DOCUMENT No.

2086X－50000D
REMARKS 12 2021

INSTRUCTION MANUAL
FOR
NIIGATA DIESEL
MODEL

MG(L)26HLX
 1. INTRODUCTION & SAFETY PRECAUTIONS

1.1 Introduction
This instruction manual gives an explanation of engine
construction, handling and maintenance procedures to
engine operators.

Engine operators should conduct the inspection, start-

up, running and stopping of engines in accordance with
the proper procedures as directed in this manual only
after reading this manual carefully to familiarize
themselves with the contents.

In particular, “Safety Precautions" of this manual

shall be read carefully to have a good understanding
of them before carrying out the work.

Furthermore, it is recommended to keep this manual near

at hand all the time while carrying out the work.

Caution

1. Contents of this manual shall be indifferent to

warranty clause.

2. Should there be any indistinct and noticeable

points, please ask our works about the matter
through the head quarter or any of the divisions,
branches, sales offices and service stations.

3. When replacing parts, please be sure to use our

genuine parts.

1-1

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 4. When ordering parts, please be sure to specify the
following items.

(1) Name of Purchaser (Plant or Vessel)

(2) Engine Model, Engine Serial No.
(3) Description of Part
(4) Parts Catalog Collation No.
(5) Quantity

Where there are any doubtful points having arisen

when ordering parts, when receiving parts and when
mounting parts, be sure to contact us.

5. For details of ancillary equipment, please refer to

individual makers' instruction manuals.

6. Contents given in this manual may differ from a

part of the engine purchased from us to some extent
due to alterations of engine specifications and
others. In addition, the contents of this manual
are subject to change without notice for the
modification of products.

Should there be any indistinct points, please

contact us.

7. This manual shall not be disclosed, presented, or

duplicated to any third parties.

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 1.2 Safety Precautions

Most of the accidents arising in handling the engine

are caused by the operator's negligence of basic
safety rules and precautions or maintenance
inspection, etc. as specified by the manufacturer.

Prior to installation, assembly, running, maintenance

service and inspection, persons engaged in these items
of work should necessarily read through the
instruction manual and all other exhibits carefully
even for the prevention of danger and use the engine
properly after familiarizing themselves with all of
the knowledge of plant and equipment, safety
information, and cautionary instructions. Besides the
above, it is recommended to keep this manual near at
hand so that the manual can be referred to at any
time in carrying out the work.

“Basic Cautionary Instructions on Safety" in this

manual gives a fundamental explanation necessary for
securement safety. At the same time, labels gibing
warnings to persons concerned are affixed for the
prevention of physical accidents caused by mishandling
during operation and those caused by inadvertence
during maintenance service. It should be noted that the
instruction manual and labels have to be followed up as
necessary.

The rank of safety precautions is classified into

“DANGER",”WARNING" and “CAUTION" in this instruction
manual as shown below.

Imminent danger of death or suffering

DANGER from serious physical injuries.

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 Where possible danger of death or
WARNING suffering from serious physical
injuries, and occurrence of serious
physical damage are presumable.

Where possible danger of suffering

from light or medium physical
CAUTION injuries, and occurrence of physical
damage are presumable.

Even such matters which fall under

CAUTION

may possibly lead to serious results depending upon the

circumstances. Be sure to observe the instructions given

by where every description covers

CAUTION

important notes.

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 1.3 Basic Cautionary Instructions on Safety

1.3.1 General cautionary instructions

Cautions to be used inside engine room and enclosure

・ Ventilate the interior of engine room of enclosure.

・ Take care against fire, especially observe no-smoking when

handling fuel oil and lubricating oil, and keep away from open
fire and sparking objects.

・ For the prevention of tumbling and upsetting, try to keep

orderly arrangement at all times and leave out no articles on
the passageway. Always try to keep clean such foothold places
as floor surface, foot-plate, etc. that are made slippery and
exposed to a danger of tumbling or falling if fouled with oil,
water, or the like.

・ Make sure of location of passageways and exits so as to take

shelter in a safe area forthwith when put in dangerous state in
the course of work.

Cautions for garments and protective outfits

・ Put on helmet and safety shoes at all times inside the engine
room and enclosure.
When carrying out any work necessitating the Protective outfits
(gloves, protective goggles, earplugs, etc.) as listed in
“Practical cautionary instructions on safety", be sure to put on
specified protective outfits.

・ Do not put on any unmatched oversize garments and worn-out

clothes. Take off jewels and accessories before starting on
work.

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 Cautions in the course of running

・ Where any unusual noise, malodor, or vibration is detected, stop the

engine depending upon the circumstances. Clear up the cause and
make repairs and restoration before restarting on running.

Cautions in handling outfits

・ Use outfits under normal condition at all times and make sure of
usage of them before starting on work.

・ Make sure that lifting outfits such as chain, hook, rope, etc. are free
from abnormalities at any time and observe service criteria and
permissible load.

・ Hang hooks on the proper positions and use stays necessary.

・ Allow slinging and crane operations to be conducted by qualified

persons.

Cautions during execution of works

・ Prior to repair and inspection work, post a signboard, " NO RUNNING ",
on the conspicuous place exposed to view to prevent the engine from
being started by mistake during the work.

・ When carrying the work by the use of foot plate, manifold, etc. as
footholds, it may lead to a serious physical accident caused by falling.
To prevent this, give careful attention to footings for the sake of safety.

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 ・ Since manual turning of the engine may lead to a danger of
serious physical accidents, be sure to carry it out by selecting the
proper method and place.

Never carry out the following.

※ Turning by the use of radiator fan.

※ Turning by the use of starter motor and start air.

・ When handling a weighty article exceeding 20kg in weight, use a

crane or hoist, or allow two persons or more to engage in the
handling work. (In the case of joint work also, the weight should
be limited to less than 20kg per person.)

・ When handling refrigerants such as liquid nitrogen, put on

protective outfits for the prevention of difficulty in breathing and
frostbite, and carry out the work in the well-ventilated area.

・ When handling combustible substances such as solvent,

degreaser, etc., carry out the work carefully in accordance with
maker's instruction manual.

・ When using compressed air for cleaning etc., put on protective

mask and safety goggles.

Cautions in replacement of parts

・ Unless our genuine parts are used for replacement of parts, it

may result in serious failures and physical accidents. To prevent
this, be sure to use our genuine parts.

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 Others

・ Do not remodel the engine and plant equipment without our

permission.

・ Should there be any indistinct points on safety and handling,

please contact us.

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 1.3.2 Practical cautionary instructions Remarks
Remarks
COMBUSTIBLE 1. Equipment and pipelines of fuel oil line, lubricating
oil line, and gas fuel line for gas engine.

WARNING

(1) In cases of fuel leakage from equipment and pipe- 2-1-01～

lines of fuel oil line and gas fuel line for gas 2-9-01
engine, there is a danger of fire hazard. 3-5-01～
Conduct inspection at all times to avoid causing 3-5-19
bolt looseness, gasket deterioration, and
equipment and pipeline cracking.

WARNING

2-1-01～
(2) In cases of lubricating oil leakage from equipment 2-9-01
and pipelines of lubricating oil line, there is a danger 3-5-01～
of fire hazard. 3-5-19
Conduct inspection at all times to avoid causing
bolt looseness, gasket deterioration, and
equipment and pipeline cracking.

WARNING
2-1-01～
2-9-01
(3) In cases of a possibility of mist-like leakage due to 3-5-01～
high pressures in fuel oil line and lubricating oil line, 3-5-19
there is a danger of fire hazard.
Stop the engine running forthwith and take
preventive measures against leakage.

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 Remarks
COMBUSTIBLE 2．Equipment and pipelines of exhaust gas line

WARNING

(1) In cases of hot exhaust gas leakage from equipment 2-1-01～

and pipelines of exhaust gas line, there is a 2-9-01
danger of fire hazard. 3-5-01～
Stop the engine running forthwith and take 3-5-19
Preventive measures against leakage.

3．Anti-freeze

WARNING

(1) Keep away from the fire since anti-freeze entails 1-4-01～
the danger of ignition to scald. 1-4-05
2-6-03～
EXPLOSION 1． Crankcase door 2-6-04

DANGER

(1) Where the engine is brought to a stop due to 2-4-01～

abnormal heat generation being detected inside 2-9-01
the engine room, there is a danger of explosion
if crankcase door is allowed to open forthwith.
Open the door after the lapse of a cooling period
of not less than 20 minutes.

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 Remarks
EXPLOSION

WARNING

(2) There are cases where scald is caused by the 2-4-01～

actuation of crankcase safety valve due to 2-9-01
abnormal pressure rise inside the crankcase.
Do not gain access to the blow-off nozzle.

2．Cylinder safety valve

WARNING

2-4-01～
(1) There are cases where scald is caused by the 2-9-01
actuation of cylinder safety valve due to
abnormal pressure rise inside the cylinder.
Do not gain access to the blow-off nozzle.

3．Exhaust flue safety valve of gas engine

DANGER －

(1) There are cases where scald is caused by the

actuation of the exhaust flue safety valve of gas
engine due to flame failure, etc.
Do not gain access to opening of safety valve.

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 Remarks
EXPLOSION 4．Battery

WARNING

(1) There is a danger of fire hazard due to emission －

of flammable gas from battery.
Keep the surroundings of battery away from the
fire.

5． Engine room for gas engine

WARNING

－
(1) In cases of gas leakage from gas fuel pipeline,
there is a danger of explosion inside the engine
room and enclosure for gas engine.
To prevent this, be sure to keep the ventilating
fan running.

WARNING

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 Remarks
EXPLOSION (2) In cases where the engine is brought to a stop －
by the actuation of gas detector, there is a
danger of explosion caused by the actuation of
gas detector.
Close the gas partition valve and turn OFF AC
power supply.
Thereafter open the doors of engine room and
enclosure to effect ventilation thoroughly.
After making sure that the concentration of leak
gas has come down to the alarm set point or
below,
carry out the repair work of gas leak location.

WARNING

－
(3) In cases where an alarm is given by the actuation
of gas detector during the period of engine stop,
there is a danger of explosion.
Close the gas partition valve and turn OFF AC
power supply.
Thereafter open the doors of engine room and
enclosure to effect ventilation thoroughly.
After making sure that the concentration of leak
gas has come down to the alarm set point or below,
Carry out the repair work of gas leak location. －

(4) When re-starting the engine after a stop due to the

delayed starting, the remaining unburned fuel gas in
the intake and exhaust lines and cylinder may ignite
to cause explosion.
In such cases, carry out “Air run" before re-
starting with gas supply valve and each cylinder
indicator cock being kept closed to purge the
interior from the residual fuel gas.

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 Remarks
1． Motor
ELECTRIFICATION

WARNING

(1) Each kind of motor entails the danger of －

electrification.
Before turning ON power supply, check if there are
any abnormality in wire connections and peel-off of
covering.

2． Electrical devices

WARNING

－
(1) Electrical devices such as various switches,
electrical governor, fuel scale level
transmitter, etc. and wiring entail the danger
of electrification.
Before turning ON power supply, check if there
are any abnormality in wire connections and
peel-off of covering.

WARNING

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 Remarks
ELECTRIFICATION (2) Electrical devices built into remote control stand, －
alarm panel, solenoid valve unit, etc. and etc. and
separately-installed accessory devices entail the
danger of electrification.
Before turning ON power supply, check if there are
any abnormality in wire connections and peel-off of
covering.

WARNING

(3) Ignition line wiring, booster coil and high tension coil －
of gas engine entail the danger of electrifi-cation due
to high voltage being applied to them while the engine
is running.
Never touch them until the engine has come to a
stop.
Before starting the engine, check if there are any
abnormality in wire connections and peel-off of
covering.

1．Mercury thermometer

CAUTION

POISON －
(1) The mercury applied to mercury thermometers is
poisonous.
Wipe off the mercury spilt from broken
Thermometers.

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 Remarks
POISON 2． Cooling water additives

CAUTION

(1) The rust-preventive agent, inhibitor and 1-4-01～

anti-freeze for use with cooling water line are 1-4-05
poisonous to the human body. 2-4-01
Handle them carefully so that they will not come 2-6-03～
into eyes or come in contact with the body. 2-6-04
3-5-01～
3．Battery 3-5-19
5-4-01～
5-4-08
WARNING

－
(1) Battery electrolyte is poisonous.
Never allow it to come in contact with skins or
come into eyes.

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 Remarks
SLIPPING 1．Foot plate

CAUTION

2-1-01～
(1) The top surface of foot plate, that is slippery if 2-9-01
led with oil etc., entails the danger of tumbling and 4-1-01～
Wipe off thoroughly the oily matter left on the foot 5-4-08
plate and shoes.

2．Topside of engine

CAUTION
2-1-01～
2-9-01
(1) The topside of engine intake manifold, air duct, 4-1-01～
etc., that is slippery in some cases, entails the 5-4-08
danger of tumbling and falling.
Do not step on their topside unless safety has
been confirmed.

FALLING 1．Topside of foot plate

CAUTION 2-1-01～
2-9-01
(1) The topside of foot plate entails the danger of 4-1-01～
falling. Watch your footing and hold the 5-4-08
handrail to the extent possible when moving on
the topside.

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 Remarks
FALLING 2．Topside of engine

CAUTION

(1) The topside of engine intake manifold, air duct, 2-1-01～

etc. entails the danger of falling. 2-9-01
Do not step on their topside unless safety has 4-1-01～
been confirmed. 5-4-08

ENTANGLED 1．Flywheel

WARNING

(1) There is a danger of parts of the body being 2-1-01～

entangled into the flywheel area in the course 2-9-01
of engine running.
Do not allow your hand, leg, etc. to gain access
to the area.

2． Rotating part

WARNING

(1) There is a danger of parts of the body being 2-1-01～

entangled into the rotating parts (coupling, 2-9-01
output shaft, radiator fan, etc.) in the course
of engine running.
Do not allow your hand, leg, etc. to gain access
to the parts.

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 Remarks
ENTANGLED 3．Turning device

WARNING
2-1-01～
2-9-01
(1) There is a danger of parts of the body being 3-2-01～
entangled into the rotating parts or gears of 3-5-19
turning device in the course of turning with 4-1-01～
the turning device. 4-11-01
Do not allow your hand, leg, etc. to gain access 5-2-01～
to the parts. 5-4-08

DANGER
2-1-01～
2-9-01
(2) There is a danger of persons, working in the 3-2-01～
inside and in the vicinity of the engine, being 3-5-19
entangled when turning the engine. 4-1-01～
Carry out the turning operation only after 4-11-01
making sure of freedom from danger. 5-2-01～
5-4-08

WARNING
2-1-01～
2-9-01
(3) There is a danger of injuries being caused by 3-2-01～
contra rotation of crankshaft if turning is carried 3-5-19
out without opening the indicator cock or 4-1-01～
explosion check plug. Be sure to open the 4-11-01
indicator cock or explosion check plug when 5-2-01～
carrying out turning. 5-4-08

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 Remarks
ENTANGLED 4．When machining

CAUTION

(1) There is a danger of hands or legs being 4-1-01～

entangled during the course of grinding, 4-11-01
turning, and drilling work.
Do not put on gloves.

PINCHED 1．Moving parts of engine

WARNING

2-1-01～
(1) There is a danger of hands or legs being pinched 2-9-01
By the moving parts (valve actuator, fuel injection
pump roller guide, governor link, stopping piston,
etc.) of the engine in the course of engine running.
Never insert your hands and legs.

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 Remarks
PINCHED 2．Doors of enclosure and engine room

CAUTION

(1) There is a danger of your body being pinched by －

the doors of enclosure and engine room that
are designed to be readily closed by the
difference in atmosphere between the inside
and outside.
Take precautions so that your body will not be
pinched.

3．When installing, disassembling & reassembling

WARNING

(1) There is a danger of your hands being pinched by 2-1-01～

the gear and cam roller of the engine. 2-9-01
Never insert your hands in the course of 3-2-01～
turning. 3-5-19

CAUTION

(2) There is a danger of your hands and legs being

pinched by weighty parts or disassembling tools 2-1-01～
during overhaul inspection of the engine. 2-9-01
Take precautions in handling such parts and 3-2-01～
tools. 5-4-08

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 Remarks
1．Fuel injection valve test pump
CUTTING/CUT OFF

WARNING

(1) There is a danger of injuries caused if high- 4-4

pressure oil droplets come in direct contact with
your skins when conducting the injection test of
fuel injection pump.
Never allow your body to gain access to the range
covered by oil droplets.
In case where high-pressure oil droplets have
come into your body through the skin, then it is
necessary to undergo forthwith specialist's
diagnosis and surgical treatment.
HOT/SCALD
1．Engine

CAUTION
2-1-01～
2-9-01
(1) Since there are many hot parts in the engine 5-2-01～
During the course of running or right after 5-4-08
stopping, there is a danger of scald caused by
them. Do not allow your skins to come in direct
contact with them.
In particular, use extreme care for the following
parts that are heated up to high temperatures.
・Exhaust line of the engine
・Indicator cock and cylinder safety valve
・Fuel oil line
・ Steam line

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 Remarks
HOT/SCALD 2．Inspection or measurement work

CAUTION

(1) In the case of carrying out the following work, 2-1-01～

there is a danger of scald caused by high- 2-9-01
temperature parts or hot fluid. 5-2-01～
Put on protective gloves and use care in 5-4-08
handling so that hot fluid will not splash over
the skin.
・Sampling work of cylinder internal pressure.
・Cleaning of lubricating oil/fuel oil filters.
・When removing the caps of radiator and
・pressurized fresh water expansion tank.

3．When checking by finger touch

CAUTION

2-1-01～
(1) In the case of checking by finger touch, there 2-9-01
is a danger of scald. To prevent this, first allow 5-2-01～
your finger to approach to the work and make 5-4-08
sure that it is not hot, followed by conducting
the check by finger touch.
If the work is hot, do not conduct the check by
finger touch to avoid causing the scald.

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 Remarks
1．Control of cooling water, lubricating oil & fuel
SAFETY/ WARNING oil, and control of clamping work

WARNING

(1) Any negligence of controlling cooling water, 2-1-01～

lubricating oil, and fuel oil, and controlling the 2-9-01
clamping in reassembly after overhaul inspection 3-2-01～
may lead to fault of the engine and result in 5-4-08
physical accidents due to failure of parts.
Unfailing control should be conducted on the
basis of instruction manual or specifications.

2．Disassembly work of spring section

CAUTION
3-2-01～
5-4-08
(1) When disassembling the spring section during the
course of overhaul inspection, parts are caused to
jump out due to disengagement of disassembly
tools.
Thus, there is a danger of injuries.
Familiarize yourselves with the construction of
component and use tools properly. Also give care
full attention to the jumping direction of parts
so that the body will be kept away from the jumping
direction.

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 Remarks
SAFETY/WARNING 3．Hydraulic tool and fuel injection valve test pump

CAUTION

(1) When using hydraulic tools or when conducting the 3-2-01～

fuel injection valve injection test, high- pressure 5-4-08
fluid will gush out , leading to the danger of injuries.
Never allow your body to gain access to the range
covered by oil droplets.
In case where high-pressure oil droplets have
come into your body through the skin, then it is
necessary to undergo forthwith specialist's
diagnosis and surgical treatment.
Apply hydraulic pressure only after making sure
that joints are securely connected.

4．Engine for auto start or remote start

WARNING
2-1-01～
(1) The engine may start abruptly without notice 5-4-08
through the auto start signal or by remote
starting. As there is a danger of entanglement
etc., do not gain access to rotating parts and
moving parts.

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 Remarks
SAFETY/WARNING 5．Prevention of mis-starting during maintenance
inspection

WARNING

(1) There is a possible danger of physical accidents 2-1-01～

that may be caused when the engine is started by 5-4-08
mistake during the inspection and repair of the
battery-started engine.
Be sure to carry out the following items to
prevent the erroneous start of the engine.
・Disconnection of battery power source.
・Capacitor discharge.

WARNING

2-1-01～
(2) There is a possible danger of physical accidents 5-4-08
that may be caused when the engine is started by
mistake during the inspection and repair of the
air-started engine.
Be sure to carry out the following items to
prevent the erroneous start of the engine.
・ Close the main valve of starting air-tank
outlet.
・ Release the residual pressure remaining
Inside the starting air pipeline. (Between the
starting air tank to the engine)

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 Remarks
SAFETY/WARNING 6．Fuel oil

CAUTION

(1) There is a danger of failure of the engine when 1-2

gasoline or alcohol is used as a fuel or mixed
into fuel oil.
Be sure to use the specified fuel oil only.

ELECTRO-MAGNE 1． Electrical governor & remote controller

TIC WAVE

CAUTION

2-1-01～
(1) There is a danger of critical accidents arising 5-4-08
From such malfunction of electronic devices
applied to electrical governor and remote
controller as is caused by electromagnetic wave.
Keep away from electromagnetic wave-
generating equipment.

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 Remarks
PROTECTION OF 1．Work necessitating protection of eyes
EYES

CAUTION

(1) Be sure to put on safety goggles in carrying out the 1-2-01～

following items of work being in danger of injury 5-4-08
to eyes.
・When handling fuel oil, lubricating oil, cool-
ing water and inhibitor, and anti-freeze
solution
・ In course of washing work
・ In course of fuel injection valve injection
test
・ When handling battery electrolyte
・ In course of grinding work
・ In course of intake/exhaust valve grinding
Work

PROTECTION OF 1． Inside the engine room and enclosure

EARS

CAUTION
1-2-01～
5-4-08
(1) There is a danger of hard of hearing caused by
noise when gaining access to the inside of engine
room and enclosure in course of engine running.
Be sure to put on ear plugs.

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 Remarks
PROTECTION OF 1． Inside the engine room and enclosure
HEAD

CAUTION

(1) There is a danger of injury to the head inside 1-2-01～

the engine room and enclosure. 5-4-08
Be sure to put on a helmet for the protection of
the head.

PROTECTIVE 1．Work necessitating protective mask

MASK

CAUTION

(1) Put on protective masks since the following items 1-2-01～

of work are in danger of adverse effect upon the 5-4-08
health due to inhalation of deleterious mist or dust.
・In course of cleaning work with compressed air
・ When handling heat insulation material
(glass cloth etc.)

SAFETY SHOES 1． Inside the engine room and enclosure

CAUTION

(1) There is a danger of injury to your legs during the 1-2-01～

work inside the engine room and enclosure. Be 5-4-08
sure to put on safety shoes for the protection of
your legs.

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 Remarks
PROTECTION 1．Inside the engine room and enclosure
OF HANDS

CAUTION

(1) There is a danger of injury to your hands during 1-2-01～

the work inside the engine room and enclosure. 5-4-08
Be sure to put on gloves for the protection of
your hands except for the case of special work.

2．During machining work

PROHIBITION
CAUTION
OF GLOVES
4-1-01～
(1) There is a danger of entanglement in the course 4-11-01
of grinding, turning and drilling work.
Do not put on any gloves.

1．Chemicals handling work

CAUTION
4-1-01～
EYE-WASH 4-11-01
(1) When handling chemicals solution such as
inhibitor, battery electrolyte, etc., there is
a danger of injuries to your eyes or skins being
contaminated with chemicals solution.
In cases of contamination, wash your eyes or
skins thoroughly with water or soapy water and
consult a physician immediately.

1-30

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 Remarks
FIRE 1． Fire extinguisher
EXTINGUISHER

CAUTION

(1) In carrying out the work inside the engine room －

and enclosure, there is a danger of flammable
liquid etc. being ignited by welding or electric
sparks.
Be sure to make a fire extinguisher ready for use
during the course of work.
When carrying out the work, be sure to install
a shielding for the prevention of the danger of
ignition.

1-31

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 CONTENTS
CONTENTS-01

SECTION 1 - OUTLINE

1.1 GENERAL ENGINE SPECIFICATIONS

1.2 FUEL OIL SPECIFICATIONS

1.3 LUBRICATING OIL SPECIFICATIONS

1.4 ENGINE COOLANT

SECTION 2 - OPERATING INSTRUCTIONS

2.1 STARTING AND WARMUP AFTER A NORMAL SHUTDOWN

2.2 SPECIAL INSTRUCTIONS FOR HEAVY FUEL OPERATION

2.3 NORMAL SHUTDOWN PROCEDURE

2.4 STARTING AFTER ENGINE OVERHAUL OR EXTENDED SHUTDOWN

2.5 RUN - IN PROCEDURE AFTER MAJOR OVERHAUL

2.6 INSPECTION AND CARE OF ENGINE DURING NORMAL OPERATION

2.7 CHART OF NORMAL OPERATING PRESSURES AND TEMPERATURES

2.8 PREPARATION OF ENGINE FOR EXTENDED SHUTDOWN

2.9 CARE OF LOW LOAD OPERATION

SECTION 3 - MAINTENANCE

3.1 GENERAL

3.2 CLEARANCE AND WEAR TABLES

3.3 TORQUE PROCEDURES

3.4 TABLE OF COMPONENT WEIGHT

3.5 MAINTENANCE AND INSPECTION SCHEDULES

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 CONTENTS
CONTENTS-02

SECTION 4 - DISASSEMBLY AND REASSEMBLY

4.1 CYLINDER HEAD AND VALVE MECHANISM

4.2 PISTON AND CONNECTING ROD

4.3 CYLINDER LINERS

4.4 FUEL INJECTION VALVE AND FUEL INJECTION PUMPS

4.5 GOVERNER DRIVE AND FUEL CONTROL LINKAGE

4.6 CRANKCASE ASSEMBLY

4.7 CRANKSHAFT

4.8 CAMSHAFT AND TIMING GEAR TRAIN

4.9 STARTING AIR DISTRIBTOR

4.10 COOLING AND LUBRICATING OIL PUMPS

4.11 TORSIONAL VIBRATION DAMPER

SECTION 5 - TROUBLE SHOOTING

5.1 BEFORE DETECTING THE CAUSE OF TROUBLE

5.2 TROUBLES BEFORE STARTING

5.3 TROUBLES AT THE TIME OF STARTING

5.4 ABNORMAL SITUATION

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 CONVERSION TABLE

Unit Conversion factor

Force 1 kgf ＝ 9.806 65 N

1N ＝ 0.101 972 kgf

Moment of force 1 kgf・m ＝ 9.806 65 N

1 N・m ＝ 0.101 972 kgf・m

Pressure 1 kgf/cm2 ＝ 0.098 066 5 MPa

1 MPa ＝ 10.197 2 kgf/cm2
1 mmHg ＝ 0.133 322 kPa
1 kPa ＝ 7.500 62 mmHg

Stress 1 kgf/mm2 ＝ 9.806 65 N/mm2

1 N/mm2 ＝ 0.101 972 kgf/mm2

Kinematic viscosity 1 cSt ＝ 1mm2/s

Work 1 kgf・m ＝ 9.806 65 J

Quantity of heat 1 J ＝ 0.101 972 kgf・m
1 kcal ＝ 4.186 8 kJ
1 kJ ＝ 0.238 846 kcal

Power 1 PS ＝ 0.735 499 kW ＝ 632.415 kcal/h

1 kcal/h ＝ 1.163 kW ＝ 1.581 24 PS
1 kW ＝ 1.359 622 PS ＝ 859.845 2 kcal/h

Specific fuel consumption 1 g/(PS・h) ＝ 1.359 622 g/(kW・h)

1 g/(kW・h) ＝ 0.735 499 g/(PS・h)

Heat release rate 1 W/m3 ＝ 0.859 845 kcal/(m3・h)

1 kcal/ (m3・h) ＝ 1.163 W/m3

Heat transfer rate 1 kcal/(m・h・℃) ＝ 1.163 W/(m・K)

1 W/ (m・K) ＝ 0.859 845 kcal/ (m・h・℃)

Heat transfer coefficient 1 kcal/ (m2・h・℃) ＝ 1.163 W/ (m2・K)

1 W/(m2・K) ＝ 0.859 845 kcal/(m2・h・℃)

Heat capacity 1 kcal/℃ ＝ 4.186 8 kJ/K

1 kJ/K ＝ 0.238 845 9 kcal/℃

Latent heat 1 kcal/kgf ＝ 4.186 8 kJ/kg

1 kJ/kg ＝ 0.238 845 9 kcal/kgf

Specific heat 1 kcal/(kgf・℃) ＝ 4.186 8 kJ/(kg・K)

1 kJ/ (kg・K) ＝ 0.238 845 9 kcal/ (kgf・℃)

Note. “kcal” indicates “kcal IT ”

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 SECTION １ - OUTLINE

CONTENTS

SECTION 1 - OUTLINE

1.1 GENERAL SPECIFICATIONS

1.2 FUEL OIL SPECIFICATIONS

1.3 LUBRICATING OIL SPECIFICATIONS

1.4 ENGINE COOLANT

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION １ - OUTLINE

1.1GENERAL SPECIFICATIONS
１－１－０１

1.1 GENERAL SPECIFICATIONS

1.1.1 Engine Specifications

Item Unit Description

Model 6MG(L)26HLX
Type Vertical inline 4-cycle diesel engines
Combustion System Direct Injection
Cylinder arrangement In-line
No. of Cylinders 6
Cylinder diameter mm 260
Stroke mm 350
Compression Ratio 13.0
Max. Output See the final document *
Rated speed See the final document *
Max. Combustion Pressure MPa 14.71 *
Direction of Rotation Clockwise or Counterclockwise, depending
upon specification
Firing Order Clockwise 1－3－5－6－4－2
Counterclockwise 1－2－4－6－5－3
Starting System Air over piston
Cooling System Fresh-water cooling or sea-water cooling,
depending upon application.
Lube Of System Dry or wet sump, depending upon application
Turning Device Ratchet handle type or motor assist,
depending upon application.
Turbocharger System Pulse system *

* Note-Other options are available depending upon the customer's specifications.

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 SECTION １ - OUTLINE

1.1GENERAL SPECIFICATIONS
１－１－０２

1.1.2 Temperature Specifications

CAUTION
The values below can be used for reference values representative of normal
operating conditions at rated speed and load.

Lubricating oil (engine inlet)

Normal operating range- 60 - 70℃
Alarm setting: on- 75 ℃
off- 65 ℃
Trip setting: on- 80 ℃
off- 70 ℃

Jacket water coolant (Measured at engine outlet)

Normal operating range- 80 - 90 ℃
Alarm setting: on- 95 ℃
off- 85 ℃
Trip setting: on- 100 ℃
off- 95 ℃

Heavy fuel oil ( ≦180 mm²/S @ 50 deg. C )

Trip on at 145 ℃

Heavy fuel oil ( ≦380 mm²/S @ 50 deg. C )

Trip on at 145 ℃

(Measured at engine inlet)

CAUTION
However, the shipping test records provide a more accurate comparison and should
always be cross-checked in the event a problem is suspected.

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 SECTION １ - OUTLINE

1.1GENERAL SPECIFICATIONS
１－１－０３

1.1.3 Pressure Specifications – Mpa

CAUTION
The values below can be used for reference values representative of normal
operating conditions at rated speed and load.

Variable Engine Speed Constant Engine Speed

Engine lubricating oil
(measured at inlet to engine)
Normal operating range- 0.35～0.60 0.50～0.60
Alarm on- 0.20 0.45
Trip on- 0.15 0.40

Jacket water (measured at inlet to engine)

Normal operating range 0.28～0.36 0.28～0.36
Alarm on- 0.05 0.15
Trip on- － －

Cooling raw water (Low temperature circuit)

Normal operating range 0.03～0.20 0.15～0.20
Alarm on- 0.01 0.10
Trip on- － －

Fuel (measured at inlet to engine)

Class A or B - (see Fuel Oil Classification)
Normal operating pressure 0.05～0.15 0.05～0.15
Class C, H1(<180 mm2/S @ 50 ℃)
Normal operating pressure 0.25～0.35 0.25～0.35
2
Class H2 (<380 mm /S @50 deg. ℃)
Normal operating pressure 0.45～0.55 0.45～0.55

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 SECTION １ -OUTLINE

1.1 GENERAL SPECIFICATIONS

１－１－０４

Starting air reservoir pressure

Normal operating pressure 1.77～2.94 2.16～2.94
Alarm on- 1.47 1.77

Turbocharger lube oil inlet (For TPS)

Normal operating pressure 0.20～0.45 0.20～0.45
Alarm on- 0.13 0.13

CAUTION
However, the shipping test records provide a more accurate comparison and should
always be cross-checked in the event a problem is suspected.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION １ -OUTLINE

1.2 FUEL OIL SPECIFICATIONS

１－２－０１

1.2 FUEL OIL SPECIFICATIONS

The Niigata engine is capable of using a wide range of fuel oils, ranging from
light (No.2 Diesel) fuel to heavy (fuels with kinematic viscosities up to 700 mm²/s
at 50 ℃).
However, those engines that are to be used with heavy fuels are configured
differently when they are shipped from the factory. (Modified to provide for
jacket-water cooling of the injectors, modified piston rings, heat-treated top
piston ring groove, modified valve rotators, additional cooling water passages
around the exhaust valves, addition of plumbing for turbocharger cleaning, etc.)
In addition to the basic engine changes, pretreatment (cleaning and heating) of
the heavy fuel is required before it reaches the engine. Specific instructions
are provided in the various sections of this manual for the different types of fuel.
Note: Improper fuel use may void the warranty.

CAUTION

There is a danger of failure of the engine when gasoline or alcohol is

used as a fuel or mixed into fuel oil.
Be sure to use the specified fuel oil only.

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 SECTION １ -OUTLINE

1.2 FUEL OIL SPECIFICATIONS

１－２－０２

1.2.1 Fuel Classification

Since fuel classifications vary among different countries, Niigata has

established the following general specifications. The customer should confirm
his particular fuel oil specifications from the supplier, and should use only
the grade specified by Niigata (or a higher grade).

CLASSIFICATION SPECIFIC VISCOSITY SULFUR RESIDUAL ASH

GRAVITY (50 ℃) CONTENT CARBON
% WT. % WT. % WT.
A(LIGHT) <0.87 <9.5 <0.1 <0.2 <.01
B(LIGHT) <0.90 <9.5 <1.0 <0.2 <.01
C1(INT.) <0.90 <30 <1.8 <1.5 <.02
C2(INT.) <0.97 >30<180 >0.3 <10 <.05
<1.8
D1(HEAVY) <0.97 >30<180 >1.8 <10 <.05
<3.0
D2(HEAVY) <0.99 >180<380 >1.5 <12 <.10
<4.0

NOTES: (Fuel Classification)

1. When using a high-viscosity fuel oil having a kinematic viscosity of 30 mm²/s

(at 50 ℃) or higher (class C and H), special treatment (heating and
purification) is required. Refer to the following section on "Use of Heavy
Fuel Oil".
2. Vanadium content should not exceed 100 ppm.
3. Kerosene and other fuels lighter than No.2 Diesel should not be used except
under emergency conditions unless prior approval has been obtained from
Niigata. The low viscosity and poor lubricating qualities may damage fuel
injection system components and reduce useful life.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION １ -OUTLINE

1.2 FUEL OIL SPECIFICATIONS

１－２－０３

1.2.2 Use of Heavy Fuel Oil

(1) Purifying of Heavy Fuel Oil

As mentioned above, engines that have been built to run primarily of heavy
fuels will be configured with special components to insure satisfactory
operation. In addition, however, external fuel treatment (purification and
pre-heating) will also be required.
A purifier must be used to remove water and solids from the fuel oil before
it enters the fuel pump. Excess moisture not only reduces the calorific
value (heat energy) of the fuel, but can cause rust and deposit problems on
internal engine components.

(2) Temperature of Heavy Fuel Oil

Suitable atomization of fuel oil is essential for proper operation of the
fuel injection pump and for complete combustion of the fuel/air charge in
the cylinder.
The viscosity of fuel oil as it enters the engine fuel pump should be
between 11.5-16 mm²/s at 50 ℃ (60-75 Redwood No1.). Viscosity of this level
can be obtained if heavy fuel oil is heated before it enters the fuel
injection pump, as indicated in the Viscosity-Temperature Chart shown in
Figure 1.2-1.
WARNING: Fuel oil temperature must not exceed 145 ℃

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 SECTION １ -OUTLINE

1.2 FUEL OIL SPECIFICATIONS

１－２－０４

(3) Use of Light Fuel Oil ( No2 Diesel)

Light fuel should always be used in the following situations:
- for 'run-in' operation after engine overhaul
- when starting and stopping the engine
- when the load is less than 1/3 of the rated load
Additional details concerning the use of light and heavy fuel oils are given
in the Operations Section of this manual.

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 SECTION1-OUTLINE
1.3 LUBRICATING OIL SPECIFICATIONS
１－３－０１

1.3 LUBRICATING OIL SPECIFICATIONS

CAUTION: Never mix different brands of lubricating oil even if they are
recommended brands.
Proper selection and monitoring of the lubricating oil is essential for
satisfactory engine performance and life. The lubricating oil must be from a
list approved by Niigata for the application and fuel-type being used.
All instructions from Niigata and its dealers concerning lubricating oil must be
followed to assure warranty coverage.

CAUTION

Be sure to put on safety goggles in carrying out the following items of

work being in danger of injury to eyes.
・ When handling lubricating oil
1.3.1 Selection of Lubricating Oil
(1) Viscosity
Lubricating oil of SAE40 viscosity must be used for this engine.
WARNING: Multi-viscosity oils (eg., 15W-40) are not to be used.
(2) Base Number
The total base number (TBN) provides a relative measure of the oil's
ability to neutralize acidic material and provides some indication of it's
antiwear and antirust capabilities. The desired TBN of new oil depends upon
the sulfur content of the fuel being used. When using heavy fuels (Class C
or D), the TBN of new oil should be 20 or higher. (Recommended values for
each class of fuel are given in the Recommended Oil List that follows).
At each periodic inspection (every 500 hours), a sample of lubricating oil
must be analyzed to determine the TBN. Minimum acceptable values (depending
upon the sulfur content of the fuel being used) are shown below:
Sulfur content Min. TBN value
of fuel
2.0% or higher 20
>1.0% but <2.0% 15
≦1.0% 8
If the analyzed values are less than the minimum values shown above, the oil
should be changed or sufficient new oil added to bring the TBN up to an
acceptable level.

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 SECTION1-OUTLINE
1.3 LUBRICATING OIL SPECIFICATIONS
１－３－０２

1.3.2 Chart of recommended lubricating oils

WARNING: Lubricating oil suitable for use with residual fuel oil is not
necessarily suitable for use with light fuel oil. Proper lubricating oil must
be selected on the basis of the sulfur content of the fuel oil.
Niigata accepts no responsibility for customer use of lubricating oil not
listed in the chart below.

fuel No2 DIESEL HEAVY FUELS

Sulfur S ≦1.0 S ≦1.0 1.0<S≦2.0 2.0<S≦3.5 3.5<S≦5
(%)
STANDARD 10～15 15～20 20～30 30～40 40
TBN
MOBIL *MOBILGARD
*MOBILGARD 412 (15) *MOBILGARD 424 (30)
442 (40)
POWERGARD
POWERGARD 42(12) POWERGARD 3040(30)
2040(20)
ESSO *EXXMAR *EXXMAR *EXXMAR
*EXXMAR 24TP40(24)
12TP40(12) 30TP40(30) 40TP40(40)
STAMARINE EXTRA 40(15) STAMARING EXTRA SR-40(30)
CALTEX *RPM DELO *RPM DELO 2000 40(20) *RPM DELO
1000 *RPM DELO 3400 40(40)
40(12) *RPM DELO 3000 40(30)
6200
40(20)
CHEVRON *DELO 1000 *DELO 3400
* DELO 2000 40(20)
40(12) 40(40)
DELO 1000 40(12)
*TARO
TEXACO *TARO XD40(16) * TARO DP40(32)
XL40(42)
CASTROL *MARINE MCL
*220 MXD(22)
40(12) *MXD
MARINE 404 (40)
MXD 304(30)
MPX40(9)
ELF * AURELIA
*DISOLA M4015(15) *AURELIA 4030(30)
XT4040
SHELL GADINIA OIL RIMURA FB OIL 40(20) ARGINA X OIL
40(11) ARGINA S OIL 40(20) 40(20)

NOTE: ASTERISK DENOTES PREFERRED BRANDS.

1.3.3 Lubricating oil for Accessories
Refer to the individual instruction manuals for lubricating oil
recommendations for the individual accessories.

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 SECTION1-OUTLINE
1.3 LUBRICATING OIL SPECIFICATIONS
１－３－０３

1.3.4 Tolerances in Lubricating Oil Properties

（1) Viscosity: Viscosity generally increases with operating time. although
could instead decrease because of fuel dilution or addition of makeup oil.
The acceptable limits of viscosity change are + 30% or - 20% from the value
of the oil when new. Viscosity should never exceed 120 mm 2 /S (at 50 ℃)
maximum value.
If only the viscosity reaches the limiting value (and the other criteria
listed below are still within acceptable limits), it is permitted to add SAE
30 oil to reduce the viscosity level. However, this should be followed-up
with an immediate oil analysis to determine the cause of the viscosity
increase.
Moisture: The presence of water in the lube oil can indicate leaking oil
coolers, leaking aftercoolers, condensation,or failed gasket joints. Traces
of moisture are inevitable, but total moisture content should not exceed 0.3
% by volume. Centrifuging is desirable to keep water content to a minimum.
If the water content exceeds 0.5% by volume, immediate action should be
taken to (a) adjust the operation of the centrifuge to lower the water
content and (b) to determine and repair the source of water entry into the oil.
(2) Pentane Insoluable Content: Should not exceed 1.5% maximum.
(3) Toluene Insoluble Content: Should not exceed 1.0% maximum.
(4) Base Number: (ASTM:D2896 JIS:K2501)
Light Fuel Oil- TBN should not be lower than 6
Heavy Fuel Oil- TBN should not be lower than 15

As discussed in the section dealing with "Selection of Lubricating Oil", the

desired TBN of new oil depends upon the sulfur content of the fuel that is
being used. TBN typically decreases with hours of use and low values
indicate that the additives are no longer effective and a complete oil
change is advisable.
Flash Point: If the flash point value drops more than 50℃.
from the value of new oil, fuel dilution is indicated and remedial
action should be taken to determine the cause. With a flash-point lower than
150 ℃ the chances of a crankcase explosion are increased.

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 SECTION1-OUTLINE
1.3 LUBRICATING OIL SPECIFICATIONS
１－３－０４

1.3.5 Analysis of Lubricating Oil

A program of routine periodic laboratory analysis is essential to detect
potential problems and prevent serious engine damage. Additionally, the
laboratory analysis should be supplemented with frequent on-site checks of the
oil condition to avoid problems that could occur during the time periods
between lab tests (see "On-site Checks" below).
(1) Laboratory analysis
Lubricating oil should be laboratory analyzed at 500 hour intervals for
viscosity, base number, detergent dispersability, moisture, and
impurities. If the engine is an emergency unit or genset which accumulates
less than 500 hours per year, the oil analysis should be conducted at least
once per year, and the oil should be changed every two years.
The results of the laboratory analyses should be recorded so that changes in
the oil properties can be traced as a function of engine operating hours.
For those engines that accumulate hours rapidly, it is also recommended that
on-site analysis of the oil condition be conducted every 100 hours.
Lubricating oil can deteriorate rapidly under certain conditions, and the
on-site tests provide a good "backup" to the 500 hour lab tests.
(2) Recommended on-site checks (100 hours) for Lube oil contamination
In the 500 hour interval between laboratory analysis, periodic field checks
can help prevent problems that might result from oil contamination caused
by fuel leaks, water leaks, etc.
Most oil manufacturers provide various test kits for this purpose. While the
test results are not as comprehensive or accurate as a lab analysis, they
are usually sufficient to provide early warning of problems.
These test kits vary among the oil manufacturers, but basically provide
information from a spot of the used oil placed on a special absorbent paper.
Visual examination of the spot indicates contamination and dispersant
characteristics, and the color of a special reagent placed on the spot shows
whether the oil is acid, neutral, or alkaline.
Complete information on the use of these test kits should be obtained from
the oil supplier.
Of course, any other obvious signs of oil contamination, such as a "milky"
color (water) or a strong odor of fuel in the lube oil should signal the
need for immediate remedial action.
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 SECTION １ - OUTLINE
1.4 ENGINE COOLANT
１－４－０１

CAUTION
Be sure to put on safety goggles in carrying out the following items of
work being in danger of injury to eyes.
・ When handling cooling water

1.4 ENGINE COOLANT

The cooling system of the engine consists of two separate circuits.
The "high-temperature" circuit is a closed system of treated coolant that circulates
through the engine block, cylinder heads, and turbocharger (if water-cooled).
The "low-temperature" circuit provides cooling for aftercooler, lube oil cooler,
and may also include provisions for fresh-water cooling, clutch cooling, and
marine gear oil cooling. This circuit may be either a closed circuit of treated
coolant or a sea-water/raw water circuit.
The desired water characteristics for closed-circuits include:
・should be clear (no sediments)
・less than 200 ppm silica
・pH value-7.0 or higher
・chlorine ion concentration - less than 100 mg/l
・total base content (residue when coolant is evaporated at 100 ℃ - less than 250 mg/l)

1.4.1 Chemical treatment of water

Generally, corrosion of the cylinder and another components cooled by fresh water
is depend upon cavitation or electrical erosion. The corrosion is pevent by proper
chemical treatment of water.
(1) Major components of corrosion inhibitors
Chromate
Passive state type
Inorganic Nitrite
Corrosion
inhibitors Ortho-phosphate
Film forming type Poly-phasphate
Silicate
Organic Non-amine type Soluble oil

a) Chromate
Little used today because nitrite corrosion inhibitors are toxic and pose waste
water problems.
b) Nitrite
Much used today because nitrite corrosion inhibitors are nontoxic and pose
no waste water problem. But waste water to be discharged must meet the
* C.O.D. requirements.

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 SECTION １ - OUTLINE
1.4 ENGINE COOLANT
１－４－０２

c) Silicate
Silicate corrosion inhibitors are completely free of toxicity and waste
water can be discharged without treating.
d) Soluble oil

CAUTION
Corosion inhibitors of soluble oil type is not suitable for the engine.
Soluble oil corrosion inhibitors are made by adding a surface active agent,
etc. into mineral oil. Waste oil to be discharged must meet the
* C.O.D. requirements and the oil content must be treated.
* C.O.D. value: When reducer (waste liquid of inhibitor in this case) is added to
fresh water (or sea water), oxygen contained in the water is
reduced and the state of oxygen deficiency is produced.
The quantity of oxygen required for eliminating this state of
oxygen deficiency is indicated as C.O.D-( )ppm.
The following method are available for satisfying this C.O.D. value.
- To dilute the water with water of a suitable volume.
- To blow air in.
- To oxidize the water by adding a suitable oxidizer (sodium
hypochlorite, etc.).

(2) Caution in using corrosion inhibitors

CAUTION
The rust-preventive agent, inhibitor and anti-freeze for use with cooling
water line are poisonous to the human body.
Handle them carefully so that they will not come into eyes or come in
contact with the body.
Be sure to put on safety goggles in carrying out the following items of
work being in danger of injury to eyes.
・ When handling cooling water

Methods of adding corrosion inhibitors, concentration, diposal of waste water, etc.

very somewhat with manufacturers. When using a corrosion inhibitor, observe the
following instructions and consult with the manufacture.
a) Adding
Generally, prepare a thick solution of 10 to 20 % in volume and gradually pour it
into the cooling water. In case an antifreeze liquid must be added into the cooling
water in cold regions, consult inhibitor manufacture because the mixture could
adversely affect both the antifreeze and the corrosion inhibitor.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION １ - OUTLINE
1.4 ENGINE COOLANT
１－４－０３

b) Concentration control
If the solution prepared is too thick or thin as compared with the required
concentration, it could accelerate corrosion. Be sure to conform to the
concentration control standard of the corrosion inhibitor manufacture.
Use a concentration control instrument available from the manufacturer.
c) Waste water disposal
Disposal of waste water is subject to the C.O.D regulations imposed by central
and local governments, which may differ from one country to another.
Study such regulations and consult inhibitor manufacturer when disposing of
waste water.

(3) Others
If air enters the cooling water, the amount of dissolved oxygen in the water will
increase to accelerate corrosion. In addition to using a corrosion inhibitor,
the following steps are recommended to protect the cooling system from corrosion.
- Be sure to provide air vents at points where air is likely to collect.
- A fresh water expansion tank must have a certain head (5 to 20 meters from the
crank center of the engine) to prevent evaporation due to the rize of cooling water
pressure.
- Partition the inside of the fresh water expansion tank with suitable plates to reduce
the waving of the cooling water to and fro.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION １ - OUTLINE
1.4 ENGINE COOLANT
１－４－０４

(4) Brands of cooling water additives

CLASSIFI CONCENTRATION
BRAND MANUFACTURE
CATION (ppm) *Note1
EXENO YAMAMIZU
DISTILLAN-RR 200～ 300
CORPORATION

SHADAN K OTSUKA CHEMICAL CO.,LTD 20000

INHIBITOR
Non-Nitrite
BLUE COOL S NIPPON OIL CORPORATION 40000～ 70000

EDLAS #25 RYOKO CHEMICAL CO.,LTD 1000～ 2000

AQUAS CHELATE D-801L 6000～ 9000

AQUAS CORPORATION
AQUAS DYNA CG-580 9000

ORGAFILM C-3 C-3:2000～ 3000

ORGANO CORPORATION
C-3S C-3S:4000～ 5000

POLYCRIN I-175 8000～ 12000

INHIBITOR KURITA WATER

KURILEX L-109 8500～ 12000
Nitrite INDUSTRIES LTD.

KURILEX L-209 8500～ 12000

HIMOL AM-5 1000～ 3000

TAIHO INDUSTRIES CO.,LTD
HIMOL L-10 8000～ 12000

NEOS PN-106 106:2000～ 3000

NEOS CORPORATION
PN-106S 106S:8000～ 12000
APOLLO LONG LIFE
APOLLO SERVICE CO.,LTD 300000～ 600000
COOLANT

SHADAN A OTSUKA CHEMICAL CO.,LTD 150000～ 300000

KYGNUS LONG LIFE

KIGNUS SEKIYU KK. 300000～ 500000
LONG LIFE COOLANT
COOLANT COSMO LONG LIFE COSMO TRADE & SERVICE
300000～ 600000
COOLANT CO.,LTD

LC SUPER SINKAITYOU CCI CORPORATION 300000～ 600000

SUPER COOLANT X NIPPON OIL CORPORATION 300000～ 600000

INHIBITOR
KURITA WATER
for cooling TOWER CLEAN S-512 150～ 300
INDUSTRIES LTD.
tower system

Notes: 1 ppm=mg/l
2 Directions given by the manufacturer should be observed for methods
of use and management.
3 Brands without toxicity were selected out of those available on the market.
It is permitted that other equivalent is used, but attention should be paid to toxicity.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION １ - OUTLINE
1.4 ENGINE COOLANT
１－４－０５

1.4.2 Anti - freeze

Use anti-freeze using ethylene glycol as the base for the engine.
Borate of nitrite type and benzoate of nitrite type may be used as the water treatment
agent together with anti-freeze of this type, but water treatment agent of chromate
type nannot be used together with anti-freeze of this type.
The following figure indicates the following relations.
- Relation between ratio (P) and specific gravity (D) of anti-freeze
It is for learning the concentration from the result of measurement using a
hydrometer and the temperature at the time of measurement.
- Ratio (P) of anti-freeze and freezing temperature (C) of cooling water.
FIGURE Freezing temperature of water/ethylen grycol mixture

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 SECTION １ - OUTLINE
1.4 ENGINE COOLANT
１－４－０６

1.4.3 Method for treatment

WARNING
Keep away from the fire since anti-freeze entails the danger of ignition to
scald.

Treating agent should not be directly input into the cooling system of the engine.
Be sure to prepare a tank for treatment and carry out treatment in this tank.
Further, use an agitating tool to produce completely homogenized solution.
If a tank of sufficient size is not available at hand, at first produce condensed
solution and pour this primary solution into the cooling system filled with untreated
water while running the cooling water pump.
Assure at the time of supply of water into the cooling system that the cooling
system is free from contamination.
There are cases where the concentration of the treating agent in the cooling
water gradually rises as the time elapses due to evaporation.
It is not necessary to add treating agent to the water that is added for making up
reduction of water level.
However, this water should satisfy the conditions specified in item 1.4.1.
The reference material prepared by the treating agent manufacturer also
indicates tolerances in the concentration besides the standard concentration
of each recommended chemical.
The effect of the water treatment agent is entirely determined by its concentration
in the cooling water.
Therefore, sufficient attention should be paid to the control of concentration.
Therefore, periodic check of concentration of the treatment agent should not
be neglected (particularly at the occasion when water is added for making up
the loss).

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION ２ - OPERATING INSTRUCTION
CONTENTS

SECTION 2 - OPERATING INSTRUCTIONS

2.1 STARTING AND WARMUP AFTER A NORMAL SHUTDOWN

2.2 SPECIAL INSTRUCTIONS FOR HEAVY FUEL OPERATION

2.3 NORMAL SHUTDOWN PROCEDURE

2.4 STARTING AFTER ENGINE OVERHAUL OR EXTENDED SHUTDOWN

2.5 RUN - IN PROCEDURE AFTER MAJOR OVERHAUL

2.6 INSPECTION AND CARE OF ENGINE DURING NORMAL OPERATION

2.7 CHART OF NORMAL OPERATING PRESSURES AND TEMPERATURES

2.8 PREPARATION OF ENGINE FOR EXTENDED SHUTDOWN

2.9 CARE OF LOW LOAD OPERATION

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 SECTION ２ - OPERATING INSTRUCTION
2.1 STARTING AND WARMUP AFTER A NORMAL
SHUTDOWN ２－１－０１

DANGER

Where the engine is brought to a stop due to abnormal heat generation being detected
inside the engine room, there is a danger of explosion if crankcase door is allowed to
open forthwith.
Open the door after the lapse of a cooling period of not less than 20 minutes.

WARNING

In cases of lubricating oil leakage from equipment and pipelines of lubricating oil line,
there is a danger of fire hazard.
Conduct inspection at all times to avoid causing bolts looseness, gasket terioration,
and equipment and pipeline cracking.

In cases of a possibility of mist-like leakage due to high pressures in fuel oil line and
lubricating oil line, there is a danger of fire hazard.
Stop the engine running forthwith and take preventive measures against leakage.
In cases of hot exhaust gas leakage from equipment and pipelines of exhaust gas line,
there is a danger of fire hazard.
Stop the engine running forthwith and take Preventive measures against leakage.

There are cases where scald is caused by the actuation of crankcase safety valve due to
abnormal pressure rise inside the crankcase.
Do not gain access to the blow-off nozzle.

There are cases where scald is caused by the actuation of cylinder safety valve due to
abnormal pressure rise inside the cylinder.
Do not gain access to the blow-off nozzle.
Each kind of motor entails the danger of electrification.
Before turning ON power supply, check if there are any abnormality in wire connections
and peel-off of covering.
Electrical devices such as various switches, electrical governor, fuel scale level
transmitter, etc. and wiring entail the danger of electrification.
Before turning ON power supply, check if there are any abnormality in wire
connections and peel-off of covering.

Electrical devices built into remote control stand, alarm panel, solenoid valve unit, etc.
and etc. and separately-installed accessory devices entail the danger of
electrification.
Before turning ON power supply, check if there are any abnormality in wire
connections and peel-off of covering.

There is a danger of parts of the body being entangled into the flywheel area in the
course of engine running.
Do not allow your hand, leg, etc. to gain access to the area.

There is a danger of parts of the body being entangled into the rotating parts
(coupling, output shaft, radiator fan, etc.) in the course of engine running.
Do not allow your hand, leg, etc. to gain access to the parts.

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 SECTION ２ - OPERATING INSTRUCTION
2.1 STARTING AND WARMUP AFTER A NORMAL
SHUTDOWN ２－１－０２

There is a danger of injuries being caused by contra rotation of crankshaft if turning is

carried out without opening the indicator cock or explosion check plug. Be sure to open
the indicator cock or explosion check plug when carrying out turning.

There is a danger of hands or legs being pinched by the moving parts (valve actuator,
fuel injection pump roller guide, governor link, stopping piston, etc.) of the engine in the
course of engine running.
Never insert your hands and legs.

There is a danger of your hands being pinched by the gear and cam roller of the engine.
Never insert your hands in the course of turning.

The engine may start abruptly without notice through the auto start signal or by remote
starting. As there is a danger of entanglement etc., do not gain access to rotating parts
and moving parts.

There is a possible danger of physical accidents that may be caused when the engine is
started by mistake during the inspection and repair of the air-started engine.
Be sure to carry out the following items to prevent the erroneous start of the engine.
・ Close the main valve of starting air-tank outlet.
・ Release the residual pressure remaining Inside the starting air pipeline. (Between
the starting air tank to the engine)

CAUTION

Since there are many hot parts in the engine during the course of running or right after
stopping, there is a danger of scald caused by them. Do not allow your skins to come in
direct contact with them.
In particular, use extreme care for the following parts that are heated up to high
temperatures.
・Exhaust line of the engine
・Indicator cock and cylinder safety valve
・Fuel oil line
・ Steam line

In the case of carrying out the following work, there is a danger of scald caused by
high-temperature parts or hot fluid.
Put on protective gloves and use care in handling so that hot fluid will not splash over
the skin.
・Sampling work of cylinder internal pressure.
・Cleaning of lubricating oil/fuel oil filters.
・When removing the caps of radiator and
・pressurized fresh water expansion tank.

In the case of checking by finger touch, there is a danger of scald. To prevent this, first
allow your finger to approach to the work and make sure that it is not hot, followed by
conducting the check by finger touch.
If the work is hot, do not conduct the check by finger touch to avoid causing the scald.

There is a danger of critical accidents arising From such malfunction of electronic

devices applied to electrical governor and remote controller as is caused by
electromagnetic wave.
Keep away from electromagnetic wave-generating equipment.

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 SECTION ２ - OPERATING INSTRUCTION
2.1 STARTING AND WARMUP AFTER A NORMAL
SHUTDOWN ２－１－０３

2.1 STARTING AND WARMUP AFTER A NORMAL SHUTDOWN

Starting should be precede by a through visual inspection of the engine and a
check of the following items:

a. Check engine lube oil level

b. Check governor and turbocharger oil levels (if supplied from separate lube systems)
c. Check coolant level for both the high-temperature and low-temperature systems.
d. Check the fuel tank level. If heavy fuel is used, also check the
operation of the heating mechanism and the centrifuge.
e. If heavy fuel is used, set the selector valves in the LIGHT FUEL position.
f. Check the air pressure in the starting air reservoir (should be 1.77～2.94 MPa
Drain any water from the reservoir.
g. Check to make sure the safety stop devices air in working order.
h. Fill the grease cup in the starting air distributor.

After completion of the above checks, the lube oil priming pump should be
started, the indicator cocks on all cylinders should be opened, and the engine
should be rotated (with the turning device) for 3 or 4 complete revolutions to
insure that no water has leaked into the cylinders during the shutdown period.
(Observe for water coming out of the indicator cocks as the engine is rotated).
If any cylinder has filled with water, the engine should not be run until the
source of the leakage has been located and repaired.
If no water is observed, the turning device should be removed and the cylinder
cocks should be closed.
With the lube oil priming pump still running, check to make sure that oil
pressure exists (will be low level, but this check is just to make certain that
the priming pump is operating correctly).
Set the governor control lever in the 'IDLE' position.
Start the engine by opening the main air valve to the starter. Disconnect the
starter (turn off air supply) as soon as the engine is running.
As soon as the lube oil pressure rises to a normal idle level, turn off the
priming pump.
Continue running at idle speed until the lube oil temperature rises to about
40℃. This will normally require only 4-5 minutes. During this time, check the

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 SECTION ２ - OPERATING INSTRUCTION
2.1 STARTING AND WARMUP AFTER A NORMAL
SHUTDOWN ２－１－０４

temperatures of all exhaust ports to insure that all cylinders are firing
normally. (These temperatures should rise 70-100 ℃ in about one minute. If an
individual cylinder is significantly cooler than the others, the fuel injector
of that cylinder should be checked for carbon buildup and plugging.
After the engine has warmed up, the speed should be increased gradually up to
the normal operating speed.
As this point, complete engine checks should be made as outline in Section 2.6
(Inspection and Monitoring During Normal Operation).

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 SECTION ２ - OPERATING INSTRUCTION
2.2 SPECIAL INSTRUCTIONS FOR HEAVY FUEL
OPERATION ２－２－０１

2.2 SPECIAL INSTRUCTIONS FOR HEAVY FUEL OPERATION

- The engine can be operated with LIGHT fuel (No 2 Diesel) under any load
conditions without any special precautions. However, operation with HEAVY
fuel (if the engine is equipped to do so) requires the following precautions:
- The engine should always be started and warmed up with LIGHT fuel. If the
switching to heavy fuel is not automated, the operator should make certain
that the fuel heater is operating and that the fuel temperature at the pump
will be in the 60-80℃ range before the switch to heavy fuel is made.
- The engine should be operated on LIGHT fuel at lightly loaded conditions (less
than 1/3 of rated load). Operation at light load with heavy fuel can cause
excessive carbon buildup, injector plugging, loss of power, exhaust
slobbering, and excess smoke.
- The engine should not be shut down when operating on heavy fuel except in
emergency situations. The heavy fuel, as it cools, will thicken and can make
restating extremely difficult. The switch to LIGHT fuel should always be
made prior to shutdown and the engine should be run long enough to flush all
heavy fuel from the fuel lines and injectors.

If it is ever necessary to shut down the engine while operating with heavy fuel,
the fuel selector switch should be switched to LIGHT fuel and the transfer pump
should be used to flush the heavy fuel from the system. This should be done as
soon as possible after shutdown before the heavy fuel begins to cool.

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 SECTION ２ - OPERATING INSTRUCTION

2.3 NORMAL SHUTDOWN PROCEDURE

２－３－０１

2.3 NORMAL SHUTDOWN PROCEDURE

Engine speed and load should be reduced gradually. The engine should run at
idle speed 2-3 minutes after the load has been disconnected before shutting
down. If possible, avoid extended periods of idling at unloaded conditions to
prevent turbocharger carboning and exhaust slobbering.
The lube oil priming pump should be turned on for 10-15 minutes as soon as the
engine is shut down to provide continued cooling for the turbocharger bearings.
This may be an automated function in some installations - if so, the operator
should check to make certain that it is functioning as intended.
Other steps to be taken after the engine has stopped are as follows:

a. Check to make sure the governor lever is in the 'STOP' position.

b. Open the indicator cocks for each cylinder

WARNING

There is a danger of injuries being caused by contra rotation of crankshaft if

turning is carried out without opening the indicator cock or explosion check
plug. Be sure to open the indicator cock or explosion check plug when
carrying out turning.
There is a danger of your hands being pinched by the gear and cam roller of the
engine.
Never insert your hands in the course of turning.
c. Rotate the engine for 3-4 revolutions to exhaust the combustion gas from
the cylinders.

WARNING

There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
d. Turn off the electrical power at the monitor panel.
e. Shut off the fuel service tank.
f. Close the fuel inlet valve every time. If the shutdown period will be of
a long duration, the fuel tank (s) should be drained. Also observe the
instructions in Section 2.8 for extended shutdowns.

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 SECTION ２ - OPERATING INSTRUCTION
2.4 STARTING AFTER ENGINEOVERHAUL OR
EXTENDED SHUTDOWN ２－４－０１

WARNING

In cases of fuel leakage from equipment and pipelines of fuel oil line there is a danger
of fire hazard.
Conduct inspection at all times to avoid causing bolts looseness, gasket
deterioration, and equipment and pipeline cracking.

In cases of lubricating oil leakage from equipment and pipelines of lubricating oil line,
there is a danger of fire hazard.
Conduct inspection at all times to avoid causing bolts looseness, gasket deterioration,
and equipment and pipeline cracking.

Any negligence of controlling cooling water, lubricating oil, and fuel oil, and
controlling the clamping in reassembly after overhaul inspection may lead to fault of
the engine and result in physical accidents due to failure of parts.
Unfailing control should be conducted on the basis of instruction manual or
specifications.

CAUTION
Be sure to put on safety goggles in carrying out the following items of work being in
danger of injury to eyes.
・When handling fuel oil, lubricating oil, cooling water and inhibitor, and anti-freeze
solution
・In course of washing work
・In course of fuel injection valve injection test
・When handling battery electrolyte
・In course of grinding work
・In course of intake/exhaust valve grinding Work

There is a danger of injury to your hands during the work inside the engine room and
enclosure.
Be sure to put on gloves for the protection of your hands except for the case of special
work.

2.4 STARTING AFTER ENGINE OVERHAUL OR EXTENDED SHUTDOWN

After major repairs have been made to the engine or after a period of extended
shutdown, all systems should be thoroughly inspected before attempting to start the engine.

Cooling system
・ If pipes or lines were disassembled, check all connections to insure that they are tight.
・ Close all drain openings, and set all valves in the operating positions.
・ Low temperature system - If equipped with a separate motor-driven pump,
start the pump and vent air from the highest point in the system as it is
filling. Recheck all connections for leaks. Check the motor-driven pump for leaks.
・ High temperature system - Same procedure as with low temperature system.
・ If a heater is provided for cold start, it should be turned on to insure
that it is operating properly.

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 SECTION ２ - OPERATING INSTRUCTION
2.4 STARTING AFTER ENGINEOVERHAUL OR
EXTENDED SHUTDOWN ２－４－０２

Lubrication system

WARNING

In cases of lubricating oil leakage from equipment and pipelines of lubricating oil
line, there is a danger of fire hazard.
Conduct inspection at all times to avoid causing bolts looseness, gasket
deterioration, and equipment and pipeline cracking.
・ The lube-oil filters should always be cleaned or replaced (if disposable type) following
major repairs to internal engine components.
・ The oil level in the sump should be checked and replenished as needed. If major repairs
have been made to the engine, a visual inspection should be made prior to starting to
insure proper oil circulation to the major engine systems. This can be done by running
the priming pump or auxiliary motor-driven lube pumps (when provided) to build up
pressure in the circuit.
・ Remove the crankcase inspection covers and check for oil flow to the crankshaft
bearings and pistons.
・ Remove the valve covers and check for oil flow to the cam bearings, cam
followers, and to the intake and exhaust rocker arms and rollers.
・ Reinstall the crankcase inspection covers. Before reinstalling the valve
covers, refer to the Mechanical Checks section below for other work to be done in this area.

Accessory lubrication
・ Check the oil level in the governor and the turbocharger (if separately lubricated) and
replenish as required using the oil specified by the individual manufacturers.

Fuel Oil System

WARNING

In cases of fuel leakage from equipment and pipelines of fuel oil line and gas fuel
line for gas engine, there is a danger of fire hazard.
Conduct inspection at all times to avoid causing bolt looseness, gasket
deterioration, and equipment and pipeline cracking
・ Clean and fill the fuel service tank (s) .
・ Check all flow valves to make certain they are in the correct operating position
・ Clean and/or replace filter elements as required.
・ Check to make certain that the fuel injection pump rack is at the zero (closed) position.
・ If the fuel feed pump is independently driven, start the pump to build up
pressure in the circuit. (light fuel).

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 SECTION ２ - OPERATING INSTRUCTION
2.4 STARTING AFTER ENGINEOVERHAUL OR
EXTENDED SHUTDOWN ２－４－０３

If heavy fuel is used:

・ Repeat the same procedures as listed above for light fuel, checking also to
make certain that the preheater, temperature switch, and filtering devices
in the heavy fuel system are operating properly.
・ Switch back to light fuel after making the above checks.
・ Run the fuel transfer pump long enough to flush all heavy fuel from the
lines before shutting off the pump.

Mechanical Checks

WARNING

There is a danger of injuries being caused by contra rotation of crankshaft if turning

is carried out without opening the indicator cock or explosion check plug. Be sure to
open the indicator cock or explosion check plug when carrying out turning.

There is a danger of your hands being pinched by the gear and cam roller of the
engine.
Never insert your hands in the course of turning.

・ Open the cylinder indicator cocks.

・ Rotate the crankshaft in the normal direction slowly with the turning bar
while observing for water or fuel coming from the indicator cocks. If
either is apparent, the leakage path must be located and repaired before
running the engine.
・ Remove the valve covers.
・ While rotating the engine manually, check to insure that the intake and
exhaust valves are opening and closing properly. Set the valve clearances
according to the instruction in the Maintenance Section of this manual.
・ At this point, the valve covers can be reinstalled.
・ Set the governor lever in the STOP position. Check the rack to make sure
it is in the "zero" position and that is moves freely for its entire length.
・ Check all electrical wiring, connectors, pressure switches, temperature
switches, shut-down switches, liquid level switches, and signal lights and
alarms to make certain that all are connected.
・ Inspect and test the air starting device:
- Fill the grease cup in the starting distributor.

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 SECTION ２ - OPERATING INSTRUCTION
2.4 STARTING AFTER ENGINEOVERHAUL OR
EXTENDED SHUTDOWN ２－４－０４

- Drain any water from the air reservoir, start the air compressor, and let ・
the pressure build up to 2.94 MPa.
・ Start the lubricating oil priming pump.
・ Open the main air valve to the engine.

WARNING

There is a danger of injuries being caused by contra rotation of crankshaft if

turning is carried out without opening the indicator cock or explosion check plug.
Be sure to open the indicator cock or explosion check plug when carrying out
turning.

There is a danger of your hands being pinched by the gear and cam roller of the
engine.
Never insert your hands in the course of turning.

・ The engine should turn over freely at this point.

WARNING

There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning
device.
Do not allow your hand, leg, etc. to gain access to the parts.
If not, check the starting distributor and the cylinder starting valves and repair as
necessary (see Maintenance Section).
・ If the engine turns freely and no problems are observed, stop the engine
and lube oil priming pump, and close all indicator cocks.

At this point, the engine is ready to start. Follow the procedures in Section
2.1 above. If major repair work has been completed, a "run-in" procedure is
required as outlined below.

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 SECTION ２ - OPERATING INSTRUCTION
2.5 RUN - IN PROCEDURE AFTER MAJOR OVERHAUL
２－５－０１

2.5 RUN-IN PROCEDURE AFTER MAJOR OVERHAUL

Run-in procedures should be conducted after installing new pistons, rings, or
cylinder liners. No run-in is required if only the main and/or rod bearings were
replaced.
The run-in can be completed in a few hours of running time and helps insure
proper "seating" of the wearing parts. The recommended schedule is as follows:
(all running is at a NO-LOAD condition).

・ Start the engine and run at low idle no-load for a period of about ten minutes.
Stop the engine.

DANGER

Where the engine is brought to a stop due to abnormal heat generation being
detected inside the engine room, there is a danger of explosion if crankcase
door is allowed to open forthwith.
Open the door after the lapse of a cooling period of not less than 20
minutes.
・ If new main and/or rod bearings were installed during the overhaul, remove
a crankcase inspection cover and carefully check by "feel" for high
temperatures on the main and rod bearing caps. If no problems are seen,
reinstall the covers.
・ Remove a valve cover and check by "feel" for unusually high operating
temperatures that would indicate inadequate oil supply. Reinstall the cover.
・ Restart the engine and run the following schedule:

ENGINE SPEED(%) RUNNING TIME TOTAL TIME

50 20min 20min
60 20min 40min
70 20min 1 HR
80 20min 1 HR 20min
90 20min 1 HR 40min
100 30min 2 HR 10min
INSPECTION OF CRANKCASE INSIDE

Cation 1: Engine speed(%) means the rate of the rated speed.

2: Tortional vibration range has to be prohibited smoothly.

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 SECTION ２ - OPERATING INSTRUCTION
2.5 RUN - IN PROCEDURE AFTER MAJOR OVERHAUL
２－５－０２

After completion of the no-road running described above,gradually apply load per
the following time-table:

RUNNING TIME LOAD

30min 25 % FULL LOAD
30min 40 % FULL LOAD
30min 50 % FULL LOAD
30min 65 % FULL LOAD
60min 75 % FULL LOAD
INSPECTION OF CRANKCASE INSIDE
15min 25 % FULL LOAD
15min 40 % FULL LOAD
15min 50 % FULL LOAD
15min 65 % FULL LOAD
60min 75 % FULL LOAD
60min 85 % FULL LOAD
60min 100% FULL LOAD
INSPECTION OF CRANKCASE INSIDE

・ While the engine is running the above schedule, observe for leaks,
excessive vibration, or excessive heat build-up. Shut the engine down
immediately if any problems are noted.
・ Check all system pressures and operating temperatures while the engine is
running to insure they are within normal operating range. (Refer to
Specifications). If the cylinder ports are equipped with pyrometers,
compare exhaust temperatures (cylinder-to-cylinder) while running under
100% load. If the exhaust from any cylinder is significantly different
from the others or if all cylinders are significantly different from the
shipping test values, corrective action should be taken (refer to
Trouble-shooting section of this manual).
・ Check cylinder pressures to insure they are all within the same range
(Refer to Maintenance and Inspection While Running).
・ Check the turbocharger speed, inlet and outlet temperatures and pressures
and compare to the shipping (new engine) test results.
・ Visually observe exhaust smoke and crankcase blowby to insure normal
operation.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION ２ - OPERATING INSTRUCTION
2.6 INSPECTION AND CARE OF
ENGINE DURING NORMAL OPERATING ２－６－０１

2.6 INSPECTION AND CARE OF ENGINE DURING NORMAL OPERATION

CAUTION
Since there are many hot parts in the engine during the course of
running or right after stopping, there is a danger of scald caused by
them. Do not allow your skins to come in direct contact with them.
In particular, use extreme care for the following parts that are heated up
to high temperatures.
・ Exhaust line of the engine
・ Indicator cock and cylinder safety valve
・ Fuel oil line
・ Steam line
In the case of carrying out the following work, there is a danger of scald
caused by high-temperature parts or hot fluid.
Put on protective gloves and use care in handling so that hot fluid will
not splash over the skin.
・ Sampling work of cylinder internal pressure.
・ Cleaning of lubricating oil/fuel oil filters.
・ When removing the caps of radiator and
・ pressurized fresh water expansion tank.
In the case of checking by finger touch, there is a danger of scald. To
prevent this, first allow your finger to approach to the work and make
sure that it is not hot, followed by conducting the check by finger touch.
If the work is hot, do not conduct the check by finger touch to avoid
causing the scald.
There is a danger of critical accidents arising From such malfunction of
electronic devices applied to electrical governor and remote controller
as is caused by electromagnetic wave.
Keep away from electromagnetic wave-generating equipment.

Once the engine has been started and brought up to load (Section 2.10), there are a
number of routine checks that should be made on a daily basis to insure continued
satisfactory operation.
IMPORTANT : A daily log should be kept to permit "tracking" engine performance.
Performance parameters should be compared to the engine test (shipping) records
if problems are suspected or if there is a question as to the correct values.
Daily checks include observing for leaks, vibration, unusual noises, and the overall
condition of the various engine and auxiliary systems, as follows:
- Fuel level in fuel service tank
- Fuel pressure at injection pump inlet (normal value at rated rpm = 0.05～0.15 MPa).
If the pressure drops to less than 80 % of its normal operating value, the pressure
regulating valve and filter condition should be checked for restriction (refer to
Maintenance Section).

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION ２ - OPERATING INSTRUCTION
2.6 INSPECTION AND CARE OF
ENGINE DURING NORMAL OPERATING ２－６－０２

- If heavy fuel is used, the heating device at the tank outlet should be checked to make certain it
is operating properly and that fuel entering the engine is at the desired temperature viscosity.
(Refer to section 1.2).
The centrifuge normally has two functions: heating the heavy fuel and centrifuging to remove
water and solids. The heater is necessary to reduce the fuel viscosity for more efficient
centrifuging. Both functions should be checked. An additional fuel filter is used for heavy
fuel applications. Some are of the automatic-cleaning type. This filter should be checked for
excessive restriction.
- Check the lube oil level. If a dry sump system is used, the level should be checked once daily.
If a wet sump system is used, it should be checked twice daily. If the oil level is low, additions
should be made (if possible) when the engine has cooled. If the engine is equipped with an
external system that maintains the oil level, it should be checked to insure that it is working
correctly. If makeup oil is added, the amount should be recorded so that accurate oil
consumption records can be maintained.
- Check the lubricating oil system operating pressure (normal value for rated speed is 0.50～
0.60MPa. If the pressure drops below 0.44Pa check the filters for excessive restriction.
If the engine is equipped with a bypass centrifugal filter, it should be removed and cleaned
at least every 100 hours : if the weight of accumulated sludge increases appreciably from the
previous cleaning, the quality of the lube oil should be checked.
An external oil pressure regulating valve (flow valve) is also included in the circuit (see
sketch). This valve is set to provide the correct pressure at normal operating conditions
and should not need frequent readjustment. However, if low oil pressure exists and
is not corrected by cleaning the filters, it can be manually reset to the correct range with
this regulating valve.
Sketches of this regulating valve and of the centrifugal lube oil filter are shown below:

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 SECTION ２ - OPERATING INSTRUCTION
2.6 INSPECTION AND CARE OF
ENGINE DURING NORMAL OPERATING ２－６－０３

- Check the lube oil operating temperature after it has stabilized.

Normal operating temperature ranges between 60-70℃. Excessive temperature can be
caused by either a restricted cooler or faulty temperature control valve. A temperature arm
should be set to activate at 75℃ and a trip (shutdown) to activate at 80℃.
- Check the lube oil level of the accessories on a daily basis:
-- Governor
-- Turbocharger (if separate oil circuit)
-- Grease cup of starting air distributor
-- Reduction Gear (for Marine application)
-- Other auxiliary equipment, as equipped
- Cooling system
Cooling systems consist of two separate circuits, or loops. The high temperature circuit
cools the internal engine components, (cylinder heads and liners) and the low-
temperature circuit cools the aircooler, the lube oil cooler, and may also be used to cool
the water used in the high-temperature circuit. These two circuits may have several
different configurations, depending upon the particular application. Typical
arrangements are as follows:
-- marine applications - The high temperature circuit is a closed system with treated
water. The low-temperature circuit may operate with either treated water from a
closed system or from sea water or river water in an open system.
-- generator plant applications - The high temperature circuit is closed and uses eated
water. The low-temperature circuit may use water from a cooling tower or radiator.
-- generator set, locomotive, and industrial drive - The high temperature circuit and the
low-temperature circuit are completely independent. Both circuits are closed, use
treated water, and each has its own radiator and cooling fan. In this type system,
there is no heat exchange between the circuits (water from the low-temperature cuit
is not used to cool the water in the high-temperature circuit, as in the Marine a
application above).
- High-temperature circuit - Routine checks during operation should be made for leaks,
operating temperature, and pressure.
A temperature regulating valve is provided at the outlet of the engine. When the
temperature reaches normal operating temperature ( 80-90 ℃), the regulating valve
redirects water flow through the high-temperature cooler to maintain that temperature.
If the temperature continues to rise, a temperature switch is closed and an alarm is
sounded. If the temperature rises further, the engine is stopped. Values for the alarm
settings are given in the chart in Section 1.1.
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 SECTION ２ - OPERATING INSTRUCTION
2.6 INSPECTION AND CARE OF
ENGINE DURING NORMAL OPERATING ２－６－０４

A pressure gage is installed at the water pump outlet. Pressure at this point serves as an
indication of the flow rate through the circuit.
Normal pressure at rated speed should be 0.30～0.45 MPa.
A lower pressure (flow) could indicate a loss of pump capacity or a major leak somewhere in
the system. If this pressure drops below a certain level (refer to Section 1.1), an alarm is
sounded and immediate remedial action should be taken.

- check the water level in the expansion tank daily. The level should not vary significantly
from day-to-day-if it does, an inspection should be made for leaks. Some variation can be
expected from
evaporation and/or heat expansion, but a mark placed at the normal level during operation
can serve as a quick method of checking for major changes.
The pH value of the treated water should be checked periodically as listed in the
Maintenance and Inspection Schedule (Section 3.5).
- Low temperature cooling circuit - As above, a pressure gage is installed at the pump
discharge. Normal values for both temperature and pressure are given in the table in
Section 1.1. These values should be routinely checked to insure proper operation. Lack
of flow (low pressure) or high temperatures in this circuit can cause excessive exhaust
temperatures with resulting performance deterioration and potential engine damage.

- Intake and exhaust system - Routine checks should include inlet and exhaust gas
temperature, inlet manifold pressure, and general observation of engine performance,
exhaust smoke levels, and fuel consumption trends.
If pressures or temperatures vary significantly from the shipping test values, the cause
should be determined.
If inlet manifold pressure is low and exhaust temperatures are uniformly high, turbocharger
conditions should be checked.
Turbocharger speed can provide an indication of the condition or degree of contamination
of the rotating elements within the turbocharger. Contamination can result from normal
carbon buildup or from recirculation of exhaust gases or crankcase blow by through the
turbocharger.
If necessary, the turbocharger should be cleaned as outlined by the manufacturer's
instructions. (This cleaning should also be performed according to the Maintenance
Schedule of Section 3.)

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 SECTION ２ - OPERATING INSTRUCTION
2.6 INSPECTION AND CARE OF
ENGINE DURING NORMAL OPERATING ２－６－０５

- Cylinder pressures - Combustion pressures should be checked every 500 hours as

outlined in the Maintenance Section, or whenever erratic performance is encountered.
Pressures should not vary from the shipping test values more that 0.49MPa in either
the full-load or idle condition.
Low pressure within a cylinder is usually the result of a malfunctioning injector.
The valve should be removed and bench-checked as outlined in the Maintenance
section.

- Operate the emergency stop device every month and confirm that it operates normally.
If air leaks from the piping, fittings, or flexible hose to the air cylinder, the emergency
stop device may not be able to stop the engine. If an air leak is found during the
inspection, take measures to stop the leak.

Engine operation to avoid the critical torsional vibration:

You should operate the engine to avoid immediately the barred speed range written on
torsional vibration calculation sheets.
 SECTION ２ - OPERATING INSTRUCTION
2.7 CHART OF NORMAL OPERATING
PRESSURES AND TEMPERATURES ２－７－０１

2.7 CHART OF NORMAL OPERATING PRESSURES AND TEMPERATURES

CAUTION
The values below can be used for reference values representative of normal
operating conditions at rated speed and load.

variable engine speed constant engine speed

Fuel System – (rated speed)
- Pressure at fuel injection pump inlet
Standard value A oil 0.05～0.15 MPa 0.05～0.15 MPa
C oil ≦ 180mm2/s 0.25～0.35 MPa 0.25～0.35 MPa
C oil ≦ 380mm2/s 0.45～0.55 MPa 0.45～0.55 MPa

Minimum value 0.05 MPa 0.05 MPa

Lubricating Oil System –(rated speed)

- Pressure at engine inlet
Standard value 0.35～0.60 MPa 0.50～0.60 MPa
Minimum value (alarm) 0.20 MPa 0.45 MPa
- Temperature at engine inlet
Standard value 60-70 ℃ 60-70 ℃
Maximum value (alarm) 75 ℃ 75 ℃
Maximum value (trip) 80 ℃ 80 ℃

Coolant
- Temperature at engine outlet (high temperature circuit)
Standard value 80-90 ℃ 80-90 ℃
Maximum value (alarm) 95 ℃ 95 ℃
Maximum value (trip) 100 ℃ 100 ℃
- Pressure at pump discharge port (rated engine speed)
Low temperature circuit 0.03～0.20 MPa 0.15～0.20 MPa
High temperature circuit 0.28～0.36 MPa 0.28～0.36 MPa

CAUTION
However, the shipping test records provide a more accurate comparison and
should always be cross-checked in the event a problem is suspected.

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 SECTION ２ - OPERATING INSTRUCTION
2.8 PREPARATION OF ENGINE EXTENDED
SHUTDOWN ２－８－０１

2.8 PREPARATION OF ENGINE FOR EXTENDED SHUTDOWN

If the engine is to be shut down for more that 2 weeks, certain precautions should be
taken to prevent damage caused by rust and/or corrosion.

1. For shutdown periods of 2 weeks to 3 months:

- Cover the exhaust opening if necessary to prevent the entrance of moisture.
- Every two weeks, start the lube oil priming pump and rotate the engine for 3-4
revolutions. Stop the rotation at a different crank position than original so that the
pistons are stopped at different positions each time.
- Clean the outside surfaces of the engine and protect any unpainted surfaces with
grease or corrosion inhibitor.

2. For shutdown periods longer than 3 months:

- Follow the procedures for a Normal Shutdown listed in Section 2.3.
- Lube oil system
- Completely drain the lube oil system, including the crankcase, filters, lines, etc.
- It is recommended that the system be filled with a special protective lubricating
oil (consult oil manufacturer). This oil may be a blend with normal lube oil.
It can be circulated throughout the engine by using the lube oil priming pump.
- Every six months, protective oil should be sprayed on the internal engine parts
through the inspection doors.
- Once every six months, silica gel (at least 100 grams for a six cylinder engine
or 140 grams for an eight cylinder engine) should be placed in the crankcase
a moisture adsorbent.
- Lube oil inlet and outlet ports and the crankcase breather pipe should be
plugged if they are to be disconnected.

- Cylinder head area

Spray protective lube oil on the rocker arms and valve mechanisms at the time
of shutdown.

- Outside surface of engine

Apply an anti-corrosive coating to all unpainted surfaces.

- Cooling system
- Completely drain the cooling water from the engine and all coolers, pumps,
pipes, etc.
- Seal all inlet and outlet ports.

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 SECTION ２ - OPERATING INSTRUCTION
2.8 PREPARATION OF ENGINE EXTENDED
SHUTDOWN ２－８－０２

- Starting air systems

- If the engine is to be disconnected from the starting air reservoir, make certain
that the inlet and outlet ports are sealed to prevent dirt and moisture from entering
the system.

- Intake and exhaust systems

- Place silica gel in the intake air duct and seal the duct as required to keep out
about 60-80 grams of dirt and moisture. Make certain that a conspicuous tag is
attached so that the seal and gel will be removed before the engine is put back
into service.
- Seal the turbocharger air inlet.
- Seal the exhaust pipe.

- Accessories
- Seal the inlet and outlet ports of the starting air reservoir if the lines are
disconnected.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION ２ - OPERATING INSTRUCTION
2.9 CARE OF LOW LOAD OPERATION
２－９－０１

2.9 CARE OF LOW LOAD OPERATION

In supercharged engines for improvement of thermal efficiency, valve overlap,

which means the timing both exhaust and intake valves are opening, is prepared.
But in low load operation, the supercharger does not work fully for too few
exhaust gas. The change air pressure, is lower than the exhaust gas pressure.
so the exhaust gas turns back to the combustion chamber.
Therefore imperfect combustion increases and carbon depositsin a combustion
chamber. Otherwise combustion pressure is useful for oil control of piston rings.
The liner contact pressure is increased by the back pressure of rings.
But in low load operation, this function does not work usefully, so oil rises to
the combustion chamber. This carbon deposits also in the chamber.
These deposit tend to occur ring stick or piston scuffing Therefore the load rate
of diesel engine with supercharger should be more than 30%, and after
operating at no load or low load, you should to operated at more than 50% load
for removing the carbon deposit by high temperature and high gas volume.
For the engines operated continuously, air heater cooler or central cooling or
etc. are considered for improvement of low load combustion.
But for the emergency, the combustion improvement is scarcely considered on
the situation. so,it is the most important that the maintenance and inspection
are carried out following the schedule.

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 SECTION ３ - MAINTENANCE
CONTENTS

SECTION ３ - MAINTENANCE

3.1 GENERAL

3.2 CLEARANCE AND WEAR TABLE

3.3 TABLE OF TORQUE VALVES

3.4 TABLE OF COMPONENT WEIGHT

3.5 MAINTENANCE AND INSPECTION SCHEDULES

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION ３ - MAINTENANCE
3.1 G E N E R A L
３－１－０１

3.1 GENERAL
3.1.1 Introduction
This manual is intended to the operation and maintenance departments,
containing the instructions necessary for maintaining the engines.
However, the content is shown as standard, practical maintenance varies by
application of engine, fuel oil to used, etc.. Therefore, maintenance
method of each plant should be amended according to the actual results.

Caution :

CAUTION
Be sure to put on safety goggles in carrying out the following items of work being
in danger of injury to eyes.
・ When handling fuel oil, lubricating oil, cooling water and inhibitor,
and anti-freeze solution
・In course of washing work
・In course of fuel injection valve injection test
・When handling battery electrolyte
・In course of grinding work
・In course of intake/exhaust valve grinding work

There is a danger of injury to your hands during the work inside the engine room
and enclosure.
Be sure to put on gloves for the protection of your hands except for the case of
special work.

There is a danger of your body being pinched by the doors of enclosure and engine
room that are designed to be readily closed by the difference in atmosphere
between the inside and outside.
Take precautions so that your body will not be pinched.
(1) Carry out the periodic maintenance according to settled schedule.
However, if abnormality is detected when running, carry out・
trouble-shooting and counter-measure as soon as possible.
(2) Criterion of parts which is repaired or exchanged is identified follows.
LA ＝ Limit beyond which the part dimension may reach LR prior to the next
routine inspection.
LR ＝ Limit beyond which the use of the part is hazardous rework or immediate・
rejection.
MO ＝ Theoretical dimension on the drawing.
(3) Grasp the number of parts in stock usually. Prepare the necessary parts
before next periodical maintenance.
(4) In order to prepare the emergency, arrange the tools for disassemble and reassemble.

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 SECTION ３ - MAINTENANCE
3.1 G E N E R A L
３－１－０２

3.1.2 Definition and technical term

(1) Position of observer for defining the rotational direction and identifying
the cylinders.
Fig. Position of observer

(2) Rotation direction

The observer denotes the two rotational directions of the crankshaft of the
engine as "clockwise" and "counter-clockwise" as following figure.

Fig Rotation direction

(3) Identification of the cylinder

Identification of the cylinder is described 1,2,3 ・・・, and of the bank is
described A,B ・・.
a) In line type engine
The cylinder 1 is the first cylinder located the nearest by the observer
as following. (see T.G.O.S. ［Timing Gear Opposite Side ］)

Fig. Identification of the cylinder of in-line type engine

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 SECTION ３ - MAINTENANCE
3.1 G E N E R A L
３－１－０３

b) Vee type engine

The bank A is nearest on the left of the observer. Identification of the
cylinder is combination of the bank and of the number as following.

Fig. Identification of the cylinder of Vee type engine

C) Identification of main bearing
The main bearing 1 is first one located the nearest by the observer.

3.1.3 General Comments

WARNING
The engine may start abruptly without notice through the auto start signal or by
remote starting. As there is a danger of entanglement etc., do not gain access to
rotating parts and moving parts.
There is a possible danger of physical accidents that may be caused when the
engine is started by mistake during the inspection and repair of the air-started
engine.
Be sure to carry out the following items to prevent the erroneous start of the
engine.
・Close the main valve of starting air-tank outlet.
・ Release the residual pressure remaining Inside the starting air pipeline.
(Between the starting air tank to the engine)
CAUTION
Be sure to put on safety goggles in carrying out the following items of work being
in danger of injury to eyes.
・When handling fuel oil, lubricating oil, cooling water and inhibitor, and
anti-freeze solution
・In course of washing work
・In course of fuel injection valve injection test
・When handling battery electrolyte
・In course of grinding work
・In course of intake/exhaust valve grinding work
There is a danger of injury to your hands during the work inside the engine room
and enclosure.
Be sure to put on gloves for the protection of your hands except for the case of
special work.
- Cleanliness is important during repair work, both for the success of the repairs and
the safety of the personnel doing the work. Clean up all, fuel, and coolant spills.
Do not permit oil, fuel, or other debris to accumulate on or near the engine.

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 SECTION ３ - MAINTENANCE
3.1 G E N E R A L
３－１－０４

- Repair any fuel, oil, or coolant leak as soon as it is noticed.

- Clean all parts carefully before they are reinstalled. Cover parts that
will not be reassembled immediately.
- Always use the correct bolts and fasteners during repairs. Bolts that are
too long can "bottom-out" and will not provide the required clamping forces.
Bolts that are too short may not have enough thread engagement to carry the load.
- Use the proper torque values. (Refer to the Torque Tables in Section 3.3).
Improper tightening can result in bolt loosening or bolt failure.
- Use the proper tools when making repairs to avoid damage to parts. Special
tools are provided for several major repairs and are described in the
appropriate sections of this manual.
- Reinstall all exhaust manifold and turbocharger heat shields before running
the engine to reduce fire hazard.
- After major engine repairs, be certain to run the lubricating oil priming
pump for several minutes before attempting to start the engine. Starting
without the necessary lubrication to critical parts can cause extensive
damage very quickly.

3.1.4 Safety
- Install all guards and protective shields before starting the engine. If
the engine must be started when the shields are removed, use extreme care
and make sure all personnel are clear. Reinstall the shields when the work is completed.
- Make certain that all personnel are clear before starting the engine.
- Disable or disconnect the engine starting device before making repairs to
the engine to prevent the chance of accidental starting or starting from a
remote location.
- Use proper lifting procedures when handling major components to avoid damage
and possible injury. Consult the Weight Table in Section 3.4. Make certain
that all chains, hoists, slings, and jacks are in good condition and of the
correct capacity.
- Eye bolts should be stressed in the vertical direction only-do not side-load them.
- Do not store flammable or hazardous materials near the engine.
- Always keep fire extinguisher in highly visible areas and insure that
regular inspections are made to keep them charged.

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 SECTION ３ - MAINTENANCE
3.1 G E N E R A L
３－１－０５

- When using corrosion inhibitors in the cooling system, avoid contact with
eyes or prolonged contact with the skin (the inhibitors contain alkali). In
case of contact, immediately wash the skin with soap and water. If the
inhibitor gets into the eyes, flush with water for at least 15 minutes and
contact a physician.
- Use proper blocking to support heavy components while they are being worked
on. Do not rely on jacks or hoists to support the work.
- Wear protective glasses and safety shoes when working. Do not wear loose
fitting or torn clothing that could become entangled in rotating equipment.
- Use caution when removing lines, plugs, or caps from compartments that may
be pressurized. Bleed the pressure and hold a rag over the opening to avoid
being sprayed with pressurized fluid. Special care is required when the
engine is hot.
- Do not remove the crankcase covers for 15 minutes after an emergency
shutdown. Explosive vapors may be present. Avoid sparks or flames in the
immediate area when removing the covers.
- Dispose of oily rags in a safe manner - do not leave rags near the engine.
- Provide safe disposal of waste oil, fuel and coolant.

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.
 SECTION ３ - MAINTENANCE
3.2 CLEARANCE AND WEAR TABLE
３－２－０１

3.2 CLEARANCE AND WEAR TABLE

3.2.1 Clearance and wear table

MO ：Theoretical dimension on the drawings.

LA ：Limit beyond which the part dimension may reach LR prior to the
next routine inspection.
LR ：Limit beyond which the use of the part is hazardous rework or
immediate rejection.

NOTE
1. A component reaching LA limit may be used on.
2. A component more worn than LA may be safely used on but not for a time
sufficient to reach the next inspection time.
< A component beyond LA limit recommend to repair or replace >
3. A component reached LR limit must be repaired or replaced immediately.
4. Oversize (crank shaft, piston ring groove)
M1：1st stage oversize
M2：2nd stage oversize
5. In case of measured with the thickness gauge ,actual dimensions are
following.
Actual dimension = measured dimension + 0.01～0.02 mm

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０２

The hereafter given values are in metric mm

NO Description MO LA LR Sketch, Remarks

1 Fuel injection valve － 33.0 MPa － － Adjust with injection test pump
opening pressure

2 Crankshaft main Replace when the copper-lead coating is

visible on more than 1/3 of the bearing
bearing D1 － －
+0.22 surface.
・Inner diameter 210 +0.16
・Clearance C 0.16～0.25 0.35 －
(Crank shaft-bearing）

3 Thrust bearing C 0.31～0.49 0.6 0.8 No.1 bearing

clearance

clearance
4 Crankshaft
0
・Crankpin diameter A 195 -0.029 194.87 －

・Crankjournal 0
diameter B 210 -0.029 209.87 －

・Maximum Amax － 0.04 －

out-of-straitness -Amin

Bmax － 0.04 －
-Bmin

・Maximum Dmax － 0.10 －

out-of-roundness -Dmin

・Cam wear φd2 － 0.010 0.015

- d1

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０３

NO Description MO LA LR Sketch/Remarks
・Crankshaft undersize
measurements
194.75 0
Crankpin M1 － -0.03 － －
194.5 0
M2 － -0.03 － －
209.75 0
Crankjournal M1 － -0.03 － －
209.5 0
M2 － -0.03 － －
5 Crank deflection The deflection measurements should be
made when the engine is cold (Refer to
・dv Section 4.7)
－
Each slows dv ±0.04 ±0.07

Flywheel side slow dV － +0.07 －

-0.14
・dn dn ±0.01 ±0.02 －

6 Cylinder liner
+0.04
・Bore diameter D 260.0 0 260.5 260.8

measurement point (mm)

A B C D
60 250 455 570
・Maximum out-of- Dmax- 0.02 0.2 0.4
roundness
Dmin

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０４

NO Description MO LA LR Sketch/Remarks
7 Piston
・Clearance between A 16 ±0.7 － －
top of piston and
top of liner flange
・Ring groove C
clearance
1st compression ring 0.18～0.22 0.35 0.4
2nd compression ring 0.09～0.13 0.25 0.3
3rd compression ring 0.07～0.11 0.25 0.3
oil ring 0.03～0.07 0.25 0.3
・Ring width B
-0.01
1st compression ring 5 -0.03 － －
-0.01
2nd compression ring 5 -0.03 － －
-0.01
3rd compression ring 5 -0.03 － －
-0.01
oil ring 8 -0.03 － －
・Groove height E
+0.19
1st compression ring 5 +0.17 － －
+0.10
2nd compression ring 5 +0.08 － －
+0.08
3rd compression ring 5 +0.06 － －
+0.04
oil ring 8 +0.02 － －
Over size of the
grooves M1
+0.19
1st compression ring 5.5 +0.17 － －
+0.10
2nd compression ring 5.5 +0.08 － －

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０５

NO Description MO LA LR Sketch, Remarks

・Ring Thickness T
+0.15
1st compression ring 8.5-0.15 － －
+0.15
2nd compression ring 9.0-0.15 － －
+0.15
3rd compression ring 9.0-0.15 － －
+0.15
oil ring 5.5 -0.15 － －

1st compression ring a 1.4 ～ 1.7

2nd compression ring 1.0 ～ 1.3 3.5 4

3rd compression ring 1.1 ～ 1.3 3.5 4

oil ring 0.8 ～ 1.1 － －

Over size of the

grooves M2
+0.19
1st compression ring 6 +0.17 － －
+0.10
2nd compression ring 6 +0.08 － －
+0.06
・Piston pin bore dia- D 105 +0.04 105.07 105.08
meter

+0.02
8 Piston pin diameter D 105 -0.04 104.93 104.91
 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０６

NO Description MO LA LR Sketch/Remarks
9 Connecting rod

・Maximum out-of-
round of big end bore
B+C
OV=A- OV － ±0.05 －
2

0.14～0.22 0.35 －
・Bearing clearance
(big end) Replacement when the copper lead is
visible on more than 1/3 of the bearing
+0.19 friction surface.
・Bearing inner 195 +0.14 － － Overlay is occurred partial damage by
diameter the ”hydraulic action.
(big end) But the copper lead is not visible, may be
used on.
+0.13
・Piston pin bushing d2 105 +0.09 － －
inner diameter
・Piston pin to D2-d2 0.11～0.17 0.3 －
bushing clearance

10 Cam shaft
+0.16
・Bushing inner diameter D 142 +0.10 － －
-0.04
・Cam shaft diameter d 142 -0.08 － －
・Bearing clearance C 0.14～0.24 0.4 －

・ End-play 0.2～0.4 0.7 1.0

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０７

NO Description MO LA LR Sketch/Remarks
11 Gear train backlash

Crank gear－Gear＊idle 1 0.30～0.46 0.6 0.8 Refer to Sketch

Gear＊idle 1－Cam gear 0.26～0.39 0.6 0.8
Cam gear－Gear＊governor 0.28～0.42 0.6 0.8
Gear＊idle 1－Idle gear＊CWP 0.18～0.30 0.5 0.7
Idle gear＊CWP－Gear＊CWP 0.16～0.29 0.5 0.7
Crank gear－Gear idle 2 0.36～0.48 0.6 0.8
Gear idle 2－Idle gear＊LOP 0.24～0.32 0.5 0.7
Idle gear＊LOP－Gear＊SWP 0.16～0.29 0.5 0.7
Idle gear＊LOP－Gear＊LOP 0.20～0.35 0.5 0.7

Screw gear＊governor 0.14～0.48 0.6 0.8 Circumferential backlash

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０８

NO Description MO LA LR Sketch/Remarks
12 Starting air distributor
・Angular clearance
C 0.03～0.06 － 0.5

13 Valve gear
+0.03
・Tappet bore diameter D1 50 0 － －
-0.01
・Tappet shaft d1 50 -0.03 － －
diameter
・Clearance D1-d1 +0.01～ 0.10 －
(Tappet-Shaft) +0.05
+0.10
・Roller bushing bore d2 25 +0.08 － －
diameter
+0.03
・Roller pin diameter d2 25 +0.02 － －
・Clearance D2-d2 +0.05～ 0.16 －
(Roller pin-Bush) +0.08
+0.07
・Roller inner diameter D3 36 +0.05 － －
-0.02
・Roller bushing outer d3 36 -0.05 － －
diameter
・Clearance D3-d3 +0.07～ 0.24 －
(Roller-Bush) +0.12
・Longitudinal cleara- C +0.50～ － －
nce +0.70
(Roller-Tappet)

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－０９

NO Description MO LA LR Sketch/Remarks
14 Cylinder head
・Tappet clearance of C1 0.5 － －
the intake valve
・Tappet clearance of C2 0.5 － －
the exhaust valve
+0.08
・Rocker arm bushing D1 55 +0.02 － －
inner diameter
-0.03
・Rocker arm shaft d1 55 -0.05 － －
diameter
・Clearance D1-d1 0.13～0.17 0.2 －
(Shaft-Bush)
+0.02
，CROSSHEAD bore D2 26 0 － －
diameter
-0.02
・Crosshead guide d2 26 -0.03 － －
outer diameter
・Clearance D2-d2 0.02～0.05 0.1 －
(cross headguide to
bore)
15 Intake & Exhaust valve
-0.06
・IV stem diameter d1 18 -0.08 17.80 17.65
+0.02
・IV guide bore diame- D1 18 0 18.25 18.40
ter
・Clearance D1-d1 0.06～0.10 0.45 0.75
(IV-Guide)
-0.06
・EV stem diameter d2 18 -0.10 17.80 17.65
+0.02
・EV guide bore D2 18 0 18.25 18.40
diameter
・Clearance D2-d2 0.08～0.12 0.45 0.75
(EV-Guide)
・Intake valve head T1 7 6 5.5
thickness
・Exhaust valve head T2 5 4 3.5
thickness

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 S E C T I O N ３ - M A I N T E N A N C E
3.2 CLEARANCE AND WEAR TABLE
３－２－１０

NO Description MO LA LR Sketch/Remarks
16 Lubricating oil pump
+0.05
・Bushing bore D1 45 0 － －
diameter
-0.05
・Gear shaft diameter d1 45 -0.08 － －

・Clearance D1-d1 0.05～0.13 0.2 －

(shaft-Bushing)

17 Water pump
・Clearance C 0.15～0.30 0.6 －
(Impeller-Liner
ring)

18 Damper
・Dimension T +0.05
(Metal-side case) 0.1 0 0.05 －

19 Fuel injection pump

Roller guide
+0.02
・Roller bore diameter D1 36 0.01 － －
-0.03
・Bushing outer d1 36 -0.04 － －
diameter
・Clearance D1-d1 0.04～0.06 0.1 －
(Roller-Bushing)
+0.05
・Bushing inner D2 30 +0.04 － －
diameter
-0.01
・Roller pin diameter d2 30 -0.02 － －
・Clearance D2-d2 0.04～0.07 0.12 －
(Bushing-Roller pin)

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 SECTION ３ - MAINTENANCE
3.3 TABLE TORQUE OF VALUES
３－３－０１

3.3 TABLE OF TORQUE VALUES

CAUTION
There is a danger of your hands and legs being pinched by weighty parts or
disassembling tool during overhaul inspection of the engine.
Take precautions in handling such parts and tools.
There is a danger of injury to your hands during the work inside the engine room
and enclosure.
Be sure to put on gloves for the protection of your hands except for the case of
special work.
3.3.1 General
Tighten the main parts according to the tightening table for main parts
positively. (refer to section 3.3.3)
Full care must be taken at the time of tightening, paying full consideration to the following.
(1) Clean the threads and seat surface of bolts and nuts fully and confirm that
they are not damaged. For it, screw them with hand up to the seat.
(2) Coat the lubricant described in section 3.3.3 on the threads and seat
surface, and tighten the main parts.
(3) In order to tighten uniformly, formal tightening must not be suddenly but
through the following 3 steps.

Pre-tightening → Intermediate tightening → Formal tightening

3.3.2 Tightening method

(1) Tightening operated by manual
Nut or bolt is rotated by force (F) that affect the length of lever (L) as
follows. F×L is shown tightening torque, indicated by N･m.
Torque = F × L N･m

F : force of arm L : length of lever(m)

(245～294 N)
There are two method to control of the torque.
- Control by torque wrench
- Angle of rotation after pre-tightening
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 SECTION ３ - MAINTENANCE
3.3 TABLE TORQUE OF VALUES
３－３－０２

a) Control by torque wrench

Assure the condition of screw which is not damaged or rusted.
Apply the lubricant described in section 3.3.3 (or equivalents),and then
tighten using torque wrench properly.
Rickety screw or insufficient tightening is dangerous as same as excessive
tightening.

b) Angle of rotation from pre-tightening

This operation is applied for important parts (crankpin bolts, etc.)
At the first stage, tighten the bolt by initial torque using torque
wrench. And second stage, tighten more to determined angle. These
initial torque and angle of second stage are described in section 3.3.3.
Inspection of the angle is as follows.
- If the angle is a multiple of 30°: Countermark are stamped on screws or nuts directly.
- Others : Stamp the countermark on spanner or socket.
c) Countermark
Countermark of bolts and nuts are those at the time of manufacture. For
the reasons of elongation of screw and adaptability of touch adjusting
surface of nuts, usually they are clamped more than the position of
countermark when clamped with a specified torque. Accordingly, the
countermark cannot be used forever as reference ones. Therefore, in the
case of re-tightening, countermark must be again stamped.

(2) Tightening by hydraulic tools

Main bearing stud bolts and cylinder-head stud bolts are tightened by
special hydraulic tools. This operation realize proper and forceful
tightening. Details of this operation (disassemble and reassemble) is
described in section 4.

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 SECTION 3- MAINTENANCE
3.4 TABLE OF COMPONENT WEIGHT
３－４－０１

3.4 TABLE OF COMPONENT WEIGHT

Component weights are shown as following table.
Weight of this table is mean value. If weight is varied by its specification, max. weight is shown.

CAUTION
When lift the heavy part, use sufficiently powerful device. (chain block, hoist, etc.)
When handling a weighty article exceeding 20kg in weight, use a crane or hoist,
or allow two persons or more to engage in the handling work. (In the case of
joint work also, the weight should be limited to less than 20kg per person.)

Main parts weight table (unit:: kg)

No Parts Number Weight Remarks
1 Oil pan ass'y 1 232
2 Main bearing cap 1 47
3 Main bearing cap 6 47
4 Crankshaft ass'y 1 1465 With balance weights
5 Flywheel 1 371 With bolts
6 Cylinder block 1 5040 With stud bolts and bearings
7 Cylinder liner 6 101
8 Camshaft ass'y 1 170 With drive gear
9 Piston ass'y 6 49 With piston pin and rings
10 Connecting rod ass'y 6 67
11 Starting air distributor ass'y 1 12
12 Idle gear ass'y 1 70 No1 idle gear
13 Cover, cylinder block T.G.S 1 52 Timing gear side
14 Cover, camshaft drive gear 1 46
15 Cover, LOP driving gear 1 47
16 Cover, CWP driving gear 1 44
17 Flyer cover T.G.S. 1 31 Timing gear side
18 Flyer cover T.G.O.S 1 42 Timing gear opposite side
19 Roller follower＊I/E valve driving 6 10
With I/E valve, starting valve,
20 Cylinder head ass'y 6 210
safety valve, indicator cock, etc.
21 Fuel inj. pump a'ssy 6 26
22 Intake air manifold duct 6 12
23 Exhaust manifold 1 203
24 Turbo charger 1 410 TPS 57D
25 Air cooler 1 340
26 Lub. oil pump 1 55
27 Cooling water pump (high temp.) 1 58 With driving gear
28 Cooling water pump (low temp.) 1 52 With driving gear

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０１

3.5 MAINTENANCE AND INSPECTION SCHEDULE

The content of this section shows generally, however, practical maintenance
should be varied by application of engine, fuel oil, load, etc..
Establish the optimum maintenance schedule which is considered the conditions
of each plant based on this inspection manual.

DANGER

Check the lifting rope and lifting devices. Never stand right under the lifted heavy
parts. Only qualified person will use the crane.

WARNING
In cases of fuel leakage from equipment and pipelines of fuel oil line and lubricating
oil line, there is a danger of fire hazard.
Conduct inspection at all times to avoid causing bolts looseness, gasket
deterioration, and equipment and pipeline cracking.

There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
There is a danger of injuries being caused by contra rotation of crankshaft if turning
is carried out without opening the indicator cock or explosion check plug. Be sure to
open the indicator cock or explosion check plug when carrying out turning.

There is a danger of your hands being pinched by the gear and cam roller of the
engine. Never insert your hands in the course of turning.

Any negligence of controlling cooling water, lubricating oil, and fuel oil, and
controlling the clamping in reassembly after overhaul inspection may lead to fault of
the engine and result in physical accidents due to failure of parts.
Unfailing control should be conducted on the basis of instruction manual or
specifications.

The engine may start abruptly without notice through the auto start signal or by
remote starting. As there is a danger of entanglement etc., do not gain access to
rotating parts and moving parts.

There is a possible danger of physical accidents that may be caused when the
engine is started by mistake during the inspection and repair of the air-started
engine.
Be sure to carry out the following items to prevent the erroneous start of the engine.
・Close the main valve of starting air-tank outlet.
・Release the residual pressure remaining Inside the starting air pipeline.
(Between the starting air tank to the engine)

CAUTION

The rust-preventive agent, inhibitor and anti-freeze for use with cooling water line are
poisonous to the human body.
Handle them carefully so that they will not come into eyes or come in contact with
the body.

There is a danger of your hands and legs being pinched by weighty parts or
disassembling tool during overhaul inspection of the engine.
Take precautions in handling such parts and tools.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０２

When disassembling the spring section during the course of overhaul inspection,
parts are caused to jump out due to disengagement of disassembly tools.
Thus, there is a danger of injuries.
Familiarize yourselves with the construction of component and use tools properly.
Also give care full attention to the jumping direction of parts so that the body will be
kept away from the jumping direction.

When using hydraulic tools or when conducting the fuel injection valve injection test,
high- pressure fluid will gush out, leading to the danger of injuries.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the skin,
then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
Apply hydraulic pressure only after making sure that joints are securely connected.

Be sure to put on safety goggles in carrying out the following items of work being in
danger of injury to eyes.
・When handling fuel oil, lubricating oil, cooling water and inhibitor, and
anti-freeze solution
・In course of washing work
・In course of fuel injection valve injection test
・When handling battery electrolyte
・In course of grinding work
・In course of intake/exhaust valve grinding Work

There is a danger of injury to your hands during the work inside the engine room and
enclosure.
Be sure to put on gloves for the protection of your hands except for the case of
special work.

3.5.1 Caution
- Carry out the periodical maintenance according to settled schedule, except emergency.
- If abnormality is detected when running, carry out trouble-shooting and counter-measure
as soon as possible. Do not restart without appropriate counter-measure.
- Before disassemble, assure the countermark on required parts. (If necessary stamp the
countermark renewal)
- Countermark of bolts and nuts are those at the time of manufacture.
Therefore, tighten with properly torque (indicated torque, angle or hydraulic pressure).
- Replace the special parts which is determined by running hours.
If abnormality of these parts are neglected, serious accident will occur.
- Replace O-rings, washers, gaskets, split pins etc. when every disassembling.
- Grasp the number of parts in stock usually. If necessary, prepare the parts before next
periodic maintenance.
- Apply anti-corrosives for spare parts in stock.
- In order to prepare the emergency, arrange the tools for disassembling and reassembling.
- Carry out sufficient flushing after overhaul.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０３

3.5.2 Periodical inspection and overhaul

- N, A1, A2, B, C inspection requires only few disassembling of parts,
therefore, inspection can be carried out by operators and a term in normal stopping.
- D, E, F inspection requires many disassembling parts and special operation,
therefore, the period of engine stopping is required. If possible, it is recommended to
prepare the spare parts which is inspected and repaired. And exchange it by assembly.

Inspection When Operated continuously When operated rarely

for a long time
S Check if required Check if required
N Every day Once per week
A1 Every 100 hours
Every 1～3 months
A2 Every 500 hours
B Every 1250 hours or every 3 months Every 6 months～every year
C Every 2500 hours or every 6 months Every 2～3 years

D Every 5000 hours or every year

Every 4～5 years
E Every 15000 hours or every 3 years
F Every 25000 hours or every 5 years Every 8～10 years
G Every 50000 hours or every 10 years Every 15～20 years
- The engine running periods given as intervals between maintenance operations practically
depend upon engine availability and therefore may vary by ±20. For instance, the D
inspection is 5000 hours operation which can take place 4000～6000 hours depending both
on the engine yearly running duration and the time at which the engine can be conveniently
stopped.
- They are defined for a 90% M.C.R. continuous engine operation, and defined for using
light fuel oil, if it is not provided.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０４

- The rare operating means the emergent engine which operating hours are less than 100 in a
year. The emergent engine is rarely run usually, but if necessary has to display the of ability
the equipment fully and certainly. Accordingly, maintenance and inspection have to be carried
out certainly, considering the yearly ageing of rubber ring, the corrosion and rust of water line
and air line the lubricating oil ageing, and the stain and corrosion of exhaust gas line for
imperfect combustion by low load, more than considering mechanical wear. The standard
maintenance items are shown at above by operating years. but for the property of the
emergency, the inspection of fuel injection valve, starting air valve, starting air distributor and
filter nseed to be carried out every year for safety.

● Inspection S
Following inspection have to carried out before normal inspection (except daily inspection),
disassembling and overhaul. Record the result of following inspection on log book.

S1 - Inspection before stopping

No Maintenance work reference

S1-01 Check pressure of lub. oil, cooling water, starting air etc.
S1-02 Check if mist of crankcase is normal
S1-03 Check leakage of lub. oil, cooling water, air, exhaust gas
S1-04 Check leakage from drain port of cooling water pump
S1-05 Collect the sample of lub. oil to analysis

S2 - At the occasion of stopping of the engine

No Maintenance work reference

S2-01 Check the turbo charger for abnormal noise
S2-02 Check if the lub. oil pressure drop safety device and alarm
properly operate

S3 - When the engine has completely stopped

No Maintenance work reference

S3-01 Collect the sample of high temperature cooling water
to analysis

Note) It follows the manual of TURBO CARGER for the handling of TURBO CHARGER.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０５

● Inspection N
Interval : Daily
No Maintenance work reference
N -01 Lubricating oil system
- Oil level check on oil sump.
- Check function of self cleaning filter.(if equipped)
- Read temperature and pressure of lub. oil at engine inlet.
- Read pressure of turbo charger lub. oil.(in case external
oil supply)
- Check oil level of turbo charger.(for NHP type T.C.)
N -02 Fuel oil system
- Level check on fuel tank.
- Read pressure drop at fuel filter.
- Drain from fuel filter.
N -03 Cooling water system
- Level check on high temperature water tank.
- Level check on low temperature water tank.(if necessary)
- Read pressure of high temperature water.
- Check leak from cooling water pump.
N -04 Starting air system
- Check pressure of air reservoir.
- Drain water from air reservoir.
- Check grease on starting air distributor.
N -05 General inspection
- Check any leak.
- Check tightening of bolts and nuts.
- Check any abnormal noise.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０６

● Inspection A1
Interval : 100 hours
No Maintenance work reference
A1-01 Lub. oil and cooling water analysis
・Lub. oil
- Check aspect, water content.
- Check TBN level by spot test.
・High temperature cooling water
- Analyze and re-adjust inhibitor concentration.
A1-02 Lub. oil filter Manual of
- Overhaul filter when pressure difference exceeds 2times of lub. oil
normal value and check metal particles in the sludge. filter
Fuel oil filter
- Remove Sludge from filter and check any abnormality.
- Overhaul filter when pressure difference exceeds 2times of
normal value.
A1-03 Clean centrifuge filter (if equipped)
- Overhaul rotor ass'y.
- Remove sludge and check any metal particles.
A1-04 General inspection of the engine
- Check any leak from joints, sealings.
- Check tightening of bolts, nuts and pins on fuel linkage, lay shaft.
- Check tightening of bolts and nuts on pipe joints.
- Check tightening of engine fixing bolts.(at first
maintenance A1, and D afterwards)
A1-05 Turbo charger Manual of
- Check tightening of bolts and nuts at first 100hours. T/C
- Clean suction sponge filter at every 250hours.(no need to
stop engine)
- Turbine washing at every 250hours.(on heavy fuel
operation,no need to stop engine)
A1-06 Crank shaft deflection measurement (at first 100h and
maintenance C afterwards)

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０７

● Inspection A2 Interval : 500 hours

No Maintenance work reference
A2-01 Note engine performance data at nominal output and compare with Shipping
shipping test records test
- fuel handle pointer. record
- Max. combustion pressure.
- Charge air temperature at air cooler inlet and outlet.
- Exhaust gas temperature.
- Charge air pressure.
- Temperature and pressure of cooling water and lub. oil.
A2-02 Sample lub. oil for analysis
A2-03 Turbo charger
Section
- Compressor washing. (no need to stop engine)
1.3
A2-04 Fuel injection valve
- Injection test by means of test pump. (at first 500hours and maintenance
B afterwards)
A2-05 Fuel control lay shaft, governor linkage
- Check smooth function.
A2-06 Emergency stop device
- Check to operate normally every month.

● Inspection B Interval : 1,250 hours

No Maintenance work reference
B -01 Lub. oil
- Renewal, in case wet sump or dry sump less than 0.6 ℓ /PS.
- In case dry sump more than 0.6 ℓ /PS, measures should be taken
according to the lub. oil analysis.
B -02 Fuel injection valve
- Injection test by means of test pump.
- Replace gasket.
B -03 Crank case
- Check water condensation in the crank case, any corrosion on the
crankcase wall.
B -04 Rocker gear
- Check valve spring.
- Tightening rocker arm support.
- Measure and adjust tappet clearance at cold condition.
 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０８

● Inspection C
Interval : 2,500 hours
No Maintenance work reference
C -01 Cylinder head (heavy fuel operation)
- Check intake and exhaust valve/valve seat and recondition.
- Clean deposit on combustion surface.
- Measure valve guide wear and check any hard mark.
C -02 Crank shaft deflection measurement
C -03 Cam shaft
- Cam and roller inspection through inspection doors.
C -04 Renewal governor oil
C -05 Flexible coupling (if equipped)
- Check tightening.
C -06 Engine fixing bolts
- Check tightening.
C -07 Fuel injection pump
- Verify smooth function of fuel control rack.
C -08 Over speed trip (if equipped)
- At idling in warm condition, verify the function of
over speed trip.(at no load or clutch-off)
C -09 Starting air distributor
- Visual inspection.
C -10 Air motor (if equipped) Manual of
- Check pinion. air motor
C -11 Turbo charger Manual of
- Clean air filter elements. T/C
C -12 Coolers (sea water cooling)
- Check zinc bar on
・Fresh water cooler
・Lub. oil cooler
・Air cooler

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－０９

● Inspection D
Interval : 5,000 hours
No Maintenance work reference
D -01 Cylinder head (MDO operation)
- Check intake and exhaust valve/valve seat, and recondition.
- Clean deposit on combustion surface.
- Measure valve guide wear and check any hard mark.
D -02 Piston
- Clean piston and inspect visually.
- Measure ring groove clearance.
- Visual check on piston ring.
- Measure diameter of piston pin.
D -03 Cylinder linear
- Check inner surface.
- Measure bore diameter and make deglazing.
D -04 Connecting rod inspection
- Crank pin bolts
- Piston pin bush
- Big end bearing
D -05 Crankshaft and main bearing (at first 6000hours)
- Inspection on central main bearing cap and bearing shell.
- Check crank journal at central bearing and all crankpins.
D -06 Inspection timing gears
D -07 Starting air system
- Overhaul starting air distributor.
- Overhaul starting air valve.
D -08 Thermostatic valve element inspection
D -09 Measurement tools
- Calibration.
D -10 Turbo charger Manual of
- Overhaul. T/C
- Measure clearance.
- Replace bearing.(NHP type)
D -11 Air cooler
- Clean air and cooling water side.
D -12 Fuel injection pump overhaul
- Check deflector and replace if necessary.
- Replace delivery valve spring, ball retainer and ball valve.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１０

No Maintenance work reference

D -13 Governor driving
- Gear inspection.
D -14 Inspection and cleaning of filters Manual of
D -15 Flexible coupling (if equipped) geislinger
- Inspection of inside of coupling at first 6000hours. coupling
D -16 Fuel feed pump
- Replace oil seal and gaskets.
D -17 Cooling Water pump
- Replace mechanical seal and oil seal.
- Replace ball bearings.
- Check pinion.

● Inspection E
Interval :15,000 hours
No Maintenance work reference
E -01 Cylinder head
- Replace all gaskets.
- Remachine intake/exhaust valve and valve seat.
Replace if necessary.
- Replace valve rotator.(if equipped)
- Replace cotter on intake and exhaust valve.
- Measure clearance rocker arm and rocker arm shaft.
E -02 Piston
- Replace piston rings.
- Check piston ring grooves.
E -03 Cylinder liner
- Check inside of cylinder liner. Re-horning by means of
special tool is recommended.
- Remove liner and check scaling on water jacket side ; on
any 2 cylinders at first maintenance E.
E -04 Gear train
- Measure back lash.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１１

No Maintenance work reference

E -05 Fuel injection union
- Check seat and inner surface of drilled hole at extremity.
- Replace O-rings.
E -06 Fuel injection pump
- Replace delivery valve.
- Check plunger spring.
E -07 Overhaul of flexible coupling (if equipped)
E -08 Cleaning of lub. oil sump tank, if necessary
E -09 Overhaul governor at specialized shop Manual of
governor
E -10 Overhaul self cleaning filter, especially self cleaning Manual of
device (if equipped) filter
E -11 Centrifuge filter (if equipped) Manual of
- Overhaul and cleaning. filter
- Replace bearing and jet nozzle if necessary.
E -12 Overhaul torsional vibration damper (if equipped) Manual of
damper
E -13 Cooling water and lub. oil cooler
- Overhaul and clean inside of tubes.
- Replace O-rings and gaskets.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１２

● Inspection F
Interval : 25,000 hours
No Maintenance work reference
F -01 Crankshaft
- Overhaul all main bearing cap.
- Visual inspection of crank journal.
- Measure crank pin diameter. Check the shaft cam wear.
- Replace main bearing.(every 18,000-24,000hours)
F -02 Camshaft
- Remove camshaft.
- Visual inspection on cam and bearing.
- Visual inspection on camshaft bearing shell.
F -03 Crankcase
- Check inside and outside of crankcase.
F -04 Gear train
- Overhaul all gears.
- Check cracks on the gears by dye penetration test.
- Replace bearings.
F -05 Connecting rod
- Replace piston pin bush and big end bearing.
- Replace crank pin bolts at every 20,000-25,000 hours even
if no abnormality is found.
-Measure the big end innercircle.
F -06 Cylinder liner
- Remove cylinder liner.
- Clean and replace O-rings.
- Dye penetration test on upper flange for cracks.
F -07 Cylinder head
- Replace rocker arm bushings.
- Replace valve springs.
- Replace intake and exhaust valve guides.
- Replace o-ring of outer of fuel injection valve at every
15,000-25,000 hours even.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１３

No Maintenance work reference

F -08 Valve gear
- Overhaul tappet and shaft.
F -09 Fuel injection pump
- Pump overhauling at specialized shop.
- Replace plunger ass'y.
F -10 Governor driving device
- Check gears.
- Measure backlash.
- Replace oil seals.
- Replace ball bearings.
F -11 Fuel feed pump
- Replace coupling.
- replace ball bearings.
F -12 Lub. oil pump
- Overhaul.
- Replace bushings and O-rings.
F -13 Exhaust manifold
- Replace expansion joints.
F -14 Torsional vibration damper (if equipped).
- Replace springs and bearings.

● Inspection G
Interval : 50,000 hours
No Maintenance work reference
G-1 Replace piston.
G-2 Replace cylinder liner.
G-3 Replace camshaft bearing.

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１４

3.5.3 Maintenance schedule

Maintenance schedule is shown in the next tables. Symbols of the tables
indicate as follows.

Symbol Description
○ Operation carried out by skillful operator
● Operation carried out by a service man
□ Operation carried out by two service men and a assistant
■ Operation carried out by three service men
＊ Operation carried out by specialized shop

Maintenance (hours)
１ ２ ３ ５ ７ １ １ １ １ １ １ ２ ２ ２ ２ ２
Maintenance work ２ ５ ７ ０ ５ ０ ２ ５ ６ ７ ８ ０ １ ２ ３ ５
and inspection part ５ ０ ５ ０ ０ ０ ５ ０ ２ ５ ７ ０ ２ ５ ７ ０
No ０ ０ ０ ０ ０ ０ ０ ０ ５ ０ ５ ０ ５ ０ ５ ０
０ ０ ０ ０ ０ ０ ０ ０ ０ ０ ０

Lub. oil system N -01 Daily（○）

daily inspection

Fuel oil system N -02 Daily（○）

daily inspection

Cooling water system N -03 Daily（○）

daily inspection

Starting air system N -04 Daily（○）

daily inspection

General inspection N -05 Daily（○）

｜ ｜
A1-04 Every 100 hours （○）

Lub. oil and cooling A2-02 Every 100 hours （○）

water analysis
Emergency stop
device A2-06 Monthly （○）
monthly inspection
 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１５

Maintenance (hours)
１ ２ ３ ５ ７ １ １ １ １ １ １ ２ ２ ２ ２ ２
Maintenance work ２ ５ ７ ０ ５ ０ ２ ５ ６ ７ ８ ０ １ ２ ３ ５
and inspection part ５ ０ ５ ０ ０ ０ ５ ０ ２ ５ ７ ０ ２ ５ ７ ０
No ０ ０ ０ ０ ０ ０ ０ ０ ５ ０ ５ ０ ５ ０ ５ ０
０ ０ ０ ０ ０ ０ ０ ０ ０ ０ ０

Collect lub. oil A2-01 Every 500 hours （＊）

sample for analysis

Check engine A2-01 Every 100 hours （○）

performance data

Renewal of lub. oil B -01 □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □

Crank case B -03 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

F -03 ●

Crank shaft and A1-06 At first 100 hours only （□）

main bearing C -02 □ □ □ □ □ □ □ □

D -05 ■

F -01 ■

Cam shaft C -03 □ □ □ □ □ □ □ □

F -02 ●

Gear train D -06 ● ● ● ●

E -04 ■ ■

F -04 ■

Connecting rod D -04 ■ ■ ■ ■

F -05 ■

Piston D -02 ■ ■ ■ ■

E -02 ■ ■

Cylinder liner D -03 ● ● ● ●

E -03 ■ ■
F -06 ■

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１６

Maintenance (hours)
１ ２ ３ ５ ７ １ １ １ １ １ １ ２ ２ ２ ２ ２
Maintenance work ２ ５ ７ ０ ５ ０ ２ ５ ６ ７ ８ ０ １ ２ ３ ５
and inspection part ５ ０ ５ ０ ０ ０ ５ ０ ２ ５ ７ ０ ２ ５ ７ ０
No ０ ０ ０ ０ ０ ０ ０ ０ ５ ０ ５ ０ ５ ０ ５ ０
０ ０ ０ ０ ０ ０ ０ ０ ０ ０ ０
Valve gear F-08 ●
Cylinder head,intake B-04 □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □
and exhaust valve C-01 ■ ■ ■ ■ ■ ■ ■ ■
(heavy fuel operation) E-01 ■ ■
F-07 ■
Cylinder head, intake B-04 □ □ □ □ □ □ □ □ □ □ □ □ □ □ □ □
and exhaust valve D-01 ■ ■ ■ ■
(MDO operation) E-01 ■ ■
F-07 ■
Starting air distributor C-09 ● ● ● ● ● ● ● ●
and starting air valve D-07 ● ● ● ●

Fuel injection valve A2-04 At first 500 hours only （●）

B-02 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Fuel injection pump C-07 ● ● ● ● ● ● ● ●
D-12 ● ● ● ●
E-06 ● ●
F-09 ＊
Fuel injection union E-05 ● ●
Governor and driving C-04 ● ● ● ● ● ● ● ●
device D-13 ● ● ● ●
F-10 ●
E-09 ＊ ＊

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１７

Maintenance (hours)
１ ２ ３ ５ ７ １ １ １ １ １ １ ２ ２ ２ ２ ２
Maintenance work ２ ５ ７ ０ ５ ０ ２ ５ ６ ７ ８ ０ １ ２ ３ ５
and inspection part
５ ０ ５ ０ ０ ０ ５ ０ ２ ５ ７ ０ ２ ５ ７ ０
No
０ ０ ０ ０ ０ ０ ０ ０ ５ ０ ５ ０ ５ ０ ５ ０
０ ０ ０ ０ ０ ０ ０ ０ ０ ０ ０
Over speed trip C -08 □ □ □ □ □ □ □ □
Lub. oil pump F -12 □
Cooling water pump D -17 ● ● ● ●
Fuel feed pump D -16 ● ● ● ●

and driving device F -11 ●

Exhaust manifold F -13 ●

Turbo charger A1-05 Every 100 hours （○）

( Refer to the A2-03 Every 500 hours （○）

manual of turbo
charger ) C -11 □ □ □ □ □ □ □ □

D -10 ● ● ● ●
Air cooler C -12 ● ● ● ● ● ● ● ●

D -11 ● ● ● ●
Torsional vibration E -12 □ □

damper F -14 ●
Flexible coupling C -05 □ □ □ □ □ □ □ □

D -15 □ （At first 6000 hours only）

E -07 □ □
D -08 ● ● ● ●
Thermostatic valve

Filters N -02 Daily（○）

A1-02 Every 100 hours （●）

D -14 ● ● ● ●
Self cleaning filter E -10 ● ●

Centrifuge filter A1-03 Every 100 hours （●）

E -11 ● ●
Lub. oil cooler and C -12 ● ● ● ● ● ● ● ●

cooling water cooler E -13 ● ●

Lub. oil sump tank E -08 ● ●
Engine fixing bolt C -06 ● ● ● ● ● ● ● ●
Measurement tools D -09 ● ● ● ●
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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１８

3.5.4 Maintenance schedule of the engine which running about 8000 hours every year

Maintenance schedule of main parts are shown in the following tables.

They are defined for using light fuel oil, therefore, establish the optimum

maintenance schedule considering the condition of each plant.

Mark ○ : Maintenance should be carried out

year 1 year 2 years 3 years 4 years 5 years

running hour

Maintenance work ×1000 4 8 12 16 20 24 28 32 36 40

Check and reconditioning intake/
exhaust valve and valve seat ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Check and replace fuel injection valve ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Inspection and cleaning filters ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Overhaul turbo charger and
replace ball bearing ○ ○ ○ ○ ○
Overhaul and inspection piston
(replace piston rings) ○ ○ ○ ○ ○
Overhaul fuel injection pump, replace
deflector and delivery valve spring ○ ○ ○ ○ ○
Overhaul cooling water pump,
replace oil-seal, mechanical seal ○ ○ ○ ○ ○
O-ring and ball bearing
Replace cotter of intake and
exhaust valve ○ ○
Replace valve rotator ○ ○
Replace plunger ass'y and delivery
valve ass'y of fuel inj. pump ○ ○
Replace intake/exhaust valve
and valve seat ○ ○
Replace intake and exhaust valve ○ ○
guide
Replace thermostatic valve element ○ ○
Replace snap-ring of piston pin fitting ○ ○
Overhaul governor at specialized
shop (invalve GV motor) ○ ○ ○ ○
Inspection governor drive gear
and replace ball bearing ○ ○

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 SECTION ３ - MAINTENANCE
3.5 MAINTENANCE AND INSPECTION SCHEDULE
３－５－１９

year 1 year 2 years 3 years 4 years 5 years

running hour

Maintenance work ×1000 4 8 12 16 20 24 28 32 36 40

Replace crank-pin bolt of ○
connecting rod
Replace big-end bearing shell ○ ○
Replace expansion joint of ○ ○
exhaust manifold
Inspection torsional vibration damper ○ ○
Overhaul lub. oil pump, ○
replace bushing and O-ring
Replace ball bearing of idle gear shaft ○
Replace intake and exhaust valve ○
spring
Replace main bearing shell ○
Replace thrust collar of crank case ○
Overhaul and inspection safety ○ ○
valve of cylinder head
Remove and inspection cylinder liner ○
Overhaul coolers ○ ○ ○ ○ ○
Replace casing of turbo charger ○
Replace fuel injector and ○
fuel inlet pipe(union)
Overhaul compressor ○ ○ ○ ○ ○
Inspection Air starting ○ ○ ○ ○ ○
valve , Distributor
Inspection Cam metal ○
Reconditioning Crank shaft cam wear ○ ○
Replace Piston pin metal ○
Inspection Valve gear roller ○ ○ ○ ○ ○
Replace Ball bearing and Ball joint ○
for fuel control linkage
Replace fuel cam roller and Bush ○
Inspection fuel feed pump ○
Check the rod big end inner circle ○ ○

Note) It follows the manual of TURBO CARGER for the handling of TURBO CHARGER.

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 SECTION ４- DISASSEMBLY AND REASSEMBLY
CONTENTS

SECTION 4 - DISASSEMBLY AND REASSEMBLY

4.1 CYLINDER HEAD AND VALVE MECHANISM

4.2 PISTON AND CONNECTING ROD

4.3 CYLINDER LINER

4.4 FUEL INJECTION VALVE AND FUEL INJECTION PUMP

4.5 GOVERNER DRIVE AND FUEL CONTROL LINKAGE

4.6 CRANKCASE ASSEMBLY

4.7 CRANKSHAFT

4.8 CAMSHAFT AND TIMING GEAR TRAIN

4.9 STARTING AIR DISTRIBTOR

4.10 COOLING AND LUBRICATING OIL PUMP

4.11 TORSIONAL VIBRATION DAMPER

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1CYLINDER HEAD AND VALVE MECHANISM

４－１－０１

DANGER

Check the lifting rope and lifting devices. Never stand right under the lifted heavy
parts. Only qualified person will use the crane.

WARNING

Any negligence of controlling cooling water, lubricating oil, and fuel oil, and
controlling the clamping in reassembly after overhaul inspection may lead to fault
of the engine and result in physical accidents due to failure of parts.
Unfailing control should be conducted on the basis of instruction manual or
specifications.

CAUTION

There is a danger of your hands and legs being pinched by weighty parts or
disassembling tool during overhaul inspection of the engine.
Take precautions in handling such parts and tools.

When disassembling the spring section during the course of overhaul inspection,
parts are caused to jump out due to disengagement of disassembly tools.
Thus, there is a danger of injuries.
Familiarize yourselves with the construction of component and use tools properly.
Also give care full attention to the jumping direction of parts so that the body will
be kept away from the jumping direction.
When using hydraulic tools or when conducting the fuel injection valve injection
test, high- pressure fluid will gush out , leading to the danger of injuries.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the
skin, then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
Apply hydraulic pressure only after making sure that joints are securely connected.

Be sure to put on safety goggles in carrying out the following items of work being
in danger of injury to eyes.
・When handling fuel oil, lubricating oil, cooling water and inhibitor, and
anti- freeze solution
・In course of washing work
・In course of fuel injection valve injection test
・When handling battery electrolyte
・In course of grinding work
・In course of intake/exhaust valve grinding work
There is a danger of injury to your hands during the work inside the engine room
and enclosure.
Be sure to put on gloves for the protection of your hands except for the case of
special work.

There is a danger of entanglement in the course of grinding, turning and drilling

work.
Do not put on any gloves.

When handling chemical solution such as inhibitor, battery electrolyte, etc., there is
a danger of injuries to your eyes or skins being contaminated with chemicals
solution.
In cases of contamination, wash your eyes or skins thoroughly with water or soapy
water and consult a physician immediately.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1CYLINDER HEAD AND VALVE MECHANISM

４－１－０２

4.1 CYLINDER HEAD AND VALVE MECHANISM

4.1.1 Tappet adjustment:
(see Maintenance and inspection Schedule in Section 3.5 for adjusting frequency)
procedure:
・ Tappets should be adjusted with a cold engine. Remove the cylinder head cover.
・ Rotate the engine to top dead center (TDC) on the combustion stroke for the
piston being checked.

WARNING

There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
There is a danger of injuries being caused by contra rotation of crankshaft if
turning is carried out without opening the indicator cock or explosion check
plug. Be sure to open the indicator cock or explosion check plug when carrying
out turning.
・ Both the intake and exhaust valve stems should be tight against the
crosshead ①. If not, adjust the push-screw ② to zero clearance and
tighten the lock-nut ③.
・ Measure and adjust the clearance between the rocker arm ⑥ and the
crosshead ① with a feeler gage. The correct clearance is 0.50 mm for both
the intake and exhaust valves. The 0.50 mm gage should slip between the two
surfaces, a 0.55 mm gage should not. The clearance is adjusted by turning
screw ④. Once the correct clearance has been obtained, tighten the
lock-nut ⑤ while holding the screw to prevent it from turning.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1CYLINDER HEAD AND VALVE MECHANISM

４－１－０３

4.1.2 Cylinder head removal

CAUTION

There is a danger of your hands and legs being pinched by weighty parts or
disassembling tool during overhaul inspection of the engine.
Take precautions in handling such parts and tools.
・ Drain the coolant from the engine down to the level of the water pump.
・ Remove the cylinder head cover.
・ Disconnect the fuel injection lines from the head.
・ Remove the nuts holding the rocker arm support and rocker arms to the
cylinder head ⑦.
・ Remove the push rod ⑧.
・ Remove the cylinder head nuts by using the hydraulic jack device, as
follows:
- Fit spacers (A1), removal studs (A5), and jacks (A3,A4) over two
diagonally opposite cylinder head studs.
- Connect the lines from the jack (A12) to the hydraulic pump.
-Open the valve of the hydraulic pump to drain the jacks. Then loosen the
nuts by 1/4 turn.
- Close the drain valve of the hydraulic pump and begin pumping until the
pressure of tightening table. At that point, the cylinder head nuts can
be loosened by using the special turning rod (A11). Each nut should be
loosened one turn.
- Bleed pressure from the jacks slowly using the pump drain valve. Remove
the spacers, removal studs, and jacks and finish removing the cylinder
head stud nuts by hand
- Loosen the remaining two stud nuts in the same manner.
Reinstallation of the stud nuts is the reverse of removal:
- Tighten the nuts finger-tight on the studs.
- Install the hydraulic jack hardware and drain the jacks as outlined above.
- Raise pressure to the specified value of tightening table. ・
- Using the tightening rod, tighten the cylinder head stud nuts hand-tight.
- Remove pressure from the jacks.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1CYLINDER HEAD AND VALVE MECHANISM

４－１－０４

Disassembly of the Cylinder Head

Once the cylinder head stud nuts have been removed, the inlet and exhaust
manifolds can be disconnected and the heads remover by using a suitable sling
and eye-bolts. The cylinder liners should be covered to protect against the
entry of dirt.

DANGER

Check the lifting rope and lifting devices. Never stand right under the lifted
heavy parts. Only qualified person will use the crane.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1 CYLINDER HEAD AND VALVE MECHANISM

４－１－０５

4.1.3 Valve Removal and Inspection

CAUTION
When disassembling the spring section during the course of overhaul inspection,
parts are caused to jump out due to disengagement of disassembly tools.
Thus, there is a danger of injuries. Familiarize yourselves with the construction of
component and use tools properly. Also give care full attention to the jumping
direction of parts so that the body will be kept away from the jumping direction.
- Place the cylinder head on a flat surface so that the bottom of the valves
are supported (to prevent them from falling when the springs are removed).
- Install the retainer removal tool. Tighten the nut ① enough to compress
the valve springs and remove the keepers from the valve retainers. Remove
the tool, remove the retainers, and position the cylinder head on its side
to remove the valves.
- Mark the valves with the cylinder number and position (intake or exhaust)
so that they can be reinstalled in the same position.
- Clean the valves carefully with a non-metallic scraper, mild steel wool, or
a descaling agent. Avoid scratching the valve surfaces.

- The valve stems must be free from scratches or scuff marks and the valve
faces must not be cracked or pitted. Check the contact between the valve
face and the valve seat by coating the valve seat with Prussian Blue (or
equivalent) and reinstalling the valve (do not rotate the valve). A full
360 degrees contact line should appear approximately centered on the valve
face. If not, the valves should be reface (instructions below) or new
valves installed. Measure the stem diameters (Refer to Clearance and Wear
Tables) and install new valves if the maximum wear limits are exceeded.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1 CYLINDER HEAD AND VALVE MECHANISM

４－１－０６

4.1.4 Valve Seat Inserts - Inspection

Inspect the valve seats for wear, pitting, cracking or incorrect seat angle.
If suitable for reuse, the seat may be reface (instructions below). If
damage is too extensive to repair, new inserts should be installed.
4.1.5 Valve and Insert Reconditioning
The correct face angle for the intake valves is 120 degrees minus 0, plus 1/4
degree. The angle for the exhaust valves is 90 degrees, minus 0, plus 15'.
Valve head thickness should not be less than the minimum values shown in the
Clearance and Wear Charts.
The correct face angle for the valve seat inserts is 120 degrees for the
intake valve seats and 90 degrees for the exhaust valve seats. Insert
grinding should be limited to a light, clean-up trueing - the depth should be
as small as possible. After grinding, a new valve should be used to check
contact pattern with Prussian Blue (as outlined above). If new inserts are
necessary, make certain that the bore is clean and that the seat is pressed
completely to the bottom of its bore. Contact pattern should be rechecked
after the new inserts are installed.
4.1.6 Valve Guides - Inspection
Clean the valve guide bores with a soft brush or solvent to remove all gum and
carbon deposits. Inspect the guides for cracks, chipping, scoring, or
excessive wear. Measure the valve guide bores and replace and that exceed the
wear limits listed in the Clearance and Wear Charts.
4.1.7 Valve Springs - Inspection
Clean the valve springs with fuel oil or other suitable solvent and dry with
compressed air. Do not use any cleaning tool that might scrach or nick the
springs. Replace any springs that are pitted or cracked.
4.1.8 Valve Crosshead and Crosshead Guide - Inspection
Measure the bore in the pusher and the diameter of the pusher guide. Replace
any parts that exceed the wear limits shown in the Clearance and Wear Charts.
4.1.9 Cylinder head installation
- Install new gaskets and seals for each of the components that has been
removed. Install a new cylinder head gasket, and carefully lower the head
down onto the gasket. Tighten cylinder head stud nuts as outlined above
under 'Cylinder Head Removal'.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.1 CYLINDER HEAD AND VALVE MECHANISM

４－１－０７

4.1.10 Valve Push Rods and Tappets

CAUTION

There is a danger of your hands being pinched by the gear and cam roller of
the engine.
Never insert your hands in the course of turning.
A visual inspection of the camshaft and cam rollers can be made by removing
the camshaft inspection covers. if any damage is visible, disassemble the
parts as follows:
Remove the rocker arm support ① and rocker arms. Remove the push rods ②.
Loosen the bolts ③ that secure the tappet arm shaft ⑤ and remove the
tappet arms and shaft.
Any bent push rods should be replaced and a careful check should be made to
determine the cause of the bending. Likely cause are engine overspeeding,
a valve seizure, or a frozen rocker arm.
Inspect the ends of the push rods for damage - light pitting is normal and
will not affect operation.
The tappet rollers and roller bushings should be measured and replaced if
clearances exceed the maximum values shown in the Clearance and Wear Table.
The rollers should be replaced if any pitting is apparent on the camshaft
contact surface.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

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４－１－０８

4.1.11 Starting Air Valves

The starting air valves (if equipped) are used only with the air-over-piston
starting arrangement. The valves are mounted on the cylinder head and
supplied with sequenced blasts of pressurized air that essentially "motor" the
engine until combustion occurs. The sequenced air is supplied by a camshaft
driven distributor mounted externally at the rear of the camshaft.
If starting air valves are not used (in the case of air-motor starting), the
openings in the cylinder head are plugged.
To remove the starting valves, disconnect the air line to the valve, remove
bolts ①, and lift the valve from the cylinder head. To disassemble the
valve, remove the cover ②.

CAUTOIN

When disassembling the spring section during the course of overhaul

inspection, parts are caused to jump out due to disengagement of
disassembly tools.
Thus, there is a danger of injuries.
Familiarize yourselves with the construction of component and use tools
properly. Also give care full attention to the jumping direction of parts so that
the body will be kept away from the jumping direction.
Inspect the valve and valve body ③ and ④ for
damage or scratches. If necessary, lap the surfaces to insure smoothness.
Coat the valve and the valve bore in the body with oil, and reassemble using a
new copper gasket underneath the cover. Torque the bolts ① to fixed torque
(Refer Tightening Torque Table).

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.2 PISTON AND CONNECTING ROD

４－２－０１

4.2 PISTON AND CONNECTING ROD

The pistons are one-piece nodular iron pistons with three compression rings and
two oil-control rings each. The connecting rod is a two-piece assembly with an
angled serrated joint for the rod bearing cap. Each rod bearing cap is
connected to the shank of the rod by four bolts. The angled joint provides
enough clearance to permit removing the rod upward through the cylinder liner.
The piston pin is secured by snap rings at both ends.
Tools required for servicing
The following special tools are provided for working on the piston and
connecting rod assemblies:
- Socket and wrench for tightening the rod cap bolts
- Hanger for lifting the piston and rod assembly
- Piston ring compressor

4.2.1 Piston and Rod Assembly Removal

-Remove the cylinder head (Refer to Section 4.1) and remove the crankcase
inspection cover for the cylinder involved.
-Turn the crankshaft manually until the piston is slightly below the top dead center position.
-Fill the gap between the top of the piston and the cylinder liner with grease (to prevent debris
from dropping into the gap) and clean the carbon ridge from the top of the cylinder liner.
- To remove the rod bearing cap, rotate the crankshaft until the rod bearing
journal is about 30 degrees from top dead center on the camshaft side of the engine.

WARNING
There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
There is a danger of injuries being caused by contra rotation of crankshaft if
turning is carried out without opening the indicator cock or explosion check plug.
Be sure to open the indicator cock or explosion check plug when carrying out
turning.
-Clean the lifting bolt hole in the top of the piston, screw in a lifting
eye, and support the piston with a hoist or other device to prevent the
piston from falling when the rod bearing cap is removed.
-Loosen the connecting rod cap bolts using the special tools provided. Do
not turn the crankshaft from this point on - if the connecting rod separates
from the crankshaft journal, the piston and rod assembly could fall and result in injury.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.2 PISTON AND CONNECTING ROD

４－２－０２

- Remove the upper bearing shell from the connecting rod.

- Wrap the big end of the rod with shop towels or other cloth to prevent
scratching the liner as the piston and rod assembly is removed.
- Pull the piston and rod assembly from the bore. The force should be in a
straight line parallel to the bore in the cylinder liner to prevent cocking
of the piston in the liner. Care must also be taken to avoid damaging the
cylinder head studs.
- Place the assembly on a flat surface with the piston head down so that the
piston pin and rod can be removed.
- Remove one of the piston pin snap rings and push out the pin - do not push
on the center plug of the pin.
- Remove the connecting rod.
4.2.2 Inspection of Parts
Piston
- Visually inspect the chrome plating on the top ring. If chipping or peeling
is apparent, the ring should be replaced.
- Inspect the oil control rings and replace any that show damage.
- The rings should move freely in the ring grooves. If a buildup of carbon or
gum is visible in the bottoms of the grooves, the rings should be removed
and the grooves cleaned with a suitable solvent.
- Clean and remove carbon deposits from the piston with fuel oil and dry with
compressed air. If fuel oil does not remove the carbon deposits, use an
approved chemical solvent - do not wire brush or use a metal scraper.
Note: Extensive carbon buildup or excessively worn piston skirts, liners,
or rings may be an indication of improper maintenance, poor lubricating oil
quality, poor fuel oil quality, or unusual operating conditions (long
periods of operation at idle speed, or overheating). The cause should be
determined and corrected to prevent recurrence of the problem.
- Using a dye penetrant, check the piston head area and pin bore area for
cracking. Install a new piston if any cracks are apparent.
- Using a new ring, measure the top two ring groove clearances at four points
90 degrees apart around the circumference of the piston. If the maximum
wear limit is exceeded (Clearance and Wear Chart), recondition the grooves
to one of the available oversizes (Clearance and Wear Chart) and install
corresponding thicker (oversize) rings.
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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.2 PISTON AND CONNECTING ROD

４－２－０３

Connecting Rod
- Clean the rod assembly and blow compressed air through the oil ports to
insure they are open. Do not remove the piston pin bushing unless
measurements (discussed later) indicate that it should be replaced.
- Inspect the connecting rod bearing shell. Slight scratching of the lead-tin
overlay is normal and not detrimental. However, if the underlying
copperlead surface is visible for more than 1/3 of the bearing area, or if
deep scratches or grooving is apparent, a new bearing should be installed.
- Measure the rod bearing bore diameter and roundness by installing the
bearing cap and tightening the cap bolts with the bearing shells removed.
The procedure and limits are shown in Section 3.2.
- Check the serrated joint between the rod shank and the bearing cap using
Prussian Blue or equivalent. Each face should contact over 80 % of its area.
- If the crankshaft has been reground, there are two options for oversize
bearings, as shown in Section 3.2.

Connecting Rod Bolts

- The connecting rod bolts should be replaced at or before the 24000 hour
inspection, as outlined in the Maintenance Schedules. If they are removed
before that time for other work, they should be closely inspected for
pitting, cracking, or other signs of distress (a dye penetrant is test
recommended for crack determination). If any problems at all are noted, 
new bolts should be installed.

Piston pin/pin bushing

- Measure the piston pin diameter and the bushing bore diameter as outlined
in the Wear and Clearance Chart. Replace any part that exceeds the maximum
wear limit. If a new bushing must be installed, make certain that the oil
hole is aligned with the mating hole in the rod shank. Recheck the bushing
inner diameter after it is installed to make certain that it is within the
'new' spec range as outlined in the Clearance Chart.

4.2.3 Reassembly
- Install rings on piston. Arrange the ring gaps as shown below insure they
are staggered.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.2 PISTON AND CONNECTING ROD

４－２－０４

- When installing new piston rings (or reinstalling the original rings),
install the rings from the bottom up - that is, the two oil rings first,
then the two compression rings, then the top ring. Be careful not to
overstretch the rings, as this could cause cracking. Make certain that the
rings are installed with the correct side up (one side will be marked).
- Assemble the rod, piston, piston pin, and pin retainer rings - the pin
should slide freely into the bore without forcing.
- Coat the crankshaft journal, the rod bearing, and the cylinder liner with oil.
Note: do not lubricate the backsides of the bearing shells - they should be
clean and dry when assembled.
- Rotate the crankshaft journal (if it has been moved since the piston and rod
assembly were removed) so that the rod journal is about 30 degrees from top
dead center toward the camshaft side of the engine.

WARNING
There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
There is a danger of injuries being caused by contra rotation of crankshaft if
turning is carried out without opening the indicator cock or explosion check plug.
Be sure to open the indicator cock or explosion check plug when carrying out
turning.
- Install the piston ring compressor sleeve (part of special tools provided),
lift the piston and rod assembly with a suitable hoist, then lower the
assembly carefully into the liner. Each piston is stamped with an "A/A"
that should face the intake valve side of the cylinder head. It should be
pushed or tapped gently to avoid breaking the rings. Install the upper half
of the rod bearing (has drilled oil passage) into the rod shank and
carefully guide the rod over the crankshaft journal as it is being lowered
into place. The correct positioning of the rod depends upon the normal

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.2 PISTON AND CONNECTING ROD

４－２－０５

direction of engine rotation, as shown by the arrows. (The direction of

rotation is viewed from the flywheel end of the engine.)
- Install the lower half of the bearing shell in the rod cap, install the rod
cap, coat the rod cap bolts with Molykote or similar lubricant, and loosely
install the bolts. Make certain that the cylinder number stamped on the rod
cap and on each cap retaining bolt matches the number on the rod shank. The
individual bolts are also stamped with a number so they can be replaced in
their original locations. If new bolts have been installed, they should be
stamped accordingly.
- Tighten the rod cap bolts in the sequence. Tightening should be done in two
steps, as shown in the Tightening Torque Table, Section 3.3.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.2 PISTON AND CONNECTING ROD

４－２－０６

- If it is necessary to install new rod cap bolts, (either because of damage

or scheduled maintenance), the new bolts should first be installed and
torqued in the rod assembly without the bearings installed. Coat the
threads with Molykote or similar lubricant, tighten to the specified value
minus 10 degrees, loosen and repeat the procedure one more time. Then
install the cap with the new bolts, and tighten to the final torque spec
shown in Section 3.3. Stamp the bolts with a mark aligning with the mark on
the rod cap and also stamp with the cylinder number and bolt location
(position 1.4). Finally install the bearings and tighten to the mark.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.3 CYLINDER LINER

４－３－０１

4.3 CYLINDER LINERS

4.3.1 Description
The cylinder liners are cast iron, replaceable, wet (water-cooled) liners. As
shown below, a flange at the top of each liner rests on top of the engine
block. The liners are clamped in place when the cylinder heads are bolted to
the block.
A sealing compound is used between the liner flange and the top surface of the
block. O-ring seals ③ are used on the OD of the liner to seal the water
passages in the block.

4.3.2 Visual Inspection

- After removing the cylinder head and the piston, visually inspect the
cylinder liner bore.
- If deep scratches or surface galling is apparent on the surface of the bore,
a new liner should be installed.
- Deglazing the Liner
- If the liner is to be reused, carefully check the surface of the bore in the
ring travel area. If the surface is very highly polished and no
circumferential "tool marks" are visible under a strong light, deglazing may
be required. Deglazing forms microscopic oil grooves in the liner surface
to retain an oil film and improve lubrication.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.3 CYLINDER LINER

４－３－０２

Procedure:

CAUTION

Be sure to put on safety goggles in carrying out the following items of work
being in danger of injury to eyes.
- If the liners are not to be removed, they can be deglazed in place, either
by hand or by a honing machine. If done by hand, a fine (No 40) emery paper
should be used, and sanding should be in a circumferential direction, NOT in
an up-and-down direction.
- Close the bottom of the liner with plastic or similar material to prevent
abrasive material from falling into the crankshaft and sump areas while
sanding.

4.3.3 Measurement of Liner Bore

- After deglazing, measure the liner bore using a dial indicator or
micrometer. Measuring points are described in the Clearance and Wear Table.
If the measured values exceed the maximum wear limits, the liner must be
replaced.
- If the out-of-roundness of any liner exceeds 0.2 mm, check for the
following:
・ Improper seating between the liner flange and the top surface of the
block.
・ Improper installation of the o-ring seals at the bottom of the liner.
・ Excessive liner wear (if out-of-roundness still exceeds 0.2 mm after
checking the above, a new liner should be installed.
- Removal and Reassembly of Cylinder Liner

4.3.4 Removal
- Install the liner puller as shown below
- Tighten nut ① to force the liner up and out of the block.
- Extract the liner using a hoist or other device.
- Mark the cylinder number on the liner. If the liners are to be re-used,
they must always be reinstalled in their original positions.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.3 CYLINDER LINER

４－３－０３

4.3.5 Inspection of liner after removal from engine block

Scale Deposits in coolant area
-If scale formation on the OD of the liner exceeds 0.5 mm, it should be
removed by wire brushing. In addition, when the engine is put back into
service, a descaling agent should be added to the cooling system to remove
scale from the rest of the system. DO NOT use acid solutions for descaling.
Dye Penetration Test
- Cylinder liner flanges should be checked for cracking by using a dye
penetrant. A new liner should be installed if any cracks are found. Make
sure that the liners are clean before using the dry penetrant, otherwise
false indications could occur.

4.3.6 Reassembly
- Paint SDC 402 COAT or equivalent anti-rust epoxy paint on the jacket side
surfaces of liner.
- Install new liner o-rings.
-Coat the upper and lower bores in the block with a silicon compound.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.3 CYLINDER LINER

４－３－０４

- Coat "THREE BOND 1107" or equivalent on the bottom surface of the liner
flange.
- Reinstall the liners using the proper tools as shown below.
- Make sure that the liner is firmly seated against the top surface of the
block.
- Recheck the bore diameter and roundness at the O-ring location to insure
that the o-rings have properly seated.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY
4.4 FUEL INJECTION VALVES AND FUEL INJECTION
PUMPS ４－４－０１

4.4 FUEL INJECTION VALVE AND FUEL INJECTION PUMP

4.4.1 Injection valve

WARNING

There is a danger of injuries caused if high-pressure oil droplets come in direct

contact with your skins when conducting the injection test of fuel injection pump.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the
skin, then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
CAUTION

When using hydraulic tools or when conducting the fuel injection valve injection
test, high- pressure fluid will gush out , leading to the danger of injuries.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the
skin, then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
Apply hydraulic pressure only after making sure that joints are securely connected.
Be sure to put on safety goggles in carrying out the following items of work being
in danger of injury to eyes.
・When handling fuel oil
・In course of fuel injection valve injection test
Each fuel injection valve consists of a forged steel body, an injection
nozzle, and an injector pressure regulating mechanism. The diameter, number
of spray holes, and angle of the holes in the nozzle are selected to provide
optimum performance for the particular rating being used. For those
applications where heavy fuel is used, the nozzles are water-cooled to reduce
the rate of carbon buildup on the tips.
The injection valves should be checked every 1500 hours for spray pattern,・
leakage, and opening pressure. Procedures are give below.
Special tools supplied
Tools are supplied for removing the injector valves,cleaning the nozzle tips,
and for pressure/leakage testing of the valves.
Injection valve Removal
- Remove the fuel inlet pipe ①.
- Remove the injection valve retainer ②.
- Install the puller (Tool “A”) and lift injector from its bore.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY
4.4 FUEL INJECTION VALVES AND FUEL INJECTION
PUMPS ４－４－０２

Checking injection valve performance

- Insert the fuel injection valve into the sleeve (F) that was provided with the special tools.
- Connect the calibration pump (C) to the injection valve with the test line
(D) that was supplied with the special tools.
- Actuate the pump with several short strokes to bleed the air from the lines
and valve. (Make certain that only clean, filtered fuel is used for the testing).
- Once the air has been bled from the system, the valve opening pressure can
be checked. Increase the pressure to 27.0 MPa - the nozzle should
remain dry valve should not open). Increase the pressure further to
30.0 MPa release the lever and observe the time required for pressure to leak down.
If the pressure drops below 13.0 MPa in less than 10 seconds,
the injection valve should be disassembled and inspected, then reset to the
- correct opening pressure as outlined below.
If the opening pressures are satisfactory, continue pumping and observe the
spray pattern from each of the holes in the nozzle. The patterns should be
uniform - if not, clean the nozzle using the needles supplied with the special tools.
- Finally adjust the correct opening pressure 33.0 MPa.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY
4.4 FUEL INJECTION VALVES AND FUEL INJECTION
PUMPS ４－４－０３

WARNING

There is a danger of injuries caused if high-pressure oil droplets come in direct

contact with your skins when conducting the injection test of fuel injection pump.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the
skin, then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
CAUTION

When using hydraulic tools or when conducting the fuel injection valve injection
test, high- pressure fluid will gush out , leading to the danger of injuries.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the
skin, then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
Apply hydraulic pressure only after making sure that joints are securely
connected.
Setting the Injection Valve Opening Pressure
- Loosen the locknut at the top of the injection valve (Item 8 in Figure)
- Loosen the adjusting screw ④ two turns.
- Operate the calibration pump lever several times to force fuel through the
injector to flush away any dirt that may have been introduced.
- Tighten the adjusting screw ④ about two turns and recheck the valve
opening pressure continue adjusting the screw until the valve opening・
pressure is correct (30.0 MPa).
- Retighten the lock nut ⑧. Hold the adjusting screw firmly while
tightening the lock nut to make certain that it does not turn.
- If the injection nozzle is not to be used immediately, plug all openings and
wrap it securely to keep it clean.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY
4.4 FUEL INJECTION VALVES AND FUEL INJECTION
PUMPS ４－４－０４

- Disassembly and Inspection - Fuel Injection Valve

- Clamp the injection valve in a vice with the nozzle at the bottom.
- Remove the locknut ⑧, the adjusting screw ④, spring ⑥, and spindle ⑦.
- Turn the valve in the vice so the nozzle is at the top, unscrew nut ⑤ and remove the nozzle ③.
- Carbon deposits can be removed from the nozzle tip with a soft metal brush and the nozzle
holes can be cleaned with the wire cleaners mentioned above. Needle seats can be lapped
with lube oil only - lapping compound should never be used. If lapping with oil fails
to correct a leakage problem, a new nozzle should be installed.

Reassembly
- Reinstall the nozzle with a new o-ring and torque the nut ⑤ (Refer Tightening Torque Table).
-Reinstall the spindle ⑦, spring ⑥, and adjusting screw ④.
- Set the valve opening pressure, as outlined above.
- You should clean up the surface of FV sleeve before setting the gasket on it,
and pay attention to putting the gasket ⑩ on the surface with watching
the projection of it, and please refer to the following figure.
-Insert the injection valve into the cylinder head and align the locating
mark with the corresponding mark on the cylinder head.
-Install the retainer ②, and hand-tighten the nuts.
-Install the fuel inlet tube and union.
-Torque the injection valve nuts to 44 N･m.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY
4.4 FUEL INJECTION VALVES AND FUEL INJECTION
PUMPS ４－４－０５

4.4.2 Fuel Injection Pump

Each cylinder has an individual fuel injection pump that is directly driven by
the engine camshaft.
Each pump consists of the following main parts
- Delivery valve assembly ①, ⑩, ⑪ and ⑫.
- A plunger with a helix-cut groove that meters the amount of fuel injected
each stroke ④.
- Plunger barrel ②.
- Fuel control rack ⑤.
- Rack control sleeve ⑥.
- Cam roller guide assembly ⑦, ⑧ and ⑯ that provides the drive link
from the engine camshaft to the plunger.
The pumps can be visually inspected without removing them from the engine. If
problems are found that require disassembling the pumps, it is recommended
that the pump be removed and taken to an approved shop because of the close
clearances and critical nature of the work.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.4 FUEL INJECTION VALVES AND FUEL INJECTION

PUMPS ４－４－０６

Inspections on the engine

- Remove the camshaft inspection covers.
- Visually check the fuel pump camshaft rollers ⑦ for pitting or other damage. If damage
is apparent, the pump should be removed and sent to an approved shop to install
new rollers and to conduct a complete inspection.
- Remove the fuel delivery valve from the top of the pump by removing bolts ③.
The delivery valve contains two ports, each with a ball-type check valve.
Remove the two bolts that secure the valve assembly ⑪, and inspect the check balls and
springs. If any damage is apparent, install new parts, and reassemble using a new o-ring ⑫.
Torque the bolts to the values shown in the Tightening Table, Section 3.3 of this manual.
- Remove and inspect the two deflectors ⑬. These deflectors are provided to protect
the pump body from erosion due to high-pressure return oil at the end of injection.
Erosion of the deflector tips is normal and they should be replaced as indicated
by inspection (this is part of the normal 6000 hour maintenance procedure outlined in
Section 3.5)
Pump Overhaul - (To be done at an approved shop)

Roller guide assembly

- Remove the guidepin ⑭ from the pump body and remove the roller guide assembly and
plunger. Extreme care must be taken not to damage or scratch the plunger.
- Dimension 'A' determines the timing of the pump. This dimension is controlled by shims ⑮,
and should be measured and recorded when the roller guide assembly is removed.
- Remove the shims ⑮.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY
4.4 FUEL INJECTION VALVES AND FUEL INJECTION
PUMPS ４－４－０７

- Remove the roller pin ⑯, and roller ⑦.

- Measure the inner diameter of the roller, the outer diameter of the pin, and
the inner and outer diameters of the roller bushing ⑰. Refer to the maximum
wear limits shown in Section 3.2 and replace any parts that exceed
the clearance limits. If pitting or chipping is apparent on the roller wear
surface, install a new roller.
- When the roller guide assembly is reassembled, recheck the dimension 'A' as
shown in Figure. It should be the same as the original measurement (plus
0.0, minus 0.1 mm) to insure that pump timing is not changed. If the
measurement differs from the original (because of new parts installation),
the shim thickness should be changed as required to maintain the original
dimension.

Plunger Barrel Assembly

- With the plunger, the roller follower assembly, and the delivery valve
assembly removed, next remove the control rack ⑤ and the control sleeve⑥.
Remove the deflectors ⑬ and the locating screw ⑲. The plunger
barrel ② can now be removed and inspected.
- An adjusting mark is stamped on the plunger and barrel assembly to indicate
the start of injection. If new parts are installed, review.
- When reassembling the plunger assembly, install new o-rings ⑳ and 21 .
Install the control sleeve ⑥ and rack ⑤, mating the end tooth of the
sleeve to the end tooth of the rack, as shown.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.4 FUEL INJECTION VALVES AND FUEL INJECTION

PUMPS ４－４－０８

- When reinstalling the injection pump assembly onto the engine, first install
the special locating screw that is provided with the engine as shown in
Figure. Then install the pump over the locating bolt. Install the
remaining three pump mounting bolts and hand-tighten. (The locating screw
positions the pump in the "nominal" (new) location). This location should
normally be satisfactory, but should be checked as follows:
- Apply Prussian Blue to the pump roller and rotate the crankshaft manually
for two revolutions. Inspect the contact area between the pump cam roller
and the engine camshaft. If the contact pattern is satisfactory, remove the
locating bolt, install the normal bolt and tighten all four mounting bolts
to 177 N･m.
- If the contact pattern is uneven, remove the locating bolt and move the pump
by hand until a satisfactory contact pattern is obtained. Then install the
remaining mounting bolt and torque all four bolts to the value specified
above.
- Reassemble the rack drive mechanism, reinstall the camshaft covers, and
connect the fuel lines to the pump.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.5 GOVERNOR DRIVE AND FUEL CONTROL LINCAGE

４－５－０１

4.5 GOVERNOR DRIVE AND FUEL CONTROL LINKAGE

The governor controls the engine speed and amount of fuel injected into each
cylinder by controlling the displacement of the fuel injection pump racks.
It is driven by the engine camshaft through three input gears, as shown by
following figures.
The camshaft drive gear drives input gear ①, which in turn drives input
gears ② and ③.
This section describes the removal and installation of the governor, the rack
control linkage, and the inspection of the governor gear drive mechanism. It
does not provide details of the construction or maintenance of the governor
itself - refer to the Governor Instruction Manual for those details.
The lubricating oil in the governor should be changed every 3000 hours, as
outlined in the Maintenance Schedule. Clean, filtered oil should be used and
care should be taken not to introduce any dirt into the governor during the
process.

4.5.1 Removal
-The governor assembly can be removed by disconnecting the cables and
linkage, removing the four mounting bolts, and lifting the assembly
vertically from its base.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.5 GOVERNOR DRIVE AND FUEL CONTROL LINCAGE

４－５－０２

4.5.2 Inspection of Drive Gears

- Remove the governor from the bearing case ⑥ and remove the
inspection cover ⑦. Inspect the tooth contact surface of each
of the drive gears for unusual wear or pitting. Measure the backlash
of each gear set before removing the drive gears.
- Remove the bolts ⑧ and remove the bearing housing ⑥.
- Remove the snap ring ⑩ and the drive gear ③. Remove the
remaining snap ring ⑨ and ball-bearing and spacer ⑪ and ⑫.
- Remove the control lever bracket by removing bolts ⑮ and remove
the driveshaft ④. Remove the shaft bearings ⑰.
- Visually inspect the condition of all bearings and the condition of the
drive gear teeth. Install new parts if any damage is apparent.
- Assemble the drive group in the reverse order of disassembly.

4.5.3 Fuel Control Linkage

The governor is connected to the individual fuel pump control racks by a
lay shaft arrangement. When the governor linkage is removed, or when any
injection pump is removed, special care needs to be taken to insure that
the linkage is properly readjusted.

4.5.4 Adjustment of fuel injection pump rack

- Before installing the injection pump, check to make certain that the
rack moves freely by hand through its full stroke. If not, the pump
should be returned to an approved shop for exchange.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.5 GOVERNOR DRIVE AND FUEL CONTROL LINCAGE

４－５－０３

- After the pump has been mounted, connect the rack to the layshaft lever①.
-Move the governor control lever to the 'STOP' position.
-Loosen nut ② and screw ③.
-Set the injection pump rack to the '0' (zero) position, and tighten nut ②.
- Recheck the stroke of the fuel pump rack by manually actuating the
lay shaft. Make certain that full rack stroke is obtained and that the
rack does not bind in any position.

4.5.5 Adjustment of governor control linkage

The governor is connected to the layshaft through two levers (bellcranks)
and a rod, as shown by following Figure. A return spring ④ is
attached to the lower bellcrank.
- Apply clean lube oil to each joint in the linkage.
- Operate the governor control lever by hand and make certain that the
linkage moves freely with no binding.
- Set the governor at the 'STOP' position and make certain that the
control lever indicator is at the "ZERO" position on the console scale.
If necessary, adjust the rod link ② so that the marks align.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.5 GOVERNOR DRIVE AND FUEL CONTROL LINCAGE

４－５－０４

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０１

4.6 CRANKCASE ASSEMBLY

The engine block is a solid, one-piece cast-iron box-girder design with mounting
rails extending along the entire length of the engine. Lightweight access covers
permit inspection of the various internal components without major disassembly.
Periodic inspection of the block assembly, camshaft bearings, and main bearings
is called for at 24000 hour intervals (Refer to Section 3.5) and should also be
conducted at any other time that problems are suspected.
This section outlines the procedures to be used during inspection of the block assembly.

4.6.1 General
- Any time that the inspection covers are removed, the interior should be
checked for evidence of water. As mentioned earlier, traces of
moisture from condensation are normal, but if water entry into the sump
is heavy enough that the oil appears milky, a major leak is indicated
and the engine should not be put back into service into the source is
located and repaired.
- When disassembling the main bearings, removing the pistons, or
performing other major internal work. It is always good practice to
seal oil ports, protect exposed crankshaft surfaces with cardboard, and
cover exposed parts during the course of the work to prevent damage and
contamination from dirt.
- Always make certain the starting mechanism is disabled to prevent
accidental engagement. (Shut off main air valve or - better -
disconnect the main air line).
- Always use the proper lifting devices and procedures to avoid injury to
personnel or damage to parts.
- Internal block surfaces and components should be cleaned with suitable
brushes and solvents and blown dry with compressed air. The use of
rags is not recommended because of the possibility of pieces tearing
loose and plugging lubrication ports.
- All new gaskets and seals should be used at reassembly.
- If the protective paint on the internal block surfaces is deteriorated,
new high-quality, oil-resistant paint should be applied to the bad areas.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０２

4.6.2 Camshaft bearings

The camshaft bearings are pressed in and should not be removed from the
block unless inspection shows excess wear of other damage. special tools
are required to replace the bearings and should be obtained through the
Niigata office if required.
Once the camshaft has been removed (Section4.8), the bearings can be
visually inspected and measured. The procedure for measuring and the wear
limits are given in section 3.2 (Clearance and Wear Tables).

4.6.3 Main Bearings

The crankshaft main bearings are shell-type bearings of a steel-backed
copper-lead alloy with a lead-tin overlay. They are secured both
vertically and laterally in the block. Lubricating oil is provided to
the bearings through internal ports in the block. The rear ( No 1)
main bearings includes the crankshaft thrust bearings.
Disassembly and Inspection (Main Bearings)
- Two hydraulic jacks are included in the special tools for removing the
main bearing caps. One is simply a small bottle jack used to support
the weight of the cap while the retaining nuts are removed. The other
is a bolt tensioning jack assembly, consisting of many of the same
parts as the arrangement used for removing the cylinder head nuts.
- The procedure for removing the main bearings for inspection are
outlined below (refer also to comments at end of this section for the
rear main bearing and thrust bearings).
- Install the bolt tensioning jacks by supporting the jacks underneath
the main bearing studs while engaging the draw-bolts (A-2) on the
main bearing studs. The spacer (A3) is held in place during this
operation by bar A4.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０３

- Hand tighten nut (A5) with bar A4, then back off the nut about 1/4 turn
to keep it from binding during disassembly.
- Connect the jacks to the hydraulic pump.
- Remove the side bolts ② from the main bearing cap that is being
removed and loose the side bolts from the two adjacent main bearing
caps.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０４

-Pump up the hydraulic pressure (refer to tightening table), then loosen

the main bearing stud nuts one turn using bar A4.

CAUTION
When using hydraulic tools or when conducting the fuel injection valve
injection test, high- pressure fluid will gush out , leading to the danger of
injuries.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through
the skin, then it is necessary to undergo forthwith specialist's diagnosis and
surgical treatment.
Apply hydraulic pressure only after making sure that joints are securely
connected.
-Release the hydraulic pressure and remove the jacks. Attach the hydraulic pump
now to the small bottle jack and position the jack underneath the main bearing cap
to support its weight.
Remove the two stud nuts and lower the bearing cap off of the studs.
-Remove the lower half of the main bearing shell the cap.
-To remove the upper half of the main bearing shell, rotate the crankshaft until
the removal tool (Item B1) can be inserted in the lube oil hole in the crankshaft journal.

WARNING
There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
There is a danger of injuries being caused by contra rotation of crankshaft if
turning is carried out without opening the indicator cock or explosion check plug.
Be sure to open the indicator cock or explosion check plug when carrying out
turning.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０５

Continue rotating the crankshaft in the direction indicated by the sketch

until the upper bearing shell is loose.(The upper bearing shell has a tang
on one end to lock it in place - it can only be removed by turning in the
direction indicated - otherwise the shell will be damaged.

-Inspect the condition of the main bearing shells and the mating surface
of the crankshaft, and main bearing cap. (Refer to Section 3.2).
Reassembly
-Install the upper bearing shell by rotating the crankshaft until the oil hole in the journal
is in view on the RH side of the block (as viewed from the front, or timing gear end).
Insert the removal tool in the oil hole and install the dummy bearing cap that is
supplied with the special tools. The dummy bearing cap has a slot in the center
to provide clearance for the locking tang on the upper bearing shell while it is being
rotated into position. Install the upper bearing shell in the dummy cap with the
tang-end next to the removal tool. Using the bottle jack, lift the main bearing cap
until the bearing shell comes into contact with the crankshaft journal.

WARNING
There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.
There is a danger of injuries being caused by contra rotation of crankshaft if
turning is carried out without opening the indicator cock or explosion check plug.
Be sure to open the indicator cock or explosion check plug when carrying out
turning.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０６

- Carefully rotate the crankshaft in the direction indicated by the

sketch until the upper shell is in its correct position. Release the
hydraulic pressure on the bottle jack, lower the bearing cap, and
remove the dummy bearing cap.
- Place the lower main bearing shell in the cap, raise the cap into place
by using the hydraulic jack, and install the stud nuts hand-tight (use
Molykote or similar lubricant on the studs).
- Tighten the LH side bolt (as viewed from the front or timing gear end)
to 245 N･m. (Note that this is only about half the final torque value
- it will be tightened again in the last step).
- Install the stud tensioning jacks on the studs (same as was done when
the stud nuts were removed, as outlined above), raise the jack pressure
(refer to tightening table), and tighten the stud nuts by hand using the bar A4.
- Bleed the pressure from the tensioning jacks and remove them.
- Tighten the LH side bolt and the LH side-bolts of the adjacent
bearings to the final torque value as above. (refer to tightening table)
- Tighten the RH side bolt and the RH side-bolts of the adjacent
bearings to the same final torque value as above.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.6 CRANKCASE ASSEMBLY

４－６－０７

Rear Main Bearing and thrust Bearing

- Before disassembly, measure the crankshaft end-play to determine if a
new thrust bearing is required.
- To measure the end-play, pry the crankshaft forward (toward the timing
gear end of the engine) with a bar placed between a surface on the
block and an unmachined surface on the crankshaft balance weight. Then
install a dial indicator, either on the flywheel face or crankshaft
hub. Set the dial indicator to "0" and observe the displacement as the
crankshaft is barred toward the rear of the engine. If the end-play
exceeds the settled value, new thrust bearings should be installed.
- The procedure for disassembling the rear main bearing is the same as for
the other main bearings (as discussed above), except that it is
recommended that the flywheel or coupling weight be supported during
the process to avoid stressing the crankshaft. This can be done by
blocking or by placing a jack under the flywheel or coupling prior to
removing the main bearing cap.
- Once the rear main bearing cap has been removed, the thrust bearing can
be removed for inspection.
- Reassembly procedure is the same as for the other main bearings.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.7 CRANKSHAFT
４－７－０１

4.7 CRANKSHAFT

The crankshaft is a one-piece, continuous grain flow forged steel crank with
induction hardened journals. Balance weights are located and secured by bolts
and dowels.
Crankshaft removal is required only if remachining of the main or rod bearing
journals is indicated by clearance or wear measurements, as outlined in Section 3.2.
If remachining is required, it should only be done in an approved service shop.
Periodic inspection of the rod bearings is recommended at settled intervals, and
inspection of the main bearings is recommended at other settled intervals
(Section 3.2). During these inspections, the condition of the crankshaft
journals should also be noted - if serious wear or
scuffing is apparent,
complete measurements should be obtained to determine if remachining is
required. Crankshaft deflections should be measured after the initial 100 hours
of operation and afterwards at 3000 hour intervals (Section 3.2).

Procedure for measuring crankshaft deflections

- Deflection is measured in both vertical and lateral directions. As

indicated in Section 3.2, slightly higher deflections are normal at the rear
main bearing because of the cantilever affect of the flywheel and/or
coupling.

CAUTION

Deflection measurements should be made when the engine is cold and with the
indicator cocks open at each cylinder.
- Install the dial indicator (supplied with special tool group) on the
crankshaft journal that is being measured in the position shown by 'A' in
Figure.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.7 CRANKSHAFT
４－７－０２

- Set the dial indicator to the 'zero' position.

- Rotate the crankshaft slowly to the 'B' position, record the reading on the
dial indicator (be sure to note and record whether is a plus or minus
reading), then continue to points 'C', 'D', and 'E'.

WARNING

There is a danger of parts of the body being entangled into the rotating parts
or gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.

There is a danger of injuries being caused by contra rotation of crankshaft if

turning is carried out without opening the indicator cock or explosion check
plug. Be sure to open the indicator cock or explosion check plug when
carrying out turning.

-When all five readings have been recorded, calculate the deflection as

follows:
Vertical deflection = the value at 'C' minus the average of the values at
'A' and 'E'. Ie., dV = C-(A+E)/2.
Horizontal deflection = the value at 'D' minus the value at B.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.7 CRANKSHAFT
４－７－０３

- Once the deflection values have been calculated for all cylinders, they
should be compared to the maximum wear limits shown in Section 3.2. If the
values are exceeded, or if there is significant difference in the deflection
values from one cylinder to another, it generally indicates a problem with
the engine foundation. The cause should be determined and corrected as soon
as possible.

Crankshaft Journal Inspection

- The rod and main bearing journals should be visually inspected for scoring
and/or scuffing whenever any of the bearings are removed. The rod journal
diameters should be measured (at two points degrees apart) both at the
center of the journal and at each end about 20 mm from each of the crank
arms. The measurements should be compared to the values shown in
Section 3.2. If the wear limits are exceeded, the crankshaft should be
remachined and appropriate undersize bearings used.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.8 CAMSHAFT AND TIMING GEAR TRAIN

４－８－０１

4.8 CAMSHAFT AND TIMING GEAR TRAIN

4.8.1 Camshaft
The camshaft is an integral two-piece design that can be separated for easy
removal, if required. It is driven through the timing gear train at the front
of the engine and turns at 1/2 engine speed. There are three camshaft lobes
for each cylinder; one for the fuel injection pump, one for the exhaust valve,
and one for the inlet valve. The camshaft can be removed from either end of
the engine, depending upon the space available.
Removal and Inspection
- The camshaft, cam followers, and rollers can be visually inspected by
removing the inspection covers on the side of the block. Unless damage is
apparent, there will normally be no need to remove the camshaft from
the block until the scheduled settled interval maintenance check. Removal
procedure is as follows:
- Remove the camshaft inspection covers.
- Remove the timing gear cover and any auxiliary equipment at the timing gear
end.
- Remove the valve train rocker arms and push rods (Refer to Section 4.1).
- Remove the fuel injection pumps (Refer to Section 4.4).
- Remove the camshaft drive gear, then remove the camshaft through whichever
end of the engine has been deemed appropriate. If space is restricted and
the camshaft must be separated into two section for removal, slide the shaft
out through the block until the coupling joint is outside the block,
disconnect the two sections, and remove each section individually.
(Refer to Figure). Use care not to damage the camshaft bearing shells in
the block while removing the shaft.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.8 CAMSHAFT AND TIMING GEAR TRAIN

４－８－０２

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.8 CAMSHAFT AND TIMING GEAR TRAIN

４－８－０３

- After the camshaft is removed, clean it carefully with a suitable detergent and dried
with compressed air.
- Measure the camshaft bearing journals and the bearings according to the instructions
given in Section 3.2. If the bushing clearance exceeds the maximum wear value,
new bearings must be installed.

Re-installation of camshaft
- Coat all friction surfaces on the camshaft and the bearing surfaces with clean lube oil.
- Re-install the camshaft in the reverse order of disassembly. If it has been separated
into two section for removal, insert the first section into the block until the coupling
joint is just outside the block, bolt the two sections together to insure proper alignment,
and slide the assembly the rest of the way into the block. Then remove the bolts
that fasten the camshaft sections together, apply Locktite 242 or equivalent,
and torque them the settled value.
- Install the camshaft drive gear. Apply Locktite 242 or equivalent and torque
the bolts to the settled value.

4.8.2 Timing Gear Train

WARNING

There is a danger of your hands being pinched by the gear and cam roller of the
engine.
Never insert your hands in the course of turning.
The timing gear train consists of eleven spur gears (Figure 4.8-2) located at
the front of the engine. The gear train should be visually inspected and gear
backlash measured at the settled intervals (Refer to Maintenance Schedule, Section 3.5).

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.8 CAMSHAFT AND TIMING GEAR TRAIN

４－８－０４

Camshaft drive inspection

To obtain access to the camshaft drive, remove the cam gear housing (with
governor and governor drive).
- Inspect the condition of the teeth on the cam gear and the mating drive gear
(Idler gear # 1) carefully for signs of pitting near the pitch line or other
unusual wear. A new gear (s) should be installed if damage is apparent.
- Measure the camshaft end-play with a dial indicator. If the end-play
exceeds the settled valve, a new thrust bearing should be installed.
- Measure the backlash between the cam gear and the idler gear with a dial
indicator. The backlash should not exceed the settled value.

Idler Gear Bearing Replacement

The two idler gears in the timing gear train run on back-to-back roller
bearings, as shown by Figure. In the event that problems are suspected
with these bearings, they can be removed for inspection or replacement as

follows:
- Loosen bolts ① a few turns and tap lightly on the bolt heads
to release the shaft from the housing.
- While supporting the gear and shaft by hand, finish removing
the two bolts and remove the gear, shaft, and bearing assembly in the
through the opening housing.
- Place the assembly on a workbench, remove the snap rings ③,
and drive the bearing from the shaft with a soft (bronze) punch.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.8 CAMSHAFT AND TIMING GEAR TRAIN

４－８－０５

Reassembly

- Before installing the roller bearings back onto the shaft, coat the bearing
outer diameter and the inner diameter of the gear bore with Locktite 601 or
equivalent. Make certain that the Locktite does not enter the bearing cage.
- Complete the reassembly in the reverse order of disassembly.

Lube Oil Pump Idler Gear Bearings

The lube oil pump idler gear can be removed as follows:

- Remove the housing ①, bolt ②, then support the gear by hand while
removing the shaft ④.
- Place the gear assembly on a workbench and remove the bearings with the same
procedure as described for the main idler gears above.
- Reinstallation of the bearings is the same as outlined above for the main
idler gears. Install a new o-ring seal ⑨ on the shaft.
- After the bearings have been reinstalled in the gear, hold the gear in the
housing and insert the shaft. Tighten the retaining bolt ② to the settled
torque.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.8 CAMSHAFT AND TIMING GEAR TRAIN

４－８－０６

Adjusting Timing of Timing Gear Train

WARNING

There is a danger of your hands being pinched by the gear and cam roller of
the engine.
Never insert your hands in the course of turning.

CAUTION

The reference cylinder to be used when adjusting timing will always be the
cylinder that is located to the timing gear.
The camshaft idler gear and camshaft drive gear must be timed with respect to
the crankshaft. Use the following procedure:
- Rotate the engine until cylinder No.6 or No.8 (cylinder at timing gear end of
the engine) is at top dead center. The keyway on the crankshaft gear should
be at the top position, as shown by Figure.
- The timing mark on the camshaft gear and idler gear should be positioned, as
shown by the insert of Figure.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.9 STARTING AIR DISTRIBUTOR

４－９－０１

4.9 STARTING AIR DISTRIBUTOR

With the air-over-piston starting arrangement, the engine is started by

supplying compressed air to the tops of the pistons in a timed sequence, thereby
forcing the crankshaft to rotate.
The timing of the air blasts to each cylinder is provided by the starting air
distributor. The distributor is driven by the engine camshaft and is mounted
externally at the rear of the engine. The distributor is connected by air lines
to the individual cylinders.
As shown by the sketch, the principal parts of the distributor are the body ④
and a rotating disc ② that is keyed to the driveshaft ①.
When compressed air is supplied through the main air line, it passes
through an opening in the rotor to the appropriate cylinder. As the crankshaft
begins to turn, the rotor also turns (since it is driven by the camshaft) until
the port for the next cylinder is aligned. This sequence continues turning the
crankshaft until combustion occurs and the engine begin to run under its own
power - at that time the main air supply to the starting distributor must be
shut off by the operator.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.9 STARTING AIR DISTRIBUTOR

４－９－０２

Inspection

The distributor can be inspected without removing it from the engine.

- Close the main air supply valve. Remove the air supply line to the
distributor, and remove the cover ⑥.
- Remove the rotor by using two M6 bolts in the puller holes that are
provided.
- Clean the rotor, key, and body bore. Check the angular clearance as
outlined in Section 3.2 . If the clearance exceeds the limit, a new key
and/or shaft should be installed.
- When reassembling, coat the disc and the mating surfaces on the distributor
body with grease. Fill the grease cup with grease.

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.10 COOLING AND LUBRICATING OIL PUMP

４－１０－０１

4.10 COOLING AND LUBRICATING OIL PUMPS

Generally both the cooling water pump and lubricating are engine driven.
(Operations are available, however,for separate pumps for both circuits in those
instances, refer to the appropriate service manuals provided with the pumps).
This section describes the procedure for inspecting and/or rebuilding the engine
-driven pumps.

4.10.1 Cooling Water Pumps

The pump is driven by the timing gear train through an input gear ①.
The impeller is keyed to the shaft (a taper fit),and secured by a retaining nut ⑧.
The shaft runs on two ball bearings ⑪.Two seals are use;(a) a mechanical
face-type seal to prevent coolant leakage into the oil into the compartment ⑤
and (b),a lip-type oil seal to prevent oil transfer into the coolant ⑥.
To remove and disassemble the pump:
- Drain the cooling system and remove the pump from the engine.
- Remove the impeller housing ④
- Loosen the impeller retaining nut and remove the impeller,withdrawing it
carefully so that the mechanical seal and shaft are not damaged.
- Remove the nut ⑧ that secures the drive gear to the shaft. Remove the gear.
- Remove the shaft and bearings from the housing.(The bearings are positioned by
snap rings that must be removed).
- Inspect the impeller and housing for signs cavitation erosion - if the damage
is severe,new parts should be installed. Measure the clearance between the
impeller and the liner ring (refer to Section 3.2)and replace pitting or
other damage.(New bearings should generally be installed whenever the water
pump is disassembled unless they have few hours of use).
- Clean all parts and rebuild the pump in the reverse order of disassembly.
A new mechanical seal, oil seal and ball bearings should be used.
Apply of the shaft and bearings, but be careful not to get oil onto the faces
of the mechanical seal.
- Use LOCKTITE 242 or equivalent on the impeller and drive gear retaining nuts.
Tighten the nuts ti the values given in the Toque Table(Section 3.2)

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.10 COOLING AND LUBRICATING OIL PUMP

４－１０－０２

4.10.2 Lubricating Oil pump

The gear-type lube oil pump is driven by the timing gear train through a main
idler gear and an oil pump idler gear,as shown in Figure no 3.2.11.The gear
shafts run in sleeve-type bushings.

Disassembly:
- Remove the pump from the engine. Remove the drive gear retaining nut and the
drive gear④ and ①.
- Remove the front and rear covers⑤ and⑥.
- Remove the drive gear and driven gear.
- Inspect the tooth surfaces of the two oil pump and gears and the drive gear
for pitting or unusual wear. Inspect the bushings in the two end covers.
- Replace any parts that show damage or excessive wear.
- Reassembly is in the reverse order. Apply sealing compound to the mating faces
of both covers and the pump body. Tighten the drive retaining nut to the value
shown in the Torque Table ( Section 3.2 ).

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 SECTION ４ - DISASSEMBLY AND REASSEMBLY

4.11 TORSIONAL VIBRATION DAMPER

４－１１－０１

4.11 TORSIONAL VIBRATION DAMPER

4.11.1 Hulsen damper
(1) Description
If necessary, torsional vibration damper is equipped, in order to reduce
the stress generated by torsional vibration. Generally, hulsen damper is
provided, which is constructed with circular leaf springs and keys.
(2) Inspection of springs
Inspection of the damper springs should be done without removal the damper
ass'y. After the bolts ② and the side cover ① were removed, pull out the
springs and inspect them.
Remove the key ③ and circular leaf springs ④ by the half number of them.
After inspection and reassembly, remove the remainder.
If deformation or damage is found, replace it.
(3) Inspection bushes
Remove the damper ass'y from the crankshaft. Remove the both side cover 1
and 6. Clean and inspect the parts. Check the bushes ⑤ which should be
jutted from side cover ①. If necessary, replace the bushes ⑤.
(4) Reassembling
Replace O-rings. Tighten the bolts ② as per tightening torque table.
(Clean and apply the "LOCKTITE 242")

4.11.2 Geislinger damper

In some plants, geislinger damper is equipped. Refer to the manufacturer's
instruction manual.
 SECTION ５ - MAINTENANCE
CONTENTS

SECTION 5 - TROUBLE SHOOTING

5.1 BEFORE DETECTING THE CAUSE OF TROUBLE

5.2 TROUBLES BEFORE STARTING

5.3 TROUBLES AT THE TIME OF STARTING

5.4 ABNORMAL SITUATION

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 SECTION ５ - MAINTENANCE

5.1 BEFORE DETECTING THE CAUSE OF TROUBLE

５－１－０１

WARNING

There is a danger of parts of the body being entangled into the rotating parts or
gears of turning device in the course of turning with the turning device.
Do not allow your hand, leg, etc. to gain access to the parts.

There is a danger of injuries being caused by contra rotation of crankshaft if

turning is carried out without opening the indicator cock or explosion check plug.
Be sure to open the indicator cock or explosion check plug when carrying out
turning.

Any negligence of controlling cooling water, lubricating oil, and fuel oil, and
controlling the clamping in reassembly after overhaul inspection may lead to fault
of the engine and result in physical accidents due to failure of parts.
Unfailing control should be conducted on the basis of instruction manual or
specifications.

The engine may start abruptly without notice through the auto start signal or by remote
starting. As there is a danger of entanglement etc., do not gain access to rotating parts
and moving parts.

There is a possible danger of physical accidents that may be caused when the
engine is started by mistake during the inspection and repair of the battery-started
engine.
Be sure to carry out the following items to prevent the erroneous start of the
engine.
・Disconnection of battery power source.
・Capacitor discharge.

There is a possible danger of physical accidents that may be caused when the
engine is started by mistake during the inspection and repair of the air-started
engine.
Be sure to carry out the following items to prevent the erroneous start of the
engine.
・Close the main valve of starting air-tank outlet.
・Release the residual pressure remaining Inside the starting air pipeline. (Between
the starting air tank to the engine)

CAUTION

There is a danger of your hands and legs being pinched by weighty parts or
disassembling tool during overhaul inspection of the engine.
Take precautions in handling such parts and tools.

Since there are many hot parts in the engine during the course of running or right
after stopping, there is a danger of scald caused by them. Do not allow your skins
to come in direct contact with them.
In particular, use extreme care for the following parts that are heated up to high
temperatures.
・Exhaust line of the engine
・Indicator cock and cylinder safety valve
・Fuel oil line
・Steam line

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 SECTION ５ - MAINTENANCE

5.1 BEFORE DETECTING THE CAUSE OF TROUBLE

５－１－０２

In the case of carrying out the following work, there is a danger of scald caused
by high-temperature parts or hot fluid.
Put on protective gloves and use care in handling so that hot fluid will not splash
over the skin.
・Sampling work of cylinder internal pressure.
・Cleaning of lubricating oil/fuel oil filters.
・When removing the caps of radiator and
・pressurized fresh water expansion tank.

In the case of checking by finger touch, there is a danger of scald. To prevent

this, first allow your finger to approach to the work and make sure that it is not
hot, followed by conducting the check by finger touch.
If the work is hot, do not conduct the check by finger touch to avoid causing the
scald.

When disassembling the spring section during the course of overhaul inspection,
parts are caused to jump out due to disengagement of disassembly tools.
Thus, there is a danger of injuries.
Familiarize yourselves with the construction of component and use tools
properly. Also give care full attention to the jumping direction of parts so that the
body will be kept away from the jumping direction.

When using hydraulic tools or when conducting the fuel injection valve injection
test, high- pressure fluid will gush out , leading to the danger of injuries.
Never allow your body to gain access to the range covered by oil droplets.
In case where high-pressure oil droplets have come into your body through the
skin, then it is necessary to undergo forthwith specialist's diagnosis and surgical
treatment.
Apply hydraulic pressure only after making sure that joints are securely
connected.

There is a danger of critical accidents arising from such malfunction of electronic

devices applied to electrical governor and remote controller as is caused by
electromagnetic wave.
Keep away from electromagnetic wave-generating equipment.

Be sure to put on safety goggles in carrying out the following items of work
being in danger of injury to eyes.
・When handling fuel oil, lubricating oil, cooling water and inhibitor, and
anti-freeze solution
・In course of washing work
・In course of fuel injection valve injection test
・When handling battery electrolyte
・In course of grinding work
・In course of intake/exhaust valve grinding work

There is a danger of injury to your hands during the work inside the engine room
and enclosure.
Be sure to put on gloves for the protection of your hands except for the case of
special work.

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 SECTION ５ - MAINTENANCE

5.1 BEFORE DETECTING THE CAUSE OF TROUBLE

５－１－０３

5.1 BEFORE DETECTING THE CAUSE OF TROUBLE

If any abnormality is observed in operating conditions, particularly when

abnormal situation arises during starting attempt or immediately after the
engine has started, check for erroneous operation or any other error with
reference made to the description in this section. In this case, do not
indiscriminately conduct test. Do not restart the engine until abnormality is deleted.
Refer to section 3 MAINTENANCE MANUAL and section 4 DISASSEMBLING AND
REASSEMBLING OPERATION, in which instructions related to disassembly and
reassembly required for eliminating abnormal situation are given.
(1) Early detection of trouble
If there is a possibility that the engine will be troubled, its sign will
be shown in advance except special troubles. If any slight abnormality
should be observed, check the related parts and minimize the trouble.
(2) Before starting operation
Before starting operation, keep the following points in mind and check the
problematical point thoroughly and start with the next operation.
If any alarm before trouble?
If any same trouble caused past?
Repair and maintenance was done past?
When detecting the cause of trouble, the engine can be kept running?
(3) Detection of cause of trouble
Start with the cause of trouble from simple symptom. Check easy and clear
point at first and detect more complicated points. If such way, time and
work should be saved.
(4) Re-inspection before disassembly
In many cases, causes of trouble should be related with other parts. Check
whether or not there is any mistake in counter-measure. Re-check before
disassembly so that evidence of associated parts is not lost.
(5) Counter-measure of cause of trouble
Repair trouble but also study on the cause of trouble. Take for instance,
the seizure of the plunger of the fuel injection pump can be corrected if
the part is reconditioned or replaced. But the cause of seizure of the
plunger is not removed.

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 SECTION ５ - MAINTENANCE

5.2 TROUBLE BEFORE STARTING

５－２－０１

5.2 TROUBLES BEFORE STARTING

Trouble phenomenon and probable cause → Remedy

DANGER

5.2.1 Crankshaft fails to turn

Turning of crankshaft is Check for presence of tools, dust,
obstructed by foreign matters. pieces of wood alike in gearing,
cylinder interior or coupling flanges.

5.2.2 Water flows out of indicator cock

(1) Water is condensed in air cooler. Check for presence of moisture in the
intake manifold.

(2) Entry of rain water through Check for accumulation of water at the
exhaust manifold. bottom of turbo charger's exhaust
outlet case. Attach protective hood
to the exhaust outlet at the occasion of
suspension of engine running for a long time.

(3) Cracked liners and cylinder Check for abnormality in cylinders.

heads (due to reduced level inspect interior of crankcase through
of high temperature cooling inspection doors. Conduct hydraulic
water in expansion tank). pressure test of liners and cylinder
heads. If abnormality is found,
replace parts as required.

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 SECTION ５ - MAINTENANCE

5.2 TROUBLE BEFORE STARTING

５－２－０２

Trouble phenomenon and probable cause → Remedy

(4) Water leakage in air cooler. Check air cooler and its piping for
abnormality. Seal the leaking point.
(5) Water leakage from turbo Check for accumulation of scale in
charger cooling system turbo charger.
(reduced level of high temperature
cooling water in expansion tank).

5.2.3 Water is mixed in lub. oil

(1) Water entered through cylinders Check cylinders for cracks.
(Refer to 5.2.2 (3))

(2) Water leakage in lub. oil cooler. Check lub. oil cooler.

(3) Entry of water of a minor volume Check if thermostat is normally

into lub. oil due to condensation operating.
(when oil temperature is
extremely low).

(4) Entry of water through plug Check cylinder heads.

of sand discharge hole for Replace plugs (apply sealing product
cleaning located at cylinder and screw in).
head top. Conduct hydraulic pressure test of
cylinder heads.

CAUTION

Even if water is found in cylinders, it is not necessarily due to water leakage.

There are cases where water of a small volume enters cylinders
through the manifold if intake and exhaust valves are kept open during
suspension of running.
If water is found in cylinders, find out its cause, take corrective measures
and then check the entry of water into the lub. oil of the engine and to clean
the sump tank and oil pan.

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 SECTION ５ - MAINTENANCE

5.3 TROUBLES AT THE TIME OF STARTING

５－３－０１

5.3 TROUBLES AT THE TIME OF STARTING

Trouble phenomenon and probable cause → Remedy

5.3.1 Crankshaft fails to turn

(1) If cylinder heads are equipped
with starting valves:
- Low air pressure in air reservoir. - Elevate the pressure to 2.94 MPa.
- Closed air valve of air tank or - Open the starting air valve.
attached to the engine for
starting valve.
- Damaged starting distributor.
- Malfunction of starting valve of - Check the distributor. (Refer to 4.9)
cylinder located in starting position. - Check the starting valve. (Refer to 4.9)

(2) If equipped with air motor - Check the starting device.

starting device (Refer to instruction manual provided
by the manufacturer)

5.3.2 Crankshaft turns, but no ignition occurs

(1) Fuel injection pump rack position Check the rack position.
is "zero" or is too low.

(2) Fuel does not reach fuel injection Check the fuel oil system (for closing
pumps. of valves or solenoid valves).

(3) Entry of air to piping between fuel Vent air with air valves of fuel inlet loosened
injection pumps and fuel valves. while feeding fuel by a manual or pump.
motor-operated

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 SECTION ５ - MAINTENANCE

5.3 TROUBLES AT THE TIME OF STARTING

５－３－０２

Trouble phenomenon and probable cause → Remedy

5.3.3 Fuel feed is irregular

(1) Air vent of fuel oil system Carry out air vent.
has not been made.

(2) Entry of water into fuel oil. Drain water from fuel tank.

(3) Plugged fuel injection valves. Check fuel valve operating pressure.
(Refer to 4.4)

(4) Plunger of fuel injection Check fuel injection pumps

pumps is seized (Refer to 4.4)

5.3.4 Engine stalls after normal start

(1) Malfunction of safety device. Check if the safety device normally
operates.

(2) Obstruction to starting by engine's Check the operation panel.

abnormality stopping device.

5.3.5 Lub. oil pressure fails to rise after engine start

Abnormality in lub. oil pump. Immediately stop the engine and
Abnormality in lub. oil inspect the entire lub. oil system.
pressure regulator valve. Then apply pressure using the priming
pump.

CAUTION

If starting attempt is made with much fuel feed rate and if ignition failure
occurs even when the crankshaft turned, open indicator cocks, set fuel
injection pump rack position at "zero" and turn the crankshaft a number of
turns.
This work is required for discharging the fuel remaining in cylinders in
order to avoid rapid ignition.

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０１

5.4 ABNORMAL SITUATION

When a serious abnormal situation arises, do not hesitate to reduce

the engine speed or stop the engine as a rule.
Find out the cause for the abnormality and take corrective measure
before restating the engine.

Trouble phenomenon and probable cause → Remedy

5.4.1 Abnormal noise

(1) Abnormal noise which accompany
combustion
- If noise stops when fuel
injection is discontinued:
a) Gas leakage from cylinder a) Check cylinder heads for looseness.*
head joint. -Replace gaskets if necessary.
b) Gas leakage from exhaust b) Replace gaskets.
flanges of cylinder heads
c) Faulty sealing between c) Remove fuel valves and check
fuel valves and cylinder heads sealing to cylinder heads.
d) Plugged fuel valves or d) Replace fuel valves.
contaminated or smashed
needles

Note : Carry out this work with the engine stopped, after the
temperature has dropped.
Loosen nuts for cylinder heads, and retighten them with
reference made to 4.1. and 4.4.

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０２

Trouble phenomenon and probable cause → Remedy

(2) Abnormal noise due to failure to Immediately stop the engine.

mechanical parts.
- If noise does not stop even when
fuel injection is discontinued:
a) Seized rocker arm fulcrum pins. a),b),c)
b) Damaged intake/exhaust valves - Replace damaged parts.
or seizure of intake/exhaust - If damaged parts fell into cylinders,
valves to guides. carefully inspect pistons,
c) Broken valve springs. connecting rods and turbine side of
turbo charger.

5.4.2 Smoke emission

(1) Color of exhaust smoke is black.
a) Insufficient feed air pressure.
a) Clean the turbo charger in accordance
with instruction manual for turbo charger.
b) Unsuitable fuel valve opening b) Inspect fuel valves.
pressure or faulty spraying (Refer to section 4.4.)
conditions.

(2) Color of exhaust smoke is bluish white.

- Worn piston rings or cylinder liners - Inspect pistons, piston rings and
(accordingly, lub. oil enters cylinder liners.
combustion chambers and burns).

DANGER

Where the engine is brought to a stop due to abnormal heat generation being
detected inside the engine room, there is a danger of explosion if crankcase
door is allowed to open forthwith.
Open the door after the lapse of a cooling period of not less than 20 minutes.

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 SECTION ５ - MAINTENANCE
5.4 ABNORMAL SITUATION
５－４－０３

Trouble phenomenon and probable cause → Remedy

(3) Emission of mist pipe. Immediately stop the engine.

- As there is a possibility of
occurrence of explosion, do not
immediately open inspection doors
after the engine has stopped.
Wait for about 15 minutes before
opening inspection door.
a) Moving parts such as a) Tactually check the following parts:
pistons are about to be Bearings, connecting rod big ends,
seized. cylinder liner bottoms (with pistons
placed at top dead center). etc.
Compare with recent running record
(pressure, temperature) and find
out sources of abnormality.

b) Stuck piston rings b) Excessive oil temperature:

Check flow rates of lub. oil system
and cooling water system.
Check if the lub. oil is matched
with the used fuel.

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０４

Trouble phenomenon and probable cause → Remedy

5.4.3 Sudden engine stall

(1) Fuel is short. Check the fuel oil level in the fuel
oil system and fuel service tank.
(2) Mixture of water in fuel. Drain water out of the fuel service
tank.
(3) Operation of overspeed Find out the cause for operation
stopping device. and then reset the overspeed stopping
device.
Caution: If the overspeed stopping
device has operated during normal
running, it is an abnormal
situation.
Exercise sufficient care at the time
of restart of the engine. (Inspect
the governor and fuel regulating
mechanism in particular.)

(4) Malfunction of governor Inspect the governor.

(If looseness of parts related
to fuel regulating link is
found, return the fuel pump
rack to the stop position.)

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０５

Trouble phenomenon and probable cause → Remedy

5.4.4 Change in running conditions

(1) Revolution has dropped. Incomplete fuel feed.
- Check the filter for plugging.
- Refer to Items 5.3.2, 5.3.3
- Check for overloaded running.
-
(2) Intake/exhaust valves are stuck. Remove cylinder head covers and
inspect failed intake/exhaust valves.

(3) Abnormality in turbo charger (Refer to the manual of turbo charger)

(elevated exhaust Gas
temperature)

a) Contaminated turbo charger a) Clean the turbo charger.

b) Contaminated air cooler b) Clean the air cooler.
c) Check conditions of bearings.

(4) Pistons are about to be seized. Refer to Item 5.4.2.

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０６

Trouble phenomenon and probable cause → Remedy

5.4.5 Abnormality in exhaust gas temperature

(1) Reduced exhaust gas
temperature
a) Faulty temperature sensor a) Check the pyrometer and its
mounting conditions.
b) Faulty fuel valve (stuck needles) b) Replace fuel valves.
c) Faulty fuel oil system c) Quickly take necessary measure so
that the trouble will not reach
fuel valves.

(2) Elevated exhaust gas temperature

a)Unsuitable load a)Observe fuel injection pump rack
position and check load conditions.
b)Faulty cooling of suction air b)Increase cooling water.
c)Excessive suction resistance of c) Inspect the air filter.
suction air
d)Application of back pressure d)Check if protective food has been
from exhaust system. removed from exhaust outlet.
e) Malfunction of turbo charger. e) Check if the turbo charger is normally
operating. (Refer to Section 5.4.4 (3))
f) Burning of exhaust valve. f)Replace exhaust valve and valve seat.

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０７

Trouble phenomenon and probable cause → Remedy

5.4.6 Abnormality in lub. oil system

(1) Reduction of pressure of lub.
oil entering the engine
a) Oil leakage from pressure gauge a) Check pressure gauge and its joint.
b) Plugged lub. oil filter b) Check differential pressure of the filter
when the differential pressure becomes
two times of normal value.
c) Faulty lub. oil pressure c) Check the pressure regulator valve.
regulator valve (kept open)

(2) Rise of pressure of lub. oil

entering the engine
a) Faulty lub. oil pressure a) Check the pressure regulator valve.
regulator valve (fails to open)
b) Dropped lub. oil temperature b) Check the oil temperature

(3) Rise of lub. oil temperature

a) Faulty lub. oil thermostat a) Replace faulty sensing element.
b) Shortage of cooling water flow rate b) Check the cooling water system.
c) Abnormal heat-up of engine c) Refer to Item 5.4.2 (3).

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 SECTION ５ - MAINTENANCE

5.4 ABNORMAL SITUATION

５－４－０８

Trouble phenomenon and probable cause → Remedy

5.4.7 Abnormality in cooling water system

(1) Temperature rise of high
temperature cooling water
a) Faulty cooling water thermostat a) Replace faulty sensing element.
b) Shortage of low temperature b) Check if low temperature cooling
cooling water flow rate water system.
c) Priming water was not supplied c) Vent air from high temperature
to cooling water pump. cooling water system.
- Check the water level in the
expansion tank.
d) Failed cooling water pump d) Remove and inspect the cooling
water pump.

(2) Reduced pressure of low Check low temperature cooling water

temperature cooling water system (cooling water pump in particular)

This document is property of NIIGATA POWER SYSTEMS CO., LTD. It must be neither reproduced nor communicated nor published without permission.