CHAPTER

Control of Fuel Oil, Lubricating Oil, and Cooling Water 6

ITEM
Fuel Oil Characteristics and Control DK.2O 1.2

Table 6-1.2 Standards for Clean Fue! Oil

Component Standards

Water 0.2okvlv or less

Solid Content 50 mg/kg or less

particles
Size 5 7-r m or less

Vanadium combines with sodium to yield a

compound that acls as an oxidatlon catalyst,
accelerating the corrosion due to sulfuric acid
(vanadium attack).
Further, waler accelerates the corrosion of
luel injection system parts. Parlicularly in
case that sea water is mixed in water, it will
further accelerate the corrosion due to
sulfuric acid as above said, and therefore
remove the impurities together with solid
particles by the luel oil cleaning equipment,
to the best possible extent.

DAIHATSU a-"
 Control ol Fuel Oil, Lubricating Oil, and Cooling Water

Selection and Control of Lubricating Oil

6-2 Lubricating Oil Characteristics and Control

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

6-2.1 Selection of Lubricating Oil 6-2.2 Controlof Lubricating Oil

(1) Engine system oil
As the system oil for engine, high-grade lubricating
oil (CD of API service category, or higher) lor
diesel engine shall be used.
Select the lubricating oil of the suitable grade,
according to the quality of the fuel oil to be used.
The recommended lubricatlng brands are shown in
a separate table.
Table 6-2.1 "Recommended Lubricaling Oil
Brands"
Be minded to use the lubricating oil of the
sarne brand, not mixing the lubricating oil with
the oil of any other brand.
lf the lubricating oil is mixed with the oil of
dif{erent brand, the additives contained in the
both oils react for each other, and this may
result in the degradaiion of the lubricatlng oil.
(2) Lubricating Oils lor Other Equipment
ln case that separate lubricating system is
employed apart from the engine lubricating
system, as in the case ol the governor, air motor,
lurbocharger, generator, deduction gear, etc., be
rninded to refer to the instruction manual ol each
equipment.
'El "lnstruclion Manual ol each equipmen"
(1) Cleaning of Lubricating Oil
Since Iine dust or combustion residue from the
combustion chamber enter and mix in the
lubricating oil, a centrifugal separator is installed to
the engine, to eliminate such foreign matters, in
addition to the lilters attached to engine. Use such
equipment in correct manner, referring to the
instruction manual bf each manufacturer.
Do not conduct cleaning by injecting water into
lubricating oil.
Mixing water into lubricating oil will cause
degradation ol the lubricating oil, such as the
emulsification of oil, the decrease of total base
number, and the increase ol insoluble
substances.
(2) Control ol Lubricating Oil Characteristics
Perrodically conduct the sampling and analysis ol
lubricating oil (every 500 hours), and in case that
the analyzed value of the lubricating oil
characteristics has reached the control standard
value, immediately consult the lubricating oil
manulacturer, so that the replacement or makeup
can be carried oul.
Table 6-2.2 "Lubricating Oil Control
Standards"

DAIHATSU ll - )
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM

2,2 DK-20 Selection of Lubricating Oil

a) Sampling Procedure. (lnformation to be Attached to Sample

i ) Cotlect samples lrom the air vent pipe ol the Receptacle)
lilter during the operation of engine.
lf the samples are collected from the drain O Name ol your company and your name
cock, the analyzed value ol the @ fuoOet number ol engine
characleristics may show a dilferent value @ Engine number
due to the mixing of sludge or solid @ Oate and location of samPling
deposits. @ tne amount of time the engine is
ii) The minimum amount of sampling shall be @ operated
500 cm'. O Lubricating oil brand
iii) Attach on the sampling receptacle with the The total operation time and quantity ol
label indicating the inlormation as shown on lubricating oil
the right. @ Replenishment record (Date and quantity
ol replenishment)
b) Lubricating Oil Control Standards
The lubricating oil control standards are as
shown in the Table 6-2.2 below.
Of all the lubricating oil control standards, the 1) Total Base Number (TBN)
total base number and n-pentane insoluble are Total base number represents the quantity of
particularly important for the purpose of checking potassium hydroxide (KOH) that corresponds
the degradation degree of lubricating oil. to the quantity ol acid required to neutralize
the base component contained in 1 g of
Table 6-2.2 lubricating oil, and is indicated by the unit of
Lubricating Oil Control Standards (System oil)' mgKOH/9,
Total base number indicates the lubricating
Fuel oil Used Diesel Heavy oil capabilities to prevent the corrosion due to
fueloil fueloil
sulfuric acid generated from sullur contained
Total base
number"
mgKOH/g 3 or more 10 or more in fuel oil, and other acids, and further it
indicates the capabilities o{ lubricating oil to
Visconsitl, +3Oo/" or less I -2O/"
cSt clean and disperse the louled sections in the
or more of new oil
engine.
F ash pc nt 'c 180'C or higher
2) lnsoluble ( = n-pentane soluble)
I r =.= .lnsoluble is louling subslance that do not
0.3 or less
dissolve in oil, and the main component is
,.,i :. 2.5 or less soot which is a product of combustion, and
calcium sulfate which is a neutralized
Note I 1) The total base number represents the product.
vaX.Es rreasued according to ASTM D664,
JIS les0l (tldoct*cric acid method). Since these substances do not dissolve even
.- - - - TBll ffd Base Number) in n-pentane which is a solvent, n-pentane
2) n-pentane ixdnb represents the values
measured accorAE !o ASTM D8938. insoluble seryes as an index to indicate the
ln case thd fie rreaqred vajue has quickly degradation and fouling degree of lubricating
increased, or lra su.eassed 1.5, measure
the insolubles d Erene with the same oil,
melhod, and h race cl n?eni,ane insolubles
- toluene insolubles 0.5. replace the
lubricating oll. =

DK-20 A 00-9 DAIHATSU

 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Recommended Lubricatin'g Oil Brands DK.2() 2.2

Table 6-2.1 Recommended Lubricating Oil Brands

Kind of F,O, Gas oilor Up to 200 Sec. Up to 1500 Sec. Up to 7000 Sec.
Dieseloil R.W. No.1 R.W. No.1 - R.W. No.1

Class ll Class ilt Class lV Class V

Name of 7 Supplying or \ lSupplying or1 7Supplying or 1 7 Supplying or \
Company \ Replacing oil / \Replacing oil/ \Replacing oil/ \ Replacing oil/

BP BP ENERGOL BP ENERGOL BP ENERGOL BP ENERGOL

DL-MP3O tc-HF253 tc-HF303 1C-HF303
CASTROL MLC3O CASTROL TLX2O3 CASTROL TLX3O3 CASTROL TLX3O3

CHEVRON DELO 1000 Marine DELO 2000 Marine DELO 3000 Marine DELO 3000 Marine
TEXACO oilsAE30 oilsAEso oilsAE30 oitsAE30
TARO XD SAE3O TARO DP SAE3O TARO DP SAE3O

EXXON MOBIL EXXMAH 12TP3O EXXMAR 30 TP3O EXXMAR 3OTP3O EXXMAR 3OTP3O
MOBILGARD 312 MOBILGARD 330 MOBILGARD 330 EXXMAR 4OTP3O
MOBILGARD M33O MOBILGABD M33O MOBILGARD 330
MOBILGARD M33O

GULF GULF VERITAS GULF VERITAS GULF VEBITAS

DPO3O SEFECT3O SERECTsO

PETROBRAS MARBRAX MARBRAX MARBRAX MARBRAX

ccDs10 ccD320 ccD330 ccD330

SHELL GADINIA3O ARGINA S3O ARGINA T3O ARGINA T3O

TOTAL RUBIA S SAE3O RUBIA ST SAEsO HAM SAE3O HAM SAE3O

FINA DISOLA M3015 HAM SAE3O AURELIA 303O AURELIA 3O3O $
Er-i

AUHELIA 3O3O Ei

Note: 1 ) This table shows lubricating oils classif ied as SAE30. Be sure to use lubricating oils classified as SAE40
only when the minimum ambient temperature is 20"C
I
We recommend that multigrade oil (SAE10W-30 or 5W-30) be used in extremely cold locations
(minimum ambient temperature: 5"C or less).
2) Be sure to consult with oil manufaclurers before selecting the lubricating oil proper brand that best suits
the fuel oil and operating conditions.

DAIHATSU -r-i- ----'

-
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Cooling Fresh Water (Raw Water) and Corrosion
3.1.3.2 DK.2O

6-3 Cooling Water Characteristics and Control

Always use fresh water as cooling water in the cylinder jacket systern and add
corrosion prevention agent to cooling water to maintain cooling eflect and prevent
corrosion due to scale bonded on the piping surface.
lmproper cooling water control can cause localized heating of the jacket line parts due
to corrosion or scale, resulting in excessive wear on or damage to the iacket line
parts.

6-3.1 Cooling Fresh Water (Raw Water)
As cooling fresh water (raw water), be minded to
use the soft water that meets water quality
standards shown in Table 6-3.1 below, or the.
water to which soltening processing has been
administered
6-3.2 Corrosion Prevention Agent
(1) As corrosion prevention agent, we recommend C
the agent which is nitrous acid type.
(2) Commercially available brands in Japan are
shown in Table 6-3.2.
When using them, carelullY read the
manufacturer's inslruclion manual, and properly
use the agent in accordance with lhe use
standard as well as the control siandard.

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

Elfect (reference)
Item Standards
Corrosion Scale

PH (25'C) 6.5 to 8.5 (neutral) o r) I

Total hardness ()
(CaCOs PPM) 100m9/kg Max.

Chlorine ion
lConcentration: Cl-1)
100m9/kg Max. o
'.r - a'kalinity (PH4.B) 150m9/kg Max. C
Sullate ion
(C,<xrcentratio n : SO+-2) 100m9/kg Max. o
- -'= ':n iFe) 0.3m9/kg Max. o
50mg/kg Max. o
0.05mg/kg Max. C
400mg/kg Max. C

DK-20 Z 99-B DAIHATSU

_l
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water 6
ITEM
Cooling Fresh Water (Raw Water) and
Prevention Aqent DK.2O 3.2.3.3

Table 6-3.2 Brands ol Commercially Available Corrosion Prevention Agents

I
Brand Name Manulacturer Constituent Amount to added (ppm)

DEWI-NC 3,000 - 4,500

Drew Chemical Corp. (U.S,A.) Nitrite
MAXIGARD 20,000 - 22,000

CWT DIESEL 102 VECOM B.V. Nitrite 1,250 - 5,000

6-3.3 Control of Cooling Water

o (1) As cooling water, be minded to use fresh water
added with corrosion prevention agent, from the
stage of very lirst beginning, without fail.
Corrosion prevention agent is poisonous and
toxic substance. Therefore, be minded never
to drink the cooling water that is added with
corrosion prevention agent.
Further, regarding the handling ol the cooling
water added with corrosion prevention agent,
be sure to wear the protective gears such as
rubber gloves and masks, so that your hands
or skin do not directly touch lhe cooling water.
ll the corrosion prevention agent has
accidentally touched your skin or entered your
eyes or moulh, immediately wash them with
fresh water suff iciently.
(2) Controlling Fresh Water with PH Value
Measure the PH value ol cooling water once
every week, using a PH value, and in case that
the value has exceed the standard value
specilied by the manufacturer, discharge 10 to
20 "h of the cooling water to add new water.
(3) Replace the entire amount of cooling water
once every year or 2 years.
Be minded never to directly discharge the
cooling water, which are added with corrosion
agent, into sea or river, without adequate
piocessing. I
When disposing the cooling water, be sure to
conducl the water examination, to ensure that
the CDD concentration of cooling water is
diluted to be within the specilied value.

DAIHATSU r.. .:
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM

1 DK.2() Precautions for Troubleshooting

7. Troubleshooting and Countermeassures

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

7-1. Precautions lor Troubleshooting

(1) Take proper measures immediately when you find a defect or problem.
lf any of the following delects and failures is found, stop the engine for inspection. Never attempt to
restart the engine until you Iind the cause, take proper measures, and restore the engine to the normal
. operating conditions. Resuming operation without taking proper measures may rapidly aggravate the
defect or lailure, resulting in injuries or accidents.
OActivation ol protective device: "Alarm", "Emergency Stop"
Overspeed, low lubricating oil pressure, high cooling waterlemperature, etc.
@ Abnormal sounds (specially mechanical sounds), abnormal vibrations
OOverheating of the engine
eAbnormal increase of exhaust temperature or maximum explosion pressure, or abnormal decrease of
exhaust lemperature or maximum explosion pressure
3 Defective parts on or around the engine control (governor, control device), or protective device, 2nd a
lcosened link, or detachment ol link
3 Darnage to piping or joint bolts (specially fuel and lubricating oil systems)

(2) lns;ect. c sassemble, and adjust the engine correclly according to the instruction manual. To prevent
acc :eits, -e,,,er neglect "Safety Precautions". '

(3) Be sii'e :c -se i'e genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the parts
,'', -:: :'e'eailer guarantee the proper operation of the engine unless such parts are used.
lis'|. VJe
ll yc; a'e : -: :' :-: s:are pafts for servicing, immediately contact us for replenishment.

lnstrumentS Suct as tachometers, thermometers, and pressure gauge may provide

incorrect ind caiion e't,€n if the engine is running normally.
lnspect the ir:str-rments on a daily basis to make sure their indication is correct.
Replace any defec:,e:nstrument. Always use correct indications as an index for
determining the eng,r,e co-ditions.

DK-20 Z 99-8 DAII{ATSU

I
 CHAPTER
Troubleshooting and Countermeasures
7
ITEM
When Starting ls Difficult DK.2O 2.1

7-2 Troubleshooting and Countermeasures

7-2.1 When Starting ls Difficult
(1) Direct System
[Phenomenon) [TroubteJ [Countermeasures]
lnsulficient starting air pressure -- lntake air.
[-leafs lrom main slop/salely valve on air tank-- Maintenance/Replace.
l- Faulty air f illing unit --------- " " -- ----------- Repair.
ILFaulty
(".g.compressor)
pressure gauge Repair/Replace.
Defective starting air piping system
lnsufficient stop valve "-""-
fL "Ctosed" piping Open valve.
starting Clogged Clean valve.
air
Faulty starting device
l-sticxing of starting air operation valve " Maintenance/Replace.
f-Sticl<ing of starting air valve ""--"-'-" Mainlenance/Modify.
L Fough seat surlace on starting air rotary valve " Maintenance/Modify.

Flywheel Defective control system - Maintenance/Modify.

does not lnterrupted power supply
rotate Delective automatic control panel
DelecVbroken wiring of
electrical contacls for control
Defective solenoid valve for control
Turning device: ON '-- -----'-r " 'Turn it'OFF'.
Rotation preventive device: ON '

High resislance ol moving parls (such as seizure) Maintenance/Modify.

Non- f- Culinder liners. Piston
Engine smooth t'
'-Crankshaft
does not turning -
Too high lubricating oil viscosity lncrease cooling water temperature.
start i -..
O No ignition Low room temperature "-"'-'
Replace with less viscous lubdcating oil.

lncrease room temperalure.

Flywheel
rotate,
in all Low cooling water lemperature --'--------- lncrease water lemperature.
cylinders Degraded fuel oil
but fuel
properties (ignitability) ------- Use high-grade oil.
mixture f lmproper
in fuel oil
is not l-Water Separateandeliminalewaler
ignited -Air in luel oil Remove air.

The normal Delective fuel injection valve

rotation
speed iFaulty nozzle Maintenance/Replace
Llmproper valve opening pressure "" Adjust.
is not a::
No ignition Defective {uel oil injection pump-'----' MaintenanceiRe:
reached
in some of rack
[.Sticking
.Sticking of plunger
I
| I

l. Faulty delivery/isobaric valve.l

lmproper fuel injection tlming" - ' Adjust
lnsuff icient compression pressure
Non-airtight piston ring (slicking,wear,damage) t,l:
f
f-Non-airtight intake/exhaust valve'
Llrnproper valve end clearance
on intake/exhaust valve

DAIHATSU lr.-!I : 9F.t

 \:s:S\sSrsS:s5>tt\\sttr\>.r.rts>s>t>s

shooting and Countermeasures

7-2.1 When Starting ts Ditticutt
[r) DtreclSyslem
tPtrenornenon\ $rsub\e) -*: _-':Fe6d.q!r
lnsulf icient starting air pressure ..... . --a. : 3r,"
\-Leaks trom main slop/salely valve on air tank Maintenance/Replace
--
--.-.----. .......--.-.-. Repair.
l-Faulty air lilling unit
(e.O.compressor)
|-Faulty pressure gauge Repair/Fleplace.
Def ective starling air piping system

f "Closed" stop valve .-----.- Open valve.

'Clogged piping Cban valve.
Fau/ty starting device
l
7€ftklng o(sbr(rhg aft opera(rbn va(ve 'Mathbnance/Rephce.
iLSticti.rq ot sta(rnq ak vatve Maintenance/Modr\.
Bough seat surface on starting air rolary valve -' Maintenance/Modify.

Flywheel Delective control system 'Maintenance/Modity.

does not lnterrupted power supply
rotate Delective aulomatic control panel
DefecVbroken wiring of
electrical contacts for control
Defective solenoid valve for conlrol
Turning device: ON ""-'-""'-: Turn il'OFF'.
Rotation preventive device: ON"j

- High resistance ol moving parls (such as seizure) Maintenance/Modify.

|-cytinOer liners, Piston
Engine L Crankshaft
does not Too high lubricating oilviscosity lncrease cooling watet lemperalure.
start i-_--
O Flywheel
Low room temperature "'--""" --'-""--'
Replace with less viscous lubricaling oii

lncrease room temperature.

Low cooling water temperature --' ------ --- lncrease water lemperatu re.
rotate,
but fuel Degraded lueloil
mixture Use high-grade oil.
Separate and eliminale water,
is not
ignited
The normal Defective {uel injection valve
rotation nozzle '"---Maintenance/Rep e:e
speed l-faulty -
-lmproper valve opening pressure Adjust.
is not
Defective luel oil injection pump------' ' -'Maintenance,/Be: a::
reached
[.SticXing ol rack I
|
.SticXing ol plunger I

l. Faulty delivery/isobaric valve,l

lmproper {uel injection timing --------- Adjusi
lnsuff icient compression pressure
Non-airtrght piston ring (sticking,wear,damagei
r.':
I
l-Non-airtight intake/exhaust valve ' '.''.
L l*prop"r valve end clearance II
on intakeiexhaust valve

DAIHATSU a_ J
 CHAPTER
Troubleshooting and Countermeasures 7
ITEM
When Starting ls Ditficult ,
DK.2O 2.1

7-2 Troubleshooting and Countermeasures

7-2.1 When Starting ls Difficult
(1) Direct System
IPhenomenonj [TroubleJ ICountermeasuresJ
lnsulficient starting air pressure lntake air.
[- Leafs lrom main stop/salety valve on air tank '- Mainlenance/Replace.
l-Faulty air lilling unit----.----'
""'---""' Repair.
ILFaulty
(e.g.compressor)
pressure gauge ---Repair/Replace.
Defective starting air plping system
l-"CtoseO" stop valve '---'-- open valve.
LClogged piping - -----Clean valve.
Faulty starting devlce
l-sticfing of starting air operation valve-' Mainlenance/Replace.
f sti"t ing ol starting air valve
L
Mainlenance/Modify.
Hough seat surface on starting air rolary valve -' Maintenance/Modify.

Flywheel Delective control system ---'MaintenanceiModify.

does not lnterrupted power supply
rotate Defective aulomatic control panel
DelecUbroken wiring of
electrical contacts for control

Turn il'OFF'.

High resrstance of moving parls (such as seizure).'Maintenance/Modify.

[- Cytinaer. liners, Piston
l-Crankshaft
Too high lubricating oil viscosity - i '-'lncreasecoolingwatertemperature.
o Flywheel
:- "- Replace with lessviscous lubrlcating
Low room temperature -''------'-----'-- '---' lncrease room temperalure.
cri

rotate, Low cooling waler temperature - - - - --- -' - --' lncrease water lemperature.
but fuel Degraded fueloil
mixture ftmproper properties (ignitability) -.--.-- Use high-grade oil.
is not f-Water in f uel oil Separate and eliminale water.

ignited 'Air in fuel oil Remove air.

The normal Defective fuel injection valve

rolation
speed fFaulty nozzle Maintenance/Repiace
-lmproper valve opening pressure" "- Adjust.
is not
Defective luel oil injection pump-"---- "-Maintenance/Be: a::
reached .Sticking ol rack
f
.Stict<ing ol plunger
I
| I

[. Faulty delivery/isobaric valve,l

lmproper fuel injection timing' Adjust.
lnsuff icient compression pressure
I Non-airtrghl piston rinQ (sticking.wear,damage) l.'z -'.'
Non-airtight intake/exhaust valve " '.'= -'='
ILl.prope,
valve end clearance : - - -'
on intake/exhausl valve

DAIHATSU r.ut\'eu r J;'g