INSTRUCTION MANUAL (OPERATION) | @ Replacement Parts 1. Be sure to use our genuine parts or specified parts. When other parts are used, the quality of our products cannot be guaranteed, 2, When placing an engine part, be sure to specify its part name and part pick een Aoi M RT number shown in the Parts List and further inform us of the engine type and engine number @ Inquiry and Order Order ; Parts sales Inquiry ; Service Department Daihatsu Diesel Parts Service Co.Ltd. 12-94, Tanaka-cho, Ibaraki, Osaka, 567-0025 Japan TEL61-726-21-3482 Fax:81-726-21-3484 “TEL. (06) 6945-5326 FAX. (06) 6945-5304~6 Or, get in touch with our offices listed below. DAIHATSU DIESEL MFG.CO.,LTD. upsowadbutcogp Osaka Head Ortice. Monyama Factory. Tokyo Office. Sydney Office Jokarta Offic. Manila Office. Korea Office. Daihatsu Diesel (Europe) Lt. Dalnatsu Diesel (AMERICA), Ine. Dalhaisu Diesel {ASIA PACIFIC) Pete. Daihatsu Diesel {SHANGHAN) Co,Ltd Delhatou Diese! Pets Servis Co.,Ltd 4 Amuracche,Moryamaccity,Shiga.523-0038 Japan TEL:81-77-582-255! FAX 8'-77-582-6714 2:10, 2chome, NicnbashiHloncho Chuo-ku Tokyo, 103-0023 Japan TELE1-G-8278-0827 FAXB!-3-3246-C395 PO Box519. oth Sydney N'SW.2060 Ausreli TEL.61-2-9923-1155 FAXGI-2-9623-1592 45th Feoy Wisma Antara Bldg, J Nedan Mordoks, Selatan No.17, Jakarta Pusatndones.a TEL2.21-904-541) FAX 221-936-0812 Uni 1010 Horiera Tower Hovtora Corner Valeo Ste, Salcedo Vilage, akat City 1206 Phippiros TEL.69-2-759-0211 65-2-617-1279/1205 FAK.93-2-045-0691 clo Jonghap Meritime Engineering Ie. 183-38 Dongsemr-dong. Young‘, Pusan, Korea TEL:82.61-105-1020 FAX82-61-403-2400 66h Foor, Perinsuler House 38 Monument Sreel,London EC3R SLI, UK TEL se4.20-7626-4600 FAX:44-20-7626-6020 1a0 Adams Avenue Hauppauge NY 11788U.S.4 TEL1+63)-194 3787/8/8 FAK 1-631-434-8760 128 Piovee! Roav Singapore 609865 TEL/65-6270-7235 FAX 65.6270-6236 Suite 3103 Nan Zhong Buldng 880 NanJing Wes! Road Shanghai, China TEL:E6-2)-5234-1228-9 FAXB6-21-5294-1062 42.84, Taneka-eho, Ibaraki, Obaka, 567-0025 Jaoen TEL'81-72-621-3682 FAXBI-72-02 1-3066-8DK-28 INSTRUCTION MANUAL (OPERATION) CHAPTER Introduction General General Construction Engine Adjustment Standards Operation Inspection and Maintenance Fuel Oil, Lubricating Oil, Cooling Water Troubleshooting and Countermeasures ©As for the disassembly,maintenance,assembly,and the parts to be replaced, refer to the separately provided Instruction Manual (Maintenance) and parts List. © Keep this Instruction Manual and the related documents (drawings,materials,etc.) in the specified place so that the persons engaged in operation of the engine can refer to them whenever necessary, and in case that the supervisor of the engine is. changed, be minded that these documents, along with the duties, shall be transferred to the successor without a fall. 6+ 8DK-28 8 02-2Te) CONTENTS 6-8DK-28) Chapter 0 INTRODUCTION 1. Before Running Daihatsu Diesel Engine 2, Basic Information on Satety Operation « 24. Safety Precautions "22 Safety Signs and Symbol Marks 2.3. Indleation of Waming: Waring Labels -. 2.4. Indication of Waming: Warning Label Pesitions 3. Engine Conforming to NOx Technical Code ++++++++-+ 3.4 Outing «++... e 3.2 The parts to be Specified 3.3 Engine settings 4. General information... 4.1. Notation of Engine Types « 4.2 Definition of Terms 4.3 Units - Chapter 1 GENERAL . 1. Engine Specifications "4 2. Auxiliary Equipment E 12 3. Engine Outline and Equipment Layout 13 aa GENERAL CONSTRUCTION «+....0000:s0sssssssessesnsasnseeees 2 . Engine : Bato ea © 4.1. Engine Frame, Cylinder Liner, and Main Searing +--+. sisseme MA 1.2. Cranksheft and Bearing Camshatt and Timing Gear Piston and Connecting Rod... a4 2 3 4 5 Cylinder Head 6 7 38 8 1 1 2418 1.8. Fuel Injection Device «---...--+. 246 1.7. Valve Opatation Device 247 4.8 Fuel Control Device 2418 4.9. Intake and Exhaust System --- 249 2. Piping Systems .. . 22 2.1 Starting Phoumatic System «.- sttentteeneeseetecsestesees Bet 2.2 Fuel Gil System 2.3. Lubricating Oil System 2.4. Cooling Water System 2.5 Nozzle Cooling System 6+ 8DK-28 Z 01-3CONTENTS 3. Controlling Engine Operation: Protective Device . ro 28 3.1. Starting Control 3.2 Stoppage Control --- 3.3. Engine Protection System Chapter 3 ENGINE ADJUSTMENT STANDARDS 0 -..0sceceeeie 8 1. Operating Speciticetions Naan Z BH 2. Valve Settings 32 Chapter 4 OPERATION 4 1. Precautions for Operation Ad 1.1 Incase of Starting ce td 1.2. Incase of Operation 412 1.3: In case of Stoppage 443 2. Preparation for Operation 42 2.1 Preparation for Daily Operation - 424 22. Preparation for Initial Starting after Installation and 422 Starting efter Extended Disuse or Overhaul 3. Starting 43 38.1 Starting Procedure - ox 434 8.2. Inspection and Check Items Immediately after Starting 432 4, Operation 4.4” Running-in 4.2. Warming up and Connecting Load to the Engine 4.3. Operation with Load (Normal Operation) 4.4 Operation Using Heavy Fuel Oil (for Heavy Fuel Oil Engines) ------ At 4.5. Allowable Operating Range 5. Special Operation 5.1, Low-load Operation , 5.2. Operation with Air Cooler Cutoff 452 5.3 Non Turbocharger Operation «+++ : 453 5.4 Operation with Reduced Number of Cylinders - serene 54 6. Stoppage 6.1, Normal Stoppage 6.2 Emergency Stop 6.3. Long-term Shutdown 6+ 8DK-28 Z 01-3 PEN Caes1e)CONTENTS 6-8DK-20| Chapter 5 INSPECTION AND MAINTENANCE ......... 5 1. Precautions for Inspection and Maintenance 54 1.1 Safety Precautions «....s+.10+. soto Bela 4.2 Cautionary Items When Finishing Inspection and Maintenance 51.2 2. Inspection and Maintenance Item Table - see BR 3. Measurements and Adjustments -.. 5 53 3.1 Maximum Explosion Pressure and Exhaust Temperature 634 3.2. Pressure and Temperature of Each Part Sse ee ia, 4, Inspection and Maintenance ° 4.1. Inspecting Paris on and around Intake and Exhaust Valves, and 5-44 ‘Adjusting Valve End Clearance 4.2. Inspection and Maintenance of Fuel Injection Valve 5.42 4.3 Cleaning Fiters am: 5-43 4.4 Cleaning Turbocharger Blower 5-44 4.5. Cleaning Turbocharger Turbine Side 5-45 4.6 Measuring Crankshait Deflection + . 54.6 4.7 Inspecting and Replacing Protective Zine sete) Chapter 6 FUEL OIL, LUBRICATING OIL, COOLING WATER, 6 4. Fuel Oil Characteristics and Control 64 1.1 Selecting Fuel Oil .....s.sseeeerereeee me 1.2 Fuel Oil Characteristics and Contiol ....e-sceees tess eeseeeseseeneees 61.2 e 2. Lubricating Oil Characteristics and Control : sees ve 2 2.1 Selecting Lubricating Oil .... : +621 2.2. Lubricating Oil Characteristics and Control 62.2 8. Cooling Water Characteristics and Control eee Nene 63 3.1. Cooling Fresh Water (Raw Weter) event e e163 8.2 Corrosion Prevention Agent 632 Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES 7 1. Precautions for Troubleshooting PAAR oy 2. Troubleshooting and Countermeasures 2.1. When Starting is Difficult 2 When Engine Revolution Is Not Smooth Insufficient Output 2.4 When Exhaust Gas Temperature or Maximum Explosion Pressure Is Abnormal DAIH. 6+8DK-28 Z 01-3TEM 6-8DK-28 CONTENTS 2.5 When Exhaust Gas Shows Abnormal Color 2.8 Abnormal Noise/Abnormal Vibration 2.7 When Engine Stops Suddenly 2.8 Unable to Stop Engine 2.9 Overspeed 2.10 Low Lubricating Oil Pressure 2.11 High Lubricating Oil Temperature 2.12 Low Cooling Water Pressure (Jacket Line) 2.13 High Cooling Water Temperature (Jacket Line) “728 726 127 728 729 72M 7-242 7-213 6° 8DK-28 Z 01-3 DAIHATSUIntroduction TEM Before Running Daihatsu Diesel Engine 6:BDK-28} 4.4 | 0. Introduction 0-1 Before Running Daihatsu Diesel Engine This instruction manual describes the proper operation procedure of the DK-20 engine, its daily maintenance and inspection procedure, and other necessary information on the engine. To maintain the engine in good operating condition and ensure that it provides the specified performance, be sure te read through this manual and become sufficiently familiar with the proper procedures before operating the engine. Do not use your engine for applications or under the conditions other than these it is designed for. Be sure to observe the procedures described in this manual. Improper practices can cause damage to the engine or result in injuries or fatel accidents. (1) Fuol oil or lubricating oll coming in contact with extremely hot parts of the machine may catch fire. {@) Be attentive to oil leakage curing operation. If any leakage is found, immediately stop the engine and eliminate the leakage. (©} Strictly observe the ‘Caution: Flammables" sign when adding fusl oil or lubricating oil If the engine is stopped due to failure or defect failure, be sure to eliminate the cause of defect and restore it to the normal operating condition before resuming the engine operation. 6+ 8DK-28 Z 01-3 DAIHATSUIntroduction 39-99 6-BDKe28) Engine Conforming to NOx Technical Cod 3.1~3.2! "£0] Outline/Parts to be Specified/Engine Setting Values 0-3 Engine Conforming to NOx Technical Code 0-3.1 Ou e (1} The marine dissel engines to which the 13th tule "Nitrogen Oxides (NOx)" in Supplement VI "Rulos to Prevent Air Pollution by Ships" to MARPOL73/78 Treaty applies shauld conform to NOx Technical Code. (2) The engines conforming ts NOx Technical Code are authorized as an engine group or an engine farnily, and itis allowed to apply the engine parameter chack method to them, when receiving the NOx discharge inspection on board. ‘The engine parameter check method is a method for verifying that the engine components and seting values conform to the requirements specified in the technical fle, NOx discharge. To the engines that are not conferming to the requirements of the technical file, the engine parameter check method cannot be applied. For such engines, the measurement of NOx discharge shall bbe required, nd does not require the measurement of 0-3.2 The parts to be Specified ‘The technical file states the engine components that can affect the NOx discharge specified in NOx Technical Code, and shows the identification marks siamped on them, and the user is cequired to maintain the technical file for each engine. When repiacing any parts shown in the technical file, be sure 1o use our genuine paris stamped with the identification marks. In the case that any parts without the identification mark is used, it shall bo regarded as nenconformance to the requirements of the technical fil, and in euch a case, inepoction by the engine parameter check mathod cannot be applied. ‘The followings are the parts that have the identification marks sp any of these parts, be sure toc fed in the technical fle. When replacing \eck the icentification marks. ({ELJ: "Technical fle") < 1} Cylinder head 2} Piston 3} Turbocharger 4) Aircooler 5) Fuel cam 6) Fuel injection pump 7) Fue! injection pump plunger 8) Fuel injection valve 9} Fuel injection valve nozzle 0-3.3 Engine settings The engines conforming to NOx Technical Code are adjusted to conform to the specifications before shipment. After shipment, they should not be adjusted to such a manner that the setting values specified in the technical tle may be deviated. It any change Is made in the manner that may deviate trom the settings specified in the technical fe, it shall be considered to be nonconformance to the requirements of the technical file, and the inspection by the engine parameter check method cannot be applied The followings are the items that have been set to conform to NOx Technical Code: Diesel fuel oil | oO gz = 0.2-0.3(2-0) . Fusloil | Engineinter | 270-92-2) € 0.5-0.6(5-6) ° Engineiniet | 040-050 | 0.25 (020) 2 Lubricating ot _Lflterourlet)_| (40-50) 25 20} | é Turbocharger | 0.0 —Yinease of MET | &: filter outlet) (0. turbocharger ‘Jacket Ina 0,25~0.35 Consider state and Cooling water Llaciet inlet) dynamic pressure ean Cooler line due to tank head and (cooler inlet) pipe resistance Intake air | Airintako duct Cylinder outlet 500, | © Exhaust gas | Tubochargorinot 600 g “ubochargereutet 500 § Faaceca | eae . Eubmeating elt (cooler outlet) 65 5 Engine inlet g Jacket line Bo itech wate) 2 Engine outlet 85 (00) 8 | cooter ina] Engine inte ae Notes: (1) As for the alarm setting value and emergency stop value, each item of the pressure represents the lower limit value. and each item cf the temperature represents the upper limit value. (2) Manometer, thermometer, and alarm/emergency stop device will be provided depencing on the Individual specttications. (3) The actual data found on each engine may differ from those shown in the above table, and therefore refer to the Test Run Record Table (included in the final documents) for the details, 6° 8DK-28 Z 01-3 Py EME| Engine Adjustment Standards TEM | Valve Setting Values 6-8DK-28 2 3-2 Valve Setting Values jem | Adjustment vaiue Femara $+ : ele | Opening start angle | ei (betore top dead center) Closing end ang : (after bottom dead center) | (35) Valve end clearance 0.5mm - (Valve end clearance adjusting procedure) Opening start ange 9 (oelore bottom dead contor) 65) (1) Nave ard clearance data reprosenis the clearance available. when tho 8 engine is cold 8 — (2) AGUSt valve erd clearance “A” ard : | 3° chown abovo. such that Tt a | becomes equal 10 °0" frst, Then 2 Clesing end angle a Bdjust valve nd claarance "C" such a (after top dead center) | 60) thet it becomes equal to the val | hon itis abe Valve end clearance 0.5mm 3 Opening tat angle ~ Se (before top dead center) | 4 3 Ea £8 Closing end anglo | & (after lop dead cente) | (130° Pumping start angle by ~ May vary depanang onthe engine | inging ert angie by bat sgracons Hae (before top dead certer - the nal documents). cwaee Fuel ol injaotion valve opening pressure 34.4MPa ‘acstmont va) | esoegttems = Way vary depsncirg onthe engine Jaximum combustion pressure Qutput and specitestons, eter to Maximum combuson pressure | cee eee an tho final documents _ Cylinder safety valve opening pressure 19.2MPa (adjustment value) {195kgflem4) DAIHATSU 6° 8DK-28 Z 01-3Operation TEM 1.1,1.2|6:8DK-28) Precautions for Operating Engine 4-1 Precautions for Operating Engine 41.1 Precautions for Starting CO) ry conde reparations before set ol the cporaon of engin, such as the specton to, water onda tvas ex walla proper operation of eves vith land be mide tsar pean cay afer na baer contrat alte codon aera tb sae ange (2) Ris extremely dangercus fo it the opeaten of engine wh he turing bar nse i the Ayre. Be minded to remove ina bar ends it Ia speciiod place tuning i coplted (8) Gon a here se no wok i around teenie. Vihn anyone is aru he eng, be inde sere signaled cot say before stain tne opeatono erg / 4-1.2 Precautions for Operation e © 6 vAlter stating th engine, nspec te following ters and conta thatthe eng sina goed ares normal operating concltons fr. case that an detect is ound, immediate stp the eng, thal he causes of detect carte mesgaledand ne measures fr ecorry canbe akon Any abnormal data of the enaines, such 2s Inadequate lubricating oll pressure, inadequate exhaust temperature, et, # abnormal sound, excessive nesting, et «Any leakage trom pioing, (Partculry. leaks from ol piping wil esultin tre) Be minded never to aitempt to resume the operation cf engine, untl the causes ofthe problem or cetec ae ‘ound and eliminated, and the engine is restored to normal cperatng conditions. (2) Inadvertent coniact of the hody of working stator objects withthe rotary pars (eg. wheel and coupling) wil result in dangerous accidents such es that he staff may be caught up ar the chips of the abjects caught may ily out in ll dictions. Therefore, be minded that both person or cbjact may rot touch the olary pats Further, ensure that the protective covers of the rotary parts are always attached without fail @ AX, (2) During the operation of engine, pariculady the flowing parts are extremely het, and therefore there is danger of buinif touched with bare hands or skin, Be mindd to wear sally gloves or protective gears whenever maintenance or inspection woiks are condtod Further, be sure to operate tho engine withthe protective Exhaust manifold Turbocharger vars of those parts alwaye attached. ®@ Air cooler inlot pipe © Cylinder head ® Indicator valve © Ful injoction pump and high-pressure coupling ‘© Fuel oil fer and fuel oll pipe (in case of heavy fuel cl 6+ BDK-28 Z 01-3 DAIHATSUOperation TEN. Precautions for Operating Engine 6-8DK-28 443 4-1.3 Precautions for Stoppage (1) Make sure eney (2) In case that the engine is stopped in emergency stop, be minded never attempt to resume the operation until the causes of the problems is found and eliminated, and the engine is restored (3) Do not open the crankcase for at lease 1 minutes after the engine 's stopped and fully cooled down. Otherwise. there is a danger of explosion since the in‘lammable mist gas in the crankcase may catch fire (4) The engine immediately after itis stopped is sill extremely hot like during the operation, and there isa danger of burn. Therefore, be minded to wear the protective gears whenever inspection or 9 maintenance works is conducted without fal. the engine is stopped after load is taken off the engine, except in the case of emer PYLE LS) 6+ 8DK-28 Z 00-12Operation TEM. 2.1|6°8DK-28) Preparation for Daily Operation 4-2 Preparation for Operation It is essential to keep the engine in "Operable Conditions" whenever the engine is being operated. Therefore, be sure to perform pre-operation inspections before the starting of engine, and take proper corrective actions and countermeasure whenever any problem is found, to confirm that the engine is in normal conditions for operation, before starting the operation of engine, If the engine is started without pre-operation inspections or preparations, it will cause not only the troubles when starting the engine but also result in a sudden stoppage or damaging accidents. 4.2.1 Preparation for Daily Operation Instruction Manual") @ — — 4) Reduction gear (in case of marine propulsion The number of tha inspection items required engine) before starting the operation varies depencing (ICL: Separately proviced "Reduction Gear on how long the engine has been out of Instruction Manuat") operation © cally staning: Short period of aisuse (thin one month) © Initial starting after a long period of disuse, fo of after overhaul or maintenance. s The daily sterting procedures is ceseribed in | SS Uoper imi this section. As for the latter (rita! stating), A Lower int refer to the following section, 4.2.2 "Proparation for Initial Starting! ‘a (1) Inspection before Operation a) Inspection and Feeding of Lubricating Oil Check the cil level of the oll tank, and feed new oil to the upper limit level of the oll gauge. Further, in case that the lubricating oil is found Inadequate after examination, proceed with makeup or replace the entire amount of the lubricating ail //spectng Engine Lubresting 01 —Oilpor per }): 6-2 "Lubricating Ol Characteristics and Contio}) Le page 4) Separately installed lubricating ol tank or engine lubricating oll tank Engine lubricating oil tank (Base plate common to diferent engines) 2) Governor Lubricating oll evel : 1.9L (RHD10) 1.5L (UBIO) 3) Generator (in case of sel-ubricating type) aes ({D): Separately provided “Generator Inspecting Governor lubricating Oil Level 6+ 8DK-28 Z 01-3 UreOperation TEM Preparation for Daily Operation 6-8DK-28} 2.4 b) Inspection, lubrication, and Operation + Check around the Fuel Regulation System cts nner Manually ubroate the bearing and sicing parts rf of fine, after checking for any loose or missing =a } lovers, link pins, and bolts around the foON govornor, common rod, stoppage system, and Kt OO) pee fuel injection pump rack. Set the operation lever to "STOP" position and confirm that the rack scale is "O°, and than alternately move the lever to "STOP" and “RUN” positions. to confirm that the common a fed and pump rack moves smoothly. $ €) Draining of Condensed Water fram Intake f | Air Inlet Duct L ‘Open the drain cock of the intake air inlet duct of the engine frame, and drain the condensed — 1 5 water out = 11g ports Around governor link ial njaction pump Pey Always keep the drain cock of the engine frame inlet air duct open about 1/4, after draining the condensed water by fully pening the drain cack In case that the humidity is high and the 5 temperature of the air cooler is low, a large 5 amount of condensed water wil accumulate, and may cause abnormal wear or tear on <=: Olina points various parts by flowing into the cylinder. Around fuel injection pump Ly EXE 6°8DK-28 Z 01-3Operation TEN, 2.1|6-8DK-28) Preparation for Daily Operation d) Draining Condensed Water from, and Supply of Air to Air Tank In case of automatically supplying air, first drain the condensed water out of the starting air tank and starting air control tank, and then confirm that air prossuros in these tanks is above the lower limit value, In case of manually supplying air (including manual staring of the air compressor), supply arto the upper limit value. em] Upper Tmt Set 30MPa | 20MPa farting 8ir | ‘goKgticm?} | [20kgtiom?} Contolair | O8MPa | 0.6MPa (okgtiony | fekgtiem’) @) Checking and Feeding of Fresh Cooling Water hook the level of fresh cooling water, and i the love eat tho lowor limi, uppy fresh wator Up to the upper lim, and at the same time add 2 proper amount of the adciive, Further, in case that each properties of water has reached the limit level, replace the entire amount of water. ((ED): 6-3 “Cooling Water Characeristes anc Control") 1) Draining of Fuel Oil and Supply of Oit Firsi drain fuel oll out of the fuel ail service tank, and then check the oil level and supply oil up to the upper limit of the level gauge. 9) Confirmation of the Clutch Being "Neutral" {in case of the clutch-mounted engine) In case of the engines si propulsion engine, make sure that the clutch is in ‘Neutral pesition. as the marine fh) Opening and Closing of valves Repeat "Fully open” and ‘Fully close" operation of the vaives on the piping system 2 ta 3 times to confirm that the valves move smoothly, and then set the valves to RUN’ position, Some of the examples are shown as follows. Since the layout positions of the piping systems and valves differ depending on each engine, refer to the piping diagrams of the final documents for the details, [Examples] 1) Valves for fuel cil inlat pipe and return pipe: ‘Open 2) Valves for cooling water Gacket and cooler), inlet pipe, and outlet pipe: ‘Oper 3) Valves for starting air pipe: "Closec" (‘Opan’ only when starting operation} 4) Valves for operation air pipe: “Open” 5) Valves for pipe coupling parts provided for emergency, priming, cleaning, ete.: "Closed! H the scre stato of half-open, the valve handle may be turned during operation and the opening degree may bo changed, causing mall ‘Therefore, the valves should be fully turned toward either "Open" ar "Clase" position, and should be locked tightly, In case that the valves must necessarily be left half open for the sake of tlow adjustment, be sure to secure the valve handles with wire ring and the like, and fix them to prevent their loosening and turning ightening valves are used on the inctions. 6+ 8DK-28 Z 01-3Operation Preparation for Daily Operation TTEN 6-8DK-28} 2.4 (2) Standby Preparation (Engine on standby) Before entering the operation of engine, conduct the ‘following preparations: 2) Priming with Lubricating Oil Start the motor-driven lubricating oil priming pump (or, reserve pump) § minutes before starting the operation of engine, and confirm that there is no oil leaks from various paris of the piping, 1) Unless turing Is not conducted at the time f priming of the engine, lubricating oil wil not sufficiently be supplied to each par of the crank pin shells and piston sliding section, and consequently the shells and pistons may be damaged Further, lubricating oil will drop off from the valve stem section into the combustion chamber, and a large amount of while ‘smoke may be generated at the time of starting the engine, 2)Pertorm turning of the engine after confirming that the lubricating oil pressure \s established, b) Turning or Air Running Conduct turning or air running to discharge the dusts or water crops that has collected in the cylinder while the engine is stopped. Further, when the engine is started after the inspection of various parts of the engine, or after 2 long period of disuse of the engine, conduct turning before air running to confirm tho cafoty, AN —§_— In case that a large amount of water or oil is accumulated in the cylinder due to the leakage from the cylinder head or fuel Injection valve, there is a possibilty of serious accidents such as bending damage of the connecting rod by water hammer. When conducting turning or ait running, if water or cil has gushed out of the indicator valve, immediately stop the starting of 0 that the causea can be engine, investigated and the countermeasure can be propared and taken. < Turning > i) Conduct priming with lubricating oil i) Set the operation lever to "STOP" position. (Do not inject fuel oi.) i) Set the indicator valve to "Fully open" positien. iv) Conduct turning 1 to 2 times, and confirm that the engine rotates emoothy. Open Close Indicator Valve Operation Lever Pr R19) 6° BDK-28 Z 01-3Operation TEM. 2.1|6-8DK-28| Preparation for Daily Operation «Air Running (abbreviated as Air Run.) > < Work Procedure > ') Conduct priming with lubricating cil. }) Set the operation lever to "STOP" position, ii) "Fully open" the indicator valve iv) Open the starting air valve and control air valve, and press the push button for the starting operation valve. Then, starting alt flows inte the starting air valve, and the engine starts its rotation. Keep pressing the push button for 3 to 4 seconds. (for air run) vi) Release the push button, Then, the starting air valve closes, and the engine stops its rotation, Ii the engine starts its rotation during the | inspection of the inside of the engine or rotary parts, it is extremely dangerous since the working stafl may be caught up or the cbjects thet has been caught up may tly out in all directions. ‘When conducting alr run, strictly observe the following points: 1) Confirm that the turing device or turning bar is set OFF" 2) Send a signal to coworkers and confirm safety before starting to press the push button of the starting operation valve. | v Do not fully open the starting air valve during air ran, keeping the opening at about 1/3, and carefully conduct air running at low speed. Ii air run is conducted at high speed by fully ‘opening the starting air valve, it will not only expend air uselessly. but also will result in | serious accidents such as agaravation of the detects it any defect had been caused ©) Heating of Fuel Of! (when heavy fuel ollie used.) In case thet heavy fue ilis used, heating shall bo mado aecorcing to the fllowing terns ) Turn on the fuel of heating deview i) Operate the motordrivan el feed pure (EL) 6-1 *Fual Cil Charactaristies and Controt) As —— Heated heavy fuel oll is extremely hot (100°C. cor more), and may cause burn if touched by naked hands or skin. ‘Therefore, in case of handling the equipment of fuel oil system that carties heat oil, be sure to wear safety gloves and never touch them with bare hands. ) Turning "ON" of Protective and Alarm Circuit Tur ‘ON" the protective and alarm cireuit on the monitor panel, and confirm that the warning lam is lit up, ©) Operation of Motor-Driven Pumps In case that the engine is equipped with the motor-criven cooling water pump and tuel oll teed pump, stam the pumps 5 minutes before the starting of engine, and confirm that there is no oll leaks from various parts of piping, 6+ 8DK-28 Z 01-3 PCEOperation Disuse, and Overhaul or Maintenance Preparation for Initial Starting after A Long Period of e-80K28| 2.2 4-2.2 Preparation for Initial Starting after A Long Period of Disuse and Overhaul or Maintenance Since the engine is not ready for immediate sterling of operation efter a long petied of douse, and overhaul or maintenance, itis particularly necessaty to thoroughly conduct tne preparations for eparation Before the preparation for daily operation, conduct the following preparation works ((EI: 4-2.1) (1) Inspection of Crankcase and Cylinder Liner, © ane SuppIy oF Gi a) Inspection of the Inside of Crankease Open the side cover of the engine frame, and check and ensure that tools, waste clothes, foreign matters such as desiccants are rot left behind, and that there is no rusting on the ylinder liners, crankshaft, and so on, b) Supplying Lubricating Oil to Cylinder Liner ‘Atter a long period of disuse, the various parts of engine are not covered with sufficient amount of lubricating oil, Particularly around the cylinder, lubricating oil cannot be supplied sufficiently with priming alone, and therefore supply lubricating oil on the following orocecire 1) Conduct turing to alow te pistons to move e upward, and appl oiatrg ol onthe lorer part ofthe oyinder ines by @ spray device and the ke i) Sequential concuct the above procedure to ich ir (2) Inspection of Connections and Joints Inspect again the extemal connections or joints fo confirm that there is ne ecnnections that has been forgetten to bo tightened, or loosened joins. (8) Opening, Cleaning, and Cleansing of Filters Dust or foreign objects, that had been collected into piping during transportation, and outfitting or installation, is accumulated in the filters of the engine inlet Open the fcllowing titers, and cleanse the inside end the elements ofthe fiers: 4) Sterting ar fiter and controlar fiter 2) Fuel ol titer | (2): §-4.9 'Cleening Filters!) 2) Lubricating of fiter ((ZL}: 54.3 "Cleaning Filters") 4) Lubricating ol iter for turbocharger 5) Centitugal lubricating oil Eypassfiter 6) Cooling water fier Silcagel should be presen Applying Procedure of Lubricating Oi (4) Priming with Lubricating Air Conduct priming with lubricating oil and exhausting air on the following procodure: a) Operate the lubricating oil priming pump for about 5 minutes, and during this period conduct turning 2 te 3 times by apening the indicator valve, so that it can be confirmed that 1no fuel oil, lubricating ol, and water do not flow out of the indicator valve. b) At the same time, open the each cover and check the dripping-down conditions of lubricating oll from each part. and Exhausting 6+ 8DK-28 Z 00-12 6+ 8DK-28 Z 01-3 4 aOperation ITEM: Preparation for Initial Starting after A Long Period of 2.2|6°8DK-28) Distise, and Overhaul or Maintenance 1) Engine frame: Main bearing, crank pin, piston (cooling chamber), and piston pin 2) Cam case: Cam bearing, swing arm, and tappet 3) Cylindor head: Rocker arm and valve retaining tec ¢} Operate the priming pump, open the air vent valve for lubricating oil filter, and drain lubricating oil until air bubbles in the oll are completely vanish 4) Check that there is no oil leakage from various Par's of the piping during priming (5) Priming with Fuel Oil and Exhausting Air Conduct priming with fuel oil and exhausting alr bubbles en the following procedure: 1) Operate the fuel cil feed pump (in case of the engine equipped with a motor-driven cil feed pump) jl) Open the fuel oil inlet valve, after confirming that the operation lever is cot to "STOP® iil) Open the air vent valve of the fuel olf filer, and drain oil until air bubbles in oil are completely vanished. iv) Open the air vent valve of the fuel injection Pump, and drain oi! until air bubbles in oil are completely vanished, Walter completely removing air bubbles securely tighten the air vent plug Praiter ‘Turbocharger (6) Cleaning of Turbocharger Pre-Filter Dust or debris are collected in the pre-fiter of the turbocharger during transportation, outfitting, and installation, causing the filter to be stained or damaged, Thoraforo, cloan it or replace it with a new one before starting the operation Air vant valve Exhausting Air of Fuel Injection Pump 6 8DK-28 Z 01-3 ey weOperation Starting Procedure 6-80K-28] "3.4 4-3 Starting > Inadvertent contact of working staff or objects with the rotary parts is extremely dangerous since the person may be caught up or the object that hes been caught up may fly out in all directions. Therefore, strictly observe the following items when starting the operation 1} Coniirm that the protective covers of rotary parts are mounted in normal state, and that the rotary parts are free of any obstacle. 2)Contirm that the turning device or turning bar is set to “OFF” | 3)Send a signal to a coworker it there is any, and contirm safety before starting the operation of engine. 4:3.1 Starting Procedure (1) Starting from Engine Side (Locally) Starting procedure can be classified into the three types: engine side sterting (local starting), remote starting, and automatic starting, and which of these should be employed depends on the specifications. However, local starting (starting from engine sice) by manual operation should always be employed after a long period of disuse or after overhaul or maintenance < Work Procedure > i) Open the staring valve and control air vaive, it) Set the operation lever to “START” position. li) Press the push bution for the starting operation valve. iv) If the rotation speed of the engine has rapidly increased and starting has been established along with continuous ignition sounds, release the push button, vv} Affor confirming that the rotation speod of the engine has reached the specified spood, and each pressure has reached the specified value, set the operation lever to "RUI position vi) Close the starting air valve. (Leave the control air valve "Open* as ts) |) Operation 1 ite! Position of Operation Lever (2) Remote Starting (Manual and Push Button Starting) < Work Procedure > i) Switeh the starting mode to the remote mode (com monitor chamber) from local mode (from engine side). ii) Set the operation lever to "RUN" position, ii) Open the starting air valve and control air valve, aftor coniimming that "READY" incicator lamp has lit up. iv) Pross the starting push button V)Confirm that "RUN" indicator lamp on the panel has lit up as the rotation spead of the engine has reached the specified rate, and each pressure has reached the specified value. vi) Close the starting air valve. (Leave the contro) ait valve “OPEN” as itis.) (3) Automatic Starting In case of automatic starting, the engine starts, automatically by the starting command based on preset starting conditions, such as the overload conditions of powor shutdown or othor engines {in case of plural engines), and therefore it is essential that the engine should always be kept in operable conditions Engines should be kept in the following conditions at all times 1) Starling mode: "AUTO" 2) Operation lever position: "RUN' 3) Starting air valve and control air valve: OPEN" 6+ 8DK-28 Z 01-3Operation EM Starting Procedure / Inspection and Check Items 3.1,3.2|6-8DK-28) immediately After Starting (4) Corrective Measure In Case of Faulty Starting 1 case that the engine has failed to start or has not started smoothiy, take corrective measures by refering to a separetely provided eoction. ({£L) :7 "Trouble Shooting and Countermeasures") “ In caso that the engine has repeatedly failed to start in an extremely cold weather while the engine is still in cold condition, the unbumt mist of fuel oil may remain in the exhaust manifold, having a possibility of catching fire or explosion being caused by high-temperature combustion gas. When starting failure has been repeated, conduct alr running and exhaust the unburnt mist in the exhaust manifold, before restarting the engine. 4-3.2 Inspection and Check Items Immediately After Starting Check the following items immediately after starting When any abnormal error has been found, immediately stop the engine and take proper measures (LQ): 7 "Trouble shooting ané Countermeasure’) — After conducting overhaul or maintenance of the sliding parts or rotary parts, be sure lo once stop the engine and check that there is no error or failure by hand-touching, (1) Engine Rotation Speed Confirm that the engine rotation speed (the number of idle rotation speed, in case of the marine propulsion engine) has reached the specified rotation speed, and hunting (swinging of tachometer is not occurred (2) Pressure Reading of Each Section Confirm that the ingicator of pressure reading, for the manometer with blue mark, is within the blue mark, showing the pressure is within the specified valve. [HseBoot a) [Ful Teor] Gauge Board (9) Abnormal Sound Carefully listen to the sound of the following engine parts, and check if there is any abnormal sound or net 1] Cylinder head and surrounding parts (intake and exhaust valves) 2) Crankcase 3) Crankcase and tming gear and auxiliary drive gear 4) Turbocharger (4) Exhaust Temperature Check the exhaust temperature of each cylinder, and confirm that all the cylinders are properly burnt (at 200°C or mere). (6) Gas Leakage trom Starting Valve If gas has leaked from the starting valve, the starting air main pipe becomes hot Check if the starting air main pipe is not heated fr not by lightly touching the pipe (6) Leakage and Loosening of Each Part Check if the bolts and nuts of installation part or connecting part are not loosened, and if oll water, or gas Is not leaked. 6+ 8DK-28 Z 01-3 PyeOperation Running-In Operation TEM 6°8DK-28} 4.4 4-4 Operation 4-4.1 Running-In Operation When the engine is started for the first time or immediately after replacement of the parts, such as the cylinder liners and piston, since the sliding parts of the engine are not yet sufficiently ready to work smoothly or freely, falure such as abnormal wear or seizure of the sliding parts may occur, it the load is abruptly applied in the stage of such conditions. Gonduct the runringsin operation to ensure smooth and tree working of the sliding parts on the following procedure, before entering normal operation (1) Inti Running-n Operation ill eubetartialy affect tho engine performance, especially the combustion porformaneo and consequently the consumption efficiency of Lubricating ol, whathor the piston anc il tings move smocthly and freely, oF not. Further, itis assumed that they wil be decided by the intial operation ot a few hours. When the oylinder liner, piston, pston ring, and slaing pers eround cyiincer are replaced, be sure to conduct running-in operation in accordance tothe figure shown below (CD): Fig. 4.1 “iia! Runningn Petter’) (2) Operating Conditions during Running-In Operation Be sure to operate the engine during the running. in period under the following conditions: 1) Load: 80% or less 2) Fuel oil to be used: Diesel fusl cil Note: For the engines of heavy fuel oil specttication, be minded to use diesel ‘ual cil during the running-in period 3} Lubricating oil to be used shall comply with the {uel oil to be used. Note that in case of the engine with heavy fuel cil specttication, lubrication oll for heavy fuel of can be used from the start of engine driving, notwithstanding the avove prescriptions of 2) 4) Running-in period is 150 hours. (8) Inspection lems during Initial Running-In Operation To detect the potential problems and eliminate the causes to previously provent such probleme, perficulatly hood cautions to the following items: 1) Abnormal sound 2) Partial heating 3) Leakage from connection parts, and loosening cf screws 4) Explosion pressure, exhaust temperature. imeguiar exhaust color: Abnormal burning ot fuel 5) Excessive consumption of lubricating oil Improper working of liners and rings (4) Inspection and Works after Completion of Running-In Operation Al the time when the running-in operation is completed, conduct the following inspection works and confirm that there is not any abnormality bofore entering the normal and regular oporation of ongine: 1) Inspection of foreign matters and stains in the crankeasa 2) Visual inspection of the inner surface of the cylinder liner 3) Inspection and cleaning of the element ot each filter 4) Remove the flushing filter attached to the element of the fue! ol titer. Be minded never to perform the operation of engine using heavy fuel oil, while the flushing fier is attached. 6+ 8DK-28 Z 01-3 EgOperation Running-In Operation min Shutdown i nr ‘Gontnuous Sparaton eration, mio 60min Stutown imi ! sen nensen | twain = @ Fig. 4.1 Initial Running-In Pattern 6 + 8DK-28 Z 01-3 DAIHATSUOperation a Warming-Up and Connecting Load to the Engine 4-4.2 Warming-Up and Connecting Load to the Engine In case that the engine is started while itis stil in a cold state, first perform the warm-up operation, except for the case of emergency, ané gradually connect the load after the engine has sufficiently been warmed up. It the load is hastily connected while the various parts of the engine are sill cold and not yet in the conditions for proper uel combustion and lubrication, malfunctions such as faulty combustion, excessive wear of tha sliding parts, and seizure may be caused. (1) Warming-up Operation of Engine a) Use diesel tuel oll for warming-up operation Be sure to use dizsel fuel oil for warming up the engine, even in case of the engine with heavy ‘uel cil specification 'b) No load (Idle operation in cage of warming up the marine propulsion engine) First operate under no load or light load, and connect the load aftor jacket cooling water and lubricating cil temperature has increased Load cc ; (Normal lead) 5 No lead 8 10 A 85 minded to parm no-load cperation on ‘or warminguup operation, and resran the duration of no-loae operation within 10 rites. Running the engine under no-ead for long hours will resut in malfunctions such as | tauty combustion and eolecion of carbons inthe conbuston chamber (2) Connecting Load to the Engine The lower the engine temperature (temperatures of jacket cooling water and lubricating cil) is, the longer time it is needed to connect the load, ‘The standard load connection time is shown in the ‘igure below. Fig-4.2 'Load Connection Pattern") In case of the marine propulsion engine (direct, connection by propeller), be minded to gradually eee t40°e use 4 :Jacket coating water and lubricating oi! terrperature at stanup 2 3084. TIME(min) Fig.4.2 Load Connection Pattern 6° 8DK-28 Z 01-3Operation 43 6-8DK-28) Operation with Load (Normal Operation) b) Compare each ofthe measured data with the aly introduced, and judge if there is any problem and shook tho dogroe of dotriraton (EL): "Tost Run Rocerd Tab" inthe irl docurront 4-4.3 Operation with Load (Normal Operation) Inspect the running concitions of the engine and measure the operating performance data in regular intervals, during the continuous operation with load {including period of the running-in operation) In case that any problem is found as the results of the inspection and measurement, take proper data obtained when the engine wes ne < Measurement Items > measures such as adjustment or repair of the 1) Room temparature elective paris. (Refer to a separately provided 2) Load (output) section.) 3) Rotation speed ...... In case of variable ((QQ): 5-3 “Measurement and Adjustment’) speed engine ({LL): 7 “Troubleshooting and Countermeasures") 4) Maximum combustion pressure (each e cylinder) (1) Inspection of Operating Conditions 5) Intake air temperature (turbocharger inlet) 6) Exhaust temperature (cuilet of each cylinder) 4) Abnormal sound 7) Intake air pressure (engine inl) 2) Partial overheat 8) Lubricating ol preseure (engine inlet) 3) Leakage from connections and looseness of 9) Lubricating oil pressure for turbocharger sorews (Turbocharger inlet) 4) Abnormal combustion pressure, exhaust 410) Costing water proscure (ongine inlat) temperature, and exhaust ecler.... Abnormal 11) Fuel ol pressure (engine inlet) combustion In case of heavy fuel ol specification 5) Excessive consumption of lubricating oil 412) Inlet air temperature (engine inlat Damaged eylinder liner and ting 13) Lubricating oil temperature (engine inlet) 14) Cooling water temperature (engine inlet and A cute | During the operation of engine, particularly 15) Fuetol temperature (engine init) | the following parts become extremely hot In case of heavy fuel ol specification e ard touching these parts with bare ands or 16) Reading on fuel injection pump rack scale skin may cause burs. Therefore, be minded to use the protective (8) Regular inspection and Maintenance gears such as safely gloves when working on them, © Exhaust manifold © Turbocharger © Air cooler inlet pipe Cylinder head ® Indicator valve © Fuel cil systam equipment and piping (in case of heavy fuel cil) (2) Measuring Performance Data a) Measure the operating performance data at least once every day, when the load variation is less and the load Is stable, Conduct inspection and maintenance of the vaxious pats of engine regulary (Roles to.a coperately provided cootion) (GD): 5 "inspection and Maintenance’) (4) Operation Records After completion of the inspection and measurement, keap the records of the works performed on adjustment or repair in the log book. 6° 80K-28 Z 01-3 ar wee)Operation Operation with Load (Normel Operation)/ Operation using |p any og! 13 4 Heavy Fuel Oil Operation records are very important documents when understanding the conditions of engine and tracing the history of the inspection or maintenance that nas been performed, Keep and store them carefully, and when the supervisor is changed, be sure to tansfer the records 10 the successor without fail l = 4-4.4 Operation Using Heavy Fuel Oil (in case of Heavy Fuel Oil Specification Engine) Heavy tual cll is lower in ts quality anc higher in its Miscosity than diesel fuel ol When using heavy fuel ol, proper operation control, such as swkching to the operation using diesel fuel il depending on the load conditions is required, in adcition te proper fuel oil anc luoticeting oil control (refer to the separate sections.) (QQ): 64 "Fuel Oil Characteristics and Control") ((]:6-2 “Luvticeting Oi| Charactorictios and Control’ (1) Operation with Diesel Fuel Cit Bo minded to use heavy fuel cil only under stable load conditions, and be sure to use diesel fuel ol in the folowing cases a) During Running-in Operation Period (150 hours} 1) Immediately alter installation 2) After replacement of the sliding paris around cylinder (e.g. cylinder liner, piston, and piston ring) (LD): 4.4.1 *Running-tn Operation’) b) During Starting or Warming-Up Opsration (LQ): «3 ‘Starting’ (LD): 44.2 "Wamming-Up Operation ) During Idling or Low-Load Operation When the engine is operated under low load, the compressed air temperature in the cylinder {and fuel injection pressure of fuel oil is low, and therefore if the heavy fuel, of which combustion quality is lower than that of diesel fuel ol, is used, combustion will become unstable, resulting in undesirable conditions, such as worsening of the exhaust smoke, sticking of the ting, and so on. the load that is below the lowor limit doserbod in the engine specitication, be minded to use diesel fuel oll. In case of the connection of 4) In Case Load Variation Is Heavy 1) When entering or leaving port 2) When weather is rough and stormy 8) When cargo is being loaded cr unloaded ) Before Stopping Engine (ICL): 46 ‘Stoppage") (2) Switching Fue! Oil Types Heavy fuel oil is normally heated up to 80 to 90°C in the service tank, and 100°C or moro at the engine inlet, and the temperature difference is lerger a2 compared with that of ciosel fuel ol {non-heated}, and therefore if fuel ol is suddenly switched between these oils, it may cause maliunetions such as sticking of the {ual injection pump, vapor lock, and so on 2) Slowly switch from diesel fuel oil to heavy fuel cil, so that the rate of change in the fuel oll temperature at the engine inlet is between 5 and 10°C per minute (CD): Fig.4-3 Switching Pattern from Diese! Fuel Oil to Heavy Fuel Oil b) Maintain the viscosity (temperature) of heavy fuel oil et the engine inlet at the specified ¢) Do not reise the temperature of ciesel fuel oil beyond the flashing point (60°C is tho standard point) 4) To prevent the generation of vag the pressure of fual cil atthe spectied value. Further, remove the air bubbles in fuel cil in the various equipment of the fuel oll system (beater, filter, tank, etc) from time to te, so that the accumulation of vapor can be prevented maintain 6 +8DK-28 Z 01-3Operation SY 4.4 6-80-28 Operation using Heavy Fuel Oil e) Confirm that the heat traces on piping and ‘equipment is prover functioning. pas Heated heavy fuel oll s extremely ct, and if touched with bare hands or skin, it may cause @ bum. Therefore, be minced not to directly touch the exposed metallic parts such as the valves and cocks, and wear the protective gear cuch as safety gloves when working on them, © Switching from Diesel Fuel Oil to Heavy Fuel Oil Tee es Viseosity at engine iniot yarenss \s0 6 70 see AW No.4 Temperature ot heavy fuel oi Switching epaed Bto 10cm oiterperaue | et ‘engine F Zs In ease that emargancy stop is made during the operation with heavy fuel oil, immadiataly switch the {uel oil to diesel fuel oil, move the motordriven pump, and perform flushing of the fuel of system. HH the engine is cooled down with the heavy fuel oil jeft unchanged, the ofl will be solicitied and the operation will be prohibited. © Switching from Heavy Fuel Oil to Diesel Fue! Oil acoxity at angina inet [31 14 NS 0 #3 70 poe. AW Not Temperaiuie 0 heavy fue! all Switohing speed to 10:imin Temperature of Temperate 0! Seoattea a devel eto a Switening from 8 sSuttoning trom é dese fuel oll to é diesel fuel oll to @ operation win BES E91" persion with ston win S531 SH © operaton wth dieseituel cil" * heavy fuel oll Hy fuel hoary fuel 2 > E | [check the = ; E a 5 || sae te ata ale bes 2| Speretor |] ofneavy tue! oil | (above the lover load lint) $| [at heavy tet £)| suo 2 & || sete 8 Note: 1. Since the preireetment of fuel oil differs depending on the use purpase of tho engine, the operating method suitable to each system is necessary. Tho diecel fuel oll tomporature when switching on heated condition shall be €0°C or more. Fig.4-3 Switching Pattorn from Diesel Fuel Oil to Heavy Fuel Oil 6+ BDK-28 Z 01-3Operation Allowable Operating Range TEM 6-8DK-28) 45 4-4.5 Allowable Operating Range (in case of the marine propulsion engine) tn case of the m ine propulsion engine, the load changes with the marine characteristics, and according to the changes in the rotation speed. in accordance Tho allowable operating rango and recommended ‘operating range within the marine characteristics are shown in the figure below. When actually cparating, be minded to select a proper rotation speed and engine torque (Pme, to be judged based on the reading an the rack scale), and keep operating within the recommended operating range as tar as possivle, 0 prevent being overloaded. Note that the lower load Imit is normaly 20% whien using heavy fuel of, and if he load to be connected is lower than this limit value, use diesel fuel ol (10D): Fig.4.4 ‘Allowable Operating Range’ ‘As for the output characteristics cf the engine to be actually operated, refer to “Test Pun Record Table" in the separately provided final documents 190 60 \ \ (1) In case of Fixed Pitch Propeller (FPP) ‘The fixed pitched propeller is generally designed by including the sea margin, which has taken into consideration the fouled hull surface, in addition to the absorbed horsepower due to the marine characteristics In case that fouling of the hull surface has advanced, increasing the resistance, and has exceedad beyond the sea mergin, the absorbed horsepower increases to such an extent that the excessive torque occurs even if the rotation speed is maintained constant. Therefore, alweys heed cautions to the rotation speed and the reading on the rack scale to prevent excessive torque. Further, particularly be careful when the absorbed propeller horsepower suddenly increases, for example when in stormy weather and 80 on, since this will often cause the excessive torque to ocsur, eventually loading to surging of the turbocharger. \ Propeller design point "| lowable operating rance (7AM, Pecerendes conics a P-curve : Manne oropoller Character etc cue Meourve : Curve with sea rargin {aken into consideration 20 Zp Allowable range ot ~ Shertima speralion ondioee tusl olin the case of standard Ey 0 70 2 0 Fig.4.4 Allowable Operating Range 7a Eaue-1 2 5100 108 —> Revolutions.%) 6+ 8DK-28 Z 01-3Operation TEN 4,5|6-8DK-28} Allowable Operating Range (2) n case of Changeable Pitch Propeller (CPP) The changeable nich propeller capable o changing i propeler pith sede eng), vine maintaining fo gio rational speed onda and ic thoroby cape of onangig tho horeopower, Threats propeller has amor thatthe rotat charged acorn oth conden the shar auxiliary machinery driven by the mating prepusion ancne an the ul estan Fowever since tne cnanceabs pich oper tends ttn undor excessive frau fo 38 much extent 26 fh a eae todo ots operaten e be minded to operate Ine engine propery preventing the excessive torque, by always grating tno load conto sorbed ional speed and load can be 6+ 8DK-28 Z 01-3Operation Off Low-Load Operation and Operation with Air Cooler Cut- 6-8DK-28 Bt 52 4-5 Special Operation 4.5.1 Low-Load Operation Since running the engine with a low load lower than a certain limit can lead to unfavorable combustion conditions such as the reduction of intake air pressure and blowing-back of exhaust alr, if the engine |s operated under such conditions for long hours, it may result in the various maliunetions such as fouling of the turbocharger and combustion chamber, faully combustion, and Therefore, be sure to minimize the low-load operation to a shorter periad of time as much as possible, and in case that the engine must bo inovitably “un undor 2 low load for long hours, bo sure to observe the following conditions: (1) Low Load Limit The low load limit varies depending on each specification, Confirm the low load limit described on the specication supplied wth the engine (2) Use of Diesel Fuel Ol In case of the heavy fuel ol specification, be sure fo switch i to diesel fuel ol @) Increase of Intake Air Temperature To improve the combustion conditions, increase the intake air temperature and adjust to as a higher level as possible, within tho following Fit © Intake air: 75°C or locs © Exhaust air temperature (cylindar outlet): 400°C. orless (2): 5-3.2/2) "Measurement and Adjustment of Intake Air Temperature") (4) Cleaning of Turbocharger Properly increase the number of times of cleaning the turbocharger according to necessity. (6) Intermittent High Load Operation If the load is switched to the high load (60 % or more) for about 30 minutes during low-load operation, it will have an effect to restrain or reduce the fouling of the combustion chamber, as well as the intake and exhaust air systems. 4-5.2 Operation with Air Cooler Cut-Off In case that the defects such as breakage of the fing tube in the air cooler or water leakage from a caulked sections is found, and the repairing cannet be performed quickly, an emergoney measure can be taken by cutting off the air cooler on tho following procedure: (1) Preparation for Operation a) Stop water supply to the cooler cooling system, and draw out the water from the air cooler, b) Insert a shielding plate (A) into the flange part cf the air cooler cooling water inlet pipe and outlet pipe. ¢) "Fully open" the bypass valve of the air cooler. d) Operate the cooler cooling water pump, and confirm thet no water is leaked from the flange packing ere. Airco ee SBS Fp J cooing water Le wie ee Shiecng pate A Bypass vave Rea BAL cose Air Cooler Adjusting Valve << Operating Conditions >> 4) The fuel oil t be used shall be ciesol fuel ol b) Restrain the output as low as possible, referring to the following values as the standard #Pme (average elfective pressure): O.8MPa {8 katfom"} ‘Exhaust alt temperature (cylinder outlet) 400 °C {Max 450°C} PYG EE) 6° 8DK-28 Z 01-3Operation TEN 5.3|6°SDK-28) Special Operation: Non-Turbocharger Operation 4-5.3 Non-Turbocharger Operation In case of the marine propulsion engine, @ nen turbocharger operation implement (turbocharger blind plate) is provided, so that operation in emergency can be made even when the turbocharger may have been damaged, (The gonerator is optional) The non-turbochargor operation procedure is as the followings ({LL J: Turbocharger insteuetion Manual’) (1) Preparation for Operation a) Remove the cooling water inlet and outlet pipes, lubricating oil inlat and oullet pipes, and mist drawing-out pipes aut of the turbochara: bb) Remove the turbocharger out of the engine ©) Remove the gas inlet casing according 10 the Turbocharger Instruction Manual d) Install implement to the gas inlet casing as shewn in the figure on the night. ©) Install the gas inlet casing te the engine. f) Romove tho intake connecting pipe (oeliows), and the non-turbocharger operation II the air ctrainor go a not to inhale dust through the air inlet saction of the air cooler inlet pips. Non turboomarger operation Turbocharger MET-SR, TPS. 9) Close the cooling water inlet and outlet pipes, fas well as the lubricating oil inlet and outlet ppes. ln cage of VTR> a) Flomove the turkocharger. bb) Remove the bearings on the turbine side and blower side according to Turbocharger Instruction Manual ©) Draw out the rotor shaft, and install the non: turbocharger operation implement as shown in the figure on the right ¢) Install the turbocharger in the previous position. €) Remove the intake connecting pipe (bellows), and install the air strainer so as not to inhale dust through the air inlet section of the air cooler inlet pipe. f) Normally supply cooling water to the turbocharger. In case of TPS> a) Stop the lubricant eupply to the engine. b) Rlemove the turbocharger out of the engine. ¢) Remove the gas inlet casing accarding to the Turbocharger Instruction Manual d)Install the non-turbocharger operation implement fo the gas inlet casing as shown in the figure on the nant €) Install the aas inlet ce ato the engine. operation erplement Turbocharger VTR 6+ 8DK-28 B 02.2Operation ‘Special Operation: Non-Turbocharger Operation / Operation with Reduced Number of Cylinders 6-80K-281 5.3.5.4 4) Remove the intake connecting pipe (bellows), and instal the air strainer so as not to inhele dust through the air inlet section of the air cooler inlet pips. g)Stert the lubricant eupply 10 the engine, At thi timo, verily that any lubricant doos not leak ftom the non-supercharged operational tool and the supercharger support base, ahs During operation or immediately aiter stopping the engine, the turbocharger is extremely hot, and if the turbocharger is touched with pare hands or skin, it may cause burns, ‘Therefore, perform the cisassembly work afier the turbocharger is completely cooled down. > a) The fuel cil to be usedis diesal fuel oll b) Restrain the output as at a lower level as possible, referring to the following values as the standard © Pre (average effective pressure) 0.43 MPa {4.5 kgi/om’} © Exhaust air temperature (cylinder outlet) 400°C (Max 450°C] 4-5.4 Operation with Reduced Number of Cylinders ‘Adoption of the operation with the reduced number af cylinders impose such problems as the torsional vibration of the shaft system as well as the external vibration of the engine, and therefore this operation should be limited as a secondary measure to be sod only in omargoncy. The operation with the reduced number of cylinders may ke conducted in various cases such as the case of only reducing the fuel oil, or the case in which the operating sections are needed to be removed. Further, since the prohibited items for the operation vary depending on each case, be sure to inquire our company tor the working procedures, cautionary items on the operation, and 80 on, abiain the necossary instructions, and etricly obsorve them, when the operation with the reduced number of cylinders is conducted <> a) The tual cil to be used is diesel fuel oil b) The output shall be as below: (No. of esingers}-iNo. of reduce cyinders) a (total No. of cylinders) However, the output may be reduced according to the turbocharger surging or eyhaust air temperature in each case. ¢) Exhaust air temperature: 450°C (Max 450°C} ie AN Be altentive of the external vibration of 6° 8DK-28 B 02-2Operation TER 6.1 |6°8DK-28} Normal Stoppage 4-6 Stoppage 4-6.1 Normal Stoppage (1) Preparations for Stoppage a) In case that Neavy uel oil Is used, switch the fue! oil to diesel fuel cil 30 minutes belore stopping the engine. b) Immeciately before stopping the engine, stari the operation of lubricating oil priming pump. ) Confirm thet the starting air pressure is at 2.0 MPa {20 kgt/om’) or more. (Tho preparation for the next round of starting) (2) Stoppage a) Conduct the stoppage operation on the following procedures: Lin case of local operation} Shit the operation lever to “STOP” position Then, fuel oll injection will be shut off by means of the common rod, and the engine will be stopped, [in case of remote control] i] Press the "STOP" push button on the control panel, Then, tho fus! oil injoction solancid valve will bo activated to operate the fuel shutdown device, and the engine will be stopped. ii) Shift the operation lever to "STOP" position, b) Aiter stoppage operation, he attentive of any abnormal sound in the engine and turbocharger. and confirm that there is not any abnormal sound, Zs In case that the engine does not stop even when the stoppage operation is conducted, forcibly stop the engine on the following procedure: 1) Forcioly cot the rack of the fuol injection pump to" 2) Fully close the valve of the fuel oil inlet main pipe Operation Lever Position (3) After Stoppage a) Operate both the lubricating oil priming pump and cooling fresh water pump for about 20 minutes, and ccol down the engine and turbocharger. Pi oiainnsotosnintnevinciniatnii ‘The turbocharger continues to run at high speed even after the engine is stopped. Lubrication of the turbocharger provided with, this engine is made using the system cil, and therefore if the supply of lubricating oil is stopped immediately after the engine is stopped, it may damage the bearing, b) Fully open the indicator vaive to conduct air running for 3 to 4 seconds, and exhaust the combustion gas oul of the combustion chamber. €) Close the valves on all the aystems. 6+ 8DK-28 Z 01-3Opera n Emergency Stop TEM, 6-8DK-28, 6.2 4-6.2 Emergency Stop (7) When Emergency Stop Is Required. Immediately stop the encine when any of the following abnormalities is found. 4) Announcement of "Emergency" or "Alarm" (‘Activation of the protective device --- Automatic stop ...... Depending on each specification) * @Qvorspeed * ©Docroase of lubricating oll pressure * @Suspension of water supply/increase of cooling water temperature @Other alarming (depending on each specification) 2) Abnormal sound 3) Heating of the bearings or other moving sections, oF generation of smokes, or abrupt Increase of mist 4) Loosening or falling-off of the governor, common rod rink, each lever arcund the fuel il injection pump, link pin, or bot. 5} Deterioration of fuel oll or lubricating oil, oF damage of the cooling water pipe 6) Abrupt increase or decrease of rotation speed 7\ Abrupt increase of lubricating oil temperature 8) Water supply disability due te suspension of cooling water supply Tee In case that the engine is overheated due to 9). Mixing of water into lubricating oll 10) Abrupt increase of exhaust air temperature 11) Abrupt decrease of the turbocharger rotation speed or intake air pressure 12) Generation of abnormal sound in the propeller or the stain shaff system In case of the marine propulsion engine 13) Breakage or loosening of the bolts of each section (2) Measures after Emergency Stop In case that the engine is stopped by activation of the protective device or stopped automatically, take the following measures: 4) In case that the engine is stopped by remote operation or stopped automatically, set the operation lover to "STOP" position after the engine is stopped bb) In cage that the operation had been made using heavy fuel oil, immediately switch the fuel oil to diesel fue! oil, operate the motor. driven oil feed pump, and conduct flushing of the fuel oil system. (However, this procedure does not apply when the fuel oil pipe is broken.) Further, conduct turning of the engine, ano exhaust the heavy fuel of remaining in the fue! injection pump or fuel valve. Se In case that the engine is stopped during the operation using heavy fuel oll and the engine is cocled down without changing the fuel cil, heavy fuel cil in the equipment of the fue! ol system (e.g. pump, ilter, etc.) and piping will rot only selidity to prohibit restarting, but alsc incur substantial labor to clean and cleanse after the accident, ©) Disconnect the load off the engine, and return the operation lever, each valve, and the state of all other equipment to “STOP” position In case that an emergency stop is conducted, be minded not to restart the engine until the cause is determined, the countermeasures ara taken, and rocovary is completed, In case that the engine is started without romoving the cause of the abnormality, the maliunetion may be aggravated and serious accidents may be caused, | a 71 6+ 8DK-28 Z 01-3Operation TEM 6: , 6.3 6-8DK-28) Emergency Stop / Long-Term Shutdown T earemqumcawane 4-6.3 Long-Term Shutdown In case thet the operation of engine is suspended for e long term (one month or more), take the precorvation measures (mainly, anti-rusting measure) on the following procodures: (1) Shutdown within 3 Months aj Fully open the indicator valve once every week, and conduct turning of the crankshaft several times while conducting priming wth lubricating oil In this case, stop the crankshaft at 2 position different from that before turning, Alter tuming, securely close the indicator valve. In case that there is a risk of freezing in extremely cold season, be minded to remove cooling water from the engine. b) (2) Shutdown beyond $ Months Measures for Long-Torm Storage In case that the operation of engine is suspended for 3 months or mora, the following measures for long-tatm storage is requiredt a) Remove cooling water irom the engine ) Add tust-preventive all to lubricating all, open the indicator vaive, and conduct turning of the crankshait several times while conducting priming wih the lubricating ol. Alter turning, securely close the indicator valve, ¢} Open each cover of the engine frame, cam case, and the cylinder head, and spray rust: preventive oil to the internal parts. d) Insert the moisture-proof agent such as siicagel into the crankcase, according fo the ambient air conditions (e.g. weather and humidity] and according to nacessity 9) Place the cover cn the outside air opening section of the exhaust air pipe and the mist pipe, ) Cover the engine with a sheet, and carefully cover the,electric equipment with particular attention to prevent collection of dust on them Measures for Long-Term Storage 6+ 8DK-28 Z 01-3 Py EUOperation Long-Term Shutdown 6-8DK-28) 6.3 te (>) sey ((O*R ~ HE monte We || e (Rust preventive Spray (est preventive Sgn ‘Measure for Long-Term Storage ey EEA 6+ 8DK-28 Z 01-3Inspection and Maintenance TEN 4.1|6-8DK-28) Precautions for Inspection and Maintenance 5.1 Precautions for Inspection and Maintenance When conducting the inspection and maintenance works of engine, be minded to read this manual carefully, understend the structure of the related parts and the work contents, carefully examine the working procedures, and prepare the consumable parts and tools in advance, before starting these works. If the works are conducted without previous and sufficient examinations, it will not only lead to the expense of useless labors, but also result in failure or damage of the ‘engine due to mistaken assembling, and further in personal accidents. Be sure to replace all the damaged parts, or the parts that have reached replacing limit, both of which have been so found after the results of inspections. In case that replacing these parts are difficult on site, or the necessary parts are not e readied, inform the Parts Sales Department, Service Department, Daihatsu Diesel Manufacturing Co., Ltd. or the nearest branch oftice or shop, and take proper actions. 5-1.1 Safety Precautions (1) Do not open the crank case side cover for at least 10 minutes after the engine is stopped and is completely cooled dawn, While the engine is overheated, there is a danger that ail mist may catch ire and explode if new air is flowed into the crank case when # is opened ') Open the indicator valve (6) with a special wrench for indicator valve before installing the indicator (A), and close the indicator valve after lighlly releasing it 1 or 2 times. i) Install the indicator to the indicator catch (0), and securely lock it by turning the lock nut (0). ii) Close the exhaust valve (E) of the incicator. iv) Open the indicator valve vy) Check the reading of the pressure on the indicator, vi) Close the indicator. vii) Open the exhaust valve of the indicator, and remove the indicator atter indicating reading has become "| * Maximum value (when fully joaded 19.7 MPa {160 kat/em*} * Difference between cylinders: 0.6 MPa (6 kgtiom2] or less (2) Exhaust Air Temperature ‘The exhaust temperature at each cylinder outlet slightly varies from one cylinder to another depending on the factors such ae the offect of other cylinders as well as the distance to the turbocharger inlat The exhaust temperature can be adjusted by increasing or increasing the reading on the fu injection pump rack, however, the adjustment is ordinary unnecessary as long as the difference between cylinders is within the following value. (3) Adjustment of Reading on Fuel Injection Pump Rack In case that the exhaust temperature differs from those of other eylinders in excess of the range epecified in the above (2), for examplo, when the fuel injection plungor oF the fuel injection valve nozzle is replaced, adjust the fuel injection ‘amount by increasing or decreasing the reading cn the rack scale, The recing on the ack scale can ba nereases gy cor decreased by adjusting screw (A) of the tue! Injection pump rack lever. 1) Loosen the lock nut (6). jl) Turn the adjusting reading on the rack scak © Clockwise tuming "Increase" (Increase of exhaust air temperature) © Counterclockwise turning "Decrease" (Dezrease of exhaust air temperature) ii) Confirm that the exhaust air temperature ie within the specitied value. iv) Securely tighten tha lock nut. sw A and change the * Difference 0 less pveen cylinders: 1.5 mm or ask edlustn sev Adjusting Rack 6+ 8DK-28 Z 01-3+ 4A... Inspection and Maintenance Measurement and Adjustment: Pressure and Temperature of Each Part 6:8DK-28| 3.0 5-8.2 Pressure and Temperature of Each Part The pressure and temperature of lubricating oll, fuel oi, and cooling water, etc. are controlled by the relief valve, so thet they should be proper values being within each specified value during the operation of ongine, however, when actually operating tho engine, the pressure end temparature of these fluids may not be within the specified and proper values In such a case, readjust the satting values of valves, and perform the operation within the specttied proper range. (1) Intake Air Prosoure Since the intake air pressure changes in accordance with load, each prossure whon the engine was new (or, after adjustment) becomes areterence value The more the turbochargat is fouled, the more the intake air will decrease, resuliing in the deterioration of the engine parformance e.g inctease of the exhaust air temperature and increase of the fuel consumption rate), and ‘hetefore regulary conduct the Dlower cleaning and prevent the progress offouing, ((fL): §-4.4 Cleaning Turbocharger) Vis impossible to completely remave the fouls even when cleansed by blower cleaning, and 10 prevent the deterioration of engine performance by the elapse of time, however, if the cleaning is neglected, fouling will eeselerate, resulting in worsening of the engine performance, and as the result it will be required to disassemble and clean the turbocharger much earlier than when the leaning is periodically conducted. (2) Intake Air Temperature tFeowrenpenteiss-<6¢ | * Proper temperature: 45 - 55 Intake air, that is either higher or lower then the specified range, will affect the engine, and therefore be minded te adjust and koop the temperature to be within the specified proper range, as far as possible. When the intake air temperature is too low, it causes abnormal or excessive wear o! the cylinder liner, intake air valve, etc., since the water diops is formed by the dew condensation, Further, if the intake air temperature is too high, it damages the parts around the combustion chamber such as the exhaust valve, ‘exhaust air temporaturo will increase. ince the (Exhaust air tomporaturo varies in proportion 10 the intake air tomperature, and also varies in the rate of approximately 2 times the chango of tha suction air tamperature of the turbocharger.) Tho intake air adjustment can be made by changing the cooling water flow rate in the air cooler. i) Operate the handle of the bypass valve (A), and change the opening angle of the valve. © Open the bypass valve. (Handle facing sideways} © Close the bypass valve (Handle facing downward) Decrease of temperature li) Be attentive to changes of the intake air temperature, and cpen the bypass valve so as {0 be within the proper range, and acjust the angie Increase of temperature Ortice (6)! BP Intake Air Temperature Adjustment Procedure DAIHATSU 6+ BDK-28 Z 01-5Inspection and Maintenance TEM 3.2(6-8DK-28 Measurement and Adjustment: Pressure and Temperature of Each Part a 1) In case of changing the orifice (B), be attentive tothe temperature and pressure. | changes of the related equipment such as tho lubricating oil cooler connected to tho same cooling water channol as wall 2) Do not totally close the office (8). lL In case that the intake air does rot fall within the proper range even when the bypass valve is fully opened anc the entire amount of cooling water is flowed into the air cooler, it is required to disassemble and adjust the alr cooler since the ‘outing ofthe air cooler can be considered ((CQ) : 12-3 “Air Coole" in the Instruction Manual, “Maintenance Version’) (3) Lubricating Oil Pressure * Proper range of engine inlet lubricating oil pressure (Blue zone range of manometer) 0.4 - 0.58 MPa (4.0 - 5.5 kafiom’} * Prope! range of turbocharger inlet lubricating oil pressure (Blue zone rance ot manometer): 0.06 - 0.15 MPa {0.6 = 1.5 kgller Lubricating oil pressure changes in accordance with the changes in the viscosity and temperature of lubricating oi. When the engine is started in extremely cold weather, and the temperature of the lubricating oil is still low and the viscosity is high, tho pressure reading may go up beyond the blue mark rango, howsver, it doos nat impose any problem if the reading falls back within the blue mark range when the engine is warmed up In case that the pressure reading is beyond or under the blue mark range, adjust the pressure tn the following procedure: Gs 7 Labreating cil pressure dacreeses when the Titer is fouled. Be sure to perlorm the | adjustment of otessure etter the filter is cleaned well. | ((CO): 5-43 “Cleaning Fiters") | When adjusting the lubricating cil pressure, use the adjusting screw on the lubricating oil roliof valve. j) Remove the screw cap (A) of the relief valve, and loosen the leck nut (B) li) Turn the adjusting screw (C), and adjust the pre Clockwise turning (tightening) Increase of pressure @Counterciockwise turning (loosening) Decrease of pressure i) Be attemtive to changes of the pressure, and confiim that the pressure has entered within ure, the blue mark range. iv) Tighten the lock mi (B), and attach the cap (A\. Air vent valve Aajusting Leck nut 8) ren (C) 6-8DK-28 Z 01-3 ee are 8)Inspection and Maintenance Measurement and Adjustment: Pressure and Temperature of Each Part 6-80K-28)" 3.9 a 1) Do not loosen the adjusting screw beyond, the loosening limit (2=40mm), The cap may not be installed back, if the screw is loosened excessively. 2)ln caso that the lubricating pressure dose not change even when the adjustmont screw is tuned, there is the possibiltios of sticking of the ralief valve, suction of air, pump failure, and so on, and therefore Investigate the causes of the trouble (4) Lubricating Oil Temperature [_ Proper range: 60 - 60°C (cooler cute Lubricating oil temperature is controlled to remain within the proper range of temperature by the automatic temperature control valve insialled at th lubricating oll cooler outlet. 4) Lubricating Oil Temperature Control Valve The tomperaturo contrel valve is an automatic bypass valve, that changes the flow rate of lubricating oil passing through the cooler, according to its temperature, and when the engine is started while it is sfil in cold stato, this valve rapialy raises the lubricating oil by letting the cil bypass through the cooler, and When the engine is operated normally, this valve maintains the lubricating of to be within the suitable range of the specified value. In case that the lubricating oil does not fall within the proper range, for example, because the cooling water (secondary water) temperature is different from the design temperature, the temperature of lubricating oil can be adjusted by the adjusting screw of the temperature control valve, Howover, in case that the actual temperature is exceoding the correctable range and the adjustment is impossible, contact us for consutation on the problem b) Manual Adjustmen-Emergency Measures In case that the temperature control valve has become ‘aulty and the temperature control nas become impossible, the engine can continuously be operated by performing the emergency measures on the following procedure, (EL): Separately provided “Instruction Manual ef Temperature Contel Value!) + Use range: 30 - 80°C (Cocler outlet) Singe the oil temperature changes according | to the load, be minded to set the oil temperature at a rather lower level, 60 that it will not exceed the limit when heavily loaded. Temperature convol valve Lock rut (A) Agjustng sovew (8) Lubricating oll cooler (6) Cooling Water Pressure +» Proper range: 0.25~0.35MPa (25 - 3. kotiom9] Jacket cooling water pressure substantially changes depending on the extemal conditions such as the cooling water expansion tank head, Fipe resistance, and so on. When cooling water pressure is too low, tt will cause corrosion of the encine frame or cylinder liner, and therelore adjust the cooling water pressure at the engine outlet using the valve or orifice, so that the pressure should be proper Curing the operation of engine. 6+ 8DK-28 Z 01-3Inspection and Maintenance TEM .8DK-28| Measurement and Adjustment: 3.2|6°DK-28) Pressure and Temperature of Each Part (6) Cooling Water Temperature + Proper range’ 70 - 75°C (engine outa’ 2) Warming-Up Operation When jackot cooing water temporature is too lou, itwill eause faulty combustion oF the corosion or wear of the pars around the combuistion chamber, and therelore the minded to start the operation of engine with load after raising the cooing water temperature by warming-up operation (LQ: 4-4.2 ‘Warming-Up Operation") b) Temperature Control Cooling water temperature is controlled to remain within the proper range by the temperalure control valve installed between the jacket cooling water inlet and outlet pipe ((resh water cooler inlet and outlet pipe). “hie tomporature valve io en automatic bypass valve that is functionally identical with the lubricating oil tomporaturo control valve. (EL): $8.2 (4) Lubricating Oil Temperature") (7) Fuel Oil Prossure a) Engine using Heavy Fuel Oil When using heavy fuel oil, the pressure of heavy fuel oll must be adjustad to be within the following range, so that generation of vapor Cue to heating-up of the fuel oll can be Prevented + Proper range: 0.5-0.6 MPa {5-8 kgtiom’} Adjustment of fuel ol pressure cen be made by the pressure adlusting screw of the fuel oil relief valve. i) Remove the screw cap (A) of the relief valve, and loosen the lock nut (B). ii) Tum the adjusting screw (C), and adjust tho Pressure, © Clockwise turning (tightening) Increase of pressure © Counterclockwise turning (loosening) Decrease of pressure ii) Closely watch the changes of the pressure, and confirm that the pressure reading is within the proper renge. iv) Tighton the look nut (8), end attach the sorew cap (A) Lock nut (8) Fuel Oil Pressure Adjusting Procedure Aalusting s When the engine with neavy ‘vel oil epzccatinisoperetec ty deseltuel i.e @ fuel of oreesure does not cecrsece sce he tuelol cannot be pressure 25 nthe heavy tue ol supply Ine, however, the adustment cf the fue a pressure isnot requred # the pressure is wit the folowing range + Proper range: 0.2 MPa (2 kgficm’) bb) Engine using Diesel Fuel Oil + Proper range: 0.2-0.3 MPa {2-3 katfcm’} In case of diesel fuel oll specification, the pressure adjustment procedure is the same as in case of heavy fue! oil specification, since the same type of the fuel reliet valve is used in doth cases. 6+ 8DK-28 Z 01-3Inspection and Maintenance | Ss 5 Measurement and Adjustment: z ITEM | Pressure and Temperature of Each Part 6-8DK-28)_3.2| (8) Fuel Oil Temperature..... When Using Heavy Fuel Gil Heavy fuel oll must be heated so as to make its viscosity suitable for injection, before the oll s supplied to the engine. + Proper viscosity (engine init) dynamic | viscosity: 1421 mm/s Since the temperature appropriate for proper viscosity varies depending cn the properties (ieeosity) of heavy fuel oil, be minded to keep he proper viecosity referring to the following figure as a standarc: (EL): Fig.6-1-1 "Fuel Ot Temperature Curve) In casa that the viscosity controlle (automatic viscosity regulator is installed to the engine, control the fuel oll viscosty in accordance with instruction manuel, and-be minded 10 carefully keep the manual. (IED): 4-4.4 “operation Using Heavy Fuel Cit’) uel Oil Characieristics and DAIHATSU: 6 + 8DK-28 Z 01-3Inspection and Maintenance Te inspecting Parts around intake and Exhaust Valves, and 4,1 |6°8DK-28| AGlusting Adjusting Valve End Clearance 5-4 Inspection and Maintenance 5-4.1 Inspecting Parts around intake and Exhaust Valves, and Adjusting Valve End Clearance (1) Replacing Consumables, Implements, and Measuring instruments 2) Replacing Coneumables ( {J}: "Pers List) 1) Head cover rubber seal 2-20 No.6 ») Implements and Measuring Instruments 4) General tools (2): ‘implements List" in the final documents} (2) Inspecting Parts around intake and Exhaust Valves Bath intake and exhaust valves are the parts that ere exposed to the most severe conditions ‘emong ail other perts of the engine. Therefore, be minded to poriodically inepect these valves, znd confirm that both valves operate normally. 2) Confirm that thers is no abnormal operating sounds in both the intake and exhaust valves during the operation of engine ) Check the following points on these valves removing the cylinder head cover when the engine is stopped, 1) Lubricating conditions of the rocker arm and push rods 2) Lubricating and sludge collecting concitions of the intake and exhaust valve cotters, and valve rotators 3) Sludge collecting conditions around the valve spring 4) Rotating conditions of the valve rotators 5) Valve end clearance # (@) Adjusting Valve End Clearance Sine valve end clearance decreases due to the wear of the valve seat part, and therefore be minced to periodically inspect and adjust It, When the valve end clearance Is too small, it will ‘cause improper setting of the valve on Its seat during the operation of engine due to thermal ‘expansion of the valve itself and push rod, resulting in burning of the seat. Further, the valve system of thie engine is 4. valve type, having 2 intake valves and 2 exhaust valves, and a single valve holder tee is provided to simultaneously push down both pairs of intake and exhaust valves, and therefore unless the valve end clearance of each pair of both intake and exhaust valves Is equal, the valve pushing force will be unbalance, resulting in abnormal weer or damage of the valve holder tee and the guide parts. Push roe Adjusting screw (6) et Adjusting screw mses | Look nut oo Valve reteter —- Cotter ~/ Valve retainer tes Valve End Clearance Adjusting Procedure i) Place tho oylindar in the explosion stroke, and close the iniake and exhaust vaives. i) Loosen the lock ruts of the acjusting screws (A) and (B), and tur back the adjusting screw (A) and (8), it) Closely fit the valve end "A‘, place the dial 6+ 8DK-28 Z 01-3 — Rocker armInspection and Maintenance Inspecting Parts around inf and Exhavet Valves, and Adjusting VaWve Je any og| "4 5 End Clearance / Inspecting and Maintenance of Fuel oil Injection Valve gauge against the valve holder tee, and Lighten the adjusting screw (A) until the scale pointer swings, so that it can be confirmed thet the valve ends ‘A’ and "B" are bath closely fit cet the same time. iv) Engage @ spanner around the hexagonal head of the adjusting scrow (A), and tighten the loo rut while paying sttention so that the screw ‘and nut do not slip and turn viInsert a thickness gauge of the specified thickness into the clearance *C' on the top part of the valve holder tee, and adjust the clearance using the adjusting serew (8), + Proper clearance: 0.5 mm (for both intake and exhaust valves) in 5-4.2 Inspecting and Maintenance of Oil Fuel Injection Valve Since the conditions of the fuel injection valve substantially affect the performance of engine operation, be minded to periodically inspect it end conduct the maintenance. However, in case that remarkable anges have boon found in the maximum combustion prossure, ‘exhaust tomporature, oxhaust color, and 60 on, bo minded to conduct immodiate inspection and maintonance, regardless of the standard inspection and maintenance period Since the items mentioned in this section will be the parts to which engine setting value specitied in NOx Technical Code shall be confirmed, be sure to use the carts naving the Asctiminating notch marks (1: 0-3 "Engine Conforming to NOx chinical Code") (1) Replacing Consumables, Implements, and Measuring Instruments a) Replacing Consumables 1) Circular gasket 3-18,1 No.508 "Parts List") 2) Gasket 318.1 No.519 3) O-ring 3-18.1 No.10 4) O-ring 3-18.14 No.510 5) Oxing 918.1 Nostt 6) O-ing 3-18.1 No.612 b) Implements and Measuring Instruments 4) General toole and moasuring instrumants ({LL): Final Documents) 2) Nozzle holder extracting implement 3) Fuse! ol injection testing device 4) Nozzle cleaning implement (2) Extracting Fuel Oil Injection Valve Extraction of the {uel oil injection valve can be conducted on the following procedure: < Extracting Procedure > (In case of heavy fuel oll specification) ) Remove the cylinder head cover and heat box cover (upper side only). * i) Close the valve of the nozzle cooling water and drain the water completely Fah Fuel nection valve ia} | circular gasket «@) inlet connecter (C) just couping () onlng Bot (F) heprossure Bolt |) YU ENE 6+8DK-28 A 02.2Inspection and Maintenance TEM 4.2|6-8DK-28 Inspecting and Maintenance of Fuel Oil Injection Valve ) Loosen the bolt (@) and(H), and remove the high-pressure fuel coupling (block) (I). iv) Remove the inlet connector (L). v} Remove tho tightening nut (M) using @ box vi) Extract the fuel cil injection valve (N) using a {ual cil injection extracting implement (2) vil) Remove the circular gasket (0) Ls 1) Be careful so that the circular gasket (C) may not be left behind in the cylinder head, 2) Alter removing the high-pressure fuel coupling and fue! injection valve, be minded to place the cover both on the coupling part of the fuel oll injection pump and the insertion part of the cylinder head (9) Injection Test Conduct a fuel injeotion test of the fuel injection valvo, to check if the opening procsure and the spraying conditions of the fuel injestion valve isin proper and normal state. Conduct the fuel injection test using the fue injection tast device (3) installed to the engine a) Inspecting Valve Opening Pressure i] Install the fue! injection valve on the injection {est device, after removing the carbon stuck (on| the tip of the injection vaive, and cleaning the tip of the injection valve. ii) Connect the test pump and fuel injection yelve using a high-pressure hose for testing, ii] Quickly operate the test pump lever several times, and drain the air until the valve state injoction of the fuel as the prossure indicating scale swings, wv) Slowly turn the test pump lever (once every second, or $0), check the pressure reading (the pressure, that has once increased gradually, suddenly starting to decrease due to opening of the valve). » Normal pressure: $1.4 - 34.4 MPa (820 - 350 kgfiem') Nozele holder Sxacting implement (2) Nozzle Holder Extracting Procedure Higr-oressure hese Liat courier Fuel of sweat Fiat Nez rolecn lore holder va) Toateump se Injection Test Procedure 6+ 8DK-28 Z 01-3Inspection and Maintenance Inspecting and Maintenance of Fuel Oil Injection Valve b) Adjusting Valve Opening Pressure When reassembling the fuel injection valve after conducting the maintenance werk by extracting the valve out of the engine, and when the nozzle is replaced with @ new one, adjust the valve pressure on the following procedure, Since the items mentioned in this section wil be the parts to whicn engine setting value speotied in NOx Technical Code shall be applied, be sure to use the parts naving the aiseninating notch marks (EDD: 0-3 “Engine Contcrming to NOx Technical Code") < Valve Opening Pressure Adjustment Procedure > i) Remove the cap nut (2) i) Loveen the lock nut (forthe aqusting screw). i) Agjust the pressure te the epocifed precsure by turning the adjusting serew using a sctowdhiver, while conducting the injection of the fue! oi, as in the same procedure as in case of the fuel ol nection test @Screwing-in of adjusting screw -—- High Turning-back of adjusting serew = Low iv) Tighten the lock nut (c). ¢) Inspecting Fuel Oil Injection Inspect the fuel oil injecting conditions on the following procedure. )) Quickly operate the tes! pump lever several times (2 to 9 times every second), and ingpect the fuel cil injecting conditions. (Let the fuol oll injected against a blank paper eo that the concitions can be batter inepected.) © Check if the cutting-off of injection is good cor nat, —-- Injection sound © Check if injection is evenly and clearly sprayed, © Check it injection is not of bar pattem, nor dripping down. 1) Check ff there is no dripping-down of fuel oil from the tip of the nozzle after the injection test, Cap nut (a) / a> Adusingscew 0) (| Lock nut fe) Pressure Adjusting Procedure * Setting pressure: 34.4 MPa {350 kgvern*} Be minded to set the pressure of the fuel injection valve at a rather higher level taking into consideration the initial accusioming, in case that a new injection valve is introduced, 90.4 MPa (310 kgfert} Ss, es (©) Divopy nozzle 1A Clogged nezile (8) Improper ‘Neesle wave acton Abnormal Injection Be minded not to approach your face or hands near the fuel spray during testing. If the high-pressure fuel has hit your face or hands, it will cause injuries, DYE E18) 6+ 8DK-28 Z 01-3Inspection and Maintenance TEM. 4.2 |6-8DK-28) Inspecting and Maintenance of Fuel Oil Injection Valve (4) Disassembling and inspecting Nozzle In case that a remarkable decrease of the valve opening pressure, faulty injection of fuel oil, or dripping-down of fuel oll after injection is found as the results of the fuel injection test, conduct, disassembling, cleaning, and inspection on the following procedure: a) Disassembling the Nozzle {) Remove the cap nut (a) ji) Loosen the adjusting nut (b) il) Fix the holder housing (4) in a vise, and loosen the retaining nut (f. lv) Extract the neecle valve out of the Nozze (). ¥) Extract the nozzle out of the retaining nut by stiking with a hammer, while placing a pipe- type patch on the nozzle so as not to amage the injection hole of nozzle, “~—— - | Ifthe retaining nut is turned while the adjusting nut is sill tghtonod, it will damage the nozzle or nozzle holder paris. | In case that heavy fuel oil is used, tho retaining nut and nozzle may be siuck together with carbon accumulated on tham It the nut is loosened in this state, the nozzia will turn together with the nut, and may damage the nozzle, or the knock pin of spacer, and therefore first lubricate the nut | with gas oil, and then carefully loosen the nut by striking the nozzle with a hammer, while placing a patch on the nozzle. b) Inspecting Nozzle ’) Clean the nozzie nut and needle valve with gas oil ii) Clean the nozzle hole using a nozzle cleaning implement (4) li) Push in and push out the needle valve with your hand, and check the movement. © Gheck if the movement is smooth oF not. © Check if the movement is too loose. | Nozze) { {= eh. : Ah oo ii = NE = Holder housing i Extracting needle waive —Nezae exrecing implement Nozzle Cleaning Procedure aN —————, @ 1) Since tne nozzle ane needle valve i a pair functioning together, be minded not to replace either of them separately 2)Do not ty to reuse a faulty nozzle by | wrappirg, but be sure to replace it with a rowone 6+ 8DK-28 Z 01-3Inspection and Maintenance Inspecting and Maintenance of Fuel oi Injection Valve (5) Assembling Fuel Oil Injection Valve Assemble the fuel oil injection valve in the reverse order of the disassembling procedure. i) Clean each of the disassembled parts with clean gas cil, and insert each of them back into the helder housing (¢). ii) Put the spacor and the knock pin of nozzle together, and install them into the holder housing. Apply the lubricating agent (Molykote U paste) on the holder housing thread, the seating face of the retaining nut (t), and the outer periphery of the nozzle, and screw the retaining nut Into the holder housing oy your hand, |v) Loosen the adjusting nut (b) v) Tighten the retaining nut with the specified torque +* Spacitied torque: 35d - 382 N.m {36 - 39 kal.m} e careful not to tighten the retaining nut with the toque over the spacitied value, since it may cause the sticking of the needle valve of the nozzle. ul) S2t the fuel ll injection velve on the ijecton lest device, and adjust the valve opening pressure. (CD}:5-42 ey njection Test (6) Mounting Fuel Oil Injection Valve Mount the fuel injeotion valve to the eyfinder head inthe roverse order of tho extracting procedures. i) Apply heat-resistant agont on the O-rings, land attach them to the holder housing (4) Apply giease on the circular gasket, and fit it to the holder housing (d). (To prevent the circular gaskat from falling off into the guide hole ot the cylinder head.) Apply heat-resistant agent on the circular gasket, and attach it to the holder housing. ii) Insert the fuel oll injection valve into the guide iiy hole of the cylinder head, after confirming thet the old gasket is not left behind in the guide hole. Fit the O-ring of the nozzle holder flangs (Q), and apply groase on the O-ring. Insert the nozzle holder flange into the iniet connector (L), and apply lubricating oll 1o the thread, then tighten them with the specified torque after serewing them into the holder housing vy y) * Specified torque: 49 - 59N.m {5-8 kgf) vi) Apply lubricating agent (Molykote 1090 spray) to the thread of the holder tightening bolt and nut seating face, and evenly tighten the holder tightening nut (M) with the specified torque, * Specified torque: 59 N.m | (6 kof) vil) Attach the O-rings on the cylinder head side of the high-pressure fuel coupling and on the {uel oil injection pump side, and apply the lubricating agent (Molykote 1000 spray) to the thread surfaces of the high-pressure fuel coupling tightening bolt (G) and (H), then lighten them with the specified torque. *Spocified torque Tightening bolt (G): 59 N.m (6 kgf.m} Tighiening bolt (H): 53 N.m {6 kam} DYN PNB) 6+ 8DK-28 Z 01-3Inspection and Maintenance "" 4.3[68DK-28| Cleaning Filters 5-4.3 Cleaning Filters Fuel oil filters and lubricating cil fiters have very important roles, i¢., removing foreign matters or sludge in oil and keeping the oil clean, and maintaining the normal operation of the various parts of engine, Therefore, it is important to periodically overhaul and clean, so that filtering capabilities can be maintained, The notch-wire duplex type filler is used as the filter for fuel oil and lubricating oil {including the filter for turbocharger), and the centrifugal type lubricating ol bypass filter (Y-type) are used as the filtor for lubricating oil of the tual cil injection pump, both of which are equipped as the standard specification of the engine, However, which type should be used depends on the specification of each engine, and please reler to the Engine Specttication, ({CL): Separately provides “Engine Specitication’ (1) Notch-Wire Duplex Type Filter ‘The noteirwire duplex type fiter is normally used es boitrside-parallel application Since both the fuel oil pressure and lubricating ol pressure decreases if the filter has been fouled, be minded to periodically conduct blow-off cleaning. In case that the cil pressure does rot Airvent vale (0) Notch-Wire Type Filter inorease even altar the blow-off cleaning has bee conducted, overnaul the titer and then clean it @) Replacing Consumables (For fuel of] (CL: ‘Parts Uist) 1) Gaskel 4-2.2,1 No.174 (Diesel fuel oil) 2) Gaske! 422.1 No.144 (Diesel fue! oi) 3) Eement gasket 422.1 No.260 (Diesel fue il) 4) Gasket 42.2.1 No.t06 (Heavy fuel oi) 5) Gasket 4221 No.267 (Hoavy fuel oi) 6) Eement gasket 42.2.1 NoZ65 (Heavy fue! ol) {For lubricating oi ( ("Pacts List’) 1) Gasket 4.3.4.1 No.168 2) Gasket 4-3.4.1 No.150 3) Element gasket 43.4.1 No.246 [For turbocharger] ( () : “Parts List’) 1) Gasket 4:3.5.1 No.173 2) Gaskel 4.3.5.1 No.143 3) Element gasket 4-2.5.1 No.260 b) Blow-Off Cleaning In case of blow-off cleaning, deposits can be removed by reversely flowing the fluid through the element on one side, and this type of cleaning has no cleaning effect whon the element is substantially clogged, and therefore be minded to conduct the blow-off cleaning in an earlior state, while the fouled degree of filter is sill ight. (The cleaning should be conducted at least once a week) 6+ 8DK-28 2 01-3 PYTTAE)Inspection and Maintenance Cleaning Filters TEM, 6-8DK-28) 4.3 < Blow-Off Cleaning Procedure > ’) Open the drain cock B at the bottom part of filter. At this time, be careful so that waste oil may not scatter or overflow out of the diain cook. ii) Tum the selector c handle (A) (usually, set to "Used position on beth sides" (P)) to the "Blow-oif* position (Q) (about G0AK), and quickly conduct the operation to return the handle to the previous position (within 0.5 - 1 sec) lil) Repeat this operation 2 - 3 times. 'v) Also conduct the above same procedure on he other side. ) Close the drain cock. ZN Conduct the blowot cleaning qucky. | Further, do not pace the lever onthe middle Position, But quickly move to the epeciod postion (knock poston Ifo0 meh tine hab boon taken in blowot clearing and switching the lever positions the pressure wil decrease, and may actuate the alaim or emergency step ©) Overhaul and Cleaning of Filters Be minded to conduct the overhaul and cleaning of filters when the engine Is stopped, as far as possible. Be sure to wear the safety gloves when operaling the filiers, and be careful so as not to let high-temperature oi splash on your skin or clothes. aA Wen vsirg the heavy fl othe fuel ol io heated up and concoquonty tho fiter and the pining are extremely hat, Thorstore, when raning the fier be sure to wear the salty Gloves. and be cautious so thatthe high- temperature ol may not spash onthe stn or csctnes ij Turn the selector handle (A) to the "Close’ Position (R) (90°) on the side to be overtiauled, Beth sas usea (P) 10) Lek sive / iow off (@) Right sice blow off Lett site +g igh sice closed Handle (A) © When bot Right sices One side cosea Sopsis isec plow ott Gasket ( Gasket () Drain cock Hardie (A G2" Oranges or cock cute! Male Inlteckng igeover cock tow of dreinhale een tare } i Tightening nut (E} / Air vent valve (D) knoe tH) ack raising bot Filter Overhaul Procedure Py TY 6+ 8DK-28 Z 01-3Inspection and Maintenance TEM 4.3|6°8DK-28) Cleaning Filters ii) Open the drain cock (B), loosen the air veni valve {D) at the top of the Case (G), and discharge oil, il) Loosen the tightening nut (E), remove the caso (C), and then take cut the oloment (F), iv) Clean tha clement with washing cil or gas cil and conduct blow-off cleaning from the inside. v) Clean each of the parts overhauled, and clean the grooves for case gasket of the filter’ housing (G). d) Assembly and Restoration i] Attach the gasket (I) to the element (F), and attach the gaske! (J) 10 the filter housing (0). li) Put the spring (K) on the element, place the case (C) over the spring, and screw the nut (E) into the case while hokling the case with your hard, ii] Close the drain cock (B). iv) Shift the hance (A) to "Biow-off* position "" vy) When the filtor is overhauled and cleaned hilo the engine is stopped, conduct priming and fil the case with cil, Close the air vent valve (0), after oll has been let overflow and air bubbles have completely vanished from the oil flowing cut of the air vent pipe. Return the nandle to "Both sides used position” (P vill Check I! thee is any oll leakage ‘rom the gasket sections. ts Confirm that the knock (H) of the handle (A) is engaged in its pesition. If the knock is not properly engaged in the position, the handle will be overturned by vibration during the operation of engine, and it may incur of spill ut accidents. pee | 1)Gheck conditions of the sludge collected on th Parlicularty in case of the lubricating oil titer, if metallic particles are foun investigate the causes and take the countermeasures, 2)When the element is damaged, or when the element is excessively fouled and clogging cannot be removed even by cleaning, replace the element with a new one. 9) Since the gaskets and Orrings are casiy © be damaged, be very careful in handing these parts. Particularly, the heavy fue! cil filer tends 10 be deteriorated in high- temperature conditions, and therefore be minded to raplace the fiker every time the overhaul is conducted (2) Y-Type Filter 9) Overhaul and Cleaning i) Remove the plug, ii) Remov ii) Clean the strainer with w 19 strainer. ishing oll or gas oll b) Mounting ‘When mounting the Y-type filter, be minded to mount with tne plug side facing downwara, so @ that sludge may be accumulated in the strainer. Y-type Filter Overhaul Procedure 6+ 8DK-28 Z 01-3Inspection and Maintenance Cleaning Turbocharger Blower 680K-28, 4.4 5-4.4 Cleaning Turbocharger Blower Ifthe fouled degree of the turbocharger blower has. progressed, the efficiency of the turbocharger will decrease and the operating performance of engine will be worsened. Particularly when heavy fuel oil is used, the turbocharger blower tends to be fouled © degree, and therefore be minded to conduct blow-off cleaning and restrain the progress of fouling, in fast (1) Interval of Cleaning Clean the blower when intake air prossure has Gecreased 10 % at the same load, or at least ‘every 150 to 200 hours of cperation. (2) Load during Cleaning Make sure that the engine shall be operate under the load of 79 % or higher, and continue the loaded operation for 1 hour or more after cleaning, Type ot ubbensraer MET25SA | _ 15,000-19,000min METSOSR 45.000-19,000min’ vTR254 vTRa04 TPSS7D TPS619 Turbocharger rotation speed (3) Cleaning Liquid Be sure to use the specified cleaning laud. In case that the specified cleaning liquid is not available, use fresh water. (Note that cleaning effects inferior with fresh water.) as Be minded never fo use gas oil or any other flammable liquid for cleaning, since these liquids will be the cause of fire. (4) Cleaning Mothod Cloaning of the turbocharger blower can be made using the cleaning device that is supplied together with the engine. ’) Pour cleaning liquid into the blower syringe (A). i) Connect the syringe socket to the filing pipe (©) that is connected to the turbocharger inlet side, ii) Fully open the drain cock of the inlet duct. wv) Oparate the syringe to inject cleaning liquid. v) When 3 to 5 minutes has passed after the injection of cleaning liquid, inject fresh water of the same amount on the same procedure [Injection Amount and Injecting Time] weer Filganent] Fling ime | meresh | 1.0 20-40 MET30SR 10 | 20-40 | virase [_vineos TPS570 TPSO1D vIn case that thers ie no chango in intake air proseura before and after the cleaning, repeat cleaning aftor 10 minutes, in case that intake air pressure does not change even when the cleaning is repeatedly conducted, conduct the overhaul and cleaning of the whole of turbocharger (£0): Separately provided "Turbocharger Instruction Manual’) Gyiinder (8) > pian Connect here pe =te- dS SS Socket — Filing pive + a LAS Turbocharger ‘Turbocharger Blower Cleaning Procedure [DAIHATSU] 6+ 8DK-28 A 02-2Inspection and Maintenance 4s I6-8DK-28} Cleaning Turbocharger Turbine Side 5-4.5 Cleaning of Turbocharger Turbine Side < In case of Turbocharger Model "MET" (Cleaning solid matter) > If staining of the turbocharger turbine side progresses, engine performance will be worsened dus to decrease of the efficiancy as in the the blower side. Particularly. it tends to be more stained in case of heavy fuel oil specification Periodically clean the turbine side, and restrain the progress of staining When cleaning the solid matter in the turbine, charge vegetable solid particle in front of the turbine, and temove the adhered matiers on the turbine nozzle or turbine rotor blade by the impact force produced by the vegetable solid particle se of accelerated by the exhaust gas. (1) Interval of Cleaning Conduet the cleaning with the interval of 200 to 250 hours in the intial etago, sinco the effect of cleaning will be lost if the layers of the accumulatad matters have become thick As for the cleat cleaning. properly increase or decrease depending on the factors such as the exhaust temperature. intake air pressure. and the degree of performance decrease of the tur rotation speed jing interval after the initial jarger (2) Load during Cleaning Perform cleaning by making the load of engine to be 75 to 85% as the standard. Although it is possible to perform cleaning at a low load of around 60%, cleaning liquid may sometime be accumulated at the gas outlet casing, and therefore avoid the cleaning of such a low load as far as possible. The maximum allowable rotation speed of the turbocharger when cleaning is performed is as shown in the following table, and therefore in case that the normal load value is higher than these, decrease the load. [Maximum allowable turoocharger rotation speed and exhaust temperature when cleaning] Turbocharger | Max. Allowable | Turbocharger inlet model” | rotation speed _| exhaust emperature MET26sA | 27,400mn' | 500°C ore: METIOSA | 22, 500°C oF less ann’ | (8) Cleaning Liquid Use the specified cleaning liquid as shown bolow. © Husk of walnut: Diameter of grain: 1.7 to 24mm (Marine grid #10) © Grain (nce, wheat, etc.): Diameter of to 2.4mm Close the drain hole of the turbecharger gas outlet casing while cleaning, ain: 1.7 (4) Cleaning Method a) Procedure for one time cleaning i) After opening the valve (B), open the valve (A) ard cool the equipment by passing air for 1102 minutes i) Close the valve (A), and close the valve (B) ii) Fill the specified use amount of vegetable solid cleaning agent into the tank, and socuraly tighten the eap of the tank iv) Open the vaive (A) and (B) in this erder, and charge tha cleaning agent with air pressure ¥) Close the vaive (B) and (A) in this order Tank varus purpose a oa oenpe Turbine Rotor Blade Cleaning Procedure 6+ 8DK-28 A 02.2 [DAIHATSU] eInspection and Maintenance Cleaning Turbocharger Turbine Side 6-8DK-28) "4.5 b) Repeated cleaning In case that a sudden change, such as surging, has occurred in the engine when charging the cleaning agent, try the cleaning by using a half of the specified use amount of solid cleaning agent for single time cleaning, and perform tho cleaning after confirming that there is no more sudden cchango in the engine. Afterwards, make this method as the standard, li) After finishing the cleaning, repeat the above the procedure of Item a), if no particular change is not found in the performance values such as the exhaust temperature, intake air pressure, and turbocharger rotation ‘speed. In case that any change Is not found even after the cleaning has been repeated, it Is necessary to perform the overnaul and cleaning, [Specified use amount of solid cleaning agent] Tubochaiger made! | Spacitiad use arrount MeTz6sA | oa weresa | onus ((GL) = rstruction Manual of Turbocharger As the procedure of the water cleaning method of turbine, inject fresh water from watering nozzle located on the exhaust pipe to the front of the turbine, remove the adhered matters on the turbine nozzle, turbine rotor blade, otc. by the impact force of the water drops accelerated by the exhaust gas and the solution force of water. A pari of the fresh water will evaporate, and the remaining wil be discharged from the drain hole of the turbine chamber. Do not evaporate the fresh water entirely (1) Interval of Cleaning Conduct the cleaning with the interval of 200 to 250 hours in the initial stage, since the effect of cleaning will be lost if the layers of the accumulated matiers have become thick. As Jor the cleaning interval after the initial cleaning, properly increase or decrease depending on the facters such as the exhaust tomporaturo, intake air proscure, and tho dagree of performance decroase of the turbocharger rotation speed (2) Lead during Cleaning The maximum allowable rotation speed of the turbocharger when cleaning is performed is as shown in the following table, and therefore in case that the normal load value is hicher than nese, decrease the load, [Turbocharger Rotation Spood and Exhaust Temper “ea Cah. RRR, VTRa04 4000-6,000 300"Cor lees vrr2se —5,000-7,500 _S0"Corless However, the turbine rotation speed will be decreased more or less if water is poured, and therafote readjust the rotation sped. Confirm that the drain including water is discharged from the drain hole of the turbine chamber within the range of this rotation spzed. DAIHATSU 6+ 8DK-28 Z 01-3Inspection and Maintenance 1 4.5 (6-8DK-28 Cleaning Turbocharger Turbine Side (8) Fresh water for cleaning Use fresh water containing no additives. Never use sea water. (4) Cleaning method 1) Close the drain cock (2 2) Connect the pipe connected to tho exhaue! pipe with the hose provided with the manometer and the stopper valve with the hose connection 3) Open the stopper valve, and fill the pipe and hose connected to the nozzle with water, then close the stopper valve. 4) Totally open the valve inside the nozzle located on the exhaust sips. 5) Open the drain cock (1), and contirm that the drain cock and the pipe are not clogged. 6) Slowly open the stopper vaive so as to obtain the water pressure of 0.08 (0 0. iMP2 {0.5 to 1.0 kg/cm’) while watching the manometer 7) Confirm that crain comes out of the drain ipo. 8) Constantly watch the discharge of drain while pouring water, and pay attention to the change of water pouring amount and clasing of the drain pipe 8) Continue the pouting of water for about 10 minutes, 10) Close the valve inside the nozzle, and close the drain cack (1) after confirming that drain Isno more discharges. 11) Open the drain cock (2). (Prevention of .gging of the drain pipe) Close the stopper valve, loosen the hose connection, and remove the hose provided with the manometer and the stopper valve, Alter cleaning water ia completely discharged, drive the turbine fer about 10 12 13 minutos with the constant rotation speed in order to dry the turbochargor. 14) After finishing the cleaning, conlirm the changes of the performance values such as the exhaust temperature, intake air pressure farger rotation speed, etc. In case that there is no change, repeat the turbos above procedure. In case that there Is no change even ater repeating the procedure, is necessary to perform the overhaul and Tearing ( {ELD ‘nstrvtion Manuel of Turbocharger Nozzle urbocharger Drain cock (2) Drain cock (1) Manometer Stopper valve \ Water pressure on Hose connection ’ Hose Hose connect Water-Pouring Cleaning Procedure of Turbine 1 peuring amount Turbine model Fim) VTRI54 VTRI04 30-120 As the pouring water washing method of the supercharger, tresh water is sprayed in tront of the turbine from the pouring water nozzie on the supercharger. Thus, the extraneous matter is removed through the difference 9! the cooled turbine nozzle with fresh water, turbine blade and the thermal expansion extraneous matter. (1) Washing interval Sinca the washing offect is reduced when tho dopesit layer becomes thick, apply the washing every approx. 200 hours. (2) Load during washing Apply the washing at such a load as the exhaust 6+ 8DK-28 A 02-2 DAIHATSUInspection and Maintenance TEN, Cleaning Turbocharger Turbine Side 6-8DK-28 4.5 temperature of the cylinder outlet is 300 to 950°C. As the exhaust temperature is lower, the washing elfect decreases. As it is higher, the turbine nozzle or similar part may be damaged. Take spocial care for the oxhaust temporature, (3) Fresh water for washing As the fresh water for washing, use the fresh water which does not include any additives. Never use any seawater. (4) Washing method @ 1) Connect the hoses of the pressure gauge and the check-valve hose to the pipe connected to the exhaust pipe. 2) Open the chock valve, fil the wator into the pipe and hose up to the nozzle, and close the check valve, 3) Fully open the valve in tha nozzle on the exhaust pipe. 4) Observing the pressure gauge, slowly open the check valve 1o gain the water valve of 0.45 to 0.7 MPa (4.5 t0 7.0 kg/cm") 5) Continue peuring water 15 to 30 seconds. 6) Apply the washing three times. Here, provide the interval shown in the table below afer washing of one time os Ciose the vaive, loosen the hose connection . Disassemble the manometer and the hase e@ vith valve, 8) To dry the supercharger, run it eppiox. 10 iminutes at the same load. 9) If any variation is not observed on the performance values of the exhaust temperature, charge proscure, suporchargor revolution speed and so an, repeat the procedure above aiter completion of the washing. If any variation is not cbserved after repetition of several times, it is necessary fo open and dean it 7 Supershargor po terval tne (rinwiod TPss7 3 Teset (LD): “Operation Manual tor Supercharger’) DAIHA’ 6-8DK-28 A 02-2TEM Inspection and Maintenance 4.6\6°8DK-28| Measuring Crankshaft Deflection 5-4.6 Measuring Crankshaft Detlection ws a Whe crankshaft deflection excoeds is iit the sess to be apple to the erankshatt wit | become excessive, and it will result in the | breakage of crankshaft ifthe excess of defection too ge Therefore, ast the crankshalt deflection to a propor value when being installed, and | porodcaly moacure the deletion, a0 that t can be corrected whenever itis over the limit (1) Replacing Consumables and Measuring Instruments 2) Replacing Consumables (([Il]- "Pars 1) O-rng 3:2No.AS b) Implements and Measuring Instruments. 1) General tools ((£[]]: “implement List’ in the final documents) 2) Deflection gauge 8) Mirzor (2) Conditions for Measuring Deflection a) Doilection of the crankshaft varies according to tho temperature, and thoreiore be sure to measure it when the engine is in cold state. b) Bafore measurement, push the contact piece of the deflection gauge with a finger, and confirm that both the contact piece and dial gauge retum to the ©) In case of the marine engine. since the deflection varies according to the loaded cargo conditions, be minded to record the conditions of loaded cargo, dratt, temperature, and so on, at the same time, riginal posttions correctly, (3) Measuring Deflection i) Open the indicator valve, and conduct tuming. ii) Place the crank pin at the point of 20"(position ) past the bottom dead center li) Install the datlection gauge to the position as shown in the Figure, iv) Set the reacing on me gauge scale to +20 at the position "B" in the Figure. (To make clear the positive and negative directions) v) Slowly turn the engine in the normal direction the reading on the scale when the crankshaft is at the angel of E", and "A" respectively, of which data shall be recorded, of rotation, and measure 2025 6+ 8DK-28 A 02-2 PYATTEInspection and Maintenance Measuring Crankshaft Deflection (4) Calculating Detlection (d) Calculate tne deflection values as based on the measured values and in accordance with the following formula, and record the calculated values: © Vorteal (V| deflection: dv D-A*® 2 © Horizontal (}) detlection: dh = C- E © Pcsitive/negative deflection: Open downward (4), open upward (=) A, B, C, D, and E represent the measured values respectively at each corresponding position shown in the figure cn the right. (5) Correction Limit for Detlection a) The correction limit shall apply to whichever is larger of dV and dH as shown in the following tabie (Unit: mm) Adjusted value Allowable limit Direction D041 orloss 0.118, nr2doriess | 0.165 xStokexa 3 ‘00c0 Note: Measurement point revised value a= 1.06 bb) Deflection varies depending an the connection method (direct connection oF flexible coupling) between the crankshalt and drive equipment, however, usually, the detlection becomes maximum at the crank throw that is closest to the tlywheel Adjust tho drive equipment using the adjusting shim or chock liner, so that the doflection falls within th limited values as shown in the above table “Top dead cente! Deflection Measuring Position Seen trom tlywheel side D (Top deas Dial Gauge Reading The deflection of the crankshaft shall be represented by the value when the engine is cold, and since the calues the measured when me engine is warm sometimes differ significantly depending on the measurement conditions, be minded not to use the value measured when the engine is warm as the standard TE 6+ 8DK-28 A 02.2Inspection and Maintenance ev 4,6 |6°8DK-28) Measuring Crankshaft Deflection < Reference > Deflection in warm condition In-case of the directly connected generating engine with the both-side bearing, the deflection in the warm conditions generally tends to vary as compared to This is because the temporature increase of tho engine base ic larger than the temperatura increase of the generator to be directly connected, tho values in the cold conditions, so that the crankshaft core relatively increases, the deflection varies toward 3) Jp. direction (downward closing). and thereby the diflerence manifests itself as the deflection dif between the cold and warm conditions. Further, in case of the generating engine or marine erence propulsion engine, which is directly connected with the flexible coupling, and which is net provided with the outside bearing, and the directly connected generating engine with the one-side bearing, the deflection difference rarely exists between the cold and werm conditions, both theoretically and in the actual measurement. Like this. in ease of the directly connected genorating engine with the both-sido bearing, the deflection difference between the cold and warm conditions differs depending on the bearing dimansions and temperature difference of the engine and generator so that the adjustment is impossible, and it will be the value undue to the generating devic Consequently, in case of the generating engine with the both-side bearing, the adjustment is made with the target of the conditions near to + side upper limit 3/7\s. ward opening) of the specified value in the cold conditions, The measured value of the deflection value in the warm conditions varies according to the temperature, and the different values tend to be obtained every time the measurement is conducted, however, based on tho actual measurement rasults of our company, the value is approximately 3~4/10,000% stroke and within the range of.) 1, (downward closing). ‘There is a possibilty that the measurement results of the deflection in the warm conditions cifier from the real value due to the reasons that the engne temperature may suddenly increase after the engine is stopped, and due to the effects of the to the temperature difference of thecrankshaft, Be careful of this fact. thermal expansion owing 6+ BDK-28 A 02.2 PY)Inspection and Maintenance Inspecting and Replacing Protective Zinc a 6:80K-28| 4.7 5e 7 Inspecting and Replacing Protective Zinc In case thal sea waler is used as the cooling water in the cooling system, a protective zine is provided in each cocler Conduct periodical inspection and ceplacement of the parts on the following procedure (1) Replacing Consumables, Implements, and Measuring Instruments a) Replacing Consumbables e Lubricating cooler (EL: "Parts List 1) No.12 2) Protective zinc No.1 Ai cooler ([L)}:"Parts List) 3) Gasket No.2 4) Gasket No. 5] Protective zinc No.1 6) Protective zing No.3 b) implements and Measuring nstuments 1} General tools (EL "implements List the fine! documents) (2) Locations of rote Interval @Front and rear covers tor lubricating e cooler. Every&merdks Front and rear covers fr sr cool. Every érmenths p> Efficiency of tne protectve zinc substartialy varles depending on the purlly. Therefore, be minded to use the genuine pants supplied by Dahaisu Desel Manufacturing. Co, Lid /9 Zine and Inspection (8) Inspection and Replacement a) Inspection i] Romove the mounting flange for protective ii) Replace the protective zino of which volume is reduced mare than 50 % (20 % by dimension) as compared to the original shaoe, iil) On the contrary, in case that the protective zine is rarely worn out, the following failures may be suspected: aulty conduction on 1 © Purity failure of zinc 2 mounting surface b) Replacement and Mounting i} Romove the ‘ust or scale from the mounting surfaces of the protective zine and the mounted flange ta expose the metallic surlace, and securely mount the pretective zinc to the flange in such a way that the both paris are closely in contact each other. li! In case that the protective zinc is reused, shave scale of! the surface of the protective zing and expose the zinc surface, EYE 6+8DK-28 A 02-2an | Inspection and Maintenance ] J 6+ 8DK-28 A 02-2 DAIHATSUControl of Fuel Oil, Lubricating Oil, and Cooling Water 4.1 6-8DK-28) Selecting Fuel Oil TEM 6-1 Fuel Oil Characteristics and Control How well the fuel oil characteristics is controlled will greatly affect the smooth operation of engine, maintenance intervals, es well as the working life of various parts. When supplying the fuel oil, it is required not only to confirm the characteristics referring to the characteristics analysis table, but also to conduct the control of the cil in accordance with each characteristics. Particularly when using heavy fuel oil, conduct the preprocessing of fuel oil, the control of viscosity (temperature), and the control of lubricating oil without fail, so that troubles arising from fuel oil can be prevented, 6-1.1 Selecting Fuel Oil Therefore, be minded to chack the characteristics The standard characteristics of the fuel oil __ analysis values of the fusl cls after each delivery applicable to this engine is as shown ina separate and try to avoid using the fuel ail of which table characterises is excessively cifferent from those ((D) Table 6-1.1 "Standard Fuel Oil Characteristics") shown in the standard characteristics table. Commercialy available tual oils are considerably diferent in the charactersstics, and even the sama type of the fuel oll may show a greatly diferent characteristics depending on tne location and period of supply. pds SJ Kh 1) The engine specification varies depending Bottoms olls resulting from operation by FCC. | on the pee of the fue oll 9 be used. Be method (catalytic cracking method) are often | minded to confirm the type of the fuel olf mixed in fuel ois recently referring to the specification of ongino, and The mixed oils, such as this, contain rigid do not use the cil of which grade is lower alumina silica (catalyst particles), and will than that shown in the specification. cause abnormal weer of the various paris of In case that the fuel oil of lower grade is ongino, particularly the parts of the fuel used, troubles may be incurred on the ijection system, operation of engine, due to the faulty Remove the solid particles by fully utlizing the combustion, troubles on the fuel oil system existing fuel oil pretreatment equipment, and | equipment, premature wearing of the parts, and so on, 2) Avoid using the fuel oil by mixing with the other oils whose production of origin is different, In case that fuel ol is mixed the oil with inferior affinity, a large amount of sludge may be generated, causing troubles on the operation of engine. by intensifying the cleaning of fuel oi In case that the removal of the solid particles cannot sulticiently be made with the existing fuel oil pretreatment equipment, the reinforcement of the cleaning equipment will be required, and when such reinforcement is net possible, it may be required to change the current fuel oll fo the oil of a better quality 6*8DK-28 Z 01-3 DAIHATSUControl of Fuel Oil, Lubricating Oil, and Cooling Water Fuel Oil Characteristics and Control ITEM 6:8DK-28) 4.2 61.2 Fuel Oil Characteri (1) Heavy Fuel Oil Since heavy fuel ail contains more carbon residue and Impurities, and is higher in its viscosity as compared 10 clesel fuel ol, heavy fuel oil cannct De Used as the fuel oll for diesel enoine, when its in the state of bunker fuel oil ‘Thereiore, it will be a prerequisite to use heavy fuel cil that the oil must properly be preprocessed beiore being supplied to engine (including the removal of impurities by cleaning, and the assurance of proper viscosity by heating). ics and Control a) Cleaning Fuel Oil Water, and solid contents such as vanadium, sodium, alumina, and silica, contained in heavy fuel oll accelerate the corrosion and wear of the various parts of fuel injection system and ‘vel combustion chamber system, substantially affecting and reducing the working life of these parts. For the purpose of removing such impurities, the fuel oil preprocessing equipment, such as the centrifugal separator end precisien filters, are inetelled. Since these equipment will not exhibit the efficiencies unless each equipment is properly handled, ke minded to operate oach equipment in accordance with the corrasponding instruction manual, ({EDy"instruction Manuat for each equipmen’) Since wasie fuel or sludge will be the causes cf environmental contamination or pollution, be sure to entrust the treatment of these to the authorized waste disposal company, not Girectly handling or disposing these mat en your own, b) Heating Fuel Oil Since the viscosity of heavy fuel oll is vary high, it is required to heat the cil, ¢0 that a propor viscosity for fuel injection can be obtained. Since the heating temperature varies depending ‘on the viscosity of fuel cil, heat the oil and obiain the proper viscosity, by referring to the fuel of Viscosityemperature curve an a separato page as a standard. In case that a viscontrolr (zutematic viscosty requator) § installad on the engine, contol the fuel ot viseesty Is proper value according to the attached instruction manual (1D) Fig.5-1.1 *Fuet Ol Vscosity/Tempereture Cure" Ye Proper vscoaty forfueloi engine rie) | Kinematic viscosity: 1441 St If the temperature control of fuol oi is imoroper, anc the fuel ol with high viscosty has been supplied to engine, it will not only | incur fauty combustion, tut also wil resuit in tne accicents such as the clogged or damaged ‘uel oil filter, and the breakage of fuel injection system parts. | (2) Diese! Fuel Oil a) Water tends to extract and separate out of iesel fuel oil, and further diesel fuel oll tends to generate 2 large amount of sludge when mixed with the cil of diferent base cl Daily conduct the draining-off of the Precipitation tank and settling tank, so that water or sludge doee not flow into the engine. To remove water or sludge, the centrifugal separator is an affective davice. bb) Diesel fue! oil, shat has been cut back by using the gas oil refined by FCC method, may incur faulty start or ignition, and this tendency is particularly obvious in case of low sulfur diese! oil for land vehicles, due to its low cetane number, if the environmental conditions, such as the ambient temperature o1 water temperature, are unfavorable. In such a case, special measures will be become necessary to improve starting capability and combustibility of engine, and in ‘such occasions, contact our company for consultation. 6+ 8DK-28 Z 01-3Control of Fuel Oil, Lubricating Oil, and Cooling Water TEM 4.2 |6-8DK-28 Fuel Oil Characteristics and Control @) Gas ow Athough gas oll does not contain few impurities, It may cause problems on ignition when the gas oil is refined by FCC method, just like the case with diesel fuel oil, and therefore be minded to pay particular attentions to the cetane number of gas oil Further, since gas cil is low in its viscosity and io inferior in its lubricty, it may cause abnormal wear on the sliding parts of fuel ol injection system, and therefore be minded to conduct the inspection of the fuel injection pump and fuel injection valve in the earlier stage than usual (4) Kerosene Olt As a countermeasures to prevent envirnmental contamination (air pollution), there may a case in which kerosene oil may be used. Since kerosene oil is further lower in its number and is lower in its viscosity than gas oil, it is required to carry out a special arrangement on the engine, and therefore contact our company for consultation before using the oll. fane Table 6-1.1 Fuel Oll Standard Characteristics General___| Diesal fuel ol! = Heaiy fuel ol 9 type ot tet ot us (62295 ype 1) 2205 ype 3 = (OMA) RMATO | RME2S | AMGSS | RMS caaac = Ato | =25 | aos | Hs | Density (15°C) gent | mex | 0800 | oe7s | oset | asst | oset nec ESE | im | sere) | somo | 25100 | sero | s5700 [wat 10°F [max 30-50 ‘300 | 1500 | 3500 | 7000 Flash paint in 80 © | 6 | 6 | 6 Pour point *< max ° « | 2% | 2 | 2 “Caibon residue —m% | mx | 02 | 0 |i | ve | 2 ash we | max oo aro | aw | 015 | o20 | Water max a4 s | 10 | 1 | 10 Suitor max is 3s | 50 | 50 | 60 Vanadium mx | — | 150 | 200 | 900 | 600 Sodium | max =o co | 30 | 50 | 9 [arin tea max = 20 | 30 | a0 | 8 Catane number "3 in 4048) —/- T= T= COAL valve = =o max _= eso | eso | aso | eso | Notes: 1) Since there are a wide range of the tandard values for diesel fuel characteristics, the recommenced values are shown in the above table. 2) IMAG (1990). Heavy fuel oil characteristics represent the values of "Residual marine fuel oil" proposed in 3) Cetane number represent the calculated values based on JIS K 2280-1996. Figures shown in (J indicate the vaiues besed on the old method of JIS K2204-1992. 4) CAI (Calculated Carbon Arcmaticity Index) value is calculated by the following formula, and indicates the reference value for starting capability. CCAI value’ 1000 D-141 Log Log (VK + C) - 81 D: Density g/emS (15°C), VK: Viscosity cSt (50°C), C: Constant (0.85 for heavy fuel cil) 6+8DK-28 C 03-2Control of Fuel Oil, Lubricating Oil, and Cooling Water TEM Fuel Oil Characteristics and Control 6:8DK-28} 4.2 Table 6-1.2 Standards for Clean Fuel Oil Component Standards | Water Solid | Content 50 mg/kg or less particles |. " Size 5 xm or less ‘A i\— oe Vanadium combines with sodium to yield a compound that acts as an oxidation catalyst, accelerating the corrosion due to sulluric acid (vanadium attack). Further, water accelerates the corrosion of fuel injection system paris. Particularly in case that sea water is mixed in water, it will lurther accelerate the corrosion due to sulfuric acid as above said, and therefore emove the impurities together with solid Particles by the fuo! oll cleaning equipment, ‘o the best possible extent (FL) Table 6-1 2 "Standard for Clean Fuel ory DAIHATSU 6+ 8DK-28 Z 01-3Fuel Oil, Lubricating Oil, Cooling Water my _2|6-8DK-28) Fuel Oil Viscosity-Temperature Curve Ponts 1000 500 Kinematic “000 a) OSD 7080 GO «100 «14D «+120 «130 14D 160 TemperatureC) Fig. 6-1-1 Fuel Oil Viscosity / Temperature Curve Example) We find the temperature, under which heavy fuel oil of S80cSt can be heated, so as to obtain tho propor viscosity of t4cSt at the engine inlo. To find this temperature, tracing the curve No.9 downward, and from the point that intersects kinematic viscosity 14¢S1, goes down verticaly to obtain 130°C, Note: 1, Notes: 1.The viscosity/temperature characteristics of fuel oll may slightly differ depending on the origin place of production or it refining process, and therefore confirm the viscosity with a viscometer. and datermine the proper value when actually operating the engine. 2. 2. Kinematic viscosity 1cS1 = 1 mmVS 6+8DK-28 Z 01-3 DAIHATSUControl of Fuel Oil, Lubricating Oil, and Cooling Water Selection and Control of Lubricating Oil TEM 6:BDK-28) 2.4, 2.2 6-2.1 Selection of Lubricating Oil (1) Engine system oll As the system oil for engine, high-grade lubricating oil (CD of API service category, or higher) for diesel engine shall be used. Solect the lubricating oil of the suitable grade, accorcing to the quality of the fuel oil to be used, ‘The recommended lubricating brands are shown in a separate tablo. {EE Table 6.2.1 "Recommended Lubricating Oi Brands") Be minded to use the lubricating oil of the ‘same brand, not mixing the lubricating oil with the cil of any other brand, If the lubricating oil Is mixed with the oil of different brand, the additives contained in the both oils react for each other, and this may result in the degradation of the |ubricating oil (2) Lubricating Olls for Other Equipment In ease that eoparate lubricating eystom io employed apart from tho ongine lubricating systom, as in the case of the govomer, ar motor, turbocharger, generator, decution goat, ot, be minded to reler to tha instruction manual of each equipment ((C) “instruction Manual of each equipmen’) 6-2 Lubricating Oil Characteristics and Control Lubricating oil only plays an extremely important roles for engine, not only lubricating the sliding parts but also cooling the various parts, ensuring air tightness, acting as a Getergent-dispersant, or acting as a neutralizing acids. For the purpose of maintaining the engine in proper conditions and assuring the smooth operation, it Is Indispensable to select suitable lubricating oil brands taking into consideration the use purpose of engine, the fuel oll to be used, the load to be connected, ete., and to conduct an appropriate control of the lubricating oll. 6-2.2. Control of Lubricating Oil (1) Cleaning of Lubricating Oil Since fine dust or combustion residue from the combustion chamber enter and mix in the lubricating cil, a centrifugal separator is installed to the engine, to eliminate such foreign matters, in addition to the fitters attached to engine. Use such equipment in correct manner, referring to the instruction manual of each manufacturer. A— Do rot conduct cleaning by injecting water into lubricating oil Mixing water into lubricating oil will cause degradation of the lubricating oil, such as the emulsification of cil, he decrease of total base number, and the increase of insoluble substances. (2) Control of Lubricating Oil Characteristics Poviedicaly conduct the sampling and analysis of lubricating oil (every 500 hours), and in case that the analyzed value of the lubricating cil characteritios has reached the control standard value, immediately consult the lubricating oil manufacturer, s0 thal tho replacomont or makoup can be carried out ({CD) Table 8.22 “Lubricating Ol Control Standards") DAIHAT: 6+ 8DK-28 Z 01-3Control of Fuel Oil, Lubricating Oil, and Cooling Water ITEM 2.2|6-8DK-28| Selection of Lubricating Oil a) Sampling Procedure i} Collect samples from the ait vent pipe of the filter during the operation of engine. If the samples are collected from the drain cock, the analyzed value of the characteristics may show a different value due to the mixing of sludge or sold oposite. The minimum amount of sampling shall be 300 cm iil) Atach on the sampling receptacle with the label incicating the information as shown on the right. b) Lubricating Oil Control Standards The lubricating oil control standards are as shown in the Table 62.2 below. Of all the lubricating oll control standards, the total base number and npentane insoluble are particularly important for the purpose of checking the degradation degree of lubricating oll Table 6-2.2 Lubricating Ol! Control Standards (System oll) ] Diesel | Hea Fuel ol Used | RSI | huslel Total ASE egKOHG| 3 ormore | 10 or more number | 30% or lass | -20%%) Visconsity ost |* 20% or less | 20 Flash point °¢ 180°C or higher Water content | VO% 0.3 orless Tepentane | insoluble? | “7% 25 orless Note :t) The total base number represents the values measures according to ASTM D864, JIS K2501 {hydrochloric acid method), ‘TEN (Total Basic Number) 2) Insoluble represents the values, measured according fo ASTM 08938, In case that the meesure value rapidly increased or exceaded 1.5, measure toluene Insoluble according to the same ASTM 08933, and in case of n-peniane insoluble - iovere insoluble 205, replace the lubricating oll. << Information to be Attached to Sample Receptacle >> 1)Name of your company and your name 2) Model number of engine 8) Engine number 4) Date and location of sampling 5) The amount of time the engine is operated 6) Lubricating oll brand 7) The total operation time and quantity of lubricating cil 8) Replenishment record (Date and quantity of replenishment) 1)Total Base Number (TBN) Total base number represenis the quantity of potassium hydroxide (KOH) that corresponds to the quanity of acid required to neutralize the base component contained in 1 g of lubricating cil, and is indicated by the unit of mgKOHg, Total base number indicates the lubricating oil capabilities to provent the corrosion dus to sulfuric acid generated from sulfur contained in fuel cil, and other acids, and further it indicates the capabilities of lubricating ail to clean and dsperse the fouled sections in the engine 2)Insoluble ( = n-pentane soluble) Insoluble is fouling substance that do not dissolve in oll, and the main component is soot which is @ product of combustion, and calcium suliate which is a neutralized product Since these substances do not dissolve even in r-pentane which is a solvent, n-pontano inccluble serves as an indox to indicate the degradation and fouling degree of lubricating oil 6+ BDK-28 Z 01-3| Control of Fuel Oil, Lubricating Oil, and Cooling Water | i Cooling Fresh Water (Raw Water) and Corrosion 21,3. 6-80K-28, Sosling Fresh We 6-3 Cooling Water Characteristics and Control Always use fresh water as cooling water in the cylinder jacket system and add corrosion prevention agent to cooling water to maintain cooling effect and prevent corrosion due to scale bonded on the piping surtace. Improper cooling water control can cause localized heating of the jacket line parts due to corrosion or scale, resulting in excessive wear on or damage to the jacket line parts. = 6-3.1 Cooling Fresh Water (Raw Water) 6-3.2 Corrosion Prevention Agent {As cooling fresh water (raw water), be minded to. _(1) As corrosion prevention agent, we recommend use tho soft water that meets water quality the agent which is nitrous acid type. standards shown in Table 8-3.1 below, or the (2) Commercially available brands in Japan are water to which softening processing has been shown in Teble €-3.2. administered When using them, carefully read the manufacturors inetruction manual, and properly use the agent in accordance with the use standard as well as the control standard, Table 6-3.1 Frosh Wator (Ran Weter) Quality Standarde Effest (reference) ttem Standards Coxtosion | Scale | PH (25°C) 651035 (neta) | o| | a 1oomarkg Max. ° "_ Ghlorine ion iy? (Concentraton: CI*) noone taibar, OE M- akaiinty (PH4.8) 150mg/kg Max. ° Sulfate ion 7 (concentatoe’soe) | 100mg Max | O | | Total iron (Fe} 0.3mg/kg Max. ° | ° Silica (Si0:) S0mg/kg Max. | | “Ammonium ion eel |__ (Concentration: NH) 0.05mg/kg Max. ° | Evaporation residue 400mg/kg Max Ore LS es ema renee ard | eisControl of Fuel Oil, Lubricating Oil, and Cooling Water Prevention Agent | Cooling Fresh Water (Raw Water) and Corrosion 680k ARG Table 6-3.2 Brands of Commercially Available Corrosion Prevention Agents T Brand Name | Manufacturer Constituent | Amountto added ipom) | DEWENG 3,000 ~ 4,500 +— Drew Cherical Corp. (U.S.A.) Nitvite MAXIGARD 20,000 ~ 22,000 CWT DIESEL 102 VECOM B.V. Nitrite 1,250 ~ 5,000 63.3 Control of Cooling Water (1) As cooling water, be minded fo use fresh water ——______ added with corrosion preventicn agent, from the stage of very first beginning, without fail. Corrosion pravention agent is poisonous and toxic substance. Therefore, be minded never te drink the cooling water that is acced with | corresion prevention agent. | Further, regarding the handling of the cooling water added with corrosion preveniion agent, be sure to wear the proteciive gears such as rubber gloves and masks, so that your hands oF skin co not dirsctly touch the cooling water. If the corrosion prevention agent has accidentally touched your skin or entered your eyes or mouth, immadiately wash them with fresh water sufficiently. (2) Controlling Fresh Water with PH Value Measure the PH value of cooling water once ‘every week, using a FH value, and in case that the value has exceed the standard value specified by the manufacturer, discharge 10 to 20 % af the cooling water to add new water. (3) Replace the entire amount of cocling water once every year or 2 years. as Be minded never to directly discharge the cooling water, which are added with corrosion agent, into sea or river, without adequate | proceasing. When dispesing the cccling water, be aure to conduct the water examination, to oneure that the CDD concentration of cooling water is diluted to be within the specified vaiue. PA 6 *8DK-28 A 02-11Troubleshooting and Countermeasures 1|6-8DK-28| Precautions for Troubleshooting 7. Troubleshooting and Countermeassures Defect or failure of the engine is caused not only by faulty or improperly adjusted engine parts, but also by faulty equipment, improper operation and maintenance work, in addition to the couses attributable to fuel oil characteristics. More often than not, ‘ach engine problem is caused by two or more causes that are interrelated. Therefore, is Impossible to provide the descriptions of the countermeasure for every single detect or failure. This chapter describes the defects and problems that are frequently found on engines, as well as the generally probable causes and countermeasures for such defects and problems. if your engine has a defect or failure that is not described in this section, or if you cannot discover the causes after inspection, contact our Service @ Department. 7-1. Precautions for Troubleshooting (1) Take proper measures immediately when you find a defect or problem. If any of the following defects end failures is found, stop the engine for inspection. Never attempt to restart tho ongine until you find the cause, take proper measures, and restore the engine to the normal eperating echditions, Resuming cporation without taking proper measures may repidly aggravate the dBlect or failure, rasuiting in injuries or accidonte. Activation of protactive device: ‘Alarm’, "Emergency Stop" 2)Qverspeed, low lubricating cil pressure, high cocling water temperature, ate. 3)Abnormal sounds (spacially mechanical sounds), abnormal vibrations 4) Overeating of the engine ‘Abnormal increase of exnaust temperature or maximum explosion pressure, or abnormal decrease of S)exhaust tempereture or maximum explosion pressure @ Defective parts on or around the engine control (governor, contiol devica), oF protective device, 2nd 6)loosened link, or detachment of link Damage to piping or joint botts (specially fue! and lubricating cil systems) (2) Inspect, disassemble, and adjust tho engine correctly according te the instruction manuel. To prevent accidents, never neglect *Safoty Precautions”, )Be sure to use the gentine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the paris list, We will not thereafter guarantae the proper operation of the engine unless such parts are used. Ifyou are out of the snare parts for servicing, immediatly contact us for replenishment. Instruments such as tachometers, thermometers, and pressure gauge may provide incorrect indication even if the engine is running normally, Inspect the instruments on a daily basis to make sure their indication is correct. Replace any defective instrument. Always use correct indications as an index for determining the engine conditions. 6+ 8DK-28 Z 01-3 DAIHATSUTroubleshooting and Countermeasures When Starting Is Difficult 7-2 Troubleshooting and Countermeasures 7-2.1 When Starting Is Difficult [Phenomenon] treouble] {Countermeasures} Insutiiont staring a presbure Intake ar | Ftetstonmancoytaesna: tic Marte epee Fault ar filng ont Fepal (ea conoresson Faulty pressure gouge Repaliep Detective stating a ling system isifcent | Clseo" sop vave oper va Stating | Chogged sng Clean vale | 8 aut staring device "stcking osterng i cperaton vehe- Mertenarce/Repace Stoxing of staring arvatve.- Meirtenance Moi. Fough sae on string eo oe ~ Maitenance/Modiy Fiywheal] | Detective contol system Maintenances oa [7 does not } Intercupted pow: rotate | | Detective eulomate contol panel | Detecvoroken ving of | Social cortzts for cont | Detective solencc valve 11 conte Turing core. ON Rotalon oreverne device: ON High estan olan pa suchas sis) Maintenance/Modiy ; [Non] ["ECytnger ress, Piston Engine smooth | L crankshaft {Sees net turning | Ltoo igh ubricting oilviscosiy Fyanear) | [Norton] Low room temperature ee) | inal tow coing wat omperature 4 ends eet | | Lew Dogrades uo! cit | ere improper prepares (antabilty) lanat Water in fuel ol ignited “icin fvo' {he normal Detective fuel injection valve rotation || Faulty nozzle speed |__| ingxeparvaive opening pressure Noigntion] —Deloctve ius ol injection pump Leeached | in some 14 Sticking of rack cys | Stocking of plungor \ Feutty celivenvisob Improper tuel injection tr — Insufficient compression pressure f-weaiig piston ing atckng wear danag LNor-ainight inaxclexnaust valve improper valve end clearance on intake/exheust valve Inevease room terperture t se: temperature Use high-grade oil Seperate endelmnate wae Remove ait Er Maintenance/Replace. Adjusi Maintenanca/Replace, Adjust 6+ 8DK-28 Z 01-32.2, 2.3 |6-8DK-28) Troubleshooting and Countermeasures When Engine Revolution Is Not Smooth / Insufficient Output 1-2.2 When Engine Revolution Is Not Smooth [Phenomenon] —_— Detective fuel car [Trouble] ‘al sysiem Defective gave = Control link is eaught or shaky. [--—— bateatve tue! supaty system irregular revolution of engien Uneven ‘combuston__/ between oylingers ‘“Varations in exhaus temperature and pressure 7-2.3 Insufficient Output [Phenomenon] Cannot insert the- ——————p, —— — Ineulfisiant eupply proseure (defective relia! valva/pump) Clogged fuel ol fit = Water in fuel of Ain tus oll improper viscesty of fuel ol{heavy tel oi fective fuel injection valve Feulty nozzle Improper valve opening pressure Defective fuel oi injection pump ( Stoking of rack |_ Sticking o' plunger | Fauty impreper fuel injection timing insufficient campress Non-artight pisten ring (sticking, wear, damage) — Norvairightintakelexnaust valve ivery!sotaic valve [Countermeasures] Meintenence’Mepeie MairconencatPepcir, Meinonence’Repeie Clean Separe andalrnae wt Remove ait, ig erpentce yey. e MeincenencelRepeir Ajust MaircenancesRepair Ajit the spctied vate Msingor olRopair Meincenence/Repeir — improper valve end clearance ‘Adjust. on intakevexhaust valve [rroupte} [Countermeasures] fective fuel control sysiem Detective governor Control link is caught or shaky. Tr yzahuet vetoed (excessive ore) rack Figh emote Excessive onrack |] reengine | | scale Low sara | | exhaust ataion | leno sees. | [ Uneven | ees ret | compusion ae between | ostnders | Large resistance on mosingpars (2.9. selzng) Cylincor linars, piston Granksnatt insufficient fuel oll supply pressure = Defeciive fue! oil relief valve — Detective fue! cil feed pump Coaged tua! ail iter Water in fuel ei Air in ful il (@:722 MeintonancelRepsir. Maintenance‘Repair Reduce loa egal. Mainenance’Pepaic lean, ate adelinnae nal Remove air, 6+ 8DK-28 Z 01-3Troubleshooting and Countermeasures | When Exhaust Gas Temperature ore ay nl a Maximum Combustion Pressure Is Abnormal 7-2.4 When Exhaust Gas Temperature (Te) or Maximum Combustion Pressure (Pmax) Is Abnormal Phenomenon} {Troubie} [Countermeasures] High | | High |_ overtead {excessive torque) Reduce load To & + ead! Large resance on moving pats (9. sezig)- NamenenceMa'y [Pmax} | jo pump| inder liners, piston aa: Crankshat esis \ sya [ze Improper fuel ol ropertios Joe igh aalty fel Lenora (improper tuo viscosity theavy fuel ail) Canc rey ae" eo | Low | 7 Fowed tutocnarger Te, low | ake sirt, [Clogged pre-fiter Clean. e Pmaxt [itt Focled blower side Clean, ees Fouled turbine side Clean. Clean Clean Negative presouro in engine room=-="-"~ Improve vention, Ss ———— - Fauty air cooler ‘When High Foulea/cogged fin: Clean. exhaust gas| L intake aL High coaling water temperature: Adjust temperature tenperue| | Insuticen’ cooing water uantly-—-~~ Adjust or, max High intake av temperature Improve ventilation. combustion} pressure is ne atmos. FiGh] jaar — Excessively arg ful ineston To& {en pw ult dg Ad | flomax] | pimp Steg ot rack WanienancetPepice ack Defective tv! injection vate aul nozzle NaintenancetReplace High Ciimproper valve opening pressure =~ Adust © Le, low Deteclve fue injection pump NanienanceReplace Pmax Sticking of rack ) _ Sticking of punges Some | Faulty delveryisebare valve colncers Improper tal nition timing sat ae ——neufiirt compresstonproseure Lcd Nonairight pion ig Nainenance! (etioing, Wear, eamnage) Non-alightirteke/eshavstvalve-----MantenencelReplae Improper valve end clearance ov —--~-Adust inakelexhaust valve Detective tel injection vave sean och ha Faull nozzle ManerencelRepi Note: Aaya check that | gay Dropin valve oponing proseuro =~" Aust not fauity and that | T®, & ———— Defective fuel oil injection pump ‘Mainienance’Replac treldeworvahe Prax Siicking of rack isnot cosa Sticking of plunger ity deliveryiscbaric valve, Leakage fm ar damage fo fue injecton system Repai Ens 6-80K-28 Z 01-3Troubleshooting and Countermeasures TEN 2.5|6-8DK-28 When Exhaust Gas Shows Abnormal Color 7-2.5 When Exhaust Gas Shows Abnormal Color [Phenomenon] Ea Lo ie OF| intake air white | temperature When exhaust gas shows |abnormal: color_| Black or dark —_ gray [rroubte} Engine not warmed up “Low cocling water temperature Excessive amount of lubricating oil Up to the lop part of piston Wear or sticking of piston ring or ol ing Wear of cylinder liners. Low room temperature |_Low cooling water temperature Oatectve fuel injecton valve Faulty nozzle improper valve opaning pressure elective fue! oil injection pump. (Sticking of rack Sticking o! plunge: Faulty delvaryisobaric valve graded fuel ol improper properties (\gnkabiity) FFiaterinfuat ot Arr in fuel of Insufficient compression pressure Non-airtight piston ring icking, wear, damage) Non-aitight intake/oxhaust valve Imp vae or dean an aes “Low ioad operation for long hours e [Countermeasures] Warm up engine. inotease water temperature MaintonancelRepiace. MaintonanceiRepiace, Aust cooling water and quantty in ar coor. Maintenance/Replace. Adjust Maintenance/Repiace. Use high quaity tuel oil pert and elmira water jemove air. Maintonance!Repiace, Maintenence/eplace. Adjust Increase the load {fouled combustion chamberiethaust system) Favioe turbocharger « Giogged previter Giean ed blower side Clean —Foules turbine side Clean Faull air cooler ouleelclagged fn Clean. igh cooling water temperature Adust Insufficient cocling water quantty---- Adjust Negative pressure in engine room. —High intake air temperature Overload (excessive torque) Improve ventilation Change the lo propery 6+ 8DK-28 Z 01-3 PATE)Troubleshooting and Countermeasures Abnormal Noise / Abnormal Vibration TEM 6-8DK-28) 2.6 7-2.6 Abnormal Noise / Abnormal Vibration [Phenomenon] [Trouble] Knocking ‘Abnormal combustion — Overcooling of engine Defective {uel cil injection pump re Faulty spraying by nozzle rom Improper fuel ol properties, cylinder Faulty cylinder safety valve [safety valve} Sticking of valve Sleok spring Impropor load conditions ‘ sOverload (excessive torque) ‘Ronormal] ‘Abrupt change in load noise | +Excossve lsd.comected or disconnected Defective turbocharger — Fouled blower side Fouled turbine side —Detormed or damaged paris (diffuser, turbine nozzle, turbine rotor) — Clogged exhaust manifold __ Mectianica Clogged or fouled air cooler sounds — Defective fue! oil injection pump besharger surging Loose mounting bol's nai Locse bolls on holding moving paris normal z mn sively worn oylinder liners (sole ponormat .cossively worn cylinder liners (seizing) — Excessive intake and exhaust valve end clerance Increase in goar backlash [Countermeasures] Warm up engine. Maintenance!Repiace. Meintenence’Replace. Use high quality oi Maintenance:Repiace, CCharge the load propaty. Clean Clean Replace. Clean Clean Maintenance/Replace Tighten bolts, Tighten bolts, Mainterance/Replace Adjust AdjustiRepair. PLE 6+ 8DK-28 Z 01-3Troubleshooting and Countermeasures When Engine Stops Suddenly 7-2.7 When Engine Stops Suddenly [Phenomenon] Trouble} {Countermeasures} Overoad (GQ 729) Protective — Decrease of lubricating ol pressure ( {J 7-2.10 device Abnormal cooling water temperature ~~~ ( {p) 7-2.13) vated Crankshaft Timing gear Camshaft impossible, Defective drive equipment Repair, “Generator Reduction gear, propeller shalt system sOtners engine stops suddenly Defective fuel oil supply system No oil in oil tank — Clogged fuel oil fi Defective speed regulator system Normal Defective governor Repair. turning | Control link has come off or is caught -Ropair. _ — Defective fue cil injection pump Maintonance/Replace | Sticking of rack *Sticking of plunger “Faulty deliveryisobaric valve Defective fuel injection valve auity nozzle ‘AdjusReplace improper valve opening pressure ~~~ Adjust sure coupling Repait/Replace. 6+ 8DK-28 Z 01-3 DAIHATSUTroubleshooting and Countermeasures Unable to Stop Engine / Overspeed TEM 6-8DK-28) 2.8,2.9 7-2.8 Unable to Stop Engine/7-2.9 Overspeed [Phenomenon] Unable to stop engine Overspeed ‘Actvation ot protective device Trovbie} Detective speed regulator syste | -vetective governor l Control has come off or is caught Sticking of fuel cil injection pump rack Detective control power system —Deiectiva automatic control panel |_Faulty/disconnected contaots Detectve solencid valve Delectve speed detector ure [Countermeasures] Repair. aintenance'Repatr Maintenance'Repeir Maintenance'Repatr. Maintenance'Repat Maintenance'Repa. Maintonance'Repait DAIHATSU 6+8DK-28 Z 01-3Troubleshooting and Countermeasures TEM 2.10, 2.11 |6-8DK-28} Low Lubricating Oil Pressure / High Lubricating Oil Temperature 7-2.10 Low Lubricating Oil Pressure [Phenomenon] (Ciroubie} [Countermeasures] Low lubricating oil level in tank Replonish, (below lower lit) lubricating 0} Prasue He] [= Improper cil viscosity Repiace. Merete — Clogged lubricating oil fiter (svetion side) Clean. [|specified level| Air sucked from intet side Maintenance/Repar. | during startup * Damaged piping | ——— +Non-eirtight joint | —— Leak tom or damage to oping (discharge sids}-Maintenanca/Ropair. Low + Defective lubricating cil pump Maintenanc: lubricating + Sticking of safety valve, broken spring oil * Wear of pump gear [pressure] -— |+ Wear of bearings Defective relief valve Maintenance/Repair Damaged coding water piirgin|ubrtatingoil coole~ Repair. Clogged lubricating il iter (cise Clean, [Dropin] [High |! Wear ef bearings Msintenanco/Ropar. rossure lubricating a Petring -] ot} 72st operation tempera 7-2.11 High Lubricating Oil Temperature [Phenomenon] Trouble] [Countermeasures] Fouled lubricating oll cooler Clean Defective lubricating oltemparature control vako: Maintenanco/Ropair. + Damaged pollo! [+ Sticking of valve Insufficient cooling water vanity [High] Defective cooing water pume Nirtenancaepar. lubricating (@.g, damagediwomn impeller) oil Clogged fitericooling water piping ~~ Clear {temperature} Improperly regulated water quantity ~~ Adjust. Overload Acjust the load Les airtight eyindors NairtonancoPopa * Wear and sticking of pieton ring Wear of cylinder liners —— Seizing of bearings tenanceiRepair. 6+ 8DK-28 Z 01-3Troubleshooting and Countermeasures Low Cooling Water Pressure (Jacket Line) / High Cooling Water Temperature (Jacket Line) TEU 6:8DK-28] 2.12, 2.13 7-212 Low Cooling Water Pressure (Jacket Line) [Phenomenon] [roubie} —Insutficient cooling water quantty [Countermeasures] Large — Defective cooling water pump Malntenance/Repair temperature | (ami impelled diference ease tens mele) ck Low baer cot logged fitericooling water piping lean. cooling |_| | and outet Improperly regulated water quantity-----~ Adjust. water Defestve cooling wate temperature central valve» Meintenanco/Ropair. pressure ‘Small | Airin cooling water system Remove air. temperature Excessively large cooling water quantity @ difference — Improperly regulated water quantity. Adjust. etewson iio —Detestve cooling water temperature centl vave-~ Maintenance/Repair and outlet 7-2.13 High Cooling Water Temperature (Jacket Line) (Phenomenon) (rou {Countermeasure} Airn oaing water system Remove air Fouled fresh water cooler Clean. high cooling water temperature in cooler system Adjust. igh at “reticent pling waar uy ee Defective coving water pump vineranceep et | (eg demagedom impel) | Clogged filtericooling water piping Improperly regulated water quantity High —- cooling | water temperature “overioad (excessive torque} some oylindors ‘Overheating of cylinders ‘Clogged cooling water channel Seizing of pision and cylinder liners High U exhaust ——— (({):7-24) fempelatue |HDofective ccoing water temperature control valve Clean Adjust MainterancelRepair Adjust load. Clean, ie Repel 7 is YN EELS) 6+ 8DK-28 Z 01-3