CHAPT,ER

2 General Construction
Operation Control, Protective Device :
3.1 DK.2() rControl

2-3 Engine Operation Control and Protective Device

Control and protective devices such as the starting air valve and stoppage cylinder
are activated by low-pressure control air.l
This section describes a system generally used for the power station that is remotely
controlled for starting and stopping. The engine that is actually delivered may 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 Starting Control

(1) For Generator (Bemote control) d) When the engine reaches the specified
a) ln case of starting the engine by remote rotation speed, the low-speed relay (14) is
control, the control lever must always be set to activated, canceling the start command and
'RUN' position. The handle switch (HS) will be resetting the protective circuit, so that the
turned "ON" at this state, and if the turning engine is set to operating state.
I safety switch (TC) is also turned "ON", the
engine will be on standby and ready lor (2) Automatic Starting
operation. When the engine is started automatically, the
b) ln case of directly starting the engine, lhe engine solenoid is activated in response to the
starting solenoid (88V) is powered, excited, starl command issued automatically in the
and activated by a start command, so that specified sequence, so that the control air llows
control air flows into the starting air valve via into the starting air valve and the engine starts its
starting operation valve, and the starting air rotation.
reaches the starting valve as the main valve is Further, in case of air motor starting system, the
opened. solenoid valve of the starter relief valve is
Furlher, in case ol air motor starting system, activated by a sta rt co m ma n d, an d
the solenoid valve of the starter relief valve is decompressed air llows into the air motor, so that
activated by a start command, and the the engine starts its rotation.
decompressed air reaches the air motor lo
push the pinion gear. (3) Engine Side Starting (Localstarting)
When the pinion gear is engaged with the ln case of starting the engine from the engine
wheel gear, the main air circuit ol the air motor side (locally), the operation mode must be set to
will be opened. 'LOCAL' position, and in case of direct starting
c) Meanwhile, the same stad command allows system, if the push button ol the starting
the f uel control solenoid (88L) to activate, operation valve is pressed, control air flows into
causing control air to flow into {uel regulating the starting air valve, and starting air flows into
cylinder, and allows the common rod to be held the cylinder. n
in position, so that tne fuel injection amount is Further, in case ol air motor startlng system, if
controlled not tc be excessive at the time of the push button of the slarling operation valve is
starting. pressed, the main circuit of the starter relie{ vaive
is opened and the decompressed starting a I
flows into the air molor.

DK-20 Z 99-8 DAIHATSU

 CHAPTER
General Construction
2
Elgile Operation Control, Protective Device :
DK.2O
Starting Control 3.1

Governor molor Governor Pulse sensor

Tuming bar Starting operation valve
A a,
I'l- loz 5*l
.Starting air valve Speed swilch
lFrom L.o. pipins ffil (12,13,14)

H
Turning safety
switch
Explosion plate

Starting air iL
Stoppage cylinder Controlcylinder
rod
To meter
(4-20mA)

rotary valve l6
io Fuel shutdown
+
+ +c
+ HE
+6
)!
7\
ll
Fuel injection pump
t,
Air tank'- -' Stoppage cylinder

To fuel injection pump of

each cylinder

Control air
0.8t 1Pa Handle swilch (HS)
lalglcmzl

Fuet shutdown Fue[ shutdown

Slarting solenoid Fuel control solenoid
solenoid (5V) solenoid (5S)
(88v) (881)

Starting and Stoppage System (Direct starting type)

Turning bar _t Governor motor Governor

\ LJ EI
T
Juil )From L.O. piping Speed switch
'y1htr (12, 13, 14)
l*
Turning safety Starling solenoid (88V) To meler
, switch Starler reliel valve (with regulator)
(a-20mA)
Stbppage cylinder
rod

Fuel shutdown device

Fuel in.iection pump

Startini push
button
Stoppage cylinder

rst arting operalion valve

I
I
START
l= To luel injection pump ol
STOP
ro each cylinder
JC
FYE
$6(t)
t
)-
Flywheet
\/
rl
-
Air lank- -
Conlrol air
Fuel shutdown Fuelcontrol Fuel shutdown
0.8MPa
solenoid solenoid solenoid
(sv) (881) (ss)
iSkg/cm2l

ing and Stoppage System (Air motor starting type)

DAIHATSU DK-20 Z 99-8

r
CHAPTER

2 Operation
Engine Operation Control, Protective Device :
3.1 DK-20 Startinq Control

(4) For marine propulsion engine

a) Engine Side Starting (Local starting) b) Remote Starting (Starting from the bridge)
i ) ln case of starting the engine from the i ) When the engine is to be started remotely
engine side (locally), the changeover valve on (starting from the bridge), set the control
the engine must be set to the local side, and handle of the bridge to "NEUTRAL" position,
the control lever must be changed to and set lhe operating lever to "RUN" position.
'START' position lrom "STOP" position. At Then, the handle switch (HS) will be turned
this state, the handle switch (HS) will be "ON", and the turning salety switch (TC) will
turned to "ON", and the protective circuit will also be turned to "ON", so that the engine is
be released. on standby position for starting.
ii ) When the push button ol the starting ii ) The starting solenoid (88V) is powered,
operating valve is pressed, control air flows excited, and activated by a start command,
into the starting valve, and starting air (high
pressure) llows into the starting valve as the
and control air flows into the starting valve via
starting operalion valve, so that the main
a
main valve ol the starting air valve is opened. valve is opened, and starting air flows into the
iii) When the engine reaches the specified starting valve.
rotalion speed, the low-speed relay (1a) is
activated, so that the start command is
canceled and the protective circuit is reset,
allowing the engine to be at starting state.
iv) When the idle rotation speed becomes
stable, turn the operating lever to 'RUN'
position from "START" position.

Starling oPeration valve

A SS
U o' startino air valve r+
lFrom L.o. pipins ffil
Explosion plate

Fuel shutdown
and conlrol device
I
Fuel iniection pump
Fuel inieition pump

Stoppage cylinder

Governor boost
solenoid (GVB)
To luel inlection pump
ol each cvlinder
Conlrol air
0.8MPa
iSkg/cm2l +{ _l
Fuel shutdown
Handle switch (HS)

Fuel shuldown solenoid (5S)

Governor boost air solenoid (5V)
Governor air (lrcm control handle)
0.1-0.4MPa 'r -akgcm2l

Starting and Stoppage System (Marine propulsion engine side)

DK-20 Z 99-8 TSU

 CHAPTER
General Construction 2
ITEM
Engine Control, Protective Device :
Stoppaqe/Enqihe Protective Device DK.2O 3,2.3.3

2-3.2 Stoppage Control 2-3.3 Engine Protection SYstem

(1) As lor the errors that may be led to serious
The fuel shutdown solenoid (5V) is activated by a accidents or failures, alarm is issued and
stoppage command, causing control air to llow emergency stop is made.
into the fuel shutdown device, so that the Each abnormal operalion data or value is
common rod is turned toward stoppage direction, detected by a switch or sensor, and the fuel
and then the engine is stopped. shutdown solenoid is activated by an emergency
ln case of stopping the engine from the engine stoppage command, so that the engine is
side (locally), turn the operating lever to "STOP" immediately stopped.
position. (2) Depending the specifications, the dual safety
Note that the fuel control cylinder above system will be provided. ln such a case, in
-described is the monolithic type assembled with addition to the normal engine stoppage, control
the luel shutdown device. air is f lowed into the stoppage air cylinder
attached to the fuel injection pump to stop the
(21For Marine propulsion engine engine.
The luel shutdown solenoid (5S) is activated by a (3) When the forward clutch of the reduction gear is
stoppage command, causing control air to llcvr engaged, the governor boost solenoid is
into the stoppage cylinder, so that the rack of tne activated by movement of the control handle,
fuel injection pump is moved loward the stoppage causing the governor air boost to reach the
direction, and then the engine is stopped. governor, so that the reduction of the engine
rolation speed is prevenled.
Furtfrer, the engine rotation speed is controlled by
go\rerrxlr air via govemor, and at the same time
the gonemor air rerches the FO control cylinder
to oontrol ttle rctatbn speed ol the common rod,
so that the excessive supply of fuel lnjection is
restrained- (for the specilications of the marine
propr*$ffr engine)

Table 2.3-1 Alarm and Stoppage lterns (Eramples)

Detection item Alarm Qn'.--,- --)' Remarks

Overspeed
Decrease ol lubricating
oil pressure
x63Q1 a:-a : - = c-

lncrease of fresh cooling TB4:Combined use

water temperalure
I'TB4 Za,',Z i-:-::-t;et for issuing command
Decrease of turbocharger
lubricating oil pressure 63QT :-::::atger inlet
lncrease ol exhaust
>.iTB3 Combined..l:se lor
temperature
i:3 rs;n1.1
issuinq command
lncrease of exhaust --'::charger.inlet Combined use for
temperature
:r rD :r', outlet) issuinq command
Oil leakage fronr higir-pressure Tan< ie',,e1 of leaked or
fuel oil pipe coupling )i'33F
rvaste oil
Decrease of lubricating
oil level
)i,336 r E'cl^e iubricating oiltank
X Marked : Option

DAIHATSU DK-20 Z 99-8

 CHAPTER
General Construction
2
Engine Control, Protective Device :
3.3 DK-20 Protective Device

Oil leakage lrom

Ii: / /
. Speed sensor (TS)

\t
I
1-*-1 aSpeed switch
unitttz'rs'r+r
!i9!:!letsul:lYel
oil prpe couPilng
Leverswirch
,arEr
r-- Levet swirch (33Q)

(
t:@ )j=l
Fuel oil leakage
(Resistance bulb)

OContact ol each switch indicates

C : Controlpanel C the slate during operation.

lfr,xffill
I L.J]

Engine Protection System (Example)

DK-20 Z 9e-8 DAIHATSU

 CHAPTER
Engine Adjustment Standards 3
ITEM
Valve Setting Values DK.2O 2

3-2 Valve Setting Values

Adjustment value Remarks

Item
(design value)

8D
(so'1
6D
Opening start angle
(before top dead center)
5D (so'1
o
(6
3D (so";
vo (6

t C
Closing end angle
(after bottom dead center)
(es';
w
$:i
w.
ru

Valve end clearance "C" 0.31mm w,

B.{
(Valve end clearance s{
adjusting procedure)
Opening start angle
(before bottom dead center) (ss'1 (1) Valve end clearance data
represents the clearance available
o when the engine is cold.
(! (2)Adjust valve end clearance "A"
and "B" shown above such that it
o becomes equal to "0" first. Then,
(=!
-c Closing end angle (so'I adjust valve end clearance "C"
x (after top dead center) such that it becomes equal to the
r.u
value given in this table.

Valve end clearance 'C' 0.31mm

{ '(! Opening start angle
o)o (before top dead center) ( 4") ln case of direct starting system.
c>
Ero
(!> Closing end angle
(t eo' ;
a (after top dead center)
Pumping start angle by May vary depending on the engine
fuel injection pump output and specilications. Refer to
the Test Run Becord Table (included in
(before top dead center) the iinal documents),

Fuel oil injection valve opening pressure 29.4MPa

(adjustment value) {3ookgf/cm'r
May vary dependrng on the engrne
output and speci{ications. Refer to
Maximum combuslion pressure
the Test Run Becord Table (included in
the final documents).

Cylinder safety valve opening pressure 19.1MPa

(adjustment value) itsskgt/cm')

DAIHATSU DK-20 : :2-11

 Operation
4

1.1, 1.2 DK.2O Precautions for Operating Engine

4-1. Precautions for Operating Engine

4-1.1 For Start
A
\-/
tt I 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.
^
$v tZt lt 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.
.A lgl Confirm that there are no working staff around the engine. When anyone is around the engine, be
V minded to send a signal and confirm safety before starting the operation of engine.

4-1.2 For Operation

a) (1)Afterthe starting engine, inspectthe following items, and confirmthatthe engine is in a good and
\-/ removal operating for. ln 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.
r Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate
exhaust temperature, etc.
r Abnormal sound, excessive heating, etc.
r Any leakage from piping. (Particularly, leaks from oil piping will result in fire.)
Be minded neverto attemptlo resume the operation of engine, untilthe causes of the problem
z\. or defect are found and eliminated, and the engine is restored to normal operating conditions.
\12 (2) lnadvertent contact of the body of working staff or objects with the rotary parts (e.9. flywheel and
coupling) will result in dangerous accidents such as that the staff may be caught up orthe chips of
the objects caught mayfly out in alldirections. Therefore, be minded that both person orobject
may not touch the rotary parts.
Further, ensurethatthe protective covers of the rotary parts are always attached withoutfall.
l\^ (3) During the operation of engine, particularly the following parts are extremely hot, and therefore
there is a dangerof burn if touched with bare hands orskin. Be minded to wearsafetygloves or
protective gears whenever maintenance or inspection works are conducted.
After the completion of the work, restore the lagging, heat covers, combustible oilsplash preven-
tive means (FN tape) and protective covers that have been removed for maintenance and inspec-
tion.
o Exhaust pipe
r Turbocharger
. -r: cooler inlet pipe
r C; inder head
'-- ---^-..^1,,^VdIVU
a I -Lc--l

. Fuel irjedbn pump and high-pressure coupling

. Fuel ol fiIer and tuel oil pipe (in case of heavy fuel oil)

DK-20 A 05-3
CHAPTEB

4 Operation

2.1 DK-20 Preparation for Daily Operation

4-2 Preparation for Operation

It is essential to keep the engine in "Operable Conditions" whenever the engine is

being operated. Therefore, be sure to perform pre-operation inspections belore the
starting ol engine, and take proper corrective actions and countermeasure whenever
any problem is found, to confirm that the engine is in normal conditions lor operation,
belore starting the operation of engine.
lf the engine is started without pre-operation inspections or preparations, it will cause
not only the troubles when starting the engine but also result in a sudden stoppage 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.
\upper timit
o Daily starting: Short period ol disuse (within
one month)
o lnitial starting after a long period of disuse,
or afler overhaul or maintenance.
The daily starting procedures is described in
this section. As for the latter (initial starting),
refeLto the following section.
(l , 4-2.2 "Preparation for lnitial Starting")

lnspecting Engine Lubricating Oi!

!nspecting GovernorLubricating Oil Level

DK-20 A 00-9 DAIHATSU

 CHAPTER
Operation 4
Preparation for Daily Operation DK.2() 2.1

(1) lnspection before Operation +Oil leeding poinls

a) lnspection and Feeding of Lubricating Oil
Check the oil level ol the oil tank, and leed new
oil to the upper limit levelof the oil gauge.
Further, in case that dhe hibricating oil is found
inadequate after examination, proceed with
makeup or replace the entire amount of the
lubricating oil.
( tffil : 6-2 "Lubricating Oil Characteristics and

Control) Manualoilfeeding: Around common rod and

O Engine lubricating oiltank fuelinjection pump
(Base plate common to different engines)
Fuel injection pump
ngine model 3DK / 5DK 6DK 8DK
No.
-ubricating oil 500 \ 740 1
'100 1 400
level(L)
Note: The oil level shcjwn-above may vary
depending on the specificalions. +- Oil feeding points 'rrqf

@ Governor C: Around operation lever

Otl
Lubricating oillevel RHD6 : 1.3L, <-Oil leeding points
UG10 : 1.71 View B : Around fuel injection pump
I
@ Generator (in case of self . . . lubricating type)
i
I
( {ffit, Separately provided "Generalor Potenliometer
t
Instruction Manual")
@ Beduction gear (in case of marine
propulsion engine)
( Separately provided "Reduction
{ffi],
Gear lnstruclion Manual")
+-Oil leeding points

b) lnspection, lubrication, and Operation View A : Around potentiometer link

Check around the Fuel Hegulation System
Manually lubricate the bearing and sliding parts
of pins, after checking for any loose or missing
levers, link pins, and bolts around the governor,
Back scale
common rod, stoppage system, and fuel
injection pump rack.
Set the operation lever to "STOP' position and
conlirm that the rack scale is'O', and then
alternately move the lever to ST0P and "HUN
positions, to confirm that the common rod and STOP
pump rack moves smoothly.

Operation lever

DAIHATSU DK-2C i :3-9

CHAPTER

4 Operation

2.1 DK-20 Preparation for Daily Operation

c) Draining of Condensed Water from lntake d) Draining Condensed Water lrom, and
Air lnlet Duct Supply Air, to Air Tanks
Open the drain cock o{ the intake air inlet duct, ln case of automatically supplying air, first drain
and drain the condensed water out. the condensed water out of the starting air tank
and starting air control lank, and then confirm
1. Close 2. Open that air pressures in these tanks is above the
1) Drain cock of engine frame inlet air duct lower limit value.
ln case of manually supplying air (including
manual staring ol the air compressor), supply
air to the upper limit value.
","""8,
1) Drain cock of engine Upper limit Lower limit
Item
lrame inlet air duct
Direct 2.9MPa 1.5MPa
'(!
starting
O) {30kgf/cm'?) {15kgf/cm'z}
c
E
(6
Air molor 2.9MPa 1.0MPa
a starting
{30kgf/cm'?} {10kgf/cm'z}

0.9MPa 0.7MPa
Controlair
{9kgf/cm'?} {7 kgf/cm'?}

e) Checking and Feeding of Fresh Cooling

Water
Check the level of fresh cooling water, and if
the level is at the lower limit, supply fresh water
Engine Frame lnlet Air Duct
up to the upper limit, and at lhe same lime add
a proper amount of the additive.
Further, in case that each properties ol water
Always keep the drain cock ol the engine
has reached the limit level, replace the entire
frame inlet air duct open about 114, aller amounl of water.
draining the condensed water by fully ( Iffit, 6-3 "Cooling Water Characteristics and
opening the drain cock.
Control")
ln case that the humidity is high and the
temperafure ol the air cooler is low, a large
amotrft of condensed water will accumulate,
and may car.Jse abnormal wear or tear on
va*xrs pails byfrorying into the cylinder.

DK-20 Z 99-8 DAIHATSU

 CHAPTER
Operation 4
Preparation for Daily Operation DK.2O 2.1

f ) Draining of Fuel Oiland Supply ol Oil

First drain fuel oilout of the lueloil service tank,
and then check the oil level and supply oil up to
the upper limit ol the level gauge.

g) Confirmation of the Clutch Being "Neutral"

(in case of the clutch-rnounted engine)
ln case ol the engines such as the marine
propulsion engine, make sure that the clutch is
in "Neutral" position.

h) Opening and Closing of valves

Repeat "Fully open" and "Fully close" operation
of the valves on the piping system 2 to 3 times
to confirm that the valves move smoothly, and
then set the valves to RUN" position.
Some of the examples are shown as follows.
Since the layout positions of the piping systems
and valves dilfer depending on each engine,
reler to the piping diagrams of the final
documents lor the details.
:i*

IExamples] ii
O Valves for fuel oil inlet pipe and return pipe: iI
"Open"
@ Valves for cooling water (jacket and cooler),
inlet pipe, and outlet pipe: "Open"
@ Valves for starting air pipe: "Closed" ("Open"
only when starting operation).
@ Valves lor operation air pipe: "Open"
O Valves for pipe coupling parts provided for
emergency, priming, cleaning, etc.: "Closed"

lf the screw-tightening valves are used on the

state of hall-open, the valve handle may be
turned during operation and the opening
degree may be changed, causing
mal{unctions.
Therefore, the valves should be fully turned
toward eilher "Open" or "Close" position, and
should be locked tightly.
ln case that the valves must necessarily be
left half open for the sake ol flow adjustment,
be sure to secure the valve handles with wire
ring and the like, and fix them to prevent their
loosening and turning.

DAIHATS.U DK-20 Z 99.8

 CHAPTER
Operation 4
Preparation for Daily Operation DK.2O 2.1

f ) Draining of Fuel Oiland Supply ol Oil

First drain fuel oil out of the fueloil service tank,
and then check the oil level and supply oil up to
the upper limit ol the level gauge.

g) Confirmation of the Clutch Being "Neutral"

(in case of the clutch-mounted engine)
ln case ol the engines such as the marine
propulsion engine, make sure that the clutch is
in "Neulral" position.

h) Opening and Closing of valves

Repeat "Fully open" and "Fully close" operation
ol the valves on the piping system 2 to 3 times
to confirm that the valves move smoothly, and
' then set the valves to RUN" position.
Some of the examples are shown as follows.
Since the layout positions of the piping systems
and valves differ depending on each engine,
reler to the piping diagrams of the final
documenls for the details.

IExamples]
O Valves lor {uel oil inlet pipe and return pipe:
"Open"
@ Valves lor cooling water (jacket and cooler),
inlet pipe, and outlet pipe: "Openx
'

O Valves for starting air pipe: "Closed" ("Open"

only when starting operation)
@ Valves lor operation air pipe: "Open"
O Valves lor pipe coupling parts provided for
emergency, priming, cleaning, etc.: "Closed"

lf the screw-tightening valves are used on the

state of hall-open, the valve handle may be
turned during operation and the opening
degree may be changed, causing
malfunctions.
Therelore, the valves should be fully turned
loward either "Open" or "Close" position, and
should be locked tightly.
ln case that the valves must necessarily be
left half open for the sake of flow adjustmenl,
be sure to secure the valve handles with wire
ring and the like, and fix them to prevent their
loosening and turning.

DAIHATS.U DK-20 Z 39-8

 CHAPTER
Operation 4
ITEM
Preparation for Daily Operation DK.2O 2.1

f ) Draining of Fuel Oiland Supply ol Oit

First drain fuel oil out of the lueloilseruice tank,
and then check the oil level and supply oil up to
the upper limit ol the level gauge.

g) Confirmation of the Clutch Being "Neutral"

(in case of the clutch-rnounted engine)
ln case ol the engines such as the marine
propulsion engine, make sure that the clutch is
in "Neutral" position-

h) Opening and Closing of valves

Repeat "Fully open" and "Fully close" operation
of the valves on the piping system 2 to 3 times
to confirm that the valves move smoothly, and
then'set the valves to RUN" position.
Some of the examples are shown as follows.
Since the layout positions of the piping systems
and valves differ depending on each engine,
reler to the piping diagrams of the final
documents lor the details.
i:::!l

IExamples]
O Valves for fuel oil inlet pipe and return pipe:
"Open"
@ Valves for cooling water (jacket and cooler),
inlet pipe, and outlet pipe: "Openx '

@ Valves for starting air pipe: "Closed" ("Open"

only when stdrting operation)
@ VaMes for operation air pipe: "Open"
@ Valves lor pipe coupling parts provided Ior
emergency, priming, cleaning, etc.: "Closed"

lf the screw-tightening valves are used on the

state of haltopen, the valve handle may be
turned during operation and the opening
degree may be changed, causing
mallunctions.
Therefore, the valves should be fully turned
toward either "Open" or "Close" position, and
should be locked tightly.
ln case that the valves must necessarily be
left half open for the sake of flow adjustment,
be sure to secure the valve handles with wire
ring and the like, and fix them to prevent their
loosening and turning.

DAIHATSU DK-20 Z 99.8

CHAPTER

4 Operation

2.1 DK.2O Preparation tor Daily Operation

(2) Standby Preparation (Engine on standby) [Turning J

Before entering the operation of engine, conduct <Work Procedure>

the lollowing preparations: i ) Conduct priming with lubricating oil.
ii ) Set the operating lever to "STOP" position.
a)Priming with Lubricating Oil (Do not iniect {uel oil.)
Start the motor-driven lubricating oil priming
rii) Set lhe indrcalor valve lo "Fully open"
pump (or, reserve pump) 5 minutes before
position.
starting the operation of engine, and confirm
iv) Conduct turning 1 to 2 times, and confirm that
that there is no oil leaks from various parts of
the engine rotates smoothlY.
the piping.

[Priming by Manual PumP]

When priming is conducted by manual pump, in (
stead of motor-driven pump, follow the following
procedure:
i ) Open the valve of the manual pump outlet,
ii ) Operate the pump lever.
iii) Conduct priming for about 5 minutes, while
confirming the swing of the indicator or the
lubricating oil gauge.
iv) After the completion of priming, securely
close the outlet valve.

b) Turning or Air Running

lndicator Valve
Conduct turning or air running to discharge the
dusts or water drops that has collected in the
cylinder while lhe engine is stopped.
Further, when the engine is started alter the
inspecticn of various parts of the engine, or Rack scale
after a long period of disuse of the engine, (
ccnduct turning before air running lo conlirm
.L-
U ^^l-.., c-v.
te :d

-
= z':. a"r^ount of water or oil is
cas= '.-='
-1'.:
z.:-- - - :-e aVlrnder due tO the
ea/.z:: ":- "-. ., 'Cer head or f uel
rr e:: :' .= .. '-.'. s a possibility ol
Sera-S -r:,::-:: S-:- =S :er'Clng damage Operation Lever
cf :-:::'-a-' -- -:::. r,=::''a'r-rmef.
When c:-.-,'l=',-- : --"a"unning, if
-
watef c': -:: l-:-:::-':':-= fdtCatOf
valve, in,-e: 'a'a i':: - = :';'irn! of
engine, sc '.-=''-: ::_::: :aa be
investigated a.::-: ::_-'='-a1:_-: ::^ 5e
prepared and:a":-

DK-20 Z 99-8 DAIHA

 Operation
4

Preparation for Daily Operation DK.2O 2.1

[Air Running (abbreviated as Air Run.)]

<Work Procedure> Do not fully open the starting air valve during
i) Conduct priming with lubricating oil. air run, keeping the opening at about 113, and
ii) Set the operation lever to "STOP' position. carefully conduct air running at low speed.
iii) "Fully open" the indicator valve. lf air run is conducted at high speed by fully
opening the starting air valve, it will not only
iv) Open the starting air valve and the control air
valve, and press the push button forthe start-
expend air uselessly, but also will result in seri-
ing operation valve. Then, starting air flows ous accidents such as aggravation of the
into the stsrting air valve, and the engine defects if any defect had been caused.
start its rotation.
tn''in case of air motor starting system, operate c) Heating of Fuel Oil (when heavy fuel oil is
the solenoid of the starter relief valve. Then, used.)

L pilot air flows into the air motor, and the

engine starts its rotation.
ln case that heavy fueloil is used, heating
shall be made according to the following items:
v) Keep pressing the push button for 3 to 4 sec- i ) Turn on the fuel oil heating device.
onds. (for air runy'- ii) Operate the motor-driven oilfeed pump.
vi) Release the push button. Then, the starting (M : 6-1 "Fueloilcharacteristics and
air valve closes, and the engine stops its
rotation. Control")
ln case of air motor starting system,stop the
operationof the solenoid. Then, the air motor Heated heavy fuel oil is extremely hot
stops, and the engine stops its rotation. (100C or more), may cause burn if you touch
the piping or equipment on the fuel oil system.
lf the engine starts its rolation during the Therefore, in case of handling the equipmenl of
inspection of the inside of the engine or rotary fuel oil system that carriers heat oil, be sure to
parts, it is extremely dangerous since the wear safety gloves and never touch them with
working staff may be caught up or the objects bare hands.
that has been caught up may fly out in all
directions. d) Turning "ON" of Protective and Alarm
When conducting air run, strictly observe the Circuit
following points. Turn "ON" the protective and alarm circuit on
1) Confirm that the turning device or turning the monitor panel, and confirm that the warning
bar is set "OFF". lam is lit up.
2) Send a signal to coworkers and confirm
safety before starting to press the push but
ton of the starting operation valve. e) Operation of Motor-Driven Pumps
ln 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.

DK-20: :a-3
 Operation
4
Preparation for operation: Preparation of lnitial Starting after A
2.2 DK-20 Long Period of Disuse, and Overhaul

4-2.2 Preparation for lnitial Open the following filters, and cleanse the
Starting after Long Period inside and the elements of the filters:
of Disuse 0 Starting air filter and control air filter
Since the engine is not ready for immediate
O Fuel oil filter (including oil filters on the
outside of the engine)
starting of operation after a long period of disuse,
and overhaul or maintenance, it is particularly nec- O Lubricating oil filter (filters on the engine,
for T/C)
essary to thoroughly conduct the preparations for
operation. @ Cooling water filter
Before the preparation for daily operation, con- ( ru : 5-4.3 "cleaning Filters")
duct the following preparation works (4-2.1).
(1) lnspection of Grankcase and Cylinder Liner,
and Supply of Oil
a) Inspection of the lnside of Crankcase a
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
behind, and that there is no rusling on the cylin-
der liners, crankshaft, and so on.
b) Supplying Lubricating Oil to Cylinder Liner
After a long period of disuse, the various parts
of engine are not covered with sufficient amount
of lubricating oil. Particularly around the cylin-
der, lubricating oil cannot be supplied sufficiently
Spray(Spra;r
with priming alone, and therefore supply lubricat- lubricaiting oil)
ing oil on the following procedure:
i ) Conduct turning to allow the pistons to move
upward. and apply lubricating oil on the lower
part of the cylinder liners by a spray device No foreign rnatters
and the like sucir as desiccant
or silicagel slioud
ii) Sequentially conduct the above procedure to be preseni.
each cylinder. a
(2) lnspection of Connections and Joints Applying Procedure of Lubricating Oil
lnspect again the external connections or
jo:nrs 1: ::"'r lhat there is no connections that
Oiland Exhausting
(4) Priming with Lubricating
has:e;^ ':'-r::er to be tightened, or loosened Air
JLrrrr:
:^i-J^
,":.ible oil splash preventive
i ^---^ ^.

rneans ' F). ::t: *

2s been removed from joints, Conduct priming with lubricating oil and
nervly'tle:: t-: .: -:s 'n the same manner after exhausting air on the following procedure:
the cc r-: g: : - .' :-: ,., :'< a) Run the lubricating oil priming pump for 5 min-
utes. While the pump is operating, open the
(3) Opening. Cleaning. and Cleansing of Filters
turning plug (on the cylinder head top surface) to
Dusi : ": -: - : :.:::s :- :l had been collect-
_: perform turning two or three times, and check for
ed into g,F-J :--- _: "2-s::iation. and outfit- leakage of fuel oil, lubricating oil and water from
ting or insta a: :- : ;::--- =:=: ln the filters of the turning plug.
the engine inle:
b) At the same lime, open the each cover and
check the dripping-down conditions of lubricating
oil from each part.

DK-20 A 05-3
Operation 4
Preparation for operation: Preparation of lnitial Starting after A
Period of Disuse, and Overhaul DK.2O 2.2

parts (exhaust pipe, turbocharger, etc.), exhaust

@ Engine frame: Main bearing, crank pin,
piston (cooling chamber), and piston pin pipe cover and heat box cover that were
removed for disassembly and servicing have
@ Cam case: Cam bearing, swing arm, and
been restored as they were.
tappet
Check that the joints that were once discon-
@ Cylinder head: Rocker arm and valve retaining
nected are provided with combustible oil splash
tee
preventive means (NF tape).
c) Operate the priming pump, open the air vent
valve for lubricating oil filter, and drain lubricat-
ing oil until air bubbles in the oil are completely
vanished. Take care not to splash the oil.
O) Check that there is no oil leakage from various
parts of the piping during priming.

(5)Priming with Fuel Oil and Exhausting Air

Conduct priming with fuel oil and exhausting
air bubbles on the following procedure:
i )Operate the fuel oil feed pump (in case of the
engine equipped with a motor-driven oil feed
pump). Turhocharger
ii)Open the fuel oil inlet valve, after confirming Air vent
that the operation lever is set to "STOP' valve
position.
I,..{AF,\
ovs
iii)Open the air vent valve of the fuel oil filter,
and drain oil until air bubbles in oil are com-
pletely vanished.
iv)Open the air vent valve of the fuel injection
pump, and drain oil until air bubbles in oil
are completely van ished.
v)After completely removing air vent, securely
tighten the deflator.

The heavy fueloil is heated to a high temper-

ature (100C or more). Exhaousting Air of
Touching the splashing oil may scald your Notcfi-Wre Filter
hands. lf high-temperature parts are splashed
with the oil, a fire may occur. Take care not lo Air"vent piug
splash the oilwhen discharging air.

(6) 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.

(7) Checking the covers are fitted

Exhausting Air oi
Check that the lagging for high-temperature Fuel I njecticn Pi.:''nc

DK-z} A 0s-3
CHAPTER

4 Operation

3.1 DK.2O Starting Procedure

4-3 Starting
Rack scale

lnadvertent contact of working staff or objects

with the rotary parls is extremely dangerous
since the person may be caught up or the
object that has been caught up may fly out in
alldirections.
Therefore, strictly observe the following items
when starting the operation.
o Conlirm that the protective covers ol rotary
parts are mounted in normal state, and that
Operating Lever
lhe rotary parts are free of any obstacle.
o Confirm that the turning device or turning bar
is set to "OFF'. (2) Remote Starling (Manual and Push Button
o Send a signal to a coworker if there is any, Starting)
and conlirm safety before starting the <Work Procedure>
operation of engine. i ) Switch the starting mode to the remote mode
(lrom monitor chamber) lrom local mode (from
engine side).
4-3.1 Starting Procedure ii ) Set the operating lever to "RUN" position,
iii) Open the starting air valve and control air
(1) Starting from Engine Side (Locally)
valve, alter confirming that "READY" indicator
Starting procedure can be classified into the
lamp has lit up.
three types; engine side starting (local starting),
iv) Press lhe starting push button.
remote starting, and automatic starting, and
which of these should be employed depends on
v ) Confirm that "RUN" indicator lamp on the
panel has lit up as the rotation speed ol the
the specilications. However, local starting
engine has reached the specilied rate, and
(starling from engine side) by manual operation
eadh pressure has reached the specified value.
should ah,vays be employed after a long period of
vi) Close lhe stading air valve.
disuse or after overhaul or maintenance.
(Leave the control air valve 'OPEN' as it is.)
<Work Procedure>
i ) Open the starting valve and control air valve. (3) Automatic Stading
i ln case ol automatic starting, the engine starts
) S€t the operation lever to "START' position.
-) Press the push button for the starting automatically by the starting command based bn
operation \rahre- preset starting conditions, such as the overload
iv) lf tE rdation speed of the engine has rapidly conditions of power shutdown or other engines
increased and starting has been eslablished (in case ol plural engines), and therefore it is
along with continuous ignition sounds, release essential that the engine should always be kept
the push button- in operable conditions
v ) After confrm-rg ftat trre rolation speed ol the Engines should be kept in the following
engine has reacfied tfie specified speed, and conditions al all times:
each pressure has reached the specilied O Starting mode: 'AUTO'
value, set the operating lever to ,'RUN, @ Operation lever position: "RUN"
position. @ Starting air valve and control air valve:
,OPEN'
vi) Close the starting aL yahre.
(Leave the control airrrahre Open. as it is.)

DK-20 Z 99-8 DAII{ATSU

 CHAPTER
Operation 4
IIEM
Starting Procedure / lnspection and Check ltems
lmmediatelv After Starti nq DK.2O 3.1,3,2

(4) Corrective Measure ln Case ol Faulty Starting

ln case that the engine has lailed to start or has FBoosfq FRUBoTLq

O@
not started smoothly, take corrective measures

@
by referring to a separately provided section.
( tffil : 7'Trouble Shooting and Countermeasures')
FiACKETq
px0ziEq
FRPMq

ln case that the engine has repealedly lailed

to start in an extremely cold weather while the
engine is still in cold condition, the unburnt
mist oi fuel oil may remain in the exhaust
@reoolETq @ @FFUELoC
manifold, having a possibility of catching lire
or explosion being caused by high-
L temperature combustion gas.
When starting failure has been repeated,
conduct air running and exhaust the unburnt
@ @
mist in the exhaust manifold, before restarting Gauge Board
the engine.
(3) Abnormal Sound
4-S.2lnspection and Check ltems Carelully listen to the sound of the lollowing
lmmediately After Starting engine parts, and check if there is any abnormal
sound or not:
Check the following items immediately after e CytinOer head and surrounding parts (intake
starting. and exhaust valves)
When any abnormal error has been lound, @ Crankcase
immediately stop the engine and take proper O Crankcase and timing gear and auxiliary drive
measures. gear
(
m: 7 "Trouble Shooting and Countermeasure")
@ Turbocharger

(4) Exhaust Temperalure

After conducting overhaul or mainlenance of
Check the exhaust temperature ol each cylinder,
the sliding parts or rotary parts, be sure to once
and confirm that all the cylinders are properly
stop the engine and check that there is no error
burnt (at 200'C or more).
or lailure by hand-touching.
(5) Gas Leakage from Stading Valve
(1) Engine Rotalion Speed lf gas has leaked from the starting valve, the
Confirm that the engine rotation speed (the slartrng air main pipe becomes hot.
number ol idle rotation speed, in case of the Check if the starting air main pipe is not heated
marine propulsion engine) has reached the or not by lightly touching the pipe.
specified rotation speed, and hunting (swinging of
tachometer) is not occurred. (6) Leakage and Loosening of Each Pad
Check il the bolts and nuts of installation pai cr
(2) Pressure Reading of Each Parts
connecting part are not loosened, anC f:
Confirm that lhe indicator ol pressure reading, for
water, or gas is not leaked.
the manometer with blue mark, is within the blue
mark, showing the pressure is within the specified
value.

DAIHATSU DK-20 Z 99-8

CHAPTER

4 Operation

4.1 DK.2O Running-ln Operation

4-4 Operation (3) lnspection ltems during lnitial Running-ln

Operation
4-4.1 Running-ln Operation To detect the potential problems and eliminate
When the engine is started lor the lirst time or the causes to previously prevent such problems,
immediately alter replacement of the parts, such particularly heed cautions to the following items:
as the cylinder liners and piston, since the sliding O Abnormalsound
parts ol the engine are not yet sufficiently ready to @ Partiatheating
work smoothly or freely, lailure such as abnormal @ Leakage lrom conneclion pads, and loosening
wear or seizure of the sliding parts may occur, if of screws
the load is abruptly applied in the stage of such @ Explosion pressure, exhaust temperature,
condilions. irregular exhaust color: Abnormal burning of
Conduct the running-in operation to ensure smoolh fuel
and lree working of the sliding parts on the @ Excessive consumption of lubricating oil: (
following procedure, before entering normal lmproper working of liners and rings
operation:
(4) lnspection and Works alter Completion of
(1) lnitial Running-ln Operation Running-ln Operation
It will substantially affect the engine At the time when the running-in operation is
performance, especially the combustion completed, conduct the {ollowing inspection
performance and consequently the consumption works and confirm that there is no abnormalities,
efficiency of lubricating oil, whether the piston before entering lhe normal and regular operation
and oil rings move smoothly and freely, or not. of engine:
Further, il is assumed that they will be decided O lnspection ol foreign matlers and stains in lhe
by the initial operation of a few hours. crankcase
When the cylinder liner, piston, piston ring, and @ Visual inspeclion ol the inner surface of the
sliding parts around cylinder are replaced, be cylinder liner
sure to conduct running-in operation in @ lnspection and cleaning of the element of
accordance to the figure shown below. each filter
(tffit: Fig. 4.1 "lnitiat Running-tn Pattern") @ Remove the llushing filter attached to the (
element of the fuel oil filter.
(2) Operating Conditions during Running-ln
Operation
Be sure tc c!€'a:e the engine during the running-in Be minded never to perform the operation of
period un:e: :-e'c ci.,ing conditions: engine using heavy fuel oil, while the flushing
C,
br' : 3' ,e SS
..1- LOaO: lilter is attached.
@ Fuel c;i:c Le -sec: iieselfueloil
Note: Fc':-: E-3.ies of heavy fuel oil
specifica'i .^ :e ^. -:el :o use diesel fuel oil
'--- -l- - ::.: j
during the
@ Lubricairr^c : :: :: ,ssa s::ail comply with
the fuel oii tc c: -s::
Note that fcr:-e :-; -= ".,:^ -eavy fuel oil
specificatron. :-:':=':- : ':. -earry fuel oii
can be use: '.-- :-: :e-cinning,
notwithstanding:-e 3:.:.= :-:::-:: :-*= of ?.
@ Running-in period is 1 51 - : - -:

DK-20 Z 99-8 DAIHATSU

CHAPTER

4 Operation
ITEM

4.2 DK.2O Warming-Up and Connecting Load to the Engine

4-4.2 Warming-Up and Connecting Load

to the Engine Be minded to perform no-load operation on
for warming-up operation, and restrain the
ln case that the engine is slarted while it is still in a duration of no-load operation within 10
cold state, lirst perform the warm-up operation, minutes.
except lor the case of emergency, and gradually Running the engine under no-load for long
connect the load after the engine has sulficiently hours will result in malfunctions such as faulty
been warmed up. combustion and collection of carbons in the
lf the load is hastily connected while the various combustion chamber.
parts of the engine are still cold and not yet in the
conditions for proper f uel combustion and
(2) Connecting Load to lhe Engine
lubrication, malfunclions such as faulty
The lower the engine temperalure (temperalures
combustion, excessive wear of the sliding parts,
of jacket cooling water and lubricating oil) is, the
and seizure may be caused.
longer time it is needed to connect the load.
The standard load connection time is shown in
(1) Warming-up Operation ol Engine
the figure below.
a) Use diesel luel oil for warming-up
( m : Fig. 4.2 "Load Conneclion Pattern")
operation
ln case ol the marine propulsion engine (direct
Be sure to use diesel fuel oil for warming up
connection by propeller), be minded to gradually
the engine, even in case of the engine with
increase the rotation speed, since the load will
heavy fuel oil specification.
increase according to the rotation speed.

b) No load (ldle operation in case of warming

up the marine propulsion engine)
When increasing the rotation speed, be
First operate under no load or light load, and
minded to quickly pass the dangerous
connect the load after jacket cooling water and
running speed zone, under which lorsional
lubricating oil temperature has increased.
vibration causes damages (the red mark
zone), on the lachometer.
Running the engine within this zone for long
hours may cause the breakage of the
crankshaft.l

Lmd
(%)

(ilomdl@d)

t : Jacket cooling water and lubricating oil

'_ '5 20 25 30 40 TIME(min)

Fic J 2 Load Connection pattern

DK-20 Z 99-8 DAIHATSU

 CHAPTER
Operation 4
Operation with Load (Normal Operation) DK.2O 4,3

4-4.3 Operation with Load (Normal introduced, and judge if there is any problem
Operation) and check the degree of deterioration.
( Iffil: "Test Run Record Table" in the final
lnspect the running conditions of the engine and documents)
measure the operating performance data in regular
inlervals, during the continuous operation with load <Measurement ltems>
(including period of the running-in operation).
@ Room temperature
ln case that any problem is found as the results of
@ Load (output)
lhe inspection and measuremenl, take proper @ Rotation speed
measures such as adjusiment or repair of the ..-...|n case of variable-speed engine
defective parts. (Refer to a separately provided Maximum combustion pressure (each
@
section.) cylinder)
( fiff,$: 5-3 "Measurement and Adjustment") @ lntake air temperature (turbocharger inlet)
L (
6ff$: 7 "Troubleshooting and Countermeasures")
@ Exhaust temperature (outlet of each cylinder)
@ lntake air pressure (engine inlet)
(1) lnspection of Operating Conditions
@ Lubricating oil pressure (engine inlet)
<Check llems>
@ Cooling water pressure (engine inlet)
O Abnormalsound @ Fuel oil pressure (engine inlet)
@ Partiatoverheat . . ' ...ln case of heavy fuel oil specilication

@ Leakage from connections and looseness of

@ lnlet air temperature (engine inlet)
screws
@ Lubricating oil temperature (engine inlet)
@Abnormal combustion pressure, exhaust
@Cooling water temperature (engine inlet and
temperature, and exhaust color
outlet)
......Abnormal combustion
@ Fuel oil temperature (engine inlet)
@ Excessive consumption of lubricating oil ..'...|n
case of heavy luel oil specification
......Damaged cylinder liner and ring
@ Reading on luel injeclion pump rack scale

(3) Regular inspection and Maintenance

During the operation of engine, particularly
Conduct inspection and maintenance of the
the following parts become extremely hot, ' various parts of engine regularly.
and touching these parts with bare hands or
(Refer to a separately provided section.)
skin may cause burns.
t lffil : 5 "lnspection and Maintenance")
Therefore, be minded to use the protective
gears such as safety gloves when working on
(4) Operation Records
them.
Afler completion ol the inspection and
o Exhaust manilold
measurement, keep the records ol the works
o Turbocharger
performed on adjustment or repair in the log
o Air cooler inlet pipe
book.
o Cylinder head
o lndicator valve
o Fuel oil system equipment and piping (in
Operation records are very important
case ol heavy fuel oil)l documents when understanding the
conditions ol engine and tracing the history ol
(2) Measuring Performance Data
the inspection or mainlenance that has been
a) Measure the operating perlormance data at performed.
least once every day, when the load variation is
Keep and store them carefully, and when tre
less and the load is stable.
supervisor is changed, be sure to transler tte
b) Compare each of the measured data with the
records to the successor without fail.
data obtained when tie engine was newly

DAIHATSU lX-,ll
-J-!
 Operation
4

4.4 DK-20 Operation Using Heavy Fuel Oil

4-4.4 Operation Using Heavy Fuel Oil d) ln Case Load Variation is Heavy
(in case of Heavy Fuel Oil @ \Mren entering or leaving port
Specification Engine) @ When weather is rough and stormy
@ \Mren cargo is being loaded or unloaded
Since heavy fuel oil is lower in its quality and
higher in its viscosity as comperared with diesel e) Before Stopping Engine
fuel oil, it is required to carry out an appropriate (
operation control, such as operating the engine by ED :4.6 "stoppage")
changing to diesel fuel oil depending on the load
(2) Switching Fuel Oil Types
conditions, in addition an appropriate control of the
fuel oil and lubricating oil, when this type of oil is to Heavy fuel oil is normally heated up to 80 to
be used.
90C in the service tank, and 100'C or more at
the engine inlet, and the temperature difference
Further, the starting and stopping the engine, is larger as compared with that of diesel fuel oil
when heavy oil is used, is only allowed on the
engine of the heavy-fuel-oil starting-and stopping
(non-heated), and therefore if fuel oil is suddenly
switched between these oils, it may cause mal-
a
specification. functions such as sticking of the fuel injection
pump, vapor lock, and so on.
( ru I 6.1 "Fueloilcharacteristics and Control")
a) Slowly switch from dieselfueloilto heavy fuel
( [fD]] : 6.2 "Lubricating Oil Characteristics and oil, so that the rate of change in the fuel oiltem-
perature at the engine inlet is between 5 and
Control")
10C per minute.
( ro : Fig.4.3 "switching Pattern from Diesel
(1) Operation with Diesel Fuel Oil
Be minded to use heavy fuel oil only under Fuel Oilto Heavy Fuel Oil")
stable load conditions, and be sure to use diesel b) Maintain the viscosity (temperature) of heavy
fuel oil in the following cases: fuel oil at the engine inlet at the specified value
c) Do not raise the temperature of diesel fuel oil
a) During RunningJn Operation Period(I50 hours) beyond the flashing point (60C is the standard
(J, lmmediately after installation point).
rO After replacement of the sliding parts around d) To prevent the generation of vapor, maintain
cylinder (e.9. cylinder liner, piston, and piston the pressure of fuel oil al the specified value.

(
ring)

=
'.
4.4 1 'Running-ln Operation")
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 prevent-
t
b) During Starting or Warming-Up Operation ed.

( E ; 4.121/lfarming-Up Operation") lf high-temperalure parts are splashed witl'i

the oil, a fire may occur. Take care not to
c) During idling or Lo,*-Load Operation splash the oilwhen discharging air.
!\her :-: :-: -.= s :p:rated under low load, e) Conflrm that the heat traces on piping and
the cornc':r=.. . -:=-::-a1ure in the cylinder equipment is properly functioning.
and fuel rn e:::^ :-::s--= :i fuel oil is low, and
therefore if :^: - ...', '-. :' vrhich combustion
quality is lc.',:' '.-.- '.':: :' diesel fuel oil, is
The fuel oil is heated, and the filter and the
used, comb!si :- ,', :a:: -: ,:nstable, result- piping are at high-temperatures. lf touched
ing in undesirac : ::-:' --: :-,' as lvorsening with bare hands or skin, it may cause a burn.
of the exhaust sr:. = .' :. - = :' :'e ring. and Therefore, be minded not to directly touch the
so on. ln case of t-: :.--.-' -' -''.-.lcad that exposed metallic parts such as the valves and
is below the lower r-: ::::-::t - :^: engine cocks, and wear the protective gear such as
specification, be min;=::: -:: : =-= '-= :'l safety gloves when working on them.

DK-20 B 05-3
 CHAPTER
Operation 4
Operation using Heavy Fuel Oil

ln case that emergency stop is made during

the operation with heavy luel oil, immediately
switch the luel oil to diesel fuel oil, move the
motor-driven pump, and perform llushing ol
the fueloilsystem.
lf the engine is cooled down with the heavy
luel oil left unchanged, the oil will be solidified
and the operation will be prohibited.

OSwitching lrom Diesel Fuel Oitto Heavy FuelOil OSwitching from Heavy Fuel Oil to Diesel Fuel Oil

L 13- 14cst Viscositv al 13-14cst

E
l
E
70 sec, HW N01 :p
E /-
engine intet 50 to 70 sec,
&E a-e
cc
cc Heavy luel oil lemporature
ee6) ge
'6
'6 6)
XChange spped XChange spped:
eE
:
aS
[6 5 to 1o'C/min. u6 5 to lo"C/min.

co
e Switching Operation Operation SwitchirE rrom
a over lo heavy with heavy with C heavy heavyfuel oil, Operation with diesel fud oil
d Operation with diesel luel oil fuel oil to diesel luel oil (warmirE up)

Check heavy fuel oil Check that load is stable Check that load is stabl€ Check heavy luel oil
E
supply equipment (above lower load limit) (above lower load limit) supply equipment
T for proper operation during switching during switching for proper operation
o

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

Fig.4-3 Switching Pattern from Diesel Fuel Oil to Heavy Fuel Oil

DAIHATSU DK-20 Z 99-8

 Operation
4

5.1,5.2 DK-20 Low-Load Operation and Operation with Air Cooler Cut0ff

4-5. Special Operation reduce the fouling of the combustion chamber,

as well as the intake and exaust air systems.
4-5.1 Low-Load Operation
Since running the engine with a low-load lower 4-5.2 Operation with Air Cooler Cut-Off
than a certain limit can lead to unfavorable com-
bustion condilions such as the reduction of intake ln case that the defects such as breakage ofthe
air pressure and blowing-back of exhaust air, if the fine tube in the air cooler or water leakage from a
engine is operated under such conditions for long caulked sections is found, and the repairing cannot
hours, it may result in the various malfunctions be performed quickly, an emergency messure can
such as fouling of the turbocharger and combus- be taken by cutting off the air cooler on the follow-
tion chamber, faulty combuslion and so on. ing procedure:

Therefore, be sure to minimize the low-load

operation to a shorter period of time as much as (1) Low-Load Limit
possible, and in case that the engine must be a) Stop water supply to the cooler oolng s
inevitably run under a low-load for long hours, be and draw out the water from the air 1ire-
sure to observe the following conditions:
b) lnsert a shielding plate A into the flarge
(1) Low-Load Limit the air cooler cooling water inlet pipe ard r

The low-load limit varies depending on each pipe.

specification. Confirm the low load limit c) "Fully open" the bypass valve of the air c
described on the specification supplied with the
engine. d) Operate the cooler cooling water punp,
confirm that no waler is leaking fom the fl
(2) Use of Diesel Fuel Oil packing area.
ln case of the heavy fuel oil specification, be
sure to switch it to diesel fuel oil.

(3) lncrease of lntake Air Temperature

To improve the combustion conditions, increase
the intake air temperature and adjust to as a high-
er level as possible, within the following limit:
, lntake air '. 7 5 "C or less
r-
r Exhaust air temperature (cylinder outlet)
450 'C or less
: t.
( '. a-3 2t2) "Measurement and Adjustment:
=
Inta ke i.ir Ter--cerature")
(4) Cleaning of Turbocharger
Prope' ; : t'e 3Se the number of times of
cleaning i-. :-T::t''afger according to necessity. Cooling lvater ililet lJcciinE ,,.3..:. ,
Air Cooler Bypass Vaive
lne:-'4.--= -= : at a high-temperature (2) Prerequisites for aaOperation
-' .^: ust after the engine is
during a..'z'.
stoppec '..:-:---.- with bare hands during a) The fuel oilto be used is diesel fuei :
cleanirg ):- -., :- m your hands. Wear b) Restrain the output as low as poss c : -:'
safety gloves ,.. :- : -' ': ring to the following values as the sia-::-:
Pme (average effective pressure):
(5) lntermittent High Load Operation 0.8MPa t8 kgflcnf
lf the load is switched to tlrc high load (60%
Exaust air temperature (cylinder ouUe{
or more) for about 30 minutes
operation, it will have an effec 450 "C or less

DK-20 A 05-3
 Operation
4
IEM
Non-Turbocharger C on and Operation with
Reduced Number of linders DK.2O 5.3,5.4

4-5.3 Non-turbocharger Operation 4-5.4 Operation with Reduced Number

ln case of the marine propulsion engine, a non- of Cylinders
turbocharger operation implement (turbocharger Adoption of the operation with the reduced num-
blind plate ) is provided, so that operation in emer- ber of cylinders impose such problerns as the tor-
gency can be made even ehwn the turbocharger sional vibration of the shaft system as well as the
may have been damaged. ( The generator is opti- external vibration of the engine, and therefore this
nal.) operation should be limited as a secondary meas-
The non-turbocharger operation procsdure is as ure to be used only in emergency.
the followings: ln case of 3DK and 5Dk engines, the operation
with the reduced number of cylnders is prohibited
(1) Preparation for Operation due to the axternal vibration of engine.
lnstall the non-turbocharger operation implement The operation with the reduced number of cylin-
in accordance wilh the Turbocharger lnstruction ders may be conducted in various cases such as
L Manual. the case of only reducing the fuel oil, or the case in
which the operating parts are needed to be
removed. Further, since the prohibited items for
the operation vary depending on each case, be
During operation or immediately after stop- sure to inquire our company for the working proce-
dures, cautionary items on the operation, ansd so
ping the engine, the turbocharger is extremely
on, obtain the necessary instructions, and strictly
hot, and if the turbocharger is touched with observe them, when the operation with the
bare hands or skin, it may cause burns. reduced number of cylinders is conducted.
Therefore, perform the disassembly work
after the turbocharger is completely cooled <Preparation for Operation>
down. a) The fuel oilto be used is diesel fuel oil..
lf it must be removed before it cools down, b) The output shall be as below:
wear safety gloves, and remove it taking care (No. of cylinders)-(No. of reduced cylinders)
/\, ,no,^
IUlO
not to burn your hands.
However,the outpui may be reduced accord-
ing to the turbochager sursing or exhaust air
(2) Prerequisites for Operation
temperature in each case.
a) The fuel oil to be used is diesel fuel oil. c) Exhaust temperature : 450C or less
(each cylinder outlet)
b) Restrain the output as a lower level as possi-
ble, referring to the following values asthe stan-
dard:
o Pme(average effective pressure): Be attentive of the external vibration of
0.44MPa {4.5 kgf/cm'} engine and the gear sound, and if any abnor-
Exaust air temperature (cylinder outlet): mality is found, immediately stop the engine. lf
"
400'C or less the engine is kept operating dlsregarding such
abnormality, serious accidents may be caused.

D K-20 : ::-3
 Operation
4
IEM
Non-Turbocharger Operation and Operation with
Reduced Number of Cvlinders DK-20 5.3,5.4

4-5.3 Non -turbocharger Operation 4-5.4 Operation with Reduced Number

ln case of the marine propulsion engine, a non- of Cylinders
turbocharger operation implement (turbocharger Adoption of the operation with the reduced num-
blind plate ) is provided, so that operation in emer- ber of cylinders impose such problems as the tor-
gency can be made even ehwn the turbocharger sional vibration of the shaft system as well as the
may have been damaged. ( The generator is opti- external vibration of the engine, and therefore this
nal.) operation should be limited as a secondary meas-
The non-turbocharger operation procsdure is as ure to be used only in emergency.
the followings: ln case of 3DK and 5Dk engines, the operation
with the reduced number of cylnders is prohibited
(1) Preparation for Operation due to the axternal vibration of engine.
I nstall the non-tu rbocha rg er operatio n implement The operation with the reduced number of cylin-
in accordance with the Turbocharger lnstruction ders may be conducted in various cases such as
L Manual. the case of only reducing the fuel oil, or the case in
which the operating parts are needed to be
removed. Further, since the prohibited items for
the operation vary depending on each case, be
During operation or immediately after stop- sure to inquire our company for the working proce-
dures, cautionary items on the operation, ansd so
ping the engine, the turbocharger is extremely
on, oblain the necessary instructions, and strictly
hot, and if the turbocharger is touched with observe them, when the operation with the
bare hands or skin, it may cause burns. reduced number of cylinders is conducled.
Therefore, perform the disassembly work
after the turbocharger is completely cooled <Preparation for Operation>
down. a) The fuel oilto be used is diesel fuel oil..
lf it must be removed before it cools down, b) The output shall be as below:
wear safety gloves, and remove it taking care (No. of cylinders)-(No. of reduced cylinders) , ,no,
A IUrc
not to burn your hands.
However,the output may be reduced accord-
ing to the turbochager sursing or exhaust air
(2) Prerequisites for Operation
temperature in each case.
a) The fuel oil to be used is diesel fuel oil. c) Exhaust temperature : 450C or less
(each cylinder outlet)
b) Restrain the output as a lower level as possi-
ble, referring to the following values asthe stan-
dard:
* Pme(average effective pressure): Be attentive of the external vibration of
0.44MPa {4.5 kgf/cm'?} engine and the gear sound, and if any abnor-
e Exaust air temperature (cylinder outlet): mality rs found, immediately stop the engine. lf
400 "C or less the engine is kept operating disregarding such
abnormality, serious accidents may be caused,

DK-20: :5-3
CHAPTEB

4 Operation

6.1 DK.2O Normal Stoppage

4-6 Stoppage
4-6.1 Normal Stoppage Rack scale

(1) Preparations for Stoppage

a) ln case that heavy fuel oil is used, switch the
fuel oil to diesel fuel oil 30 minutes before
stopping the engine.l
b) lmmediately before stopping the engine, start
the operation ol lubricating oil priming pump.
c) Confirm that the starting air pressure is at 2.0
MPa {20 kg{/cm,} or more.
(The preparation for the next round ol starting)
Operating Lever
(2) Stoppage
a) Conduct the stoppage operatton on the. (3) After Stoppage
lollowing procedure: a) Operate both the lubricating oil priming pump
and cooling fresh water pump for about 20
[n case of local operation] minutes, and cool down the engine and
Shift the operation lever to 'STOP' position. turbocharger.
Then, fuel oil injection will be shut off by means
of the common rod, and the engine will be
stopped. The turbocharger continues to run at high
speed even alter the engine is stopped.
In case of remote control] Lubrication of the turbocharger provided with
i ) Press the "STOP" push button on the control this engine is made using the system oil, and
panel.
therelore if the supply of lubricating oil is
Then, the fuel oil injection sotenoid valve will stopped immediately aller the engine is
be activated to operate the fuel shutdown stopped, it may damage the bearing.
device. and the engine will be stopped.
ii ) Shifl ihe operating lever to "STOP" position.
b) Fully open the indicator valve to conduct air
b) Afte' sicpoage operation, be attentive ol any running for 3 to 4 seconds, and exhaust the
abncrrral scund in the engine and combustion gas out o{ the combustion
turtcc.a!'_oer'. and confirm that there is not any chamber.
abncr a s::rC. c) Close the valves on allthe systems.

ln case thd tp enghe does not stop even

when the ffiE operation is conducted,
lorcibly stop the engine on the lollowing
procedure:
1) Forcibly set the rd d the luel injection
pumplo'O'-
2) Fully close the vah,e d the fuet oil inlet
main pipe.

DK-20 Z 99-8 DAII{ATSU

 CHAPTER
Operation 4
ITEM
Emergency Stop DK.2O 6.2

4-6.2 Emergency Stop (2) Measures after Emergency Stop

ln case that the engine is stopped by activation of
(1) When Emergency Stop ls Required.
the protective device or stopped automatically,
lmmediately stop the engine when any ol the
take the lollowing measures:
following abnormalities is lound:
a) ln case that the engine is stopped by remote
O Announcement ol "Emergency" or "Alarm" operalion or stopped automatically, set the
( * Activation of the protective device ---
operating lever to 'STOP' position after the
Automatic stop)
engine is stopped.
* r Overspeed b) ln case that the operation had been made
* . Decrease of lubricating oil pressure using heavy fuel oil, immediately switch the fuel
* o Suspension ol water supply/increase of
oil to diesel fuel oil, operate the motor-driven oil
cooling water temperature
feed pump, and conduct flushing of the fuel oil
i
o lncrease ol exhaust air temperature
L o Other alarming
system. (However, this procedure does not
apply when the luel oil pipe is broken.)
(depending on each specilication)
Further, conduct turning of the engine, and
@ Abnormal sound
exhaust the heavy fuel oil remaining in the luel
@ Heating of the bearings or other moving parls,
injection pump or fuel valve.
or generation of smokes, or abrupt increase of
mist.
@ Loosening or falling-ofl of the governor, ln case that the engine is stopped during the
common rod rink, each lever around the luel
operation using heavy fuel oil and lhe engine
injection pump, link pin, or bolt.
is cooled down without changing the fuel oil,
O Deterioration ol fuel oil or lubricating oil, or heavy fuel oil in the equipment of the fuel oil
damage of the cooling water pipe
system (e.9. pump, filter, etc.) and piping will
@ Abrupt increase or decrease of rotation speed
not only solidily to prohibit restarting, but also
@ Abrupt increase of lubricating oiltemperature
incur substantial labor to clean and cleanse
@ Water supply disabled due to suspension of
after the accident.
cooling water supply

c) Disconnect the load off the engine, and return

ln case that the engine is overheated due to the operating lever, each valve, and the state of
suspension ol water su,pply, do not hastily all other equipment to "STOP" position.
supply cooling waler. . ,
lf cooled down abruptly, each part of the
engine may be delqrmed, resulting in In case that an emergency stop is conducled,
mallunction or accidents be minded not to restart the engine until the
cause is determined, the countermeasures
are taken, and recovery is completed.
@ nlixing ol water into lubricating oil
ln case that the engine is started without
@ Abrupt increase of exhaust air temperature
removrng the cause of the abnormality, the
@ ROrupt decrease of the turbocharger rotation
malfunction may be aggravated and sericus
speed or intake air pressure
accidents may be caused.
@ Generation of abnormal sound in the propeller
or the stern shaft system
"'"'ln case of the marine propulsion engine
@ Breakage or loosening of the bolts of each
section

DAIHATSU DK-20 Z 9g.B

CHAPTEB

4 Operation
ITEM

6.2.6.3 DK.2() Emergency Stop / Long-Term Shutdown

c) Open the covers for the crank and cam cases

Be minded not to open the crank case for at as well the cylinder head, and spray rust-
least 10 minutes afler the engine is stopped preventive oilto the internal parts.
and is completely cooled down. d) lnsert the moistureprool agent such as
lf the crank case is opened immediately atter silicagel into lhe crank case, according to the
the engine is stopped, {lammable mist in the ambient air conditions (e.9. weather and
crank case may catch fire and explode. humidity) and other necessitY.
Particularly be careful when a large amount e) Place the cover on outside air opening part of
of mist is generated due to overheat or the exhaust air pipe and the mist pipe.
seizing of ihe engine. f ) Cover lhe engine with a sheel, and carefully
Be minded never to let flames or sparks cover the electric equipmenl with particular
approach the crank case even after it is attention to prevent collection of dust on them.
opened.

4-6.3 Long-Term Shutdown

ln case that the operation ol engine is suspended
for a long term (one month or more), take the
preservation measures (mainly, anti-rusting
measure) on the lollowing procedure;

(1) Shutdown within 3 Months

a) Fully open the indicator valve once every
week, and conduct turning of the crankshafl
several times while conducting priming with
lubricating oil.
ln this case, stop the crankshatt at a position Spray
different f rom that before turning. (Bust-preventive
agent)
After turning, securely close the indicator
valve.
b) ln case that there is a risk of lreezing in
extrerr,ely cold season, be minded lo remove
coolir_o water f rom the engine.

(2) Shutdown beyond 3 Months

Measures lor Long-Term Storage
ln case tha::-e cgeration of engine is
suspencec ':' 3 :3'il'iS o!' more, lhe following
measures ior :-:-:€- s:3,'age is required:
a) Remove ccc, .,: ita:E- '':'n :he engine. Spray
(R ust-p reventive
b) Add rust-p.e,e::,: : ::
"bicating oil, open agent)
the indicatof va ,,e a-: l:-1J.1 turnlng of the
crankshaft severa : -3s .., - e conducting
priming with the lu!r'rca: -: :
After turning, secu.et. .:s: :-: -ci ,cator
valve. Measures lor Long-Term Storage

DK-20 Z 99-8 DAIHATSU

 CHAPTER
lnspection and Maintenance
5
Measurement and Adjustment: Maximum Combustion
Pressure and Exhaust Air Tem DK.2O 3.1
A
5-3 Measurement and Adjustment
Since the indicator valve is extremely hot
5-3.1 Maximum Combustion Pressure during the operation ol engine, there is a
and Exhaust Temperature danger ol burns if it is touched by bare
hands.
Maximum combustion pressure and exhaust
Therelore, be sure to wear safety gloves
temperature serve as the important indicators lor
when handling the valve.
knowing the engine combustion conditions and the
changes according to the elapse of time.
Normally, the decrease of the engine pertormance
can be indicated by the lollowing items:
o Decrease of the maximum combustion pressure Exhaust valve @

o lncrease ol the exhaust temperature Lock nut @

lndicator catch O
Conduct the measurement with the interval of once
a week or so, and record the results, so that the
tendency of the change can be identified and the
data can be used as the judgment materials when
determining the interval of the adjustment.

(1) Maximum Combustion Pressure

(hereinafter relerred to as Pmax)
a) Pmax
Prnax is determined by load, and varies
depending on the factors such as the luel oil
viscosity, intake air pressure, and intake air- lndicator valve @
temperature. Ordinarily, however, this Salety valve
adjustment is not necessary.
Pmax varies accoiding to the initial f uel
injection pumping angle, however, it is readily
Be sure to "Fully open" or "Fully close" both
t adjusted and set at an optimum value at the
the indicator valve and the exhaust valves ol
time of shipment from our factory.
the indicator, whenever these valves are
The fuel cam is fixed to the camshalt by shrink
used.
litting, and therefore, ordinarily, it cannot be
lf these vaives are used on the "Half-open"
adjusted.
state, high-ternperature gas will flow into the
threaded parls of the valve, and the screws
may be seized.
Since the items mentioned in this section will
be the items, to which the engine setting
value specified in Nox lechnical code shall
be applied, do not make any change that
may deviate from the setting value.
(lffi|, 0-3 "Engine Conforming to Nox
Technical Code")

DAIHATSU DK-20 Z 33-8

 CHAPTEB
lnspection and Maintenance
5
Measurement and Adjustment: Maximum Combustion
3.1 DK.2(} Pressure and Exhaust Temperature

b) Measuring Pmax (3) Adjustment of Reading on Fuel lniection

Perform the measurement of Pmax alter the Pump Rack
warming-up operation of engine has been ln case that the exhaust temperature differs from
completed and the load has become stable. those of other cylinders in excess of lhe range
During measuremenl, the measured values specified in the above (2l,lor example, when the
may change due to such factors as the luel injection plunger or the fuel injection valve
occurrence of the load fluctuation. ln such a nozzle is replaced, adjust the luel injection
case, perform the measurement again to amount by increasing or decreasing the reading
obtain a stable data. on the rack scale.
( tffil , "Tesl Run Record" included in fhe linal
documents) <Rack Adjusting Procedure>
The reading on the rack scale can be increased
<Measuring Procedure> or decreased by adjusting screw @ ol the fuel
i ) Open the indicator valve @ with a special injection pump rack lever.
wrench for indicator valve belore installing the i ) Loosen the lock nut @.
indicator @, and close the indicator valve after ii ) Turn the adjusting screw A and change the
lightly releasing it '1 or 2 times. reading on the rack scale.
ii ) lnstall the indicator to the indicator catch @, o Clockwise turning "lncrease" (lncrease of
and securely lock it by turning the lock nut @. exhaust ai r temperatu re)
iii) Close the exhaust valve @ of the indicator. .Counterclockwiseturning "Decrease"
iv ) Open lhe indicator valve. (Decrease of exhaust air temperature)
v ) Check the reading of .the pressure on the iii) Confirm that the exhaust air lemperature is
indicator. within the specilied value.
vi) Close the indicator. iv ) Securely tighten the lock nut.
vii) Open lhe exhaust valve ol the indicator, and
remove the indicator after indicating reading * Diflerence between cylinders: 1.5 mm or
has become "0". less

* Maximum value (when lully loaded):

15.7 MPa {160 kgf/cm,}
lever
* Diflerence between cylinders:
0.6 MPa {6 kgf/cm,} or less nut @

Back adjusting
(2) Exhaust Temperature screw @
The odraust lemperature at each cylinder outlet
lncrease
slightly varies lrom one cylinder to another
depending on the factors such as the elfect ol
Decrease
other cylinders as well as the distance to the
turbocharger inlet
The exhaust temperature can be adjusted by
increasing or irueasing lhe reading on the fuel
Rack link
. injection pump raclq trowever, the adjustment is
ordinarily unnecessary as frng as the difference Adjusting Rack
belween cylinders is wilhh the lolbwing value.

* Difference betweer c. ^::-s :- I :. ess

DK.2O Z 99-B DAIHATSU

 Inspection and Maintenance
5
Measurement and Adjustment:
Pressure and Temperature of Each,Part DK.2O 3.2

5-3.2 Pressure and Temperature of ture to be within the specified proper range, as far
Each Part as possible.
When the intake air temperature is too low, it
The pressure and temperature of lubricating oil, causes abnormal or excessive wear of the cylin-
fueloil, and cooling water, etc. are controlled by der liner, intake air valve, etc., since the water
I

I
the relief valve, so that they should be proper val- drops is formed by the dew condensation.
ues being within each specified value during the Further, if the intake airtemperature is too high, it
operation of engine, however, when actually damages the parts around the combustion cham-
operating the engine, the pressure and tempera- ber such as the exhaust valve, since the exhaust
ture of these fluids may not be within the speci- air temperature will increase. (Exhaust air tem-
fied and proper values. perature varies in proportion to the intake airtem-
ln such a case, readjust the setting values of perature, and also varies in the rate of approxi-
the valves, and perform the operation within the mately 2 times the change of the suction air tem-
specified proper range. perature of the turbocharger.)

L (1) lntake Air Pressure

lf the intake air temperature gets out of the
proper range owing to a low room temperature, or
Since the intake air pressure changes in accor- when automatic adjustment of intake air tempera-
dance with load, each pressure when the engine
ture cannot be made for some reasons, operate
was new (or, after adjustment) becomes a refer-
ence value. the following procedure.
The more the turbocharger is fouled, the more
<lntake Air Adjusting Procedure>
the intake air will decrease, resulting in the deteri-
oration of the engine performance (e.9. increase The intake air adjustment can be made by chang-
of the exhaust air temperature and increase of ing the cooling water flow rate in the air cooler.
the fuel consumption rate), and therefore regular- i ) Operate the handle of the bypass valve @ , .
ly conduct the blower cleaning and prevent the and change the opening angle of the valve.
progress of fouling.
r Open the bypass valve. (Handle facing side-
( M : 5-4.4"Cleaning Turbocharger Blower") ways) lncrease of tnmperature
r OpenClose the bypass valve (Handle facing
downward) Decrease of tnmperature
The turbocharger is at a high-temperature ii) Be attentive to changes of the intake airtem-
during operation and just after the engine is perature, and open the bypass valve so as to
stopped. lf you touch it with bare hands during
be within the proper range, and adjust the
cleaning, you may burn your hands. Wear
safety gloves without fail. angle.

s valve@
It is impossible to completely remove the
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, foulinqwill 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.

(2) lntake Air Temperature

&
>* Proper temperature: 45-55C (at full load) I
C r--roii n L: vr,;iler it ilet
lntake air, that is either higher or lowerthan the \.
specified range, will affect the engine, and there- Air Cooler Bypass a

fore be minded to adjust and keep the tempera-

I A-)tl _
 CHAPTER
lnspection and Maintenance
5
ITEM
Measurement and Adjustment: Maximum Combustion
3.1 DK.2() Pressure and Exhaust Temperature

b) Measuring Pmax (3) Adiustment of Reading on Fuel lnjection

Perform the measurement of Pmax after the Pump Rack
warming-up operation of engine has been ln case that the exhaust temperalure differs from
completed and the load has become stable. those of other cylinders in excess of lhe range
During rneasurement, the measured values specified in the above (2), lor example, when the
may change due to such factors as the fuel injection plunger or the fuel injection valve
occurrence of the load fluctuation. ln such a nozzle is replaced, adjust the luel injection
case, perform the measurement again to amount by increasing or decreasing the reading
obtain a stable data. on the rack scale.
( Iffil : "Tesl Run Record" included in fhe final
documents) <Rack Adjusting Procedure>
The reading on the rack scale can be increased
<Measuring Procedure> or decreased by adjusting screw @ of the luel
i ) Open the indicator valve @ with a special injection pump rack lever.
C
wrench for indicator valve before installing the i ) Loosen the lock nut @.
indicator @, and close the indicator valve after ' ii ) Turn the adjusting screw A and change the
lightly releasing it 1 or 2 times. reading on the rack scale.
ii ) lnstall the indicator to the indicator catch @, r Clockwise turning "lncrease" (lncrease of
and securely lock it by turning the lock nut @. exhaust air temperature)
iii) Close the exhaust valve @ ol the indicator. oCounterclockwiseturning "Decrease"
iv ) Open the indicator valve. (Decrease ol exhaust air temperature)
v ) Check the reading ol.the pressure on the iii) Conlirm that the exhaust air temperatufe is
indicator. within the speci{ied value.
vi) Close the indicator. iv) Securely tighten the lock nut.
vii) Open the exhaust valve of the indicator, and
remove the indicator after indicating reading * Difference between cylinders: 1,5 mm or
has become "0". less

* Maximum value (when lully loaded):

15.7 MPa {160 kgf/cm,}
* Diflerence between cylinders:
0.6 MPa (6 kgf/cm,) or less

(2) Erhaust Temperature

The odrausl temperature at each cylinder outlet
lncrease
slightly varies from one cylinder to anolher
depending on the factors such as the eflect ol
Decrease
other cylinders as well as the distance to the
turbocharger inlet
The exhaust temperature can be adjusted by
increasing or lrrcreasirg the reading on the luel
Back link
injection pump raclq ]pwever, the adjustment is
ordinarily unnecessarlr as long as the difference Adjusting Rack
between cylinders is wiffu the lolkrwing value.

* Diflerence betwee- c, - =.-s : _ I :, ess

DK-20 Z 99-B DAIHATSU

 lnspection and Maintenance
5
Measurement and Adjustment:
Pressure and Temperature of Each,Part DK.2O 3.2

5-3.2 Pressure and Temperature of ture to be within the specified proper range, as far
Each Part as possible.
When the intake air temperature is too low, it
The pressure and temperature of lubricating oil, causes abnormal or excessive wear of the cylin-
fueloil, and cooling water, etc. are controlled by der liner, intake air valve, etc., since the water
the relief valve, so that they should be proper val- drops is formed by the dew condensation.
ues being within each specified value during the Further, if the intake airtemperature is too high, it
operation of engine, however, when actually damages the parts around the combustion cham-
operating the engine, the pressure and tempera- ber such as the exhaust valve, since the exhaust
ture of these fluids may not be within the speci- air temperature will increase. (Exhaust air tem-
fied and proper values. perature varies in proportion to the intake airtem-
ln such a case, readjust the setting values of perature, and also varies in the rate of approxi-
the valves, and perform the operation within the mately 2 times the change of the suction air tem-
specified proper range. perature of the turbocharger.)
lf the intake air temperature gets out of the
(1) lntake Air Pressure proper range owing to a low room temperature, or
Since the intake air pressure changes in accor- when automatic adjustment of intake air tempera-
dance with load, each pressure when the engine
ture cannot be made for some reasons, operate
was new (or, after adjustment) becomes a refer-
ence value.
the following procedure.
The more the turbocharger is fouled, the more
<lntake Air Adjusting Procedure>
the intake airwilldecrease, resulting in the deteri-
oration of the engine performance (e.9. increase The intake air adjustment can be made by chang-
of the exhaust air temperature and increase of ing the cooling waler flow rate in the air cooler.
the fuel consumption rate), and therefore regular- i) Operate the handle of tfre bypass valve @,
ly conduct the blower cleaning and prevent the and change the opening angle of the valve.
progress of fouling.
r Open the bypass valve. (Handle facing side-
( M : 5-4.4"Cleaning Turbocharger Blowed') ways) lncrease of tnmperature
r OpenClose the bypass valve (Handle facing
downward) Decrease of tnmperature
The turbocharger is at a high-temperature
during operation and just after the engine is
ii ) Be attentive to changes of the intake air tem-
perature, and open the bypass valve so as to
stopped. lf you touch it with bare hands during
be within the proper range, and adjust the
cleaning, you may burn your hands. Wear
safety gloves without fail. angle.

valve@
It is impossible to completely remove the ooo
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, foulinqwill 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.

(2) lntake Air Temperature

A
* Proper temperature: 45-55C (at full load) I
Cr;oiir-rit v\,alet' ii ilei watei 0utlei
lntake air, that is either higher or lowerthan the
specified range, will affect the engine, and there-
Air Cooler Bypass Valve
fore be minded to adjust and keep the tempera-

DK-20 A 05-3
CHAPTER

5 lnspection and Maintenance

Measurement and Adjustment:
3.2 DK.2O Pressure and Te ure of Each Part

ln case that the intake air does not fall within the r Counlerclockwise turning (loosening)
proper range even when the bypass valve is lully Decrease ol pressure
opened and the enlire amount of cooling water is iii) Be attentive to changes of the pressure, and
flowed into the air cooler, it is required to confirm that the pressure has entered within
disassemble and adjust the air cooler since the the blue mark range.
louling of the air cooler can be considered. iv) Tighten the lock nut @, and attach the cap @.
( fftg1 12-3 "Air Cooler" in the lnstruction
Mdffi l, "Mainlenance Version") Air vent valve

(3) Lubricating Oil Pressure

* Proper range (Blue zone range of

manometer): 0.4-0.5 MPa {4 - 5 kgf/cm'}

Lubricating oil pressure changes in accordance

with the changes in the viscosity and
temperature ol lubricating oil.
When the engine is started in extremely cold
wealher, and the temperature of the lubricating
oil is still low and the viscosity ls high, the
pressure reading may go up beyond the blue
mark range, however, it does not impose any
problem il the reading falls back within the blue
Adjusling screw
mark range when the engine is warmed up. Lock nut
ln case that the pressure reading is beyond or
under the blue mark range, adjust the pressure
on the following procedure:

1) Do not loosen the adjusting screw beyond

Lubrcating oil pressure decreases when the the loosening limit ( 4 =30mm). The cap
filter is fouled. Be sure to perform the may not be installed back, if the screw is
adjustmeni of pressure after the filter is loosened excessively.
cleaned u,'e 2) ln case that the lubricating pressure dose
( fR : 5-4.3'Cleaning Filters") not change even when the adjustment
screw is turned, there is the possibilities of
sticking ol the relief valve, suction of air,
<Lt-ricdhg Oil. Pressure Adju sti n g pump failure, and so on, and therelore
Procedre investigate the causes o{ the trouble.
When aOFSiB [re lsri:aiing oil pressure, use
the adiusniq scrEwqr tre lubrbating oil relief
vahre. Since the rate of the oil supply to the periphery of
i ) Remove the screw cap € of the relief valve, the rocker arm is set at the pressure of 0.1 MPa
and loosen the loct< nut g- {1 kgf/cm'} or more by the reliel valve located at
ii ) Turn the adjusting screw O, and adjust the the cylinder head inlet, the adjustment is not
pressure. required.
oClockwise tu.n ^: : l-'.- -, .arease
of pressure

DK-20 Z 99-B DAIHATSU

 CHAPTER
lnspection and Maintenance
5
Measurement and Adjustment: ITEM

Pressure and Temperature of Eactt Part DK.2O 3.2

(4) Lubricating Oil Temperature screw, and set the lock nut when the
temperature has entered the following range:
* Proper range: 50-60'C (cooler outlet)
* Use range: 30-60'C
Lubricating oil temperature is controlled to Since the oiltemperature changes according
remain within the proper range of temperature by to the load, be minded to set the oil
the automatic temperature control valve installed temperature at a rather lower level, so that it
at the lubricating oilcooler outlet. will not exceed the limit when heavily loaded.

a) Lubricating Oil Temperature Control Vatve

Temperature conlrol valve
The temperature conlrol valve is an automatic Lock nut @
I
bypass valve, that changes the llow rate ol Adjusting screw @
lubricating oil passing through the cooler, -
according to its temperature, and when the
engine is started while it is still in cold state,
this valve rapidly raises lhe lubricating oil by
letting the oil bypass through lhe cooler, and
when the engine is operated normally, this
valve maintains the lubricating oil to be within
the suitable range of the specified value.
ln case that the lubricating oil does not lall
within the proper range, for example, because
Lubricating oil cooler
the cooling water (secondary water)
temperature is different f rom the design
lemperature, the temperature of lubricating oil (5) Cooling Water Pressure
can be adjusted by the adjusting screw ol the
temperalure control valve. However, in case * Proper range: 0.25-'0.35MPa
that the actual temperature is exceeding the {2.s - s.5 kgl/cm2))
correctable range and the adjustment is
impossible, contact us for consultation on the Jacket cooling water pressure substantially
problem. changes depending on the external conditions
such as the cooling water expansion tank head,
b) Manual Adjustmen-Emergency Measures pipe resistance, and so on.
ln case that the lemperature control valve has When cooling water pressure is too low, it will
become faulty and the temperature control has cause corrosion of the engine lrame or cylinder
become impossible, the engine can liner, and therefore adjust the cooling water
continuously be operated by pedorming the pressure at lhe engine outlet using the valve or
emergency measures on the following orifice, so that the pressure should be proper
procedure. during the operation ol engine.

<Adjusting Procedure>
i ) Loosen the lock nut @, and screw the
adjusting screw @ down to its bottom.
Totally close the passage ol the cooler.
ii ) Closely watch the changes of the oil
temperature while returning the adjusting

DAIHATSU DK-20 Z 39-8

-l

CHAPTER
lnspection and Maintenance
5
ITEM Measurement and Adjustment:
3,2 DK.2O Pressure and Temperature of Each Part

(6) Cooling Water Temperature iii) Closely watch the changes of the pressure,
and confirm that the pressure reading is within
* Proper range: 70-75'C (engine outlet) the proper range.
iv) Tighten the lock nut @, and attach the screw
a) Warming-Up Operation cap @.
When jacket cooling water temperature is too
low, it will cause faulty combustion or
the corrosion or wear of the parts around the
combustion chamber, and therefore
be minded lo staft the operation of engine with
load after raising the cooling water temperature
by warming-up operation.
( lffil : 4-4.2 "W arming-Up Operation")
a
b) Temperature Control
Cooling water temperature is controlled to.
remain within the proper range by the
temperature control valve installed between
the jacket cooling water inlet and outlet pipe
Lock nut
(lresh water cooler inlet and outlet pipe).
This temperalure valve is an automatic bypass lncrease Decrease
Adjusting screw
valve that is functionally identical with the
lubricating oil temperature control valve.
tlffil : 5-3.2 (4) "Lubricating Oit Temperature") screw cap --m
(7) Fuel Oil Pressure
a) Engine using Heavy Fuel Oil Fuel Oil Pressure Adlusting Procedure
When using heavy luel oil, the pressure of
heavy fuel oil must be adjusted to be within the When the engine with heavy fuel oil specification
following range, so thal generation of vapor is operated by diesel fueloil, the fueloil pressure

due to heating-up ol the fuel oil can be does not decrease since lhe luel oil cannot be
prevented: pressurized as in the heavy luel oil supply line,
however, the adjustment ol the fuel oil pressure
* Proper ranEe: 0.5-0.6 MPa {5-6 kgf/cm,} is not required if the pressure is within the
following range.
<Fuel Oil Pressure Adiusting Procedure>
Adjustrtqfi of fnel oil pressure can be made by * 0.2 MPa {2 kgf/cm'?} or more
the prcssrre aqu$irg screw ol the luel oil reliel
valve. b) Engine using Diesel Fuel Oil
i ) Remove the scrw €p @ of the reliel valve,
and loosen ttp lod( nut @. * Proper range: 0.2-0.3 MPa {2-3 kgf/cm'?}
ii ) Turn the adjustilg screw @, and adjust the
pressure. ln case of diesel luel oil specification, the
o Clockwise tuming (tightening) lncrease pressure adjustment procedure is the same as
of pressure in case of heavy fuel oil specification, since the
o Counlerclockwise turning (loosening) same type ol the fuel relief valve is used in
Decrease of pressure both cases.

DK-20 Z 9e-8 DAIHATSU

 CHAPTER
lnspection and Maintenance 5
Measurement and Adjustment:
Pressure and Temperature of Each Part DK.2O 3.2

(8) Fuel Oil Temperature......When Using Further, in case that nozzle cooling is conducted
Heavy Fuel Oil using lresh water, it is not required to regulate
Heavy fuel oil musl be heated so as to make its both the pressure and temperature, since jacket
viscosity suitable for injection, before the oil is cooling water is used in such a case.
supplied to the engine.
b) Nozzle Cooling Oil Temperature
'.....When
{< Proper viscosity (engine inlet) dynamic Using Heavy Fuel Oil
viscosity: 14*1 cSt
* Proper range: 50-60'C
Since the temperature appropriate for proper
viscosity varies depending on the properties Nozzle cooling oil temperature is regulated by
(viscosity) ol heavy fuel oil, be minded to keep the temperature control valve.
the proper viscosity referring to the following This temperature control valve is the same type
t_
figure as a standard: as the one used for regulating lubricating oil. As
( [$: Fig.6-1.1 "Fuel Oil Temperature Curve") for the regulating procedure, reler to the <
' ln case that the viscontroller (automatic viscosity Adjusting Procedure > of (4) Lubricating Oil
regulator) is installed to the engine, control the Temperature.
fuel oil viscosity in accordance with instruction ln case that nozzle cooling oil temperature is too
manual, and be minded to carefully keep the low, it willcause sulfated corrosion on the tip part
manual. ol the fuel injection valve nozzle, and in case that
( @ :4-4.4 "Operalion Using Heavy FuelOil") the temperature is too high, it will cause
( t[CI: 6-1 "FuelOilCharacterislics and generation ol carbon flower on the nozzle.
'Control")

(9) Nozzle Cooling Oil Pressure and Temperature

.....When Using Heavy FuelOil
ln case that nozzle cooling system ls
incorporated as an separate system as
independently installed, and diesel fuel oil is
D used as the relrigerant carrier in stead of cooling
water, it is required to control the pressure and
temperature to be within a proper range ol the
value.

a) Nozzle cooling oil pressure

.....When Using Heavy FuelOil

* Proper range: 0.1 --0.3 MPa {1 "--3 kgf/cm,}

ln either case of DO or HO, be rninded to leed

nozzle cooling oil. Since nozzle cooling oil
passes through the high-temperature parts, it
may block the passage il the llow has become
stagnant or stopped, and therelore be minded to
secure the specified pressure for nozzle cooling
oil..

DAIHATSU DK-20 Z 99-8

r

CHAPTER
Inspection and Maintenance
5
ITEM Parts around lntake and Exhaust Valves, and
4.'.| DK-20 Adiustinq Valve End Clearance

5-4 lnspection and Maintenance valves, and a single valve holder tee is provided
to simultaneously push down both pairs of intake
5{.1 Inspecting Parts around lntake and and exhaust valves, and therefore unless the
Exhaust Valves, and Adjusting Valve valve end clearance ol each pair ol both intake
End Clearance and exhausl valves is equal, the valve pushing
force will be unbalanced, resulting in abnormal
(1) Feplacing Consumables, lmplements, and
wear or damage of the valve holder tee and the
Measuring lnstruments
guide parts.
a) Replacing Consumables (tml: 'Parts List")
O Head cover rubber seal No.D'lO Valve retainer tee
b) lmplemenls and Measuring lnslruments lntake and exhaust
e Generaltools valve rocker arm

t tffit : "lmplements List" in the final

documents)

(2) lnspecting 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 ol the engine. Therelore,
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 lnlake and exhaust valve cotter
durlng the operation of engine.
Valve End Clearance Adjusting Procedure
b) Check the following points on these valves
removing the cylinder head cover when the <Valve End Clearance Adjusting Procedure>
engine is stopped. i ) Place the cylinder in the explosion slroke,
O Lubricating conditions of the rocker arm and and close the intake and exhaust valves.
push rods ii) Loosen the lock nuts of the adjusting screws
O Lubricating and sludge collecting conditions
@ and @, and turn back the adjusting screw
of the intake and exhaust valve cotters, and @ and @.
vaive rctators iii) Closely fit the valve end 'Au, place the dial
3 Stuoge collecting conditions around the gauge against the valve holder tee, and tighten
val'v'€ SDr ng
the adjusting screw @ until the scale pointer
€ Rcta: ^g condiiions of the valve rotators swings, so that it can be confirmed that the
€ Valr,e e'l3 c earance valve ends "A" and "8" are both closely lit at
lhe same time.
(3) Adjusting Valve End Clearance
iv)
Since vaii'e ei: a eara.rce decreases due to the
wear of ti"e ,a ,e s€a: part, and therefore be
@
minded tope:.=.2 , ^spect and adjust it.
When the vai,,'e e',= ..a.arce is too small, it will
v ) lnsert a thickness gauge of the specified
thickness into the clearance "C" on the top part
cause improper se: -l :' :-e vaive on its seat
during the operal .- '-' z-J -e cue to thermal
ol the valve holder tee, and adjusl the
clearance using the adjusting screw @.
expansion oi ti-e ,a ,e :3:, a-: push rod,
resulting in burn,n: a':-: ::::
* Proper clearance: 0.31 mm
Further, the valve s:,s::- :. :- : :-: re is 4-
(for both intake and exhaust valves)
valve type, having 2 iniarre ,: ,:: :-:2 exraust

DK-20 A 03-02 DAIHATSU

 CHAPTER
lnspection and Maintenance
5
lnspecting and Maintenance of Fuel lnjection Valve DK.2() 4.2

5-4.2 lnspection and Maintenance of Fuel

Injection Valve lnlet connector

Since the conditions of the fuel injection valve

substantially affeci the performance of engine
operation, be minded to periodically inspect il and
conduct the maintenance.
However, in case that remarkable changes have
been found in the maximum combustion pressure,
exhaust temperature, exhaust color, and so on, be gasket @
minded to conduct immediate inspection and Fuel injection valve @
maintenance, regardless of the standard
inspeclion and mainlenance period.

Since the items mentioned in this section will

be the parts to which NOx Technical Code High-pressure fuel
coupling @
shall be applied,'when replacing any ol these
parts, be sure to use the parts provided with
the identification marks. View "P"
( ffi :0-3 "Engine Conforming to NOx
TechnicalCode")

(1) Replacing Consumables, lmplements, and

Measuring lnstruments ffi

a) Replacing Consumables (lml: "Parts List") p.n

e Circular gasket No.507

{rl
@ Gasket No.2'18 E:il

@ O-ring No.12
@ O-ring No.5o3
{g O-ring No.5o4
@ O-ring No.505

b) lmplements and Measuring lnstruments

O Generaltools and measuring instruments
(t[h, Final Documents)
@ Nozzle holder extracting implement
@ Fuet injection tesiing device
@ Nozzle cleaning implement Nozzle Holder Extracting Procedure

(2) Extracting Fuel lnjection Valve

Extraction of the fuel injection valve can be 1) Be careful so that the circular gasket 3
conducted on the following procedure: may not be left behind in the cylinder heac
2) Afler removing the high-pressure f.le
<Extracting Procedure>
coupling and {uel injectron val,. e te
i ) Close the valve of the nozzle cooling water
minded to place lhe cover bcil c- l-:
(or, oil) pipe system, and drain the water (or,
coupling part of the luel injectrc- :--: e-:
oil) completely. (tn case of heavy luel oil
on the insertion part of the c, r:e'-:a:
specifications)

DAIHATSU DK-20 A CO-g

CHAPTER

5 lnspection and Maintenance

IIE,M

4-2 DK-20 lnspecting and Maintenance of Fuel lnjection Valve

ii) Remove bolh the cylinder head cover and

heat box cover.
iii) Loosen the bolt @ and @, remove the high-
pressure fuelcoupling (block) @.
iv) Remove the inlet connector @.
v ) Remove the tightening nut @ using a box
Tester side
wrench.
v ) Extract the fuel injection valve @ using a luel
injection extracting implemenl.
vii) Remove the circular gasket @.

(3) lnjection Test

Conduct a fuel injection test of the luel injection
valve, to check if the opening pressure and the
spraying conditions ol the luel injection valve is Nozzle holder side
in proper and normal slate.
Conduct the fuel injection test using the luel
lnjection Test Procedure
injection test device installed to the engine.

a) lnspecting Valve Opening Pressure

i ) lnstall the fuel injection valve on the injection
Cap nut @ Screw drive
test device, after removing the carbon stuck on
the tip of the valve, and cleaning the tip. Adjusting nut
ii ) Connect the test pump and fuel injection
valve using a high-pressure hose for testing.
) Quickly operate the test pump lever several
iii
times, and drain the air until the valve starts
injection of the fuel as the pressure indicating
:F Lock nut

scale swings.
iv) Slowly turn the test pump lever (once every
second, or so), check the pressure reading
(the piessure, that has once increased
gradua y. suddenly starting to decrease due to
openir': :f :re valve).

*Norrnal prc$sure: 27.4-29.4 MPa

{28O-3OO kg/cm'z)
Pressure Adjusting Procedure

b) A$usling YCrre Opening Pressure

When reassembling the luel injection valve * Setting pressure: 29.4 MPa {300 kgf/cm'}
after conducting the mainlenance work by Be minded to set the pressure of the fuel
extracting the valye out ol the engine, and injection valve al a rather higher level,
when the noule is rep&aced with a new one, taking into consideration the initial working
adjust the valve pressure on the following adjustment, in case that a new injection
procedure: valve is introduced.
" " " 30.4 MPa {310 kgf/cm'?}

DK-20 Z 9s-8 DAIHATSU

 CHAPTER
lnspection and Maintenance
5
ITEM
lnspecting and Maintenance of Fuel lnjection Valve DK.2O 4,2

Since the items mentioned in this section will

be the parts to which engine setting value r..-1\

specified in NOx Technical Code shall be

(I\ '- 4/
,-fi
\:::::::r\
Eti,tl

confirmed, do not make any change lhat may w

lt .,\
deviate from the setting values. , 2.,:::iil
liiil \:'::,,\
( l[lt: 0-3 "Engine Conforming to NOx
EY fiiil "{,
TechnicalCode")
Normallnlection

gMM
<Valve Opening Pressure Adjustment
Procedure>
i ) Hemove the cap nut @.
ii ) Loosen the lock nut O for the adjusting
screw O,
iii ) Adjust the pressure to the specified pressure,
by lurning the adjusting screw using a (A)Gbgjed nozzle (B) lmiroper (C) Droopy nozzle
needle valve action
screwdriver, while conducting the injection ol
thb fuel, as in the same procedure as in the Abnormal lnJection
case ol the fuel injection test.
o Screwing-in of adjusting screw High
.Turning-back of adjusting screw Low
iv ) Tighten'ihe lock nut O. nut @

c) lnspecting Fuel lniection nut O

lnspect the fuel injecting conditions on the
following procedure:
i ) Quickly operate the test pump lever several

q
times (2 to 3 times every minute, or so), and Adjusting screw O
inspect the fuel injecting conditions.
@
(Let the fuel injected against a blank paper,
so that the conditions can be better
inspected.)
e Check il cutting-off injection is good or not.
'..'..lnjection sound tnt.t.onn.(o,. O
@
o Check il the injeciion is made in clear spray,
not being in spray of bar pattern injeclion, rod
/6\
v
nor dripping down.
Spray lubncating agent
pin @
ii ) Check if there is no dripping-down ol luel (Molykore 1000)
from the tip of the nozzle alter the iniection
tcst.
ll
Fuel lnjection Valve (A)
Be minded not to approach your f ace or
hands near lhe f uel spray during testing.
lf the high-pressure fuel has hit your face or
hands, it will cause injuries.

DAIHATSU DK-20 Z ?g-8

I

CHAPTER

5 lnspection and Maintenance

ITEM

4.2 DK.2O lnspecting and Maintenance of Fuel lnjection Valve

(4) Disassembling and lnspecting Nozzle

ln case that a remarkable decrease ol the valve
O (k-
K
Nozzle
opening pressure, laulty injection of fuel oil, or
dripping-down of fuel oil after injection is found
nut @
as the results of the fuel injection test, conduct
disassembling, cleaning, and inspection on the
following procedure:

a) Disassembling the Nozzle

i ) Remove the cap nut @.
O.
ii ) Loosen the adjusting nut
iii ) Fix the holder housing @ in a vise, and
loosen the retaining nut @.
H* (
iv) Extract the needle valve out of the Nozzle O. """0''
v ) Extract the nozzle out ol the retaining nut, by [.5'g"o'"n
striking with a hammer, placing a pipe-type
patch on the nozzle, so as nol to damage the
nozzle hole.

cleaning implement
lf the retaining nut is turned while the
adjusting nut is still lightened, it will damage
the nozzle or nozzle holder parts.
ln case that heavy luel oil is used, the
retaining nut and nozzle may be stuck
together with carbon accumulated on them.
lf the nut is loosened in this state, the nozzle
will turn together with the nut, and may Nozzle Cleanin g Procedure
damage the nozzle, or the knock pin of (
spacer. and therelore first lubricate the nut
with gas oil, and then carefully loosen the nut
by slriking the nozzle with a hammer, while Since the nozzle and needle valve is a pair
placing a patch on the nozzle. functioning together, be minded not to
replace either of them separately.
Do not try to reuse a laulty nozzle by
U) Ursprlcnrg ilozde
wrapping, but be sure lo replace it with a new
i ) Cban fie nozde nut and needle valve with
one.
gas oI.
ii ) Cban fte rDde hob with a nozzle cleaning
implement.
fr ) Push in ard pusrr orrt with hand, and check
the movement
o Check if the rrosleal b smooth or not.
o Check if the molernent is too bose.

DK-20 Z 99-8 DAIHATSU

 CHAPTER
lnspection and Maintenance
5
ITEM
lnspecting and Maintenance of Fuel lniection Valve DK.2O 4,2
(5) Assembling Fuel lnlection Valve iv) Attach the holder tightening nut @, and
Assemble the fuel injection valve in the reverse evenly tighten with the specified torque.
order of the disassembling procedure.
i ) Clean each of the disassembled parts with * Specif ied torque: 59 N'm {6 kgf 'm}
clean gas oil, and insert each of them back
into the holder housing @. v ) Screw in the inlet connector with hand, and
ii ) Put the spacer @ and the knock pin @ of tighten it with the specilied torque.
nozzle together, and install them into the
holder housing. :l Specilied iorque: 88-98 N'm
iii) Apply the lubricating agent (Molykote 1000 (9-10 kgl'm)
U-paste) on the holder housing thread, the
seat face of the retaining nut @, and the outer vi) Attach the high-pressure fuel coupling and O-
t periphery of the nozzle, and screw the
retaining nut into the holder housing by hand.
rings on the cylinder head side and fuel
injection pipe side, tighten the high-pressure
iv ) Loosen the adjusting nut O. fuel coupling tightening bolt @ and O with the
v ) Tighten the retaining nut with the specified specified torque.
torque.
x Specified lorque: 34-45 N'm
{, Specified torque: 196- 226 N ' m kgf 'm}
{s.s.-4.s
l20-23 kgf 'm)

Be careful not to tighten the retaining nut with

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

vi) Set the fuel injection valve on the injection

test device, and adjust the valve opening
pressure.
(tEEl' 5-4.2 (3) "Fuet tnjeclion Test)

(6) Mounting Fuel lnjection Valve

Mount the fuel injection valve to the cylinder
head in the reverse order ol the extracting
procedures.
i ) Apply heat-resistant agent on the O-rings,
and attach them to the holder housing @.
ii ) Apply heat-resistant agent on the circular
gasket, and attach it to the holder housing.
iii ) lnsert the fuel injection valve into the cylinder
head guide hole, afler confirming that the old
gasket is not lelt behind in the guide hole.

DAIHATSU DK-20 Z 39-8

(

CHAPTER
lnspection and Maintenance
5
ITEM

4.3 DK.2() Cleaning Filters

5-4.3 Cleaning Filters an earlier state, while the louled degree of filter
is still light. (The cleaning should be conducted
Fuel oil filters and lubricating oil filters have very
at least once a week.)
important roles, i.e., removing foreign matlers or
sludge in oil and keeping the oil clean, and
maintaining the normal operation of the various
parts of engine. Therelore, it is important to
periodically overhaul and clean, so that filtering
capabilities can be maintained.
The notch-wire duplex type filter and centrifugal
type lubricating oil bypass filter are used lor fuel oil
and lubricating oil, and which type should be used
shall be decided depending on the specification ol (
each engine.
( EE: Separately provided "Engine
Specification")

(1) Notch-Wire Duplex Type Filter

The notch-wire duplex type liller is normally used
as both-side-parallel application. Drain cock

Since both the fuel oil pressure and lubricating oil Notch-Wire Type Filter
pressure decreases il the filter has been fouled,
be minded to periodically conduct blow-olf
cleaning. ln case that the oil pressure does not Filters used on both sides'P"
increase even after lhe blow-olf cleaning has
been conducted, overhaul the lilter and then
clean it.
Blow-off on Blow-off on
lelt lilter "O' right lilter "Q"
a) Replacing Consumables (
Left lilter Rioht lilter
For lubrrcating oil 32XP (tELh: "Parts Lisl") shut ot sh"ut otf
.3 Gasket No.157
€ Gasiei No.1 86
€ Elemer^t gasket No.28'l
For fuer o:l 32PED ( lffil: "Pars List")
3 O-n"g i'i:.106
2 Gast<et l',:. i 52
3 Gasi<e: li:.'-:l
O Gaskei l.: 2ii

b) Blow-Ofl Cleaning
When both lilters Blow-ofl on One side shut oft
ln case of bic,,,-:'' :.?' ' 3. Ceposits can be are used right lilter
removed by reve's:,, ':r, --: :i-e {luid through """Right and lefl elemenls
E1 E2 l
the element on:-. s:: a.f, this type of C1 """Seleclor cock inlet hole [ lnterlocke
,.

cleaning has no c aa- -; e"e:: when the c2 '.....serecror.o"r ori"i'io1 |

C3 " " "Selector cock blow-otf and draining hole r
element is substani a t, : : l;:: a- : therefore
be minded lo conduci :-= : :,...:- : =:^i1o in

DK.2O Z 99-B DAIHATSU

I
 CHAPTER
lnspection and Maintenance 5
ITEM
Cleaning Filters DK.2O 4.3

<Blow-Off Cleaning Procedure>

i ) Open the drain cock @ at the bottom part of
filter. At this time, be careful so that waste oil
may not scatter or overllow out ol the drain
Tighlening nut @
cock. Element @

ii ) Turn the selector cock handle @ (usually, set

to "Used on both sides" (P) position) to the
"Blow-off" position (about 60rc), and quickly
conduct the operation to return the handle to
the previous position (within 0.5- 1 sec.).
iii ) Flepeat this operation 2-3 times.
Case @
iv) Conduct the above same procedure on the
( other side.
v ) Close the drain cock.

Conduct the blow-off cleaning quickly.

Further, do not place the lever on the middle
position, but quickly move to the specified
position (knock position).
lf too much time has been taken in blow-off Handle @ Knock @ raising bolt
cleaning and switching the lever positions,
the pressure will decrease, and may activate Filter Overhaul Procedure
the alarm or emergency stop. Rir{}&r!L'ilj

c) Overhaul and Cleaning ol Filters

Be minded to conduct the overhaul and
cleaning of filters when the engine is stopped,
as far as possible. ln case that the overhaul
and cleaning is performed during the operation
ol engine, first conduct the blowing-off cleaning
on the opposite side, and then perform the
overhaul and cleaning while the engine is in an
idle operation or is under a low-load operation.

When using the heavy fuel oil, the fuel oil is

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

DAIHATSU DK.20 Z --:-3

CHAPTER
lnspection and Maintenance
5
ITEM

4.3 DK.2O Cleaning Filters

<Overhaul and Gleaning>

i ) Turn the selector handle @ to "Close" 1) Check conditions of the sludge collected
position (901 on the side to be overhauled. on the element.
ii ) Open the drain cock @, loosen the air vent Particularly in case of the lubricating oil filter,
valve @ at the top of the Case @, and if metallic particles are lound, investigate
discharge oil. the causes and take the countermeasures.
iii ) Loosen the tightening nul @, remove the 2) When the element is damaged, or when
case @, and then take out the element @. the element is excessively louled and
iv) Clean the element with washing oil or gas oil, clogging cannot be removed even by
and conduct blow-off cleaning lrom inside. cleaning, replace the element with a new
v ) Clean each of the parts overhauled, and one.
clean the case gasket grooves of the filter 3) Since the gaskets and O-rings are easily
housing @. be damaged, be very carelul in handling
these parts. Particularly, the heavy luel oil
<Assembly and Bestoration> filter tends to be deteriorated in high-
i ) Attach the gasket O to tne elemenl @, and temperature conditions, and therefore be
attach the gasket e to tne lilter housing @. minded to replace the {ilter every time the
ii ) Put the spring @ on the element, and place overhaul is conducted.
the case @ on the top of the spring, and screw
the nut @ into the case while holding the case
with hand. (2) Y-Type Filter
iii ) Close the drain cock @. a) Overhaul and Cleaning
iv ) Shifl the handle @ to "Blow-off" position. i ) Remove the plug.
v ) When the filter is overhauled and cleaned ii ) Remove the slrainer.
during the engine being stopped, conduct iii ) Clean the strainer with washing oil or gas oil.
priming and filllhe case with oil.
vi) Close the air venl valve @, after the oil has d) Mounting
been let overf low and air bubbles have When mounting the Y-type lilter, be minded to
completely vanished from the oil flowing out of mount it with the plug side lacing downward, so
air vent pipe. that sludge may be accumulated in the
vi) Return the handle to "Both sides used" (P) strainer.
position.
w) Check ii rhere is any oil leakage lrom the
gasket seciicns.
lnlgl + + Outlet

Confirm ttlat tle knock @ ol the handle @ is

engaged in its position.
ll the knock is rrct properly engaged in the
position, the handle will be overturned by
vibration during the operation of engine, and
rnay incur oil spilFout acciJents. Disassembling Y-type Filter

DK-20 Z 99-8 DAIHATSU

 lnspection and Maintenance
5

Cleani ng Turbocharger,Blower DK-20 4.4

5-4.4 Cleaning Turbocharger Blower Cleaning of the turbocharger blower can be

made using the cleaning device that is supplied
lf the fouled degree of the turbocharger blower
together with the engine.
has progressed, the efficiency of the turbocharger
will decrease and the operating performance of i ) Pour cleaning liquid into the blower syringe @.
engine will be worsened. Particularly when heavy ii) Connect the syringe socket to the filling pipe
fuel oil is used, the turbocharger blower tends to (D that is connected the turbocharger inlet side.
be fouled in faster degree, and therefore be mind- iii) Fully open the drain cock of the air intake duct.
ed to conduct blow-off cleaning and restrain the iv) Operate the syringe to injecl cleaning liquid.
progress of fouling.
v) \Mren 3 to 5 minutes has passed afier the
(1) lnterval of Cleaning injection of cleaning liquid, inject fresh water of
the same amount on the same procedure.
Clean the blowerwhen intake air pressure has
decreased 10o/o atthe same load, or at least Injection Amount and lnjecting Time]
o every 150 to 200 hours of operation.
(21 Load during Cleaning
vi)) ln case thal there is no change in intake air

Make sure that the engine shall be operated Type of Injection Injecting
under the load of 75Yo or higher, and continue the turbocharger anrount (L) time (sec)
Ioaded operation for t hour or more after cleaning.
123
(3) Cleaning Liquid 0.1s
Be sure to use the specified cleaning liquid. ln 133
case that the specified cleaning liquid is not avail-
able, use fresh water. (Note that cleaning effect 14s
is inferior with fresh water.) RH 0.2 4-10
163

Be minded never to use gas oil or any other

183
--.. ---. -l
i
-- 0.3
flammable liquid for cleaning, since these liq- 203 i

48
TPS 4.4 4- 10
a 52

pressure before and afterihe cleaning, repeat

cleaning after 10 minutes.

Ccnrrect i-rere O) ln case that intake air pressure does nol

change over when the cleaning is repeatedly
conducted, conduct the overhaul and clean-
ing of the whole of turbocharger.
( M : Separately provided "Turbocharger
lnstruction Manual")

turbocharger is at a higt-i:--
perature during operation and just after the
-l'trrLrol'har.rjei' engine is stopped. lf you touch il wilh Ec
hands during cleaning, you may burn yr
Turbocharger Biower Cleaning Procedure hands. Wear safety gloves withoutH-

(4) Cleaning Method

- lnspection and Maintenance
5

4.5 DK-20 Gleaning Turbocharger Turbine

5-4.5 Cleaning Turbocharger Turbine @ after water is led for 5 minutes, close the.
nozzle @ to discharge drain at a rate ol about
0.'l l/min.
The turbocharger is at a high-temperature ix) After the completion of water cleaning, close
during operation and just after the engine is the nozzle @.
stopped. lf you touch it with bare hands during
x) Make sure thal no drain is discharged, and
cleaning, you may burn your hands. Wear
safety gloves without fail. close the drain cock @.
xi) After water cleaning, keep the engine running
<Turbocharger type "RH" (water washing)> for about 5 to 10 minutes under the same load.
(Applicable lo heavy fuel oil engine)
lnject water through lhe water injection nozzle
fitted on the exhaust pipe at the turbocharger inlet,
and the combustion deposit on the turbine side
can be removed by the mechanical effect ol collo-
o Keep a close watch on the turbine during
sion of water drops and the dissolving effect. water injection. Take care that the injection
Part of the water evaporates, and the remaining' rate is not loo high or the drain pipe is nol
water is discharged through the drain hole in the clogged with removed deposit.
gas outlet duct. o Even if drainaQe is not observed, do not feed
water for 7 minutes or more.
(1) Frequency of cleaning . After the completion of cleaning, remove the
Clean the lurbine every 250 hours. connected hoses.
(2) Engine running conditions during cleaning
Clean the turbine after running the engine for
( ffi : Separately provided "Turbocharger
lnstruction Manual")
about 20 minutes or more at a power at which a
turbocharger inlet gas temperature of 300 to 350"C
is obtained.

(3) Cleaning procedure

i ) Connect the water injection tube O connected
to the bxhaust pipe and the gauge board @
with a hose.
ii ) Ccnnect i1-,e rvater supply hose @ to the
gauge board @.
Open the sfiop valve @ to leed water to the
t:v>ayt
ttbe and hase to the nozzle @. When the
pressure gauge @ stabilizes, close the stop
vafue.
iv) Open iie :'a
v) Fully cper :-:
vi) Slowlyopen:-. s::: .a .: 3 , seeing the
pressure gaug: 3 --: :-: ,','ater pressure
becomes0.05::::a'.'=': - i :c 0.8 kg/cm').
vii) Feed water {cr abc'-: 5 :: - - --::s iF-7=*-2:z=>
viii) lf no drain is discha:;=: -'-- '-
= :-=
- ccck

DK-20 Z 05-03 DAII{ATSU

 lnspection and Maintenance
5

Cleaning Turbocharger, Turbine DK.2O 4,5

<Turbocharger type "TPS" (pouring water charge pressure, supercharger revolution

washing)> speed and so on, repeatthe procedure above
As the pouring water washing method of the after completion of the washing. lf any varia-
supercharger, fresh water is sprayed in front of tion is not observed after repetition of several
the turbine from the pouring water nozzle on the limes, it is necessary to open and clean it.
supercharger. Thus, the extraneous matter is
removed through the difference of the cooled lur- Supercharger type lnterval time (minutes)
bine nozzle eith fresh water, turbine blade and TPS48 3
the thermal expansion extraneous matter.
TPS52 3
(1) Washing interval
Since the washing effect is reduced when the ( [f[ : "Operating Manualfor Supercharger")
deposit layer becomes thick, apply the washing
every approx. 200 hours. <Turbocharger type "VTR" (Water cleaning)>
As the procedure of the water cleaning method
(2) Load during washing
of turbine, inject fresh water from watering nozzle
Apply the washing at such a load as the
located on the exhaust pipe to the lront of the tur-
exhaust temperature of the cylinder outlet is 300
to 350'C. Asthe exhaust temperature is lower, the bine, remove the adhered matters on the turbine
washing etfect decreases. As it is higher, the tur- nozzle, turbine rotor blade, etc. by the impact
bine nozzle or similar part may be damaged. lorce of the water drops accelerated by the
Take special care for the exhaust temperature. exhaust gas and the solution force of water.
A part of the fresh water will evaporate, and the
(3) Fresh water for washing
remaining will be discharged lrom the drain hole
As the fresh water for washing, use the lresh
ol the turbine chamber. Do not evaporate the
water which does nol include any additives.
Never use any seawater. fresh water entirely.

(1) lnterval of cleaning

(4) Washing method :
Conduct the cleaning with the interval of 200 to
i ) Connect the hoses ol the pressure gauge and
250 hours in the initial stage, since the effect of
the check-valve hose to the pipe connected to cleaning will be lost if the layers of the accumulat-
the exhaust pipe. ed matters have become thick.
ii) Open the check valve, fill the water into the As lor the cleaning interval after the initial
pipe and hose up to the nozzle, and close the cleaning, properly increase or decrease depend-
check valve. ing on the factors such as the exhaust tempera-
iii) Fully open the valve in the nozzle on the ture, intake air pressure, and the degree of per-
formance decrease of the turbochager rotation
exhaust pipe.
speed.
iv) Observing lhe pressure gauge, slowly open
the check valve to gain the water valve of (2) Load during Cleaning
0.45 to 0.7 MPa (4.5 to 7.0 kgf/cm') The maximum allowable rotation speed of the
v) Continue pouring water 25 to 30 seconds. turbocharger when cleaning is performed is as
shown in the following table, and therfore in case
vi) Apply the washing three times. Here, provide
that the normal load value is higher than these.
the interval shown in the table below after decrease ihe ioad.
washing of one time.
vii) Close the valve, loosen the hose connection. [Turbocharger Rotaition Speed and Exhaust
Temperaturel
Disassemble the manometer and the hose
with valve.
Turbocharger Rotation
viii) To dry the supercharger, run it applox. 10 model speed mm-1
minutes at the same load.
wR160,161 9,000-'13,500
ix) lf any variation is not observed on the perform-
ance values of the exhaust temperature,

DAIHATSU
 lnspection and Maintenance
5
Cleaning Turbocharger, Turbine DK-20 4.5

<Turbocharger type "TPS" (pouring water charge pressure, supercharger revolution

washing)> speed and so on, repeatthe procedure above
As the pouring water washing method of the after completion ol the washing. lf any varia-
supercharger, fresh water is sprayed in front of tion is not observed after repetition of several
the turbine from the pouring water nozzle on the times, it is necessary to open and clean it.
supercharger. Thus, the extraneous matter is
removed through the difference of the cooled lur- , Supercharger type lntervaltime (minutes)
bine nozzle eith fresh water, turbine blade and TPS4B 3
the thermal expansion extraneous matter.
TPS52 3
(1) Washing interval
Since the washing effect is reduced when the ( [f$ : "Operating Manualfor Supercharger")
deposit layer becomes thick, apply the washing
every approx. 200 hours. <Turbocharger type "VTR" (Water cleaning)>
As the procedure of the water cleaning method
(2) Load during washing
ol turbine, inject fresh water from watering nozzle
Apply the washing at such a load as the
exhaust temperature of the cylinder outlet is 300 located on the exhaust pipe to the front of the tur-
to 350"C. Asthe exhaust temperature is lower, the bine, remove the adhered matters on lhe turbine
washing effect decreases. As it is higher, the tur- nozzle, turbine rotor blade, etc. by the impacl
bine nozzle or similar part may be damaged. force of the water drops accelerated by the
Take special care for the exhaust temperalure. exhaust gas and the solution force ol water.
A part of the fresh water will evaporate, and the
(3) Fresh water for washing
remaining will be discharged from the drain hole
As the lresh water for washing, use the fresh
water which does nol include any additives.
ol the turbine chamber. Do nol evaporate lhe
Never use any seawater. fresh water entirely.

(1) lnterval of cleaning

(4) Washing method
Conduct the cleaning with the interval of 200 to
i ) Connect the hoses of the pressure gauge and
250 hours in the initial stage, since the effect of
the check-valve hose to the pipe connected to cleaning will be lost if the layers of the accumulat-
the exhaust pipe. ' ed matters have become thick.
ii) Open the check valve, fill the water into the As for the cleaning interval alter the initial
pipe and hose up to the nozzle, and close the cleaning, properly increase or decrease depend-
check valve. ing on the factors such as the exhaust tempera-
iii) Fully open the valve in ihe nozzle on the ture, intake air pressure, and lhe degree of per-
lormance decrease of the lurbochager rotation
exhaust pipe.
speed.
iv) Observing lhe pressure gauge, slowly open
the check valve to gain the waler valve of (2) Load during Cleaning
0.45 to 0.7 MPa (4.5 to 7.0 kgf/cm') The maximum allowable rotation speed of the
v) Continue pouring water 25 to 30 seconds. turbocharger when cleaning is performed is as
shown in the following table, and therlore in case
vi) Apply the washing three times. Here, provide
that the normal load value is higher than these,
the interval shown in the table below after decrease the ioad.
washing of one time.
vii) Close the valve, loosen the hose connectton. [Turbocharger Rotaition Speed and Exhaust
Temperaturel
Disassemble the manometer and the hose
with valve.
Turbocharger Rotation Tu:'b:c;.'::' - ='
viii) To dry the supercharger, run it applox, 10 model speed mm-1 -.,1- i-:. -.
eA : 1 -.
-=
minutes at the same load.
wR160, 161 9,000-13,500
ix) lf any variation is not observed on the perform-
ance values ol the exhaust temperature,

DAIHATSU DK-2t - -:-3

 Inspection and Maintenance
5

4.5 DK.2O Cleaning Turbocharger Turbi ne

However, the turbine rotation speed willbe the manometer and the stopper valve.
decreased more or less if water is poured, and xiii) After cleaning water is completely dis-
therfore readjust the rotaition speed. charged, drive the turbine for about 10 minutes
Conlirm that the drain including water is dis- with the constant rotation speed in order to dry
charged lrom the drain hole of the turbine cham- the turbocharger.
ber within the range of this rotation speed. xiv) After finishing the cleaning, confirm the
changes of the performance values such as
(3) Fresh water for cleaning the exhaust temperature, intake air pressure,
Use fresh water containing no additives. anever turbocharger rotation speed, etc.
use sea water. ln case that there is no change, repeat the
above procedure. ln case that there is no
(4) Cleaning method
change even after repeating the procedure, it
i ) Close the drain cock @ . is necessary to perform the overhaul and
ii) Connect the pipe connected to the exhaust cleaning.
pipe with the hose provided with the hose pro-
vided with the manomeler and the stopper
(m i "lnstruction Nmanual of Turbocharger")
valve with the hose connection.
iii) Open the stopper valve, and lill the pipe and
hose connected to the nozzle with water, then
close the stopper valve.
iv) Totally open the valve inside the nozzle locat- Turbocharger
ed on the exhaust pipe.
v) Open the drain cock @ ,.and confirm that the
drain cock and the pipe are not clogged.
vi) Slowly open the stopper valve so as to obtain
the water pressure of 0.05 to 0.1 MPa {0.5 to
Drain cock @
1.0 kgf/cm') while watching the manometer.
vii) Confirm that drain comes out of the drain
pipe.
viii) Constantiy watch the discharge of drain while
pouring r',,ater. and pay attention to the change
of lvater pouring amounl and closing of the
Water pressure
drarr pice.

, ',:''aier pouring amount

Water pouring amount WaterPouring Cleaning Procedure of Turbine
(l/min)
2-3
ix) Gontir.e the po.ritg of water lor about 10
mirxrEs-
x) Glosefievdwilsib tetr,zzb, and close
the drain cock @ after confirming that drain is
no more discharged,
xi) Open the drain cock @ . (Prevention of clog-
'ging ol the drain pipe.) "#
xii) Close the stopper valve, loosen the hose con-
nection, and remove the hose provided with

DK-20 Z 05-3 DAIHATSU

 lnspection and Maintenance
5
IEM
Measuri ng Crankshaft Deflection DK.2O 4.6

5-4.6 Measuring Crankshaft Deflection iii) lnstallthe deflection gauge.

lnstallation position shall be approximately on
the identical line with the outer diameter of the
journal, and shall be on the intersecting poinl
on the center line of the crank arm.
lf the crankshaft deflection exceeds its limit,
the stress to be applied to the crankshaft will iv) Set the reading on the gauge scale to +20 al
become excessive, and it will result in the the position "8" in the Figure. (To make clear
breakage of crankshaft if the excess of deflec- the positive and negative directions.)
tion is too large. v) Slowly conduct turning of the engine in the nor-
Therefore, adjust the crankshaft deflection to mal direction of rotation, and measure the
a proper value when being installed, and peri- reading on the scale when the crankshaft is at
odically measure the deflection, so that it can the angle of "8", "C", "D", 'iE", and "A" respec-
be corrected whenever il is overthe limit value. tively, of which data shall be recorded.

(1) Replacing Consumables and Measuring

lnstruments
a) Replacing Consumables ( m : "Parts List') o
Q O-ring (frame side cover) No.11
L__
b) lmplements and Measuring lnslruments I

@ Generaltools
( t
M : "lmplement List" the finaldocu-

[J
in
\
ments)
f:) Deflection gauge iI {
(:) Motor

(2) Conditions for Measuring Deflection

a) Deflection of the crankshaft varies according to \*\ ,r]
a the temperature. Be sure to measure it when
the engine is in cold state.
Defiectlon Gauge Mounting Position
b) Before measurement, push the contact piece
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) ln case of the marine engine, since the deflec-
tion varies according to the loaded cargo con-
ditions, be minded to record the conditions of
loaded cargo, draft, temperature, and so on,
al the same time.

(3) Measuring Deflection

<Measurement procedure>
i ) Open the turning plug, and perform turning the
crankshaft.
ii) Place the crank pin at the point of 30 (position
"B") past the bottom dead center.

DT.i: -
 lnspection and Maintenance
5

4.6 DK-20 Measuring Crankshaft Deflection

(4) Calculating Detlection (d)

Calculate the dellection values as based on the
measured values and in accordance with the foi-
lowing formula, and record the calculated values:

o Vertical (V)deflection: dV = D -
A+B
ltl T [\f [\l
t-,1

&'4 6 d 6
2
r
Horizontal (H) deflection: dH = C - E
.
Positive/negative deflection: Open down-
n
ward (+), closing downward (-) E
A, B, C, D, and E represent the measured val- B rop dead center A
ues respectively at each corresponding position
Deflection Measuring Position
shown in the figure on the right.

(5) Correction Limit for Deflection

a) tre correction limil shall apply to whichever is
'
larger of dV and dH as shown in the following
Seen from flywheel side
table.

(Unit:mm)

Adjusted value Allowable limit Direction

t:.E
x6 0.03 or less 0.08
Tl E!-

H9"X
!!EPE ax 2.8 $-/e D (ToP dead center)
stroke SITOKE
_:808, 10,000 10,000
c
aa
-e
0.03 or less 0.08
Dial Gauge Reading
ax 2.8 */-\&

-fr-
stroke stroKe
9F.9E. 10,000 10,000

g; 0.09 or less 0.12 o

-o
^,O.'c
3 ,sfoke 4 *stroke
$-ie
10,(m 10,000

_w_
b) Dei e3: :- .:' := :::=- jing on the connection
me:-:. r'.:: ::--=:::- or flexible coupling)
be:,',€3' '.-=.'z' -s-a::-: drive equipment,
hc,',:,:' -:- z '.': l:'::::n becomes The de{lection of the crankshaft shall be rep-
resented by the value when the engine is cold,
f'na.\:- -- ?'.'.-a -'=--'.'-:,'.:.a1 ,S ClOSeSttO
tha i ' -:: and since the values measured when the
engine is warm sometimes difler significantly
nOl"s: '.'a
='.=::- --:-' -. -: iht adjust- depending on the measurement conditions, be
ing shrr: :' :-: -. =' : - -:: :-: ::jleciion
-
minded not to use lhe value measured when
falls with -:-: -:=- : -:: :: :^:,',- ,n the
the engine is warm as standard.
above tab e

DK.2O Z 99-B DAIHATSU

 lnspection and Maintenance
5

Measuri ng Crankshaft Deflection DK-20 4.6

Deflection in warm condition

ln case of the directly connected generating There is a possibility that the measurement
engine, the deflection in the warm conditions gen- results of the deflection in the warm conditions
erally tends to vary as compared to the values in differ from the real value due to the reasons that
the cold conditions. the engine temperature may suddenly increase
This is because the temperature increase of the after the engine is stopped, and due to the effects
engine base is largerthan the temperature of the thermalexpansion owing to the tempera-
increase of the generator to be directly connect- ture difference of the crankshafl. Be careful of
ed, so that the crankshaft core relatively increas- this fact.
es, the deflection varies towarJL direction
(downward closing), and thereby the difference
manifests itself as the deflection difference
between the cold and warm conditions.
Like this, in case of the directly connected gen-
erating engine, the deflection differencelb"t*""n
\

the cold and warm conditions differs dep[nding

on the bearing dimensions and temperature dif-

ference of the engine and generator, so that the

adjustment is impossible, and it will be the value
unique to the generating device.
Consequently, in case of the generating engine,
the adjustment is made with the target of the con-
I

ditions near to + side upper limft .Xflp(downward

opening) of the specifled value in the cold condi-
tions.
The measured value of the deflection value in
lhe warm conditions varies according to the tem-
perature, and the different values tend to be

obtained every time the measurement is conduct-

ed, however, based on the actual measurement
results of our company, the value is approximate-
ly 3lo 4110,000 x stroke and within the range of

,ll*- (oownward closing).

: ;t, -i0 . ::-:

 lnspection and Maintenance
5

4.7 DK.2O lnspection and Replacing Protective Zinc

5-4.7 lnspecting and Replacing iii) On the contrary, in case that the protective
Protective Zinc zinc is rarely worn out, the following failures
may be suspected:
ln case that sea water is used as the cooling r Faulty condition on the mounting surface
water in the cooleig system, a protective zinc is . purity failure of zinc
provided in each cooler.
Conduct periodical inspection and replacement
b) Replacement and mounting
of the parts on the following procedure:
i ) Remove the rust or scale from the mounting
(1 ) Replacing Consumables, lmplements and surfaces of the protective zinc and the mounted
Measuring lnstruments flange to expose the metallic surface, and
a) Replacing Consumables securely mount the protective zinc to the flange
Lubricating cooler ( M : "PartsList") in such a way that the both parts are closely in
contact each other.
O Gasket No.12
@ Protective zinc No.1'l ii) ln case that the protective zinc is reused,
(M shave scale off the surface of the protective
Air cooler . "PartsList')
zinc and expose the zinc surface.
O Gasket No.2
@ Gasket No.4
'@ Protective zinc No.1
'@ Protective zinc No.3
b) lmplements and Measuring Inslrumenls
(D Generaltools
( ffi i "lmplements List'in the finaldocuments)

(2) Locations of Protective Zinc and lnspection

lnterval
. Front and rear covers for lubricating cooler
\
Location of Protective Zinc far
-------Every 3 months
Lubricating Oil Cooler
' Front and rear covers for air cooler-----Every
6 months
a

Efficbncy of the protective zinc substantially

varies depending on the purity. Therfore, be l3a0o

+".:"
)
minded to use the genuine parts supplied by "P"*
Daih$u Diesel llanufacturing. Co., Ltd. '@
lr

(3) lnspectior ar: ie: =,-ement

a) lnspeci :-
i) Remove :-: - - --' - _-' =- == '- - l-c,tectlve
zinc.
ii) Replace ti: :'-'=- .: : - - -' - :^ .,iume rs
reducedrrc-::-=- --', -- : l^-:-s:^ Vieior "F" View ''Q"
as comparec '.' : -- . - = a- :: =
Location of Protective Zinclar Air Cooler

oK-20 z 99-8
CHAPTER
Control ol Fuel Oil, Lubricating Oil, and Cooling Water
5
ITEM

1.1 DK-20 Selecting Fuel Oi!

6-1 Fuel Oil Characteristics and Control

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

6-1.1 Selecting Fuel Oil

The standard characteristics ol the fuel oil Therefore, be minded to check the characteristics
qpplicable to this engine is as shown in a separate analysis values ol the luel oils after each delivery,
table. and try to avoid using the luel oil ol which
Table 6-1.1 "Standard FuelOil characleristics is excessively different lrom those
Characteristics" shown in the standard characteristics table.
Commercially available luel oils are considerably
different in the characteristics, and even lhe same
type of the luel oil may show a greatly dillerent
characleristics depending on the location and
period of supply.

1) The engine specilication varies depending Bottoms oils resulting lrom operation by FCC
on the types of the fuel oil to be used. Be method (catalytic cracking method) are often
minded to conlirm the type of the fuel oil mixed in luel oils recenlly.
relening to the specification of engine, and The mixed oils, such as this, contain rigid
do not use the oil of which grade is lower alumina silica (catalyst particles), and will
ftan hd shown in the specification. cause abnormal wear of the various parts of
ln case tnl fte fuel oil of lower grade is used, engine, particularly the parts ol the f uel'
trouHes rnay be incuned on the operation of injection system.
engine, due to the laulty combustion, Remove the solid particles by fully utilizing the
troubles on the fuel oil system equipment, existing fuel oil pretreatment equipment, and
premature weaitg d the parts, and so on. by intensilying the cleaning of fuel oil.
2) Avctid using the frrc{ d by mixing with the ln case that the removal of the solid particles
other oils whose production ol origin is cannol sulliciently be made with the existing
differenl- ln case tral td tfl is mixed the oil fuel oil pretreatment equipment, the
with inferior affttfy, a bge anpunt ol sludge reinforcement of the cleaning equipment will be
may be generated, catiqg troubles on the required, and when such reinforcement is not
operation of engirn- possible, it may be required to change the
current luel oil to the oil of a better quality.

DK-20 Z 99-8 DAIHATSU

 CHAPTER
Control ol Fuel Oil, Lubricating Oil, and Cooling Water
6
Fue! Oil Characteristics and Control DK.2() 1.2

6-1.2 Fuel Oil Characteristics and Control on the viscosity of luel oil, heat the oil and obtain
the proper viscosity, by referring to the fuel oil
(1) Heavy Fuel Oit
viscosity/temperature curue on a separate page
Since heavy fuel oil conlains more carbon residue
as a standard.
and impurities, and is higher in its viscosity as
ln case that a viscontroller (automatic viscosity
compared to diesel luel oil, heavy fuel oil cannot
regulator) is installed on the engine, control the
be used as the fuel oilfor diesel engine, when it is
luel oil viscosity to its proper value according to
in the state of bunker luel oil.
the attached instruction manual.
Therefore, it will be a prerequisite to use heavy luel
Fig.6-1.1 "Fuel Oil Viscosityffemperature
oil that the oil must properly be preprocessed
Gurve"
belore being supplied to engine (including the
removal ol impurities by cleaning, and the
assurance of proper viscosity by heating). *Proper viscosity for fuel
oil (engine inlet)
Kinematic viscosity: 14+ 1 mm'/S
a) Cleaning Fuel Oil
ll the temperature control ol fuel oil is
Water, and solid contents such as vanadium,
improper, and the luel oil with high viscosity
sodium, alumina, and silica, contained in heavy
has been supplied to engine, it will not only
fuel oil accelerate the corrosion and wear ol the
incur faulty combustion, but also will result in
various parts ol fuel injection system and luel
the accidents such as the clogged or
combustion chamber system, substantially
damaged fuel oil filter, and the breakage ot
affecting and reducing the working life of these
luel injection system parts.
parts.
For the purpose of removing such impurities, the
fuel oil preprocessing equipment, such as the (2) Diesel FuelOi!
centrifugal separator and precision filters, are a) Water tends to extract and separate out ol
installed. Since these equipment will not exhibit diesel fuel oil, and lurther diesel luel oil tends
the efficiencies unless each equipment is to generate a large amount ol sludge when
properly handled, be minded to operate each mixed with the oilof diflerent base oil. ffi
equipment in accordance with the corresponding Daily conduct the draining-ofl ol the #
&
gs
instruction manual. precipitation tank and settling tank, so that *:
l|EEl "lnstruction Manual" for each equipment water or sludge does not llow into the engine. e:
To remove water or sludge, the centrifugal
separator is an et{ective device.
Since waste luel or sludge will be lhe causes b) Diesel fuel oil, that has been cut back by using
of environmental contamination or pollution, the gas oil refined by FCC method, may incur
be sure to enlrust the lreatment of these to faulty start or ignition, and this tendency is
the authorized waste disposal company, not particularly obvious in case of low sulfur diese
directly handling or disposing these matters oil for land vehicles, due to its low ceia-g
on your own. number, il lhe environmental conditions. s-:-
as the ambient temperature or i.,;:s'
temperalure, are unfavorable.
b) Heating Fuel Oit ln such a case, special measur:s ,, ::
Since the viscosity of heavy fuel oil is very high, become necessary to imp':,: :'=- -;
it is required to heat the oil, so that a proper -- capability and combustibility' :' .-; -: =--i: .
r\scoS\ \or \ue\\nlec\ron e,anhe qb\arned. suc\ occas\ons, cor'\a:' ^- -- ----- --:- - '---
Since the heating temperature varies depending consultation.

DAIHATSU a- I --
CHAPTEB
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM

1.2 DK.2() Fuel Oil Characteristics and Control

(3) Gas oil (4) Kerosene Oi!

Although gas oil does not contain few impurities, it As a countermeasures to prevent environmenlal
may cause problems on ignition when the gas oil is conlamination (air pollution), there may a case in
refined by FCC method, just like the case with which kerosene oil may be used.
diesel fuel oil, and therelore be minded to pay Since kerosene oil is further lower in its cetane
particular attentions to the cetane number of gas number and is lower in its viscosity than gas oil, it
oil. is required to carry out a special arrangement on
Further, since gas oil is low in its viscosity and is the engine, and therefore contact our company for
inferior in its lubricity, it may cause abnormal wear consultation before using the oil.
on the sliding parts ol luel oil in.iection system, and
therelore be minded to conduct the inspection of
the fuel injection pump and fuel injection valve in
the eadier stage than usual.

Table 6-1.1 FuelOil Standard Characteristics

General Diesel luel oil nol€ t) Heavy luel oil noto2)

JIS (|<22ss Vpe 1) K 2205 type 3

Type of luel oil
ISO-F (DMA) BMAlO RME25 RMG35 FIMH55

CIMAC 410 825 G35 H55

Density (15"C) dcm' max 0.890 0.975 0.991 0.991 0.991
Kinematic viscosity 3.0-(s0'c) 10/40 35/380 55/700
cSt max 251180
1 oo/50 "c
Viscosirty
Ftw#1 100"F sec max 30-50 300 1 500 3500 7000
Flash point "c min 60 60 60 60 60

Pour point "c max 0 6 30 30 30

Carlcon residue wl, "/" max o.2 10 15 18 22

Ash wl. Y" max 0.0.1 0.10 0.'10 0. 15 a.20

Waler vol. "/" max 0.1 0.5 1.0 1.0 1.0
Sullur wl. 1" 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 JU 30 30

Cetane number not€ 3)
mtn 40 (45)
CCAI Value not64)
max 850 850 850 850

Notes: 1) Since there are a wide range of the standard values for diesel fuel characterislics, lhe recommended
values are shown in the above table.
2) Heavy fuel oil characleristics represent the values ol "Residual marine fuel oil" proposed in CIMAC
(1eeo).
3) Cetane number represent the calculated values based on JIS K 228G1996. Figures shown in ( )
indicate the values based on the old method of JIS K2204-1992.
4) CCAI (Calculated Carbon Aromaticity lndex) value is calculated by the following formula, and indicales
lhe reference value for starting capabitity.
CCA|value = 1000 D-141 Log Log (VK + C) - 81
D: Densiiy g/cm3 (15'C), VK: Vis;osity cst isOb), C: Constant (0.85 for heavy fuel oil)

DK-20 B 03-2 DAIHATSU