PENDA BULKER DAIHATSU DIESEL ENGINE OT UO DAIHATSU DIESEL MFG.CO.,LTD.CONTENTS AX ORDERED BY fet XE LUZ FB HE) Be DESTINED FOR fh oA % BBE HR) SNO.1289 Bw ENGIN. MODEL ENGINE NO DC517Z0189 DCS17Z0191 Bow = sDC-17 % WH S DC517Z0190 DATE OF HFG Sef 2004/11/29 Tnstruction Parts list Rk KAS ed CH HD Cl ammanet enema (ee nen ee pee Be 1. Na of Cylinders (S08) 8. FQ. injection pump (Hea 7] Gs Oe unger dia 19 2. Speed CHBAEIER) ©. Nozzle cooling (XH) TZ s00rnin=t = 3. Direction of revolution [4B EME ATA] 10. F.0. injection nozzle LAREN] Ei standarckR) #28 fo sine RHEO2BXE 4, Turbocharger type GASES) 11. Capacity of LO. Cooler iaeaiaae Az] ara Liners Gl ssa 5. Arrangement turbocharger (Asian) 12, Inter cooler type LEESUAADEE Fst] (ZFront side a opp004 BLF 6. Turbocharger system (3848230) 13. GW. pume CinitActt 7 ose (Aimpotor aia 180 7. Governor type (aiaeeERe st] Qucie = rue NOTE; Items marke are applied for your Diesel Engines. OA VMAAMARMICG Hen CLO tT. DAINATSU:DC-17 INSTRUCTION MANUAL (OPERATION) curren INTRODUCTION : GENERAL GENERAL CONSTRUCTION ENGINE ADJUSTMENT STANDARDS OPERATION 7 INSPECTION AND MAINTENANCE 7 FUEL OIL, LUBRICATING OIL AND COOLING WATER a 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. ‘OKeep this Instruction Wanual 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 mind- ed that these documents, along with the duties, shall be transferred to the successor without a fall. DC-17 Z 02-03Contents DC-17 Chapter 0 INTRODUCTION 1, Before Running Daihatsu Diesel Engine ~. 2, Basic Information on Safety Operation 24. Safety Precautions O24 22. Safety Signs and Symbol Marks 02.2 2.3. Indication of Warning: Warning Labels ~~ 02.3 24 Indication of Warning: Warning Label Positions: ~~ O24 3. Engine Conformirg to NOx Technical Code 03 3A Outline mrs ost 3.2 Parts to be Specitied —-n-- O32 3.3 Engine Setting Value 0.3.3 4, General information ~ 4a 42 43 Chapter 1 GENERAL ---~ 1. Engine Specifications aemmnennnno 2, Ausiliary Equipment - 3. Engine Oulline and Equipment Layout ~ Chapter 2 GENERAL CONSTRUCTION 4. Engine 4 12 13 14 15 16 17 18 19 oad 0-4.2 0.4.3 Notation of Engine Type ~- Definition of Term Unit wn Engine Frame, Cylinder Liner, and Main Bearing Crankshaft and Bearing Camshaft and Timing Gear - Piston and Connecting Red ~~~ Cylinder Head ~—- ~ wee Fuel Injection Device Valve Operatng Device Fuel Control Device e-em sence: DAB Intake and Exhaust System - Py) DC-17 Z 02.03DC-17 Contents 2 Chapter 3 ENGINE ADJUSTMENT STANDARDS ----- 1 2 Piping Systems 24 Starting Pneumatic System 22 Fuel Cil System -. 23. Lubricating Oil System 24 Cooling Water System mun Contrclling Engine Operation and Protective Device 3.4 Start Control 32 Stop Control. 3.3. Engine Protection System ‘Operating Specificatons 34 Valve Settings snnennn Chapter 4 OPERATION .. —— 4 1 Precautions for Operation 14 Incase ofStart —— 1.2. Incase of Operation 1.3 Insase of Stop Preparation for Operation 24 Preparation for Dally Operation 2.2 Preparation for Initial Siarting after Long Period of Disuse and Overhaul ww. 42.2 Starting 3.4 Staring Procedure 32 Inspection and Check llems Immediately after Starting Operate 44 Running-in 4.2 Warming up and Connecting Load to the Engine 43° Oferation with Load (Normal Operation) mwsem 44° Oferation Using Heavy Fuel Oil (for Heavy Fuel Oil Engines) =~ 45 Allbbwabie Operating Renge ‘Special Operation —— 51 Low-load Operation 52 _Non-turbocharger Operation and Operation with Reduced Number of Oyiinders ABA 482 DC-17 Z 02-03 DAIHATSUContents DC-17 6 Stop ~ 6.1 Normal Stop 6.2 Emergency Stop 6.3 Long-term Shuldown Chapter § INSPECTION AND MAINTENANCE 5 1, Precautions for Inspection and Maintenance B4 1.1. Safety Precautions nn ve Ba 1.2. Cautionary Items When Finishing inspection and Maintenance =~ 512 Chapter 6 FUEL OIL, LUBRICATING OIL AND COOLING WATER ~~ 1 Inspection and Maintenance Item Table Measurements and Adjustments 3.1 Exhaust Air Temperature 3.2 Pressure and Temperature of Each Patt wsennnmennnnnnnn Inspection and Maintenance === 4.1 Inspecting Pats on anc arcond intake and Exhaust Valves, and Adjusting Valve End Clearance =~ 54.4 4.2. Inspection and Maintenanca of Fuel Injection Velve ~~ 43° Cleaning Fitters 4.4 Cleaning Turbocharger Blower 4.5 Cleaning Turbocharger Turbine - 46 Measuring Crankshaft Deflection Fuel Oil Control 1.1 Fuel Oil Selection ~~ 1.2. Fucl Oil Control ~n---~ Lubricating Of Control ~ 2.1 Lubricating Gil Selection 22 Lubricating Cll Control Cooling Water Control ~ 3.1 Cooling Fresh Water (Raw Water) ~~ . ne 3.2 Corrosion Prevention Agent ~ DAIHATSU DC-17 Z 02-03[Tew DC-17 Contents Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES -- 4. Precautions for Troubleshooting 2, Troubleshooting and Countermeasures at 22 28 24 25 26 27 28 29 210 2a 212 213 214 Starting Detect Engine Revolution is Not Smooth Insufficient Output ~ Abnormal Exhaust Gas Temperature Abnormal Exhaust Gas Color ‘Abnormal Noise/Abnormal Vibration Engine Sudden Stop Unabie to Stop Engine Overspeed Low Lubricating Oi Pressure ~ High Lubricating Oil Temperature. ~ Low Cooling Water Pressure (Jacket Line) High Cooling Water Temperature (Jacket Line) Low Cooling Water Temperature (Jacket Line) ~~~ DC-A7 Z 02-03 DAIHATSUIntroduction Before Running Daihatsu Diesel Engine pe-17|™" 4 0, Introduction ao) 0-1. Before Running Daihatsu Diesel Engine This i daily maintenance and inspection procedure, and other necessary maintain the engine in good operating condition and ensure that it provides the specified per- formance, be sure to read through this manual and become sufficiently familiar with the proper procedures before operating the engine Strictly avoid use of the engine for a purpose other than the original purpose of use of the engine or under conditions different from the specified condi tions or handling against the descriptions given herein, since such operation will cause acci- dents or troubles. a. D A\ zzch pece ofthe information is an important safety precautions end provided as a “Warning” or “Caution” B, The features and structure of your engine may be different from those provided in this manual depend- ing on the specifications of the engine delivered. In this case, the engine specifications and final docu- merts supplied separately have priority over this manual. C. Forthe details onthe following machine or device, see their instruction manual supplied with this man- ual: 1, Turbocharger 2. Governor 3. Air motor 4. Control equipment 5. Cther special devices D. Be sure touse the genuine parts of DAIHATSU DIESEL MFG. CO.,LTD. or those specified in the parts list. We will not guarantee the proper operalien of the engine unless such parts are used, For replacement of the parts er service on your engine, contact our Daihatsu Diese! Parts Service Co,, Lid., Service Departmen: branch office, or the nearest DAIHATSU DIESEL MFG. Co., Lid. provided on the cover page. Be sure to provide us with the "type ard number of your engine” when contacting us, Ifyou use any parts other than the genuine parts or specified parts, unexpected troubles may be caused, and you cannot make insurance claims owing to nonconformity to terms and conditions of damage insurance. E, To prevent environmental contamination, do net dispose of waste products, tiquids, etc, thoughilessl. Be sure to entrust the disposal of such waste products, liquids, etc. to the authorized waste disposal company. CYTE DC-17 Z 02-03Introduction Prem 2.1|DC-17 Basic Information on Safety Operation: Safety Precautions 0-2, Basic Information on Safety Operation 0-2.1 Safety Precautions The diese] engine uses flammable oil, It hes the high-speed rotational parts, the parts that become extremely hot, or the parts that are under high pressure fluid, during operatior Improper handling of the engine can result in serious injury or fatal accidents, Be sure to ‘observe the safety precautions provided in this manual, A. Beware of Rotational Parts D ris engine nas the high-speed rotational parts. Inadvertent contact of personnel or objects with such parts can cause that person ta get caught in the engine, or cause the chips of objects to fly in all directions, a. Never attempt to touch the rotational parts such 2s the flywhee! and couplings during operation. Also, be sure to place the protective cover in place befcre operation. bb. Before starting operation, check that no personnel is around the engine. Warn any nearby personnel by signaling thal the engine is about to start operation. Beware of Hot Parts A\ the engine parts are very hot during and immediately after operation. Toucting them with bare hands or skin can cause burns. Note that the exhaust manifold, turbocharger, indicator valve periphery, cylinder head, air cooler intet, and heated heavy fuel oil pipes become extremely hot. ‘a. Never attemptto touch any part of the engine with bare hand o- skin during or immediately after opera- ton b. Be sure to wear satety gloves or other pro:ective gear for making measuremonts orinspection. . Allow the engine to sufficienlly cool dawn before performing inspection or maintenance work ©. Prevent Oil from Catching Fire Fuel oil or lubricating oil coming in contact with extremely hot parts of the machine may catch fire, a. Be attentive to oll leakage during operation. If any leakage fs found, Immedictely stop the engine and eliminate the leakage. b. Strictly observe the "NAKED FIRE FORBIDDEN’ sign when adding fucl olf or lubricating oi 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 con the engine operation. ion before resuming DC-7 Z 02-03 DAIHATSU:Introduction Basic Information on Safety Operation: Safety Signs and Symbol Marks 0-2.2 Safety Signs and Symbol Marks This instruction manual and warning labels affixed to the engine carry one of the following sefety signs and symbol marks: A. Safety Signs and “Signal words"

warring: Procauton reid osfery of pereonra{Poteral hazard whi couldesut death or srous ny) AX, "caution: Precauion etd to safty of personnel (Pctental hazard wich may resultin minor ormodera Inu) © --Pronbion: ried practice thet can tt te sey of persone andthe onine "Precautions for handling”: Information on handling of the engine to prevent damage © vrosigeoy a Reconmenisdpacicer ston lobe loneda ese si fprsoma and ene Symbal tarks Warning Signs b, Prohibition Signs YT: cenesat waning ]& = Non-specitc general prohbitien Flammable -> Fire © re smorng Explosive — Explosion or Bursting © nae te toriaten BB. Potsonous — Potsning © : venortouen o Voltage — Electiic Shock ©. Signs for Obligatory Acts High temperature ~ Burn + Wear Eye Protection Gear (safely goggles, et) Wear Head Protection Gear (hard hat, ete.) 2% Rotationaltioving Part — Getting Caught We edge cut = Wear are Potaction Sear (ar pgs, ee) «High-Pressure Fluid Jet — Injury + Wear Hand Protection Gear fsalety gives, ete) 86004 High Location -> Fal ‘Wear Foot Protection Gear (safety shoes, eta) Others (CLD = sec ote pages ati nate ter sour ores DC-17 Z 02-03Introduction rem 2.3| DC-17 Warning Labels 0-2.3 Indication of Warning: Warning Labels Basic Information on Safety Operation: Indication of Warning: ‘The waming labels shown below, are used on the DAIHATSU DIESEL MFG. CO., LTD. OY @) BURU EE 1, it a CAO, EL, RECHT FAD, RUNMRR ANRC REENT EAH o TRAD, sBORRALARBAC 74882 CHANIET. 2 SMOCAALAREHRA LOBEL. LOREEN BB, GET OS CARL 2 CFA. 3, TARE RUTEES A. Fuel injection timing B. Fuel injection valve opening pressure DAIHATSU DC47 Z 02-03Introduction 41-4. | DC-17 | General Information: Notation of Engine Type, Definition of Term, and Unit 0-4. General information 0-4.1 Notation of Engine Type + Number of cylinders *Name of seriss ~ Cylinder bore (em) 0-4.2. Definition of Term Definitions of the terms used in this manual are follows: * Rear side of engine: Output end side (flywheel side) * Front side of engine: Opposite side to te output, end + Exhaust side: Exhaust manifold side (on the right when seen from the output end) + Pump side: Fuel injection pump side (on the left when seen from the output end} + Normel rotation {rightward rotation): Clockwise Exhaust side rotation when seen fom the output end Fret ie Normal rotax Cylinder and journal numbers... 1, 2, 3, starting tion (Righiward from the'output end t \retationy 0-4.3 Unit Basically, SI units are used on the engine end in this manual DC-47 Z 02-03 EEIntroduction (elec DC-17 Z 02-03General Construction rr" 1,2] DC-17 Engine Specifications and Auxiliary Equipment 14, Engine Specification Mode! SDC-17 6DC-17 Type Vertical water-cooling direct injection type 4-cycle diesel engine Number of oylinders 5 6 Cylinders bore | mm 170 Piston stroke | _mm 270 Rotational speed | min 900 / 1000 Output kw Ignition sequence 1-35-42 1-5-3-6.2-4(900minr W/1-2-4-6-5-3(1 00min") Rotation direction Clockwise when seen from the flywheel ‘Turbocharging method Turoocharged by exhaust gas turbine equipped with eir cooler _ [Starting method _ Air motor Cooling Jacket Fresh water method Cooler Fresh water Note: (1) Since the output, which are marked with *, differ depending upon each specifications, be minded to emer the data after referring to the “Engine Specifications’ and "Test Rin Record”, 1-2, Auxiliary Equipment Auxiliary / Equipment Type _ “Remarks Turbocharger Radial turbine type _ Air cooler Fin tube type Governor Hydraulic type : Fuel injection pump ____ Bosch ype Fuel cil vave ~~ Bosch lype “| Lubricating oil pump Gear type _ Lubricating oll cooler - Plate ‘ype Lubricating ol filter Notch wire, duplex ype Labrening ie tr bose Notch wire, duplex ype | Lubricating oi!tank | Common base plate incorporated Coolingwateraump | Centrifugal type Note: The data given in the above table show those in the case ofthe standard specifications, harefore, the data of your engine may differ flor those shewn in this table, and in such a case be minded to refer to the "Engine Specifications’, DC-17 A 04-08 DAIHATSU.General Construction Engine Outline and Equipment Layout pea7["" 1-3. Engine Outline and Equipment Layout Turboctarcer Gauge board \ Govemar, \ = Aho ogo s ree MS 0g Air cooler = r Operation lever = facrny VAL t — WP ——H , " my Coding water pump Lubricating oil cooler Air ricior — lhe ating ofl titer for turbocharger SOs Temperature conto! \ valve for lubricating oil | valve _- Lubricating oll filer DAIHATSU DC-17 Z 02-03General Construction 1.1~1.5|DC-17 | Engine 24, Engine 2.1.4 Engine Frame, Cylinder Liner, and Main Bearing The frame is a monoblock structure made of cast iron, and the upper section of the frame forms: a cooling jacket, together with the cylinder liner The main bearing is @ suspension type, and ‘mounted to the engine frame with 2 mounting bolts and 2 side bolts. Intake air, lubriceting cil, and each cooling water channel, and the timing gear case are incorporat- ed inthe engine frame. The timing gear case is mounted on the engine frame front side, and the turbocharger, air cooler, lubricating oil cooler, cool ing water pump and lubricating oil pump are installed in the frame. A frame safely valve is provided on the frame side cover. 2-1.2. Crankshaft and bearing The crankshaft is an iniegral forged part. A fly- whee! is mounted at the rear (output sde) of the crankshaft, and a crank gear for driving the camshafi and an auxiliary pump driving gear are mounted atthe front. The main bearing and crank ph beating are thin bearings composed of two parts, Thrust beatings are fited on tho front and rear sides of the rear bearing No.1 A ting gear is aitached to the flywheel for air motor starting 2.1.3 Camshaft and Timing Gear ‘The camshaft is located on the left side of the engine (wher seen from the output side} ‘The intake, exhaust and fuel cams are integral parts of the camshaft. The camshaft is a unit Composed of two parts The cam gear for driving the camshaft is installed on the front side of the engine, and the cam gear is driven from the crank gear via the idie gear. Exhaust pe 2-1.4 Piston and Connecting Rod The piston is an integral forged part made of duefile cast iron. tts top ring groove is induction- hardened. The piston is cooled with lubricating oil that is fed from the connecting rod through the pis- ton pin. The connecting rod is fromtumed forged prod- uct with the farge end, which is horizontally spit into three parts, to allow overhaul of the piston without disassembling the bearing unit 24.5 Cylinder Heater The oylinder head is of a highly rigid structure made of special cast iron, and is hydraulically secured to the piston with 4 botts. Four velve system is employed having 2 intake valves and 2 exhaust valves, and a water cooling valve seat, which is directly attached to the cylin- der head, is installed for each exhaust valve, The cylinder head is provided with a turning plug, Rocker armdevice Intake vave and exnauet vai cyinder nead Fuel nezce Fi ih re Yok Fuel ijcten pam ie geatg ese earn shatt Erde tame Crankshall DC-17 Z 02-03General Construction Engine 21.6 Fuel Injection Device The fuel injection pump is a Bosch type and high pressure pump of integrated with tappet, and it's installed on plunger barrel of closed type and isobaric valve. Also, the high-pressure oil inlet coupling, which is a horizontabinsertion type, is connected to the fuel injection pump via the high-pressure coupling made of forged steel 24.7 Valve Operating Device The intake and exhaust valves are driven by mation transferred from the camshaft via the swing ‘am, push rod, and rocker arm, 2-1.8 Fuel Control Device The governor is installed at the rear of the ‘engine, and is driven by the governor gear driven, by the camshatt The operation fever is located beside the instru- ment board at the rear of he engine, 2-1.9 Intake and Exhaust System The turbocharger and air cooler are mounted on the front side of the engine. (LL :"Instruction Manual of Turbocharger’) The exhaust pipe and Intake duct are installed on the same side of the engine, and the intake ‘duct is incorporated in the engine frame, Governor Crankehalt ile gear Cooling water pump —~ Auallary otive gaar Nein bearing Lubriestng oll pump. rank gear ALE) DC-17 Z 02-03General Construction TEM 2.1 | DC-17 | Piping systems: Starting Pneumatic System 2-2, Engine Piping systems and related equipment vary depending on the engine applications, type of fuel used, and specifications, This section describes the typical tions. For more details, refer to the piping system: iping systems of standard specifica- \cluded in the final documents. 2-21 Starting Pneumatic System The engine is started by an air motor operating with compressed air. To start the engine remotely or automatically, press the start button on the engine conirol panel or the operation panel (monitor pane), and the solenoid valve of the starter relay valve provided with a pressure control function (with an integral reducing valve) will be actuated, and low-pres- sure air will push out the pinion gear of the air moter. ‘When the pinion gear engages with the wheel gear on the fywheel, the air motor main air circuit will open. The air motor will be driven by the main air, and the engine vail stat To start the engine on the engine side, press the start button on the engine, and It will start in. the same manner as when started remotely, To protect the air motor, @ strainer is provided between the airtank and the relay valve, The relay vave and the air motor are installed on the exhaust side at the rear of the engine To stat the engine in case of emergency after occurrence of a trouble, such as a power failure, press the start button for emergency provided on the relay valve ( (2) : 4.2 1staning Procedure"? 4 Regulator and reay valve TEP, ot ston fr emergency Start button wn -< = Starting air Starting air system DC-17 Z 02-03 PyeGeneral Construction Piping Systems: Fuel Oil System 2-2.2 Fuel Oil System Fuel oil system vary depending on the grade of the oil used, and a typical example of the fuel oi system for heavy fuel cil is as shown below. When heavy fuel oil is used, ojl must be heated ‘and kept at a constant temperature to maintain the oll viscosity suitable for injection. Oil heated by the heater and pressurize by the fuel feed pump is transferred to the fuel all injec- tion pump via fiter. Hey uel oi supplying pump Air segeuntor " Fuel Oil System Fuctinhe Surplus of oil is retumed to the inlet side of the oil feed pump via pressure regulating valve (relief valve), and is then circulated again. High-pressure oil fed by the fuel injection pump Js introduced into the fuel cil injection valve con- nector from the cyinder head side via high-pres- sure piping coupling ({C0):5-4.3 B "FLushing filter") pM EROT Doe ee rete ( Ft i tattene | f four ~ Fietigectin | btn PT aU Aches DC-17 B 03-07General Construction 2.3|DC-17 Piping Systems: Lubricating Oi System 2.2.3 Lubricating Oil Systems Lubricating oil transferred to the lubricating cil cooler from the lubricating oil pump is regulated to reach the specified temperature and pressure, by means of the temperature control valve and reliet valve respectively, and the lubricating oil is trans- ferred to the oil channel of the engine frame from the cooler via filter. Then, from this oll channel, the lubricating oil is supplied to the piston through the holes of the connecting rod via each main bearing shell and crank pin shell Further, lubricating oil is supplied @s branched from the same oll channel to the camshaft, valve- operating swing arm, fuel oil injection pump, around the locker arm, ard various gears. mari Lutriating i cooler Latccareg vi pura OC) xe Base aloo anigine (et tri The iubricating pump is of a gear type provided with a safety valve, and is installed on the front side of the engine, The lubricating oil fter is a notch-wire duplex type, and blow-off cleaning during operation is possible with this filter. Lubricating oil is supplied to the turbocharger and fuel injection pump via special lubricating oil ther respectively. Lubricating oi, that has citculated through and has lubricated each part, retuns to the base plate ofthe engine (ol tank). Feelinietion pump Lubricating Oil System DC-17 Z 02-03 DAIHATSUGeneral Construction Piping Systems: Cooling Water System pe-17|"" 4, 2:2.4 Cooling Water System The cooling water system is a single fresh water circulating system in which jacket line water (high temperature) and cooler line water (low tem- perature} are mixed. Normally, fresh water is used as cooling water. A. Jacket Line The Jacket line can be fed uncer pressure to cooling water pump from the part of lubri- cating oil cooler outlet by the cooling water pump. The water enters the engine cylinder Jacket through the alr cooler and returns to the fresh water cooler through the tempera- lure control valve case ai the ceoling water outlet of the engine after cocling the parts in the jacket. Fresh water cooler oad tank | Temperatwe 1 penital unis cling water pump G ~. Coola syst J} ‘The temperature control valve in the tem- perature control valve case keeps the cool- ing water at the specified temperature, B. Cooler Line The codler line cooling water is low-tem- perature fresh water fed under pressure by the cooling water pump. The water retums to the fresh water cooler through the air cool- er and the lubricaling oil cooler. Turbocharger oN WY | sores Cooling Water System DAIHATSU. DC-17 Z 02-03General Construction EM " 3,1 | DG-17 | Engine Operation Control, Protective Device: Start Control 2-3. Engine Operation Control, Protective Device Control and protective devices such as the stop cylinder are activated by low-pressure control ail This section describes a system generally used for the power station that is remotely con- trolled for starting and stopping. The engine that is actually delivered may differ from the exam- ples shown in this section depending on the specifications, and therefore refer to the final docu- 2-3.1 Start Control A. For generator a.Remote Control (1)In case of starting the engine by remote con- ‘rol, the control lever must ahvays be set to “"RUN' position, The handle switch (HS) will be tumed "ON" at this state, and ifthe turning safety Switch (TC) is also turned "ON", the engine will be on standby and ready for opera- tion (2) When a start command is given, the solencid valve of the starter relay vaiva operates to feed low-pressure air lo the air moter, and the pnion gear is pushed out. When the pinion gear engages with the wheel gear, the main ar circud of [he air motor opens, (@)Meanwhile, the same start cemmand allows the fuel control solenoid (881) to acivate. causing control air to flow into fuel control oylinder, and allows the common rad to be held in position, so that the fuel injection amount is contiolled not to be excessive al the time of starting, (4)Whea the engine reacies the specified rota- lion speed, the low-speed relay (14) is activat- ed, canceling the start command and resetting the protective circuit, so thal the engine is set tc operaiing state, ments, which are separately provided, for the detal As for the starting air system {high pressure), refer to the previous section 2.2.1. bAutomatic Starting When @ start command is given, the sole- noid valve of the starter relay valve operates to feed low-pressure ait to the air motor, and the pinion gear is pushed oul. When the pin- ion gear engages with the wheel gear, the main air circuit of the air moter opens Engine Side Starting In the case of automatic starting, a start ‘command is automatically given according to the specified sequence, and the sofenoid valve of the starter relay valve operates to feed low-pressure alr to the air motor and start the engine. DC-17 Z 02-03 CE)General Construction re Engine Operation Control, Protective Devi DC-17 a o,,_ uses a Lopbing Fuel oortral yider wa . (ae tis —— t Gy ais Virnieg wowsew an Ns eer SEY iitoKTE) Starter rely vlveGath reel? a Operation iver Handle siviteh(H5) Start and Step System tious 3.1 Eye DC-17 Z 02-033.2,3.3 | DC-17 23.2 Stop Control When a stop command is given, the fuel shute dow solenoid valve (SV) operates to feed control alr to the fuet control cylinder, turn the common fod in the direction for stopping and stop the engine. To stop the engine on the engine side, turn the operation lever to the step position, Further, there may be case that control eir is flowed into the stop cylinder attached to the fuel oil injection pump by a stop command so that the engine can be stopped. General Construction Engine Operation Control, Protective Device: Stop Control / Engine Protection System 2-3.3 Engine Protection System As for the errors that may be led to serious acc dents or failures, alarm is issued and emergency stop is made. Each of the abnormal operation data or value is detected by a switch or sensor, and the fuel shut- down solenoid is activated by the fuel shutdown solenoid valve, so that the engine is immediately stopped. Table 2-3.1 Alarm and stop Items (Example) [Detection item ‘Alarm [Shutdown Location Remarks _| lOverspeed 12 ‘Cam gear Decrease aflubricating ul pressue | 63Q1 | 6aQ2 Engine iniet CConined use fr issuing cmmand reali eiprdrecrcgwtetnpare| TSWH | 26WH2 Engine outlet Cones fr isurg ommend reeolutadagalbirgddpesne | 63QT ‘Turbocharger inlet increase of hbicatng of temperiue | TSQ | ~~ Engine inlet ‘Coin use fr stig eonmane [increase of exhaust temperature | TSTI ~ | Turbocharger inlet(or outlet) | Contneduse risuirg cere [Olleekegettomfalhion pessue tik | 33F - Oil leakage detector [Decrease of lubricating oillavel | 33Q | | Engine lubricating oil tank |_ | Decrease of sarting at pressue | 63AS Before reguletor relzy value fcexethghonprnecoipuaerenue] GSWH Jacket inlet Corbied use fer isung men DC-17 Z 02-03 EAEGeneral Construction Engine Operation Control, Protective Device: pc17/™ 33 Engine Protection System saS_39F 930 SG Z 2g \ lee aa Cor ie wera PLP ouROLate Engine Protection System (Example) PETE DC-417 Z 02-03ITEM pe-17 Engine Adjustment Standards Operating Specifications 3-1. Operating Specifications Temp: ig water | {cooler outlet) line gine inlet Jacket line (jacket inlet) BU~ BE Cooler tine (cooler inlet) Aldecared pow: Kaira seting em Normal value vel energency | Reference . Air tank Staring air - Air motor Safety valve: 0.9 Control air | Air tank n | falles defiendirg on intake | Intake air dunt_| ee _| the engine oulsue i _ |e Ho} 05~1.0 ©: | cz | Fuelo | Engine | — ~ § et | De 0.20.3 | 27 nm ~ 4 - S Engine inlet | 5 (ker outlet) 0.4~0.5 0.4(0.3) 3 Lubricating af cote oop ~ g oi Turbocharger 5 | a inlei(filter outled) G2~08 0.2 l | Cansider static and Jackel line, 5 dynarnic pressure duc ; Gacket inlet 0.15-~0.35 0.15 tank howd and pipe. Cooling |_ aeket ned | cose eer’ water sr + ee ~ Note: (1) As for the alarm setting value and emergency stop value, each item of the pressure represents the lower fimil value, and each item of the temperature represents the upper limit value, (2) Manometer, theimometer, and alarnvemergency stop device will be provided depending on the individual specifications. (8) The actual data found on each engine may differ trom these shown in the above tab, and there- fore refer to the Test Run Record Tatle (included in the final documents) for the detail DC-17 Z 02-03 PRsEngine Adjustment Standards rem Valve Setting Values oC-17 2 3-2. Valve Setting Values ttem Adjustment value(design value) Reference 6D (45°) Opening start angle before top dead center, 5! p op a" ) 2 g @ % | Closing end angle es) | (after bottom dead center) Valve end clearance "C" 03mm (alve end clearance adjusting Opening start angle 5 ) procedure) (before bottorn dead center) (1) Valve end clearance date repre- g sents the lzarance available s —~|__when the engine is cold. 3 rere ey eet ee % | Closing end angle and "B" shown above such that i © | (after top dead center) becomes equal to '0" fist 5 5D Then, adjust valve end clear- | ance *C" such that t becomes equal to the value given in this Valve end clearance "C" o3mm table, Fuel injection valve opening pres 44 MPa sure (adjustment value) Pye DC-17 Z 02-03 ahOperation 4.1~1.3| DC-17 | Precautions for Operating Engine 4-1, Precautions for Operating Engine 4-1.1 For Start CO * Conetct preparations before start ofthe operation of engine, such asthe inspection of oi, water, and air lvels, as well as proper operation of the valves without feult, and be minded to star opera- tion only after it has been confirmed that allthe conditions are ready for the start of engino. Dw. itis cuemeryaangeros to str ine operation of engine wih the terug barestod te hy ‘wheel, Be minded to rermove the bar and store itn a specified place efter turning Is completed. Dc. Confirm inat there are no working staff around the engine, When anyone Is around the ena be minded to send a signal and confirm safely before starting the operation of engine 4-1.2 For Operation oO A. After the starting engine, inspect the following items, and confirm that the engine is in a good and temoval operating for. In case that any defect is found, Immediately stop the engine, so tht the causes of the defect can be investigated and the measures for recovery can be taken * Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate CG __Bihaustremperature ete * Abnormal sound, excessive heating, etc. “Any leakage rom piping. (Particularly, leaks from oll piping will result in fire.) Be minded never to attempy to resume the operation of engine, until he causes ofthe problem or defect are found and eliminated, and the engine is restored to normal operating conditions, } B. Inadvertent contact of the body of working staff or objects with the rotary parts (e.g. flywheel and coupling} will resull in dangerous accidents such as that the staff may be caught up or the chips of the objects caught may fly out in all directions. Therefore, be rinded that both person or otject may not touch the rotary parts. Further, ensure that the protective covers of the rotary parts are always attached without Fall AX c. Durng ite operation o engi, partly te felons pats ate extemal hot, en neretore there is a danger of bum if touched with bare hencs or skin. Be minded to wear safely gloves or protective gears whenever maintenance or inspeciion works are conducted. Further, be sure to operate the engine with the protective covers of these parts always attached. - Exhaust pipe + Turbocharger + Air cooler inlet pipe + Cylinder head Turning plug + Fuel injection pump and high-pressure block *Fuel ol pipe (when heavy fuel oils used) 44.3 For Stop ©) A. Make sure that ne engine fs stopped after had is aken off he engine, exceplin the case of emer geney. © & Incase tat the engines storped in emergency stop, De minded never temp to resume the operation until the causes of the problems is found and ciminated, and the engine is restored d ©. Do not open the crankcase for at lease 10 minutos afler the engine is stopped and fully cookd Gown. Otherwise, there is 2 danger of explosion since the inflammable mist gas in the crankcase may cath fire, DA. The engine immediately after itis stopped is stil extremely hot like during the operation, and there isa danger of burn, Theretore, be minded fo wearthe protective gears whenever insgection or maintenance works 1s conducted without fat DC-17 Z 02-03 DAIHATSUOperation Preparation of operation: Preparation of Daily Operation |DC-17 " 24 4-2. Preparation of Daily Operation {tis essential to keep the engine in "Operable Conditions" whenever the engine is being operat- ed. ‘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 eng If the engine is started without pre-operation inspections or preparations, it will cause not only the troubles when starting the engine but also resutt in a sudden stop or damaging accidents. 42.1 Preparation for Daily Operation ‘The number of the inspection items required before starting the operation varies depending on how long the engine has been out of opera~ tion. + Daily starting: Short period of disuse (with- in one month) + Initial starting afer a long period of disuse, or after overhaul or maintenance. ‘The daily starting procedures is described in this section. As for the latter (initial starting), refer to the folowing section, CD): 4-2.2 Preparation for intial Starting after Long Period of Disuse and Overhaul’) Upper frit ‘A, Inspection before Start a, inspection and Feeding of Lubricating Oil ‘Check the cil level of the oil tank, and feed new cil to the upper limit level of the oil gauge (evel gauge) Further, in case that tie lubricating oil is found inadequate after examination, proceed Inspection of Engine Lubricating wilh makeup or repiace the entire amount of the luoricating oil ¢ 6-2 "Lubricating Oil Control") Oi port Oi por, 41.Engine lubricating oil tank (Base plate common to engines) ngineype | SDK | DK [Amount of wbricating oil|L) | 460 | 840 Note: The amounts of oil shown above may vary depending on specifications. 2. Governor Lubricating cil level. RHD6: 1.3L. UG10: 4.7L 2. Generator (in case of self-lubricating type) (LD) : Separately provided "Generator Inspection of Governor Lubricating Oil Level Instruction Manual") DAIHATSU DG-17 Z 02-03Operation [TEM 2.1| DC-17 | Preparation for operation: Preparation for Daily Operatio: b. Inspection, lubrication, and Operation Check around the Fuel Regulation system Manually lubricate the bearing and sliding Parts of pins, after checking for any loose or rising levers, ink pirs, and bots eround the governor, common rod, stop system, and fuel inspection pump rack, Set the operation lever to "STOP" position ‘and confirm that the rack scale is "0", end then alternately move the lever to “STOP* and "RUN" positions, to confirm that the common rod and pump rack moves stroothly. ¢. Draining of Condensed Water from Intake Air Inlet Duct Open the drain cock of the intake air inlet duct of tie engine frame, and draln the con- densed water out. A fee cies the ad7 Doran cock of engine acl Engine frame alr tnlake duct Always keep the drain cock of the engine frame inlet air duct epen about 114, after draining the condensed water by fully ‘operating the drain cock. In case ‘hat the humidity is high and the tem- perature of the air cooler is low, a large amount of condensed water will accurulate, any may cause abnormal wear or teat on various: Fuel ijection pump __Gavemar poration se Lubrication point Manual lubrication: Around the common rad and operation lever ‘thom Lubtization pnt Manuat lubrieatio: Around the tuet injection pump: Poker ‘Operation lever DC-17 Z 02-03 DAIHATSUOperation Preparation for operation: Preparation for Daily Operation|DC-17| 2.4 . 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 tank and starting air control tank, and then confirm that air pressures in these tanks is above the lower lit value. In case of manually supplying air (including ‘manual starting of the air compressor), supply air to the upper limit value. 5, Valves for pipe coupling parts provided for emergency, priming, cleaning, ete.: "Closed" Tem (Upper limit Lower limit Starting air |__3.0MPa 4.5 MPa Control air | 0.9MPa 0.8 MPa e. Checking and Feeding of Fresh Cooling Water Check the level of fresh cooling water, and if the level is at the lower limit, supply fresh walter up to the upper lim, and at the same time add a proper amount of the additive, Further, in case that each properties of water has reached the limit level, replace the entire amount of water. (LJ) » 6-3 "cooling Water Contro! f. Draining of Fuel Oil and Supply of Oil rain fuel ol out of the fuel oil service tank, and then check the oil level and supply oil up fo the upper limit of the leve: gauge 4. Opening and Closing of valves Repeal "Fully open" and “Fully close" operas tion of the vaives on the piping system 2 to 3 times fo confirm thai the valves mave smoothly, and thon sel the valves to "RUN" position. ‘Some of the examplas are shown as follows. Since the layout posttions of the piping systems ‘and velves difer depending on each engine, refer to the piping diagrams of the final docu- ments for the detais. (Example) 1. Vaives for fuel ol inet pipe and retum pipe: "Open" 2. Valves fer cooling wator (jacket and cook ef, inlet pipe, and oulle pipe: "Open" 3, Valves for starting air pipe: “Closed” Open" only when staring operation 4, Valves for operation air pipe: "Open A Ifthe screvstichtening valves are used on the state of hal-open, the valve handle may be turned during operation and the opening degree may be changed, causing mattunctions. ‘Therefore, the valves should be fully turned toward either “Open” or "Close" postion, and should be locked tightly. in case that the valves must necessarily be left nalf open for the sake of fow adjustment, be sure to secure the valve handles with wre ting and the like, and fix them to prevent their loosening and turning. B, Standby Preparation (Engine on standby) Before entering the operation of engine, con- duct the following preparations: a, Priming with Lubricating O11 Run the moto--driven priming pump (or 2 reserve pump) for lubricating oil five minutes before starting the engine, and check that the lubricating oil pressure rises end no ail leaks from piping parts, b, Turing or AirRunning Conduct turning or air running to discharge the dusts or water drops that has collected in the cylinder while the engine is stopped. Further, when the engine is started after the. inspection of various pails of tie engine, or after a long period of disuse of the engine, con- duc turning before air running to confirm the safely, Peet DC-17 Z 02-03Operation 2.1| DC-17 | Preparation for operation: Preparation for Daily Operation] 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 vaive, ‘there is possibilty of serious accidents such as bending damage of the connecting rod by ‘water hammer. if water of oil gushes out of the tuning plug {on the cylinder head top suriace) during tum- ing or air running, step starting the engine, investigate the causes, and take meesures, <> (1) Condust priming with lubricating oi. (2) Set the operation lever to "STOP" position, (Do net injected fuel oi.) (3) Sel the indicator vaive to "Fully open" posi- tion. (4) Conduct turning 1 102 times, and confirm that the engine rotates smoothly. Operation tever <> (1) Conduct priming with lubricating of. (2) Sel the operation lever to "STOP" position, (2) "Fully cpen® the indicator valve. (4) Open the starting air valve and the control air vaive, and press the start button on the engine. ‘The solenoid valve of the starter relay valve will operate to feed starting al to the air motor, and the engine will ster, (5) Keep pressing the push button for 3 to 4 sec- onds. {for airrun) (6) Release the siart bution on the engine. The air motor will stop operating, and the engine will stoa. DC-17 Z 02-03 yale)Operation Preparation for operation: Preparation for Daily Operation] DC-17 i 24 If the engine starts its rotation during the inspection of the inside of the engine or rotary parts, it is extremely dangerous since the working staff may be caught up or the abjects that has been caught up may fly out in all directions. When conducting air run, strictly observe the following points. 1) Confirm that the turning bar should be insert- ed into the turning holder. 2) Send a signal to coworkers and confirm safety before starting to press the push but- ton of the starting operation. ¢. Heating of Fuel Oil (when heavy fuel oil is used.) In case thai heavy fuel oil is used, heating shall be made according to the following lems (1) Tum on the fuel oil heating device. (2) Operate the motor-driven oll feed pump. (DQ): 6-1 "Fuel oil Control”) Heated heavy fuel oll is extremely hot (100% oF more), and may cause burn if jouched by naked hands orskin, ‘Therefore, in case of handling the equipment of fuel cil system that carriers heat oil, be sure to wear safely gloves and never touch them with bare hand: 4. Turning "ON" of Protective and Alarm Circuit Tum "ON" the protective and alarm circuit on the monitor panel, and confirm that the warning lam is [it up. €, Operation of Motor-Driven Pumps In case thai the engine is equipped wit the motor-driven cooling water pump and fuel oil feed pump, slat the pumps § minules before the starting of engine, and confirm that there Is 1 oll leaks from various perts of piping. Pye DC-7 Z 02-0317 | Preparation for operation: Preparation of In 2,2/DC-17 Long Period of Disus: 4-2.2 Preparation for Initial Starting after Long Period of Disuse Since the engine is not ready for immediate starting of operation after a long period of disuse, and overhaul or maintenance, it s particularly nec- essary (0 thoroughly conduct the preparations for operation. Before the preparation for dally operation, con- duet the following preparation works (4-2.1), A. Inspection of Crankcase and Cylinder Liner, and Supply of a, Inspection of the Inside of Grankcase Open the side cover of the engine frame, and check and ensure that tyols, waste clothes, for- ign matters such as desiccants are rot left behind, and that there is no rusting on the oyfin- der liners, crankshaft, and so on. b. Supplying Lubricating Oil to Cylinder Liner After a jong period of disuse the various parts of engine are not covered with sufficient ameunt of lubricating oil, Particularly around the cylin- der, lubricating o1 cannot be supplied sufficiently with priming alone, and therefore supply lubri- cating oil on the following procedure: (1) Conduct turning to allow the pistons to move upward, and apply lubricating oil on the lower part of the cylinder liners by a spray device and the like (2} Sequentially conduct the above procedure to each cyinder. 8, Inspection of Connections and Joints Inspect again the externat connections or joints to confirm that there is no connections that has been forgotten to be tightened, or lnosened joints €. Opening, Cleaning, and Cleansing of Filters Dust of foreign objects, that had been collect- ed into piping during transportation, and outfit. ting or installation, is accumulated in the filters of the engire inlet, ‘Open the following filters, and cleanse the inside and the elements of the fiters: 1 Starting air filler and control air fter 2.Fuel cil fiter (including oil filters on the out. side of the engine) S.Lubricating oil filter {filers on the engine, for e, and Overhaul Spray ISpley lubricating of) Tio foreign matters sual sesicant or sileagel ‘ould te present Applying Procedure of Lut ie) 4.Cooling water fiter CLL £5-4.3 “Cleaning Fiters"> D. Priming with Lubricating Oil and Exhausting Air Conduct priming with lubricating oll and exhausting air on ihe fallowing procedure: a. Run the lubvicating of priming pump for 5 minutes. White the pump is operating, open the turning plug (on the cylinder head top surface} to perform tuning two or three limes, and check for leakage of fuel cil, lubricating oll and water rom the turning plug. b, At the same time, open the each cover and check the dripping-dewn conditions of lubricat- ing oil from each pad. 1.Engine frame: Main bearing, crank pin, piston (Cooling chamber), and pis:on pin 2.Cam case: Cam bearing, swing arm, and tappet 3.0ylinder head: Rocker arm and valve retaining tee . Operate the priming pump, open the alr vent valve for lubricating oil fter, and drain lubricat- ing oil until air bubbles in the cll are completely venished, , Check that there is no oll pakage fram varie ‘cus parts of the piping during priming, DC-17 Z 02-03 PYLEOperation Preparation for operation: Preparation of Initial Starting after A | y¢.47 |" Long Period of Disuse, and Overhaul 2.2 E. Priming with Fuel Oil and Exhausting Air Conduct priming wth fuel oil and exhausting air bubbles on the following procedure: (Operate the fuel oil feed pump (in case of the engine equipped with a motor-driven oil feed pump). (2)Open the fuel oil inlet valve, after confirming that the operation lever is set to "STOP" post- tion. (3)Open the air vent valve of the fuel oil filler, and ‘drain cil unti air bubbles in oil are completely vanished. (Open the air vent valve ofthe fuel injection ump, and drain off until air bubbles in cil are completely vanished. (After completely removing air vent, securely tighten the deflator. Airvent plug Exhausting Air of Notch-Wire Filter F, Cleaning of Turbocharger Pre-ilter <= Dust or debris are collected in the pre-fiter of le the turbocharger during transportation, outfitting, ai and installation, causing the filler io be stained or dameged. ‘Therefore, clean it or replace it with a new one before starting the operation Prefitat Detlator \ ~ Exhausting air of Fuel lojection Pump Turbocharger PPA DC-17 Z 02-03Operation [rem 3.1| DC-17 | starting: Starting Procedure 4-3, Starting ? Inadvertent contact of working staff or objects with the retary parts is extremely dangerous since the person may be caught up or the ‘object that has been caught up may fly out in all directions, Therefore, strictly observe the following items when starting the operation. * Confirm that the protective covers of rotary arts are mounted in normal state, and that the rotary parts are free of any obstacle. + Confirm that the turning device or tu is set to "OFF" ~ Send a signal to a coworker if there |s any, and confirm safely before stating the opera- tion of engine. bar 4-3.1 Starting Procedure Slarting prosedure can be classified into the three types; engine side starting (local starting), remote starting, and aulomaiic starting, end which of these shoukl be employed depends on the specifications. Howovor, local starting (Starting from engine side) by manual operation Should always be empioyed afler a long period of disuse o- after overnaul or maintenance. A. Starting from Engine Side When powers ‘ON" the engine and the conirol and protective devices ave in operation. (Open the starting valve and control air valve (2)Sel the operation lever in "RUN," and hold the ‘operation lever. (3)Press the start button on the engine. (4)if the rotation speed of the engine has rapicily increased and starting has deen established along with continuous ignitien sounds, release the push button {5)Close the starting air valve. (Leave the contol air valve "Open" as it is.) Operation lever B. Remote Starting (Manual and Push Button Starting) (1)Switen the starting mode to the remote mode {from monitor chamber) fram local mode (irom engine side), (Set the operation lever to "RUN" position. (Open the starting air valve and control at vaive, after confirming that "READY™ indicator lamp has it up. (Press the sterting push button, (Confirm that "RUN" indicator lamp on the Panel has litup as tne rotation speed of he engine has reached the specified rate, and each pressure has reached the specifiee value. (Close the starting air valve (Leave the control air valve “OPEN” its.) C. Automatic Starting In case of aulomatic starting, the engine starts ulomatically by the starting command based on preset siarting conditions, such es the overload conditions of power shutdown or other engines Gin 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 eondi- tions at all times: 1.Starting mode “AJTO" 2.Operation lever position "RUN" 3 Starting air valve and control ai valve----~ "OPEN" DC-17 A 03-07Operation Starting: Starting Procedure/Inspection and Check Items Immediately After Starting DCc-17 313.2 D, Starting on engine side When starting the engine at a loss of power or without making the control and protective devices operable. (1)Open the starting air valve and contro! air vaive, (@)Set the operation lever in "START," and hold the operation lever. (@)Press the emergency start button on the starter relay valve. (The button must be pressed by another person.) (lif the rotation speed of the engine has rapidly increased and starting has been established along with continsous ignition sounds. release the push button. {6)Make sure that the rotation speed of the engine has reached the specified speed and each pressure value has reached the specified value, and set the operction lever in “RUN.” (6)Close the starting air vaive. (Leave the control air valve "Oper" as itis.) E. Starting on engine side in case of emergency ‘when the solenoid valve of the starter relay valve cannot be operated, press the button fer ‘emergency on the starter relay valve, and the air motor main sir circuit will open F, Measures to be taken against starting failure When a starting failure or a starting jam. has occurred, take measures in accordance with a separate section (QQ): 7 “Trouble Shooting and Countermeasure") } In case that the engine has repeatedly failed to start in an extremely cold weather vile the engine is stil in cold condition, the unburnt mist of fuel oll may remain in the exhaust manifold, having a possibilily of catching fire or explo: being caused by high-temperature combustion gas. When starting failure has been repeated, conduct air running and exhaust the unturnt mist in the exhaust manifold, before restart the engine 4-3.2 Inspection and Check ttems Immediately After Starting Check the following items imnedialeiy after starting When any abnormal error has been fourd, immediately stop the engine and take proper mneasures, (EL) "Treubte Shooting and Countermeasure") A Ater conducting overhaul or maintenance of ‘he sliding parts or rotary parts, be sure to once stop the engine and check that there is no error or failure by hand-touching. A. Engine Rotation Speed Make sure that the specified rotation speed has been attained and the engine is rotating sta- Gauge beard B, Pressure Reading of Each Section Confirm that the indicator of pressure reading, for the manometer with biue mark, ts within the blue mark, showing the pressure is within the specified value. If he temperature of lubricating oil is love just ailer the engine starts, pressure values may be out cf the specitid ranges. Check that the pressure values come into the specified ranges. as the temperature of lubricating oil rises. ©. Abnormal Sound Carefully listen to the sound of the following engine parts, and check ifthere is any abnermal sound or not 1.Cylinder head and surrounding parts (intake and exhaust valves) 2.Crankcase 3.Crankcase and tiring gear and auvitary drive gear 4 Turbocharger D. Exhaust Temperature Check the exhaust temperature of each eyline der, and confirm that all the eylinders are prop- erly urnt (ai 200% or more}, E, Leakage and Loose from each parts Confirm that mounting parts, Boks and nuts of connecting parts should not been loosed. And cheek if oil, water, and gas should not leaked. PYLE DC-17 A 03-07Operation [TEM 4.4|DC-17 Operation: Running-in 4-4, Operation 4-41. Running-in 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 siding parts of the engine are not yet sufficiently ready to work smoothly of treely, failure such as abnormal war or seizure of the sliding parts may occur, if the load is abruptly apoliec in the stage of such condi tions, Conduct the running-in operation to ensure srrocth and fee working of the sliding parts on the following procedure, before entering normal operation: A, Initial Running-in ‘twill substantially affect the engine perform ance, especially the combustion performance and consequently the consumption efficiency of lubricating cil, wrether the piston and oil rings move smoothly and freely, or ot. Further, it is assumed that they will be deciied by the initial operation of a fev hours. When the cylinder liner, piston, piston ring, and sliding parts around cylinder are replaced, be sure to conduct running-in cperation in accordance to the figure shown below, COLL © Fig. 4.1 "itial Running-in Pattern") B. Operating Conditions during Running-in Be sure fo operate the engine during the run- rning-in period under the following conditions: 4.Lead: 80% or tess 2.Fuel oll to be us2d: Diesel fue! oll For the engines of heavy fue! oil specification, be minded to use diesel fuel oll during the run- 3.Lubricalirg oii to be used shall comply with the fuel oil to be used, Note that in case of the engine with heavy fuel cil spectication, lubrication oil for heavy fuel oil can be used from the stari of engine driving, notwithstanding the above prescriptions of 2. 4.Running-in period is 150 hours. C. Inspection items during Initial Running-in To detect the potential problems and elimi. nate the causes to previously prevent such problems, partcularly heed cautions to the fol- lowing items: 1-Abnormal sound 2Partial heating 3.Leakage from connection parts, and loosening of scrows 4.Explosion pressure, exhaust temperature, irrea- ular exhaust color: Abnormal burning of fue! ‘5 Excessive consumption of lubricating oil: Improper working of liners and rings D. Inspection and Works after Completion of Running Al the time when the runaing-in operation is completed, conduct the following inspection works and confirm thal there is not any ebnor- ality before entering the normal and regular operation of engine, inspection of forcign maitets and stains in the crankcase 2.Visual inspection of the inner surface of the oylinder liner 3.Inspediion and cleaning of the element of each filter 4 Romove the fushing filer attached in the fuel inlet box. Be minded never to perform the operation of engine using heavy fue! oll, while the flushing filer is attached, oa _ Conon al 2 : coi shana in STERI ‘STEPS os ss = 3m CL ts . pont lowey Bot oh foecpsoruay iio 2 we w 3 Initial Running-n Pattern DC-17 Z 02-03 PELE)Operation Operation: Warming-Up and Connecting Load to the Engine | DC-17 en 42 4.4.2 Warming-Up and Connecting Load to the Engine tn case that the engine is started while i is stil in a cold state, first perform the warm-up opera- tion, except for the case of emergency, and gradu- ally conreet the load after the engine has suffi. ciently been warmed up. If the load is hastily connected while the various perts of the engine are still cold and not yet in the ‘conditions for proper fuel combustion and lubrica- tion, matfunctions such as faulty combustion, excessive wear of the sliding parts, and seizure may be caused, ‘A. Warmning-up Operation of Engine a, Use diesel fuel oil for warming-up opera- ‘tion Be sure to use diesel fuel oll for warming up the engine, even in case of the engine with heavy fuel oil specification. (sormaltoos)| 2s No tena b, No load First operate under no load oF light load, and connect the load after jacket cooling water and lubricating oil temperature has increased, A Be minded to perform no-load operation on for warming-up operation, and restrain the duration of no-load operation within 10 min- utes. Running the engine under no-load for ong hours will result in malfunctions such as fauity ‘combustion and collection of carbons in the combustion chamber. B, Connecting Load to the Engine The lower the engine lemperature (tempera- tures of jacket cooling water and lubricating oil) is, the longer time It is needed to connect the load, The standard foad connecting time is shown in the figure below. (CDI): Fig. 4.2"Load Connection Pattern"? I: Jacket zeoting water ard lubricating of ure st saa Timea Load Connection Pattern Cys DC-17 Z 02-03Operation 4,3|DC-17 Operation: Operation with Load (Normal Operation) 4-4.3. Operation with Load (Normal Operation) Inspect the running conditions of the engine and measure the operating performance data in regu- Jar intervals, during the continuous operation with Toad (including period of the runsing-in operation). In case that any problem is found as the results of the inspection and measurement, take proper measures such as adjustment or repair of the defective parts. (Refer to a separately provided section.) € ({Q) ‘8:3 "Measurement ang Agjustment’) ¢ (()) °7 “Troubleshooting and Countermeasures") A. Inspection of Operating Conditions 1.Abnormal sound and abnormal vibration 2.Partial overheat 3. Leakage from connections and looseness of screws 4-Exhaust temperature, and abnormal exhaust color ... Abnorral combustion 5.Excessive consumption of lubvicating oil As During the operation of engine, particulerly the following parts become extremely hat, end touching these pasts with bare hands or skin ‘may cause burns. Therefore, be minded to use the protective gears such as safely gloves when working on them, * Exhaus! pipe * Turbocharger + Air cooler inlet pipe * Cylinder head * Fue! oll system equipment anc! piping (in case ofheavy fuel ol) A. Weasuring Performance Data a. Measure the operating performance data at least once every day, when the load variation is less and the [oad is stable b, Compare each of the measured data with “he data obtained when the engine was nevi intro- duced, and judge if there is any problem and check the degree of deterioration {CT} < "Test Run Record Table" in the final documents) Room temperature Load (output) Intake air temperature (turbocharger inlet) Exhaust temperature (each cylinder) Exhaust temperature (lurbocharger inlet) Intake air pressure (engine inlet) Lubricating ofl pressure (engine inlet) High-temperature cooling water pressure (engine inlet) Low-temperature cooling water pressure (engine intety 10. Fuel cil pressure (engine inlet) . In case of heavy fuel oll specification 14, Inlet air temperature (engine inlet) 12. Lubricating temperature (engine inlet) 13. Cocling water temperature (engine inlet) 14. Fuel oll temperature (engine inlet) In case of heavy fuel oil specification 18, Fuel injection pump rack scale eNonsene €. Regular inspection and Maintenance Conduct inspection and maintenance of tke vari= ous parts of engine regularly. CAD) + 5 “inspection and Maintenance’ D. Operation Records Record the resuits of inspection and measure- ment and the contents of performed adjust- ments and repairs in the engine control log. Operation records are very important docu- ments when undersianding the conditions of engine and tracing the history of the inspection or maintenance that has been perfermed, Keep and store them carefully, and when the supervisor is changed, be sure to transfer the records to the successor without fal DC-17 Z 02-03 [ete eieOperation Operation: Operation Using Heavy Fuel Oi pea7} 44 44.4 Operation Using Heavy Fuel Oil (in case of Heavy Fuel Oil Specification Engine) Heavy fuel oils lower in its quality and higher in its viscosity than diesel fuel oll. When using heavy fuel oll, proper operation control, such as switching tothe operation using diesel fuel oil depending on the load conditions is required, in addition to prop er fuel oit and lubricating oll control (refer to the separate sections.) (LQ 6.1 "Fuel oll Contre") CIELY | 6.2 “Lubricating Oi! Controt") A. Operation with Diesel Fuel Oil Be minded to use heavy fuel of only under stable load conditions, and he sure to use diesel fuel ol in the following cases: ‘a, During Runningn Operation Peiod(150 hours) ‘immediately after installation 2.After replacement of the sliding parts arcund cylinder (e.g. cylinder liner, piston, and piston. ring) (GEL): 4.4.1 "Running-In Operation”) b, During Starting or Warming-Up Operation CEL) 143 "starting? (ED) : 4.4.2 "Warming: Up Operation") ¢. During idling or Low-Load Operation When the engine is cpercted under low load, the compressed air temperature in the cylinder and ye! injection pressure cf fuel oil is low, and therefore if the heavy fuel, cf which comtustion quality is lower than that of diesel fuel oil, is used, combustion will become unstable, result- ing in undesirable conditions, such 2s worsening of the exhaust smoke, sticking of the ring, and so on. in case of the connection of the load that Is below the lower limit described in the engine specification, be minded to use diesel fuel ci 4d. In Case Load Variation is Heavy 1. When entering or leaving port 2. When cargo is being loaded or unloaded €, Before Stopping Engine (LQ) : 4.5 "stop? B. Switching Fuel Oil Types Heavy fuel oil is normally heated up to 80 to 90°C in the service tank, and 100°C or more at the engine inlet, and the temperature difference is larger as compared with that of diese! fuel oil (non-heated), and therefore if fuet cil is suddenly swilcned between these oils, it may cause mal functions such as sticking of the fuel injection pump, vapor lock, and so on, ‘a Slowly switch from diesel fuel oll to heavy fuel oil, so that the rate of change in the fue! oil tem- pereture at the engine inlet is between § and 10 per minute. ¢ (GE) : Fig. 4.3 “switching Pattem from Diesel Fuel Oil to Heavy Fuel Cit") b.Mantain the viscosity (temperature) of heavy fuel oil at the engine inlet at the specified value ¢.Do not raise the temperature of diesel fuel oll beyond the flashing point (60°C is the standare point), .To prevent the generation of vapor, maintain the pressure of fuel oll al the specified value. Further, remove the air bubbles in ‘vel oll in the various equipment of the fuel oll system {hester, filer, tank, ete.) from lime to time, 50 ‘that the accumulation of vapor can be prevent: 0. €.Confirm that the heat traces en pioing and equipment is properly functioning, Heated heavy fuel cil is extremely hot, and if touched wih bare hands or skin, it may cause a burn, Therefore, be minded not to direcily touch the exposed metallic parts such as the valves and cooks, and wear the protective gear such as safety gloves when working on them, A In case thal emergency stop is made during the operation with heavy fue! oll, immediately switch the heavy ‘uel oil fo diesel fuel cil, oper- ale the separate purnp, and perform flushing of the ‘vel oil system, Ifthe engine is cooled down with the heavy fuel oil left unchanged, the oil will be solidified and the operation will be prohibited PY neaea) DC-17 Z 02-03Operation ITEM 4,4| DC-17 | Operation: Operation Using Heavy Fuel Oil ‘Switching from Diese! Fue! Oil to Heavy Fuel Ol! Switching from Heavy Fuel Oli to Diesel Fuel Oil Vacosiy a Viscosity at engine inlet (E=iaaara} cngine inka SESaaaa) : 8 agine inter =a] gL... 2 foe 3.3 | Temperature a neavy wel oh 4 | Temperature of Es Boar 2 z 2e ae Bg | Temperanire ee Temperature of locale al esol tint Swing om i ‘Sinteting trom Heavy doze! fel oto : Foote Devel id Operation with — MOA Os crtion with & | operation with poration with eceifual ot | | neawy ve penne! ff aoe FT * ~ - § | eats Site ata eae Waa § |[Swttiatagabie oad | (Satcnngnan] E | besasen oe. | |fStorotnatovertocd 2 |[Bhow Aeteerond | [agg ot | Resta | ft = fimo feel fst 3 | feet : or Letletont S {lL | Note: 1 Since he pretaatmet cue! sitters cependting on tho use purpase of Ure erigina, ie operating meth aubable to gach sysign isnecessay 2 The oiteo fla temperature wher systehing cn heated candtion shall ke 80°C oF mare Fig. 4.3 Switching Pattern from Diese! Fuel Gil te Heavy DC-17 Z 02-03 ALES)Operation ‘Special Operation: Low-Load Operation/Non-turbocharger pea7 |" Operation and Operation with Reduced Number of Cylinder 5.1,5.2 45. Special Operation 45.1 Low-Load Operation Since running the engine with a tow-load lower than a certain Imit can lead to unfavorable com- bustion conditions such as the reduction of intake air pressure anc blowing-back of exhaust air, if he engine is operated under such conditions for long hours, it may result in the various malfunctions such as fouling of the turbocharger and combus- tion chamber, faulty combustion and so on, Therefore, be sure to minimize the low-load operation to a shorter period of time as much as possible, and in case that the engine must De inevitably run under a low-load for long hours, be ‘sure to ebserve the following conditions: A. Low-Load Limit ‘The low-load limit which the engi ate continuousy is shown below. SDC-17; 70 kWe @DC-17: 90 kWe can oper B. Use of Diesel Fuct Oil In case of the heavy fuel oll specification, be sure lo switch itto diesel fuel €. Cleaning of Turbocharger Properly increase the number of times of deaning the twbocharger aceording to necessity, D. Intermittent High Load Operation During continuous low-load operation, overate the engine at the highest load possible (60% or more) for about 30 min, This is effective in pre- venting fouling in the combustion chamber and the air intake and exisust systems. 4-5.2 Non-turbocharger Operation and Operation with Reduced Number of Cylinders Non-turbocharger operation owing to damage to the turbocharger and operation with reduced num- ber of cylinders under special circumstances are allowed as temporery measures in case of emer gency, However, the use of such operations is limited to a short time. (When the engine is sup- Ported with rubber vibration insulators, such oper- ations are not allowed.) Various limitations and prohibitions are added 10 the operating conditions. The procedures for such operations vary depending on circumstances. Be sure to consult us, receive instructions in operation procedures and sefety precautions, and follow the instructions. a.Use diesel fuel ol b.Output (Totalumber of cylinders}-iN umber of cylinders out of se) x (Totalnurnber of eyinders) m The output may decrease depending on surging of he tursocharger or the exhaust tem perature ¢.Eshaust lemperature: 450°C or more 0% DAIHATSU: DC-17 A 03-07 Le |Operation ITEM 6.1| DC-17 | stop: Normal Stop 46. Stop 4-6.1 Normal Stop A, Precautions for stop incase that heavy fuel ols used, switch the ‘uel oil o diese! fuel cil 30 minutes before stopping the engine. b, Immediately before stopping the engine, start the operation of lubricating cil priming pump. ¢. Confirm that the starting air pressure Is at 2.0 MPa {20 kat/er?} or more. (The preparation for the next round of starting) B. Stop a. Conduct the stop operation on the following procedures: lin case of local operation} Shift the operation lever to "STOP" position. Then, fuel ol injection will be shut off by means of the commen rod, and the engine will be stopped [incase of remote controf] (1)Press the "STOP" push button on the control panel. Then, the tue! oil injection solenoid valve will be activated to operate the fuel shutdown device, and the engine will be stopped, {2)Shifl the operation lever to "STOP" positior. b, After stop operation, be aitentive of any abnormal sound in the engine and tur= bochaiger, and confirm that there Is not eny abnormal sound, A In G250 that the engine does not lop even when the stop speraian is corte, To cy Shope engine ne tery procedures ‘pForeibiy set the rack of ie fel ingction pimp i-0" fal cse the vahe ofthe fe! linet msn tia stor Pp. @ C. After Stop Operate both the lubricating oil priming pump and cooling fresh water pump for about 20 minutes, and cool down the engine and tur- bocharger The turbocharger continues to run at high speed even aller the engine is stopped, Lubrication of the turbocharger provided with this engine is made using the system oll, and therefore if tne supply of lubsicating oil is stopped immediately after the engine is stopped, il may damage the bearing, 'b, Fully open the indicator valve to conduct air running for 3 {0 4 seconds and exhaust the combustion gas out of the combustion cham- ber ¢. Close the valves on alll the systems. DG-17 Z 02-03 ela wee)Stop: Emergency Stop pea7[™ 62 46.2 Emergency Stop A. When Emergency Stop is Required. Immediately stop the engine when any of the folowing abnormalities is found: ‘Announcement of "Emergency" of "Alarm" (-FAcdivation of the protective device —> Automatic) **Overspeed % Decrease of lubricating oll pressure Suspension of water supplyfinerease of cool. ing water temperature ‘increase of exhaust air temperature ‘Other alarming (depending on each specifi- cation) 2.Abnermal sound and abnormal vibration 3.Heating of tie bearings or other moving sec- tions, or generation of smokes, or abrupt increase of mist. 4.Loosening or falling-off of the governer, com- ‘mon rod rink, each lever around the fuel oil injection pump, link pin, or bolt §.Deterioration of fuel olf or lubricating oil, or damage of the cooling weter pipa. 6.Abrupt increase or decrease of rotation speed. 7-Abrupt increase of lubricating oil temperature 8 Water supply disability due to suspension of ‘cooling water supply In case that the engine is overheated due to suspension of water supply, do not hastily sup- ply costing water. If cooled down abruptly, each part of the engine may be deformed, resulting in maltunc- tion or accidents, @.Mixing of water into lubricating cil 10.Abrupt increase of exhaust air temperature 11 Abrupt dectease of the turbocherger rotation ‘speed or intake air pressure 12.Breakage o loosening of the bolts of each ‘section 5. Measures after Emergency Stop In case thal the engine is stopped by activa. tion of the protective device or stopped automat. ically, teke the following mezsures: ‘a. In case that the engine is stopped by remote ‘operation or stopped automatically, set the ‘operation lever to "STOP" positian after the engine is stopped, 'b, Incase that the operation had been made using heavy fuel oi, immediately switch the fuel oll to diesel uel oi, operate the motor- dhiven oil feed pump, and conduct flushing of the fuel oil system (However, this procedure. does not apply when the fuel oll pipe is bro- ken.) Further, conduct turning of the engine, and exhaust the heavy fuel oll remaining in the fuel injedtion pump or fuel vaive. A In case that the engine is stopped curing the operation using heavy fuel oil and the engine cooled down without changing the fuel ci heavy fuel oil in the equipment of the fuel oil system (e.g. pump, fier, etc.) and piping will not only solidify to prohibit starting, but also 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 othar equipmentto "STOP" position, A — In case that the emergency stop is conduct- ed, be minded not to restart the engine using the cause is determined, the countermeasures are taken, and recovery is completed, In case that the engine is started without removing the cause of the abnormality, the matunction may be aggravated and serious accidents may be caused. > B2 minded not to open the crank case for at least 10 minutes after engine is stopped and is completely cooled down. If the crank case is opened immediately after the engine is stopped, flammable mist in the crank case may catch fire and explode Particularly be careful when a large amount of mist is generatad due to overheat or seizing of ite engine Be minded never to let tlames or sparss approach the crankcase even after it is over- havled. Tabac) DC-17 Z 02-03 arOperation ITEM 6.3| DC-17 | stop: Long-Term Shutdown 4-63 Long-Term Shutdown Incase that the operation of engine is suspended for a long term (one month or more), take the preservation measures (mainly, antl-fusting meas- ure) on the fllowing procedures: A. Shutdown within 3 Months a, Fully open the indicator valve once every week, and conduct turning of the crankshaft several times while conducting priming with lubricating oil. In this case, stop the crankshaft at a position different from that before tuming. Afler tuning, securely close the indicator valve. bb, In case that there is a risk of freezing in ‘extremely cold season, be minded to remove cooling water from the engine. B. Shutdown over 3 Months ~ Measures for Long-Term Storage In case that the operation of engine is suspended for 3 months or more, the following measures for longterm siorage is required a, Remove cooling water from the engine. b. Add rust-preventive oll to lubricating oil, open the indcator valve, and conduct turning of the crankshaft several times while conducting prim- ing with the lubricating of Afler tuning, securely close the indicator valve. ©. Open each cover of the engine frame, cam case, anc the cylinder head, and spray rust-pre- ventive ol to the internal pasts. 4d, Insert the moisture-proof agent such as silicage! into the crankcase, accordirg to the ambient air conditions (2.9. weather and humidity) and according to necessiy. €. Place the cover on the outside air opening sec- tion of he exhaust air pipe and the mist pipe f. Cover the engine with a sheet, end carefully cover the eleatic equipment with particular attention to prevent ocllection of dust on them spray Gestecan itpmeri Measures for Long-Term Storage DC-17 Z 02-03 DAIHATSUOperation MEMO pe-17 |" TTA DC-17 Z 02-03 ceInspection and Maintenance ne 4.1| DC-17 | 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, understand the structure of the related parts and the work contents, carefully examine the working procecures, and prepare the consumable parts and tools in advance, before starting these works. the works are conducted without previous and sufficient examinations, it will not only tead 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 readied, inform the Parts Sales Department, Service Department, Daihatsu Diesel Manufacturing Co,, Ltd. or the nearest branch office or shop, and take proper actions. 5-11 Safety Precautions The reading on the rack scale can be increased or decreased by aljusting screw (A) of the fuel injection pump rack lever (1) Loosen the lock nut (B) Q) Turn the adjusting screw A and change the reading on the rack scale. ‘*Clockwise tuming "Increase" (Increase of exhaust airtemperature) *Couriterclockwise iuming “Decrease” (Decrease of exhaust air temperature) 3) Confirm that the exhaust air temperature is within the specified value. (#) Securely tighten the lock nut. ~*billeence vetween eyincers: 1.5 mm artess | Fuel injection pump Rack lever / Leck nut (8) C Increase Decrease Adjusting Rack 5-3.2 Pressure and Temperature of Each Part ‘The pressure and temperature of lubricating oil, fuel oil, and cooling water, etc, are controlled by the relief valve, so that they should be proper values being within each specifies value during the operation of engine, however, when actually operatng the engine, the pressure and tempera- ture of these fluids may not be within the speci- fied and proper values. in such a case, readjust the setting values of ‘the vaives, and perform the operation within the specifiad proper range. A, Intake AirPressure Since the intake ar prossure changes in accordance with load, each pressure when the engine was naw (or, after adjustment) becomes a reference value, The more the turbocharger is fouled, the more the intake air will decrease, resulting in the dete. rioraticn of the engine performance (e 9. increase of the exhaust air iemperature: and increase of the fuel consumption rate), and ‘therefore regularly conduct the blower cleaning and prevent the progress of fouling CELU : 5-4.4 "Cleaning Turbocharger Blower") Fock austin cow A) Cy DC-17 Z 02-03ITEM 3.2|DC-17 ILis impossible to completely remove the fouls even when cleansed by blower cleaning, and to pravent the deterioration of engine per- formance by the elapse of time, however, ifthe cleaning is neglected, fouling will accelerate, resulting in worsening of the engine perform- ance, and as the result it will be required to dis- assemble and clean the turbocharger much earlier than when the cleaning is periodically conducted B. Intake Air Temperature Proper temperature: 45-85°C (at full load) Measurement and Adjustment: Pressure and Temperature of Each Part Intake air, that is either higher or lower than the specified range, will affect the engine, and there- fore be minded to adjust and keep the tempera- tureto be within the specified proper range, as far es possible ‘When the intake air iemperature is too lovr, it causes abnormal or excessive wear ofthe cylin- derliner, intake air valve, otc. since the water drops is formed by the dew condensation, Further, ifthe intake air temperature is too high, it damages the parts around the combustion cham= ber such as the exhaust vaive, since the exhaust air tempereture will increase, (Exhaust air ler- perature ver'es in proporiion to ihe intake air tem- perature, and alse varies in the rate of approxi- ‘mately 2 limes the change of the suction air tem- erature of the turbocharger.) Ifthe intake air temperature gets out of the Proper range owing to a low room temperature, or when automatic adjustment of intake air tem- perature cannot be made far some reasons, operate the following procedure ‘The intake air adjustment can be made by chang- ing the coaling water flow rate in the alr ccoler. (1)Tum clockwise the adjusting screw (B) of the cooling water bypass valve. (2)Be altensive to changes of the intake alr tem- peralure, aad open the bypass valve so as to be withir the proper range, and adjust the angle. Inspection and Maintenance LN Do not screw in the adjusting screw 12 mm or more. The bypass valve will be seated. In case that the intake air does not fall within the proper range even when the bypass valve is, fully opened ard the entire amount of cooting water is flowed into tho air cooler, itis required to disassemble and adjust the it cooler since the fouling cf the air cooler can be considered. (CLD : 12-3ir Cooter, “Maintenance Version") Adjusting screw (8) 1 — ol in | l > {coating wate pnp SS - Cooling water bypass valve The cooling water bypass vahe cetects oad with a intake air pressure switch, Under a low load, he coving water bypass valve shuts off cooker Fe cooling water to air cooler, anc bypasses the water fo heal he intake girth jacket Ene cooling water A the time intake airtemgerature will goup to about 80°C athough based on a surounting condition. DC-17 A 03-07 PEELE)Inspection and Maintenance Measurement and Adjustment: Pressure and Temperature of Each Part pe.17/"™ a2 ©. Lubricating Oil Pressure Proper range, (blue mark range on manometer) 0.4-0.5MPa Lubricating oil pressure changes in accordance with the changes in the viscosity and temperature cof lubricating oll. ‘When the engine is started in extremely cold weather, and the temperature of the lubricating «il is stil low and the viscosity is high, the pres~ ‘sure reeding may go up beyond the blue mark range, however, it does not impose any problem ifthe reading falls back within the blue mark. range when the engine is warmed up. In ease thal the pressure reading is beyond or under the blue mark range, adjust the pressure cn the following procedure: —A- Lubricating oil pressure decreases when the filter is fouled. Be sure to perform the adjust- ment of pressure after the fter is cleaned well. CEQ) : 5.4.3 "cleaning Fitters") Lubricating Oil Pressure Adjusting Procedure> Wher adjusting the lubricating cil pressure, use the adjusting screw on the lubricating cit reg- lating valve. (1) Loosen the lock nut (8). @) Tum the adjusting screw (C), and adjust the pressure, * Clockwise turning (tightering) > Increese of prossure # Counterclockwsise turing (loosening) —> Decrease cf pressure {@) Be attentive to changes of the pressure, and cconirm that the pressure has entered within the blue mark range (4) Tighten the lock nut (8) In case that the lubricating pressure does not change even when the adjustment screw is tumed, there is the possibilities of sticking of regulating valve, suction of air, pump failure, and so on, and therefore investigate the caus- es of the trouble. Adjusing acres f Una Re en? Labricaing el 17M we DC-17 Z 02-03Inspection and Maintenance ITEM Measurement and Adjustment: 3.2| DC-17 | pressure and Temperature of Each Part D. Lubricating Oit Temperature ‘Proper rangs: 85 - 85°C (cooler outlet) Lubricating oil temperature is controlled to remain within the proper range of temperature by the zutomatic temperature control valve installed at the lubricating oi cooler outlet a._Lubricating Oil Temperature Control Valve The temperature control valve is an automatic. bypass valve, that changes the flow rate of lubri- cating oil passing through the cooler, according to its temperature, and when the engine is started while itis sill cold state, this valve rapidly rals- e the lubricating oil by leting the oll bypass. ‘through the cooler, and when the engine is oper- ated normally, this valve maintains the lubricating oll to be within the suitable range of the specified value Incase thai the lubricating oil dees not fall with- in the proper range, for example, because the cooling water (low temperature} temperature Is different from the design temperature, the terr- perature oflubricating oll can be adjusted by the ‘adjusting screw ofthe temperature control valve. However, in case that the actual temperature is exceeding the correctable range (approximately 5°C) and the adjustment is impossible, contac! us for consvitetion on the problem. b. Manual AdjustmentEmergency Measures Incase that the temperature control valve has become faulty and the temperature control has become impossible, the engine can continuously be operated by per‘orming the emergency meas- ures on the following procedure. Turn the adjusting screw (C) fo adjust the tem- perature, ‘Turn clockwise (lighten). The temperature will drop. Tum countercteckwise (lcosen). + The tem perature will ise, (1)Futly loosen the adjusting screw (C), > The cooler passage will be fully ciosed, (2)Observe the changes in the oil temperature while tightening the adjusting screw, and set the lock nut when the temperature comes into the following range. ate (B) “Temperatute. coniral va Do not screw in the adjusting sciew 8 mm or more. * Use range: 30 - 85°C (Cooler outlet) Since the oil temperature changes according to the load, be minded to set the oil tempera ture at a rather lower level, so that it will net exceed the limit when heavily loaded DC-17 Z 02-03 py TES)