hours per year.
operation. Total operating time at the 10% overload power shall not exceed 25 hours
per year,
CONTINUOUS POWER RATING is the power that the engine can continue to use
under the prescribed speed and the speci c environment condition in the normal
maintenance period stipulated in the manufacturing plant. And continuous power
applicable for supplying utility power at a constant 100% for an unlimited number of
hours per year. No overload capability is available for this rating.
Ratings
1500rpm / 50Hz 1800rpm / 60Hz
(kW/PS)
D30AP D30A D30A1 D30A2 D30A3 D30BP D30B1 D30B2 D30B3 D30B4
Prime 1000/1360 920/1238 875/1190 795/1081 705/959 1000/1360 920/1265 880/1197 825/1122 750/1020
Standby 1100/1496 1020/1387 960/1306 880/1197 780/1060 1100/1496 1020/1388 965/1312 910/1238 850/1156
Continous 770/1047 705/958 665/904 604/821 536/728 770/1047 707/961 669/909 627/852 570/775
GENERAL ENGINE DATA

Engine Model D30AP D30A D30A1 D30A2 D30A3 D30BP D30B1 D30B2 D30B3 D30B4
Firing order 1-15-6-12-8-5-16-7-11-4-9-2-14-10-3-13
Flywheel 18{PCD:543mm/31.38inch}
ENGINE MOUNTING

Combustion Air Consumption (m³/h) 7115 6368 5651 5154 4591 7351 6580 5881 5330 4978
Max.Exhaust Temp.(After Turbo°C) 518 510 500 487 473 665 540 506 480 475
Exhaust Gas Flow (m³/h) 17461 15366 13462 12071 10556 18735 16487 14119 12368 11476
Cooling fan air flow (m³/h) 1755 1755 1755 1755 1365 1750 1750 1750 1400 1400
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Engine Model D30AP D30A D30A1 D30A2 D30A3 D30B0 D30B1 D30B2 D30B3 D30B4
- With Clean Filter Element (m³/h) 7115 6368 5651 5154 4591 7351 6580 5881 5330 4978
- With Dirty Filter Element (m³/h) 20491 18340 16275 14844 13222 21171 18950 16937 15350 14337
COOLING SYSTEM
Coolant flow rate 1040 liters / min @1800 rpm, 860 liters / min @1500 rpm
Pressure Cap 49 kPa
LUBRICATION SYSTEM
Lube oil pressure
Oil capacity 78 L
FUEL SYSTEM
In-line pump with integrated, HEINZMANN electromagnetic actuator
Governor Electric type ( HEINZMANN Speed governor )
Feed pump Mechanical type in injpump
Fuel feed pump Capacity
Fuel Diesel fuel
Standby power- 100% load (l/h) 295 268 248 224 197 301 274 250 219 206
Prime Power - 100% load (l/h) 266 241 223 200 175 272 248 224 197 180
- 75% load (l/h) 197 179 166 149 127 201 183 164 148 138
- 50% load (l/h) 138 125 116 104 91 145 131 116 104 96
- 25% load (l/h) 81 74 69 61 53 81 74 67 60 56
Continous power - 100% load (l/h) 202 184 170 152 133 207 188 170 150 137
Lowest Fuel Consumption Ratio(g/kW.h) 225 210 198 197 198 228 217 205 197 197
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ELECTRICAL SYSTEM
Starting motor 11kW
Battery Voltage 24V
VALVE SYSTEM
Valve timing
Opening Close

Heat Rejection to Exhaust (kW) 898 839 773 701 614 916 856 782 685 644
Heat Rejection to Coolant (kW) 392 366 337 306 268 399 373 341 298 281
Heat Rejection to Intercooler (kW) 261 244 225 204 178 266 249 227 199 187
Radiated Heat to Ambient (kW) 143 134 124 112 98 147 137 125 109 103

Heat Rejection to Exhaust (kW) 815 762 705 633 555 835 780 713 621 568
Heat Rejection to Coolant (kW) 355 332 307 276 242 364 340 311 271 248
Heat Rejection to Intercooler (kW) 236 221 205 184 161 243 227 207 180 165
Radiated Heat to Ambient (kW) 131 122 113 101 89 134 125 114 99 91
Water Temperature
Sensor NPTF 3/8
C1=2016mm
C2=1991mm
300
255
153
Oil Pressure
Sensor NPTF 1/8-27
A1=1808mm B1=2306mm
A2=2140mm B2=2702mm
The size of A1 B1 C1 for D30A3 & D30B4
The size of A2 B2 C2 for D30AP D30A D30A1 D30A2 &D30BP D30B1 D30B2 D30B3
1.3 Diesel engine model, order number and serial number

The engine model and serial number are printed on the engine label.
These numbers are required when requesting warranty and ordering parts.
1.3.1 Diesel engine model
Power code: Using 1 ~ 9, basic model is not numbered
Development sequence code: represented by A, B, C…
Displacement, 22 represents displacement of 22L
Fuel form code: D represents “diesel engine”
Example 1: D22A1 represents VMAN diesel engine, displacement of 22 L, for rst power change.
Example 2: D22B1 represents VMAN diesel engine, displacement of 22 L, for second power change.
1.3.2 Diesel engine model

Diesel engine product order number and feature code are represented by Arabic numerals and letters, the
sequence is shown as below：
Model con guration type: 01 ~ 99
Rated speed：A says “1500r/min”

B says “1800 r/min”
Example：A01 says 1500 r/min, rst type of con guration.
1.3.3 Diesel engine serial number

Diesel engine serial number is made up of Arabic numerals and letters, having nothing to do with diesel
engine model, only related to the year. The order is shown as below:
Serial number is expressed as a number of 00001 ~ 99999
Production year is represented by the last two number of the year
Diesel engine series
Example：D15 1300001 means model D15 serial number 00001 produced in 2013
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VMAN ENGINE
1.4 Engine performance curve
1.5 Engine Assembly

1.5.1 Engine sectional view (longitudinal)
4 5 6 7 8 9 10
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2 1 18 17 16 15 14 13 12
1.Oil seal 2. Vibration damper 3. Water pump 4. Thermostat 5. Piston pin

6. Piston. 7. Valve 8. Locking clip. 9. Valve shaft guide 10. Bearing
11. Oil seal 12. Flywheel 13. Flywheel house 14. Pressure reducing valve
15. Cam shaft 16. Oil drain plug. 17. Oil suction pipe 18. Crank shaft

VMAN ENGINE
1.5.2 Engine sectional view (Cross)
1. Cylinder head 2. Cylinder head cover
3. Push rod 4. Injection pump
5. Intake manifold 6. Injection pipe
7. Oil ller cap 8. Cylinder block
9. Oil lter 10. Oil cooler
11. Connecting rod 12. Exhaust manifold
13. Cylinder liner 14. Starter
1.6 Dimensions and clearances for commonly used parts of diesel engine
No Items Speci cations(mm) Limit （mm）

1 Liner's projection 0.04～0.08
Valve projecting amount -0.65～-0.95 -2.5
2
Cylinder head lower face warp and heigh ≤0.05 0.20
3 Head gasket thickness (after tightening bolts) 1.163～1.297
4 Piston and cylinder liner clearance (min.) 0.243～0.271 0.45
1st ring end part clearance 0.35～0.50 1.5
5 2nd ring end part clearance 0.40～0.60 1.5
Oil ring end part clearance 0.30～0.70 1.5
1st ring axial direction clearance —-
6 2nd ring axial direction clearance 0.050～0.082 1.5
Oil ring axial direction clearance 0.030～0.070 1.5
7 Piston pin and pin hole clearance 0.003～0.015 0.08
8 Crankshaft neck and Main bearing clearance 0.066～0.132 0.166
9 Crankshaft's axial direction's clearance 0.190～0.322 0.452
10 Con rod bearing and crank pin clearance 0.056～0.118 0.154
11 Con rod bush oil clearance 0.055～0.071 0.12
Con rod small end part axial direction clearance 0.064～0.126
12
Con rod axial direction clearance 0.240～0.392
13 Camshaft neck and sleeve clearance 0.060～0.109 0.17
14 Camshaft axial direction clearance 0.20～0.90
Intake valve rod and valve guide clearance 0.020～0.058 0.20
15
Exhaust valve rod and valve guide clearance 0.045～0.083 0.25
16 Rocker arm shaft and rocker arm bushing clearances 0.015～0.068 0.14
17 Tappet clearance 0.035～0.077 0.13
18 Nozzle and cylinder head extrude height 0.9～1.8
Backlash (crankshaft gear & oil pump drive gear) 0.10～0.45 0.3
19 Backlash (crankshaft gear & camshaft gear) 0.118～0.242 0.3
Backlash (driving gear & injection pump gear) 0.102～0.338 0.45
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2. ENGINE STRUCTURE OVERVIEW
2.1 Engine Block and Cylinder Head

- The cylinder block is a single piece of alloy cast iron. To increase its rigidity, area below the crankshaft
centerline has been toughened. The engine has replaceable wet cylinder liners and each cylinder has a
head, each head has replaceable valve seat rings and valve guides.
- The forged crankshaft has screwed-on counterweights. Replaceable radial seals on crankshaft and ywheel
can prevent lubrication leaking from crankcase.
- The connecting rods are die-forged, miter articulate shaped positioned, and can be pulled out of the top of
cylinder together with piston. Crankshaft and connecting rod are made of typically steel back lead and
copper alloy bearings.
2.2 Gas Distribution System

- Rear gear transmission system is inside ywheel, including crankshaft gear, camshaft gear, oil pump gear
and injection pump gear.
- Valve is driven by camshaft through tape, push rod and rocker arm.
2.3 Fuel System

Fuel pump supplies fuel to fuel ler and then to injection pump, then through high-pressure pipe to injector.
Some fuel is sprayed into cylinder through injector, the remaining ows-back through relief valve to fuel tank.
1. Fuel tank
2. Strainer
3. Fuel Filter
4. Fuel lter assembly
4a. Fuel water drain plug
4b. Air bleeding plug
5. Fuel pipe connector
6. Injection pump
7. Injector
8. Fuel pressure relief valve
9. Fuel return pipe
10. Fuel feed pump
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2.3.1 Injection Pump

- No adjustment can be made to the injection pump. If the lead seal is damaged the warranty on the engine
will be invalid.
Faults
- Any fault occurred in the use of injection pump shall be repaired by injection pump manufacturer
appointed services.
Fuel System Bleeding
- Relieve bleed screw and bleed air in fuel lter. The suction chamber of the injection pump will continuously
bleed fuel via the relief valve. If the suction chamber is empty or with a new injection pump, then oil lling
2.3.2 Fuel Feed Pump

- Fuel feed pump is driven by the camshaft cam drive of injection pump.
2.3.3 Maintenance for Injector
Injector is composed of nozzle holder and nozzle needle. Injector is used to amortize fuel and then sprays
them into combustion chamber; a copper gasket on the injector is to ensure the gas tightness and nice
radiating function; the opening pressure of the injector can be changed by adjusting compression spring
and gasket.
1. Nozzle holder
2. Cap nut
3. Adjust gasket
4. Compression spring
5. Compression pin
6. Shim block
7. Cap nut for xed nozzle
8. Nozzle needle
2.3.4 Fuel Installations

- Oil water separator shall be installed between fuel tank and engine. For tank is always in humidity,
water often in ltrates into fuel and then into the engine which would result in nozzle stuck and engine
ef ciency drop etc.
- Fuel System Installation Example:
- The position of fuel tank should be higher than the feed pump; if fuel tank is lower, then sanction lift
should be within 1 m; fuel pipe shall not be partly bended in case of bubble.
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2.4 Turbocharger Structure Overview

The bleeding gas passes through the turbine rotor of turbocharger. Turbo rotor takes in fresh air with air
impeller mounted on the same shaft and delivers air with high pressure to the combustion chamber. The
turbocharger is air-cooled. Lubrication of the main bearing is supplied by engine lubrication system.
1. Compressor casing
2. Turbine casing
3. Compressor wheel
4. Impeller
5. Turbine
A. Air inlet
B. Gas outlet
C. Gas inlet
D.Oil supply
E. Oil return
2.5 Lubrication System

- Abstract
Oil pump extracts oil through oil pan, and then delivers to oil cooler and oil lter, after ltering and cooling,
oil goes to cylinder block main gallery, and then distributed to parts lubrication and injection pump to make
sure engine can work normally
- Speci cations
Item Speci cations Item Speci cations

Lubrication system Forced pressure cycle Oil lter type Full ow
Filter element bypass
Oil pump type Gear 2.1±0.3kg/cm2
valve opening pressure
Whole oil lter bypass
Relief valve opening pressure 8.5 ～ 10kg/cm2 4.5±0.2kg/cm2
valve opening pressure
Oil nozzle regulating valve
1.6 ～ 1.9kg/cm2
opening pressure
- Diagram of Lubrication System

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2.6 Cooling System

- Abstract
This engine is water-cooling type. Heat generated from the combustion chamber and engine oil is
discharged via coolant, so the engine can run properly.
Oil coolant absorbs oil heat via water pipe, water pump transfers coolant to water jacket of cylinder block
and water passage of cylinder head to absorb the heat generated from combustion chamber.
Water absorbing oil and combustion chamber heat goes to thermostat through water passage, and re ows
via the water pump to block water chamber when water temperature is lower than the thermostat valve
opening temperature, forming a small (inner) loop; when water temperature is higher than valve opening
temperature, water will ow to radiator, forming a big (outer) loop, and distribute coolant absorbed heat
through radiator, and then coolant recirculates to water pump.
- Speci cations
Part Name Item Speci cation
pump ow about 650 liter/min
water pump speed 3060rpm/min
back pressure 0.1MPa
thermostat adjustment range 71～83℃

fan diameter - number of blades φ915mm-7
cooling fan and belt
fan belt tension 15mm/manually deviation
2.6.1 Intercooler
- The intercooler is air to air, having a large cooling fan. Service life and performance depends on the quality
of the air taken in. Contaminated air would clog the air ns of intercooler, lower the engine output. So intake
system such as air lter element should be frequently checked to make sure it hasn’t been damaged or
contaminated.
- Cleaning of intercooler ns : Every 600 hours.
2.6.2 Coolant Fill (only after engine cool down completely )

Fill in the coolant slowly and make sure all air has been removed from the cooling system. Run the engine a
little and then check coolant surface position again.
If something unexpected occurs, check the coolant surface position when engine is still warm. Turn the
smaller valve cap to rst notch, reduce the pressure and then close the valve cap, so that operator won’t be
hurt by radiator cap when disassemble. Coolant shall be lled in through radiator cap, do not ll in when
engine is still warm. If lacks hot water, ll in warm water very slowly when engine is running to the correct
position.
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WARNING: If working valve’s cap is open, is likely to result that system required high-pressure
unaccessible, premature boiling and coolant loss. To prevent damage to the engine, only in the case of no
other choice can open the cap, and shall change a new one as soon as possible.
2.7 Electrical equipment

2.7.1 Alternator
- The alternator is equipped with integral silicon recti ers. Internal transistor regulator can limit the voltage
of AC generator.
- Don’t start alternator unless regulator is connected with battery in case burn out the recti er and regulator.
- The alternator maintains automatically, nevertheless, it must be protected against dust, moisture and water.
Illustrative Diagram
2.7.2 Starter
In engine maintenance, soak pinion and ring gear in fuel and wash thoroughly, then smear with lubrication.
Starter is anged to the left side of ywheel housing gear.
As part of normal engine inspection, starter pinion and ring gear should be cleaned with a brush dipped in
fuel and then smear with lubrication.
WARNING: Do not start electrical system when battery ground wire is connected. Make sure there is no
short cut, and then connect battery ground wire
2.8 Electronic Governor System for D Series Diesel Engine

2.8.1 D11/D15/D22 Series Engine Speed Control Unit for GAC EEG6500
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2.8.2 D30 Series Engine Speed Control Unit for HEINZMANN DC9
Digital Governor DC 9
The control device contains the control electronics. At the core of the control unit is a very fast and powerful
16-bit microprocessor (CPU). The actual controller program, on the basis of which the microprocessor
operates, is permanently stored in a so-called FLASH- EPROM.
When the engine is started, a magnetic pickup on the starter gear induces voltage and transmits it to the
control device. The voltage activates the control device and the frequency of the voltage signal is read as
actual speed.
After the engine is started, the engine runs up a programmable ramp until it reaches a pre- set xed speed or
an analogue set-point. Afterwards, the pre-set speed set-point can be offset with the aid of two digital switch
inputs (speed increase/decrease). At each new engine start this offset is automatically returned to zero.
The control device is executed as PID control device, according to application the functions droop zero
(isochronous operation) or droop are possible.
Droop, i.e. a continuous speed deviation dependent on engine load, is necessary for vehicle applications but
also when existing generator systems are retro tted or modernized whereby a mechanical speed governor is
substituted with an electronic one but a control device not from HEINZMANN used for synchronization and
power output setting is kept.
For synchronization and load sharing the HEINZMANN unit AT 10-01 can be used and connected. This unit
carries out only a single-phase performance reading, during which the speed governor always functions in
isochronous mode. For more information on this device see the manual "AT 10-01" (manual no. E 05 001-d).
HEINZMANN digital control devices of the ORION series are speed governors with limited functionality. But
beside speed control several other functions are available
HEINZMANN digital control devices of the ORION series are speed governors with limited functionality. But
beside speed control several other functions are available:
1) Speed Setting
Speed set-point may be transmitted by analogue set-point adjusters (supply 0..5 V, voltage 4-20 mA, AT 10 or
5 kOhm potentiometer).
In addition, the speed set-point can be modi ed with a push-button for speed increase and speed decrease
around the xed speed. The permissible rate of speed increase/decrease can be determined with a
parameter. After start-up the engine runs up a separately parametrizable starting ramp until it reaches the pre-
set xed speed.
2) All-speed Governor with adjustable Droop

For several applications, e.g. for parallel operation of generators without a HEINZMANN load measuring unit,
speed control with droop is required. This can be adjusted as desired. When the setting is droop = 0 the
control device operates in isochronous mode.
3) Idling / Maximum Speed Control

For vehicle application, the governor can be made to operate as an idling and maximum speed controller.
With a digital switch it is possible to switch over from all speed governor to idle / maximum speed control.
4) Adjustment of Speed Range

The minimum and maximum speeds that can be reached with the speed set-point can be adjusted with
parameters.
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5) Starting Fuel Adjustment

When setting starting fuel, starting minimum fuel or starting maximum fuel are available as alternatives.
Furthermore, variable starting fuel can be provided, by which starting fuel is increased automatically during
start-up.
6) Fixed Fuel Limitation

For the stop-position and the maximum fueling position "electric catches" can be provided. This will prevent
the governor's thrust from affecting the terminal stops of the injection pump, etc.
7) Speed Dependent Fuel Limitation

For variable speed governors, there is provided an option of programming speed dependent limit curves.
Thus, for any speed, torque can be reduced as is permissible for the engine or desired by the user.
8) Boost Pressure dependent Fuel Limitation

For turbocharged engines, fueling can be reduced to achieve smokeless operation in case of missing boost
pressure (e.g., starting or load change). The respective limit curves can be programmed accordingly.
9) Engine Stop
When the switch input for engine stop is activated the power supply to the actuator is automatically cut, so
that the internal spring can extract the actuating bar after the engine has stopped.
10) Overspeed Protection

An overspeed limit can be set. If this limit is surpassed, the control device transmits an alarm message and
the power to the actuator is cut.
11) Oil Pressure Monitoring

For the purpose of oil pressure monitoring, speed/pressure dependent limit curves can be provided. If oil
pressure is too low, an alarm is given; if oil pressure continues to drop, the engine is shut down.
12) Correction of PID-Parameters

To optimize dynamic behavior for every point of operation the PID parameters can be corrected depending
on speed or load with the aid of freely programmable stability maps.
13) Automatic Synchronizing and Load Sharing

For automatic synchronizing and load sharing, the single-phased synchronizing and real load sharing device
AT 10 can be connected to an analogue input.
14) Running Hour Meter

Records the sum total of hours the engine is running (speed is recognized).
15) Failure Diagnosis and Display

If a sensor error or an actuator error happens, an alarm message is transmitted; if necessary, the engine is put
in emergency operation mode or stopped. Internal errors are recognized too and memorized and counted
like all other errors. On each occurrence of error, in addition selectable data related to the circumstances of
the error may be re- corded.
All errors can be read out with an external handheld programmer or with a PC/laptop, if the communication
program and cable are available
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16) Communication
The unit may be connected to all HEINZMANN handheld programming devices or to a PC/laptop with
installed communications software DcDesk 2000 using a 9-pin Sub-D connector.
For connection use only the cable provided by HEINZMANN. On one end, this cable contains an
electronic circuit developed especially for HEINZMANN control devices.
If other cables are used for communication, the connected components (control device, PC, laptop) may
suffer damage.
Set-point Adjuster
For the control devices of the ORION series different speed set-point adjusters are available, depending on
the application.
1) Link for Constant Speed Governor with Generator Application

In the standard version the control devices of the KG-LC-D are delivered as xed speed controllers for
generator applications in isolated operation and in this type of application no additional transducer is
needed, with exception of a bridge between terminals 12 (+4V) and set-point 13 (SP).
2) Set-point Potentiometer SW 01 - 1 - o (1- turn)

Displacement angle approx. 312°
Resistance 5 kOhm
Temperature range -55°C up to +120°C
Protection grade IP 00
3) Set-point Potentiometer SW 02 - 10 - o (10- turn)

Displacement angel 10 turns
Resistance 5 kOhm
Temperature range -55°C up to +105°C
Protection grade IP 00
On request, the potentiometers, as speci ed under 7.2 and 7.3 can be supplied with analogue adjustment
knob with lock in place of the standard rotating knob. In this case, ordering speci cation is SW..-..-m.
Equally, instead of the knob a clamping xture can be installed. Ordering speci cation must be changed to
SW .
4) Speed Adjustment by Voltage Signal

Instead of a set-point potentiometer a voltage signal can be connected directly. The analogue control device
KG-LC-D works with an input signal range of ca. 2.5 V. The digital control device DC 9 uses an input signal
range of max. ca. 0.5 V.
5) Speed Adjustment by Current Signal

Instead of a set-point potentiometer, a voltage signal can be connected directly to the DC-9. This is set by
parameters. A maximum input signal range of ca 3.22 mA is allowed.
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In order to directly connect a .20 mA signal to the analogue control device KG-LC-D, an additional ampere
measuring resistance of 200 Ohm must be connected to terminals 13 "SP" and 14 "GND". Maximum speed at
20 mA is adjusted with the potentiometer "SPEED", the required minimum speed must be determined with
the control signal.
6) Pneumatic Set-point Adjuster

For pneumatic set-point adjustment the set-point adjuster SW 05-P can be used with a pressure range from 1
to 6 bars. For more informations refer to the manual E 81 002 - e.
7) Set-point Adjustment by Foot Pedal

The non- contact signal transducer unit EFP is basically an angular position transducer that translates a foot
pedal into a proportional current or voltage for 0 - 45° rotation. The resulting output can be used for
speed setting. For more information refer to the manual E 83 005 - e
Control Unit DC 9
a) Speci cations
Operating voltage 12/24 V DC
Maximum voltage 32 V DC
Minimum voltage (shortly at start-up) 9 V DC
Maximum ripple voltage at maximum actuator current max. 10 % at 100 Hz
Acceptable voltage drop at maximum actuator current max. 10% in control unit
Fuse protection of governor 12 A
Overall current consumption maximum 5A
in steady state condition 1.7 A
Storage temperature -40°C up to +85°C
Ambient temperature in operation -40°C up to +80°C
Humidity up to 98% at 55°C, with thawing
Frequency range 0 up to 9000 Hz
Steady state variation ±0,25 %
Droop parametrizable
max. 2 mm at 10 up to 20 Hz,
Vibration resistance max. 0.24 mm at 21 up to 63 Hz,
max. 7 g at 64 up to 2000 Hz,
Shock 30 g, 11 ms- half-sine
Protection IP 00
Dielectric resistance > 1 MOhm at 48 V DC
Weight approx. 0.5 kg
EMC 89/33/EEC
CE EN 61000-6-2, EN 61000-6-4
b) All inputs and outputs are protected against cross-connection and short-circuit against battery positive
and negative
Inputs and Outputs

Speed input for inductive sensor with = 25 up to 9000 Hz, Ui = 0.5 up to 30 V AC
Actuator travel reading internal in actuator with reference feedback
Actuator magnet output Imax = 6.4 A, Icont. = 3.5 A
Digital output error lamp Isink < 0.3 A, Urest < 1,0 V, low-side switching
Input terminal 7
0.5 V or 4.20 mA
analogue
U0 < 1 V, U1 > 6 V, Rpd = 100 kΩ
or digital
Analogue input terminal 4 0.5 V
Digital input terminal 9 U0 < 1 V, U1 > 6 V, Rpd = 100 kΩ
Digital input terminal 11 U0 < 1 V, U1 > 6 V, Rpd = 100 kΩ
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c) Mounting of Control Units

For installation, any place can be chosen where there is the least possible amount of vibration and the lowest
possible ambient temperature. There should be no strong magnetic elds in the vicinity of the control unit to
avoid disturbances.
In addition, the place chosen for mounting should be easily accessible for reading and adjusting
parameters as well as for the substitution of the unit under eld conditions.
Since the max. admissible cable length between the control devices and the actuators is 6 m, the control
devices must be installed in immediate proximity of the engine.
Electrical Details
1) Connection of Power Supply
Inappropriate choice of power supply or insuf cient battery capacitance or incorrect connection of the
power supply line or too small cable sizes of the feed line and the motor line of the actuator are bound have
an adverse effect upon the performance of the speed governor. In steady state operation, this will cause a
heavy increase of current consumption and unnecessary vibration of the actuator drive. The high current
consumption will in its turn lead to overheating of the actuator or the ampli er in the control unit, and the
vibration will result in premature wear of the gear and bearing parts or of the linkage.
NOTE: As a rule, the lifetime of the control system is distinctly reduced by the errors described above.
In order to avoid that the voltage supply is not interfered by the „hum voltage“ of the battery charger – and
as a consequence the voltage at the control unit will not suddenly drop too much when starting – the control
unit must be connected directly over a fuse and a switch with the battery.
In case the control unit is directly connected with the battery charger or the starter there might happen a
failure of the control unit or actuator after a certain time. The necessary repair of the units resulting thereof
is not covered by warranty.
If there are battery chargers with rapid charge mode installed in the plant, the rapid charge mode should
no be used during operation.
If there is no battery provided, it is absolutely necessary that a three phase power supply or a stabilized one
phase power supply with at least 24 VDC, 10 Amps output power be used as a power source.
Cable sizes and maximal cable lengths indicated in the following chapter must be respected at all costs!
2) The following gure shows both a wrong and a correct cabling:
(1) Coils (e.g. stopping solenoid, gas valve) have to be equipped with a protective circuit to eliminate inductance voltages. Diode type
e.g. 1N4002
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When power supply, battery and cabling have been correctly dimensioned, then on starting the engine or
with the actuator operating at maximum current consumption (approx. 6.4 Amps), a drop of the supply
voltage directly at the control unit of approx. 2 Volts maximum only will be admissible.
3) Correct Connection of Shielding

Trouble-free operation of the electronic governor of the series requires a shielding for low level signal
connection lines.
The shielding concept of KG-LC-A is different from DC 9.
4) Connection of Shielding at KG-LC-D

In this case the shielding has to be connected on one side only, that means only to the control unit KG-LC-D,
the other side has not to be connected and has not to be any connection to ground or an other potential.
The separated insulated terminals on the control device are internally all directly connected to negative
potential.
If a line with shielding is wired via a terminal strip, the shielding has to be connected to a separate isolated
terminal strip without any connect to a negative line or ground. Never use PE-terminals!
Correct shielding connection

The following arrangements are frequently encountered, but they may
cause governor disturbances.
Wrong! Shielding is discontinued
Battery
Wrong! Right and left side of shielding connected to different negative

terminals
Battery
Wrong! Shielding is additionally connected to minus on the terminal strip
Recapitulating: The shielding has to be connected to the control unit on one side only. That means it may
have no contact anywhere else to negative potential or ground. Failure to observe this rule causes
unnecessary high currents in the actuator and considerably reduces its useful life!
5) Checking of Shielding at KG-LC-D

- Remove the cable contacts of shielding at the control unit and check against ground. No connection has to
be indicated.
- With connected shielding to the control unit connect the other side of the shielding to the negative line via
a test instrument. The test instrument must indicate a connection
Ready mounted HEINZMANN cables are checked in the factory
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6) Connection of Shielding at DC 9 according to EMC-Guideline

To avoid electromagnetic in uences here it is necessary to connect cable shields at both ends directly to the
housing and not to minus potential unlike described with KG-LC-D. This includes shielding from control
housing to sensors, from control housing to potentiometers, from control housing to actuator and from
control housing to accessory units. If there is a potential difference between the controller housing and any
of these other components, to avoid currents via the shielding it is necessary to run a separate wire from the
controller housing to each of these components.
At cable ends without plugs (e.g. terminal strip or pins) the shielding must be connected at the housing near
the contacts.
With the plug the strain relief presses directly on the cable screen. In addition, a separate wire connects the
strain relief section to the plug housing.
7) Checking of Shielding at DC 9
Remove the cable connect of shielding at the control unit and check against ground. Connection has to be
indicated.
NOTE: Ready mounted HEINZMANN cables are checked in the factory
8) Wiring between Control Unit and Actuator

Basically two separate cables are required for the engine lines (M+ and M-) and the disturbance-sensitive
feedback signal.
For the engine lines a 2 x 1,5 mm2 cable and for the feedback signal a shielded 3 x 0,75 mm2 cable should
be used.
Maximum cable length between actuator and electronic control unit may not exceed 6m due to the
special feedback system! Accordingly the electronic control unit has to be mounted in immediate vicinity
of the engine.
NOTE: As actuator cable, it is recommended to use the HEINZMANN cable with a ready mounted
connector to the actuator. This cable is called L2
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9) Wiring between Control Unit and Magnetic Pickup

For the wiring to the speed pickup a shielded 2 x 0,75 mm2 cable must be used. Maximum cable length is 30
meters.
It is recommended to use the ready made HEINZMANN speed pickup cable on which the connector to the
magnetic pickup is already mounted. This cable is called L4.
10) Wiring between Control Unit and Power Supply

Cross-section of the cable between control device and battery should be 2x2.5 mm up to a length of 10
meter; and 2x4.0 mm for lengths between 10 meters and the maximum of 20 meters. When a stabilized
power supply unit is used, cable length between supply unit and control device should not exceed 3 meters.
11) Further Wiring

Cross-section of the cable between control device and battery should be 2x2.5 mm up to a length of 10
meter; and 2x4.0 mm for lengths between 10 meters and the maximum of 20 meters. When a stabilized
power supply unit is used, cable length between supply unit and control device should not exceed 3 meters.
12) Connect Diagram of DC 9
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Parametrization of Governor DC 9
The software for the HEINZMANN digital controller DC 9 is conceived so that parametrizing can be done
either by the engine manufacturer or by the nal customer if the necessary instruments (communications
tool) are available. Only a few basic parameters are pre-set in the HEINZMANN factory. This means that the
digital governor usually gets its de nitive set of data from a source external to HEINZMANN.
An exception is made for control units delivered in greater numbers. If HEINZMANN has been provided in
advance with a de nitive set of data, this data can be transferred to the units in the factory.
As a principle, initial programming should always be conducted by experienced personnel and must be
checked before rst commissioning the engine.
How parameter are adjusted and what meaning they have is explained in detail in the manual "Basic
information DC 9".
The following sections describe the possibilities of parametrizing the control unit.
1) Parametrization with the Hand Held Programmer 3
All parametrization can be done by means of the hand held programmer ‘Programmer 3’. This handy device
is particularly suited for development and series calibration as well as for servicing. This unit needs no
external power supply.
2) Parametrization with the PC / Laptop
Parametrization can also be conducted using a PC and the comfortable HEINZMANN communication
software DcDesk 2000. As compared with the hand held programmer, it offers the great advantage of having
various curves graphically represented on the screen and being at the same time able to introduce changes
as well as of having time diagrams displayed without an oscilloscope when commissioning the control unit
on the engine. Furthermore, the PC offers a better overview as the PC program has a menu structure and
allows to have several parameters continuously displayed.
Besides, the PC program permits to save and download the operational data to and from data mediums.
Additional there is the following useful application:
Once parameterization has been completed for a speci c engine type and its application, the data set can be
stored to disk. For future applications of similar type, the data sets can be downloaded and re-used with the
new control unit.
Troubleshooting
Symptoms Possible Causes
1. Engine stop switch activated
2. Power supply not activated
a) Measure voltage at the corresponding terminals
b) At KG-LC-D: Control lamp must be lit when power supply is on and must go out from
starting frequency upwards
Governor does not open on starting 2. No signal from magnetic pickup
a) Resistance of pickup 52 Ohm
b) Starting speed voltage minimum 0.5 V (Multimeter)
3. At KG-LC-D: no link or set-point source connected
a) Control unit defective
b) Actuator defective
1. Wrong mounting of actuator (turn direction)
Governor moves to maximum fuel
2. Wiring of actuator wrong
when power supply is switched on
3. Control unit defective
1. Speed setting too high
2. At DC 9: Idle speed is speed setpoint plus droop offset
Engine overspeeds on starting
3. Actuator has only power in direction 100 %, replace control unit and measure actuator
resistance
1. Cable of magnetic pickup or setpoint receive disturbance
2. Linkage between actuator and fuel system has backlash or to much friction
Governor is not working stably 3. Voltage is unstabil, check residual ripple of max. 10 %
4. In case of carburetor and gas engines, check ignition and spark plugs.
5. At diesel engines check injection system. Governor adjusted incorrectly.
1. Droop is activated. At KG-LC-D check position of droop potentiometer. at counter-
clockwise stop is droop zero. At DC 9 check parameters of droop
Reduced speed with load
2. Engine is overloaded, actuator is at maximum position
3. Control unit defective
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NOTE: The digital governor DC 9 offers the additional possibility to export error texts via a
communications tool. The appropriate reaction to the respective error is described in the Section
"Troubleshooting" of manual "Basic information DC 9.
Order Speci cation

The Basic System ORION consists of the following components:
Control unit KG-LC-D or DC 9
Actuator StG 3005 or LStG 25
Magnetic pickup IA.
Harness:
Basically, it is recommended to use a harness prepared by HEINZMANN. To this purpose the cable lengths
required for each connection must be indicated.
The cabling to the actuator and to the speed pickup should always be prepared by HEINZMANN since these
connections use HEINZMANN connectors and the cables are soldered to their terminals. For ordering, please
indicate the respective cable lengths for cable L2 (to actuator) and L4 (to pickup).
Further Options
Setpoint potentiometer for all-speed governors
Setpoint potentiometer SW 01 - 1 - 0 (5k) (1-turn)
Setpoint potentiometer SW 02 - 10 - 0 (5k) (10-turn)
NOTE: The control devices are delivered as tting to the actuator. All other required adjustments must be
made by the customer during commissioning.
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3. USE OF DIESEL ENGINE
3.1 Diesel Fuel

In order to ensure the diesel engine can reach good performance, meet the national emission standards and
lengthen the life of the engine, only low-sulfur fuel oil that satis es national Ⅲ emission standard can use.
Item Unit Limit

Cetane number ≥51
Density（15℃） kg/m³ 820~845
Sulphur content mg/kg ≤50
Ole n %（m/m） ≤11
Dust %（m/m） ≤0.01
Minimun ash point ℃ ≥55
Water & precipitate mg/kg ≤200
Granule mg/kg ≤24
Oxidation stability g/m³ ≤25
Viscosity（40℃） mm³/s 2.0~4.5
95%Distillation Temperature ℃ ≤360
• Select diesel fuel grade according to the environment. Select light fuel with high condensation point in hot
climate areas and select heavy fuel with low condensation point in cold climate areas. The condensation
point of fuel must be at least 10 ℃ lower than the lowest using temperature to ensure fuel liquidity.
• The fuel running viscosity must be over 1.3 mm²/s when the engine is running to ensure the fuel system is
fully lubricated
3.2 Diesel Oil

• In China, diesel engine oil speci cations are expressed as a combination of SAE (Society of Automotive
Engineers) viscosity grade and API ( United States Petroleum Institute) quality grade, rst half of which
represents viscosity grade, latter part of which represents viscosity level. E.g. viscosity grade is 15W/40,
quality grade is CF-4, so diesel engine speci cation should be represented as 15W/40 CF-4.
• Only engine oil grade≥CF are applicable to the D series diesel engine, viscosity grade should be chosen
according to ambient temperature.
- Check oil level with the oil level gauge and replenish if necessary after the engine cooled.
- If the engine is warm, allow 5~10 minutes for oil drain into the crankcase before checking oil level. The oil
level must be between Max and Min. lines on the gauge.
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- Lubrication Oil Capacity.

Engine Series Lubrication Oil Capacity in Oil Pan（L）
Max. Min.
D11 19 15.5
D15 21 17
D22 40 33
- Oil replacement period:

- The rst oil replacement period is 50 operating hours, then oil should be replaced at the speci ed intervals
(200 hr), with oil lter changed together.
3.3 Coolant
• Only soft water rather than hard water can be used as coolant for diesel engines.
• Coolant can be mixed with 40% of anti-freezing solution and 3~5% of the additive for rust prevention (DCA4).
• The density of above mentioned solution must be checked every 500 hours to keep it in proper range.
• Quantity of anti-freeze in winter
Ambient Temperature （℃） Coolant （%） Anti-freeze （%）
Above -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
How to use coolant to test kit

1) When the coolant temp of engine is within 10~50℃, loosen the plug for coolant discharge and ll the
plastic cup about a half.
2) Soak a slice of test paper in the water samples, stir the water, take out the test paper after 3~5 seconds,
and then shake off the water drops.
3) Wait for about 45 seconds till the color change of test paper.
4) Figure out the numerical value by comparing the test paper whose hue has changed with the color list of
label on storage bottle.
5) Compare the yellowish green or so test paper with the green color indication of test paper storage bottle,
con rm the density. (Then, the density indication must be in the hue range of 33% to 50%).
6) The brown at the middle of test paper and the lower pink color represent the additive state for rust
prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color
(horizontal) within the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle.
7) In case of less than 0.3, replenish rust prevention (DCA4), and in case of more than 0.8, pour out the
coolant about 50% and then readjust the density after re lling with clean fresh water.
8) Change coolant every 6 months, or else produced lime and corrosion deposition will affect the engine
cooling system
3.4 Engine Adjustment

3.4.1 Valve Clearance Adjustment
• Adjust valve clearance when cylinder head is removed on overhaul or nd abnormal noise between valve
and valve seat or the engine is on abnormal running while the fuel system is trouble-free.
• Let #1 cylinder piston be at top dead center by turning the crankshaft, and then adjust the valve clearance.
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• Loosen the lock nuts of rocker arm and adjust screws, push the feeler gauge between a rocker arm and a
valve stem and adjust the clearance with adjusting screw and then lock the screw nut.
• As for the valve clearance, adjust it when cold, standard as follows:
Model Intake Valve Clearance (mm) Exhaust Valve Clearance (mm)
D11 / D15 / D22 0.3 0.4
• Method for Valve Clearance Adjustment:

D11 Series
Cylinder Firing Order (valve closed) 4 2 5 3 6
Cylinder Corresponding with Valve Adjustment 3 6 1 4 2
D15 Series
Cylinder Firing Order (valve closed) 1 5 7 2 6 3 4 8
Cylinder Corresponding with Valve Adjustment 6 3 4 8 1 5 7 2
D22 Series
Cylinder Firing Order (valve closed) 1 12 5 8 3 10 6 7 2 11 4 9
Cylinder Corresponding with Valve Adjustment 6 7 2 11 4 9 1 12 5 8 3 10
3.4.2 Belt Adjustment

• Use a belt of speci ed dimensions, and replace if damaged, worn, or deteriorated.
• Check the belt tension of fan belt and alternator belt. If belt tension is lower than the speci ed limit, adjust the
belt tension by relocating the alternator and idle pulley. (speci ed de ection: 10~15 mm when pressed down
with thumb
3.5 Engine Startup
• Fill oil and water within limit in case of engine damage.
• At room temperature, check the fuel and oil quantity, by starting the motor to drive the diesel engine rotation;
start when the engine is idling without load and immediately turn off the starting motor switch after diesel
engine began to re; starting motor rotation should not exceed 10s, next operation should be after more than
1min; for a smooth start, can manual pump the oil pump, can respectively loosen the fuel lter cover fuel joint
bolt, remove the the air in fuel, and at the same time, check if the oil line is smooth.
• After ignition, run idling for more than 5 min.
3.6 Engine Breaking-in

• For new or overhauled engine, breaking-in for 50 hours is recommended.
• Break-in Precautions:
• Engine should run at fast idling until the temperature of the engine reaches normal operating condition.
• Overload or continuous high speed operation should be avoided.
• High speed operation with no load should be prevented.
• Abrupt start and stop should be avoided.
• Engine speed must be under 70% of its maximum speed.
During the break-in period, check the engine oil level timely. Oil pressure will rise as speed rises or oil
temperature decreases.
Check the water temperature gauge, make sure it’s normal.
Change oil ler and oil after break-in
3.7 Operation
• Do not full-load or overspeed engine, while engine is not preheated suf ciently.
• Do not disconnect the battery or electrode terminals or the cables.
• During operation, if battery indicator suddenly shining, stop the engine immediately and troubleshooting the
electrical system.
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• Please stop and check the engine immediately if there is unusual color , sound or smell in exhaust.
• Running Detection:
- Engine oil pressure: Iding （90～300）kPa[(0.9～3.0)kg/cm2]
• full load (300～650）kPa[(3.0～6.5) kg/cm2]]
- Coolant temperature: The coolant temperature should be approx. 80 to 95℃ under normal working
environment.
3.8 Winter Operation
• Pay special attention to coolant freeze and oil viscosity when run in winter.
• Anti-freeze is recommended to use. When do not use antifreeze, evacuate coolant after operation.
• Overcooling could result in decreased thermal ef ciency and increase fuel consumption.If the coolant
temperature can’t reach the normal condition (80~95°C) after continuous running, please check the
thermostat and other cooling lines
3.9 Inspection after Continuous Operation

To make sure engine is always working under good condition, it should be examined and adjusted thoroughly
every year (spring is preferred). Components affecting performance should be examined:
- Intake & exhaust components: gas lter, intercooler and turbocharger, etc
- Lubrication and cooling parts: oil cooler Ass’y, oil lter and anti-freeze, etc
- Gas distribution and fuel components: valve clearance and fuel lter, etc
3.10 Diesel Engine Shutdown
After engine running at full capacity, speed controller should switch to idle, then running about 5 minutes, so
that engine can cool down gradually and evenly, shut down the engine when coolant temperature decreases
to 60°C
3.11 Engine Operation and Turbocharger Periodic Inspection

3.11.1 Engine Operation
To protect the turbocharger when engine start, run and stop, following items must be aware of:
State Of Operation Precautions Causes
Startup Inspect oil quantity If engine start up quickly, the rotating parts haven’t been
Only when oil pressure rises by starter startup (until the lubricated, then bearing will wear abnormally or stuck.
pointer of oil pressure gauge moves or pressure
indicating lamp turns on) can start up engine. In case that engine stalled for long time and in cold weather,
In case that oil , oil lter and lubrication system parts the uidity of oil may be get very bad.
need to be replaced or engine has been stalled for long
time (more than a week), and in case of operation under
cold weather, loosen the inlet oil pipe connecting part of
turbocharger, and start motor until oil comes out of the
connecting parts. After the mentionedabove has been
con rmed, retighten the pipe connecting parts and
proceed with the normal startup.
After Perform idling operation for about 5 min. immediately Sudden load at time soon after engine starting and at the
Startup after engine startup. state when
turbocharger did not yet reach to smooth revolution, if
Various inspections must be performed to ensure that abrupt load is applied to engine, some parts where oil did
there are no leakage of oil, gas and air. still not reach may cause a burn and get stuck.
If there are the leakage of oil, gas, air, particularly oil, for low
oil pressure would cause a burn of bearing to get stuck.
During Following items must be con rmed. If the pressure is too low, abnormal wear or stuck may be
Operation Oil pressure caused. Or if too high, oil leakage may be generated.
at idling: 90～300kPa (0.9～3.0 bar)
at full load: 300～650kPa (3.0～6.5 bar) If engine runs with coutinusous abnormal noises and
2) When abnormal noises and vibration accurr, slow vibration, will cause troubles that can not be repaired or
down the speed and stop to nd out the causes. some other troubles.
Stop When stop the engine, perform the idling operation for After heavy load operation, if engine stops suddenly, heat
5 min. and then stop. would be transferred to bearing parts from turbine blades
that would result in oil burning, and further more bearing
and revolving shaft stuck.
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3.11.2 Turbocharger Periodic Inspection

Rotor axial clearance shall be examined per below illustration:
Wear limit: 0.20 mm
• Rotor radial clearance shall be examined by below illustration:

• Wear limit: 0.65 mm
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4.1 Disassembly of Major Components

• Disassemble major components as per following procedures.
• Get ready for the tools for disassembly and shelves for components storage.
• Keep hands and environment clean during disassembly.
4.1.1 Engine oil

• Take out the oil level gauge, remove oil drain plug from oil pan, discharge engine oil into speci ed container
4.1.2 Cooling water

• Disassemble drain plug and hoses from oil cooler and discharge cooling water into speci ed container
4.1.3 Cooling fan

• Disassemble fan xing bolts, and remove the fans
4.1.4 V-belt
• Loosen the V-belt tension and adjust bolt, then remove the V-belt
4.1.5 Alternator
• Disassemble the supporting guide plate for and bolt.
• Remove the alternator.
4.1.6 Vibration damper

• Disassemble the pulley bolt in the reverse
• Direction, remove pulley and vibration damper
4.1.7 Oil lter

• Disassemble the oil lter with special tools.
• Remove the lter, the disassembled one can’t be used again
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4.1.8 Water pump

• Loosen the various hose clamps that connect water pump.
• Disassemble outlet pipe, and remove thermostat.
• Disassemble cooling water pump xing bolts
and remove the cooling water pump
4.1.9 Starter
• Disassemble xing bolts from starter, and remove starter
4.1.10 Fuel lter

• Loosen the intake and outlet fuel hoses.
• Disassemble the xing bolts from fuel lter and remove the lter
4.1.11 Injection pipe

• Loosen the coupling nut between injection pump
and nozzle holder and remove injection pump
4.1.12 Oil cooler

• Disassemble the drain plug from oiler cooler cap and discharge cooling water.
• Disassemble the xing bolts from oil cooler and remove the oil cooler.
4.1.13 Turbo charger

• Loosen the hose clamp that connects the intake hose
and remove air intake hose.
• Loosen the bolts for turbocharger lubrication pipes, and remove oil pipe.
• discharge, and tear the pipes down.
• Loosen the turbocharger xing bolts and remove the turbocharger
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4.1.14 Intercooler
• Disassemble the various hoses from inter cooler.
• Disassemble the intercooler xing bolts and remove intercooler.
4.1.15 Exhaust manifold

• Disassemble the exhaust manifold xing
bolts and remove the manifold from cylinder head.
4.1.16 Intake manifold

• Disassemble the manifold xing bolts and
remove the manifold from the cylinder head.
4.1.17 Flywheel housing cover

• Disassemble the ywheel house cover xing bolts.
• Remove ywheel house cover
4.1.18 Fuel injection pump

• Disassemble the fuel hoses and lubrication hoses.
• Disassemble the xing bolts for injection pump and
take off the injection pump
4.1.19 Cylinder head cover

• Disassemble the xing bolts of cylinder head
cover and remove cylinder head cover
4.1.20 Nozzle holder

• Loosen the nozzle holder with special tool.
and remove the nozzle holder
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4.1.21 Rocker arm

• Disassemble the rocker arm bracket xing bolts and remove the rocker arm.
• Remove the push rod
4.1.22 Cylinder head

• Loosen the cylinder head xing bolts and remove the cylinder head.
• Remove the cylinder head gasket and scrap it.
• Clean the cylinder head surface and body binding surface
Be careful not to damage the contact surface between gasket and cylinder head
4.1.23 Valve
• Use special tool to press the valve spring and remove the locking clip.
Remove the intake and exhaust valves
4.1.24 Valve guide

• Remove the valve guide from the combustion room side of cylinder
head by means of a special tool
4.1.25 Valve seat

• Pull out the valve seats can by a special tool or by welding two
welding slips on valve seat.
4.1.26 Oil pan

• Remove the oil pan xing bolts and separate the pan.
• Remove the oil pan gasket and scrap it.
4.1.27 Oil pump

• Disassemble the oil suction pipe xing bolts and remove the oil suction pipe.
• Disassemble the oil pump xing bolts and remove the oil pump
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4.1.28 Piston
• Remove the connecting rod cap bolts in the reverse order of assembling.
• Tap the upper and lower parts of connecting rod caps
• with an rubber hammer and remove the connecting rod cap.
• Push the piston assembly with a wooden stick toward the cylinder head’s
• direction and remove the piston connecting.
• Remove the piston ring with cir-clip.

• Clean the piston.
• Pull out the piston pin cir-clip with a cir-clip plier.

• Push the piston pin, remove the connecting
rod and assemble with connecting road cap
Be careful for the removed pistons not to collide each other

or with the other parts. At the storage of pistons, maintain them
in the order of cylinders. (In order for connecting rod caps not to
mix one another, temporarily assemble them to the corresponding
connecting rods.)
4.1.29 Front oil seal holder

• Remove the oil seal holder xing bolts and tear down.
• Remove the oil seal and gasket from the oil seal holder and scrap them
4.1.30 Flywheel
• Remove the ywheel xing bolts in the order of disassembling
and remove the ywheel
• Remove the ywheel ring gear.

- Heat the ring gear evenly with a gas burner (up to 200 ℃) to invite
• volumetric expansion.
- Tapping around the edges of the ring gear with a brass stick to remove it,
4.1.31 Flywheel housing

• Remove the ywheel housing xing bolts and remove the ywheel housing.
• Remove the crankshaft rear oil seal from the ywheel housing
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4.1.32 Crankshaft
• Remove the main bearing cap xing bolts in the order of disassembling.
• Assemble the bolts at the both sides of crankshaft,
and lift the shaft with a rope,
Place the main bearing caps and main bearing in turn.
4.1.33 Camshaft and tappet

• Pull out the tappet from the cylinder block.
• Remove the camshaft carefully not to damage the camshaft and its bearings.
4.1.34 Piston cooling nozzle

• Remove the piston cooling nozzle xing
bolts and tear down the Piston cooling nozzle.
4.1.35 Cylinder liner

• By means of a special tool (Extractor),
pull out the liner from the cylinder block.
4.2 Inspection of major Components

4.2.1 Cylinder block
• Clean the cylinder block thoroughly and check if there is any crack or damage on the block.
• Replace if cracked or severely damaged and correct if slightly damaged.
• Check the oil and water ducts for restriction or corrosion.
• Inspect if the cylinder block’s camshaft liner damaged, if damaged severely or abnormally, replace it.
• Make a seal test to cylinder block: block each outlet port of water and oil passages in the cylinder block,
apply air pressure of about 5 kg/cm2 against the inlet ports, then immerse the cylinder block in water for
about 1 minute to check any leaks. (Water temperature:70 ℃)

• Assemble the cylinder liner on the cylinder block and measure inner
diameter at upper, middle, lower parts with a pitch of 45° and calculate the
average value without maximum and minimum values.
• If the average or limit values are very close
to the limit value or beyond, replace it.
Standard（mm） Limit（mm）
Liner inner
Φ127.99 ~
diameter Φ128.16
Φ128.01
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4.2.3 Cylinder head

• For cracks of damages on cylinder head may be inspected by a hydraulic
test or a magnetic powder test.
• Measure the cylinder head atness with an horizontal ruler and feeler
at six positions shown in the gure.
• If the measured value exceeds the standard value, retrace the head
with grinding paper.
• If the measured value exceeds the maximum allowable limit, replace
Standard （mm） Limit（mm）

Flatness
≤0.015 0.03
4.2.4 Valve
• After cleaning the valves with diesel oil, measure the valve stem’s outer
diameter at upper, middle, and lower to determine the wears and
when the wear limit is more than 0.15 mm, replace the valves.
Valve Standard (mm) Limit(mm)
Intake Φ11.96~Φ11.98 Φ11.81
Exhaust Φ11.935~Φ11.955 Φ11.785
• If valve head thickness (H) is beyond the limit, Then replace the valve.
Valve Standard (mm) Limit (mm)

Intake 2.6~3.0 1.6
Exhaust 1.9~2.3 1.3
4.2.5 Valve guide

• Insert the valve into valve guide and measure the clearance between
valve and valve guide. If the clearance is big, measure the valve stem
with a dial gauge or replace the worn valve guide.
• Replace the valve guide and reaming with the same hole of valve hold,
if still bigger or abnormal, then repair or replace.
Valve Standard (mm) Limit (mm)
Intake 0.020~0.058 0.20
Exhaust 0.045~0.083 0.25
4.2.6 Valve seat

• Inspect the damage and wear of valve seat and replace if necessary
• Measure the valve relative subsidence of the cylinder head plane
after assembly, if the measured value is beyond limit, replace the
valve seat.
.<Valve seat subsidence>
Standard Limit
0.65~0.95 mm 2.5 mm
<Valve seat angle>

Intake Valve 30°
Exhaust Valve 45°
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4.2.7 Valve spring

• Inspect the valve spring if rusted or distorted and replace it if necessary.
• By means of spring tester, measure the tension, free length and verticality of
the spring. In case that the measured valve exceeds the limit value, replace it.
Free length（mm） 72
Inner spring When given a regular load（154～170) N（mm） 46.3
When given a regular load（285～315）N（mm） 32.3
Free length（mm） 68.8
Outer spring When given a regular load（360～400）N（mm） 46.8
When given a regular load（602～672）N（mm） 32.8
4.2.8 Rocker arm and rocker arm bracket

Inspect the rocker arm surface that contacts with the valve stem for any
scratch, wear and correct the minor degree of wear with an oil stone or
the ne grinding paper and replace if severe.
Measure the outer diameter of rocker arm bracket with outside
micrometer at the position that the rocker arm is installed,
and in case that it exceeds the limit value, replace.
Standard Limit
Bush Inner dia. Φ25.005 ~ Φ25.035 mm Φ25.055 mm
Roackiam outer dia. Φ24.967 ~ Φ24.990 mm Φ24.837 mm
clearance 0.015 ~ 0.068 mm 0.25 mm
4.2.9 Tappet
• By inspecting the tappet surface that contacts with the camshaft’s cam
for any crack and scratch etc., and if the degree is small, correct
them with an oil stone or the grinding paper but if severe replace them.
• By means of outside micrometer, measure the outer diameter of tappet
and replace the severe ones.
Standard (mm) Limit (mm)

Tappet clearance 0.035~ 0.077 0.25
4.2.10 Push rod

• Roll the push rod on the surface, inspect the curving degree of the push rod,
the limit should be less than 0.3mm, should replace if beyond.
4.2.11 Camshaft
• Put the dial gauge toward the gear side which drive the camshaft, wrench
the gear and measure the camshaft’s axial clearance. If it is beyond the
limit 0.2~0.9 mm, then use thrust plate.
• Inspect the cam surface for any damage with naked eyes and correct any
minor scratches by means of an oil stone grinding and if severe, replace it.
• Use a micrometer to measure the cam lobe height and journal diameter.
• If the measured number is less than the speci ed limit, the camshaft
must replace.
Item Standard （mm） Limit（mm）
Intake 56.3478 55.17
Cam lobe height (C)
Exhaust 56.4058 55.11
Cam journal diameter (A, B) Φ69.921~ Φ69.94
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• Measure the camshaft bush inner diameter with a cylinder gauge and
if exceeds the limit, should replace.
Limit（mm）
front Φ70~Φ70.03
back Ф70.07～Ф70.09
• Clearance between camshaft journal and body

Standard Limit
0.060~0.109 mm 0.17 mm
• Place the micrometer on the two v-blocks and measure the beat,
adjust or replace if severe
Standard 0.05 mm
4.2.12 Camshaft
• Inspect for any scratch or damage with naked eyes, and inspect for any crack
by means of magnetic powder and color check, and replace the cracked ones.
• Measure the diameter of crank journal and crank pin at the direction and
position shown in the gure.
<Crankshaft journal outside diameter>

Standard Φ103.98~Φ104.00mm
<Crankshaft pin outside diameter>

Standard Φ89.98~Φ90.00mm
• In case that the lopsided wear is more than the limit value, grind to
the undersize, and use the undersized bearing.
• There are 4 kinds as above, and the crankshaft also can be used by
regrinding as above
<“R part” standard value>

1.Crank pin ‘R’: 4.0
2.Crank journal ‘R’: 4.0
In case of crankshaft regrinding, the “R part” at the end of bearing must accurately be ground without fail and
should avoid any processed jaw or coarse surface.
1) Place the crankshaft on the V-block.

Place the dial gauge on the surface plate and measure the run out of
crankshaft rotating the crankshaft
Standard Limit
0.04mm 0.4mm
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2) Inspection and measurement.

Assemble the main bearing at the cylinder block and after tightening the
bearing cap at the speci ed torque, measure the inside.
Journal bearing nominal diameter Φ104.056~

Φ104.102 mm
Bearing cap Initial 30 kg·m

Bolt torque + angle 90°
• Inspection and measurement

Assemble the bearing at the bigger end of connecting rod, and after
tightening the bearing cap at the speci ed torque, measure the diameter
diameter
Φ90.04~
Connecting rod bearing journal diameter
Φ90.082 mm
Connecting rod Initial 10 kg.m

Bolt torque + angle 90°
• Crankshaft pin and bearing clearance in case that this clearance value
exceeds the limit value, grind the crankshaft journal and pin and then use
the undersized bearing
Standard(mm) Limit (mm)
Crankshaft pin and bearing clearance 0.056~0.122 0.156
Connecting rod pin and bearing clearance 0.04~0.102 0.134
3) End play.
• Assemble the crankshaft in the cylinder block, Install the dial gauge, and
measure the end play of crankshaft by pushing the crankshaft to axial
direction.
0.190~0.322 0.452
4.2.13 Piston
• With naked eyes, inspect the piston for any wear, crack and scratch and
particularly inspect carefully at the ring grooves for any wear.
• With the outside micrometer, measure the piston’s outside diameter the
measuring position is 68mm from the piston lower end, and the direction of
measurement must be perpendicular to the piston pin direction.
Standard Φ127.726~Φ127.774 mm
• By comparing the measured value of the piston outside diameter with the
cylinder liner inside diameter, the bigger clearance is replaced.
Standard 0.216~0.284 mm
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4.2.14 Piston ring

• Insert the piston ring at the cylinder liner’s upper part perpendicularly.With a
feeler gauge, measure the gap clearance of piston ring.
• If the measured value exceeds the limit value, replace it
<Piston ring gap>

Division Standard(mm) Limit (mm)
1st ring 0.35~0.50
2nd ring 0.40~0.60 1.5
Oil ring 0.40~0.70
• Assemble the piston ring at the piston.

• Measure the each ring’s side clearance and if the measured value exceeds
the limit value, replace rings or piston.
<Piston side clearance>

Division Speci ed value(mm) Limit value (mm)
2nd ring 0.050~0.082
1.5
Oil ring 0.03~ 0.07
4.2.15 Piston pin

• With the outside micrometer, measure the piston pin’s outside diameter and
if the value is same as the use limit value or less, replace it.
Φ49.994 ~ Φ50.000 ≤ Φ49.983
Piston pin and connecting rod bush clearance

• Inspect the clearance between the piston pin and the connecting rod bush,
if it is more than the use limit value, replace either one that is more severe.

0.055~0.071 0.15
4.2.16 Connecting rod

• Measure the distortion of the bigger and smaller end bearing boles after that
do as regard parallel of both holes and if abnormal, replace the connecting
rod.
Standard Limit
0.02 mm 0.2 mm
Amounts of wear
• After assembling the connecting rod in the crankshaft measure the
clearance between connecting rod bigger hole and crank pin diameter
using ller gauge.
• Assemble the connecting rod in the piston and then measure the clearance
of these parts.If it is more than the use limit value, replace the connecting
rod.
Standard （mm）
0.24~0.392
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• Standard length of bolt and use limit:

(from head seat to bolt tip)
Standard(mm) Limit (mm)
67.2～67.5 69
4.2.17 Water temperature inspection

• Inspect the wax case and spring for any damage.
• With putting the water temperature gauge into water and heating the water
at the indirect method, when the water temp reaches to 71 ℃, the valve
begin to open and fully open when it reaches to 83 ℃.
• Measure the valve opening temperature and the valve full opening
temperature and inspect if the valve lift is more than 6.5mm and if abnormal,
replace it.
4.2.18 Injection nozzle

• Remove the nozzle nuts and disassemble the inner parts.
• Inspect the disassembled parts if there is any damage, replace it.
• After assembling the nozzle, set it in the injection pressure measuring
tester.By manipulating the tester handle, inspect the injection pressure and
atomizing state.
<Operating >
pressure （MPa） 27~28
• In case of low or high injection pressure, adjust by adding or reducing the

spring tension adjusting shims. In case that atomizing state is not good, it
should be replaced
4.3 Engine Reassembly

4.3.1 General Preparation and Precautions
• Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they
are free from restrictions.
• Arrange the general and special tools in order for engine assembly operation.
• To wet each sliding part, prepare the clean engine oil.
• Prepare service materials such as sealant, gaskets, etc.
• Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply only the speci ed torque for bolts in the speci ed tightening order and avoid over-tightening.
• Be sure to check that all the engine parts operate smoothly after being reassembled.
• After completing the engine re-assembly operation, check if there is missing parts or shortage of parts.
• Keep your hands clean during the working
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4.3.2 Tightening torque of main and standard bolts

• Tightening torque of main bolts
No. Speci cation Screw Strength Tightening Torque
Cylinder block bearing cap
M18×2.0 12.9T 294N.m+90º；
-main bolt
M12×1.5 10.9T 78.5 N.m；
1 -side bolt
M12×1.5 10.9T 98.1 N.m；
Flywheel housing
M10×1.5 12.9T 73.6 N.m；
-tightening bolt
Counter weight M16×1.5 98.1N.m+90º；
10.9 T
Crank pulley M16×1.5 206 N.m；
2 10.9 T
Vibration damper M10 58.9 N.m；
10.9T 12.9 T
Flywheel M16×1.5 255.1 N.m；
3 Connecting rod cap M16×1.5 10.9 T 98.1N.m+90º
Cylinder head M15×2 12.9 T 78.5 N.m+147.2 N.m+90º+90º；
4
Cylinder head cover M8 8.8 T 21.6 N.m
Rocker arm bracket M10 10.9 T 63.7 N.m；
5
Lock nut (adjusting screw) M12×1 8.8 T 49.1 N.m；
Oil pump M8 8.8 T 21.6 N.m；
6 Oil cooler M12 10.9 T 49.1 N.m；
Oil pan M8 8.8 T 21.6 N.m；
Exhaust manifold M10 10.9 T 49.1 N.m；
7
Intake manifold M8 8.8 T 21.6 N.m；
Starting motor M12×1.5 8.8 T 78.5 N.m；
8
Alternator bracket M14 8.8 T 117.7 N.m；
9 Water temperature switch M14×1.5 - 19.6 N.m；
Fuel injection pump M10 10.9 T 63.8N.m；
Nozzle holder M28 CK60 (68.7±4.9)N.m；
10
Fuel lter M12×1.5 8.8 T 78.5 N.m；
Injector pipe M14×1.5 - 24.5 N.m；
• Tightening torque of main and standard bolts(reference)

Screw Tightening Torque (N.m)
4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

M5 1.9 2.5 2.2 3 4.2 4.9 7.4 8.8
M6 2.9 4.4 3.9 5.4 7.6 8.8 12.3 4.9
M7 4.5 6.9 6.2 8.1 11.8 13.7 19.1 23
M8 7.4 10.8 9.8 13.7 18.6 21.6 30.4 37.2
M8×1 7.8 11.8 10.8 14.7 20.6 23.5 34.3 40.2
M10 13.7 21.6 18.6 26.5 36.3 43.2 60.8 72.6
M10×1 15.7 24.5 20.6 30.4 42.2 49 68.7 82.4
M12 24.5 36.3 32.4 46.1 61.8 73.6 103 122.6
M12×1.5 26.5 39.2 34.3 49 66.7 78.5 109.9 131.5
M14 38.2 58.9 51 73.6 98.1 117.7 166.8 196.2
M14×1.5 42.2 64.7 55.9 81.4 108.9 127.5 181.5 215.8
M16 58.9 88.3 78.5 112.8 175.6 176.6 255 304.1
M16×1.5 63.8 95.1 84.4 122.6 166.8 196.2 274.7 323.7
M18 81.4 122.6 107.9 157 206 245.3 353.2 421.8
M18×1.5 93.2 142.2 122.6 181.5 240.3 274.7 402.2 480.7
M20 117.7 176.6 157 215.8 309 353.1 500.3 588.6
M20×1.5 132.4 201.1 176.6 245.3 343.4 402.2 569 667
M22 157 240.3 206 294.3 412 480.7 657.3 735.8
M22×1.5 181.5 274.7 235.4 333.5 461.1 549.4 735.8 833.9
M24 210.9 323.7 264.9 392.4 539.6 618 804.4 902.5
M24×1.5 245.3 363 304.1 441.5 598.4 725.9 912.3 1010.4
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• Tightening torque of standard plug screw (reference)

Screw M10 M12 M14 M16 M18 M22 M24 M26 M30
Torque(N.m) 49.1 49.1 78.5 78.5 98.1 98.1 117.7 117.7 147.2
• Tightening torque of hollow bolts (reference)

Screw M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
Torque (N.m) 7.8 17.7 29.4 39.2 54 63.7 107.9 157 196.2 343.4
4.3.3 Cylinder block

• Cover the oor of the workshop with wood plate or thick paper to prevent
damage to the cylinder head and place the head face of the cylinder block
towards downward.

• Replace the used O-rings with new ones and insert the O-rings in the cylinder
liner upper side, but the other one in the cylinder block lower side separately.
• Coat the joint parts where O-ring contacts with oil.
• After slipping the cylinder liner smoothly into the cylinder block, press it in
being careful for O-ring not to damage.
• After completion of assembling the cylinder liner, con rm no leaks with
0.4MPa hydraulic test.
4.3.5 Oil spray nozzle

• Assemble the oil spray nozzle.
• Tighten the xing bolts.
Torque 11.8N.m
4.3.6 Tappet
• Coat the tappet wholly with clean oil and push in the tappet hole of the
cylinder block
4.3.7 Crankshaft
• Put the wear ring to the heater to heat it up to 150~200 ℃ level, push it
over the crankshaft by a jig.
• Assemble the main bearing to the cylinder block and coat it with engine
oil.
• Then assemble the bearing that has a hole to the cylinder block side and
one that has no hole to the bearing cap and be careful not to change.
• Assemble temporarily one bolt each at both bolt’ holes and by connecting
the wire to the bolts, lift it with crane or chain block and put down on the
cylinder block carefully.
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• Coat the crankshaft journal and pin parts with clean engine oil, and after
tting the main bearing into the bearing cap and assemble it to the cylinder
block making sure of the number in order not to change the bearing cap.
• Coat the bearing cap bolt and its bolt seat part with engine oil necessarily
and according to the tightening order, tighten them with 30 kg·m and with
rotating angle method (90° +10°) and tightening order is as follows.
<Bearing cap bolt’s Tightening Order>

1.First step: Coat the bolts with engine oil.
2.Second step: Screw down 1~2 threads.
3.Third step: Tighten with about 15 kg·m by wrench.
4.Fourth step: Tighten with about 25 kg·m by torque wrench.
5.Fifth step: Tighten with 30 kg·m by torque wrench.
6.Sixth step: Tighten with nal rotating angle method 90° +10°.
However, according to above tightening order, tighten step by step
• Inspect if the crankshaft’s rotation is smooth.

• Assemble the crankshaft gear on the crankshaft and coat a white paint
mark on “1” part in order to nd easily.
4.3.8 Camshaft
• Coat the cam bush of cylinder block and camshaft with engine oil.
• Assemble the cam bush and camshaft for them not to be damaged.
• Assemble the crankshaft gear and the camshaft gear making sure that the
gear marks on both gears are aligned together as right gure.
4.3.9 Flywheel housing

• Coat the thrust washer xing bolt with an adhesive and tighten it with
speci ed torque
Torque 39N.m
• Coat the oil seal with lubricating oil and assemble it carefully not to be
deviated or damaged by means of special tool.(Mandrel for assembling)
• Temporarily assemble guide pin for installing the ywheel housing to the
cylinder block.
• Attach the gasket on the surface of cylinder block where the ywheel
housing is to be installed. (In order to prevent the gasket slip down, coat
a grease on the cylinder block surface.)
• After tting the ywheel housing holes to the guide pins and engage
temporarily 2~3 threads of xing bolts, and according to the tightening
order (zigzag method) tighten them in the speci ed torque.
Torque 73.5N.m
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4.3.10 Speed sensor

• Loosen the lock nut to hexagonal side of sensor.Rotate (CW) the tacho-
sensor on y wheel housing, until the end of it reach on y wheel ring gear
as gure.
• Rotate (CCW) the tacho-sensor for 270° (gap: about 1.0 mm) and x the
lock nut.
• Tolerance limit is 27°. (gap±0.1mm)
4.3.11 Flywheel
• Installation of ywheel ring gear with a gas burner, heat the ring gear
evenly until heat expansion takes place, then install it using a hammer.
• Do not allow the temperature of the ring gear to exceed 200℃
• By means of mandrel, press in the wear ring at the backward face.
• Install two guide bolts for installing the ywheel to the crankshaft.
• After letting the guide pin insert through the ywheel holes and
engaging the xing bolts by 2~3 threads temporarily, tighten them to
the speci ed torque according to lightening order.(Zigzag order)
Torque 255N.m
4.3.12 Oil cooler

• Attach a gasket on the surface in the oil cooler housing where the oil
cooler is installed.
• Tighten the oil cooler with xing bolts install the oil cooler assembly by
tightening the xing bolts in the zigzag order.
4.3.13 Starting motor

• Install stud bolts at the bolt holes on the ywheel housing for installing the
starter.Insert the starter into the ywheel housing and tighten the xing
bolts
Torque 78.5N.m
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4.3.14 Piston and connecting road assembly

• Line up the piston assembly in the order of cylinder number and t the
bearings to the connecting rods and bearing caps. However, take care not
to swap between the connecting rods and bearing caps. Coat the pistons
and connecting rod bearings suf ciently with clean engine oil.
• By means of a special tool, insert the piston rings and adjust the angles
between the ring gaps at 120° as right gure.
• Push in the piston with hands or wooden bar into cylinder. (Be careful for
piston and rings not to be damaged.)
• Pushing the piston down, rotate the crankshaft about 180° and t the
bearing cap to the connecting rod.
• Coat the tap parts of connecting rod bolts and their seats with engine oil,
and after engaging 2~3 threads of bolts primarily rind then tighten them to
the speci ed torque. (98N.m + 90°+10°)
<Connecting rod bolt Tightening Order>

1) First step: Coat the bolts with engine oil.
2) Second step: Engage 2~3 threads by hands.
3) Third step: Tighten to about 7 kg·m with wrench.
4) Fourth step: By means of torque wrench tighten to 10 kg·m.
5) Fifth step: Finally assemble by means of rotation angle method 90°+10°.
6) However, according to above tightening order, tighten them step by step
• By moving the connecting rod bearing cap by hands, make sure if there is
any play in left and right.
• With same ways as above, assemble in each cylinder rotating the
crankshaft.
4.3.15 Front oil seal holder

• After placing the oil seal in the oil holder hole properly, press it in with a
mandrel. (Be careful for oil seal not be damaged.)
• Attach the gasket at oil seal holder.
• Align the dowel pin with the oil seal holder dowel hole and assemble them
by tapping lightly the dowel pin part with an urethane hammer. When in
assembling, take care not to hurt the oil seal by the crankshaft.
• Tighten the xing bolts in the zigzag method.
Without coating the oil seal with oil or lubricant, assemble it in the dry
state.
4.3.16 Vibration damper

• Assemble the vibration damper on the crankshaft pulley.
• Insert the crankshaft pulley assembly to the crankshaft and tighten the
xing bolts in the method of zigzag to the speci ed torque.
torque 196N.m
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4.3.17 Oil pump

• Attach a gasket and pressure reducing valve on the surface of oil pump.
• Tighten the xing bolts and x the oil pump.
• Attach the gasket at the surface of the oil pump where the oil suction pipe
is to be installed, and install the oil suction pipe by tightening the xing
bolts.
• Assemble the pipe bracket on the cylinder block side with bolts.
4.3.18 Oil pan

• Clean thoroughly the gasket that is projecting at junction parts of front oil
seal holder and ywheel housing of cylinder block’s lower face with a
scraper. In the process of gasket removal, be careful for the gasket pieces
not to fall into the engine inside.
• Attach the gasket to the cylinder block.Install the oil pan and tighten the
xing bolts. Then take care not to squeeze out the gasket.
• Install the guide tube and insert the oil level gauge.
torque 30.4N.m
4.3.19 Cylinder head

• Blow the cylinder head bolt holes with compressed air to remove the
foreign material thoroughly.
• Clean the junction part of cylinder block and head gasket.
• Assemble the gasket tting with the xing pin of the cylinder block.
• Fit the cylinder head assembly on the cylinder block aligning with its dowel
pin.(Take care mot to damage the head gasket.)
• Coat the cylinder head bolts with engine oil and tighten them to the
speci ed torque according to step by step. However, prior to tightening
the bolts, with a long steel rule, the parallel between the cylinder heads
must be adjusted.
<Cylinder head bolts tightening order>

1) First step: Coat the bolts with engine oil.
2) Second step: Tighten temporarily 1~2 threads by hands.
3) Third step: Tighten to about78.4N.m with a wrench.
4) Fourth step: Tighten to 147N.m with a torque wrench.
5) Fifth step: Rotate 90°by rotation angel method.
6) Sixth step: Finally tighten additionally rotating 90°.
Standard length of bolt and use limit:

(from the head seat face to tip)
Bolt No. Standard length Use Limit
3,6 168mm 171mm
2,4,5 144mm 147mm
1 109mm 112mm
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4.3.20 Nozzle
• Install new nozzle seal ring in .
• Install nozzle and put it into cylinder head,
• Tighten the to the speci ed torque.
Torque 68.7 N.m
4.3.21 Rocker arm

• Coat the push rod with engine oil and put it into the push rod hole.
• Install the rocker arm on the cylinder head and tighten the xing bolts to
the speci ed tightening torque.
Torque 61N.m
4.3.22 Checking and adjusting valve clearance

• After removing the head cover loosen the lock nuts of rocker arm adjusting
screws using a spanner and push the ller gauge of speci ed value
between rocker arm and valve stem.
• Tighten the adjusting screw using a driver until the inserted feeler gauge
can be taken a slight resistance between the valve stem and the rocker arm.
Then tighten the lock nut simultaneously on not moving the adjusting
screw.
• After checking the clearance once more if necessary re-adjust it
4.3.23 Cylinder head cover

• Attach the new gasket on the surface of cylinder head where cover is to be
installed.
• Assemble the cylinder head cover by tightening the xing bolts.Insert the
oil ller cap.
4.3.24 Fuel injection pump

• Rotate the crankshaft to TDC(Top Dead Center) of the rst cylinder Rotate
the crankshaft to reverse about 30°(in order to remove a backlash), and
then rotate it to engine rotating direction to set the fuel injection timing
angel.
• Coat the O-ring with grease and insert it at the lower part of fuel injection
pump.(Be careful O-ring not to be removed).
• Prior to install the fuel pump drive gear, t the rubber gasket rst. Tighten
temporarily the fuel injection pump drive gear with aligning the pointer on
drive gear with injection pump pointer.
• Fit the injection pump in the appropriate position with a special tool.
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4.3.25 Flywheel housing cover

• Attach the gasket to the ywheel housing cover.
• Install the ywheel housing cover and tighten the xing bolts by zigzag
method.
4.3.26 Oil lter

• Assemble the new O-ring.
• Install new oil lter.
4.3.27 Water pump

• Attach the gasket of the water pump. (at cylinder block side)
• Assemble the fresh water pump by tightening the xing bolts. (zigzag
method)
• Insert the thermostat, gasket and the thermostat cover and tighten the
xing bolts.
4.3.28 Intake manifold

• Install a new gasket to the cylinder head side.
• Assemble the intake manifold and tighten the xing bolts
4.3.29 Exhaust manifold

• Connect the exhaust manifold which consists of two sets and insert the
seal ring between them..
• Attach a new gasket to the exhaust manifold.
• Attach an exhaust elbow to exhaust manifold, and tighten the nuts.
• Assemble both sides of the exhaust manifold to the cylinder head
4.3.30 Turbo charger

• Attach a gasket to the exhaust elbow and assemble the turbocharger
with xing bolts.
• Attach a gasket on the oil supply pipe and assemble the pipe with the
xing bolts.
• Attack a gasket on the oil discharge pipe and assemble the pipe by
tightening the bolts.
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4.3.31 Fuel injection pipe

• Connect the fuel injection pipes to the fuel injection pump and the
nozzle respectively and then assemble them by tightening nuts.
• Assemble the fuel return pipes and tighten the xing nuts.
4.3.32 Fuel lter

• Assemble the fuel lter to the intake manifold and tighten the bolts
4.3.33 Alternator
• Assemble the alternator bracket to the lower part of cylinder block by
tightening the xing bolts.
• Install the alternator supporting plate.
• Connect the crankshaft and the alternator and water pump pulleys with
V-belts.
• Adjust the alternator support nut until the belt tension can be
10mm~15mm when pressed by a thumb.
4.3.34 Idler pulley

• Install the idler pulley.
• Connect fan pulley, crank and idler pulleys with driving V-belts.
• Tighten bolts and nut. (press 10mm~15mm or so with a thumb)
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5. Diesel Engine Troubleshooting

5.1 Electronic Governor System for D Series Diesel Engine
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Fault Possible Causes Solutions
Startup dif cult 1）Valve poor shut, stem distortion Repair or replace
2）Valve spring damage Replace valve spring
3）Cylinder gasket leak Replace gasket
Adjust or replace
4）Wear of piston, piston ring
Adjust
5）Injection timing error
Remove air
6）Air mixed in injection pump
Idle peration abnormal 1）Injection timing error Adjust
2）Air mixed in injection pump Remove air
Engine output insuf cient 1）Valve clearance error Adjust valve clearance
(1) Continuous output 2）Valve tightness poor Adjust
insuf cient 3）Cylinder head gasket leak Replace cylinder head gasket
Replace piston ring
4）Worn, adhesive or damaged piston ring
Adjust
Adjust injection pump
6）Fuel injection quantity insuf cient
Adjust or replace
7）Nozzle injection pressure improper or Repair or replace
adhesive Repair
8）Fuel pump bad perform Clean or replace air cleaner
9）Fuel pipe system clogged Repair or replace
10）Air suction quantity insuf cient
11）Supercharger bad
1）Compression pressure insuf cient Disassemble engine
(2) Output insuf cient when Adjust
accelerate Adjust injection pump
3）Fuel injection quantity insuf cient
Repair or replace
4）Fuel supply advance angle wrong
Repair, replace
5) Nozzle injection pressure, injection angle
Repair or replace
improper
Clean or replace air lter
6）Fuel pump perform badly
7）Intake air insuf ciently
Diesel Engine overheating 1）Engine oil insuf cient or bad Replenish or replace oil
2）Cooling water insuf cient Replenish or replace
3）Fan belt loosened, worn or damaged Adjust or replace
Repair or replace
4）Cooling water pump perform badly
Replace
5）Thermostat break down
Adjust
6）Valve clearance error
Clean or replace
7）Exhaust system resistance increased
Engine noise 1）With the abrasion of bearing or Replace bearing or crankshaft
Crankshaft crankshaft, clearance increases Grind or replace
2）Unbalanced crankshaft wear Clean oil duct
3）Oil supply insuf cient due to oil duct Grind or replace bearing
obstruction
4）bearing stuck
Con rod and Con rod bearing
Piston, Piston pin & piston ring

Unbalanced con rod bearing wear Replace bearing
Unbalanced crank pin wear Grind crankshaft
Con rod distortion Repair or replace
Oil supply insuf cient due to oil duct Clean oil duct
obstruction
Abrasion of piston or piston pin Replace
Piston stuck Replace piston
Piston ring damaged Replace piston ring
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Fault Possible Causes Solutions
Others Abrasion of crankshaft, thrust bearing Replace thrust bearing

increase of camshaft axial clearance Replace thrust plate
gear gap increase Replace thrust washer
Timing gear backlash excessive Repair or replace
Valve clearance excessive Adjust valve clearance
Abnormal wear of tappet, camshaft Replace tappet or camshaft
Supercharger inner part damaged Repair or replace
Fuel consumption excessive Injection timing error Adiust
Inject fuel excessively Adjust injection pump
Oil Consumption Excessive Clearance between cylinder liner & piston Replace cylinder liner or piston;
Oil level rise increase Replace piston or piston ring
Wear of piston ring, oil ring Replace piston ring
Piston ring damage, stick, wear Modify opening combination
4) Piston ring opening’s disposition improper Replace piston
5) Piston peripheral part damage or abnormaly Replace piston ring
wear Replace oil ring
6)Oil ring’s return hole clogged
7)Oil ring loose
Oil level descend
Oil leakage
Valve stem & guide loose Replace

Valve seal wear Replace valve seal
Cylinder head gasket leak Replace cylinder head gasket
Connection parts loose Replace or repair gasket
Bad parts packing Replace package
Bad oil sealing Replace oil gastket
5.2 Cooling system diagnostics and troubleshooting

Fault Possible causes Solutions
Engine overheating Lack of coolant Replenish coolant

Radiator cap pressure valve spring weakened Replace cap
Fan belt loosened or broken Adjust or replace fan belt
Fan belt fouled by oil Replace fan belt
Thermostat inoperative Replace thermostat
Water pump defective Repair or replace
Stuck in water duct due to scale Clean radiator and water
Injection timing error duct
Stuck in radiator core Correct injection timing
Gas leaking into water jacket due to broken cylinder Clean exterior of radiator
head gasket Replace cylinder head gasket
Engine overcooling Thermostat inoperative Replace thermostat
Ambient temperature too low Install radiator baf e
Lack of coolant Radiator leakage Repair or replace
Radiator hoses loosely connected or damaged Retighten clamps or replace hoses
Radiator cap spring weakened Replace cap
Coolant pump leakage Repair or replace
Radiator hose connect loosely or broken Tighten or replace hoses
Cylinder head gasket leakage Replace cylinder head gasket
Cylinder head or cylinder block cracked Replace cylinder head or block
Cooling system noise Coolant pump bearing defective Replace bearing
Fan t loosely or bent Retighten or replace fan
Fan unbalance Replace fan
Fan belt defective Replace fan belt
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5.3 Lubrication system diagnostics and troubleshooting
Fault Possible causes Solutions
Excessive black smoke Air lter elements clogged Replace or clean

Exhaust pipe clogged Inspect or repair
Intake manifold leak Inspect or repair
Turbocharger too big to work Disassemble / repair or replace
Blades of turbine and compressor are broken or Disassemble / repair or replace
collided Inspect or repair
Exhaust pipe deformed or clogged
Excessive white smoke Fuel leak into turbine and compressor Disassemble / repair or replace
Seal ring’s abnormal wear or damage due to excessive Disassemble / repair or replace
wear of bearing
Output low Gas leak from various parts of exhaust system Inspect and repair
Air lter elements clogged Replace or clean
Turbocharger’s contaminated or damaged Disassemble / repair or replace
Air leaks from discharge part of compressor side Inspect and repair
Abnormal noise or Rotor assembly interfere with each other Disassemble / repair or replace
vibration Uneven rotor operation Disassemble / repair or replace
Too big Disassemble / repair or replace
Connections loose Inspect or repair
5.4 Turbo charger diagnostics and troubleshooting
Oil consumption Insuf cient oil Use suggested oil

excessive 2）Oil seal or package leakage Replace
3）Pistons or piston rings damaged Replace pistons and/or piston
4）Cylinder liner damaged rings
5）Piston rings adhesive Replace cylinder liner
6）Valve guide oil seals or valve guides, or valve Replace pistons and/or piston
stem damaged rings
Replace
Oil pressure too low Insuf cient oil Use suggested oil
Safety valve adhesive Replace
Obstructions in oil pump strainer Clean strainer
Oil pump gear worn Replace
Oil pump feed pipe cracked Replace
Oil pump defective Repair or replace
Oil pressure gauge defective Repair or replace
Various bearing worn Replace
Oil deteriorates quickly Obstruction in oil lter Replace lter element
Gas leakage Replace piston rings and
cylinder liner
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5.5 Fuel system troubleshooting
Fault Causes possible Solutions
1. Engine can’t start 1）Fuel pipe obstruction or air in duct Clean

Oil transfer pump does not 2）Valve of Oil transfer pump doesn’t work properly Replace
supply 3）Fuel pump piston or push rod gripped Disassemble, repair
Injection pump doesn’t inject
Fuel injection timing error

Nozzle doesn’t inject
1）Fuel lter obstruction Clean
2）Air in injection pump or fuel lter Remove
3）Plunger or oil bleeding valve gripped or bad Disassemble, repair
1）Injection pump improperly installed on bracket Calibrate, repair
2）Injection pump tappet adjusted improperly Calibrate, repair
3）Camshaft’gear is axcess abrasion Replace
1）Needle gripped Repair or replace
2）Nozzle needle fuel leakage Repair or replace
3）Injection pressure error Replace
2. Engine stopped right after 1）Fuel duct from fuel pump to injection pump or fuel lter Clean
start obstruction Remove
2）Air in fuel Disassemble, repair
3）Insuf cient fuel in fuel pump Replace vent pipe
4）Fuel tank vent pipe blockage, fuel supply insuf cient
3. Engine output insuf cient 1）Injection pump plunger wear excessively Replace
2）Fuel injection timing error Adjust
3）Oil bleeding valve bad Replace
Repair or Replace
4）Excessive nozzle leakage
Disassemble, repair
5）Nozzle work improperly
5. Engine with strange noise, 1）Fuel injection timing error Adjust
exhaust black smoke 2）Nozzle injection pressure too low Adjust
3）Nozzle spring damaged Replace
Replace
4）Nozzle work abnormally
Adjust
5）Plunger wear excessively
Replace
6）Oil bleeding valve bad sealing
Inspect fuel pump
7）Fuel supply too much
6. Engine output unstable 1）Fuel supply insuf cient Inspect fuel pump
2）Air in fuel Remove
3）Water mixed with fuel Replace fuel
Disassemble, repair
4）Plunger move in exibly
Disassemble, repair
5）Rack move in exibly
Disassemble, repair
6）Nozzle defect
Adjust
7）Plunger sleeve injection starting point pressure incorrect Disassemble, repair
8）The injection advance abnormal
7. Engine cannot reach 1）Nozzle doesn't work properly Disassemble, repair
maximum speed 2）Governor defect Disassemble, repair
8. Diesel engine idle speed 1）Control rod drift Disassemble, repair
instable 2）Plunger move in exible Disassemble, repair
3）Control gear doesn’t mesh with control lever properly Disassemble, repair
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6. Attention Users to Re ect Product Quality

6.1 Feedback
In order to better understand and analyze the troubles and reasons, and to improve quality and better serve
our customers, please state below items when feedback to us about quality situation:
6.1.1 Place and time of which trouble occurs.
6.1.2 Series number, model, ordering number, shipping date and exact delivery address.
6.1.3 Work environment, cumulative work time (hours), working condition (output, speed), fuel and oil brands.
6.1.4 Characteristics (e.g. model, power and structure) of driven machine.
6.1.5 Please send the damaged parts for claim or repair together with trouble process report or statement to
our company for further analysis. As to severe trouble, please keep the site and immediately notify us to solve
the problem together.
6.2 Processing Requirements for Handling Quality Problems

6.2.1 Users should abide by our maintenance manual, and we will provide free replacement or repair for
damaged parts or machines which are resulted from poor assembly or production and have technical records
to trace in the warranty period of 12 months or 1,000 operation hours (whichever comes rst) after engine
shipment.
6.2.2 Users should be responsible for troubles in result of improper use and also for troubles owing to
improper repair or replacement.
6.2.3 Normally as for bad spare parts, uses can call the immediate manufacturers who produce the spare parts
for quick solution.
Whenever comes to a trouble during use or maintenance, please call our after-sales department. We will
provide you with patient and satisfactory answers, and also we will supply with repair training.
Service hotline: +86 21 65186706

Address: 125 Zhenyuan Road, Shanghai 200444, China rocessing Requirements for
Handling Quality Problems
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D11 Technical Specifications

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D11 Technical Specifications

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3

D series Technical Document

TO USERS AND OPERATORS

VMAN ENGINE Technical Documentation

1. SAFETY PROCEDURES& DIESEL ENGINE SPECIFICATIONS

1.1 Safety Procedures

1.1.2 Operation cautions

1.2 Diesel engine speci cations

Standby 360/490 314//427 292/397 264/359 390/530 340/462 317/431

Continuous 249/338 217/295 201/273 182/247 260/353 242/329 219/297

GENERAL ENGINE DATA

AIR INDUCTION SYSTEM

Engine Data with Dry Exhaust Manifold (Standby Power)

Engine Data with Dry Exhaust Manifold (Prime Power)

D11 (V6) Series diesel engine drawing

Sensor NPT 1/8-27

1.2.2 D15 series

GENERAL ENGINE DATA

INTAKE & EXHAUST SYSTEM

AIR INDUCTION SYSTEM

Engine Data with Dry Exhaust Manifold (Standby Power)

Engine Data with Dry Exhaust Manifold (Prime Power)

D15 (V8) Series diesel engine drawing

1.2.3 D22 series

GENERAL ENGINE DATA

INTAKE & EXHAUST SYSTEM

AIR INDUCTION SYSTEM

Engine Data with Dry Exhaust Manifold (Standby Power)

Engine Data with Dry Exhaust Manifold (Prime Power)

D22 (V12) Series diesel engine drawing

Sensor NPTF 3/8

1.2.4 D30 series RATINGS DEFINITION

GENERAL ENGINE DATA

INTAKE & EXHAUST SYSTEM

Technical Documentation VMAN ENGINE

AIR INDUCTION SYSTEM

VMAN ENGINE Technical Documentation

Engine Data with Dry Exhaust Manifold (Standby Power)

Engine Data with Dry Exhaust Manifold (Prime Power)

D30 (V16) Series diesel engine drawing

1.3 Diesel engine model, order number and serial number

1.3.1 Diesel engine model

Power code: Using 1 ~ 9, basic model is not numbered

Development sequence code: represented by A, B, C…

Displacement, 22 represents displacement of 22L

Fuel form code: D represents “diesel engine”

1.3.2 Diesel engine model

Model con guration type: 01 ~ 99

Rated speed：A says “1500r/min”

Example：A01 says 1500 r/min, rst type of con guration.

1.3.3 Diesel engine serial number

Serial number is expressed as a number of 00001 ~ 99999

Production year is represented by the last two number of the year

Diesel engine series

1.4 Engine performance curve

1.5 Engine Assembly

1.Oil seal 2. Vibration damper 3. Water pump 4. Thermostat 5. Piston pin

1.5.2 Engine sectional view (Cross)

1. Cylinder head 2. Cylinder head cover

3. Push rod 4. Injection pump

5. Intake manifold 6. Injection pipe

7. Oil ller cap 8. Cylinder block

9. Oil lter 10. Oil cooler