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    Daihatsu 6DK 20 Diesel Engine Operation Manaul - Compressed

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    vignesh dhanapal

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    M2- 6 (2/3) CENTURY RIVER De ee TEU cee LEE DAIHATSU DIESEL MFG. CO.,LTD. an ORDERED BY ; oR x 2: DESTINED FOR ; ® ine SE: KOYO DOCKYARD CO. LTD. ‘SNo. 2106, . a DK620Z0613 ENGINE MODEL 6DK-20 ENGINE NO. : DK62020614 ame Ft BS! Dk eonmels DATE OF MFG ; i A mes BR; le Ba HW Forward AMR E BRT SROMRLHD ST This instruction book deals with the UREDR UTES RmRMET EM SERNESOTHEV ETHOS, +O SOLTUREE, ME LURUCRME AREY. MANOM LENT. BRO [29] EDAZATOREGHE, OM OBGEDIEL, WORTHRET CER MECHEL TOREMSLELHLET. RABI OREAEBR t FAL TRS, HEMIEBBIUF CBRE ht BS, BHEBMORELHRELA, HBO BAE CPM < MRI, RCRMLTHSBERSSUBRBBIC SOTUREK ERIC, DFM Cw MBS ESMSET SSSI SMUUEL et. BMShe, TRL Fa TMT & BLIBBUOKLET. CRN; PLAS SMSt: ERB DANI Fs — CNRS ABU REAHET2 TE 4 14-8 w540.0025 SEMMSRO — TEL. (06) 6945-5325 FAX, 06) 6945-S904~6 TEL, (08) 6946-5227 FAX, (06) 6945-5204~6 + o-exaeO fundamental knowledge required for operation and handling. It is, therefore, ardently requested to follow the working as well as maintenance instructions, so that you may enjoy the utmost durability and satistactory operation of our Diesel Engine for many years to come. For renewal parts, use our genuine ones, otherwise we cannot guarantee the part quality. 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 or for further information, please contact. Orders; PARTS SALES DEPT. Information; AFTER SALES SERVICE DEPT. DAIHATSU DIESEL MFG.CO.,LTD. 4:14, TOKUL-CHO 2-CHOME, CHUO-KU, OSAKA 1540-0025 JAPAN FAX, (06)6945-5904~€ TLX, 6242723 DAIHAT-J PARTS SALES DEPT. - TEL. (06) 6945-5925 AFTER SALES SERVICE DEPT.-------TEL, (06) 6945-5325, CONTENTS KR Instruction PREBRA Parts list BR) OOMD.O. Engine ADA aR He 6 BL MAE a FR Cs (150089) Hie 1. Sp W720, 750m a ia (900rpm 1 1000%om 2. Draction of revolutpn eae Ae jtandard (R) ee CiReverse (L) ae 8. Front P10. With 2979 wee a whi pvitnout = 4. Cam shat SfS0tid ah me CBult-up an 8. Turpgoharger type eeeEs Cvtrie1 OVvtR214 CvTR201 CRHI83 Ribs 6. Arrangomet turbooysroer ee "Front side wat CiReer side Rs 7. Governor type CIYG10 wmaRER A086 8. F.0, nection pump serREAD 7 Cl Prager da 20 4B 20 ‘hanger dia 21 sh 2 1 wy fuel Engine (180 cSt/50°C) avy fuel Eneine (380~700 cSt/50°C) (6 MRF FB HN C Le (3500~ 700089) MW 10. 12. NOTE ; Items marked (M are applied for your diesel engines. = (OR Vinee mmm sn TUSRa TT. F.0. nozzle ed Hole ois 0.26 RE 020 Hole dia 028 Rie 028 ioe dia 030 RE 0.30 DiHole aia 032 RE 032 Capacity of 1.0. cooler MAREE er Oem Ore Inter cooler type .0K30 DHEP-3O SREB okas D0KasHe p07 Sos Singer da_170 (00%) 1785 170 (00K) Ciinper ia, 180 (0K) 4754 180 (BOK) OW. pump Ra 7 Operating & Maintenance Manual ta os AMER SOMA oC WC fee nid tea TI SE Ht Sean bate ls Sah Reh Cent TiQyeNe cA THEI, eM HEEL, wOe TOME T 8 aM HER Lhe Sibel ar SMS BORER Eas hm L TR St MIE hae eet 3 Se MARSA RRR HA, themes ant WML THOMSAH USS SIC PoTUnece suai He aE SAME aT aBape, = ALS Bia ok MSS BMS +—EAw FANIFs — EA AW PRARS ANITA ULE mBAo-oN5 Ce see RR AAS Forward Trea insicuation book emake with tne fundamental knowledge raquinad {or operation and handling It 3, ardently mquested to follow the working as well Bs maint so that yu may -e6joy) the utmowt durability and Aaliatatary operation of our Dissel Engine tur many years to, cum For renewal ones, otherwise wo Carnot quarantt thh par quaity, Yeren orgring son paris of the Diesel Engina, please soccity the Tod fw NO af Enews, loypther with pames bh netales and teir retyrenc ps cosaticd in this: book, Whe you give for furtner informa us, your onlar er conisal. plea: Orders; PARTS SALES DEPT. Information; AFTER SALES SERVICE DEPT. DAIHATSU DIESEL MFG. CO.,LTD. & tLe bpaeres ie Te woe Gest TEL “PARTS SOLES OF + ACTER SALES 461 STANDARD MANUAL CONTENTS TYPE SECTION 0 DK-20 | sheer l 1 BEFORE RUNNING DAIIATSU DIESEL ENGINE +++ GENERAL Notation of Types Bingine Cross-section of Engine Engine Specifications, ENGINE ADJUSTMENT STANDARDS 1. Assembly Adjustment Table 2. Operating Specifications A Capacities of Lubricating Oil and Cooling Water 4, Tightening Torque Table 5. Cle 6. Weights af main parts - NERAL CONSTRUCTION tance and Wear Limit G 1. Engine Consteuction + 2 Starts 3. Fuel Oil System and Related Pacts: 4, Lubricating Oil System and Related s. 6 ce 1 icumativ System and Rekuted Parts os Cooling Water System and Related Parts, Nozzle Coli DPERATION AND DAILY MAINTENACE Daily Operation System and Related Parts (1) Preparation for star (2) Starting (daily operation) (3) Initial starting after installation and starting after ng: (daily operation) extended disuse or overhaul (4) Operation (5) Runni 2. Daily Maintenance and Inspection (1) Measurement of engine performance QM (3) Adi 1) Hixhaust temperature iment 2) Cylinder maximum explosion pressure 3) Fuel pump rack amount 4) Intake air temperat 5) Intake air pressure 6) Lubricating oil press surement of Lubricating oil consumption level she. : 5 5 SHER DAIHATSU. SECTION | TYPE 0 ser DK-20 STANDARD MANUAL CONTENTS, 2 7) Lubricating oil temperature v+e+466+ 59 8) Cooking water temperature 5 9) Reoker arm lubricating oi 5-10 10) Nozzle cooling (when heavy fuel oil is used) soul 11) Fuel oil pressure: sou (4) Maintenance sreteeseeeteees sou 1) Fitter washing feet ee eet s-1l 2) Daily maintenance procedure of filters 5-11.12 3) Drain-np of intake pipe S12 4) Washing of turbocharger 5.1 5) Protectors Stee (5) Inspection 5 12 3. Stoppage Cone eeay aoe 513 (J) Preparation for stoppage : 5-13 (2) Stoppage operation ceeeeeees 513 (3) When engine must be stopped immediately - so1B (4) Actions to be tiken after emergency stop + S18 (6) For long-term shutdown + sou 4, Allowable Operating Range s-1s (2) In the case of LPP (fixed pitch propeller) S15 (2) In the case of CPP (changeable pitch propeller) 5-15 5. Speciat Operation Freres 5 16 (1) Low-load operation s+++esssreees 5 16 (2) Non-tusbocharger operation 5-16 (3) Operation with intercooler cut off from main line 5-16 (4) Operation with reduced number of cylinders - 517 (5) Mallunction of lubricating, oil temperature control valve 5.17 (6) Break of lubricating oi cooler ++++e48e eee rsrees v 6. MAINTENANCE SCHEDULE (1) General precaution 64 (2) Periodic inspection frequency table (when diesel fuel oil used) + 6 m4 (3) Periodic inspection frequeney table (when heavy fuel oil is used) 6 5-7 (4) Manual lubrication intervals: +++ 55-0 6-8 DAIHATSU. STANDARD MANUAL CONTENTS TYPE) SECTION 0 DK-20 | SHEET [eeeeal 3 MAINTENACI Disassembly, Assembly and Adjustment of Main Parts Cylinder Head and Related Parts (1) Cylinder head (2) High pressure fuel pipe (3) Buet nazzie (4) Nozzle holder guide (5) Fitting extiaust valve (6) Witting intake valve (7) Valve guide removing and fitting procedure (8) Valve seat removing and fitting procedure (9) Valve rotator (10) Adjustment of valve end clearance (11) Startio Piston, Connecting Rod and Related Parts (1) Piston overhaul (2) Piston (3) Piston ring and oil (4) Connecting rod (5) Crankpin bearing, metal (6) Connecting, rod bolt Engine Frame, Cylinder Lit (1) Engine frame (2) Cylinder liner Main Bearing, Crankshaft and Related Parts (1) Main bearing (2) Main bearing metal (3) Thrust bearing metal (4) Crankshaft (5) Measurement of crankshaft defection Timing Gear, Camshatt and Related Parts (1) Timing gear (i (2) Camshatt 8) Cam (4) Adjustment of fuel cam sembly of idle gear) «+ neral Precautions for Disassembly, Assembly and Adjustment rund Related Parts» 7 9,10 7 au 7 Ou 7 118 7 1243 744 7-14 7015 7 16 7 1218 7 19-20 7 19 7 19,20 7 21-26 7 2 7 24 yo08 7 25,26 7 6 7 26-30 7% 7 7-29 7 29,30 DAIHATSU SECTION | TYPE SHEET DK-20 STANDARD MANUAL CONTENTS 4 6 Fuel Injection Pump and Vappet 7 30 (1) Buel injection pumps+++++2ee sees ccee 7-30 (2) Installation and adjustment of fuel injection pump: + - : v7 30 (3) Intake and exhaust tappets 7 30 7, Governar, Governor Driving Gear and Fuel Control Device recal (1) Governor 731 (2) Governor driving gear 731 (3) Fuel control device 731 8. Pump Driving Gear Cushion «+++5+e2+2ec0ee+ 7-32 9. ‘Turbocharger, Intercouler and Related Parts 7 32033 (Turbocharger rece (2) Intercooler 7. 32 (3) Exhaust pipe + 7-33 10. Gauges 7-33 11. Air Starting System and Related Partss +++ 7 34-35 (1) Starting, conirol valve and starting air valve + 7 44 (2) Starting rotary valve 7 34,35 (3) Starting air receiver : 7-38 12, Buel Oil System Related Parts «++ +++ 7 35-36 (1) Fuel oi! pump 7-35 (2) Fuel oil fitter 7 36 (3) Fuel oil pressure regulating valve + 7 36 13. Lubricating Oil System Related Parts 7 36-37 (1) Lubricating ot 7-36 (2) Lubricating oil cooler certettee eens 7-37 (3) Lubricating oil pressure regulating valve 7:37 (4) Lubricating oil fitter + : 73 14, Cooling Water System Related Parts, : 7 38-39 (1) Cooling water pump 7. 38,39 15, Protective Zine : 7-40 Cae Eel tera rere rue eevee rte tera rere errr TYPE] SECTION | 0 STANDARD MANUAL CONTENTS ' K-20 | sneer 5 USABLE LIMIT OF HEAVY FUEL OIL AND ENGINE OPERATION CONTROL 1 neral Preeautions 81 2. Usable Limit of Heavy Fuel Oit sol 3. Kngine Operation Control si (1) Operation with diesel fuel oil w12 (2) Temperature control 8 2 (3) Changeover between diese! and heavy fuel oils 8-2 (4) Precautions in changeover between diese! fuel oil and heavy fuel oil 83 (5) Countermeasures for emergency stop during op using heavy fuel ail» sa (6) 1.0. (Heavy fuel oil) starting & stop: ~ 8 3 4. Starting, Operation & Suspension of Heavy Fuel Oil Engine 84,5 9, PULL, LUBRICATING OIL, NOZZLE COOLING, COOLING WATER 1, Fuel Characteristies and Control 94,2 Recommended Lubricating Oil and Its Control - + 9-34 3. Nozzle Cooling --- 9-4 4. Cooling Water Control and Rust Inbibitor 9- 5,6 (Appendix) Recommended Lubricating Oi Brand List 97 (Appendix) Fuel Viscosity Temperature Graph 98 (Appendix) Blended Oil Viscosity Expectancy Graph: 99 10, USE OF VARIOUS EQUIPMENT AND APPARATUS 210-17 Blow-off and Overhauling Procedure for Nolch-wire Filter 0-1 Water Cleaning of Vurboehst sw 2 (J) urhocharger blower side cleaning procedure 2 (2) urbocharger turbine side cleaning procedure 034 Non Turbocharged Operation 10-5 Overhauling Procedure for Fucl Injection Pump 10 6,7 Measurement of Crankshaft Deflection : 10 8,9 Use and Mainicnance of Hydrantie kick 0 10.11 DAIHATSU SECTION Ea SHEET 6 TYPE] DK-20 STANDARD MANUAL CONTENTS 1. TROU DK-20 |Z [94-3] JBLESHOOTING AND COU (When Stacting ts Difficult (When Kngine Stops Suddenly ++ Insufficient Ouiput (4)When Abnormal Sound fs Audible during Operation (S)Surging settee (6)When Exhaust Gas Shows Abnormal Color: +++ (DWhen Engine Revolution Is Not Smootiy +++ +++ (8)When Fuel Consumption Is Excessive «+++ ++ ‘TERMEASURES (When Lubricating Oil Consumption Is Excessive (10)When Engine Is Overheated (1)When Oil Pressure Gauge Shows Abnormal Indication (12)When Exhaust Gas Temperature or Explosion Pressure Is Abnormal (13)Fucl Rack Pulls in Excessively «+1601 0 60sec eee (14)When Cylinder Safety Valve Gets Opened +++ DAIHATSU TYPE | SECTION BEFORE RUNNING DAIHATSU DIESELENGINE | p4.99 ~ sitet area 1, This manual describes impon ines. Read thiy manual ly over andover ay Operation not conforming to the rules specified herein will cause will possibly cause a large effect on performance and life of engines or lead a serious accident. ems marked w tion, Be fully careful in particular. Deseriptions h ines of standard specifications. Users are thus requested to understand that the contents of this Manual may differ from thoxe ofthe engines to be actually operated by them. 2. ‘The contents of this manual shall not he related with the guarantee agreement, 3. Copying and disclosure of the contents of this manual to a third party shall be prohibited. 4. Engine sped ssembly drawings shall have priority over this manual. In the ease of ef necessitated after ie Service Departm For operation of the following units, see separate manuals, Turbocharger ih ali¢ governor Air motor . Air motor stating engine tore auto control wigan prowective units cating oil, eooling, water, ete) 1.0 thermostatic valves (for Reduction gears and operating units ++" oe Marine propulsion engine Genero . eens se Generator engine Heavy fuel ol system related ae ++ When heavy fuel oil is uso Other units as per special specification es [onc ob man DK-20 |B 96--7| DAIHATSU) SECTION | TYPE 2 SHEET | DK-20 Sia GENERAL Notation of Types Engine Notation of Types Engine 6615) (8) DK (M) - 20 (L)(F) 6 (58)... Number of eylinders 20......Cylinder bore (em) DK ......Name of series L ......Reverse rotation specifications M Marine propulsion engine F ......Front end power fakeoff specifications Exhaust side Right side Y HO PRGHIS Ha SHH OPH 7 a Opensonsie A canst Aa Fiywheel side conse mf Engine as viewed feom flywheel side ‘Note Carefully that the cylinder number is different from those of conventional engin DAIHATSU ‘SECTION GENERAL | unite Lae Cross-section of Engine DK-20 | at DK-20 | Aj96-7| SECTION | TYPE 2 GENERAL Steet DK-20 Engine Specifications a “Mosel "SDK = 20 “oK-20 | sOK- | ‘Type. Vertical, water-cooled, direct-injection type, four-cycle diesel engine Number of ylinders ae 6 8 Cylinderbore | mm ~ : ‘Stoke om | "300 Engine speed smin= kW(PS} Output Rotating direction ‘normal ditection: Clockwise Exhaust gas turbine turbocharger ( PS} ‘Normal or reverse rotation direction as viewed from flywheet side) anecnse DPS turbocharging bes turbocharging system or DPS turbocharging system Pulse tubeorgig system sem Starting method Air motor Direct starting with compressed air Sogn [iss sn 4n2 Firing order He - 9-2-5-8-6-1-4 — - 1=2-4-6-5~3 3K Engine speed and output vary according to specifications. ‘operation test result Please fill them in while referring to the factory _B/ 96-7 DK-20 __ENGINE ADJUSTMENT STANDARDS | Assembly Adjustment Table Adiustment value (design value} i é w ae a = Open (elore T D.C 8b, sD 0" Intake valve | Close (alter BDC) 6 Clearance (A) o3imm open lehine B.C) ss° Est | Gg aer INC % Cearance (A) | o3tmm Opentbsiae EL) ® Rete | Ine rinse cong Clase fatier LD.) haw 24MPa Buel nozzle injection pressure nua {300% Hen") : Vill she value in whe reerring 10 he Ms factory operation fest sta the vale ( kgtien ties wilh anda eninespeciticions snd opt Masi firing pressure ime | {i9stgtim’y | Pressure of eylinder safety valve j filth sal in while referring to the Fuel injection punip timing (before T.D.C), i sara je spins ! aid uth DK-20 |B | 96-7 SECTION] TPE 3 SHEET | DK-20 2 ENGINE ADJUSTMENT STANDARDS Operating Specifications ‘Alarm setting ee tem Design value | (Emergency slop Remarks é ee seting) Intake air ‘According to turbo ce charger specications in case of direct start 15+ 5 ie ag, | reetanetser Ai ank p———— ae i 10-29 10 In case of air motor Staring ai {10-30} {10} staring, P oe 05-09 044 In case of air motor Pres | Reducing valve ies a a feat/ea? | Eyet oit ” 05-06, a Note 3) See the speci _ | 180-60) ae cation cas, 04-05 03130) Pebaeaina oil i {40-50} 0.35(25)) i i Gee 025-0.34 Tank head and Cool 25-35) ___| externa piping e conditions should be a ____| considered 01-03 {110-310} BaCaeE Intake air (engine inlet) 45-55 T cylinder out xt |Cvlinder outlet 480 898 Turbocharger inlet specifications I mea fo al 185150 : Fuel oil (engine inet) (Bo sec RW Wises for heavy Temper. (CO sec RW. uel a ature -— ee. Tub“ spine ve Lento | Eminent a ae Ta case of output (ogee | Engine inlet » control system Cooting) Westy | Engine water | “9 | outlet = 85 (90) a | [Cem encine inet | a2 Design value Nozzle coolant (main pipe ink) 50-00 Dies depending Notes) 1) Lower limit values are used for pressure settings; uppeslimit values are used for temperature settings for alarm and emergency stop. 2) Installation of pressure gauge, thermometer, alarm and emengency stopping devices differs depending on specifications. 3) Diesel fuel oil: 0.2 ~0.3 MPa (2.0-3.0 keffem’) 4) The design values shown in the above table are those when the engine is operated atthe rated speed. DK-20_[E| 98 a DAIHATSU TYPE | SECTION ENGINE ADJUSTMENT STANDARDS —__ Capacities of Lubricating Oil and Cooling Water DK-20 a Unit: & em Cait Remarks Engine la + tnclading piping 14 (Sn) Lubricating. oil cooler 212m) 28 (1om') i Lubeicatng ot | “Turbocharger LS«VTRIBN) | | : i 1 a4R1un) saver: fae a0 GDE) ers depending on 1 Common bed 1100 (6k) eee cea : _{ !s00 (8D) we 70 (SDK) bey SSGODK} Incding ping HgSDR) 9 (80°) saing vner | Uricting il cooker Ham) Cooling water U2 | 10(DK2s, DH31) 15(DK30, DH29, DEI, DHI8) [25 (Kaa, DIS2, DIT3) Lao (bbs?, Digs} Inierevoler Notes) D Capacity in this table may differ according to specifications. @ When replacing lubricating oil, be sure to discharge oldubricating ol inthe fer, lubricating el cooler. ete Roplensh oil upto the position marked “UL onthe level gauze. Check the oil level with the level gauge again or operation for S=6 minutes. The ol level is proper fis within the range Between “UL and “LL on the level gage DK-20 | A|96--7] ENGINE ADJUSTMENT STANDARDS | DK-20 Tightening Torque Table a [Width acros] Tightening rome cal Names of bolts and nas sie | flats Remarks ee (om) ace 7 Hydric 1 |Cotinger head ightening nwt | M139 3.0 z eee tightening i! ee 2 | Cylinder bead stud bolt M9 x30 | * 3 | Man bearing ghtening aut — | M139 30 | Hydraulic | Oil presure78¥ipa 4 | Main beating sud bot M39x 3.0 tightening {800Kgfm)) 245-294 | zea (25-30) a 5 | site nor 9 x30 Oi an hie | Ts ie eed yk 6 | Ftywhet mounting bolt M0 x 20 ee te 7 weox20| 30 seo etc te ‘196Nem{20kef-m}+40° we 8 | Crankpin bolt M22x20} 27 (8 torque 392Nem {40kgt-m) S8Nem0kgF}s20" | (torque :255N-m {254g¢-m) | 9 | Connecting rod bolt maox20| 27 10] ide garstetmoming a | sn0x30[ a1 (eg SAMBO" * 11 dle earshot moaning tt | MMtox 20 | Holes 14 cs * rafhategeartigteningtok | Miax20| 24 ie 13]cam germane sgn ng | MIO | Hole8 - a valcoiongarieneningnsr | Man x20| 6s a | is|igainrame veo ane | ane | testa t 16 |Foetnozaemooningcapnt | — | 27 a * Hrfpometowerincanste anoxis| i | aes 1 FOR oN ana] ar ot, Perce reer ie | = 20]Swingam nomingbor | 6x20] 24 7 21 [sting vane cap owning tt] M12 175] 17 2 22]indctorsahe noun Ma L758 3 25[Nentetokernomingnn [irxizs| | DK-20 | A|95—4) DAIHATSU ‘SECTION ___ ENGINE ADJUSTMENT STANDARDS __ ane Tightening Torque Table DK-20 a Rah ates Namvsoftatsandaus | Size] ox Remarks Beat a saeneagueaict muoxis| 7 Macias) wy 24 | General bolts and nuts | M4» 20 2D wine2s) 2 : i Notes) 1) Miia ols aad ur asarked with * should he tightened according tothe following speetf ications CCrankpia bolt and connecting, rod bolt tion 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 boits and nuts must be tightened in a diagonally aliernti 3) Be sure to check for boose cylinder heal tightening nuts and connecting rod bolts afte efor i Section 6 fort inspection frequency 4) Anti-seirune agent shoukt be applied belize Lighteniag to bolt seats anid theals ised for the parts aromcad dhe esbaust pipe, which are to be subjecteal wo hugh temperature 5) Retighten holis used for insealstion during stop of the e rotightening, 6) Torque wrenches used for tightening shall be inspected peisodically 7) Anti-seiruee agent (MOIYKOTE 1000 spray type) should be applied before tight tightening bolis and! nuts marked with sf 8) When use of a hytiraulie jack ts Maintenance” in Sectvon 10. n period of operation ne. He sure 16 check the crankshaft direction alter ing (0 the Seats and theeals of inled, refer (0 the sheets 10-11 “Hydraulic Jack Operating Method and DK-20 | A]95-4] ENGINE ADJUSTMENT STANDARDS Clearance and Wear Limit Schematic drawing Nominal sie Clearance Remarks a — +10 | as ‘—o—4n, |D=200 Partial wear| Replace liner g 03 ‘A=200 | az0.66-0.76 B=200 |b-0.12-0.21 | Replace piston c-20 feso10-019 | 0 | jest [25 [Replace rn 90-110 Clearance with 75-095 | 2 i new liner. Ass 2013-017 | 03 1 Replace ring, Use oversized Bes 20.09-0.13 | 03 |ring, if wear on piston groove s i excessive C5 c=0075-0115| 03 A=1.05-1.25 | 32 | Replace ring ___|Measure | clearance with D=7 4=0.04-008 | 03 |newliner: _ Replace the 2004-008 | 01S | mare worn one. |A=90 —— ATN b=0.09-0.16 | 03 — [Replace metal Asi70— |ac0.10-019 | 03 | Replace metal Use undersized f- metal, if wear on B20 |b=0.11-021 | 03 | 92 d=0.13-0.30 | 06 * |Be280— |e=0.55-0.75 3# Replace chromium: plated ring when its original surface appears due to wear TYPE ‘SECTION ENGINE ADJUSTMENT STANDARDS 3 Clearance and Wear Limit DK-20 | sheer Pon coninal sind Clea . | oe [ao fasootot2 | 02 — | Replace meta ‘Camshaft “ =} A sey a Casts : place thes ie Lay on 045 | hearing Lappe and taped bo Sones oe tan Po fasmos-oors | 02 sat b-007-013 , pers appt rte | ap [Replace beating ance | gnats bearing bo 5 thin) ee HO | Thcnotssoox2 Inuakeevhast tocker an shalt pe facnosora | 02s as Vs aan ase at totake valve | cam (Stes par and asia fasoovo.13 | 03 | Recker, if won pont F shai valve ne cia [Replace bear {at ig wenovats | aa | Renee if ! 1 tna valve : a (face part) I Intake and | j bss ! alves, [Take vale sea = |p2 os i i Replace Feshaus valve j | ‘(race pan} Le jeeaste a Bhs son | ' wegearsrst | AY | Lacgs— |acousors | 025 |renacrgar ining PD | seat a ~ Hackl os ores | pga Ape somos | os peas cs Cooling 1 Mou sing and | t water inpeller 8 FT A=105 05-056 | 1.0 [Replace hearing rm" SES : DK-20 [Z][94~3 DAIHATSU ENGINE ADJUSTMENT STANDARDS: SECTION | TYPE 3 st | DK-20 | Mass of Main Parts Mass of Main Parts Unit: ke | DK = 20 Remarks Cylinder head, complete 129 ace Piston and connecting rd . complete 0 ace Cylinder liner a | sox aeeeeee| Camshaft, complete | 6DK 160 __| One-piece consruction spk 210 33 Including gear of max. dia Cooling water pumy 39 Including gear of max. dia VIRI6I 204 RHI33 37 Rinas 4s ‘Turbocharger ~ RING 11s t RUI83 214 RH203 214 | px25, DHS 150 bK30, DHS | , fe DH39, DH48 en ergo 1 7 D4, DHS? DH ee [ pps7, DH9s 300 DK-20 [B[96-7] — DAIHATSU ) TYPE, SECTION | DK-20 | “sHEET | DAIHATSU SECTION 4 Te GENERAL CONSTRUCTION __ ‘SHEET | DK-20 Engine Construction Hae 1. Engine Frame Frame is of tough cast iron of integral understung ‘etal construction, ‘The main bearing cap is fixed to the frame with two mounting bolts and side bolt 0 be tightened hydraulically. The timing gear case, imtake pipe, lubricating oi! main tube and cooling ‘water main tube are integral with the frame 2. Crankshaft Crankshaft of high-strength forged stel is de- signed (0 drive the camshaft with the cear end and pumps with the frontend 3. Connecting Rod ‘Connecting rod is made of solid forged ste). The largeend is split horizontally into three 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 Im the case of heavy fuel oil specifications, top and second ring grooves ace Induction-hardened t0 improve wear resistance 5. Cylinder Head Cylinder head is made of special east iron and fixed with four bolts. To cope with mechanical sess due to high combustion pressure and thermal siress due to combustion temperature, the combs tion wall thickness is increased, To enhance the cooling effect, the hore 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 facili- tated adoption of a high-pressure injection pump of high rigidity, 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 1s bushing made of lead bronze. DK-20 | A/95—10} DAIHATSU SECTION (GENERAL CONSTRUCTION ee 4 Starting Pneumatic System and Related Parts (Direct Starting Type) DK-20 | SHEET 9.1 Starting Pneumatic System and Related Parts (Direct Starting Type) is mea by a pilot pressed air. When the air reccive opened and push button ofthe starting control va valve is deiven fram the front of the camshaft is pressed, the starting valve is opened by low- In order to protect the system against back flow of jure operating air, and compressed air is combustion gas, a check valve and a safety plug is Gisinhuted ¢o cylinders in explosion stroke acon provided atthe inlet of the starting air main pipe ig to the igaition sequence, to Sam the engine Tn the case of avio/remore starting engine. refer to separate instructions. peraing aie f Starting operation valve Starting ir main pipe safety pag sang ar a The starting valve and the starting air valve ate Jocated at the front of the engine, the staring rotary Starting rotary wave Check valve Starting Pneumatic System Diagram (Direct Starting Type) SECTION | TYPE 4 SHEET | DK-20 2-2 GENERAL CONSTRUCTION __ Starting Pneumatic System and Related Parts (Air Motor Starting) 9.2 Starting Pneumatic System and Related Parts (Air Motor Starting Type) ‘The engine is started with an air motor which uses compressed air as the mechanical power soures When you press the start operating valve after ‘opening the air receiver tank stop valve, the pilot ait reduced in pressure by the reducing valve pushes cout the air motor pinion, When the pinion is engaged with the wheel gear fixed to the flywheel, te pilot air is transmitted from the air motor to the relay valve fo open the main pncumatic circuit ofthe relay valve to thereby drive and start the engine with rain air. Starting operation c25 valve Relay valve Safety valve For automatic starting and remote ~ sianing ‘engine, refer to the separate inanuals. ‘The reducing valve is located near the air receiver tank. The relay valve is installed on the side of sole plate located near the air motor. ‘The start operating valve is mounted on the engine front. To protect the air motor from a trouble caused by a fault with the reducing valve, a safety valve is installed atthe outlet ofthe reducing valve. Reducing valve Air roceiver tank Starting Pneumatic System and Related Parts (Air Motor Starting Type) DK-20 | Z|96~7 GENERAL CONSTRUCTION Fuel Oil System and Related Parts TYPE | SECTION 4 DK-20 "SHEET | 3 10. Fuel Oil system and Related Parts Specilicatinns of fue oil system differ accondin to the grade of the panicular fuel oil used Shown below is typical fuel oil system setup. Fuel oil pressure-fed 10 the fuel injection pump goes through the fuel high pressure pining block and ts injected tnvo eylinders through the fuel novzle at high pressure Suiphis oil psssed dhrouphh the wel injection pumps teturnedt from via the pressure regulating valve tothe intake side of the uel oil feed par. Ai separator Vhe final fuel filter is tached co the engine. ‘The fucl injection pumps ate 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 oi! spect Cations, the nozzle is designed fo be of construction tw be cooled down, Novi leak i main pine pace pressure pipe leaked figh-pressue pining block Tih pressure Pipe Puci nozzie [ eee il feed pomp Fier Pressuee regulating val Fuel Oil System Fuel inlet main Pipe ——— uc outlet main pipe [= Leaked oll tank Diagram DK-20 | Aj94—3| DAIHATSU SECTION | TYPE | 4 SHEET | DK-20 4 ___ GENERAL CONSTRUCTION Lubricating Oil System and Related Parts 11, Lubricating Oil System and Related Parts Lubricating oil pressure-fed hy the lubricating oi 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. Pact of the lubricating oil system is branched off for tappet, camshaft and cylinder head lubrication lines, and lubricating wi having lubricated respec- tive portions and been cooled down is returned to the sole plate. Lubrication around the rocker arm is shut off by the pressure regulating valve at the time of start of the engine until the stationary pressure is reached, 0 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 oii 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, uel injection pump Lubricating oil cooler ‘Swing arm Pres vale ter [Goong water pan ile ex] Temperature control valve Turbocharger Safety valve 6 ‘amp Leaked all ank Lubricating Ol System Diagram [_bk-20 [8] 96-7 ECTIOL ____ GENERAL CONSTRUCTION ee Cooking Water System and Related Parts | DK-20 ae 12. Cooling Water System and Related Parts The cooling warer system is divided into two lines; the jacket line and the cooler line, The standard cooling medium used for the jacket line 1s fresh water and that for the cooler line is sea water emperatane contol valve {In both diesel fuel oil and heavy fuel oil specifi- ‘cations, the water-cooled type extiaust valve seat is adopied. Facke ine outlet main pipe Fresh water cooler Jacket line fresh wwater pump (Cooler Hine 009) ing water pump Cooling Water System Diagram DK-20 96-7 DAIHATSU ‘SECTION | TYPE | DK-20 13. Nozzle Cooling Water System and Related Parts, (For engine operated on heavy fuel oll) When the engine is run on heavy fuel oil, the nozzle end has to be cooled down to prevent generation of carbon flower in the FO. nozzle. For prevention of super-cooling of RO. nozale ___GENERAL CONSTRUCTION __ Nozzle Cooling Water System and Related Paris (For engine operated on heavy fuel oil) In the case of engine of independent oil feeding system running on diesel fuel oil, a gear type pump is installed on the engine front cooling water (oil) is controlled to optimum temper- ature at all times. Standard cooling is made by fresh water branched from the jacket system, Orifice Valve \ tit Outlet main pipe Orifice Valve \ - i Inlet main pipe f uel nozzle vu Jacket cooling Jacket type heah water pump Nozzle Cooling System Diagram (Fresh water cooling) Pressure regulating valve Outlet main pine ra nal valve Inet main pipe Pump La Fuel nozzle Nozzle Cooling System Diagram (Diesel fuel oll cooling) DK-20 [Bjos-6] DAIHATSU TYPE, SECTION DK-20 | SHEET DAIHATSU SECTION TYPE | 5 SHEET | DK-20 | 4 L OPERATION AND DAILY MAINTENANCE Preparation for starting (daily operation) 1. Daily Operation Required preparation for starting of engine {depends on the condition of disuse of the engine + Daily operation (short-time siop) + Init starting after installation + Siarting afer extended disuse + Siarting after overhaul Preparation and iaspection shall he made in conformance with respective cases deseribes above. AN Never touch the folowing areas doring run. It ‘may cause bum or injury 10 you ‘+ Exhaust pipe cover top + Turbocharger inlet and outlet exhaust pipes + lake air cooler inlet duct + Safety valve end indicator + Rotating areas such as eraksh, et (1) Preparation for starting (daily operation) 1) Inspection of tanks @abricating oi level in oil pan (along. with reduction gear in the case of maine propulsion engine) uel service tank oil level ‘ooling water tank water leve ) Turbocharger oil level (WK) ®Governor oil level Staring aie tank pressure 2.5-2.9 MPa){25 ~30 kylie’) arting aic reducing valve outlet (ait motor starting) (0.5 -0.9MPa) (5-9 keller? | @ Correct level of lubricating oil in oll pan HDS use Correct level of oll in governor 2)Im the case of heavy fuel oil specifi- cations, allow the fuel heater to start. 3) Discharge drain (this may be omitted, if ‘considered proper.) @Foel service tank @Starting air tank Dinake pipe 4) Put all valves in run state. 5) Put the clutch in neutral position (in the case of marine propulsion engine). DK-20 |Bl96-7| DAIHATSU OPERATION AND DAILY MAINTENANCE Preparation for starting (daily operation), Starting (daily operation) 6) Lubricating oil priming Fully open the pressure indicator valve. Then allow: turning annd- paring far about $ minutes Check that no fuel oil, water or lubricating oil leaks from the pressure indicator valve as a result of turning, When priming with a hand pump és intended ‘open the pumportlet valve, cand allow pit lescrihed above at the oi pressure of about 0 MPa fabout LC kylie’). Close the valve completely afier em of priming, nism operates smoothly. 8) If motor pumps are installed, start them 9)'Turn ON the protective device and ‘warning device power switches. AX 10) Ascertain that the engine rotary se tion is free from any obstacte. 11) Air running (this may he omitted, if it is judged proper.) Conidact ar runonng.widh the como lever in the STOP pasition valve fully opeaed. Close te pressure indicator valve completely after end of air runni In cose of ditvet starting engine: To keep the sir receivertank open a about 1/3 tar is desiable in consideration of stantabilty and ai consunyy the air meeiver tank, ] TYPE SECTION 5 | DK-20 | SHEET se 2) Starting (daily operation) 1) Precautionary instructions for starting Be sure to make it rate to check the following points before starting + The control [ever is ser at STOP and the saick amount is redoced to 7 + Rotary section is mot abstracted by a tuening tod oF other. ‘The turning gear Shall be disengaged + ‘The fuel systom i changed over to that for | diesel fuel oil (in the case of dieset fuel oi starting specifications) + For initial staring or starting after a tong Tnterruption. he sure to start the eny jeenuaty 2)Put the control lever in the RUN position. In the case of manual engine starting specifi cations, put the contra! lever in an intermediate position beuween STOP and RUN, an adjust the: Condition of rick engagement at stam DK-20 |B /96—7| papa OPERATION AND DAILY MAINTENANCE. SHEET | DK-20 Starting (daily operation), Initial starting after installation fe 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. ely after starting Dlabricating oil pressure anc cooling, water essure (see Section 3, Shect 2.) @Check temperatures of exhaust gas from all cylinders to make sure of combustion in all eylinders @ Vibration and soon Pilot lamps in the protective circuit If lubricating oil pressure or cooling water pressure does not rise sufficiently, stop the engine, focate 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. 6) Close the tank valve. ‘method specified in Section (8) Initial starting after installation and starting after extended disuse or ‘overhaul ‘Add following works to the daily operation Sheet 1) Preparation for starting Check if no foreign matter sueh as a tool i kel over in the crank chamber or the lubricating oil suction port is not clogged with clean rag, or others. ® Feed fresh water ino the expansion tank @Make sure of freedom from loosening in any portion @Check if the fuel pump rack and fink mecha- nism operate smootily. Check further if the rack graduation indicates “0” when the control lever is put in the STOP position. Oil the link ‘mechanism manually ‘©Check the fuel fine 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 fier. @Filier disassembly washing AAs to fuel oi! and lubricating of filters, be sure to dissemble and wash them before operation 0 as to remove dusts and other foreign matter deposited on them during transponation or ‘outfitting For the disassembly washing procedure, see Section 10, Sheet | Lubricating oi primin Conduct priming for about § minutes while tuming the engine, and check the main bear ing, piston pin, crankpin and cam bearing. for oil drop. if strong resistance is felt during turning of the engine, remove the possible case before start of operation Bleed air from the lubricating ol ier DK-20 | A|96--7] DAIHATSU TYPE] SECTION OPERATION AND DAILY MAINTENANCE 5 ‘Initial starting after installation and starting after extended DK-20 | SHEET 4 disuse or overhaul, Run Inthe panicular case of starting atte extended disuse, be Fully careful so that the lubricating oi maybe spread 10 the line and the piston sufficiently. IP the line surface 1s not wet, drop about $0 ce of lubricating oil fron the p valve In audition, apply lubricating the finer ly fron te lines underside with a sprayer or the Tike Afier omaking sure of sufficient application of lubricating oil 10 the whole liner surface, conduct air Funning. in slate with the pres sure indiealor valve open. In this case, sure ixdicatey lubyicaring. oil seater from tlhe pressure indicator valve Therefore, prevent it with waste cloth ar the Tike. @WFuel oil primin 1. Make sure that she governor control lever is in the STOP position 2.0p ind air bleeding, the fel filler air went cock e purge pen the inivetion purnp air vent plug to purge a 4. Fully open the pressure indicator valve, push in the fel rack on i air from the nozzle by ning state to purge “6, ‘Air bleeding from fuel and lubricating oll fitters ‘TH Air bleeding from fuel injection pump 5. Stat the heavy fuel wil sy 6, Stan te mojor riven oil Feed pump. pply line heater 7. {pon end of air bleeding, select dese fuel oi 8.Sinp the motoralriven oil feed pump. when replacement of the fue! in the piping, with diese] fuel oil is ascertained. 8 : poe Lngine fuel inex main pipe HO Example of piping per heavy fuel oll specifications. OPERATION AND DAILY MAINTENANCE Initial starting after installation and starting after extended disuse or overhaul, Run 3) Inspection after starting @ Listen carefolly for abnormal sound from the engine. IP abgormal sound is heart, stop the engine immediatly @Stop the engine after operating for $ minutes at idling speed, and check the main bearing, crankpin bearing, piston lines, ete. for abnor smal overheating @heck the lubricating oil level and cooling water level again, and make replenishment, if necessary @If vo abnormality is foun, start the engine again fo chock for leakage feo all connec ind the amount of fucl leakage from the @Touch the sang ae pipe to check for blowby in the staing rotary vaive. (Direct stating engine) @ Purge air from all puns and coolers (@) Run 1) Warming-up @Warm up’at the sated engine speed (ling speed for marine propulsion engine) for about 10 minutes under no Fx @Warm up with diesel fue ol. @set the governor speed adjusting handle to the ile speed position @Press the stating operation buston to star the ‘engine Speed adjusting handle 2) How to increase load and engine speed Dum the govemor speed adjusting bande to inorease the speed. gradually. Apply. load gradually afterall portions of the engine ave Stabilized, Especially, when the engine is stated in cold stave, apply load, taking further Jonge time @n the cave of the marine propulsion engine, the load increases sit an increase in th engine speed. ‘Therefore, be sure to increase the engine speed gradually @If there 8 a cisical_aumber of revolution within the normal speed range, avoid it quickly 3) Check of operating condition during load increase Lubricating oil pres @Cooling water pressure a @uel purmp rack amount @Cylinder outlet exaust temperature ®lntake air pressure and temperature id temperature 4) Changeover to heavy fuel ofl See Section 8, She 2 OPERATION AND DAILY MAINTENANCE _ Running-in ‘SECTION fauEoE ‘SHEET 6 (6) Running-in In run after initial staning, extended disuse or overhaul, cain of sliding portions is nor suifieient Ir is thus equised 1 pay panicularly careful auention to rue. Unsstisfaciory runing: in causes, seisure, blowhy or abnoumtl wear stem vil for for heavy fuel oil may he used as system oil used during running-in period after instalation. (See S Sheet 7) When engine BS operited om cliesel feel oil in excess of the running-in time specified below. Class IT oil shall be used Use diesel fuel oil alter piston ring and liner of engine operated om heavy fuel oi ate replaced vith new ones or for 180 hours after installation, The load pattern after replacement of piston sing and evlinder liaer with new ones is: as shown below Mirus ansaid aerene sped) Pee eee eee ete tse [70-0 fo eer Frater eon arn cpu an ‘2ibe especially careful of the following dy unniig-an Chock the cylinder liner inside surface condition from the cylinder liner bowtom face Iowiee; after 100 hours after starting of run on hheaey Fuel olf ane 150 hours thensalter Abnormal sound, abnormal everteating Operating, condition of pumps. Leakage from connections, ioasening Cylinder combustion condition (exhaust gas temperature, maximum explosion pressure) + Lubricating oil consumption fevel (a) The engine és shipped with the sponge state Hlushing filter mounted on the pepery: of the fuel filter element so as (© trap Foreign matier the pipe, Remove the filler before changing ov to keavy fuel oil or remove i in about 150 hours after stat of ru Do not use the filter in run on beavy fuel ol DK-20 |A|96-7 DAIHATSU SECTION | TYPE 7 OPERATION AND DAILY MAINTENANCE SHEET | DK-20 Measurement of engine performance, Measurement of 7 lubricating oil consumption level, Adjustment 2, Daily Maintenance and Inspection (1) Measurement of engine pertormance + Measure the following values when load is stabilized. Becareful so tat the load does not fluctuate during measurement + Take measurement at least once a day. When values are compared, compare them on the ssime conditions of the fuel pumpruck amount and the turbocharger intake aur lenperature. + 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 #f combustinn is normal 1) Measuring items @Exhaust temperature av the outlet of each cylinder @Exhaust temperature at the inlet of turbo- charger Maximum explosion pressure for each eylinder el pump 1a¢k amownt for each eytinder rbocharger intake air femperature @atake aie pressure and temperature @Lubsicating oil pressure and temperature Cooling water pressure an vemperature @Fvet oil pressure and temperature @ Nozzle cooling oil pressure and temperature (2) Measurement of lubricating oil consumption level Measure 1.0. consumption level of cach engine, and total the data every: month so as to grasp the trend of 1.0. consumption. In the case of shon-time run or frequent start and stop of the engine, excessive consumption may result. Therefore, when measvrement of normal consumption level is intended. take measuring ducing long-time continuous run of the engine. If the oil level is measured during stop of the en- pine,nove carefully that the oil Fevel may ¢uen high ‘owing to drop of oi from fitter or cooler onto the oi pan If the fubcicating oil consumption level i abnor- mally low or the oil level is high, a possible cause is infiltration of fuel or cooling water. I infittration of fuel or cooling, water is found, locate the cause, take corrective ations, and rephace the lubvicating of (B) Adjustment 1) Exhaust temperature AS a cylinder outlet is located closer to the turbocharger, the eylinder outlet exhaust temper- ature tums higher because it is more affecied by other cylinders. Normally, the fluctuation of exhaust temperatures among cylinders is about 20 SC. To correct the irregularly, various adjust ment has to be: made: 2) Cylinder maximum explosion pressure The maximum explosion pressure (Prax) depends on properties of fuel oil, intake ait temperature, etc,, but the fluctuation among cylinders is acceptable, if it is within the range of 0.6 MPa (6 kgficm’}. (But, it shall not exceed the value of rated pressure + 0.3 MPa {3 kgf/cm’ }.. Sampling for explosion pressure shall be mae aecording (0 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 andl take sampling, “The theeaded seas will possibly be seized, unless the valve is fully opened @Fally close the pressure indicator valve after end of sampling @Afier reading the maximum explosion pres sure, open the exhaust valve of the pressure indicator valve, and dismount the pressure indicator valve whew indication reads "0" MPs Exhaust valve (Notes) @Be sure to wear gloves, since the pressure indicator hecomes hot @Measure explosion pressure after the engine is vrarmed upsulficiently and the load is sabi- lized DK-20 [C| 98-6 DAIHATSU _OPERATION AND DAILY MAINTENANCE 5 Adjustment TPE | SECTION DK-20 | SHEET 8 cl pump rack amount the exhaust temperature of a cylinder is langely different from those of other cylinders after replacement of the fuel injection pump or ovale, adjust the graduation of the fuel rack using the adjusting serew shown at right The fluctuation of the exhaust temp cylinders is acceptable, so far as it is the range of about 30°C Keep the rack amoua Huctaattion at about | t grtuation, Da hot make further adjustment of the rack aniogat ‘Whea the exhaust temperature rises gradually, it is often because of stained turbocharger or intercooler in general Sualden rise of the exhaust temperature is ofte antribuiable to causes athe as damage with te propeller han the engine such Adjust the rack graduation using the adjusting serew as shown below Chetwis tum = froma inch amount (@stiuse eosin Hse Connteatockaise tam Device am raek wet (shane eps edn 'C. Adjust the cooling water flew ‘with the valve provided on the inlet side of the intercooler accoring to the sea water temperature and room temperature. Ja the factory run explosion pressure data with the intake air em peratursand justed 1 45-55 °C under Full loa are pled TF we intake aly vempera ccondenssteis formed with the resultant damage ‘with the intake air valve ané reduction in tubs cating performance. Therefore, sufficien! care has 10 be token in adjustment of the intake air temperature In is generally claimed that the temper cextis! gas will change a abot twice the rake a which intake aie fempersiare changes. Howe since the temperature change is affected by the fuel oil used, hack pressure, cleanliness: of the turbocharger and intake and exhaust valves, and also by the degree of staining on the ship's hull or Ihe navigation conditions (including dhe shape of the propeller sued), eke in the case of narine propulsion engine, 18 aulvisable that the condi lion of the installed engine ts fully undersioved with reference fo the factory operation dat TF the intercooler cooling water inlet and outlet temperature difference is eliminated and the temperature of 45~55°C cannot be maintained in spite of operation of the cooling water outlet ceock, wash the interooler according 10 the proveaure described in Section 7, Sheet 32 is super cooled, DK-20 | A 96-2] DAIHATSU SECTION TYPE | Seer] DK-20 f OPERATION AND DAILY MAINTENANCE Adjustment «intake dure> Increase or decrease the volume of cooling water by adjusting the opcning amount of the regulating valve A to thereby adjust the intake air temperature temperature adjusting proce- Adjusting] valve A igh 5) Intake air pressure Increase in the intake air pressure involves rise ‘of the exhaust emperature. ‘The possible cause is din on the turbine side of the turbocharger. Disassemble and wash the turbucharger in accor dance with the turbocharger Instruction Manual Reduction in the intake air pressuce is possibly attributable to dirt on the blower side of the turbocharger. Wash the turbocharger according 10 the procedure described in Section 10, Sheet 2. 6) Lubricating oil pressure The lubricating oil pressure range is 04-05 MPa (4-5 kefiem’). Pressure aujustment is ake 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 with the lubricating oil system in addition to sticking of the valve. Conduct chick an Pressure adjusting 7) Lubricating oil temperature The temperature control valve works to raise the lubricating ol temperature ina short ime for start of the engine in cold stale and keep the temperature with an appropriate range (50~60°C ) But itis difficult @ maintain strit accuracy. Nor maintenance of such accuracy is required If the sea temperature changes langely depend: ing on the season or the sea zone, the Jubricating oi control emperatute is also affected a ite, but such 2 difference can he corrected with’ the adjusting screw. ‘The cap and lock nut positions are adjusted in advance in accordance with characteristics of wax. Do not loosen them unnecessarily Even if the temperature control. valve is normal, carefulat tention has to be paid, since the lubricating oil temperature may tise owing. to extreme staining of the Inbricating oil cooler reduction in the cooling water flow, overheating of lubricating oil due 1 abnormal combustion, etc. If the control temperature is abnormally high, turn in the adjusting screw (about 8. myn max.) and open the passage on the cooler sie as a make-shift measure oes eR HEL | Pawn secu A When no temperature contsol valve isnot provided, it is requice 10 adjust the lubricating oil cooler bypass valve manually for control of the lubricating oil temperature When the lubricating oil temperature is low due to cold weather, vibration noise may be generated duc to high viscosity of lubricating oil ia the area around the lubricating. oil outlet pipe and. the pressure regulating valve. In such a case, itis advisable 0 fully open the lubricating oil cooter bbypass valve and saise the lubricating. oil temper- ature tthe proper temperature abruptly. For details of the temperature control valve, see the separate Temperature Contvol Valve Insirue- tion Manual DAIHATSU __OPERATION AND DAILY MAINTENANCE _ Adjustment TYPE | DK-20 | ‘SECTION 5 SHEET 10 8) Cooling water temperature ine, the fresh water we contol I the jacket cooling water temperature is (00 low, sufficient combustion cannot be obtained 0 corrasion of mM memers- may especial fuel oil is used. Th fore, appropriate temperature contra is neces Stoning at valve Stoting air conti vals ZoAi Lubricating el coofer Lubricating ei temperature Intake air temperature 9) Rocker ar Rock lubricating oi h 011 MPa{1.0 kgfienr}iin. co ensure the required lav pining: The Iubricating oil rate to the ing oil volusne around she bearing daving rocker art sembly is set in advance, ‘Therefore, no further adnustntent fs equi Rocker food ress tegolating valve Fel pessbie aru Intercooler contol valve DK-20 A|95- 10 DAIHATSU. igi) Cane OPERATION AND DAILY MAINTENANCE sHeeT | DK-20 | ‘Adjustment, Maintenance 10) Nozzle cooling (when heavy fuel oil is used) Fresh water cooling Concerning, nozzle cooling water, jacket cooling water is used in both cases’ of start and stop of D.O. and HO. The flow is adjusied in advance. Thus, no further adjustment is required, ®Dieset fuel oil cooking AAs to the nozzle cooling oil, use diesel Fuel cil for both cases of start 1.0. and start oF HO. ‘The cooling oil temperature: shovld be ad justed to $0-60°C with the temperature control valve 11) Fuel oil pressure The fuel oif pressure differs langely with the viscosity of the fuel used. Therefore, read the engine inlet temperature prior to adjustment t0 make sure of proper viscosity of the fuel, and then conduct adjustment. ‘When heavy fuel oil is wsed, keep the pressure at the seiting value for use of heavy fuel oil, See Section 3, Sheet 2 If changeover is made to diesel fuel oi, the oil pressure reduces, but it is not necessary to make adjustment (4) Maintenance 1D 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 Fue filter The fuel filter is a notch-wvire type duplex filer. Therefore, in the case of use of heavy fuel oil, disassemble and) wash it with sufi cient care, urs of the Fuel oi IF possible, washing during stop of the engine is advisable The engine is shipped wita the sponge ~ state flushing filter mounted on the periphery of the fuel filter element so as to trap foreign mater inthe pipe. Remove the filter before changing ‘ver to heavy fuel oil ar remove it in about 150 hours after start of run AX do aot use the ft it run on heavy fuel ol @) Lubricating ofl full Now fer This is a notch-wire type duplex filter. Normally, both can be used. When reduction in the lubricating cil pressure is seen, conduct blow-off operation ofthe filer I the pressure cannot be recovered after blow off, wash the filter after disassembly 2) Daily maintenance procedure of filters During normal operation, the lever should be kept at the common position, where both filters are in use. Change the lever position over to the right o left for selection of washing only ‘When changing over the lever position, it is necessary to attempt to do so with care taken 10 the handle stopper and marking positions white observing the pressure gauge. (Conduct selection of the lever position during idling ofthe engine or under low load.) If pressure drop is seen during run, blow-off operation is required. if pressure cannot be recovered even afier blow-off operation, wash the filter after disassembly To perform blow-off, recline the lever to either Fight or left side blow-off pasition (about 60 °) and then return i (0 the normal position again, Repeat this step several times for t~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 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 he accumulated ‘Open the intake pipe drain eve kfront ime to time to fully discharge the rain If much drain is seen, it is possibly due to leakage of water from the intercooler. DK-20 | C| 98-6 DAIHATSU Maintenance, Inspection OPERATION AND DAILY MAINTENANCE _ 5 TYPE | SECTION DK-20 | SHEET 42 4) Washing of turbocharger IF the turbocharger i tamed, exhaust temper ‘ature rises oF exhaust color is blackened duc 10 reduction of the inlake air pressure (0 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 1s equipped wash the turbocharger appropeiately, when the pressure loss excceds 1961Paf 200mmAq) or the intake air pressure reduees by about 10%. As to the pre-filler wrapped around the silencer filter.conduct washing once a week or 50 For the washing procedure of the silencer filter, see the Turbocharger Instruction Manual When the degree of staining of the turbo ‘charger i light, the methox! of wasting with water injected can be used during run of the tutho. charger. Execute this metho! appropriately 10 ‘operate the turbocharger in state of good effi ciency. As to the method of injection washing om the blower side, see Section 10, Sheet 2. For the tucbine side injection washing: method, see Sec- tion 19 Sheets 3-4 5) Protectors For details of each protective device, see the separate Instruction Manual (Aan alarm is issued ducing un of the engine, stop the engine immediately ant locate the suse Especially, keep persons concerned taformed of aetions w be taken in ease of issue of an alarm on the deck section so. as 1 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 «est, Ihrotile the pressure switch takeoif valve « reduce the pres In such a case, the pressure reduction is of the pressure switch circuit only. Therefore, the test may conducted during normab run of the engine. Conduct the temperature switch test using separate hot water (5) Inspection Keep the engine in clean state a all times so a 10 Find leakage fom connections, crack, ete. at an carly slage 1 Daily inspection @)Fuct tank oil level 2) 031 pan oil level G) Fresh water tank water level (A) Starting air pressure, B) Discharge of drain from intake air pipe {@Leakage from mechanical seal of cooling water pump, fuel oil feed pump and nozzle cooting cil pump @Rate of Tue! leakage from nozzle holder (4)'Tactsle check tor overheating of Fuel injection ppamp, cooling water pump and other punyps (Tactile check of eyliads starting air pipes for biow by in saming rotary valve (Direct starting engine) @Leakage from connections Loosening 2) Weekly maintenance and inspection {Removal of slug accumulated On the in sind exhaus! valve cote @Hand lubrication vo fink mechanism @Blow-off operation of switching wpe fi @Discharge of sludge when lubricating oi centrifuga filter is provided ®Washins of iwsbocharger pre-flter (sponge at the hlower suction port) §)Disehanze of dra trom start ar tank @Niseharge of drain from starting wary valve (Direct siacting engine) @Staniing test and maintenance operation of engine shut down for more than one week {miore than 30 minvtes) ‘Concerning items of the inspection period of more than moth, se Section 6 DK-20_|D| 98-6 DAIHATSU SECTION | TWPE OPERATION AND DAILY MAINTENANCE 5 Sere eee ero 2 SHEET | DK-20 _ Preparation for stoppage, Stoppage operation When engine must be: 13 stopped immediately, Actions to be taken after emergency stop 3. Stoppage (1) Preparation for stoppage ‘Make sure thatthe starting air pressure is within the range of 2.5~2.9 MPa (25~30 kgtficm'}. In case of air motor starting engine, check that the reducing valve pressure is set at 05 -0.9MPa) (5-9 kefiom2 } Jn the case of ren on heavy fuel oi, change over to diesel fuel oil in 30 minutes before stoppage. See Section &, Sheet 2 (2) Stoppage operation 1)Reduce the load gradually, and run the engine under no toad to leave the engine sitting, for ‘cooling down 2)Put the operation handle in the STOP position to stop the engine 3) Check for abnormal sound from the engine and the turbocharger during the period after stop- age operation 10 completes top page of the engine, 4) Fully open the pressure indicator valve to ‘conduct air running for discharge of combus- tion gas from the combustion chamber. 5) Perform priming of lubricating cil for about 2 minutes to-cool down respective sections In case of separate lubricating (ype turbo: charger (RH ~ 3scries') The turbocharger is of non-cooling co struction. Conduct priming for at least $ | minutes after stop, and cool clown bearings, 6) Close al line valves Tin the case of long-term shutdown of the engine, drain cooling water in he engine, Note: When freezing is likely in a cold season, be sure io drain cooling water (8) When engine must be stopped immediately 1) When alarm monitor functions. 2)When abnormal noise is heard from the working pars 3) When smoke is observed at bearings or other working pans. 4) When lubricating oil pressure drops suddenly 5) When lubricating. oil tempe denly 6) The engine revolutions increase rapidly due to trouble inthe governor or fuel injection pump. ‘7)When supply of cooling water kas stopned and water cannot be supplied) immediately {Refrain from supplying cold water suddenly after overheating) 8)When temperature of the cooling water has risen too high and no adjustment is effective in lowering it 9) When any damage or looseness of screws or bolts of working arts is detected. 10)When piping for fuel oil, lubricating ol or cooling, water is found to be broken 11)When moisture is found: mixed in the lubri- cating oi 12)When turbocharger rpm and discharge sit pressure decrease or discharge air temperature rises to abnormal level 13) When propeller or shaft is aut of order. (This applies to marine propulsion engine.) (4) Actions to be taken after emergency stop 1) Operate the lubvicating ofl priming pump. IF motor-driven lubricating oil pump and cooling, ‘water pump are installed, operate them to coat down the engine gradually. 2)Do not open the frame inspection window immediately after sionpage of the engine Especially, if much mist is generated, there #8 possibilty that such mist catches fire. ‘Thus, abstain from opening the window for 10 minutes after stoppage. Even after the window is opened, do not allow approach of naked fire 3) When the engine operated on heavy fuel oil is stopped, replace heavy fuel oil in piping with diesel fuel oil immediately. DK-20 | B\96~-7 DAIHATSU For long-term shutdown OPERATION AND DAILY MAINTENANCE TYPE | SECTION (Het DK-20 [SHEET 44 (8) For long-term shutdown 1) Shutdown for period within 3 months (Uy Turn the crankshalt several revolutions ance a day while priming lubrizaing oil Stop the cankshalt at a position different from st before turnin @ Daan cooling, water in eokE Season, Mere is possi of reer (DEW covers co the exh pipe and mist pipe 11s exposed to atmosphere Close the pressure indicator valve to keep the __ cylinder inside air-tighe ®Cover the engine with sheet 1 prevent dust from depositing. Especially, apply cover over all the electric’ equipment so that insulation resistance will aor bo impstied 2) Shutdown in excess of 3 months Gm oosler form air passage protective film spray sustpreventive oil (0 the Lurbocharger suction port inmediaiely before stopping the Add sus preventive vil to lubricating oil and tin the engine 2-3 revolutions while con ducting, paming, Pull oot the nozele holler, ands preventive vil in state with the piston locited at the Botton dead center @Apply rust preventive of! 10 the eylinder head cover inside, gears in geansase under the cevlindes Finer with piston Hoeated al che top sul center, and ser unpainted anes {81 Put anwistane iibtors sch as silica gel in the corankease as nevess > outside ait ceondition, (Fi covers to the eshaust pipe and mist pipe parts esposed to atmosphere. Close the pressure indicator valve t© keep the y Rust Cover the engine with sheet to prevent dust Trou depositing. Especially, apply cover over all the cleetsie equipment so that inst resistance will not be impaired 3) Starting after long-term shutdown [Remove all anoisture anhiitrs pat aN the crankcase. if any @ivscharge the lubvcaring oil with nist pevemive cil added, and put in new hubri- cating ()Chock fv freedom from rsting, ew conden sation ad sticking. of working. pats itn the case of a eneralor engine, Ury the generator nse sufficiently (5) Start the engine manually. For ethor details, refer to the starting, method descr in Section 5, Shect 2 DK-20 |Z /94~3 DAIHATSU ‘SECTION ] Gieel sHeeT | DK-20 1s | lad OPERATION AND DAILY MAINTENANCE ‘Allowable Operating Range {in the case of marine propulsion engine) 4, Allowable Operating Range (in the case of marine propulsion engine) The figure below shows the ranges of allowable continuous operation and recommended continuous normal operation ‘When heavy fuel oil is used, the low load limit depends on output, but is about 35% normally and about 204% in the case of specifications with ‘countermeasures worked out against low load, (1) In the caso of FPP {fixed pitch propetler) Absorbing engine of the propelir is designed as shown below in general bases! on nrarine propeller cearacterisic curve with the sea mang (ships hull resisiance) due to contaminatinn of the. ship's, bottom taken into consideration. If the ship's, bottom is contaminated much heavier than the sea margin, the engine is put in the torque-rich state likely to cause damage with parts constituting the combustion chamber or inability of retention of proper inspection and maintenance period of the engine. Therefore, it is alisable ta operate the weed continuous oper- ating. range at all times in correct and ful under standing of the operating performance. Ifthe engine is put in extreme torque-rich state, surging of the turbocharger is induced (2) In the case of CPP (changeable pitch propeller) CPP can select engine output (load) freely by changing. its blade angle in conformance with the ‘engine speed. Therefore, the fuel consumption can be saved, or the engine can be operated properly in ‘combination with other auxiliary machinery driven by the marine propulsion engine. In this case, however. operation tends to be in torque-rich state because of large degree of fre- dom. Therefore, itis advisable o operate the engine as scheduled in combined use of ALC (automatic, foad control unit), if possible, after undersianding the allowable operating range of the enginesut ficiently ‘When driving the shaft generator or other aunil iary machinery where the generator i driven by the marine propulsion engine, it is advisable to operate the engine within the recommended continuoy normal operating range with sufficient care taken for the load owing to combined operation of the propulsion propeller and an auxiliary machinery or owing to independent operation IF the operating range goes out of the allowable operating. range shown below hecause_ of special specifications, such operation shall conform to the specifications of the customer or be subject 10 separate agreement with the customer. 1 ~ - ie \. L ITY | vos ese pee “i ~~ EES] orev reine ne up ae Ressmmenddconinis oe) oe Qo | ESSS Sa eKcrenginee Praarve: Marin prope etc ve Marve Gare with ce mrgin ton ia Ee | 3% guowane range of sn ine r prance fs fen specs |__2 erage of shi Ale Gee Ka ston on de Kl a 10% | J Weca’eensend cima esses r LT selicatom secrete esac eee 136 @ © © 3 EF tog seed > Revoton (8) DK-20 |Z |94-3) __ OPERATION AND DAILY MAINTENANCE Special Operation 5. Special Operation (1) Low-load operation 1 Operating the engine at lowe speed for a Tong sivetch of time should be avoided insofar ax possible, as this may result in contamination of the combustion chamber due to coutter flow of the eshaust- gas, incomplete combastion ar abnormal west of indivi paces 2p Lows ft limit vaties. aecontings 10 the engine siweifications. {Penge mst be yun below the Jow-load lini, use diesel fuel oil without fai and restrict operation to. as short period as possible 3)To maintain a satisfactory combustion state xlhist dhe intake air cooler nuslet valve Incsease the intake air tempernune with ca faken We keep the eylinder outlet estou) temperature below 400 [the water is reduced until intake air exceeds 25°C. scales are formed in fin tube. ‘There- Tore, be sure to keep the intake air temperature below 75°C Yd or more lol operon for about 30 minutes st day as effective for prevention of Hhustiow chamber and ‘eoniamination of the ce imakevexhaunt systerns, 4) 1s desirable to on nize kew-losul operation. insofar as possible, If it takes a long ime "unavoidably, be sure to increase the number of Himes af injection wasbing, oF the turbine or ower (2) Non-turbocharger operation ship is proviled with a set of turhocharger blank plates (generator engine: optional) so thatthe engine can be operated when the turbocharger is out fof onder. Load in this case is generally at me {average effective presse), which equals to Ould MPa(Skyeny Yahout 25-30% of the raed owt pout, Since dhe earn andthe piston ae conditioned for tucbocharged operation, efit sas tempetat becomes quite high. Thus, when eontinvous oper tion is required under nos-torbechargeds condition take greater care with the eshous! gas temperature than fou; operate the engine with dhe estaust gas Kepe below 481°C usins diesel fue! oi T TYPE. SECTION 5 | 9-20 ‘SHEET 16 H)Remuwe the hlowerrator side of the tube changer, ail moat turbocharger blavk plate See Section #0, Sheet 5. 2) Attach $ wire gauze 10 the intercooler inlet for prevention of infiltration of foreign mater 4) Remove the lubricating oil inlet and outlet pipes, and blind the inlet and the outlet. Cover the turhochagger lubricating oil inlet and outlet ports wit tape (® preweny iaifeation af dust (3) Operation with intercooler cut off from main line IW fin twhe for the turbocharger is broken or if water leaks into the air supply system, cooling water (ea water} may flow into the esbinders through the intke Hine This nay vesull in corrosion dr the air intake Lie ‘oF in the pants constitosing the combustion chamber ‘or ghamage 10 these pacts. “To avoid this, take the following countermeasures promptly, if a failure in the intercooler is detected, 1) Stop Feeding water to intercooler and dea ‘cooing water remaining inside the intercooler 2) As a inake-shift meastie, aperate the engine wih diese! fuel ail with the amake ai semper ature kept at 75°U ar lower and the exhaust gas temperature at less than 450°C When resuming supply of cooling water after temporary suspension, check carefully for any leakage of water through packings 3) When the intcreooler ean be overhauled, check fi he following and repair (Din ube dare (Pin tube expansion failure Detective packing at air intake side drain hole If the fin tube has broken, plug the cooling water in let and outlet associated with the damaged! the with the woodenplups supplied, and continie operation Since the cooling efficiency of the inter nishel in this case as well, ration, paying attention «the emperagure, cooler is continue 0} estas! DK-20 | A|94—-5 DAIHATSU SECTION ] TYPE SHEET | DK-20 47 5 __OPERATION AND DAILY MAINTENANCE Special Operation (4) Operation with reduced number of cylinders Operation of diesel engine with reduced number of cylinders should be restricted to emergency use for only a short period, because of possifle torsional vibration or extemat vibration which may accom ppany such an operation. Care should be taken of the following points when performing such an opera tion 1) Expected output should be limited t: (Number of (Number of ‘eylinder) — “cylinders inoperative) : oa x 10% Number of eylinders IF outlet temperature of each cylinder exceeds the tolerance, reduce the load further. 2) Because of the increased vibration torque exerted on flexible joints and reduction gear in the case of a marine propulsion engine, care should be taken to prevent damage thereto, and also for chatiering Refrain from operation at the rpm at which chaatering takes place. 3) Inthe case of an engine use for generator, the vibration stress exerted on the generator shaft may exceed the allowable limit specified by the Ships Classification Societies. In such a case, pay attention (0 the sound of the gears located a the frontend of the engine, and refrain from ‘operation if the level of the sound is greater than norinal However, it is possible to change rotation in the permissible frequency range of dynamo ‘and operate at rotation with minimum gear sound. 4) Wher the engine is operated with some pistons aand connecting rods removed, external vibra: tion of the engine may increase. In such a case, refrain from using il, if the vibration is This is particularly true with a flexible mount- ing system, so special care is necessary for the type of engin. It is preferable to inquire of the manufacturer and observe the instructions Biv For proper treatment of the lubricating oil feed holes, etc. eft open as a result af removal of sonie_ pistons and connecting, rods, please contact our Service Division, DK-20 5) Afier pulling out pistons, there may be a case ‘where the engine cannot be started depending ‘on the crank position. In such a case, turn the crankshaft to change the erank position 6)1F surging takes place, reduce the load until surging stops. Ifthe toad cannot be reduced, open drain cock to purge air. In this case, take due care of increase in exhaust gas temperature, (6) Malfunction of lubricating off temperature control vaive or nozzle cooling oil temperature control valve Oil can be fed to the full flow lubricating oil cooler oF nozzle by tightening the screw on the top of the temperature control valve. Jn operation under low toad, sulfuric acid corro- sion isikely to occur due to supercooling ofthe fuel nozzle, Check after disassembly. (6) Break of lubricating oil cooler If the tube has broken, plug the cooling water inlet and outlet of the tube with the wooden plugs supplied, as a make shift measure, and continue ‘operation, Infiltration of cooling water can be checked by sampling lubricating oil from the lubricating oil cooler brain plug. TYPE DK-20 SECTION SHEET | DAIHATSU SECTION | TYPE 6 SHEET | DK-20 4 1. Periodic Inspection (1) General precaution Period inspection and niantenance are esseniat to keep performance from the engine. Standart periodic inspection intervals differ largely according to the application and_ working conditions ofthe engine an quality and contral of fuel oil and lubricating cil used. Ib recommended thata schedule is worked out to mach the individual engines, using the table showvh on the nest page as a side The standard periodic inspection intervals shown here are intended for engines that have undergone running-in and entered! normal operation. ‘The fits inspection on nevily built ships should he performed Heer than normal, an! the engine condition should be Fully understood [As for periodic inspection intervals of the turbo- charger and governor, refer to wespoctive instruction manuals. MAINTENANCE SCHEDULE General Precaution ‘The periodic inspection intervals shown here apply when engines are operated on the following, conditions 1. Lubricating oil of brand recommended by us is used in conformance with the control rules 2, Fuel of properties observed at time of conclusion ‘of the contrac! is used on specified conditions. 3. The engine is operated on the specified condi- tions, DK-20 |Z /94-3 (DAIHATSU) MAINTENANCE SCHEDULE _ | TYPE a Periodic Inspection Frequency Table DK-20 [sheet | (When diesel fuel oil is used) 2 {Whe diesel Fel wi is used) 1 : Tewing Hos 1) aut A 1 peany|3 mofo mon veacty Diy Ween) 3001300" 2008" 0007 Sa [1500 | 3000 | 00 vcsnarae [CHECK injection pressure, condition of ie Tara Fuctworde | Synying and cen 7 wo tobe valve [aspect par sem ea | Faust vive [Inspect apace stem se * | Stasingsiv vane |tinpect, | g [snare lio || $ |evtinder satay sa 100 Bue taspeet, fe & | Rotator Trepect afer Gascony { Valve sping z & [eaters [ewes ; J Mae | pet an ; Ag sa sent team ater disassembly stiles head ; 7 } seen Chock hea bot igening ong = ~—Ttac, lean, ase, inspect alae r i pian i Vision fren |} amu-toeors ean, ise psn Prov Htc, cea and inspect ! vot Insp piston pin Ising | — Bn - } tomtom trspest cinpi bearing meal Connecting Replace crankpin bearing etl a yeeann-2ao0) Check connecting ol ol tightening ae wan | Heplice connecting ead al 1 0 (em 2ne zal Measure inside uae, isp anno a rac line, inspect jacket i z ensure, spent rap, joumal \ 1 ]oyr(s000-i2ae E Jevnkshan [Measure deftection, adjust ay heck face waht bot ghtning : a 2 tonne spot ain eng ta i Lae ont Main waving [Replace mi bearing nth [seca gen) [Check main bearing bot gbiening | 3S Inspect can and ot iting To ] Inspect tappet sad bushing fing 2 se (4002000 Menai, nner canst : seta neni j {pert cum bearing et ee er ing and bucks Timing gear co bushing. ye (pon a0) Chock ol wlucning rane i 2 iso) No Te athed wh drvote thse to Be check a tne of Ist npecton “Ue Tat aspen Torta ens soa be mae as eaulyonpravtaie. tian itv sl fos eesscsbly for fp sshd earn aeextngt Te ato ings fhe Tse itspection [pK20_[Blse—6 TYPE ____ MAINTENANCE SCHEDULE DK-20 Poriodic Inspection Frequency Table (When diesel fuel oil is used) QWhen diesel fuel oft is used) ‘Running Hours (ip) tnspcton lem Task ents 5 mon fo mon | Yearly Daily vecy "300-120 4000. S00 | ‘00 Check working Mid fv ° g |Govemor Cheek, reptice working Muid. a ore Hee HEHE a Inspect sam part after disassembly, Tol FI covemor drive [Tek gear tooth meshing, backlash, | 2yeqana< 2000119 Inspect bushing and bearing, 2 (0001200011) ‘Ads, lbricat o uel cont ink Disasseobl, inspect ° GJ Winneveretage 6 : pie sel in 5 acanlce ; z inspect press BaHleal aeeecaa z inspec pressure et 3 | caus thermometers [Caves spect gauge ple Vibration z jf ; Rel pure pair awe 2600-20018) Protective deviees| spect, test, adjust. ° ae ; ae ced apne heck lubcating oi eve 3 | ee rep € Replace Invi 500-1001 a emetic 7 monn} 2 Clean ir leaner ° | urbocharger [Disassemble lean and i oO 3 eae a wiching i pve being ie ciate, 3 Flush Mowerside 150-200 z Wash pe-fites. ° Disassemble, clean, peform Baar ___fisereooter | iygrontati ek te i Siang stacing A cont bsp. > valve Es. Inspect rotary valve and et Dirge 4 sonia sty [tm save and sen etsy ene $ [rave Drain condensate Direct sang engine & e Check ar pressure ° E [tuning irtank [

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