Chapter 13 ADJUSTMENT AND OPERATION

1.

Engine - Adjust ...................................................................................................... 13-3

1.1
1.2
1.3
1.4
1.5
1.6

2.

Break-in operation ................................................................................................. 13-7

2.1
2.2
2.3

3.

Turning gear - Use.................................................................................................................. 13-3

Valve bridge and Adjusting screw - Check ............................................................................. 13-4
Valve clearance - Check......................................................................................................... 13-4
Fuel injection timing - Check................................................................................................... 13-4
Fuel system - Bleed air ........................................................................................................... 13-4
Belt and belt tension - Inspect and Adjust .............................................................................. 13-6
Preparation before engine starting ......................................................................................... 13-7
Engine start-up ....................................................................................................................... 13-7
Break-in operation .................................................................................................................. 13-7

Engine Test and Adjustment ................................................................................ 13-9

3.1
3.2
3.3
3.4
3.5
3.6

Engine performance test......................................................................................................... 13-9

Emission test .......................................................................................................................... 13-9
Governor performance test..................................................................................................... 13-9
Alarm action and emergency stop tests.................................................................................. 13-9
Maximum fuel injection volume - Set ...................................................................................... 13-9
Seal ...................................................................................................................................... 13-10

13-1

Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust

Chapter 13 ADJUSTMENT AND OPERATION

1.1 Turning gear - Use

Before starting the engine, make sure that the turning gear is in the pulled-out position.If the engine is started while
the turning gear is engaged (pushed-in position), it will cause not only damage to the ring gear but also could result
in personal injuries.
(1) Loosen two bolts, and remove the plate from the slot of
the shaft.
Shaft
Bolt

Bolt

(2) Push in the shaft all the way so that it engages with the

Plate

Turning gear - Use (for operation)

ring gear.

(3) Using a socket and ratchet handle, rotate the shaft to

turn the gear.
(4) After the turning is completed, pull out the shaft, insert

Turning gear - Use (push-in)

Socket

the plate into the slot of the shaft, and tighten the bolts.
Make sure that the plate is firmly fitted in the slot of
shaft.
Ratchet handle

Turning gear - Use (turning)

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Chapter 13 ADJUSTMENT AND OPERATION

1.2 Valve bridge and Adjusting screw - Check
Check the adjustment of the valve bridge and adjusting
screw.If it is unadjusted, adjust it to the standard value.
For the adjusting procedure, refer to "Valve bridge and
Adjusting screw - Adjust" of "ASSEMBLY OF BASIC
ENGINE."

1.3 Valve clearance - Check

Check the valve clearance.
If it is unadjusted, adjust it to the standard value.
For the adjusting procedures, refer to
"Valve clearance - Inspect and Adjust" of "ASSEMBLY OF
BASIC ENGINE. "

1.4 Fuel injection timing - Check

Check the fuel injection timing.
If it is unadjusted, adjust the timing to the specified value.
For the adjusting procedures, refer to
"Fuel injection timing - Check and Adjust" of "ASSEMBLY
OF BASIC ENGINE. "

1.5 Fuel system - Bleed air

(a) Wipe off fuel spilled from the air vent plug thoroughly.Spilled fuel can cause fires.
(b) After bleeding of air is completed, be sure to lock

[Unlock]

[Priming]
Turn left

[Lock]
Move up
and down

the priming pump cap. If locking is insufficient, it

could cause damage to the priming pump and
result in fuel leaks and fires.
To bleed air from the fuel system, start the air bleeding at
the place nearest to the fuel tank, i.e. water separator, fuel
filter and injection pump (in that order), while feeding fuel

Priming pump - Operate

with the priming pump.

1.5.1 Fuel filter (paper element) - Bleed air
If the air vent plugs, thread portion of bracket or sealing washers are damaged, replace them with new

Air vent plug

9 1 Nm
{0.9 0.1 kgfm}
[6.5 0.7 lbfft]

ones.
(1) Loosen the air vent plugs of the fuel filter by approx.
1.5 turns.
(2) Feed fuel by moving the priming pump up and down.
(3) When fuel flowing from the vent holes no longer contains air bubbles, tighten the air vent plugs to the specified torque.

13-4

Fuel filter (paper element) - Bleed air

Hold and
turn right

Chapter 13 ADJUSTMENT AND OPERATION

1.5.2 Fuel injection pump - Bleed air
(1) Loosen the air vent plugs of the fuel injection pump by
approx. 1.5 turns.

(2) Feed fuel by moving the priming pump up and down.

(3) When fuel flowing from the vent holes no longer con-

Air vent plug

15 2 Nm
{1.5 0.2 kgfm}
[11 1.4 lbfft]

tains air bubbles, the air vent plugs should be tightened.

However, before tightening the last air vent plug, lock
the priming pump by turning the cap clockwise while
pushing it down.
Note:(a) If all the vent plugs are tightened before the priming
pump cap is locked, fuel pressure acts on the feed

Priming pump
cap

Fuel injection pump - Bleed air

pump, making it hard to press the pump. However,

the check valve operation condition can be checked
because the pressure is stabilized at the check valve
opening pressure.
(b) Wipe off fuel spilled from the air vent plug thoroughly.

1.5.3 Priming pump cap - Lock

If the priming pump cap is not locked sufficiently, the
screw inside wears due to engine vibration, which may

Position where
hand-tightening
becomes suddenly
heavy

90 10
Priming pump

cause the priming pump cap to pop off and fuel to leak.
If it is over-tightened, the head of the priming pump
can be damaged. Make sure to tighten at the correct
angle.

Check the head packing of the priming pump for defor-

Priming pump cap - Lock

mation and damage. If there is any deformation or

damage, replace the priming pump with a new one.
(1) Tighten the priming pump cap fully by hand, and mark

Head packing

this position.
(2) Using a wrench, further tighten the priming pump cap
by 90 10from the mark position.
(3) Check the mounting condition of head packing. If any
defects such as deformation or dent are found, replace
the priming pump with a new one.
Priming pump cap packing

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Chapter 13 ADJUSTMENT AND OPERATION

1.6 Belt and belt tension - Inspect and Adjust

If any defects such as cuts or surface separations are found during inspection, replace the belt with a new one.
Keep oil and grease off the belt. Oil or grease on the belt causes the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt. Adjust
the belt tension accurately by following the procedures below:
1.6.1 Belt - Inspect
(1) Inspect the belt visually for separation or damage.If any defects are found, replace the belt with a new one.
(2) Inspect the deflection of V-belt.
Inspect the V-belt deflection by pressing it with approx. 98 to 147 N {10 to 15 kgf} [22 to 33 lbf] force at the center of its
span. The belt deflection should be 10 to 15 mm [0.39 to 0.59 in.].
If the deflection is out of standard, adjust the belt tension.
1.6.2 Belt tension (alternator) - Adjust

10 to 15 mm
[0.39 to 0.59 in]

(1) Remove the belt cover.

(2) Loosen all the fixing bolts of alternator.
(3) Turn the adjusting rod to adjust the belt tension.
(4) Tighten all the fixing bolts of alternator.
(5) Install the belt cover.

Mounting
bolt

Lock nut (Left-hand

thread)
Adjusting bolt
Lock nut (Left-hand
thread)

Belt tension (alternator) - Adjust

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Chapter 13 ADJUSTMENT AND OPERATION

2. Break-in operation
2.1 Preparation before engine starting
Check the levels of fuel, engine oil, and coolant, and also bleed air from the fuel system and cooling system.
Inspect the link between the governor output lever and the fuel injection pump rack. Check that the fuel control rack is in the
no-injection position when the engine is stopped. Check that the control rack is in the "0" position when the stop lever is
pulled.
Check the wiring of the electrical system (sensor, meter alarm panel, starter, alternator, stop solenoid, and battery), and check
that there is no abnormality when the controller main switch is turned ON.
Set the governor speed lever so that the engine runs at a low idle speed after the start-up.
Operate the stop solenoid, and check that the fuel injection pump rack moves to the no injection position.
Install the pressure gauge, thermometer and flowmeter as required.

2.2 Engine start-up

(1) With the stop lever pulled in the no injection position, rotate the crankshaft for approx. 10 seconds using the starter to allow
the engine oil circulation around the engine. Repeat this 2 or 3 times with one minute rest between them.
Check that there are no defect such as abnormal noise or rotational fluctuation.
(2) Start the engine in the normal way.
Make sure the engine can run at a low idle speed after start-up.
(3) Make sure that the oil pressure increases immediately and the coolant circulates.
(4) Make sure there is no leakage of oil, coolant, fuel and gas (air), and there is no abnormal noise and abnormal vibration.
(5) After making sure that the engine can run at a low idle speed without any problem, turn the key switch to OFF position,
and make sure that the engine has stopped.

2.3 Break-in operation

To be prepared for unforeseeable circumstances during engine operation, make sure that an emergency stop is
available.
2.3.1 Break-in operation load and operation time
The load during break-in operation should be increased progressively as shown in the table.
Note that the time shown in the table is the minimum time required to check the engine in a stable condition.
Break-in operation
Rotation speed (min-1)

Load (PS)

Time
(min)

1 Low rotation speed

600 to 900

No-load

20

Medium rotation
2
speed

1000 to 1200

No-load

10

3 High rotation speed

1400 to rated speed

No-load

10

25 %

20

50 %

20

75 %

30

100 %

20

4
5
6
7

Rated speed

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Chapter 13 ADJUSTMENT AND OPERATION

2.3.2 Inspection while the engine is running
During the break-in operation, pay attention to followings and make sure there are no abnormalities.
Oil pressure and oil temperature

Exhaust temperature

Coolant level and water level

Differences between right and left banks

Any leakage of oil, coolant fuel, and gas (air)

Blow-by gas (amount and color)

Noise and vibration

Rotational fluctuation

Intake air pressure and intake air temperature

Face and radial runouts of rotating parts

Exhaust color and odor

Indication and operation of meter and alarm

2.3.3 Inspection and adjustment after break-in operation

Valve clearance

Belt tension

Fuel injection timing

Inspection of defects such as oil leakage, and repair

Bolts and nuts around the engine - Retighten

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Chapter 13 ADJUSTMENT AND OPERATION

3. Engine Test and Adjustment

(a) Engine test, adjustment and seal should be performed at the appointed maintenance shop only.
When the seal of engine is performed at a service shop other than the appointed shops, ask an appointed
shop for the presence of qualified person for test, adjustment and seal.
(b) Performance check and adjustment of the engine shall be conducted when the water and oil temperatures
become stable after sufficient warm-up operation.
After the break-in operation is completed, and the engine runs normally, check the performance and functions of the engine.
Record the test results by referring the engine data at the time of delivery.

3.1 Engine performance test

Fuel consumption rate, various temperatures and pressures,
and exhaust density

3.2 Emission test

Exhaust analyses
3.3 Governor performance test
Minimum speed at no-load (low idle speed) - Set
Maximum speed at no load (high idle speed) - Set
Load application and load dump tests
Governor regulation, hunting, and rotational fluctuation - Check
Setting conditions of governor controller and others - Check

3.4 Alarm action and emergency stop tests

Oil pressure decrease, water temperature increase, and overspeed

3.5 Maximum fuel injection volume - Set

(1) With the rack set cap at the end of the fuel injection
pump rack (front side) removed, apply rated (maximum) load.

Increase
the fuel injection
volume

Spring case

(2) Secure the nut at the position that the double nut at the
rack end comes into contact with the spring case end
face.

33 3.3 Nm
{3.37 0.34 kgfm}
[24.34 2.43 lbfm]
The rack position in maximum load
The position that the fuel injection pump rack is 0

Maximum fuel injection volume - Set

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Chapter 13 ADJUSTMENT AND OPERATION

3.6 Seal
After all performance tests and adjustments are completed, stop the engine, and seal the specified portion between governor
actuator and fuel injection pump rack.
3.6.1 Tamper proof - Remove
Tamper proof nut is composed of double structure, and can-

Inner nut

not be removed by rotating.

To remove, cut the outer cylinder nut and remove the inner
nut.

Self-locking nut

Outer cylinder nut

Tamper proof - Remove

3.6.2 Tamper proof - Install
Tighten the tamper proof nut to the specified torque, and
make sure that the inner nut has been separated.

Tamper proof nut

201.0 Nm
{2.040.1kgfm
[14.80.7 lbfft]
Self-locking nut
171.7 Nm
{1.730.17kgfm
[12.51.25 lbfft]

Tamper proof - Install

13-10