TBD236 Series Diesel Engine

Operating & Maintenance Manual

Henan Diesel Engine Group Co., Ltd.

Luoyang HND Engine CO., LTD
 TBD236 Series Diesel Engine

Operating & Maintenance Manual

Henan Diesel Engine Group Co., Ltd.

Luoyang HND Engine CO., LTD

October, 2001
 Preface

TBD236 series diesel engines (hereinafter referred to as 236 diesel engines) are high level, high
speed and big engine, which developed base on Henan Diesel Engine Group Co., Ltd. Introduced
license of TBD234 series engine from DEUTZ AG. Through enlarge cylinder displacement, adopt
4-valve technique, increase injection pressure, improve facility for turbocharger and so on technique to
enhance performance, increase power, improve emission purpose, this kind of engines are able to
widely used in ship, power station, engineering, petroleum drilling, vehicle drive and other fields.

This manual explains the basic characteristics of 236 diesel engines, and then, emphatically
describes its installation, operation, maintenance, typical problems, possible causes and troubleshooting,
as well as its structure, assembly and disassembly of main parts, especially, more newly contents have
been added for maintenance and repair.

Before using 236 diesel engines, the consumer must read this manual carefully, so as to
operate and maintain the equipment correctly.

Address: No.173, Zhongzhouxi Road, Luoyang City, Henan Province, China

Zip code: 471039
Telephone of Marketing Department: 0086-379-64076120
Fax: 0086-0379-64225395
 Cross section through engine TBD236
Assemblies
01 Crankcase, Oil pan 02 Cylinder head
03 Crank assy 04 Valve timing
05 Fuel system 06 Speed governing
07 Lube oil system 08 Cooling system

Components
1 Pushrod 2 Injection pump with governor
3 Intake pipe 4 Rocker arm
5 Cylinder head 6 Injection valve
7 Piston 8 Cylinder liner
9 Mushroom Tappet 10 Lube oil filter
11 Oil cooler 12 Lube oil pump
13 Crankcase 14 Cooling nozzle for piston cooling
15 Connecting rod 16 Exhaust pipe
17 Exhaust valve
 Longitudinal section through engine TBD236
Assemblies
01 Crankcase, Oil pan 03 Crank assy
04 Valve timing 05 Fuel system
06 Speed governing 09 Turbocharging
11 Control, monitoring

Components
1 Intercooler 2 Injection pump driver
3 Fuel pressure pipe 4 Injection pump
5 Speed governor 6 Speed adjustment lever
7 Stop lever 8 Intake pipe
9 Turbocharger 10 Big-end bearing
11 Flywheel 12 Oil drain plug
13 Crankshaft 14 Oil pan
15 Lube oil intake pipe 16 Main bearing
17 Camshaft 18 V-belt pulley
19 Anti-vibration damper 20 Tachogenerator
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MWM Content •1•

Content
1 Main Characteristics of 236 Series Diesel Engines ....................................... 1
1.1 Brief Introduction...................................................................................................... 1
1.2 Basic Principle of 236 Series Diesel Engines .................................................................. 3
1.2.1 Intake stroke ................................................................................................................... 3
1.2.2 Compression stroke ........................................................................................................ 4
1.2.3 Power stroke ................................................................................................................... 4
1.2.4 Exhaust stroke ................................................................................................................ 5
1.3 Main Technical Data of 236 Series Diesel Engines ........................................................ 6
1.3.1 Data of structure and capability...................................................................................... 6
1.3.2 Amount of oil and water................................................................................................. 8
1.3.3 External dimension and weight ...................................................................................... 8
1.3.4 Torque for major thread.................................................................................................. 9
1.3.5 Main type of sealant and use ........................................................................................ 10

2 The Mounting of 236 Series Diesel Engine ................................................. 11

2.1 Hoisting and Foundation.........................................................................................11
2.1.1 Hoisting .........................................................................................................................11
2.1.2 Foundation.....................................................................................................................11
2.2 Arrangement and Ventilation Quantity of the Cabin (Room) ..................................... 12
2.2.1 Arrangement of the cabin (room) ................................................................................. 12
2.2.2 The ventilation of the cabin (room).............................................................................. 12
2.3 The Mounting of Diesel Engine.............................................................................. 14
2.3.1 Rigid mounting............................................................................................................. 14
2.3.2 Elastic mounting........................................................................................................... 14
2.4 Points for Attention in Mounting Diesel Systems ......................................................... 18
2.4.1 Exhaust system ............................................................................................................. 18
2.4.2 Fuel system................................................................................................................... 19
2.4.3 Raw water system......................................................................................................... 20

3 The Use of 236 Series Diesel Engine ................................................... 21

3.1 Points for Attention in the Use of Diesel Engine........................................................... 21
3.2 Fuel, Engine Oil and Cooling Water .......................................................................22
3.2.1 Fuel............................................................................................................................... 22
3.2.2 Engine oil ..................................................................................................................... 22
3.2.3 Cooling water ............................................................................................................... 22
3.3 The Startup of the Diesel Engine ............................................................................25
3.3.1 The preparation before startup...................................................................................... 25
3.3.2 The startup of the diesel engine.................................................................................... 26
3.4 The Operation of the Diesel Engine........................................................................ 28
3.5 Shut-Down of Diesel Engine ..................................................................................31
3.5.1 Normal shut-down ........................................................................................................ 31
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•·2·• Contents MWM

3.5.2 Emergent shut-down..................................................................................................... 31

3.6 Power Correction of the Diesel Engine...................................................................33

4 Maintenance and Storage.............................................................................. 36

4.1 Maintenance Plan.................................................................................................... 44
4.2 Main Maintenance Methods ...................................................................................44
4.2.1 Replace lubricating oil.................................................................................................. 44
4.2.2 Replace strainer core of oil filter .................................................................................. 45
4.2.3 Clean wet air filter........................................................................................................ 46
4.2.4 Clean oil bath air filter.................................................................................................. 47
4.2.5 Replace strainer core of dry air filter............................................................................ 48
4.2.6 Inspect belt drive and lubricating water pump ............................................................. 49
4.2.7 Inspect zinc-protected plug........................................................................................... 50
4.2.8 Inspect and readjust valve clearance ............................................................................ 51
4.2.9 Replace fuel filter core or the component .................................................................... 52
4.2.10 Inspect monitoring device and braking device of diesel engine................................... 53
4.2.11 Clean heat exchanger.................................................................................................... 54
4.2.12 Clean intercooler .......................................................................................................... 56
4.2.13 Preservation of diesel engine........................................................................................ 57
4.3 Diesel Engine Malfunction and Troubleshooting .......................................................... 60
4.3.1 Diesel engine's start-up is difficult or complete failure ................................................ 60
4.3.2 The diesel engine is underpower .................................................................................. 62
4.3.3 The running is not smooth............................................................................................ 64
4.3.4 Abrupt pause................................................................................................................. 65
4.3.5 Running away............................................................................................................... 66
4.3.6 Pressure of engine oil is too low................................................................................... 66
4.3.7 Temperature of engine oil is too high ........................................................................... 67
4.3.8 Oil dilution ................................................................................................................... 67
4.3.9 Exhaust temperature is too high ................................................................................... 68
4.3.10 Airout of breather is abnormal ..................................................................................... 68
4.3.11 Temperature of cooling water is too high ..................................................................... 69
4.3.12 Exhaust is black smoke ................................................................................................ 70
4.3.13 Exhaust is blue smoke .................................................................................................. 70
4.3.14 Exhaust is white smoke ................................................................................................ 71
4.3.15 Vibration of diesel engine is greater ............................................................................. 71
4.3.16 Engine oil contain moisture.......................................................................................... 72
4.3.17 Abnormal noises........................................................................................................... 72
4.3.18 Malfunction of supercharger ........................................................................................ 73
4.3.19 Malfunction of cylinder cover ...................................................................................... 73
4.3.20 Malfunction of monitoring system ............................................................................... 74
4.4 Tool List and Specification ..................................................................................... 76
4.4.1 Attached tool ................................................................................................................ 76
4.4.2 Repair tool .................................................................................................................... 77

5 The Structure of Diesel Engine Series 236 and the Disassembly, Overhaul
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and Assembly of its Main Components ............................................................. 79

5.1 Main Fixed Assemblies’ Structure and Their Disassembly, Overhaul and
Assembly.......................................................................................................................................... 79
5.1.1 Engine body.................................................................................................................. 79
5.1.2 Cylinder head ............................................................................................................... 85
5.1.3 Cylinder line ................................................................................................................. 90
5.1.4 Oil pan .......................................................................................................................... 91
5.1.5 Front end shield and rear end shield............................................................................. 93
5.1.6 Flywheel shell............................................................................................................... 96
5.1.7 Breathing apparatus-oil and gas segregator.................................................................. 97
5.2 Main Moving Components’ Structure and Their Disassembly, Overhaul and
Assembly ...........................................................................................................................98
5.2.1 Crankshaft .................................................................................................................... 98
5.2.2 Piston group................................................................................................................ 102
5.2.3 Subassembly of connecting rod.................................................................................. 106
5.2.4 Balancing shaft ............................................................................................................110
5.2.5 Flywheel ..................................................................................................................... 113
5.2.6 Belt pulley .................................................................................................................. 114
5.3 The Structure of the Fuel System and the Overhaul and Assembly of Its Main
Components ...................................................................................................................116
5.3.1 The manual fuel pre-feed pump ................................................................................. 116
5.3.2 Fuel feed pump........................................................................................................... 117
5.3.3 Oil ejector ....................................................................................................................119
5.3.4 Fuel injector................................................................................................................ 125
5.3.5 Checking and adjusting the fuel feeding lead angle ................................................... 128
5.3.6 Speed governor........................................................................................................... 132
5.3.7 Fuel filte ..................................................................................................................... 141
5.3.8 High-pressure fuel pipe .............................................................................................. 142
5.3.9 Drive mechanism of injection pump .......................................................................... 143
5.4 The Structure of Lubricating System and the Disassembly, Overhaul and Assembly
of Its Main Components .................................................................................................. 147
5.4.1 Motor oil pump........................................................................................................... 148
5.4.2 Motor oil filter ............................................................................................................ 150
5.4.3 Motor oil cooler.......................................................................................................... 152
5.4.4 By-pass valve ............................................................................................................. 154
5.5 The Structure of Gas Distribution System and the Disassembly, Overhaul and
Assembly of Its Main Components ................................................................................. 156
5.5.1 Camshaft..................................................................................................................... 156
5.5.2 Valve groups ............................................................................................................... 159
5.5.3 Drive mechanism........................................................................................................ 162
5.6 The Structure of Cooling System and the Disassembly, Overhaul and Assembly of
Its Main Components ...................................................................................................... 164
5.6.1 Sea water pump .......................................................................................................... 166
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5.6.2 Fresh water pump ....................................................................................................... 171

5.6.3 Heat exchanger ........................................................................................................... 173
5.6.4 Radiator ...................................................................................................................... 176
5.6.5 Bossing ....................................................................................................................... 178
5.6.6 Drive system of fan .................................................................................................... 178
5.6.7 Tension pulley ............................................................................................................ 180
5.6.8 Thermostat.................................................................................................................. 181
5.7 The Structure of Intake and Exhaust System, the Overhaul and Assembly of Its
Main Components ........................................................................................................... 183
5.7.1 Intake system.............................................................................................................. 183
5.7.2 Exhaust system ........................................................................................................... 194
5.8 The Structure of Starting System and the Disassembly, Overhaul and Assembly of
Its Main Components ...................................................................................................... 199
5.8.1 Start motor starting system......................................................................................... 199
5.8.2 Air motor start system ................................................................................................ 204
5.8.3 Compressed air starting system .................................................................................. 206
5.8.4 Hansa flame starting system....................................................................................... 207
5.9 The Structure of Speed Control Mechanism and Stop Mechanism, and the
Disassembly, Overhaul and Assembly of Its Main Components.................................... 210
5.9.1 Lever speed control mechanism ................................................................................. 210
5.9.2 Manual speed control mechanism ...............................................................................211
5.9.3 Electromotor speed control mechanism ......................................................................211
5.9.4 Stop mechanism ......................................................................................................... 214
5.10 Monitoring System................................................................................................ 218
5.10.1 The panel chart of control box.................................................................................... 218
5.10.2 The electric part position of monitoring system on the diesel and wire position . 218
5.10.3 Brief introduction of electric theory ........................................................................... 218
5.10.4 Operating requirement of monitoring system............................................................. 220

6 Others.......................................................................................................... 227
6.1 Packaging and Transportation............................................................................... 227
6.2 Open-case Inspection ............................................................................................ 227
6.3 Manufacturer’s Promises ...................................................................................... 227
6.4 The manufacturer bears no responsibility for the follow matters ......................... 227
6.5 Delivery Conditions .............................................................................................. 227
6.6 Tools......................................................................................................................228
6.7 Fire Safety............................................................................................................. 228
6.8 After Service ......................................................................................................... 228

Appendix: Limits of Sizes of Attrited Parts ..................................................... 229

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MWM Section 1 Brief Introduction •1•

1 Main Characteristics of 236 Series Diesel Engines

1.1 Brief Introduction

236 series diesel engines are reliable and have high performance. 236 series diesel engines have
the characteristics of “3H, 3L and 3N”, namely high power, high efficiency, high reliability; low heat
dispersion, low cost, low maintenance workload; and normative design, normative technique, normative
materials, coming up to an international advanced level of diesel engines. In addition, facing the
appearance of oil crisis and environmental protection, this model of diesel engines are designed with the
prominent features in energy saving, environmental protection as well as reliable in quality.
The power range of 236 series engines is 230kW-765 kW, and the rotate speed range is 1500
r/min-2300 r/min. The power can be output from front end and back end, the power from back end
(flywheel) can reach 100%, and the power from the front end (free end) varies depending on the
models.

Designation of 236 series diesel engines:

Example: T B D 236 V8
Number of cylinders

V-arranged cylinder

Series No. of diesel engine

Denote diesel engine and natural-suction type diesel engine

(not pressurized)

Intermediate cooling

Exhaust turbocharging

236 series diesel engines are four-stroke, high-speed and water-cooled engines, exhaust
turbocharged with intermediate cooling (TBD type). The cylinders are V arranged, the included angle is
60°, and facing flywheel, the left side is A row, the right side is B row. The number of cylinders is 6, 8,
or 12. The direction of rotation is counterclockwise when facing the flywheel. The body of 236 series
diesel engines is as pedestal, and crankshaft linkage is installed inside it, the camshaft is in the center
hole of the body, the balancing shaft of 8-cylinder engine is mounted in frame downside hole of A row,
the balancing shaft of 6-cylinder engine is mounted in 1, 4 main bearing saddle hole. The cylinder cover
is over the body, oil pan is mounted in the bottom. The gear assembly and front cover are installed in the
front of the body; the flywheel, flywheel casing, and back cover are installed in the back of the body, the
injection pump and gear assembly are installed inside the V included angle. The air inlet pipe is inside
and the air exhaust pipe is outside. Generally, the exhaust gas turbocharger of diesel engine is supported
by flying wheel casing, and the inter-cooler is supported by front cover. For land-use diesel engine,
there is fan, fan gear system and radiator in the front of it; and for ship-used diesel engine, there is heat
exchanger in the front of it. The front supporting of diesel engine is installed at the both sides of body,
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•·2·• Chapter 1 Main Characteristics of 236 Series Diesel Engines MWM

and back supporting is installed at both sides of flying wheel casing. Engine oil cooler and oil filter are
installed outside the B row, the starting motor, charging generator and sea water pump (for ship use) are
installed outside A row.
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MWM Section 2 Basic Principle of 236 Series Diesel Engines •3•

1.2 Basic Principle of 236 Series Diesel Engines

The basic principle of the diesel engine is to burn the diesel oil in the combustion chamber first, emit
heat energy, and then this heat energy is changed into the mechanical work. Because 236 series diesel
engines are four-stroke, so the principle of these engines is just the principle of four-stroke diesel engine.
In four-stroke engines, each cycle requires four strokes: intake, compression, power and exhaust; and
two revolutions of the crankshaft are completed at same time.
Before explaining the four strokes, two important nomenclatures should be introduced.
TDC: Top dead center (also called top dead point): It is the highest point the piston can reach in the
cylinder, when the piston reaching this point (TDC), the distance between piston and center line of
crankshaft is maximum, and the connecting rod is in alignment with crank pin.
BDC: Bottom dead center (also called bottom dead point): It is the lowest point the piston can reach
in the cylinder, when the piston reaching this point (BDC), the distance between piston and center line of
crankshaft is minimum, and the connecting rod is also in alignment with crank pin.
When the piston does reciprocating movement in the cylinder, the following processes happen in
sequence circularly and continuously.

a b c d

Fig. 1-2-1, Schematic drawing of four-stroke diesel engine working process

1: inlet valve open 2: inlet valve close

3: exhaust valve open 4: exhaust valve close

1.2.1 Intake stroke (Fig. 1-2-1a)

In this process, the piston moves from TDC to BDC, and the inlet valve is opened by valve train, then
the cylinder is filled with fresh air for combustion.
In order to obtain sufficient inlet air in the cylinder, the mode of early open and late close is adopted
for all the inlet valves. That is, the inlet valve does not open up when the piston reaching TDC exactly, but a
certain angle of crankshaft before the TDC. Because the opening of inlet valve will take time, therefore, the
inlet valve opens ahead, and the area of inlet cross-section is larger when the piston moves down from TDC,
the resistance is reduced when the airflow through the inlet valve, thus, the air intake is increased. However,
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•·4·• Chapter 1 Main Characteristics of 236 Series Diesel Engines MWM

the angle of crankshaft should be proper to prevent the return flow of exhaust gas. The most suitable ahead
angle for opening of inlet valve is generally determined by design and experiment.
In the inlet stroke, when the piston moves down near the BDC, the airflow and inertia are greater.
Accordingly, when the piston reaches BDC, the inlet valve does not close and still open with certain angle,
so as to use the airflow’s inertia for air intake. Of course, the delay angle should be proper for inlet valve,
and similarly, the most suitable time of closing inlet valve should be determined by design and experiment.
After repair, the inlet valve should be checked up and adjusted termly according to the requirements of this
manual to keep the best angle when it open and close.

1.2.2 Compression stroke (Fig. 1-2-1b)

In this process, the air in the cylinder is compressed for increase of its pressure and temperature, so as
to create the condition of self ignition for combustible gas formed with diesel oil, and also, to create the
condition for power with expanded gas which is under the state of high temperature and high pressure after
combustion.
During the compression process, the inlet and exhaust valves are all closed, and the piston moves
from BDC to TDC. With the gradual reduction of the cylinder volume, the air in cylinder is compressed and
its temperature and pressure rise along with it. Consequently, after the diesel oil is injected into the
cylinder at near the end of compression process, being heated and vaporized rapidly, at same time, it is
mixed with air to form combustible gas to self ignite and burning, without any special ignition device. Heat
is exchanged between interior air and cylinder wall during the whole process. When the compression stroke
starts, the cylinder wall heats the air, and the temperature of compressed air is raised until reaching the
temperature of cylinder, from that time, the air releases heat to cylinder wall. It is generally agreed that heat
dissipating capacity is more than heat absorption capacity, so the heat can be lost in this process. Also, the
gas leakage due to bad seal of combustion chamber is energy loss. Therefore, all of the abnormal states such
as excessive friction between piston ring and cylinder sleeve, bad seal between inlet valve and valve seat,
etc, will cause deterioration of combustion chamber seal, influencing diesel engine’s start up and operation.

1.2.3 Power stroke (also called expansion stroke) (Fig. 1-2-1c)

This process is composed of two stages: diesel oil combustion and expansion for power, it is main
process of energy transformation in the diesel engine.
At the end of compression stroke, atomized diesel oil is injected into cylinder; touch and mix with
heated and compressed air, and form combustible gas rapidly to self ignite and burning, emitting a lot of
heat energy, so the temperature and pressure of air inside cylinder are raised sharply. With the
high-temperature and high-pressure gas, the piston moves down towards BDC, and drive the crankshaft to
run by connecting rod, transferring power to outside . Along with the piston moves towards BDC, gradually,
the space inside cylinder increases and the gas pressure in cylinder is reduced.

1.2.4 Exhaust stroke (Fig. 1-2-1d)

In the exhaust stroke, after working, the exhaust gas is discharged out of cylinder, prepare to fill up
fresh air for next operating cycle. The requirements of exhaust stroke are that exhaust gas should be
discharged thoroughly and the loss of power should be less.
In this process, the exhaust valve is opened by valve train, and the piston moves from BDC to TDC.
When the piston reaches certain crank angle near the BCD, the exhaust valve starts opening. Here, the
exhaust gas pressure in cylinder is quite high, so, it is discharged impulsively, and the free exhaust process is
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MWM Section 2 Basic Principle of 236 Series Diesel Engines •5•

finished, then, the gas pressure in cylinder is decreased rapidly to reduce the losses of power (push work)
during exhaust stroke when the piston moves up, When the piston moves from BDC to TDC droved by
crankshaft and connecting rod, the residual exhaust gas is discharged out of cylinder continuously, and this
process is called compulsive exhaust process. When the piston moves up near TDC, the velocity of airflow
is still high, the exhaust valve will be closed when the piston moves through TCD at certain crank angle, so
as to use exhaust inertia for discharging exhaust gas wholly, this is called inertia exhaust. To reduce the
losses of power and discharge exhaust gas completely, the mode of early open and late close is also adopted
for exhaust valve. Similarly, the best time of valve’s open and close is determined by design and experiment,
the accuracy of it should be ensured during actual operation.

As described above:
① Near the TDC in the inlet stroke, the inlet valve is opened ahead, and the exhaust valve is closed
later. The inlet valve and exhaust valve open simultaneously for some time, and in this time, the
included angle of crankshaft is called valve overlap angle.
② The piston will moves up and down for 4 times to finish one cycle of four-stroke diesel engine, and
reaches TDC and BDC for two times respectively, these should be made clear before adjusting
and repairing diesel engines. Especially, TDC is compression stroke's TDC or exhaust stroke’s
TDC should be distinguished; the mode will be explained later.
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•·6·• Chapter 1 Main Characteristics of 236 Series Diesel Engines MWM

1.3 Main Technical Data of 236 Series Diesel Engines

1.3.1 Data of structure and capability

NO. Name Unit TBD236 TBD236 TBD236

V6 V8 V12
1 Work process Four strokes
2 Burning mode Eject directly
3 Cylinders arrangement V model and 60°
4 Number of cylinders 6 8 12
5 Cylinder bore/stroke mm 132/140
6 Cylinder piston displacement dm3 1.9
7 Total swept volume dm3 11.5 15.3 23
8 Compression ratio ε 15:1
9 Maximal explosion pressure MPa 15
10 Rated rotating speed range r/min 1500-2300
11 Lowest steady rotating speed r/min 45 percent of Rated rotating speed
12 Lowest steady rotating speed for r/min 700-750 commonly
no-load (idle)
13 rotating speed for ignite when r/min 115
20℃
14 Rotate direction Anticlockwise(from flywheel)
15 Firing sequence A1-B2A3-B1-A A1-B2-A3-B1-A4-B3 A1-B5-A5-B3-A3-B6-A6
2-B3 -A2-B4 -B2-A2-B4-A4-B1
16 Air pressure for start when using MPa Min0.15,max0.3(reducing valve)
gas motor
17 The diameter of connecting mm 92×29.2
rod×bearing breadth of
connecting rod
18 The main diameter of crank mm 105×32.7
shaft× breadth of main bearing
19 Number of main bearings 4 5 7
20 Diameter of piston pin×breath of mm 50×43.8
bearing
21 Air filter oil bath mode, wet mode or dry mode(cleaner using in desert)
22 Oil filter Fine filter
23 Oil pump Bosch Piston pump
24 Injection pump(holistic mode) Bosch PE6… PE8P… PE12P…
25 Speed governor (mechanical or Bosch RSUV or adjust by electricity
electronic )
26 Injection valve Bosch KDEL90P51
27 Nozzle Bosch 8 orifices nozzle
28 Open pressure of nozzle MPa +0.8 +0.8 +0.8
26 28 31
-0.5 -0.5 -0.5
29 Lubrication mode Pressure lubricate
30 lubricating oil filter Fine filter( installed on the main oil circuit)
31 Oil pressure low alarming MPa 0.12~0.15
32 Oil pressure too low stopping MPa 0.08~0.10
33 Lubricating oil pressure after
cleaning under Rated speed
MPa 0.35~0.60
34 Temperature of cooling water
(The best)
℃ 76~82
Max. cooling water rtemperature
35 ℃ Indirect cooling 85; fan cooling 90
(outlet)
Alarm temperature of cooling ℃ 90~96
36
water
37 Lube temperature of oil in pan ℃ 120

38 Cooling mode Fan cooling indirect cooling

39 Diameter of fan Φ710~Φ915
Cooling water capacity without
40 20 24 35
radiator (fresh water)
41 Turbocharger(KKK) 1×K361 1×K361/K37 2×K361
42 Exhaust temperature before ℃ ≤750
turbine
43 Max. temperature sea water ℃ 32
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MWM Section 3 Main Technical Data of 236 Series Diesel Engines •7•

No. Item Units TBD236V6 TBD236V8 TBD236V12

Installed Longitudinal 8 6
inclination Transversal -
Inclination Longitudinal 10 18 15
for long
Allowed time
max. operation Transversal 22.5
★ inclinatio (max.
°
44 n of oil 2hours)
pan for Inclination Longitudinal 14 22.5 18
vehicle for short
time
operation Transversal 14 22.5
(max.
3min)
Installed Longitudinal 10 8
inclination Transversal -
Inclination Longitudinal 14 22.5 18
for long
Allowed
time
max.
operation Transversal 22.5
inclinatio
★ (max.
n of oil °
45 2hours)
pan for
marine Inclination Longitudinal 18 22.5
for short
time
operation Transversal 26 22.5
(max.
3min)
Installed Longitudinal 12 10
Allowed
inclination Transversal -
max.
inclinatio Inclination Longitudinal 45
★ for long
n for dry °
46 sump time
lubricatio operation Transversal 30
n (max.
2hours)
The housing of fly wheel/
48 SAE 1/0
the flange connected with fly wheel
49 Starter 24V kW 5.4/6.6
50 Storage battery 24V AH 2×180
51 Alternator 28V27A

Note: ◆ Unsuitable for high-speed ship;

★ Installed inclination has already been included.
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•·8·• Chapter 1 Main Characteristics of 236 Series Diesel Engines MWM
1.3.2 Amount of oil and water ( dm3 )

TBD236V6 TBD236V12
TBD236V8
Cooling water capacity(without radiator) (L) 20 24 35
Lube oil capacity, to top notch of dipstick★(L) 22 28 35
Lube oil capacity, to bottom notch of dipstick★(L) 16 16 20
Lube oil quantity injected by injection pump before grinding-in
1.1 1.2 1.7
experiment (L)
Capacity of lube oil filter (L) 2.0 2.0 3.5
★ If the structure is in special, the amount should be enlarged.

1.3.3 External dimension and weight

Fig. 1-3-1, External dimension of diesel engine

Engine type Engine weight Engine weight Dimensions

(for (for vehicle, A A1 B C D E F1)
ship, include include water
water tank ) tank )
TBD236V6 1300 1350 1080 1390 865 370 1135 142 700
TBD236V8 1600 1650 1250 1565 910 365 1130 142 700
TBD236V12 2200 2300 1590 1835 910 365 1130 142 700

Note: The weight (unit: kg) denotes the engine’s approximate net weight, without accessional
weight.
Superscript 1): For elastic supporting, cooling water and lubricant oil should be filled;
2): Flywheel flange SAEO: 832 mm. (In outline drawing, the elastic supporting is little
casting stabilizer.)
 HND
MWM Section 3 Main Technical Data of 236 Series Diesel Engines •9•

1.3.4 Torque for major thread

Name Bolt(nut) standard Moment

Main bearing cover M18-12.9 200N·m+ 90o
Bolt connecting rod M16×1.5-12.9 90N·m+ 60o or 230 +10 N·m
Balance weight M16-10.9 260 +10 N·m
20-100-200-400N·m
Cylinder head M18-10.9
or 20-100-150N·m+ 60o
Exhaust pipe M10-10.9 50 +5 N·m
Rocker arm bracket M10-10.9 65+5 N·m
Lock nut of fuel injector clamp plate M8-8 15+5 N·m
Slotted nut of fuel injector hole compact
bush
M36×1.5 30+10 N·m
Flywheel end of crankshaft M16×1.5-12.9 380 +10 N·m or 200N·m+ 60o
Belt pulley end crankshaft M16×1.5-12.9 380 +10 N·m or 200N·m+ 60o
Vibration absorber M12-10.9 115+5 N·m
Engine foundation M14-12.9 220 +10 N·m
Belt pulley of fresh water pump M16×1.5 140 +10 N·m
M18-12.9 430 +10 N·m or200N·m+ 60o
Fan driving journal
M16-10.9 210 +10 N·m
Driving unit gear of injection pump
(number of teeth is 44)
M10-12.9 85+5 N·m
Driving unit gear of injection pump
(number of teeth is 59)
M 10-10.9 65+5 N·m
Coupling of injection pump (slice
pattern)
M12-10.9 100 +10 N·m
Coupling of injection pump(tooth form) M10-10.9 35+5 N·m
Hexapod bolt of injection pump shaft
coupling driving side
M12-10.9 100 +10 N·m
Tension pulley M14-8.8 100 +10 N·m
Camshaft gear (loop type) M10×1.25-12.9 90 +5 N·m
Camshaft gear (boss type) M10-10.9 65+5 N·m
Slave end nut of slice pattern shaft
coupling of injection pump
M18×1.5 100 +10 N·m
M20×1.5 240 +10 N·m
M12-12.9 140+5 N·m
flywheel casing
M16×1.5-12.9 370 +10 N·m or 100N·m+ 60o
 HND
•·10·• Chapter 1 Main Characteristics of 236 Series Diesel Engines MWM

1.3.5. Main type of sealant and use

Name and type Use Range of and feature Using place illustration
Belongs to anaerobic thread locking and Rock arm bracket, injection
Thread Locking sealing adhesives. For general use, pump driving mechanism,
and Sealing medium strength, thixotropic viscosity. nozzle, bolts and nuts in
Adhesive For locking and sealing threads smaller camshaft and other places
(High strength) than M26 which enduring strong vibration
TianShan1262 or and impact
LOCTITE242
Thread Locking
and Sealing
Belongs to anaerobic thread locking and
Adhesive
sealing adhesives. Ultrahigh strength,
(High strength and stud
medium viscosity. For locking and sealing
high viscosity)
threads smaller than M36
TianShan1277or
LOCTITE271
Sealant for engine block casing cap,
Retaining Bowl Belongs to sealant for retaining bowl cylinder cover casing cap
Stopper stopper. For sealing and retaining bowl and bush shaft gland
TianShan15747 or stopper in engine
LOCTITE11747
Belongs to flange sealant. For anaerobic,
Flange Sealant general use, flexible adhesive layer after
Oil pan, front cover,
TianShan1515 or curing ， high fluid endurance, non
lubricating pump
LOCTITE515 corrosiveness, low extensibility, sealant
used for specialized car
lubricating system, air passage
Belongs to anaerobic pipe thread sealant.
Pipe Thread Sealant sealing, thread union swivel,
Medium viscosity and medium strength,
TianShan1569 or cutting sleeve blowout patch,
can seal hydraulic and pneumatic pipe
LOCTITE569 cone sealed blowout patch,
system threads
hose coupling nipple and so on
Flange sealant Main for gasket type sealing flange,
TianShan7304 screwed connection point and other flat
junction plane
Belongs to high performance cleanser,
Special cleanser for metal surface. Can
Cleanser
effectively remove dirties on surface, and On pasting point before
TianShan1755 or
increase the bonding strength between gumming
LOCTITE755
repairing/locking adhesives with their
substrates.
Binder204 For affixing water chamber’s metal and Methbond--- acetal binder
sponge
Blend motor oil and graphite to thick, for
thread part under high temperature, avoid Bolts, studs, plug screw in
Antitack agent
high temperature sintering, easy to exhaust system
disassembly

Caution: The sealants used in factory are Ke Sai Xin sealants produced by Beijing TianShan
New Materials and Technologies Company, and Loctite sealants can also be used, but,
without permission of the factory, it is not allowed to use other sealants!
 HND
MWM Section 1 Hoisting and Foundation • 11 •

2 The Mounting of 236 Series Diesel Engine

2.1 Hoisting and Foundation

2.1.1 Hoisting

The hoisting of diesel engine uses wire rope with sufficient bearing ability, fixed at the hoisting
rings of the body through suitable hoisting tools.

Caution: The steel wire rope should not squeeze the spare parts on the diesel engine. In
hoisting，the diesel engine should be horizontal, and the process of hoisting should be slow
and steady.
The hoisting position of generator set is located at the lifting hole or lifting pins at the
both sides of the common foundation. The caution is the same as above mentioned.

2.1.2 Foundation

236 Series Diesel Engine can be mounted in rigid manner as well as in elastic manner. No matter
which kind of mounting is used, there must be enough rigidity in the foundation to ensure the ship or the
vehicle not to change its shape in loading, and to be able to endure bad conditions at sea surface and
shock load of various kinds of road. In rigid mounting, the diesel engine must be integrated into one
with the foundation, and it is not allowed to put the diesel engine and rigid foundation on the hull or
other carriers with lower rigidity. All the forces coming from diesel engine and foundation should be
attenuated by the connection of the large area, and then transmitted to the carrier. In elastic mounting,
all inertial force, especially torque are mainly absorbed by elastic support, therefore, only a little impact
load acts on the foundation.
The flatness of several supporting surfaces of the foundation should less than 0.1mm.
The design of the foundation should make the inclination angle of mounting for the diesel engine
less than the inclination angle of mounting allowed by the oil pan of the diesel engine. (See the Main
technical data of 236 Series Diesel Engines in the Chapter 1 of the instruction).
 HND
•·12·• Chapter 2 The Mounting of 236 Series Diesel Engine MWM

2.2 Arrangement and Ventilation Quantity of the Cabin (Room)

2.2.1 Arrangement of the cabin (room)

In order to ensure the diesel engine to operate well in the environment where it is located, a total
plan should be made. Enough space must be left for all the interfaces. In addition, one- meter space
should be left around the diesel engine or generating set, so as to facilitate operation, maintenance, and
repair.
In time of mounting with twin engines, the interval of axes should ensure not be less than 1700mm
for V6/V8 diesel engine, and not be less than 2000mm for V12/V16 diesel engine, with the passage
between the two engine to reach 600-750mm. The height of the cabin should be high enough to make it
easy to tear down the cylinder head and cylinder liner with lifting device. The minimum space is
probably 750mm for height from crankshaft center, with width 470mm from crankshaft center; or for
height up to 622mm, with width up to more than 650mm. The opening in each cabin should be large
enough, to lift the whole diesel engine or generating set in the case of not breaking down.

2.2.2 The ventilation of the cabin (room)

The ventilation of the cabin (room) is indispensable for reducing the radiant heat of the diesel
engine, and improving inlet condition and working environment. So, every design unit and construction
department must treat it seriously.
1. The ventilation quantity of the cabin (room) should include the following aspects:
(1) The air quantity needed for the combustion of diesel engine (in the conditions of inlet in the

cabin), and the air consumption for the burning of diesel engine is about 5 m / kW ⋅ h .
3

(2) The air quantity for discharging the radiant heat from the diesel engine, driven machine and
accessory equipment (such as pipeline, vent-pipe, silencer, radiator, pump set) .
(3) Air quantity needed by other device to consume gas, such as, air needed by air compressor.
However, they run discontinuously, this part of air amount is ignored generally.

2. The computation method of the air quantity needed for discharging radiant heat
The radiant heat of the diesel engine accounts for 5% of heat of fuel (The vent-pipe of the
water-cooling is about 3%):

Q M = PM ⋅ b e ⋅ H u ⋅ 5%

Q M (kJ / h ) The radiant heat of the diesel engine

PM (kW ) The power of the diesel engine

b e (kg / kW ⋅ h ) The consumption rate of fuel

H u (kJ / kg) The low calorific value of fuel (42700kJ/kg)

The radiant heat of generator:

 HND
MWM Section 2 Arrangement and Ventilation Quantity of the Cabin (Room) • 13 •

1
Q G = PG ⋅ cosφ ⋅ ( ) ⋅ 3600
ηG − 1

Q G (kJ / h ) The radiant heat of generator

PG (kVA) The generator power

cosφ Power factor

η G (%) The generator efficiency

It is difficult to calculate the radiant heat of the accessory equipment. According to experience, the
heat of this part accounts for about 10% of the radiant heat of diesel engine:

Q H = 10% ⋅ Q M

QH The radiant heat of accessory equipment

QM The radiant heat of diesel engine

Total radiant heat is: Qs = Q M + QG + Q H

The needed quantity of cooling air:

QS
VB =
ΔT ⋅ C P

VB (kg / h ) The quantity of cooling air

QS The total radiant heat

ΔT(k ) Difference in temperature inside and outside the cabin

C P (kJ / kg ⋅ k ) Specific heat of air ( 1kJ / kg ⋅ k )

According to the air density in the cabin，the value of quantity of discharged air with which to
3
discharge the radiant heat can be calculated ( m / h ).

3. The ventilation inlet of cabin:

The ventilation inlet of cabin should be as close as possible to the inlet of diesel engine. The design
of the air inlet and outlet must make ensure air convection in the whole cabin. In general, axial flow unit
is adopted for ventilation, and because the pressure head of the ventilation devices is limited, so the
cross section of fan duct must be considered seriously, the recommended value of the velocity of air in
inlet duct is 5-10m/s, with the velocity in outlet duct up to about 10m/s.
 HND
•·14·• Chapter 2 The Mounting of 236 Series Diesel Engine MWM

2.3 The Mounting of Diesel Engine

2.3.1 Rigid mounting
For rigidity mounting, after the diesel engine has been mounted on the foundation, the stand bar
and the bearing surface should contact well. The contact situation of each stand bar and bearing surface
should be checked with 0.05mm feeler gauge, and the feeler gauge should not pass the surface more
than 1/3 of the stand bar, otherwise it is not allowed to screw down the bolt for stand bar. If the contact
situation is not good, one can adjust it with steel washer or check the positioning situation of positioning
flange of stand bar and the plane situation of the foundation.
In centering of diesel engine, full consideration should be given to the axial clearance of thrust ring
of crankshaft for diesel engine. If there is an axial thrust to flywheel and crankshaft in operation, the
thrust ring will be worn out resulting in damage of the diesel engine. In order to avoid this kind of
phenomenon, the centering should be taken according to the following provisions:
1. In mounting diesel engine, and exterior devices, such as coupling, gear case, etc, respective
requirements on mounting should be met, to make the interconnected flange parallel to each other and
coaxial. It is demanded to use the shaft coupling with high elasticity, and the coupling should be
selected and matched through the calculation of torsion vibration for shafting, and rigid connecting
should be avoided.
2. At any time, the original gap of crankshaft thrust ring for diesel engine in free state must be
ensured. Therefore, push the crankshaft first, confirm the total clearance with clock gauge, then remove
the crankshaft to the mid position, make clearance for the both sides of thrust ring equal to each other.
And then make centering.

Caution: It is a must to ensure no mounting axial thrust for diesel engine and no fleeing
axial thrust for coupling device in operation.

3. Make centering according to requirement on mounting of the coupling. One can adjust it with
steel plate washer under stabilizer. One can make centering with steel washer under stand bar.
Recalibrate the centering periodically after normal operation of diesel engine. It is suggested to make
the first inspection & measurement after the diesel engine has been put into operation, then two weeks
later, three months later, and then every half year.
4. The clearance of the thrust ring must be checked in mounting or shafting adjustment each time.
It should be checked while in recalibrating centering after the normal operation of the diesel engine.
5. In order to avoid the influence upon the centering of diesel engine coming from the distortion of
ship or car body, the final centering should be made after all of the equipment have been mounted in
ship or car, and all of the oil boxes and water tanks have been filled at least up to 50%,.

2.3.2 Elastic mounting

The heavier vibration upon the ship body or vehicle body will be found when diesel engine is
running. And the distortion of ship hull for ship navigation or the vibration of cars in running will
influence normal operation of the diesel engine. In order to reduce the their mutual influence, elastic
mounting is adopted, namely elastic bearings are mounted between stand bar and foundation
(Fig.2-3-1).V6/V8/V12 diesel engine uses four elastic stand bars, while V16 diesel engine uses six
 HND
MWM Section 3 The Mounting of Diesel Engine • 15 •

elastic stand bars. If the rotation speed of diesel engine is more than or is equal to 2200r/min, the elastic
stand bar with tapered damping block is used (Fig. 2-3-2).
In elastic mounting, the coupling with high elasticity must be installed between diesel engine and
gear case or other machines.
1. The mounting of elastic stand bar:
Put the elastic stand bar on the
foundation, and then put the diesel engine or
the weight identical to diesel engine on it for
7-10 days. And then make regulation for
centering according to the provisions for rigid
mounting.
Caution: In order to compensate
for the plastic deformation in the
rubber piece of elastic stand bar and
the sinking resulting from extra impact, the
centering of the diesel engine should be
higher than the gear case or other machines
already mounted, the quantity should be the
greatest allowed value of radial deviation of
the coupling with high elasticity, at least not
less than 70% of the value.
Centering recalibration should be made
periodically after normal operation of the
diesel engine (The method is the same as above -mentioned). If out-of-tolerance is found, centering
must be made again. It is suggested that elastic
stand bar be changed after 5 years.
In order to prevent the diesel engine from
swinging too much in starting resulting in the
damage of the coupling with high elasticity,
banking screw should be designed and mounted
on the stand bar of diesel engine, to ensure a
clearance of 1.5-2mm between the head of the
bolt and supporting surface of foundation.

Fig. 2-3-1 Schematic diagram for

outline of shell-shaped damper

Caution: Rubbers of the elastic stand bar should avoid touching all sorts of oil.
2. The mounting of tapered damping block:
Install the supporting horse for engine with tapered damping blocks and intermediate blocks on the
supporting surface of foundation first, then install the diesel engine on the supporting horse for engine,
making the bolt in the middle of damping block pass through the hole in the middle of the stand bar for
engine, and screw down the nut. Measure the distance between the bottom of each stand bar and
intermediate block after the diesel engine is filled with cooling water and lube oil. During the
 HND
•·16·• Chapter 2 The Mounting of 236 Series Diesel Engine MWM

measurement, the measuring position of each horse should be identical as possible, and the deviation of
each measured value should less than or equal to 1.35mm, otherwise they should be adjusted.
The adjusting method is as
follows: Loosen the bolts connecting
the tapered damping blocks and the
supporting horse for engine, and take
them away from mounting holes of
supporting horse for engine. Loose the
bolts on the supporting horse for
engine fixing the intermediate blocks,
move the damping blocks and the
intermediate blocks between the horse
for engine and the support of horse for
engine forward or backward up to a
distance between two holes (27mm),
and screw the bolts down again.
Measure the distance between the
bottom of each stand bar and the
intermediate block again, check
whether the deviation value fulfils
requirements, if not, adjust again, put
the diesel engine for 7-10 days after
the adjustment, make the tapered
damping blocks have a natural
compression. If it is OK, then make
centering again. The centering method
is the same as above, but attention
should be paid to adjust with proper
Fig.2-3-2 Schematic for outline of tapered absorber
steel washer between the horse for
engine and the horse support for engine
(See Fig.2-3-2).
After centering regulation, record the measured value between the horse bottom for engine and the
intermediate block. Take it as maximum value for the inspection of the sinking value for engine and
print out it on the corresponding horse for engine; Use this value to detract the surmount for the center
of the crankshaft of diesel engine more than the gear case (or the other machines),and then detracts 60%
of the allowed greatest radial deviation of the coupling with high elasticity. Take this as the minimum
sinking value for the inspection of sinking value for diesel engine, and print it on the corresponding
horse for engine too. In the course of using diesel engine thereafter, when the sinking value exceeds the
minimum value, recalibration of centering should be made.
In addition, the tapered damping blocks under the effect of the allowable greatest static load
(5500N for each horse of engine) will produce slow deformation according to the logarithm function of
time, resulting in the sinking of diesel engine. Thus, without the permission of the diesel engine factory,
it is not allowed to fix abutment, instrument box or other devices on the diesel engine, to avoid
increasing extra load on the horse for engine. It is suggested to replace the tapered damping blocks after
5 years.
The replacement of tapered damping block can only go on in a whole way, the method for
replacement is as follows: unscrew and move downwards the bolt, in the center hole of the tapered
damping block, take it away from the hole on the horse for engine, screw down the bolt used to fix the
intermediate block, draw out the regulation washer, then take out the tapered damping block together
with the intermediate block from the flank of the horse for engine. After replacing the block, the shaft
should be regulated for centering again according to the specified procedure.
 HND
MWM Section 3 The Mounting of Diesel Engine • 17 •

Points for attention in mounting coupling with high elasticity:

(i) The rubber articles of coupling should avoid touching all sorts of oil.
(ii) The coupling should avoid the harmful effect of heat radiation.
(iii) The ventilation situation is good.
(iv) The connecting bolt between coupling and flywheel is M12-10.9, the torque of screwing
+10
down is 1200 N gm . The strength of connecting bolt between coupling and the connected devices,

such as gear case must be more than or less than class 10.9, and the torque of screwing down should
follow the provisions of the coupling factory.
 HND
•·18·• Chapter 2 The Mounting of 236 Series Diesel Engine MWM

2.4 Points for Attention in Mounting Diesel Systems

2.4.1 Exhaust system

1. The resistance of the whole exhaust system should be as small as possible. The exhaust
backpressure ought to less than or equal to 5kPa (500mm water column). For the exhaust pipeline not
more than 10m and with less than three elbows, its inner-diameter should be more than or equal to the
value showed in Table 2-3-1. If the length exceeds 10m or the elbow is more than 3, it is more necessary
to increase the internal diameter.
Internal diameter of exhaust pipe
Table 2－3－1

TBD236
Rotation
speed
r/min V6 V8 V12

1500 125 125 150 2×125

1800 125 150 200 2×125

2100 125 150 200 2×125

2300 150 200 200 2×125

2. A good working condition for diesel and the operators should be ensured. Therefore adiabatic
measures must be taken for exhaust pipe for reducing its radiant heat.
3. For compensating for expansion distortion of the exhaust pipe after heated, the corrugated
pipes must be installed after the exhaust pipe of diesel. The corrugated pipes must be installed in the
condition of no pressure and enough clearance (15~25mm), without obvious distortion, with small
deflection as possible. The biggest distortion of corrugated pipe is 25mm.
For the steel exhaust pipe, the length per meter will elongate 1mm when the temperature of exhaust
o o
rises 100 C .So the elongation per meter is 5mm as the temperature of exhaust is 500 C . This

deformation quantity should be considered in designing the exhaust system.

4. In order to ensure the normal operation of corrugated pipe and supercharger, the exhaust pipe
after corrugated pipe should be restricted downwards, and be fixed the site outside the diesel engine in
non-rigid way, such as on the wall or on the ceiling, so as to ensure the requirements of expansion.
 HND
MWM Section 4 Points for attention in mounting diesel systems • 19 •

2.4.2 Fuel system (Figure 2-4-1)

—— provide d by mainframe factory

– – ---provided by users (according to the length of installation distance, augment the pipe diameter
properly)
Figure 2-4-1 Schematic diagram for fuel system

Points for attention in mounting :

1. Blow-off valve should be set up at the lowest position of the bottom for the fuel box to
remove the water and feculence deposited on the bottom. The oil-out of the oil box must be
100-150mm higher than the bottom of the box, so as to prevent the impurities deposited on the bottom
from getting into diesel.
2. The fuel box should be put on the place to facilitate direct flow into the hand-operated
pre-provided fuel-oil pump. If the fuel is put on a lower place, attention should be paid to the
self-absorption ability to be only 1.5m for the hand-operated pre-provided fuel-oil pump and fuel
transport pump. Attention should be made to the seal of the pipelines.
3. Steel or copper pipes should be selected for fuel pipe, without the use of zincky material. When
the velocity of admission pipe is less than or equal to 1.0m/s, the cross-section area should ensure two
or three times the fuel feeding quantity by the fuel consumption of the diesel, the velocity of the fuel
return pipe should be no more than 2.5m/s.
4. In order to ensure the quality of fuel feeding and the use life of fuel fine filter for diesel engine,
coarse filter must be installed between fuel tank and diesel engine.
 HND
•·20·• Chapter 2 The Mounting of 236 Series Diesel Engine MWM

2.4.3 Raw water system(Figure 2-4-2)

------ sea water pipe (provided by dockyard)

—— freshwater pipe (provided casually)

------sea water pipe (provide casually)
Figure 2-4-2 Raw water system

Points for attention in mounting:

1. Inlet filtering net for raw water made based on impact with metallic plate should be set near the

ship body, with the maximal aperture of the filter up to φ 2.5mm or 2 × 2mm.
2. Raw water inlet must be under the surface of water at any time in the running of ship, the
distance from the raw water pump should be as close as possible. The number of syphon in the pipe
system should be as few as possible; They must be connected with diesel by elastic tie-in or flexible
tubes.
3. Suction height of the raw water pump is 4m.
4. The raw water pump should be filled with water before the start of the diesel engine. The valve
connected to the sea, for passing and out of the raw water, must be shut up in time after stopping the
diesel (opened before the start).
5. In order to ascertain the quantity of cooling water accurately, needed to cool lubricating oil of
gear case, the dockyard must expand the drilling aperture to corresponding aperture (or controlled with
the installed valve) in considering the maximal lubricating oil temperature running in full power,
prescribed by gear case factory.
6. Bleeding faucet should be placed on the rock bottom of the pipe system.
 HND
MWM Section 1 Points for Attention in the Use of Diesel Engine • 21 •

3 The Use of 236 Series Diesel Engine

The selection of 236 series diesel engines should be based on the requirements on the
configuration and working environment for the driven machinery to make rational selection of the
suitable type and specification to enable to bring into effective play of its benefit. It should be pointed
out that the nominal power of so-called different types refers to the output power of single machine,
including the output power of the exterior auxiliary components such as the fan, etc. We must have a
comprehensive consideration of the impact of inlet guiding-pipe of air filter exhaust pipelines and the
cooling circulation manner of the diesel engine on the effective output power in selection.

3.1 Points for Attention in the Use of Diesel Engine

In using the diesel engine, the operator should strictly observe the following points for attention:
(1) Read the manual seriously, grasp the structural characteristics of 236 series diesel engines and
the operating method.
(2) Select fuel and engine oil according to the variety and trademark stipulated in the manual. The
container for storing the oil should be clean. The oil should be precipitated and filtered prior to use, and
is not allowed to contain the moisture and impurity. Control cooling water quality strictly, and add the
NL emulsification oil according to the specified requirements.
(3) Carry out the provisions for technical maintenance, and make every technical maintenance, in
accordance with the specified cycle.
(4) Pay attention to the operating conditions of the diesel engine during the process of use. Make
the operating record well according to the provisions. If any unusual phenomenon is found in operation,
the cause(s) should be looked up and eliminated in time.
(5) Strictly prohibit dismantling the spare parts of the diesel engine at will (especially the
precision couplings, connecting rod, crankshaft and supercharger etc. for fuel feeding system). If it is
needed to dismantle and inspect, it is a must to operate according to fixed procedure and demand strictly
by the skilled operator subject to technical training of the manufacturer or under the guidance of
technical staff of the manufacturer. In dismantling the positions influencing the various technical
parameters (such as valve clearance and advance angle of fuel supply, etc), one must check and adjust
again after reinstallation.
(6) When new machines are beyond the time of sealing up for keeping or old machines are put
into use again after sealing up for a long time, they can't operate and use directly. One must make a
comprehensive inspection and make the test of removing the seal before put into use again, and must
change the oil and water. If any obvious corrosion and other unusual phenomena are found, it is a must
to dismantle and to make exam. They can be used only after the maintenance up to the standard.
 HND
•·22·• Chapter 3 The Use of 236 Series Diesel Engine MWM

3.2 Fuel, Engine Oil and Cooling Water

3.2.1 Fuel

Fuel used by the diesel engines must accord with the variety and specification of the GB252-94
light diesel oil, one should select the light diesel oil of No. 0 in summer, and select light diesel oil of
No.10,No.20 or No.35 according to the difference in regional climatic conditions.

3.2.2 Engine oil

It is suggested for 236 series diesel engine to use the diesel oil of CD level, whose main
performance index should accord with the provisions of GB11122-1997. The concrete trademark of
engine oil used by diesel should depend on the environment temperature. It can be selected referring to
the following chart.

-30 -25 -20 -15 -10 -5 0℃ 5 10 15 20 25 30

10W/40CD(SAE 10W-40)
15W/40CD(SAE 15W-40)

20W/40CD(SAE 20W-40)

40CD(SAE40)

Attentions:
1.
1. The content of ( ) is the trademark of engine oil in conformity with API-CD/CE viscidity level.
2. The engine oil must be clear, preventing water and impurity from interfusion into the engine oil.
3. The engine oil of different specifications can't be used in a mixed way.
4. If the pressure of engine oil is on the low side, one can use the 40CD engine oil with a grade
higher in trademark of temperature.
5. The diesel oil of CD class produced by Lanzhou Oil Refining Chemical General Factory, Jinxi
Oil Refining General Factory and China Petroleum Chemical Great Wall High-graded Lubricant
Company is recommended for use based on the validation of the factory. If users do not use the
product(s) not recommended by the factory, the product(s) can be used only after the contact is made
with the factory.
Lithium-based grease can be used as the grease for bearing. No. 2 Lithium-based grease is
generally used in the factory. Attention should be paid to that it could not be replaced by butter !

3.2.3 Cooling Water

1. Cooling water for 236 series diesel engine：

 HND
MWM Section 2 Fuel, Engine Oil and Cooling Water • 23 •

Airframe is cooled with water supplied by fresh water pump，and the water for airframe cooling
ought to select clean water with alkalescence，not containing corrosive compound, such as chloride,
vitriol or acid etc..
Its primary indicator requirements are listed as follows:
Minimum Maximum
Total hardness(Germany) 3GH° 3 12
Hardness of carbonate (Germany) 3GH° 3
Total hardness in using chemical 3GH° 0 12
repellent
PH value 6.5 8.5
Chlorine ion content mg / dm 3 100
Sulfate ion content mg / dm3 100
Total content of anion mg / dm3 150
Attentions
It is not allowed to have direct use of seawater. It is not suitable to the hard water such as well
water and spring water etc. as the cooling water for airframe. Seawater possesses severe corrosion
action and it is very easy to make damage to machine members. The water with over-hard water quality
contains many minerals and is easy to form scale, and thus exerts influence on the cooling effect,
resulting in over-heating of diesel engine or reduction in power. The water with over-hard water quality
can be used as cooling water only after it experiences softening treatment.

2. Emulsified oil for corrosion proof added in cooling water

In order to reduce or avoid the corrosion and scale accumulation for the machine parts of cooling
system, suitable amount of emulsified oil for corrosion proof should be added in cooling water.
As for emulsified oil for corrosion proof, The NL type emulsified oil (produced by Suzhou Special
Type Oil Plant) should be selected. For the preparation method, refer to the working instruction of the
emulsified oil manufacturer.
When emulsified oil for corrosion proof is used in diesel engine for the first time, the upper limit
should be taken for the content of emulsified oil for corrosion proof, as the surface of metal can absorb
one layer of oil film. The emulsified oil for corrosion proof possesses the action of anti-rust,
corrosion-proof, scale-proof, and anti-cavitation. And it should be used in a continuous manner from the
beginning for the new machine. When the diesel engine is reused with scale found in it, it is easy to
result in chemical reaction to influence the cooling effect.

注 Attentions:

(1) It is necessary to add (or supplement) the NL type emulsified oil no matter in
replacing or supplementing the lost cooling water due to leakage.
(2) In time of supplementing the suitable cooling water due to evaporation,, it is allowed
not to use NL emulsified oil .
(3) The factory takes no responsibility for the kickback resulting from the other brand of
emulsified oil for corrosion –proof.
3. Anti-freeze fluid
In freezing cold season, it is better to use anti-freeze fluid. There are two kinds of anti-freeze
fluid in common use, namely glycerol--water and glycol--water，its preparation methods are shown as
 HND
•·24·• Chapter 3 The Use of 236 Series Diesel Engine MWM

follows:

freezing glycerol--water glycol--water

point

°C glycerol quality(%) density glycol quality(%) density

-5 21 1.0495 - -
-10 32 1.0780 28.4 1.0340
-15 43 1.1074 32.8 1.0426
-20 51 1.1290 38.5 1.0506
-25 58 1.1483 45.3 1.0586
-30 64 1.1647 47.8 1.0627
-35 69 1.1785 50.9 1.0671
-40 73 1.1894 54.7 1.0713
-45 76.5 1.1980 57.0 1.0746
Glycerol has the benefit of small volatility and it is not easy to result in fire. But the glycerol is not
so economic due to its poor effect in reducing the effect of freezing point. In addition, the glycerol is
strong in absorbing water, therefore it is necessary to seal for the container in preservation.
Due to the poisonous property of glycol, protective measures must be taken in the keeping,
preparation and use, so as to avoiding suffering from poisoning. Glycol is strong in water absorption, so
the container should be sealed in its preservation, so as to prevent spillage resulting in loss after
absorbing water. Water is lost in evaporation for glycol—water anti-freeze fluid in use, so attention
should be paid to supplementing water.

The anti-freeze fluid should be recovered and well kept after its use. It can be continuously used
with water added to regulate its concentration after deposition and filtration. It can be generally used for
3~5 years.

Attention:

In time of using antifreeze liquid, the selected freezing point should be 5 ° C lower than the
lowest temperature in the local area. It is necessary to prepare in accordance with the higher make-up
ratio, and gradually add glycerol or glycol. It is allowed for the user to have direct selection of the
antifreeze liquid already prepared by the manufacturer.
 HND
MWM Section 3 The Startup of the Diesel Engine • 25 •

3.3 The Startup of the Diesel Engine

3.3. 1. The preparation before startup

Before the startup, the following work must be finished:

1. Inspection of the appearance and installation status

Inspect whether the parts and elements of the diesel engine are complete and whether the pipelines
of the oil or water or gas are firm. There could not have sundries around the moving positions, such as
flywheel and belt-wheel and the protective cover should be fixed and reliable.

2. The fuel supply system:

(1) Check whether the oil in the fuel box is in conformity with the stated variety and the
specification in the instructions. The fuel box should be filled with enough fuel. The filled fuel
should have deposited for 48 hours and be filtrated. .
(2) Open the fuel return valve, switch on the fuel route. In starting or stopping for the first with
longer time, it is necessary to press the manual pre-supplied fuel pump, disentangle the gas
discharging plug screw on the fuel filter, and discharge the air in the fuel system until there is
not any air bubble in the discharged oil.

3. Lubrication system:
Check the capability of diesel oil to ensure the appropriate amount of diesel oil. The ordinal
method is to inspect the height of the engine oil level in the oil bottom shell and keep it between the
upper reticle and the lower reticle, and it is better to close to the upper reticle. When necessary, it is a
must to fill the clean engine oil in conformity with the specified requirements in the oil bottom shell.
When it is the first time to use the diesel engine, demount the bolt on the upper end of the
mechanical speed-controller, and fill in about 200 ml of local diesel oil.

4. The cooling system:

(1) Check the quantity of cooling water in the radiator or the heat exchanger. Add the cooling
water according to the requirements listed in the section 2 if necessary. Disentangle the plug
screw on the admitting pipe (higher position), discharge out the gas in the water channels of
the engine body.
(2) For the diesel engine with pump for raw water pump, open the valves for admitting and
discharging water, connect the pipeline for raw water, which is filled into the pump for raw
pump from the funnel, until its overflowing.

5. The startup system:

(1) In using the startup system for pneumatic motor, open the total revolving valve for air source,
check whether the pressure of air source reaches 1.5-3Mpa and the air transport pipes should
not leak.
(2) In using the electric startup system, check the voltage of accumulator pressure or the density
of electrolyte (where the specific gravity between 1.23 to 1.28 kg/L is normal). If it is less
than 1.21kg/L, there needs charging up. The water level of the accumulator should be at the
 HND
•·26·• Chapter 3 The Use of 236 Series Diesel Engine MWM

position of about 15 cm of the edge of electrode board. Add the distilled water if necessary.

6. The operation and the safeguard equipment and the other equipment:
(1) Open the power supply of control box, press the shut- down button. Check whether the
electromagnetic shut- down equipment is flexible and in the right position. The urgent shutdown button
and the shut- down valve for stopping the oil supply and the electromagnetic shutdown equipment
should be reliable credibility and act in a synchronous way.
(2) For the hand handler to control the rotating - speed, the operation should be brisk and flexible;
Disentangle it to make the engine in the status of the startup.
(3) If the diesel is in connection with the gear case, ensure the gear case is in the empty gear. If the
engine is equipped with the clutch, the clutch should be in the disconnected status.
(4) Check the alarm equipment to ascertain whether the installation of its circuitry is right and its
tie-ins are firm or not.
(5) For the diesel stopped for use for a long time, check the air cleaner before the startup, and add
the engine oil in the oil bath typed air cleaner according to the provisions.

7. Provide the engine oil in advance and jigger

For the diesel with pre-supply pump with engine oil mounted, provide the engine oil in the pump in
advance and in the same time, use the manual tray to turn the crankcase more than two turns, until the
press gauge of engine oil sways slightly and pay attention to check running situation of the fresh water
pump and the raw water pump.

8. Start up the ventilation equipment in the engine room or machine room.

3.3.2 The startup of the diesel engine:

The start can begin only after the completion of the preparation work for the startup and the check
to confirm no-error.
1. The startup process of the startup system for pneumatic motor:
Open the startup valve for air source to let the compressed air in the air bottle flow in the cylinder
through the air dispenser and push the piston down resulting in driving the crankshaft to rotate. When
the diesel engine is ignited for starting, close the startup valve for air source immediately.
In case of using the startup system of pneumatic motor, press the pneumatic switch after opening
the total revolving valve for air source. The pneumatic motor begins to run due to aerating and drives
the diesel engine to ignite and start. Then relax the switch button, and close the startup valve for air
source immediately.

Attention:
(i) Break off the air supply immediately after the diesel engine starts to prevent the pneumatic
motor and the air distribution tray from damage.
(ii) The running for pneumatic motor could not exceed 10 seconds every time. After the
completion of startup, close the rotary valve for pneumatic motor immediately to prevent the pneumatic
motor from damage due to false contacting the button in the operation of diesel.
2. The startup process of the electric startup system:
 HND
MWM Section 3 The Startup of the Diesel Engine • 27 •

Press the startup button to let the startup motor drive the diesel engine to ignite and start, and the
time could not exceed 10 seconds each time. If starting-up fails in the first time and it needs the startup
for the second time, the interval time should exceed 60 seconds to protect the accumulator.

Attention:
Strictly prohibit pressing the startup button when the flywheel does not completely stops
rotating, so as to prevent striking the gear of electrical motor and the gear ring of flywheel to damage.

For the diesel engine without installing the pump for pre-supplying engine oil, it is allowed to use
the mode of electrical jigger to provide the engine oil in advance if the engine has not worked for a long
time. Namely, put the electromagnetic shut- down valve in the position of shut- down to prevent the
diesel engine from ignition. Press the startup button to let the startup electric motor drive the crankshaft
to rotate. Operate three times with each tine not more than 10 seconds. Pay attention to the swinging
situation of the pointer of the oil manometer.
After the diesel engine starts, release the startup button instantly to prevent the flywheel from
drives conversely to bring the small gear to rotate, resulting in the startup electric motor to work at the
excessive speed leading to damage to the startup electric motor.
It is allowed to startup directly at the rated rotating speed for the automatic power station in the
state of preheating of oil and water and supplying engine oil at regular time.
3. Points for attention in the startup:
(1) After the start-up of the diesel engine, it is possible to use the shut -down hand- handle
to control the diesel engine. Reduce the oil supply properly even shut down if necessary
to prevent the rotate speed of the diesel engine from rising fleetly in an instantaneous
way or the occurrence of serious fault.
(2) After the startup, the diesel engine should runs at the idle speed in a period of time and
check whether the operation is normal. Then raise the rotating speed gradually.
(3) If the start-up fails for the third time to startup, it is necessary to find out the reason,
eliminate the fault and startup again.
 HND
•·28·• Chapter 3 The Use of 236 series diesel engine MWM

3.4 The Operation of the Diesel Engine

When the diesel engine switches to the normal operation after the startup, it is necessary to pay
attention to the following matters:
1. The lowest and steady rotating speed with no-load for the 236 series (the idle speed):
(1)650-700r/min for the rated speed of the diesel engine less than 2100 r/min;
(2) 700-750r/min for the rated speed of the diesel engine more than 2100 r/min;
(3) 900-950r/min for the diesel engine for the dynamotor set.
(4)1150-1200r/min for the diesel engine in the 50 HZ-based power plants equipped with
equipment for trimming electric speed;
2. It is necessary to operate with no-load after the startup of the diesel engine and check the
following aspects:
(1) The pressure of the engine oil: not less than o.2 MPa with idle speed. In time of higher oil
temperature, and with oil temperature less than 0.2MPa, it is a must to properly step up the idle rotating
speed, so as to ensure the oil pressure more than 0.2MPa.
(2) Turn on the filler valve a little on the top of the raw water pump. If there is a forceful water
column dashing out, the water supply of the raw water pump is normal.
(3) Check the appearance of the diesel engine, to confirm non-existence the phenomena of oil
leakage or water leakage or gas leakage.
(4) The smoke color of exhaust gas is normal.
(5) All parts should be firmly fixed according to the requirements, without the phenomena of
unusual sound and acute vibration.
(6) Check the position of the engine oil. After the diesel engine operates for a little time, the
various lubricated positions will be filled with engine oil, and the oil position will drop. Add the engine
oil if necessary, but the position cannot exceed the reticle on the oil staff gauge.
3. The user needs no longer to make running-in, as the running-in test has been made before the
new machine leaving the factory. In order to improve further the reliability of the diesel engine, it is
necessary to change the engine oil and the core of the strainer for engine oil r and then clean the oil
bottom shell after the new machine has been put into use for 60 hours.
4. The load is allowed to add gradually only after the temperature of the cooling water goes up to
40 ℃. The load increase should be slow and even in increase of rotating speed Otherwise the
transitional warm-up is needed under the partial load.
5. In normal operation of the diesel engine operates, the temperature of the cooling water is
generally in the range of 65 ℃ to 85 ℃. For the speed of the diesel engine up to 1500 r/min, the
pressure of engine oil press is not less than 0.35 MPa. For the speed of the diesel engine between 1800
and 2100 r/min, the pressure of engine oil should be not less than 0.45 MPa. The temperature of the
engine oil for the supercharged diesel engine should be not more than 120 ℃. For the diesel engine
with natural absorption of gas, the temperature of the engine oil should be not more than 110 ℃. The
temperature of the exhaust gas depends on various engine types, and generally it can not be 30 ℃ than
the exhaust temperature behind the turbine listed in the test table in the technical documentation along
with the engine in leaving the factory (The environmental condition is close to that leaving the factory)
and meanwhile it can not exceed 600 ℃. If it is found not in conformity with the above-mentioned
conditions or there is unusual condition, it is necessary to reduce speed and stop operation immediately,
 HND
MWM Section 4 The Operation of the Diesel Engine • 29 •

and to find out the reason. The restart can be made after the elimination of the failure.
6. When diesel engine is in the state of heat engine, do not add a lot of cooling water and engine oil
in the diesel engine to avoid sudden distortion or crack resulting from sudden cooling of the parts with
high temperature. In the state of heat engine, it is necessary to avoid the water with high temperature or
the steam dashing out to scald the operator in time of opening the observation cover for the radiator or
the heat exchanger.
7. The diesel engine should avoid long time working with the low load for a long time. In general,
it can run for a long time when the load is more than and equal to 20℅ of the load.
8. When the diesel engine is in continuous running for a long time, the load can run without
exceeding the specified sustaining power.
9. In the running of diesel engine, it is not allowed to cut off the circuit connection between the
charging dynamotor and the accumulator etc., otherwise it will burn out the charging dynamotor.
10. In the running of diesel engine, it is not allowed to cut off or move the switches for power
supply of the control system, so as to prevent the false operation resulting from the sudden change in
electric current and affecting normal operation of the machine
11. In time of not use, shut down in time when the temperatures of the oil and water drop.
12 .In the process to use the diesel engine, rationally choose the running configuration according to
the characteristic of the diesel engine so as to bring into full play the efficiency of the diesel engine and
prolong the using time. It is strictly prohibited to run the diesel engine for a long time with idle speed or
no- load and with excessive load for various configurations.
Now take the characteristic curve of the airscrew as example to make clear the question of
excessive load.
 HND
•·30·• Chapter 3 The Use of 236 series diesel engine MWM

MCR: maximum rated sustained power

I: range of sustained operation

II: range of working for a short time

Fig.3-4-1 Schematic diagram for curve to show characteristics of air screw

The characteristic curve of the airscrew connected by the working points for different load in the
figure shows the characteristic working states of the mainframe. The black line towards the left
underneath from the 100 ℅ working point is the line with equal torque, while the succeeding dark line is
the curve showing that the power is proportionate to the cube of the speed, to show the limiting line of
the work for the diesel engine. It can be seen that the range I enveloped by the dark real line is the
sustaining power scope for this type of machine could work for a long time, while range II is the
expanded use range of this type of machine to work for a short time .When the matching is decided and
it is running with excessive load at the 100 ℅ point, and then with the other speed on the curve showing
the state of exceeding load. So when the excessive load at the 100 ℅ point occurs, the practice is wrong
for the user to use the speed reduction as the measure to reduce load. If it is running for a short time, the
measure to reduce the rotating speed is allowed, but if it is running for a long time, the state must be
replaced and the matching must be adjusted. This will require to select the power lower than the black
line in the initial design as more rational (and meanwhile in consideration of the distortion of the hull
and the other resistances). The excessive load phenomena could be judged by the following
characteristics: (i) high temperature in discharging,(ii) high consumption in oil, (iii) the load can not
meet the requirements even the manual controlling handle has touched the screw limiting the highest
rotating speed.
 HND
MWM Section 5 Shut-Down of Diesel Engine • 31 •

3.5 Shut-Down of Diesel Engine

3.5.1 Normal shut-down
Under the normal situation, it is necessary to remove the load gradually before shut-down of the
diesel engine. Reduce rotating speed，up to operation with idle speed or 10 minutes. After the water
temperature drops to some extent，and then press the button for shut-down .Or promote directly the
electromagnetic valve for shut-down to make the diesel engine shut down..
Cautions:
If the temperature of engine oil higher and the pressure of engine oil in idle operation is less
than 0.2MPa, it is a must to increase properly the idle rotating speed to make the pressure of engine oil
more than 0.2Mp. The shut-down with reduced speed will be made when oil temperature drops and the
pressure of oil increases.

Attention should be given to the following matters during and after the shut-down of the
diesel engine：
(1) Unless the contingencies of propeller flying or the occurrence of flammable gas etc. in the working
place, shut-down of the diesel engine with load under the configuration of high-speed is forbidden
under the normal situation .Because after shut-down of the diesel engine under the state of
high-temperature state, all oil pump, water pump, and fresh water pump stop working, cylinder liner,
cylinder cover and piston etc. can produce overheating resulting from not getting cooled, and it is
apt to make the piston locked, make the rubber seal piece aging, and supercharger bearing and its
seals overheated to lead to failure or reduction of use life.
(2) When the environment temperature is lower than 5 °C , and the antifreeze liquid or other
cold-proof measures have not been taken, and if it is not put into use at once or it is leaved outside
in the winter, it is a must to discharge all cooling water in time through the valves for discharging
water located at the side of machine body and the cooler for engine. .For diesel engine equipped
with radiator, it is necessary to set water free from radiator too through the plug screw for
discharging water located at the low side of radiator. In severe cold areas, it is necessary to take the
necessary cold-proof measures.
(3) When the environment temperature is lower than the freezing point of engine oil, the engine oil
should be set free after shut-down.
(4) In time of needing the replacing of the engine oil, it is necessary to set free the engine oil when it is
hot for the purpose to rinse， when the impurity has not been precipitated in the engine oil after
shut-down.
(5) If it is needed to seal up for safekeeping for a long time after shut-down, it should proceed
according to demand on sealing up for safekeeping for diesel engine.
(6) The handle for speed regulation should be completely relaxed after shut-down, to prevent too high
speed of vehicle in the next start.
(7) After shut-down, it is necessary to close the oil route, waterway, electric circuit and exhaust valve
of diesel engine in time, and close the aerator in the cabin in time.
3.5.2 Emergent shut-down
During the use of diesel engine, when unexpected failure occurs, if shutdown is not made in time,
the security of personal and equipment will be endangered. It is necessary to press rapidly the shutdown
button or the emergency button, to push directly the electromagnetic valve to cut off oil supply by the
 HND
•·32·• Chapter 3 The Use of 236 Series Diesel Engine MWM

oil injection pump, to make the diesel engine shut down in an emergent way.
When the control system for the oil amount of diesel engine breaks down (such as the gear pole for
adjusting oil amount of the injection pump is blocked, the governor does not work to lead to propeller
racing and so on) or the flammable gas appears in the workplace, shutdown can not be made promptly
in the manner of normal shutdown, it is a must to use the urgent shutdown button to shut off the oil
route of the high-pressure oil pump to stop promptly. When that is invalid, the passage of air admission
should be cut off in time to force the diesel engine to shut down.
When the protector of security effects, the phenomenon of prompt shutdown will appear too.
Cautions:
After the diesel engine makes an emergent shutdown, it is a must to use manual hand-operated
jigger for a period of time continuously, and should make lubricating oil full spread over each rubbing
surface at the same time to pump oil by use of engine oil supplied in advance. If manual jigger cannot
rotate the diesel engine, then the starting device cannot be used to start the diesel engine in the next time.
The diesel engine can be started only when the reason is found out and the failure is eliminated.
 HND
MWM Section 6 Power Correction of the Diesel Engine • 33 •

3.6 Power Correction of the Diesel Engine

Standard ambient conditions:

Atmospheric pressure: P0 = 100KPa
Relative humidity: Φ0 = 30%
Ambient temperature: T0 = 298K (25℃)
Inlet temperature for cooling medium of air cooler: Tcx =298K (25℃)
Note: For marine engine using in navigation area should adopt ambient conditions IACS regulated.
Atmospheric pressure: Px = 100kPa
Relative humidity: Φ0= 60%
Ambient temperature: Tx = 318K(45℃)
Inlet temperature for cooling medium of air cooler: Tcx =305K (32℃)
When engine operation on the substandard conditions, its power should amended to actual power by
ISO standard ambient conditions.
Engine power is amended to actual power from standard ambient conditions.

Px = ƒ 1 ·ƒ 2·P-PL

In the equation that

Px — actual power kW

P — ISO power kW

P L — fan consumption power kW

ƒ 1 = altitude and air inlet temperature factor

ƒ 2 = cooling medium inlet temperature of air cooler

Indirect cooling: Tcx = cooling water inlet temperature of air cooler

Fan cooling: single cycle: Tcx = 348K (75℃)
Double cycle (air to water): Tcx = pre-fan-cooling air temperature+ 10K
Double cycle (air to air): Tcx = pre-fan-cooling air temperature
 HND
•·34·• Chapter 3 The Use of 236 Series Diesel Engine MWM

The temperature of the cooling medium （ °C ）

 HND
MWM Section 6 Power Correction of the Diesel Engine • 35 •

The temperature of the cooling medium （ °C ）

--------The cooled air temperature in intercooler（ °C ）
Temperature of water at the entrance of the intercooler

Fig. 3-6-1 Coefficient drawing for power correction

 HND
•·36·• Chapter 4 Maintenance and Storage MWM

4 Maintenance and Storage

4.1 Maintenance Plan

Only according to our specifications, the normal operation of diesel engines can be ensured, and
thus, your equipments will be reliable, operation and maintenance costs will be reduced.
Therefore, maintenance and inspection works have to be done by the trained personnel.
Spare parts should be qualified products, and fuel oil, lubricating oil and cooling water should
meet the requirements of relevant standards and specifications.
If necessary, our service department will offer our help and consultation for clients at any time.
The general conclusions of operation time and modes of inspection and maintenance in this
manual are based on our experiences of years during operating. Hence, we offer all of following
operating time and each work plan for reference only.

Caution: ○
1 Under the special operating condition, the maintenance plan can be modified, and

shorten maintenance interval.

○2 Replacing lubricant oil should be according to stipulation strictly. Use lubricant

oil according with the specification, and replace filter element under
pollution-free circumstance.
○3 Accumulated operating time or overhaul interval reaches maintenance grade first,

this maintenance grade is carried out.

Clarification for maintenance:

----- The diesel engine should be kept clean all the time, so as to find leakage, avoiding undesirable
effects due to the leakage.
----- Some parts are made of rubber or composite materials, they can be dry-cleaned only, and in
principle, they should not be washed by chemical cleaning agents.
It is classified to 6 maintenance grades for maintenance plan, namely W1 -- W6.
The main characteristics of maintenance grades are:
W1 - Daily operation monitoring;
W2、W3、W4 - Periodic maintain, inspection, and current repair. It doesn’t need to disassemble
midsection of engine, and these works can be finished during the time the equipments are not
running.
W5 – medium repair, parts restoration. It is need to disassemble part and midsection of diesel
engine.
W6 – overhaul. The diesel engine should be disassembled completely.
According to different uses, the maintenance intervals of W2 – W6 are stipulated as follows:
 HND
MWM Section 1 Maintenance Plan • 37 •

Maintenance interval

n>2200r/
Grade of maintenance n<1800r/min 1800r/min<n<2200r/min
min
Maintenance daily Every day Every day (operating) Every day
W1
(operating) (operating)
Maintenance after operating 250 hours 250 hours 250 hours
W2
time
Maintenance cycle 6 months 6 months 6 months
Maintenance after operating 500 hours 500 hours 500 hours
W3
time
Maintenance cycle 1 year 1 year 1 year
Maintenance after operating 3000 hours 2000 hours 1500
W4
time hours
Maintenance cycle 3 years 2 years 2 years
Maintenance after operating 10000 hours 5000 hours 3000
W5 time hours
Maintenance cycle 6 years 5 years 4 years
Maintenance after operating 20000 hours 20000 hours 6000
W6
time hours
Maintenance cycle 12 years 10 years 8 years

One-off additional work

After running for 60 hours, the following inspection and maintenance should be done for new
diesel engine or the diesel engine after overhauling of w5 or w6:
Part Job type of checking and maintaining
Valve organization Check the valve clearance, if needed, adjust. Check the
fastening situation of ranging arm, the bolt and nut of
ranging arm.
Intake organization Check the fastening situation of the bolt and nut
Exhaust organization Check the fastening situation of the bolt and nut
Fuel system Wash the strainer on the ship, check the elasticity situation
of the fuel filter
Diesel engine lubricating oil Change lubricating oil and engine lubricating filtering
cartridge; wash the bottom of oil shell.
Bearing of diesel engine
 HND
•·38·• Chapter 4 Maintenance and Storage MWM

W1 – Operation monitoring
Part Job type of checking and maintaining
Exhaust organization Turn on the water (only when equipped with the tap of
turning on the water)
Intake organization Check the displacement of the condensation drain pipe of
the supercharging air-cooler
Fuel Check the situation of storing
Cooling water of diesel engine Check the water level
Diesel engine lubricating oil Check the oil level
Compressed air Check the atmospheric pressure
Gearing Check the tension of the triangle strap , lubricate the water
pump
Air starter Check the oil level of the lubricating oil
Stopping system Check the function of stopping, urgent parking system
Alarm system Function of the alarm system
Check the temperature of cooling water and engine oil and
lubricating oil pressure, the liquid level
Check whether the raw water pump produces water
Operation of diesel engine Check the sealing of the diesel engine and external
pipeline
Checking that the operation noise, the rotational speed of
diesel engine and every instrument's work are normal
Check the color of exhaust

W2
Part Job type of checking and maintaining
Stopping system Check the function of stopping, urgent parking system
Alarm system Function of the alarm system
Cooling water of diesel engine Draw the cooling water sample and test
Lubricating oil of diesel engine Change lubricating oil(breathe in the diesel engine every
500 hours naturally); Draw the oil style and test
Change the filtering cartridge (strain core)
Lubricating oil filter Go on together with the change of engine oil.
(breathe in the diesel engine every 500 hours naturally)
Respirator Wash the respirator, connect the respirator after checking
the situation of giving vent while operating.
Air filter Wash air filter (Marine wet type air filter every 100 hours)
Raw water pump Add the lubricating grease
Zinc protect screw plug Check zinc protect plug whether normal, change it when
corrosion volume is greater than 1/3
Crankshaft Check the axial clearance of crankshaft
 HND
MWM Section 1 Maintenance Plan • 39 •

W3

Part Job type of checking and maintaining

Stopping system Check the function of stopping , urgent stopping system
Alarm system Function of the alarm system，check it by simulation test
Cooling water of diesel engine Draw the cooling water sample and test
Diesel engine lubricating oil Change lubricating oil (breathe in the diesel engine every
500 hours naturally); Draw the oil sample and test
Change the filtering cartridge ( filter core)
Lubricating oil filter (breathe in the diesel engine every 500 hours naturally)
go on together with change of lubricating oil
Respirator Wash the respirator; connect the respirator tube after
checking the situation of out gassing while operating.
Air cleaner Wash air cleaner ( Air filter of wet type for ship every 100
hours)
Raw water pump Add the lubricating grease
Zinc protect screw plug Check zinc protect tuck in normal condition, change it
when corroded volume is greater than 1/3
Valve organization Check the rotation of the valve and the lubrication of the
ranging arm .Check the valve gap and adjust
Exhaust organization Check the drainage system; Check and exhaust the tight
situation of the exhaust organization.
Fuel prefilter Wash the fuel prefilter on the ship
Fuel filter Exhaust , change the fuel filtering cartridge , filter core
Seawater system Check the situation of water supply; Wash the filter on the
ship
Electronic governor Check whether the electronic governor works normally,
add the lubricating grease to the lever and joint
Air starter Wash the filter
Crankshaft Check the axial gap of crankshaft
Check the tight situation of the fixed bolt; Check the state
Bearing of diesel engine of the elasticity bearing.
Check the diesel engine to the situation of hitting

Caution: The detached filtering cartridge can be inspected carefully to observe the change of
metal filings.

W4
Part Job type of checking and maintaining
Exhaust turbocharger Check the axial gap of the rotor , pendulum difference and
oil leak
Stopping system Check the function of stopping , urgent stopping system
Alarm system Function of the alarm system，check it by simulation test
Cooling water of diesel engine Draw the cooling water sample and test
Diesel engine lubricating oil Change lubricating oil (breathe in the diesel engine every
500 hours naturally); Draw the oil sample and test
Change the filtering cartridge ( filter core)
Lubricating oil filter (breathe in the diesel engine every 500 hours naturally)
go on together with change of lubricating oil
 HND
•·40·• Chapter 4 Maintenance and Storage MWM

Respirator Wash the respirator; connect the respirator tube after

checking the situation of out gassing while operating.
Air cleaner Wash air cleaner ( Air filter of wet type for ship every 100
hours)
Raw water pump Add the lubricating grease
Zinc protect screw plug Check zinc protect tuck in normal condition, change it
when corroded volume is greater than 1/3
Valve organization Check the rotation of the valve and the lubrication of the
ranging arm .Check the valve gap and adjust
Exhaust organization Check the drainage system; Check and exhaust the tight
situation of the exhaust organization.
Fuel prefilter Wash the fuel prefilter on the ship
Fuel filter Exhaust , change the fuel filtering cartridge , filter core
Seawater system Check the situation of water supply; Wash the filter on the
ship
Electronic governor Check whether the electronic governor works normally,
add the lubricating grease to the lever and joint
Air starter wash the filter, check the wearing of gear
Valve organization Check the part
Oil injection nib Pull down , check the spraying pressure and atomization
(every 1000 hours)
Injection pump Check the advance angle of fuel supply
Cooling water of diesel engine Flush the cooling water system, change the cooling water
Intercooler Clean the intercooler, change the sealing washer
Crankshaft
Heat exchanger Wash the heat exchange core, change the seal
Check start electric machine , charging engine, the
Electric part electromagnetic stopping valve , cable and the connecting
situation
Bearing of diesel engine Check the axial gap of crankshaft
Check that every electronic element , tie-in, sensor should
Local control box be fasten reliably to join to the machine, have not been
worn out, corroded, polluted
 HND
MWM Section 1 Maintenance Plan • 41 •

W5

Caution: The diesel engine should be partly dissembled when carrying out medium repair of
W5. Besides inspection and maintenance of W2 – W4, the following works of
inspection and maintenance should be done.

Part Job type of checking and maintaining

Valve organization Pull down and check ranging arm, rocker arm seat and
mandrill.
Pull down the cylinder head; disassemble the intake and
Cylinder head exhaust valves, overhaul valve seat and valve; Change the
spacer on the cylinder head, oil and water seal rings;
Check the wearing situation of the valve duct.
Check the cylinder liner running-in surface; Check the tip
of piston (visual measurement); In each line pull down a
Movement parts set of pistons , piston ring , connecting rod and
connecting rod tile to examine; Pull down a cylinder liner,
check whether there is corrosion or capitation in the
cooling water antrum surface of cylinder liner .
Exhaust turbocharger Take down, disassemble and wash accessories. Examine
wearing, oil leakage situation of every part by eye.
Air inlet pipeline Take down the air inlet pipe and wash it, change the seal
washer.
Exhaust line Take down the exhaust line and clean it, change the seal
washer, bellows, bolt, whorl post.
Intercooler Take down the intercooler and wash it, change the sealed
washer.
Heat exchanger Wash core of heat exchanger , change the seals
Injection pump Check injection pump, examine advance angle of fuel
supply.
Fuel Wash the oil box, check and change seal part and pipeline.
Fresh water pump Examine the part , change rolling bearing and seal in
pump item of fresh water
Raw water pump Examine parts by eye, change rolling bearing and seal.
High pressure fuel pipe Check-up or change
Cooling water of diesel engine Check preheating of the device ; Wash the water tank,
check seal part and pipeline
Cooling water thermostat Check the thermal sensing element
Lubricating oil cooler Take down, clean and check the sealing or wash , change
the cooler core
Starting air system Check the sealing of kick-off valve; Check the sealing of
air flask and air container
Starting air pipeline Take down and wash
Starting air distributor Take down, check up and readjust
In addition, each exterior rubber hose, liner and V- belt should be replaced.

W6
The diesel engine should be disassembled completely for inspection. Measures the wear of
moving parts and damaged structural parts, then, repair the unqualified parts, replace and adjust them
again if they are not repaired. The fresh water pump, sea water pump, lubricating pump and
high-pressure pump should be tested and checked up at the test desk to conform their performance
indexes are reached. Only the test of running-in is passed, the newly-reassembled diesel engine can be
 HND
•·42·• Chapter 4 Maintenance and Storage MWM

put into normal operation. If the clients have testing bed, the stipulations of list 4-1-1 can be complied
for running-in test, and for the clients without testing bed, the stipulations of table 4-1-2 can be
complied. So, not only the some equipment, test condition but also the team of skilled technical
personnel is needed for this work. To avoid unnecessary losses, it is better to do this work by
manufacture or the professional repairmen trained by the manufacture.

Table 4-1-1

Speed Power min Remark

% rated speed % rated power
startup 0
45 9.1 20
50 12.5 20
63 25 20
72.1 37.5 20
79.4 50 20
85.5 62.5 20
90.9 75 20
96.6 90 20
100 100 20
103.2 110 20 Only for marine engine
Idle speed 0 10
Stop

If the diesel engine does not run for a long time, the maintenance should be carried out according
to the stipulated interval; additionally, manual barring should be done once a month for the diesel
engine. When not operating more than 3 months, the diesel engine should be oil-sealed.
 HND
•·44·• Chapter 4 Maintenance and Storage MWM

4.2 Main Maintenance Methods

4.2.1 Replace lubricating oil
The lubricating will wear out, so, it should be replaced even
the working time is not than six months.
As soon as the engine stopped, the lubricating oil
temperature is relatively high, the impurity is not precipitated
wholly, and the oil liquidity is good, so it is better time to
replace the oil.
Step of replace:
1 Drain the oil

Fig. 4-2-1 （A） Requirement for the position of drainage:

Oil must be drained from the lowest place of
diesel engine.

（1）For two oil plugs at both ends, the one plug at the lowest
place can be selected to drain oil (according to
the concrete installation condition).
(2) For the oil pan with middle flange at bottom, the
position of draining oil is at the threaded
connection of oil temperature sensor.
Fig. 4-2-1 （B）

2 Replace oil
(1) Set oil basin below the plug (fig.4-2-1（A）), and remove
the plug (fig.4-2-1（B)). It is at the drain outlet of oil pan’s
both ends.
(2) Remove the strainer core of oil filter with zonal spanner
(The removed strainer core is not reused, and should be
replaced by new one.)
Fig. 4-2-1（C）
Fig. 4-2 Replace oil
（3）Screw the new strainer core, until reaching the surface of seal, then, fasten it with hand, and
the screwed thread is not less than 1/2 cycle.
(4) Inject the new lubricating oil from the oil port, and wash the oil pan properly, then re-screw and
fasten oil plug, and add oil to the oil level between oil pan and lower oil line.
 HND
MWM Section 2 Main Maintenance Methods • 45 •

（5）Use advanced pump or turn engine until the oil pressure is displayed, and at that time, the
manual brake device should be at the position of stop. (Fig. 4-2-1（C）direction of arrow)
(6) Adding the oil again until to the level of upper oil line.
(7) When the engine is running, it should be confirmed that oil plug is in good seal and oil filter
doesn’t leak out. If find leakage, the seal ring should be replaced.

Caution: ○
1 First time to replace oil after the diesel engine is running for 60 hours;

○2 For pressed diesel engine，replace oil every 250 hours after first replacing oil;

○3 The strainer core should be replaced when replacing oil.

4.2.2 Replace strainer core of oil filter

In lubrication system, the function of the oil filter is filtrating lubricant oil, so as to prevent
particulate and dust from entering into the bearing. However, these particulates will clog the strainer
core, reduce the oil pressure and flow after filtration. When the core is clogged badly, core safety will
open, and some un-filtrated oil with impurities then enters into the oil duct, cause the damage of
equipment.
So, replacing strainer core and oil termly should be done
together; if the oil pressure drops fast, the replace
frequency should be increased, and find out the cause, so
as to ensure the lubricating property.
If the bidirectional filter is mounted, the core can be
replaced when the diesel engine is running with low load,
but the relevant filter chamber should be cut off.
After replacing, the two filters should be operative.

Fig. 4-2-2 （A）

Replace strainer core

1. Loose strainer core with the special zonal tool and remove
it.
2. Scrub the seal support of new core carefully.
3. Screw the new core on the head of filter until it reaches the
seal support, and then fastens 1/2~3/4 cycle of thread by
hand.
4. Inspect the seal state of filter when the diesel engine is
running.
Fig. 4-2-2 （B）

Caution: ① After running for 250 hours or 6

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•·46·• Chapter 4 Maintenance and Storage MWM

months, the strainer core of pressed

diesel engine should be replaced.
② If the oil is polluted, the filter and
oil should be replaced together.

Fig.4-2-2 （C）
Fig. 4-2-2 Replace strainer core of oil filter

4.2.3 Clean wet air filter

The external air enters into the wet air filter, and passes through the crooked path; as a result of
centrifugal force, the particles of dusts in air are thrown up onto the wall of filter mesh and adsorbed by
its oil film.
When filter is too dirty, dusts on it will be
more resistance for the filter, thus, the ingoing air
will be insufficient, combustion will be inadequate,
and the power will be reduced. Therefore, cleaning
wet air filter should be done every 100 hours
termly, and the interval should be shortened if it is
too dirty.
Step of cleaning:
1. Loose the screw of pipe clamp, and then
remove the filter;
2. Clean it with diesel oil.

Caution: Do not use water and soapy

water, and otherwise, the filter
will be abandoned due to the
clogging of meshes. If the
filter mesh is cracked and
heavy rusty, this filter should be
replaced by new one.

3. Blow it dry, and re-coat filter mesh with

oil, or put the mesh into the oil basin
and then cast off excess oil.
Fig. 4.2.3 Clean wet air filter 4. Place the air filter into the intake port,
then screw the bolt of pipe clamp tightly.

Caution: ① Before diesel engine is put into first use, the wet filter should be lubricated with
 HND
MWM Section 2 Main Maintenance Methods • 47 •

oil of this engine.

②The outside surface of filter should not lubricated with various paints, such as
lacquer.

4.2.4 Clean oil bath air filter

After filtrated by strainer core, the external air is turned and enters into suction tube when
rapidly pass though the oil tray, the particles of dust is thrown into oil by centrifugal force, so, the
strainer core should be cleaned after every 250 working hours of filter, and the interval should be
shortened if it is too dirty. The strainer core must be replaced after 4000 working hours.

Step of cleaning oil bath air filter

1. Unscrew the clamping device② or fixing nut of upper
cover (fig.4-2-4（A） ），remove the upper cover.
2. Unscrew the bolt of pipe clamp (fig.4-2-4（A）），and
then remove the filter case with oil tray.
3. Take out the strainer core from the filter case, wash it
with diesel oil, then blow it dry with compressed
air（fig. 4-2-4（B）).
4. Wash oil tray with diesel oil and dry it with cloth.

Fig. 4-2-4 (A）

5. Put the oil into the oil level line in the oil tray,
and then re-install the filter.
6. Re-install the strainer core and cover.

Fig. 4-2-4 （B）

Fig. 4-2-4 Clean oil bath air filter
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•·48·• Chapter 4 Maintenance and Storage MWM

Caution: ① Before diesel engine is put into use for the first time, oil of this engine should
be added in oil groove, and after that, clean strainer core every 250 hours and
replace oil every 500 hours.
②After cleaning for many times or cumulate running time reaches 2000 hours,
the strainer core can be disassembled, take out palm-fiber mesh, clean and
whisk it, and then re-install the strainer core in its case for use.
③After use for 4000 working hours or two years, the core should be replaced.

4.2.5 Replace strainer core of dry air filter

For use of dry air filter, entered air should be passed through micro slot of paper core and enter
into the air duct. The particles of dust are blocked by the core
and adhered to filter, cause the increase of vacuum degree
back of filter, and therefore, after use for some time, the core
should be cleaned or replaced. If vacuum gauge is mounted
on filter, cleaning or replacing can be done when red marking
appears.
Generally, the core should be cleaned every 100 hours, but it
must be replaced if it does not meet the requirement of use
due to wet or deformation, or its working time is two years.
Fig. 4-2-5 (A）

Caution: Do not inspect and replace filter when diesel engine is running.

Replace strainer core

1. Unscrew hexagon nut 5, remove pan 6.
2. Unscrew hexagon nut 7, take out core 3
from body case 8.
3. Clean out the dust and dirty particles in
case with clean cloth.
4. Re-install the core. Inspect its seal when
installation, and replace the seal if necessary.

Fig. 4-2-5（B）
Replace strainer core of dry air filter
Sweep strainer core (only for special circumstances):
1. Take out core according to above-mentioned method.
2. Brush away the dust of core lightly with hair brush.
3. Use compressing air to blow off the dust from inside to outside along the longitudinal wrinkle
of core.

Caution: Do not clean core with oil, water and other dissolvent and do not hit or strike it!
4. Re-install it.
 HND
MWM Section 2 Main Maintenance Methods • 49 •

4.2.6 Inspect belt drive and lubricating water pump

The belt driving device is mounted at the free end

of diesel engine to drive the raw water pump, fresh
water pump, generator, etc.

Fig. 4-2-6 (A）

When the V belt can be pressed lower 1-2cm

with the thumb, the tension of the V belt is
correct at the moment, otherwise the tension
of the V belt must be readjusted.

Step of inspection and readjustment for V belt tension Fig. 4-2-6（B）

1. Remove the protective cover of belt.
2. Inspect the belt tension（fig.4-2-6（A）direction as arrow）.
3. Loose the bracket of tension pulley, and unscrew the bolt 4
of generator.
4. Move the tension pulley and generator to readjust belt tension.
5. Tighten the bolt 4.

Caution: If belt is too much tight, the wear will be aggravated and easy to be broken, but if
too much slack, the belt will be slide and also easy to be broken due to overheat,
influencing normal operation. As soon as finding belt wobble and other wear
circumstances, the belt should be replaced. Checking belt should rotate the diesel
engine, but should be safety-conscious when operating.
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•·50·• Chapter 4 Maintenance and Storage MWM

Lubricating raw water pump

Add No.2 lithium grease into the pipe joint with
nozzle oil gun (fig.4-2-6（B）and fig.4-2-6（C）,
position as arrow ).

Fig.4-2-6（C）

Fig.4-2-6 Inspect belt drive and lubricating water pump

4.2.7 Inspect zinc-protected plug

Because seawater is heavy corrosive, the river water is also corrosive, so, the cooling water tube is
eroded easily, especially the intercooler and heat exchanger. To protect the cavity wall from damage, the
plug on the raw water pipe (at B end of heat exchange) is equipped with zinc protection block. Because
of the dissolution of zinc block with time, it should be inspected after 250 working hours or every 6
months.
Disassembly and assembly of zinc-protected plug

Fig. 4-2-7 (A） Fig.4-2-7（B）

Fig 4-2-7 Inspect zinc-protected plug

1. Close the raw water pump;

2. Open the drainage plug ① of raw water pump, and drain off the water.
3. Disassemble the zinc-protected plug (see arrow shown in the figure) and inspect it; it should be
renewed if the volume is consumed by 1/3.
4. Re-install the stopple with new seal ring.
5. Close the drainage plug of raw water pump.
6. Before use, open the inlet raw water, fill raw water pump with water.
 HND
MWM Section 2 Main Maintenance Methods • 51 •

Caution: Inspecting zinc block is very important, it is effective measure to protect diesel engine
from damage due to corrosion and break of intercooler and heat exchanger’ cores. If the
diesel engines are used in subtropical or tropical sea areas, the interval of inspection and
replacement for zinc block should be shortened properly because of the heavy corrosion in
sea water.
4.2.8 Inspect and readjust valve clearance
The push rod and valve rod will be lengthened due to heat, and consequently, the valve on the air
cylinder cover will be moved in the direction of opening. While working, if the valve can not be closed
completely, the seal of combustion chamber can not be sealed and the power will be reduced, the air
valve and valve seat will be burnt out, and furthermore, it will cause the damage of diesel engine
because the piston hits against air valve.

If the valve clearance is oversize, the impact load

will be increased when the valve is opened, the driving
device of air valve will be damaged，and meanwhile, the
reduction of opening time and size will cause the
reduction of air input and power output. Also, the push
rod will deviate from ball socket of set screw, the piston
hit valve and damage the diesel engine. Accurate valve
clearance can ensure that the valve' open-close is reliable
and perfect in time for diesel engine at thermal state.

Caution: ① First time to check and adjust the

valve clearance should be done after
Fig. 4.2.8 Inspect and readjust valve clearance the diesel engine is running for 60
hours;
② After first checking and readjusting, the valve clearance should be rechecked and readjusted every
500 hours.
③ If the environment is heavy dusty, the interval of checking and adjusting should be shortened
properly base on status (normally, it should be adjusted if the variable range is outside of ±0.1 mm).

intake valve exhaust valve

Valve clearance 0.3mm 0.5mm

Check and readjust valve clearance (in condition of cold machine) (see parts in above figure).
1. Remove the cylinder cover;
2. Rotate the diesel engine until the valve 2 is closed, then rotate it again for about 1/2 cycles;
3. Measure the distance (clearance) between the top end of valve and the rocker with clearance
gage, if the clearance is not meet the requirement in above list, the clearance should be
readjusted.
4. Readjust the valve clearance, unscrew the lock nut 4, and make the post reach the base circle,
readjust the set screw, the clearance gauge should be passed through and contact with it exactly,
and have obvious feeling of friction when pulling the gauge with hand.
5. Tighten the locknut, readjust the valve clearance according to step 3, after finish of adjustment,
the barring should be done for recheck.
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•·52·• Chapter 4 Maintenance and Storage MWM

6. Re-install the cylinder cover.

The detailed methods are explained in section 5 of chapter V.

4.2.9 Replace fuel filter core or the component

The fuel filter can prevent dusts from entering into the fuel injection pump and fuel injector. If the
dust is adhered to the core of the filter, the flux of the fuel will be reduced, then, the power output is
reduced.

Replace filter core (single-barrel filter, fig 4-2-9（A））

1. Loose filter barrel with spanner, and take it out.
2. Screw the new barrel on the head of filter until it
reaches the seal ring, and then tightens it for 1/2
~3/4 cycle of thread by hand.
3. If the dual fuel filter is mounted, its core can be
replaced when the diesel engine is running in low
load.
Fig. 4-2-9 (A）

Caution: When replacing the core of filter, the

corresponding cavity must be closed. When
normal operating, the two filters should be
in working state.

Fig. 4-2-9（B）
Replace filter core (double-barrel filter, fig 4-2-9（A））
1． Loose bolt 2 and remove fuel filter cover 3.
(see fig.4-2-9（B）).
2. Take out core 4 from filter shell (see fig.4-2-9（C） ）,
and clean the inside of filter shell.
3. Wet new core with fuel completely.
4. Install new filter core, tighten the cover with bolt 3. Be
careful not to damage the seal ring, otherwise, the
ring should be replaced if damaged. The air should
be exhausted before connecting oil.
Fig.4-2-9（C）

Air exhaust of fuel filter:

1. Loose the exhaust plug 9 (see fig. 4-2-9（D）and
fig.4-2-9（E）） ，exhaust air in the fuel filter with hand
 HND
MWM Section 2 Main Maintenance Methods • 53 •

pump until the coming oil has not air bubble, then
tighten the exhaust plug.
2. Continue pump oil several times.
3. When operating, check the filter to confirm whether it
leaks.

Fig.4-2-9 （D）

Caution: ○
1 The fuel filter should be cleaned and

its core should be replaced after every

500 working hours of diesel engine.
② After one year, and the working hours
is even less than 500 hours, the core of
fuel filter should also be replaced.
③ If the diesel oil is dirty and the
primary filter is not installed, the
interval of replacing core should be
shortened.

Fig. 4-2-9 (E）

Fig. 4.2.9 Replace fuel filter core or the component

4.2.10 Inspect monitoring device and braking device of diesel engine

To avoid the malfunctions of lubricating system and cooling system, and losses due to overspeed,
the diesel engine is equipped with the monitoring device. If the temperature of cooling water is too high
and the pressure of oil is too low, the alarm device (indicating lamp, buzzer) will give an alarm. If the
pressure of lubricating oil is too low, the solenoid valve will receive signal to stop the diesel engine
while the alarm is sounded.
1. Check and lubricate hand-operated braking device
Press spherical handle towards the direction as the arrow,
then release it, the braking device should back to its
original position. If the result is abnormal, each rod
should be inspected to confirm whether they are smooth.
Lubricate joint 2 and rod 3 of solenoid valve with
supramoly lithium base grease.

Fig.4-2-10 Check and lubricate

hand-operated braking device
2. Check the function of audible and visual alarm
Press “test” button of monitoring device, all the alarm indicating lamp should be light up, and the
buzzer should be sounded, if one of them is not turned on, it should be replaced.
3. Check oil pressure monitoring device
 HND
•·54·• Chapter 4 Maintenance and Storage MWM

Turn off the power of 24V DC, and disconnect the line 61 in terminal box, then turn on the power,
the indicating lamp of “operation" will light up, and after 25 seconds, the indicating lamp of “low fuel
pressure” will also light up and the buzzer will be sounded. If the diesel engine is used in ship, the
electromagnet will work at same time, and its position is at “stop”. Press the button of “reset”, alarm
state should be released, after checking, turn off the power and connect the line 61. If the indicating
lamp doesn’t light up, cross-over connect two lead wires of oil pressure controller; if it is monopole
connection, make it earthing, when the lamp lights up, the controller should be replaced, if not,
something is wrong at the control circuit, check up the circuit and parts of it to eliminate the source
based on electric schematic diagram. If the braking electromagnet doesn’t work, measure the voltage
between two lead wires of electromagnet with multimeter, if it has 24V voltage, the electromagnet is in
short circuit, and it should be replaced, and if it has lower voltage, the circuit should be checked up.
When reaching W3 at maintenance, additionally, under the condition of shut-down, load and then
unload pressure on the oil pressure controller with the stimulant method to check up the accuracy of
alarm.
4. Check monitoring device of cooling water temperature
Drain the cooling water, disconnect the coupler plug of temperature sensor 6, and dissemble the
temperature sensor, hang it into the container and heat it, when the temperature reach 90-95 ℃, the
indicating lamp should light up and alarm. If the status is abnormal, the sensor should be replaced or the
circuit should be checked up.
5. Check overspeed protecting and monitoring device
Run diesel engine at no-load condition, check it with stimulant method. The value of overspeed
for ship-used engine is 120%, and for generating set used is 115%; press the “85%” button on the panel
of overspeed protecting delay in controller box, gradually increase the rotate speed of diesel engine,
when increased rotate speed reaches 85% of setting value ( rated speed ×120% or 115%×85%） ，the
diesel engine should stop and the “overspeed” indicating lamp should light up at the same time, release
the test button and press “reset” button, the checking is finished. If the actual value of stop is different
from setting value, after confirming the errorless of connection, readjust the “adjust” button on panel
anticlockwise to reduce the setting value, or clockwise to increase the setting value.

Caution: The inspection interval is according to the requirement of W2.

4.2.11 Clean heat exchanger

The cooling system of 236 diesel engines is

divided into raw water circulation and fresh water
circulation. The fresh water absorbs emanated heat of
diesel engine, and transfers the heat to raw water in
heat exchanger.
Fig. 4-2-11（A） For high efficiency of heat exchange, the sediment
and scale on the tube bundle of heat exchanger should
be eliminated.
Dissemble and clean tube bundle
1. Close the switch of raw water。
2. Drain off from drainage plug of both sides of
 HND
MWM Section 2 Main Maintenance Methods • 55 •

crankcase and collect cooling-fresh-water

stand-by. Drain off the cold water from raw
water pump drainage plug.
3. Dissemble fuel filter and bracket.

Caution: Dot not twist hose

Fig. 4-2-11 (B）

4. Dissemble raw water pipe joint ( ④ in
fig.4-2-11（A）)and fresh back water pipe joint
(① in fig.4-2-11 （B）).
5. Dissemble connecting flange of fresh back water pipe (arrow in fig.4-2-11 （B）).
6.Dissemble the copper setscrew (⑤ in fig.4-2-11（A）) and the bolt (③ in fig.4-2-11（A）) at the
cover of heat exchanger.
7. Take out the cooling core from the shell (fig.
4-2-11（C）), and wash it in the metal detergent
with brush.
If it is too dirty, the method of cleaning tube
bundle can be according to that of intercooler
(see 4.2.12 clean intercooler). Check up the
welding quality of water jacket. If necessary,
re-weld it.
8. Clean other components with metal detergent,
Fig. 4-2-11（C） and check inlet water pipe to confirm whether
there is scale on the wall, if necessary, wash it.
9. Dissemble gasket of connecting flange of fresh
backwater pipe (arrow in fig.4-2-11 （D）),
clean the sealing surface, and mount new one
with sealant.
10. Replace all other sealing parts.
11. Put the special-purpose bolt M8×100 (or
exceed 100) into the adjusting hole, and put
the cover into the tube bundle. (fig.4-2-11
（E））
12. Dissemble the special-purpose bolt, and install
Fig. 4-2-11（D） the copper setscrew.
13. Coat the surface of cover with gasket sealant
(arrow in fig. 图 4-2-11 （F）), then put the
tube bundle into the shell, and screw the
setscrew with little strength.
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•·56·• Chapter 4 Maintenance and Storage MWM

Fig. 4-2-11 (E）

. Fig. 4-2-11（F）
14. Coat the second surface of cover with gasket sealant, and then install it

Caution: For pressure differential between cover and inside shell, the end face should be
coated with sealant except O ring, so as to ensure good seal.
15. Install the connecting flange, and make sure
that the position of gasket is correct.
16. Tighten the cover (fig.4-2-11（G）).
17. Install the fuel filter and connecting fittings
of raw water pump and fresh pump.
18. Finally, supply the fresh water to the lower
mark.

Fig.4-2-11（G） Caution: The interval of maintenance is

according to the requirement of W4.
Fig. 4-2-11 Clean heat exchanger If the raw water is too dirty or its
temperature is excessive high, the interval
of cleaning should be shortened.

4.2.12 Clean intercooler

The intercooler is used for cooling high-temperature compressed air from the turbocharger; with
the intercooler, the air amount (density) of entering cylinder will be increased. The prerequisite
condition of good cooling effect is no scale in the cooling water pipe and no dust or oil sludge on the
cooling fin of air chamber.
The dust and oil sludge in the inlet of cooler will increase the
airflow resistance, causing the reduction of air input and
cooling effect.

Clean the intercooler

1. Discharge the cooling water of diesel engine from water
drain valve.
 HND
MWM Section 2 Main Maintenance Methods • 57 •

2. Remove the fresh water pipe (② in fig. 4-2-12（A）) and

heat exchanger.
Fig. 4-2-12 (A） 3. Loosen the clamp of hose，unscrew the bolt (④ in fig.4-2-12
（A））, and remove the elbow of air inlet pipe.
4. Remove the joint of raw water pipe (⑤ in fig. 4-2-12（A）).
5. Loosen the mounting screw of intercooler (⑥ in fig.4-2-12
（A）), and remove the intercooler.
6. Remove the elbow (⑦ in fig. 4-2-12（A）).
7. Loosen the mounting screw ( ⑧and ⑨ in fig.4-2-12（B）） ，
then remove the cover⑩ and side plate○ 11 .

Fig. 4-2-12（B）
Fig.4-2-12 Clean intercooler

8. Put the tube bundle into the container of cleaning liquid， (the liquid concentration is according to
the requirement of manufacture), the foam will appears in the liquid due to the reaction. After at
least 15 minutes next to the finish of reaction, take out tube bundle from the cleaning liquid, then
clean tubes and cooling fins with tube cleaning device, then swash the tube bundle and cooling fins
with clean water, and put the core of intercooler into neutral liquid for about 10 minutes, finally,
wash the tube bundle thoroughly.
9. Inspect the seal condition of tube bundle with the method of expanding, if necessary, re-expand
them.
10. Re-install them.

Caution: ① The cooling fins on the inlet are very weak, do not damage and deform them
when cleaning.
② For there are some greasy dirt on the fins, so, clean them with oil dissolution
solvent or bake them with the blow lamp then blow the dust off. Dot not uses
the stick to clean inside wall, so as to avoid damage of the tube.
③ Bolt: M8×22 and M8×45, the interval of inspection should be according to the
grade of W4. If the raw water system or air is too dirty or supercharger oil
leaks, the interval of cleaning should be shortened.

4.2.13 Preservation of diesel engine

If the diesel engine is unused for a long time, it should be anticorrosion treated to protect diesel
engine from corrosion and damage. Eliminating and derusting should be done for all unpainted mental
parts, then coat anti-corrosive grease on them. Because the grease will be changed due to air oxidation,
so, anticorrosion treatment should be done at least one time every three months or six months. The
actual implementation method is according to the requirement of anticorrosion grease. After coated with
anticorrosion grease, the diesel engine is oil sealed inside, and then covers it with paulin.
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•·58·• Chapter 4 Maintenance and Storage MWM

Preservation of inside diesel engine

1. Discharge the engine oil (see drainage plug ①in
fig.4-2-13（A)), and then screw the drainage plug.
2. Discharge the fuel oil of from oil box, pour mixture
into the oil box, and the mixture is fuel oil and
anticorrosion oil according to the proportion of 9:1.
3. Dissemble the core of lubricating oil filter, discharge
the oil, and re-install it. The requirement for
screwing the core: screw it to the sealing surface,
then re-screw it (1/2~3/4 circle) by hand, and do not
use the tool.
Fig. 4-2-13 (A） 4. Put machine oil of anticorrosion oil seal into the oil gun
of diesel engine (③ in 4-2-13（A）) to the lower mark
of oil line. Run diesel engine with starting device,
supply machine oil beforehand until the count is
displayed at oil-pressure gauge.
5. Discharge the cooling water (⑤ in fig. 4-2-13（A）) and
put NL emulsified oil with certain concentration
(concentration value should be increased by 2 %
than that of the specification in the operation manual
for normal conditions) into the water chamber of the
diesel engine. Discharge air from air release plug (⑥
fig.4-2-13（B）), and inject water to the bottom mark
of the water inlet.
Fig. 4-2-13（B）
6. Run the diesel engine until the reading of pressure is displayed at pressure gauge , increase the rotate
speed to 2/3 of rate speed, then run it under no-load condition for about 15 minutes.
 HND
MWM Section 2 Main Maintenance Methods • 59 •

7. Put out preserving oil and cooling water for re-use.

Preservation for surface of parts

1. Coat all bright parts with anticorrosion oil, such as
connecting fittings of control rod (fig.4-2-13（C））.
2. Coat all rubber parts with talcum powder (hose, damping
block).
3. Inspect the paint of parts, if the paint came off, repair it.
Fig. 4-2-13 （C）
Fig. 4-2-13 Preservation of diesel engine
4. Cover them with paulin.
5. Label the date of preservation, and put the caution of " Dot not turn crankshaft!” in
eye-catching position. The period of oil seal is according to its specification, it is one year generally.

Preservation of environment
The site of installation, test, oil sealing, and packing for diesel engines should be clean and level
without corrosive gas. The relative humidity should be low.
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4.3 Diesel Engine Malfunction and Troubleshooting

During operating, the diesel engine is hindered and not able to perform normal functions, or even
can not work due to the damage of some part or misoperation, such cases of influencing diesel engine’s
normal running are called malfunction.
Generally, diesel engine malfunction appears with following abnormal situations:
(1) Abnormal sound, such as abnormal knocking, booming, squeaky, etc.
(2) Abnormal action, such as difficult for start up, deficient output, serious vibration, etc.
(3) Abnormal appearance, the colour of exhaust gas is black, blue or white; leakages of oil, water
or gas, etc.
(4) Abnormal temperature, such as overheat of cooling water, exhaust gas, or bearing, etc.
(5) Abnormal pressure, for instance, the pressure of machine oil is too low, etc.
(6) Abnormal smell, such as stench, smell of burning, smoky, etc.
When the diesel engine malfunction occurs, the causes should be analyzed and make a judgment
based on the malfunction status and operation conditions, then take effective measures, eliminate the
trouble, so as to ensure the safe operation of diesel engine.
The causes of common malfunctions and remedy methods of troubleshooting are listed in
following table for reference, the users can accord with the principle “Easy fist and difficult later” when
analyzing and judging the causes, check every relevant position sequentially, and find out the exact
cause, so as to eliminate it in time.

4.3.1 Diesel engine's start-up is difficult or complete failure

Causes Remedies
(1) Starting system defective(3-6:by air, 7-11
by electricity.)
1. starting motor is damaged 1. repair or displace starting motor
2. starting gears mesh badly 2. Adjust or adapt so as to make suitable
3. starting air pressure deficiency 3. air is charged with tension to standard
4. air pump volume is too small 4. increase air jar volume
5. 5. get rid of leaking
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 61 •

Fault Causes Required Methods

6. Gas control valve failure 6. Disconnect and check the gas control valve
7. Wiring (start switch 、relay) failure 7. Examine and repair or replacing the element
8. Electric power of accumulator isn’t full 8. Check the specific gravity of liquor and charge
9.Wirings contact badly or off 9. Examine and repair and reconnect hard
10.The section of electrical source lead is small and 10. Replace the coincident lead
line is too long
11.The little gear of dynamoelectric motor 11. Check the lead and the charge electromotor
disengage badly or error action

(2) Fault of fuel system

1. Fuel lacks or the oil inlet and return valve of oil 1. Add fuel and open the valve
box closes
2. The quality of fuel is bad or intermixing water 2. Replacing with coincident fuel, drainage water in
gasoline tank
3. The position of oil box is lower 3. Place the oil box according to regulate
4. There is air in the high pressure fuel duct 4.Loosen the screw cap and jigger to exhaust the air
in conduit
5. Remain air in the fuel system or leak air, and 5. Exhaust the air in the fuel system , exchange the
the manual pump oil continually conduit of leak air

6. The fuel filter jammed 6. Wash the fuel filter, changing the filter core

7. The spray appliance atomize badly or the high 7.Wash or changing mate element of spray
pressure pump don’t work appliance, check oil pump
8. The forward angle of giving fuel is not in the 8. Adjust the forward angle of giving fuel
right place
9. The adjust haulm in gear locked, the haulm isn’t 9.Ccheck or changing mate element
in the right position
10 The protect device of excessive speed not return 10. Push the return haulm , drop the cut-off valve
11. The adjust bolt of slacking velocity in the core ,the up- screw cap don’t screw closely
velocity adjuster become flexible 11. Readjust
12. The length of the connect screw between the
electromagnetism parking valve and the parking 12. Readjust
haulm in adjust bolt adjusts inappropriately or
places falsely

(3) The enter and exhaust air system fault

1. The air filter core jammed 1. Clear the air filter
2. The conduit of entering and exhausting air 2.Clear the conduit of entering and exhausting air
jammed 3.Adjust the time of mix air afresh, check gear’s
3. The time of mix air is wrong transmission machine and valve’s transmission
machine
4.Research and repair the valve , changing piston
4. Exhaust air in the valve, piston ring and cylinder ring and cylinder mat
lid

(4) Fault of lubricate system 1. Warm-up lube

1. Lube temperature is too low , viscosity is too
high 2.Check and repair the pump , check the unilateral
2. The press is low of the prep-giving oil pump valve if there is something of block
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4.3.2 The diesel engine is underpower

Fault Causes Required Methods
(1) Faults of fuel system
1. Fuel quality is bad or mixing water 1. Change fuel , vent water in the oil box
2. Fuel pipeline get jammed , pipe leak oil 2. Dredge the fuel pipeline, repair pipe
3. Fuel filter get jammed 3. Clear fuel filter
4. The spray appliance atomize badly 4. Clear , repair or changing fittings
5. The time of giving oil is wrong 5. Emendation ahead- angle again
6.The unilateralism valve of high press pump and 6. Install the unilateralism valve again
parking valve get blocked or didn’t install then
arose giving oil not sufficient
7. The stopper fittings of spraying pump get fray 7. Changing fittings and debug
8. Restricting bolt in velocity adjuster become 8. Debug again and obdurate again
flexible
9.The high of oil probe is fall short of prescribing 9. Check the number of airproof gaskets
10. Camshaft of spraying pump get fray 10. Changing the camshaft
11. Bolt of velocity adjuster screw much or install 11. Readjust
wrong position , gear haulm spread short

（2）The enter and exhaust air system fault

1. The air filter jammed 1. Clear the air filter
2. Enter and exhaust pipe get jammed 2. Clear the pipe
3. The time of mixing air is wrong 3. Check and adjust the mixing time
4. Cylinder cover or piston ring leak air 4. Changing cylinder cover or piston ring
5. Enter and exhaust valve leak air 5. Research and repair valve
6. Middle condenser get dirty 6. Wash the middle condenser
7. Enter and exhaust cam get frayed 7. Changing the cam shaft
8. Enter air conduit not airproof 8. Take apart and check then changing the
airproofing component
9.Suction pump of exhausting excessive resistance , 9. Setting the exhausting pipe and muffle
muffle don’t fit according to prescribe
10. Density small of air in the high area 10. Choose high power machine
11. Exhaust pump leak air badly , supercharged press 11. Check and repair airproofing status of
is low every combine place on exhausting pipe
and little ripple pipes
12. Temperature is high of entering air 12. Ameliorate the air convection

(3) Supercharger fault

1. Supercharger get jammed or leak machine oil 1. Clear the feculence in supercharger ,
deposit carbon . check and repair the
airproofing component
2. Supercharge matching improperly , enter air press 2. Choose the correspond supercharger
is low according to the different model

(4) Cooler system malfunction

1. The entering air temperature is high 1. Check the seawater pump , ameliorate the
condition of entering air
2. Middle condenser get jammed 2. Wash the middle condenser

(5) Diesel engine exceed burthen overly ,making Check and adjust the burthen matching
the exhausting air temperature hoisting , power
can't adding
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 63 •

4.3.3 The running is not smooth

Fault Causes Required Methods

(1) Fault of fuel system
1. There is air in the fuel pipe or spewing 1. Exhaust the air in the fuel system , check the
oil pump join of oil pipe
2. The spewing oil filter too dirty , leading 2. Wash the spewing oil filter or change core of
giving oil liquidity shortage it
3. Spray oil appliance leak oil or jammed 3. Check and repair or change the incidentally
component of spray oil appliance
4. Spring of column plug of the spewing oil 4. Change the spring of column plug
appliance crack or spring too strong
5. The fittings of column plug of the fuel 5. Change the incidentally component of
pump get blocked column plug
6. The dent form ring of accommodating fuel 6. Debug the giving oil and screw down the
quantity of fuel pump become flexible screw
7. The gear haulm get blocked and not smart 7. Check and repair or change the gear haulm
and the incidentally component of column
plug
8. Spring of exhausting oil valve cracked or 8. Change the spring , check and repair the
blocked incidentally component of valve
9. Controlling system didn’t lock 9. Screw down the controlling system
(2) Fault of velocity adjuster
1. The machine oil too much or dirty in the
velocity adjuster 1. Exhaust the superabundance machine oil ,
2. Bush of rapid hammer get frayed wash and change oil
3. Cushion spring of velocity adjuster crack or 2. Change the bush
fray too much 3. Change the spring
4.The movement component of velocity 4. Check and repair or change component
adjuster fray too much or get blocked
5. Rubber of cushion gear crack or axletree fray 5. Check or change
too much
(3) Use and maintain
1. The velocity of turning too slow 1. Heighten the velocity properly
2. Burthen fantasticality 2. Check and clear up
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4.3.4 Abrupt pause

Fault Causes Required Methods

(1) Fault of fuel system
1. No oil in the fuel tank 1.Add fuel and exhaust the system air
2. Adulterate water in fuel 2. Find out the causation , change fuel , wash
pipeline
3. The fuel pipe or the filter core get jammed 3. Dredge and wash the pipeline
4. Air come into the fuel pipe 4. Exhaust air and find out the causation
(2) The action of the protecting equipment
1. Excessive low automatism pause equipment 1. Find out the causation and remove
operate
2. Fault of excessive low automatism pause 2. Check and repair and adjust again
equipment
3. Diesel engine run over speed , the over speed 3. Find out the causation and remove
equipment operate
4. The over speed equipment malfunction 4. Check and repair and adjust again
5. The link of autoalarm become flexible , error 5. Check the tie-in if it become flexible and
action deal with thrum accurately
(3) Movement system malfunction
1. Piston grip the cylinder cover 1. Find out the causation , change correlative
component
2. Crank or linker griped 2. Find out the causation , change correlative
component
3. Equalizing axletree cover fall off or griped 3. Find out the causation , change correlative
component
(4) Use and maintain
1.The time gear or fuel pump equipment 1.Disconnect and check and change the
joining haulm mangle correlative component
2. Load enhance greatly 2. Avoid the load enhance greatly
3. Turn slow , load enhance rapidness 3. Heighten the turn velocity , increase load
gently

When the diesel engine stops suddenly, do not re-start it before the cause is found out. If the
diesel engine stops at high speed and high load, we should hand jigging at least two circles with jigger
haulm.
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 65 •

4.3.5 Running away

Running away is that the rotate speed of diesel engine is suddenly increased, and runs faster and
faster, generate great inertia force, it will cause the damage of the parts or even the serious accident of
diesel engine destruction.
Fault Causes Required Methods
(1) Fault of nozzle fixture
1.oil pump’s gear pole lock 1.check or replacing gear pole
2.oil pump’s plug spring broken, gear ring 2.check and replacing accessory of spring and
break off and lock gear pole gear ring
(2) Fault of velometer
1. Dowel fall off in tie-in of pole or bolt of 1. Fixup after anew adjust
pole.
2.Fly hammer unskillful 2.Check and repair
(3) Use and maintain
1. Excessive speed safety failure 1.Check excessive speed safety failure
2.Missplace the orientation of linking 2.Reinstall according to position of stipulate
member, and make the rear pole clip the
position of adding fuel

When running away occurs, do not feel panic, and then rapidly, take decisive measures calmly.
1． Cover the air inlet (inlet of air filter) with cardboard or rubber, it is the most efficient
method;
2． Press the button of emergency stop magnet valve to stop oil supply;
3． Push the stop magnet valve by hand to stop engine.

4.3.6 Pressure of engine oil is too low

Fault Causes Required Methods

（1）Lubricating system faults
1. Pressure-adjusting valve is locked or 1. Rinse and grind
padded with sundries.
2. Oil in bottom oil shell lacks, or quantity of 2. Add engine oil up to regulated level
oil is not enough so that evacuation occurs.
3. The type of used engine oil doesn’t qualify 3. Replace qualified engine oil
the regulation.
4. Engine oil is diluted by mixing with diesel 4. Replace engine oil, find out the reason and
exclude it
5. Leakage or suction of lubricating system 5. Overhaul and replace relevant spare parts
6. Oil pressure meter is broken or connecting 6. Change oil pressure meter, and clean
pipe jams connecting pipe
7. Engine oil pump wears seriously or breaks 7. Replace or overhaul relevant spare parts
8. Sucking port of engine oil pump jams 8. Clean sucking port and bottom oil shell

（2）Cooling system faults

1. Engine oil cooler jams 1. Rinse core of engine oil cooler
2. Cooling effect of engine oil cooler is bad, 2. Overhaul cooling system, rinse core of heat
and oil temperature is high exchanger, match and replace bearing pad
to make sure clearance.
（3）Use and maintenance
Bearing pad burns, or clearance is excess
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4.3.7 Temperature of engine oil is too high

If the temperature of engine oil is too high, its viscosity will be reduced and the oil film can not
be formed effectively, getting serious wear of working pieces or even seized up each other. In addition,
the another function of oil is to take away the heat caused by friction between the working pieces, if the
temperature of oil is too high, the taken heat will be reduced, the working pieces will be overheated and
their strength will be decreased.

Fault Causes Required Methods

(1) Fault of cooling system
1. Lubricating oil cooler jams 1. Rinse lubricating oil cooler
2. Cooling water lacks or temperature of 2. Add cooling water, evacuate gas, examine
water is too high and repair cooling system
3. Strap of fan slacks 3. Adjust tension pulley
4. Thermostat locks 4. Replacing thermostat
(2) Use and maintain
1. Diesel engine overloads in long time 1. Reduce load
2. Abrasion of piston ring and cylinder 2. Replacing piston ring and cylinder jacket
jacket leads to leakage of air
(3) Fault of lubricating system
1. Oil temperature meter shatters 1. Replacing thermostat
2. Supply of lubricating oil pump lacks 2. Examine and repair pump of lubricating oil
3. Lubricating oil filter jams or impurity in 3. Clear lubricating oil filter or replacing
lubricating oil excesses. lubricating oil

4.3.8 Oil dilution

Fault Causes Required Methods

(1) Fault of fuel oil system
1. Leakage of oil occurs at plugs of supply 1. Examine and repair supply pump and high
pump and high pressure pump pressure pump
2. Oil drops and leaks, and atomizes badly 2. Examine and repair, or replacing couple of
(2) Fault of cooling system oil injector
1. Watertight ring of cylinder jacket leaks
2. Leakage occurs on top of jacket of oil 1. Replace watertight ring
injector on cylinder head 2. Replace sealing ring of jacket
3. Lubricating oil cooler’s pipe-plate 3. Replace core of lubricating oil cooler
dehisce caused by freezing or welding
line dehisce
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 67 •

4.3.9 Exhaust temperature is too high

The exhaust temperature is very important parameter of measuring whether the diesel engine
works normally, it shows the situation of combustion process, and establish the working reliability of
pieces, and also, it influence the working reliability of the exhaust gas turbo-supercharger.

Fault Causes Required Methods

(1) Fault of inlet and exhaust air system
1. Inlet passage and exhaust passage jam 1. Clean inlet and exhaust passage
2. Air filter jam 2. Clear air filter
3. Clearance of valve is wrong 3. Adjust clearance of valve
4. Resistance of exhaust leading-pipe and 4. Setup exhaust leading-pipe and muffler
muffle is too more according to regulation
5. Temperature of air inlet is too high or 5. Reduce inlet temperature, improve the
ventilation is bad convection of air
(2) Fault of fuel oil system
1. Quality of fuel is disqualification 1. Replace eligible fuel
2. Oil injector leaks, and atomization is bad 2. Repair or replace relevant accessory
3. Supply angle of advance is too small, 3. Readjust Supply angle of advance
injection time is too late so that lag
burning occurs
(3) Use and others
1. Mismatch of machine and screw 1. Reduce load and solve load mismatching
propeller (or pump) with overloading
2. Air pressure is low in altiplano area 2. Change the model of machine or use in
load limit to use according to modification
3. Supercharger jam or lubricating oil leaks 3. Clean supercharger and inspect sealing part
4. Breather overflows lubricating oil 4. Add lubricating oil after excluding
position-surpass, or air contacts each other
when the piston ring is worn
5. Serious leakage of air in exhaust system, 5. Exclude phenomenon of leaking air
leading to low rotating speed of
supercharger

4.3.10 Airout of breather is abnormal

Fault Causes Required Methods

1. Piston ring is worn seriously or broken 1. Replace piston ring
2. Piston and cylinder jacket are worn 2. Replace piston or cylinder jacket, inspect
seriously, and are pull or burn nozzle
3. Bearing pads burn out 3. Replace bearing pad, inspect crank and
connecting rod level

4. Openings of every piston ring overlaps 4. Adjust the opening position of piston ring
5. Piston cracks 5. Replace piston
6. Lubricating oil supplied is excess so that 6. Drain some lubricating oil until it reachs
splash is serious and oil flees scale.
7. Breather passage is not easy and smooth 7. Clean breather
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4.3.11 Temperature of cooling water is too high

Fault Causes Required Methods

(1) Fault of cooling system
1. Cooling water in water tank lacks or air 1. Add cooling water, vent air at high point
exists in system
2. Supply of water pump lacks 2. Inspect and repair water pump
3. Straps of fan or water pump looses or 3. Adjust tension pulley
skids
4. Radiating core in water tank or heat 4. Rinse water tank or heat exchanger
exchanger jams
5. Cooling pipeline jams 5. Rinse cooling pipeline
6. The install direction of thermal-saving 6. Reinstall or replacing thermal-saving
equipment is wrong, or thermal-saving equipment
equipment defaults (choked) so as to
affect the water supply into heat
exchanger or water tank.
(2) Use and maintain
1. Water thermometer is broken 1. Replace thermometer
2. Diesel engine is overloaded 2. Reduce loading, solve the problem of
matching
3. Temperature of environment and 3. Use according to power after modification
seawater is too high; the power is not
modified.
4. Usage of cooling water falls short of 4. Disassemble and clean water chamber, use
requirements, the scaling in water cooling water correctly
chamber is serious.
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 69 •

4.3.12 Exhaust is black smoke

Fault Causes Required Methods

（1）Fault of inlet and exhaust system
1. Inlet and exhaust pipeline jam 1. Clean inlet and exhaust pipeline, open
protecting door exhaust pipeline
2. Air filter jam 2. Clear air filter
3. Resistance of exhaust leading-pipe and 3. Setup exhaust leading-pipe and muffle
muffle is too much according to regulations
4. Supercharger jams, lubricating oil leaks 4. Clean supercharger, overhaul sealing parts
or replacing supercharger
5. Intercooler jams 5. Clean intercooler
6. Timing of air distributor and clearance 6. Inspect and adjust Timing of air distributor
of valve is wrong and clearance of valve
7. Air leakage of exhaust system is serious, 7. Exclude the phenomenon of air leaking
rotate speed of supercharger is low

(2) Fault of fuel system

1. Oil leakage occurs in oil injector, and 1. Overhaul or replace couple
atomization is not well
2. Supply angle of advance doesn’t meet 2. Adjust supply angle of advance
requirements; injecting time is too late,
some fuel burns badly.
3. Spring of oil outlet valve is broken or 3. Overhaul or replace spring and outlet valve
cracks; or valve is locked of oil
4. Fuel filter jams 4. Clean fuel filter, replace cartridge
5. Fuel disqualification 5. Replace qualified fuel

(3) Use and maintain

Overload Running Reduce loading, resolve mismatching of
overload

4.3.13 Exhaust is blue smoke

In general, burning fuel oil will cause blue smoke at outlet.

Fault Causes Required Methods

1. Level of engine oil is too high 1. Let out excess engine oil
2. Oil ring is worn seriously 2. Replace oil ring
3. Abrasion of piston and cylinder jacket 3. Replace piston or cylinder jacket
serious or scratch
4. Position of piston loops superposition 4. Adjust the opening position of piston ring
5. Oil sealing of supercharger is invalid 5. Overhaul and replace oil sealing of
supercharger
6. Leading pipe of valve and rod of valve is 6. Replacing
worn seriously
7. After initial assembly of diesel or replacing 7. It can disappears after running 8 to 10
of piston ring and cylinder jacket, engine hours
oil tends to flee due to deficient grinding.
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4.3.14 Exhaust is white smoke

The cause of white smoke is that the oil droplets of diesel are not burnt in cylinder, or the water is
leaked into the combustion chamber.
Fault Causes Required Methods
1. Water leaks into cylinder from intercooler 1. Overhaul intercooler
2. Temperature of cooling water is too low 2. Increase loading after warming of engine
3. Water exists in fuel oil 3. Water accumulates in exhaust fuel tank
4. Atomization is bad when speed of oil 4. Shorten operating time of low speed, or
injector is low. replace couple
5. Rain falls into external exhaust pipe and 5. Add a lid on external exhaust pipe
flows into combustion chamber, or it was
vaporized by heating of high waste air.

4.3.15 Vibration of diesel engine is greater

Fault Causes Required Methods

1. Damper of twisting vibration is invalid 1. Overhaul or replace damper of twisting
vibration
2. Flywheel is unbalanced (only with V6 2. Inspect position of locating pin in flywheel,
engine), or the connection is loosen and fasten flywheel
3. Alignment between diesel and driven 3. Readjust assembling position
machinery is bad
4. Assembly setscrew is loosen, or contacts 4. Refasten and readjust
badly with foundation
5. The rigidity of diesel foundations is bad 5. Strengthen foundation
6. Bearings wear seriously and clearance is 6. Replace bearing
excess
7. Assembling position of gear on balancing 7. Reinstall according to remark position of
shaft is wrong assembly
8. Cylinders are unbalanced 8. Debug again uniformity degree of oil
supply to every cylinder of oil injector
9. Single row of 2300 r/m diesel may 9. Avoid running at low speed and low
shutdown loading
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 71 •

4.3.16 Engine oil contain moisture

Fault Causes Required Methods

1. Sealing O ring of cylinder jacket is broken 1. Replace sealing ring
2. Sealing shim of cooling core for engine oil 2. Replace core of engine cooler or sealing
is broken, or assembling procedure is ship
invalid so that sealing shim wasn’t pressed
closely, or core of engine oil cooler cracks
3. Cylinder head or cylinder jacket cracks 3. Replacing spare parts
4. Water exists in injected engine oil 4. Replace engine oil
5. Water leaks into cracked core of intercooler 5. Replace core or amend it
6. Inlet pipe’s water chamber runs through air 6. Replace inlet pipe or repair it
chamber

4.3.17 Abnormal noises

Fault Causes Required Methods

(1) The knocking during burning
1. Quality of fuel oil is bad 1. Replace qualified fuel oil
2. Injecting pressure of oil is too high 2. Inspect and debug injecting pressure of oil
3. Injecting quantity of oil is excess 3. Inspect and debug quantity of oil supply
from oil injecting pump
4. Oil drops and leaks, and atomizes badly 4. Inspect and replace couple of oil injector
5. Supply angle of advance is too early 5. Inspect and adjust supply angle of advance
6. Spring of exhaust oil valve cracks or locks 6. Replace spring or valve
7. Timing of air distribution is wrong 7. Inspect and adjust, or replace related spare
parts
(2) Mechanical knocking
1. Clearance between piston and cylinder 1. Replace piston and cylinder jacket
jacket is too big
2. Clearance of valve is too big 2. Inspect and adjust clearance of valve
3. Piston shocks with valve 3. Inspect clearance of valve and replace
related spare parts
4. Clearance of bearing is too big 4. Match and replace bearing
5. Piston ring wears badly 5. Replace piston ring
6. Mechanical object falls into cylinder 6. Get mechanical object away
7. Matching clearance of piston pin is big 7. Replace spare part after inspection
8. Spring of valve breaks or mandril bends 8. Replace spare parts
9. Adjustment of axial clearance with high 9. Readjust
stretch coupling is wrong, or deflection of
alignment is too big or axial pushing exists.
10. The lowest rotate speed of running is too 10. Increase rotate speed of running
low
(3) Gear noises
1. Clearance of gear is too much 1. Adjust clearance of engagement
2. Broken tooth exist in gear system 2. Replacing gear
3. Clearance of bearing is too much 3. Match and replace bearing
Setscrew is loosen Fasten bolt
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4.3.18 Malfunction of supercharger

Fault Causes Required Methods

(1) Surge in compressor
1. Air filter is blocked by dirt 1. Clear air filter
2. Inlet pipe is blocked 2. Rinse inlet piping
3. Intercooler is dirt 3. Rinse intercooler
4. Resistance in leading pipe for exhaust 4. Set exhaust leading pipe according to
is too much regulation
1. Muffler is mismatched 5. Configure muffler according to
regulation
2. Supercharger is blocked by dirt 6. Rinse supercharger
3. Exhaust piping is blocked by dirt 7. Rinse exhaust piping
(2) Leakage of oil in supercharger
1. Air filter is blocked by dirt so that 1. Clear air filter
resistance is too much
2. Oil sealing of supercharger is invalid 2. Replace oil sealing
3. Sealing of supercharger is blocked 3. Dredge air piping

4.3.19 Malfunction of cylinder cover

Fault Causes Required Methods

(1) Leakage of water or oil between cylinder
head and casing
1. Mangling or aging of O ring 1. Replace O ring
2. Meddle small sleeve for leading water or 2. Replace bushing
oil is distorted or broken
3. External protecting sleeve doesn’t 3. Reassembly
ferrule upper and lower O ring at the
same time, elasticity of O ring is
decreased so as to leak water and oil
(2) Leakage of water on the side of cylinder
head
The plug on side of cylinder head become Reinstall plug and lay on sealing glue
loosen or falling
(3) Leakage of air at cylinder head
1. Sealing pad is broken 1. Replace pad
2. The sealing position is sordid 2. Rinse the sealing surface
3. Sealing surface of cylinder head and 3. Replace accessory
cylinder sheath have damnification
(4) Others
1. Leakage of water at sleeve of oil injector
on cylinder head 1. Replace sleeve and O ring, clear the sealing
2. Cylinder head cracks, or water cavity surface
perforate with oil cavity and air cavity 2. Replace cylinder head
HND
MWM Section 3 Diesel Engine Malfunction and Troubleshooting • 73 •

4.3.20 Malfunction of monitoring system (read it with fig.5-10-2）

Fault Causes Required Methods

(1) None indicator lights and voltage meter
doesn’t indicate while power supply is on.
1. Switch Q for automatic protection is off.
2. Short circuit occurs in input circuit of 1. Inspect and switch on protective switch
power supply 2. Inspect input of electrical source
(2) Switch Q for automatic protection
disconnects automatically after power supply is
switched on
1. Short circuit default occurs in stage 1. Inspect and exclude
circuit of automatic switch.
2. Short circuit occurs in connecting lines 2. Inspect and exclude connecting line or
or elements to diesel engine. organ
(3) When engine shutdown, the running light
works, shutdown light works or not, diesel
engine cannot start up.
1. The 61# line carve out a way 1. Inspect circuit of 61 line
2. Generator for electrification faults 2. Replace charging generator
(4) Diesel engine cannot start up after pushing
button down
1. The voltage of storage battery is lower 1. Charge storage battery, and check if the
than 24V, connecting line of storage battery is normal
2. Start circuit faults, doesn’t rotate, or no 2. Inspect and exclude faults in circuit
voltage of 24V in 50# line.
3. Start motor defaults with 24V in 50# line 3. Inspect and replace start motor
(5) Light of shutdown works and light of
running doesn’t work while diesel engine is
running 1. Replace charging generator
1. Charging motor faults 2. Inspect circuit
2. Circuit of No.61 line faults
(6) False alarm of high temperature of water
1. Modification of thermal controller 1. Readjust the setting temperature
offsets setting temperature
2. Circuit of relay faults 2. Inspect and exclude
3. No. 61 line faults 3. Replace sensor
(7) False alarm of low oil pressure and low
excessively of oil pressure
1. Setting value of pressure controller is 1. Readjust or replace pressure controller
too big or faults
2. Circuit of relay faults 2. Inspect and exclude
(8) False alarm of overspeed
1. Overspeed protective device fault 1. Inspect, adjust or replace
2. Speed-measuring generator faults such 2. Inspect, exclude or replace
as inner loose or bad welding of 3. Inspect and exclude
connecting line in terminal box. 4. Inspect the connection of rotating speed
3. Circuit or relay faults sensor, terminal box, and control box
4. Disposal of cable end is bad or loosen so
as to be connected
(9) DC voltage exceeds 29V while diesel
engine is running
1. Voltage meter is inaccurate 1. Adjust or replace
2. External charging equipment doesn’t 2. Stop charging
stop charging monitor system
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·• 74 •· Chapter 4 Maintenance and Storage MWM

3. Charging motor faults 3. Inspect and replace

(10) Indication of speed meter is unstable or
reversal
1. Connection of circuit is bad 1. Inspect and exclude
2. Connection of speed meter is reverse, 2. Exchange any two connections of speed
causing reverse phase input meter
(11) Engine can’t be shutdown while pushing
buttons of stop or emergency down
1. Circuit of stopping or emergency faults 1. Inspect and exclude
2. Electric magnet of shutdown and electric 2. Inspect and exclude, or replace
magnetic valve faults 3. Readjust
3. Rod of electric magnet for shutdown
isn’t positioned
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·• 76 •· Chapter 4 Maintenance and Storage MWM

4.4 Tool List and Specification

The tools of 236 series diesel engines are classified into two categories: attached tools and repair tools, the
attached tools are included in equipment and provided to users, and they are mainly used to dissemble,
assemble and repair exterior of diesel engine and its common parts. The repair tools shall be purchased by
users with order, they are mainly used to check and repair main parts of diesel engine.

4.4.1 Attached tool

Item Drawing No. Designation Qty Remark

1 4.085.610.8001.5 Toolbox 1
2 1M55.50 Pliers 150 1
3 1M55.53A Thickness gauge 1
4 4.086.417.0091.1 Double-ended fixed spanner 9×11 1 GB4388-84
5 4.086.417.0101.2 Double-ended fixed spanner 10×12 1 GB4388-84
6 4.086.417.0131.6 Double-ended fixed spanner 13×16 1
7 4.086.417.0141.7 Double-ended fixed spanner 14×17 1 GB4388-84
8 4.086.417.0192.2 Double-ended fixed spanner 19×22 1 GB4388-84
9 4.086.427.0151.5 Amphibious wrench 19×22 1 GB4388-84
10 4.086.418.2503.0 Wrench 250×30 1 GB4440-84
11 4.086.418.0131.6 Double-ending club spanner13×16 1
12 4.086.424.0017.2 Sleeve 17×12.5 1 GB3390.1-82
13 4.086.424.0019.2 Sleeve 19×12.5 1 GB3390.1-82
14 4.086.424.0022.2 Sleeve 22×12.5 1 GB3390.1-82
15 4.086.424.0024.2 Sleeve 24×12.5 1 GB3390.1-82
16 4.086.424.0027.2 Sleeve 27×12.5 1 GB3390.1-82
17 4.086.445.0112.2 H type handler of sliding-head12.5 1 GB3390.3-82
18 4.086.445.1120.2 JG type splicing pole 12.51×2.5 1 GB3390.4-82
19 4.086.460.5000.9 Crowbar YS125×6 1 GB10639-89
20 4.086.442.100.1 Spanner for oil filter 1 W9690-040
21 4.086.420.0018.2 Spanner for injection pipe 1
22 4.086.421.0017.2 Articulated spanner 1 W9690-050
23 4.086.422.0408.2 Medium joint 1 W9833-002
24 4.086.422.0614.2 Medium joint 1 W9833-010
25 4.086.422.1806.2 Hexagonal socket t-shaped spanner (S6) 1 W9690-077 L=180
26 4.086.422.3308 Hexagonal socket t-shaped spanner (S8) 1 W9690-077 L=330
27 4.086.446.0008.2 Round nut spanner for grooving 1 W9690-047
28 4.086.446.0009.5 Spanner (2 pc assembly) 1 W9690-076A
29 4.086.447.0001.5 Timer of fuel injection 1
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 79 •

5 The Structure of Diesel Engine Series 236 and the Disassembly,

Overhaul and Assembly of its Main Components

5.1 Main Fixed Assemblies’ Structure

and Their Disassembly, Overhaul and Assembly

Main fixed assemblies include engine body, cylinder head, cylinder line, oil pan, front end shield, rear
end shield and flywheel shell.

5.1.1 Engine Body

Fig. 5-1-1 Engine Body

1, 2 Balancer shaft bush 3 Thrust ring of crankshaft in axile direction 4 Main shaft tile
5 Bolt of bearing cap 6 Piston’s cooling nozzle 7 Relief valve
8 Balancer shaft 9 Sealing gasket 10 Middle baffle
11, 12 Cam shaft bush 13 Cylinder linear 14 Cylinder linear’s O-ring

1. Main function
a: Supporting the moving assembly and cylinder head of diesel and keeping their accurate location
when they work;
b: Forming cavities and channels of cooling water, lube and gas and keeping sealed;
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··80·· the Disassembly, Overhaul and Assembly of its Main Components MWM

c: Outside the engine body, there are kinds of assistant equipments of diesel, such as sea-water pump,
lubricating pump，lubricating oil filter;
d: There are many underprops that support the whole diesel on engine body.

2. Structure:
Engine body is main strained assembly of diesel, and it is founded from alloy cast iron. The form is
planer-type engine body.
Inside engine body, there are crankshaft, cam shaft and balancer shaft which is only for 6 or 8
cylinder diesel, and on its side B, there are main oil channels and main distribution oil channels. In the
baffle of every gear, there are oil channels to main bearing and cam shaft.
Both sides of main bearing of the first gear of engine body are assembled with a thrust ring
respectively which limits the crankshaft’s axial displacement when it works but cannot bear the output
power. After put crankshaft into main bearing hole of engine body, put the thrust ring in, and then put the
bearing case in the proper location. This gear bearing’s sides are also assembled with a semicircle locating
snap ring respectively which prevents the thrust ring from breaking off when the crankshaft rotates.
Inside the main bearing hole is main bearing tile which is based on iron and whose surfaces are
pb-SnCu-plating. Its thickness is about 0.022mm and it is used to increase running-in property and
oil-storage property.
Cooling water cavity is formed between engine body and the outer surface of cylinder line. There are
two annular canals which are used to locate the rubbery seal ring of type o. When the o ring is assembled,
it cannot be twisted, or it may cause leakage of water.
Above the main bearing of engine body is a cam shaft hole, inside which is shaft bush. The cam shaft
bush is made of iron and its working surface is Pl-Cu.
Only the engine of 6 or 8 cylinders has a balancer shaft hole. Balancer shaft hole of 8 cylinder engine
is designed on B side of engine body, and balancer shaft hole of 6 cylinder engine is located below the first
and fourth main bearings.

3. Overhauling
Engine body is the main strained assembly, so when we overhaul a diesel or some related trouble
occurs, we must overhaul the engine body or clean its oil channels.

Supplementary Materials and Wearing Spare Parts

Table 5-1-1
Supplementary Cleaning petrol, bottle brush, seal tape of belling plug, engine oil, liquid
materials nitrogen, lithium soap base grease of two, screw thread locking sealant,
planer sealant
Tools Torque spanner, ring wrench S27, electric hand drill, drill bit φ8, bore
dial indicator, microcaliper
Balancer shaft bush 6.232.0.432.006.4 1/set (V6)
Rapid Balancer shaft bush 6.232.0.432.007.4 1/set (V6)
wearing Balancer shaft bush 6.232.0.432.005.4 1/set (V8)
spares Balancer shaft bush 6.232.0.432.004.4 4/set (V8)
Main shaft tile 6.236.0.430.001.7 Number of cylinders
/2+1/set
Aluminium plug 6.205.1.327.001.4 Number of cylinders
/2/set
Blocking bowl 6.0215.21.8.0025 3/set
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 81 •
Middle baffle gasket 6.232.0.853.015.4 1/set
Spring burr 6.0216.01.0.0080 9/set
Cylinder’s o ring 6.0493.13.1.4202 Number of cylinders
×2/set
Steps of overhauling:
（1）Disassemble the assemblies of engine body and check main bearing tile, balancer shaft bush and
cam shaft bush, etc.
|（2）The overhauling of main bearing tile:
a. If the main bearing tile is seriously scotched, Cu material is
bare or the plating layer breaks off and serious corrosion occurs,
the old tile should be replaced with new one;
b. If the main bearing tile is scotched and corroded slightly,
we can use smooth arc stick and engine oil to repair it;
c. Check whether the location pin of the main bearing tile
is deflective or deformed, if that, we must replace it.
Fig. 5-1-2 Measurement Sketch Map
Note: Generally, the repairing work should be finished by the manufacturer or the
professional skilled worker trained by the manufacturer.

Wearing Limit of Seating Holes and Shaft Tile Bush of Engine Body
Table 5-1-2
Seating hole Items New assembled Wearing limit
engine (mm) (mm)
Main Dimension of main bearing seating hole ф113+0.0220 Ф113.032
bearing
Ovality of main bearing seating hole 0．022 0.03
seating
hole Taper of main bearing seating hole 0．015 0.02
Application degree of main bearing ≥85％ ≥85％
seating hole and main bearing tile
Dimension of hole with tile of main Measuring actually to support the
Hole bearing seating allowance
with Ovality of hole with tile of main bearing 0.030 0.040
tile of main seating ★
bearing Taper of hole with tile of main bearing 0.02 0.025
seating seating
Clearance between hole with tile of main 0.12-0.17 0.19
bearing seating and main axle neck ★★
Main shaft tile rising value (free state) ≥113.3 113.25
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··82·· the Disassembly, Overhaul and Assembly of its Main Components MWM

Shrink range of seating hole and the cam 0.035-0.06 0.035-0.06

shaft bush’s outer diameter
Inner diameter of cam shaft bush ф55+0.030 ф55.065
Cam shaft
bush Ovality/taper of cam shaft bush ★ 0.025/0.015 0.045/0.025
Axiality of cam shaft bush hole (mandrel 0.02
check available)
Fit clearance of cam shaft bush and axle 0.06-0.11 0.18
neck
Shrink range of balancer bush and seating 0.035-0.05 0.03-0.05
hole V6/V8
Inner diameter of balancer shaft bush ф52±0.02/ф60±0.02 ф52.05/ф60.04
V6/V8
Balancer Ovality of balancer shaft bush V6/V8 ★ 0.03 0.040
shaft
bush Taper of balancer shaft bush V6/V8 0.02 0.03
Axiality of balancer shaft bush hole 0.02
(mandrel check available) V6/V8
Fit clearance of balancer shaft bush and 0.06-0.11 0.18/0.15
axle neck V6/V8 ★★

Note: “★” means: If the ovality of hole with tile of main bearing seating is too large, its value
must be decided according to the fit clearance. The minimal value must not
be less than the low limit. Its taper means the difference of the dimension
between maximum and minimal of two measuring straps at the same
position, see Fig. 5-1-2.
“★★” means: That clearance size must depend on the rotation speed and the pressure of
oil. As to special problems, please inquire to the manufacturer.
(3) The overhauling of cam shaft bush
① If cam shaft bush is seriously sprained, corroded to change its color, Cu layer breaks off and fit
clearance is larger than the limit value, it must be replaced.
When we replace the bush, the new bush
(semi-finished article without precise boring of inner
hole) with shrink range of 0.035-0.06mm is proper. Put
the new one in liquid nitrogen to cool down for one or
two minute(s), and then mount it on seating hole quickly.
Its oil hole must be collimated with the oil hole of engine
body, and meanwhile the bush in flywheel must be
concaved with 5mm in engine body (see Fig. 5-1-3) and
the bush on head must be consistent with engine body.
Take the plug head of pushrod oil channel, and then drill
through the oil channel of two tiers pushrod of A, B and
cam shaft bush in two sides. At last, bore the holes inside
bush according to requirement. The radial difference
between its diameter and cam shaft neck is about
0.06-0.11mm. The limit value is 0.18mm. If the cam
shaft is replaced by a new one, the hole must be bored to Fig. 5-1-3 Cam Shaft Inspection
Φ55+0.03.
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 83 •

Note: a: These repairing works must be finished in the manufactory where it was made.
b: Cam shaft bush should be cooled down in liquid nitrogen before it is pressed into
engine body hole. Cam shaft bush can’t be used directly after assemblage, because it should be bored after
being pressed into engine body to guarantee the axiality and coordinates dimension of holes. If the bush is
damaged, it must be repaired in the special boring machine (in the manufactory) after being replaced.
② If the cam shaft bush is damaged lightly, it can be repaired smoothly by golden sandpaper.
③ If the cam shaft bush is corroded lightly because of engine oil (different brand, oil change is
overdue), we should repair it with stick and engine oil, and measure the dimension to make sure that it
suits requirement of Table 5-1-2.
④ If cam shaft bush rotates, the hole must be checked. If there are crackles, color turned to black and
the hole is deformed, the engine body should be rejected.

(4) The overhauling of balancer shaft bush

① If the balancer shaft bush is seriously sprained, corroded to change its color, Cu layer breaks off
and fit clearance is larger than limit value, it must be replaced by a new one.
② If the balancer shaft bush is damaged lightly or corroded, it should be repaired by smooth stick and
engine oil, and measure its dimension according to table 5-1-2.
③ If balancer shaft bush rotates, the hole must be checked. If there are crackles, color turned to black
and the hole is damaged, the engine body should be rejected.

(5) Check the cooling water cavity and sealed surface

Check the cavitation of engine body’s water cavity with eyes. If the cavitation is lower than 3mm, it
can go on working. Otherwise, it should be repaired to be level.

Note: The cooling water must be added with milky oil according to requirement when it is used.
In addition, the cylinder sealed surface should be checked. There can’t be breakthrough bruise and
corrosion by gas. If so, it can be repaired by special repairing glue for cast iron or process the sealed
surface downwards with 0.10mm. All these work have to be finished in professional factories.

(6) Check and clean the oil channels of engine body

If the oil pressure of diesel engine is low, we should check the main distribution oil channel in
pressurizer and filter. This should be made on the special testing equipment of the manufactory, or let the
engine body stand, and then plug up the oil holes related with the main distribution oil channel. An oil hole
in the upper engine body full of coal oil or engine oil is left to check whether the expand duct has leakage.
If there is any leakage, we should seal it again with rising-duct equipment.
When the diesel engine is overhauled or there is great
trouble with more metal fillings, we should take out
the oil channel aluminium stopper with blind segment
by electric portable drill and bore an oil channel hole (ф25mm)
offsetting from the center for the blind segment with
the screwdriver. All the oil channels should be cleaned.
4. Assembling:
①Every oil channel, hole and inner cavity
of engine body must be cleaned and blown
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··84·· the Disassembly, Overhaul and Assembly of its Main Components MWM

clearly with compressed air.

②Assemble the oil channel aluminium stopper again,
and make sure that it is solid and reliably sealed.
Assemble the oil channel hole again, and it must be
put at the end of the oil channel after it is besmeared
with sealing glue.
③When we change the balancer shaft bush, we can
use the special tool to take down the bush without
damaging the hole (see Fig. 5-1-4). The shrink range
must be 0.035-0.05mm when a new bush is used. Fig. 5-1-4 Press Tool
Before assembling, the balancer bush should be
cooled in liquid nitrogen for about 1 minute. Take
it out and then put it in the hole with special tool
quickly (see Fig. 5-1-5). Measure the inner
diameter of bush to make sure it conforms to the
requirement of Table 5-1-2, and the measuring
stick can pass through it without trouble. Otherwise,
the bush must be replaced by a new one.
Fig. 5-1-5 Guidance Tool
Note:
a. All balancer shaft bushes can be interchanged except the one for oil feeding of the first gear.
When the bush has been pressed into engine body, it can’t be processed. So if some one is
damaged, it can be changed individually. The bush should be cooled in liquid nitrogen before
it is pressed into engine body.
b. The oil hole of the balancer shaft bush should be aligned with the oil hole of engine body (V8
the first gear aligned with inner oil hole).

④ Assembling in advance and selected measuring of the main shaft bush. First, we must clean the tile
seat and tile ridge. The top tile should be in alignment with the engine body oil hole. The upper and lower
tiles must be aligned. Assemble the bearing cap according to requirement and put it at the end. The order
can’t go wrong. Location pin and half hole of the shaft tile can’t be extruded. First gear starts with the
flywheel and the number is signed on the bearing cap.

a. Note:
a. New main shaft tile can be interchanged. But because the main bearing hole, the axleneck of
crank shaft and the main shaft tile have working allowance, the main shaft axleneck of crank
shaft must have an accurate radial allowance after the main shaft tile is assembled, which
shall be selected through measuring. At the same time, when we assemble the upper shaft tile,
the oil hole in tile must be in alignment with hole in engine body and the upper and lower
tiles must be aligned, too.
b. Since the axleneck and shaft tile of the crank shaft tend to be abraded after a long period
working, and this can lead to that the radial clearance is too large, the old tile must be
replaced by a new one.
c. Main bearing hole is composed of engine body and bearing cap. Because main bearing hole
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 85 •

requires very high concentricity, the bearing caps from different type diesel engines can’t be
interchanged, even the bearing caps of the same diesel can’t be interchanged. When the
bearing cap has been assembled in engine body, there are letters of 1, 2, 3, 4 --- marked on it
from the rear to the front end. So when we disassemble it, we must be careful.
⑤ According to the principle of first inner then outer and first centre then ends, twist the bearing cap
bolt strictly with a torsion of 200Nm, and then twist it strictly in two steps of 60 and 30 degree. According
to the requirement of table 5-1-2, measure the main bearing hole in six measuring points of two measuring
bands. Their dimensions should conform to the requirements of table 5-1-2 and make sure that the fit
clearance of main axleneck is between 0.12mm and 0.17mm. If the original oil pressure is too low, the
value of clearance should be 0.11-0.15mm (actual data is subjected to rotation speed and oil pressure), or
the thickening shaft tile is used when crankshaft is milled for repair.
⑥ Loosen the bolt at the opposite order of twisting the bolt, then take off the bearing cap. But the
main shaft tile can’t get loose, or the upper and underside tiles can’t be aligned when assembled.
⑦ Check the locking half ring of the main bearing cap at the first gear to make sure that the sinking
screw doesn't get loose, or take off the screw, clean the screwthread free of oil and spread it with glue to
prevent form being loose, after twist it strictly, rivet it solidly at the screw breakup. If the tapered surface
of the screw of locking half ring is deformed and it does harm to the screw to be twisted strictly, replace it
with a new one.
⑧ Spread the O ring of cylinder line with lithium base grease of two and then put it in sealing
channel. Clean the cylinder line and press it to the end of the hole, and assemble the pressure test
equipment. Testing water is the common water with the pressure of 0.5-0.6MPa. Check the sealing of the
cylinder O ring and shoulder, and then discharge the water. If they are not assembled rapidly, some rust
prevention engine oil should be spread on the joint surface.

5.1.2 Cylinder Head

1. Function:
As one main part of combustion chamber, cylinder head, together with cylinder line and piston head,
forms the combustion chamber. It guarantees the feeding of fuels and air to the chamber and the expelling
of exhaust gas. It is an important fixing piece.
2. Structure:
The supercharged diesel engine and naturally-aspirated diesel engine have different cylinder head
structure.
The cylinder head of 236 series diesel is made of alloy cast iron. In it there are an inlet valve and an
outlet valve, inlet and outlet valve seating, valve guide, oil sprayer, rocker arm and rotating seating and so
on. Inside the cylinder head, there are inlet and outlet channels and cooling water cavity.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··86·· the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig.5-1-6 Cylinder Head

1. Screw 2. Gasket 3. Cylinder cover 4. Cylinder head gasket 5. Rocker arm seat of valve
6. Bridge 7. Outlet valve 8. Inlet valve 9. Outlet valve seat 10. Inlet valve seat
11. Valve guide 12. O ring 13. Spring seat 14. Spring of valve inner 15. Spring of valve outer
16. Spring seat 17. Clip 18、21、22、23、25、28. O ring 19. Stud 20. injector seat
24. Injector 26. Round nut with groove 27. Gasket 29. Sleeve

There is a sealing gasket between the cylinder head and the cylinder line. There are three locking tongue
pieces on the sealing gasket. The locking tongue pieces should be covered downwards on the cylinder line
when assembling. The sealing gasket of cylinder head should be replaced with a new one in every
dismantling and assembling.
Cooling water to cool down the cylinder head is supplied with two big and a small spigot of the engine
body, and it enters into the inlet cavity through the water hole of inlet surface. The grease oil of rocker arm
and valve of cylinder head flows back
to the oil pan through a small outer spigot. Grease oil
is connected by small spigot with engine body. There
are two O rings on every spigot to seal (See Fig. 5-1-7).
When we dismantle the cylinder head, we shouldn’t
make it break off or agley. If the O ring is deformed, loses
elasticity, aging crack or being damaged, it should be
replaced with new one.
3. Overhauling
If there is crack in the cylinder head, leakage
Fig. 5-1-7 Sleeve and Its Sealing
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 87 •

of water and/or gas, or looseness of the duct of

valve, and if the valve is abraded seriously or it reaches the level of W4, W5’s maintenance or there are
some related troubles occur, the cylinder head should be taken off and checked.
Supplementary Materials and Rapid Wearing Spares
Table 5-1-3
Supplementary Diesel oil or mental cleaning agent, abraser paste, engine oil, hair brush,
materials tinting oil or pencil, seal tape of belling plug, liquid nitrogen,
screwthread locking sealant
Tools Socket spanner S13, S17, special bend spanner S22, guidebar of cylinder
head, lengthened steel pipe, tool to dismantle the duct of valve, tool to
press the valve seating, abrasion tool, rubber mallet, cylinder bill,
micrometer.
Sealing gasket of cylinder head 4.236.0.855.105.4 1/cylinder
Small O ring 4.0493.28.0.0002 2/cylinder
Big O ring 4.0493.28.0.0001 2/cylinder
Inlet valve seat 4.236.0.345.110.4 1/cylinder
Outlet valve seat 4.236.0.345.113.4 1/cylinder
Rapid Inlet valve 4.236.0.460.107.4 1/cylinder
Outlet valve 4.236.0.460.105.4 1/cylinder
Liner (fuel injector) 4.236.0.460.104.4 1/cylinder
wearing O-ring for Liner (fuel injector) 6.0493.13.0.2404 1/cylinder
Exhaust pipe gasket 6.234.0.852.002.4 1/cylinder
Air inlet pipe gasket 4.236.0.853.601.4 1/cylinder
spares
Steps of overhauling:
（1）When we want to disassemble one or some cylinder heads from the diesel engine, we need to
discharge the cooling water of diesel and disassemble the high pressure oil channel, cylinder head lantern,
oil sprayer and rocker arm firstly, and then disassemble the duct for gas inlet or outlet (If overhaul
inspection is made to a single cylinder head, can pull out the to-inspect bolts of inlet and outlet pipes and
unscrew other bolts connecting with cylinder head on the outlet pipe of the same row, draw the outlet pipe
away lightly but can't bend the small corrugated pipe for gas exhausting, otherwise loosen the fixing hoop
of small corrugated pipe). At last, twist the bolt off.
(2) Disassemble the rocker arm and take the valve push rod out. Check the pusher head and blow the
oil hole throughout, if it can’t be throughout or it bends, a new one is needed.
(3) Decompact the cylinder head by a rawhide hammer, then the cylinder head shall be pulled
together with its armor tubing out from the gap between inlet and outlet ducts normally (A bolt can be
twisted to the rocker arm screw as a handle).
(4) Check whether there is damage or burn in the sealing gasket.
(5) Disassemble the inlet and outlet valves (Fig. 5-1-9).

Fig.5-1-8 Disassembling of Inlet and Outlet Valves

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
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Assemble the special remover by use of assembling bolt hole of rocker arm seating. And then twist the nut
of the remover until the springs of inner and outer the air valves are pressed strictly. Take off the valve
locker, and disassemble the remover, spring seating, springs inside and outside the valve and rotating seat.
At last, take out the inlet and outlet valves (Fig. 5-1-9 (A)).
Check the abrasion of the valve. If the diameter of valve bar is smaller than 9.94mm or there are cracks on
the bar, or there is burn, pockmark and serious wearing without grinding repair value, the valve must be
replaced with a new one. We must check the dimension of X (Fig. 5-1-9 (B)) after the valve is mounted in
cylinder head, if X>2mm for outlet valve and supercharger X> 1mm for inlet valve and naturally gas
absorber X>2mm, valve and its seating have to be replaced by new ones.
(6) Clean every part and remove the carbon deposit. The carbon deposit on the sealing surface can’t be
removed by hard thing.
(7) Disassembling and assembling of valve guide (Fig. 5-1-10)
If the inner diameter of the valve guide is larger than 9.04mm, it must be replaced with a new one.
Insert a special tool or aluminum bar into the cylinder head through its bottom to beat out valve guide.
Insert the valve guide end with the chamfering of 10°into the hole of cylinder head. In order to guarantee
safe assembling, the cylinder head should be heated to 200℃ evenly or cool the valve guide down in liquid
nitrogen. After assembling, valve guide must bulge with 14±0.1mm above cylinder head (see Fig.
5-1-9(B)).

Fig. 5-1-9 Dismantling Assembling of valve guide

(8) Disassembling and assembling of valve seat ring
The valve seat ring should be replaced with new one if there are such serious damages as abrasion,
pockmark or burn on the sealing surface of valve seat ring or the abrasion to sealing cone of valve seat ring
is larger than 4mm (see Fig. 5-1-9(B)).
The valve seat ring should be removed from cylinder head with vertical lathe or boring machine. If there
are not the tools, we can use pneumatic grinding wheel to abrade one side of the valve seat ring to leave a
thin valve seat ring which can’t damage valve seat ring hole in the cylinder head and then eliminate it with
flat chisel carefully.
Heat the cylinder head to 200℃ at most or cool the new valve seat ring down in liquid nitrogen evenly
when assembling, then press it into cylinder head hole with the location stander of new valve. The new
valve seat ring doesn’t need to be machined after being pressed into cylinder head hole.
(9) Grinding of valve seat ring and valve cone
If we only need to change valve or valve seat and if there are light burn, pockmark, leakage and chafing,
the two ones only need matched grinding. If both the valve and valve seat ring are replaced with new ones,
grinding is not necessary, but we must check its sealing property. They also need matched grinding if they
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 89 •

are not sealed well.

Steps of grinding：
① Spread the valve cone with a thin layer of abraser paste.
Note: There cannot be abraser paste on valve stick. Spread the valve stick with some engine
oil and then insert it into valve guide.
② Grip the valve head with sucker disk of the grinding tool and grind with rotating handhold. We
also can wrap the valve stem with thin copper sheet and grind the valve with electric hand drill or
drillpress, moving up and down.
③ Checking sealing property: clean valve cone and valve seat ring cone firstly, and then spread the
valve cone with color oil or with a pencil. Insert the valve into valve guide and press it lightly with hand,
then rotate 60°left and right. The sealing surface contact strip of valve seat ring must be continuous and
proper in width. If pencil is used, the pencil on valve surface must be unsharpness, or step 2 must be
repeated.
(10) When the oil sprayer leaks water or needs overhaul, we should disassemble the bolt and vessel,
then clean cylinder head vessel cone. Spread the new vessel with seal tape of belling plug, and then put it
in cylinder head and meanwhile put O ring and gasket in. Press the vessel and O ring strictly with bolt, or
change the thickness of gasket to adjust (two gaskets utmost). We also should check the seal property of
the cylinder head under the pressure of 0.4-0.5MPa.
(11) Check whether there is crack and rag on valve spring, if there is any one, it should be replaced with a
new one. Spring should be checked when overhaul.

4. We must notice the following items during assembling cylinder head:

Assemble the cleaned cylinder head and valve, etc. with the opposite order of disassembling, we must
notice that:

(1) Note: (1) Valve stick should be spread with proper engine oil. It can move up and down and
rotate flexibly when put into conduit;
(2) Valve rotating seat should be flexible when it rotates and there is no binding. Its furring strips should
be assembled downwards;
(3) Press the spring stably and put locking vane in,
which should be reliable. Press the valve to
move down for10mm after the locking vane is
assembled. Again and again, until the valve can
rotate, or change the rotating seat;
(4) All disassembled O rings and seal ring should be
replaced with new ones. Assemble the cylinder
water bush, O ring, iron gasket and outer bush
according to Fig. 5-1-7. The outer bush should
be located between the top and bottom O rings Fig.5-1-10
(can be glued with lithium base grease). The Screwing Sequence of Cylinder Bolt
(5) Every cylinder head is fixed on the engine body by 4 bolts. Screw thread of bolt must be spread with
the engine oil (castor oil preferred) when it is assembled. In order to guarantee the sealing of tailpipe,
the exhausting side face of every array cylinder head should be in the same plane before they are
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··90·· the Disassembly, Overhaul and Assembly of its Main Components MWM

twisted strictly. Bolt is twisted strictly in four steps: firstly, it is twisted with 20Nm, and then with
100-200-400Nm. Twisting order is shown in Fig. 5-1-10.

5.1.3 Cylinder line

1．Function and working condition
Just as saying above, cylinder line is also an important part of combustion chamber of diesel engine.
So cylinder line suffers high temperature and high pressure, too. Besides that, inner surface of cylinder line
has strong friction because pistons are moving quickly in cylinder line. Because of the poor greasing
condition in cylinder line, it is often in the state of half-dry friction. Additionally, cylinder line’s inner
surface is corroded chemically by gas, and its outer surface suffers cavitation and corrosion by cooling
water. Working in such a bad condition, cylinder line is one of the rapidly wearing parts of diesel engine.

2. Structure:
236 series diesel engine adopts wet cylinder line. It is spun with high
phosphorous iron. There are reticular lines formed by flattop honing
on the inner surface, which are used to store greasing oil and reduce
friction. There is no sealing gasket between cylinder line and engine
body, and it doesn’t need to be grinded, it depends on work. Transition
region between shoulder and column of cylinder line is reeled
specially to increase fatigue resistance.

Fig. 5-1-11 Cylinder line

3. Disassembling and overhauling:
Cylinder line is an element of thin wall casting iron. When it is assembled or disassembled, it is
forbidden to throw it or knock on it with hard thing, otherwise it may be broken down. Disassembling the
cylinder line should use the special tool; when assembling, the joint surface between cylinder line and
engine body should be clean and smooth. We can use rubber hammer or wooden hammer to lightly knock
the cylinder line, if the resistance force is too large, the cylinder line should be taken out, and then check
whether the two water sealing o rings are matched well and whether there are ickle and rabbish in the outer
surface of cylinder line or engine cylinder line holes. In order to facilitate assembling, the surface of o
rings should be spread with lithium base grease of two.
If the inner diameter of cylinder line is larger than 132.3mm or the reticular lines on the inner surface
of cylinder line are not clear or the vertical scuffing is serious by handfeeling or the outer surface
cavitation is larger than 3mm, the cylinder line should be replaced with new one. Slight vertical scuffing
﹟
can be repaired by 80-100 sand paper along honing lines. If there is no bulge by handfeeling, the slight
cavitation on outer cylinder surface can wok still after rotated by 90°.

5.1.4 Oil Pan

1. Function:
Oil pan is used to seal the engine body and works as pond of the greasing oil. Engine oil of diesel is
stored here and is sent to every friction surface through cooling, pressure strengthening and filter of engine
oil pump. It flows back to oil pan after greasing and cooling.
2. Structure
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 91 •

Oil pan is founded with aluminium alloy in order to reduce the weight. Oil pan is not only bound with
engine bottom but also with the bottom surfaces of front and end shell covers. Since the engine body, front
shell cover and end shell cover are not processed at the same time, their bottom surfaces cannot be in the
same plane. When the oil pan is assembled, besides assembling the sealing gasket, joints of front shell
cover, oil pan and end shell cover should be spread with planar sealing glue in order to prevent from oil
leakage.

Fig. 5-1-12 Oil pan

1 Wet oil pan 2 Sealing gasket of oil pan 3 Bleeding plug screw 4 O ring
5 O ring 6 Cap 7 Filter sieve 8 O ring
9 Round flange 10 Cap 11 Middle flange 12 Middle flange
13 Engine oil zerk 14 O ring 15 Engine oil scale

There is an apron in the oil pan with an oil spiral on its each side，from here we can discharge the
engine oil. Zerk can be installed in both sides of oil pan, which depends on the user’s requirement. An oil
scale is mounted on the side of oil filler, which is used to measure the oil level in the diesel engine. In the
bottom of oil pan can add a spacer flange, used for assembling the sensor which measures the temperature
of engine oil of diesel engine.
The oil pan is divided into wet type and dry type. The wet type is of simple structure, its disassembly
and assembly is convenient. The dry type oil pan is more complicated. There is a sealed chamber in the
center of the pan, an oil pump pumps the engine oil of both ends of oil pan to the sealed chamber, and then
the engine oil pump pumps the engine oil from sealed chamber to oil channels of diesel engine body.
Because the sealed chamber of dry type oil pan always has enough lubricating oil, diesel engine can work
normally when inclines 45 degrees vertically and 30 degrees horizontally. Dry oil pan is adopted for ship’s
main engine which has special requirements, ship-used generating set and special vehicles with special
requirements.
Disassembling, cleaning and installation of oil pan:
Auxiliary Materials and Wearing Spare Parts
Table 5-1-4
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··92·· the Disassembly, Overhaul and Assembly of its Main Components MWM

Auxiliary materials Diesel oil, local engine oil, fluid sealant 7304, lithium base grease of No. 2

Tools Spanner S=13、14、19

Wearing spare parts Seal gasket of oil pan V6, V8, 6.232.0.853.025.4/026.4 1
V12
Seal gasket of oil pan V8, V12 6.232.0.853.023.4/024.4

O ring (lubricator fitting) 6.0493.10.6.0404 1

O ring (lower cover) 6.0493.10.4.1404 2

Sealed gasket (drain plug) 6.0492.01.01824 2

Oil temperature sensor joint 4.234.0.355.718.4 1

After several times of normal oil change (250 hours diesel engine), oil pan should be cleaned, that is
to say, after the engine oil is discharged totally, add right amount of engine oil in the pan, then open oil pan
cover board and drain plug to discharge cleaning engine oil, and also check whether there is unusual filings
on the coarse screen of cover board. If every thing is in normal state, reinstall it and O ring should be
replaced with a new one. If there are unusual filings, or oil pan needs to be dismantled for repair, engine oil
should be discharged before the oil pan is pulled down. Notice that ground surface sealing glue should be
spread on the joints of front and rear-end shields after oil removed, twist double guiding screw bolts in the
screw, loosen the bolt of the lower cover and install oil pan, then screw the bolt of lower cover.

5.1.5 Front end shield and rear end shield

1. Function
The front-end shield seals the driving gear in the front end of diesel engine and crankshaft front end,
assembled with some appurtenances and oil pan. The rear-end shield seals the driving gear of balance shaft
of diesel engine and crankshaft rear end, assembled with oil pan.
2．Structure：
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 93 •

Fig.5-4-13 Front end cover

1 Front-end shield 2 Radial seal ring of crankshaft 3 Seal gasket of the front end cover 4 Cover
5 Cover board 6 Respirator 7 O ring 8 O ring
9 O ring 10 O ring 11 O ring 12 O ring
13 Adjusting washer 14 Bush 15 Bearing cover 16 Pin
Front end cover is founded with cast iron and assembled in the front end of diesel engine. In the
bottom is a radial seal ring for radial sealing of crankshaft, in the middle part is the tachometer sending
unit connecting with camshaft and in the upside is a hole sealed by the cover board 5. When the diesel
engine adopts compressed air starting, starting air distributor can be assembled. There is a hole sealed by
cover board 4 in the top-left, where can install auxiliary device such as hydraulic pump or
compressor-turbine unit. There is a fan-driven bracket in the front part of front end cover, or the bracket,
tension pulley for supporting heat exchanger and intercooler. In its both sides are installed with breathing
apparatus (oil and gas separator), fresh water pump and charging generator, etc.
The rear-end shield is founded with aluminum alloy,

simple in structure with a balance shaft axle transmission

gear inside. There is also a radial seal ring in the rear-end
shield for radial sealing in the rear end of crankshaft. The
seal ring is housed on a cushion ring. The rear-end shield
is covered by flywheel and flywheel shell without exposure.

Fig. 5-1-15 Rear-end Shield

3. Dismantling and overhauling:

Auxiliary Materials and Wearing Spare Parts
Table 5-1-5
Auxiliary Diesel oil, sealant 7304, No 2 lithium base lubricating grease, hairbrush, bell plug
materials sealant
Tools A set of standard tool, special purpose clamp plate, hand hammer, aluminum bar
(diameter: 30)
Wearing spare Radial seal ring of the front end cover 6.0496.06.5.0951 1
parts
Radial seal ring of the rear-end shield 6.0496.06.5.1332 1

Seal gasket of the front end cover 6.232.0.853.009.4 1

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··94·· the Disassembly, Overhaul and Assembly of its Main Components MWM

Seal gasket of the rear-end shield 6.232.0.853.017.4 1

 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 95 •

After the front-end shield is dismantled, check oil seal slip surface
of the crankshaft. If there is obvious scratch or abrasion mark in the
slip surface, can use polishing linen to polish. If we can still feel the
scratch or abrasion mark with the fingernail, seal ring can be shifted.
We can check sealing of the rear-end shield in the same way as the
front one. If necessary，the steel ring mounted on crankshaft can be
changed with direction or replaced.
The radial seal rings of the front and rear-end shields adopt the
structure that has spring of self tightening ring, the tension of the
spring makes the sharp hoop of rubber on the journal to seal engine oil,
see Fig. 5-1-15. If the sharp crest of seal ring wears and tears seriously,
it will cause the oil leakage. If engine oil is too dirty, it is also apt to rub Fig. 5-1-15
the journal out the flute. So, when the oil leakage happens or overhaul is Radial Seal Ring
made, the seal ring should be replaced.
⑴ Dismantling and check of the radial seal ring of the front-end shield and its installment:
① Pull down all parts of the front-end shield and triangular pulley;
② Pull down the front-end shield, check wearing state of rubber sharp crest of radial seal ring, if
rubber mouth is abraded flat or ruptures, replace it;
③ Mark the position of the radial seal ring to dismantle before wetting off；
④ Spread sealant of bell tap on the new radial seal ring, beat and push down in symmetry and
equality from the face of the front-end shield, no deflection permitted. If the journal rubs and
gets off the mark of the ditch, the position of new radial seal ring must stagger 2-4mm with the
original position, so as to guarantee reliable sealing and prolong the life-span of seal ring;
⑤ Install every part against the order of dismantlement.

Note:
① When renewing the sealing gasket on the front-end shield, spread sealant on the both sides
in about 200-250mm of underpart evenly (cut away the surplus part in the bottom);
② When assembling front-end shield, pay special attention not to damage the sharp crest of
seal ring and prevent the drop of self-tightening spring ring; And spread No. 2 lithium base
grease on seal ring and journal;
③ Positioning pin has been assembled on the front-end shield during engine assembly, when
repair it, please don't destroy the pin hole to ensure the reliable fix of front-end-shield and
no lopsided wear of radial seal ring;
④ The torque moment of the tightening screw of V-belt pulley is 380＋10N•m or 200N•m＋
60°，screwed down evenly.
⑤ If a new front-end shield is to be installed, inspect whether there is interference with gears
and front shield intracavity (jigger) during trial assembling.
(2) Overhaul inspection of radial seal ring on the rear-end shield and its assembling:
① Pull out flywheel connecting flange and flywheel;
② Dismount sealing ring and inspect radial seal ring, if there is any abrasion, pull out
rear-end shield and replace it in the same way as repairing the radial seal ring of front-end
shield.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
··96·· the Disassembly, Overhaul and Assembly of its Main Components MWM

③ Inspect the sealing ring at the rear end of crankshaft, if there is groove mark abraded out
but not in the just middle position, it can be installed on the reverse side, or install the
radial seal ring 2-4mm away from the original position but must be installed rightly;
④ Install rear-end shield and flywheel, etc. in the reverse order of disassembly.

Note:
① Damaged sealing gasket on the rear-end shield should be replaced and spread sealant on
the both sides of new gasket 200-250 mm below evenly (cut away the redundance part in the
bottom and spread sealant);
② In order to prevent damaging the sharp crest of seal ring, rear-end shield should be
installed before sealing ring done and spread No. 2 lithium base grease on the seal ring and
outside diameter;
③ The torque moment of flywheel binding screw is 380＋10N•m or 200N•m＋60°，screwed
down evenly.

5.1.6 Flywheel Shell

1. Function:
The shell of the flywheel is fixed on rear end of the engine, can offer fastness flange rabbet for
connection that motives force outputs.
2. Specification and structure:
The flywheel shell has two kinds of specifications: SAE1and SAE0.
Generally, SAE1 is used in V6, V8, V12 cylinder diesel, (SAE–Society of American engineers);
SAE0 is used in V12, cylinder diesel.
Adopting international universal standard, the flywheel shell can easily work with other universal
machinery.
There are two props in both sides of diesel engine. Start-up electromotor or pneumatic motor can be
installed in the left hole inside. Supercharger bracket can be mounted on the upside.

Fig.5-1-16 Shell of the Flywheel Fig. 5－1－17 Measurement of Positioning Rabbet

3. Installation of flywheel shell
(1) It is necessary to take apart and install flywheel shell when it is overhaul or relevant trouble
occurs. There are two positioning pins on the flywheel shell, don’t change the position of
positioning pins when pulling down flywheel shell.
(2) During assembling, when fixing bolt is screwed down on the shell of flywheel, use dial indicator
and magnetic stand to check the ending beat and radial runout of positioning rabbet of flywheel
 HND
MWM Section 1 Main Fixed Assemblies Structure and Their Disassembly, Overhaul and Assembly • 97 •

shell. It should be guaranteed that the outer end face of flywheel shell has an ending beat not
larger than 0.25 mm against the center line of crankshaft, the concentricity of the center hole of
flywheel shell and crankshaft center is not larger than 0.25 mm (see Fig. 5-1-17). Otherwise
adjust flywheel shell and reinstall positioning pin. If there is large deformation, repair or replace
flywheel shell.
+5
(3) The wresting torque moment of fixed bolt of flywheel shell is 140 N•m for M12 bolt and

+10
370 N•m or 200N•m＋60°for M16×1.5 bolt;

(4) We should lean positioning rabbet against engine body and the underside of flywheel shell, the
+10
torque moment of fixed bolt is 220 N•m.

5.1.7 Breathing Apparatus-Oil and Gas Segregator

1. Operating principle:
After the oil and gas admixture passes through oil and gas separator, gas is drawn out by external inlet
angle pipe and enters combustion chamber with fresh air, and engine oil flows back to oil pan through
filtration netting. The function of breathing apparatus lies in reducing the gas pressure inside engine body,
which facilitates the sealing of engine body and normal running of moving parts.
2. Structure:
Breathing apparatus is installed on the upper side of front end cover
and connects with crankcase (the configuration is shown in Fig. 5-1-18).
It is made of sheet iron and looks like a hopper sealed with a cover
in the upside and a tube is mounted on respiration tracheae through
clip in the downside, beside it a tubule connects with inlet pipe
(negative pressure), inside it is filtration netting woven by steel wire.

Fig. 5-1-18 Breathing apparatus

Note: The breathing apparatus needs gasoline cleaning after every 250 hours of diesel running.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·98·· the Disassembly, Overhaul and Assembly of its Main Components MWM

5.2 Main Moving Components’ Structure and Their Disassembly,

Overhaul and Assembly

The diesel engine involves such main moving components as crankshaft, connecting rod, piston
assembly, drive gear, flywheel, belt pulley, balancing shaft (12-cylinder engine has no balancing shaft),
etc. Camshaft is also one of the main moving components, but described as the part of valve
mechanism.

5.2.1 Crankshaft

1. Function:
Crankshaft, as the most important part of the diesel engine, bears the most complex force action,
and is most difficult to machine. On the one hand, it gathers reciprocating forces which each connecting
rod transfers, and transfers them into rotary torsion to output power; on the other hand, it drives various
auxiliary devices of the diesel (various pumps, valve mechanism, etc.).
2. Structure:

Fig. 5-2-1 Crankshaft

1 Shaft assembly 2 Front end gear 3 Timing gear 4 Back end gear 5 Gear ring
6 Balance weight 7 Flywheel 8 Flywheel gear ring 9 V-belt pulley
10 Absorber 11 V-belt pulley 12 Absorber 13 Jigger wheel

In diesel engine series 236, crankshaft is forged by material of alloy steel, total nitrification.

Caution! If crankshaft passed nitrification, its flywheel end face will be marked with “N” sign.
There is oil hole in the main shaft journal and the connecting rod shaft journal and the oil holes
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 99 •

are connecting. Lubricating oil passes through main shaft journal oil hole and comes to connecting rod
journal.
Crankshaft is equipped with timing gear, which drives camshaft and injection pump driving
mechanism and high pressure oil pump as well; with front end gear, which drives oil pump; with back
end gear (not for 12-cylinder engine), which drives balancing shaft; with balance weight on the
corresponding crank arm, technologic oil hole is plugged in the crank slope.
Crankshaft is equipped on the back end with flywheel to output power, on the front end with
V-belt pulley to drive freshwater pump, fan, charging generator and seawater pump, etc. Front end with
additional flange can output power.
Jigger wheel is installed on the belt pulley for hand-barring.
Crankshaft assembly (excluding belt wheel, flywheel, absorber), after dynamic balance test, is
drilled with holes of different amount and depth in its balance weights to meet dynamic balance
requirement. So balance weights can’t be interchanged. Pay attention to it if it is necessary to
disassemble the weights.

Caution!
(1) Tightening moment of the balance weight bolt is 260-270 N.m.
(2) If disassembly balance weight or general overhaul is implemented, dynamic balance test
must be redone.

3. Disassembly and overhaul:

On diesel engine series 236, its main bearing bush and connecting rod bearing bush both adopt
floating thin wall bearing bush. In order to establish good oil film lubrication, it is necessary to
guarantee appropriate radial clearance and enough small ovality and taper. When diesel receives general
overhaul or main bearing bush wears severely (bigger gap, lower oil pressure), plating top brushes off or
rusts, etc., crankshaft and main bearing bush should be disassembled and overhauled.

Supplementary Materials and Rapid Wear Spare Parts

Table 5-2-1
Supplementary Diesel oil, brush, calico, nursing bottle brush, CD40 engine oil, No. 2
materials lithium base grease, polishing ointment, felt, compressed air, rubber
＃
hammer, emery cloth 180 , metallographic sand paper 400#
Tools A suit of standard tools, a suit of special overhaul tools
Thrust loop 6.234.0.340.002.4 2 per engine
Rapid wear Main bearing bush 6.234.0.430.001.7 (Number of
spare parts (O) cylinder/2)+1 per
engine
Timing gear 6.234.0.371.001.4 1 per engine
Front end gear 6.234.371.002.4 1 per engine
Gearwheel 6.234.371.011.4 1 per engine
(V6, V8)

Steps of disassembly and overhaul:

（1） Exhaust out the oil and the water, then remove outer parts, front-end cover, back-end
cover, connecting rod, T-belt pulley, flywheel, etc.;
（2） Measure crankshaft’s axial clearance and engagement clearance of gears by
magnetometer and dial indicator, renew thrust loop and gears if their values reach or
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·100·· the Disassembly, Overhaul and Assembly of its Main Components MWM

approach limits;
（3） Loosen equably main bearing shell’s bolts (don’t take them out), draw them out it with
tongs, or draw them out by rubber hammer;
（4） Loosen respectively two flywheel’s bolts on the end of crankshaft, take equably
crankshaft out with tightwire, remove thrust ring;
（5） Check-up crankshaft: during overhaul, crankshaft detection and dynamic balance test. If
crankshaft journal are slightly scraped, nicks require to be polished, if vivid nick, slight
crack or abrasion is bring out.

Caution!

(1) Measure crankshaft journal by two measurable circularity belts necessarily, the result is gotten by
arithmetical average of three directions；
(2) Round the roots of each oil hole and crankshaft journal；
(3) If there is large area copper exposure, serious scratching or plating brushing off, the main bush
needs replacement. If there are few slight scratches, the main bush can be rolled by smooth round
metal bar with engine oil.

Caution!
① Install the main shaft bush according to the requirement of assembling, screw down the bolt;
② Measure the size of inner hole according to the measurement band and measurement point in
Fig. 5-1-4, and the corresponding journals as well, and calculate their fit clearance, ovality and taper;
③ If any of the above measurement values reaches or closes to the extreme of wearing, select a
new bush or a thick–wall one;
④ The wearing limit is not absolute, mainly depending on the fit clearance. If the oil pressure is
lower, try to control the fit clearance less than 0.14mm.

(5) The thrust loop made of lead bronze adjusts and guarantees the axial clearance of crankshaft. If the
thrust loop reaches or approaches wearing limit or has serious scratch and galling, replace it;
If the locating surface between crankshaft and thrust loop has obvious grinding defect, polish it or
regrind it (otherwise it will accelerate the surface’s wearing). Choose thrust loop alone according to the
actual size, so as to ensure the axial clearance ranges in 0.1-m 0.26mm.

Caution:
If thrust loop wears seriously in one side, it proves that there is outside axial thrust. It is
necessary to inspect the system installation and remove axial thrust.

(6) If the abrasion of gear reaches or closes to abrasion limit, and the gear wheel have crazing and
spalling, replace the gear with other matching gear first; When it is necessary to replace crankshaft gear
wheel, adopt big shrink range when installing crankshaft gear wheel on crankshaft. Wash front shaft
journal of gear wheel clean while dismantling, spread a little of engine oil (so as not to damage shaft
journal) then remove gear wheel using draw yard (warm gear wheel evenly ) or polish, process a gap to
break down the gear wheel with a chisel .
While installing the gear wheel, measure its inner hole and crankshaft journal first, so as to
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 101 •

guarantee the shrink range of assembling, then heat the gear wheel evenly to 220-270℃, after keeping
warm for 60 minutes, put it on the crankshaft rapidly and respectively by special positioning tool.

6-cylinder Engine 8-cylinder Engine 12-cylinder Engine

Fig.5-2-2 Position of Timing Gear on Crankshaft (facing free end)

Caution!
① Crankshaft gear wheel needs strict localization and spacing, so it has to be installed by the
manufactory with special positioning tool; put timing gear on the crankshaft at the position
stated in Fig. 5-2-2, its “0” mark gear wheel center line forms 30°±15 with the crank pin center line of
A3－B3 of V6, A4－B4 of V8 and A6-B6 of V12 (from freed end）；the “0” mark gear wheel center line
of the rear gear wheel is in superposition with the crank pin center line of A1-B1, the allowed
inaccuracy is ±15´;
② It is not allowed to smear oil on the gear wheel when installing it;
③ Pay attention to protecting radial axle seals of front crankshaft, no scratch permitted.

(7) Don’t move the plug on the crankshaft inclined plane; If engine oil is polluted, should remove
the end and clean oil channel carefully. Assemble the plug again using the professional tool.

4. Notice of Assembly:
(1) Clean cylinder body and crankshaft, especially every oil hole should be blown clean with
compressed air repeatedly, and clean every combining surface with the silk;
(2) The main bearing bush should be localized in advance. The bush back can’t be smeared with
oil, put upper set and lower set in order, make locating hole aim at the locating pin, screw
down the bolt and unscrew it, pull out the axle cover. Upper set and lower set can’t be
misplaced;
(3) Spread clean engine oil on the main shaft journal bush, hang the crankshaft steadily and set it
to seat hole, install the second and third gears’ main axle cover (the fist gear starts from
flywheel end). Hit the axle cover to the end by rubber hammer, then tighten bolts evenly in
advance (from inside to outside);
(4) Put the thrust ring painted with clean engine oil on both sides into the slots of the first gear
separately, measure the axial clearance of crankshaft and guarantee it range between 0.1mm
and 0.2mm (extreme value is 0.4mm), then fit on band bush, axle cover with locating
semi-ring (countersunk screw must be riveted after being tightened);
(5) Requirement of tightening the main bearing bolt: use 200N•m torsion in advance (mark it),
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·102·· the Disassembly, Overhaul and Assembly of its Main Components MWM

0
then twist 90 (by twice), namely one half arris surface;

Caution! The order of tightening the bolt: the same gear’s bush is from inside to outside, the
complete machine is from the middle to both ends.
（1） Rotate the crankshaft and check the flexibility, there should not be jamming. Then check
the interval between each counterweight and the cylinder body, it should be even and be greater than or
equal to 2.0mm, but should reexamine the torsion;
（2） Check the tightening situation of hexagonal screw in the counterweight with the torsion
+10
moment of 260 N.m;

（3） Assemble all parts in the inverse order of disassembly, “O” ring and seal gasket should
be renewed.

5.2.2 Piston Group:

The piston group includes piston, three piston rings, piston pin and elastic collar.

1． Function:
(1) Make up one wall of combustion chamber; transmit the force to the crankshaft through connecting
rod because of gas action;
(2) Guarantee the sealing of the combustion chamber, prevent the gas from leaking into the crankshaft
case, and also prevent the lube oil from spreading into the combustion chamber;
(3) Finish breathing in and forcing exhausting through upper and lower movement.
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 103 •

2． Structure:

TBD D

Fig.5-2-3 Piston Group

1 Piston pin 2 Piston 3 Coil-spring-loaded oil control ring 4 Tapered face ring
5 Trapezoid ring 6 Cooling oil chamber 7 Elastic check ring

In order to reduce reciprocating mass force, the piston is made of aluminum alloy. The piston of
naturally aspirated diesel engine and supercharged diesel engine are not the same, but other parts are the
same. Cast cooling oil channel near the first piston ring of piston head of supercharged diesel engine,
through the nozzle installed on the cylinder body inject engine oil to piston oil inlet, in order to cool the
piston. The piston surface has carried on graphite treatment in order to reduce the piston friction
resistance while moving. Disassemble and assemble piston ring with piston ring pincers. Don’t scrape
the piston surface or break the piston ring.
There are three piston rings on the top of piston pin, the first is trapezoid ring, the second is conical
surface ring and they are all gas ring in order to avoid leaking gas of combustion chamber to the engine
and conduct heat to cylinder liner. Because these two rings have positive and negative surfaces, ensure
word “TOP ” facing the crown when installing. The third is coil-spring-loaded oil control ring, used to
scrape extra engine oil on the inner wall of cylinder liner, prevent engine oil from spreading into the
combustion chamber.
3. Disassembly and overhaul:
Auxiliary Materials and Rapid Wear Spare Parts TBD236

Table 5-2-3
Auxiliary materials Metal cleaner, brush, 14# engine oil
Tools A suit of spacer gauge, lock ring pincers, a suit of overhaul tools, piston ring
pincers
Rapid wear spare Piston ring I (trapezoid ring) 4.236.0.160.901.4 1/cylinder
parts Piston ring II (conical surface 4.236.0.160.902.4 1/cylinder
ring)
Piston ring III 4.236.0.160.903.4 1/cylinder
(coil-spring-loaded oil control
ring)

Steps:
(1) Drain the cooling water first when removing cylinder cover to prevent the cooling water from
flowing into the combustion chamber;
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·104·· the Disassembly, Overhaul and Assembly of its Main Components MWM

(2) Remove air intake and outlet pipe bolts of the cylinder to overhaul, then loosen (needn't take down)
all these outlet pipe bolts of the row, draw back the outlet pipe a bit;
(3) Remove the cylinder cover and rocker seat, take out gas valve push rod;
(4) Remove bolt on the cylinder cover evenly, remove cylinder cover by means of screwing up two bolts
or suspending ring (M10) on the cylinder cover. Allow to loosen cylinder cover with rubber hammer;
(5) Remove oil pan, park to the suitable position, remove the connecting rod cover;
(6) After eliminating accumulated carbon at the top of cylinder liner, push up connecting rod and piston
from cylinder (Don’t push up the connecting rod bush);

Caution! ① Prevent carbon deposit from falling into the gap between the piston and cylinder
liner;
② Don't scratch cylinder liner;
③ Don't collide cylinder liner and cooling nozzle;
④ Mark every cylinder carefully, no disorder.

(7) Remove lock ring at one side of piston-pin, pull out piston-pin, fetch connecting rod, remove
piston ring;
(8) Mark every cylinder well and clean the piston. Accumulated carbon can be soaked in metal
cleaner, heated to 60-80℃, using cork and brush;

Caution! Clean accumulated carbon with cork along circumference direction in order to
prevent scratching wove veins of the wall.

（9） Check the parts of piston group, renew those that are close to or have reached the abrasion
limit or are damaged by pull, sinter or crack;
① Inspection of piston ring and piston ring notch
tbd 236

Fig. 5-2-4 Notch Interval of Piston Ring Fig.5-2-5 Piston Ring Groove
a. Measure piston ring notch interval instead of the size of external diameter of the piston ring, place
the piston ring at the unworn place of the top cylinder sleeve, vertical to the axial line, measure its notch
interval with a piston feeler set, if the interval value of the notch is greater than 1.5mm, replace it with a
new ring; (Fig.5-2-4) If the piston ring touches discontinuously, or there are scrapes, replace it. If touch
band width of rings ⅠandⅡ accounts for more than 2/3 of the bandwidth, replace it with a new one.
When the abrasion area of the scraper surface of Ⅲ scraper ring reaches 1mm, replace it;
b. After diesel engine runs long, piston ring grooves will be abraded. The first groove is inlayed in a
cast iron ring groove. When there are obvious abrasion marks, replace the complete set of new pistons.
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 105 •

The size of limit of the second ring groove is 3.115mm, the largest axial clearance allowed is 0. 170mm,
and the limit value of the third ring groove is 3.550mm. The largest axial clearance is 0.100mm.When
this limit is achieved, replace it with a complete set of new pistons.
② Inspection of piston body
When the diameter of piston skirt under piston pin hole is smaller than φ131.830mm, or a piston is
scratched heavily, replace the complete set of pistons. When a new piston pin is put into piston pin hole,
if there is interval is felt, replace the complete set of pistons;
③ Inspection of piston pin
If the surface of a piston pin is felt scratched or scuffed by hand or their diameters are smaller than
φ49.99mm, replace with a new one.
A piston and its piston pin should be matched well. If a piston or a piston pin is replaced, its
subassembly must be weighed and matched. The difference of its mutual weight of the whole machine
should be smaller than 20g.

（10）While overhauling, pistons and piston pins should be detected with flaws. If there is a flaw, it
must be replaced.

4. Notice of Assembly:
（1）Install piston rings by piston ring pincer. Piston rings should rotate flexibly in the groove and not
be nipped. Guarantee its side gap;

Caution! ① The side having word (TOP) of rings I, Ⅱ is upward (toward the top of piston );
② The joint of spring ring of the Ⅲ scraper ring is tied with steel wire，stagger with
split of scraper ring by 180°.

（2）Under the normal temperature above 20℃, the piston pins painted with small amount of
lubricating oil are put into seat hole, and the radial clearance can’t be felt by hand. For facilitating
assembling, it is allowed to heat pistons evenly to 40-50°. The bush of small end of the connecting rod
and the surface of piston pins are spread with lubricating oil and then fitted together with pistons.

Caution! The direction of big end of connecting rod is opposite to the direction of the arrow on
the top of piston (Fig.5-2-7).

（3）While fitting the lock ring, don’t break pin boss hole. Connecting rod pin is fit before lock ring. In
this way, the hole will be not vulnerable;
（4）Piston surfaces and piston ring should be spread with lubricating oil;
（5）With a special guidance, the group of piston-rods could be pushed into cylinder jackets. The arrow
marked on the top of piston points to the cylinder body center. Don’t drop connecting rod bushing. Fit
the big end of connecting rod with bushing. Notice the direction while fitting connecting rod cap.
Connecting rod cap should have the same direction and number with the matching number of
connecting rod.

Caution! Don't bump the connecting rod on the counterweight and the connecting rod journal.
Rotate the crankshaft at the time of installation and avoid bumping on the counterweight and
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·106·· the Disassembly, Overhaul and Assembly of its Main Components MWM

the connecting rod journal. The piston ring joint should have the difference of 120° with it.
（6）Install in the reverse order of disassembly.

Caution! The cooling spray nozzle is corrected at special experimental device, so do not adjust
it at the time of repair. If there is a collision mark or crack, exchange it. Check whether the
cooling spray nozzles aim at the right position after the piston reaches its lowest position.

5.2.3 Subassembly of Connecting Rod

1. Function：
The function of the connecting rod is to connect the piston to the crankshaft and to transmit the
piston thrust to the crankshaft. It changes the straight line reciprocating motion of the piston into rotary
motion of the crankshaft, so it is not only a connecting piece but also a driving medium.
2. Structure：
A subassembly includes a bar, a big end of connecting rod, a connecting rod bearing shell, a
connecting rod bolt, a bush of small end, a bush locating stud. This engine does not have the main or
subsidiary connecting rod. Two rows are mounted in parallel on the same connecting rod journal.
The connecting rod is forged and its body is shallow I-shaped. This kind of structure can both
reduce weight and obtain enough rigidity and the inside is solid. The bush is pressed in the top head in
order to improve the wearability. The oil hole of bush should be adjusted to align with the oil hole of the
connecting rod. The splashed lubricating oil through the oil hole lubricates the surface, which contacts
the piston pin. The big end has the slanting incision on which the teeth are made. In this way, the face of
the joint is joggled and achieves the orientation. Use two bolts to fix the two parts and the bearing
saddle comes into being, which is fit with a pair of the connecting rod bearing shell and use a
localization pin. The bearing shell is made of mild steel and its surface is plated with aluminium bronze.
The shaft journal is lubricated by the pressure lubricating oil that is transported by its oil hole. At last,
the lubricating oil overflows from both ends. While installing or exchanging, an engine should use the
connecting rod of the same grade weight. In an especial case, it is allowed that the adjacent grade
weight is used. There is the figure or mark on the connecting rod to distinguish.

1 Connecting rod
2 Little end bush
3 Connecting rod bearing shell
4 Connecting rod bolt
5 Guide pin

Fig.5-2-6 Subassembly of Connecting Rod

 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 107 •

Caution! If the grade of weight is not clear, inquire the factory.

Weight and Color Grade

Table 5-2-4
Grade Weight Color Grade Weight Color
(homemade) g (importation) (homemade) g (importation）
1 ＞3335-3360 Brown white 9 ＞3535-3560 Blue white
2 ＞3360-3385 Brown green 10 ＞3560-3585 White
3 ＞3385-3410 Green white 11 ＞3585-3610 White white
4 ＞3410-3435 Green red 12 ＞3610-3635 White red
5 ＞3435-3460 Green 13 ＞3635-3660 Red
6 ＞3460-3485 Green green 14 ＞3660-3685 Red red
7 ＞3485-3510 Blue blue 15 ＞3685-3710 Red blue
8 ＞3510-3535 Blue 16 ＞3710-3735 Blue green

1. Disassembly and overhaul:

Auxiliary Materials and Rapid Wear Spare Parts
Table 5-2-5
Auxiliary Diesel, brush, engine oil CD40
materials
Tools A suit of repair tools, torque spanner, a guide sheath for piston, micrometer, a
suit of bore dial indicator, circlet tongs
Rapid wear spare Connecting rod 4.236.0.430.700.7 1/cylinder
parts bearing shell
Connecting rod 4.236.0.431.201.4 1/cylinder
bush
Elasticity pin 6.0220.15.0.0420 1/cylinder
4×20

Steps of disassembly and overhaul:

(1) Disassemble the connecting rod according to the disassembly steps 1-7 of the piston;
(2) Overhaul the connecting rod bearing shell. Check the connecting rod bearing shell and the
connecting rod journal;
① If there is serious scratch, copper exposure or plating shedding or corrosion, replace it. For low
scratch, repair it by rolling. Namely, use rolling pole which is bedewed with oil and roll on the damaged
place gently;
② Check the expanding of the connecting rod bearing shell in the free state, it should be greater
than or equal to 98. 20mm, otherwise replace it;
③ According to the position stated in the Table of Limits of Sizes of Attrited Parts, measure the
size of connecting rod hole and journal. Referring to Table 5-2-6, if it reaches the limit size, exchange it;
If connecting rod journals are scuffed heavy, according to the part of the overhauls of crankshafts, grind
the crankshaft and make a special bearing shell to match it.

Caution! The abrading or nitrogen treatment of the crankshaft having received nitrogen
treatment must be done by its factory. It is not allowed to deal with it without the
manufacturer’s authorization.

（9）The overhauling of connecting rod bush:

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·108·· the Disassembly, Overhaul and Assembly of its Main Components MWM

If the abrasion of the connecting rod bush has caused that internal diameter size reaches or closes
to the extreme of abrasion (of overhaul) or there are heavy scratches or the plating peels off, exchange
the connecting rod bush. If there isn’t the connecting rod bush and the parallelism of the connecting rod
hole exceeds the permitted area, exchange the connecting rod (if the connecting rod body is out of shape,
replace with a new one). Its method is as below:
① Using pressing tools to extrude the connecting rod bush;
② Put the new connecting rod bush into the liquid nitrogen and cool it for 1-2 minutes, then
press it in the connecting rod seat hole. Its oil hole should be able to be inserted excellently with the
inspection bar of Ф6mm;

Parameter Table of Wear Limit of Connecting Rod

Table 5-2-6
Items Original (mm) Wear limit (mm)
Connecting rod big hole φ980+0.022
(without bearing shell）
Expanding value of connecting ≥98.3 ≥98.2
rod bearing shell
Connecting rod big hole (with -0.012 measure
bearing shell)/thickness of Measure/3
bearing shell -0.024
Axial clearance of fitting 0.09-0.135 0.15
Ovality 0.030 0.040
Taper 0.020 0.025
Big end face and side 0.2-0.5 0.8
clearance of crankshaft
Connecting rod bush +0.07 φ50.10
Φ50
+0.03
Ovality 0.025 0.035
Taper 0.015 0.025
Axial clearance of fitting 0.05-0.09 0.10
Depth of parallelism of 0.02 0.025
connecting rod hole and bush

Caution! When the ovality is larger, it must be determined according to the gap of the gear, and
the smallest clearance should be larger than or equal to the lower limit value. The taper is the
difference between the largest size and the smallest size in the same azimuth of two
measurement bands, as shown in Fig. 5-1-2.
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 109 •

Fig. 5-2-7 Assembly of Connecting Rod and Piston

(10) Upon overhaul or when big trouble occurs, the magnetic detection must be made to engine
connecting rod. When serious bump, overheat decarburization or crack is found, the connecting rod
should be replaced.

4．Notice of Assembly:
(1) Clean all components and ensure the fit clearance, and assemble the connecting rod and piston on
their own original positions. When assembling the connecting rod and piston, the connecting rod
bend direction is opposite to the arrowhead direction, but is in accordance with the direction of the
gap of piston skirt.
(2) The locating resilient pin of con-rod bearing should be renewed when a major repair happens.
The resilient pins should be hammered from outside in, and should not project out of the bushing
surface with the height C of 2 0.3mm.
＋

(3) The adjacent rings, in the direction of opening of piston ring, are stagger by the angle of 120°. The
opening of combined scraper ring and spring ring interface is stagger by 180°. Special tool is used
to hitch the piston and push it into the cylinder liner.

Caution!
(1) After cleaning the side of piston and cylinder liner, spread the mobile oil;
(2) When thrusting, the connecting rod can’t collide with the crankshaft;
(3) The top arrowhead of the piston points to body axes. But skirt fan-shaped gap is against
cooling jet;
(4) Connecting rod bush and connecting rod seat hole must be cleaned, bush back can’t be oiled,
the bush’s positioning gap is aimed at positioning pin, and the upper and down bushes must be aligned.
The bush’s underside and connecting rod bolt are spread with mobile oil. Connecting rod cap and the
relative pair number of connecting rod must be on the same side with the same number. Before
installing, pre-tighten at first, knock down the connecting rod cap with bush to fix together, and it is not
allowed to be loosened and dislocated;
(5) When screwing down connecting rod bolt, tap the connecting rod cap to make positioning
teeth joggle well, then uniformly screw it with the torque moment of 90N•m, mark it and screw another
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·110·· the Disassembly, Overhaul and Assembly of its Main Components MWM

60°, that is, a bolt facet, the big end of connecting rod can be shaken with hand to do axial action with
agility;
(6) If the cooling jet is knocked down and is installed again, oil supply hole in the piston must be
aligned with the cooling jet when the piston is at the bottom dead center (be aligned with the gap of
naturally aspirated supercharger). Turn the crankshaft to check the big end of the connecting rod. The
safety gap between piston and cooling jet should be≥1.5mm;
(7) According to the description in the cylinder head overhaul, install the cylinder head well;
(8) Assemble all components in the reverse order of disassembling, its “O” ring and seal gasket
should be replaced with new ones, exhaust-pipe bolt should be spread with antiblocking agent.

5.2.4 Balancing Shaft

The V6/V8 engine of diesel engine series 236 is installed with balancing shaft. As the V12 engine
has good balance itself, it is not necessary for it to install the balancing shaft.

1． Function:
The subassembly of the piston connecting rod will produce the reciprocating mass force and the
reciprocating inertia moment in the course of running. For the V8 engine and V6 engine of series 236,
the fire cutting clearance are unequal, which is caused by the factors such as fire sequence and the V
type angle, and the simple and quadratic reciprocating mass forces are produced, and so the vibration of
engine is strengthened. In order to ensure the calm run of the engine, the balancing shaft is installed.
2. Structure:
The balancing shaft is a straight cylinder shaft for the V6 engine. Two sector balance weights are
installed on the front and back of the shaft respectively, which have the same rotation speed as the
crankshaft, and there is no transition gear in the middle. The balancing shaft balances the simple
reciprocating mass force of the crankshaft connecting rod system (As shown in Fig. 5-2-8).
The balancing shaft of the V8 engine is a mass eccentricity shaft. It is driven by the transition gear,
of which rotation speed is the twice of crankshaft rotation speed. The balancing shaft balances the
quadratic reciprocating mass force (Shown in Fig. 5-2-9).

Fig. 5-2-8 Balancing shaft for V6 Engine Fig. 5-2-9 Balancing shaft for V8 Engine

1 Balance weight of balancing shaft 1 Balancing shaft

2 Positioning pin 2 Journal of transition gear of balancing shaft
3 Thrust loop 3 Transition gear of balancing shaft
4 Balancing shaft 4 Thrust baffle
5 Balance weight of balancing shaft
6 Gear
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 111 •

3. Disassembly and overhaul:

There is a faster abrasion at the bush and journal of the balancing shaft because of the mass
eccentricity. The faults, such as pull and sinter, often occur in the case of shortage of oil, or when the oil
is too dirty. And if these faults can’t be found and remedied, the engine seating hole will burn out.
Therefore, in general, the balancing shaft bush and its status of abrasion should be checked when the
pressure of the oil is too low, the oil is too dirty and an overhaul is conducted.
Auxiliary Materials and Rapid Wear Spare Parts
Table 5-2-7
Auxiliary materials Diesel oil, brush, CD40 engine oil, compressed air, No. 2 lithium base
grease, polishing cream, felt, emery cloth, worm locking sealing glue,
sealing glue 7304
Tools A suit of standard tools, torque spanner, special tools for installing and
disassembling the bush, dial indicator, micrometer, magnetometer shelf
Rapid wear spare V8
parts Balancing shaft bush 6.232.0.432.004.4 4/set+1
Balancing shaft big 6.232.0.432.005.4 1/set
bush (with oil hole)
Drive gear 6.232.0.371.014.4 1/set
Intermediate gear (with 6.232.0.371.013.4 1/set
balancing shaft bush)
Baffle 6.232.0.680.001.4 1/set
Seal gasket for back 6.232.0.853.017.4 1/set
cover
Seal gasket for oil pan 6.232.0.853.023.4 1/set
Seal gasket for oil pan 6.232.0.853.025.4/026.4 Each 1/set
V6
Balancing shaft bush 6.232.0.432.006.4 1/set
Balancing shaft sheath 6.232.0.432.007.4 1/set
bush (with oil hole)
Gear wheel 6.232.0.371.007.4 1/set
Thrust half ring 6.234.0.673.002.4 1/set
Seal gasket for oil pan 6.232.0.853.025.4/026.4 Each 1/set

Steps of disassembly and overhaul:

(1) Remove oil pan, flywheel shell, flywheel, back end cover;
(2) Measure gear backlash and axial clearance of balancing shaft gear wheel firstly with
magnetometer shelf and dial indicator. If reaching or nearing to the extreme of abrasion, the worn part
should be replaced;
(3) Remove gear wheel, fan-shaped balance weight and thrust loop;
(4) Remove balancing shaft from the rear part of cylinder body carefully, can’t damage the bush;
(5) Wash every part and seat hole clean, especially the oil channel;
(6) Measure the balancing shaft journal, if its diameter is smaller than 51. 91mm or it can be felt
obvious scratch with nail, or fit clearance exceeds the range after polishing, should change the balancing
shaft
(7) Check balancing shaft bush in the cylinder body, when the bush wears down the copper layer or
the working surface has more scratches or plating spalls, replace the bush;

Caution! Balancing shaft bush can be changed alone, guaranteeing axiality (checking with
mandril).
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·112·· the Disassembly, Overhaul and Assembly of its Main Components MWM

(8) If there is serious abrasion mark on the thrust loop or the thickness is smaller than 6.65mm, or
after installing balancing shaft, axial clearance is greater than 0.3mm, should be changed.

Caution!
If balancing axle’s axial locating slot has obvious abrasion mark, it should be polished. After
changing the thrust ring, if the axial clearance exceeds 0.35mm, it is allowed to install thrust ring
singly (through soft nitrogen treatment) to make the axial clearance kept in the range of 0.1-0.
3mm.

Fig. 5-2-10 Disassembly of V6 Fig. 5-2-11 Disassembly of

Balancing Shaft V8 Balancing Shaft

1 Balance weight 2 Positioning pin 1 Baffle

3 Thrust ring 4 Balancing shaft 2 Gear wheel
5 Balance weight 6 Balancing shaft 3 Shaft journal
7 Balancing shaft liner 8 Balancing shaft liner 4 Balancing shaft

Steps of Overhaul about Balancing Shaft of V8:

(1) Remove oil pan, flywheel shell, flywheel and back end cover;
(2) Check gear backlash and axial clearance of balancing shaft, if it reaches the extreme of
wearing, the gear wheel and baffle should be replaced. Refer to the table about the extreme of wearing;
(3) Remove baffle 1, the middle gear wheel 2, journal 3;
(4) Pull out the balancing shaft with gear wheel from cylinder body carefully along arrow
direction;

Caution! Make mass eccentricity in the low position and hold it in the palm, don’t damage the
bush.
(5) After washing the part clean, check and measure the wearing of balancing shaft, bush, gear
wheel, shaft journal and baffle, and shaft journal jumping;
(6) Measure the axle journal, if the diameter is smaller than 59. 91mm or there is obvious scratch
with nail, and the fit clearance exceeds the stated range after polishing, the balancing shaft should
be replaced;
(7) If the baffle has serious abrasion mark or the axial clearance is larger than 0.25mm after
balancing shaft is installed, replace the baffle;
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 113 •

(8) The method of checking balancing shaft bush is the same as V6 cylinder machine;
Caution!
① Select the bush of shrink range of 0.035-0.05mm to assemble;
② The cooling time of bush in liquid nitrogen shouldn't be too long, generally, it needs 0.5-1
minute. Take out the bush with steering tool, and fix rapidly in case that the bush will be fixed
crookedly;
③ The first bush oil hole should be aimed at the hole inside the engine body and Ф5
examination staff should be permitted to go through. And the bush must be lower than the
engine body end face;
④ If there is abrasion mark, scratch or excess jumping in the balancing shaft and shaft journal, it
is allowed to grind to repair it, but it should be ensured that its fit clearance with bush is
0.06-0.11mm and the limitation value is 0.18mm;
⑤ Proper adjustment is permitted to make the skip ≤0.03mm, if the jumping isn’t so severe.

4. Notices of Assembly:
（1）Clean all parts and blow the oil holes with compressed air repeatedly;
（2）Spread engine oil on balancing shaft journal, held in the palm and enclosed slowly.
Caution!
Bush must not be destroyed; agile turn should be guaranteed when hand operates.

（3）The “0” label number of the balancing shaft gear must joggle with “0” label number of
crankshaft gear for V6 engine. While the “0” label number of the transition gear must
joggle with “1” label number of crankshaft gear at the same time for V8 engine;
（4）Baffle bolt's spring washer should be replaced with a new one. There should be certain
clearance between baffle and balancing shaft boss after fastening to avoid interference, and
the axial clearance is 0.05-0.20mm. If the axial clearance is too small to adjust by abrading
the baffle (because the wearable compound on surface is of tenuity). The axial clearance
can only be enlarged by means of spraying the shaft journal end plane of mid gear, at the
same time baffle plane should be inspected, if it has distortion, change it;
（5）The bolts fastening gear wheel balance weight should be deoiled and then spread with screw
thread lock sealant;
（6）All parts should be assembled in the reverse order of disassembly.

Caution! When changing the balancing shaft gear of V8 engine, it is the manufacturer that uses
special positioning tool to implement. The gear needs to be heated uniformly to 220-270℃, and keep
the temperature for 20-30 minutes. Install the gear rapidly after balancing shaft being calibrated by the
positioning tool (hand aligns with balancing shaft reticle) and being fixed, to make the teeth labeled
with “1” joggle with V slot, with the side of “1” label number outside.

5.2.5 Flywheel

1. Function：
Flywheel is used to store energy, and is the part for diesel engine to output power.
2. Structure:
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·114·· the Disassembly, Overhaul and Assembly of its Main Components MWM

Flywheel is fixed at the back end of crankshaft by twelve high-strength bolts (M16×1.5-12.9) and
twelve high-strength gaskets, the moment of bolts is about 380 10Nm or 200+60°Nm. There is a gear
＋

ring on flywheel, and the gear ring is joggled with the pinion of starting motor or air starting motor, and
thereby start diesel engine. Heat the gear ring to the temperature of 220℃-270℃ before fixing it. The
flywheel’s shape and size is not fixed, following the size of transmission gear. If there is no special
requirement, commonly 14″ is proper; if there is special requirement, negotiation is needed. The
flywheels of V6 engine and V8 engine can not be interchanged. There is a balance weight hole (mass
eccentricity) on the flywheel of V6 engine, the flywheel size of V8 engine and v12 engine is the same.

Caution!
The flywheel of V6 engine must be installed according to the position of
positioning pin hole.

3. Installation:
(1) According to the installation requirement, adjust and fix flywheel
Fig. 5-2-12 Flywheel housing, then pull out the positioning pin and ream the positioning pin hole
of engine body, noticing to clear the ream sweepings after reaming, then fit
the positioning pin;
(2) The flywheel is installed by bolts and washers, screwing moment of the bolts is at the range of
380-390Nm;
(3) According to the Fig.5-1-18, measure the circular jump of the flywheel end face, the range of
circular jump is 0-0.25mm;
(4) When fixing flywheel on V6 engine, notice to install the flywheel and crankshaft in the fixed
position by pins of the washer.

5.2.6 Belt Pulley

1. Function:
The belt pulley is used to drive fan, charge generator, fresh water pump and sea water pump, etc.
2. Structure:
 HND Section 2 Main Moving Components’ Structure and Their Disassembly,
MWM Overhaul and Assembly • 115 •

Fig. 5-2-13 Belt Pulley

The main belt pulley is fixed on the front end of the crankshaft by 8 socket head cap screws,
which are the same as that on flywheel, with screwing moment about 380 10N•m. If there is a
＋

vibroshock on the front end of belt pulley, the vibroshock will be fixed on belt pulley by 12 socket head
cap screws, with screwing moment about 115 5N•m. The jigger wheel is fixed on the belt pulley.
＋

Caution!
① There is a molten balance weight (mass eccentricity) on V-belt pulley of V6 engine, the
positioning pin hole must be installed in the same azimuth as crankshaft, but the V-belt pulley of V8
engine is the same as v12 engine.
② Definite requests must be claimed to the manufactory, the material and size of V-belt pulley
are different with different output power.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 116 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

5.3 The Structure of the Fuel System and the Overhaul and
Assembly of Its Main Components

The fuel system consists of oil tank, fuel pre-filter, manual pre-feeding fuel pump, fuel feeding pump,
fine filter, injecting fuel pump (high pressure oil pump), high pressure oil pipe, oil injector and some pipes.
When the diesel works, the fuel oil is extracted from the oil tank by fuel oil pump, and then the fuel
oils goes through the pre-filter →manual feeding oil pump →fine filter on the diesel →injecting fuel pump
→high pressure oil pump →oil injector. If the diesel is installed with overspeed protection devices, the fuel
oil from the fine filter enters into the overspeed protection device first, and then goes into injecting oil
pump.

Notice: the pre-filter used on the equipment shall be prepared by the user himself and it is very
necessary to be installed. The filter is required to be able to filter the impurity that the size is greater than
0.1-0.2mm.

Fig. 5-3-1 Fuel feeding system

1. oil tank 2 overflow pipe 3 oil return pipe 4 high pressure oil pipe 5 fuel oil filter
6 injecting oil pump 7 overflow valve 8 fuel feeding pump 9 oil injector 10 fuel pre filter
11 manual feeding oil pump

5.3.1 The manual fuel pre-feed pump

Generally the manual fuel pre-feed pump is installed before the fuel feed pump and is fixed on the
intake pipe of the diesel engine. It is used to pre-feed oils and drive the air out of the low pressure fuel oil
pipe when the diesel engine is being started.
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 117 •

Manual pre-feed fuel pump is a plunger pump

with simple structure. There is a plunger, two one
way valves for oil input and oil output in side it..
Before the diesel engine is started, twitch it with your
hand and it will take the fuel out of the tank. The
manual pre-feed fuel pump can suck oils about 1.5m
high. If the position of the output oil orifice on the
tank is relative low, please reduce oil the amount of
pipe elbows and the length as possible to avoid not
sucking the oil Fig. 5-3-2 manual fuel pre-feed pump
Notice: the input oil pipe must adopt the copper pipe with a diameter of more than 8mm.In this way to
prevent from sucking flatly and influencing the amount of oil. The connector must be sealed and credible,
don’t let air enter into the pipe.

5.3.2 Fuel feed pump

1. Function
The function of the fuel feed pump is to take the fuel out from the fuel tank and send the fuel into the
low-pressure cavity of the spray pump with certain pressure. Generally its oil supply amount is 3-4 times as
the oil supply quantity of the spray pump.
2. Main structure

Fig.5-3-3 The decomposition chart of the fuel feed pump

1 fuel feed pump body 11 copper gasket

2 mandril 12 non-return valve spring
3 piston 13 non-return valve
4 piston spring 14 non-return valve
5 copper gasket 15 non-return valve cap
6 large plug screw 16 non-return valve cap
7 copper gasket 17connecting of oil pipe
8 connecting of oil pipe 18 contact roller assembly
9 copper gasket 19 steel wire locking collar
10 non-return valve spring 20 copper gasket
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 118 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

The serial number of the fuel feed pump：

FP/K22P5（SDP22）-Single function type
FP/K22P12（SP22）-double function types

The fuel feed pump is installed on the side of the spray pump and driven by the partial wheel on the
camshaft. It is mainly composed of the fuel feed pump body ,a non-return valve ,a piston ,a spring and a
gyro wheel body and so on. Its main structure and the assembling relationship are shown in Fig. 5-3-3.
3 Working process：
The working process (single function type) of the fuel feed pump is shown in Fig. 5-3-4.

Fig. 5-3-4 （A） Fig. 5-3-4 （B） Fig. 5-3-4 （C）

Fig 5-3-4 The working process of the fuel feed pump
(1)The partial wheel drives the body of gyro wheel of the fuel feed pump (shown in Fig. 5-3-4
(A ))upward to jack the piston, The volume of the above oil chamber is compressed and the oil pressure
rises, at the same tine, the fuel feed pump spring is compressed. At this moment, the left side non-return
valve is turned on and the right side non-return valve is off. The fuel on the piston is replaced into the
pressure chamber below the piston.
(2)As the partial wheel is down, the piston is shifted down under the push of the spring pressure, at this
moment, the non-return valve of the left side of the oil output is shut off, the right side non-return valve is
turned on. Fuels are sucked into the piston by the negative pressure. And the fuel of the pressure chamber
below the piston is driven out to the spray pump. (as shown in Fig. 5-3-4 (B )).
(3) The piston stops going down when the pressure of the fuel output achieves the fuel pressure of
the pressure cavity and are balanced with the piston spring .As the piston stops go down, fuel feed pump
stops the fuel supply (as shown in Fig. 5-3-4 (C )).
The working process of fuel feed pump of the single function type is same as the one of the double
function type. The chamber on the piston or below it all could be use as the working chamber because there
are two input non-return valves and two output non-return valves in the fuel feed pump of the double
function type. So there are two feed course in the fuel feed pump when the piston reciprocates once.
4.Precautions for overhaul and assembly：
（1）The fuel from the fuel feed pump must be filtrated directly by the filter before it goes into the
spray pump.
(2) The fuels that come from the fuel feed pump must be more than the fuels that the diesel needs. One
reason is to meet the need of the degree of consistency of every cylinder; another is to fulfill the need of
cooling the plunger of the spray pump .The excessive fuels must directly and alone get back to the fuel tank.
As return oil of the injection pump is very large, furthermore the oil temperature is very high, returning oil
to fuel oil inlet pipe directly will affect injection pump' cooling, and leads to the seizing of plunger associate.
At the same time, too high oil temperature affects the oil quantity of entering the cylinder, furthermore
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 119 •

reduces the power. Return oil needs feed back into oil tank by a separate return oil pipe, although its
capacity is little. Return oil of the Injection pump is forbidden to connect into entry oil pipe. Because the
latter oil has a press, which made the return oil of the Injection pump isn’t fluent and there is leakage on the
return oil pipe of Injection pump.
(3) The return oil site of injection pump and overflow-safeguarded electromagnetic valve is necessarily
equipped with overflow valve connecting bolts.

5.3.3 Injection pump

The Model 236 diesel engine employs P-type high pressure Injection pump. But because this series
diesel engine has wide coverage of rotate speed and output power, there are variable models of P-type pump
and velometer to match up it.
1. serial number
Bosh serial number:
PE 8 P 120 A 520/5 R S427
1 2 3 4 5 6 7 8
1------------injection pump with camshaft, flat-bottomed pedestal fixing.
2------------the number of injection pump cylinder (4,6,8,10,12)
3------------the type of injection pump (for example P pump, A pump etc)
4------------the diameter of column piston D (mm)*10
5------------project the variable type
6------------the No. of assemblage (show the constructional position of the number of axis, velometer
and oil transfer pump)
7------------the roll direction of camshaft(R is the clockwise, L is the anticlockwise)
8------------the type of pump

National injection pump type

B H M 8 P 120 Y S Y 301
1 2 3 4 5 6 7 8 9 10
1------------the number of the injection pump
2 ------------complex pattern
3 ------------flat-bottomed fixing
4------------the number of cylinder
5------------the type of injection pump
6------------the diameter of column piston D (mm)*10
7------------the direction of control groove
8------------oil capacity control
9------------the roll direction of camshaft
10----------design number
2. Function:
(1) Supply Injection pump after enhance the diesel oil pressure Fig. 5-3-5
(2) Supply the definite diesel oil to Injection pump accurately “P” type injection fuel pump
according to load
(3) Ensure that the time of the supply oil and oil capacity are the same.
3. Configuration:
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 120 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

P type injection pump is the direct range pattern and compages type injection pump, it is mostly
composed of injection pump body, pumping system, oil control outfit and drive. As shown in Figure
5-3-5.
P type injection pump is divided into conventional type and super aggrandizement type.

(1) Conventional type:

Injection pump body: P type injection pump is made of aluminum platinum, it has no watch windows of
whole configuration, but it has super intensity and rigidity, so it can bear super pump pressure. The
transportation pump is installed on its side face, its back part is connected to the velometer, the screw for
fuel and lube passing in and out is on the pump body, screw of fuel exit is with isobarically export oil tube,
which retains oil lacuna pressure invariable.
Pump oil system: As shown in Figure 5-3-6, pump oil system is mostly composed of oil valve base,
flange jacket, export oil valve coupling apparatus, export oil valve spring, reduced vessel, export oil valve
underlay and column piston coupling apparatus. Each element of pump oil system as a whole adopts
preassemble and suspension type configuration, it is fixed up in pump body center hole with the bolt, there
is a rotating waist hole of 10ºfreeness in the flange jacket to adjust equality scale of each pump oil supply, a
pair of hatch underlay is installed between the flange and pump body (As shown in Figure 5-3-10), it can
change underlay thickness and adjust oil supply pretravel.
Oil control organ: As shown in Figure 5-3-7, oil control organ
is mostly composed of angle control oil haulm and oil control
jacket. Control oil haulm is assembled above of pump body
through oriented jacket of two sides and connected to the
velometer. Organ journey is controlled by velometer. Oil supply
control jacket arm soldered a steel ball to joggle with squareness
trough of organ. Its underside flat trough is joggled blow of the
column piston, this kind of organ movement makes column piston
circumvolve through control jacket and changes the relative
position of inclined trough and return oil hole of the column
piston, namely the oil supply is changed.
Drive organ: As shown in Figure 5-3-8, drive organ is Fig. 5-3-6 injection fuel system
composed of camshaft, idler wheel body, up and down spring
base and column piston spring. Camshaft is assembled within pump body and camshaft axes body(pump
body is installed with middle axletree )through a pair of taper roller axletree(As shown in Figure 5-3-10,
27 ,53) .it is forward connected to with the drive organ, and backward tones with flexibility gear of
velometer, camshaft drives each pump idler wheel body and makes column piston move upward(oil supply)
according to fire order of diesel engine, downward movement of column piston depends on the spring thrust
of column piston.
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 121 •

The drive scale of eject camshaft and diesel engine is 1:2.

1
2 1. Feeding pull rod,
2.Fuel inlet-outlet drillings,
3. Plunger,
4. Steel ball,
5. Fuel quantity control sleeve
6. Plunger piece,
7. Plunger sleeve,

Fig.5-3-7 Drive mechanism

1. Delivery valve spring, 2. Delivery valve,

3. Inlet-outlet fuel drillings,
4. Fuel quantity control sleeve
5. Roller body, 6. Camshaft.
7. Plunger spring, 8. Plunger,
9. Plunger sleeve, 10. Orientation pin,
11. Flange sleeve, 12. Delivery pipe connection

Fig. 5-3-8 Feeding control mechanism

(2) More intensified type

Beside P type pump matching with general type engine, more intensified P type fuel injection pump
(RP25-PE12P120A520/5RS7146) is also applied to the Model 236 series high speed marine diesel engine.
All the excellences of P general type injection fuel pump also exist in intensified injection pump. Some
measures to more strengthen its construction have been taken: such as the cam base-circle is enlarged,
stronger pump housing tappet is changed with drumstick roller, and flange sleeve is changed for whole
flange etc… The performance of injection pump appears some improvement, the outlet maximum pressure
of injection pump has attained to 115MPa. Higher fuel feeding rate is used to improve the matching
property for high-speed engine. It deserves to pay more attention for injection pump in design is that we not
only consider its delivery characteristic at full-load, but also have regard for null-load and lower speed
operating condition performance (about less than 10% load), workless in single row cylinders (different
structure of plunger, workless cylinder of even number plunger 2,4,6,8---). The LPA supercharge pressure
compensator is provided on injection pump, which makes the pump keep excellent property of feeding
performance in both null-load and lower speed operating conditions.
4. Operating principle of injection pump
Oil supply procedure of injection pump is illustrated as in Fig. 5-3-9. The oil supply procedure is
divided into four phases when the plunger moves from bellow dead centre (BDC) to top dead centre (TDC)
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 122 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

（A） （B） （C） （D）

（A）plunger at BDC （B）forehand stroke end
（C）forehand compression stroke （D）geometric feeding termination
Fig. 5-3-9. Theoretic stroke of plunger couple action

Fuel inlet stroke: as Fig.5-3-9(A), when the plunger is at BDC position, the fuel inlet-outlet is opened
and connected to with the fuel inlet passage, at this time the fuel supplied by delivery pump flows under the
high pressure and enter into and fulfill the chamber formed by plunger via the fuel inlet-outlet drillings.
Forehand stroke: plunger moves up to that the top surface just closes inlet-outlet drillings, fuel stops
flowing, and at this time the theoretical fuel feeding begins, As Fig. 5-3-9(B).
Forehand compression stroke: As Fig.5-3-9(C), plunger goes up continually the fuel in chamber is to
be compressed, but no fuel is supplied due to the needs to overcome residual pressure in pressure fuel pipe
system and spray force of delivery valve and fuel elastic transformation etc. , this process is called
forehand compression stroke:
Effective fuel delivery stroke: As Fig.5-3-9(D), at the end of forehand compression stroke, plunger
goes up continually, injection pump begins to supply fuel until top edge of plunger flume is connected with
fuel outlet drilling, the fuel flows out of the plunger chamber via fuel outlet drilling, the pressure in chamber
reduces and fuel delivery process is over, which is called effective fuel delivery stroke.
The distance from plunger effective stroke end to top dead centre is generally called remained stroke,
the movement from plunger TDC to its BDC is affected by thrust of spring. Camshaft of injection pump
rotates one revolution; plunger completes one process mentioned above, i.e. one fuel feeding cycle.
Fuel supply sequence and interval angle of injection pump (calculated from driven end) is shown as
below
Pump for 6-cylinders: 1——6——3——2——5——4——1
90o 30 o, 90 o, 30 o, 90 o, 30 o
Pump for 8-cylinders: 1——8——5——4——7——2——3——6——1
30 o 60 o 30 o 60 o 30 o 60 o 30 o 60 o
Pump for 12-cylinders 1— 2 — 9 — 10 —5 — 6 — 11 — 12 — 3 — 4 — 7 — 8 — 1
30 o 30 o 30 o 30 o 30 o 30 o 30 o 30 o 30 o 30 o 30 o 30 o
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 123 •

5. Disassembly，checking and assembly of injection pump

The relationship of main parts of injection pump and its assembly is illustrated As Fig.5-3-10.

Fig.5-3-10. Disassembly illustration of injection pump

1. Pressing seat of fuel delivery value. 2. O ring
3. Capacity reducer 4. Spring of delivery valve
5. Pressure seal gasket 6. Couple of delivery valve
7. Plunger couple 8. Gasket
9. Coupling sleeve 10. Adjustable pad
11. Shield ring for fuel seal 12. O ring
13. Pad of fuel shield ring 14. Fuel shield ring
15. Steel thread shield ring 16. O ring
17. O ring 18. Bolt
19. Guard cover 20. Nut
21. Screw sleeve 22. Pull rod sleeve
23. Pin 24. Pull rod
25. Adjustable pad 26. Bearing sleeve ring
27. 7505 bearing 28. Flow over valve
29. Copper gasket 30. Bolt for fuel inlet-return pipe
31. Copper gasket 32. Bolt for oil pipe
33. Copper gasket 34. Bolt for fuel inlet-return pipe
35. Copper gasket 36. Screw plug
37. Copper gasket 38. Nut
39. Spring gasket 40. Pad of delivery pump
41. Middle bearing 42. Bolt
43. Pad 44. Bottom cover plate
45. Bolt 46. Fuel quantity control sleeve
47. Spring top seat 48. Plunger spring
49. Spring bottom seat 50. Roller body parts
51. Half-circle bond 52. Camshaft
53. 7505 bearing 54. O ring
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 124 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

55. Adjustable pad 56. Bearing cover

57. Bolt 58 Flame fuel seal
59. Bolt 60. Indicator plate
61. Pull rod sleeve 62. Injection pump housing
63. Screw plug

The overhaul and assembly of injection pump shall be carried out in the clean place and
operating condition. The sequence of disassembly can be referenced as following.
Caution: This work must be undertaken by the skillful worker of professional manufactory.
(1). Clean the surface of injector, check the working status of all handle lever which, turn camshaft
manually, observe visually if it is normal ,drain to empty oil in chamber, make records on file if necessary.
(2). Fix the injection pump on a bracket (if fasten on clamping table, pay attention to clamping part
and force).
(3) Remove technologic plugs on corresponding cylinder roller body individually with inner hexagon
socket wrench.
(4). Remove governor assy.
(5). Remove fuel delivery pump assy. Disassembly and checking if necessary.
(6). Remove bottom plate and seal ring (or seal gasket) (see 43-45 in Fig. 5-3-10).
(7). Remove the bolts of camshaft middle bearing, take out of middle bearing (see 41-42 in Fig.
5-3-10) .
(8). Rotate camshaft. When the individual cam turns to TDC, insert ordinal special tool and put up the
roller body to make it departs from the cam.
(9). Loosen the bolts of bearing seat with the inner hexagon socket wrench, remove bearing seat and
camshaft (see 51-59 in Fig. 5-3-10).
Caution: Note the number and thickness of adjustable gaskets of bearing seat, as shown in Fig.
5-3-11, this set of gaskets is used for adjusting axial clearance (0.05~0.1mm) of camshaft.

Fig. 5-3-11. Adjustable gasket

(10). By means of tool for press assembly roller-body, ordinal press down the roller-body and remove
it (after press down, at first remove the roller-body holder).
(11). Remove plunger orderly (put in clean fuel by sequence for matching to sleeve thereafter) and
bottom spring seat, remove plunger spring, feeding control sleeve and top spring seat.
(12) Remove the cap guard bolts on top part of pump housing and take down the cap guard.
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 125 •

(13). Loosen nuts fitting on flange sleeve, take out of elements of pumping fuel system according to
sequence by special tool. According to sequence number make the partnership with plunger and put in clean
diesel.
(14). Remove the screw sleeve fixing pull-lever by a special tool; take down the pull-lever orientation
sleeve and pull-lever (see 21-24 in Fig. 5-3-10).
(15). Disassemble all parts and components of pumping fuel system if necessary.
(16). Clean and check all of parts, if discovering any lack such as serious wear or clip of precision
couple, distortion and crack), renew corresponding part, all of O rings and seal gaskets shall be renewed.
For assembly of injection pump can refer to reverse sequence of disassembly.
Caution: Plunger couple and delivery valve couple of injection pump are precision components, and
mate individually. When take apart any component, they can not be mixed with each other.
While replace them, be in pairs please. Repairing injection pump shall be carried out in
manufactory.

5.3.4 Fuel injector

1. Function
The working status of injector directly affects the dynamic performance of engine and economic
indicator, temperature of exhaust gas and emission indicator The basic action of injector is that the fuel is
sprayed into combustion chamber with certain quantity and on time in suitable macroscopic condition
(direction of fuel bundle, manner of atomizing shot range etc.) and microcosmic condition (granularity and
distribution) in order to match well with the shape of combustion chamber and combustion mode and form
perfecting combustion process. The Model 236 diesel engines adopt the nozzle that with many nozzles,
small diameter nozzle, big injecting angle and high pressure, which is good fitted with the form and the
combustion mode of combustion chamber, get perfect combustion process and good emission index.
The injector endures the relatively high mechanical- and thermo-load when the engine works,
following the intensification of diesel engine, the work condition becomes increasingly rigorous, so the
requirement for the injector is not only to satisfy high frequency, large fuel feeding and high injection
pressure of the diesel engine, but also to be compact construction, reliability, long lifetime and good
technologic characteristics so on, which put forward higher standard on the design and manufacturing of the
diesel engine.

2. Main parameters
Type: little-inertia, long-model, multi-hole, close-style.
Mounting mode: flange-shield
Mounting length: 90 mm
Injection pressure: 26-0.8-0.5 M Pa ; 28-0.8-0.5 M Pa ; 31-0.8-0.5 M Pa
Number×Diameter of injection drilling：
8×0.29 mm ; 8×0.31 mm
Stroke of needle valve: 0.4 mm
Spray cone angle: 150 degree
Edge-type filters (in injector).
3. Numbering
Numbering of Bosch Corporation
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 126 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

K DE L 90 p 51
---- ---- ---- ---- ---- ----
1 2 3 4 5 6
1. Injector symbol 2. Mounting with flange-shield
3. With edge-type filter 4. Effective encased length
5. Series of nozzle couple component 6. Numbering for design

4. Design feature.
The fuel injector consists of injector body, needle valve couple parts, adjusting pressure spring,
adjusting pressure gasket and edge-type filter etc., its main parts and assembly relationship are illustrated in
Fig. 5-3-12.

Fig. 5-3-12 Injector

1. Injector compl. (No P/N) 7. Thrust rod 1. Injector 2. Flange sleeve
2. Delivery pipe connection 8. Lock pin 3. Botton head stud 4, 5, 6. O ring
3. Fuel leakage hole 9. Nozzle shield 7. Packing ring 11.Gasket for pressure adjusting
4. Gasket for pressure adjusting 10. Valve needle body 12. Compressing spring 13. Thrust rod
5. Injector body 11. Valve needle 14. Locking plate 15. Pump element
6. Compressing spring 12. Locking plate 16. Nozzle shield
Low inertia injector: The trait of the low inertia injector is that the adjustable spring is located at the
middle of injector and near nozzle, so the mass of moving parts as needle tappet is smaller (smaller inertia
force), which abates the strike force of needle to seat surface. The quick open-close move of needle reflects
obvious effect on avoiding the gas flow-back and preventing the adverse factors such as cementations on
nozzle and lock, latter injection of engine etc., at the same time the spring for adjusting pressure is infused
into diesel fuel, that may improve the work condition of spring, but due to the limitation of the dimension in
injector body, and its location is near to heating area, the demand on quality of compression spring is very
strict.
Injector is tightened by press-plate with two bolts; the operation torque must be even and uniform in
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 127 •

order to prevent decline or over load and locking of needle couple.

5. Disassembly and checking maintenance

The seal and agility of precision needle couple in injector may be easily damaged by the extra
exiguous impurity, assembly action force and high temperature.
In Model 236 diesel engine, beside the fuel filter paper element which filtrate effect is very nice, the
high pressure edge-type filter is installed in the fuel inlet drilling of injector. But it can't filter impurity
100%, the fuel and fuel system must be operated and maintained correctly.
In general, when the engine continually operates for 1000 hours or you suspect that the injector is
faulted, check and adjust it please. As Fig.5-3-14
Auxiliaries and rapid wear spare parts Table 5-3-1
Auxiliaries: Clean diesel fuel, pressure air, dilution with grind cream plus lube oil,
aluminum oxide cream.
Tool: spanner S17-14, S10-12, S19-22
Torque wrench 45 Nm, screw driver 8"
Grind tool for seat drilling of injector.
Rapid wear spare Injector gasket 4.236.0.855.807.4 1 piece/cylinder
parts: Fuel return gasket 6.0492.01.0.0610 2 pieces/cylinder.
O ring 6.0493.10.4.0203 1 piece/cylinder.
The steps for disassembly and adjusting
1. Remove the injector；Observe the carbon lay-down on needle.
2. On the checking device for injector (diesel fuel shall be clean), examine the atomizing quality and
pressure of injector by pumping fuel (during injection, the index of pressure gauge rise and wobble).
3. If checking result does not accord with the requirements specified in table 5-3-2, you must
disassemble the injector and check it i.e. put the injector clamp slightly on clamping table, screw down the
nozzle nut, and remove all the parts accordingly.
Checklist for fuel injector Table 5-3-2
Engine type contents demand value bar Limit for repair
Supercharging response pressure 26-5+8 ; 28-5+8 ; 25, 27, 30
engine 31-5+8
About one time injection per second Atomization: uniform, nice, no fuel stopping or
8 injection drilling, dropping
About 2~3 time injection per second Atomization: uniform, nice, no fuel stopping or
dropping, and no buzz noise

4. Clean all of parts in clean diesel fuel pay special attention to the cleanness of the couple parts.
Check the seal-band of needle cone, e.g. if the seal-band width is too large, being in existence of abrasion
sinter, the needle couple components shall be replaced. If there are some carbon lay-down on the needle
head can not use hard metal to scrape. When any injection drilling is clogged, do not permit to modify with
pin or steel wire, which is easy to wound the outer sharp edge of injection drilling, and make the radiation
of atomized fuel. The best method is to repair by electric spark, otherwise replace it with a new needle
couple component.
5. If the carbon lay-down or fuel leakage are taken place, and if the seal band of needle cone isn’t
wide enough, you are allowed to grind the cone of needle and needle body each other, after grinding,
clean them carefully and blow to dry with pressure air( grinding cream is aluminum oxide cream and lube
oil).
6. If the response pressure of needle is less than limiting value, then thicken the adjusting gasket about
0.1mm in general which can increase the response pressure of injection about 10 bar. If in the absence of
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 128 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

one suitable gasket, permit to use two corresponding adjustable gaskets.

Caution: The hardness after heat-treatment of adjustable gasket material is HRC45-52, prohibit from
using general gasket instead.
7. Reassemble it in reverse sequence of disassembly , especially pay attention to clean both sides of
localizer and needle body surface, all of parts shall be directly taken out of clean diesel fuel for assembly,
don't rub out with cloth.
8. Retest injector on checking device until measuring up, otherwise repair again.
9. Rub up the seal surface of injector seat drilling for each cylinder head with screw driver coating
cloth, if it is in existence of burn trace, may use the tool for grinding injector seat drilling and grinding
cream to grind seat drilling seal surface, erase up to clean, paint some 2# lithium-base lubricating grease on
two faces of injector seal gasket, put on injector and fit them into seat drilling.
10. Press O ring into the position under the groove of crown nut with a screw driver and hold down
injector uniformly with press-plate and nut press.

5.3.5 Checking and adjusting the fuel feeding lead angle

Fuel feeding lead angle is an important parameter affecting the combustion process of diesel engine. If
the lead angle is too large, during beginning to inject fuel into combustion chamber, the temperature and
pressure of air in cylinder aren't higher; the fuel can't burn and accumulate in the space of cylinder. When
the temperature of air in cylinder is risen up to the fuel ignition point, a great lot of fuel burn at same time,
so the maximum ignition pressure appears near TDC which makes fuel burning roughly, the ignition
pressure increases, knock-cylinder noise and severe vibration take place. If lead angle is too small, the fuel
begins to burn when the piston is moving toward below, the temperature and pressure fall, so the
combustion process evolves slowly, although the combustion process is smooth and the ignition pressure is
reduced, but it not only reduces the economic property, but also makes the exhaust temperature quick rise
with bad combustion and engine emits black smoke due to burning delay (latter combustion).

Drawing 5-3-14 injector mounting

1. Hexagon nut M14×1.5 (20+5 N·m)
2. Round nut M8×60-10.9 (15+5 N·m)
3. Shield nut (48+2 N·m)
4. Packing ring (2mm )
Fuel feeding lead angle of 236 series engine Table 5-3-3
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 129 •

Item
Injection Pump type Fuel feeding lead angle (ºCA)

S1000pump 26±0.5

S7100pump 22.5±0.5

The method for checking and adjusting:

Auxiliaries and rapid wear spare parts Table 5-3-4

Auxiliaries Clean diesel fuel,
Tools Special capillary, spanner S19, wrench S17, tool for
disassembly valves
Rapid wear spare seal pad of cylinder 4.236.0.855.105.4 1 piece/cylinder
parts head cover,

1. Checking steps (method of capillary):

(1). Open the observation hole of the flywheel housing, dismantle the cylinder cover of the standard
cylinder (cylinder B3 of V6, cylinder B4 of V8, cylinder B6 of V12), remove the injection pipe of the
injection pump of the cylinder, mounting the fuel injection timer.
(2). Engine barring to the zero margin line of the flywheel and line up with the pointer of the observation
hole of the flywheel housing, touch the push rod of the inlet/outlet valve of the cylinder, if it can be rotated,
means it is the upper dead center of the compressing stroke, if it can not be rotated, go on barring the engine
360° to the upper dead center of compressing stroke.
(3) Engine barring as far as the capillary of the fuel injection timer inject outward and without air bladder,
then discharge some fuel, make the oil level on the middle of glass pipe; reverse the crankshaft
(anti-clockwise) to the front 35°of the top dead center, then ahead engine barring (clockwise), if see the oil
level of the capillary of the injection pump rise suddenly, stop rotating, check whether the dial of flywheel
compressing to the front 26° of the top dead center (1000-type injection pump is 26°, 7100-type injection
pump is 22.5°), if it is, needn’t to adjust, if it isn’t, or when new mounting, overhaul, check the injection
pump, should adjust the following steps:
(4).Reverse engine barring (anti-clockwise from front end) 35°, then ahead engine barring (clockwise from
front end) to the front 26° of the top dead center (1000-type injection pump is 26°, 7100-type injection
pump is 22.5°), screw off the 2 nuts of the driving side of the injection pump coupling.
(5). Reverse engine barring (anti-clockwise) by spanner, then rotate the camshaft (coupling driven end) of
injection pump according to clockwise (from front end) make the oil level rise in capillary, stop right away.
(6).Carefully screw on the loosing nut and screw of coupling to tight by 2 S19 spanners.
(7). Re-check the fuel feeding lead angle according to step 3, as far as comply with the requirement of form
5-3-3.
(8). Dismantle the fuel injection timer, re-mount injection pipe, cylinder cover and observation hole cover
of the flywheel.
Caution: This operation must be carried out by skilful workers.

5.3.6 Speed governor

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 130 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

1. Numbering mark
Bosch Cop. governor numbering
EP / RSUV 300-750 P10 A 320 D R
--- --- --- --- --- --- --- ---
1 2 3 4 5 6 7 8
1. Injection pump symbol. 6. Numbering of transmutation
2. Speed increasing and full speed type 7. Numbering of design
3. Minimum speed 8. Calibrating mechanism
4. Maximum speed 9. Mounting position
5. Speed emendation

Chinese governor numbering (GB10177-88)

TP J 300-750 P E Y 420
--- --- ---- --- --- ---- ----
1 2 3 4 5 6 7
1. Governor. 5. Injection type
2. Mechanical type 6. With regulator
3. Minimum speed 7. Added device
4. Maximum speed 8. Numbering of design

2. Design feature
The RSUV type speed governor is the mechanical, speed increasing, and full speed type. By means of
changing transmission rate of speed gears, it may suit the matching requirements of middle- and
low-speed diesel engine. The main structure consists of driving gears, centrifugal flyweight component,
lever system, governor spring set, and front-rear housing component, shown As Fig.5-3-15.
(1). driving gears: It consists of drive gear and driving gear shaft. The drive gear is matched with rear
end of camshaft, driving gear shaft is supported by two ball bearings in front housing, and its extended end
is inserted into the flyweight guiding frame.
(2). Centrifugal flyweight component: It consists of flyweights, weight guiding flame and slide piece.
The rotation of camshaft by means of gears is transformed to centrifugal force, Based on the opening size of
weights, the slide piece on weight moves parallel, and pushes the slide sleeve (cross-head piece) on the
below end of lever system to move and drive lever system.
(3). Lever system: It chiefly consists of swivel lever; tension lever, guiding lever, and linkage (see Fig.
5-3-15, Fig. 5-3-16). The swivel lever is fitted on the pin-shaft of middle of guiding lever, its below end is
inserted in stopping forked –lever, and linked with stopping handle, and the upper end is connected with
feeding pull rod of fuel injector via linkage. The upper end of swivel lever through linkage is connected
with feeding pull rod of injector, the starting spring is fitted on the top of swivel lever (other end is hang at
the front housing). Cross-head slide sleeve is mounted on the below end of guiding sleeve and driven by
flyweight centrifugal force, its upper end and tension lever altogether hanged with pin-shaft on the upper
part of governor rear housing. The below end of tension lever is supported thrust of cross-head piece, under
full load operating condition tension lever is stand at the full load limit bolt, the governor spring is hang at
the middle.
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 131 •

1. Linkage,
2. Starting spring
3. Swivel lever,
4. Tension lever,
5. Controlling lever,
6. Starting idling limit,
7. Governor spring,
8. Supplementary idling spring,
9. Guiding lever,
10. Idling speed and load spring,
11. Full load limit piece,
12. Centrifugal flyweight,
13. Governor cover,
14. Governor housing,
15. Drive gear.
Fig. 5-3-15 The longitudinal section through speed governor
(4). The governor spring component：It mainly consists of governor spring, swivel lever（external to
connect governor handle），and governor bolt etc., the governor spring is the chief part, its below end hangs
on the tappet of tension lever, upper end on the rocker arm of swivel lever. Under the stable operating
condition the force of governor spring is balanced by centrifugal force of flyweight, one end of swivel
extended out of rear housing is fitted on the governor handle. The different positions of handle pay out
dissimilar spring forces, these forces are matched with centrifugal forces produced by the flyweight. The
governor screw is fitted on the swivel lever, following the screw-in position the different compress force of
spring can be gained by adjusting governor speed drop.
(5). Front-rear housing components: Front housing is mounted on the fuel injector body with bolts. At
outer side surface is fitted the maximum speed limit bolts. On the rear end surface of rear housing is fitted
idling speed screw set, supplementary idling spring. The governor handle and stopping mechanism are fitted
on the side surface, the filling limit screw for adjusting fuel quantity is installed on the inner below end, the
pin-shaft for hanging clever parts is fitted on the upper end, the front and rear housings are connected with
bolts.

1. Starting spring,
2. Governor handle,
3. Swivel lever,
4. Tension lever,
5. Stud bolt,
6. Cross-head piece,
7. Flyweight,
8. Spring rocker arm,
9. Governor spring,
10. Feeding pull rod,
11. Starting,
12. Full load, 13. Idling speed 14. Stopping
Fig. 5-3-16 starting operating condition
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 132 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

3. Operating principle
(1). Starting operating condition: As show in Fig.5-3-16, governor handle is in free manner, the below
end of tension lever is depending on the stud screw (full load limit screw), flyweight state is in closing
manner. The starting spring force is strong enough to push the feeding pull rod to the maximum feeding
position, once the engine is stared, the starting spring is elongated by the action of flyweight centrifugal
force, and feeding lever moves quickly to decrease-feeding direction.

1. Starting spring,
2. Governor handle,
3. Swivel lever
4. Tension lever,
5. Supplementary idling spring,
6. Flyweight,
7. Feeding pull rod,
8. Stopping,
9. Idling speed,

Fig. 5-3-17. Idling speed operating condition

(2). Idling speed operating condition: As shown in Fig, 5-3-17. The governor handle is depending on
the idling screw (really leaning on the rocker arm nose of swivel lever), Governor spring is similar to the
vertical position, flyweights splay quickly by means of pull rod system, the feeding pull rod moves to
decrease-feeding direction, the tension lever is separated from the stud screw, until that the flyweight
centrifugal force and governor spring force as well as the supplementary idling spring and with the starting
spring are balanced. At this time, diesel engine is running at idling speed.
(3). Part and normal operating conditions: As shown in Fig.5-3-18. The governor handle is against the
maximum speed limit screw (it is adjustable according to various engine operating conditions), the pull
force of governor spring increases, tension lever is depending tightly on stud screw, by means of lever
system to make the feeding increase, keep it on the full load position, the centrifugal force of flyweight is
balanced with spring force, diesel engine is running stably at normal operating condition.
(4). Maximum idle speed operating condition: As shown in Fig. 5-3-19. The diesel engine is running
at normal operating condition, when speed is rising, the centrifugal force of flyweight is increased, first of
all, it overcomes the force of spring, and pushes tension lever to move backwards and to compress idle
supplementary spring, and to drive the feeding pull rod to the decrease-feeding direction until the
centrifugal force is balanced by with the spring force. At this time, the engine speed is at the maximum
idling speed, if this speed is over stated value, then it is necessary to adjust the handle position.
1.Governor handle
2. Swivel lever,
3. Guiding lever,
4. Tension lever,
5. Stud bolt
6. Cross-head piece,
7. Flyweight,
8. Governor spring
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 133 •

9. Feeding pull rod,

10. Stopping,
11. Full load,
Fig. 5-3-18. Partial operating condition
(5). Stopping operation condition; show as Fig, 5-3-20. Stopping handle is fitted on governor side
surface, press down stopping handle, by means of forked lever to control swivel lever pulling the feeding
pull-lever to stopping position, this situation is independent of flyweights and governor handle position. So
at any operating condition, if press down the stopping handle, can all make the engine stopping
.
1. Swivel lever,
2. Guiding lever,
3. Supplementary idling spring,
4. Tension lever
5. Stud bolt,
6. Flyweight,
7. Governor spring
8. Feeding pull rod,
9. Stopping,
10. Idling speed

Fig. 5-3-19. Maximum idling speed operating condition

1. Governor handle,
2. Swivel lever,
3. Guide lever,
4. Tension lever,
5. Stopping handle,
6. Flyweight,
7. Governor spring
8. Feeding pull rod,
9. Stopping,

Fig. 5-3-20. Stopping operating condition

4. Disassembly, checking and assembly

The main parts and its assembly relationship are shown in Fig.5-3-21.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 134 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig. 5-3-21. Governor disassembly figure

1. Locked ring for shaft. 2. Bearing. 3. Locked ring for hole
4. Adjusting gasket 5. Flyweight component 6. Spring gasket
7. Camshaft nut 8. Sliding sleeve 9. Bearing.
10. Adjusting gasket. 11. Guide lever. 12. Linkage
13. Starting spring 14. Ringent pin 15. Swivel lever
16. Forked lever pin 17. Stopping fork lever 18. Spring rocker arm
19. Adjusting spring 20. Gasket on rear housing 21. Rear housing
22. Gasket 23. Spring gasket 24. Screw plug
25. Bolt 26. Ringent locked ring 27. O ring
28. Shaft sleeve for rocker arm 29. Plug 30. Idling speed limit bolt
31. Copper gasket . 32. Nut 33. Copper gasket
34. Cap nut 35. Screw sleeve. 36. O ring
37. Torsion spring 38. Cap housing 39. Stopping handle
40. Gasket 41. Spring gasket. 42. Bolt
43. Gasket 44. Supplementary idling spring 45. Nut
46. Copper gasket 47. Cap nut 48. Gasket on rear cover
49. Rear cover 50. Copper gasket 51. Screw plug .
52. Bolt 53. Gasket 54. Nut
55. Bolt 56. Spring gasket 57. Gasket
58. Ringent locked ring 59. O ring 60. Rocker arm sleeve
61. O ring 62. Gasket 63. Half-circle bond
64. Governor handle 65. Screw plug 66. Tension lever shaft
67. Tension lever 68. Stud bolt 69. Ringent pin
70. Half-circle bond 71. Driving gear wheel 72. Bearing
73. Orientation sleeve 74. Bolt 75. Spring gasket
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 135 •

76. Gasket 77. Bearing seat 78. Plug

79. Front housing 80. Nut 81. Maximum speed limit bolt
82. Gasket 83. Spring gasket 84. Bolt
85. Drive gear 86. Spring gasket 87. Camshaft nut
88. Bolt 89. Spring gasket
The disassembly steps of governor can refer to the following process.
Caution： This operation must be carried out by skilful specialist of professional factory.
(1). The work of disassembly shall be operated in clean condition, at first clean its outer surface,
check the position of all handles, drain empty lube oil in chamber.
(2). Loosen the bolts on rear housing cover, remove rear cover (49-53, in Fig. 5-3-21) loosen the
clamping bolts of front-rear housing to separate them (don’t take it down).
(3). By using screw driver press down spring-piece connecting linkage and feeding pull rod, poke
pin-shaft (see item 12 in Fig. 5-3-21), by use of pliers, take away starting spring from the front housing
(remove rear housing component).
(4). Loosen and remove idling supplementary spring set and nuts of idling limit screw set.
(5). Loosen screw plugs on double sides of rear housing, reel off the tension lever shaft (see 65,66
in Fig 5-3-21), remove tension lever, lever parts system (11,67 in Fig. 5-3-21) and governor spring.
(6). If necessary remove governor handle (64 in Fig. 5-3-21), locked ring and sleeve on two sides
of rear housing, remove swivel lever (see 58-63,18 in Fig.5-3-21).
(7).Unscrew the camshaft nuts of drive- and driving gears with special tool (7, 87 in Fig 5-3-21).
(8) Remove flyweight component with special tool.
(9). Loosen bolts on bearing cover of driving gear (see 74-77 in Fig 5-3-21), remove drive- and
driving gear shaft components with special tool..
(10) Remove stopping handle device from rear housing (see 35-42 in Fig. 5-3-21).
(11). If necessary, loosen the bolts connecting the front housing and pump body, remove the front
housing.
(12). After disassembly check all parts and components, if it is in existence of severe abrasion,
distortion or crack etc., it shall be replaced. Generally, all O-shape rings and seal gaskets shall be replaced
without exception.

Caution The common fault of governor is the rubber breaking on the driving gear 85 caused by
the abrasion of the bearings 72, 2, 9. During disassembly and checking, by all means avoid removing other
part or component, but permit to clean it in the diesel fuel carefully.
For assembly steps of governor may use the reverse sequence of disassembly steps as a reference
5. Adjusting
Adjusting for governor is carried out based on technical demand to diesel engine; generally this work
is carried out through injection pump test-bed with injection pump together (part items must be carried
out on diesel engine, also may give a reference to adjusting method mentioned below), before testing a
quantitative oil shall be fed into the governor.

a. Feeding pull rod position

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 136 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

b. Speed

Fig.5-3-22. Adjusting characteristics curve

The adjusting characteristics curve of governor RSUV is shown in Fig. 5-3-22.
SM ------Starting feeding position
SA -------Normal load feeding position
SB -------Maximum idling speed feeding position
nB ------- Maximum idling speed
nA --------Normal speed
nM --------Idling speed
(1). Affirming the Zero-location of the feeding pull rod: Set the trechometer for feeding pull rod,
unscrew idling speed limit bolt, turn governor handle toward decrease-feeding direction, accelerate the
rotating speed of the test-bed, make the flyweight splay (flying operation), at this time the position of
feeding pull rod is the zero-location.
(2). Mark the feeding quantity----adjustment of the full load limit bolt:
When the governor handle is lean against the maximum speed limit bolt, test-bed speed is adjusted to
normal speed nA, check the displacement of feeding pull rod, whether it is on the normal load feeding
position SA (i.e. Check the feeding quantity), if not, adjust the full load limit bolt: screw-in (clockwise) is
increased-feeding, screw–out (counter clockwise) is decreased-feeding.
(3). Adjustment of the acting speed:
Put the governor handle against the maximum speed limit bolt, check the acting speed nA (normal
maximum speed) whether it is in accordance with the requirements, if not, adjust the maximum speed limit
bolt, please. So called the acting speed (nA ) is that when test-bed speed exceeds over nA a little (for general
about 10-15 revolutions),and then the feeding pull rod begins to move toward decrease-feeding direction.
The acting speed evidently influences the diesel engine’s operation.
(4). Adjustment of the speed drop (called also governor speed rate):
When the test-bed runs at speed over nA, the governor is acting to move the feeding pull rod from SA to
SB (maximum idling speed position ), at this time the speed drop is decided by nB (maximum idling speed ):
The calculation formula is
δ = (nB- nA ) / nA *100 %
If the speed drop does not accord with the requirement, adjust the governor bolt on swivel lever (when
this operation is carried out, at first the idling limit bolt shall be screwed out).
Screw-in (clockwise) the governor bolt ----decrease of speed drop (nB).
Screw–out (counter clockwise) ----increase of speed drop (nB).
Caution: After screwing the governor bolt, the governor spring force is changed too, the acting speed
nA is also changed correspondingly, so recheck it again. If necessary, adjust them repeatedly until the
demand is satisfied.
(5). Adjustment of the idling speed operating condition
When the governor handle is lean against the idling speed bolt through swivel lever, the test-bed speed
is adjusted to nB , adjust the idling speed limit bolt, put the feeding pull rod at SH position (than SB higher a
little), namely the idling speed feeding quantity of diesel engine. Screw in the supplementary idling limit
bolt to make the spring-end contact with tension lever, then screw-out one cycle and lock it tightly (the
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 137 •

generator engine shall be adjusted when it is at the maximum idling speed ).When screw in the idling-speed
limit bolt, the fuel feeding quantity is increased, and contrarily the fuel feeding quantity is decreased.
After adjustment, check the fuel feeding quantity, active speed, and maximum idling speed again If
necessary, adjust it repeatedly until all requirements are satisfied.
(6). Check and adjustment of the for the stopping device
Whenever turn the stopping handle, the injector shall stop fuel supply, if any unconventionality
appears, check the corresponding parts please.
Caution！. The abovementioned adjustment must be carried out on the engine test-bed carefully.

6. Accessional devices:
(1). Corrector. As shown in Fig. 5-3-23, the corrector is fitted on the below end of tension lever,
when the engine speed is lower than normal speed, the tension lever
is pulled tensely against the stud bolt, the crosshead piece of
corrector is pushed gradually by spring tappet, and the feeding pull
rod is driven to move toward the increase-feeding direction, the
distance “A” of tappet holding out of tension lever is the corrector
journey. The injection pump increases the feeding quantity
corresponding to the displacement of feeding pull rod “A”. The
corrector mounting on the vehicle is also called “torque
supplementary spring”.
(2). Supercharging pressure compensator is called smoking
restricting element too, as shown in Fig, 5-3-24, it is mainly used on
vehicle supercharging diesel engine. Fig. 5-3-23 Corrector

1. Screw pinion, 2. Pad,

3. Governor cover, 4. Lever,
5. Starting spring, 6. Governor housing,
7. Control lever, 8. Bending lever,
9. Control shaft, 10. Guiding sleeve,
11. Compression spring,
12. Film piece,
13. Connection for supercharging pressure tube.

Fig.5-3-24.Supercharging pressure compensator

During operating at lower speed or load, when the accelerator is increased suddenly, the diesel engine
without installations of the smoking restricting element can't increase the supercharging pressure at once,
which make much more fuel to be added into the combustion chamber very quickly, but the air in the
combustion chamber is thin, so that the bad combustion is brought into being existence. If the smoking
restricting element is installed on the engine, when supercharging pressure is shortage, the bending lever is
kept static to limit the accelerator to rise. When supercharging pressure is increased, the film is acted by
supercharging pressure and extruded to below, push the spring to move down and drive the bending lever to
turn (the size is decided by supercharging pressure) and break away the limit, so the feeding pull rod can
move freely and control feeding quantity. It is obvious that the smoking restricting element is effective on
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 138 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

nicer match of fuel and air; it can make the engine smoking-grade, acceleration, and power etc. optimum.
7. Electronic speed governor:
When the requirement for the technical index of generator set is higher (the 2nd class or 1st class
generator station), the electronic speed governor must be selected: comparing the electronic speed governor
with the mechanical speed governor, it reflects better speed governing properties, simple drive-mechanism,
and simplified automatically control. Electronic speed governor chiefly consists of speed sensor, controller,
executor and speed adjusting potentiometer, as shown in Fig. 5-3-25.

1. Speed sensor,
2. Controller,
3. Ball-ties,
4. Bearing,
5. Adjusting lever,
6. Speed control potentiometer,
7. Executor.

Fig.5-3-25. Disassembly illustration for electronic speed governor

Operating principle: The rim gear of fly-wheel incises the inner magnetic stick magneto-line of speed
sensor，the solenoid on magnetic stick inducts and produces alternate pulse voltage signal（ its frequency is
direct ratio with speed ）. Comparing this voltage signal with the voltage signal corresponding to the speed
value set by speed adjusting potentiometer. Its different value is controlled and adjusted by means of
proportional-，integral- and differential-electro circuits，and after difference amplification input to executor，
the direct current servo-motor in executor turns toward positive or negative direction corresponding by the
sign of voltage signal，and through lever system to control the rack of engine injection pump to move
toward increase-or decrease-fuel direction，thus controls the engine to operate stably at the setting speed.

Caution: The electronic speed governor has been debugged ex works, in operating process, the user
can't adjust it optionally. If the fault takes place, and need to be checked and adjusted, it must be carried out
by the people trained specially, to avoid influencing the governing precision, even the normal operation of
the engine.
The equivalent positions of two ends of speed adjusting potentiometer switch are in correspondence
with the idling speed and normal speed. During starting diesel engine put the switch on idling speed i.e. left
position. After starting, based on the demand once more adjust the switch to the speed needed by means of
manual or electrical remote control. Manual speed switch shall be turned slowly and equably. For automatic
generator station or emergency power supply, if there is special demand, may set up the idling at normal
speed. But before starting engine, must warm up the engine to stand by status.
The electric source for electronic speed governor shall be DC 24V power supply; electric voltage is
undulate less than 10 %. Don't use the DC electric source rectified from AC electric source, and don't use
the same electric source together with starting storage battery for preventing undulate and unstable
operation.
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 139 •

The electronic speed governor is provided in a complete set with appropriative cable, it has been well
debugged before delivery, the user shall not replace its main transmission cable, or intermixed with
electronic speed governor else.
During the normal stopping screw the speed adjusting potentiometer toward minimum position counter
clockwise, if in the case of emergency, stop engine, and cut off the power supply directly..
The lever system between electronic speed governor and injection pump shall not be in existence of
the clearance or loosing in adjusting process, and move flexibly without lock or stagnant phenomenon. In
four ball-ties and bearings in the lever shall be cleaned and painted with the molybdenum disulfide lithium
saponified grease periodically to ensure no clearance and locked or stagnant phenomenon occur(if the
clearance exists, it shall be eliminated by adjusting bolt).

5.3.7 Fuel filter

1. Function:
Fuel filter is an important component for ensuring fuel system clean and even normal operation of
diesel engine. Beside the fine-filter fitted in engine fuel system, the external fuel system must be equipped
with the pre-filter, on the one hand, it increase the fuel cleanness, and on the other hand, it prolongs the
service life of the fine-filter.
The marine fuel pre-filter had better to posse the fuel-water separating function
2. Structure:
(1). Single cartridge fuel filter

1. Filter assembly
2. Filter head.
3. Filter cartridge.
4. Bleeding bolt.
5. Seal gasket
6. Pipe connection bolt.
7. Seal gasket.

Fig. 5-3-26. Single cartridge fuel filter

There is a rectangular section O type gasket between the filter head and the filtering cartridge,
connected by the threads in the middle of oil outlet.
The structure of the filter is simple. The filtering cartridge can’t be washed for it is disposable
structure. stop the machine before replacement When replacing the filtering cartridge ,the new one must
be full of fuel. In installation process, make the filter cartridge screw into the head until gasket ring contacts
and use the hand to screw down 1/2 ~ 3/4ring.
The filter head has a vent screw. Before starting, manually draw up the pre-fuel injection pump;
loosen the vent screw until there is no air in fuel.
(2)Dual fuel filter, reversible
When the diesel engine is working, both fuel reversible filters shall be used at the same time. Under
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 140 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

low load operating condition, its filter element may be replaced. When replacing, the filter element, it shall
be soaked in fuel. And exhaust all the air after the installation.

1 Dual fuel filter,reversible

2 Mid-body 3 Cover
4 Airfoil screw
5 Packing ring
6 Stud 7 Stud
8 Handhold 9 Check ring
10 Spring seat 11 Spring 12 O
ring
13 Revolving valve
14 O ring
15 Spring
16 Spring seat
17 Filter element
Fig.5-3-27 Dual fuel filter, reversible 18 Packing ring
19 Cover 20 Screw 21 Exhaust screw

3. Disassembly and assembly of the dual fuel filter:

(1) Screw off the airfoil screw 4, remove cover 3 and its gasket;
(2) Screw off screw 6 and 7, remove mid-body 2 and packing ring 5;
(3) Screw off screw 20, remove cover 19 and packing ring 18, take out the filter element 17;
(4)Remove handhold 8;
(5)Take off check ring 9, take out spring seat 10, spring 11 and its washer, revolving valve 13, O
ring 12,14; Check scuffing of the cock and seat holes to ensure leak proofness by grinding,. O
ring shall be replaced with a new one.
(6) Assemble them in the opposite order

5.3.8 High-pressure fuel pipe

1. Functions:
Fuel high-pressure pipe connects injection pump and fuel injector. The Fuel high-pressure pipes of
236 Series of Diesel have the same length and different bend shapes. The Figure below shows the
connecting method of the injection pump and each cylinder.
Flywheel end
6 cylinders engine 8 cylinders engine 12 cylinders engine
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 141 •

Fig.5-3-28 the connection of injection pump and fuel injector

2. Notes on installing the fuel high-pressure fuel pipe:

(1)Wash the inside and outside of pipes
(2)Install pipes in the right connecting order and make sure each plunger delivery valve connects to
its fuel injector
(3)When screwing down, the cap nut of the Fuel high-pressure pipe it shall be screwed to the end by
hand easily and screw it down but not too tight. Its moment is 25-35Nm.
(4)You must install the clamps of fuel high-pressure pipes on the air inlet pipe to avoid vibrating
damage
(5)No contact between pipes and keep 2mm interval to vibrating abrasion
Caution!
Have to use N.0 or N.-10 diesel, which accords with The National Quality Index GB252-94 of light
diesel fuel.

5.3.9. Drive mechanism of injection pump

1. Functions:
Drive mechanism of injection pump is installed in the median septum between the forward end
cover and the engine block. It is driven by camshaft gear. Its function is to hold the parts of injection pump,
to pass the power of the gear train to drive injection pump.
2. Structures
Injection pump’s structure has two kinds: one is the slice shaft coupling, which is used by the
general nature air admission diesel and supercharged diesel engine(less than 2200r/min);the other is the
crowned teeth shaft coupling, which is used by supercharged marine diesel engine (more than
2200r/min).Both of them have few differences to their structures.
The two different structures of injection pump are shown in Fig.5-3-29 and Fig.5-3-30.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 142 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig.5-3-29 Drive mechanism of injection pump with the slice shaft coupling
1 Drive mechanism of injection pump assy 2 Case 3 Shaft 4 Bearing
5 Bearing 6 Check ring 7 Radial self-adjusting gasket ring
8 Woodruff key 9 Gear 10 O type gasket 11Pin
12 The slice shaft coupling 13 Connection strap 14 Spacer flange
15 the slice shaft coupling 16 clamping screw

Fig.5-3-30 Drive mechanism of injection pump with teeth shaft coupling

1 Drive mechanism of injection pump assy 2 Teeth shaft coupling 3 Shaft 4 Bearing
5 Case 6 Check ring 7 Stuff ring 8 Bearing 9 O type gasket
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 143 •

10 O type gasket 11 Stuff ring 12 Gasket ring 13 Blocking nut

3. Disassembly an installment
Here mainly introduces the disassembly of the slice shaft coupling.
Supplementary materials and rapid wear spare parts list
List 5-3-1
Supplementary Diesel oil ,hairbrush, industry lithium grease, bell stuff sealant, sealant
materials 7304, thread locking-fixing sealant
Tools A suit of standard tools、internal lock ring forceps（big）, hand lead,
aluminum bar φ 25, screwdriver 6”
Rapid wear Billet（shaft 6.0690.40.3.0004 12 slice/ table
equipment coupling）
Big rolling bearing 6.0320.04.0.6011 1/ table
6011
Small rolling bearing 6.0320.04.0.6206 1/ table
6206
Radial gasket ring 6.0496.01.0.6040 1/ table
O type gasket 6.0493.10.4.0803 1/ table
Gear 6.234.0.371.015.4 1/ table
Woodruff key 6 × 10 6.0235.20.0.6010 1/ table
The disassembly and check of drive mechanism of injection pump with the slice shaft coupling
(1)Take off forward end cover
(2)Loose clamp screw 16 (As Fig.5-3-29 )and use the screwdriver to separate the shaft coupling15 a
little;
(3)Back off drive mechanism of injection pump from the median septum
(4)Disassemble drive mechanism of injection pump (Fig.5-3-29)
1. Screw out binding bolts of the gear , pull out the gear
2. Crack off elastic collar6 and Woodruff key 8;

3. Use the core rod (≤ φ 25mm) to push the shaft out of the case

4. If sealing strip of radial self adjusting seal 7 is damaged, worn, remove the radial self adjusting
gasket ring and replace it;
5. Use the core rod ( φ 40-50mm) to force the bearing 5 out of the case and check the flexibility of the
bearing’s rolling and it has no jamming, otherwise replace it.
6. Set up the shaft of bearing 4 and use the core rod to cog own the shaft 3 to separate the bearing and
the haft. Check the flexibility of the bearing’s rolling and make sure it has no jamming, otherwise
replace it.
Installation：
(1)Assembly of drive mechanism of injection pump:
1. Heat the two balling bearings up to about 100 ℃ and suit them to the shaft
2. Dip the case of drive mechanism of injection pump into the oil bath or electrical heating container
and heat it to 100℃-150 ℃. Smear N.2 lithium soap base grease on the bearings in right mount
and insert elastic collar(lock ring);
3. Smear some lubricating grease in the inner ring of radial self adjusting seal ,suit it to the shaft and
use the sheath press it into the case carefully ,parallel to the end
Caution!
Smear bell stuff sealant outside of the seal ring and press it in stably to make sure self tightening spring
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 144 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

not drop out.

4. Install the elastic pin and the gear and tighten them up with the bolt. The bolt screw moment is
85-90Nm and smears some sealant to lock and hold.
(2)Install drive mechanism of injection pump, which has the gear, in opposite disassembling order
Caution!
The position of the gear of drive mechanism of injection pump: co rotate the shaft until timing gear in
the shaft and the “O” mark position of the camshaft middle big gear are adjusted well according to the
request of the tooth gear. Make teeth with “O” mark of timing gear and two teeth with “O” mark of the
camshaft middle big gear mate and make the teeth with “O” mark of drive mechanism of injection pump’s
gear and the teeth in the middle gear strip of camshaft mate. Screw down fixing nut and replace its washer.
Suit driving disc shaft coupling to the shaft and hold by the clamp screw.
4. Replace the slice of shaft coupling (Fig. 5-3-31)

1 Bolt
2 Clamp screw
3Flange of shaft
coupling
4The joining slice
5 Flange shaft
6 Bolt

F
ig.5-3-31 The joining
slice of shaft coupling

Steps:
(1)Mark double end flange of shaft coupling at same direction;
(2)Screw out bolt 1;
(3)Loose clamp screw 2, separate flange 3 a little by the screwdriver and push flange 3 in the direction
of arrow;
(4)Screw out bolt 6, pull out flange 5 and the joining slice (flange 5: long of the cylinder 12, only a
flange in the cylinder 6 and 8, no shaft) and replace the joining slice;
(5)Screw out the bolt of high-pressure oil pump ,push high-pressure oil pump back a little and replace
the joining slice 4.The function of this method is same as 3;
(6)Install in the opposite order and assure identical to marking position;
Caution!
1. The half-circle of two ends of shaft coupling must have an angel of 180 between the cylinder 6 and 8
and are in the same direction in the cylinder to assure injecting in compression stroke.
2. After dismounting drive mechanism of injection pump or replacing the joining slice adjust advance
angle of fuel supply, please;
3. The moment of binding bolt of the joining slice is 100-110Nm;
4. 6 joining slices are a group. Their surfaces ought to be clean and flattening and replace them
according to the direction marks all together. After 4 screws are tightened up (it will be easily broken
due to uneven stress), they can not be bend, protruding, position the bush and its ring, otherwise
HND Section 3 The Structure of the Fuel System and the Overhaul and
MWM Assembly of Its Main Components • 145 •

untie the bolt and reassemble them.

 HND Section 4 The Structure of Lubricating System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 147 •

5.4 The Structure of Lubricating System and the Disassembly, Overhaul and Assembly of
Its Main Components

Fig.5-4-1 Sketch Map of the Lubricating System

1 Turbocharger 2 Injection pump 3 Tappet 4 Rocker arm 5 Valve push rod

6 Piston 7 Camshaft 8 Crankshaft 9 Lube oil pump 10 Cooling jet
11 Lube oil filter 12 Lube oil cooler 13 By-pass valve (cracking pressure: 0.6Mpa)
14 Pressure reducing valve (cracking pressure: 0.6Mpa) 15 Lubricating path to cam tappet

1. Function:
Diesel lubricating system continuously sends cleaning lube oil with certain pressure and temperature to
every friction surface and parts demanding for cooling, avoiding dry wearing and moderating wear of parts,
and takes away heat from friction and washes abrasive dusts and impurity in friction surfaces. It can assure
each part work well.

2. Structure:
Directions of lube oil flowing in lubricating system show as below:
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·148· the Disassembly, Overhaul and Assembly of its Main Components MWM

1. Injection pump 2. Pre-pump 3. Main oil line 4. Turbocharger 5. Nozzle oil line Bank B

6. Each oil line stopping 7. balance shaft 8. Main bearing seat 9. Camshaft

10. Main shaft diameter 11. sliding tappet 12. Push rod 13. Rocker arm

14. Connecting rod bearing diameter 15. Piston assembly, cylinder liner

16. Piston Bank B 17. Piston Bank A 18. Nozzle Bank B 19. Nozzle Bank A

20. Nozzle oil line Bank A 21. Pressure reducing valve 22. By-pass valve

23. Oil pump 24. Oil cooler 25. Oil filter

Caution!
Diesel with hand-operated or electric pre-fuel-supply pump has to supply fuel in advance before
starting until it builds fuel pressure (not less than 2 min).

3. Composition:
Lubricating system: lube oil pump, lube oil filter, lube oil cooler, by-pass valve, some oil ducts and oil
pipes.

5.4.1 Lube oil Pump

1. Composition:
Lube oil pump is also gear pump.
The composition shows in Fig. 5-4-2.
 HND Section 4 The Structure of Lubricating System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 149 •

1 Driving gear 2 Pump case

3 Oil pump gear 4 Bearing bush

Fig.5-4-2 Lube oil Pump

2. Disassembly, overhaul and assembly:
If oil pressure is low and the pressure has not yet boosted up after excluding other possible reasons, you
can overhaul lube oil pump to check wearing condition. Lube oil pump must be replaced or overhauled when
general overhaul comes.

Supplementary Materials and Rapid Wear Spare Parts

Table 5-4-1
Supplementary Diesel, sealant 7304, hairbrush
materials
Tools Spanner 10-12, spanner 13
Rapid wear spare O ring (inlet of pump) 6.0493.10.6.0353 1/set
parts O ring (inlet of pump) 6.0493.10.6.0204 1/set
Lube oil pump (v8) 6.234.0.730.004.6 1/set
Lube oil pump (V12) 6.234.0.730.700.6 1/set
Disassembly of the whole pump:
The disassembly of lube oil pump is very convenient. After dismounting front end shield, remove 3 bolts
used to fix lube oil pump and 2 bolts of oil suction pipe, then the whole lube oil pump can be disassembled.
Caution!
O-ring doesn’t drop off.

The gear backlash between front end gear of crankshaft and driving gear of lube oil pump should be
0.1-0.2mm when assembling. It can be achieved by loosening bolt and moving lube oil pump.

Overhaul of lube oil pump:

Lube oil pump must be replaced or overhauled when general overhaul time comes.
Overhaul items are shown inset 5-4-2.
Overhaul of Lube oil Pump
Table 5-4-2
Order Check items New Limit Repair
number installing of method
request wear
(mm) (mm)
1 Gear of lube oil pump and the 0.08-0.155 0.20 Overhaul: replacement or
axial float mm (test axle head grinding mend subjects to
by dial indicator) wear condition, the gear
should reach new installing
request after installed.
2 Radial clearance between the 0.02-0.054 0.08 Push down bearing bush and
shaft and bearing bush (mm) replace it.
3 The gear of lube oil pump Replace it.
wears seriously.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·150· the Disassembly, Overhaul and Assembly of its Main Components MWM

4 Driving gear wears seriously. Push it down and replace,

heat it evenly up to 220-270
℃ when installing, suit it to
the shaft in hot state and its
shrink range is 0.042-0.065.

Disassembly and assembly of lube oil pump:

(1) Heat the two small gears of lube oil pump evenly up to 220-270℃ and suit them to the two small
shafts respectively, the distance between gear face and small shaft face is 14.5±0.1mm;
(2) Put the bush into fluid nitrogen to cool down and press it into the pump cover and the pump body.
Locating slot of the bush is forth. Keep outside end face of the bush and end face of pump cover and pump
body align. Shrink range is 0.022-0.048;
Caution!
Align oil hole in the bush with oil holes in pump cover and pump body in pressing and suiting.

(3) Embed the two shafts with gears into the pump and smear lube oil;
(4) Smear surface sealant in pump sealing surface before installing pump cover and note two locating
pins, screwing-down bolts. The measuring axial clearance is 0.08-0.155mm. If oil pressure is lower, control it
under 0.08-0.10mm;
(5) Heat driving gear of lube oil pump to 220-270℃ and suit it to the small shaft out of the pump cover.
Assure the distance between gear flange outside end face and the end face of small shaft is 5±0.2mm, the
shrink range is 0.042-0.065mm;
(6) Disassemble lube oil pump in the opposite order.

Check:
(1) Axial clearance of lube oil pump has an important impact on oil mass pressure. When it exceeds
0.20mm, it needs to replace gear or pump cover, pump body. For example, pump cover and pump body wear
and terminate in big clearance, adjust it by milling, but assure the new axial clearance.
(2)The clearance between small shaft and the bush is 0.02-0.054mm. If it exceeds 0.08mm, bush wears,
plating comes off or the bush has obvious scratches that can be felt by nails, replace the bush.

5.4.2 Lube oil filter

Diesel series 236 adopts two kinds of lube oil filters. One is with one cartridge, the other is dual filter,
reversible. Each filtering cartridge is one-off.

1. The filter with one cartridge

 HND Section 4 The Structure of Lubricating System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 151 •

Fig.5-4-3 The filter with One Cartridge

1 Filtering cartridge 2 Top cover of lube oil filter 3 Pressure relief valve assembly
4 Pressure-relief valve seat 5 Friction balls 6 Spring of pressure relief valve
7 Washer 8 Cap nut 9 O ring
10 O ring 11 Plug screw 12 Bolt
Special strap tool is used for disassembling filtering cartridge of the filter with one cartridge. When
installing it, smear some lube oil on the thread of filtering cartridge and screw it until contact sealing surface.
After that, screw it down with hand by 1/2 ~3/4 circle.

Pressure relief valve

(1) Function:
Pressure relief valve opens when oil pressure exceeds 0.6Mpa. Some oil will run back to the oil pan.
Pressure relief valve is composed of valve seat, friction balls, spring, washers and cap nuts. It is used to limit
the pressure, but it can not adjust lube oil pressure. If sealing between friction ball and valve seat is not good,
or sealing surface of valve seat isn’t flat or there are impurities on sealing surface, it will cause the falling of
oil pressure.
(2) Steps of disassembly:
① Screw off blind nut of pressure relief valve, take off the spring and check its free length (used for a
long time). It should be 90+1.5mm. For example, if it is not long enough, add gaskets in head nut and boost
opening pressure of the valve. Generally, the added gasket is 1mm thick, which can boost about 0.01Mpa
opening pressure.
In engine trial, the spring is proved to be good if oil pressure has no change, then take off the added
gasket;
② Screw off the filtering cartridge of lube oil filter and check the leakproofness of pressure relief valve.
If leakage is serious, overhaul it again;
③ Screw off blind nut of pressure relief valve, take off the spring, friction balls and pressure relief valve
body, check weather sealing zone between end faces of the valve and seat holes is continuous or damaged or
not, then abrade it to mend;
④ Install it in the opposite order of disassembly and its O rings and gasket rings should be replaced.

2. Reversible dual lube oil filter:

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·152· the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig. 5-4-4 Reversible Dual Lube oil Filter

1 Filtering cartridge 2 Pressure relief valve assembly 3 Pressure-relief valve seat

4 Friction balls 5 Spring of pressure relief valve 6 Washer
7 Cap nut 8 Screw plug 9 Gasket ring

Reversible dual lube oil filter has a change-over valve (cock) and two filtering cartridges, compared to
the lube oil filter with one cartridge. It is permitted to replace filtering cartridge under low load when the
engine is working.
The change-over valve (cock) is installed in the filter body and outside end face has 3 lines according to
the figure:

Position 1 of the cock: left filter closed

Position 2 of the cock: both filters open

Position 3 of the cock: right filter closed

Fig.5-4-5 Sketch Map of Change-over Valve

Disassembly and assembly of reversible dual lube oil filter:

(1) Take down the two filtering cartridges by special strap tool;
(2) Clamp the body of the filter in the jaw vice according to the surface graphic arrow points;
(3) Screw out cap nut 1 of pressure relief valve and take off spring 2 and friction ball 3;
(4) Screw out valve 4;
(5) Screw off the clamp bolt of flange 5 and take off the flange
(6) Force off change-over valve (cock) from
the case;
(7) Assemble in the opposite order.

Smear some lube oil in screw in installment and

screw down the filtering cartridge by hand 1/2~3/4
circle.

1 Cap nut 2 Pressure relief valve

3 Friction ball 4 Pressure relief valve spring
5 Flange 6 Change-over valve
 HND Section 4 The Structure of Lubricating System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 153 •

Fig.5-4-6 Disassembly of dual lube oil filter

5.4.3 Lube oil Cooler

(1) Function:
Lube oil cooler cools the lube oil down to certain temperature range to assure good lubrication and
cooling in every diesel friction surface and high-temperature parts. Lube oil flows across cartridge of the
cooler and the cooling water outside of the cartridge takes away redundant heat by conduction.
Two elliptic gaskets are used to seal suction and discharge flange and cover board of lube oil cartridge.
Lube oil cooler is fixed in outside of engine body B row, sealed with two O rings 3 which are installed on the
cover board with cartridge like cantilever. So two round flange suits of cartridge have O rings, which support
cartridge in cooler casing seat hole softly.

Fig. 5-4--7 Lube oil Cooler

1 Lube oil cooler assembly 2 Cover board 3 O ring 4 Gasket 5 Cartridge of cooler
6 O ring 7 Gasket 8 Body of cooler 9 Draining valve

(2) Overhaul:
Supplementary Materials and Rapid Wear Spare Parts
Table 5-4-2
Supplementary Diesel, compressed air，hydrochloric acid，No.2 lithium base grease，sealant,
materials hairbrush
Tools Spanner S10-12, hexagon spanner S8，screwdriver
Rapid wear spare parts O ring (in the cooler) 6.0493.10.0.0504 2/set
O ring (the inlet and outlet of lube oil) 6.0493.13.0.2202 2/set
Elliptic sealing gasket 6.234.0.852.001.4 2/set
Spring washer B8 6.0216.01.0.0080 4/set
O ring (overflow valve) 6.0493.13.0.3501 1/set
Casing sealing gasket V6 6.234.0.853.002.4 1
Casing sealing gasket V8 6.234.0.853.003.4 1
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·154· the Disassembly, Overhaul and Assembly of its Main Components MWM

Lathe dog 6.0401.53.6.0380 2

Drain all the cooling water in the engine when disassembling the cooler.

Steps:
① Unscrew the lathe dog connecting lube oil cooler and cooling water pipes and move flexible
pipes;
② Screw off screws or nuts used to fasten lube oil cooler and take the cooler off;
③ Remove bolts around the body of lube oil cooler and take off cooling cartridge. Check O ring,
if there is any damage or aging, replace it;
④ Remove 4 bolts of fixing cartridge of cooler, check elliptic sealing gasket and replace it;
⑤ Check whether there is incrustation and impurity in cooling fin surfaces, whether there is
blockage in the cartridge. If:
a. There is scale on the cartridge surface, remove it with dilute hydrochloric acid and use cooling
water according to requirements;
Caution!
When hydrochloric acid is used to get rid of scale and finishes the work, take it out immediately
and flush it with clear water or carbonated water to neutralize.

b. If there are some foreign matters jamming inside the cartridge, such as fatlute and filings, firstly
soak it in diesel or gasoline for a while, then drain diesel or gasoline. Blow inside with pressured
air from the oil outlet (at the end of flywheel) and repeat it several times until no filing or other
foreign matters blown off. Or put the cartridge into lube oil, heat it (＜150℃), wash it and blow
it with pressured air;
⑥ If there is leakage in the overflow valve, screw with M8 bolt till the overflow valve is pushed
out. Check O ring, if there is damage or aging, replace it. And check friction balls and the
flexibility of the spring, and whether there is foreign matter chocking up;
⑦ Assemble lube oil cooler in the opposite order of disassembly.

(3) Notes of assembly:

① Replace O ring and sealing gasket after disassembly;
② Smear No.2 lithium base grease on O ring and smear sealant in both sides of elliptic sealing gasket
 HND Section 4 The Structure of Lubricating System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 155 •

when installing;
③ Smear surface sealant on both sides of sealing gasket of cooler casing slightly and evenly;
④ Screw down 4 bolts for fixing the cartridge of the cooler and screw down bolts around the casing of
cooler after putting it in the safe place;
⑤ Elastic pin in the overflow valve has to be vertical against the horizon. It should be on the upper
position, aligned to the location hole of the cooler.

5.4.4 By-pass Valve:

By-pass valve is installed inside oil duct of the engine body, no exposure. It can be seen only when the
lube oil cooler is disassembled.
By-pass valve can avoid breaking oil because of polluted blocking in lube oil cooler. In normal condition,
by-pass valve is closed. Lube oil continues to flow into extending oil duct inside the engine body through lube
oil cooler. When oil pressure exceeds 0.6Mpa, oil pushes away friction ball and lube oil flows into extending
oil duct inside the engine body directly, not through lube oil cooler.
When removing by-pass valve, screw a M8 bolt into it and draw it out of the engine body.
When installing by-pass valve, elastic cylindrical pin 6 should stand up towards the direction of the
cylinder head, no reverse direction!
After removing by-pass valve, it needs to check valve seat sealing strip (contact surface with friction ball).
If valve seat sealing zone is discontinuous, restore it through grinding. Otherwise replace the whole by-pass
valve.

1 By-pass valve 2 Cap nut

3 Friction ball 4 Pressure relief valve spring
5 O ring 6 Elastic cylindrical pin

Fig.
5-4-8 By-pass valve
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·156·· the Disassembly, Overhaul and Assembly of its Main Components MWM

5.5 The Structure of Gas Distribution System and the Disassembly, Overhaul and
Assembly of Its Main Components

Valve mechanism’s main function is achieving timing of inlet and exhaust process. That is to say,
fill fresh air into the cylinder regularly and clean up the waste gas after burning in the cylinder. Valve
mechanism is mainly composed of three parts: camshaft, air valves, drive mechanism.
Camshaft: camshaft, camshaft gear, connecting ring, ring, thrust half loop and so on.
Valve group: inlet valve and exhaust valve, inlet valve and exhaust valve bracket, valve guide,
valve lock clamp, valve inside and outside spring and so on.
Drive mechanism: tappet, push rod, rocker arm bracket, rocker arm, bridging, set screw, blocking
nut.

5.5.1 Camshaft
1. Function:
It controls opening and closing of inlet valve and exhaust valve to assure the diesel’s normal air
exchange.
2. Structure:
Row A and row B of 236 series of diesels share a camshaft. The camshaft is entirety type, which is
installed in the holes above engine body center main bearing holes. Camshaft gear is a dual gear. The
greater gear meshes with crankshaft timing gear. The smaller gear meshes with injection pump gear to
drive injection pump. There is a connecting ring pressed in the center of the camshaft gear hole. The
small tongue in driving shaft of the tachometer drive mechanism extends into the groove of connecting
ring. And use it to measure the speed of the engine.

The camshaft structure diesels

Fig.5-5-2 The camshaft of ≥2200r/min V12 engine

1 Camshaft 2 Camshaft gear 3 Wheel boss 4 Washer
5 Bolt 6 Bulkhead 7 Flange of tachometer drive
8 Bolt 9 Thrust ring

3. Disassembly, overhaul and assembly:

HND Section 5 The Structure of Gas Distribution System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 157 •

The diesel controls valve gas distribution timing through camshaft, tappet, push rod and rocker
arm to assure the diesel work normally and reliably. If tappet is broken (chill mould pig iron in the oil
pan), push rod bends (adjust incorrectly), gear screws is off and other relevant faults appear or it has
come to medium repair and heavy repair time, it needs to overhaul the camshaft and relevant parts. If
push rod bends, check valves and the piston.
Overhaul of the camshaft is related to overhaul of tappet, push rod and rocker arm. They are
narrated together here. So in late drive mechanism, it will not narrate overhaul of tappet, push rod and
rocker arm.
Overhaul of camshaft, tappet, push rod, and rocker arm

Supplementary Materials and Rapid Wearing Spare Parts

Table 5-5-1
Supplementary
Diesel, hairbrush, motor oil, screw locking-and-fixing sealant
materials
A suit of standard tool, torque spanner, rubber hammer, screwdriver 6″,
Tools
external lock ring forceps (small)
Thrust half loop 6.234.0.673.007.4 1/set

Socket head cap screw 6.0200.70.0.1030 6/set

Valve push rod 4.236.0.321.103.4 2/cylinder

Rapid wearing
spare parts Adjusting screw
4.236.0.358.003.4 2/cylinder
(for rocker arm)
Adjusting screw
4.236.0.358.004.4 2/cylinder
(for bridging)

Check ring 6.0305.01.0.0025 2/cylinder

(1) Steps of overhaul:

① Remove cylinder head cover, rocker arm and take out push rod;
② Remove parts in the front cover, the front cover and oil pan;
③ Measure backlash between camshaft gear, crankshaft gear and driving gear of high pressure
pump. If it exceeds 0.4mm, replace the gear. Measure axial clearance of the camshaft. If it
exceeds 0.4mm, it needs to replace thrust half loop;
④ Remove driving gear of high pressure pump, camshaft gear and thrust half loop;
⑤ Reverse the engine body. Rotate the camshaft to make tappet come away and then draw out
the camshaft and tappet. If there are not conditions of reversing in overhaul places, then make
a simple lifting-and-pulling tool according to Fig. 5-5-2 (two such tools for single cylinder).
Draw out the camshaft after lifting tappet and loosen the tool to take out tappet.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·158·· the Disassembly, Overhaul and Assembly of its Main Components MWM

1 M6 thumb nut
2 M6 screw (470mm)
3 Rubber band
4 Φ10×1 (450mm)
5 Washer
6 Φ12 Rubber thick welled tube
7 Tappet

Fig.5-5-2 Lifting-and-pulling Tool

⑥ Wash every part waiting for checking, check them and measure them. If it has come to the
limit of wear (see dimension list of limit of wear), replace it or mend it.

Caution!

① Install tappet in the seat hole. If there is obvious radial clearance felt by hand, replace it at
once. If there are obvious galling, crack and spalling in the bottom of drum head, replace it;
② If push rod bends (forbid to adjust again), void closes and buttonhead part wears seriously,
replace it with a new one. Generally, contact surfaces between push rod and tappet and
adjusting screws should have 50% continuous contact zone or surfaces in the top of the
buttonhead. If the whole buttonhead contacts or contact zone leans below, it is nonideal and
had better replace it in heavy repair;
③ Replace adjusting screws of rocker arm and check rings in heavy repair.

(2) Notes of assembly:

① Fill motor oil in ball pits of tappet, press with thumb and there is motor oil flowing out of oil
holes in the oil groove. It can check passage clear in oil holes of tappet. Install tappet in the
seat hole and assure rotation flexibility and no jamming. Install the camshaft. Rotate it flexibly
and there is no jamming;
② Fix half circular ring and screws of camshaft gear. It needs to smear little screw
locking-and-fixing sealant to prevent from loosening (get rid of oil in screws);
③ The moment of camshaft set screws（M10-10.9）is 65~70Nm. Smear screw locking-and-fixing
glue. Beat the gear to the bottom with the rubber hammer before screwing down. Beat the
location pin to the bottom after screwing down. “O” marked tooth of its gear and “O” marked
tooth of timing gear are in mesh;
④ Axial clearance of the camshaft is 0.15～0.35mm, max0.38mm；
⑤ “O” marked tooth of high-pressure oil pump driving gear and “O” marked tooth of camshaft
gear is in mesh (at the same time “O” marked tooth of camshaft gear meshes with “O” marked
tooth of the crankshaft). Smear some screw locking-and-fixing sealant in clamping screws
HND Section 5 The Structure of Gas Distribution System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 159 •

(M10). Its moment is 85~90N•m (M10X35-12.9) or 65~70 N•m (M10X30-10.9) .

⑥ Blow off push rod with compressed air to assure clear. Dip it with oil and put it in lightly;
⑦ Check gas distribution timing after installing rocker arm to determine exactness of assembly.
And readjust valve clearance;
⑧ Install each part in opposite disassembly order.

5.5.2 Valve Groups

Valve groups contain inlet valve and exhaust valve, inlet valve and exhaust valve bracket, valve
guide, valve lock clamp, valve spring and so on. Dismounting of these parts has been told in cylinder
head. Here tell of checking gas distribution timing and clearance adjustment of inlet valve and exhaust
valve in detail.
1. Check of gas distribution timing:

Supplementary Materials and Rapid Wear Spare Parts

Table 5-5-2
Supplementary
Washing diesel
materials
Tools Double offset ring spanner S14-17, clearance gauge, screwdriver 6″
Cylinder head cover
Rapid wear 4.236.0.853.108.4 1/cylinder
sealing washer
spare parts
Seal washer 6.0492.01.0.0814 5/set

Working of the diesel is composed of the operating cycle: intake air→compress→expand to do

work→exhaust air. It relies on valve mechanism to realize. Inlet valve and exhaust valve are requested
to open and close in right time. It is called gas distribution timing. Accurate gas distribution timing is
essential to the diesel’s normal and reliable work.
236 series of diesels are V type engines. They have a root of camshaft to control gas distribution
timing of A and B rows of inlet valves and exhaust valves. So in new installment and heavy repair or in
remodeling of gears, camshaft and crankshaft, we only need to check gas distribution timing of a
cylinder instead of checking gas distribution timing of the whole engine. Check whether valve drive
mechanism, assembly of gears and parts are right and eligible.
Generally, check the last cylinder of B row (the first one in forward end) because the cylinder is
on the top dead point of compression stroke. Camshaft gears of V6 and V8 engines mesh with both
crankshaft gear and injection pump driving gear in “O” marked place. It is able to check easily.

Steps of checking gas distribution timing:

(1) Unfold the observe hole cover of the flywheel shield.
(2) First turn checking cylinder to TDC in compression stroke and adjust clearances of inlet valve
and exhaust valve to 1mm (to magnify tolerance). Then rotate valve push rod with hand continuously.
At the same time, rotate the engine slowly (anticlockwise to the flywheel) and check. The moment from
push rod’s moving to its not rotating is the opening moment of the valve, which is pointing scale of the
pointer. It can be seen in Table 5-5-3.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·160·· the Disassembly, Overhaul and Assembly of its Main Components MWM

（1mm）Table of checking gas distribution timing

Table 5-5-3
Valve phase angle is crankshaft rotation angle，
tolerance is ±2°
Inlet valve opens（move→just not rotate） 7° bef. TDC

Inlet valve closes（not move→just rotate） 28° after BDC

Exhaust valve opens（move→just not rotate） 37°bef. BDC

Exhaust valve closes（not move→just rotate） 4°after TDC

(3) Go on to rotate the crankshaft. The moment of upper end of push rod’s moving from its just not
rotating is the closing moment of this valve, which is pointing scale of the pointer.

Data of gas distribution timing in working clearance is according to Table 5-5-4.

Gas Distribution Timing
Table 5-5-4

Valves in working clearance Inlet 0.3mm， Exhaust 0.5mm

Inlet valve opens ±2° 24°bef. TDC
Inlet valve closes ±2° 41°after BDC
Exhaust valve opens ±2° 46°30´about bef. BDC
Exhaust valve closes ±2° 13°about after TDC
2. Checking of valve clearance:
Valve clearance is the distance between the top of valve stem and rocker head contact point in the
state of cold engine when the valve closes completely.
Metallic materials expand after heating and both valves and push rod extend after heating, so
valve clearance is essential to the diesel. Valve clearance is so little that the valve and push rod extend to
push away valve and the valve becomes leaky. Then high-temperature combustion gas will flow out.
Valve clearance is so great that its acceleration of first motion is great and drive mechanism’s parts will
be damaged. At the same time, opening lift and opening time reduce. Then there is not enough fresh air
entering the cylinder, scavenging is not enough and it deteriorates the process of scavenging period.
Adjustment and check of valve clearance must be done under the condition of cold engine and
completely closing state of valves. Generally, adjust inlet valve and exhaust valve of each cylinder (in
compression stroke).
Adjustment of valves should be under the premise that gas distribution timing is accurate. Its
check steps are as follows:
(1) Remove each cylinder head cover;
(2) Rotate the engine and make any cylinder is at TDC of compression stroke. At the time both
inlet valve and exhaust valve close completely and start to adjust valve clearance of the cylinder;

Caution! Judge TDC of compression stroke:

Rotate the engine. The cylinder is about at TDC of compression stroke;
HND Section 5 The Structure of Gas Distribution System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 161 •

(3) Before adjusting, loosen lock nut, screw down set screw and press down the valve to make
sure tappet sit in cam generating circle reliably. Screw back set screw.
(4) Insert clearance gauge in the clearance according to demands and rotate set screw until
clearance gauge can be twitched free and moderately. The amount of looseness can be seen in list 5-5-5.
Screw down lock nut (its moment is 34-40 N•m), Check it again until it is eligible;
Valve Clearance

Table 5-5-5
Inlet valve clearance mm 0.3
Exhaust valve clearance mm 0.5
(5) Adjust other valve clearances in firing order. Install the cylinder head cover after it is eligible.
Note that the washer should be set positive. If it has heavy impression or is damaged, replace it.
Adjust other valve clearances in following firing order:

A1 A3 A2
V6： 180° 60°180° 60°180° 60°
B3 B2 B1 B3

A1 A3 A4 A2
V8： 60° 120°60° 120°60° 120° 60° 120°
B4 B2 B1 B3 B4

A6 A2 A4 A1 A5 A3
V12： 60° 60° 60° 60° 60° 60°60° 60° 60° 60° 60° 60°
B6 B2 B4 B1 B5 B3 B6

5.5.3 Drive Mechanism

1. Function:
Rotating camshaft does reciprocating motion in the engine body to drive tappet, which makes
rocker arm rock through push rod. And it makes valves open. But the closing of valves relies on elastic
force of valve spring.
2. Structure:
Tappet is founded by chilled cast iron which is highly rigid and fragile. There is a spherical socket
in the center of tappet to receive the spherical head of push rod. There has been beaten a vertical hole in
the center of the spherical socket connecting with a level oil hole in annular recess around the circle. Its
motor oil flows to push rod from here.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·162·· the Disassembly, Overhaul and Assembly of its Main Components MWM

1. Rocker arm 2. Bridge component 3. Lock arm 4. Bridge 5. Adjusting screw

6、19. Lock nut 7、16. Snap ring 8、17. Gasket 9. Rocker arm for outlet valve
10、15. adjusting screw for valve clearance 11. Packing ring 12. Protection pipe
13. sliding tappet 14. Push rod 18. Rocker arm for inlet valve 20. Rocker arm seat
21、22. Socket cap screw
The two heads of push rod are welded with 2 spherical heads which mate spherical sockets of
tappet and set screw respectively. The center of push rod is empty. Lubricating oil flowing out of the
push rod’s center hole flows through the center hole of push rod and lubricates rocker gear and valve
stem.
Components of rocker arm is composed of rocker arm bracket, rocker arm, set screw, washer,
elastic collar, blot and so on. Double ends of rocker arm contact with valves and push rod (through set
screw). It transfers rotary motion into reciprocating motion.
Set screws of valves are used to adjust valve clearance. Force of screwing down should not be too
great because set screws are highly rigid and fragile, otherwise they will be twisted off.
Rocker arm bracket is fixed in the cylinder head cover by 3 bolts and M10 screw bolt
screwing-down moment is 80+5N•m, M12 screw bolt is 140+5N•m. When the journal diameter of rocker
arm bracket is less than Ф24.94mm and the diameter of rocker arm hole is more than Ф25.04mm, it
needs to replace. Replace the washer if it has obvious galling.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·164· · the Disassembly, Overhaul and Assembly of its Main Components MWM

5.6 The Structure of Cooling System and the Disassembly, Overhaul and Assembly of
Its Main Components

The function of cooling system is to absorb heat from every high temperature component with
cooling water and keep their temperature in the allowable range for normal work.

Diesel series 236 has two kinds of cooling systems:

A Indirect cooling system: mainly used in marine diesel engine.

—————Fresh water cooling loop –––– Sea water (raw water) cooling loop

Fig. 5-6-1 Indirect Cooling

1 Raw water loop 2 Heat exchanger 3 Thermostat
4 Fresh water from self-heating exchanger to pump 5 By-pass pipe 6 Fresh water pump
7 Oil cooler 8 Plug cock 9 Raw water pump
10 Sea water screen
Draw out sea water out of sea water pump. It firstly flows into air intercooler (There is no
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 165 •

intercooler in naturally aspirated diesel), then into heat exchanger after cooling compressed air and into
the sea finally. Fresh water is cooled by sea water in the heat exchanger and flows into the fresh water
pump. The water after compressed by fresh water pump is divided into two ways. One flows into motor
oil cooler and it enters back end from engine body B after cooling motor oil. The other enters forward
end directly from engine body A, cooling water from cylinder liner flows from the head of the engine
body to cylinder head and enters watercourse of air inlet pipe. If the temperature of water is high, it
flows through the thermostat and enters heat exchanger. If the temperature of water is low, it flows into
fresh water pump directly bypassing the thermostat.

B Fan cooling system:

Fig. 5-6-2 Fan Cooling

1 Thermostat 2 Cooling water supply for cylinder row B 3 Oil cooler

4 Cooling water pump 5 Cooling water supply for cylinder row A
6 Radiator for intercooler circuit 7 Fan 8 Bypass pipe
After fresh water of the diesel is cooled by fan’s blowing in the radiator, it flows into fresh water
pump. Latter direction of fresh water is same as indirect cooling. For supercharged diesel engine,
supercharged air is cooled by the same fan in another radiator and it is called air-to-air cooling mode.
Indirect cooling system is composed of sea water pump, fresh water pump, heat exchanger,
thermostat, tension gear, cone belt and some pipes. Fan cooling system is composed of fan, fan
transmission device, fresh water pump, radiator, fairwater, thermostat, tension gear, cone belt and some
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·166· · the Disassembly, Overhaul and Assembly of its Main Components MWM

pipes.

5.6.1 Sea Water Pump

1. Function:
Suck sea water to boost pressure and send it into intercooler and heat exchanger to cool air and
fresh water, which ensures that the diesel engine works well.

2. Structure:
The sea water pump is self-priming centrifugal pump. Before starting the engine, fill the chamber
of sea water pump from the tundish and check whether sea water pump can pump in or not (Open the
screw plug and there should be water column rushing out). The sucking height of the sea water
pump is 4m. Sea water pump is installed in front end cover of row A of diesel engine. It is driven by
cone belt in the forward of belt pulley. It is composed of the pump, impeller, driving shaft, pore plate,
rolling bearing, bearing block, gasket ring, belt pulley and so on.

3. Overhaul and assembly:

If water leak is serious (damage of axial parts); oil leak is serious (damage of radial gasket ring);
pressure is not enough (wearing); there is abnormal noise; belt pulley swings great (damage of impeller
or rolling bearing), there is dead blockage (foreign matter seizes the impeller) and so on, it needs to
overhaul the sea water pump.
(1)Sea water pump of V6/V8 engine

1 Bolt, nut
2 Flooding case
3 Impeller
4 O ring
5 Cotter pin
6 Horned nut
7 Orifice plate
8 Axial gasket ring
9 Radial gasket ring
10 Axial sleeve
11 Bearing
12 Adjusting washer
13 Slotted nut

Fig. 5-6-3 Sea Water Pump of the V6 and V8 Engine

HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 167 •

Supplementary Materials and Rapid Wear Spare Parts

Table 5-6-1
Supplementary Metal cleaner，No.2 lithium base grease，sealant，hairbrush
materials
Tools Spanner S14-17，box spanner S24, 22, removable, specially-hauled tray，
compressor gun, torque wrench, hand vice
Rapid wear spare Axial sealing member 4.0690.72.1.0021 1/set
parts Axial sealing member 4.0690.64.9.0610 1/set
Radial gasket ring 4.0690.12.9.0315 1/set
Axial sleeve 4.0690.29.7.0114 1/set
O ring 4.0690.12.8.0129 1/set
Adjusting washer 4.0690.72.5.1401-1406 A suit/set
Ball bearing (with dust 4.0690.38.4.0509 1/set
prevention ring)
Ball bearing 206 4..0322.25.0.0206 1/set
Impeller 4.0609.64.2.0803 1/set
Pulley conical disk 6.0345.02.1.1400 1/set
Pulley conical 6.0345.02.1.1425 1/set
disk( ≥ 2200r/min)
O ring 6.0493.10.4.0485 1/set
O ring(outlet) 6.0493.10.0.0504 1/set
Lathe dog 6.0401.53.1.0501 2/set

Steps of overhaul:
① Disengage inlet and outlet water pipes of the sea water pump;
② Unscrew the lock nut of the pulley conical disk of sea water pump, disengage the cone belt and
take off the sea water pump;
③ Remove the lock bolt 1 of sea water pump case and take off inlet water case 2;
④ Take off cotter pin 5, screw down horned nut 6, pull the impeller out by special pulling disk. If
the impeller is damaged, replace it with a new one;
⑤ Take off the orifice plate and axial sealing parts. Check the orifice plate. If it has mottling and
damage, replace it. Check gasket ring and replace it if it is damaged. Check the group of seal rings. If it
finds wear in trails in hand feeling, burnish with linens and rub it. If it still has nail-felt trails after that,
replace it;
⑥ If it leaks oil, continue to disassemble it. Remove the nut of water exit case and take off the
baffle;
⑦ Screw down slotted nut 13. Block up the pump body. Press the shaft from the driving end.
Check radial gasket ring and axial sleeve and replace them if they wear out;
⑧ Check rolling bearing after washed cleanly. Press it out and replace it if it wears seriously.

Notes of assembly:
(1) Wash every part cleanly;
(2) Assemble in opposite order of disassembly and replace O ring;
(3) Smear some bell stuff sealant outside of radial gasket ring in installing. Flatten it, not lean.
Self-tightening spring ring can not come off and loosen;
(4) Smear some bearing sealant in inner ring of axial sleeve. Sealant can not flow to the shaft and
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·168· · the Disassembly, Overhaul and Assembly of its Main Components MWM

clean away excess sealant. Smear grease on outer ring;

(5) Ball bearing has dust prevention ring, facing outside. But there is no ring inside and take it
away if it has;
(6) Sealing surface of axial sealing parts should be clean, install flattened with no scuffing;
(7) Put fixing dummy club in orifice plate in locating slot of the pump;
(8) Make sure the distance in both sides of the impeller is 0.25-0.36mm (limit of repairing engine
is 0.45mm) and pressing lead wires (Φ1mm) on three positions of the circle is able to measure the data.
If the distance is not suitable, it needs to exchange the adjusting washers. If the distance is excessive,
replace the orifice plate or grind some sealing surface of back case in order to adjust it;
(9) The radial distance of the impeller is 0.12-0.25mm (limit of repairing engine is 0.38mm).
Replace impeller if it exceeds the limit;
(10) The moment of impeller lock-horned nut is 25-30Nm. Install the cotter pin;
(11) Smear No.2 lithium base grease or high-speed bearing grease on rolling bearing from
lubricator fitting;
(12) Fixing nut of pulley conical disk should be smeared with little screw-lock sealant and its
moment is 70Nm;
(13) Replace the cone belt if it wears seriously. After straining the cone belt, screw up fixing bolt in
the tension pulley of the cone belt. Its moment is 100 10N•m. It is good to press the cone belt to a
＋

distance of 10-20mm.

（2）The sea water pump for V12 engine

Fresh water of 236 series V12 diesel has a large amount of heat to reject, so it uses the sea water
pump with large displacement as Fig. 5-6-4.

Fig. 5-6-4 The Sea water Pump for V12 Engine

1 Set screw 2 Bearing cap 3 Cotter pin 4 Slotted nut

5 Washer 6 Nut 7 Gasket ring 8 Gasket ring
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 169 •

9 Shaft 10 Bearing 11 Radial shaft gland 12 Shaft

13 Elastic ring 14 Bearing 15 Case 16 Pan
17 Impeller 18 Washer 19 Fixing nut 20 Water seal
21 Viewing window 22 Cover 23 Bearing 24 Adjusting ring

Supplementary Materials and Rapid Wear Spare Parts

Table 5-6-2
Supplementary Metal cleaner, No.2 lithium base grease, sealant
materials
Tools Pull head, rubber hammer, vice and sleeve
Rapid wear spare Shaft seal A28 × 40 × 7 0115 1122 ES 2/set
parts End surface seal 28 × 47 × 22 1202 7382 KZ 2/set
1202 7383 UE
Shaft seal φ 25 × 37 × 7 1202 8433 EE 1/set
Bell gasket ring 1202 8432 EE 2/set
Thrust ring (to seal axial end 0400 9574 EZ 2/set
surface)

Disassembly:
① Loosen the connecting between pipes, screw off fixing bolt in the pump flange (in the middle
of the cover) and take off pulley conical disk from pump.

Caution!
Mark every part of the pump before disassembly.
② Screw off fixing screw 1. Maybe it needs to take off fastening bolt in the bottom or the top of
driving-end center cover;
③ Screw out ball bearing cover 2, take off the cotter pin 3, screw out slotted nut 4 and fasten the
shaft;
④ Screw out nut 6. Take cover 22 with pull head. Ball bearing cover 2 and a M10 bolt can be used
as the disassembling tool if needed. Draw out water seal 20;
⑤ Loosen and screw off fixing nut 19. Disassemble further in driving journal, screw off bearing
cover 14 with screws, take out shaft-used elastic ring 13;
⑥ Knock out shaft 12 with rubber hammer lightly. Use the pull head if needed. Draw out water
seal 20, disengage pan 16 and press impeller out.

Installation:
Caution!
New gasket ring must be used.
① Press and install the impeller on the shaft and use the fixing nut, including lock washer, to
screw it down;
② Clamp the shaft in the vice vertically and the driving end is adown;
③ Install the water seal 20 and press a sleeve in to protect rubber components, free from damaged
by sharp edges.

Caution!
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·170· · the Disassembly, Overhaul and Assembly of its Main Components MWM

Don’t forget to draw out the pressed-in sleeve!

④ Install the cover, including shifting ring together with radial gasket ring, install washer 5 and
ball bearing 23, screw on slotted nut and use open slot to lock it;
⑤ Turn the pump and install from forward end. Fit on new gasket ring 7 and pan 16;
⑥ Install the water seal as mentioned above;
⑦ Install gasket ring 8, case 15 and shaft seal 9;
⑧ Install tooth lock washer, screw on nut 6 and screw down the connecting bolt evenly and
lightly.
⑨ Press in ball bearing 10, with no inner race. Press inner race in and its depth is 3/4;
⑩ Align the case and the cover and screw down the bolt.

Adjustment of the impeller:

① Use 5mm round bar to adjust the impeller through rushing-down port in the cover. The impeller
has the axial distance, so adjust it adequately to ensure no friction while rotating;
② Screw adjusting ring away from the driving end until the limit position (the blade locates one
end and the shaft can't rotate);
③ Screw the cover of ball bearing 2 down to the bottom and mark the location! Unscrew the
cover of ball bearing 2 and rotate adjusting ring 24 reversely for about 1 circle;
④ Screw the cover of ball bearing 2 down to the bottom (the blade locates opposite side) and also
mark the location. Set the cover of ball bearing 2 in the middle of two marks, located with setscrew 1;
⑤ Screw the adjusting ring down to the bottom in opposite direction again and is also located by
setscrew 1;

Caution!
The shaft should rotate free now. The impeller is adjusted to the mid position.
⑥ Press in the inner race 10 of ball bearing and ensure the axial distance is 0.2mm. Locate it with

the circlip 13;

⑦ Screw in the bearing cover 14 with screws and axial shaft gland 11. Locate it with setscrew 1;
⑧ Inject grease into two bearings from charging connector;

Caution!
The dimension of the sealing group: thickness 0.4+0.04mm, a 0.3mm gasket ring and a 0.1mm
gasket ring.

(3)The sea water pump for V12 engine with water-cooling exhaust pipes
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 171 •

Fig.5-6-5 The sea water pump for V12 engine with water-cooling exhaust pipes

1 Raw water pump 2 Shaft 3 Key 4 Woodruff key 5 Distance ring

6 Socket head cap screw 7 Adjusting pin 8 Screw pin 9 Grease oiling cup 10 Plug screw
11 Stud 12 Nut 13 Plug screw 14 Impeller 15 Stud
16 Wing shape washer 17 Nut 18 Locating ring 19 Washer
20 Locknut 21 Pin 22 Cover

The disassembly of this pump is same as the second kind of pump, so not to mention it again.

5.6.2 Fresh water pump

1. Function:
It makes fresh water of the system produce certain pressure and circulate to every cooling part of
the diesel so as to ensure the normal work of every part.

2. Structure:
Fresh water pump is centrifugal pump and is installed in the front end cover of diesel's side B. It
is driven by the cone belt in forward-end pulley conical disk. It is composed of case of pump, closed
type blade, flooding bend pipes, ball bearing, axial gasket ring components, belt pulley and so on.
The tightness degree of the cone belt is adjusted by tension pulley.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·172· · the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig. 5-6-6 Fresh Water Pump

1 Pump cover 2 Impeller 3 Shaft 4 Thrust seal ring 5 O ring

6 Ring 7 Axial seal component 8 Bearing 9 Lock ring 10 Locknut
11 Washer 12 Bush 13 Case of fresh water pump

1. Overhaul and disassembly:

Supplementary Materials and Rapid Wear Spare Parts
Table 5-6-3
Supplementary Metal cleaner，No.2 lithium base grease，sealant，hairbrush
materials
Tools Spanner 10-17, 13-15, sleeve spanner S22, torque wrench, sleeve spanner
S24
Rapid wear spare Axial sealing member 6.0496.15.5.0001 1/set
parts Axial sealing member 6.0496.15.9.0002 1/set
O ring 6.0493.10.5.1014 1/set
Ball bearing 6304 6.0320.07.3.6304 2/set
Lathe dog 6.0401.53.1.0701 2/set
Lathe dog 6.0401.53.6.0380 2/set
Cone belt (fan cooling) 6.0345.13.1.1375 3/set
cone belt (sea water cooling) 6.0345.02.1.1075 1/set

Steps of disassembly:
(1) Unscrew fixing bolt of cone belt tension pulley and take off the cone belt;
(2) Disconnect soft tube in the water pipe used to connect inlet and outlet of fresh water pump;
(3) Screw down binding bolt of fresh water pump and take off the pump;
(4) Remove flooding bend pipes;
(5) Clamp pulley conical disk in the bench clamp (not to damage cone belt slot), screw down fixing
and locking nut and take off the cone belt;
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 173 •

(6) Underlay fresh water pump (not to damage sealing surface), press out the shaft with Ф15 steel
bar (having the impeller), check axial sealing member’s junction surface. Replace it if it has grinding
defect or is damaged;
(7) Pull down lock ring 9 and press out rolling bearing from impeller end with pressing and
installing tool. Wash the bearing cleanly and check its wear condition. If it wears seriously or has burn
mark, replace it;
(8) Press the impeller down and replace it if it is damaged.

Assembly:
(1) Wash each part cleanly;
(2) Fill between rolling shafts with No.2 lithium base grease or high-speed bearing lubricating
grease;
(3) Assemble in opposite order of disassembly and replace O ring;
(4) Smear screw locking-fixing sealant in fixing nuts of belt pulley. The moment is 140-150Nm;
(5) Sealing end face of flooding bend pipes should be smeared with little sealant;
(6) If replace the impeller, it should be heated to 200-220℃ and hold heat for 5-10 minutes. Its
shrink range is 0.034-0.056mm to the shaft;
(7) Installed fresh water pump should rotate flexibly and have no jamming;
(8) Replace the cone belt if it seriously wears. The moment of fastening bolt M14 in cone-belt
tension pulley is 100-110Nm. Adjust the cone belt and ensure the pressing distance is 10-20mm. Often
smear belt wax to avoid sliding.

5.6.3 Heat Exchanger

1. Function:
Use sea water to cool fresh water to ensure the temperature of fresh water is in defined range and
make sure the machine works well. Sea water flow across the slay pipe in the heat exchanger to cool the
fresh water in the cooling case to normal working temperature. Heat exchanger also acts as accessory
expansion tank and compensates different volume under variable temperature. In order to reduce the
volume and increase heat exchange effect, the cooling slay water pipe are divided in half to make sea
water flow across half-zone pipe and flow out of another half-zone pipe so as to prolong flowing time,
improve cooling efficiency and reduce external dimensions. The cooling water also flows across outer
leading cover from one end of the slay to another end to improve heat abstraction effect.

2. Structure:
Heat exchanger is installed in the support, which is in the top of diesel forward end. It is
composed of expansion tank, end cap, pipe bundle and so on.
Generally, sea water pump uses corrosion prevention substance to improve noncorrosibility. In

addition, add corrosion prevention zinc spelter and the case uses aluminum alloy cast.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·174· · the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig.5-6-7
Heat Exchanger
1, 2 Heat exchanger 3 Case 4 Slay 5 O ring
6 Protection zinc spelter 7 Setscrew 8 Washer 9 Front end cover
10 Gasket ring 11 Gasket ring 12 Steam valve assembly 13 O ring
14 Pipe-connecting flange 15 O ring 16 Spacer flange 17 O ring
18 Rear-end shield

3. Overhaul and disassembly:

Supplementary Materials and Rapid Wear Spare Parts

Table 5-6-4
Supplementary Metal cleaner, hydrochloric acid, compressed air, No.2 lithium base grease,
materials sealant, feeding bottle brush, bond
Tools Spanner 14-17, screwdriver 8″, hexagon spanner S12, box wrench S24,
rubber hammer
Rapid wear spare O ring (on the cooling 6.0493.10.4.1405 4/set
parts slay)
O ring (on the cover) 6.0493.10.4.1655 (V8)3/set,
(V6)2/set
O ring (on the water out 6.0493.10.5.0803 1/set
flange)
Gasket ring (on the water 6.0493.10.4.0354 1/set
out flange)
Seal washer A42×49 6.0492.01.5.4249 1/set
Seal washer A8×14 6.0492.01.0.0814 1/set
Vibration damping block 6.0650.01.0.0007 4/set
Lathe dog 6.0401.53.1.0501 4/set
Protection zinc spelter 6.1489.01.0.804.4 1/set
Slay of heat exchanger 6.232.0.944.006.5 1/set
(V8/V12)
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 175 •

Slay of heat exchanger 6.232.0.944.003.5 1/set (<2200r/min)

(V6)
O ring (sea water flange) 6.0493.10.0.0504 2/set

Steps of disassembly:
(1) Drain cooling water in the side B of engine body and water drain valve of the motor oil cooler.
If sea water doesn’t enter cooling water, go on to use it after precipitation;
(2) Close the inlet and outlet water valve. Send out sea water from sea water pump. Remove inlet
and outlet sea water pipe and water exit flange of cooling water. Screw down the bolts and localization
copper bolts in two end covers of heat exchanger, take off the two end covers and check O ring. Replace
it if it is aging or damaged.
Caution!
May not remove two ends and it should be according to trouble conditions.

(3) Take off the slay. Check pipes are unobstructed, have no foreign matters to block and don’t
produce incrustation scale;
(4) Clean the pipes in the slay with lengthened feeding bottle brush or log soft rod. You’d better
clean jam from back flow direction.
Caution!
Pipes in the slay of heat exchanger are thin wall copper tubes, so they can not be cleaned with
hard rod or the aiguille.
(5)To scale formation of the slay, remove it in the method of maintaining intercooler;
Caution!
After cleaning out incrustation scale with hydrochloric acid, neutralize it with soda water at
once to prevent corroding copper tubes further.
(6) Check whether impression in the gasket ring of waterexit flange is lean or not. If there is lean,
it needs to correct diversion mouth in the slay.
(7) If the pipe on the slay breaks or has crack in its end, replace the pipe or use special swage
tool to repair it or use copper bar to cap it and rived with both ends.
(8) Screw down zinc protection screw plug 16 and check protecting zinc spelter. Replace it if it
has corroded 1/3.

Assembly:
(1) Smear little motor oil or No.2 lithium base grease on all O rings. Suit O ring 5 to the slay 4 of
the heat exchanger. O ring 17 is set in the front and back end cover;
(2) Screw the stud, M8 and 100mm, into location bolt hole of the slay. Press an end cover to the
slay of heat exchanger. The stud must pass through location bolt hole of the end cover and install
another end cover. It needs to smear surface sealant in the sealing surfaces of the front and back end
cover. It allows to uses rubber hammer or wooden hammer to knock;
（3）Screw out the stud and take it up with copper setscrew;
（4）Install adjutage flange 14. Replace it if rectangular ring has heavy impression. If it is lean,
correct the position of the slay through slightly rotate the cover of the heat exchanger;
(5) Fasten the front and back end covers and install small accessories;
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·176· · the Disassembly, Overhaul and Assembly of its Main Components MWM

(6) Do water pressure test after assembly and observe whether the slay has water leakage. The test
pressure is 0.6Mpa, the temperature of water is normal and the time is 15 minutes. It should not have
any leakage.

5.6.4 Radiator
1. Function:
Cooling air delivered by fan takes away redundant heat through the slay and cooling fins, which
makes fresh water in the radiator reaches normal working temperature. The radiator is additional
expansion tank and compensates different volumes forming under variable temperature.

2. Structure:
It is composed of radiator, water drain screw plug, steam valve and so on.

Fig. 5-6-8 Cooling System of the Radiator

1 Radiator 2 Water drain valve 3 Steam valve

4 Throttle valve (minor cycle return pipe) 5 Thermostat

3. Overhaul:

Supplementary Materials and Rapid Wear Spare Parts

HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 177 •

Table 5-6-5
Supplementary Gasoline, compressed air, hydrochloric acid, hairbrush, glue 204
materials
Tools Screwdriver 8″, spanner 10-12, spanner 14-17, hexagon spanner S8
Rapid wear spare Lathe dog 6.0401.53.6.0380 4
parts Lathe dog 6.0401.53.1.0701 2
Sponge δ =10 About
4 × 1000 × 20

Steps of overhaul:
(1) Drain cooling water and remove the fan and the tank;
(2) Clean cooling fins with gasoline again and again if they are blocked and repeat to blow them
with compressed air in back air flow direction until they are completely clean;
Caution!
① Do fire prevention in place for gasoline;
② Don’t brush forcibly to prevent cooling fins from falling down, which will affect
transmission of heat;
③ Wash with P3-T288 and its concentration is according to factory instruction. Or use
emulsifier or dilute hydrochloric acid. Don’t use nitric acid or sulphuric acid because they are
able to corrode copper tube.

(3) Don’t use scale remover to dispose of incrustation scale forming in the radiator. Because
incrustation falls off in chips and the inner gaping of radiator is small, the gaping will be blocked and
incrustation can’t drain away. It needs to use hydrochloric acid to clean away slowly.

Caution!
① It had better use hydrochloric acid to clean and repeat it to avoid blocking gaping. And
blow from the water outlet with compressed air again and again;
② Not vibrate the radiator and avoid incrustation falling off in chips;
③ Get rid of incrustation with hydrochloric acid and neutralize it with soda water immediately.
And clean with pure water to prevent from corrosion further.

(4) Assemble the radiator in opposite order of disassembly. Replace the sponge gland strip if it is
damaged and smear phenolic aldehyde and acetal binder (glue 204) to bind.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·178· · the Disassembly, Overhaul and Assembly of its Main Components MWM

5.6.5 Bossing

1. Function:
The bossing concentrates cooling air from the fan and blow it to the radiator in certain direction in
order to cool both fresh water in the radiator and air in the intercooler.
2. Structure:
The bossing is welded together with sheet iron. One end is rectangle and connected with the
radiator and another end is roundness to accommodate the fan.
3. Overhaul and assembly:
The structure of bossing is so simple that there are not too many requirements for disassembly. It
only needs to keep the dismanted bossing appropriately to prevent it from damage or deforming. Fill
sponge gland strip and binder in junction surface between the bossing and the radiator to ensure sealing.
If welding line shakes open, it needs repair welding.
Caution!
Clearance between the bossing end surface and the fan blade end surface should be even. It
must ≥6mm.

5.6.6 Drive System of Fan

1. Function:
Drive system of fan is driven through cone belt of main belt pulley in the crankshaft and it drives
the fan to rotate through the spacer flange.

2. Structure:
It is composed of belt pulley, rolling bearing, bush, bracket, lock ring, bolt and so on.

3. Overhaul and assembly:

When belt pulley of drive system of fan swings great, it has abnormal noise or continuous running
time reaches W4 Repair Level, it needs to overhaul drive system of fan and replace grease. If rolling
bearing wears, replace it.
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 179 •

Supplementary Materials and Rapid Wear Spare Parts

Table 5-6-6
Supplementary Metal cleaner, hairbrush, No.2 lithium base grease, thread locking-fixing
materials sealant, diesel
Tools Spanner 13-15, 14-17, sleeve spanner head S24, torque wrench, bench
clamp, spanner 10-12
Rapid wear spare Rolling bearing 6207 6.0320.07.5.6207 2/set
parts Cover 6.232.0.950.073.4 1/set
Spring washer B10 6.0216.01.0.0100 4/set

Steps of disassembly:
(1) Remove the drive system of fan from the diesel;
(2) Clamp parts of pulley conical disk and connecting bolt of the bracket in the bench clamp, screw
off nut and carry down parts of pulley conical disk;
(3) Remove bolt in the cover, take off the cover and check it. Replace if crankshaft seal wears
seriously;
(4)Remove lock ring and press the shaft and rolling bearing out. Check the wearing condition of
rolling bearing. Replace it if it wears seriously or swings great.

1 Bolt
2 Nut
3 Belt pulley
4 Shaft
5 Bolt
6 Circular flange
7 Ring
8 Lock ring
9 Bearing

Fig.5-6-9 Drive System of Fan

Assembly
(1) Wash parts cleanly and rolling bearing should be washed in diesel;
(2) Press rolling bearing in with soft metal rod, not lean. It allows to heat belt pulley to 100-120℃
for installing it easily;
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·180· · the Disassembly, Overhaul and Assembly of its Main Components MWM

(3) Fill up No.2 lithium base grease or high-speed bearing grease between rolling bearings;
(4) Install the cover. Make sure it rotates free and has no jamming;
(5) Fix fixing nut M16 of pulley conical disk and smear thread locking-fixing sealant. Its moment
is 210-220Nm;
(6) Install drive system of fan in the opposite order of disassembly.

5.6.7 Tension Pulley

1. Function:
Tension pulley is a component of idler pulley and is installed under the bracket of fresh water
pump and heat exchanger.
2. Structure:
There are 3 kinds of tension pulleys of 236 series of diesels: three grooves, double grooves
and one groove. Tension pulley is composed of belt pulley, lever, rolling bearing, backing ring, bush,
tension ring and so on. When tension pulley swings great, rotates not well or reaches W4 Repair Level,
it needs overhaul and replacing lubricating grease.

1 Double-groove tension pulley

2 Bush

3 Lever

4 Check ring

5 Bolt

6 Front cover

7 Bolt

Fig. 5-6-10 Tension Pulley

3. Overhaul and assembly:

Steps of overhaul:
(1) Screw down fixing bolt 7 of the tension pulley and carry down the pulley;
(2) Clamp the lever of the tension pulley in the bench clamp and screw off bolt 5;
(3) Beat and press out the lever and rolling bearing with aluminum bar;
(4) Wash rolling bearing cleanly and check its wearing condition If it wears seriously, replace it.
(Bearing drawing number: 6.0320.07.4.6204)
Assembly:
（1） Install tension pulley in the opposite order of disassembly, fill up No. 2 lithium base
grease or high speed bearing grease between rolling bearings, replace spring washer;
（2） Rolling bearing has a dust prevention ring, facing outside. No such ring inside for
HND Section 4 The Structure of Cooling System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 181 •

convenient lubricating. Single groove tension pulley is only installed with a bearing with dust
prevention rings in both sides (pull down one side when washing and replacing grease);
Caution!
New rolling bearing has a dust prevention ring on each side. Such ring installed inside must be
dismounted for three grooves or double grooves tension pulley.
（3） Install tension pulley, the torque moment of binding bolt M14×60 is 100＋10N•m, the
pressing distance of cone belt with thumb is 10-20mm.

5.6.8 Thermostat

1. Function：
The thermostat is a waxen one which is the self-regulating device of cooling system of the diesel. It
can adjust the temperature of the water from the cooling chamber for intake pipe cooling by adjusting
the flow of the cooling freshwater through the heat exchanger or radiator. The temperature of cooling
water can be controlled in a proper range by the thermostat even when the diesel works with part load.

2．Structure

1 Fresh water goes into thermostat

2 Fresh water goes into heat exchanger or radiator
3 Fresh water goes into fresh water pump (small
circulation)
4 Thermostatic element
5 Valve disk

Fig. 5-6-11 Thermostat

The thermostat is installed before the fresh water inlet of the heat exchanger. Each raw of A and B
has one. It consists of sheet iron housing and thermostatic controller. There are three interfaces on the
sheet iron housing.
Caution!
Install the thermostat according to the direction in which the water flow indicated by the arrow.
Any wrong connection to the three interfaces will cause severe damage to the engine.

3. Operation:
On 236 series of diesels, generally, the thermostat is setup to work at 75o on marine diesel engine
and 65o on land diesel engine respectively. Soak the thermostat in hot water to check that if it works
correctly when it is necessary. When the thermostatic controller opens partly, all of or part of fresh water
from cooling chamber of intake pipe cooling of the diesel flows to the inlet of the fresh water pump
directly through bypass pipe. It is helpful to preheat the diesel just start and to keep the temperature of
the water in a good range when diesel works with part load.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·182· · the Disassembly, Overhaul and Assembly of its Main Components MWM

After the diesel starts, if there is no increase in the temperature of oil and water or although the
temperature of water is high, the temperature in the fresh water pipe after the thermostat is low, it may
be caused by the damage of the thermostat or the assembly in wrong direction. Now remove the
thermostat and soak it in a container with hot water. Change a new thermostat if the thermostatic
controller can not open or open partly.
HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 183 •

5.7 The Structure of Intake and Exhaust System, the Overhaul and Assembly of Its
Main Components

The intake and exhaust system consists of intake system and exhaust system. When the diesel
works, the fresh air filtrated by the air filter is pumped into compressor in which the pressure of air is
increased to a higher value. Then, it is sent to intercooler to decrease the higher temperature caused by
the increase of pressure. After that, the air passes intake pipes and inlet valves, finally, it goes into the
cylinder to help the fuel burn. The exhaust generated after burning goes into exhaust pipe through outlet
valves, and it is sent to turbocharger. The energy of it is used to rotate the rotor of the turbocharger.
Finally, the exhaust gas is exhausted through exhaust main.

5.7.1 Intake System

The intake system of the supercharger is complex. The pressure, temperature and density of the
fresh air influence the combustion and emission closely. Fresh air goes through air filter and goes into
compressor which is coaxial with the turbocharger. After being compressed, the air is cooled in the
intercooler. Then, the absorbed air goes into combustion chambers through intake pipe, air channel and
inlet valves.
The intake system consists of air filter, exhaust turbocharger, intercooler and intake pipes, etc.

1. Air filter
2. Compressor
3. Turbocharger
4. Intercooler
5. Exhaust gas
6. Compressed air
7. Inlet valve
8. Exhaust pipe
9. Exhaust valve
10. Cooling medium or cooling air

Fig. 5-7-1 (1) Intake System of Supercharged Marine Diesel Engine

 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·184· the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig. 5-7-1 (2) Intake System of Supercharged Diesel Engine for Land Use

1 Air filter
(1) Function:
Air filter is mainly used to prevent the dust in the air from entering the interior of the diesel, reduce
the wearing of moving components of diesel caused by impurities in the air and ensure the diesel can
work normally for a long time.
(2) Structure and Operation:
There are three kinds of air filter to be used normally. They are oil-bath air filter, wet air filter, dry
air filter.
Not being used correctly, the air filter will not protect the diesel engine, and such damages will
occur as follows:
① The dust and oil mist that comes from breather combines to produce oil sludge, which will
pollute the turbocharger, intercooler and intake pipe, and reduce the supercharge pressure and the
amount of intake air, increase intake resistance, consequently cause higher exhaust temperature,
dark smoke and more diesel oil consumption.
② It will accelerate the abrasion of inlet/outlet valves, valve seats, piston rings and cylinder
sleeves and maybe cause the break of the piston ring and scuffing of cylinder bore. As the result, it
will cause the deviant higher exhaust temperature, higher fuel consumption, and decline of the
power. And the diesel’s life will be shortened greatly.
③ The aperture of the air filter will be jammed by the dust if it can not be cleaned in time. The
higher inlet resistance caused by it will cause the decline of the power, and deviant higher exhaust
temperature and dark smoke.
④ The air filter will be damaged before its time and the engine will be damaged if there are
chippings from the air filter.

（3）Disassembly and assembly

HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 185 •

Auxiliary Materials and Rapid Wear Spare Parts

Table 5-7-1
Auxiliary Cleaning diesel oil, CD40 lube oil, compressed air, spanner S14-17, brush
materials
1/set（V6m, V8）
Wet air filter（Ф150mm） 6.0541.33.1.0010
2/set (V12)
Rapid wear 1/set（V6, V8）
Wet air filter（Ф200mm） 6.0541.33.1.0009
2/set (V12)
spare parts
1/set（V6, V8）
Oil-bath air filter（Ф150mm） 6.0541.29.2.0009
2/set (V12)
Filter core of dry air filter 1/set（V6, V8）
KLQ6--200
（Ф150mm） 2/set (V12)

① Oil-bath air filter:

It is mainly used for the land diesel engine, which breathes the air with more dust.

Disassembly and cleaning method:

a. Unscrew the wing-bolt 4 and remove the cover 5;
b. Take out the filter core 7 from the shell 9, dump the dirty oil and clean the inner;
c. Put the filter core into the gasoline tank or diesel oil tank to clean it and blow it dry with
compressed air;
d. Prize the cap of filter core 7, take out
the fiber, wash it with gasoline and
blow it dry with compressed air.
Quiver it loose and put it in the filter
core then cover the net cap to
resume it;
e. Fill engine oil the same as used in
diesel engine to the shell up to the
lower oil lever mark;
f. Fit the oil-bath air filter in reverse
order.

1 Filter 2 Clamp 3 Safety cover 4 Wing-bolt 5 Cover 6 Seal gasket

7 Filter core 8 Seal gasket 9 Housing 10 Clamp 11 Hand-bolt
Figure 5-7-2 oil-bath air filter
Caution!
1） Do not upend the oil-bath filter when installing it, otherwise, the engine oil will flow
out;
2） The engine oil must be filled before the first operation;
3） Generally, clean the air filter once after 250 continuous operating hours and the filter core must be
replaced after 4000 operating hours.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·186· the Disassembly, Overhaul and Assembly of its Main Components MWM

② Wet Air Filter:

It has simple structure and is mainly used in the place where there is little dust. It is generally
installed on marine diesel engine.
Soak the wet air filter in the lube oil and take it out, mount it on the intake pipe when there is no
oil trickling on the surface in order to make sure that the air can pass it successfully and the dirt particles
can be caught by it. So-called “wet air filter” means that it is soaked in the lube oil, and a thin oil film is
established on the filter fabric. The dirt particles can be pasted on the filter fabric when the air carrying
them passes the filter fabric so that the air can be purified. While after long time operation, the dirt
particles will jam the filter fabric and the oil film will disappear little by little. Now, the inlet resistance
increases, which will also cause the higher fuel consumption and higher exhaust temperature. Therefore,
it is necessary to remove the dirt timely and soak the filter in the lube oil to establish the oil film on the
surface. Otherwise, the performance of the air filter will be affected badly. Generally, the wet air filter
should be cleaned after 100 operating hours of the diesel.
Caution!
a. Before a diesel engine which is mounted on the ship operates the first time, the air filter
should be removed to be soaked in the engine oil to establish an oil layer;
b. Should the diesel engine need to be stored in a long time, it is necessary to clean the air
filter and store them after having the air filter oiled. Clean the air filter and oil them before use them
again.
c. Because there are more dust in the air in the coastland and freshwater area and the
temperature is higher there, the cleaning interval for the wet air filter which is used in the area above
should be shortened or use the oil-bath air filter or dry air filter instead.

Fig. 5-7-3 Wet Air Filter

Cleaning method:
Ⅰ Remove the air filter from the engine;
Ⅱ Remove the foreign matters in the filter by knocking its shell with a soft wood stick;
Ⅲ Wet air filter should be soaked in diesel oil and cleaned with a hairbrush and blown it dry
with compressed air from inside to outside；
Ⅳ Put the filter fabric of the wet air filter in the engine oil or smear it with sufficient engine oil
HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 187 •

and drip dry;

Ⅴ Renew the wet air filter if it is corroded severely or cracks.

(3) Dry air filter

The dry air filter can provide better filtering effect than oil-bath air filter and wet air filter and
can be used in the place with more dust in the air.

Fig. 5-7-4 Dry Air Filter

1 Dry air filter 2 Shell 3 Vacuum indicator 4 Find-filter core 5 Nut

6 Pre-filter core 7 Nut 8 Seal ring 9 Inter-seat 10 Disk 11 Nut

Disassembly and cleaning method:

a. The filter must be cleaned when the vacuum indicator 3 appears on the filter;
b. Unscrew the hexagon nut 11, remove the disk 10 and inter-seat 9, seal ring 8;
c. Unscrew the nut 7, take off the pre-filter core 6 from the shell;
d. Unscrew the nut 5, take off the fine-filter core 4;
e. Remove the cover 2 and vacuum indicator 3;
f. Wipe the shell and blow it dry with compressed air from inside to outside.
g. Fit the dry air filter in reverse sequence.

Caution! The resistance consumption of the air filter should be not more than 3KPa (300mm

water column)

2. Exhaust Turbocharger
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·188· the Disassembly, Overhaul and Assembly of its Main Components MWM

(1) Objective:
Turbocharger is used to enhance the power of the engine in the same speed. To make the
determinate work volume export more power, it is necessary to supply more heat to each working stroke,
i.e., more fuel should be imported into the cylinder to burn. Therefore, more fresh air should be supplied.
The turbocharger can enhance the intake pressure so that more air can be pumped into the cylinder.
(2) Working principle:
The exhaust turbocharger utilizes the energy of the exhaust gas from cylinder to rotate the turbine
so that the turbocharger impeller in the same axle will rotate in high speed and add the pressure of
absorbed air.

1 Turbine housing 2 Seal ring

3 Thrust ring 4 Sleeve
5 Oil baffle 6 Thrust button
7 Gland bushing 8 Seal ring
9 Compressor impeller 10 Axle head nut
11 Compressor housing 12 Bearing ring
13 O-ring 14 Bearing seat
15 Elastic collar 16 Bushing
17 Insulator 18 Turbine
19 O-ring 20 Cover of bearing seat
21 Elastic collar 22 Nomenclature plate
23 Arching plane 24 Bolt 25 Clamp
LE bolt LA air outlet
GE exhaust inlet GA exhaust outlet
Fig. 5-7-5 Exhaust Turbocharger

Caution!
Every time after the turbocharger has been broken down, when it needs to be assembled over
again, the little parts series should be replaced as whole set. The series consists of little parts
of 2, 6, 8, 10, 12, 13, 15, 16, 19, 24, etc. The order code for the little parts series of K37 series
supercharger (imported) is 6.0690.17.7.0016.
（3）Disassembly and assembly
The higher exhaust temperature which is caused by bad burning or overload，and the high rotation
speed of rotor impeller of turbocharger will accelerate the abrasion of the moving components of the
turbocharger. Once the abrasion occurs, it will spread rapidly and increase the clearance, cause
unreliable sealing and burn the lube oil. As the result, the exhaust turbocharger will be discarded as
useless with some relative important components damaged. So the end users are suggested to remove
the crooked outlet pipe to check the radial swing and axial clearance of turbine rotor after every normal
running of 1000 hours. If they overstep the maximum limit, disassemble the turbocharger and repair it.
HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 189 •

Auxiliary Materials and Rapid Wear Spare Parts

Table 5-7-2
Auxiliary Metal cleaner or diesel oil, brush, CD40 lube oil, supramoly lithium grease,
Materials antiblocking agent
Screwdriver 6″, open spanner 13-15, 14-17, interlocking ring forceps (little)、bench clamp,
Tools
spanner 9-11
Sealing gasket 6.234.0.853.007.4 2/set
Spare part for rotor impeller
6.0690.40.6.0007 1set（importation）
(K36）
Gasket of exhaust elbow 4.234.0.851.004.4 2/set
Bellows 6.234.0.652.044.4 2/set
Rapid wear Tube (turbocharger outlet） 6.234.0861.018.4 1/set
spare parts Clamp 6.0402.21.1.0002 4/set
Locknut 4.0210.15.0.0010 16/set
Elliptical gasket for oil inlet
6.232.0.852.004.4 1/set
pipe
Elliptical gasket for oil return
6.441.0.852.001.4 1/set
pipe

Steps of Disassembly and Overhaul:

(1) Remove the crooked exhaust pipe of the turbine, put the lever indicator in front of the turbine
impeller to measure the axial clearance and radial swing of the turbine rotor. If one of them
oversteps the maximum limit or the turbocharger operates to W4 maintenance level or the lube oil
leaks from the head or end of the rotor, break down the turbocharger and repair it;
(2) Remove the air outlet crooked pipe arranged near the compressor, check that if the lube oil is sealed
up. Dismount and repair it if the lube oil leaks;
(3) Remove the air pipe, lube oil inlet pipe, oil return pipe and thermo-isolation cover, and check the
lubricating oil return pipe and the oil return chamber (hose joint position) of supercharger are
through or not. Do this once after every 1000 operation hours;
(4) Remove the bolt for the housing of the turbocharger, strike out the housing of the compressor with
rubber hammer and remove it;
(5) Remove the V-clamp form the housing of the turbine, remove the turbocharger body carefully and
check that if there is corresponding remark for compressor impeller and axis. Mark it if there is no
remark according to Fig. 5-7-6;
(6) Put the impeller head of the turbine on the table-forceps，unscrew the bolts for the impeller and put
the turbocharger body into the heater box. Keep the temperature at 120~140oC for 5~10 minutes,
then take it out and fetch the impeller. (It is not necessary to heat the homemade turbocharger);
(7) Remove the lock ring from the supercharger body with inner lock ring clamp, remove the outer
cover of the bearing with two screwdrivers and take out shaft sleeve, seal gasket and oil baffle, etc.;
(8) Remove the lock ring in the supercharger body with little lock ring clamp and take out the bearing
sleeves at the two ends of the axis;
(9) Clean every part, especially the oil hole and the bearing seat hole and oil return chamber；
(10) Check the dimension of every important part. Renew those whose dimensions are not suitable or
there is abrasion, crack, etc. Check the abrasion condition of the orbicular slot in the rotor axis, and
renew it if it has worn out severely. Reject the turbocharger if there is severe abrasion at the
corresponding area of the orbicular slot in the rotor axis.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·190· the Disassembly, Overhaul and Assembly of its Main Components MWM

Fig. 5-7-6 Balance Mark

Notes in the assembly:

① Clean the parts carefully and blow it clean with compressed air, especially the oil
channel;
② Fix it in reverse order of disassembly and renew the o-ring and seal gasket;
③ The seal ring on the rotor axis should rotate freely and the clearance should be less than
or equal to 0.1mm. Apply stated lubricant on the parts before assembling them;
④ Heat the impeller of the compressor to 120~140oC and keep the temperature for 5
minutes, then amount it on the rotor axis according to the assembly mark (the homemade
turbine can be heated to 60oC);
⑤ Do not wrest the V-clamp for the turbine housing with extra torsion to prevent it from
being damaged by expanding;
⑥ The rotor’s axial float 0.03~0.12mm and its radial swing 0.20~0.50mm, are acceptable
which are measured at the turbine end. By the way, the radial clearance between turbine
housing and impeller should be symmetrical, 0.65~0.90mm, and the radial clearance
between compressor housing and impeller should be in the range of 0.65~0.80mm and be
symmetrical too. The impeller should rotate freely;
⑦ Before mounting the oil inlet tube, it is required to eject the clean lube oil CD40 into the
oil inlet holes (φ4mm) at the two side of the oil inlet hole of the supercharger, about
100ml, by using oil ejector, and rotate the rotor at the same time to lubricate it
completely;
⑧ The air tube should be connected to the supercharger comfortably. Adjust the position of
the relative parts if the air tube pulls or extrudes against the supercharger;

3. Air Intercooler---Intercooler
(1) Function:
After being compressed by exhaust turbocharger, the temperature of the fresh air will rise even up
to 160℃. In order to cool the temperature of the compressed air and improve the density of absorbed air,
it is necessary to cool the compressed air. The intercooler in the engine is designed for this purpose.
(2) Structure:
Two kinds of intercooler are used in diesel engine series 236.
Air-air intercooler: its compressed air is cooled by wind (fan) and it is mainly used for land diesel
HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 191 •

engine.
Water-air intercooler: its compressed air is cooled by sea water and it is mainly used for marine
engine.
① Air-air intercooler
In fact, the air-air intercooler has the similar structure to the radiator. The difference between them
is that the medium in the radiator (tank) pipe is water while air in the air-air intercooler. The air-air
intercooler and the radiator are mounted together and they are cooled by a same fan.
The clean method for the intercooler is same as the one for radiator.
② Water-air intercooler

1 Intercooler element
2 End cover of intercooler
3 End cover of intercooler
4 Seal gasket
5 Bolt
6 Gasket
7 Bolt
8 Gasket

Fig. 5-7-7 Water-air Intercooler

Auxiliary Materials and Rapid Wear Spare Parts

Table 5-7-3
Auxiliary Gasoline or metal cleaner, hydrochloric acid, compressed air, brush with long
Materials handle, surface sealant
Tools Open spanner 14-17, 13-15, hexagon spanner S6, screwdriver
Seal gasket of inlet/outlet housing 6.234.0.851.001.4 2/set
Seal gasket of end cover of the
6.0690.12.9.036.4 2/set
Rapid wear intercooler
spare parts O-ring 6.0493.10.0.0504 2/set
Seal gasket （between inlet pipe
6.234.0.851.003.4 2/set
and intercooler）

The components of the water-air intercooler are displayed in Fig. 5-7-7, the overhaul process is
described as follows:
a. Remove the intake shell (front end) of the intercooler and seawater inlet pipe, and check that
whether the radiator fan of the air chamber is jammed or dirty, and whether the copper pipe of the
water chamber is jammed or produces scale, if there is any one, it is necessary to overhaul;
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·192· the Disassembly, Overhaul and Assembly of its Main Components MWM

b. Remove the intercooler from the diesel engine and pull out the outlet shell which is connected with
the intake pipe;
c. Clean the radiator fan of the air chamber with gasoline or organic solvent and blow it with
compressed air in the reverse direction of the intake air again and again;
d. If the copper pipe of the water chamber has been jammed or produced scale, remove the two covers
of the intercooler and clean it;
e. The hydrochloric acid cleaning liquid (5％) can be used to clean the furring. Soak the intercooler
element in the liquid while being cleaned. Brush it with the brush with long handle or soft wood
stick (Ф7mm), no hard stick can be used. Clean it and neutralize it with 5% content carbonated
water, then wash it with fresh water.
f. Clean all the parts and assemble them in the reverse sequence of disassembly. Renew the asbestos
seals and O-rings and mount the intercooler to the diesel engine.

Caution！
① Flange sealant should be applied at the both sides of the asbestos gasket for the copper tube
end. If there is any crack in the copper tube, the intercooler element must be replaced. Some tube that
has crack can be blocked by copper stick as the temporary treatment. A hydraulic pressure test is
recommended if it is convenient. The recommended condition is at 6 bar pressure and in 10~15 minutes.
② The side of the intercooler which has nameplate on the surface should placed towards the
top.
③ Preparation of cleaning acid liquid:
For example: the volume concentration 36% hydrochloric acid should be diluted with 6 times
water.
The formula is described as follows:
r
Vwater = ( − 1) • Vacid
5%
Vwater - Volume of water (L) Vacid - Volume of hydrochloric acid (L)

r- Volume concentration of hydrochloric acid(%) 5%- Concentration of cleaning acid

liquid
④ When the intercooler is put on the bracket to connect the two intake pipes, the adjusting

pad may be needed because its highness is not always suitable. Otherwise, the flange connecting the

intake pipe and intercooler maybe be damaged because of the large weight of the intercooler and

vibration during the operation of the engine.

⑤ An antileak valve is amounted to observe whether there is leakage of intercooler. Before
running the engine every time, it is necessary to open the antileak valve to observe (it is normal to see
little condensed water, if there is lots of seawater flowing out, it is necessary to check intercooler and
relevant parts). Close the valve when running the engine.

4 Intake Pipe

(1) Function:
It seals and connects with intake system (cylinder head), through it fresh air goes into the cylinder
HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 193 •

head.
(2) Structure:
The intake pipe is mounted inside the cylinder head and connects with the intake duct，the structure
is shown in Fig. 5-7-8.

Fig. 5-7-8 Intake Pipe

1 Intake pipe 2 Intake gasket 3 Crooked water intake pipe

The intake pipe (1) has fresh water cooling chamber, the cooling water and the intake air are led

to the cooling chamber and air chamber respectively through the manifolds which are in the same

quantity with the cylinders. The intake gasket (2) is used between the manifolds and cylinder. The fresh

water from every manifold respectively flows to the intake pipe and then enters the heat exchanger

through the front water outlet pipe. The intake air goes in through the air inlet in front of the pipe and

enters intake pipe rows A and B through the elbow pipe. A water temperature sensor is mounted on the

top of the pipe.

(3) Disassembly and assembly

Auxiliary Materials and Rapid Wear Spare Parts

Table 5-7-4
Auxiliary Materials Gasoline or metal cleaner, surface sealant
Tools Open spanner S10-12, torque spanner, screwdriver
Rapid wear Seal gasket of intake pipe 4.236.0.853.601.4 6/set (V6)
Spare parts 8/set (V8)
12/set (V12)
Gasket 6.0491.10.0.5015 4/set
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·194· the Disassembly, Overhaul and Assembly of its Main Components MWM

Pane gasket 6.234.0.851.003.4 4/set

Hose e 6.0401.01.0.6065 1/set

Caution!

① Let all cooling water out of the diesel before removing the intake pipe;
② When installing inlet pipe, the planeness error of end faces of two inlet pipes
connecting with intercooler is not larger than 0.1mm, leveling rule can be used;
③ When removing the intake pipe, renew the seal gasket if there is any impress on it.
Smear surface sealant on the area around the water chamber hole on both sides of the seal gasket;
④ During overhaul, the pressure test must be applied to the water chamber of the intake
pipe (0.6MPa, water at normal temperature).

5.7.2 Exhaust System

1. Function:
Seal and connect exhaust system (cylinder head), let the exhaust gas out of the cylinders.
2. Structure:
The exhaust system is mainly composed of exhaust pipe, exhaust elbow, corrugated pipe, thermal
isolation cover for exhaust pipe, etc.
(1) Exhaust pipe: There are two kinds of exhaust pipe (including elbow pipe) including dry exhaust
pipe and water cooling exhaust pipe.
① Dry exhaust pipe（take V8 engine as the example）
HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 195 •

Structure 1
1 Exhaust pipe 2 Bellows 3 Exhaust elbow 4 Seal gasket
5 Tee pipe 6 seal gasket 7 Elliptical gasket 8 bolt for exhaust pipe

Structure 2
1 Exhaust pipe 2 Exhaust pipe 3 Right exhaust elbow
4 Left exhaust elbow 5 Tee pipe 6 Exhaust pipe seal gasket
7 Bellows 8 Clamp 9 Bolt 10 Tee pipe gasket
Fig. 5-7-9 Dry-type Exhaust Pipe（take V8 engine as the example）
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·196· the Disassembly, Overhaul and Assembly of its Main Components MWM

The exhaust pipe 1 connects two branches. The short one connects with cylinder 2 and cylinder 3,
the long one connects with cylinder 1 and cylinder 4. They are screwed to the relative exhaust channel
on the cylinder head with exhaust pipe screws and the joints are sealed with gaskets. The exhaust pipe
only has two exhaust tubes and no cooling water channel is designed for it. The exhaust pipe end is
connected with exhaust elbow and there is a seal gasket between them. The exhaust elbow is the
two-in-one type. It bents towards the middle position and its outlet and a tee pipe tube are connected
together with a bellows to exhaust gas. Check the planeness of the combination surface of the exhaust
pipe when repairing it, mill it slightly when the distortion is severe.

② Water-cooling Exhaust Pipe:

The diesel engine adopting water-cooling exhaust pipe has a surface temperature of 80℃ ( 650℃
for diesel engine with a dry-type exhaust pipe) while the engine capacity doesn't descend, Its fuel
consumption rate only rises by about 1%. The diesel engine adopting water-cooling exhaust pipe has an
exhaust temperature around 470℃ after turbo machine, about 100℃ lower than that of the diesel
engine with dry-type exhaust pipe. It can reduce the temperature of engine compartment effectively. But
this type of exhaust pipe has high cost, high price and large maintenance workload.

Fig. 5-7-10 Water Cooling Exhaust Pipe

HND Section 7 The Structure of Intake and Exhaust System,
MWM the Overhaul and Assembly of Its Main Components • 197 •

（2）Bellows:
Bellows is expansion pipe, providing the space for heating expansion of exhaust system
components. Bellows is made of heating resisting metal material and has certain expansion and
contraction ability. It connects with exhaust elbow and tee pipe through triangular flanges at its ends
with gasket sealed between them (structure 1). It needs to mention that the current ex-works diesel
engine (structure 2) adopts lengthened bellows to connect and uses clamps to clamp the trapezia joint of
elbow and tee pipe, which avoids the vulnerableness of the former connecting mode because of short
bellows.

(3) Tee Pipe:

Tee pipe is installed on the middle-upper position of the back end of engine body, connecting two
rows of exhaust pipe with turbo machine. Inside it is two air channels connecting with two rows of air
pipe respectively. Its outflow point connects with two inlets of turbo machine of exhaust turbine
supercharger through bolts. If there is any air leak, add a steel plate washer to seal it.
The exhaust gas after turbo machine is drained out through exhaust manifold, the exhaust
manifold has no special structure but on its midway are a bellows and a silencer.
3. Disassembly:

Auxiliary Materials and Rapid Wear Spare Parts

Table 5-7-5
Auxiliary
Gasoline or metal cleaner, antiblocking agent, flange sealant
Materials
Tools Open spanner S10-12, torque spanner, screwdriver
6/set (V6)
Elliptic gasket 6.234.0.852.005.4 8/set (V8)
12/set (V12)
Gasket 6.234.0.853.007.4 6/set (structure 1)
Bellows 6.234.0.652.002.5 2/set (structure 1)
Rapid wear
Tee pipe gasket 4.234.0.851.600.4 1/set
spare parts
Bellows 6.234.0.652.044.4 2/set (structure 2)
6/set (structure 1)
Bolt 6.0201.10.8.1031
10/set (structure 2)
Locknut 4.0210.15.0.0010 10/set
Clamp 6.0402.21.1.0002 4/set

Caution! (1) All bolts and nuts should be smeared with antiblocking agent for easy
disassembly;
（2）Neither compress nor twist when installing corrugated pipe;
（3）Gasket is one-way part, generally replace it after disassembly;
（4）For new diesel engine or the diesel after exhaust pipe dismantled, screw up the screw of exhaust
pipe in 60 hours first, then screw it every 100 hours or 500 hours respectively, with the torque moment
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·198· the Disassembly, Overhaul and Assembly of its Main Components MWM

of 50-55N·m;
（5）External exhaust pipe is 10m and the inside diameter of three 90° angle pipes is not less than
Ф125mm;
 HND Section 8 The Structure of Starting System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 199 •

5.8 The Structure of Starting System and the Disassembly, Overhaul and Assembly
of Its Main Components

The starting system of diesel drives the crankshaft to rotate. When the rotation reaches the ignition
rotation rate, diesel engine begins to run by itself. The start speed of TBD236 is 115r/min.
Diesel engine series 236 has two types of starting modes that are start motor starting, air motor
starting.
5.8.1 Start Motor Starting System
The start motor starting is the most popular start mode of the diesel engine series 236. Its basic
principle is to use the direct current start motor through the medium of coaxial pinion to drive the
flywheel with ring gear and make the crankshaft rotate to start up the motor.
The start motor’s start system is mainly composed of start motor, accumulator, charging start
motor and other parts.

1 Starting Motor
(1) Structure
The start motor is with 24V, 5.4KW or 6.6KW DC, and it can work for 10s continuously. It is
installed at the outside of the back of the A row. There are three bolts to fix it on the flywheel’s shell.
The start motor is composed of shell, magnetic pivot pole, electric brush, front and back end covers and
others. There are two electromagnetic switches installed in the back end cover which is in the rear of the
motor. One makes use of the shaft’s back and forth movement to push the engaging lever which leads to
the simple motor starter gear and the flywheel engaging. The other builds initial voltage as the charging
start motor after the movement, and then uses the electric signal to cut off the start motor power and
retract the pinion. This step makes sure that the motor will not be burned out by the reverse induced
voltage generated by the high speed rotation of start motor driven by the flywheel. So there are two
wires from the accumulator and one from the diesel engine.

1 Starting gear
2 Driving shaft
3 Clutch housing
4 Clutch screw splined sleeve
5 Engaging lever
6 Screw spline
7 Clutch cushion
8 Flywheel ring gear

Figure 5-8-1 Clutch of Starter

Friction clutch and the start motor which are supported by the rolling bearing are installed in the
same front end cover at the head of the motor (Fig 5-8-1). The start motor clutch is composed of the
clutch housing, driving shaft, engaging lever, starting gear, clutch cushion, clutch screw splined sleeve.
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 200 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

The clutch housing is connected with the motor’s rotor by the clutch driving plate at the middle. The
starting gear and the engaging lever are installed together with the driving shaft. The driving shaft with
its head fixed on the starting gear is installed outside the engaging lever. The rear of the engaging lever
is in front of the electromagnetic switch’s axis and its head is fixed in the front end cover by the roller
bearing. There is one loop of screw spline on the driving shaft above which there is a sleeve installed on
the spline fit sheath. The clutch spider is fixed in the sleeve.

(2) Disassembly and assembly:

Auxiliary Materials and Rapid Wear Spare Parts

Table 5-8-1
Auxiliary materials No. 2 lithium base grease, diesel oil, brush
Tools Spanner S14-17, screwdriver 8″
Start motor (land) 6.0572.01.0.0005 1/set
Rapid wear spare parts
Start motor (ship) 6.0572.01.0.0101 1/set

Steps of disassembly:
① Take down the ground cable of the accumulator;
② Make a mark and take down the cable of the start motor;
③ Screw out three hexagonal bolts and discharge the start motor;
Install them in the inverse order.

Caution! Before the start motor’s installation, smear a film of No. 2 lithium base grease on the
starting pinion. Then check the pinion carefully, and once finding its breakage, change it.

Fig. 5-8-2 (A) Fig. 5-8-2 (B)

 HND Section 8 The Structure of Starting System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 201 •

Fig. 5-8-2 (C) Fig. 5-8-2 (D)

Fig. 5-8-2 (E)

Fig. 5-8-2 Overhaul of Electric Brush
(3) Overhaul of electric brush:
The electric brush of the starting motor is a rapid wear spare part. The abrasion of the brush is one
of the reasons leading to the diesel engine’s start failure, so it is necessary to check it. The method is
follows:
① Screw out the starting motor by the screwdriver, and then take out the shell;
② Pull out the springs of the brushes with hook 2 (Fig. 5-8-2 (A)). Make sure that the spring is
not curved and the brush is flexible in the guide sleeve. And there must be no carbon dust,
mobile oil or grease on the brush and the brush carrier. If these parts are polluted, then take out
the brush (Fig 5-8-3(B)), and clean it with the cloth that is not cottony. The pipe is cleaned
with compressed air.

Caution!
Before the brush is taken down, mark the place of the brush and the insulation brush wire on
the sleeve and cable. If the brush bursts, unsolders or abrades, and if the spring or the brush wires in the
brush nearly touch the brush carrier, then the brush should be replaced. The spring should be set in the
correct place on the brush when fixing.

③ Clean the commutator gutter before installing new electric brush. Unscrew the cable 1(Fig.
5-8-2 (B)), and screw out five lock nuts 1(Fig5-8-2 (C));
④ Take down the whole end cover 1 (Fig 5-8-2 (D)) from the mount;
⑤ Clear the commutator gutter 1(Fig. 5-8-2 (E)) with hardwood stick, and then clean the
commutator with clean cloth that is not cottony.
⑥ When the commutator has bottomless scratch or is out of round, it needs to be trimmed.

Install them in the inverse order.

2. Accumulator:
The accumulator’s capacity is 180A.h and the voltage is 24V. It can be used to start the motor 12
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 202 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

times after it is fully charged.

Caution!

① check the electrolyte’s level height at fixed period frequently. When the level is low, add some
clean distilled water;
② Check the electrolyte’s density at fixed period frequently (the density changes with
temperature of the environment, so the checking should follow the instructions). If the electricity is not
sufficient, charge it in time.

3. Charging generator:
(1) Structure:
In order to supply electricity to the equipment of the diesel, such as the start motor, monitoring
device and so on, it is insufficient to only use the electricity in the accumulator. So it is necessary to
charge the accumulator with the charging generator, which can ensure that the accumulator has
sufficient electricity. There is a transistor adjuster (manostat) installed beside the imported generator. It
is used to ensure the voltage matching of the start motor and the accumulator when the rotational speed
of the start motor is over 1500r/min. The generator is installed in the middle of the front end cover of
the A row and is motivated by the main pulley through a cone belt.

Fig. 5-8-3 Charging Generator

1 Charging generator 28V/27A 2 Start motor bracket 3 Start motor bracket

4 Belt pulley 5 Fan 6 Strap compensating roller board 7 Cone belt
8 Rubber jacket 9 Protector 10 Electric brush 11 Adjuster

(2) Disassembly and assembly:

Auxiliary Materials and Rapid Wear Spare Parts
 HND Section 8 The Structure of Starting System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 203 •

Table 5-8-2
Auxiliary materials Belt wax
Tools Spanner S14-17, S19-22, S13-15, screwdriver 10″, 8″
Start motor (land) 6.0571.01.0.0146 1/set
Start motor (ship) 6.0571.01.0.0104 1/set
Transistor voltage regulator
6.0571.11.2.0003 1/set
Rapid wear spare parts (imported)
Cone belt 6.0345.02.0.1100 1/set
Cone belt (slime pump
6.0345.02.1.1075 1/set
engine)

Steps of Disassembly:
① Take down the minus wire of the accumulator, and mark on the cable. Take down the start motor
cable 3;
② Screw out the bolt 4 of the clamping device 5;
③ Unscrew the nut 6, and rotate the start motor down, take down the cone belt;
④ Screw out the nut 6 and take down the start motor 7.
Install them in the inverse order.

Fig. 5-8-4 (A) Fig.5-8-4(B) Fig.5-8-4(C)

Fig. 5-8-4 Disassembly and Assembly of Start Motor

(3) Check brush:

① Screw out the bolts 8 and then take down the adjuster with the brush;
② If the brush is destroyed or abraded to only 5mm along the brush carrier, it needs to solder
the cable head 10 and changes the brush.

Steps of Starting:
When starting the machine, turn down the switch to put through the loop of the accumulator and
the start motor. Then the motor’s rotor axis, or the clutch body shell rotates clockwise and brings along
the clutch driving plate to run. Then on the one hand the clutch doesn’t close, and on the other hand the
electromagnetic switch starts, which make the middle shaft move ahead so that it can push the engaging
lever to bring along the driving shaft and the starting gear forward. The middle shaft clogs with the
flywheel ring gear. At the same time the splined sleeve and the driven disk are at quasi friction quick
condition. The driving shaft moves ahead and rotates at the same time because of the driving shaft
screw splined. So these two ring gears work in together perfectly. At this time the torsion can’t push the
flywheel to run.
After these two ring gears have clogged, the driving shaft stops moving ahead. At the same time
the driven disk is at quasi friction state, and the belt sleeve moves afterward at the spiral scroll so that it
can press the clutch more closely until the clutch shuts. The torsion of the body shell impacts on the
 Chapter 5 The Structure of Diesel Engine Series 236 and HND
·• 204 •· the Disassembly, Overhaul and Assembly of its Main Components MWM

driving shaft through the clutch and the sleeve. So the gear drives the flywheel to overcome the
machine’s rest inertia and resistance of motion to run. When the rotational speed reaches the ignition
rotation rate (115r/min), the diesel in the cylinder begins to burn by itself. Then the fire gas does work
and impels the piston to run and the machine begins to work.

Let out the switch and cut off the power as soon as hearing the diesel engine begins to fire. The
rotational speed after the machine starting is overspeed (which won’t destroy the motor) because of the
flywheel ring gear’s driving. At the same time the start motor’s rotor changes initiative for passivity, so
under the impact of the screw spline, the driving shaft, the gear and the engaging lever move afterward.
Then these two gears come away gradually and the start process finishes.

In order to avoid of not letting out the switch in time, which can lead to the motor destroyed, the
charging start motor builds the initial voltage at the start time and makes the movement of another
electromagnetic switch of the motor retract. This voltage disappears when the machine stops. The
switch turns off as the beginning so that it is convenient to start next time. When the starting current is
very large, and in order to avoid of wires and the motor being destroyed and recover the electricity of
the accumulator, it is necessary to restart after not less than 1 minute.

5.8.2 Air Motor Start System

The principle of the air motor start system is the same with the start motor start system. But the air
motor start system drives the pinion with gas.
The air motor is also fixed on the flywheel shell by 3 bolts.

(1) Structure:
Please see Fig. 5-8-5, consist of air bottle, flexible pipe, filter, starter, flange, gear, atomized lubricator
and copper pipe ф 4×1. Capacity of air bottle is 60L, air pressure is 3MPa, 12 times star should be
ensured. Atomized lubricator should use 10# oil or turbine oil.

(2)Principle of Operation:
Press the button, compressing air into air starter form air bottle, The small gear of driving air starter
begin to rotate and gearing the flywheel ring gear, make the shaft rotated, when the engine up to ignition
speed (115rpm), engine can do combustion initiation and push the piston to move and crankshaft rotate,
small gear and flywheel gear ring disengage after starting. Atomized lubricator is using for lubricating.
 HND Section 8 The Structure of Starting System and the Disassembly,
MWM Overhaul and Assembly of Its Main Components • 205 •

Fig. 5-8-5 Air Motor

 Chapter 5 The Structure of Diesel Engine Series 234 and HND
·210· · the Disassembly, Overhaul and Assembly of Its Main Components MWM

5.9 The Structure of Speed Control Mechanism and Stop Mechanism, and the
Disassembly, Overhaul and Assembly of Main Components

The speed control mechanism connects with fanning strip of speed governor directly. The fanning
strip is installed on the operating lever of high pressure oil pump, changes the position of rack，so
changes diesel rotational speed.

5.9.1 Lever Speed Control Mechanism

Fig.5-9-1 Speed Control Mechanism of Marine Engine

1 Bracket 2 Lever 3 Joint Plate 4 Screw 5 Dextrogyrate angle joint
6 Levogyrate angle joint 7 Bush 8 Bush 9 Bush 10 Bush

It is mainly used at marine main engine and mobile machinery shop. Connect with flexible axle
and cylinder, make lever 2 traverse, make joint plate 3 traverse through the angle joint 5, 6 and screw 4,
thereby drive fanning strip of speed governor to change oil supply and rotational speed.
It is convenient to disassemble and assemble speed control mechanism of marine diesel, but should
notice the positions of each small bush 7, 8, 9, 10, don't lose them while disassembling, don't went
wrong while assembling. It should spread supramoly lithium base grease on angle joints and bush 8.
HND Section 9 Structure of Speed Control Mechanism and Stop Mechanism,
MWM and the Disassembly, Overhaul and Assembly of Its Main Components • 211 •

5.9.2 Manual Speed Control Mechanism

Fig. 5-9-2 Manual Speed Control Mechanism

1 Operating hand wheel 2 Bracket 3 Lever 4 Screw

5 Dextrogyrate angle joint to right 6 Laevogyrate angle joint to left 7 Joint plate

Operating hand wheel 1 makes lever 3 traverse, makes joint plate 7 traverse through angle joints 5,
6 and screw 4, thereby drives fanning strip of speed governor to change oil supply and rotational speed.
Manual speed control mechanism is mostly used for land diesel of manual engine operation.
Install manual speed control mechanism in the intake pipe (A row) side, its angle joint, hand wheel
worm and lever bush ought to be smeared with supramoly lithium grease.

5.9.3 Electromotor Speed Control Mechanism

1 Function：
Electromotor speed control mechanism is fitted on diesel intake pipe (A row) by use of one bracket.
It can adjust diesel rotational speed accurately, make engine rotational speed match with the frequency
of other units or electric network for parallel operation.
2．Structure:
It is mainly composed of junction box cover, cable shield, angle joint, tension spring, shell and so
on.
 Chapter 5 The Structure of Diesel Engine Series 234 and HND
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1 Junction box cover

2 Cable shield
3 Angle joint
4 Tension spring
5 Nut
6 Shell
7 Bolt
8 Screw
9, 10 Adjusting bolt
11 Lever

Fig.5-9-3 Electromotor Speed Control Mechanism

3. Disassembly and assembly:

（1）Dismantle accumulator grounding cable;
（2）Open junction box cover 1，dismantle cable and mark，screw off cable shield 2 and pull
out cable;
（3）Loosen two nuts of angle joint 3 and remove screw 11;
（4）Remove tension spring 4;
（5）Screw out nut 5, remove the shell 6 with electromotor;
（6）Remove bolt 7 and remove bracket;
（7）Install it with reverse order .

Caution! Smear supramoly lithium grease on both angle joints and electromotor screw before
assembly.

4．Adjustment:
（1） Remove adjusting bolt 9 and 10 from shell a little;
（2） Adjust diesel to maximum rotational speed;
（3） Screw adjusting bolt 9 carefully until feel resistance, then screw adjusting bolt 9 back
with 1/3 circle，give a good screw and lock;
（4）Adjust engine to minimum rotational speed, and adjusting bolt 10 with the same means;
（5）Check engine at maximum and minimum rotational speed, if improper, fine adjust bolt 9 or
10 for correction.

Caution! If angle of lever 11 is not proper in the range of maximum speed or minimum speed,
adjust the length of screw 8 to achieve it. The two ends of screw 8 are fixed by a
left-handed nut and one right-handed nut.

5． Disassembly and assembly of Electromotor velocity tuning mechanism

HND Section 9 Structure of Speed Control Mechanism and Stop Mechanism,
MWM and the Disassembly, Overhaul and Assembly of Its Main Components • 213 •

Fig.5-9-4 Electromotor Speed Tuning Mechanism

1 Electromotor cover 2 Cable guide bush 3 Cable 4 Bolt

5 Cover board 6 Limit switch 7 Adjusting bolt 8 Lever
9 Axle 10 Locking nut 11 Bolt 12 Screw 13 Shell

(1) Screw out electromotor cover 1 and loosen cable guide bush 2，then loosen cable, after
marking, pull out cable 3;
(2) Screw out four bolts 4 and loosen junction box cover;
(3) Pull out limit switch 6 after marking its cable, and then remove junction box with cover and
cable;
(4) Loosen locking nut of two adjusting bolts 7, and screw out bolt;
(5) Mark the position of level 8 and screw out axle 9 with cam switch and limit switch 6，draw it
out according to arrow direction;
(6) Screw out two limit switches 6;
(7) Screw out locknut 10;
(8) Screw out bolt 11 and remove motor with decelerating gear, remove a group of disk spring,
washer and drive sheath from square axis of electromotor;
(9) Screw out screw 12 from shell 13;
(10) Assemble it with reverse order

Caution!
① Spread some lubricant grease on screw 12 before assembling;
②Assemble disk spring according to Fig. 5-9-4;
③When screw locknut 10, when feeling resistance, screw another circuit.
 Chapter 5 The Structure of Diesel Engine Series 234 and HND
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5.9.4 Stop Mechanism

1. Electromagnetic engine stop valve mechanism
(1) Function:
The Electromagnetic engine stop valve could stop engine by remote control or manual drive, its
theory is that when electromagnetic valve is excited, it will push adjusting lever of injection pump to
zero oil supply position through lever mechanism and cut off fuel supply and hereby lead to engine stop.
（2）Structure:

Fig. 5-9-5 Electromagnetic Stop Mechanism

1 Electromagnetic engine stop valve 2 Bracket 3 Bracket 4 Forked joint
5 Dextrogyrate angle joint 6 Laevogyrate angle joint 7 Screw
8 Lever 9 Dextrogyrate nut 10 laevogyrate nut 11 Bracket 12 Knob
13 Shock damper 14 Tension spring 15 Bush

（3） Disassembly and assembly:

① Remove accumulator grounding cable;
② Screw out the bolt of electromagnetic engine stop valve junction box cover, remove cover and
remove wire after marking;
③ Remove fixing nut 9 of angle joint 5 and 6, loosen two nuts of screw 7，one turned to the right
and the other to the left, and remove screw 7;
④ Screw out nut and bolt of fastening lever 8，remove lever 8;
⑤ Screw out fixed bolt of bracket 2 and 3, dismount electromagnetic engine stop valve with
bracket 2 and 3;
⑥ Remove bracket 2 and 3 from electromagnetic engine stop valve
⑦ Install electromagnetic engine stop valve with reverse order.
HND Section 9 Structure of Speed Control Mechanism and Stop Mechanism,
MWM and the Disassembly, Overhaul and Assembly of Its Main Components • 215 •

4）Wiring diagram of the electromagnetic engine stop valve:

Remove the cover of electromagnetic engine stop valve，connect as follows:

Fig.5-9-6 Wiring Diagram of Electromagnetic Engine Stop Valve

（5）Adjustment of the electromagnetic stop mechanism:
The electromagnetic stop mechanism should ensure diesel to stop and start smoothly, which can
be achieved by adjusting the length of screw 7.
① Loosen nut 9 (dextrorotation) and 10 (laevorotation) of screw 7;
② Push knob to the end (with stop direction), and push speed governor stop lever to the end,
link lever 8 and lever of speed governor together by the screw 7 of angle joint 5 and 6;
③ Loosen screw 7 to adjust flex;

Caution! While installing, after pulling electromagnetic valve to stop position totally, there
ought to be 0.5-2.5mm clearance between engine stop lever of speed governor and
limit surface, which helps preventing the engine from being damaged for excessive
electromagnetic valve coil current. All moving joints and lever 8 should be smeared
with supramoly lithium grease.

④ Screw down fixing nut 9 and 10 of screw;

⑤ Start engine，then stop. Check it whether starting and stopping is better, otherwise adjust the
length of screw.

2. Overspeed protective device

（1） Function:
Overspeed protective device ensures that when the diesel’s rotational speed exceeds its rated speed
by 15％(generating electricity) or 20% (main engine), it will automatically cut off fuel supply to stop
engine.
 Chapter 5 The Structure of Diesel Engine Series 234 and HND
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（2） Structure:
1-Electromagnetic
valve
2-Bracket
3-Screw thread
4-Screw thread
5-Screw thread
6-Pipe joint bolt
7-Overflow hose
8-Pipe joint bolt
9-High pressure oil
pump inlet hose
10-Overflow valve
11-Oil inlet hose
Fig.5-9-7 Overspeed Protective Device

（3）Disassembly and Assembly:

① Cut off fuel inlet and return valve;
② Screw out overflow valve 10，remove overflow hose 7;
③ Screw out screw thread 5，remove oil inlet hose 11;
④ Screw out two pipe joint bolt 8 and 6 which connect electromagnetic valve 1 and high
pressure oil pump inlet hose, then remove hose 9;
⑤ Screw out screw thread 4 and 3;
⑥ Remove wire and mark it; dismount electromagnetic valve 1;
⑦ Screw out bolt and dismount bracket 2;
⑧ Install it with reverse order.

（4） Inspection and adjustment:

Auxiliary Materials and Rapid Wear Spare Parts
Table 5-9-1
Accessory
Worm lock sealant
materials
Tools Spanner S14-17, spanner S17-19, screwdriver 4″
Seal gasket A14×18 6.0492.01.0.1418 4
Rapid wear Seal gasket A8 ×14 6.0492.01.0.0814 2
spare parts Seal gasket A22×27 6.0492.01.0.2227 3
Electromagnetic valve 1214 5601 1
HND Section 9 Structure of Speed Control Mechanism and Stop Mechanism,
MWM and the Disassembly, Overhaul and Assembly of Its Main Components • 217 •

Steps of inspection and adjustment:

① Start diesel, adjust rotational speed to 85％ tolerance of the 115％（generator set）or 120％
（main engine）of rated speed. For example rated speed is 1500r/min，then rotational speed should be
adjusted to 1500×115％×85％＝1466r/min;
② If exceed, readjust. Namely open the door of control box, there is a square box inside which is
overspeed protective relay, press button 2 by right hand, turn adjusting screw 3 laxly and carefully with
screwdriver by left hand until electromagnetic valve acts (cut off fuel supply）to stop engine;

图 5-9-8 1 Overspeed protection relay

2 Simulation button
3 Adjusting screw

Fig.5-9-8 Overspeed Protection Relay

③ Check overflow valve，which should be sealed well. While normal running，it should have
more oil overflowing, otherwise adjust spring pre-stressing;
④ Each seal gasket should be replaced while installing，thread should be smeared with thread lock
sealant after removing of oil, pay attention to the assembly direction of electromagnetic valve;
⑤ Pay attention to the position of electromagnetic valve body manual button，which should be in
starting state.
 Chapter 5 The Structure of Diesel Engine Series 234 and HND
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5.10 Monitoring System

Monitoring system of the diesel mostly consist of diesel control box (cabinet) and electric parts
installed on the diesel (such as engine stop electromagnet, pressure controller, temperature sensor). It is
used to control diesel starting, running and stopping, monitor rotational speed of diesel, temperature of
cooling water, temperature and pressure of engine oil. If the diesel appears abnormal (such as high
temperature of water, low oil pressure and overspeed) when running, the monitoring system can give an
alarm automatically; when diesel appears to overspeed, or has low oil pressure and so on, it can stop the
diesel automatically.
The structure of monitoring system includes box type and cabinet type，method of installation
includes hanging type, machine carrying type and fixed type. For different use, function of monitoring
system is also different. Take marine main engine control box (4.029.2.011.001.7) as an example，
introduce its theory, use and inspection.
Caution: The electric parts in the control box renew quickly, should refer to instruction of control box
carefully.
5.10.1 The panel chart of control box refers to Fig. 5-10-1.
5.10.2 The electric part position of monitoring system on the diesel and wire position,
shown on Fig. 5-10-2.
5.10.3 Brief introduction of electric theory (refer to Fig. 5-10-3)

1. Inactive state
When the diesel is in the state of stopping，charging generator G doesn’t work，its no.61 connecting
terminal is low potential (namely voltage between no. 61 wire and no.31 wire of electrical source
cathode is zero volt), halt indicator HL1 is light, relay KA2 works, its normally closed contact opens
thereby time relay KT doesn’t work, at the same time, alarm protective circuit doesn’t either (such as
low oil pressure), the other set of normally opened contact of KA2 closes, which makes no.32 wire of
starting circuit has positive electricity source，thereby diesel is in a state of readying to start.
2. Starting
Switch on starting button SB2，then relay KA3 works，its normally opened contact closes, which
makes no.50 wire of starting motor get 24 volt，then starting motor works, and makes diesel crankshaft
rotate thereby diesel starts.
3． Running
After diesel starts successfully, charging generator begins to generate electricity, its no.61 wire
translates from low potential to high potential (about 28 volt)，then running indicator HL2 works，halt
indicator HL1 and electrical relay KA2 lay off because of no voltage，the normally open contact of the
KA2 translates from close state of stopping to open circuit state, so switch off power source of starting
 HND
MWM Section 10 Monitoring System • 219 •

circuit no.50 wire, thereby make starting motor exit working automatically. The other set normally
closed contact of KA2 translates from open circuit state of stopping to close state，power source through
its contact makes timing relay KT work and time at the same time, after thirty second retardation, the
normally opened contact of KT closes, which makes power source of diesel and gear case oil pressure
alarm protective circuit switch on, in the state of working.
4． Stop
Normal stop: Switch on stop button SB4 to make no.39 get power source，then contactor KM
works，its normally open contact closes, the positive power source makes stop electromagnet work
through no.81 wire installed on the diesel，thereby make diesel out of work, at the time charging
generator lays off too，voltage of no.61 wire changes from high potential to low potential, then run
indicator HL2 extinguishes, but relay KA2 and halt indicator work, which thereby makes diesel in an
inactive state.
Emergency stop: If diesel needs emergency stop when running, can press emergency stop button
SB6, power source makes through no.79 wire emergency stop electromagnetic valve installed on the
diesel work to switch off diesel fuel gateway. At the same time, relay KA4 which connects to no.79 wire
works，its normally open contact closes，which makes normal halt circuit work simultaneously.
5． Alarm
High water temperature: When diesel runs, water temperature sensor through no.55 and 56 wire
transmits temperature signal to temperature relay WK. When the temperature of cooling water is higher
than the setting value of temperature relay WK (about 90℃) , its contact closes to make electrical relay
KA9 work that its normally open contact closes and power source makes high water temperature
indicator light HL8 illumine through no.53 wire .
Low oil pressure: While diesel running，if lube oil pressure is under 0.15MPa, the contact of
pressure controller (namely low oil pressure switch) installed on the diesel closes, power source makes
relay KA7 work through no.2 wire, its normally open contact closes to illumine low oil pressure indictor
light hl6.
Too low oil pressure: When diesel lube oil pressure is below 0.1MPa，the contact of pressure
controller (namely too low oil pressure switch) installed on the diesel closes to connect no.3 and no.4
wires，power source by no. 4 and no. 44 wires makes relay KA5 work, its first set of normally open
contact closes to make KA5 self lock，the second set of normally open contact closes to switch on
emergency stop circuit and lead diesel to stop，the third set of normally open contact closes to make too
low oil pressure indictor light HL4 light.
Overspeed: While diesel rotational speed exceeds 115％ (engine set) or 120％ (main engine) of
rotational speed rating，normally open contact of overspeed relay closes, then relay KA6 works，the first
set of normally open contact closes to make KA6 self lock，the second set of normally open contact
closes to switch on emergency stop circuit，next set of normally open contact closes to make overspeed
indictor light HL5 light.
 Chapter 5 The Structure of Diesel Engine Series 234 and HND
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6. Obligate connecting end

Supply status signal and alarm signal of machine to user through circumscribed terminal, user also
can operate diesel’s starting, stop and emergency stop through remote mode.

5.10.4 Operating requirement of monitoring system

1. While using monitoring system for the first time or doing inspection service, check whether
connection of each part is right and firm.
2. If diesel is not used frequently, should press “stop” button before each starting，at the same time,
check whether stop electromagnet is in proper place and whether there is bound phenomena，the
ammeter should not exceed 10A too.
3. When starting diesel，every running time of starting motor should not exceed 10 seconds，every
starting interval is 1 minute，look up cause if can’t start diesel for three times.
4. While diesel running, can’t switch off the connecting wire of charging generator and
accumulator, in case of damaging parts of charging generator.
5. If the diesel has had charging generator，when running, can’t charge up accumulator using
environment charging set，for fear causing control circuit out of normal working because of too high
voltage.
6. Check and maintain monitoring system biannually or termly, content: checking whether
connection of every part is firm; whether operation of button and switch and so on is agile; whether
function of starting, stop, emergency stop, experimental light and replacement and so on is normal;
whether overspeed protective function is normal using analogy method; in the state of stopping, check
two outgoing wires of pressure controller using millimeters, resistance value should approach 0 Ohm;
check or adjust display instrument in order to show working parameter of diesel right.
 HND
MWM Chapter 6 Others • 227 •

6 Others
6.1 Packaging and Transportation
The user can choose one suitable packaging according to own transportation mode (railway
transportation and road transportation are available, can be chosen by the user according to his actual
condition.) No matter which kind of transportation and packaging mode is taken, the manufacturer can
offer agent service.

6.2 Open-case Inspection

1. Inspect that whether the case is in good condition and whether there is serious collision in
transportation before open it.
2. Inspect the appearance of the diesel after opening the box. For example, whether there is collision
mark on the diesel, whether the painting is in good condition and the type of the diesel is consistent with
the mark on the name plate.
3. Inspect the amount of the documentation and the accessories according to the loading list.

6.3 Manufacturer’s Promises

The manufacturer promises that its diesels are designed and manufactured according to the
performance figure prescribed in the technical documentation. If the user operates and maintains the
equipment totally according to the manufacturer’s instruction, the manufacturer is responsible for the
maintenance for diesel whose accumulative running doesn’t reach 1000 hours within 12 months since
delivery date. If diesel parts are damaged in the warranty period and there is relevant technical record,
the manufacturer shall provide free maintenance or replacement to the parts damaged by bad design,
manufacturing or assembly.

6.4 The manufacturer bears no responsibility for the follow matters:

1. Normal wear of the components;
2. The damages caused by incorrect storage and maintenance, overload, incorrect operation, using
of inapplicable fuel, lube oil and/or cooling water, irresponsible fundamental, incorrect assembly,
chemical corrosion, electric effect; and any other damages not caused by the manufacturer.

6.5 Tools
As the necessary tools for the special maintenance and repair, all devices, hauling equipments and
special tools should be self-contained and be in good status. These tools can be ordered from the
manufactory or be provided for oneself.

6.6 Fire Safety

Because lots of fuel oil and lube oil are required and exhaust in high temperature is caused while
running the engine, fire will occur easily. To prevent the fire from coming, many components of the
diesel are covered with safety cover, such as the lube oil filter and fuel filter, and the exhaust pipe and
supercharger are packed and spread. In addition, the operators are supposed to be careful enough. The
following matters should be noticed:
 HND
•·228·• Chapter 6 Others MWM

1. Check the interface of the fuel filter and lube oil filter frequently. No leakage is allowed.
2. Pay attention to checking the sealing status of fuel and lube oil joints, such as fuel pump, fuel
injector, supercharger, pressure sensor, etc. Eliminate the abnormity in time.
3. The oil return of fuel injector should be guaranteed to singly enter oil sump.
4. Check the exhaust pipe and turbocharger are well packed and spread, and insure that their
isolation from oil and heat sources is dependable.

6.7 After Service

The manufacturer’s after service department takes charge of after service. The after service
telephone number is 0379-4076739. The requirement of the end user will be answered within 48 hours.
 HND
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