6-8DK-28 INSTRUCTION MANUAL (OPERATION) cuapren| Introduction General General Construction Engine Adjustment Standards Operation Inspection and Maintenance , Cooling Water Fuel Oil, Lubricating Troubleshooting and Countermeasures OAs for the disassembly,maintenance,assembly,and the parts to be replaced, refer to the separately provided Instruction Manual (Maintenance) and parts List. 0 that the supervisor ofthe engine is ‘changed, be minded that these documents, slong with the duties, shall be transferred to the successor without a fall, 6+ 80K-28 B 02-11CONTENTS 6-80K-29) Chapter 0 INTRODUCTION 1. Before Funsing Daihatsu Diese! Engine 2, Basic Information on Safely Operation 21 Salaty Precautions 22 Salety Signs and Symbol Marks 23. Indeation of Warring: Warning Labels 24 Indeation of Watning: Waring Label Postions {3 Engine Conforming to NOx Technical Code 34 Outline 32. Tho pars tobe Specifod 29 Engine settings 4. General Information 44 Notation of Engine Types 42 Detinton of Terms 43 Units Chapter 1 GENERAL 1. Engine Specitations 2. Auilny Equipment 3, Engine Outine and Equipment Layout ‘Chapter 2. GENERAL CONSTRUCTION 1. Engine 1.1 Engine Frame, Cylinder Liner, and Main Bearing 112 Crankshat and Besring 1. Camehatt and Timing Gear 1.4 Piston and Connecting Ros 15 Oylinder Head 1.6 Feel Injection Device 1.7. Valve Operation Device 1.8 Fual Conte! Device 19 ntoke and Exhaust System 2, Piping Systems 24. Staring Preumaic System 22 Fuel Oi System 23 Lubvicating Ox System 24 Cooling Water System 125. Nozzle Cooling System DAIHATSU on 0 oz o22 o23 ozs oss oz 033 Oo oat 42. 043. 1 ay 13 2 as aaa 212 218 218 216 2a7 218 219 22 zea 222 228 224 226 6+ 80K-28 2 01-9,(6-8DK-28) CONTENTS 3. Controling Engine Operation: Protective Device 8.1 Starting Control 382 Stoppage Contol 33, Engine Protecton System Chapter 3 ENGINE ADJUSTMENT STANDARDS: 1. Operating Speciicaions 2, Valve Settings Chapter 4 OPERATION 1. Precautions far Operation 11. Incase of Staring 1.2 Incase of Operaton 1.2. Incase of Stoppage 2. Preparation for Operation 2.1 Preparation for Daily Operation 22 Preparation for Ina Starting ater Instatation and Starting ater Extended Disuse or Overhaul 3. Staring 3.4 Starting Procedue 82 Inspection and Check hems imme 4. Operation 44 Runniog-n 42 Warming up and Connecting Loa tthe Engine 43. Operation with Load (Normal Operaton) 444 Operation Using Heavy Fuel Ol (for Heavy Fue! Ol Engines) 45. Alowable Operating Range 5. Special Operation 5.1 Lowload Operation 52 Operation with At Cooler Cut ot 53. Non Turbocharger Operation 54 Operation with Reduced Number of Cylinders 6. Stoppage 6.41, Normal Stoppage 62 Emergency Stop 63 Long-term Shutdown oly ater Starieg 6-8DK-28 Z 01-3 DAIHAT: 2a 204 292 233 a 32 4n2 413 42 424 43 asa 4a2 “4 442 443 444 4s 45 451 452 45 454 46 461 462 463CONTENTS 6-aDk-29) Chapter § INSPECTION AND MAINTENANCE 1. Precautions for Inspection and Maintonance 11. Satety Precautions 112 Cautionary toms Whon Frishing Inspection and Maintenance 2. Inspection and Maintenance lem Table 8, Measurements and Adjustments 3.1 Maximum Explosion Pressure and Exhaust Temperature 3.2. Prescure and Temperature of Each Part 4, Inspection and Maintenance 41 Inspecting Parison and around Intake and Exheust Valves, and Adjusting Valve End Clearance 42 Inepecton and Maintonance of Fue! injection Vale 4.3. Cleaning Fiters 444 Cleaning Turbocharger Blower 45. Clearing Turbocharger Turbine Sie 46 Measuring Crankshatt Detection 47 Inspecting and Replacing Protective Zine ‘Chapter 6 FUEL OIL, LUBRICATING OIL, COOLING WATER 1. Fue! Oil Characteristios and Contr! 1 Selecting Fuel Oi 1.2 Fuel Ol Charactrstes and Contot 2. Lubricating Ol Characteristics and Control, 21 Selecting Lubricating OF 22. Lubricating Ol Characters and Control 5. Cooling Water Characteristics and Cont 8.41 Cooling Fresh Water (Raw Water 382 Contosion Prevention Agent Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES, 1. Precautions for Troubleshooting 2, Troubleshooting and Countermeasures 2.1 Whon Stating is Oiticut 22 When Engine Revolution Is Not Smooth 23; Insticient Output 24 When Exhaust Gas Temperature or Maximom Explosion Pressure ls Abnormal DAIHATSU 51 54. B12 52 53 531 502 54 54a 542 543 saa 54s 546 5a7 oa era 12 62 621 622 eat 62 72 724 723 724 6 80K-28 Z 01-3\6-8DK-26) CONTENTS 6 25. When Exhaust Gas Shows Abnormal Color 26. Abnormal Noise/Abnormal Vibration 2.7 When Engin Stops Suddenly 28 Unableto Stop Engine 29 Overepecd 2.10 Low Lubricating 01 Pressure 2.11 High Lubteating 08 Temperate 2.12 Low Cooling Water Pressure (Jacket Line) 2.19 High Cooling Water Temperature (Jacket Line) K-28 7 01-3. DAIHATSU 728 726 727 728 729 7210 ren 7212 72.18Introduction Before Running Daihatsu Diesel Engine l6-90K-28| 4.4 ©. Introduction (044 Before Running Daihatsu Diesel Engine This instruction manual describes the proper optration procedure of the DK-20 engine, its daily maintenance and inspection procedure, and other ne Information on the engine. ‘To maintain the engine in good operating condition and ensure that it provides the spectied performance, be sure to read through this manual and become sufficiently familar withthe proper procedures before operating the engine. Do not use your engine for applications or under the coneitions other than those itis designed for. Be sure to observe the procedures described In this manual. Improper practices can cause damage to the engine or result in injuries or fatal accident «0 & A\eeen pace of he nomaton enclosed in he square box i an portant aalety procaine en prone ess wang or cat ) ‘The features and structure of your engine may be alerent from those provided inthis manual depending onthe specications of te engine delivered. In thie case, the engine specications and final documents supplied saparataly have pronty over this manual, (@) For the details on the folowing machine or device, see ther instruction manual supplied with his 1) Turbocharger 2) Governor 3) Air motor 4) Contol equipment 5) Other speca devices Be sure t use the genuine parts of DAIHATSU DIESEL [Link]. or thate specified inthe pars ts. ‘We wi net guarantee the proper operation of he engine ines such parts are used For replacement of the pats or service on your engine, contact our Paris Sales Department, Service Department branch ofce, othe nearest DAIHATSU DIESEL [Link],.Ltd provided on the cover page. Bo sure te provde us with he “ype and number of yout engine” when contacting us @ (6) To provent environmental contamination, do not dispose of waste products, liquids, et. thoughtlessly, Be sure to entrust the disposal of such waste products, liquids, et. to the authorged waste dsposel company. | __ The contents of this manual are subject to change without notice. DAIHATSUIntroduction 9 1 [-80K28| EER oration or Seely Operation: (0-2, Basic Information on Safety Operation 0-21 Safety Precautions | The diese! engine uses flammable ol. thas the high-speed rotational pars, the parts that become extremely hot, or the parts that are under high pressure fluid, during | operation. Improper handling of the engine can result in serious injury or fatal accigents, Be ‘sure to observe the safety precautions provided inthis manus (1) Beware of Rotational Parts ‘This engine has the high-speed rotational parts. Inadvertent contact of personnel or objects with such parts can cause that person to ‘get caught inthe engine, or cause the chips of objects to ty inal directions (a) Never attempt to touch the rotational parts such as the flywheel and couplings during ‘operation. Aso, be sue to place the protective cover in glae before operation, (©) Botor starting operation, check that no personnel is zround the engine. Warn any nearby personel by signaling that he engine is about to start eration, (@) Beware of Hot Parts 'A\ The engine parts are very hot during and immediaaly after operation. Touching them with bare hands or skin can cause burns. Note thatthe exhaust manifold turbocharger, Indicator valve periphery cylinder head, ar eacer ine, and heated heavy fuel ol pipes become extremely hot. (2) Never atiempt to touch any pat of the engine with hare hand or skin during or immecsately ater operation (©) Be sure to wear saety gloves or other proactive gear formaking measurements or inspection. (©) Allow the engine to suticinty cool down before performing inspection or maintenance work (@) Prevent Oil from Catching Fire 1) Cylinder nea 2) Piston 8) Tubocharger 4) Aircooer 5) Fuel cam 6) Fue! injection pump 7) Fool injcton pup plunger 8) Fuel jection vane {9} Fuel ijecton valve nozate 03.3 Engine settings values ‘The engines conforming to NOx Technical Code are adjusted tc conform tothe specications before shipment Aer shipment, they shuld not be adjusted eich a maner thatthe setng values spected in the technical le maybe deve any change is made inthe manner that may devia rom the setings specie nthe technical le, shal bo considered to be noncenformance tothe requvements ofthe techneal fle, and he inepection by the engine parameter neck method canet be apple “Te flowings are the tems that have beens 10 contorm te NOx Technical Coe: -ttoms set betoreshipment> (1) Ful injecton ising {@) Fuslinjecton vale opening pressure 6+ 8DK-28 A 02-10 DAIHATSUIntroduction Notatlon of Engine Types, Definition of Terms, and Units _|6'8DK-28|41~43 (0.4.1 Notation of Types Engine 68 ok M2 mw “sNumber of eyinders ‘sNome of series “Marne propulsion engine ‘0ylinder bor (rm) “Front end cive ‘Reverse rotation (0-42 Detintion of Terms Definitions of the terms used in this manual are rotons ‘Rear side of engine: Output end side (ywhee! 7 ar ‘io ‘Front side of engine: Opposte side 10 the output ‘ona ‘Exhaust side: Exraust mano side (on the ght ‘when seen fromthe output ena) sie, | irae rt cay Kua from the output ena ee 7 Be careful with cylinder ang Journal numbers. Numbers are. ven in ne |_ reverse order for eonventonal engines. 0-43 Units Basically, Si unis are used on the engine and inthis manval Noe that gues in {are reference values gWen in the conventional unt PAI 68DK-28 Z 01-3General Construction “1, 2|6-8DK-28| Engine Specifications and Auxiliary Equipment 144 Engine Specification 7 OK - Vertcl water cocing rect Numberofeyinders | Gyindersbore mm = Piston stoke mm Engine speed mi output Ignition eau tating ection Turbocharging method Staring method ‘Compressed ait (Siang valve yee) : sng moves 82ke Fresh water ieoemmecnteet | oka Fresh or Sea) water "Nolo Bah he iglon sequence and the roan rection sow the dala nthe case of normal rotalonvespecvly (2) Since the engina speed and th cuput, whien 10 maked wth x, diler depending upon ooh specications. be mined to enter ine daar retring to he “engine Spach! nd Teet Rum Record 1-2 Auxiliary Equipment ‘lary equipment Te Ramens ___Turbocharger__| Exhaust gas turbine ype - ‘Arcooler | Fivwube ype Governor | el nection pug Fusovave | Gai taceldige | aegis a Gate | Tetra du ta | tank Aailay ene: Ca yo Ramat | pezonig section aang pe ate Cosi wale puny | Cetin pe Nie The deta gre sve ale stow hse nh ase ro anda speceaton “Therefore, the cat of your engine may ster om hose shew nthe able, and in suzh a case the minded reerto th “Engine Specfeatons” 6+8DK-28 Z 01-3, DAIHATSUGeneral Construction Engine Outline and Equipment Layout le-e0K-28| 3 1-3 Engine Outline and Equipment Layout ree festa y ST Either ne) ‘rating pnp eee trig utr yanest DAIHATSU 6-80K-28 Z 01.3General Construction 11-145|6-8DK-28| Engine 241 Engine 2.1.1. Engine Frame, Cylinder Liner, and Main Bearing ‘The fame is 8 monoblock srvctie made of cast iron, andthe upper section ol the ieme forme. & cooing jek, together wth he eyiner ine. ‘The main bearing is @ suspension type. and mounted tothe engin ame wih 2 mounting Bots and? #8 bois Intake ak, ubteating ol, and each cooling water channel andthe timing gear case ae incorporated inte eng frame, ‘tame satety valves provided ote cover on the engine tame se, 21.2 Crankshaft and Bearing ‘The crankshaft i mage ofa foged and monothie structure, and te bearing part he crank pn and lournad s uench-hardaned ‘The tyne ie installed atthe rear end (output ie) ofthe crankshaft, and the erank gear for ving the camshaft is installed atte ont end of the camshat topeher wih the auxin ive ‘The main bearing and crank pn bering have a thin-walled, twopieco stucture, and a thrust smell tached 9 he ont a rer end of ‘he No.1 Beaing located atthe ear end 241.3. Camshaft and Timing Gear ‘The camahat is located on te le side of he engine (when seen om the auput Sie) ‘The intake car, exhaust cam, and fl cam ae incorporates to the camshaft, and itis a unt ype divided for each porton of 2 cyiners Each unit is connected tothe flange section that combines the sliding section with the ‘beams. ‘The cam goat for driving the camshat ie Inataled onthe font sco of he engine, and {he cam ger is drven Hom the exe goat vn ‘he ie gor (On the rear side of the engine, he drive coupling of the starting air rotary valve is inetaes 6+80K-28 Z 01-3 2.1.4 Piston and Connecting Rod ‘he piston is ofan assambly ype made ot special ay steet with duce cast iron, own by the ubreating otal i varsfred fom the connecting rod via piston rod. ‘The connecting re i for-uned forged product wih the lage end, whien vs horizontally spt nto three parts, to allow overhaul of he piston without ‘teassomblng th bearing uit 2415 Cylinder Hear The cylinder head i of a highly rigid structure secured one piston wih 4 bats Four vave system is employed having 2 intake vales and 2 exhaust valves, and a water cooing valve seat, ich is rectly tached to he cylinder head endl fr each exhaust valve, Tho inlet val and eyliner ate vale ae Instaled on the upper face of tho cylinder nese ana 8 starting vale i oeated onthe dof he Gray Sirens Ege tone PREEETGeneral Construction Engine 6°80K-28)1.6~1.9 241.6 Fuel injection Device ‘Tho fue! injction pump is a Bosch-type high prossure pump, and itis povided with isobaric vate Fuel ol injection pump is installed on the fel of Injection pump tape ‘The ajuting screws ate incorporated tothe fuel cil injection pump tappet for the purpose of adjusting he pump instalation height. ‘Also, te high-pressure one coupling, which is hofizoiakinserion ype, i connected othe ue of injection pump via the high-pressure coupling made of forge sea 24.7 Valve Operating Device ‘The Intake and exhaust valves are aiven by motion transferred rom he camhat va the sing farm, push 0, an oes em 21.8 Fuel Controt Device ‘The govemor i installed onthe front sido ofthe engine, and is driven by a coupe of the bevel gear ven by tho cam gear shat ‘The corto levers leated nest the gauge board on the font side of the engine, together withthe ‘tartngvabe and starting operation valve, 219 Intake and Exhaust System ‘Te turbocharger and ai cooler are mounted on the rear side of the engine as the standard cexvpment ‘The specication ofthe turbocharger may vary according tothe engine type, output, and the _pectication ot each order (LD: tstton Manual of Turbocharger) ‘The exiaust manifold and ir intake cuct are instates onthe same sido of tho engine, and the Intake dit incorprated a the engin rae, DAIHATSU 6+8DK-28 2 01-9,General Construction Piping Systems: 2.4] 6-8DK-24 Starting Pneumatic System 2.2 Piping Systems type of fuel used, and specifications. || Tis section describes the type! piping systems of standard specifications. For | Piping systems and related eauiment vary depanding onthe engine applications, | || more details, refer to the piping systems included in thefinal documents. 2.2.1 Starting Pneumatic System ‘The staring operaion of engine Is made by the pilot starting valve system activated by compressed a nan the pushbutton forthe staring operation valve i pressed, conta at wil owt he starting ir valve to open the main valve, and the Ccomprossed air acs tothe stating valve of ech ovine. Meanie, the compressed ar branched off fom the main siaring air pipet sequently sped to teach cylinder by the starting ar rotary valve fsecording to the ignition order, and opens the faring va ofeach onder ‘Te conpressd ar sent rough the main staring tir pipe eticts th piston, causing the engine 12 (nee ted sao eg) i ~o Beene statis rote, ‘The starting operaton vate and staring ar valve ar installed onthe front side ofthe engine, and the staring air rotary valve onthe rear sie of he engin, andthe stating ai weary valve is civen from the rer endothe camshat, Not tht a salty valve and a check vale are insaled inthe main a pie for prevention of be reversed ew of combustion ai Incase thatthe engine is started remotely sulomateay, the staring operation wil be mace tyr means the solenoid vale, allowing contol aie to reach te saring operon valve. (LD) *steeng Mato — Sey vane 1A stag ary vee ( Star ae Starting Pneumatic Systom (lot Starting Valve Type) 6+80K-28 Z 01-3 DAIHATSGeneral Construction Piping System: Fuel Oil Sy stem 6-80K-28)"" 2.2 2.22 Fuel Oil System Fall sytem vary depending onthe rads ofthe cil used, and atypical example of the fuel ol system fr heavy hol is as shown Blom ‘Wien heavy fel olf wed, of must Be hosted and kept a @ constant temperature to maintain the cel viscosity stale orien, (01 heat by the heater and pressurized by the ‘uel food pump is wanseredo the fuel of rection ump vie iter. Supls of os retumed 10 the pressure of bythe fel scbon pump is induce ito te fol nection valve connector from the cylinder head sie via high-pressure eg eusig. In cate ot Reavy ue oll specication, naz cooling a provided 1 prevent he formation ot carbon foe. ((ED)' 224 Nozze Cooing System) ‘Wen esl fel oe used, heating or heating inulin of a8 wet as nose cecing are not Mot sie fhe cl feed pump va gresture ‘wed oan Theodore pov wh aus tng ary cc eS tae ead Siomracocntengeurs Fre hare eho etn pur a rsa tt ol este a tr purus ted mer ced stem on crs (222 useage eta wero | jj, er i ci i) le) See _ _ 7 | & | Cl Saae| - Ee: e ee I a fo erm go econ | iE O ‘contraler & Ors OY poe i ig otto] Fat, LL ccc erecta eceecartetiaastitdiiia Cal Fon yt DAIHATSU 6+ 8DK-28 A 02-10‘General Construction 'g.3(6°8DK-28| Piping Systems: Lubricating Oil System 2.23 Lubricating Oil System ‘The ubriating ol system s as shown below. Lubricating ol transterrd fo the Iuonicating ol cooler rom he lubricating of pump is regulate to reach the specied temperature and presse, by ‘means of the automate empertue contol valve nator reer to as temperature contol ectvely, and the the oi channel of the engine tame tom the cooler va liter. Then, ‘rom th al ehanne the ubristng ol cupped to the piston trough the holes ofthe connecting shel Fortor,rbreaing oi supplied as branches trom the Same ol enannel tothe camahat valve Oa operating swing arm, tue ol injection pump, found thelecke am. and various gears, The lubrestig pump is ea type provides tale on the font fey vale, ane ‘Te uovetng ol es @notch-nte duplex ype, and blows! cleaing ding operation possible wth hi a Lubricating ott cupped to te turbocharger and fuel injection pump va each spacial btn of ‘mer respective. Luieating i, that has cielo hough and has lubniated aach par, retuns tothe base plate of the engine (olan MVM Fier [sles] [amma Lubricating 01 Sysytem 6-80K-28 Z 01-3 DAIHATSUGeneral Construction Piping Systems: Cooling Water System 6-8DK-28] 2.4 2.2.4 Cooling Water System ‘The cooing water system is dvd int the jacket ‘ne (penary wate) and he cade’ ine (Secondary wate) and noxmally the jacket line Is used for fresh water, andthe cooler line is used for sea tor (neat of uso for vessel) as he standard sppteaten (0) docket Line The jacket ine drevates cooing water, and he ater cooled by the kesh water ecole ery fed ito te cylinder jacket ot the engin by the coating water pump. so thatthe wator cools, various part ofthe engine and returns tothe ‘resh water cooler though the out callectve 2 torporatre contol valve i provided between ‘he inlet a outlet tthe engine (or, esh water cooler) to maintain the water temperature (2) Cover tine Cocing water nthe cole ina is fori ee by 8 spacal pump exclusive for cole ine, which separately installed, to the ait cooler, hiesing fi cooler, and fesh water cooler, ana is then dieerged foe ey d ) - | — Cooling Water System 6+ 80K-28 Z 01-3General Construction 2.5|6:8DK-28| Piping Systems: Nozzle Cooling System 2.2.5 Nozzle Cooling System Nezale cooing eystom i installed inthe engine that vse hoary tue ol In order to prevent the formation of the carbon flower that ocour an the moze tip ofthe fal Injection valve when fuel cil temperature is intensely neated, cooling of the nozzle tip is required, and ierlore the nozzle cooking using cooling water ose fel ols cated out [As the standard specification, cooling water is omplyed [As he cooling water, pat af the water used ooo! he ylnder head is branched out and reaches the {ual ci injection vae treugh the int main pipe, ot 50 that it ox0s the nozle tp and then retuns 16 the tet ain pip. Incase of he spec specication using se! ue the cooing system Iso independent feeding tom, and the nozze-cocing pur sisted ‘tontpar ofthe engine. Cling oi teaches the fof injection valve rom the cooling pump through the inet main pipe 10 cool the nezle tp. Aer cooling the nez20 tip, the ol rtins tothe out main pipe, and then returns tone ase! fel tank though the rele! vale and emperature contol vee. Thi 6 the forced feesorcultin system, Nozzle Cooling System Diagram (Diese! ue ol coating) 6+80K-28 2 01-3,General Construction gine Operation Conia, Protective Device: re Subting Conor one Protestve Device 6-80-28) 3.4 2-3 Engine Operation Control and Protective Device Control and protective devices such a the starting air valve and stoppage cylinder ‘are activated by low-pressure contol a ‘This section describes a system generally used for the power station that is remotely | controlled for starting and stopping. The engine that Is actually delivered may ditfer from the examples shown In this section depending on the specifications, and ‘therefore refer to the final dacumente, which are seperately provided, forthe det ‘Astor the starting ar system (high pressure), refer tothe previous section 22.1. | 23.1 Starting Controt Tous tothe starting st vave and the engine (1) For generator stars ts rotation 18) Remote Contro! i) In ease of starting the engine by remote ©) Engine side stating (loca starting) cnt the cota ver must aways be st In cae of starting the engine trom the engine to "RUN" postion, The handle etch (HS) ‘de local), slect the operation medo to the wale tunes “ON" at his slate, and the “LOCAL (engin sce poston, andi he push turning eaety awiteh (TC) ie lao turned button of the starting operation valve is “ON the engine wil be on standby and rested, conta it wil ow int the staring at ready fer operaton vate In ease of recy stating the engi, the faring solenoid (SEV) is powered, excted, (2) For marine propulsion engine nd seivated by @ stan command, so that a) Engine side starting (local stating) ent ows ito the starting ar vale via I) Imease of starting the engine trom the toring operation ve, an the staring ait ‘engine sie (cath), me cnangeover vane reaches the tang vave as the main vave ‘onthe engine must be se othe teal si, ‘e opened ‘and the conto ever must be changed 10 i) Meanwhile, the same start command alows ‘START pestion rom “STOP "poston. ‘he fuel conte solenoid (88 to activate, i Wren tho push button of the starting ‘eausing Cot! aio twit ue regulating ‘operating valve pressed, conto! a flows ‘ylnder, and allows the comman 10d © Be ln the staring valve, and staring a (righ held in position, so that the fel injection pressure) tows it he staring va asthe amount is contlled nt to be excessive at main valve of the starting air valve is the time of starting, opened. Iw When the engine reaches the specitied __—&) When the engine reaches the speciieg totaton speed, the low-speed ely (14) e rotaton speed, the low-speed ely (14s ‘actvate, canceling the stat command are factvated, so that the start command is resetting the protective cc, so thatthe cxreslee engine is sto operating state, iw When the idle rotation speed becomes: stable, turn the operation lever to "RUN ») Automatic Starting postion tom “START” postion, At this ‘Winen te engine is stated eutomatesly, the See, he hance seh (HS) wa be tures engine solenoid is actvted in reponse othe to ON", end the protective circuit wil be start command iesued automatically in the fomed so hat be operating sate reed. specitied sequence, so thatthe control air When the changeover valve onthe engine is DAIHATSU 6+ 8DK-28 Z 01-3,General Construction '3.4[6-e0k29| Enaiee Starting Gor jon Control, Protective Device: 1 switened tothe remote contal side, the fengine operating condition by the canta handle ofthe bridge wil be ready ') Remote starting (starting rom the bridge) 1) When the operation lever is set to "RUN" handle switch (HS) wil Bo ‘Then, by turing the saetysaitch (70) to “ON, the engine wil be on sanaby poston for starting 1 When tne conto! handle ofthe bie is et to "NEUTRAL" poston, he engin willbe on standby postion or staring dl t pew ‘Seeage cine By 2 stan command, the stating solenod (88V) will be powered, excited, and activates, and conta ir wl ow into the Staring valve vi the staring operation vale, ‘otha he main valve is opened and staring ‘ir tons into the stating valve wp When the engine rtaton is reached the specied speed, he lw speed rely (14) wl cancied, andthe protective cut wil be formed 5 thatthe engine ws be on stacey postin or tating, Roh cotter \ amar. ‘oats tes 1) | ae fra i ; ! | eae ire ea “rants ono) Starting and Stoppage System (Generator side remote control) 6 80K-28 Z 01-3General Construction ration 1, Protective Device: ad ation Contr z '6-8DK-28| Engine Starting Control Beh Bi 3 tone ened FE stant ne ete _tsiner an oe ee Oe tn eee Bi Ges = [ee fer | fe |e Geren tom conta nan) or) ‘Stating ar k Starting and Stoppage System (Marine propulsion engine side) 6+ 8DK-28 2 01-3General Construction Tor le. Engine Control, Protective Device: 3.2~3.3)6'8DK-28) Controting Engine Stoppage/Engine Protective Device 23.2 Stoppage Control 233 Engine Protection System ‘The ua shutdown solenoid (SV) is acWslec bya (H) As forte errors that may be led to serious stoppage command, causing cont air to few accidents of fallues, alarm is issued and into the fuel shutdown device, so that the emergent is mage ‘common rods tured tard stoppage crecton, Each of he abnormal operation data or vale is and en the engines stopped. elected by a switch or sensor, and the Wve! Funner, there may be case that contol alls shutdown scanod eased by an emergency flowed ita the sloppage cyander attached othe stoppage command, s0 that the angina le ‘uel ol injection pump by a stop command so that _immadately stopped the engine can be lopped {@) Depencing on the speciticatons, the dual ‘safely system is provided. In such 8 case in acdition tthe normal engine stoppage, conta Airis toed into te bah stoppage ar cyindors Injection pump 60 that tne engine ean be stopped {@)1n case of the maine propulsion engine ar contol system, when the forward catch of the reduction gear i engaged the govermor boost ‘solenoid ll be activated by the movement of he conrl hard, causing the governor boost a 0 reach the governor so thatthe decrease ofthe {engine wotten speed canbe prevented. Further, tbe engine ration speed is controled time the governor ai reaches the FO control, cylinder‘ contol the rotation epead of the ommon 10 0 ta he excessive supply oo Injection canbe restrained 6+ 80K-28 2 01-3, DAIHATSUGeneral Construction Engine Control, Protective Device, i Controlling Engine Stoppage/Engine Protective Device _|6-8DK-28] 3.3, Table 23-1 Alarm and Stoppage tons (Examples) Detection tem | Alarm | Shutdown {Location Remarks Overspeed 2 ‘Cam gear Decrease of brian ssretumncinag | sesor | esce Engine net incase fresh cocina | yrpe Toa Contined ie ‘water temperature Powe Engine outiet {or issuing command | Dagreaae of osha | oar “Turbocharger inet remem | +768 tngpwiont [Seger mei Son oes aa Tama eadar Saye or | was | Doneasg tiger | waa | Engine brcating lank -Haved Option et pate OY om . I aaa T | Engine Protection System (Example) DAIHATSU 6+ 8DK-28 Z 01-3,Engine Adjustment Standards 16-80-28) Operating Specifications 3. Engine adjustment standard 341 Operating Specifications | Sanngar | Artnk Conotar | Artank ao Fite | ect | i Fuel oit Engine iniet | ; eane| 2 Lubricating ot outet) i ‘30 Turbocharger é it ia ey “chet ine etsy Cootng water | Weel et onary wane ar | Aiike cc i vine co | exer as raberein ’ Tweed ot 5 — sa | Engine inlet 3 | earcang or | (coders # Tcl Ere F rcretine _E9 2 (Seine out & | cooerine) Engrs inet Reference Vales depending on ‘rbecharger “Consider sae and Syname pressure (Soe totank heed and (oral vate |ABrm sing ate Normal value rapes ae (20-39, cs, 08 (60) Deceit i 92-038-3) Mao | sees or [025,620 Ps eo) (os-15) 025-038 (25-38), 01-02 ‘eal __| 45-55 00 2 Notes (1) As forthe alarm seting value and erpergency sop valve each tom ofthe pressure ropresents ‘th ower imi value, and esch te ofthe temperate represents he upper it value (2) Manometer, termometer, and alarmiemergency stp deice wil be provided depending on he inaveua specications. (9) The acta! data found on each engine may der fom ‘hose shown inthe above table, and 'nertoro retort the Test Run Fecord Table (cuded in he nal document) forthe deta, 6+80K-28 A 01.8Engine Adjustment Standards Valve Setting Values [6-8DK-28) 2 3-2 Valve Setting Values Opening stant ang (betoe top dead carer = | — z Closing end ange (ater botiom dead corer) Opening stan angle (voter botem dead Bont) Ctesng ond angle (aertp doa carten) Exteust vate ‘Pumping stert angle by uel wjecton pump belore ep dead canter) (aajucrment aus) Maximum combustion pressure isojusment ae) Fst ejection vave opening pressure Cylinder sat vaveepering pressure | ‘Adjustment vals (so) teu 195kqtem (Geaign value). Remarks (Valve end clearance ‘adjusting procedure) (0) Yate end clearance de represents trp eco (2) Kat vie ond corarce A" ane "ay vas sepnding onthe srane ite woke nd dearer frost Run Record Table nuded in (Ine inal documents (dot end specehans eter {ho Teet Aunt Record Table need 9 [Beis ceamens 6-80K-28 Z 01-3Operation 1.1,1.2\6°8DK-28| Precautions for Operating Engine 4-1 Precautions for Operating Engine 4.4 Precautions for Starting © conduct preparations before stat of the operation of engine, such as the inspection of of, water, ‘nd air eves, a6 woll as proper operation ofthe valvas without fai, and be minded fo start ‘operation only ater thas been confimed tat all he condone ar ead fr the sta of engine (2) 11s extremely dangerous to ster the operation of engine with the turning bar inserted inthe ‘yhoo. Be minded o rome the bar and sire tina spected place atte tuning is complet. (2) Contr tat have ate no woking stat around he engine. When anyone round the engine, be ‘ined o senda signal snd conte sae beloe stating te operation of engine. 4-12 Precautions for Operation O crates ne ene, nett lonng tens dete at he engi in 8 i re orl para cndn fb cse al synods spe reso that be cause etc an onetime rove ca eaten ‘Any sina nae anger, tch at deg hing pea, adeine ina enpertie ara oa reson Mig ‘hnylonage tom poine (Presa leks oro ping il eit ne) Serr over stale enne te sputn engine at te pte or dott ae nd andere and rg esred mal epi contre & emacrert conta! the 2) tng sa or esha pars oy Mee and upg nat nrg eet sha te ha Ca ee pet the one cagt nay fy ol recone Tort be min at ah Forno eect my oth ye Fares er at opr cover the tay pare aye sched wou a AN @ bung We option serge, para eer pas re eter ho an eee Thre rg clu # tached wih tare anos Be raed ower ey oer Protcive gens were mea or epecin wor cone Fern be sre oop henge ih be lie cre ese pte say atch ears manos Stueacarger Sarco nt pe oye nad Sina ae ‘rat neon emp adin esi oping Fes oie nae pe coe of ay 6+ 8DK-28 Z 01-3 DAIHATSUOperation Precautions for Operating Engine eaokal 1.3 41.3 Precautions for Stoppage (1 Mae seta eng apd ater ade tan beni, excep ne cane of energy (2) cara hale engi stepped in emerency op, be minded never at ear te ern lie cues cle cls oud td cine, ard eget edo at pan be cantare oa ete 10 mindes ste wage estopped a iy cone down Oferta, ete ener xo ans ha rat tps cacase AN 6 rae mre tar tis sloped een ot hein eon, and are iss cage bum. Tarte, be mnced omer be roche gers wtenovermepecion 3 tonienance wee cone att DAIHATSU 6+ 8DK-28 Z 00-12Operation '2.1|680K-28| Preparation for Daily Operation 4-2 Preparation for Operation It is essential to keep the engine in “Operable Conditions” whenever the engine is bing operated. Therefore, be sure to perform pre-operation inspections befor | __ starting of engine, and take proper corrective actions and countermeasure whenever | ny problem is found, to confirm thatthe engine isin normal conditions for operation, before starting the operation of engine. It the engine Is started without re-operation inspections or preparations, it wil cause ‘ot only the troubles when starting the engine but also result in a sudden stoppage or || damaging accidents. Inston Manua) 4) Retin gear incase of matin propulsion “The numberof the inspection tems required | engin) before starting the operation varies depending (CL): Separately provided “Reduction Gear fon how long the engine has bean out of Intuion Manual) operation © Daly staring: Shor period of dsuse (within ‘one month) | 1 Iti stating ater along period of suse, | cfr overalormanterance “The daly staring procndues te deserbd in tha section, As fre it ital tring), | C | tetera talonnneecton. iA {(EL)- #22 "Preparation for nial Stating?) AK ‘4 1 (1) Inspection before Operation 8) Inspection and Feecing of Lubricating Oi! (Chack te ol vel of te oi tank, ani toed ne ‘10 the upper mt vel fhe ol gauge. > Futher, case thatthe lian of found Zn Engine Lubriating Ot inadequate ater examination, proceed with makeup of replace the enlre amount ofthe _ eating ol (CLD: 62 “Lubresting 01 Characteristics and conti) 1) Separately installed Iricaing ol tank or ‘engine ubriting ol tank Engine lubricating ol an (Base plate commen to ierent engines) Nae ), poten Olt aanener ‘arcngall 120 1) lle Denne ineawecteotveretayee) — wae gaye Ce) ED: Soper rane Cera aer ate 6+0K-28 Z 01-9, DAIHATSU.Operation Preparation for Daily Operation ) Inspection, lubrication, and Operation ‘Check around the Fuel Regulation System Manualylubsate he bearing and sling pats ‘of pins, ater checking for any loose or missing levers. link pins, and bolts around the ‘vera, commen Ye, stoppage eysiom, and ‘uo injection pum rack Sel the operation eve to "STOP" poston and ‘confirm that the rack scale is "0", and then ltenately move the lever to "STOP" and "RUN" postions, to conti thatthe common [Link] pump ack moves seat. ©} Draining of Condensed Water trom Intake Open he can cock of te rake ait ctr) L of he engine tame, ard cain te concensod - pb 3 B l Lo <= otma poise Around governor in i Brora tame _ [Fiat infecton pane * lool i Ko) oO ~ “ f Anis ‘ondenced weer by ty a | Ce | ~~ — aa ‘and: may eause abnormal wear 0° teat on ota oie ‘various pat by flowing ine he vind, ‘Around fel injection pump PEE 6+ 8DK-28 Z 01-3Operation "9.4 |6°8DK-28| Preparation for Daily Operation 4) Draining Condensed Water from, and ‘Supply of Ai to Air Tank Incase of automaticaly supplying fst in the condensed water ut of the staring tank ‘an stating si cant tank, and then eon nat ar pressures in these tanks i above the In-caae of manually supplying ai ncuding manual staring ofthe air eompresson. supp sift he upper val, Tem] Dpperint | Lower im] savings | 30MPa | 20MPa Stateg sr | okgtem’)|_(2okgem?) ‘09MPa | OGMa conto! ir (oratem | fekateont 19) Checking and Feeding of Fresh Cooling Water (Check me ove of rash cooking water, and tha velit te lower It supply eh water ‘p10 the upper it, and atthe same time 363 proper amount fhe ave Further, n ease thet each propetes of water (DD: 63 "Co0lng Water Characters and ‘contor) ‘) Dralning of Fue! Ol and Supply of Oi First ain fue! all ot of the tet ol service tank, and then check he level and upp ol po he upper Et ofthe lve gauge ‘9 Confirmation of the Clutch Belng “Neutral (incase ofthe clute- mounted engine) In case of the engines such as the marine ‘Propulsion engin, make sue thatthe cuch is In-Newtar posi, 1) Opening and Closing of valves Repeat Fuly open" and ‘uty lose” operation ‘ofthe vales onthe piping system 2 to 3 tes to confi thatthe vales move smooth, end ‘en sete vals to FUN" positon ‘Some of the examples are shown as olows. Sinco the layout postions of the piping systems and valves difer depending on ach engine, eer oe piping sagrams othe nal [examples] 1) Vales foe fel of inlet pipe anc eet pipe "Open 2) Vates for cooling water (jacket and cool), Ine pipe, ac ot pipe: "Open" 1) Vanes for staring ar pipe: “Closest Open ont when stating operon) 4 Vas for apeation a pipe: “Open 5) Valves for pipe coupling parts provided for emergency, priming, eaing, ete: “Clesee™ A— Ihe sew tightening valves are used onthe state of haltopen, the vale handle may be turned suring eperation and the opening | degree may be changed, causing ralonctons ‘Tereloe, the valves should be hy tumed should te locked boty. In ease thal the valves most necessary be let hat apen forthe sake a ow ajusmat, be sure to secur he vaive handles wh wie | tng ant te, an them to prevent ir loosening and wining. 6-80K-26 Z 01-9 DAIHATSIOperation Preparation for Daily Operation \6-8DK-28) 2.4 {@) Standby Preparation Engine on standby) water oF of has gushed out of he indeator ‘ator entng te operaton ot enghe conduct | vale, Immediately stop the starting of the folowing preparations: fengine, $0 that the causes can be Investigated andthe countermeasure can be 2) Priming wth Lubricating 0 Start the metor-aiven lubricating ol priming ‘bump (er, reserve pump) 5 minutes betore Stating the operation of engine, and confim —— bat ae oaks Hom varus pars ot ya Process 2 ing. 1) Conduct riming win Wrcting ot A : i Sethe operation lever tothe “STOP” positon, = Tis acton proven ue ol fom injecting, i) -Futy open” te nator valve. IM) Condit tuning #12 tenes, and confi that ‘ho engine oats smeatly. eS Festa nperetreeraten | ics ona | pecteit [E== 1) Turing or Ai Running Conduct turing er a runing to decharge the ey ust or water crop that has ealeced in the Clade white the engine i toppee Further. when the engine is stared after the inspection of various pats ofthe engine, or alter along period of disuse ofthe eng conduct turing beore ai runing te coat the sale, In cas that a lege amount of water ofa accumulated inthe eylinder due to the leakage from the eylinder head or fuel Injection vate, theo possbiy of serious accidents such as bending damage ofthe ‘connecting fod by wate: hammer. ‘When conducting turning or air runing, if L : CITT 6+ 8DK-28 Z 01-3Operation '2.1|6:8DK-28| Preparation for Daily Operation < Air Running (abbreviated as Alr Run) > << Work Procedure > 1) Condit pining wth beating ot i) Set he operation evr to “STOP” position ii) "Fay oper” heres va, 1s) Open the stating ait valve and conto! ait valve, and press the push button forthe staring operaon vale. Thon, starting air flows ino the stating air valve, and the engine tans ts rotation, -y Keep pressing the push button for 3 0 4 seconds. or arn) 1) Release the push button. Then, the staring air valve closes, and the engine slope | eeeoeeeerseeas apie | Vin entng net bee ‘tone ne | Net ia doin orig areca Orr | oa | Pate sng en an | Sern syste > ot uly open he stating ar valve ding iran kooping the opening at about 13, and ‘caetly condita ning a low speed air uni conducts a highspeed by fay pening the starting a vale, wil rot ony expend air useessy, but aso wl result in serous accidents such as aggravation ofthe [ eres tany tect tadbsen caer 6+80K-28 Z 01-3 ing oF Fuel Oi (when heavy fue ols sea) In ese that heavy fel suse, heating shal bbe made accosing he folowing toms: }) Turon he fell eating device. 1) Opetate the metordrven ct tee pup (2D) 6-1 “Fue! O1 Characteristics and conta) AS ested any tuoi extemay net 00°C more. and may cause bur if tuched by rake rnd kn ‘Therefore, n caso of handing he equpment cf ol ol eystom that cares Rea of Be sure ‘0 woar safety gloves and raver ouch thm vi bare rand —eGCr7" } 0) Turning “ON” of Protective and Alarm Cireut Turn °CN* the protective and alam cicult on the moritor panel, and cont tat he warning tami up, 1) Operation of Motor-Drvan Pump In ease thatthe engine is equipped withthe rmotor-aiven cocing water punp an fue il food pump, start the pumps § minutos betore the staring of engine, and ont thal wer noo leak rom vareus pas of ppg.Operation Preparation for initial Starting after A Long Period of Disuse, and Overhaul or Maintenance \é-80K-28|"" 2.2 4-22 Preparation for Initial Starting after ‘A Long Period of Disuse and ‘Overhaul or Maintenance Since the engine is not ready for immediate Staring of eperation ater along ered of ise, and overhaul or maintenance, i ie pesteuarly nocessaty to thoroughly conduct the preparations for operation. Before the preparation for daily operation, conduct the fooning preparation works (I): 2.1) (1) Inspection of Crankease and Cylinder Liner, | and Supply of Ot 2) Inspection ofthe inside of Crankease (Open the ede cover ofthe engine fame, and check and ensure thal tos, waste clothes, foreign mater auch as deiccants are nol et behing, and that there i no rusting onthe yonder ners, cranksha, and <0 0, ») Supplying Lubvicating Oi to Cylinder Liner ‘Aer along period of use, te varous pais fof engine are not covered with sutticient amount af usieating oll Pariculary srouna the cyinde, lubricating 08 cannot be supped Supply lubricating oll on the following procedure: 9) Condit ting to allow he pistons to mave Uupwar,snd apply beating oon he lower ar ofthe eying ints by & spray device and th iy Sequontaty conduct the above procedure to 20h onde. (2) Inspection of Connections and Joints Inepect again the extemal connections or oie to confirm that there leno connectons that nas bon forgotten to be tightened, or loosened (9) Opening, leaning and Cleansing of Fiters Dust or foregn obecs, hat had been eoteted into piping dung transportation, and outing or instalation, i accumated inthe thers of the aie int (Open he fasowing Mere, and ceanse the inside rh lente ot he itor: 4) Stang ae raed cont a tr 2) Fud ol ter EL): 5-43 “Cearng Fito) 5) Lutveating iter (I): $4.3 "Clearing Fite 4) Lobisting ol iter for trbochrger 5) Cental beating of bypass er 6) Coding water ier Applying Procedure of Lubricating Oi (4) Priming with Lubricating Ol end Exheusting hic Condsct priming with lubricating oll and acing sion the folowing precede! 8) Opetate the Ibricaing oi priming pump for abcut 5 minutes, and during this period coniuet turning 216 9 tines by epening the Indeator vatve, so that can be contemed that no ue 0 ubieting a, and water do not flow ou oth ndeater valve. ‘Atte same time, open the each cover ana check the ripping-down conditions of lubreating ol rom each part 6+ 8DK-28 Z 00-12 6-80K28 Z 01-3Operation mew Preparation for initial Starting after A Long Period of isuse, and Overhaul or Maintenance: 2.2|6:8DK-28) bi 1) Engine frame: Main bearing, erank pin, stn (cooing chamber, an pson pin 2} Cam ease: Cam searing, swing erm, and tappet 2) Cylinder head: Rocker arm and valve retaning te ©) Operate the priming pump, open the air vent valve for lubricating ol filler, and drain lubieating of unt air bubbles in the ot are completly vanishes 1) Check tat here i no al leskage em various ars ofthe piping curing priming, (6) Priming with Fuel Ot and Exnausting Ale ‘Conduct priming with uo ail and exhausting ae bobble onthe folowing precede: nOperte the ue oi eed pum (incase of the ‘engine equipped with @ motor-ven al feed orp) 1) Open the fuel ont valve, ater confeming ‘that the operation lever is set to “STOP” poston 1)Open te a vent vae of the tue He, and Crain ol unt ar bubbles ino are completly IM)Open the ai eat vate ofthe tue injection ump, and arin ol unt ar bles in ot are completly vanished, walter completely removing air bubbles, Securely tighten the a ven pg. (6) Cleaning of Turbocharger Pre-Fiter Dust or debris aro colecte nthe prefitrof he turbocharger during Wansporaton, otting, and Instalaten, causing the fier tobe stained oF damaged “Therefore clean ito replace it wth @ new one Deore stating th operation. sent, fon “Turbocharger 6+80K-26 Z 01-3, Exhauiting Air of Fue Injection PumpOperation Starting Procedure 433 Starting Inadvertent contacto woking stator cbjecte ith ho rotary parts i exromety dangerous ‘since the person may be caught up oF the ‘bjt hat has Been caught up may By ut in “Trsior, srt observe the folowing ters ‘whan staring the operation. 4).Centiem wat he protective covers of rlary ‘ans are mounted in neal tte, and hat the rotary pars are free of any obstacle 2)Centim thatthe turing devi o tring paris sto "OFF" 3) Senda signal 0 coworker if here is ay, and conti satety betore starting the operation of engine. 4.3.1 Starting Procedure (1) Starting trom Engine Side Locally) Stating procedure can be classified into the ‘twee ype: engine side string fecal slang), remote starting, and automatic starting, and ‘hich ofthese shouldbe employed depends on the specilications. However, local stating (staring tom engine side) by manual operation ‘should always be employed ator along period of use o ater ovemaut ormaintonanes, << Work Procedure > ') pen the staring vo aed conrl ava, 1) Sethe operation evr to"START positon, lw) Press the push button for the st operation valve IW the rtaton speed ofthe engine as rapidly Increasod and starting has been established ‘atog with continous ignition sounds, release the push baton, Alter contin thatthe oation speed of he engine has reached the specie speed, and ‘ach pressure has reached the spectied value, set the operation lever to "RUN" Poston ‘W) Case the staring ava (Leave te contal a vate “Open” a tis) Position of Operation Lever (@) Remote Stating (Manual and Push Button Staring) << Work Procedure > ') Sch the slang made to the remote mode (tron mentor cramer tom eal made om engine sie). iy Sette operon over to*RUN' positon, Open the starting ae valve andl contol air ‘ane, aftr contiming tht "READY" indator wp Pres the staring push but, \) Gostrm that “RUN incieator lamp on the ane has it up asthe rotation speed of te reached the specified rate, and Clothe starting eva, (Letve me contol a vave “OPEN as tis) (2) Automate Starting In cass of automate starting, the engine starts automaticaly by the slang command tased on Preset staring condions, such the overload conditions of power shutdown or ether engines (incase of poral engin), and theratore ossontl thatthe engine should always be kept in opeabieconions Engines should be kept in the following condone at limes 1) Steting mode: AUTO" 2) Operation evr poston: RUN" 5) Stating si valve and contol air valve: ar 6-80K-28 Z 01-3Operation ve Startag Procedure /Inepection and Check Teme 1,3.2|6°8DK-28| immediately After Starting (1) Corrective Measure In Case of Faulty Staring tn cae tat he engi Pas tae to taro has tol sated snooty, ke coectne messes by tengo separately roid econ ((L2):7 “rose Soong an Curteressies) > ——____ meet oer Seas ieee coins (1) Engine Rotation speed Conlrm thatthe engine rotation speed (the umber of ile rotation speed, in ease of the marine propulsion engine) has reached the pected rotation speed, and hunting (swinging ‘ofiaehemety) eno occured (2) Pressure Reading of Each Section ‘Gone that the indicator of pressure teasing, or mark. showing the pressure 's within the 6+ 8DK-28 Z 01-9, spect ue ‘Gauge Boare (9) Abnormal Sound Carefully Hsten fo the sound of the folowing engin pers, and eneck there ary atronmal 4) Cylinder need and eurcunding pats (nts sd echt valor 2) Crankesse 9) Crankease and timing gear and usar dive ear 4) Turodrarger (4) Exhaust Temperature ‘Chock the extaust temperature ofeach clindr, ‘and conte that al the cylinders are property ust (21 200°C ox mre, (6) Gas Leakage from Starting Valve If gas has leaked from the starting valve, the stating at ran pipe becomes hot. Chock he staring a main pipe not heated ‘x nt by Ky ovening te pip, (6) Leakage and Loosening of Each Part (Check ine bots and ute ot nstalaton part or connecting part are net loosened, and ito ter, or 8818 not waked,Operation Running-In Operation 6-80K-28| "4.1 4-4 Operation 44.1 Running-in Operation nen the engine i stared forthe ist time of lmmesatly ater replacement ol te pts such a3 the oylnder ners and piston, since the sliding ats ofthe engin ae net yet suconty ready to ‘work smecthiy or freey, fare such as abrormal wear oF seizure ofthe siding pans may oceut, the toad i abruptly applied inthe stage of such Conduct the runnin operation to ensure smooth and tree working of the sliing parts on the following procedure, betore entering normal (1) ntat Running in Operation wal substantaly tect the engine pcormance, ‘especially the combustion performance and Consequently the consumption eiiency of luviatng al, whether the piston and al ngs move smecthly and Keely, oF nol. Furber [sume that hey wil be decided by the intial ‘operation ofa few hours en te evn tne. ston. plston rng. and sling parts around cylinder are replaced, be ure {© conduct [Link] operation in ‘accordance tthe gute shown below (EDD: Fg 4.1 inna Rurning-n Patter’) (2) Operating Conditions during Running:in Operation ‘sure to operate he engine curing he runing in pated und he folowing eanetions 1) Lose: 80% orless 2} Fuel tobe wood: Dose tel ot Note: For tho engines of heavy fue! oll specteatin, be minded to ute dese! fe ai dng te running prod 3) Lubaicating lobe used shal comply withthe fuel oto be used "Noo that incase he engine wth heavy tue i specfeaton, breton oor heat tel al can be used trom the start of engine driving, notitstanding the above pescrinione of 2. 4) Funnng:n petods 150 hours. (2) Inspection tems during Initia! Running-n Operation To delet the potential problems and eliminate the causes to previously prevent such problems, Paria heed cautons to he follwing toms 1) Abrormal sound 2) Pata heaing 2) Leskage rom connecon pars, an! loosening olen 4) Explosion pressure, exhaust temperature, regular oxnaust eal Abnormal burning af '5) Excessive consumption of lubricating oi Imgroperwerking of ners and ings (@) Inspection and Works at Funning-n Operation [AL he tie when the running-n operation is ‘completed, conduct tha following inepection works and confirm that there i aot any [Abnomalty betore entering the normal and regular operation of engine: 1) Inspection of reign raters and stains in the 2) Visual nepacton of the loner eurace of he cyinder ner 29) tnszection and cleaning of the element of 4) Remove the flushing iter attached tothe ‘loment of heft iter an Be rinded never te perform the operation of engine using heey el we the fuehing | tris atache. Completion ot 6-8DK-28 Z 01-3Operation Running-In Operation Fig. 41 ttl RunninginPatern 6 80K-28 2 01-9, DAIHATSU.‘Operation Warming-Up and Connecting Load to the Engine 6-80K-28) "4.2 4-42 Warming-Up and Connecting Load tothe Engine In caso thatthe engine fs started while ts sili a ‘cold state, fst perform the warm-up operation, ‘except lor the case of emergency, and gradualy ‘connect the lead afar the engine has suteenty been warmed up. Ihe lead is hastily connectod while the various parts of te engine are sl cold and not yet nthe Conditions for proper fuel combustion and lubrication, matiunctions such as. faulty ‘combustion, excessive wear ofthe sing pars, (0) Warming-up Operation of Engine 2) Use diesel fuel ol for warming-up ‘operation Be sure Yo use esl ful ol for warming up the engine, even in cage of the engine with aye a specteatin. 1) No load (le operation in ease of warming ‘up the marine propulsion engine) Fist operate under no load or fight load, and lubneaing ot emporture hes inreaced a Be minded to parton no-eas operation on for warming-op operation, and reste the duration of no-ioad operation within 10 Fumsing the engine under nooad fr long hours will ult in malfunctions such a8 fauly combustion and cotton of carbons (2) Consecting Load tothe Engine ‘The loner the engine temperature (lempertues ot acet cooing water and iting of i, te longer tine is needed o connect he lead ‘The sansa oad connection te is shown in 10 fire Bolom, (1D) Fe 2 Load Comecton Pater’) Incase ofthe marine propulsion engine (direct connection by propeller), be minded 0 gradualy Increase the rotation speed, since the load wit Inerogte according tthe rotation speed Wren increasing the rotation spe | mindes to quickly pass the dangerous | ration causes damages (the red mark 2oneon the tachometer) | Fuming the engine win tis zone for ong how's may cause the breakage of the erantenat tore ‘erpersive Sap Beas we Tenn) Fig2 Load Connection PatternOperation 4.3|6°8DK-28| Operation with Load (Normal Operation) 44 Operation with Load (Normal Operation) Inspect the unning condtons of the engine and measure the operating performance data equa Intervals, during the crtinuous operation wit oad (incucing period ofthe runing in operation). In eas that any peebem i ound asthe resus of the inaction and measurement, take proper measures such as adjusiment of repair of the detective parts. (Refer to a separately provides (LLY 52 Measurement ang Adjustment) (EL): “rousiesheoing and Countermeasures") (1) Inspection of Operating Conitons 1) Abornal sound 2) Panal overheat 8) Leakage tom connections and lonceness of 4) Abnormal combustion pressure, exhaust temperate, and exhaust eo". AbNoM '5) Excessive consumption of lubricating oil fay uring the operation of engine, partiuly the folowing pars become extremely ho, and touching these pans wth bare hands of skin may cause burs. ‘Theretore, be minded fo use the protective gears such seat loves when woking on ‘Exnaust manold | sTutecharger Aircooer inet pipe ‘*ovinder nea | (°F cl system equament an ping (hn case of heavy Wel) ere ad ring, (2) Measuring Pertormance Data ') Measure the operating performance data at loast ance everyday, when the iad variation 1) Compare each ofthe moasures data wth ho ‘ata ebained when the engine was new'y ‘trodused, snd judge H here sary prblem and chk the degree of deterioration. (LL): "Test Run Record Table nthe final ocamonts) 1) Rom temperature 2) Leastouput) 5) Rotaion speed... In ease ol variable speed engine 4) Maximum combustion prassure (each yin) 5) intake a emperatue (ubocharge it) 6) Exhasc temperature (ult of e30% ner) 7) intake at pressure (engine int) 18) Lureatng al pressure engine lt) 8) Lubreating 0! pressure for turbocharger (Turtocnarger inte) 10) Coalng water pressure engin net) 13) Fuel pressure engine inet) Ir ease et heavy Wel a specication 12) Int a terperture engine et) 12) Lubictng ol empersune engine lt) 18) Cookng water temperature (engine lt ane out) 18) Fue omporature (engine ret) Ir ease at heavy tel o spectcaon 16) Reading on uel injection pump ack seale (2) Regula inspection and Maintenance Conduct inspection ané maintenance of he ‘arovs par t engine vga. (Peter x spar provided ston ) (ED): 5 nepecion na Manone) (4) Operation Records ‘ter completion of the inspection and measurement, Keep the records ofthe works performed on adjustment or repair in the log ls lees and loads sabe 6 80K-28 2 01-3,Operation ‘Operation with Load (Normal Operation) / Oper Heavy Fuel Oil on using 1.8K. 281 43,44 Operation records are very important ocuments. when understanding. the conditions of engine and racing the history {ofthe inspection or maintenance that has been pertormod. Keep and sore them corfu, and when he ‘uporiser is changed, bo sure otranctor the | records othe successor without fi 44.4 Operation Using Heavy Fue! Oil (in ‘case of Heavy Fuel Oil Specification Engine) Heavy fol i ower ints quality a higher int ‘ecosty than deel tel of, When using Neary {uel al, proper operaten conto, such as switching to the operation using ciesel fel ail dopenng on head consenssrequted, in aon to proper fuel ot and lubricating oil conto (reer to the separate soctons) (GL 6 Ft Ot Charactorises and Contel) (£2):6-2 “Lubricating OW Characteristics and Contr) (1) Operation with Diese Fuel Ot Beminded toute heavy fetal ony under sabe lond eonitons, and be sure ose diesel fe ot Inthe folowing cases: {2 During Runningsin Operation Period (150, ‘nows} 1) immed aterinstatation 2} Atarralacement cf the sling pats around ‘tnd (eg oyinder ner, piston, and piston 9) (£1) 4-41 “Running n Operon) ') During Starting or Warming-Up Operation (2D):43"3enig) (LL): 442 Warming Up Operation) «During ling or Low-Load Operation "men the engine is operated under lw load the compressed a termperaur inthe cylinder and uo njcton pressure of ue os ow, snd ‘oreo fhe Reavy fue of wach combustion ual slower than that of csel fel oli Uses, combustion wil become unstable, resuting in undesirable contons, such 9¢ ‘worsening fhe exheust sek, sting of he fing, and soon. In case ofthe conection of the ba tate balw the lower dasebeo in the engine specicaton, be minded to use hes veto 64) In Case Load Variation is Heavy 1) Yen entering or leaving port 2) When weathers ough an stormy 9) Wen cargo is being onde or unloaded ©) Before Stopping Engine (CD: +6 Stppage?) Heavy fuel ol Ie normally hested up to 60 to 80°C hte service tank, aod 100°C or mare at the ergne int ane the temperature citerenco i trgor as compared wih ato dese! Wel ot (non-eted), and teretre ul is sudceny ‘switched betwean these ils it may cause ump, vapor lock and soon. 2) Slowy switch rom cose fel oto hea fel i, 0 thatthe rate of change in the fel ei lenpertur athe engin inlet ts Betwoon 5 sand 10°C per minute (ED: Fig43 Swiching Pater rom Diese! Fud Oi Heavy Fel Or) 1) Mansi the viscosity (lemperatre) of heavy tel ol atthe engine inet at the species ©) Dono ase the temperature of ces ul ol beyond the flashing point (60°C is the stardard pont) 4) To event the generation of vapor, maintain the pressure 0! Nelo atte spectiod vale, Fret, remove the air Bubbles i We! on ‘he various equipment ofthe fel ol sytem (eater, ter, tank. et) fom time to tine, $0 tha: the accumulation of vapor can be proven 6+ 8DK-28 Z 01-3Operation "™4.4|68DK-28| Operation using Heavy Fuel Oil ©) Contim mat the nest traces on piping and A— ‘equpment is propery urcionng Incase that emergency sp is made ding the operation wth heavy fl i. medially mmetortiven pump, and perform fushing ot Heated heavy Wet ol extomey ot an it touched with bare hands of skin, It may the flo eye cause a bur, Thetetor, be minded at 10 I" the engine cooled down with the heswy ‘rect touch he exposed metalic pats even fuel oi lett unchanged, the oi wil be fas the valves and cooks, and woar the soited anne operation wil be prohibited protective gear euch ae safely gloves when working on hem. ‘* switching trom Diesel Fuel Oi te Heavy Fuel Oil @ Switching from Heavy Fue! Oto Diesl Fuel Ot vaso strona net [EERE] acon stenneine [EERE eon BEF ce 8 artaay BBE a : 4 eae ; mana Note. Since the pretectment of utc fers depending on the ute purpose othe engine, the operating etn sutabe to each systam i necessary, 2, The deco fel ol temperature when swchng on heated corson shal be 60°C o mor, Fig Sultching Pattern from Diesel Fuel illo Heavy Fuel ll 6+80K.28 Z 01-3, DAIHATSUOperation Allowable Operating Range 6-80K28)""" 4.5 445 Allowable Operating Range (in ‘ease of the marine propulsion engine) In case of the marine propulsion engine, the lad fenanges in accordance with the marine characterises, and according o the changes in the rotaton epee. ‘Te alowable operating range and recommended eperating range win the marine enaracterstes {are shown in he igure below. When actually operating, be minded to select a ‘proper oation speed and engine torus (Pe. 0 ‘be udged based on the reading on the rack sal), fang keep operating within the recommended ‘operating range as far as possible, to prevent being overeaded. "Nota thatthe lover led imi normaly 90% when ‘sing heavy fue oi, and ifthe oa to be connected (LD: Fig4.¢“Atowable Operating Range) {As fore ouput characterises of he engine to be actualy operated, eer o “Test un Record Tabie™ Inthe separately provide nal documents. (1) In cate of Fined Pitch Propeller (FPP) ‘The fod pzhed propeler i genealy designed by ining th sea margin, which has taken into consort the fouled hl stace, in aden to the absorbed horsepower due to the marine characerstes In cace that fouling of the hull surface has advansed, increasing the resistance, and has fxcaoted beyond the £28 magi, the absorbed horsepower increases to seh an extent hat the excessive torque occurs even i the rotation speeds maintained constant. Theol, always heed cautions tothe rotation speed and the reading onthe rach scale to prevent excessive torque Further, particularly be careful when the absorsed propeller horsepower suddenly Increses, for example when in stormy weather ‘and > on, since this will often cause the fexcesive torque to occur, eventual leading surging ofthe turbocharger rete design point —- omen 8 EE wom cpera ene ‘omaloeucing one vow! Spetheatons Tee 105 Reesor Fig.4 Allowable Operating Range 6 80K-28 Z 01-9,‘Operation "4.5|6-8DK-28| Allowable Operating Range (2) In case of Changeable Pitch Propeller (CPP) ‘The changeable pitch propeller is capable of changing its propeller pitch (lade angle), while maintaining the engine rotational speed constant, Sd is ereby capale of changing the absorbed horsepower. Teter, tis propeerhas a mrt thatthe rotational speed and load can be ‘changes according fo the condtions ofthe other propulsion engine, an he hul sistance. Honever, since the changeable pitch propeler tends fo run under excessive torque To 8 much fenent 98 thas a ares treedom of ts operation, be minded to operate the engine properly preventing the excessive torque, by always ‘7aing te toad condor 6+ 80K-28 Z 01-8 POI‘Operation owLoad Operation and Operation with Air Cooler Cut- 6-80K-2815.1,5.2 45 Special Operation 45.1 Low-Load Operation Since runing the engine with a low load lower than @ certain limit can lead to unfavorable combustion consitons such asthe reduction of Intake ai pressure and blowing-back of exhaust air ihe engine ie operatod undor such contons for tong hovrs, it may result in the various mmatuncions such 98 fouing ofthe turbocharger land combustion chamber, faulty combuston, an Thorelore, Be sute 10 minimize the low-load operation 1 a shonerpeted ot ime as much 25 possible, and in case that the engine must be Freshy run under lo load or lng Hour, be sre to cbuerve th folowing condtona: (6) Low Lose Limit Te low load lit varies depending on each specitication. Confirm the low load limit eserbed onthe specieaton supped wth the engine. (2) Use of Diesel Fuel oi! (0) Increase of Intake Air Temperature To improve the combustion conten, ineease the inlake air temperature and aejust to a @ higher level as possie, within the folowing imi ‘lta air: 75°C or ess 1 Ewraust ampere (evince owe: 400°C (DD: 53242) Measurement and Adjustment cl iake Ai Temperature’) (4) Cleaning of Turbocharger Properly increase the number of times of tears te utocharger according to neces (6) mermitent High Load Operation the load eswiched othe High lead (60 % or more) for about 90 minutes during low-load operation. twill have an etfect to restrain or reduce the fouling ofthe combustion chamber, a ‘wal asthe infake and exhaust ar eyo, 45.2 Operation with Air Cooler Cut-Off In cas thatthe detects such as breakage of the fe tobe nthe air cooler or wate leakage rom & ‘aud sections i ound, andthe repaing cant be pertemed qucly, an emergency measure can be taken by cuting off the air cooler on the {otiowing procedure (1) Preparation for Operation 12) Step water supply 10 the cooler cooling tyler, and draw out te water fom the at acer nae a sheng plate (A) ito te ange pat of fe air cooler coating water inlet pe anc ute pe ©) "Futy open” the bypass vale af the ar coo. {) Operate the cooler cooing water pump. and centr that no wer eke tom the Nang packing oe aches \ croup seins bps abe [Ar Cooler Adjusting Valve << Operating Conditions >> {2) The el ito be used sal be ese tue b) Restrain the output as low as possible, relerring to the following values as tne stondard ‘Pre (average elective pressure} 29M gem inaust ar temperatre (yander out 400°C (Max 450°C) DAIHATSU 6-80K28 2 01-3Operation "3.3 (6°8DK-28| Special Operation: Non-Turbocharger Operation 45.3 Non-Turbocharger Operation In cate of the marine propulsion engine, @ non- turbocharger operation implement (turbocharger blind plate) is provided, so that operation in ‘emergency can be made even when the turbocharger may have boon damaged. (The ‘generators optional) The norstubocharger operation procedure Is as tha fllowngs: ((E)"Tebocharger nsrucon Manus!) (1) Preparation for Operation ‘lo case of MET-SR> 18) Remove the cooling water inlet and outet ‘pes, ubrcating ol it and ott pipes, and it crawing-ou pipes out ofthe turbocharger by Remove he hochager cut be engine. €) Remove the ga iret casing acearing to the “Turbocharger netoston Rs A)install the non-turbocharger operation ‘plement tothe gas inet casing as shown in ‘he igure on the right «naa he ga nt casing to the engine. 4) Remove the intake connecting pipe (bellows), ust through the ai inet section of the at cooler it pipe. ‘Turbocharger MET-SR, TPS. 19) Clee he cooing wale inland ou pies, 8 wel as the iatng al it and tet Pipes. ‘dense of VIR 1) Remove ho turbocharger. ) Romow the bearings on te tine 86 and lowe” side according to Turbocharger Ineruion Manual 6) Draw cut the foto shat, and intl the non ‘urboerarger operation imiament as shown ‘he geen te igh. {install the turbocharger in the previous positon. ©) Remove the intake cannecting pipe (ollows, and inal the ar steiner eo 38 otf hale {ust trough the arnt ction ofthe ait cooler net pp. ‘t)Normelly supply cooling water to the sumbocarge. incase of TPS> 8) Stop te brant supply ote engine b) Remove the turbocharger out lhe engine. Remove the ge lel casing sccordng othe “TurboerargerIrsruction Manual @ Install the non-turbocharger operation implomant tothe gas int casing as shown in {he Hur onthe Fm 2) natal he gas niet casing one engine Emus “poo t Leet WY ‘peraion element “Turbocharger VIR 6 80K-28 6 02-2‘Operation ‘Special Operation: Non-Turbocharger Operation / Operation with Reduces lumber of Cylinders 6-80K-28}5.3,5.4 1) Remove the intake connecting pipe (blows), nd natal the aie stair 0 38 nt nha Gust though the ai inlet section of the ar cooler lt pipe 1)Start the iubricant supply to the engine. At ‘his tine, verty that any lubricant dove not leak trom the non-superarged operational tool anne supercharger suppor base A During operation or immediately after stopping the engine, the turbocharger is extremely hot, and if the turbocharger is touched with bare hands of skin it may ‘Thereore, perform the disassembly work alte the turbocharger is completely cooled -<> 48) The ue of tobe vee «ese fo ')Resirain tho output as ata lower level as possible, refering to he following values as the standart ‘*me (average etecve pressure) 049 MPa 5 kglen) ‘Exhaust er omporaturo(eyinder out "00°C (Max 45010} 45.4 Operation with Reduced Number of Cylinders ‘Adoption of he operation with the reduced number of einders impose such problems a he torsional ‘bration ofthe shat system as welas the exoral ‘bration ofthe engine, and thoefore tis operation ‘sheudd be lnited as 4 secondary measure to be used ont i emergency The operation with the reduced number of finders may be conducted in various cases such 2s the case of only reducing the fuel el, or the ase in which the operating sections are needed to be removed. Further, since the prohibited Home {or me operation vary depending on each case, be sure to inquire our company for the working PRET procedures, cautionary toms on he eperation, and 450 on, obtain the necessary instructions, and strctycoserve them, when the operation withthe reduced number of eyiners is conducted. -<> 2) Thefuel ol to be used s cose fet ol 1) The output sha be as below (oer No, fede endere) (otal No, evades) “7 However, the output may be reduced According to the turbocharger surging or ‘xhaus air emperature in each ease ©) Exraus ai omperatue: 450°C (Mae 450°C) ss le attentive of he extemal vibration of fengine and the gear sound, and if any abnormality is found, immediately stop the | enne. if the engine is kept operating disregarding such abnor cadens may be caused K-28 8 02-2Operation 6.1 |6-8DK-28) Normal Stoppage 46 Stoppage 4.6.1 Normal Stoppage (1) Preparations tor toppage 8) n case that heavy fue ol is used, switch the uel oi to ees fuel ol 30 minutes betore stopping ne engine. by immediately before stopping the engine. star ‘he operation of ubrcating el priming pump. ©) Cont atthe staring a pressure at 20 Pa (20 item or moe. (The preparation fore nex round etartng) 2) stoppage '2) Conduct the stoppage operation on the ‘oloing procedures: {in e280 offal operation) Shi he operation lever to "STOP" position. Than, te rection wil be shutoff by means ‘of the common r0d, andthe engine wil be stopped [in ease of emote control} 1) Press the “STOP” uh buon onthe conto! pane. “Then, the fel ol inscton solenoid vale wil be activated to operate the te! shutdown eve, and te engine wi be stopped 1) Shit the operation ever to “STOP” postion, ‘by Aer stoppage operation, be atlonive of any abnormal sound inthe engine and ‘turbocharger, and confm that there snot any [abnormal sine Intae thatthe engine does not sep even | wien he siopeapeepeaton ls conde forebly stop the engine on the flowing | eco {Fore et he rack ofthe Wl injection | poe. 2yFuly close te va ofthe ue of net. main pe 6-8DK-28 2 01-3 Operation Lever Position (2) Aner Soppage 8) Operate Bot the Mbrestng ll ming pum fad esoling Iresh water pump for about 20 ‘minutss, and cao! down the engine and turbocharger. a eee cane asreeeae Scrat ») Fully cpen the Indestor valve to conduct aie runing fr 3 to 4 seconds, and exhaust he ‘combustion gas out of the combustion chamber ©) Close the vales onal the ests PRET)Operation Emergency Stop (6-8DK-28} 4-62 Emergency Stop (1) When Emergency Stop Is Required. Immediately stop the engine when any of the ‘olny abrrmatis i fund 1) Aenoucerant of “Emergency of “Alarm (CActvation of the protective deviee —~ ‘Automatic stop... Depending on each spectication) + eOverepeed +e Decrease of Mbrcating ll pressure ‘ eSusponsion of water supplyfinerease of cooing water temperate ‘omer siarming (depending on each spectiatin) 2) Aesermal sound 23} Heating of the bearings or other moving sectns,or generation of smokes, of sbrupt Loosening or faling-ff of the governor, ‘omman red rik. each lever aun the ful ‘tinction pump, ink pn or bal, Deterioration ous lor Mbrieating oi, oF ‘damage of he cooing water ine 6) Abrupt ineranse of decrease of rotation 1) Abrupt ncress of Moricatng al emperature 8) alr supply sabity duo to suspension of cooing war supply icasenetrarereemerar| suspension of water supply, do n01 hasty supply cooling wae. W eooled down abruptly, each part ofthe ‘engine may be detormed, resulting in mrallancton or aceon 9) Mixing of water into ua a 10) Abrupt increase of exaust ar tampeature ) Abrupt decrease othe turbocharger rotation peed orntke a prossure 12) Generation of abnormal sound in the ‘rope ortho stor shat eystom Incase ofthe marine propulsion engine 13) Breakage or loosening of the bots ofeach (2) Measures after Emergency Stop Incase tha the engine is topped by acivation of the prstectie device oF stopped automaticaly, take te folowing measures: 8) case thatthe engine stopped by remee ‘operation oF stopped automatically, set the ‘operation lever to “STOP* postion ater the ‘oncine is stoppec. Dyin case thatthe operation had been mace sig heavy ue! oi immediately swteh the fue oo dese ue ol, operate the motor Aven ol fed! pump, and conduct tshing of the fel ol sytem, (However, this procedure ‘dots net apply when the fuel oll pipe is broven) Frther, conduct turning ofthe engine, ana ‘exhaust he heavy tel remaining he fel incon pump or ue valve. L In ase thatthe engine is stopped curing the ‘operaton using hea fel lan the engine | fe ected down without changing the fue ol hoaty fel ol nthe equipment ofthe fel a yee (0.g pr, Sart) and ing wl rot nly solly to prob restating, bu aio | incw auteantal labor fo clean and clesnae ster the acisent 6) Disonnact ne load he engin, and retun ‘he operation lever, each va, and the state of chor equipment t0"STOP* positon. ah [ ree at an aerery sp ine | Socinedretiomsarte cog ues | cae t cuuriea t coment otien andere cme == ‘removing the cause of the abnormality, the | rmatunction may be aggravated and serious acedens may be caused 6+8DK-28 2 01-9,