Operation & Maintenance Manual For M11NG Series Gas Engine

Operation & Maintenance Manual for
M11NG Series Gas Engine

Operation & Maintenance Manual For M11NG Series Gas Engine
4M11 Series Gas Generators
6M11 Series Gas Generators
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Foreword
M11 NG series natural gas engine for power generation is made by improving the previous
Baudouin M11 series diesel engine for power generation through removing of engine fuel
system and adding of gas supply system and relevant devices. This natural gas engine is
characterized by compact structure, reliable operation, excellent technical performances in
reliability, power, economical efficiency and exhaust emission, quick start-up, easy operation
and least maintenance, etc. It has already become a new power source of power generation
equipment and is frequently used as a main or standby power source in coal mine, oil field,
farm, gas station and other places. In addition, it can be fueled by natural gas, methane and
biomass gas, etc.
This manual briefly introduces the technical parameters, performance indicators, structural
features and usage & maintenance precautions of M11NG series natural gas generator. The user
shall comply with various specifications stipulated in this manual when using this natural gas
engine.
This manual deals with the basic model M11NG series stand-alone natural gas generator.
As the product structure is improving as the product develops continuously, this operating
manual may lag behind such improvement.
Any user’s comments and suggestions are always welcomed.
We shall cooperate sincerely, continue to stay together and strive for the development of
our clean energy industry of China!
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Dear customers,
Welcome to use Baudouin products! Thanks for your love to Baudouin products!
Please read carefully the operation & maintenance manual of the natural gas engine and operate it in
strict accordance with relevant specifications so that you can operate and maintain it properly.
Please read the followings carefully before your use for the purpose of running the engine
effectively.
● The natural gas engine has been tested in strict accordance with the test specification before its
delivery. Do not adjust ECU data or increase the engine power without permission. Otherwise,
the company's warranty service will become invalid.
● ECU is precise part which user can’t remove without permission. Otherwise, the company's
warranty service will become invalid.
● Turbocharger rotor shaft is a precision high-speed rotating component, which shall not be
dissembled or collided; otherwise, the company's warranty service will become invalid.
● The engine’s main bearing bolts and connecting rod bolts have strict torque and corner
requirements, and shall not be loosened or dissembled by user. Connecting rod bolts for
one-time use of bolts, shall not be reused; otherwise, the company's warranty service will
become invalid.
● The engine shall always be filled with oil of grade specified in this Manual. It is recommended
to use the special oil for Baudouin gas engine and filter the oil with a special cleaning filter.
Each time the engine is started, make sure to check whether the filling amount of coolant and
oil is proper.
● Never run the engine without an air filter.
● A new engine must be subject to running-in for 50 h before being put into service.
● Each time the spark plug is replaced, tighten them to the specified torque and ensure the
ceramic body is clean.
● If the ambient temperature is likely to be below 0 °C and no coolant containing antifreeze
additive is used in the engine after parking, the coolant shall be completely drained from the
water tank and engine.
● The electrical system components must be inspected and maintained by electrical technicians
only.
● The electronically controlled system components must be inspected and maintained by
professionals from Baudouin authorized service station only.
● After starting a cold engine, never run it at an idle speed for a long time; do not stop the engine
immediately after running under heavy load (except under special circumstances); instead, run
it at a low speed for 5~10 min before parking.
● Before starting a new engine, check the gas pipe, gas supply device and electrical system. Pay
special attention to checking whether the electrical connection is loosened and the high-voltage
coil is connected incorrectly.
● If the engine cannot be started after three successive attempts, check the gas system and the
circuit carefully again.
● The engine has been sealed to prevent rust and corrosion before its delivery. Generally, the
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sealing period is one year. The engine beyond the sealing period should be checked and
necessary remedies should be taken.
● For inspection and maintenance, please go to the service station designated by Baudouin.
Spare parts designated by Baudouin must be used for maintenance. Baudouin will not be
responsible for any damage to the engine caused by using the undesignated spare parts.
● Replace emission-related key parts (such as turbocharger, ECU, and pressure reducer) with
those of the same make and model as original ones; otherwise, Baudouin will not be
responsible for any consequences.
！
Please read this manual carefully before
发动机使用前必须阅读本说明书
operating the engine
Precautions before maintenance and repair

● Avoid long-time repeated exposure to the used oil.
● Wear the protective clothing and water-proof gloves, if available.
● Do not put the oil-immersed rag in your pocket.
● Avoid contaminating clothes with oil, and in particular, underwear.
● Wash operating clothes regularly. Discard clothes and shoes that are immersed with oil and can
not be cleaned.
● In case of cut and injury, take first-aid measures as soon as possible.
● Before operating, always apply some protective cream which will make it easier to remove the
oil when the skin is contaminated with mineral oil.
● Use soap and hot water, or liquid soap and nail brush to wash your hands for the purpose of
removing all oil stains. If the grease secreted by skin is washed off, the product containing
lanum can substitute the grease secreted by skin to moisturize the skin.
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● Do not clean the skin with gasoline, kerosene, fuel, thinner or solvent.
● If the skin irritation is felt, seek for medical care immediately.
● Remove oil from the parts before handling, if possible.
● If the eyes are endangered, wear goggles or a protective mask. Eye washing fluids must be
readily available.
● When repairing the engine, do not splash oil or other liquid on the floor. If hydrocarbon or
other liquid leaks unexpectedly, take all essential measures to isolate the area so as to keep the
environment clean and protect the persons from injury;
● The hydrocarbon, ethylene, glycol or petroleum should be handled, stored and recycled
according to the safety and environment standard being effective in the country.
● Shut down the engine during the maintenance or repair.
● Periodic maintenance and repair of the fuel system should be carried out in a professional
repair shop that has obtained a certificate from the relevant qualification department.
● The mechanics performing fuel system maintenance and repair should have received
professional training and have obtained a certificate, and any other person may not repair the
fuel system without permission.
● No smoking is allowed during the maintenance, and fire prevention measures should be taken
at the site. If the gas tank has been inflated, the maintenance shall not be done when the
vehicle is close to the surrounding open flame.
● During the maintenance and repair, it is forbidden to knock or collide gas tanks, pressure
reducing valves, pipes, steel cylinders and various valves.
● If the maintenance and troubleshooting is involved with removal/refitting, adjustment and
other operations of pipe fittings, valves, instruments and pressure relief devices, the
maintenance staff should first disconnect the battery power supply circuit and close the master
valve and the cylinder valve to release the pressure inside before removing the failure points. If
it is difficult to diagnose the leakage or failure points accurately, the master valve can be
opened for pressure check under the premise that there is no fire within 10 m around the
vehicle. After the leakage point is determined, the master valve and all cylinder valves should
be closed immediately to release the pressure before removal and repair.
● During the troubleshooting of gas supply system failure, the master valve and all cylinders
valves must be closed to release the pressure in the pipe. It is prohibited to carry out any repair
task under pressure.
● Make sure to check whether the ferrule is not damaged. High-pressure pipes and ferrules
connector cannot be used again and must be replaced with new ones. After the repair, the gas
detector or soapy water should be used to carry out the leakage test.
● After dissembling the pipe and various connectors, it is necessary to purge the pipe to prevent
dust from entering the gas pipe.
● When cleaning the engine, special care should be taken to avoid electrical control system
components such as spark plugs, ignition coils, and so on.
 Valve clearance adjustment shall be carried out in Weichai professional service station. It is
strictly prohibited for users to adjust. All engine problems caused by users' private adjustment
shall be borne by users themselves.
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Content
Foreword.................................................................................................................................................................... 2
Content ...................................................................................................................................................................... 7
Chapter 1 Product Technical Overview ..................................................................................................................... 9
1.1 Model implication of M11NG Series Natural Gas G-Drive Engine ............................................................ 9
1.2 Outline of 4M11NG series gas engine ....................................................................................................... 10
1.3 Outline of 6M11NG series gas engine ....................................................................................................... 13
1.4 Main technical parameters of M11 NG Series Natural Gas G-Drive Engine ............................................ 16
Chapter 2 Natural Gas Engine Control System ....................................................................................................... 18
2.1 Engine control system main parts technical requirements and installation requirements.......................... 18
2.1.1. EFR valve ...................................................................................................................................... 18
2.1.2.Wiring harness ................................................................................................................................ 18
2.1.3.Engine control unit (ECU) .............................................................................................................. 19
2.1.4 Inlet temperature, pressure sensor (T/MAP) ................................................................................... 19
2.1.5 Camshaft signal sensor ................................................................................................................... 20
2.1.6 Water temperature sensor ................................................................................................................ 20
2.1.7 Oxygen sensor (UEGO) .................................................................................................................. 21
2.1.8 Engine speed sensor （optional） ................................................................................................. 22
2.1.9. Electronic throttle .......................................................................................................................... 22
2.1.10. Ignition coil.................................................................................................................................. 23
2.1.11. Ignition cable ............................................................................................................................... 23
2.1.12. Sparking plug ............................................................................................................................... 23
2.1.13. Generator ..................................................................................................................................... 24
2.1.14 Starter............................................................................................................................................ 24
2.3Communication interface of Gas engine..................................................................................................... 25
2.3.1communication interface of Gas engine .......................................................................................... 25
2.3.2 Control interface of Gas engine ...................................................................................................... 25
Chapter 3 Installation and use of the engine ............................................................................................................ 29
3.1 Unpacking of natural gas engines .............................................................................................................. 29
3.2 Lifting of natural gas engines .................................................................................................................... 29
3.3 Installation of the natural gas engine ......................................................................................................... 29

3.3.1 Engine installation .......................................................................................................................... 29
3.3.2 External engine system installation ................................................................................................ 30
3.3.3 Installation of the gas equipment .................................................................................................... 30
3.4 Preparations before starting the engine ...................................................................................................... 31
3.5 Engine starting ........................................................................................................................................... 31
3.6 Engine operating ........................................................................................................................................ 32
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3.7 Engine shut-down ...................................................................................................................................... 32
3.8 Power Definition and Operation Conditions of natural gas Engine for Power Generation ....................... 33
3.9 Environmental conditions .......................................................................................................................... 34

Chapter 4 Gas Generators Maintenance .................................................................................................................. 35
4.1 Fuel, Lubricating Oil ,Coolant and Auxiliary materials............................................................................. 35
4.1.1 Fuel ................................................................................................................................................. 35
4.1.2 Gas Generator Lubricating oil ..................................................................................................... 35
4.1.3 Coolant............................................................................................................................................ 36
4.1.4 Auxiliary materials .......................................................................................................................... 36
4.2 Routine maintenance of the gas generator ................................................................................................. 38
4.3 Regular maintenance of the engine ............................................................................................................ 40

4.4 Notice for Using the New Gas generator ........................................................................................... 42
4.5 Gas generator for long-term storage of maintenance ................................................................................. 45
4.5.1 Clean gas generator......................................................................................................................... 45
4.5.2 Protection during storage ................................................................................................................ 45
4.6 Operation and maintenance specifications for main accessories of gas engines ....................................... 45
4.6.1 Operation and maintenance of turbocharger ................................................................................... 45
4.6.2 Operation and maintenance of water pump .................................................................................... 45
Chapter 5 Analysis and Removal of Common Faults .............................................................................................. 50
5.1 Diagnostic method ..................................................................................................................................... 50
5.2 Common faults and trouble removal.......................................................................................................... 50

Appendix 1 Recommended Torque for Main bearing Bolts of WP4/WP6NG Series .......................................... 53
1.1 Torque and method for tightening main bolts & nuts of engine ................................................................ 53
1.2Recommended Torque for Standard Bolts was seen in follow table 1........................................................ 55
Appendix 2 Q/WCQTG0007 “Specification of Spark Plug Removal and Refitting of Weichai Natural Gas
Engine” .................................................................................................................................................................... 56
I. Scope ............................................................................................................................................................ 56
II. Normative references .................................................................................................................................. 56
III. Requirements and steps for removal and refitting of spark plug ............................................................... 56
Appendix 3 Correction Coefficient Of Power of Engine ...................................................................................... 62
Appendix 4 Correction Coefficient Of Power of Engine ...................................................................................... 63
Contact Us .................................................................................................................................. 错误!未定义书签。
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Chapter 1 Product Technical Overview

1.1 Model implication of M11NG Series Natural Gas G-Drive Engine
4M11 G 2 N 0 /6
Speed Code
Emission Stage
Fuel Code
Rating Code
Usage Code
Product Series
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1.2 Outline of 4M11NG series gas engine
Figure 1-1 Outline of 4M11NG series industrial engine
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11
12
1.3 Outline of 6M11NG series gas engine
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Figure 1-5 Outline of WP6NG series industrial engine
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1.4 Main technical parameters of WP6/WP4NG Series Natural Gas G-Drive

Engine
Table 1-1 Main technical parameter of 4M11NG series natural gas generator
Engine model 4M11G4N0/5 4M11G4N0/6
Intake type Supercharged inter-cooling

Rated power（kw） 70 70
Overlond power 77 77
Generator unit power 60 60
Rated speed (r/min) 1500 1800
Type In-line, water-cooling, dry sleeve, proportional mix, sparking plug ignition
Ignition sequence 1-3-4-2
Minimum fuel consumption
216.5 218.2
(g/kW.h)
Cold state air valve gap
Inlet valve 0.2; exhaust valve 0.3
(mm)
Cylinder diameter/stroke
105x130
(mm)
Number of cylinders 4
Number of air valves per
2
cylinder
Displacement (L) 4.5
Thermostat opening
Opening begins at 70℃, and in full at 95℃
temperature
Engine oil grade Special oil for gas engine
Cooling mode Forced circulation water-cooling
Engine oil pressure (kPa) 350~650 (absolute value)
Idling engine oil pressure
200~350 (absolute value)
(kPa)
Crankshaft rotation direction
Clockwise
(seeing from free end)
Machine oil 9
Net weigit 450±50
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Table 1-2 Main technical parameter of 6M11NG series natural gas generator
Engine model 6M11G4N0/5 6M11G4N0/6
Intake type Supercharged inter-cooling
Rated power（kw） 120 120
Overlond power / 132
Generator unit power 100 100
Rated speed (r/min) 1500 1800
In-line, water-cooling, dry sleeve, proportional mix, sparking plug

Type
ignition
Ignition sequence 1-5-3-6-2-4
Minimum fuel consumption

≤210
(g/kW.h)
Cold state air valve gap (mm) Inlet valve 0.2; exhaust valve 0.3
Cylinder diameter/stroke (mm) 105x130
Number of cylinders 6
Number of air valves per cylinder 2
Displacement (L) 6.75
Thermostat opening temperature Opening begins at 70℃, and in full at 95℃
Engine oil grade Special engine oil 15W/40CF

Cooling mode Forced circulation water-cooling
Engine oil pressure (kPa) 300～600 (absolute value)
Idling engine oil pressure (kPa) ≥120 (absolute value)
Crankshaft rotation direction

Clockwise
(seeing from free end)
Machine oil 18
Net weigit 620±50
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Chapter 2 Natural Gas Engine Control System

2.1 Engine control system main parts technical requirements and installation
requirements
2.1.1. EFR valve
Fuel valve
Gas inlet
DP sensor
Air inlet
Figure 2-1EFR valve
Technical parameters:
1. Fuel type: natural gas, LPG, methane
2. Inlet pressure: 2 kPa ~3kPa
3.Working temperature: -40℃~121℃
Installation requirements and operating instructions:

●Pay attention to arrow pointed airflow direction during installation
●Regulate mixer’s installation angle a in -90°～+90°，to prevent the condensation of water back。
2.1.2.Wiring harness
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Figure 2-2 Engine wiring harness

Installation requirements:
●Wiring harness is not allowed to be laid at exhaust pipe side to avoid high temperature damage.
Wiring harness is more than 150mm away from exhaust pipe and vortex end of turbocharger;
●Wiring harness shall be fixed reliably to prevent interference or friction with sharp matters. If not,
please take protective measures.
● Wiring harness shall be free from intertwining and overlapping and reasonably aligned,
convenient for later maintenance.
2.1.3.Engine control unit (ECU)
ECU collects inlet manifold pressure (MAP), inlet manifold temperature (MAT), engine phase,
revolving speed, outlet water temperature, exhaust oxygen concentration and other signals and
controls the action of electronic throttle, ignition timing and ignition orders after calculation so as to
accomplish electronic control of engine.
Engine control unit (ECU) installed in control panel to realize real-time monitoring of engine
parameters.
Working voltage: 24V;
Working environment: -40℃～105℃;
Figure 2-3Engine control unit

2.1.4 Inlet temperature, pressure sensor (T/MAP)
T/MAP sensor integrates pressure and temperature measurement. Engine control unit (ECU)
uses sensor signals to calculate engine’s mixture air input.
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1.Applicable pressure: 20 kPa～300kPa；
2.Applicable temperature: -40℃～130℃
3.Voltage: 4.75V～5.5V;
Figure 2-4T/MAP sensor
2.1.5 Camshaft signal sensor

Camshaft signal sensor is mainly used for ECU to get exactly the camshaft position and
engine’s revolving speed. Engine control unit (ECU) uses revolving speed to control many
parameters, including air input, ignition advance angle, etc. Control requirements of these
parameters need engine control unit (ECU) to know engine’s camshaft position (for example which
cylinder is ignited) and revolving speed.
Figure 2-5 amshaft signal sensor

1.Normal working temperature: measuring terminal: -40℃～150℃;
2.Rated working voltage: 5V±0.25V
3. All magnetic field allowable: ≤2kA/m
4. Maximum torque allowable shall be （8±2）N·m during assemble (when 8.8 M6X12 bolts are
used), installation gap shall be （0.5~1.5）mm
2.1.6 Water temperature sensor
Water temperature sensor is mainly used to measure cooling water temperature. ECU may
regulate idle speed and ignition advance angle in different water temperatures according to ECU
stored data.
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1.Rated working voltage: （5±0.15）V
2.Temperature measuring range:

-40℃～﹢140℃
3. Normal working temperature of

connectors: -40℃～+130℃
Figure 2-6Water temperature sensor
2.1.7 Oxygen sensor (UEGO)
Figure 2-7Oxygen sensor

The oxygen sensor is used to measure the oxygen content in the exhaust gas and convert the
measured value into electrical signal and sent the signal to ECU. ECU adjusts the fuel supply
amount by adjusting the injection pulse width according to the air-fuel ratio set in the pulse chart,
achieving the closed-loop control against the engine.
Precautions for oxygen sensor are as follows:
● The installation position of the oxygen sensor is very important for the correct operation of the
system, so the oxygen sensor must be installed in strict accordance with the requirements.
● The oxygen sensor should be installed at a distance of 3 to 5 times the exhaust pipe diameter
from the turbocharger outlet.
● The oxygen sensor may not be installed at or after the exhaust pipe bends.
● In order to prevent the oxygen sensor screw thread from being sintered on the exhaust pipe and
causing the difficulty in disassembly, molybdenum disulfide should be applied evenly on the threads
of the oxygen sensor.
● If the vehicle is equipped with an exhaust brake, the oxygen sensor should be installed at
15cm-25cm downstream of the exhaust brake and should be placed as close as possible to the
turbocharger.
● The wire harness and connector of the oxygen sensor should be far away from the exhaust pipe,
eliminating the possibility of sintering.
● The height of the oxygen sensor’s screw base welded to the exhaust pipe should be less than
10mm, and the length of the oxygen sensor’s probe into the exhaust pipe should be no less than
13mm.
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● If the oxygen sensor is involved with failure or poor contact of wire harness and connector, high
gas consumption and instable idling speed may be caused.
● The oxygen sensor should be installed on the side of the exhaust pipe (circumferentially) away
from the engine.
● The oxygen sensor that meets the above conditions should be placed as close as possible to the
turbocharger.
● The angle between axis of the sensor and the direction of gas flow is from（ 90°+15°）to(90°
- 30°)（avoid the direction of gas flow faced to measurement hole）.
Figure 2-8 Angle between axis of the sensor and the direction of gas flow
2.1.8 Engine speed sensor （optional）
Engine speed sensor is mainly used to measure engine’s revolving speed. We can use it to
compare with engine’s revolving speed of Camshaft signal sensor. By this way, engine working will
improve stability and reliability.
1.Normal working temperature:

measuring terminal: -40℃～150℃;
plugging terminal: -40℃～120℃；
2. All magnetic field allowable:
≤2kA/m；
3. Maximum torque allowable shall be
（8±2）N·m during assemble (when 8.8
Figure 2-9 Engine speed sensor M6X12 bolts are used), installation gap
shall be 0.5 mm ~1.5mm.
2.1.9. Electronic throttle
Electronic throttle is mainly used for controlling mixture flow, engine idling and maximum
revolving speed. ECU uses 1600Hz PWM signal to control the action of throttle and its working
stroke is limited to 10％～90％ (opening of butterfly valve ) by ECU.
Failure of electronic throttle or bad contact of connectors will lead to: unstable revolving speed,
unable to start, inhibited acceleration, unable to acceleration and other failures. Use multi-meter to
check contact status of connectors; in case that connectors and wiring harness have no problems,
and its feedback signal bounces, replacement of new parts shall be taken into consideration.
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Figure 2-10 Electronic throttle

Installation requirements
●Electronic throttle shall be installed in low-temperature environment.
●Pay attention to arrow pointed airflow direction during installation
2.1.10. Ignition coil
This system adopts independent cylinder ignition coil, ECU controls coil’s charging hours,
charging time and discharging hours and engine charge current shall be maintained at 6.5A under
any conditions.
●Ignition coil wiring harness shall be

free from stresses;
●Use multimeter to check the contact

situation of wiring harness and
connectors;
●Ignition coil shall be kept away from

Figure 2-11 Ignition coil engine metal rack to prevent breakdown
of sparking
2.1.11. Ignition cable
Ignition cable is used to transmit high pressure spot generated by ignition coil to sparking plug
so as to generate electric spark for ignition of combustible mixture.
● Ignition cable assembly insertion

pressure is not greater than 80N, and
withdrawal force shall be 30 N～70N；
Figure 2-12 Ignition cable

2.1.12. Sparking plug
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Sparking plug is used to receive high voltage generated by ignition coil, generate electric spark
and ignite flammable gas. This engine uses double-platinum sparking plug.
Installation requirements
● Installation torque of sparking

plug: 25 N·m～28 N·m
● Sparkling plug gap: 0.35mm ±

0.05mm (regulate with plug gauge)
Figure 2-13 Sparking plug
2.1.13. Generator
When installing and connecting the generator, attention should be paid to the followings:
● The generator must be fully cooled;
● The generator must be dust-proof, splash-proof, oil-proof;
● The tension of the motor belt must be checked;
● The generator can only be connected with the voltage regulator and battery.
The generator’s rated voltage is 28V, and the schematic diagram is shown in Fig. 2-14.
Fig. 2-14 Generator schematic diagram
2.1.14 Starter
The starter is a DC starter which features electromagnetic control, gear transmission and torque
transmission with the friction plate isolator. The starter circuit is shown in Fig. 2-15.
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Fig. 2-15 Starter circuit

In order to ensure trouble-free starter operation, attention should be paid to the followings:
● The starter should be protected from splash water, road mud and oil, and should be equipped
with guard plate when necessary;
● The starter should be protected from high temperature, and the allowable temperature on the
housing should be no more than 100°C;
● If the driver fails to monitor the start-up process (for example, the commercial vehicle with rear
engine mounted), a starter relay must be installed to protect the starter from tooth engagement. The
current capacity of the starter relay should be greater than 80A and the starter circuit should be shut
off immediately after the engine starts to operate normally; the starter relay axis should be parallel
with the ground and be perpendicular to the vehicle running direction, preventing the starter from
accidental engagement due to vibration, shock or other reasons.
2.3Communication interface of Gas engine

2.3.1communication interface of Gas engine
Communication interface of 12M26 can provide CAN interface，USB-485 debug interface.
2.3.2 Control interface of Gas engine
KEY ON switch：If the switch is on，plug into power，the ignition can be on power.
RUN/STOP switch：This switch can controlled the engine’s run or stop, if the switch was on，the
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engine run，contrarily ，the engine stopped.
IDLE /RATED switch：The switch is off，the speed reduced to idle speed of 700rpm；if the switch
is on，the speed increase to rated speed.
EXTERNAL SHUTDOWN：If the switch is on，the engine come to a sudden stop.
GENERATOR BREAKER SWITCH：If the switch is on，the generators can be operated in parallel
and synchronously。Contrarily，the generators cannot working synchronously.
SPEED BIAS ：If the switch is on，the voltage signal of control panel was transferred to Speed Bias
26
interface.
RAISE SPEED AND LOWER SPEED: This switch can be connect or reserved，the engine’s speed
can be controlled by manual.
If the engine is at the rated speed, the RAISE SPEED switch is on then the engine’s speed raised to
the maximum limited speed according to a certain rate. The switch is off then the speed is kept in
current speed.
If the engine is at the rated speed, the LOWER SPEED switch is on then the engine’s speed reduced
to the minimum limited speed according to a certain rate. The switch if off then the speed is kept in
current speed.
ALARM RESET：If the switch is on，all alarm informations can be reset.
Fault diagnosis interface：It can be used to data calibration and fault diagnosis.
Fault diagnosis interface：It can be used to fault diagnosis.
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Chapter 3 Installation and use of the engine
3.1 Unpacking of natural gas engines
After unpacking the engine box, please first check the engine and its accessories
according to the delivery list, and check the engine appearance for damage and loose
connections before carrying out the following tasks:
◆ Wipe the antirust coat and corrosion inhibitor on the exposed parts;
◆ If the oil pan is not filled with oil, according to the agreement between the manufacturer
and the user, fill oil into it. If the oil pan is filled with engine oil containing running-in
accelerating agent before leaving our factory, we suggest that the user drain off the old oil
and replace with new oil after 50 hours of trial operation.
◆ If the engine is filled with coolant before leaving our factory based on the user needs,
according to the agreement between the manufacturer and the user, the user shall check
the performance of coolant after unpacking the engine. The coolant is usable if it can
lower the freezing point down to -30℃ or -35℃, with a PH value between 7 and 8
(neutral) and the total hardness value is between 5 and 15°d [9 and 15°f (hardness)];
otherwise, the user shall drain off the coolant, and refill coolant containing anti-freeze
additive into the engine.
3.2 Lifting of natural gas engines

Being lifted, the center line of engine crankshaft shall keep horizontal. Lifting when
engine is not upright or without lifting frame is strictly prohibited. The lifting up and down
shall be carried out slowly (see Figure 3-1).
Correct Wrong
Figure 3-1 Lifting diagram of natural gas engines
3.3 Installation of the natural gas engine

3.3.1 Engine installation
(1) The engine and chassis must be connected with a flexible shock absorber.
(2) Use flexible connection and ensure that the crankshaft centerline concentric with the input
shat of the transmission (gear box, transmission box) so that the crankshaft is not affected by
the additional force originated from the installation. Concentricity requirements: flexible
connection ≤0.3mm, rigid connection ≤0.1mm.If such requirements cannot be guaranteed, it
is recommended to use flexible coupling plus universal joint.
3.3.2 External engine system installation
The engine exhaust pipe should avoid excessive bending. The pipeline should be fitted with
intermediate expansion joints and additional support. The inner diameter of the exhaust pipe
shall not be less than 120mm, and the exhaust back pressure shall not exceed 6kPa.
The outdoor exhaust pipe should be equipped with the rain cover to prevent rainwater from
entering the exhaust system.
Fuel tank capacity should be able to meet the requirements of8 hours of work under rated load.
The location of the fuel tank should not be lower than the fuel supply pump inlet of the
injection pump. The inner diameter of the fuel pipeline should not be less than 12 mm.
3.3.3 Installation of the gas equipment
Gas line ： Gas source—Gas equipment—Gas shut-off valve—Gas filter—Pressure
regulator—Back-fire relief valve—Fuel valve—Mixer
The gas should meet the requirement which mentioned in 4.1.1.
Notice：
1.To guarantee the normal work of the engine, the fuel gas pressure should not be less than
105 kPa (absolute pressure).If the gas press above 20 kPa, should be equipped with
regulator.The normal gas pressure is （3-5） kPa. The pipe from gas source to pressure
regulator should be connected by flange or thread. The gas pipe after pressure regulator can
use rubber horse，the length of the pipe should be less than 1m，the inner-diameter of the pipe
should be greater than the gas diameter of the mixer.
2.The dust inside the pipes should be purged with high-pressure air before connecting them.
The connecting pipes may not be scratched or crushed.
3.If the gas resource is in low pressure，in order to ensure the long-term stable operation ,it
should be installed the buffer tank before the gas engine pipe , ensure 7.5 second gas volume
as buffer capacity.
4.The natural gas system design shall minimize the number of connection points on the
high-pressure pipeline and guarantee the convenient construction, good sealing, easy-to-check
and high reliability of connection points on the pipeline.
5.The high-pressure pipeline of natural gas system shall be provided with an upstream
over-current protection device to cut off the natural gas line reliably when the ignition switch
is off, the engine is not running or a lot of gas is leaking from the low-pressure pipeline
accidentally.
6.Test each connection point of the natural gas system with leakage detecting liquid under the
rated working pressure of the natural gas system, and each connecting point shall be free from
any bubble within 1 minute. Alternatively, test each connection point of the natural gas system
with a gas detector which is not lower than 25ppm in measurement accuracy, and the detector
shall not give an alarm.
7.The pipe of gas valve can’t be assembled under stress. Wire harness can’t connect with
water.
30
8.The power ground wire and the digital/analogue ground wire of the system shall be
connected to the negative electrode of battery separately.
3.4 Preparations before starting the engine
1.Check the coolant level

If the engine has been installed in the vehicle, check the coolant level before each use. When
the coolant is not enough, open the filler cap to add more coolant. When opening the filler cap
with the pressure relief valve and exhaust button, press the exhaust button first if the engine is
still hot. It is prohibited to add a large amount of coolant when the engine is still hot for it will
cause damage to the parts due to sudden temperature change. Start the engine, keep adding
coolant until the liquid level reaches the specified position and maintains stable. And finally
close the filler cap.
2.Check the engine oil level
Engine oil level should be maintained between upper and lower scale lines of the dipstick.
Add oil from the oil filler if necessary.
3.Check various engine accessories
◆ Check the connection reliability of various accessories, and exclude abnormal
phenomenon.
◆ Check the starting system circuit connection, and see if battery charging is sufficient.
4.Check gas systerm
Ensure no electrical equipment, fire and heat source near the gas pipe.
Ensure the engine power is closed.
Open the gas valve, let the gas by gas pipe line, from the source to the mixer in the pipe joint
measured with gas leak fluid leaks. Measure the gas pipe from the source to the mixer with
gas leak fluid leaks.
5.Check electronic system
The system uses 24V DC power supply. The current from the battery enters the system and
the engine control module (ECU) in two ways: in one way, it enters the system via the
ignition key switch, serving as the main power source of the system; in the other way, it enters
the system directly via the fuse, providing the uninterrupted power supply for the system.
ECU also collects the system’s operating voltage signals and controls the actuator based on
the real-time correction of the operating voltage.
3.5 Engine starting
◆Before starting the engine，it must be ensure that the crankshaft rotated smoothly.
◆When the conditions of starting are ready, start the engine.
◆If the conditions of starting are ready, yet the engine still cannot be started within （5～10）
seconds, then wait 30 seconds before repeating the start-up process. But if the engine fails to
start for three consecutive times, stop starting to find out the reason and starting
troubleshooting before trying to start the engine again. After the engine starts, take note of the
meter reading for the oil pressure gauge should show the pressure immediately. After the cold
start, the engine should be idling for （2～3）minutes instead of suddenly operating at high
speed.
3.6 Engine operating
◆ After starting the engine, idle for（2～3）minutes before adding part of load. Only when the
water temperature is above 60℃, the oil temperature is above 50℃, and the oil pressure is
higher than the oil pressure seen in sheet 1-1 or1-2,it is allowed to operate the engine at full
load. Load and speed increases should be gradual to avoid sudden loading and unloading.
◆There might be air in the pipe of gas when the engine is started at the first time or after
long-term stop，which might cause the engine failed to start. It might be tried several times，
and in order not to affect the life of starting motor，starting time mentioned above must strictly
obey.
◆When the engine is in normal use, it is allowed to continuously operate it at rated power
and rated speed. After unloading, the engine should idle for 1 to 2 minutes before shutting
down.
During operation, pay attention to the following parameters and the locations:
Main oil passage pressure: seen as in table 1-1 and 1-2；
Main oil passage temperature: 85℃~ 105℃;
Coolant outlet temperature: 75℃~90℃;
◆ Check the exhaust color to inspect the operation quality and load status of the fuel injector.
If there is a lot of black smoke or white smoke, stop the engine to check.
◆ Check the engine for air, water and oil leakages. If leakages are found, stop the engine to
exclude the leakages.
◆ Take notice of following items when running in a cold environment:
Lubricating oil: choose different grades of lubricating oil according to different ambient
temperatures.
Coolant: Coolant must be added to the cooling system. Choose the coolant of different
freezing points according to different ambient temperatures.
Battery: Before the cold season begins, be sure to check the electrolyte liquid level, viscosity
and unit voltage. If the engine is not going to be operated for a long time and under very low
temperatures, the battery should be removed and stored in a warmer room.
3.7 Engine shut-down
Avoid shutting down the engine at full load. Before the shut-down, engine load and speed
should be reduced, and the engine should be operated at idle speed or low-load condition for 3
to 5 minutes to allow the piston, cylinder head, liner, bushing and turbocharger have enough
32
time to be cooled, in order to avoid cylinder and bearing damage. This is particularly
important for turbocharging engines because the bearing and oil seal in the turbocharger are to
be affected by the high temperature of the exhaust gas. When the engine is running, the heat
will be transferred away by the cycling lubricating oil. But when the engine shuts down
suddenly, the turbocharger temperature will increase greatly and cause the bearing get stuck or
oil seal failing.
For the engines that there is no antifreeze in the circulating water, drain the cooling water
after shut-down in cold weather to prevent freezing damage to the engine. The draining valve
under the oil cooler can be used to drain the water inside the engine. The drain plug on the
radiator should also be removed to discharge the cooling water in the radiator.
3.8 Power Definition and Operation Conditions of natural gas Engine for
Power Generation
3.8.1 Power Definition
Continuous Power (COP)
It is the maximum power of engine that operated continuously under a constant load with
unlimited yearly operation time. It is the ISO standard power.
Prime Power (PRP)
It is the maximum power of engine that operated continuously under variable load with
unlimited yearly operation time. It is ISO standard power that 10% overload is available.
Emergency Standby Power (ESP)
The maximum power amidst a certain variable engine power series with yearly operation time
reached 200h.
3.8.1 Operation conditions and applications of the Power
Operation conditions and applications of the natural gas engine at different powers are shown
in Table 3-1.
Table 3-1 Operation conditions and applications of the natural gas engine
Power Category Operation Conditions Applications
1. Unlimited yearly operation time; Can be operated under

Continuous
2. Operating with 100% of rated load; high temperature and
Power (COP)
3. Without overload capacity. plateau conditions.
1. Unlimited yearly operation time;

2. The average load rate shall not exceed 70% within It's used for the specified
each 250h running duration; power output. If the utility
Prime Power 3. The yearly operation time with 100% of rated load power is reduced, the
(PRP) shall not exceed 500h; generating set can be
4. 1h overloaded operation with110% of rated power connected to the utility
within 12h is allowed; the yearly cumulative overload grid.
operation time shall not exceed 25h.
1. The yearly operation time shall not exceed 200h,

including no more than 25h operation with 100% rated
Emergency Provide emergency power
load yearly;
Standby Power supply during power
2. The average load rate shall not exceed 80% within
(ESP) interruption.
24h operation cycle;
3. Without overload capacity.
Note: 1. The continuous power is 0.85 times of the prime power;

2. The emergency standby power is 1.1 times of the prime power; the usage condition
should be clearly described to the users when sales.
3.9 Environmental conditions
The natural gas engine can be normally started when the ambient temperature is above -15℃;
if the ambient temperature is between -15℃ and -35℃, auxiliary start device should be used
for normal starting of natural gas engine. If it's used in the area where the altitude and
temperature is relatively high, the engine power may reduce. The engine should stay far away
from the combustible and explosive environment.
34
Chapter 4 Gas Generators Maintenance
4.1 Fuel, Lubricating Oil ,Coolant and Auxiliary materials
4.1.1 Fuel
NG: Pipeline natural gas with a heating value of 36MJ/m³(or above.)，CH4＞80%.
Gas quality requirements(measure within 1 meter of engine gas inlet)

Into the engine intake pressure is （3~5）kPa(after the pressure regulator),customers can
choose their own regulator.
Pressure change rate ≤1kPa/min;
H2S≤20mg/Nm³;
Impurity particle size≤5μm;
Impurity content≤30mg/Nm³;
Ammonia≤20mg/m³;
Tar content≤50mg/m³;
Moisture content≤20mg/Nm³.
If the fuel is not used as specified,there will be some loss of engine power, and emissions may not meet
the non-road Ⅲ stage regulations. Higher heating value can’t improve the power of the engine，but
the lower heating value will lead to loss of the engine’s power. If the gas with the heating value is
under 20.5MJ/m³and the content of CH4 is under 60% will cause the engine can not work.
4.1.2 Gas Generator Lubricating oil
Gas Generator Lubricating oil capacity :9L(4M11)/16L(6M11),The actual filling volume
should base on the markings of oil dipstick. (Different models of its oil slightly different)
Selection of Lubricants: in order to make your gas generator safe and reliable operation,
special lubricating oil for gas engine shall be used. Specific standards Refer to Table 4-1.
Table 4-1 Baudouin power special oil selection specifications
Variety Packaging specifications Application of model type
Gas Engine
4L，18L，170kg Gas Engine
Lubricating oi
Notice: 1) Check the oil level in the oil pan before starting the gas engine.
2) Do not check the oil level while the gas engine is running.
3) The oil with different quality grade cannot be used by mixing.
The oil filling volume and the number of filters of M11 series Gas Generators is shown in
Table 4-2
Table 4-2 Oil filling volume and number of filters
Engine Oil filling Gas Generators
model capacity (L) Oil filter Gas filter

6M11 16~24 1 1
4M11 9~12 1 1
Remarks:
1) The oil filling volumes above are for reference only. The actual filling volume should base on
the markings of oil dipstick.
4.1.3 Coolant
The cooling system of the natural gas engine must be filled with pure coolant, which has the
antifreeze and anti-boiling properties, can avoid freezing in cold weather or "boiling" under
high temperature and is applicable for vehicles under different temperature, which gives a
special protection for the water tank and the engine cooling chamber.
The properly selected coolant can effectively protect the engine components and extend the
service life of the engine. See Table 4-3 for more details.
Table 4-3 Natural gas engine coolant

Coolant grade -#25 -#35 -#45 -#50 Remarks
Since the coolant of gas engine needs to provide the

Applicable min. heat exchange for the vaporizer, the freezing point
temperature(℃) -15 -25 -35 -40 of antifreeze selected for gas engine should be at
least 10°C below the local minimum temperature.
Notice: 1) Check the coolant regularly to prevent corrosion damage. Replace the coolant if necessary.
2) Never use water or low-grade coolant.
4.1.4 Auxiliary materials
Auxiliary materials please see Table 4-4. Application of sealant for Gas Generators please see
Table 4-5.
Table 4-4 Auxiliary materials
No. Name Color Function and application
Molykote Pulver
1 (fine molybdenum Black Applied on flat and smooth metal surfaces to prevent seizing
powder)
36
Molykote G-N plus Achieve lubrication function before lubricating oil pressure is
2 (Molybdenum disulfide, Dark grey built up
oil solution) For instance: Applied onto intake valve stem
Table 4-5 Application of sealant for Gas Generators
Grade Major application Application part Supplements
Camshaft thrust plate bolt

Camshaft timing gear bolt
Middle idler bolt
Front cover bolt
Baudouin Applied onto the threads to Oil filter seat bolt
special prevent looseness due to
sealant 242 Oil cooler bolt
vibration, with moderate Alternatively,
strength. Oil cooler regulator plug DriLoc204
Oil pumpreturn pipe fixing bolt thread-locking
Air compressor shaft thread adhesive can be used
for pre-coating
Suction filter bolt
Sensor and harness fixing bolt
Baudouin Applied onto the outer

special surface of the thread
sealant 262 Cylinder head vice bolt
lock,seal and prevent
loosening
Baudouin
special Locking and tightening Bowl-shape plug for oil hole
sealant 271
Baudouin
For sealing between core
special Other bowl-shape plugs
and hole
sealant 277
Baudouin
For sealing of cylinder head
special Push rod tube and cylinder head
top surface
sealant 270
Baudouin Mating faces of cylinder block and crankcase
special Cylinder block front end face and the front end
sealant 518 Applied on shining metal cover,Connecting plate between the rear end
(updated surface for sealing face and flywheel housing
product based Mating faces of oil filter seat and crankcase
on 510) Water pump rear cover and cylinder block front
end face
Flywheel housing and connecting plate
Mating faces of cylinder block and oil cooler
cover
Mating faces of cylinder block and oil filler port
cover plate
4.2 Routine maintenance of the gas generator
◆ Check the coolant level, oil level and gas pressure; and refill if necessary;
◆ Check for oil, water and gas leakages;
◆ Check the connection reliability of external parts and accessories;
◆ Check the tension of belt;
◆ Check the oil pressure of engine;
◆ Check the connector and wire connection;
◆ Check the water temperature of engine;
◆ Check the temperature and color of exhaust gas, sound, vibration and speed of engine;
◆ Check the liquid level and coolant temperature.
Check the coolant level through the glass sight hole. And if it is insufficient, open the filler
port cap to add coolant, as shown in Figure 4-1.
Figure4-1 Coolant filler port cap

Notice: Before opening the filler cap, push down the air bleeding button to avoid personal
injuries by the hot coolant while the engine is hot.
◆ Check the oil level
Oil level as shown in Figure 4-2.
It is not allowed to start the engine when the oil level is below the lower marking or above the
upper marking.
When checking the oil level, stop the engine and wait for at least 5 minutes, enabling the oil
to flow back to the oil pan.
38
Figure 4-2 Checking of oil level
◆Check gas
Check for gas pressure and leakages.
◆Check for leakages
Check the external surface of gas generators for water, air/gas and oil leakage.
◆Check the fan
Visually check the fan blade for damage, and check the connecting bolts. As shown in
Figure 4-3.
Figure 4-3 Check the fan

◆Check the belt tension
The belt is automatically tensioned by the tensioner. You can check the tension of belt by
pushing the belt with hand. As shown in Figure 4-4.
Figure 4-4 Check the belt tension

◆Check the running sound of the gas generator
◆Check the speed and vibration of gas generator
4.3 Regular maintenance of the engine

◆ Replace the engine oil
（1）Unscrew the drain plug at the bottom of oil pan, drain off the oil completely, discharge
the oil by operating the hand oil pump, and then screw in the drain plug again.
（2）Open the oil filler cap, add new oil through the filler port the oil should be filtered by
a strainer when filling; check the oil level through the scale mark of oil dipstick, tighten the
filler port cap finally. As shown in Figure 4-5.
Oil filter port
Drain plug
Figure 4-5 Oil filler port ,Drain plug

◆ Replace the oil filter or filter element(As shown in Figure 3-6.)
（1）Remove the old oil filter;
（2）Fill the new filter with clean oil;
（3）Apply lubricating oil on the sealing gasket before installing the new oil filter;
40
（4）After the sealing gasket touches the filter seat, tighten 3/4 to 1 more turns to seal tight;
（5）Start the engine to check for oil leakage.
Figure 4-6.Oil filter
◆ Check and adjust intake/exhaust valve clearance（seen in appendix 1.3）

◆ Check the intake system
Check the intake hose for cracks due to aging, and check the clamp for loosening. When
necessary, tighten or replace the related parts to ensure the tightness of intake system.
◆ Check the Air Filter Element
When the intake resistance indicator alarm (Reddish status as shown in Figure 4-7), should be
shot down maintenance of air filter outside the filter.
Figure 4-7 Indicator

Type I: Radial seal air filter
(1) Check whether the inner surface of the outer filter and the outer surface of the safety
filter are dusty, if there is dust, the outer filter is damaged or the installation is not in place,
which should be highly valued;
(2) Use less than 0.5MPa clean air from the inside out on the outer filter dust, prohibit the
use of oil, water filter cleaning.
Notice: (1) Safety filter is forbidden to dismantle and clean.
(2) Forbidden to purge the outer filter from the outside to the inside .If there is
more dust on the outer surface of the filter, the dust may fall off by hand. Safety filter is
forbidden to dismantle and clean.Safety filter will be replaced together with the outer filter. As
shown in Figure 4-8.
Figure 4-8 Filter element cleaning

Type II: 93 Dust filter (Figure 4-9)
(1) Loosen the buckle connecting the back cover and the housing, then remove the back cover,
and clean the dust of the back cover completely.
Note: When the engine shut down to inspect, the dust can be removed by dust valve in time,
the dust valve damage and loss should be promptly replaced dust valve.
(2) Turn the yellow sealing cap counterclockwise and remove it, at this time you can see the
outer filter.
(3) Grasp the nose of the outer filter cover by hand and pull the outer filter cartridge out of the
hollow space of the hollow filter housing.
(4) Follow the maintenance instructions of the air filter outside the filter.
(5) Before replacing the outer filter, clean the inner cavity of the filter and the inner cavity
thread with dust, brush or cloth to clean the dust to ensure that the thread is smooth and
prevent the dust from entering the inner part of the outer filter.
(6) In reverse order to restore all parts, should pay attention to the correct installation to
ensure the seal, do not omit parts.
Figure 4-9 93 Dust filter

Note: It is not permissible to use the engine without an air filter as the entry of dust and
impurities into the engine can lead to early wear of the engine.
4.4 Notice for Using the New Gas generator
◆Within the first 60h for using the new gas engine, the load of gas engine should not exceed
75% the rated load.
42
Industrial power gas generator for the first inspection and feeding cycle see Table 4-6, gas
generator maintenance items see Table 4-7.
Table 4-6 Industrial power gas generator for the first inspection and feeding cycle
First inspection After running (30~50) hours
Routine inspection (P) Every 250 hours of running
Level 1 maintenance (WD1) Every 250 hours of running
Level 2 maintenance(WD2) Every500 hours of running
Level 3 maintenance(WD3) Every 1,000 hours of running
Level 4 maintenance(WD4) Every 3,000 hours of running
Note:
The maintenance cycle mentioned here is calculated based on the condition that the engine is running 1500
hours per year. For engines running time less than 500 hours per year, the maintenance cycle is half.
Table4-7 Maintenance items of the gas generator

First
Routine
Maintenance items mainte WD1 WD2 WD3 WD4
inspection
nance
Replace lubricating oil and oil
▲ ▲ ▲ ▲ ▲
filter element
Check and adjust valve
▲ ▲ ▲ ▲ ▲
clearance
Check the coolant and add
▲ ▲ ▲ ▲ ▲ ▲
enough capacity
check whether the natural gas
system is leaking; check the
▲ ▲ ▲ ▲ ▲ ▲
natural gas supply pressure in
natural gas system
Check the water pump for
▲ ▲ ▲ ▲ ▲
leakages
Clean the natural gas filter ▲ ▲ ▲ ▲
Fasten the air intake pipe and
▲ ▲ ▲ ▲ ▲
hose
Clean the oil cooler core ▲ ▲
Clean the intercooler core ▲ ▲

Clean the fan and water tank ▲ ▲
clean up the mixer and
▲
electronic throttle valve
Check the high-voltage line and
▲ ▲
recommended to replace it
Check spark plug and
▲ ▲ ▲
recommended to replace it
Clean the air filter ▲ ▲
Check and replace air filter

▲ ▲ ▲ ▲
element
Check the tightening belt ▲ ▲ ▲ ▲ ▲ ▲
Replace heat exchanger zinc
▲ ▲ ▲ ▲ ▲
block
Check the turbocharger ▲
Note: ▲ Indicates that maintenance is needed.
Description：The maintenance cycle mentioned here is calculated based on the condition
that the engine is running 1500 hours per year. For engines running time less than 500
hours per year, the maintenance cycle is half.
◆ Please perform daily maintenance according to the relevant provisions of the
44
instructions.
◆ Correct operation will extend engine life, and get better performance and more
economic benefits. The above maintenance schedule for the general industrial use of
power, you should use the environment and working conditions to develop a suitable
maintenance schedule, if the gas machine working environment is relatively poor, should
shorten the maintenance cycle.
4.5 Gas generator for long-term storage of maintenance

4.5.1 Clean gas generator
◆ After warm up of the gas generator, clean the oil filter, and add rust resisting oil.
◆ Start the engine and run it at idle speed for (15~25) minutes.
◆ Discharge all the engine oil and coolant.
◆ Take protective measures for other positions.
4.5.2 Protection during storage
Use cap or plastic cloth to seal each oil, gas and water inlet and outlet; use VCI film to cover
the whole engine.
Note: Outer packing is needed for transportation.
4.6 Operation and maintenance specifications for main accessories of

gas engines
4.6.1 Operation and maintenance of turbocharger
The engine oil of turbocharger is drained from the main oil line of engine, and returns to the
bottom of crankcase after lubricating and cooling the turbocharger are complete.
（1） A good lubrication is crucial to the normal operation of turbocharger. Therefore, the
engine oil filter element shall be cleaned up or replaced regularly.
（2）The turbocharger works at an extremely high rotating speed. Therefore, the engine shall
run idle (for about 5 minutes; the duration may be shortened as appropriate in case of a
short-term shutdown) before it is loaded. Do not shut down the engine immediately when it is
running at a high speed under a heavy load. The load and rotating speed shall be lowered
gradually and the engine shall idle for 3 to 5 minutes; otherwise the turbocharger bearing will
be damaged and become unusable.
（3）Disassemble and check the compressor casing and turbine casing regularly, and clean up
the impeller and the flow passage in casing. When reassembling the turbocharger, fill clean
engine oil via the filler opening.
（4）Notice : Turbocharger rotor shaft for precision high-speed rotating parts, dismantling,
collision, or factory warranty failure.
4.6.2 Operation and maintenance of water pump
WP4/WP6 series engine pump installed in the front of the engine, the pump turbine housing
above the timing gear chamber, cast into one, the turbine shell water directly into the right
side of the water chamber, cooling water across the oil cooler, from the lower right channel
hole Into the cylinder tube water sandwich, cooling cylinder tube and then through the water
hole into the cylinder head water chamber, after cooling the cylinder head from the cylinder
head outlet into the outlet pipe, outlet pipe end thermostat. Thermostat has two outlets, all the
way to the tank, the other way to the pump inlet is a small cycle. When the cooling water
temperature in the thermostat open to fully open temperature, then all the cooling water after
cooling by the radiator into the body by the pump, but when the cooling water is lower than
the opening temperature, the thermostat cut off the access, Cooling water directly into the
pump inlet, so that the engine heat up as soon as possible to meet the operational requirements
of the thermal state, to avoid low temperature wear and prolong the service life of the engine.
If you find the water pump leaks, you need to replace the pump seal.
4.6.3 Operation and maintenance of starter
（1） Starter is a short-time service device. Its starting time shall not exceed 10s every time.
The interval between successive starting shall be longer than 2 min.
（2） The engine shall be preheated when the temperature is below 5℃ in winter.
（3） Release the starting switch immediately once the engine is started up so as to disengage
the drive gear of starter from the flywheel ring gear.
（4） Energizing the starter before the engine stops running is strictly prohibited, so as to
avoid damage due to collision between the flywheel and the starter gear.
（5） The wiring of a starter must be based on the wiring diagram of the starter during
installation. Make sure that the battery is disconnected from the main starting line of starter.
（6）The fastening pieces of starter and wire insulation must be checked frequently for
damage; the wires shall be well-contacted and the dirt shall be removed.
4.6.4 Operation and maintenance of generator
（ 1 ） Reasonable allocation: The basic electricity consumption of common electric
appliances in the complete machine shall be satisfied when the generator is idling. Any
unreasonable match between the generator and electric appliances in the complete machine
may cause low battery energy or even regulator damage or stator burnt-out due to overheating
of generator. The minimum working speed of generator must be guaranteed. If the idle speed
of generator is set too low, the generator speed will be too low, which will cause the above
mentioned faults as well.
（2） Secure installation: The generator shall be mounted on engine correctly, securely and
reliably. The mounting bolts must match the mounting holes on generator and be tightened up.
The pulley groove and the driving wheel groove shall be in the same plane. The mounting
bracket of generator must meet the requirements for necessary strength and rigidity; otherwise
the generator may be damaged due to the insecure installation.
（3） The belt tension shall not be overloose or overtight. Usually the belt tension is proper
when the belt can be pressed down by 10 to 20 mm under a force of 150N (15 kilogram force)
by hand at the 1/2 center distance between two pulleys. The belt tension shall be checked once
46
every 2 months of operation. The generator may “rotate less turns” when the belt is overloose,
which may cause insufficient power generation, low battery energy, stator burnt-out and
bearing damage, etc.
（4） Keep away from heat source and splashing mud; prevent external splashes from
entering into the generator and causing damage; try to guarantee a good application
environment for generator. Usually the working ambient temperature of generator is between
-40℃ and 93℃. The generator shall be mounted in a place which is away from the heat
source upon the approval of generator manufacturer or supplier (the distance from heat source:
≥400mm; or an effective thermal baffle is mounted).
（5） The wire shall be sized reasonably and connected correctly and securely. Each
connection terminal of generator should not be connected in a wrong way to avoid wires
burnt-out or generator electrical parts damage. Selecting a reasonable wire diameter should be
based on the premise that the complete output of generating capacity of generator be
guaranteed, and it is also the foundation for electricity safety for the complete machine.
（6）The wiring of battery and generator must be disconnected before the generator is
disassembled or the complete machine is being welded. The disassembly and repair of
generator must be carried out by professionals. During installation, check whether each
insulation pad and sleeve is in good condition; any damaged or broken insulation pad and
sleeve must be replaced! The positive electrode side of generator and the generator shell shall
not have a short circuit to avoid serious accidents involving the complete machine.
（7）After the engine is started, it shall reach a high speed from a low speed. Observe whether
the charging indicator is on when the speed is low, and off when the speed is high. If not,
please find out the reason immediately.
（8） Observe whether the polarity of battery is “negative grounded”; if not, the generator
and regulator will be burnt out.
（9） When the generator is in service, do not check whether the generator is generating
electric power by means of “testing sparks while grounded”; otherwise, the test lamp or
diode may be burnt out.
（10） When connecting the rectifier to the stator winding, do not check the insulation
condition of generator using a mega-ohm meter or 220V AC power supply.
（11）The generator must be reliably connected to the battery. The sudden disconnection will
generate a high voltage and damage the generator or voltage regulator.
（12） When selecting a regulator matching the AC generator, the voltage class of AC
generator must be identical to that of regulator; the ground type of AC generator must be
identical to that of regulator; the power of regulator shall not be lower than that of generator.
（13）The wire connection must be correct.
4.6.5 Operation and maintenance of oil pump
Oil pumps are of external gear type. Each gear pump uses two gears with identical number of
teeth to engage with each other and brings engine oil to the oil outlet from the low pressure oil
chamber via the reverse rotation of two gears and the clearance between them. The constant
rotation of gears keeps the engine oil volume in oil chamber increasing and the pressure
increasing, so as to guarantee the sufficient oil supply for each lubricating system of engine.
（1）Oil pump equipped with pressure limiting valve. The role of pressure limiting valve is to
prevent excessive pressure in the oil pump and lubrication system to ensure the safe and
reliable work of all components. Pressure limiting valve both bypass valve role, when the oil
pump oil pressure exceeds the predetermined value, the pressure limiting valve call, part of
the oil flow to the oil pan, thereby reducing the oil pressure. Pressure limiting valve by the
spring to adjust the oil pressure, the spring preload factory has been adjusted, the user
generally do not need to adjust.
（2）The performance of engine oil pump mainly depends on the clearance (end clearance and
radial clearance) between oil pump gear and casing. When the clearance is overlarge, the
engine oil will leak seriously, and the engine oil pressure will drop and the oil volume will
decrease. When the clearance is undersize, the gear will wear out seriously.
（3）If the oil supply pressure drops, the oil pump shall be maintained when the other engine
faults are eliminated. When maintaining an engine oil pump, the maintenance personnel shall
observe the oil pump for oil leak and burn first. If there is no oil leak or burn, the maintenance
personnel shall check the pressure relief valve and disassemble the oil pump. Check whether
the spring of pressure relief valve is softened or whether the gear, pump body or end cap is
worn seriously. Replace the oil pump if necessary.
（4）If the oil pressure is overhigh, the pressure relief valve shall be disassembled for
inspection. on The most important is to inspect whether the pressure relief valve can be
opened or not.
（5）Be careful not to damage the end cap, pump body junction surface and each locating pin
when disassembling and reassembling an oil pump.
4.6.6 Operation and maintenance of air filter
Warning! The service life of your engine may be shortened greatly due to wrong
maintenance methods.
（1） The air filter shall match the performance index of engine in a strict way; otherwise, the
dynamic property and economy performance of engine will be influenced.
（2） If the air filter is provided with a warning device, the warning device shall be observed
first before the natural gas engine is started. When the intake resistance indicator give an
alarm (turns red), the air filter element shall be maintained.
（3） The filter adopting multistage filtration technology must be provided with a coarse
strainer.
（4） When mounting the dust exhausting pipe, the pipe shall not be bend sharply and shall
be free from air leakage.
（5） Prevent water from entering into the air filter.
（6）When maintaining an air filter with a safety filter element, do not disassemble the safety
48
filter element.
（7） In normal working conditions, the paper main filter element of fine filter shall be
maintained once every 100 to 200 operation hours of engine. Remove the main filter element
and tap or shake off the dust inside. Check each sealing element of it and replace any
damaged one. The clean and dry compressed air not exceeding 500kpa may be used from
blowing from inside of filter element. Put a lit bulb inside the filter element and observe
externally whether any light can pass through the filter element, in order to confirm whether
there is crack, pierced hole or other damages. Cleaning the main filter element with oil or
water is strictly prohibited.
（8）The main filter element shall be replaced after having working for 1000 to 2000 hours. In
the meantime, the safety filter element shall be replaced.
（9） The filter element assembly shall be replaced in the following cases:
◆The filter element is broken.
◆The warning device is still giving alarm after a clean filter element has been mounted.
◆After the filter element has been cleaned up for 3 to 6 times.
◆When replacing a filter element, the operator must use the filter element of a reliable
quality in order to guarantee the reliability of engine. It is recommended to purchase the
genuine parts.
Chapter 5 Analysis and Removal of Common

Faults
M11NG Series natural gas engines are designed and manufactured in compliance with a
strict quality assurance system. Each engine leaving our factory is tested as specified. In
addition, natural gas engine is a kind of precision machinery. Its long-term performance
guarantee is inseparable from the normal maintenance. Usually the following causes may lead
to the early failure of an engine:
◆ Unprofessional operation and poor management and operation;
◆ The engine has not been maintained or repaired as per schedule or even has been
repaired instead of being maintained;
◆ The accessory quality is poor; especially the counterfeit and shoddy products will
shorten the service life of an engine greatly;
◆ The grade of lubricating oil is improper or disqualified.
5.1 Diagnostic method

The common faults diagnostic methods of natural gas engine include:
◆ Observational method: Determine the fault by observing the fault characteristics such
as smoke exhaust from engine;
◆ Listening method: Determine the nature and degree of faulty parts by listening to the
abnormal sound from the engine;
◆ Cylinder disconnection method: Stop one cylinder and determine whether this
cylinder is in fault. Usually the maintenance personnel stop supplying natural gas to
the targeted cylinder and compare the changes in engine state before and after that in
order to further find out the faulty parts and cause, or to narrow down the range;
◆ Comparison method: the maintenance personnel replace some assemblies or parts to
determine whether they are in fault.
Note:
① The causes for engine faults shall be determined carefully. Do not disassemble the
engine arbitrarily before figuring out the causes; otherwise, the fault cannot be removed
and a more serious fault may be further caused due to improper reassembly after
disassembly.
② Please send the key parts such as ECU, electronic throttle valve and turbocharger to
the maintenance stations appointed by Weichai for maintenance and inspection.
5.2 Common faults and trouble removal
50
Table 5-1 Engine faults and analysis
Common Faults Possible Causes Fault Inspection and Treatment
1. The natural gas bottle is empty or the
hand valve on gas bottle is not opened.
Check the gas pipeline for gas leak.
Check the gas valve for being open.
2. The gas pressure is too low.
Check the solenoid cut-off valve is
work.
Check the air filter and gas intake system
3. There is no sufficient gas intake
for blockage and air leak.
4. The start-up rotating speed is too low
Check whether the battery voltage can
(the minimum start-up rotating speed is
reach 24V.
100r/min)
1. The engine
5. The intake and exhaust valve adjustment Check the valve clearance according to the
cannot be
is wrong operation manual for engine.
started
6. The engine control module (ECU) is
Replace the ECU.
damaged.
7. The melted connector clip of oxygen
Replace the oxygen sensor.
sensor causes short circuit.
Test the electronic throttle valve using
8. The electronic throttle valve is broken.
software.
Check the clearance between fluted disc
9. The velocity sensor is in fault.
and sensor.
10.MAP is broken. Check the MAP by sofeware.
Check the wiring harness is monted
11.Earth trap wire is loose.
firmly.
1. There is air leak in the air intake pipeline Check the air intake pipeline
2. The spark plug or ignition system is in Check the spark plug and high-pressure
fault line.
2. The idle
Check whether the pressure reducer
speed is 3. The pressure of gas metering valve is too
solenoid valve and gas pipeline are
unstable low
smooth.
Check or replace the electronic throttle
4. The electronic throttle is in fault
valve.
The blasting is mainly caused by the
secondary combustion of unburned gas in
exhaust pipe.
3. The exhaust 1. One or more cylinders do not work (for
pipe blasts example: ignition coil is broken; the wires
Check the spark plug、ignition coil and
in ignition coils of some cylinders are
wiring harness.
exchanged by mistake; the spark plug does
not work properly, etc.)
Table 5-1(continued)
Common Faults Possible Causes Fault Inspection and Treatment
2. The natural gas supplied is overthick or
Check the oxygen sensor and gas
overthin (the pressure reducer works
metering valve.
3. The exhaust improperly)
pipe blasts Check the ignition advance angle by
3. Overlarge phase difference in ignition
ignition rob and the clearance between
advance angle.
phase sensors.
1. The manual valve on natural gas bottle is
Check the gas bottle.
not fully opened.
Check whether the pressure reducer, gas
2. The gas pressure is too low.
pipeline and gas filter are smooth.
Check the spark plug、ignition cable and
3. The ignition system is in fault.
ignition coil
4. The engine is 4. The pressure reducer is out of order. Check the gas pressure.
under-powered Check the air filter and gas intake system
5. There is insufficient gas intake
for blockage and air leak.
6. Overlarge phase difference in ignition Check the ignition advance angle and the
advance angle.. clearance between phase sensors.
7. The clearance between gas intake and Check the valve clearance according to
exhaust valves is adjusted improperly the operation manual for engine.
8.the temperature of intake gas is high. Check the inter cooler and water tank .
1. The intercooler is cracked or the
connecting pipe of intercooler is loose or Check the air intake pipeline
is full of cracks
2. The manual valve on gas bottle is not fully
Check the gas bottle.
opened.
5. The vibration 3. The ignition system is in fault. Check the spark plug、oxygen
amplitude is 44. The pressure reducer is out of order
large (incomplete combustion due to the overhigh Regulate the pressure reducer.
oxygen concentration).
Carry out an overall inspection in accordance with the troubleshooting methods for fault
1, 2, 3 and 4 above.
Carry out an overall inspection in accordance with the troubleshooting methods for fault
1, 2, 3, 4 and 5 above.
6. The gas
Check whether the wires are connected
consumption is 1. The oxygen sensor is out of order.
securely and replace the oxygen sensor.
large
The methane content is low，check the
2.the component of gas is changed.
component of the gas source.
52
Appendix 1 Recommended Torque for Main
bearing Bolts of M11NG Series
1.1 Torque and method for tightening main bolts & nuts of engine
Table 1 Torque and Method for Tightening Main Bolts & Nuts
Repeated
Bolt Tightening torque (N²m)+re-tightening
Bolt designation times
specification angle (°)
allowable
70 N٠m +（90°±4°） (reach to 165 N٠m

,
Main bearing bolt M14-10.9 -230N٠m simultaneously) 2
, see figure1、
figure2
Connecting rod bolt M12³1.5-12.9 30 N٠m +（90°±5°） 0
Connecting rod bolt M10³1 （30±2）N٠m +（120°±5°）
30 N٠m +2³（120°±4°） (reach to 200
Cylinder head bolt M14-12.9 3
N٠m -300N٠m simultaneously)
30 N٠m +2³（120°±4°） (reach to
Cylinder head bolt M14-10.9 3
190-285N٠m simultaneously)
Flywheel bolt M16-10.9 （285～295）N٠m 2
Flywheel bolt M12³1.5-12.9 40 N٠m +（90°+60°） 2
Camshaft gear bolt M10×1.25-12.9 85 N٠m～90 N٠m 2
intake pipe bolt M10 （45～50） N٠m 2

Exhaust manifold
M10 （45～50） N٠m 2
bolt
Standard M6 bolt 8.8 8 N٠m
Sparking plug M14³1.25 （20～25）N٠m
Oxygen sensor M18³1.5 50 N٠m±5N٠m

Water temperature
M14³1.5 25 N٠m±5N٠m
sensor
Note:
① Indices value is allowable tolerance.
② Angle value shall be re-screwed angle after screwing to specified torque.
③ Value before angle value is the times for turn angle.
④ Strength grade of all bolts and nuts on the machine shall meet corresponding requirements.
Bolts and nuts in same specification and different strength grade shall not be wrongly
mounted and arbitrarily changed. Allowable times for repeated use shall not be exceeded,
otherwise serious consequences may be caused.
Figure 1-1 Tightening Sequence of Main Bolts for WP6
Figure 1-2 Tightening Sequence of Main Bolts for WP4

1. tightening process of cylinder head bolt
2. Tightening order of cylinder bolt：3-4-5-2-1-6
3. Tightening order of each cylinder bolt see figure 3
Figure 1-3 Tightening Sequence of Each Cylinder
54
1.2Recommended Torque for Standard Bolts was seen in follow table 1.
Table 2 Recommended Torque for Standard Bolts
Friction
0.125 (zinc plated) 0.14 (polished)
coefficient
Strength 6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
grade
Bolt size Recommended torque (N·m)
M4 2.3 2.7 3.8 4.6 2.4 2.9 4.1 4.9
M5 4.7 5.5 8.0 9.5 5.0 6.0 8.5 10
M6 8.0 9.5 13.0 16.0 8.5 10 14.0 17
M8 19 23 32 39 21 25 35 41
M10 39 46 64 77 41 49 69 83
M12 67 80 110 135 72 86 120 145
M14 105 125 180 215 115 135 190 230
M16 165 195 275 330 180 210 295 355
M18 225 270 390 455 245 290 405 485
M20 325 385 540 650 345 410 580 690
M22 435 510 720 870 465 550 780 930
M24 560 660 930 1100 600 710 1000 1200
M27 830 980 1400 1650 890 1050 1500 1800
M30 110 1350 1850 2250 1200 1450 2000 2400
0
M8×1 21 25 35 42 23 27 38 45
M10×1.25 41 49 66 82 44 52 73 88
M12×1.25 74 88 125 150 80 95 135 155
M12×1.5 70 83 115 140 76 90 125 150
M14×1.5 115 140 195 235 125 150 210 250
M16×1.5 175 210 295 350 190 225 315 380
M18×1.5 255 305 425 510 275 325 460 550
M20×1.5 360 425 600 720 385 460 640 770
M22×1.5 480 570 800 960 520 610 860 1050
M24×1.5 610 720 1000 1200 650 780 1100 1300
M27×1.5 890 1050 1500 1800 970 1150 1600 1950
M30×1.5 125 1450 2050 2500 1350 1600 2250 2700
0
Appendix 2 Q/WCQTG0007 “Specification of

Spark Plug Removal and Refitting of Weichai
Natural Gas Engine”
I. Scope
This specification stipulates the technical requirements regarding spark plug removal and
refitting of Baudouin series engines such as 4M11NG, 6M11NG, WP7NG, 6M16NG,
6M21NG, 12M26NG and ect.
II. Normative references
The following documents are indispensable for the application of this specification. For dated
references, only those dated references applies. For undated references, the latest edition
(including all amendments) applies.
GB/T20734-2006 Installation Requirements of Special Equipment of LNG Vehicle
QC/T755-2006 Technical Conditions of Special Equipment of LNG Vehicle
QWCQTG4.22-2010 Technical Specifications of Accessories of LNG Engine
III. Requirements and steps for removal and refitting of spark plug
1. Before removing spark plug
Before removing the spark plug, purge the cylinder head surface with an air nozzle or high
pressure air as far as possible.
Then remove the high-voltage coil (when removing the high-voltage coil, make sure to pinch
the head, do not pull the high-voltage coil body).
56
Please remove high-voltage
coil as shown
And then use an air nozzle or high-pressure air to purge water, stain or dust inside spark plug
sleeve.
2. Removal of spark plug

When removing the spark plug make sure the stem of spark plug wrench is perpendicular to
cylinder head surface.If it is hard to remove spark plug, please using instrument to increase
the length of arm of force.
Do not remove it forcedly when removing the spark plug, otherwise it may cause damage to
the spark plug nut and the fixed parts or spark plug thread remaining in the cylinder head.
Correct removal method: After starting the engine, heat the cylinder head, fill the penetrating
liquid into the threaded of the spark plug (CRC penetrating oil, etc.), five to ten minute later
and then remove it.
ATTENTION: CRC penetrating dust-removal oil

3060 is an industrial lubricating rust inhibitor
with low viscosity, which can remove the rust and
It is strictly forbidden to remove the ignition coil bushing and the pressing plate of ignition
coil bushing to prevent the spark plug bushing from turning and moving.
If the spark plug bushing has occurred when removing spark plug bushing, the spark plug
must be reset and rotate back to the initial state, and the ignition coil bushing clamp to verify
whether meet the installation torque (25~28Nm), complex tightly solid bolt after dismantled
if did not meet the requirements of installation torque.
If none of the above methods can be successful, the liner or cylinder head shall be replaced.
It is necessary to check the tightening torque regularly and decide whether to tighten it
according to the inspection result. The specific requirements are as follows:
For the newly launched vehicle, the first guarantee is check the tightening torque of the
ignition coil liner, and it needs to meet the requirements of (20 ~ 25) Nm. If it is not satisfied,
it needs the torque to be tightened. After the normal operation of the vehicle, the pressure
plate bolts should be checked and tightened during the first grade maintenance, and the
requirements need to be tightened.
The ignition system failure vehicle needs to check the ignition coil liner bolt tightening torque
when replacing the spark plug.
All complex tight operation should be in accordance with the following requirements
standardize operation: Firstly checking the spark plug twist moment whether meet the
requirements (25 to 28) Nm, and the spark plug should be tightened to the required torque
range if not meet, and try to ensure that the two bolt screwing in depth are equal,Checking
whether lack of antifreeze, at the same time also need to remove the spark plug again.
Checking whether impurity or liquid inside the cylinder, if not , installing the spark plugs
accordance to specification.
As long as remove the clamp bolts to loosen bolts or other external forces of bolts should be
removed and the thread end daub glue in all operations, according to the requirements of the
torque range after screw down the bolt.
3. Cleaning of spark plug

Keep the spark plug dry and clean: Before installing, remove the stain or dirt on the ceramic
body with a clean cloth or facial tissue.
For stubborn rust or stain, you can gently polish away it with sandpaper.
4. Cleaning of spark plug wrench

When installing the spark plug, make sure that the wrench sleeve is clean and dry.
58
Before installing, remove the stain or dirt in the spark plug wrench sleeve with a clean cloth
or facial tissue! See the figure below.
5. Keep the cylinder head spark plug mounting hole dry and clean
Use a clean cloth to remove the oil/water stains and other dirt in the cylinder head spark plug
mounting hole.
6. Spark plug clearance adjustment

Adjustment method: If the clearance is wide, insert the feeler gauge into the clearance, and tap
the corner of the side electrode gently with a small wrench; if the clearance is narrow, widen
the clearance slowly with a vise, insert the feeler gauge, and then gently tap the side electrode
with the wrench!
Spark plug clearance: 0.35±0.05mm (must be adjusted with a feeler gauge);
ATTENTION: Make sure that the side and center electrode faces are parallel!
Here to be
parallel
7.Refitting of spark plug

After cleaning, pinch the spark plug thread, insert the spark plug wrench or high voltage coil,
and then install it with the spark plug wrench.
Do not throw the spark plug directly into the spark plug mounting hole.
60
Strictly
forbidden
When installing, keep the instrument and other part of engine from touch with the outer
electrode, so as not to change the spark plug clearance!
Insert the spark plug as

shown here
ATTENTION: Do not touch the spark plug ceramic body to prevent the production of
flying arcs!
The flying arcs produced
Tighten the spark plug: the spark plug installation torque: 25-28 Nm. When installing with a
torque-free wrench, rotate the wrench for 90 degrees after the new spark plug thread is
screwed to the end; for the spark plug installed for the second time, rotate the wrench for 15
degrees after the thread is screwed to the end.
8.After tightening the spark plug, insert the high-voltage coil, and tighten the
high-voltage coil anti-fouling cap onto the sleeve mounting hole.
Tighten the anti-fouling
cap onto the sleeve
Appendix 3 Correction Coefficient Of Power

of Engine
The power of the gas engine decrease very little under the altitude of 1000 meters. It is not
necessary to adjust. When the engine work at the altitude above 2000 meters，the power of
the engine or generator will decrease sharply because of the loss of air intake and the
speed limit of the turbocharger . It need to correct. And the correction oefficient table is as
follow：
Table1 The derating power table for ambient and altitude

50 0.97 0.97 0.97 0.97 0.96 0.93 0.9 0.87 0.84 0.81 0.79 0.77 0.74
45 0.98 0.98 0.98 0.98 0.98 0.98 0.92 0.89 0.86 0.83 0.81 0.78 0.75
40 0.99 0.99 0.99 0.99 0.99 0.98 0.95 0.91 0.89 0.86 0.83 0.8 0.77
Ambient
35 1.00 1.00 1.00 1.00 0.99 0.99 0.97 0.94 0.91 0.88 0.85 0.82 0.80
30 1.00 1.00 1.00 1.00 0.99 0.99 0.99 0.96 0.92 0.90 0.87 0.84 0.81
℃
25 1.00 1.00 1.00 1.00 0.99 0.99 0.99 0.97 0.94 0.91 0.88 0.85 0.82
20 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.99 0.96 0.93 0.90 0.87 0.84
15 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.97 0.94 0.91 0.88 0.85
10 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.96 0.93 0.90 0.87
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
62
Appendix 4 Correction Coefficient Of Power
of Engine
Table2 Fuel rate table forambient and altitude
50 1.1 1.1 1.11 1.125 1.125 1.14 1.14 1.15 1.15 1.15 1.15 1.15 1.175 1.175
45 1.05 1.05 1.075 1.075 1.075 1.1 1.1 1.1 1.1 1.15 1.15 1.15 1.175 1.175
40 1.025 1.025 1.05 1.05 1.05 1.075 1.075 1.075 1.1 1.1 1.1 1.15 1.15 1.15
Ambient
35 1.015 1.015 1.025 1.025 1.025 1.025 1.025 1.05 1.05 1.05 1.075 1.075 1.1 1.15
30 1.01 1.01 1.015 1.015 1.015 1.015 1.025 1.05 1.05 1.05 1.05 1.05 1.075 1.1
℃
25 1 1 1 1.015 1.015 1.025 1.025 1.05 1.05 1.05 1.05 1.05 1.075 1.1
20 1 1 1 1.01 1.01 1.01 1.015 1.025 1.025 1.025 1.05 1.05 1.05 1.075
15 0.995 0.995 0.995 1.005 1.005 1.005 1.01 1.015 1.025 1.025 1.025 1.05 1.05 1.075
10 0.99 0.99 0.99 1 1.005 1.005 1.005 1.01 1.025 1.025 1.025 1.05 1.05 1.075
0 250 500 800 1000 1200 1400 1600 1800 2000 2200 2500 2800 3000
Note：the consumption of gas in above tables aimed to natural gas（12T gas according to GB
10847），if the fuel is methane or CBM or others ，the data of correction coefficient in above
tables were as a reference

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Operation & Maintenance Manual for

M11NG Series Gas Engine

4M11 Series Gas Generators

6M11 Series Gas Generators

Any user’s comments and suggestions are always welcomed.

Precautions before maintenance and repair

1.2 Outline of 4M11NG series gas engine ....................................................................................................... 10

1.3 Outline of 6M11NG series gas engine ....................................................................................................... 13

3.2 Lifting of natural gas engines .................................................................................................................... 29

3.3 Installation of the natural gas engine ......................................................................................................... 29

3.5 Engine starting ........................................................................................................................................... 31

3.6 Engine operating ........................................................................................................................................ 32

3.9 Environmental conditions .......................................................................................................................... 34

4.3 Regular maintenance of the engine ............................................................................................................ 40

5.2 Common faults and trouble removal.......................................................................................................... 50

II. Normative references .................................................................................................................................. 56

Chapter 1 Product Technical Overview

1.2 Outline of 4M11NG series gas engine

Figure 1-1 Outline of 4M11NG series industrial engine

Figure 1-2 Outline of 4M11NG series industrial engine

Figure 1-3 Outline of 4M11NG series industrial engine

1.3 Outline of 6M11NG series gas engine

Figure 1-4 Outline of 6M11NG series industrial engine

Figure 1-5 Outline of WP6NG series industrial engine

Figure 1-6 Outline of 6M11NG series industrial engine

1.4 Main technical parameters of WP6/WP4NG Series Natural Gas G-Drive

Engine model 4M11G4N0/5 4M11G4N0/6

Intake type Supercharged inter-cooling

Engine model 6M11G4N0/5 6M11G4N0/6

Intake type Supercharged inter-cooling

Rated power（kw） 120 120

Overlond power / 132

Generator unit power 100 100

Rated speed (r/min) 1500 1800

In-line, water-cooling, dry sleeve, proportional mix, sparking plug

Ignition sequence 1-5-3-6-2-4

Minimum fuel consumption

Cylinder diameter/stroke (mm) 105x130

Number of air valves per cylinder 2

Displacement (L) 6.75

Thermostat opening temperature Opening begins at 70℃, and in full at 95℃

Engine oil grade Special engine oil 15W/40CF

Engine oil pressure (kPa) 300～600 (absolute value)

Idling engine oil pressure (kPa) ≥120 (absolute value)

Crankshaft rotation direction

Net weigit 620±50

Chapter 2 Natural Gas Engine Control System

Installation requirements and operating instructions:

Figure 2-2 Engine wiring harness

Working voltage: 24V;

Working environment: -40℃～105℃;

Figure 2-3Engine control unit

1.Applicable pressure: 20 kPa～300kPa；

2.Applicable temperature: -40℃～130℃

Figure 2-4T/MAP sensor

2.1.5 Camshaft signal sensor

Figure 2-5 amshaft signal sensor