INSTRUCTION [List ka MD-2 DAIHATSU DIESEL MFG. CO., LTD. | WESTERN TIDE FINISHED PLAN DAIHATSU DIESEL ENGINE BOOKorn REaEERRERRON Daihatsu Diesel's engines, gas engines, reduction gears and other products are manufactured under excellent quality assurance systems which conform to ISO 9001 “The indistry4eading quality assurance systoms of Dalhalsu Diesete Headquarters and Moriyama Works, covering every aspect of design, evelopment, production and offsite maintenance —the fist ‘manufacturer inthis field in japan to be accredited for tis aspect 428 certiied as satisfying the requirements of 10 9001. As a result all engines, gas trbines and marine-use equipment of Daihatsu Diesol are manufactured under qualty assurance systems thal also rect the requirements of EN 29001, JIS 29901 and BS 6750. The compliance audit was performed by Lioy's Register Quality ‘Assurance, LidORDERED BY; a2 x 2 ee ies QSUNEISHL SHIPBUILDING GO., LTD. 3 sho.’ 1065. ENGINE MODEL; ; ENGINE NO; 0x6200096 om mot, OORB-O aM % B; DK6200007 DATE OF MFG; : gw & = AB: MWar., 1995 Brew Forward ABB EAT 2 RORRLM oT Oh Hie Fale RANE SE OF SERA EOTHN STO S, +I REL TORE BE LORY SIRO RAB, MOML ET, BURLD Fl OROHIATUREU TE, BIO ASCMTEL, VOR THBETK< ERE CHRRLTURHUS CE LBL ET. ARHRDN OD BBR & EBC TE TEC BEUE Ud, ABV CHOLES LORE (ko TOR CLA, TRANS E SME E MOLT SSL 5 MOR at SMAbt, TERT OME SSLFEMORLET. MX; F-EABMRAMER BMA; F-EABY-ECAR BANS F 4 — BNR AUR BHMZT A414 540 > BMI TEL. (06)945—5325" FAX. (08)045—8304~6 yea TEL. (08)948—327 FAX. (08)945—5904~6 This instruction book deals with the fundamental knowledge required for operation and handling, It is, therefore, ardently requested to follow the workit as well as maintenance _ instructions, so that you may enjoy the utmost durability and satisfactory operation of ‘our Diesel Engine for many years to come. 1 When ordering some parts of the Diesel Engine, please specify the Type and No. of Engine, together with names of articles and their reference numbers, as detailed in this book. When you give us your order ot for further information, please contact. Orders; AFTER SALES SERVICE DEPT. PARTS SECTION Information ; AFTER SALES SERVICE DEPT. SERVICE SECTION DAIHATSU DIESEL MFG. CO.,LTD. 4-14, TOKUI-CHO 2-CHOME, CHUO-KU, OSAKA, 540 JAPAN FAX. (08)945—5304~6 * PARTS SECTION + SERVICE SECTION ~~ TLX, 6242728 DAIMAT-3 TEL. (06)945—8328, TEL. (08)945~0326,CONTENT: a RK Instruction a BA S| Parts list Bm OMD.O. Engine A Bat AES CHeavy fuel Engine (180 cSt/50°C) BLS FB A C HGH (15008) MHeavy fuel Eneine (380~700 cSt/50°C) 46: Se Ch (3500~7000%) 1. Speed 4720, 750pm 8. £0. nozzle ole dia 0.26 BRK —_E o00%9m Sm SE RE 0.28 7 CHole dia 0.28 11 1000°pm ee eS 2. Direotion of revolutjon ChHole dia 0.30 ME — A/Standard (A) RE 0.30 -” Dole dia 0.32 GReverse (L) RE 032 : ae 11, Capacity of L.0. cooler 3. Front P.O, | Clwith Miisoeeh Veo 2927 shies eros aan without z C69 cam shat W018 10. Intr cooler type Coke CDKeoHe Pf DKAS a bh ae PUEOBER Oo oKsa CoKaste DBuitt-up Gp087_ Goosauz aa 12. C.W. pump Pinper dia 170 (6k) 5. Turbocharger type RADAR OT 42554 120 (0K) ) sine = CvTRIe! CIVTR214 Cinper dia 180 (DK) CvtRaot DaHi8s 47554 180 (BOK) VIRGO Onate/A 6. Arrangemet turbooharger WRAL — CO) Front side wa rear sido 8 7. Governor type JUG10 BARES RYDE 8. F.0. injootion pump MERA’ 7 WAPlanger dia 20 Tove rh D OPlanger dia 21 . Fav o EA NOTE ; Items marked M aro applied for your diesel engines. 2 OAM PARAM Ce TOS CT,Operating & Maintenance Manual RASDAIHATSU TYPE | SECTION STANDARD MANUAL CONTENTS. DK-20 | -SHEer 1 SEC. — SHEET BEFORE RUNNING DAIHATSU DIESEL ENGINE «+++ +++ GENERAL 1. Notation of Types Bingine 2. Cross-section of Engine «+++ + +++ 3. Engine Specifications ---- ENGINE ADJUSTMENT STANDARDS 1. Assembly Adjustment Table 3-1 Operating Specifications: 3-2 Capacities of Lubricating Oil and Cooling Water - 3-3 Tightening Torque Table - sree n etna 3-4,5 Clearance and Wear Limit Dimension of disassembly, Weights of main parts~ GENERAL CONSTRUCTION Engine Construction - Starting Pneumatic System and Related Parts ~ Fuel Oil System and Related Parts: -- Lubricating Oil System and Related Parts Cooling Water System and Related Parts «+++++++-++++ Nozzle Cooling Oil System and Related Parts - OPERATION AND DAILY MAINTENACE 1. Daily Operation -- (1) Preparation for starting (daily operation) (2) Starting (daily operation) - (3) Initial starting after installation and starting after extended disuse or overhaul - = (4) Run (5) Running-in - 2. Daily Maintenance and Inspection (1) Measurement of engine performance: -- ++ ++ (2) Measurement of lubricating oil consumption level: -- ayer ay ayer 5~ 1-6 5-1,2 5-2,3 5-35 oe S— 7-12 (3) Adjustment----++++ S- 7-11 1) Exhaust temperature serene 5-7 2) Cylinder maximum explosion pressure 5-7 3) Fuel pump rack amount -- 5-8 4) Intake air temperature 5-89 5) Intake air pressure: - 5-9 6) Lubricating oil pressure -- : 5-9 DK-20 | A|95—4|DAIHATSU SECTION | TYPE 0 [SHEET | DK-20 STANDARD MANUAL CONTENTS 2 7) Lubricating oil temperature ©+++++000++0eeeeereeeeeeees 8) Cooking water temperature +++ 9) Reoker arm lubricating oil 10) Nozzle cooling (when heavy fuel oil is used): 11) Fuel oil pressure ©+++++00 000208 (4) Maintenance + 1) Filter washing 2) Daily maintenance procedure of filters -- 3) Drain-up of intake piper++00+0+00 + seetetttesteteees 4) Washing of turbocharger « 5) Protectors (8) Inspection - ++ 3. Stoppage (1) Preparation for stoppage (2) Stoppage operation +++ +++++++++ (3) When engine must be stopped immediately - (4) Actions to be taken after emergency stop +++ +++ (©) For long-term shutdown 4, Allowable Operating Range -- (1) In the case of FPP (fixed pitch propeller) «+--+ (2) In the case of CPP (changeable pitch propeller) Special Operation - : (1) Low-load operation - (2) Non-turbocharger operation + + (3) Operation with intercooler cut off from main tin (4) Operation with reduced number of cylinders «++ (5) Malfunction of lubricating oil temperature control valve or nozzle cooling oil temperature control valve +++++-+ (© Break of lubricating oil cooler * cee 6. MAINTENANCE SCHEDULE (1) General precaution « (2) Periodic inspection frequency table (when diesel fuel oil used) © Period’ frequency table (when heavy fuel oil is used) +++ +++ (4) Manual lubrication intervals ~ inspet 5—9,10 S-1 5-11 5-u s-11 5-1 s- 5— 11,12 5-12 5-12 5-12 5-12 5-13 5-13 5-13 5-13 5-13 5-14 5-15 5-15 5-15 5-16 5-16 5-16 5-16 5-17 5-17 5-17 6-1 6-2-4 6-5-7 6-8 DK-20 [z{94~3| TYPE] SECTION STANDARD MANUAL CONTENTS DK-20 |-sreer 3 MAINTENACE 71. General Precautions for Disassembly, Assembly and Adjustment 7-1 7-2 Disassembly, Assembly and Adjustment of Main Parts 7-2 Cylinder Head and Related Parts - . 7 = 211 (1) Cylinder head: : tee . 1-23 (2) High pressure fuel pipe 1-3 (@) Fuel nozzle +--+ +> 7-3-5 (4) Nozzle holder guide 1-5 (5) Fitting exhaust valve : 7-6-8 (6) Fitting intake valve -- 1-8 (7) Valve guide removing and fitting procedure>+++++++ +++ 7-9 (8) Valve seat removing and fitting procedure «+ T= 9,10 (9) Valve rotator 7-10 (10) Adjustment of valve end clearance 1-11 (A1) Starting air valve «+ 1-1 2. Piston, Connecting Rod and Related Parts -++++++ v7 128 (1) Piston overhaul «+++ +++ 7~ 12,13 (2) Piston ++ vee see TO 14 (3) Piston ring and oil ring -~ 7-14 (4) Connecting rod + +++ ++ 7-15 (5) Crankpin bearing metal - 1-16 (6) Connecting rod bolt -- 7- 17,18 3. Engine Frame, Cylinder Liner and Related Parts 7 — 19-20 (1) Engine frame «++++0++0 000s eeeeeeeeeeeee 7-19 (2) Cylinder liner +++ 7-19, 20 4. Main Bearing, Crankshaft and Related Parts <++++++++00000+ se T= 21-26 (1) Main bearing 7-21 (2) Main bearing metal ++ 7-21-25 (3) Thrust bearing metal « sete 7-25 (4) Crankshaft «++ 7 25, 26 (5) Measurement of crankshaft deflection - - + 7-26 5. Timing Gear, Camshaft and Related Parts +++ ++ 7 26-30 (1) Timing gear (disassembly of idle gear) - 7 26-28 (2) Camshaft + 7 7-29 7 (3) Cam . sete 1-29 (4) Adjustment of fuel cam++++++++++> 7— 29, 30 DK-20 | Z|94—-3)SECTION | TYPE oO SHEET | DK-20 4 STANDARD MANUAL CONTENTS (1) Governor - (2) Governor driving gear > +++ (3) Fuel control device 8 Pump Driving Gear Cushion 9. Turbocharger, Intercooler and Related Parts: (1)Turbocharger- - (2) Intercooler (3) Exhaust pipe 10. Gauges -- 11. Air Starting System and Related Parts (1) Starting control valve and (2) Starting rotary valve - (3) Starting air receiver 12. Fuel Oil System Related Parts - (1) Fuel oil pump: + (2) Fuel oil filter « (3) Fuel oil pressure regulating valve 13. Lubricating Oil System Related Parts (1) Lubricating oil --- (2) Lubricating oil cooler «++ (3) Lubricating oil pressure regulating valve - (4) Lubricating oil filter 14. Cooling Water System Related Parts--- (1) Cooling water pump -- 15. Nozzle Cooling Oil System Related Parts~ (1) Nozzle cooling oil pressure regulating valve **+++++ settee 16. Protective Zinc ++ Fuel Injection Pump and Tappet «++ +++++++0+0000+ (1) Fuel injection pump: +++ +++ (2) Installation and adjustment of fuel injection pump: (3) Intake and exhaust tappets «+--+ +00000002+ 7. — Governor, Governor Driving Gear and Fuel Control Device. starting air valve °-~ 71-30 7-30 7-30 7-30 7-31 7-31 1-31 7-31 7-32 7 ~ 32-33 7-32 7-32 7-33 1-33 7 ~ 34~35 1-34 1 34,35 7-35 7 — 35~36 7-35 7-36 7-36 1 36-37 1-36 1-37 1-31 1-37 7 38~39 7 = 38,39 7-39 7-39 7-40 Dk-20 [Z|94~3]TYPE | SECTION STANDARD MANUAL CONTENTS DK-20 10. USABLE LIMIT OF HEAVY FUEL OIL AND ENGINE OPERATION CONTROL. 1. General Precautions -++++-~ 2. Usable Limit of Heavy Fuel Oil 3. Engine Operation Control --- (1) Operation with diesel fuel oil (2) Temperature control (3) Changeover between diesel and heavy fuel oils - () Precautions in changeover between diesel fuel oil and heavy fuel oil -~ (5) Countermeasures for emergency stop during operation using heavy fuel oil --+-~ (6) H.O. (Heavy fuel oil) starting & stop + 8-3 4, Starting, Operation & Suspension of Heavy Fuel Oil Engine «+++» 8- 4,5 FUEL, LUBRICATING OIL, NOZZLE COOLING OIL, COOLING WATER 1. Fuel Characteristics and Control -~ 9-1,2 2. Recommended Lubricating Oil and Its Control - 9-3,4 3. Nozzle Cooling Oil - teens 9-4 4. Cooling Water Control and Rust Inhibitor --- 9-5,6 (Appendix) Recommended Lubricating Oil Brand List - 9-7 (Appendix) Fuel Viscosity Temperature Graph -- 9-8 (Appendix) Blended Oil Viscosity Expectancy Graph 9-9 USE OF VARIOUS EQUIPMENT AND APPARATUS - 10- 1-7 Blow-off and Overhauling Procedure for Notch-wire Filter «+++*~ + 10-1 Water Cleaning of Turbocharger - : + 10-2 (Turbocharger blower side cleaning procedure - 10-2 (2)Turbocharger turbine side cleaning procedure - -- 10-34 Non Turbocharged Operation -- oe + 10-5 Overhauling Procedure for Fuel Injection Pump: 10~ 6,7 Measurement of Crankshaft Deflection ----- 10-89 Use and Maintenance of Hydraulic Jack 10-1011 DK-20 [Z[94~-3SECTION TYPE 0 SHEET | _DK-20 6 STANDARD MANUAL CONTENTS. cu ‘TROUBLESHOOTING AND COUNTERMEASURES - -- (1)When Starting Is Difficult (2)When Engine Stops Suddenly « (@)Insufficient Output - (4)When Abnormal Sound Is Audible during Operat (5)Surging (©)When Exhaust Gas Shows Abnormal Color’ +++ (DWhen Engine Revolution Is Not Smooth +++ ++ +++ (8)When Fuel Consumption Is Excessive pi (9)When Lubricating (10)When Engine Is Overheated - (11)When Oil Pressure Gauge Shows Abnormal Indication - (12)When Exhaust Gas Temperature or Explosion Pressure Is Abnormal (13)Fuel Rack Pulls In Excessively --- (14)When Cylinder Safety Valve Gets Opened Consumption Is Excessive + = 1-12 -l-1 71-2 u-3 “1-4 “11-5 1-6 u-7 u-8 1-8 “1-9 “11-10 u-u “1-12 1-12 DK-20 |Z 94—3|) (DAIHATSU) TYPE | SECTION’ 1 BEFORE RUNNING DAIHATSU DIESEL ENGINE DK-20 | "SHEET 1 This manual desribr imgortant rules for operation of Daihatse Diesel Engioes. Read ehis manual carefully over andover again to master the correct operating methods of the engines in addition to careful ‘enalngbeforeune Speraton ot conforming to the rules specified herein wil euse wil pony case large effect on performance and life of engines or lead a serious accident. Kreme marked with 74 are very important for safety operation. Be fully eareful in parthulr. Descriptions herein cover engines of standard specifications. Users are thus requested to understand that Deseret wine ieeydais tena wineries ger cinceeomnl eee ee ‘The contents of this manual shall not be related with the guarantee agreement. Copying and disclosure of the contents of this manual to a third party shall be probit ited. Engine specifications and separate assembly drawings shall have priority over this manual. In the ease of change in the fuel oll and/or in the working load, which is not shown in the specification, necessitated after delivery, some modification is necessary on the engine side. For details, get in touch with the Service Department of Sales Department of our company. For operation of the following units, see separate manuals. ‘Turbocharger Hydraulic governor Remote auto control unit and protective units L.O. thermostatic valves (for lubricating oil, cooling water, etc.) Reduction gears and operating units ~ Marine propulsion engine Generator Generator engine Heavy fuel oil system related « ‘When heavy fuel oil is used Other units as per special specification Contents of this manual are subject to change for improvement without notice. DK-20 |A|95—4DAIHATSU SECTION e a GENERAL SHEET DK-20 Notation of Types Engine Notation of Types Engine 6 (8) DK (B)(M) - 20 (LF) 6 (8)......Number of cylinders 20.....Cylinder bore (em) DK ......Name of series L ....-Reverse rotation specifications B Low output specifications F .....Pront end power takeoff specifications M......«.Marine propulsion engine Exhaustside Right side opemicnside A ute CSbi Aad Ted Pb Frontside Jam a, Flywheel side Engine as viewed from flywheel side engines. Note Carefully that the cylinder number is different from those of conventional DK-20 | Z|94—3)DAIHATSU | TYPE | SECTION 2 ___ GENERAL | Cross-section of Engine | BK20 eal ay. DK-20 | Z|94~-3)SECTION TYPE 2 GENERAL SHEET DK-20 Engine Specifications Model 6DK — 20 SDK — 20 ‘Type Vertical, water-cooled, direct-injection type, four-cycle diesel engine Number of cylinders 6 8 Cylinder bore: mm 200 ‘Stroke, mm 300 Engine speed min"! cg Output ew(rs) [3 ( Ps} Normal or reverse rotation Rotating di (normal direction: Clockwise direction as viewed from flywheel side) : Exhaust gas turbine turbocharger ‘Supercharger Pulse turbocharging system Pulse converter system ‘Starting method Compressed air ‘Constant : 1-5-3-6-2-4 Firing order speed 1-3-2-5-8-6-7-4 Variable arias 1-2-4-6-5-3 speed 3 Engine speed and output vary according to specifications. Please fill them in while referring to the factory ‘operation test result [_ok-20 [z 94-3DAIHATSU TYPE ‘SECTION ENGINE ADJUSTMENT STANDARDS 3 Assembly Adjustment Table DK-20 | SHEET Adjustment value ea (design value) Remarks 6DK 50° Open (before T.D.C.) 8DK 70° Intake valve | Close (after B.D.C.) 38° Clearance (A) o3imm 6DK 55° Open (before T.D.C.) : spk | 45° Exhaust 6DK 50° valve Close (after B.D.C.) 8DK 45° (1) Vale clearance i with engine co (2) should be set at “0” prior to the |_| Clearance (A) 031mm Sette Open (before T.D.C.) ae Starting rotary valve Close (after T.D.C.) 125° (29.4MPa_ Fuel nozzle injection pressure Pier Fill the value in while referring to the MPa factory operation test result, as the value ‘Maximum firing pressure { kefiem’y | varies with individual enginespecifications and output. cylinder safety val 19.1MPa Pressure of eylinder safety valve eee Fuel injection pump timing (before T.D.C.) Fill the value in while referring to the jon test result, as the value ividual enginespecifications and output DK-20 |ZDAIHATSU SECTION | TYPE 3 ENGINE ADJUSTMENT STANDARDS sueeT | DK-20 Operating Specifications J ‘Alarm siting Item Design value | (Emergency sop Remarks setting) According to turbo- aa charger specifications | Staring at Ee is il 05~0.6 Note 3) See the speci- Fuel oil (5.0~6.0) fication. mee 04-05 DETER Pressure | Lubricating ol pean ea | 0,25~0.34 ‘Tank head and Coating | Skee (25-33) external ping water 7 conditions should be Cooter 7 considered. oz ool presue Pisa, Intake air (engine inlet) 45-50 ink “480 Exhaust Turbocharge let 2 der_| Turbocharger outlet 580 specifications outlet) [Recording to ran turbocharger _ 14eS050°C TacS050C Temper. | Fuels engine ints) (65sec. RW (60sec. RW Mscasites for heavy Temper. Notfi00°F) | Not/t00°) Taba Tae i | Ensine inet so-60 7. ; Jacket tine | Engine inlet 0 oe eecuee | cote] sh [Ean = a water outlet )) [eel encincintx | 32 Desig vale Nozzle coolant (main tube inet 50-60 Dies depending on Notes) ') Lower limit values are used for pressure settings; upperlimit values are used for temperature settings for alarm and emergency stop. 2) Installation of pressure gauge, thermometer, alarm and emergency stopping devices differs depending on specifications. 3) Diesel fuel oil: 0.2 ~0.3 MPa (2.0~3.0 kgtem’) 4) The design values shown in the above table are those when the engine is operated at the rated speed. Dk-20_|Z|94-3DAIHATSU SECTION ENGINE ADJUSTMENT STANDARDS ile A Capacities of Lubricating Oil and Cooling Water DK-20 oe Unit: 2 tem Capacity Remarks Engine 2 Including piping 12 (8m) - Lubricating oi cooter 18 (12m) 23 (16m’) 15 (VTRIGI) Lubricating ot | Turbocharger 0.8(VTR201) LS (VTR2I4) . 1.3 (RHD6) Governor 13 He : 1100 (6DK) Difers depending on Common bed 1500 (8DK) specifications 85 (6DK) . Engine san Including piping 128m’) - Lubricating ol cooter 15 (12m) Cooling water 18 (6m) LL (VTRI61) Turbocharger 15(VTR201) : 10 (VTR214) | 15 (DK — 30) | imercooter | 25(0K - 4) | | 3000057) Notes) © Capacity in this table may differ according to specifications. ® When replacing lubricating oil, be sure to discharge oldlubricating oil inthe filter, lubricating oil cooler, etc. Replenish oil up to the position marked “UL” on the level gauge, Check the oil level with the level gauge again after operation for S~6 minutes. The oil level is proper, if tis within the range between “UL” and “LL” on the level gauge. Dk-20 |Z[94-3‘SECTION TYPE 3 ENGINE ADJUSTMENT STANDARDS aw DK-20 Tightening Torque Table [Width across] Tighening orque Names of bolts and nuts Sie | naw ) Remarks (om) {kgf i i x30 | Hydraulic | Oilpressue 54¥%pa 1 |optinder head tightening nat | M930 | Pera een ® 2 [evinerteadaudton | nap x30 Fey & as Hydraulic | Oil pressure 78Mpa 3 | Main bearing ightening ut | M39 «3.0 | Hose fries ® 4 | Main bearing stud bole M39 x30 ton * Hydraulic | Oil pressure 69Mpa | #€To be veumed by 1-12 5 | side bate wae x30 | eee (700Kem") {um after compete screwing. 6 | Flywheet mounting bolt Ms0x20| at fo ca 980 7 | Balance weight mounting bolt | M30x20| $0 co * eT y 196Nem (20k mp 40 8 |Crankpin bl wax20} 27 |g ahem aera eK ‘98Nem (10kgf+m}+20" 9 | Connecting od bot 0x20] 27 |g ae ahem) ok T96N-m (20kgF-m)--40" to tae gearshat mounting bot | M3030] a1 | geabemCarony * 11 [Idle gearshaft mounting bolt | M16 x 20 | Hole: 14 ra * 12 | te gear tightening bote Miax20| 24 na (Cam gear mounting main plate 7 30 2 ae Mio | Hole:8 3) 498 14 [cushion gear tightening mut | Max 20] 65 a Injection pump delivery valve 137-197 1 | ightening bolt M6 | Hote: 14 (4-16) 16[ norte mouingcapm | — | 27 a & 17| Nozzle holder inlet connector | MIx1S| 19 a FO high-pressure tube mounting 3a 18 fa Mizxi7s| 17 oe ‘Governor drive shaft tightening 118 RHDS 19 | jut tightening bolt ee 12) U nut 20 | Swing arm mounting bot misx 20] 24 al Staring rorary valve cap ss 39 cape aor Mi2x175| 17 ia 2 Indicator valve mounting nut |MI2x 1.75) 19 a 25] Nantetoermouningnar [2x 175) 18 es DK-20 | A|95—4DAIHATSU SECTION ENGINE ADJUSTMENT STANDARDS. TYPE 3 Tightening Torque Table DK-20 SHEET Width acca] Tighienng torque Names oftotsand nuts | Size | flats Remaks (mun) mioxis| 17 Mi2x175| 19 24 |General bts and nts Miax20| 22 misx20| 24 misx2s| 27 Notes) 1) Main bolts and nut marked with * should be tightened according to the following specifications Crankpin bolt and connecting rod bolt ......Section 7, sheets 17~18 Main bearing tightening nut and side bolt ...Section 7, sheets 21~25 Cam gear mounting spanne ring. ‘Section 10, sheet 12 2) Other bolts and nuts must be tightened in a diagonally alternating sequence. 3) Be sure to check for loose cylinder head tightening nutsand connecting rod bolts after a certain period of operation. Refer tg Section 6 fort inspection frequency. 4) Anti-seizure agent should be applied before tightening to bolt seats and threads used for the parts around the exhaust pipe, which are to be subjected to high temperature. 5) Retighten bolts used for installation during stop of the engine. Be sure to check the crankshaft direction after retightening, 6) Torque wrenches used for tightening shall be inspected peirodically. 7) Anti-seizure agent (MOLYKOTE 1000 spray type) should be applied before tightening to the seats and threads of tightening bolts and nuts marked with 2 '8)When use of a hydraulic jack is intended, refer to the sheets 10-11 “Hydraulic Jack Operating Method and Maintenance” in Section 10. DK-20 [A|95—4]SECTION | TYPE 3 ENGINE ADJUSTMENT STANDARDS eal | Zax! Clearance and Wear Limit | Part Schematic dawing Nomivalsiod Clearnce | Weata®4 | Remarks | 7 +1.0 | Inner dia. of + 5 - Taser din D=200 Parl wea Replace liner | | | | os A 1 A=20 — |a-066-0.76 liner and | t piston Outer * | dia of | B b-0.12-0.21 Replace piston piston i _ c | c-200 Jecoto019 | 04 Ring end cl=1.3-15 325 [Replace ring. > clearance in eel ©2=0.90-1.10 Clearance with cylinder may 090-110 | ye [clearance °? Ist ring As |ao13-017 | 03 Piston ring | Replace ring. aly Use oversized 2nd ring | Cats [pes 009-013 | 03 — [ring it wearon * aa piston groove is a excessive. ‘3rd ring a, e=0.075~0.1 15] 03 eit | Ring end |cleatane in ito #2 Oitring | eylinder rears Cotidg, See in 7 Oil ring — D=7 03 [new liner. Piston pin and ale 7 Replace the boss 20.00.08) O15 more worn one. Piston pin “ ~ A=90, zo pin and 009.016 | 03 | Replace metal Crankpin metal =0.10-0.19 03 |Replace metal Use undersized men on. crankshaft is Main bearing seott-o2t | 03 fier Crank | | shaft ] Thrust bearing a Replace thrust clearance 90.13-030 | 0.6 | bearing, F ll | Bear tower eass.07s 38 Replace chromiumplated ring when its orginal surface appears due to wear. TI DK-20 |Z|94—a|DAIHATSU TYPE SECTION ENGINE ADJUSTMENT STANDARDS, | 3 Clearance and Wear Limit DK-20 | SHEET Part Schematic drawing Nominal size Clearance | wear and, | Remarks Cams He [as [ssooor | 02° freee meat cae Any | " Camshaft thrust | “SSS z Replace thrust bearing A Ce 045 | bearing Tappetand poet (FO Jacoos-o.07s | 025 Valve \ : ; 30,070.13 SERRE | tappetrole | o20 | Replee bearing nism and |Saftand bearing a (bushing) tappet jaikioes |nvakeloxhanst - rocker arm shaft D-5o— |a-0.05-0.14 | 0.25 ___|and bearing - Intake valve . : Replace, if worn Gee part) and | | Acid 0=0.09-0.13 03 more than limit. > [Exhaust valve “ o Replace bearing (aes pan) and IL }a'=0.09-0.13 03 lieing) Intake valve | (ace part) feed oo Intake and exhaust, | alves, Intake valve seat | D=2 os t Ld T “Tt Replace gear. Exhaust valve / - (Face part) c a al | wy | Exhaust valve seat, | oe _ | F _ I | te gear stat ey cos |acoas-o1s | 025 | Replace ea. tine ee |e - _ gear | Backlash | b=0.20-0.30 Os iter Louisa s-o30-050 | 08 | Cooling | Cater | Mout ing and actos 05-050 | 10 |Repoe baring pump oes DK-20 |Z |94~3DAIHATSU ‘SECTION 3 TYPE ENGINE ADJUSTMENT STANDARDS cia DK-20 Dimensions of Disassembly, Mass of Main Parts Dimensions of Disassembly oh — oxo By saae/) IM 4 Ta ce (ee Tre) Mass of Main Parts Unit: kg DK - 20 Remarks Cylinder head, complete 120 | Piston and connecting rod , complete 70 Cylinder liner _o | Camshaft, complete 160 One-piece construction Lubricating oil pump __33___| Including gear of max. cia. | Cooling water pump 9 Including gear of max. dia VIRI6I 204 Turbocharger | VIRSOL 280 vrrai4 350 DK30 240 Intercooler | DK44 310 pps? 300 DK-20 |Z/94~3|DAIHATSU TYPE DK-20 ‘SECTION “SHEET DK-20 Z\94—-3DAIHATSU ‘SECTION | TYPE 4 SHEET | DK-20 1 GENERAL CONSTRUCTION Engine Construction 1. Engine Frame Frame is of tough cast iron of integral underslung ‘metal construction. ‘The main bearing cap is fixed to the frame with two mounting bolts and side bolt to be tightened hydraulically. The timing gear case, intake pipe, lubricating oil main tube and cooling ‘water main tube are integral with the frame. 2. Crankshaft Crankshaft of high-strength forged steel is designed to drive the camshaft with the rear end and pumps with the front end, 3. Connecting Rod Connecting rod is made of solid forged steel. The largeend is split horizontally into thret to reinforce rigidity of the large end, 4. Piston Piston made of nodular cast iron is cooled forcedly with lubricating oil flowing via connecting rod and piston pin. In the case of heavy fuel oil specifications, top and second ring grooves are chromium-plated to improve wear resistance. 5. Cylinder Head Cylinder head is made of special cast iron and fixed with four bolts. To cope with mechanical stress due to high combustion pressure and thermal stress due to combustion temperature, the ‘combustion wall thickness is increased. To enhance the cooling effect, the bore cooling type is adopted. 6. Fuel Injection Pump Fuel injection pump is of closed type plunger barrel capable of high-pressure short-time injection. For prevention of cavitation, a constant-pressure valve is adopted. Simple construction is designed with the tappet integrated with the injection pump. 7. Swing Arm ‘Swing arm type has been adopted instead of the conventional vertically sliding type to make the construction simple and compact. This has facilitated adoption of a high-pressure injection ump of high rigiity 8. Bearing Metal Main bearing, crankpin bearing and crankshaft thrust bearing made of aluminum alloy metal are thin wall complete bearings high in load capability and corrosion resistance, while piston pin bearing is bushing made of lead bronze DK-20 | Z|94—-3DAIHATSU GENERAL CONSTRUCTION ‘4 Starting Pneumatic System and Related Parts TYPE | SECTION DK-20 | SHEET 2 9. Starting Pneumatic System and Related Parts Starting is mac by a pilot system, using compressed air. When the air receiver tank stop valve is opened and push button of the starting control valve is pressed, the startingvalve is opened by low-pressure operating air, and compressed air is distributed to cylinders in explosion stroke according to the ignition sequence, to start the engine. In the case of auto/remote starting engine, refer to separate instructions. Operating air Starting aie valve ‘Starting air main pipe safety plug kT 4 sang ae \, Check valve ‘Air reoeiver tank Pilot tube The starting valve and the starting air valve are located at the front of the engine; the starting rotary valve is driven from the front of the camshaft In order to protect the system against back flow of combustion gas, a check valve and a safety plug is provided at the inlet of te starting air main pipe. Starting rotary valve Starting valve Starting air main pipe t Starting Proumatic System Diagram DK-20 | Z|94—3DAIHATSU SECTION | TYPE | 4 | SHEET | DK-20 3 GENERAL CONSTRUCTION Fuelo Oil System and Related Parts “10, Fuel Oil system and Related Parts Specifications of fuel oil system differ according to the grade of the particular fuel oil used. Shown below isa typical fuel oil system setup. Fuel oil pressure-fed to the fuel injection pump goes through the fuel high pressure piping block and is injected into cylinders through the fuel nozzle at high pressure. Surplus oil passed through the fuel injection pump is returned from via the pressure regulating valve to the intake side of the fuel oil feed pump. 1 Air separator Oil feed pump Fuel high-pressure pipe leaked cilimain pipe High-pressure piping block ‘The final fuel filter is attached to the engine.The fuel injection pumps are of Bosch high-pressure type and installed independently per cylinder. ‘The fuel nozzle is of Bosch type incorporated in a nozzle holder which is mounted at the center of the cylinder head. In the case of heavy fuel oil specifications, the nozzle is designed to be of Construction to be cooled down, Nozze leaked oil main pipe Pipe Fuel nozzle ms Fuck pum Pressure regulating valve injection uel inlet main Pipe Fuel outlet main pipe Leaked oil tank Fuel Oil System Diagram DK-20 94-3DAIHATSU GENERAL CONSTRUCTION Lubricating Oil System and Related Parts TYPE | SECTION 4 DK-20 | SHEET 4 41. Lubric Lubricating oil pressure-fed by the lubricating oil pump is regulated to the specified pressure by the pressure regulating valve, passe through the filter, and then fed to the main bearing metal, crankpin metal and piston for lubrication. Part of the lubricating oil system is branched off for tappet, camshaft and cylinder head lubrication lines, and lubricating oil having lubricated respective portions and been cooled down is retumed to the sole plate. 1g Oil System and Related Parts Lubrication around the rocker arm is shut off by. the pressure regulating valve at the time of start of the engine, so that priority of lubricating oil flow is given to the bearing lubrication system over other systems. The gear-type lubricating oil pump installed on the lower front of the engine is equipped with a safety valve, ‘The lubricating oil cooler is of multitubular type. Lubricating oil full flow filters are notch-wire type duplex filters, and normally allow the use of both sides for blow-off (backwash) during operation, ‘Some types of the turbocharger uses system oil for lubrication, Fuel injection pump Lubricating ol cooler ee Timing gear Governor driving sear Pressure regulating valve Fer |», Coating water pump ile gar ‘Temperature control valve Filter ‘Turbocharger Safety valve Leaked oil tank Lubricating Oil System Diagram DK-20 | A|95—4|DAIHATSU | TPE GENERAL CONSTRUCTION sHeeT | DK-20 Cooking Water System and Related Parts 12. Cooling Water System and Related Parts ‘The cooling water system is divided into two lines; thejacket line and the cooler line. The In both diesel fuel oil and heavy fuel oil standard cooling medium used for the jacket line is specifications, the water-cooled type exhaust valve fresh water and that forthe cooler line is sea water. seat is adopted. ‘Temperature control valve Jacket lie outlet main pipe poe “|Z | Jacket line fesh water pump Fresh water cooler]. Cr Intercooler Lubricating oil cooler foley F Cooler line cooling water pump Wve ‘Adjustment valve Cooling Water System Diagram DK-20 | Z/94—3{DAIHATSU} ___ GENERAL CONSTRUCTION ]SPE | SECTION Nozzle Cooling Oil System and Related Paris (For engine operated on heavy fuel oil) DK-20 ral 13, Nozzle Cooling Oil System and Relat (For engine operated on heavy fuel ‘When the engine is operated on heavy fuel oil, it is necessary to cool down the nozzle tip so as'to prevent generation of carbon flower from the fuel nozzle. For prevention of supercooling, a temperature control valve is provided to put the fuel nozzle temperature under control so that it may be appropriate at all times. Presoure regulating valve The cooling oil used is diesel fuel oil. The pump is of gear type and is driven by the camshaft end gear. ‘Outlet main pipe Inlet main pipe cl Fuel nozzle Nozzle Cooling oll System Diagram Dk-20 [Z[94—3DAIHATSU SECTION] TYPE] 5 SHEET | DK-20 | 1 OPERATION AND DAILY MAINTENANCE Preparation for starting (daily operation) 4. Daily Operation Requited preparation for starting of engine depends on the condition of disuse of the engine. + Daily operation (short-time stop) + Initial starting after installation + Starting after extended disuse + Starting after overhaul Preparation and inspection shall be made in ‘conformance with respective cases described above. Never touch the following areas during run, It may cause bum or injury to you. + Exhaust pipe cover top + Turbocharger inlet and outlet exhaust pipes, + Intake air cooler inlet duct + Safety valve and indicator + Rotating areas such as crankshaft, et. Turbine side Blower side Correct level of olin turbocharger (1) Preparation for starting (WTR type) (daily operation) 1) Inspection of tanks @Lubricating oil level in oil pan (along with reduction gear in the case of marine propulsion engine) @Fuel service tank oil level @Cooling water tank water level @Turbocharger oil level (VTR) ©Governor oil level @Starting air tank pressure (25-29 MPa)(25 ~30 keflcm’) RHD 6 uss Correct level of oil in governor + 2)In the case of heavy fuel oil spe cations, allow the fuel heater to start. 3) Discharge drain (this may be omitted, if it is considered proper.) Fuel service tank @Starting air tank intake pipe Correct level of lubricating oil in oil pan 4) Put all valves in run state. 5) Put the clutch in neutral position (in the case of marine propulsion engine). DK-20 | A|95—4]DAIHATSU OPERATION AND DAILY MAINTENANCE Tyre | SECTION Preparation for starting (daily operation), DK-20 | SHEET Starting (daily operation) 2 6) Lubricating oil priming Fully open the pressure indicator valve. Then, allow turning and priming for about 5 minutes. Check that no fuel oil, water or lubricating oil Jeaks from the pressure indicator valve as a result of turning, When priming with a hand pump is intended, cen the pumpoullet valve, and allow priming as described above atthe oil pressure of about 0.1 MPa (about 1.0 keficm'}. Close the valve completely after end of priming. 7) Check if the link mechanism operates smoothly. 8)If motor pumps are installed, start them. 9)Turn ON the protective device and warning device power switches. AX10) Ascertain that the engine rotary section is free from any obstacle. 11) Air running (this may be omitted, if it is judged proper.) Conduct air running with the contro! lever in the STOP position and the pressure indicator valve fully opened. Close the pressure indicator valve completely after end of air running It is desirable to keep the air tank valve at 1/3 turn in consideration of high stability and low air consumption. (2) Starting (daily operation) 1) Precautionary instructions for starting Be sure to make it rule to check the following points before starting ‘The control lever is set at STOP and the rack amount is reduced to zero, + Rotary section ig not obstructed by a tuming rod or others. The turning. gear shall be disengaged. + The fuel system is changed over to that for diesel Fuel oil (in the case of diesel fuel oil starting specifications. + For inilial stating or starting after a long interruption, be sure to start the engine esas 2)Put the control lever in the RUN position. In the case of manval engine starting specifications, put the control lever in an intermediate position between STOPand RUN, and adjust the condition of rack engagement at starting. DK-20 |A|95—4|DAIHATSU caeeal lane OPERATION AND DAILY MAINTENANCE, SHEET | DK-20 Starting (daily operation), Initial starting after installation 3 and starting after extended disuse or overhaul * 3) Press the starting control valve to start the engine. In the case of starting failure, conduct check. Starting Sdatol valve 4) Check items immediately after starting DLabricating oil pressure and cooling water pressure (see Section 3, Sheet 2.) @Check temperatures of exhaust gas from all cylinders to make sure of combustion in all cylinders. @ Vibration and sound @Pilot lamps in the protective circuit If lubricating oil pressure or cooling water pressure does not rise sufficiently, stop the engine, locate the causeand take corrective actions immediately. 5) If no abnormality is found among items in 4), increase the engine revolution quickly to eliminate excessive torsional vibration. Refrain from continuous running at below the specified idling speed. ©) Close the air tank valve, (8) Initial starting after installation and starting after extended disuse or ‘overhaul ‘Add following works to the daily operation method specified in Section 5, Sheet 1. 1) Preparation for starting Check if no foreign matter such as a tool is left over in the crank chamber or the lubricating oil suction port is not clogged with clean rag or others Feed fresh water into the expansion tank. @Make sure of freedom from loosening in any portion. @Check if the fuel pump rack and link mechanism operate smoothly. Check further if the rack graduation indicates “O” when the control fever is put in the STOP position. Oil the link mechanism manually. Check the fuel line heater (in the case of heavy fuel oil specifications) @If the valve operating mechanism is released, check the valve clearance. @Wash the turbocharger blower suction port filter. @Filter disassembly washing AAs to fuel oil and lubricating ol filters, be sure to dissemble and wash them before operation 0 as fo remove dusts and other foreign matter deposited on them during transportation or outfitting For the disassembly washing procedure, see Section 10, Sheet 1 @Lubricating ot priming Conduct priming for about 5 minutes while turning the engine, and check the main bearing, piston pin, crankpin and cam bearing for oil drop. If strong resistance is felt during tuming of the engine, remove the possible case before start of operation. Bleed air from the lubricating ol filter. DK-20 | Z/94~3DAIHATSU OPERATION AND DAILY MAINTENANCE eae initial starting after installation and starting after extended DK-20 | SHEET disuse or overhaul 4 of be fully careful so that che lubricating oil may be spread to the liner | and_the piston suffcienly. If the liner surface is not wet, drop about SO cc of lubricating oil from the pressure indicator valve. In addition, apply lubricatingoil to the liner surface sufficiently from the liner underside with a sprayer or the like. ‘After making sure of sufficient application of lubricating oil to the whole liner surface, conduct air running in state with the pressure indicator valve open. In this case, lubricating oil scatters from the pressure indicator valve. Therefore, prevent it with, waste cloth or the like . ®Fuel oil priming and air bleeding 1. Make sure that the governor control lever is inthe STOP postion 2. Open the fuel filter air vent cock to purge ain 3. Open the injection pump air vent plug to purge air. 4. Fully open the pressure indicator valve, push jin the fuel rack on in-running state to purge air from the nozzle holder. Air bleeding from fuel and lubricating oil filters. a ene TT ‘Air bleeding from fuel injection pump 5. Start the heavy Fue ol supply line heater. 6. Star the motor-driven ol feed pump. 7. Upon end of air bleeding, select diesel ful oil 8.Stop the motor-driven oil feed pump when replacement ofthe fue inthe piping with diesel fuel ol is ascertained. 6 bY bo Engine fuel inlet main pipe Ho Example of piping per heavy fuel oll specifications DK-20 | Z|94-3DAIHATSU camellias OPERATION AND DAILY MAINTENANCE SHEET | DK-20 Initial starting after installation and starting after extended 5 disuse or overhaul, Run * 2) Starting 2) How to increase load and engine speed Be sure to start the engine manually. 3) Inspection after starting Listen carefully for abnormal sound from the engine. If abnormal sound is heard, stop the engine and remove the cause immediatly @Siop the engine after operating for $ minutes at idling speed, and check the main bearing, crankpin bearing, piston liner, etc. for abnormal overheating. @Check the lubricating oil level and cooling ‘water level again, and make replenishment, if necessary. @If no abnormality is found, start the engine again 10 check for leakage from all connections and the amount of, fuel leakage from the nozzle holder. ®Touch the starting air pipe to check for blowby in the starting rotary valve Purge air from all pumps and coolers. (@) Run 1) Warming-up @Warm up at the rated engine speed (idling speed for marine propulsion engine) for about 10 minutes under no load, @Warm vp with diese fuel of. @Set the governor speed adjusting handle to the idle speed position @Press the starting operation button to start the engine. Speed adjusting handle @Tum the govemor speed adjusting handle to increase the speed gradually. Apply load gradually after all portions of the engine are stabilized. Especially, when the engine is stated in cold state, apply load, taking further longer time. @in the case of the marine propulsion engine, the toad increases with an increase in the engine speed. ‘Therefore, be sure to increase the engine speed gradually. @If there is a critical number of revolution within the normal speed range, avoid it auickly. 3) Check of operating condition during load increase Lubricating oil pressure and temperature Cooling water pressure and temperature @Fuel pump rack amount @Cylinder outlet exhaust temperature lntake air pressure 4) Changeover to heavy fuel oil See Section 8, Sheet 2 Dk-20 [Z|94—3(DAIHATSU) OPERATION AND DAILY MAINTENANCE ee ce —— Runningin DK-20 ca (6) Running-in In run after initial starting, extended disuse or ‘overhaul, run-in of sliding portions is not sufficient. It is thus required to pay particularly careful attention to run. Unsatisfactory running-in causes seizure, blowby or abnormal weer. AS to engine of heavy fuel oil specifications, system oil for for heavy fuel oil may be used as system oil used during running-in period after installation. (See Section 9, Sheet 7.) ‘When engine is operated on diesel fuel oil in excess of the running-in time specified below, Class Hil shall be used. Use diesel fuel oil after piston ring and liner of engine operated on heavy fuel oil are replaced with new ones or for 150 hours after installation. The load pattern after replacement of piston ring and cylinder liner with new ones is as shown below. Manual stat (avid ude ineresein speed) | Cheek rier i ir oe 15 mi 70-80% ood retention for about 24h then normal Fun Fy f cae al 5 min 1 e a Be especially careful of the following during sunning, Check the cylinder liner inside surface condition from the cylinder liner bottom face twice; after 100 hours after starting of run on heavy fuel oil and 150 hours thereafter. ‘Abnormal sound, abnormal overheating Operating condition of pumps Leakage from connections, loosening Cylinder combustion condition (exhaust gas temperature, maximum explosion pressure) + Lubricating oil consumption level Dk-20 |Z|94~3DAIHATSU aaa OPERATION AND DAILY MAINTENANCE SHEET | DK-20 ‘Measurement of engine performance, Measurement of 7 lubricating oil consumption level, Adjustment ‘2. Dally Maintenance and inspection (1) Measurement of engine performance * Measure the following values when load is stabilized. Becareful so that the load does not fluctuate during measurement. + Take measurement at least once a day. When values are compared, compare them on the same conditions of the fuel pumprack amount and the turbocharger intake air temperature. + For details of the standard temperature and pressure, see the operating specifications in Section 3, Sheet 2 or the factory operation test result. + Measure the exhaust concentration from time to time to check if combustion is normal 1) Measuring items @Exhaust temperature at the oiltlet of each cylinder @Exhaust temperature at the inlet of turbo- charger @Maximum explosion pressure for each cylinder @ Fuel pump rack amount for each cylinder @Tourbocharger intake air temperature @®intake air pressure and temperature @Lubricating oil pressure and temperature ® Cooling water pressure and temperature @Fuel oil pressure and temperature @Nozzle cooling oil pressure and temperature (2) Measurement of lubricating oi! consumption level Measure L.O. consumption level of each engine, and total the data every month so as to grasp the trend of LO. consumption. In the case of short-time run or frequent start and stop of the engine, excessive consumption may result. Therefore, when measurement of normal consumption level is intended, take measuring during long-time continuous run’of the engine. If the oil level is measured during stop of the en- sine,note carefully that the oil level may tum high owing to drop of oil from filter or cooler onto the oil pan. If the lubricating oil consumption level is abnor mally low or the oil level is high, a possible cause is infiltration of fuel or cooling water. If infiltration of fuel or cooling water is found, locate the cause, take corrective actions, and replace the lubricating ol. (@) Adjustment 1) Exhaust temperature As a cylinder outlet is located closer to the turbocharger, the cylinder outlet exhaust temper- ature turns higher because itis more affected by other cylinders. Normally, the fluctuation of ‘exhaust temperatures among cylinders is about 30 °C. To correct the irregularity, various adjust- ‘ment has to be made. 2) Cylinder maximum explosion pressure The maximum explosion pressure (Pmax) depends on properties of fuel oil, intake air temperature, etc., but the fluctuation among cylinders is acceptable, if itis within the range of 0.6 MPa {6 kgficm'). (But, it shall not exceed thevalue of rated pressure + 0.3 MPa (3 keficm’) ‘Sampling for explosion pressure shall be made according to the following procedure. Allow a pressure indicator valve to blow one time. @®Mount the pressure indicator valve. @Be sure to fully open the pressure indicator valve and take sampling. The threaded areas will possibly be seized, unless the valve is fully opened. @Fully close the pressure indicator valve after ‘end of sampling AX@Arter reading the maximum explosion pres- sure, open the exhaust valve of the pressure indicator valve, and dismount the pressure indicator valve when indication reads “O" MPa. Exhaust valve (Notes) AXOBe sure to wear gloves, since the pressure indicator becomes hot. @®Measure explosion pressure after the engine is warmed upsufficienly and the load is stabi- lied, DK-20 |A|95—4|DAIHATSU OPERATION AND DAILY MAINTENANCE TYPE | SECTION Adjustment DK-20 a 3) Fuel pump rack amount When the exhaust temperature of a cylinder is largely different from those of other cylinders after replacement of the fuel injection pump or nozzle, adjust the graduation of the fuel rack using the adjusting screw shown at right ‘The fluctuation of the exhaust temperatures among cylinders is acceptable, so far as it is within the range of about 30°C . Keep the rack amount fluctuation at about + 1 graduation. Do not make further adjustment of the rack amount ‘When the exhaust temperature rises gradually, it is often because of stained turbocharger or intercooler in general. ‘Sudden rise of the exhaust temperature is often attributable to causes other than the engine such as damage with thepropeller. » ‘Adjust the rack graduation using the adjusting screw as shown below. tress in rack amount (Eats temperature rit) Counerceckise tum — Decrease i rack amour (Gaus temperate elution) Cloke tn a 4) Intake air temperature Itis desirable to keep the temperature of intake air at 45-50 °C. Adjust the cooling water flow with the valve provided on the inlet side of the intercooler according to the sea water temperature and room temperature. In the factory run, explosion pressure data with the intake air tem peratureadjusted to 45-50 °C under full load are sampled, If the intake air temperature is supercooled, condensateis formed with the resultant damage with the intake air valve and reduction in lubri- cating performance. Therefore, sufficient care has to be taken in adjustment of the intake airtemperature. It is generally claimed that the temperature of exhaust gas will change at about twice the rate at which intake air temperature changes. However, since the temperature change is affected by the fuel oil used, back pressure, cleanliness of the turbocharger and intake and exhaust valves, and also by the degree of staining on the ship's hull or the navigation conditions (including the shape of the propeller sued), etc. in the case of marine propulsion engine, itis advisable that the condi- tion of the installed engine is fully understood with reference to the factory operation data If the intercooler cooling, water inlet and outlet temperature difference is eliminated and the temperature of 45~50 °C. cannot be maintained in spite of operation of the cooling water outlet ‘cock, wash the intercooler according to the procedure described in Section 7, Sheet 32 Dk-20 |z]94—3DAIHATSU. SECTION | TYPE | sneer DK-20 9 OPERATION AND DAILY MAINTENANCE Adjustment Normally, make adjustment with the adjusting valve A with the adjusting valve B on the outlet side fully open. If the intake air temperature does not rise in spite of full opening of the adjusting valve A, conduct adjustment with the adjusting valve B in state with the adjusting valve A fully open. Do not fully close the adjusting valves A and B simultaneously. 5) Intake air pressure Tacrease in the intake air pressure involves rise of the exhaust temperature. ‘The possible cause is dirt on the turbine side of the turbocharger Disassemble and wash the turbocharger in accor- «ance with the turbocharger Instruction Manual. Reduction in the intake air pressure is possibly attributable to dint on the blower side of the turbocharger. Wash the turbocharger according to the procedure described in Section 10, Sheet 2 ‘Temperature Adjusting serew ©) Lubricating oil pressure The lubricating oil pressure range is 0.4~0.5 MPa (4 ~5 kefiom'}. Pressure adjustment is made with the pressure adjusting screw of the lubricating pressure regu- lating valve. It the oil pressure does rise in spite of tightening of the adjusting screw, possible causes are suction of air or trouble withthe lubricating oil system in addition to sticking of the valve. Conduct check. Lubricating oil pressure regulating valve 7) Lubricating oil temperature ‘The temperature control valve works to raise the lubricating oil temperature in a short time for slart of the enginein cold state and keep the ‘temperature with an appropriate range (50~60°C ) Bult, itis difficult to maintain strict accuracy. Nor maintenance of such accuracy is required If the sea temperature changes largely depend- ing on the season or the sea zone, the lubricating oil control temperature is also affected a litte, but such a difference can be corrected with’ the adjusting screw. ‘The cap and lock nut positions are adjusted in advance in accordance with characteristics of ‘wax. unnecessarily Even if the temperature control. valve is normal, carefulatention has to be paid, since the lubricating oil temperature may rise ‘owing to extreme staining of the lubricating oil cooler, reduction in the cooling, water flow, overheating of lubricating oil due to abnormal’ combustion, etc. If the control temperature is abnormally high, tur in the adjusting screw (about 8 mim max.) and open the passage on the cooler side as a make-shift measure Do not loosen them DK-20 94-3 Pressure adjustingDAIHATSU SECTION OPERATION AND DAILY MAINTENANCE a A Adjustment DK-20 eal When no temperature control valve is not For details of the temperature contol valve, see proved, tis required to adjust the lubricating oi the separate Temperature Control Valve Instruction cooler bypass valve manually for control of the Manual lubricating oll temperature ‘When the lubricating oil temperature is low due to cold weather, vibration noise may be generated due to high viscosity of lubricating oil in the area around the lubricating oil outlet pipe and the pressure regulating valve. In such a case, it is advisable t0 fully open the. lubricating oil cooler bypass valve and raise the lubricating oi temper- ature tothe proper temperature abruptly Nozzle cooling oil pressure regulating valve H covers csi tae conteol valve’ pe AT iM Govemor Nozzle cooling oit temperature contol valve a pa Starting air valve” Starting rotary valve Rocker arm oil feed pressure Fuel pressure regulating valve ‘regulating valve (each eylinder) Lubricating oil pressure regulating valve Lubricating oil temperature control valve Intake ar temperature contol valve Intercooler Lubricating ci cooler DK-20 | Z|94—-3DAIHATSU SECTION | TYPE SHEET ] 5 | | | 1 __OPERATION AND DAILY MAINTENANCE Adjustment, Maintenance 8) Cooling water temperature In order to raise the jacket line cooling water temperature in a short time for starting of the engine in cold state and further keep the cooling ‘water temperature within @ proper temperature range during run of the engine, the fresh water cooler is provided with a temperature control valve. If the jacket cooling water temperature is too low, sufficient combustion cannot be obtained or corrosion of important members may result, especially when heavy fuel oil is used. There fore, appropriate temperature control is neces- sary, 9) Rocker arm lubricating oi! Rocker arm assembly is lubricated with system oil. A pressure regulating valve is provided at the cylinder head inlet. Oil is fed at the pressure of 0.1 MPa{ 0 kgficm*}min, to ensure the required fubricating oil volume around the bearing during priming ‘The lubricating oil rate to the rocker arm assembly is set in advance. Therefore, no further adjustment is required 10) Nozzle cooling (when heavy fuel oil is used) As to the nozzle cooling oil, use diese! fuel oil for both cases of start of DO and start of HO. The cooling oil temperature should be adjusted to 50~60°C with the temperature control valve. 11) Fuel oil pressure ‘The fuel oil pressure differs largely with the viscosity of the fuel used. Therefore, read the engine inlet temperature prior to adjustment to make sure of proper viscosity of the fuel, and then conduct adjustment. When heavy fuel oil is used, keep the pressure at the setting value for use of heavy fuel oil. See Section 3, Sheet 2 If changeover is made to diesel fuel oil, the oil pressure reduces, but it is not necessary to make adjustment. (4) Maintenance 1) Filter washing Disassemble and wash all filters periodically to keep them in clean state at all times. For detail washing procedure of filters, see Section 10, Sheet 1 OFuel filter The fuel filter is a noich-wire type duplex filter. Therefore, in the case of use of heavy fuel oil, disassemble and wash it with suffi- cient care, since temperatures of the fuel oil and the filter are high. IF possible, washing During normal operation, the lever should be kept at thecommon position, where both filters are in use. Change the lever position over to the right or let for selection of washing only. ‘When changing over the lever position, it is necessary to attempt to do so with care taken to the handle stopper andmarking positions while observing the pressure gauge. (Conduct selection of the lever postion during idling ofthe engine or under low oad.) If pressure drop is seen during run, blow-off operation is required. If pressure cannot be recovered even after blow-off operation, wash the filter after disassembly. To perform blow-off, recline the lever to either right or left side blow-off position (about 60 °) and then return ito the normal position again Repeat this step several times for {~2 times per * time for one side. Conduct the same operation on the opposite side as well For the washing method, see Section 10, Sheet 1. The blow-off and washing methods are described on the filter nameplate as well DK-20 |Z|94-3(DAIHATSU) OPERATION AND DAILY MAINTENANCE 5 Maintenance, Inspection TYPE | SECTION DK-20 | sheer 2 Blow-off operating position 3) Drain-up of intake pipe A high turbocharging engine shows high intake air pressure and also has a large intercooler capacity. Thus, drain is likely to be accumulated. Open the intake pipe drain coc kfrom time to time to fully discharge the drain. If much drain is seen, it is possibly due to leakage of water from the intercooler 4) Washing of turbocharger If the turbocharger is stained, exhaust temper- ature rises or exhaust color is blackened due to reduction of the intake air pressure to affect the engine performance or life largely. Therefore, wash the turbocharger periodically in accordance with the schedule shown in Section 6, When a differential manometer is equipped, wash the turbocharger appropriately, when the pressure loss exceeds 1961Pa{200mmAg} or the intake air pressure reduces by about 10%. AS to the pre-filter wrapped around the silencer filter;conduct washing once a week or so. For the washing procedure of the silencer filter, see the Turbocharger Instruction Manual When the degree of staining of the turbo- charger is light, the method of washing with water injected can be used during run of the turbo- charger. Execute this method appropriately to ‘operate the turbocharger in state of good effi- ciency. ‘AS to the method of injection washing on the blower side, see Section 10, Sheet 2. For the urbine side injection washing method, see Sec- tion 10-Sheets 3-4. 5) Protectors For details of each protective device, see the separate Instruction Manual. @If an alarm is issued during run of the engine, stop the engine immediately and locate the cause. Especially, keep persons concerned informed of actions to be taken in case ofissue of an alarm on the deck section so as to prevent an accident. @ Conduct protector function tests at least once a ‘month to check if all sections of the protector operate normally and alarms are issued at the preset values ‘When conducting the pressure reduction test, throttle the pressure switch takeoff valve to reduce the pressure. In such a case, the pressure reduction is of the pressure switch circuit only. Therefore, the test may conducted during normal run of the engine. Conduct the temperature switch test using separate hot water. (©) Inspection Keep the engine in clean state at all times 50 as to find leakage from connections, crack, etc. at an carly stage. 1) Daily inspection Fuel tank oil level @Oil pan oil level @ Fresh water tank water level QSiarting air pressure Discharge of drain from intake air pipe ®Leakage from mechanical seal of cooling water pump, fueloil feed pump and nozzle cooling coil pump Rate of fuel leakage from nozzle holder @Tactile check for overheating of fuel injection pump, cooling water pump and other pumps @Tactile check of cylinder starting air pipes for blowby in starting rotary valve @Leakage from connections ‘@Loosening 2) Weekly maintenance and inspection @Removal of sludge accumulated on the intake and exhaust valve cotter @ Hand lubrication to link mechanism @Blow.off operation of switching type filter @Discharge of sludge when lubricating oil centrifugal ter is provided Washing of turbocharger pre-fiter (sponge at the blowersuction port) ®Discharge of drain from starting air tank Discharge of drain from starting rotary valve @Starting test and maintenance operation of engine shut down for more than one week (more than 30 minutes) Conceming items of the inspection period of more than Imonth, see Section 6 DK-20 | A|95—4