DC-17A

INSTRUCTION MANUAL
( OPERATION )
 ٨ Replacement Parts

・Hazards and nonconformities of imitation parts

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

Daihatsu Diesel supplies reliable engines. Use genuine parts to

operate your engine safely.

http://www.dhtd.co.jp

Head Office 1-30, Oyodo Naka 1-chome, Kita-ku, Osaka, 531-0076 Japan
TEL : 81-6-6454-2346 FAX : 81-6-6454-2680
Tokyo Office 2-10, 2-chome, Nihonbashi-Honcho, Chuo-ku, Tokyo, 103-0023 Japan
TEL : 81-3-3279-0827 FAX : 81-3-3245-0359
Jakarta Office 16th Floor, Wisma Antara Bldg., Jl. Medan Merdeka, Selatan No.17, Jakarta-Pusat, Indonesia
TEL : 62-21-384-8411 FAX : 62-21-384-8412
Taiwan Office No.14 Tai-Tang RD, Lin-Hai Industrial Zone, Kaohsiung, 812 Taiwan
(c/o Marine Technical Industries Co., Ltd.)
TEL : 886-7-803-1082 FAX : 886-7-801-9179
Daihatsu Diesel (Europe) Ltd. 5th Floor, Devon House, 58-60 St. Katharine's Way, London E1W 1LB, U.K.
TEL : 44-20-7977-0280 Fax : 44-20-7702-4325
Daihatsu Diesel (AMERICA), Inc. 180 Adams Avenue, Hauppauge, NY 11788, U.S.A.
TEL : 1-631-434-8787/8/9 FAX : 1-631-434-8759
Daihatsu Diesel (ASIA PACIFIC) Pte.Ltd. 128 Pioneer Road, Singapore 639586
TEL : 65-6270-7235 FAX : 65-6270-6236
Manila Office Unit 1010 Herrera Tower Herrera Corner Valero Sts., Salcedo Village, Makati City 1226 Philippines
TEL : 63-2-753-3211 63-2-817-1279/1285 FAX : 63-2-845-0691
Daihatsu Diesel (SHANGHAI) Co.,Ltd. Room A, Floor 9, Huamin Empire Plaza, No. 726 Yanan RD (w), Shanghai, China
TEL : 86-21-6225-7876/7 FAX : 86-21-6225-9299
 DC-17A ENGINE
HOW TO ORDER PARTS

For the DC-17A engine, we have newly adopted a parts control system. To properly control the parts at
the production stage and delivery stage, we have stored the data of each engine, such as specifica-
tions and applicable parts, in the database. For the conventional engines, customers used 11-digit or
10-digit codes to order parts. For the DC-17A engine, however, customers can order parts using
engine number and 8-digit codes.
Before ordering parts, be sure to check your engine number so that we can promptly send you the right
parts.

Example: How to order parts

Before ordering a part, be sure to check the engine number, part name, and part code.
Engine number: DC617A0001
(Check the engine number shown in the operation result sheet or the engine
number marked on the actual engine.)
Part name: Fuel nozzle
(Check the part name shown in the parts list.)
Part code: 00007-007
(Check the part code shown in the parts list.)

Notes regarding ordering parts:

Various parts of our engines are controlled for each engine. If you use the part once ordered to the
other type of engine, please contact our sales company, and ask whether the part can be used for the
other engine.
Use of the part for the other type of engine may not be possible due to difference in the specifications,
improvement of the part, etc.
If a wrong type of part is used for your engine, an unexpected problem may occur. In addition, if your
engine is designed in accordance with MARPOL ANNEX VI, the certificate may lose its validity.
For the NOx control parts, be sure to write the parts replacement history in the engine record book to
properly control the parts.
 DC-17A INSTRUCTION MANUAL (OPERATION)
CHAPTER

INTRODUCTION 0

GENERAL 1

GENERAL CONSTRUCTION 2

ENGINE ADJUSTMENT STANDARDS 3

OPERATION 4

INSPECTION AND MAINTENANCE 5

FUEL OIL, LUBRICATING OIL AND COOLING WATER 6

TROUBLESHOOTING AND COUNTERMEASURES 7

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

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

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ITEM
Contents
DC-17A

Chapter 0 INTRODUCTION 0
1． Before Running Daihatsu Diesel Engine 0-1
2． Basic Information on Safety Operation 0-2
2.1 Safety Precautions 0-2.1
2.2 Safety Signs and Symbol Marks 0-2.2
2.3 Indication of Warning: Warning Labels 0-2.3
2.4 Indication of Warning: Warning Label Positions 0-2.4
3． Engine Conforming to NOx Technical Code 0-3
3.1 Outline 0-3.1
3.2 Parts to be Specified 0-3.2
3.3 Engine Setting Value 0-3.3
4． General Information 0-4
4.1 Notation of Engine Type 0-4.1
4.2 Definition of Term 0-4.2
4.3 Unit 0-4.3

Chapter 1 GENERAL 1
1． Engine Specifications 1-1
2． Auxiliary Equipment 1-2
3． Engine Outline and Equipment Layout 1-3

Chapter 2 GENERAL CONSTRUCTION 2

1． Engine 2-1
1.1 Engine Frame, Cylinder Liner, and Main Bearing 2-1.1
1.2 Crankshaft and Bearing 2-1.2
1.3 Camshaft and Timing Gear 2-1.3
1.4 Piston and Connecting Rod 2-1.4
1.5 Cylinder Head 2-1.5
1.6 Fuel Injection Device 2-1.6
1.7 Valve Operating Device 2-1.7
1.8 Fuel Control Device 2-1.8
1.9 Intake and Exhaust System 2-1.9

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DC-17A

2． Piping Systems 2-2

2.1 Starting Pneumatic System 2-2.1
2.2 Fuel Oil System 2-2.2
2.3 Lubricating Oil System 2-2.3
2.4 Cooling Water System 2-2.4
3． Engine Operation Control, Protective Device 2-3
3.1 Start Control 2-3.1
3.2 Stop Control 2-3.2
3.3 Engine Protection System 2-3.3
3.4 Detecting valve 2-3.4

Chapter 3 ENGINE ADJUSTMENT STANDARDS 3

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

Chapter 4 OPERATION 4
1． Precautions for Operation 4-1
1.1 For Start 4-1.1
1.2 For Operation 4-1.2
1.3 For Stop 4-1.3
2． Preparation for Operation 4-2
2.1 Preparation for Daily Operation 4-2.1
2.2 Preparation for Initial Starting after Long Period of Disuse and Overhaul 4-2.2
3． Starting 4-3
3.1 Starting Procedure 4-3.1
3.2 Inspection and Check Items Immediately after Starting 4-3.2
4． Operation 4-4
4.1 Running-in 4-4.1
4.2 Warming up and Connecting Load to the Engine 4-4.2
4.3 Operation with Load (Normal Operation)） 4-4.3
4.4 Operation Using Heavy Fuel Oil (for Heavy Fuel Oil Engines) 4-4.4
5．Special Operation 4-5
5.1 Low-Load Operation 4-5.1
5.2 Non-turbocharger Operation and Operation with Reduced Number of Cylinders 4-5.2

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6． Stop 4-6
6.1 Normal Stop 4-6.1
6.2 Emergency Stop 4-6.2
6.3 Long-Term Shutdown 4-6.3

Chapter 5 INSPECTION AND MAINTENANCE 5

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

Chapter 6 FUEL OIL, LUBRICATING OIL AND COOLING WATER 6

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

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Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES 7

1． Precautions for Troubleshooting 7-1
2． Troubleshooting and Countermeasures 7-2
2.1 Starting Defect 7-2.1
2.2 Engine Revolution is Not Smooth 7-2.2
2.3 Insufficient Output 7-2.3
2.4 Abnormal Exhaust Gas Temperature or Maximum Combustion Pressure 7-2.4
2.5 Abnormal Exhaust Gas Color 7-2.5
2.6 Abnormal Noise/Abnormal Vibration 7-2.6
2.7 Sudden Engine Stop 7-2.7
2.8 Unable to Stop Engine 7-2.8
2.9 Overspeed 7-2.9
2.10 Low Lubricating Oil Pressure 7-2.10
2.11 High Lubricating Oil Temperature 7-2.11
2.12 Low Cooling Water Pressure (Jacket Line) 7-2.12
2.13 High Cooling Water Temperature (Jacket Line) 7-2.13
2.14 Low Cooling Water Temperature (Jacket Line) 7-2.14

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0
ITEM
Before Running Daihatsu Diesel Engine DC-17A 1

0． Introduction
(1) Only skilled operators who have carefully read and fully understood the instruction
manual should operate, inspect and service this machine.
0
Operation, inspection or servicing by persons inadequately familiar with the machine
may result in personal injury, equipment damage or environmental hazard.
(2) No responsibility shall be assumed whatsoever for product damage or any associated
fires, oil spills or other environmental hazards, personal injuries, property damage or
economic losses caused by the use of non-genuine parts or operation, inspection or
servicing that deviates from the instruction manual.
(3) We shall repair new parts or replace any flawed parts made or sold by us, however no
compensation shall be provided for damage to any equipment not of our manufacture
or cargo, or personnel, fire-fighting, towing or other expenses arising from the use of
such flawed parts or fowled fuel, lubricant, cooling water or other medium.
(4) This instruction manual is subject to change without notice.

0-1．Before Running Daihatsu Diesel Engine

This instruction manual describes the proper operation procedure of the DC-17 engine, its
daily maintenance and inspection procedures, and other necessary information on the
engine.To maintain the engine in good operating condition and ensure that it provides the speci-
fied performance, be sure to read through this manual and become sufficiently familiar with the
proper procedures before operating the engine.Strictly avoid use of the engine for a purpose
other than the original purpose of use of the engine or under conditions different from the speci-
fied conditions or handling against the descriptions given herein, since such operation will
cause accidents or troubles.

A． Each piece of the information is an important safety precautions and provided as a

"Warning" or "Caution".

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

C． For the details on the following machine or device, see each instruction manual supplied with this man-
ual:
1. Turbocharger 3. Air motor 5. Other special devices
2. Governor 4. Control equipment

D． Be sure to use the genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the parts
list. We will not guarantee the proper operation of the engine unless such parts are used.
For replacement of the parts or service on your engine, contact Daihatsu Diesel Parts Service Co., Ltd.,
our Service Department, or the nearest DAIHATSU's branch office provided on the cover page.
Be sure to provide us with the "type and number of your engine" when contacting us.
If you use any parts other than the genuine parts or specified parts, unexpected troubles may be
caused, and you cannot make insurance claims owing to nonconformity to terms and conditions of
damage insurance.
E． To prevent environmental contamination, do not dispose of waste products, liquids, etc. thoughtlessly.
Be sure to entrust the disposal of such waste products, liquids, etc. to the authorized waste disposal
company.

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ITEM
Basic Information on Safety Operation: Safety Precautions
2.1 DC-17A

0-2．Basic Information on Safety Operation

0-2.1 Safety Precautions

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

A． Beware of Rotational Parts

This engine has the high-speed rotational parts.

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

B． Beware of Hot Parts

The engine parts are very hot during and immediately after operation. Touching them with bare
hands or skin can cause burns. Note that the exhaust manifold, turbocharger, cylinder head,in-
dicator valve periphery,air cooler inlet, and heated heavy fuel oil pipes become extremely hot.
a. Never attempt to touch any part of the engine with bare hand or skin during or immediately after opera-
tion.
b. Be sure to wear safety gloves or other protective wear for making measurements or inspection.
c. Allow the engine to sufficiently cool down before performing inspection or maintenance work.

C． Prevent Oil from Catching Fire

Fuel oil or lubricating oil coming in contact with extremely hot parts of the machine may catch
fire.
a. Be attentive to oil leakage from the oil pipes during operation. If any leakage is found, immediately stop
the engine and eliminate the leakage.
b. Strictly observe the "NAKED FIRE FORBIDDEN" sign when adding fuel oil or lubricating oil.

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

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0
Basic Information on Safety Operation: ITEM
Safety Signs and Symbol Marks DC-17A 2.2

0-2.2 Safety Signs and Symbol Marks

This instruction manual and warning labels affixed to the engine carry one of the following safety signs
and symbol marks: 0
A． Safety Signs and "Signal words"

："Warning": Precaution related to safety of personnel (Potential hazard which could result in death or serious injury)

："Caution": Precaution related to safety of personnel (Potential hazard which may result in minor or moderate injury)

："Precautions for handling": Information on handling of the engine to prevent damage

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

："Obligatory acts": Recommended practice or instruction to be followed to ensure safety of personnel and the engine
B． Symbol Marks
a.Warning Signs
b．Prohibition Signs

：General warning
：Non-specific general prohibition

：Flammable → Fire
：No Smoking

：Explosive → Explosion or Bursting

：Naked fire forbidden

：Poisonous → Poisoning
：Do Not Touch

：Voltage → Electric Shock

c. Signs for Obligatory Acts

：High temperature → Burn ：Wear Eye Protection (safety goggles, etc.)

：Rotational/Moving Part → Getting Caught ：Wear Head Protection (hard hat, etc.)

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

：High-Pressure Fluid Jet → Injury ：Wear Hand Protection (safety gloves, etc.)

：High Location → Fall ：Wear Foot Protection (safety shoes, etc.)

d. Others

：See other pages in this manual or other documents.

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ITEM
Basic Information on Safety Operation: Indication of Warning:
2.3 DC-17A Warning Labels

0-2.3 Indication of Warning: Warning Labels

The warning labels shown below, are used in the DAIHATSU DIESEL MFG. CO., LTD.
㩿㪈㪀 㩿㪉㪀 㩿㪊㪀

㩿㪋㪀 㩿㪌㪀

㩿㪍㪀 㩿㪎㪀 㩿㪏㪀 㩿㪐㪀

㩿㪈㪇㪀 㩿㪈㪈㪀 㩿㪈㪉㪀 㩿㪈㪊㪀 㩿㪈㪋㪀

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0
ITEM
Basic Information on Safety Operation: Indication of Warning:
Warning Label Positions DC-17A 2.4

0-2.4 Indication of Warning: Warning Label Positions

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












Fuel test pump Hydraulic jack

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Introduction
0
ITEM Engine Conforming to NOx Technical Code:
3.1,3.2 DC-17A Outline/Parts to be Specified

0-3. Engine Conforming to NOx Technical Code

0-3.1 Outline

A． The marine diesel engines to which the 13th rule "Nitrogen Oxides (NOx)" in Supplement VI "Rules to
Prevent Air Pollution by Ships" to MARPOL73/78 Treaty applies should conform to NOx Technical
Code.

B． The engines conforming to NOx Technical Code are authorized as an engine group or an engine fami-
ly, and it is allowed to apply the engine parameter check method to them, when receiving the NOx dis-
charge inspection on board.
The engine parameter check method is a method for verifying that the engine components and setting
values conform to the requirements specified in the technical file, and does not require the measure-
ment of NOx discharge. To the engines that are not conforming to the requirements of the technical
file, the engine parameter check method cannot be applied. For such engines, the measurement of
NOx discharge shall be required.

0-3.2 Parts to be Specified

The technical file states the engine components that can affect the NOx discharge specified in NOx
Technical Code, and shows the identification marks stamped on them, and the user is required to main-
tain the technical file for each engine. When replacing any parts shown in the technical file, be sure to use
our genuine parts stamped with the identification marks. In the case that any parts without the identifica-
tion mark is used, it shall be regarded as nonconformance to the requirements of the technical file, and in
such a case, inspection by the engine parameter check method cannot be applied.
The followings are the parts that have the identification marks specified in the technical file. When
replacing any of these parts, be sure to check the identification marks
（ ："Technical file"）

<Parts with identification marks>

1. Cylinder head
2. Piston
3. Turbocharger
4. Air cooler
5. Cam shaft
6. Fuel injection pump
7. Fuel injection pump plunger
8. Fuel injection valve
9. Fuel injection valve nozzle

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0
ITEM
Engine Conforming to NOx Technical Code:
Engine Setting Value DC-17A 3.3

0-3.3 Engine Setting Value

The engines conforming to NOx Technical Code are adjusted to conform to the specifications before 0
shipment. After shipment, they should not be adjusted to such a manner that the setting values specified
in the technical file may be deviated.
If any change is made in the manner that may deviate from the settings specified in the technical file, it
shall be considered to be nonconformance to the requirements of the technical file, and the inspection by
the engine parameter check method cannot be applied.
The followings are the items that have been set to conform to NOx Technical Code:

<Items to be set before shipment>

A. Fuel injection timing
B. Fuel injection valve opening pressure

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0
ITEM
General Information:
4.1-4.3 DC-17A Notation of Engine Type, Definition of Term, and Unit

0-4．General Information

0-4.1 Notation of Engine Type

5 6 DC- 17A

• Number of cylinders
• Name of series
• Cylinder bore (cm)

0-4.2 Definition of Term

Definitions of the terms used in this manual are follows:
・ Rear side of engine: Output end side (flywheel side)
・ Front side of engine: Opposite side to the output
end
・ Exhaust side: Exhaust manifold side (on the right
when seen from the output end) Front side
・ Pump side: Fuel injection pump side (on the left 6
5 Exhaust side
when seen from the output end) 4
3
・ Normal rotation (rightward rotation): Clockwise 2
1
rotation when seen from the output end Normal rota-
・ Cylinder and journal numbers ..... 1, 2, 3, starting tion (Rightward
from the output end rotation)

Pump side
Rear side

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

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0
ITEM
MEMO DC-17A

0
CHAPTER
General
1
ITEM

1, 2 DC-17A Engine Specifications and Auxiliary Equipment

1-1．Engine Specification

Model 5DC-17A 6DC-17A

Type Vertical water-cooling direct injection type 4-cycle diesel engine
Number of cylinders 5 6
Cylinders bore mm 170
Piston stroke mm 270
Rotational speed min-1 900 / 1000
Output kw
*
Ignition sequence 1-3-5-4-2 1-5-3-6-2-4(900min-1)/1-2-4-6-5-3(1000min-1)
Rotation direction Clockwise when seen from the flywheel
Turbocharging method Turbocharged by exhaust gas turbine equipped with air cooler
Starting method Air motor

Cooling Jacket Fresh water

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

1-2．Auxiliary Equipment

Auxiliary / Equipment Type Remarks

Turbocharger Radial turbine type
Air cooler Fin tube type
Governor Hydraulic type
Fuel injection pump Bosch type
Fuel oil valve Bosch type
Lubricating oil pump Gear type
Lubricating oil cooler Plate type
Lubricating oil filter Notch wire, duplex type
T/C lubricating oil filter Notch wire, duplex type
Lubricating oil tank Common base plate incorporated
Cooling water pump Centrifugal type
Note: The data given in the above table show those in the case of the standard specifications.
Therefore, the data of your engine may differ from those shown in this table, and in such a case be
minded to refer to the "Engine Specifications".

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General
1
ITEM
Engine Outline and Equipment Layout DC-17A 3

1-3．Engine Outline and Equipment Layout

Turbocharger Governor Gauge board 1

Air cooler
Operation lever

Cooling water pump Lubricating oil cooler

Air motor

T/C lubricating oil filter

Lubricating oil filter

Lubricating oil
thermostat valve
Lubricating oil relief valve

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General Construction
2
ITEM

1.1～1.5 DC-17A Engine

2-1．Engine 2-1.4 Piston and Connecting Rod

2-1.1 Engine Frame, Cylinder Liner, and
Main Bearing
The frame is a monoblock structure made of
cast iron, and the upper section of the frame forms
a cooling jacket, together with the cylinder liner.
The main bearing is a suspension metal type,
and mounted to the engine frame with 2 mounting
bolts and 2 side bolts.
Intake air, lubricating oil, and each cooling water
channel are incorporated in the engine frame. The
timing gear case is mounted on the engine frame
front side, and the turbocharger, air cooler, lubri-
cating oil cooler, cooling water pump and lubricat-
ing oil pump are installed in the frame.
A frame safety valve is provided on the frame
side cover.
2-1.2 Crankshaft and Bearing
The crankshaft is an integral forged part. A fly-
wheel is mounted at the rear (output side) of the
crankshaft, and a crank gear for driving the
camshaft and an auxiliary driving gear are mount-
Exhaust pipe
ed at the front.
The main bearing and crank pin bearing are thin
bearings composed of two parts. Thrust bearings
are fitted on the front and rear sides of the rear
bearing No.1.
A ring gear is attached to the flywheel for air
motor starting.
The piston is an integral forged part made of
ductile cast iron. Its top ring groove is induction-
hardened. The piston is cooled with lubricating oil
that is fed from the connecting rod through the pis-
ton pin.
The connecting rod is from-turned forged prod-
uct with the large end, which is horizontally split
into three parts, to allow overhaul of the piston
without disassembling the bearing unit.
2-1.5 Cylinder Heater
The cylinder head is of a highly rigid structure
made of special cast iron, and is hydraulically
secured to the piston with 4 bolts.
Four valve system is employed having 2 intake
valves and 2 exhaust valves, and a water cooling
valve seat, which is directly attached to the cylin-
der head, is installed for each exhaust valve.
The cylinder head is provided with a indicator
and cylinder safety valve.
Rocker arm device
Intake valve and
exhaust valve
Cylinder head
Fuel high
presure block
Fuel injection
pump

2-1.3 Camshaft and Timing Gear Piston

The camshaft is located on the left side of the
Cylinder liner Valve operating
engine (when seen from the output side). device
Intake duct
The intake, exhaust and fuel cams are integral Cam shaft
parts of the camshaft. The camshaft is a unit com- Connecting
rod
posed of two parts. Engine frame
The timing gear for driving the camshaft is
installed on the front side of the engine, and the
cam gear is driven from the crank gear via the idle
gear. Cranck shaft
Cranck pin
bearing
Side bolt

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2
ITEM
Engine DC-17A 1.6～1.9

2-1.6 Fuel Injection Device The operation lever is located beside the instru-
The fuel injection pump is a Bosch type and high ment board at the rear of the engine.
pressure pump of integrated with tappet, and it is 2-1.9 Intake and Exhaust Systems
installed on plunger barrel of closed type and iso- The turbocharger and air cooler are mounted on
baric valve. the front side of the engine.
Also, the high-pressure oil inlet coupling of fuel The Turbocharger Specifications differs accord-
injection valve, which is a horizontal-insertion type, ing to the engine model, output and orders
is connected to the fuel injection pump via the received.
high-pressure coupling made of forged steel.
（ :"Instruction Manual of Turbocharger")
The exhaust pipe and intake duct are installed
2-1.7 Valve Operating Device
The intake and exhaust valves are driven by
on the same side of the engine, and the intake
duct is incorporated in the engine frame.
2
motion transferred from the camshaft via the swing
arm, push rod, and rocker arm.
2-1.8 Fuel Control Device
The governor is installed at the rear of the
engine, and is driven by the governor gear driven
by the camshaft.

Governor

Gauge board

Cam gear

Idle gear
Cranck shaft

Cooling water Main bearing

pump

Aux. machine
driving gear

Thrust bearing
Lubricating oil
pump

Cranck gear

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ITEM

2.1 DC-17A Piping Systems: Starting Pneumatic System

2-2．Piping system

This section describes the typical piping systems of standard specifications. For more details,
refer to the piping systems included in the final documents.

2-2.1 Starting Pneumatic System

The engine is started by an air motor operating
with compressed air.
To start the engine remotely or automatically,
press the start button on the engine control panel
or the operation panel (monitor panel), and the
starting solenoid valve is actuated, and control air
reaches starting valve. Then the main circuit of the
starting valve is opened, and low-pressure air
reaches the air moter to pushes out the pinion
gear of the air motor.
When the pinion gear engages with the ring gear
on the flywheel, the air motor main air circuit
opens. The air motor is driven by the main air, and
the engine starts.
To start the engine on the engine side, press the
start button on the engine, and it starts in the same
manner as when started remotely.
To protect the air devices, a strainer is provided
in front of the pressure regurating valve.
To start the engine in case of emergency after
occurrence of trouble, such as a power failure, turn
the starting valve for emergency provided on the
starting solenoid valve.
（ ：4.3.1"Starting Procedure"）

Starting push button

Starting solenoid valve

Detecting valve
Control air

Air motor

Ring gear
Starting solenoid valve
Starting valve
Pressure
regurating valve

Air filter
Starting valve for emergency
Starting air

Starting air system

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ITEM
Piping Systems: Fuel Oil System DC-17A 2.2

2-2.2 Fuel Oil System

Fuel oil system vary depending on the grade of
the oil used, and a typical example of the fuel oil
system for heavy fuel oil is as shown below.
When heavy fuel oil is used, oil must be heated
and kept at a constant temperature to maintain the
oil viscosity suitable for injection.
Oil heated by the heater and pressurized by the
fuel feed pump is transferred to the fuel oil injec-
tion pump via the filter.
Surplus of oil is returned to the inlet side of the
oil feed pump via the pressure control valve (relief
valve), and is then circulated again.
High-pressure oil fed by the fuel injection pump
is introduced into the fuel oil injection valve con-
nector from the cylinder head side via the fuel
high-pressure block.
( :5-4.3 B "Fuel Oil Flushing filter"）

Heavy fuel oil supplying pump

Air separator

Fuel injection valve leakage main pipe

Heavy
fuel oil Diesel
tank fuel oil Fuel high-pressure block leakage
Accumulator tank oil main pipe

Fuel high- Fuel injection

pressure block valve
Filter

Oil feed
Viscosity
pump
controller

Inlet connector
Fuel injection
Fuel inlet pump
Filter
block 1
Heater Inlet main pipe

10Ǵ Pulse absorber

Auto back wash filter
Flushing filter (*) Return main pipe Waste leakage
Pressure
oil tank
control valve
(*) To be removed 200 to 300 hrs. after the initial start of the engine or when fuel oil is switched to heavy fuel oil.

Fuel Oil System

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2
ITEM

2.3 DC-17A Piping Systems: Lubricating Oil System

2-2.3 Lubricating Oil System

Lubricating oil transferred to the lubricating oil
cooler from the lubricating oil pump is regulated to
reach the specified temperature and pressure, by
means of the temperature control valve and pres-
sure control valve respectively, and the lubricating
oil is transferred to the oil channel of the engine
frame via the filter. Then, from this oil channel, the
lubricating oil is supplied to the piston through the
holes of the connecting rod via each main bearing
and crank pin.
Further, the lubricating oil is supplied as
branched from the same oil channel to the
camshaft, valve-operating swing arm, fuel oil injec-
tion pump tappet, around the rocker arm, and vari-
ous gears.
The lubricating pump, which is of a gear type
provided with a safety valve, is installed on the
front side of the engine and is driven by the crank-
shaft.
The lubricating oil filter for the engine is auto-
matic backwashing type, and while engine running,
cleans sludge continuously captured by the filter
element.
Lubricating oil is supplied to the turbocharger
and fuel injection pump via the special lubricating
oil filter respectively.
Lubricating oil, that has circulated through and
has lubricated each part, returns to the base plate
of the engine (oil tank).

Rocker arm
Lubricating oil cooler
Fuel oil injection pump (FIP)

Filter
Filter
Thermostat
valve
Swing arm

Relief valve Camshaft

Filter

Lubricating oil
Turbocharger
pump
(T/C)
Timing gears
Safety
Governor drive unit Governor driving gear
valve
Auxiliary machine driving gear
Cooling water pump

Engine base plate (oil tank)

Lubricating Oil System

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ITEM
Piping Systems: Cooling Water System DC-17A 2.4

2-2.4 Cooling Water System The temperature control valve in the tem-
perature control valve case keeps the cooling
The cooling water system is a single fresh water
water at the specified temperature.
circulating system in which jacket line water (high
temperature) and cooler line water (low tempera-
ture) are mixed. Normally, fresh water is used as B． Cooler Line
cooling water. The cooler line is also a circulating system
in which the cooler line cooling water is low-
A． Jacket Line temperature fresh water fed under pressure
by the cooling water pump. The water returns
The jacket line is a circulating system, to the fresh water cooler through the air cooler
which can be fed part of cooling water in the and the lubricating oil cooler.
cooler line under pressure from the lubricating
oil cooler by the cooling water pump. The 2
water enters the engine cylinder jacket
through the air cooler and returns to the fresh
water cooler through the temperature control
valve case at the cooling water outlet of the
engine after cooling the parts in the jacket.

Fresh water cooler

Turbocharger

Temperature
control valve Cooler line cooling
water pump

Lubricating oil cooler

Air cooler

Jacket line cooling

water pump

Temperature
control valve

Cooling W ater S ystem

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2
ITEM

3.1 DC-17A Engine Operation Control, Protective Device: Start Control

2-3．Engine Operation Control, Protective Device

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

2-3.1 Start Control

A． For generator b.Automatic Start
a.Remote Control In the case of automatic start, a start com-
mand is automatically given according to the
(1)In the case of starting the engine by remote specified sequence, and the starting solenoid
control, the control lever must be always set to valve operates to feed low-pressure air to the
the "RUN" position. The handle switch (HS) is air motor and to start the engine.
turned "ON" at this state, and if the turning
safety switch (TC) is also turned "ON", the c.Engine Side Start
engine is on standby and ready for operation. In the case of engine side start, the opera-
(2)When a start command is given, the starting tion mode is switched to the engine side.
solenoid valve operates to open the main air Press the engine side start button to operate
circuit of the starting valve, and to feed low- the starting solenoid valve and to feed low-
pressure air to the air motor, and the pinion pressure starting air to the air motor.
gear is pushed out. When the pinion gear
engages with the ring gear, the main air circuit
of the air motor opens.
(3)Meanwhile, the same start command allows
the fuel control solenoid (88L) to activate,
causing control air to flow into fuel control
cylinder, and allows the common rod to be
held in position, so that the fuel injection
amount is controlled not to be excessive at the
time of starting.
(4)When the engine reaches the specified rotation
speed, the low-speed relay (14) is activated,
canceling the start command and resetting the
protective circuit, so that the engine is set to
the operating state.

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ITEM
Engine Operation Control, Protective Device: Start Control DC-17A 3.1

Turning bar Pulse sensor

From L.O.piping Fuel control cylinder 12

13 Speed switch
14
C
(12,13,14)
Meter display
Turning
g
2
(4-20mA)
safety switch(TC)
Starting solenoid valve(88V)
(With valve for emergency) Common rod
Governor motor
Air motor
Starting push button

Governor

Detecting valve Operation lever

Starting valve
Flywheel

Pressure regurating valve RUN

Air filter START

Starting air

STOP

Handle switch (HS)

Ring gear Air tank

Control air Fuel suppression
pp Fuel shutdown Fuel shutdown
0.6-0.9MPa solenoid valve solenoid valve solenoid valve
(88L) (5S) (5V)

Start and Stop System

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2
ITEM
Engine Operation Control, Protective Device:
3.2,3.3 DC-17A Stop Control / Engine Protection System

2-3.2 Stop Control 2-3.3 Engine Protection System

When a stop command is given, the fuel shut-
down solenoid valve (5V) operates to feed control
air to the fuel control cylinder, turns the common
rod in the direction for stopping and stops the
engine. To stop the engine on the engine side,
turn the operation lever to the stop position.
As for the errors that may be led to serious acci-
dents or failures, alarm is issued and emergency
stop is made.
Each of the abnormal operation data or value is
detected by a switch or sensor, and the fuel shut-
down solenoid valve is activated by the emergency
stop command, so that the engine is immediately
stopped.

Table 2-3.1 Alarm and stop Items (Example)

Detection item Alarm Shutdown Location Remarks

Overspeed 12 Cam gear
Decrease of lubricating oil pressure 63Q1 63Q2 Engine inlet Combined use for issuing command
Increase of high-temperature cooling water temperature TSWH 26WH2 Engine outlet Combined use for issuing command
Decrease of turbocharger lubricating oil pressure 63QT Turbocharger inlet
Increase of lubricating oil temperature TSQ Engine inlet Combined use for issuing command
Increase of exhaust temperature TSTI Turbocharger inlet(or outlet) Combined use for issuing command
Oil leakage from fuel high pressure block 33F Oil leakage detector
Decrease of lubricating oil level 33Q Engine lubricating oil tank
Decrease of starting air pressure 63AS Before regulator relay valve
Decrease of high-temperature cooling water pressure 63WH Jacket inlet Combined use for issuing command

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2
ITEM
Engine Operation Control, Protective Device:
Engine Protection System DC-17A 3.3

GM COS 㧿㨀㧭㧾㨀 HS TC 88V 88L 5V 5S SVB 63BU 63BL 63Q2 26WH2 63QT 63AS 33F 33Q
BLACK
WHITE
RED

B W R 㧝 㧞 㧝㧞 4 1 43 1 12 1 2 1 2 1 1 2 2 1 3 2 1 3 3 12 2 14 2 13 1 1 2 1 2


21
11



12

20








6

18


25




10

17
16

19
1
2
3
4
5

26
13
14
15

22
23


24
2
TSTI TSQ TSWH SSE
C

SOURCE
AC100㨪110V
or S+ -
AC200㨪220V
W
B R
RAISE LOWER
C
91
69

92
68

90

93
67

88
89

97
98
99

PM

U VW
SOURC
DC24V
C : Control panel C F S + - 㧼㧺
Speed switch unit

TO PRIMING PUMP
C
CONTROL PANEL
㧝㧞㨏㧝㧞㨍 㧝㧞㨎㧝㧠㨏㧝㧠㨍㧝㧠㨎

Engine Protection System (Example)

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2
ITEM
Engine Operation Control, Protective Device:
3.4 DC-17A Detecting Valve

2-3.4 Detecting Valve

When air leak from the starting valve, the cap of
this detecting valve lifts.
This facilitates detection of nonconformance of
the valve seat during daily visual inspection.
When minor air leak occurs, the leaked air is let Valve body
out to avoid protrusion of the air motor pinion and Tightening torque
55 N.m
idling.
These functions prevent abnotrmal engagement Valve
of the ring gear and the air motor pinion gear.
At the normal start, the control air pushes down
Cap
the valve in the detecting valve, so that the starter
air flow into the air motor without leaking from the
detecting valve.

1) When air leak occurs, immediately check the

starter relay valve. Detecting valve
2) Accumulation of dust in the valve sliding part
in the detecting valve may cause malfunc-
tion.
periodically overhaul the valve.
3) When mounting the detecting valve, apply
lube oil to the valve sliding part.
4) When mounting the detecting valve, tighten
it to the specified torque.

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2
ITEM
MEMO DC-17A

2
CHAPTER
Engine Adjustment Standards
3
ITEM

1 DC-17A Operating Specifications

3-1．Operating Specifications

Alarm setting
Item Normal value value (emergency Reference
stop value)
Air tank 1.5 - 3.0 1.5
Starting air
Air motor 0.6 Safety valve: 0.9
Control air Air tank 0.6 - 0.9 0.6
Varies depending on
Intake Intake air duct  the engine output

Engine HO 0.5 - 1.0 0.5

Fuel oil
Pressure (MPa)

inlet DO 0.2 - 0.3

Engine inlet
(filter outlet) 0.4 - 0.5 0.35(0.3)
Lubricating
oil Turbocharger
inlet(filter outlet) 0.2 - 0.5 0.2
Consider static and
Jacket line dynamic pressure due
(jacket inlet) 0.15 - 0.35 0.15 to tank head and pipe
Cooling resistance
water Cooler line
(cooler inlet) 0.15 - 0.35 0.15

Intake Intake air duct 45 - 55 At declared power

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

Turbocharger outlet  500

O

Lubricating Engine inlet

oil (cooler outlet) 55 - 65 70
Jacket line
(jacket inlet) 70 - 80 90(95)
Cooling
water Cooler line
(cooler inlet) 36 - 38

Note: (1) As for the alarm setting value and emergency stop value, each item of the pressure represents the
lower limit value, and each item of the temperature represents the upper limit value.
(2) Manometer, thermometer, and alarm/emergency stop device is provided depending on the individ-
ual specifications.
(3) The actual data found on each engine may differ from those shown in the above table, and there-
fore refer to the Test Run Record Table (included in the final documents) for the details.

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Engine Adjustment Standards
3
ITEM
Valve Settings DC-17A 2

3-2．Valve Settings

Adjustment value
Item Reference
(design valve)
o
6D (45 )
Opening start angle
(before top dead center)
5D
o
(35 ) C
Intake Valve

Closing end angle o

(after bottom dead center) (35 )

A 3
Valve end clearance "C" 0.3 mm (Valve end clearance adjusting
procedure)

(1) Valve end clearance data repre-

Opening start angle o
(55 ) sents the clearance available
(before bottom dead center)
Exhaust Valve

when the engine is cold.

(2) Adjust valve end clearance "A"

o and "B" shown abave such that
6D (65 ) it becomes equal to "0" first.
Closing end angle
(after top dead center) Then, adjust valve end clearance
o "C" such that it becomes equal to
5D (65 )
the value given in this table.

Valve end clearance "C" 0.3 mm

Fuel injection valve opening

pressure (adjustment value) 44 MPa

May vary depending on the engine

out put and specifications.Refer to the
Maximam combustion pressure
Test Run Record Table (included in
the final documents).

Cylinder safety valve opening

19.1 MPa
pressure (adjustment value)

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Operation
4
ITEM
Preparation of operation: Precautions for Operating Engine
1.1～1.3 DC-17A

4-1．Precautions for Operating Engine

4-1.1 For Start
A．Conduct preparations before start of the operation of engine, such as the inspection of oil, water,
and air levels, as well as proper operation of the valves without fault, and be minded to start opera-
tion only after it has been confirmed that all the conditions are ready for the start of engine.
B．It is extremely dangerous to start the operation of engine with the turning bar inserted in the fly-
wheel. Be minded to remove the bar and store it in a specified place after turning is completed.
C．Confirm that there are no working staff around the engine. When anyone is around the engine, be
minded to send a signal and confirm safety before starting the operation of engine.

4-1.2 For Operation

A．After the starting engine, inspect the following items, and confirm that the engine is in a good con-
dition. In case that any defect is found, immediately stop the engine, so that the causes of the
defect can be investigated and the measures for recovery can be taken.
・Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate
exhaust temperature.
・Abnormal sound, excessive heating, etc.
・Any leakage from piping. (Particularly, leaks from oil piping results in fire.)
Be minded never to attempt to resume the operation of engine, until the causes of the problem or
defect are found and eliminated, and the engine is restored to the normal operating conditions.
B．Inadvertent contact of the body of working staff or objects with the rotating parts (e.g. flywheel and
coupling) results in dangerous accidents such as that the staff may be caught up or the chips of
the objects caught may fly out in all directions. Therefore, be minded that both person or object
may not touch the rotating parts.
Further, ensure that the protective covers of the rotating parts are always attached without fall.
C． During the operation of engine, particularly the following parts are extremely hot, and therefore
there is a danger of burn if touched with bare hands or skin. Be minded to wear safety gloves or
protective gears whenever maintenance or inspection works are conducted.
After the completion of the work, restore the lagging, heat covers, combustible oil splash preventive
means (FN tape) and protective covers that have been removed for maintenance and inspection.
・Exhaust pipe
・Turbocharger
・Air cooler inlet pipe
・Cylinder head
・Indicator valve (fitted to the cylinder head)
・Fuel injection pump and high-pressure block
・Fuel oil pipe (when heavy fuel oil is used)

4-1.3 For Stop

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

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ITEM
Preparation of operation: Preparation for Daily Operation
DC-17A 2.1

4-2．Preparation for Daily Operation

It is essential to keep the engine in "Operable Conditions" when starting the engine. Therefore,
be sure to perform pre-operation inspections before the starting of engine, and take proper cor-
rective actions whenever any problem is found, to confirm that the engine is in normal conditions
for operation, before starting the operation of engine.
If the engine is started without pre-operation inspections or preparations, it will not only cause
the troubles when starting the engine but also result in a sudden stop or damaging accidents.

4-2.1 Preparation for Daily Operation

The number of the inspection items required
before starting the operation varies depending on
how long the engine has been out of operation.
・ Daily starting: shutdown for a short period
of time (within one month)
・ Initial starting after installation, after shut- Upper limit
down for a long period of time, or after overhaul
or maintenance. Lower limit
The daily starting procedures is described in
this section. As for the latter (initial starting), 4
refer to the following section.
（ ：4-2.2 "Preparation of Initial Starting after a
Long Period of Disuse and Overhaul"）

A．Inspection before Start

a ．Inspection and Feeding of Lubricating Oil
Check the oil level of the oil tank, and feed
new oil to the upper limit level of the oil gauge
(level gauge).
Inspection of Engine Lubricating Oil
Further, in case that the lubricating oil is
found inadequate after examination, proceed
with makeup or replace the entire amount of Oil port Oil port
the lubricating oil.
（ ：6-2 "Lubricating Oil Control"）
Level gauge
1.Engine lubricating oil tank (Base plate common
to engines)
Engine type 5DK 6DK
Amount of lubricating oil (L) 460 540

Note: The amounts of oil shown above may vary

depending on type.
2. Governor
Lubricating oil level, RHD6: 1.3L RHD6 UG10
UG10: 1.7 L
3. Generator (for self-lubricating type) Inspection of Governor Lubricating Oil Level
（ ：Separately provided "Generator
Instruction Manual"）

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4
ITEM

2.1 DC-17A Preparation for operation: Preparation for Daily Operation

b Inspection, Lubrication, and Operation

Check around the Fuel Regulation System
Manually lubricate the bearing and sliding Fuel injection pump Governor
parts of pins, after checking for any loose or Operation
lever
missing levers, link pins, and bolts around the
governor, common rod, stop system, and fuel
inspection pump rack.
Set the operation lever to the "STOP" posi-
tion and confirm that the rack scale is set at
"0", and then alternately move the lever to the
"STOP" and "RUN" positions, to confirm that
Lubrication point
the common rod and pump rack moves
smoothly. Manual Lubrication:
Around the Common Rod and Operation Lever
c Draining of Condensed Water from Intake
Air Inlet Duct
Open the drain cock of the intake air inlet
duct of the engine frame, and drain the con-
densed water out.Confirm draining the con-
densed water or discharging the air during
engine running.
Open

Close
Drain cock of engine
frame air intake duct

Lubrication point

Manual Lubrication:
Around the Fuel Injection Pump

Pointer

Engine Frame Air Intake Duct

Rack scale

Always keep the drain cock of the engine

RUN
frame inlet air duct open about 60 (2/3), after
draining the condensed water by fully operating RUN

the drain cock.

In case that the humidity is high and the cool-
ing water temperature of the air cooler is low, a STOP STOP

large amount of condensed water will accumu-

late, any may cause corrosion or abnormal
wear on various parts flowing into the cylinder
and may cause serious accident as the case
may be. Operation Lever

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4
ITEM
Preparation for operation: Preparation for Daily Operation DC-17A 2.1

d ．Draining Condensed Water from, and 5. Valves for pipe coupling parts provided for
Supply of Air to Air Tank emergency, cleaning, etc.: "Closed"
In the case of automatically supplying air,
first drain the condensed water out of the
starting air tank and control air tank, and then
confirm that air pressures in these tanks is
If the screw-tightening valves are used on
above the lower limit value.
the state of half-open, the valve handle may be
In the case of manually supplying air turned during operation and the opening
(including manual starting of the air compres- degree may be changed, causing malfunctions.
sor), supply air to the upper limit value. Therefore, the valves should be fully turned
Item Upper limit Lower limit toward either "Open" or "Close" position, and
should be locked tightly.
Starting air 3.0 MPa 1.5 MPa
In the case that the valves must necessarily
Control air 0.9 MPa 0.6 MPa be left half open for the sake of flow adjust-
ment, be sure to secure the valve handles with
e ．Checking and Feeding of Cooling Water wire ring and the like, and fix them to prevent
Check the level of cooling water in the cool- their loosening and turning.
ing water tank, and if the level is at the lower
limit, supply fresh water up to the upper limit,
and at the same time add a proper amount of
B．Standby Preparation (Engine on standby)
the additive.
Further, in the case that each property value
Before entering the operation of engine, con-
duct the following preparations:
4
of water reaches the limit level, replace the
entire amount of water.
a ．Priming with Lubricating Oil
（ ： 6-3 "Cooling Water Control"） Run the motor-driven priming pump (or a
reserve pump) for lubricating oil five minutes
before starting the engine, and check that the
f ．Draining of Fuel Oil and Supply of Oil lubricating oil pressure rises and no oil leaks
First drain fuel oil out of the fuel oil service from piping parts.
tank, and then check the oil level and supply oil
up to the upper limit of the level gauge.
b．Turning or Air Running
g．Opening and Closing of Valves Conduct turning or air running to discharge
Repeat "Fully open" and "Fully close" opera- the dusts or water drops that collects in the
tion of the valves on the piping system 2 to 3 cylinder while the engine is stopped.
times to confirm that the valves move smoothly, Further, when the engine is started after the
and then set the valves to the "RUN" position. inspection of various parts of the engine, or after
Some of the examples are shown as follows. a long period of disuse of the engine, conduct
Since the layout positions of the piping systems turning before air running to confirm the safety.
and valves differ depending on each engine,
refer to the piping diagrams of the final docu-
ments for the details.
[Example]
1. Valves for fuel oil inlet pipe and return pipe:
"Open"
2. Valves for cooling water (jacket and cooler),
inlet pipe, and outlet pipe: "Open"
3. Valves for starting air pipe: "Closed"
("Open" only when starting operation)
4. Valves for operation air pipe: "Open"

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4
ITEM

2.1 DC-17A Preparation for operation: Preparation for Daily Operation

In the case that a large amount of water or oil Pointer

is accumulated in the cylinder due to the leak-
age from the cylinder head or fuel injection Rack scale

valve, there is possibility of serious accidents

such as bending damage of the connecting rod
by the water hammer.
If water or oil gushes out of the indicator
valve(on the cylinder head top surface) during
turning or air running, stop starting the engine,
investigate the causes, and take measures.
RUN

<<Turning>>
<Work Procedure>
STOP
(1) Conduct priming with lubricating oil. STOP

(2) Set the operation lever to the "STOP" posi-

tion. (Do not inject fuel oil.)
(3) Set the indicator valve to the "Fully open"
position.
Operation Lever
(4) Conduct turning 1 to 2 times, and confirm that
the engine rotates smoothly.

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

<Work Procedure>
(1) Conduct priming with lubricating oil.
(2) Set the operation lever to the "STOP" posi- Close
tion.
(3) "Fully open" the indicator valve
(4) Open the starting air valve and the control air
valve, and press the start button on the
engine.
The solenoid valve of the starter relay valve
operates to feed starting air to the air motor, Open
and the engine starts.
(5) Keep pressing the push button for 3 to 4 sec-
onds. (for air run)
(6) Release the start button on the engine. The
air motor stops operating, and the engine Indicator Valve
stops.

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4
ITEM
Preparation for operation: Preparation for Daily Operation DC-17A 2.1

If the engine starts its rotation during the

inspection of the inside of the engine or rotat-
ing parts, it is extremely dangerous since the
working staff may be caught up or the objects
that has been caught up may fly out in all
directions.
When conducting air run, strictly observe the
following points.
1) Confirm that the turning bar should be insert-
ed into the turning holder.
2) Send a signal to coworkers and confirm
safety before starting to press the push but-
ton of the starting operation.

c ．Heating of Fuel Oil (when heavy fuel oil is

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

（ ：6-1 "Fuel Oil Control"）

Heated heavy fuel oil, which is extremely hot

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

d．Turning "ON" of Protective and Alarm

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

e ．Operation of Motor-Driven Pumps

In the case that the engine is equipped with
the motor-driven cooling water pump and fuel oil
feed pump, start the pumps 5 minutes before the
starting of engine, and confirm that there is no
oil leaks from various parts of piping.

DC-17A Z 08-10
CHAPTER
Operation
4
ITEM
Preparation for operation: Preparation of Initial Starting after a
2.2 DC-17A Long Period of Disuse and Overhaul

4-2.2 P r e pa r a t i o n f o r I n i t i a l
Sta r t i n g a ft e r L o n g P e r i o d
of Disuse and Overhaul
Since the engine is not ready for immediate
starting of operation after installation, shutdown
and overhaul for a long period or maintenance, it is
particularly necessary to thoroughly conduct the
preparations for operation.
Before the preparation for daily operation, con-
duct the following preparation works (4-2.1).
A．Inspection of Crankcase and Cylinder
Liner, and Supply of Oil
a ．Inspection of the Inside of Crankcase Spray
(Spray lubricating oil)
Open the side cover of the engine frame, and
check and ensure that tools, waste clothes, for-
eign matters such as desiccants are not left No foreign matters such
desiccant or silicagel
behind, and that there is no rusting on the cylin- should be present.
der liners, crankshaft, and so on.
b．Supplying Lubricating Oil to Cylinder Liner
After a long period of disuse, the various parts Applying Procedure of Lubricating Oil
of engine are not covered with sufficient amount
of lubricating oil. Particularly around the cylin- 3.Lubricating oil filter (filters on the engine, for
der, lubricating oil cannot be supplied sufficiently T/C)
with priming alone, and therefore supply lubricat-
4.Cooling water filter
ing oil on the following procedure:
（ ：5-4.3 "Cleaning Filters"）
(1) Conduct turning to allow the pistons to move
upward, and apply lubricating oil to the lower
D．Priming with Lubricating Oil and
part of the cylinder liners by a spray device
Exhausting Air
and the like.
Conduct priming with lubricating oil and
(2) Sequentially conduct the above procedure to
exhausting air in the following procedure:
each cylinder.
a．Run the lubricating oil priming pump for 5 min-
B．Inspection of Connections and Joints
utes. While the pump is operating, open the
Inspect again the external connections or indicator valve (on the cylinder head top surface)
joints to confirm that there is no connections that to perform turning two or three times, and check
has been forgotten to be tightened, or loosened for leakage of fuel oil, lubricating oil and water
joints. If combustible oil splash preventive from the indicator valve.
means (FN tape) has been removed from joints,
b．At the same time, open the each cover and
newly treat the joints in the same manner after
check the dripping-down conditions of lubricating
the completion of the work.
oil from each part.
C．Opening, Cleaning, and Cleansing of Filters 1.Engine frame: Main bearing, crank pin, piston
Dust or foreign objects, that collected into pip- (cooling chamber), and piston pin
ing during transportation, and outfitting or instal- 2.Cam case: Cam bearing, swing arm, and tappet
lation, is accumulated in the filters of the engine
3.Cylinder head: Rocker arm and valve retaining tee
inlet.
c．Operate the priming pump, open the air vent
Open the following filters, and cleanse the
valve for lubricating oil filter, and drain lubricat-
inside and the elements of the filters:
ing oil until air bubbles in the oil are completely
1.Starting air filter and control air filter vanished. Take care not to splash the oil.
2.Fuel oil filter (including oil filters on the out- d．Check that there is no oil leakage from vari-
side of the engine) ous parts of the piping during priming.

DC-17A Z 08-10
 CHAPTER
Operation
4
ITEM
Preparation for operation: Preparation of Initial Starting after a
Long Period of Disuse and Overhaul DC-17A 2.2

E．Priming with Fuel Oil and Exhausting Air Air vent plug
Conduct priming with fuel oil and exhausting
air bubbles in the following procedure:
(1)Operate the fuel oil feed pump (for the engine O S O S
equipped with a motor-driven oil feed pump).
(2)Open the fuel oil inlet valve, after confirming
that the operation lever is set to the "STOP"
position.
(3)Open the air vent valve of the fuel oil filter, and
drain oil until air bubbles in oil are completely
vanished.
(4)Open the deflector of the fuel injection pump,
and drain oil until air bubbles in oil are com-
pletely vanished.
(5)After completely removing air vent, securely
tighten the deflector.
Exhausting Air of Notch-Wire Filter

The heavy fuel oil is heated to a high temper-

ature (100℃ or more).
Touching the splashing oil may scald your
4
hands. If high-temperature parts are splashed
with the oil, a fire may occur. Take care not to
splash the oil when discharging air. Deflector

F．Cleaning of Turbocharger Pre-Filter

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

Pre-filter
Exhausting Air of Fuel Injection Pump

G. Checking the covers are fitted

Check that the lagging for high-temperature
parts (exhaust pipe, turbocharger, etc.), exhaust
pipe cover and heat box cover that were
removed for disassembly and servicing are
restored as they were.
Check that the joints that were once discon-
nected are provided with combustible oil splash
preventive means (NF tape).

Turbocharger

DC-17A Z 08-10
CHAPTER
Operation
4
ITEM
3.1 DC-17A Starting: Starting Procedure
4-3．Starting
Inadvertent contact of working staff or objects
with the rotating parts is extremely dangerous
since the person may be caught up or the
object that caught up may fly out in all direc-
tions.
Therefore, strictly observe the following items
when starting the operation.
・Confirm that the protective covers of rotary
parts are mounted in normal state, and that
the rotary parts are free of any obstacle.
・Confirm that the turning device or turning bar
is set to "OFF".
・Send a signal to a coworker if any, and con-
firm safety before starting the operation of
engine.
4-3.1 Starting Procedure
Starting procedure can be classified into the
three types; engine side starting remote starting,
and automatic starting, and which of these
should be employed depends on the specifica-
tions. However, engine side starting (starting
from engine side) by manual operation should
always be employed after installation, a long
period of disuse and overhaul or maintenance.
<Work Procedure>
A．Starting from Engine Side
When power is "ON" the engine and the control
and protective devices are in operation.
(1)Open the starting air valve and control air
valve.
(2)Set the operation lever at "RUN," and hold the
operation lever.
(3)Press the start button on the engine.
(4)After the rotation speed of the engine rapidly
increased and starting established along with
continuous ignition sounds, release the start
button.
(5)Close the starting air valve.
(Leave the control air valve "Open" as it is.)
DC-17A Z 08-10
Pointer
Rack scale
RUN
RUN
START
STOP STOP
Operation Lever
B．Remote Starting (Manual and Push Button
Starting)
(1)Switch the starting mode to the remote mode
(from monitor chamber) from the engine side.
(2)Set the operation lever to the "RUN" position.
(3)Open the starting air valve and control air
valve, after confirming that the "READY" indi-
cator lamp lights up.
(4)Press the starting button.
(5)Confirm that "RUN" indicator lamp on the panel
lights up as the rotation speed of the engine
reached the specified rate, and each pressure
reached the specified value.
(6)Close the starting air valve.
(Leave the control air valve "OPEN" as it is.)
C．Automatic Starting
In the case of automatic starting, the engine
starts automatically by the starting command
based on preset starting conditions, such as the
load conditions of power shutdown or other
engines (in the case of plural engines), and
therefore it is essential that the engine should
always be kept in operable conditions
Engines should be kept in the following condi-
tions at all times:
1.Starting mode "AUTO"
2.Operation lever position "RUN"
3.Starting air valve and control air valve "OPEN"

Operation
Starting: Starting Procedure/Inspection and Check Items
Immediately After Starting
D．Starting on engine side
When starting the engine at a loss of power or
without making the control and protective
devices operable.
(1)Open the starting air valve and control air
valve.
(2)Set the operation lever at "START," and hold
the operation lever.
(3)Press the emergency start button on the starter
relay valve. (The button must be pressed by
another person.)
(4)After the rotation speed of the engine rapidly
increases and starting is established along
with continuous ignition sounds, release the
start button.
(5)Make sure that the rotation speed of the
engine reaches the specified speed and each
pressure value reaches the specified value,
and set the operation lever at "RUN."
(6)Close the starting air valve.
(Leave the control air valve "Open" as it is.)
E．Starting on engine side in case of emergency
When the solenoid valve of the starter relay
valve cannot be operated, press the button for
emergency on the starter relay valve, and the air
motor main air circuit opens.
F．Measures to be taken against starting failure
When a starting failure or a starting jam
occurred, take measures in accordance with the
separate section.
（ ：7 "Trouble Shooting and Countermeasures"）
In the case that the engine repeatedly failed
to start in an extremely cold weather while the
engine is still in cold condition, the unburnt mist
of fuel oil may remain in the exhaust manifold,
having a possibility of catching fire or explosion
being caused by high-temperature combustion
gas.
When starting failure repeats, conduct air
running and exhaust the unburnt mist in the
exhaust manifold, before restarting the engine.
4-3.2 Inspection and Check Items
Immediately after Starting
Check the following items immediately after
starting.
When any abnormal error is found, immediately
stop the engine and take proper measures.
（ "Trouble Shooting and Countermeasure"）
CHAPTER
4
ITEM
DC-17A 3.1, 3.2
After conducting overhaul or maintenance of
the sliding parts or rotary parts, be sure to once
stop the engine and check that there is no error
or failure by hand-touching.
A．Engine Rotation Speed
Make sure that the specified rotation speed
attains and the engine is rotating stably.
B．Pressure Reading of Each Section
BOOST LUB.OIL
RPM
H.T. CW FUEL.OIL
T/C RUB.OIL L.T. CW
4
Gauge Board
Confirm that the indicator of pressure reading,
for the manometer with blue mark, is within the
blue mark, showing the pressure is within the
specified value.
If the temperature of lubricating oil is low just
after the engine starts, pressure values may be
out of the specified ranges. Check that the pres-
sure values come into the specified ranges as
the temperature of lubricating oil rises.
C．Abnormal Sound
Carefully listen to the sound of the following
engine parts, and check if there is any abnormal
sound or not.
1.Cylinder head and surrounding parts (intake
and exhaust valves)
2.Crankcase
3.Crankcase and timing gear and auxiliary drive gear
4.Turbocharger
D．Exhaust Temperature
Check the exhaust temperature of each cylin-
der, and confirm that all the cylinders are proper-
ly burnt (at 200℃ or more).
E．Leakage and Loose from each parts
Confirm that mounting parts, bolts and nuts of
connecting parts should not been loosed. And
check if oil, water, and gas should not leaked.
DC-17A Z 08-10
CHAPTER
Operation
4
ITEM
4.1 DC-17A Operation: Running-in
4-4．Operation
4-4.1 Running-in
Do not apply a load abruptly since the sliding
parts of the engine are not yet sufficiently ready
to work smoothly or freely when the engine is
started for the first time after its installation or
immediately after replacement of the parts such
as the cylinder liners and the piston ring.
Conduct the running-in operation to ensure
smooth and free working of the sliding parts
according to the following procedure before get-
ting into the steady mode of operation.
A. Initial Running-in
Whether or not the pistons and the oil rings
move smoothly and freely will substantially affect
the engine performance, especially the combus-
tion performance and consequently the con-
sumption of lubricating oil. Further, it is assumed
that they will be decided by the initial operation
of a few hours.
The revolution of the engine should be gradu-
ally increased, then the engine should be
stopped after it is driven for two or three minutes
without a load and then conduct the following
inspection that is to be effected after completion
of the initial running-in when the engine is start-
ed for the first time after its installation or
replacement of any of parts located in the
periphery of the cylinder such as the cylinder
liner, the piston, the piston ring. And especially
the following items in the checking list for the ini-
tial running-in should be watched and checked
during the engine operation in order to find out
any symptom of a trouble as soon as possible or
to prevent it from occurring.
<Inspection Items during the Initial Running-in>
1. Abnormal sound.
2. Partial heating.
3. Leakage from connection points and loosening
of the bolts and nuts.
4. Exhaust temperature, irregular exhaust color,
combustion pressure:.. Abnormal combustion.
5. Excessive consumption of lubricating oil :
....... Poor adaptability of liners and rings.
<Inspection after Completion of the Initial
Running-in>
1. Checking the condition of sliding portions of the
cam and the roller, and the cam metal by tactile
feeling of the finger.
2. Checking the condition of the internal surface
of the cylinder liner.
3. Checking the condition of the main shaft, the
crankpin metal and the cylinder liner by tactile
feeling of the finger.
DC-17A Z 08-10
B. Operating Conditions during the Running-in
Be sure to operate the engine during the run-
ning-in period under the following conditions,
gradually increasing the load referring to the fig-
ure 4.1 and paying special attention to the
inspection items during the initial running-in indi-
cated in the section A.
1. Load: 80% or less.
2. Fuel oil to be used: Diesel fuel oil.
Even for the engines of heavy fuel oil type, use
diesel fuel oil during the running-in period.
3. Notwithstanding the prescription given by the
item 2 above, the lubricating oil specified for the
engines of heavy fuel oil type may be used for
such engines from the start of engine driving.
4. Running-in period is 20 to 30 hours.
At the time when the running-in operation is
completed, conduct the following inspection
works and confirm that there is not any abnor-
mality before entering the normal and regular
operation of engine.
1.Inspection of foreign matters and stains in the
crankcase.
2.Visual inspection of the inner surface of the
cylinder liner.
3.Inspection and cleaning of the element of each
filter.
4.Remove the flushing filter attached the fuel inlet
box.
Be minded never to perform the operation of
engine using heavy fuel oil, while the flushing
filter is attached.
Load
(%)
100
Continuous
operation
75
15 min
50
15 min
25
Preparatio
Start (Manual)
0
0 30 60 Time(min)
Fig. 4.1 Running-in Pattern (Example)
 CHAPTER
Operation
4
ITEM
Operation: Warming-Up and Connecting Load to the Engine DC-17A 4.2

4-4.2 Warming-Up and Connecting lubricating oil temperature increases.

Load to the Engine
In the case that the engine is started while it is
still in a cold state, first perform the warm-up oper-
ation, except for the case of emergency, and grad-
ually connect the load after the engine is sufficient-
ly warmed up.
If the load is hastily connected while the various
parts of the engine are still cold and not yet in the
conditions for proper fuel combustion and lubrica-
tion, malfunctions such as faulty combustion,
excessive wear of the sliding parts, and seizure
may be caused.
A．Warming-up Operation of Engine
a ．Use diesel fuel oil for warming-up opera-
tion
Be sure to use diesel fuel oil for warming up
the engine, even in the case that the engine is
sufficiently heavy fuel oil.
Be minded to perform no-load operation only
for warming-up operation, and restrain the
duration of no-load operation within 10 minutes.
Running the engine under no-load for long
hours results in malfunctions such as faulty
combustion and collection of carbons in the
combustion chamber.
B．Connecting Load to the Engine
The lower the engine temperature (tempera-
tures of jacket cooling water and lubricating oil)
is, the longer time it is needed to connect the
load.
The standard load connecting time is shown in
the figure below.
（ ：Fig. 4.2 "Load Connection Pattern"）

b．No load
4
First operate under no load or light load, and
connect the load after jacket cooling water and

Load
㩿㩼㪀

䌴 䋺 㪋㪇°䌃 䌴 䋺 㪈㪌°䌃
(Normal load)

75

50

25

t: Jacket cooling
c water
t and lubricating
i oil
temperature
r at startup
a
No load

5 10 15 20 25 30 35 40
Time(min)
Load Connection Pattern

DC-17A Z 08-10
CHAPTER
Operation
4
ITEM
4.3 DC-17A Operation: Operation with Load (Normal Operation)
4-4.3 Operation with Load (Normal
Operation)
Inspect the running conditions of the engine and
measure the operating performance data in regular
intervals, during the continuous operation with load
(including period of the running-in operation).
In case that any problem is found as the results
of the inspection and measurement, take proper
measures such as adjustment or repair of the
defective parts. (Refer to the separately provided
section.)
（ ：5-3 "Measurement and Adjustment"）
（ ：7 "Troubleshooting and Countermeasures"）
A．Inspection of Operating Conditions
<Check Item>
1.Abnormal sound and abnormal vibration
2.Partial overheat
3.Leakage from connections and looseness of
screws
4.Exhaust temperature, and abnormal exhaust
color ... Abnormal combustion
5.Excessive consumption of lubricating oil
During the operation of engine, particularly
the following parts become extremely hot, and
touching these parts with bare hands or skin
may cause burns.
Therefore, be minded to use the protective
wears such as safety gloves when working on
them.
・Exhaust pipe
・Turbocharger
・Air cooler inlet pipe
・Cylinder head
・Reducing valve
・Fuel oil system equipment and piping (for
heavy fuel oil)
B．Measuring Performance Data
a．Measure the operating performance data at
least once every day, when the load variation is
less and the load is stable.
b．Compare each of the measured data with the
data obtained when the engine was newly intro-
duced, and judge if there is any problem and
check the degree of deterioration.
DC-17A Z 08-10
（ ："Test Run Record Table" in the final
documents）
<Measurement Item>
1. Room temperature
2. Load (output)
3. Intake air temperature (turbocharger inlet)
4. Exhaust temperature (each cylinder outlet)
5. Exhaust temperature (turbocharger inlet)
6. Intake air pressure (engine inlet)
7. Lubricating oil pressure (engine inlet)
8. High-temperature cooling water pressure
(engine inlet)
9. Low-temperature cooling water pressure
(engine inlet)
10. Fuel oil pressure (engine inlet)
... for heavy fuel oil type
11. Inlet air temperature (engine inlet)
12. Lubricating temperature (engine inlet)
13. Cooling water temperature (engine inlet)
14. Fuel oil temperature (engine inlet)
... for heavy fuel oil type
15. Fuel injection pump rack scale
C．Regular Inspection and Maintenance
Conduct inspection and maintenance of the vari-
ous parts of engine regularly.
（ ：5 "Inspection and Maintenance"）
D．Operation Records
Record the results of inspection and measure-
ment and the contents of performed adjustments
and repairs in the engine control log.
Operation records are very important docu-
ments when understanding the conditions of
engine and tracing the history of the inspection
or maintenance that has been performed.
Keep and store them carefully, and when the
supervisor is changed, be sure to transfer the
records to the successor without fall.

Operation
Operation: Operation Using Heavy Fuel Oil
4-4.4 Operation Using Heavy Fuel Oil
(for Heavy Fuel Oil Engine)
Heavy fuel oil is lower in its quality and higher in
its viscosity than diesel fuel oil. When using heavy
fuel oil, proper operation control, such as switching
to the operation using diesel fuel oil depending on
the load conditions is required, in addition to prop-
er fuel oil and lubricating oil control (refer to the
separate sections.)
（ ：6.1 "Fuel Oil Control"）
（ ：6.2 "Lubricating Oil Control"）
A．Operation with Diesel Fuel Oil
Be minded to use heavy fuel oil only under
stable load conditions, and be sure to use diesel
fuel oil in the following cases:
a ．During Running-In Operation Period(150 hours)
1.Immediately after installation
2.After replacement of the sliding parts around
cylinder (e.g. cylinder liner, piston, and piston
ring)
（ ：4.4.1 "Running-In Operation"）
b．During Starting or Warming-Up Operation
（ ：4.3 "Starting"）
（ ：4.4.2 "Warming-Up Operation"）
c ．During idling or Low-Load Operation
When the engine is operated under low load,
the compressed air temperature in the cylinder
and fuel injection pressure of fuel oil are low,
and therefore if the heavy fuel, of which combus-
tion quality is lower than that of diesel fuel oil, is
used, combustion becomes unstable, resulting
in undesirable conditions, such as worsening of
the exhaust smoke, sticking of the ring, and so
on. In the case of the connection of the load
that is below the lower limit described in the
engine specification, be minded to use diesel
fuel oil.
d．In the Case that Load Variation is Heavy
1. When entering or leaving port
2. When cargo is being loaded or unloaded
e ．Before Stopping Engine
（ ：4.6 "Stop"）
CHAPTER
4
ITEM
DC-17A 4.4
B．Switching Fuel Oil Types
Heavy fuel oil is normally heated up to 80 to
90℃ in the service tank, and 100℃ or more at
the engine inlet, and the temperature difference
is larger as compared with that of diesel fuel oil
(non-heated), and therefore if fuel oil is suddenly
switched between these oils, it may cause mal-
functions such as sticking of the fuel injection
pump, vapor lock, and so on.
a.Slowly switch from diesel fuel oil to heavy fuel
oil, so that the rate of change in the fuel oil tem-
perature at the engine inlet is between 5 and
10℃ per minute.
（ ：Fig. 4.3 "Switching Pattern from Diesel
Fuel Oil to Heavy Fuel Oil"）
b.Maintain the viscosity (temperature) of heavy
fuel oil at the engine inlet at the specified value.
c.Do not raise the temperature of diesel fuel oil
over the flashing point (60℃ is the standard
point).
d.To prevent the generation of vapor, maintain
the pressure of fuel oil at the specified value. 4
Further, remove the air bubbles in fuel oil in
the various equipment of the fuel oil system
(heater, filter, tank, etc.) from time to time, so that
the accumulation of vapor can be prevented.
If high-temperature parts are splashed with
the oil, a fire may occur. Take care not to
splash the oil when discharging air.
e.Confirm that the heat traces on piping and
equipment is properly functioning.
The fuel oil is heated, and the filter and the
piping are at high-temperatures. If touched
with bare hands or skin, it may cause a burn.
Therefore, be minded not to directly touch the
exposed metallic parts such as the valves and
cocks, and use the protective wear such as
safety gloves when working on them.
In case that emergency stop is made during
the operation with heavy fuel oil, immediately
switch the heavy fuel oil to diesel fuel oil, oper-
ate the separate pump, and perform flushing of
the fuel oil system.
If the engine is cooled down with the heavy
fuel oil left unchanged, the oil will be solidified
and the operation will be prohibited.
DC-17A Z 08-10
CHAPTER
Operation
4
ITEM

4.4 DC-17A Operation: Operation Using Heavy Fuel Oil

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

Viscosity at
Viscosity at engine inlet 13䌾14mm2/s
engine inlet 13䌾14mm2/s
Fuel oil temperature

Fuel oil temperature

at engine inlet

at engine inlet
Temperature of heavy fuel oil Temperature of
heavy fuel oil

Temperature of Temperature of
diesel fuel oil diesel fuel oil
Operation

Switching from Operation Switching from Heavy

diesel fuel oil to Fuel Oil to Diesel Fuel Oil
heavy fuel oil
Operation with Operation with Operation with Operation with
diesel fuel oil heavy fuel oil heavy fuel oil diesel fuel oil
Check item

Check item

Check the Switch at a stable load Switch at a stable load Switching from
operation of (above the lower load (above the lower load heavy fuel oil
heavy fuel oil limit) limit) to diesel fuel
supply oil
equipment

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

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

DC-17A Z 08-10

Operation
Special Operation: Low-Load Operation/Non-turbocharger
Operation and Operation with Reduced Number of Cylinder
4-5. Special Operation
4-5.1 Low-Load Operation
Since running the engine with a low-load lower
than a certain limit can lead to unfavorable com-
bustion conditions such as the reduction of intake
air pressure and blowing-back of exhaust air, if the
engine is operated under such conditions for long
hours, it may result in the various malfunctions
such as fouling of the turbocharger and combus-
tion chamber, faulty combustion and so on.
Therefore, be sure to minimize the low-load
operation to a shorter period of time as much as
possible, and in case that the engine must be
inevitably run under a low-load for long hours, be
sure to observe the following conditions:
A ．Low-Load Limit
The low-load limit which the engine can oper-
ate continuously is shown below.
5DC-17: 70 kWe
6DC-17: 90 kWe
B ．Use of Diesel Fuel Oil
In case of the heavy fuel oil type, be sure to
switch it to diesel fuel oil.
C ．Cleaning of Turbocharger
Properly increase the number of times of
cleaning the turbocharger according to necessity.
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.
D ．Intermittent High Load Operation
During continuous low-load operation, operate
the engine at the highest load possible (60% or
more) for about 30 min. This is effective in pre-
venting fouling in the combustion chamber and
the air intake and exhaust systems.
CHAPTER
4
ITEM
DC-17A 5.1, 5.2
4-5.2 Non-turbocharger Operation and
Operation with Reduced Number
of Cylinders
Non-turbocharger operation owing to damage to
the turbocharger and operation with reduced num-
ber of cylinders under special circumstances are
allowed as temporary measures in case of emer-
gency. However, the use of such operations is
limited to a short time. (When the engine is sup-
ported with rubber vibration insulators, such opera-
tions are not allowed.)
Various limitations and prohibitions are added to
the operating conditions.
The procedures for such operations vary
depending on circumstances. Be sure to consult
us, receive instructions in operation procedures
and safety precautions, and follow the instructions.
<Operating conditions> 4
a.Use diesel fuel oil.
b.Output
(Total number of cylinders)-(Number of cylinders out of use)
×70%
(Total number of cylinders)
The output may decrease depending on
surging of the turbocharger or the exhaust tem-
perature.
c.Exhaust temperature: 450℃ or less
(each cylinder outlet)
DC-17A Z 08-10
CHAPTER
Operation
4
ITEM

6.1 DC-17A Stop: Normal Stop

4-6. Stop Pointer

4-6.1 Normal Stop

A ．Precautions for stop Rack scale

a．In the case that heavy fuel oil is used, switch

the fuel oil to diesel fuel oil 30 minutes before
stopping the engine.
b．Immediately before stopping the engine, start
the operation of lubricating oil priming pump. RUN
c．Confirm that the starting air pressure is at
2.0 MPa or more. RUN

(The preparation for the next round of starting)

B ．Stop STOP STOP

a．Conduct the stop operation on the following

procedures:

[For local operation]

Shift the operation lever to "STOP" position.
Then, fuel oil injection will be shut off by
means of the common rod, and the engine will
be stopped.
[For remote control]
(1)Press the "STOP" button on the control panel.
Then, the fuel shutdown solenoid valve is acti-
vated to operate the fuel shutdown device,
and the engine is stopped.
(2)Shift the operation lever to the "STOP" posi-
tion.
b．After stop operation, be attentive of any
abnormal sound in the engine and turbocharg-
er, and confirm that there is not any abnormal
sound.
Operation Lever
C ．After Stop
a．Operate both the lubricating oil priming pump
and cooling fresh water pump for about 20
minutes, and cool down the engine and tur-
bocharger.
The turbocharger continues to run at high
speed even after the engine is stopped.
Lubrication of the turbocharger provided with
this engine is made using the system oil, and
therefore if the supply of lubricating oil is
stopped immediately after the engine is
stopped, it may damage the bearing.

In case that the engine does not stop even
when the stop operation is conducted, forcibly
stop the engine in the following procedure:
1)Forcibly set the rack of the fuel injection
pump at "0".
2)Fully close the valve of the fuel oil inlet main
pipe.
b．Fully open the indicator valve to conduct air
running for 3 to 4 seconds and exhaust the
combustion gas out of the combustion cham-
ber.
c．Close the valves on all the systems.

DC-17A Z 08-10

Operation
Stop: Emergency Stop
4-6.2 Emergency Stop
A．When Emergency Stop is Required.
Immediately stop the engine when any of the fol-
lowing abnormalities is found:
1.Announcement of "Emergency" or "Alarm"
(＊Activation of the protective device → Automatic
stops)
＊● Overspeed
＊● Decrease of lubricating oil pressure
＊● Suspension of water supply/increase of cool-
ing water temperature
● Increase of exhaust air temperature
● Other alarming (depending on each specifi-
cation)
2.Abnormal sound and abnormal vibration
3.Heating of the bearings or other moving sec-
tions, generation of smokes, or abrupt
increase of mist.
4.Loosening or falling-off of the governor, com-
mon rod rink, each lever around the fuel oil
injection pump, link pin, or bolt.
5.Deterioration of fuel oil or lubricating oil, or
damage of the cooling water pipe.
6.Abrupt increase or decrease of rotation speed.
7.Abrupt increase of lubricating oil temperature
8.Water supply disability due to suspension of
cooling water supply
In case that the engine is overheated due to
suspension of water supply, do not hastily sup-
ply cooling water.
If cooled down abruptly, each part of the
engine may be deformed, resulting in malfunc-
tion or accidents.
9.Mixing of water into lubricating oil
10.Abrupt increase of exhaust air temperature
11.Abrupt decrease of the turbocharger rotation
speed or intake air pressure
12.Breakage or loosening of the bolts of each
section
B ．Measures after Emergency Stop
In case that the engine is automatically
stopped by activation of the protective device or
stopped manually, take the following measures:
a．In case that the engine is stopped by remote
operation or stopped automatically, set the
operation lever to the "STOP" position after
the engine is stopped.
CHAPTER
4
ITEM
DC-17A 6.2
b．In case that the operation had been made
using heavy fuel oil, immediately switch the
fuel oil to diesel fuel oil, operate the motor-
driven oil feed pump, and conduct flushing of
the fuel oil system (However, this procedure
does not apply when the fuel oil pipe is bro-
ken.)
Further, conduct turning of the engine, and
exhaust the heavy fuel oil remaining in the fuel
injection pump or fuel valve.
In case that the engine is stopped during the
operation using heavy fuel oil and the engine is
cooled down without changing the fuel oil,
heavy fuel oil in the equipment of the fuel oil
system (e.g. pump, filter, etc.) and piping not
only solidify to prohibit starting, but also incur
substantial labor to clean and cleanse after the
accident.
4
c．Disconnect the load off the engine, and return
the operation lever, each valve, and the state
of all other equipment to the "STOP" position.
In case that the emergency stop is conduct-
ed, be minded not to restart the engine until the
cause is determined, the countermeasures are
taken, and recovery is completed.
In case that the engine is started without
removing the cause of the abnormality, the
malfunction may be aggravated and serious
accidents may be caused.
Be minded not to open the crankcase for at
least 10 minutes after engine is stopped and is
completely cooled down. If the crankcase is
opened immediately after the engine is
stopped, flammable mist in the crankcase may
catch fire and explode.
Particularly be careful when a large amount
of mist is generated due to overheat or seizing
of the engine.
Be minded never to let flames or sparks
approach the crankcase even after it is over-
hauled.
DC-17A Z 08-10
CHAPTER
Operation
4
ITEM

6.3 DC-17A Stop: Long-Term Shutdown

4-6.3 Long-Term Shutdown

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

A．Shutdown within 3 Months

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

B．Shutdown over 3 Months ... Measures for

Long-Term Storage
In the case that the operation of engine is sus-
pended for 3 months or more, the following meas-
ures for long-term storage is required:
a．Remove cooling water from the engine.
b．Add rust-preventive oil to lubricating oil, open
the indicator valve, and conduct turning of the Spray
crankshaft several times while conducting (desiccant)
priming with the lubricating oil.
After turning, securely close the indicator
valve.
c．Open each cover of the crank cam case, and
the cylinder head, and spray rust-preventive
oil to the internal parts.
d．Insert the moisture-proof agent such as sil-
icagel into the crankcase, according to the
Spray
ambient air conditions (e.g. weather and
(rust-preventive oil)
humidity) if required.
e．Place the cover on the outside air opening
section of the exhaust air pipe and the mist
pipe.
f．Cover the engine with a sheet, and carefully Silica gel
cover the electric equipment with particular (desiccant)
attention to prevent collection of dust on them.

Measures for Long-Term Storage

DC-17A Z 08-10
 CHAPTER
Operation
4
ITEM
MEMO
O DC-17A

4
CHAPTER
Inspection and Maintenance
5
ITEM

1.1 DC-17A Precautions for Inspection and Maintenance

5-1. Precautions for Inspection and Maintenance

When conducting the inspection and maintenance works of engine, be minded to read this
manual carefully, understand the structure of the related parts and the work contents, carefully
examine the working procedures, and prepare the consumable parts and tools in advance, before
starting these works.
If the works are conducted without previous and sufficient examinations, it not only leads to
the expense of useless labors, but also results in failure or damage of the engine due to mistaken
assembling, and further in personal accidents.Be sure to replace all the damaged parts, or the
parts that reached replacement limit, both of which were so found after the results of inspections.
In the case that replacing these parts are difficult on site, or the necessary parts are not read-
ied, inform the DAIHATSU DIESEL PARTS SERVICE CO., LTD., Service Department of Daihatsu
Diesel Manufacturing Co., Ltd. or our nearest branch office or shop, and take proper actions.

5-1.1 Safety Precautions

A．Do not open the crankcase side cover for at least 10 minutes after the engine is stopped and is
completely cooled down. While the engine is overheated, there is a danger that oil mist may
catch fire and explode if new air is flowed into the crankcase when it is opened.

B．If the engine is rotated during disassembly or inspection works, it may impose serious dangers
such as caught-up accidents and so on.
Be minded to start these works, after returning the operating lever to the "STOP" position, secure-
ly closing the starting air valve, and confirming that the engine is not running.
When conducting the turning of engine, be minded to start it after confirming that nothing is in
contact with the rotational parts, and no danger is imposed on coworkers by the rotation of
engine, and after sending the signal to them.
Perform a proper preventive measures to prevent the crankshaft from freely turning.

C．Be minded to use the protective wears such as safety glove, helmet, safety shoes, safety goggles,
according to the circumstances.
During the operation of engine and immediately after stopping the engine, the engine parts, partic-
ularly exhaust manifold, turbocharger, indicator valve,parts round the cylinder are extremely hot.
Therefore, be sure to wear safety gloves, and proceed the works taking care not to incur burns.
The engine room floors and the surrounding areas are slippery due to oils stuck on them.
Therefore, be minded to start the works after sufficiently wiping off the oils stuck on floors or shoe
soles. Particularly when working on high-rise places such as foot-step board, pay enough atten-
tions to the periphery of your feet, so that falling-off accidents should not happen.

D．When disassembling the piping systems, "Close" all the valves of the external connection parts,
gradually release the air vent plug, and start the disassembly after removing residual pressure.
Immediately after stopping engine, when disassembling the filters and connection parts of piping
systems, you may burn on your skin due to a injected high temperature oil or water of residual
pressure. If high temperature parts are splashed with the fuel oil or the lubricating oil, a fire may
occur. Take utmost care when disassembling them.

E．When disassembling the spring-loaded devices such as the regulation valves, proceed the works
paying careful attentions, since there is a risk that the springs may fly out and injury accidents
may occur.

F．Be minded to use wire rope and chain block when suspending the heavy-weight parts or equip-
ment, and do not try to forcibly raise these parts or equipment by physical force. Further, be
minded not to approach the areas immediately under the suspended parts or equipment.

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Precautions for Inspection and Maintenance DC-17A 1.1, 1.2

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

H．When handling the liquids, be minded to strictly observe the following items:
● Fuel oil, lubricating oil = Flammable --- Use of fire is strictly prohibited.

● Rust-preventive agent for fresh water, anti-freeze solution for fresh water and mercury (thermome-

ter) = Poisonous --- Drinking is prohibited and cleaning when adhered.

● Battery liquid = Poisonous and flammable gas generation --- Drinking is prohibited, cleaned when

adhered and use of fire is strictly prohibited.

◎For the sake of preventing environmental contamination, be minded to entrust the disposal and
treatment of the waste oils and liquids to the authorized special waste disposing company.

5-1.2 Cautionary Items When Finishing Inspection and Maintenance

A．Restore the lagging or heat-preventive covers, combustible oil splash preventive means (FN tape)
and protective covers, that were removed for inspection and maintenance, to each original posi-
tion.

B．After the completion of assembling, confirm that there is no abnormality in each part, by conduct-
ing the turning of engines and the priming with each corresponding oil.
After checking the parts during turning, close the indicator valve without fail.

C．After the completion of working, return the turning equipment and turning bar used to the "OFF"
position.

D．Record the work contents of the inspection and maintenance and the replaced parts in the daily
5
report respectively.

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM

2 DC-17A Inspection and Maintenance Table

5-2. Inspection and Maintenance Table

This table shows the inspection and maintenance work items (basically, those to be performed within 6
months). As for the work items concerning the full-scale open and maintenance after the long-term opera-
tion, refer to the corresponding sections of "Maintenance" version, which is separately provided.
（○：Normal, ▲：Initial operation and 1st operation after overhaul, ●：Initial operation after installation, overhaul, and
maintenance, ◎：Replacement）
Note: This table shows the standard inspection intervals for inspection and maintenance to be conducted
under normal operating conditions when heavy fuel oil is used. Determine the most adequate interval
of inspection and maintenance in accordance with the operating conditions and inspection results.

Intervals (Hours)
before operation
Inspection

Ref.

1000-1500

2000-3000
3 months

6 months
300-500
Monthly
Weekly
Parts to be Daily Remarks
inspected Descriptions

Engine appearance Check loosened parts and leaks.

Piping system Check loosened parts and leaks.
Cylinder head cover Check internally (Valve end clearance, rotator). 㪌㪄㪋㪅㪈
Cylinder head Check and retighten head bolt. Including during opening
Fuel injection pump Remove and check valve. Clean and adjust it. 㪌㪄㪋㪅㪉
Connecting rod Check and retighten connecting rod bolt. Including during opening
Cylinder liner Visually check internal surface.
Crankshaft Measure and adjust deflection. 㪌㪄㪋㪅㪌
Camshaft Check cam and roller.
Governor Check and supply hydraulic oil. 㪋㪄㪉㪅㪈 Replace hydraulic oil.
Fuel control link Check movement and supply oil. 㪋㪄㪉㪅㪈
Clean filter. 㪋㪄㪉㪅㪉 150-200 hr
Turbocharger Clean blower. 㪌㪄㪋㪅㪋 150-200 hr
Refer to the separate volume
Clean turbine. "Turbocharger Manual"

Check pressure. 㪋㪄㪉㪅㪈

Starting air tank
Drain discharge. 㪋㪄㪉㪅㪈
Reducing valve Adjust and check pressure.
Relay valve Check opening and clean valve.
Air strainer Check opening and clean strainer. 㪛㫌㫉㫀㫅㪾㩷㪈㩷㫄㫆㫅㫋㪿㩷㪸㪽㫋㪼㫉
㫀㫅㫀㫋㫀㪸㫃㩷㫆㫇㪼㫉㪸㫋㫀㫆㫅
Lubricate pump rack. 㪋㪄㪉㪅㪈
Fuel injection pump
Check rack scale position. 㪌㪄㪊㪅㪈
Flushing filter core Check opening and clean. 㪈㫐㫉㪅㩷㩿㪋㪃㪇㪇㪇㪄㪍㪃㪇㪇㪇㩷㪿㫆㫌㫉㫊㪀 㪌㪄㪋㪅㪊
Drain discharge.
Lubricating oil filter
(for engine and Clean by blowing-off. 㪌㪄㪋㪅㪊
turbocharger) Open, check, and clean filter. 㪌㪄㪋㪅㪊
Lubricating oil tank Check oil level and supply oil. 㪋㪄㪉㪅㪈
Analyze and examine oil. 㪍㪄㪉
Lubricating oil thermostat
valve
Open, check, and clean valve. 㪌㪄㪊㪅㪉
Fresh cooling Open, check, and clean tank.
water tank Check water quality. 㪍㪄㪊
Gauge Check thermometer and pressure gauge.
Control and protective device Check and confirm movement.

DC-17A Z 08-10

Inspection and Maintenance
Measurement and Adjustment: Exhaust Air Temperature,
Pressure and Temperature of Each Part
5-3. Measurement and Adjustment
5-3.1 Exhaust Air Temperature
The exhaust air temperature is a critical index
for indication of the engine combustion conditions
and changes over time.
Normally, degradation of the engine perform-
ance is indicated as a rise in the exhaust air tem-
perature.
Measure and record the temperature everyday
to reveal a tendency of degradation. Use such
records to determine the interval of servicing.
A．Exhaust Air Temperature
The exhaust air temperature at each cylinder
outlet slightly varies from one cylinder to another
depending on the factors such as the effect of
other cylinders as well as the distance to the tur-
bocharger inlet.
The exhaust air temperature can be adjusted
by increasing or decreasing the fuel injection
pump rack, however, the adjustment is ordinarily
unnecessary as long as the difference between
cylinders is within the following value.
＊Difference between cylinders: 40℃ or less
B．Adjustment of Amount of Fuel Oil Injection
Pump Rack
In the case that the exhaust temperature differs
from those of other cylinders in excess of the
range specified in the above A., for example,
when the fuel oil injection plunger or the fuel
injection valve nozzle is replaced, adjust the fuel
oil injection amount by increasing or decreasing
the reading on the rack scale.
<Rack Adjusting Procedure>
The reading on the rack scale can be increased
or decreased by the adjusting screw (A) of the
fuel injection pump rack lever.
(1) Loosen the lock nut (B)
(2) Turn the adjusting screw A and change the
reading on the rack scale.
● Clockwise turning → "Increase" (Increase of
exhaust air temperature)
● Counterclockwise turning → "Decrease"
(Decrease of exhaust air temperature)
(3) Confirm that the exhaust air temperature is
within the specified value.
(4) Securely tighten the lock nut.
＊Difference between cylinders: 1.5 mm or less
CHAPTER
5
ITEM
DC-17A 3.1, 3.2
Fuel oil injection pump
Rack lever
Lock nut (B)
Rack adjusti )
Increase
Decrease
Rack link
Adjusting Rack
5-3.2 Pressure and Temperature of
Each Part
The pressure and temperature of lubricating oil,
fuel oil, and cooling water, etc. are controlled by
the relief valve and the thermostat valve, so that
they should be proper values being within each
specified value during the operation of engine,
however, when actually operating the engine, the
pressure and temperature of these fluids may not
be within the specified and proper values.
In such a case, readjust the setting values of
5
the valves, and perform the operation within the
specified proper range.
A．Intake Air Pressure
Since the intake air pressure changes in accor-
dance with load, each pressure when the engine
was new (or, after adjustment) becomes a refer-
ence value.
The more the turbocharger is fouled, the more
the intake air will decrease, resulting in the deteri-
oration of the engine performance (e.g. increase
of the exhaust air temperature and increase of
the fuel consumption rate), and therefore regular-
ly conduct the blower cleaning and prevent the
progress of fouling.
（ ：5-4.4 "Cleaning Turbocharger Blower"）
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.
DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
3.2 DC-17A Pressure and Temperature of Each Part

It is impossible to completely remove the Do not screw in the adjusting screw 12 mm

fouls even when cleansed by blower cleaning,
and to prevent the deterioration of engine per-
formance by the elapse of time, however, if the
cleaning is neglected, fouling will accelerate,
resulting in worsening of the engine perform-
ance, and as the result it will be required to dis-
assemble and clean the turbocharger much
earlier than when the cleaning is periodically
conducted.
B．Intake Air Temperature
or more. The bypass valve is seated.
In the case that the intake air does not fall with-
in the proper range even when the entire amount
of cooling water is flowed into the air cooler, it is
required to disassemble and adjust the air cooler
since the fouling of the air cooler can be consid-
ered.
（ ：12-3 Air Cooler, "Maintenance Version"）

＊Proper temperature: 45-55℃ (at rated out-

put)

Intake air, that is either higher or lower than the

specified range, will affect the engine, and there-
fore be minded to adjust and keep the tempera-
ture to be within the specified proper range, as far
as possible. Adjusting screw (B)
When the intake air temperature is too low, it
Cooling water
causes abnormal or excessive wear of the cylin- pump
der liner, intake air valve, etc., since the water
drops is formed by the dew condensation.
Further, if the intake air temperature is too high, it
damages the parts around the combustion cham-
ber such as the exhaust valve, since the exhaust
air temperature increases. (Exhaust air tempera- Cooling water bypass valve
ture varies in proportion to the intake air tempera-
ture, and also varies in the rate of approximately
2 times the change of the suction air temperature
of the turbocharger.)
If the intake air temperature gets out of the
proper range owing to a low room temperature, or
when automatic adjustment of intake air tempera-
ture cannot be made for some reasons, operate
the following procedure.

<Intake Air Adjusting Procedure>

The intake air adjustment can be made by chang-
ing the cooling water flow rate in the air cooler.
(1)Turn the adjusting screw (B) of the cooling
water bypass valve clockwise.
(2)Be attentive to changes in the intake air tem-
perature, and adjust the adjusting screw feed
so as to be within the proper range.

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DC-17A 3.2

C．Lubricating Oil Pressure

＊Proper range In the case that the lubricating pressure does

(blue mark range on manometer) not change even when the adjustment screw is
0.4 - 0.5 MPa turned, there is the possibilities of sticking of
relief valve, suction of air, pump failure, and so
Lubricating oil pressure changes in accordance on, and therefore investigate the causes of the
with the changes in the viscosity and temperature trouble.
of lubricating oil.
When the engine is started in extremely cold
weather, and the temperature of the lubricating oil
is still low and the viscosity is high, the pressure
reading may go up beyond the blue mark range,
however, it does not impose any problem if the
reading falls back within the blue mark range
when the engine is warmed up.
In the case that the pressure reading is above
or under the blue mark range, adjust the pressure
in the following procedure:
Adjusting screw (C)

Lubricating oil pressure decreases when the

filter is fouled. Be sure to perform the adjust- Lock nut (B)
ment of pressure after the filter is cleaned well. Lubricating oil
relief valve
（ ：5-4.3 "Cleaning Filters"）
5
Lubricating oil
<Lubricating Oil Pressure Adjusting Procedure> cooler
When adjusting the lubricating oil pressure, use
the adjusting screw on the lubricating oil relief
valve.
(1) Loosen the lock nut (B).
(2) Turn the adjusting screw (C), and adjust the
pressure.
● Clockwise turning (tightening) → Increase of

pressure
● Counterclockwise turning (loosening) →

Decrease of pressure
(3) Be attentive to changes in the pressure, and
confirm that the pressure entered within the
blue mark range.
(4) Tighten the lock nut (B).

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
3.2 DC-17A Pressure and Temperature of Each Part

D．Lubricating Oil Temperature

＊Proper range: 55 - 65℃ (cooler outlet)

Lubricating oil temperature is controlled to

remain within the proper range of temperature by
the relief valve installed at the lubricating oil cooler
outlet.

a ．Lubricating Oil Thermostat Valve

The thermostat valve is an automatic bypass
valve, that changes the flow rate of lubricating oil Adjusting
passing through the cooler according to its tem- screw (C)
perature, and when the engine is started while it Thermostat
valve
is still in the cold state, this valve rapidly raises
the lubricating oil temperature by letting the oil Lubricating oil
cooler
bypass through the cooler, and when the engine
is operated normally, this valve maintains the
lubricating oil temperature within the suitable
range of the specified value.
In the case that the lubricating oil temperature
does not fall within the proper range, for example, 䇭
because the cooling water temperature (low tem-
perature) is different from the design temperature,
the temperature of lubricating oil can be adjusted
by the adjusting screw of the thermostat valve.
However, in case that the actual temperature is
exceeding the correctable range (approximately
5℃) and the adjustment is impossible, contact us
for consultation on the problem.

b．Manual Adjustment-Emergency Measures

In the case that the thermostat valve fails and
the temperature control becomes impossible, the
engine can continuously be operated by perform-
ing the emergency measures in the following pro-
cedure. Do not screw in the adjusting screw 8 mm or
more.
<Adjusting Procedure>
Turn the adjusting screw (C) to adjust the tem-
perature.
● Turn clockwise (tighten). → The temperature
＊ Use range: 30 - 65℃
Since the oil temperature changes according
rises.
● Turn counterclockwise (loosen). → The tem-
to the load, be minded to set the oil tempera-
ture at a rather lower level, so that it does not
perature drops.
exceed the limit when heavily loaded.
(1)Fully loosen the adjusting screw (C). → The
cooler passage fully closed.
(2)Observe the changes in the oil temperature
while tightening the adjusting screw, and set
the lock nut when the temperature comes into
the following range.

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DC-17A 3.2

E．Cooling Water Pressure

＊Proper range: 0.15 - 0.35 MPa

Cooling water
Jacket cooling water pressure substantially thermostat valve case
changes depending on the external conditions (jacket cooling water
outlet pipe)
such as the cooling water expansion tank head,
pipe resistance, and so on.
When cooling water pressure is too low, it will
cause cavitation corrosion of the engine frame or
cylinder liner, and therefore adjust the cooling
water pressure at the engine outlet using the ori-
fice, so that the pressure should be proper during
the operation of engine.
Thermostat
F．Cooling Water Temperature valve

＊Proper range: 70 - 80℃ (engine outlet)

a ．Warming-Up Operation
When jacket cooling water temperature is too
low, it causes faulty combustion or the corrosion High-temperature
cooling water
or wear of the parts around the combustion cham- outlet
ber, and therefore be minded to start the opera-
tion of engine with load after raising the cooling
water temperature by warming-up operation. 5
（ ： 4-4.2 "Warming-Up Operation"）

b．Temperature Control
The cooling water temperature is controlled
appropriately by the thermostat valve at the jacket
cooling water outlet.

G．Fuel Oil Pressure

a ．Engine using Heavy Fuel Oil
When using heavy fuel oil, the pressure of
heavy fuel oil must be adjusted to be within the
following range, so that generation of vapor due
to heating-up of the fuel oil can be prevented.

Proper range: 0.5 - 1.0 MPa

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
3.2 DC-17A Pressure and Temperature of Each Part

<Fuel Oil Pressure Adjusting Procedure>

Adjustment of fuel oil pressure can be made by
the pressure adjusting screw of the fuel oil relief
valve.
(1)Remove the screw cap (A) of the relief valve,
and loosen the lock nut (B).
(2)Turn the adjusting screw (C), and adjust the
pressure.
● Clockwise turning (tightening) → Increase of
H．Fuel Oil Temperature ... When Using Heavy
Fuel Oil
Heavy fuel oil must be heated so as to make its
viscosity suitable for injection, before the oil is sup-
plied to the engine.
＊Proper viscosity (engine inlet) dynamic
viscosity: 14 ± 1.5 cSt

pressure Since the temperature appropriate for proper

● Counterclockwise turning (loosening) →
Decrease of pressure
(3)Be attentive to changes in the pressure, and
confirm that the pressure reading is within the
proper range.
(4)Tighten the lock nut (B), and attach the screw
cap (A).
When the engine using heavy fuel oil is operat-
ed by diesel fuel oil, the fuel oil pressure decreas-
es since the fuel oil cannot be pressurized in the
heavy fuel oil supply line, however, the adjust-
ment of the fuel oil pressure is not required if the
pressure is within the following range.
＊Proper range: 0.2 MPa
b．Engine using Diesel Fuel Oil
viscosity varies depending on the properties (vis-
cosity) of heavy fuel oil, be minded to keep the
proper viscosity referring to the following figure as
a standard:
（ ：Fig. 6-1.1 "Fuel Oil Viscosity
/Temperature Curve"）
In the case that the viscontroller (automatic vis-
cosity regulator) is installed to the engine, control
the fuel oil viscosity in accordance with instruction
manual, and be minded to carefully keep the man-
ual.
(Refer to the following pages)
（ ：4-4.4 "Operation Using Heavy Fuel
Oil"）
（ ：6.1 "Fuel Oil Control"）

＊Proper range: 0.2 - 0.3 MPa

In the case of diesel fuel oil, the pressure

adjustment procedure is the same as in the case
of heavy fuel oil specification, since the same
type of the fuel relief valve is used in both cases.
Heated fuel oil is extremely hot. Touching it
or metallic parts of the oil carrying equipment
with bare hands or skin can cause burns.
Be sure to wear protective gear such as
safety gloves when handling oil or the oil car-
rying equipment.

Fuel oil relief

valve

Fuel oil block Lock nut (B)

Increase
Cap (A)

Decrease

Adjusting screw

Fuel Oil Pressure Adjusting Procedure

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
Maximum Combustion Pressure DC-17A 3.3

5-3.3 Maximum Combustion Pressure b) Measuring Pmax

Maximum combustion pressure and exhaust
temperature serve as the important indicators for
knowing the engine combustion conditions and the
changes according to the elapse of time.
Normally, the decrease of the engine perform-
ance can be indicated by the following irems.
٨ Decrease of the maximum combustion pressure
٨Increase of the exhsust temperature
Conduct the measurement with the interval of
once a week or so, and record the resuits, so that
the tendency of the change can be identified and
the data can be used as the judgment materials
when determining the interval of the adjustment.
(1) Maximum Combustion Pressure
(hereinafter referred to as Pmax)
a) Pmax
Pmax is determined by load, and varies
depending on the factors such as the fuel oil
viscosity, intake air pressure, and intake air
temperature. Odinarily, however, this adjust-
ment is not necessary.
Pmax varies according to the initial fuel injec-
tion pumping angle, however, it is readily
adjusted and set at an optimum value at the
time of shipment from our factory.
Perform the measurement of Pmax after the
warming-up operation of engine has been
completed and the load has become stable.
During measurement, the measured values
may change due to such factors as the occur-
rence of the load fiuctuation. In such a case,
perform the measurement again to obtain a
stable data.
（ ："Test Run ecord" included in the final doc-
uments）
Be sure to "Fully open" or "Fully close" both
the indicator valve and the exhaust valves are
used.
If these valves are used on the "Hlf-open"
state, hogh-temperature gas will flow into the
threaded parts of the valve, and the screws
may be seized.
5

Since the items mentioned in this section will

be he items, to which the engine setting value
specified in Nox techical code shall be applied,
do not make any change that may deviate from
the setting value.
（ ：0-3 "Engine Conforming to Nox Tec
hical Code"）

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
3.3 DC-17A Maximum Combustion Pressure

Since the indicator valve is extremely hot

during the operation of engine, there is a dan-
ger of burns if it is touched by bare hands.
Therefore, be sure to wear safety gloves
when handling the valve.

Indicator A
Exhaust valve E
<Measuring Procedure>
i ) Open the indicator valve B with a special Lock nut D
wrench ffor indicator valve before installing the Indicator catch C
indicator A , and close the indicator valve after
lightly releasing it 1 or 2 times.
ii) Install the indicator to the indicator catch C , Close
and securely lock it by turning the lock nut D .
iii) Close the exhaust valve E of the indicator.
iv) Open the indicator valve. Open
v) Check the reading of the pressure on the indi-
cator.
vi) Close the indicator.
vii) Open the exhaust valve of the indicator, and
remove the indicator after indicating reading Wrench for
has become "O". indicator valve

Maximum value (when fully loaded): Safty valve Indicator valve B

17MPa

DC-17A Z 08-10

Inspection and Maintenance
Inspection and Maintenance: Inspecting Parts around Intake
and Exhaust Valves, and Adjusting Valve End Clearance
5-4．Inspection and Maintenance
5-4.1 Inspecting Parts around Intake
and Exhaust Valves, and
Adjusting Valve End Clearance
A．Replacing Consumables, Implements and
Measuring Instruments
a ．Replacing Consumables （ "Parts
List"）
1.Seal (cylinder head cover) 2-14 No.4
b．Implements and Measuring Instruments
1.General tools
( ："Implements List" in the final documents)
B．Inspecting Parts around Intake and Exhaust
Valves
Both intake and exhaust valves are the parts
that are exposed to the most severe conditions
among all other parts of the engine. Therefore, be
minded to periodically inspect these valves, and
confirm that both valves operate normally.
a. Confirm that there is no abnormal operating
sounds in both the intake and exhaust valves
during the operation of engine.
b. Check the following points on these valves
before removing the cylinder head cover when
the engine is stopped.
1. Lubricating conditions of the rocker arm and
push rods
2. Lubricating and sludge collecting conditions of
the intake and exhaust valve cotters, and valve
rotators
3. Sludge collecting conditions around the valve
spring
4. Rotating conditions of the valve rotators
5. Valve end clearance
C．Adjusting Valve End Clearance
Since valve end clearance decreases due to the
wear of the valve seat part, and therefore be mind-
ed to periodically inspect and adjust it.
When the valve end clearance is too small, it
causes improper setting of the valve on its seat
during the operation of engine due to thermal
expansion of the valve itself and push rod, result-
ing in burning of the seat.
Further, the valve system of this engine is 4-
CHAPTER
5
ITEM
DC-17A 4.1
Valve retainer tee
㩿㪙㪀
Intake/exhaust
valve rocker arm
㪚
㩿㪘㪀
㪙
㪘
Valve rotator
Push rod
Valve End Clearance Adjusting Procedure
valve type, having 2 intake valves and 2 exhaust
valves, and a single valve retaining tee is provided
to simultaneously push down both pairs of intake
and exhaust valves, and therefore unless the valve
end clearance of each pair of both intake and
exhaust valves is equal, the valve pushing force is
unbalanced, resulting in abnormal wear or damage
5
of the valve retaining tee and the guide parts.
<Valve End Clearance Adjusting Procedure>
(1)Place the cylinder in the explosion stroke, and
close the intake and exhaust valves.
(2)Loosen the lock nuts of the adjusting screws
(A) and (B), and turn back the adjusting screw
(A) and (B).
(3)Bring the valve end "A" into close contact with
the valve retainer tee, fit a dial gauge to the
valve retainer tee, and tighten the adjusting
screw (A) until the pointer swings. Make sure
that the valve ends "A" and "B" simultaneously
get into contact with the valve retainer tee.
(4)Engage a spanner around the hexagonal head
of the adjusting screw (A), and tighten the lock
nut while paying attention so that the screw
and nut do not slip and turn.
(5)Insert a thickness gauge of the specified thick-
ness into the clearance "C" on the top part of
the valve retaining tee, and adjust the clear-
ance using the adjusting screw (B).
＊Proper clearance: 0.3 mm (for both intake and
exhaust valves)
DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
4.2 DC-17A Inspecting and Maintenance of Fuel Injection Valve

Tightening nut (D)

5-4.2 Inspecting and Maintenance of Bolt (S)
Inlet connector (C)
Fuel Oil Injection Valve
Fuel oil high-pressure block (B)
Since the conditions of the fuel injection valve
Flange (R) Bolt (E)
substantially affect the performance of engine
operation, be minded to periodically inspect it and View P
conduct the maintenance.
However, in the case that remarkable changes Holder housing
were found in the maximum combustion pressure, (K)
exhaust temperature, exhaust color, and so on, be Nozzle holder
minded to conduct immediate inspection and main- guide
Circular Fuel oil injection pump
tenance, regardless of the standard inspection and
packing 䇭(G) Fuel oil high-pressure block (B)
maintenance period.
Fuel oil high-pressure flange (2)
䇭
Since the items mentioned in this section are Fuel oil high-pressure joint (3)
the parts to which engine setting value speci-
fied in NOx Technical Code shall be confirmed,
be sure to carry out no change deviated from Bolt (F)
the setting values.
( :0-3 "Engine Conforming to NOx Technical Code"）

A．Replacing Consumables, Implements, and Fuel oil injection pump

Measuring Instruments View P

a ．Replacing Consumables （ :"Parts List"） Fuel injection system

1. Circular packing 2-22 No.25
Extraction (b)-(4)
2. O-ring 2-22 No. 4
3. O-ring 2-22 No.26 (b)-(2)
(b)-(3)
4. O-ring 2-22 No.27
5. O-ring 2-22 No.28
6. O-ring 2-22 No.16
(b)-(1) (b)-(5)
b．Implements and Measuring Instruments
1. General tools and measuring instruments
( ："Maintenance" 3-1.2）
2. Fuel oil injection valve extracting tool
3. Fuel oil injection testing device
4. Nozzle cleaning implement

B．Extracting Fuel Oil Injection Valve (b)-(1),(2),(4) are common to valve spring tool

Extraction of the fuel oil injection valve can be
conducted in the following procedure:
<Extracting Procedure>
(1)Remove the cylinder head cover and heat box
cover.
(2)Loosen the bolts (E) and (F), and remove the
fuel high-pressure block (B).
(3)Remove the inlet connector (C).
(4)Remove the tightening nut (D) using a box
wrench.
(5)Extract the fuel oil injection valve (A) using a
fuel oil injection extracting implement.
Fuel injection valve extracting procedure
(6)Loosen the circular packing (G).
1)Be careful so that the circular packing (G)
may not be left behind in the cylinder head.
2)After removing the fuel oil high-pressure
block and the fuel oil injection valve, be
minded to place the cover both on the cou-
pling part of the fuel oil injection pump and
the insertion part of the cylinder head to pre-
vent foreign matter from entering them.

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
Inspecting and Maintenance of Fuel Oil Injection Valve DC-17A 4.2

C．Injection Test
Conduct the injection test of the fuel injection Test pump
valve, to check if the opening pressure and the
Pressure gauge
spraying conditions of the fuel oil injection valve is
in the proper and normal state.
Conduct the fuel injection test using the injection High pressure pipe Test tool (1)
test device (3) installed to the engine.
Lever
a ．Inspecting Valve Opening Pressure "Push"
(1)Install the fuel oil injection valve on the injec-
tion test device, after removing the carbon
stuck on the tip of the injection valve, and
cleaning the tip of the injection valve.
(2)Connect the test pump and the fuel oil injection
valve with an high-pressure pipe for testing. Fuel oil injection valve
(3)Quickly operate the test pump lever several
Test tool (2)
times, and drain the air until the valve starts
injection of the fuel oil as the manometer scale
swings. Injection Test Procedure
(4)Slowly turn the test pump lever (once every
second, or so), check the pressure reading
(the pressure, that increased gradually, sud-
denly starting to decrease due to opening of Screw driver
the valve).

＊Normal pressure: 41 - 43 MPa

Cap nut (A)
5
b．Adjusting Valve Opening Pressure Adjusting
screw (1) Lock nut (J)
When reassembling the fuel injection valve
after conducting the maintenance work by extract-
ing the valve out of the engine, and when the noz-
zle is replaced with a new one, adjust the valve
pressure in the following procedure.

Since the items mentioned in this section are

the parts to which engine setting value speci-
fied in NOx Technical Code shall be applied, be
sure to carry out no change deviated from the
setting values.
( :0-3 "Engine Conforming to NOx Technical Code"）

<Valve Opening Pressure Adjustment Procedure> Pressure Adjusting Procedure

(1)Remove the cap nut (A).
(2)Loosen the lock nut (J) for the adjusting screw
(I).
(3)Adjust the pressure to the specified pressure
by turning the adjusting screw using a screw-
driver, while conducting the injection of the fuel
oil, as in the same procedure as in the case of
the fuel oil injection test.
●Screwing-in adjusting screw → High
●Turning-back adjusting screw → Low
(4)Tighten the lock nut (J).
＊Setting pressure: 43 MPa
Be minded to set the pressure of the fuel
injection valve at a rather higher level, taking
into consideration the initial conformity, in the
case that a new injection valve is introduced.
45MPa

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
4.2 DC-17A Inspecting and Maintenance of Fuel Oil Injection Valve

Needle valve
c ．Inspecting Fuel Oil Injection
Inspect the fuel oil injecting conditions on the
following procedure: Fuel oil
(1)Quickly operate the test pump lever several
times (2 to 3 times every second), and inspect Blank
Nozzle paper
the fuel oil injecting conditions. (Let the fuel oil
injected against a blank paper so that the con-
ditions can be better inspected.)
● Check for drop due to injection --- Injection Normal Injection
sound
● Check if injection is evenly and clearly

sprayed, is not of bar pattern, not dripping

down.
(2)Check if there is no dripping-down of fuel oil
from the tip of the nozzle after the injection
test.
(A) Clogged nozzle (B) Faulty movement (C) Dripping-down
of needle valve of fuel oil

Be minded not to approach your face or Abnormal Injection

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

D．Disassembling and Inspecting Nozzle Hammer

Retaining nut (M)
In the case that a remarkable decrease of the Patch
valve opening pressure, faulty injection of fuel oil,
or dripping-down of fuel oil after injection is found
as the results of the fuel injection test, conduct dis-
assembling, cleaning, and inspection in the follow- Holder
housing (K)
ing procedure:

a ．Disassembling the Nozzle

(1)Remove the cap nut (H).
(2)Loosen the adjusting screw (I).
(3)Fix the holder housing (K) in a vise, and loosen Vise
Remove the
the retaining nut (M). needle valve
(4)Extract the needle valve out of the Nozzle (L).
(5)Extract the nozzle out of the retaining nut by
striking with a hammer, while placing a pipe-
type patch on the nozzle so as not to damage
the injection hole of nozzle.

b．Inspecting Nozzle
(1)Clean the nozzle nut and needle valve with
Nozzle cleaning imp
gas oil.
(2)Clean the nozzle hole using a nozzle cleaning
implement.
(3)Push in and push out the needle valve with
your hand, and check the movement.
●Check if the movement is smooth or not.

●Check if the movement is too loose.

Nozzle Cleaning Procedure

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
Inspecting and Maintenance of Fuel Oil Injection Valve DC-17A 4.2

(6)Set the fuel oil injection valve on the inspection

If the retaining nut is turned while the adjust- test device, and adjust the valve opening pres-
ing nut is still tightened, it causes damage the sure.
nozzle or fuel oil injection valve parts. （ ： 5-4.2 C "Injection Test"）
In the case that heavy fuel oil is used, the
retaining nut and nozzle may be stuck together
with carbon accumulated on them.
If the nut is loosened in this state, the nozzle Cap nut (H)
turns together with the nut, and may damage
the nozzle, or the knock pin of spacer, and
therefore first lubricate the nut with gas oil, and
then carefully loosen the nut by striking the Lock nut
nozzle with a hammer, while placing a patch on
the nozzle.

Since the nozzle and the needle valve is a

pair functioning together, be minded not to
Adjusting nut (I)
replace either of them separately.
Do not try to reuse a faulty nozzle by wrap- Holder housing (K)
ping, but be sure to replace it with a new one.

E ．Assembling Fuel Oil Injection Valve

Assemble the fuel oil injection valve in the
reverse order of the disassembling procedure.
Spring (N) 5
(1)Clean each of the disassembled parts with
Push rod
clean gas oil, and insert each of them back Inlet connector (C)
into the holder housing (K).
(2)Put the spacer (P) and the knock pin (Q) of Spacer (P)
nozzle together, and install them into the hold-
Knock pin (Q)
er housing. Apply lubricant
Retaining nut (M) (Molykote U paste).
(3)Apply the lubricant (Molykote U paste) on the
holder housing thread, the seating face of the
retaining nut (M), and the outer periphery of Nozzle (L)
the nozzle, and screw the retaining nut into the
holder housing by your hand.
(4)Loosen the adjusting nut (I)
(5)Tighten the retaining nut with the specified
torque.
Fuel Oil Injection Valve
＊Specified torque: 206 - 236 N・m

Be careful not to tighten the retaining nut with

the torque over the specified value, since it
may cause the sticking of the needle valve of
the nozzle.

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
4.2 DC-17A Inspecting and Maintenance of Fuel Oil Injection Valve

F．Mounting Fuel Oil Injection Valve

(1)Check the tightening state of nozzle holder
guide by tightening torqe 147 N・m.
( Maintenance3-1.7"Nozzle holder guide")
(2)Secure the flange (R) on the holder housing
(K) with the bolt (S). Ttightening nut (D)
Bolt (S)
(3)Apply heat-resistant agent to the O-rings, and Inlet connector (C)
attach them to the holder housing (K). Fuel oil high-pressure
block (B)
(4)Apply grease to the circular packing, and fit it Bolt (E)
to the holder housing.
(5)Insert that fuel oil injection valve into the noz- Flange (R) View P
zle holder guide hole, after confirming that the
old gasket is not left behind in the guide hole. Holder
housing (K)
(6)Tighten them with the specified torque after fit-
ting tightening nut (D). Circular
packing (G)
Fuel oil injection pump
＊ Specified torque: 39 N・m
Nozzle holder guide
(7)Insert the inlet connector (C) into the cylinder
head.
(Set the slit of the inlet connector (C) on the
Fuel oil high-pressure
fuel high-pressure block (B) side.) block (B)
(8)Fit the fuel high-pressure flange (2) on the fuel 䇭 Fuel oil high-pressure
oil injection pump side through the O-ring. flange (2)
䇭
Fuel oil high-pressure
(9)Fit the O-ring between the fuel high-pressure joint (3)
block (B) and the fuel high-pressure flange (2),
and insert the fuel oil high-pressure joint (3)
into the fuel oil high-pressure flange (2). Bolt (F)
(10)Fit the fuel high-pressure block (B) and the O-
ring on the cylinder header side, apply lubri-
cant (Molykote 1000 Spray) to the seats and
threads of the fuel high-pressure block tighten-
Fuel oil injection pump
ing bolts (E) and (F), and tighten them to the
specified torque. View P

＊ Specified torque: 39 N・m

Mounting Fuel Oil Injection Valve

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance: Cleaning Filters DC-17A 4.3

5-4.3 Cleaning Filters

The filters for lubricating oil, fuel oil and starting
air are important parts necessary to remove for- Air vent valve (D)
eign matters and sludges in oil to keep oil and
airclean and operate engine parts normally.
Therefore, it is necessary to periodically open and
clean the filters to prevent degradation of their fil-
tering capabilities. Case (C)

A Lubricating oil filter for turbocharger

The lubricating oil filters for turbocharger is of
Handle (A)
the notch-wire duplex type.
The notch-wire duplex type filter is normally
used as both-side-parallel application.
Since the pressure decreases if the filter has
been fouled, be minded to periodically conduct
blow-off cleaning. In case that the pressure does
not increase even after the blow-off cleaning, over-
haul the filter and then clean it. Drain cock (B)

Notch-Wire Type Filter

a Replacing Consumables
The lubricating oil filter for turbocharger

:"Parts List"
1. O-ring 3-3.8 No. 28
Both sides used (P)
5
2. Packing 3-3.8 No. 10
3. Packing 3-3.8 No. 11 90̓ 90̓
(Q) (Q)
Left side
60̓ 60̓ Right side
blow off blow off

b Blow-Off Cleaning Left side closed Right side

In the case of blow-off cleaning, deposits can closed
Handle (A)
be removed by reversely flowing the fluid through
the element on one side, and this type of cleaning Blow off
C1 C1
has no cleaning effect when the element is sub- C1
stantially clogged, and therefore be minded to C3
C3
conduct the blow-off cleaning in the earlier state, C3
while the fouled degree of filter is still light. (The E1 E2 E1 E2 E1 E2
cleaning should be conducted at least once a
week.)

C2 C2 C2
When both sides Right sides blow One side closed
are closed

E1E2 ...... Elements on the left and right

C1 ...... Changeover cock inlet hole
Interlock
C2 ...... Changeover cock outlet hole
C3 ...... Changeover cock blow off, drain hole

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM

4.3 DC-17A Inspection and Maintenance: Cleaning Filters

<Blow-Off Cleaning Procedure> [Overhaul and Cleaning of Filters]

(1)Open the drain cock (B) at the bottom part of
filter. At this time, be careful so that waste oil
may not scatter or overflow out of the drain
cock.
(2)Turn the selector cock handle (A) (usually, set
to "Used position on both sides" (P)) to the
"Blow-off" position (Q) (about 60°), and quick-
ly conduct the operation to return the handle to
the previous position (within 0.5 - 1 sec.)
(3)Repeat this operation 2 - 3 times.
(4)Also conduct the above same procedure on
the other side.
(5)Close the drain cock.
(1)Turn the selector cock handle (A) to the
"Close" position (R) (90°) on the side to be
overhauled.
(2)Open the drain cock (B), loosen the air vent
valve (D) at the top of the case (C), and dis-
charge oil.
(3)Loosen the tightening nut (E), remove the case
(C), and then take out the element (F).
(4)Clean the element with washing oil or gas oil,
and conduct blow-off cleaning from the inside.
(5)Clean each of the parts overhauled and the
grooves for case packing of the filter housing
(G).

Conduct the blow-off cleaning quickly.

Further, do not place the lever on the middle
position, but quickly move to the specified posi-
tion (knock position).
Spring䋨K䋩
If too much time has been taken in blow-off
cleaning and switching the lever positions, the
pressure decreases, and may activate the
Tightening nut(E)
alarm or emergency stop. Element(F)
Air vent valve(D)
c ．Overhaul and Cleaning of Filters
Be minded to conduct the overhaul and clean-
ing of filters when the engine is stopped, as far as
possible.
Be sure to conduct the overhaul and cleaning
of filters at low-load operation after clean the
blow-off of opposite side during the engine is Case(C)
operated. Packing(I)
Packing(J)

Air vent
Drain cock(B) pipe

The filter and the piping are extremely hot. Filter

Therefore, when handling the filter, be sure to housing
(G)
wear the safety gloves, and be cautious so that
the high-temperature oil may not splash on the
skin or clothes.
Handle(A) Knock(H)

Filter Overhaul Procedure

DC-17A Z 08-10

Inspection and Maintenance
Inspection and Maintenance: Cleaning
[Assembly and Restoration]
(1)Attach the packing (I) to the element (F), and
attach the packing (J) to the filter housing (G).
(2)Put the spring (K) on the element, place the
case (C) over the spring, and screw the nut (E)
into the case while holding the case with your
hands.
(3)Close the drain cock (B).
(4)Shift the handle (A) the "Blow-off position" (Q).
(5)When the filter is overhauled and cleaned
while the engine is stopped, conduct priming
and fill the case with oil.
(6)Close the air vent valve (D), after oil is let over-
flow and air bubbles are completely vanished
from the oil flowing out of the air vent pipe.
(7)Return the handle to "Both sides used posi-
tion" (P).
(8)Check if there is any oil leakage from the gas-
ket sections.
Confirm that the knock (H) of the handle (A)
is engaged in its position.
If the knock is not properly engaged in the
position, the handle is overturned by vibration
during the operation of engine, and it may incur
oil spill-out accidents.
(1)Check conditions of the sludge collected on
the element.
If metallic particles are found, investigate the
causes and take the countermeasures.
(2)When the element is damaged, or when the
element is excessively fouled and clogging
cannot be removed even by cleaning,
replace the element with a new one.
(3)Since the packing and O-ring are easily be
damaged, be very careful in handling these
parts. Be minded to replace the deteriorate
parts in high-temperature conditions.
CHAPTER
5
ITEM
Filters DC-17A 4.3
B．Fuel Oil Flushing Filter
This filter is attached at the fuel oil inlet of the
fuel oil block installed in the engine.
The flushing filter like paper is wound around a
core (coarse notch-wire filter). Remove the flush-
ing filter after the completion of running-in opera-
tion or when changing the operation oil to heavy
fuel oil.
If the piping from the separate fuel oil filter to the
engine inlet is disassembled, keep the flushing fil-
ter attached until flushing ends.
When disassembling the piping from the sep-
arate fuel oil filter to the engine inlet after stop-
ping the operation with heavy fuel oil, wear
safety gloves to prevent burns, and take care
not to splash the high-temperature oil on your
skin or clothes.
Never operate the engine with heavy fuel oil
without removing the flushing filter.
Filter cover
5
Flushing filter
Fuel oil block
Fuel Oil Flushing Filter
C．Lubricating Oil Filter for Engine
The lubricating oil filter adopted for the engine is
automatic backwashing type.
The filter element will catch the sludge, and the
backwashing nozzle driven by the hydraulic motor
will rotate to sequentially backwash the internal
parts by continuously flowing back the filtrated
clean lubricant oil.
For a detailed description of the filter handling
method, refer to the separate document.
( :"Operation and Maintenance Manual for
Lubricant Oil Automatic Backwashing Filter".
DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM

4.3 DC-17A Inspection and Maintenance: Cleaning Filters

D．Air filter (2) Carefully check the air strainer screen. If it

The air strainer has a critical role in removing
foreign matters in starting air and drain to ensure
normal operations of the pressure regulator, start-
ing valve and air motor. Therefore, it is important
to periodically overhaul and clean it to prevent
deterioration in filtering ability.
Since contamination may be left in the piping
at the start of operation, overhaul the strainer
every week for one month after the start of the
engine. After a lapse of this one month, if con-
tamination is not discharged, overhaul it once a
month.
The air strainer incorporates a flushing filter so
that the filter can catch foreign matters in the
pipeline at the early stages of operation.
When all the foreign matters are eliminated, the
flushing filter can be removed. It is, however, rec-
ommended that the filter should be continuously
used without removal for the reason of equipment
protection.
is clogged heavily or damaged, replace it
with a new one.
d. Assembly
Assemble the air strainer in reverse order
from its disassembly.
(1) Screw the air strainer (c) in the strainer
block (D), and tighten the air strainer.
Make sure that the threaded portions of the
strainer block (D) and the strainer (C) are free
from contamination.
(2) Fit the flushing filter (F).
(3) Fit the O-ring (E) (new) onto the strainer
cover (A), and apply grease thin.
(4) Fit the strainer cover (A).
(5) At the start of the engine, check for air leak
from joints.
Starting magnetic valve

Starting valve
If the flushing filter is clogged, the starting per-
formance will be deteriorated. In this case,
Pressure regulator
remove the filter and replace it with a new one.
Gauge
a．Replacing Consumables （ :"Parts List"） (D) Block, strainer
1. O-ring 3-1.1 No. 518
2. Flushing filter 3-1.2 No. 62 (E) O-ring

(F) Flushing filter

b. Overhauling
(C) Strainer

Make sure that the main valve for the sup-
plied high-pressure air is closed.
Remove the air strainer in accordance with
the following procedures.
(1) Remove the bolts (B), and remove the
strainer cover (A).
(2) Remove the flushing filter (F).
(3) Loosen the strainer (C) holding the hexago-
nal part with a spanner, and draw it out.
c. Inspection, cleaning and maintenance
(1) The removed parts are stained with rust and
mud. Clean them with clean wash oil or gas
oil, and blow air over them.
(A) Cover, strainer
(B) Bolt
Air Strainer
E．Fuel injection pump oil filter
A coin filter is fitted as an integral part of the pip-
ing part on the engine frame side of the oil feed
pipe connected to the fuel oil injection pump of
each cylinder.
After cleaning the filter with wash oil or gas oil,
blow air over the filter.

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:Cleaning Turbocharger Blower
DC-17A 4.4

5-4.4 Cleaning Turbocharger Blower D．Cleaning Method

If the fouled degree of the turbocharger blower
progresses, the efficiency of the turbocharger
decreases and the operating performance of
engine is worsened. Particularly when heavy fuel
oil is used, the turbocharger blower tends to be
fouled in faster degree, and therefore be minded to
conduct blow-off cleaning and restrain the
progress of fouling.
A．Interval of Cleaning
Clean the blower when intake air pressure
decreases 10% at the same load, or at least
every 150 to 200 hours of operation.
B．Load during Cleaning
Make sure that the engine shall be operated
under the load of 75% or higher, and continue the
loaded operation for 1 hour or more after cleaning.
Cleaning of the turbocharger blower can be
made using the cleaning device that is supplied
together with the engine.
(1)Pour cleaning liquid into the blower syringe
(A).
(2)Connect between the plug of the feed hose (B)
and the syringe socket.
(3)Fully open the drain cock of the air intake duct.
(4)Remove the plug (M8) on the front face of the
silencer of the turbocharger.
(5)Insert the plug pin at the tip of the feed hose
(B) into the plug hole, and operate the syringe
to feed the cleaning liquid.
(6)When 3 to 5 minutes has passed after the
injection of cleaning liquid, inject fresh water of
the same amount in the same procedure.

C．Cleaning Liquid [Injection Amount and Injecting Time]

Be sure to use the specified cleaning liquid. In
case that the specified cleaning liquid is not avail-
able, use fresh water. (Note that cleaning effect Type of Filling amount Filling time
is inferior with fresh water.) turbocharger (L) (sec.)
AT14 0.2 4 - 10

Be minded never to use gas oil or any other

(7)In case that there is no change in intake air
pressure before and after the cleaning, repeat
5
flammable liquid for cleaning, since these liq- cleaning after 10 minutes.
uids will be the cause of fire. ◎In case that intake air pressure does not
change over when the cleaning is repeatedly
conducted, conduct the overhaul and cleaning
of the whole of turbocharger.
Syringe (A) Fit Plug
（ ：Separately provided "Turbocharger
Instruction Manual"）

Socket
Feed hose (B)
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
Turbocharger
safety gloves without fail.

Plug pin

Cleaning Turbocharger
Blower Procedure

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:Cleaning Turbocharger Turbine
4.5 DC-17A
5-4.5 Cleaning Turbocharger Turbine
<Turbocharger type "AT14" (water washing)> C．Cleaning Method
As dirt collects on the turbine side of the tur-
bocharger as on the blower side, the turbocharger
efficiency lowers, and the engine performance
deteriorates.
Particularly, when heavy fuel oil is used, the tur-
bine is easily contaminated. Periodically clean the
turbine to inhibit the progress of contamination.
To clean the turbine, feed water to the inlet of
the turbine, and accelerate the speed of water
drops with exhaust gas. The impact of the water
drops removes scale from the turbine nozzle and
the turbine moving blades.
（ ：Separately provided "Turbocharger
Instruction Manual"）
A．Cleaning Interval
When the deposit layer becomes thick, the
cleaning is not effective. At the initial stage, clean
the turbine every 250 hours or 7 to 10 days. After
the initial stage, increase or decrease the clean-
ing interval appropriately depending on the
degree of decrease in the performance character-
istics, such as the exhaust temperature, intake air
pressure and the rotation speed of the tur-
bocharger.
The cleaning interval shall be up to 500 hours.
B．Exhaust Temperature (Load) During
Cleaning
Clean the turbine when the exhaust temperature
at the turbine inlet is 300 to 350℃.
Run the engine at the exhaust temperature of
300 to 350℃ for 20 minutes or more to ensure the
temperature equilibrium of the turbocharger.
Clean the turbine in such a state that the load
does not fluctuate (the exhaust temperature does
not change).
DC-17A Z 08-10
For water washing, use additive-free fresh
water (not containing rust preventive at a temper-
ature of 60℃ or less.
Supply water at a water pressure of 0.13 MPa.
(1)Connect the rubber hose (D) to the nozzle
water filling pipe provided on the exhaust gas
pipe.
(2)Connect the water filling rubber hose (E) to the
gauge unit.
(3)Fully open the drain cock (C), and make sure
that the drain hole is not blocked.
(4)After fully opening the nozzle (A), take approxi-
mately 30 seconds to open the valve (B) slow-
ly.
(5)The cleaning time shall be 5 to 7 minutes.
If drain is not discharged even when water is
fed for 5 minutes, adjust the water filling pres-
sure to set the drain rate to approx. 0.1 L/min.
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.
Exhaust gas pipe
Turbocharger
Drain cock (C)
Nozzle (A) Rubber hose (D)
Gauge unit
Valve (B)
Hose connection
Rubber hose (E)
(CUSTOMER SUPPLY)
P
Water (Press 0.13MPa )
Turbine Washing
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:Cleaning Turbocharger Turbine
DC-17A 4.5

Do not feed water for more than 7 minutes. It

may damage parts.
Carefully observe the change in color of the
drain to confirm the effect of cleaning.
During water washing, you must operate high-
temperature parts. Take care not to burn your
hands.

(6)Fully close the nozzle (A).

(7)Fully close the valve (B).
(8)Remove the water filling rubber hoses (D) and
(E).
(9)After the drain is completely discharged, fully
close the drain cock (C).

D．Increase of Engine Output

After the completion of cleaning by feeding
water, run the engine under the same load for
about 10 minutes, and restore the engine output
to the normal state.

If component parts are dried completely, the

casing may be corroded. 5
E．Verification of Engine Performance After
Cleaning
After cleaning, measure the engine perform-
ance (exhaust temperature, intake air pressure,
etc.) to verify the effect of cleaning.
If the effect is insufficient, perform cleaning
repeatedly 2 or 3 times.
If the engine performance cannot be restored,
overhaul the engine.

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
4.6 DC-17A Measuring Crankshaft Deflection

5-4.6 Measuring Crankshaft Deflection
If the crankshaft deflection exceeds its limit,
the stress to be applied to the crankshaft
becomes excessive, and it results in the break-
age of crankshaft if the excess of deflection is
too large.
Therefore, adjust the crankshaft deflection to
the proper value when being installed, and peri-
odically measure the deflection, so that it can
be corrected whenever it is over the limit value.
tion "B") past the bottom dead center.
(3)Install the deflection gauge to the position.
The position is about the same line of the jour-
nal outer diameter, and it is a point of intersec-
tion of center line in crank arm.
(4)Set the reading on the gauge scale to +20 at
the position "B" in the Figure. (To make clear
the positive and negative directions.)
(5)Slowly turn the engine in the normal direction
of rotation, and measure the reading on the
scale when the crankshaft is at the angle of
"B", "C", "D", "E", and "A" respectively, of
which data shall be recorded.

A．Replacing Consumables and Measuring

Instruments
a ．Replacing Consumables （ ："Parts List"）
1.O-ring (frame side cover) 2-2 No.11

b．Implements and Measuring Instruments

1. General tools

135
80
（ ："Implement List" in the final documents）
2. Deflection gauge
3. Mirror

B．Conditions for Measuring Deflection

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

C．Measuring Deflection
<Measurement procedure>
(1)Open the indicator valve, and perform turning
the crankshaft.
(2)Place the crank pin at the point of 30° (posi-

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
Measuring Crankshaft Deflection DC-17A 4.6

D．Calculating Deflection (d)

Calculate the deflection values as based on the
measured values in accordance with the following
formula, record the calculated values:
Ａ＋Ｂ
●Vertical (V) deflection: dV = D －
The deflection of the crankshaft shall be rep-
resented by the value when the engine is cold,
and when the engine is warm sometimes differ

２ significantly depending on the measurement

conditions, be minded not to use the value
●Horizontal (H) deflection: dH = C - E
measured when the engine is warm as stan-
●Positive/negative deflection: Open downward
dard.
(+), closing downward (-)
A, B, C, D, and E represent the measured val-
ues respectively at each corresponding position
shown in the figure on the right.

E．Correction Limit for Deflection

a．The correction limit shall apply to whichever is O

larger of dV and dH as shown in the following 30

table.

(Unit : mm)
C D E
B Top dead center
A
Adjusted value Allowable limit Direction
Deflection Measuring Position
(One-side bearing
In case of direct

0.027 or less 0.075

connection :
generator)

1
10,000
x stroke
2.8
10,000
x stroke 5
(Both-side bearing
In case of direct

0.027 or less 0.075 Seen from flywheel side

connection :
generator)

O O

1 2.8 A 30 30 B
x stroke x stroke
10,000 10,000
connection with
In case of direct

0.081 or less 0.108 E C

coupling:
flexible

3 4
x stroke x stroke
10,000 10,000
D (Top dead center)

b．Deflection varies depending on the connec-

tion method (direct connection or flexible cou-
pling) between the crankshaft and drive Dial Gauge Reading
equipment, however, usually, the deflection
becomes maximum at the crank throw that is
closest to the flywheel.
Adjust the drive equipment using the adjust-
ing shim or chock liner, so that the deflection
falls when the limited values as shown in the
above table.

DC-17A Z 08-10
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Maintenance:
4.6 DC-17A Measuring Crankshaft Deflection

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

DC-17A Z 08-10
 CHAPTER
Inspection and Maintenance
5
ITEM
MEMO DC-17A

5
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
1.1, 1.2 DC-17A Fuel Oil Control: Fuel Oil Selection/Fuel Oil Control

6-1 Fuel Oil Control

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

6-1.1 Fuel Oil Selection

The standard characteristics of the fuel oil appli-
cable to this engine is as shown in the separate
table.
（ ：Table 6-1.1 "Fuel Oil Standard
Characteristics")
Commercially available fuel oils are consider-
ably different in the characteristics, and even the
same type of the fuel oil may show a greatly dif-
ferent characteristics depending on the location
and period of supply.
Check the characteristics analysis values of the
fuel oils, and avoid using the fuel oil that exceeds
the limit value.
1. The engine specification varies depending
on the types of the fuel oil to be used. Be
minded to confirm the type of the fuel oil
referring to the specification of engine, and
do not use the oil of which grade is lower
than that shown in the specification.
In the case that the fuel oil of lower grade is
used, troubles may be incurred on the oper-
ation of engine, due to the faulty combus-
tion, troubles on the fuel oil system equip-
ment, premature wearing of the parts, and
so on.
2. Avoid using the fuel oil by mixing with the
other oils whose production of origin is dif-
ferent. In the case that fuel oil is mixed the
oil with inferior affinity, a large amount of
sludge may be generated, causing troubles
in the operation of engine.
Bottoms oils resulting from operation by FCC
method (catalytic cracking method) are often
mixed in fuel oils recently.
The mixed oils contain rigid alumina silica
(catalyst particles) and causes abnormal wear
of the various parts of engine, particularly the
parts of the fuel injection system.
Remove the solid particles by fully utilizing
the fuel oil pretreatment equipment, and by
intensifying the cleaning of fuel oil.
In the case that the removal of the solid parti-
cles cannot sufficiently be made with the exist-
ing fuel oil pretreatment equipment, the rein-
forcement of the cleaning equipment is
required, and when such reinforcement is not
possible, it may be required to change the cur-
rent fuel oil to the oil of a better quality.
6-1.2 Fuel Oil Control
A．Heavy Fuel Oil
Since heavy fuel oil contains more carbon
residue and impurities, and is higher in its viscosity
as compared to diesel fuel oil, heavy fuel oil can-
not be used as the fuel oil for diesel engine, when
it is in the state of bunker fuel oil.
Therefore, it is a prerequisite to use heavy fuel
oil that the oil must properly be preprocessed
before being supplied to engine (including the
removal of impurities by cleaning, and the assur-
ance of proper viscosity by heating).
a ．Cleaning Fuel Oil
Water, and solid contents such as vanadium,
sodium, alumina, and silica, contained in heavy
fuel oil accelerate the corrosion and wear of the
various parts of fuel injection system and fuel
combustion chamber system, substantially affect-
ing and reducing the working life of these parts.

DC-17A Z 08-10

Control of Fuel Oil, Lubricating Oil, and Cooling Water
Fuel Oil Control:Fuel Oil Selection/Fuel Oil Control DC-17A
For the purpose of removing such impurities,
the fuel oil preprocessing equipment, such as the
centrifugal separator and precision filters, are
installed.
Since these equipment does not exhibit the effi-
ciencies unless each equipment is properly han-
dled, be minded to operate each equipment in
accordance with the corresponding instruction
manual.
( ：Instruction Manual" for each equipment")
Since waste fuel or sludge is the causes of
environmental contamination or pollution, be
sure to entrust the treatment of these to the
authorized waste disposal company, not direct-
ly handling or disposing these matters on your
own.
b．Heating Fuel Oil
Since the viscosity of heavy fuel oil is very high,
it is required to heat the oil, so that a proper vis-
cosity for fuel oil injection can be obtained.
Since the heating temperature varies depend-
ing on the viscosity of fuel oil, heat the oil and
obtain the proper viscosity, by referring to the fuel
oil viscosity temperature curve on the separate
page as a standard.
In the case that a viscosity controller (automatic
viscosity regulator) is installed on the engine,
control the fuel oil viscosity to its proper value
according to the attached instruction manual.
( ：Fig. 6-1.1 "Fuel Oil
Viscosity/Temperature Curve")
＊ Proper viscosity for fuel oil (engine inlet)
Kinematic viscosity: 14 ± 1.5cSt.
If the temperature control of fuel oil is
improper, and the fuel oil with high viscosity is
supplied to engine, it not only incurs faulty com-
bustion, but also results in the accidents such
as the clogged or damaged fuel oil filter, and
the breakage of fuel injection system parts.
CHAPTER
6
ITEM
1.2
B．Diesel Fuel Oil
a．Water tends to extract and separate out of
diesel fuel oil, and further diesel fuel oil tends
to generate a large amount of sludge when
mixed with the oil of different base oil.
Daily conduct the draining-off of the precipita-
tion tank and setting tank, so that water or
sludge does not flow into the engine.
To remove water or sludge, the centrifugal
separator is an effective device.
b．Diesel fuel oil, that has been cut back by
using the gas oil refined by FCC method, may
incur faulty start of ignition, and this tendency
is particularly obvious in the case of low sulfur
diesel oil for land vehicles, due to its low
cetane number. If the environmental condi-
tions, such as ambient temperature or water
temperature, are unfavorable, insufficient
starting and ignition defect may occur.
In such a case that special measures become
necessary to improve starting capability and
combustibility of engine, contact our company
for consultation.
C．Gas Oil
Although gas oil does not contain few impuri-
ties, it may cause problems on ignition when the
gas oil is refined by FCC method, just like the
6
case with diesel fuel oil, and therefore be minded
to pay particular attentions to the cetane number
of gas oil.
Further, since gas oil is low in its viscosity and
is inferior in its lubricity, it may cause abnormal
wear on the sliding parts of fuel oil injection sys-
tem, and therefore be minded to conduct the
inspection of the fuel oil injection pump and fuel
oil injection valve in the earlier stage than usual.
D．Kerosene Oil
As a countermeasures to prevent air pollution,
there may a case in which kerosene oil may be
used.
Since kerosene oil is further lower in its cetane
number and is lower in its viscosity than gas oil, it
is required to carry out a special arrangement on
the engine, and therefore contact our company
for consultation before using the oil.
DC-17A Z 08-10
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM

1 DC-17A Fuel Oil Control: Fuel Oil Standard Characteristics

Table 6-1.1 Fuel Oil Standard Characteristics

General Diesel fuel oil 1) Heavy fuel oil 2)
JIS K2205 type 1 K2205 type 3
Type of fuel oil
ISO-F (DMA) RMA10 RME25 RMG35 RMH55
CIMAC ⎯ A10 E25 G35 H55
Density (15°C) g/cm3 max 0.890 0.975 0.991 0.991 0.991

Kinematic viscosity 100/50°C mm2/s max 3.0 - (50°C) 10/40 25/180 35/380 55/700

Flash point °C min 60 60 60 60 60

Pour point °C max 0 6 30 30 30
Carbon residue wt. %max 0.2 10 15 18 22
Ash wt. %max 0.01 0.10 0.10 0.15 0.20
Water vol. %max 0.1 0.5 1.0 1.0 1.0
Sulfur wt. %max 1.5 3.5 5.0 5.0 5.0
Vanadium mg/kg max ⎯ 150 200 300 600
Sodium mg/kg max ⎯ 50 50 50 50
Aluminum mg/kg max ⎯ 30 30 30 30
Cetane number 3) ⎯ min 40 (45) ⎯ ⎯ ⎯ ⎯
CCAI value 4) ⎯ max ⎯ 850 850 850 850
Note: 1) Since there are a wide range of the standard values for diesel fuel characteristics, the recom-
mended values are shown in the above table.
2) Heavy fuel oil characteristics represent the values of "Residual marine fuel oil" proposed in CIMAC
(1990)
3) Cetane number represent the calculated values based on JIS K 2280-1996. Figures shown in ( )
indicate the values based on the old method of JIS K2204-1994.
4) CCAI (Calculated Carbon Aromatic Index) value is calculated by the following formula, and indi-
cates the reference value for starting capacity.
CCAI = 1000 D-141 Log Log (VK + C) - 81
D: Density g/cm3 (15℃), VK: Viscosity mm2/s (50℃), C: Constant (0.85 for heavy fuel oil)

Table 6-1.2 Standards for Clean Fuel Oil

Vanadium combines with sodium to yield a
Component Standards compound that acts as an oxidation catalyst,
Water 0.2% vol or less accelerating the corrosion due to sulfuric acid
Content 50 mg/kg or less (vanadium attack).
Solid particles Further, water accelerates the corrosion of
Size 5 μm or less
fuel oil injection system parts. Particularly in
the case that sea water is mixed in water, it fur-
ther accelerates the corrosion due to sulfuric
acid as above said, and therefore remove the
impurities together with solid particles by the
fuel oil cleaning equipment.

DC-17A Z 08-10
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Fuel Oil Control: Fuel Oil Viscosity/Temperature Curve DC-17A 1

1000F 500C
9000
7000 Trace 1 Gas oil
curve 3 mm2/s @500C

5000 " 2 MDF 6.2 " "

4000 Rw#1
" 3 TFO 30 " "
3000 11 4 60
10000
" " " "
2000 10 " 5 " 80 " "
1500 6 120
(

" " " "

9
mm2 / S

5000
" 7 " 180 " "
1000
800 8 8 280
" " " "
)

600 7 " 9 MFO 380 " "

Kinematic Visconsity

500 2000
" 10 " 500 " "
400 1500
6 11 700
300
250 1000
5
200
150 4 500

100
80
3
60
50 200
40
30
25 100
20

14 15 65

10 2 50
8
6 40
5
1
4
3 6
2 30
-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Temperature ( 0 C)

Fig. 6-1.1Fuel Oil Viscosity / Temperature Curve

Example) We find the temperature, under which heavy fuel oil of 380mm2/s can be heated, so as to obtain
the proper viscosity of 14mm2/s at the engine inlet.
To find this temperature, trace the curve No. 9 downward, and from the point that intersects kine-
matic viscosity 14mm2/s, go down vertically to obtain 130℃.

Note: 1. The viscosity/temperature characteristics of fuel oil may slightly differ depending on the original
place of production or its refining process, and therefore confirm the viscosity with a viscome-
ter, and determine the proper value when actually operating the engine.
2. Kinematic viscosity 1cSt = 1 mm2/s

DC-17A Z 08-10
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Lubricating Oil Control:
2.1, 2.2 DC-17A Lubricating Oil Selection/Lubricating Oil Control

6-2 Lubricating Oil Control

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

6-2.1 Lubricating Oil Selection 6-2.2 Lubricating Oil Control

A．Engine system oil
As the system oil for engine, high-grade lubricat-
ing oil (CD of API service category, or higher) for
diesel engine shall be used.
Select the lubricating oil of the suitable grade,
according to the quality of the fuel oil to be used.
The recommended lubricating brands as shown in
the separate table.
（ : Table 6-2.1 "Recommended Lubricating
Oil Brands"）
Be minded to use the lubricating oil of the
same brand, not to mix the lubricating oil with
the oil of any other brand.
If the lubricating oil is mixed with the oil of dif-
ferent brand, the additives contained in the
both oils react for each other, and this may
result in the degradation of the lubricating oil.
B．Lubricating Oils for Other Equipment
In the case that separate lubricating system is
employed apart from the engine lubricating sys-
tem, as in the case of the governor, air motor, gen-
erator, etc., be minded to refer to the instruction
manual of each equipment.
（ : "Instruction Manual of each equipment"）
A．Cleaning of Lubricating Oil
Since fine dust and combustion residue from the
combustion chamber enter and mix in the lubricat-
ing oil, a centrifugal separator and a cleaner are
installed to the engine, to eliminate such foreign
matters, in addition to the filters attached to
engine. Use such equipment in the correct man-
ner, referring to the instruction manual of each
manufacturer.
Do not conduct cleaning by injecting water
into lubricating oil.Mixing water into lubricating
oil causes degradation of the lubricating oil,
such as the emulsification of oil, the decrease
of total base number, and the increase of insol-
uble substances.
B．Control of Lubricating Oil Characteristics
Periodically conduct the sampling and analysis
of lubricating oil (every 500 hours), and in the case
that the analyzed value of the lubricating oil char-
acteristics reached the control standard value,
immediately consult the lubrication oil manufactur-
er, so that the replacement or makeup can be car-
ried out.
（ : Table 6-2.2 "Lubricating Oil Control
Standards"）

DC-17A Z 08-10
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Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Lubricating Oil Control:Lubricating Oil Control DC-17A 2.2

a ．Sampling Procedure <Information to be Attached to Sample

(1) Collect samples from the air vent pipe of the Receptacle>>
filter during the operation of engine.
If the samples are collected from the drain 1. Name of your company and your name
cock, the analyzed value of the characteristics 2. Model number of engine
may show a different value due to the mixing
of sludge or solid deposits. 3. Engine number
(2) The minimum amount of sampling shall be 500 4. Data and location of sampling
cm3.
5. The amount of time the engine is operated
(3) Attach on the sampling receptacle with the
label indicating the information as shown on 6. Lubricating oil brand
the right. 7. Total operation time and quantity of lubricat-
ing oil
b．Lubricating Oil Control Standards
8. Replenishment record (Data and quantity of
The lubricating oil control standards are as
shown in the Table 6-2.2 below. replenishment)
Of all the lubricating oil control standards, the
total base number and n-pentane insoluble are
particularly important for the purpose of checking (1) Total Base Number (TBN)
the degradation degree of lubricating oil. （Total Basic Number）
Total base number represents the quantity of
Table 6-2.2 potassium hydroxide (KOH) that corresponds
to the quantity of acid required to neutralize the
Lubricating OIl Control Standards (System oil)
base component contained in 1 g of lubricating
Diesel Heavy oil, and is indicated by the unit of
Fuel oil used fuel oil fuel oil mgKOH/g.Total base number indicates the
Total based lubricating oil capabilities to prevent the corro-
mgKOH/g 3 or more 10 or more sion due to sulfuric acid generated from sulfur
number 1)
Kinematic
Viscosity
mm2/S
o
(@ 40 C)
+30% or less / -20%
or more of new oil
contained in fuel oil, and other acids, and fur-
ther it indicates the capabilities of lubricating oil 6
to clean and disperse the fouled sections in the
Flash point o
180 or higher engine.
C

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

vol. % 0.3 or less
content Insoluble is a fouling substance that does not
n-pentane dissolve in oil, and the main component is soot
wt. % 2.5 or less
insoluble 1) which is a product of combustion, and calcium
sulfate which is a neutralized product.Since
Notes:
1) The TBN (Total Basic Number) represents the values measured these substances do not dissolve even in n-
according to ASTM D664, JIS K2501. (Hydrochloric acid method). pentane which is a solvent, n-pentane insoluble
2) Insoluble represents the values measured according to serves as an index to indicate the degradation
ASTM D893B. In case that the measure value rapidly increased
or exceeded 1.5, measure toluene insoluble according to the and fouling degree of lubricating oil.
ASTM D893B, and in case of [ n-pentane insoluble - toluene
insoluble ] > 0.5, replace the lubricating oil.

DC-17A Z 08-10
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Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM

2 DC-17A Lubricating Oil Control:Recommended Lubricating Oil Brands

Table 6-2.1 Recommended Lubricating Oil Brands

Kind of fuel oil Gas oil or Up to 200 Sec. Up to 1500 Sec. Up to 7000 Sec.
Diesel oil R.W. No.1 R.W. No.1 R.W. No.1

Class II Class III Class IV Class V

Supplying or Supplying or Supplying or Supplying or
Name of company
Replacing oil Replacing oil Replacing oil Replacing oil

BP ENERGOL BP ENERGOL BP ENERGOL BP ENERGOL

BP DL-MP40 IC-HF254 IC-HF304 IC-HF304
CASTROL MLC40 CASTROL TLX204 CASTROL TLX304 CASTROL TLX304

DELO 1000 Marine DELO 2000 Marine DELO 3000 Marine DELO 3000 Marine
CHEVRON Oil SAE40 Oil SAE40 Oil SAE40 Oil SAE40
TEXACO
TARO XD SAE40 TARO DP SAE40 TARO DP SAE40

EXXMAR 12TP40 EXXMAR 24TP40 EXXMAR 30TP40 EXXMAR 30TP40

EXXON MOBIL EXXMAR 40TP40
MOBILGARD 412 POWERGARD 2040 MOBILGARD 424 MOBILGARD 424

GULF GULF VERITAS GULF VERITAS GULF VERITAS

DPO40 SERECT40 SERECT40

PETROBRAS MARBRAX MARBRAX MARBRAX MARBRAX

CCD410 CCD420 CCD430 CCD430

SHELL GADINIA 40 ARGINA S40 ARGINA T40 ARGINA T40

TOTAL
TOTAL‫ޓ‬ RUBIA S SAE40 RUBIA ST SAE40 HAM SAE40 HAM SAE40
‫ޓ‬FINA
FINA HAM SAE40
DISOLA M4015 AURELIA 4030 AURELIA 4030 AURELIA 4030

Note:(1) This table shows lubricating oils classified as SAE40. Be sure to use lubricating oils classified as
SAE30 only when the minimum ambient temperature is 20℃ or less.
We recommend that multigrade oil (SAE10W-30 or 5W-30) be used in extremely cold locations
(minimum ambient temperature: 5℃ or less).

(2) Be sure to consult with oil manufacturers before selecting the lubricating oil proper brand that
best suits the fuel oil and operating conditions.

DC-17A Z 08-10
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Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Cooling Water Control: Cooling Fresh Water (Raw Water) /
Corrosion Prevention Agent DC-17A 3.1, 3.2

6-3 Cooling Water Control

Always use fresh water and add antirust to cooling water to maintain cooling effect and prevent
corrosion due to scale.
Improper cooling water control can cause localized heating due to corrosion or adhered scale,
resulting in excessive wear or damage.

6-3.1 Cooling Fresh Water (Raw Water) 6-3.2 Antirust

As cooling fresh water (raw water), be minded to
use the soft water that meets water quality stan-
dards shown in Table 6-3.1 below, or the water to
which softening processing is administered.
A. As antirust, we recommend the agent which is
nitrous acid type.
B. Commercially available brands in Japan are
shown in Table 6-3.2.
When using them, carefully read the manufac-
turer's instruction manual, and properly use
the agent in accordance with the use standard
as well as the control standard.

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

Effect (reference)
Item Standards
Corrosion Scale
PH (25 C) 6.5 to 8.5 (neutral)
Total hardness
(CaCo3 PPM)
100 mg/kg Max. 6
Chlorine ion
-1 100 mg/kg Max.
(Concentration: CI )
M-alkalinity (PH4.8) 150 mg/kg Max.
Sulfate ion
-2 100 mg/kg Max.
(Concentration: SO4 )
Total iron (Fe) 0.3 mg/kg Max.
Silica (SiO2) 50 mg/kg Max.
Ammonium ion
0.05 mg/kg Max.
(Concentration: NH4)
Evaporation residue 400 mg/kg Max.

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6
ITEM
Cooling Water Control:
3.2, 3.3 DC-17A Antirust / Control of Cooling Water

Table 6-3.2 Brands of Commercially Available Antirust

Brand Name Manufacturer Constituent Amount to added (ppm)

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

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

6-3.3 Control of Cooling Water B. Controlling Fresh Water with PH Value

A. As cooling water, be minded to use fresh water
added with antirust, from the early stage with-
out fail.
Measure the PH value of cooling water once
every week, using a PH value meter, and in the
case that the value exceeds the standard value
specified by the manufacturer, discharge 10 to
20% of the cooling water to add new water.

Antirust is a poisonous and toxic substance.

C.Replace the entire amount of cooling water
Therefore, be minded never to drink the cooling
water that is added with antirust.
Further, regarding the handling of the cooling
water added with antirust, be sure to use the
protective wear such as rubber gloves and
masks, so that your hands or skin do not direct-
ly touch the cooling water.
If the antirust accidentally touched your skin
or entered your eyes or mouth, immediately
wash them with fresh water sufficiently.
once every year or 2 years.
Be minded never to directly discharge the
cooling water in which are added with corrosion
agent, into sea or river, without adequate pro-
cessing.
When disposing the cooling water, be sure to
conduct the water examination, to ensure that
the COD concentration of cooling water is dilut-
ed to be within the specified value.

DC-17A Z 08-10
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Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
MEMO DC-17A

6
CHAPTER
Troubleshooting and Countermeasures
7
ITEM

1 DC-17A Precautions for Troubleshooting

7．Troubleshooting and Countermeasures

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

7-1 Precautions for Troubleshooting

A. Take proper measures immediately when you find a defect or problem.

If any of the following defects and failures is found, stop the engine for inspection. Never attempt to
restart the engine until you find the cause, take proper measures, and restore the engine to the normal
operating conditions. Resuming operation without taking proper measures may rapidly aggravate the
defect or failure, resulting in injuries or accidents.

1. Activation of protective device: "Alarm", "Emergency Stop"

Overspeed, low lubricating oil pressure, high cooling water temperature, etc.
2. Abnormal sounds (specially mechanical sounds), abnormal vibrations
3. Overheating of the engine
4. Abnormal increase of exhaust temperature or abnormal decrease of exhaust temperature
5. Defective parts on or around the engine control (governor, control device), or protective device, loos-
ened link, or detachment of link
6. Damage to piping or joint bolts (specially fuel and lubricating oil systems)

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

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

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

DC-17A Z 08-10
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Starting Defect DC-17A 2.1
7-2 Troubleshooting and Countermeasures

7-2.1 Starting Defect

[Phenomenon] [Trouble] [Countermeasures]
Insufficient starting air pressure Fill air
Leak from main stop/ Maintenance/
safety valve on air tank
Replacement
Faulty air filling unit Repair
Insufficient (e.g. compressor)
Faulty pressure gauge Repair/Replace
starting air Defective starting air piping system
"Closed" stop valve Open valve
Clogged piping Clean valve
Defective control system Maintenance/
Interrupted power supply Repair
Defective automatic control panel
Flywheel Defective solenoid valve for control
"Removed" turning bar Turn it "Fit"
does not Improper Faulty starting device
rotate air motor Sticking of starting air Maintenance/
push button Replace
operation
Improper pressure of Adjustment/
reducing valve Repair
Sticking of relay valve Maintenance/Repair
Air motor troubles
Sticking of bearing Maintenance/Repair
Engine Improper engagement Perform turning
of pinion gear
Defect
High resistance of moving parts Maintenance/Repair
Non-smooth (such as seizure)
Cylinder liners, Piston
turning Crankshaft
Flywheel Too high lubricating oil viscosity Increase cooling
rotates, but water temperature.
fuel mixture Replace with less
is not ignited viscous lubricating oil
Low room temperature Increase room
No ignition temperature
in all
cylinders
Low cooling water temperature

Fuel oil troubles

Increase water
temperature 7
The normal Improper properties (ignitability) Use high-grade oil
rotation Water in fuel oil Separate and
speed is not eliminate water
reached Air in fuel oil Remove air
Defective fuel injection valve
Faulty nozzle Maintenance/Replacement
No ignition Faulty opening pressure valve Adjustment
Defective fuel oil injection pump Maintenance/Replacement
in some
.Sticking of rack
cylinders .Sticking of plunger
.Faulty delivery/isobaric valve
Insufficient compression pressure
䇭䇭 Non-airtight piston ring Maintenance/
(slicking, wear, damage) Replacement
䇭䇭 Non-airtight intake/ Maintenance/
exhaust valve Replacement
䇭䇭 Improper valve end Adjustment
clearance

DC-17A Z 08-10
CHAPTER
Troubleshooting and Countermeasures
7
ITEM
2.2, 2.3 DC-17A Engine Revolution is Not Smooth/Insufficient Output

7-2.2 Engine Revolution is Not Smooth

[Phenomenon] [Trouble] [Countermeasures]
Defective fuel control system
ųų Defective governor Maintenance/Repair
‫ ޓޓ‬Control link is caught or shaky Maintenance/Repair

Defective fuel oil supply system

‫ ޓޓ‬Insufficient supply pressure Maintenance/Repair
(defective relief valve and pump)
Irregular Clogged fuel oil filter Clean
revolution ‫ ޓޓ‬Improper viscosity of fuel oil Adjust to proper
of engine (heavy fuel oil) temperature by heating
‫ ޓޓ‬Water in fuel oil Separate and
eliminate water
Air in fuel oil Remove air
Defective fuel oil injection valve
ųų Faulty nozzle Maintenance/Replacement
ųų Improper opening pressure valve Adjustment
Uneven
Defective fuel oil injection ųų Maintenance/Replacement
combustion
between cylinders ųųȷSticking of rack
ȷSticking of plunger
Variations in exhaust ųųȷFaulty delivery/isobaric valve
temperature
Insufficient compression pressure
ųų Non-airtight piston ring Maintenance/Replacement
ųų (slicking, wear, damage)
Non-airtight intake/exhaust valve Maintenance/Replacement
ųų Improper valve end clearance Adjustment

7-2.3 Insufficient Output

[Phenomenon] [Trouble] [Countermeasures]
Cannot
insert the Defective fuel control system
rack 䇭䇭Defective governor Maintenance/Repair
䇭䇭Control link is caught or shaky Maintenance/Repair

High
Overload (torque-rich) Reduce load
exhaust
temperatur High resistance on moving parts Maintenance/Repair
(e.g. seizing)
䇭䇭Cylinder liners, piston
Insufficient 䇭䇭Crankshaft
Excessive
Output reading on Insufficient fuel oil supply pressure
.The engine rack scale
Low 䇭䇭Defective fuel oil relief valve Maintenance/Repair
cannot run exhaust 䇭䇭Defective fuel oil feed pump Maintenance/Repair
temperatur
with full 䇭䇭
Clogged fuel oil filter Clean
load. Water in fuel oil Separate and
.Rotation eliminate water
speed does Air in fuel oil Remove air
not go up. Uneven
combustion (䇭䇭䇭 :7-2.2䋩
between

DC-17A Z 08-10
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Abnormal Exhaust Gas Temperature or Maximum
Combustion Pressure DC-17A 2.4

7-2.4 Abnormal Exhaust Gas Temperature or Maximum Combustion Pressure

[Phenomenon] [Trouble] [Countermeasures]
High
High reading Overload (excessive torque) Reduce load
Te & Pmax on pump
Large resistance on moving parts (e.g. seizure) Maintenance/Modify
rack scale
Cylinder Liner, Piston
Crankshaft
All
cylinder Improper property of the fuel oil Use high quality fuel oil
are
Improper viscosity of the fuel oil (heavy fuel oil) Adapt the viscosity
abnormal
Fouling of the turbocharger
Clogging of the pre-filter Clean
High Te, Low Fouling of the blower Clean
low Pmax intake air Fouling of the turbine Clean
pressure
Clogging of the fins of the intercooler Clean
Clogging of the exhaust manifold (too much resistance) Clean
Negative pressure of the engine room Improve the ventilation
Abnormal Foulty air cooler
exhaust gas High
Fouling and clogging of the fins Clean
temperature intake air
High cooling water temperature Adjust
or, maximaum temperature
Insufficient cooling water quantity Adjust
combusion
pressure High intake air temperature Improve ventilation
High
High reading Excessively large fuel injection
Te & Pmax on pump
Incorrect adjustment of the injection pump rack Adjust
rack
Sticking of rack Effect maintenance/repair

Defective fuel injection valve

Faulty nozzle Effect maintenance/replacement
Improper valve opening pressure Adjust
High Te, Defective fuel injection pump Effect maintenance/replacement
low Pmax Sticking of rack

Some
Sticking of plunger
Faulty delivery/isobaric valve 7
cylinder Improper fuel injection timing Adjust within the rated value
are Insufficient compression pressure
abnormal Non-airtight piston rings Maintenance/replace
(Sticking, Wear, Damage)
Non-airtight intake/exhaust valve Maintenance/replace
Improper valve clearance (intake/exhaust) Adjust
Defective fuel injection valve
Faulty nozzle Maintenance/replace
Improper valve opening pressure Adjust
Low
Defective fuel oil injection pump Maintenance/replace
Te & Pmax
Sticking of rack
Sticking of plunger
Note: Always check that Faulty delivery/isobaric valve
thermameters are
not faulty and that Leakage from the fuel injection system Repair
the indicator valve
is not clogged.

DC-17A Z 08-10
CHAPTER
Troubleshooting and Countermeasures
7
ITEM

2.5 DC-17A Abnormal Exhaust Gas Color

7-2.5 Abnormal Exhaust Gas Color

[Phenomenon] [Trouble] [Countermeasures]
Engine not warmed up Warm up engine
Low cooling water temperature Increase water temperature
Excessive amount of lubricating oil drawn up to the top part of piston
䇭䇭Wear or sticking of piston
ring or oil ring Maintenance/Repair
䇭䇭Wear of cylinder liners Maintenance/Repair
Low air
supply Low room temperature Adjust cooling water
temperature Low cooling water temperature and quantity in air cooler
Blue or white
Defective fuel injection valve
䇭䇭Faulty nozzle Maintenance/Replacement
䇭䇭Improper opening pressure valve Adjustment

Defective fuel oil injection pump 䇭䇭 Maintenance/Replacement

䇭䇭䊶Sticking of rack
䊶Sticking of plunger
䇭䇭䊶Faulty delivery isobaric valve

Exhaust Degraded fuel oil

gas shows 䇭䇭Improper properties (ignitability) Use high quality fuel oil
abnormal 䇭䇭Water in fuel oil Separate and
eliminate water
Air in fuel oil Remove air
Insufficient compression pressure
䇭䇭Non-airtight piston ring Maintenance/Replacement
䇭䇭(slicking, wear, damage)
䇭䇭Non-airtight intake/exhaust valve Maintenance/Replacement
䇭䇭Improper valve end clearance Adjustment

Black or Low load operation for long hours

dark gray (fouled combustion chamber/ Increase load
exhaust system)
Fouled turbocharger
䇭䇭Clogged pre-filter Clean
䇭䇭Fouled blower side Clean
Fouled turbine side Clean

Faulty air cooler

Fouled/clogged fin Clean
䇭䇭Fouled/cooling water temperature Adjustment
䇭䇭Insufficient cooling water quantity Adjustment

High intake air temperature Improve ventilation

Negative pressure in engine room

Overload (torque-rich) Reduce load

DC-17A Z 08-10
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Abnormal Noise/Abnormal Vibration DC-17A 2.6

7-2.6 Abnormal Noise/Abnormal Vibration

[Phenomenon] [Trouble] [Countermeasures]

Knocking Abnormal combustion

䇭䇭Overcooling of engine Warm up engine
䇭䇭Defective fuel oil injection pump Maintenance/Repair
䇭䇭Faulty spraying by fuel oil injection nozzle Maintenance/Replacement
䇭䇭Improper fuel oil properties Use high-grade oil

Improper load conditions Change the load

䇭䇭䊶Sticking of rack properly

䊶Sticking of plunger
Turbocharger 䇭䇭䊶Faulty delivery/isobaric valve
surging
Abnormal Defective turbocharger
noise 䇭䇭Fouled blower side Clean
Fouled turbine side Clean
䇭䇭Deformed or damaged parts Replace
䇭䇭(diffuser, turbine nozzle, turbine rotor)

Fouled/clogged air cooler fin Clean

Engine
sounds Clogged (resistance: high) exhaust Clean
outlet (exhaust pipe)
Defective fuel oil injection pump 䇭䇭 Maintenance/Replacement
Loose mounting bolts Tighten bolts
Abnormal Loose bolts on holding moving parts Tighten bolts
vibration Excessively worn cylinder liners (seizing) Maintenance/Replacement
Excessive intake and exhaust valve end clearance Adjustment
Increase in gear backlash Adjustment/Repair

DC-17A Z 08-10
CHAPTER
Troubleshooting and Countermeasures
7
ITEM

2.7 DC-17A Engine Sudden Stop

7-2.7 Engine Sudden Stop

[Phenomenon] [Trouble] [Countermeasures]
Overload (torque-rich) ( :7-2.9)

Low lubricating oil pressure ( :7-2.10)

Protective
Abnormal cooling water temperature ( :7-2.13)
device activated
Defective control power system Repair
Defective fuel oil shutdown device Repair

Seizing of or damage to moving parts

䇭䇭Piston Repair
䇭䇭Crankshaft Repair
Turning is not
䇭䇭Timing gear Repair
smooth or
䇭䇭Camshaft Repair
impossible
Defective drive equipment Repair
Engine stops
䇭䇭Generator
suddenly 䇭䇭Others

Defective fuel oil supply system

䇭䇭No oil in oil tank Supply
Clogged fuel oil filter Clean
Defective fuel oil relief valve Repair
Defective supply pump Repair
䇭䇭Air in oil Remove air
䇭䇭Improper viscosity of fuel oil Adjust to proper
Normal turning (heavy fuel oil) temperature by heating
Defective fuel control system
䇭䇭Defective governor Maintenance/Repair
䇭䇭Control link is caught or shaky Maintenance/Repair

Defective fuel oil injection pump Maintenance/Replacement

䊶Sticking of rack
䊶Sticking of plunger
䊶Faulty delivery/isobaric valve

Defective fuel oil injection valve

䇭䇭Faulty nozzle Adjustment/Replacement
䇭䇭Improper opening pressure valve Adjustment

Leakage from fuel oil high-pressure block Repair/Replacement

DC-17A Z 08-10
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Unable to stop Engine / Overspeed DC-17A 2.8, 2.9

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

[Phenomenon] [Trouble] [Countermeasures]

Defective fuel oil control system
Defective governor Maintenance/Repair
Unable to
Control link is caught or shaky Maintenance/Repair
stop engine

Sticking of fuel oil injection pump rack 䇭䇭 Maintenance/

Replacement
Abnormal control power supply system Maintenance/Repair
Abnormal automatic control panel
Abnormal/broken electrical contacts for control
Overspeed Defective solenoid valve for control
Abnormal rotation preventive device
䊶Activation of
protective device
Defective fuel oil shutdown system
䇭䇭 Defective fuel shutdown device Maintenance/Repair
䇭䇭 Defective speed detector Maintenance/Repair
䇭䇭 Insufficient control air pressure Maintenance/Repair
.Clogged piping/filter
.Drop in pressure

DC-17A Z 08-10
CHAPTER
Troubleshooting and Countermeasures
7
ITEM
2.10,2.11 DC-17A Low Lubricating Oil Pressure

7-2.10 Low Lubricating Oil Pressure

[Phenomenon] [Trouble] [Countermeasures]
Low lubricating oil level in tank (below lower limit) Replenish

Improper oil viscosity Replace

Pressure does not
Clogged lubricating oil filter (pump suction side) Clean
reach the specified
Air sucked from inlet side Maintenance/
level during startup Replacement
ὉDamaged piping
ὉNon-airtight joint
Leak from or damage to oil piping (discharge side) Maintenance/Repair
Defective lubricating oil pump Maintenance/Repair
Low ὉSticking of safety valve
lubricating oil ὉBroken spring
ὉWear of pump gear
pressure ὉWear of bearings
Defective relief valve Maintenance/Repair
Damaged cooling water piping in lubricating oil cooler Repair
Clogged lubricating oil filter (pump discharge side) Clean
Wear of bearings Maintenance/Repair
Drop in High
pressure during lubricating oil ᾉ7-2.11
operation temperature

7-2.11 High Lubricating Oil Temperature

[Phenomenon] [Trouble] [Countermeasures]

Fouled lubricating oil cooler Clean

Defective lubricating oil Maintenance/Repair

thermostat valve
䊶Damaged pellet
䊶Sticking of valve

Insufficient cooling water quantity

䇭䇭Defective cooling water pump Maintenance/Repair
䇭䇭 (damaged/worn impeller)
High
lubricating oil 䇭䇭Clogged filter/cooling water piping Clean
temperature 䇭䇭Improperly regulated water quantity Adjustment

Overload Adjust load

Low airtight cylinders Maintenance/Repair
䊶Wear and sticking of piston ring
䊶Wear of cylinder liners

Seizing of bearings Maintenance/Repair

DC-17A Z 08-10
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
Low Cooling Water Pressure (Jacket Line)/High Cooling Water
Temperature DC-17A 2.12,13,14

7-2.12 Low Cooling Water Pressure (Jacket Line)

[Phenomenon]
Large temperature
difference between
inlet and outlet
Low cooling
water
pressure Small temperature
difference between
inlet and outlet
Low cooling water
pressure on low
temperature side
[Trouble] [Countermeasures]
Insufficient cooling water quantity
Defective cooling water pump (damaged/worn impeller) Maintenance/Repair
䇭䇭Contaminated air cooler Clean
䇭䇭Clogged piping Clean
䇭䇭Improperly regulated water quantity Adjustment
Defective cooling water thermostat valve Maintenance/Repair
䇭䇭Defective cooling water stop valve (seizing) Maintenance/Repair
Air in cooling water system Remove air
Excessively large cooling water quantity Remove air
䇭䇭Improperly regulated water quantity Adjustment
Defective cooling water thermostat valve Maintenance/Repair
Contaminated cooler on low-temperature line Clean / Maintenance
Insufficient amount of water in head tank Inspection/Supply

7-2.13 High Cooling Water Temperature (Jacket Line)

[Phenomenon] [Trouble] [Countermeasures]
Air in cooling water system Remove air
High cooling water temperature in cooler system Adjustment
Insufficient cooling water quantity
䇭䇭Defective cooling water pump Maintenance / Repair
䇭䇭(damaged/worn impeller)
High High at cylinder 䇭䇭Clogged filter/cooling water piping Clean
cooling collective outlet / 䇭䇭Improperly regulated water quantity Adjustment
water
High some cylinders
temperature Defective cooling water temperature control valve Maintenance / Repair
Overload (excessive torque) Adjust load
Overheating of cylinder
䇭䇭Clogged cooling water channel
7
Clean
䇭䇭Seizing of piston and cylinder liners Repair

High exhaust
䋨 䇭䇭䇭 䋺7-2.4䋩
temperature

7-2.14 Low Cooling Water Temperature (Jacket Line)

[Phenomenon] [Trouble] [Countermeasures]
Excessive flow rate of warming-up water to standby engine Adjust the flow rate of warming
Low cooling (particularly under low load) -up water to standby engine
Jacket temperature
water Defective cooling water temperature control valve Maintenance/ replace
does not rise
temperature Low cooling water temperature on low temperature side Adjustment

DC-17A Z 08-10