‫ޓ‬MAINTENANCE CHECKING (Precaution in Maintenance Checking)

6. MAINTENANCE CHECKING

6-1. Precautions in Maintenance Checking

To use an engine always in good order, checking is necessary periodically for trouble prevention. The
period of checking can not be fixed indiscriminately because it is influenced by application of the engine,
conditions of use, quality of fuel oil and lub. oil used, and daily handling circumstance.

• The following tables of checking show the standard checking frequency. Perform the initial overhaul
servicing according to these checking tables. Then, based on the obtained checking (on wear corro-
sion, accumulation of carbon, accumulation of sludge and others), make the most economical check-
ing schedule suitable for your engine, and conform to the specified schedule from the second
checking.
• As for the items whose checking frequency is shown by both the accumulated operation hours and
number of days, schedule the checking at the earlier timing.

6-2. Table of Periodical Checking

For marine service engine
1) Table of Routine Maintenance Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-1.
2) Checking Table for Engine Using Marine Diesel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-2.
3) Checking Table for Engine Using Heavy Fuel Oil
(R.W. No.1 at 100q F 1,500 㨪 7,000-sec. Equivalent Fuel Oil). . . . . . . . . . . . . . . . . . . . . See Table 6-3.

6-3. Routine Maintenance Checking & Adjustment Procedures

6-3-1. Measurement of Running Performance
6-3-2. Measurement of Max. Combustion Pressure (Pmax)
6-3-3. Regulation of Fuel Injection Volume (Rack Scale)
6-3-4. Adjustment of Fuel Injection Timing
6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure
6-3-6. Adjustment of Suc./Exh. Valve Head Clearance
6-3-7. Adjustment of Lub. Oil Pressure
6-3-8. Adjustment of Lub. Oil Temperature
6-3-9. Adjustment of Fuel. Oil Pressure
6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valve
6-3-11. Cleaning of Lub. Oil Bypass Strainer
6-3-12. Cleaning of Lub. Oil Strainer
6-3-13. Cleaning of Fuel. Oil Filter
6-3-14. Cleaning of Strainer Element
6-3-15. Washing of Turbocharger Blower
6-3-16. Maintenance of Pressure Gauge
6-3-17. Measurement of Crankshaft Deflection
6-3-18. Adjustment of Fuel. Injection Pump Pinion Lubricating Volume (for Engine Using H.F.O.)
6-3-19. Maintenance of Fuel. Oil Seal Pot (for Engine Using H.F.O.)
6-3-20. Checking & Replacement of Anticorrosive Zinc

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‫ޓ‬MAINTENANCE CHECKING (Routing Maintenance Checking)

Table 6-1. Table of Routine Maintenance checking

Nature of Work
Checking Area
Daily Weekly Monthly (or 300-500hrs.)
Starting air tank Pressure check Draining
Checking & lubrication of
Governor gear Gov. oil volume check
linkage system
Check on leak from oil
Fuel feed pump
seal
Fuel oil filter Draining Back-washing (blow-off) Overhaul cleaning
Fuel Oil System

Check on rack scale

Fuel injection position
Pump *Check on pinion lubri-
cating Volume
Injection timing Check on looseness of
adjust bolt lock nuts
Lub. oil cleaning
Common bed
Oil volume check The batch cleaning by Lub. oil property analysis
(or oil pan)
the purifier
Lub. Oil System

Back-washing (blow-off) Overhaul cleaning

Lub. oil strainer Draining
(2 㨪 3 days) (10 㨪 15 days)
Lub. oil bypass
Overhaul cleaning
strainer
Turbocharger Back-washing (blow-off) Overhaul cleaning
lub. oil strainer (2 㨪 3 days) (10 㨪 15 days)
Cooling water Check on leak from
pump mechanical seal
Prefilter washing
Turbocharger
Blower washing
Check that electrical wir-
ing is fastend firmly.
Starting air motor Check that no air leaks
from the air pipe and the
joint.
Each pressure Check on defective indi-
Instrument

gauge cation
Each thermom- Check on defective indi-
eter cation
Check on looseness of
bolts & nuts
Check on leaks of vari-
Engine appearance ous parts
(cooling water, fuel oil,
lub. oil, boost air &
exhaust gas)
Each pipe system Leak check

Note: An asterisk ( ) refers to only for engine using heavy fuel oil (H.F.O.)

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‫ޓ‬MAINTENANCE CHECKING (Engine Using Marine Diesel Oil)

Table 6-2. Checking Table for Engine Using Marine Diesel Oil (1/3)

An asterisk ( ) given in the following tables refers to the timing of initial check after the initial start or
part replacement. Perform the check from the second time and onward at the ordinary frequency.

Checking & Servicing

Frequency (hrs.)

2 㨪 3 yr. or 8,000 㨪 10,000

5 yr. or 16,000 㨪 20,000
3 mo. or 1,000 㨪 1,500
6 mo. or 2,000 㨪 2,500
1 yr. or 4,000 㨪 5,000
Part to Be
Div. Nature of Service
Checked

Fuel injection
Drawing-out check & adjustment 1,500 㨪 2,000 1st time:500 㨪 800hrs
valve
Check & adjustment of the valve head clearance ٤
Check of valve spring
Cylinder head

٤
Check disassembly & check of valve rotator ٤
Disassembly, check & cleaning ٤
Cylinder head
Grinding of suc./ehx. valve seat ٤
Scale cleaning & hydraulic test of water chamber ٤
Replacement of stem seal (Suc./Ehx. Valve) ٤
Check of cyl. head bolt tightening force 㧖 ٤
Drawing-out, cleaning, checking & measurement
of piston ٤
Piston
Check & measurement of piston rings ٤
Check & measurement of piston pin ٤
Check & measurement of piston pin metal ٤
Connecting Check & measurement of crank-pin metal ٤
rod Check of connecting rod bolt tightening force ٤
Change of connecting rod bolts 20,000 hrs.
Inner dia. checking, cleaning & measurement ٤
Cyl. liner Drawing-out, check & cleaning of water jacket
part ٤
Major Moving Parts

Measurement of crank pin outer dia. & journal ٤

Crankshaft
Measurement & adjustment of deflection ٤
Disassembly, metal checking & measurement ٤
Check on tightening force of main bearing clamp-
Main bearing ٤
ing bolts
Check on tightening force of side bolts ٤
Check of cam & roller bearing ٤
Disassembly & check of fuel pump tappet ٤
Camshaft Disassembly, check & measurement of swing arm ٤
Drawing-out of crankshaft & bearing check &
measurement ٤

Check of tooth bearing & backlash ٤

Disassembly of idle gear & check & measurement
Timing gear ٤
of bearing
Check of idle gear mounted shaft tightening force ٤

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‫ޓ‬MAINTENANCE CHECKING (Engine Using Marine Diesel Oil)

Table 6-2. Checking Table for Engine Using Marine Diesel Oil (2/3)
Checking Servicing
Cycle (hrs.)

2 㨪 3 yr. or 8,000 㨪 10,000

5 yr. or 16,000 㨪 20,000
3 mo. or 1,000 㨪 1,500
3 mo. or 2,000 㨪 2,500
1 yr. or 4,000 㨪 5,000
Part to Be
Div.

Nature of Service
Checked
Major Moving Parts

Fuel feed Check of tooth bearing & backlash ٤

pump, lub. oil
pump, & cold
Disassembly, check & measure-
water pump ٤
ment of bearing
driving
intermediate Check of gear mounted shaft tight-
gear. ening force ٤

Change of hydraulic fluid 㧖 ٤

Gov. Gear

Governor
Disassembly & check ٤
Governor Disassembly & check of tooth bear-
driving gear ing & bearing ٤

Check of injection timing ٤ 1st time: 300 - 500

Fuel injec-
Check of deflector & replacement ٤
Fuel Oil System

tion pump
Disassembly, cleaning & check ٤
Fuel feed Disassembly & check ٤
pump Replacement of oil seal ٤
F.O.control &
stop air pis- Replacement of o-ring ٤
ton
Change (depended on results of
Lub. oil ٤
property analysis)
Lub. oil Disassembly, check, cleaning &
cooler hydraulic test ٤

Thermostatic
Lub. Oil System

Disassembly, check & cleaning ٤

valve
Disassembly, check & measure-
ment ٤
Lub. oil pump
Disassembly & check of pres. reg.
valve & safety valve ٤

Change the element

Turbo-
Change the element of lub. oil 1,000- When the lub. oil
charger lub.
strainer 2,000 pressure dropped by
oil strainer
0.3MPa(3kgf/cm2)

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‫ޓ‬MAINTENANCE CHECKING (Engine Using Marine Diesel Oil)

Table 6-2. Checking Table for Engine Using Marine Diesel Oil (3/3)
Checking Servicing
Cycle (hrs.)

2 㨪 3 yr. or 8,000 㨪 10,000

5 yr. or 16,000 㨪 20,000
3 mo. or 1,000 㨪 1,500
3 mo. or 2,000 㨪 2,500
1 yr. or 4,000 㨪 5,000
Part to Be
Div.

Nature of Service
Checked

Thermostatic
Disassembly, check & cleaning ٤
valve
Cooling Water System

Cooling water Disassembly, check & measurement ٤

pump Replacement of mechanical seal ٤
Fresh water Disassembly, check, cleaning & hydrau-
cooler lic test ٤

Cooling water Change (depended on results of prop-

(Fresh water) erty analysis) ٤

Sea water cool- Check of anticorrosive zinc & replace-

ing parts ment (Air cooler & Lub. oil cooler) ٤

Turbocharger Disassembly & cleaning ٤

Disassembly, check, cleaning & hydrau-
Boost air cooler ٤
lic test
Disassemble and clean the muffler ele-
ment. (Clean with neutral detergent.) ٤

Remove the starting motor from the

engine and turn the pinion gear manu-
ally, check that it turns smoothly and it ٤
emits no abnormal sound.
Disassembly, inspection, cleaning and
Other

Starting air replacement of grease of moving parts.

motor replacement of o-ring, first reduction ٤
gear bearing and special grease inside
the reduction gear.
Disassembly, inspection, cleaning and
replacement of grease of moving parts.
replacement of o-ring, 1st & 2nd reduc- ٤
tion gear bearings and special grease
inside the reduction gear.
Engine tachome-
Calibration of indication ٤
ter
Alarm switch Actuation test ٤

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‫ޓ‬MAINTENANCE CHECKING (Engine Using Heavy Fuel Oil)

F 1,500 㨪 7,000-sec. Equiv-

Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100q
alent Fuel Oil) (1/3)

An asterisk ( ) given in the following tables refers to the timing of initial check after the initial start or
part replacement. Perform the check from the second time and onward at the ordinary frequency.

Checking & Servicing

Frequency (hrs.)

2 㨪 3 yr. or 8,000 㨪 10,000

5 yr. or 16,000 㨪 20,000
3 mo. or 1,000 㨪 1,500
6 mo. or 2,000 㨪 2,500
1 yr. or 4,000 㨪 5,000
Part to Be
Div. Nature of Service
Checked

Fuel injection
Drawing-out check & adjustment 1,500 㨪 2,000 1st time:500 㨪 800hrs
valve
Check & adjustment of the valve head clearance ٤
Cylinder head

Check of valve spring ٤

Check disassembly & check of valve rotator ٤
Disassembly, check & cleaning ٤
Cylinder head
Grinding of suc./ehx. valve seat ٤
Scale cleaning & hydraulic test of water chamber ٤
Replacement of stem seal (Suc./Ehx. Valve) ٤
Check of cyl. head bolt tightening force 㧖 ٤
Drawing-out, cleaning, checking & measurement
of piston ٤
Piston
Check & measurement of piston rings ٤
Check & measurement of piston pin ٤
Check & measurement of piston pin metal ٤
Connecting Check & measurement of crank-pin metal ٤
rod Check of connecting rod bolt tightening force ٤
Change of connecting rod bolts 20,000 hrs.
Inner dia. checking, cleaning & measurement ٤
Cyl. liner Drawing-out, check & cleaning of water jacket
٤
Major Moving Parts

part
Measurement of crank pin outer dia. & journal ٤
Crankshaft
Measurement & adjustment of deflection ٤
Disassembly, metal checking & measurement ٤
Check on tightening force of main bearing clamp-
Main bearing ٤
ing bolts
Check on tightening force of side bolts ٤
Check of cam & roller bearing ٤
Disassembly & check of fuel pump tappet ٤
Camshaft Disassembly, check & measurement of swing arm ٤
Drawing-out of crankshaft & bearing check &
measurement ٤
Check of tooth bearing & backlash ٤
Disassembly of idle gear & check & measurement
Timing gear ٤
of bearing
Check of idle gear mounted shaft tightening force ٤

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‫ޓ‬MAINTENANCE CHECKING (Engine Using Heavy Fuel Oil)

F 1,500 㨪 7,000-sec. Equiv-

Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100q
alent Fuel Oil) (2/3)
Checking Servicing
Cycle (hrs.)

2 㨪 3 yr. or 8,000 㨪 10,000

5 yr. or 16,000 㨪 20,000
3 mo. or 1,000 㨪 1,500
3 mo. or 2,000 㨪 2,500
1 yr. or 4,000 㨪 5,000
Part to Be
Div.

Nature of Service
Checked

Check of tooth bearing & backlash

Major Moving Parts

Fuel feed ٤
pump, lub. oil Disassembly, check & measure-
pump, & cold ment of bearing ٤
water pump
driving Check of gear mounted shaft tight-
intermediate ening force ٤
gear.
Change of hydraulic fluid 㧖 ٤
Gov. Gear

Governor
Disassembly & check ٤
Governor Disassembly & check of tooth bear-
driving gear ing & bearing ٤

Check of injection timing ٤ 1st time: 300 - 500

Fuel injec-
Check of deflector & replacement ٤
tion pump
Disassembly, cleaning & check ٤
Fuel feed Disassembly & check ٤
Fuel Oil System

pump Replacement of oil seal ٤

Pressure Check on filling of ethylene glycol ٤
gauge seal
pot Change of ethylene glycol ٤
Replacement of Accumulator (for
Accumulator Fuel oil line: F.O. Main pipe & Pres- ٤ optional part
sure regulating valve.)
F.O.control &
stop air pis- Replacement of o-ring ٤
ton
Change (depended on results of
Lub. oil ٤
property analysis)
Lub. oil Disassembly, check cleaning, &
cooler hydraulic test ٤

Thermostatic
Lub. Oil System

Disassembly, check & cleaning ٤

valve
Disassembly, check & measure-
ment ٤
Lub. oil pump
Disassembly & check of pres. reg.
valve & safety valve ٤

Change the element

Turbo-
Change the element of lub. oil 1,000- When the lub. oil
charger lub.
strainer 2,000 pressure dropped by
oil strainer
0.3MPa(3kgf/cm2)

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‫ޓ‬MAINTENANCE CHECKING (Engine Using Heavy Fuel Oil)

F 1,500 㨪 7,000-sec. Equiv-

Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100q
alent Fuel Oil) (3/3)
Checking Servicing
Cycle (hrs.)

2 㨪 3 yr. or 8,000 㨪 10,000

5 yr. or 16,000 㨪 20,000
3 mo. or 1,000 㨪 1,500
3 mo. or 2,000 㨪 2,500
1 yr. or 4,000 㨪 5,000
Part to Be
Div.

Nature of Service
Checked

Thermostatic
Disassembly, check & cleaning ٤
valve
Cooling Water System

Cooling water Disassembly, check & measurement ٤

pump Replacement of mechanical seal ٤
Fresh water Disassembly, check, cleaning & hydrau-
cooler lic test ٤

Cooling water Change (depended on results of prop-

(Fresh water) erty analysis) ٤

Sea water cool- Check of anticorrosive zinc & replace-

ing parts ment (Air cooler & Lub. oil cooler) ٤

Turbocharger Disassembly & cleaning ٤

Disassembly, check, cleaning & hydrau-
Boost air cooler ٤
lic test
Disassemble and clean the muffler ele-
Every 6 months
ment. (Clean with neutral detergent.)
Remove the starting motor from the
engine and turn the pinion gear manu-
Every 6 months
ally, check that it turns smoothly and it
emits no abnormal sound.
Disassembly, inspection, cleaning and
Other

Starting air replacement of grease of moving parts.

motor replacement of o-ring, first reduction ٤
gear bearing and special grease inside
the reduction gear.
Disassembly, inspection, cleaning and
replacement of grease of moving parts.
replacement of o-ring, 1st & 2nd reduc- ٤
tion gear bearings and special grease
inside the reduction gear.
Engine tachome-
Calibration of indication ٤
ter
Alarm switch Actuation test ٤

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3. Routine Maintenance Checking & Adjusting Procedures

6-3-1. Measurement of Running Performance
Check and record the following engine performances once a day while the load is stable.

(1) Each cylinder internal max. combustion pressure (Pmax)

(2) Each cylinder outlet exhaust gas temperature
(3) Turbocharger inlet exhaust gas temperature
(4) Lub. oil temperature (at the cooler inlet)
(5) Lub. oil temperature (at the engine inlet)
(6) Cooling water temperature (at the engine inlet)
(7) Cooling water temperature (at the engine outlet)
(8) Cooling water temperature (at the air cooler inlet)
(9) Cooling water temperature (at the air cooler outlet)
(10) Cooling water temperature (at the lub. oil cooler outlet)
(11) Boost air temperature
(12) Engine inlet fuel temperature (for engine using H.F.O.)
(13) Each pressure indicated on the gauge panel
(14) Room temperature

Drawing 6-1 (1/2) Running Performance Confirming Points

Operating Side

Fuel Oil Pressure Gauge

Drawing 6-1 (2/2) Running Performance Confirming Points

Non-operating Side Engine Front End

ԡ Ԡ Ԣ Ԝ ԛ ԟ Ԟ
ԝ

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Compare readings with corresponding valves given in the Records of Shop Trial or the Records of Transfer
Trial, and if found to be abnormal, carry out an adjustment or servicing required.

Refer to the following items since the engine performance vary according to the room temperature,
water temperature, condiltions of load, etc.
(1) The dispersion of the maximum combustion pressure (Pmax) among cylinders is normal if it is
within 0.5Mpa (5kgf/cm2).
• Pmax may rise considerably as depended on properties of fuel oil. However, in any case, run the
engine to keep Pmax below 18.1Mpa (185kgf/cm2).
• Reflation between the Pmax and the boost air temperature
If the room temperature rises, Pmax falls; conversely, if the room temperature drops, Pmax rises.
There is a tendency of Pmax 0.1 MPa (1kgf/cm2) against the room temperature change 3 ͠ .
(2) Exhaust temperature refers to the corresponding temperature recorded in the Transfer Trial.
• The dispersion of the exhaust temperature among the respective cylinder outlets is normal if it is
within 40 ͠ .
Even if this temperature is found not uniform among cylinders, it is unnecessary to force revising this
non-uniformity if the fuel injection volume and Pmax are found uniform among cylinders.
• Relation between the room temperature and the exhaust temperature.
The exhaust temperature varies at the rate of about twice the room temperature change. Neverthe-
less, use the engine within the limit values, maintaining a good servicing of the engine, etc. and
reducing the load because fouling of turbocharger and suction/exhaust passage, exhaust pressure,
properties of fuel oil, etc. may influence this relation.

6-3-2. Measurement of Max. Combustion Pressure (Pmax)

Wear gloves when taking a measurement because the pressure indicator becomes hot.

(1) Prepare the following exclusive tools:

No. Exclusive Tool Description Part No.

Ԙ Pressure indicator cock turning handle 153605 - 92360

ԙ Pressure indicator 137600 - 93751

Drawing 6-2. Pmax Measurement Procedures

Turning Handle
Inserting Hole

Valve
Max. Pressure Indicator Cock

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(2) Open the valve of pressure indicator cock with use of pressure indicator cock turning handle Ԙ , and
lightly race/rev up the engine for two to three times.
(For prevention of dust and foreign matter from intruding into pressure indicator)
(3) Attach the pressure indicator ԙ , and close its exhaust valve Ԛ .
(4) Be sure to fully open the valve of pressure indicator cock withe use of turning handle, and close the
indicator cock when the pressure becomes the highest.
(5) After reading out the Pmax, open the exhaust valve of pressure indicator.
(6) Detach the pressure indicator when its needle shows 0 MPa (0 kgf/cm2).

(When the pressure indicator cock is found hard to loosen, use the turning handle.)

(1) Should the dispersion in Pmax among cylinders exceed 0.5MPa(5kgf/cm2), adjust it with the injec-
tion timing of within 1q.
(2) Should the Pmax exceed its limiting value, adjust the injection timing upon examining the engine
performances.

6-3-3. Regulation of Fuel Injection Volume (Rack Scale)

(1) Should the dispersion in exhaust temperature among cylinders exceed 40 ͠ under the serviced
state of the fuel injection valve, adjust the rack of the corresponding fuel injection pump.
(2) Keep the range of dispersion of rack adjustment among cylinders within one scale graduation.

Drawing 6-3. Fuel Injection Volume Regulating Procedures

FUEL VOL.
FUEL DECREASE FUEL INCREASE Fuel Injection Pump
Rack

(1) Loosen the lock nut Ԙ .

(2) Turn the adjusting screw ԙ as follows:
Clockwise: To increase the injection volume (exhaust temperature rise)
Counterclockwise: To decrease the injection volume (exhaust temperature drop)
(3) Tighten the lock nut.

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-4. Adjustment of Fuel Injection Timing

If it is necessary to adjust the fuel injection timing as based on the data recorded during a load run, stop
the engine, and adjust the timing according to the following procedures:

1) Procedures for checking the fuel injection timing

(1) Turn the flywheel to align the marked-off line on the body of fuel injection pump with that on the
plunger guide.
(2) The scale graduation pointed out by the flywheel pointer at this time indicates the fuel injection timing.
(The flywheel scale within the range of r 10 to 30qfrom the T.D.C. is graduated in 2q, and outside the
range, 5q.)

2) Adjustment of the injection timing

Do not bring your fingers close to the lock nut nor oil shield plate while turning the flywheel. Other-
wise, your fingers may be caught in, resulting in an injury.

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Single-ended wrench (M24) for adjusting bolt 138603 - 92510

Double-ended wrench 28110 - 220240

Ratchet handle for turning 147673 - 92851

Socket (M24) for turning 147673 - 92841

Drawing 6-4. Fuel Injection Timing Adjusting Procedures

Maked-off Line
Fuel Injection Pump

Oil Shield Plate

(2) Turn the flywheel to position the adjusting bolt Ԙ at the lowermost.
(3) Loosen the lock nut ԙ .
(4) Turn the flywheel in the direction of engine rotation so as to align the flywheel pointer with the injection
timing (indicated by the flywheel scale) of a cylinder to be adjusted.

Advance the injection timing: Pmax rises.

Delay the injection timing: Pmax drops.

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(5) Turn the adjusting bolt to align the marked-off line on the pump body with that on the plunger guide.
(6) Turn the flywheel to position the adjusting bolt at the lowermost.
(7) Tighten the lock nut.
(Have the adjusting bolt fixed with use of a wrench so as not to allow the bolt to turn together when
lock nut is tightened.)

After having adjusted the injection timing, turn the flywheel in the direction of engine rotation. When
the adjusting bolt has come to its uppermost position, further push up the oil shield plate to make sure
there is allowance for the pump stroke. (Use the fuel pump priming tool.)

Drawing 6-4-2. Fuel Injection Pump Priming Tool

No. Exclusive Tool Description Part No.

Operate
Ԙ Priming lever 147673 - 92920

ԙ Lever support 147673 - 92930

Tappet

6-3-5. Checking of Fuel Injection Valve &

Adjustment of Injection Pressure
Improper servicing of fuel injection valve greatly affects the fuel combustion and output. However, it is gen-
erally difficult to specify the servicing frequency which depends on such as the fuel oil used and service
load. Therefore, determine the proper servicing frequency based on such as changes of exhaust tempera-
ture and exhaust color.

In the engine using high viscosity fuel oil, the fuel injection nozzle is indirectly cooled. For servicing
and dismantling the fuel valve, refer to Fig. 36-C: Fuel injection maintenance procedure.

1) Drawing-out of a fuel injection valve

(1) Prepare the following exclusive tools:

No. Exclusive Tool Description Part No.

Ԙ Body of fuel injection valve drawing-out tool 147673 - 92340

ԙ Drawing-out bolt 147673 - 92330

Ԛ Nut 26732 - 160002

Hexagonal wrench key (M8) 28150 - 080000

Hexagonal wrench key (M6) 28150 - 060000

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Drawing 6-5. Fuel Injection Valve Drawing-out Procedures

Rocker Arm
Shaft Pedestal

Fuel Valve Tightening Nut

Fuel Valve Guard

Nozzle Sleeve

Case Nut Packing

(2) Remove the clamping bolts Ԝ of fuel injection pipe joint ԛ with use of hexagonal wrench key. (Also
remove the bolts on the fuel injection pump side.)
(3) Loosen the cap ԝ nut of fuel injection pipe Ԟ , and remove it with the fuel injection pipe.
(4) Remove the fuel valve tightening nut.

Handle the injection pipe with care because oil leakage takes place if the spherical surface on either
end of fuel injection pipe is flawed.

(5) Screw the drawing-out bolt ԙ into the fuel valve guard.
(6) Attach the body of drawing-out tool Ԙ .
(7) Tighten the nut Ԛ to draw out the fuel valve.
(8) Draw out the case nut packing. (It may be drawn out together with the fuel valve.)

2) Incorporating the valve

After cleaning, check or replacement of the fuel valve and adjustment of fuel injection pressure is finished,
incorporate the fuel valve while observing the following point:

(1) Take care not to damage the tip of nozzle sleeve when clearing the fuel valve mounting hole.
(2) Replace the case nut packing with new one.
(3) First tighten the cap nut ԝ of fuel injection pipe, and then tighten the fuel valve tightening nut.
(4) Do not make a mistake in the incorporating direction because spherical washers are used to the
injection pipe joint clamping bolts on the fuel injection pump side.
(5) Tighten the clamping bolts of fuel injection pipe joint ԛ on the cylinder head side and the fuel injec-
tion pump side alternately and gradually in two or three times.

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‫ޓ‬MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

3) Leaked oil check

During a run immediately after servicing of a fuel injection valve, check for oil leaked from the overflow
pipe.
(A) Leaked oil take-off part of the injection pipe and injection pipe joint
(B) Leaked oil take-off part from the nozzle clearance.

Drawing 6-6. Leaked Oil Take-off Parts

Injection Pipe Joint

4) Disassembly & cleaning of a fuel injection valve

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Socket for case nut 146673 - 92260

Single-ended wrench (M41) for pressure regulation 146673 - 92270

Hexagonal wrench key (M8) 28150 - 080000

(2) Clean carbon adhered to the nozzle exterior, and then disassemble the fuel injection valve. (Removal
of carbon is facilitated by soaking the nozzle in the carbon remover or stock solution of cresol.)
(3) First remove the fuel valve guard, and then disassemble the valve sequentially in the ascending order
of numbers shown in the drawing below.

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Drawing 6-7. Fuel Valve Disassembling Sequence

Fuel Injection Valve Holder Set Bolt

Guard (Flange) Flange

Fuel Injection Valve

Holder Fuel Injection Valve
Holder

O-ring O-ring

O-ring

O-ring
O-ring

(4) Check & servicing of various parts

٤ Check for sulfuric acid corrosion on the periphery of nozzle ԛ . If found noticeable corroded, replace the
nozzle with a new one.
٤ If the nozzle valve has stuck of it does not move smoothly, replace it with a new one.

٤ When the stepped wear "A" of valve stop spacer Ԝ exceeds 0.15mm, replace it with a new one.

٤ Replace the case nut Ԛ and O-rings of body of fuel injection valve with the respectively new ones.

٤You are recommended to hold spare parts of nozzle, supposing that its average service life is about 2,500

hours.

(5) Reassemble a fuel injection valve in the sequence reverse to disassembly, paying attention to the fol-
lowing paints:

(1) Do not make a mistake in the incorporating direction of the spring seat ԝ , spring shoe ԟ and
spring shoe guide Ԡ .
(2) Tighten the case nut to the specified torque using an exclusive socket. Excessively tightening it
may cause the nozzle to malfunction and the straight pin to be broken.

Chapter9. Table or Tightening Torques of Major Bolts

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5) Injection test & injection pressure regulation

When operating the nozzle tester, be careful not to expose any part of your body to spray from the
injection valve.
If exposed, you would be seriously wounded because the injection pressure is very high at 34MPa
(347kgr/cm2)

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Nozzle tester 737600 - 93110

Injection pipe for nozzle tester 141616 - 93420

Single-ended wrench (41) for pressure regulation 146673 - 92270

Socket for case nut 146673 - 92260

Double-ended wrench (41 ˜ 46) 28110 - 410460

Drawing 6-8. Injection Test & Injection Pressure Regulating Procedures

Injection Pipe
for Nozzle Tester

Nozzle Tester

Case Nut

Set the fuel injection valve downwards.

(2) Attach the injection valve to the nozzle tester.

(3) While slowly operating the hand lever of the tester, adjust the screwing-in of the pressure adjusting
nut Ԙ to attain the specified injection pressure.
(4) Quickly operate the hand lever of the tester (at rate of two to three strokes per second), and check the
state of spray. If the hand lever of the tester is operated slowly at this time, fuel oil runs down after the
hand lever is stoked, and you might err in judgment that the nozzle is defective. Thus, pay attention to
this regard.
• Replace such a clogged nozzle or nozzle which gives a streaky injection with the new one.
(5) The nozzle can be used continually if the oil tightness of the seat part maintains a pressure 2.0 MPa
(20kgf/cm2) lower than the specified injection pressure and allows the fuel oil to such an extent of
oozing out from the nozzle tip.

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(1) When replacing the nozzle, remove the case the case nut under the loosened state of the pressure
adjusting nut. If the case nut is loosened under a high state of the injection pressure, the mating
surfaces of nozzle and spacer and the straight pin may be damaged.
(2) Tighten the case nut to the specified torque with use of exclusive socket.

(6) When the injection test and adjustment of injection pressure are finished, tighten the lock nut ԙ with
an exclusive single-ended wrench. (To prevent the adjusting nut Ԙ from being turned together with
the lock nut, lock it with a double-ended wrench.)

6-3-6. Adjustment of Suc./Exh. Valve Head Clearance

Adjust the suction/exhaust valve head clearance according to the following procedures because the valve
mechanism of this engine is so constructed to retain two suction (or exhaust) valves by means of the T-
shaped valve guard which will be distorted to cause an abnormal wear to the valve guard guide and/or
valve guide unless adjusted to retain two valves simultaneously:

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Feeler gauge 0.4-mm thick (suction) 28312 - 400750

Feeler gauge 0.5-mm thick (exhaust) 28312 - 500750

Drawing 6-9. Valve Head Clearance Adjusting Procedures

A B

Valve Guard

(2) Turn the flywheel to bring the cylinder for which the clearance is to be adjusted to assume the T.D.C.
of the compression stroke.

Do not mistake the T.D.C. of overlap for the instructed T.D.C.

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(3) Loosen the lock nuts ԙ & ԛ , and then loosen the rocker arm adjusting screw Ԙ and valve guard
adjusting screw Ԛ .
(4) Press down the center of the valve guard from above (so that the clearance ㅀ becomes zero under
this condition). Gradually tighten the valve guard adjusting screw Ԛ so that the clearance ㅁ
becomes zero. After the adjustment, lock the adjusting screw Ԛ not to turn, and securely tighten the
lock nut ԛ .
(5) Put a feeler gauge into a clearance ㅂ between the rocker arm adjusting screw Ԙ and the valve guard,
and gradually tighten the rocker arm adjusting screw Ԙ until the clearance becomes narrow enough
to permit the feeler gauge to be smoothly drawn out. Then, lock the adjusting screw Ԙ , and tighten
the lock nut ԙ .
(6) After having securely tightened the lock nut ԙ , check that the feeler gauge can be smoothly drawn
out.

The valve head clearance of a suction valve and that of an exhaust valve are different. Be careful not
to mistake the clearance of one valve for that of the other.

Valve head clearance: Chapter 3. Table of Engine Standard Adjustments

6-3-7. Adjustment of Lub. Oil Pressure

The lubricating oil pressure regulating valve has been integrated in the lubricating oil pump.
Should the lubricating oil pressure go out of the specified value, adjust it according to the following proce-
dures:

(1) Before adjusting the lub. oil pressure, first clean the lubricating oil strainers.
(2) Run the engine, and then adjust the lubricating oil pressure to the specified value only after the
lubricating oil temperature is stabilized.

Drawing 6-10. Lub. Oil Pressure Adjusting Procedure

(1) Remove the cap nut Ԙ , and loosen

the lock nut ԙ .

(2) Adjust the screwing-in of the adjusting

bolt Ԛ to regulate the pressure.
Pressure Regulating Valve
ԙ Ԙ Clockwise ... The pressure rises.
Counterclockwise ...
The pressure drops.

(3) Securely tighten the lock nut and cap

nut.

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6-3-8. Adjustment of Lub. Oil Temperature

An automatic thermostatic valve has been equipped to the lubricating oil cooler to rise the lubricating oil
temperature in a short time after the engine is started and to maintain the temperature in the proper range
during a run. The lubricating oil temperature varies with a change of the cooling water temperature in each
season and sea aria, a fluctuation in the cooling water flow rate, fouling of the lubricating oil cooler, etc.

The automatic thermostatic valve has been set so that the lubricating oil temperature at the engine inlet
becomes 50 to 65 ͠. However, if the lubricating oil temperature exceeds this range, adjust and check it
according to the following procedures:

1) Adjustment of lubricating oil temperature

Drawing 6-11. Lub. Oil Temperature Adjusting Procedures

Element

Piston

A
ԙ
Ԛ
Ԙ
ԛ
Nameplate

Cover

(1) Remove the cap nut Ԙ , and loosen the lock the lock nut ԙ .
(2) Check the projecting dimension ㅀ of the adjusting bolt Ԛ .
(3) Screw the adjusting bolt in the direction of an arrow shown on the nameplate, and make sure the tem-
perature drops. (The bolt screwing-in depth must be 17mm or less.)

Should the temperature do not drop even after the above adjustment, fouling of the lubricating oil
cooler, sticking of a piston of malfunction of the element, etc. may be suspected. Investigate the
cause, and restore the engine to the former proper condition.

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2) Check of automatic thermostatic valve

Stop the engine discharge the lubricating oil from the lubricating oil cooler, and then check the automatic
thermostatic valve according to the following procedures:

(1) Loosen the bolt ԛ shown in Drawing 6 -12, and then detach the cover.
(2) Check if the piston moves smoothly. (If the piston is catching or stuck, restore it to the proper condi-
tion.)
(3) Take out the piston (incorporating the element withe a circlip)
(4) Soak the element in cold water and warm water for 3 to 5 minutes, respectively, and measure the lift
ㅁ of element spindle.

Drawing 6-12. Element Checking Procedures

Element

Piston

Spring

Circlip

Element Spindle

Lift of the element spindle (normal part)

Checking Water Temperature Lift ㅁ

Cold water of 30 ͠ or less 5 r 0.1mm

Warm water of 65 ͠ or more Greater than 23mm

(5) If the lift of element spindle does not satisfy the values shown in the above table, replace the element
with the new one.
(6) Adjust the projecting dimension ㅀ of the adjusting bolt Ԛ to 36mm, and then attach the cover.

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6-3-9. Adjustment of Fuel Oil Pressure

The fuel oil pressure regulating valve is equipped to the end of fuel oil return pipe together with a damper
which absorbs the pulsating pressure inside the return pipe.

Drawing 6-13. Pressure Regulating Valve Equipped Point

Fuel Oil Pressure Gauge

Pressure Regulating Valve

Damper

(1) Before adjusting the fuel oil pressure, first clean the fuel oil filters.
(2) Adjust the fuel oil pressure, taking the tank head pressure into consideration.

Drawing 6-14. Fuel Oil Pressure Adjusting Procedures

Adjusting Screw Fuel Oil Inlet

Fuel Oil Outlet

(1) Turn the pressure adjust screw as follows:

Clockwise ... The pressure rise.
Counterclockwise ... The pressure drops.

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6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valves

An automatic thermostatic valve has been equipped to cylinder jacket to rise the cylinder jacket cooling
water temperature in a short time after the engine is started and to maintain the temperature within the
proper range during a run. The cooling water temperature varies with the load conditions and the cooling
water (cold fresh water) temperature at the boost air cooler inlet. This automatic thermostatic valve has
been set so that the cooling water at the engine outlet becomes 85 ͠ when the cold fresh water tempera-
ture is 38 ͠ . However, if this cooling water temperature is not within the range from 80 ͠ to 90 ͠ as for
your guide, overhaul check the thermostatic valve according to the following procedures:

Drawing 6-15. Thermostatic Valve Removing Procedures

Air Bleeder
Thermostatic Valve Element

Throttle Plate

Throttle Plate

Cold Water Pump Hot Water (Jacket Cooling Water) Pump

1) Removal of thermostatic valve elements

(1) Close each valve at the inlet and outlet of the cooling water system, and then discharge the cooling
water from inside the cylinder jacket.
(2) Remove the air bleeder.
(3) Detach the side cover.
(4) Remove the thermostatic valve case, and take out the elements.

Be careful not to drop the thermostatic valve elements.

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2) Check of thermostatic valve elements

The thermostatic valve is equipped with two elements of different valve opening temperatures.
Check the elements according to the following procedures:

(1) Check for crack of the valve, broken spring and foreign matters caught on the valve seat face.
(2) Soak the elements in cold water and hot water for 2 to 3 minutes, respectively, and measure the valve
lift ㅀ .

Drawing 6-16. Element Checking Procedures

Valve Valve Opening Temp. Stamp

Valve lift of the element (normal part)

Checking Water Temperature Lift ㅀ

Cold water of 30 ͠ or less 45 r 1mm

Hot water of 95 ͠ to 100 ͠ Greater than 55 r 1mm

(3) If the valve lift does not satisfy the values shown in the above table, replace the elements with new
one.

3) Incorporation thermostatic valve elements

Incorporation thermostatic valve element in the sequence reverse to removal.

(1) Do not make a mistake in the element incorporating direction.

(2) Do not forget to incorporate throttle plates at thermostatic valve case inlet and outlet sides.

6-3-11. Cleaning of Lub. Oil Bypass strainer

The lubricating oil system is equipped with a centrifugal bypass strainer in addition to a notch-wire oil
strainer. During a run, keep open a cock at outlet of lub. oil pump to allow the lubricating oil to flow through
the strainer regularly. When any problem has occurred to the bypass strainer, close the cock to stop the oil
flow.

Stop the engine before cleaning the bypass strainer.

If you disassemble the bypass strainer during a run, oil mist may be blown off, causing you to get a
burt.

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GF-2type Bypass Strainer

1) Disassembly & cleaning

Disassemble and clean the lub. oil bypass strainer according to the following procedures:

Drawing 6-17. GF-2type Bypass Strainer Disassembling Procedures

Bearing

Spindle

Body
Nozzle

Bearing

Lub. Oil Inlet

Lub. Oil Outlet

(1) Loosen the tightening nut Ԙ of the body cover ԙ , and then remove the cover ԙ .
(2) Remove the rotor assembly (spindle, rotor cover ԛ and rotor body Ԝ ).
(3) Lock the nozzle section of rotor assembly.

When locking the nozzle section, take care not to flaw the nozzle hole and the spindle bearing.

(4) Loosen the rotor cover tightening nut Ԛ , and then detach the rotor cover ԛ .
(5) Completely remove the sludge adherent to the rotor body Ԝ and inside of rotor cover ԛ , and then
wash them.

Completely remove the sludge. Otherwise, the residual sludge may cause an unbalance in rotation,
resulting in a damage to the bearing.

(6) Check for flaws of the bearings of body and body cover.

2) Reassembly

Reassemble the lub. oil bypass strainer in the sequence reverse to disassembly, paying attention to the
following points.

(1) Check for clogging of the nozzle and damage of the nozzle hole before incorporating the rotor
cover.
(2) Incorporate the body cover after incorporating the rotor assembly into the body and making sure it
rotates smoothly.

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6-3-12. Cleaning of Lub. Oil Strainer

Engine Main Lubricating Oil Strainer
The lubricating oil strainer is of the manual back-washing, duplex changeover type, and its element are of
the notch-wire type. In a normal run, the lubricating oil passes through both sides (both elements) of the
strainer.
Besides, a differential pressure indicator which detects the oil pressure at the inlet and outlet of the strainer
has been fitted to the lubricating oil cooler so as to detect clogging of the strainer.

When the difference between the oil pressures at the inlet and outlet of the strainer reaches 0.09 MPa
(1kgf/cm2), the differential pressure alarm is issued.

Be careful not to get burnt by touching this strainer because it assumes a high temperature during a
run.

• Should the differential pressure not drop even if back-washing is done, overhaul and clean the
strainer.
• Should the strainer be fouled noticeably, a lub. oil pressure drop alarm may be issued when one side
of this strainer is used. Therefore, check the oil pressure while cleaning the strainer.

1) Back washing (blow-off)

Wash both sides of this strainer, one at a time, according to the following procedures:
(1) Align the red mark of the changeover cock Ԙ with the LEFT (or RIGHT) CHANGE position on the
nameplate.
(2) Loosen the drain plug ԙ two to three turns.
(3) Carry out the changeover cock with the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds.
(4) Return the changeover cock with the CHANGE position.
(5) Repeat the above operation steps (3) & (4) three or four times.
(6) Tighten the drain plug.
(7) Return the changeover cock to the NORMAL RUN position.

Drawing 6-18. Lub. Oil Strainer Cleaning Procedures

Changeover Cock Nameplate

LEFT CHANGE

22.5

LEFT BLOW-OFF O-ring

NORMAL RUN

Case

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2) Disassembly & cleaning

When disassembling this strainer during a run, do so one side of the strainer at a time according to the fol-
lowing procedures:
(1) Align the red mark of the changeover cock Ԙ with the LEFT (or RIGHT) CHANGE position.
(2) Loosen the drain plug ԙ of red mark side.
(3) Loosen the air vent plug Ԛ of red mark side.
(4) Discharge the lubricating oil in the case, loosen the nut ԛ , and then detach the blow-off pipe Ԝ .
(5) Loosen the center bolt ԝ , and remove the case and element.
(6) Clean the removed.

6-3-14. Cleaning of Strainer/Filter Element

3) Incorporation

Incorporation a strainer element in the sequence reverse to disassembly, paying attention to the following
points.

• Do not make a mistake in the element incorporating direction.

• Take care not to permit the O-ring bit in the case.
• When setting the changeover cock in the NORMAL RUN position, shift it slowly. If shifted rapidly, the
oil pressure may temporarily drop before the case is filled with the lubricating oil, causing the lubricat-
ing oil pressure drop alarm to be issued.

Turbocharger Lubricating Oil Strainer

The lubricating oil strainer is of the duplex changeover type and its elements are of the paper type. In a
normal run, the lubricating oil passes through both sides (both elements) of strainer.
Besides, a pressure switch is provided on the outlet side of strainer to detect clogging of the strainer.

When the lub. oil pressure at the outlet of strainer has dropped to 0.29 MPa (3kgf/cm2), replace the
elements of the strainer.
• When the lub. oil pressure at the outlet of strainer has dropped to 0.29 MPa (3kgf/cm2), the pressure
drop alarm will be issued.
Simultaneously, the relief valve of strainer will open to allow sludge and contaminant in the strainer
to flow to the turbocharger, thereby damaging the bearing. Take care not to let the lub. oil pressure
to drop excessively.
• If the strainer is fouled noticeably, the lub. oil pressure drop alarm may be issued when one side of
this strainer is used. Therefore, keep checking the pressure carefully while operating one side of this
strainer.

Be careful not to get burnt by touching this strainer because it assumes a high temperature during a
run.

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1) Disassembly & cleaning

If you disassemble the strainer during a run, disassemble and clean on element then the other sequen-
tially.
(1) Align the red mark of the changeover cock with the LEFT (or RIGHT) CHANGE position.
(2) Remove the drain plug of red mark side, and discharge the lub. oil from the case.
(3) Loosen the air vent plug of red mark side.
(4) Loosen the center bolt, and remove the case and element.
(5) Replace the element.

Drawing 6-19.

Pressure Gauge
Air Vent Plug
Changeover Cock
Pressure Switch

LEFT CHANGE RIGHT CHANGE

O-ring

NORMAL RUN Case

Relief Valve
Element

Drain Plug
Center Bolt

2) Incorporation

Incorporate a strainer element in the sequence reverse to disassembly, paying the attention to the follow-
ing points.

• Do not make a mistake in the element incorporating direction.

• Take care not permit the O-ring bite in the case.
• When setting the changeover cock in the NORMAL RUN position, shift it slowly. If shifted rapidly, the
oil pressure may temporarily drop before the case is filled with the lubricating oil, causing the lubricat-
ing oil pressure drop alarm to be issue.

6-3-13. Cleaning of Fuel Oil Filter

The fuel oil filter equipped is of the heat-insulating, manual back-washing, duplex changeover type, and its
elements are of the notch-wire type. In a run, the fuel oil passes through both sides (both elements) of this
filter.

Be careful not to get burnt by touching this filter because it assumes a high temperature during a run
on H.F.O.

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• Should the filter be fouled noticeably, the revolution of the engine may decrease as the fuel oil pres-
sure drops when one side of this filter is used. Therefore, check the fuel oil pressure while cleaning
the filter.
• A positioning notch is provided to the changeover handle. In a blow-off or disassembly, tilt the handle
to align the notch with the knock pin.

1) Back-washing (blow-off)

Wash both sides of this filter, one at a time, according to the following procedures:
(1) Open the drain cock Ԙ .
(2) Hold the changeover handle in the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds, and then
return it to the BOTH SIDES IN USE position.
(3) Repeat the above step (2) three or four times.
(4) Close the drain cock.

Drawing 6-20. Fuel Oil Filter Cleaning Procedures Drawing 6-21.

H.F.O. Filter M.D.O. Filter

BOTH SIDES IN USE BOTH SIDES IN USE

LEFT
BLOW - OFF
80
50 LEFT 90 60
BLOW - OFF

LEFT
DISASSEMBLY

LEFT
DISASSEMBLY

2) Disassembly & cleaning

When disassembly this filter during a run, do so one side of the filter at a time according to the following
procedures:
(1) Tilt the changeover handle ԙ to the LEFT (or RIGHT) DISASSEMBLY position.
(2) Open the drain cock Ԙ to discharge the fuel oil.
(3) Open the air vent cock Ԛ .
(4) Lift up the heat-insulating case ԛ , loosen the clamping bolt of filter cover Ԝ , and then remove the
cover.
(5) Remove the circular nut ԝ .
(6) Remove the element, and clean it.
6-3-14. Cleaning of Strainer/Filter Element

(7) Clean the inside of the filter body.

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3) Incorporation

Incorporation a filter element in the sequence reverse to disassembly, paying attention to the following
point.

(1) When setting the handle in the BOTH SIDES IN USE position, shift it slowly. If shifted rapidly to the
BOTH SIDES IN USE position, the oil pressure may drop before the filter is filled with the fuel oil.
(2) Open the air vent cock to bleed air.

6-3-14. Cleaning of Strainer/Filter Element

Clean a notch-wire type element of lubricating oil strainer or fuel oil filter according to the following proce-
dures:

Drawing 6-22. Notch-wire Type Element Cleaning Procedures

8/6 Pipe Cock

Smash to about 1mm

(1) Soak the element in the light oil or cleaning fluid to remove the sludge adherent on the surface with a
wire brush.
(2) Prepare a nozzle as shown in the above drawing, and spray the compressed air of 0.3 to 0.5 MPa (3
to 5 kgf/cm2) from the inside of the element.
(3) Lighting the element form its inside, make sure the dirt and foreign matters have been removed.
(4) Check for flaws, wire breakage, corrosion, etc. on the surface of notch wire.

6-3-15. Washing of Turbocharger Blower

When the blower of turbocharger is fouled, the exhaust temperature may rise, shortening the service life of
fuel injection valves and exhaust valves.
Also, the effect of late washing is lower than that of timely washing. Therefore, record the boost air pres-
sure before and after such a washing, and referring to the recorded data, periodically wash the blower.

(1) Wash the blower during a run of abut 75% or more load. After washing it, continue a load run for at
lest one hour.
(2) Should the boost air pressure not restored even after washing the blower, overhaul and clean it.
(3) Fresh water alone does not have the effect of cleaning the blower. For washing the blower, use the
cleaning fluid (P/#137616-18400).

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Drawing 6-23. Turbocharger Blower Washing Procedures

Hand Pump

Water Filler Plug

Cap

(1) Open the drain cock on the outlet side of boost air cooler.
(2) Suck one washing’s usage of the cleaning fluid into a hand pump.

Type RH163: 0.2 ltr.

One washing’s usage
Type RH183, RH203: 0.3 ltr.

(3) Connect the land pump with the water filler plug, and pour in the cleaning fluid in 4 to 10 seconds.
(4) Repeat the above steps (2) & (3) three of four times.
(5) Pour fresh water of the same quantity as the cleaning fluid into the washer, and carry out washing with
fresh water in the same way above procedures.
(6) After the washing, attach the cap to the water filler plug, and close the drain cock.
(7) If the boost air pressure is not restored, wait next 10 minutes, and then repeat the above washing.

6-3-16. Maintenance of Pressure Gauge

Glycerin aqueous solution is sealed in a pressure gauge equipped on the gauge panel to prevent wear of
the gear and link mechanism inside the gauge.
Handle a pressure gauge, observing the following items:
(1) When removing the gauge panel or a pressure gauge for its servicing, have the rubber cap of a pres-
sure gauge faced upward.
(If faced sidelong, the sealing liquid will leak through the ventilating hole in the rubber cap.)
(2) Always maintain the sealing liquid at the specified level.

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Drawing 6-24. Level of Pressure Gauge Sealing Liquid

Rubber Cap

B
A Minimum liquid level A = 18mm
Higher Liquid level B = 25 26mm

(3) Should the sealing liquid become contaminated or its level drop, detach the rubber cap, and change
the sealing liquid or replenish the pressure gauge with its sealing liquid.
(Sealing liquid (P/#42111-002800) is optionally available.
(4) When a pressure gauge is replaced with the new one, use it after cutting off the navel of the rubber
cap to open a ventilating hole to the gauge.
(If the gauge is not provided with an opened ventilating hole, the indication becomes be out of order.)

Adjustment of Pressure Take-off Main Valve

Check and adjust the operating of a needle valve provided at the piping part of a pressure gauge or
pressure transmitter in order to prevent the damage or malfunction of the pressure gauge and pres-
sure transmitter that are subject to pulsation.
• Fuel pressure main valve: Open 1/4 turn from the completely closed position.
• Other pressure main valve: Open one turn from the completely closed position.

Adjustment of Remote Indicating Pressure

In the case of remote indication of a pressure, a pressure transmitter has been equipped. If the indication
on the remote side has to be adjusted, proceed to the adjustment according to the following procedure:

[ Adjusting Procedure ] Drawing 6-25. Top Cover

• Detach the top cover from a pressure
transmitter. Screwdriver
• Lightly press a small screwdriver (of
which head is 2mm in diameter)
against the ZERO or SPAN adjust
screw, and turn the screw as the need 2mm
Press.Transmitter
arises.
Adjusting Screw

Test Valve

Connector

• As the screw is turned clockwise, the ZERO ADUJUSTMENT SPAN ADUJUSTMENT

indicated value varies in the direction
mA mA
of an arrow shown in the following
graphs. 20 20
Current

Current

4 4

0 Po P P kgf/cm2 0 P P kgf/cm2
Pressure (MPa) Pressure (MPa)

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6-3-17. Measurement of Crankshaft Deflection

If the crankshaft deflection enlarges excessively, the crankshaft may be broken, resulting in an accident.
Consequently, periodically measure the crankshaft deflection.

(1) Measure the crankshaft defection under the cold state of the engine.
(2) When you have removed of further tightened the engine installation (anchor) bolts, common bed
clamping bolts or driven machine (such as generator) clamping bolts, are disassembled or retight-
ened, measure the crankshaft deflection.
(3) Move the contactor of deflection gauge, and make sure the needle of dial gauge returns to the orig-
inal position.

1) Deflection measuring procedures

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Deflection gauge 42111 - 002520

Deflection gauge mirror 42111 - 001420

Ratchet handle for turning 147673 - 92851

Socket (M24) for turning 147673 - 92841

(2) Open the pressure indicator cocks of all cylinders.

(3) Turn the flywheel to bring it to the position EB of 30 degrees after the B.D.C.
(4) Fit the deflection gauge, and set the needle of dial gauge in the zero indication.
(5) Slowly turn the flywheel in the rotational direction of the engine, and take and record readings of the
dial gauge at the position E, T, P and PB.

Drawing 6-26. Position for Fitting the Deflection Gauge Drawing 6-27. Deflection Measuring Positions
T

P E
D
L
D/2

PB EB

Crank Pin Position

Deflection Gauge EB 30 after B.D.C. (measuring reference)

E 90 before T.D.C.
D = Diameter of crankshaft of 200mm
L = Width across arms of 96mm T Top Dead Center (T.D.C.)
P 90 after T.D.C.
PB 30 before B.D.C

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2) Criteria on results of the deflection measurement

The relation between the deflection valve (reading of dial gauge) at each measured position with the refer-
ence taken at the position EB and the crankshaft is as shown in the below table.

Drawing 6-28.
Reading of Dial Gauge 㧗 㧙

Crankshaft
(lower spread) (lower contract)

(1) Should the deflection increase every time it is periodically measured, this is caused by the wear of the
crankshaft and/or main bearings. If the deflection of only a certain cylinder increases suddenly, it is
suspectable that the corresponding main bearing metal is abnormally worn. In these cases, check for
the pertinent parts.
(2) Since the deflection value measured under the hot state of the engine varies as depending on the
temperature existing at the measurement, it cannot be relied on as the reference. However, accord-
ing to out test results, that deflection is roughly 2/10,000 to 3/10,000 ˜ stroke (lower contract).

3) Allowable value of the deflection

Should the crankshaft deflection exceed the allowable value, correct the deflection by redistributing the
installation shims and shaft centers of the engine and driven machine (or outer bearings).

(1) In case of the direct coupling systems ㅀ , ㅁ , & ㅃ , the normal deflection for the No.1 cylinder is
lower contract.
(2) In case of the direct coupling systems ㅂ , adjust the deflection for the No.1 cylinder to lower spread
because the temperature rise of engine bearings becomes larger than that of generator bearings
during a run and thus the shaft center of crankshaft becomes comparatively higher.

Table: Allowable value of the deflection

[Unit:1/100mm] Note: "S" stands for s stroke
No.1 㨪 2 Cyl.
Installation No.1 Cyl. No.2 Cyl.
Coupling System Driven machine P-E No.3 㨪 8 Cyl.
System T-PB/EB T-PB/EB
(direction)
(direction) (direction)
-5.8 㨪 +2.9 -5.8 㨪 +2.9 r 2.9 r 2.9
Generator, single- Direct
ㅀ (Direct coupling) 1S 1S
(stationary) -2S 㨪 +1S -2S 㨪 +1S
side bearing
ާ‫ިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓ‬
10,000 10,000 10,000 10,000
-5.8 㨪 +2.9 -5.8 㨪 +2.9 r 2.9 r 2.9
Generator, single- Vivration
ㅁ (Direct coupling) -2S 㨪 +1S -2S 㨪 +1S 1S 1S
side bearing insulation
ާ‫ިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓ‬
10,000 10,000 10,000 10,000
r 2.9 r 2.9 r 2.9 r 2.9
Generator, both- Direct
ㅂ (Direct coupling) 1S 1S 1S 1S
side bearing (stationary) ާ‫ިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓ‬
10,000 10,000 10,000 10,000
-10.2 㨪 +2.9 -5.8 㨪 +2.9 r 2.9 r 2.9
ㅃ (Air clutch & flexi- Pump & coupres- Direct
1S 1S
(starionary) -3.5S 㨪 +1S -2S 㨪 +1S
ble coupling) sore
ާ‫ިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓާިޓޓޓޓޓ‬
10,000 10,000 10,000 10,000

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Drawing 6-29. Driven Machine Direct Coupling Sistem.

Rubber Vibration Insulator

Air Clutch & Flexible Coupling

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6-3-18. Adjustment of Fuel Injection Pump Pinion Lubricating Volume (for Engine Using
H.F.O.)
The pinion sleeve of fuel injection pump of an engine using the heavy fuel (equivalent to 3,500-sec. or
7,000-sec. fuel oil) has been lubricated by lub. oil. Adjust the lubricating volume according to the following
procedures:

(1) First run the engine, and then adjust the lubricating volume when the lubricating oil temperature
becomes 55 to 65 ͠ .
(2) Adjust the lubricating volume so that the lubrication becomes 1 dropful per 10 to 12 seconds.

Drawing 6-30. Lubricating Volume Adjusting Procedures

Oil Flow Rate

Regulating Valve

Lubricating Point

(1) Remove the cap nut Ԙ from the lub. oil flow rate regulating valve, and loosen the lock nut ԙ .
(2) Fully screw in the lub. oil flow rate adjust screw Ԛ .
(3) Remove the plug ԛ on the fuel injection pump side to check the lubricating volume.
(4) Gradually loosen (turn counterclockwise) the adjust screw until the lubricating volume becomes as
specified.
(5) When the lubricating volume has become as specified, securely tighten the lock nut ԙ, cap nut Ԙ and
plug ԛ .

6-3-19. Maintenance of Fuel Oil Seal Pot (for Engine Using H.F.O.)
Maintenance servicing of mentioned in Section 4-1-2. (Page4-6)

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6-3-20. Check & Replacement of Anticorrosive Zinc

In the case of the fresh & sea water 2-line cooling specification, anticorrosive zincs have been fitted to the
boost air cooler, lub. oil cooler. Check them according to the following procedures:
• In the case where such anticorrosive zinc is found consumed more than 70% of the state retained by the
new article, replace it with the new one.

Dimensions (mm)
Fitting Area (Q’ty)
Diameter (DǾ) Length (L)

Cooling water inlet/outlet cover (2)

Boost air cooler 40 40
Water return cover (2)

Inlet side cover (1)

Lub. oil cooler 40 40
Outlet side cover (1)

Cooling water inlet/outlet cover (4)

Fresh water cooler 40 40
Water return cover (2)

• In the case of continuous use of such anticorrosive zinc, get rid of the oxide layer from the surface of the
zinc to expose the metallic texture.
• The anticorrosive zinc for boost air cooler upper part is of the plug type. Detach the inspection window
cover from the boost air duct, and remove the plug, using a hexagonal wrench key (having the width
across flats of 17mm).

After checking and replacing an anticorrosive zinc and before fitting the inspection window cover,
check that there is no water leakage.

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Drawing 6-31. Anticorrosive Zincs Equipped points

Boost air cooler Anticorrosive Zinc Fitting Prosedures

‫ޣ‬A-Flange Type‫ޤ‬

Nut
Flange

Packing

Anticrrosive
L Zinc

Lub. Oil cooler

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