Professional Documents
Culture Documents
Installation Manual - MHI PDF
Installation Manual - MHI PDF
Installation Manual - MHI PDF
INSTALLATION MANUAL
July 2011
Pub. No. 98CAB-71000
CONTENTS
2. Fuel General···········································································································································47
2.1 Fuel Properties and Composition Affecting the Engine Trouble ·························································47
2.2 Flash Point··········································································································································47
2.3 Distillation Characteristics ··················································································································47
2.4 Pour Point (PP)···································································································································47
2.5 Cloud Point (CP)·································································································································47
2.6 Cold Filter Plugging Point (CFPP) ·····································································································47
2.7 Carbon Residue (10% Residual Oil)···································································································48
2.8 Cetane Number ··································································································································48
2.9 Cetane Index ······································································································································48
2.10 Kinetic Viscosity································································································································48
2.11 Sulfur (High Sulfur Content Fuel)······································································································49
2.12 Desulfurized Diesel Fuel, Ultra-Low Sulfur Diesel Fuel ···································································49
2.13 Water Content···································································································································49
2.14 Sediment···········································································································································49
2.15 Ash····················································································································································49
2.16 Copper Plate Corrosion Test ············································································································49
2.17 Coking···············································································································································49
2.18 Aromatics ··········································································································································50
2.19 Asphaltene ········································································································································50
2.20 Impurities ··········································································································································50
2.21 Lubrication Performance of Fuel (Indicated by the Wear Trace Diameter in HFRR Wear Tester)···50
2.22 BDF: Bio-Diesel Fuel (Fatty Acid Methyl Ester: FAME)····································································50
2.23 Vanadium, Nickel and Sodium··········································································································50
2.24 Salt Content ······································································································································50
11. Concentration of Coolant to be Used (in the Case of GLASSY and PG GLASSY
Coolants) ········································································································································68
2. Property···············································································································································73
2.1 Performance Requirement ·················································································································73
2.2 Recommended Viscosity ····················································································································73
2.3 Additive ···············································································································································75
Chapter 7 RIGGING
1.Exhaust System································································································································83
1.1 Types of Exhausting Device ···············································································································83
1.2 Dry Type Exhaust Line························································································································84
1.2.1 Condensed Water and Draining Cock ·························································································85
1.2.2 Position of Exhaust Port···············································································································86
1.3 Wet Type Exhaust Line·······················································································································87
1.3.1 Exhaust Line Capacity (Size and Dimensions)············································································87
1.4 Exhaust Flow Resistance Pressure····································································································88
1.5 Acceptable Exhaust Flow Resistance·································································································88
2. Breather Pipe····································································································································89
2.1 Air Bleeding of Crankcase ··················································································································89
2.2 Piping··················································································································································90
Read the Safety Precautions and General Information in this installation manual carefully before servicing or operating the
engine.
IMPORTANT
The following special warning symbols are found in this manual. Also you will find these symbols on the engine.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Be
sure to obey the instructions.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Below is a list of the risks that you must always be aware of and the safety measures you must always carry out.
Plan in advance so that you have enough room for safe installation and (future) dismounting. Plan the engine compartment
including other rooms for inspection and servicing to be safe and easy for the work. Make sure it is not possible to come into
contact with rotating components, hot surfaces or sharp edges when inspecting and servicing the engine.
Ensure that all equipment such as pump drives and compressors has protective covers.
Stop the engine and turn off the power at the main switch (breaker) before starting work on the electrical system. Keep the
switches in the OFF position during the work, and set up a warning notice not to operate the machine at the controlling,
operating and steering points.
Do not work on a running engine. However, some works such as adjustments are allowed on a running engine if it is
absolutely necessary. Approaching an engine that is running is dangerous. Loose clothing or long hair can be tangled with
rotating parts, and may result in a serious injury.
Take precautions to avoid hot surfaces (exhaust pipes, turbochargers, inlet air manifolds and others), hot lubrication oil and
water during engine running and immediately after the stopping.
Reinstall all protective parts removed during service operations before starting work on the engine.
Ensure that the warning or information decals on the product are always visible. Replace a decal if it is damaged or illegible.
Be sure to install the air cleaner or pre-cleaner to the engine. Never start the engine without installing the air cleaner or
pre-cleaner. The rotating compressor parts in the turbocharger can cause serious personal injury. Also the operation without
air cleaner or-pre-cleaner will cause damage to the compressor, piston rings and cylinder liners.
-1-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
Never use a flammable starting aid such as ether spray into the air intake. Use of such products could result in an explosion in
the air inlet pipe and may cause personal injury.
Never open the filler cap for the engine coolant when the engine is hot. Steam or hot engine coolant can be ejected by the
pressure in the cooling system. Open the filler cap slowly and release coolant system pressure progressively, if the filler cap
or drain cock must be opened, or if a plug or engine coolant pipe must be removed on a hot engine.
Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the oil system is depressurized before starting working
on it. Never start or run the engine without the oil filler cap in place because of the risk of oil being ejected.
If the boat is in the water, stop the engine and close the bottom valve before starting operations on the cooling system.
Start the engine only in an area that is well ventilated. Exhaust gas is toxic. Do not breathe in. When operating in an enclosed
area, use exhaust extraction to lead the exhaust and crankcase gases away from the place of work.
Always wear protective goggles if there is a risk of splinters, grinding sparks and splashes from acid or other chemicals. Or
you may loose your eye sight.
Avoid skin contact with oil. Long term or repeated skin contact with oil can lead to the loss of natural oils from the skin. This
leads to irritation, dry skin, eczema and other skin problems. Old oil is more dangerous to your health than new oil. Wear
protective gloves and avoid oil-soaked clothes and rags. Wash hands regularly, especially before meals. Use protective skin
creams to help clean and to stop dry skin.
Most chemicals intended for the product (engine and marine gear oils, glycol in coolant, gasoline and diesel fuel), or such
chemicals used in the workshop as solvents are harmful to your health. Read the instructions on the packaging carefully.
Always obey the protective measures (using a protective mask, goggles, gloves etc.). Make sure that other personnel are not
unknowingly exposed to harmful substances, in the air that they breathe for example. Ensure that ventilation is good. Dispose
of used and excess chemicals as instructed.
Be careful when tracing leaks in the fuel system and when testing injectors. Wear protective goggles. The jet from an injector
is under very high pressure and fuel can penetrate deep into tissue, causing serious injury with a risk of blood poisoning.
All fuels and many chemicals are flammable. Keep away from naked flames or sparks. Gasoline, some solvents and hydrogen
from batteries in the correct proportions with air are very flammable and explosive. Do not smoke! Maintain good ventilation
and take necessary safety measures before welding or grinding in the vicinity. Always keep a fire extinguisher accessible in
the workplace.
Store oil- and fuel-soaked rags, old fuel and oil filters properly. Oil-soaked rags can, in certain circumstances, ignite
spontaneously. Old fuel and old filters are environmentally harmful. Carry them with used lubrication oil, contaminated fuel
and solvents to a proper refuse station and dispose of them as environmentally harmful material.
-2-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
Ensure that the battery compartment is designed according to current safety standards. Never allow an open flame or electric
sparks near the batter area. Never smoke near the batteries. The battery discharge hydrogen gas during charging and the gas
and air mixture is explosive. This gas is easily ignited and highly explosive. Incorrect connection of the battery can cause
sparks sufficient to cause an explosion and damage the battery. Do not lean over the battery when charging the battery or
operating the engine.
Always ensure that the plus (positive) and minus (negative) battery leads are correctly installed on the corresponding terminal
posts on the battery. Incorrect installation can result in serious damage to the electrical equipment. Pay special attentions to
install the electric leads to electronic controllers for the correct wiring. Refer to the wiring diagrams.
Always wear protective goggles when charging and handling batteries. The battery electrolyte contains extremely corrosive
sulfuric acid. If this electrolyte comes in contact with the skin, immediately wash with soap and plenty of water. If the
electrolyte comes in contact with an eye, flush immediately with plenty of water and seek medical advice.
Use the lifting eyes fitted on the engine or marine gear when lifting. Check the capacity of the lifting equipment and ensure
the capacity enough to lift the engine and marine gear. (The weight of marine gear and other equipment are sometimes
included in the engine weight.)
To ensure safe lifting and avoid damage to components installed on the engine, us an adjustable lifting beam. Hitch all chains
and cables in parallel to each other and square to the engine as far as possible.
If extra equipment is installed and the center of gravity is shifted, prepare a proper lifting device and keep the correct balance
for lifting.
Never work alone when installing heavy components, even when using secure lifting equipment such as lockable block and
lifting jig. Most lifting devices require two people. One handles the lifting device and the other keeps watch on components
not to get caught and damaged.
The components in the electrical system and fuel system used in marine engines are designed and manufactured to minimize
risks of fire and explosion. Do not operate the engine in an environment with a possibility of explosion.
Always use fuels recommended by MHI. Refer to the Operation and Maintenance Manual. Use of a low quality fuel can be
the cause of engine failure. On a diesel engine low quality fuel can cause the fuel control rack to stick causing the engine to
over-speed with resulting risk of damaging the engine and personal injury. Low quality fuel can also lead to higher
maintenance costs.
Never operate the engine by controlling the fuel rack manually. This will lead to over-speeding of the engine and engine
and/or generator will be damaged. Parts thrown from the over-speeding engine and generator can lead to personal injury.
-3-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
2. General Information
2.1 About this Installation Manual
This manual is intended as a guide for the installation of marine engines for inboard use. This manual is not comprehensive
and does not cover every possible installation. This manual is to be regarded as recommendations and guide lines by MHI.
These recommendations are the results of time-proven experiences of practical engine installations all over the world.
However, departures from recommended procedures are sometimes inevitable or preferable. In those cases, MHI will be glad
to offer assistance in finding a solution of installation procedure for the customer’s requirement. It is solely the installer’s
responsibility to ensure the smooth and complete installation work. The work must be in a good order, use approved material
and accessories, and comply with the rules and regulations.
This installation manual has been published for professionals and qualified personnel. Therefore the persons using this
manual are assumed to have the basic knowledge of marine drive systems and be able to perform the related mechanical and
electrical work.
MHI continuously improves its products and reserves the right to make changes. All the information contained in this manual
is based on the product data available at the time of editorial work. Notification of any important modifications to the product
will be made in Service Bulletins.
It is very important when installing the engine that no dust or other foreign substances get into the fuel, cooling intake and
turbocharger systems. Or the engine will be suffered from seizure or failure. For this reason, the systems must be covered.
Clean supply lines and hoses before connecting them to the engine. Remove the protective engine plug only when making a
connection to an external system.
○ Adjustment of injection timing, and inspection and repair of fuel injection pump, fuel injection nozzle and turbocharger
must always be performed by an approved MHI workshop.
○ Installation of exhaust pipes and intake ducts for the engine compartment must be carefully planned. If the ventilation
capacity is insufficient, exhaust gas components may be affected.
○ Never break the seals which set the fuel injection amount.
CAUTION
Use only MHI genuine parts.
Using of non-genuine parts will mean that MHI will no longer take responsibility for the engine meeting the certified design.
All damages and costs caused by the use of non-genuine replacement parts will not be covered by MHI.
-4-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
Certain systems such as components in the fuel system may require special expertise and special testing equipment. Some
components are sealed at the factory for the prevention of failure and accident or environmental reasons.
Never work on sealed components except for the case worked on by authorized personnel.
Most chemical products damage the environment if used incorrectly. MHI recommends the use of biodegrading degreasing
agents for cleaning engine components, unless otherwise indicated in the manual. Take special care when working on board to
ensure that oil and waste are stored as environment destructive material and not accidentally pumped into the environment
with bilge water.
Before sea trial, all systems are tested by the shipyard and MHI or its dealer as a collaborative work. When these test are
performed and approved by the parties, the vessel is ready for the sea trial.
In the sea trial, the engine performance, propeller matching, vessel maneuverability and others are tested. The vessel systems
must be approved by the all parties in all items.
Vessels are classified by use, and all systems and function must be tested and approved by a local surveyor. If extra equipment
is installed, it must satisfy the classification rules. Some equipment have type approval document which means the equipment
can have the classification certificate.
All the classification rules are made to provide a safe sailing for on board personnel and to prevent accidents which can lead
to negative environmental effects.
Normally vessels with classification signs are safer and have classification surveyors check the vessel regularly.
-5-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
-6-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
-7-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
4. Propeller Matching
We recommend the guideline below for the installation of engine to achieve a satisfying service life.
The optimized condition is that the real engine speed at the maximum
lever position is the same to that of the maximum load condition.
Normally the error is 1.5 to 3 % or below.
○ The engine speed at C shows a too heavy propeller.
If the deviation is significant readjust the propeller matching.
The dirt on hull after long hour services increases the load to the
engine.
○ The engine speed at D shows a too light propeller.
If the deviation is 3 to 5 % or more change the propeller to a heavy
one.
Select a light propeller by 3 to 5 % than the propeller curve,
considering the dirt on hull after some sailings.
○ Normally, a propeller having a performance between the A and B lines is considered to be a good matching.
The proper matching to the load with a controllable pitch propeller is an easy job. Pay attention only to a high-pitch
slow-speed operation when the propeller is set to an excessively high pitch. This results in over load (when the propeller is set
to be over pitch).
The engine operation at the point C will cause problems due to the overload condition, and frequent maintenance will be
required. With the reduced propeller load, the vessel speed will be changed little but the problems will be much reduced.
-8-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
5. Operating Environment
5.1 World Operating Temperature
Seawater temperature
Design seawater temperature is according to classification societies and is normally 32℃ (90℉).
Environmental temperature
The lowest ambient temperatures in the world for the consideration of engine installation are shown below.
The world is divided into the following temperature zones:
A North Europe: 35 ℃
B South Europe: 40 ℃
C Scandinavian countries and UK: 30 ℃
D North America, Canada, Central and South America, Parts of Asia: 40 ℃
E Africa, Middle and Far East, Australia and the South Pacific countries: 50 ℃
The temperatures specified for various parts of the world are base on the average of the highest monthly shaded ambient
temperatures recorded over a number of years.
It is the responsibility of the ship yard / customer to ensure that the cooling system specification is suitable for the area where
the application is operated.
However, no matter how the cooling tests are carried out under the various conditions, it does not guarantee that occasional
overheating of machines in service will not occur.
Considering hotter weather than that of the average or recent abnormal weather, it is advisable that the cooling systems are
designed with some margins.
-9-
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 10 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
7.1.2 Engine-Marine Gear Directly Connected, Coaxial Down Angle Drive Type
The marine gear is directly connected to the engine. A conical gear is installed on the output gear of the marine gear. The
output shaft is angled by 7 to 10 degrees.
The engine and marine gear form one unit. The propulsion force from the propeller is absorbed by a shaft bearing in the
marine gear.
- 11 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
7.1.3 Engine-Marine Gear Directly Connected, Drop Center Parallel Drive Type
The marine gear is directly installed to the engine, and the engine’s crankshaft and the marine gear’s output shaft are
positioned in parallel.
The output shaft is on a lower level than that of the crankshaft.
The engine and marine gear form one unit. The propulsion force from the propeller is absorbed by a shaft bearing in the
marine gear.
7.1.4 Engine-Marine Gear Directly Connected, Drop Center Down Angle Drive Type
The marine gear is directly connected to the engine. A conical gear is installed on the output gear of the marine gear. The
output shaft is angled by 7 to 10 degrees.
The engine and marine gear form one unit. The propulsion force from the propeller is absorbed by a shaft bearing in the
marine gear.
- 12 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
7.1.5 Separately Positioned Marine Gear, Drop Center Parallel Drive Type
Marine gear is separately positioned from the engine and connected through a flexible coupling. The crankshaft and propeller
shaft are in-parallel, and the output shaft is on a lower level than that of the crankshaft.
The remote marine gear is first installed aligning with the propeller shaft center. Then install the engine through the flexible
coupling.
- 13 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 14 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 15 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
The drive package consisting of engine, flexible coupling and marine gear supplied by MHI is constructed as one unit and has
the lowest possible torsional vibration level in terms of a standard propeller system.
MHI conducts the TVC if other combinations are to be used. Incorrectly selected components in the drive package can result
in abnormally high stress in the engine crankshaft.
- 16 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 17 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
Plan the engine room so as not to restrain the engine servicing work.
Refer to the maintenance manuals and make sure that all filter replacement, oil change and other servicing measures can be
carried out normally.
Also ensure the installation and removing of the engine.
Before starting any installation work, make sure that up-to-date dimensional drawings for the engine and its equipment are
used. Dimensional drawings provide all the necessary measures for installation, such as the distance from the center of the
crankshaft to the engine brackets (marine gear brackets) and to the center line of the propeller shaft.
NOTE: Do not use the small silhouette drawings on leaflets and brochures for the installation job.
The engine and drive line should be installed in such a way as to minimize the noise and vibrations, in other words air noise
and body noise (vibrations).
Vibrations from the engine and propeller are transmitted through the suspension and engine bed to the hull. Other channels
are through the exhaust pipe, coolant pipes, fuel pipes, cables and control cables.
Pressure shocks from the propeller are transmitted through the water into the hull. Pulsation force on the propeller goes into
the hull through the support brackets, bearings and seals.
If the propeller is at a large angle this pulsating pressure and force can be considerable. Use of an incorrect propeller can
result in cavitation, which also causes noise and vibration.
Tosional vibrations from correctly selected components in the drive package are often negligible.
NOTE: Always consider international and local requirements and regulations.
○ Engine room layout
Use only updated and approved dimensional drawings. Study the drawings carefully. Consider the engine’s movements
when running and the accessibility for servicing and repair.
For the twin-engine twin-shaft installation, the distance between the engines should be sufficient to allow an easy access
for inspection and service work.
○ Selection of engine mounting type
Select the appropriate type of engine suspension based on the comfort requirements, type of use and engine/marine gear
arrangement.
The engines are mainly mounted by fixed mounting or elastic mounting type.
In the fixed system, the engine and marine gear are directly bolted to the engine bed.
While in the elastic system, the engine and marine gear are installed on flexible mounts. Select a shaft system depending on
the type of coupling (fixed or elastic), shaft support, stuffing box and others.
○ Fuel system
Determine the type of fuel system. Select the use of fuel hoses or fuel pipes. And consider the classification rules. Decide
where to place the extra water separated from fuel filters and plan for the routing of fuel hoses and pipes, fuel filter and
venting hoses, shut-off devices and others.
Fuel feed and return hoses or pipes must be dimensioned correctly.
○ Cooling system
Determine the type of cooling system. Select where to place seawater intake, seawater filter, keel cooler and others. Plan
the routing and dimensions of water pipes.
○ Exhaust system
Determine the type of exhaust system. Plan the installation of the exhaust line components, such as silencer and exhaust
pipe.
○ Starting system
Select starting system suitable for the intended type of use. MHI offers electric and air starting systems.
○ Electrical system
Plan the routing cables and .check the length of instrument cable harnesses. Decide where to place the fuse box and main
switch.
CAUTION
Avoid joints and cable connections where there is a risk of moisture or water. Do not make any joints or connections behind
fixed bulkheads or similar where the access becomes difficult after finishing the vessel.
- 18 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
○ Electrochemical corrosion
The potential problem of galvanic and stray current corrosion must be considered when planning the electrical installation
and selecting the equipment to be used. Plan the protected anodes.
○ Air supply, ventilation and soundproofing
Carefully study the size of sufficient duct area. And pay attention to optimize the design of air inlet.
Plan the routing of the ducts (hoses) for the engine’s air consumption and ventilation so that they do not impede the
installation of batteries, fuel tank and others.
Sound insulation of the engine room is very important. To keep the sound level as low as possible, sufficient space for
sound proofing material must also be planned for. A condition for good sound insulation is a sealed engine room with ducts
as the only openings.
○ Control and monitoring systems
Plan the routing of control cables, steering systems, and others allowing the accessibility for servicing and replacement.
Place the cables as short in length, having few bends and large curbs as possible, when using mechanical control cables. As
a result the cable operation is smooth, and the risk of cable breakage and other troubles is reduced.
If the vessel has an electronic control system, it is very important to define all signals between the engine and the control
system. All the parties must have the interface concept in common and know the type of signals transmitted and received.
This must be stated in the order acknowledgement to the ship yard. No undefined signals are to be found later on.
○ PTO
In order to operate miscellaneous small auxiliary apparatus, PTO can be fitted to an additional pulley.
If greater output is needed, a mechanical PTO can be fitted at the front end of crankshaft. The outputs permitted from the
PTOs are described in Engine Data and Drawing.
- 19 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 20 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 21 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 22 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 23 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 24 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 25 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 26 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 27 -
Chapter 1 OUTLINE OF ENGINE INSTALLATION
- 28 -
1. Centering Procedure
- 29 -
CHAPTER 2 CENTERING OF SHAFTS
5 Make a marking of center line on square wood. Place the wood on the engine bed aligning its mark to the leveling line.
6 Referring to the position of propeller shaft flange face, make marks of holding-down bolt positions based on the calculation.
Then, drill the holes. Measure the height of engine bed top face and shaft center position. Calculate the clearance between
the marine gear mounting bracket and the engine bed. Ensure the clearance wide enough to accommodate chock liners of
several mm thick for the adjustment.
- 30 -
CHAPTER 2 CENTERING OF SHAFTS
- 31 -
CHAPTER 2 CENTERING OF SHAFTS
5 Bring the laser leveler in the engine room and change the beam to the leveling mode.
Illuminate a vertical beam to the marked center position and make the vertical line mark.
6 Calculate the height distance between the propeller shaft and the bottom face of mounting bracket from drawings or others.
Make a make of the height.
7 Illuminate a horizontal laser beam to the bracket height mark and make the horizontal line mark.
The height difference between the horizontal line and the board lower edge (top face of the bed) is the clearance for chock
liner adjustment.
* The engine bed must be horizontal for this procedure.
- 32 -
1. Size of Engine, Engine Bed and Engine Room
- 33 -
CHAPTER 3 INSTALLATION OF ENGINE
2.Verification of Engine Room Carry-In Entrance Size and Protection of Engine Room Devices
- 34 -
Chapter 3 INSTALLATION OF ENGINE
- 36 -
Chapter 3 INSTALLATION OFENGINE
- 37 -
Chapter 3 INSATALLATION OF ENGINE
6. Centering Procedure
Measure the axial runout and face runout at four positions on the
mating face of marine gear output flange referring to the propeller
shaft flange.
Adjust the difference between the opposite positions of top/bottom
and right/left to be within the standard (even) by moving the marine
gear position with adjusting bolts and jack bolts.
- 38 -
Chapter 3 INSTALLATION OF ENGINE
- 39 -
Chapter 3 INSTALLATION OF ENGINE
3 The lateral direction adjustment of axial runout is made by tightening and loosening of right and left direction adjusting
bolts of the engine. Loosen the adjusting bolts in the opposite side of the tightening. The vertical direction adjustment of
axial runout is made by tightening and loosening of jack bolts.
Check the flatness frequently with the straight gauge and thickness gauges / dial indicator to adjust.
4 The front-back direction adjustment of face runout is made by tightening and loosening of forward and backward direction
adjusting bolts of the engine. Same to the axial runout adjustment, loosen the adjusting bolts in the opposite side of the
tightening.
Check the clearance frequently at four places in mating faces by inserting thickness gauges during the adjustment.
- 40 -
Chapter 3 INSTALLATION OF ENGINE
- 41 -
Chapter 3 INSTALLATION OF ENGINE
◦Resin Liner
Another method to fix the engine is available. Pour epoxy resin
into the space to engine bed after the centering with jack bolts
on the engine and marine gear mountings is finished.
The resin to be used must be approved by the Maritime Technology
and Safety Bureau.
Verify the temperature at mounting is 60 ℃ or less.
Refer to the operation manual supplied by manufacturer for detail.
- 42 -
Chapter 3 INSTALLATION OF ENGINE
- 43 -
Chapter 3 INSTALLATION OF ENGINE
- 44 -
Chapter 3 INSTALLATION OF ENGINE
10. Deflection
- 45 -
Chapter 3 INSTALLATION OF ENGINE
- 46 -
1. Outline
The fuel cost takes the most part of engine operational cost. And the fuel property affects largely the engine performance and
life. Also many components composing the fuel system, besides the engine mounted ones, are installed in an engine room.
The proper knowledge of function and construction of these components is essential for the planning of installation.
2. Fuel General
2.1 Fuel Properties and Composition Affecting the Engine Trouble
If the fuel properties are designated by maritime emission regulations in each country, obey the regulations. Even in this case,
make sure the required performance specified for the degradation of lubricity caused by the reduction of fuel sulfur content.
A low grade fuel is often used for marine engines when the emission regulation is not applied. In this case, the use of a fuel
having MHI recommended properties is specified. Especially in the maritime market, low grade fuel with high sulfur contents
is widely used. Consideration is necessary for the sulfur content and the fuel quality to be used.
If the sulfur content is 0.2% or more, use the fuel which conforms to the [Limit of Fuel Property] on P53.
- 47 -
Chapter 4 FUEL SYSTEM
- 48 -
Chapter 4 FUEL SYSTEM
2.14 Sediment
The fuel, which was carried in a contaminated tank truck after a low grade oil delivery of the truck or stored in a
contaminated fuel tank, causes the wear of injection system parts, injection nozzle stick and premature clogging of fuel filter.
Un-burnt sediment forms sludge and rapidly contaminates the lubrication oil.
2.15 Ash
Ash consists of metals and other contaminants. It forms the gray-brown deposit on the combustion system parts such as
pistons and valves as it is an incombustible substance. For this reason, ash accelerates the sliding face wear of piston ring,
cylinder liner, inlet valve and turbocharger. It also wears the sliding faces of injection system.
2.18 Aromatics
Aromatics are poor in ignitability, and cause the starting trouble and white smoke. The aromatics are components which have
a characteristic fume called aroma.
Aromatics are one of the causes of low cetane number, and may cause the valve stem sticking by retarding the combustion
and increasing the exhaust temperature.
Reclaimed light oil is of aromatics and one of materials used in low grade diesel fuels. When a fuel has a high specific gravity
and low cetane number, it is thought to contain much amount of aromatics.
2.19 Asphaltene
Asphaltene is a component of asphalt and a blackish brown solid or semisolid containing much sulfur, oxygen and nitrogen.
It is flame resistant and tends to produce unburned carbon and soot. This results in the increase of combustion chamber
deposit, and the wear of piston rings and liners.
This can also be a cause of sticking of the fuel injection pump plunger and the fuel injection nozzle. A much amount of
asphaltene causes the fuel filter clogging. Sometimes it contains heavy metals such as vanadium and nickel.
The distillated fuel does not contain the asphaltene, but a fuel mixed with low grade oil sometimes contains it.
2.20 Impurities
Miniaturized rust generated in the outer fuel system and others become impurities.
When the impurities go through the fuel filter and entered the combustion chamber, scuffing of piston ring and cylinder liner
may occur in some very extreme cases.
2.21 Lubrication Performance of Fuel (Indicated by the Wear Trace Diameter in HFRR Wear Tester)
The lubrication performance is indicated by the wear scar diameter (measured mean wear scar diameter: MWSD) in μm unit.
The trace is generated by contacting the test disk and test steel ball immersed in a fuel of 60 ℃ in the controlled condition of
the high frequency reciprocating rig (HFRR).
After the humidity correction of wear diameter in the standard vapor pressure condition of 1.4 kPa (10.5 mmHg), the wear
scar diameter is used for the indication of lubrication performance of the fuel.
- 50 -
Chapter 4 FUEL SYSTEM
- 51 -
Chapter 4 FUEL SYSTEM
Specification Classification
EN 590 DIESEL-FUEL
- 52 -
Chapter 4 FUEL SYSTEM
Limit of fuel property
JIS K 2269:1987
Pour point (PP) 6°C [42.8°F] or lower than ambient temperature ISO 3016
JIS K 2288:2000
Cold filter plugging point (CFPP) 3 °C [37.4 °F] or lower than ambient temperature IP 309/96
JIS K 2270:2000
Carbon residue (10 % residual oil) 0.4 weight % or lower 1.0 weight % or lower ISO 6615
ISO 10370
JIS K 2280:1996
Cetane number 45 or higher
ISO 5165
JIS K 2280:1996
Cetane index (new type) 45 or higher
ISO/DIS 4264
Lubricity: MWSD (Measured mean Wear Scar 460 μm [0.02 in.] or less
Diameter) by HFRR wear test at 60 °C (calculated wear scar diameter at WS - ISO 12156-1
[140 °F] fuel temperature 1.4 kPa {0.0143 kgf/cm2} [0.2031 psi])
- 53 -
Chapte 4 FUEL SYSTEM
(1) For the selection of the fuel tank, additional fuel filter and the fuel piping to the related equipment, it is essential that the
products which have capacities large enough to ensure the fuel supply to the engine.
(2) Fuel leak from the fuel system is very dangerous to cause a fire. Use the high grade piping material which complies with
the required fire safety standards, and pay attention to install and construct piping safely.
- 54 -
Chapter 4 FUEL SYSTEM
- 55 -
Chapter 4 FUEL SYSTEM
- 56 -
Chapter 4 FUEL SYSTEM
- 57 -
Chapter 4 FUEL SYSTEM
5.1 Dilution Caused by the Fuel Leak from Plunger in Fuel Pump
(1) During the engine operation, the clearance between plunger and barrel is sealed with fuel film, and the whole amount of
compressed fuel is discharged from the plunger to the injection nozzle. However, when the fuel temperature is excessively
high, or a low viscosity fuel is used, the fuel film becomes extremely thin. The fuel leaks through the clearance between the
plunger and barrel, and drips down to the cam chamber of fuel pump. Then the fuel goes down to the oil pan, and dilutes
the lubrication oil.
In a cold district, when the low cetane number fuel oil A mixed with a light oil to lower the pour point, as described before,
is used for a prolonged time of low-idling,, the fuel leak amount tends to be significant.
(2) Pay attention to the height of fuel tank when planning its installation.
The maximum head drop from the fuel plane to the fuel pump and the negative head drop are specified for MHI engines.
If the fuel tank is installed at a position higher than the specification, a static pressure is applied to the plunger chamber by
the head drop from the fuel plane. When the engine is left un-operated, the fuel may leak through the clearance between the
plunger and barrel with the elapse of the time, drip down to the cam chamber of fuel pump and dilute the lubrication oil.
5.2 Dilution Caused by Defective Combustion or Faulty Spray from Injection Nozzle
(1) In a cold district, the cooling water temperature in the water jacket around the cylinder line is low. In this condition, if a
low cetane number fuel is used, the dilution may occur when a prolonged time no-load low-idling operation is made. The
un-burnt fuel moves down to the lubrication oil as the fuel can not burnt completely.
(2) In case of the use of low quality crud fuel containing much carbon residue, the hard combustion product accumulates
around the nozzle orifice, and the fuel spray is disturbed. This may results in the production of un-burnt fuel caused by the
degraded combustion. Also, a foreign substance may be caught at the needle seat of nozzle tip and cause a defective sealing.
This also results in the lubrication oil dilution by the un-burnt fuel with the incomplete combustion resulted from the spray
failure. A portion of the un-burnt fuel is discharged through the exhaust port. The remaining un-burnt fuel goes through the
clearance on the cylinder and gets mixed with the lubrication oil in the oil pan. This phenomenon is often seen in the light
load operations.
- 58 -
1. Outline
The installation personnel of the cooling system has the responsibility to ensure the function of cooling system in accordance
with the written orders and drawings.
The capacity of heat exchanger used in the cooling system must be designed to have a capacity enough to be free from the
cooling performance shortage affected by the surface deposit on the heat exchanger after a long period of service or
re-painting.
Select the equipment which does not reduce the circulating flow amount or increase the pressure more than the allowable
value of the circulating pump installed on the engine.
Too small pipe diameter, improper routing and incorrect connection reduce the cooling capacity and cause the abnormally
high temperature of the engine cooling water. Special attention must be paid to install a long cooling channel for such cooling
systems as the keel cooling and central cooling.
To verify the cooling capacity and the proper installing work, the engine must be operated to check the pressure, temperature
and flow rate.
Design the proper combination of pipes and valves, ample capacity of expansion tank and correct pressure setting of the
expansion tank cap to construct a proper pressure cooling system and minimize the corrosion and erosion. Also, the use of a
coolant having MHI recommended brands (recommended quality properties) is necessary.
The quality control of coolant is very important to protect the various materials of external cooling system as the charge air
cooler when the engine is connected to an external cooling system such as a keel cooling, central cooling or other systems.
Always use the genuine coolant which is a mixture of antifreeze and antirust for MHI engines.
The quality of coolant affects the engine cooling performance.
- 59 -
Chapter 5 COOLING SYSTEM
2. Cooling Passage
- 60 -
Chapter 5 COOLING SYSTEM
- 61 -
Chapter 5 COOLING SYSTEM
3. Seawater Cooling
As described before, two cooling channels, one low-temperature channel for inlet air cooler and the other high-temperature
channel for the heat exchanger of water jacket, are recommended to install. Also, one cooling channel which goes through the
low-temperature inlet air cooler and then the high-temperature heat exchanger of jacket water cooler is available.
○ Seawater channel
The seawater flows through the system with the seawater pump.
A rubber impeller type and a metal impeller types are used in the
seawater pump. In the small size engine, the rubber impeller is
widely used.
○ Seawater inlet port, seawater valve, filter and seawater piping
Place the seawater inlet port at a position where the pipe to the
pump becomes the shortest. Also the position is secured not to suck
air when the vessel is rolled by waves.
The flow area of the seawater inlet port, valve and strainer must be
large enough.
In the case of the planning craft, the slotted water inlet port is
recommended.
Design the seawater inlet port not to be disturbed to sail in an ice
field.
The seawater valve must be placed at a place which allows an easy
access in case of emergency.
The service life of pump or impeller is reduced when the pump suck
significantly contaminated seawater or seawater near a coast which
includes sand and trash.
Also, the accumulation and clogging of these foreign materials may
result in the engine damage with the reduced cooling performance.
The installation of a seawater filter is necessary to minimize the
intrusion and accumulation of foreign materials in the cooling system.
Install the seawater filter at a place which allows an easy access for
the inspection and maintenance.
Design the curb of an inlet pipe is gradual and the pipe diameter is
big to avoid a big flow resistance.
When a rubber hose is use at a place above the sea level, avoid
the breakage and deformation by the suction force. Use a high grade
rubber hose with multiple fiber layers. To fix the both ends, use two
clamps made of stainless steel at each end.
○Heat exchanger
The seawater flowed with the sea pump driven by the engine cools
the air cooler, exchanges heat with the jacket water and then is
discharged.
Many thin pipes are installed in the heat exchanger (expansion
tank) to provide a large surface area and increase the cooling
efficiency.
The seawater flows through the tube reduces the jacket water
temperature by transferring heat from the high temperature jacket
water to the low temperature seawater.
○ Seawater pipe size
Refer to the drawing of the engine for the flange dimensions of sea-
water pipe on the engine.
- 62 -
Chapter 5 COOLING SYSTEM
4. External Cooling
The sealed cooling system is recommended to use in a port where seawater contains much foreign objects such as sand and
suspended mater.
In the external cooling system, generally, the standard cooling water pump installed on the engine circulates the engine
cooling water to an external cooler. Use the coolant which complies with the MHI recommended standard.
Refer to the section of Coolant for detail.
The external cooling devices applicable to the external cooling system are as below:
○ Keel cooling (pipe cooling)
○ Skin cooling (double hull)
○ External cooling tank
○ Box cooling
- 63 -
Chapter5 COOLING SYSTEM
- 64 -
Chapter 5 COOLING SYSTEM
The external cooling system must be designed and calculated considering the various factors below.
In the case of keel cooler the proper pipe diameter and length, in the case of double hull cooler the height and width in the
tank must be appropriate for the back pressure, flow rate and heat release.
The design of flow must avoid the flow impingement at a steep curb and the tank end.
To design the cooling passage, consider the factors below:
○ Technical data of the engine
○ Output power and revolution speed of the engine
○ Operation pattern
○ The lowest vessel speed at the maximum output power
○ The highest seawater temperature
○ Cooler dimensions
○ Cooler material
○ Thickness of cooler coating
○ Exhaust system, wet type or dry type
○ Engine load and speed when the power take off is used in a vessel stable condition
○ Concentration of coolant affecting cooling performance
5. Expansion Tank
An expansion tank must be installed when the standard expansion
tank on the engine is too small or the tank is not attached. Place
the expansion tank at the highest position in the engine cooling system.
The capacity of the expansion tank must have 10 % or more of the
total coolant amount. With a 5 % margin, preferably 15 %.
Connect the expansion tank to the suction side of jacket water pump
through the static line. Install a vent pipe from the engine to the tank
with 1/20 up grade.
- 65 -
Chapter 5 COOLING SYSTEM
- 66 -
Chapter 5 COOLING SYSTEM
Chemical Recommend
Item Unit Limit Main adverse effect
symbol value
Corrosion and rust, scale
pH (25°C [77°F]) - - 6.5 to 8.0 6.5 to 8.5 formation
Electrical conductivity (25°C Corrosion and rust, scale
- mS/m < 25 < 40
[77°F]) formation
Total hardness CaCO3 ppm < 95 < 100 Scale formation
M alkalinity CaCO3 ppm < 70 < 150 Scale formation
Chlorine ion Cl- ppm < 100 < 100 Corrosion and rust
2-
Sulfuric acid ion SO4 ppm < 50 < 100 Corrosion and rust
Total iron Fe ppm < 1.0 < 1.0 Scale formation
Silica SiO2 ppm < 30 < 50 Scale formation
Residue from evaporation - ppm < 250 < 400 Scale formation
9. Requirement to Coolant for Stable Antirust and Anti-Corrosion Performance for Long-
Hour Engine Operation
The performance of antirust and anti-corrosion additives used in coolant is as below:
(1) Use a non-amine type antirust additive which does not contain any amine to ensure the antirust performance of copper
family material. Also the use of heat and acid resistant additives without containing nitrite salt, borate salt and silicate is
required.
(2) The antirust performance varies depending on the kinds of additives, their mixing balance and the degree of
degradation.
However amine type antirust is difficult to maintain mixing balance, and amine itself is a short life additive.
For this reason, amine family is an obstacle to perform a stable antirust performance. MHI does not recommend the use of
amine type antirust for this reason.
(3) Additives have different target metals. Some additives have adverse effect to accelerate corrosion on some metal other
than the target. Amine attacks copper metal strongly, and it accelerates the consumption of antirust/anti-corrosion additives
for copper metal. Contrarily, a coolant without amine reduce the consumption of antirust/anti-corrosion additives for
copper metal, and the reduced copper metal corrosion result in a reduced secondary corrosion of iron and aluminum metals.
(4) Silicate is unstable and precipitated in gelatinization. It loses the antirust effect on aluminum and the gelated silicate
accelerates the wear of water pump mechanical seal.
(5) Nitrite salt is a low cost and effective antirust/anti-corrosion additive for iron and cast iron. However, its life is short
and will strongly attack copper metal by producing ammonium ion in an iron-rust rich condition. Also it may produce
carcinogenic nitrosamine in a coexistent condition with amine.
(6) Borate gives hostile effect on aluminum parts at the high temperature (heat conducting) surface and accelerates
corrosion with the use of phosphate.
(7) Even in a non-amine coolant the lowered concentration of antirust agent causes corrosion of aluminum, bras, solder
and others. Be sure to obey the specified coolant maintenance procedure, and keep the coolant concentration.
11. Concentration of Coolant to Be Used (in the Case of GLASSY and PG GLASSY Coolants)
(1) The concentration of coolant must be kept to 30 volume % or more in the case of GLASSY (ethylene glycol) and 40
volume % or more of PG GLASSY (propylene glycol) all through the year under any temperature conditions for the
protection of the water pump and prevention of cylinder liner cavitation.
(2) The concentration of coolant as a function of antifreeze is decided by the lowest ambient temperature through year. Keep
the using coolant concentration range as the table below.
- 68 -
Chapter 5 COOLING SYSTEM
12. Precautions to Use MHI Genuine Long Life Coolant: GLASSY and PG GLASSY
(1) Pour the genuine LLC after washing thoroughly inside of the cooling system. The consumption of additives is
accelerated and they can not work fully if rust or scale remains in the cooling system. Be sure to repair the leak in the
cooling system before using the coolant, if necessary.
(2) Use tap water as dilution water in Japan.
(3) Pour in the required amount of genuine LLC first. Then fill with dilution water. Start the engine to circulate fully in the
cooling system. Bleed air thoroughly from the cooling system.
(4) Never add water only when the coolant becomes low level. The concentration will be lowered.
Be sure to blend the same concentration of coolant as initially poured GLASSY, and add the blend.
(5) Dilute GLASSY in the range of 30 to 60 volume % or PG GLASSY 40 to 85 % and use the cooling water as the coolant.
The concentration of ethylene glycol in GLASSY is 91 weight %.
The concentration of propylene glycol is 65 weight %.
(6) Replace the genuine LLC two years after pouring or 8000 service hours, whichever comes first.
(7) Do not mix the genuine LLC with other brand antirust, antifreeze or coolant or the performance of the LLC is impaired.
- 69 -
Chapter 5 COOLING SYSTEM
LLC specification
Property Standard
Appearance No precipitation
Minimum 1.112 g/cm3 [69.4199 lb/ft3] (20/20°C)
Density [68/68°F]
(Stock solution)
Water content Maximum 5.0 weight % (Stock solution)
30 vol % Maximum -14.5°C [6°F]
Frozen temperature
50 vol % Maximum -34.0°C [-29°F]
Boiling temperature 155°C [311°F] or higher (Stock solution)
pH 7.0 to 11.0 (30 vol %)
30 vol % 4.0 ml or less
Bubbling character
(ASTM D3306-01) 150 ml [0.032 gal] or less, Disappearance of
331/3 vol % bubble within 5 seconds.
Hard water adaptability 1.0 or less (50 vol %)
Aluminum ±0.30 mg/cm2
Cast iron ±0.15 mg/cm2
- 70 -
Chapter 5 COOLING SYSTEM
LLC specification
Property Standard
Aluminum ±0.60 mg/cm2
- 71 -
- 72 -
1. Outline
Use MHI genuine lubrication oil. In a case when a lubrication oil other than the genuine one by necessity, check the oil grade
and it must conform with the MHI quality standard. Sample the oil for analysis after engine operation to know the oil
replacement interval. A defect in relation to lubrication oil will not be guaranteed when the lubrication oil does not satisfy the
MHI standard.
Engine lubrication oil not only retains oil film on sliding surfaces and gears to suppress wear, but also treats and cleans
combustion products to prevent wear, oxidation, and corrosion. And, the lubrication oil, which works as coolant, removes heat
from high-temperature portion to keep an appropriate temperature. Thus, the lubrication oil is extremely important for the
functions and service life of engine and also it is an expendable part.
2. Property
The properties of engine lubrication oil must meet strict conditions because it is exposed to high-temperature combustion gas,
oxides of fuel, etc. during engine running.
- 73 -
Chapter 6 LUBRICATION SYSTEM
In a cold weather, increased viscosity of lubrication oil increases engine rotational resistance and decreases cranking speed of
starting motor, thereby impairing engine startability. Lubrication oil must have appropriate viscosity to retain oil films at
sliding surfaces even at a high temperature and curb the rotational resistance growing at a low temperature.
Lubrication oil conforming to the table [Temperature range and SAE viscosity number] is recommended to use for the
MHI diesel engine.
Temperature range and SAE viscosity number
SAE viscosity number of Appricable temperature range (Note)
usable lubricating oil
Lowest temperature (ºC) Highest temperature (ºC)
SAE 30 0 +35
In general, lubrication oil viscosity is indicated by the SAE (Society of Automotive Engineers in the United States) viscosity
number. Viscosity index is the indicator to express relation between lubrication oil viscosity and temperature. Larger index of
lubrication oil shows that its viscosity is less influenced by its temperature. Like SAE 15W-40, the lubrication oil with two
numbers is called multi-grade oil. The viscosity number of 15 indicates the viscosity at a low temperature (W is derived from
Winter), and 40 indicates the kinematic viscosity at the oil temperature of 100°C. This lubrication oil guarantees both
startability at a low temperature and oil film at a high temperature for engine. [Temperature range and SAE viscosity
number] is shown below.
- 74 -
Chapter 6 LIBRICATION SYSTEM
2.3 Additive
The lubrication oil used in engine requires various additives to realize the functions described below. The table shows the
typical additives and their functions.
Major additives and functions
Additives Type (additive amount) Properties and functions Typical components
Detergent Organometallic salt imide s Disperses soot or sludge formed with Sulfonate-phenate of Ca,
dispersants (Nitrogen type) fuel combustion or dust into oil to Ba, Mg
(0.5 to 3.0 %) prevent them from depositing as solid or Ashless dispersant
matter.
s Neutralizes acid of combustion
products to prevent sludge
formation.
Antifoam Silicon polymer substance s Quickly collapses foam which Silicon oil
(1.0 to 100 ppm) promotes oxidation degradation of Ester oil
lubricating oil.
- 75 -
Chapter 6 LUBRICATION SYSCTEM
- 76 -
Chapter 6 LUBRICATION SYSTEM
API/JASO CF class *1 -
JIS K 2249
ISO 3675
Density 15°C [59°F] g/cm3 0.87 to 0.90 ISO3838
ISO 649-4
ISO 91-1
JIS K 2283
Viscosity - - ISO 3107
ISO 2904
JIS K 2265
225 to 250 ISO 3679
Flash point °C [°F] [437 to 482] ISO 2719
ISO 2592
JIS K 2501
ISO 3771
Acid number mgKOH/g 1.5 to 2.0 ISO 6618
ISO 6619
ISO 7537
JIS K 2541
Sulfur content % 0.5 or less ISO 4260
ISO 8754
JIS K 2272
Sulfuric acid ash % 2.0 or lower ISO 3987
ISO 6245
JIS K 2270
Carbon residue content % 2.0 or lower ISO 10370
ISO 6615
JIS K 2269
Pour point °C [°F] -25 [-13] or lower ISO 3015
ISO 3016
I 10/0
Forming test*2 mL JIS K 2518
II 30/0 ISO 6247
III 10/0
- 77 -
Chapter 6 LUBRICATION SYSTEM
4.1 Factor
In addition to the deterioration of lubrication oil itself, mixing with combustion products, oxygen, or foreign objects
accelerates further the deterioration and contamination of lubrication oil.
4.1.2 Contaminant
Oxides mixed into the lubrication oil from combustion blow-by and cylinder liners, combustion products such as soot and
unburned fuel, and dust that enters from air intake system lead to engine lubrication oil deterioration.
Metallic powder caused by wear inside the engine acts as a catalyst of oxidation reaction to accelerate the deterioration
together with the moisture contained in combustion blow-by. Sulfur contained in fuel is oxidized to form sulfur dioxide (SO2),
which is bonded with moisture by catalyst such as metallic oxide to form the serious contaminant of sulfuric acid (H2SO4).
And, nitrogen oxides formed by combustion is also included in the corrosive contaminants.
4.1.3 Oxygen
Oxygen that remains unused in the fuel combustion, because excessive air is sucked into the diesel engine combustion
chamber, is mixed into combustion blow-by to enter the crankcase. The oxygen that enters the crankcase oxidizes
high-temperature lubrication oil. As the high-temperature oxidation degradation progresses, the oil viscosity increases by
polymerization of oxides to form the sludge and varnish. The biggest factor in oxidation deterioration is the continuous use of
high-temperature lubrication oil due to the long-hour, heavy-load continuous running of the engine.
4.1.4 Fuel
Viscosity of fuel is approximately 1/40 of that of lubrication oil. The fuel mixing dilutes the lubrication oil to reduce its
viscosity. The materials which dilute lubrication oil are limited, and dilution in engine only indicates the fuel mixture.
Dilution factors are as follows:
Injection pump
Generally, the injection pump has the plunger reciprocating in barrel to compress fuel to a high pressure. And, a narrow
clearance of several microns is made between the plunger and barrel to lubricate them with fuel. When the engine is
running, the clearance is sealed by fuel oil film formed with sliding movement of the plunger. Therefore, almost all the
compressed fuel is pushed from the plunger into the injection line.
However, the fuel oil film becomes extremely thin when the fuel temperature is excessively high, or the fuel has a low
viscosity unsuitable for the temperature around engine is used. Then, the fuel may be leaked from the clearance to drip into
the injection pump oil pan easily. Especially, kerosene (that MHI does not approve in principle) must not be used because it
tends to cause the fuel leakage. Fuel may leak during engine stop, depending on the conditions.
Generally, the plunger of the in-line type injection pump is positioned almost vertically. Therefore, the fuel which remained
at a clearance between the plunger and barrel flows into pump oil pan gradually to be replaced with the fuel stored in the
clearance at the upper part of plunger and barrel. The head between the fuel level of fuel tank and injection pump creates
pressure at the fuel inlet of barrel. Large pressure applied to the pump fuel inlet during engine stopping period accelerates
the fuel leakage from the clearance between plunger and barrel. In the engine equipped with the general in-line type
injection pump, lubrication oil may be diluted because the pump is not equipped with a drain for leaked fuel. For less
frequently running engines such as the generator set for stand-by use or emergency use, and fire pump set, the higher fuel
level at fuel tank accelerates dilution. Therefore, in planning the installation, the tank height must be specified carefully. For
the MHI engines, the maximum and negative heads between injection pump and tank fuel level are specified. Therefore, in
planning the installation, refer to the chapter 4 [FUEL SYSTEM].
- 78 -
Chapter 6 LUBRICATION SYSTEM
Injection Nozzle
Solid combustion products such as carbon and sludge deposited on the injection nozzle hole may disturb the fuel splay to
cause incomplete combustion, thereby producing unburned fuel. When the nozzle does not close tightly due to adhering
solid matters, un-atomized fuel may drip directly without burning. In any case, some raw fuel that remained in the
combustion chamber is discharged together with the exhaust gas from exhaust port. However, the other remaining fuel
dissolves in the oil film at cylinder liner to mix with the lubrication oil in oil pan finally.
Operating Condition
When the engine is running under a light load or no load for a long period of time, the combustion becomes unstable
because combustion chamber remains in a low-temperature. Then, it is highly possible that the unburned fuel may be mixed
into the lubrication oil to cause the dilution.
4.2 Effect
This section describes the effect of lubrication oil deterioration caused by various factors in engine.
4.2.1 Viscosity
Viscosity is one of the most basic and important performances of lubrication oil. The increase of viscosity caused by the
polymerization of oil oxides and the mixing with soot and dust indicates the progress of contamination and deterioration of
the lubrication oil. And, sludge formed in the process of deterioration deposits inside the engine, and clogs lubrication oil
filter in the worst case. Sludge and varnish cause the poor lubrication and the low heat transfer to cause the piston ring
sticking. Acidic matter formed by the oxidation corrodes bearings.
As lubrication oil viscosity becomes low, oil film thickness required for sliding surface cannot be maintained at a high
temperature in running. Then, poor lubrication accelerates the wear. When the dilution reduces lubrication oil viscosity
considerably, the oil film is broken easily. Then, scuffing occurs on the piston and cylinder liner at the time of engine starting,
which may lead to serious problems in the worst case.
Experience shows that, when the kinematic viscosity of lubrication oil is reduced to 10 mm2/s or less while the engine is
running, wear at the sliding surface and lubrication oil consumption increase extremely.
4.2.4 Moisture
Moisture is combined with the combustion product of sulfur dioxide to form sulfuric acid, which causes the severe corrosive
wear and the poor lubrication at sliding surfaces inside engine. And, when a large amount of water is mixed into lubrication
oil, the emulsion may block the oil filter.
- 79 -
Chapter 6 LUBRICATION SYSTEM
5. Change Interval
It is difficult to uniformly specify the lubrication oil change interval because the contamination and deterioration in
lubrication oil depend on various conditions. However, knowing the correct usable time of lubrication oil before changing is
very important for the functions and service life of engine. Lubrication oil must be changed before the internal contamination
and wear begin to have harmful effects on the engine. The usable time of lubrication oil should be determined based on the
contamination inside engine and the wearing conditions of moving parts. However, it is extremely difficult for the users and
OEM customers of engine-driven unit.
Therefore, in practice, the lubrication oil should be changed adequately before the permissible property limit of the
lubrication oil, based on the technological experiences accumulated up to now by MHI, is exceeded.
When the lubrication oil is changed, used oil must be completely discharged from the engine and tank to avoid the mixing of
different brand oil.
5.1 Standard Interval
MHI specifies the basic usable time of lubrication oil for engine using fuel with sulfur content of 0.2 % or less.
The basic interval is 250 hours. And refer to the operation and maintenance manual for your specific engine.
Obey this service limit hours to decide the lubrication oil change if the oil analysis is not to be done.
- 80 -
Chapter 6 LUBRICATION SYSTEM
- 81 -
- 82 -
1. Exhaust System
1.1 Types of Exhausting Device
The exhaust device in marine engine has two types.
○ Dry type exhaust line – heat insulation required
○ Wet type exhaust line
The dry type is easy to maintain and has a long life with durability.
The exhaust line requires a heat insulation treatment. The insulation is for the safety of personnel and avoids effect of exhaust
temperature to the engine performance from the heat in the engine room as the exhaust pipe surface temperature is very high.
In the case of wet type exhaust system, the cooling water used for the engine heat exchange is sprayed into the exhaust line
and cools the exhaust gas. The water is exhausted with the gas. The exhaust temperature is significantly lowered with the
supplied water in the exhaust line. Elastic rubber hose can be used for the exhaust piping connector.
Also, the wet type system does not require the insulation treatment as the heat radiation from the exhaust pipe is low.
The key point to adopt the wet type exhaust system is a proper designing of the exhaust line to prevent the engine from the
intrusion of cooling water such as seawater flowing backward.
CAUTION
The designing and construction must be proper so that the back pressure (resistance) of exhaust gas flow in the pipe may be
the engine allowable value or lower. Refer to the specification sheet of each engine or the technical data for the value of
allowable back pressure.
Pay attention to the overheating of facility installed near the engine exhaust line.
Construct the piping to prevent the exhaust gas from entering into the cabin.
- 83 -
Chapter 7 RIGGING
- 84 -
Chapter 7 RIGGING
CAUTION
Bind the heat insulation material to the exhaust pipe to prevent the
fragment from being sucked into the turbocharger inlet port.
Be sure to install the flexible pipe at the exhaust pipe connection
near the turbocharger exhaust port to absorb the heat expansion
of the exhaust pipe and protect the turbocharger from vibration.
Support the exhaust pipe at a position within 1m downstream from the
flexible pipe.
The exhaust pipe at turbocharger exhaust port should be as short and
straight as possible.
The exhaust line including the silencer after the flexible pipe should
be supported with a flexible bracket, and constructed to allow the
movement by the heat expansion.
Provide a drain pipe of condensed water in exhaust gas, and place a
drain cock at a position which is the lowest in the pipe line and close
to the engine.
The exhaust gas pipe must be designed and constructed to allow the
back pressure (exhaust gas flow resistance) of the total exhaust system
to be the allowable value of the engine or lower.
When the exhaust pipe is long, the back pressure becomes high
(gas flow resistance). So, a bigger diameter of the exhaust pipe is
required.
- 85 -
Chapter 7 RIGGING
- 86 -
Chapter 7 RIGGING
CAUTION
In the case of cooling water spraying into the exhaust pipe, the flow
resistance is increased by the droplets to 1.5 to 2.0 times of the
exhaust gas only flow. So, the design study of water spray into the
exhaust pipe is very important.
Also, the design to prevent the water from flowing back to the engine
is also important.
- 87 -
Chapter 7 RIGGING
- 88 -
Chapter 7 RIGGING
5. Breather Pipe
WARNING
Never connect the breather pipe from crankcase to any other pipe. Especially, an explosion may result when the pipe is
connected to the exhaust pipe. Also, each breathing device is required to each engine.
CAUTION
The breather pipe must be heat insulated to avoid freezing in a cold district where the condensed water may be frozen.
- 89 -
Chapter 7 RIGGING
2.2 Piping
Ramp the pipe 3 degree upward or more. The pipe diameter B after the drain tank must be larger than the diameter A of
flexible hose side pipe by 50 % or more. The pipe diameter B farther than 10 m from the engine must be larger than the
diameter A by 100% or more when the pipe is longer than 10 m.
The blow-gas will be pressurized with the accumulation if the breathing device is not sufficient. The engine crankshaft, seal
and gaskets will wear when the pressure becomes excessive.
Moreover the engine oil leak may result.
Check the crankcase pressure to know the engine and crankcase breather conditions.
Measure the pressure at the time of sea trial, and use the value as the standard for the future pressure measurement.
The pressure in crankcase must not exceed the maximum allowable crankcase pressure of (+-30 mmAq).
WARNING
Never leak blow-by gas into the engine room. Blow-by gas is toxic consisting of the components similar to exhaust gas and
lubrication oil. The efficiency of turbocharger will be decreased when the gas is sucked in with air and the inlet blower is
contaminated.
- 90 -
Chapter 7 RIGGING
3. Starting Device
3.1 Type of Starting Devices
Electric starter, air motor starter or air starting system can be selected as usage.
*Use the cable of 100 mm2 in sectional area between *Use the cable of 200 mm2 in sectional area between
the battery and battery switch. the battery and battery switch.
When the 200 mm2 cable is not available, use two
100 mm2 cables.
- 91 -
Chapter 7 RIGGING
The starter relay monitors the synchronized operation of two motors. When a motor is detected to be ceased its function, a
signal is send to the terminal M and the starting sequence is cancelled after three seconds.
In a normal starting condition, the terminal M of the starting relay is supplied with a voltage.
- 92 -
Chapter 7 RIGGING
- 93 -
Chapter 7 RIGGING
4. Electrical System
4.1 Electrical Equipment
Install the electrical equipment after full investigation and with much care. The simplicity is an important factor of the
electrical system designing.
Use the cable and connector of electrical equipment which types are approved for the marine use.
Use the cable with protective sheath, and fix the cable properly.
Place the cable avoiding the heating part such as the high temperature part of engine and others. Also avoid the place to be
abraded.
Use a protective pipe if necessary.
Reduce the electrical system connectors as few as possible. Consider the accessibility for inspection and repair especially for
the planning of connectors.
The total electrical system diagram is recommended for the marine regular possession. It will ease the identification of failure
and the addition of equipment.
WARNING
Cover the cables perfectly and fix properly. A serious breakage or fire will result if the insulated cable wears or breaks by the
engine vibration or the contact with a sharp edge.
CAUTION
Do not place the connector at a low position in the engine room. Place the all connectors at a position higher than the
alternator.
4.2 Battery
4.2.1 Capacity
Measure the capacity by ampere hour (Ah). The capacity of starter battery is usually shown by 20 hour capacity. It means the
battery can discharge the current continuously for 20 hours with the voltage of 1.75 V/cell (X 6cells = 10.5V).
Example: When a battery can discharge 3A for 20 hours, the capacity is 60 Ah. The capacity is affected by the temperature.
The battery capacity is shown at the temperature of 25 ℃ (77 °F). The capacity of battery is significantly
reduced for discharging energy when the temperature is low. The table below shows the change of capacity with
the change of temperature between 25 ℃ and -18 ℃.
- 94 -
Chapter 7 RIGGING
CAUTION
Use the same type of batteries. (the same capacity and voltage)
Also, use the batteries of the same production year.
The recharging current differs depending on the battery service year.
The load is evenly distributed. (All the batteries share the equipment load.)
* Serial connection
The capacity does not change but the voltage becomes twofold when two batteries are connected in series. Each battery
receives the same current of the supply from the alternator. The battery voltage of the two serial-connection batteries must not
exceed the charging voltage of alternator.
Example: The voltage is 24 V and the capacity is 190 Ah when two batteries of 190 Ah and 12 V are connected in series.
* Parallel connection
The capacity becomes the total of two batteries but the voltage is the same when two batteries are connected in parallel. Each
battery receives the lower current of the supply from the alternator. To measure the charging current to each battery, use a
current meter and measure the each battery.
Example: The capacity increases when the serial-connected batteries of 190 Ah 12 V are connected in parallel.
In this case the capacity is 380 Ah.
Usually the marine system voltage is 24 V which is the same to the serial-connected batteries.
- 95 -
Chapter 7 RIGGING
WARNING
The diluted sulfuric acid is highly volatile and easy to be ignited. It will cause an explosion or fire when it directly contacts
with a spark or open flame.
Be sure to cut the charging current before disconnecting the cable terminal.
Use sealed batteries when contained in a box.
Provide a vent pipe when non-sealed batteries are necessarily contained in a box to exhaust the air in the box to outside.
- 96 -
Chapter 7 RIGGING
The excitation force generated by the engine rotation excites the engine structure through various pathways.
The excited structure creates radiated sounds to our ears as diesel engine sound.
The vibrating power generated by the engine rotation excites the engine structure after transferring through multiple passages,
and is emitted as the radiated sound of diesel engine. The sound from inlet and exhaust mechanism and auxiliary equipment is
the other factor to increase the engine total sound level.
- 97 -
Chapter 7 RIGGING
These types are not separately use. A complex combination is used to attenuate the target sound deadening characteristics.
- 98 -
Chapter 7 RIGGING
6.2 For the Engine Room Ventilation, Satisfy the Condition Below:
○ Supply the air amount enough for the engine combustion.
○ Be sure to ventilate the engine room to keep the temperature in engine room in an allowable range. Supply air enough to
avid the pressure in the engine room to become a negative pressure.
The ventilation is also important to keep the temperature of electric appliances and injection system of the engine at a low
level, and to cool down the engine total body.
Install ventilating facilities such as the air vent and ventilator which have an ample capacity for safety when personnel
assignment is necessary.
NOTE: Obey the local safety rules and legal requirements.
Also obey the proper classification society standards if necessary.
CAUTION
The heat load becomes high if the maximum output operation is kept without reducing the fuel injection amount in an
environmental where the temperature is high. A high maintenance cost will be the result by the wear of piston, piston ring,
cylinder liner and others, deterioration of lubrication oil, abnormally rapid wear of bearings, and others.
- 99 -
Chapter 7 RIGGING
- 100 -
Chapter 7 RIGGING
The inlet air temperature at the air filter must be lower than 35 ℃ at the maximum output.
The engine itself has parts which become very hot. Place the electrical components such as charging controller and relays at a
relatively low temperature place such as the bulkhead or other place.
The maximum temperature is 70 ℃ for the installation of electrical components. Install the starter and alternator to the
specified positions respectively.
- 101 -
Chapter 7 RIGGING
- 102 -
Chapter 7 RIGGING
- 103 -
Chapter 7 RIGGING
- 104 -
Chapter 7 RIGGING
- 105 -
Chapter 7 RIGGING
- 106 -
Chapter 7 RIGGING
- 107 -
Chapter 7 RIGGING
- 108 -
Chapter 7 RIGGING
- 109 -
- 110 -
1. Inspection of Components and Checking of Valves and Switches
- 111 -
Chapter 8 SEA TRIAL ANDDERIVERY
- 112 -
Chapter 8 SEA TRIAL AND DERVERY
- 113 -
Chapter 8 SEA TRIAL AND DERIVERY
- 114 -
Chapter 8 SEA TRIAL AND DERIVERY
- 115 -
Chapter 8 SEA TRIAL AND DERIVERY
- 116 -
Printed in Japan Pub. No. 98CAB-71000
July 2011 MEDIUM & LARGE MARINE ENGINE INSTALLATION MANUAL Pub. No. 98CAB-71000