Environmentally Friendly Engines Compliant withIMO Secondary Regulations

Technology of
DAIHATSU
DE series Engine
6DE-18 / 6DE-23 / 6DEM-23

Environmentally Friendly Engines

We have successfully developed an environmentally friendly engine with highpotential for meeting future emission regulations that are expected to become
increasingly strict, such as those targeting the reduction of CO2 emissions.
We have complied with the IMO emission standards by adding advanced
combustion technology to the engine.

D-Power
for the Earth
6DE-18 / 6DE-23

Environmentally Friendly Engines Compliant withIMO Secondary Regulations

hContents
1 External View Photo of the Engine

1

2 Output Range and Principal Particulars

2

3 Engine Cross Sectional View: 6DE-18

3

4 Engine Cross Sectional View: 6DE-23

4

5 Comparison of the Outside Dimensions

with Conventional Models

5

6 External View (Equipment Layout)

6

7 Development Concept and Scheme

77-1 Earth-Friendly Environmental Harmony

8〜11

●
●

●

Decreasing Exhaust Gas Emissions
Reduction and Management ofHazardous Materials
Low Vibration and Low Noise

7-2 Enhancement in Durability andReliability for the Long Life

12〜16

●

Reduction of Operation Costs●

Stable and Certain Engine Start●

Securing the Lub.Oil Performance in the Long Life●

Maintenance Intervals and Life Expectancy

7-3 Improvement in Safety and Assurance

17〜19

●

Perfect Fire Prevention Measures●

Simplified Connection Points for Easier Installation●

Engine Controller with Easy Handling

8 Structure of Main Parts

20

8-1 Frame and Main Bearing

21

8-2 Crankshaft

22

8-3 Cylinder Liner

23

8-4 Piston and Connecting Rod

24

8-5 Cylinder Head

25

8-6 Intake Air and Exhaust System

26

8-7 Fuel Injection System

27

8-8 Lubricating Oil Module28

1External View Photo of the Engine

6DE-186DE-23 / 6DEM23■ Marine Gensets Diesel Engine

1■ Marine Propulsion Diesel Engine

DE series

2

Output Range and Principal Particulars

Output Range■ Lineup: Marine Gensets Diesel Engine■ Lineup: Marine Propulsion Diesel Engine
MarinePropulsion
DieselEnginePrincipal Particulars
Engine Model
Cylinder Diameter
StrokeNo. of Cylinders
Engine Revolutions
Engine Output
Generator Output

Brake Mean Effective Pressure

Average Piston Speed
Combustion Pressure
Starting Method
Turbocharging System
Overall Length※1
Overall Width※2
Overall Height※3
Piston Overhaul Height※4
Generator Set Dry Mass※5

Marine Gensets Diesel Engine

mm
mm
min-1
kWm
kWe
MPa
m/s
MPa

mm
mm
mm
mm
kg

6DE-18
185
280
6
720
400〜680360〜635
1.5〜2.5
6.72

900
440〜850400〜808
1.3〜2.5
8.4

Max.20Compressed Air Start
Dynamic Pressure
4,850
1,070
2,400
2,300
12,0006DE-23
230
320
6

720
800〜1,200
760〜1,140
1.7〜2.5
7.68

900
1,040〜1,500
988〜1,425
1.7〜2.5
9.6

Max.20Compressed Air Start
Dynamic Pressure
6,100
1,110
2,840
2,860
23,000Marine Propulsion Diesel Engine
6DEM-23
230
320
6

750
950〜1,200

900
1,200〜1,500

1.8〜2.48

2.0〜2.5
9.6

Max.20Compressed Air Start
Dynamic Pressure
3,160
1,050
1,870
1,710
14,000※1 Varies depending on the generator. Main engine specification dimensions extend from the crankshaft end.
※2 The maximum width of the common baseplate mounting surface. Main engine speciﬁcations indicate the maximum width of the engine mount.
※3 The height of the exhaust port from the common baseplate mounting surface. Main engine speciﬁcations indicate the height from the center of the crankshaft.
※４ The height from the common baseplate mounting surface. Main engine speciﬁcations indicate the height from the center of the crankshaft.
※５ Varies depending on the generator. Main engine speciﬁcations indicate only the engine body.

2

3

6DE-18：Engine Cross Sectional View

Exhaust pipe●●

With a fire prevention
type cover
Dynamic pressure
exhaust pipe

Cylinder head●●●

Intake andexhaust valves●●

Heat resisting steel typewith a valve rotator
Exhaust valve seat ring:
Water-cooling type

Piston●●●Composite type
Crown: Alloyed steel
Skirt: Ductile cast iron
Chrome plated ringgroovesThree compression
rings and one oil ring

Automatic
backwash filter●

Nominal: 30 μm

Connecting rod●●

Marine type
Crankpin bolt:
Hydraulically tightenedEngine frame●●

Monoblock structureof high stiffness
Main bearing bolt,
side bolt:
Hydraulically tightened

Fuel injection
device●●3

Corrosion and wear
resistance: Aluminumalloy metal

Block type high pressure
pipes

Fuel injection
pump
●

●
●

High-pressure injection
type, optimized injection
Anti-cavitation
Plungers for low sulfur fuel

Fuel nozzle●

Uncooled nozzle

Cylinder liner●●

Thick wall high stiffness
performance
Wear resistance special
cast ironCamshaft●

Large diameter two-split
unit camshaft

Crankshaft●

Main metal,
crankpin metal

Stiffness enhancement
by a thick wall structure
Combustion face coolingby a bore cooling method
Hydraulically tightened
four studs●●

High stiffness
performance: Large
diameter pins, journals
Die forged material
Securing sufficient oilfilm thickness, reducing
oil film pressureDE series

4

6DE-23：Engine Cross Sectional View

Cylinder head

The heat-resistant highstrength special cast iron
The double shelf structureof high stiffness
Cooling enhancement
around the exhaust valve
seat by effective coolingwater passage
Hydraulically tightened
four studs

Intake andexhaust valves

Exhaust pipe

Fuel injection
device

●

●

●

●

●

●

●

Excellent loadcorrespondence enabledby the pulse turbo
charging method
Optimized matching with
the intake/exhaust timing
The passage shapemaximizing theturbocharger efficiency●●

Fuel nozzle
●

●

●

●
●

Bore cooling type:
Effective cooling
The special cast iron
excellent in wear resistanceWith the protect ring
Optimized cooling area

Automatic
backwash filter●

Enhancement of thefiltering performanceand simplified
maintenance work

Engine frame
●

●

●

●

Monoblock structure ofhigh stiffness
The main bearing bolts
and side bolts tightenedwith oil pressure
Good accessibility for
inspection andmaintenanceIntegration of the passages
for the cooling water, airintake, and lubrication oil

Main metal,
crankpin metal●

Special aluminum alloy
metal excellent in wear
resistance performance,
corrosion resistance
performance, and load
capacity performance

Uncooled nozzle

Block type high pressure
pipes

Fuel injection pump●●

Cylinder liner●With a valve rotator
Exhaust valve seat ring:
Water-cooling typeHigh-pressure injection
type, optimized injection
Plungers for low sulfur
fuel

Fuel system●

Main pipe with damper

Piston●●●Composite type
Crown: Alloyed steel
Skirt: Ductile cast iron
Hardened top andsecond ring grooves
Three compression
piston rings and one
oil ring

Camshaft●●

The large diameter unit
camshaft of a two-cylinder
integrated typeThe valve drive mechanismof a simple swing arm type

Connecting rod●●

Marine typeHydraulically tightened
big end bolts

Crankshaft●●●

CGF RR forging
Optimized shape by
FEM analysis
Optimized shaft diameterto secure bearing oil film
thickness, reducing oil
film pressure

45Comparison of the Outside Dimensions
with Conventional Models

6DE-18■ Comparison of the Outside Dimensions with Conventional Models (5DK-20)
Blue：6DE-18 Red：5DK-20e

Weight6DE-1812.0 t

5DK-20e 13.5 t

6DE-23■ Comparison of the Outside Dimensions with Conventional Models (8DK-20)
Blue：6DE-23 Red：8DK-20e

Weight56DE-2325 t

8DK-20e

22 t

DE series

6

External View (Equipment Layout)

High Pressure Ratio,
High Efficiency
Turbocharger

C.W.Thermostat
Governor

Air Cooler(High temp. side)

C.W.Pump(High temp.)
Fuel Feed Pump
Fuel Filter(with Splash Prevention Cover )Wiring Rail

Condition Display

Air Cooler(Low temp. side)

Junction Box
Lub.Oil Pressure
Regulator

Intake Air
Heating Switch
Valve
C.W. Pump(Low temp.)

Lub.Oil Auto
Backwash Filter
Lub.Oil Cooler
Crankcase Safety Valve with
Flame Arrestor

Lub.Oil Pump
Lub.Oil Bypass Filter
Lub.Oil Priming Pump

6

Development Concept and Scheme

7■ Concept

12■ Scheme

1. Earth-Friendly
Environmental Harmony

Decreasing Exhaust Gas Emissions
Conformity with IMO NOx regulations
Tier 2 and Tier 3● Compatibility to low sulfur fuel oil● Reduction of CO2 emissions with low fuelconsumption and smokeless●

Reduction and Management ofHazardous Materials

Compliance with the “Ship Recycling Convention”● Reduction of the hazardous materials
within the scope

3

2. Enhancement in Durability andReliability for the Long Life
Reduction of Navigation Costs

Enhancing the reliability and the durability ofparts and securing the longevity● Achieving the low lubricating oil consumption
and the fuel consumption● Simple maintenance finished in a short time●

Stable and Certain Engine Start●●

3. Improvement in Safety
and Assurance

Adoption of the compressed air start system,
not influenced by air quality

Securing the Lub.Oil Performance in theLong Life●

Adoption of a large centrifugal filter andan automatic backwash filter

Perfect Fire Prevention Measures●●

Perfect protection of high temperature parts
Perfect splash prevention of fuel oil and lubricating oil

Simplified Connection Points for Easier Installation●●

Converged arrangement of external connection points at the front-end part
Simplification in workability by unitization

Engine Controller with Easy Handling●●

7

Integration of engine ignition, start, stop, and protection devices and installation on the engine
Simplification of communications by the sea-land communication system

DE series

7-1

Earth-Friendly Environmental Harmony

Decreasing Exhaust Gas Emissions■ Environmental consciousness

Technology for the conformity with IMO NOx regulations Tier 2

Reduction by 15- 22%

Reduction by 80% (Emission Control Area (ECA))

Combustion
technology
for the conformity
with IMO NOx
regulations Tier 2

Optimized fuel injection timing● High-pressure fuel injection● Specifications for the optimized combustion chamber configurationand fuel nozzle spray holes● Optimized valve timing with consideration to the start performanceand the transient response characteristics● Optimized matching of the high pressure ratio andthe high efficiency turbocharger●

NOx Emission Compliance Concept
主要目
Optimized
Compression Ratio
SafetyReliability● Durability
●
●

With

Retarded Injection
TimingOptimized Valve
TimingOptimized T/C
Matching

NOx Emission
Compliance Concept

Optimized Piston Bowl
and Injection Nozzle
Geometry

CFD Combustion Calculation

8

7

Development Concept and Scheme

7-1

Earth-Friendly Environmental Harmony

Decreasing Exhaust Gas Emissions■ Compatibility to low sulfur fuel oil
Countermeasures forlow viscosity
Carbon coated plunger● Plunger oiling● Addition of lubricity improvers● Fuel feed pump for low
viscosity● Engine inlet viscosity:
2 mm2 /s or higher●

1. Adoption of the carbon coated plunger●

Improvement in the slide performance and the wear resistance

Structure of coating

Affinity layer

・Reduced wear forcontacting material

Functionallayer

・Low friction
・Reduced wear

Intermediate
layer

・Superb load bearing
characteristic

Base material

・Improved fatigue limit

Results of durability tests
under practical conditions
A small amountof accumulationof unmoisturizedfuel on a collar
part

Used for 2,000 hours

2. Adoption of plunger
oiling●Able to enhance the sealing
performance and the lubricity

Used for 5,000 hours

Drain

No damage inthe sliding part;the coating film
pressure and theadhesivenessalmost as goodas new

LO

3 . Adoption of lubricity improvers●

An example of the addition rate of theadditives and a high-frequency
reciprocating rig (HFRR)

4. Wear protection measures for thefuel feed pump●

Kinematic
viscosity

Additive concentration (ppm)

9

Kinematic viscosity

Limitation recommended
by the manufacturer

Special treatment is applied to both of the innerrotor and the outer rotor to prevent abnormal
abrasion of the diesel oil pump.

5. A plan (option) includes a fuel cooler(cooler or chiller).
Securing the viscosity at the inlet tothe engine

DE series■ Low fuel consumption and smokeless for the reduction of CO2 emissions
Low fuel consumption●●●

Diesel engine

High Pmax
High-pressure fuel injection
pumpHigh efficiency, high-pressure
ratio turbocharger●

Combustion system matching●

Reduction of mechanical loss

Smokeless●●

Optimized fuel control at transient response by an electronic governor
Improvement in turbocharger response by pulse turbo charging

Reduction and Management of Hazardous Materials
Existing vessels

Newly built vessels

16th May 2009

2 years
Adopting thetreaty(Hong Kong)

Satisfying therequirements
to make thetreaty effective

The treaty
effective

5 years
The time limit to make theinventory of the vessels in operation

Shipyards issue the inventories of newly built vessels

1. Compliance with the “Ship Recycling Convention”
2. Reduction of designated hazardous materials
10

7

Development Concept and Scheme

7-1

Earth-Friendly Environmental Harmony

ResultLow
Frequencyof vibration
andmeasurements
Low Noise■ Result of vibration measurements
6DE-23 VIBRATION MEASUREMENT
900/min x 1500kWm
11.7
17.6
12.2

X

Axis

Y

Horizontal

Z

Vertical

Unit : mm/sec.
RMS 200Hz

6.4
10.7
6.2

4.6
4.6
3.6

2.6

2.5

4.6

8.1

6.0

4.4

4.4

9.0

JIS F0906

1.6

2.7

4.2

6.7

ISO TC108 CLASS 28mm/s■ Result of noise measurements
6DE-23 SOUND LEVEL
900/min x 1500kWm Distance：1m
１０１ｄＢ
（Ａ）

１０１ｄＢ
（Ａ）

１０３ｄＢ
（Ａ）

11

30mm/s

DE series

7-2

Enhancement in durability and reliability
for the long life

Reduction of Operation Costs■ Cooling enhancement of the high stiffness cylinder head

The stiffness of the cylinder head is increased, and an
effective cool down is achieved to mitigate heat load,
too. The cool down is augmented around the fuel valvesin particular.

Cylinder head cooling water model

Result of computational fluid
dynamics analysis of the cylinder
head cooling water■ Adoption of valve stem oil seals with a backpressure lip
The stem oil seal with the double lip and the backpressure lip is adopted for theintake and exhaust valve stems, which intensifies the gas seal performance.
The proper lub.oil control enhances durability.
Double lip
Backpressure lip

127Development Concept and Scheme

7-2

Enhancement in durability and reliability
for the long life

Reduction of Operation Costs■ High stiffness crankshaft

Optimal shape for stress reduction● Continuous grain flow forging of the low alloy steel● Large shaft diameter to secure bearing oil films●■ Horizontal three split connecting rod (Marine type)Stress reduction in the crankpin bolt thread under
the combustion load
● Stress reduction in the serration● Reduction of the piston overhaul height● No need to disassemble the big end part to remove the piston●13

DE series■ Piston

The two-split structure is adopted for the piston, which comprises the alloyed steel crown
and the ductile iron body.
An effective cooling is achieved to mitigate the heat load brought by the combustion
pressure of 20 MPa.

Protect ring

Chrome plated ring grooves

Enhancement of the wear
resistance performance
Piston rings

Enhancement of the wear
resistance performance■ Achievement of low fuel consumption proper lubricating oil consumption
Low lubricating oil consumption
Reduction and stabilization of lubricating oil consumption

Low fuel consumption

High Pmax
High-pressure fuel injection pump
● High efficiency, high-pressure
ratio turbocharger● Combustion system matching● Reduction of mechanical loss●●

Protect ring14

7

Development Concept and Scheme

7-2

Enhancement in durability and reliability
for the long life

Reduction of Operation Costs■ Simple maintenance finished in a short time

Cylinder head

Main bearing

Connecting rod

Stable and Certain Engine Start
The direct air injection system is adopted, which is not influenced
by air quality.

Pilot airStarting air main pipe15

DE series

Securing the Lub.Oil Performance in the Long Life
■ Large centrifugal filter■ 30μm automatic backwash filter

Maintenance Intervals and Life Expectancy■ Maintenance intervals
0Fuel nozzle
Cylinder liner
Intake valve
Exhaust valve
PistonCrankpin metal
Main metal

5,000

15,00020,000Time

12,00012,00012,00012,00012,00016,000■ Life expectancy
0

Fuel nozzle
Exhaust valve
Crankpin metal
Main metal
Intake valve
Cylinder liner
Piston10,0002,000

10,00020,00030,00040,00050,00060,000Time

8,000
24,00024,00032,00036,00060,00060,000167Development Concept and Scheme

7-3

Improvement in safety and assurance

Perfect Fire Prevention Measures
Sealed structure
exhaust pipe cover

Crankcase safety valve
with a flame arrestor

Application of thesplash prevention
tape on thefuel/lubricating oil joint

Indicator/safety valve
heat insulation coverHeat box cover

Fuel filter(With a splash
prevention cover)17

DE series

Simplified Connection Points for Easier Installation■ Converged arrangement of external connection

points at the front-end part
Exhaust gas outlet

Turbocharger

Crankcase vent

Starting air inlet
Cooling water pump
(Low temp.)

Lubricating oil pump

Cooling water pump(High temp.)

Fuel transfer pump

Fuel inlet/outlet
Cooling water
inlet/outlet
Lubricating oil inlet/outlet

18

7

Development Concept and Scheme
Improvement in safety and assurance

7-3

Engine Controller with Easy Handling
Integration of engine start, stop, and protection devices andMerit1 installation on the engine

The newest safety/control functions are implemented.
● The engine state data (events) at the ignition, start, and stop are automatically collected,
which enables efficient investigations for maintenance and troubleshooting.
● The easy operability and appropriate interlock circuit prevent incorrect operation
to run the engine.
●

Liquid crystal
gauge board
Engine side
operation panel
PC
Engine controller
Wirelessportable terminal

Merit2 Simplification of communications by the sea-land communication system
Sea going vessel
Junction box
controller

Inmarsatsatellite

Wiring rail

Information device
such as PC

LAN in the vessel

Priming pump board

A new engine and engine controller of Daihatsu

Sea-landtelecommunications
equipment

Monitoring system of land19

DE series

8

Structure of Main Parts

DE-type diesel engine incorporates the tried and tested
technology of the DK-type engine, of which over 6,000
engines have been delivered. This technology has beenfurther complemented by new technologies through ourdevelopment for the purpose to adequately handle future
global environmental issues.
At the phase of designing, we made use of all-out
computer analysis including CAD, CAE, CFD, andperformance simulation. For the reliability and durability, weused testing machines for sufficient prototype endurance
tests. We verified that neither fault nor problem was found.
Each component is produced in the method with many
types of jigs, tools, and special facilities under strict quality
control, which provides excellent precision. Moreover, thematerials are particularly screened to have logicalcorrectness for the function of each part and to have
durability, too.
Furthermore, major components are under strict inspection
throughout all the processes from material selection,
treatment processes, and assembly processes.

20

8Structure of Main Parts

8-1

Frame and Main Bearing

The frame has a monoblock structure made of cast iron. Each of the flow
paths is formed integrally with the frame, which includes the air intake
path, the lubricating oil path, and the cooling water inlet.
Since the hanging metal method is adopted, the main bearing is firmly
mounted by the mounting bolts and the side bolts tightened with hydraulicjack. Thus, the rigidity around the main bearing is enhanced.

21

DE series

8-2

Crankshaft

The crankshaft is integrally forged from alloyed steel. The crankpin
diameter and the journal diameter are so large that adequate bearing
surface pressure and sufficient oil film thickness are generated.
Moreover, the combination with the large-capacity balance weight adjusts
the rotation balance to suppress vibration. There is a flywheel on the rearend (on the output side) of the crankshaft and a camshaft drive crank gearon the front end together with the drive gears for the pumps and therelevant components.
The main bearing and the crankpin bearing are made of thin-wall aluminumalloy metal split into two. There are thrust bearings mounted at the front
and the rear of Bearing 1 on the rear side of the engine.

22

8

主要部構造

8-3

シリンダライナ

6DE-18シリンダライナは特殊鋳鉄製で、フレーム水室から導かれた高温冷却水がフレームとライナとで形成される水室を下から上方向へと流れ、ライナを効果的に冷却し、その後シリンダヘッドの水室に入ります。

効果的な
冷却

6DE-23シリンダライナは厚肉ボアクーリングタイプを採用しております。
高温冷却水は架構の冷却水通路からシリンダライナのボアクーリング孔へ導かれ
ライナ上部を効果的に冷却した後、シリンダヘッド下部水室へ入ります。
右下の図はシリンダライナの冷却水流れ解析です。冷却水がライナのボアクーリング
穴に均一に分配される様子を示しています。

23

DE series

8-4

ピストン・連接棒

ピストンは長い経験から蓄積された技術を生かしたダクタイル鋳鉄製のスカー
ト、合金鋼製のクラウンの組立ピストンを採用しています。
リング溝は表面硬化処理を行い、耐摩耗性を高めています。
ピストンの冷却は連接棒からピストンピンを経由した潤滑油により効率よく強制冷却されています。
連接棒は型鍛造品で、大端部は水平３分割としています。これによりクランク
ピン径を充分に太くすることが可能となり、クランクの剛性を高めることができます。また、クランクピン軸受部を分解せずにピストン開放が可能で、分解、組立が容易になるとともに、ピストン抜き取り高さを低く抑えることができます。

24

8

Structure of Main Parts

8-5

Cylinder Head

The cylinder head is made of special cast iron, which has excellent heat
resistance performance. This cylinder head is fastened with four bolts as isin numerous proven examples of Daihatsu diesel engines; its disassembly
and assembly are very easy. With the structure with high rigidity and withthe four bolts tightened with hydraulic jack, the structure is reliable enoughto resist the combustion pressure.
There are four valves, two intake valves and two exhaust valves, with avalve rotator attached. The drive force comes from the camshaft by way ofthe swing arm, the pushrod, and the valve arm. The exhaust valve has awater-cooled valve seat directly attached on the cylinder head.
The fuel injection valve and the relevant components are cooled by the
special passages that particularly enhance the cooling effect. This makes it
possible to make use of the uncooled fuel nozzle even during the operation
with low quality fuel.
As pipes are not arranged on or around the cylinder head, the easiness inhandling the cylinder head is greatly improved.

25

DE series

8-6

Intake Air and Exhaust System

The turbocharger includes an radial turbine with high efficiency andhigh-pressure ratio, which is not cooled but forcibly lubricated as
standard.
Each of the turbocharger and the air cooler is independently fixed on
the gear case in this structure in consideration of maintenanceworkability.
A pulse turbocharging method is adopted for the exhaust pipe, which
enhances the turbocharging efficiency and is excellent in the transient
response characteristics. The exhaust pipe is arranged on the sameside as the air intake duct integrated with the frame, improving theeasiness in handling.
6DE-186DE-2326

8Structure of Main Parts

8-7

Fuel Injection System

The fuel injection pump is a high-pressure pump of the bosch type with an
integrated built-in tappet, in which a closed type plunger barrel and acarbon-coated plunger are adopted as standard.
The joint of the fuel injection valve at the high-pressure oil intake is side
mounted and linked with the fuel injection pump by way of a forged highpressure joint. This structure provides the high reliability in respect to thehigh injection pressure and the excellent easiness in handling at the sametime.
The fuel injection valve, which is uncooled type, has been processed by
the heat treatment that enables excellent heat resistance.

27

DE series

8-8

Lubricating Oil Module

The equipment related to the lubrication system is converged andarranged on a side surface on the exhaust pipe side.
The lubricating oil cooler, the thermostat, the pressure regulator andthe automatic backwash filter are connected by the block unit. This
module is brought by the consideration to accessibility andworkability.
To effectively remove foreign substances and foreign particles, alarge-capacity centrifugal filter is equipped in the front part of anengine side as standard.
Lubricating oil pressure
regulator
Automatic backwash
filterLubricating oil thermostat
Lubricating oilcoolerLubricating oil
pump

Centrifugal
filter28

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Tokyo OfficeMoriyama Division

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