NingBo G6300ZCA MaintenancesManuals 01

Operation and Maintenance Manual
For
Series G300 Diesel Engines
Ningbo C.S.I. Power & Machinery Group Co., Ltd.

Please fill the following form after the first operation and mail it to us, thanks!
Ningbo C.S.I. Power & Machinery Group Co., Ltd.

75, Daqing South Road, Ningbo, Zhejiang, China
Post Code: 315020
E-mail: cnpower@mail.nbptt.zj.cn
H0TU UTH
Gentlemen,
The following diesel engine has been put into operation in our company. Now the corresponding
information is given as follows.
Engine model No.

Ex-works date
Installation date
Installation company
Company
Address
Department in charge
User Contact person
Telephone
E-mail
Post code
Starting date
Remarks
Foreword
This manual consists of two parts. Part one describes general technical features, operation and
maintenance information, and Part two describes detail constructions of the G300 diesel engines.
For details of turbocharger, governor and others, please refer to correspond manuals.
Users, especially operators, are advised to read the manual carefully prior to first time operation.
The Ningbo C.S.I. Power & Machinery Group Co., Ltd. does not assume any responsibility for
damage caused by wrong operation even not if nothing has been mentioned about the case in the
manual.
Only when the engine has been operated according to the manual and repaired and maintained in
time, the engine can be in better technical conditions to have longer service life and provide user
with best benefit.
The manual is only for those persons who are operating the G300 diesel engine and it is not allowed
to place the manual at the disposal of third parties.
Part Ⅰ
Operation and Maintenance Manual

Contents
1. General descriptions
1.1 Designation
1.2 General description
1.3 Main technical specifications
1.4 Engine rotation direction
1.5 Cylinder numbering and ignition sequence
1.6 Engine accessories
1.7 Power transmission
1.7.1 Generator
1.7.2 Marine diesel engine
1.7.3 Torsional vibration
2. Main technical data

2.1 Characteristics curves
2.2 Performance data
2.3 Adjustable data
2.4 Operating data
3. Fuel, lube oil and cooling water

3.1 Fuel
3.1.1 Light diesel oil
3.1.2 Heavy fuel oil
3.2 Lube oil
3.2.1 Circulating lube oil
3.2.2 Lube oil for turbocharger
3.3 Cooling water
4. Transit and storage

4.1 Lifting the engine
4.2 Transit
4.3 Storage
5. Installation
5.1 Engine room
5.2 Installation foundation
5.3 Exhaust gas system
5.4 Installation and alignment
5.4.1 Marine engine
5.4.1.1 Rigid coupling
5.4.1.2 High-flexible rubber coupling
5.4.1.3 Geislinger damping flexible coupling
5.4.2 Generating set
5.4.2.1 Adjusting block
5.5 Piping lay out and installation
5.5.1 Basic requirements
5.5.2 Fuel piping
5.5.3 Lube oil piping
5.5.4 Cooling water piping
5.5.5 Starting air piping
5.5.6 Injector cooling oil piping
6. Preparations for first time start

6.1 Unpacking
6.2 Basic requirements
6.3 Cooling water system
6.3.1 Close circuit for marine diesel engine
6.3.2 Open circuit for generating set
6.4 Lubricating oil system
6.4.1 Pump lubricating oil
6.4.2 Check lubricating oil level
6.5 Fuel oil system
6.6 Turbine oil for governor
6.7 Lubricating oil for turbocharger
6.8 Charging of air bottle
7. Operating instruction
7.1 Inspection for starting
7.1.1 Inspection for first starting after a long period of rest or extensive overhauling
7.1.2 Inspection for starting
7.2 Pre-lubrication prior to starting engine
7.3 Revolving engine with compressed air before starting
7.4 Starting engine
7.4.1 Starting reversible marine
7.4.2 Starting non-reversible engine
7.4.3 Emergency starting
7.5 Engine warm-up
7.5.1 First-time operation of new engine or overhauled engine
7.5.2 Daily operation
7.6 Engine speed regulating and reversing
7.6.1 Generating set
7.6.2 Reversible marine engine
7.6.3 Marine engine with gearbox
7.7 Monitoring engine operation
7.7.2 Lube oil temperature and pressure
7.7.3 Cooling water temperature and pressure
7.7.4 Exhaust gas temperature and color
7.7.5 Scavenging air pressure
7.7.6 Starting air pressure
7.7.7 Leakage
7.8 Shutdown
8. Conservation for a long period rest

8.1 Outer surface conservation
8.2 Inner parts conservation
8.2.1 Lube oil system
8.2.2 Fuel system
8.2.3 Cooling water system
8.2.4 Inner parts
9. Maintenance instruction
9.2 Maintenance schedule
9.3 Maintenance tasks after the first 50 operating hours
10. Trouble and remedy

10.1 The engine does not turn in starting position
10.2 Ignition fails
10.3 The engine does not stop in stopping position
10.4 The lubricating oil pressure is too low
10.5 The engine speed increases violently (over-speed)
10.6 The pressure drop of lube oil filter exceeds 1.0 bar
10.7 The lube oil temperature is too high
10.8 The oil level in lubricating oil tank rises
10.9 Abnormal noise
10.10 The engine speed falls off
10.11 The engine slows-down suddenly or stops
10.12 The temperature of the main starting air pipe to the starting air valves rises
10.13 The exhaust gases are visible
10.14 The exhaust gas temperature is too high or too low
10.15 The peak pressure is too high
10.16 The cooling water temperature is too high
10.17 The engine fails to reverse or fails to start after reversing
10.18 The maneuvering gearbox does not reverse properly
1. General descriptions
1.1 Designation
G 6 300 Z C 1 B
G -----------Series version
6 ------------Number of cylinders
300 ---------Cylinder bore, mm
Z ------------Turbocharged
C ------------For marine diesel engine; D for stationary diesel engine
1 ------------ Design version, odd number for port engine; even number for starboard engine
B ------------Non-reversible, default for reversible engine
1.2 General descriptions

Series G300 diesel engines are modern medium speed high performance engines for all applications
such as: Generator prime movers-all types, ships equipment, pumps, compressors, and ships power
units.
According to usage the engines are flexible and may be supplied in a variety of arrangements.
The engine types being equipped with four-valve cylinder heads are manufactured in various power
ratings with exhaust turbocharger and after-cooler
All types in the G300 series operate on the four-stroke cycle; the firing technique is direct fuel
injection through an injector into a ω-shape combustion chamber. The incoming combustion air is
given a rotary movement by the air entry feed.
The construction of the engine may be seen from the cross and longitudinal section views shown in
1.1 and 1.2 of Part Ⅱ, the external appearance can be seen from the general outlines in PartⅡ.
1.3 Main technical specifications
1.3.1 6-cylinder engines
Starboard G6300ZC G6300ZC12 G6300ZC10

G6300ZCBa G6300ZC8B G6300ZC6B G6300ZC16B G6300ZC18B G6300ZC20B G6300ZCA G6300ZC16Bs G6300ZD6 G6300ZD8
engine G6300ZCB G6300ZC12B G6300ZC10B
Model
G6300ZC1 G6300ZC13 G6300ZC11
Item Port engine G6300ZCBa1 G6300ZC9B G6300ZC7B G6300ZC17B G6300ZC19B G6300ZC21B G6300ZCA1 G6300ZC17Bs
G6300ZC1B G6300ZC13B G6300ZC11B
Four-stroke, water cooled, in-line, direct injection, turbocharged,

Four-stroke, water cooled, in-line, direct injection, turbocharged, after cooled, non-reversible
after cooled, reversible or non-reversible
1 Number of cylinders 6
2 Cylinder bore, mm 300
3 Piston stroke, mm 380
4 Total displacement, L 161
5 Mean piston speed, m/s 5.07 5.42 6.33 7.6 6.97 7.6 6.33 7.28 6.33 7.6
6 Rated speed, r/min 400 428 500 600 550 600 500 575 500 600
Continuous rated power
7 750(1020) 882(1200) 662(900) 971(1320) 993(1350) 1103(1500) 1471(2000) 1323(1800) 1323(1800) 735(1000) 1471(2000)
kW (Hp)
Rated 1-hour rated power 825(1122) 971(1320) 728(990) 1068(1452) 1092(1485) 1213(1650) 1618(2200) 1455(1980) 1455(1980) 809(1100) 1618(2200) 1213(1650) 1618(2200)
8
output kW (Hp)/r/min /412 /412 /412 /441 /515 /515 /618 /568 /618 /515 /593 /500 /600
12-hr rated power，
9 1103(1500) 1471(2000)
kW(PS)
Mean effective pressure
10 1.4(14.3) 1.65（16.8） 1.23(12.55) 1.69(17.24) 1.48(15.1) 1.65(16.8) 1.825(18.63) 1.79(18.28) 1.65(16.8) 1.1(11.2) 1.91(19.49) 1.65(16.8) 1.825(18.63)
MPa (kgf/cm2)P P
11 Compression ratio 13
12 Starting system Compressed air starting
13 Cooling system Marine engine：close circuit water cooling Stationary engine：Close circuit water cooling or open circuit water cooling
14 Lubricating system Pressure lubricating
15 Distance for lifting, mm 2600
16 Overall dimensions, mm 4740×1580×2800
17 Net weight, kg 17500

1.3.2 8-cylinder engines
Starboard
G8300ZC6B G8300ZC18B G8300ZC20B G8300ZC16B G8300ZC22B G8300ZD6 G8300ZD8 G8300ZD10 G8300ZC16Bs
engine
Item Model
Port engine G8300ZC7B G8300ZC19B G8300ZC21B G8300ZC17B G8300ZC23B G8300ZC17Bs
1 Type Four-stroke, water cooled, in-line, direct injection, turbocharged, after cooled, non-reversible
2 Number of cylinders 8
3 Cylinder bore, mm 300
4 Piston stroke, mm 380
5 Total displacement, L 215
6 Mean piston speed, m/s 6.33 6.97 6.33 7.60 6.97 6.33 7.60 6.33 7.28
7 Rated speed, r/min 500 550 500 600 550 500 600 500 575
Continuous rated power
8 1471(2000) 1765(2400) 1765(2400) 2000(2720) 2000(2720) 2000(2720)
KW (Hp)
Rated 1-hour rated power
9 1618(2200)/515 1942(2640)/568 1942(2640)/515 2200(2992)/619 2200(2992)/568 1618(2200)/500 2200(2992)/600 1942(2640)/500 2200(2992)/593
output kW (Hp)/r/min
12-hr rated power
10 1471(2000) 2000(2720) 1765(2400)
kW (Hp)
Mean effective pressure
11 1.65(16.8) 1.79(18.3) 1.97(20.1) 1.86(19.0) 2.03(20.7) 1.65(16.8) 1.86(19.0) 1.97(20.1) 1.91(19.49)
MPa (kgf/cm2 )P P
12 Compression ratio 13
13 Starting system Compressed air starting
14 Cooling system Marine engine：close circuit water cooling Stationary engine：Close circuit water cooling or open circuit water cooling
15 Lubricating system Pressure lubricating
16 Distance for lifting, mm 2600
17 Overall dimensions, mm 5680×1540×2870
18 Net weight, kg 21500

1.4 Engine rotation direction
port engine starboard engine port engine starboard engine
6- cylinder diesel engine 8- cylinder diesel engine
The arrow marks in Fig denote rotating directions.
1.5 Cylinder numbering and ignition sequence

a. Cylinder numbering:
The cylinders are numbered consecutively in the direction of the flywheel. Thus the cylinder
adjacent to the flywheel is No. 1 cylinder, as shown in above figure.
b. Ignition sequence
6- cylinder diesel engine:
1-5-3-6-2-4 for starboard engine
1-4-2-6-3-5 for port engine
8- cylinder diesel engine:
1-5-7-3-8-4-2-6 for starboard engine
1-6-2-4-8-3-7-5 for port engine
Note:
Ignition sequence for reverse running is contrary to that of ahead running.
Ignition sequence for stationary engine is the same as that of starboard engine.
1.6. Engine accessories
Item Accessories 6-cylinder engine 8-cylinder engine

Speed(r/min) 400 428 500 550 575 600 500 550 600
1 Turbocharger Model: VTR251
2
2 Air cooler Cooling surface KLQ48/48m P P KLQ58/58 m2P P
Speed (r/min) 672 719 840 924 966 1008 840 924 1008
3 Lubricating oil pressure pump Capacity (m3/h)
P P ≥18 ≥19.3 ≥22.5 ≥24.8 ≥25.9 ≥27.6 ≥30 ≥33.1 ≥36.8
Pressure (MPa) 0.343~0.441
Speed (r/min) 800 856 1000 1100 1150 1200 1000 1100 1200
4 Lubricating oil suction pump Capacity (m3/h) ≥21.4 ≥22.9 ≥26.8 ≥29.48 30.82 ≥33.1 ≥35.7 ≥39.3 ≥44.1
Pressure (MPa) 0.294
Speed (r/min) 1200 1284 1500 1650 1725 1800 1500 1650 1800
5 Fuel oil supply pump Capacity (L/h) 967 1035 1209 1330 1391 1451 1209 1330 1451
Pressure (MPa) 0.2
Speed (r/min) 1974 2112 2468 2715 2838 2962 2468 2715 2962
3
6 Seawater pump and fresh water pump Capacity (m /h)
P P 30 31.1 37.5 41.25 43.13 45 37.5 41.25 45
delivery head（m） 11 12.6 17.2 20.8 22.7 24.77 17.2 20.8 24.77
7 Fuel injection pump Plunger diameter (mm)

24 26
No. of holes×diameter 8×0.40 8×0.45 8×0.45 8×0.45 8×0.45 9×0.45 9×0.45 9×0.45 9×0.45
8 Fuel injector Spray angle degree 135° 135° 135° 135° 135° 145° 145° 145° 145°
Open pressure (Mpa) 24.52+0.5MPa 27.45+0.5MPa 27.45+0.5MPa 27.45+0.5MPa 27.45+0.5MPa 29.4+0.5MPa 29.4+0.5MPa 29.4+0.5MPa 29.4+0.5MPa
9 Governor Model YT111-G level type hydraulic governor for marine engine, Model YT111-Bdial type hydraulic governor for stationary engine.
10 Lube oil filter Model: SBL80Ⅱ, mash size:118/in2 P P
11 Lube oil centrifugal filter Model: FLL175, rotor speed: minimum 5000r/min, flow capacity: 3m3/h, lube oil pressure: 0.588 Mpa
P P
2
12 Fuel preliminary filter Model: SPL25CT or SBL25, mash size: 158/in P P
2
13 Fuel fine filter Model: SPL25CT or SBL25, mash size: 363/in P P
Lube oil cooler/tube and shell type Cooling surface m2 25 30

14
P P
2
/plate type Cooling surface m P P 12.88
2
Fresh water cooler/tube and shell type Cooling surface m 25 30
15
P P
/plate type Cooling surface m2 P P 12.88

16 Air bottle Capacity liter 500 (300 for 6-cylinder stationary engine)
17 Injector cooling oil cooler Type: tube and shell, cooling surface: 3.2m2 P P
1.7 Power transmission
1.7.1 Generator
For generating set below 1000 kilowatts, rotor flange of single bearing generator is rigid coupled
with flywheel of diesel engine. For generating set above 1000 kilowatts, rotor flange of two-bearing
generator is coupled with flywheel of diesel engine by flexible coupling.
1.7.2 Marine diesel engine

The following power transmission arrangement can be adopted for marine diesel engines:
a. 6-cylinder reversible diesel engine + rigid coupling + shaft
b. Reversible diesel engine + flexible coupling + clutch
c. Non-reversible diesel engine + flexible coupling + gearbox
The specifications of coupling and gearbox shall be selected according to torque transfer ratio of
the diesel engine.
The following gearboxes and couplings are recommended:
a. Gearbox
Model GWC39/41 gearbox
Model GWC42/45 gearbox
b. Coupling
Model BD56/125/5/65 Geislinger coupling
Model BC56/15/140 Geislinger coupling
Marine diesel engine can output power from both ends. Under the condition of total output not
exceed rated power, engine can develop torque of 4900Nm from front end.
1.7.3 Torsional vibration

The reciprocating and rotating masses of the diesel engine including the crankshaft, the thrust shaft,
the intermediate shaft(s), the propeller shaft and the propeller are for calculation purposes
considered as a system of rotating masses (inertias) interconnected by torsional springs. The gas
pressure of the engine acts through the connecting rod mechanism with a varying torque on each
crank throw, exciting torsional vibration in the system with different frequencies.
If adequate countermeasures are considered from the early project stage, the influence of torsional
vibration can be minimized or fully compensated.
Owing to the very large variety of possible shafting arrangements that may be used in combination
with a specific engine, only detailed torsional vibration calculations of the specific plant can
determine whether or not the influence of torsional vibration be minimized. The following data is
provided for torsional vibration calculations.
Mass table for torsional vibration calculation
a. 6-cylinder diesel engines without frequency adjusting flywheel and counterweight
No. Mass Rotating inertia kgm2
P P Stiffness coefficient kNm/rad
1 Free end 6.8303 61893.132
2 No.1 cylinder 11.8964 50404.246
3 No.2 cylinder 11.8964 50404.246
4 No.3 cylinder 11.8964 50404.246
5 No.4 cylinder 11.8964 50404.246
6 No.5 cylinder 11.8964 50404.246
7 No.6 cylinder 11.8964 50404.246
8 Rear end gear 3.8893 89969.266
b. 6-cylinder diesel engines with frequency adjusting flywheel without counterweight

1 Free end 36.096 62494.510
2 No.1 cylinder 11.8964 50404.246
3 No.2 cylinder 11.8964 50404.246
4 No.3 cylinder 11.8964 50404.246
5 No.4 cylinder 11.8964 50404.246
6 No.5 cylinder 11.8964 50404.246
7 No.6 cylinder 11.8964 50404.246
8 Rear end gear 3.8893 89908.260
c. 6-cylinder diesel engines with frequency adjusting flywheel and counterweight

1 Free end 36.096 62494.510
2 No.1 cylinder 15.297 50385.600
3 No.2 cylinder 15.297 50385.600
4 No.3 cylinder 15.297 50385.600
5 No.4 cylinder 15.297 50385.600
6 No.5 cylinder 15.297 50385.600
7 No.6 cylinder 15.297 64473.680
8 Rear end gear 3.8893 89908.260
d. 8-cylinder diesel engines with torsional vibration damper, frequency adjusting flywheel and
counterweight
No. Mass Rotating inertia kgm2P PStiffness coefficient kNm/rad
1 Free end 6.830 61891.013
2 Torsional vibration damper 11.900 1500.000
2 No.1 cylinder 15.297 50385.600
3 No.2 cylinder 15.297 50385.600
4 No.3 cylinder 15.297 50385.600
5 No.4 cylinder 15.297 50385.600
6 No.5 cylinder 15.297 50385.600
7 No.6 cylinder 15.297 50385.600
8 No.7 cylinder 15.297 50385.600
9 No.8 cylinder 15.297 64473.680
10 Rear end gear 3.8893 89908.260
Note:
1. Rotating inertia of flywheel If = 1874.13 kgm2
B B P P
2. Rotating inertia of flywheel gear Ifg = 107.35 kgm2

B B P P
3. Crank radius r=190mm, connecting rod length l=760mm.

4. Mass of piston = 89 kg
5. Mass of connecting rod = 116.55 kg, reciprocating mass = 39 kg, rotating mass = 77.55 kg
6. Reciprocating mass of piston and connecting rod = 128 kg
7. Angular velocity of crankshaft ω=πn/30=52.4 l/s (rated speed to be 500 r/min)
ω=πn/30=62.8 l/s (rated speed to be 600 r/min)
8. Mechanical efficiency ηm=0.88
B B
2. Main technical data
2.1 Performance curves
Pz Maximum combustion pressure

B B tt Exhaust gas temperature inlet to turbocharger
B B
tr Exhaust gas temperature for each cylinder

B B Pk Charging air pressure outlet from turbocharger
B B
Pt Exhaust gas pressure inlet to turbocharger

B B Ne PowerB Bge Special fuel oil consumption
B B
Load characteristics curve for Model G6300ZC engine (400r/min)

B B

B B

B B
Propeller curve for Model G6300ZC diesel engine (400r/min)

B B

B B

B B
Load characteristics curve for Model G6300ZC6B diesel engine (500r/min)

B B

B B

B B
Propeller curve for Model G6300ZC6B diesel engine (500r/min)

B B

B B

B B
Load characteristics curve for Model G6300ZC18B diesel engine

B B

B B

B B
Propeller curve for Model G6300ZC18B diesel engine

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B
Load characteristics curve for Model G6300ZCA diesel engine

B B

B B

B B
Propeller curve for Model G6300ZCA diesel engine

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

B B

2.2 Performance data
Performance Unit Data

g/kW.h ≤428 r/min 500 r/min~600 r/min
Specific fuel oil consumption
205 209
Specific lube oil consumption g/kW.h 2.18
Min. Steady speed 40% of rated speed
Speed fluctuation % ≤ 0.5 ≤ 1.5
Instantaneous speed regulation % Stationary ≤ 15 Marine ≤ 15
Steady speed regulation % engine ≤ 5 engine ≤ 8
Time for steady S ≤ 7
Cold state starting time will not exceed 10 seconds
when ambient temperature is above 8℃.
Starting performance
When ambient temperature is below 8℃, water
and lube oil preheat is permitted.
Max cold reversing air pressure: 1.47Mpa
Reversing performance for marine
Max hot reversing air pressure: 1.176Mpa
engine
Max reversing time: 15 seconds
Noise dB(A) ≤ 105
Notes:
1. The specific fuel consumption is based on the following ISO3046/1 standard ambient conditions:
Air temperature: 25℃
Total barometric pressure: 100Kpa
Charge air coolant temperature: 25℃
Relative humidity: 30%
Fuel oil lower calorific value: 42700kJ/kg
2. Ratings are the total output capability of the engine equipped with standard accessories: lube oil, fuel
oil and water pumps.
3. The Specific fuel oil consumption (SFOC) guarantee is given with a margin of 3%.
2.3 Adjustable data
a. Fuel injection advance angle and injection pressure
Fuel injection advance angle

Before T.D.C
Injection Reversible marine engine Irreversible
6-cylinder 8-cylinder Pressure Generating set
marine engine
Mpa Ahead Astern
750~882 kW 25.5+0.50
971~1103 kW 1471kW 27.5+0.50 13°-14° 11°-15° 15°-17° 15°-17°
1323~1471 kW 1765kW 30+0.50
Note:
Measure fuel injection advance angle when injection pump plunger completes a pre-stroke of 5-6mm.
b. Valve timing
Intake valve Exhaust valve

Engine Opens Closes Opens Closes
Before T.D.C After B.D.C Before B.D.C After T.D.C
6-cylinder 65°±2.5° 50°±2.5° 50°±2.5° 40°±2.5°
8-cylinder 73°±2.5° 42°±2.5° 50°±2.5° 40°±2.5°
Under cold engine condition clearances between valve bridge and rocker end should be 0.5mm for intake valve
and 0.7mm for exhaust valve. Both intake valves/exhaust valves shall come into contact with their valve bridge.
When one end is in full contact, the clearance in another end should be not more than 0.05mm.
c. Starting timing
Opening 5°± 4°after T.D.C
Intake duration 134 °
d. Height of compression chamber

When piston is at T.D.C., the distance between piston top surface and cylinder head bottom
surface shall be 12±0.5mm.
e. Height of injector protruding from cylinder head bottom surface is 4-5mm.

2.4 Operating data
No. Item Unit Data

1 Exhaust gas temperature ℃ ≤ 470
2 Max allowable temperature at turbine inlet ℃ 570
3 Charging air temperature after after-cooler ℃ 40-55
4 Supercharging pressure kPa >196
10.3 for engines with mean
effective pressure below 14bar
effective pressure below
5 Max combustion pressure MPa
17.9bar
effective pressure above
17.9bar
Inlet temperature 50-60
6 Lube oil Outlet temperature ℃ 60-80
Alarming temperature 85
Inlet temperature 50-60 for close circuit; 25-30
for open circuit
Outlet temperature 60-70 for close circuit; below
7 Cooling water ℃
45 for open circuit
Class 1 alarming temp. 80
Class 2 alarming temp. 85
Main piping pressure under rated power
0.343-0.441
(after filter)
8 Lube oil MPa
Class 1 alarming pressure 0.196
Class 2 alarming pressure 0.147
9 Fuel pressure MPa 0.147-0.245
10 Injector cooling oil pressure MPa 0.098-0.196
11 Cooling water inlet pressure MPa 0.098-0.196
12 Starting air pressure MPa 1.18-2.94
13 Maneuvering air pressure MPa 0.98
3. Fuel, lube oil and cooling water
3.1 Fuel
3.1.1 Light diesel oil
China Standard GB252-2000 Class RC0 and RC-10
British Standard BS2869 Class A2 and D
ASTM Standard ASTM D396-98 Grade No.1 and No.2
Similar oils may also be used.
Naturally, light diesel oils having low sulfur content are preferable as special measures have to be
taken for oils with higher sulfur contents as regards the lubricating oil to be used. (See under
Lubricating oil)
The following China Standard GB252-2000 specifications and British Standard BS2869
specifications for light diesel fuel are given for reference.
China Standard GB252-2000
Property RC-0 RC-10 Test method
Colour No. Max. 3.5 Max. 3.5 GB/T6540
Total sediment, mg/100mL Max. 2.5 Max. 2.5 SH/T0175
Sulfur content, %m/m Max. 0.2 Max. 0.2 GB/T380
Acid value, mgkoH/100mL Max. 7 Max. 7 GB/T258
Ramsbottom carbon residue on 10% Max. 0.3 Max. 0.3 GB/T268
distillation residue, %m/m
Ash, %m/m Max. 0.01 Max. 0.01 GB/T508
Copper strip corrosion rating max 3h Max. Class 1 Max. Class 1 GB/T5096
at 50℃
Water content, %v/v Trace Trace GB/T260
Mechanical impurities None None GB/T511
Min. 3.0 Min. 3.0 GB/T265
Kinematic viscosity, mm2/s at 20℃
Max. 8.0 Max. 8.0
P P
Freezing point, ℃ Max. 0 Max. -10 GB/T510

Cold freezing point, ℃ Max. 4 Max. -5 SH/T0246
Flashpoint(closed cup), ℃ Min. 55 Min. 55 GB/T261
Cetane number Min. 45 Min. 45 GB/T386
Distillation temperature
50% v/v recovered, ℃ Max. 300 Max. 300
Max. 355 Max. 355 GB/T6536
90% v/v recovered, ℃
95% v/v recovered, ℃ Max. 365 Max. 365
GB/T1884
Density at 20℃, kg/m3
GB/T1885
P P
British Standard BS2869: 1998
Property Class A2 Class D Test method
Kinematic viscosity at 40℃, mm2/s:
P P
Summer (16 March to 30 September) Min. 2.0 Min. 1.5 ISO3104

Max. 5.5 Max. 5.5 ISO3104
Min. 1.5 Min. 1.5 ISO3104
Winter (1 October to 15 March) Max. 5.5 Max. 5.5 ISO3104
Density at 20℃, kg/m3 P P Min. 820 - ISO3675

ISO12185
Cetane number Min. 45 - BS5580
Ramsbottom carbon residue on 10% Max. 0.30 Max. 0.30 ISO10370
distillation residue, %m/m
Distillation:
Recovery at 250℃, %v/v Max. 65 Max. 65 BS7392
Recovery at 350℃, %v/v Min. 85 Min. 85 BS7392
Flashpoint(closed cup), ℃ Min. 56 Min. 56 ISO22719
Water content, mg/kg Max. 200 Max. 200 ASTM D1744
Sediment, %m/m Max. 0.01 Max. 0.01 ISO3735
Ash, %m/m Max. 0.01 Max. 0.01 ISO6245
Sulfur content, %m/m Max. 0.20 Max. 0.20 ISO8754
Copper corrosion 3h at 100℃ Max. Class 1 Max. Class 1 ISO2160
Cold filter plugging point, ℃
Summer (16 March to 30 September) Max. -4 Max. -4 BS EN 116
Winter (1 October to 15 March)
Max. -12 Max. -12 BS EN 116
Strong acid number Zero Zero BS2000-139
3.1.2 Heavy fuel oil (HFO)

Most commercially available HFO with a viscosity below 380 cSt at 50℃ (3500 sec. RedwoodⅠ
at 100℉) can be used.
For guidance on purchase, reference is made to ISO 8217, British Standard 6843 and to CIMAC
recommendations requirements for heavy fuel for diesel engines, third edition 1990, in which the
maximum acceptable grades are RMH35 and K35.
The data in the above HFO standards and specifications refer el as delivered to the ship, i.e. before
on board cleaning.
In order to ensure effective and sufficient cleaning of the HFO i.e. removal of water and solid
contaminants – the fuel oil specific gravity at 15℃ (60℉) should be below 0.991.
Higher densities can be allowed if special treatment systems are installed.
Current analysis information is not sufficient for estimating the combustion properties of the oil.
This means that service results depend on oil properties, which cannot be known beforehand, this
especially applies to the tendency of the oil to form deposits in combustion chambers, gas passages
and turbines. It may, therefore, be necessary to rule out some oils that cause difficulties.
Based on our general service experience we have, as a supplement to the above-mentioned
standards, drawn up the guiding HFO specification shown below.
Heavy fuel oils limited by this specification have, to the extent of the commercial availability, been
used with satisfactory results on our medium speed diesel engines.
The data refers to the fuel as supplied i.e. before any on board cleaning.
Property Units Value

Density at 15℃ kg/m3 P P max. 0.991
Kinematic viscosity
At 100℃ cSt max. 35
At 50℃ cSt max. 380
Flash point ℃ min. 60
Pour point ℃ min. 30
Carbon residue % m/m max.
Ash content % m/m max.
Sulphur content % m/m max.
Water % v/v max.
Vanadium mg/kg max.
If heavy fuel oils with analysis data exceeding the above figures are to be used, especially with
regard to viscosity and specific gravity, please contact us for advice regarding possible fuel oil
system changes.
With engine equipped for heavy fuel oil operation, starting and maneuvering can be carried out on
heavy oil, as all pipes carrying fuel can be heated by means of steam. It is, nevertheless,
recommended that the engine should be started on diesel oil, if possible, and also maneuvered on
diesel oil. A changeover to diesel oil should be made prior to shutting down.
3.2 Lube oil
3.2.1 Circulating lube oil
The circulating oils must be rust and oxidation inhibited engine oil, of SAE class CD.
In order to keep the crankcase and piston cooling space clean of deposits, the oils should have
adequate dispersion and detergent properties.
Alkaline circulating oils with TBN 5-10 are recommended during heavy fuel oil (HFO) operation.
China Standard GB1122-1997 (EN SAE J183-91 and MIL-L-2104F)
Class CD10W/40 lube oil is recommended in summer, class CD 10W/30 lube oil is recommended
in winter.
The following China Standard GB11122-1997 specifications for lube oil are given for reference.
Property CD10W/30 CD10W/40 Test method

Kinematicc viscosity at 100℃, mm2/sP P
10~12.5 12.5~16.3 GB/T265
Kinematic viscosity at -20℃, mPa.s Max. 3500 Max. 3500 GB/T6538
Cold filter plugging point, ℃ Min. -25 Min. -25 GB/T9171
- - GB/T2541
Viscosity index
GB/T1995
Flash point(open cup), ℃ Min. 205 Min. 205 GB/T3536
Pour point, ℃ Max. -30 Max. -30 GB/T3535
Sediment, %m/m Max. 0.01 Max. 0.01 GB/T6531
Water content Trace Trace GB/T260
Bubbling tendency/
Bubbling stability , mL/mL Max.25/0 Max.25/0 GB/T12579
At 24℃ Max. 150/0 Max. 150/0 GB/T12579
Max. 25/0 Max. 25/0 GB/T12579
At 93.5℃
At second 24℃
Acid value, mg KOH/g Actual measurement GB/T7304

Carbon residue, %m/m Actual measurement GB/T268
Sulphuric acid ash content, %m/m Actual measurement GB/T2433
Sulfur content, %m/m Actual measurement GB/T387
Phosphorus content, %m/m Actual measurement SH/T0296
Calcium content, %m/m Actual measurement SH/T0270
Zinc content, %m/m Actual measurement SH/T0226
Magnesium content,%m/m Actual measurement SH/T0061
Nitrogen content, %m/m Actual measurement GB/T9170
3.2.2 Lube oil for turbocharger
Lube oil for turbocharger should be rust and oxidation inhibited turbine oil. China Standard
GB11120-1989 No.32 turbine oil and ISO Standard 8068-87 ISO VG32 turbine oil are
recommended.
The following China Standard GB11120-1989 specifications for No. 32 turbine oil are given for
reference.
Property No. 32 Test method

Kinematic viscosity at 40℃, mm2/s
P P
28.8-35.2 GB/T265
Viscosity index Min. 90 GB/T1995
Flash point(open cup), ℃ Max. -7 GB/T3536
Pour point, ℃ Min. 180 GB/T3536
Density at 20℃, kg/m3P P Actual measurement GB/T1884
GB/T1885
Acid value, mg KOH/g Actual measurement GB/T264
Mechanical impurities None GB/T511
Water content None GB/T260
Demulsibility at 54℃ (40-37-6 ml), min Max.15 GB/T7305
Max.450/0 GB/T12579
Defoamant, mL/mL Max. 100/0 GB/T12579
At 24℃ Max. 450/0 GB/T12579
At 93.5℃
At second 24℃
Copper corrosion 3h at 100℃ Max. Class 1 GB/T5096
Lube oil should be changed at least once every 1000 operating hours, or in accordance with the
increments of its acid value and viscosity, Max. Increment of acid value must not exceed 2 mg
KOH/g. Max. Increment of viscosity must not more than 20% of its original value.
3.2.3 Change intervals and limited values of lube oil

Lube oil change intervals are specified in chapter 9. The change interval depends on actual
operating conditions. Lube oil must be changed when one of indexes exceeds the limited value,
even though the specified operating hours have not been reached.
The lube oil change limited values are specified as follows according to China Standard
GB/T7607-1995.
Property Limited value Test method
Kinematicc viscosity change rate at 100 Max. +25 GB/T11137
℃, % Min. -25
Alkali value change rate, % Max. 50 SH/T0251
Petroleum ether unsolvable substance, — SH/T0473
%m/m
Benzene unsolvable substance, %m/m Max. 1.5 GB/T8926
Max. 150 SH/T0197
Ferrum content, mg/kg
Max. 100 SH/T0077
Acid value change value, mg KOH/g Max. 2.0 GB/T7304
Flash point(open cup), ℃ Min. 180 GB/T3536
Water content, %m/m Max.0.2 GB/T260
3.3 Cooling water

Engine and turbocharger should be cooled by fresh water. For marine diesel engine, after-cooler,
injector cooling oil cooler, lube oil cooler and fresh water cooler can be cooled by seawater. For
stationary diesel engine, the above-mentioned coolers are cooled by fresh water.
In winter when the temperature in engine room is below 5℃, cooling water in the engine and all
coolers must be drained out after shutdown so as to prevent them from being frozen.
Preferably only pure water, free from solid matter and of not excessive hardness must be used for
cooling. The use of hard water will give rise to a quick formation of scale.
Fresh water quality shall comply with following stipulation.
Limited values
Items
Content, %v/v ppm Content, mg/cm3 P P
Chloride content Max. 40 Max. 4.28×10-2 P P
Sulphide content Max. 100 Max. 9.93×10-2 P P
Soluble soild content Max. 340 Max. 0.34

Hardness Max. 170 Max. 0.17
4. Transit and storage
4.1 Lifting the engine

Two studs for lifting should be respectively fastened to the fourth pull-rod bolt on injection pump
platform and the third pull-rod bolt (all counted from flywheel end) beside exhaust pipe. Mount the
lifting beam on the studs and tighten the nuts. Fasten steel cable to both ends of beam. Lift the
engine slowly and take care to prevent engine from being inclined.
4.2 Transit
The engine has been protected against rust during transportation and storage by grease before
ex-works.
During transportation the engine shall be protected with waterproof material. When arriving at the
destination the engine should be cleaned in time and stored indoors.
Caution! During lifting or transportation external forces are permitted only to apply to stipulated
parts. Any transit tools such as ropes and levers must not be allowed to come into direct contract
with any part of the engine.
4.3 Storage
One year effective conservation period from the ex-works date is guaranteed on the following
conditions:
a. The store is dry, ambient temperature is within 5-30℃ and temperature difference
between day and night is not more than 10℃. No corrosive materials such as
chemical products, rubber products, batteries etc. are stored together with the engine.
b. After arriving at the destination, unpack the engine within ten days, dry the engine
with clean cloth and check the conservation. In case of any damage the part in
question must be coated again and the corroded spots, if present, shall be carefully
removed first.
c. The conservation coat must be checked at least once a month.
d. The store ground shall be level.
5 Installation
5.1 Engine room

The engine room is referred for generating set only.
Room including control room for one engine preferably has an area of 14m×12m with a height not
less than 6m.
One single bridge type overhead traveling crane for maintenance purpose shall be provided, the
capacity of the crane shall be at least 5 tons.
Minimum height from centerline of crankshaft to carne hook for dismounting cylinder liner shall be
2.6 meters.
The engine room ventilation system shall be laid out to maintain the temperature inside the engine
room at max 8℃ above the outside temperature.
Proper measures should be taken to protect the environment from being polluted by engine noise.
Engine room must be located at the site accessible to transportation.
5.2 Installation foundation

The quality of engine installation foundation directly affects its operation and durability.
a. Marine engine
The top surface of engine foundation must be machined so as to make it flat and smooth.
25% of the bolts that fasten the engine to the foundation must be reamer bolts. The boltholes should
be reamed through engine bedplate, block and foundation together.
b. Generating set
Diesel engine and generator are installed on a common base frame. Common base frame
foundation drawing is attached to generating set technical documents. User is recommended to
build the foundation according to the drawing.
The ground strength for foundation shall be 0.1Mpa (1kgf/cm2) and if it is soft, reinforcement by
P P
pile driving or other technique is necessary.

Never build a foundation on soft soil, river- bed or vegetal soil.
The foundation structure also affects engine vibration. In general, the larger is the foundation, the
smaller is the vibration intensity. Therefore, user shall build the foundation according to the
foundation drawing strictly. In order to minimize engine vibration to surrounding accurate
equipment, anti-vibration ditches may be dug around the foundation, or an anti-vibration plate may
be laid under the foundation.
5.3 Exhaust gas system

The exhaust gas piping system conveys the gas from the outlet of the turbocharger to the
atmosphere.
The exhaust piping system for the diesel engine consists of exhaust gas pipes, exhaust gas boiler
(for heavy oil), silencer, expansion compensator and pipe bracings
At specified MCR, the total backpressure in the exhaust gas system after the turbocharger –
indicated by the static pressure measured in the piping after the turbocharger – must not exceed 300
mm water-column (0.03bar). In order to avoid too much pressure loss in the piping, the pipe
diameter shall be bigger than 300mm. Bends shall be avoided as possible and must be not more
than two, bend radius shall be not less than 300mm.
The expansion compensator is to be arranged to absorb the thermal expansions of the exhaust gas
pipe and components.
Engine plants are usually designed for utilization of the heat energy of the exhaust gas for steam
production or for heating the oil system. The exhaust gas passes an exhaust gas boiler that is
usually placed near the engine top or in the funnel.
When the noise level at the exhaust gas outlet to the atmosphere needs to be silenced, a silencer can
be placed in the exhaust gas piping system after the exhaust gas boiler.
The exhaust gas silencer is usually of the absorption type and can be designed based on the
required damping of noise. In the event that an exhaust gas silencer is required – this depends on
the actual noise level requirements, which is normally maximum 60-70 dB(A) – a simple flow
silencer of the absorption type is recommended.
5.4 Installation and alignment

5.4.1 Marine engine
The installation quality of a marine diesel engine directly affects its durability. Poor installation
quality likely causes engine vibration and increase shafting alignment deviation. It also results in
engine to run abnormally and even causes crankshaft or other main component to be damaged.
Thus, the engine service life would be greatly shortened.
The installation quality primarily depends upon the foundation on the ship and the correct
alignment of the engine with the shafting.
After first 100 operating hours the difference in crankshaft web distance and bolts on cylinder block
and engine bedplate must be checked. After 500 operating hours the entire shafting must be
rechecked. In the case of appearing any change, correction should be made.
After cleaning the engine thoroughly, lift it horizontally into the engine room to be aligned with the
shafting.
5.4.1.1 Rigid coupling

Mounted on thrust shaft is an angle bracket, at the end of which are two adjusting screws, locked
with nuts. On the flywheel is also mounted an angle bracket with two tight bolts. When the two
bolts are aligned, turn the flywheel and thrust shaft and set them at the upper, lower, right and left
positions successively for measuring the radial clearance S1 and axial clearance S2 with a feeler at
the four positions respectively. When measuring S2, try to prevent the flywheel and thrust shaft
from axial displacement to ensure the measuring accuracy.
The difference between the maximum and minimum of the radial clearance S1 measured at the four
positions (upper, lower, right and left) should not exceed 0.10mm.
The difference between those of the axial clearance S2 should not exceed 0.05 mm.
When exceeding the stipulated value, use the adjusting screws fitted on both sides of the engine up
or down, to right or left according to the requirement of alignment.
5.4.1.2 High-flexible rubber coupling
For high-flexible rubber coupling the radial clearance should be not more than 0.20mm and the
axial clearance must not exceed 0.10mm.
Their measuring method is the same as above-mentioned.
During installation the center of reduction gear case must be set slightly above that of the engine in
order to meet the requirement about the difference in crankshaft arm distance.
5.4.1.3 Geislinger damping flexible coupling

The installing and measuring methods are the same as those of high flexible rubber coupling.
Radial clearance difference max. 0.12mm
Axial clearance difference max. 0.06mm
During installing the center of reduction gear case must be also set slight above that of the engine.
After having finished the alignment, fit in four locating blocks. Then drill and ream holes. Set four
reamer bolts into the reamed holes. Loosen the adjusting screws before tightening the bolts.
Recheck alignment as followings:
Fit in other blocks in batches. Check the number of contact points on the blocks, which should be
no less than three per 25X25 mm. The contact surface should be so tight that a 0.05mm feeler
cannot be inserted.
After having fitted all the blocks, loosen the bolts and check the axes again and measure the
difference in crankshaft arm distance, which value should comply with the stipulation.
Caution!
If the engine is installed before the launching of the ship, it must be checked again after launching.
Check the axial clearance S1 between the thrust shaft and thrust bearings on the crankshaft, when
alignment of the engine is finished and the flanges of the crankshaft and thrust shaft are being
finally jointed. The clearance S1 should be less than the clearance S3 during ahead running and
S1<S2 during astern running. The thrust force of the ship should not act on the engine and must be
born by a special thrust bearing.
5.4.2 Generating set engine with common base frame
Engine and generator are installed on a common base frame and aligned with each other before
delivery. For the conveniences of transit the engine, generator and common base frame are packed
separately.
User installs generating set on the spot as follows.
a. Place common base frame on the foundation. Tighten the foundation bolts and check the
plainness of interfaces on which the engine and generator are installed. The plainness deviation
of interfaces for installing engine should be not more than 0.15mm. The plainness deviation of
interfaces for installing generator must not exceed 0.10mm. In addition, parallelism deviation
of two interfaces should be not more than 0.10mm. This can be achieved by regulating the
thickness of adjusting blocks under the base frame.
b. Place the engine and generator on their interfaces respectively. Insert the locating pins. Check
and adjust the coaxiality of engine and generator to meet the requirements. Removes the
generator’s near bearing cover and check the clearances between the bearing terminal faces and
journal collars whether they are the same and equal to 2.5mm. After having tightened all bolts,
readjusting must be done. Then insert the locating pins to the bottom. If the pins cannot be
inserted to the bottom, the plainness of base frame must be corrected.
c. Check the difference in crankshaft arm distance for meeting the requirements.
5.4.2.1 Adjusting block

Adjusting block should be composed by two piece of steel with tapered interface, which must be
used in pair so as to easily adjust the base frame.
Two sets of adjusting block must be placed directly beside each foundation bolt. After 200
operating hours, recheck the coaxiality and difference in crankshaft arm distance of engine and
generator. Correct them if necessary. Meanwhile seal adjusting blocks.
5.5 Piping layout and installation
Reasonable layout and correct installation of the piping help extend engine service life and ensure
normal operation. Therefore, the following directions should be observed:
a. Lube oil piping, fuel piping, cooling water piping and cooling oil piping must be independent
respectively and free of leakage.
b. Piping arrangement should be convenient to inspection and maintenance. In particular, pipes
laid on floor must facilitate operator’s work and ensure safety.
c. Pipe diameters and materials must comply with the specifications provided by engine
manufacturer.
d. All fuel pipes, lube oil pipes and air pipes must be acid-treated to remove rust inside. Pipe
installation must be firm and free of bolt loosening. All piping systems are preferably provided
with hydraulic test to remedy leakage.
e. The piping layout for marine engine should be designed by the department in charge of
designing marine power plant according to key diagrams of piping systems, supplied by engine
manufacturer.
f. The piping layout for generating set engine may be done according to the following diagrams,
in which thin lines represent the pipes existing on the engine and thick lines represent pipes
being installed by user himself.
5.5.2 Fuel piping

Fuel piping includes all fuel pipes from daily fuel tank to injection pumps.
Daily fuel tank capacity for one diesel engine shall allow a continuous operation at 100% load for
at least 12 hours without refilling. Fuel tank of 1.3m×1.5m×2m for one diesel engine is
recommended. The fuel tank shall be of welded steel plate construction and be mounted in a height
of about 3m above engine foundation.
The daily fuel tank should be equipped with fuel level indicator to indicate oil level inside the tank.
When designing the tank, fire control and security must be also taken into account. Fuel tank
should be provided with a vent pipe on its top and an emergency discharge valve with a discharge
pipe under its bottom to drain fuel quickly out of the engine room if necessary.
Fuel oil system for 8-cylinder engine
1. Fuel injection pump 2. Injector 3. High pressure fuel pipe 4. Return oil main pipe
5. Return fuel pipes 6. Fuel pipe for pressure gauge 7. Model SBL25 Fuel preliminary filter
8. Valve 9. Daily fuel tank 1.3m*1.5m*2m 10. Fuel level indicator 11. Fuel pipe 12. Drainage valve
13. Pressure gauge 14. Fuel main inlet pipe 15. Fuel supply pump 16. Fuel pipe from fuel supply
pump to fuel fine filter 17. Model SBL25 fuel fine filter 18. Fuel pipe from fuel fine filter to fuel
main inlet pipe 19. Injection pump fuel inlet pipe 20. Overflow valve
Fuel oil system for 6-cylinder engine
1. Fuel level indicator 2. Daily fuel tank 3. Fuel pipe from daily fuel tank to fuel preliminary filter
4. Fuel preliminary filter 5. Fuel pipe from fuel preliminary filter to fuel supply pump
6. Fuel pipe from injector return oil pipe 7. Fuel oil pipe from overflow valve to daily fuel tank
5.5.3 Lube oil piping

The lube oil system is a two-pump system, in which the lube oil suction pump draws the engine
return oil from bedplate through a lube oil cooler, and delivers it to lube oil tank, the lube oil supply
pump then delivers lube oil from lube oil tank through a pressure regulating valve to a duplex lube
oil filter, thence to the main lube oil pipe. The lube oil is fed separately to each main bearing and to
the camshaft and its driving gears. From the main bearings the lube oil passes via the drilled
crankshaft up to the connecting-rod bottom-end bearings and up to the top-end bearings, where it
passes into the piston for cooling purposes.
In order to measure the oil inlet and outlet temperatures, temperature sensors or thermometers
stated in the following drawings should be installed on the lube oil pipes.
Minimum lube oil tank volume shall be 1.2m3, the recommended tank dimension is 1.4m×1.4m×
P P
0.8m. The lube oil tank shall be mounted to ensure that the oil level inside the lube oil tank be
higher than the inlet of lube oil supply pump.
An independent Pre-lubricating manual pump is provided for the lube oil system, which is used for
pumping lube oil before starting.
Lube oil tank shall be equipped with oil level indicator and vent port.
Lubricating oil system for 8-cylinder marine engine
1. Lube oil filter 2. Pressure sensor 3. Lube oil suction pump 4. Pressure regulating valve
5. Pre-lubricating manual pump 6. Valve 7. Lube oil supply pump 8. Main bearing lube oil pipe
9. Lube oil pipe 10. Main lube oil pipe 11.Temperature sensor 12. Valve 13.Lube oil suction pipe
14. Pressure sensor 15. Centrifugal filter 16. Vent pipe 17. Lube oil tank 18. Valve
19. Plate type lube oil cooler, 12.88m2 20.Temperature sensor
P P
Lubricating oil system for 8-cylinder generating set
1. Lube oil filter 2. Pressure sensor 3. Lube oil suction pump 4. Pressure regulating valve
5. Pre-lubricating manual pump 6. Valve 7. Lube oil supply pump 8. Main bearing lube oil pipe
9. Lube oil pipe 10. Main lube oil pipe 11.Temperature sensor 12. Valve 13. Lube oil suction pipe
14. Pressure sensor 15. Centrifugal filter16. Vent pipe 17. Lube oil tank 18. Valve
19. Plate type lube oil cooler, 12.88m2 20. Temperature sensor
P P
Lube oil system for 6-cylinder engine
1. Oil level indicator 2. Lube oil tank 3. Oil pipe from lube oil tank to lube oil supply pump
4. Non-return valve 5. Pre-lubricating manual pump 6. Pressure regulating valve
7. Oil pipe from lube oil suction pump to lube oil tank 8. Thermometer 9. Lube oil cooler
10. Oil pipes from lube oil pressure pump to lube oil filter 11. Lube oil filter
12. Oil pipe from lube oil filter to main lube oil pipe 13. Pressure gauge 14. Pressure sensor
15. Thermometer 16.Temperature sensor 17. Inlet and outlet oil pipes for pressure adjusting valve
18. Oil pipe to centrifugal filter 19.Inlet and outlet oil pipes for pre-lubricating manual pump
20. Centrifugal filter
5.5.4 Cooling water piping

The following open circuit cooling water system is used for generating set.
Cooling water drawn by water pump from water reservoir passes through after-cooler, injector
cooler and lube oil cooler, and then enters cooling water main inlet pipe. The cooling water is
discharged from main outlet pipe to cooling tower and collected in cooling pond.
The recommended water reservoir size for one engine is usually 5m×4m×3m. Water level in the
reservoir should be higher than the inlet of water pump. Water supplement device should be
provided, which can be used to regulate reservoir water temperature in case of cooling tower failure.
The reservoir must be equipped with a discharge valve to drain water away for cleaning the pond.
Model GBL-50 high-temperature fiberglass reinforced plastics cooling tower is recommended for
each diesel engine. For two or more diesel engines, cooling tower with larger cooling water volume
can be used.
Cooling water system for 6-cylinder engine

1. Water pipe from water reservoir to water pump, DN100mm
2. Water pipe from water pump to after-cooler, 3 inches/4 inches
3. Water pipe from lube oil cooler to main inlet pipe, 3 inches
4. Thermometer (0-100℃)
5. Lube oil cooler
6. Water pipe from after-cooler to lube oil cooler, 3 inches
7. Injector cooler
8. Water pipe from after-cooler to lube oil cooler, 3 inches.
9. Thermometer (0-100℃)
10. Temperature sensor
11. Water pipe from main outlet pipe to cooling tower, 4 inches
Cooling water system for 8-cylinder engine
1. Temperature sensor 2.Temperature sensor for each cylinder head 3.Temperature sensor
4. Pressure sensor 5. Valve 6. Injector cooler 7. Lube oil cooler 8. Water pump 9. Valve
10. Water reservoir 11. Cooling tower
5.5.5 Starting air piping

Compressed air from air bottle passes through the tube-shaped air filter, main starting valve and air
main pipe and then enters air distributor, which regulates the supply of control air to the starting
valves according to the firing sequence.
Inlet pipe of main starting valve : ф38mm×4mm copper pipe.
Air bottle outlet pipe: Φ38mm×4mm copper pipe.
Charging pipe from air compressor to air bottle: Φ26mm×3mm copper pipe.
5.5.6 Injector cooling oil piping
Cooling oil drawn by the cooling oil pump from cooling oil tank passes through injector cooler, and
then enters injectors. Finally the oil flows back to the cooling oil tank.
The recommended cooling oil tank size is 1m×0.5m×1m.
Inlet and outlet oil pipes of the injector cooler: Φ25mm×2mm.
Injector cooling oil system for 6-cylinder engine
1. Oil pipe from injector return oil main pipe to cooling oil tank 2. Cooling oil pump
3. Cooling oil tank 4. Oil level indicator 5. Oil pipe from cooling oil pump to injector cooler
6. Oil pipe from cooling oil tank to cooling oil pump 7.Injector cooler
Injector cooling oil system for 8-cylinder engine
1. Injector cooler 2. Thermometer 3. Pressure gauge 4. Cooling oil pump
5. Injector 6. Cooling oil tank 7. Cooling oil pipes
Injector cooling oil system for 8-cylinder stationary engine
1. Pressure sensor 2. Injector 3. Cooling oil pump Thermometer 4. Valve 5. Level indicator
6. Cooling oil tank 7. Injector cooler 8. Valve
6. Preparations for first time start
6.1 Unpacking
Before putting the engine into operation, unpack the engine as follows:
a. Remove crankcase covers, clean the preservation grease on crankshaft, connecting rods
and cylinders with cloth imbibed light diesel oil or kerosene oil, which is heated to 35-40
℃ if possible.
b. Pump lube oil with per-lubricating oil manual pump until the lube oil flows from all the
bearings and other oil holes. After pumping, the dirty oil in the engine bedplate should be
drain out and wiped off with a cloth.
c. Wipe off the preservation grease on outer moving parts such as maneuvering, controlling
and fuel regulating mechanisms.

For first starting after a long period of rest or extensive overhauling the following operation must
be carried out:
Check all pipes, bolts and connections for tightness and leakage.
Check governor and maneuvering mechanism for easy movement and proper operation.
Check monitoring and shutdown devices as well as coupling for proper operation and good
condition.
6.3 Cooling water system

6.3.1 Close circuit for marine diesel engine
Fill the expansion tank until the water flows from vent valve on outlet water pipe.
Fill the seawater pump with water.
6.3.2 Open circuit for generating set
Open all valves for cooling water; fill water pump and water pipes by the pressure difference
between water reservoir and engine.
6.4 Lubricating oil system

6.4.1 Pump lubricating oil
Start the pre-lubricating oil pump (electrical or manual) and prime the lube oil pipes up to the feed
points. Turn the changeover handle of duplex lube oil filter to T-position, in which both filters are
in operation. Open the vent valve on the lube oil filter until lube oil flows free of air bubbles from it.
Loose the vent screw on the end of lube oil main pipe until lube oil flows free of air bubbles from
lube oil main pipe.
6.4.2 Check lubricating oil level

Lube oil tank level can be checked only when the engine is pre-lubricated and lube oil pipes, lube
oil filter and lube oil are filled.
The lube oil in the lube oil system includes both in lube oil tank and in crankcase.
It is recommended that check the lube oil level after a short time running.
6.5 Fuel oil system
Turn the changeover handles of fuel preliminary filter and fuel fine filter to T-position, in which
both filters are in operation. Open the valves of fuel oil system or start the priming pump to prime
the fuel system. Loose the vent screws on the filters for about 2~3 turns until fuel oil flows free of
air bubbles from them. Loose the vent screw on the end of main inlet pipe until fuel oil flows free
of air bubbles from it. Prime the fuel injection pump by means of a special priming lever. If
injection pressure cannot establish, loose the delivery valve holder until fuel is leaking out.
6.6 Turbine oil for governor

The oil for governor should be high bubbling stability turbine oil, free from sediment or mechanical
impurity. China Standard GB11120-1989 No.32 turbine oil and ISO Standard 8068-87 ISO VG32
turbine oil are recommended. For the detail specifications of No.32 turbine oil, see 3.2.3 turbine oil
for turbocharger.
Impurity is one of important causes of deteriorating governor performance. The turbine oil should
be deposited before using, only upper part of the oil may be filled in the governor through a mesh
filter. During first-time operation, there is an additional consumption of the oil due to adjusting and
venting through compensating throttle needle valve, oil level of the governor must be rechecked
after first-time running.
6.7 Lubricating oil for turbocharger
For lube oil specifications for turbocharger, please see 3.2.2.
Remove the plugs on both sides of turbocharger bearing seat, pour oil into filler until oil level
remains near the mark on oil level indicator.
6.8 Charging of air bottle

Check the lube oil level of the air compressor.
Start up the air compressor and bring the pressure in the air reservoirs up to above 2.5 Mpa, in
which the normal working pressure is 2.94 Mpa.
In the case of using two air reservoirs, charge one air reservoir at first, as soon as the required
pressure is reached, close its charging valve at once and open another charging valve
simultaneously to charge another air reservoir.
If the pressure in air reservoir exceeds the limited value, the safety valve on air reservoir will open
automatically. In this cases, stop the air compressor immediately.
Open pressure for safety valve: 3.04-3.19 MPa
Return pressure for safety valve: 2.35-2.65 MPa
7. Operating instructions
7.1 Inspection for starting

7.1.1 Inspection for first starting after a long period of rest or extensive overhauling
Check outer bolts of engine for tightness and remove all remains left on the engine.
Check bolts inside crankcase for tightness.
Start the pre-lubricating oil pump until lube oil flows from main bearings, connecting rod bearings,
connecting rod bushes, camshaft bearings and gear bushes; check lube oil pipes for leakages.
Start the stand-by cooling water pump; put the cooling water system under working pressure of
0.196 Mpa and check the rubber seal rings on lower part of cylinder liners and interfaces between
cylinder heads and engine block as well as water pipes for leakage.
Check fuel pipes for leakage.
Check fuel injections advance angle.
Check clearance between valve bridges and valve stem tops, clearance between valve bridges and
rocker arms. Check the valve timing as well as starting timing.
Check oil level in governor.
For reversible marine engine, check oil level in reversing cylinder, test ahead and astern reversing
operation by hand once time.
Check the air pressure in air reservoir; drain water in it.
Open the test valve and start the engine without supplying fuel so as to inspect whether there is any
water or fuel in the cylinder and check if the starting valve and air distributor work in normal
condition.
Pump the injection pump by hand until injection pressure is established.
Clean fuel oil filters and lube oil filters.
7.1.2 Inspection for daily starting

Check if there are remained tools and others on shafting, clutch, coupling and engine.
Check if the barring mechanism is disengaged; check the maneuvering mechanism for easy
movement and proper operation.
Check the position of all valves for starting air, fuel lube oil and cooling water.
Check oil levels in governor, fuel tank and lube oil tank.
7.2 Pre-lubrication prior to starting engine

If the engine is out of service over an hour, pre-lubricating should be carried out with an
independently driven pre-lubricating pump (electrical or manual) before starting. The
pre-lubricating pressure should be above 0.1 Mpa.
7.3 Revolving engine with compressed air before starting

Revolving engine with compressed air before starting has the following two functions:
The first is to blow off the cold fuel likely remained in cylinder during last shutdown to avoid
violent ignition.
The second is to get bearings uniformly lubricated after pre-lubricating.
In especial, it is necessary to revolve engine with compressed air after a long period of rest, which
can be also used to check if there is water leakage in cylinder.
Open test valves and cut-off fuel supply, disengage gearbox with the engine if applied, In the case
of applying gearbox, the gears should be disengaged, push the starting handle to revolve engine
with compressed air.
7.4 Starting engine

7.4.1 Starting reversible marine engine
For reversible marine engine, it is started with a maneuvering hand-wheel. When starting the
engine, turn the hand-wheel to the required starting position (3~4 divisions on scale).
7.4.2 Starting non-reversible engine

For all non-reversible engines, marine type or generating set type, depressing the starting button
can start the engines.
Caution!
Before starting, check whether the fuel throttle is set in smaller starting delivery condition (4~5
divisions on scale of fuel pump rack) and adjust it if necessary.
Before shutdown the engine, slow down engine speed below 40% of rated speed and then depress
the shutdown button or handle.
7.4.3 Emergency starting

For engine of all types, if above-mentioned starting fails, emergency starting can be carried out
with starting handle.
7.5 Engine warm-up

7.5.1 First-time operation of new engine or overhauled engine
a. After running under 25%, 50% and 75% of load for 3-4 hours, stationary engine is allowed to
develop rated output.
b. Under above –mentioned loads marine engine should run at 63%, 75% and 90% of rated speed
for 3-4 hours and then is allowed to develop rated output.
Caution!
After first time starting and running for 0.5-1 hour the engine should be stopped. Remove
crankcase covers to inspect all moving parts inside.
7.5.2 Daily operation

It is recommended that run the engine at 50% rated speed in the initial period after starting and then
increase speed and load slowly. Only when fresh water and lube oil temperatures reach 40~50℃,
the engine can be up to full load. In general, it will take at least 30min from cold engine starting to
running under full load.
7.6 Engine speed regulation and reversing

7.6.1 Stationary engine
Engine speed is regulated with accelerating and decelerating buttons on local control desk beside
the engine.
When these buttons fail, the speed-regulating knob on dial hydraulic governor may also be used for
regulating speed.
7.6.2 Reversible marine engine

Engine speed regulation and reversing operation are program-controlled and carried out by a
hand-wheel. No matter on what running condition, turning the hand-wheel to the position of
required rotating direction and speed causes engine to reverse and change speed in
program-controlled mode.
Caution!
a. If operator makes a mistake reversing, the next reversing operation cannot be made until the
first reversing is over.
b. If the reversing operation cannot complete, i.e. camshaft does not reach the reversing position,
it is prohibited to start the engine. The causes of faults must be found out and remedied.
c. When the program-controlled reversing operation cannot be made by the hand-wheel, the
emergency reversing device may be put into operation. During emergency reversing, make sure
that hand-wheel is in shutdown position, open the air inlet cock on the upper part of emergency
valve beside control box, turn the valve rod through a 180°angle, pull the valve rod out for
running ahead and push it in for running astern. After the reversing operation is finished, the
manual emergency reversing valve should be resumed to original condition. The resuming
procedure is contrary to that of above-mentioned.
d. Emergency reversing operation can also be carried out by turning the outstanding square head
at the end of reversing cylinder shaft with a special spanner. Meanwhile, the hand-wheel must
be in shutdown position.
7.6.3 Marine engine with gearbox

Engine speed regulation and gearbox reverse are program-controlled and maneuvered with a
hand-wheel. No matter what running condition the engine is on, turning the hand-wheel to the
position of required rotating direction and speed enables engine and gear box to regulate speed,
disengage and engage gears as well as reverse direction in program –controlled mode.
When the program-controlled system fails to reverse, directly operate the handle on gearbox to
disengage gear or reverse engine.
7.7 Monitoring engine operation

The engine conditions should be paid special attention to during running. Besides reading gauges
and instruments on the engine, the operator can also observe the engine by looking, listening and
touching.
The gauges and instruments on the engine include:
Pressure, temperature and speed gauges on engine and instrument board;
Visible and audible alarming device;
Automatic shutdown device
In general, these devices are used in the combination mode.
Caution!
Stop the engine immediately in case of an alarm.
Do not start the engine before the fault is remedied if the engine is stopped by automatic shutdown
device.
Looking monitor includes observing exhaust gas color, smoke on vent openings as well as positions
and movements of the exposed parts, inspecting leakage and checking if there is abnormal
vibration.
Listening monitor includes distinguishing engine noise to check whether there are knocking noises
in cylinder, pounding noises of loosened parts and abnormal vibration noises.
Touching monitor includes touching such parts as crankcase covers, starting air pipes, fuel injection
pumps, high pressure fuel pipes and cylinder heads to check their temperatures are on normal
conditions.
7.7.2 Lube oil temperature and pressure

After starting engine, check or adjust lube oil pressure at once. Lube oil pressure of the engine
should not exceed 0.6 MPa and must be not less than 0.196 MPa at idle speed.
Caution!
If the reading of lube oil pressure is zero or less than 0.196 MPa after 10 seconds from starting,
stop the engine immediately and check lubricating oil system.
The pressure drop of duplex lube oil filter should be no more than 0.1 MPa, otherwise, and
otherwise, the lube oil filter should be cleaned. If the pressure drop falls suddenly, filter mesh is
likely broken, change over to another filter and check the first filter.
If lube oils pressure drops suddenly during running, shut the engine down at once and find out the
causes.
In order to increase lube oil temperature as quick as possible after starting, open the by-pass valve
in cooling water system to let cooling water by-pass the lube oil cooler temporarily. In any case,
lube oil temperature should not exceed the value stipulated in section 2.4.
7.7.3 Cooling water temperature and pressure
For cooling water temperature, see section 2.4.
Fill the expansion water tank up to stipulated level; check if cooling water flows fluently in cooling
water system.
Caution!
If water thermometer rises suddenly, decelerate or stop the engine at once to check whether air
enters the cooling water system. In this case, do not refill water tank or water reservoir with cooling
water hurriedly to prevent the heated parts from cracking.
7.7.4 Exhaust temperature and color

Exhaust temperature must be checked at regular intervals. (See section 2.4) If exhaust temperature
rises evidently during running, check and remedy it immediately.
Combustion, in general, can be judged by the color and temperature of exhaust gas. If the exhaust
gas is smoky, check the fuel oil system.
Caution!
The backpressure in the exhaust gas system after the turbocharger should not exceed the stipulated
value in section 5.3.
7.7.5 Supercharging pressure

Check whether supercharging air pressure complies with the stipulated value mentioned in Section
2.4.
Caution!
If supercharging pressure is considerably below the stipulated value on full load, check and clean
air filter element first, and then check and clean turbocharger.
7.7.6 Starting air pressure

The stipulated pressure in air reservoir is 2.94 MPa.
Start the air compressor and bring the pressure in air reservoir up to the stipulated pressure when
the pressure is below 2.1 Mpa.
7.7.7 Piping connections

Check all pipes and connections for leakage.
Pay attention to the pipes installed in ditches or under deck.
Pay special attention to the pipe connections into which air likely be sucked..
Caution!
Check compressed air pipes to starting valves for leakage. If temperature of the starting air pipe
rises, the corresponding starting valve may be leakage. In the case of serious overheating shut
engine down and remedy fault.
7.8 Engine shutdown

a. In order to avoid overheat, unload the engine in steps and slow it down to a speed of 160-200
r/min, run the engine at no load for 3-5 minutes before stopping. For marine engine, turning the
hand-wheel to shutdown position or shifting the remote handle to shutdown position can stop
the engine. For generating set, depressing the shutdown button on the instrument board or
shifting the handle of manual shutdown valve can stop the engine.
b. If the engine will not start again, close all valves on fuel, lube oil, compressed air and cooling
water systems
c. If the engine is put out of service for more than one day in winter, all cooling water in the
cooling system must be drained.
d. If necessary, remove crankcase covers; check the temperature and tightness of bearings.
Caution!
After shutdown, each deviation from normal conditions should be put right and ready for next start.
8 Conservation for a long period rest
If the engine is put out of service for a longer period, then it must be thoroughly cleaned, and
machined parts must be protected against rust by greasing.
8.1 Outer conservation
Clean the outer surfaces of engine parts with a cloth imbued with gasoline. Coat the machined
surfaces without painting with anticorrosive grease.
8.2 inner parts conservation

8.2.1 Lube oil system
Prime lube oil with the pre-lubricating manual pump until lube oil flows from all feed points,
revolve the crankshaft for 3-4 turns when pumping.
Pump lube oil with the pre-lubricating oil pump and revolve the crankshaft for 3-5 turns per five
days
8.2.2 Fuel system

Fill the fuel system with fuel oil; pump the fuel injection pumps with lever to fill injection pumps,
high-pressure fuel pipes and injectors.
8.2.3 Cooling water system

Drain out all cooling water in the cooling water system and dry it with compressed air.
8.2.4 Inner parts

Remove the cylinder head shields, feed lube oil on the valve stems, and turn the crankshaft to
distribute lube oil between valve stems and valve guides.
Open the camshaft covers, feed lube oil on rollers and camshaft.
Open the crankcase covers, feed lube oil on connecting rods and crankshaft.
Check the above parts per five days.
9 Maintenance instructions

In order to maintain the engine in good condition and always ready for service, various parts have
to be dismantled and inspected at regular intervals. How frequently this has to be done depends
largely on the service conditions, the quality of fuel and, to a large extent, on the care and ability of
the engineers in charge to detect irregularities in their early stages and to correct them before they
become serious.
Besides the following recommended maintenance schedule, some additional maintenance may be
required or the recommended intervals may be shorted by user according to the actual conditions.
Maintenance record should be made
9.2 Maintenance schedule

20000
10000
8~12
5000
1000
500
100
Maintenance tasks
50
Check the oil level in lube oil tank; fill it if
necessary. If the oil level rises or drops
suddenly, find the trouble and remedy it
Check governor oil level; fill it if necessary. If
the oil level rises or drops suddenly, find the
trouble and remedy it.
Check the fuel level in daily fuel tank. Drain
9.3
the water accumulated in the fuel tank and

fuel filter.
See
Check the pressure in the air reservoir and

drain the accumulated water.
Inspect the turbocharger bearing oil level.
Check temperatures of cylinder head, cylinder
block, bedplate, injection pumps, air
distributor and starting air pipes by touch.
Open the cylinder head inspection holes to
check and observe the working condition of
rocker arms and valves.
Check turbocharger, after-cooler and pipes for
vibration.
Check crankcase, cylinder head, driving gears,
camshaft and turbocharger for abnormal noise
Observe exhaust color and density of fuel mist
emerging from vent hole of crankcase.
Check all pipes for leakage and repair
leakages.
Clean the water, oil, grease and dust on the
engine
Clean preliminary fuel filter.
Clean turbocharger lube oil filter.
Check all pipe connectors on cylinder head
for leakages and remedy the leakages.
20000
10000
8~12
5000
1000
500
100
Maintenance tasks
50
Check if the valve bridge is in contacts with
valve stem tops on its both ends and when one
end is in full contact, the clearance in another
end should not exceed 0.05mm. Readjust the
clearance, if required.
Check axial clearance of turbocharger; replace
its thrust component if the clearance exceeds
stipulated value.
Clean the turbocharger and air filter.
Check pressure –regulation bolt of injector,
adjusting bolts and lock nuts on
valve-actuating mechanism and injection
pump tappet nuts for tightness.
Clean fine fuel filter, lube oil filter, lube oil
centrifugal filter.
Clean injector filter.
Test injector for injection pressure,
atomization quality and leakage. Clean and
repair it if required.
Check bolts and nuts of rocker shafts,
injectors and starting valves on cylinder heads
for tightness.
Check main bearing bolts, connecting rod
bolts and nuts as well as their lock parts for
tightness. If any looseness is found, retighten
them according to the guide specifications and
lock them again.
Check ball bearing of water pump and fill it
with grease. Check water-seal components
and remedy or renew them if necessary.
Clean turbocharger guides wheel, compressor
blade wheel and diffuser channel.
Check all monitoring and protective devices
including thermometers, pressure gauges and
tachometers. Remedy them if required.
Change engine lube oil and governor oil.
Check working surfaces of cam and rollers. In
the case of being slightly damaged, smooth
them with an oilstone.
Check freedom of movement of fuel
regulation mechanism and governor linkage
as well as the clearances between the pin and
its socket of all lever joints in maneuvering
system and remedy them if required.
20000
10000
8~12
5000
1000
500
100
Maintenance tasks
50
Check all valves on maneuvering system for
easy movement and leakage and remedy them
if required.
Change turbine oil in turbocharger
Start the pre-lubricating pump, open
crankcase covers and camshaft covers,
revolve crankshaft for two turns to check if
lube oil flows through the piston cooling
cavities and rollers fluently.
Check injector and replace nozzle if
necessary.
Check injection pumps delivery valve for
tightness and lap it if required.
Check or replace the anticorrosive zinc plates
in after-cooler, lube oil cooler and fresh water
cooler.
Dismount cylinder head, lap contact surfaces
between valve and valve seat, starting valve
and its seat, replace valves and valves seats if
required.
Check nozzle bush in the middle of cylinder
head. Remedy or replace it if damage or
leakage is found.
Check anticorrosive zinc plate and sealing
parts of cylinder head. Replace them if
necessary.
Check distance difference between crank
webs of crankshaft when piston and
connecting rod is not dismantled. Dismount
piston and connecting rod assembly and check
piston ring grooves and clean the carbon
deposit on piston.
Measure outer diameter of piston pin and
make detection of defects. Check piston rings
and replace them if required.
Check serrated interfaces of connecting rod.
Check bolts, nuts and their interfaces. Make
detection of defects on bolts.
Check and measure big and small end
bearings of connecting rod, replace them if
excessive wear or insufficient expansion is
found.
Check and measure cylinders. Polish the
cylinder with an oilstone if slight defect is
found, replace it, if excessively worn.
Check injection pumps. Replace the plunger
couple if leakage or damage is found.
Check valve –actuating mechanism, such as
rocker shaft, bearing, valve adjusting screw
and block. Replace them if required.
20000
10000
8~12
5000
1000
500
100
Maintenance tasks
50
Check intake and exhaust valves, rollers and
roller pins for injection pumps. Replace them
if necessary.
Check all transmission gears and idle gears,
Measure gear lashes, Replace them if
required.
Disassemble and check water pump, lube oil
pump, fuel transfer pump and etc. Replace the
damaged parts.
Check air distributor, main starting valve and
valves on air reservoir.
Inspect and clean lube oil cooler, fresh water
cooler and after-cooler for leakage.
Check turbocharger and governor according to
their instruction books.
Dismantle No.4 and 5 main bearing bushes,
check their alloy layer worn conditions.
Dismantle and check other bushes if
necessary.
Check or replace monitoring instruments,
alarming system and electric wires
Remove cylinder liner from the cylinder
block, measure its inner diameter and check
its outer surface for corrosion. Repair or
replace the cylinder liner if necessary.
Replace the cylinder liner seal rings and
gaskets.
Check all main bearing bushes and thrusts.
Replace them if required. Measure diameters
of crank pins and make a record.
Measure wears of main journals of crankshaft
with a bridge gauge in four positions,
calculate the average value and make a record.
Check wears of camshaft bearings. Replace
them if required.
Check flexible transmission parts of output
coupling. Replace them if required.
Check cylinder head safety valve and
explosion-proof door on crankcase.
Check valve push rods, push rod seats, push

rod rollers, injection pump rollers and
injection pump supporters. When getting
back, recheck if fuel supply pre-stroke of
injection pump plunger is up to requirements.
Check engine installation foundation, pipes

and vessels. Adjust and clean them if required.
Dismantle and overhaul the diesel engine.
9.3 Maintenance tasks after the first 50 operating hours
The following maintenance tasks are only carried out on new or overhauled engine after the first 50
operating hours.
Item Maintenance tasks
1 Change engine lube oil, turbocharger lube oil and governor oil.
2 Clean oil filters.
Check and adjust valve lash. Make sure that Valve Bridge is in contact with two valve
3 stem tops on its both ends (when one end of Valve Bridge is in full contact, the clearance
between another end and valve stem top should be less than 0.05mm).
4 Check all bolted or threaded connections and apparatuses including piping.
Check connection between engine and its power output device. Retighten foundation bolts
5
and bolts on power output device.
6 Check lubricated surfaces of cams and rollers. Remove greasy dirt in cam casing.
10. Trouble and remedy
Each deviation from normal conditions should be put right at once and mentioned when changing
watch. Some possible troubles and deviations from normal, also the most probable causes and
remedies, are itemized below.
10.1 The engine does not turn in starting position
Item Probable causes Remedies

Check the air pressure in air reservoir.
1 The pressure of starting air is too low.
Replenish it sufficiently if required.
The main starting valve may not work properly
2 Clean or replace the main starting valve.
due to dirt, rust, worn or loose parts.
The starting valves at the cylinders may not
3 Clean or replace the starting valve.
function due to dirt, rust, worn or loose parts.
The stop valve at the starting air receiver may
4 Open the stop valve.
not be open.
The pipes from air distributor to cylinders are Make sure that these pipes are connected
5
incorrectly connected. correctly.
One of the valves of the starting air distributor
6 Check the air distributor.
has stuck.
10.2 Ignition fails

The fuel tank is empty or the valve on the fuel Check the fuel tank and open the fuel valve.
1
suction pipe has not been opened.
2 There is air locked in the fuel oil system. Get rid of air from the fuel oil system.
3 The fuel contains water. Drain the service fuel tank regularly.
The fuel may be too viscous owing to
4 The engine should be started on light fuel.
insufficient heating.
Clean or replace the nozzle and grind-in if
5 The injector needle may be stuck.
necessary.
The fuel control valve may be stuck, or the Check the fuel control valve and
6
fuel-regulating shaft may be stuck. fuel-regulating shaft sticks.
Compression may be too low on account of:
Renew piston ring, renew the cylinder liner
Badly worn or broken piston ring
7 if necessary.
Check the valve springs and valve, lap the
Leakage in intake or exhaust valves.
valves if necessary
8 Leakage in more than two starting valves. Check the starting valves.
10.3 The engine does not stop in stopping position

Check the solenoid valve, and stop the
1 The solenoid valve fails to actuate. engine by means of emergency shutdown
handle immediately.
2 The fuel cut-off valve may be stuck. Check the fuel cut-off valve.
Pull out the inserted pin of injection pump
One or some injection pumps remain to supply rack and disengage the injection pump to
3
fuel. stop the engine. Check and adjust the zero
delivery position.
10.4 The lubricating oil pressure is too low

Check the oil level in circulating oil tank
1 Insufficient oil in lubricating oil tank.
and replenish the tank with oil.
Air has entered the pump through a leaky
2 Check the oil suction pipe.
suction pipe.
3 The suction filter may be choked. Clean the suction filter.
4 Serious oil leakage in pressure piping. Check the piping and eliminate the leakage.
Excessive wearing of lube oil pump gear or
5 abnormal operation of the gear due to Dismantle and inspect the lube oil pump.
mal-assembly.
6 The valve of lube oil pump is damaged. Dismantle and examine the valve.
7 The oil pressure gauge pipe is choked. Clean or renew the pipe.
8 The oil pressure gauge is damaged. Renew the gauge.
9 Spring of the overflow valve is broken. Renew the spring.
Check the clearance. Renew the bearing if
10 Excessive clearance in bearing.
required.
10.5 The engine speed increases violently (over-speed)

Stop the engine immediately and check the
1 The governor fails to work normally.
governor.
Stop the engine immediately and check the
2 The gear rack of injection pump is stuck.
rack.
Disengaging of inserted pin from injection
3 Insert the pin into the rack groove.
pump rack.
4 Excessive lash in fuel regulating control system. Adjust or renew the excessively worn parts.
10.6 The pressure drop of lube oil filter exceeds 1.0 bar
If the pressure drop of lube oil filter exceeds 1.0 bar, the filter may be clogged. Change over to
another filter and clean the first filter immediately.
10.7 The lube oil temperature is too high.

1 The engine is over-loaded Reduce the load.
2 Clogging of lube oil cooler by dirties. Clean the lube oil cooler.
3 Poor quality of lube oil. Change the lube oil.
10.8 The oil level in lubricating oil tank rises

The rise of oil level in the lubricating oil tank is most probably due to presence of water in lube oil.
As a result, yellowish foam can be found in lube oil, or water bubbles may be found on the wall of
the lubricating oil tank sometimes. Take about 300 grams of lube oil and settle it in a glass for
about one hour to see whether there is any water deposited in the bottom of the glass.
Damage of water seal rubber ring in the cylinder Check drain hole on the exhaust side of
1
liner. cylinder block. Renew the rubber ring.
Make hydraulic test on the cooler. Eliminate
2 Water leakage in the oil cooler.
water leakage. Replace the oil thoroughly.
Presence of small holes resulting from gaseous
3 corrosion in the cylinder liner leads to water Replace cylinder liner.
leakage.
Check valve seat and injector bush for leaks
4 Water leakage in cylinder head.
and eliminate the faults.
Make a hydraulic test to find out leaks and
5 Water leakage in after-cooler.
eliminate them.
10.9 Abnormal noise

A knock at top dead center, at the end of the Readjust injection timing or reduce fuel
1 compression stroke, may be caused by too much supply quantity.
pre-ignition.
Fuel is injected too late; a low dull knock inside Readjust injection timing.
2
the cylinder can be caused.
3 Air-bound in fuel system. Get rid of air.
4 Engine runs with pounding noise:
Clearance between piston and cylinder liner is
a too large. After warming up the engine, Renew the cylinder liner if necessary.
pounding noise is to be mitigated.
Piston pin is fitted too loosely. The engine runsCheck piston pin seat and the clearance
b with a light and clear noise especially when it is
between connecting rod small end bush and
idling. piston pin. Replace them if required.
Check connecting rod bearing. Check
Connecting rod bearing is fitted too loosely. A connecting rod bolts for tightness and check
c low and heavy pounding noise is heard when the the clearance of bearing. If necessary,
engine speed drops suddenly from its full speed. replace connecting rod bearing to keep
prescribed tolerance.
Valve spring is broken. Valve stem is stuck so
Renew the spring. Check the clearance
that it cannot move freely with rocker arm.
d between the valve and its guide. Renew the
When piston is at T.D.C, a pounding noise is
valve if necessary.
heard.
Piston begins to be seized and a low but Stop the engine immediately for inspection.
e gradually increasing noise due to friction Renew piston and cylinder liner if
between metals is heard. necessary.
Pounding noises due to excessive wearing of
Renew the gear and related parts if they are
f gears and excessive gear lash are heard when
worn seriously.
the engine speed drops suddenly.
Gear knocking noise is heard when engine runs
g This is critical speed that should be avoided.
at certain speed.
10.10 The engine speed falls off

No ignition or mal-combustion in certain
1 Check injection pump or injector.
cylinder.
Non-uniformity of injection pressure, injection
2 Readjust.
quantity and injection timing in each cylinder.
Fuel pipe is leakage or there is water in the
4 Check fuel pipe and drain water from fuel.
fuel.
Non-uniformity of compression pressures in Check valves for tightness. Readjust cylinder
5
each cylinder. compression pressures.
Excessive backpressure due to blocking of
6 Clean exhaust gas pipe.
exhaust gas pipe.
7 Mal-functioning of governing system. Check governing system.
10.11 The engine slows-down suddenly or stops

Check water content in fuel. Drain out the
1 Fuel contains water. fuel containing water from fuel system and
fill up the system with clean fuel if necessary.
Reduction of fuel delivery into the engine
Replenish the tank with fuel and check if all
2 because the fuel in daily service tank is used
valves on fuel system are opened correctly.
up.
Operating oil pressure of governor is not Check the operating oil pressure in the
4
enough to actuate regulating pivot. governor.
Stop engine, repair or renew related parts if
5 Piston has seized.
necessary.
Check if lube oil flows fluently in piping or
6 Bearing has seized.
leaks.
10.12 The temperature of the starting air pipe to the starting air valves rises.
A rise in temperature indicates a leaky starting air valve, which should be changed or rectified as
soon as possible.
10.13 The exhaust gases are visible

Although the cam adjustment, the combustion and the performance are not necessarily correct
when the exhaust is clear, something is certain to be wrong when the gases become visible or the
exhaust temperature starts rising. The exhaust is a very good general check on the performance of
the engine.
A visible exhaust may have different colors.
a. A dark grey or black exhaust is due to bad combustion.
b. A white exhaust is due to steam in the exhaust gases.
c. A blue exhaust is due to vaporization and combustion of lubricating oil.
Overloading of the engine causes rise of
1 Reduce the load.
exhaust temperature and black exhaust.
Check the exhaust temperature of each
Black exhaust due to overloading in certain
2 cylinder and adjust fuel supply quantity of
cylinders.
each cylinder.
Fuel dripping from injector during injection, Adjust injection pressure. Replace injector if
3
poor atomization and low injection pressure. required.
Delayed injection causes burning of some fuel
4 Adjust the injection advance angle.
in the exhaust pipe.
Inspect valve spring. Check bolts of valves
Insufficient compression pressure and air
5 and cylinder head for tightness. Check, clean
leakage in valves or cylinder head.
or renew piston ring.
Entry of lube oil into the combustion chamber
6 due to excessive wear and insufficient Clean or renew piston rings.
elasticity of piston rings.
Oil from the crankcase causes rise of oil level
and entry of lube oil into combustion chamber Stop engine, Check oil level in crankcase.
7
results from oil splashing onto the surface of Check if lube oil suction pump is faulty.
cylinder liner.
Water is present in fuel or combustion Inspect if there is any crack in the cylinder
8
chamber. head. Change fuel if water content is found.
Change fuels or add necessary device in fuel
9 Poor quality of fuel.
system.
10.14 The exhaust gas temperature is too high or too low.

1 Exhaust temperature is too high.
a Overloading of engine or supercharging Reduce engine speed and load. Check
pressure is too low. supercharging system.
b Delayed fuel injection. Adjust injection advance angle.
c A nozzle has become choked or carbon has Clean injector and adjust injection pressure.
settled on it. Renew the injector if necessary.
d Incorrect reading from thermometer. Renew thermometer.
2 Exhaust temperature is too low.
a Incorrect reading from thermometer. Renew thermometer.
Insufficient inserting of thermometer into the The thermometer should be inserted into the
b branch pipe. branch pipe over one third of its diameter.
If exhaust temperature of certain cylinder is
Regulate the fuel supply quantity so as to
3 35℃ higher than that of others, this cylinder
balance the load of various cylinders.
is overloaded.
10.15 The peak pressure of cylinder is too high.

1 Fuel is injected too early. Check and adjust injection advance angle.
Reduce the pressure by increasing the
2 Compression pressure is too high.
thickness of cylinder head gasket.
3 Injection hole of injector is too large. Renew the injector.
10.16 The cooling water temperature is too high.

1 No delivery or insufficient delivery of water from cooling water pump:
a Closing or failure of inlet water valve. Inspect inlet water valve.
b Clogging of inlet water filter. Clean filter.
c Inspect the pipe and secure all joints in piping
Air leakage into inlet water pipe.
tightness.
d Check water pumps, adjust the water pump
Damage of impeller in water pump
clearance or renew the impeller.
e Failure of seals. Renew seal rings, rubber liners and springs.
2 Cell is formed in cylinder head or water pipe. Get rid of air and make water flows fluently.
3 Incorrect reading from water-thermometer. Renew thermometer.
4 Engine is overload Reduce engine load
10.17 The engine fails to reverse or fails to start after reversing

1 Insufficient air pressure in air reservoir. Charge the air reservoir.
2 Oil level too low in oil reservoir. Fill up the oil reservoir.
The seal rings between reversing piston and
3 Replace the damaged seal rings
cylinder are damaged.
Reversing sleeve has not reached to position; Adjust the relative position of interlocking
4 air passage leading to main starting valve is valve to inter1ocking cam or adjust the lever
still closed by the interlocking valve. for actuating reversing sleeve.
Duration of releasing air by time delay valve
5 is so short that there is no time for engine to Adjust time delay valve.
ignite.
Trace the cause of sticking and eliminate the
6 Sticking of certain valve in the system.
fault.
10.18 The maneuvering gearbox does not reverse properly

1 Insufficient air pressure in air reservoir. Charge the air reservoir
2 Certain valve in the system leaks or sticks. Inspect, clean or renew seal rings.
Action of time delay valve cannot meet
3 Adjust action time of time delay valve.
requirements.
Disengaging valve or reversing control valve Inspect and clean the valve. Eliminate
4
fails to release air in time or in a fluent way. releasing fault.
Pressure relay or solenoid remains unmoved Check pressure relay and solenoid. Repair or
5
and fails to release air. renew them.
Air-oil reversing valve of gearbox fails to be
Check reversing valve according to gearbox
6 turned with hand or becomes more difficult to
instruction book.
be turned with hand.

NingBo G6300ZCA MaintenancesManuals 01

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Operation and Maintenance Manual

Series G300 Diesel Engines

Ningbo C.S.I. Power & Machinery Group Co., Ltd.

Ningbo C.S.I. Power & Machinery Group Co., Ltd.

Engine model No.

Operation and Maintenance Manual

2. Main technical data

3. Fuel, lube oil and cooling water

4. Transit and storage

6. Preparations for first time start

8. Conservation for a long period rest

10. Trouble and remedy

1.2 General descriptions

Starboard G6300ZC G6300ZC12 G6300ZC10

Four-stroke, water cooled, in-line, direct injection, turbocharged,

2 Cylinder bore, mm 300

3 Piston stroke, mm 380

4 Total displacement, L 161

12 Starting system Compressed air starting

14 Lubricating system Pressure lubricating

15 Distance for lifting, mm 2600

16 Overall dimensions, mm 4740×1580×2800

17 Net weight, kg 17500

3 Cylinder bore, mm 300

4 Piston stroke, mm 380

5 Total displacement, L 215

13 Starting system Compressed air starting

15 Lubricating system Pressure lubricating

16 Distance for lifting, mm 2600

17 Overall dimensions, mm 5680×1540×2870

18 Net weight, kg 21500

port engine starboard engine port engine starboard engine

6- cylinder diesel engine 8- cylinder diesel engine

The arrow marks in Fig denote rotating directions.

1.5 Cylinder numbering and ignition sequence

Item Accessories 6-cylinder engine 8-cylinder engine

7 Fuel injection pump Plunger diameter (mm)

Lube oil cooler/tube and shell type Cooling surface m2 25 30

/plate type Cooling surface m2 P P 12.88

1.7.2 Marine diesel engine

1.7.3 Torsional vibration

b. 6-cylinder diesel engines with frequency adjusting flywheel without counterweight

c. 6-cylinder diesel engines with frequency adjusting flywheel and counterweight

No. Mass Rotating inertia kgm2

2. Rotating inertia of flywheel gear Ifg = 107.35 kgm2

3. Crank radius r=190mm, connecting rod length l=760mm.

2.1 Performance curves

Pz Maximum combustion pressure

tr Exhaust gas temperature for each cylinder

Pt Exhaust gas pressure inlet to turbocharger

Load characteristics curve for Model G6300ZC engine (400r/min)

tr Exhaust gas temperature for each cylinder

Pt Exhaust gas pressure inlet to turbocharger

Propeller curve for Model G6300ZC diesel engine (400r/min)

tr Exhaust gas temperature for each cylinder

Pt Exhaust gas pressure inlet to turbocharger

Load characteristics curve for Model G6300ZC6B diesel engine (500r/min)

tr Exhaust gas temperature for each cylinder

Pt Exhaust gas pressure inlet to turbocharger

Propeller curve for Model G6300ZC6B diesel engine (500r/min)

tr Exhaust gas temperature for each cylinder

Pt Exhaust gas pressure inlet to turbocharger

Load characteristics curve for Model G6300ZC18B diesel engine