Engine Repair Manual

MC11 Series

SINOTRUK

Spanis
h
SINOTRUK
Engine maintenance manual
MC11 series diesel

China National Heavy Duty Truck Group Co., Ltd. (Sinotruk)

December 2012
 MC11 Series Diesel Engine Maintenance Manual
PREFACE
This manual helps to correctly carry out the maintenance of the engine assembly, which describes all the
technical information that has been published up to the date of publication. The diagrams and related
instructions in this manual are typical momentary records and do not necessarily match the engine assembly
or its peripherals for maintenance.
Personnel using this manual must have the necessary professional experience in maintaining the vehicle and
engine assembly.
The bolt specification method in this manual is: M nominal diameter (× fine pitch) × length - performance level,
for example, M8 × 40-10.9 means the nominal diameter is 8mm, standard pitch, the length is 40mm and the
performance rating is 10.9 bolts. M8×0.75×40-8.8 means nominal diameter is 8mm, fine pitch is 0.75m, with
length 40mm, performance rating is 8.8 bolts.
In this manual, maintenance tools and process tools have two numbering, for example the numbering of
piston ring clamping tool are: JD6805-0018 and 80.99602-0016, the first one is SINOTRUK tool numbering,
this Last is the MAN company tool numbering, to facilitate service stations to purchase and use them
according to their own needs.
Maintenance operations are divided into chapters and sections. Necessary work prerequisites are listed on
the main page of each section. These work prerequisites contain important provisions regarding the described
maintenance procedures, which may be followed by detailed work instructions.
Important notes related to technical safety and personal safety will be highlighted, as highlighted below.
Attention
Type and source of danger
• They relate to work procedures and operating methods that must be followed to avoid
endangering personal safety.
Attention
Type and source of danger
• They relate to work procedures and operating methods that must be followed to avoid
damaging or destroying materials.
Warning
Explanatory notes to understand the work procedures and operation methods to be carried out.

Pay attention to general safety regulations in all maintenance work.

This manual was prepared by Sinotruk Leading Marketing and Product Service Training Group.
Main editor: Zhang Xiaodong
Lead Reviewer: Jiang Ailiang
Reviewed by: Li Wenge
Editor: Yang Biao Zhu Ping Zhang Zongyuan Liu Bin
Thanks to all units of the Group, especially the technology development center and the Jinan Department of
Energy for their support and great help given to the book, our sincere thanks!
Due to the rush of time, it is inevitable that there will be errors in the manual. I also hope that readers will
submit valuable opinions!
The final interpretation of this manual belongs to Sinotruk.
Security instructions
Generality
Only trained personnel can carry out use, maintenance and repair work on the trucks. Hazard warnings are
marked in the relevant descriptions of possible hazardous locations.
If an accident still occurs after taking all safety precautions, you should immediately seek help from your
doctor. The main reasons for these accidents are: Contact with corrosive acid, fuel intrusion into the skin, hot
oil burns, antifreeze spray in the eyes and compressed limbs etc.
1. Provisions to avoid personal injury accidents
1) Inspection, adjustment and maintenance
- Take protective measures for the engine assembly during disassembly.
- Support is required when operating on a pneumatic spring or spring device or frame.
- There should be no grease on the motor assembly, ladders, connecting plates and around it.
- Only use tools that work well.
- Inspection, adjustment and repair work is only permitted by authorized professionals.
 MC11 Series Diesel Engine Maintenance Manual
2) Engine operation
- Only authorized personnel may start and run the engine.
- When the engine is running, do not get too close to rotating parts and wear tight-fitting overalls.
- Avoid the danger of burns when working near the engine during high temperatures.
- There is a risk of burns when the cooling circulation system is turned on in a hot car.
3) Lifted heavy objects
- Personnel cannot remain under the suspended weight.
- Use only appropriate and well-functioning lifting equipment, and the load handling device must have
sufficient load capacity.
4) Work related to high pressure pipes
- Do not retighten or open the pipe or hose (lubrication circuit, coolant circuit or hydraulic oil circuit) in the
working state:
Pressurized liquid spray can cause personal injury!
5) Inspection of the oil injector nozzle
- Wear appropriate protective equipment
- When testing the oil injector nozzle, do not place the body part under the fuel sprayer
- Do not inhale fuel mist, maintain adequate ventilation
6) Work related to automotive electrical equipment
- Never remove the battery cable while the engine is running!
- When operating on automotive electrical equipment, central electrical equipment, generators and
starters, be sure to remove the battery cable. When removing the battery cable, first remove the cable
from the negative terminal. When you connect it, first install the positive terminal wire.
- Use only suitable inspection lines or test adapters when making measurements at plug connections!
- When the temperature may exceed 80°C, turn the main battery switch to the "off" position, then
disassemble the EDC.
7) Welding
- When performing welding operation, you should remove the battery terminal wire, and make a fixed
connection of the positive wire and the negative wire (conductive). Otherwise, it may damage the
engine's electrical equipment, such as EDC.
- After the welding work is finished, first turn off all electrical appliances, remove all wiring (restore to
original state), and then connect the battery.
- In any case, the ground connection of the welding device should be as close to the weld as possible.
When laying the wiring of the welding device, it should not be parallel to the car cables.
8) Work to be done when having the cabin plastered
9) Leave a tipping area in front of the cab.
10) Do not stand between the cab and the chassis during the tipping process. This is a dangerous area!
11) The cab must be tilted over the inflection point, or with an effective support bar it will be
You can take security measures for the cabin.
2. Tips to avoid damage to the engine assembly and premature wear
1) Generality
- The motor assembly may only be used for applications that are compatible with the scope of supply
(specified by the component manufacturer and in accordance with the regulations), and any use outside
the intended scope will be considered a violation of the regulations. The manufacturer will not be
responsible for any damage caused, all related risks will be borne by the user.
- Use in accordance with regulations also includes compliance with the operating conditions and
maintenance conditions specified by the manufacturer.
- The engine assembly may only be used, maintained and repaired by personnel familiar with it and who
understand the risks involved.
- If you make a change to the engine yourself, the manufacturer is not responsible for the damage caused.
- Adjusting the fuel delivery system hardware and software will also affect the
power characteristics and exhaust emission characteristics of the engine assembly, so compliance with
legal environmental protection obligations will no longer be guaranteed.
- In the event of a failure, the cause must be identified and eliminated immediately.
- Carefully clean the engine assembly before servicing, which should be noted: For all openings that do not
allow contaminants to enter for safety and functional reasons, they must be closed and locked.
- Never let the engine run without oil or coolant.
 MC11 Series Diesel Engine Maintenance Manual
- Engine assemblies that are not ready for operation must be marked with a sign.
- Observe the specified maintenance intervals.
- Do not exceed the maximum and minimum fill mark when filling engine oil.
- The engine must operate without exceeding the maximum allowable tilt angle.
3. Limitation of liability for spare parts and accessories
For engines produced by SINOTRUK, only original accessories and accessories approved by SINOTRUK are
allowed to be used, otherwise SINOTRUK "Three Guarantees" service will not be available.
4. Provisions to avoid damage to health and the environment
1) Preventive measures to protect health
Avoid prolonged skin contact with various oils. Protect skin with appropriate protection (e.g. gloves).
2) Operating materials and auxiliary operating materials
Food containers or beverage containers should not be used when discharging or storing various oils.
3) Cleaning the air filter element
When blowing cleaning the filter element, be careful that the dust on the filter is sucked through the suction
device or collected in the dust collection bag; Otherwise, the respiratory protection device should be used.
When cleaning the filter element, it should be protected with rubber gloves or hand cream, since the detergent
has a strong grease solvency.
4) used engine oil
Prolonged or repeated skin contact with any type of motor oil can cause degreasing from the skin and may
result in dry skin, skin irritation or dermatitis. In addition, used motor oils also contain harmful substances that
can cause serious skin diseases. Wear gloves when changing the oil.
5. Working Tips of High Pressure Common Rail Injection System
1) Generality
- High pressure fuel can cause harm to humans. There is a risk of fire in atomized fuel.
- When the engine is running, do not loosen the threaded pipe joint on the high pressure side of the high
pressure common rail fuel injection system (high pressure pipe route: From high pressure pumps to duct
assemblies (from common duct assemblies to injectors). During engine operation, the fuel pressure in
these pipes remains at 1800 bar or more. Wait at least one minute before loosening the threaded
connection until the pressure is relieved, and if necessary, check the pressure relief in the common rail
assembly with a SINOTRUK special diagnostic tool.
- When the engine is running, do not touch the conductive parts of the rotating parts and electrical
connections of the engine.
2) Risk of damage from contaminant intrusion
- Extremely high cleanliness must be maintained when servicing high-pressure common rail fuel injection
systems, as the components of the diesel injection system are composed of high-precision parts that are
subjected to extremely high loads.
- Contaminant particles exceeding 0.002 mm can already cause component failure.
3) Before repairing the fuel supply system
- The fuel supply system must be turned off before cleaning the engine. Do not use strong water flow to
clean electrical components.
- Take the car to a clean area in the repair shop where dust-causing work (grinding, welding, brake repair,
brake inspection and power check etc.) cannot be carried out.
- Air movement in this clean area should be avoided as much as possible (when the engine starts, the
workshop ventilation system/heating system is running, there is wind in the building etc. they can stir up
dust).
- Before learning the fuel supply system you must clean and blow out the components of the fuel supply
system with compressed air.
- In areas where contaminant particles may fall, such as an overturned cab, cover with new clean film.
- Wash your hands and put on clean overalls before starting maintenance work.
4) When repairing the fuel supply system
- The tool must be cleaned first before starting work and only non-destructive tools are allowed (note
cracking of the chrome layer).
- During the disassembly process, the appropriate suction device, such as a vacuum cleaner, should be
used to clean contaminants. Do not use compressed air to clean.
- Only lint-free cleaning cloths are permitted for repairs. Materials such as towels, cardboard or wood are
not permitted as these materials will disperse particles and fibers.
- If paint separation occurs when the joint is loosened, the paint separation must be completely eliminated
 MC11 Series Diesel Engine Maintenance Manual
before loosening the joint.
- To remove fuel delivery system components, immediately use a suitable clean sealing cap to close the
fitting connection opening. And they should be stored carefully in a clean, sealed container.
- New parts should be used immediately after they are removed from the original packaging.
- Repair work for parts that have been removed must be performed at a station
dedicated.
- If shipping a removed part, be sure to use the original packaging of the new part.
5) Operations that prevent contaminants from entering the fuel system
- Before learning the fuel supply system, with compressed air clean the area around high pressure oil pipe
connector, fuel injection pipes, common rail assembly and valve chamber cover.
- After removing the valve chamber cover, the joint of the high-pressure oil pipe, the fuel injection pipe and
the surrounding area of the common rail assembly should be cleaned again.
- The high pressure oil pipe connector can only be completely disassembled after the injector and line have
been removed to prevent dirt from entering the injector and line.
- When cleaning the injector, the high pressure connection hole of the injector should face downward to
prevent contaminants from entering.
6. Emergency drive program for engine assembly
General indication
The engine assembly has an EDC which is a system that monitors the engine assembly and itself (EDC
diagnostic system).
In case of failure, the following actions are automatically taken based on the failure evaluation:
- A fault alarm signal containing the fault code is output.
- Transfer it to a suitable alternative function state in which execution can continue,
but the operation is limited and the fault must be eliminated immediately.
- Connect to Sinotruk special diagnostic tool to directly send the fault code.
7. Assembly notice
1) Pipe assembly
- Do not subject the pipe to mechanical deformation or breakage during assembly.
2) Assembly of seal parts
- Only use original Sinotruk seal parts.
- The sealing surface must be clean and undamaged.
- Do not use sealants or adhesives - to simplify the assembly operation, lubricating grease can be used if
necessary to allow the seal piece to adhere to the part to be mounted.
- Tighten the bolts evenly using the specified tightening torque.
3) Engine inspection and repair
- Engine life is affected by many factors and it is impossible to predict when to overhaul the engine. If the
engine exhibits good performance and the following operating parameters are not significantly abnormal,
there is no need to open the engine or carry out heavy repair:
♦ Boost pressure;
♦ Temperature of gasofexhaust;
♦ Temperature of refrigerant and lubricant oil;
♦ Oil pressure and oil consumption;
♦ Smoke level.
 Manual de mantenimiento del motor diesel de la serie MC11
MC11 Series Diesel Engine Maintenance Manual
Index

Engine maintenance manual MC11 series diesel.....................................................................................2

Chapter I Introduction of MC11 Engine...............................................................................................1
Chapter II Disassembly and assembly of series engine components....................................................6
MC11.....................................................................................................................................................6
TO...........................................................................................................................................................89
TO.........................................................................................................................................................133
Accessories........................................................................................................................................265
 MC11 Series Diesel Engine Maintenance Manual
Chapter I Introduction of MC11 Engine
SECTION I ENGINE OVERVIEW
The MC11 engine technology is completely derived from the MAN D20 engine, a newly designed engine introduced by
German MAN company in 2004, adopting the design concept of torque rise instead of power increase, a modular design, It
has good fuel saving performance and high reliability, excellent performance, light engine weight and low fuel consumption.
The emission level has reached the Euro V standard.
I. Crankcase
The crankcase is made of vermicular iron. The structure features a deep skirt design that gives the crankcase strong rigidity.
The cross member structure at the bottom of the front and rear ends of the crankcase provides a sealing surface for the oil
pan.
The main bearing cap is manufactured by a breaking process. The rough rising section can produce high lateral support
effect and achieve precise positioning; It is beneficial to reduce the wear of the bearing cover and improve its service life.
The cylinder sleeve is suspended on the top of the cylinder bore, it is a wet cylinder sleeve. The water jacket is sealed at the
lower edge of the cylinder sleeve by two O-rings mounted in the crankcase. There are seven main bearings in the body, all
the same width. Thrust washers are placed on each side of the sixth main bearing seat.
II. Crankshaft
The crankshaft is a piece made of forged steel with 7 main shaft necks and 4 counterweights. A radial hole is machined in
the circumferential surface of the counterweight for final balancing of the crankshaft; A silicone oil damper is mounted at the
front end of the crankshaft, and the whole structure has high strength and rigidity.
III. Connecting rod
The rising connecting rod is precisely forged in the mold, through the surface structure formed by the breaking process can
make the meshing effect between the connecting rod cap and the connecting rod body more precise and with higher quality.
stable, and avoids confusion during assembly, achieving high coupling precision and lateral stability.
IV. Piston
The built-in oil-cooled channel piston with forced cooling is made of a new material resistant to higher heat load, the small
end of the connecting rod has a wedge-shaped structure, which increases the strength of the piston.
There are two gas rings and a scraper ring on the piston. The first gas ring is a double-sided trapezoidal barrel surface ring
and the working surface is PVD coated, which is beneficial to the rolling and anti-texturing and anti-wear effect, ensuring
good adhesion and heat transfer. The second gas ring is a chrome plated conical ring. The third ring is a spring alloy oil ring
with a double-edged surface, and it has strong oil scraping ability.
V. Butt
The cylinder head is designed with an integral type overhead camshaft, cast from gray cast iron. The intake manifold is
integrated into the cylinder head, reducing the sealing parts. It adopts a 4-valve intake and exhaust system. The four-valve
design of each cylinder makes the injection distribution more uniform and the aeration coefficient higher, which effectively
reduces emissions. The intake and exhaust passages in the cylinder head are distributed on both sides. According to the
requirements of direct injection combustion system, the intake passage generates a certain eddy current. The convex
injector mounting plate is cast in the cylinder head, which is very beneficial to improve the heat dissipation of the injector and
improve the operating reliability of the injector. The cooling water side flow mode is a reasonable design and has good
cooling effect. SAW. Camshaft
The camshaft is cross-laminated by a steel wedge and subjected to case-hardening and cooling. It is placed on the
camshaft shaft cover in the cylinder head and has seven support points. The drive of the camshaft is carried out by a
cylindrical gear on the flywheel side.
VII. Engine lubrication
The lubrication system is pressure lubricated by the oil pump. Crankcase ventilation, oil cooling and oil filtration functions are
integrated into the oil filter module. The crankcase ventilation adopts a cyclone structure without additional maintenance
costs; The oil filter element adopts a metal-free structure design, which can be completely incinerated after replacement,
and will not pollute the environment. Maintenance costs are lower compared to traditional metal filter elements. VIII. Cooling
system
The MC11 series engine cooling circuit is a thermostatically regulated forced circulation cooling system, using V-ribbed belt
driven cooling water pump. The thermostat is replaceable and contains paraffin-sensitive thermal expansion material. All
vehicle engines use a silicone oil bimetallic fan. The fan is driven by the crankshaft front end gear (maintenance free), it is a
ring-shaped plastic fan with a diameter of Ф704mm/Ф750mm.
The expansion tank can remove steam in the low pressure part of the cooling system, and will not cause gas resistance, but
also can supplement the cooling water. The pressure in the expansion tank is maintained at approximately 75+20 kPa.
IX. Intake/exhaust device
The three-section exhaust manifold is made of high temperature resistant ductile iron with multiple metal seal rings between
the exhaust manifolds for effective sealing; In the central exhaust manifold, an exhaust turbocharger is equipped with a
radial flow bleed valve, the supercharged air enters the engine cooled by the internal cooler. After the turbocharger, the
engine brake disc valve is equipped in the exhaust pipe to improve the engine braking efficiency with the engine.
X. Fuel system
The fuel system is divided into two parts: a low pressure part and a high pressure part. Fuel lines, manual oil pumps and fuel
filters are from the low pressure system. The fuel module guarantees the fuel quality required by the common rail system. In
addition, the low pressure system also includes the heating unit and flame preheating device. The fuel pump is the interface

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 MC11 Series Diesel Engine Maintenance Manual
that connects the high pressure system.
The high pressure system consists of a high pressure pump with adjustable flow, high pressure oil lines and a common rail
pressure pipe with a common rail pressure sensor and a pressure limiting valve.
In the high pressure system, the setting of the injection pressure is independent of the fuel injection. The injection pressure
is generated by the high-pressure oil pump, regardless of the engine speed and the required injected fuel quantity. The high
pressure oil pump delivery is regulated by a proportional valve. The injection time and fuel injection quantity are calculated in
the engine control unit (EDC) and executed by the solenoid valve controlling the injector.
XI. engine brake system
The MC11 series motors standardly equip the EVB device. Compared with conventional engine throttle valve braking, the
braking efficiency of EVB is increased by 60%. A hydraulic piston and a pressure relief hole are installed on the exhaust
valve shaft. The hydraulic piston is subjected to engine oil pressure, and the oil pressure is released through the pressure
relief hole. There is a reversing bracket on the valve shaft. When the exhaust valve is closed, the pressure receiving piece
on the reversing bracket closes the pressure relief port. When the valve is opened, the pressure relief hole opens and the oil
pressure in front of the hydraulic piston is removed. If the engine brake is closed against the force of the torsion spring by
the action of the follower cylinder, a pressure wave is established in the exhaust pipe, causing the exhaust valve to open
again for a short period of time. time. In other words, the exhaust valve will open again for a short period of time after each
shutdown. The hydraulic pistons that are subject to oil pressure are pushed by the jumping piston for a short time. As the
reversing bracket closes the pressure relief hole and the one-way valve closes the oil supply hole, the hydraulic piston
cannot be returned. Therefore, in the compression stroke and subsequent working stroke, the exhaust valve remains in the
open state, which increases the braking power of the engine.
XII. Starting motor
The starter motor is a direct current type starter motor, controlled by electromagnetic, gear driven and transmits torque in the
form of friction plate type unidirectional device. Rated power is 5.5 kW.
XIII. Generator
The generator has a nominal voltage of 28V with a transistor regulator. The generator works in parallel with the battery in the
car. The generator is automatically energized during operation. The speed of the generator is 4 times the speed of the
engine.

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 MC11 Series Diesel Engine Maintenance Manual
SECTION II MAIN TECHNICAL PARAMETERS OF MC11 SERIES MOTOR
TABLE 1-1 MAIN TECHNICAL PARAMETERS OF MC11 SERIES NATIONAL LEVEL III MOTOR
machine model
Number Items Unit
MC11.43-30 MC11.39-30 MC11.35-30 MC11.31-30
1 Number of cylinders 6
2 Cylinder diameter mm 120
3 Route mm 155
Number of valves in each
4 4
cylinder
5 Total displacement l 10.518
6 Compression ratio 19:1

7 Maximum rated net power kW 316 287 257 228

8 Rated rotation speed rpm 1900

9 maximum torque Nm 2100 1900 1750 1550

10 Maximum torque rotation rpm 1000～1400

speed

11 Minimum fuel consumption g/kWh ≤186

rate of full power test

Fuel consumption rate in the

12 g/kWh ≤210
nominal operating state

13 Maximum rotation speed rpm 2150±20

without load
Idle rotation speed
14 rpm 550±50

15 Firing order 1－5－3－6－2－4

Intake valve interval (cold mm 0.5±0.03
state)
16
Exhaust valve range (cold mm 0.8±0.03
state)
17 EVB adjustment range (cold mm 0.6±0.03
state)
18 Lubricating oil pan capacity l 40

19 Net quality (not including kg 975

post-processing part)
20 Clockwise (from free end)
Crankshaft rotation direction
Maximum allowable engine
21 rpm 2400
brake speed

Cold start without

preheating of -20
admission
22 ℃

Cold start (with air intake -40

preheat)
Angle of inclination ° 15
maximum (lateral)
23
Angle of inclination
° 15
maximum (longitudinal)

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 MC11 Series Diesel Engine Maintenance Manual
Table 1-2 Main technical parameters of MC11 series national level IV motor
machine model
Number Items Unit
MC11.44-40 MC11.40-40 MC11.36-40 MC11.32-40
1 Number of cylinders 6
2 Cylinder diameter mm 120
3 Route mm 155
Number of valves in each
4 4
cylinder
5 Total displacement l 10.518
6 Compression ratio 19:1
235
7 Maximum rated net power kW 324 294 265

8 Rated rotation speed rpm 1900

1600
9 maximum torque N·m 2100 1900 1800

10 Maximum torque rotation rpm 1000～1400

speed

11 Minimum fuel consumption g/kW·h ≤186

rate of full power test
Fuel consumption rate in the
nominal operating state
12 g/kW·h ≤210

13 Maximum rotation speed rpm 2150±20

without load
14 Idle rotation speed rpm 550±50

15 Firing order 1－5－3－6－2－4

Intake valve interval (cold mm 0.5±0.03
16 state)
17 Exhaust valve range (cold mm 0.8±0.03
state)
17 EVB adjustment range (cold mm 0.6±0.03
state)
18 Oil bottom casing volume l 40

19 Net quality (not including kg 975

post-processing part)
20 Clockwise (from free end)
Crankshaft rotation direction
Maximum allowable engine
21 rpm 2400
brake speed

start cold
(without -20
air intake preheat)
22 ℃

Cold start (with air intake -40

preheat)
° 15
Maximum tilt angle (lateral)
23
Maximum tilt angle
° 15
(longitudinal)

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 MC11 Series Diesel Engine Maintenance Manual
Table 1-3 Main technical parameters of MC11 series V national level motor
machine model
Number Items Unit
MC11.44-50 MC11.40-50 MC11.36-50 MC11.32-50
1 Number of cylinders 6
2 Cylinder diameter mm 120
3 Route mm 155
Number of valves in each
4 4
cylinder
5 Total displacement l 10.518
6 Compression ratio 19:1
235
7 Maximum rated net power kW 324 294 265

8 Rated rotation speed rpm 1900

1600
9 maximum torque N·m 2100 1900 1800
Maximum torque rotation
10 speed rpm 1000～1400
Minimum fuel consumption rate
of full power test
11 g/kW·h ≤186

Fuel consumption rate in the

12 nominal operating state g/kW·h ≤210

13 Maximum rotation speed rpm 2150±20

without load
Idle rotation speed
14 rpm 550±50

15 Firing order 1－5－3－6－2－4

Intake valve interval (cold mm 0.5±0.03
16 state)
17 Exhaust valve range (cold mm 0.8±0.03
state)
17 EVB adjustment range (cold mm 0.6±0.03
state)
18 Oil bottom casing volume l 40

19 Net quality (not including post- kg 975

processing part)
20 Clockwise (from free end)
Crankshaft rotation direction
Maximum allowable engine
21 rpm 2400
brake speed
start in cold
(without -20
preheating of the
22 air intake) ℃
start in cold (with
preheating of the -40
air intake)
15
Maximum tilt angle (lateral)
23 °
Maximum tilt angle
15
(longitudinal)

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 MC11 Series Diesel Engine Maintenance Manual
Chapter II Disassembly and assembly of series engine components
MC11
SECTION I ELECTRICAL COMPONENTS
1. Sensor

Fig. 2-1 Engine sensors

1 Oil Pressure Sensor 2 Intake Air Temperature Pressure Sensor 3 Water Temperature Sensor 4 Camshaft
Signal Sensor
5 Speed sensor 6 Common rail pressure sensor 7 Fuel pressure sensor
1. Technical data
Name Specification Technical
requirements
Engine oil pressure sensor M18×15 45+5Nm
Air intake temperature and pressure M4×14 2~5Nm
sensor
Water temperature sensor M16×15 45+5Nm
Camshaft signal sensor M6×16 8-10Nm
Speed sensor M6×12 8-10Nm
Common rail pressure sensor M18×15 70Nm
2. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified tightening
torque value.
• Final tightening must be done manually with a torque wrench.

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 MC11 Series Diesel Engine Maintenance Manual
II. Electronic control unit (EDC)

Fig. 2-2 Electronic Control Unit (EDC)

1. Bracket mounting bolt 2. EDC mounting bolt 3. Electronic control unit (EDC) 4. Electronic control unit support
1. Technical data
Name Specification Technical parameters
Mounting bolts (2) M6×30-10.9 10±2Nm
Bracket mounting bolts (1) M8×40-10.9 12-14Nm
2. Auxiliary accessories
Loctite 270
3. Important information
Warning
/ !\ Improper tightening of the connecting bolts can cause damage to the
components.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• Final tightening must be done manually with a torque wrench.
Grades
UH} After installing the engine, you must reconfigure the engine control unit parameters.
engine and delete the error storage log.

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 MC11 Series Engine Maintenance Manual
4. Disassembly of the engine control unit
Disengagement he connection connector
electrical engine control unit

Unscrew the mounting bolt (1)

Remove the bracket (3) together with the
rubber washer (2)

• Disconnect the cable band (3)

• Open completely and remove the electrical
connection connectors (1) and (2)
Removal of the engine control unit

• Unscrew the mounting bolt (2)

• Removal of engine control unit (1)
Removing the engine control unit bracket

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 MC11 Series Engine Maintenance Manual
5. Mounting the engine control unit Mounting
the engine control unit bracket

• Apply a thin coat of Loctite 270 to the threads

of the new mounting bolt (1)
• Locate the bracket (3) along with the rubber
washer (2)
• Screw in the mounting bolt (1) and tighten it
to 12-14 Nm
Engine control unit assembly
Warning:
The engine control unit may have
irrecoverable damage When installing the electrical connection
connector, first fully open the latch and
then insert and lock the electrical
connection connector
Insert and lock the electrical connection connector
(1) and (2) into the engine control unit
Adjust the harness wiring and tie it with a cable tie
(3)

• Positioning of the engine control unit (1)

• Screw in the new mounting bolt (2) and tighten it diagonally to 10±2 Nm
Connect the electrical connection connector of the engine control unit

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 T MC11 Series Engine Maintenance Manual
SECTION
O
II C OOLING SYSTEM

Fig. 2-3 Cooling system piping

1. Curved cooling water pipe 2. Cooling water pipe 3. thermostat housing

Fig. 2-4 Cooling system layout diagram

1. Water pump 2. Distribution housing

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 MC11 Series Engine Maintenance Manual

YO. Fan

Fig. 2-5 Fan

1. Silicone oil clutch 2. Fan 3. Fixing bolt 4. fan support
1. Technical data
Name Specification Technical parameters
Fixing bolts (3) M8×1.25 22Nm
2. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• The angle must be done manually with a torque wrench.

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 MC11 Series Engine Maintenance Manual
3. Disassembly of the fan Dismantle the fan

• Unscrew the fixing bolt (1)

• Remove the fan (3) from the fan bracket (2) • Mount the fan (3) to the fan bracket (2)
Silicone Oil Fan Clutch Disassembly • Screw in the new retaining bolt (1) and tighten it

• Unscrew the fixing bolt (2)

• Remove the silicone oil fan clutch (1) from the
fan (3) according to the forward direction
4. Fan assembly
Silicone Oil Fan Clutch Assembly

• Mount the silicone oil fan clutch (1) from the front
end surface to the fan (3)
• Screw in the retaining bolt (2) and tighten it to a
torque of 22 Nm.
Fan assembly

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 TO MC11 Series Engine Maintenance Manual
II. fan support
1. Additional works
- Disassembly and assembly of the fan see page 11
- Disassembly and assembly of curved cooling water pipes see page 20
- Disassembly and assembly of the distributor housing is seen on page 32
- Disassembly and assembly of the belt driven device is seen on page 44
- Disassembly and installation of the crankshaft front oil seal see page 188
- Disassembly and assembly of the front cover plate can be seen on page 错误!未定义书签.
- Disassembly and assembly of the shock absorber see page 208

Fig. 2-6 Fan support

1. Fixing bolt 2. Fan support 3. Fan hub 4. Fixing bolt (left turning bolt)
2. Technical data
Name Specification Technical parameters
First tighten to 100 Nm
Fixing bolt (left-hand thread) (4) M16×55
90° angle
0.20 – 0.55mm
Fan bracket axial range (2)
0.035-0.076mm
Radial range of fan support (2)

Inner diameter of fan shaft bearing 35,000 – 35,025mm

device
34,949 – 34,965mm
Fan shaft outer diameter

3. Auxiliary materials
Loctite 5900
Lubricant oil

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4. Important information O
Attention
If the PTFE seal ring has come into contact with grease, dust or other impurities before
assembly, the seal ring cannot be used.
• Before assembly clean the fan support housing and press the process tools
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• The angle must be done manually with a torque wrench.
5. Special tools

SINOTRUK
Number Sketch Description MAN numbering
Numbering

[1] Impact type extractor JD6805-0018 80.99602-0016

• Remove the shaft seal ring
to radial with the following
tools
• Pull hook [2]
[2] Pull hook JD6805-0019 80.99602-0137

g
• Remove the shaft seal ring
radial

[3] game handle JD6805-0020 80.99617-0187

• Together with the following
tools are pressed to the radial shaft
seal ring
• Press the punch [5]
• Washer [4]
[4] Washer JD6805-0021 80.99617-0144

%
• Press shaft seal ring
radial

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 T MC11 Series Engine Maintenance Manual

[5] O
Press the punch JD6805-0022 80.99604-0289

( • Press radial shaft seal ring

[6] Engine crankshaft rotating device JD6805-0023 80.99626-6008

• Lock the engine crankshaft

Fo LÉ-Ow-
D

[7] JD6805-0024 08.71000-3217

1
r Ag)* v Micrometer
• Check the diameter interior of the
fan shaft bearing
• Along with the following tools
check the axial span and radial span of
the fan mount
• Micrometer holder [8]
• Positioning pin [9]
[8] Micrometer holder JD6805-0025 08.71082-0005
• Check the axial span and the span
radial fan mount

[9] Locating pin JD6805-0026 80.99605-0197

• Check the axial span and the span
radial fan mount

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 MC11 Series Engine Maintenance Manual
Check fan support Inspection of the outside diameter of the fan shaft 18
Check fan mount axial span Check the inner diameter of the fan shaft bearing,
see Inspection of the inner diameter of the fan shaft
bearing 18

• Install the micrometer holder [8] (2), the

micrometer [7] (1) and pin
positioning [9]
• With a certain pretensioning force, place the
positioning pin [9] into the drive gear (3)
• Press the drive gear (3) towards the crankcase
• Zero the micrometer [7] (1)
• Pull the drive gear (3) to the final position and
read the difference
The allowable axial range is 0.20 to 0.55 mm.
If the axial span is out of tolerance, the fan mount
must be replaced.
Check Radial Span of Fan Mount

Install the micrometer holder [8] (2), the

micrometer [7] (3) and the pin
positioning [9]
• With a certain pretensioning force, place the
positioning pin [9] into the fan hub (1)
• Press the fan hub (1) horizontally to the left to
the final position
• Zero the micrometer [7] (3)
• Pull the fan hub (1) along the micrometer
direction [7] (3) until
final position and read the difference
The allowable radial interval is 0.035 - 0.076 mm.
If the radial gap is out of tolerance, check the fan
shaft and fan shaft bearing.
Check the outside diameter of the fan shaft, see

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 MC11 Series Engine Maintenance Manual
Disassembling the fan bracket Assembling the fan support
engine crankshaft rotating device
• Install the engine crankshaft rotating device [6] (1) Removing the fan support
into the flywheel housing and lock it
Remove the fan hub

• Mark the mounting position (1) and (2) of the fixing

With the impact type extractor [1] (4) and
bolt
the
• Remove the flywheel housing seal cover • Unscrew
removal hook the fixing
[2] (3)bolt (1) and
remove the(2)seal ring (2)
• Extract thefanO-ring
from the (4) radial shaft (1)
support
• Fix the crankshaft gear (4) with fixing bolts (5) • Extract the fan support (3)
• Unscrew the fixing bolt (thread
left) (1)
• Remove the fan hub (2) from the bracket
fan (3)

Remove the radial shaft seal ring from the

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 MC11 Series Engine Maintenance Manual
Check fan support Fan Shaft Outer Diameter Inspection
Disassemble the fan support

• Remove the fan shaft (2) from the housing the fan shaft (2).
(1) • Install fan shaft (2) into housing
Check the inner diameter of the fan shaft bearing (1)

• Using the micrometer [7] (1) and the inner probe

(4) check the inner diameter of the front bearing
(2)
• Repeat the previous work process to the rear
bearing
Permissible inner diameter of the bearings (2) is Ø
35,000 - 35,025 mm.
If the inner diameter is out of tolerance, the housing
(3) must be replaced
Using the outside diameter micrometer (1) on the
working surfaces (2) and (3) check the outside
diameter of the fan shaft
The allowable external diameter of the working surfaces
(2) and (3) is Ø34.949 - 34.965 mm. If the outside
diameter is out of tolerance, the fan shaft must be
replaced Fan Bracket Assembly

• Apply a thin coat of clean engine oil to the neck of

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 MC11 Series Engine Maintenance Manual

Fan bracket assembly • Install the new fan hub (2) to the fan bracket (3)
Fan bracket assembly • Apply a thin coat of Loctite 5900 (5)
on the contact surface of the hub
• Screw the retaining bolt (threaded to the
left) (1) and make an initial tightening to the
torque of 100 Nm
• Turn the fixing bolt (left-hand thread) (1) at an
angle of 90°
• Unscrew the fixing bolt (4)
Remove the rotating device from the engine
crankshaft

• Apply a thin coat of lubricating oil to the new O-

ring (4)
• Install the O-ring (4)
• Install the bracket fan (3)
• Screw in the bolt fixing (1) and (2)
according to
new brands
• Tighten the fixing bolt (1) and (2) Press the radial
shaft seal ring

• Remove the engine crankshaft rotating device

[6] (1) from the flywheel housing, install the seal
cover on the flywheel housing/timing gear
chamber

• Using the set handle [3] (4), washer [4] and

pressure punch [5] (3), press the radial shaft seal
ring (2) into the fan bracket (1), until than the
position of the block.
Fan hub assembly

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O
III. Curved Cooling Water Pipes

Fig. 2-7 Curved Cooling Water Pipes

1. O-ring 2. Curved cooling water pipes 3. Fixing bolt 4. Connection tube 5. Connection tube 6. Curved Cooling
Water Pipe
1. Technical data
Name Specification Technical parameters
M16×15 45-50Nm
Water temperature sensor

2. Auxiliary materials
Cooling device antifreeze, special Vaseline
3. Important information
Attention
/Yo Incorrect tightening when connecting threads can cause damage to components
l • If a pneumatic wrench is to be used, it can only be used for initial tightening. Tightening torque
Maximum used for initial tightening will be 50% of the specified tightening torque value.
• The angle must be done manually with a torque wrench.
4. Special tools
Number As shown in the figure Description Numbering Numbering
of of
SINOTR MAN
UK
[10] hose clamp for clamp JD6805- 08.99605
• Assembly and disassembly of the intake manifold 0028 9003
air compressor

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O
5. Disassembly of curved cooling water pipes Disassembly of curved cooling water pipes
Intake manifold removal

• Unscrew the fixing bolt (1)

• Unplug the bent cooling water pipe (2)
• Remove the O-ring (5)
• Take out the connection tube (3) and (4)
Disassembly of the water temperature sensor

• Unscrew the fixing bolt (1)

• Using the hose clamp pliers [10] loosen the
clamp (3)
• Repeat the above work process for the clamp on
the turbocharger intake manifold
• Remove the intake manifold (2)
• Remove the molded hose retaining clamp (6) on
the cable pack bracket
• Using the hose clamp pliers [10] loosen the Warning
clamp (4) The water temperature sensor can also be
• Unplug molded hose (6) from connector (5) disassembled and mounted on the curved
cooling water pipe in the mounting state.

Unscrew the water temperature sensor (1) with

the sealing ring (2) from the bent cooling water
pipe (3)

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O
Disassembly of curved cooling water pipes

• Unscrew the fixing bolt (3)

• Remove the curved cooling water pipe (2) with the O-ring (1)
• Clean the sealing surface

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O water pipes
6. Assembly of curved cooling Assembly of curved cooling water pipes
Assembly of curved cooling water pipes

Assemble the bent cooling water pipe (2) with

the new O-ring (1) Screw in the new retaining • Apply a thin layer of special Vaseline to the
bolt (3) and tighten it mounting surfaces of the new connecting tubes
(3) and (4)
Mounting the water temperature sensor • Mount the connecting pipes (3) and (4) to the
curved cooling water pipe (2)
• Apply a thin layer of special Vaseline to the new
O-ring (5) and mount it to the curved cooling water
pipe (2).
• Mounting the curved cooling water pipes (2)
• Screw in the new retaining bolt (1) and tighten it

• Screw the water temperature sensor (1) with the new seal ring (2) into the curved cooling water pipe (3) and
tighten it to the torque of 45-50 Nm.

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IV. Thermostat O

Fig. 2-8 Thermostat

1. Fixing bolt 2. Fixing bolt 3. Thermostat elbow 4. Thermostat
1. Technical data
Name Technical parameters
Thermostat activation temperature (5) 83°C
2. Important information
Attention
/T Using a thermostat with an incorrect start temperature can cause damage
—* to the engine
• You must use a thermostat with a specified start temperature

Attention
/YO Incorrect tightening when connecting threads can cause damage to the
—* components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• The angle must be done manually with a torque wrench.

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O
3. Disassembly of the thermostat 4. Thermostat assembly
Disassembly of the thermostat elbow Thermostat assembly

• Mark the mounting position (4) and (5) of the • Install new seal ring (2) to thermostat housing (3)
fixing bolt • Mount the thermostat (1) with the ball valve or
• Unscrew the fixing bolts (4) and (5) TOP brand up
• Remove thermostat elbow (2) and bracket (3) Thermostat Elbow Assembly
(current model does not have this bracket)
• Remove the O-ring (1) from the thermostat
• Clean the sealing surface
Thermostat disassembly

• Install the new O-ring (1) on the thermostat

• Mount thermostat elbow (2) to housing
of the thermostat
• Screw in the new retaining bolts (4) and
(5) and tighten them according to the marks
Remove the thermostat (1) with seal ring (2) from the
thermostat housing (3) Clean the sealing surface

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v. thermostat housing O
1. Additional jobs
- Disassembly and assembly of the thermostat is seen on page 24

Fig. 2-9 Thermostat housing

1. Thermostat housing 2. Hose connector 3. Composite sealing washer 4. Large washer 5. Fixing bolt 6. O-
ring
2. Consumable materials
Special Vaseline
3. Important information
Attention
/T\ Incorrect tightening when connecting threads can cause damage to the
— components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• The angle must be done manually with a torque wrench.

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 T MC11 Series Engine Maintenance Manual

O housing
4. Disassembly of the thermostat Replace the connecting tube
Unscrew the fixing bolt

• Unscrew the fixing bolt (1) from the distributor Remove the connection tubes (2) and (3) from the
housing (2) thermostat housing (1)
Removing the thermostat housing Apply a thin layer of special Vaseline to the
mounting surfaces of the new connecting tubes (2)
and (3)
Mount the connecting pipes (2) and (3) to the
thermostat housing (1)

Dismantle the thermostat housing (1) and the

connection tube
Remove the washer (3) from the distributor
housing (2)
Clean the sealing surface

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 T MC11 Series Engine Maintenance Manual

O housing
5. Assembling the thermostat
Assembling the thermostat housing

• Assemble the thermostat housing (1) with the new

washer (3) and the new connection tube to the
distributor housing (2).
Screw the fixing bolt

• Screw the new retaining bolt (1) to the distributor

housing (2) and tighten it

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 T MC11 Series Engine Maintenance Manual

O
SAW. Water Pump

Fig. 2-10 Water pump

1. Fixing bolt 2. Fixing bolt 3. Water pump 4. Washer 5. Distributor housing 6. Grooved pulley 7. fixing bolt
1. Important information

Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• The angle must be done manually with a torque wrench.

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 T MC11 Series Engine Maintenance Manual

Opump
2. Disassembly of the water Removal of the grooved pulley
Loosen the fixing bolt

Unscrew the fixing bolt (1)

Unplug the sheave (2) from the hub (3)

Disassembly of the water pump

• Loosen the fixing bolt (2)

• Turn the idler pulley (1) of the grooved pulley
clockwise to the block position, and secure it
• Remove the ribbed belt (3)
• Carefully loosen the V-belt tensioner pulley (1)

Attention
The idler pulley of the sheave is under
spring tension
• By reverse clamping, the tensioner pulley
of the grooved pulley is prevented from
accidentally rebounding.
Mark the mounting position (1) and (4) of the
fixing bolt
Unscrew the fixing bolts (1) and (4)
Remove the water pump (2) and washer (3)
Clean the sealing surface

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O
3. Water pump assembly Water Tighten the fixing bolts
pump assembly

Attention
• Install the water pump (2) with the washer (3) The idler pulley of the sheave is under
• Screw in the new fixing bolts (1) and (4) according spring tension
to the markings and tighten them.
Mounting the sheave
Reverse clamping prevents the
tensioner pulley of the grooved
pulley from have
accidental rebound
• Turn the idler pulley (1) of the grooved pulley
clockwise to the block position, and secure it
• Install the ribbed belt (3)
• Carefully lay down the V-belt tensioner pulley (1)
• Tighten the fixing bolt (2)

md26/6K1h8D06

• Mount the grooved pulley (2) to the hub (3)

• Tighten the fixing bolt (1) manually

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 T MC11 Series Engine Maintenance Manual
VII. distributor housing
1. Additional works O
- Disassembly andmounting of the fan seen on page 11
- Disassembly andmounting of the belt driven device seen on page
44
- Disassembly andmounting of curved cooling water pipes seen in
page 20
- Disassembly andmounting thermostat see on page 24
- Disassembly andmounting of the thermostat housing is seen on page 26
- Disassembly andmounting of the water pump is seen on page 29

Fig. 2-11 Distributor Housing

1. Fixing bolt 2. Distributor housing 3. Fixing bolt 4. fixing bolt
2. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified
tightening torque value.
• The angle must be done manually with a torque wrench.

3
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 T MC11 Series Engine Maintenance Manual
•
Odistributor housing
Mark the mounting position (1) and (2) of the fixing bolt
3. Disassembly of the 4. Distributor housing assembly

• Unscrew the fixing bolts (1) and (2) Install the distributor housing (3) with new
• Remove the distributor housing (3) with washer washer
• Clean the sealing surface Screw the fixing bolts (1) and (2) according to
the markings and tighten them

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 T MC11 Series Engine Maintenance Manual

O SECTION III ENGINE ACCESSORIES

Fig. 2-12 Engine Accessories

1. Starter motor; 2. Intake; 3. Single cylinder air compressor; 4. Power steering pump 1; 7. Generator sheave;
8. High pressure pump driving device sheave; 9. Grooved tensioner pulley; 10. refrigeration compressor;
11.V-ribbed belt pulley; 12. Molded hose

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 T MC11 Series Engine Maintenance Manual

1. Intake pipe; 2.O

Fig. 2-13 Air compressor
Molded hose; 3. Single cylinder air compressor; 4. Power steering pump;
1. Technical data
Name Specification Technical parameters
Straight screw type connector M16×15 30-35Nm
air tube connector M26×15 45Nm
2. Auxiliary materials
YO. Air compressor

Loctite 5900
3. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified tightening
torque value.
• In the end you must tighten manually with a torque wrench.

3
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 MC11 Series Engine Maintenance Manual

4. Special tools
Number As shown in the Description MAN numbering
figure Numbering of
SINOTRUK

[27] The hose uses the clamp clip JD6805-0028 08.99605-9003

w
• Disassembly and assembly of the
collector
air compressor intake

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 T MC11 Series Engine Maintenance Manual

O
5. Removal of the air compressor Disassembly of cooling water pipes
Removal of the intake manifold

Press the spring clip (2) to disengage and

remove the cooling water pipe quick insert
connector (1)
Repeat the above work process for the rest of
the cooling water pipes

• Unscrew the fixing bolt (1)

• Using the hose clamp pliers [27] loosen the clamp (3) and push it onto the intake manifold (2).
• Repeat the above work process for the clamp on the turbocharger intake manifold
• Remove the intake manifold (2)
• Remove the molded hose retaining clamp (6) on the cable pack bracket
• Using the hose clamp pliers [27] loosen the clamp (4) and push it onto the connector (5).
• Unplug molded hose (6) from connector (5)

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 T MC11 Series Engine Maintenance Manual

O
Disassembly of the air compressor Disassembly of the tube collector

• Mark the mounting position (1) and (2) of the fixing

bolt
• Unscrew the fixing bolts (1) and (2)
• Remove the air compressor (3)
• Clean the sealing surface

Unscrew the reducer connections from the intake pipe (2) and exhaust pipe (3) and remove them
together with the seal ring
Unscrew the connector (1) and remove it together with the seal ring

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O
6. Air Compressor Assembly Tube Air Compressor Assembly Instructions
Manifold Assembly

• Apply a thin coat of Loctite 5900 (1) to the sealing

surface as shown in the figure.
Air compressor assembly

Screw the pipe connector of the inner diameter

of the intake pipe (2) and the exhaust pipe (3)
that have new sealing rings and tighten them to
the torque of 30-35 Nm. Screw the connector (1)
with the new ring of seal and tighten it to the
Install the air compressor (3)
torque of 45 Nm
Screw the fixing bolts (1) and (2) according to the
markings and tighten them

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O
Mounting the cooling water pipes Intake manifold assembly

Attention
Loose quick connect connectors can
cause component damage
• Check the tightness of the joint
after the cooling pipe quick insert
connector has been attached.
• When the quick
insert connector is • Install the retaining clamp
loose, loosen by the
pressing the spring clip and molded hose (6) on wire harness bracket
reassemble and secure it. • Using the clamp hose clip [27] mount the clamp
• Cooling Water Pipe Quick Insert Connector (4)
Assembly (1) • Install the intake manifold (2) and the
• Press the spring clip (2) to disengage the cooling clamp (3)
water pipe quick insert connector (1) if • Screw in the new retaining bolt (1) and
necessary, and reassemble and secure it. squeeze it
• Repeat the above work process for the rest of the • Using the clamp hose clip [27] mount the clamp
cooling water pipes (3)
• Push the molded hose (6) with the • Repeat the above work process for the clamp on
clamp (4) to connector (5) the turbocharger intake manifold

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11. Starting motor
O

Fig. 2-14 Starter Motor

1. Fixing bolts; 2. Starting motor; 3. steering wheel housing
1. Technical data
Name Specification Technical parameters
Fixing bolt (1) M12×35-10.9 110Nm
Clamping nut (terminal) M10 22Nm
Number of teeth of starter motor 12
sprocket
Starter motor power 5.5kW，24V
2. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified tightening
torque value.
• Final tightening must be done manually with a torque wrench.

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 T MC11 Series Engine Maintenance Manual
3. Special tools
Number O
As shown in the figure
Description SINOTRUK
MAN numbering
Numbering
[59] JD6805-0023 80.99626-6008
<6€ FTo Wg O- Engine crankshaft rotating device
• Along with the following
tools to turn the engine
crankshaft:
• ratchet wrench for
gears [60]

[60] Ratchet gear wrench JD6805-0038 80.99627-0001

• Rotate the engine crankshaft

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 T MC11 Series Engine Maintenance Manual

Remove the rotatingO

device from the engine Starter motor assembly
crankshaft Engine crankshaft rotating device assembly

Remove the engine crankshaft rotating device Remove seal cover on flywheel housing/timing
[59] (1) from the flywheel housing, fit the seal gear chamber
cover to the flywheel housing/timing gear • mount the engine crankshaft rotating device [59]
chamber (1) to the flywheel housing
Starter motor disassembly Starter motor assembly
Unscrew the fixing bolt (1)

The engine crankshaft rotating device [59] and

• Remove the starter motor (2) from the flywheel gear ratchet wrench [60] rotate the engine
housing crankshaft through 360° and check the flywheel
ring gear for damage during this process.
Replace the flywheel ring gear if necessary
Mount starter motor (2) to flywheel housing/timing
gear chamber
Screw in the new retaining bolt (1) and tighten it
to a torque of 110 Nm.

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III. Belt drive mechanismO

Fig. 2-15 Belt Drive Mechanism

1. Ribbed belt pulley; 2. fixing bolt; 3. V-belt tensioner pulley; 4. Generator V-belt tensioner pulley;
5. High pressure pump driving device casing grooved pulley; 6. fixing bolt; 7. Refrigeration compressor
sheave;
1. Technical data

Name Specification Technical parameters

Fixing bolt (6) M10×70-10.9 42-52Nm
Fixing bolt (2) M12×55-10.9 50-70Nm
2. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.

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O
3. Disassembly of the belt drive mechanism Removing the V-belt tensioner pulley

Removing the V-belt

Unscrew the fixing bolt (1)

Remove the V-belt tensioner pulley (2)
Attention
V-belt tensioner pulley is under spring
tension
• Reverse clamping prevents accidental rebound
of the V-belt tensioner
pulley.
* Turn the V-belt tensioner pulley (1) clockwise to the block position, and secure it
* Remove the ribbed belt (2)
* Carefully loosen the belt tensioner pulley
ribbed (1)
Disassembly of the guide wheel

Mark the mounting position of the guide wheel (3)

and the interval bushing (4)
Unscrew the fixing bolt (1)
Remove the washer (2)
Remove the idler wheel (3) and interval bushing
(4)

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4. Assembly of the belt drive mechanism Ribbed belt assembly

V-belt tensioner pulley assembly

Attention
V-belt tensioner pulley is under spring
Mount the V-belt tensioner pulley (2) to the
tension
distributor housing
• Reverse clamping prevents the V-belt
Screw in the new retaining bolt (1) and tighten it
tensioner pulley from have
to a torque of 47 Nm.
rebound
Guide wheel assembly accidental

Turn the idler pulley (1) of the grooved pulley

clockwise to the block position, and secure it
Install the multi-ribbed belt (2)
Carefully loosen the V-belt tensioner pulley (1)

• Install the guide wheel (3) and the interval bushing

(4) according to brands
• Install the washer (2)
• Screw in the new retaining bolt (1) and tighten it to a torque of 60 Nm.

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IV. Generator O

Fig.2-16 Generator
1. Threaded bracket; 2. Pressurized air elbow support; 3. Generator;
4. High pressure pump driving device casing support; 5. fixing bolt; 6. V-belt pulley; 7. Clamping nut;
1. Technical data

Name Specification Technical parameters

Clamping nut (7) M16 80-100Nm
Retaining nut that connects to the positive M8 9-13Nm
battery terminal
2. Auxiliary materials
Loctite 270
3. Important information
Attention
Incorrect tightening when connecting threads can cause damage to components
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified tightening
torque value.
• In the end you must tighten manually with a torque wrench.

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4. Special tools O
Number Description SINOTRUK
As shown in the figure MAN numbering
Numbering
[61] JD6805-0039 80.99603-6029
special key

c<
• Along with the following
Tools to disassemble and
assemble the V-belt pulley:
• Lever [62]

[62] Lever JD6805-0040 08.06460-0002

T
• Remove and install the pulley
ribbed belt

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 T MC11 Series Engine Maintenance Manual

O
5. Disassembly of the generator Disassembly of the high pressure pump drive
Removing the V-belt device bracket

Attention • Unscrew the retaining nut (3) from the retaining

V-belt tensioner pulley is under spring bolt (1)
tension • Unscrew the fixing bolt (4) and remove the
• Reverse clamping prevents accidental bracket (2)
rebound of the V-belt tensioner Disassembly of the device from the upper support
pulley.
• Turn the idler pulley (1) of the grooved pulley
clockwise to the block position, and secure it
• Remove the ribbed belt (2)
• Carefully loosen the V-belt tensioner pulley (1)
Dismantle the electrical connection of the
generator

Unscrew the retaining nut (4)

Unscrew the fixing bolt (3)
Remove the generator
Unscrew the fixing bolt (2) and remove the top
bracket (1)

Loosen and remove the compact connector (3) Unpack the cable retaining clamp (2)
Unscrew the retaining nut (1) that connects to the positive battery terminal Loosen the generator wire
harness

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 T MC11 Series Engine Maintenance Manual

O
Loosen the multi-ribbed belt pulley retaining nut. 6. Generator assembly
V-belt pulley assembly

• Place the special key [61] (2) with the

lever [62] (3) on the multi-ribbed belt pulley
retaining nut
• Mount the spanner wrench (1) to the generator • Mount the V-belt pulley (2) to the generator shaft
bearing gear tooth (3)
• Hold the open end wrench (1) and loosen the • Apply a thin coat of Loctite 270 to the threads of
clamping nut the new set bolt (1) and the mounting surface
Removing the V-belt pulley • Screw on the new retaining nut (1) Tighten the
multi-ribbed belt pulley retaining nut

Unscrew the retaining nut (1) Place the special key [62] (3) with the
Remove the V-belt pulley (2) from the generator lever [61] (2) on the multi-ribbed belt pulley
shaft (3) retaining nut
Mount the spanner wrench (1) to the generator
bearing gear tooth
Hold the open end wrench (1) and loosen the clamping nut to the torque of 80 -100 Nm

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O device
Assembling the top clamping Establish the electrical connection for the
generator

• Mount the upper bracket (1) and screw in the • Store the generator wire harness
new fixing bolt (2) • Screw the retaining nut (1) that connects with the
• Mount the generator to the clamping device positive terminal of the battery and tighten it to
• Screw in the new fixing bolt (3) the torque of 9 - 13 Nm
• Screw and tighten the new retaining nut • Mount and lock the compact connector (3)
(4) • Hold the generator wire harness with
• Tighten the fixing bolt (2) and (3) the cable clamp (2)
High pressure pump drive device bracket Ribbed belt assembly
assembly

Attention
• Mount the bracket (2) and screw in the new fixing V-belt tensioner pulley is under spring
bolt (4) tension
• Mount the new fixing bolt (1) and screw the new • Reverse clamping prevents the V-belt
retaining nut (3) tensioner pulley from have
• Screw the clamping nut (3), during operation you rebound
accidental
must hold the clamping bolt (1)
• Tighten the fixing bolt (4) Turn the idler pulley (1) of the grooved pulley
clockwise to the block position, and secure it
Install the multi-ribbed belt (2)
Carefully loosen the V-belt tensioner pulley (1)

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 MC11 Series Engine Maintenance Manual
SECTION IV INTAKE AND EXHAUST SYSTEM

Fig. 2-17 Turbocharger

1. Turbocharger 2. Washer 3. Oil return pipe 4. Mounting bolt 5. Washer
6. Exhaust manifold 7. Mounting nut 8. Mounting nut 9. Oil inlet pipe

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Fig. 2-18 Exhaust Manifold

1. Heat protector 2. Rear exhaust manifold 3. Exhaust pipe washer 4. Central exhaust manifold 5. front
exhaust manifold

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 MC11 Series Engine Maintenance Manual
Fig. 2-19 Exhaust Manifold
1. Mounting bolt 2. Exhaust manifold 3. Washer 4. Cylinder head 5. Mounting bolt 6. Heat protector 7.
Mounting bolt 8. heat protector
2. Technical data
Name Specification Technical parameters
Mounting bolts (5) M10×50
Mounting bolts (5) M10×50
Initial torque is 60 Nm 90° angle
Mounting bolt (1) M10×95
Mounting bolt (1) M10×95
3. Important information
YO. Manifold
1. Auxiliary work
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the turbocharger can be seen on page 61
- Disassembly and assembly of the oil module is seen on page 167

Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.

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O
4. Exhaust Manifold Removal Heat Exhaust manifold removal
Shield Removal

Remove the exhaust manifolds (1) and (3) from

• Unscrew the mounting bolt (2) the exhaust manifold (2)
• Remove the heat shield (1) and (3) Remove the sealing ring from the exhaust
Exhaust manifold removal manifolds (1) and (3)
Clean the contact surface
Mark the mounting position (2) and (3) of the fixing bolt
Unscrew the mounting bolt (2) and (3)
Together with the washer (1) remove the exhaust manifold
(4)
Clean the contact surface

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 MC11 Series Engine Maintenance Manual
5. Exhaust Manifold Assembly Exhaust manifold assembly
Exhaust Manifold Assembly

mBN—™eEEF )i U
Position the washer (1) so that its convex part
faces the exhaust manifold (4).
• Insert a new seal ring into the exhaust Position the exhaust manifold (4)
manifolds (1) and (3), and the four seal ring Screw the new mounting bolt (2) and (3) as
spaces are moved sequentially by 90°. shown in the figure
• Insert the exhaust manifolds (1) and (3) to the Screw the new mounting bolt (2) and (3)
exhaust manifold (2) according to the sequence shown to the initial
Exhaust manifold tightening sequence torque of 60 Nm
Screw the new mounting bolt (2) and (3)
according to the sequence shown at the 90°
angle

Mounting the heat shield

Starting from A, tighten the exhaust manifold

(1) in the order of A, B, C, D, E, F

Position the heat shield (1) and (3) Screw and

tighten the new mounting bolt (2)

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6. Technical data
Name
O Specification Technical parameters
M6 10Nm
Intake manifold clamp (7)

7. Consumable materials
II. Intake

Fig. 2-20 Intake pipe

1. Mounting bolt 2. Support support 3. Mounting bolt 4. Mounting nut 5. Intake pipe 6. Intake
7. Intake manifold 8. Screw cap 9. Signet ring 10. mounting bolt

Special Vaseline
8. Important information
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
Grades
Shareable for all types of intake pipes.
Disassembly and assembly are essentially the same.

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 MC11 Series Engine Maintenance Manual
9. Disassembly of the intake pipe 10. Intake pipe assembly

• Unscrew the mounting bolt (1) (2) and (7) Together with the clamp (5) position the
• the intake pipe (6) intake manifold (4) on the turbocharger and
• Loosen the clamp (5) align it with the intake manifold (6)
• Together with the O-ring (3) remove the intake Apply a thin layer of special Vaseline on the
manifold (4) new O-ring (3) and insert it into the intake
manifold (4).
Insert the intake tube (6)
Screw in and tighten the new mounting bolt (1)
Screw and tighten the new mounting bolt (2)
Insert the new mounting bolt (7), then screw
and tighten the new mounting nut Tighten the
clamp (5) to the torque of 10 Nm

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III. Intake manifold
1. Auxiliary jobs O
- Disassembly and assembly of the belt transmission mechanism is seen on page 44

Fig. 2-21 Intake manifold

1. Flame glow plug (special configuration) 2. Solenoid valve 3. Mounting bolt 4. Support 5. Mounting bolt 6.
Mounting bolt 7. Intake manifold 8. sensor
air intake pressure 9. mounting bolt
2. Auxiliary materials
Loctite 5900
3. Important information Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• Final tightening must be done manually with a torque wrench.

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 MC11 Series Engine Maintenance Manual
4. Removal of the intake manifold 5. Intake manifold assembly Intake
Removal of the support manifold assembly

• Unscrew the mounting bolt (1) and (2) and remove

the bracket (3)
Intake manifold removal

Apply a coat of Loctite 5900 to the mating

surface.
Position the intake manifold (2)
Screw in the new mounting bolt (1)
Together with the new O-ring, insert it to the
boost sensor (4)
Screw and tighten the new mounting bolt (5)
Connect the electrical connection connector (3)

Mounting the bracket

Disengagement the connection connector

electric (3)
Unscrew the mounting bolt (5) and remove the
boost sensor (4) Unscrew the mounting bolt (1)
Remove the intake manifold (2) Clean the
contact surface

Position the support (3)

Screw in the new mounting bolt (1) and (2)
Tighten the mounting bolt (2)
Tighten the mounting bolt (1)

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IV. Turbocharger
1. Auxiliary work O
Disassembly and assembly of intake pipes see page 57

Fig. 2-22 Turbocharger

1. Turbocharger 2. Washer 3. Oil return pipe 4. Mounting bolt 5. Washer 6. exhaust elbow
8. Mounting nut 9. Oil inlet pipe

2. Technical data
Name Specification Technical parameters
Mounting nut (8) M10 Initial torque 10 Nm
Mounting nut (8) M10 90° angle
3. Auxiliary materials
Calcium-based lubricating grease
4. Important information
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
Final tightening must be done manually with a torque wrench.

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5. Special tools
Number O
As shown in the Description Numeration of Numeration of
figure SINOTRUK MAN
[165] JD6805-0083 80.99603-0323

Yes,
Closed plum key, size 15i = 1:
1.22
• Unscrew and tighten the
mounting nut on
turbocharger
[166] Detector JD6805-0168 80.99606-0399

g
• Check if the plug of the
Compressed air tube is
reliable

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 MC11 Series Engine Maintenance Manual
6. Disassembly of the turbocharger Remove the oil return pipe
Disassembly of the compressed air pipe

Unscrew the mounting bolt (3)

Unscrew the oil return tube (2) on the threaded
tube
Remove washer (4) and seal ring
(1)
Dismantle the compressed air tube (1) Clean the contact surface
Disassembly of the compressed air tube (2)
from the cylinder with butterfly valve (3) Turbocharger disassembly
Removal of the curved exhaust pipe

• Unscrew the clamp bolts (3) Unscrew the mounting bolt (1) with the star
• Remove the washer and the bent tube wrench [165]
exhaust (2) from turbocharger (1) Dismantle the turbocharger and washer (3)
• Clean the contact surface together
Disassembly of the hydraulic pipe Clean the contact surface

• Remove the oil inlet manifold (1)

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 MC11 Series Engine Maintenance Manual
7. Installing the turbocharger Turbocharger mounting nut, bottom left
Position the turbocharger

Warning Warning
Incorrect use of special tools can cause Incorrect use of special tools can
damage to components cause damage to components
Using a star wrench [165] (1) and a

• Position and mount the new washer (3) and the

• Using a star wrench [165] (1) and a torque
turbocharger (2) and tighten them
wrench (2) tighten the mounting nut to the initial
• Screw in the new mounting bolt (1) and tighten
torque of 10 Nm
it with the star wrench [165] to the initial torque
• Tighten the mounting nut to 90° angle
of 10 Nm
• Tighten the mounting bolt (1) to 90° angle Connection with oil return pipe
Turbocharger mounting nut, bottom right

Screw the oil return pipe (2) with the new seal
ring (1) to the crankcase
Position the oil return tube (2) and the new
washer (4)
Screw in and tighten the new mounting bolt
(3)
Warning Tighten the oil return pipe nut (2)
Incorrect use of special tools can
cause damage to components

torque wrench (2) tighten the lock nut

assembly to initial torque of 10 Nm
Tighten the mounting nut to 90° angle

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 MC11 Series Engine Maintenance Manual
Grease the turbocharger Installing the curved exhaust manifold

• The curved exhaust pipe (2) with the new

Warning washer is positioned on the turbocharger (1).
If not greased, the turbocharger will be damaged • Screw and tighten the new clamp bolt (3)
when the vehicle is first started. Compressed air tube connection

• Before connecting the oil inlet pipe, you must

inject clean engine oil into the turbocharger.
• Using a funnel (1) pour clean engine oil into the
turbocharger fill port (2) until the pilot tube on
the turbocharger (2) is full
Hydraulic pipe connection

Connect the compressed air tube (1) Screw the

new nut onto the throttle valve cylinder (3) and
tighten it. Attach the compressed air manifold
(2) and check whether the installation is secure
with the detector [166]
Repeat the above work if the connector loosens
from the locking bolt

Connect the oil inlet manifold (1) Tighten the oil inlet pipe nut (1)

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O SECTION V CYLINDER HEAD

Fig. 2-23 Cylinder head

1. Crankcase 2. Cylinder head washer 3. Cylinder head 4. Mounting bolt 5. cylinder head cover

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 TO MC11 Series Engine Maintenance Manual
YO. Butt
1. Auxiliary jobs
- Removal and assembly of the engine control unit is seen on page 7
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the thermostat is seen on page 24
- Disassembly and assembly of the thermostat housing is seen on page 26
- Disassembly and assembly of the exhaust manifold is seen on page 54
- Disassembly and assembly of intake pipes see page 57
- Disassembly and assembly of the turbocharger is seen on page 61
- Verification and configuration of the valve interval is seen on page 79
- Disassembly and assembly of the oil injection pump and common rail components is seen on page 134
- Disassembly and assembly of the fuel supply center is seen on page 156
- Disassembly and assembly of the oil module is seen on page 167

Fig.2-24 Cylinder head

1. Crankcase 2. Cylinder head washer 3. Cylinder head 4. Mounting bolt 5. cylinder head cover
2. Technical data
Name Specification Technical parameters
cylinder head bolt M18×2×246-10.9 Initial torque 10 Nm
cylinder head bolt M18×2×246-10.9 The second torque 150 Nm
cylinder head bolt M18×2×246-10.9 The third torque 300 Nm
cylinder head bolt M18×2×246-10.9 90° angle
cylinder head bolt M18×2×246-10.9 90° angle
cylinder head bolt M18×2×246-10.9 90° angle
Articulating arm device mounting bolts M12×60-10.9 105+10Nm
Mounting bolt (4) 10Nm
Cylinder sleeve protruding amount 0.035-0.085mm

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3. Auxiliary materials
OWhen reassembling the cylinder head, you should apply a small amount of White
White T Lubricating Grease--
T lubricating grease to the bearing surface of the cylinder head bolt.
4. Important information
Warning
/ !\ Damaged cylinder head bolt mounting surface can cause damage to the
components
• It is not allowed to use old cylinder head bolts, they must be replaced even if they have
only been used once.
Warning
/! Common rail system can be damaged
• All work performed on the common rail system must be carried out by specially trained
personnel.
• To relieve the pressure in the common rail assembly, the engine must be stopped for at
least 5 minutes before starting work, or check the pressure relief condition by SINOTRUK
EOL diagnostic tool (required value 0).
• During work you must ensure absolute cleanliness of all areas.
• Avoid any humidity that may appear
• Once the common rail connecting tube is loosened, it needs to be repaired
immediately.
• Reuse of the high-pressure pipe seal rings, common rail assembly and injector rings is not
permitted, even if they have only been used once.
• When tightening the fuel injection pump, the high pressure oil pipe, common rail assembly
and common rail connecting pipe operate in the order indicated.
Warning
/.N Incorrect sequence of operation when tightening connecting bolts can cause
damage to components.
If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
5. Special tools
Number As shown in the figure Description SINOTRUK
MAN numbering
Numbering

6
[175]
Torque boost i = 1:3.5
• Unscrew and tighten
the bolts of
the
cylinder head, using:
• Support [176]
• pipe wrench, size
22 [183]
JD6805-0084 80.99619-0007
• Pipe wrench [184]
• Measuring disc of
angle [177]
• Device of
fastening [178]
• Screw of head
flat [179]
• connecting pin

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK

MAN numbering
Numbering
[180]
• Rubber ring 42mm
[181]
• Washer [182]
[176]
Medium
• Unscrew and tighten JD6805-0085 80.99606-0551
cylinder head bolts
[177] Angle measuring disc
• Unscrew and tighten
cylinder head bolts
JD6805-0086 80.99607-0172

[178] Clamping device

• Unscrew and tighten
cylinder head bolts

JD6805-0087 80.99606-0641

[179] Flat head screw

• Unscrew and tighten
cylinder head bolts
•@

JD6805-0088 06.02191-0407

[180] connecting pin

4,
• Unscrew and tighten
cylinder head bolts
JD6805-0089 06.22729-0006

[181] Rubber ring 42mm

(
• Unscrew and tighten
cylinder head bolts
JD6805-0090 08.06142-9006

[182] Washer
• Unscrew and tighten
cylinder head bolts
JD6805-0091 80.99609-0033

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK

MAN numbering
Numbering

6
[183] Pipe wrench, size 22
• Unscrew and tighten
cylinder head bolts
JD6805-0092 80.99612-0024

6
[184] Pipe wrench
• Unscrew and tighten
cylinder head bolts
JD6805-0093 80.99603-0327

[185] Engine crankshaft rotating

device
• Rotate the crankshaft
Ae É \ V '82=1.3-3 engine, using:
MO o7- • Key of ratchet
JD6805-0023 80.99626-6008

[186]

[186] Ratchet wrench

• Rotate the crankshaft
engine JD6805-0038 80.99627-0001

[187]

e
A(8
oop
A:
Crossbar
• Disassembly and
assembly
of the cylinder head,
using: JD6805-0094 80.99629-6008
• hook chain
[188]
• lifting hook
[189]

•
[188] hook chain
• Disassembly and
assembly
of the cylinder head JD6805-0095 80.99629-6009

[189] lifting hook

• Disassembly and
assembly
of the cylinder head JD6805-0096 80.99629-0040

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK

MAN numbering
Numbering
[190]
Micrometer holder
• Check the quantity
outstanding of
the
cylinder sleeve, using:
• Micrometer [191] JD6805-0024 08.71000-3217
• Disk ofmeasurement
[192]
• Cap screw hexagonal
[193]
• Washer [194]
[191] Micrometer

T
• Check the quantity
outstanding of
the JD6805-0024 08.71000-3217
cylinder sleeve

[192] Measuring disc

Ak ( 0—
4 or “00

• Check the quantity

77 0.7

outstanding of
the JD6805-0097 80.99605-0286
cylinder sleeve

[193] hex bolt

TO
• Check the quantity
outstanding of
the JD6805-0098 06.01499-0015
cylinder sleeve

(/P \
[194] Washer

%\
• Check the quantity
outstanding of

1NN ) the
cylinder sleeve
JD6805-0099 06.15013-0417

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 MC11 Series Engine Maintenance Manual

6. Cylinder head disassembly Removing the cylinder head cover

Disconnect the speed sensor electrical
connection connector

Grades
The mounting bolt has to be removed
• Disconnect the electrical connection connector along with the cylinder head cover pad and
(1) the spacer from the cylinder head cover.
Remove the cover of the wire harness assembly • Unscrew the mounting bolt (3)
• Remove the cylinder head cover (2) from the
cylinder head (1)
Engine crankshaft rotating device assembly

• Rotate 90°, open the locking pin (2)

• Remove the wire harness assembly cover (1)
Removing the wire harness bracket Remove the display port cover from the steering
wheel housing
Install the engine crankshaft rotating device
[185] (1) to the flywheel housing

Unscrew the mounting bolt (1)

Place the harness bracket (2) and harness aside and secure them

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 MC11 Series Engine Maintenance Manual

Turn the engine toward the top dead center mark Remove the valve stem

• Adjust the engine according to the engine

running direction, using the engine crankshaft
rotary device [185] (1) and the ratchet wrench
[186] until cylinder 1 is protruding from the
point marked TDC (top dead center). (2)
Disassembly of the articulated arm device

Grades
Depending on the type of maintenance service
used, the cylinder head may also be disassembled
when the articulated arm device is mounted.
Engine maintenance manual MC11 series diesel 2
Chapter I Introduction of MC11 Engine.......1
Chapter II Disassembly and assembly of series engine components 6
MC11.................................................6
TO.......................................................89
TO.....................................................133
Accessories...............................................265
• mounted.
• Clearancehearticulated arm shaft Mark the mounting position (1) and (2) of the
valve together (2) valve shaft
and the articulated arm support (1) • Disassemble the valve shaft (1) and (2) Special
Grades assembly tools
Depending on the type of maintenance
service used, the cylinder head may also
be disassembled when the valve stem is

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 MC11 Series Engine Maintenance Manual

Unscrew the cylinder head bolts

• Insert torque booster i=1:3.5 [175] (1) to

bracket [176] (2)
• Using the flat head bolt [179] (4) and washer Unscrew the cylinder head bolt (1)
[182] (3) mount the clamping device [178] (5) Cylinder head disassembly
to the bracket [176] (2)
• Mount the angle measuring disc [177] (10) on
the torque booster i = 1: 3.5 [175] (1)
• Mount the socket wrench, size 22 [183] (8) on
the torque booster i = 1: 3.5 [175] (1) and lock
it with the connecting pin [180] (9) and the
locking ring. rubber 42mm [181] (7)
• Insert socket wrench[184] (6) into size 22
socket wrench [183] (8)
Loosen the cylinder head bolts

Install all lifting hooks [189] (6) on the cylinder head

(4) and camshaft
Mount the hook chain [188] (3) to
lifting hook [189] (6) and crossbar [187] (5)
Description Using the lifting device, lift the cylinder head (4)
Loosen the cylinder head bolts from the from the crankcase
outside to the inside. Remove the cylinder head washer (2)
Clean the contact surface
• Mount the special tool (1) on the cylinder head Clean the cylinder head bolt screw cap hole
bolt to be loosened Remove special tools
• Using the special tool (1) and wrench (2) 7. Cylinder head assembly
loosen all cylinder head bolts Set the camshaft to the TDC mark

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 MC11 Series Engine Maintenance Manual

Zero the micrometer [191] (3)

Carefully place the tip of the micrometer (1) into the
cylinder sleeve and observe the changes in the
micrometer
Cylinder head assembly

• Rotate the camshaft (3) so that the TDC mark (1)

aligns with the face of the cylinder head (2)
Check the protruding part of the cylinder sleeve

Install the lifting hook [189] (6) on the cylinder head

Place the measuring disc [192] (2) on the cylinder
(4) and the camshaft
sleeve
Mount the hook chain [188] (3) to
Screw the hexagon head bolt [193] (4) together with
lifting hook [189] (6) and crossbar [187] (5)
the washer [194] (5) and tighten
Fit a new cylinder head washer (2) to the locating
Attach the micrometer holder [190] (6) and the
pin in the crankcase (1)
micrometer [191] (3) on disk
Place the cylinder head (4) on the crankcase (1)
measurement [192] (2)
Remove special tools
The allowable cylinder sleeve protrusion amount is 0.035-0.085mm.
If the protrusion amount of the cylinder sleeve is out of tolerance, a new cylinder sleeve/crankcase must be
fitted, see "Cylinder sleeve removal and installation". 202

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 MC11 Series Engine Maintenance Manual
Cylinder head tightening Screw in the cylinder head bolts
sequence

To intake side
B Exhaust side
Screw the mounting bolt according to the sequence
shown (1 to 26) clockwise
Warning
Damaged cylinder head bolt mounting surface
can cause component damage
It is not allowed to use old cylinder head bolts, they
must be
replace them even if they have only been used once.
Apply a coat of White T lubricating grease to the
mating surface of the new cylinder head bolt (1).
• Screw in the cylinder head bolt (1) and tighten it
manually.
• Tighten the cylinder head bolt (1) according to the
sequence shown to the initial torque of 10 Nm
• Tighten the cylinder head bolt (1) according to the
sequence shown to the second torque of 150 Nm
Mount the special tool (1) on the cylinder head bolt to
• Tighten the cylinder head bolt (1) according to the be tightened
sequence shown to the third torque of 300 Nm According to the sequence shown, with the special
Final tightening of the cylinder head bolt tool (1) and the wrench (2) tighten the cylinder head
bolt to an angle of 90°
According to the sequence shown, with the special
tool (1) and the wrench (2) tighten the cylinder head
bolt to an angle of 90°
According to the sequence shown, with the special
tool (1) and the wrench (2) tighten the cylinder head
bolt to an angle of 90°

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 MC11 Series Engine Maintenance Manual

Assembling the articulated arm device

Check the camshaft TDC mark

Install the link arm bracket (1) on the cylinder

head
Check the TDC mark (1) on the camshaft (3)
The TDC mark (1) must align with the face of the
cylinder head (2).
If the mark is not aligned, remove the camshaft (3)
and reinstall it.
Valve shaft assembly

Grades
The valve stem recess should face the
camshaft.
Assemble valve shaft (1) and (2) as shown
• Mount the valve link arm shaft (2) to the link
arm bracket (1) Cylinder head cover assembly
• Screw the mounting bolt (3) and (4)
• Tighten the mounting bolt (4) to 105+10 Nm
• Tighten the mounting bolt (3) to 105+10 Nm
• Install the EVB pressure block (6)
• Screw in and tighten the new mounting bolt
(5)
Cylinder head cover tightening sequence

A Intake side B Exhaust side

• In the subsequent work steps, strictly follow the
tightening sequence of mounting bolt 1 to 18 as
shown in the figure above.

7
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 MC11 Series Engine Maintenance Manual

Check the cylinder head cover washer (2),

replace it with a new one if necessary.
Clean the grease on the gasket and groove
before installing the cylinder head cover. Pay
attention to the difference of the bolts when
installing the gasket. The 8 bolts on the
exhaust side are bolt sets without rubber
cushioning. The remaining 10 bolts are bolt
assemblies with rubber buffers.
Install cylinder head cover (2) on cylinder head
(1)
• Screw in the mounting bolt (3)
• Tighten the mounting bolt (3) to 10 Nm
according to the specified sequence
Installing the cable guide bracket
Install the cable guide cover

• Install the cable guide cover (1)

• Rotate 90° to lock the locking pin
(2)
Connect the speed sensor electrical connection
connector

7
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 MC11 Series Engine Maintenance Manual

Together with the cable harness, position the

cable guide bracket (2) so that it does not get
pressed, bent or worn. Screw and tighten the
mounting bolt (1) • Connect the electrical
connection connector (1) Disassemble the
engine crankshaft rotating device

Remove the engine crankshaft rotating device

[185] (1) from the flywheel housing. Install the
viewing port cover of the flywheel housing.

7
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 MC11 Series Engine Maintenance Manual

II. Check and adjust valve span

Fig. 2-25 Valve Span Adjustment

1. Exhaust valve adjusting bolt 2. Lock nut 3. Intake valve adjusting bolt 4. Lock nut
5. EVB pressure block locknut 6. EVB adjusting bolt

1. Technical data
Name Technical parameters
Intake valve range 0.5±0.03mm
Exhaust valve range 0.8±0.03mm
EVB pressure block adjustment range 0.6±0.03mm
Locknut (2), (4) 45Nm
EVB Pressure Block Locknut (5) 45Nm
Cylinder head cover mounting bolt 10Nm
2. Important information
Warning
Insufficient engine output or engine damage may occur
• Adjust the valve interval in the cold engine state
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.

8
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 T MC11 Series Engine Maintenance Manual

As shown inO
3. Special tools
Number the figure Description SINOTRUK
MAN numbering
Numbering
[195] Engine crankshaft rotating
device
• Rotate the crankshaft,
RNÉ8 k F'o L O7- using: JD6805-0023 80.99626-6008
• Ratchet wrench
[196]

[196] Ratchet wrench

• turn the crankshaft

JD6805-0038 80.99627-0001

[197]

W Fastening tools
• Check and adjust the
interval between valve
and EVB, using:
• Calibrator
thicknesses 0.5 [198]
• Calibrator
thicknesses 0.6 [199]
JD6805-0100 08.75300-0000
• Calibrator
thicknesses 0.8 [200]
• adjustment wrench
valve, size 14 [201]
• adjustment wrench
valve, size 21 [202]
• torque wrench
[203]

[198] .S ) - $3 - Thickness gauge 0.5

• Check and adjust the
valve span
JD6805-0101 80.99607-0177

[199] Thickness gauge 0.6

9
• Check and adjust the
valve span
JD6805-0102 80.99607-0178

[200] Thickness gauge 0.8

• Check and adjust the

g7 valve span
JD6805-0103 80.99607-0179

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 T MC11 Series Engine Maintenance Manual
Number
O
As shown in the figure Description SINOTRUK
Numbering
MAN numbering

AC
[201] Valve Adjustment Wrench,
Size 14
• Check and adjust the
valve span JD6805-0104 80.99603-6031

8
[202] Valve adjustment wrench,
size 21
• Check and adjust the
valve span
JD6805-0105 80.99603-6032

[203] torque wrench

• Set the interval
between valve and
EVB JD6805-0036 08.06450-0006

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 MC11 Series Engine Maintenance Manual

4. Check and set the valve span Remove the Connect the engine crankshaft rotating device
cover of the wire harness assembly

• Rotate 90°, open the locking pin (2) Remove

• the wire harness assembly cover (1)

Removing the cylinder head cover the

A Articulated arm contact B Free

engine running
articulated arm direction until the link arm is in
contact
• with the link arm shaft.
Adjust the free articulated arm according to
Grades the table
The mounting bolt can only be removed
from the with
together cylinder head cover.
the cylinder head cover pad
Unscrew
and spacerthe mounting bolt (3)
Remove the cylinder head cover (2) from the
cylinder head (1)
Remove the display port cover from the
steering wheel housing
• Mount the engine crankshaft rotating device [195]
to the flywheel housing
Move the engine to the set position

Use the engine crankshaft rotation device [195]

and ratchet wrench [196] to rotate the crankshaft in

8
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 MC11 Series Engine Maintenance Manual

Check intake valve clearance Check exhaust valve interval

• Insert a holding tool [197] (4) with a 0.5 the oil into the EVB piston (5)
thickness gauge [198] (2) between the ball seat Insert a holding tool [197] (3) with a 0.8
(1) and the valve shaft (3) thickness gauge [200] (4) between the ball seat
If the valve gap is not 0.5mm, you need to adjust it. (1) and the valve shaft (2)
Intake valve span adjustment If the valve gap is not 0.8 mm, you will need to
adjust it.
Move the EVB piston to the set position

Loosen the locknut (2) and adjusting bolt (1)

Insert a holding tool [197] (5) with a 0.5
thickness gauge [198] (6) between the ball seat Warning
(3) and the valve shaft (4) Incorrect valve span may occur
Screw in the adjusting bolt (1) until the 0.5 [198]
feeler gauge (6) can move between the ball • Do not press the EVB piston completely to the
seat (3) and the valve shaft (4), and meets a valve shaft
slight obstruction • Loosen the locknut (2) and unscrew
Using the valve adjusting wrench, size 14 [201] by several turns
hold the adjusting bolt (1) Tighten the locknut • Screw in the adjusting bolt (1) to
(2) to 45 Nm with a torque wrench [203] tighten the valve shaft (3) several
Check again and configure, repeat the times until the pressure point is reached.
configuration procedure if necessary. All engine oil must be expelled from the EVB piston
Repeatedly press the valve shaft (2) to expel (4).

8
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 MC11 Series Engine Maintenance Manual

Adjust the exhaust valve interval Adjust EVB piston interval

• Loosen the locknut (3) When the adjusting bolt is screwed in, the
• Screw in the adjusting bolt (2) to tighten the valve shaft cannot move the exhaust valve.
valve shaft (6) several times until the pressure Loosen the locknut (2)
point is reached. Unscrew the adjusting bolt (1) until the
• Use the adjusting bolt (1) to lock the valve shaft clamping tool [197] can be inserted (3)
(6) in this position mounted with a caliper
• Insert a holding tool [197] with a 0.8 thickness thickness 0.6[199](4)
gauge [200] (5) between the ball seat (4) and Screw the adjusting bolt (1) with the thickness
the valve shaft (6) gauge inserted 0.6 [199] (4) until the valve shaft
• Screw in the adjusting bolt (2) until the 0.8 [200] encounters obstruction - it can be distinguished
feeler gauge (5) can move between the ball by significantly higher resistance
seat (4) and the valve shaft (6), and meets a Using the valve adjusting wrench, size 21 [202]
slight obstruction hold the adjusting bolt (1)
Using the valve adjusting wrench, size 14 [201] Tighten the locknut (2) to 45 Nm with a torque
hold the adjusting bolt (2) Tighten the locknut wrench [203]
(3) to 45 Nm with a torque wrench [203] Check again and configure, repeat the
Check again and configure, repeat the configuration procedure if necessary.
configuration procedure if necessary. Remove the rotating device from the engine
Check EVB piston fit size crankshaft

Description
• Slightly press down on the valve stem (1)
• Insert a holding tool [197] (3) with a 0.6
thickness gauge [199] (2) between the
reverse bracket (4) and the valve shaft (1)
If the adjustment range is not 0.6 mm, you need
to adjust it.
Remove the engine crankshaft rotating device
[195] (1) from the flywheel housing. Install the
viewing port cover on the flywheel housing.
Cylinder head cover tightening sequence
5 7 6
gold"------------T---«9

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 MC11 Series Engine Maintenance Manual

Check the cylinder head cover washer (2),

replace it with a new one if necessary.
• Clean the grease on the gasket and groove
before installing the cylinder head cover.
Pay attention to the difference of the bolts
when installing the gasket. The 8 bolts on
the exhaust side are sets of bolts
without
rubber cushioning. The remaining 10 bolts
are sets of bolts with
rubber shock absorbers.
• Install cylinder head cover (2) on cylinder
head (1)
• Screw in the mounting bolt (3)
To intake side • Tighten the mounting bolt (3) to 10 Nm
B Exhaust side according to the sequence shown
• In the subsequent work steps, strictly follow Install the wire harness assembly cover
the tightening sequence of mounting bolt 1
to 18 as shown in the figure above.
Cylinder head cover assembly

• Install the wire harness assembly cover (1)

• Turn 90° to lock the locking pin (2)

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 MC11 Series Engine Maintenance Manual

III. Valve oil seal

1. Auxiliary jobs
- Check and adjust the valve interval seen on page 79
- Disassembly and assembly of the injector and common rail assembly see page 134

Fig. 2-26 Valve spring and valve oil seal

1. Cylinder head 2. Valve oil seal 3. Valve spring 4. Valve locking clip
2. Technical data
Name Specification Technical parameters
10Nm
Cylinder head cover mounting bolt

Articulating arm bracket flat head M12×60-10.9 105+10Nm

bolt
3. Important information

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 MC11 Series Engine Maintenance Manual

Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• Final tightening must be done manually with a torque wrench.

8
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 MC11 Series Engine Maintenance Manual

4. Special tools
Number As shown in the figure Description SINOTRUK MAN numbering
Numbering

[204] Engine crankshaft rotating device

JD6805-0023 80.99626-6008
• Rotate the crankshaft, using:
<6•- A $o • O7- • Ratchet wrench [205]

[205] Ratchet wrench JD6805-0038 80.99627-0001

• turn the crankshaft
to

[206] JD6805-0106 80.99613-6000

Valve spring compression tool
• Disassembly and assembly of
valve spring, using:
• Tube connector [207]
6" Rhu. • Support [211]
• Support [210]
• Extension rod [209]
• Tool of
assembly [208]

[207] tube connector JD6805-0107 80.99613-0042

• Disassembly and assembly of
Valve spring

[208] Assembly tool JD6805-0108 80.99606-6092

G\
• Disassembly and assembly of
Valve spring
Pll

[209] Extension rod JD6805-0109 80.99606-6094

• Disassembly and assembly of
Valve spring

[210] -
Medium JD6805-0110 80.99613-0052

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK MAN numbering

Numbering

• Disassembly and assembly of

Valve spring

[211] Medium JD6805-0111 80.99613-0053

• Disassembly and assembly of
Valve spring

[212] JD6805-0112 80.99639-0009

electromagnetic sensor
• Disassembly of the caliper
valve lock, using:
• Tube connector [207]
• Support [210]
• Support [211]
• Tool of
valve spring compression
[206]
• Extension rod [209]
• Tool of
assembly [208]
[213] Assembly tool JD6805-0113 80.99606-6088
• Remove the seal

9
valve oil

[214] Pipe wrench assembly JD6805-0114 80.99606-0287

• Oil seal assembly
of the valve, using:
'— • Tool of
assembly [213]

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 TO MC11 Series Engine Maintenance Manual

5. Remove the valve oil seal Remove the wire Connect the engine crankshaft rotating device
harness assembly cover

• Rotate 90°, open the locking pin (2) • Remove the seal cover from the flywheel
• Remove the wire harness assembly cover (1) housing
Removing the cylinder head cover • Mount the engine crankshaft rotating device
[204] to the flywheel housing
Move the engine to the set position

Grades A Articulated arm contact

The mounting bolt can only be removed together B Free articulated arm
with the cylinder head cover pad and the spacer • Use the engine crankshaft rotation device
from the cylinder head cover. [204] and ratchet wrench [205] to start the
• Unscrew the mounting bolt (3) engine with the lever in the engine running
• Remove the cylinder head cover direction until the link arm is in contact with the
(2) from the link arm shaft.
cylinder head (1) • Disassembly and installation of the valve-free
oil seal according to the table
Disassembly of the articulated arm device

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 MC11 Series Engine Maintenance Manual

Engine maintenance manual MC11 series diesel 2

Chapter I Introduction of MC11 Engine......1
Chapter II Disassembly and assembly of series engine components 6
MC11............................................................6
TO..................................................................89
TO................................................................133
Accessories...............................................265
•
• Clearance he arm device
articulate
(2) together with the articulated arm seat
support (1)
Remove the valve stem

Special assembly tools

9
2
 Grades on Manual
MC11 Series Engine Maintenance the valve spring compression tool [206] (1) and
• The lock washer and bracket [211] have left- screw it by turning the thread axis
hand threads. Screw the lock washers (2) and (6)
Position the bracket [210] (5) and bracket [211] (3) Position lever (8) on valve spring compression tool
[206] (1) and secure with mounting bolt (7)
Mark the mounting position (1) and (2) of the valve shaft
Disassemble the valve shaft (1) and (2)

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 MC11 Series Engine Maintenance Manual

Fasten the mounting device Hook the valve spring compression tool [206] (2)
onto the assembly tool [208] (3)
Mount the extension rod [209] (1) to the valve
spring compression tool [206] (2)

• Screw the tube connector [207] (2) into the

bearing bracket (1)
• Screw the mounting tool [208] (3) into the tube
connector [207] (2)
Valve Spring Compression Tool Assembly

Position the bracket [210] (4) and bracket [211] on

the spring seat and extension bar by turning the
threaded shaft (5)

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 MC11 Series Engine Maintenance Manual

Disassembling the valve locking clip 6. Install the valve oil seal Install the
valve oil seal

Grades
:
Valve spring rebound can cause injury
• Make sure bracket [210] and
bracket [211] are properly seated in spring
seat
• Disassembly is not allowed
manually the valve locking clamp
of the valve spring.
• Using the extension bar [209] press down on
the valve spring compression tool [206] (1)
• Using the electromagnetic sensor [212],
remove the valve locking clip (2) from the valve
stem (3). The red one is mounted on the intake
• Release the valve spring compression tool valve.
[206] (1) The brown one is mounted on the exhaust valve.
• Remove the valve spring along with the • Apply a coat of clean engine oil to the
washer and spring seat. mounting socket wrench [214] (2) and valve oil
• Repeat the same procedure for all valves seal (3)
• Special disassembly tools Remove the valve • Press the assembly socket wrench [214] (2)
oil seal onto the valve stem (1)
• Insert the valve oil seal (3) into the assembly
tool [213] (4) and fasten it
• Press the assembly tool [213] (4) into the
assembly socket wrench [214] (2)
• Using an impact hammer (5) tap the valve oil
seal (3) to the valve lever (1)
• Remove the assembly tool [213] (4) and the
assembly socket wrench [214] (2)
Assembly tool assembly

Grades
Intake and exhaust valve seals have
different colors.

Press the assembly tool [213] (2) into the valve

oil seal (1) Fasten the assembly tool [213] (2)
Using an impact hammer, pull the valve oil seal
(1) out of the valve guide tube.

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 MC11 Series Engine Maintenance Manual

Mount the extension rod [209] (1) to the valve

spring compression tool [206] (2)

• Screw the tube connector [207] (2) into the

bearing bracket (1)
• Screw the mounting tool [208] (3) to the tube
connector [207] (2)
Valve Spring Compression Tool Assembly

Mount bracket [210] (4) and bracket [211] to spring

seat and extension bar by rotating threaded shaft
(5)
Hook the valve spring compression tool [206] (2)
onto the assembly tool [208] (3)

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 MC11 Series Engine Maintenance Manual

Valve spring assembly Install the valve locking clip

Grades
:
articulated arm bracket (1)
• Screw the mounting bolt (3) and (4)
• Tighten the bolt of
mounting (4) to 105 Nm
• Tighten the bolt of
mounting (3) to 105 Nm
The valve.
• Mount the block of pressureEVB (6)
• Screw and tighten the new mounting bolt (5)
On the valve stem insert the washer (3), the valve Remove the rotating device from the engine
spring (2) and the spring seat (1) crankshaft
Repeat the same procedure for all valves
Valve spring rebound can cause injury
• Make sure bracket [210] and bracket [211] are
properly seated in spring seat
• It is not permitted to manually insert the valve
locking clip into the valve spring.
Using the extension bar [209] press down on the
valve spring compression tool [206] (1)
Insert the valve locking clip (2) into the groove of
the valve stem (3) with a suitable tool
• Release the valve spring compression tool [206] (1)
• Remove special tools
Valve shaft assembly
Assembling the articulated arm device

Grades
The valve stem recess should face the
camshaft.
Assemble the valve shaft (1) and (2) according
to the markings

• Install the link arm bracket (1) on the cylinder

head
• Mount the articulated arm device (2) to the

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 MC11 Series Engine Maintenance Manual

Cylinder head cover tightening sequence

To intake side
B Exhaust side
• In the subsequent work steps, strictly follow
the tightening sequence of mounting bolt 1 to
18 as shown in the figure above.
Remove the engine crankshaft rotating device [204] (1) from the flywheel housing. Install the viewing port
cover on the flywheel housing.

9
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 T MC11 Series Engine Maintenance Manual

O
Cylinder head cover assembly

Check the cylinder head cover washer (2), replace it with a new one if necessary.
• Clean the grease on the gasket and groove before installing the cylinder head cover. Pay attention to the
difference of the bolts when installing the gasket. The 8 bolts on the exhaust side are sets of bolts
without
rubber cushioning. The remaining 10 bolts are bolt assemblies with rubber buffers.
• Install cylinder head cover (2) on cylinder head (1)
• Screw in the mounting bolt (3)
• Tighten the mounting bolt (3) to 10 Nm according to the sequence shown
Install the wire harness assembly cover

• Install the wire harness assembly cover (1)

• Turn 90° to lock the locking pin (2)

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 MC11 Series Engine Maintenance Manual

SECTION VI VALVE TIMING

Fig. 2-27 Valve Timing

1. Camshaft gear 2. Intermediate gear 3. Camshaft 4. Cylinder head 5. camshaft cover

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 MC11 Series Engine Maintenance Manual

1. Camshaft / camshaft cover

2. Auxiliary jobs
- Verification and configuration of the valve interval is seen on page 79
- Valve timing check seen on page 114

Fig. 2-28 Camshaft / camshaft cover

1. Camshaft gear 2. Intermediate gear 3. Camshaft 4. Cylinder head 5. camshaft cover
3. Technical data
Name Specification Technical parameters
Camshaft gear mounting bolts (1) M8×30-10.9 Initial torque 15 Nm

M8×30-10.9 90° angle

Mounting bolts, camshaft gear (1)
Idler gear mounting bolts (2) M8×30-10.9 30Nm
Cylinder head cover mounting bolt 10Nm
M12×60-10.9 105+10Nm
Articulating arm device mounting bolts
Camshaft axial interval (3) 0.05-0.85mm
Camshaft bearing neck diameter Ø 39.925 - 39.950mm
Camshaft cover depth 42,095-42,150mm
9,000-9,100mm
Camshaft gear mounting depth (1)
Width of the seventh camshaft bearing seat 32,500-32,700mm

Camshaft cover width 25,700-26,000mm

Articulated arm radial range 0.030-0.066mm
Inner diameter of articulated arm seat Ø 32,005-32,025 mm
Outer diameter of articulated arm shaft Ø 31,959-91,975 mm

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 MC11 Series Engine Maintenance Manual

4. Auxiliary materials
Omnifit 200 Adhesive
5. Important information
Warning
Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
Final tightening must be done manually with a torque wrench.
5. Special tools
Number As shown in the figure Description MAN numbering
SINOTRUK
Numbering

[215] JD6805-0024 08.71000-3217

1
Micrometer
• Checkthe axial and radial interval
From the tree of cams, using:
• Check the radial intervalof the
articulated arm, using:
• Micrometer holder [216]
• Barrette of positioning
[217]

[216] Micrometer holder JD6805-0025 08.71082-0005

• Check the axial and radial interval
camshaft
• Check the radial interval of the
articulated arm

[217] JD6805-0026 80.99605-0197

6
Locating pin
• Check the axial and radial interval
camshaft
• Check the radial interval of the
articulated arm
[218] JD6805-0032 08.71195-9003
Depth gauge (electronic)
• Check the depth of the
camshaft cover
• Check the depth of
camshaft gear assembly

[219] Insert the lever, JD6805-0020 80.99617-0187

6 •

•
hit
using:
the top

Compression disk [220]

of seal,

[220] Compression disc JD6805-0115 80.99604-0301

((©)
• Strike seal cap

[221] crankshaft rotating device JD6805-0116 80.9626-6008

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MC11 Series Engine Maintenance Manual

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK MAN numbering

Numbering

engine
• Rotate the crankshaft, using:
• Ratchet wrench [222]

[222] Ratchet wrench JD6805-0038 80.99627-0001

• turn the crankshaft
g

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 T MC11 Series Engine Maintenance Manual
Check the articulated arm Connect the engine crankshaft rotating device
Remove the cover of the Owire harness assembly

• Rotate 90°, open the locking pin (2) • Remove the display port cover from the
• Remove the wire harness assembly cover (1) steering wheel housing
Removing the cylinder head cover • Mount the engine crankshaft rotating device
[221] to the flywheel housing
Move the engine to the check position

A Articulated arm contact

Grades B Free articulated arm
The mounting bolt can only be removed together • Use the engine crankshaft rotation device [221]
with the cylinder head cover pad and the and ratchet wrench [222] to start the engine
spacer from the cylinder head cover. with the lever in the engine running direction
• Unscrew the mounting bolt (3) until the link arm is in contact with the valve
• Remove the cylinder head cover (2) shaft.
from the • Check the free articulated arm according to the
cylinder head (1) table

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 MC11 Series Engine Maintenance Manual

Check the radial range of the articulated arm Disassembly of the articulated arm device

• Install the micrometer holder [216] (2), the shaft

micrometer [215] (3) and the pin Disassemble the valve shaft (1) and (2)
positioning [217]
• With a certain pretensioning force, position the
positioning pin [217] in front of the articulated
arm (1)
• Vertically press the articulated arm (1) down as
far as it will go
• Zero the micrometer [215] (3)
• Pull the articulated arm (1) to the tail and read
the difference
Repeat this procedure for the remaining
articulated arms
The allowable radial range of the articulated arm (1)
is 0.030-0.066 mm.
If the radial interval is outside the tolerance range,
check the inner diameter of the link arm (1) and the
outer diameter of the link arm shaft.
Check the inner diameter of the articulated arm (1),
see "Checking the inner diameter of the articulated
arm", page . 103
Check the outer diameter of the link arm shaft, see
"Checking the outer diameter of the link arm shaft",
page . 103
Unscrew the mounting bolt (5)
Disassemble the EVB pressure block (6) Unscrew
the mounting bolt (3) and (4) Remove the articulated
arm device (2) together with the articulated arm seat
support (1)
Remove the valve stem

Mark the mounting position (1) and (2) of the valve

1
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 MC11 Series Engine Maintenance Manual

Disassembly of the articulated arm device

• Clean the articulated arm shaft (2)

• Check the outer diameter of the articulated arm
Dismantle the snap ring (4)
shaft (2) with the micrometer gauge (1)
Remove the washer (3)
• Repeat this procedure for the remaining
Mark the mounting position (1) of the articulated
articulated arm axles (2)
arm
The admissible external diameter of the articulated
• Pull the link arm (1) off the link arm axis (2)
arm shaft (2) is Ø 31,959-31,975 mm.
Check the inner diameter of the articulated arm
If the inner diameter is outside the tolerance range, a
seat
new articulated arm (2) must be fitted.
Unscrew the adjusting bolt

• Remove the articulated arm (1) from the bearing

• Check the inner diameter of the link arm with the Unscrew the locknut (1)
micrometer [215] (3) and an inner diameter Unscrew the adjusting bolt (3) of the articulated
gauge (2) arm (2)
• Repeat this procedure for the remaining
articulated arms
The internal diameter of the permissible articulated
arm seat is Ø 32.005-32.025 mm.
If the inner diameter is outside the tolerance range, a
new articulated arm (1) must be fitted.
Check the outer diameter of the articulated arm
shaft

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 MC11 Series Engine Maintenance Manual

Unscrew the EVB adjustment bolt Assemble the articulated arm device Screw the
adjusting bolt

Unscrew the adjusting bolt (1) from the EVB arm (2)
pressure block (2) • Screw the locknut (1)
• Screw the adjusting bolt (3) to the articulated Screw in the EVB adjustment bolt

Screw the adjusting bolt (1) to the EVB pressure

block (2)
Screw the locknut (3)

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 MC11 Series Engine Maintenance Manual

Assemble the articulated arm device Check camshaft

Check camshaft axial range

Apply a coat of clean engine oil to the link arm

shaft (2). • Install the micrometer holder [216] (2), the
Press the articulated arm (1) to the articulated micrometer [215] (1) and pin
arm shaft (2) as shown in the figure positioning [217]
• With a certain pretensioning force, position the
Retaining washer (3) positioning pin [217] in front of the camshaft (3)
Install the spring (4) • Push the camshaft (3) horizontally into the
flywheel housing as far as it will go.
• Zero the micrometer [215] (1)
• Pull the camshaft (3) all the way, aiming at the
micrometer [215] (1) and read the difference
The allowable axial range of the camshaft (3) is 0.05
to 0.85 mm.
If the radial interval is out of the tolerance range,
you need to check the depth of the camshaft cover,
the mounting depth of the camshaft gear and the
width of the camshaft cover seat 7.
Check the camshaft cover depth, see "Checking
Camshaft Cover Depth 7" on page . 108
Check the mounting depth of the camshaft gear, see
"Checking the camshaft mounting depth" on page .
108
Check the width of camshaft cover seat 7, see
"Checking the width of camshaft cover seat 7" on
page . 108

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 MC11 Series Engine Maintenance Manual
Check camshaft radial range

Install the micrometer holder [216] (1), the • Check the TDC mark (1) on the camshaft (3)
micrometer [215] (2) and the pin The TDC mark (1) on the camshaft (3) must
positioning [217] align with the face of the cylinder head (2).
With a certain pretensioning force, position the If the marks are not aligned, you must continue
positioning pin [217] in front of the camshaft (3) cranking the engine in the 360° engine running
Vertically press the camshaft (3) down all the direction until the TDC mark on the flywheel is
way reached.
Zero the micrometer [215] (2) Hold the engine crankshaft rotating device [221]
Pull the camshaft (3) all the way, aiming at the
micrometer [215] (2) and read the difference
The allowable radial range of the camshaft (3) is
0.024 to 0.090 mm.
If the radial span is outside the tolerance range, you
need to check the inner and outer diameter of the
camshaft cover.
Check the inner diameter of the camshaft shaft
cover, see "Checking the camshaft shaft cover" on
page . 107
Check the outer diameter of the camshaft shaft
cover, see "Checking the outer diameter of the
camshaft shaft cover" on page . 108
Remove the camshaft
Turn the engine to the TDC mark

• Adjust the engine according to the engine

running direction, using the engine crankshaft
rotating device [221] (1) and the ratchet wrench
[222] until cylinder 1 is protruding from the point
marked TDC (top dead center). (2)
Check the camshaft TDC mark

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Check camshaft cover for out of roundness

Remove the camshaft • Mark the mounting (2) from the

• Clean the cover and

place them together
as shown
• Measure he
size
micrometer (1)
• Measure he

position of the camshaft.

bearing cap (1) Grades
• Unscrew the ID The difference
mounting bolt (2) between size
• Mark the mounting A and size B is
the non-
position of the
roundness of
camshaft shaft the camshaft
cover cover.
• Remove the camshaft shaft (2) on a
bearing cover (1) flat surface
together with the
camshaft shaft TO with he Caliper
cover.
• Remove the b with he Caliper
camshaft (3) micrometer (1)
together with the The maximum out of
camshaft shaft roundness allowed for
cover. the camshaft shaft
Remove the camshaft cover is 1.00 mm. If the
gear out-of-roundness is
outside the tolerance
range, a new camshaft
shaft cover (2) must be
fitted.
Check camshaft shaft
cover

Unscrew the
mounting bolt (4)
Remove the
pressure plate (3)
and camshaft gear

• C
l
e
a
n

1
1
1
MC11 Series Engine Maintenance Manual

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MC11 Series Engine Maintenance Manual

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MC11 Series Engine Maintenance Manual

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1
1
4
MC11 Series Engine Maintenance Manual

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1
1
5
MC11 Series Engine Maintenance Manual

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The
perm
itted
inner
diam
eter
for
the
cam
shaft
shaft
cove
r is
Ø
39.9
74 -
40.0
15
mm.
If the
inner
diam
eter
is
outsi
de
the
toler
ance
rang
e, a
new
cam
shaft
shaft
cove
r
must
be
fitted
.

1
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MC11 Series Engine Maintenance Manual

Check camshaft gear mounting depth

Check the outer diameter of the camshaft shaft

neck
• Clean the The permissible depth
camshaft (3) of the seventh
• Using the camshaft cover (2) is
micrometer gauge 42,095-42,150 mm.
(2) measure the If the depth is outside
outer diameter of the tolerance range, a
the camshaft new camshaft must be
shaft collar (1). fitted.
• Repeat procedure • Clean the
for all remaining camshaft gear (2)
camshaft shaft • Using depth
collars gauge (electronic)
The permitted external [218] (1) measure
diameter for the neck the mounting
of the camshaft shaft is depth of the
Ø 39.925 – 39.950 camshaft gear
mm. The permissible
If the outer diameter is mounting depth for the
outside the tolerance camshaft gear (2) is
range, a new camshaft 9,000-9,100 mm.
(3) must be fitted. If the mounting depth
Check the depth of is outside the tolerance
the 7th camshaft range, a new camshaft
cover gear (2) must be
installed.
Check the seat width
of the 7th camshaft
cover

• Using depth
gauge (electronic)
[218] (1) measure
the depth of the
seventh camshaft Clean the seat of
cover

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MC11 Series Engine Maintenance Manual

the seventh
camshaft cover
(2)
Using the
micrometer gauge
(1), measure the
width of the seat
of the seventh
camshaft cover
(2).
The permissible seat
width of the seventh
camshaft cover (2) is
32,500-32,700 mm.
If the width is outside
the tolerance range, a
new cylinder head
must be fitted.

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 MC11 Series Engine Maintenance Manual

Remove the
camshaft
intermediate gear
Remove the seal
cover

• Using the
screwdriver (1)
insert the lower
edge of the liner
(2)
• Open and remove
the liner (2)
Unscrew the idler
gear mounting bolt
Remove the
camshaft
intermediate gear

Unscrew the mounting bolt (2) from the idler

gear (1)

Using the idler gear

shaft (2) move up to
pull the idler gear (1)
from the cylinder head.
Pull the idler gear (1)
from the idler gear
shaft (2)

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 MC11 Series Engine Maintenance Manual

Install the camshaft idler gear Screw in the idler gear mounting bolt
Install the camshaft idler gear Install the bowl plug

Apply a coat of clean engine oil to the idler gear Apply a layer of Omnifit 200 adhesive to the
shaft (2). mating surface of the new liner (3)
Insert the idler gear shaft (2) into the idler gear Assemble the extrusion plate [220] (1) and
(1) insert the lever [219] (2)
• Insert the idler gear (1) and idler gear shaft (2) Insert the liner with a special tool until
together to the cylinder head from the top obstruction is found

Align the idler gear (1) and idler gear shaft with the holes in the cylinder head
Screw in the mounting bolt (2) and tighten it to 30 Nm

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 MC11 Series Engine Maintenance Manual

Install the camshaft Tighten the camshaft cover mounting bolts

Camshaft gear assembly
Align
the

camshaft gear (3) and compression plate (4) with Screw in the new mounting bolt (4) and hand
the locating pin (2) tighten it, never twist the camshaft (5)
Install camshaft gear (3) and compression plate Tighten the mounting bolt (1)
(4) on camshaft (1) Release the engine crankshaft rotating device
Screw in the mounting bolt (5) and tighten it to the
initial torque of 15 Nm.
Tighten mounting bolt (5) to 90° angle
Install the camshaft

Release the engine crankshaft rotating device

[221] (1)
Check Engine Timing
Apply clean engine oil to the lower camshaft shaft
cover.
Insert the lower camshaft shaft cover as shown
Insert the camshaft (5) so that the TDC mark (1)
aligns with the face of the cylinder head (2)
Apply clean engine oil to the upper camshaft shaft
cover.
Insert the upper camshaft shaft cover to the
bearing cap (3) as shown
Install the bearing cover (3)

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 MC11 Series Engine Maintenance Manual

Using the ratchet wrench [222] in the direction of

engine operation by 720°, turn the crankshaft until
it reaches the TDC mark (2).
Hold the engine crankshaft rotating device [221]
(1)

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 MC11 Series Engine Maintenance Manual

Check the camshaft TDC mark Valve shaft assembly

• Check the TDC mark (1) on the camshaft (3) Grades

The TDC mark (1) on the camshaft (3) must The recess of the valve shaft must always
align with the face of the cylinder head (2). face the camshaft.
If the mark is not aligned, remove the camshaft Assemble the valve shaft (1) and (2) as
(3) as shown and reinsert it. shown in the figure
Assembling the articulated arm device
Assembling the articulated arm device

• Install the link arm seat bracket (1) to the

cylinder head
• Mount the articulated arm device (2) to the
articulated arm seat bracket (1)
• Screw the mounting bolt (3) and (4)
Engine maintenance manual MC11 series diesel
Chapter I Introduction of MC11 Engine
Chapter II Disassembly and assembly of series engine components

1
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 MC11 Series Engine Maintenance Manual

MC11
TO
TO
Accessories
•
• Screw and tighten the new bolt
mounting
(5)

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 MC11 Series Engine Maintenance Manual

Cylinder head cover tightening sequence rubber cushioning. The remaining 10 bolts are
bolt assemblies with rubber buffers.
• Install cylinder head cover (2) on cylinder head
(1)
• Screw in the mounting bolt (3)
• Tighten the mounting bolt (3) to 10 Nm
according to the sequence shown
Install the cable guide cover

• Install the cable guide cover (1)

• Rotate 90° to lock the locking pin
(2)
Remove the rotating device from the engine
crankshaft

To intake side
B Exhaust side
• In the subsequent work steps, strictly follow the
tightening sequence of mounting bolt 1 to 18 as
shown in the figure above.
Cylinder head cover assembly

Remove the engine crankshaft rotating device

[221] (1) from the housing
steering wheel
Install the cover on the steering wheel housing

Check the cylinder head cover washer (2), replace it with a new one if necessary.
Clean the grease on the gasket and groove before installing the cylinder head cover. Pay attention to the
difference of the bolts when installing the gasket. The 8 bolts on the exhaust side are bolt sets without

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 MC11 Series Engine Maintenance Manual

II. Valve timing

1. Auxiliary jobs
- Verification and configuration of the valve interval is seen on page 79

Fig. 2-29 Valve Timing

1. Camshaft 2. Steering wheel housing 3. Engine crankshaft rotating device
2. Technical data
Name Technical parameters
Continuous valve lift measurement
Intake valve 10±0.2mm, exhaust valve 12±0.2mm

Cylinder head cover mounting bolt 10Nm

3. Important information
Warning
Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• Final tightening must be done manually with a torque wrench.
Grades
The valve timing check must be performed with the correct configured valve span.

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 T MC11 Series Engine Maintenance Manual

O
4. Special tools
Number Description SINOTRUK
As shown in the figure MAN numbering
Numbering
[223] JD6805-0024 08.71000-3217
Micrometer
• check of the
valve timing, using:
• Medium of the micrometer
[224]
• Barrette of
positioning [225]
[224] Micrometer holder JD6805-0025 08.71082-0005
• Check synchronization
from valvule

[225] Locating pin JD6805-0026 80.99605-0197

6
• Check synchronization
from valvule

[226] Engine crankshaft rotating device JD6805-0023 80.99626-6008

• Rotate the crankshaft, using:
É x M'o • Ratchet wrench [227]
6Ow-

[227] Ratchet wrench JD6805-0038 80.99627-0001

• turn the crankshaft

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 MC11 Series Engine Maintenance Manual

5. Check valve timing Remove cable guide Connect the engine crankshaft rotating device
cover

• Turn 90° and open the locking pin (2) brand

• Remove the cable guide cover (1) The articulated arm of the sixth cylinder must be in
Removing the cylinder head cover contact.
If the sixth cylinder link arm is not in contact,
continue turning the steering wheel 360° until the
TDC mark is reached.
Check valve lift

Grades
The mounting bolt can only be removed
together with the cylinder head cover pad
and the spacer from the cylinder head cover. Warning
Unscrew the mounting bolt (3) /N If the motor rotates in the opposite direction to
Remove the cylinder head cover (2) from the the motor running direction, it will cause
cylinder head (1) erroneous data reading.
• You can only rotate the motor in the direction of
• Remove the display port cover from the steering
motor operation
wheel housing
• Mount the micrometer [223] (4) with the locating
• Mount the engine crankshaft rotating device
pin [225] (2) and the micrometer holder [224] (3)
[226] (1) to the flywheel housing
on the intake valve disc of cylinder 3
Turn the engine to the TDC mark
• Zero the micrometer [223] (4)
• Continue rotating the crankshaft in the direction
of engine operation until the micrometer pointer
is stationary.
In this position, the correct lift should be 10 ± 0.2 mm
on the intake valve, 12 ± 0.2 mm on the exhaust
valve.
Cylinder head cover tightening sequence

According to the running direction of the engine,

using the engine crankshaft rotating device
[226] (1) and the ratchet wrench [227] adjust the
flywheel until the TDC (top dead center) mark
(2) on the flywheel is aligned with the TDC

1
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 MC11 Series Engine Maintenance Manual

To intake side
B Exhaust side
• In subsequent work steps, strictly follow the
tightening sequence of mounting bolt 1 to 18 as
indicated.

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 T MC11 Series Engine Maintenance Manual

O
Cylinder head cover assembly

Check the cylinder head cover washer (2),

replace it with a new one if necessary.
Clean the grease on the gasket and groove
before installing the cylinder head cover. Pay
attention to the difference of the bolts when
installing the gasket. The 8 bolts on the exhaust
side are bolt sets without rubber cushioning. The
remaining 10 bolts are bolt assemblies with
rubber buffers.
Install cylinder head cover (2) on cylinder head
(1)
Screw in the mounting bolt (3)
Tighten the mounting bolt (3) to 10 Nm according
to the sequence shown

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 T MC11 Series Engine Maintenance Manual

O
Install the cable guide cover

• Install the cable guide cover (1)

• Turn 90° to lock the locking pin (2) Remove the rotating device from the engine crankshaft

Remove the engine crankshaft rotating device [226] (1) from the housing
steering wheel
Mount the display port cover to the steering wheel housing

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MC11 Series Engine Maintenance Manual
III. Rear timing gear
1. Auxiliary jobs
- Removal and assembly of the engine control unit is seen on page 7
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the thermostat is seen on page 24
- Disassembly and assembly of the thermostat housing is seen on page 26
- Disassembly and assembly of the starter motor is seen on page 41
- Disassembly and assembly of the exhaust manifold is seen on page 54
- Disassembly and assembly of intake pipes see page 57
- Disassembly and assembly of the turbocharger is seen on page 61
- Disassembly and assembly of the cylinder head is seen on page 67
- Verification and configuration of the valve interval is seen on page 79
- Valve timing check seen on page 114
Engine maintenance manual MC11 series diesel 2
Chapter I Introduction of MC11 Engine 1
Chapter II Disassembly and assembly of series engine components 6
MC11 6
TO 89
TO 133
Accessories 265
-

Fig.3-36 Engine rear gear

1. Crankshaft rear gear 2. Air compressor intermediate gear 3. Mounting bolt 4. Rear end idler gear assembly 5.
Mounting bolt 6. crankcase intermediate gear

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MC11 Series Engine Maintenance Manual
2. Technical data
Name Specification Technical parameters
Mounting bolts (5) M14×80-10.9 Initial torque 150 Nm
Mounting bolts (5) M14×80-10.9 90° angle
Mounting bolt (3) M12×55-10.9 115Nm
Crankcase intermediate gear mounting bolts (6) M8×20-10.9 30Nm
Tooth Span, Rear End Intermediate Gear Assembly (4)- Rear 0.052-0.176mm
Crankshaft Gear (1)
Tooth Span, Rear End Idler Gear Assembly (4)- Crankcase Idler 0.052-0.176mm
Gear (6)
Axial span, air compressor intermediate gear (2) 0.100-0.240mm
Height, air compressor intermediate gear (2) 25,900-26,000mm
4,800-5,000mm
Height, thrust washer, air compressor idler gear (2)

Ø 60.00 - 60.03 mm
Inner diameter, air compressor intermediate gear (2)

Ø 59,921 - 59,940 mm
Outer diameter, air compressor idler gear shaft

Height, air compressor idler gear shaft 26,100-26,140mm

0.100-0.290mm
Axial span, rear end idler gear assembly (4)

0.060-0.109mm
Radial interval, rear end idler gear assembly (4)

52,950-53,000mm
Height, rear end idler gear assembly (4)

Ø 80,000 - 80,030 mm
Bore diameter, rear end idler gear assembly (4)

Ø 79,921 - 79,940 mm
Outer diameter, rear end idler gear assembly bearing

56,200-56,240mm
Height, rear end idler gear assembly bearing

Axial interval, crankcase intermediate gear (6) 0.100-0.290mm

Radial interval, crankcase intermediate gear (6) 0.060-0.109mm
Height, crankcase intermediate gear (6) 17,950-18,000mm
Inner diameter, crankcase intermediate gear (6) Ø 60,000 - 60,030 mm
Outer diameter, crankcase idler gear shaft Ø 59,921 - 59,940 mm
Height, crankcase intermediate gear shaft 21,200-21,240mm
3. Important information
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum tightening
torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.

Grades
Idler gears and pins do not need to be replaced in sets.
They can be replaced individually depending on the degree of wear.
Grades
The intermediate gear of the air compressor is divided into two parts to reduce noise.
You cannot measure the tooth interval here.

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 T MC11 Series Engine Maintenance Manual
4. Special tools
Number O
As shown in the figure
Description SINOTRUK
MAN numbering
Numbering
[233] JD6805-0117 80.99617-0020

[234]
8 Alignment Drill Lever
• Disassembly and assembly of
crankshaft rear gear

JD6805-0118 80.99617-0209

8
Alignment tools
• Disassembly and assembly of
air compressor intermediate
gear
[235] JD6805-0024 08.71000-3217

F
Micrometer
• Check the diameter
intermediate gear interior
• Interval Check
of intermediate gear tooth,
using:
• Interval Check
axial and radial of the
intermediate gear, using:
• Micrometer holder
[236]
• Pin
positioning [237]

[236] JD6805-0025 08.71082-0005

Micrometer holder
• Check the interval
intermediate gear tooth
• Check axial span
and intermediate gear radial

[237] JD6805-0026 80.99605-0197

g
Positioning pin
• Check the interval
intermediate gear tooth
• Check axial span
and intermediate gear radial

[238] depth gauge JD6805-0032 08.71195-9003

• Check axle height
of the intermediate gear

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 MC11 Series Engine Maintenance Manual

Check timing gear tooth interval Set the crankshaft gear to the marked position
Check tooth gap between crankshaft gear/rear Install the crankshaft gear
end idler gear assembly

• Screw the mounting bolt (2) and (3) to mount the

crankshaft gear (1)
• Assemble the micrometer holder [236] (3) that has the Set the crankshaft gear to the marked position
micrometer [235] (2) and positioning pin [237]
• With a certain pretensioning force, mount the locating
pin [237] to the rear end idler gear assembly (1)
• Measure the tooth gap between the crankshaft gear
(4) and the rear end idler gear assembly
The allowable tooth range is 0.052-0.176 mm.
If the tooth interval is outside the tolerance range, you
must install a new crankshaft gear (4) and a new rear end
idler gear assembly (1).
Check tooth gap between pin idler gear/rear end idler
gear assembly

• Rotate the crankshaft until mark (1) aligns with

mark (2)
Align mark (1) with mark (2)
Unscrew the crankshaft gear mounting bolt

Mount the micrometer holder [236] (2) that has the

micrometer [235] (1) and the locating pin
[237] (3)
With a certain pretensioning force, install the locating
pin [237] (3) on the intermediate gear of the
crankcase (4)
Unscrew the mounting bolt (2) and (3) to
release the crankshaft gear (1)
• Measure the tooth interval at the middle of the crankcase idler gear (4).
The allowable tooth range is 0.052-0.176 mm.
If the tooth interval is outside the tolerance range, you must install a new crankcase idler gear (4) and a new rear end idler
gear assembly.

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 MC11 Series Engine Maintenance Manual

Remove the rear end idler gear assembly

Measure the axial span of the rear end idler gear
assembly

• Mount the micrometer holder [236] (3) that has

the micrometer [235] (2) and
the
positioning pin [237]
• With a certain pretensioning force, mount the
locating pin [237] to the rear end idler gear
assembly (1)
• Push the rear end idler gear assembly (1) all the
way
• Set the micrometer [235] (2) to zero
• Pull the rear end idler gear assembly (1) to the
end position and read the difference
The allowable axial range is 0.100-0.290 mm.
If the axial span is outside the tolerance range, you
must check the height between the rear end idler
gear assembly (1) and the bearing of the rear end
idler gear assembly.
Check the height of the rear end idler gear assembly
(1), see “Checking the Height of the Rear End Idler
Gear Assembly,” page . 125
Check rear end idler gear assembly bearing height
(4), see "Checking Rear End Idler Gear Assembly
Bearing Height", page . 125
Remove the rear end idler gear assembly

Unscrew the mounting bolt (1)

Remove the rear end idler gear assembly (3) along
with the idler gear shaft (2).

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 MC11 Series Engine Maintenance Manual

Check height of rear end idler gear assembly Measure the height of the idler gear shaft
• Clean the rear end The allowable inner

idler gear assembly diameter is Ø 80,000

(1)
• Measure -
measurement A of 80,030 mm.
the rear end idler If the inner diameter is
gear assembly (1) outside the tolerance
The allowed range for range, a new rear end
measurement A is 52,950- idler gear assembly (3)
53,000 mm. must be installed.
If measurement A is • Clean the idler gear
outside the allowable shaft (1)
range, you must install a • With a depth gauge
new rear end idler gear (electronic) [238]
assembly (1).
Check the inner (2) measure the
diameter of the rear end height of the
idler gear assembly rear end idler gear
assembly bearing
(1).
The permitted height is
56,200-56,240 mm.
If the height is outside the
tolerance range, a new
rear end idler gear
assembly bearing (1)
must be installed.
Measure the outside
diameter of the rear end
idler gear assembly
bearing
• Using the micrometer
[235] (2) and a bore
gauge (1) measure
the bore of the rear
end idler gear
assembly (3)

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 MC11 Series Engine Maintenance Manual

• Using a micrometer
caliper (2), measure
the outside diameter
of the rear end idler
gear assembly
bearing (1).
The allowable external
diameter is Ø 79.921

-
79,940 mm.
If the outside diameter is
outside the tolerance
range, a new rear end
idler gear assembly
bearing (1) must be
installed.

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 MC11 Series Engine Maintenance Manual

Crankcase intermediate Crankcase intermediate

gear disassembly gear disassembly
Measure the axial span of the
crankcase idler gear

Unscrew the mounting bolt

(1)
Mount the micrometer
Remove the crankcase
holder [236] (3) that has
idler gear (3) together with
the micrometer [235]
With a certain pretensioning force, fit the
locating pin [237] to the crankcase intermediate
gear (3).
Push the crankcase idler gear (3) all the way

• Set the micrometer [235] (1) to zero

• Pull the character intermediate gear (3) to the
end position and read the difference
The allowable axial range is 0.100-0.290 mm.
If the axial span is outside the tolerance range, you
must check the height between the crankcase idler
gear (3) and the crankcase idler gear shaft.
Check the height of the crankcase idler gear (3), see
"Checking the crankcase idler gear height",
page .127 Check the crankcase idle gear shaft
height, see "Checking the crankcase idle gear shaft
height", page . 127

the crankcase idler gear

(1) and the shaft (2).
positioning pin [237] Check Crankcase Idler
Gear Height

1
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 MC11 Series Engine Maintenance Manual

If the inner diameter is

outside the tolerance
range, a new crankcase
idler gear (3) must be
fitted.
Measure the height of the
crankcase idler gear shaft

• Clean the crankcase

intermediate gear (1)
• Measure the
dimension A of the
crankcase
intermediate gear (1)
The allowed range for
measurement A is
17,950-18,000 mm.
If measurement A is
outside the permitted • Clean the crankcase
range, a new crankcase intermediate gear
intermediate gear (1) must shaft (1)
be fitted. • Using a depth gauge
Check the inner diameter (electronic) [238] (2)
of the crankcase idler measure the height of
gear the crankcase
intermediate gear
shaft (1).
The permissible height of
the crankcase intermediate
gear shaft is 21,200-
21,240 mm.
If the height is outside the
tolerance range, a new
crankcase intermediate
gear shaft (1) must be
fitted.
Measure the outer
• Using the micrometer diameter of the
[235] (2) and a bore crankcase idler gear
gauge (1) measure shaft
the bore diameter of
the crankcase
intermediate gear (3).
The permissible inner
diameter of the crankcase
intermediate gear is Ø
60,000 - 60,030 mm.

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 MC11 Series Engine Maintenance Manual

• Using a micrometer With a lever (3) press to

caliper (2), measure remove the crankshaft
the outside diameter gear (2) from the
of the crankcase crankshaft (1)
intermediate gear Remove the air
shaft (1). compressor intermediate
The allowable external gear
diameter is Ø 59.921 Measure the axial span
of the air compressor
- idler gear
59,940 mm.
If the outside diameter is
outside the tolerance
range, a new crankcase
idler gear shaft (1) must be
fitted.
Crankshaft gear
disassembly

M
o
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t

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1
4
1
MC11 Series Engine Maintenance Manual

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MC11 Series Engine Maintenance Manual

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4
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MC11 Series Engine Maintenance Manual

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1
4
4
MC11 Series Engine Maintenance Manual

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4
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MC11 Series Engine Maintenance Manual

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4
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MC11 Series Engine Maintenance Manual

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7
MC11 Series Engine Maintenance Manual

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4
8
MC11 Series Engine Maintenance Manual

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The
allo
wabl
e
axial
rang
e is
0.10
0-
0.24
0
mm.
If the
axial
span
is
outsi
de
the
toler
ance

1
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MC11 Series Engine Maintenance Manual

rang
e,
you
shou
ld
chec
k the
heig
ht
betw
een
the
air
com
pres
sor
idler
gear
(2)
and
the
idler
gear
shaft
.
Che
ck
the
heig
ht of
the
air
com
pres
sor
idle
gear
(2),
see
"Che
ckin
g the
heig
ht of
the
air
com
pres
sor
idle
gear

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MC11 Series Engine Maintenance Manual

",
page
. 129
Che
ck
the
idler
gear
shaft
heig
ht,
see
“Che
ckin
g the
Air
Com
pres
sor
Idler
Gear
Shaf
t
Heig
ht,”
page
. 130

1
5
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 MC11 Series Engine Maintenance Manual

Screw alignment tool C

h
e
c
k

Air Compressor Idler Gear Height

• Unscrew one washer (2) behind
mounting bolt (1) the air compressor
• Screw the alignment idler gear (1)
tool [234] (2) • Unscrew the
• Unscrew the rest of alignment tool [234]
the mounting bolts • Remove the air
(1) from the air compressor idler
compressor idler gear (1) along with
gear shaft (3) the thrust washer (2)
Remove the air and the air
compressor compressor idler
intermediate gear gear shaft (3).
• Clean the air
compressor idler
gear (1) and thrust
washer (2)
• Measure the height of
the air compressor
idler gear (1) and the
thickness of the
thrust washer (2)
The allowed range for
measurement A is 25,900-
26,000 mm.
If measurement A is
Warning outside the allowable
/ Thrust washer may fall range, you must install a
into oil pan new air compressor
• Before intermediate gear (1).
removing the The allowable thickness of
intermediate the thrust washer (2) is
gear, make sure 4,800-5,000 mm.
that the If the thickness is outside
Thrust washer does the tolerance range, a
not fall off. new thrust washer (2)
• Fasten the thrust

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 MC11 Series Engine Maintenance Manual

must be fitted. Check the Clean the air

inner diameter of the air compressor
compressor idler gear intermediate gear (3)
Using the micrometer
[235] (2) and an
inside diameter
gauge (1) measure
the inside diameter of
the air compressor
idler gear (3).
The allowable inner
diameter of the
intermediate gear (3) of
the air compressor is Ø
60.000 - 60.03 mm.
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3
MC11 Series Engine Maintenance Manual

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1
5
4
MC11 Series Engine Maintenance Manual

m
p
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d
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e
r

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e
a
r

(
3
)
.

1
5
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 MC11 Series Engine Maintenance Manual

Measure the height of the air compressor idler

gear shaft

Timing Gear Assembly Air Compressor Idler Gear

Assembly Instructions
• Clean the air
compressor idler
gear shaft (1)
• Using a depth gauge
(electronic) [238] (2)
measure the height
of the air compressor
idler gear shaft (1).
The allowable height of
the air compressor idler
gear shaft is 26,100-
26,140mm.
If the height is outside the
tolerance range, you must • Clean the air
install a new air compressor idler
compressor idler gear gear shaft (1)
shaft (1). • Using a micrometer
Measure the outer caliper (2), measure
diameter of the air the outside diameter
compressor idler gear of the air compressor
shaft idler gear shaft (1).
The permissible outer
diameter of the air
compressor intermediate
gear shaft is Ø 59.921 -
59.940 mm.
If the outer diameter is
outside the tolerance
range, you must install a
new air compressor idler
gear shaft (1).
Assemble the air

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 MC11 Series Engine Maintenance Manual

compressor Apply clean engine

intermediate gear oil to the air
which can be divided compressor idler
into two parts, make gear shaft (3).
its widest face (1) Insert the air
face towards the compressor idler
crankcase. gear shaft (3) into the
The rubber element of the air compressor idler
air compressor gear (1)
intermediate gear points Mount the thrust
towards the crankcase. washer (2) onto the
Position the air air compressor idler
compressor gear shaft (3) so that
intermediate gear the chamfered side
faces the crankcase.

Install the air secure with the

compressor idler gear alignment tool [234]
(2)
• Screw in the new
mounting bolt (1)
• Unscrew the
alignment tool [234]
(2)
• Screw in the rest of
the new mounting
bolts (1)
• Tighten the mounting
bolt (1) to 115 Nm
Crankcase intermediate
Insert the air gear assembly
compressor idler
gear and air
compressor idler
gear shaft (3) along
with the thrust
washer into the
crankcase and

1
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 MC11 Series Engine Maintenance Manual

(4) is vertical to the

oil pan
• Screw the alignment
lever [233] (3) and (5)
• Align the crankshaft
gear (1) and the
centering pin (4)
• Push the crankshaft
gear (1) to
crankshaft
• Unscrew the
alignment lever [233]
Apply clean engine (3) and (5)
oil to the crankcase Install the rear end idler
gear assembly
intermediate gear
shaft (2).
Mount the crankcase
idler gear (4) so that
its flat contact
surface (3) points
towards the shaft of
the crankcase idler
gear (2).
Insert the crankcase
idler gear (4) together
with the crankcase
idler gear shaft (2) Apply clean engine
into the crankcase oil to the rear end
Screw in the new idler gear shaft (2)
mounting bolt (1) and Insert the rear end
tighten it to 30 Nm idler gear assembly
Install the crankshaft shaft (2) to the rear
gear end idler gear
assembly (3)
Install the rear end
idler gear assembly
(3) so that the mark
on the rear end idler
gear assembly (3)
aligns with the
crankshaft gear, see
"Checking crankshaft
gear marks", page .
132
Screw in the new
mounting bolt (1) and
tighten it to the initial
• Rotate the crankshaft
torque of 150 Nm
until the centering pin
• Turn the mounting bolt (1) 90°

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 MC11 Series Engine Maintenance Manual

Check the brand of the crankshaft gear

• Check if the mark (1) on the rear end intermediate gear assembly aligns with the mark (2) on the crankshaft
gear.
If the marks (1) and (2) are not in a straight line, you must remove the rear end idler gear assembly and
reinsert it so that it is in the marked position.

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 TO MC11 Series Engine Maintenance Manual

SECTION VII FUEL SUPPLY SYSTEM

Fig. 2-30 Fuel Supply System

1. Mounting nut 2. Injector wire harness 3. Common rail connecting tube 4. Pressure nut 5. Fuel Service
Center Support
6. Fuel service center 7. Oil feed pump 8. High pressure oil pump 9. Mounting bolts 10. High pressure oil
pump sheave
11. Mounting bolts 12. High pressure oil pipe 13. Cylinder head 14. Pressure flange 15. Mounting bolt 16.
Injector
Important information
Warning
/ Improper tightening of the connecting bolts can cause damage to the
g< components.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.

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 TO
MC11 Series Engine Maintenance Manual
1. injector and common rail assembly
2. Auxiliary jobs
- Disassembly and assembly of the engine control unit see page 7

Fig. 2-30 Injector and common rail assembly

1. Pressure nut 2. Common rail connecting tube 3. Cylinder head 4. Pressure flange 5. Pressure plate bolt 6.
Injector
7. Mounting nut 8. Injector wire harness 9. Common rail assembly 10. mounting bolt
2. Technical data
Name Specification Technical parameters
High pressure oil pipe (first use) Initial torque 10 Nm
High pressure oil pipe (first use) 60° angle
Initial torque 10 Nm
High pressure oil pipe (repeated use)

30° angle
High pressure oil pipe (repeated use)

Mounting bolt (10) M8×50-10.9 hand tighten

Mounting bolt (10) M8×50-10.9 Final torque 35 Nm
Pressure screw (1) Initial torque 10 Nm
Pressure screw (1) The final torque is 20 Nm and the angle
is 60°.
Mounting bolts (5) M8×50-10.9 Initial torque 1-2 Nm
Mounting bolts (5) M8×50-10.9 The final torque is 25 Nm and the angle
is 90°.
Mounting bolt (7) 1.8+0.25Nm
M4 cable protection tube nut

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 TO
MC11 Series Engine Maintenance Manual
Name Specification Technical parameters
4+0.5 bar
Pressure Loss Pressurization Test

Voltage drop 10 minutes 0.1 bar

Common rail pressure sensor M18×15 70±5Nm
Pressure limiting valve M18×15 100±5Nm
M6×16-10.9 15Nm
Injector wire harness mounting bolt

Cylinder head cover mounting bolt 10Nm

3. Auxiliary materials
Special Vaseline
4. Important information
Warning
Common rail system can be damaged
• All work performed on the common rail system must be carried out by specially trained personnel.
• To relieve the pressure in the common rail assembly, the engine must be stopped for at least 5 minutes
before starting work, or check the pressure relief condition by SINOTRUK EOL diagnostic tool (required
value 0).
• During work you must ensure absolute cleanliness of all areas.
• Avoid any humidity that may appear
• Once the common rail connecting tube becomes loose, it should be repaired immediately.
• Reuse of high pressure pipe seal rings, common rail assembly and injector rings is not permitted.
• When tightening the injector, the high pressure oil pipe, common rail assembly and common rail
connecting pipe operate in the order indicated.
Warning
Dirt ingress can cause damage
• Every time the oil pipe is disassembled, the corresponding interface should be blocked with a clean
protective sleeve.
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum tightening
torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
5. Special tools
Number Description
As shown in the figure SINOTRUK Numbering MAN numbering

[79]
tube connector
• Disassemble the
YO ( *- connection of the JD6805-0053 80.99603-0173
common rail
assembly, using:
• Extractor [80]
[80] Extractor
• Disassemble the
common rail

7/0)
JD6805-0054 80.99602-0011
assembly
connection
V

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2
 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK Numbering MAN numbering

[81]

c
Pipe wrench, size 17
• Disassembly and
assembly of high
pressure oil pipe, JD6805-0055 80.99603-0309
using:
• rod
extension [83]

[82]

g
Pipe wrench, size 19
• Disassembly and
assembly of high
pressure oil pipe, JD6805-0056 80.99603-0310
using:
• rod
extension [83]

[83]
Extension rod •
Disassembly and
JD6805-0057 08.06139-9025
high pressure oil
pipe assembly

[84]

Extractor
• Extract the

ñ
injector, using:
• Disc [85]
• 66 bolt JD6805-0058 80.99601-6022
mm [86]
• 70 bolt
mm [87]
• Nut
hexagon M12
[88]
[85] Disk

TO
• Extract the
injector
JD6805-0059 80.99602-0176

[86] 66mm bolt •

Extract the
injector JD6805-0060 80.99602-0193

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK Numbering MAN numbering

[87] 70mm bolt

• Extract the
injector JD6805-0061 80.99602-0194

[88] M12 hex nut

(©
• Extract the
injector JD6805-0062 06.11226-8306

[89]

Torque screwdriver
• Connection of the
N.B. injector wire
harness, using:
JD6805-0063 08.06510-9024
• connector
tube [90]
• Pipe wrench,
size 7 [91]

[90]

<)
socket wrench
connector
• Assembly of the JD6805-0064 08.06139-9029
injector wire
harness

[91]

Pipe wrench, size 7 JD6805-0065 08.06141-0700

• Assembly of the
injector wire
harness
[92] pressure element
• Assembly of the
injector JD6805-0066 80.99606-0609

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 MC11 Series Engine Maintenance Manual

[93]
Pressure loss detector
• Check the
high pressure
system leak,
using:
• connector JD6805-0067 80.99607-6027
tube [94]
• Connection
threaded [95]
• Seal Ring
with lip

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure Description SINOTRUK Numbering MAN numbering

elastomeric
sealing [98]
• hollow bolts
[96]
• connector
ring [97]

[94]
tube connector
• Check the
JD6805-0068 80.99620-0033
high pressure
system leak

[95] Threaded connection

• Check the

TO high pressure
system leak
JD6805-0069 81.98130-0614

[96] hollow bolt

• Check the
high pressure
system leak
JD6805-0070 51.98150-0715

[97] ring connector

• Check the
high pressure
system leak
JD6805-0071 51.98103-0037

[98]
Seal ring with
elastomeric sealing lip
• Check the JD6805-0072 06.56639-0017
high pressure
system leak

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 MC11 Series Engine Maintenance Manual

Removal of injector and common rail Remove the oil return pipe
assembly
Disconnect the common rail pressure sensor
electrical connection connector

Unscrew the mounting bolt (2)

Hold the bracket on the side with the
oil dipstick (1)
• Disconnect the electrical connection Warning
connector (1) Fuel in the combustion chamber can
Remove the oil dipstick bracket cause damage to components
• Before disassembling the injector
you must drain the oil in the oil return pipe
Warning
Environmental pollution
Collect the remaining fuel in a suitable container
Unscrew the hollow bolt (1), drain the oil in the oil
return pipe
Unscrew the fuel tube (2) from the T-connector (3)
Unscrew the fuel tube (4) from the T-connector (3)
Unscrew the T-connector (3) from the ring
connector (6)
Unscrew the hollow bolt (5)
Disassemble the ring connector (6) with seal ring
Disassembly of high pressure oil pipe

Unscrew the mounting bolt (2)

Remove the high pressure oil line (3) from the
high pressure oil pump (4) and common rail
assembly (1), using a socket wrench, size 19
[82] and extension rod [83 ]

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 MC11 Series Engine Maintenance Manual

Disassembly of high pressure oil pipe Remove the common rail pressure sensor and
pressure limiting valve

Warning
Warning / Lack of lubrication can cause
Dirt ingress can cause damage • * damage to components
• Every time the oil pipe is disassembled, • Do not flush the pressure limiting valve
the corresponding interface should be and common rail pressure sensor because the
blocked with a clean protective sleeve. threads and rim lips are coated with lubricating
Mark the mounting position of the high grease.
pressure oil pipe (2) • Unscrew the pressure limiting valve (1)
Remove the high pressure oil line (2)
• Unscrew the common rail pressure sensor (2)
with a socket wrench, size 17 [81]. (1) and
extension rod [83] (3) Removing the wire harness cover
Disassembly of the common rail assembly

Unscrew the mounting bolt (2) • Open the locking pin (2) turn 90°
Remove the common rail assembly (1) • Remove the cable harness cover (1)

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 MC11 Series Engine Maintenance Manual

Removing the cylinder head cover Disassembly of injector cables

• Unscrew the mounting bolt (3) • Remove the mounting nut (2)
• Remove the cylinder head cover (2) from • Remove the injector cable (1)
the cylinder head (1) Injector wire harness removal
Disassembly of the common rail connecting
pipe

Carefully remove the injector wire harness (4)

from the camshaft cover (1)
Unscrew the pressure nut (3)
Unscrew the mounting bolt (3)
Remove the common rail connecting pipe (2)
from the cylinder head (1), using the pipe Carefully remove the flange (2) from the
connector [79] and extractor [80]. cylinder head
• Carefully remove the injector wire harness (4) from
the cylinder bore
Compression Plate Bolt Removal

Unscrew the mounting bolt (2) and remove it

together with the spherical washer (1).

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 MC11 Series Engine Maintenance Manual

Special assembly tools

Description
Assemble the disc [85] and the 66 mm bolts [86] You must mount the injector first on the
(1), the 70 mm bolts [87] (5) and the M12 hex nuts compression flange then mount it integrally, it is not
[88] (2) allowed to mount the injector first and then
Insert the extractor [84] (3) into the disc [85] (4) mount the compression plate bolt,
Warning • Remove the old seal ring (5)
• Check to make sure the hole
Remove the injector
of the cylinder in the cylinder head is
clean
• The injector (2) can only be removed from the
injector storage liner [69] when assembly is
required.
• Remove the protective cover
• Turn the compression flange (1) on the injector
(2) to ensure the fuel inlet (3) faces the injector
inlet connection (4)
• Insert the injector (2) and the new O-ring (6)
and the new seal washer (5) into the cylinder
head
Improper disassembly of the injector • Completely press the injector (2) into the
can cause damage to components cylinder head with the pressure element [92]
• Before disassembling the injector you Injector initial torque
must dismantle the connection pipe of
the rail corresponding common
Only one injector can be removed
Take out the special tools (1)
Insert the extractor [84] into the slot of the
pressure flange
Hold the clamping sleeve (5) with a
knurled nut (2)
Remove the injector (4) from the cylinder head by
turning the knurled nut (3)
Injector Assembly and Common Rail Assembly
Install the injector

Screw the ball washer (1) into the compression

flange along with the new mounting bolt (2).
Tighten the mounting bolt (2) to the initial
torque of 1-2 Nm

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 MC11 Series Engine Maintenance Manual

Common rail connecting pipe assembly Common Rail Assembly Connection Final
Torque

that uses the injector wire harness (4)

Warning Carefully insert the injector wiring harness (4)
Press the conical ring on the common rail through the cylinder hole Carefully insert the flange
connecting pipe (2) into the cylinder head Screw in the mounting
• The conical ring of the common rail bolt (3) and tighten it to 15 Nm
connecting pipe cannot be reused Carefully insert the injector wire harness (4) from
Insert the new common rail connecting pipe (2) into
the camshaft cover (1)
the cylinder head (1) so that the tapered ring of the
common rail connecting pipe (2) inserts into the
tapered groove of the cylinder head.
Screw the pressure nut (3) and tighten it to the
initial torque of 10 Nm
Injector final torque

Tighten the injector pressure flange mounting bolts

(1) to the final torque of 25 Nm+90°
• Tighten the pressure nut (1) to the final torque of 20
Nm and turn 60°
Injector wire harness assembly

Apply a coat of special Vaseline on the new O-ring

17
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 MC11 Series Engine Maintenance Manual

Injector wire harness assembly

Warning
Possible circuit interruption may cause
damage to components
• When tightening the mounting nut, make sure
there is a gap between the harness plugs.
Special assembly tools, socket wrench, size 7
[91] (2), pipe connector [90] and torque screwdriver
[89] (3) Using special tool, tighten the mounting nut
(1) of the wiring harness of the injector a1.8+0.25
Nm
Cylinder head cover tightening sequence
A Intake face B Exhaust face
• In subsequent work steps, strictly execute the
tightening sequence of mounting bolt 1 to 18
Cylinder head cover assembly

• Check cylinder head cover washer (2), replace with

new one if damaged
• Clean the grease on the gasket and groove before
installing the cylinder head cover. Pay attention to the
difference of the bolts when installing the gasket. The
8 bolts on the exhaust side are bolt sets without
rubber cushioning. The remaining 10 bolts are bolt
assemblies with rubber buffers.
• Fasten the cylinder head cover (2) on the cylinder
head (1)
• Screw in the mounting bolt (3)
• Tighten the mounting bolt (3) to 10 Nm according to
the sequence shown

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 MC11 Series Engine Maintenance Manual

Install the wire harness tube cover

• Install the wire harness tube cover (1)

• Turn 90° and close the locking pin (2) Unscrew
the common rail pressure sensor and pressure
limiting valve

Connecting the common rail assembly

• Determine the position of the common rail

assembly (1) on the cylinder head
• Screw in the new mounting bolt (2) and hand
tighten it
High pressure oil pipe connection

1
7
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 MC11 Series Engine Maintenance Manual

Warning
/ Lack of lubrication can cause L: damage to
components
• Do not flush the pressure limiting valve and
common rail pressure sensor because the
threads and rim lips are coated with
lubricating grease.
• Screw the new common rail pressure sensor
(2) and tighten it to 70±5 Nm
• Screw in the new pressure relief valve (1)
and tighten it to 100±5 Nm
Warning
Cluttered high-pressure oil pipe can cause
component damage
• After initial tightening, check the layout of the
high pressure oil pipe and change the position if
necessary • If it is repeated use, with the socket wrench,
According to the marking, connect the high size 17 [81] (1) and extension rod
pressure oil pipe (2) and common rail assembly (3) [83] (3) tighten the high pressure oil pipe (2) to
and common rail connecting pipe (1) the final torque of 30°
Using the socket wrench, size 17 [81] and the • With the pipe wrench, size 17 [81] (1)
extension rod [83], tighten the high-pressure oil pipe and extension rod [83] (3) tighten the new high
to the initial torque of 10 Nm pressure oil pipe (2) to the final torque of 60°
Common rail assembly final torque High pressure oil pipe connection

• Tighten the mounting bolts (1) to the final Connect the high pressure oil pipe (3) and the
torque of 35 Nm high pressure oil pump (4) and the common rail
High pressure oil pipe final torque assembly (1)
Using the socket wrench, size 19 [82] and the
extension rod [83], tighten the high-pressure oil
pipe (3) to the initial torque of 10 Nm
• Check the high pressure oil line (3) to
determine if it is out of pressure
• Screw and tighten the new mounting bolt (2)
• If repeated use, with the size 19 socket wrench
[82] and extension rod [83] tighten the high

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 MC11 Series Engine Maintenance Manual

pressure oil pipe (3) to the final torque of 30°

• Using the socket wrench, size 19 [82] and
extension rod [83], tighten the high-pressure oil
line (3) to the final torque of 60°
Mounting the pressure loss detector

Screw the annular connector [97] into the

cylinder head using a hollow bolt [96] and a
seal ring [98] with an elastomeric sealing lip
Mount the pipe connector [94] (1) and the
threaded connection [95] and the pressure loss
detector [93] to the ring connector [97]

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 MC11 Series Engine Maintenance Manual

Check pressure loss Oil dipstick bracket assembly

Warning
The injector may be damaged Locate the bracket (1) along with the oil
• Leak test pressure should not exceed dipstick
4+ 0.5 bar • Screw and tighten the mounting bolt (2)
• Pressurize the pressure loss Connect the common rail pressure sensor
detector [93] with 4 + 0.5 bar compressed air electrical connection connector
• Disconnect the compressed air pipe connector
(2)
• Check the maximum allowable pressure loss on
the pressure gauge (1)
• The allowable pressure loss is 0.1 bar in a
maximum of 10 minutes
Connection with oil return pipe

Connect the electrical connection connector (1)

Locate the ring connector (6) with a new seal ring

Screw in the hollow bolt (5)
Screw the T-connector (3) into the ring connector (6) and tighten it
Screw he tube of fuel (2) in he
T connector (3)
Screw he tube of fuel (4) in he
T connector (3)
Screw the new hollow bolt (1) with a new seal ring and tighten it
Tighten the hollow bolts (5)
Tighten the oil pipe pressure nut (2) and (4)

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MC11 Series Engine Maintenance Manual
II. High Pressure Oil Pump / High Pressure Oil Pump Drive Device
1. Auxiliary tools
- Disassembly and assembly of the generator is seen on page 47

Fig. 2-31 High pressure oil pump and the driving device of high pressure oil pump
1. Fuel service center 2. High pressure oil pump 3. Oil fill port 4. Mounting bolts 5. High pressure oil pump
sheave
6. Washer 7. Mounting bolt 8. High pressure oil pump drive device
9. High pressure oil pipe 10. Medium
2. Technical data
Name Specification Technical parameters

High pressure oil pump mounting bolt (2) M10×55-10.9 60-70Nm

Oil fill port (3) M38×15 35Nm

High pressure pump drive mounting bolt (8) M12×90-10.9 115Nm

High pressure oil pipe (9) (first use) Initial torque 10 Nm

High pressure oil pipe (9) (first use) 60° angle
High pressure oil pipe (9) (repeated use) Initial torque 10 Nm
High pressure oil pipe (9) (repeated use) 30° angle
3. Auxiliary materials
Loctite 5900 Sealant Curil T Adhesive

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MC11 Series Engine Maintenance Manual
4. Important information
Warning
/.N Common rail system can be damaged
• All work performed on the common rail system must be carried out by specially trained personnel.
• To relieve the pressure in the common rail assembly, the engine must be stopped for at least 5 minutes
before starting work, or check the pressure relief condition by SINOTRUK EOL diagnostic tool (required
value 0).
• During work you must ensure absolute cleanliness of all areas.
• Avoid any humidity that may appear
• Reuse of high pressure pipe seal rings, common rail assembly seal rings, and injector seal rings is not
permitted.
Warning
Dirt ingress can cause damage
• Every time the oil pipe is disassembled, the corresponding interface should be blocked with a clean
protective sleeve.
Warning
Contact with oil or grease before assembly may cause PTFE seal rings to become unavailable
• Clean the high pressure pump drive device and mounting liner before assembly
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum tightening
torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
5. Special tools
Number As shown in the figure SINOTRUK MAN numbering
Description
Numbering

(
[103] Impact tools JD6805-0076 80.99606-6078
• Disassembly of the
high pressure oil pump,
using:
• Tools of
disassembly [104]
[104] Tools of JD6805-0077 80.99601-6021
(a/ / W \

disassembly
• Disassemble the pump
/e) / /A-

of oil of high
k\

pressure
•-N

[105] Impact extractor JD6805-0018 80.99602-0016

• Remove the shaft seal
radial, using:
·Hook [106]

[106] Hook JD6805-0019 80.99602-0137

• Remove the shaft seal
radial

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 MC11 Series Engine Maintenance Manual

[107] JD6805-0020 80.99617-0187

Insert the lever,
• Press the seal
axis radial,
using:
• pressure disc
[109]
• Washer [108]

•
[108] Washer JD6805-0021 80.99617-0144
• Press the seal
radial shaft

(
[109] pressure disc JD6805-0022 80.99604-0289
• Press the seal
radial shaft

[110] Pipe wrench JD6805-0078 08.06556-9300

• Disassembly
and
oil fill port assembly

J
[111] Tools of JD6805-0079 80.99606-0625
release, size 1
• Open the connection
release fast,
using:
• Lever of
liberation [104]

>
[112] Release lever JD6805-0080 80.99606-0597
• Open the connection
quick release

[113] Pipe wrench, size 19 JD6805-0056 80.99603-0310

• Disassembly
and
mounting of
the
high oil pipe
pressure,
using:
• Extension rod

4
[114] Extension rod JD6805-0057 08.06139-9025
• Disassembly
and
mounting of
the
high pressure oil pipe

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 MC11 Series Engine Maintenance Manual

Remove the high pressure oil pump Remove the high pressure oil pump
Remove the oil fill port

Unscrew the mounting bolt (1)

Remove the high pressure oil pump (2) from
• With the pipe wrench, size 27 [110] (2)
the high pressure oil pump drive (4) Remove
unscrew the oil filler port
the intermediate drive shaft (3) off the drive
Remove the high pressure oil pipe
shaft

Disconnect the connection connector

electrical (2) measuring unit
• Unscrew the mounting bolt (3)
• Using the socket wrench, size 19 [113] and extension rod [114], remove the high-pressure oil line (4) from
the high-pressure oil pump (5) and common rail assembly (1 )

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Disassemble the high pressure oil pump Special mounting tools

Disassembly of the high pressure oil pipe
• Disconnect the electrical connection connector (2)

from the measuring unit

• Unscrew the mounting bolt (3)
• Using the socket wrench, size 19 [113] and
extension rod [114], remove the high-pressure oil
line (4) from the high-pressure oil pump (5) and
common rail assembly (1 )

• Dismantle the fuel service center, see "Removal

and installation of the fuel service center", 156
• Unscrew the high pressure oil pump mounting
bolt (5)
• With the impact tool [103] (1)
Screw the threaded main bearing (2) into the
plate (3) of the disassembly tool [104] (4) up to
the same height
• Using two bolts, mount the disassembly tool [104]
(4) to the high-pressure oil pump (5)
Remove the high pressure oil pump

With impact tool [103] (1) and disassembly tool

[104] (2) ,
Remove the high pressure oil pump (3) from the
high pressure oil pump drive device by gently
tapping

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Remove the high pressure oil pump drive device Disassemble the high pressure oil pump drive
Remove the multi-ribbed belt pulley device

Unscrew the mounting bolt (1) and disassemble

• Unscrew the mounting bolt (1) and (2)
• Remove the washer (3) the high-pressure oil pump drive device (2)
• Remove the multi-ribbed belt pulley (4) off the Clean the contact surface
spline shaft (5)
Remove the high-speed oil pump drive radial
shaft seal.
pressur
e

With the impact type extractor [105] (1) and the hook [106] (3) remove the shaft seal
radial (2)

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 MC11 Series Engine Maintenance Manual

Install the oil pump drive Press radial shaft seal

high pressure
High pressure oil pump drive assembly
instructions

Using insertion lever [107] (1) and washer [108]

and pressure plate [109] (2) press the new
radial shaft seal (4) into the high oil pump drive
As shown, apply a thin coat of Loctite 5900 device. pressure (3)
sealant (1) to the mating surface of the pump
drive.
Install the V-belt pulley
high pressure oil
Install the high pressure oil pump drive

Grades
M When replacing a new radial shaft seal, the
multi-ribbed belt pulley must also be
Locate the high pressure oil pump drive device replaced
(2) Apply a thin coat of Loctite 5900 sealant to the
Screw in the new mounting bolt (1) and tighten pulley teeth of the new V-belt (4).
it to 115 Nm Position the mounting washer (3) and screw in
the new mounting bolt (2)

Push the multi-ribbed belt pulley (4) onto the spline

shaft (5) until it encounters obstruction
Screw in and tighten the new mounting bolt (1)
Tighten the mounting bolt (2)

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 MC11 Series Engine Maintenance Manual

High pressure oil pump assembly High pressure oil pipe connection
High pressure oil pump assembly

• Connect the high pressure oil pipe (4) to the

Grades high pressure oil pump (5) and common rail
If you use a special tool to disassemble assembly (1)
the high pressure oil pump, please • Using the socket wrench, size 19 [113] and the
assemble the fuel service center first extension rod [114], tighten the high-pressure
before oil pipe (4) to the initial torque of 10 Nm
Install the high pressure oil pump. • Check the high pressure oil line (4) to ensure it
• Place the intermediate drive shaft (3) onto the is depressurized.
high pressure oil pump drive shaft (2) • Screw and tighten the new mounting bolt (3)
• Insert the high pressure oil pump (2) to the high • If repeated use, with the size 19 socket wrench
pressure oil pump drive device along with the [113] and extension rod [114] tighten the high
new O-ring pressure oil pipe (4) to the final torque of 30°
• Using the socket wrench, size 19 [113] and
extension rod [114], tighten the high-pressure
oil line (4) to the final torque of 60°
Screw in the new mounting bolt (1) and tighten • Connect the electrical connection connector (2)
it to 60-70 Nm of the measuring unit
If necessary, install the fuel service center, see
"Removal and installation of the fuel service
center", 156

Oil Fill Port Assembly

• Apply a layer of Curil T adhesive to the oil fill port

(1)
• Using the socket wrench, size 27 [110] (2), screw
the oil fill port (1) to the high pressure oil pump
drive device
• Tighten the oil filler port (1) to 35 Nm

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 T MC11 Series Engine Maintenance Manual
III. fuel service center
O

Fig. 2-32 Fuel Service Center

1. Intake manifold 2. Flame preheating plug 3. Solenoid valve 4. Hollow bolt 5. Ring connector 6. T connector
7. Oil return pipe (cylinder head - common rail assembly) 8. Oil Return Pipe (Common Rail Assembly - Fuel
Service Center)
9. Oil return pipe (fuel service center / high pressure oil pump - fuel tank) 10. fuel service center
11. Oil pipe (fuel tank -fuel service center) 12. Oil pipe (fuel service center- fuel supply pump)
13. Oil pipe (fuel service center - high pressure oil pump) 14. Oil pipe (fuel pump- fuel service center)
15. Oil pipe (fuel service center-solenoid valve)
1. Technical data
Overflow valve working pressure is 1.1-1.5 bar
2. Important information
Warning
/! Dirt ingress can cause damage
• Every time the oil pipe is disassembled, the corresponding interface should be blocked with a
clean protective sleeve.
Warning
/.N Environmental pollution
• Collect the remaining fuel in a suitable container

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 MC11 Series Engine Maintenance Manual

Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• Final tightening must be done manually with a torque wrench.
Grades
Before disassembling all molded oil tubes you must mark their correct alignment and mounting
position.
3. Special tools
Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[142] JD6805-0079 80.99606-0625
Tools of
release, size 1
• Open the connection
release fast,
using:
• Lever of
J. liberation [143]
[143] Release lever JD6805-0080 80.99606-0597
• Open the connection
quick release

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4. Disassembly of the fuel service center Disassemble the service center

Remove the oil return tube from the common rail fuel- high pressure oil pump oil pipes
assembly.

• Using the release tool, size 1 [142] and release

• Remove the oil tube (5) lever [143] remove the oil tube (1) and (2)
• Unscrew the hollow bolt (2) Remove the oil return pipe from the fuel service
• Remove the oil tube (3) center
• Unscrew the hollow bolt (4) and dismantle the
three-way joint device (1)
Disassemble fuel service center- fuel pump oil
pipes

• Unscrew the support caliper mounting bolt (1)

• Using the release tool, size 1 [142] and release
lever [143] remove the oil tube (2)
Remove the solenoid valve - oil pipe from the
fuel service center
Unscrew the mounting bolt (1)
Using the release tool, size 1 [142] and release
lever [143] remove the oil tube (2) and (3)

Unscrew the hollow bolt (1) and (3) and remove

it together with the washer.
Remove the oil tube (2)

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 MC11 Series Engine Maintenance Manual

Disassemble fuel service center 5. Assembly of the fuel service center

Mount fuel service center

Unscrew the mounting bolt (2)

Remove fuel service center (3) Position the support (4)
Screw in and tighten the new mounting bolt
Unscrew the mounting bolt (1) (1)
Position the service center
Remove the support (4)
fuel (3)
• Screw and tighten the new mounting bolt
(2)
Connect solenoid valve - fuel service center oil
pipe

Position the oil tube (2)

Screw in the new hollow bolt (3) together with a new
washer
Screw the new hollow bolt (1) together with the new
washer and tighten it
Tighten the hollow bolt (3) to 15 Nm

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 MC11 Series Engine Maintenance Manual

Connect the oil return pipe from the fuel service Connect fuel service center- fuel pump oil pipes
center

• Connect the oil tube (2) • Connect the oil tube (2) and (3)
• Check if the oil tube (2) is securely mounted. If • Check if the oil pipe (2) and (3) are securely
necessary with release tool, size 1 [142] and mounted. If necessary with release tool, size 1
release lever [142] and release lever
[143] remove it and reconnect it [143] remove it and reconnect it
• Screw and tighten the new support caliper • Screw in and tighten the new mounting bolt (1)
mounting bolt (1) Connect the oil return tube to the common rail
Connect fuel service center- high oil pump oil assembly
pipes

pressur
e

Position the three-way joint device (1) and

• Connect the oil tube (1) and (2) screw the hollow bolt (4) together with the new
• Check if the oil tube (2) is seal ring. Turn the oil pipe (3) to the three-way
securely mounted. If necessary with release joint device (1)
tool, size 1 [142] and release lever Screw the new hollow bolt (2) together with the
[143] remove it and reconnect it new washer and tighten it.

Tighten the oil pipe nut (3)

Tighten the hollow bolt (4)
Connect the oil tube (5) to the nut and tighten

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O
6. Replacing the fuel filter
1) Auxiliary work
- Disassembly and assembly of the fuel service center is seen on page 156

Fig.2-33 Fuel Service Center

1. Fuel filter core 2. Cover 3. Signet ring 4. Deck 5. Pressure sensor 6. Water drain plug 7. Mounting bolt 8.
Seal Ring
9. Heating element 10. Hollow bolt 11. Cover 12. Filter 13. Signet ring 14. Casing 15.
hand oil pump
16. Mounting bolt

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 MC11 Series Engine Maintenance Manual

2) Technical data
Name Specification Technical parameters
Pressure sensor (5) M18×15 45Nm
Cover (11) 20+2.5Nm
Lid (2) 25Nm
Water drain plug (6) 3Nm
3) Important information
Warning
Dirt can invalidate the common rail system
• Before replacing the fuel filter you will need to drain the oil from the fuel service center
• Only use fuel filters that are dedicated to the common rail system or have this marking
• Do not reuse used filter elements
Warning
Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque
value.
• Final tightening must be done manually with a torque wrench.
4) Special tools

Number As shown in the figure Description SINOTRUK Numbering MAN numbering

[153]

(9 •
Pipe wrench, size 36
Disassembly and
fuel filter cap assembly

Pipe wrench, size 19

JD6805-0081 80.99603-0325

• Disassembly and
[154] JD6805-0082 08.06141-9061
fuel prefilter cover
assembly

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Drain fuel service centerO

5) Disassemble the fuel service center Disassembly of the pressure sensor

Warning
Environmental pollution
• Collect the remaining fuel in a suitable
container
Using the socket wrench, size 36
[153] turn
about 2-3 turns to disassemble the
cap (1)
Open the water drain plug (2) and drain the fuel
service center
• Retighten the water drain plug (2) to 3 Nm.
Remove the heating element

•
With pipe wrench, size 36 [153]
unscrew the cap (1)
• Remove the cap (1) and fuel filter core (3) from
the fuel service center housing
• Remove the seal ring (2)
• With pipe wrench, size 19 [154]
unscrew the cap (7)
Unscrew the mounting bolt (2) • Remove the filter element (6) from the
Remove the heating element (3) and seal ring hand oil pump housing (4)
(4) from the fuel service center (1) • Remove the seal ring (5)
• Unscrew the pressure sensor (1) and seal ring Remove the hand oil pump housing
(2) together
Remove the fuel filter

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 MC11 Series Engine Maintenance Manual

Unscrew the mounting bolt (2) from the fuel service

center (3)
Remove the hand oil pump housing (1)
6) Assemble fuel service center
Install the hand oil pump housing

Locate the position of the manual oil pump

housing (1) in the fuel service center (3)
Screw and tighten the new mounting bolt (2)

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 T MC11 Series Engine Maintenance Manual
Fuel filter assembly
O Tighten the fuel filter cap

• Using the socket wrench, size 36 [153] (1) tighten

the fuel filter cover to 25 Nm
• Apply new seal ring (5) with • Screw on the pressure
Pressure sensor assembly

clean diesel sensor (1) along with the

• Fasten seal ring (5) on seal ring (2)
manual oil pump housing • Tighten the pressure
(4) sensor (1) to 45 Nm
• Insert a filter element (6) Heating element assembly
• Screw the cover (7)
and tighten it
manually
• Insert a new element
filter
fuel (3) in the cap (1)
• Apply clean diesel to the
new seal ring (2)
• Screw the cover (1)
together with the seal ring
(2) and tighten it manually
Tighten the hand oil pump
cap

Insert the heating element

(3) into the fuel service
center (1) along with the
new seal ring (4)
Screw and tighten the new
mounting bolt (2)

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MC11 Series Engine Maintenance Manual

• Using the socket wrench, size 19 [154] (1) tighten the hand oil
pump cover to 20+2.5 Nm

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T MC11 Series Engine Maintenance Manual

O SECTION VIII ENGINE LUBRICATION SYSTEM

Fig. 2-37 Engine Lubrication System

1. Oil pan; 2. oil suction pipe; 3. Oil pump; 4. Oil cooler; 5. oil module;

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 TO MC11 Series Engine Maintenance Manual
1. oil module
2. Auxiliary jobs
- Disassembly and assembly of intake pipes see page 57

Fig. 2-38 Oil module

1. Oil cooler; 2. Pad; 3. Screwing device; 4. Air duct; 5. Mounting bolts;
6. Oil module; 7. Screwing device; 8. Mounting bolts;

2. Technical data
Name Specification Technical parameters
Oil module screw cap (6) M38×15 80+10Nm
Screwdriving device (3) M24×15 4Nm
Screwdriving device (7) M24×15 4Nm
Decompression valve M27×15 40+5Nm
oil filter cover 40+10Nm
Oil cooler mounting bolt (1) M8×55-8.8 30-35Nm
Oil cooler mounting bolt (1) M8×80-8.8 30-35Nm
3. Auxiliary materials
Loctite 243 Glue
Multi-purpose calcium-based lubricating grease Lubricant P80
4. Important information
Warning
Oil emulsification can cause engine damage
• All coolant must be drained before removing the oil module; Otherwise, coolant
will enter the oil pan when the oil module is removed from the pan.

1
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7
 Warning MC11 Series Engine Maintenance Manual
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening.
The maximum tightening torque used for initial tightening will be 50% of the
specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
5. Special tools
Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[239] Pipe wrench (size 32) JD6805-0119 80.99603-0326

(
• Disassembly and assembly of
the top of the filter of
fuel

[240] JD6805-0028 08.99605-9003

Pliers of mounting with
hose clamp for small pipe clamps •
Clearance he tube of
admission from he
air compressor

[241] Detector JD6805-0168 80.99606-0399

• Check coupling
of compressed air push
connection

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 MC11 Series Engine Maintenance Manual

Disassembly of the oil module. Remove the oil module pipe

Removing the heat shield

clamps [240] remove the small pipe clamp (2)

• Remove the vent pipe (1) from the oil and gas
• Remove the heat shield (1)
separator
Remove the oil return pipe from the oil and gas
Drain the coolant
separator.

• Unscrew the mounting bolt (1)

• Remove the oil return pipe (3) from the screw
devices (2) and (4)
• Unscrew the screwing devices (2) and (4)
Unscrew the fuel pump mounting bolt
• Using hose clamp assembly pliers for small pipe
water

Unscrew the mounting bolt (1) and (2) of the

water pump from the oil module

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 MC11 Series Engine Maintenance Manual

Warning Unscrew the mounting bolts (4) and (5)

Oil emulsification can cause engine damage Remove the oil module (1) from the crankcase
• All coolant must be drained before removing the oil (3) together with the gasket (2)
module; Otherwise, the refrigerant will enter Clean the contact surface
in the oil pan when the oil module is removed Oil cooler removal
from the pan
Unscrew the screw plug (3) from the oil module
(1) together with the seal ring (2)
Drain the coolant
Oil Module Disassembly Instructions

Warning
Improper placement of the oil /I\
module can cause component damage
• Place the oil module on one side to
prevent damage to the oil cooler
• Mark the mounting position of the mounting bolt
(4)
• Unscrew the mounting bolt (4)
• When disassembling the oil module (1), you must
• Remove the oil cooler (3) from the oil module (1)
not unscrew the mounting bolts (2) and (3) of together with the gasket (2)
the oil cooler • Clean the contact surface
Disassembly of the oil module. Disassembly of the decompression valve

Mark the mounting position of mounting bolt (4)

and (5)
Unscrew the decompression valve (2) from the
oil module (1)

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 MC11 Series Engine Maintenance Manual

Disassembly of the connection manifold Remove the oil filter

• Dismantle the connecting tube (5) from the

angle flange (3)
• Unscrew the mounting bolt (4)
• Remove the angle flange (2) from the
oil module (2) together with gasket (1)
• Clean the contact surface
Disassembly of the oil and gas separator

• With the socket wrench (size 32) [239]

unscrew the oil filter cover (1) from the oil
module (4)
• Remove the O-ring (2) from the cover
oil filter (1)
• Remove the oil filter core (3)
from the oil filter cover (1)

Unscrew the mounting bolt (1)

Remove the oil and gas separator (2) from the oil module

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O
Oil module assembly
Oil filter assembly

On the oil filter cover (1) fit the new O-ring (2)
• Insert the oil and gas separator (2) into the oil
and apply clean engine oil
module
• Insert the new oil filter (3) into the oil filter cap
(1) • Screw and tighten the mounting bolt (1)
• With the socket wrench (size 32) [239] Connection manifold assembly
Screw the oil filter cover (1) onto the oil module
(4) and tighten it to 40+10 Nm
Mounting the oil and gas separator

In the oil module (2) together with the new

gasket (1) position the connection manifold (3)
Screw and tighten the new mounting bolt (4)
Apply a thin layer of P80 lubricating oil to the
new connecting tube (5) and insert it into the
connecting manifold (2).

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Decompression valve assembly Oil module assembly
Oil module assembly

• Screw the decompression valve (2) into the oil

module (1) Warning
• Tighten the decompression valve (2) to 40+5 incorrect tightening sequence can cause
Nm component damage
Oil cooler assembly • The following should be followed

tightening sequence; otherwise the casing will

be broken
• In the crankcase (3) together with the new
gasket (2) position the oil module (1)
• As shown, screw in the new mounting bolt (4)
and (5) and hand tighten.
Screw in the water pump mounting bolt

• Together with the new gasket (2) insert the oil

cooler (3) into the oil module (1)
• As shown, screw in the new mounting bolt (4)
and hand tighten it.
Tighten the oil cooler mounting bolt

Screw and tighten the new mounting bolt (1)

and (2)
Tighten the oil module mounting bolt

Place the oil module on one side to prevent damage to the oil cooler
Tighten the mounting bolt (3) to 30-35 Nm
Tighten the mounting bolt (2) to 30-35 Nm

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Mounting the screw cap Oil module piping assembly

Push the breather tube (1) all the way into the
oil separator
• Together with the new seal ring (2) screw the
threaded plug (3) into the oil module (1) and
tighten to 80+10 Nm
Vent pipe assembly

Install the heat shield (1)

Apply Loctite 242 to the threads of the

screwdriving device (4)
Screw the screwing device (4) into the
crankcase and tighten it to 4 Nm
Apply Loctite 242 to the threads of the
screwdriving device (2)
Screw the screwing device (2) into the oil
module and tighten it to 4 Nm
Vent pipe assembly (3)
Screw and tighten the mounting bolt (1)
and gas
• Using hose clamp mounting pliers for small
pipe clamps [240] assemble the small pipe
clamp (2)
Mounting the heat shield

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II. Oil pan and oil suction pipe

Fig. 2-39 Oil pan and oil suction pipe

1. Oil pan seal washer; 2. Oil pan; 3. Oil pan block; 4. Oil pan block;
5. Mounting bolt; 6. oil suction pipe;

1. Consumables
Special Vaseline
2. Important information Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
Final tightening must be done manually with a torque wrench.

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Disassembly of the oil pan and oil suction pipe Assembly of oil pan and oil suction pipe
Disassembly of the oil pan Oil suction pipe assembly

• Unscrew the mounting bolt (4) • Insert the oil suction tube (2) into the crankcase
• Remove the oil pan block (3) • Screw in and tighten the new mounting bolt (1)
• Remove the oil pan (2) Oil pan assembly
• Remove the oil pan seal washer (1) from the oil
pan (2)
• Clean the contact surface
Disassembly of the oil suction pipe

Place the new oil pan washer (1) on the oil pan
(2)
Position the oil pan (2)
Install the oil pan block (3)
Unscrew the mounting bolt (1) Screw in the new mounting bolt (4) and hand
Remove the oil suction tube (2) from the tighten it
crankcase Tighten the mounting bolt (4)
Remove the O-ring (3) from the crankcase
• Apply a thin layer of special Vaseline on the
new O-ring (3)
• Insert the O-ring (3) into the crankcase

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III. oil injector nozzle
1. Auxiliary work O
- Disassembly and assembly of the oil pan and oil suction tube see page 175

Fig. 2-30 Oil injector nozzle

1. Oil injector nozzle; 2. mounting bolt
2. Technical data
Name Specification Technical parameters
Mounting bolts (2) M6×12-10.9 15Nm

3. Important information Warning

Improper tightening of connecting bolts may cause damage to components.
L. • If a pneumatic wrench is to be used, it can only be used for initial tightening. The torque
The maximum amount of tightening used for the initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.

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Disassembly of the oil injection nozzle Install the oil injector nozzle Insert

Unscrew the mounting bolt (2)

Remove the oil injection nozzle (1) from the
crankcase (3)
the oil injection nozzle (1) into the crankcase (3)
Screw and tighten the new mounting bolt (2), to a tightening torque of 15 Nm

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IV. Oil pump
1. Auxiliary jobs
- Disassembly and assembly of the fan see page 11
- Disassembly and assembly of the fan support is seen on page 13
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the thermostat is seen on page 24
- Disassembly and assembly of the thermostat housing is seen on page 26
- Disassembly and assembly of the belt drive is seen on page 44
- Disassembly and assembly of the distributor housing is seen on page 32
- Disassembly and assembly of high pressure pump / high pressure pump drive device see page 148
- Disassembly and installation of the crankshaft front oil seal see page 188
- Disassembly and assembly of the front cover can be seen on page 200
- Disassembly and assembly of the shock absorber see page 208

Fig. 2-31 Oil pump

1. Mounting bolts; 2. Geared ring (outer rotor); 3. Oil pump sprocket (inner rotor);
4. Mounting bolts; 5. O-ring; 6. Bearing; 7. Deck; 8. Sump; 9. Oil pump cover;
10. Mounting bolts;
2. Technical data
Name Specification Technical parameters
Mounting bolt (1) M6×20-10.9 15Nm
Mounting bolt (4) M10×35-10.9 65Nm

Name Technical parameters

Ring gear (outer rotor) (2) - crankshaft gear tooth 0.092-0.272mm
interval
Axial span, ring gear (outer rotor) (2) 0.030-0.093mm
Radial interval, ring gear (outer rotor) (2) 0.1-0.210mm
Outer diameter, bearing, ring gear (rotor 96,853-96,888mm

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exterior) (2)
Height of ring gear (outer rotor) (2) 29,952-29,970mm
Outer diameter, bearing (6) 36,950-36,965mm
29,955-25,970mm
Height of oil pump sprocket (inner rotor) (3)
36,985-37,050mm
Inner diameter of oil pump sprocket (inner rotor) (3)
3. Important information
Warning
Damage to the oil pump can cause damage to the crankcase
• Always ensure absolute cleanliness when assembling the oil pump
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The
maximum tightening torque used for initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.
4. Special tools
Number As shown in the figure MAN numbering
SINOTRUK
Description
Numbering

[242] Micrometer

T
• Verification of the interval
tooth, using:
• Verification of the axial interval and
radial of the ring gear (outer rotor), JD6805-0024 08.71000-3217
using:
• Micrometer holder [243]
• Positioning pin
[244]
[243] Micrometer holder
• Check tooth interval
• Check the axial interval and
radial ring gear (outer rotor)
JD6805-0025 08.71082-0005

[244]
Locating pin

6 • Check tooth interval

• Check the axial interval and
radial ring gear (outer rotor)
JD6805-0026 80.99605-0197

[245]

8 Alignment Drill Lever

• Disassembly and assembly of
crankshaft front gear
JD6805-0117 80.99617-0020

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Number As shown in the figure MAN numbering

SINOTRUK
Description
Numbering

[246] Impact extractor

F •

•
•
Removing the cover,
using:
Tube connector [248]
Extraction device [247]
JD6805-0018 80.99602-0016

[247] Extraction device

• Cover Removal

JD6805-0120 80.99602-0300

[248] tube connector

4
• Cover Removal
JD6805-0121 80.99602-0207

[249] Tool
• Press the cover
JD6805-0122 80.99604-6038

[250]

Depth gauge (electronic)

• Check the height of the sprocket JD6805-0032 08.71195-9003
oil pump (inner rotor)
• Check crown height
toothed (outer rotor)

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Check the oil pump

Check crankshaft gear/ring gear tooth span
(outer rotor)

• Assemble the micrometer holder [243] (1) that has the

micrometer [242] (3) and positioning pin [244]
• With a certain pretensioning force, mount the
• Mount the micrometer holder [243] (2) that has positioning pin [244] on the ring gear (outer rotor) (2)
the micrometer [242] (1) and • Press the crown toothed (rotor abroad) (2)
the pointing towards the crankcase
positioning pin [244] • Put the micrometer [242] (3) tozero
• With a certain pretensioning force, mount the • Extract the crown toothed (rotor abroad) (2)
positioning pin [244] on the ring gear (outer pointing towards the oil pump cover and read the
rotor) (3) difference on the micrometer
• Check the tooth gap between the crankshaft The allowable axial range of the ring gear (outer rotor) is
gear and the ring gear (outer rotor) (3) 0.030-0.093 mm.
The allowable tooth range is 0.092-0.272 mm. If the axial gap is outside the tolerance range, a new oil
pump must be installed.
If the tooth interval is outside the tolerance range,
Check the radial gap of the ring gear (outer rotor)
you must install a new crankshaft gear and oil pump.
Crankshaft gear disassembly

• Assemble the micrometer holder [243] (3) that has the

micrometer [242] (1) and positioning pin [244]
• With a certain pretensioning force, mount the
Screw the alignment lever [245] (3) and (4)
positioning pin [244] on the ring gear (outer rotor) (2)
Remove the crankshaft gear (2)
• Horizontally push the ring gear (outer rotor) (2) as far
Unscrew the alignment lever [245] (3) and (4) as it will go.
Clean the crankshaft gear (2) and crankshaft • Set the micrometer [242] (1) to zero
mating surface
• Pull the ring gear (outer rotor) (2) pointing towards the
Check the axial gap of the ring gear (outer rotor) micrometer [242] (1) to the end position and read the
micrometer difference
The admissible radial range of the ring gear (outer rotor)
(2) is 0.100-0.210 mm.

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Disassembly of the oil pump Cover Removal

Removing the oil pump cover

Unscrew the mounting bolt (1) Insert the extraction device [247] (2) into the
Remove the oil pump cover (2) from the crankcase cover (4) and enlarge the opening
(3) Mount the pipe clamp (3) on the extraction device
Disassembly of the oil pump [247] (2) and tighten it
Install the tube connector [248] (1)
Screw the impact extractor [246] into the tube
connector [248] (1)
Using the impact extractor [246] remove the cover
(4)

• From the crankcase (3) remove the ring gear (outer rotor) (1) and the oil pump pinion (inner rotor) (2)
Remove the oil pump pinion bearing (inner rotor).

Unscrew the mounting bolt (1)

From the crankcase (4) remove the bearing (3) together with the O-ring (2)

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Check oil pump bearing Check the inner diameter of the pinion (rotor
Check the outer diameter of the ring gear inside) of the oil pump
bearing (outer rotor)

• Clean the ring gear (outer rotor) (1)

• Check the outer diameter of the ring gear (outer
rotor) (1) with the micrometer gauge (2
The allowable external diameter is 96.853-96.888
mm.
If the outer diameter is outside the tolerance range,
a new oil pump with bearing must be installed.
Check the height of the ring gear (outer rotor)

• Clean the oil pump sprocket (inner rotor) (2)

• Using the micrometer [242] (1) and the inner
diameter gauge, check the inner diameter of
the pinion (inner rotor) (2) of the oil pump.
The internal diameter of the pinion (inner rotor) (2) of
the permissible oil pump is 36.985-37.050 mm.
If the inner diameter is outside the tolerance range, a
new oil pump with bearing must be installed.

• Clean the ring gear (outer rotor) (2)

• With depth gauge (electronic) [250] (1) check the height of the crown
toothed (outer rotor) (2)
The allowed measurement is 29,952-29,970 mm.
If the measurement is outside the tolerance range, a new oil pump with bearing must be installed.

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Check the height of the oil pump sprocket (inner Check the outer diameter of the bearing
rotor)

• Clean the bearing (1)

• Check the outer diameter of the bearing (1)
with the micrometer gauge (2)
The allowable external diameter is 36,950-36,965
mm.
If the outer diameter is outside the tolerance range,
a new oil pump with bearing must be installed.

• Clean the oil pump sprocket (inner rotor) (2)

• With the depth gauge (electronic) [250] (1)
check the height of the pinion (outer rotor) (2) of the oil pump
The permitted measurement A is 29,955-29,970 mm.
If the measurement is outside the tolerance range, a new oil pump with bearing must be installed.

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Oil pump assembly • Holding cover (2)

Screw thread main bearing Clamping guide plate

Together with the cover (1) insert into the guide

• Clean the threaded main bearing (1) plate (2) so that the secondary support (3) slides
• Clean the bearing contact surface into the oil pump hole (4)
main thread (1) in the crankcase Press the cover
• Screw the threaded main bearing (1) with the
special tool [249] and tighten it
Prepare the installer

Screw the hex head nut (1) Press the cover (3) by
screwing the hex head nut (1) until it meets the
• Align the recess in the cover (2) with the obstruction
mark on the special tool [249] (1)
Remove the special tool [249] (2)

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Install the oil pump pinion bearing (inner rotor) Screw in the new mounting bolt (1) and
tighten it to 15 Nm
Install the crankshaft gear

Grades
5}
The locating pin determines the mounting
position of the bearing. Screw the alignment lever [245] (3) and (4)
• Apply a coat of clean engine oil to the new O-
Place the crankshaft gear (2) on the crankshaft
ring (2)
(1), make sure it reaches the end Unscrew the
• Install an O-ring (2) on the bearing (3)
alignment lever [245] (3) and (4)
• Insert the bearing (3) into the crankcase (4)
• Screw in and tighten the new mounting bolt
(1)
Install the oil pump

Apply clean engine oil to the bearing surface of

the ring gear (outer rotor) (1) and the pinion
(inner rotor) of the oil pump (2).
Insert the ring gear (outer rotor) (1) into the
crankcase (3)
Slide the oil pump sprocket (inner rotor) (2) into
the bearing so that the mark (4) is visible.
Install the oil pump cover

Locate the oil pump cover (2) on the crankcase (3)

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v. Crankshaft front oil seal
1. Auxiliary jobs
- Disassembly and assembly of the fan see page 11
- Disassembly and assembly of the shock absorber see page 208

Fig. 2-32 Front Oil Seal

1. Cover plate; 2. Crankshaft front oil seal;
2. Important information
Warning
/ Contact with oil or grease before assembly may cause the seal rings / * PTFE are not available
• Before assembly clean the crankshaft and insertion tools Warning
/l\ Improper tightening of connecting bolts may cause damage to components.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.

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3. Special tools
Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[251]
crossover plate
• Remove the oil seal
of the crankshaft, using:
• Pressure plate [252]
• Hex nut [255] JD6805-0123 80.99606-0298
• Hook [253]
• Threaded spindle [256]
• head bolt flat
[257]
• Guide plate [258]
[252] Pressure plate
• Remove the oil seal
of the crankshaft
JD6805-0124 80.99609-0038

[253] Hook

[254]
g • Remove the oil seal
of the crankshaft JD6805-0125 80.99606-6013

AND Press the liner

• Press the seal
crankshaft oil, using:
• Hex nut [255]
• Threaded spindle [256]
• flat head bolt
[257] JD6805-0126 80.99606-0659
• Guide plate [258]
• Washer [259]
• flange nut
hexagonal [260]
• Washer, 6mm [261]
• Washer, 3mm [262]

[255] Hex nut

• Remove the oil seal
of the crankshaft
EITHER • Press the seal JD6805-0127 06.11069-0064
crankshaft oil

[256] Threaded spindle

• Remove the oil seal
of the crankshaft
• Press the seal JD6805-0128 80.99606-0299
crankshaft oil
C )M
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Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[257] flat head bolt
• Remove the oil seal
of the crankshaft
— • Press the seal
crankshaft oil
JD6805-0129 06.02191-2822

[258] guide plate

To and • Remove the oil seal
of the crankshaft
• Press the seal JD6805-0130 80.99606-0658
crankshaft oil

[259] Washer

EITHE • Press the seal

crankshaft oil
JD6805-0131 06.15230-0609

R
[260] Hexagon flange nut • Press the

(GC))
Wy
seal
crankshaft oil JD6805-0132 06.11222-0211

[261] Washer, 6mm

• Press the seal

()
crankshaft oil
JD6805-0133 81.90711-0195

[262] Washer, 3mm

• Press the seal

()
crankshaft oil
JD6805-0134 81.90712-0984

[263] Depth gauge (electronic)

• Determine the depth
pressed crankshaft oil seal
JD6805-0032 08.71195-9003

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Remove the crankshaft oil seal

Warning
The crankshaft oil seal can be damaged
• Carefully separate the disc from the
transfer sleeve with a suitable tool
Mount guide plate [258] (4) on crankshaft (1)
with flat head bolt [257]
Position the crankshaft oil seal (2) with the
transfer sleeve (3) and push the crankshaft oil
seal (2) to the guide plate [258] (4)
Remove the transfer hose (3)

• Assemble the guide plate [258] (3) and

pressure plate [252] and flat head bolt [257] (1)
together on the crankshaft
• Together with the hexagonal nut [255] screw
the threaded spindle [256] (6) onto the cross
plate [251] (5)
• Screw the second hex nut [255] onto the
threaded spindle [256] (6) and secure it with the
hex nut [255].
• Insert hook [253] (4) through cross plate [251]
(5) between crankshaft oil seal (2) and
crankshaft
• Turn the hook [253] (4) 90° so that the recess
faces outwards
• Hold the hex nut stably on the cross plate [251]
(5)
• Remove the crankshaft oil seal (2) by screwing
the threaded spindle [256] (6)
• Special disassembly tools
Crankshaft Front Oil Seal Assembly
Position the crankshaft oil seal

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Crankshaft oil seal assembly

• Together with the washer, 3 mm [262] push the pressure liner [254] (2) into the guide plate [258]
• Screw the hexagonal flange nut [260] (3) onto the threaded spindle [256] (4)
• Screw the hexagonal nut [255] onto the threaded spindle [256] (4)
• Screw the second hex nut [255] onto the threaded spindle [256] (4) and secure it with the hex nut [255].
• Screw the threaded spindle [256] (4) into the guide plate [258] with the washer [259]
• Hold the hexagon nut [255] stably on the threaded spindle [256] (4)
• Press the crankshaft oil seal (1) by screwing the hexagonal flange nut [260] (3) until the
pressure coating [254] (2) with
washer, 3 mm [262] is located on the guide plate [258]
• Special disassembly tools

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SAW. Crankshaft rear oil seal.
1. Auxiliary jobs
- Disassembly and assembly of the steering wheel is seen on page 212

Fig. 2-33 Crankshaft rear oil seal

1. Crankshaft oil seal; 2. Steering wheel housing;
2. Technical data
Bushing mounting temperature is approximately 120°C
3. Auxiliary materials
Loctite Antipor Sealant (Loctite 5900 Sealant)
4. Important information
Warning
Contact with oil or grease before assembly may cause PTFE seal rings to become
unavailable
• Before assembly clean the crankshaft and insertion tools Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
Final tightening must be done manually with a torque wrench.

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5. Special tools
Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[264]
Impact extractor

SW
• Remove the oil seal
of the crankshaft, using: JD6805-0018 80.99602-0016
• Extraction hook
[265]
[265] Extraction hook

2
• Remove the oil seal
of the crankshaft
JD6805-0135 80.99602-0175

[266] Disassembly device

• Bushing removal,
<e P (vli •
using:
Threaded spindle [267]
JD6805-0136 80.99601-0182

• Pressure plate [268]

[267] Threaded spindle

6
• Remove the bushing
JD6805-0137 80.99601-0156

[268] Pressure plate

• Remove the bushing

) JD6805-0138 80.99601-0183

[269]
Insert the lever,
• bushing extrusion,
using:
• Compression disc
[271]
• Washer [270]
JD6805-0020 80.99617-0187
• Seal assembly
crankshaft oil, using:
• Washer [270]
• Guide bushing [272]
• Compression disc
[273]

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MC11 Series Engine Maintenance Manual
[270] Washer
• extrusion bushing
• Seal assembly
crankshaft oil JD6805-0021 80.99617-0144

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Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[271] Compression disc • extrusion
bushing

JD6805-0139 80.99617-0017

[272] guide bushing

• Seal assembly
crankshaft oil JD6805-0140 80.99604-0286

6
[273] Compression disc
• Seal assembly
crankshaft oil
JD6805-0141 80.99604-0069

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 MC11 Series Engine Maintenance Manual

Remove the crankshaft rear oil seal

Using the impact puller [264] (1) and the puller

hook [265] (2), remove the crankshaft oil seal
(3) from the flywheel housing
Install the crankshaft rear oil seal

Push guide bushing [272] (4) in the

crankshaft
Assemble the extrusion plate [273] (6),
insert the lever [269] (1) and the washer [270]
(2)
Mount the closed surface of the crankshaft oil
seal (3) on the special tool
Push the special tool to the guide bushing [272]
(4)
Press the crankshaft oil seal (3) into the
flywheel housing (5) until the compression disc
[273] (6) is on the guide bushing [272] (4)
Special disassembly tools

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MC11 Series Engine Maintenance Manual
SECTION IX CRANKCASE ASSEMBLY

Fig. 2-34
Mounting parts on crankcase assembly
1. Mounting bolt 2. Wheel hub 3. O-ring 4. Cylinder sleeve 5. steering wheel housing
6. Front cover 7. Shock absorber 8. mounting bolt

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YO. steering wheel housing

1. Auxiliary work
- Disassembly and assembly of the starter motor is seen on page 41
- Disassembly and assembly of the crankshaft rear oil seal see page 193
- Disassembly and assembly of the steering wheel is seen on page 212

Fig. 2-35 Flywheel housing

1. Mounting bolts; 2. steering wheel housing
2 Technical data
Name Specification Technical parameters
M10×30-10.9 65Nm
Flywheel housing mounting bolt (1)

M10×40-10.9 65Nm
Flywheel housing mounting bolt (1)

M16×1.5×55-10.9 280Nm
Flywheel housing mounting bolt (1)

3 Auxiliary materials
Loctite 5900
4 Important information Warning
Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.

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Disassembly of the flywheel housing Flywheel housing assembly
Disassembly of the flywheel housing Flywheel Housing Assembly Instructions

• Apply Loctite 5900 (1) to the mating surface as

shown in the figure.
Flywheel housing assembly

Grades:
Heavy components may cause
personal injury.
• Remove the flywheel housing
with support
Unscrew the mounting bolt (1)
Remove the flywheel housing (2)
Clean the contact surface

Grades:
Heavy components may cause
personal injury.
• Remove the flywheel housing
with support
• Install the flywheel housing (2) onto the
centering pin
• Screw in and tighten the new mounting bolt
(1)
M10 bolt tightening torque is 65 Nm
M16 bolt tightening torque is 280 Nm

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II. Front cover plate

1. Auxiliary jobs
- Disassembly and assembly of the fan see page 11
- Disassembly and assembly of the thermostat is seen on page 24
- Disassembly and assembly of the thermostat housing is seen on page 26
- Disassembly and assembly of the distributor housing is seen on page 32
- Disassembly and assembly of the belt drive is seen on page 44
- Disassembly and installation of the crankshaft front oil seal see page 188
- Disassembly and assembly of the shock absorber see page 208

Fig. 2-36 Front cover

1. Mounting bolt 2. Front cover 3. Washer 4. Fan support 5. Sump
2. Technical data
Name Specification Technical parameters
Mounting bolt (1) M8×25-10.9 35Nm
Mounting bolt (1) M8×40-10.9 35Nm
Mounting bolt (1) M12×70-10.9 115Nm
3. Auxiliary materials
Loctite 5900
Special Vaseline
4. Important information
Warning
/h Improper tightening of bolts can cause damage to components.
You • If a pneumatic wrench is to be used, it can only be used for initial tightening. The torque
The maximum amount of tightening used for the initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.

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Removing the front cover
O Front cover assembly
Front Cover Assembly Instructions

Mark the mounting position of the mounting bolt

(1)
Unscrew the mounting bolt (1) • Fit a new O-ring (2)
Remove the front cover (2) together with the • Apply the special Vaseline on the new O-ring
washer (3) from the crankcase (2)
Clean the contact surface • Apply Loctite 5900 sealant (1) to the mating
surface as shown in the figure.

Front cover assembly

• Position the front cover (2) together with the new

washer (3)
• As shown, screw in the new mounting bolt (1) and
hand tighten it.
• Tighten the mounting bolt (1)
M8 bolt tightening torque is 35 Nm
M12 bolt tightening torque is 115 Nm
III. cylinder sleeve
1. Auxiliary jobs
- Removal and assembly of the engine control unit is seen on page 7
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the generator is seen on page 47
- Disassembly and assembly of the exhaust manifold is seen on page 54
- Disassembly and assembly of intake pipes see page 57
- Removal and assembly of the intake manifold is seen on page 59
- Disassembly and assembly of the turbocharger is seen on page 61
- Disassembly and assembly of the cylinder head is seen on page 67
- Disassemblyandmounting of the injector and assembly of the common rail seen in
the page 134
- Disassemblyandmounting of the oil module seen on page 167

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- Disassemblyandmounting of the oil pan and pipeoil suction HE goin the page
175
- Disassemblyandmounting of the piston and connecting rod seen in page 221

Fig. 2-37 Cylinder sleeve

1. Crankcase 2. O-ring 3. cylinder sleeve

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2. Technical parameters
O
Name Technical parameters
Cylinder sleeve protruding amount 0.035-0.085mm
8.0±0.015mm
Crankcase cylinder sleeve seat depth

Bottom O-ring area hole Ø 139,500 - 139,540 mm

3. Important information Warning
Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
4. Special tools
Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[330] removal tool
and-- • Cuff removal
of the cylinder, using:
• Extraction disk JD6805-0169 80.99602-6035
[331]
gg
[331] Extraction disk

(
• Cuff removal
of the cylinder JD6805-0170 80.99601-0217

[332]
Micrometer
• Check the diameter of the
cylinder sleeve
• Check the quantity
protrusion of the cylinder
sleeve, using:
• Micrometer holder JD6805-0024 08.71000-3217
[333]
• Disc of measurement
[334]
• Bolt head
hexagonal [335]
• Washer [336]
[333] Micrometer holder
• Check the quantity
cuff protrusion JD6805-0147 80.99605-0172

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Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[334] Measuring disc
.8Co • Check the quantity
cylinder liner protrusion
K9) JD6805-0097 80.99605-0286

—e9D
[335] hex bolt

g
• Check the quantity
cylinder sleeve protrusion
JD6805-0098 06.01499-0015

[336] Washer

G)
• Check the quantity
cylinder sleeve protrusion JD6805-0099 06.15013-0417

[337] Depth gauge (electronic)

• Check the seat of the
cylinder sleeve
JD6805-0032 08.71195-9003

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 MC11 Series Engine Maintenance Manual

Cylinder sleeve disassembly Cylinder sleeve removal

Check cylinder sleeve diameter

Secure the removal tool [330] (3) with the nut

Using the micrometer [332] (2) and a bore (2)
gauge (1), measure the cylinder sleeve (3). Using the removal tool [330] (3) remove the
Repeat the measurement several times with an cylinder sleeve (1)
offset of 120° Clean the cylinder sleeve (1)
Repeat measurements at four different heights O-ring disassembly

If the cylinder sleeve (3) is elliptical, a new cylinder

sleeve must be fitted.
Assembling the extraction tools

Remove the O-ring (2) from the crankcase

Clean the cylinder sleeve seat (1) and the O-
ring seat

Warning
Damaged oil nozzles can damage the engine
• Do not damage the oil injector nozzle when inserting the disc.
extraction [331]
• Mark the correct placement and mounting position of the cylinder sleeve (1)
• Push the extraction tool [330] (3) and the folded extraction disc [331] (2) into the cylinder sleeve (1)

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Cylinder sleeve assembly Cylinder sleeve assembly

Check the seat of the cylinder sleeve

Apply clean engine oil to the new O-ring (2) and

seat it into the O-ring seat in the crankcase.
• Using the depth gauge (electronic) [337] (1) Apply clean engine oil to the outside of the
check the seat of the cylinder sleeve bottom of the cylinder sleeve (1)
• Measure the cylinder sleeve seat at four Insert the cylinder sleeve (1) as shown and
opposite points push it in as far as possible.
The permissible depth of the cylinder sleeve seat is
8.0 ± 0.015 mm.
If the cylinder sleeve seat is outside the tolerance
range, a new crankcase must be fitted.
Check the protruding amount of the cylinder
sleeve

• Place the measuring disc [334] (2) in the

cylinder sleeve
• Screw together with washer [336] (5) and tighten hex head bolt [335] (4)
• Place the micrometer holder [333] (6) with the micrometer [332] (3) on the measuring disc [334] (2)
• Place the pointer (1) of the micrometer on the crankcase
• Set the micrometer [332] (3) to zero
• Carefully place the micrometer pointer (1) on the cylinder sleeve and observe the changes in the micrometer
The allowable cylinder sleeve overhang amount is 0.035-0.085mm.
If the protruding amount of the cylinder sleeve is out of the tolerance range, you need to fit a new cylinder sleeve/new
crankcase.

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SECTION
O
XC URVED CRANK CONNECTING ROD MECHANISM

Fig. 2-38 Curved Crank Connecting Rod Mechanism

1. Steering wheel 2. Crankshaft 3. Connecting rod 4. Bearing cover 5. Shock absorber 6. Piston

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I. Shock absorber
II. Auxiliary jobs O
- Disassembly and assembly of the fan, see 11

Fig. 2-39 Shock Absorber

1. Mounting bolts 2. Shock absorber 3. Mounting bolt 4. wheel hub
2. Technical data
Name Specification Technical parameters

Initial torque 150+10 Nm

Mounting bolt (3) M16×85-10.9
Angle 90+10°
Mounting bolt (1) M10×25-8.8 50-55Nm
3. Important information
Warning
/ Incorrect tightening of bolts may cause damage to components.
L: • If a pneumatic wrench is to be used, it can only be used for initial tightening. The torque
The maximum amount of tightening used for the initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.

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4. Special tools
Number O
As shown in the figure Description
SINOTRUK
MAN numbering
Numbering
[274] Engine crankshaft rotating device J D6805-0023 80.99626-6008

ÉÉ k
• lock motor

[275]
P'o Pipe wrench, size 14

TO
• Unscrew and tighten the
shock absorber mounting bolts

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Shock absorber disassembly Wheel hub removal

Engine crankshaft rotating device assembly

Unscrew the mounting bolt (3)

Remove the wheel hub (1) from the shock
absorber (2)
Remove the display port cover from the
steering wheel housing
Mount and lock the engine crankshaft rotating device [274] (1) to the flywheel housing
Shock absorber disassembly

Unscrew the mounting bolt (1) with the socket wrench, size 14 [275]
From the crankshaft gear, remove the shock absorber (3) together with the wheel hub (2).

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O
Shock absorber assembly
Wheel hub assembly
Remove the rotating device from the engine
crankshaft

Insert hub (1) into shock absorber (2)

Screw in the mounting bolt (3) and tighten it to Remove the engine crankshaft rotating device
50-55 Nm [274] (1) from the housing
steering wheel
Shock absorber assembly
Mount the display port cover to the steering
wheel housing

Hold the shock absorber (3) together with the hub (2)
Screw in the mounting bolt (1)
Tighten the mounting bolt (1) with the socket wrench, size 14 [275] to the initial torque of 150 Nm
Tighten mounting bolt (1) with socket wrench, size 14 [275] to 90° angle

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III. Steering wheel

1. Auxiliary jobs
- Disassembly and assembly of the crankshaft rear oil seal see page 193

Fig. 2-40 Flywheel

1. Steering wheel 2. Mounting bolts 3. steering wheel
2. Technical data housing
Name Specification Technical parameters
Mounting bolts (2) M16×1.5×81-12.9 Initial torque 100+10 Nm
Mounting bolts (2) M16×1.5×81-12.9 Angle 180+10°
Mounting temperature of crown 200-230℃
flywheel teeth
Measurement between the flywheel wall to the Maximum 9.5mm
friction surface (maximum size)
3. Important information Warning
Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
Final tightening must be done manually with a torque wrench.

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4. Special tools
Number Ofigure
As shown in the
SINOTRUK
MAN numbering
Description
Numbering

[280] Alignment Drill Lever

g
• Disassembly and assembly of
steering wheel
JD6805-0117 80.99617-0020

[281] Micrometer
• Check deviation
side of the steering wheel,
using:
JD6805-0024 08.71000-3217
• Micrometer holder
[282]
• Pin
positioning [283]
[282] Micrometer holder
• Check deviation
steering wheel side
JD6805-0025 08.71082-0005

[283] Locating pin

6
• Check deviation
steering wheel side JD6805-0026 80.99605-0197

[284]

p
Depth gauge (electronic)
• Check the wear of the
steering wheel, using: JD6805-0032 08.71195-9003
• Measuring accessory
[285]

[285] Measuring accessory

g
• Check the wear of the
steering wheel JD6805-0142 08.71109-0000

A
[286]
Torque boost i = 1:3.5
• Unscrew and tighten the
steering wheel mounting bolt,
using:
• Support [287]
• Measuring disc
JD6805-0084 80.99619-0007
angle [288]
• Support devices
[289]
• Washer [290]

N
• flat head bolt
[291]

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Number As shown in the figure MAN numbering

SINOTRUK
Description
Numbering

• Connecting pin [292]

• Rubber ring 42mm [293]
• Pipe wrench, size 19
[294]
[287] Medium
• Unscrew and tighten the
steering wheel mounting bolt JD6805-0085 80.99606-0551

[288] Angle measuring disc

T • Unscrew and tighten the

steering wheel mounting bolt
JD6805-0086 80.99607-0172

[289] Support devices

• Unscrew and tighten the
steering wheel mounting bolt
JD6805-0143 80.99606-0553

[290] Washer

EITH • Unscrew and tighten the

steering wheel mounting bolt JD6805-0091 80.99609-0033

[291]
ER Flat head screw
•@

• Unscrew and tighten the

steering wheel mounting bolt
JD6805-0088 06.02191-0407

[292] connecting pin

• Unscrew and tighten the
steering wheel mounting bolt JD6805-0089 06.22729-0006

[293] Rubber ring 42mm

• Unscrew and tighten the
steering wheel mounting bolt
EITHER JD6805-0090 08.06142-9006

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 MC11 Series Engine Maintenance Manual

Number As shown in the figure MAN numbering

SINOTRUK
Description
Numbering

[294] Pipe wrench, size 19

• Unscrew and tighten the
steering wheel mounting bolt
JD6805-0144 80.99603-0311

[295]
Insert the lever,
• Press the bearing JD6805-0020 80.99617-0187
clutch guide, using:
• Thrust washer [296]
• Compression disk [297]
[296] Thrust washer

G)
• Press the bearing
clutch guide
JD6805-0021 80.99617-0144

[297] Compression disk

©
• Press the bearing
clutch guide JD6805-0145 80.99604-0302

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 MC11 Series Engine Maintenance Manual

Flywheel disassembly Unscrew the steering wheel mounting bolt

Special assembly tools

• Insert the i = 1:3.5 torque booster [286] (1) into • Unscrew two mounting bolts (1) opposite
the bracket [287] (9) Screw the alignment lever
• Install the support device [289] (6) and the flat
head bolts [291] (8) and the
washers [290] (7) on the bracket [287] (9)
• Mount the angle measuring disc [288] (2) on the
torque booster i = 1: 3.5 [286] (1)
• Mount the socket wrench, size 19 [294] (3) on
the torque booster i = 1: 3.5 [286] (1) and
secure it with the connecting pin [292] (5) and
the locking ring. rubber 42mm [293] (4)
Unscrew the steering wheel mounting bolt

Screw the alignment lever [280] (1) and (2)

• Unscrew the remaining mounting bolts

Remove the steering wheel

Mount the special tool (1) on the mounting bolt

to be loosened
Unscrew the mounting bolt
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MC11 Series Engine Maintenance Manual

Attention
Heavy components may cause personal
injury
• Remove the steering wheel with lifting
device
Remove the steering wheel (1) from the
alignment lever [280] (2)

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 MC11 Series Engine Maintenance Manual

Disassembly of the flywheel ring gear

Clutch Guide Bearing Disassembly

Warning
Yo Point drilling of the steering wheel
possibly cause damage to components
Remove the clutch guide bearing (2) from the •
flywheel (1) •
By drilling points into the flywheel ring gear, the flywheel cannot be damaged.
Using the electric drill (2), drill the flywheel gear
ring (3) in points, forcing it to open.
Remove the flywheel ring gear (3) from the
flywheel (1)
Clean the contact surface of the flywheel gear
ring (3) and flywheel (1) and check for damage.

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 T MC11 Series Engine Maintenance Manual

O
Flywheel ring gear assembly Check the steering wheel
Check steering wheel wear

Heat the flywheel ring gear (1) to 200-230°C

Install the flywheel gear ring (1) so that the
chamfer of the tooth (3) faces away from the • Clean the steering wheel
flywheel (2). • Check the steering wheel for cracks, fit a new
Install the flywheel gear ring (1) so that the hole steering wheel if necessary
in the flywheel ring gear (1) aligns with the hole • Check if there is burn and wear on the friction
in the flywheel (2). surface (1); Fit a new steering wheel if
Adjust the flywheel ring gear (1) if necessary necessary
• Check the top tooth of the flywheel ring gear (2)
for wear; Fit a new steering wheel if necessary
Check the size between the flywheel wall (only
for flywheel with hub) and the friction surface

• With the depth gauge (electronic) [284] (2) and the

measuring accessories [285] (3) check the
measurement between the flywheel wall and
the friction surface (1)
The allowable size of the handwheel wall is 9.5mm
maximum after the handwheel is in operation.
If the steering wheel wall measurement is outside
the tolerance range, a new steering wheel must be
fitted.

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 MC11 Series Engine Maintenance Manual

Steering wheel
Steering wheel assembly assembly
Press the clutch guide bearing

Grades:
Heavy components may cause
personal injury
Mount the steering wheel with lifting device
• Align he steering wheel (1) with he
Barretteof
crankshaft gear positioning
• Mountain he steering wheel
(1) in the lever of
alignment [280] (2)

With the insertion lever [295] (1), the

thrust washer [296] (2) and compression disc
[297] (3) assemble the
special tools
With a special tool, press the clutch guide
bearing (4) on the flywheel (5) until it
encounters obstruction.

Screw in the new steering wheel mounting bolt

Unscrew the alignment lever [280] (1) and (2)

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 MC11 Series Engine Maintenance Manual

Screw in the steering wheel mounting bolt

• Screw in the remaining mounting bolts (1)

Tighten the mounting bolt

Grades
Note the torque boost ratio: i=1:3.5.
Tighten the mounting bolt with the special tool (1) to the initial torque of 100+10 Nm
Tighten the mounting bolt with the special tool (1) to the angle of 180°+10°
III. Piston and connecting rod
1. Auxiliary jobs
- Removal and assembly of the engine control unit is seen on page 7
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the exhaust manifold is seen on page 54
- Disassembly and assembly of intake pipes see page 57
- Disassembly and assembly of the turbocharger is seen on page 61
- Disassembly and assembly of the cylinder head is seen on page 67
- Verification and configuration of the valve interval is seen on page 79
- Disassembly and assembly of the injector and common rail assembly see page 134
- Disassembly and assembly of the fuel supply center is seen on page 156
- Disassembly and assembly of the oil module is seen on page 167
- Disassembly and assembly of the oil pan and oil suction tube see page 175

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Fig. 2-41 Piston and connecting rod

1. Piston 2. Connecting rod 3. Connecting rod bolt 4. Connecting rod bushing 5. Piston pin 6. Spring retaining
ring
7. Piston ring 8. Lower connecting rod cover 9. Connecting rod upper cover

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 TO
MC11 Series Engine Maintenance Manual
2. Technical data
Name Specification Technical parameters
Initial torque 100±10 Nm
Connecting rod bolts (3) M12×64-11.9
Turning angle 90° + 10°
Connecting rod axial range 0.130-0.330mm
Connecting rod radial interval 0.044-0.106mm
Piston pin bushing inner diameter Ø 52,060 - 52,065 mm
Crank Width 43.170-43.270mm
Connecting rod bushing hole Ø 95,000 - 95,022 mm
Weight difference of each set of connecting rods in the engine Maximum of 50g
Lack of roundness of the connecting rod bushings (8) and (9) 2.0mm maximum
Standard size of connecting rod bushings (8) and (9) Ø 90.060 - 90.102 mm
2.468+0.010mm
Standard wall thickness of connecting rod bushings (8) and (9)

Piston ring open space (trapezoidal ring) 0.40-0.55mm

Piston ring gap (taper ring) 0.9-1.1mm
Axial range 0.08-0.13mm
0.25-0.55mm
Piston ring (oil ring) gap (double bevel ring)

Axial range 0.03-0.07mm

Weight difference of each piston set in the engine Maximum of 60g
piston pin Ø 51,992 - 52,000 mm
Protruding quantity of the piston (crankcase-piston) 0.0235-0.3435mm
3. Important information
Warning
The teeth on the large head section of the connecting rod are easily damaged. If it
continues to work it will be destroyed
• If the section teeth are damaged, you need to replace the connecting rod
• They should prevent the section teeth from being damaged by hard and sharp targets.
• When cleaning the teeth of the connecting rod section, you should clean them in a clean
cleaning solution.
• When finishing cleaning, you should use compressed air to dry the section teeth
• Objects removed after cleaning are not allowed to enter the engine
Warning
• Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The torque
The maximum amount of tightening used for the initial tightening will be 50% of the specified
tightening torque value.
• Final tightening must be done manually with a torque wrench.
Grades
The piston diameter measurement should be perpendicular to the piston pin bore.

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 T MC11 Series Engine Maintenance Manual
4. Special tools
Number O
As shown in the figure Description
SINOTRUK
MAN numbering
Numbering
[308] Piston ring mounting pliers
• Disassembly and assembly of
piston ring JD6805-0034 83.09144-6090

[309] Caliber
• Check the axial interval and the
piston ring radial gap JD6805-0146 08.75310-0808

[310]

T
Micrometer
• Check the inner diameter
of connecting rod bushing and
piston bushing
• Check the quantity
piston protrusion, using:
• Support micrometer [311] JD6805-0024 08.71000-3217
• Check the axial interval and
radial of the connecting rod,
using:
• Support micrometer [312]
• Pin positioning
[313]
[311] Micrometer holder
• Check the quantity
piston protrusion
JD6805-0147 80.99605-0172

[312] Micrometer holder

• Check the axial interval and
connecting rod radial
JD6805-0025 08.71082-0005

68
[313] Locating pin
• Check the axial interval and
connecting rod radial JD6805-0026 80.99605-0197

[314]
Depth gauge (electronic)
• Check the depth JD6805-0032 08.71195-9003
piston insert

[315] piston ring plier

2
• Piston assembly
JD6805-0148 80.99613-0038

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 MC11 Series Engine Maintenance Manual

Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[316] Adjustment tools

<
• Align the connecting rod bushing
JD6805-0149 80.99622-0052

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 MC11 Series Engine Maintenance Manual

Check the connecting rod (4) is 0.044-0.106 mm.

Check the axial span of the connecting rod If the radial interval is outside the tolerance range,
you need to check the connecting rod bushing and
bearing collar.
Check the inner diameter of the connecting rod
bushing, see "Checking the inner diameter of the
connecting rod bushing", page . 228
Check the outside diameter of the connecting rod
bearing collar, see "Checking the outside diameter
of the connecting rod bearing collar", page . 240

Mount the micrometer holder [312] (2) that has

the micrometer [310] (1) and
the
positioning pin [313] in crankcase (3)
With a certain pretensioning force, mount the
positioning pin [313] on the connecting rod (4)
Push the connecting rod (4) horizontally
towards the flywheel housing to the tail position
Set the micrometer [310] (1) to zero
Pull the connecting rod (4) pointing towards the
micrometer [310] (1) to the bottom position and
read the micrometer difference
Repeat this procedure for the remaining
connecting rods
The allowable axial interval of the connecting rod (4)
is 0.130-0.330 mm.
If the axial span is outside the tolerance range, you
must check the width of the connecting rod (4), see
"Checking connecting rod width", page . 229
Check the radial gap of the connecting rod

Mount the micrometer holder [312] (1) that has

the micrometer [310] (2) and
the
positioning pin [313] in crankcase (3)
With a certain pretensioning force, mount the
positioning pin [313] on the connecting rod (4)
Press the connecting rod (4) vertically down to
the tail position
Set the micrometer [310] (2) to zero
Pull the connecting rod (4) pointing towards the
micrometer [310] (2) to the bottom position and
read the micrometer difference
Repeat this procedure for the remaining
connecting rods
The allowable radial interval of the connecting rod

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 MC11 Series Engine Maintenance Manual

Disassembly of the piston and Piston disassembly and verification

connecting
Disassemblyrod
of the connecting rod bushing Piston pin removal
cover

Warning • Mark the relative position of the piston (1),

The teeth on the large head section of piston pin (5) and connecting rod (3)
the connecting rod are easily • Remove spring retaining ring (2) and (4)
damaged. If it continues to work it will • Remove by pushing the piston pin (5) out of the
be destroyed piston (1)
• If the teeth of the section are damaged, • Remove the piston (1) from the connecting rod
you must replace the connecting rod (3)
They should prevent the teeth of the section from Measure the diameter of the piston pin
being damaged by hard and sharp targets. Mark the
correct placement and mounting position of the
connecting rod cover cap (3) and connecting rod
bushing (2)
Unscrew the connecting rod bolts (4)
Remove the connecting rod bushing cover (3)
together with the connecting rod bushing (2)
Push out the piston and connecting rod (1) in the
direction of the cylinder head
Piston disassembly

• Measure the diameter of the piston pin (2) with

the micrometer caliper (1)
The allowable diameter of the piston pin (2) is Ø
51,992 - 52,000 mm.
If the diameter is outside the tolerance range, you
must mount a new piston that has piston pin (2).
Measurement of the axial interval of the ring
piston

• Remove the piston (1) together with the

connecting rod (2) from the cylinder sleeve (4)
• Mark the correct placement and mounting
position of the connecting rod (2) and
connecting rod bushing (3)
• Remove the connecting rod bushing (3) from
the connecting rod (2)

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 MC11 Series Engine Maintenance Manual

Descriptions
5} Description
It is only allowed to check the piston ring
Measuring the axial interval on the
gap when the cylinder sleeve bore is
trapezoidal ring is not allowed.
correct, otherwise incorrect piston ring
With the thickness gauge [309] (1)
gap data will be generated.
Measure the axial interval between the rings of
the • Check the inside of the cylinder sleeve, see
piston (2) and (3) and piston (4) "Removal and installation of the cylinder
The allowable axial range of the double bevel ring sleeve". 202
(3) is 0.03 to 0.07 mm. • Deeply and evenly insert the piston ring (3) into
the cylinder sleeve (1)
The allowable axial range of the conical ring (2) is
• With depth gauge (electronic) [314] measure
0.08 to 0.13 mm.
the average inserted depth of the piston ring (3)
If the axial interval is outside the tolerance range,
• Repeat this verification step for different
you must mount a new piston (4) that has piston ring
(2), (3) and ring insertion depths
trapezoidal. • With the thickness gauge [309] (2)
Piston ring disassembly check piston ring gap
The allowable trapezoidal ring opening space is
0.40-0.55mm.
The allowable conical ring opening space is 0.9-
1.1mm.
The allowable double bezel ring opening space is
0.25-0.55mm.
If the piston ring open space is outside the tolerance
range, a new piston ring must be fitted.

Set the piston ring mounting pliers [308] (1) to

the piston diameter
Remove piston ring (2) from piston (3) with
piston ring mounting pliers [308] (1)
Carefully clean the piston ring groove
Check piston ring clearance

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 MC11 Series Engine Maintenance Manual

Check the connecting rod and connecting rod Check the inner diameter of the connecting rod
cover Correctly pair the connecting rod and bushing
connecting rod cover cap

Warning
Incorrect pairing of the connecting rod
and connecting rod cover cap will cause
damage to the
components
Ensure correct pairing of the
connecting rod and connecting rod cover cap
Check the pairing numbers (1) and (2) on the
connecting rod (3) and connecting rod cover
cap (4)
• Insert the upper connecting rod cover into the
connecting rod (4)
• Insert the lower connecting rod cover into the
connecting rod cover cap (1)
• Screw in the connecting rod bolt and tighten it to
the initial torque of 100 Nm
• Using the micrometer [310] (2) and an inner
diameter gauge (3) measure the inner diameter
of the connecting rod bushing
The standard measurement of the inner diameter of
the connecting rod bushing is Ø 90.060 - 90.102
mm.
If the inner diameter is outside the tolerance range,
you must fit a new connecting rod bushing.
Check piston pin bushing

• Check the piston pin bushing bore diameter with

bore gauge (3) and micrometer [310] (2)
The allowable diameter of the piston pin bushing (3)
is Ø 52.060 - 52.065 mm.
If the inner diameter is outside the tolerance range,
you must install a new connecting rod (1).

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O
Check the width of the connecting rod

• Check the width of the connecting rod (1)

• Disassembly of the connecting rod hub cover
The allowable measurement A is 43,170-43,270 mm.
If measurement A is outside the tolerance range, you
must fit a new connecting rod (1).
Piston and connecting rod assembly
Piston ring assembly

• Install a new retaining ring

spring (2) in piston groove
• As shown in the figure, assemble the
• Set the piston ring mounting pliers [308] (1) to piston (1) on connecting rod (3)
the piston diameter • Apply clean engine oil to the piston pin (5)
• Using the piston ring mounting pliers [308] (1) • Push the piston pin (5) past the piston (1) and
insert the piston ring (2) into the corresponding connecting rod (3) as shown, making sure it is
piston ring groove of the piston (3), making sure pushed into position.
the TOP mark points towards the top of the • Install a new spring retaining ring (4) in the
piston piston groove
Piston pin assembly • Check correct assembly of spring retaining
rings (2) and (4)
If the assembly of the spring retaining rings (2) and
(4) is not correct, they must be removed and
reassembled until they are installed correctly.

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Connecting rod cover assembly instructions Using piston ring pliers, install the piston

Warning along with the connecting rod until the piston is

The teeth on the large head section of pushed out of the piston ring pliers [315] (2)
the connecting rod are easily damaged. • Push the piston (1) until the connecting rod with
If it continues to work it will be connecting rod cover is on the crankshaft
destroyed
• If the teeth of the section are damaged,
you must replace the connecting rod
They should prevent the teeth of the section from
being damaged by hard and sharp targets. Clean the
contact surface between the connecting rod cover
and the connecting rod cover cap on the connecting
rod.
Insert the lower connecting rod cover into the
connecting rod cover cap so that the flange (1)
recesses into the recess (4)
Insert the connecting rod upper cover into the
connecting rod so that the flange (2) recesses into
the recess (3)
Using the adjusting tool [316] align the connecting
rod cover and connecting rod bushing cap
Grades
ID There is a mounting arrow on the piston surface.
This arrow must point to the water pump during
assembly.
• Turn the crankshaft to TDC (neutral
superior)
Place piston ring openings 120° apart
• Apply clean engine oil to the upper cover of the
connecting rod
• Insert the connecting rod top cover into the
connecting rod
• Apply clean engine oil to the piston (1) and
cylinder sleeve (3)
• Install the piston ring pliers [315] (2) on the
piston (1) and hold it.
• Push the piston (1) into the cylinder sleeve (3)

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Check connecting rod layout Connecting rod bushing cap assembly

Warning
The teeth on the large head section
of the connecting rod are easily
damaged. If it continues to work it
will be destroyed
• If the section teeth are
damaged, you need to replace the
connecting rod
They should prevent the section teeth from
being damaged by hard and sharp targets
Check the arrangement of the connecting rod
cover (2) on the connecting rod (1), adjust if
necessary with the adjustment tool [316] (3)
Warning
The teeth on the large head section of the
connecting rod are easily damaged. If it
continues to work it will be destroyed
• If the section teeth are damaged, you need
to replace the connecting rod
They should prevent the section teeth from
being damaged by hard and sharp targets.
Check the arrangement of the lower connecting
rod cover (2), adjust it if necessary with the
adjustment tool [316] (3)
Apply clean engine oil to the lower connecting
rod cover (2)
As shown in the figure, position the connecting
rod cover cap (3) on the connecting rod (1)
Screw the new connecting rod bolt (4) and
tighten it to the initial torque of 100±10 Nm
Tighten the connecting rod cover bolt (4) at the
angle of 90°+10°

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Check crank span
O

• Check the connecting rod interval by moving the connecting rod (1) in the longitudinal direction of
the engine
If the connecting rod (1) cannot move freely, check whether the connecting rod and connecting rod
bushing cap match correctly.
Check the connecting rod cover. If the wrong connecting rod is installed, you must replace it with a
new one.
Check the piston protrusion amount

• Move the piston (2) to the dead center

superior
• Mount the micrometer [310] (4) that has the
micrometer support [311] (1) and with a certain
pretensioning force mount the positioning pin
[313] (3) in the crankcase (5)
• Set the micrometer [310] (4) to zero
• Hold the micrometer [310] (4) having the micrometer holder [311] (1) and positioning pin [313] (3)
on the piston (2) and read the micrometer difference (piston protruding amount)
The allowable piston protrusion amount is 0.0235-0.3435mm.

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MC11 Series Engine Maintenance Manual
IV. Crankshaft
1. Auxiliary jobs
- Removal and assembly of the engine control unit is seen on page 7
- Disassembly and assembly of the curved cooling water pipes see page 20
- Disassembly and assembly of the thermostat is seen on page 24
- Disassembly and assembly of the thermostat housing is seen on page 26
- Disassembly and assembly of the distributor housing is seen on page 32
- Disassembly and assembly of the starter motor is seen on page 41
- Disassembly and assembly of the belt drive is seen on page 44
- Disassembly and assembly of the exhaust manifold is seen on page 54
- Disassembly and assembly of the turbocharger is seen on page 61
- Disassembly and assembly of the cylinder head is seen on page 67
- Verification and configuration of the valve interval is seen on page 79
- Disassembly and assembly of the injector and common rail assembly see page 134
- Disassembly and assembly of the fuel supply center is seen on page 156
- Disassembly and assembly of the front drive gear is seen on page 243
- Disassembly and installation of the rear timing gear is seen on page 120
- Disassembly and assembly of the oil module is seen on page 167
- Disassembly andmounting of the oil pan and pipe suction oil
seen on page 175
- Disassembly andmounting of the front cover go on page 200
- Disassembly andmounting of theshock absorber looks in page 208
- Disassembly andmounting of thepiston and connecting rod can be seen in page 221

Fig. 2-42 Crankshaft

1. Steering wheel 2. Crankshaft 3. Connecting rod 4. Crankshaft cover cap 5. Piston

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MC11 Series Engine Maintenance Manual
2. Technical data
Name Specification Technical parameters
Initial torque 50 Nm
The second torque 150 Nm
Mounting bolt, crankshaft cover cap (4) M18×160.5
. The third torque 300 (0/30) Nm
Turning angle 90° + 10°
Axial interval, crankshaft (2) 0.200-0.401mm
99.975-99.995mm
Crankshaft bearing collar, centered, crankshaft front gear

Crankshaft bearing collar, standard size Ø 103,980 - 104,000 mm

Crankshaft bearing cover, standard size Ø 104,044 - 104,090 mm
3.466+0.012mm
Crankshaft Bearing Cover Wall Thickness, Standard Size

Lack of roundness of the crankshaft cover Maximum 1.2 mm

Connecting rod bearing collar, standard size Ø 89,980 - 90,000 mm
Thrust Washer Thickness, Standard Size 3,350-3,400mm
3. Important information
Warning
/l\ The teeth on the large head section of the connecting rod are easily damaged. If it still works
You it will be destroyed
• If the section teeth are damaged, you need to replace the connecting rod
• They should prevent the section teeth from being damaged by hard and sharp targets.
• When cleaning the teeth of the connecting rod section, you should clean them in a clean cleaning
solution.
• When finishing cleaning, you should use compressed air to dry the section teeth
• Objects removed after cleaning are not allowed to enter the engine
Warning
/Ik Improper tightening of bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum tightening
torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
4. Special tools
Number As shown in the figure MAN numbering
SINOTRUK
Description
Numbering

[317]

7
Micrometer
• Check the diameter
inside crankshaft cover
• Check the axial interval and
crankshaft radial, using: JD6805-0024 08.71000-3217
• Micrometer holder
[318]
• Pin
positioning [319]

[318] Micrometer holder

• Check the axial interval and
crankshaft radial
JD6805-0025 08.71082-0005

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Number As shown in the figure MAN numbering

SINOTRUK
Description
Numbering

[319] Locating pin

g
• Check the axial interval and
crankshaft radial JD6805-0026 80.99605-0197

[320]

AND
Torque boost i = 1:3.5
• Unscrew and tighten the
crankshaft cover cap
mounting bolt, using:
• Support [321]
• Measuring disc
angle [322]
• Pillar frame [323] JD6805-0084 80.99619-0007
• Washer [324]
• flat head bolt
[325]
• connecting pin [326]
• Rubber ring 42mm [327]
• Pipe wrench, size 27
[328]

[321] Medium
• Unscrew and tighten the
JD6805-0085 80.99606-0551
crankshaft cover cap
mounting bolt
[322] Angle measuring disc

,T • Unscrew and tighten the

crankshaft cover cap
mounting bolt JD6805-0086 80.99607-0172

[323] pillar frame

• Unscrew and tighten the
crankshaft cover cap
mounting bolt JD6805-0150 80.99606-0584

[324] Washer

(
• Unscrew and tighten the
crankshaft cover cap JD6805-0091 80.99609-0033
mounting bolt

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 MC11 Series Engine Maintenance Manual

[325] flat head bolt

Unscrew and tighten the

•@
•
crankshaft cover cap
mounting bolt JD6805-0088 06.02191-0407

2
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 MC11 Series Engine Maintenance Manual

Number As shown in the figure MAN numbering

SINOTRUK
Description
Numbering

[326] connecting pin

• Unscrew and tighten the
crankshaft cover cap JD6805-0089 06.22729-0006
mounting bolt

[327] Rubber ring 42mm

EI
• Unscrew and tighten the
crankshaft cover cap
mounting bolt JD6805-0090 08.06142-9006

[328] Pipe wrench, size 27

• Unscrew and tighten the
crankshaft cover cap JD6805-0151 80.99603-0312
mounting bolt

[329] Adjustment tools

<?
• Cover Alignment
crankshaft bearing JD6805-0149 80.99622-0052

2
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Check the crankshaft
O
Check crankshaft axial gap

• Mount the micrometer bracket [318] (3) that has

the micrometer [317] (2) and with some
pretensioning force mount the positioning pin
[319] on the crankshaft (1)
• Push the crankshaft (1) horizontally towards the
flywheel housing to the tail position
• Set the micrometer [317] (2) to zero
• Pull the crankshaft (1) pointing towards the
micrometer [317] (2) to the bottom position and
read the micrometer difference
The allowable axial interval of the crankshaft (1) is
0.200-0.401 mm.
If the axial gap is outside the tolerance range, you
must mount a suitable thrust washer.
Mount a suitable thrust washer with a thickness of
3,350-3,400 mm.

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Crankshaft disassembly
Special assembly tools

• Insert the i = 1:3.5 torque booster [320] (1) into

the bracket [321] (9)
• Mount the pillar frame [323] (6) and flat head Mark the correct placement and mounting
bolts [325] (8) and washers [324] (7) to the position of the cover cap (4)
bracket [321] (9) • Unscrew the mounting bolt (1)
• Mount the angle measuring disc [322] (2) on the • Together with the thrust washer (2) and (3)
torque booster i = 1: 3.5 [320] (1) remove the cover cap (4)
• Mount the socket wrench, size 27 [328] (3) on • Mark the mounting position and correct
the torque booster i = 1: 3.5 [320] (1) and secure placement of the crankshaft cover, then
it with the connecting pin [326] (5) and the disassemble it
locking ring. rubber 42mm [327] (4) Disassembly of the cover plate
Unscrew the crankshaft cover cap mounting bolt crankshaft

Mark the mounting position and correct

placement of the cover cap (2)
Unscrew the mounting bolt (3)
Remove the cover plate (2)
Unscrew the cover cap mounting bolt with the
Mark the mounting position and correct
special tool (1)
placement of the crankshaft cover (1), then
Crankshaft Cover Cap Thrust Washer Removal disassemble it
Repeat the above work steps for cover caps 2,
3, 4, 5 and 7

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Crankshaft disassembly sixth cover seat (1).
Check crankshaft and crankshaft cover Check
inner diameter of crankshaft cover

Grades:
Heavy components may cause personal
injury.
Warning
• Insert the upper and lower crankshaft bearing cover
Incorrect lifting device can cause into the cover seat as shown
component damage • As shown in the figure, assemble the cover cap (3)
• Dismantle the crankshaft with support • Screw in the cover cap mounting bolt (3) and tighten it
• Do not use steel cables or other to the initial torque of 50 Nm.
sharp tools to lift the crankshaft • Check the crankshaft cover with a bore gauge (2) and
• Lift and remove the crankshaft (3) micrometer [317] (1)
• Repeat the check several times with an offset of 120°
from the crankcase (2)
• After verification, remove the cover plate (3) again.
• Mark the mounting position and
See technical data sheet for crankshaft cover bore diameter
correct positioning of the crankshaft bearing . 234
cover (1), then dismantle it from the crankcase If the inner diameter is outside the tolerance range, a new
(2) crankshaft bearing cover must be fitted. Check the outer
Removing the upper thrust washer diameter of the connecting rod bearing neck

Remove the thrust washers (2) and (3) from the

• Clean the crankshaft connecting rod bearing collar (1)
• Using the micrometer caliper (2) measure the
connecting rod bearing collar
• Repeat the check several times with an offset of 120°
Refer to the technical data sheet for the outside diameter
of the connecting rod bearing collar . 234
If the outer diameter is outside the tolerance range, a new
crankshaft (1) must be fitted.

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Check the outside diameter of the crankshaft Crankshaft assembly
bearing collar Crankshaft assembly

• Clean the crankshaft bearing collar (1) Warning

• Using the micrometer gauge (2) measure the Incorrect lifting device can cause
crankshaft bearing collar component damage
• Repeat the check several times with an offset of • Do not use steel cables or other sharp
120° tools to lift the
crankshaft
Refer to the technical data sheet for the outside
Apply clean engine oil to the cover
diameter of the crankshaft bearing collar. 234 crankshaft bearing (1)
If the outer diameter is outside the tolerance range, • Insert the crankshaft bearing cover (1) into the
a new crankshaft (1) must be fitted. cover seat as shown
and align it with the adjustment tool [329]
Insert the crankshaft (3) into the crankcase (2)

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Upper Thrust Washer Assembly Apply clean engine oil to the crankshaft bearing
crankshaft cover

Grades
cover and thrust washer (1) and (2)
Only use thrust washers with the same
Insert the crankshaft bearing cover into the
wall thickness for the upper and lower
bearing cap (3) as shown and align it with the
thrust washers.
adjusting tool [329].
• Determine the thrust washer (2) to be used, see
Insert the thrust washer (1) and (2) into the
"Checking Crankshaft Axial Span", 237
bearing cap so that the oil groove points toward
Apply clean engine oil to the thrust washer(2)
the crankshaft
Insert the thrust washer (2) into the seat of the
Together with the thrust washer (1) and (2)
sixth cover so that the oil groove points towards
install the bearing cap (3)
the crankshaft (1) Insert the thrust washer (2)
Screw in the new mounting bolt (4) and tighten
into the seat of the cover by gently squeezing it to the initial torque of 50 Nm
Install the cover thrust washer Tighten the mounting bolt (4) to the second
150 Nm torque
Check the crankshaft to ensure free movement
If the crankshaft cannot rotate or rotates with
obstruction, you need to dismantle the crankshaft
together with the crankshaft cover.
Recheck the crankshaft cover and crankshaft and
install a new crankshaft or new crankshaft cover if
necessary.

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Install the crankshaft cover cap Tighten the crankshaft cover cap mounting bolt

Warning
The teeth on the large head section of
the connecting rod are easily
damaged. If it still works
it will be destroyed
• If the section teeth are damaged, you need (1) to the third torque of 315 Nm
to replace the connecting rod Tighten the mounting bolt with the special tool
• They should prevent the section teeth from (1) to the 90° angle
being damaged by hard and sharp targets.
• Apply clean engine oil to the crankshaft
bearing cover (1)
• Insert the crankshaft bearing cover (1) into
the cover cap (2) as shown and align it with
the adjusting tool [329].
• Install the cover plate (2)
• Apply clean engine oil to the head of the
new mounting bolt (2).
• Screw in the new mounting bolt (3) and
tighten it to the initial torque of 50 Nm
• Tighten the mounting bolt (3) to the second
torque of 150 Nm
Description
Note the torque boost ratio: i=1:3.5
Tighten the mounting bolt with the special tool

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v. Front Drive Gear MC11 Series Engine Maintenance Manual
1. Auxiliary jobs
- Disassemblyandmounting of the fan seen on page 11
- Disassemblyandmounting of the fan support is seen on page 13
- Disassemblyandmounting of curved cooling water pipes seen on page 20
- Disassemblyandmounting thermostat see on page 24
- Disassemblyandmounting of the thermostat housing is seen on page 26
- Disassemblyandmounting of the distributor housing is seen on page 32
- Disassembly and assembly of the belt drive device is seen on page 44
- Disassembly and assembly of high pressure pump / high pressure pump drive device see page 148
- Disassembly and installation of the crankshaft front oil seal see page 188
- Disassembly and assembly of the front cover can be seen on page 200
- Disassembly and assembly of the shock absorber see page 208

Fig.2-35 Engine front gear

1. High pressure pump drive intermediate gear 2. intermediate gear shaft
3. Idler gear shaft mounting bolts 4. Crankshaft front gear 5. Oil pump

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2. Technical data
Name Specification Technical parameters
Idler Gear Shaft Mounting Bolts M12×50-10.9 110Nm
Interval gear, crankshaft gear - high pressure pump drive 0.057-0.183mm
intermediate gear
0.100-0.029mm
Axial range of high pressure pump drive idler gear

0.060-0.109mm
Radial interval of high pressure pump drive idler gear

21,950-22,000mm
Height, high pressure pump drive intermediate gear

Ø 60,000 - 60,030 mm
Bore diameter, high pressure pump drive idler gear

Outer diameter, idler gear shaft Ø 59,921 - 59,940 mm

Height, intermediate gear shaft 27,200-27,240mm
3. Important information
Warning
Improper tightening of connecting bolts can cause component damage.
• If a pneumatic wrench is to be used, it can only be used for initial tightening. The maximum
tightening torque used for initial tightening will be 50% of the specified tightening torque value.
• Final tightening must be done manually with a torque wrench.
Grades
Idler gears and pins do not need to be replaced in sets. They can be replaced individually
depending on the degree of wear.
4. Special tools
Number SINOTRUK
As shown in the figure Description MAN numbering
Numbering
[228] JD6805-0117 80.99617-0020

g
Alignment Drill Lever
• Disassembly and assembly of
crankshaft front gear

[229] JD6805-0024 08.71000-3217

F
Micrometer
• Interval Check
of tooth, using:
• Interval Check
axial of the intermediate
gear, using:
• Interval Check
radial of the intermediate
gear, using:
• Micrometer holder
[230]
• Pin
positioning [231]

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 MC11 Series Engine Maintenance Manual

[230] JD6805-0025 08.71082-0005

Micrometer holder
• Check the interval
tooth
• Interval Check
intermediate gear axial
• Interval Check
intermediate gear radial

[231] JD6805-0026 80.99605-0197

6
Locating pin
• Check the interval
tooth
• Interval Check
intermediate gear axial
• Interval Check
intermediate gear radial

[232] depth gauge JD6805-0032 08.71195-9003

• Check axle height
of the intermediate gear

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 MC11 Series Engine Maintenance Manual
Check drive gear Check the axial range of the pump drive idler
Forward gear.
Hold the crankshaft gear

• Mount the micrometer holder [230] (2) that has

• Screw the alignment lever [228] (1) and
the micrometer [229] (3) and with some
(3)
pretensioning force mount the positioning pin
• Screw and tighten the mounting bolt (2) Check
[231] on the intermediate gear (1)
the crankshaft gear/tooth range of the high • Push the intermediate gear (1) to the bottom
pressure pump drive idler gear position
• Zero the micrometer [229] (3)
• Pull the intermediate gear (1) to the end
position and read the difference from the
meter
The allowable axial range of the intermediate gear
(1) is 0.100-0.290 mm.
If the axial span is outside the tolerance range, you
need to check the height between the idler gear (1)
and the idler gear shaft.
Check the height of the idler gear (1), see
• Mount the micrometer holder [230] (4) that has "Checking the height of the high-pressure pump
the micrometer [229] (3) and with some drive idler gear", page . 248
Check the idler gear shaft height, see "Checking
pretensioning force mount the positioning pin
the idler gear shaft height", page . 125
[231] on the intermediate gear (1)
Check the radial range of the pump drive idler
• Check crankshaft gear (2) and idler gear tooth
gear.
interval (1)
high pressure
The allowable tooth range is 0.057-0.183 mm.
If the tooth interval is outside the tolerance range,
you must install a new crankshaft gear (2) and a
new intermediate gear (1).
high pressure

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• Mount the micrometer holder [230] (1) that has • Unscrew the mounting bolt (1) Crankshaft gear
the micrometer [229] (2) and with some disassembly
pretensioning force mount the positioning pin
[231] on the intermediate gear (3)
• Push the intermediate gear (3) to the bottom
position
• Zero the micrometer [229] (2)
• Pull the intermediate gear (3) pointing at the
micrometer [235] (2) to the position of
the
end and read the difference from the meter
The allowable radial range of the intermediate gear
(1) is 0.060-0.109 mm.
If the radial span is outside the tolerance range,
you should check the idler gear (3) and the idler Remove the crankshaft gear (2)
gear shaft. Unscrew the alignment lever [228] (3) and (4)
Check the inner diameter of the intermediate gear Clean the contact surface between the crankshaft
(3), see "Checking the inner diameter of the high-
gear (2) and the crankshaft (1)
pressure pump drive idler gear", page . 248
Check the outer diameter of the idler gear shaft,
see "Checking the outer diameter of the idler gear
shaft", page . 249
Crankshaft gear disassembly
Unscrew the mounting bolt

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Disassembly of the high pressure pump drive Measure the inner diameter of the high pressure
intermediate gear Disassembly of the pump drive idler gear
intermediate gear

• Clean the intermediate gear (3)

• Unscrew the mounting bolt (2) • With the micrometer [229] (2) and a caliper
• Remove the idler gear (1) together with the idler inside diameter (1) measure the inside
gear shaft (3) diameter of the idler gear (3)
Measure the height of the high pressure pump The allowable inner diameter of the intermediate
drive gear gear (3) is Ø 60,000 - 60,030 mm.
If the inner diameter is outside the tolerance range,
a new intermediate gear (3) must be fitted.
Measure the height of the idler gear shaft

• Clean the intermediate gear (1)

• Measure the measurement A of the
intermediate gear (1)
The allowed range for measurement A is 21,950-
22,000 mm.
If measurement A is outside the permitted range, a
new intermediate gear (1) must be fitted.
• Clean the idler gear shaft (1)
• Using a depth gauge [232] (2) measure the
height of the axis of the gear
intermediate 1).
The height admissible of the axis of the
gear
intermediate (1) is 27,200-27,240 mm.
If the height is outside the tolerance range, a new
idler gear shaft (1) must be installed.

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Measure the outer diameter of the gear shaft Drive Gear Assembly
Forward
Intermediate gear assembly

• With a micrometer caliper (2) measure the outer

diameter of the intermediate gear shaft (1)
The permissible external diameter of the Apply a coat of clean engine oil to the idler gear
intermediate gear shaft (1) is Ø 59.921 - 59.940 shaft (3).
Insert the idler gear shaft (3) into the idler gear
mm. (1)
If the outside diameter is outside the tolerance Install the idler gear (1) together with the idler
range, a new idler gear shaft (1) must be fitted. gear shaft (3) into the crankcase

• Screw in the new mounting bolt (2) Install

the crankshaft gear

Screw in the idler gear shaft mounting bolts

Screw the alignment lever [228] (3) and (4)

Place the crankshaft gear (2) on the crankshaft
(1), make sure it reaches the end Unscrew the
alignment lever [228] (3) and (4)

Tighten the mounting bolt (1) to 110 Nm

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MC11 Series Motor Maintenance Manual Chapter
III Fault Diagnosis and Elimination S ECTION I
F E A
O
AULTS OF LECTRICAL PPLIANCES
YO. EDC Diagnostic Tool and Invalid Communication Connection
Causes of failure Solutions

1. The vehicle key switch is in the "OFF" position Move the vehicle key switch to the "ON" position

2. Battery voltage at engine harness connector is low or no

Check battery voltage at engine harness connector
voltage

3. No voltage at EDC electronic control unit Check voltage at electronic control unit connector

4. Engine wiring harness fuse is blown Replace the engine electrical control system fuse

5. The data interface connector is defective Check the voltage and polarity of the data interface
line
II. Generator does not generate electricity
Causes of failure Solutions

1. Wiring is broken, short circuit, connector is loose Check generator wiring and ammeter, repair

2. Open circuit, short circuit or grounding of rotor coil, stator Repair or replacement of the assembly

3. Rectifier damage Replacing the assembly

4. Regulator setting voltage is too low Repair
5. Regulator contact points are melted Repair or replacement of the assembly
III. Generator generates insufficient electricity
Causes of failure Solutions

Repair
1. Wiring is broken, short circuit, connector is loose

2. Partial open circuit and discontinuity of rotor, stator coil Repair or replacement of the assembly

3. Loosening of the generator belt Check and adjust belt tension

4. The generator rectifier is damaged, there is poor contact Repair
with the brush
5. Regulator voltage setting is too low Adjustment
6. Disconnection of the regulator magnetic field coil or Repair or replacement
resistance wiring

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7. The battery electrolyte is too small or the battery is old Fill electrolyte or replace battery

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 T MC11 Series Engine Maintenance Manual

O
IV. Charging current is unstable
Causes of failure Solutions
1. The rotor or stator coil is about to short circuit, open
Repair or replacement
circuit
2. Poor brush contact Repair
3. The head of the wiring stack is loose and the contact is
Repair
poor.

4. Voltage regulator is defective Repair

5. Improper voltage regulation Check and adjust
v. Generator carrying too much load
Causes of failure Solutions
1. Battery internal short circuit Repair or replacement

2. Regulator voltage is too high Repair and adjust

3. Poor regulator ground connection Repair

4. Failure and contamination of regulator contact,

Repair or replacement
disconnection of voltage coil or resistance wiring

28
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 T MC11 Series Engine Maintenance Manual

O (starter does
YO. Engine cannot be started
S II UECTION NABLE TO BOOT
not work or engine is weak)
Causes of failure Solutions
1. Insufficient battery charge Recharge or replace the battery
2. The end of the battery connection wiring has poor
Arrange the lines and screw the wiring terminal
contact.

3. Poor brush contact Clean the brush surface or replace the brush

4. Starter motor failure Engine repair or assembly replacement

5. Key switch has poor contact Check the switch and repair it

6. Friction clutch slip

Adjust clutch working torque or replace assembly
7. Excessive engine oil viscosity Replace recommended oil

8. Electrical system failures Please consult the authorized service station

II. The engine cannot be started (starter motor works normally)

1. EDC electronic control unit connector is not
Plug the EDC electronic control unit connector
connected

2. No voltage at EDC electronic control unit Perform the diagnostic lamp test

3. It shows that the fault code exists Check the fault code table to find the solution

4. Blockage of oil circuit such as inlet filter or fuel

Check and clean dirt and check fuel cleanliness
supply pump hose

5. Oil tank is out of oil Fill the oil

Disassemble the filter body, remove internal dirt and

6. Clogged fuel filter
moisture, and replace the filter if necessary

7. There is air in the fuel system

Exclude air, check sealing of connectors and repair them

8. Air distribution timing is incorrect Check and adjust

9. There is water in the oil tank Sewer system

10. Air intake blockage (air filter filter element
blockage) Check air filter, intake pipe, clean or replace filter element
11. Oil supply pump is faulty Replacing the oil pump
12. The injector is faulty Check injector atomization and repair it
13. Damage and oil leakage from high pressure oil
Repair and replacement
pipes

Check valve seal, cylinder gasket seal, piston ring wear,

14. Insufficient cylinder inflation pressure
repair or replacement

15. Temperature is too low

Increase in the size of auxiliary starting equipment

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 MC11 Series Engine Maintenance Manual

III. Immediate shutdown after booting

Causes of failure Solutions
Disassemble the filter body, remove internal dirt and moisture, and replace
1. Clogged fuel filter
the filter if necessary
2. Air entry into the fuel system
Check the tightness of the pipe and joints, if the ventilation screws are
tight to eliminate stored air

3. Poor fuel quality, contains too Clean filter, fuel replacement

much water

4. Idle speed is too low Recalibrate control system idle speed settings

IV. Unplanned stop or shutdown when decelerating

Causes of failure Solutions

1. Fault code exists Check the fault code table to find the solution

2. The supply voltage at the EDC electronic control unit Check battery power supply lines and control system
is too low fuses
Check if the key switch circuit is loose in connection or
3. Key switch or other line has failed
shorted

2
8
7
 T MC11 Series Engine Maintenance Manual

O
YO. Engine vibration at idle
SECTION III DEFICIENT POWER

Causes of failure Solutions

1. It shows that the fault code exists Check the fault code table to find the solution
2. The temperature of the engine this Warm the engine to operating temperature for 2 to 3 minutes
Too low
3. Idling load is too large Lower load to idle
4. Loosening the accelerator pedal
Accelerator pedal check, repair or replacement
5. Intercooler or interface leaks
Check intercooler, connecting hose and interface

6. Leaks in the intake system Check the connection port and connection hose of the intake
system
Adjust valve span
7. Air distribution timing is incorrect

II. Violent engine idle speed

Causes of failure Solutions
1. It shows that the fault code exists Check the fault code table to find the solution
2. The temperature of the engine this Warm the engine to operating temperature for 2 to 3 minutes
Too low
3. Idling load is too large Lower load to idle
4. Loosening the accelerator pedal
Accelerator pedal check, repair or replacement

Check timing, adjust valve span

5. Air distribution timing is incorrect

6. Mechanical failures Check whether the crankshaft, piston, camshaft and other
mechanical parts are damaged
III. Poor acceleration performance
Causes of failure Solutions
1. Fault code exists Check the fault code table to find the solution
2. Obstructed movement of the accelerator
Accelerator pedal check and repair
pedal

3. Air leaks from the intake system Check the intercooler, connecting hose and interface for leaks,
secure the connector and replace the hose

4. Air intake blockage (air filter blockage) Check air filter, intake pipe, clean or replace filter element

5. Rear exhaust pressure is too high Check whether the exhaust pipe is blocked, adjust and repair it.

6. Incorrect calibration of the EDC electronic

Recalibration
control unit

7. Air intake pressure sensor failures Repair or replacement

8. The valve of exhaust of the Check and repair

supercharger is always open
9. Air distribution timing Check valve timing and adjust interval

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 T MC11 Series Engine Maintenance Manual
It is incorrect
O
IV. Rough running or engine misfire
valve

Causes of failure Solutions

1. Fault code exists Check the fault code table to find the solution

2. The temperature of thesystem of Check and repair

engine cooling is too low

3. Air distribution timing is incorrect Adjust valve span

4. Incorrect camshaft timing Check the position of the camshaft gear and gear

5. Camshaft or link arm wheel damage Check camshaft and rotating wheel

v. Insufficient engine power

Causes of failure Solutions

1. Fault code exists Check the fault code table to find the solution
2. The accelerator pedal is not fully pressed Check and repair

3. Air intake blockage (air filter blockage) Check air filter, intake pipe, clean or replace filter element

4. Rear exhaust pressure is too high Check if the exhaust pipe is blocked, repair it.

5. Insufficient pressure of the boost system Check for leaks at pipe connections

6. Functioning abnormal of
the Replacing the assembly
supercharger
6.1 Air compressor, Too much oil
Cleaning or replacement
contamination in the turbine channel

6.2 Invalidity of floating bearing Replace

6.3 Turbine, carbon tank at the back of Washing and cleaning
compressor, oil sludge

6.4 Supercharger exhaust bypass valve is Check the exhaust valve, reducer outlet pressure of pressure
always open of air, check the valve
Electromagnetic shunt with diagnostic equipment
6.5 Invalidity of oil seal Replace

7. Intercooler damage and air leaks Replacement or repair

Check the tightness of the tubes and joints, contamination of

8. Oil leaks or fuel line obstruction the filter and fuel lines, repair or remove dirt and blockage,
replace the filter elements

9. There is air in the fuel system Exclude air, ensure pipe sealing
10. Poor quality of fuel that does not comply Clean the fuel tank, filter and pipe, and replace the appropriate
with what is required diesel

11. Clogged fuel filter Disassemble the filter body, remove internal dirt and moisture,
and replace the filter if necessary

12. Air distribution timing is incorrect Check and adjust

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 T MC11 Series Engine Maintenance Manual
Causes of failure
O Solutions

13. Oil level in oil pan is too high Check the oil dipstick and drain excess oil

14. Cylinder washer air leaks Replace damaged cylinder washers

15. The piston ring wears and breaks, and the

Replace worn parts or perform heavy engine repair
bearing cover gap is too large.

Heavy engine repair

16. Wear of cylinder sleeve or piston or tie rod

17. System voltage is low or abnormal Check voltage at electronic control system fuses and relays

Use diagnostic equipment to detect the inlet pressure sensor,

18. Air intake pressure sensor failures
repair or replace it
19. Brake jam Please consult the authorized service station

20. Parking brake is tight Fully rotate the parking brake lever

SAW. Very slow engine idling

Causes of failure Solutions

1. Fault code exists Check the fault code table to find the solution

2. Obstructed accelerator pedal movement or connector

Check the pedal and its circuit
and circuit failures

3. Incorrect deceleration air cut setting Recalibrate control system deceleration settings

VII. Unstable rotation speed

Causes of failure Solutions

1. Poor fuel quality Clean fuel system, replace fuel

2. The fuel suction pipe leaks air Check the tightness of the oil pipe and joints, exclude air

Check and repair

3. Unstable atomization of the oil injector nozzle
Check, clean the compressor flow path, remove the ground
4. Supercharger surge plug and remove the carbon deposit from the exhaust
channel
5. Supercharger bearing damage Replace
VIII. Limited engine torque
Causes of failure Solutions
Check oil pipes for blockage, replace he
1. Low pressure oil line pressure is relatively large element filter of
fuel
2. Water temperature is too high Check the cooling system
3. Low intake pressure or high intake resistance Check the intake pipes

4. Higher exhaust resistance

Check for obstruction in the exhaust system
Check the appliance circuits
5. Sensor short circuit
electrical

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 T MC11 Series Engine Maintenance Manual

Causes of failure
O SECTION IV HIGH FUEL CONSUMPTION
Solutions
Check air filter, intake pipe, clean or replace filter
1. Air intake blockage (air filter blockage) element

2. Rear exhaust pressure is too high Check the exhaust pipe, muffler and brake valve

3. Oil leaks or fuel line blockage Check and repair

4. Poor fuel quality Replace better quality fuel

5. Poor injector oil injection atomization Check and adjustment or repair

6. Incorrect distribution timing Check, adjust

7. Insufficient cylinder compression pressure Check the sealing of the valve, piston ring and cylinder
sleeve, cylinder washer, etc. and repair them
8. Bearing cover interval is Check and heavy repair
Too big
9. Pressure insufficient of the system of Check and exclude piping leaks of the supercharging
overfeeding system

10. Supercharger bypass valve cannot be opened Check and repair

11. Abnormal supercharger operation Repair or replacement of the assembly

12. Intercooler damage or air leaks Repair or replacement

13. Engine requires heavy repair Timely verification and repair

14. Tire underinflation Adjustment for specified inflation

15. Clutch slip Check the free travel of the clutch pedal

16. Brake delay Please consult the authorized service station

17. Failure code exists Refer to the fault code table to find the solution.

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 T MC11 Series Engine Maintenance Manual

Osmoke
YO. Exhaust pipe has black
S ECTION V ABNORMAL SMOKE COLOR

Causes of failure Solutions

1. Air intake blockage (air filter blockage) or exhaust back Check air filter, intake pipe, clean or replace filter
pressure is too high element

2. Poor fuel quality Cleaning and replacement

3. Air distribution timing is incorrect Adjustment according to regulations

4. Poor atomization of the oil injector nozzle Verification, repair or replacement

5. Pressure insufficient of the system of

Check for leaks in pipes and connections
overfeeding
6. Abnormal supercharger operation Check and replace assembly

7. Intercooler damage or air leaks Replacement or repair

8. Idle speed is too high Recalibrate control system idle speed settings

9. Quickly step on the accelerator pedal Cannot quickly depress the accelerator pedal

10. Check if the engine malfunction indicator light is on Please consult the authorized service station

II. Exhaust pipe has white or blue smoke

Causes of failure Solutions

1. Bad quality of fuel, contains Replace fuel

too much water
Check the working temperature of the thermostat,
2. Cooling water temperature is too low replace it if necessary.

3. Air distribution timing is incorrect Adjustment according to regulations

4. Poor atomization of the oil injector nozzle Verification, repair or replacement

5. Low compression pressure, incomplete combustion Check the piston ring, cylinder sleeve and cylinder
and piston expansion washer, and repair them

Continue filming
6. Insufficient running-in of piston ring, cylinder sleeve

7. Piston ring openings are not staggered Adjust, reassemble

8. Piston oil ring invalidity Replace

Repair, replacement
9. Piston cylinder sleeve meeting gap is too large.
10. Wear of the ring of seal of the
Verification, replacement
supercharger
11. Thrust bearing wear
Verification, replacement
supercharger

12. Supercharger oil return pipe blockage Cleaning or repair

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 T MC11 Series Engine Maintenance Manual

O SECTION VI LUBRICATION SYSTEM FAILURE

1. Enriched engine oil in the intake port and supercharger intake pipe
Causes of failure Solutions
1. Invalid supercharger sealing Supercharger Repair or Replacement
2. Oil level in oil pan is too high, too much oil has been Check and drain the correct amount of oil to meet the
filled requirements
II. Oil pressure is too low
Causes of failure Solutions

1. Oil level of oil pan is too low or lack of oil Check the oil level and if there is an oil leak, add oil
2. The pressure regulating valve of the main oil
Check valve, clean and repair
conductor is faulty

3. Filter, pipeline, connector washers etc., if there is Check the filter, pipe connectors, if there is loose
blockage or breakage casting in the oil passage, repair it

Replace the oil according to the regulations and

4. The brand of oil does not meet the requirements choose the correct brand oil

5. Oil pump inlet pipe leak Check oil pipe and connector, repair or replace

6. Cooling system water temperature is too high, oil

Check cooling system and correct
temperature is too high

Replace with new filter element

7. Oil filter resistance is too large
8. Oil cooler lock Check and clean
9. Main oil passage blockage Check and clean

Check and replace

10. Excessive interval or bearing cover damage

11. Excessive component wear, heavy repair required Check engine working hours, heavy repair required
III. Oil pressure is too high
Causes of failure Solutions
1. Oil pressure gauge failure Check the oil pressure gauge
2. Excessive oil viscosity Replace recommended oil
3. Pressure limiting valve failure Check/replace pressure limiting valve

Check the cooling system, fan or thermostat failure, replace

4. Cooling system temperature is too low
it in time if necessary.

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 T MC11 Series Engine Maintenance Manual

Causes of failure O
IV. Excessive oil consumption
Solutions
1. Use of inappropriate oil Replace recommended oil
2. Oil level is too high Drain excess oil

3. Check for oil leaks Check and repair mounting surface and associated
threaded plugs
4. Ignorance of oil change Replace at appropriate time intervals
5. Oil filter blockage Replacing the filter filter element
6. Ignorance of engine preheating Properly preheat the engine

7. Crankcase pressure is too high, pumping oil out of Piston ring and cylinder sleeve wear, piston ring openings
oil-gas separator are in the same position, check and repair;

8. Supercharger oil leaks into the intake or exhaust Check for oil leaks at the air connection, I fixed either
replace he set of the
system
supercharger

SECTION VII HIGH WATER TEMPERATURE

Causes of failure Solutions

Check for water leaks, add water

1. The water level of the water tank is too low
2. Water tank lock Check water tank, clean or repair

Adjust the tension according to the regulations

3. Loosening of the water pump belt

Check and repair or replace

4. Pump washer is damaged, pump impeller is worn
5. Thermostat failure Replace
Check hose, connector and washer etc., replace damaged
6. The water pipe is damaged and leaks into the air
parts

7. Oil level of oil pan is too low or lack of oil Check oil level and oil leaks, repair and add oil

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 T MC11 Series Engine Maintenance Manual

Causes of failure
O SECTION VIII PREMATURE WEAR
Solutions
1. The filter element of the air filter is unqualified or Check, replace a element filter
damaged skilled
Check intake duct, washer and connecting tube, repair
2. Intake system short circuit
or replace

3. Oil level of oil pan is too low or lack of oil Check oil level and oil leaks, repair and add oil
4. Oil passage blockage Clean the oil passage

5. The brand of oil does not comply with regulations Replace oil according to regulations
6. Piston ring breakage or wear Replace damaged parts
Disassemble and check the piston and cylinder sleeve,
7. Wear of cylinder sleeve or piston or tie rod
repair or replace
8. The filter element of the oil filter has not been
Replace according to requirements
replaced in time

9. Excessive component wear, heavy repair required Check mileage

10. The crankshaft is not concentric with the main axis

Check mounting bracket, repair
of the driven part
11. The quality of the oil is not in accordance with what
Use engine oil that meets the standard requirements
is required

26
2
 T MC11 Series Engine Maintenance Manual

O noiseS
YO. The engine has abnormal
ECTION IX ABNORMAL NOISE

Causes of failure Solutions

1. Belt loosening Adjust the belt to the specified tension
2. Insufficient engine oil Add engine oil
II. Very loud noises
Causes of failure Solutions
1. Poor fuel quality Replace fuel

2. Cooling water temperature is too low Check thermostat, replace if necessary.

3. Air distribution timing is incorrect Check and repair adjustment

4. Poor atomization of the oil injector nozzle Check and repair adjustment

Check for damage, condition of connecting bolts,

5. Shock absorber is damaged
replace damaged parts
Disassemble and check the valve, adjust the valve
6. Valve air leaks or improper valve span adjustment
span

7. Excessive gear span or tooth breakage Check and replace damaged parts

8. Wear of cylinder sleeve or piston or tie rod Check, repair or replace

9. Piston ring breakage or wear Check or replace damaged parts

10. Excessive bearing cover wear Check and replace bearing cover
11. Excessive crankshaft thrust range Replace thrust washer

12. Main bearing cover is not concentric Check and repair

13. The main bearing of the crankshaft driven part is Check mounting bracket bolt, repair
not concentric
Check he mileage, HE requires a
14. Excessive component wear, heavy repair required heavy repair

Remove dirt blockage from compressor air duct and

15. Supercharger Surge
carbon deposit from exhaust duct

16. Sintering of thering of seal of the

Replacing the assembly
supercharger

17. Supercharger bearing damage, rubbing between Replacing the assembly

rotating parts and fixed parts
18. Foreign objects entering the supercharger turbine
Replacing the assembly
or compressor impeller

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 T MC11 Series Engine Maintenance Manual

Causes of failure O
III. Excessive engine vibration
Solutions

1. Unstable motor rotation speed Check unstable motor rotation speed

2. Engine idle speed is too low Recalibrate control system idle speed settings

3. Looseness or damage to the engine support seat Check engine mount, replace if necessary.

4. Fan or accessory failure Check and replace vibration parts

5. Fan connection flange failure Check/replace fan connection flange

6. Shock absorber is damaged Check/replace shock absorber

7. The main bearing of the crankshaft driven part is not Check mounting bracket bolt, repair
concentric
Check he mileage, HE requires a
8. Excessive component wear, heavy repair required
heavy repair

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 MC11 Series Engine Maintenance Manual
Accessories
Summary table of MC11 series engine maintenance special tools

SINOTRUK MAN company

Name Use Image
Numbering numbering

Check the cylinder sleeve

JD6805-0098 06.01499-0015 hex bolt
protruding amount bolt

Cylinder head bolt

JD6805-0088 06.02191-0407 Flat head screw assembly and
disassembly

Press and remove the

JD6805-0129 06.02191-2822 Flat head screw
crankshaft oil seal

JD6805-0127 06.11069-0064 Hex nut

Press and remove the
crankshaft oil seal
©
Hex nut with d
JD6805-0132 06.11222-0211 Press crankshaft oil seal
shoulder

JD6805-0062 06.11226-8306
Hex nut with
shoulder
Remove the injector
4
JD6805-0099 06.15013-0417 Washer
Check the cylinder sleeve
protruding amount
(/
washer \ 41 \ A
3I

Press and install the

JD6805-0131 06.15230-0609 Washer
crankshaft oil seal c

Connecting pin on
JD6805-0089 06.22729-0006 connecting pin
crankshaft main bearing Yes,

26
5
 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0072 06.56639-0017 Sealing rubber ring

Check high pressure
system leak (CN
1J
JD6805-0057 08.06139-9025
Angle measuring
disc
Disassembly and
assembly of high
pressure oil pipe
—=P
JD6805-0064 08.06139-9029 Splint Install the injector
-5 D
JD6805-0065 08.06141-0700 Splint Install the injector
<
JD6805-0082 08.06141-9061 M19 ferrule
Removing the fine fuel
filter cover
Q
Sealing ring in the
JD6805-0090 08.06142-9006 Rubber ring
crankcase

JD6805-0037 08.06450-0002 torque wrench Measuring torque

JD6805-0036 08.06450-0006 torque wrench Measuring torque

JD6805-0040 08.06460-0002 Lever Pulley disassembly

—
26
6
 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0063 08.06510-9024 Torque screwdriver injector wire assembly

5
<Ce
JD6805-0078 08.06556-9300 Allen screw cone
Removal and installation
of oil filler port
p
JD6805-0024 08.71000-3217 Micrometer Interval measurement

JD6805-0025 08.71082-0005 Micrometer holder Interval measurement

Check steering wheel

JD6805-0142 08.71109-0000 Plus Axis
assembly

Measure the height of the

JD6805-0032 08.71195-9003 Slide depth gauge
gear shaft

JD6805-0100 08.75300-0000 Thickness gauge Adjust the EVB interval

(M

«
JD6805-0028 08.99605-9003 Divide the pieces Division

26
7
 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

Pump shaft removal

JD6805-0029 08.99605-9014 tripod puller
device

JD6805-0043 09.81020-1000
Energy Storage
Pipe Wrench
Energy Saving Pipe
Wrench BB63
JD6805-0071 51.98103-0037 ring connector
Check special connector
for fuel pressure leaks CCD

JD6805-0137 80.99601-0156 Bearing Remove the seat ring

JD6805-0136 80.99601-0182 Mobile device Remove the seat ring

ig 3,
(k®3)

JD6805-0138 80.99601-0183 Pressure plate Remove the seat ring

©
JD6805-0170 80.99601-0217
Extractor pressure Remove the chassis from
disc the cylinder sleeve
(6
JD6805-0077 80.99601-6021 Assembly tool
Remove the radial
bearing seal CD
Remove the injector
JD6805-0058 80.99601-6022 Extractor
process tool

JD6805-0054 80.99602-0011 Extraction tools

Oil Pressure Pipe
Disassembly Tools B8,
26
8
 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0018 80.99602-0016
Impact type
extractor
Oil pump axial seal ring
remover
AP
Oil Pump Seal Ring
JD6805-0019 80.99602-0137 Hook type extractor
Puller Hook

JD6805-0059 80.99602-0176 metal plate

Remove the injector disk
tool
c9?

3-
Support lever Remove the injector lever
JD6805-0060 80.99602-0193

_
66mm

Support lever
JD6805-0061 80.99602-0194 Remove the injector lever
70mm

Cylinder sleeve Cylinder Sleeve Puller

JD6805-0169 80.99602-6035
remover Bracket

Disassembly and
JD6805-0055 80.99603-0309 Connector assembly of M17 high
pressure oil pipe

_
Disassembly and
JD6805-0056 80.99603-0310 Connector assembly of M19 high
pressure oil pipe

26
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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

<e ))
Disassembly and
JD6805-0144 80.99603-0311 Splint installation of steering
wheel bolts

JD6805-0151 80.99603-0312 Ferrule M27

Disassembly and
assembly of tools Gs '
JD6805-0083 80.99603-0323 star key
Removal and installation
of supercharger nuts Gse,

JD6805-0081 80.99603-0325 M36 ferrule

Disassembly and
installation of the fuel
filter cover
(AA) ((W
Removal and installation
JD6805-0119 80.99603-0326 M32 ferrule
of the oil filter cover

Removal and installation

JD6805-0093 80.99603-0327 Connector
of the cylinder head bolt

JD6805-0039 80.99603-6029 special key Pulley disassembly

c<g
JD6805-0104 80.99603-6031 14 opening wrench Measure valve span
8
27
0
 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0105 80.99603-6032 21 opening key Adjust the EVB interval

2
Crankshaft oil seal
JD6805-0141 80.99604-0069 Pressure plate
assembly

Crankshaft oil seal

JD6805-0140 80.99604-0286 guide sleeve
assembly
( AP, I J %or 2---77
b

JD6805-0022 80.99604-0289 Awl

Oil pump axial seal ring
pressure socket wrench

AN
JD6805-0115 80.99604-0301 Pressure plate hit on the head

Cylinder Sleeve
Protruding Amount
JD6805-0147 80.99605-0172 micrometer clamp
Measuring Micrometer
Caliper

JD6805-0026 80.99605-0197 Measuring lever Interval measurement

Aés> 2- • a 3& 6,
Measuring
Pedestal measuring ~IRe9/D
JD6805-0097 80.99605-0286 cylinder sleeve protruding
plate
amount

27
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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

—
Valve Lever Seal Liner
Mounting sleeve Assembly
JD6805-0114 80.99606-0287

Remove the
JD6805-0123 80.99606-0298 Bottom crossbar
crankshaft oil seal

JD6805-0128 80.99606-0299 Threaded bearing

Remove
crankshaft oil seal
the
652
Test if the respirator
JD6805-0168 80.99606-0399 Testing device
assembly is combined

Support during assembly

JD6805-0085 80.99606-0551 Medium
of the main bearing bolt

Disassembly and
JD6805-0143 80.99606-0553 Clamping device assembly and tightening
of steering wheel bolts

Disassembly and
installation of the
JD6805-0150 80.99606-0584 Medium
crankshaft main bearing
bolt cylindrical support

Quick Release Pipe

Connector Opening Tool
JD6805-0080 80.99606-0597 Release lever ^* ^~~ _y
(for use with JD6805-
0079/80.99606-0625)

27
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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0066 80.99606-0609 pressure block Install the injector

Screw and unscrew the

Special Purpose
JD6805-0041 80.99606-0610 plug on the high pressure
Inserts
oil pipe

=51
Special Purpose Screw and unscrew the -11*,
JD6805-0042 80.99606-0611
Inserts plug on the intake pipe

Quick Release Pipe

Loosen low Connector Opening Tool
JD6805-0079 80.99606-0625
pressure pipe tool (for use with JD6805- Fi-
0080/80.99606-0597)

Unscrew and tighten the

JD6805-0087 80.99606-0641 Medium
cylinder head bolts

Remove the crankshaft

MR
JD6805-0130 80.99606-0658 guide plate
oil seal
x 9)

Compression
JD6805-0126 80.99606-0659 Press crankshaft oil seal
sleeve

<

JD6805-0165 80.99606-0692 Locating pin Mount PriTarder WILDEBEEST

27
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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

Disassembly and
JD6805-0164 80.99606-0693 Bushing
assembly of PriTarder

JD6805-0166 80.99606-0697 Barrette

Disassembly and
assembly of PriTarder
and"
JD6805-0162 80.99606-0698 Barrette Disassembly of PriTarder
c<
JD6805-0163 80.99606-0699
Special purpose
extractor
Disassembly and
assembly of PriTarder
5,
JD6805-0125 80.99606-6013 Extraction hook
Remove the crankshaft
rear oil seal.
c==
JD6805-0076 80.99606-6078 Awl
Remove the high
pressure oil pump
46
JD6805-0113 80.99606-6088 Cleaner
Remove the valve lever
seal liner
ge"
Valve spring disassembly
JD6805-0108 80.99606-6092 hand fork
and installation

27
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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

Valve spring disassembly

JD6805-0109 80.99606-6094 Amplifier
and installation

Hold air compressor

JD6805-0033 80.99606-6118 Locator
angle device

Torque angle The disc that measures

JD6805-0086 80.99607-0172
meter the angle of the bolt

0.5mm thickness
JD6805-0101 80.99607-0177 Check valve span
gauge

0.6 mm thickness
JD6805-0102 80.99607-0178 Check EVB interval
gauge

JD6805-0103 80.99607-0179
0.8 mm thickness
gauge
Check valve span

5?
JD6805-0067 80.99607-6027
Pressure loss
measuring device
Measure pressure loss TO

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 MC11 Series Engine Maintenance Manual

©
Disassembly and
JD6805-0091 80.99609-0033 Washer installation of the main
bearing bolt washer

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SINOTRUK MAN company

Name Use Image
Numbering numbering

Remove the crankshaft

JD6805-0124 80.99609-0038 pressure disc
oil seal

JD6805-0092 80.99612-0024
Card case, power Removal and installation
outlet of the cylinder head bolt
4 ) "e)_I

•
Piston mounting
Piston mounting clamp
JD6805-0035 80.99613-0035 clamp

JD6805-0148 80.99613-0038
Piston Ring Snap
Fitting Plier
Test and fit the piston
ring
"AND
Connector, Valve spring disassembly
JD6805-0107 80.99613-0042
adapter and installation

Valve spring disassembly

JD6805-0110 80.99613-0052 Medium
and installation

Valve spring disassembly

JD6805-0111 80.99613-0053 Medium
and installation

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Name Use Image
Numbering numbering

Valve spring
Valve spring disassembly
JD6805-0106 80.99613-6000 compression
and installation
device

JD6805-0167 80.99615-0036 threaded bolt

Remove the hydraulic
retarder bolt

Disassembly and
c
JD6805-0154 80.99617-0013 Impact pin
assembly of bearing tools

JD6805-0139 80.99617-0017
Push-in mounting
bushing
Snap Seat Ring
(
JD6805-0117 80.99617-0020 guide lever
Install the crankshaft
gear and flywheel

a
JD6805-0030 80.99617-0029
Impact pressure
tool
Impact pressure tool

9
( ((
Thrust retaining \n
JD6805-0021 80.99617-0144 Seal Ring
ring

Sealing ring mounting

JD6805-0020 80.99617-0187 Remove the lever
lever

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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0031 80.99617-0191 Bushing assembly

Sealing ring assembly
socket wrench
<•
JD6805-0118 80.99617-0209 Calibration tool Timing Gear Assembly
and
63
Disassembly and
JD6805-0084 80.99619-0007 strength booster installation of the main
bearing bolt force booster

Check special high

JD6805-0068 80.99620-0033 Connector pressure fuel pressure
leak connector

crankshaft alignment
JD6805-0149 80.99622-0052 Assembly tool
sheet

Booster Pump Flange

JD6805-0153 80.99622-6002 Support frame
Lever

Air Compressor Intake

JD6805-0028 08.99605-9003 hose clamp Manifold Clamp Removal
and Assembly

JD6805-0023 80.99626-6008
Engine turning disc
gear
turning disc
89
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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0038 80.99627-0001 Ratchet turning disc

Disassembly and
JD6805-0096 80.99629-0040 Hook assembly of the cylinder
head

a
Disassembly and
JD6805-0094 80.99629-6008 Crossbar assembly of the cylinder
head

Disassembly and
JD6805-0095 80.99629-6009 Chain assembly of the cylinder
head

JD6805-0155 80.99632-0012 Connection device bearing installer

S
JD6805-0112 80.99639-0009 Iron absorption tool Attract iron filings

W
JD6805-0133 81.90711-0195 Washer, 6mm Press crankshaft oil seal

JD6805-0134 81.90712-0984 Washer, 3mm Press crankshaft oil seal

(©)
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Name Use Image
Numbering numbering

JD6805-0073 81.96002-0117 protection bushing

Z12*16 Quick Release
Pipe Connector Plug Co

JD6805-0049 81.96002-0512 protection bushing

Z14*15 Quick Release
Pipe Connector Plug Co
Z28 Quick Release Pipe
JD6805-0075 81.96002-0514 protection bushing
Connector Plug *20

JD6805-0050 81.96002-0518 Game Threaded fuel pipe cap

«9

JD6805-0044 81.96002-0520 Threaded End Plug

Seal the inner diameter
of the injector hole ~P

High and low pressure oil

JD6805-0048 81.96002-0521 Threaded End Plug
pipe plug

Injector solenoid valve

JD6805-0045 81.96002-0522 protection bushing
protective cover

JD6805-0046 81.96002-0523 protection bushing

Injector Oil Fill Port
Sealing Cover «

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 MC11 Series Engine Maintenance Manual

SINOTRUK MAN company

Name Use Image
Numbering numbering

JD6805-0047 81.96002-0541 Plug, plug

High Pressure Oil Pipe
Sealing Cover
R
1
JD6805-0052 81.96002-0555
Protection bushing Seal pressure sensor and
Z 18 x 15 pressure limiter
d'
B~ (/
g
Seal pressure sensor and
JD6805-0051 81.96002-0556 Threaded End Plug
pressure limiter oil pipes

Check special high

Threaded
JD6805-0069 81.98130-0614 pressure fuel pressure
connection
leak connector

Piston Ring Snap

JD6805-0034 83.09144-6090 Piston ring assembly
Fitting Plier

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 MC11 Series Engine Maintenance Manual
Summary table of tightening torque and angles for bolts, nuts, threaded plugs and main pipe connectors of MC11 series diesel engine

Strength/material Tightening Pretightening Tightening

Number Name Bolt specifications mm Grades
level torque Nm torque Nm angle ∡

50 Apply little amount of oil on the

90 ° + support surface
1 main bearing bolt M18×2 10.9
150 300+30 10 °
Can't be used again

2 Locking bolts on the crankcase M22×1.5 80+5

Apply little amount of oil on the
90 ° + support surface Cannot be used
3 connecting rod bolt M13×1.5 11.9 100±10
10 °
again
Shock absorber and wheel hub connecting
4 M10 8.8 50＋5
bolts
Shock absorber and crankshaft connecting 90 ° +
5 M16×1.5 10.9 150＋10
bolts 10 °
Apply little amount of oil on the
6 steering wheel bolts M16×1.5 12.9 100＋10 180°＋ 10° support surface
Can't be used again
Apply a small amount of oil to the
bearing surface of the new cylinder
10 head.
7 cylinder head bolt M18×2 10.9 150 3×90° If there is damage to the cylinder
300 head supporting surface, apply a
small amount of White T.
Can't be used again
8 Cylinder head threaded plug M16×1.5 40
9 Articulating arm seat screws M12 10.9 105＋10
10 Articulating arm adjustment nut M10×1 45

11 EVB pressure plate adjusting nut M14×1 45

12 Camshaft gear bolts M8 10.9 15 90 °

13 Rear end idler gear assembly bearing M14 10.9 150＋10 90 °

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 MC11 Series Engine Maintenance Manual

14 Oil pan oil drain plug M22×1.5 80

15 Oil module screw cap M16×1.5 25+5

16 Oil module screw cap M33×2 80+10
17 Oil module screw cap M38×1.5 80+10
18 Pressure limiting valve M27×1.5 40+5
19 Oil filter M20 40+10
Return oil connecting pipe from oil and gas
20 M24×1.5 PA66-GF30 4±0.5 Loctite 242
separator
21 Oil filler connector tube M38×1.5 PA6-GF30 35

22 Fan wheel hub and fan shaft connecting bolts M16×1.5-LH 850-1000N/ mm2 100 90°＋10°

23 Timing casing screw cap M14×1.5 30

24 Short exhaust manifold bolts M10 Heat resistant bolts 60＋5 90°＋10°

25 Long exhaust manifold bolts M10 Heat resistant bolts 60＋5 90°＋10°

26 Supercharger retaining nuts M10 21CrMoV5-7 10+5 90°＋10°

1-2
27 Injector pressure plate bolt M8 10.9 90°＋10°
25

10
28 Oil inlet connector pipe pressure nut M24×1.5 40Cr 60 °
20

29 Common rail assembly fixing bolts M8 10.9 35±5

30 Cylinder 1 to 6 high pressure oil pipe nut M14×1.5 10 60 °

31 High pressure oil line from pump to rail M14×1.5 10 60 °

32 injector wire harness M4 1.8+0.25

33 ECU bracket fixing bolt M8 10.9 12-14
34 EDC Fixing Bolts M6 10.9 10±2

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High pressure oil pump and transmission case
35 M10 10.9 60-70
connecting bolts
36 fuel filter cap SW39 25+5
37 Fuel prefilter cover SW19 10+5
Selection type connector for low pressure oil
38 M14×1.5 30-35
pipes
39 Water temperature sensor M16×1.5 45-50
40 Speed sensor M6 10.9 8-10
41 Front engine mount M14 12.9 230
NG12 Screw Type Air Compressor Straight
42 M16×1.5 30-35
Connector
Air Compressor Straight Hose Type
43 M26×1.5 45-50
Connector
Automatic tensioner pulley fastening
44 M10 10.9 42-52
countersunk screw
45 Idle wheel fixing bolts M12 10.9 50-70

Oil filler connector pipe on high pressure oil

46 M38×1.5 35
pump transmission case

47 Oil Gauge Tube Transition Connector M14×1.5 30

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MC11 Series Engine Maintenance Manual
Coupling interval summary table of main components of MC11 series motor
Number Item Coupling value (mm)
1 Protruding value of the piston from the upper surface of the crankcase +0.0235～+0.3435
2 Protruding value of the piston from the top surface of the cylinder head -0.0615～+0.3085
3 Protruding value of the cylinder head from the upper surface of the crankcase +0.035～+0.085
4 Crankshaft axial range 0.200～0.401
5 Main bearing radial range 0.044～0.110
6 Connecting rod bearing radial range 0.044～0.106
7 Connecting rod axial range 0.130～0.330

8 Radial gap between connecting rod small head bushing and piston pin 0.055～0.073

9 Empty radial gap between piston pin and piston pin seat 0.010～0.024

10 Radial gap between piston and cylinder sleeve Min 0.101

11 Protruding amount of intake and exhaust valve passage 16.1～16.5
12 Camshaft radial range 0.024～0.090
13 Camshaft axial range 0.05～0.85
14 Articulated arm radial range 0.030～0.066
15 Intake valve lever radial range 0.023～0.052
16 Exhaust valve lever radial range 0.036～0.065
17 intake valve recession 0.5～0.8
18 Exhaust valve recession 0.5～0.8
19 Cold State Intake Valve Range 0.47～0.53
20 Cold State Exhaust Valve Range 0.77～0.83
21 EVB interval 0.57～0.63
22 Oil pump outer rotor axial range 0.030～0.093
23 Oil pump outer rotor radial interval 0.10～0.210
24 Oil pump inner rotor axial range 0.030～0.090
25 Oil pump inner rotor radial interval 0.02～0.10
26 Gap between water pump housing and impeller 3.7～4.3
Before of the spot dead
27 Intake valve opening
top 24CA

28 Intake valve closure After top dead center 12CA

Before of the spot dead

29 Exhaust valve opening
top 60CA

30 Exhaust valve closure After top dead center 30CA

31 Fan drive shaft axial range 0.2～0.55

32 Radial range of fan drive shaft 0.035～0.076
Lateral gap between crankshaft rear gear and rear end intermediate large
33 0.052～0.176
gear

34 Lateral gap between rear end idler sprocket and crankcase idler gear 0.052～0.176

35 Lateral gap between crankcase idler gear and cylinder head idler gear 0.052～0.232

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MC11 Series Engine Maintenance Manual
Number Item Coupling value (mm)

36 Lateral gap between cylinder head idler gear and camshaft gear 0.054～0.180

Lateral gap between crankshaft rear gear and air compressor intermediate
37 0.051～0.177
gear

38 Air compressor intermediate gear and air compressor gear 0.051～0.177

39 Lateral gap between air compressor gear and steering assist pump gear 0.050～0.244

40 Lateral gap between rear end large center gear and PTO gear 0.051～0.177

41 Lateral gap between crankshaft front gear and front end intermediate gear 0.057～0.183

42 Lateral gap between front end idler gear and high pressure oil pump gear 0.053～0.247

43 Lateral gap between front end idler gear and fan gear 0.054～0.246

44 Lateral gap between crankshaft front gear and oil pump outer rotor 0.092～0.272

45 Rear End Idler Gear Assembly Radial Span 0.060～0.109

46 Rear End Idler Gear Assembly Axial Span 0.100～0.290

47 Radial interval between crankcase idler gear and cylinder head idler gear 0.06～0.109

48 Axial range of intermediate gear in crankcase 0.100～0.290

49 Axial interval of intermediate gear in cylinder head 0.200～0.390
50 Air Compressor Intermediate Gear Radial Span 0.060～0.109
51 Air Compressor Intermediate Gear Axial Span 0.100～0.240
52 Front End Idler Gear Radial Span 0.060～0.109
53 Front End Idler Gear Axial Span 0.100～0.290
54 High pressure oil pump drive shaft axial span 0.200～0.700
55 High Pressure Oil Pump Drive Shaft Radial Span 0.035～0.076
56 Air Compressor PTO Shaft Axial Span 0.100～0.700
57 Air Compressor PTO Shaft Radial Span 0.040～0.100
58 Air Compressor Axial Span 0.100～0.400
59 Air Compressor Radial Range 0.0400～0.100

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MC11 Series Motor Glue Application Summary Table

Glue application plate Color Function Pasting area

number

The contact surface of high pressure oil

pump impeller casing and crankcase
Air compressor contact surface
Sealant 5900 Grey Sealed Crankcase rear end surface Refrigeration
compressor contact surface
Between high pressure oil pump pulley and
drive shaft
Between bolts and fan wheel hub
High pressure oil pump drive shaft
Crankcase front end surface PTO
intermediate gear assembly
Contact surface of intercooler intake pipe
and cylinder head

Oil and Gas Separator Return Oil Pipe

Loctite 243 Glue Sky Blue Anti-loosening Transition Connector
EVB Exhaust Valve Shaft Assembly Bolts

Loctite 2701 Red Sealed Generator pulley and drive shaft

When the cylinder head is reassembled,

you should apply a small amount of grease
White T lubricating grease White Wear resistant
White T lubricant in the
cylinder head bolt supporting surface.

Note: Color may vary from manufacturer to manufacturer.

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