DK-20 Instrauction Manual (Operation)

DK-20
INSTRUCTION MANUAL
( OPERATION )
٨ Replacement Parts
Hazards and nonconformities of imitation parts

<Use of imitation parts causes accidents.>
1. Recent engines have compact bodies and high power, and are designed to prevent fuel
deterioration and to reduce NOx discharge. Even if imitation parts are similar in shape
to the genuine parts, the use of imitation parts will degrade the engine performance
because of their fragile materials and low machining accuracy. Since the service life of
such parts is short, the engine
2. If imitation parts are used for the engines designed in accordance with MARPOL VI, the
certificate (EIAPP) may lose its validity, and operation of the engine may be inhibited.
3. If you use imitation parts, you will not be supplied with parts improved in quality and per-
formance.
4. If imitation parts are used, it may be difficult to make insurance claims for the engine
when any accident occurs.
5. We take no responsibility for the engine in which imitation parts are used.
Daihatsu Diesel supplies reliable engines. Use genuine parts to

operate your engine safely.
http://www.dhtd.co.jp
Head Office 1-30, Oyodo Naka 1-chome, Kita-ku, Osaka, 531-0076 Japan
TEL : 81-6-6454-2346 FAX : 81-6-6454-2680
Tokyo Office 2-10, 2-chome, Nihonbashi-Honcho, Chuo-ku, Tokyo, 103-0023 Japan
TEL : 81-3-3279-0827 FAX : 81-3-3245-0359
Jakarta Office 16th Floor, Wisma Antara Bldg., Jl. Medan Merdeka, Selatan No.17, Jakarta-Pusat, Indonesia
TEL : 62-21-384-8411 FAX : 62-21-384-8412
Taiwan Office No.14 Tai-Tang RD, Lin-Hai Industrial Zone, Kaohsiung, 812 Taiwan
(c/o Marine Technical Industries Co., Ltd.)
TEL : 886-7-803-1082 FAX : 886-7-801-9179
Daihatsu Diesel (Europe) Ltd. 5th Floor, Devon House, 58-60 St. Katharine's Way, London E1W 1LB, U.K.
TEL : 44-20-7977-0280 Fax : 44-20-7702-4325
Daihatsu Diesel (AMERICA), Inc. 180 Adams Avenue, Hauppauge, NY 11788, U.S.A.
TEL : 1-631-434-8787/8/9 FAX : 1-631-434-8759
Daihatsu Diesel (ASIA PACIFIC) Pte.Ltd. 128 Pioneer Road, Singapore 639586
TEL : 65-6270-7235 FAX : 65-6270-6236
Manila Office Unit 1010 Herrera Tower Herrera Corner Valero Sts., Salcedo Village, Makati City 1226 Philippines
TEL : 63-2-753-3211 63-2-817-1279/1285 FAX : 63-2-845-0691
Daihatsu Diesel (SHANGHAI) Co.,Ltd. Room A, Floor 9, Huamin Empire Plaza, No. 726 Yanan RD (w), Shanghai, China
TEL : 86-21-6225-7876/7 FAX : 86-21-6225-9299
DK-20 INSTRUCTION MANUAL (OPERATION)
CHAPTER
INTRODUCTION 0
GENERAL 1
GENERAL CONSTRUCTION 2
ENGINE ADJUSTMENT STANDARDS 3
OPERATION 4
INSPECTION AND MAINTENANCE 5
FUEL OIL, LUBRICATING OIL AND COOLING WATER
6
TROUBLESHOOTING AND COUNTERMEASURES
7
䃁 As for the disassembly, maintenance, assembly, and the parts to be
replaced, refer to the separately provided INSTRUCTION MANUAL
(MAINTENANCE) and PARTS LIST.
䃁 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 succes-
sor without a fall.
DK-20 B 02-11
CHAPTER
ITEM
CONTENTS DK-20
Chapter 0 INTRODUCTION 0
1. Before Running Daihatsu Diesel Engine 0-1
2. Basic Information on Safety Operation 0-2
2.1 Safety Precautions 0-2.1
2.2 Safety Signs and Symbol Marks 0-2.2
2.3 Indication of Warning: Warning Labels 0-2.3
2.4 Indication of Warning: Warning Label Positions 0-2.4
3. Engine Conforming to NOx Technical Code 0-3
3.1 Outline 0-3.1
3.2 The parts to be Specified 0-3.2
3.3 Engine settings 0-3.3
4. General Information 0-4
4.1 Notation of Engine Types 0-4.1
4.2 Definition of Terms 0-4.2
4.3 Units 0-4.3
Chapter 1 GENERAL 1
1. Engine Specifications 1-1
2. Auxiliary Equipment 1-2
3. Engine Outline and Equipment Layout 1-3
Chapter 2 GENERAL CONSTRUCTION 2

1. Engine 2-1
1.1 Engine Frame, Cylinder Liner, and Main Bearing 2-1.1
1.2 Crankshaft and Bearing 2-1.2
1.3 Camshaft and Timing Gear 2-1.3
1.4 Balancing Shaft 2-1.4
1.5 Piston and Connecting Rod 2-1.4
1.6 Cylind Head 2-1.5
1.7 Fuel Injecti Divice 2-1.6
1.8 Valve Operating Divice 2-1.7
1,9 Fuel Control Divice 2-1.8
1.10 Intake and Exhaust Systems 2-1.9
2. Piping Systems 2-2

2.1 Starting Pneumatic System 2-2.
2.2 Fuel Oil System 2-2.2
2.3 Lubricating Oil System 2-2.3
2.4 Cooling Water System 2-2.4
DK-20 Z 99-8
CHAPTER
ITEM
DK-20 CONTENTS
3. Controlling Engine Operation : Protective Device 2-3

3.1 Starting Control 2-3.1
3.2 Stoppage Control 2-3.2
3.3 Engirie Protection System 2-3.3
Chapter 3 ENGINE ADJUSTMENT STANDARDS 3

1. Operating Specifications 3-1
2. Valve Settings 3-2
Chapter 4 OPERATION 4
1. Precautions for Operation 4-1
1.1 In case of Starting 4-1.1
1.2 In case of Operation 4-1.2
1.3 In case of Stoppage 4-1.3
2 Preparation for Operation 4-2
2.1 Preparation for Daily Operation 4-2.1
2.2 Preparation for Initial Starting after Installation and 4-2.2
Starting after Extended Disuse or Overhaul
3 Starting 4-3
3.1 Starting Procedure 4-3.1
3.2 Inspection and Check Items Immediately after Starting 4-3.2
4 Operation 4-4
4.1 Running-in 4-4.1
4.2 Warming-up and Connecting Load to the Engine 4-4.2
4.3 Operation with Load (Normal Operation) 4-4.3
4.4 Operation Using Heavy Fuel Oil (for Heavy Fuel Oil Engines) 4-4.4
4.5 Allowable Operating Range 4-4.5
5. Special Operation 4-5
5.1 Low-load Operation 4-5.1
5.2 Operation with Air Cooler Cut-off 4-5.2
5.3 Non-Turbocharger Operation 4-5.3
5.4 Operation with Reduced Number of Cylinders 4-5.4
6 Stoppage 4-6
6.1 Normal Stoppage 4-6.1
6.2 Emergency Stop 4-6.2
6.3 Long-term Shutdown 4-6.3
DK-20 Z 99-8
CHAPTER
ITEM
CONTENTS DK-20
Chapter 5 INSPECTION AND MAINTENANCE 5

1 Precautions for Inspection and Maintenance 5-1
1.1 Safety Precautions 5-1.1
1.2 Precautions after Inspection and Maintenance 5-1.2
2. Inspection and Maintenance Item Table 5-2
3. Measurements and Adjustments 5-3
3.1 Maximum Explosion Pressure and Exhaust Temperature 5-3.1
3.2 Pressure and Temperature of Each Part 5-3.2
4. Inspection and Maintenance 5-4
4.1 Inspecting Parts on and around Intake and Exhaust Valves, and 5-4.1
Adjusting Valve End Clearance
4.2 Inspection and Maintenance of Fuel Injection Valve 5-4.2
4.3 Cleaning Filters 5-4.3
4.4 Cleaning Turbocharger Blower 5-4.4
4.5 Cleaning Turbocharger Turbine 5-4.5
4.6 Measuring Crankshaft Deflection 5-4.6
4.7 Inspecting and Replacing Protective Zinc 5-4.7
Chapter 6 FUEL OIL, LUBRICATING OIL AND COOLING WATER 6

1. Fuel Oil Characteristics and Control 6-1
1.1 Selection Fuel Oil 6-1.1
1.2 Fuel Oil Characteristics and Control 6-1.2
2. Lubricating Oil Characteristics and Control 6-2
2.1 Selection Lubricating Oil 6-2.1
2.2 Lubricating Oil Characteristics andControl 6-2.2
3. Cooling Water Characteristics and Control 6-3
3.1 Cooling Fresh Water (Raw Water) 6-3.1
3.2 Corrosion Prevention Agent 6-3.2
Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES 7

1. Precautions for Troubleshooting 7-1
2. Troubleshooting and Countermeasures 7-2
2.1 When Starting is difficult 7-2.1
2.2 When Engine Revolution is Not Smooth 7-2.2
2.3 Insufficient Output 7-2.3
2.4 When Exhaust Gas Temperature or Maximum Explosion 7-2.4
Pressure is Abnormal
DK-20 Z 99-8
CHAPTER
ITEM
DK-20 CONTENTS
2.5 When Exhaust Gas Shows Abnormal Color 7-2.5

2.6 Abnormal Noise / Abnormal Vibration 7-2.6
2.7 When Engine Stops Suddenly 7-2.7
2.8 When Unable to Stop Engine 7-2.8
2.9 Overspeed 7-2.9
2.10 Low Lubricating Oil Pressure 7-2.10
2.11 High Lubricating Oil Temperature 7-2.11
2.12 Low Cooling Water Pressure (Jacket Line) 7-2.12
2.13 High Cooling Water Temperature (Jacket Line) 7-2.13
DK-20 Z 99-8
CHAPTER
Introduction 0
ITEM
Before Running Daihatsu Diesel Engine DK-20 1.1
0. Introduction
1) Only skilled operators who have carefully read and fully understood the instruction
manual should operate, inspect and service this machine.
0
Operation, inspection or servicing by persons inadequately familiar with the machine
may result in personal injury, equipment damage or environmental hazard.
(2) No responsibility shall be assumed whatsoever for product damage or any associated
fires, oil spills or other environmental hazards, personal injuries, property damage or
economic losses caused by the use of non-genuine parts or operation, inspection or
servicing that deviates from the instruction manual.
(3) We shall repair new parts or replace any flawed parts made or sold by us, however no
compensation shall be provided for damage to any equipment not of our manufacture
or cargo, or personnel, fire-fighting, towing or other expenses arising from the use of
such flawed parts or fowled fuel, lubricant, cooling water or other medium.
(4) This instruction manual is subject to change without notice.
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 to 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 those 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 fatal accidents.
(1) Each piece of the information enclosed in the square box is an important safety precautions
and provided as a warning or caution.
(2) 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-
ments supplied separately have priority over this manual.
(3) For the details on the following machine or device, see their instruction manual supplied with this manual:
1 Turbocharger 2 Governor 3 Air motor
4 Control equipment 5 Other special devices
(4) Be sure to use the genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the
parts list.
We will not guarantee the proper operation of the engine unless such parts are used.
For replacement of the parts or service on your engine, contact our Parts Sales Department, Service
Department branch office, or the nearest DAIHATSU DIESEL MFG.Co.,Ltd provided on the cover page.
Be sure to provide us with the "type and number of your engine" when contacting us.
(5) To prevent environmental contamination, do not dispose of waste products, liquids, etc. thoughtlessly.
Be sure to entrust the disposal of such waste products, liquids, etc. to the authoriqed waste disposal
company.
DK-20 A 08-2
CHAPTER
3 Engine Adjustment Standards
ITEM
1 DK-20 Operating Specifications
3-1 Operating Specifications
Item Alarm setting value

Normal value (emergency stop value) Reference
Air tank 1.5 ~ 3.0 1.5

{15 ~ 30} {15}
Starting air
Air motor 0.5 ~ 0.6
{5.0 ~ 6.0}
Control air Air tank 0.7 ~ 0.9 0.6

{7.0 ~ 9.0} {6.0}
Pressure MPa (kgf/cm2)‫ޓ‬
Varies depending on
Intake air Intake air duct the engine output
0.5 ~ 0.6
Fuel oil Engine inlet {5.0 ~ 6.0}
Engine inlet 0.4 ~0.5 0.25(0.20)
(filter outlet) {4.0 ~ 5.0} {2.5 (2.0)}
Lubricating oil
Turbocharger Varies depending on
inlet(filter outlet) the turbocharger spec.
Jacket line 0.25 ~ 0.35
(jacket inlet) Consider static and
{2.5 ~ 3.5}
Cooling water dynamic pressure due
Cooler line 0.1 ~ 0.2 to tank head and pipe
(cooler inlet) {1 ~ 2} resistance
Nozzle cooling oil Inlet main 0.1 ~ 0.3
(independent oil
feed system) pipe port {1 ~ 3}
Intake air Intake air duct 45 ~ 55
Cylinder outlet 500

Exhaust gas Turbocharger inlet 600
Temperature ( C)
O
Turbocharger outlet 500

Engine inlet
Lubricating oil (cooler outlet) 50 ~ 60 65

Engine inlet 65 ~ 70 85(90)
Cooling water
Jacket line
(fresh water)
Engine outlet 70 ~ 75
Cooler line Engine inlet ~ 32

Varies depending on
Nozzle cooling oil Inlet main pipe port 50 ~ 60 the specifications
Note: (1) As for the alarm setting value and emergency stop value, each item of the pressure represents the
lower limit value, and each item of the temperature represents the upper limit value.
(2) Manometer, thermometer, and alarm / emergency stop device will be provided depending on the
individual specifications.
(3) The actual data found on each engine may differ from those shown in the abave table, and therfore
refer to the Test Run Record (includes in the final documents) for the details.
DK-20 C 08-5
CHAPTER
Operation
4
ITEM
1.1, 1.2 DK-20 Precautions for Operating Engine
4-1 Precautions for Operating Engine

4-1.1 For Start
(1) Conduct preparations before start of the operation of engine, such as the inspection of oil, water,
and air levels, as well as proper operation of the valves without fault, and be minded to start opera-
tion only after it has been confirmed that all the conditions are ready for the start of engine.
(2) It is extremely dangerous to start the operation of engine with the turning bar inserted in the fly-
wheel. Be minded to remove the bar and store it in a specified place after turning is completed.
(3) Confirm that there are no working staff around the engine. When anyone is around the engine, be
minded to send a signal and confirm safety before starting the operation of engine.
4-1.2 For Operation
(1) After the starting engine, inspect the following items, and confirm that the engine is in a good and
removal operating for. In case that any defect is found, immediately stop the engine, so that the
causes of the defect can be investigated and the measures for recovery can be taken.
٨ Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate
exhaust temperature, etc.

٨ Abnormal sound, excessive heating, etc.
٨ Any leakage from piping. (Particularly, leaks from oil piping will result in fire.)
Be minded never to attempt to resume the operation of engine, until the causes of the problem
or defect are found and eliminated, and the engine is restored to normal operating conditions.
(2) Inadvertent contact of the body of working staff or objects with the rotary parts (e.g. flywheel and
coupling) will result 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 minded that both person or object
may not touch the rotary parts.
Further, ensure that the protective covers of the rotary parts are always attached without fall.
(3) During the operation of engine, particularly the following parts are extremely hot, and therefore
there is a danger of burn if touched with bare hands or skin. Be minded to wear safety gloves or
protective gears whenever maintenance or inspection works are conducted.
After the completion of the work, restore the lagging, heat covers, combustible oil splash preven-
tive means (FN tape) and protective covers that have been removed for maintenance and inspec-
tion.
٨ Exhaust pipe
٨ Turbocharger
٨ Air cooler inlet pipe
٨ Cylinder head
٨ Indicator valve
٨ Fuel injection pump and high-pressure coupling
٨ Fuel oil filter and fuel oil pipe (in case of heavy fuel oil)
DK-20 A 05-3
CHAPTER
Operation
4
ITEM
Preparation for Daily Operation DK-20 2.1
[Air Running (abbreviated as Air Run.)]

<Work Procedure> Do not fully open the starting air valve during
i ) Conduct priming with lubricating oil. air run, keeping the opening at about 1/3, and
ii) Set the operation lever to "STOP" position. carefully conduct air running at low speed.
iii) "Fully open" the indicator valve. If air run is conducted at high speed by fully
opening the starting air valve, it will not only
iv) Open the starting air valve and the control air
valve, and press the push button for the start- expend air uselessly, but also will result in seri-
ing operation valve. Then, starting air flows ous accidents such as aggravation of the
into the stsrting air valve, and the engine defects if any defect had been caused.
start its rotation.
In case of air motor starting system, operate c) Heating of Fuel Oil (when heavy fuel oil is
the solenoid of the starter relief valve Then, used.)
pilot air flows into the air motor, and the In case that heavy fuel oil is used, heating
engine starts its rotation. shall be made according to the following items:
v) Keep pressing the push button for 3 to 4 sec- i ) Turn on the fuel oil heating device.
onds. (for air run) ii) Operate the motor-driven oil feed pump.
vi) Release the push button. Then, the starting
6-1 "Fuel Oil Characteristics and
air valve closes, and the engine stops its
Control"
4
rotation.
In case of air motor starting system,stop the
operationof the solenoid. Then, the air motor Heated heavy fuel oil is extremely hot
stops, and the engine stops its rotation. (100 or more), may cause burn if you touch
the piping or equipment on the fuel oil system.
If the engine starts its rotation during the Therefore, in case of handling the equipment of
inspection of the inside of the engine or rotary fuel oil system that carriers heat oil, be sure to
parts, it is extremely dangerous since the wear safety gloves and never touch them with
working staff may be caught up or the objects bare hands.
that has been caught up may fly out in all
directions. d) Turning "ON" of Protective and Alarm
When conducting air run, strictly observe the Circuit
following points. Turn "ON" the protective and alarm circuit on
1) Confirm that the turning device or turning the monitor panel, and confirm that the warning
bar is set "OFF". lam is lit up.
2) Send a signal to coworkers and confirm
safety before starting to press the push but-
ton of the starting operation valve. e) Operation of Motor-Driven Pumps
In case that the engine is equipped with the
motor-driven cooling water pump and fuel oil
feed pump, start the pumps 5 minutes before the
starting of engine, and confirm that there is no
oil leaks from various parts of piping.
DK-20 A 05-3
CHAPTER
Operation
4
ITEM
Preparation for operation: Preparation of Initial Starting after A
2.2 DK-20 Long Period of Disuse, and Overhaul
4-2.2 P r e p a r a t i o n f o r I n i t i a l Open the following filters, and cleanse the

Starting after Long Period inside and the elements of the filters:
1 Starting air filter and control air filter
of Disuse
2 Fuel oil filter (including oil filters on the
Since the engine is not ready for immediate outside of the engine)
starting of operation after a long period of disuse,
3 Lubricating oil filter (filters on the engine,
and overhaul or maintenance, it is particularly nec-
essary to thoroughly conduct the preparations for for T/C)
operation. 4 Cooling water filter
Before the preparation for daily operation, con- 5-4.3 "Cleaning Filters"
duct the following preparation works (4-2.1).
(1) Inspection of Crankcase and Cylinder Liner,
and Supply of Oil
a) Inspection of the Inside of Crankcase
Open the side cover of the engine frame, and
check and ensure that tools, waste clothes, for-
eign matters such as desiccants are not left
behind, and that there is no rusting on the cylin-
der liners, crankshaft, and so on.
b) Supplying Lubricating Oil to Cylinder Liner
After a long period of disuse, the various parts
of engine are not covered with sufficient amount
of lubricating oil. Particularly around the cylin-
der, lubricating oil cannot be supplied sufficiently
with priming alone, and therefore supply lubricat- Spray(Spray
lubricaiting oil)
ing oil on the following procedure:
i ) 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 No foreign matters
and the like. such as desiccant
or silicagel shoud
ii) Sequentially conduct the above procedure to be present.
each cylinder.
(2) Inspection of Connections and Joints Applying Procedure of Lubricating Oil
Inspect again the external connections or
joints to confirm that there is no connections that
(4) Priming with Lubricating Oil and Exhausting
has been forgotten to be tightened, or loosened
Air
joints. If combustible oil splash preventive
means (FN tape) has been removed from joints, Conduct priming with lubricating oil and
newly treat the joints in the same manner after exhausting air on the following procedure:
the completion of the work. a Run the lubricating oil priming pump for 5 min-
utes. While the pump is operating, open the
(3) Opening, Cleaning, and Cleansing of Filters
turning plug (on the cylinder head top surface) to
Dust or foreign objects, that had been collect- perform turning two or three times, and check for
ed into piping during transportation, and outfit- leakage of fuel oil, lubricating oil and water from
ting or installation, is accumulated in the filters of the turning plug.
the engine inlet.
b At the same time, open the each cover and
check the dripping-down conditions of lubricating
oil from each part.
DK-20 A 05-3
CHAPTER
Operation
4
ITEM
Preparation for operation: Preparation of Initial Starting after A
Long Period of Disuse, and Overhaul DK-20 2.2
1 Engine frame: Main bearing, crank pin, parts (exhaust pipe, turbocharger, etc.), exhaust
piston (cooling chamber), and piston pin pipe cover and heat box cover that were
removed for disassembly and servicing have
2 Cam case: Cam bearing, swing arm, and
been restored as they were.
tappet
Check that the joints that were once discon-
3 Cylinder head: Rocker arm and valve retaining
nected are provided with combustible oil splash
tee
preventive Exhaousting
means (NF tape).
Air of
c Operate the priming pump, open the air vent Notch-Wire Filter
valve for lubricating oil filter, and drain lubricat-
Pre-filter
ing oil until air bubbles in the oil are completely
vanished. Take care not to splash the oil.
d Check that there is no oil leakage from various
parts of the piping during priming.
(5) Priming with Fuel Oil and Exhausting Air

Conduct priming with fuel oil and exhausting
air bubbles on the following procedure:
i )Operate the fuel oil feed pump (in case of the
engine equipped with a motor-driven oil feed
4
pump). Turbocharger
ii)Open the fuel oil inlet valve, after confirming Air vent
that the operation lever is set to "STOP" valve
position.
O S O S
iii)Open the air vent valve of the fuel oil filter,
and drain oil until air bubbles in oil are com-
pletely vanished.
iv)Open the air vent valve of the fuel injection
pump, and drain oil until air bubbles in oil
are completely vanished.
v)After completely removing air vent, securely
tighten the deflator.
The heavy fuel oil is heated to a high temper-

ature (100 or more). Exhaousting Air of
Touching the splashing oil may scald your Notch-Wire Filter
hands. If high-temperature parts are splashed
with the oil, a fire may occur. Take care not to Air vent plug
splash the oil when discharging air.
(6) Cleaning of Turbocharger Pre-Filter

Dust or debris are collected in the pre-filter of
the turbocharger during transportation, outfitting,
and installation, causing the filter to be stained
or damaged.
Therefore, clean it or replace it with a new one
before starting the operation.
(7) Checking the covers are fitted

Exhausting Air of
Check that the lagging for high-temperature Fuel Injection Pump
DK-20 A 05-3
CHAPTER
4 Operation
ITEM
4.1 DK-20 Running-in Operation
4-4 Operation
4-4.1 Running-in (2) Operating Conditions during the Running-in
Be sure to operate the engine during the run-
Do not apply a load abruptly since the sliding ning-in period under the following conditions,
parts of the engine are not yet sufficiently ready gradually increasing the load referring to the fig-
to work smoothly or freely when the engine is ure 4.1 and paying special attention to the
started for the first time after its installation or inspection items during the initial running-in indi-
immediately after replacement of the parts such cated in the section A.
as the cylinder liners and the piston ring.
Conduct the running-in operation to ensure
smooth and free working of the sliding parts Load: 80% or less.
according to the following procedure before get- Fuel oil to be used: Diesel fuel oil.
ting into the steady mode of operation. Even for the engines of heavy fuel oil type, use
diesel fuel oil during the running-in period.
(1) Initial Running-in
Whether or not the pistons and the oil rings Notwithstanding the prescription given by the
move smoothly and freely will substantially affect item above, the lubricating oil specified for the
the engine performance, especially the combus- engines of heavy fuel oil type may be used for
tion performance and consequently the con- such engines from the start of engine driving.
sumption of lubricating oil. Further, it is assumed Running-in period is 20 to 30 hours.
that they will be decided by the initial operation
of a few hours. At the time when the running-in operation is
completed, conduct the following inspection
The revolution of the engine should be gradu- works and confirm that there is not any abnor-
ally increased, then the engine should be mality before entering the normal and regular
stopped after it is driven for two or three minutes operation of engine.
without a load and then conduct the following
inspection that is to be effected after completion .Inspection of foreign matters and stains in the
of the initial running-in when the engine is start- crankcase.
ed for the first time after its installation or .Visual inspection of the inner surface of the
replacement of any of parts located in the cylinder liner.
periphery of the cylinder such as the cylinder .Inspection and cleaning of the element of each
liner, the piston, the piston ring. And especially filter.
the following items in the checking list for the ini- .Remove the flushing filter attached to the ele-
tial running-in should be watched and checked ment of the fuel oil filter.
during the engine operation in order to find out
any symptom of a trouble as soon as possible or
to prevent it from occurring. Be minded never to perform the operation of
<Inspection Items during the Initial Running-in> engine using heavy fuel oil, while the flushing
Abnormal sound. filter is attached.
Partial heating. Load
Leakage from connection points and loosen (%)
ing of the bolts and nuts. 100
Continuous
Exhaust temperature, irregular exhaust color : operation
....... Abnormal combustion.
Excessive consumption of lubricating oil : 75
....... Poor adaptability of liners and rings.
<Inspection after Completion of the Initial 15 min

50
Running-in>
Checking the condition of sliding portions of
the cam and the roller, and the cam metal by 15 min
tactile feeling of the finger. 25
Checking the condition of the internal surface
of the cylinder liner. Preparatio
Start (Manual)
Checking the condition of the main shaft, the 0
0 30 60 Time(min)
crankpin metal and the cylinder liner by tactile
Fig. 4.1 Running-in Pattern (Example)
feeling of the finger.
DK-20 A 07-06
CHAPTER
Operation 4
ITEM
Warming-Up and Connecting Load to the Engine DK-20 4.2
4-4.2 Warming-Up and Connecting

Load to the Engine
Be minded to perform no-load operation on
In case that the engine is started while it is still in for warming-up operation, and restrain the
a cold state, first perform the warm-up operation, duration of no-load operation within 10 minutes.
except for the case of emergency, and gradually Running the engine under no-load for long
connect the load after the engine has sufficiently hours will result in malfunctions such as faulty
been warmed up. combustion and collection of carbons in the
If the load is hastily connected while the various combustion chamber.
parts of the engine are still cold and not yet in the
conditions for proper fuel combustion and lubrica- B Connecting Load to the Engine
tion, malfunctions such as faulty combustion, The lower the engine temperature (tempera-
excessive wear of the sliding parts, and seizure tures of jacket cooling water and lubricating oil)
may be caused. is, the longer time it is needed to connect the
load.
(1) Warming-up Operation of Engine The standard load connecting time is shown in
a) Use diesel fuel oil for warming-up operation the figure below.
Be sure to use diesel fuel oil for warming up Fig. 4.2 "Load Connection Pattern"
the engine, even in case of the engine with In case of the marine propulsion engine (direct
heavy fuel oil specification. connection by propeller), be minded to gradually
increase the rotation speed, since the load will
increase according to the rotation speed.
4
b) No load (Idle operation in case of warming
up the marine propulsion engine)
First operate under no load or light load, and When increasing the rotation speed, be
connect the load after jacket cooling water and minded to quickly pass the dangerous running
lubricating oil temperature has increased. speed zone, under which torsional vibration
causes damages (the ref mark zone), on the
tachometer.
Running the engine within this zone for long
hours may cause the breakage of the crank-
shaft.
Load
(%)
䌴䋺 40°䌃䌴䋺 15°䌃
(Normal ioad)
75
50
25
䌴䋺 Jacket cooling water and lubricating oil
temperature at stsrtup
No load
5 10 15 20 25 30 35 40 TIME (min)
Fig. 4.2 Load Connection
DK-20 Z 99-8
CHAPTER
Operation
4
ITEM
4.3 DK-20 Operation with Load (Normal Operation)
4-4.3 Operation with Load (Normal duced, and judge if there is any problem and
Operation) check the degree of deterioration.
"Test Run Record Table" in the final
Inspect the running conditions of the engine and
measure the operating performance data in regular documents
intervals, during the continuous operation with load <Measurement Item>
(including period of the running-in operation). 1 Room temperature
In case that any problem is found as the results 2 Load (output)

of the inspection and measurement, take proper 3 Intake air temperature (turbocharger inlet)
measures such as adjustment or repair of the 4 Exhaust temperature (each cylinder)
defective parts. (Refer to a separately provided 5 Exhaust temperature (turbocharger inlet)
section.) 6 Intake air pressure (engine inlet)
5-3 "Measurement and Adjustment" 7 Lubricating oil pressure (engine inlet)
7 "Troubleshooting and Countermeasures" 8 High-temperature cooling water pressure

(engine inlet)
(1) Inspection of Operating Conditions
9 Low-temperature cooling water pressure
<Check Item> (engine inlet)
1 Abnormal sound and abnormal vibration
10 Fuel oil pressure (engine inlet)
2 Partial overheat ... In case of heavy fuel oil specification
3 Leakage from connections and looseness of 11 Inlet air temperature (engine inlet)
screws 12 Lubricating temperature (engine inlet)
4 Abnormal combustion pressure, exhaust tem- 13 Cooling water temperature (engine inlet)
perature, and exhaust color 14 Fuel oil temperature (engine inlet)
...... Abnormal combustion ... In case of heavy fuel oil specification
15 Fuel injection pump rack scale
5 Excessive consumption of lubricating oil
...... Damaged cylinder liner and ring
(3) Regular Inspection and Maintenance
Conduct inspection and maintenance of the vari-
ous parts of engine regularly.
During the operation of engine, particularly (Refer to a separately provided section.)
the following parts become extremely hot, and
touching these parts with bare hands or skin 5 "Inspection and Maintenance"
may cause burns.
Therefore, be minded to use the protective (4) Operation Records
gears such as safety gloves when working on After completion of the inspection and meas-
them. urement, keep the records of the works per-
٤ Exhaust pipe
formed on adjustments or repairs in the log
٤ Turbocharger
book.
٤ Air cooler inlet pipe
٤ Cylinder head
٤ Indicator valve
٤ Fuel oil system equipment and piping (in Operation records are very important docu-
case of heavy fuel oil) ments when understanding the conditions of
engine and tracing the history of the inspection
(2) Measuring Performance Data or maintenance that has been performed.
a) Measure the operating performance data at Keep and store them carefully, and when the
least once every day, when the load variation is supervisor is changed, be sure to transfer the
less and the load is stable. records to the successor without fall.
b) Compare each of the measured data with the
data obtained when the engine was newly intro
DK-20 Z 99-8
CHAPTER
Operation 4
ITEM
Operation Using Heavy Fuel Oil 4.4
DK-20
4-4.4 Operation Using Heavy Fuel Oil d) In Case Load Variation is Heavy
(in case of Heavy Fuel Oil 1 When entering or leaving port
Specification Engine) 2 When weather is rough and stormy
3 When cargo is being loaded or unloaded
Since heavy fuel oil is lower in its quality and
higher in its viscosity as comperared with diesel e Before Stopping Engine
fuel oil, it is required to carry out an appropriate
operation control, such as operating the engine by 4.6 "Stoppage"
changing to diesel fuel oil depending on the load
conditions, in addition an appropriate control of the (2) Switching Fuel Oil Types
fuel oil and lubricating oil, when this type of oil is to Heavy fuel oil is normally heated up to 80 to
be used. 90 in the service tank, and 100 or more at
the engine inlet, and the temperature difference
Further, the starting and stopping the engine, is larger as compared with that of diesel fuel oil
when heavy oil is used, is only allowed on the (non-heated), and therefore if fuel oil is suddenly
engine of the heavy-fuel-oil starting-and stopping switched between these oils, it may cause mal-
specification. functions such as sticking of the fuel injection
pump, vapor lock, and so on.
6.1 "Fuel Oil Characteristics and Control"
a) Slowly switch from diesel fuel oil to heavy fuel
6.2 "Lubricating Oil Characteristics and oil, so that the rate of change in the fuel oil tem-
Control" perature at the engine inlet is between 5 and
(1) Operation with Diesel Fuel Oil

10 per minute.
Fig. 4.3 "Switching Pattern from Diesel
4
Be minded to use heavy fuel oil only under Fuel Oil to Heavy Fuel Oil"
stable load conditions, and be sure to use diesel b) Maintain the viscosity (temperature) of heavy
fuel oil in the following cases: fuel oil at the engine inlet at the specified value
c) Do not raise the temperature of diesel fuel oil
a) During Running-In Operation Period(150 hours) beyond the flashing point (60 is the standard
1 Immediately after installation point).
2 After replacement of the sliding parts around d) To prevent the generation of vapor, maintain
cylinder (e.g. cylinder liner, piston, and piston the pressure of fuel oil at the specified value.
ring) Further, remove the air bubbles in fuel oil in
4.4.1 "Running-In Operation" the various equipment of the fuel oil system
(heater, filter, tank, etc.) from time to time, so
that the accumulation of vapor can be prevent-
b) During Starting or Warming-Up Operation ed.
4.3 "Starting"
4.4.2 "Warming-Up Operation" If high-temperature parts are splashed with
the oil, a fire may occur. Take care not to
c) During idling or Low-Load Operation splash the oil when discharging air.
When the engine is operated under low load,
e) Confirm that the heat traces on piping and
the compressed air temperature in the cylinder
equipment is properly functioning.
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 oil, is
used, combustion will become unstable, result- The fuel oil is heated, and the filter and the
piping are at high-temperatures. If touched
ing in undesirable conditions, such as worsening
with bare hands or skin, it may cause a burn.
of the exhaust smoke, sticking of the ring, and Therefore, be minded not to directly touch the
so on. In case of the connection of the load that exposed metallic parts such as the valves and
is below the lower limit described in the engine cocks, and wear the protective gear such as
specification, be minded to use diesel fuel oil. safety gloves when working on them.
DK-20 B 05-3
CHAPTER
4 Operation
ITEM
4.4 DK-20 Operation Using Heavy Fuel Oil
In case that emergency stop is made during

the operation with heavy fuel oil, immediately
switch the heavy fuel oil to diesel fuel oil, oper-
ate the separate pump, and perform flushing of
the fuel oil system.
If the engine is cooled down with the heavy
fuel oil left unchanged, the oil will be solidified
and the operation will be prohibited.
㪪㫎㫀㫋㪺㪿㫀㫅㪾㩷㪽㫉㫆㫄㩷㪛㫀㪼㫊㪼㫃㩷㪝㫌㪼㫃㩷㪦㫀㫃㩷㫋㫆㩷㪟㪼㪸㫍㫐㩷㪝㫌㪼㫃㩷㪦㫀㫃㪪㫎㫀㫋㪺㪿㫀㫅㪾㩷㪽㫉㫆㫄㩷㪟㪼㪸㫍㫐㩷㪝㫌㪼㫃㩷㪦㫀㫃㩷㫋㫆㩷㪛㫀㪼㫊㪼㫃㩷㪝㫌㪼㫃㩷㪦㫀㫃㩷㩷
㪭㫀㫊㪺㫆㫊㫀㫋㫐㩷㪸㫋㪈㪊䌾㪈㪋㩷㫄㫄㪉㪆㫊㪭㫀㫊㪺㫆㫊㫀㫋㫐㩷㪸㫋㪈㪊䌾㪈㪋㩷㫄㫄㪉㪆㫊

㪼㫅㪾㫀㫅㪼㩷㫀㫅㫃㪼㫋㪼㫅㪾㫀㫅㪼㩷㫀㫅㫃㪼㫋
㪍㪇㩷㫋㫆㩷㪎㪇㩷㫊㪼㪺㩷㪩㪮㩷㪥㪦㪅㪈㪍㪇㩷㫋㫆㩷㪎㪇㩷㫊㪼㪺㩷㪩㪮㩷㪥㪦㪅㪈
㪝㫌㪼㫃㩷㫆㫀㫃㩷㫋㪼㫄㫇㪼㫉㪸㫋㫌㫉㪼
㪝㫌㪼㫃㩷㫆㫀㫃㩷㫋㪼㫄㫇㪼㫉㪸㫋㫌㫉㪼
㪟㪼㪸㫍㫐㩷㪽㫌㪼㫃㩷㫆㫀㫃㩷㪟㪼㪸㫍㫐㩷㪽㫌㪼㫃㩷㫆㫀㫃㩷
㩷㩷㩷㩷㩷㫋㪼㫄㫇㪼㫉㪸㫋㫌㫉㪼㩷㩷㩷㩷㩷㫋㪼㫄㫇㪼㫉㪸㫋㫌㫉㪼
㪸㫋㩷㪼㫅㪾㫀㫅㪼㩷㫀㫅㫃㪼㫋
㪸㫋㩷㪼㫅㪾㫀㫅㪼㩷㫀㫅㫃㪼㫋
㪁㩷Charge spped :䇭㪁㩷Charge spped :

O O
5 to 10 C/min 㩷㩷䇭5 to 10 C/min
㪛㫀㪼㫊㪼㫃㩷㪽㫌㪼㫃㩷㫆㫀㫃㩷㪛㫀㪼㫊㪼㫃㩷㪽㫌㪼㫃㩷㫆㫀㫃㩷
㩷㩷㩷㩷㩷㩷㫋㪼㫄㫇㪼㫉㪸㫋㫌㫉㪼㩷㩷㩷㩷㩷㩷㫋㪼㫄㫇㪼㫉㪸㫋㫌㫉㪼
Operation
Operation
Switching from Operation Operation Switching from

Operation with diesel fuel oil to with heavy with heavy heavyfuel oil to Operation with diesel
diesel fuel oil heavyfuel oil fueloil fueloil diesel fuel oil fuel oil (warming up)
Check items
Check items
Check heavy fuel oil Check that load is stable Check that load is stable Check heavy fuel oil
supply equipment (above lower load limit) (above lower load limit) supply equipment
for proper operation during switching during switching for proper operation
㪥㫆㫋㪼㩷㪑㩷㪈㪅㩷㪪㫀㫅㪺㪼㩷㫋㪿㪼㩷㫇㫉㪼㫋㫉㪼㪸㫋㫄㪼㫅㫋㩷㫆㪽㩷㪽㫌㪼㫃㩷㫆㫀㫃㩷㪻㫀㪽㪽㪼㫉㫊㩷㪻㪼㫇㪼㫅㪻㫀㫅㪾㩷㫆㫅㩷㫋㪿㪼㩷㫌㫊㪼㩷㫇㫌㫉㫇㫆㫊㪼㩷㫆㪽㩷㫋㪿㪼㩷㪼㫅㪾㫀㫅㪼㪃㩷㫋㪿㪼㩷㫆㫇㪼㫉㫊㫋㫀㫅㪾㩷
㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫄㪼㫋㪿㫆㪻㩷㫊㫌㫀㫋㫊㪹㫃㪼㩷㫋㫆㩷㪼㪸㪺㪿㩷㫊㫐㫊㫋㪼㫄㩷㫀㫊㩷㫅㪼㪺㪼㫊㫊㪸㫉㫐㪅
㩷㩷㩷㩷㩷㩷㩷㩷㩷㪉㪅㩷㪫㪿㪼㩷㪻㫀㪼㫊㪼㫃㩷㪽㫌㪼㫃㩷㫆㫀㫃㩷㫋㪼㫄㫇㪼㫉㫊㫋㫌㫉㪼㩷㫎㪿㪼㫅㩷㫊㫎㫀㫋㪺㪿㫀㫅㪾㩷㫆㫅㩷㪿㪼㪸㫋㪼㪻㩷㪺㫆㫅㪻㫀㫋㫀㫆㫅㩷㫊㪿㪸㫃㫃㩷㪹㪼㩷㪍㪇㩷㫆㪚㩷㫆㫉㩷㫄㫆㫉㪼㪅
㪝㫀㪾㪅㩷㪋㪄㪊㩷㪪㫎㫀㫋㪺㪿㫀㫅㪾㩷㪧㪸㫋㫋㪼㫉㫅㩷㪽㫉㫆㫄㩷㪛㫀㪼㫊㪼㫃㩷㪝㫌㪼㫃㩷㪦㫀㫃㩷㫋㫆㩷㪟㪼㪸㫍㫐㩷㪽㫌㪼㫃㩷㪦㫀㫃
DK-20 B 05-3
CHAPTER
Operation 4
ITEM
Allowable Operating Range DK-20 4.5
4-4.5 Allowable Operating Range (In

case of marine propulsion engine)
In case of the marine propulsion engine, the (1) In case of Fixed Pitch Propeller (FPP)
load channges in accordance with the marine The fixed pitched propeller is generally designed
characteristics, and according to the changes in by including the sea margin, which has taken into
the rotation speed. consideration the fouled hull surface, in addition to
the absorbed horsepower due to the marine char-
The allowable operating range and recommend-
acteristics.
ed operating range within the marine characteris-
tics are shown in the figure below. In case that fouling of the hull surface has
advanced, increasing the resistance, and has
When acutually operating, be mineded to select
exceeded beyond the sea margin, the absorbed
a proper rotation speed and engine torque (Pme,
horsepower increases to such an extent that the
to be judged based on the reading on the rack
excessive torque occurs even if the rotation speed
scale), and keep operating within the recommend-
is maintained constant. Therefore, always heed
ed operating range as far possible, to prevent
cautions to the rotation speed and the reading on
being overloade.
the rack scale to prevent excessive torque.
Note that the lower load limit is normally 30%
Further, particularly be careful when the
when using heavy fuel oil, and if the load to be
absorbed propeller hordepower suddenly increas-
connected is lower than this limit value, use diesel
es, for example when in stormy weather and so
fuel oil.
on, since this will often cause the excessive torque
Fig.4.4 "Allowable Operating Range"
As for the output characteristics of the engine to
to occur, eventually leading to surging of the tur-
bocharger.
4
be actually operated, refer to "Test Run Record
Table" included in the separately provided final
documents.
100
Propeller design point

85
Output
80
Allowable orerating range
2OG Recommended continuous
$ /'2
㧔%㧕㧑 OG normal operating range
60 / ' 2 2
$
㧑 P-curve : Marine propeller
characteristic curve
M-curve M-curve : Curve with sea margin

40 taken into consideration
P-curve
㪊㪇㩷䋦 Allowable range of
short-time operation
20 on diesel fuel oil in the
case of standard
㪈㪇㩷䋦 specifications
50 60 70 80 90 95 100 105 Revolution (%)

Idling speed
Fig. 4.4 Allowable Operating Range
DK-20 Z 99-8
CHAPTER
4 Operation
ITEM
4.5 DK-20 Allowable Operating Range
(2) Incase of Changeable Pitch Propeller (CPP)

The changeable pitch propeller is capable of
changing its propeller pitch (blade angle), while
maintaining the engine rotational speed constant,
and is thereby capable of changing the absorbed
horsepower. Therefore, this propeller has a merit
that the rotational speed and load can be changed
according to the conditions of the other auxiliary
machinery driven by the marine propulsion engine,
and the hull resistance.
However, since the changeable pitch propeller
tends to run under excessive torque to as much
extent as it has alarger freedom of its operation, be
minded to operate the engine properly preventing
the excessive torque, by always grabbing the load
conditions.
DK-20 Z 99-8
CHAPTER
Operation 4
ITEM
Low-Load Operation and Operation with Air Cooler Cut-Off DK-20 5.1,5.2
4-5. Special Operation reduce the fouling of the combustion chamber,

as well as the intake and exaust air systems.
4-5.1 Low-Load Operation
Since running the engine with a low-load lower 4-5.2 Operation with Air Cooler Cut-Off
than a certain limit can lead to unfavorable com-
bustion conditions such as the reduction of intake In case that the defects such as breakage of the
air pressure and blowing-back of exhaust air, if the fine tube in the air cooler or water leakage from a
engine is operated under such conditions for long caulked sections is found, and the repairing cannot
hours, it may result in the various malfunctions be performed quickly, an emergency messure can
such as fouling of the turbocharger and combus- be taken by cutting off the air cooler on the follow-
tion chamber, faulty combustion and so on. ing procedure:
Therefore, be sure to minimize the low-load
operation to a shorter period of time as much as (1) Low-Load Limit
possible, and in case that the engine must be a) Stop water supply to the cooler cooling system,
inevitably run under a low-load for long hours, be and draw out the water from the air pipe.
sure to observe the following conditions:
b) Insert a shielding plate A into the flange part of
(1) Low-Load Limit the air cooler cooling water inlet pipe and outlet
The low-load limit varies depending on each pipe.
specification. Confirm the low load limit
c) "Fully open" the bypass valve of the air cooler.
described on the specification supplied with the
engine. d) Operate the cooler cooling water pump, and
confirm that no water is leaking from the flange
4
(2) Use of Diesel Fuel Oil packing area.
In case of the heavy fuel oil specification, be
sure to switch it to diesel fuel oil.
(3) Increase of Intake Air Temperature
Shielding plate A
To improve the combustion conditions, increase
the intake air temperature and adjust to as a high-
er level as possible, within the following limit:
o
٨ Intake air : 75 C or less
٨ Exhaust air temperature (cylinder outlet) :
o
450 C or less
5-3.2(2) "Measurement and Adjustment:
Intake Air Temperature"
Open
(4) Cleaning of Turbocharger
Close
Properly increase the number of times of Cooling water inlet Cooling water outlet
cleaning the turbocharger according to necessity. Air Cooler Bypass Valve
The turbocharger is at a high-temperature (2) Prerequisites for aaOperation

during operation and just after the engine is
stopped. If you touch it with bare hands during a) The fuel oil to be used is diesel fuel oil.
cleaning, you may burn your hands. Wear b) Restrain the output as low as possible, refer-
safety gloves without fail. ring to the following values as the standard:
٨ Pme(average effective pressure):
(5) Intermittent High Load Operation 0.8MPa {8 kgf/cm2}
If the load is switched to the high load (60% ٨ Exaust air temperature (cylinder outlet):
or more) for about 30 minutes during low-oad 450 oC or less

operation, it will have an effect to restrain or
DK-20 A 05-3
CHAPTER
4 Operation
ITEM
Non-Turbocharger Operation and Operation with
5.3,5.4 DK-20 Reduced Number of Cylinders
4-5.3 Non-turbocharger Operation 4-5.4 Operation with Reduced Number

In case of the marine propulsion engine, a non- of Cylinders
turbocharger operation implement (turbocharger Adoption of the operation with the reduced num-
blind plate ) is provided, so that operation in emer- ber of cylinders impose such problems as the tor-
gency can be made even ehwn the turbocharger sional vibration of the shaft system as well as the
may have been damaged. ( The generator is opti- external vibration of the engine, and therefore this
nal.) operation should be limited as a secondary meas-
The non-turbocharger operation procsdure is as ure to be used only in emergency.
the followings: In case of 3DK and 5Dk engines, the operation
with the reduced number of cylnders is prohibited
(1) Preparation for Operation due to the axternal vibration of engine.
Install the non-turbocharger operation implement The operation with the reduced number of cylin-
in accordance with the Turbocharger Instruction ders may be conducted in various cases such as
Manual. the case of only reducing the fuel oil, or the case in
which the operating parts are needed to be
removed. Further, since the prohibited items for
the operation vary depending on each case, be
During operation or immediately after stop- sure to inquire our company for the working proce-
dures, cautionary items on the operation, ansd so
ping the engine, the turbocharger is extremely
on, obtain the necessary instructions, and strictly
hot, and if the turbocharger is touched with observe them, when the operation with the
bare hands or skin, it may cause burns. reduced number of cylinders is conducted.
Therefore, perform the disassembly work
after the turbocharger is completely cooled <Preparation for Operation>
down. a) The fuel oil to be used is diesel fuel oil..
If it must be removed before it cools down, b) The output shall be as below:
wear safety gloves, and remove it taking care (No. of cylinders)-(No. of reduced cylinders)
X 70%
not to burn your hands. (Total number of cylinders)
However,the output may be reduced accord-
ing to the turbochager sursing or exhaust air
(2) Prerequisites for Operation
temperature in each case.
a) The fuel oil to be used is diesel fuel oil. c) Exhaust temperature : 450 or less
b) Restrain the output as a lower level as possi- (each cylinder outlet)
ble, referring to the following values asthe stan-
dard:
٨ Pme(average effective pressure): Be attentive of the external vibration of
0.44MPa {4.5 kgf/cm2} engine and the gear sound, and if any abnor-
٨ Exaust air temperature (cylinder outlet): mality is found, immediately stop the engine. If
400 oC or less the engine is kept operating disregarding such
abnormality, serious accidents may be caused.
DK-20 A 05-3
CHAPTER
Operation 4
ITEM
Normal Stoppage DK-20 6.1
4-6. Stoppage
Indicator
4-6.1 Normal Stoppage Rack scale
(1) Preparations for stoppage
a In case that heavy fuel oil is used, switch the
fuel oil to diesel fuel oil 30 minutes before RUN
stopping the engine.
b Immediately before stopping the engine, start
the operation of lubricating oil priming pump. RUN
STOP
c Confirm that the starting air pressure is at
STOP
2.0 MPa {20 kgf/cm2} or more.
(The preparation for the next round of starting)
(2) Stoppage Operating Lever

a Conduct the stop operation on the following
procedures:
[In case of local operation] (3) After Stop

Shift the operation lever to "STOP" position. a Operate both the lubricating oil priming pump
and cooling fresh water pump for about 20
Then, fuel oil injection will be shut off by
means of the common rod, and the engine will minutes, and cool down the engine and tur-
bocharger.
4
be stopped.
[In case of remote control]

i ) Press the "STOP" push button on the control
panel.
The turbocharger continues to run at high
Then, the fuel oil injection solenoid valve will speed even after the engine is stopped.
be activated to operate the fuel shutdown Lubrication of the turbocharger provided with
device, and the engine will be stopped. this engine is made using the system oil, and
ii) Shift the operation lever to "STOP" position. therefore if the supply of lubricating oil is
stopped immediately after the engine is
b After stop operation, be attentive of any abnor- stopped, it may damage the bearing.
mal sound in the engine and turbocharger,
and confirm that there is not any abnormal
b Fully open the indicator valve to conduct air
sound.
running for 3 to 4 seconds and exhaust the
combustion gas out of the combustion cham-
ber.
In case that the engine does not stop even c Close the valves on all the systems.
when the stop operation is conducted, forcibly
stop the engine on the following procedure:
1)Forcibly set the rack of the fuel injection
pump to "0".
2)Fully close the valve of the fuel oil inlet main
pipe.
DK-20 Z 99-8
CHAPTER
4 Operation
ITEM
6.2 DK-20 Emergency Stop
4-6.2 Emergency Stop (2) Measures after Emergency Stop

In case that the engine is stopped by activa-
(1) When Emergency Stop is Required.
tion of the protective device or stopped automat-
Immediately stop the engine when any of the fol- ically, take the following measures:
lowing abnormalities is found:
a In case that the engine is stopped by remote
1 Announcement of "Emergency" or "Alarm" operation or stopped automatically, set the
( Activation of the protective device ---Automatic) operating lever to "STOP" position after the
٨ Overspeed
engine is stopped.
b In case that the operation had been made
٨ Decrease of lubricating oil pressure
using heavy fuel oil, immediately switch the
٨ Suspension of water supply/increase of
fuel oil to diesel fuel oil, operate the motor-
cooling water temperature driven oil feed pump, and conduct flushing of
Increase of exhaust air temperature
٨ the fuel oil system (However, this procedure
does not apply when the fuel oil pipe is bro-
٨ Other alarming (depending on each speci-
ken.)
fication)
Further, conduct turning of the engine, and
2 Abnormal sound and abnormal vibration
exhaust the heavy fuel oil remaining in the fuel
3 Heating of the bearings or other moving parts, injection pump or fuel valve.
or generation of smokes, or abrupt increase of
mist.
4 Loosening or falling-off of the governor, com-
mon rod rink, each lever around the fuel oil In case that the engine is stopped during the
injection pump, link pin, or bolt. operation using heavy fuel oil and the engine is
5 Deterioration of fuel oil or lubricating oil, or cooled down without changing the fuel oil,
damage of the cooling water pipe. heavy fuel oil in the equipment of the fuel oil
6 Abrupt increase or decrease of rotation system (e.g. pump, filter, etc.) and piping will
speed. not only solidify to prohibit restarting, but also
incur substantial labor to clean and cleanse
7 Abrupt increase of lubricating oil temperature
after the accident.
8 Water supply disability due to suspension of
cooling water supply c 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 the engine is overheated due to
suspension of water supply, do not hastily sup-
ply cooling water.
If cooled down abruptly, each part of the In case that the emergency stop is conduct-
engine may be deformed, resulting in malfunc- ed, be minded not to restart the engine until the
tion or accidents. cause is determined, the countermeasures are
taken, and recovery is completed.
9 Mixing of water into lubricating oil In case that the engine is started without
removing the cause of the abnormality, the
10 Abrupt increase of exhaust air temperature
malfunction may be aggravated and serious
11 Abrupt decrease of the turbocharger rotation accidents may be caused.
speed or intake air pressure
12 Generation of abnormal sound in the propeller
or the stem shaft system
(In case of the marine propulsion engine.)
13 Breakage or loosening of the bolts of each
section
DK-20 Z 99-8
CHAPTER
Operation 4
ITEM
Emergency Stop / Long-Term Shutdown DK-20 6.2,6.3
d Insert the moisture-proof agent such as sil-

icagel into the crankcase, according to the
Be minded not to open the crank case for at ambient air conditions (e.g. weather and
least 10 minutes after engine is stopped and is humidity) and according to necessity.
completely cooled down. If the crank case is e Place the cover on the outside air opening sec-
opened immediately after the engine is tion of the exhaust air pipe and the mist pipe.
stopped, flammable mist in the crank case may
catch fire and explode. f Cover the engine with a sheet, and carefully
Particularly be careful when a large amount cover the electric equipment with particular
of mist is generated due to overheat or seizing attention to prevent collection of dust on them.
of the engine.
Be minded never to let flames or sparks
approach the crankcase even after it is over-
Sheet cover
hauled.
4-6.3 Long-Term Shutdown

In case that the operation of engine is suspend-
ed for a long term (one month or more), take the
preservation measures (mainly, anti-rusting meas-
ure) on the following procedures:
4
(1) 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 Spray
different from that before turning. After turn- (Rust-preventive
ing, securely close the indicator valve. agent)
b In case that there is a risk of freezing in
extremely cold season, be minded to remove
cooling water from the engine.
(2) Shutdown over 3 Months ... Measures for

Long-Term Storage Silicagel
In case that the operation of engine is suspend-
ed for 3 months or more, the following measures
for long-term storage is required:
a Remove cooling water from the engine.
b Add rust-preventive oil to lubricating oil, open
the indicator valve, and conduct turning of the Spray
crankshaft several times while conducting (Rust-preventive
priming with the lubricating oil. agent)
After turning, securely close the indicator
valve.
c Open each cover of the engine frame, cam
case, and the cylinder head, and spray rust-
preventive oil to the internal parts.
Measures for Long-Term Strage
DK-20 Z 99-8
CHAPTER
Inspection and Maintenance
5
ITEM
Precautions for Inspection and Maintenance DK-20 1.1, 1.2
(5) When disassembling the spring-loaded devices such as the regulation valves, proceed the works
paying careful attentions, since there is a risk that the springs may fly out and injury accidents
may occur.
(6) Be minded to use wire rope and chain block when suspending the heavy-weight parts or equip-
ment, and do not try to forcibly raise these parts or equipment by physical force. Further, be
minded not to approach the areas immediately under the suspended parts or equipment.
(7)When handling the electric parts, be sure to cut off the power source.
(8) When handling the liquids, be minded to strictly observe the following items:
٨ Flammable liquids such as fuel oil and lubricating oil, the sources of fire, e.g.: The source of fires
such as flames or sparks are strictly prohibited.
٨ Poisonous substances such as rust-preventive agent for fresh water, anti-freeze solution for fresh
water, mercury (thermometer): Drinking is prohibited, and if any of these has stuck on hands or
skin, immediately wash it off.
٨ Poisonous substance or substance which generate flammable gas, such as battery liquids:
Drinking is prohibited, and if any of these has stuck on hands or skin, immediately wash it off, and
the source of fires such as flames or sparks are strictly prohibited.
٨ For the sake of preventing environmental contamination, be minded to entrust the disposal and
treatment of the waste oils and liquids to the authorized special waste disposing company.
5-1.2 Cautionary Items When Finishing Inspection and Maintenance 5

(1) Restore the lagging or heat-preventive covers, combustible oil splash preventive means (FN tape)
and protective covers, that have been removed for inspection and maintenance, to each original
position.
(2) After the completion of assembling, confirm that there is no abnormality in each part, by conduct-
ing the turning of engines and the priming with each corresponding oil.
After checking the parts during turning, close the reducing valve without fail.
(3) After the completion of working, return the turning equipment and turning bar, that have been
used, to "OFF" position.
(4) Record the work contents of the inspection and maintenance that have been performed, and the
replaced parts in the daily report respectively.
DK-20 A 05-03
CHAPTER
5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DK-20 3.2
5-3.2 Pressure and Temperature of ture to be within the specified proper range, as far
Each Part as possible.
When the intake air temperature is too low, it
The pressure and temperature of lubricating oil, causes abnormal or excessive wear of the cylin-
fuel oil, and cooling water, etc. are controlled by der liner, intake air valve, etc., since the water
the relief valve, so that they should be proper val- drops is formed by the dew condensation.
ues being within each specified value during the Further, if the intake air temperature is too high, it
operation of engine, however, when actually damages the parts around the combustion cham-
operating the engine, the pressure and tempera- ber such as the exhaust valve, since the exhaust
ture of these fluids may not be within the speci- air temperature will increase. (Exhaust air tem-
fied and proper values. perature varies in proportion to the intake air tem-
In such a case, readjust the setting values of perature, and also varies in the rate of approxi-
the valves, and perform the operation within the mately 2 times the change of the suction air tem-
specified proper range. perature of the turbocharger.)
If the intake air temperature gets out of the
(1) Intake Air Pressure proper range owing to a low room temperature, or
Since the intake air pressure changes in accor- when automatic adjustment of intake air tempera-
dance with load, each pressure when the engine
ture cannot be made for some reasons, operate
was new (or, after adjustment) becomes a refer-
ence value. the following procedure.
The more the turbocharger is fouled, the more
<Intake Air Adjusting Procedure>
the intake air will decrease, resulting in the deteri-
oration of the engine performance (e.g. increase The intake air adjustment can be made by chang-
of the exhaust air temperature and increase of ing the cooling water flow rate in the air cooler.
the fuel consumption rate), and therefore regular- i ) Operate the handle of the bypass valve A ,
ly conduct the blower cleaning and prevent the and change the opening angle of the valve.
progress of fouling.
5-4.4 "Cleaning Turbocharger Blower"
٨ Open the bypass valve. (Handle facing side-
ways) Increase of tnmperature 5

٨ OpenClose the bypass valve (Handle facing
downward) Decrease of tnmperature

he turbocharger is at a high-temperature ii ) Be attentive to changes of the intake air tem-
during operation and just after the engine is perature, and open the bypass valve so as to
stopped. If you touch it with bare hands during
be within the proper range, and adjust the
cleaning, you may burn your hands. Wear
safety gloves without fail. angle.
Bypass valve A
It is impossible to completely remove the
fouls even when cleansed by blower cleaning,
and to prevent the deterioration of engine per-
formance by the elapse of time, however, if the
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. Open
(2) Intake Air Temperature
Close
Proper temperature: 45-55 (at full load)
Cooling water inlet Cooling water outlet
Intake air, that is either higher or lower than the
specified range, will affect the engine, and there-
Air Cooler Bypass Valve
fore be minded to adjust and keep the tempera-
DK-20 A 05-3
CHAPTER
5
ITEM
Inspecting and Maintenance of Fuel Injection Valve DK-20 4.2
㪫㫀㪾㪿㫋㪼㫅㫀㫅㪾㩷㫅㫌㫋㩷㩷㪛㪞㪸㫊㫂㪼㫋
5-4.2 Inspecting and Maintenance of
㪠㫅㫃㪼㫋㩷㪺㫆㫅㫅㪼㪺㫋㫆㫉㩷㩷㪚
Fuel Injection Valve
Since the conditions of the fuel injection valve 㪦㪄㫉㫀㫅㪾
substantially affect the performance of engine 㪙㫆㫃㫋㩷㩷㪝
operation, be minded to periodically inspect it and
conduct the maintenance.
However, in case that remarkable changes have P
been found in the maximum combustion pressure,
exhaust temperature, exhaust color, and so on, be
minded to conduct immediate inspection and main- 㪚㫀㫉㪺㫌㫃㪸㫉㩷㪾㪸㫊㫂㪼㫋㩷㩷㪞
tenance, regardless of the standard inspection and
maintenance period. 㪝㫌㪼㫃㩷㫀㫅㫁㪼㪺㫋㫀㫆㫅㩷㫍㪸㫃㫍㪼㩷㩷㪘
Since the items mentioned in this section will

be the parts to which NOx Technical Code shall 㪙㫆㫃㫋㩷㩷㪜
be applied, when replaacing any of these parts,
be sure to use the parts provided with the iden-
㪟㫀㪾㪿㪄㫇㫉㪼㫊㫊㫌㫉㪼㩷㪽㫌㪼㫃
tification marks. 㪺㫆㫌㫇㫃㫀㫅㪾㩷㩷㪙
( :0-3 "Engine Conforming to NOx
Technical Code"
(1) Replacing Consumables, Implements, and 㪭㫀㪼㫎㩷㩹㪧㩹

Measuring Instruments
a Replacing Consumables :"Parts List"
1 Circular gasket No.507 5
2 Gasket No.218
3 O-ring No.12
4 O-ring No.503 㪝㫌㪼㫃㩷㪠㫅㫁㪼㪺㫋㫀㫆㫅㩷㪛㪼㫍㫀㪺㪼
5 O-ring No.504
6 O-ring No.505
b Implements and Measuring Instruments
1 General tools and measuring instruments
( Final Documents
2 Nozzle holder extracting implement
3 Fuel oil injection testing device
4 Nozzle cleaning implement
(2) Extracting Fuel Oil Injection Valve Nozzle Holder Extracting Procedure
Extraction of the fuel oil injection valve can be
conducted on the following procedure:
1)Be careful so that the circular packing G
<Extracting Procedure> may not be left behind in the cylinder head.
i ) Remove the cylinder head and heat box cover 2)After removing the high-pressure fuel cou-
(upper side only). pling and fuel injection valve, be minded to
place the cover both on the coupling part of
the fuel oil injection pump and on the inser-
tion part of the cylinder head.
DK-20 B 06-5
CHAPTER
5
ITEM
4.2 DK-20 Inspecting and Maintenance of Fuel Injection Valve
ii) Close the valve of the nozzle cooling water (or

Special gasket
oil) pipe system. (In case of heavy fuel oil spec-
ifications.) Sash PT3/8
iii) Loosen the bolts E and F , and remove the

high-pressure fuel coupling (block) B . High-pressure
hose
iv) Remove the inlet connector C . Tester side
v) Remove the tightening nut D using a box
wrench.
vi) Extract the fuel oil injection valve A using a
fuel oil injection extracting implement 2 .
vii) Remove the circular gasket G .
Nozzle holder sash
(3) Injection Test Nozzle holder side

Conduct a fuel injection test of the fuel injection
valve, to check if the opening pressure and the Nozzle holder sash
spraying conditions of the fuel injection valve is in Injection Test Procedure
proper and normal state.
Conduct the fuel injection test using the fuel
injection test device installed to the engine.
a) Inspecting Valve Opening Pressure
Cap nut H Screw driver
i ) Install the fuel injection valve on the injection
test device, after removing the carbon stuck on
the tip of the injection valve, and cleaning the Adjusting nut I
tip.
ii) Connect the test pump and the fuel injection
Lock nut
valve using a high-pressure hose for testing.
iii) Quickly operate the test pump lever several
times, and drain the air until the valve starts
injection of the fuel as the pressure indicating
scale swings.
iv) Slowly turn the test pump lever (once every
second, or so), check the pressure reading
(the pressure, that has once increased gradu-
ally, suddenly starting to decrease due to
opening of the valve). Pressure Adjusting Procedure
Normal pressure: 27.4 - 29.4 MPa

{280-300 kgf/cm2}
tting pressure : 29.4MPa {300 kgf/cm}
b) Adjusting Valve Opening Pressure Be minded to set the pressure of the fuel
When reassembling the fuel injection valve injection valve at a rather higher level, taking
after conducting the maintenance work by extract- into concideration the initial working adjust-
ing the valve out of the engine, and when the noz- ment, in case that a new injection valve is intro-
zle is replaced with a new one, adjust the valve duced.
pressure on the following procedure. -------30.4 MPa {310 kgf/cm2}
DK-20 A 06-5
CHAPTER
5
ITEM
Cleaning Turbocharger Blower DK-20 4.4
5-4.4 Cleaning Turbocharger Blower (4) Cleaning Method

Cleaning of the turbocharger blower can be
If the fouled degree of the turbocharger blower
made using the cleaning device that is supplied
has progressed, the efficiency of the turbocharger
together with the engine.
will decrease and the operating performance of
engine will be worsened. Particularly when heavy i ) Pour cleaning liquid into the blower syringe A .
fuel oil is used, the turbocharger blower tends to ii) Connect the syringe socket to the filling pipe
be fouled in faster degree, and therefore be mind- B that is connected the turbocharger inlet side.
ed to conduct blow-off cleaning and restrain the iii) Fully open the drain cock of the air intake duct.
progress of fouling. iv) Operate the syringe to inject cleaning liquid.
(1) Interval of Cleaning v) When 3 to 5 minutes has passed after the
Clean the blower when intake air pressure has injection of cleaning liquid, inject fresh water of
decreased 10% at the same load, or at least the same amount on the same procedure.
every 150 to 200 hours of operation. [Injection Amount and Injecting Time]
(2) Load during Cleaning
Make sure that the engine shall be operated
under the load of 75% (In case of "MET", Intake air 㪫㫐㫇㪼㩷㫆㪽㪠㫅㫁㪼㪺㫋㫀㫆㫅㪠㫅㫁㪼㪺㫋㫀㫅㪾
㫋㫌㫉㪹㫆㪺㪿㪸㫉㪾㪼㫉㪸㫄㫆㫌㫅㫋㩷㩿㪣㪀㫋㫀㫄㪼㩷㩿㫊㪼㪺㪀
pressure is 0.03~0.07 MPa) or higher, and contin-
ue the loaded operation for 1 hour or more after
cleaning. MET18SRC 0.25 20䱊40
(3) Cleaning Liquid 133 0.15
Be sure to use the specified cleaning liquid. In
case that the specified cleaning liquid is not avail- 143
able, use fresh water. (Note that cleaning effect RH 0.2 4䱊10
is inferior with fresh water.) 163
5
183
0.3
Be minded never to use gas oil or any other 203
flammable liquid for cleaning, since these liq-
uids will be the cause of fire. 48
TPS 0.4 4䱊10
52
vi)) In case that there is no change in intake air

pressure before and after the cleaning, repeat
cleaning after 10 minutes.
Syringe A
Connect here
٧ In case that intake air pressure does not
change over when the cleaning is repeatedly
Filling pipe B conducted, conduct the overhaul and clean-
Socket
ing of the whole of turbocharger.
Separately provided "Turbocharger
Instruction Manual"
The turbocharger is at a high-temperature

during operation and just after the engine is
Turbocharger
Turbocharger Blower Cleaning Procedure cleaning, you may burn your hands. Wear
safety gloves without fail.
DK-20 B 08-5
CHAPTER
5
ITEM
4.5 DK-20 Cleaning Turbocharger Turbine
5-4.5 Cleaning Turbocharger Turbine 8 after water is fed for 5 minutes, close the
nozzle 6 to discharge drain at a rate of about
0.1 l/min.
The turbocharger is at a high-temperature ix) After the completion of water cleaning, close
during operation and just after the engine is the nozzle 6 .
x) Make sure that no drain is discharged, and
cleaning, you may burn your hands. Wear
safety gloves without fail. close the drain cock 8 .
xi) After water cleaning, keep the engine running
<Turbocharger type "RH" (water washing)> for about 5 to 10 minutes under the same load.
(Applicable to heavy fuel oil engine)
Inject water through the water injection nozzle
fitted on the exhaust pipe at the turbocharger inlet,
and the combustion deposit on the turbine side
can be removed by the mechanical effect of collo-
٨ Keep a close watch on the turbine during
sion of water drops and the dissolving effect. water injection. Take care that the injection
Part of the water evaporates, and the remaining rate is not too high or the drain pipe is not
water is discharged through the drain hole in the clogged with removed deposit.
gas outlet duct. ٨ Even if drainage is not observed, do not feed
water for 7 minutes or more.

(1) Frequency of cleaning ٨ After the completion of cleaning, remove the
Clean the turbine every 250 hours. connected hoses.

(2) Engine running conditions during cleaning
Separately provided "Turbocharger
Clean the turbine after running the engine for
Instruction Manual"
about 20 minutes or more at a power at which a
o
turbocharger inlet gas temperature of 300 to 350 C
is obtained. Water filling pipe 䋱
Nozzle 䋶
(3) Cleaning procedure
i ) Connect the water injection tube 1 connected Turbocharger
to the exhaust pipe and the gauge board 2
with a hose.
ii ) Connect the water supply hose 4 to the
gauge board 2 .
Rubber hose 䋳䋨䋱䋵䌁䋩
iii) Open the stop valve 5 to feed water to the
Drain cock 䋸
tube and hose to the nozzle 6 . When the
pressure gauge 7 stabilizes, close the stop
valve. Pressure gauge 䋷
㩿㱢㪉㪇㪀
iv) Open the drain cock 8 .
Stopper valve 䋵
v) Fully open the nozzle 6 .
vi) Slowly open the stop valve 5 , seeing the Rubber hose 䋴
pressure gauge 7 , until the water pressure
becomes 0.05 to 0.08 MPa (0.5 to 0.8 kg/cm2). Water pressure
Hose connection Gauge board 䋲
vii) Feed water for about 5 to 7 minutes.
viii) If no drain is discharged from the drain cock Water-Pouring Cleaning Procedure of Turbine
DK-20 Z 05-03
CHAPTER
5
ITEM
Cleaning Turbocharger Turbine DK-20 4.5
<Turbocharger type "TPS" (pouring water

washing)> Supercharger type Interval time (minutes)
As the pouring water washing method of the TPS48 3
supercharger, fresh water is sprayed in front of
the turbine from the pouring water nozzle on the TPS52 3
supercharger. Thus, the extraneous matter is
removed through the difference of the cooled tur- "Operating Manual for Supercharger"
bine nozzle eith fresh water, turbine blade and
the thermal expansion extraneous matter. < In case of Turbocharger Model "MET"
(Cleaning solid matter) >
(1) Washing interval If staining of the turbocharger turbine side pro-
Since the washing effect is reduced when the gresses, engine performance will be worsened due
deposit layer becomes thick, apply the washing to decrease of the efficiency as in the case of the
every approx. 200 hours.
blower side. Particularly, it tends to be more
(2) Load during washing stained in'case of heavy fuel oil specification, peri-
Apply the washing at such a load as the odically clean the turbine side, and restrain the
exhaust temperature
o
of the turbocharger intlet is progress of staining.
400 to 450 C. Asthe exhaust temperature is
lower, the washing effect decreases. As it is high- When cleaning the solid matter in the turbine,
er, the turbine nozzle or similar part may be dam- charge vegetable solid particle in front of the tur-
aged. bine, and remove the adhered matters on the tur-
Take special care for the exhaust temperature. bine nozzle or turbine rotor blade by the impact
force produced by the vegetable solid particle
(3) Fresh water for washing
As the fresh water for washing, use the fresh accelerated by the exhaust gas.
water which does not include any additives. (1) Interval of Cleaning
Never use any seawater.
Conduct the cleaning with the interval of 200 to
(4) Washing method
i ) Connect the hoses of the pressure gauge and
250 hours in the initial stage, since the effect of
cleaning will be lost if the layers of the accumulat- 5
the check-valve hose to the pipe connected to ed matters have become thick.
the exhaust pipe. As for the cleaning interval after the initial clean-
ii) Open the check valve, fill the water into the ing, properly increase or decrease depending on
pipe and hose up to the nozzle, and close the the factors such as the exhaust temperature,
check valve. intake air pressure, and the degree of performance
iii) Fully open the valve in the nozzle on the decrease of the turbocharger rotation speed.
exhaust pipe.
iv) Observing the pressure gauge, slowly open (2) Load during Cleaning
the check valve to gain the water valve of Perform cleaning by making the load of engine
0.45 to 0.7 MPa (4.5 to 7.0 kgf/cm2) to be 75 to 85% as the standard. Although it is
v) Continue pouring water 25 to 30 seconds. possible to perform cleaning at a low load of
vi) Apply the washing three times. Here, provide around 50%, cleaning liquid may sometime be
the interval shown in the table below after accumulated at the gas outlet casing, and there-
washing of one time. fore avoid the cleaning of such a low load as far as
possible.
vii) Close the valve, loosen the hose connection.
Disassemble the manometer and the hose Intake air pressure when cleaning is performed
with valve. is as shown in the following table, and therefore in
viii) To dry the supercharger, run it applox. 10 case that the normal load value is higher than
minutes at the same load. these, decrease the load.
ix) If any variation is not observed on the perform-
ance values of the exhaust temperature, [Intake air pressure and Exhaust Temperature]
charge pressure, supercharger revolution Turbocharger Intake air Turbocharger inlet
speed and so on, repeat the procedure above
model pressure exhaust temperature
after completion of the washing. If any varia-
tion is not observed after repetition of several MET18SRC 0.1~0.15 MPa 510 oC or less
times, it is necessary to open and clean it.
DK-20 A 08-5
CHAPTER
5
ITEM
4.5 DK-20 Cleaning Turbocharger Turbine
(3) Cleaning Liquid b) Repeated cleaning

Use the specified cleaning liquid as shown i) In case that a sudden change, such as surging,
below. has occurred in the engine when charging the
٤ Husk of walnut: Diameter of grain: 1.7 to 2.4
cleaning agent, try the cleaning by using a half
mm {Marine grid #10) of the specified use amount of solid cleaning
٤ Grain (rice, wheat, etc): Diameter of grain:
agent for single time cleaning, and perform the
1.7 to 2,4 mm cleaning after confirming that there is no more
٧ Close the drain hole of the turbocharger gas
sudden change in the engine.
outlet casing while cleaning.
Afterwards, make this method as the standard.
(4) Cleaning Method ii) After finishing the cleaning, repeat the above
a) Procedure for one time cleaning the procedure of Item a), if no particular change
i) After opening the valve (B), open the valve (A) is not found in the performance values such as
and cool the equipment by passing air for 0.5 to the exhaust temperature, intake air pressure,
1 minutes. and turbocharger rotation speed. In case that
any change is not found even after the cleaning
ii) Close the valve (A), and close the valve (B).
has been repeated, it is necessary to perform
iii) Fill the specified use amount of vegetable solid the overhaul and cleaning.
cleaning agent into the tank, and securely tight-
en the cap of the tank.
iv) Open the valve (A) and (B) in this order, and [Specified use amount of solid cleaning agent]
charge the cleaning agent with air pressure.
Turbocharger model Specified use amount
v) Close the valve (B) and (A) in this order.
MET18SCR 0.05 ~ 0.1 /1
"Instruction Nmanual of Turbocharger"

Various purpose air
0.4-0.5MPa Tank
{4-5kgf/cm2}
(A)
(B)
Turbine Rotor Blade Cleaning Procedure
DK-20 A 08-5
CHAPTER
5
ITEM
Measuring Crankshaft Deflection DK-20 4.6
5-4.6 Measuring Crankshaft Deflection iii) Install the deflection gauge.

Installation position shall be approximately on
the identical line with the outer diameter of the
journal, and shall be on the intersecting point
on the center line of the crank arm.
If the crankshaft deflection exceeds its limit,
the stress to be applied to the crankshaft will iv) Set the reading on the gauge scale to +20 at
become excessive, and it will result in the the position "B" in the Figure. (To make clear
breakage of crankshaft if the excess of deflec- the positive and negative directions.)
tion is too large. v) Slowly conduct turning of the engine in the nor-
Therefore, adjust the crankshaft deflection to mal direction of rotation, and measure the
a proper value when being installed, and peri- reading on the scale when the crankshaft is at
odically measure the deflection, so that it can the angle of "B", "C", "D", "E", and "A" respec-
be corrected whenever it is over the limit value. tively, of which data shall be recorded.
(1) Replacing Consumables and Measuring

Instruments
a) Replacing Consumables "Parts List"
1 O-ring (frame side cover) No.11
b) Implements and Measuring Instruments

1 General tools
165
"Implement List" in the final docu-
100
ments
2 Deflection gauge
5
3 Motor
(2) Conditions for Measuring Deflection

a Deflection of the crankshaft varies according to
the temperature. Be sure to measure it when
the engine is in cold state.
Deflection Gauge Mounting Position
b Before measurement, push the contact piece
of the deflection gauge with a finger, and con-
firm that both the contact piece and dial
gauge return to the original positions correct-
ly.
c In case of the marine engine, since the deflec-
tion varies according to the loaded cargo con-
ditions, be minded to record the conditions of
loaded cargo, draft, temperature, and so on,
at the same time.
(3) Measuring Deflection

<Measurement procedure>
i ) Open the turning plug, and perform turning the
crankshaft.
ii) Place the crank pin at the point of 30 (position
"B") past the bottom dead center.
DK-20 Z 99-8
CHAPTER
5
ITEM
Measuring Crankshaft Deflection DK-20 4.6
<Reference>
Deflection in warm condition
In case of the directly connected generating There is a possibility that the measurement
engine, the deflection in the warm conditions gen- results of the deflection in the warm conditions
erally tends to vary as compared to the values in differ from the real value due to the reasons that
the cold conditions. the engine temperature may suddenly increase
This is because the temperature increase of the after the engine is stopped, and due to the effects
engine base is larger than the temperature of the thermal expansion owing to the tempera-
increase of the generator to be directly connect- ture difference of the crankshaft. Be careful of
ed, so that the crankshaft core relatively increas- this fact.
es, the deflection varies towar direction
(downward closing), and thereby the difference
manifests itself as the deflection difference
between the cold and warm conditions.
Like this, in case of the directly connected gen-
erating engine, the deflection difference between
the cold and warm conditions differs depending
on the bearing dimensions and temperature dif-
ference of the engine and generator, so that the 5
adjustment is impossible, and it will be the value
unique to the generating device.
Consequently, in case of the generating engine,
the adjustment is made with the target of the con-
ditions near to + side upper limit (downward
opening) of the specified value in the cold condi-
tions.
The measured value of the deflection value in
the warm conditions varies according to the tem-
perature, and the different values tend to be
obtained every time the measurement is conduct-
ed, however, based on the actual measurement
results of our company, the value is approximate-
ly 3 to 4/10,000 x stroke and within the range of
(downward closing).
DK-20 Z 99-8
CHAPTER
5
ITEM
4.7 DK-20 Inspection and Replacing Protective Zinc
5-4.7 Inspecting and Replacing iii) On the contrary, in case that the protective
Protective Zinc zinc is rarely worn out, the following failures
may be suspected:
In case that sea water is used as the cooling ٨ Faulty condition on the mounting surface
water in the cooleig system, a protective zinc is ٨ purity failure of zinc

provided in each cooler.
Conduct periodical inspection and replacement
b) Replacement and mounting
of the parts on the following procedure:
i ) Remove the rust or scale from the mounting
(1) Replacing Consumables, Implements and surfaces of the protective zinc and the mounted
Measuring Instruments flange to expose the metallic surface, and
a) Replacing Consumables securely mount the protective zinc to the flange
Lubricating cooler "Parts List" in such a way that the both parts are closely in
1 Gasket No.12 contact each other.
2 Protective zinc No.11 ii) In case that the protective zinc is reused,
shave scale off the surface of the protective
Air cooler "Parts List"
zinc and expose the zinc surface.
3 Gasket No.2
3 Gasket No.4
4 Protective zinc No.1
4 Protective zinc No.3
b) Implements and Measuring Instruments

1 General tools
"Implements List" in the final documents
(2) Locations of Protective Zinc and Inspection

Interval
٨ Front and rear covers for lubricating cooler
Location of Protective Zinc for
-------Every 3 months
Lubricating Oil Cooler
٨ Front and rear covers for air cooler-----Every
6 months
Efficiency of the protective zinc substantially

varies depending on the purity. Therfore, be
minded to use the genuine parts supplied by "P" "Q"
Daihatsu Diesel Manufacturing. Co., Ltd.
(3) Inspection and Replacement

a) Inspection
i ) Remove the mounting flange for protective
zinc.
ii) Replace the protective zinc of which volume is
reduced more than 50% (20% by dimension) View "P" View "Q"
as compared the original shape. Location of Protective Zinc for Air Cooler
DK-20 Z 99-8
CHAPTER
5
ITEM
MEMO DK-20
DK-20 Z 99-8
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water 6
ITEM
Fuel Oil Characteristics and Control DK-20 1.2
6-1.2 Fuel Oil Characteristics and Control page as a standard.

(1) Heavy Fuel Oil In case that a viscosity controller (automatic
Since heavy fuel oil contains more carbon viscosity regulator) is installed on the engine,
residue and impurities, and is higher in its viscosi- control the fuel oil viscosity to its proper value
ty as compared to diesel fuel oil, heavy fuel oil according to the attached instruction manual.
cannot be used as the fuel oil for diesel engine,
when it is in the state of bunker fuel oil. ( Fig. 6-1.1 "Fuel Oil Viscosity/Temperature
Therefore, it will be a prerequisite to use heavy Curve")
fuel oil that the oil must properly be preprocessed
before being supplied to engine (including the
removal of impurities by cleaning, and the assur-
ance of proper viscosity by heating).
Proper viscosity for fuel oil (engine inlet)
Kinematic viscosity: 14 1.5 cSt.
a) Cleaning Fuel Oil If the temperature control of fuel oil is
Water, and solid contents such as vanadium, improper, and the fuel oil with high viscosity
sodium, alumina, and silica, contained in heavy has been supplied to engine, it will not only
fuel oil accelerate the corrosion and wear of the incur faulty combustion, but also will result in
various parts of fuel injection system and fuel the accidents such as the clogged or dam-
combustion chamber system, substantially aged fuel oil filter, and the breakage of fuel
affecting and reducing the working life of these injection system parts.
parts.
For the purpose of removing such impurities, (2) Diesel Fuel Oil
the fuel oil preprocessing equipment, such as a) Water tends to extract and separate out of
the centrifugal separator and precision filters, are diesel fuel oil, and further diesel fuel oil tends
installed. to generate a large amount of sludge when
Since these equipment will not exhibit the effi- mixed with the oil of different base oil.
ciencies unless each equipment is properly han- Daily conduct the draining-off of the precipi-
dled, be minded to operate each equipment in tation tank and setting tank, so that water or
accordance with the corresponding instruction sludge does not flow into the engine.
manual.
Instruction Manual" for each equipment")
To remove water or sludge, the centrifugal
separator is an effective device.
6
b) Diesel fuel oil, that has been cut back by
Since waste fuel or sludge will be the causes
using the gas oil refined by FCC method,
of environmental contamination or pollution, be may incur faulty start or ignition, and this ten-
sure to entrust the treatment of these to the dency is particularly obvious in case of low
authorized waste disposal company, not sulfur diesel oil for land vehicles, due to its
low cetane number, if the environmental con-
directly handling or disposing these matters on
ditions, such as ambient temperature or
your own. water temperature, are unfavorable.
In such a case, special measures will be
become necessary to improve starting capa-
b) Heating Fuel Oil bility and combustibility of engine, and in
Since the viscosity of heavy fuel oil is very such occasions, contact our company for
high, it is required to heat the oil, so that a proper consultation.
viscosity for fuel injection can be obtained.
Since the heating temperature varies depend-
ing on the viscosity of fuel oil, heat the oil and
obtain the proper viscosity, by referring to the
fuel oil viscosity temperature curve on a separate
DK-20 B 08-5
CHAPTER
6 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
1.2 DK-20 Fuel Oil Characteristics and Control
(3) Gas Oil (4) Kerosene Oil

Although gas oil does not contain few impuri- As a countermeasures to prevent air pollution,
ties, it may cause problems on ignition when the there may a case in which kerosene oil may be
gas oil is refined by FCC method, just like the used.
case with diesel fuel oil, and therefore be minded Since kerosene oil is further lower in its cetane
to pay particular attentions to the cetane number number and is lower in its viscosity than gas oil, it
of gas oil. is required to carry out a special arrangement on
the engine, and therefore contact our company
Further, since gas oil is low in its viscosity and
for consultation before using the oil.
is inferior in its lubricity, it may cause abnormal
wear on the sliding parts of fuel oil injection sys-
tem, and therefore be minded to conduct the
inspection of the fuel injection pump and fuel
injection valve in the earlier stage than usual.
Table 6-1.1 Fuel Oil Standard Characteristics
General call Diesel fuel oil note 1) Heavy fuel oil note 2)
JIS (K2205 type 1) (K2205 type 3)
Type of fuel oil
ISO-F (DMA) RMA10 RME25 RMG35 RMH55
CIMAC A10 E25 G35 H55
Density (15 oC) g/cm3 max 0.890 0.975 0.991 0.991 0.991
Kinematic viscosity
cSt max 3.0 - (50 oC) 10/40 25/180 35/380 55/700
100/50 oC
Viscosity
RW#1 100 oF sec max 30 - 50 300 1500 3500 7000
o
Flash point C min 60 60 60 60 60
o
Pour point C max 0 6 30 30 30
Carbon residue wt % max 0.2 10 15 18 22
Ash wt % max 0.01 0.1 0.10 0.15 0.20
Water vol % max 0.1 0.5 1.0 1.0 1.0
Sulfer wt % max 1.5 3.5 5.0 5.0 5.0
Vanadium mg/mg max 150 200 300 600
Sodium mg/mg max 50 50 50 50
Aluminum + silica mg/mg max 80 80 80 80
note 3)
Cetane number min 40
CCAI value note 4) max 850 850 850 850
Notes : 1) Since there are a wide range of the standard values for diesel fuel characteristics, the recommended
values are shown in the above table.
2) heavy fuel oil characteristics represent the values of "Residual marine fuel oil" proposed in CIMAC
(1990).
3) Cetane number represent the calculated values based JIS K 2280-1996.
4) CCAI (Calculated Carbon Aromatic 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/cm3 (15 oC), VK: Viscosity cSt (50 oC), C: Constant (0.85 for heavy fuel oil)
DK-20 B 03-2
CHAPTER
6 Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
1.2 DK-20 Fuel Oil Viscosity-Temperature Curve
1000F 500C
9000
7000 Trace 1 Gas oil
curve
2 0
3 mm /s @50 C
5000 " 2 MDF 6.2 " "
4000 Rw#1
" 3 TFO 30 " "
3000 11 4 60
10000
" " " "
2000 10 " 5 " 80 " "
1500 6 120
(
" " " "

9
mm2 / S
5000
" 7 " 180 " "
1000
800 8 8 280
" " " "
)
600 7 " 9 MFO 380 " "

Kinematic Visconsity
500 2000
" 10 " 500 " "
400 1500
6 11 700
300
250 1000
5
200
150 4 500
100
80
3
60
50 200
40
30
25 100
20
14 15 65
10 2 50
8
6 40
5
1
4
3
2 30
-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Temperature ( 0 C)
Fig. 6-1.1Fuel Oil Viscosity / Temperature Curve
Example) We find the temperature, under which heavy fuel oil of 380mm2/s can be heated, so as to obtain
the proper viscosity of 14mm2/S at the engine inlet.
To find this temperature, tracing the curve No. 9 downward, and from the point that intersects
kinematic viscosity 14mm2/S, goes down vertically to obtain 130 .
Note: 1. The viscosity temperature characteristics of fuel oil may slightly differ depending on the original
place of production or its refining process, and therefore confirm the viscosity with a viscome-
ter, and determine the proper value when actually operating the engine.
2. Kinematic viscosity 1cSt = 1 mm2/S
DK-20 B 08-3
CHAPTER
6 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
2.2 DK-20 Selection of Lubricating Oil
a) Sampling Procedure <Information to be Attached to Sample

i ) Collect samples from the air vent pipe of the fil- Receptacle>>
ter during the operation of engine.
If the samples are collected from the drain 1 Name of your company and your name
cock, the analyzed value of the characteris- 2 Model number of engine
tics may show a different value due to the
mixing of sludge or solid deposits. 3 Engine number
ii) The minimum amount of sampling shall be 500 4 Data and location of sampling
cm3. 5 The amount of time the engine is operated
iii) Attach on the sampling receptacle with the
label indicating the information as shown on 6 Lubricating oil brand
the right. 7 The total operation time and quantity of
lubricating oil
b) Lubricating Oil Control Standards
8 Replenishment record (Data and quantity of
The lubricating oil control standards are as
shown in the Table 6-2.2 below. replenishment)
Of all the lubricating oil control standards, the
total base number and n-pentane insoluble are
particularly important for the purpose of checking
the degradation degree of lubricating oil.
(1) Total Base Number (TBN)
Total Basic Number
Table 6-2.2 Total base number represents the quantity of
Lubricating OIl Control Standards (System oil) potassium hydroxide (KOH) that corresponds
to the quantity of acid required to neutralize
Fuel oil used Diesel Heavy the base component contained in 1 g of lubri-
fuel oil fuel oil cating oil, and is indicated by the unit of
Total based
mgKOH/g 3 or more 10 or more mgKOH/g.
number 1) Total base number indicates the lubricating
Kinematic mm2/S +30% or less / -20% oil capabilities to prevent the corrosion due to
sulfuric acid generated from sulfur contained
o
Viscosity (@ 40 C) or more of new oil
in fuel oil, and other acids, and further it indi-
o
Flash point C 180 or higher cates the capabilities of lubricating oil to clean
and disperse the fouled sections in the engine.
Water
vol. % 0.3 or less
content
(2) Insoluble (= n-pentane soluble)
n-pentane
wt. % 2.5 or less Insoluble is fouling substance that do not
insoluble 1) dissolve in oil, and the main component is soot
Notes: which is a product of combustion, and calcium
1) The TBN (Total Basic Number) represents the values measured
according to ASTM D664, JIS K2501. (Hydrochloric acid method).
sulfate which is a neutralized product.
2) Insoluble represents the values measured according to Since these substances do not dissolve
ASTM D893B. In case that the measure value rapidly increased even in n-pentane which is a solvent, n-pen-
or exceeded 1.5, measure toluene insoluble according to the
ASTM D893B, and in case of [ n-pentane insoluble - toluene
tane insoluble serves as an index to indicate
insoluble ] > 0.5, replace the lubricating oil. the degradation and fouling degree of lubricat-
ing oil.
DK-20 B 08-10

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DK-20

Hazards and nonconformities of imitation parts

Daihatsu Diesel supplies reliable engines. Use genuine parts to

Chapter 2 GENERAL CONSTRUCTION 2

2. Piping Systems 2-2

3. Controlling Engine Operation : Protective Device 2-3

Chapter 3 ENGINE ADJUSTMENT STANDARDS 3

Chapter 5 INSPECTION AND MAINTENANCE 5

Chapter 6 FUEL OIL, LUBRICATING OIL AND COOLING WATER 6

Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES 7

2.5 When Exhaust Gas Shows Abnormal Color 7-2.5

0-1. Before Running Daihatsu Diesel Engine

4 Control equipment 5 Other special devices

3-1 Operating Specifications

Item Alarm setting value

Air tank 1.5 ~ 3.0 1.5

Control air Air tank 0.7 ~ 0.9 0.6

Intake air Intake air duct 45 ~ 55

Cylinder outlet 500

Turbocharger outlet 500

Cooler line Engine inlet ~ 32

1.1, 1.2 DK-20 Precautions for Operating Engine

4-1 Precautions for Operating Engine

4-1.2 For Operation

exhaust temperature, etc.

٨ Air cooler inlet pipe

٨ Fuel injection pump and high-pressure coupling

[Air Running (abbreviated as Air Run.)]

4-2.2 P r e p a r a t i o n f o r I n i t i a l Open the following filters, and cleanse the

(5) Priming with Fuel Oil and Exhausting Air

The heavy fuel oil is heated to a high temper-

(6) Cleaning of Turbocharger Pre-Filter

(7) Checking the covers are fitted

<Inspection after Completion of the Initial 15 min

4-4.2 Warming-Up and Connecting

Fig. 4.2 Load Connection

In case that any problem is found as the results 2 Load (output)

7 "Troubleshooting and Countermeasures" 8 High-temperature cooling water pressure

(1) Operation with Diesel Fuel Oil

In case that emergency stop is made during

㪭㫀㫊㪺㫆㫊㫀㫋㫐㩷㪸㫋 㪈㪊䌾㪈㪋㩷㫄㫄㪉㪆㫊 㪭㫀㫊㪺㫆㫊㫀㫋㫐㩷㪸㫋 㪈㪊䌾㪈㪋㩷㫄㫄㪉㪆㫊

㪁㩷Charge spped :䇭 㪁㩷Charge spped :

Switching from Operation Operation Switching from

4-4.5 Allowable Operating Range (In

Propeller design point

M-curve M-curve : Curve with sea margin

50 60 70 80 90 95 100 105 Revolution (%)

(2) Incase of Changeable Pitch Propeller (CPP)

4-5. Special Operation reduce the fouling of the combustion chamber,

The turbocharger is at a high-temperature (2) Prerequisites for aaOperation

or more) for about 30 minutes during low-oad 450 oC or less

4-5.3 Non-turbocharger Operation 4-5.4 Operation with Reduced Number

(2) Stoppage Operating Lever

[In case of local operation] (3) After Stop

[In case of remote control]

4-6.2 Emergency Stop (2) Measures after Emergency Stop

d Insert the moisture-proof agent such as sil-

4-6.3 Long-Term Shutdown

(2) Shutdown over 3 Months ... Measures for

5-1.2 Cautionary Items When Finishing Inspection and Maintenance 5

㪭㫀㫊㪺㫆㫊㫀㫋㫐㩷㪸㫋㪈㪊䌾㪈㪋㩷㫄㫄㪉㪆㫊㪭㫀㫊㪺㫆㫊㫀㫋㫐㩷㪸㫋㪈㪊䌾㪈㪋㩷㫄㫄㪉㪆㫊

㪁㩷Charge spped :䇭㪁㩷Charge spped :