6DE-18

INSTRUCTION MANUAL
( OPERATION )

V04
 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 must be maintained more frequently.
2. If imitation parts are used for the engine conforming to NOx Technical Code, the certifi-
cate (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 : 81-6-6454-2393 FAX : 81-6-6454-2686

Tokyo Office 16-11, Nihonbashi 1-chome, , Chuo-ku, Tokyo, 103-0027 Japan

TEL : 81-3-3279-0827 FAX : 81-3-3245-0359

Moriyama Division 45 Amura-cho, Moriyama-city, Shiga, 524-0035 Japan

TEL : 81-77-583-2551 FAX : 81-77-582-5714

Taiwan Office c/o Marine Technical Industries Co., Ltd.

No.14 Tai-Tang RD, Lin-Hai Industrial Zone, Kaohsiung, 812 Taiwan
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

Daihatsu Diesel (SHANGHAI) Co.,Ltd. Room A-B Floor 14, Huamin Empire Plaza, No. 728 Yanan Rd (w), Shanghai, China
TEL : 86-21-6225-7876/7 FAX : 86-21-6225-9299
 DE-18 ENGINE
HOW TO ORDER PARTS

For the DE-18 engine, we have newly adopted a parts control system. To properly control the parts
at the production stage and delivery stage, we have stored the data of each engine, such as specifica-
tions and applicable parts, in the database. For the conventional engines, customers used 11-digit or
10-digit codes to order parts. For the DE-18 engine, however, customers can order parts using engine
number and 8-digit codes.
Before ordering parts, be sure to check your engine number so that we can promptly send you the
right parts.

Example: How to order parts

Before ordering a part, be sure to check the engine number, part name, and part code.
Engine number: DE618Z0001
(Check the engine number shown in the operation result sheet or the engine
number marked on the actual engine.)
Part name: Fuel nozzle
(Check the part name shown in the parts list.)
Part code: 06473-013
(Check the part code shown in the parts list.)

Notes regarding ordering parts:

Various parts of our engines are controlled for each engine. If you use the part once ordered to the
other type of engine, please contact our sales company, and ask whether the part can be used for the
other engine.
Use of the part for the other type of engine may not be possible due to difference in the specifica-
tions, improvement of the part, etc.
If a wrong type of part is used for your engine, an unexpected problem may occur. In addition, if your
engine is conformed to NOx Technical CodeI, the certificate may lose its validity.
For the NOx control parts, be sure to write the parts replacement history in the engine record book to
properly control the parts.
 DE-18 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

◎ As for the disassembly, maintenance, assembly, and the parts to be
replaced, refer to the separately provided INSTRUCTION MANUAL
(MAINTENANCE) and PARTS LIST.

◎ Keep this Instruction Manual and the related documents (drawings, materials, etc.) in the
specified place so that the persons engaged in operation of the engine can refer to them
whenever necessary, and in the case that the supervisor of the engine is changed, be
sure that these documents, along with the duties, shall be transferred to the successor
without a fall.

DE-18 Z 12-01
 CHAPTER

ITEM
Contents
DE-18

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 Matters Requiring Attention for NOx Regulation Compliance 0-3.2
4． General Information 0-4
4.1 Notation of Engine Type 0-4.1
4.2 Definition of Term 0-4.2
4.3 Unit 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
2． Piping Systems 2-2
2.1 Starting Pneumatic System 2-2.1
2.2 Fuel Oil System 2-2.2
2.3 Lubricating Oil System 2-2.3
2.4 Cooling Water System 2-2.4
3． Engine Operation Control, Protective Device 2-3
3.1 Start Control 2-3.1
3.2 Stop Control 2-3.2
3.3 Engine Protection System 2-3.3

DE-18 A 12-03
CHAPTER

ITEM
Contents
DE-18

Chapter 3 ENGINE ADJUSTMENT STANDARDS 3

1． Operating Specifications 3-1
2． Valve Settings 3-2

Chapter 4 OPERATION 4
1． Precautions for Operating Engine 4-1
1.1 For Start 4-1.1
1.2 For Operation 4-1.2
1.3 For Stop 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 Long Period of Disuse and Overhaul 4-2.2
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 (for Heavy Fuel Oil Engines) 4-4.4

5． Special Operation 4-5

5.1 Low-Load Operation (Power Generator Specifications) 4-5.1

5.2 Allowable Operating Range (for Propulsion Engine) 4-5.2
5.3 Non-turbocharger Operation 4-5.3
5.4 Operation with Reduced Number of Cylinder 4-5.4
6． Stop 4-6
6.1 Normal Stop 4-6.1
6.2 Emergency Stop 4-6.2
6.3 Long-term Shutdown 4-6.3

DE-18 B 12-08
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ITEM
Contents
DE-18

Chapter 5 INSPECTION AND MAINTENANCE 5

1． Precautions for Inspection and Maintenance 5-1
1.1 Safety Precautions 5-1.1
1.2 Cautionary Items When Finishing Inspection and Maintenance 5-1.2
2． Inspection and Maintenance Table 5-2
3． Measurement and Adjustment 5-3
3.1 Exhaust Air Temperature 5-3.1
3.2 Pressure and Temperature of Each Part 5-3.2
3.3 Maximum Combustion Pressure 5-3.3
4． Inspection and Maintenance 5-4
4.1 Inspecting Parts around Intake and Exhaust Valves, and Adjusting Valve End Clearance 5-4.1
4.2 Inspection and Maintenance of Fuel Oil Injection Valve 5-4.2
4.3 Cleaning Filters 5-4.3
4.4 Cleaning Turbocharger Compressor 5-4.4
4.5 Cleaning Turbocharger Turbine 5-4.5
4.6 Measuring Crankshaft Deflection 5-4.6

Chapter 6 FUEL OIL, LUBRICATING OIL AND COOLING WATER 6

1． Fuel Oil Control 6-1
1.1 Fuel Oil Selection 6-1.1
1.2 Fuel Oil Control 6-1.2
2． Lubricating Oil Control 6-2
2.1 Lubricating Oil Selection 6-2.1
2.2 Lubricating Oil Control 6-2.2
3． Cooling Water Control 6-3
3.1 Cooling Fresh Water (Raw Water) 6-3.1
3.2 Antirust 6-3.2
3.3 Cooling Water Control 6-3.3

DE-18 A 14-03
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ITEM
Contents
DE-18

Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES 7

1． Precautions for Troubleshooting 7-1
2． Troubleshooting and Countermeasures 7-2
2.1 Starting Defect 7-2.1
2.2 Engine Revolution is Not Smooth 7-2.2
2.3 Insufficient Output 7-2.3
2.4 Abnormal Exhaust Gas Temperature or Maximum Combustion Pressure 7-2.4
2.5 Abnormal Exhaust Gas Color 7-2.5
2.6 Abnormal Noise / Abnormal Vibration 7-2.6
2.7 Sudden Engine Stop 7-2.7
2.8 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
2.14 Low Cooling Water Temperature (Jacket Line) 7-2.14

DE-18 Z 12-01
 CHAPTER
Introduction
0
ITEM
Before Running Daihatsu Diesel Engine DE-18 1
0． Introduction
(1) Only skilled operators who have carefully read and fully understood the instruction manual
should operate, inspect and service this machine.
Operation, inspection or servicing by persons inadequately familiar with the machine may
0
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 devi-
ates from the instruction manual.
(3) We shall repair new parts or replace any flawed parts made or sold by us, however no com-
pensation 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 DE-18 engine, its daily
maintenance and inspection procedures, 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.
Strictly avoid use of the engine for a purpose other than the original purpose of use of the
engine or under conditions different from the specified conditions or handling against the
descriptions given herein, since such operation will cause accidents or troubles.

A． Each piece of the information is an important safety precaution and provided as a "Warning"
or "Caution".

B．The features and structure of your engine may be different from those provided in this manual depend-
ing on the specifications of the engine delivered. In this case, the engine specifications and final documents
supplied separately have priority over this manual.

C．For the details on the following machine or device, see each instruction manual supplied with this manual:
1. Turbocharger 2. Governor 3. Lubricating oil cooler 4. Lubricating oil auto back wash filter
5. Lubricating oil bypass filter 6. Lubricating oil priming pump 7. Control equipment
8. Other special devices

D．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 Service Department or the nearest
DAIHATSU's branch office provided on the cover page.
Be sure to provide us with the "type and number of your engine" when contacting us.
If you use any parts other than the genuine parts or specified parts, unexpected troubles may be caused,
and you cannot make insurance claims owing to nonconformity to terms and conditions of damage
insurance.

DE-18 A 12-03
CHAPTER
Introduction
0
ITEM
Before Running Daihatsu Diesel Engine
1 , 2.1 DE-18 Basic Information on Safety Operation:Safety Precautions

E．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 authorized waste disposal
company.

0-2．Basic Information on Safety Operation

0-2.1 Safety Precautions

The diesel engine uses flammable oil. It has dangerous parts, such as the high-speed rotational
parts, the parts that become extremely hot, or the parts that are under high pressure fluid, dur-
ing operation.
Improper handling of the engine can result in serious injury or fatal accidents. Be sure to
observe the safety precautions provided in this manual.

A．Beware of Rotational Parts

This engine has the high-speed rotational parts.
Inadvertent contact of operators or objects with such parts can cause that the person to get
caught in the engine, or cause the chips of objects to fly in all directions.
a. Never attempt to touch the rotational parts such as the flywheel and couplings during operation. Also, be
sure to place the protective cover in place before operation.
b. Before starting operation, check that no person is around the engine. Warn any nearby person by signal-
ing that the engine is about to start operation.

B．Beware of Hot Parts

The engine parts are very hot during and immediately after operation. Touching them with bare
hands or skin can cause burns. Note that the exhaust manifold, turbocharger, cylinder head,
indicator valve periphery, air cooler inlet, and heated heavy fuel oil pipes become extremely hot.
a. Never attempt to touch any part of the engine with bare hand or skin during or immediately after operation.
b. Be sure to wear safety gloves or other protective wear for making measurements or inspection.
c. Allow the engine to sufficiently cool down before performing inspection or maintenance work.
C．Prevent Oil from Catching Fire
Fuel oil or lubricating oil coming in contact with extremely hot parts of the machine may catch fire.
a. Be attentive to oil leakage from the oil pipes during operation. If any leakage is found, immediately stop
the engine and eliminate the leakage.
b. Strictly observe the "NAKED FIRE FORBIDDEN" sign when adding fuel oil or lubricating oil.

If the engine is stopped due to failure or trouble, be sure to eliminate the cause of defect and
restore it to the normal operating condition before restarting the engine operation.

DE-18 A 12-03
 CHAPTER
Introduction
0
Basic Information on Safety Operation: ITEM

Safety Signs and Symbol Marks DE-18 2.2

0-2.2 Safety Signs and Symbol Marks

This instruction manual and warning labels affixed to the engine carry one of the following safety signs
and symbol marks:
0
A. Safety Signs and "Signal words"
："Warning": Precaution related to safety of personnel (Potential hazard which could result in death or
serious injury)
："Caution": Precaution related to safety of personnel (Potential hazard which may result in minor or
moderate injury)
："Precautions for handling": Information on handling of the engine to prevent damage

："Prohibition": Prohibited practice that can affect the safety of personnel and the engine

："Obligatory acts": Recommended practice or instruction to be followed to ensure safety of personnel

and the engine

B. Symbol Marks b. Prohibition Signs

a. Warning Signs
：Non-specific general prohibition
：General warning

：No Smoking
：Flammable → Fire

：Naked fire forbidden

：Explosive → Explosion or Bursting

：Do Not Touch

：Poisonous → Poisoning

：Voltage → Electric Shock c. Signs for Obligatory Acts

：Wear Eye Protection (safety goggles, etc.)

：High temperature → Burn

：Wear Head Protection (hard hat, etc.)

：Rotational/Moving Part → Getting Caught

：Wear Ear (Noise) Protection (ear plugs, etc.)

：Edge → Cut

：Wear Hand Protection (safety gloves, etc.)

：High-Pressure Fluid Jet → Injury

：Wear Foot Protection (safety shoes, etc.)

：High Location → Fall

d. Others
：See other pages in this manual or other
documents.

DE-18 Z 12-01
CHAPTER
Introduction
0
ITEM
Basic Information on Safety Operation:
2.3 DE-18 Indication of Warning: Warning Labels

0-2.3 Indication of Warning: Warning Labels

The warning labels used in our engines are basically as given below.

(1) (2) (3)

(4) (5)

(6) (7) (8) (9)

DE-18 Z 12-01
 CHAPTER
Introduction
0
ITEM
Basic Information on Safety Operation:
Indication of Warning: Warning Label Positions DE-18 2.4

0-2.4 Indication of Warning: Warning Label Positions

For safety, the warning labels shown below are affixed to the engine. The numbers carried by labels corre-
spond to those given on Item 2.3 of Chapter 0. 0
If a label is broken or falls, replace it with a new label, and make arrangement so that it may be visible
clearly at any time.

(4) (6) (1)

(9) (5) (2) (3)

(8) (7)

Fuel test pump Hydraulic jack

DE-18 Z 12-01
CHAPTER
Introduction
0
ITEM
Engine Conforming to NOx Technical Code: Outline / Matters
3.1,3.2 DE-18 Requiring Attention for NOx Regulation Compliance

0-3. Engine Conforming to NOx Technical Code

0-3.1 Outline
A. The marine diesel engines to which the 13th rule "Nitrogen Oxides (NOx)" in Supplement VI "Rules to
Prevent Air Pollution by Ships" to MARPOL73/78 Treaty applies should conform to NOx Technical Code.
B. The engines conforming to NOx Technical Code are authorized as an engine group or an engine family,
and it is allowed to apply the engine parameter check method to them, when receiving the NOx discharge
inspection on board.
The engine parameter check method is a method for verifying that the engine components and setting
values conform to the requirements specified in the technical file, and does not require the measurement of
NOx discharge. To the engines that are not conforming to the requirements of the technical file, the engine
parameter check method cannot be applied. For such engines, the measurement of NOx discharge shall
be required.

0-3.2 Matters Requiring Attention for NOx Regulation Compliance

A. Introduction
NOx Regulation obliges the administration to execute Port State Control (PSC) and regular inspection to
confirm that the regulation is satisfied even after the ship has entered service. Please pay attention to the
following points and make sure to comply with the regulation and carry out inspections smoothly. Replacing
parts with those other than the authorized parts or performing remodeling or revision after adjustment would
invalidate the certificate.

B. Inspection Method
For confirmation of the NOx emission level of our engine, parameter checking method will be applied, in
principle, and the details will be confirmed as given in the method described in the technical file.
[Engine Parameter Checking Method]
Verification will be conducted to ensure that books stored onboard (Final Document (FD)) are available
and are appropriately managed. Replacement/remodeling and revision of engine components and set val-
ues (engine parameter) that would affect the NOx emission volume given in the record book of engine
parameter will be surveyed to verify that they are within the allowable range specified in the Technical File
(TF). Inspection will be conducted at the engine parameter site, as necessary, to verify that the parameters
are within the range specified in TF.

C. Books Stored Onboard

During the time this engine is mounted on a vessel which is under the authority of the relevant administra-
tion, it is obligated to keep the FD stored in the vessel. Documents obligated to be stored onboard under the
NOx technical code (2008), are as given below.
1) Engine International Air Pollution Prevention Certificate with Supplement (EIAPP Certificate)
2) Technical File (TF)
3) Record Book of Engine Parameters
4) Documents on operation values based on load characteristics of engine or an engine parameter list
(Test records of the diesel engine at shop trial and/or Engine Parameter Inspection Record for NOx
Verification) (PIR)

5) Technical Documentation on remodeling of components [If applicable] ( ：“Technical File”)

DE-18 Z 12-01
 CHAPTER
Introduction
0
ITEM
Engine Conforming to NOx Technical Code:
Matters Requiring Attention for NOx Regulation Compliance DE-18 3.2

D．Inspection Items (Engine Parameters)

Engine components and set values that affect the NOx emission are defined as follows:
Components: Fuel injection valve, fuel injection nozzle, fuel injection pump, fuel injection pump plunger, 0
fuel cam, piston, cylinder head, turbocharger and air cooler.
Set value: Fuel injection timing

NOx technical code compliant engine is adjusted to comply with the regulation before shipment.
Therefore, do not perform revision after shipment as it would cause deviation from the set value given in
the technical file.

E. Inspection Procedure
1) Obtain confirmation on the latest engine parameters stated in the record book of engine parameters,
whether it complies with the parameters designated in TF or not.
For components, confirmation is conducted by checking the seals, but for the fuel injection timing,
confirmation is conducted by checking the injection timing of the actual engine.
2) In 1), if remodeling or revision in the engine parameters has been made exceeding the allowable range
approved by TF, it must undergo inspection to confirm that the Technical Documentation regarding such
remodeling or revision is stored along with TF, and that it has been approved by the administration.
3) An engine parameter inspection will be conducted on the actual engine, as necessary, to verify that it is
within the range specified in TF.

F. Revision Procedure of Components and Set Values That are Engine Parameters
Parts that are specified as engine parameters are parts that relate to the NOx emission rate. When replac-
ing them or performing service on them, parts with prescribed seals attached shall be used and adjusted to
the prescribed set values.
If it has become necessary to change the use of parameter parts, please follow the procedure given
below.

F-1. Revision of Parts and Set Values within the Range Approved in TF
1) Check that the identification number of the parts or the set value to change is within the allowable range
specified in TF.
2) Fill in the Record Book of Engine Parameters.

F-2. Revision of Parts and Set Values or Remodeling of Parts not Approved in TF
Revision or remodeling can be performed only when the administration judges that engines that had parts
replaced or set values changed or had parts remodeled satisfy the NOx emission limit value and gives
approval. Please let us know, as we must issue necessary documents and consider obtaining approval from
the administration.

DE-18 Z 12-01
CHAPTER
Introduction
0
ITEM
Engine Conforming to NOx Technical Code:
3.2 DE-18 Matters Requiring Attention for NOx Regulation Compliance

G. How to Fill in the Record Book of Engine Parameters

During regular and interim inspections, parameter check is conducted to confirm that NOx parameter parts
replacement and adjustment are being conducted correctly. Therefore, it is obligated to have necessary
information on the date of execution and the details, in the order by date, each time replacement or remodel-
ing of components that fall within the engine parameters or adjustment and revision of set values are made.
~ Matters to be entered ~
1) Date of replacement (revision)
2) Place of replacement (revision) (cylinder No., etc.)
3) Seal of replacement part or the set value that was changed
4) Signature of responsible person
5) Reason of replacement, etc.

When Technical Documentation on remodeling of components has been issued, the reference number
of Technical Documentation and signature of inspector of NOx inspection shall be affixed.

Please refer to the technical code for the details of the above.

DE-18 Z 12-01
 CHAPTER
Introduction
0
ITEM
General Information:
Notation of Engine Type / Definition of Term / Unit DE-18 4.1～4.3

0-4．General Information
0-4.1 Notation of Engine Type 0
6 DE 18

•Number of cylinders
•Name of series
•Cylinder bore (cm) (actual size: 185 mm)

0-4.2 Definition of Term

Definitions of the terms used in this manual are fol-

lows:

•Rear side of engine: Output end side (flywheel side)

•Front side of engine: Opposite side to the output end

•Exhaust side: Exhaust manifold side (on the right

when seen from the output end)

•Pump side: Fuel injection pump side (on the left

when seen from the output end)

•Rotation: Clockwise rotation when seen from the out-

put end

•Cylinder and journal numbers: 1, 2, 3 …, starting

from the output end

0-4.3 Unit
Basically, SI units are used for the engine and in this manual.

DE-18 Z 12-01
CHAPTER
General
1
ITEM

1, 2 DE-18 Engine Specifications / Auxiliary Equipment

1．General
1-1．Engine Specifications

Note: (1) Since the output, which are marked with *, differ depending upon each specification, be minded to
enter the data after referring to the "Engine Specifications" and "Test Run Record".

1-2．Auxiliary Equipment

DE-18 Z 12-01
 CHAPTER
General
1
ITEM
Engine Outline and Equipment Layout DE-18 3

1-3．Engine Outline and Equipment Layout

DE-18 Z 12-01
CHAPTER
General Construction
2
ITEM

1 DE-18 Engine

2. General Construction
2-1. Engine

Governor

Gaue board

Starting air
Cam gear rotation valve
Crankshaft
Idle gear

Crank gear
Thrust
bearing metal

Mainbearing metal
Auxiliary
drive gear

DE-18 Z 12-01

General Construction
Piping Systems: Starting Pneumatic System
2-2．Piping system
This section describes the typical piping systems of standard specifications. For more details,
refer to the piping systems included in the final documents.
2-2.1 Starting Pneumatic System
The starting pneumatic system piping area has
white headband coating applied.
It is started by pilot/starting valve method using
compressed air.
The engine operating lever, the start button and
the starting valve are located on the front side of
engine and the starting rotation valve is located on
the rear side of engine. Also, for protection against
possible back flow of fuel gas, a check valve is
provided at the main starting valve exit.
Pressing the start button on the engine side or
on the operation panel (monitoring panel) activates
the control air solenoid valve, feeding control air to
the starting valve, causing main valve to open and
compressed air to reach the starting valve of each
cylinder head.
CHAPTER
2
ITEM
DE-18 2.1
On the other hand, compressed air diverged
from the starting air main pipe is fed to each cylin-
der in accordance with the ignition order from the
starting rotation valve to open the starting valve
and depress the piston to rotate the engine.
2
In case of automatic starting, the control sole-
noid valve opens in accordance with the sequence
and starts the engine.
To add, for protection of each equipment, a
strainer is provided at the front of the engine inlet
decompression valve.
Also, at the time of an emergency due to prob-
lems such as loss of power, starting can be made
by manually operating the starting solenoid valve.
（ ：4-3.1 "Starting Procedure"）
DE-18 Z 12-01
CHAPTER
General Construction
2
ITEM

2.2 DE-18 Piping Systems: Fuel Oil System

2-2.2 Fuel Oil System

The oil pipe is provided with various heat insulat-
The fuel oil system piping area has red head-
ing arrangements such as steam trace or ragging,
band coating applied.
and is kept at a constant temperature. The lubrica-
Fuel oil system varies depending on the grade of
tion of the fuel injection pump is made by means of
the oil used, and a typical example of the fuel oil
fuel oil circulation system, and the plunger is lubri-
system for heavy fuel oil is as shown below.
cated by means of forced-feed lubrication system
When heavy fuel oil is used, oil must be heated using lubricating oil.
and kept at a constant temperature to maintain the
( : 2-2.3 "Lubricating Oil System"）
oil viscosity suitable for injection.
High-pressure oil fed by the fuel injection pump
Oil heated by the heater and pressurized by the is introduced into the fuel oil injection valve con-
fuel feed pump is transferred to the fuel oil injec- nector from the cylinder head side via the fuel
tion pump via the filter. Surplus of oil is returned to high-pressure block.
the inlet side of the oil feed pump via the pressure
control valve (relief valve), and is then circulated
again.

Leakage waste
oil tank

DE-18 Z 12-01

General Construction
Piping Systems: Lubricating Oil System
2-2.3 Lubricating Oil System
The lubricating oil system piping area has yellow
headband coating applied.
Lubricating oil transferred to the lubricating oil
cooler from the lubricating oil pump is regulated to
reach the specified temperature and pressure, by
means of the temperature control valve and pres-
sure control valve respectively, and the lubricating
oil is transferred to the oil channel of the engine
frame via the filter. Then, from this oil channel, the
lubricating oil is supplied to the piston through the
holes of the connecting rod via each main bearing
and crank pin.
CHAPTER
2
ITEM
DE-18 2.3
Further, the lubricating oil is supplied as
branched from the same oil channel to the
camshaft, valve-operating swing arm, fuel oil injec-
tion pump tappet, around the rocker arm, and vari-
ous gears.
The lubricating pump, which is of a gear type
provided with a safety valve, is installed on the front
side of the engine and is driven by the crankshaft.
The lubricating oil filter for the engine is auto-
matic backwashing type, and while engine running,
cleans sludge continuously captured by the filter
2
element.
Lubricating oil, which has circulated through and
has lubricated each part, returns to the base plate
of the engine (oil tank).
DE-18 Z 12-01
CHAPTER
General Construction
2
ITEM

2.4 DE-18 Piping Systems: Cooling Water System

2-2.4 Cooling Water System cooling each part, it returns to the fresh water cool-
er via the temperature control valve case installed
The fresh water cooler has blue headband coat-
at the cooling water engine outlet.
ing applied.
The temperature control valve in the tempera-
The cooling water system is a single fresh water
ture control valve case keeps the cooling water at
circulating system in which jacket line water (high
the specified temperature.
temperature) and cooler line water (low tempera-
ture) are mixed. Normally, fresh water is used as
B．Cooler Line
cooling water.
The cooler line is also a circulating system,
through which the low temperature fresh water
A．Jacket Line
coming out of the fresh water cooler is pumped by
The jacket line is a circulating system, through
the cooling water pump and is fed back to the
which a part of cooling water in the cooler line that
fresh water cooler via the lubricating oil cooler and
passed through the lubricating oil cooler and air
the air cooler.
cooler is pumped by cooling water pump and
enters into the engine cylinder jacket and after

DE-18 Z 12-01
 CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device: Start Control DE-18 3.1

2-3．Engine Operation Control, Protective Device

Control and protective devices such as the stop cylinder are activated by low-pressure control air.
This section describes a system generally used for the generator that is remotely controlled
for starting and stopping. The engine that is actually delivered may differ from the examples
shown in this section depending on the specifications, and therefore refer to the final docu-
ments, which are separately provided, for the details.
As for the starting air system (high pressure), refer to the previous section 2-2.1.

2-3.1 Start Control 2

A．For Generator
a. Remote Control
(1) For starting the engine by remote control, the
operation mode must be changed to
"REMOTE" and the control lever must be set to
the “RUN” position. The handle switch (HS) is
turned "ON" at this state, and if the turning
B．For Main Engine
safety switch (TC) is also turned "ON", the
engine is on standby and ready for operation.
(2) When a start command is given, the starting
solenoid valve (88V) operates and control air is
fed to the starting valve to open the main valve
and the starting air reaches the cylinder head
starting valve.
(3) Meanwhile, the same start command allows
the fuel control solenoid (88L) to activate, caus-
ing control air to flow into fuel control cylinder,
and allows the common rod to be held in posi-
tion, so that the fuel injection amount is con-
trolled not to be excessive at the time of start-
ing.
(4) When the engine reaches the specified rota-
tion speed, the low-speed relay (14) is activat-
ed, canceling the start command and resetting
the protective circuit, so that the engine is set
to the operating state.
b. Engine Side Start
For the engine side start, switching the
operation mode to "LOCAL" and pressing the
start button on the engine side will operate the
starting solenoid valve (88V), feeding the con-
trol air to the starting valve to start the engine.
c. Automatic Start
For automatic start, a start command is
automatically given according to the specified
sequence, and the starting solenoid valve
(88V) operates to start the engine. The opera-
tion mode shall be set at "REMOTE".
a. Engine Side Start
(1) For the engine side start, set the engine side -
remote changeover valve at "LOCAL" and shift
the operation lever from the "STOP" position to
the "START" position.
(2) Pressing the start button will operate the start-
ing solenoid valve (88V), feeding the operation
air to the starting valve to start the engine.
(3) When the engine reaches the specified rota-
tion speed, the low-speed relay (14) is activat-
ed, canceling the start command.
(4) When idle rotation becomes stable, shift the
operation lever from the "START" position to
the "RUN" position. In this state, the handle
switch (HS) turns "ON", configuring the protec-
tive circuit and setting the engine to an operat-
ing state.
(5) Switching the changeover valve on the engine
side to "LOCAL" makes it possible to perform
engine operation by the bridge operation han-
dle.

DE-18 Z 12-01
CHAPTER
General Construction
2
ITEM

3.1 DE-18 Engine Operation Control, Protective Device: Start Control

DE-18 Z 12-01
 CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device: Start Control
/ Stop Control / Engine Protection System DE-18 3.1～3.3

b. Remote Control (Starting from the Bridge)

(1) Placing the operation lever on the "RUN" posi-
(Please refer to the final documents regarding
tion in the "REMOTE" status, turns the handle
the destination-specific systems.)
switch (HS) "ON" and with this state, and with
As for the errors that may be led to serious acci-
the turning safety switch (TC) in "ON" state,
dents or failures, alarm is issued and emergency
standby conditions are met making it ready for
stop is made.
engine operation.
Each of the abnormal operation data or value is
(2) The operation handle of bridge being in the
detected by a switch or sensor, and the fuel shut-
"NEUTRAL" state is the very condition that
down solenoid valve is activated by the emergency
makes starting possible.
(3) When the start button on the operation panel
stop command, so that the engine is immediately 2
stopped.
is pressed, start command is given to energize
and operate the starting solenoid valve (88V),
feeding the control air to the starting valve via 2-3.3 Engine Protection System
the starting solenoid valve to start the engine. (Please refer to the final documents regarding
(4) When the engine reaches a specified rotation the destination-specific systems.)
speed, the low speed relay (14) is activated to As for the errors that may be led to serious acci-
cancel the starting command and restore the pro- dents or failures, alarm is issued and emergency
tection circuit, putting the engine into operation. stop is made.
Each of the abnormal operation data or value is
2-3.2 Stop Control detected by a switch or sensor, and the fuel shut-
When a stop command is given, the fuel shut- down solenoid valve is activated by the emergency
down solenoid valve (5V) operates to feed control stop command, so that the engine is immediately
air to the fuel control cylinder, turns the common stopped.
rod in the direction for stopping and stops the
engine. To stop the engine on the engine side,
shift the operating lever to the stop position.

Detection item Alarm Shutdown Location Remarks

Overspeed 12 Cam gear
Decrease of L.O. pressure PTQ 63Q2 Engine inlet Aiso used as the indicator
Increase of high-temperature Jacket inlet Aiso used as the indicator
cooling water temperature TRWS 26WH2
Increase of L.O. pressure TRQ Engine inlet Aiso used as the indicator
Increase of exhaust temperature TRT1 Turbocharger inlet Aiso used as the indicator
Oil leakage from fuel high 33F Oil leakage detector
pressure block
Decrease of L.O. level 33QL Engine L.O. tank
Decrease of high-temperature Aiso used as the indicator
cooling water pressure PTWH Jacket inlet
Increase of L.O. filter
differential pressure 63QDM L.O. filter

Table 2-3.1 Alarm and stop Items (Example)

DE-18 A 12-03
CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device:
3.3 DE-18 Engine Protection System

DE-18 Z 12-01
 CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device:
Engine Protection System DE-18 3.3

Differential pressure Intake air

of bearing lubricating temperature
oil filter
Increase of exhaust
gas outlet temperature
Decrease of
priming pressure Decrease of turbine
Decrease of jacket lubricating oil pressure
cooling water pressure
Stop for decrease of
lubricating oil pressure
Alarm for decrease of
lubricating oil pressure
Solenoid valve for
emergency stop
Solenoid valve for

2
starting
Solenoid valve for
stopping
Solenoid valve for
prevent starting

Increase of jacket
cooling water
temperature Increase of jacket
cooling water
temperature

Revolution
pick up
Increase of
fuel oil
temperature

High-pressure
pipe leakage
oil level

DE-18 Z 12-01
CHAPTER
Engine Adjustment Standards
3
ITEM

1 DE-18 Operating Specifications

3. Engine Adjustment Standards
3-1．Operating Specifications

Refer to
SHOP
SHO P TRIA
TRIAL TES
TEST RECORDS
㽢㻝㻝㻞䡚㻝㻝㻡䠂

㻝㻚㻡䡚㻟㻚㻜

㻜㻚㻣䡚㻜㻚㻥
Refer to
SHOP
SHO P TRIA
TRIAL TES
TEST RECORDS
㻜㻚㻡䡚㻝㻚㻜

㻜㻚㻞䡚㻜㻚㻟

㻜㻚㻠䡚㻜㻚㻡

㻜㻚㻞䡚㻜㻚㻡

㻜㻚㻜㻢䡚㻜㻚㻝㻡

㻜㻚㻝㻡䡚㻜㻚㻠

㻜㻚㻝㻡䡚㻜㻚㻠

㻠㻡䡚㻡㻡
Refer to
SHOP
SHO P TRIA
TRIAL TES
TEST RECORDS
Refer to
SHOP
SHO P TRIA
TRIAL TES
TEST RECORDS
Refer to
SHOP
SHO P TRIA
TRIAL TES
TEST RECORDS

㻡㻜䡚㻢㻜

㻣㻜䡚㻤㻜 85 90

㻟㻢䡚㻟㻤

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 is provided depending on the indi-
vidual specifications.
(3) The actual data found on each engine may differ from those shown in the above table, and there-

DE-18 B 13-11
 CHAPTER
Engine Adjustment Standards
3
ITEM
Valve Settings DE-18 2

3-2．Valve Settings

32.5∼ 33.5 MPa

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM Precautions for Operating Engine:
1.1～1.3 DE-18 For Start / For Operation / For Stop
4．Operation
4-1．Precautions for Operating Engine
4-1.1 For Start
A. 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.
B. 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.
C. 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
A. After the starting engine, inspect the following items, and confirm that the engine is in a good condi-
tion. 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.
•Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate exhaust temperature.
•Abnormal sound, excessive heating, etc.
•Any leakage from piping. (Particularly, leaks from oil piping results 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 the normal operating conditions.
B. Inadvertent contact of the body of working staff or objects with the rotating parts (e.g. flywheel and
coupling) results 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 rotating parts.
Further, ensure that the protective covers of the rotating parts are always attached without fall.
C. 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 preventive
means (splash proof tape), and protective covers that have been removed for maintenance and
inspection to their former state before performing operation.
• Exhaust pipe • Indicator valve (fitted to the cylinder head)
• Turbocharger • Fuel injection pump and high-pressure block
• Air cooler inlet duct • Fuel oil pipe (when heavy fuel oil is used)
• Cylinder head

4-1.3 For Stop

A. Make sure that the engine is stopped after load is taken off the engine, except in the case of emer-
gency.
B. In case that the engine is stopped in emergency stop, be minded never attempt to resume the oper-
ation until the causes of the problems is found and eliminated, and the engine is restored.
C. Do not open the frame for at least 10 minutes after the engine is stopped until it is fully cooled down.
Otherwise, there is a danger of explosion since the inflammable mist gas in the frame may catch fire.
D. The engine immediately after it is stopped is still extremely hot like during the operation, and there
may be danger of burn. Therefore, be minded to wear the protective clothing whenever inspection or
maintenance works is conducted without fail.

DE-18 Z 12-01
 CHAPTER
Operation 4
ITEM
Preparation for Operation: Preparation for Daily Operation DE-18 2.1

4-2．Preparation for Operation

It is essential to keep the engine in "Operable Conditions" when starting the engine.
Therefore, be sure to perform pre-operation inspections before the starting of engine, and take
proper corrective actions whenever any problem is found, to confirm that the engine is in nor-
mal conditions for operation, before starting the operation of engine.
If the engine is started without pre-operation inspections or preparations, it will not only cause
the troubles when starting the engine but also result in a sudden stop or damaging accidents.

4-2.1 Preparation for Daily Operation 2. Governor

Lubricating oil level, RHD6: 1.3 L
The number of the inspection items required
UG10: 1.4 L
before starting the operation varies depending
UG25+: 2.1 L
on how long the engine has been out of 3. Generator (for self-lubricating type)
operation. （ ：Separately provided
・Daily starting: shutdown for a short period of
"Generator Instruction Manual"）
time (within one month)
・Initial starting after installation, after shut-
down for a long period of time, or after over-
haul or maintenance.
The daily starting procedures are described
4
in this section. As for the latter (initial start-
ing), refer to the following section.
（ ： 4-2.2 "Preparation of Initial
Starting after a Long Period of Disuse and
Overhaul"）

A. Inspection before Start

a. Inspection and Feeding of Lubricating Oil
Check the oil level of the oil tank, and feed
new oil to the upper limit level of the oil gauge
(level gauge).
Further, in case that the lubricating oil is
found inadequate after examination, proceed
with makeup or replace the entire amount of
the lubricating oil.

（ ：6-2 "Lubricating Oil Control"）

1. Engine lubricating oil tank (Base plate common
to engines)
1100 L for lubricating oil
Note: The amounts of oil shown above may vary
depending on type.

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM

2.1 DE-18 Preparation for Operation: Preparation for Daily Operation

b. Inspection, Lubrication, and Operation

Check around the Fuel Regulation System
Manually lubricate the bearing and sliding parts of
pins, after checking for any loose or missing levers,
link pins, and bolts around the governor, common
rod, stop system, and fuel inspection pump rack.
Set the operation lever to the "STOP" position
and confirm that the rack scale is set at "0", and
then alternately move the lever to the "STOP" and
"RUN" positions, to confirm that the common rod
and pump rack moves smoothly.

c. Draining of Condensed Water from Intake

Air Inlet Duct
Open the drain cock of the intake air inlet duct of
the engine frame, and drain the condensed water
out. Confirm draining the condensed water or dis-
charging the air during engine running.

Always keep the drain cock of the engine

frame inlet air duct open about 30° (1/3), after
draining the condensed water by fully operat-
ing the drain cock.
In case that the humidity is high and the cool-
ing water temperature of the air cooler is low, a
large amount of condensed water will accumu-
late, any may cause corrosion or abnormal wear
on various parts flowing into the cylinder and
may cause serious accident as the case may be.

DE-18 Z 12-01

Operation
Preparation for Operation: Preparation for Daily Operation
d. Draining Condensed Water from, and
Supply of Air to Air Tank
In the case of automatically supplying air, first
drain the condensed water out of the starting air
tank and control air tank, and then confirm that air
pressures in these tanks is above the lower limit
value.
In the case of manually supplying air (including
manual starting of the air compressor), supply air
to the upper limit value.
Item Upper limit Lower limit
Starting air 3.0 MPa 1.5 MPa
Control air 0.9 MPa 0.6 MPa
e. Checking and Feeding of Cooling Water
Check the level of cooling water in the cooling
water tank, and if the level is at the lower limit,
supply fresh water up to the upper limit, and at the
same time add a proper amount of the additive.
Further, in the case that each property value of
water reaches the limit level, replace the entire
amount of water.
（ ：6-3 "Cooling Water Control"）
Cooling water inventory level inside
the engine 65 L
f. Draining of Fuel Oil and Supply of Oil
First drain fuel oil out of the fuel oil service tank,
and then check the oil level and supply oil up to
the upper limit of the level gauge.
g. Opening and Closing of Valves
Repeat "Fully open" and "Fully close" operation
of the valves on the piping system 2~3 times to
confirm that the valves move smoothly, and then
set the valves to the "RUN" position.
Some of the examples are shown as follows.
Since the layout positions of the piping systems
and valves differ depending on each engine, refer
to the piping diagrams of the final documents for
the details.
CHAPTER
4
ITEM
DE-18 2.1
[Example]
1. Valves for fuel oil inlet pipe and return pipe:
"Open"
2. Valves for cooling water (jacket and cooler),
inlet pipe, and outlet pipe: "Open"
3. Valves for starting air pipe: "Closed" ("Open"
only when starting operation)
4. Valves for operation air pipe: "Open"
5. Valves for pipe coupling parts provided for
emergency, cleaning, etc.: "Closed"
If the screw-tightening valves are used on
the state of half-open, the valve handle may be
turned during operation and the opening
degree may be changed, causing malfunctions.
Therefore, the valves should be fully turned
toward either "Open" or "Close" position, and
should be locked tightly.
4
In the case that the valves must necessarily
be left half open for the sake of flow adjust-
ment, be sure to secure the valve handles
with wire ring and the like, and fix them to pre-
vent their loosening and turning.
B. Standby Preparation (Engine on standby)
Before entering the operation of engine, conduct
the following preparations:
a. Priming with Lubricating Oil
During engine stop, it is systematically controlled
for the motor-driven priming pump to work auto-
matically. Therefore, please check the lubricating
oil before starting.
b. Turning or Air Running
Conduct turning or air running to discharge the
dusts or water drops that collects in the cylinder
while the engine is stopped.
Further, when the engine is started after the
inspection of various parts of the engine, or after a
long period of disuse of the engine, conduct turn-
ing before air running to confirm the safety.
DE-18 Z 12-01
CHAPTER
4 Operation
ITEM

2.1 DE-18 Preparation for Operation: Preparation for Daily Operation

In the case that a large amount of water or

oil is accumulated in the cylinder due to the
leakage from the cylinder head or fuel injec-
tion valve, there is possibility of serious acci-
dents such as bending damage of the con-
necting rod by the water hammer.
If water or oil gushes out of the indicator
valve (on the cylinder head top surface) during
turning or air running, stop starting the engine,
investigate the causes, and take measures.

<<Turning>>

<Work Procedure>
(1) Conduct priming with lubricating oil.
(2) Set the operation lever to the "STOP" position.
(Do not inject fuel oil.)
(3) Set the indicator valve to the "Fully open"
position.
(4) Conduct turning 1 to 2 times, and confirm that
the engine rotates smoothly.

<<Air Running (abbreviated as Air Run)>>

<Work Procedure>
(1) Conduct priming with lubricating oil.
(2) Set the operation lever to the "STOP" position.
(3) "Fully open" the indicator valve
(4) Open the starting air valve and the control air
valve and press the start button on the engine
side.
The solenoid valve of the starter air relay
valve operates to feed starting air to the start-
ing valve to start the engine.
(5) Keep pressing the push button for 3 to 4 sec-
onds (for air run).
(6) Pressing the engine side start button stops the
engine.

DE-18 Z 12-01
 CHAPTER
Operation 4
ITEM
Preparation for Operation: Preparation for Daily Operation DE-18 2.1

e. Operation of Motor-Driven Pumps

In the case that the engine is equipped with the
If the engine starts its rotation during the
motor-driven cooling water pump and fuel oil feed
inspection of the inside of the engine or rotat-
pump, start the pumps 5 minutes before the start-
ing parts, it is extremely dangerous since the
ing of engine, and confirm that there is no oil leaks
working staff may be caught up or the objects
from various parts of piping.
that has been caught up may fly out in all
directions.
When conducting air run, strictly observe
the following points.
1) Confirm that the turning bar should be insert-
ed into the turning holder.
2) Send a signal to coworkers and confirm
safety before starting to press the push but-
ton of the starting operation.

c. Heating of Fuel Oil

(when heavy fuel oil is used.)
In the case that heavy fuel oil is used, heating 4
shall be made according to the following items:
(1) Turn on the fuel oil heating device.
(2) Operate the motor-driven oil feed pump.
（ ：6-1 "Fuel Oil Control"）

Heated heavy fuel oil, which is extremely

hot (100℃ or more), may cause burn if you
touch the piping or equipment on the fuel oil
system.
Therefore, in case of handling the equip-
ment of fuel oil system that carriers heat oil,
be sure to wear safety gloves and never touch
them with bare hands.

d. Turning "ON" of Protective and Alarm

Circuit
Turn "ON" the protective and alarm circuit on the
monitor panel, and confirm that the warning alarm
lights up.

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM
Preparation for operation: Preparation of Initial Starting
2.2 DE-18 after a Long Period of Disuse and Overhaul

4-2.2 Preparation for Initial Starting C. Opening, Cleaning, and Cleansing of Filters
after Long Period of Disuse and Dust or foreign objects, which collected into pip-
Overhaul ing during transportation, and outfitting or installa-
tion, are accumulated in the filters of the engine
Since the engine is not ready for immediate
inlet.
starting of operation after installation, shutdown
Open the following filters, and cleanse the inside
and overhaul for a long period or maintenance, it is
and the elements of the filters:
particularly necessary to thoroughly conduct the
1. Starting air filter and control air filter
preparations for operation.
2. Fuel oil filter (including oil filters on the outside
Before the preparation for daily operation, con-
of the engine)
duct the following preparation works (4-2.1).
3. Lubricating oil filter (filters on the engine, for
A. Inspection of Crankcase and Cylinder Liner, T/C)
and Supply of Oil 4. Cooling water filter
a. Inspection of the Inside of Crankcase （ ：5-4.3 "Cleaning Filters"）
Open the side cover of the engine frame, and
check and ensure that tools, waste clothes, foreign
matters such as desiccants are not left behind, and
that there is no rusting on the cylinder 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 cylinder,
lubricating oil cannot be supplied sufficiently with
priming alone, and therefore supply lubricating oil
on the following procedure:
(1) Conduct turning to allow the pistons to move
Spray
upward, and apply lubricating oil to the lower (Spray
part of the cylinder liners by a spray device and lubricating
oil)
the like.
(2) Sequentially conduct the above procedure to
each cylinder.

B. Inspection of Connections and Joints

Inspect again the external connections or joints
to confirm that there is no connection that has
been forgotten to be tightened, or loosened joints.
If combustible oil splash preventive means
(splashproof tape) has been removed from joints,
newly treat the joints in the same manner after the
completion of the work.

DE-18 Z 12-01
 CHAPTER
Operation 4
ITEM
Preparation for operation: Preparation of Initial Starting
after a Long Period of Disuse and Overhaul DE-18 2.2

D. Priming with Lubricating Oil and Exhausting

Air
Conduct priming with lubricating oil and exhaust-
ing air in the following procedure:
a. Run the lubricating oil priming pump for 5 min-
utes. While the pump is operating, open the indi-
cator valve (on the cylinder head top surface) to
perform turning two or three times, and check for
leakage of fuel oil, lubricating oil and water from
the indicator valve.

4
b. At the same time, open the each cover and
check the dripping-down conditions of lubricating
oil from each part.
1. Engine frame: Main bearing, crank pin, piston
(cooling chamber), and piston pin
2. Cam case: Cam bearing, swing arm, and tappet
3. Cylinder head: Rocker arm and valve retaining tee
c. Operate the priming pump, open the air vent
valve for lubricating oil filter, and drain lubricat-
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.
E. Priming with Fuel Oil and Exhausting Air
Conduct priming with fuel oil and exhausting air
bubbles in the following procedure:
(1) Operate the fuel oil feed pump for the motor-
driven oil feed pump attached type. Also, for
the oil pump for the engine drive, open the
bypass valve on the piping block to let oil flow.

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM
Preparation for operation: Preparation of Initial Starting
2.2 DE-18 after a Long Period of Disuse and Overhaul

(2) Open the fuel oil inlet valve, after confirming
that the operation lever is set to the "STOP"
position.
(3) Open the air vent valve of the fuel oil filter,
and drain oil until air bubbles in oil are com-
pletely vanished.
(4) Open the air vent plug of the fuel injection
pump and drain oil until air bubbles are com-
pletely vanished.
(5) After completing bleeding air, securely tighten
the air vent plug.
F. Cleaning of Turbocharger Pre-Filter
Dust or debris is collected in the pre-filter of the
turbocharger during transportation, outfitting, and
installation, causing the filter to be stained or dam-
aged.
Therefore, clean it or replace it with a new one
before starting the operation.

The heavy fuel oil is heated to a high

temperature (100℃ or more).
Touching the splashing oil may scald your
hands. If high-temperature parts are splashed
with the oil, a fire may occur. Take care not to
splash the oil when discharging air.
G. Checking the Covers are Fitted
Check that the lagging for high-temperature
parts (exhaust pipe, turbocharger, etc.), exhaust
pipe cover and heat box cover that were removed
for disassembly and servicing are restored as they
were.

H. Checking the Ethylene Glycol Inventory

Level
For heavy fuel oil specification, check that the
ethylene glycol level inside the seal pot located at
the fuel pressure indicator piping system satisfies
the specified level.

DE-18 Z 12-01
 CHAPTER
Operation 4
ITEM
Starting: Starting Procedure DE-18 3.1

4-3．Starting B. Remote Starting (Manual and Push Button

Starting)

Inadvertent contact of working staff or objects (1) Change the starting location selector switch to
with the rotating parts is extremely dangerous "REMOTE".
since the person may be caught up or the object (2) Set the operation lever to the "RUN" position.
that caught up may fly out in all directions.
Therefore, strictly observe the following
items when starting the operation.
・Confirm that the protective covers of rotary
parts are mounted in normal state, and that
the rotary parts are free of any obstacle.
・Confirm that the turning device or turning bar
is set to "OFF".
・Send a signal to a coworker if any, and confirm
safety before starting the operation of engine.

4-3.1 Starting Procedure

Starting procedure can be classified into the
4
(3) Open the starting air valve and control air
three types; engine side starting remote starting,
valve, after confirming that the "READY" indica-
and automatic starting, and which of these should
tor lamp lights up.
be employed depends on the specifications.
(4) Press the starting button.
However, engine side starting (starting from
engine side) by manual operation should always (5) Confirm that "RUN" indicator lamp on the
be employed after installation, a long period of dis- panel lights up as the rotation speed of the
use and overhaul or maintenance. Also, perform engine reached the specified rate, and each
air run before starting, as necessary.( ：4-2.1) pressure reached the specified value.
<Work Procedure> (6) Close the starting air valve. (Leave the control
A. Starting from Engine Side air valve "OPEN" as it is.)
When power is "ON" and the control and protec-
tive devices are in operation:
(1)Open the starting air valve and control air valve.
(2)Set the starting location selector switch at
"LOCAL".
(3)Set the operation lever at "RUN" and hold the
operation lever.
(4)Press the start button on the engine.
(5)After the rotation speed of the engine rapidly
increased and starting established along with con-
tinuous ignition sounds, release the start button.
(6) Close the starting air valve. (Leave the control
air valve "Open" as it is.)

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM

3.1 DE-18 Starting: Starting Procerdure

C. Automatic Starting E. Starting on engine side in case of emer-

In the case of automatic starting, the engine gency
starts automatically by the starting command When the solenoid valve of the starting air relay
based on preset starting conditions, such as the valve cannot be operated, press the emergency
load conditions of power shutdown or other valve on the starting air relay valve on the front
engines (in the case of plural engines), and there- side of engine to open the main circuit of air motor.
fore it is essential that the engine should always be
kept in operable conditions.
Engines should be kept in the following condi-
tions at all times:
1. Starting mode "AUTO"
2. Operation lever position "RUN"
3. Starting location selector switch "REMOTE"
4. Air valve and control air valve "OPEN"

D. Starting on engine side

When starting the engine at a loss of power or
without making the control and protective devices
operable:
(1) Open the starting air valve and control air
valve.
(2) Set the operation lever at "START," and hold
the operation lever.
(3) After the rotation speed of the engine rapidly
increases and starting is established along with
continuous ignition sounds, release the start
button.
(4) Make sure that the rotation speed of the
engine reaches the specified speed and each
pressure value reaches the specified value,
and set the operation lever at "RUN."
(5) Close the starting air valve. (Leave the control
air valve "Open" as it is.)

DE-18 Z 12-01
 CHAPTER
Operation 4
ITEM
Starting: Starting Procerdure DE-18 3.1

F. Measures to be taken against starting failure

When a starting failure or a starting jam
occurred, take measures in accordance with the
separate section.
（ ：7 "Trouble Shooting and
Countermeasures"）

In the case that the engine repeatedly failed

to start in an extremely cold weather while the
engine is still in cold condition, the unburnt
mist of fuel oil may remain in the exhaust
manifold, having a possibility of catching fire
or explosion being caused by high-tempera-
ture combustion gas.
When starting failure repeats, conduct air
running and exhaust the unburnt mist in the
exhaust manifold, before restarting the 4
engine.

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM
Starting:
3.2 DE-18 Inspection and Check Items Immediately after Starting

4-3.2 Inspection and Check Items C. Abnormal Sound

Immediately after Starting
Check the following items immediately after starting.
When any abnormal error is found, immediately
stop the engine and take proper measures.
Carefully listen to the sound of the following
engine parts, and check if there is any abnormal
sound or not.
1. Cylinder head and surrounding parts (intake
and exhaust valves)

（ ："Trouble Shooting and Countermeasure"） 2. Crankcase

3. Crankcase and timing gear and auxiliary drive
gear
After conducting overhaul or maintenance
4. Turbocharger
of the sliding parts or rotary parts, be sure to
once stop the engine and check that there is
D. Exhaust Temperature
no error or failure by hand-touching.
Check the exhaust temperature of each cylinder,
A. Engine Rotation Speed and confirm that all the cylinders are properly burnt
Make sure that the specified rotation speed (at 200℃ or more).
attains and the engine is rotating stably.
E. Leakage and Loose from each parts
Confirm that mounting parts, bolts and nuts of
B. Pressure Reading of Each Section
connecting parts should not been loosed. And
Confirm that the indicator of pressure reading,
check if oil, water, and gas should not leak.
for the manometer with blue mark, is within the
blue mark, showing the pressure is within the
specified value.
If the temperature of lubricating oil is low just
after the engine starts, pressure values may be out
of the specified ranges. Check that the pressure
values come into the specified ranges as the tem-
perature of lubricating oil rises.

DE-18 Z 12-01
 CHAPTER
Operation 4
ITEM
Operation: Running-in DE-18 4.1

4-4．Operation <Inspection Items during the Initial Running-in>

1. Abnormal sound.
4-4.1 Running-in
2. Partial heating.
Do not apply a load abruptly since the sliding
3. Leakage from connection points and loosening
parts of the engine are not yet sufficiently ready to
of the bolts and nuts.
work smoothly or freely when the engine is started
for the first time after its installation or immediately 4. Exhaust temperature, irregular exhaust color,
after replacement of the parts such as the cylinder combustion pressure: Abnormal combustion.
liners and the piston ring. 5. Excessive consumption of lubricating oil: Poor
Conduct the running-in operation to ensure adaptability of liners and rings.
smooth and free working of the sliding parts
according to the following procedure before getting <Inspection after Completion of the Initial
into the steady mode of operation. Running-in>
1. Checking the condition of sliding portions of the
A. Initial Running-in cam and the roller, and the cam metal by tactile
Whether or not the pistons and the oil rings feeling of the finger.
move smoothly and freely will substantially affect
the engine performance, especially the combustion
performance and consequently the consumption of
2. Checking the condition of the internal surface
of the cylinder liner.
4
lubricating oil. Further, it is assumed that they will 3. Checking the condition of the main shaft, the
be decided by the initial operation of a few hours. crankpin metal and the cylinder liner by tactile
feeling of the finger.
The revolution of the engine should be gradually
increased, then the engine should be stopped after
B. Operating Conditions during the Running-in
it is driven for two or three minutes without a load
Be sure to operate the engine during the run-
and then conduct the following inspection that is to
ning-in period under the following conditions, grad-
be effected after completion of the initial running-in
ually increasing the load referring to Figure 4.1 and
when the engine is started for the first time after its
paying special attention to the inspection items
installation or replacement of any of parts located
during the initial running-in indicated in Item A.
in the periphery of the cylinder such as the cylinder
liner, the piston, the piston ring. And especially the
following items in the checking list for the initial 1. Load: 80% or less.
running-in should be watched and checked during 2. Fuel oil to be used: Diesel fuel oil. Even for the
the engine operation in order to find out any symp- engines of heavy fuel oil type, use diesel fuel
tom of a trouble as soon as possible or to prevent oil during the running-in period.
it from occurring. 3. Notwithstanding the prescription given by Item
2 above, the lubricating oil specified for the
engines of heavy fuel oil type may be used for
such engines from the start of engine driving.
4. Running-in period is 20~30 hours.

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM

4.1 DE-18 Operation: Running-in

At the time when the running-in operation is

completed, conduct the following inspection works
and confirm that there is not any abnormality
before entering the normal and regular operation
of engine.

1.Inspection of foreign matters and stains in the

crankcase.
2.Visual inspection of the inner surface of the
cylinder liner.
3.Inspection and cleaning of the element of each
filter.
4.Remove the flushing filter attached the fuel oil
filter.

Be minded never to perform the operation

of engine using heavy fuel oil, while the
flushing filter is attached.
（ ：Refer to Item B in Section 5-4.3）

DE-18 Z 12-01

Operation
Operation:
Warming-up and Connecting Load to the Engine
4-4.2 Warming-up and Connecting
Load to the Engine
In the case that the engine is started while it is
still in a cold state, first perform the warm-up oper-
ation, except for the case of emergency, and grad-
ually connect the load after the engine is sufficient-
ly warmed up.
If the load is hastily connected while the various
parts of the engine are still cold and not yet in the
conditions for proper fuel combustion and lubrica-
tion, malfunctions such as faulty combustion,
excessive wear of the sliding parts, and seizure
may be caused.
A．Warming-up Operation of Engine
a．Use diesel fuel oil for warming-up operation
Be sure to use diesel fuel oil for warming up the
engine, even in the case that the engine is
sufficiently heavy fuel oil.
b．No load
First operate under no load or light load, and
connect the load after jacket cooling water and
lubricating oil temperature increases.
CHAPTER
4
ITEM
DE-18 4.2
Be minded to perform no-load operation
only for warming up operation and keep it
within 10 minutes.
Running the engine under no-load for long
hours results in malfunctions such as faulty
combustion and collection of carbons in the
combustion chamber.
B．Connecting Load to the Engine
The lower the engine temperature (temperatures
of jacket cooling water and lubricating oil) is, the
longer time it is needed to connect the load.
The standard load connecting time is shown in
the figure below.
（ ：Fig. 4.2 "Load Connection Pattern"）
4
DE-18 Z 12-01
CHAPTER
4 Operation
ITEM
4.3 DE-18 Operation: Operation with Load (Normal Operation)
4-4.3 Operation with Load (Normal
Operation)
Inspect the running conditions of the engine and
measure the operating performance data in regular
intervals, during the continuous operation with load
(including period of the running-in operation).
In case that any problem is found as the results
of the inspection and measurement, take proper
measures such as adjustment or repair of the
defective parts. (Refer to the separately provided
section.)
（ ：5-3 "Measurement and Adjustment"）
（ ：7 "Troubleshooting and Countermeasures"）
A．Inspection of Operating Conditions
<Check Item>
1.Abnormal sound and abnormal vibration
2.Partial overheat
3.Leakage from connections and looseness of
screws
4.Exhaust temperature, and abnormal exhaust
color ... Abnormal combustion
5.Excessive consumption of lubricating oil
DE-18 Z 12-01
During the operation of engine, particularly
the following parts become extremely hot, and
touching these parts with bare hands or skin
may cause burns.
Therefore, be minded to use the protective wears
such as safety gloves when working on them.
・Exhaust pipe
・Turbocharger
・Air cooler inlet pipe
・Cylinder head
・Indicator valve
・ Fuel oil system equipment and piping (for
heavy fuel oil)
B. Measuring Performance Data
a. Measure the operating performance data at
least once every day, when the load variation is
less and the load is stable.
b. Compare each of the measured data with the
data obtained when the engine was newly intro-
duced, and judge if there is any problem and
check the degree of deterioration.
（ ："Test Run Record Table" in the final
documents）

Operation
Operation: Operation with Load (Normal Operation)
/Operation Using for Heavy Fuel Oil Engine
<Measurement Item>
1. Room temperature
2. Load (output)
3. Intake air temperature (turbocharger inlet)
4. Exhaust temperature (each cylinder outlet)
5. Exhaust temperature (turbocharger inlet)
6. Intake air pressure (engine inlet)
7. Lubricating oil pressure (engine inlet)
8. High-temperature cooling water pressure
(engine inlet)
9. Low-temperature cooling water pressure
(engine inlet)
10. Fuel oil pressure (engine inlet)
... for heavy fuel oil type
11. Inlet air temperature (engine inlet)
12. Lubricating temperature (engine inlet)
13. Cooling water temperature (cylinder head out-
let main pipe)
14. Fuel oil temperature (engine inlet)
... for heavy fuel oil type
15. Fuel injection pump rack scale
C. Regular Inspection and Maintenance
Conduct inspection and maintenance of the vari-
ous parts of engine regularly.(Refer to the
separately provided section.)
（ ：5 "Inspection and Maintenance"）
D. Operation Records
Record the results of inspection and measure-
ment and the contents of performed adjustments
and repairs in the engine control log.
Operation records are very important docu-
ments when understanding the conditions of
engine and tracing the history of the inspec-
tion or maintenance that has been performed.
Keep and store them carefully, and when
the supervisor is changed, be sure to transfer
the records to the successor without fall.
CHAPTER
4
ITEM
DE-18 4.3,4.4
4-4.4 Operation Using (for Heavy Fuel
Oil Engine)
Heavy fuel oil is lower in its quality and higher in
its viscosity than diesel fuel oil. When using heavy
fuel oil, proper operation control, such as switching
to the operation using diesel fuel oil depending on
the load conditions is required, in addition to prop-
er fuel oil and lubricating oil control (refer to the
separate sections.)
（ ：6-1 "Fuel Oil Control"）
（ ：6-2 "Lubricating Oil Control"）
A．Operation with Diesel Fuel Oil
Be minded to use heavy fuel oil only under sta-
ble load conditions, and be sure to use diesel fuel
oil in the following cases:
a. During Running-In Operation Period
(20~30 hours) 4
1.Immediately after installation
2.After replacement of the sliding parts around cylin-
der (e.g. cylinder liner, piston, and piston ring)
（ ：4-4.1 "Running-In Operation"）
b. During Starting or Warming-Up Operation
（ ：4-3 "Starting"）
（ ：4-4.2 "Warming-Up Operation"）
c. During idling or Low-Load Operation
When the engine is operated under low load, the
compressed air temperature in the cylinder and
fuel injection pressure of fuel oil are low, and
therefore if the heavy fuel, of which combustion
quality is lower than that of diesel fuel oil, is used,
combustion becomes unstable, resulting in unde-
sirable conditions, such as worsening of the
exhaust smoke, sticking of the ring, and so on. In
the case of the connection of the load that is below
the lower limit described in the engine specifica-
tion, be minded to use diesel fuel oil.
（ ：4-5.1 "Low\load Limit"）
d. In the Case that Load Variation is Heavy
1.When entering or leaving port
2.When cargo is being loaded or unloaded
DE-18 A 12-03
CHAPTER
4 Operation
ITEM
Operation: Operation Using Heavy Fuel Oil
4.4 DE-18 (for Heavy Fuel Oil Engine)

B．Switching Fuel Oil Types

Heavy fuel oil is normally heated up to 80~90℃ If high-temperature parts are splashed with
in the service tank, and 100℃ or more at the the oil, a fire may occur. Take care not to
engine inlet, and the temperature difference is splash the oil when discharging air.
larger as compared with that of diesel fuel oil (non-
heated), and therefore if fuel oil is suddenly e.Confirm that the heat traces on piping and
switched between these oils, it may cause mal- equipment is properly functioning.
functions such as sticking of the fuel injection
pump, vapor lock, and so on.
The fuel oil is heated, and the filter and the
a. Slowly switch from diesel fuel oil to heavy fuel piping are at high-temperatures. If touched
oil, so that the rate of change in the fuel oil tem- with bare hands or skin, it may cause a burn.
perature at the engine inlet is between 5~10℃ Therefore, be minded not to directly touch the
per minute. exposed metallic parts such as the valves and
（ ：Fig. 4.3 "Switching Pattern from Diesel cocks, and use the protective wear such as
Fuel Oil to Heavy Fuel Oil"） safety gloves when working on them.
b. Maintain the viscosity (temperature) of heavy
fuel oil at the engine inlet at the specified value.
c. Do not raise the temperature of diesel fuel oil In case that emergency stop is made during
over the flashing point (60℃ is the standard the operation with heavy fuel oil, immediately
point). switch the heavy fuel oil to diesel fuel oil,
d. To prevent the generation of vapor, maintain operate the separate pump, and perform
the pressure of fuel oil at the specified value. flushing of the fuel oil system.
Further, remove the air bubbles in fuel oil in the If the engine is cooled down with the heavy
various equipment of the fuel oil system (heater, fuel oil left unchanged, the oil will be solidified
filter, tank, etc.) from time to time, so that the and the operation will be prohibited.
accumulation of vapor can be prevented.

Switching from Diesel Fuel Oil to Heavy Fuel Oil Switching from Heavy Fuel Oil to Diesel Fuel Oil

Viscosity at engine inlet 11~14 mm2/s Viscosity at engine inlet 11~14 mm2/s
Fuel oil temperqture

Fuel oil temperqture

Temperature of heavy fuel oil Temperature of

at engine inlet

at engine inlet

heavy fuel oil Temperature fluctuation

Temperature fluctuation of 5 to 10 oC per minute
of 5 to 10 oC per minute or less
Temperature of or less Temperature of
diesel fuel oil diesel fuel oil
operation

operation

Switching from diesel Switching from heavy

fuel oil to heavy fuel oil fuel oil to diesel fuel oil
Operation with Operation with Operation with Operation with
diesel fuel oil heavy fuel oil heavy fuel oil diesel fuel oil
Check items

Check items

Check the Check the

operation of Switch at a stable load Switch at a stable load operation of
heavy fuel oil (above the lower load limit) (above the lower load limit) heavy fuel oil
supply equipment supply equipment

Notes: 1. Since the pretreatment of fuel oil differs depending on the use purpose of the engine, the operating method suitable to
each system is necessary.
2. The diesel fuel oil temperature when switching on heated condition shall be 60K or less.

Fig. 4.3 Switching Pattern from Diesel Fuel Oil to Heavy Fuel Oil

DE-18 B 12-08

Operation
Operation: Operation Using Heavy Fuel Oil
(for Heavy Fuel Oil Engine)
C. Cleaning Operation before Engine Stop
Follow the steps below when switching fuel oil to
stop the heavy fuel oil engine or when making
operation to stop the engine:
1. Switch the fuel oil with a load as stable as possi-
ble that is equal to or larger than the low load
limit described in the engine specifications. Do
not switch the fuel oil if there is no load applied.
2. Before stopping the engine, use diesel fuel oil
for the cleaning operation. Continue the operation
with a load as high as possible that is equal to or
larger than the low load limit for as long a time as
possible that is a time longer than 30 minutes.
3. Idle the engine for about five minutes before
stopping the engine.
After stopping the engine, check the movement
of the fuel rack. If the movement is not smooth,
apply some oil to the rack. Move the rack back
and forth to confirm its smooth movement.
4. If the engine is not used for a long time, espe-
cially when you are going to dock the boat, keep
the cleaning operation for about half a day, which
removes foreign substance out of the combustion
chamber, piston ring grooves, etc. Keep the oper-
ation by applying a load as heavy as possible
(60% or more) with diesel fuel oil.
Example of Operation at Engine Stop
CHAPTER
4
ITEM
DE-18 4.4
[Objectives of cleaning operation]
After the heavy fuel oil engine is stopped, the
fuel rack may adhere to adjacent components,
causing troubles when the engine is started
some time later. While the engine is operating
with heavy fuel oil, some of the oil enters the
sliding parts on the plunger of the fuel oil injec-
tion pump and the rotating parts of the control
sleeve. The oil cools off to be sludgy when the
fuel oil is switched to diesel oil and then the
engine stops. Thus, the fuel rack adheres to
adjacent components.
When you take sufficient time to continue load
operation with diesel fuel oil, the oil having
entered adjacent components is gradually
washed away by the diesel fuel oil, preventing
the fuel rack from adhering to adjacent compo-
nents.
4
DE-18 Z 12-08
CHAPTER
4 Operation
ITEM

5.1 DE-18 Special Operation: Low-load Operation

4-5 Special Operation

D. Intermittent High Load Operation
4-5.1 Low-load Operation (Power
During continuous low-load operation, operate
Generator Specifications)
the engine at the highest load possible (60% or
Since running the engine with a low-load lower more) for about 30 min. This is effective in prevent-
than a certain limit can lead to unfavorable com- ing fouling in the combustion chamber and the air
bustion conditions such as the reduction of intake intake and exhaust systems.
air pressure and blowing-back of exhaust air, if the
engine is operated under such conditions for long
hours, it may result in the various malfunctions
such as fouling of the turbocharger and combus-
tion chamber, faulty combustion and so on.
Therefore, be sure to minimize the low-load
operation to a shorter period of time as much as
possible, and in case that the engine must be
inevitably run under a low-load for long hours, be
sure to observe the following conditions:

A. Low-load Limit
The low-load limit varies depending on each
specification. Confirm the low load limit described
on the specification supplied with the engine.

B. Use of Diesel Fuel Oil

In case of the heavy fuel oil type, be sure to
switch to diesel fuel oil if operation is conducted
below the load limit given in Item A.

C. Cleaning of Turbocharger
Properly increase the number of times of clean-
ing the compressor of the turbocharger according
to necessity.

The turbocharger is at a high-temperature

during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.

DE-18 B 14-03
 CHAPTER
Operation 4
ITEM
Special Operation: Allowable Operating Range DE-18 5.2

4-5.2 Allowable Operating Range When hull pollution spreads and resistance
(for Main Engine) increases exceeding the sea margin, absorption
horse power increases even when the rotation
For the main engine, the load changes with the
speed is the same, causing a torque-rich phenome-
rotation speed in conformity with the marine char-
non. So make sure to use care on the rotation speed
acteristics. Allowable operating range and recom-
and rack scale to avoid causing torque rich problem.
mended operating range regarding marine charac-
teristics are shown in the figure below. For actual Also, when propeller absorption horse power
operation, appropriate rotation speed and engine changes rapidly due to foul weather, particular
torque (judged by Pme and rack scale) shall be care must be exercised as it tends to become
selected and operation shall be conducted within torque-rich, triggering surge in turbocharger.
the recommended operating range as much as
possible to avoid overload. (2) Variable Pitch Propeller (CPP)
For variable pitch propeller, absorption horse
To add, the low-load limit at the time heavy oil is
power can be changed by changing the propeller
used shall be 30% for normal cases and if the load
pitch with the engine rotation speed at constant.
is less than 30%, then diesel fuel oil shall be used.
Therefore, it is advantageous, as rotation speed
For the output characteristics of actual equip-
and load are adjustable in accordance with the
ment, please refer to the "Engine Test Run Record
Table" in the final documents.
conditions of other auxiliaries of the main engine 4
drive as well as ship resistance.
However, large freedom degree means that it
(1) Fixed Pitch Propeller (FPP)
has a tendency to become torque rich in operation.
Fixed pitch propeller is designed with the sea
Always grasp the load conditions and perform
margin added, taking into account the absorption
operation appropriately so as not to cause torque-
horse power, based on the marine characteristics
rich phenomenon.
and pollution of hull.

DE-18 Z 12-01
CHAPTER
4 Operation
ITEM
Special Operation: Non-turbocharger Operation
5.3,5.4 DE-18 / Operation with Reduced Number of Cylinders
4-5.3 Non-turbocharger Operation
For the main engine, non-turbocharger operation
tools (turbocharger blind patch) are provided in
order that temporary operation can be performed
even if turbocharger is damaged. (Power genera-
tion engine is optionally available.)
The operating procedure is as follows:
<Preparation for Operation>
Install non-turbocharger operation tools in accor-
dance with the turbocharger operation manual.
Turbocharger is at a high temperature dur-
ing operation or immediately after the engine
is stopped. Touching the turbocharger with
your bare hands or exposing your bare skin to
it may cause burns.
Make sure to allow enough time to let it cool
down before performing disassembly.
If you must remove it before it is cooled
down out of necessity, make sure to wear
safety gloves and engage in work paying
attention not to get burnt.
<Operating Conditions>
a) Diesel fuel oil shall be used.
b) Output shall roughly be as follows, and be kept
as low as possible.
● Pme (average effective pressure): 0.44 MPa
● Exhaust temperature (each cylinder outlet):
450℃ or less
DE-18 Z 12-01
4-5.4 Operation with Reduced Number
of Cylinders
Operating with reduced number of cylinders
would cause problems in the torsional vibration of
shafting and external vibration of engine. Thus, its
use is limited to a short-time, only as an emer-
gency measure.
Operating with reduced number of cylinders
occurs in various cases, such as when cutting off
only the fuel oil or when it is necessary to remove
the operating part. Prohibitions concerning opera-
tion differ according to each case. If you are per-
forming operation with reduced number of cylin-
ders, make sure to contact our office and receive
instructions on the work procedure and matters to
attend to in operating the engine. Also, make sure
to follow the instructions.
<Operating Conditions>
a) Use diesel fuel oil.
b) Output
(Total number of cylinders) - (Number of cylinders out of use)
Ｘ70％
(Total number of cylinders)
The output may decrease depending on surging
of the turbocharger or the exhaust temperature.
c) Exhaust temperature (each cylinder outlet):
450℃ or less
Pay attention to external vibration and gear
sound. If you feel any abnormality, stop the
engine immediately. Continuing operation with-
out doing anything may lead to a big accident.
 CHAPTER
Operation 4
ITEM
Stop: Normal Stop DE-18 6.1

4-6. Stop C. After Stop

a. Operate both the lubricating oil priming pump
4-6.1 Normal Stop
and cooling fresh water pump for about 20 min-
A. Precautions for Stop
utes, and cool down the engine and turbocharger.
a. In the case that heavy fuel oil is used, switch the
Normally, the system is designed so the priming
fuel oil to diesel fuel oil 30 minutes before stop-
pump operates at the same time the engine
ping the engine.
stops.
b. Immediately before stopping the engine, start
the operation of lubricating oil priming pump.
c. Confirm that the starting air pressure is at 2.0
The turbocharger continues to run at high
MPa or more.
speed even after the engine is stopped.
(The preparation for the next round of starting)
Lubrication of the turbocharger provided
with this engine is made using the system oil,
B. Stop and therefore if the supply of lubricating oil is
a. Conduct the stop operation on the following pro- stopped immediately after the engine is
cedures: stopped, it may damage the bearing.

[For local operation]

(1) Shift the operation lever to "STOP" position.
(2) Then, fuel oil injection will be shut off by
means of the common rod, and the engine will
be stopped.
b. Fully open the indicator valve to conduct air run-
ning for 3~4 seconds and exhaust the combus-
4
tion gas out of the combustion chamber.
c. Close the valves on all the systems.

[For remote control]

(1) Press the "STOP" button on the control panel.
Then, the fuel shutdown solenoid valve is
activated to operate the fuel shutdown device,
and the engine is stopped.
(2) Shift the operation lever to the "STOP" position.

b. After stop operation, be attentive of any abnor-

mal sound in the engine and turbocharger, and
confirm that there is not any abnormal sound.

In case that the engine does not stop even

when the stop operation is conducted, forcibly
stop the engine in the following procedure:
(1) Forcibly set the rack of the fuel injection
pump at "0".
(2) Fully close the valve of the fuel oil inlet main
pipe.

DE-18 A 12-08
CHAPTER
4 Operation
ITEM
6.2 DE-18 Stop: Emergency Stop
4-6.2 Emergency Stop
A．When Emergency Stop is Required
Immediately stop the engine when any of the fol-
lowing abnormalities is found:
1. Announcement of "Emergency" or "Alarm"
(＊Activation of the protective device →
Automatic stops)
＊● Overspeed
＊● Decrease of lubricating oil pressure
＊● Suspension of water supply/increase of
cooling water temperature
● Increase of exhaust air temperature
● Other alarming (depending on each speci-
fication)
2. Abnormal sound and abnormal vibration
3. Heating of the bearings or other moving sec-
tions, 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
injection pump, link pin, or bolt.
5. Deterioration of fuel oil or lubricating oil, or
damage of the cooling water pipe.
6. Abrupt increase or decrease of rotation speed.
7. Abrupt increase of lubricating oil temperature
8. Water supply disability due to suspension of
cooling water supply
In case that the engine is overheated due to
suspension of water supply, do not hastily
supply cooling water.
If cooled down abruptly, each part of the
engine may be deformed, resulting in malfunc-
tion or accidents.
9. Mixing of water into lubricating oil
10. Abrupt increase of exhaust air temperature
11. Abrupt decrease of the turbocharger rotation
speed or intake air pressure
12. Breakage or loosening of the bolts of each section.
DE-18 Z 12-01
B．Measures after Emergency Stop
In case that the engine is automatically stopped
by activation of the protective device or stopped
manually, take the following measures:
a．In case that the engine is stopped by remote
operation or stopped automatically, set the opera-
tion lever to the "STOP" position after the engine
is stopped.
b．In case that the operation had been made
using heavy fuel oil, immediately switch the fuel
oil to diesel fuel oil, operate the motor-driven oil
feed pump, and conduct flushing of the fuel oil
system (However, this procedure does not apply
when the fuel oil pipe is broken.)
Further, conduct turning of the engine, and
exhaust the heavy fuel oil remaining in the fuel
injection pump or fuel valve.
In case that the engine is stopped during
the operation using heavy fuel oil and the
engine is cooled down without changing the
fuel oil, heavy fuel oil in the equipment of the
fuel oil system (e.g. pump, filter, etc.) and pip-
ing not only solidify to prohibit starting, but
also incur substantial labor to clean and
cleanse after the accident.
c．Disconnect the load off the engine, and return
the operation lever, each valve, and the state of
all other equipment to the "STOP" position.
In case that the emergency stop is conduct-
ed, be minded not to restart the engine until
the cause is determined, the countermeasures
are taken, and recovery is completed.
In case that the engine is started without
removing the cause of the abnormality, the
malfunction may be aggravated and serious
accidents may be caused.
 CHAPTER
Operation 4
ITEM
Stop: Emergency Stop / Long-term Shutdown DE-18 6.2,6.3

c. Open each cover of the crank cam case, and

Be minded not to open the crankcase for at
least 10 minutes after engine is stopped and
is completely cooled down. If the crankcase is
opened immediately after the engine is
stopped, flammable mist in the crankcase may
catch fire and explode.
Particularly be careful when a large amount
of mist is generated due to overheat or seizing
of the engine.
Be minded never to let flames or sparks
approach the crankcase even after it is over-
hauled.
the cylinder head, and spray rust-preventive oil to
the internal parts.
d. Insert the moisture-proof agent such as silica
gel into the crankcase, according to the ambient
air conditions (e.g. weather and humidity) if
required.
e. Place the cover on the outside air opening sec-
tion of the exhaust air pipe and the mist pipe.
f. Cover the engine with a sheet, and carefully
cover the electric equipment with particular atten-
tion to prevent collection of dust on them.

4-6.3 Long-term Shutdown

In the case that the operation of engine is sus-
pended for a long term (one month or more), take 4
the preservation measures (mainly, anti-rusting
measures) in the following procedures:

A. Shutdown within 3 Months

a. Fully open the indicator valve once every week,
and conduct turning of the crankshaft several
times while conducting priming with lubricating oil.
In this case, stop the crankshaft at a position
different from that before turning. After turning,
securely close the indicator valve.
b. In the case that there measures a risk of freez-
ing in extremely cold season, be minded to
remove cooling water from the engine.

B. Shutdown over 3 Months ... Measures for

Long-term Storage
In the case that the operation of engine is sus-
pended for 3 months or more, the following meas-
ures 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
crankshaft several times while conducting priming
with the lubricating oil.
After turning, securely close the indicator valve.

DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM

1.1 DE-18 Precautions for Inspection and Maintenance: Safety Precautions

5. Inspection and Maintenance

5-1. Precautions for Inspection and Maintenance

When conducting the inspection and maintenance works of engine, be minded to read this
manual carefully, understand the structure of the related parts and the work contents, carefully
examine the working procedures, and prepare the consumable parts and tools in advance,
before starting these works.
If the works are conducted without previous and sufficient examinations, it not only leads to
the expense of useless labors, but also results in failure or damage of the engine due to mistak-
en assembling, and further in personal accidents. Be sure to replace all the damaged parts, or
the parts that reached replacement limit, both of which were so found after the results of inspec-
tions.
If it is difficult to replace these parts at the site, or if necessary parts are not ready for use,
please contact our Service Department or the nearest DAIHATSU's branch office and receive
instructions for appropriate measures to take.

5-1.1 Safety Precautions

A. Do not open the crankcase side cover for at least 10 minutes after the engine is stopped and is
completely cooled down. While the engine is overheated, there is a danger that oil mist may catch
fire and explode if new air is flowed into the crankcase when it is opened.
B. If the engine is rotated during disassembly or inspection works, it may impose serious dangers
such as caught-up accidents and so on.
Be minded to start these works, after returning the operating lever to the "STOP" position, secure-
ly closing the starting air valve, and confirming that the engine is not running.
When conducting the turning of engine, be minded to start it after confirming that nothing is in con-
tact with the rotational parts, and no danger is imposed on coworkers by the rotation of engine, and
after sending the signal to them.
Perform proper preventive measures to prevent the crankshaft from freely turning.
C. Be minded to use the protective wears such as safety glove, helmet, safety shoes, safety goggles,
according to the circumstances.
During the operation of engine and immediately after stopping the engine, the engine parts, partic-
ularly exhaust manifold, turbocharger, indicator valve, parts round the cylinder are extremely hot.
Therefore, be sure to wear safety gloves, and proceed the works taking care not to incur burns.
The engine room floors and the surrounding areas are slippery due to oils stuck on them.
Therefore, be minded to start the works after sufficiently wiping off the oils stuck on floors or shoe
soles. Particularly when working on high-rise places such as foot-step board, pay enough attentions
to the periphery of your feet, so that falling-off accidents should not happen.
D. When disassembling the piping systems, "Close" all the valves of the external connection parts,
gradually release the air vent plug, and start the disassembly after removing residual pressure.
Immediately after stopping engine, when disassembling the filters and connection parts of piping
systems, you may burn on your skin due to an injected high temperature oil or water of residual
pressure. If high temperature parts are splashed with the fuel oil or the lubricating oil, a fire may
occur. Take utmost care when disassembling them.

DE-18 Z 12-01
 CHAPTER
Inspection and Maintenance 5
Precautions for Inspection and Maintenance: ITEM

Safety Precautions / Inspection and Maintenance DE-18 1.1, 1.2

E. 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.
F. 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.
G. When handling the electric parts, be sure to cut off the power source.

H. When handling the liquids, be minded to strictly observe the following items:
● Fuel oil, lubricating oil = Flammable --- Use of fire is strictly prohibited.
● Rust-preventive agent for fresh water, anti-freeze solution for fresh water and mercury (thermome-
ter) = Poisonous --- Drinking is prohibited and cleaning when adhered.
● Battery liquid = Poisonous and flammable gas generation --- Drinking is prohibited, cleaned when
adhered and use of fire is strictly prohibited.
◎ 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

A. Restore the lagging or heat-preventive covers, combustible oil splash preventive means (splash-
proof tape) and protective covers, which were removed for inspection and maintenance, to each
original position. 5
B. After the completion of assembling, confirm that there is no abnormality in each part, by conducting
the turning of engines and the priming with each corresponding oil. After checking the parts during
turning, close the indicator valve without fail.
C. After the completion of working, return the turning equipment and turning bar used to the "OFF"
position.
D. Record the work contents of the inspection and maintenance and the replaced parts in the daily
report respectively.

DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM

2 DE-18 Inspection and Maintenance Table

5-2. Inspection and Maintenance Table
This table shows the inspection and maintenance work items (basically, those to be performed within 6
months). As for the work items concerning the full-scale open and maintenance after the long-term opera-
tion, refer to the corresponding sections of "Maintenance" version, which is separately provided.
（○：Normal, ▲：Initial operation and 1st operation after overhaul, ●：Initial operation after installation,
overhaul, and maintenance, ◎：Replacement）

compressor

DE-18 A 14-03

Inspection and Maintenance
Measurement and Adjustment: Exhaust Air Temperature
/ Pressure and Temperature of Each Part
5-3. Measurement and Adjustment
5-3.1 Exhaust Air Temperature
The exhaust air temperature is a critical index
for indication of the engine combustion conditions
and changes over time.
Normally, degradation of the engine perform-
ance is indicated as a rise in the exhaust air tem-
perature.
Measure and record the temperature everyday
to reveal a tendency of degradation. Use such
records to determine the interval of servicing.
A. Exhaust Air Temperature
The exhaust air temperature at each cylinder
outlet slightly varies from one cylinder to another
depending on the factors such as the effect of
other cylinders as well as the distance to the tur-
bocharger inlet.
The exhaust air temperature can be adjusted by
increasing or decreasing the fuel injection pump
rack, however, the adjustment is ordinarily unnec-
essary as long as the difference between cylinders
is within the following value.
＊Difference between cylinders: 40℃ or less
B. Adjustment of Amount of Fuel Oil Injection
Pump Rack
In the case that the exhaust temperature differs
from those of other cylinders in excess of the
range specified in the above A., for example, when
the fuel oil injection plunger or the fuel injection
valve nozzle is replaced, adjust the fuel oil injec-
tion amount by increasing or decreasing the read-
ing on the rack scale.
CHAPTER
5
ITEM
DE-18 3.1, 3.2
<Rack Adjusting Procedure>
The reading on the rack scale can be increased
or decreased by the adjusting screw (A) of the fuel
injection pump rack lever.
(1) Loosen the lock nut (B)
(2) Turn the adjusting screw A and change the
reading on the rack scale.
●Clockwise turning → "Increase"
(Increase of exhaust air temperature)
● Counterclockwise turning → "Decrease"
(Decrease of exhaust air temperature)
(3) Confirm that the exhaust air temperature is
within the specified value.
(4) Securely tighten the lock nut.
＊Difference between cylinders: 1.5 mm or less
5
5-3.2 Pressure and Temperature of
Each Part
The pressure and temperature of lubricating oil,
fuel oil, and cooling water, etc. are controlled by
the relief valve and the thermostat valve, so that
they should be proper values being within each
specified value during the operation of engine,
however, when actually operating the engine, the
pressure and temperature of these fluids may not
be within the specified and proper values.
In such a case, readjust the setting values of the
valves, and perform the operation within the
specified proper range.
DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM
Measurement and Adjustment:
3.2 DE-18 Pressure and Temperature of Each Part

A．Intake Air Pressure
Since the intake air pressure changes in accor-
dance with load, each pressure when the engine
was new (or, after adjustment) becomes a refer-
ence value.
The more the compressor of the turbocharger is
fouled, the more the intake air will decrease,
resulting in the deterioration of the engine perform-
ance (e.g. increase of the exhaust air temperature
and increase of the fuel consumption rate), and
therefore regularly conduct the compressor clean-
ing and prevent the progress of fouling.
（ ：5-4.4 "Cleaning Turbocharger Compressor"）
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.
It is impossible to completely remove the
fouls even when cleansing by compressor
cleaning, and to prevent the deterioration of
engine performance by the elapse of time.
However, if the cleaning is neglected, fouling
will accelerate, resulting in worsening of the
engine performance, and as the result it will
be required to disassemble and clean the tur-
bocharger much earlier than when the clean-
ing is periodically conducted.
When the intake air temperature is too low, it
causes abnormal or excessive wear of the cylinder
liner, intake air valve, etc., since the water drops is
formed by the dew condensation.
Further, if the intake air temperature is too high,
it damages the parts around the combustion cham-
ber such as the exhaust valve, since the exhaust
air temperature increases. (Exhaust air tempera-
ture varies in proportion to the intake air tempera-
ture, and also varies in the rate of approximately 2
times the change of the suction air temperature of
the turbocharger.)
It is systematically designed, in case the engine
load is below the specified load, to automatically
activate the cooling water bypass, to let water in
the low temperature line to bypass so the air sup-
ply temperature can be increased to improve com-
bustion at the time of low load.
If the intake air temperature gets out of the prop-
er range owing to a low room temperature, or
when automatic adjustment of intake air tempera-
ture cannot be made for some reasons, operate
the following procedure.
<Intake Air Adjusting Procedure>
The intake air adjustment can be made by chang-
ing the cooling water flow rate in the air cooler.
(1) Turn the adjusting screw (B) of the cooling
water bypass valve clockwise.
(2) Be attentive to changes in the intake air tem-
perature, and adjust the adjusting screw feed
so as to be within the proper range.

B．Intake Air Temperature

Do not screw in the adjusting screw 12 mm

＊Proper temperature: 45~55℃ (at rated output)
or more. The bypass valve is seated.

Intake air, that is either higher or lower than the

specified range, will affect the engine, and there-
fore be minded to adjust and keep the temperature
to be within the specified proper range, as far as
possible.

DE-18 A 14-03
 CHAPTER
Inspection and Maintenance 5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DE-18 3.2

In the case that the intake air does not fall within
the proper range even when the entire amount of
cooling water is flowed into the air cooler, it is
required to disassemble and adjust the air cooler
since the fouling of the air cooler can be consid-
ered.
( :12-3 "Air Cooler" in "Maintenance Manual")
C．Lubricating Oil Pressure
<Lubricating Oil Pressure Adjusting
Procedure>
When adjusting the lubricating oil pressure, use
the adjusting screw on the lubricating oil relief
valve.
(1) Remove the hexagon cap nut (A) and loosen
the nut (B).
(2) Turn the adjusting screw (C), and adjust the
pressure.
● Clockwise turning (tightening)
→ Increase of pressure
● Counterclockwise turning (loosening)
→ Decrease of pressure
(3) Be attentive to changes in the pressure, and
confirm that the pressure entered within the
blue mark range.
(4) Tighten the lock nut (B) and attach the hexa-
gon cap nut (A).

＊Proper range (blue mark range on manometer)

0.4~0.5 MPa

Lubricating oil pressure changes in accordance

In the case that the lubricating pressure
does not change even when the adjustment
5
with the changes in the viscosity and temperature screw is turned, there is the possibilities of
of lubricating oil. sticking of relief valve, suction of air, pump
When the engine is started in extremely cold failure, and so on, and therefore investigate
weather, and the temperature of the lubricating oil the causes of the trouble.
is still low and the viscosity is high, the pressure
reading may go up beyond the blue mark range,
however, it does not impose any problem if the
reading falls back within the blue mark range when
the engine is warmed up.
In the case that the pressure reading is above or
under the blue mark range, adjust the pressure in
the following procedure:

Lubricating oil pressure decreases when the

filter is fouled. Be sure to perform the adjust-
ment of pressure after the filter is cleaned
well.
（ ：5-4.3 "Cleaning Filters"）

DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM
Measurement and Adjustment:
3.2 DE-18 Pressure and Temperature of Each Part

D. Lubricating Oil Temperature <Adjusting Procedure>

Turn the adjusting screw (C) to adjust the
＊Proper range: 55~65℃ (cooler outlet) temperature.
● Turn clockwise (tighten)
Lubricating oil temperature is controlled to → The temperature rises.
remain within the proper range of temperature by
● Turn counterclockwise (loosen)
the relief valve installed at the lubricating oil cooler
→ The temperature drops.
outlet.
(1) Fully loosen the adjusting screw (C).
a. Lubricating Oil Thermostat Valve
→ The cooler passage fully closed.
The thermostat valve is an automatic bypass
(2) Observe the changes in the oil temperature
valve, that changes the flow rate of lubricating oil
while tightening the adjusting screw, and set
passing through the cooler according to its temper-
the lock nut when the temperature comes into
ature, and when the engine is started while it is still
the following range.
in the cold state, this valve rapidly raises the lubri-
cating oil temperature by letting the oil bypass
Do not screw in the adjusting screw 8 mm
through the cooler, and when the engine is operat-
or more.
ed normally, this valve maintains the lubricating oil
temperature within the suitable range of the speci-
fied value.
In the case that the lubricating oil temperature
does not fall within the proper range, for example,
because the cooling water temperature (low tem-
perature) is different from the design temperature,
the temperature of lubricating oil can be adjusted
by the adjusting screw of the thermostat valve.
However, in case that the actual temperature is
exceeding the correctable range (approximately
5℃) and the adjustment is impossible, contact us
for consultation on the problem.

b. Manual Adjustment-Emergency Measures

In the case that the thermostat valve fails and
the temperature control becomes impossible, the
＊ Use range: 30~65℃
engine can continuously be operated by perform-
Since the oil temperature changes accord-
ing the emergency measures in the following pro-
ing to the load, be minded to set the oil tem-
cedure.
perature at a rather lower level, so that it does
not exceed the limit when heavily loaded.

DE-18 Z 12-01
 CHAPTER
Inspection and Maintenance 5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DE-18 3.2

E. Cooling Water Pressure

Cooling water
＊Proper range: 0.15~0.35 MPa thermostat
valve case

Jacket cooling water pressure substantially

changes depending on the external conditions
such as the cooling water expansion tank head,
pipe resistance, and so on.
When cooling water pressure is too low, it will
cause cavitation corrosion of the engine frame or
cylinder liner, and therefore adjust the cooling
water pressure at the engine outlet using the ori-
fice, so that the pressure should be proper during
the operation of engine.

F. Cooling Water Temperature (Jacket Line)

<Fuel Oil Pressure Adjusting Procedure>
Adjustment of fuel oil pressure can be made by
＊Proper range: 70~80℃ (engine outlet)
the pressure adjusting screw of the fuel oil relief
valve.
a. Warming-up Operation
(1) Remove the screw cap (A) of the relief valve,
When jacket cooling water temperature is too
low, it causes faulty combustion or the corrosion or
and loosen the lock nut (B). 5
wear of the parts around the combustion chamber, (2) Turn the adjusting screw (C), and adjust the
and therefore be minded to start the operation of pressure.
engine with load after raising the cooling water ● Clockwise turning (tightening)
temperature by warming-up operation. → Increase of pressure
（ ：4-4.2 "Warming-up Operation"） ● Counterclockwise turning (loosening)
→ Decrease of pressure
b. Temperature Control
(3) Be attentive to changes in the pressure, and
The cooling water temperature is controlled
confirm that the pressure reading is within the
appropriately by the thermostat valve at the jacket
proper range.
cooling water outlet.
(4) Tighten the lock nut (B), and attach the screw
G. Fuel Oil Pressure cap (A).
a. Engine Using Heavy Fuel Oil
When using heavy fuel oil, the pressure of heavy
fuel oil must be adjusted to be within the following
range, so that generation of vapor due to heating-
up of the fuel oil can be prevented.

＊Proper range: 0.5~1.0 MPa

DE-18 A 12-03
CHAPTER
5 Inspection and Maintenance
ITEM
Measurement and Adjustment:
3.2 DE-18 Pressure and Temperature of Each Part
b. Engine Using Diesel Fuel Oil
＊Proper range: 0.2~0.3 MPa
In the case of diesel fuel oil, the pressure adjust-
ment procedure is the same as in the case of
heavy fuel oil specification, since the same type of
the fuel relief valve is used in both cases.
DE-18 A 12-08
H. Fuel Oil Temperature ... When Using Heavy
Fuel Oil
Heavy fuel oil must be heated so as to make its
viscosity suitable for injection, before the oil is
supplied to the engine.
＊Proper viscosity (engine inlet) dynam-
ic viscosity: 11~14 mm2/s
Since the temperature appropriate for proper
viscosity varies depending on the properties (vis-
cosity) of heavy fuel oil, be minded to keep the
proper viscosity referring to the following figure as
a standard:
（ ：Fig. 6-1.2 "Fuel Oil Viscosity
/Temperature Curve"）
In the case that the viscontroller (automatic vis-
cosity regulator) is installed to the engine, control
the fuel oil viscosity in accordance with instruction
manual, and be minded to carefully keep the man-
ual.(Refer to the following pages)
（ ：4-4.4 "Operation Using Heavy Fuel Oil"）
（ ：6.1 "Fuel Oil Control"）
Heated fuel oil is extremely hot. Touching it
or metallic parts of the oil carrying equipment
with bare hands or skin can cause burns.
Be sure to wear protective gear such as
safety gloves when handling oil or the oil car-
rying equipment.

Inspection and Maintenance
Measurement and Adjustment:
Maximum Combustion Pressure
5-3.3 Maximum Combustion Pressure
Maximum combustion pressure and exhaust
temperature serve as the important indicators for
knowing the engine combustion conditions and the
changes according to the elapse of time.
Normally, the decrease of the engine perform-
ance can be indicated by the following items.
●Decrease of the maximum combustion pressure
●Increase of the exhaust temperature
Conduct the measurement with the interval of
once a week or so, and record the results, so that
the tendency of the change can be identified and
the data can be used as the judgment materials
when determining the interval of the adjustment.
A. Maximum Combustion Pressure (hereinafter
referred to as Pmax)
a) Pmax
Pmax is determined by load, and varies depend-
ing on the factors such as the fuel oil viscosity,
intake air pressure, and intake air temperature.
Ordinarily, however, this adjustment is not neces-
sary.
Pmax varies according to the initial fuel injection
pumping angle, however, it is readily adjusted and
set at an optimum value at the time of shipment
from our factory.
Since the items mentioned in this section
will be the items to which the engine setting
value specified in NOx technical code shall be
applied, do not make any change that may
deviate from the setting value.
（ ：0-3 "Engine Conforming to NOx
Technical Code"）
CHAPTER
5
ITEM
DE-18 3.3
Since the indicator valve is extremely hot
during the operation of engine, there is a dan-
ger of burns if it is touched by bare hands.
Therefore, be sure to wear safety gloves
when handling the valve.
After the measurement is completed, make
sure to attach a heat shield cover over the
indicator valve.
Be sure to "Fully open" or "Fully close" both
the indicator valve and the exhaust valves are
used.
If these valves are used on the "Half-open"
state, high-temperature gas will flow into the
threaded parts of the valve, and the screws
may be seized.
b) Measuring Pmax
Perform the measurement of Pmax after the
warming-up operation of engine has been complet-
5
ed and the load has become stable.
During measurement, the measured values may
change due to such factors as the occurrence of
the load fluctuation. In such a case, perform the
measurement again to obtain a stable data.
（ ："Test Run Record" included in the final
documents）
DE-18 A 12-03
CHAPTER
5 Inspection and Maintenance
ITEM
Measurement and Adjustment:
3.3 DE-18 Maximum Combustion Pressure

<Measuring Procedure>
i) Open the indicator valve with a special wrench
for indicator valve before installing the indica-
tor, and close the indicator valve after lightly
releasing it 1~2 times.
ii) Install the indicator to the indicator catch, and
securely lock it by turning the lock nut.
iii) Close the exhaust valve of the indicator.
iv) Open the indicator valve.
v) Check the reading of the pressure on the indi-
cator.
vi) Close the indicator.
vii) Open the exhaust valve of the indicator, and
remove the indicator after indicating reading
has become "O".
viii) Attach a heat shield cover over the indicator
valve.

＊Maximum value (when fully loaded):

20 MPa or less

DE-18 A 12-03
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance: Inspecting Parts around Intake and
Exhaust Valves, and Adjusting Valve End Clearance DE-18 4.1

5-4．Inspection and Maintenance C. Adjusting Valve End Clearance

Since valve end clearance decreases due to the
5-4.1 Inspecting Parts around Intake
wear of the valve seat part, and therefore be mind-
and Exhaust Valves, and ed to periodically inspect and adjust it.
Adjusting Valve End Clearance
When the valve end clearance is too small, it
A. Replacing Consumables, Implements and
causes improper setting of the valve on its seat
Measuring Instruments
during the operation of engine due to thermal
a. Replacing Consumables （ "Parts List"） expansion of the valve itself and push rod, result-
1. Seal (cylinder head cover) 2-15 No.2 ing in burning of the seat.
b. Implements and Measuring Instruments Further, the valve system of this engine is 4-
1. General tools valve type, having 2 intake valves and 2 exhaust
valves, and a single valve retaining tee is provided
( ："Implements List" in the final documents)
to simultaneously push down both pairs of intake
and exhaust valves, and therefore unless the valve
B. Inspecting Parts around Intake and Exhaust
end clearance of each pair of both intake and
Valves
exhaust valves is equal, the valve pushing force is
Both intake and exhaust valves are the parts
unbalanced, resulting in abnormal wear or damage
that are exposed to the most severe conditions
of the valve retaining tee and the guide parts.
among all other parts of the engine. Therefore, be
minded to periodically inspect these valves, and
confirm that both valves operate normally.
a. Confirm that there are no abnormal operating
sounds in both the intake and exhaust valves
5
during the operation of engine.
b. Check the following points on these valves
before removing the cylinder head cover when
the engine is stopped.
1. Lubricating conditions of the rocker arm and
push rods
2. Lubricating and sludge collecting conditions of
the intake and exhaust valve cotters, and valve
rotators
3. Sludge collecting conditions around the valve
spring
4. Rotating conditions of the valve rotators <Valve End Clearance Adjusting Procedure>

5. Valve end clearance (1) Place the cylinder in the explosion stroke, and
close the intake and exhaust valves.
(2) Loosen the lock nuts of the adjusting screws
(A) and (B), and turn back the adjusting screws
(A) and (B).

DE-18 A 12-03
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance: Inspecting Parts around Intake and
4.1 DE-18 Exhaust Valves, and Adjusting Valve End Clearance

(3) Bring the valve end "A" into close contact with
the valve retainer tee, fit a dial gauge to the
valve retainer tee, and tighten the adjusting
screw (A) until the pointer swings. Make sure
that the valve ends "A" and "B" simultaneously
get into contact with the valve retainer tee.
(4) Engage a spanner around the hexagonal
head of the adjusting screw (A), and tighten the
lock nut while paying attention so that the
screw and nut do not slip and turn.
(5) Insert a thickness gauge of the specified thick-
ness into the clearance "C" on the top part of
the valve retaining tee, and adjust the clear-
ance using the adjusting screw (B).

＊Proper clearance : 0.3 mm

(for both intake and exhaust valves)

DE-18 A 12-03
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance:
Inspecting and Maintenance of Fuel Oil Injection Valve DE-18 4.2

5-4.2 Inspecting and Maintenance of

Fuel Oil Injection Valve
Fuel oil high-pressure
Since the conditions of the fuel injection valve block (B)
substantially affect the performance of engine
operation, be minded to periodically inspect it and
conduct the maintenance. However, in the case
Fuel injection
that remarkable changes were found in the maxi- valve (A)
mum combustion pressure, exhaust temperature,
exhaust color, and so on, be minded to conduct Nozzle holder
guide Fuel oil
immediate inspection and maintenance, regardless injection pump
Circular
of the standard inspection and maintenance peri- packing (G)
od.

Since the items mentioned in this section Fuel oil

are the parts to which engine setting value high-pressure
joint (3)
specified in NOx Technical Code shall be con-
firmed, be sure to carry out no change deviat- Fuel oil
high-pressure
ed from the setting values. flange (2) Fuel oil
( ：0-3 "Engine Conforming to NOx injection pump
Technical Code"）

A. Replacing Consumables, Implements, and 5

Measuring Instruments
a. Replacing Consumables

（ ："Parts List"）
1. O-ring 2-24.1 No.11
2. O-ring 2-24.1 No.14
3. O-ring 2-24.1 No.502
4. O-ring 2-24.1 No.503
5. O-ring 2-24.1 No.505
6. Gasket 2-24.1 No.506
b. Implements and Measuring Instruments
1. General tools and measuring instruments

( ：Final documents)
2. Fuel oil injection valve extracting tool

( ：3-1.2 in Maintenance Manual）

3. Fuel oil injection testing device
4. Nozzle cleaning implement

DE-18 A 12-03
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance:
4.2 DE-18 Inspecting and Maintenance of Fuel Oil Injection Valve

B. Extracting Fuel Oil Injection Valve C. Injection Test

Extraction of the fuel oil injection valve can be Conduct the injection test of the fuel injection
conducted in the following procedure: valve, to check if the opening pressure and the
spraying conditions of the fuel oil injection valve
<Extracting Procedure> are in the proper and normal state.
(1) Remove the cylinder head cover and heat box Conduct the fuel injection test using the injection
cover. test device installed to the engine.
(2) Loosen the bolts (E) and (F), and remove the
a. Inspecting Valve Opening Pressure
fuel high-pressure block (B).
(1) Install the fuel oil injection valve on the injec-
(3) Remove the inlet connector (C).
tion test device, after removing the carbon
(4) Remove the tightening nut (D) using a box
stuck on the tip of the injection valve, and
wrench.
cleaning the tip of the injection valve.
(5) Extract the fuel oil injection valve (A) using a
(2) Connect the test pump and the fuel oil injec-
fuel oil injection extracting implement.
tion valve with a high-pressure pipe for testing.
(6) Loosen the circular packing (G).
(3) Quickly operate the test pump lever several
times, and drain the air until the valve starts
injection of the fuel oil as the manometer scale
1) Be careful so that the circular packing (G)
swings.
may not be left behind in the cylinder head.
(4) Slowly turn the test pump lever (once every
2) After removing the fuel oil high-pressure
second, or so), check the pressure reading (the
block and the fuel oil injection valve, be
pressure, that increased gradually, suddenly
minded to place the cover both on the cou-
starting to decrease due to opening of the
pling part of the fuel oil injection pump and
valve).
the insertion part of the cylinder head to
prevent foreign matter from entering them.
＊Normal pressure: 32.5~33.5 MPa

(b)-(1) b．Adjusting Valve Opening Pressure

When reassembling the fuel injection valve after
conducting the maintenance work by extracting the
(b)-(3) valve out of the engine, and when the nozzle is
replaced with a new one, adjust the valve pressure
(b)-(2) in the following procedure.
(b)-(4)

<Valve Opening Pressure Adjustment

Procedure>
(1) Remove the cap nut (A).
(2) Loosen the lock nut (J) for the adjusting screw
(I).

Fuel Injection Valve Extracting Procedure

DE-18 B 12-11
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance:
Inspecting and Maintenance of Fuel Oil Injection Valve DE-18 4.2

(3) Adjust the pressure to the specified pressure

by turning the adjusting screw using a screw-
driver, while conducting the injection of the fuel
oil, as in the same procedure as in the case of
the fuel oil injection test.
●Screwing-in adjusting screw → High
●Turning-back adjusting screw → Low
(4) Tighten the lock nut (J).

Be minded to set the pressure of the fuel

injection valve at a rather higher level, taking
into consideration the initial conformity, in the
case that a new injection valve is introduced.
34~35 MPa

c. Inspecting Fuel Oil Injection

Inspect the fuel oil injecting conditions on the fol-
lowing procedure:
(1) Quickly operate the test pump lever several
times (2~3 times every second), and inspect
the fuel oil injecting conditions. (Let the fuel oil
injected against a blank paper so that the con-
5
ditions can be better inspected.)
● Check for drop due to injection --- Injection
sound
● Check if injection is evenly and clearly sprayed,
is not of bar pattern, not dripping down.
(2) Check if there is no dripping-down of fuel oil
from the tip of the nozzle after the injection test.

Be minded not to approach your face or

hands near the fuel spray during testing.
If the high-pressure fuel oil has hit your face
or hands, it causes injuries.

DE-18 A 12-03
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance:
4.2 DE-18 Inspecting and Maintenance of Fuel Oil Injection Valve

D. Disassembling and Inspecting Nozzle

In the case that a remarkable decrease of the
valve opening pressure, faulty injection of fuel oil, If the retaining nut is turned while the
or dripping-down of fuel oil after injection is found adjusting nut is still tightened, it causes dam-
as the results of the fuel injection test, conduct dis- age the nozzle or fuel oil injection valve parts.
assembling, cleaning, and inspection in the follow- In the case that heavy fuel oil is used, the
ing procedure: retaining nut and nozzle may be stuck togeth-
er with carbon accumulated on them.
If the nut is loosened in this state, the noz-
a. Disassembling the Nozzle
zle turns together with the nut, and may dam-
(1) Remove the cap nut (H). age the nozzle, or the knock pin of spacer,
(2) Loosen the adjusting screw (I). and therefore first lubricate the nut with gas
(3) Fix the holder housing (K) in a vise, and oil, and then carefully loosen the nut by strik-
loosen the retaining nut (M). ing the nozzle with a hammer, while placing a
patch on the nozzle.
(4) Extract the needle valve out of the Nozzle (L).
(5) Extract the nozzle out of the retaining nut by
striking with a hammer, while placing a pipe-
type patch on the nozzle so as not to damage
Since the nozzle and the needle valve is a
the injection hole of nozzle.
pair functioning together, be minded not to
b. Inspecting Nozzle replace either of them separately.
(1) Clean the nozzle nut and needle valve with Do not try to reuse a faulty nozzle by wrap-
gas oil. ping, but be sure to replace it with a new one.
(2) Clean the nozzle hole using a nozzle cleaning
implement.
(3) Push in and push out the needle valve with
your hand, and check the movement.
● Check if the movement is smooth or not.
● Check if the movement is too loose.

Nozzle cleaning
implement

DE-18 A 12-03
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance:
Inspecting and Maintenance of Fuel Oil Injection Valve DE-18 4.2

E. Assembling Fuel Oil Injection Valve

Assemble the fuel oil injection valve in the
reverse order of the disassembling procedure.
(1) Clean each of the disassembled parts with
clean gas oil, and insert each of them back into
the holder housing (K).
(2) Put the spacer (P) and the knock pin (Q) of
nozzle together, and install them into the holder
housing.
(3) Apply the lubricant (Molykote U Paste) on the
holder housing thread, the seating face of the
retaining nut (M), and the outer periphery of the
nozzle, and screw the retaining nut into the
holder housing by your hand.
(4) Loosen the adjusting nut (I).
(5) Tighten the retaining nut with the specified
torque.

＊Specified torque: 210 N•m

5
Be careful not to tighten the retaining nut
with the torque over the specified value, since
it may cause the sticking of the needle valve
of the nozzle.

(6) Set the fuel oil injection valve on the inspec-

tion test device, and adjust the valve opening
pressure.
（ :5-4.2 (2) "Injection Test"）

DE-18 A 12-03
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance:
4.2 DE-18 Inspecting and Maintenance of Fuel Oil Injection Valve

F. Mounting Fuel Oil Injection Valve

(1) Secure the flange (R) on the holder (K) with
Fuel oil high-pressure
the bolt (S). block (B)
(2) Apply grease to the O-rings, and attach them
to the holder housing (K).
(3) Apply grease to the circular packing, and fit it Fuel injection
to the holder housing. valve (A)

(4) Insert that fuel oil injection valve into the noz-
Nozzle holder
zle holder guide hole, after confirming that the guide Fuel oil
old gasket is not left behind in the guide hole. Circular injection pump
packing (G)
(5)Tighten them with the specified torque after
fitting tightening nut (D).

Fuel oil
＊ Specified torque: 60 N•m high-pressure
joint (3)

(6) Insert the inlet connector (C) into the cylinder Fuel oil
high-pressure
head. flange (2) Fuel oil
(Set the slit of the inlet connector (C) on the fuel injection pump

high-pressure block (B) side.)

(7) Fit the fuel high-pressure flange (2) on the fuel
oil injection pump side through the O-ring.
(8) Fit the O-ring between the fuel high-pressure
block (B) and the fuel high-pressure flange (2),
and insert the fuel oil high-pressure joint (3)
into the fuel oil high-pressure flange (2).
(9) Fit the fuel high-pressure block (B) and the O-
ring on the cylinder header side, apply lubricant
(Molykote 1000 Spray) to the seats and threads
of the fuel high-pressure block tightening bolts
(E) and (F), and tighten them to the specified
torque.

＊ Specified torque: 40 N•m

DE-18 B 12-11
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance: Cleaning Filters DE-18 4.3

5-4.3 Cleaning Filters

The filters for fuel oil and lubricating oil are
important parts that are necessary for removing
foreign matters and sludge from oil to keep oil and
air clean and ensure that each part of the engine
operates normally. Therefore, it is necessary to
periodically open and clean the filters to prevent
degradation of their filtering capabilities.
For fuel oil, notch wire duplex filter is used, and
for lubricating oil, auto back wash filter and cen-
trifugal bypass filter are used.

A. Notch Wire Duplex Filter (Fuel Oil)

The notch-wire duplex type filter is normally
used as both-side-parallel application.
Since the pressure decreases if the filter has
been fouled, be minded to periodically conduct
blow-off cleaning. In case that the pressure does
not increase even after the blow-off cleaning, over-
haul the filter and then clean it.

a. Replacing Consumables
5
（ ："Parts List"）
1. O-ring 3-2.5.1 No.514
2. Packing 3-2.5.1 No.152
3. Packing 3-2.5.1 No.266

b. Blow-Off Cleaning
In the case of blow-off cleaning, deposits can be
removed by reversely flowing the fluid through the
element on one side, and this type of cleaning has
no cleaning effect when the element is substantial-
ly clogged, and therefore be minded to conduct the
blow-off cleaning in the earlier state, while the
fouled degree of filter is still light. (The cleaning
should be conducted at least once a week.)

DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM

4.3 DE-18 Inspection and Maintenance: Cleaning Filters

<Blow-off Cleaning Procedure>
(1) Open the drain cock  at the bottom part of
filter.
At this time, be careful so that waste oil will
not scatter or overflow from the valve.
(2) Turn the selector cock handle  (usually, set
to "Used position on both sides" ) to the
"Blow-off" position  (about 60°), and quickly
conduct the operation to return the handle to
the previous position (within 0.5~1 sec.)
(3) Repeat this operation 2~3 times.
(4) Also conduct the above same procedure on
the other side.
(5) Close the drain valve.
(2) Open the drain valve  and loosen the air
vent valve  at the top of the case  and dis-
charge oil.
(3) Pull out the hexagon cap nut  and air vent
valve  to remove the air vent pipe .
(4) Clean the element with washing oil or gas oil,
and conduct blow-off cleaning from the inside.
(5) Clean each of the parts overhauled and the
grooves for case packing of the filter housing
.

Conduct the blow-off cleaning quickly.

Further, do not place the lever on the mid-
dle position, but quickly move to the specified
position (knock position).
If too much time has been taken in blow-off
cleaning and switching the lever positions, the
pressure decreases, and may activate the
alarm or emergency stop.

c. Overhaul and Cleaning of Filters

Be minded to perform overhauling and cleaning
of filters when the engine is stopped.

When heavy fuel oil is in use, the fuel oil is

heated causing filters and piping to be
extremely hot. Therefore, when handling the
filter, be sure to wear the safety gloves, and
be cautious so that the high-temperature oil
may not splash on the skin or clothes.

[Overhaul and Cleaning of Filters]

(1) Turn the selector cock handle  to the
"Close" position  (90°) on the side to be over-
hauled.

DE-18 Z 12-01
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance: Cleaning Filters DE-18 4.3

[Assembly and Restoration]

(1) Attach the packing  to the element , and
attach the packing  to the filter housing .
(2) Put the spring  on the element, place the
case  over the spring, and screw the nut 
into the case while holding the case with your
hands.
(3) Attach new packing to the upper and lower
sides of air vent pipe  joint and assemble the
hexagon cap nut  and air vent valve  and
tighten with the hexagon cap nut .
(4) Close the drain cock .
(5) Shift the handle  the "Blow-off position" .
(6) When the filter is overhauled and cleaned
while the engine is stopped, conduct priming
and fill the case with oil.
(7) Close the air vent valve , after the oil is let
overflow until air bubbles are completely van-
ished from the oil flowing out of the air vent
pipe. 5
(8) Return the handle to "Both sides used posi-
tion" .
(9) Check if there is any oil leakage from the gas-
ket sections.

After blow-off operation or after overhauling,

check that the detent plug  is fit into the
selector cock .
If the detent plug  is not properly engaged
in the position, the handle is overturned by
vibration during the operation of engine, and it
may incur oil spill-out accidents.
(1) Check conditions of the sludge collected
on the element.
If metallic particles are found, investigate
the causes and take the countermeasures.
(2) When the element is damaged, or when
the element is excessively fouled and clog-
ging cannot be removed even by cleaning,
replace the element with a new one.
(3) Since the packing and O-ring are easily be
damaged, be very careful in handling these
parts. Be minded to replace the deteriorate
parts in high-temperature conditions.

DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM

4.3 DE-18 Inspection and Maintenance: Cleaning Filters

B. Auto Back Wash Filter (Lubricating Oil) (3) Fix the nozzle part of rotor assembly with a
Please refer to the separately provided, vice, etc.
“Maintenance Edition”, for instructions on how to
handle this filter.
（ ：Separately provided "Lubricating Oil When fixing the nozzle part of rotor assem-
Auto Back Wash Filter"） bly, use care not to damage the nozzle or the
spindle bearing.
C. Centrifugal Bypass Filter (Lubricating Oil)
(4) Remove sludge deposited on the inner side of
• Centrifugal bypass filter systematically supple-
case cover (2) and rotor assembly with a spatu-
ments sludge to the rotor inner wall by the cen-
la, etc.
trifugal force mechanically generated by the
(5) Clean the case cover (2) and rotor assembly
rotational movement of rotor induced in
with washing oil, etc.
response against the squirting of lubricating oil
triggered from the internal rotor nozzle. (6) Pour washing oil into the rotor assembly and
observe how it comes out from the nozzle to
• Keep the valve at the filter inlet fully open during
check if it is clogged or not.
engine operation and close it during cleaning of
the filter or when any error occurs in the filter,
e.g. when abnormal sound or abnormal vibra-
Remove the sludge completely. If any
tions are generated.
sludge is remaining, vibration will occur during
• When sludge is deposited and the rotor
rotation due to lack of balance, causing dam-
becomes heavy, the rotation speed may be
age in the bearing.
slowed or the rotation may come to a halt, dis-
abling further supplementation of sludge. Make (7) Check for any damage in the case cover (2) or
sure to perform cleaning at least once every case assembly bearing.
week. (Generation quantity of sludge differs
according to the operating condition of the
b. Assembly and Restoration
engine. Adjust the cleaning cycle by observing
Conduct the assembly by reversing the order of
the supplementing conditions.)
disassembly.

Perform bypass filter cleaning at the time of Check if there is any damage in the O-ring.
engine shutdown. Performing disassembly Before assembling the case cover (2), con-
while the engine is in operation is dangerous, firm that the rotor assembly rotates smoothly.
as mist gas may gush out.

a. Disassembly and cleaning

Disassembly and cleaning shall be performed
according to the following procedure.
(1) Remove the band clamp (1) and remove the
case cover (2).
(2) Remove the cover nut (3) and extract rotor
assembly.

DE-18 Z 12-01
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance: Cleaning Filters DE-18 4.3

Winding the paper (4) entirely around the inner

side of rotor assembly makes sludge removal from
the rotor assembly easy.
（ ：Separately provided "Lubricating Oil
Bypass Filter"）

DE-18 Z 12-01
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance:
4.4 DE-18 Cleaning Turbocharger Compressor

5-4.4 Cleaning Turbocharger Compressor

If the fouled degree of the turbocharger com-
pressor progresses, the efficiency of the tur-
bocharger decreases and the operating perform-
ance of engine is worsened. Follow the instruc-
tions on each turbocharger manual, is performed
compressor cleaning on a regular basis, please
inhibiting the progression of the fouled.
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.

（ ：Separately provided "Turbocharger

Instruction Manual"）

Be minded never to use gas oil or any other

flammable liquid for cleaning, since these liq-
uids will be the cause of fire.

AT14 MET TPS

CKT CKT
CKT

Cleaning Turbocharger Compressor Schematic Diagram

DE-18 A 14-03
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance:
Cleaning Turbocharger Turbine DE-18 4.5

5-4.5 Cleaning Turbocharger Turbine

As dirt collects on the turbine side of the tur-
bocharger as on the compressor side, the tur-
bocharger efficiency lowers, and the engine per-
formance deteriorates.
Particularly, when heavy fuel oil is used, follow
Exhaust
the instructions on each turbocharger manual, is manifold
performed turbine cleaning on a regular basis,
please inhibiting the progression of the fouled.
（ ：Separately provided "Turbocharger
Instruction Manual"） Cap [2]

Cleaning
piping
Compressed air
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during Valve [1]

cleaning, you may burn your hands. Wear Valve [3]

safety gloves without fail.
Tank

Turbine Cleaning (MET)

5
Exhaust manifold

Nozzle

Cleaning
piping Cleaning
piping

Valve (V1)

Drain valve (V3)

Valve (V2)
(0.15 MPa)

Fresh water
Fresh water
Regulate the water pressure 0.15 MPa Regulate the water pressure 0.25~0.5 MPa

Turbine Cleaning (AT14) Turbine Cleaning (TPS)

DE-18 A 14-03
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance:
4.6 DE-18 Measuring Crankshaft Deflection

5-4.6 Measuring Crankshaft Deflection C. Measuring Deflection

If the crankshaft deflection exceeds its limit,
the stress to be applied to the crankshaft
becomes excessive, and it results in the
breakage of crankshaft if the excess of deflec-
tion is too large.
Therefore, adjust the crankshaft deflection
to the proper value when being installed, and
periodically measure the deflection, so that it
can be corrected whenever it is over the limit
value.
<Measurement procedure>
(1) Open the indicator valve, and perform turning
the crankshaft.
(2) Place the crank pin at the point of 30° (posi-
tion "B") past the bottom dead center.
(3) Mount the deflection gauge as shown in the
figure (Deflection Gauge Mounting Position).
Be careful not to interfere with the threaded
connecting rod bolt during turning the crank
shaft.

A. Replacing Consumables and Measuring (4) Set the reading on the gauge scale to +20 at
Instruments the position "B" in the Figure. (To make clear
a. Replacing Consumables the positive and negative directions.)
（ ："Parts List"） (5) Slowly turn the engine in the normal direction
1. O-ring (frame side cover) 2-2 No.3 of rotation, and measure the reading on the
b. Implements and Measuring Instruments scale when the crankshaft is at the angle of
1. General tools "B", "C", "D", "E", and "A" respectively, of which
data shall be recorded.
（ ："Implement List" in the final docu-
ments）
Crank-pin
2. Deflection gauge
3. Mirror

B. 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.
200

b. Before measurement, push the contact piece

(143)

of the deflection gauge with a finger, and confirm

that both the contact piece and dial gauge return
to the original positions correctly.
c. In the case of the marine engine, since the
98

Deflection gauge
deflection varies according to the loaded cargo
conditions, be minded to record the conditions of Balance weight
loaded cargo, draft, temperature, and so on, at Gauge head
the same time.

DE-18 A 12-11
 CHAPTER
Inspection and Maintenance 5
ITEM
Inspection and Maintenance:
Measuring Crankshaft Deflection DE-18 4.6

D. Calculating Deflection (d) E. Correction Limit for Deflection

Calculate the deflection values as based on the a. The correction limit shall apply to whichever is
measured values in accordance with the following larger of dV and dH as shown in the following
formula, record the calculated values table.
Ａ＋Ｂ
● Vertical (V) deflection：dV＝Ｄ－
２
● Horizontal (H) deflection：dH＝Ｃ－Ｅ

0.034 or less 0.096

● Positive/negative deflection: Open downward
(+), closing downward (-) 2.8
x x
A, B, C, D, and E represent the measured val-
ues respectively at each corresponding position 0.034 or less 0.096
shown in the figure on the right.
2.8
x x

0.103 or less 0.138

3 4
x x

Note 
Measurement point correction factor = 1.23

b. Deflection varies depending on the connection

5
method (direct connection or flexible coupling)
between the crankshaft and drive equipment,
however, usually, the deflection becomes maxi-
mum at the crank throw that is closest to the fly-
wheel.
Adjust the drive equipment using the adjust-
ing shim or chock liner, so that the deflection
falls when the limited values as shown in the
above table.

The deflection of the crankshaft shall be

represented by the value when the engine is
cold, and when the engine is warm sometimes
differ significantly depending on the measure-
ment conditions, be minded not to use the
value measured when the engine is warm as
standard.

DE-18 A 12-11
CHAPTER
5 Inspection and Maintenance
ITEM
Inspection and Maintenance:
4.6 DE-18 Measuring Crankshaft Deflection

<Reference>
Deflection in warm condition
Values of deflection measured in the hot state
are usually different from those measured in the
cold state.
This is reasoned by the fact that temperature
increase of the engine bed is more than that of the
bearing housing of a generator that is directly driv-
en by the engine, and this raises the crankshaft
more in relation to the driven shaft causing change
in deflection to (deflection is narrower with
the crank pin positioned at the upper side than at
the lower side). This makes difference in deflection
between the hot state and the cold state.
Since this difference in deflection between the
cold and the hot states is thus caused by differ-
ence in dimension of the bearing and in the tem-
perature between the engine and the generator, its
adjustment is not possible and this characteristic of
deflection is considered as the one unique to the
electric generator unit.
We try to adjust the deflection so that the deflec-
tion may be as near to the positive (+) limit (like
/wider with the crank pin positioned at the
upper side) as possible in the cold state in order to
minimize the absolute value of deflection in the hot
state.
Deflection measured in the hot state varies with
temperature, and the value usually changes meas-
urement to measurement. However, to our experi-
ence, they almost fall within a range of 3-4/10000 x
stroke and the direction of deflection is (nar-
rower with the crank pin positioned at the upper
side than at the lower side).
Beware of the fact that temperature of the
engine sometimes quickly increases after its stop-
page and measurements are different from the
proper value due to influence of thermal expansion
caused by temperature difference between the
measurement instrument and the crankshaft.

DE-18 Z 12-01
 CHAPTER
Inspection and Maintenance 5
ITEM
MEMO DE-18

5
CHAPTER
6 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
1.1 GENERAL Selecting Fuel Oil

6-1 Fuel Oil Characteristics and Control

How well the fuel oil characteristics is controlled will greatly affect the smooth operation of
engine, maintenance intervals, as well as the working life of various parts.
When supplying the fuel oil, it is required not only to confirm the characteristics referring to
the characteristics analysis table, but also to conduct the control of the oil in accordance with
each characteristics.
Particularly when using heavy fuel oil, conduct the preprocessing of fuel oil, the control of vis-
cosity (temperature), and the control of lubricating oil without fail, so that troubles arising from
fuel oil can be prevented.

6-1.1 Selecting Fuel Oil

The standard characteristics of the fuel oil appli-
cable to this engine is as shown in a separate
table.
( : Table 6-1.1 "Standard Fuel Oil
Characteristics")
Commercially available fuel oils are consider-
ably different in the characteristics, and even the
same type of the fuel oil may show a greatly dif-
ferent characteristics depending on the location
and period of supply.
Check the characteristics analysis values of the
fuel oils, and avoid using the fuel oil that exceeds
limit value.
1) The engine specification varies depending
on the types of the fuel oil to be used. Be
minded to confirm the type of the fuel oil
referring to the specification of engine, and
do not use the oil of which grade is lower
than that shown in the specification.
In case that the fuel oil of lower grade is
used, troubles may be incurred on the
operation of engine, due to the faulty com-
bustion, troubles on the fuel oil system
equipment, premature wearing of the parts,
6-1.2 Fuel Oil Characteristics and
and so on.
Control
( : Fig.6-1.1 [Combustibility of Fuel Oil;CCAI])
2) Before mixing different kinds of fuel oil,
check the affinity by using a small amount
of sample. If mixed oil has low affinity, a
large amount of sludge will form, which
may be harmful to the operation..
Engine Inlet])
Therefore, be minded to check the charac-
teristics analysis values of the fuel oils after
each delivery, and try to avoid using the fuel
oil of which characteristics is excessively dif-
ferent from those shown in the standard char-
acteristics table.
Bottoms oils resulting from operation by
FCC method (catalytic cracking method) are
often mixed in fuel oils recently.
The mixed oils, such as this, contain rigid
alumina silica (catalyst particles), and will
cause abnormal wear of the various parts of
engine, particularly the parts of the fuel injec-
tion system.
Remove the solid particles by fully utilizing
the existing fuel oil pretreatment equipment,
and by intensifying the cleaning of fuel oil.
In case that the removal of the solid parti-
cles cannot sufficiently be made with the exist-
ing fuel oil pretreatment equipment, the rein-
forcement of the cleaning equipment will be
required, and when such reinforcement is not
possible, it may be required to change the cur-
rent fuel oil to the oil of a better quality.
In order to prevent engine components from
abnormal wear due to fuel oil property, fuel oil
characteristic criteria at engine inlet should be ref-
fered to table 6-1.2.
( : Table.6-1.2 [Fuel Oil Control Criteria at

GENERAL Z 12-10

Control of Fuel Oil, Lubricating Oil, and Cooling Water
Fuel Oil Characteristics and Control
(1) Heavy Fuel Oil (H.F.O.)
Since heavy fuel oil contains more carbon
residue and impurities, and is higher in its viscosity
as compared to diesel fuel oil, heavy fuel oil can-
not be used as the fuel oil for diesel engine, when
it is in the state of bunker fuel oil.
Therefore, it will be a prerequisite to use heavy
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).
a) Cleaning Fuel Oil
Water, and solid contents such as vanadium,
sodium, alumina, and silica, contained in heavy
fuel oil accelerate the corrosion and wear of the
various parts of fuel injection system and fuel
combustion chamber system, substantially affect-
ing and reducing the working life of these parts.
For the purpose of removing such impurities, the
fuel oil preprocessing equipment, such as the cen-
trifugal separator and precision filters, are installed.
Since these equipment will not exhibit the efficien-
cies unless each equipment is properly handled, be
minded to operate each equipment in accordance
with the corresponding instruction manual.
( : Instruction Manual" for each equipment")
Since waste fuel or sludge will be the caus-
es of environmental contamination or pollu-
tion, be sure to entrust the treatment of these
to the authorized waste disposal company, not
directly handling or disposing these matters
on your own.
b) Heating Fuel Oil
Since the viscosity of heavy fuel oil is very high,
it is required to heat the oil, so that a proper vis-
cosity 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
page as a standard.
In case that a viscosity controller (automatic
viscosity regulator) is installed on the engine,
CHAPTER
6
ITEM
GENERAL 1.2
control the fuel oil viscosity to its proper value
according to the attached instruction manual.
( : Fig. 6-1.2 "Fuel Oil Viscosity/Temperature
Curve")
* Proper viscosity for fuel oil (engine inlet)
Kinematic viscosity: 11~14 mm2/s
If the temperature control of fuel oil is
improper, and the fuel oil with high viscosity
has been supplied to engine, it will not only
incur faulty combustion, but also will result in
the accidents such as the clogged or dam-
aged fuel oil filter, and the breakage of fuel
injection system parts.
(2) Diesel Fuel Oil (M.D.O.)
a) Water tends to extract and separate out of
diesel fuel oil, and further diesel fuel oil tends
to generate a large amount of sludge when
mixed with the oil of different base oil.
Daily conduct the draining-off of the precipita-
tion tank and setting tank, so that water or
sludge does not flow into the engine.
To remove water or sludge, the centrifugal
separator is an effective device.
b) Diesel fuel oil, that has been cut back by using
the gas oil refined by FCC method, may incur
faulty start or ignition, and this tendency is
particularly obvious in case of low sulfur
diesel oil for land vehicles, due to its low 6
cetane number, if the environmental condi-
tions, such as ambient temperature or water
temperature, are unfavorable.
In such a case, special measures will be
become necessary to improve starting capability
and combustibility of engine, and in such occa-
sions, contact our company for consultation.
(3) Gas Oil
Although gas oil does not contain few impurities,
it may cause problems on ignition when the gas oil
is refined by FCC method, just like the case with
diesel fuel oil, and therefore be minded to pay par-
ticular attentions to the cetane number of gas oil.
Further, since gas oil is low in its viscosity and
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.
GENERAL Z 12-10
CHAPTER
6 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
1.2 GENERAL Fuel Oil Characteristics and Control

(4) Kerosene Oil is required to carry out a special arrangement on

As a countermeasures to prevent air pollution, the engine, and therefore contact our company
there may a case in which kerosene oil may be for consultation before using the oil.
used.
Since kerosene oil is further lower in its cetane
number and is lower in its viscosity than gas oil, it

Table 6-1.1 Standard Properties of Fuel Oils

Heavy Fuel Oil

Type of Fuel Oil Diesel Fuel Oil
IF380 IF700

Classification [ ISO-F ] DMA DMZ DMB RMG380 RMG700

o
40 C 2.0 ~ 6.0 3.0 ~ 6.0 2.0 ~ 11.0
Kinematic Viscosity mm2/s o
50 C 380 700
o
Density (15 C) kg / m3 max 890 890 900 991
o
Flash Point C min 60 60 60 60
o
Pour Point, Summer C max 0 0 6 30
o
Pour Point, Winter C max -6 -6 0 30
Carbon Residue of % max 0.3 0.3
10% residual m/m
Carbon Residue % max 0.3 18
m/m
Ash % max 0.01 0.01 0.01 0.1
m/m
Moisture % max 0.5
v/v 0.3
Sulfur % max 1.5 1.5 2.0 Statutory requirements
m/m
Vanadium mg/kg max 350
Aluminum + Silica gel mg/kg max 60
Cetane Number min 40 40 35

(ISO8217:2010)

Table 6-1.2 Fuel Oil Control Criteria

at Engine Inlet Vanadium combines with sodium and so
forth and makes an alloy, which is highly cor-
Component Standards
rosive and advances high temperature corro-
Water 0.2 vol. % or less sion (vanadium attack).
Moreover, moisture advances corrosion on
20 mg/kg or less components in the fuel injection system.
Solid Content
(Aluminum content<5 mg/kg) When, in particular, seawater intrudes, such
particles
5 m or less corrosion accelerates because the above-
Size
mentioned high temperature corrosion also
Lubricity, corrected occurs. You must use the fuel oil cleaning
460 m or less
wear scar diameter
o (Diesel Fuel Oil) device and try to remove seawater and solid
(wsd 1.4 at 60 C)
substance as much as you can.

GENERAL Z 12-10
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water 6
ITEM
Fuel Oil Characteristics and Control GENERAL 1.2

Density kg/m3
CCAI : Combustibility
900 1040

Increasingly 890
difficult
to burn 880 1020

870

May be
860 1000
troublesome

850

840 980

830
Normal
820 960

810

800 940

790

780 920

770 6
760 900
860 880
750
0 100 200 300 400 500 600 700
VISCOSITY mm2/s at 50͠

Fig 6-1.1 [Combustibility of Fuel Oil : CCAI]

Combustibility of fuel oil

CCAI = D-81-141xloglog (Vk+0.85) We recommend fuel oil CCAI value below 850
CCAI : Combustibility for heavy fuel oil. Since heavy fuel oil exceed-
o
Vk : Viscosity mm2/s at 50 C ing CCAI value 850 might have engine start
D : Density kg/m3 at 15 oC failure, start the engine on M.D.O. even
though it is H.F.O. starting and stopping speci-
fication. A high CCAI value fuel oil leads to
the possibility of engine damage by unstable
combustion at low load operation.

GENERAL Z 12-10
CHAPTER
6 Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
1.2 GENERAL Fuel Oil Viscosity-Temperature Curve

o o
100 F 50 C
9000
7000
5000
4000 Rw#1
3000 11 10000
Kinematic Viscosity (mm2/s)

2000 10
1500
9 5000
1000
8 2
800
600 7
500 2000
400 1 1500
6
300
250 1000
5
200
150 4 500

100
80
3
60
50 200
40
30
25 100
20

14 15
60
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

Fig. 6-1.2 Fuel Oil Viscosity / Temperature Curve

Example) ԘWe find the temperature, under which heavy fuel oil of 380 mm2/s can be heated,
so as to obtain the proper viscosity of 14 mm2/s at the engine inlet.
To find this temperature, tracing the curve No. 9 downward, and from the point that
intersects kinematic viscosity 14 mm2/s, goes down vertically to obtain 130oC.
ԙWe find the temperature, under which heavy fuel oil of 700 mm2/s can be heated,
so as to obtain the proper viscosity of 14 mm2/s at the engine inlet.
To find this temperature, tracing the curve No. 11 downward, and from the point that
intersects kinematic viscosity 14 mm2/s, goes down vertically to obtain 140oC.
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 viscometer,
and determine the proper value when actually operating the engine.
2. Kinematic viscosity 1 mm2/s= 1 cSt

GENERAL Z 12-10
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water 6
ITEM
Selection and Control of Lubricating Oil GENERAL 2.1,2.2

6-2 Lubricating Oil Characteristics and Control

Lubricating oil only plays an extremely important roles for engine, not only lubricating the
sliding parts but also cooling the various parts, ensuring air tightness, acting as a detergent-dis-
persant, or acting as a neutralizing acids.
For the purpose of maintaining the engine in proper conditions and assuring the smooth oper-
ation, it is indispensable to select suitable lubricating oil brands taking into consideration the
use purpose of engine, the fuel oil to be used, the load to be connected, etc., and to conduct an
appropriate control of the lubricating oil.

6-2.1 Selecting of Lubricating Oil 6-2.2 Control of Lubricating Oil

(1) Engine system oil
As the system oil for engine, high-grade lubricat-
ing oil (CD of API service category, or higher) for
diesel engine shall be used.
Select the lubricating oil of the suitable grade,
according to the quality of the fuel oil to be used.
The recommended lubricating brands as shown in
a separate table.
(1) Cleaning of Lubricating Oil
Since fine dust or combustion residue from the
combustion chamber enter and mix in the lubricat-
ing oil, a centrifugal separator is installed to the
engine, to eliminate such foreign matters, in addi-
tion to the filters attached to engine. Use such
equipment in correct manner, referring to the
instruction manual of each manufacturer.

( : Table 6-2.1 "Recommended Lubricating

Oil Brands")
Be minded to use the lubricating oil of the
same brand, not mixing the lubricating oil with
the oil of any other brand.
If the lubricating oil is mixed with the oil of
different brand, the additives contained in the
both oils react for each other, and this may
result in the degradation of the lubricating oil.
(2) Lubricating Oils for Other Equipment
In case that separate lubricating system is
employed apart from the engine lubricating sys-
tem, as in the case of the governor, air motor, tur-
bocharger,generator,reduction gea, etc., be mind-
ed to refer to the instruction manual of each equip-
ment.
( : "Instruction Manual of each equipment")
Do not conduct cleaning by injecting water
into lubricating oil.
Mixing water into lubricating oil will cause
degradation of the lubricating oil, such as the
emulsification of oil, the decrease of total base
number, and the increase of insoluble sub-
6
stances.
(2) Control of Lubricating Oil Characteristics
Periodically conduct the sampling and analysis
of lubricating oil (every 500 hours), and in case
that the analyzed value of the lubricating oil char-
acteristics has reached the control standard value,
immediately consult the lubrication oil manufactur-
er, so that the replacement or makeup can be car-
ried out.
( : Table 6-2.2 "Lubricating Oil Control
Standards")

GENERAL Z 12-10
CHAPTER
6 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
2.2 GENERAL Selection of Lubricating Oil

a) Sampling Procedure <Information to be Attached to Sample

i ) Collect samples from such as the air vent pipe Receptacle>>
of the filter 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 characteristics ② Model number of engine
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 ④ Data and location of sampling
500 cm 3.
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
The lubricating oil control standards are as ⑧ Replenishment record (Data and quantity of
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
Lubricating OIl Control Standards (System oil) of potassium hydroxide (KOH) that corre-
sponds to the quantity of acid required to neu-
Diesel Heavy tralize the base component contained in 1 g of
Fuel oil used fuel oil fuel oil lubricating oil, and is indicated by the unit of
Total base mgKOH/g.
mgKOH/g 3 or more 10 or more
number 1) Total base number indicates the lubricating
Total base oil capabilities to prevent the corrosion due to
mgKOH/g 5 or more 15 or more sulfuric acid generated from sulfur contained
number 2)
in fuel oil, and other acids, and further it indi-
Kinematic mm2/S +30% or less / -20% cates the capabilities of lubricating oil to clean
o
Viscosity (@ 40 C) or more of new oil and disperse the fouled sections in the
o engine.
Flash point C 180 or higher

Water (2) Insoluble (= n-pentane soluble)

vol. % 0.3 or less
content Insoluble is fouling substance that do not
n-pentane dissolve in oil, and the main component is
wt. % 2.5 or less 4) soot which is a product of combustion, and
insoluble 3)
calcium sulfate which is a neutralized product.
Notes: Since these substances do not dissolve even
1) The TBN (Total Base Number) represents the values measured
according to ASTM D4739, JIS K2501 (Hydrochloric acid method). in n-pentane which is a solvent, n-pentane
2) The TBN (Total Base Number) represents the values measured insoluble serves as an index to indicate the
according to ASTM D2896, JIS K2501 (Perchloric acid method).
3) Insoluble represents the values measured according to
degradation and fouling degree of lubricating oil.
ASTM D893B.
4) In case that the measure value rapidly increased or exceeded 1.5,
measure toluene insoluble according to the ASTM D893B,
and in case of [ n-pentane insoluble - toluene insoluble ] > 0.5,
replace the lubricating oil.

GENERAL Z 12-10
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water 6
ITEM
Recommended Lubricating Oil Brands GENERAL 2.2

Table 6-2.1 Recommended Lubricating Oil Brands

Kind of fuel oil DMA, DMZ, DMB RMA10, RMB30 RME180, RMG180 RMG380, RMG500
RMG700
(ISO) (ISO) (ISO) (ISO)
Marine gas oil Up to 200 Sec. Up to 1500 Sec. Up to 7000 Sec.
Name of company or
Marine diesel oil R.W. NO.1 R.W. NO.1 R.W. NO.1
BP ENERGOL BP ENERGOL BP ENERGOL
BP ENERGOL
IC-HFX204 IC-HFX304 IC-HFX404
DS3-154
IC-HFX404
BP CASTROL
CASTROL MHP154 CASTROL CASTROL
TLX PLUS204 TLX PLUS304 TLX PLUS404
TLX PLUS404

CHEVRON DELO 1000 Marine

TARO 20 DP 40 TARO 30 DP 40 TARO 40 XL 40
( CHEVRON, TEXACO, CALTEX ) Oil SAE40

MOBILGARD M430
EXXON MOBIL MOBILGARD 412 MOBILGARD M430 MOBILGARD M440
MOBILGARD M440

GULF VERITAS GULF VERITAS GULF VERITAS

GULF
DPO40 SERECT40 SERECT40

MARBRAX CCD430
PETROBRAS MARBRAX CCD415 MARBRAX CCD420 MARBRAX CCD440
MARBRAX CCD440

ARGINA T40
SHELL GADINIA AL40 ARGINA T40 ARGINA X40
ARGINA X40

DISOLA M4020 AURELIA TI4030

TOTAL DISOLA M4015 AURELIA TI4040
AURELIA TI4030 AURELIA TI4040

Note:(1) This table shows lubricating oils classified as SAE40. Be sure to use lubricating oils classified as 6
SAE30 only when the minimum ambient temperature is 20oC or less.
We recommend that multigrade oil (SAE10W-30 or 5W-30) be used in extremely cold locations
(minimum ambient temperature: 5oC or less).
(2) Be sure to consult with oil manufacturers before selecting the lubricating oil proper brand that best
suits the fuel oil and operating conditions.

GENERAL Z 12-10
CHAPTER
6 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
Cooling Fresh Water (Raw Water) and Corrosion
3.1,3.2 GENERAL Prevention Agent

6-3 Cooling Water Characteristics and Control

Always use fresh water as cooling water in the cylinder jacket system and add corrosion pre-
vention agent to cooling water to maintain cooling effect and prevent corrosion due to scale
bonded on the piping surface.
Improper cooling water control can cause localized heating of the jacket line parts due to cor-
rosion or scale, resulting in excessive wear on or damage to the jacket line parts.

6-3.1 Cooling Fresh Water (Raw Water)
As cooling fresh water (raw water), be minded to
use the soft water that meets water quality stan-
dards shown in Table 6-3.1 below, or the water to
which softening processing has been adminis-
tered.
6-3.2 Corrosion Prevention Agent
(1). As corrosion prevention agent, we recom-
mend the agent which is nitrous acid type.
(2). Commercially available brands in Japan are
shown in Table 6-3.2.
When using them, carefully read the manufac-
turer's instruction manual, and properly use
the agent in accordance with the use standard
as well as the control standard.

Table 6-3.1 Fresh Water (Ran Water) Quality Standards

Effect (reference)
Item Standards
Corrosion Scale

o
PH (25 C) 6.5 to 8.5 (neutral)
Tortal hardness
100 mg/kg Max.
(CaCO3 PPM)
Chlorine ion
100 mg/kg Max.
(Concentration:Cl-1)
M-alkalinity (PH4.8) 150 mg/kg Max.
Sulfate ion
100 mg/kg Max.
(Concentration:SO4-2)
Total iron (Fe) 0.3 mg/kg Max.

Silica (SiO2) 50 mg/kg Max.

Ammonium ion
0.05 mg/kg Max.
(Concentration:NH4)
Evaporation residue 400 mg/kg Max.

GENERAL Z 12-10
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water 6
ITEM
Cooling Fresh Water (Raw Water) and Corrosion
Prevention Agent GENERAL 3.2, 3.3

Table 6-3.2 Brands of Commercially Available Corrosion Prevention Agents

Brand Name Manufacturer Constituent Amount to added (ppm)

DEWT-NC 3,000~4,500
Drew Chemical Corp. (USA) Nitrite
MAXIGARD 20,000~22,000
COOLTREAT 101
Hauseman Marine Chemical (USA) Nitrite 1,250~5,000
COOLTREAT 102
CWT DIESEL 102 VECOM B.V. Nitrite 1,250~5,000

Note: Adjust the amount appropriately in the specified range depending on circumstances.

6-3.3 Control of Cooling Water
(1). As cooling water, be minded to use fresh
water added with corrosion prevention agent,
from the stage of very first beginning, without
fail.
(2). Controlling Fresh Water with PH Value
Measure the PH value of cooling water once
every week, using a PH value, and in case that
the value has exceed the standard value speci-
fied by the manufacturer, discharge 10 to 20% of
the cooling water to add new water.

(3).Replace the entire amount of cooling water

Corrosion prevention agent is poisonous
once every year or 2 years.
and toxic substance. Therefore, be minded
never to drink the cooling water that is added
with corrosion prevention agent.
Be minded never to directly discharge the
Further, regarding the handling of the cool-
cooling water, which are added with corrosion
ing water added with corrosion prevention
agent, into sea or river, without adequate pro-
agent, be sure to wear the protective gears
such as rubber gloves and masks, so that
your hands or skin do not directly touch the
cessing.
When disposing the cooling water, be sure
6
cooling water. to conduct the water examination, to ensure
that the COD concentration of cooling water is
If the corrosion prevention agent has acci-
diluted to be within the specified value.
dentally touched your skin or entered your
eyes or mouth, immediately wash them with
fresh water sufficiently.

GENERAL Z 12-10
CHAPTER
Troubleshooting and Countermeasures
7
ITEM

1 DE-18 Precautions for Troubleshooting

7. Troubleshooting and Countermeasures

Defect or failure of the engine is caused not only by faulty or improperly adjusted engine
parts, but also by faulty equipment, improper operation and maintenance work, in addition to the
courses attributable to fuel oil characteristics. More often than not, each engine problem is
caused by two or more causes that are interrelated. Therefore, it is impossible to provide the
descriptions of the countermeasure for every single defect or failure.
This chapter describes the defects and problems that are frequently found on engines, as well
as the generally probable causes and countermeasures for such defects and problems. If your
engine has a defect or failure that is not described in this section, or if you cannot discover the
causes after inspection, contact our Service Department.

7-1 Precautions for Troubleshooting

A. Take proper measures immediately when you find a defect or problem.
If any of the following defects and failures is found, stop the engine for inspection. Never attempt to
restart the engine until you find the cause, take proper measures, and restore the engine to the normal
operating conditions. Resuming operation without taking proper measures may rapidly aggravate the
defect or failure, resulting in injuries or accidents.
1. Activation of protective device: "Alarm", "Emergency Stop"
Overspeed, low lubricating oil pressure, high cooling water temperature, etc.
2. Abnormal sounds (especially mechanical sounds), abnormal vibrations
3. Overheating of the engine
4. Abnormal increase of exhaust temperature or abnormal decrease of exhaust temperature
5. Defective parts on or around the engine control (governor, control device), or protective device, loosened
link, or detachment of link
6. Damage to piping or joint bolts (especially fuel and lubricating oil systems)

B. Inspect, disassemble, and adjust the engine correctly according to the instruction manual. To prevent
accidents, never neglect "Safety Precautions".

C. Be sure to use the genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the parts
list. We cannot thereafter guarantee the proper operation of the engine unless such parts are used.
If you are out of the spare parts for servicing, immediately control us for replenishment.

Instruments such as tachometers, thermometers, and pressure gauge may provide incorrect indica-
tion even if the engine is running normally.
Inspect the instruments on a daily basis to make sure their indication is correct. Replace any defects
instrument. Always use correct indications as an index for determining the engine conditions.

DE-18 Z 12-01
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Starting Defect DE-18 2.1
7-2 Troubleshooting and Countermeasures
7-2.1 Starting Defect
[Phenomenon] [Trouble] [Countermeasures]

DE-18 Z 12-01
CHAPTER
Troubleshooting and Countermeasures
7
ITEM
2.2, 2.3 DE-18 Engine Revolution is Not Smooth / Insufficient Output

7-2.2 Engine Revolution is Not Smooth

[Phenomenon] [Trouble] [Countermeasures]

7-2.3 Insufficient Output

[Phenomenon] [Trouble] [Countermeasures]

DE-18 Z 12-01
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Abnormal Exhaust Gas Temperature or Maximum
Combustion Pressure DE-18 2.4

7-2.4 Abnormal Exhaust Gas Temperature or Maximum Combustion Pressure

[Phenomenon] [Trouble] [Countermeasures]

DE-18 A 14-03
CHAPTER
Troubleshooting and Countermeasures
7
ITEM

2.5 DE-18 Abnormal Exhaust Gas Color

7-2.5 Abnormal Exhaust Gas Color

[Phenomenon] [Trouble] [Countermeasures]

DE-18 A 14-03
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Abnormal Noise / Abnormal Vibration DE-18 2.6

7-2.6 Abnormal Noise / Abnormal Vibration

[Phenomenon] [Trouble] [Countermeasures]

DE-18 A 14-03
CHAPTER
Troubleshooting and Countermeasures
7
ITEM

2.7 DE-18 Engine Sudden Stop

7-2.7 Sudden Engine Stop

[Phenomenon] [Trouble] [Countermeasures]

DE-18 Z 12-01
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Unable to stop Engine / Overspeed DE-18 2.8, 2.9

7-2.8 Unable to Stop Engine / 7-2.9 Overspeed

[Phenomenon] [Trouble] [Countermeasures]

DE-18 Z 12-01
CHAPTER
Troubleshooting and Countermeasures
7
ITEM
2.10,2.11 DE-18 Low Lubricating Oil Pressure / High Lubricating Oil Temperature

7-2.10 Low Lubricating Oil Pressure

[Phenomenon] [Trouble] [Countermeasures]

7-2.11 High Lubricating Oil Temperature

[Phenomenon] [Trouble] [Countermeasures]

DE-18 Z 12-01
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Low Cooling Water Pressure (Jacket Line)
/ High Cooling Water Temperature / Low Cooling Water Temperature DE-18 2.12,13,14

7-2.12 Low Cooling Water Pressure (Jacket Line)

[Phenomenon] [Trouble] [Countermeasures]

7-2.13 High Cooling Water Temperature (Jacket Line)

[Phenomenon] [Trouble] [Countermeasures]

7-2.14 Low Cooling Water Temperature (Jacket Line)

[Phenomenon] [Trouble] [Countermeasures]

water to standby engine

DE-18 Z 12-01