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 HUDONG-ZHONGHUA SHIPBUILDING(GROUP)CO..LTD.

DIESEL GENERATOR ENGINE

DOCUMENT LlST
#-----.-------.------.-------------.-----..-----.------------;

Approval plans Please confirm documents in this list and

return each one of this list & documents with
your signature for approval as soon as
~ossible.
' , Working plans Please receive documents in this list and
return one of this list with your signature.

Finish plans Please receive documents in this list and

return one of this list with your signature.

customer s~gnature

DAIHATSU DIESEL MFG. CO., LTD.

TECHNICAL DEPARTMENT
JAPAN

HULL No. H 1389N1390A DRAWN BY K. TANABE

TYPE 5DK-20
CHECKED BY
LIST No. QE31317020FZ
DATE Aug.10,2005 APPROVED BY M// 8 -
REVISION

ADK20-421 ( -3
?
I 1 (1/3)

--
. ~ . ~
 LlST No.
DOCUMENTS LIST Q ~ 3 1 3 1 7 0 2 0z~

I
FOR

NAME
- PLAN
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 TEST RECORDS O F THE DIESEL ENGINE
AT SI-IOP. TRIAL
. . F4- e)L&Rag$&!i$g's

ORDERED BY :
1 , . 2. , : MESSRS. HMJONG-ZHONCHUA SHIPBUILDING(GROUP)CO.,LTD.
. . , . . .
DEUVER. TO : : .
. ...R'4.g. , . .
h T h p i - : DITTO. SNO, 1 3 9 0 h
ENGINE TYPE :

B M g d : 5DK-20
ENGINE NO. :

RECORDS O F S H O P TRIAL

R U N . N l N G T E S T

E W E
O V E R H A U L INSPECTION
9 - Nov. - 2005

DAIHATSU DIESEL M F G CO.. LTD. CHECKED BY:

MORIYAMA FACTORY. SHIGA
QUALITY CONTROL DEPT. APPROVED BY: yy- &,

JUDGMENT

APPROVED BI:/&ai-amy
 SPECIFICATIONS z3!2€3 L

DIESEL ENGINE ?=-f-?-lL#bt

.... . ......_.............
glnr madoi G; rype
, -. --- - . .- .
@mfl-& ' ,J,Z
~-CYLIPd ~ wonclne,
l
.L ~ ( D I ~ . Y . ~ ~ ~ ~ $ L @ P ~ - . ? / L & I Y ! . 5DK-20 , ..............
,
..........
lhb
.....
Nu. 8
--- %........ DK52021378 , DK620Z1379
....... - . DK520Z1380 _... . . . . . . . . . . .
ted out(~111 R rwolu~ion ZE&WIZiiJ'B&
-. ...... , . .... . .
: " cvllnder.8ure&
- 574 kW
.........
( 780
.,..
) PS,
...... 720-. mic-'
............... . ,

0
w>y-*\ iag.fi% 5 \ 200 rnm . 300 rmn
A. C. GENERATORS mi%%tt",
. .
........ -- . . . . - -..--- - ..
11iuiactu;c.
.. . . . . I . . .
' i!?Qf:Bi .. _ NISHISHIBA ELECTRIC CO.,LTD.
. . , made
............
, CYclcV I 530
t
. --
.. . . . - . . --- - . 662.5
. ' KVA
..
' ..( __i_&__
' )I'!W.
. G.O. . . ,132 . . , ,
itw we, ~ u r &hP.F. I . $ 3 450 V ,. 850 A:,: *,80 % , :;
I ,

, ....... - ,ACCESSORY
..................... ..................................... WE'Bi% '
,,. .,.

. , . , ........ M f i ....................
( .
Type %% Spec. . .IL.#
........... , . .......
,
. ....
urbu-chsrgcr C35206 DO1 110
.
3 gj!!i 1.
..
1 .H .I. -. RH143
.......-
TO3208 1~163608
.
,

Air coolcr --
9 .... D.D.K:
%.................... OH-3QtIZ-1
.........................
,, . .
Governor D ~ s i g nNo 105856-5381. ,
ZEXEL RHDG-MC .......... . . . .
3 iBL% Serial No. 1
59039307 59039306 159039305 1
..
SURVEYOR'
....
s MARK
--- .
3E I%
. . . . . . . . . ,.
...... ... -. ..... --- ...............................
No.i Enp. N o 2 Eng. .,... -, ..,... No.3............
Eng. . 7-

a, ABPQA
,

ABPQA & AUPQA

. J @ N0.DK5207,1300
@ N O . D K ~ ~ O %379

.--- - . . . . . . . _ -.
9-11-05
. . .- -.
9-11-05
..
.
... - .- ...
9-11-05
... . . .
.
. . . . . .
ABS 'IYPE APPROVAL ABS TYPE APPROVAL A85 TYPE APPROVAL
A.C,Generator KO 649296 KO 649296 KO 649296
% N0.61Y904AIB-1 N0.619904AlR-2 N0.619904A1B-3
17-0CT.-05 17-0CT.-05 17-0CT.-05

VALVE ADJUSTMENTS
... .. ..-......
% % .
..
~ ~ ~~
&
OPOII (bcroln
ila ~ t 4 .s .. q. .) . . . . Dnprmn ..,, . . . 30 . . . . ., . . .Top
clsarsncr
.Y7.l.>lbi%;
.. ..
r
Ii~Lrkev d v e Close (sRc: B.U.C) '
Oa 35
%!%ii- F , ,(TR&&I.................. , ...... ,. . . .
Injrclion 18rm~1m
Clcarancc. It9 1% rnm 0.31 W"ZblKn
, .

Lxhaust vdve
%%* . . . i
..........
Bseinnlnn uFPu~uplne(buh~reT,D.C.)
Clrar~ncc VJ 119
,
.
1)errea
mn
. . .
147
. .
0.31
10
,. .
Firine ordcr
j$d<{am I.. .
1-3-5-4-2
.

'
Cluck winc
~ l i & l i a nulcrnnk rola:ioc
l%:l lilill
[Vlcvcd h.w Ule flywh:cU

( EOK'J~J(774W1M1&i5T)
7z7E;

1 'd 1 1 6 b 'ON Kmlw~lfi-~LWh

 -
l.ub. uil
lemperaturt
--
Couling
u'aler
tenlpernturc
-...-.- -

Exhnust gu
telllperaturc
 DAlHATSU DIESEL ENGINE Nu. 2 E s
E m Z M k W ~ & I~YPE ~ ; 5DK-20
R U N N I N G TEST DATA SHEET (1/2) ~ I S X 4& 5 680A,
~ E n s N o . 1pK520Z1374
The kind oilonrl
, ,
Tins af recording

-,--,G ~ n ' e n t o rout.----,

.~
Fuel consbrnpllon
( ~ c c o r d 4 t cwith 150 j

Lub. uil Dresswe

P ~ l a ! l > g ~ r n ~ ~.-
. -,--
. .

.....

M u i n i d n combuctiui~prernre

~S-4~1 .
' l l b b 'ON ! @ ~ l ~ ~ l l ~ - ~ ~ OK6Gkli
l l ~ b05 B l $ 9 0 0 2
. ~

.
.........................
~ ~
.......................
LuL, oil
Iempmtur,

Cooling
wotsr
tenperalurr
-

bhaust gas
temperalure

i '

1 'd l l 6 b 'ON
DAIHATSU DIESEL ENGINE N o , 3 ENG,
n p :~ QJ-20
RUNNlNG TEST DATA SHEET (2/2) E~IOIW,
5 7 4 k W C ~ a o P s j ~
450" 6004 Eas.No. :OK520Zj.3&

Protecthg Device ~ c s ~

Over speed
blov)

................... .......... I I-.. .- . .

 IY
M E TEST SHEET OF AUTOMATIC CONTROL DEVICE
B%#Ia3;ea%s

Q,,,, I Eng. Stop

TEST RECORD
. m J a t * a I*

NlSHlsHlEA ELECTRIC CO., LTO.

No. 1000. HAMADA. ABOSHImKU.HIMEJI-SHI. JAPAN

&@!PI &it#* m=Flz %B 1000 SMI
TEL 0792-71-2353
FAX 0792-71-2416
 INVOICE FOR TEST RECORD
i i t @ & ~ * % + t : % m

Messrs.
ZSXZ DAIHATSU DIESEL MFG. CO. , LTD.

Ship No. Work No.

86' B H-139OA (HUDONG-ZHOUGHUA) ISBE
Subject
a"a 4 Generator

Job No. Record No.

%iEBE 61 9904 @EB%

Date
t+

C e r t i f i c a t e No.
Output & Use
~h%kUH% *
Quantity
ii3 ZMSB%
3 S % % a
530kW
NO. 1 (NO. 2) (NO. 3) DIESEL GENERATOR
 TEST RECORD 3%&@% P-1/3

* M%%E&
'7
Customer & ik DAIHATSU DIESEL MFG. CO.,LTD.
Article % % 65 530 kW SYNCHRONOUS GENERATOR
Test No. %%%% 619904AlB-1,2,3 Ship No. #&% H-1390A (HUDONG-ZHONGHUA
uUse
,
Quantity $ 3 Standard Specification %.% ABS CO. LTD.)
R A T I N G d.%
Type,Form @% NTAKL-VC (Brush-less Excitation System) Phases @ & 3
No. of Poles & 10 P Speed H 720 mid' Frequency 60 Hz
Voltage 8%? 450 V Current % ifi 850 A Power Factor a$ 0.8
Servise ZZ;P$O%% CONT. Class of Insulation & ~ D S BF
Excitation 165V 67A Excitation of A.C.Exciter $&EBB&BB 70 V 8.0 A
Type of Enclosure %BWI,i$ Enclosed Ventilated Machine with Air Filter
Exciter iEb%% 16 kVA Permanent Magnet Gen. 1.4 kVA (IP23)
Evaluation : Acceptable
*Jd:Ei

3. CONVENTIONAL EFFICIENCY %.&%$ (%)

Output ffl h 1 25 1 50 1 75 1 100 1 125
Power Factor 0.8 1 90.9 1 93.9 1 94.4 1 94.3 1 93.8
a$ 1.0 1 91.6 1 95.0 1 95.9 1 96.1 1 96.0 CT Secondary Wdg.
-
ZR% =R*B
5. OVER SPEED TEST %%&ES%
120 % Speed H&%L!% 864 min? 2 min. 9 Good i
3
6. MOMENTARY OVER LOAD .TEST@E%3B%S%
150 % Current %% 450 V P.F.2% 0.6 2 min. 9 Good &

8. MEAN VALUE of AIR GAP Unit --- mm

No. 1 Gen. 2.25 Ex. 1.81 No.2 Gen. 2. 30 Ex. 1.18 No. 3 Gen. 2.22 Ex. 1.84
Tested by %%% P-fiwl, Approved BY
- Date OCT. -15,17- 2005
u
N I S H I S H I B A E L E C T R I C C O . ,LTD
mEE&RXi%Et
 Test No. %%%% 619904AlB-1 2 3

nce Method
E:Embedded Temp. Detect. Method KdE@%& ( ):Reading Value %.3+@

lo. C H A R A C T E R I S T I C T E S T % % 11. T R A N S I E N T
CHARACTERISTICS
AND VOLTAGE
WAVE-FORM.
@RmE%%mzFzEE%
-1 Induction motor direct start

a. Presumptive transient
voltage regulation
(at 80% starting kVA o f
generator capacity)
%W%REPZ@$l
( E %g%@&O 80 %
%% kVAR)
14.x
b. Recovery time f@.%@h?
0 . sec. @
-2 No-load voltage wave-form
%BR%Frn%%
Deviation factor %%Sb'@
2%

(Remarks)
A. V. R. No. 619904ElC-1,2,3
 Criteria T a b l e

530 kW SYNCHRONOUS GENERATOR QB No. 619904AlB

Test Item Criteria
Winding Resistance at 115°C Within +lo% to designed
designed value (PMG. 0.450) value
(GEN.A r m . 0.0084) (GEN. Fi. 2.07)
[Ex. A r m . 0.170) (Ex. Fi. 6.89)
Insulation resistance Arm. not less than lOOMQ jactory standard Good
Fi. not less than 5 0 M Q
Dielectric strength test No-injury
Efficiency (at full-load,PF 0.8) Not less than - %
Set position of Static exciter Refer to item 10,ll
Over speed test No-in jury ABS rule(2003) 1 Good
( 120 % soeed for 2 min.
Over load test No-in jury
:150% current,P.F.4 . 6 for 2 min.
Vibration Not more than 20/1000mm JEM 1274-1997
Air gap Within f15% to designed JEM 1274-1997
(designed value Gen. 2.5 mi) value
(designed value Ex. 2.0 mm)
Temperature rise Not more than insulation ABS rule(2003)
class F rise
1 Good
Load characteristic test

Voltage adjustable range test

Voltage regulation within ABS rule(2003)

Not less than 5 % JEM 1274-1997

I Good

Transient voltage regulation Not more than 15 % JEM 1274-1997

(at 80% starting kVA)
Recovery time Not more than 0.6 s
(-3.0% final steady-state

Construction inspection
voltage)
No-load voltage wave form Not more than 10 %
No difference from
J E M 1274-1997 1
Good
Factory standard Good
aporoved drawing
 ...................................................

SPECIFICATIONS
FOR
MARINE DIESEL GENERATOR ENGINE

(530kW A C G x 720rpm 3setslship)

, ...................................................,

HUDONG-ZHONGHUA SHIPBUlLDlNG(GROUP)CO.,LTD

74500DWT BULK CARRIER

DAIHATSU DIESEL MFG.CO.,LTD.

TECHNICAL DEPARTMENT
OSAKA JAPAN

SHIP NO. I H 1389Al H 1390A I DRAWN BY I K. TANABE

ENG.MODEL 5DK -20

CHECKED BY
LIST NO. QE413208lOF.Z

DATE 2. AUG. 2005 APPROVED BY / -

REVISION
I . 1 Rules and Regulations

The diesel generator engine will be complied with the requirements of the following rules and
regulations of the latest issue.

1) American Bureau of Shipping ------ ABS + ACCU

2) Compliance for Engine International Air Pollution Prevention with Marpol Annex VI
3) Japanese industrial standard JIS
4) Miscellaneous
The other not specifically mentioned in this specifications will be manufactured on the basis of
manufacturer's quality control standard.

1.2 Conditions

hi^^^^ arnb.temp. max.45"C

.------...------

relative humidity max.85% barometric press.100kPa

Generator & El.motor ---- amb.temp. max.5O0C

General power source --- AC440V 60Hz 3phase

Control power source AC 220V 60Hz 1phase and DC 24V

Starting air source ------- 3.0MPa (30kgf/cm2)

Control air source 0.7 - O.9MPa (7 - 9kgf/cmZ]
Steam source ------------- 0.7MPa [7kgf/cm3saturated

1.3 Installations

Diesel engine will be rigidly coupled to the generator and placed together on the common bed of
steel plate fabrication.
Diesel generator set should be epoxy installed onto the hull structure.

1.4 Pipe connection flanges

Pipe connection flanges which are connected to the shipyard's piping will be provided of JIS
JIS counter-flanges will not be supplied by Daihatsu.

1.5 Name and caution plates

The plates will be written in English

Unit is SI system.

1.6 Painting

After coating with anti-corrosive paint in accordance with manufacturer's standard, the finished color
will be painted with customer's instruction as follows.

Engine and accessories Munsell 7.5BG712

Hot surface over 100°C --- Aluminum heat resisting paint

1.7 Plans
Approval 0 copy
Working plan ------- 8 copies for first vessel and 8 copies for each next vessel
Final plan 5 copies for first vessel and 5 copies for each next vessel
Certificate 1original and 2copies
1.8 Fuel oil

Heavy Fuel Oil (hereinafter called HFO) 600cSt/5O0C

Marine Diesel Oil (hereinafter called MDO) 1.5 - 6.0cStI40"C

HFO specification

density 115'C (kgll) j I 0.991 '1 I sulpher (wt %) j 2 5.0

flash point ("C) j 2 60 1 vanadium (mglkg) 1 300

pour point ("C) :5 30 aluminum(mg1kg) j 5 30 : '2

water (vol %)

Notes for HFO pre-treatment

- j S 1.O : '2
CCAl : '3

'1 : Upon deliberation with separator maker.shipyard should apply the best centrifugal
separation system.
'2: To be eliminated as much as possible before engine.
Contents of aluminum and water are to be eliminated less than 1Omglkg and
0.2vol% respectively.
*3: CCAl means the Calculated Carbon Aromaticity Index.

1.9 Fuel oil when engine starting and stopping : HFO

1.10 Notices for operation

The engine.together with proper external system arrangements.can be operated on fuel of

viscosity up to 600cSt at 50°C ,still:

-fuel oil viscosity at the inlet port of engine should be kept to 1 4 k 1.5cSt(65+ 5sec.R.W.NO.l)
in any case.
- Recommendable low load on HFO burning is 20%(1 10kW) in generator output.

1.1 1 Recommended lubricating oil

System oil API service grade CD SAE30 TBN30 to 40

Governor oil ----- same as system oil SAE30

1.12 Fluid holdings in engine

Lub.oil : LO cooler 22 lit. + LO tank 740 lit. = initial filling quantity about 762 lit.
(engine in running condition 70 lit.)

Gov.oil : 1.3 lit.

C.Water : engine 70 lit.

air cooler 15 lit. + LO cooler 11 lit.
 , .
2. PRINCIPAL PARTICULARS

2.1 Type of Engine vertical in-line 4-storoke direct injection trunk piston type
with exhaust turbocharger and air cooler

2.2 Direction of rotation ------ clockwise as viewed from generator end

2.3 control start : remote, automatic and engine-side

stop : remote, engine-side and emergency-automatic
speed adjust : remote and engine-side

2.4 Starting method ---------- air motor start

motor required compressed air 0.6 - 0.9MPal6 - 9kgf/cm21

2.5 Cooling system ----------- central cooling (36°C LT-FW)

2.6 camshaft built-up type

2.7 Engine data

Engine model 5DK - 20

Quantity of cylinders 5

( Cyl.bore x Piston storoke \ 200mm x 300mm 1

I Engine rated output 574kWl78OPSl 1
Engine speed 720rpm

Mean effective pressure : 2.03MPa 120.69kgfIcrn7

Mean piston speed 7.2mls

Maximum pressure 5 15.7MPa (160kgf/cm2]

- ~p

Overload capacity 1 10% for a hour every 12 hours

Required combustion air : 3750m1/h at 25%

1 Exhaust gas volume 3600Nm3lh 1

( Exhaust gas temperature j about 370% at TIC outlet I
Permissible exh.gas
back pressure j
1 Lub.oil consumption 1. l g/(kWh)(0.8g/(PSlh)]estimated value at full load I
1 Fuel oil consumption '1 : 20lg/(kW h) +5% 1 148g/(PS/h) +5% I 1

'1 Fuel oil consumption is based on the engine output(kW) using fuel lower calorie of 42700kJlkg.
under 100% generator load, on condition that the engine drives each one of LO pump and CW
pump.
2.8 Type of generator synchronous self-exciting brushless self-ventilated drip-proof
bracket type

Maker NlSHlSHlBA ELECTRIC CO.,LTD.

2.9 Generator data

The full detail is given in documents of generator maker.

Generator capacity j 662.5kVA

Generator rated output j 530kW

I Power factor 0.8 lagging I

Voltage Phase Freq. AC 450V 3-phase 60Hz

Rating full load continuous

I TYpe self-exciting brushless I

I Cooling self-ventilation air cooling type I
Insulation class F

Enclosure IP23

I Bearing self-lubricating double sleeve bearing I

1 Junction box IP44 with cable glands I
2.1 0 Generator supplier Daihatsu

2.1 1 Quantity of DIG set Three(3) setslship

2.1 2 Speed governor

When full load(kW) of generator is suddenly taken off or, when the load(kW) of the generator is
suddenly thrown on by steps of 0+ 45- 85+ 1OD%, the speed variations will be come to within 1 0
% momentary and within 5% permanently.

Momentary speed variations with load changes as above are to be stabilized and in the steady-
state condition within 5seconds.
The steady-state condition is considered to have been reached when the residual speed variation
does not exceed + 1% of the speed associated with the set load.

IMPORTANCE: Shipyard should offer the Daihatsu the electric load analysis.
And Daihatsu should offer the classification society that the Shipyard's electric load
analysis is ertified as not to exceed the loading steps of 0 - 4 5 - + 8 5 - 100% in any
case, and get the special consideration of the classification society.
3. ENGINE FITTINGS

Each one(l)set is to be attached to the engine except mentioned specially

3.1 Speed regulating system

Governor Bosch made type RHD6 - MC

Hydralic type with speed adjustment and speed droop control

Governor motor ----------- power source DC24V . Speed changing time 8 - 1 2seconds/Hz

Governor spped control unit --- Installed on MSB.

Input: AC220V 60Hz 1 phase. Output: DC24V

3.2 Fuel oil system

Fuel oil final filter ------- 200mesh notch wire duplex type with manual blow off device

Press.relief valve at oil return pipe end

Pressure damper ------- at oil return pipe end and inlet side

3.3 Charge air system

Exhaust turbo-charger ----lshikawajirna-Harima Heavy Industries Co..Ltd, made

radial turbine type with the cleaning device of blow side and turbine side
type RH 143

Air cooler with fin type fresh water cooled

type DH39HZ

3.4 Starting air system

Starting operation valve -for manual start at engine-side

Air motor turbine type

Regulator and relay valve --- with starting magnetic valve(88V), safety valve

Starting air strainer Y-type. 300 mesh

3.5 Lub.oil system

L.O. suction strainer ----- punching board type built in L.O. tank

L.O. pump engine driven gear type

13.4m3lh x O.6MPa 6kgflcm' 1

L.O. cooler multi-tubular type fresh water cooled

1 2m2

Thermostatic valve ------- wax type with hand operating bypass device

L.O. relief valve setting pressure 0.4 - 0.5MPal4- 5kgf/cm21

L.O. filter 200mesh notch wire duplex type with manual blow off device

Turbocharger
L.O. filter ----- 280mesh notch wire duplex type with manual blow off device

L.O. tank incorporated in common bed with overflow port

capacity 740 lit.

L.O. priming pump ----- motor driven gear rotary type

pump 2.5ma/h x 0.2MPa
motor 0.75kW A C 440V 60Hz 3phase 1.6A
TEFC(IP44) class B insulation

L.O. hand pump wing pump

L.O. bypass filter port ---I 5 A

3.6 Cooling water system

HT-FW pump engine driven centrifugal +qpe

30ma/h X 25mTH

3.7 Safety devices

Crankcase relief valve --required quantity by the classification society

3.8 Sundries

Leakage oil tank --------- capacity 1 lit,

Flywheel turning
device hand operating ratchet type

Flywheel guard steel plate fabrication

Exhaust manifold
cover steel plate fabrication with inside lagging

Common bed welded steel plate fabrication

Jack bolts screwed into the common bed

3.9 Local gauge board (consists of following gauges)

Tachometer mechanical type for engne speed

Press.gauge bourdon tube type
each one(1) of FO. Charge air, LO, Turbine LO, HT-FW. LT-FW and
SA

3.10 Local thermometer liquid filled glass stem type

- Fuel oil ----engine inlet
- Charge air -----intake manifold
- Exhaust gas --each cylinder outlet and TIC outlet (YAMAZAKI made)
- Lub,oil cooler inlet and engine inlet
- HT-FW ---------engine inlet, engine outlet
and nozzle cooling common outlet
- LT-FW LO cooler inlet

3.1 1 Control system

Remote start magnetic valve (88V) ----- DC24V 5.5W

Fuel control magnetic valve (88L) DC24V 15W

for fuel control in process of starting

Remote stop magnetic valve (5V) DC24V 15W

for the fuel shutdown device of control system and
safety system

FO injection pump
fuel-cut magnetic valve ( 5 s ) DC24V 15W
for each cylinder fuel cut devices of safety system

Handle switch (HS) remote start stand-by

Turning safety switch(TC1 for remote start stand-by

Speed sensor(TS1 pulse sensing type for engine speed

Speed switch unit signal output for Low speed and Over speed
(installed into Engine local control panel)

L.O. priming press eng.starting interlock and alarm(below 0.03MPa off)

Automatic LT-FW valve 2-way valve operated with LO pressure

Start switch box(START & C0S)-----------with remote and local change over switch

3.1 2 ONIOFF switch

Safety stop switch (normal-open dry contact)

--------- L.O. low press. 0.20MPal2.0kgflcrn~

- ---- overspeed 112 - 115% by Speed switch unit
-------- CFW high temp. 90°C

Alarming switch (normal-close dry contact)

---- - F.O. leakage from injection pipe

(high level alarm in the leakage oil tank)
------ Turbocharger L.O. low press.
.-- 0.20MPa[2.0kgflcrn'l
3.13 Analogue sensor for remote displaylalarrn

3.1 3.1 Pressure transmitter DC 24V output 4 - 20mA

> -
measuring point I scale range j normal operation alarm setting j qtyleng

LO engine inlet I 0 - 1.OMPa I 0.40 - 0.50MPa : 0.25MPa low 1

HT-FW engine inle I 0 - O.6MPa : 0.25 - 0.35MPa I O.15MPa low I 1

( Starting air inlet :0 - 4.0MPa : 1.5 - 3.0MPa I 1.5MPa low ! I )

Control air inlet :0 - 1.OMPa : 0.6 - O.9MPa : O.6MPa low I 1

3.1 3.2 Thermo-resistance bulb P t l 00 R1001RO= 1.3850

I measuring point I scale range I alarm setting : q 'tylengine

Exh.gas turbochager inlet : rnax.70O0C 600°C high : I

LO engine inlet : max.200°G 65°C high : 1

I HT-FW engine outlet : max.200°C 85°C high : 1

Generator stator windings : max.20O0C 140°C high : 3+ 3(spare)

 , \ !
4. Separate accessories

Accessories stated below will be included in the supply scope of Daihatsu, but are to be
installed by shipyard.

Expansion joint stainless steel bellows size 250A x 300A

for exh.gas turbine outlet
( 1 pc.lengine)

Auxiliav starting air reservoir ------------------ 150 lit. 3.0MPa~30kgflcm21

( 1 bottlelship)

JW preheater unit electric heater:AC44OV.3phase.60Hz.l OkWx2

pump:6.0m3/h
motor:AC440V.3phase.60Hz,O.75kW.IP44.insu.F
paneMP44 with cable glands
( Isetlship)

Engine local control panel wall hanging drip-proof type(lP44) with cable glands
power source AC220V 3phase 60Hz IDC24V
panel is to be installed near engines
( 1 panell3engines)

L.O. priming pump starter wall hanging drip-proof type(IP44) with cable glands
power source AC 440V 60Hz 3phase
starter is to be installed near engines
( 1 panell3engines)

5. Spare parts and Tools

Spare parts and tools will be supplied in accordance with Daihatsu standard practice which is
satisfied the requirements of classification society.

Details will be described in "SPARE PARTS LIST" and "TOOLS LIST".

6 Instruction for DIG set installation

6-1 Exhaust gas system

A section of exhaust gas bellows is supplied to protect the turbocharger from both thermal expansion and
vibration from engine, but not to absorb the distortion and weight of the structures on hull including piping
and thermal expansion.
The exhaust gas piping should be fixed immovably with hull part as close as expansion joint on
turbocharger.
The load from the exhaust piping on the hull can damage the turbocharger and exhaust gas bellows.

6-2 Starting air system

1) The air supply pipe should be drained at the lowest part of the hull side.
2) The piping of hull side should be flushed before initial running.
3) The air filter at starting air inlet should be disassembled and cleaned at least following period
Before first running
Afler official test
Before sea trial
Before ship delivery
4) Dried air (0.7-0.9MPa) should be supplied for control air.
 -
lv mE

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'OR PREL l M INARY REV. NO. DESCR l PT l ON DATE
- REV.
- -
AWR.

CUSTOMER
DA I HATSU D I ESEL MFG. GO. , LTD.

D l ESEL GENERATOR
 I N D E X
S. NO. H-l389A/H-1390A

USE NO. 1 (NO. 2. NO. 3) D l ESEL GENERATOR

DRAWING NAME DRAWING NO. REMARKS

SPECIFICATION 61 9903AlB

SHAFT 3GT1556

ASSEMBLY 3613854

TERM l NAL ARRANGEMENT 2GT0036

OURS 61 9903/4A1 B
 32
SPECIFICATION OURS 619903A1 B

USE NO. 1 (NO. 2. NO. 3) DIESEL GENERATOR SH l P NO. H-1389A/H-1390A

SET/VESSEL 3
PART l CULARS CODE ABS
I A. C. GENERATOR

! A. C. EXCITER

3 RAT ING (CONT INUOUS)

6 LUBR l CAT l NG 0 I L (SELF LUB. )

7 MACH lNE QUANT l T l ES

T (Sec)
d' : 0.24 Td": 0.01 7 Ta: 0.032

8 D IST l NGU l SHl NG PHASES COLORS U: RED V: WHITE W: BLUE

9 PA INTI NG (OUTS IDE) MUNSELL 7.5BG7/2

REVISION 0 1
 MACHINE CABLE GLAND POSITION
(VIEW FROM GENERATOR TO ENGINE) NO.l ( N0.2,N0.3) GEN. G
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1230
2085
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SPACE FOR WITHDRAWAL
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THE AIR FILTER
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j THERMOMETER
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@ 3 2 DRILL 8HOLES

SPACE FOR'REMOVING
THE BEARING BRACKET

ADJUSTING PLATES

@ 16TAPER REAMER 2HOLES M ~ ~ S C R E4HOLES

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(MI 6X95TAPER DOWEL PIN)
ROTOR MASS (APPROX.); 1 7 5 0 kg
 FAN ROTOR EXCITER

F GD2=290kgo rnZ

"X"

M24 SCREW 2HOLES

SECTION 'A"- 'A"

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DETAIL OF " X "

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SHIP NO. TOOL LIST FOR USE
StlS m
VESSEL
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H-1390A

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SKELETON TYPE
TITLE QT. OUTLINE
DIAGRAM RATING
\lO.l-~0.3DIESEL GENERATOR
I I 1O P - ~ ~ O ~ W - ~ ~ O V - ~ O H Z - O . ~ P F - ~ ~ O A
(3)

SKELETON DIAGRAM FOR I I

STATIC EXCITER

3HEOSTAT FOR AVR

SPARE PARTS LIST 1 SL-619903EY1

 SKELETON DlAG RAM _N:619903MC:_!

-
TO ANOTHER AVR TERM.
TAKE CARE CROSS CONNECTION.
C3 C4

MAX.
(9.9A) '
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SET 670

1OP-530kW-450V-60Hz-0.8PF-850A
USE ; NO.l -N0.3 DIESEL GENERATOR
XMARK:SHIPYARD SERVICE
'REMARK' THE CURREWIN THE BRACKETS SHOWS
THE VALUE TO SELECT THE CABLE SIZE.
 CONNECTION DIAGRAM

CROSS CURRENT COMPENSATING CIRCUIT

R S T

i U V W C3 C4 U V W C3

STATIC EXCITER STATIC EXCITER STATIC EXCITER

(N-619903ElC-1) (N-619903ElC-1)

!
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1
H1 H2

220V AC SOURCE
SPACE HEATER
SEARCH COlL
CIRCUIT
220V AC SOURCE
SPACEHEATER
-
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SPACE HEATER
SEARCH COlL

XMARK:SHIPYARD SERVICE

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NISHISHIBA ELECTRIC CO., LTD.
HIMEJI JAPAN REGISTERED N-61 9903E1 C-2
MOUNT P A N E L

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PANEL CUT

LETTERS
 No. BOX No. P
1
SETS PER
SHIP No. SPARE PARTS LIST FOR U S E LIL VESSEL

H-1389A STAT l C EXC l TER NO. 1 -NO. 3 D l ESEL GENERATOR

I QUANTITY I REMARKS
-EM NAME OF OUTLINE
NO. PART
- -
PER 'ER
S€r IES!
- -

RHEOSTAT FOR
1 3

- -

AUTOMAT l C VOLTAGt
2 0 2 REGURATOR (AVRI 1 3

- -

3 9

- -

- -

- -

-
1 REVISION

- -

L -
NlSHlSHlBA ELECTRIC CO., LTD DRAWING NO
1000,HAMADA,ABOSHI.HIMEJI.JAPAN,PHONE:0792.7+2111

%PLEASE INFORM US ITEM NO. NAME O F PART, DRAWING NO. MFR'S

&QUANTITY ORDERING SPARE PARTS. ni*
 INSTRUCTION MANUAL
FOR A C G E N E R A T O R
(NMG SERIES)

NISHISHIBA ELECTRIC GO., LTD.

 CONTENTS
Page
Generator Construction
Connection Diagram
1.AC Generator Construction

1.1 General Construction

1.2 Stator
1.3 Rotor
1.4 Bearing
1.5 AC Exciter
1.6 Sub-exciter
2. Static Exciter
2.1 Automatic voltage regulator
2.2 Voltage adjusting device
3. Operation
3.1 Pre-operation to normal operation
3.2 Parallel operation
3.3 Overall characteristic of generator
and automatic voltage regulator
4. Maintenance
4.1 Maintenance inspection check list
4.2 Maintenance inspection method
5. Troubleshooting
6. Disassembly and Re.assembly Precautions
6.1 Disassembly Precautions
6.2 Re-assembly Precautions
7. Additional Ordering of Spare parts
Disassembly of AC Generator
NO. Part's Name- No. Part's Name - No. Part's Name
Stator frame @ Terminal box Rotary rectifier
@ Stator core a Shaft @ Bearing bracket
@ Stator coil @ Rotor
I coil 0 Thermometer
@ Space heater @ Rotor core @ Oil gauge
@ Embedded thermometer @ Darnpcr winding
Pig 1 . L GENERATOR CONSTRUCTION
 AVR

Fig 1. 2 Connection Diagram

1 . AC Generator Construction

1. 1General Construction

This brushless AC generator is made up, as shown in Fig. 1.1,is composed of the
following parts.
( 1) Generator main body part
( 2 ) AC exciter
( 3 ) Rotating rectifier
( 4 ) Sub-exciter
This generator, a s shown in Fig. 1.2, converts sub-exciter output to direct current
with AVR (automatic voltage regulator), excites the .4C exciter stator while
controlling current, converts 3-phase output of AC exciter rotor to direct current
through the rotating rectifier, and supplies exciting current to the field winding.
The rotor is supported with the sleeve bearing, and the sleeve bearing on the
opposite side has a structure where the shaft current is prevented from flowing by
means of the insulating seat. Also, the rotor is supported by 2 systems; the
double bearing system for supporting the driven side and the non driven side, and
the single bearing system for supporting only the non driven side.
The housing of generator has a drip-proof structure where stator frame, bearing
bracket, protective cover, etc. are assembled into one unit.
The cooling system is a self-ventilation type.

1 . 2 Stator
The stator is composed of stator frame, stator iron core, stator winding, AC exciter
stator, etc.
@ Stator kame
The stator frame is made of a structural steel material. The kame is
manufactured by welding assembly. It is made strong enough with due
consideration for hull vibration, the atmosphere in the engine room, etc., and the
ventilation ducts for sufficiently cooling the generator is also provided.
I n the upper part of stator frame, a terminal box for main and auxiliary circuits
is mounted. Also, i n the lowermost part, there is a drain hole for quick draining
in case water comes in.
W S t a t o r core & stator winding
The stator consists of stator core with silicon steel sheets laminated and stator
winding housed in the slot on its inner circumference side. I t is attached to the
stator kame.
For the stator winding, class F insulation enamel wires are housed in the slot
provided in the stator iron core, and the stator winding is applied with varnish
dipping treatment after the wedge of insulation material is firmly driven in and
securely fixed.
Space heater
To prevent moisture absorption and dew condensation while the generator has
stopped, a space heater is installed on the lower side surface inside the stator
frame.
Resistance thermometer bulb for embedded t e m ~ e r a t u r edetector (Option)
To measure the coil temperature inside the stator core, the resistance-type
embedded temperature sensor may be installed in the internal part of the coil.
This sensor is a 3-wire type resistor whose resistance value is 0 "C - 100 Q .
 In each phase of U, V, W, one ordinary use and one spare sensors are embedded
(6 in total).
@ Terminal box
The terminals for main circuit, exciter circuit (including the sub-exciter), space
heater circuit, etc. of the generator are concentrated a t one place. They are
gathered in the terminal box of IP-44 structure.

1.3 Rotor
The rotor is composed of shaft, rotor core, rotor winding, damper winding, rotating
rectifier, etc.

Shaft
The generator shaft is manufactured with carbon steel forgings that sufficiently
satisfy the Ship's Classfication Standard. It h a s satisfactory strength for the
characteristics of driving prime mover, and is made into the optimum size
considering torsional vibration.
Field coil
The field coil is prepared by varnishing the enamel wires wound around the iron
core. The class F insulation is regarded a s standard.
Rotor core
The rotor core has a structure where the blanked sheet steel is laminated and
integrated by pressure tightening with the core retaining plates from the both
sides.
Damper winding
The damper winding is composed of copper rod winding inserted into the holes
provided i n the circumference of core outer and a short-circuit plate brazed to
the both ends of the winding. It limits voltage drop caused by rush load during
load operation and increases electrical stability of the generator when
unbalanced trouble in parallel operation occurs.
Rotating rectifier
In the rotating rectilier, silicon-rectifying element is connected to be a 3-phase
full-wave rectification circuit. I t is attached onto the shaft.

1 . 4 Bearing
The bearing lubrication system contains the self.lubrication and the forced
lubrication systems. In the self-lubrication system, the bearing is lubricated with
the oil ring.
@ The bearing is made of casting white metal into the back metal of cast iron.
The inner diameter is precisely finished so t h a t the appropriate clearance is
secured for oil lubrication.
@ Bearing bracket
The bearing bracket is made of cast iron. I t is provided with an oil sump in
which the enough oil for bearing can be stored, and structured so that both
disassembly and re-installation are easy.
@ Thermometer
The bearing is equipped with a rod-type alcohol thermometer. Also, the
temperature sensing part is covered with a n insulating tube to prevent shaft
current.
 O Orifice
I n the case of forced lubrication, an orifice for adjusting the oil quantity is
provided on the oil inlet side of the bearing bracket. Also, the orifice is adjusted
i n a factory before shipment so that oil quantity becomes adequate.
@ Oil gauge
The self-lubrication type bearing is provided with a n oil gauge to check for the oil
level and the contamination in the oil sump.
For the operation, apply oil until the oil surface exceeds the red mark position of
the oil gauge.

1. 5 AC Exciter
AC exciter is a rotary armature type 3-phase generator. The stator is k e d and
attached inside the frame, and the rotor has a common shaft with the generator .

1 . 6 Sub.exciter
The sub-exciter is a permanent magnet type 3-phase AC generator. The rotor is
coupled with the generator shaft using bolts, and the stator is attached to the
bearing bracket on the non driven side.
The output cable of sub.exciter stator goes through the cable hole provided in the
bearing bracket and connects to the relay terminal provided in the stator frame of
AC exciter.

2 . Static Exciter
Figure 2.1 is the standard connection diagram of the exciter.
Table 2-1 shows the standard parts List.

Table 2-1 Static Exciter Component Parts

Parts Name Type No. Q'ty
AVR I
Automatic voltage regulator /
VZKUP- 4 A I 1
I , , I Current transformer for I I ,I I
L 1
cross current compensation
VAD Voltage Adjusting device NRV3- 101 1
R S Resistor ! 1

2 . 1 Automatic voltage regulator

This regulator compares the generator terminal voltage and the reference voltage
with each other, and continuously makes a n automatic adjustment of exciter field
current according to the difference of the voltages, thereby maintaining the
generator terminal voltage to the constant value regardless of the amount of load.
I t is also possible to regulate the generator terminal voltage in the range of approx.
f5% of the rated value, using the voltage setting device.
2 . 2 Voltage adjusting device
The voltage adjusting device VAD is a variable resistor used to set the generator
voltage. I t is normally installed a t a n easy-to-operate location on the main
switchboard.
 : ~ ......... ........
~ ~~
~ ........ .........2
~~~

Fig. 2.1 Exciter Connection Diagram

3 . Operation
Before operating the generator, fully check the inside of the generator. Check if
there are any foreign substances, protrusions, loose screws, etc. Also, see to it that
the area around the machine is always kept clean.

3 .1 Pre-operation to normal operation

3 . 1 . 1 Precautions before operation
Prior to operation, inspect the followings and check for equipment and
operational safety.

Inspection & Remarks

Criteria & Methods
Confirmation Items
1.Interfusion of
Remove chips and dust.
foreign substance
2.Electric wire
Check if there are no loose screws
connection part
Ensure that the lubricating oil level
3.Lubricating oil exceeds the red mark on the gauge.
(in the case of self-lubrication)
1M W min. for both stator and rotor
4.Measurement of Using a 500V
windings megger.
insulation resistance

3 . 1 . 2 Operation before generator running

Adjust the resistor for voltage setting (VADhearly to the center (the scale
position) "6".
3 . 1 . 3 Precautions a t the start of operation
1 ) Check for each section
At the start of operation, check the following items and stop generator
operation if a n abnormality is present, and investigate the faulty point.
Be careful not to touch the rotating part by the hand during operation.

Inspection & Remarks

Criteria & Methods
Checking Items
No abnormal noise caused by
1.The sound Refer to Section 4.
interfusion of foreign matter, etc.
when start
is allowed
I n case of self-lubrication, the oil
2. Lubricating ring should rotate smoothly.
condition In the case of forced lubrication,
check for oil flow.

2 Voltage establishment
Since the PMG corresponds to separately-excited power supply, no initial
excitation is required. When the voltage not is established, refer to Section
5 "Troubleshooting".

3 . 1 . 4 Normal Operation
1) Inspection and checking for each portion
When the operation is started, check the following items.
Inspection & Remarks
Criteria & Methods
Checking Items
No-1oad & On-
Note the vibration of a cover, etc.
load vibration and Refer to Section 4.
caused by poor tightening.
abnormal noise
2. Bearing
Note rapid temperature increase.
temperature rise
Check the inside after operation
3. Oil leakage
stops.
Voltage adjustment
The voltage is set so that the rated voltage is generated near the center of
voltage regulating resistor (VAD) (near the scale position "6")in the factory
test. Also, the adjustment range is *5% max.

3 . 2 Parallel operation
When the generator is operated in parallel with other generators already in
on-load operation, always use the following method for smooth and careful
operation.

3.2.1 Putting into parallel operation

1) Operate the prime mover governor and adjust i t nearly to the frequency of
the
generator intended to parallel with the bus bar. The difference between them
should be within approx. 0.2 Hz (the synchronism indicator pointer turns once
per 5 seconds). This is the recommendable value for easy operation and
paralleling without giving large shocks to the generator.
 2 ) Ensure that the difference of voltages between the generator for paralleling
and the bus bar is within 10 V. If the difference is large, the circuit breaker
may be tripped due to no-load current after paralleling, or abnormal voltage
may be generated in the field circuit and cause field circuit failure.
3 ) Make fine-adjustment of the governor and synchronizing, checking the
synchronism indicating lamp or synchronism indicator, then throw in the
circuit breaker.
[CAUTIONS]
(a) In the synchronism indicating lamp, the phase agrees when the center
lamp goes out and the other two lamps reach the maximum brightness.
(b) In the synchronism indicator, the phase agrees when the pointer comes
just above the center (zero hour point of the clock).
(c) When the bus bar side load significantly fluctuates, i t is difficult to
operate the governor to make the synchronism indicator stand still a t the
synchronous point. If the indicator pointer angle deviates zk 10 degrees
or more from just above the center, be careful not to turn on the circuit
breaker.
(d) In expectation of the circuit breaker turn-on time, start the operation to
turn on the circuit breaker before the synchronous point comes, and throw
it on just a t the synchronous point. I t is the correct method. In
particular, be careful with a manual circuit breaker.

3 . 2 . 2 Electric power sharing adjustment

When synchronizing is completed, control the bus bar-side generator governor
to decrease the speed, minding the eequency, and control the synchronized
generator governor to increase the speed. The load is gradually shifted and
shared.
3 . 2 . 3 Reactive power adjustment
With the load balanced a t the load-sharing ratio of each generator, check to see
if there is no significant difference in generator power factor and current ratio.
Normally no adjustment is required, but when a substantial differential is
present, carry out fine-adjustment according to the following procedure:
With VAD of the generator in lagging power factor down and that of the
generator in leading power factor up, adjust so t h a t t h e power factor becomes
the same.
3 . 2 . 4 Separation from bus
When the generator in parallel operation i s separated from the bus bar, follow
the procedure described below.
1 ) Control the governor of driver for the generator to be paralleled off to
decrease the speed, and control the governor of driver for bus bar side
generator to increase the speed. The load of the generator to be
~ E p a r a l l e l e dis shifted around zero.
2 ) When kW has been reached nearly " 0 , trip the parallel-off device circuit
breaker.
3 . 3 Overall characteristics of generator and automatic voltage regulator
3.3.1 Static characteristics of automatic voltage regulator
The static characteristics ofAVR used
for this series of generator are as shown
in Fig. 3.1.

--
3
a.
6
u
>
6

0 450V I n w r voliage
Fig. 3.1 Characteristics of AVR

3 .3.2 Overall characteristics of generator and automatic voltage regulator

The generator no-load & full load saturation characteristics are as shown in Fig.
3.2 1 and 2. The field current characteristics A.B controlled with AVR
characteristics (Fig. 3.1) are superposed on them.
Now, assuming that the generator is
operating by the rated rotation with 1 No-load sa~urarioncurve
no load, the generator terminal
voltage becomes voltage VO a t the
intersecting point B ofAVR output
curve and no-load saturation curve
for setting. If the load is increased
here, the saturation curve moves .-
to the direction of 1'. Assuming
that the exciting current (equal I :
to AVR output current) does not I, ''
increase remaining I'B,the generator
-
voltaee lowers to VL. However.
T:
I 8 I'D i '.\ Field c u r r e n r
since AVR has the characteristics
Fig. 3.2 Overall characrerirtic of A.C. generator
shown in Figure
- 3.2 A-B, it detects
micro changes in voltage caused by
load increase, increases the exciting current up to I'B to reduce the difference
f?om the reference voltage (formed inside AVR) to zero, and maintains the
generator terminal voltage a t the value B" .
Thus, the generator voltage is maintained a t a certain point on the curve A-B,
whereas the load increases and decreases. Also, if curve A'-B' is vertical to the
voltage axis, AV = 0, and the voltage variation becomes zero. On the contrary,
if the angle formed by the voltage axis becomes small, the voltage variation
becomes large.
For our generator, the variation is adjusted to approx. f1%, considering the
stability during operation. However, when parallel operation is performed, a
reactive compensating circuit is provided and the voltage is adjusted so that it
4 . Maintenance Check
It is advised to frequently carry out the maintenance inspection of a generator.
Periodic maintenance inspection extends the Lifetime of a generator.
4 . 1 Maintenance inspection check list
Interval Maintenance 1 Refer t o
Daily 1. Check bearing
- L.O.condition
- oil,ring
- nolse
-vibration
- tempenlure
2. Check electric circuit
- Earth fault by earth lamp
3. Check loading condition
- Voltage, output kW, current
Monthly 1. Check insulation resistance
Caution: Before checking insulation resistance, disconnect and earthed
the ldadr from A.V.R.
I 2. ~ o ~andt s nuts I
I Tighten all bolts and nuts. I
3. Check ventilation openings Refez t o separated
Check air intake opening and its air idler, clean or replace the filter, a i r m l e r manual
i l neceirarv.
~~ ~~~

Every 6 1. Change lubrication oil and clean bearing(s).

rnontllly At the same time, check lilting or seating o i bearing
;
I
2. Clean generator
inspect generator winding and air I i r e r i ior dirt, dust and ail and salt vapor
accumulation.
i
Blow out contamination by dry and oil free compressed air.
Wipe ofraccumulated vapor by a lint iree cloth and adequate solvent
3. Check electrical connection 1
- Inspect far loose electrical connection
- inspect cracked, frayed, or oil soaked insulation.
Tighten or replace as neccerrary.
4. Check static exciter
-Check all wirs and cables l o r frayed or damaged insulation.
- Check all conneclionr t o b e sure they are tight.
- Remove cover and remove dirt and dust by lowpressure moisture-free
compressed air or wiping with a clean cloth.

4 . 2 Maintenance inspection method

Maintenance inspection of each part should be carried out smoothly with a
correct method.
4 . 2 . 1 Temperature rise
Equipment temperature rise is one of the effective means for judging the
absence or presence of nonconforming portions.
Referring to the following table, check the temperature a t each section.

Table 4.1Allowable Temperature Rise Limit (Ambient Temperature 45'C)

Measurement Allowable Temp.

Equipment Place
Method Rise Limit
Armature winding Resistance
95
(Class F insulation) method
Rotor winding Resistance
95
(Class F insulation) method
Thermometer
Bearing 4 5
method
4 . 2 . 2 Rectifier check method
For the silicon rectifier, use the resistance range of "Tester" and check
according to the following procedure.
1 ) Remove the lead wire to the field winding connected to the rectifier stack,
either one of the DC side protecting resistors, and two of the three AC
exciter output lead wires.
If this is not done, the measurement cannot be made since it is affected by
the resistance of field winding and exciter winding.

2 ) Rectifier acceptability should be judged according to Table 4.2 below.

Table 4.2 Rectifier Acceptability Judgement Criteria

Polarity

Reverse

4 . 2 . 3 Air gap measurement

Unbalanced air gap (stator & rotor iron cores) causes abnormal vibration of
the generator and worsens its electrical characteristics, resulting in shorter
service life of the machine. Also, such unbalance is attributable to loose
mounting bolts, base strain, depression
caused by a worn bearing, etc. Sraior
When unbalance exceeding the specified
value occurs, be sure to adjust the gap as
well as the centering. S O O K io
measured
The following is the air gap measurement
procedure:
1 ) Prepare a clearance (gap) gauge.
(Preferably 300mm to 500mm long)
2 ) Remove the generator cover. Fig. 4 . 1 Spoir lo bc m e a l l r e d for g a p
3 ) As shown in Fig. 4.3, measure 4 spots
on the circumference of a circle.
4 ) Check if the difference between the maximum and minimum values of gap
falls within 20% of the average values of the gap measurement. Adjust
the gap if it exceeds the above value.
5 ) When a clearance gauge is inserted, always Gap gauge
do it a t an angle of approx. 15 degrees to the
shaft center.
Since the rotor surface is slotted and the
rotor does not have a concentric circle,
the minimum gap may not always be
measured if the gap gauge is inserted ~ i g 4.4
. Inserting m g ~ or c gap gauge
in parallel with the shaft.
4 . 2 . 4 Bearing and Lubricating Oil
Since the bearing and related parts are critical i n particular in mechanical
functions of a generator, maintenance inspection should be carried out
carefully according to the procedure described below:
1 ) Check the oil level and degree of contamination periodically with a n oil
gauge.
2 ) At the start of operation, ensure that the oil ring is rotating.
3 ) When the forced oil lubrication system is employed, check the lubricating oil
for flow and color through the oil sight on the oil outlet side, and ensure that
no abnormal condition is found.
4 Control the temperature with a bearing thermometer.
Check the temperature regularly every day, and be careful with rapid
changes in temperature rise. The bearing temperature 80 to 85°C on the
thermometer reading is the maximum standard during normal operation.
The possible causes of bearing overheat are a s follows. Remove the cause.
a. Low level of lubricating oil
b. Contamination and deterioration of lubricating oil
c. Excessive thrust load is applied due to installation failure
d. The shaft journal part makes intense contact with the upper half part of
bearing due to the failure of direct coupled centering
e. The bearing journal part is rough due to electrolytic corrosion caused by
shaft current
f. Bearing abrasion or wear causes the bearing gap to increase, and abnormal
contact is made.
For the bearing gap, measure the shaft outside diameter and bearing
inside diameter in a few or more places with a micrometer.
Also, the most precise measurement method is such that before taking out
the bearing lower half part, a thin lead wire is placed on the shaft, the
upper half part of bearing & bearing cover are put thereon for tightening,
and the gap is calculated according to the compressed lead wire size.
Calculate the bearing gap by the following equation, and replace the
bearing if the calculated gap is exceeded.

C = T h e gap on the top part

c = D ~ & +o.I or the bearing (mm)
1000 D = Sllaft diameter (mm)
The prerred lead

Bearing
"

Shall

Fig. 4 . 5 Mcmmcrnenf of gap 01 bearing

5 ) Check that the oil ring side face is not abnormally worn and the screws in the
divided part are not loose.
6) To clean the hearing, use a soft waste cloth free from fiber fray and wipe
away
 oil. Also completely mop up all oil sediments, dust and metallic powder if
deposited a t the oil reservoir bottom.

7 ) For lubricating oil in the case of self-lubrication, use the followings or their
equivalents:
Additive turbine oil IS 0 V G 6 8
For lubricating oil in the case of forced lubrication, the equivalent to the
prime mover lubricating oil is supplied. The oil quantity is described in
the completion document for both lubrication systems.

4 . 2 . 5 Vibration
The balance is satisfactorily adjusted during in-shop test. However, when a
significant change occurred in vibration value for some cause, this abnormality
may lead to machine failure; i t is, therefore, necessary to investigate the cause
i n order to take adequate action therefor.
1 ) Cause and countermeasure
Cause for abnormal vibration I Countermeasure
1.Foreign material is attached I Remove the foreign material
I to the rotor
2.Unbalance of electrical load Remove the unbalance of load
to each phase
3.Inequality of air gap Adjust the air gap
4.Miss-alignment Check the deflection of couplings and
correct
1i t within the value 5 1 lOOmm
5.Loosen bolts and nuts / Retighten the bolts and nuts of each part
6.Inproper bearing touch or Adjust the fitting or replace with spare
wide bearing gap bearing
7.Layer short of rotor coil The rotor coil needs to be either repaired
or replaced

4 . 2 . 6 Cleaning of coil, etc.

When lower insulation resistance is identified in the stator or rotor, clean
them according to the following procedure.
Also, when no insulation resistance returns to normal even if the following
work is conducted, contact the specialist or our company.
1) Cleaning agent used
Use non-flammable solvent.
2 ) Cleaning method
Using a clean waste cloth moistened in solvent, wipe off the seriously
stained portion.
The rotor has a bare live part and if dust adheres to such a part, lower
insulation resistance may be caused. Therefore, careful cleaning is required.
4 . 2 . 7 Insulation resistance
The insulation resistance is one of the important factor for judging the
acceptability of electrical equipment performance.
An insulating material will change with time due to heat, moisture,
vibration, mechanical damage, dust or dirt, oxidation, chemical changes by
acid or alkali, independent or combined influence of salt contents, air and oil
or the like.
The degree of deterioration depends on the environment in the installation
place, operating condition and handling frequency. Even if close attention
is paid to this equipment, oxidation etc. may give rise to deterioration.
Particularly, storing the generator without being used is not preferable.
Insulation resistance lowers due to deterioration of the insulator itself,
granted that the other factors are constant.
From this reason, measuring insulation resistance i n a given period of time
is useful to check the insulation condition and to check if that equipment is
suitable enough to use. Therefore, it is necessary to take the followings into
consideration in measuring the insulation resistance.
a .Measure insulation resistance and record the measurements periodically.
(Also measure the temperature and humidity.)
b .Measure this insulation resistance in a hot condition immediately after
equipment stop.
c . When the equipment is subjected to overload operation or exposed to
moisture, water contents, seawater and dust or dirt and always indicates
the low resistance value, measure the insulation resistance frequently.
d .In addition to measurement in a hot condition, measure it occasionally even
during shutdown a t a room temperature. (By measuring it in a cold
condition, the record for influence of moisture and temperature upon its
machine insulation resistance is obtained.)
e . Prior to this measurement, the portion using a semiconductor (AVR, etc.),
such a s a transistor and silicon rectifier, should be isolated from the circuit
so that no abnormal voltage is applied, or short-circuited.
1) Measuring Method
D.C.500V megger shall be prepared.
a . Cut off electrical connections as far as possible.
Normally the connections and auxiliary equipment can be isolated by
opening the power switch, circuit breaker and contactor. However, when
the measurement data is judged to be below the proper value for
operation, detach all cables in the terminal p a r t before measurement.
The equipment insulation resistance may often be higher compared
with the cables, etc. and the measurement value may make no sense.
When the measured value of equipment itself is too low, proceed with
this measurement sequentially to the individual portions while cutting
off the internal connections until the place where the measurements are
lowering is made clear.
b . Short-circuit each terminal of main circuit and exciter circuit, etc. by the
blocks. Ground the terminal group on the non-measured side.
 c . At the initial moment, the insulation resistance tester pointer may
deflect near zero depending on the equipment distributed capacity.
Since the resistance value will increase gradually as the charging goes
on, read the value of megger after one minute.

d . After completion of this measurement, do not forget to disconnect the

short-circuited conductor or lead. (NEVER leave it connected.)
2 ) Judgement of measurements
Statorwinding. 1MQmin.
Rotor winding ... . 1MQmin.

3 ) Countermeasures taken when the insulation resistance is faulty

a . When lower insulation resistance was judged to be attributable to
external conditions, including existence of excessive moisture, dew
condensation water on the insulator surface and conductive dust
sticking, ensure that the insulation resistance has returned to the
satisfactory value after cleaning and drying, then start operation.
b . When the variation &om the previous data has become suddenly large
even with moisture and other conditions taken into consideration,
separate each section to a small part sequentially as described in para.
1)-a above, and check the cause of lower insulation resistance.
4 . 2 . 8 Check for Exciter
The resistors are attached inside the terminal box in the generator upper part:
check to see periodically (approx. once per 6 months) if the screws in the
connection part and mounting part are not loose or broken.
5. Troubleshooting
6. Disassembly and Re-assembly Precautions
6 . 1 Disassembly Precautions
1 ) During disassembly work, exercise the greatest possible care so as not to damage
the insulators and other equipment.
2 ) For a protective board, use a press board 0.8 to 1.6 mm thick.
3 ) To lift up the whole generator, never fail to use the lifting lugs on the stator frame.
4 ) Store the adjustable liners and bolts, etc. used for the stator frame leg in bulk in
the respective locations.
5 ) During disassembly work, check to see if the space heater circuit is OFF.
6 ) When the bearing is taken out from the bearing bracket, check the alignment
marks so that the insertion direction is not confused.
6 . 2 Reassembling Precautions
1) Clean the interior rotor and stator with dry compressed air. Check and maintain
the journal part carefully in particular.
2 ) When the parts in the rotary part were detached, ensure that the turning stopper
is provided securely.
3 ) Clean the bearing and bearing bracket internal sections with cleaning agent or
detergent, such as perchloroethylene, and take meticulous care so that no foreign
matter intrudesinto the lubricating oil.
4 )When the bearing is assembled, apply lubricating oil to the bearing journal surface
and insert the bearing.
5 ) When the bearing thermometer is inserted, apply lubricating oil into the hole for
bearing thermometer.
6 ) Do not fail to remove all protectors or guards used during operations work.

7 . Additional Ordering of Spares

To place a n additional order with us for the spare parts, specify your required parts
according to the following:
1 ) DWG No. in Spare Parts List
As shown in Fig. '7.1, "DWG No." is described a t the right lower corner in the
Spare Parts List.
2 Item No. of the spare parts

Fig. 7.1 Space parts list

 DISASSEMBLY OF AC. GENARATOR

Referring to the attached drawing a t next page, carry out the works as follows.

1.Remove the oil drain plug of bearing bracket and discharge the oil.(In case of the
forced lubricating system bearing, also remove oil supplying and oil discharging
pipes and the oil sight box)
2.Remove the cover @ , and disconnect the lead cable of the exciter (J , K) and the
sub-exciter(Ul,Vl,Wl) a t the terminal on the exciter frame.
3.Remove the connecting bolt of sub-exciter stator @ from bearing bracket , then
install the stud holt(1ength : 200-250mm) to the right and left side bolt holes of the
bearing bracket.
4.Insert the protective board (thickness : about 0.5mm) into the air gap part of the
sub-exciter.
5.Remove the sub-exciter stator along the stud bolt. Incase of this work, be careful
not to damage the lead cable a t the cable hole of the bearing bracket.
(It's necessary t o use the protective board and the stud bolt , so the sub-exciter rotor
is permanent magnet type)
6.Remove the thermometer a.
7.Remove the cover @.
&Remove the bolt joining the upper and lower parts of the bearing bracket , and
remove
the cap 8 and the upper half of insulating seat@ , and the upper half of bearing.
9.Remove the oil ring @. (In case of forced lubrication , this work is not required
because
it has no oil ring)
10.Take the fan @ off from the fan boss.
1l.Remove the bolts connecting the prime mover coupling and generator coupling.
12.Li"C" part of the shaft with rope , t u r n upward the lower half of the bearing, and
draw i t off.
13.Hang the bearing bracket @ ,turn it upward along the shaft and remove it.
14.Apply rust preventing oil on the shaft journal and cover i t with protective wrapper.
15.Insert the protective board into the exciter rotor.
16.Insert the protective board into the generator gap. (Insert i t up to the thickness a s
close to the measurement of gap as possible.)
17.Remove the fixing bolt of the exciter frame @ and place the exciter stator on the
 exciter rotor.

18.Slacken the rope a t "C" p a r t , place the rotor on the generator stator core, and
withdraw the exciter stator frame.
19.Hang a t " Band " C parts of the s h a f t , transfer the rotor to the non-driven end
, and separate faucet from the driving shaft, and transfer the rotor further.
20.Place the rotor on the stator core , and withdraw the fan @.
21.Attach the joint shaft a to the flange, change the rope hanging to "A"part and
with further moving, and the center of position "G"of the rotor goes out of stator.
22.Bind the rope a t the center of gravity "G"and , with single rope lifting, pull the
rotor out of the stator.
 NISHlSHlBA ELECTRIC CO., LTD.

Head Office & 1000 Hamada, Aboshi - ku,Himeji, 671 - 1280,Japan.

Factory:

Tokyo Bran& Shiba SIA Building, 6 - 10,

Shiba 1-chome,Minatn - ku, Tokyo, 105 - 0014, Japan.
Phone : Tokyo (03) 3454 - 6411 Facsimile : (03)3454 - 6340

Tohoku Branch: Takeyama Kousan Kimati - dori Building, 8 - 28,

Kimati - dori 1- chome ,Aoba - ku, Sendai, 980 - 0801, Japan.
Phone : Sendai (022) 262 - 4820 Facsimile : (022) 215 - 3263

Kansai Branch: Shin - Osaka Iida Building, 5 - 33,

Nishimiyahara 1-chome, Yodogawa - ku, Osaka 532 - 0004, Japan.
Phone : Osaka (06) 6397 - 3472 Facsimile : (06) 6397 - 3475

Chubu B m c h : Toshiba Nagoya Building , 3 3 - 10,

Meisei 2 - chome, Niihi - ku,Nagoya 451- 0064, Japan.
Phone :Nagoya (052) 532 - 1831 Facsimile : (052) 532 - 1861

kyushu Branch Toshiba Fukuoka Building, 4 - 1,

Nagahama 2 - chome,Chuo - ku, Fukuoka 810 - 0072, Japan.
Phone : Fukuoka (092) 722 - 2448 Facsimile : (092) 722 - 2300

Chugoku Branch : Grand Otemachi Bdding, 11- 2,

Otemachi 2 - chome, Naka - ku,Himshima 730 - 0051, Japan.
Phone : Himshima (082) 244 - 1830 Facsimile : (082) 247 - 4098
 Operat i o n Manual

for

Air Filter

IMPORTANT
Before operating the product, read thoroughly the Safety
Precautions and Notes on Operation and Maintenance described
in this Operation Manual so as to become familiar to their
contents.
Keep this operation manual at your fingertips even after
reading it. --

NlSHlSHlBA ELECTRIC GO., LTD.

 1 Safety P r e c a u t i o n s 1
1. Foreword
Thank you for your purchasing our product, Nishishiba Generator.
T h e product and the operation manual contain important information on safe use of
the product and preventive measures against personnel injury and product
damage.
Operators should read this operation manual before starting operation and observe
the contents of the manual.
Besides the operation manual, be sure to read the safety indications and
operation name plates designed to prevent injury to operators or bystanders,
and material d a m a ~ eand attached to the Kenerator mainframe before operation.
Keep these safety-indications and operation nameplates clean so that they can
be read at any time, and d.0 not detach any of them.
In the case of dirty or damaged name plate, contact us for a new name plate.
Keep the operation manual at your fingertips even after reading it for your
daily operation.
Ahen you hand the generator to end user, be sure to attach this operation
manual to the machine.
2 .Qualification of Operator
I
.This generator shall be operated by qualified operator in accordance with
laws and regulations (the Industrial Safety and Health law, and the likes)
.Even in work not regulated by laws and regulations, work shall be carried
out under the guidance of expert who is well informed of generator and i t s
operation.
3 . Safety Indications and Safety Signs
The product and the operation manual contain important information on safe use of
the product and preventive measures against personnel injury and product damage.
Understand the follow in^- safety indications and read the text and observe the
contents described.
[ Explanations of Safety Indications]

Indication Meaning of indication

This indicates pressing D A N G E R , and if it is not avoided,
personnel death or serious injury results, therefore, it is
the most emphasized special information.
C A U T I O N This indicates potential danger, and if it is not avoided,

A middle or slight injury may result, therefore, i t is a

special information. O r it indicates potential danger
leading to only physical damage.
NOTE 1 : Serious injury includes loss of sight, injury, burn (high
temperature and low temperature), electric shock, fracture,
poisoning, and so on ca;sing aftereffect and requiring
hospitalization or regular outpatient treatment for a long term.
NOTE 2 : Medium damage or injury includes burn, electric shock and so o n
not requiring hospitalization or regular outpatient treatment f o r
a long term, and material damage includes damages in properties,
and facilities.
 / Safety P r e c a u t i o n s /
[ Explanations of Safety Signs ]

1 Sign I Meaning of Signs -

Indicates what is prohibited (what should not be done).

Its concrete prohibited contents are indicated by
illustration or text in or around the sign.

Q
Indicates what is compulsive (what should be done)
Its concrete compulsive contents are indicated by
illustration or text in or around the sign.
 Contents

1. Necessity of Air F i l t e r .........................................

5

2 , Mounting position of Air .......

5-6

3. Structure of Air F i l t e r .........................................

6-7

4. Material of Air F i l t e r .........................................

7

5. D e t a c h m e n t a n d Attachment o f Air F i l t e r ........................ 7

.....................................
6. M a i n t e n a n c e and I n s p e c t i o n 8
1.Necessity of Air Pilter
An electric system functions as the nervous system of vessels, and especially in
an A t generator, i t functions as the cardinal system, thus, it has the most
important function in vessels.
Different from generators to be used on land, AC generators for vessels are used
under rather bad conditions such as atmosphere containing a lot of oil drops, salt
content, uater content, dust and so on, and high temperature and severe humidity.
An air filter i:, arranged to filter oil, salt, water, dust and so on in air, and
thereby supply purified cooling air to a generator, and maintain its performance.
2.Mounting Position of Air Filter
An air filter is mounted at the cooling air supply side of a drip-proof generator.
There are 2 mounting methods of air filter, namely mounting at only one side of
the generator main body (as shown in Pig.l), and mounting at both the mainframe
s i d e and the terminal box (as shown in Pig. 2).

I
Air filter
 I It- Air filter

Air f i l t e r

Fig. 2

3 . S t r u c t u r e of Air F i l t e r
The s t r u c t u r e of a i r f i l t e r i s shown i n F i g . 3 and P i g . 4 .
A-A cross section

Air f i l t e r
mounting f r a m e

Air f i l t e r

P i g . 3 S c r e ~t y p e
 . A i r filter

Air filter
mounting frame

Air flow

Fig. 4 Insertion type

4.Material of Air Pilter

We use the following air filter as our standard one:
Manufacturer Toyobo G o . , Itd.
Product No. F / #292-K
Material Polyester (flame resistance)
Retention volume 580gl
I Heat resistanre temperature 1 100
Recycle through cleaning Up to 10 times

5. Detachsent and Attachment of Air Filter

T h e filter frame is of screw type for easy detachment and attachment.
T h e air filter is of screw type or of insertion type. In the case of screw type,
remove screws to take out air filter, while in the case of insertion type, pull up
a i r filter frol the cover.
6.Maintenance and Inspection

1. Before maintenance inspection work, be sure to turn OFF

the generator .Otherwise, you may be caught in .
2. Do not carry out work in a hot line status.
Otherwise, electric shock may result.
Clogging of air filter owing to dust and dirt will decrease the cooling air amount
of generator and cause overheat of generator, therefore, pay sufficient attention
in your inspection.
(1)Check the air filter for clogging owing to dirt about once a month.
Judge the dirt degree by the measurement of supply and exhaust temperatures of
power generation.
(2)Cleaning Interval : Cleaning interval may differ with service environment, but
clean the air filter once in 3 to 5 months.
(3)Cleaning Method : Remove the air filter from the mounting frame, and clean it
in the following procedures:
(a)In the case of dust with much carbon or oil, dip the air filter in neutral
detergent liquid for several minutes, and push and clean the air filter by
use of its cushioning property.
D o not use organic solvent such as benzene.
(b)Wash dust away by jetting cold or hot water by use of a hose.
(c)In the case of only dry dust, blow dust away by jetting compressed air.
($)Notes in Cleaning
(a)In water cleaning, avoid strong water jet. (The use of spray nozzle ill not
damage the air filter and will be effective.)
(b)Do not rub or squeeze the air filter. (Be sure to push and clean it. The
material of air filter is hydrophobic, so leave it alone after cleaning to
dry it up.)
(c)Rhen attaching the air filter to the mounting frame after cleaning, make
sure that it is completely dry.
(d)The air filter can be recycled up to 10 times or so.
 NISHlSHlBA ELECTRIC CO., LTD.

Head Offioe & 1000 Hamada, Aboshi - ku, Himeji, 671 - 1280, Japan.
Factory:

Tokyo Branch: Shiba SIA Building, 6 - 10,

Shiba 1-chome,Minato - ku, Tokyo, 105 - 0014, Japan.
Phone :Tokyo (03)3454 - 6411 Facsimile : (03) 3454 - 6340

Tohoku Branch: Takeyama Kousan Kimati - dori Building, 8 - 28,

h a t i - don 1 - chome ,Aoba - ku, Sendai, 980 - 0801, Japan.
Phone : Sendai (022) 262 - 4820 Facsimile : (022) 215 - 3263

K m a i Branch: Shin - Osaka Iida Building , 5 - 33,

Nishimiyahara 1-chome, Yodogawa - ku,Osaka 532 - 0004, Japan.
Phone :Osaka (06) 6397 - 3472 Facsimile : (06) 6397 - 3475

Chubu Branch : Toshiba Nagoya Building, 33 - 10,

Meisei 2 - chome, Nishi - ku, Nagoya 451 - 0064, Japan.
Phone :Nagoya (052) 532 - 1831 Facsimile : (052) 532 - 1861

kyushu Branch: Toshiba Fukuoka Building, 4 - 1,

Nagahama 2 - chome,Chuo - ku, Fukuoka 810 - 0072, Japan.
Phone : Fukuoka (092) 722 - 2448 Facsimile : (092) 722 - 2300

Chugoku Branch : Grand Okmachi Building, 11- 2,

Otemachi 2 - chome, Naka - ku,Hiroshima 730 - 0051, Japan.
Phone :Himshima (082) 244 - 1830 Facsimile : (082) 247 - 4098
IHI
8F%fl29- t?>iM$i@
.EXHAUST GAS TURBOCHARGER

TYPE RH143/163

@&%%IS
Instructions for operation
and maintenance

GJllE##&fE8#4;3tt%#

Ishikawaj ima-Harima Heavy Industries Co., Ltd

TOKYO JAPAN
 Water washing procedure
of
RH.. 3 type Turbo Charger
turbine side

D A I H A T S U D I E S E L MFG. C O . , L T D .
TECHNICAL DEPARTMENT
OSAKA, JAPAN
.

CHECKED BY

APR. 15, 2 0 0 2 APPROVED BY

----- -
.-
 W~~
Water Washing procedure of RH..3 type Turbo Charger turbine side.
( A p p l i c a b l e for t h e engine specified to use HFO.)

To remove ond reduce the corbon occumulotion on tul.bine blades by impoct

force of fresh wader drips occderoled with i-iigh velocity exiiaust gos flow, conduct
the water-injection fro~n\~ate~,pouringnoule fitled ot furbo chorger inle! exlioust
gas pipe.
Water injected is portiolly evc~porotedand the remaining is clischorged tlhrougli
droin pipe.

1 .Interval of the Water Washing

Conduct the woshing with the interval oi every 250 hours

2.Engine Load Conditions for Washing.

Adjust ond keep the engine Iood to produce the exhaust gas of turbochcrger inlet
temperature to be from 300 to 350°C for about 10 min.ond then corry out the
woshing.

3. Washing method
( 1 )Connect gouge boord @ with rubber hose @ to the water-pouring nozzle @
on I
turbo chorger inlet exhaust pipe .
(2)Connect the rubber hose @ I gauge boord @.
to the
(3)Open the stopper volve 13.ond fill fresh water in the line before the
water-pouring noule Q oncl close the stopper volve O after woter pressure
settled down.
(4)Openthe droin cock @I.
(5)Fullyopen the water-pouring noule @.
(6)Slowly open the stopper valve @ to obtain the water pressure of 0.05 to
O.OBMPo(0.5 to O.Bkg/crn2) watching the pressure gouge a.
(7)Water-pouringtime is about 5 to 7 minutes.
(8)Incase of woter doesn't disc:horge through drain pipe over 5 rnin. woter-pouring .
adjust wafer pressure to obloin the volume of woter discharge to be obouf
0.1Llmin.
(9)Closewoter-pouring noule 0 offer specified 5 - 7 rnin.
(10)Confirmthat woter discharge has finished, close the droin cock @.
( 1 1JAfier wafer-pouring cleaning. keep the engine running with some load for
about 5 l o 10 minutes.

Note:
'While the woter-pouring, keep watching and poy otlention not fo lead excess of
water-pouring or drain pipe blocking with carbon.
"Even if dischorge of drain can't confirmed, do not conduct woier-pourifig over 7
~ninutes.
'After woter-pouring cleaning, remove the lubber hose from woshing noule?.
 I .

- -

/water-pour i n 9 C l e -a n i n s P r o c e d u r e o -
f ~urbine]

G a u e e (0-0. 2 M P a ) Detai I " A "

/ Q

Wat e r pressure
-- --
Water
( 0 . 05-0. OBMPa)
b o a r d

/ ~ o s e c o n n e c t ion-
A Supplement to instructions
manual of RH143/163,1831203

1. The points o f Inspection

=
1.1 Every 400 hours: Check all fixing bolts
Note
This check is to prevent a leakage of exhaust
gas and lubrication oil due to looseness of bolt
and nut.
1.2 1200 U+BEJS:
!?-E>0-9cr)B$iK%
1.2 Every 1200 hours: Check the (Photol)

A caution
rotation of rotor
A"/f>n-9%+BLL.
2%
~I#WI\YB%<B
Check if the rotor rotates smoothly by hand. If the <BhI~iEST3-0
rotor rotates heavily or touching noise occurs, the
turbocharger must be dismantled for inspection.
E<B6Ee+%&Ea~6%el~z%T
(Refer to the Instruction . P U I P H ~ Q ~ ~ % E ~ ~ T(FdB32
TFSL\~
BAPBu 1.3.3 qi??%,FLT<f?$l\,
ZzZq
1.3 Every 4800 hours: Chec 1.3 4800 U+W&
1.3.1 9-P>0-9D9')75>Xfi@/Eti1ll
1.3.1 How to measure clearances Z%
@)Axial clearance ~i5!Jzm9')77>Xa~ti14
Photo 2
: Push turbine shaft to turbine side end by hand. : 9-f>~-9%9-f>fl4l~H-6tt8+~
:Set dial gauge to zero.

: Push turbine shaft to compressor side by hand.

:Record the reading on dial gauge.
:This reading is axial clearance.
@Radial clearance
: Set the dial gauge pointer at the top end of
compressor impeller and set dial gauge to Zero.

Repeat the measurement at least 3 times, and

check if the average recording is within
permissible range in below Table 1.3.2. In case
of overhaul or inspection, refer to the Instructions
manual and Chap. 1.3.3.
A Caution
Cover Lub. oil inlet and outlet with rag to avoid
dust invasion.
Compressor impeller is made of ALalloy. Be
careful not to make the impeller blades bent or
damaged.

1.3.2 Permissible range of clearance (mm)

1.3.2 9 1 ) 7 7 > ~ 3 % @ (&fi rnrn )
Turbo- Radial
Axial
charger (When delivered)
RH143 0.06-0.12 (0.45-0.60)

0.08-0.15
/203 (0.45-0.60)
1.3.3 Overhaul and inspection
Instructive points of overhaul
It is recommendable to have overhaul cleanina FiJlJ
and ins~ectionat everv about 4800 hours use. ;I 1 7
case heavy contaminaiion is found, the interval of
overhaul should be adjusted as occasion
demands.
Be careful the carbon covered over the shroud
part of turbine housing is quite hard to remove it
and looks like metallic surface. Gas passage

Check if there is groove due to erosion on th

surface of gas passage.

Radial tip clearance at gas outlet part

Clearance R1+R3. R2+R4
(Design value in mm)
RH143/163 0.70 x 2 = 1.40

RH183/203 0.90 x 2 =1.80

Clearance R
Measuring
Position R4 R2

R3
:Clearance gauge

Please check and clean if carbon and sludge of

lubricating oil accumulate at back wall of turbine
impeller and groove of seal ring.
(Refer to Chap.3)
 m
Soak only turbine
wheel part up to
Recommended replacement interval of floating rear wall in hot This part must
and thrust bearing is 2 years. water or carbon be covered by
removal solvents. rust preventive
oil.

In case of turbine wheel cleaning by soaking in

hot water or carbon removal solvent, rust
preventive oil must be applied to the turbine shaft
from groove for seal ring to the end of
compressorwheel side before soaking of it. If
protection is not enough, corrosion can be
occurred. (Refer to Fig. 2)

Seal ring must be replaced at every overhaul and

remove the carbon deposits from sealing groove,
if accumulated. As for the wear of sealing groove
of turbine shaft, refer to Fig. 3.

I[ Worn area
@Rix For reference:Standard Dimension
Unusable
G %- :@%22€ISE
2. Cleaning of Turbine side parts
Carbons at shroud part of turbine housing and
turbine wheel normally include very hard layer of
Calcium and Vanadium. Therefore clean them by
hard wire brush or scraper. (Remove the dropped
deposits in turbine housing surely alter cleaning.)

2.1 Cleaning procedure

Turbine wheel (Sample after cleaning: Photo 6)
1) Remove the carbon carefully by wire brush or
scraper.
2) If it's hard to remove the carbon, soak only
turbine wheel in hot water or carbon removal
solvents according to Chap. 1.4 Fig. 2.

Turbine housing (Shroud part)

1) Remove the carbon carefully by wire brush or 9-f>/\95>!7-(5179F3)
scraper. 1) E1\74-t?775+X9b-/fl=TTSl
2) If it's hard to remove the carbon, penetrate the h-*>g%kLr<t:si\o
cleaning solvents in way of covering by wet rag
that is soaked with solvents. 2) h-*>h~%kLIZ<l\%eI$31X%Iz
3) Photo 7, 8 show a sample of utilizing cleaning % I ~ ; Z % ~ % ~ T ~ ~ ~ ~ F
tools. This pneumatic tool that has bundled B$eT<t:$l\o
about 30 wires (2mmlpc) works effectively to
remove carbon deposits on gas passage. Use
it not to damage material of turbine housing
3) Photo 7. 8 I&17-74?775TcT)ISE
(O%FP%. x@ % 2mm/l *kt 30 *
EE%;tahbT6;L). T/H f i X S B 3 0 h
itself. Also do not use it for cleaning of turbine
wheel in order to prevent the damage for -*>EU~~*~*Y~%~LIZG%
turbine wheel. Z O ) A ~ ~ Z E % E H $ ~ ~ ~
>~D@H5hllL)&!htbl\%.
ZZLTR
HLT<t3L\,
~.@H5E&96%HW&L)Z3-DT9
-f>~~aI~~l=lk~HLGL\T<t
L\,
RH143-203AP-1 .RO
.The degree of contamination on turbine wheel
and its surrounding area differs from the
individual operating condition. Even after the
certain running hours shorter than the
recommendable overhaul interval, thick carbon
may accumulate on turbine wheel and the area
surrounding it. Excessive unbalance causes
touching of turbine impeller and compressor
wheel at shroud part, which may lead to
damage of bearing part. Therefore special care
should be taken so as to overhaul and clean
earlier for prevention if engine is running with
heavy fuel oil.

Remove the carbon deposits on turbine wheel

evenly as much as possible. Uneven cleaning
may cause the unbalance of rotor.

Confirm that the rotor can turn smoothly by

hand after cleaning.

In case of the coated turbine housing, do not

damage or tip the coated parts when cleaning
gas passage.(Fig 1 XPos.1)

3. Accumulation of carbon deposits

Oil leakage or bearing damage can be occurred
by coking of lubrication oil around the sealing
section, because of heat soaking from turbine
impeller alter engine stopped.
Photo 10 shows slightly coked deposits in LO
space around seal ring at turbine side
Photo l l a n d 12: After cleaning. If accumulated
carbon deposits are observed around it, remove
deposits and do not damage the sealing surface.
The seal ring must be renewed at every overhaul.
In order to mitigate the coking phenomenon,
idling operation before engine stop is
recommended for more than 15 minutes.
(Ref. Fig 4)
In case it is impossible to do idling, start a priming
pump as soon as engine stopped and supply
Lub. oil for more than 15 minutes.
(Remark 1)

Remark 1
Such priming pump may automatically or always
be operated during standstill according to the
engine specification. For the detail, consult with
engine builder

A Caution
In case the engine is forced to stop emergency,
the following measures must be done.
Coolingdown by Lub. oilpriming pump should
be done immediately.
Before restarting of the engine, check the rotor
i'l
LO stop

Engine stop with cooling

condition according to Chap. 1.2. (Inspection at

every 1200hours) In case abnormal condition of 779-9-1)>9%WE
rotor is observed, carry out the cleaning and
overhaul inspection of the turbocharger.
 FOREWORD

To make full utilization of the IHI Exhaust-Gas

turbocharger (hereinafter briefly called
"turbocharger"), i t is important to comply with
the procedures for operation and maintenance as
well as instructions contained in this instruction
manual.
Operate the turbocharger after reading through
this instruction manual.

CAUTION

1. Order and inquiry

(1)When ordering the parts, clearly indicate the
following symbols in your order sheet.

Type RH.. .
Serial - No. As stamped on the rating
plate of turbocharger
(Refer to Fig. 1)

J
Part number
and designation As pre Fig. 2 and parts list
Quantity

(2) Address your order and inquiry to our agencies

and service offices or engine builder's
service stations.

2. Exemptions of liability
In respect of accidents during the guarantee
period that are recognized as being clearly
attributable to IHI' s design or manufacture,
IHI will make repairs free of charge, but IHI
will assume no responsibility even during the
guarantee period for the following accidents.

(1)Accidents due to the use contrary to the

instructions contained in this manual
(2) Accidents due to a neglect of periodic
replacement of wearing parts
(3)Accidents due to the use of parts other than
IHI genuine parts
( 4 ) Accidents due to the use in excess of the
rated capacity

3. Communication
Regarding the doubts about this instruction
manual, obscure points therein, special cases not
stated therein or any disorder, etc. ,
please contact the engine manufacture or the
nearest IHI business office.
1. Construction and function
1.1 Construction of turbocharger
The RH143/163 type turbocharger consists
essentially of a mixed flow turbine and a
radial flow compressor, assembled as a single
unit.

(1) Turbine
The exhaust gas from the diesel engine flows
through the turbine housing to the turbine
wheel and provides the rotating torque to
the turbine shaft.
The exhaust gas flows through the exhaust
housing to the atmosphere.
Seal ring and heat shield are provided
so that gas may not adversely affect the
bearings.

(2) Compressor
The compressor wheel fitted to the turbine )
shaft receives the rotating torque, induces
air through the silencer, and delivers it to
the cylinders after compression.
Seal plate and seal ring are provided
so that air and oil may not leak.

(3) Bearing
A . Thrust bearing
Since thrust force is constantly applied
to the turbine shaft, the thrust bearing is
provided to prevent move of the shaft due to
thrust force.

B. Journal bearing
A floating type is employed. In comparison .
with the ordinaly fixed type, a dual oil
film is formed on the internal and external
faces of. the bearing. The bearing bush
rotates and the sliding speed of each
bearing face is lower than the turbine
shaft speed, resulting in an increase of
dynamic stabilization.
1.2 %@iE!.% o m 1.2 SecLional drawing and p a r t s lis

49H 2. R H 1 4 3 / 1 6 3 %i@k$h%@i%~
fq& 1. %%25 Fig. 2. Sectional drawing for t y p e of RH143/163
Table P a r t s list .

Thrusl c o l l a r (bearing side)

- 5 S e a l i n g bush
- 6 S h a l t end hexagon n u t
- 1 Sealring
20 - I Compressor wheel
30 - I Compressor h o u s i n g
- 2 C r o s s - r e c e s s e d head screw M6x21
- 3 Compressor s i d e c l a m p
- 4 llexagon head b o l t M8xZO
- 5 Compressor s i d e l o o 1
- 6 Hexagon head b o l t M8x25
- 1 S p r i n g l o c k washer 8
- 8 Plua C3/8
- 9 Pueiing
35 - I Diffuser
10 - I Seal p l a l e (compressor r i d e )
- 2 Seal p l a l e ( b e a r i n g s i d e )
50 - I Dearing housing
- 2 Bearing bush
Snap r T n g
Hexagon head b o l l M6x35
S p r i n g l o c k washer 8
0 ring
Heat s h i e l d
Knock p i n
Blaind flange
Pucking
Hexagon head b o l l Max25
S p r i n g l o c k washer 8
F l o a l i n g journal bearing
Thrust bearing
Turbine housing
Turbine s i d e clamp
Hexagon head b o l l Max16
Silencer
Air liller
llexagon head b o l l hl8x30
S p r i n g l o c k washer 8
-
Exhaust h o u s i n a
Plug
Pucking
Turbine s i d e Tool
Sludboll M8
llexaaon n u t Y6
 1.3 Structual drawing

4 3. R H 14311 63%Bf%.%&8H
Fig. 3. Structual drawing for t y p e of RH1431163

6 R H 3 4 0 IS
 2. Operation ,c., :,-
:,. -.
2. 1 Lubricating oil i
The RH turbocharger can be connected to the
lubricating oil system of the diesel engine.
Therefore the lubricating oil must have the
quality mentioned in this manual as well as
according to the engine builder' s
recommendation.

2.1.1 Recommendable oil specification

I
API Service class CC. CD
SAE No. 20 30 40
SAE No. 20 30 40

Maximum 1.0. temper-

ature at the inlet 60 80 90
of turbocharger (' C)

2.1.2 Interval for oil changes and replacement

of filter
The oil must be changed according to the
engine builder's recommendation.
Ensure that the fine filter preceding the
turbocharger is kept clean, and the filter
element must be cleaned or replaced
periodically.

2. 2 Operation
For new or overhauled turbocharger. note the
following points.

2 . 2. 1 Before taking into service

All pipes have to be fixed in a way that
there are no forces which could deform the
casing.
Any deformations on the casing can affect
the bearings.

All lubricating oil pipes must be cleaned

thoroughly before taking into service.

Before starting the engine, always operate

the prelubrication system with inlet oil
pressure 0.5 - 1.0 (kg/cmzC).

Cooling-water must be circulated in the

bearing housing.

Pipeworks must be vented at the highest

point.

Use only fresh water.

2. 2. 2 When first taking into service
Check all gas, air, oil, and water pipe
connections for tightness.

Oil inlet pressure must be 2 - 5 (kg/cm2)

during operation at least 1 (kg/cm2)
at idling.
Oil inlet pressure must be at least 1.2
(kg/cm2) at low load operation (gas inlet
temperature is less than 450°C and
turbocharger speed is less than Nmax X 0 . 6 )

Temperature increase of cooling water in

bearing housing must be adjusted 4 - 8
('C) at full load by putting orifice plate
in water exit line to get property water
quantity.

Before stopping engine, idling must be done

at least for 5 minutes not to carbonize the
oil by the heat from turbine wheel.
In case i t is impossible, the engine must
be stopped after starting up of priming
pump.
Priming pump must be operated at least
5 minutes after stopping the engine.
 according to operating conditions, following
intervals are recommended

2.3.1 Periodical inspection and maintenance

Application lnspection interval

item Inspection Marine engine & generator Every Every Every Every
points 4 0 0 hrs 1200 hrs. 2400 hrs. 4800 hrs.

Checking of clamped parts for tightness

Rotating condition of turbine shaft

Checking of clearance of turbine shaft

Disassembling. cleaning and inspection

Cleaning and inspection of oil filter

In accordance with instruction manual of the
Engine oil change engine manufacture.

lnspection of oil pipe system

lnspection of intake
and exhaust pipe system
 , ..
2.3.2 EPJI&S~~ 2. 3. 2 Procedures for periodical inspection
2. 3. 2. 1 %$%6lf%Dfi$% 2. 3. 2. 1 Checking of clamped parts for Lightness
LTFS
&SD$'lbE. t ~ E D @ a + % f i @ Check up clamped parts(bo1ts & nuls) for
L'o tightness.

2. 3. 2. 2 Rotating condition of turbine shaft

After removing suction pipe or silencer.
check up the rotating condition of the
rotor by listening to the rubbing noise.
II' there are any during rotation or the
rotor does not rotate smoothly, the
turbocharger shoud be dismantled.

2. 3. 2. 3 Checking of clearance of turbine shaft

Clearances must be measured in accordance
with following figure.

Allowable axial clearance is shown as

follow.
( ~ x i a lclearance) 0.06 - 0.12 (rnm)]

Allowable radial clearance is shown a s

follow.

When measured clearances are over the

high limits or when the scoring o r
excessive wear is observed on the bearing
surfaces, replace thrust and journal
bearing.

For safety operation, replacement of thrust

and journal bearing every 2 years is
recommended independent of operation hours
or clearance measurements.

I 4. kb52P~Wi01,3i!$Jgfl
Pig. 4 . Measuremenl ol bearing clearances
10
 I 6"
2. 3. 2. 4 Disassembling. cleaning and inspection
Dismantle the turbocharger from engine.
disassemble, clean, and inspect i t in
accordance with following 3.

2. 3. 2. 5 Cleaning and inspection of oil filter

& engine oil change
In accordance with instruction manual of
the engine manufacture.

2. 3. 2. 6 Inspection of oil pipe system

Check up the clamped parts for tightness
and oil leak from oil pipe connections.

2 . 3. 2. 7 Inspection of intake and exhaust pipe

system.
Check up the clamped parts for tightness
and air & gas leak from pipe connections.

2. 3. 3 Operation figure of engine

I t is advisable to keep a close check on the
whole engine data and record i t in a log
book, since this allows conclusions to be
drawn regarding the condition of the
turbocharger.

If these data deviate appreciably from

earlier figures, find out the causes.

The following should be entered in the

engine log book.

.Output of the engine

.Engine speed
.Air inlet temperature
.Pressure of charged air
.Air temperature after compressor
.Air temperature after charged air cooler
.Exhaust gas temperature after cylinder
.Exhaust gas temperature before turbocharger
.Lubricating oil temperature before
turbocharger
.Lubricating oil pressure at the inlet of
turbocharger or the outlet of oil tank
 3. Maintenance I C \I
3.1 Cleaning \
3.1. I Turbine shaft, casing and compressor wheel
Dip the parts in warmed solvent to make
deposit soft.
Remove the deposit with a plastic scraper
or a hard-bristled brush.
Do not use a wire brush.

3.1.2 The other parts and filter of silencer

Clean them in light oil.

3.1. 3 Notice
Do not dip a silencer in solvent.

Do not dip a O-ring in light oil

Clean all parts by blowing air and wipe them

by waste clothes after washing.
Especially, clean the oil passage in the
bearing casing and the thrust bearing by
blowing air.

3.2 %#MZg 3.2 Tools

3.2.1 fizfd#l#gS 3. 2.1 Necessary tools
3.2.1.I (53$@%& LT*&lci$E) 3. 2.1.1 Special tools (supplied by IH1)
,,-9azgg ------------- 1 fl Designation Quantity
y-k1)7?'a]~~7'j{+ -------- 1 rn Turbine shaft locking tool ------- 1
rn
;If77' '179. HRT7' j 4 t ------ 1 Seal ring ST plier --------------- 1
Snap ring RT plier --------------- 1

3. 2. 1. 2 General tools
Open ended spanners (10/13/24)
Torque wrench (13mm. 80kgf .em)
Torque wrench (13mm. 250kgf .cm)
Torque wrench (24mm. 510kgf .cm)
:left-hand thread
Torque driver (45kgf .cm)
Plastic hammer
Screw driver

3. 2.2 Measuring tools

Magnetic base
Dial gauge
3. 3 MTlkZfB ,LI .. - 3.3 Disassembling the turbocharger
m% 5. i!%%&%@$m~%%P.c?~& Refer to fig. 5. Disassembling and assembl ing.
~&wB Caution
i!a%@%17~. ?to GK$5-$gZiZli, !l3+9-t. 7ffllJ Before removing turbocharger from engine.
@iq@jlaRS L&%H6-laflS iZflifTFSL x 0 fit clamps on turbine side foot .as shown o n
Fig. 6-1.

3. 3.2 fgEs0@9k L - 5-1 %g.c?TS

L\ 3.3.2 Removing silencer -Refer to fig.5-1
@l;;R$.kE (M8) %~Q%%o O R e m o v e hexagon bol ts(M8).
@im%%@~b%o @Remove silencer.

!%I%, & @& ~ 3 % 7 % @ ~L 3fi

~ ~ ~ cl% Take care no to damage the punched metal
L \ L 5 IZ <*.&ST
?5 L \ o when dismantaling silencer.

3. 3. 3 177' b1i)zg$af119L L - (qm 5-1 Bp,BT&L \ 3. 3. 3 Removing compressor housing

-Refer to fig. 5-1
@Remove hexagon head bol ts(M8x20.25)
@Remove compressor side clamps.
@Remove compressor housing.

Take care not to damage the compressor

blades when removing compressor housing.

3. 3. 4 Removing diffuser -Refer to fig. 5-1

@Remove a cross-recessed head screw(M6).
@Remove diffuser.

Do not remove diffuser except for inspection

or replace.

3. 3. 5 Removing exhaust housing & turbine side

3. 3. 6 ln.bvi)%$Dl$.$$ L -
5-1 %!gF 3 L \
09-t' ?$bBliZEa%?-t' ?$~f~kbt:oji./r.
l~@i$1?6.
O$lbltrE (Ml2) &fl@b%~
+DR. S d M t v E liZ%Y. T%DTC&ST
$L \ o
@1?7' blt3$%%@60
127' b,14t3Slaf&fl1 9 hiBil%fJ%@kk.
% 100 ('c)E~TDZET%$K@&T~>
%81? T F S L \ o
foot -Refer to fig. 5-1
@Remove exhaust housing.
@Remove turbine side foot.
Before removing turbine side foot, insert
a support under turbocharger.
!$a
3. 3. 6 Pulling out compressor wheel
-Refer to fig. 5-1
Olnstall turbine shaft locking device t o
gas outlet flange of turbine. housing.
@Remove shaft end hexagon nut (M12).
This nut is left-hand threaded.
%$ @Pull out compressor wheel.
G When i t is difficult to pull out by hand.
heat compressor wheel evenly below 100 ' C .
 7 Removing seal plate -Refer to fig.5-1
@Remove hexagon head bolts(M8) and ;&
spring lock washers.
@Using the removed 2 bolts. push up seal
plate (compressor side. turbine side)
with sealing bush.
Take care not to damage the '0" ring and
not to dip in the light oil.

8 Removing thrust collar and thrust bearing

-Refer to fig. 5-1
@Remove thrust collar (compressor side)
@Using the removed 2 bolts for seal plate.
push up thrust bearing.
@Remove thrust collar (bearing side)

9 Removing turbine housing -Refer to fig.5-2

@Remove hexagon head bol ts(M8).
@Remove turbine side clamps.
@Remove turbine housing.

The material of the bolts(M6) for turbine

hosing is heat-resisting steel, therefore do
not mix them with other bolts.

When removing is difficult, tap the turbine

housing by using plastic hammer.

10 Pulling out turbine shaft

-Refer to fig. 5-2
Do not remove seal ring except for
inspection or replace.

11 Removing heat shield -Refer to fig. 5-2

When removing is difficult, tap heat shield
by using plastic hammer.

12 Removing seal ring -Refer to fig.5-3

3. 3. 12. 1 Removing seal ring (compressor side)
@Remove sealing bush from seal plate.
@Remove seal ring from sealing bush by
using seal ring plier which is supplied
as a tool.

3. 3. 12. 2 Removing seal ring (turbine side)

@Remove seal ring from turbine shaft by
using seal ring plier which is supplied
as a tool.

When removing seal ring by using seal

ring plier, hold seal ring by finger.
not to apply excessive stress.
3. 3. 13 Disassembling bearing -Refer to fig. 5-4
@Remove outer snap ring by using snap ring
plier which is in the tools.
Take care to prevent damage to floating
journal bearing by using plier.
@Remove floating journal bearing.

Do not remove inner snap ring except for

inspect ion or rep1 ace.

Handle these bearing parts with care to

prevent damage.

3.3.14 Removing compressor side foot

O R e m o v e hexagon head bolt (Ma) .
@Remove compressor side foot.
3 . 4 Reassembling the turbocharger
Refer to fig. 5. Disassembling and assembling

Reassemble components after cleaning. I

Check and replace the damaged parts if
5
necessary.

3 . 4 . 1 Reassembling compressor side foot

alnstall compressor side foot to bearing
housing.

3. 4 . 2 Reassembling bearing -Refer to fig. 5-4

@Install floating journal bearings in
bearing bush.
Before inserting the journal bearings.
dip them in the lubricating oil.
@Install outer snap ring in bearing bush
by using snap ring plier.

Make sure snap rings are firmly seated in

bearing bush grooves.

Install snap rings in the direction that

the smooth rounded surface to the floating
journal bearing.

Turn gap of snap rings to downwards

Take care to prevent damage to floating

journal bearing by using plier.

3 . 4 . 3 Reassembling seal ring -Refer to fig. 5-3

3 . 4 . 3 . 1 Reassembling seal ring(turbine side)
@Install seal ring in turbine shaft groove
by using seal ring plier.

3 . 4 . 3. 2 Reassembling seal ring(compressor side)

@Install seal ring in sealing bush groove
by using seal ring plier.

When installing seal ring by using plier.

always hold seal ring by finger.

3. 4 . 4 Reassembling heat shield -Refer to fig. 5-2

@Install heat shield to bearing housing.
 3 . 4 . 5 Reassembling turbine shaft
-Refer to fig. 5-2
@After installing seal ring to turbine
shaft, install turbine shaft to bearing
housing from turbine side.

- Before installing turbine shaft, apply

lubricating oil on the shaft.

- T u r n gap of seal ring to upwards.

9-t. ~ $ h ~ $ l h & c i i ; i i ~ ~ ~ ~ ~ m l cBefore -

~ % ainstalling turbine shaft, ascertain
that there is no foreign body in the bearing
#%L'$%@z L-CT & L\,,
housing.
- 9-t. ?flll~-kY~V.%.l Y Z $ i ~ t $ h % A k &
F o r saftey inserting of turbine side seal
?-t*?$hii&i!sl7?mfi~G$H+iACiS%E%C\
f: L % % , ring, vertical installing of turbine shaft
+ D @ ~ lip-'c*
c ?flllY-klJ?l+$bG9-'c- ?@'$ is recommended.
L~k%b*T%hL77:SL\o At inserting of turbine shaft, place the
center of it to the center of turbine shaft.

3. 4. 6 9 - 7 - (;fa 5-2 S E T S L \ 3 . 4 . 6 Reassembling turbine housing

@$?Mii;ilcEP L f : 4 ~ I i z $ ; h + 2 ~ 9 - t .r s B -Refer to fig. 5-2
%u%ss~z$~+&~~ Olnstall turbine housing to bearing housing
09-t'yfllllltt8REtj.lv;'fiffit'kE(Ma) %HX by aligning the mark.
i3lf60 @Install turbine side clamps and hexagon
k%i;tEb1ii 250 (kgf.cm) T T o head bol ts(M8).
t \ f f i t ' ~ b ~ i ~ i i i % i $ r f k ~ ]L
%T ~T $ S L\O Tighten bolts by 250 (kgf.cm).
0 9 - k ' Y $ l f i ~ ~ Z ? ~ % @%Hz ~i~ifL , T Apply seizure prevent compound on bolts.
% < o @Install turbine shaft locking device.

3.4.1 X j A b f i ? . ~i~Ei9fia$KC 3 . 4 . 7 Reassembling thrust collar and thrust

- i3H 5-1 SETS L \ bearing -Refer to fig. 5-1
@;li~Ei)i( $E?flI l)
%9-k'Y$b7iCBh%ao @Insert thrust collar(bearing side) to
@XiAEi91b%$$%~8aI*11t' YDDgiC$b* turbine shaft.
- ~ m i $ i f6. @Set thrust metal into the knock pin of
~iAb$?biLii& 5 h >k&fl.#&b%mk L. % bearing housing.
:&EBit$h9s~D%:&Xk%b*TTHiqCf 6 . Apply lubricating oil on the thrust
OXiAEfii ( 1 ~ 7brYflll)
' Gf-9-t.~$hi;#A% 6 . bearing. Install thrust bearing to bearing
housing with aligning lubricating hole.
3. 4. 8 Y-lb7. k-ba&a- (qR 5-1 Z%!flT$L' @Insert thrust collar(compressor side) to
a'&a4 %Y-lb7. b - b l ~ # A % 6 0 turbine shaft.
+ a @ , .&inY l~HXi;tlj54af:Y-lb'IY!/. a %
U h ~ + l ; i l $ l ~ f i 6 ~ 5 i ~ # A L 7 T ~ 3.
L 4.8
~ o Reassembling seal plate -Refer to fig.5-1
0011~1'G $ ~ ~ E & Z Z D % ~ ~ C $ ~ ~ ~ A G ~ @Insert sealing bush in seal plate.
+ D @ , 01171'hi& I:t%f:b?!El~f~ 6fi~'dr Turn gap of seal ring to upwards.
5 :-&%T 8 L'o @Insert " 0 " ring in the groove of bearing
@.&a Y GTBiAAf:Y-h7' )-I%, $$%g$iC housing not to be twisted.
$H&O0 Olnstall seal plate inserted sealing bush
@I\'$@&, z m t ' b b (M8) % @ i q l f 6 0 to bearing housing.
Hi3;fEb'lli 80 +
5 (kgf.cm) T % , @Install spring lock washers and hexagon
head bolts.
Tighten bolts by 80 5 (kgf.cm). +
4. Faults
4.1 Symptoms of faults and possible causes
When any troubles have occured in turbocharger.
its function can not be obtained sufficiently.
In such case, after making sure that there is
no abnormality in the engine, check
turbocharger in accordance with the following
procedure and take an appropriate measure.

4.1.1 Exhaust gas temperature higher than normal

or charged air pressure lower than normal
Possible causes ;
@Dirty filter of silencer
@Dirty compressor wheel or diffuser
@Damaged turbine wheel
@Exhaust back pressure too high

4.1.2 Vibration or noise of turbocharger larger

than normal
Possible causes ;
@Heavy dirty or damaged turbine wheel
@Heavy dirty or damaged compressor wheel
@Damaged bearings
@Bad fitting of air and gas piping
@Bad fitting of turbocharger

4.1.3 Lubricating oil pressure too low

Possible cause :
@Dirty or clogged lubricating oil filter

4.1.4 Too large lubricating oil consumption

Possible causes ;
@Too high lubricating oil pressure
@Worn seal ring
@Bad fitting of lubricating oil piping

4. 1. 5 Surging of the compressor

' Possible causes :
@Increase of the friction resistance
in the charged-air cooler or filter of
silencer
 5. Cleaning the compressor wheel in service
5. 1 General
Compressor wheel should be cleaned periodically

The cleaning interval differs depending upon

operating condition, but i t is suitable to
clean about once a week in service.

The compressor wheel can be cleaned during

operation by injecting water.

I f the deposit is very heavy and hard, the

compressor wheel must be dismantled for
cleaning.

The injected water does not act as a solvent.

the cleaning effect can be achieved by the
physical impact of the drops on the deposit.

Use "Blower Wash" or clean water containing no

additives either in the form of solvents or
softening agents.

Regular cleaning of the compressor wheel

prevents or delays the formation of a deposit;
but i t does not eliminate the need for normal
overhauls, for which the turbocharger has t o be
completely dismantled.

5.2 BEZ& 5. 2 Procedure

@ % h F i E % L dFZ%EP?#D E. b 7 E % %MEL 7 @Open all drain cocks in charged air pipe.
T * L'o @The water should be injected during the
@17Y 7h;@& 4 , Z B 3 (75%B{3Uk)Tl-9 engine is running warm and at the highesl
& L L L G \ P S ~ I Z - &L~7~7 ; S 1 r \ ~ possible load. (above 15 % load)
0 7 k % 4 - 10 $ ! b ~ ~ 7 . & 7 k btr%5?mfij&$%hiji'
a @For an effective cleaning, inject all the
Xa -&0 water required within 4 to 10 seconds.
- E l D ' & 7 k B i i R11143/163 # K 0 . 2 (liter) This water quantity is 0. 2 (liter)
T3-0 for RH143/163.
a
@&7kit1\;r~'K 77' t;rtt.:-k.w,z%@~ ~7 @For injection a hand-pump or a vinyl injecter
T * L'o may be used.
33%Bk L U r n . ; r h c ~ i % g @ 7 k h i % f i i A & a % The specified water quantity should be
t . S & ~ m ~9t .33-DT. ti & 7 k ~ r i ~ a ~observed, because entering uncontrolled water
% g w ' q 9 -cT s L\,, to turbocharger and engine causes a trouble.
6 & 7 k D j j ; j G 2 T % h Z E d f:Cif;llZEEhi%4L L d @Either charged air pressure or exhaust gas
3- 0 temperature changes after injecting water.
@.G7kt~I&at&iik@4Lhi.i'& 5 & f s ~ \ g 4 i ilo. @ I f pressure or temperature does not change.
f)G2izRE&7k L T T $ L \ ~ i t may only be repeated after 10 minutes.
0'&7k?&E$% 3 - 4 l E l t T 9 7 ti!~fjk~4LhiZ!Y, O T h e r e is no change in performance even
L itwD177. I , , / W ~ & f i ht ~L repeating 3 or 1 times injection, which
<E Xa iZ&% causes the deposit to be very heavy and hard
%i.m L177' wwFjtsat:it~;wsL T T S L \ O or the compressor wheel to be damaged.
@.G7k'l&i%%/J,fs < t. t 15 !dp~7ktBfi$kgT17 In this case, the compressor wheel should be
Y 7 % L E@ s .t?.-cTsC \ a dismantled for checking or cleaning.
@After injection, the engine should be run
loaded for at least 15 minutes.
 PNUn
Lutlricating oil inlet
n

Enrm
Lubricating oil outlet

flR5- 1 . e$afiWIR (1I F E - 3 . :/-U27' fiEUCi8

Fig.5-1.Disassembling and assembling (11 Rh Fia.5-3.Seal rinss arranqement
Disassembling

Lutricating oil outlet

* BUIIWCPUIH,~TZI'.
w l y sellure prevent c o w o u M on Dolt d e n tlgntening

F~E-2.m fimnfl (21 flR5-4..?177' IJi?' RR'dh841

Fig .5-2.Disassembling and assembling 121, Fig .5-4.Snap rings arrangement

Fig.5 .Disassembling and assembling

Service office
 \IL
TSU 9-$-;/XYA;1: TSU Turbo Systems United
Co., Ltd.

Tokvo
%E1*9-PXB East Japan Service Dept.
7130-0013 %SS@ZEIE#% 1T B 2-1 Area Central Building 18F 2-1, Kinshi
711.*+;/ I- 711.h'lb 18 E 1-chome, Sumida-ku,Tokyo 130-0013,
JAPAN
TEL 03-5611-5983-5986 TEL +81-(0)3-5611-5983-5986
03-5950-0491(24hrs) +81-(0)3-5950.0491(24hrs)
FAX 03-5611-5997 FAX +81-(0)3-5611-5997

*H*9-EX27-2~ > East Japan Service Station

T 130-0004 %S%b~E!X*filT22.1 22-1, Honjo 1-chome, Sumida-ku,
Tokyo 130-0004,JAPAN
TEL 03-5619-5021 TEL +81-(0)3-5619-5021
FAX 03-5619-5022 FAX +81-(0)3-5619-5022

T@H*ff-EXI% West Japan Service Dept.

EEt*tk-EXXY-2s > West Japan Service Station
T651-0073 !%@!%@icPT/i$*E 3-2, Wakihamakaigandori 2-chome,
B%.%%B 2 TH 3-2 Chuo-ku, Kobe-shi, Hyogo 651-0073,
JAPAN
(EH*+- EX%) (West Japan Senrice Dept.)
TEL 078.200-3092 TEL +81-(0)78-200-3092
FAX 078-200-3096 FAX +81-(0)78-200-3096

@ § E i * - T - ~ Z Z ~ -3)
~3 (West Japan Service Station)
TEL 078-200-3093 TEL +81-(0)78-200-3093
FAX 078-200-3096 FAX +81-(0)78-200-3096

#mB%F% Takamatsu Branch

T760-0056 ?&)llEZ&&*$fjriu
11.1 11-1, Nakashin-cho, Takamatsu-shi,
IHS S%!!22%EFI Kagawa-ken 760-0056, JAPAN
TEL 087-863-6538 TEL +81-(0)87-863-6538
FAX 087-863-6538 FAX +81.(0)87-863-6538

%MB%B Fukuoka Branch

~815-0032 ~ R E M $ E ~ 2-2-5
%E 2-2-5,Shiobara, Minami-ku,
IHS GltiB%%EP1 Fukuoka-shi, Fukuoka-ken 815-0032,
JAPAN
TEL 092-544-6030 TEL +81-(0)92-544.6030
FAX 092-544-6030 FAX +81-(0)92.544-6030
 1 2 3 4 5 6 113 7
)IESEL ENGINE^ AC GENERATOR I
TYPE 5DK-20 T Y P E NTAKL-VC I
0 . OF C Y L O U T P U T 662. 5 k V A
lEVOLUT l ON 7 2 0 nin" F R E Q U E N C Y
7000 k g M A S S 3900 k g No. 5 C Y . c e n t e r Len. c e n t e r I
IIHATSU DIESEL MFG. CO.. LID. N l S H l S H l B A ELECTRIC CO.. LTO. 2
-
-
0
mv-
0
I - - - - - I
- 0,
- -
I

:OMMON B E D MASS 1920 kg D r i 1 1 2 3 5 (M301 - 1 B H o l e s 1 0 - M 2 4 X 3 . 0 - t r h/

/for jack bolts
4CCESSORY MASS 2000 kg

-
SET T O T A L MASS 14820 kg (DRY)

ROTAT lON

Remark: R i b s o f h u l l c o n s t r u c t i o n
s h o u l d be a r r a n g e d t o m e e t
e a c h R i b o f common bed.
I I
I 2) Wd~1WO
l J'iOlM~MY!,%6t~~f
344- = 480 - i3 ~ i i a f i o ~ ~ ~ m ~
BE&UIL\~?.

I-' 2080
APPROVED No. A D K 2 0 - 4 2 1 1 - 3 ( 1 0 ) # 0 0 3
I O SCALP 1 : 2 5

CHECKED
BEFORE

REF.
MASS.

TYPE 5nK-70
@a 1 ~ 3

I I I
DRAWN
K ~ ~ D A DIESEL
K. TANABE I H HFC.
Ato.,
TLIDS U
l r a r i n ~i s lhe properlr 01 Daihalsu Diesel I l ~ . C o . , l l B . Re~roduclioa,use or lisclosure
:8~94~\sir-rk#b~ltnfi~#ttrnr./1his
:W(@.~ t ~ ~ k : ~ ~ ~ ~ * l h~ i r fl ~t a~r t i~e srt i l .h o~u l l express
o a u l b o r i l r o l Dailalru i s s l r i c l l r lorbidden. DATE Aor. 90. 7 n O 5 OSAKA JAPAN
 Detai I " A"

CW P U M P HYDRAULIC JACK (for s i l e boll1

/

I
CENTER CENTER (for s i l e b ~ l t l

L 1400
K uM I
TURNING SPACE HATERIAL
I 0 SCALE: 1 : 2 0
MASS.

TYPE
&I OTY. @ ( ~ 3
OK-20 29435
NAME ENGINE D I SASSEMBL I NG
SPACE
PARTS NO.
E200050530
D W G . NO.
Z D
803932
1 I
 n l
m ]ENGINE CONTROL SWITCH BOX

.IVIWI IUII oun

irn"Ton! , VALVE
, -,,-, BOX
A,.,.-m.,

d l
Z GAUGE BOARD
v 1

- -
2 z
I I I
N/& NAME
*"I\ L Y

A R R A N G E M E N T OF F I T T I N G S
I

m
DRAWN K. TANAjE
DAIHATSU D I E S E L HFG. GO., LTD.
A ~ ~ ~ g 4 1 \ ~ i i - ~ k l i 2 ~ 1 t 0 f i f i # r ti rha 1v i ~n o/ 1i sh lihse ~ r o ~ e r ol lr D a i h a l s u D i e s e l HIo.Co.,LId. Re~roBuclion,use or lisclosore
a
m? l o l h i r l p a r l i e s r i l l o u l express a a l h o r i l r o l Daihalsu i s s l r i c l l r lorbidden. DATE HAY. 25,2005 OSAKA JAPAN PARIS NO. I I
z
0 D W G . NO.
Q802333610BZ 1.-
 Remarks
I +b I B i t e j o i n t
I 0 1 ~ a n i oj o i n t I
I-'++ F l e x i b l e t u b e 1 STP 1 S t e e l
BFlfl@tg*tr
i2fiiticrTWR < t : & L ' o
A i r o u t l e t from the venlilater t o Heat i n s u l a l i on f o r exhaust gas p i p i n g
O u l l e t o f DO t a n k t o b e a r r a n g e d be arranged near the turbocharser ~ x h a u s tg a s p i p i n g s h o u l d b e f i x e d o f h u l l side including the expansion
h i g h e r t h a n 1. 5m I r o n t h e c e n t e r air inlet immovablv w i t h h u l l p a r t a s c l o s e as j o i n t s h o u l d b e c a r r i e d o u t by s h i p y a r d .
1 l ~ 1 C hl e c k valve I a l crankshaft.
Rubber hose
e x p a n s i o n j o i n t on t u r b o c h a r g e r .
I cock I J o i n t ($
v i ~ e I 20x1.2 CUP
(DAIHATSU SUPPLY1
i side cleaning
D r\I/a i n
Drain 3

HI Exhaust manifold Damper

E x p a n s i o n joint, \

($1 J I SEF(I)877'/9P$#L$i!L.
(NOTICE) J I S Companion f l a n e e s a r e
n o t s u p p l i e d b y DAIHATSU.

V I O I Steam i n l e t

\ 27.2X2. 9 STP

\Re1 ief valve

-*
L

rn
-
:
-
,15x2.3 STP

F b ' / . @ e s $!-B+&T3%TEfi.
D r a i n p i p e s on engine a r e t o b e l e d
t o h o t l a m a l common b e d b y D A I H A T S U
APPROVED ,Z>Y? No. A D K 2 0 - 3 4 3 7 - 9 ( 1 0 ) # 0 0 5 W"ERlaL 0 SCALE: -

CHECKED
BEFORE

REF.
MASS.

TYPE
&lory. @ I A ~
5DK-20
NAME
P I P I N G D I A G R A M ( 1 )
DRAWN
N J ~ D A IDIESEL
K. TANAIE H AWFG.
Tto.,SLTD.
U F U E L O I L & EXHAUST GAS
DATE HAY. 2 5 , 2 0 0 5 OSAKA JAPAN PARTS NO. I
I D W G . NO.
- -

0 8 3 1 3 3 7 9 9 0 8 2
 Joint
(DAIHATSU SUPPLY)
a

I ~ ~ T IJ C
I S EC o)m p a n i o n f l a n g e s a r e
n o t S U P P Il e d hu DAIHATSU.
--
"
>
H a e n e t i z e d ahen
BXl. 6 CUP
normal s t a r t i n g

Normal c l o s e d
:Opened when s t a r t in8
\
7
4- QIOXI.
B STP
:Push b o l l o n m a n u a l l y
when s t a r t i n 9
from dead s h i p

I
1
. ,

I0Xl.B CUP
I

f r o m dead s h i p
1
7)
Safety valve
e t press. 0. 9HPa

Air vent v a l v e

'GI' T y p e
F-r o-m -a i -r -- Transmitter F.O. c o n t r o l p i s t o n
J 6 ~ u e l s h u t down d e v i c e

Drain - - -- -

Reeulator 6 Relay v a l v e

10x1. 6 CUP
-- -

Air slarler
,
k
f . ); ; ;~.0
X .6

down
magnetic v a l v e
CUP

masnelic valve
F. O.~;;;;~OI, ,
.O. s h u t down
3snetic valve
15s)

i?
I

\IDXI. 6 CUP

I I
C.H E-.
CK.
E.
D I REF. I TYPE 5OK-20
I
A1REV:STARTING P I P I N G FROM DEAD S H I P 1 JUN, 27,2005 1 K. T I=
K. Tanabe
DAIHATSU DIESEL HFG. CD.,LTD.
NAME
P I P I N G D I A G R A M (2)
~RAwN STARTING AIR
h u ~ 9 f 1 \ ~ ; r - r h & b i ~ r r ) ~ t i ~ ~d tr a~r~i n~~/i s~ hl hie sm e r l r 01 Drihalsu Diesel Hl~.Co.,Lld. Re~roduction,use or l i s t l o s o r e OSAKA JAPAN P A R I S NO.
ililR(t$, ~ ~ ~ ~ ~ - ~ l o ~l h i r~d p a~r l i e*s r i~l h o :u l elbless t ~ r ~u t h otr i l r. ot ~D r i h r t s u i s s l r i c l l r lorbidden. DATE APR. 20, 2005
D W C . NO. 0633334690 BA
Remarks

F l i n s e a
I O A I H A T S U SUPPLY)
Joint
(DAIHATSU SUPPLY)
0
D r\,Ia i n

To b y - p a s s $
filler

(LO t a n k l e v e l s a u e e l

D r a i n p i p e s o n e n g i n e a r e lo be l e d
l o b o t t o m o f common b e d b y DAIHATSU.
bppRQVED
I/%) No A D K 2 0 - 3 4 3 7 - 9 ( 1 0 1 # 0 0 7
GROUP 0 SCALp -

CHECKED
BEFORE

REF.
MASS

TYPE
&IoTY @ 1 ~ 3
5DK-20
NAIIE
PIPING DIAGRAM (3)
DRAWN
f lJ
K. TANAEE HATSU
e DIESEL
~ HFG. to.,
~ LTD. ~ LUB. OIL
DATE HAY. 2 5 . 2 0 0 5 OSAKA JAPAN PARTS NO I I
I DWG. N O . ~~

Q834337300BZ
-~
 1 2 3 4 5 6 \\y 7
Rernar ks ~tt ' ~ - ~ 3 > m f f i k t 1 @Et ~B ~ P, Y ~ ~ ~ ~ R
&BRhEfih<0.2 5 - 0 . 3 5 M P a t 8 5 d r i . @ M 9 7 ' / 9
-IF Flanse lwl v a l v e (;ii,h,,) - 6 3- I O r n ~ ~ L i f i ~ ~ T ~ t ~ 8 1
111 Union j o i n t w V a l v e (Union) An e x p a n s i o n t a n k s h o u l d b e p o s i t i o n e d s o t h a t i t c a n
p r o v i d e a d e q u a t e s r a v i l ~l o p r e s s u r e t h e c o o l i n s w a t e r
Bite joint IMI C h e c k v a l v e l o 0.25-0. 3 5 M P a b e f o r e e n g i n e s t o p r e v e n t c a v i t a t i o n .
LD
rm C o c k T h e t a n k b o t t o m s h o u l d b e ~ o s i t i o n e d 3-10m a b o v e t h e -
N I:I Orifice
crank s h a f t c e n t e r o f the ensine.
K 0 Banjo j o i n t STP Steel pipe
w
-
+A- F l e x i b l e tube
Flex-master @
CUP Copper p i p e
Press. aauae
-
Butterfly valve @ Thermometer M
-
I I -
--- ----- --- -lit -
4
- ---1
- BY DAl HATSU Thermo b u l b
/ Expansion tank I I f necessary / I n
c o n n PF3/4
--- Press. s u i t c h (SHIPYARD SUPPLY) I
BY SHIPYARD T I

( 1 J I StfF~h377>5M~@LZttL. T o F. W. c o o l e r
(NOTICE) J I S C o m ~ a n i o nf l a n s e s a r e
n o t s u p p l i e d b y DAIHATSU.

-
N 76.3X4. 2 STP
+
-
a
m
!u
a#:
+2
m*
%=+;
LLm
[1

*
4
IP
I
h 89. 1 X 4 . 2 STP -
H

=
0
m

-
4)
\
m
LL
-a
w-
K
.t
1
1 Cooler line 1
3
CO
+;
m

DWG. N O .
0836337210BZ

--. ~ . ~ ..
~~ ~
-
~~~~ ~
 OFF d e l a r B seconds
Over 112-1151. c o n t a c t . . . 112C-12AlON
P u l s e sensor t r p e

Excitin~
liiv

1 HS I Handle s n i t c h
I
PM 1 1 . 0 . P r i m i n g v u o v n o t o r
0C24Vm0.1A FO c o n t r o l i n s t a r l i n g P r o c e s :
when s o l e n o i d o a o n e t i z e d
When t u r n i n g bar u s e d Normal
c o n t a c t 13-11 ... ..OFF close
II S t a n d - b-v
~ ~
At r u n n i n g v o s i l i o n
c o n t a c t 12-41.. ON. 11-21,. OFF
I AC 440V. 39, 6OHz. 0.75tw. I. 6~

\
,
I1
,
,. /
L

x
G l a n d 20b
L
I

I'
II
Gland 20c
L L

'\Gland .20. \ .
J u n c l l o n box
L

Gland 2 5 b
L

Gland 25c
53
OPYC-1.5 L~YPCY-I. 5 A P Y C Y - 2 7 S P Y C Y - 5 3% T T Y C Y S - 4 3% T T Y C Y S - 7
j%G
TO PRIMING PUMP
Note: CONTROL PANEL
1. T h i s d r a w i n g s h o w s t h e n o r m a l r u n n i n g .
RAISE I 2 . W i r i n a b e t w e e n e a c h d e v i c e and j u n c t i o n b o x s h o u l d be
c a r r i e d o u l b y t h e e n s i n e maker.
(DAIHATSU SUPPLY] 3 . Z M a r k e d c a b l e and t h e w i r i n g w o r k s should b e c a r r i e d o u t
Speed s w i t c h u n i t - 0 by the ship builder.
I I IDA1 HATSU SUPPLY1
4. D i o d e f o r m a s n e l i c v a l v e : 10DDA40/NIHON INTER CO., LTD.
A5. S u r g e k i I I e r f r o m s o v e r n o r motor:ERZVIOD390/MATSUSHITA ELECTRIC INDUSTRIAL CD., LTD.
Governor speed
conlrol unit APPROVED / A L I S 1 No. A D K 2 0 - 3 4 3 7 - 9 ( 1 0 ) # o o ~ ~ ~ ~ GROUP ~ E0 ~SCALE: ~ - ~ ~
IDAIHATSU SUPPLY)
I I I
I
BEFORE MASS.

I TYPE
&I OTY. I@a
IA:
I I I
CHECKED 1
, MDAIHATSU
,.
- REF.

DIESEL IFG.GO..LTD.
P? W I R I N G DIAGRAM
NAME
~ n vL Y- ~ n
*"I\
I
I
h I ~ 0 ~ : G l a n PdO c , S u r g e k l l l e r . R E V : C a b l e size. n o t e I J U L . 4. 2 0 0 5 1 K . T
drarin! i s lhe properlr ol Oaihalsu Diesel Wl~.Co.,Lld. Re~roduclion,use or disclosure
;~~941\~~ir-rhtb&ttn6fi#rtmr~~~his DRAWN K. IANAIE
t ~ ~ tr i.l hj oluol express a u l h o r i l r ol Oaihalru i s s l r i c l l r l o r b i d h .
~ * ~ ( ~ ~ , ~ 8 R ~ $ ~ * ~ m f l h~i r~l :parties DATE APR. 20. 2005
~~ ~
OSAKA JAPAN I
P A R T S NO. II II
D W G . NO.
Q 8 1 1 3 1 1 7 4 0 B A
 HUDONG & ZHONGHUA SHIPBUILDING (GROUP) CO.,LTD.
S.No.Ii1389A
S.No.HI39OA

DAIHATSU DIESEL MFG. CO., LTD.

MAIN DIESEL GENERATOR ENGINE

LOCAL CONTROL PANEL

RULE : ABS-ACCU

-I
I-
-
\I
f
I
3
4'
C
3
c
c
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0
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li

DWG. No. K S 2 0 0 5 0 4 1
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L
 DRAWlNG
CASE I
EFT SI0E)I
J INTERNAL W I R I N G OF STRANDED TYPE
AND F L A M E R E T A R D A N T
S Y P - I S O V - 1 . 5 s s. S C P - 6 0 0 V - 2 . 5 s q
m I N ACCORDANCE W I T H J I S 3 4 1 0 ( 1 9 9 7 )

SEPARATOR /
P R O T E C T I O N GRADE IP44
P A I N T COLOR
CONSUMPTION POWER(1ENGINE)
GLAND
MUNSELL 7.SBG7/2
(AT STARTING sow WEIGI4T ABOUT 300l:g
APX. A T RUNNING 25W(MIN)
(AT STOPPING l o w (MAX) ONE ( I ) S E T PER VESSEL

PA"IL, I MAIN D I E S E L G E N E R A T O R FNGINF

.-
LOCAI. CONTROL PANEL
O U T LINE
 TO L.O. PRIM. PUMP STARTER
L-MPYC-4 (250)

KTM WP
I

MAIN DIESEL GENERATOR ENGINE

LOCAL CONTROL P A N E L
TERMINAL ARRANGEMENT
 KTM IIP I

TO No.? D/G ENG. JUNCTlO

(SPEED SENSOR) L-MPYCS-4 %
TO No.2 O/G FNG. JUNCTIONBOX
L-MPYC-37 (35b)

TO L.O. PRIM. PUMP STARTER

L-MPYC-4 (250)
 p " / , ,..,,,,.
(SPEED SENSOR) L-MPYCS-4 (250)

TO No 3 D/G FNG ,lUNCTlQN

TO L.O. PRIM. PUMP STARTER

L-MPYC-4 (250)

MAIN DIESEL GENERATOR ENGINE

L O C A L CONTROL P A N E L
iWRCE
!20V 6Wz No.' G/E
CONTROL CIRCUIT

No.1 G/C
SAFETY ClRCUlT
SWRE
OC24V

Na.1 G/E
LAMP ClRCUlT

FROM N0.l
G/E

No.2 G/E
CONTROL CIRCUIT

SAFETY
No.2 G/ECIRCUIT
FROM N a l
G/E

No.? G/E
LAMP CIRCUIT

FROM No.2
G/E

No.3 G/E
CONTROL CIRCUIT

No.3 G/E
FROM No.2 SAFETY ClRCUlT
G/E

~ 0 . 3G/E
LAMP ClRCUll

MAIN DIESEL GENERATOR ENGINE

-'"L"
-OATS LOCAL CONTROL PANEL
- %5.JUL.'05 CIRCUIT D I A G R A M
-0"hW"
"+P
11

-
1111
MAIN DIESEL GENERATOR ENGINE
L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
5
13SHIP INSTALLATION
MAIN DIESEL GENERATOR ENGINE
m:7
ATTACHED ENCINE
L O C A L CONTROL P A N E L
SEOUENCE DIAGRAM
MAIN DIESEL GENERATOR ENGINE
LOCAL CONTROL P A N E L
 HANDLE SWITCH t

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z
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0
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0

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E13ATTACHED ENGINE
-"*"
-m~,s
/ MAIN DIESEL G W E R A T O R ENGINE
LOCAL CONTROL P A N E L
25.JUL.'OS SEQUENCE DIAGRAM
. D""",,
E17SHIP INSlAUAnDN :scALc / MAW DIESEL GENERATOR ENGINE
E:7 EmNE
ATTACIIEO
-
o.7~
25.JUL.'05
L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
.01"1(,1 : . .L.*;,,
"am ~ ~ Y N P ~ O I ~
I oT t z ~r, 14. T ,K kl , (;5I"1i,!
b IKS2005041-206
Kyoean E l e c t r i c M f g . CO., Ltd
-'"""
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/
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MAIN DIESEL GENERATOR ENGIIqE
LOCAL CONTROL P A N E L
- 25JUL.'05 SEQUENCE DIAGRAM
.m.w"
k:7SHIP INSTALLATION -""" / MAIN DIESEL GENERATOR ENGINE
E:7 ATlACHED ENGINE .mame
Z~.JUL:O~
L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
.n n l w
 SPEED SMTCH UNIT
,

SHIP INSTALLATION
-I""- / I MAIN DIESEL GENERATOR ENGINE
L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
SHIP INSTALLATION
MAIN DIESEL GENERATOR ENGINE
L O C A L CONTROL P A N E L
ATTACHE0 ENGINE
SEQUENCE DIAGRAM

"A". " C V ~ S ~ " "

KS200504-1-211
1
Kyosan Electric Mtg. Co., Ltd.
E:7 SHIP INSTALLATION
E13 A ~ A C H E O ENCINE
-"*"
.OATS
/ MAIN DIESEL GENERATOR ENGINE
L O C A L CONTROL PANEL
- 25.JUL.'O5 SEQUENCE DIAGRAM
 SOURCE

STiWID-BY

STARTING

nn
ALARM BLOCK -
X!? RUNNING

S T M T FAILURE

SAFETI STOP

STOP

SAFER STOP V A L M

LOCAL

REMOTE

RUNNiNC

SOURCE F A I L

SAFETY STOP CIRC.

TROUBLE

START FAILURE

S A F E R STOP

L O . PRESS. SWITCH
(LOW PRESS. : OFF)

? : l 5 % ~ ~ ~ ~ ~ ~

LO. k
F.O. LOW PRESS.
(REPOSING : ON)
NlI>
hL
RXI

1 1 1 1 I 1 I
0 DELAY
I
011 DELAY
SE'i zowc. YT BSEC.

--
MAIN DIESEL GENERATOR ENGINE
L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
1"*" // I MAIN DIESEL GENERATOR ENGINE
-~ -

oh<= LOCAL CONTROL P A N E L

25.JUL.'O5 SEQUENCE DIAGRAM
.on"""
 SPEED SWTCH UNIT

,
1IP

N32
OY DELAY 0 4Y
SET ISCC. si ic.

E:7 SHIP INSTXLATION

m
SHEET Nm.

" / i MAIN DIESEL GENERATOR ENGINE

L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
 MAIN DIESEL GENERATOR ENGINE
LOCAL CONTROL P A N E L
7 2 ,1111 '"5 SEQUENCE DIAGRAM
MAIN DIESEL GENERATOR ENGINE
L O C A L CONTROL P A N E L
SEQUENCE DIAGRAM
\
FOR ENGINE CONTROL ROOM CONSOLE
,
FOR M N N SMTCH B O W 0
C

ti d
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8
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NORMAL CLOSE
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2 I
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25.JLL.05
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MAIN DIESEL GENERATOR ENGINE
LOCAL CONTROL P A N E L
SEQUENCE DIAGRAM

1 (- 7)
1
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l < S 2 0 0 5 0 4 1 - 21 9

Kyosan Electric Mfg. Co., Ltd.

i l P No. SPARE PARTS LIST FOR U S E SETS PER
VESSEL
I

r I
LOCAL C O N T R O L PANEL MAIN DIESEL GENERATOR ENGINE
11390A
I

REMARKS
.EM NAME OF
W
-OF
N o. PART
'ER 'ER
;ET

I-
84 84

'
- - OMRON CO.

9 9

- - OMRON CO

3 RELAY 12

3
12

-
3
I
- G684BNO DC24V
OMRON CO.

( W I T H S P A R E I)
OMRON C O ,

/ mb
+
5 TIMER 24 24

- - OMRON CO

6 OC POWER T
m
0,
3 3

k - - OMRON CO
6 6
- -
7 FUSE ELEMENT 12 12
- -
UTSUNOM I Y /
15 15
- -

+---
DISCONNECTING 6 6

SElKO ELEl
-

DISCONNECTING
3 3
SWITCH

- - SElKO E L E

CONTROL 3 3
lo SWITCH
SElKO E L E
KYDSAN ELECTRIC
MFR'S NAME M A N U F A C T U R I N G CO.. L T O
DRW. NI KS2005041-30
i I P N o . SPARE PARTS LIST FOR U S E S E T S PER
VESSEL

LOCAL CONTROL PANEL MAIN DIESEL GENERATOR ENGINE

11390A

- -
f -
EM NAME OF
OUTLINE
Uo. PART ARE

PUSH BUTTON jR30GPR-10

SW l T C H 1
'In lock t y p e

- F U J I E L E C-
1 HlTE
PILOT LAMP 1
-
GLOBE 2
-
1
- LUE I I Z U M l DENK I

PUSH BUTTON
l3 SWITCH
I 4BN110

- lZUMl DENK -
I

SELECTOR
l4 SWITCH I

lZUMl OENK I

P6B-Y 1
15 RELAY PULLER 1 FOR G 6 B - 4 B N D

OMRON C O ,-

16 PILOT LAMP 33

- NlHON CHEMI-CO N

4 lOE4
INTERNATIONAL
- R E C T I F I E R CO..

YOSAN E L E C T R I C
ANUFACTUR l NO C O . L T D
HUDONG & ZHONGHUA SHIPBUILDING (GROUP) CO.,LTD.

DAIHATSU DIESEL MFG. CO., LTD.

MAIN DIESEL GENERATOR ENGINE

L.O. PRIMING PUMP STARTER

RULE : ABS-ACCU
 3 I 4 I 5 6 I 7 I 8
1 I 2 I

I N S I D E LAYOUT
No. I

PROTECTION QRADE I P 4 4

P A I N T COLOR
MUNSELL 7,5BG7/2

WElOHT ABOUT 75K9

ONE ( 1 ) SET PER VESSEL

NAME PLATE
H 0 . l H A I H D I E S E L 8EH. EHO. NAL'E P L A T E
L . O . P R l U l H O PUMP I T l R T F l l
"e.1 Y l l l i DIESEL OF". THO.
L . 0 . P R l Y l H P PUYP S I A R T E R
Ha.3 Y l l H O l E I F L (IEH FHO.
LO. PRIIIIHa P U P ITlATSR

PAL<
I An 1 MAIN DIESEL GENERATOR ENGINE
L.O. PRIMING P U M P STARTER
O U T LINE
 SOURCE
AC440V 60Hz

L.O. PRIMING PUMP

(FOR NO.^ G/E)

THERMAL RELAY

SCOPE
1.4-2.2A

--

n MAIN DIESEL GENERATOR ENGINE

n L.O. PRIMING P U M P STARTER
A BY ,,,, SEQUENCE DIAGRAM (No.1 G/E)

1
ARK REVISION

/
DATE SCALE DWO.NO.

/
ESIGNED CHECKED

~~.JuL.'O~ K S 2 0 0 5 0 4 1A-201
, . K , p p p B
Kyosan Electric Mfg. Co., L t d .
 1 I 2 e
I 3 I 4

SOURCE ENG. RUNNING

AC440V 60Hz (FROM D/G ENG. L.C.P)
R2 52 T2 v
% Z
0

E
a
0
5
6
0 0
"3 "I
(L IL
Y0 W
>
0

251
I1

---1

243 OFF
M

OFF O K A Y
SET 1SEC.

L.O. PRIMING PUMP

(FOR N o 2 G/E)

KT25 KTM
I-

THERMAL RELAY

ADJUSTING
SCOPE
I SETTING I MOTOR

AI I MAIN DIESEL GENERATOR ENGINE

6I
A I I I L.O. PRIMING PUMP STARTER

KS2OO5041A-202

Kyosan E l e c t r i c Mfg. Co., L t d .

 1 I 2 I 3
ENG. RUNNING
SOURCE (FROM D/G ENG. L.C.P)
AC440V 60Hz , LL
\
R3 53 T3 LL Z
0 0

E E
F
0
e
0
0 0
rCI 0

IL n
W W
> >
0 0

351
JI
I

L-----__I
L.O. PRIMING PUMP
(FOR N0.3 G/E)

THERMAL RELAY

SCOPE
1.4-2.2A

4I I I M A I N DIESEL GENERATOR ENGlNt

4I
A I I I L . O . PRIMING P U M P STARTER
 SETS PER
HIP No. SPARE PARTS LIST FOR U S E VESSEL

-11390A
L.O. PRIMING PUMP STARTER MAIN DIESEL GENERATOR ENGINE

I
4
NAME OF OUTLINE
N1 -
-
N
- G
'ER
Y

'ARE
REMARKS

a mT -
IS5

1 I SCONNECT I N G CHRl6-A202EF-
3 I 0221 -F088-PE
;W l TCH HH 3
F1 5 4 k-484 - - KRAUSBNAIMER

MAGNET l C SC-013H
CONTACTOR & 3 I C O I L AC220V
THERMAL RELAY THERMAL 1 . 4-2. 2P
- - M l T S U B l S H l ELEC

3 1

- - OMRON G O

H3CR-HBL ( 5 )
T l MER 3 1 OFF DELAY
AC220V
- -

P I L O T LAMP
GLOBE 3 1

- - IZUMI DENK
I
P I L O T LAMP
GLOBE 3 I

- - I lZUMl DENK

P I L O T LAMP 6 6

- -

FUSE ELEMENT 1-1 0; 12 12 12 UC- 1, 3 A

UTSUNOM l Y i
k 5 0 4 T
- - ELEI

- -
KYOSAN E L E C T R I C
MFR'S NAME MANUFACTUR I NG CO., L T D
DRW. Nc
l NPUT

w
OUTPUT
DCO-24V
V A R l ABLE
.......................................................................
DIESEL GENERATOR ENGINE

L. 0. PR I M I NG PUMP
TYPE: TLGM-2. 5

PUMP: 2. 5ma,'h x 0.2MPa

0.75kW.1.6A, CLASS B
MOTOR:AC440V.3 ~5.60Hz.
........................................................................
L. 0. PRIM I NG PUMP
 ~ m ~ i % ~ B l &
THREE-PHASE [ N D U C T L O N MOT .'

Rated Current : 1 .6A SIIIELD NMIK 6 2 0 4 7 , ~ 6 z o d z z

Starting Current : 9.5A

CABLE -
GLAND 2UB

~ ~ U g?Lfis:
I F IP44 -I$- rcccssoar
 (MANUFACTURE LENGTH)

\1 ( S E T LENGTH) 1

l'k 43
SPECIFICATIONS

1- EX1 NSlON CONTRACT l ION

FLOW

a LATERAL MOVE A Y
;tss~mt
WORKING P.
bREh
WORKINFG 1.
@RS"@
AY
ECCENTRIC

0. 0 0 3
MAX. 5 50
MPaG
4'
SPRING RATON
/<2Z&

APPLICATIONS E N G I N E EXHAUST GAS

L=220

( Nhw. &Mrt%TBZ,
AilllllKL
TO B E REMOVED
AFTER I N S T A L L T I O N
0
m
a DRA l N
 ?$Y

......................................................................................................

DIESEL GENERATOR ENGINE

JACKET WATER PREHEATER UNIT

DAIHATSU DIESEL MFG. CO., LTD.

TECHNICAL DEPARTMENT
OSAKA, JAPAN

-
SNo.
TYPE
-
DRAWN BY
CHECKED BY
wq Qf&l

LIST No. QZZZ466950FB

- -- - -.- - -- - --- - -- -- - -.- -
. -

DATE Sep. 12,2001 APPROVED BY

-
A : Rev i sed on Jan. 15,2003 (by Quan)
REV I S ION B :Rev i sed on Aug. 8,2003 (Gland s i ze) (by Quan)

adk20-3291-3 [lo] I #465 1 (1/15)

 ;HIPYARD

AESSRS
i U DONG SHIPYARD
PREHEATER UNIT

IAIHATSU DIESEL MFG. CO.. LTD.

I CLASS

S-NO.
I ABS-ACCU

I I
IEAD FRONT SELF SUPPORTING AMBIENT
YPE TFMP 50'C

;ID€ COVERS SHEET STEEL

30TTOM PLATES S H E n STEEL

--
'AINT COLOR MUNSELL NO. 7.5BG 7 / 2

.FTER OF
UAME PLATE
ENGLISH I MATERIAL I PHENOLIC

3RAWING &
ENGLISH
3OCUMENT -
A C 4 4 0 V 3 0 6 0 H Z 1 0 KW 2 SET
HEATER
AC V 0 HZ KW SET

PUMP AC 4 4 0 V 3 0 6 0 HZ 0 . 7 5 6.0
~ ~ rnvh 1 SET
SOURCE -
CAPACITY
TRANSFORMER
/
AC 4 4 0 2 2 0 V 1 0 6 0 H Z
24V
4 0 0 VA
SO

CONTROL CIRCUIT I AC 2 2 0 V 6 0 HZ / AC 24V

SOURCE AC 4 4 0 V 3 0 6 0 HZ
---
POWER CIRCUIT CONTROL CIRCUIT : NUMBERING
COLOR OF R(U) : GREEN . P(+) : RED EARTH : GREEN/YELLOW
VINYL CAP S(V) : YELLOW . N(-) : BLUE
T(W) : BROWN

INTERNAL POWER CIRCUIT : 660V SCP BLACK

WIRING CONTROL CIRCUIT : 660V SCP or 600V STYLE 1 0 1 5 1 .25rnm2
REMARK CIRCUIT :
-.
DRAWING APPROVAL DWG WORKING DWG COMPLETION DWG
COPIES 3 COPIES 3 COPIES 3 COPIES
... --- ... -
MODEL I PART NO I WEIGHT
REMARKS
SSE20000
-.--.
1 -. - . -
SSE000751A ABT 1 5 0 k g
- -

-- -- -. - --.

2 z K z z - - ~
-

--
APD

CHK
SHEET hO.
02
SCALE
N / 5
-
-- '

-- ..
DWN Y. K. KIM
=@
~

DATE . DESCRIPTION
-- - -, -. - -.

459 sims~oougEOo&ri~
TEI. : +82-55-231-6707-8.
G6kDW.
FAX : -8709
TITLE ; 1304

GENERAL SPECIFICATION

I D R A W I N G NO. ; SSE000751A
 SYMBOL NAME 1 SYMBOL
I
NAME
-
$ F I FUSE
.

OVER LOAD
- Y Y I

H I --I- I CONNECTION OF

-- - @
HEATER

AC MOTOR
COIL OF
-I ELECTRIC WIRE

TERMINAL OF PARTS

-- - @ AUXILIARY RELAY OUT SIDE WIRE

COIL OF
@ MAGNETIC RELAY
CONTACTOR OROF
PUSH BUTTON
SIGNAL LAMP CO CONTACT OR
OF
- PUSH BUTTON

@ PUMP . MOTOR ITGI TOGGLE SWITCH

BALL VALVE
@ --
@ SAFATY VALVE

ALARM & BUZZER

u
m lr
TRANSFORMER

f- >lh
THERMAL RELAY

I [ Eb I TEMPERATURE SWITCH I
CONTACT
NORMALLY OPEN
CO CONTACT
NORMALLY CLOSED

~ ~ -
TRANSFER SWITCH

-.- ~

I I APD ( - - NOT
SHEEl

-- Y. K. KIM
DESCRIPTION
TITLE ; 1304
-
TEL : +82-55-231-8707-8, FAX : :6709 1 SYMBOL LIST I
 2HTR
IHTR lOKW BOTH
1 OKW 2OKW

OFF 0
130

F -
1 JACKET WATER PREHEATER UNIT
C

SINSUENG ELECTRIC CO LTD.

/ Fox : 231-6706'
I
re1 : t82-55-231-6707-8
-- -u ,.
Moteriol : SUS304, O.f

-. -. . - - -- - -.
~ - ..... ~ ... . . ..~
SCALE
.- .- -- -,-- CHK
2003.08.02 FOR
- APPROVAL
-- - -. ... . . . . -. .
REV 1 DATE DESCRIPTION
-.--- .--.... -DWN Y. K. KIM

@a S!mSuomg EOmQrie Gaokd.

TEL : t82-55-231-8707-8,
--

FAX : -0709
-
TITLE : 1304
-

NAME PLATE TABLE & LIST

- .--.... . -, . .. - ... .. -... . ... . ..-. - .. - -. -- -
 -.

.
N A M E
......... .
.
TYPE I SPECIFICATION REMARK Q'TY MPKER

NO FUSE BREAKER 4 c ; -
MAGNETIC CONTACTOR

OVER CURRENT RELAY

..............

....... ..

. . . . . . .
FUSE
-
PlLOT LAMP

PILOT LAMP
WHITE

GREEN

GREEN
1 IYONGSUNG
I

2 YONGSUNG

.....
RED 1 4 JYONGSUNG

....
PUSH BUTTON
--- RED 1 1 JYONG SUNG

CAM SWITCH
. . .
I 1 1 HANYOUNG
TEM'P CONTROLLER
.....
LIMIT THERMOSTAT

..
COMPOUND GAUGE
----- .- .
THERMOMETER

-.
-- -
. --
-
APO
SHEET
05
NT
....... -~ -- ---- SCALE
CHK

Y. K. KIM
.-- --. . .,.
.
-..... DESCRIPTION
TITLE : 1304

TEL : +82-55-231-8707-8, FAX : -8709 MATERIAL LIST

~

--

DRAWING NO. ; SSE000751A

 I W N I R O L PANEL

WATER WATER
INLET OUnEl

2 T E M P SENSOR 1N S 304 I I PllOD Ohm

I !CONTROL PANEL I SSLW I 1 I I

TITLE : 1304
63 8h1%@~ilg
SHEET NO.

0 2003.08.02 FOR APPROVAL

akb%.
~ k @
PIPE WORKING DIAGRAM
4PD

CHK
s w
06
N / S
AC 440V 30 60HZ 20KW
TEL : +82-55-231-6707-8. FAX : -6709
'EV DATE DESCRIPTION OWN Y. K. KIM @-
1 I 7 I I I I

I I DRAWING NO. ; SSE000751A

 ... -

a*
~

......... .. WAKE SUPPLY

YlWO POWER : 3Oc:l 900 . -80. - 950 .WATER REMOVE SPACE
CONIROL
MNORLUL
: 25b:I
: 1 5 ~ 1 180 A 500 , JIS 5K-10A W N G E
/WITH COMPlUllOH FLPNCC. GASKET
BdLTS & NUT
JIS 5K-404 W G E
Yrm COYPUllON W G E . LUKE1
BUTS & NUr
F N P 4 I

01.

03. RUNNNC
0.
P~IEC~MI
02. INSUMION

PUNT COLOR
05. DYER H ~ N C; asc
: IPII
:F
: ON(7O.C). OfT(75.C)
: V U H S N NO. 7.5BG 7/2
06. DESIGN TDI'P : BSC
07. DESIGN PRESS : 0.2Mp.
0 . -
08. w o G n r
-
: - FRONT VIEW

: 1 5 0 ~ ~
SIDE VlEW

I i TITLE ; I304
APD
SHEET NO.
I 8BrmSusrmg E O Q E ~ W. SWE
07
J.W PREHEATER UNIT CHK
N / S
0 2005.08.02 1 FOR APPROVAL AC 440V 30 60HZ 20KW
I TEL : +82-55-231-8707-8, FAX : -6709 OWN Y. K. KIM
EV DATE DESCRIPTION =-@
I I -
7 I 1
" I 7
I .=, I c I 7

DRAWING NO. : SSE000751A

 I
VlSL0003SS : 'ON 3NMV8.a
i 0
" 0 c 4, " 7

1'. 5 -@+a
I I I I I I I
d
L

WIW 'X 'A NMO 6OL9- : XVJ '8'-LOL9-162-SS-ZR+ : 13L NOUdIKlS30 31VO N U
'.<
I-_. MXOZ ZH09 0 C AOW 3 V 1VAOtldaV 803 ZO'BO'COOZ 0
I 3110s XH3 3 , W V XOE l O t l l N 0 3
8 3 80 OdV --
I ; I O N U3-5 VOEl : 31111

I. I
L

DRAWING NO. ; SSE000751A

. .. .... . .. ..... . --- . ..~..~... . .- .. . ~ ..- .. . I .. . .. . . , - _.
,
 1
I 2 I 3
I 4
5
I l-vh
, L

i
POWER SUPPLY

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8SC(OFF)

1 C

- NO.l HEATER ON
-N0.2 HEATER ON
-
-PUMP RUN

:L- 1-
SHEET NO.
APD
10
I SCALE

.
-.
TEL : +82-55-231-8707-8.
-.-- -. -- .. --
FAX : -8709
-- -----.-.... .- - 1 TERMINAL ARRANGEMENT
-.

DRAWING NO. : SSE000751A

 A-A SECTION UNION FOR HEATER SCREWED CAP

ELEMENT DmNL
!
I 69 S6wSuowg E k @ k CQ kd. TITLE ; 1304

HEATER CONSTRUCTION
APO

CHK
SHEFI NO.
)I
SmE
N / 5
3 ( 2003.08.02 FOR APPROVAL
AC 440V 30 60HZ lOKW
EV I DATE DESCRIPllON TEL : +82-55-231-6707-8. FAX : -670s OWN Y. K. KIM @
- .

I I DRAWING NO. ; SSE000751A

 VISLOOOZSS 'ON 3NIMVMa

PUMP MATERIAL

O M E R PMTS

.. - - .~~ L

-
6%S!m%@mg EUmbk @ Wm
TITLE : 1304

CIRCULATING PUMP CHK

SULE
N
12
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0 200.3.08.02 FOR APPROVAL LM4O-160/165
DATE TEL : c8Z-55-231-6707-8. FAX : -6708 OWN Y . K. KIM
EV DESCRIPTION @
I 7 I I I I I
NOTE
;. P A N CHECK VALVE
2 . MATERIAL : B C 6 I
3. SIZE : 1 6 K - 4 0 A
VIEW A-A

I I .-
I I 13
SCALE
--. .--- CHK
0 1 2003.08.02 I FOR APPROVAI N / S

TEL : +82-55-231-6707-8, FAX : -6709 1 VAN L H t

 1 2 I 3 I 4 5 ij2

3-04.3 HOLES

-
1 /P.C.D 78

-
-
+q
ID - -

- -

D NOTE
--

1 . 'JODEL : P 2 9 0 2 M
2 . ACCURACY : f 1.59. F.S
- 3. UATERIAL
a ) CASE : BLACK FINISHED STEEL
b) COVER : BLACK FINISHED STEEL
c ) WINDOW : GLASS
a) ELEMENT : BRASS
E e) MOVEMENT : BRASS
4. RANGE : 0-0.6Mpo (PRESSURE G4UGE)
RANGE : 76cmHg-D.6Mpo (COUMPOUND GAUGE)
5 . TYPE : LIQUID FILLED
- --
APD SHEET NC.
14
..... .-
SCALE
...... -. ... .- CHK
N / 5
- - -.- -- - -,
DWN Y. K. KIM
... ..... DESCRIPTION - -......
.---.... - -.
TITLE : 1304

TEL : +82-55-231-6707-8, FAX : - 8 7 0 9 PRESS GAUGE DETAIL

I ' DRAWING NO. ; SSE000751A

-.
-
 N A M E S K E T C H REMARK
---
-.

MAGNETIC
CONTACTOR
-. ~ ~

--
OVER CURRENT
RELAY
--

CONTROL
RELAY
. . ~

FUSE

GLOVE , 250
GLOVE FOR
SIGNAL LAMP GLOVE . 250
- ... .- -.

BULB FOR
SIGNAL LAMP

BALL BEARING 1 SET 1 SET

SEAL

.- .. -...

SPARE BOX
, -.

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I
I SCALE
 I H I STORY OF DWF

VIEW A

A I R OUTLET VALVE

P R E S S U R E GAUGE
AVSl/lXb10Ox5~~~/~0'/

- V-I EW B
 I SPECIFICATION 1
PLUNGER D I A .

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LEVER STROKE

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CHECKED AFTER

By 0 : . REF. 4 8~1 5 4 6 D ~ N O 1 Z L E T E S T PUMP ASSY. G

DY" M. OHMURO CO.
DAIHATSU DIESEL WFG. I LiD.
PARTS wa
DATE
MAY 29. ' 9 8 OSAKA JAPAN .
0000 000@ DIGNa 1
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( DAIHATSU SUPPLY)

DRAtN K. S H l H O K A f A
DATE Nor. 2 8 m 2 0 0 1 OSAKA JAPAN
O W G . NO.
Q990307230ElZ
- -

T h i s d o c u m e n t ( 8 r a w i n d i s t h e D r o p e r l v o f D a i h a l s u D i e s e l Mfu.Co.,Ltd.
Reproduction,use o r d i s c l o s u r e l o t h i r d p a r t i e s w i l h o u l express
a u t h o r i t y 01 D a i h a t s u i s s t r i c t l y f o r b i d d e n .

D l ESEL ENG l NE
L I S T OF S P A R E P A R T S

D A I HATSU D I E S E L M F G . CO. , LTD.

TECHN l CAL DEPARTMENT
OSAKA JAPAN

1389A/1390A DRAWN B Y K. TANABE

t-=-l
L I S T No.
5DK-20
QE01344500FZ
2005. 08. I 0
I
C H E C K E D BY

A P P R O V E D BY
I
x / a
REVISION

H I S T O R Y O F R E V I S I O N
' "?P
 PAGE

- -
BOX No.
SUI -
- LY
ORK 'ARI DRAW l NG
N A M E S K E T C H I NG
'ER
'ER
U S E 1IP
- HlP
-
INTAKE VALVE No. I 00 100
I D= 64. 0
L= 291.5
30 2
E 2 0 5 7 5 WE l G H T
INTAKE VALVE 9520 I. 150
- - Ko
iXHAUST VALVE No.
I
I 00 100
D= 64. 0
4SSY
\{*I'2 ASSY L= 291.5
30 4
WEIGHT
!XHAUST VALVE 1.150
- - Ko
l O Z Z L E HOLDER- No. I 01 107
L= 2 99. 0
l L F 3 0 1 0 ASSY.
/ a ' JbitclC9' - D L F 3 0 1 H= 267. C
3ASSY 15 3
WEIGHT
F. 0. I N J E C T I O N : 4. I 0 0
VSTEM - - Ko
P l STON R I N G ( 3 ) No. I 0 1500
D= 200. C
T= 5. C
15 I
WEIGHT
P l STDN 0. 162
- - Ko
P l STON R I N G ( 2 ) No. I 01 500
D= 200. C
T= 5. C
15 I
WEIGHT
0. 162
- -
Ko
PISTON RING ( 1 ) No. I 0 1500
D= 200. C
T= 5. C
15 1
WEIGHT
0. 1 6 2
- - K0
No. I 0 1600
D= 200. C
T= 7. C
30 2
R I K 21A WEIGHT
SWP A 0. 090
- - Ka
MFR'S NAME D A l H A T S U D I E S E L MFG. C O . , L T D .
& ADDRESS 4-14, 2-CHOME, TOKU I - C H O , CHUO-KU, O S A K A , J A P A N
 PAGE
(

-
I301 No.

*
- --
SU
- - DRAW l NC
OR1 E
-
S K E T C H NG REMARKS
'ER
IIP
-
)

--
I

15
ID K - 2 0 WEIGHT
017 6. 8 0 0
- --
D= 100. 0
a x L ~ ~t 7 ~. 9 1 L= loo. 0
15
I WE l G H T
I
0. 7 5 0
- --
Ke

EARINC SHELL

15
WEIGHT I
I

- --

60

i
WEIGHT
0. 8 0 0
- --
D= 210.0

18
WEIGHT
1. 770
- --

6
WEIGHT
0. 900

-
--
METAL C A P BOLT No. 1 02919
ASSY L= 485.0
$ 9 1 b * t ' Y 7 3 ' JbE A S S
l4 Y ASSY 36
FRAME M - -
WEIGHT
4. 4 0 0

M F R ' S NAME D A I H A T S U D I E S E L M F G . CO. , L T D .

& ADDRESS 4-14, 2 - C H D M E , T O K U I - C H O , C H U O - K U , O S A K A , J A P A N
 PAGE
SH l P NO.
T Y P E 5DK-20 BOX No.
DRAW l NC
40. N A M E S K E T C H MATERIAL
U S E
FO PUMP, C 2 1 T G - L No. I 03203
42D. N L= 370. 0
FOiii"7" C2 1 T C - L B= 141.0
l 5 42D, N E 2 0 6 4 5 WE l G H T
F . 0. I N J E C T I O N P 0070 16. 800
L
UMP
F. 0. I N J E C T I O N No. 03406
P I P E , WITH J O I N T L= 129.0

16 ASSY WE l G H T
3. 300

V A L V E ASSY
97FF7.P. >\. . ASSY
L=

WEIGHT
194. 0

2. 0 0 0
ETY V A L V E
-.
O I L RELIEF No. I 04200
V A L V E ASSY ( L . 0 ) L= 295.0

ASSY WEIGHT

--
THERMOMETER ( P ) 5 No. I 06800
2OX4X18OX95 L= 275.0
i>E"r4P520X4X18 - - m v ~
OX95 WEIGHT
THERMOMETER (EX.
GAS)
I_ L 4 Ka
THERMOMETER ( P I 5 No. I 06800
20X4X240X95 L= 335.0

WEIGHT

Ko
THERMOMETER 06900
IOOCX3/8P-40 L= 169.0

PCHS WEIGHT
THERMOMETER
0 C)
(I0
L 4 Ka

M F R ' S NAME I1 D A l H A T S U D l E S E L MFG. CO. . LTD. II

& ADDRESS 4 - 1 4 , 2 - C H O M E , T O K U I - C H O , C H U O - K U , O S A K A , JAPAN
 PAGE
S H l P NO.

- -
B O X No.
Su -
- LY
DRAW l NG
401 N A M E I S K E T C H M A T E R l A1
IORU
I NG
PER
PAR
PER
U S E HIP
- iH l F
-
THERMOMETER 2 0 0 No. I 06900
CX1/2P-100

3 I
PCHS WEIGHT
I
- -
H= 110.0
L= 157. 0
3 I
PCHS WEIGHT

- -
L= 169. 0

THERMOMETER (10
PCHS
6 1
WE l G H T I
- -
O I L SEAL No. 07000
SC3555l 1

3 I
PCHS WEIGHT

I - -
O I L SEAL TC3550 No. I 07000
0R
T= 8. 0
3 I
PCHS WEIGHT

I I - -
MECHANICAL SEAL No. I 07200
::EA100305-21

3 1
PCHS A E O l I 0 WEIGHT
20 10 0. 0 8 7
I - -
MOUTH R I N G No. I 07400
D= 115.0
12. 0
6 1
WEIGHT I
- -
M F R ' S NAME
& ADDRESS
I D A I H A T S U D I E S E L MFG. CO. , LTD.
4-14, 2-CHOME, T O K U I - C H 0 3 CHUO-KU, O S A K A , J A P A N
I
ADK20-4211-3 11 QE01344500FZ - 6 /12
 PAGE
? H I P NO.
T Y P E 5DK-2( B O X No.
-
1S K E T C H
SUI
-
'ORK
ING
DRAW l NC
PER
HIP
-
No. IPE
No. I 07600

3
l E l GHT
O . 03r
- K I

No. I 07600

I\' 3. 5. 5 x 3 6 . 5 x 1
3
iWPA
L. 0 . F I L T E R F I T
-
SPR l NG No. I 07600

3
YEIGHT
L.O. FILTER F I T 0. 14'
- K
SPRING::4. OX12 No. 1 07600
5x45. 6
I \ ' * : : 4 . 0 x 1 2 . 5X
15
NNOOOO YEIGHT
I N D I C A T O R & SA 2012
- K
0 RING G I 1 5 No. I 08200

3
YEIGHT

-
K
No. I 08200

3
YEIGHT

K
-
No. I 08200

3
IBR YEIGHT

I -
K
M F R ' S NAME DA l H A T S U D l E S E L MFG. CO. , LTD.
& ADDRESS 4 - 1 4 , 2-CHOME, TOKU I-CHO, CHUO-KU, OSAKA, JAPAN
 PAGE
? H I P NO.

BOX No.
DRAW l NC
N A M E S K E T C H
U S E No. IP~'
I RlNG P31 No. I 08200

llJ~9' P3 1
FPM
=.0. P I PING

3 RlNG G35 No. I 08200

NBR
FRAME

0 RlNG 258 X No. I 08200

SPEC
CYLINDER LINER

0 R l N G G230 No. I 08200

0 C230
NBR
CYLINDER LINER

0 RING(SI)S71 No. I 08200

C Y L I N D E R HEAD

0 R l N G (FLUORO: No. I 08200

OlJ>9' ( 7 Y Y l
FPM
C Y L I N D E R HEAD

0 RING G40(4D) No. I 08200

FPM
C Y L I N D E R HEAD

M F R ' S NAME D A l H A T S U D I E S E L MFG. C O . , L T D .

& ADDRESS 4 - 1 4 , 2-CHOME, T O K U I -CHO, CHUO-KU, OSAKA, J A P A N
SPARE P A R T S ~ I PAGE
S H l P NO.

-
-
B O X No.
SU
-
IORK DRAW l NG
S K E T C H IATER I Al INC
PER
HIP
-

15
HE l G H T

- K

15
HE l G H l

45
HEIGHT

- K

15

'PM
30
HEIGHT

-
K

15

30
F. 0. P I P I N G
-
D I E S E L MFG. CO. , LTD.
ADK20-4211-3 11 QE01344500FZ - 9/12
 PAGE
H I P NO.
T Y P E 5DK-20 101 No.
0
o1 N A M E
U S E
GASKET, S I D E
COVER ( 4 )
k73Y179k' a t 7 E
I S K E T C H

No. I 08402
*
DRAW l NG

O (4)
S I D E COVER Dl3
I-!+-
I20035
1150

GASKET, CAMGEAR No. I 08403

COVER

I
b&+' ? k / \ ' - b ' z t Y E

S l DE C O V E R

G A S K E T . S l DE No.
ED
P=i
I 08402
B= 262. (
COVER ( 7 )

Em!
L= 920. 1
k13Y179b' l b 7 C
l 2
(7) #EIGHT
S I D E COVER
M K I

G A S K E T , G A S OUT No. I 08600

D = 231.1
L E T DUCT (RH 1 6 3 )

WEIGHT
0. 341
TTlNG Kt
GASKET, A I R MOT0 No. I
R BRACKET

NON A S B I WEIGHT
STOS
MOTOR F I T T I N G K
GASKET BEND, I N T No. I 083 15
B= 128.
AKE M A N I F O L D
& L: 145.
55 ,,.
h. x ' I Y ,, +~9=Wl,\.

I N T A K E MAN I F O L D

GASKET, EXHAUST No. I

7'
08609
SPEC WEIGHT

PIPE
/\4+ll,k' X ' I Y \
56
EXHAUST MAN1 FOL

M F R f s NAME I D A I H A T S U D I E S E L MFG. CO. , LTD. II

h ADDRESS 1 4 - 1 4 , 2-CHOME, T D K U I - C H O , CHUO-KU, OSAKA, J A P A N
 PAGE
S H l P NO.
T Y P E 5DK-20 - BOX No.
-
Su
-
IORU
S K E T C H MATER lAl I NG
PER
HIP
-
G A S K E T , C. W. 0 8 8 0 0

60
NBR, WEIGHT I
CYLINDER HEAD SUS304
I -
RUBBER SEAL, I No. 0 8 6 1 0
HEAD COVER

'U
4 7 1 ' h/\' 1. h3-lb
58 SPEC
15
CYLINDER HEAD C
OVER
I ,L i
_B_ -
WEIGHT
I
GASKET, CY L l NDER No. I 0 8 6 0 0
HEAD

15
WEIGHT
0. 1 3 0
I -
GASKET 19 No. I 0 8 6 0 0

15
F. 0. I N J E C T I O N S
WEIGHT I
YSTEM
-
GASKET 21 No. 1 0 8 6 0 0

I \ * 2I

F . 0. P I P I N G
0 SPCC-A
12
2 5 6 5 0 0 WEIGHT
2 1OOCC
I I -
GASKET 17 No. I 0 8 6 0 0

Y*Y I7
SPCC-A
3
WEIGHT
F . 0. P I P I N G 0. 1 0 0
I -
GASKET 13 No. I 0 8 6 0 0

SPCC-A 30
WEIGHT

-
M F R ' S NAME I D A I H A T S U D I E S E L MFG. C O . , L T D . I
& ADDRESS 4 - 1 4 , 2-CHOME, T O K U I - C H O , CHUO-KU, O S A K A , J A P A N
I
ADK20-4211-3 11 QE0 1 3 4 4 5 0 0 F Z - 1 1/12
 PAGE
iHl P NO.
T Y P E 5DK-20 301 No.
- -

SU
lORn DRAW l NG
N A M E S K E T C H IATERIAL I NG
PER
U S E HIP
-
EARINC-LM4030 No. I 09004

15
VEIGHT
. 0. PUMP
- -
EAR I N G . 3 5 No. I 09000

6
VEIGHT

-
No. I 09000

007 3
YE l G H T
OVERNOR M O U N T
G PARTS - -
A T T A C H E D PAD No. I 99800
OCK. B O X - I Z T Y P I
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H= 300.
YE l G H T

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No. I

VEIGHT

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No. I

YEIGHT

K
-
No. I

YEIGHT

- K
M F R ' S NAME D A l H A T S U D I E S E L MFG. CO. L T D . I

& ADDRESS 4-14, 2-CHOME, T O K U I - C H O , C H U O - K U , O S A K A , J A P A N

 TURBO-CHARGER (TYPE :RHI 43.163TWA03)
L I S T OF SPARE PARTS

{IHI No NU23A85C10)

DA I H A T S U D I E S E L MFG. CO..LTD.
T E C H N I C A L DEPARTMENT
OSAKA. JAPAN

.,
l-TqLl
,
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L l ST No. B683300150FD CHECKED BY
~ - ; ~ ~ ~ ~ - ~ I~ ~ . ~ ~
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Type R H 1431163 Turbocharger o x No.

Drawing
Name Sketch Material Remarks
'arts No.

eaded Tin
JOURNAL BEARlNG ronze Cast ins

eaded Tin
THRUST GEARING ronze Casting:

Special
Allov u t s i d e diameter
34 i s i n case
ao 0. 48.

Maker.s name and ISHIKAWAJ IMA-HARIMA H E A V Y INDUSTRIES CO. . LTD.

address TOKYO JAPAN
 .......................................................................
D l ESEL GENERATOR ENG l NE

L. 0. PRIM I NG PUMP
i L I S T OF SPARE PARTS i

D A I H A T S U D I E S E L MFG. CO..LTD.
TECHNICAL DEPARTMENT
OSAKA, JAPAN

S H I P No.

TYPE I DK-20

L l ST No. QYLP339000FZ
-
DATE OCT. 17, 2 0 0 2 APPROVED BY

R E V I S I O N
SPARE ?ARTS Ll ST I PAGE
7!%,o,EE I <-.>
: HORIZONTAL TROCHOID PUMP
L. 9. PRIMING PUMP SH I P NO.
YODEL: TLGM-2. 5 1 SETS

NAME
3 & % 8
SKETCH IMATER I AI -
A2DS
NO.
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BALL BERRING
r-4 9 NO. 6303

BALL BEAR1 NG
aa m UO. 620322

31L SEAL
h-fJL>-lL

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IALL BEAR1 NG
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8 ADDRESS 1 - SH I NMACHI 3-CHOME. N I SHI -KU
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 L l ST OF STANDARD TOOLS

D l E S E L ENG l NE

D A l HATSU D l ESE LTD.

TECHN l CAL DEPARTMENT
I T E M S M A R K E D BY
OSAKA JAPAN % SHOWS ' O U T O F B O X '
SET TOTAL WEIGHT
(W I THO

APR. 25 2000 i ~ p p ~ o v ~ o
E2 1995
REV l S l ON I?!/

H I S T O R Y O F R E V I S I O N

l-4-t-
IUN.2'99 R e v i s e d s k e t c h No. 2

--
s k e t c h No. 46

No. 4 5 De l e t e

I
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MFR' NAME
d ADDRESS
(
I
D A I H A T S U D I E S E L M F G . CO. , L T D .
4 - 1 4 . 2-CHOME. T O K U I - C H O . CHUO-KU. OSAKA. JAPAN
I
 T O O L
I PAGE
S H l P NO.
I?<' J

T Y P E D K - 2-0
(--

D= 240. 0
H= 180. 0

E l GHT
0020 lo. 500
--K o
8- 400. 0
L= 930. 0

E l GHT
18. 0 0 0
K 0
-
B= 154. 0
T= 19. 0

'EIGHT
2.200
K 0
4

FO N O Z Z L E No. L= 457.0
SPANNER 1 9 8- 330. 0
F O J x ' h 3 9 ~ 1 \f'
I9 VE I G H T
ST T O O L : E 2 1 9 9 5 1 2. 0 0 0
K 0
4
PIN. MAIN No. I 81 000 L= 23.0
BEAR l NG

5
$ 4 > $ 9 k 3 9 t 0s

ST T O O L : E 2 1 9 9 5 1
ID c HE l GHT
0. 0 3 0
4 PJ K 0
-
EYE B O L T No. I 95000 L= 90. 0
MI6 0. 35.0
74ili. h \ D
6 I WEIGHT
0. 500
-
ST T O O L : E 2 1 9 9 5 1
4 9 l J s 9 * \ 7 \ ' YIJ
REMOVER. N O Z Z L E No. 1
b-4 92801
K0

L= 550. 0
HOLDER

WEIGHT
I. 5 0 0
K0

D l ESEL MFG. CO. LTD.

L- & ADDRESS 4 - 1 4 , 2 - C H O M E . T O K U I -CHO. C H U O - X U . O S A K A , J A P A N 1
Q7LT320300FE - 3 11;
 T O O L PAGE
H I P NO.

101 No.
DRAW l NG
rp? -

E21995 YE l GHT
0. 1 3 0

L= 1000. 0

COO l UE I G H T
0080 3. 1 9 0

L= 70. 0
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10 WE lCHT
ST T O O L : E 2 1 9 9 5 9 0. 3 0 0
4 / z ' k7' 2 h 4 3 3 F--- -
S E T T I N G TOOL No. 934 13
D=
VALVE STEM SEAL
L= 140. 0

WEIGHT
I. 5 0 0
4 Ko
JIG. COOLING VAL No. I 9740 6
VE S E A T

12 ,.
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I I -

M F R ' sNAME 1 D A I HATSU Dl E S E L MFG. CO, , L T D ,

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I I. 0 0 0
K9 1I
& ADDRESS 1 4 - 14. 2-CHOME, T O K U I -CHDv CHUO-KU, OSAKA, J A P A N I
 H I P NO.
-
TYPE DK-20 -
-
OX No.
,
NuAsM
iNO/- ;, iM
BOX S P A N N E R
65x130
96101
SUP
E
NG
ER
I IP
--
IRAN l NG

1
23990 YE l G H T
390
- -

1
CHS i 2 3 9 9 5 NE I G H T
1030
- -. . .. -
GR N O l N C T O O L . N o . 1 4 0 2
I N . EX. VALVE
\' 7 2 ' 1 7 7 t 3 9 9 ' - 9 :
1
iPEC/SS4 i 2 1 9 9 5 WE l G H T
ST T O O L : E 2 1 9 9 5 1 , I )O/SCP 11 00 0 . 7 0 0
- .-.
FO P U M P SPANNER No. I 80505
L= 580. 0
24

l8
F O ho >7' 3921\'
24
+ 1
;GP i 2 1 9 9 5 WE l G H T
ST T O O L : E 2 1 9 9 5 1 I530 1 . 2 0 0
4

L= 100. 0

1
PCHS WEIGHT

4 fib+. P 7 . > b 4 3 3
-I I-
+-..
-- -
ADAPTER No. I 87600
19x12. 7

0
1
7 9 ' 7' 9 -
20 I
PCHS WEIGHT
ST T O O L : E 2 1 9 9 5 1
4 bb+' i 7 ' >I1433
JACK CYLINDER No.
1
I
-4 831 11
~. -
0. 3 6 5
Ko

4
SPEC WEIGHT
ASSY X
-
M F R ' s NAME I DA I HATSU D I E S E L MFG. CO. , L T D - I
& ADDRESS 1 4 - 1 4 , 2-CHOME, TOKUI-CHD, CHUO-KU, OSAKA, J A P A N I
 -
I - 1
T O O L I PAGE
-
H I P NO.

.-
.
IOX No.
SUI
-
IRK
N NG
ER
I IP
-
JACK STAND No. 1 83113

2 4
WE l GHT
4. 5 7 0
Ko
- ... -

2 1
WE lGHT
0. 0 8 0
K P
- - -
(TENSI ON B O L T I No. 1 83114
D= 60. 0
L- 164. 0
1 4
WE lGHT
I. 6 8 0
K 0
- -
I J A C KS T A N D I No. 1 831 18
D= 90. 0
L= 65. 0
2
SPEC W E lGHT

I ?: I. 4 2 0
Ko
t --

I
PCHS W E lGHT
1
14. 0 0 0
-.
K 0-
- -.
+H&
-I G H-
+P RI
E-
-S,
S . H O S E) ; N 83001

2, 1 1 9 7 ~it-a
6
PCHS W E I GHT
r: 2. 5 0 0
K0
- -
L= 58.0

2
PCHS AEOI I 9 WE lGHl
9026

M F R ' s NAME I DA l HATSU D I E S E L MFG. CO. . L T D

& ADDRESS 4- 14, 2-CHOME, TOKU I -CHO# CHUO-KU, OSAKA, JAPAN
-- --
 iI P NO.
T Y P E DK-20 -
O X No.
-
SUI
IRK
S K E T C H ATER II NC
ER
i I P
-
83003

CHS
7
VE l GHT
0.20C
-- -- Ka

I
HE l GHT

--
REMOVER. PROTEC No. I 80119
L=2 8 5
T RING-ASSY
l J ~ 9? '+ L IJ339'
I
WE l G H T

I
WE l G H T

I
WE l G H T
0.200
I
K0
SPANNER No. I 95100
( 2 ) 8X I0

PCHS WE l G H T
0. 0 2 9
4 Ko
-
SPANNER No. I 95100
(2) 1 1 x 1 3

PCHS WEIGHT
0. 0 8 0
.-
K0

M F R ' s NAME I D A I H A T S U D I E S E L MFG. CO. LTD.

& ADDRESS 1 4- 14, 2-CHOME, T O K U I -CHO, CHUO-KU9 OSAKA, JAPAN
 T O O L 1 PAGE
O X No.
;UPPLY
RK SPARE
0. N A M E-- " PER EMARKS
iR
U S E IP SHIP

SPANNER No. I
(2) 17x19
1J377' XI\^ f ( 2 ) 1 7
Ei XI,
1
l E l GHT
ST T O O L : E 2 1 9 9 5 5 . 0 . 1 3 5
4
SPANNER No. I 95100
L= 215.0
(2) 22x24
I
YE l G H T

1
PCHS
ST T O O L : E 2 1 9 9 5 !
4
OFFSET WRENCH-L No. I 95302
(1) 17x19 L
L - I
Zfi' 3by.f-L
39 I
PCHS WE I G H T
ST T O O L : E 2 1 9 9 5 f 0 . 2 1 0
A
1 . I
G= 4
H E X . WRENCH K E Y No. I 97300
4

1
WEIGHT
0 . 0 2 0
1- I
H E X . WRENCH K E Y No. I 97300
5

1
WEIGHT

I I -
IHEX.WRENCH KEY ( No. 1 97300

I
WEIGHT I

I M F R ' s NAME I D A I H A T S U D I E S E L M F G . CO. , L T D . I

1 b ADDRESS I 4 - 1 4 , 2-CHOME, T O K U I - C H O , CHUO-KU, OSAKA, J A P A N I
 T O O L 1

TYPE DK-20
-

o 1 N A M E
U S E
1 .-
S K E T C H
SUI
-
IRK
NG
ER
I IP
-
HEX. WRENCH K E Y No. I 97300
10

I
I E l GHT
0. 1 5 0
I' I -
Ko
H E X . WRENCH K E Y No. I 97300
14

'CHS
1

- - -

L= 260. 0

I
PCHS HE l G H T
0. 3 3 0
-
K-0
- IT I
S C R E W DRIVER No. I 97500
L = 150. 0
8x150
I
PCHS WEIGHT
0. 3 0 0
4 Ko
- -
+ S C R E W DRIVER No. I 97600
L= loo. 0
I
PCHS WEIGHT
0. 0 5 3
-
K0

L= 200.1

I
PCHS WEIGHT
0 . 02'
K 0

Mints NAME I .
D A l H A T S U D I E S E L MFG. CO. LTD.
& ADDRESS 1 4 - 14, 2-CHOME, TDKU I-CHDv CHUO-KU, OSAKA, JAPAN
 PAGE
H I P NC.

T Y P E DK-20 -
-
101 No.- -
0DRAW l NS
!EMARKS
SUI
-
DRK
NC
ER
HIP
-
i* -

L- 60. 0

1
CHS !94001 rlE l C H T
3313ZA 0.010
- K 0
-.

L= 133. 0
M A X . ?'Y1133?4-200
I
CHS L O 9 1 1 7 NE I G H T
* 0052 2. 3 9 0
K 0
- -
L= 225.0

1
'CHS WE l C H T
0. 1 9 8
K0

L= 420. 0

1
WEIGHT
0. 1 8 0
K 9
I -
T H I C K N E S S GAUGE No. / 70900
L= 80. 0

I
WE l G H T
0. 0 2 5
K 9
- -
NOZZLE No. I 70300
H= 585. C
TEST PUMP -G
J x ' )b?zkik' 27'
1
OKK-G ASSY.
ST T O O L : E 2 1 9 9 5 1 k>t' * WEIGHT
21. 2 0 0
A K 0
-
L= 106.C

ASSY WE l G H T
h>t. 0. 24C
K 0
- - .-
D I E S E L MFG. CO. , LTD.
--
1 ADDRESS
- 1 4 - 1 4 , 2-CHOME. TOKU I-CHO. C H U O K U . OSAKA. JAPAN
 T O O L PAGE
HIP NO.

- O
IX No.
SUI
-
3RK
S K E T C H ATER l A1 N C
E R
HIP
No. L 71 500 L= 510.0

5
'
I
VE l C H T
1. 740
- -

5
M3T USED

XHS
-

I
1
NE l C H T

- -

6 SS4 1 B-D
1
WE l C H T
0. 100
- -
No. I 99800
B= 400. 0
LOCK. BOX12 TYP
L= 800. 0
t ' t > I\' 3 , + - Y
t I H= 300. 0
SS4OOP WE l C H T
16. 7 5 0
-
No. I
NOT USED
I
WEIGHT

- Ko
-
No. I
NOT USED

-
L WEIGHT

MFR' S NAME D A I H A T S U D I E S E L MFG. CO. , LTD. I

& ADDRESS 4 - 14, 2-CHOME, TOKU I -CHO, CHUO-KU, OSAKA, J A P A N I
 - -

1 I P NO.
-
O X No.

U S E
I I I
NOT USED

--

NOT USED
I
-

NOT USED

I I
No. 1
NOT USED
I
NOT USED
I
I I
lOROUE WRENCH No. ] 7 1000
4 2 0 0 OLK

WEIGHT
4. 641
KI
L -
M F R ' sN A M E I D A l HATSU D l E S E L MFG. CO. . L T D .
& ADDRESS 1 4.- 14, 2 - C H O M E , T O K U I - C H O , C H U O - K U , O S A K A , J A P A N
 FOR
Dl E S E L ENGI NE

I H A T S U D I E S E L MFG. CO. , L T D .
TECHN l C A L DEPARTMENT

.FT
OSAKA JAPAN

SHIP No, DRAWN B Y yh-k

TYPE CtiECKED
L 1 ST No. Q E 1 9 3 0 1600FZ
DATE 2002. 03. 12 APPROVED BY -
-
REVISION
r
H I S T O R Y O F R E V l S l O W im b

MFR' S NAME
D A I HATSU D I E S E L MFG. CO. LTD.
I

& ADDRESS 4 - 1 4, 2-CHOME, TOKU I-CHO, CHUO-KU, OSAKA, J A P A N

T O O L 1

-
su
-
OR1 DRAW l
N A M E S K E T C H MATER l Al I NG REMARK:

DOL, T / C C L E A N -
'ER
-Hll C-J
NGl2M)-ASSY.

ASSY 1 324 5 W E I GHT

30 1 0
-

W E I GHl

W E l GHT

- KC
NO. I

W E l GHT

- - K C

W E 1 GHT

KC

WE l GHT

- K C

h'E I G H T

K C

M F R ' s NAME 1 DA I H A T S U D l E S E L MFG. CO. , L T D .

I ADDRESS 1 -

4 - 1 4 . 2-CHOME: TOKUl-CHO. CHUO-KU. OSAKA. JAPAN

-
-
 RH143 #%%%%
Type RH143 Turbocharger
---
1 Name 1 Sketch Material
Supply Per
ihi~ )raw
-i- ng
arts No.
Remarks

Rolled
Steel
-
,-)b'J > 7- !q
about 1 7 5 -
3r seal ring

7.5 < T-
. about 21 5 .-

PL IER

Maker's name anr 1SHIKA"lAJIMA-HARIMA HEAVY INDUSTRIES CO. , LT3.

address TOKYO JAPAN
Water Washing procedure of RH..3 type Turbo Charger turbine
- side.

(Applicable for the engine specified to use HFO.)

To remove ond reduce the carbon accumulalion on furbine blodes by impoct

force of fresh wofer drips accelerofed with high velocity exliausf gas flow, conduct
fhe water-injection from water-pouring noule fifted of turbo chorger ide+ exhoust
gas pipe.
Water injected is porfiolly evoporofed ond the remaining is clischarged through
drain pipe.

1 .Interval of the Water Washing

Conduct the washing with the interval of every 250 hours.

2.Engine Load Conditions for Washing.

Adjust and keep the engine load to produce the exhaust gas of furbochcrger inlet
temperature to be from 300 to 350°C for about 10 min.ond then carry out the
washing.

3. Washing method
(1)Connecfgauge board a
with rubber hose a
l o fhe water-pouring noule on
turbo charger inlet exhoust pipe .
(2jConnect the rubber hose @ to the gauge board a.
(3)Open the stopper valve 13.and fill fresh water in the line before the
water-pouring nozzle@ ancl close the sfopper valve O after water pressure
settled down.
[4)0pen ihe drain cock @.
(5)Fullyopen the water-pouring noule @.
(6jSlowly open the stopper .valve to obtain the water pressure of 0.05 to
0.08MPa(0.5 lo 0.8kg/cm2) watching the pressure gauge a.
(7)Water-pouringtime is about 5 to 7 minutes.
(8)Incase of water doesn't disc:harge through drain pipe over 5 rnin. wafer-pouring .
adjust water pressure l o obtain the volume of woter discharge lo be about
0.1Llmin.
(9)Closewafer-pouring nozzle -
after specified 5 7 min.
(10)Confirmfhot wofer discharge has finished. close the drain cock 8.
( 1 1)After water-pouring cleaning, keep the engine running with same load for
about 5 to 10 minutes.

Note:
*While the water-pouring, keep watching and pay otfenfion not lo lead excess of
water-pouring or droin pipe blocking with carbon.
'Even if discharge of drain can'l confirmed, do not conduct wafer-pourirg over 7
!minutes.
"After wafer-pouling cleaning, remove the rubber hose from woshing nozzle.
 - - --

/water-pouring Cleaning Procedure of ~ u r b d

G a u g e (0-0. 2MPa)
/ Q)
Stopper v a l v e
Q? (F;?

Water pressure
----

Water
(0. 05-0. 08MPa)

/
hose c o n n e c t i o n-
 ...................................................................
DIESEL GENERATOR ENGINE

INSTRUCTION MANUAL
FOR
AIR STARTER
MAKER : INGERSOLL RAND i
TWE : ST499

D A I H A T S U D I E S E L M F G . CO., LTD.
TECHNICAL DEPARTMENT
OSAKA, J A P A N

SHIP No. DRAWN BY I. MIYAMOTO

I I
TYPE
CHECKED BY
LIST No. Q7LT322490FZ
,
DATE JUL. 1, 1999
 INSTALLATION AND MAINTENANCE MANUAL
for
MODEL ST400 TURBINE POWERED STARTER

IMPORTANT SAFETY INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATING STARTER.

. FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT I N INJURY.

F o r safety, lop perfornlancc, and maximum
d~trabilityof parts, do not operate ST400 Starters
; i t air pressures over the pressure rating stamped
on the nanwplate. Use supply lines of adequale size
as directed in the instnllation i~lslructionsin this
After zsscn~blinga ST400 Starter, nlways lesl it in
accordance the procedures outlined in this m a n u a l .
Never i ~ ~ s t nal lreassembled s t a r l e r t h a t has not
been tested in accordance with the procedures
outlined in this manual. This manual should b e

. manual.
Always turn off the air supply and disconnect the
a i r supply hose before installing, renloving o r
. filed in a permanently availal~lelocation.
Operate this s t a r t e r only when properly i ~ ~ s l a l l e d
on the engine.
adjusting any accessory on this starter, o r before Do not remove any labels. Replace any damaged
performing any maintenance on this slarler. label.
Operate Model ST400 Starters on compressed a i r Use accessories recommended by Ingersoll-Rand.
only. They a r e not designed o r sealed for operation
on compressed gas.

T h e m e of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased s t a r t e r
p c r f o r ~ n e ~ and
~ c c increased n ~ a i ~ ~ t c n a nacned, may invalidate all warranlies.
Ingcrsoll-Rand is not responsible for customer n~odificationof starters for applications on which Ingersoll-Rand was
not consulted.
Repairs should he made only by authorized, trained personnel. Consult your nearest ingersoll-Rand Authorized
Servicenler.
It is tlw rcspol~ibilityof the cmployer to place the information in this manual into the hands of the operalor.

Ingersoll-Rand Japan,Lld.
Shin.Yokoliarna S q u a r e Bldg. 5F 3 . 1 2 ,
SIiin.Yol~oliama2.chome Kohoku-ku.
Yokohama-shi I t a n a g a w a P i e f . 2 2 2 , J a p a n
GEWSOLk#ANDo
P h o n e : 045 - 476 - 7001
1
Facsimile: 045 - 1 7 6 - 7006
ENGINE STARTING SYSTE*
 WARNING LABEL iDENnFlCATION

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT I N INJURY.2

A WARNING A WARNING

D o not usc damaged, lraycd or

Alwnys !urn o f f l l l c air supply and dcleriornlcd air hoscs and
disconnect IIICair s ~ ~ [ ~hosc ply
Ihcforc insl;llling. rclnoving or
adjusling any accessory 011lhis
srnrlcr, or beforc pcrfor~ningany
nininlcnnncc on i l ~ i slnrlcr.
s
CONTENTS
 Maintenance Items
Maintenance of Starter
*)Disassembly and Assembly of starter should be followed by disassembly a n d
assembly section on page 7.
Replace the following parts when disassembling. Whether replace or not depends on
the condition of damage.
1) Oil Change not needed
2) P a r t s Replacement (1) Replace the following parts every 5000 s t a r t s
Housing Cover Gasket (ST400-283)
Front Drive Shaft Bearing (ST400-363)
Drive Housing Seal (ST400 - 271)
(2)Replace Liner assembly every 10000 s t a r t s
This depends on the operating condition.
(startslday,rpm etc.)
3) Inspection . Cleaning Annual Inspection
Visually inspect system for defects
Wipe the liner assembly down to clean t h e liner a n d
the Housing.
. Pinion should be replaced when tooth wear i s
0.08mm
Check a l l external cap screws and make sure they
are torqued correctly.
- The optimal period to perform a ST400 Preventive
Maintenance Schedule is i n the fall season prior to
winter.
4) Operating conditions . operating (atomospheric)temperature range
: -20°C-9 0°C
maximum allowable pressure: 8.4 kgWcm2
ambient circumstance: standard atomospheric
condition

Above items 1) to 4) depends on the operating condition

MAINTENANCE SECTION
MAINTENANCE SECTION .. .,
j
 MAINTENANCE SECTION
Always wear eye protection when performing any
maintenance on this starter.
Always turn off the a i r supply and disconnect the air
supply before inslalling, rcnlo\,ing or adjusting any
accessory on this starter o r before perrorming any
n~ainlenanceon this starter.
DISASSEMBLY
General Information
I. Do not disassc~nblethe Starler any further than
necessary 10replace worn pans.
2. When grasping a pan in a vise, always use
Icatlier~overedor coppcr-covered vise jaws lo
protect the surface of (he part and help prevent
distortion, This is particularly true of llveaded
members.
3. Do not remove any par1 which is a press f i t in or on a
subassembly unless [he removal of that parl is
necessary for replacement or repairs.
4. Always have a complelc set of seals and O-rings on
hand before slarting any overhaul of a Model ST400
Starter. Never reuse old seals or gaskers.
5 . When disassembling, always mark adjacenl parts so
he members can be located in the same relalive
position when the slarlcr is reassembled.
6. Never wash the Lincr Assembly (8) i n a solvent.
Disassembly of t l ~ Sc t a r t e r
I . Remove the Drivc Pinion Screw ( I ) from the drive
shafl and remove h e Drive Pinion (2).
2. Remove the six Flange Cap Screws (3) from the
Housing (13).
3. Rcmove h e Flange Cover ( 4 ) and Flange (5)
simultaneously by pulling up on the Flange.
4. Remove the Front Drivc Shaft Bearing (IS) from the
Flange Cover.
5. Remove the Drive Housing Seal (16) from ihe Flange
Covcr.
6. Turn [he slarter over and secure i l vertically in a
Use care when ren~ovingthe Housing Cover Bolls
(12) holding tlie IIousing Cover (11) lo the starter.
The Liner (9) is spring loaded and will protrude
approxiniately one inch beyond the Housing when
released.
7. To reniove the Housing Cover (I I), slowly loosen [he
four Housing Cover Bolls (12) while holding the
Housing Cover (1 I) in place.
8. Slide tlic Liner Assembly (9) O U I ofllic Housing.
9. Rcmove 111eReturn Spring (8)
ASSEMBLY
General Instructions
I . Always press on the inner ring of a ball-lype bearing
when installing the bearing on a shaft.
2. Always press on the outer ring of a ball-lype bearing
when pressing rhe bearing into a bearing recess.
3. Whencver grasping a starler or pan in a vise, always
use lealhcr-covered or c o p p e r ~ o v e r e dvise jaws.
Take extra care with lhreaded p u t s or housings.
A s s e n ~ b l yof t h e S t a r t e r
I . Place the Housing (l3), front end down so that the
Rerurn Spring (8) can be placed into [he Housing.
2. Slide rhe Liner Assembly (9) inlo the Housing.
Orienr [he Liner so thal [he nolch aligns correcrly wilh
lhc Housing inlei pon and Liner air inlet port aligns
with (he Housing air inlet port. Auach Housing
Cover Gasket (10) to Housing Covcr.
3. Auach the Housing Cover (I I) to rhc Housing with
just one Housing Cover Bolt (12). Engage only a few
threads so thal (he Housing Cover can be easily
rotated.
4. While pushing !he Lincr Assembly down againsl the
Return Spring, rotate the Housing Cover over (he
Liner lo hold it down.
5. Tighlen the Housing Cover Cap Screws to 5 4 ft-lb
(6.7-8 Nm) torque.
6. Press the Drive Housing Seal (16) inlo the Flange
Cover (4) with [he sealing lip pointed down.
7. Press [he Front Drive Shaft Bearing (15) into the
Flange Cover.
8. Fit the Flange (5) onto [he Flange Cover so !ha1 Ihe
counlerbore of [he Flange slides over the shoulder of
the Flanee
" Cover correctlv.~,
9. Carefully slide this assembly over the drive shafi.
Be careful not to tear the Seal lip. Orienl the Flange
correcrly,
10. Tighten llic six Flange Cap Screws (3) lo 3-4 fl-lb
(4-5.4 Nm) torque and apply Loclite.
I I . Atlach the Drive Pinion (2) to the drive s l ~ a using
f~
!he Drive Pinion Cap Screw ( I ) and tighten lo
53-58 it-lb (72-79 Nm) torque and apply loclite.
 MAINTENANCE SECTION
TEST AND INSPECTION PROCEDURE
'pL

2. Free Speed (All h.Iodcls): 11mdlStartcr on a tcsi

IVhcn 90 psig air pressure is applied to the starter,
the Drivc Pillion will be rulalil~g81 2,800 rpnl and
Drivc Shaft a n d Drivc Pinion will move forward
1.25". Keep face and hands away from rollling
Drive Pinion.
1. Orienhtion: Mounting Flangc must be oricnlcd pcr
111ccustomer's order or engineering drawing. If
orientation is not specified by cuslonler, standard
orientation will be supplied.
fixture. Apply 90 psig lo lhc slnrlcr motor. Minimum
frcc spccd is 2,500 RPM.
3. Confirm O v e r r ~ ~ n n i nofg Clutch: Turn lhc Drive
Pinion by hand in the direction of rotation. The
clulch should ralchct srnoolhly.
4. Confirm Drive Rotation: Turn lhe Drive Pinion by
hand in the direction opposile of rotation. Thc clutch
should not ra~chet.
 lngersoll-Rand Service Center
UNITED STATES-
Markelin!g/Sales/Service
Headquarlers
Ingersoll-Rand Power Tool
Division
P.0.Box 1776
Liberly Corner, NJ 07938
PHONE: (908) 647 - 6000
FAX: (908) 617 - 6007
Soutllern Sales Oflice
Ingersoll-Rand Power Tool
Division
11 1 lngersoll-Rand Drive
Chamblee. GA 30341
PHONE: (404) 936 - 6200
FAX: (404) 936 - 6202
Weslern Sales Olfice
Ingersoll-Rand Power Tool
Division
5533 E. Olympic Blvd.
Commerce. CA 90022
PHONE: (21 3) 725 - 2826
FAX. (21 3) 725 - 2890
Distribution Cenler
Ingersoll-Rand Power Tool
Division
510 Hesler Drive
While House. TN 37188
PHONE: (615) 672 - 0321
- FAX: (61 5) 672 - 0601
LATIN AMERICA
Ingersoll-Rand Power Tool
Division
730 N.W. 107lh Ave.
Suile 300
Miami. FL 33172-3107
PHONE: (305) 559 - 0500
FAX: (305) 559 - 7505
TELEX: 441617 TLS VI
CANADA
Production Equipmenl Group
Ingersoll-Rand Canada Inc.
51 Worcesler Road
Rexdale, Ontario M9W 4K2
PHONE: (416) 675 - 561 1
FAX: (416) 675 - 6920
Regional Offices
1430-5555 Calgary Trail, N.W.
Calgary, Alberla. T ~ 5P9
H Singapore
PHONE: (403) 438 - 5039
FAX: (403) 437 - 3145
3501 Sl. Charles Blvd.
Kirkland, Quebec H 9 H 4 5 3
PHONE: (514) 695 - 9040
FAX: (514) 695 - 0963
201-6351 Weslminsler Highway
Richmond, B.C. V7C 5C7
PHONE: (604) 274 - 0459
FAX: (604) 278 - 2519
EUROPE IMIDDLE E A S T /
AFRICA
Ingersoll-Rand Sales
Cornpany.Lld.
Trallord House
P.0.Box 2 3
Soulhmoor Road
Wylhenshawe Road
Manchesler M23 9LN
United Kingdom
PHONE: 061 . 9 0 2 . 9098
FAX: 4461 - 946 - 6375
TELEX: 667833
ASIA
Japan
Ingersoll-Rand Japan, Lld.
Shin-Yokohama Square
Bldg.5F
2-3-12 Shin-Yokohama
Kohoku.ku, Yokohama 222
PHONE: (81) 45 - 476 - 7801
FAX: (81) 45 - 476 - 7806
Ingersoll-Rand S.E.A.Ple Ltd.
42 Benoi Road
Singapore 629903
PHONE: (65) 860 - 6836
FAX: (65) 862 - 1373
Auslralia
Ingersoll-Rand Auslralia.Lld.
A.C.N. 004 099 861
8 0 - 100 Frankslon Rd.
Dandenong, Vic 3175
PHONE: (61) 3 - 794 - 1 6 7 3
FAX: (61) 3 - 794 - 7 8 9 5
Hong Kong
Ingersoll-Rand Far East
19th Floor Malaysia Bldg.
50 Gloucesler Rd.
Hong Kong
PHONE: (852) 527 - 0183
FAX: (852) 529 - 5976
Korea
Ingersoll-Rand Korea
13lh Floor Haekwang Bldg.
158 - 13, Samsung - Dong
Kangnam - ku. Seoul
PHONE: (82) 2 - 565 - 681 5
FAX: (82) 2 - 5 6 5 - 681 8
 DIESEL GENERATOR ENGINE
INSTRUCTION MANUAL

MER : INGERSOLL-RAND i
TYPE : RR100-F30

D A I H A T S U D I E S E L M F G . CO. , LTD.
TECHNICAL DEPARTMENT
OSAKA, J A P A N

S H I P No. DRAWN BY I. MIYAMOTO

Ti ? E
L I S T No.
- -

DATE JUL. 1, 1999 APPRPvED BY

e I/- A- -,

REVISION
 Form
Edition 1
April, 1998
Rev. 2

NSTALLATION AND MAINTENANCE MANUAL

for
RR100-F30
STARTERRELAYVALVE
WITH PRESSURE CONTROL

IMPORTANT SAFETY INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATING.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD
RESULT IN INJURY.

Always bleed o f the air pressure before

attempting t o unscrew the Starter relay
valve from the Receiver o r before
attempting t o perform any maintenance
o n the Starter Relay Valve.
Never attempt t o remove the cap andlor
the housing cover until air pressure has
been bleed of. If this i s done while
there i s pressure i n the piping, internal
parts of the valve will b e blown out with
considerable force.
IF OUTLET PRESSURE IN EXCESS OF
THE REGULATOR PRESSURE SETTING
COULD CAUSE DOWNSTREAM
EQUIPEMENT TO RUPTURE OR
MALFUCTION, INSTALL A PRESSURE
RELIEF DEVICE DOWNSTREAM OF THE
4EGULATOR. THE RELIEF PRESSURE
CO?ILD AND FLOW CAPACITYOF THE
RELIEF DEVICE MUST SATISFY
REQUIREMENTS.
=Note:
This valve normally design to be activated
with its 3ways solenoid pilot valve can be
activated directly with the manual actuated
control.
This valve can also drive inertia or pre-
engaged ST400 series Starter.
Its own master regulator pressure control
the air pressure on the outlet to the starter.
Rated ooeratina conditions :
Inlet pressure : 0.1 to 3.0 MPa
(1 to 30 kgf/cd)
Outlet pressure : 0 to 1.0 MPa
(0 to 10 kgflcm')
Temperature : -20 to 80'C. With dewpoint
less than air temperature below 0°C.
Fluid : Air compressed

This Starter Relay Valve i s specially

designed and manufactured by lngersoli
Rand for use o n Starter installations..

ENGINE STARTING SYSTEMS

1
 The use of other than genuine lngersoll Rand replacement parts may result i n safety
hazards, decreased starter relay valve performance and increased maintenance, and may
invalidate all warranties.
lngersoll Rand i s not responsible for customer modification of valve for applications on
which lngersoll Rand was not consulted.
Repairs should be made only by authorised, trained personnel. Consult your nearest
lngersoll Rand Authorised Service center.
It is the responsibility of the employer to place the information i n this manual into the
hands of the operator.

Always wear eye protection when installing, removing or performing

~ ~

maintenance on this starter relay valve.

ENGINE STARTING SYSTEMS

2
 -%
')
*. ,
'1 !

W O ~ e r a t i o n: (see Fig 3)
Clockwise rotation of knob (1) will open the seat pilot regulator (4) and will build up pressure
between slave regulator and solenoid valve (5). Turn the knob since you have not reach the working
pressure. Never exceed 1.0 MPa(l0 kgWcm'). The pressure you will adjust at the slave regulator will
be the working pressure at the starter in order to adjust easily the working pressure install a gauge on
port (2) or port (3).

Fig. 3 P i l o t r e g u l a t o r solenoid ASSY P a r t s No. :ST400-K2450

Test and i n s ~ e c t i o nprocedure :

W Solenoid Valve-
Using a DC power supply, apply 9VDC minimum to 24VDC maximum to the solenoid.
The solenoid should activate the armature with a minimum of 9VDC and a (( Clicking D
sound indicates that the solenoid is functioning properly.

Trouble shouting guide-

I) CAUSE SOLUTION
System No electric signal Inspect electrical connections
doesn't

\Ioperate / Low battery II Check Battery charge 1

charge
Malfunctioning I Inspect plunger for damage 1
valve
Lack of air
pressure
ICheck air pressure and air lines 1
Blow-by Starter doesn't Check drive pinion for damage. Make sure
engage the correct drive pinion is on starter.
Check for damage flywheel. Check
backlash. Check for blocage in internal
housing port of starter
Malfunctioning lnspect plunger for damage
1 valve
Low power I Lack of air /Check air pressure and air lines
I
pressure
Malfunctioning
1 valve
I Inspect ~.
plunger for damage. Inspect
I maiter piston for dama& or proper
11
lubricatibn. Lubricate or-remilace 0 ' Ring
if necessary.

ENGINE STARTING SYSTEMS

3
ENGINE STARTING SYSTEMS
5
 2.O
MAINTENANCE SECTION 7,

Always wear eye protection when performing any maintenance o n this valve.

Always turn off the air and electrical supply and disconnect the air and electrical supply
before installing o r removing any component o n this valve, before making any adjustments o n
this valve o r before performing any maintenance o n this valve.

DISASSEMBLY

W GENERAL INFORMATION :

1. Do not disassemble the valve any further than necessary to replace worn or damaged parts.

2 . When grasping a part in a vise jaw, always use copper -covered vise jaws to protect the surface
of the part and help prevent distortion. This is particularly true of threaded members.

3. Do not remove any part which is a press fit in or on a subassembly unless the removal of that part
is necessary far replacement ar repairs.

4. Always have a complete set of seals and 0-rings on hand before starting any overhaul of a valve.
Never reuse old seals or gaskets.

W DISASSEMBLY OF THE VALVE :

1. Disconnect the pilot regulator assy from the cap of the valve

2. Using a strap wrench, unscrew and remove the housing cover ( 3 ).

3. Pull the return spring and the piston assembly ( 8 ) from the valve housing. Return the valve
housing upside down. Using a retaining ring pliers remove the retaining ring (11) .

4. Pull the the cap (2) from the valve housing.

5. Grasp and pull the master piston (5) from the valve housing. Remove all the 0' ring and gasket to
be replace.

ASSEMBLY

W GENERAL INSTRUCTIONS :

I. Whenever grasping a valve or part in a vise. Always use copper-covered vise jaws. Take extra
care with threaded parts or housings.

2 . Except for bearing , always clean every part and wipe every part with a thin film of oil before
installation.

3. Apply a film of o-rings lubricant to all o-rings before final assembly.

ENGINE STARTING SYSTEMS

 23?
ASSEMBLY OF THE VALVE :

1. Lubricate the piston shaft with O-ring lubricant. Slide the piston assembly in the valve housing
Slide the piston spring bottom of the piston.

3. Lubricate the o-ring (14) in the groove of the valve housing.

4. Install the cap (3) in the valve housing. Using a strap wrench it enough to not get it back with
hand.
5 . Return the valve housing in the vise and grasp it.

6 , Install the o-ring(l2) in the piston groove . lubricate it with an o-ring lubricant, slide the master
piston in the valve housing.

7 . Lubricate the o-ring (13) and install it in the valve housing groove.

8. Install the housing cover (2) in the valve housing. Place the retaining ring using a retaining ring
pliers.

9. Reconnect the pilot regulator assy on the cap of the valve,

ENGINE STARTING SYSTEMS

7
- ~ .. ~ . ~
~ - - --.-
~ - ~
p - ~
..~ ~ .-
 -
>3
Ingersoll-Rand Service Center

UNITED STATES CANADA ASIA

Madtelin~g/Sales/Sen/ice
Headquarters
Ingersoll-Rand Power Tool
Division
P.O.Box 1776
Liberiy Corner, NJ 07938
PHONE: (908) 647 - 8000
FAX: (908) 647 - 6007
Soulhern Sales Ollice
Ingersoll-Rand Power Tool
Divisioii
11 1 lnc~ersoll-RandDrive
Chamblee, GA 30341
PHONE: (404) 936 - 6200
FAX: (404) 9 3 6 . 6202
Weslern Sales Oflice
Ingersoll-Rand Power Tool
Division
5533 E. Olympic Blvd.
Commerce. CA 90022
PHONE: (213) 725 - 2826
FAX- (213) 725 - 2890
Dislribuiion Cenier
Ingersoll-Rand Power Tool
Division
510 Hesler Drive
While House, T N 37188
PHONE: (615) 6 7 2 - 0321
FAX: (615) 672 - 0601
LATIN AMERICA
Ingersoll-Rand Power Tool
Division
730 N.W. 1071h Ave.
Suile 300
Miami, FL 33172-3107
PHONE: (305) 559 - 0500
FAX: (305) 559 - 7505
TELEX: 441617 TLS VI
Produclion Equipmenl Group Japan
Ingersoll-Rand Canada Inc. Ingersoll-Rand Japan, Ltd.
51 Worcesler Road Shin-Yokohama Square
Rexdale, Ontario M9W 4K2 Bldg.5F
PHONE: (416) 675 - 561 1 2-3-12 Shin-Yokohama
FAX: (416) 675 - 6920 Kohoku-ku, Yokohama 222
PHONE: (81) 45 - 476 - 7801
Regional OMices FAX: (81) 45 - 476 - 7806
1430-5555 Calgary Trail, N.W.
Calgary, Alberla, T6H 5P9 Singapore
PHONE: (403) 438 - 5039 Ingersoll-Rand S.E.A.Ple Ltd.
FAX: (403) 437 - 3145 4 2 Benoi Road
Singapore 629903
3501 St. Charles Blvd. PHONE: (65) 860 - 6836
Kirkland. Quebec H9H 4S3 FAX: (65) 862 - 1 3 7 3
PHONE: (514) 695 - 9040
FAX: (514) 695 - 0963 Australia
Ingersoll.Rand Australia,Ltd
201 6 3 5 1 Westminster Highway A.C.N. 004 099 861
Richmond, B.C. V7C 5C7 80 - 100 Frankslon Rd.
PHONE: (604) 274 - 0459 Dandenong, Vic 3175
FAX: (604) 278 - 251 9 PHONE: (61) 3 - 794 - 1673
FAX: (61) 3 - 794 - 7895
EUROPE I MIDDLE EAST /
AFRICA Hong Kong
Ingersoll-Rand Far East
Ingersoll.Rand Sales
19th Floor Malaysia Bldg.
Company,Lid.
50 Gloucesler Rd.
Trallord House
Hong Kong
P.0.Box 23
PHONE: (852) 527 - 0 1 8 3
Soulhmoor Road
FAX: (852) 529 - 5976
Wylhenshawe Road
Manchesler M23 9LN
Uniled Kingdom Korea
PHONE: 061 - 902 - 9098 Ingersoll-Rand Korea
FAX: 4461 - 946 - 6375 1 3 t h Floor tlaekwang Bldg.
TELEX: 667833 158 - 13, Samsung - Dong
Kangnam - ku, Seoul
PHONE: (82) 2 - 565 - 6815
FAX: (82) 2 - 565 - 6818
 Speed Switch Unit (-D)
MDP-REV-D
Instruction Manual

Article

This is prepared for Main Diesel Generator enpine from the standard manual Q7LT333430FA
Output contact of "13" may be used for Low speed detection.

(29 pages including the front page)

DA I HATSU DIESEL MFG. CO. , LTD.

TECHNICAL DEPARTMENT
MARINE ENGINE DESIGN

K.Tanabe
TYPE
Prepared by
W. Ise
LIST No. Q7LT33349OFZ

DATE October 12,2004 Approved by

I
REVISION
 ?.>.;k
Speed Switch Unit-D Safety Precautions

This manual describes precautions for safety installation and operation of the speed switch unit-D.
Operate equipment following these precautions.

Hazards and damage likely to result from incorrect wrong use or, neglecting of the indicated
precautions, is explained below in this Manual using the following symbol marks shown below. The
symbols:

A ... CAUTION = State likely to cause damage of light or intermediate damage.

A 1. Caution against electric shock

(1) Voltage remains in the internal terminal block even after POWER is
turned OFF. See page 24(Fig.17).
(2) When using 100 or 200 VAC for signal output contacts,. be aware of
possible electrical shock from the terminal block.

2. Caution against current leakage

(1) To prevent current leakage, be sure to ground equipment properly. See
page 24(Fig.17).
1 Overview .............................................................................................................................................4
2 Features and functions ..................................................................................................................... 4
3 Specifications .................................................................................................................................... 5
4 Outline ................................................................................................................................................6
5 Configuration ..................................................................................................................................... 6
6 Operation and modes ............... ....................................................................................................... 7
6.1 Display and operation ........................................................................................................... 7
6.2 Actions when the power supply is turned on ......................................................................
8
6.3 Normal stateldisplay (normal mode) ................................................................................... 8
6.4
. .
Initial set values ....................................................................................................................
9
6.5 Set value display/setting mode and initial set value display1 setting mode ................... 10
7 Set value displaylsetting mode ....................................................................................................... 12
. .
7.1 Mode and settlng ]terns ......................... . .................................................................. 12
7.2 Start-up interlock contact (#14L)..................................................................................... 1 3
7.3 Low speed detection contact (#14) ....................... . ..........................................................14
7.4 Low speed detection contact (#13) ..................................................................................... 14
7.5 Overspeed detection contact (#12)..................................................................................... 14
7.6 Hysterisis (#14, #13, and #12) ...........................................................................................14
8 Initial setting displaylsetting mode ..............................................................................................1 6
. .
Mode and setting ~ t e m......................................................................................................
s 16
8.1
8.2 Pulse settinglreduction gear ratio set values .................................................................... 17
8.3 Full scale set value ..
................ ..........................................................................................
18
8.4 Contact output mode ...........................................................................................................
18
8.5 Analogue output zerolspan adjustment ...................... . . ...............................................19
9 Installation ..................................................................................................................................... 2 1
10 Wiring ...........................................................................................................................................
22
10.1 Inputloutput connector terminal configuration ................................................................ 22
10.2 Wiring installation to 110 connector ........................ . ...................................................... 23
10.3
. .
External w r i n g .................................................................................................................24
10.4 Connection with the pulse sensor .................................................................................. 25
10.5 Connection and branching of analogue output ................................................................. 26
10.6
. .
Precautions in w r i n g handling ......................................................................................... 27
11 Troubleshooting ............................................................................................................................
29
11.1 Troubleshooting table .........................................................................................................
29
Speed switch unit-D instruction manual

Fig. 1 Speed switch unit-D panel display

1 Overview
This product is a revolution detector available with a digital display function. It is a new
type of speed switch unit, compact in size and highly functional, that indicates measurements
digitally by a micro computer, ensuring high precision, flexible setting that meet a wide range
of applications.

2 Features and functions

-High measurement precision by digital measurement (0.05% (at ES.) k 1 digit)

- Revolution speed displayed digitally to a maximum of 4 digits.

- Three-point revolution detection and one-point contact for start-up interlock.

- High resist pressure semiconductor contact output (resist pressure 1500V. AC 100V, 0.1A)

- 4 - 20mA analogue output

- Revolution speed frequency output (1 Hz per revolution)

- Input specification and revolution range can be set at any value,

- Detachable terminal block is used.

 ,~ ~

3 Specifications ',/,
(I

I Item
Speed Number of 3 speeds (812, #13, U14)
detection detection points (U14L: contact for start-up interlock)
Detection speed
range 100-9990min.' (U14L: 1-999rnin.')
Measurement 0.5min-' when it is 1000min-'
precision (0.05% (at FS.) +. ldigit)
Setting method Detection point is set by key operation
Response time Contact output response 0.3 seconds

Display
Hysterisis
Display range
Standard 3.0% (0.0
0-9999
- 1.0%at F.S. setting changeable)

Display 4-digit red digjtal display (brightness adjustable)

Display update Approx. 0.5 sec.
Pulse input Puls input range 2-20kHz
Set number of pulses and reduction gear ratio per
Setting method

Input pulse
revolution

-
Dedicated pulse sensor (AC 2Vpp
100Vrms))
- 288Vpp (AC 0.7

Frequency lHz, 0/15V (5kQ) per revolution

output (pulse Allowable load resistance 5 K 61 or more, non-insulate,
Output signal
output) with the power supply

I [range
(output error (0.1%(2000Hz or higher)
Analogue (output signal l ~ u r r e n sigma1
t 1 output 4-20mA load resistance 50061
Output precision +.0.5%(FS)
Full scale 100-9990min-'
Contact 3 contact points
output (#12: Overspeed, U13 low speed, 814, low speed)
Output contact
1 contact points (#14L: for start-up interlock)

Contact feature set up with Contact output mode (Reference for P18)
No-voltage semi-conductor contact point,
Contact capacity
AC/DC lOOV O.lA, pressure resistance 1500V
Power supply Voltage DC24V -25-+30% (18.OV-31.2V)
rower
c
2.5W
Environments Working
5 -- 55" C (Max. 95% RH, with no dew condensation)
l conditions temperature
Storage
-20-65°C (MAX 95%RH, with no dew condensation)
temperature
Ambience No corrosive pas
4 Outline

Fig. 2 Outline drawing

5 Configuration

Power supply
DC 24"

Pulse senor
input

Tachometer.
7elernent 4-20mA
LED

s s i o n
CPU

Relay

Relay

Setting
switches 7Relay

7Relay

Fig. 3 Internal block diagram

6 Operation and modes

6.1 Display and operation

Digital display

Set key

~ ~-

Function selection key

1 Up/down
Data input key
Fig. 4 Panel display

<Display function>
Digital display: Engine revolution speed is indicated digitally on the 4-digit digital LED
display.
Set values, etc. are displayed, during various setting operations.
<LED indicator>
# 12 : Means over-speed detection and indicates that the engine is rotating faster that
the rated speed.
# 13 : Means Low-speed detection and indicates that the engine speed has passed over
the low-speed set value.
# 14 : Means Low-speed detection and indicates that the engine speed has passed over
the low-speed set value.
# 1 4 L : Indicates that the conditions for start-up interlock have been met. It is
applicable in start-up interlock circuits as it can detect complete stop of the
engine.
<InpuU
[F'l Function selection key:
Switch for changing the mode and items. Pressing this key during normal mode changes
the mode to setting displaylsetting mode.
Pressing and holding this key for more than 3 seconds changes the mode to initial setting
displaylsetting mode.

[A][V] Data input key:

Allows you to increase and decrease the set value.

[S] Set key:

Starts the setting of items and also enters and saves the set value,
6.2 Actions when the power supply is turned on

When the power supply is turned on, all LEDs turn on for about 1 second and normal mode starts.
During the above action, revolution detection, output and error detection functions are suspended
whether or not input signal exists.

Note) Before using the speed switch unit for the f m t time, various settings must be made to
enable normal function, as initially set values are only temporary values set for shipment.
Please set each parameter correctly reading this instruction manual to enable correct use of the
unit.
~~~

trhe units dilivered, as the-.

accessories of diesel engine will .-be suitably s q

6.3 Normal stateldisplay (normal mode)

During normal mode, the revolution speed presently detected is displayed. When the revolution
speed exceeds the detection set values, the relevant contact output operates and at the same time
the relevant LED indicator lights. This mode is displayed except when the setting change mode is
selected.

During normal mode, the display brightness setting can be changed by the [ r ][r] data entering
keys.(The initial setting value is set at the maximum brightness of 31, and normally it is not
particularly necessary to change it.)

The next time the power supply is turned, the brightness is displayed at the value preciously
saved.

Increase the brightness.

-
Decrease the brightness
Pressing this button for more than 3 seconds saves the present brightness,
6.4 Initial set values

Note) To use this product, it is necessary to pre-set various set values correctly.
Using this unit without setting these values may cause critical problem in engine
operation and control.

For the initial set values the following values are entered before shipment.
To encourage setting by the users, the values set in the initial setting are normally impractical
values.
..-- to the table below and set items that have no % mark attached.
Refer
k h e units delivered, as the accessories of diesel engine will be suitably set up.[
% marked items can be used without changing the initial set value.

section Set Items I Settable range llnitial Set value1 Set Value
6.5 Set value displaylsetting mode and initial set value display1 setting mode

D
Normal mode

: Press the "[F]Function selection key" once. 1: Press the "[SJset key" once.
[bsecl : Press and hold (3seconds) the "[F]Function selection key" . m
M: Press and hold (3seconds) the "[Slset key".

Fig. 5 Setting procedure list

To change the set values, it is necessary to perform setting change work using the "Set value
displaylsetting mode" and "Initial setting value displaylsetting mode".

"Set value displaylsetting mode":

A mode for setting mainly items concerning speed detection.

"Initial setting value displaylsetting mode":

A mode for setting constants that should be pre-set such as number of gear teeth and full
scale value, etc.
.

To change from the "Normal mode" to "Set value displaylsetting mode" or "Initial setting value
displaylsetting mode", press the "[F] function selection key" at normal mode.
To change to each mode, press the "[F] function selection key" as follows. Please refer to Fig. 5
Setting procedure list.

O To change to the "Set value displaylsetting mode", press the "[F] function selection key" once.
@ To change to the "Initial setting value displaylsetting mode" press and hold (3 seconds) the
"[F] function selection key".
- 10 - Q7LT333490FZ(10/29)
To increase or decrease the set values by pressing the [ A ][r] keys, pressing the key once
increases/decreases the value by f 1 step, but pressing and holding the same key changes the
mode to repeat mode and the values can be entered continuously. Keep pressing even further,
changes the mode to fast forward and values can be changed in 10-fold, 50-fold steps.
 7 Set value displaylsetting mode
7.1 Mode and setting items

Pressing the "[F] function selection key" from "Normal mode", changes the mode to "Set value
displaylsetting mode".

In this mode, each time the "[F] function selection key" is pressed, the table below is displayed
sequentially and pressing the "[F] function selection key" once again at the last item, returns the
mode to "Normal mode". (Refer to Fig. 5)

The set value displaylsetting mode consists of the following setting items.

a Setting #14L ON:

Revolution detection for start-up interlock, ON point revolution speed
@ Setting #14L OFF:
Revolution detection for start-up interlock, OFF point revolution speed
@ Setting #14L OFF Delay:
Contact start-up interlock, OFF DELAY TIMER (second)
@ Setting #14 ON:
Low speed detection ON point revolution speed
@ Setting #13 OFF:
Low speed detection OFF point revolution speed
@ Setting #12 ON:
Overspeed detection ON point revolution speed
a Hysterisis (#14, #13, #12):
ON-OFF width of #Id, #13, #12 (% at FS)

Pressing and holding the "[S] set key" during the item display changes the mode to the set value
change mode of the applicable item.

When it enters into the set value setting mode, measurement is suspended and external output and
external contact point are frozen temporarily.
(When it returns to the normal mode again, it restarts but with a delay of about 1 to 2 seconds)

To add, when no operation is made for 3 minutes when any set value is being displayed or set, it
will automatically return to normal mode.

When the brightness degree had been decreased in normal mode, the maximum brightness will b e
displayed temporarily in set value display mode but will display the original brightness again
when returned to normal mode.
 7.2 Start-up interlock contact point (#14L)
Engine
revolution
speed
Engine
complete

Fig. 6
-
14L OFF DELAY TIMER contact point operation outline
Time

Internal combustion engine employs fly wheel (inertial mass) at the output axis to reduce output
fluctuation. Therefore, when the engine is stopped, revolution remains longer than expected due
to inertia of fly wheel, and even when the users stop the machine, the output axis may not be
stopped completely. When start-up command is given to the engine under such situation, it may
bigger unexpected accidents.
Contact for start-up interlock outputs a condition that can block restarting of engine when the
output axis is rotating, with the following 3 conditions combined, so as to enable secure detection
of engine stop (refer to Fig. 6 "Engine Activation Disabled" part).

(1) "#14L ON detected revolution speed" as engine operating condition,

(2) "#14L OFF detected revolution speed" as engine condition immediately before stopping,
(3) Time counter timer from (2) to complete stop "#14L DELAY TIMER"

For using the start-up interlock contact (#14L), the following 3 values must be set.

a #14L ON setting
-
H = 1 999
@ #14L OFF setting
-
L = 1 "#I4 ON set value"
@ #14L OFF Delay setting
-
d = 0 300 sec.
Description:
a is an operation point setting for start-up interlock contact and when the engine
revolution speed exceeds this set value, #14L contact output operates.
@ #14L starts the OFF DELAY timer when the engine revolution speed becomes below
this set value.
@ is a set value of #14L OFF DELAY timer and sets the delay time in seconds. #14L
contact point output turns off when the time set by this timer is up.
 7.3 Low speed detection contact (#14)

To use the low speed detection contact (#14), the following value must be set.
When the engine revolution speed increases above this set value, #14 contact output operates.

@ #I4 ON setting
#I4 = 100 9999 -

7.4 Low speed detection contact (#13)

To use the low speed detection contact (#13), the following value must be set.
When the engine revolution speed increases above this set value, #13 contact output operates.

@ #13 OFF setting

#I3 = 100 9999-

7.5 Overspeed detection contact point (#12)

To use the overspeed detection contact (#12), the following value must be set.
When the engine revolution speed increases above this set value, #12 contact output operates.

@ #12 ON setting
#12 = 100 - 9999

7.6 Hysterisis (#14, #l3, and #12)

Hysterisis is provided to secure stability in detection operation even athen the revc~lutionspeed
sways. At the point of time the revolution speed exceeds the set value (detected revolution
speed), the contact turns on and at the point of time the revolution speed become less than set
value (return revolution speed) for the amount of hysterisis, the contact turns off.
 C h a n g e in the
revolution
speed
Pre-set
revolution
speed

Hysterisis

pq
hysterisis

Fig. 7 Hysterisis

%Chattering may generally cause relay contact depositing by contacts repeating ONIOFF in a
short time.

Detection revolution speeds for #14, #13 and #12 are set individually, but for return revolution
speed, this hysterisis value will be applied to all.
' 63 Hysterisis (#14, #13, and #12)
0.0 - 10.0% (at FS)

% 3.0% is registered as initial set value.

% It is not particularly necessary to change.

Hysterisis means the range between (detection revolution speed) - (return revolution speed), and
this value is set by the percentage value of the full scale set value in 5 8.3.

[Ex. 41 When it is F = 150, #12 = 1020, H = 3.0,

(F: analogue full scale set value, #12: overspeed detection set value, H: hysterisis set value)

Hysterisis = 1500 x 3.01100 = 45min.'

#12 ON point (detection speed) ----- 1020min"
#12 OFF point (return speed) ----- 9 7 5 m ~ '
 8 Initial setting displaylsetting mode
8.1 Mode and setting items

Pressing and holding (keep pressing for 3 seconds) the "[F] function selection key" from "Normal
mode" or "Set value displaylsetting mode" changes the mode to "Initial setting displaylsetting
mode".

In this mode, each time the "[F] function selection key" is pressed, the following display will be
displayed sequentially and pressing the "[F] function selection key" at the last item returns the
mode to normal mode. (Refer to Fig. 5)

Initial set value displaylsetting mode consists of the following setting items.

a Pulse setting:
Pulse number per revolution (number of teeth)
@ Reduction gear ratio setting:
Reduction gear ratio from the crank shaft
@ Full scale setting:
Scale range of analogue output
@ Output mode setting:
NIC, NIO modes of output contacts
@ Analogue output zerolspan adjustment:
For analogue output range adjustment

Pressing and holding the "[S] set key" during display of each item changes the mode to set value
changing mode of the relevant item.

When it changes to the initial setting mode, measurement is suspended and external output and
external contact points are frozen temporarily.
(When it returns to the normal mode again, it restarts but with a delay of 1 to 2 seconds).

To add, when either of the set value displayed or set is left for 3 minutes without any operation,
automatically returns to normal mode.

When the brightness degree had been decreased in normal mode, the maximum brightness will be
displayed temporarily in set value display mode but will display the original brightness again
when returned to normal mode.
 . ..,, ,> ,

8.2 Pulse settinglreduction gear ratio set values

Engine revolution speed (or revolution speed of rotor) is calculated from the frequency of pulse
signal impressed on the sensor input terminal based on the pulse specification set and is
displayed.

For the calculation of revolution speed, it is necessary to set the following pulse specifications.

O Number of pulses per revolution (number of gear teeth)

P=1-300
Reduction gear ratio
r=1-20

a is the number of pulses generated per revolution of the rotation axis (gear) installed with a
pulse sensor.
@ is the reduction gear ratio to set when the engine revolution speed and the rotation axis
installed with a pulse sensor are not the same.

For instance, when the revolution of the engine output axis is detected by pulse sensor in the
original condition, the reduction gear ratio of @ becomes r = 1.

[Ex. 11 Engine output axis direct measurement: when the number of gear teeth is 142.
P=142, r = l

When the pulse sensor is attached to the gear that interlocks with the cam shaft of 4 cycle
engine, r becomes 2. (Cam shaft only rotates 112 revolutions per engine revolution, so the
reduction gear ratio becomes 2).

[Ex. 21 Cam shaft measurement: number of gear teeth 75

P=75. r=2

Also when the number of pulses per revolution is not an integral number, set a value 10-times
a and at the same time set a value 10 times large also for @.

[Ex. 31 Cam shaft measurement: tacho generator 7.5 pulse

P=75, r=20

(Reference)
The pulse frequency to be impressed is expressed by the following formula.
Frequency = Revolution speed x number of pulses
+ reduction gear ratio + 60
- 17 - Q7LT333490FZ(17/29)
On the contrary, when calculating the revolution speed from the frequency, it is expressed by the
following formula.

Revolution speed = Frequency x reduction gear ratio x 60

+ number of pulses

8.3 Full scale set value

The revolution speed can be output by the analogue signal of DC 4 - 20mA.

It is necessary to set the full scale value so it meets the specification of the equipment to which
this output is connected.
To add, hysteresis (on-off difference) at the time of speed detection is calculated based on this full
scale value.

@ Analogue full scale setting range

F = 1 0 0 - 9 990min-'

The set value is determined by defining the revolution speed necessary at the time of 20mA
output to meet the specification of the equipment to be connect to and the value dividing the
revolution speed by 10 shall be the set value. 4mA is equivalent to 0 revolution speed.

[Ex. 41 Full scale= 2 5 0 0 rnin.'

F=250

8.4 Contact output mode

Contacts that operate when the contact output and the conditions of (start-up interlock contact
(#14), low-speed detection contact (#14), low-speed detection contact (#13) and over-speed
detection contact (#12)) are met can be specified whether it should be ON during operation o r
OFF by the following setting.

@ Output mode setting range

o=o-15

Note) As a standard setting, it is set at [0] (all contacts are A contact operation) at the time of
shipment from the plant.

This value is expressed by the mode numbers from 0 to 15 and is applied to each contact, #14L,
#14, #13 and#12, as follows:
 A : N / O (On when o v e r t h e v a l u e ) mode
B : N / C (Off when o v e r t h e v a l u e ) mode

8.5 Analogue output zerolspan adjustment

-
When there is a slight deflection in the analogue output range (4 20mA). this range can be
corrected by the adjustment of zero output (4mA) and full output (20mA).

Note 1)
The speed switch unit has been adjusted at the time of shipment to ensure that correct
analogue output can be made.
Normally, it is not necessary to change this setting.

Note 2)
Do not attempt to adjust the deflection in the revolution speed caused by the error in the
equipment (for instance tachometer) connected to the analogue output by this function of
speed switch unit.

O Analogue zero output/full output adjustment setting range

-9. 9 - 0. 0 -+ 9 . 9 % (no correction when it is 0.0%)

When you enter into this mode, "A" is displayed on the leftmost side of the numerical value
display and the present output on the right side.(Continuous lighting)

Under this condition the following keys are accepted.

changes to normal mode

Pressing and holding this for 3 seconds changes to "Analogue output
adjustment",
[Analogue zero output adjustment]
When you enter into this mode, "b" is displayed on the leftmost side of the numerical value
display in continuous display and the present zero correction value on the right side by flashing.
The analogue output will be fixed at "4.00mA".
The correction value is the % value added to the standard state.

Here, with the following keys, fine adjustment of output value (4mA) will be made,

Cancels the setting and changes to "full output adjustment".

Raises the correction value (output rises at the same time)
Lowers the correction value (output declines at the same time)
Pressing and holding for 3 seconds sets and saves the present indicated value.

To add, the setting range will be f 9.9% and no correction value when it is 0.0%.

[Analogue full output adjustment]

When you enter into this mode, "c" is displayed on the leftmost side of the numerical value
display in continuous display and the present zero correction value on the right side by flashing.
The analogue output will be fixed at "20.00mA".
The correction value is the % value added to the standard state.

Here, with the following keys, fine adjustment of output value (20.00mA) will be made.

Cancels the setting and changes to "full output adjustment".

Raises the correction value (output rises at the same time)
Lowers the correction value (output declines at the same time)
Pressing and holding for 3 seconds sets and saves the present indicated value.

To add, the setting range will be f 9.9% and no correction value when it is 0.0%.
 '1
-
./
(.

9 Installation
M2. 5 x 5 0

- Fixture attaching hook

.. ...- ---- - -- -- - e z 35 .

C
50
Wiringconnector

Fig. 8 Speed switch unit-D side face Fig. 9 Fixture (accessory)

Fig. 10 Panel cut dimension

Cut the panel of the place to install into in the panel cut size (Fig. 10).
a Insert speed switch unit-D from the front side of the panel cut hole. (Fig. 11)
@ After inserting, hook the attached fixture to the fixture installing hook and screw in metal
fitting screw with a slotted screwdriver to securely fasten to the panel side. (Fig. 12)

Insert from ,- Attach a fixture and

tighten in the arrow
the front side Panel d i r e c t i o n with a s l o t t e d
of panel s c r e w d r i v e r and f i x t h e
panel
. . . ..-.
..

a _

Fig. I1 Installation (insertion) Fig. 12 Installation (fixing)

a When there is vibration on the installation panel face, you can use "bracket: panel
installation (NN00262007A)" (option) which can be installed more securely.

When converting the conventional speed switch unit and speed switch unit 2 to speed switch
unit-D during maintenance, etc., you can use the speed switch unit-D available with a
compatible case attached with a bracket that fit each unit,
- 21 - QILT333490FZ(21/29)
 10 Wiring
10.1 InpuUoutput connector terminal configuration

Speed switch unit-D has double decked input/output connector on the backside of the main body.
The terminal configuration is described on the nameplate seal on the upper side of the main body
in the same way as below.
Please refer to the drawing for correct wiring.

The connector configuration and terminals are as described below.

I/O CONNECTOR ANALOG

FREOUENCY O U T P U T
Z4Vdc SENSOR OUTPUT (4-20nA)
-I- -
FG P N + S - F+F-M+M-
UPPER CONNECTOR

,
1 2 a 1 2 c 13a 13c I l a l 4 c I 4 1 I 4 L
LOWER C O N H E C l O R
I - - -
OVER W l O W LOW LUILOY

Fig. 13 Terminal configuration

pper deck terminal

Frame ground for the speed switch.
FG Make sure to connect to the around to prevent noise and the risk of electric
I Z d~rlr
-.. -.
(
I
p I~onnectthe power supply. Connect + 24V to [PI and OV to [NI
Power supply specification, power voltage: DC 24V, allowable voltage range: - 20
N + 30%, power consumption: 2. 5W
+ Connect the sensor output.
SENSOR S [+I and [-I are DC 24v power supplies.
- [Sl is for the pulse sensor output which is input in pulse.
FREQUENCY F+ Outputs the pulse of detected revolution speed. (1Hz per rotation)
0/15V, allowable load resistance is 5 K n or more and non-insulated from the powe
OUTPUT
ANALOG M+ Outputs current at 4 - 20mA by scaling determined by the full scale setting.

d ~ u r n on
s (off) the contact point when it reaches the pre-set speed limit
OVER
No-voltage semiconductor contact point, contact point rating: AC/DC lOOV 0. IA,
12c resist pressure: 1500V
Turns off (on) the contact point when it reaches the pre-set low speed.
LOW 13a
-
No-voltage semiconductor contact point, contact point rating: AC/DC IOOV 0. LA,
13c resist pressure: 1500V

dE
LOW - 14a Turns on (off) the contact point when it reaches the pre-set low speed.
No-voltage semiconductor contact point, contact point rating: AC/DC IOOV 0. lA,
14c resist pressure: 1500V
3
0 Contact attached with a start-up interlock off-delay timer when the engine stops
LOUTLOW -
14a
No-voltage semiconductor contact point, contact point rating: AC/DC IOOV 0. lA,
1 4 ~resist pressure: 1500V
 10.2Wiring installation to U 0 connector

Peeling allowance 9mm

Fig. 14 Connector Fig. 15 Peeling allowance of wiring

1) Electric wires to connect to the connector must satisfy the following specification.
Recommended: Single wire: f l.Omm (AWG 18)
Twisted wire: 0.75mm2 (AWG 20)
Strand diameter: Min. f O.18mm
Usable electric wire range
-
Single wire: f 0.4 1. O m (AWGF 26 - 18)
-
Twisted wire: 0.3 0.75mm2 (AWG 22 20) -
Strand diameter: Min. f 0.18mm

2) Secure 9mm for peeling allowance of wiring. Twist it lightly so it will not spread out.
Solderless terminal is not necessary.

Electric wire insertion hole 1

Electric wire insertion/release ,

operating unit

Fig. 16 Connector ele

3) Insert and release wiring to the connector by pressing the wire insertionlrelease operation unit
located at the side of the wiring insertion hole, with a slotted driver or the like. Insert it fully
and release the driver from the electric wire insertionltelease operation unit. Wiring is grasped
inside the connector and fixed securely.

4) Connector can be inserted, only one line to one pin. Should it become necessary to insert
multiple wirings into one pin, a separate terminal block will be necessary to bundle the wiring
into one before connecting to the wiring.

5) Connector itself can be removed easily by pulling it out. If it is difficult to install wiring,
remove the connector to make installation easier. Also at the time of speed switch unit-D
replacement, wirings can be removed in a lump at the connector, and there is no need to remove
wirings one by one.
6 ) After completing installation, be sure to check that the wiring is correct and that no short
circuiting has occurred due to spreading of wiring. Also pull the wirings to see that they do not
come off.

10.3External wiring
External wiring example of speed switch unit-D is given below.

1) Standard connection
A combination of one unit of pulse sensor and one unit of speed switch.
There are one analogue output system, three contact output systems, frequency (pulse) output and
start-up interlock contact output. The contact signal is connected to the engine control panel for
control,

-.
,-
-~
. .

-
- Engine conbol panel, ew.

Fig. 17 Standard connection with one unit of pulse sensor

and one unit of speed switch

2) Driving two units of speed switch

One unit of pulse sensor can drive up to two units of speed switches.
By parallel driving, the number of outputs can be expanded to 2-fold. (2 systems of analogue
output, 6 systems of contact output).
To connect from the first speed switch to the other, do so via separate relay terminal block.
 --- . G e a r wheel
-
-1

Pulse sensor

S p e e d switch-D Speed switch3

Fig. 18 Parallel driving connection by one unit of pulse sensor

and two units of speed switches.

10.4Connection with the pulse sensor

1) When connecting the pulse sensor NN00006014A (new type) @C series engine since 2005)

p
f Wire breaking
d e t e c t i o n LED
A S S Y Z P U L S E SENSOR
E N G I N E CONNECTOR
(NN00006014A)
! I
DC24V
0v S Sensor
Signal Out~ut 3
(N/O)
4

-
Sensor Failure
(N/Ol

Operation
display LED
(green)

Fig. 19 Pulse sensor NN00006014A Fig. 20 Pulse sensor speed switch connection diagram

When connecting this pulse sensor to the speed switch unit -D, refer to the connection diagram in
Figure 20.
This pulse sensor is provided with a wire breaking detection function for coil and the red LED at
the upper part of pulse sensor turns on when the coil wire breaks, to display the state of wire
breakage and at the same time to output it outside. When using the coil breakage detection,
prepare a separate relay as in the drawing above and connect it.
For the relay to be used in wire breaking detection, select the one with a coil rated current 30mA
or below during operation.(Omron: MY 4-Dequivalent)
This pulse sensor is compatible with the (2) pulse sensor (conventional type) in terms of the
dimension at the installation section and electrically, it is possible to use it as an alternative
model.
2) When connecting pulse sensor 50A, 100, 200 (L51131) (conventional type) (Except for the

Fig. 21 Pulse sensor (L51131) Fig. 22 Pulse sensor (conventional)

- speed switch connection diagram

When connecting this pulse sensor to the speed switch unit-D, refer to the connection diagram in
Figure 22.
This pulse sensor has no display/output function for coil breaking detection.

10SConnection and branching of analogue output

Speed switch
Revolution
speed
.+
1 unit3 analogue
output
-

Fig. 23 Analogue output connection (one system)

The speed switch unit -D has one output of analogue output signal (4-20mA signal) that outputs
the rotational speed. For the connection diagram, refer to Figure 23. The allowable load
resistance of connecting instrument is 5000 maximum.

OUQU~ T ~ C ~ O Fig. 24 Analogue

output connection
w (two systems) part 1

Fig. 25 Analogue output connection (two systems) part 2

- 26 - $7LT333490FZ(26/29)
When outputs of two systems are necessary for sending signals to the meter and data logger,
connect the instrument in serial referring to Figure 24 and 25.

However, in the following cases, use an isolator and divide the analogue signal into two.
a When load resistance is set to over 500 C2 in total.
@ When floating of the input signal is not carried out in either instrument.

Note)
a When connecting to an instrument with a load resistance exceeding 5000, nonconformity
may occur such as discrepancy between the actual revolution speed and the revolution speed
indicated on the instrument.

@ When negative terminal sides of two units of connecting instruments are grounded, current
wraparound occurs through grounding and as a result, the input of equipment on the downstream
side bypasses, causing disability in signal input to this instrument.
These incidents can be avoided by inserting an isolator and insulating the signal by direct current.
For the isolator, select the insulator type with two-outputs (M system: W2YV-AAA-R2
equivalent).

S p e e d switch speed
unit+ analogue -

Fig. 26 Analogue output connection

(isolator used for dividing into 2)

10.6Precautions in wiring handling

1 ) Wiring and shield handling
Wiring to the speed switch unit must be installed taking note of the following points.

a For power supply wirings, pair negative and positive wirings and twist them together.
@ For the pulse sensor wiring, use three-wire shield wire.
@ For analogue output, use two-wire shield wire.
@ I
For frequency output, use two-wire shield wire.
@ Use the shield wire on the basis of single-point grounding. Make sure to connect
grounding.
@ Keep wirings connected to the speed switch unit away from the power line and large size
relays.
2 ) Twisted pair wiring
Twisted pair wiring means twisting 2 wirings. This is generally done on electric wires to
improve the resistance to noise easily and reduce the effect of electromagnetic induction to the
outside.

T
\
\
2

Fig. 27 Twisted pair wiring Fig. 28 Normal parallel wiring

3 Grounding of shield wire (single-point grounding)

Grounding of three-core shield wire between pulse sensor speed switch units.

Pulse Terminal N o t connected with

block /, other shield wires
sensor
Speed switch

\ Shield w i r e is
I t is desirable to ground
h e r e b y single-point
released
grounding.

-
-
Fig. 29 Shield wire grounding (single-point grounding)

Single-point grounding is an effective connecting method for strengthening the noise resistance of
wiring, using the weak signal and pulse, by grounding the shield wire at only single point as
shown in the above diagram.

If the sensor side is also connected to the ground, two sides, the sensor side and speed switch side
would be grounded. This would cause potential difference between the two points that would
provide a good condition for the noise to adhere, it is normally not done.

But if neither grounding is available, there would be no place for noise ingredient to escape to
when external noise ingredient adheres to the shield wire, making it possible for the noise to
adhere to the signal line, which othenvise should be protected, impeding the effective use of
shield wire.

The shield wire must be connected based on single-point grounding.

 11 Troubleshooting
11.1 'Ikoubleshootine table -
I Phenomenon
1 Display/LED does n o t light
Contact signal does n o t output
The meter does n o t work
!----
I Meter indication swings during
constant rotation.
Icontact output turns off sometimes.
measurement
Contact output differs from the
revolution speed detected by the
contact output.
I Cause
The power is n o t supplied
w e r supply mis-wired.
s-wired t o pulse sensor
ong set value
.ong wiring
~ l s esensor attaching gap
appropriate
i s unit or pulse sensor failure
h e sensor attaching gap
appropriate
mseness in pulse sensor lock nut
~ l s esensor failure
oise influence
mseness, omission of wiring
c o r r e c t speed switch set value
nalogue adjustment defect (Only for
Be phenomenon of meter reading
sing different from the actual
~easurement)
ulse sensor attaching gap
appropriate
nalogue output load resistance
xceeds 500R
I Countermeasure
Turn on the power supply
I
Redo wiring work.
I
Redo wiring work.
I
Redo the setting work.
l ~ e d owiring work
Fix within the range of I t o 2 turn
return from the rotor.
It can be checked if it is detected
during operation of pulse sensor by
the meen LEO.
II --
-'2,Y
-I
Check if either t h e unit or sensor is
defective and redace with anew one
if any defect is found.
Fix within the range of 1 to 2 turn
return from the rotor.
It c a n be checked if it is detected
during operation of pulse sensor by
the ween LED.
JC
I
Retighten
I
l ~ e p l a c ethe pulse sensor with a new
one.
Contact the person in charge of
enaineering
Redo wiring work.
Redo the setting work
I
Make adjustment by analogue settint
(Correctable UD t o f 9.9%)
Fix within the range of 1 to 2 turn
return from the rotor.
It can be checked if i t is detected
during operation of pulse sensor by
JL
-w-
Lower the load resistance
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0 3 0 5 0 6 Oa OWWMDO) 6 0WMWater) E
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720rnin-1.750rnin-1 900min-1 1000rnin-1 12. F.O. injection nozzle [EHG&N#Fl
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3. Direction of revolution [##El~&z~l m0.30Xl( 00.32xlO
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4. Front P.T.0 [95>9881iiil%BfiB!&] 1 7 ~ 0 M
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valve
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5. Cam shaft [hL881] I 3 ~ i ~ ~ t
% 0 ~ 17
1 ~2
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15. Capacity o f LO. Cooler [7d;#$h%M%SPl
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Plunger dia 35>9& Impeller dia 4><5?3
020 021 0160 0170 0 180
NOTE: 1 terns marked @f are appl ied for your D i e s e l Engines.
2;urn d E P ~ ~ ~ ~ A @ H I = B R ~ ; ~T*.
TL\~IBB
F o r w a r d
This i n s t r u c t ion book deals w i t h the fundamenta l knowledge required f o r
operation and handl ing. I t is, therefore, ardently requested t o f o l low the
working as we1 l as maintenance instructions, so t h a t you may enjoy t h e
utmost durabi I i t y and s a t i s f a c t o r y operation o f our Diesel Engine f o r many
years t o come.
For renewal parts, use our genuine ones, otherwise we cannot guarantee
the p a r t qua1 i t y .
When ordering some parts o f the Diesel Engine, please specify the Type
and No. o f Engine, together with names o f a r t i c l e s and t h e i r reference
numbers, as detai led i n t h i s book.
 I Regarding replacement parts for Daihatsu Diesel engine
Hazards and nonconformities of imitation parts
<Use of imitation parts causes accidents.>
1. Recent engines have compact bodies and high power, and are designed to prevent fuel deterioration
and to reduce NOx discharge. Even if imitation parts are similar in shape to t h e genuine parts, the
use o f imitation parts will degrade the engine performance because of their fragile materials and low
machining accuracy. Since the service life of such parts is short, the engine must be maintained more
frequently.
2. If imitation parts are used for the engines designed in accordance with MARPOL VI, the certificate
(EIAPP) may lose its validity, and operation of the engine may be inhibited.
3. If you use i m i t a t i o n parts, you will not be supplied w i t h parts improved in quality and performance.
4. If imitation parts are used, it may be difficult t o make insurance claims for the engine when any
accident occurs.
5. We take no responsibility for the engine in which imitation parts are used.

Daihatsu Diesel supplies reliable engines.

Use genuine parts to operate your engine safely.

I I n a u [ w and Order I
Order ; P a r t s sales .-..-.-------------~~~.~~~~-..-.--..-
D a i h a t s u Dlesel P a r t s Service Co.,Ltd.
12-34, Tanaka-cho. Ibaraki. Osaka, 567-0025 iapan
TEL:81-72-621-3482 FAX:81-72-621-3484

Inqulry ; Sewlce Department --------------.

DAIHATSU DIESEL MF(I.CO.,LTD. O s a k a Head Offlce.
1-30, Oyodo Nakal-chome, Kita-ku, Osaka, 531-0076 Japan
TEL:81-6-6454-2346 FAX:81-6-6454-2680-1

Or, get in touch with our offices listed below.

DAIHATSU DIESEL MFG.CO.,LTD.O

Osaka Head Office. 1-30. Oyodo Nakal~home.Kila-ku. Osaka. 531-0076 Japan
TEL:816.6454-2393 FAX:81-6-M54-2686
Morlyarna Factory. 45 Amura-cho.Moriyamazity.Shiga.524-0035 Japan
TEL:81-77-583-2551 FAX:81-77-582-5714
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TEL81-3-3279-0627 FAX 81-3-3245-0395
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TEL:61-2-9923-1155 FAX:61-2-9923-1532
Jakarta Gillce. 16th Floor Wsrna Antara Blog.. ,. Modan Merdeka.Selatan No.17.Jakarla-P~sal.lndonesla
TEL 62-21-384.8411 FAX.62-21.384.8412
Manila OMce. .
Unll 1010 Herrera Tower Herrore Corner Va era Sts Sakodo VBlage. Makatt CRy 1226 Pn I'pp'nes
TEL 63-2-753-321163-2-817-127911285FAX 63-2-845.0691
Taiwan Offlce. No.14 Tai-Tang RD. Lin-Hai Industrial Zone. Kaohsiung. 812 Taiwan
( d o Marine Technical Industries Co., Ltd.) TEL:886-7-803-1082 FAX:886-7-801-9179
Dslhatsu Dlesel (Europe) Ltd. 7111 Faor. PenmsJar House.36 Monumenl StreetaLondonEWR 8W. U.r(
TEL 44-20-7626-4600FAX.44-20-7626.6020
Dalhatsu Dlesel (AMERICA), lnc. 180 A d a m Avenue.Hauppauge.NY 11788,U.S.A.
TEL:l-631-434-87871BmFAX:I-631434.8759
Dalhatsu Dl-l (ASIA PACIFIC) Pte.Ltd. 128 Pioneer Road Singapore 639586
TEL:65.6270-7235 FAX:65-6270-6236
Dalhatsu Diesel (SHANGHAI) Co.,Ltd. Suite 3004 Nan Zheng Building 580 Nan Jing Wesl Road Shanghai. China
TEL:86-21-5234-1228-9
~ - FAX:&21-5234-1062
~ ~~-
~~

Dalhntsu Dlesel Parts *Ice Co.,Ltd. 12-34, Tanaka-cho, Ibaraki, Osaka, 567-0025 Japan
TEL:81-72.621-3482 FAX81.72-621-3484
 DK-20 INSTRUCTION MANUAL (OPERATION)

0As for the disassembly,maintenance,assembly,and the

parts to be replaced, refer to the separately provided
lnstruction Manual (Maintenance) and parts List.

OKeep this Instruction Manual and the related documents (drawings,materials,etc.)

i n the specified place so that the persons engaged in operation of the engine can
refer to them whenever necessary, and in case that the supervisor of the engine is
changed, be minded that these documents, along with the duties, shall be
transferred to the successor without a fall.
 CONTENTS DK-20
Chapter 0 lNTRODUCTlON .................................................... 0
1. .....................................0-1
Before Running Daihatsu Diesel Engine
2. Basic Information on Safety Operation .......................................0-2
2.1 Safety Precautions ..........................................................0.2.1
2.2 Safety Signs and Symbol Marks ............................................ 0.2.2
2.3 Indication of Warning: Warning Labels ...................................... 0.2.3
2.4 Indication of Warning: Warning Label Positions ............................. 0.2.4
3. EngineConformingtoNOxTechnicalCode .................................. 0-3
3.1 Outline .....................................................................0-3.1
3.2 The parts to be Specified ...................................................0-3.2
3.3 Engine settings .............................................................0.3.3
4. Generallnformation ...........................................................0-4
4.1 Notation of Engine Types ...................................................0-4.1
4.2 ..........................................................0.4.2
Definition ofTerms
4.3 Units ........................................................................ 0.4.3

Chapter1 GENERAL ..............................................................1

1. Engine Specifications ......................................................... 1-1
2. Auxiliary Equipment ........................................................... 1-2
3. Engine Outline and Equipment Layout .......................................1-3

Engine Frame. Cylinder Liner. and Main Bearing ...........................2.1.1

Crankshaft and Bearing .....................................................2-1.2
Camshaft and Timing Gear .................................................2.1.3
Balancing Shaft ............................................................. 2-1.4
Pistonand Connecting Rod ................................................. 2.1.5
CylinderHead ..............................................................2-1.6
Fuel Injection Device .......................................................2.1.7
Valve Operation Device .....................................................2-1.8
Fuel Control Device ..........................................................2-1.9
1.10 Intake and Exhaust Systems ............................................... 2.1.10
.
2 Piping Systems ................................................................2-2
2.1 Starting Pneumatic System ..................................................2.2.1
2.2 Fuel Oil System .............................................................
2-2.2
2.3 Lubricating Oil System ......................................................
2.2.3
2.4 Cooling Water System ......................................................2.2.4
ITEM
DK-20 CONTENTS

3 . Controlling Engine Operation: Protective Device .............................2-3

3.1 starting control ..............................................................
2-3-1
3.2 stoppage control ............................................................2-3-2
3.3 Engine Protection System ................................................... 2-3-3

Chapter3 ENGINEADJUSTMENTSTANDARDS .........................

1. Operating Specifications ......................................................
2. Valve Settings ................................................................

Chapter 4 OPERATION ......................................................... 4

1 . Precautions for Operation ..................................................... 4-1
1.1 in case of starting ........................................................... 4.1.1
1.2 IncaseofOperation .........................................................4.1.2
1.3 incase of stoppage ......................................................... 4.1.3
2. preparation for operati on ...................................................... 4.2
2.1 preparation for ~ ~ i
operation l..............................................
~ 4.2.1
2.2 Preparation for Initial Starting after Installation and ...................... 4.2.2
Starting after Extended Disuse or Overhaul
3. Starting .........................................................................
4-3
3.1 Starting Procedure........................................................... 4.3.1
3.2 Inspection and Check Items Immediately after Starling ...................... 4.3.2
4. Operation ....................................................................... 4.4
4.1 Running-in ...................................................................
4.4.1
4.2 Warming up and Connecting Load to the Engine ............................4.4.2
4.3 Operation with Load (Normal Operation) ....................................4.4.3
4.4 Operation Using Heavy Fuel Oil (for Heavy Fuel Oil Engines) ............... 4.4.4
4.5 Allowable Operating Range ................................................. 4.4.5
5. Special Operation ..............................................................
4-5
5.1 Low-load Operation .........................................................4.5.1
5.2 ............................................4.5.2
Operation with Air Cooler Cut off
5.3 Nan Turbocharger Operation ...............................................4-5.3
5.4 Operation with Reduced Number of Cylinders ..............................4.5.4
6. Stoppage .......................................................................
4-6
6.1 Normal Stoppag ............................................................ 4-6.1
6.2 Emergency Stop .............................................................4.6.2
6.3 Long-termShutdown ........................................................ 4.6.3
 ""
CONTENTS DK-20
Chapter 5 INSpECTlON AND MAINTENANCE ...................................5
1. Precautions for Inspection and Maintenance .................................5-1
1.1 Safety Precautions...........................................................
5-1.1
1.2 Precautions After Inspection and Maintenance .............................5-1.2
2. Inspection and Maintenance Item Table ......................................5-2
3 . Measurements and Adjustments ..............................................5-3
3.1 Maximum Explosion Pressure and Exhaust Temperature .................. .5. 3.1
3.2 Pressure and Temperature of Each Part ....................................5.3.2
4 . Inspectionand Maintenance ...................................................5-4
Inspecting Parts on and around Intake and Exhaust Valves. and ........... 5.4.1
Adjusting Valve End Clearance
Inspection and Maintenance of Fuel Injection Valve .........................5.4.2
Cleaning Filters ..............................................................5.4.3
Gleaning Turbocharger Blower .............................................. 5.4.4
Measuring Crankshaft Deflection ............................................ 5.4.5
Inspecting and Replacing Protective Zinc ...................................5.4.6

Chapter 6 FUEL OIL, LUBRICATING OIL, COOLING WATER ............... 6

1. Fuel Oil Characteristics and Control .............................................6-1
1.1 Selecting Fuel Oil 1
1.2 Fuel Oil Characteristics and Control ......................................... 6-1.2
2. Lubricating Oil Characteristics and Control ...................................... 6-2
2 1 Selecting Lubricating Oil ..................................................... 6-2.1
2.2 Lubricating Oil Characteristics and Control .................................. 6-2.2
3. Cooling Water Characteristics and Control ...................................... 6-3
3.1 Cooling Fresh Water (Raw Water) .......................................... 6-3.1
3.2 Corrosion Prevention Agent .................................................
6-3.2

Chapter 7 TROUBLESHOOTING A N D COUNTERMEASURES ..........7

1. Precautions for Troubleshooting ................................................
7-1
2. Troubleshooting and Countermeasures ......................................... 7-2
2.1 When Stading is Difficult.....................................................
7-2.1
2.2 When Engine Revolution Is Not Smooth .................................... .7-2.2
.......................................................... .7-2.3
2.3 Insufficient Output
2.4 When Exhaust Gas Temperature or Maximum Explosion ...................7.2.4
Pressure Is Abnormal
.. I-"

ITEM
DK-20 CONTENTS

When Exhaust Gas Shows Abnormal Color ................................. 7.2.5

Abnormal NoiselAbnormal Vibration ......................................... 7.2.6
When Engine Stops Suddenly ............................................... 7.2.7
Unable to Stop Engine .......................................................
7.2.8
Overspeed 2.9
2.10 Low Lubricating Oil Pressure ................................................ 7.2.10
2.1 1 High Lubricating Oil Temperature ........................................... 7.2.1 1
2.12 Low Cooling Water Pressure ................................................7.2.1 2
2.13 High Cooling Water Temperature ........................................... 7.2.13
 .~

lntroduction

Before Running Daihatsu Diesel Engine DK-20 ITEM 1.I

0. lntroduction

0-1 Before R u n n i n g Daihatsu Diesel E n g i n e

This instruction manual describes the proper operation procedure of the DK-20
engine, i t s daily maintenance and inspection procedure, and other necessary
information on the engine.
To maintain the engine in good operating condition and ensure that it provides the
specified performance, be sure t o read through this manual and become sufficiently
familiar with the proper procedures before operating the engine.
Do not use your engine for applications or under the conditions other than those it is
designed for.
Be sure to observe the procedures described in this manual. Improper practices can
cause damage to the engine or result in injuries or fatal accidents.

(1) @ Each piece of the information enclosed in the square box is an important safety
precautions and provided as a warning or caution.
(2) The features and structure of your engine may be different from those provided in this manual
depending on the specifications of the engine delivered. In this case, the engine specificat~onsand
final documents supplied separately have priority over this manual.

(3) For the details on the following machine or device, see their instruction manual supplied with this
manual:
@ Turbocharger
@Governor
@ Air motor
@ Control equipment
@Other special devices

(4) Be sure to use the genuine parts of DAIHATSU DIESEL MFG.CO.,LTD. or those specified in the
parts list.
We will not guarantee the proper operation of the engine unless such parts are used.
For replacement of the parts or service on your engine, contact our Parts Sales Department,
Service Department branch office, or the nearest DAIHATSU DIESEL MFG.Co.,Ltd provided on
the cover page.
Be sure to provide us with the "type and number of your engine" when contacting us.
(5) To prevent environmental contamination, do no1 dispose of waste products, liquids, etc.
thoughtlessly. Be sure to entrust the disposal of such waste products, liquids, etc. to the
authoriqed waste disposai company.

The contents of this manual are subject to change without notice.

 Introduction
Basic lnformation on Safety Operation:
DK-20 safety Precautions

0-2. Basic Information on Safety Operation

0-2.1 Safety Precautions

The diesel engine uses flammable oil. It has the high-speed rotational parts, the parts
that become extremely hot, or the parts that are under high pressure fluid, during
operation.
Improper handling of the engine can result in serious injury or fatal acciqents. Be
sure to observe the safety precautions provided in this manual.

(1) Beware of Rotational Parts

@ This engine has the high-speed rotational parts.
Inadvertent contact of personnel or objects with such parts can cause that person to
get caught i n the engine, or cause the chips of objects to fly in all directions.
(a) Never attempt to touch the rotational parts such as the flywheel and couplings during
operation. Also, be sure to place the protective cover in place before operation.
(b) Before starling operation, check that no personnel is around the engine. Warn any nearby
personnel by signaling that the engine is about to start operation.

(2) Beware of Hot Parts

The engine parts are very hot during and immediately after operation. Touching them
with bare hands or skin can cause burns. Note that the exhaust manifold, turbocharger,
indicator valve periphery, cylinder head, air cooler inlet, and heated heavy fuel oil pipes
become extremely hot.
(a) Never attempt to touch any parl of the engine with bare hand or skin during or immediately
after operation.
(b) Be sure to wear safety gloves or other protective gear for making measurements or inspection.
(c) Allow the engine to sufficiently cool down before performing inspection or maintenance work.

(3) Prevent Oil from Catching Fire

@ Fuel oil or lubricating oil coming in contact with extremely hot parts of the machine may
catch fire.
(a) Be attentive to oil leakage during operation. If any leakage is found, immediately stop the
engine and eliminate the leakage.
(b) Strictly observe the "Caution: Flammables" sign when adding fuel oil or lubricating oil.

If the engine is stopped due to failure or defect failure, be sure to eliminate the cause
of defect and restore it to the normal operating condition before resuming the engine
operation.
-
 Introduction
Basic Information on Safety Operation:
'
; Safety Signs and Syrndol Marks

0-2.2 Safety Signs a n d Symbol Marks

This instruction manual and warning labels affixed to the engine carry one of the following safety
signs and symbol marks:

(1) Safety Signs and "Signal words"

@ ..,"Warningu : Precaution related to safety of personnel (Potential hazard which could
result in death or serious injury)
..." Caution" :Precaution related to safety of personnel (Potential hazard which may
result in minor or moderate injury)
/\ ..." Precautions for handling" : Information on handling of the engine to prevent damage
@ ..."Prohibition" : Prohibited practice that can affect the safety of personnel and the engine
0..." Obligatory acts" : Recommended practice or instruction to be followed to ensure safety
of personnel and the engine

(2) Symbol Marks

(a) Warning Signs (b) Prohibition Signs

1a ..General warning @ .,,Nan-specific general prohibition

& ...Flammable - Fire @ ...NO Smoking
&,.,Explosive - Explosion or Bursting @...Caution: Fire strictly prohibited

-&&..~oisonous - Poisoning @...Do

..
Not Touch

.,.Voltage -. Electric Shock

-(.. . , . ~ o-
4
- t Burn (c) Signs for Obligatory Acts

...RotationallMoving Part - Getting Caught @ ...Wear Eye Protection Gear (salety goggles, etc.)
,.,Edge - Cut @...wear Head Protection Gear (hard hat, etc.)

&., ~ i ~ h - p r e s s uFluid
r e Jet - Injury @...Wear Ear (Noise) Protection Gear (ear plugs, etc.)

\...High Location + Fall 0 ...Wear Hand Protection Gear (safely gloves, etc.)
0 ...Wear Foot Protection Gear (safely shoes, etc.)
(d) Others

m . . . S e e other pages in this manual or other

documents.
0-2.3 Indication of Warning: Warning Labels
The warning labels shown below are used on the DAIHATSU DIESEL MFG.CO..LTD

@%;!WARNING

personal iniuly.

NOT l CES
1 . F o l l o w i n s t r u c t i o n s l o r t h e c o r r e c t and s a l e
h a n d l i n g 01 t h e engine.
-Only l h o s e who have enough knowledge and
necessary s k i l l can handle t h e engine.
- 1 n c o r r e c l h a n d l i n g may cause i n j u r y .
2.When t h e r e i s m a l l u n c t i o n and/or o v e ~ h e a t i n
i n t h e engine, d o no1 r e s l a r t u n l i l the cause
Hot r u # l a r a % .
has been lemedied. May cause burn.
3.11 the i n s l l u c t i o n M a n u a l and W a r n i n g l a b e l
a r e damaged 01 l o s t . p l e a s e o r d e r n e w ones
l r o m us.
> C044500010Z ,

# ...
JI n l l a m m a b l e .
Airs%
Naked ( l a m e s
prohibited.

~%?&?CAlll ION

Y1, "YE. i"l"11. Hot rutlacas.

n
.
.1
:
11
6
# May cause burn.

w.., ,l,llll...
""I., ,.,/.(..,I
CO..1001102
 Introduction I
Basic Information on Safety Operation:
lndication of Warning: Warning Label Positions

0-2.4 lndication of Warning: Warning Label Positions

For safty, the warning labels shown below are affixed to the engine. The numbers carried by
gE4
labels correspond to those given on Item 2.3 of Chapter 0 . gB
&
f
If a label is broken or falls, replace it with a new label, and make arrangement so that it may be
%,@
visible clearly at any time.

(4)

*
Fuel Test pump
-Hydraulic Jack
 I Introduction
., , Engine Conforming to NOx Technical Code:
, 1
0-3 Engine Conforming to NOx Technical Code

0-3.1 Outline
(1) The marine diesel engines to which the 13th rule "Nitrogen Oxides (NOx)" in Supplement VI "Rules to
Prevent Air Pollution by Ships" to MARPOL73n8 Treaty applies should conform to NOx Technical Code.
(2) The engines conforming to NOx Technical Code are authorized as an engine group or an engine family,
and it is allowed to apply the engine parameter check method to them, when receiving the NOx discharge
inspection on board.
The engine parameter check method is a method for verifying that the engine components and setting
values conform to the requirements specified in the technical file, and does not require the measurement of
NOx discharge. To the engines that are not conforming to the requirements of the technical file, the engine
parameter check method cannot be applied. For such engines, the measurement of NOx discharge shall
be required.

0-3.2 The parts to be Specified

The technical file states the engine components that can affect the NOx discharge specified in NOx Technical
Code, and shows the identilication marks stamped on them, and the user is required to maintain the technical
file for each engine. When replacing any parts shown in the technical file, be sure to use our genuine parts
stamped with the identification marks. In the case that any parts without the identification mark is used, it
shall be regarded as nonconformance to the requirements of the technical file, and in such a case, inspection
by the engine parameter check method cannot be applied.
The followings are the parts ihat have the identilication marks specified in the technical file. When replacing
(a:
any of these parts, be sure to check the identilication marks. "Technical file")

<Parts with identification marks>

@ Cylinder head
@ Piston
@ Turbocharger
@ Air cooler
@ Fuel cam
@ Fuel injection pump
@ I
Fuel injection pump plunger
3 Fuel injection valve
@ I
Fuel injection valve nozzle

0-3.3 Engine settings

T h e engines conforming to NOx Technical Code are adjusted to conform to the specifications before
shipment. After shipment, they should not be adjusted to such a manner that the setting values specified in
the technical file may be deviated.
If any change is made in the manner that may deviate from the settings specified in the technical file, it shall
b e considered to be nonconformance to the requirements of the technical file, and the inspection by the
engine parameter check method cannot be applied.
T h e followings are the items that have been set to conform to NOx Technical Code:

<Items set before shipment>

(1) Fuel injection timing
( 2 ) Fuel injection valve opening pressure
-
Introduction
-
General Information:
Notation of Engine Types, Definitidn of Terms, and Units

0-4 General Information

0-4.1 Notation o f Types Engine

.: 5,
3, .: 6,
.: 8: DK (M) -20 (F) (L)
Number of cylinders ...................:.A .....,
: ..... i

-Marine propulsion engine ..................

*Cylinder bore (cm)

0-4.2 Definition of Terms

Definitions of the terms used in this manual are as
follows:
*Rear side of engine: Output end side (flywheel Exhaust side
side)
*Front side of engine: Opposite side to the output
Front
end side
'Exhaust side: Exhaust manifold side (on the right
Normal rotation
when seen from the output end) (Rightward rotation)
*Pump side: Fuel injection pump side (on the .left
when seen from the output end)
-Normal rotation (rightward rotation):Clockwise Pump side
rotation when seen from the output end
*Reverse rotation (leftward rotation): Rear side
Reverse rotation
Counterclockwise rotation when seen from the (Leftward rotation)
output end
*Front end drive: Output from the engine front
Cylinder and journal numbers...... 1. 2, 3, starting
from the output end

B e c a r e f u l w i t h c y l i n d e r a n d journal
numbers. N u m b e r s are g i v e n in t h e
reverse order f o r conventional engines.

0-4.3 Units
Basically, SI units are used on the engine and in this manual. Note that figures in 1 I are reference
values given in the conventional uinits.
 General

DK-20 Engine Specifications and Auxiliary Equipment

1-1 Engine Specifications

Model 3DK-20 I 5DK-20 I 6DK-20 8DK-20

Type Vertical water-cooling direct injection type 4-cycle diesel engine
Number of cylinders 3 5 6 8
Cylinders bore mm 200
Piston stroke mm 300
Engine speed min-1 X

I Output
I kW
IPS,
Constant speedl
I 1-3-2 1 1-3-5-4-2 1 1-5-3-6-2-4 1 1-3-2-5-8-6-7-1
Ignition sequence
Variable soeed I - - 1 1-2-4-6-5-3 1 1-3-2-5-8-6-7-1
Rotating direction Clockwise when seen from the flywheel
Turbocharging method ~urbochar~ed
by exhaust gas turbine equipped with air cooler
Starting method,Compressed air Air motor Direct (Starting valve)
Jacket Fresh water
Cooling method
Cooler Fresh (or Sea) water
Note : (1) Both the ignition sequence and the rotation direction show the data in the case of normal
rotation respectively.
(2) Since the engine speed and the output, which are marked wilh X, diner depending upon
each soecifications. be minded to enter the data after referrina to the "Enoine Soecifications"
and "T& Run ~ e c b r d "

1-2 Auxiliary Equipment

Auxiliary I equipment TYpe Remarks

Turbocharger Radial turbine type
Air cooler Multi-tubular type
Governor Hydraulic type
Fuel injection pump Bosch type
Fuel oil valve Bosch type
Fuel oil feed pump Gear type
Fuel oil filter Notch-wire wire, duplex type
Lubricating oil pump Gear type
Lubricating oil cooler Multi-tubular type
Lubricating oil filter Notch wire, duplex type
Lubricating oil tank Installed on the common base plale,
or on a separate base plate
Cooling water pump Centrifugal type
Fresh water cooler Multi-tubular t v ~ e
Note : The data given in the above table show those in the case of the standard s~ecifications.
~hereforerthe data of your engine may dilfer from those shown in this table, and in such a case
be minded to refer to the "Engine Specifications".
 . ,
8 . -
General

Engine Outline and Equipment Layout DK-20 3

1-3 Engine Outline and Equipment Layout

Turbocharger Gauge board Starting air operation valve Governor

\ \ / I

\ I
Lubricaling oil pump Cooling water pump Air cooler Operating lever Flywheel

Turbocharger

Lubricating oil filler Air cooler

Lubricaling oil cooler

Lubricaling oil
relief valve
Turbocharger lubricating oil liller
 General

DK-20 Engine Outline and Equipment Layout

2-1 Engine 2-1.4 Balancing Shafi

2-1.1 Engine Frame, Cylinder Liner,
and Main Bearing
The frame is a monoblock structure made of cast
iron, and the upper section of the frame forms a
cooling jacket, together with the cylinder liner.
T h e main bearing is a suspension type, and
mounted to the engine frame with 2 mounting bolts
and 2 side bolts.
Intake air, lubricating oil, and each cooling water
channel, and the timing gear case are incorporated
in the engine frame.
A frame safety valve is provided to the cover on
the engine frame side.
2-1.2 Crankshaft and Bearing
The crankshaft is made of a forged and monolithic
structure, and the bearing part (the crank pin
and journal) is quench-hardened.
The flywheel is installed at the rear end (output Exha
In 3DK engine, the balancing shaft is installed for
preventing vibration.
The balancing shaft is supported to the crankshaft
with 4 thin-walled metal and 2 automatic core-
adjusting bearing, and is driven by the auxiliary
gear located on the front side of the engine.
2-1.5 Piston and Connecting Rod
The piston is an assembly type made Of 'pecia'
alloy steel with ductile cast iron, and is cooled
down by the lubricating oil that is transferred from
the connecting rod via piston rod.
The connecting rod is form-turned forged product
with the large end, which is horizontally split into
three parts, to allow overhaul of the piston without
disassembling the bearing unit.
Rocker arm device

side) of the crankshaft, and the crank gear lor pislon

driving the camshaft is installed at the front
end of the camshaft, together with the auxiliary
drive gear for driving various pumps.
The main bearing and crank pin bearing have cylinder liner
a thin-walled, two-piece structure, and a thrust
metal is attached to the front and rear end of Intake duct

the No.1 bearing located at the rear end.

2-1.3 Camshaft and Timing Gear

The camshatt is located on the left side of the
engine (when seen from the output side).
The intake cam, exhaust cam, and fuel cam
are fixed to the camshaft by shrink fitting.
T h e timing gear for driving the camshaft is
installed on the rear side of the engine, and
the cam gear is driven from the crank gear via Balandng
the middle gear.
In 6.8DK engine, the drive coupling of the
starling air rotary valve is installed on the rear
side of the engine.
N o t e that in 3.5 DK engine, the starting air
rotary valve is not installed since the engine is
air motor starting type. 3DK-20

General Construction
2-1.6 Cylinder Head
The cylinder head is of a highly rigid structure
made of special cast iron, and is hydraulically
secured to the piston with 4 bolts.
Four valve system is employed having 2 intake
valves and 2 exhaust valves, and a water cooling
valve seat, which is directly attached to the cylinder
head, is installed for each exhaust valve.
The indicator valve and cylinder safety valve are
installed on the upper face of the cylinder head,
and the starling valve is located on the side of the
head. Note that 3.5DK engine has no starting
valve since it is motor starting type.
2-1.7 Fuel Injection Device
The fuel injection pump is a Bosch-type high
pressure pump and a tappet-incorporated
monolithic type. It is provided with a closed-type
plunger barrel and isobaric valve, and plunger
lubrication is employed.
Also, the high-pressure oil inlet coupling, which is a
horizontal-insertion type, is connected to the fuel
injection pump via high-pressure coupling made of
forged steel.
...
2-1.8 Valve Operating Device
The intake and exhaust valves are driven by motion
transferred from the camshaft via swing arm, push
rod. and rocker arm.
2-1.9 Fuel Control Device
The governor is installed on the rear of the engine,
and is driven by the cam gear.
The control lever is located near the qauqe
- - board
on the front side of the engine, together with the
starting valve.
&
2-1.10 intake and Exhaust System @?$
b A.33,.
The turbocharger and air cooler are mounted on
the front end of the engine.
The standard specification of the turbocharger is
non-cooling and forced-feed lubrication, however
the specifications may vary according to the engine
type, output, and specification of each order.
(a: "Instruction Manual of Turbocharger")
The exhaust manifold and air intake duct are
installed on the same side of the engine, and the
intake duct is incorporated in the engine frame.
 General Construction
ITEM
2.1 DK-20 Piping Systems: Starting Pneumatic System
2-2 Piping Systems

P i p i n g s y s t e m s a n d related equipment vary depending o n t h e e n g i n e applications,

type o f fuel used, a n d specifications.
T h i s s e c t i o n describes t h e typical p i p i n g s y s t e m s o f s t a n d a r d specifications. For
m o r e details, refer to the piping systems included in t h e final documents.

2-2.1 Starting Pneumatic System

Starting operation of the engine is by pneumatic
system, and direct starting system is employed for
6.8DK, and air motor starting system is employed
for 3.5DK.
(1) Direct Starting Type
Starting operation is made by means of the
piloted ignition system using compressed air.
When the push button for the starting operation
valve is pressed, control air flows to the starting
a i r valve t o open the main valve, and the
compressed air reaches to the starting valve of
each cylinder.
Meanwhile, the compressed air branched off
from the main starting air pipe is sequentially
supplied to each cylinder by the starting air
rotary valve according to the ignition order, and
opens the starting- valve of each cylinder.
The compressed air sent through the main
starting air pipe effects the piston, causing the
engine to start its rotation.
The starting operation valve, starting air valve,
and starting air rotary valve are installed on the
front side of the engine, and starting air rotary
valve is driven from the front end of the camshatl.
Note that a safety valve and a check valve is
installed in the main air pipe for prevention of the
reversed flow of combustion air.
In case that the engine is started remotely or
automatically, the starting operation is made b y
means of the solenoid valve, allowing control air
to reach the starting operation valve.
( : "Starting Method")

Enaine startina solenoid valve 4

.~
(incase of rerLote or auto starting)
- .-..-..-.. - - ---
&&L ,..,.

..........
Startinn
-.-.....a nnentinn v a l w

u Starting Pneumatic System; Direct starting type

I I
 General Construction
-

Piping Systems: Starting Pneumatic System DK-20

(2) Air Motor Starting Type
Starting operation of the engine is made by air
motor system using compressed air.
In case of remote starling or automatic starling, if
the stating push button ol the engine control
board or operation board (monitoring board) is
pressed, the starter relief valve provided with
pressure control function (monolithic type
incorporated with relief valve) activates, and the
decompressed air pushes out the pinion gear of
the air motor.
When the pinion gear is engaged with the wheel
gear attached to the flywheel, the main air circuit
of the air motor opens.
Consequently, the air motor is driven by the main
air, and the engine starts its rotation.
In case of starting from the engine side (locally), if
the starting operation valve i s pressed.
decompressed pilot air opens the main circuit of
the starter relief valve, and decompressed air
pushes out the pinion gear of air motor.
Note that a strainer is provided between the air
tank and relief valve for protection of the air
motor.
The relief valve and air motor are installed on the
base plate of the engine.
(a: "Starting Method")

, Starter reliel valve (with regulator)

Starting push button

L - - - - - - - - - - - - - - - - - - - o * - - - -
a
Air motor

Starting Pneumatic System; Alr motor starting type

 General Construction
ITEM
2.2 DK-20 Piping System: Fuel Oil System

2-2.2 Fuel Oil System

Fuel oil system vary depending on the grade of the High pressure oil fed by the fuel injection pump is
oil used, and a typical example of the fuel oil introduced into the fuel injection valve connector
system for heavy fuel oil is as shown below. from the cylinder head side via high-pressure
When heavy fuel oil is used, oil must be heated piping coupling.
and kept at a constant temperature to maintain the In case of heavy fuel oil specification, nozzle
oil viscosity suitable for injection. cooling is provided to prevent the formation of
Oil heated by the heater and pressurized by the carbon flower.
fuel feed pump is transferred to the fuel injection (m: 2-2.5 "Nozzle Cooling System")
pump via filter. Surplus of oil is returned to the When diesel fuel oil is used, heating or heating
i n l e t side of the oil feed pump via pressure insulation of oil, and nozzle cooling is not required.
regulating valve (relief valve), and i s then
circulated again.
The oil pipe is provided with various heat insulating
arrangement such as steam trace or ragging, and
is kept at a constant temperature.
The lubrication of the fuel injection pump is made
by means of fuel oil circulation system, and the
plunger is lubricated by means of forced-feed
lubrication system using lubricating oil.
a
( : "Lubricating Oil System")

Air separator

I !- r
Main pipe lor luel injection valve
return oil

Main pipe for fuel high-pressure

........ oil lank

High-pressure Fuel injection

cou~lina valve

,..
1 I
Filter
I
I
A
I
8 ,

.
A

.;.>
.'.-
,

.-...

<
Relief valve
Filter
Fuel injection
Fuel inlet
main pipe

Fuel return
main pipe p
- I.
.caked oil tank

Fuer Oil System

 General Construction

-
Piping Systems: Lubricating Oil System DK-20 ITEM2.3

2-2.3 Lubricating Oil System

The lubricating oil system is as shown below.
Lubricating oil transferred to the lubricating oil
cooler from the lubricating oil pump is regulated to
reach the specified temperature and pressure, by
means of the automatic temperature control valve
(hereinafter referred to as temperature control
valve) and relief valve respectively, and the
lubricating oil is transferred to the oil channel of the
engine frame from the cooler via filter. Then, from
this oil channel, the lubricating oil is supplied to the
piston through the holes of the connecting rod via
each main bearing metal and crank pin metal.
Lubricating oil is also supplied to the camshaft,
valve-operating swing arm, fuel
injection pump, various gears, and around the
locker arm.
The lubricating pump is of a gear type provided
with a safety valve, and is installed on the front side
of the engine, to be driven from the crankshaft.
The lubricating oil filter is a notch-wire duplex type,
and blow-off cleaning during operation is possible
with this filter.
Lubricating oil is supplied to the turbocharger and
fuel injection pump via each special lubricating oil
filter respectively.
Lubricating oil, that has circulated through and has
lubricated each part, returns to the base plate of
the engine (oil tank).

Fuel iniection pump

- 1
+
Lubricating oil cooler
.-.-. --...
Relief Filter
valve Filter I Cum
Temperature
control valve

Filter

I Timing gear
Governor driving gear I
L l ~ o o l i n water
g pump 1
Salety
valve
@pump

~ ~

I
Base plate ol engine (oil tank) Leaked oil tank
Lubricating Oil System
2-2.4 Cooling Water System
The cooling water system is divided into the jacket
line (primary water) and the cooler line (secondary
water), and normally the jacket line is used for
fresh water, and the cooler line is used for sea
water (in case of use for vessels) as the standard
application.
(2) Cooler Llne
Cooling water in the cooler line is forcibly fed by
a special pump exclusive for cooler line, which is
separately installed, to the air cooler, lubricating
oil cooler, and fresh water cooler, and is then
discharged.

(I)Jacket Line
The jacket line circulates cooling water, and the
water cooled by the fresh water cooler is forcibly
fed into the cylinder jacket of the engine by the
cooling water pump, so that the water cools
various part of the engine and returns to the
fresh water cooler through the outlet collective
pipe.
A temperature control valve is provided between
the inlet and outlet of the engine (or, fresh water
cooler) to maintain the water temperature
constant.

Nozzle cooling system

(Not required for diesel fuel oil
(Remove RH133) engines)
-..-.- -- -
?Head lank
: Turbocharaer 1 r-- 1

Fresh water cooler

4
I-. . ..
...

: Temperature
i. j Air cooler / control valve
Jacket line outlet main pipe

Cooler line cooling

cooler water pump

Jacket line
fresh water

Cooling Water System

 .- "5.5
General Construction
ITEM
Piping Systems: Nozzle Cooling System DK-20 2.5

2-2.5 Nozzle Cooling System

Nozzle cooling system is installed in the engine that
uses heavy fuel oil.
In order to prevent the formation of the carbon
flower that occur on the nozzle tip of the fuel
injection valve when fuel oil temperature i s
intensely heated, cooling of the nozzle tip i s
required, and therefore the nozzle cooling using
cooling water or diesel fuel oil is carried out.
As the standard specification, cooling water is
employed.
As the cooling water, part of the water used to cool
the cylinder head is branched out and reaches the
fuel injection valve through the inlet main pipe, so
that it cools the nozzle tip and then returns to the
outlet main pipe.
In case of the special specification using diesel fuel
oil, the cooling system is of independently feeding
system, and the nozzle cooling pump is installed on
the front parl of the engine. The oil reaches the
fuel injection valve from the cooling pump through
the inlet main pipe to cool the nozzle tip. After
cooling, the oil returns to the outlet main pipe, and
then returns to the diesel fuel tank through the relief
valve and temperature control valve. This is the
forced-feed circulation syslem.

Orilice Valve

1 - Oullel main pipe

-'
Orilice Valve
lnlel main pipe

Fuel nozzle

-
Jackel line lresh
- Jackel cooling

waler pump

N o u l e Cooling System Diagram (Fresh water cooling)

Relief valvs

I Oullet main pipe

I
Temperalure control valve

I , lnlel main pipe

Pump

N o u l e Cooling System Diagram (Diesel fuel oil cooling)

 General Construction
Engine Operation Control, Protective Device :
DK-20 starting control

2-3 Engine Operation Control and Protective Device

Control and protective devices such as the starting air valve and stoppage cylinder
are activated by low-pressure control air.]
This section describes a system generally used for the power station that is remotely
controlled for starting and stopping. The engine that is actually delivered may differ
from the examples shown in this section depending on the specifications, and
therefore refer to the final documents, which are separately provided, for the details.
As for the starting air system (high pressure), refer to the previous section 2-2.1.
I

2-3.1 Starting Control

(1) For Generator (Remote control)
a) In case of starting the engine by remote
control, the control lever must always be set lo
"RUN" position. The handle switch (HS) will be
turned "ON" at this state, and if the turning
safety switch (TC) is also turned "ON", the
engine will be on standby and ready for
operation.
b) In case of directly starting the engine, the
starting solenoid (88V) is powered, excited,
and activated by a start command, so that
control air flows into the starting air valve via
starting operation valve, and the starting air
reaches the starting valve as the main valve is
opened.
Further, in case of air motor starting system,
the solenoid valve of the starter relief valve is
activated b y a start command, and the
decompressed air reaches the air motor to
push the pinion gear.
When the pinion gear is engaged with the
wheel gear, the main air circuit of the air motor
will be opened.
c) Meanwhile, the same start command allows
the fuel control solenoid (88L) to activate,
causing control air to flow into fuel regulating
cylinder, and allows the common rod to be held
in position, so that the fuel injection amount is
controlled not to be excessive at the time of
starling.
d) When the engine reaches the specified
rotation speed, the low-speed relay ( 1 4 ) i s
activated, canceling the start command and
resetting the protective circuit, so that the
engine is set to operating state.
(2) Automatic Starting
When the engine is started automatically, the
engine solenoid is activated in response to the
start command issued automatically in t h e
specified sequence, so that the control air flows
into the starting air valve and the engine starts its
rotation.
Further, in case of air motor starting system, the
solenoid valve of the starter relief valve i s
activated b y a start command, a n d
decompressed air flows into the air motor, so that
the engine starts its rotation.
(3) Engine Side Starting (Local starting)
In case of starting the engine from the engine
side (locally), the operation mode must be set to
"LOCAL" position, and in case of direct starting
system, if the push button of the starting
operation valve is pressed, control air flows into
the starting air valve, and starling air flows into
the cylinder.
Further, in case of air motor starting system, i f
the push button of the starting operation valve is
pressed, the main circuit of the starter relief valve
is opened and the decompressed starting air
flows into the air motor.
General Construction
Engine Operation Control, Protective Device :
Starting Control

GO\ Pulse sensor

A ,,
Turning bar Starting operation v a l v e q
-kc---

3 Speed switch
(12. 13. 14)
To meter
(4-20rnA)

I A \ ,Fuel injection pump

Fuel shuldown Fuel shutdown

Starling solenoid Fuel control solenoid
solenoid (5V) solenoid (5s)
(88~) (88L)

Starting and Stoppage System (Direct starting type)

Turning bar

I
Turning salety Starling solenoid (88V) (4-20rnA)
switch Starler reliel valve lwith rec

Fuel shutdown Fuel control Fuel shutdown

Control air solenoid solenoid solenoid
0.8MPa
!akg/cm2l (5'4 (88L) (55)

Starting and Stoppage System (Air motor starting type)

 Operation
Engine Operation Control, Protective Device :
DK-20 starting control

(4) For marine propulsion engine

a) Engine Side Starting (Local starting)
i ) In case of starting the engine from the
engine side (locally), the changeover valve on
the engine must be set to the local side, and
the control lever must be changed to
"START position from "STOP" position. At
this state, the handle switch (HS) will be
turned to "ON", and the protective circuit will
be released.
i i ) When the push button of the starting
operating valve is pressed, control air flows
into the starting valve, and starting air (high
pressure) flows into the starting valve as the
main valve of the starting air valve is opened.
iii) When the engine reaches the specified
rotation speed, the low-speed relay (14) is
activated, so that the start command is
canceled and the protective circuit is reset,
allowing the engine to be at starting state.
iv) When the idle rotation speed becomes
stable, turn the operating lever to "RUN"
position from "START position.
b) Remote Starting (Starting from the bridge)
i ) When the engine is to be started remotely
(starting from the bridge), set the control
handle of the bridge to "NEUTRAL" position,
and set the operating lever to " R U N position.
Then, the handle switch (HS) will be turned
"ON", and the turning safety switch (TC) will
also be turned to "ON", so that the engine is
on standby position for starting.
ii ) The starting solenoid (88V) is powered,
excited, and activated by a start command.
and control air flows into the starting valve via
starting operation valve, so that the main
valve is opened, and starting air flows into the
starting valve.

Pulse sensor

Starting and Stoppage System (Marlne propulsion engine side)

 General Construction
Engine Control, protective Device :
Controlling Engine StoppageIEngihe Protective Device
2-3.2 Stoppage Control
(1) For Generator
The fuel shutdown solenoid (5V) is activated by a
stoppage command, causing control air to flow
into the fuel shutdown device, s o that the
common rod is turned toward stoppage direction,
and then the engine is stopped.
In case of stopping the engine from the engine
side (locally), turn the operating lever to "STOP
position.
Note that the fuel control cylinder above
described is the monolithic type assembled with
the luel shutdown device.
(2) For Marine propulsion engine
The fuel shutdown solenoid (5s) is activated by a
stoppage command, causing control air to flow
into the stoppage cylinder, so that the rack of the
fuel injection pump is moved toward the stoppage
direction, and then the engine is stopped.
Table 2.3-1 Alarm and Stoppage Items (Examples)
I Detection item I Alarm I Shutdown I
I Overspeed I I
% Marked : Option
I DK-20 13.2,3.31
ITEM
2-3.3 Engine Protection System
(1) As for the errors that may be led to serious
accidents or failures, alarm is issued a n d
emergency stop is made.
Each abnormal operation data or value is
detected b y a switch or sensor, and the fuel
shutdown solenoid is activated by an emergency
stoppage command, s o that the engine is
immediately stopped.
(2) Depending the specifications, the dual safety
system will be provided. In such a case, in
addition to the normal engine stoppage, control
air i s flowed into the stoppage air cylinder
attached to the fuel injection pump to stop the
engine.
(3) When the forward clutch of the reduction gear is
engaged, the governor boost solenoid is
activated by movement of the control handle,
causing the governor air boost to reach the
governor, so that the reduction of the engine
rotation speed is prevented.
Further, the engine rotation speed is controlled by
governor air via governor, and at the same time
the governor air reaches the FO control cylinder
to control the rotation speed of the common rod,
so that the excessive supply of fuel injection is
restrained.
..
(for the specifications of the marine
propulsion engine)
Location ( Remarks I
I Cam gear I I
 General Construction
Engine Control, Protective Device :
DK-20 Engine Protective Device

Oil leakase lram

I Fuel oil leakase

" @
(Resislance bulb)

Engine Protection System (Example)

General Construction
""
Memo DK-20
 Engine Adjustment Standards
ITEM
1 DK-20 Operating Specifications

3-1 Operating Specifications

Item Reference

Starting air
Air motor

Control air Air tank

aries depending on
Intake air Air intake duct le enqine output

Fuel oil I Engine inlet

Engine inlet
Lubricating oil
Turbocharger
-

Jacket line :onsider static and

ynamic pressure
Cooling water ue to tank head anc
I (cooler inlet) i ~ resistance
e

Intake air I Air intake duct

1 Cylinder outlet

Exhaust gas l~urbochar~er

inlei

I~utbochar~er
outle

..
m Engine inlet

a-
0 Cooler line Engine inlet
Jaries depending or
Nozzle cooling oil Inlet main pipe POI jpecifications

Notes: (1) As for the alarm setting value and emergency slop value, each item of the pressure represents the
lower limit value, and each item of the temperature represents the upper limit value.
(2) Manometer, thermometer, and alarmlemergency stop device will be provided depending on the
individual specifications.
(3) The actual data found on each engine may differ from those shown in the above table, and therelore
refer to the Tesl Run Record Table (included in the final documenls) for the details.

Engine Adjustment Standards
Valve Setting Values
3-2 Valve Setting Values
Item
I I
Opening start angle
(before top dead center)
Closing end angle
(after bottom dead center)
--
Valve end clearance "C-
Opening start angle
(before bottom dead center)
Closing end angle
(after top dead center)
- I
Valve end clearance -C'
--
! -
!
-
Pumping start angle by
fuel injection pump
(before to^ dead center)
uel oil injection valve opening pressure
(adjustment value)
Maximum combustion pressure
Zylinder safety valve opening pressure
(adjustment value)
,
ITEM
DK-20 2
Adjustment value Remarks
(design value)
(30' )
(35' )
1 0.31mm
(Valve end clearance
adjusting procedure)
(1) Valve end clearance data
represents the clearance available
when the engine is cold.
(2) Adjust valve end clearance "A'
and "B" shown above such that il
becomes equal to " 0 first. Then,
adjust valve end clearance "C"
such that it becomes equal to the
value given in this table.
0.31mm
In case of direct starting system,
May vary depending on the engine
I
output and specifications. Refer to
the Test Run Record Table (included i n
the final documents).
29.4MPa
May vary depending on the engine
output and specifications. Refer to
I the Test Run Record Table (included in
the final documents).
19.1MPa
d95kgf/cm21
 -
Operation

11.1 1.2
j 1 DK-20 I Precautions for Operating Engine I
4-1. Precautions for Operating Engine
4-1 .I For Start

'0
0 (I) Conduct preparations before start of the operation of engine, such as the inspection of oil, water,
and air levels as well as proper operation of the valves without fault, and be minded to start opera-
tion only afler it has been confirmed that all the conditions are ready for the start of engine.
! (2) It is extremely dangerous to start the operation of engine with the turning bar inserted in the fly-
wheel Be minded to remove the bar and store it in a specified place after turning is completed.
1 (3) Confirm that there are no working staff around the engine. When anyone is around the engine, be
mmded to send a signal and confirm safety before starting the operation of engine.

4-1.2 For Operation

0 (1) After the starting engine, inspect the following items, and confirm that the engine is in a good and
removal operating for. In case that any defect is found, immediately stop the engine, so that the

.
causes of the defect can be investigated and the measures for recovery can be taken.
Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate

.. exhaust temperature, etc.

Abnormal sound, excessive heating, etc.
Any leakage from piping. (Particularly, leaks from oil piping will result in fire.)
Be minded never to attempt to resume the operation of engine, until the causes of the problem
or defect are found and eliminated, and the engine is restored to normal operating conditions.
@ (2) Inadvertent contact ofthe body of working staff or objects with the rotary parts (e.g. flywheel and
coupling) will result in dangerous accidents such as that the staff may be caught up or the chips of
the objects caught may fly out in all directions. Therefore, be minded that both person or object
may not touch the rotary parts.
Further, ensure that the protective covers ofthe rotary parts are always attached without fall.
(3) During the operation of engine, particularly the following parts are extremely hot, and therefore
there is a danger of burn if touched with bare hands or skin. Be minded to wear safety gloves or
protective gears whenever maintenance or inspection works are conducted.
Afler the completion of the work, restore the lagging, heat covers, combustible oil splash preven-
tive means (FN tape) and protective covers that have been removed for maintenance and inspec-
tion.

. Exhaust pipe
Turbocharger

. Air cooler inlet pipe

Cylinder head
Indicator valve

. Fuel injection pump and high-pressure coupling

Fuel oil filter and fuel oil pipe (in case of heavy fuel oil)
 , :

Operation

L
Precautions for Operating Engine

4-1.3 Precautions tor Stoppage

0 (1) Make sure that the engine is stopped after load is taken off the engine, except in the case of
emergency.
(2) In case that the engine is stopped in emergency stop, be minded never attempt to resume the
operation until the causes of the problems is found and eliminated, and the engine is restored.
@ (3) Do not open the crankcase for at lease 10 minutes after the engine is stopped and fully cooled
down. Otherwise, there is a danger of explosion since the inflammable mist gas in the crankcase
may catch fire.
(4) The engine immediately after it is stopped is still extremely hot like during the operation, and there
is a danger of burn. Therefore, be minded to wear the protective gears whenever inspection or
maintenance works is conducted without fail.
 Operation

DK-20 Preparation for Daily Operation

4-2 Preparation for Operation

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

being operated. Therefore, be sure to perform pre-operation inspections before the
starting of engine, and take proper corrective actions and countermeasure whenever
any problem is found, t o confirm that the engine is in normal conditions for operation,
before starting the operation of engine.
If the engine is started without pre-operation inspections or preparations, it will cause
not only the troubles when starting the engine but also result in a sudden stoppage or
damaglng accidents.

4-2.1 Preparation for Daily Operation

The number of the inspection items required

before starting the operation varies depending
o n how long the engine has been out of
operation.
Daily starting: Short period ol disuse (within
one month)
Initial starting atter a lorig period of disuse,
or after overhaul or maintenance.
The daily starting procedures is described in
this section. As for the latter (initial starting),
refer to the following section.
(a : 4-2.2 "Preparation for Initial Starting")

port Oil porC,

Inspecting GovernorLubricating Oil Level

 Operation
ITEM
Preparation for Daily Operation DK-20 2.1

(1) Inspection before Operation -011 feeding points

a) lnspection and Feeding of Lubricating Oil
Check the oil level of the oil tank, and feed new
oil to the upper limit level of the oil gauge.
Further, in case that the lubricating oil is found
inadequate after examination, proceed with
makeup or replace the entire amount of the
lubricating oil.
(a
Control)
: 6-2 'Lubricating Oil Characteristics and
Fuel injection pump

Manual oil feeding: Around common rod and

@ Engine lubricating oil tank fuel injection pump
(Base plate common to different engines)
Fuel injection pump

Lubricatin oil
level (L 1100

Note: The oil level shown above may vary

depending on the specifications.
@Governor
1400
p m C: Around operation lever
Lubricating oil level RHD6 : 1.3L, +Oil feeding poihts
UGlO : 1.7L View B : Around fuel injection pump
@ Generator (in case of self. . . lubricating type)
( 0: Separately provided "Generator Potentiometer
lnstruction Manual")
@ Reduction gear (in case of marine
propulsion engine)
( a : Separately provided "Reduction
Gear Instruction Manual") +Oil feeding point

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

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

Operation lever
 Operation

DK-20 Preparation for Daily Operation

c) Draining of Condensed Water from Intake d) Draining - Condensed Water from, a n d

Alr Inlet Duct Supply Air, t o Air Tanks

Open the drain cock of the intake air inlet duct,
and drain the condensed water out.
1. Close 2. Open
1) Drain cock of engine frame inlet air duct
In case of automatically supplying air, first drain
the condensed water out of the starting air tank
and starting air control tank, and then confirm
that air pressures in these tanks is above the
lower limit value.
In case of manually supplying air (including
manual staring of the air compressor), supply

1 1 1 1
air to the upper limit value,

1) Drain cock of engine Item Upper limit Lower limit

frame inlet air duct
Direct 2.9MPa 1.5MPa
starting {30kgf/cm2) {15kgVcm2)

Air motor 2.9MPa 1.OMPa

Starting (30 kgf/cmz) (10 kgf/cm2)

-
O.9MPa 0.7MPa
Control air
{9kgf/cm2) (7 kgf/cm2)

e) Checklng and Feeding of Fresh Cooling

Water
Check the level of fresh cooling water, and if
the level is at the lower limit, supply fresh water
Engine Frame inlet Air Duct
up to the upper limit, and at the same time add
a proper amount of the additive.
Further, in case that each properties of water
Always keep the drain cock of the engine has reached the limit level, replace the entire
frame inlet air duct open about 114, after amount of water.
draining the condensed water b y fully
opening the drain cock.
(m: 6-3 "Cooling Water Characteristics and
Control")
In case that the humidity is high and the
temperature of the air cooler is low, a large
amount of condensed water will accumulate,
and may cause abnormal wear or tear on
various parts by flowing into the cylinder.
Operation

Preparation for Daily Operation DK-20 "'"2.1

f ) Draining of Fuel Oil and Supply of Oil

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

g) Confirmation of the Clutch Being "Neutral"

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

h) Opening and Closlng of valves

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

[Examples]
@ Valves for fuel oil inlet pipe and return pipe:

-
"Open"
@ Valves lor cooling water (jacket and cooler),
inlet pipe, and outlet pipe: "Open"
@ Valves for starting air pipe: "Closed" ("Open"
only when starling operation)
@Valves for operation air pipe: "Open"
@ Valves for pipe coupling parts provided for
emergency, priming, cleaning, etc.: "Closed"

If the screw-tightening valves are used on the

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

DK-20 Preparation for Daily Operation

(2) Standby Preparation (Engine o n standby)
Before entering the operation of engine, conduct
the following preparations:
a) Priming with Lubricating Oil
Start the motor-driven lubricating oil priming
pump (or, reserve pump) 5 minutes before
starting the operation of engine, and confirm
that there is no oil leaks from various parts of
the piping.
[Turning ]
<Work Procedure>
i ) Conduct priming with lubricating oil.
ii ) Set the operating lever to "STOP" position.
(Do not inject fuel oil.)
iii) Set the indicator valve to "Fully open"
position.
N) Conduct turning 1 to 2 times, and confirm that
the engine rotates smoothly.

[Priming b y Manual Pump]

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

b) Turning o r Air Running

Indicator Valve

-
Conduct turning or air running to discharge the
dusts or water drops that has collected in the
cylinder while the engine is stopped.
Further, when the engine is started after the Indciao
l r, %, ,
inspection of various parts of the engine, or scale
after a long period of disuse of the engine,
conduct turning before air running to confirm
the safety.

In case that a large amount of water or oil is

accumulated in the cylinder due to the
leakage from the cylinder head or fuel
injection valve, there is a possibility of
serious accidents such as bending damage Operation Lever
of the connecting rod by water hammer.
When conducting turning or air running, if
water or oil has gushed out of the indicator
valve, immediately stop the starting of
engine, so that the causes can be
investigated and the countermeasure can be
prepared and taken.
Operation
Preparation for Daily Operation
[Air Running (abbreviated as Air Run.)]
<Work Procedure>
i ) Conduct priming with lubricating oil.
ii) Set the operation lever to " S T O P position
iii) "Fully open" the indicator valve.
iv) Open the starting air valve and the control air
valve, and press the push button forthe start-
ing operation valve. Then, starting air flows
into the stsrting air valve, and the engine
start its rotation.
In case of air motor starting system, operate
the solenoid of the starter relief valve. Then,
pilot air flows into the air motor, and the
engine starts its rotation.
v) Keep pressing the push button for 3 to 4 sec-
onds. (for air run)
vi) Release the push button. Then, the starting
air valve closes, and the engine stops its
rotation.
In case of air motor starting system,stop the
operationof the solenoid. Then, the air motor
stops, and the engine stops its rotation.
If the engine starts its rotation during the
inspection of the inside of the engine or rotary
parts, it is extremely dangerous since the
working staff may be caught up or the objects
that has been caught up may fly out in all
directions.
When conducting air run, strictly observe the
following points.
1) Confirm that the turning device or turning
bar is set "OFF".
2) Send a signal to coworkers and confirm
safety before starting to press the push but-
ton of the starting operation valve.
DK-20
Do not fully open the starting air valve during
air run, keeping the opening at about 113, and
carefully conduct air running at low speed.
If air run is conducted at high speed by fully
opening the starling air valve, it will not only
expend air uselessly, but also will result in seri-
ous accidents such as aggravation of the
defects if any defect had been caused.
c) Heating of Fuel Oil (when heavy fuel oil is
used.)
In case that heavy fuel oil is used, heating
shall be made according to the following items:
i ) Turn on the fuel oil heating device.
ii) Operate the motor-driven oil feed pump
. .
( : 6-1 "Fuel Oil Characteristics and
Control")
Heated heavy fuel oil i s extremely h o t
(100% or more), may cause burn i f you touch
the piping or equipment on the fuel oil system.
Therefore, in case of handling the equipment of
fuel oil system that carriers heat oil, be sure to
wear safety gloves and never touch them with
bare hands.
d) Turning "ON" of Protective and Alarm
Circuit
Tum "ON" the protective and alarm circuit on
the monitor panel, and confirm that the warning
lam is lit up.
e) Operation of Motor-Driven Pumps
In case that the engine is equipped with the
motor-driven cooling water pump and fuel oil
feed pump, start the pumps 5 m-inutes before the
starting of engine, and confirm that there is n o
oil leaks from various parts of piping.
 I Operation I
Preparation for operation: Preparation of Initial Starting after A
Long Period of Disuse, and Overhaul

4-2.2 Preparation for I n i t i a l Open the following filters, and cleanse the
Starting after L o n g Period inside and the elements of the filters:
of Disuse @ Starting air filter and control air filter
Fuel oil filter (including oil filters on the
Since the engine is not ready for immediate outside of the engine)
starting of operation after a long period of disuse,
and overhaul or maintenance, it is particularly nec- @ Lubricating oil filter (filters on the engine,
essary to thoroughly conduct the preparations for for TIC)
operation. @ Cooling water filter
Before the preparation for daily operation, con- ( : 5-4.3 "Cleaning Filters")
duct the following preparation works (4-2.1).
(1) lnspection o f Crankcase and Cylinder Liner,
and Supply o f Oil
a) lnspection of the Inside of Crankcase
Open the side cover of the engine frame, and
check and ensure that tools, waste clothes, for-
'
eign matters such as desiccants are not left
behind, and that there is no nrsting on the cylin-
der linen, crankshafl, and so on.
b ) Supplying Lubricating Oil to Cylinder Liner
After a long period of disuse, the various parts
of engine are not covered with sufficient amount
of lubricating oil. Particularly around the cylin-
der, lubricating oil cannot be supplied sufficiently
with priming alone, and therefore supply lubricat- Sprayispray
lubricsiting oil)
ing oil on the following procedure:
i ) Conduct turning to allow the pistons to move
upward, and apply lubricating oil on the lower
part of the cylinder liners by a spray device No foreign matters
such as desiccant
and the like.
ii) Sequentially conduct the above procedure to
Li_l or silicagel shoud
be present.
each cylinder.
(2) lnspection of Connections and Joints Applying Procedure of Lubricating Oil
Inspect again the external connections or
joints to conlirm that there is no connections that
(4) Priming with Lubricating Oil and Exhausting
has been forgotten to be tightened, or loosened
Air
joints. I f combustible oil splash preventive
means (FN tape) has been removed from joints. Conduct priming with lubricating oil and
newly treat the joints in the same manner afler exhausting air on the following procedure:
the completion of the work. a) Run the lubricating oil priming pump for 5 min-
utes. While the pump is operating, open the
(3) Opening, Cleaning, and Cleansing o f Filters
turning plug (on the cylinder head top surface) t o
Dust or foreign objects, that had been collect- perform turning two or three times, and check for
e d into piping during transportation, and outfit- leakage of fuel oil, lubricating oil and water from
ting or installation, is accumulated in the filters of the turning plug.
the engine inlet.
b) At the same time, open the each cover and
check the dripping-down conditions of lubricating
oil from each part.
 ..
Operation

Preparation for operation: Preparation of Initial Starting after A

Long Period of Disuse, and Overhaul DK-20

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

(5) Priming with Fuel Oil and Exhausting Air

Conduct priming with fuel oil and exhausting
air bubbles on the following procedure:
i )Operate the fuel oil feed pump (in case of the ". ...w=.
.,-..
Bs?ss5
E$#>~=*
engine equipped with a motor-driven oil feed
pump). Turbocharger
$+$y,+
$<<*<$id

ii)Open the fuel oil inlet valve, afler confirming Air vent
that the operation lever is set to "STOP"
position.
iii)Open the air vent valve of the fuel oil filter,
and drain oil until air bubbles in oil are com-
pletely vanished.
iv)Open the air vent valve of the fuel injection
pump, and drain oil until air bubbles in oil
are completely vanished.
v)Afler completely removing air vent, securely
tighten the deflator.

The heavy fuel oil i s heated to a high temper-

ature (100°C or more).
Touching the splashing oil may scald your Notch-Wire Filter
hands. If high-temperature parts are splashed
with the oil, a fire may occur. Take care not to
splash the oil when discharging air.

(6) Cleaning of Turbocharger Pre-Filter

Dust or debris are collected in the pre-filter of
the turbocharger during transportation, outfitting,
and installation, causing the filter to be stained
or damaged.
Therefore, clean it or replace it with a new one
before starling the operation.

(7) Checking the covers are fitted

Exhausting Air of
Check that the lagging for high-temperature Fuel Injection P u m p
 Operation

DK-20 Starting Procedure

4-3 Starting

Inadvertent contact of working staff or objects

with the rotary parts is extremely dangerous
since the person may be caught up or the
object that has been caught up may fly out in
all directions.
Therefore, strictly observe the following items
when starting the operation.
*Confirm that the protective covers of rotary
parls are mounted in normal state, and that
Operating Lever
the rotary parts are free of any obstacle.
Confirm that the turning device or turning bar
is set to "OFF". (2) Remote Starting (Manual and Push Button
Send a signal to a coworker if there is any, Starting)
and confirm safety before starting the <Work Procedure>
operation of engine. i ) Switch the starting mode to the remote mode
(from monitor chamber) from local mode (from
engine side).
4-3.1 Starting Procedure ii ) Set the operating lever to "RUN" position,
ii ) Open the starting air valve and control air
(1) Starting
.from Engine
. Side (Locally)
~ ~

valve, alter confirming that "READY indicator

Starting procedure can be classified into the
three types; engine side starting (local starting),
remote starting, 'and automatic starting, and
which of these should be employed depends on
the specifications. However, local starting
(starling from engine side) by manual operation
should always be employed after a long period of
disuse or after overhaul or maintenance.
<Work Procedurer
i ) Open the starting valve and control air valve.
ii ) Set the operation lever to "START" position.
iii) Press the push button for the starting
operation valve.
N) Ifthe rotation speed of the engine has rapidly
increased and starting has been established
along with continuous ignition sounds, release
the push button.
v ) After confirming that the rotation speed of the
engine has reached the specified speed, and
each pressure has reached the specified
value, set the operating lever to "RUN"
position.
vi) Close the starting air valve.
(Leave the control air valve "Open" as it is.)
lamp has lit up.
iv) Press the starting push button.
v ) Confirm that "RUN" indicator lamp on the
panel has lit up as the rotation speed of the
engine has reached the specified rate, and
each pressure has reached the specified value.
v i ) Close the starting air valve.
(Leave the control air valve "OPEN" as it is.)
(3) Automatic Starting
In case of automatic starting, the engine starts
automatically by the starting command based on
preset starling conditions, such as the overload
conditions of power shutdown or other engines
(in case of plural engines), and therefore it is
essential that the engine should always be kept
in operable conditions
Engines should b e kept in the following
conditions at all times:
@Starling mode: "AUTO"
@Operation lever position: "RUN"
8 Starting air valve and control air valve:
"OPEN
 Operation
Starting Procedure / Inspection and Check Items
Immediately After Starting

(4) Corrective Measure In Case of Faulty Starting

In case that the engine has failed to start or has
not started smoothly, take corrective measures
by referring to a separately provided section.
( : 7 'Trouble Shooting and Countermeasures")

In case that the engine has repeatedly failed

to start in an extremely cold weather while the
engine is still in cold condition, the unburnt
mist of fuel oil may remain i n the exhaust
manifold, having a possibility of catching fire
o r explosion being c a u s e d b y high-
temperalure combustion gas.
When starting failure has been repeated,
conduct air running and exhaust the unburnt
mist in the exhaust manifold, before restarting Gauge Board
the engine.
(3) Abnormal Sound
4-3.2 Inspection and Check Items Carefully listen to the sound of the tollowing
Immediately Afler Starting engine parts, and check if there is any abnormal
sound or not:
Check the following items immediately after @ Cylinder head and surrounding parts (intake
starting. and exhaust valves)
When any abnormal error has been found, @Crankcase
immediately stop the engine and take proper @ Crankcase and timing gear and auxiliary drive
measures.
( m: 7 "Trouble Shooting and Countermeasure")
gear
@Turbocharger

(4) Exhaust Temperature

After conducting overhaul or maintenance of
the sliding parts or rotary parts, be sure to once
stop the engine and check that there is no error
or failure by hand-touching.
(1) Engine Rotation Speed
Confirm that the engine rotation speed (the
number of idle rotation speed, in case of the
marine propulsion engine) has reached the
specified rotation speed, and hunting (swinging of
tachometer) is not occurred.
(2) Pressure Reading o f Each Parts
Confirm that the indicator of pressure reading, for
the manometer with blue mark, is within the blue
mark, showing the pressure is within the specified
value.
Check the exhaust temperature of each cylinder,
and confirm that all the cylinders are properly
burnt (at 200°C or more).
(5) Gas Leakage from Starting Valve
If gas has leaked from the starting valve, the
starting air main pipe becomes hot.
Check il the starting air main pipe is not heated
or not by lightly touching the pipe.
(6) Leakage and Loosenlng of Each Part
Check il the bolts and nuts of installation part or
connecting part are not loosened, and if oil,
water, or gas is not leaked.
 Operation
DK-20 Running-In Operation
4-4 Operation
4-4.1 Running-In Operation
When the engine is started for the first time or
immediately after replacement of the parts, such
as the cylinder liners and piston, since the sliding
parts of the engine are not yet sufliciently ready to
work smoothly or freely, failure such as abnormal
wear or seizure of the sliding parts may occur, if
the load is abruptly applied in the stage of such
conditions.
Conduct the running-in operation to ensure smooth
a n d free working of the sliding parts o n the
following procedure, before entering normal
operation:
(1) Initial Running-In Operation
I t will substantially a f f e c t the engine
p e r f o r m a n c e , especially the combustion
performance and consequently the consumption
efficiency of lubricating oil, whether the piston
and oil rings move smoothly and freely, or not.
Further, it is assumed that they will be decided
b y the initial operation of a few hours.
When the cylinder liner, piston, piston ring, and
sliding parts around cylinder are replaced, be
s u r e to conduct running-in operation i n
accordance to the figure shown below.
(a : Fig. 4.1 "Initial Running-In Pattern")
(2) Operating Conditions d u r i n g Running-In
Operation
Be sure to operate the engine during the running-in
period under the following conditions:
Load: 80% or less
@Fuel oil to be used: Diesel fuel oil
Note: For the engines of heavy fuel oil
specification, be minded to use diesel fuel oil
during the running-in period.
@ Lubricating oil to be used shall comply with
the fuel oil to be used.
Note that for the engine with heavy fuel oil
specification, lubrication oil for heavy fuel oil
c a n be used from the beginning.
notwithstanding the above prescriptions of @.
@ Running-in period is 150 hours.
(3) lnspection Items during Initial Running-In
Operation
To detect the potential problems and eliminate
the causes to previously prevent such problems,
particularly heed cautions l o the following items:
@Abnormal sound
@ Partial heating
@ I from connection parts, and loosening
Leakage
of screws
@ Explosion pressure, exhaust temperature.
irregular exhaust color: Abnormal burning of
fuel
@ Excessive consumption of lubricating oil:
Improper working of liners and rings
(4) lnspection and Works after Completion of
Running-In Operation
At the time when the running-in operation is
completed, conduct the following inspection
works and confirm that there is no abnormalities,
before entering the normal and regular operation
of engine:
@ lnspection of foreign maHers and stains in the
crankcase
@ Visual inspection of the inner surface of the
cylinder liner
@ lnspection and cleaning of the element of
each filter
@ Remove the flushing filter attached to the
element of the fuel oil filter.
L l
Be minded never to perform the operation of
engine using heavy fuel oil, while the flushing
filter is attached.
 Operation

Running-In Operation

Load

Fig. 4.1 Initial Running-In Panern

 ,'
Operation -

DK-20 Warming-Up and Connecting Load to the Engine

4-4.2 Warming-Up and Connecting Load
to the Engine
In case that the engine is started while it is still in a
cold state, first perform the warm-up operation,
except for the case of emergency, and gradually
connect the load after the engine has sufficiently
been warmed up.
If the load is hastily connected while the various
parts of the engine are still cold and not yet in the
conditions f o r proper fuel combustion and
(2) Connecting Load t o the Engine
lubrication, malfunctions such as faulty
combustion, excessive wear of the sliding parts,
Be minded to perform no-load operation on
for warming-up operation, and restrain the
duration of no-load operation within 10
minutes.
Running the engine under no-load for long
hours will result in malfunctions such as faulty
combustion and collection of carbons in the
combustion chamber.
The lower the engine temperature (temperatures
of jacket cooling water and lubricating oil) is, the

and seizure may be caused.
(1) Warming-up Operation of Engine
a) Use diesel fuel oil f o r warming-up
operation
Be sure to use diesel fuel oil for warming up
the engine, even in case of the engine with
heavy fuel oil specification.
-
longer time it is needed to connect the load.
The standard load connection time is shown in
the figure below.
(m: Fig. 4.2 "Load Connection Pattern")
In case of the marine propulsion engine (direct
connection by propeller), be minded to gradually
increase the rotation speed, since the load will
increase according to the rotation speed.

b) N o load (Idle operation in case of warming

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

Load

Flg.4.2 Load Connection Pattern


Operation
Operation with Load (Normal Operation)
4-4.3 Operation with Load (Normal
Operation)
Inspect the running conditions of the engine and
measure the operating performance data in regular
intervals, during the continuous operation with load
(including period of the running-in operation).
In case that any problem is found as the results ol
the inspection and measurement, take proper
measures such as adjustment or repair of the
defective parts. (Refer to a separately provided
section.)
(a:
(a 5-3"Measurement and Adjustment")
: 7 "Troubleshooting and Countermeasures")
(1) lnspection of Operating Conditions
<Check Hems,
@ Abnormal sound
@ Paltial overheat
@Leakage from connections and looseness of
screws
@ A b n o r m a l combustion pressure, exhaust
temperature, and exhaust color
......Abnormal combustion
@ Excessive consumption of lubricating oil
...... Damaged cylinder liner and ring
During the operation of engine, particularly
the following parts become extremely hot,
and touching these parts with bare hands or
skin may cause burns.
Therefore, be minded to use the protective
gears such as safety gloves when working on
them.
0 Exhaust manifold
0 Turbocharger
0 Air cooler inlet pipe
OCylinder head
0 Indicator valve
OFuel oil system equipment and piping (in
case of heavy fuel oil)]
( 2 ) Measuring Performance Data
a) Measure the operating performance data at
least once every day, when the load variation is
less and the load is stable.
b) Compare each of the measured data with the
data obtained when the engine was newly
* .
A
DK-20
introduced, and judge if there is any problem
and check the degree dl deterioration.
(m : "Test Run Record Table" in the final
documents)
<Measurement Items,
Q) Room temperature
@Load (output)
@ Rotation speed
......In case of variable-speed engine
@Maximum combustion pressure (each
cylinder)
@ Intake air temperature (turbocharger inlet)
@Exhaust temperature (outlet of each cylinder)
a Intake air pressure (engine inlet)
@ Lubricating oil pressure (engine inlet)
@Cooling water pressure (engine inlet)
@ Fuel
l oil pressure (engine inlet)
...... In case of heavy fuel oil specification
0Inlet air temperature (engine inlet)
@Lubricating oil temperature (engine inlet)
@Cooling water temperature (engine inlet and
outlet)
@Fuel oil temperature (engine inlet)
...... In case of heavy fuel oil specification
@ Reading on fuel injection pump rack scale
(3) Regular inspection and Maintenance
Conduct inspection and maintenance o f the
various parts of engine regularly.
(Refer to a separate\y provided section.)
(a : 5 "Inspection and Maintenance")
(4) Operation Records
After completion of the inspection a n d
measurement, keep the records of the works
performed on adjustment or repair i n the log
book.
Operation records are very important
documents when understanding t h e
conditions of engine and tracing the history of
the inspection or maintenance that has been
performed.
Keep and store them carefully, and when the
supervisor is changed, be sure to transfer the
records to the successor without fail.
 ' l
Operation
-
Operation Using Heavy Fuel Oil
4-4.4 Operation Using Heavy Fuel Oil
(in case of Heavy Fuel Oil
Specification Engine)
Since heavy fuel oil is lower in its quality and
higher in its viscosity as comperared with diesel
fuel oil, it is required to carry out an appropriate
operation control, such as operating the engine by
changing to diesel fuel oil depending on the load
conditions, in addition an appropriate control of the
fuel oil and lubricating oil, when this type of oil is to
be used.
Further, the starting and stopping the engine,
when heavy oil is used, is only allowed on the
engine of the heavy-fuel-oil starting-and stopping
specification.
( : 6.1 "Fuel Oil Characteristics and Control")
( a ' 6.2 "Lubricating Oil Characteristics and
Control'?
(1) Operation with Diesel Fuel Oil
Be minded to use heavy fuel oil only under
stable load conditions, and be sure to use diesel
fuel oil in the following cases:
a) During Running-In Operation Period(l50 hours)
@) Immediately aHer installation
@ AHer replacement of the sliding parts around
cylinder (e.g. cylinder liner, piston, and piston
ring)
-.
( a : 4.4.1"Running-In operationv)
b) During Starting or Warming-Up Operation
( : 4.3 "Starting")
( : 4.4.2 "Warming-Up Operation")
c ) During idling o r Low-Load Operation
When the engine is operated under low load,
the compressed air temperature in the cylinder
and fuel injection pressure of fuel oil is low, and
therefore if the heavy fuel, of which combustion
quality is lower than that of diesel fuel oil, is
used, combustion will become unstable, result-
ing in undesirable conditions, such as worsening
o f the exhaust smoke, sticking of the ring, and
s o on. In case of the connection of the load that
is below the lower limit described in the engine
specification, be minded to use diesel fuel oil.
d) In Case Load Variation i s Heavy
@ When entering or leaving port
@ When weather is rough and stormy
@ When cargo is being loaded or unloaded
e) Before Stopping Engine
( : 4.6"Stoppage")
(2) Switching Fuel Oil Types
Heavy fuel oil is normally heated up to 80 to
90°C in the service tank, and 100°C or more at
the engine inlet, and the temperature difference
is larger as compared with that of diesel fuel oil
(non-heated), and therefore if fuel oil is suddenly
switched between these oils, it may cause mal-
functions such as sticking of the fuel injection
pump, vapor lock, and so on.
a) Slowly switch from diesel fuel oil to heavy fuel
oil, so that the rate of change in the fuel oil tem-
perature at the engine inlet is between 5 and
IC'C per minute.
( : Fig. 4.3 "Switching Pattern from Diesel
Fuel Oil to Heavy Fuel Oil")
b) Maintain the viscosity (temperature) of heavy
fuel oil at the engine inlet at the specified value
c) Do not raise the temperature of diesel fuel oil
beyond the flashing point (60% is the standard
point).
d) To prevent the generation of vapor, maintain
the pressure of fuel oil at the specified value.
Further, remove the air bubbles in fuel oil in
the various equipment of the fuel oil system
(heater, filter, tank, etc.) from time to time, so
that the accumulation of vapor can be prevent-
ed.
I.\
If high-temperature parts are splashed with
the oil, a fire may occur. Take care not to
splash the oil when discharging air.
e) Confirm that the heat traces on piping and
equipment is properly functioning.
The fuel oil is heated, and the filter and the
piping are at high-temperatures. If touched
with bare hands or skin, it may cause a bum.
Therefore, be minded not to directly touch the
exposed metallic parts such as the valves and
cocks, and wear the protective gear such as
safety gloves when working on them.
 Operation
ITEM
Operation using Heavy Fuel Oil DK-20 4.4

:In case that emergency stop i s made during

the operation with heavy fuel oil, immediately
switch the fuel oil to diesel fuel oil, move the
motor-driven pump, and perform flushing of
the fuel oil system.
If the engine is cooled down with the heavy
fuel oil left unchanged, the oil will be solidified
and the operation will be prohibited.

S w i t c h i n g from Diesel Fuel 011to Heavy Fuel Oil S w l t c h l n g from Heavy Fuel 011to Diesel Fuel Oil

60 l o 70 sec, RW NO1
..-. .-.. -..-. .-..-..-..-..-
Heavy luel ail Imperalure
1 XChange spped : XChange spped :
5 lo 10'Clmin. 5 l o lO"C/min.

Switching Operalion
over lo heavy wilh heavy
Operation wilh diesel fuel ail luel ail luel oil

during switching for proper operalon

Note : 1. Since the pretreatment of fuel oil differs depending on the use purpose of the engine, the operating
method suitable to each system is necessary.
2. The diesel fuel oil temperature when switching on heated condition shall be 6 0 " or
~ more.

Fig.4-3 Switchlng Pattern from Diesel Fuel Oil to Heavy Fuel Oil
 Operation
DK-20 Allowable Operating Range
4-4.5 Allowable Operating Range (In
case of marine propulsion engine)
In case of the marine propulsion engine, the load
changes i n accordance with the marine
characteristics, and according to the changes in
the rotation speed.
The allowable operating range and recommended
operating range within the marine characteristics
are shown in the figure below.
When actually operating, be minded to select a
proper rotation speed and engine torque (Pme, to
be judged based on the reading on the rack scale),
a n d keep operating within the recommended
operating range as far as possible, to prevent
being overloaded.
Note that the lower load limit is normally 30% when
u s i n g heavy f u e l oil, a n d i f the load to b e
connected is lower than this limit value, use diesel
fuel oil.
(a : Fig.4.4 "Allowable Operating Range")
As for the output characteristics of the engine to be
actually operated, refer to "Test Run Record
Table' included in the separately provided final
documents.
100
85
-s
-- 80
-
2
m Recommended continuous
a
I
60
20
Idling speed
Fig.4.4 Allowable Operating Range
(1) In case 01 Fixed Pitch Propeller (FPP)
The fixed pitched propeller is generally designed
by including the sea margin, which has taken into
consideration the fouled hull surface, in addition
to the absorbed horsepower due to the marine
characteristics.
In case that fouling of the hull surface h a s
advanced, increasing the resistance, and has
exceeded beyond the sea margin, the absorbed
horsepower increases to such an extent that the
excessive torque occurs even if the rotation
speed is maintained constant. Therefore, always
heed cautions to the rotation speed and the
reading on the rack scale to prevent excessive
torque.
Further, particularly be careful when t h e
absorbed propeller horsepower suddenly
increases, for example when in stormy weather
and so on, since this will often cause t h e
excessive torque to occur, eventually leading lo
surging of the turbocharger.
Propeller design point
Allowable operating range
normal operating range
P -curve : Marine propeller
characteristic curve
M-curve : Curve win sea margin
taken Into consideration
Allowable range of
short-lime operation
Revolutions (%)
 Operation

Allowable Operating Range DK-20 "'"4.5

(2) In case of Changeable Pitch Propeller (CPP)

The changeable pitch propeller is capable ol
changing its propeller pitch (blade angle), while
maintaining the engine rotational speed constant,
and is thereby capable of changing the absorbed
horsepower. Therelore, this propeller has a merit
that the rotational s p e e d a n d load can be
changed according to the conditions of the other
auxiliary machinery driven b y the marine
propulsion engine, and the hull resistance.
However, since the changeable pitch propeller
tends to run under excessive torque to as much
extent as it has a larger freedom of its operation,
be minded to operate the engine properly
preventing the excessive torque, by always
grabbing the load conditions.
 Operation

Low-Load Operation and Operation with Air Cooler Cut-Off

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

4-5.1 Low-Load Operation
Since running the engine with a low-load lower
than a certain limit can lead to unfavorable com-
bustion conditions such as the reduction of intake
air pressure and blowing-back of exhaust air, if the
engine is operated under such conditions for long
hours, it may result in the various malfunctions
such as fouling of the turbocharger and combus-
tion chamber, faulty combustion and so on.
Therefore, be sure to minimize the low-load
operation to a shorter period of time as much as
possible, and in case that the engine must be
inevitably run under a low-load for long hours, be
sure to observe the following conditions:
(I)Low-Load Limit
The low-load limit varies depending on each
specification. Confirm the l o w load limit
described on the specification supplied with the
engine.
(2) Use of Diesel Fuel Oil
In case of the heavy fuel oil specification, be
sure to switch it to diesel fuel oil.
(3) Increase o f lntake Air Temperature
To improve the combustion conditions, increase
the intake air temperature and adjust to as a high-
as well as the intake and exaust air systems. '.
4-5.2 Operation with Air Cooler Cut-Off
In case that the defects such as breakage of the
fine tube in the air cooler or water leakage from a
caulked sections is found, and the repairing cannot
be performed quickly, an emergency messure can
be taken by cutting off the air cooler on the follow-
ing procedure:
(1) Low-Load Limit
a) Stop water supply to the cooler cooling system,
and draw out the water from the air pipe.
b) Insert a shielding plate A into the flange part of
the air cooler cooling water inlet pipe and outlet
pipe.
c) "Fully open" the bypass valve of the air cooler.
d) Operate the cooler cooling water pump, and
confirm that no water is leaking from the flange
packing area.
Snlelduig plate @

..
er level as possible, within the following limit:
lntake air : 75 "C or less
Exhaust air temperature (cylinder outlet) :
450 "C or less
( : 5-3.2(2) "Measurement and Adjustment:
lntake Air Temperature")
(4) Cleaning of Turbocharger
Properly increase the number of times o f
cleaning the turbocharger according to necessity. Cooling water inlet Cooling water
Air Cooler Bypass Valve
Lil
The turbocharger is at a high-temperature (2) Prerequisites for aaoperation
during operation and just after the engine is
stopped. If you touch it with bare hands during a) The fuel oil to be used is diesel fuel oil.
cleaning, you may burn your hands. Wear b) Restrain the output as low as possible, refer-
safety gloves without fail. ring to the following values as the standard:
Pme(average effective pressure):
( 5 ) Intermittent High Load Operation
If the load is switched to the high load (60%
o r more) for about 30 minutes during low-oad
. 0.8MPa (8 kgflcm2)
Exaust air temperature (cylinder outlet):
450 "Cor less
operation, it will have an effect to restrain or
Operation
Non-Turbocharger Operation and Operation with
Reduced Number of Cylinders
4-5.3 Non-turbocharger Operation
In case of the marine propulsion engine, a non-
turbocharger operation implement (turbocharger
blind plate ) is provided, so that operation in emer-
gency can be made even ehwn the turbocharger
may have been damaged. ( The generator is opti-
nal.)
The non-turbocharger operation procsdure is as
the followings:
(1) Preparation f o r Operation
Install the non-turbocharger operation implement
in accordance with the Turbocharger Instruction
Manual
During operation or immediately after stop-
ping the engine, the turbocharger is extremely
hot, and if the turbocharger is touched with
bare hands or skin, it may cause burns.
Therefore, perform the disassembly work
after the turbocharger is completely cooled
down.
If it must be removed before it cools down,
wear safety gloves, and remove it taking care
not to burn your hands.
(2) Prerequisites for Operation
a) The fuel oil to be used is diesel fuel oil
b) Restrain the output as a lower level as possi-
ble, referring to the following values asthe stan-
.
dard:
Pme(average effective pressure):
. 0.44MPa (4.5 kgf/cm2)
Exaust air temperature (cylinder outlet):
400 "C or less
DK-20 5.3,5.4
4-5.4 Operation with Reduced Number
of Cylinders
Adoption of the operation with the reduced num-
ber of cylinders impose such problems as the tor-
sional vibration of the shaft system as well as the
external vibration of the engine, and therefore this
operation should be limited as a secondary meas-
ure to be used only in emergency.
In case of 3DK and 5Dk engines, the operation
with the reduced number of cylnders is prohibited
due to the axternal vibration of engine.
The operation with the reduced number of cylin-
ders may be conducted in various cases such as
the case of only reducing the fuel oil, or the case in
which the operating p a r t s are needed t o b e
removed. Further, since the prohibited items for
the operation vary depending on each case, be
sure to inquire our company for the working proce-
dures, cautionary items on the operation, ansd so
on, obtain the necessary instructions, and strictly
observe them, w h e n t h e operation w i t h the
reduced number of cylinders is conducted
p+y
J N 8-4
<Preparation f o r Operatiom
a) The fuel oil to be used is diesel fuel oil..
b) The output shall be as below:
(No. of cylinders)-(No. of reduced cylinders)
X 70%
Votal number of cylinders)
HoweverJhe outpui may be reduced accord-
ing to the turbochager sursing or exhaust air
temperature in each case.
c) Exhaust temperature : 450'C or less
(each cylinder outlet)
Be attentive of the external vibration o f
engine and the gear sound, and if any abnor-
mality is found, immediately stop the engine. If
the engine is kept operating disregarding such
abnormality, serious accidents may be caused.
 Operation

DK-20 Normal Stoppage

4-6 Stoppage

4-6.1 Normal Stoppage

(1) Preparations for Stoppage
a) In case that heavy luel oil is used, switch the
fuel oil to diesel fuel oil 30 minutes before
stopping the engine.]
b) Immediately before stopping the engine, start
the operation of lubricating oil priming pump.
c ) Confirm that the starting air pressure is at 2.0
MPa (20 kgf/cm2)or more.
(The preparation for the next round of starting)
Operating Lever

(2) Stoppage
a ) Conduct the stoppage operation on the.
following procedure:
[In case of local operation]
Shift the operation lever to "STOP" position.
Then, fuel oil injection will be shut off by means
of the common rod, and the engine will be
stopped.
[In case of remote control]
i ) Press the "STOP" push button on the control
panel.
Then, the fuel oil injection solenoid valve will
be activated to operate the fuel shutdown
device, and the engine will be stopped.
(3) After Stoppage
a) Operate both the lubricating oil priming pump
and cooling fresh water pump for about 2 0
minutes, and cool down the engine a n d
turbocharger.
u
The turbocharger continues to run at high
speed even after the engine i s stopped.
Lubrication of the turbocharger provided with
this engine is made using the system oil, and
therefore if the supply of lubricating oil is
stopped immediately after the engine is
stopped, it may damage the bearing.

.
ii ) Shift the operating lever to "STOP" position.
b) After stoppage operation, be attentive of any
abnormal sound i n the engine a n d
turbocharger, and confirm that there is not any
abnormal sound.
b) Fully open the indicator valve to conduct air
running for 3 to 4 seconds, and exhaust the
combustion gas out of the combustion
chamber.
c) Close the valves on all the systems.

In case that the engine does not stop even

when the stoppage operation is conducled,
forcibly stop the engine on the following
procedure:
1) Forcibly set the rack of the fuel injection
pump to "0".
2) Fully close the valve of the fuel oil inlet
main pipe.
 Operation

Emergency Stop DK-20 ITEM6.2

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

In case that the engine is stopped by activation of
(1) When Emergency Stop Is Required.
the protective device or stopped automatically,
Immediately stop the engine when any of the
take the following measures:
following abnormalities is found:
a) In case that the engine is stopped by remote
@ I
Announcement of "Emergency" or "Alarm" operation or stopped automatically, set the
( * A c t i v a t i o n of the protective device ---
operating lever to "STOP" position after the
Automatic stop)
engine is stopped.
* Overspeed
b) In case that the operation had been made
* Decrease of lubricating oil pressure
using heavy fuel oil, immediately switch the fuel
* Suspension of water supplylincrease of
oil to diesel fuel oil, operate the motor-driven oil
cooling water temperature
feed .pump,. and conduct flushing of the fuel oil
Increase of exhaust air temperature
system. (However, this procedure does not
Other alarming
apply when the fuel oil pipe is broken.)
(depending on each specification)
Further, conduct turning of the engine, and
@Abnormal sound
exhaust the heavy fuel oil remaining in the fuel
@ Heating of the bearings or other moving parts, injection pump or fuel valve.
or generation of smokes, or abrupt increase of

@
mist.
I
Loosening or falling-off o f the governor,
7 / \
In case that the engine is stopped during the

--
common rod rink, each lever around the fuel
operation using heavy fuel oil and the engine
injection pump, link pin, or bolt.
is cooled down without changing the fuel oil,
@ Deterioration of fuel oil or lubricating oil, or heavy fuel oil in the equipment of the fuel oil
damage of the cooling water pipe
system (e.g. pump, filter, etc.) and piping will
@ Abrupt increase or decrease of rotation speed not only solidifyto prohibit restarting, but also
a Abrupt increase of lubricating oil temperature
incur substantial labor to clean and cleanse
@ Water supply disabled due to suspension of
after the accident. '
cooling water supply

c) Disconnect the load off the engine, and return

In case that the engine is overheated due to the operating.lever, each valve, and the state of
suspension of water supply, do not hastily all other equipment to "STOP" position
supply cooling water.
If cooled down abruptly, each part of the
engine may b e deformed, resulting i n In case that an emergency stop is conducted.
malfunction or accidents. be minded not to restart the engine until the
cause is determined, the countermeasures
are taken, and recovery is completed.
@ Mixing of water into lubricating oil
In case that the engine is started without
@Abrupt increase of exhaust air temperature
removing the cause of the abnormality, the
@ I decrease of the turbocharger rotation
Abrupt
malfunction may be aggravated and serious
speed or intake air pressure
accidents may be caused.
Generation of abnormal sound in the propeller
or the stern shaft system
...... In case of the marine propulsion engine
@ Breakage or loosening of the bolts of each
section
 1 c) Open the covers for the crank and cam cases
Be minded not to open the crank case for at
least 10 minutes after the engine is stopped
and is completely cooled down.
If the crank case is opened immediately after
the engine is stopped, flammable mist in the
crank case may catch fire and explode.
Particularly be careful when a large amount
of mist i s generated due t o overheat or
seizing of the engine.
Be minded never to let flames or sparks
approach the crank case even after it is
opened.
as well the cylinder head, and spray rust-
preventive oil to the internal parts.
d ) Insert the moistureproof agent such as
silicagel into the crank case, according to the
ambient air conditions (e.g. weather and
humidity) and other necessity.
e) Place the cover on outside air opening part of
the exhaust air pipe and the mist pipe.
1 ) Cover the engine with a sheet, and carefully
cover the electric equipment with particular
attention to prevent collection of dust on them.

4-6.3 Long-Term Shutdown

In case that the operation of engine is suspended
for a long term (one month or more), take the
preservation measures (mainly, anti-rusting
measure) on the following procedure:

(1) Shutdown wlthin 3 Months

a) Fully open the indicator valve once every
week, and conduct turning of the crankshaft
several times while conducting priming with
lubricating oil.
In this case, stop the crankshaft at a position
different from that before turning.
After turning, securely close the indicator
valve.
b) In case that there is a risk of freezing in
extremely cold season, be minded to remove
cooling water from the engine.

(2) Shutdown beyond 3 Months

Measures for Long-Term Storage
I n case that the operation o f engine is
suspended for 3 months or more, the following
measures for long-term storage is required:
a) Remove cooling water from the engine.
b) Add rust-preventive oil to lubricating oil, open
the indicator valve, and conduct turning of the
crankshaft several times while conducting
priming with the lubricating oil.
After turning, securely close the indicator
valve. Measures for Long-Term Storage
 lnspection and Maintenance
..
1.1 DK-20 Precautions for Inspection and Maintenance

5-1. Precautions forlnspection and Maintenance

When conducting the inspection and maintenance works of engine, be minded t o read this
manual carefully, understand the structure of the related parts and the work contents, carefully
examine the working procedures, and prepare the consumable parts and tools in advance, before
starting these works.
If the works are conducted without previous and sufficient examinations, it will not only lead to
the expense of useless labors, but also result i n failure or damage of the engine due t o mistaken
assembling, and further i n personal accidents.Be sure to replace all the damaged parts, or the
parts that have reached replacing limit, both of which have been so found afler the results of
inspections.
In case that replacing these parts are difficult on site, or the necessary parts are not readied,
inform the Parts Sales Department, Service Department, Daihatsu Diesel Manufacturing Co., Ltd.
o r the nearest branch office or shop, and take proper actions.

5-1.1 Safety Precautions

O! (1) Do not open the crank case side cover foi at least 10 minutes afler the engine is stopped and is
completely cooled down. While the engine is overheated, there is a danger that oil mist may
catch fire and explode ifnew air is nowed into the crank case when it is opened.

@ (2) If the engine is rotated during disassembly or inspection works, it may impose serious dangers
such as caught-up accidents and so on.
Be minded to start these works, afler returning the operating lever to "STOP" position, securely
closing the starting air valve, and confining that the engine is not running.
When conducting the turning of engine, be minded to start it afler confirming that nothing is in
contact with the rotational parts, and no danger is imposed on coworkers by the rotation of
engine, and afler sending the signal to them.
Perform a proper preventive measures to prevent the crankshafl from freely turning.

(3) Be minded to wear the protective gears such as safety glove, helmet, safety shoes, safety gog-
gles, according to the circumstances.
During the operation of engine and immediately afler stopping the engine, the engine parts, partic-
ularly exhaust manifold, turbocharger, parts round the cylinder are extremely hot. Therefore, be
sure to wear safety gloves, and proceed the works taking care not to incur burns.
The engine room floors and the surrounding areas are slippery due to oils stuck on them.
Therefore, be minded to start the works afler sufkiently wiping off the oils stuck on floors or shoe
soles. Particularly when working on a high-rise places such as on the foot-step board, pay
enough attentions to the periphery of your feet, so that falling-off accidents should not happen. .

(4) When disassembling the piping systems, "Close" all the valves of the external connection parts,
gradually w a n up the air vent plug, and start the disassembly after removing residual pressure.
Immediately aner stopping engine, when disassembling the filters and connection parts of piping
systems, you may burn on your skin on a injected high temperature oil or water of residual pres-
sure. If high temperature parts are splashed with the fuel oil or the lubricating oil, a fire may
occur. Take utmost care when disassembling them.
-
lnspection and Maintenance

Precautions for Inspection and Maintenance DK-20 1.1, 1.2

O! (5) When disassembling the spring-loaded devices such as the regulation valves, proceed the works
paying careful attentions, since there is a risk that the springs may fly out and injury accidents
may occur.

@ (6) Be minded to use wire rope and chain block when suspending the heavy-weight parts or equip-
ment, and do not try to forcibly raise these parts or equipment by physical force. Further, be
m~ndednot to approach the aieas lmmed~atelyunder the suspended parts or equ~pment
/i\ (7)When nandlmg the electr~cpans, be sure to cut off the power source.

/i\ (8) When handling the liquids, be minded to strictly observe the following items:
Flammable liquids such as fuel oil and lubricating oil, the sources of fire, e.g.: The source of fires
such as flames or sparks are strictly prohibited.
Poisonous substances such as rust-preventive agent for fresh water, anti-freeze solution for fresh
water, mercury (thermometer): Drinking is prohibited, and if any of these has stuck on hands or
skin, immediately wash it off.
rn Poisonous substance or substance which generate flammable gas, such as battery liquids:
Drinking is prohibited, and if any of these has stuck on hands or skin, immediately wash it off, and

- the source of fires such as flames or sparks are strictly prohibited.

For the sake of preventing environmental contamination, be minded to entrust the disposal and
treatment of the waste oils and liquids to the authorized special waste disposing company.

5-1.2 Cautionary Items When Finishing lnspection and Maintenance

(1) Restore the lagging or heat-preventive covers, combustible oil splash preventive means (FN tape)
and protective covers, that have been removed for inspection and maintenance, to each original
position

/i\ (2) Afier the completion of assembling, confirm that there is no abnormality in each part, by conduct-
ing the turning of engines and the priming with each corresponding oil.
Afler checking the parts during turning, close the reducing valve without fail.

@ (3) Afler the completion of working, return the turning equipment and turning bar, that have been
used, to "OFF" position.

0 (4) Record the work contents of the inspection and maintenan& that have been performed. and the
replaced parts in the daily report respectively.
 Inspection and Maintenance
Measurement and Adjustment: Maximum Combustion
Pressure and Exhaust Air Temperhture

5-3 Measurement and Adjustment

Since the indicator valve is extremely hot
5-3.1 Maximum Combustion Pressure during the operation of engine, there is a
and Exhaust Temperature danger of burns if it i s touched by bare
hands.
Maximum combustion pressure and exhaust
Therefore, be sure to wear safety gloves
temperature serve as the important indicators for
when handling the valve.
knowing the engine combustion conditions and the
changes according to the elapse of time.
Normally, the decrease of the engine performance
can be indicated by the following items:
Decrease of the maximum combustion pressure
Increase of the exhaust temperature
Conduct the measurement with the intewal of once
a week or so, and record the results, so that the
tendency of the change can be identified and the
data can be used as the judgment materials when
determining the interval of the adjustment.

(1) Maximum Combustion Pressure

(hereinafter referred t o as Pmax)
a) Pmax
Pmax is determined b y load, and varies I

depending on the factors such as the fuel oil indictor valve

viscosity, intake air pressure, and intake air
temperature. Ordinarily, however, this Safely valve
adjustment is not necessary.
Pmax varies according to the initial fuel A
injection pumping angle, however, it is readily L l
Be sure to "Fully open" or "Fully close" both
adjusted and set at an optimum value at the
time of shipment from our factory. the indicator valve and the exhaust valves of
The fuel cam is fixed to the camshaft by shrink the indicator, whenever these valves are
used.
fitting, and therefore, ordinarily, it cannot be
If these valves are used on the "Half-open"
adjusted.
state, high-temperature gas will flow into the
threaded'parls of the valve, and the screws
Since the items mentioned in this section will may be seized.
be the items, to which the engine setting
value specified in Nox technical code shall
be applied, do not make any change that
may deviate from the setting value.
(0 : 0-3"Engine Conforming to Nox
Technical Code")
 2) 2?
e

Inspection and Maintenance

ITEM Measurement and Adjustment: Maximum Combustion
3.1 DK-20 Pressure and Exhaust Temperature

b) Measuring Prnax (3) Adjustment o f Reading o n Fuel Injection

Perform the measurement of Pmax after the
warming-up operation of engine has been
completed and the load has become stable.
During measurement, the measured values
may change due to such factors a s the
occurrence of the load fluctuation. In such a
case, perform the measurement again to
obtain a stable data.
(a : "Test Run Record" included in the final
documents)
<Measuring Procedure>
i ) Open the indicator valve @ with a special
wrench for indicator valve before installing the
indicator @, and close the indicator valve alter .
lightly releasing it 1 or 2 times.
ii ) Install the indicator to the indicator catch 0,
and securely lock it by turning the lock nut @.
ii ) Close the exhaust valve @ of the indicator.
iv) Open the indicator valve.
v ) Check the reading of .the pressure on the
indicator.
vi ) Close the indicator.
vii) Open the exhaust valve of the indicator, and
remove the indicator after indicating reading
has become "0".
Pump Rack
In case that the exhaust temperature differs from
those of other cylinders in excess of the range
specified in the above (2),for example, when the
fuel injection plunger or the fuel injection valve
nozzle is replaced, adjust the fuel injection
amount by increasing or decreasing the reading
on the rack scale.
<Rack Adjusting Procedure>
The reading on the rack scale can be increased
or decreased by adjusting screw @ of the fuel
injection pump rack lever.
i ) Loosen the lock nut @.
ii ) Turn the adjusting screw A and change the
reading on the rack scale.
Clockwise turning "Increase" (Increase of
exhaust air temperature)
a Counterclockwise turning "Decrease"
(Decrease of exhaust air temperature)
i i ) Confirm that the exhaust air temperature is
within the specified value.
N) Securely tighten the lock nul.
* Difference between cylinders: 1.5 mm or

*Maximum value (when fully loaded):

15.7 MPa (160 kgWcm2)
p a c k level
*Difference between cylinders:
0.6 MPa (6 kgf/cm2)or less

(2) Exhaust Temperature

The exhaust temperature at each cylinder outlet
slightly varies from one cylinder to another
depending on the factors such as the effect of
other cylinders as well as the distance to the
turbocharger inlet.
The exhaust temperature can be adjusted by
increasing or increasing the reading on the fuel
injection pump rack, however, the adjustment is
ordinarily unnecessary as long as the difference Adjusting Rack
between cylinders is within the following value.

*Difference between cylinders: 40°C or less

Inspection and Maintenance
Measurement and Adjustment:
Pressure and Tem~eratureof Each (Part
5-3.2 Pressure and Temperature of
Each Part
The pressure and temperature of lubricating oil,
fuel oil, and cooling water, etc. are controlled by
the relief valve, so that they should be proper val-
ues being within each specified value during the
operation of engine, however, when actually
operating the engine, the pressure and tempera-
ture of these fluids may not be within the speci-
fied and proper values.
In such a case, readjust the setting values of
the valves, and perform the operation within the
specified proper range.
(1) lntake Air Pressure
Since the intake air pressure changes in accor-
dance with load, each pressure when the engine
was new (or, after adjustment) becomes a refer-
ence value.
The more the turbocharger is fouled, the more
the intake air will decrease, resulting in the deteri-
oration of the engine performance (e.g. increase
of the exhaust air temperature and increase of
the fuel consumption rate), and therefore regular-
ly conduct the blower cleaning and prevent the
progress of fouling.
( : 5-4.4 "Cleaning Turbocharger Blowe?)
T h e turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.
I\
It is impossible to completely remove the
fouls even when cleansed by blower cleaning,
and to prevent the deterioration of engine per-
formance by the elapse of time, however, if the
cleaning is neglected, fouling will accelerate,
resulting in worsening of the engine perform-
ance, and as the result it will be required to dis-
assemble and clean the turbocharger much
earlier than when the cleaning is periodically
conducted.
(2) lntake Air Temperature
* Proper temperature: 45-55C (at full load)
lntake air, that is either higher or lower than'the
specified range, will affect the engine, and there-
fore be minded to adjust and keep the tempera-
DK-20 3.2
ture to be within the specified proper range, as far
as possible.
When the intake air temperature is too low, it
causes abnormal or excessive wear of the cylin-
der liner, intake air valve, etc., since the water
drops is formed by the dew condensation.
Further, ifthe intake air temperature is too high, it
damages the parts around the combustion cham-
ber such as the exhaust valve, since the exhaust
air temperature will increase. (Exhaust air tem-
perature varies in proportion to the intake air tem-
perature, and also varies in the rate of approxi-
mately 2 times the change of the suction air tem-
perature of the turbocharger.)
If the intake air temperature gets out of the
proper range owing to a low room temperature, or
when automatic adjustment of intake air tempera-
ture cannot be made for some reasons, operate
the following procedure.
<Intake Air Adjusting Procedure>
The intake air adjustment can be made by chang-
ing the cooling water flow rate in the air cooler.
i ) Operate the handle of the bypass valve @ ,
and change the opening angle of the valve.
Open the bypass valve. (Handle facing side-
ways) Increase of tnmperature
r Openclose the bypass valve (Handle facing
downward) Decrease of tnmperature
ii ) Be attentive to changes of the intake air t e r n
perature, and open the bypass valve so as to
be within the proper range, and adjust the
angle.
Bypass valve@
en
I l i . !. I-
Cuulirig water ilileI
.....,.
C~ulirlgwatel uu[lt!t
Air Cooler Bypass Valve
 1 Ins~ectionand Maintenance 1

In case that the intake air does not fall within the
proper range even when the bypass valve is fully
opened and the entire amount of cooling water is
flowed into the air cooler, it i s required to
disassemble and adjust the air cooler since the
fouling of the air cooler can be considered.
( a 12-3 "Air Cooler" in the Instruction
Manual, "Maintenance Version")
Counterclockwise turning (loosening)
Decrease of pressure
ii ) Be attentive to changes of the pressure, and
confirm that the pressure has entered within
the blue mark range.
iv) Tighten the lock nut @, and aHach the cap @.
Air vent valve

(3) Lubricating Oil Pressure

*Proper range (Blue zone range of

manometer): 0.4-0.5 MPa (4 - 5 kgf/cm2)

Lubricating oil pressure changes in accordance

with the changes in the viscosity and
temperature of lubricating oil.
When the engine is started in extremely cold
weather, and the temperature of the lubricating

-
oil is still low and the viscosity is high, the
pressure reading may go up beyond the blue
mark range, however, it does not impose any
problem if the reading falls back within the blue
mark range when the engine is warmed up.
In case that the pressure reading is beyond or
under the blue mark range, adjust the pressure
on the following procedure:
L l
1) Do not loosen the adjusting screw beyond
Lubricating oil pressure decreases when the the loosening limit ( e =3Omm). The cap
lilter i s fouled. Be sure to perform the may not be installed back, if the screw is
adjustment of pressure after the filter is loosened excessively.
cleaned well. 2) In case that the lubricating pressure dose
(a : 5-4.3 "Cleaning Filters") not change even when the adjustmen!
screw is turned, there is the possibilities of
sticking of the relief valve, suction of air,
<Lubricating Oil Pressure Adjusting pump failure, and so on, and therefore
Procedure> investigate the causes of the trouble.
When adjusting the lubricating oil pressure, use
the adjusting screw on the lubricating oil relief
valve. Since the rate of the oil supply to the periphery of
i ) Remove the screw cap @ of the relief valve, the rocker arm is set at the pressure of 0.1 MPa
and loosen the lock nut @. (1 kgflcm') or more by the relief valve located at
ii ) Turn the adjusting screw 0, and adjust the the cylinder head inlet, the adjustment is not
pressure. required.
Clockwise turning (tightening) Increase
of oressure
 Inspection and Maintenance
Measurement and Adjustment:
Pressure and Temperature of EacH Part

(4) Lubricating Oil Temperature screw, and set t h e lock nut when the
temperature has entered the following range:
*Proper range: 50-60°C (cooler outlet) - --

*Use range: 30-60°C

Lubricating oil temperature is controlled to Since the oil temperature changes according
remain within the proper range of temperature by to the load, be minded to set the o i l
the automatic temperature control valve installed temperature at a rather lower level, so that it
at the lubricating oil cooler outlet. will not exceed the limit when heavily loaded.

a) Lubricating 011Temperature Control Valve

The temperature control valve is an automatic
bypass valve, that changes the flow rate of
lubricating oil passing through the cooler.
according to its temperature, and when the
engine is started while i t is still in cold state,
-
Temperature conlrol valve
Lock nut @
Adjusting screw @

this valve rapidly raises the lubricating oil by

letting the oil bypass through the cooler, and
when the engine is operated normally, this
valve maintains the lubricating oil to be within
the suitable range of the specified value.
In case that the lubricating oil does not fall
within the proper range, for example, because
Lubricating oil cooler
the cooling water (secondary water)
temperature i s different from the design
temperature, the temperature of lubricating oil (5) Cooling Water Pressure
can be adjusted by the adjusting screw of the
temperature control valve. However, in case * Proper range: 0.25-.0.35MPa
that the actual temperature is exceeding the
correctable range and the adjustment is
impossible,contact us for consultation on the Jacket cooling water pressure substantially
problem. changes depending on the external conditions
such as the cooling water expansion tank head,
b) Manual Adlustmen-Emergency Measures pipe resistance, and so on.
In case that the temperature control valve has When cooling water pressure is too low, it will
become faulty and the temperature control has cause corrosion of the engine frame or cylinder
become impossible, the engine can liner, and therefore adjust the cooling water
continuously be operated by performing the pressure at the engine outlet using the valve or
emergency measures on the following orifice, so that the pressure should be proper
procedure. during the operation of engine.

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

Inspection and Maintenance

ITEM

I
3.2 DK-20 I Measurement and Adjustment:
Pressure and Temperature of Each Part

(6) Cooling Water Temperature iii) Closely watch the changes of the pressure,
and confirm that the pressure reading is within
L
(r range: 70-75°C (engine outlet) I the proper range.
N) Tighten the lock nut @, and attach the screw
a) Warmlng-Up Operation cap @.
When jacket cooling water temperature is too
low, it will cause faulty combustion or
the corrosion or wear of the paris around the
combustion chamber, and therefore
be minded to start the operation of engine with
load alter raising the cooling water temperature
by warming-up operation.
(a: 4-4.2 "Warming-Up Operation")

b) Temperature Control
Cooling water temperature is controlled t o -
remain within the proper range by the
temperature control valve installed between
the jacket cooling water inlet and outlet pipe
(fresh water cooler inlet and outlet pipe).
Decrease
This temperature valve is an automatic bypass
valve that is functionally identical with the
lubricating oil temperature control valve.
(a: 5-3.2 (4) "Lubricating Oil Temperature")

(7) Fuel Oil Pressure

Fuel Oil Pressure Adjusting Procedure
a) Engine using Heavy Fuel Oil
When using heavy fuel oil, the pressure of
When the engine with heavy fuel oil specification
heavy fuel oil must be adjusted to be within the
is operated by diesel fuel oil, the fuel oil pressure
following range, so that generation of vapor
does not decrease since the fuel oil cannot be
due to heating-up o f the fuel oil can be
pressurized as in the heavy fuel oil supply line.
prevented:
however, the adjustment of the fuel oil pressure
1 * Proper range: 0.5-0.6 MPa (5-6 kgflcm2] I is not required if the pressure is within the
following range.
<Fuel Oil Pressure Adjusting Procedure>
Adjustment of fuel oil pressure can be made by
* 0.2 MPa (2 kgflcm2)or more
the pressure adjusting screw of the fuel oil relief
valve. b) Engine using Diesel Fuel Oil
i ) Remove the screw cap @ of the relief valve.
and looser: the lock nut 0.
ii ) Turn the adjusting screw 0, and adjust the
I *Proper range: 0.2-0.3 MPa (2-3 kgflcm2) I
pressure. In case of diesel fuel oil specification, the
Clockwise turning (tightening) Increase pressure adjustment procedure is the same as
of pressure in case of heavy fuel oil specification, since the
Counterclockwise turning (loosening) same type of the fuel relief valve is used in
Decrease of pressure both cases.
 .\.? - )
.-.i L

Inspection and Maintenance

Measurement and Adjustment: ITEM

Pressure and Temperature ot Each Part DK-20 3.2

(8) Fuel Oil Temperature......When Using
Heavy Fuel Oil
Heavy fuel oil must be heated so as to make its
viscosity suitable for injection, before the oil is
supplied to the engine.
* Proper viscosity (engine inlet) dynamic
viscosity: 1 4 k 1 cSt
1 I
Since the temperature appropriate for proper
viscosity varies depending on the properties
(viscosity) of heavy fuel oil, be minded to keep
the proper viscosity referring to the following
figure as a standard:
(a: Fig.6-1.1 "Fuel Oil Temperature Curve")
In case that the viscontroller (automatic viscosity
regulator) is installed to the engine, control the
fuel oil viscosity in accordance with instruction
manual, and be minded to carefully keep the
manual.
( rn : 4-4.4 "Operation Using Heavy Fuel Oil")
( a: 6-1 "Fuel Oil Characteristics and
Control")
Further, in case that nozzle cooling is conducted
using fresh water, it is not required to regulate
both the pressure and temperature, since jacket
cooling water is used in such a case.
b) Nozzle Cooling Oil Temperature
..... When Using Heavy Fuel Oil
*Proper range: 50-60°C 1
Nozzle cooling oil temperature is regulated by
the temperature control valve.
This temperature control valve is the same type
as the one used for regulating lubricating oil. As
for the regulating procedure, refer to the <
Adjusting Procedure > of (4) Lubricating Oil
Temperature.
In case that nozzle cooling oil temperature is too
low, it will cause sulfated corrosion on the tip part
of the fuel injection valve nozzle, and in case that
the temperature i s too high, it will c a u s e
generation of carbon flower on the nozzle.

(9) Nozzle Cooling Oil Pressure and Temperature

.....When Using Heavy Fuel Oil
In case that nozzle cooling system is
incorporated as a n separate system as
independently installed, and diesel fuel oil is
used as the refrigerant carrier in stead of cooling
water, it is required to control the pressure and
temperature to be within a proper range of the
value.

a) Nozzle cooling oil pressure

.....
When Using Heavy Fuel Oil

*Proper range: 0.1 -0.3 MPa (1 -3 kgf/cml)

In either case of DO or HO, be minded to feed

nozzle cooling oil. Since nozzle cooling oil
passes through the high-temperature parts, it
may block the passage if the flow has become
stagnant or stopped, and therefore be minded to
secure the specilied pressure for nozzle cooling
oil..
 lnspection and Maintenance
ITEM Inspecting Parts around Intake and Exhaust Valves, and
4.1 DK-20 Adjusting Valve End Clearance

5-4 lnspection and Maintenance
5-4.1 Inspecting Parts around lntake and
Exhaust Valves, and Adjusting Valve
End Clearance
(1) Replacing Consumables, Implements, and
Measuring lnstruments
a) Replacing Consumables (a
@ Head cover rubber seal No.DI0
: 'Parts List")
valves, and a single valve holder tee is provided
to simultaneously push down both pairs of intake
and exhaust valves, and therefore unless the
valve end clearance of each pair of both intake
and exhaust valves is equal, the valve pushing
force will be unbalanced, resulting in abnormal
wear or damage of the valve holder tee and the
guide parts.

Valve retainer tee

b) Implements and Measuring Instruments nlat/ked
; valve rocker arm
exhaust
@ General tools
(m : "Implements List" in the final
documents)

(2) Inspecting Parts around lntake and Exhaust

Valves
Both intake and exhaust valves are the parts that
are exposed to the most severe conditions
among all other parts of the engine. Therefore,
be minded to periodically inspect these valves,
and confirm that both valves operate normally.
a) Confirm that there is no abnormal operating
\
sounds in both the intake and exhaust valves lntake and exhaust valve cotter
during the operation of engine.
Valve End Clearance Adjusting Procedure
b) Check the following points on these valves
removing the cylinder head cover when the <Valve End Clearance Adjusting Procedure>
engine is stopped. i ) Place the cylinder in the explosion stroke,
@ Lubricating conditions of the rocker arm and and close the intake and exhaust valves.
push rods ii ) Loosen the lock nuts of the adjusting screws
@ Lubricating and sludge collecting conditions @ and @, and turn back the adjusting screw
of the intake and exhaust valve cotters, and @ and @.
valve rotators i i ) Closely fit the valve end " A , place the dial
@ I collecting conditions around the
Sludge gauge against the valve holder tee, and tighten
valve spring the adjusting screw @ until the scale pointer
@ Rotating conditions of the valve rotators swings, so that it can be confirmed that the
@Valve end clearance valve ends "A" and "B" are both closely fit a t
the same time.
(3) Adjusting Valve End Clearance
iv)
Since valve end clearance decreases due to the
wear of the valve seat part, and therefore be
minded to periodically inspect and adjust it.
@
v ) Insert a thickness gauge of the specified
When the valve end clearance is too small, it will
thickness into the clearance " C on the top part
cause improper setting of the valve on its seat
of the valve holder tee, and adjust t h e
during the operation of engine due to thermal
clearance using the adjusting screw @.
expansion of the valve itself and push rod,
resulting in burning of the seat.
Further, the valve system of this engine is 4-
* Proper clearance: 0.31 mm
(for both intake and exhaust valves)
valve type, having 2 intake valves and 2 exhaust
 Inspection and Maintenance
ITEM
Inspecting and Maintenance of Fuel Injection Valve DK-20 4.2

5-4.2 lnspection and Maintenance of Fuel Gasket

Injection Valve Inlet connector @
Since the conditions of the fuel injection valve
substantially affect the performance of engine Bolt 0
,
operation, be minded to periodically inspect it and
conduct the maintenance.
However, in case that remarkable changes have
been found in the maximum combustion pressure,
5
exhaust temperature, exhaust color, and so on, be
minded to conduct immediate inspection and
maintenance, regardless of the standard
inspection and maintenance period.
Bolt @
Since the items mentioned in this section will
be the parts to which NOx Technical Code High-pressure fuel
coupling @
shall be applied, when replacing any of these
parts, be sure to use the parts provided with
the identification marks. Vlew "P"
(a : 0-3 "Engine Conforming to NOx
Technical Code")

(1) Replacing Consurnables, Implements, and

Measuring lnstruments
a) Replacing Consumables
a Circular gasket No.507
(a
: "Parts List")

@Gasket No.218
@ O-ring No.12
@O-ring No.503
O O-ring N0.504
8 O-ring N0.505
b) Implements and Measuring lnstruments
@General tools and measuring instruments
( : Final Documents)
@ Nozzle holder extracting implement
@ Fuel injection testing device
@ Nozzle cleaning implement Nozzle Holder Extracting Procedure

(2) Extracting Fuel lnjection Valve 1/'

Extraction of the fuel injection valve can be 1) Be careful so that the circular gasket @
conducted on the following procedure: may not be left behind in the cylinder head.
2) After removing the high-pressure fuel
<Extracting Procedure>
coupling and fuel injection valve, b e
i ) Close the valve of the nozzle cooling water
minded to place the cover both on the
(or, oil) pipe system, and drain the water (or,
coupling part of the fuel injection pump and
oil) completely. (In case of heavy fuel oil
on the insertion part of the cylinder head.
specifications)
 -7,., *
2

Inspection and Maintenance

DK-20 Inspecting and Maintenance of Fuel Injection Valve

ii ) Remove both the cylinder head cover and
heat box cover.
iii ) Loosen the bolt @ and 0, remove the high-
pressure fuel coupling (block) @.
iv) Remove the inlet connector @.
v ) Remove the tightening nut @ using a box
wrench.
v ) Extract the fuel injection valve @ using a fuel
injection extracting implement.
v i ) Remove the circular gasket @.

(3) Injection Test

Conduct a fuel injection test of the fuel injection
valve, to check if the opening pressure and the
spraying conditions of the fuel injection valve is
in proper and normal state.
Conduct the fuel injection test using the fuel Injection Test Procedure
injection test device installed to the engine.

a) Inspecting Valve Opening Pressure

i ) Install the fuel injection valve on the injection
Cap nut @ Screw driver
test device, after removing the carbon stuck on
the tip of the valve, and cleaning the tip.
ii ) Connect the test pump and fuel injection
valve using a high-pressure hose for testing.
iii ) Quickly operate the test pump lever several
times, and drain the air until the valve stark
injection of the fuel as the pressure indicating
scale swings.
iv) Slowly turn the test pump lever (once every
second, or so), check the pressure reading
(the pressure, that has once increased
gradually, suddenly starting to decrease due to
opening of the valve).

*Normal pressure: 27.4-29.4 MPa

(280-300 kg/cm2)
1 Pressure Adjusting Procedure

b) Adjusting Valve Opening Pressure

When reassembling the fuel injection valve
after conducting the maintenance work by
extracting the valve out of the engine, and
when the nozzle is replaced with a new one.
adjust the valve pressure on the following
procedure:
*Setting pressure: 29.4 MPa (300 kgflcm')
Be minded to set the pressure of the fuel
injection valve at a rather higher level,
taking into consideration the initial working
adjustment, in case that a new injection
valve is introduced.
...... 30.4 MPa (310 kgilcm2)
Inspection and Maintenance

Inspecting and Maintenance of Fuel Injection Valve DK.20 4.2

Since the items mentioned in this section will

be the parts to which engine setting value
specified i n NOx Technical Code shall be
confirmed, do not make any change that may
deviate from the setting values.
( : 0-3 "Engine Conforming to NOx
Technical Code")
Normal Injection
<Valve Opening Pressure Adjustment
Procedure>
i ) Remove the cap nut @.
ii ) Loosen the lock nut for the adjusting
screwa,
iil ) Adjust the pressure to the specified pressure,
by turning the adjusting screw using a (A) cloggednozzle (0) improper (C) rod^^ nozzle
needle vabe action
screwdriver, while conducting the injection of
the fuel, as in the same procedure as in the Abnormal lnjection
case of the fuel injection test.
.Screwing-in of adjusting screw High
Turning-back of adjusting screw Low
iv) Tighten the lock nut 0.

c) lnspecting Fuel lnjection

Inspect the fuel injecting conditions on the
following procedure:
i ) Quickly operate the test pump lever several
times (2 to 3 times every minute, or so), and
inspect the fuel injecting conditions.
& Lock nut @

(Let the fuel injected against a blank paper,

so that the conditions can b e better
inspected.)
Check if cutling-otf injection is good or not.
.....,Injection sound
Check if the injection is made in clear spray,
not being in spray of bar pattern injection. ush rod
nor dripping down. pacer @
Spray lubricating agent nock pin @
ii ) Check if there is no dripping-down of fuel (Molykote 1000)
from the tip of the nozzle after the injection -~etaining nut @
test. -ozzle o
Fuel Injection Valve (A)

hands near the fuel spray during testing.

If the high-pressure fuel has hit your face or
hands, it will cause injuries.
 -) - > - \
>, ,1
Inspection and Maintenance
ITEM
4 2 DK-20 Inspecting and Maintenance of Fuel Injection Valve

(4) Disassembllng and lnspecting Nozzle

In case that a remarkable decrease of the valve
Nozzle 0
opening pressure, faulty injection of fuel oil, or
dripping-down of fuel oil after injection is found Retaining nut @
as the results of the fuel injection test, conduct
disassembling, cleaning, and inspection on the
following procedure:

a) Disassembling the Nozzle

i ) Remove the cap nut @.

-
ii ) Loosen the adjusting nuta.
i i ) Fix the holder housing @ in a vise, and
loosen the retaining nut @.
iv) Extract the needle valve out of the Nozzle @.
v ) Extract the nozzle out of the retaining nut, by
striking with a hammer, placing a pipe-type
patch on the nozzle, so as not to damage the
Vice

Cc;n
-,:ilg needle

nozzle hole.

ozzle cleaning implement

If the retaining nut i s turned while the
adjusting nut is still tightened, it will damage
the nozzle or nozzle holder parts.
In case that heavy fuel oil is used, the
retaining nut and nozzle may be stuck
together with carbon accumulated on them.
Ifthe nut is loosened in this state, the nozzle
will turn together with the nut, and may Nozzle Cleaning Procedure
damage the nozzle, or the knock pin of
spacer, and therefore first lubricate the nut
with gas oil, and then carefully loosen the nut u
by striking the nozzle with a hammer, while Since the nozzle and needle valve is a pair
placing a patch on the nozzle. functioning together, be minded not to
replace either of them separately.
Do not try t o reuse a faulty nozzle by
b) Inspecting
- Nozzle wrapping, but be sure to replace it with a new
i ) Clean the nozzle nut and needle valve with
one.
gas oil.
ii ) Clean the nozzle hole with a nozzle cleaning
implement.
iii ) Push in and push out with hand, and check
the movement.
Check if the movement is smooth or not.
Check if the movement is too loose.
 Inspection and Maintenance
-
ITEM
Inspecting and Maintenance of Fuel Injection Valve DK-20 4.2 -

(5) Assembling Fuel Injection Valve N) Attach the holder tightening nut @, a n d
Assemble the fuel injection valve. in the reverse evenly tighten with the specified torque.
order of the disassembling procedure.
i ) Clean each of the disassembled parts with *Specified torque: 59 N.m (6 kgf.m)
clean gas oil, and insert each of them back
into the holder housing @. v ) Screw in the inlet connector with hand, and
ii ) Put the spacer @ and the knock pin 0 of tighten it with the specified torque.
nozzle together, and install them into the
holder housing.
iii ) Apply the lubricating agent (Molykote 1000
U-paste) on the holder housing thread, the
seat face of the retaining nut @, and the outer
*Specified torque: 88-98 N.m
{9-10 kgf.m)

vi) Attach the high-pressure fuel coupling and 0-

periphery of the nozzle, and screw the
retaining nut into the holder housing by hand.
iv) Loosen the adjusting nut a.
v ) Tighten the retaining nut with the specified
torque.
*Specified torque: 196-226 N.rn
{ZO-23 kgf.m)
I
rings o n the cylinder head side and f u e l
injection pipe side, tighten the high-pressure
fuel coupling tightening bolt @ and @ with the
specified torque.
*Specified torque: 34-45 N.m
(3.5-4.5 kg1.m)

Be careful not to tighten the retaining nut with

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

vi) Set the fuel injection valve on the injection

test device, and adjust the valve opening
pressure.
(a: 5-4.2 (3) "Fuel lnjection Test)

(6) Mounting Fuel Iniection Valve

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

Inspection and Maintenance

DK-20 Cleaning Filters

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

(1) Notch-Wire Duplex Type Filter

The notch-wire duplex type filter is normally used
as both-side-parallel application.
Since both the fuel oil pressure and lubricating oil Notch-Wire Type Filter
pressure decreases if the filter has been fouled,
b e minded to periodically conduct blow-off
cleaning. In case that the oil pressure does not Fillers used on both sides 'P"
increase even after the blow-off cleaning has
been conducted, overhaul the filter and then
clean it.
NA
a) Replacing Consurnables
For lubricating oil 32XP ( 0 : "Parls List")
Gasket No.157
@Gasket No.186
@Element gasket No.281
For fuel oil 32PED ( m: "Pars List")
O O-ring No.106
@Gasket No.152
@Gasket No.190
@Gasket No.266

b) Blow-Off Cleaning
When bdth lillers ~ l o w ~ oon
tl One sid; shul OH
In case of blow-olf cleaning, deposits can be are used right filler
removed by reversely llowing the fluid through
E l E2 ..-..Riaht and lell elements
the element on one side, and this type of
cleaning has no cleaning effect when the
element is substantially clogged, and therefore
C1 ~ . - ~ . ~ e i e c tcock
o r inlet hole
C2 .....Selector cock outlet hole
I
C3 .....Selector cock blow-ofl and dra~nlnghole
lnterlockr

be minded to conduct the blow-off cleaning in

 - ,
J -C

Inspection and Maintenance

Cleaning Filters

<Blow-Off Cleaning Procedure>

i ) Open the drain cock @ at the bottom part of
filter. At this time, be careful so that waste oil
may not scatter or overflow out of the drain
cock.
ii ) Turn the selector cock handle @ (usually, set
to "Used on both sides" (P) position) to the
"Blow-off" position (about 60"C), and quickly
conduct the operation to return the handle to
the previous position (within 0.5- 1 sec.).
iii ) Repeat this operation 2-3 times.
iv) Conduct the above same procedure on the
other side.
v ) Close the drain cock.

Ll
Conduct the blow-off cleaning quickly.
Further, do not place the lever on the middle
position, but quickly move to the specified
position (knock position).
If too much time has been taken in blow-off
/
Handle @ Knock @
4' Cock raising bolt
cleaning and switching the lever positions,
the pressure will decrease, and may activate Filter Overhaul Procedure
the alarm or emergency stop.

c ) Overhaul and Cleaning of Filters

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

When using the heavy fuel oil, the fuel oil is

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

DK-20 Cleaning Filters

<Overhaul and Cleaning>
i ) Turn the selector handle @ to "Close"
position (909on the side to be overhauled.
ii ) Open the drain cock @, loosen the air vent
valve @ at the top of the Case 0,
discharge oil.
iii) Loosen the tightening nut @, remove the
case0, and then take out the element @.
and
iv) Clean the element with washing oil or gas oil,
and conduct blow-off cleaning from inside.
v ) Clean each of the parts overhauled, and
clean the case gasket grooves of the filter
housing @.
<Assembly and Restoration>
i ) Attach the gasket @ to the element 0, and'
attach the gasket @ to the filter housing @.
ii ) Put the spring @ on the element, and place
the case 0 on the top of the spring, and screw
the nut @ into the case while holding the case
with hand.
iii ) Close the drain cock @.
iv) Shift the handle @ to "Blow-off" position.
v ) When the filter is overhauled and cleaned
during the engine being stopped, conduct
priming and fill the case with oil.
-1) Check conditions of the sludge collected
on the element.
Particularly in case of the lubricating oil filter,
if metallic parlicles are found, investigate
the causes and take the countermeasures.
2) When the element is damaged, or when
the element i s excessively fouled and
clogging cannot b e removed e v e n by
cleaning, replace the element with a new
one.
3) Since the gaskets and O-rings are easily
be damaged, be very careful in handling
these parts. Particularly, the heavy fuel oil
filter tends to be deteriorated i n high-
temperature conditions, and therefore be
minded to replace the filter every time the
overhaul is conducted.
(2) Y-Type Filter
a) Overhaul and Cleaning
i ) Remove the plug.
ii ) Remove the strainer.
ir ) Clean the strainer with washing oil or gas oil.

-
vi) Close the air vent valve @, after the oil has
b e e n let overflow and air bubbles have
completely vanished from the oil flowing out of
air vent pipe.
vii) Return the handle to "Both sides used" (P)
position.
hi) Check if there is any oil leakage from the
gasket sections.
d) Mounting
When mounting the Y-type filter, be minded to
mount it with the plug side facing downward, so
that sludge may be accumulated in t h e
strainer.
- Oullet

Confirm that the knock @ of the handle @ is

engaged in its position.
If the knock is not properly engaged in the
position, the handle will be overturned by Plug
vibration during the operation of engine, and
may incur oil spill-out accidenls. Disassembling Y-type Filter
Inspection and Maintenance
Cleaning Turb~charger~BIower
5-4.4 Cleaning Turbocharger Blower
If the fouled degree of the turbocharger blower
has progressed, the efficiency of the turbocharger
will decrease and the operating performance of
engine will be worsened. Particularly when heavy
fuel oil is used, the turbocharger blower tends to
be fouled in faster degree, and therefore be mind-
ed to conduct blow-off cleaning and restrain the
progress of fouling.
(1) Interval o f Cleaning
Clean the blower when intake air pressure has
decreased 10% at the same load, or at least
every 150 to 200 hours of operation.
(2) Load during Cleaning
Make sure that the engine shall be operated
under the load of 75% or higher, and continue the
loaded operation for 1 hour or more afler cleaning.
(3) Cleaning Liquid
Be sure to use the specified cleaning liquid. In
case that the specified cleaning liquid is not avail-
able, use fresh water. (Note that cleaning effect
is inferior with fresh water.)
Be minded never to use gas oil or any other
flammable liquid for cleaning, since these liq-
uids will be the cause of fire.
Turbocharger Blower Cleaning Procedure
(4) Cleaning Method
DK-20 4.4
Cleaning of the turbocharger blower can be
made using the cleaning device that is supplied
together with the engine.
i ) Pour cleaning liquid into the blower syringe a.
ii) Connect the syringe socket to the filling pipe
@ that is connected the turbocharger inlet side.
iii) Fully open the drain cock of the air intake duct.
iv) Operate the syringe to inject cleaning liquid.
v) When 3 to 5 minutes has passed afler the
injection of cleaning liquid, inject fresh water of
the same amount on the same procedure.
[Injection A m o u n t a n d Injecting Time]
vi)) In case that there is no change in intake air
Type of
tur-bocharger
I injection 1 Injecting
alnount (L) time (sec)
I
pressure before and afler the cleaning, repeat
cleaning afler 10 minutes.
@ In case that intake air pressure does not
change over when the cleaning is repeatedly
conducted, conduct the overhaul and clean-
ing of the whole of turbocharger.
( : Separately provided "Turbocharger
Instruction Manual")
The turbocharger is at a h i g h l e m -
perature during operation and just afler the
engine is stopped. If you touch it with b a r e
hands during cleaning, you may burn y o u r
hands. Wear safety gloves without fail.
 Inspection and Maintenance

4.5 DK-20 Cleaning Turbocharger Turbine

5-4.5 Cleaning Turbocharger Turbine
A 0.1 llmin.
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands during
cleaning, you may burn your hands. Wear
safety gloves without fail.
<Turbocharger type "RH" (water washing)>
(Applicable to heavy fuel oil engine)
Inject water through the water injection nozzle
fitted on the exhaust pipe at the turbocharger inlet,
and the combustion deposit on the turbine side
can be removed by the mechanical effect of collo-
sion of water drops and the dissolving effect.
Part of the water evaporates, and the remaining.
water is discharged through the drain hole in the
gas outlet duct.
(1) Frequency of cleaning
Clean the turbine every 250 hours.
(2) Engine running conditions during cleaning
Clean the turbine after &"ing the engine for
about 20 minutes or more at a power at which a
turbocharger inlet gas temperature of 300 to 350°C
is obtained
@ after water is fed for 5 minutes, close the..
nozzle @ to discharge drain at a rate of about
ix) After the completion of water cleaning, close
the nozzle @.
x) Make sure that no drain is discharged, and
close the drain cock @ .
xi) After water cleaning, keep the engine running
for about 5 to 10 minutes under the same load.
m Keep a close watch on the turbine during
water injection. Take care that the injection
rate is not too high or the drain pipe is not
clogged with removed deposit.
Even if drainage is not observed, do not feed
water for 7 minutes or more.
After the completion of cleaning, remove the
connected hoses.
( : Separately provided "Turbocharger
Instruction Manual")

(3) Cleaning procedure

i ) Connect the water injection tube @ connected
to the exhaust pipe and the gauge board @
with a hose.
ii ) Connect the water supply hose @ to the
gauge board @I.
iii) Open the stop valve @ to feed water to the
tube and hose to the nozzle @ . When the
pressure gauge @ stabilizes, close the stop
valve.
iv) Open the drain cock @
v) Fully open the nozzle @ .
vi) Slowly open the stop valve @ , seeing the
pressure gauge @ , until the water pressure
becomes 0.05 to 0.08 MPa (0.5 to 0.8 kg/cm2).
vii) Feed water for about 5 to 7 minutes.
viii) If no drain is discharged from the drain cock
Inspection and Maintenance
Cleaning Turbocharger,Turbine
<Turbocharger type "TPS" (pouring water
washing)>
As the pouring water washing method of the
supercharger, fresh water is sprayed in front of
the turbine from the pouring water nozzle on the
supercharger. Thus, the extraneous matter is
removed through the difference of the cooled tur-
bine nozzle eith fresh water, turbine blade and
the thermal expansion extraneous matter.
(1) Washing interval
Since the washing effect is reduced when the
deposit layer becomes thick, apply the washing
every approx. 200 hours.
(2) Load during washing
Apply the washing at such a load as the
exhaust temperature of the cylinder outlet is 300
to 350°C. Asthe exhaust temperature is lower, the
washing effect decreases. As it is higher, the tur-
bine nozzle or similar part may be damaged.
Take special care for the exhaust temperature.
(3) Fresh water for washing
As the fresh water for washing, use the fresh
water which does not include any additives.
Never use any seawater.
(4) Washing method
i ) Connect the hoses of the pressure gauge and
the check-valve hose to the pipe connected to
the exhaust pipe.
ii) Open the check valve, fill the water into the
pipe and hose up to the nozzle, and close the
check valve.
iii) Fully open the valve in the nozzle on the
exhaust pipe.
iv) Observing the pressure gauge, slowly open
the check valve to gain the water valve of
0.45 to 0.7 MPa (4.5 to 7.0 kgWcm2)
v) Continue pouring water 25 to 30 seconds.
vi) Apply the washing three times. Here, provide
the interval shown in the table below after
washing of one time.
vii) Close the valve, loosen the hose connection.
Disassemble the manometer and the hose
with valve.
viii) To dry the supercharger, run it applox. 10
minutes at the same load.
ix) If any variation is not observed on the perform-'
ance values of the exhaust temperature,
charge pressure, supercharger revolution
speed and so on, repeat the procedure above
after completion of the washing. If any varia-
tion is not observed after repetition of several
times, it is necessary to open and clean it.
( a : "Operating Manual for Supercharger")
<Turbocharger type "VTR" (Water cleaning)>
As the procedure of the water cleaning method
of turbine, inject fresh water from watering nozzle
located on the exhaust pipe to the front of the tur-
bine, remove the adhered matters on the turbine
nozzle, turbine rotor blade, etc. by the impact
force of the water drops accelerated by the
exhaust gas and the solution force of water.
A part of the fresh water will evaporate, and the
remaining will be discharged from the drain hole
of the turbine chamber. Do not evaporate the
fresh water entirely.
(1) Interval of cleaning
Conduct the cleaning with the interval of 200 to
250 hours in the initial stage, since the effect of
cleaning will be lost if the layers of the accurnulat-
..
ed matters have become thick.
. , As for the cleaning interval after the initial
cleaning, properly increase or decrease depend-
ing on the factors such as the exhaust tempera-
ture, intake air pressure, and the degree of per-
formance decrease of the turbochager rotation
speed.
(2) Load during Cleaning
The maximum allowable rotation speed of the
turbocharger when cleaning is performed is as
shown in the following table, and therfore in case
that the normal load value is higher than these,
decrease the ioad.
[Turbocharger Rotaition Speed and Exhaust
Temperature]
 ,
Inspection and Maintenance

4.5 DK-20 Cleaning Turbocharger Turbine

However, the turbine rotation speed will be the manometer and the stopper valve.
decreased more or less if water is poured, and xiii) After cleaning water is completely dis-
therfore readjust the rotaition speed. charged, drive the turbine for about 10 minutes
Confirm that the drain including water is dis- with the constant rotation speed in order to dry
charged from the drain hole of the turbine cham- the turbocharger.
ber within the range of this rotation speed. xiv) After finishing the cleaning, confirm the
changes of the performance values such as
(3) Fresh water for cleaning the exhaust temperature, intake air pressure,
Use lresh water containing no additives. anever turbocharger rotation speed, etc.
use sea water. In case that there is no change, repeat the
above procedure. In case that there is no
(4) Cleaning method
change even afler repeating the procedure, it
i ) Close the drain cock @ . is necessary to perform the overhaul and
ii) Connect the pipe connected to the exhaust cleaning.
pipe with the hose provided with the hose pro-
vided with the manometer and the stopper ,
(a : "Instruction Nmanual of Turbocharger")
valve with the hose connection.
iii) Open the stopper valve, and fill the pipe and
hose connected to the nozzle with water, then Nozzle
close the stopper valve.
iv) Totally open the valve inside the nozzle locat-
ed on the exhaust pipe.
v) Open the drain cock @,.and confirm that the
drain cock and the pipe are not clogged.
vi) Slowly open the stopper valve so as to obtain
the water pressure of 0.05 to 0.1 MPa {0.5 to
1.0 kgflcm2)while watching the manometer.
vii) Confirm that drain comes out of the drain
pipe.
viii) Constantly watch the discharge of drain while
pouring water, and pay attention to the change
of water pouring amount and closing of the
drain pipe. Hose connection Hose connection
Water pouring amount
Water pouring amount WaterPowing Cleaning Procedure of Turbine .
Tubine model (Ilmin)
VTR16O. 161 2-3

ix) Continue the pouring of water for about 10

minutes.
x) Close the valve inside the nozzle, and close
the drain cock @ after confirming that drain is
no more discharged.
xi) Open the drain cock @ . (Prevention of clog-
ging of the drain pipe.)
xii) Close the stopper valve, loosen the hose con-
nection, and remove the hose provided with
 > ((4 L
Inspection and Maintenance

Measuring Crankshaft Deflection DK-20

5-4.6 Measuring Crankshaft Deflection iii) Install the deflection gauge.

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

(I)
Replacing Consumables and Measuring
lnstruments
a) Replacing Consumables ( a: "Parts ~ist")
@ O-ring (frame side cover) No.11

b) Implements and Measuring Instruments

@ General tools
( : "Implement List"in the final docu-
ments)
@ Deflection gauge
(?$ Motor

(2) Conditions for Measuring Deflection

a) Deflection of the crankshafl varies according to
the temperature. Be sure to measure it when
the engine is in cold state.
b) Before measurement, push the contact piece Deflection Gauge Mounting Position
of the deflection gauge with a finger, and con-
lirm that both the contact piece and dial
gauge return to the original positions correct-
ly.
C) In case of the marine engine, since the deflec-
tion varies according to the loaded cargo con-
ditions, be minded to record the conditions of
loaded cargo, draft, temperature, and so on,
at the same time.

(3) Measuring Deflection

i ) Open the turning plug, and perform turning the

crankshaft.
ii) Place the crank pin at the point of 30" (position
" B ) past the bottom dead center.
 Inspection and Maintenance

DK-20 Measuring Crankshaft Deflection

(4) Calculating Deflection (d)

Calculate the deflection values as based on the
measured values and in accordance with the fol-
lowing formula, and record the calculated values:
A+B
Venical (V) deflection: dV = D -

.. Horizontal (H) deflection: dH = C - E

2

Positivelnegative deflection: Open down-

ward (+), closing downward (-)
A
A, B, C, D, and E represent the measured val- Top dead center
ues respectively at each corresponding position
Deflection Measuring Position
shown in the figure on the right.

(5) Correction Limit for Deflection

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

Adjusted value Allowable limit Direction

-
-8 . ?'. 0.03 or less
:3@
- & &x '"
stroke --x stroke
10,000
(Top dead center)

-%.' f
0.03 or less 0.08
Dial Gauge Reading
fi
!@
-
ez
Lx
10,000
stroke -x stroke
10.000
z.5
.- 0.09 or less
2O sP &
22.5
$ C.S I
3x stroke -x stroke
CESS
- 10,000 10,000

b) Deflection varies depending on the connection

method (direct connection or flexible coupling)
between the crankshaft and drive equipment,
however, usually, the deflection becomes The deflection of the crankshaft shall be rep-
maximum at the crank throw that is closest to resented by the value when the engine is cold,
the flywheel. and since the values measured when the
engine is warm sometimes differ significantly
Adjust the drive equipment using the adjust-
depending on the measurement conditions, be
ing shim or chock liner, so that the deflection
minded not to use the value measured when
falls within the limited values as shown in the
the engine is warm as standard.
above table.
 Inspection and Maintenance
-
1 Measuring Crankshaft Deflection I DK-20 1 4.6 1
<Reference>
Deflection in warm condition
In case ofthe directly connected generating There is a possibility that the measurement
engine, the deflection in the warm conditions gen- results of the deflection in the warm conditions
erally tends to vary as compared to the values in differ from the real value due to the reasons that
the cold conditions. the engine temperature may suddenly increase
This is because the temperature increase of the afler the engine is stopped, and due to the effects
engine base is larger than the temperature of the thermal expansion owing to the tempera-
increase of the generator to be directly connect- ture difference of the crankshafl. Be careful o f
ed, so that the crankshafl core relatively increas- this fact.
es, the deflection varies t o w a r d k direction
(downward closing), and thereby the difference
manifests itself as the deflection difference
between the cold and warm conditions.
Like this, in case of the directly connected gen-
erating engine, the deflection difference between
the cold and warm conditions differs depending
on the bearing dimensions and temperature dif-
ference of the engine and generator, so that the
adjustment is impossible, and it will be the value
unique to the generating device.
Consequently, in case of the generating engine,
the adjustment is made with the target of the con-
ditions near to + side upper limit fi(downward
opening) of the specified value in the cold condi-
tions.
The measured value of the deflection value in
the warm conditions varies according to the tern'-
perature, and the different values tend to be
obtained evely time the measurement is conduct-
ed, however, based on the actual measurement
results of our company, the value is approximate-
ly 3 to 4110,000 x stroke and within the range of
.gS
(downward closing).
 lnspection and Maintenance

lnspection and Replacing Protective Zinc

5-4.7 Inspecting and Replacing iii) On the contrary, in case that the protective
zinc is rarely worn out, the following failures
Protective Zinc
may be suspected:
In case that sea water is used as the cooling Faulty condition on the mounting surface
water in the cooleig system, a protective zinc is purity failure of zinc
provided in each cooler.
Conduct periodical inspection and replacement
b) Replacement and mounting
of the parts on the following procedure:
i ) Remove the rust or scale from the mounting
(1) Replacing Consumables, lmplements and surfaces of the protective zinc and the mounted
Measuring lnstruments flange to expose the metallic surface, and
a) Replacing Consumables securely mount the protective zinc to the flange
Lubricating cooler ( rn: "parts Lisf?) in such a way that the both parts are closely in
contact each other.
@ Gasket No.12
@ Protective zinc No.11 ii) In case that the protective zinc is reused,

Air cooler ( rn: "Parts L.W)

shave scale off the surface of the protective
zinc and expose the zinc surface.
@ Gasket No.2
@ Gasket No.4
@ Protective zinc No.1
@ Protective zinc No.3
b) Implements and Measuring Instruments
@ General tools
( : "Implements L'W in the final documents)

(2) Locations of Protective Zinc and lnspection

Interval
Front and rear coven for lubricating cooler
#
.------ Every 3 months Location of Protective Zinc for
Lubricating Oil Cooler
Front and rear covers for air cooler-----Every
6 months

Efficiency of the protective zinc substantially

varies depending on the purity. Therfore, be
minded to use the genuine parts supplied by
Daihatsu Diesel Manufacturing. Co., Ltd.

(3) lnspection and Replacement

a) lnspection
i ) Remove the mounting flange for protective
zinc.
ii) Replace the protective zinc of which volume is
reduced more than 50% (20% by dimension) View "P" View "13"
as compared the original shape. Location of Protective Zinc for Air Cooler
 . -
,-2
-) L,'

Inspection and Maintenance

MEMO DK-20
 Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
1 1 DK-20 Selecting Fuel Oil -

6-1 Fuel Oil Characteristics and Control

H o w w e l l the f u e l o i l c h a r a c t e r i s t i c s i s c o n t r o l l e d w i l l greatly affect t h e s m o o t h

operation o f engine, maintenance intervals, a s well a s t h e w o r k i n g life o f v a r i o u s
parts.
When s u p p l y i n g t h e fuel oil, it i s required n o t o n l y t o c o n f i r m t h e characteristics
referring t o t h e characteristics analysis table, but also t o conduct the control o f t h e o i l
i n accordance w i t h each characteristics.
Particularly w h e n u s i n g heavy f u e l oil, conduct t h e preprocessing o f f u e l oil, t h e
control of viscosity (temperature), a n d t h e control of lubricating oil without fail, s o that
troubles arising f r o m fuel oil can b e prevented.

6-1.1 Selecting Fuel Oil

T h e standard characteristics of the fuel oil Therefore, be minded to check the characteristics
applicable to this engine is as shown in a separate analysis values of the fuel oils after each delivery,

--
table. and try to avoid using the fuel oil o f which
Table 6-1. l "Standard Fuel Oil characteristics is excessively different from those
Characteristics" shown in the standard characteristics table,
Commercially available fuel oils are considerably
different in the characteristics, and even the same
type of the fuel oil may show a greatly different
characteristics depending on the location and
period of supply

1) The engine specification varies depending
on the types of the fuel oil to be used. Be
minded to confirm the type of the fuel oil
referring to the specification of engine, and
do not use the oil of which grade is lower
than that shown in the specification.
I n case that the fuel oil of lower grade is used.
troubles may be incurred on the operation of
engine, due to the faulty combustion,
troubles on the fuel oil system equipment,
premature wearing of the parts, and so on.
2) Avoid using the fuel oil by mixing with the
other oils whose production of origin is
different. In case that fuel oil is mixed the oil
with inferior affinity, a large amount of sludge
may be generated, causing troubles on the
operation of engine.
Bottoms oils resulting from operation by FCC
method (catalytic cracking method) are often
mixed in fuel oils recently.
The mixed oils, such as this, contain rigid
alumina silica (catalyst particles), and will
cause abnormal wear of the various parts of
engine, particularly the parts o f the fuel'
injection system.
Remove the solid particles by fully utilizing the
existing luel oil pretreatment equipment, and
by intensifying the cleaning of fuel oil.
In case that the removal of the solid particles
cannot sufliciently be made with the existing
fuel oil pretreatment equipment, the
reinforcement of the cleaning equipment will be
required, and when such reinforcement is not
possible, it may be required to change the
current luel oil to the oil of a better quality.
 Control of Fuel Oil, Lubricating Oil, and Cooling Water
Fuel Oil Characteristics and Control
6-1.2 Fuel Oil Characteristics and Control
(1) Heavy Fuel Oil
Since heavy fuel oil contains more carbon residue
and impurities, and is higher in its viscosity as
compared to diesel fuel oil, heavy fuel oil cannot
be used as the fuel oil for diesel engine, when it is
in the state of bunker fuel oil.
Therefore, it will be a prerequisite to use heavy fuel
oil that the oil must properly be preprocessed
before being supplied to engine (including the
removal of impurities by cleaning, and the
assurance of proper viscosity by heating).
a) Cleaning Fuel Oil
Water, and solid contents such as vanadium,
sodium, alumina, and silica, contained in heavy
fuel oil accelerate the corrosion and wear of the
various parts 6f fuel injection system and fuel
combustion chamber system, substantially
affecting and reducing the working life of these
parts,
For the purpose of removing such impurities, the
fuel oil preprocessing equipment, such as the
centrifugal separator and precision filters, are
installed. Since these equipment will not exhibit
the efficiencies unless each equipment is
properly handled, be minded to operate each
equipment in accordance with the corresponding
instruction manual.
a "Instruction Manual" for each equipment
-u
Since waste fuel or sludge will be the causes
of environmental contamination or pollution,
be sure to entrust the treatment of these to
the authorized waste disposal company, not
directly handling or disposing these matters
on your own.
b) Heating Fuel Oil
Since the viscosity of heavy fuel oil is vety high,
it is required to heat the oil, so that a proper
viscosity for fuel injection can be obtained.
Since the heating temperature varies depending
ITEM
DK-20 1 9
on the viscosity of fuel oil, heat the oil and obtain
the proper viscosity, by referring to the fuel oil
viscosity/temperature curve on a separate page
as a standard.
In case that a viscontroller (automatic viscosity
regulator) is installed on the engine, control the
fuel oil viscosity to its proper value according to
the attached instruction manual.
Fig.6-1.1 "Fuel Oil ViscosityiTemperature
QJICurveu
- A
L l
'Proper viscosity for fuel oil (engine inlet)
Kinematic viscosity: 14+ 1 mm2/S
If the temperature control o l fuel oil i s
improper, and the fuel oil with high viscosity
has been supplied to engine, it will not only
incur faulty combustion, but also will resull in
the accidents such as the clogged o r
damaged fuel oil filter, and the breakage of
fuel injection system parts.
(2) Diesel Fuel Oil
~ ~
a) Water tends to extract and separate out of
diesel fuel oil, and further diesel fuel oil tends
to generate a large amount of sludge when
mixed with the oil of different base oil.
Daily conduct the draining-off of the
precipitation tank and settling tank, so that
water or sludge does not flow into the engine.
To remove water or sludge, the centrifugal
separator is an effective device.
b) Diesel fuel oil, that has been cut back by using
the gas oil refined by FCC method, may incur
faulty start or ignition, and this tendency is
particularly obvious in case of low sulfur diesel
oil for land vehicles, due to its low cetane
number, if the environmental conditions, such
as the ambient temperature or water
temperature, are unfavorable.
In such a case, special measures will be
become necessary to improve starting
capability and combustibility of engine, and in
such occasions, contact our company for
consultation.
 . _,
I
,

Control of Fuel Oil, Lubricating Oil, and Cooling Water

ITEM
1 2 DK-20 Fuel Oil Characteristics and Control
(3) Gas Oil
Although gas oil does not contain few impurities, it
may cause problems on ignition when the gas oil is
refined by FCC method, just like the case with
diesel fuel oil, and therefore b e minded to pay
particular attentions to the cetane number of gas
oil.
Further, since gas oil is low in its viscosity and is
inferior in its lubricity, it may cause abnormal wear
on the sliding parls of fuel oil injection system, and
therefore be minded to conduct the inspection ol
the fuel injection pump and fuel injection valve in
the earlier stage than usual.
(4) Kerosene 011
As a countermeasures to prevent environmental
contamination (air pollution), there may a case in
which kerosene oil may be used.
Since kerosene oil is further lower in its cetane
number and is lower in its viscosity than gas oil, it
is required to carry out a special arrangement on
the engine, and therefore contact our company for
consultation before using the oil.

Table 6-1.1 Fuel OIl'Standard Characteristics

Kinematic viscosity

Notes: 1) Since there are a wide range of the standard values for diesel fuel characteristics, the recommended
values are shown in the above table.
2) Heavy fuel oil characlerislics represent the values ol "Residual marine fuel oil" proposed in ClMAC
(1990).
3) Cetane number represent the calculated values based on JIS K 2280-1996. Figures shown in ( )
indicate the values based on the old method of JIS K2204-1992.
4) CCAl (Calculated Carbon Aromaticity Index) value is calculated by the following formula, and indicates
the reference value for starling capability.
CCAl value = 1000 D;141 Log Log (VK + C) - ti
D: Density glcm3 (15 C), VK: Viscosity cSt (50 C). C: Constant (0.85 for heavy fuel oil)
 ".> <
-7 { I
-8

Control of Fuel Oil, Lubricating Oil, and Cooling Water

Fuel Oil Characteristics and Control

Table 6-1.2 Standards for Clean Fuel Oil

-
Component Standards

Water O.Z%vIv or less

solid Content 50 mglkg or less

particles
Size 5 jl m or less

Vanadium combines with sodium to yield a

compound that acts as an oxidation catalyst,
accelerating the corrosion due to sulfuric acid
(vanadium attack).
Further, water accelerates the corrosion of
fuel injection system parts. Particularly 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 fuel oil cleaning equipment,
to the best possible extent.
 -
Fuel Oil, Lubricating Oil, Cooling Water

DK-20 Fuel Oil Viscosity-Temperature Curve

1 -10 0 0 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Temperature ('C)

Fig. 6-1-1 Fuel Oil Viscosity ITemperature Curve

Example) We find the temperature, under which heavy fuel oil ol 380 mm21Scan be heated, so as to obtain the
proper viscosity of 14 mmVS at the engine inlet.
To find this temperature, tracing the curve No.9 downward, and from the point that intersects
kinematic viscosity 14 rnm11S, goes down vertically to obtain 130'~.
Note : 1. Notes: 1.The viscosity/temperature characteristics of fuel oil may slightly difier depending on the
origin place of production or its relining process, and therefore conlirm the viscosity with a
viscometer, and determine the proper value when actually operating the engine.
2. 2. Kinematic viscosity 1 mmZS = 1 cSt
 Control of Fuel Oil, Lubricating Oil, and Cooling Water

Selection and Control of Lubricating Oil

6-2 Lubricating Oil Characteristics and Control

Lubricating o i l 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, o r acting as a neutralizing acids.
For t h e p u r p o s e o f maintaining t h e engine in proper conditions a n d assuring t h e
smooth operation, it is indispensable to select suitable lubricating oil brands taking
into consideration t h e u s e purpose o f engine, t h e fuel oil t o b e used, t h e l o a d to b e
connected, etc., a n d to conduct an appropriate control o f the lubricating oil.

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

(1)
. . Engine
- system oil
As the system oil for engine, high-grade lubricating
oil (CD of API service category, or higher) for
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 lubricating brands are shown in
a separate table.
Table 6-2.1 "Recommended Lubricating Oil
Brands"
: Be minded to use the lubricating oil of the
same brand, not mixing the lubricating oil with
the oil of any other brand.
If the lubricating oil is mixed with the oil of
different brand, the additives contained in the
both oils react for each other, and this may
result in the degradation of the lubricating oil.
(2) Lubricating Oils for Other Equtpment
~ ~
In case that separate lubricating system is
employed apart from the engine lubricating
system, as in the case of the governor, air motor,
turbocharger, generator, deduction gear, etc., be
minded to refer to the instruction manual of each
equipment.
"Instruction Manual of each equipmen"
(1)
. . Cleaning.of Lubricating .Oil
Since fine 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 filters attached to engine. Use such
equipment in correct manner, referring to the
instruction manual of each manufacturer.
$\
Do not conduct cleaning by injecting water into
lubricating oil.
Mixing water into lubricating oil will cause
degradation of the lubricating oil, such as the
emulsification of oil, the decrease of total base
number, and the increase of insoluble
substances.
(2) Control of Lubricating- Oil Characteristics
Periodically conduct the sampling and analysis of
lubricating oil (evely 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
manufacturer, so that the replacement or makeup
,Q
can be carried out.
Table 6-2.2 "Lubricating Oil Control
Standards"
 \X
Control of Fuel Oil, Lubricating Oil, and Cooling Water
ITEM
DK-20 Selection of Lubricating Oil
a) Sampling Procedure
i ) Collect samples from the air vent pipe of the
filter during the operation of engine.
If the samples are collected from the drain
cock, the analyzed value of the
characteristics may show a diflerent value
due to the mixing of sludge or solid
deposits.
ii ) The minimum amount of sampling shall be
500 cm3.
iii) Attach on the sampling receptacle with the
label indicating the information as shown on
the right.
b) Lubricating Oil Control Standards
T h e lubricating oil control standards are as
shown in the Table 6-2.2 below.
Of all the lubricating oil control standards, the
total base number and n-pentane insoluble are
particularly important for the purpose of checking
the degradation degree of lubricating oil.
Table 6-2.2
Lubricating Oil Control Standards (System oil)
I visconsity I I
c ~ t + 30% or less / -20%
or more of new oil
1 Flash point 1 "C 1 180°C or higher
Water vol.% 0.3 or less
content
I n-pentane
insoluble
2.5 or less
Note: 1) The total base number represents the
values measured according to ASTM D664,
JIS K2501 (hydrochloric acid method).
..... TEN (Total Base Number)
2) n-pentane insoluble represents the values
measured according to ASTM D893B.
In case that the measured value has quickly
increased. or has surpassed 1.5, measure
the insolubles of toluene with the same
method, and in case ol n-pentane insolubles
- toluene insolubles L 0.5, replace the
lubricating oil.
(Information to b e Attached to Sample
Receptacle)
Name of your company and your name
3 Model number of engine
3 Engine number
a Date and location of sampling
9 The amount of time the engine i s
operated
5 ) Lubricating oil brand
The total operation time and quantity of
lubricating oil
8 Replenishment record (Date and quantity
of replenishment)
1) Total B a s e N u m b e r (TEN)
Total base number represents the quantity of
potassium hydroxide (KOH) that corresponds
to the quantity of acid required to neutralize
the base component contained in 1 g of
lubricating oil, and is indicated by the unit of
mgKOHIg.
Total base number indicates the lubricating
oil capabilities to prevent the corrosion due to
sulfuric acid generated from sulfur contained
in fuel oil, and other acids, and further it
I
indicates the capabilities of lubricating oil to
clean and disperse the fouled sections in the
engine.
I 2) Insoluble ( = n-pentane soluble) ,
.Insoluble i s fouling substance that do not
dissolve in oil, and the main component is
I soot which is a product of combustion, and
calcium sulfate which i s a neutralized
product.
Since these substances do not dissolve even
in n-pentane which is a solvent, n-pentane
insoluble serves as an index to indicate the
degradation and fouling degree of lubricating
oil.
 Control of Fuel Oil, Lubricating Oil, and Cooling Water

I Recommended Lubricating Oil Brands lDK-201

8 8 L,",

2.21
Table 6-2.1 Recommended Lubricating 011 Brands

\ Kind of F.O. Up to 1500 Sec. Up to 7000 Sec.

Diesel oil R.W. No.1 R.W. No.1 - R.W. No.1

\\
Name of
Class I I
S U P P I Y or)
~~~
(Replacing oil
) Class Ill
supplyhg or
Replacing oil 1 (
Class IV
Supplying or
Replacing oil
Class V
Supplying or
Replacing oil

BP ENERGOL BP ENERGOL BP ENERGOL BP ENERGOL

DL-MP30 IC-HF253 IC-HF303 IC-HF303
CASTROL TLX303 CASTROL TLX303

CHEVRON DELO 1000 Marine DELO 2000 Marine DELO 3000 Marine DELO 3000 Marine
TEXACO Oil SAE30 Oil SAE30 Oil SAE30 Oil SAE30
TARO XD SAE30 TARO DP SAE30 TARO DP SAE30

EXXON MOBlL EXXMAR 30TP30 EXXMAR 30TP30

MOBILGARD 330 EXXMAR 40TP30
MOBILGARD M330 MOBILGARD M330 MOBILGARD 330
MOBILGARD M330

GULF GULF VERITAS

DP030
I GULF VERITAS
SERECT30
GULF VERITAS
SERECT30
-

PETROBRAS MARBRAX
CCD3lO I1 MARBRAX
CCD320
MARBRAX
CCD330 II MARBRAX
CCD330

1
SHELL GADINIA30 ARGINA 530 ARGlNA T3O ARGlNA T3O

TOTAL RUBlA S SAE30 RUBlA ST SAE30 HAM SAE30 . HAM SAE30

FlNA DISOLA M3015 HAMSAE30 AURELIA 3030 AURELIA 3030
AURELIA3030

Note: 1) This table shows lubricating oils classilied as SAE30. Be sure to use lubricating oils classified as SAE40
only when the minimum ambient temperature is 20°C
We recommend that multigrade oil (SAEIOW-30 or 5W.30) be used in extremely cold locations
(minimum ambient temperature: 5% or less).
2) Be sure to consult with oil manufacturers belore selecting the lubricating oil proper brand that besl suits
the fuel oil and operating conditions.
 Control of Fuel Oil, Lubricating Oil, and Cooling Water
Cooling Fresh Water (Raw Water) and Corrosion
3.1,3.2 DK-20 Prevention Agent

6-3 Cooling Water Characteristics and Control

A l w a y s u s e f r e s h water a s c o o l i n g water i n t h e c y l i n d e r jacket s y s t e m a n d a d d

corrosion prevention agent t o cooling water t o maintain cooling effect a n d prevent
corrosion d u e t o scale bonded o n the piping surface.
Improper cooling water control can cause localized heating of the jacket line parts due
t o corrosion or scale, resulting i n excessive wear o n or damage t o t h e jacket l i n e
parts.

6-3.1 Cooling F r e s h Water (Raw Water) 6-3.2 C o r r o s i o n Prevention Agent

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 softening processing has been
administered
(1) As corrosion prevention agent, we recommend
the agent which is nitrous acid type.
(2) Commercially available brands in Japan are
shown in Table 6-3.2.
When using them, carefully read the
manufacturer's instruction manual, and properly
use the agent in accordance with the use
standard as well as the control standard.

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

Effect (reference)
Standards
Corrosion Scale

I PH (25°C) 1 6.5 to 8.5 (neutral) 1 o I o

Total hardness
(CaC03 PPM) 100mgIkg Max. 0
Chlorine ion
(Concentration: CI.') 100mglkg Max. 0
I M - alkalinity (PH4.8) I 150mglkg Max. I l o
Sulfate ion
(Concentration: 504.') 100mgkg Max. 0
I I I

Total iron (Fe) 0.3mglkg Max. 0 0

Silica (SiOz) 50mglkg Max. 0
Ammonium ion
(Concentration: NH4) 0.05mglkg Max. 0
Evaporation residue 400mglkg Max. 0

Control of Fuel Oil, Lubricating Oil, and Cooling Water
Cooling Fresh Water (Raw Water) and Corrosion
Prevention Agent
Table 6-3.2 Brands of Cornrnercially Available Corrosion Prevention Agents
-
Brand Name Manufacturer
DEW-NC
Drew Chemical Corp. (U.S.A.)
MAXIGARD
C W DIESEL 102 VECOM B.V.
6-3.3 Control of Cooling Water
(1) As cooling water, be minded to use fresh water
added with corrosion prevention agent, from the
stage of very first 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.
Furlher, regarding the handling of the cooling
water added with corrosion prevention agent,
be sure to wear the protective gears such as
nrbber gloves and masks, so that your hands
or skin do not directly touch the cooling water.
If the corrosion prevention agent has
accidentally touched your skin or entered your
eyes or mouth, immediately wash them with
fresh water sufficiently.
1 --
ITEM
DK-20 W 3 . 3
Constituent Amount to added (ppm)
3,000 - 4,500
Nitrite
20,000 - 22.000
Nitrite 1.250 - 5,000
(2) Controlling Fresh Water with PH Value
Measure the PH value of cooling water once
every week, using a PH value, and in case that
the value has exceed the standard value
specified by the manufacturer, discharge 1 0 to
20 % 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
processing.
When disposing the cooling water, be sure to
conduct the water examination, to ensure that
the CDD concentration of cooling water is
diluted to be within the specified value.
 Troubleshooting and Countermeasures
ITEM
1 DK-20 Precautions for Troubleshooting
7. Troubleshootingand 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,
i n 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 of 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 for such
defects and problems. If your engine has a defect or failure that is not described in
this section, or if you cannot discover the causes after inspection, contact our Service
Department.

7-1. Precautions for Troubleshooting

(1) Take proper measures immediately when you find a defect or problem.
If any of the following defects and failures is found, stop the engine for inspection. Never attempt to
restart the engine until you find 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 failure, resulting in injuries or accidents.
@Activation of protective device: "Alarm", "Emergency Stop"
Overspeed, low lubricating oil pressure, high cooling water temperature, etc.
@Abnormal sounds (specially mechanical sounds), abnormal vibrations
@overheating of the engine
@Abnormal increase of exhaust temperature or maximum explosion pressure, or abnormal decrease of
exhaust temperature or maximum explosion pressure
O ~ e f e c t i v eparts on or around the engine control (governor, control device), or protective device. 2 n d
loosened link, or detachment of link
Q ~ a m a g to e piping or joint bolts (specially fuel and lubricating oil systems)

(2) Inspect, disassemble, and adjust the engine correctly according to the instruction manual. T o prevent
accidents, never neglect "Safety Precautions".

(3) Be sure to use the genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the parts
list. We will not therealter guarantee the proper operation of the engine unless such parts are used.
If you are out of the spare parts for servicing, immediately contact us for replenishment.

Instruments such as tachometers, thermometers, and pressure gauge may provide

incorrect indication even if the engine is running normally.
Inspect the instruments on a daily basis to make sure their indication is correct.
Replace any defective instrument. Always use correct indications as an index for
determining the engine conditions.
 Troubleshooting and Countermeasures

When Starting Is Difficult . 2m11

IDK-20 1 "'"
7-2 Troubleshooting and Countermeasures
7-2.1 When Starting is Difficult
(1) Direct System
[Phenomenon) [Trouble) [Countermeasures)
-Insufficient starting air pressure - - - - - - - ~ . - - I n t aair.
ke

1
Leaks tram main stoplsately valve on air tank - - MaintenancelReplace.
Faulty air fillingunit ......................... -Repair,
(e.g. compressor)
Faulty pressure gauge ..................... RepairlReplace.
-Defective starling air piping system

fTI t
lnsutlicient
starting -
'Closed" valve......................... Open valve,
Clogged piping ................................
-Faulty starting device
Clean valve,

Isticking of starting air operation valve--MaintenancelReplace.

t ~ t i c k i n gof starling air valve -.-----------MaintenancelModify.
Rough seat surface on starling air rotary valve -. MaintenancelModify.

LDefective control system ......................MaintenancelModify.

does not Interrupted power supply
Defective automatic control panel
Defectlbroken wiring of
electrical contacts tor control
Defective solenoid valve for control
Turning device: ON Turn it "OFF".
Rotation preventive device: O N . :

r High resistance of moving parts (such as seizure)--Maintenance/Modify,

Cylinder liners, Piston
Engine smooth Crankshaft .
does not
- lubricating- oil viscosity
Too high ........... lncleasecwlingwa\er\emperature.
...... Replace win less W n u s lubricaling oil.
Low room temperature ........................ Increase room temperature.
in all Low cooling water temperature ............. Increase water temperature.
b u t fuel Degraded fuel oil
mixture Improper properties (ignitability) ....... Use high-grade oil.
Water in fuel oil ............................... Separateandeliminalewater.
Air infueloil ....................................Remove air,

Defective fuel injection valve

rotation Faulty nozzle Maintenance/Replace,
speed Improper valve opening pressure . A d j u s t .
is not fuel oil injection pump.. .......... MaintenancelReplace.
in some .Sticking of rack
.Sticking of plunger
Faulty deliveryhsobaric valve
Improper fuel injection t i m i n g . - - - - - - - - -Adjust.
----
Insufficient compression pressure
Non-airtightpiston ring (sticking,wear,damage)- - MaintenancelReplace.
Non-airtight intakelexhaust valve ...... MaintenancelReplace.
Improper valve end clearance . . . . . . . . . Adjust.
on intakelexhaust valve
ITEM
Troubleshooting and Countermeasures

1 DK-20 / When Starting Is Difficult 1

- -

(2) Air Motor System

[Phenomenon] [Trouble] (Countermeasures]

-Insufficient starting air pressure ------------Intake air.
Leaks from main sloplsafely valve on air lank - - MaintenanceIReplace.
Faulty air filling unit ..........................Rep air,
(e.g. compressor)
Faulty pressure gauge-...----------------- RepairlReplace.
-Defective starling air piping system

1 -starting
air I t"ClosedMstop valve.........................
Clogged piping................................
Open valve.
Clean.
-Defective control system - - - - . ~ - - - - - - - MaintenancelRepair.
-----~---
Interrupted power supply
Defective automatic control panel
Defectlbroken wiring of
electrical contacts for control
befective solenoid valve for control
does not Turning device: ON ........................ Turnit "OFF",
rotate Rotation preventive: ON -----.-.-..-.'
of air motor
-Faulty starling equipment
is oul of Sticking of starling air operation valve--MaintenancelReplace.
order. lmproper reducing valve pressure-----MaintenancelRepair.
Sticking of relay valve . . . . . . . . . . . . . . . . . . . . . . MaintenancelRepair.
-Faulty air motor
Sticking of bearings .-.-MaintenanceIRepair.
tFaulty pinion gear e n g a g e m e n l T u r n i n g

Engine High resistance of moving pads (suchas seizure)--MaintenancelRepair.

does not Cylinder liners, Piston
smooth Crankshatl
high lubricating oil viscosity -----:----- lncreasecoalingwalertemperalure.
:-.... RephceHilh less viscws lubricatingoil.
Low room temperature .....-....--------------- Increase room temperalure.
but fuel
mixture
$Z$zi~ Low coolina water tem~erature---------.-.-Increase water lemperalure.
is not
1cylinders
in 1 L ~ e ~ r a d iuel
e d oil
.-
tlmproper properlies (iqnitability) .. --..---
Water in fuel oil ----------------..........----
Use high-grade
- - oil
Separaleand eliminate waler.
The norma Air in fuel ....................................Remove air,
rotation Defective fuel injection valve
speed Faulty nozzle Maintenance/Replace,
is not
valve opening pressure - - Adjust.
fuel oil injeclion pump-....-..----MaintenancelReplace .
in some .Sticking of rack
.Sticking of plunger
.Faulty deliverylisobaric valve
Improper fuel injection timing Adjust.
Insuflicient compression pressure
Non-airlighlpislon ring (slicking,wear,darnage)-- MaintenanceIReplace.
Non-airtight intakelexhaust valve ---.-MaintenanceIReplace.
lmproper valve end clearance --------.. Adjust.
on intakelexhaust valve
 a.

Troubleshooting and Countermeasures

When Engine Revolution ISNot Smwth I Insufficient Output DK-20 . . .

7-2.2 When Engine Revolution Is Not Smooth

(Phenomenon] (Trouble) [Countermeasures)

Defective fuel control system
Defective governor........ ................... MaintenancelRepair.
Control link is caught or shaky. ......... MaintenancelRepair.
Defective fuel supply system
Insufficient supply pressure .............. MaintenancelRepair.
(defective relief valvelpump)
Clogged fuel oil filter ........................ Clean.
Water in fuel oil ............................... Separate andeliminatewater.
Air infuel oil ....................................Remove air,
Improper viscosity of fuel oil(heavy fuel oil) -.Adjusl hea6nglernperalure propew.

uengien
Uneven
combustion
Defective fuel injection valve
t Faulty nozzle ...................................
Llmpr&er valve opening pressure ...... Adjust .
MaintenancelRepair.

Defective fuel oil injection pump ..- ..-.-MaintenancelRepai r.

1
.Sticking of rack
between
.Sticking of plunger
Faulty deliverylisobaric valve
.Variations in Improper fuel injection timing ................. Adjustwithinlhe rated value
exhaust Insufficient compression pressure
temperature

I
and Non-airtight piston ring ..................... MaintenancelRepair.
combustion (sticking, wear, damage)
pressure Non-airtight intakelexhaust valve ...... MaintenanceIRepair.
Improper valve end clearance ........... Adjust.
on intakelexhaust valve

7-2.3 lnsufficient Output

[Phenomenon] (Trouble] (Countermeasures)

Cannot
- insert the Defective fuel control system
rack

High
tDefective governor .......................... MaintenanceIRepair.
Control link is caught or shaky. ......... MaintenancelRepair.
- exhaust
c o v e r l o a d (excessive torque) ................. Reduce load.
temperature Large resistance on moving parts (e.g. seizing)--MaintenancelRepair.
Insufficient Excessive Cylinder liners, piston
Output - reading kcrankshaft
on rack -
.The engine scale
- Insufficientfuel oil supply pressure
cannot run Low Defective fuel oil rel~efvalve ............. MaintenancelRepair.
with lull
load. exhaust -- tDefective fuel oil feed pump M a i n t e n a n c e l R e p a i r .
.Rotation
speed
lemperature -Clogged fuel oil filter .............................
....................................
Clean.
Uneven 'Water in fuel oil Separaleandelirninalewaler.
does not ~i~ infuel oil........................................R~~OV~ air,
combustion
90 UP - between
cylinders ( a: 7-2.2)
 Troubleshooting and Countermeasures
ITEM
When Exhaust Gas Temperature or
2.4 DK-20 Maximum Combustion Pressure Is Abnormal

7-2.4 When Exhaust Gas Temperature (Te) or Maximum Combustion Pressure (Pmax) Is Abnormal

[Phenomenon) [Trouble] [Countermeasures]

(excessive torque) .................... Reduce load.

on moving parts (e.g. seizing)-MaintenanceIModify.
on pump Cylinder liners, piston
Crankshaft

Improper fuel oil properties ...................... Use high quality fuel oil.
abnormal L_lmproper fuel oil viscosity (heavy fuel oil)- Change viscosityproperly.
-
Fouled turbocharger
Clogged pre.filter Clean,
Fouled blower side ............................. Clean,
Fouled turbine side .............................Clean.

L-
Clogged fin for air cooler .......................... Clean.
Clogged exhaust oullel (exhaust manilold)(largeresislance) -.Clean.
Negative pressure in engine room ............ Improve ventilation.

C
Faulty air cooler
Fouledlclogged fin..............................Clean.
exhaust gas intake air High cooling water temperature ........... Adjust .
temperature Insufficient cooling water quantity . . A d j u s t .
or, maximum High intake air temperature ...................... Improve ventilation.
ombustion
pressure is
abnormal H lg'1hreadinoC
High
Excessively large fuel injection
4 Te & H on ~lmproprlyadjusled readingon injeclionpump lack sale - - - Adjust.

Defective fuel injection valve

Faulty nozzle...................................... Maintenance/Replace,
tlmproper valve opening pressure A d j u s t .
Te, low Defective fuel injection pump ................... MaintenancelReplace.

cylinders
-Sticking of rack
.Sticking of plunger
Faulty deliverylisobaric valve 1
Improper fuel injection timing .................... Adjust wilhinlheratedvalue.
Insufficient compression pressure
abnormal Non-airtight piston ring............... ......... MaintenanceIReplace.
(sticking, wear, damage)
Non-airtight intakelexhaust valve ......... MaintenancelReplace.
Improper valve end clearance on ------.--Adjust.
intakelexhaust valve

Defective fuel injection valve

Maintenance/Replace,
......................................
Note: Always check that
thermometers are Drop in valve opening pressure ........... Adjust.
not faulty and that Defeclive fuel oil injection pump ............... MainlenancelReplace.
the indicator valve
is not clogged.
-Sticking of rack
.Slicking of plunger
.Faulty deliverylisobaric valve 1
Leakage lrorn or damage lo fuel injection system - - - Repair.
Troubleshooting and Countermeasures
ITEM
When Exhaust Gas Shows,Abnormal Color DK-20 2.5 -

7-2.5 When Exhaust Gas Shows Abnormal Color

[Phenomenon] [Trouble) [~ounterrneasures]

Engine not warmed up ............................ Warm up engine.
Low cooling water temperature ............... Increase water temperature.
Excessive amount of lubricating oil
drawn up to the top part of piston
Wear or sticking of piston ring or oil ring----- MaintenancelReplace.
tWear of cylinder liners ........................ MaintenancelReplace.
Blue or
white Low room temperature ............ ...........-.... Adjustcooling water and
Low cooling water temperature ......... quantity in air cooler.

-Defective fuel injection valve

t Faulty nozzle ....................................... Maintenance/Replace,

lmproper valve opening pressure.------Adjust.
-Defective fuel oil injection pump-------~.---- MaintenancelReplace.

i 1
.Sticking of rack
exhaust .Sticking of plunger
gas shows .
Faulty deliverylisobaric valve
abnormal -Degraded fuel oil

L lmproper properties (ignitability) ---.--.-Usehigh quality fuel oil.

Water in fuel oil.................................... Separateandeliminatewaler.
Air in fuel oil ......................................... Remove air,

k.
-Insufficient compression pressure
Non-airtight piston ring ....................... MaintenancelReplace.
st~ck~ng, wear, damage)
Non-airtight intakelexhaust valve ....... MaintenanceIReplace.
mproper valve endclearance on inlakelexhaustvalve -.-Adjust.
-Low load operation for long hours -.-----.-Increasethe load.
(fouled combustion chamberlexhaust system)

Fouled turbocharger
Clogged pre-filter ................................ Clean,
Fouled blower side ............................. Clean,
Fouled turbine side .............................Clean.
Faulty air cooler
Fouled/clogged fin .-............................Clean.
High cooling water temperature ......... Adjust.
Insufficient cooling water quantity ...... Adjus t.
Negative pressure in engine room ---:------ Improve ventilation.
High intake air temperature ..............
Overload .................................................. changethe loadproperly,
 -
- "
'
13
->

Troubleshooting and Countermeasures

ITEM
2 6 DK-20 Abnormal Noise l Abnormal Vibration

7-2.6 Abnormal Noise 1 Abnormal Vibration

(phenomenon) [Trouble) [Countermeasures)

Knocking Abnormal combustion

overcooling of .engine ......................... Warm up engine.
Defective fuel oil injection pump ......... MaintenancelReplace.
Pressure
released Faulty spraying by nozzle .................... MaintenancelReplace.
Improper fuel oil properties ---.--------------Use high quality oil.
cylinder Faulty cylinder safety valve ..................... Maintenancelfleplace.
I
[salety valve .Sticking of valve
.Slack spring
I
-Improper load conditions ........................... Change the load properly.

PZlnoise
.Overload (Excessive torque)
.Abrupt change in load
Excessive load connected or disconnected

Defective turbocharger
1
Fouled blower side ................................ Clean,
Fouled turbine side ................................ Clean,
Turbocharger Deformed or damaged parts ................. Replace.
(Diffuser, turbine nozzle, turbine rotor)
Clogged exhaust manifold -------------.-----------Clean.
Clogged or fouled air cooler ...................... Clean.
sounds Defective fuel oil injection pump ................ MaintenanceIReplace.

Loose mounting bolts .................................Tighten bolts,

F Loose bolts on holding moving parts ---.--.-Tightenbolts.

Excessively worn cylinder liners (seizing) - - - - Maintenancelfleplace.
Excessive intake and exhaust valve end clearance Adjust.
Increase in gear backlash-.------------------------Adjust/Repair.
 . .

Troubleshooting and Countermeasures

ITEM m7
When Engine Stops Suddenly DK-20
7-2.7 When Engine Stops Suddenly

(Phenomenon) [Trouble) [Countermeasures]

overload ................................................
: 7-2.9) (
Protective
device
Decrease of lubricating oil pressure
Abnormal cooling water temperature .......
7-2.10)
7-2.13)
....... (
(
a:
m:
activated Defective control power system ................. Repair.
Defective fuel shutdown device ................. Repair.

Seizing of or damage to moving parts

piston ...................................................... Repair.
Crankshaft ..............................................Repair
Timing gear ......................................... Repair,
Camshaft .......................................... Repair,
impossible.
L

Defective drive equipment .......................... Repair.

engine
stops
suddenly

-
.Generator
.Reduction gear, propeller shaft system
.Others

Defective fuel oil supply system

1
No oil in oil tank ...................................... Supply.
Clogged fuel oil filter Clean,
Defective fuel oil relief valve .................. Repair.
Defective supply pump Repair.
................................................... Remove air,
Improper viscosity of fuel oil (heavy fuel oil) - - - Reduce viscosity

- Defective speed regulator system

Defective governor ................................Repair.
turning Control link has come ofi or is caught R e p a i r .
- Defective fuel oil injection pump ................. MaintenanceIReplace.
-Sticking of rack
-Sticking of plunger
.Faulty deliveryhsobaric valve
- Defective fuel injection valve

t
I
Faulty nozzle ......................................... Adjust/Replace,
lmproper valve opening p r e s s u r e Adjust.
- Leakage form fuel oil hige-pressure coupling --.RepairlReplace.
- Slided fuel cam ........................................... Adjust/Maintenance,
 ?

Troubleshooting and Countermeasures

ITEM

2 8 2 9 DK-20 Unable to Stop Engine / Overspeed

7-2.8 Unable to Stop Engine 1 7-2.9 Overspeed

(Phenomenon) [Trouble) [Countermeasures]

7Defective speed regulator system

MaintenancelRepair.
L c o n t r o l has come off or is caught --------------...-

MaintenanceIRepair.
Sticking of fuel oil injection pump rack ------.-..-.--..

-1 Defective control power system---..--.------------------MaintenancelRepair

I b ~ e f e c t i v eautomatic control panel
Faultyldisconnected contacts
Overspeed ~efe'ctivesolenoid valve
.Activation of L ~ e f e c t i v espeed detector
protective device

(Defective fuel shutdown system

Defective fuel shutdown device ----------....-...----
MaintenanceIRepair.
Defective speed detector .---.---------------.-.--------Maintenance/Repair
Insufficient control air pressure ..-.....----------.--.-
MaintenancelRepair.
.Clogged pipinglfilter
.Drop in pressure 1
Troubleshooting and Countermeasures
-
ITEM
Low Lubricating Oil Preswrel High Lubricating Oil Temperature DK-20 2,10,2,11

7-2.10 Low Lubricating Oil Pressure

[Phenomenonl [Trouble 1 (Counlermeasuresl

-Low lubricating oil level in tank .................. Replenish.
(below lower limit) lubricating oil.
- Improper oilviscosity ................................. Replace,
Pressure does
not reach the
- Clogged lubricating oil filter (suction side)--Clean.
specified level - Air sucked from inlet side .......................... Maintenancelflepa

.
.Damaged piping
Non-airtight joint I
- Leak from or damage to oil piping (discharge side)-MaintenancelRepa

El
- Defective lubricating oil pump ................... MaintenanceIRepa
lubricating (.sticking of safety valve, broken spring)
.Wear of pump gear
.Wear of bearings
- Defective relief valve .................................
1
MaintenanceIRepa
- Damaged cooling water piping in lubricating oil cooler-- Repair.
- Clogged lubricating oil filter (discharge side) --Clean.
- Wear of bearings ....................................... Maintenance/Repa
Drop in High

7-2.11 High Lubricating Oil Temperature

[Phenomenon] [Trouble] [Countermeasures]

Fouled lubricating oil cooler ...................... Clean.

r
Defective lubricating oil temperature control valve: .. MaintenancelRepa
.Damaged pellet
.Sticking of valve 1
Insufficient cooling water quantity

€
High Defective cooling water ... MaintenancelRepa
lubricating - (e.g. damagedlworn impeller)
oil Clogged filter/cooling water piping ....... Clean.
temperature Improperly regulated water quantity ..... Adjust.

Less airtight cylinders ................................ MaintenanceIRepa

.Wear and sticking of piston ring
.Wear of cylinder liners 1
Seizing of bearings .................................... ~ ~ i ~ t ~ ~ ~
 6' j

1 Troubleshooting and Countermeasures

. I High Cooling Water Temperature l
Low Coolina Water Pressure (Jacket Line) I
7-2.12 Low Cooling Water Pressure (Jacket Line)

[Phenomenon] (Trouble] [Countermeasures)

-Insufficient cooling water quantity

I
Defective cooling water pump-------------------- MaintenancelRepair.
(Damagedworn impeller)
difference
Clogged filterlcooling water piping ---.--------- Clean.
beteween inlet
cooling lmproperly regulated water quantity -........-.Adjust.
water Defective cooling water temperature control valve ---Maintenance/Repair.
-Air in cooling water system -.-.--.--.--.--------------.Remove air.
temperature Excessively large cooling water quantity
difference Improperly regulated water quantity ......-..-Adjust.
beteween inlet Defective cooling water temperature control valve -.MaintenancelRepair.

7-2.13 High Cooling Water Temperature (Jacket Line)

[Phenomenon) rouble) [countermeasures)

Air in cooling water system ----.-.----...-----.--------
Remove air
F Fouled fresh water cooler...........---.---------------
Clean,
-High cooling water temperature in cooler system ----Adjust.
High at
-Insufficient cooling water quantity
cylinder

i
collective Defective cooling water pump --------------------MaintenancelRepair.
outlet (e.g. damagedworn impeller)
High Clogged filterlcooling water piping -.-----------Clean.
cooling - Improperly regulated water quantity .----.--.. Adjust.
water -Defective cooling water temperature control valve - - - - - - MaintenanceIRepair.
temperature -Overload load,
High at
some Overheating of cylinders
cylinders
t
Clogged cooling water channel .--.-.-.--..------Clean.
Seizing of piston and cylinder liners - - - - - - - - - - Repair.

exhaust (m:7-2.4)
temerature
 -, s.

Troubleshooting and Countermeasures

"'"
Memo DK-20
 I Regarding replacement parts for Daihatsu Diesel engine
Hazards and nonconformities of imitation parts
<Use of imitation parts causes accidents.>
1. Recent engines have compact bodies and high power, and are designed to prevent fuel deterioration
and to reduce NOx discharge. Even if imitation parts are similar in shape to the genuine parts, the
use of imitation parts will degrade the engine performance because of their fragile materials and low
machining accuracy. Since the service life of such parts is short, the engine must be maintained more
frequently.
2. It imitation parts are used for the engines designed in accordance with MARPOL VI, the certificate
(EIAPP) may lose its validity, and operation of the engine may be inhibited.
3. If you use imitation parts, you will not be supplied with parts improved in quality and performance.
4. If imitation parts are used, it may be difficult to make insurance claims for the engine when any
accident occurs.
5. We take no responsibility for the engine in which imitation parts are used

Daihatsu Diesel supplies reliable engines.

Use genuine parts to operate your engine safely.

1 I n a u l and
~ Order I
Order ;Parts sales ........................................
Daihatsu D i e s e l P a r t s Sewice Co.,Lld.
12-34, Tanakacho. Ibaraki. Osaka, 567-0025 lapan
TEL:81-72-621-3482 FAX:81-72-621-3484

lnqulry ;Service Department ..-..-..-----.-

DAIHATSU DIESEL MFO.CO.,LTD. Osaka Head Offlce.
1 3 0 , Oyodo Nakalchome, Kita-ku, Osaka, 531-0076 Japan
TEL:81-6-6454-2346 FAX:81-6-6454-2680-1

Or, get in touch with our offices listed below.

DAIHATSU DIESEL MFG.CO.,LTD.O

Osaka Head Offlce. 1-30. Oyodo Nakal%horne. Kila-ku. Osaka. 531-0076 Japan
TEL:816-6454.2393 FAX:81-6.6454-2686
Morlyama Factory. 45 Amura-cho.Moriyarna-city.Shiga.5240035Japan
TEL:81-77-5B3-2551 FAX:81-77-582-5714
Tokyo Offlce. 2-10,2€horne, Nihonbashi-Honcho.Chuo-ku.Tokyo,1033W23Japan
TEL:81-3-3279-0627 FAX:81-3-3245-0395
Sydney Otflce, P.O.Box 519. North Sydney N.S.W.2060 Australia
TEL:61-2.9923-1155 FAX:61-2-9923-1532
~ ~ - ~ - ~ ~~ ~ ~

Jakarta Offlce. 16th Floor,Msma Antara Bldg.. JI. Medan Merdeka.Selatan No.17.Jakarta-Pusat.lndonesia
TEL:62.21-384-8411 FAX:62-21-384-8412
Manlla Offlce. Un I1010 Herrera T o ~ e Hemra
r
TEL 632.753-321 1 632-817-127911285FAX 63-2.845-0691
.
Corner Va ero Sts Salcedo Vllage. Makat~CRy 1226 Pn Ippines

Talwan Offlce.
Dalhatsu Dlesel (Europe) Ltd.
Dalhalsu Dlesel (AMERICA), lnc.
Dalhatsu Dlesel (ASIA PACIFIC) PIe.Ltd. 128 Pioneer Road Singapore 639586
Dalhatsu Dlesel (SHANGHAI) Co..Lld.
Dalhntsu Dlesel Pam Servloe Co.,Ltd.
No.14 Tai-Tang RD. Lin-Hai Industrial Zone. Kaohsiung. 812 Taiwan
(do Marine Technical lnduslries CO., Ltd.) TEL:BB6-7-803-1082 FAX:886-7-801-9179
71n F m r . Pcn n s ar
~ House.36 Monument S1reet.London ECJR BW. U K
TEL:44-20-7626-4600FAX:&-20-7626.6020
180 Adams Avenue,Hauppauge.NY 117BB.U.S.A.
TEL:l-631-434.87871819 FAX:1-631-434-8759
TEL:65-6270-7235 FAX:65-6270-6236
Suile 3004 Nan Zheng Building 580 Nan Jing West Road Shanghai. China
TEL:86.21-5234-1228-9 FAX:86-21.5234-1062
12.34, Tanaka-cho, Ibaraki. Osaka, 567-0025 Japan
TEL:81.72.621-3482 FAX:81-72-621-3484
 DK-20 INSTRUCTION MANUAL (MAINTENANCE)

.:<~&\:....
S<.&?%<<

CHAPTER 1 EQUIPMENT ARRANGEMENT AND MAINTENANCE SCHEDULE $@:

sn&*:

%?..,.*"
>yQ
<. . .:
CHAPTER 3 CYLINDER HEAD AND VALVES $$;p
$C';<n?:r

&+*:,:*::
;. ps?.
CHAPTER 4 PISTON AND CONNECTING ROD .gk
,.:..,
r,
,..,
f"u
L*. .$
.,."$L.<.i
".<',

CHAPTER 5 ENGINE FRAME AND CYLINDER LINER

CHAPTER 6 MAIN BEARING AND THRUST BEARING

CHAPTER 7 CRANKSHAFT AND BALANCER SHAFT &:$; ii YCil

,....,- >.;.*,, :

....i",i-.
CHAPTER 8 TIMING GEAR AND CAMSHAFT )I
,,
,I.;_:
<.* r.
>i;,@:,
. ..

,.>!., . .
.,:.,.?: ,, ,
:> ,~
..,A- 2
i'&!*
CHAPTER 9 FUEL OIL INJECTION DEVICE :.: ... ~.
:,_.:,_..
., :.....
.,, *,,
. * ., ,
,
:: ..y;
CHAPTER 10 VALVE OPERATING DEVICE ::..<:<;
, : >,

CHAPTER 11 GOVERNOR DRIVING DEVICE

CHAPTER 12 INTAKE AND EXHAUST DEVICE

;?
*a, $<.*
CHAPTER 13 STARTING AIR SYSTEM :,a -::*
..,..,.

CHAPTER 14 FUEL OIL SYSTEM

% <. .,.,
55 ,.
.,.....
$*<
.
CHAPTER 15 LUBRICATING OIL SYSTEM .:x
>.,"
,~
?.
,,
:s,.*
.., . :.,.:..<
", .,:
,...
. .. .
:; <. . . :

CHAPTER 16 COOLING WATER SYSTEM

CHAPTER 17 ENGINE CONTROL AND PROTECTIVE DEVlC

CHAPTER 18 GAUGE BOARD

 . .

ITEM
CONTENTS DK-20
(J .lNTRODUCTlON ......................................................... 0
1. Prior to Start of Engine Maintenance ...................................... 0.1
2. Precautions Pertaining to Maintenance: Safety Precautions . . . . . . . . . . . . . . . . 0 .2
2. 1 Safety Precautions ................................................... 0 .2 1 .
2 . 2 Precautions for Disassembly, Maintenance. and Assembly ............. 0 -2.2
.
2 . 3 Check Items after Disassembly Maintenance. and Assembly . . . . . . . . . . 0.2.3
3. Engine Conforming to NOx Technical Code ................................ 0 .3
3. 1 Outline ............................................................... 0 - 3 . 1
3. 2 The Parts to be Specified ............................................. 0.3.2
3. 3 Engine Settings Value ................................................ 0.3.3

.
1 EQUIPMENT ARRANGEMENT AND MAINTENANCE SCHEDULE ... I
1. Equipment Arrangement ..................................................1 - 1
2. Maintenance Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .2

.
2 GENERAL MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Preparation before Maintenance Work ....................................
2. General Consurnables and Materials. General Tools.
Implements. and Measuring Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. 1 General Consumables and Materials ..................................
2 . 2 General Tools. Implements and Measuring Instruments . . . . . . . . . . . . . . . .
3. Bolt and Nut Tightening Torque. Tightening Oil Pressure . . . . . . . . . . . . . . . . . . .
4. HydraulicJack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 1 General Construction . . . . . . . . . . . . . . . . . . ;. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 . 2 Removalof Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Tighteningofnut ......................................................
4. 4 Maintenance of Hydraulic Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. CylinderHead ............................................................ 3 - 1
1. 1 General Construction ................................................. 3 - 1 . 1
1 . 2 Replacing Consumables. Implements and Measuring Instruments ...... 3 .1 . 2
1. 3 Removal of Cylinder Head ............................................ 3 - 1 . 3
1. 4 Inspection and Maintenance of Cylinder Head (Body) . . . . . . . . . . . . . . . . . . 3 .1 . 4
1. 5 Intake and Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .1 . 5
1. 6 Intake and Exhaust Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 . 6
1. 7 Mounting of Cylinder Head ............................................ 3 - 1 . 7
2. Intake and Exhaust Valves ................................................ 3 .2
2. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .2 . 1
2 . 2 Replacing Consumables. Implements and Measuring Instruments ....... 3 .2 . 2
ITEM
DK-20 CONTENTS

2.3 Disassemblyof IntakeandExhaustValves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3

2 . 4 Inspection and Maintenance of Intake and Exhaust Valves . . . . . . . . . . . . . 3 .2.4
2 . 5 Inspection and Maintenance of Valve Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .2 . 5
2. 6 Assembly of Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .2 . 6
3. StartingValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3. 1 General Construction ................................................. 3.3 . 1
3 . 2 Replacing Consumables. Implements and Measuring Instruments . . . . . . 3 . 3 . 2
3. 3 Disassembly of Starting Valve ......................................... 3 .3 . 3
3 . 4 Inspection and Maintenance of Starting Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3 .3 . 4
3. 5 Assembly of Starting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .3. 5
4. Rocker Arm Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .4
4. 1 General Construction ................................................. 3 .4 . 1
4 . 2 Replacing Consumables. Implements and Measuring Instruments ...... 3 . 4 . 2
4 . 3 Disassembly of Rocker Arm Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .4 . 3
4 . 4 Inspection and Maintenance of Rocker Arm Device . . . . . . . . . . . . . . . . . . . . 3 .4 . 4
4. 5 Assembly of Rocker Arm Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .4 . 5
5. Indicator and Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
5. 1 General Construction ................................................. 3 .5. 1
5. 2 Replacing Consumables, Implements and Measuring Instruments . . . . . . 3 .5 . 2
Disassembly of Indicator and Safety Valve ............................3 .5 . 3
5. 3
5. 4
Inspection and Maintenance of Indicator and Safety Valve . . . . . . . . . . . . . 3 . 5 . 4
5. 5
Assembly and Adjustment of Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .5 . 5
5. 6
Assembly and Mounting of Indicator and Safety Valve . . . . . . . . . . . . . . . . . 3 .5 . 6
0 Fuel Oil Injection Valve ( a
: "Operation" 5-4.2)
6. Nozzle Holder Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
6 . 1 Extraction of the nozzle holder guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .6 . 1
6 . 2 Cooling of the nozzle holder guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .6 . 2
6 . 3 Fitting of the nozzle holder guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .6 . 3

4 . PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 . Replacing Consumables. Implements and Measuring Instruments .........
3 . Disassembly of Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. 1 Extraction of Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 . 2 Disassembly of Connecting Rod Large end Part . . . . . . . . . . . . . . . . . . . . . . .
4 . Inspection and Maintenance of Piston and Connecting Rod ................
4 . 1 Inspection and Maintenance of Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 . 2 Inspection and Maintenance of Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 3 Inspection and Maintenance of Connecting Rod . . . . . . . . . . . . . . . . . . . . . . .
4 . 4 Inspection and Maintenance of Crank Pin Shell ........................
4 . 5 Replacement of Connecting Rod Bolt ..................................
 ITEM
CONTENTS DK-20

5 . Assembly of Pistonandconnecting Rod .................................. 4 - 5

5. 1 AssernblyofConnecting RodLargeEnd Part . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1
5. 2 Assembly of Pistonandconnecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2
5. 3 Confirmation and Retightening of Connecting Rod Bolt ................. 4 .5 . 3

5. ENGINE FRAME AND CYLINDER LINER .............................. 5

1. General Construction ................................. : ..............-.... 5 .1
2. Replacing Consumables. Implements and Measuring Instruments ......... 5 - 2
3. Inspection and Maintenance of Cylinder Liner Inner Surface . . . . . . . . . . . . . . . 5 .3
4. Extraction of Cylinder Liner ............................................... 5 - 4
5. lnspection and Maintenance of Cylinder Liner Outer Periphery and
Engine Frame Jacket ..................................................... 5 .5
6. Mounting of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 .6

.
6 MAIN BEARING AND THRUST BEARING ..............................
1. General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Replacing Consumables. Implements and Measuring Instruments ..........
3. Main Bearing Shell .......................................................
3 .1 Disassembly of Main Bearing Shell ....................................
-
3. 2 Inspection and Maintenance of Main Bearing Shell .....................
3. 3 Assembly of Main Bearing Shell .......................................
4 . Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 1 Disassembly of Thrust Bearing .........................................
4 .2 Maintenance of Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Assembly of Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. CRANKSHAFT AND BALANCER SHAFT ............................... 7

1. crankshaft ...............................................................7 - 1
1.1 General Construction ..................................................7 .1 . 1
1.2 Replacing Consumables, Implements. and Measuring Instruments ...... 7 - 1 .2
1.3 Inspection andMaintenanceof Crankshaft ............................. 7 - 1 .3
1.4 Inspection of Balance Weight Bolt Tightening Force .................... 7 .1 . 4
1.5 Measurement of Crankshaft Deflection ................................. 7 - 1 .5
.
2 Balancershaft ........................................................... 7-2
2.1 General Construction .................................................. 7 .2 . 1
2.2 Replacing Consumables, Implements, and Measuring Instruments ...... 7 .2 . 2
2.3 Inspection and Maintenance of Balancer Shaft ......................... 7 .2 . 3
ITEM
DK-20 CONTENTS

8.TIMING GEAR AND CAMSHAFT ........................................ 8

1. Timing Gear .............................................................. 8-1
1.1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1.1
1.2 Replacing Consumables, Implements, and Measuring Instruments . . . . . . 8 - 1 . 2
1.3 Disassembly of Idle Gear .............................................. 8 - 1 . 3
1.4 Inspection and Maintenance of Timing Gear ............................ 8 - 1 . 4
1.5 Assembly of Idle Gear .................................................8 - 1 . 5
2. Camshafi .................................................................8 - 2
2. 1 General Construction.................................................. 8 2.1 -
2 . 2 Replacing Consumables, Implements, and Measuring Instruments . . . . 8 - 2.2
2. 3 Disassembly of Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.3
2.4 InspectionandMaintenanceofCamshafi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2.4
2 . 5 Assembly of Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2 . 5
2 . 6 Inspection of Fuel Oil Cam Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.6
2. 7 Adjustment of Fuel Oil Cam Timing (When replacing cam) . . . . . . . . . . . . . . 8 -2.7

9. F.0. INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 .1
2 . Replacing Consumables. Implements and Measuring Instruments .......... 9 .2
3 . Disassembly of F.0. Injection Pump ....................................... 9.3
4 . F.0. Injection Pump ...................................................... 9-4
4 . 1 Disassembly of F.0. Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4- . 1
4 . 2 Inspection and Maintenance of F.O. Injection Pump . . . . . . . . . . . . . . . . . . . . 9 .4 . 2
4 . 3 Assembly of F.0. Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.3
5. Mounting of F.0. Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

10. VALVE OPERATING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

1. General Construction .....................................................1 0 .1
2. Replacing Consumables. Implements and Measuring Instruments .......... 1 0 .2
3. DisassemblyofValveOperatingDevice ...................................1 0 - 3
4 . Inspection and Maintenance of Valve Operating Device ....................1 0 .4
5 . AssemblyandFittingofValveOperatingDevice . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 5

.
11 GOVERNOR DRIVING DEVICE ....................................... 1 1
1. General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 .1
2 . Replacing Consumables. Implements and Measuring Instruments ......... 1 1 .2
3. Disassembly of Governor Driving Device ..................................1 1 .3
4 . Inspection and Maintenance of Governor Driving Device ................... 1 1 .4
5. Assembly of Governor Driving Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 .5
 ITEM
CONTENTS DK-20 .

.
12 INTAKE AND EXHAUST DEVICE ...................................... 1 2
1. Outline of Intake and Exhaust Device ..................................... 1 2 .1
2. Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 - 2
3. Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 - 3
3.1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . 3 . 1
3. 2 Replacing Consumables, Implements and Measuring Instruments . . . . . . 1 2 .3 . 2
.
3 3 Dismounting of Air Cooler ............................................. 1 2 .3 . 3
3.4 Inspection and Maintenance of Air Cooler ............................. 1 2 .3 . 4
3. 5 Mounting of Air Cooler ................................................ 1 2 .3 . 5

13. STARTING AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Outline of Starting Air System ............................................. 1 3 .1
2. Starting Airvalve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 - 2
2. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 .2 . f
2 . 2 Replacing Consumables. Implements. and Measuring Instruments . . . . . 1 3 .2.2
2 . 3 Disassembly of Starting Valve ......................................... 1 3 .2 . 3
2. 4 Inspection and Maintenance of Starting Air Valve. . . . . . . . . . . . . . . . . . . . . . . 13 .2.4
2 . 5 Assembly of Starting Air Valve ........................................ 13 .2.5
3. Starting Air RotaryValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
3 . 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 .3 . 1
3 . 2 Replacing Consumables, Implements and Measuring Instruments . . . . . . 1 3 .3.2
3 . 3 DisassemblyofStartingAirRotaryValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3.3
3 . 4 Inspection and Maintenance of Starting Air Rotary Valve . . . . . . . . . . . . . . . 1 3 .3 . 4
3 . 5 Assembly of Starting Air Rotary Valve .................................. 1 3 .3 . 5
4 . Starting Operation Valve and Handle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 .4

14.FUELOILSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4
1. Outline of Fuel Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 .1
2. Fuel Oil Relief Valve ..................................................... 1 4 .2
2. 1 General Construction ................................................. 1 .2.4 1
2. 2 Replacing Consumables, Implements and Measuring Instruments . . . . . . 1 4 .2.2
2. 3 Disassembly of Fuel Oil Relief Valve ..................................14.2.3
2 . 4 Inspection and Maintenance of Fuel Oil Relief Valve . . . . . . . . . . . . . . . . . . . 1 4 - 2 . 4
2. 5 Assembly of Fuel Oil Relief Valve ..................................... 1 4 .2 . 5
3. Fuel Oil Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 3
3. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . 3 . 1
3. 2 Replacing Consumables, Implements, and Measuring Instruments ..... 1 4 .3.2
3 . 3 Dismounting of Fuel Oil Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 .3 . 3
3. 4 Disassembly of Fuel Oil Feed Pump ................................... 1 4 .3.4
3 . 5 lnspectionandMaintenanceofFuelOilFeedPump .................... 14.3.5
3 . 6 Assembly of Fuel Oil Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 .3 . 6
.-
ITEM
DK-20 CONTENTS

4. Fuel Oil Feed Pump Driving Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-4

4.1 DisassemblyofFuelOilFeedPumpDrivingDevice.~.. . . . . . . . . . . . . . . . . 14-4.1
4. 2 Maintenance and Assembly of Fuel Oil Feed Pump Drive Device . . . . . . 1 4 -4.2
0 Fuel Oil Filter ( m:"Operation" 5-4.3)
.
15 LUBRICATING OIL SYSTEM ........................................... 15
1. Outline of Lubricating Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-1
2. Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 .2
2. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 .2 . 1
2. 2 Replacing Consumables, Implements and Measuring Instruments . . . . . . 15 .2.2
2. 3 Disassembly of Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 .2.3
2. 4 Inspection and Maintenance of Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . 15 .2.4
2.5 Assembly of Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 .2.5
3. Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
3.1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 .3 . 1
3. 2 Replacing Consumables, Implements and Measuring Instruments . . . . . . 1 5 .3 . 2
3. 3 Inspection and Maintenance of Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . 1 5 .3.3
3.4 Assembly of Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 .3.4
4. Lubricating Oil Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
4. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 .4.1
4. 2 Replacing Consumables, Implements, and Measuring Instruments . . . . . 15 .4.2
4.3 DisassemblyofLubricatingOilReliefValve.. . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4.3
4. 4 Inspection and Maintenance of Lubricating Oil Relief Valve . . . . . . . . . . . . . 1 5 .4.4
4. 5 Assembly of Lubricating Oil Relief Valve .............................. 1 5 .4.5
5. LubricatingOilTemperatureControlValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .5.
5 1
Replacing Consumables. Implements. and Measuring Instruments . . . . . 1 5 .5.2
Disassembly of Lubricating Oil Temperature Control Valve . . . . . . . . . . . . . 15 .5.3
lnspection and Maintenance of Lubricating Oil Temperature Control Valve .. 1 5 .5.4
Assembly of Lubricating Oil Temperature Control Valve ................15 .5.5
0 Fuel Oil Injection Valve ( : "Operation" 5-4.2)

.
16 COOLING WATER SYSTEM ........................................... 16
1. Outline of Cooling Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
2. Coolingwater ............................................................ 16.2
2.1 Generalconstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.1
2. 2 Replacing Consumables. Implements and Measuring Instruments . . . . . . 1 6 .2.2
2. 3 Disassembly of Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 .2.3
2. 4 Inspection and Maintenance of Cooling Water Pump . . . . . . . . . . . . . . . . . . . 1 6 .2.4
2. 5 Assembly of Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 .2.5
 CONTENTS DK-20

3 . CoolingWaterTemperatureControlValve ................................. 1 6 - 3
3. 1 General Construction ................................................. 1 6 .3. 1
.
3. 2 Replacing Consumables Implements, and Measuring Instruments . . . . . 1 6 .3.2
-
3 . 3 Disassembly of Cooling Water Temperature Control Valve . . . . . . . . . . . . . 1 6 3 . 3
3. 4 Inspection and Maintenance of Cooling Water Temperature Control Valve .. 1 6 - 3 . 4
3. 5 Assembly of Cooling Water Temperature Control Valve ................ 1 6 .3 . 5

17. ENGINE CONTROL AND PROTECTIVE DEVICE ..................... 1 7

1. Outline of Engine Control and Protective Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 .1
2. Fuel Oil Shutdown Device (GI Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 .2
2. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 .2. 1
2. 2 Replacing Consumables, Implements, and Measuring Instruments . . . . . 17 .2 . 2
2. 3 Disassembly of Fuel Oil Shutdown Device (GI Type) . . . . . . . . . . . . . . . . . . 1 7 .2 . 3
2. 4 Inspection, Maintenance. and Assembly of Fuel oil Shutdown Device (GI Type) . . 1 7 .2 . 4
2 . 5 Mounting and Adjustment of Fuel Oil Shutdown Device ( G I Type) ...... 1 7 .2.5
3 . Fuel Oil Shutdown Device (J2 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 .3
3. 1 General Construction ................................................. 1 7 - 3. 1
3. 2 Replacing Consumables. Implements, and Measuring Instruments ..... 1 7 .3 . 2
3. 3 Disassembly. Maintenance. and Assembly of Fuel Oil Shutdown Device (J2 Type) . . 1 7 .3 . 3
3. 4 Mounting and Adjustment of Fuel Oil Shutdown Device (J2 Type) . . . . . . 1 7 - 3 . 4

18.GAUGE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8
1. Gauge Board .............................................................. 1 8 . 1
1. 1 General Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 - 1 . 1
.
1 2 Replacing Consumables, Implements, and Measuring Instruments . . . . 1 8 .1 . 2
.
1 3 Disassembly and Maintenance of Gauge Board . . . . . . . . . . . . . . . . . . . . . . . 1 8 .1 . 3
2 . Seal Pot (Heavy Fuel Oil Specification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 .2
 lntroduction
-
Prior to Start of Engine Maintenance DK-20

0. Introduction
0-1 Prior to Start of Engine Maintenance

Before the maintenance work i s performed, please read this Manual sufficiently, fully
understand the structure of the parts concerned, and understand well the contents of the
work i n advance, and fully understand the working procedure and then start the work.
Execution of the work without sufficient advance understanding will not only result i n
spending useless labors but also lead to the troubles and damages of the engine due t o
wrong assembly, and personal accidents as well.
Strictly avoid use of the engine for a purpose other than the original purpose of the use of
engine, or o n the conditions that are different from the specified conditions or handling
against the descriptions given herein, since such operation will cause accidents or troubles.
Please be advised that the descriptions of this manual may be changed without notice.

(1) This manual bears the lollowing safety signs.

These symbol marks indicate the important descriptions concerning safety. Be fully careful, and conduct
the work with the motto of "Safety First".
@ ..,"Warning"= Precaution related to the safety of personnel (Potential hazard which could result in death
or serious injury)
A 1 ..."CautionM=Precaution related to the safety of personnel (Potential hazard which may result in minor
or moderate injury)
A ..."Noticeu= Information on handling of the engine to prevent damage
@ ..."
- ..."
0
Prohibitionv= Prohibited practice that can affect the safety of personnel and the engine

Obligatory actsM=Recommended practice or instruction

.. to be followed to ensure safety of personnel
and the engine

(2) If it is found as a result of disassembly or inspection that parts are damaged or end of their service life is
reached, be sure to replace such parts.
(3) For replacement, be sure to use our genuine parts or those specified by us. If the parts used for
replacement are other than our genuine parts or those specified by us, we shall not be held responsible for
their quality.
(4) When it is difficult to take countermeasures or corrective actions at the site, or the required replacing parts
are not prepared, please contact our Service Deparlment, Parts Sales Department, branch office or service
agent to take appropriate actions.
At that time, be sure to inform us or our agent ol the engine type and the engine number.
(5) For handling of the following equipment, refer to the individual lnstruction Manuals attached separately.
a Turbocharger @ Governor @Air motor
@ Control equipment @ Ancillaly equipment of special specifications
(6) Keep this Instruction Manual and the related documents (drawings, materials, etc.) in the specified place
at all times for ready reference by the persons engaged in the operation and maintenance of engine a t any
time, and at the same time, when the engine supervisor is changed, the predecessor is requested to
transfer his duties to the successor completely.
(7) To Prevent public pollution, do not dispose of the replaced scrapped parts or waste liquid without
Permission but entrust the disposition to an authorized professional disposal company.
 Introduction

Precautions Pertaining to Maintenance: Safety Preca~tioIls

0-2 Precautions Pertaining to Maintenance

0-2.1 Safety Precautions
@ (1) Afler stop of the engine, do not open the crankcase side cover for at least 10 minutes, until the
engine cools down sufficiently. If fresh air should flow into the engine, while the engine is not
cooled down, explosion may occur igniting on the oil mist.
@ (2) Re"qlution of the engine during the disassembly or inspection work will cause great hazards such
as mjury resultmg from entanglement.
Before starting the disassembly or inspection work, put the control handle position back to the
"STOP position, securely close the valves on the starting-air system, extract starting air on the
engine side, and confirm that the engine will not revolve.

. Be sure to turn OFF the control power.

When turning the engine, be sure to check that the rotary section is free from contact with other
sections, and that turning of the engine does not bring about hazards to the co-workers or per-
sons in vicinity, and conduct turning with signs exchanged between the workers.
When moving sections of the engine is disassembled or inspected, take the measures to pre-
vent the crankshafl from idle turning.
The turning bar should be removed from the flywheel except when the engine is turned.
(3) Before executing the work, wear protection gears such as gloves, hard hat, safety shoes, and
safety goggles depending on the applicable situations.
o While the engine is operating, and just afler the engine is stopped, particularly the exhaust
pipe, turbocharger, cylinder heads and parts around them are hot. When servicing them, wear
safety gloves to avoid bums.
(4) The engine room floor and the surroundings are slippery as a result ofthe deposit of oil. Wipe off
oil on the floor and the shoe soles. When the work is intended at a high place such as on a step
board, particularly be careful of your footing to prevent falling accidents.
(5) When disassembling each pipeline, set all the valves in the external connections to the "CLOSE
position, and gradually loosen the air vent plug to release the remaining pressure in advance. If
each filter and the joint area of piping system are disassembled immediately afler the engine is
stopped, high-temperature oil or water may spout out under residual pressure, and may cause
burn accidents.
Contact of the splashing hot oil with any high-temperature part may cause a fire. Take utmost
care not to splash the oil.

(6) When the spring-incorporated valves or devices are disassembled, conduct the assembly work
very carefully, since the spring may jump out to cause an injury to the worker.
A (7) Do not lit heavy parts and equipment forcibly with physical strength. Use wire ropes and chain
blocks to lit them. Also do not walk up to under lifled things.
,

Concerning the wire ropes used to lifl the parts, select a normal one free from break or twist of the
element wire, and of the specified dimensions conforming to the applicable weight.
6 (8) p e n inspecting and disassembling an electrical product, be sure to turn OFF the POWER
swttch, and put up a sign of "Under Construction".
6"
(9) When handling a liquid, strictly observe the following instructions:
Fuel oil, lubricating oil: Inflammable . . . . . . . .Naked flames are strictly prohibited.
Fresh water corrosion inhibitor, fresh water anti-freeze, mercury (thermometer) = Poisonous

- . . . . . . . . Drinking is prohibited. Wash away, if deposited on the skin.

Battery electrolyte = Poisonous . . .Drinking is prohibited. Wash away, if deposited on the skin.
Naked flames strictly prohibited.
0 For the sake of preventing pollution, entrust a special waste ddisposal company with the task of dis-
posing the used waste liquid and oil.
 Introduction

I I DK-20 1 2.2.2.3 1
I I EM
Precautions Pertaining to Maintenance: Precautions and
Confirmation of Disassemblv. Maintenance. and Assemblv

0-2.2 Precautions for Disassembly, Maintenance, and Assembly

:=$
' "
(IPrepare
) the replacing parts, tools and measuring instruments in advance. As forthe tools, be minded
to use those specified, and concerning the replacing parts, use our genuine parts or those specified by
US.

(2) Gaskets. O-rings, split pins and wire ring wires must be replaced with the new parts afler every disas-
sembly. Prepare the new parts according to the extent of disassembly.

(3) Block the openings resulting from disassembly with tape or clean cloth to prevent infiltration of foreign
matters.
Afler restoration, be sure to remove such tape or cloth.

(4) Place disassembled parts in neat order for prevention of the damage or loss, and for improvement o f
the assembly working efficiency.

(5) Be sure to assemble the parts provided with the assembling position marks or matchmarks, such as the
cylinder numbers and the bearing numbers, to their original positions.
Further, when these parts are replaced, be sure to provide the new parts with the same marks as those
provided on the old parts.

(6) Materials of the bolts and nuts used in high-temperature sections such as the exhaust manifold are
heat-resistant. When reassembling the engine, therefore, be careful not to confuse them with ordinary
bolts and nuts.

(7) Tighten each of the bolts and nuts uniformly with the specified torque (or specified oil pressure).
If it is necessary to apply an agent, such as a lubricant, to the bolts and nuts when tightening them,
never use an agent other than the specified ones.

(8) When parts are required to be measured during maintenance, perform the measurement correctly, and
arrange the results of the measurement as the data for the reference on later days.

(9) Afler the completion of the work, restore the lagging of the exhaust pipe and the turbocharger, the
exhaust pipe cover and the parts shielding heated parts, such as the heat box, if they have been
removed for disassembly and servicing. Newly treat the disconnected joints with combustible oil splash
preventive means (FN tape) afler the completion of the work.

(10) Be minded to promptly replenish all the used spare parts

0-2.3 Check Items after Disassembly, Maintenance, and Assembly

( I ) Check that all the bolts and nuts are free from loosening, and that specified lock washers are inselled
securely. Particularly be careful when checking the inside of the engine where visual inspection is
impracticable during operation.

(2) Turn the engine and prime each fluid to check that there is no problems such as interference of the
working area, and leakage or clogging of each area .
(3) Afler end of the work, check that the flywheel turning device and the turning bar used are in "disen-
gaged" position
(4) Record the contents of the work executed and parts replaced in the Engine Diary.
 -
Introduction

0-3. Engine Conforming to NOx Technical Code

0-3.1 Outline
(1) The marine diesel engines, to which the 13th rule "Nitrogen Oxides (NOx)" in Supplement VI "Rules to
Prevent Air Pollution by Ships" to MARPOL73nfJ Treaty applies should, conform to NOx Technical Code.

(2) The engines conforming to NOx Technical Code are authorized as an engine group or an engine family,
and it is allowed to apply the engine parameter check method to them, when receiving the NOx discharge
inspection on board.

The engine parameter check method is a method for verifying that the engine components and setting
values conform to the requirements specified in the technical file, and does not require the measurement of
NOx discharge. To the engines that are not conforming to the requirements of the technical file, the engine
parameter check method cannot be applied. For such engines, the measurement of NOx discharge shall be
required.

0-3.2 The parts to be Specified

The technical file states the engine components that can affect the NOx discharge specified in NOx Technical
Code, and shows the identification marks stamped on them, and the user is required to maintain the technical
file for each engine. When replacing any parts shown in the technical file, be sure to use our genuine parts
stamped with the identification marks. In the case that any parls without the identification mark is used, it
shall be regarded as nonconformance to the requirements of the technical file, and in such a case, inspection
b y the engine parameter check method cannot be applied.

The followings are the pads that have the identification marks specified in the technical file. When replacing
(a:
any of these parts, be sure to check the identification marks. "Technical File")

<Parts with identification marks>

a Cylinder head
@ Piston
@ Turbocharger
@ Air cooler
@ Fuel oil cam
@ Fuel oil injection pump
a Fuel oil injection pump plunger
@ Fuel oil injection valve
@ Fuel oil injection valve nozzle
 ./ -
Introduction
Engine Conforming to NOx Technical Code:
OutlinelParts to be Specified

0-3.3 Engine Setting Value

The engines conforming to NOx Technical Code are adjusted to conform to the specifications before
shipment. After shipment, they should not be adjusted to such a manner that the setting values specified in
the technical file may be deviated.
If any change is made in the manner that may deviate from the settings specified in the technical file, it shall
be considered to be nonconformance to the requirements of the technical file, and the inspection by the
engine parameter check method cannot be applied.

The followings are the items that have been set to conform to NOx Technical Code:

<Items set before shipment>

(1) Fuel oil injection timing
(2) Fuel oil injection valve opening pressure
 .

Equipment Arrangement and Maintenance Schedule

DK-20 Equipment Arrangement

1. Equipment Arrangement and Maintenance Schedule

1-1 Equipment Arrangement

,Rocker arm device

.Rocker arm device

Intake and exhaust

valves

Cylinder head
Fuel oil nozzle
Starting valve
Indicator safety
valve
Fuel oil injection
pump

Valve operaling
device

Cam shalt

Engine lrarne
 -3%$
Equipment Arrangement and Maintenance Schedule

I Equipment Arrangement ,
ITEM
1

Lubricating oil pump Cooling water

pump

gni t O
;, lever

GOveTr

, I I
Starting air valve Starting operating valve Fuel oil reliel valve

7
(Note) Equipment arrangement may b e dilferent according t o specifications.
 Equipment Arrangement and Maintenance Schedule

DK-20 Maintenance Schedule Table

1-2 Maintenance Schedule Table

This table covers the periodic disassembly and maintenance items of the engine. For the items related with
routine maintenance and inspection, refer to a separate volume. ( m:
"Operation")
(0 : Periodical inspection, A : The 1st inspection after the initial operation, and after overhaul and
maintenance, 0: Replacement.)
erhaul and maintenance period (hi
Overhaul and Work - -
man-hour I00 000
maintenance Work contents NO. Of I I
ponion norkersX ioo 000
Hours ith5 nth:
- -
Cylinder head :hecking and retightening cylinder head bol *2X0.2 A
herhaul of cylinder head (top hole) *2X1.0

>Cylinder head inspection and cleaning *1X1.5

I Intake and exhausl valve disassembly. *1X2.0
inspection and lacing-up
2 Valve rotator disassembly and inspeclio~ *tXl.O A

>Valve spring and coher inspeclion * 1XO.25 A

3 Starling valve disassembly and inspecti01 *lX1.0

2 Rocker a n disassembly and inspection *lXl.O

0 Indicator and safely valve disassembly *1X1.5
and inspection
0 Exhaust valve seat and O-ring *1X2.0
replacemenl
0 Jacket opening for removal of scale *1Xt.O
- -
Piston W o n extraction (including connecling roc *2Xl.O
mall end pan)
OPislon inspection. cleaning and measurement * lXO.5
0 Piston ring replacement *I
XO.5
0 Piston pin inspection and measurement * 1 X0.25
0 Piston pin bush inspection
-
* 1X0.25 - -
Connecting rod 2onnecllng md boll lnspecl~onand rellghienlng *2Xt.O A
Crankpin bearing overhaul inspection. t2X1.5
and bearing shell replacemenl
0 Crankpin inspection and measurement *1XO.5

o Connecting rod bcn inspection and replaceme *2Xt.O

- -
Protection ring Eairaclion, inspection, cleaning and measureme1 * 1XO.25
Cylinder liner Cylinder liner inner surface inspection and *lXl.O
measurement
Cylinder liner extraction *2X2.0
0 Inspeclion on jacket side and replacement *lXI.O
of O-ring
- -
Main bearing Main bearing bolt tightening check
Disassembly and inspeclion of main
bearing8eplacement of bearing shell
Equipment Arrangement and Maintenance Schedule

Maintenance Schedule Table DK-20

4"
-- ~p

and
Overhaul and -
No. of
maintenance Work conlenls
portion
Hours

?rankshall Delleclion measuremenl 2X1.0

Balance weight boll Ughlening check

0 Wiring inspeclion 1 XO.5

0 Inspection by torque wrench 2X3.0

Balancer shah Replacement of aulomalic core-adjuslingbearing 2 x 1.5

Timing gear Tighlening boll check and relighlening 1X1.5

Gear loolh conlacl and backlash inspeclion 1 X 1.0

Idle gear overhaul and bush inspection and 1 X 1.5

measuremenl

Camshatt Cam gear disassembly, inspeclion, and

measuremenl I 3X2.0

bearing disassembly, inspection, 2 x 1.0

and measuremenl
Cam gear I Cam gear disassembly and inspection / 1 X 1.0

Fuel oil injeclion Injection liming check *2X1.0

pump
lnjeclion pump disassembly and inspeclion * 1 X2.0
0 Delleclor inspeclion and replacement

0 Plunger assembly and delivery valve

replacemenl

0 Sprinq and sprinq seal replacemenl

I
!parale 'Operatior
molurne
Valve operaling Swing arm disassembly, roller and bush * l x 1.0
device inspection
*Governor I Disassembly and inspeclion
Governor driving
dence 1 Disassembly. inspeclion and cleaning 1 1X2.0

*Turbocharger I Disassembly, inspection and cleaninq I

Air cooler Disassembly, inspeclion, cleaning and
hydrostatic lesl
2x30 d--
'olurne manual

S l a r h g air valve I Disassembly, inspeclion and O-ringreplacemenl 1X2.0

SlarIing air rolary Disassembly and inspeclion 1X1.5

valve

Disassembly mspeclmn. and clean ng

I
Fuel Oil feed pump Disassembly and inspection, bearing 1X 2 . 0
inspection and replacemenl
Lubricaling oil
pump
I Disassembly, inspeclion and cleaning I 2 X 1.5

0 Bearing oil seal inspeclion and replacement

Lubricaling oil Inspection, cleaning and hydroslalic lest 2 X 3.0
cooler
 Equipment Arrangement and Maintenance Schedule

1 I
2 DK-20 Maintenance Schedule Table

Overhaul and mainlet ce period (hl

Overhaul and
000 1600C
maintenance Work conlenls 5 5
workersx 1500 3000 6000 !OOO 2400[
porlion !lo 410
mlhs 6 mlhs 1 yr. l yr. 5 yr.
Lubricating oil Disassembly and inspeclion 1X1.5 0
relief valve

Lubricating oil Disassembly, inspection. cleaning and 1X1.0 0 0

temperature pellel replacemenl
conlrol valve

Cooling wafer Disassembly, inspeclion and cleaning 2x20 0

pump
OOil seal, mechanical seal inspeclion and 0 0
replacemenl

0 Bearing inspection and replacemenl 0 8

Cooling waler
lem~erature
conirol valve
Disassembly, inspection. cleaning and
/element reolacemenl I IX1.O I I I 0 8

Fuel oil shuldown Disassembly, inspeclion, and O-ring

device

Gauges
replacement

Replacement of pressure gauge rubber

1X1.0

lXIO
I 110

0
hose and vibralion insulating rubber
I
I lnspeclion of pressure gauge and
lachomeler (Calibration)
I 1°1 I (0)

I I
Replacemenl of F . 0 , pressure gauge
ethylene glycol
(In case of heaw luel oil s~ecificationsl

Pressure damper Accumulalor assembly replacemenl

I
I
lXo5

1 XO.5
1 1 lo
I I I

of main fuel oil (including the 0 ring)

oi~e

Notes : 1) The above table shows standard values of the man-hour, overhaul and maintenance period under
the conditions of general use of the heavy fuel oil.
In servicing an actual engine, initially set the work man-hour larger, and set the overhaul and
maintenance interval smaller than those shown in the table. Later reset the work man-hour, the
overhaul and maintenance interval to the most appropriate values, according to the operating
conditions, work environment, and the results of overhaul.
2) The work man-hour is based on the standard values for the experienced workers who are also
skilled in restoration. Therefore, please plan to have extra times for those with inexperience. .
3) The mark " % " given in the work-hour column indicates the man-hour per unit (one cylinder or one
bearing). When the number of objects is "nu pieces, multiply the value by On".
4) Have the work marked with "if"executed by a professional technician of a maintenance
company or conduct the work under his guidance.
Equipment Arrangement and Maintenance Schedule

Memo DK-20
IICM

I I
General Maintenance lterns

1 DK-20 Preparation before Maintenance Work

1
2. General Maintenance lterns
2-1 Preparation before Maintenance Work
Make the following preparation before starting the engine disassembly and maintenance work.

(Preparation before work)

(1) Set the control handle to the "STOP" position.
(2) Close the air tank main valve.
(3) Close the fuel oil outlet and inlet valves.
(4) Close the lubricating oil outlet and inlet valves.
(5) Close the cooling water outlet and inlet valves.
(6) Open the cooling water inlet pipe drain valve to discharge cooling water in the jacket.
(7) Turn OFF the POWER switch of engine control system .
(8) Open the indicator valve.
 General Maintenance Items I

2-2 General Consumables and 2-2.2 General tools, Implements and

Materials, General Tools, Implements, Measuring Instruments
and Measuring Instruments (1) General Tools a n d Implements
@ General tools
General consumables and tools and measuring
@ Sockets (17X12.7, 19X12.7, 2 4 x 1 9 ,
instruments to be prepared for the engine 27x19)
maintenance work are shown below. The @ Double-ended spanners (8x10, 11 X 13.
consumables and tools and measuring instruments 17X19,22X24,27X30)
specially required for specific works are shown in @ Offset wrenches (17x19)
each individual section. @Hex. rod spanners (4, 5, 8, 10, 14)
@ Box spanner (19 X l8O,65X 130)
2-2.1 General Consumables and @ Adapter (19X12.7)
Materials @ Monkey wrenches
@ Pliers
@Waste cloth
@ Snap ring pliers
@Washing oil
8Lubricating oil a Screwdrivers (plus, minus)
@ Hammers (Iron, plastic)
@Grease
@Torque wrenches (1000,4200, 14000)
a Machine oil VG-10
a Ratchet handle (12.7, 19)
@ Lubricating agent (MOLYKOTE 1000 spray
@ Extension bar (19x400)
type)
@ Pipe handle
aHigh-temperature anti-seizure agent @ Eye bolts (M10, M12, M16)
@ Liquid packing
Chain block
@ Silicon rubber
@Wire rope for suspension
@ Compound medium size, fine size (for facing-
@Tap (MlOX1.5)
UP)
@ Lubricating penetrant
(2) Measuring lnstruments
@ Dye testing penetrant (for color check)
@ Blue paint lead (for confirmation of contact) @ Calipers
@Liquid nitrogen or dry ice (for cold fitting)
a Thickness gauge
@J Wire (for wire ring)
a Outside micrometer (mm)
(0-25,25-50,50-75,75-100, 100-125,
@Wire brush
150-175,175-200)
@ Sandpaper
I #80 or equivalent
@ Spherical micrometer (0 - 25mm)
@ Oil stone
Cylinder gauge (mm)
@ Corrosion-resistant paint (for liner repairing)
(10-18, 35-60, 50-100, 160-250)
@ Repairing agent (for liner repairing)
@ Dial caliper gauge (3-9mm)
@Lead wire (for measuring gear backlash, etc.)
@Adhesive (ROCK-TIGHT 242,243,271)
a Dial gauge
@ Magnet stand
 General Maintenance Items
I
Bolt and Nut Tightening Torque, Tightening Oil Pressure I
2-3 Bolts and Nut Tightening Torque, Tightening Oil Pressure
Bolt or nut width Tigjtening torque or
across flats oil pressure
Name of bolts and nuts Remarks
(N-m)
(mm) { kgf - m )
jtudding torque 245 (25)
Sylinder head bolts
Hydraulic
tightening
Oil pressure 54MPa
{550 kgf/cm2) *
196 ( 20 )+40"
Crank pin bolt 27
(8-torque 392 (40))
98 {10)+20"
Connecting rod bolt
(6-torque 255{26))
Hydraulic -0 be returned by 114 to
Oil pressure 69MPa
Side bolt 12 turn after fullv screwin
tightening (700 kgflcm2) )n the studdina Side Q
Hydraulic Oil pressure 78MPa
Main bearing tightening nut tightening (800 kgflcm2]

980
Balance weight bolt 50
{ I 00)
1270
Flywheel bolt 41
(130i

Generator fitting bolt 41

ldle gear shaft bolt ( I ) 41

ldle gear shaft bolt (2) Hole 14

ldle gear tightening bolt 24

Cam gear mounting

Hole 8
Power-Rock

Carnshafi bearing pin 27

Aux, machinery drive gear bol 27

Aux. machinery drive gear

19
cushion bolt
--
Fuel oil injection pi~~hip Applied to black stud bolt
fittino nut
--
24
*
Fuel oil injection purnp
Hole 14
delivery valve tightening bolt

Fuel oil nozzle mounting nut 27

Nozzle lholder mounting nut 19

Bolt and Nut Tightening Torque,,Tightening Oil Pressure DK-20 3

Name of bolts and nuts

3 4 - 4 9 (3.5-5)

78-98 { 8 - 1 0 )

Notes: 1) Main bolts and nuts should be tightened according to the above table wilhout fail.
2) Bolts and nuts must be tightened uniformly in a diagonally and alternating sequence.
3) Be sure to check for loose cylinder head tightening nut and connecting rod bolts after a certain
period of operation. ( : 1-1.2 "Maintenance Schedule Table".)
4) Anti-seizure agent should be applied on the threaded parts and seat surfaces around the
exhaust manifold which are subjected to high temperature for the prevention of seizure before
tightening.
5) Retighten the bolts used for installation when stopping the engine, and be sure to check the
crankshaft deflection afler retightening.
6) Torque wrenches used for tightening should be inspected periodically.
7) The symbol marks used in this table signifies the following:
x : The tightening hydraulic pressure and toque specified on the name plate attached on the
engine shall have priority.
fi : Apply the lubricating agent (MOLYKOTE 1000 spray type) to the contact surfaces and
threaded areas of the bolt and nuts.
a : Apply the lubricating agent (MOLYKOTE U-paste) to the contact surfaces and threaded
areas of the bolt and nuts.
0 : Apply lubricating oil to the threaded portions and contact surfaces.

-A
If any agent other than the specified products is applied, the friction force of the threaded portions
changes, and the bolts are tightened excessively or insufficiently. As the result ofthis, the bolts may be
broken or loosened, thereby causing serious damage to the engine.
 General Maintenance Items
ITEM

4 1 4 2 DK.20 General Construction of Hydraulic JacWRemoval of Nut

2-4 Hydraulic Jack

2-4.1 General Construction of Hydraulic
Jack
The hydraulic jack (assy.) @ is consisted of a pair
of a hydraulic cylinder and a hydraulic piston.
Operate the hydraulic pump @ connected with
high-pressure hose @ to give the rated pulling
power to the bolt by hydraulic pressure. And, in
this condition, turn the nut to tighten or loosen it.
Tighten and remove the nuts of the following bolts
using a hydraulic jack: Hydraulic cylinder
Cylinder head bolt
Main bearing bolt
Side bolt

2-4.2 Removal of Nut

Remove the nut according to the following
procedures:
(1) Clean the area around the circular nut carefully,
and confirm that there is no dirt or foreign
matters on the seat surfaces ol the hydraulic jack
stand 0, and place the hydraulic jack stand.
(2) Place the hydraulic jack assembly on the jack
I
stand, and screw the hydraulic piston @into the Circular nut
bolt. Be minded to screw the hydraulic piston
until it strikes the hydraulic cylinder @. Hydraulic Jack
(3) Atter confirming that the hydraulic jack are
closely attached to the jack stand, turn back the
hydraulic jack by about 112 turn.
(4) Confirm that the valve of coupler @ for
connecting the high-pressure hose is not stuck,
and then connect the hydraulic jack and terminal Changeover lever
@, and then connect the terminal and hydraulic
pump using a high-pressure hose.
( 5 ) Loosen the air vent plug @ of the hydraulic
pump, and release air in the oil tank into the
atmosphere.
(6) Check the hydraulic pump oil level, and in case
that the level is low, replenish the hydraulic oil.
I \
High-pressurehose Hydraulic bump@ Oil level check
I Hydraulic oil : Machine Oil VG-10 I rod (supply por0

Hydraulic Pump
 General Maintenance Items
General Construction of HydraulicJacWRemoval of Nut
(7) Tighten the release valve@ of hydraulic pump.
(8) Loosen the air vent plug @ of hydraulic jack ,
and operate the hydraulic pump lever to vent the
air in the hydraulic cylinder. Tighten the air vent
plug after confirming that the air is completely
vented.
(9) Operate the hydraulic pump lever to increase
the oii pressure up to the specified level.
Specified value.. ....To be speclfled In
each work item. ( a : 2-3)
(10) Insert the jack handle @ into the hole of the
circular nut through the oblong hole of the
hydraulic jack stand, and loosen the circular nut
by 5 to 6 holes.
(11) Slowly open the release valve of hydraulic
pump, and gradually reduce the oil pressure
down to "0".
(12) Manually loosen and remove the hydraulic
jack.
(13) Remove the hydraulic jack stand.
(14) Remove the circular nut.
When operating the hydraulic jack, oil is
highly pressurized, and if oil is leaked and
sprouted out, it is extremely dangerous.
Therefore, be minded to wear the protective
glass without fail.
2-4.3 Tightening of Nut
(1) Carefully clean around the bolt, and contirm
that there is no foreign matters on the seat
surface of the nut and jack stand. Then,
manually screw the nut until it gets in contact
with the bottom, and place the jack stand.
(2) Install the hydraulic jack, and connect to the
hydraulic pump according to the same
procedures as those lor removal, and increase
the oil pressure up to the specified level by
operating the hydraulic pump lever.
(3) Insert the jack handle through the long hole of
the jack stand, and tighten it until it gets in
DK-20
contact with the bottom.
(4) Strike the jack handle with a hammer, and
confirm that it is securely tightened.
(5) Slowly open the hydraulic pump release valve.
and gradually reduce the oil pressure down to
"0"
- ~ %&$$
$@$
(6) Manually loosen the hydraulic, and remove it.
(7) Remove the hydraulic jack stand.
@$$!
za.n'T
(8) In the case of a bolt equipped with the
protection cap, fit it with the protection cap.
2-4.4 Maintenance of Hydraulic Jack
(1) Extract the piston from hydraulic cylinder by
striking its lower area with a wooden hammer,
a n d pull out the piston from the hydraulic
cylinder.
(2) Remove the air vent plug.
(3) Wash all the parts using the washing oil, and
check them for scratch.
(4) Apply the hydraulic oil to all the parts, and
install the hydraulic piston to the cylinder.
(5) Replace the O-ring and the back-up ring with
new ones.
When installing the piston, be careful so that
the O-ring and the back-up ring may not be
fitted upside down. Wrong way of fitting will
cause the O-ring to be damaged.
(Consurnables for hydraulic jacks)
(m: "Parts List" )
@ Back-up ring (small) 9-1.1 No.18
@Back-up ring (large) 9-1.1 No.19
@ O h g (small) 9-1.1 No.506
@O-ring (large) 9-1.1 No.507
 ,

Cylinder Head and Valves

1 I
1.2 DK-20 Cylinder Head: General Construction/Replacing Consumables I
3. Cylinder Head and Valves

3-1 Cylinder Head

Cylinder head (independent) : 120 kg
3-1.1 General Construction Cylinder head assy. (with valves) : 130 kg
The cylinder head made of the special cast iron of
high strength and high thermal conductivity is
designed to assume the structure of high rigidity, 3-1.2 Replacing Consumables,
and hydraulically fastened to the engine frame Implements and Measuring Instruments
rigidly with the four large-diameter bolts via metal (1) Replacing Consumables
gasket and cylinder liner. Replace the following parts with the new ones.
The combustion surface is of the thick-walled
structure provided with the forced cooling through
( a: "Parts List")
@Cylinder head gasket 3-15 No.Al8
the drilled holes. a O-ring (fuel oil injection valve guide)
The intake and exhaust valves consist of the 4- 3-15 No.A30
valve system of 2 piece each for intake and @O-ring (Starting valve inlet) 3-15 No.A505
exhaust, with the valve seat cold-fitted to the @ O-ring (exhaust valve seat) 3-15 No.A26, 27
cylinder head, and with the exhaust valve seat @ CW connection pipe gasket 3-15 No.A56
cooled by the cooling water. @Gasket (intake air vent) 3-15 No.67
T h e fuel oil injection valve, indicator valve and @ Intake air vent seal 3-15 No.859
safely valve are mounted on the upper side of the @ Gasket (exhaust manifold) 3-29.1 No.A27
cylinder head, and the starting valve (not provided @Rubber seal (head cover) 3-21 No.Al0
in case of air-motor type) is mounted on the lateral @D Push rod rubber seal 3-22 No.14
side respectively. 0Gasket (1) 3 4 x 7 0 (CW head outlet pipe)
The leaked oil from the fuel oil injection valve as 2-1.7
well as the cooling water (or, cooling oil) of the fuel
oil injection valve, when heavy fuel oil is used, are
guided into the piping on the fuel oil injection pump
side through the hole.

Exhaust valve Fuel oil inieclion valve

/ / \
Cooling water
head oullel pipe
Safety valve lndicalor valve Exhaust valve
'/ \ intake valve
\
Cylinder head
Exhaust valve seat Intake valve seat

Cylinder Head and Valves

 Cylinder Head and Valves
ITEM
Cylinder Head: Implements and Measuring Instruments DK-20 1.2

(2) Implements and Measuring Instruments

@ General tools and measuring instruments
( : 2-2)
@ Nozzle holder extracting implement
@ Hydraulic jack @ Nozzle Holder Extracting @ Valve Gulde
@Jack cylinder ...... Head Implement Extracting Implement
@Tension bolt ...... Head
@Jack stand ......Head
@Jack handle
@Hydraulic pump
@Hydraulic pump
fi
@
;

.
.'.%
rr**xu

@High-pressure hose (2 m x 6)
@Terminal (4T)
@ Male coupler a Water Cooling Valve
@ Cylinder head suspending implement Seat Extracting
@Spring disassembling implement-2 Implement
(for common use)
@Eye bolt M I 6
@ Valve guide extracting implement (option)
aWater cooling valve seat extracting
implement (option)
@Water cooling valve seat lining tool
@Water cooling valve seat fitting tool-1
@ Water cooling valve seat fitting tool-2 @ Hydraulic Jack
(option)
@Valve seat fitting implement (option)
@Valve seat fitting implement-1 @ Water Cooling Valve
@Valve seat fitting implement-2 Seat Flnlng Tool

@ Cylinder Head Suspending lmplement

@ Hydraulic Pump @ Valve Seat Fitting lmplement

 Cylinder Head and Valves
ITEM
1.3 DK-20 Removal of Cylinder Head

3-1.3 Removal of Cylinder Head

Remove the cylinder head (top hole) on the
following procedure:

(1) Remove all the covers.

@ Exhaust manifold cover @
@Heat box cover @
@ Cylinder head cover @

li\
All the parts (the exhaust manifold and the
area around the cylinder head, in particular)
are hot immediately after stopping the
engine, and a burn may be caused if the
parts of such areas are touched with naked
hand.
Therefore, be minded to wear safety gloves
during the work and be careful to prevent a
burn.

(2) Remove all the pipingaround the cylinder

head.
@Nozzle cooling outlet and inlet piping @
@ Starting valve pilot air pipe @
@Cooling water outlet pipe flange @
@ F.O. leaked oil branch pipe @
(3) Remove the F.O. high-pressure joint and inlet
connector, and extract the fuel oil injection valve.
(a: "Operation" 5-4.2 "Inspection and
Maintenance of Fuel oil injection Valve")
(4) Remove the exhaust manifold mounting bolt.

The exhaust manifold mounting bolt is made

of stainless steel. Be careful not to mix with
other general bolts.

( 5 ) Loosen the mounting nut 0, and take out

rocker arm device @ I.
(a: 3-4"Rocker Arm Device")
(6) Extract the valve retainer tee @ and push rod
0.
 YO-'--
Cylinder Head and Valves
ITEM
Removal of Cylinder Head DK-20 1.3-

( 7 ) Remove the cylinder head mounting nut @

using the hydraulic jack 8.
(m: 2-4 "Hydraulic Jack")
a) Mount the tension bolt @-@ to the head bolt
0,and fully screw it until it gets in contact with
the bottom.
b) Place the jack stand @@ by adjusting its cut-
out parl, so as not to let it interfere with the
adjoining cylinder nut.
c) Mount the hydraulic jack @@ to the tension
bolt.
d) Mount the male coupler @-@ to the high-
pressure hose @-@, and then connect the
hydraulic pump @-a, terminal @-a, and
hydraulic jack @ with a hydraulic hose. Mounting of Hydraulic Jack
e) Increase the .hydraulic oil pressure to the
specified pressure by operating the hydraulic
pump, and remove the cylinder head by
loosening the nut using the handle @-a.
Hydraulic pump specified oil pressure:
54 MPa (550 kgflcm2)

1) Confirm the pressure to allow the nut to starl

turning, and check that the cylinder head bolt is
tightened securely to be free from loosening.

Connection of Hydraulic Hose

ITEM
- Cylinder Head and Valves
1 3 DK-20 Removal of Cylinder Head

(8) Mount the cylinder head suspending implement

0-@ and 0-@ on the upper surface of the
head, and suspend the cylinder head using a
chain block and suspending wire rope.

When suspending the cylinder head, be sure

to use the specified suspending implement,
and be minded to strictly observe the use
standard of the wire rope.

u
1) When suspending the cylinder head, Suspension of Cylinder Head
conduct the work slowly while confirming
that the head is not caught on anything. Intake duct cover Cylinder liner cover
Further, be careful so that the cooling
water i n the h e a d m a y not enter the
cylinder.
2) When lowering down the cylinder head, be
careful not to scratch the lower surface of
the cylinder head.

(9) Remove cylinder head gasket @, and place a

cover to prevent infiltration of foreign matters inlo
the cylinder liner and the intake duct.

Intake duct Cover and Cylinder Liner

 ' \

Cylinder Head and Valves

Inspection and Maintenance of Cylinder Head (Body) DK-20 1.4

3-1.4 Inspection and Maintenance of
Cylinder Head (Body)
Since the items mentioned in this section will
be the parts to which NOx Technical Code
shall be applied, when replacing any of these'
parts, be sure to use the parts provided with
the identification marks.
( a : 0-3 "Engine Conforming to NOx
Technical Code")
(6) Clean the contact surface of the cylinder head
gasket.
Ifnecessary, conduct the facing-up of the contact
surface.
(7) Inspect the inside of the jacket through the
cooling water outlet hole. If heavy scale deposits
are found, remove the plug on the upper face,
and clean the inside. ggp
After cleaning, apply the adhesive (ROCK-TIGHT
271)on the plug, and then securely tighten it. &~ps

( 1 ) Before servicing the cylinder head (body),

disconnect the following attachments. (For the ,,/heyling water
disconnecting procedure, refer to the
descriptions of the separate sections.)
a Intake and exhaust valves
Starling valve
(a (
: 3-2)
: 3-3)
a (a
Indicator and safety valves
@ Intake air pipe vent
: 3-5)

@Cooling water head outlet pipe

(2) Observe and inspect the conditions of the

carbons deposited on the combustion surface
and intake and exhaust ports, in the state that
the attachments are removed.
(3) Completely remove the carbons deposited on
the combustion surface and intake and exhaust
ports, carefully clean them, and check for the A' Cooling water
cracks by means of color check. inlet
Particularly be minded to check the combustion
surface most carefully, since the part is exposed
to the high temperature and high pressure.

Do not use a gas burner to remove carbon.

Plug
It may cause hardening of the O-ring due to
high temperature and deterioration of the
materials due to local heating.

(4) Check if there is corrosion on the intake and

exhaust p o r k
(5) Check for the corrosion ol the contact surfaces
Of the cooling water connecting pipe gasket and
starting air connecting pipe O-ring, and also
check for the leak of gases from the cylinder
head gasket surface. Cleaning and lnspectlon of Head
 Cylinder Head and Valves
ITEM
1.5 DK-20 Cylinder Head: Intake and Exhaust Valve Guides

3-1.5 lntake and Exhaust Valve Guides

The dimensions of the intake valves guide is as
same as that of the exhaust valve guide.

(1) Measurement of Inner Diameter

Inspect the intake and exhaust valve guides for
corrosion, measure the inner diameters with a
cylinder gauge and record the data.
Calculate the clearance by joining the outer
diameter measurement results of the intake and A, a: Intake valve
exhaust valve stem parts. ( a: 3-2.4) B, b: Exhaust valve

Nom. Size Standard Replacing

(mm) Clearance (mm) limit (mm)
A=$14 a=0.09-0.13 0.3
B=# 14 b=0.09-0.13 0.3 Clearance of Valve Guide

(2) Replacement of Valve Guides

Hammer
W h e n the clearance between the intake and
exhaust valve stems and the intake and exhaust
valve guides is more than the specified replacing
limit and the valve guides are found heavily worn,
remove the intake and exhaust valve guides and
replace them with the new ones according to the
following procedure:
a) Remove the valve guide.
Produce the valve guide extracting implement
@ (option), or produce t h e extracting
implement as shown i n the figure using a
round bar, and strike out the valve guide with a
hammer, by inserting such implement into the
valve guide.
b) Fit the valve guides.
Fit the valve guides by means of cold-fitting
Extraction of Valve Guide
using liquid nitrogen or dry ice.

(Cold-fitting procedure)
In case of liquid nitrogen,. . . . .Immerse the
parts in the liquid, take out the parts when
If the cooling liquid or cooled-down parts are
bubbles disappear, and fit it promptly.
touched by naked hand, frostbite may be
In case of dry ice.. . . ..Immerse the parts and
caused. Therefore, be minded to wear cotton
dry ice in alcohol, take out the parts after
arctic gloves during execution of the works.
cooling for 20 to 30 minutes, and fit it promptly.
 cLo l
Cylinder Head and Valves
-

Cylinder Head: Intake and Exhaust Valve Seats DK-20 1.6

3-1.6 lntake and Exhaust Valve Seats

(1) Valve Seat Dimensional Measurement
Welding rod
Measure the dimensions of the valve seat part,
and in case that it is worn out heavily exceeding
the replacing limit, replace the exhaust valve with
the new one.
(Replacing limit : 3-2.4 (4))

-
(2) Replacement of Valve Seat
a) Removal of valve seat
Remove the valve seats on the following
procedure:
Perform the padding welding o n the inner
surface of the valve seat, and quench it with
water. By doing this, the valve will contract
and can easily be taken out

When performing the padding welding, be Removal of Intake Valve Seat

careful not to damage the combustion
surface or valve guide hole with the spatters.
Further, when removing the valve seat, be
careful not to damage the fitting part of the
head.

b) Valve seat fitting

-
Cold-fit the valve seat using liquid nitrogen or
dry ice. (The cold-fitting procedure is as same
as the one for the valve guide. a : 3-1.5)

(3) Replacement o f Water C o o l i n g Exhaust

Valve Seat
Replace the water cooling valve seat, in case
that the valve seat part is used exceeding the
correction limit, or every 16000 to 24000 hours
(4 to 5 years).
Be minded to replace the O-ring at the same
time.
a) Removal of Valve Seat
Removal of the valve seat shall be made by
padding welding as same as in the case of the
intake valve seat, or shall be made by using
the valve seat extracting implement @ (option). Removal of Exhaust Valve Seat
 Cylinder Head and Valves
ITEM
1 (
6 DK-20 Cylinder Head: Intake and Exhaust Valve Seats

b) Valve seat fitting Water-cooling exhaust valve seat

As the O-ring is attached to the exhaust valve
seat, fit the valve seat into the cylinder head O-ring
using the water cooling valve seat tool, after
cooling and hardening the valve seat with
liquid nitrogen or dry ice on the state that the
O-ring is installed on the valve seat.
a-c3
(The cold-fitting procedure is as same as in the
case of valve guide. a : 3-1.5) Exhaust Valve Seat Cooling Procedure

(Fitting procedure)
i ) Apply grease to the O-ring at a normal
temperature, and fit the exhaust valve seat.
ii) Heat the water cooling valve seat fitting tool
@@with boiled water of 70 to 8 0 ' ~ .
iii) Insert the valve seat into the water-cooling
valve seat fitting tool @@.
A&T Round

iv) Cool down the valve seat in the state that it is

inserted in the valve seat fitting implement.
v ) Take the valve seal out of the water-cooling
valve seat fitting tool after cooling down it
using a round bar or the water-cooling valve Removal of Valve Seat from Tool
seat fining tool @ I-
and @
insert the,valve seat
in the cylinder head promptly.
Be minded to securely strike down the valve
seat using a used valve or the valve seat fitting
implement @-a and @ (option).

Fitting of Exhaust Valve Seat

 Cylinder Head and Valves
-
Mounting of Cylinder Head

3-1.7 Mountina of Cvlinder Head (9) Anach the rubber cap.

(10) Mount the fuel oil injection valve.
Mount the cylinder head according in the reversed
( : ''Operation" 5-4.2)
order of the disassembling procedure as shown in
(11) Insert the push rod.
the followings:
(1) Mount the intake a n d exhaust valve and
(12) Mount the rocker arm device. (a: 3-4.5)
(13) Mount the indicator valve and safety valves.
starting valve in the cylinder head.
( a : 3-2.6. 3.5)
(2) Fit the intake air vent.
(14) Insert the fuel oil injection valve i n l e t
connector, and tighten it with the specified
torque.
(3) Clean the cylinder head and cylinder liner head
gasket contact surface, intake air seal contact I I
Specified Torque:
surface, starting air inlet, push rod protection
88-98 N . m ( 9 - 1 0 kgt-m)
tube rubber seal fitting area.
(4) Fit the cylinder head gasket to the upper
(15) Mount the fuel oil high-pressure coupling, and
surface of liner.
tighten it with the specified torque.

A Do not apply any anti-seizure agent or

lubricant oil to the cylinder head gasket
surface.

(5) Apply grease to individual O-ring and the intake

air seal, a n d mount them i n the specified
Specified Torque: 34-44 N.m

I\
{ 3.5-4.5 kgf-rn)

All the high-pressure joint of the fuel oil

positions.
( 6 ) Mount the cylinder head suspending implement
@ on the upper surface of the head, and confirm
that there is no foreign matters in the cylinder,
and install the head.
( 7 ) Temporarily attach the exhaust manifold
mounting bolt, and attach the cylinder head
tightening nut.
injection system are connected with t h e
I
metal touch. Take enough care so that each
joint may not be damaged, and so that any
foreign matters may not be caught in them.
(16) Install the exhaust manifold and each of the
piping around the cylinder head.
(17) Mount the cylinder head cover, heat box
cover, and exhaust manifold cover.

Be careful not to mistakenly attach the

cylinder head tightening nut with the upper
and lower surface upside-down.

(8) Install the hydraulic jack in the same procedure

as that of disassembling, and tighten it with the
specified hydraulic pressure.

Specified hydraulic pump pressure:

54 MPa {550 kgf/cm2) I
 -
Cylinder Head and Valves
ITEM
2 1 DK-20 Intake and Exhaust Valves: General Construction

3-2 lntake and Exhaust Valves

3-2.1 General Construction Stem seal

-
The intake and exhaust valves consist of the 4-
valve system with 2 piece each for intake and
exhaust, having the valve rotators fitted to the
upper areas.
Stem seal are fitted to the upper areas of the
intake a n d exhaust valve guides, so as to
appropriately control the volume of lubricating oil to
be supplied to the stem

T h e intake valve and exhaust valve are

identical and can be used in common for each
other, in case of the diesel fuel oil
specifications.
However, i n case of the heavy fuel oil
specifications, the intake valve and exhaust
valve are same in the shape and dimensions,
and different in the materials, and therefore lntake Valve and Exhaust Valve
they are discriminated by cutting a slit on the
upper part of the exhaust valve.
When assembling them, be careful not to Notched mark Notched mark Notched mark
'S6Rm 'HNP' 'S637T'
mistake them with each other.

lntakelexhaust valve (independent) :

0.6 kg each

Diesel fuel oil Heavy fuel oil Heavy fuel oil

speciflcatlon speclfication specification
Inlake and exhaust valve lntake valve
exhaust valve

Discrimination Marks of Valves

 Cylinder Head and Valves
ITEM
Intake and Exhaust Valves: Consupables, Implements,
and Measurina lnstrurnentslDisassemblv DK-20 2.2.2.3

3-2.2 Consumables, Implements, and

Measuring lnstruments
(1)Replacing Consumables
Replace the following pads with the new ones:
( &Q: "Parts List")
O Valve stem seal 3-15 No.A32
(2) Implements and Measuring Instruments
@General tools and measuring instruments
( Q : 2-2)
a Valve spring disassembling implement
@ Valve Sprlng Disassembling Implement
@Valve spring disassembling implement-1
@Valve spring disassembling implement-2
@ Special bolt
a Valve facing-up implement
@Valve facing-up spring
@Valve seat cutter (option)
@Valve seat grinding implement (option)
a Stem seat striking implement
@ Valve Facing-Up
Spring
3-2.3 Disassembly of lntake and Exhaust @ Valve Facing-Up Implement
Valves'
When disassembling the intake and exhaust
valves, disassemble the four valves at the same
time using the valve disassembling implement, on
the following procedure: a Stern Seal Striking Implement
(1) In order to avoid wrong assembling, be minded
Assembling position of
to put the markings such as the discrimination
'E' of exhaust valve Cylinder number
marks of intake and exhaust, as well as the \ \
cylinder numbers on the valve head, before
starting the disassembling work.

\
'I' ol intake valve
'~ssemblingposition of
intake valve

Marking Procedure of Intake and Exhaust Valves

 Cylinder Head and Valves
lntake and Exhaust Valves: Disassembly, Inspection and
DK-20 Maintenance

(2) Mount the valve s p r i n g disassembling Nozzle holder retaining stud

implement-2 0-@ using the nozzle holder
retaining stud on the upper surface of the cylinder.
( 3 ) M o u n t the valve s p r i n g d i s a s s e m b l i n g
implement-1 @-a o n the rotator body, and
screw the special bolt 0-0 into the valve spring
disassembling implement-2.
(4) Turn the special bolt to retain the spring, and
take out the cotter.
(5) Return the bolt, and take out the disassembling
implement.
(6) Take oul the valve rotator and spring.
(7) Pull out the intake and exhaust valves from the
combustion chamber side.

3-2.4 Inspection and Maintenance of

lntake and Exhaust Valves
(I)Clean the intake and exhaust valves with
washing oil.
(2) Inspect on the following items: Colter,
a Corrosion of valve head area
@ Corrosion or bending of valve stem area
@ Blow-out or pitching of valve seat area
@ Contact conditions 01 valve seat area and
valve stem area
a Crack or corrosion of valve spring
..... Conduct color check depending on the
conditions.
(3) Measurement of Valve Stem Disassembly of lntake and Exhaust Valves
a) Measure the stem area of the intake and
exhaust valves using outside micrometer, and
record the data.
b) Calculate the clearance between the stem
a r e a a n d valve guide by c o m b i n i n g the
measurement results of the intake and exhaust
valve guide inner diameters, and in case that
the value is over the replacing limit, replace
the valve stem of which wear is larger.
The wear amount of the valve stem can be
calculated by comparing wilh the non-sliding Intake valve
area. Exhaust valve

Nom. size Standard Replacing

A= $14
B= $ 14
clearance (mm)
a = 0.09-0.13
b = 0.09-0.13
limit (mm)

0.3
A
Measurement of Valve Stem
 Cylinder Head and Valves
ITEM
Inspection and Maintenance of Intake and Exhaust Valves DK-20 2.4

(4) Measurement of head thickness and valve . ,

seats of intake and exhaust valves I I !I
Measure the head thickness of the intake and
C
exhaust valve seat areas, and the valve seat
dimensions with calipers, and record the results.
In case that the wear is over the replacing Ihmit, Intake valve Exhaust valve
replace it with a new one.
Measurement of Valve Head Thickness
Nom. size Replacing
(mm) limit (mm)
Intake valve seat area C=5.0 3.5
Exhaust valve seat area E=5.0 3.5
Intake valve seat D=2.0 0.5
Exhaust valve seat F=2.0 0.5

When corrosion of the valve stem and wear lntake valve seat Exhaust valve seat
of the intake valve seat is remarkable, a
possible cause is low-temperature corrosion. Measurement of Valve Seat
For the prevention of such corrosion, strictly
observe the followings.
1) Set the intake air temperature at a little
higher level.
2) Exhaust combustion gas by means of air
running when the engine is stopped.

(5) Facing-up of intake and exhaust valves

Facing-up of the intake and exhaust valves, the
latter i n particular, i s o n e of the most
troublesome works in the maintenance work.
The care and maintenance period largely
depends on the load factor, the fuel oil used, and
the operating conditions of the engine. Further,
delay in the maintenance of the engine leads to
the acceleration of the wear and tear of the
valves. So, execute facing-up a little earlier
according to the situations.
 Cylinder Head and Valves
ITEM
2.4 DK-20 Inspection and Maintenance of Intake and Exhaust Valves

(Facing-up procedure)
a) Apply lubricating oil to the valve stem, mount
the valve facing-up spring @ on the valve
stem, and insert the valve stem into the
cylinder head valve guide.
b) Mount the valve facing-up implement @ to the
valve.
c ) A p p l y compound to the seat area, and Valve

carefully conduct the facing-up. Use the

compound in the order of the medium grade
and fine grade.
Medium grade compound.. ...Conduct the
facing- up as if to strike.
Fine grade compound.. . . .Conduct the
finishing facing-up as if to press compound. Facing-Up of Intake and Exhaust Valves
against the seat.
Finally, wash the seat carefully, and conduct

&&
the oil facing-up.
d) Conduct the blue-lead check of the seat
surface contact conditions after finishing the
facing-up.
e) Measure the valve head thickness and the
cofirm
valve seat
that dimensions
the measuredwith
values
calipers
do not
again,
exceed
and 120' -,s

the use limit. Valve Valve seat

(6) Correction of valves Correction of lntake Valve, Exhaust Valve,

If the valve face scratch is deep and cannot be and Valve Seat
corrected with compound, conduct the correction
(rough finishing) using a machine or grinding tool
before conducting facing-up.
a) Machine the valve seat using the valve seat
cutter (option).
b) Machine the angle of the valve seat to make
the outside contact to be as shown in the
figure.

Y If the valve rear face is ground, the valve

strength will be reduced and cause cracking.
Therefore, be minded never to grind the
valve rear face.
 .
Cylinder Head and Valves
ITEM
Intake and Exhaust Valves: Inspection and Maintenance of
Valve Rotator DK-20 2.5

3-2.5 Inspection and Maintenance of

Rotator body
Valve Rotator
Since impeflect rotation of the valve rotator largely
affects the valve life adversely, be sure to conduct
the periodical inspection and maintenance.

Valve rotator rotational speed: min-'

Standard value: 2-4
Replacing limit: 112 of initial rotational speed I
Spring

(1) Disconnect the circlip and disassemble the

rotator.
(2) Wash the individual parts using washing oil.
and check the parts for the following defects:
@ Wear, deformation, and corrosion of ball
@Break, corrosi'on, and fatigue of spring
@ Compression mark on ball race
Circlip
@ Corrosion and fatigue of coned disc spring
@ Compression mark on rotator body groove
(3) Replace the defective parts.
(4) Assemble the valve rotator according in the Pads of Valve Rotator
reverse order of the disassembling procedure.

Assemble the spring in such a manner that it

rests in the oil hole side of the groove of the
rotator body.
 Cylinder Head and Valves
ITEM Intake and Exhaust Valves: Assembly of Intake and
2.6 DK-20 Exhaust valves

-
3-2.6 Assembly of lntake and Exhaust
Valves
(1) Use the stem seal striking implement a to put
the stem seal on the upper area of the valve
guide, and apply grease to the inner periphery.
(2) Insert the valve from the combustion surface
side.

1) Before inserting the valve, be minded to

confirm the identification mark of the valve
head, and b e sure to asemble the valve
into the original position.
2) If the inner periphery of the stem steal is
scratched or damage, it will affect the
lubricating oil consumption and stain of the
valve.
Therefore, be minded to apply lubricating
o i l o n the valve stem part, a n d then
gradually inserl it. Insertion of Stem Seal

(3) Assemble the valves in the reverse order of the

disassembling procedure, using the valve
disassembling implement.
 Cylinder Head and Valves
Starting Valve: General ConstructiodReplacing Consumables,
Implements, and Measuring InstrumentslDisassembly DK-20 ;.?h.3

3-3 Starting Valve

3-3.1 General Construction 3-3.2 Replacing Consumables,
The starting valve is a pneumatic valve of pilot
Implements, and Measuring
type, and the pilot air from the starting air rotary lnstruments
valve works on the starting valve piston, so that the (1) Replacing Consumables
valve opens to allow the flow of starting air into the Replace the following parts with new ones:
cylinder. ( 0 : "Parts List") 35%
The starling valve is installed on the F.O. injection a Circular gasket 3-18 No.508, 509 @ )
$$&
pump side of the cylinder head, and it can be O-ring 3-18 No.506 &&$

removed in the state of the assembly. 8Split pin 3-18 No.503

If leak has occurred from the seal of the starting
valve seat area, the combustion gas flows back
into the starling air main pipe side to cause sticking
or damage of the starting air rotaly valve, starting
air valve, and so on. and therefore make it a rule to
conduct the inspection a n d maintenance
periodically.
In case of overheating of the starting air pipe
during operation, the possible cause is gas leak
from the starling valve, and therefore conduct the
inspection of the parts.
Starting valve assy. : 1.1 kg
(2) Implements and Measuring Instruments
a General tools and measuring instruments
( 0 : 2-2)
3-3.3 Disassembly of Starting Valve
(1) Remove the starting valve cover @, and extract
the starting valve assembly from the cylinder
head.
(2) Extract the split pin 0, nut @, and starting
valve @.
(3) Remove the starting valve piston @ and spring
@.

I \
Spring @ Nut @

Starting Valve
 Cylinder Head and Valves

I
5 ( DK-20 Inspection, Maintenance, and Assembly of Starting Valve I
3-3.4 Inspection and Maintenance of
Starting Valve
(1) Clean the individual parts using washing oil.
(2) Conduct the following inspections:
a Sticking of the starting valve and starting
valve piston, and the leak of gas from the seat
area
@Corrosion or scratch of the spring
(3) Apply compound to the seat areas of the
starting valve and valve body @, assemble the
starting valve and piston into the valve body, and
conduct the facing-up.
(4) Apply blue lead to the starting valve seat area,
and check the contact.

Contact range: 75% or more

-
3-3.5 Assembly of Starting Valve
(1) Assemble the starting valve assembly on the
following procedure:
a) Insert the starting valve into the starting valve
body.
b) Insert the spring and stading valve piston,
tighten the nut, and clamp it with the split pin. Disassembly of Starting Valve

Be careful since tightening of the starting

valve nut with excessive torque will break the
threads.
The split pin is made of stainless steel. Do
not to mistake it with the one made of
ordinary materials.

(2) Assemble the starting valve assembly into the

cylinder head, and tighten with the bolt after
attaching the cover.

I Specified torque: 59 N-m (6 kgt. m) 1

Be minded to gradually tighten the bolt

alternately, and evenly. Uneven tightening
will cause the leaks of the starting air and
 Cylinder Head and Valves
ITEM
Rocker Arm Device: General Cons~ructionlConsumables,
Implements, and Measuring InstrumentslDisassembly DK-20 4.1 -4.3

3-4 Rocker Arm Device

3-4.1 General Construction
The intake and exhaust valves are driven by the
intake and exhaust cams that are shrunkfit to the
camshaft, via swing arm, push rod, rocker arm,
and valve retainer tee.
Individual areas of the rocker arm are lubricated by
the system oil fed from the piping on the fuel oil
injection pump side of cylinder head, through the
drilled holes inside the head.
For adjusting procedure of the valve end
clearance, refer to the separate "Operation".
(m : "Operation" 5-4.1 "Adjusting Valve End
Clearance")
Rocker arm assy. : 11.8 k g
3-4.2 Replacing Consumables,
Implements, and Measuring
Instruments
(1) Replacing Consumables
Replace the following parts with the new ones:
( a: "Parts List")
@O-ring 3-20 No.512
(2) Implements and Measuring lnstruments
@General tools and measuring instruments
( Q) : 2-2)
3-4.3 Disassembly of Rocker Arm Device
(1) Loosen the nut, and disconnect the rocker arm
device assembly.
(2) Remove the valve retainer tee @.
(3) Remove the snap rings @ at both ends of the
rocker arm shaft @, and disconnect the rocker
arm @and @ of the intake and exhaust valves.

Rocker Arm(inta~e1exhaust)
@. c9
Valve retainer tee @ . .

Rocker Arm Device

 Cylinder Head and Valves
ITEM

4.4 4.5 DK-20 Inspection, Maintenance, and Assembly of Rocker Arm Device

3-4.4 lnspection and Maintenance of

Rocker Arm Device
(1) Clean the individual parts using washing oil.
(2) Measure the rocker arm shafl diameter with an
outside micrometer, and measure the rocker arm
bush inner diameter with a cylinder gauge, to
calculate the clearance.
If the clearance is over the replacing limit,
replace the bush with a new one.

Nom. size Standard Replacing

clearance (mm) limit (mm)
D=$50 d=0.05- 0.14
Clearance of Rocker Arm Shafl Bush

* B u s h press-titting force :
14.7- 27.5 kN {1500- 2800 kgf)

(3) Inspect the individual parts on the following

1 Presence ol scratch.
and contact conditions
points:
a Contact conditions of me valve retainer tee
and valve retainer guide a
@ Bend, scratch on the end surface, and
abnormal contact of the push rod @ -
a Scratch and abnormal contact on the contact
areas "A" and "8" with the valve
Presence ol bending
@ Scratch, abnormal contact, and wear of the
valve relainer teea, rocker arm metal fitting
cap 0, and rocker arm screw @

3-4.5 Assembly of Rocker Arm Device

(1) Assemble the rocker arm device assembly.
Pass the intake and exhaust rocker arm through
the rocker arm shaft, and attach a snap ring. -
(2) Insert the valve retainer tee into the valve
retainer guide.
(3) Mount the rocker arm device on the cylinder Presence of scratch, and
head. contact conditions

( 4 ) After assembling, adjust the valve end

Inspection of Bush Rod
clearance.
(a: "Operation" 5-4.1(2) "Adjusting Rocker
Arm ~leara;lce")
 Cylinder Head and Valves

3-5 lndicator and Safety Valves

3-5.1 General Construction
The indicator valve and the cylinder safety valve
are incorporated in the same valve body.
The indicator valve screw is of "left hand screw",
and the valve is opened and closed by the handle
in the directions as shown in the figure.
For the pressure measuring procedure, refer to the
separate manual of the "Operation".
( : "Operation" 5-3.1)

I lndicator and safety valve assy. : 1.7kg 1

Opening and Closing of lndicator Valve

3-5.2 Replacing,Consumables,
Implements, and Measuring
Instruments
(1) Replacing Consumables
Replace the following parts with new ones:
( QJ : "Parts List")
a Circular gasket 3-19 No.A506, A507-1
No.A507-2
a Straight pin 3-19 No.A504

(2) Implements and Measuring lnstruments

aGeneral tools and measuring instruments
( a: 2-2)
Safety valve testing implements I
Salely valve
@Hydraulic pump
@ Safety valve test joint @ Safety Valve Testing Implement
@ High-pressure hose
 Cylinder Head and Valves
ITEM
5-3 DK-20 Disassembly of Indicator and Safety Valves

3-5.3 Disassembly o f lndicator and

S a f e t y Valves

The indicator and safety valve are extremely

ho! during operation. If it may be touched with
naked hands during operation or immediately
after the stop, a burn may be caused. Conduct
the maintenance work after the indicator and
salety valves are cooled down sufficiently.

(1) Removal o f lndicator and Safety Valve

Assembly
Disconnect the flange mounting nut @, and
remove the indicator and safety valve assembly
from the cylinder head.

(2) Disassembly of Safety Valve

a) Remove the safety valve (independent assy.)
@from the indicator valve body.
b) Loosen lock nut @ and adjusting screw @.
Respectively provide the lock nut, adjusting
screw, and spring retainer @ with the
matchmarks for the sake of convenience When '
0
reassembling.
c) Loosen and disconnect the spring retainer. lndicator and Safety Valves

When the spring retainer is taken out while

the spring is in compressed state, the spring
will jump out causing a hazard.
Gradually loosen the spring retainer, and
remove it after confirming that the spring
compression is eliminated.

(3) Disassembly of lndicator Valve
a) Take out hex. Plug @.
b) Extract the straight pin @, and remove the
indicator valve nut @ from the indicator valve
0.
c ) Extract the indicator valve using a screwdriver
The threaded part of the indicator valve @ is
of "left-handed screw", and the extracting
direction is clockwise as viewed from the side
of the hexagonal plug.
 Cylinder Head and Valves
lndicator and Safety Valve: Inspection and
MaintenancelAssembly and AdjustmentlMounting

3-5.4 lnspection and Maintenance of e) Fix the adjusting screw by tightening the lock
lndicator and Safety Valves nut.

(1) Wash all the disassembled parts using washing

oil to eliminate stains such as carbon.
(2) lnspection and maintenance of safety valve 3-5.6 Assembly and Mounting of
a) Check the safety valve outer periphery and lndicator and Safety Valve
seat for the marks of abnormal contact, scratch (1) Assemble the indicator and safety valve
and sticking. assembly in the reverse order of the
b) If scratch or sticking is found, correct the faulty disassembling procedure.
areas with oil stone, and apply compound to When assembling, replace the straight pins of
the seat to perform the facing-up. indicator valve with new ones, and fix them to the
(3) lnspection and maintenance of indicator valve indicator nut by caulking the three places on the
a) Check the indicator valve seat for scratch or both sides respectively.
one-sided contact. (2) Blow air to the mounting surface of the cylinder
b) When scratch is found, correct it using an oil head to clean there, and mount the indicator and
stone and apply compound to the seat to safety valve assembly while placing the circular
perform the facing-up. gasket @ between them.
(4) Check the spring for abnormal contact or (3) Apply the lubricating agent "MOLYKOTE 1000
scratch, and when scratch is found, replace the spray type" to the threaded part of the mounting
spring with a new one. nut, and tighten the nut after adjusting the
direction, so that the indicator valve will not
3-5.5 Assembly and Adjustment of protrude from the cylinder side surface.
Safety Valve
(1) Assembly of safety valve (independent assy.) Specifled torque: 59 N.m (6.0 k g f m )
Insert the valve and the spring into the safety
valve body after facing-up, and assemble the
lock nut and the adjusting screw to them.
Tighten the nuts alternately and uniformly.
(2) Adjustment of Safety Valve
Uneven tightening causes the leaks o f
Adjust the valve opening pressure according to
gases.
the following procedure:
a) Mount the safety valve test joint on the safety
valve, and connect them to the hydraulic pump
using a high-pressure pipe.
b) Screw the adjusting screw u p to the
matchmark position using a hex. rod spanner.
c) Operate the hydraulic pump lever to increase
the pressure, and read the valve opening
pressure.
d) Turn the adjusting screw, and adjust the valve
opening pressure.

When the spring is replaced with a new one,

set the value about 10% higher than the /
above value by taking into consideration the Safety valve
initial fatigue.
Safety Valve Testing Procedure
 Cylinder Head and Valves

I Nozzle Holder Guide : CoolingIFitting 1 DK-20 16.2,6.3 1 IIC M

(4) Put the entire nozzle holder guide into liquid

nitrogen just as in the state of Figure 2.
Cool it down until the air bubble, that generates
when cooling down, completely disappears.
(Required time: about 2 minutes)
(5) Install the nozzle holder as shown in Figure 3,
and remove the tool 4 by hammering with a
wooden hammer.
At this tirne, do not remove the tool 5.
Place a wood, cloth, or the like beneath the tool
4.

3-6.3 Fitting of the nozzle holder guide

<Fitting procedure>
(1) Wipe off dust, etc. on the seating face and Silicone paste
fitting part of the cylinder head with a waste cloth applied part- Snap ring installing position
or the like.
(2) Apply silicone paste to the specified places in
circumferential manner. (It can be applied easily
if a brush or the like is used.)
At this tirne, do not block the cooling water hole
inside the cylinder head with silicone paste. I \
Fining part and Cooling \ iool3
(3) Apply LOCK-TIGHT 648 to the fitting part of the sealing face water hole Nozzle holder guide
cylinder head.
X B e minded t o perform t h e work of the Nozzle holder guide fitting-in procedure
above Item 1 - 3 before cooling down the
n o u l e holder guide.
(4) install the tool 3 to the nozzle holder guide in
the state that the tool 5 is still attached, and fit in
the cylinder head by hammering.
When fitting in, be sufficiently careful so that the
nozzle holder guide should not be hammered in
the state that it is tilted.
Further, continue hammering until the nozzle
holder guide strikes the seating face.
Be careful because the fitting-in of the nozzle
holder guide will be difficult unless this work is
rapidly perlormed.
(5) Remove the tool 3 and 5.
(6) Install the snap ring to the specified place.
 -
Piston and Connecting Rod

DK.20 General Construction

4. Piston and Connecting Rod

4-1 General Construction
The connecting rod is of carbon steel die forging
with the large end part being horizontal 3-division bush
type. This structure allows the extraction of the
piston without disassembling the bearing part of
the crank pin shaft.
The large end divided surlaces (serrated) and
trunk part divided surfaces are angularly fastened
rigidly with 4 bolts @ and @, respectively.
Crank pin shell is made of aluminum alloy of high
wear resistance.
Piston pin is of full floating type, and held with the
snap ring. Further, the piston pin push is stepped
so as to allow a wide bearing area on the side.
where explosive force works.
The piston is an assembly o l the ductile integral
cast iron product, and special coating is applied to
the outer periphery of the skirt.
The piston cooling lubricating oil reaches from the
crankshaft to the cooling cavity in the piston, via
p i s t o n pin, t h r o u g h t h e d r i l l e d holes i n the
connecting rod trunk part.
The piston rings consist of the 3 compression rings
and 2 oil rings.
I n the heavy fuel oil specifications, induction Piston and Connecting Rod
hardening is conducted to the top and second ring
grooves to improve wear resistance.
Piston

Piston connecting r o d assy. : 73 k g

Piston: 18.6 k g
Piston pin: 6.8 k g
Connecting r o d assy. : 46 k g
Crank pin bolt: 2 kg
Clamp ring
Piston pin

Piston and Piston Pin

 Piston and Connecting Rod
-
Replacing Consurnables,lmplemens, and Measuring
Instruments DK-20

4-2 Replacing Consumables,

Implements, and ~ e a s u r i n ~
lnstruments
(1) Replacing Consumables
None

(2) Implementsand Measurlng lnstruments

@ General tools and measuring instruments
( Q: 2-2)
@Piston insettion frame
@ Protection ring extracting implement
@ Metal cap fitting and disengaging implement
(option)
@Cylinder liner position gauge
@Cylinder bore gauge 200 - 225
a Piston suspending implement (option) @ Piston Insertion Frame

@ I
Protection Ring Extracting Implement @ Metal Cap Flttlng and Dlsengaglnglmplemen

a Cyllnder Head Suspending Implement @ Cylinder Bore Gauge

a Piston Suspending Implement

 Piston and Connecting Rod

DK-20 Extraction of Piston

4-3 Disassembly of Piston and

Connecting Rod
4-3.1 Extraction of Piston
Extract the piston after removing the cylinder head.
(m: 3-1.3 "Removal of Cylinder Head")
I n the case of piston extraction only, it is not
necessary to disassemble the large end part, and
conduct the extraction work by separating the large
end part from the small end trunk part

1
If the crankshaft has turned when handling the
parts located i n the crank chamber when
extracting the piston, it will cause serious
accidents resulting form entanglement and it
will be very dangerous.
Therefore, be sure to conduct turning after
exchanging the signs with coworkers, and do
not fail to put the flywheel turning device in the
"disengage" position, except when the engine
is turned.
Extraction of Protection Ring
(Piston extraction procedure)
(1) Take off the cover on the engine frame side on
the both sides of the cylinder to be overhauled,
and place the piston to the position of about 50'
before the top dead center.
(2) Place waste cloth on the piston upper surlace
to facilitate easy removal of carbon.
(3) Remove the carbons deposited on the upper
areas of the protection ring @ and cylinder liner
@with sandpaper or the like.
(4) Extract the protection ring located in the upper
area of the cylinder liner using the protection ring
extracting implement @.
a) Spray penetrating lubricant to the proteclion
ring outer periphery before starling the work, to
facilitate easy removal of the protection ring.
b) When extracting the protection ring, gradually
extract it while lightly striking the lower surlace of
the extracting implement with a plastic hammer. Removal of Carbon from the Threaded
(5) Remove the carbon deposited in the piston Hole for Suspension
suspending threaded hole using a tap (MIOX 1.5).
( 6 ) Turn the crankshaft, and place the piston to be
released in the position o f 120' before the
bottom dead center.
 Piston and Connecting Rod

Extraction of Piston
--

If the big end of the connecting rod of the

cylinder that has been disassembled turns
during turning operation, it may get into
contact with the frame and may be damaged.
Slowly turn the crankshaft, taking care that
the big end does not turn.

( 7 ) Remove the rotation-stopping wire of the

connecting rod joint bolt @, and loosen the joint
bolt to extract it.
(8) Mount the eye bolt M I 0 (for piston suspension)
on the upper surface of the piston, suspend it
with the wire rope and chain block, and then
extract the is ton.
Extraction 01Piston

Securely tighten the suspending eye bolt Cylinder liner cove!

down to the seat surface. Unless securely
tightened to the seat surface, it causes
distortion or breakage of the metal fitting (eye
bolt), and is very dangerous.

When suspending the piston, be careful so

that the cylinder liner may not be damaged
being struck by the connecting rod.

(9) Fit a cover on the cylinder liner after extracting

the piston, s o that n o foreign matters may
infiltrate in the engine.
(10) Place the piston in the specified place with its
combustion surface facing downward.
(11) Lightly suspend the connecting rod, and
remove the clamp ring @ on one side of the
piston pin @ using a snap ring pliers.
(12) Extract the piston pin, and remove the piston
from the connecting rod.
(13) Remove the piston ring and oil ring

a
Since the periphery of each ring is edged
sharply after a long-time operation of the
engine, be sure to wear safety gloves and
take care n o t to suffer injuries when
disassembling the engine.
Extraction of Piston Pin
 Piston and Connecting Rod

DK-20 Disassembly of Connecting Rod Large End Part

4-3.2 Disassembly of Connecting Rod

Large End Part
Disassemble the connecting rod large end part
when the crank pin shell @ or crank pin bolt @ is
inspected or replaced. When only extraction of the
piston is intended, disassembly of the connecting
rod large end part is not required.
When only inspection of the crank pin shell is
intended, the connecting rod large end part can be
disassembled with the piston being suspended,
and without removing the cylinder head.
(1) Remove the connecting rod joint bolt @, and
suspend the piston and connecting rod small end
side. (Piston extracted or piston suspended)
(2) Turn the crankshatt, and mount the metal cap
fitting and disengaging implement @, so that the
large end part is facing sideways.
(3) Remove the rotation-stopping wire of the crank
pin bolt @, and disconnect the bolt using the
socket and extension bar.
(4) Take the top and bottom of the large end part
out of the right and left inspection windows
respectively.
(5) Remove the crank pin shell @ from the large
end parl. Place wooden piece against the claw Disassembly of Connecting Rod Large End Part
side of the bearing shell and strike it lightly.
Then, the bearing shell can be removed easily.
(6) Mark the disassembled shells with the cylinder
numbers and ID marks, so that the upper and
lower shells can be distinguished from each other.

(Disassembly of the large end parl by

suspending the piston)
a) Turn the crankshaft, and place the crank pin of
cylinder to be inspected in the position where
the crank pin bolt can be disassembled.
b) Remove the fuel oil high-pressure joint and
inlet connector, and extract the fuel oil injection
valve.
c) Insert the piston suspending bolt into the
mounting hole of the fuel oil injection valve,
screw it into the threaded hole of the upper
part of the piston, and then fix it.
d) Loosen the crank pin bolt, and remove the
large end cap.
e) Turn the crankshaft, and remove the upper
shell. Piston Suspending Procedure
 Piston and Connecting R o d

Inspection and Maintenance of Piston DK-20 ITEM 4. 1

4-4 lnspection and Maintenance of

Piston and Connecting Rod
4-4.1 lnspection and Maintenance of
Piston

Since the items mentioned in this section will

be the parts to which NOx Technical Code
I shall be applied, when replacing any of these
I parts, be sure to use the parts provided with
the identification marks.
(a: 0-3"Engine Conforming to NOx
Technical Code.")

(I) lnspection of individual parts

Inspect the individual parls of the pislon, and
record the conditions.
@ Conditions of the carbon deposited on the
piston, and the lubricating conditions
@ Scratch and abnormal contact of the sliding
areas
@ Sticking of the piston ring, and conditions of lnspection o f Piston
chrome plating
@ Conditions of the carbon sludge deposited on
the piston underside.
Color check
@ Abnormal contact of the piston pin and pin
boss inner surface
@Abnormal contact of the connecting rod small
end of the piston pin boss
(2) Eliminate the carbon deposited on the upper
part of the piston with a sandpaper of fine mesh.

Since special coating is applied to the piston

skirt area, do not use sandpaper on the
parts.

lnspection and Maintenance of Piston Parts

(3) Clean the piston and the piston ring using
washing oil.
(4) Clean the piston combustion surlace carefully,
and perform thorough inspections for crack by
means of color check.
( 5 ) Blow air to the oil hole of piston pin, and clean
the inside of the hole.
 Piston and Connecting Rod
lnspection and Maintenance of Pistonllnspection and
DK-20 Maintenance of Ring

(6) Measurement of dimensions

Measure the dimensions of individual parts, and
record the results. Calculate the clearance
based on the results of measurement, and
replace the parts with the new ones, if the
clearance is exceeding the replacing limit.
a) Piston outer diameter
Measure the four places of the piston outer
diameter using an outer micrometer, and
record the results.
Calculate the clearance based on the results of
the measurement of the cylinder liner inner
diameter.
(a: 5-3 "lnspection of the Inside Surface of
Cylinder Liner")

Nom. size Standard Replacing Clearance between Piston and Liner

(mm) clearance (mm) limit (mm)
A=200 a ~0.66-0.76
B=200 b =0.12-0.21
C1=ZOO c i =0.10-0.19 0.4
C2=200 c2 =0.10-0.19 0.4

b) Piston pin and piston pin boss

Measure the piston pin outer diameter and the
piston pin boss inner diameter, and replace the
one with larger wear.

Nom. size Standard Replacing

(mm) clearance (mm) limit (mm)
A=$90 a=0.04-0.08 0.15

4-4.2 lnspection and Maintenance of

Ring
Clearance between Piston Pin and Pin Boss
(1) Eliminate the carbon deposited on the piston
rings and oil rings, and wash the rings using
washing oil.
(2) Since hard-chrome plating is applied to the
sliding surlaces of the rings, in case that the ring
surface is exposed due to wear of the plated
layers, or the defects such as crack are found,
replace the ring with a new one, even when it is
still within the specified replacing period.
 '3

Piston and Connecting Rod

Inspection and Maintenance of Ring

(3) Measure the end clearance of ring.

Measurement of the end clearance using a new
cylinder liner is advisable. c2 Piston ring

Standard clearance Replacing limit

(mm) (mm)
C I = 1.50-1.70 2.5
I A1 1st.
C2 = 0.90-1.10
C3 = 0.75-0.95
C4 = 1.05-1.25
Cs = 1.05-1.25
1.5
1.5
2.0
2.0
- i
A2 2nd.
A3 3rd.

A4
1 Piston ring

Oil ring (upper): wilh coil

(4) Measure the width of the piston ring and oil

ring, and also measure the piston ring groove i A5 Oil ring (lower): with coil

width, and if the clearance is over the replacing

limit, replace the ring with a new one
-
T& oil ring (upper)

Norn. size Standard Replacing

(mm) clearance (mrn) limit (mm)
Piston Ring and Oil Ring
A1 = 5 81= 0.13-0.17 0.3
A2 = 5 8 2 = 0.09-0.13 0.3
A3 = 5 8 3 = 0.08-0.12 0.3
A4 = 7 84 = 0.04-0.08 0.2
As = 7 8 s = 0.04-0.08 0.2

@When wear of the piston ring groove width is

so excessive, as to require replacement with
a n oversize ring, consult our Service
Department.

1 e h . r i g periphery is edged sharply after a 1

long-time N n of the engine. Therefore, when
disassembling the engine, be sure to wear
safety gloves to prevent injuries.

Even when the wear of the ring is within the

permissible value, replace it with a new one
at every periodical inspection with the
interval of 8000-12000 hours (2-3 years).
 Piston and Connecting Rod

DK-20 Inspection and Maintenance of Connecting Rod -

4-4.3 lnspection and Maintenance o f

C o n n e c t i n g Rod
(1) Inspect the connecting rod on the following
points, record the results, and repair or replace
whenever a defect is found.
@Contact conditions of the small end part piston
pin bush @ and loosening or positional
deviation of the bush fitting area
@ Scratch and fretting on the joint surface of the
trunk part and large end part
@ Dent or peel of the threaded areas and seat
surfaces of the connecting rod joint bolt and
crank pin bolt
@ Conditions of the serrated area.....Wear and
fretting
(2) Clean the serrated area, and inspect the area
for scratch by means of color check.
(3) Blow air to the oil hole and nozzle @ that is
running through the trunk part, and clean the
parts.
(4) Measure the piston pin bush inner diameter,
calculate the clearance by combining it with the
results of measurement of the piston pin outer
diameter, and replace the piston bush with a new
one, in case that the wear is exceeding the
replacing limit.
lnspection and Maintenance of Connecting R o d
Nom. size Standard Replacing
(mm) clearance (mm) limit (mm)
A= $90 a=0.09-0.16 0.3

(Bush replacing method)

a) Take out the bush by striking with a press or
hammer.
b) Insert a new bush by pressing or cold-fitting
after confining the oil hole position of the bush.
I
<In case of pressing>
Press-fitting force of bush : 8.8-44.1 kN
1900-4500 kgfl
< I n case of cold-fitting>
Immerse the bush in liquid nitrogen, and take
out the bush when bubbles disappear (in 5 to

m 10 minutes), and then insert it.

I\ I II
( 5 ) Confirm the tightening torque and matchmarks
of the connecting joint bolt and crank pin bolt. Piston Pin Bush Clearance
 Piston and Connecting Rod
. lnspection
and Maintenance of Connecting RocUlnspection
and Maintenance of Shell

Connecting joint bolt and crank pin may

produce deviation in the relative position of the
bolt and body due to becoming accustomed
after a long period of operation, and therefore
in such a case, be minded to renew the
matchmark on the bolt side.
( : 4-4.5 ""AMark Notching Procedure")
(6) Measure and record the inner diameter of the
-
1) Be sure to replace the shell as one set of a
pair of the upper shell and the lower one.
2) When the shell is used for a long time, it
shows reduction of th'e tension and
hardening of its surlace, resulting in crack
or peel of the shell, even if the wear is,
withi &-allowance
9 value. Therefore,
large end housing in the state that the replacelhe sh11with a new one after use
connecting rod is independently assembled (the for 20.000 hr (4ho 5 years).
I'
state that the large end part and trunk part are ' .
assembled without the shells, and the connecting
joint bolt and crank pin bolt are tightened with the
Check for peeling, cavitation,
specified value), and inspect if there is any and fore~gnrnaners. .
distortion of the shape.
( : 4-5 'Assembly of Piston and Connecting Rod')

-
4-4.4 lnspection and Maintenance of
Crank Pin Shell
(1) Inspect if there is no fretting on the crank pin
shell rear surface and the joint surface, and also
inspect the inner surface for the seizure mark,
peel, cavitation, or any imbedded foreign
matters. When such defects are of light degree,
repair the crank pin shell using an oil stone.

The shell is the thin-wall finished metal, and

is provided with appropriate interference
(cmsh) and tension so as to closely fit to the . dheck for fretiing-andseizure.A
housing surface. Therefore, do not correct
lnspection of Crank Pin Shell
the rear surface and joint surfaces with a file
or scraper.

(2) Wash the shell, and measure the thickness of Connecting rod
large end
the shell using a spherical micrometer, and
record the results.
(3) Calculate the clearance from the measurement
results of the inner diameter of the large end
housing, thickness of the shell: and diameter of
the crank pin. If the result is over the replacing
limit, replace the shell with a new one.

Nom. size Standard Replacing

clearance (mm) limit (rnm)
a=o.to-0.19
Crank Pin Shell Clearance
4-4.5 Replacement of Connecting Rod
Bolt
Be minded to replace the crank pin bolt and Bolt side matchmark Body side matchmark
connecting rod joint bolt every 16,000 to 24,000
hrs (4 to 5 years), even when the appearance
problem is not found.

(Bolt replacing procedure)

(1) Use the red lead or blue paint lead to check the
contact of the bolt head seat surface, and correct
the seat surface of the connecting rod, in case
that there is any fault or problem.
(2) Stamp the identification number of the engine
B mark
to be replaced, the cylinder number, and the bolt A-torque
Rotating angle
number on the head part of a new bolt.
(3) Apply the lubricating agent (MOLYKOTE 1000 Angular Tightening Matchmark
spray type) on the threaded part and seat
surface of the bolt, and repeat loosening and
tightening 2 to 3 times using a torque wrench, Engine identilication number
with B-mark equivalent torque, so as to make the
parts to be accustomed.
\ /Bo"number

(B-mark equivalent torque) When replacing the

Connecting rod Joint bolt: bolt, be sure to notch
the same number as
255N.m (26 kgf,ml that of the old bolt.
Crank pin bolt: 392N.m (40 kgf.ml
Bolt Identification Mark
(4) Notch the A-mark on the following procedure:
a) Apply the lubricating agent on the threaded
area and seat surface of the bolt.

7/\
1) Use of the lubricating agents of different
brands causes difference in the bolt axial
tension. Therefore, be sure to use the
lubricating agent "MOLYKOTE 1000 spray
type" (genuine parts).
2) MOLYKOTE brings about changes in the
frictional force after drying. Therefore,
quickly tighten the bolts after spraying
before it dries.

Application of Lubricating Agent

Piston and Connecting Rod

Replacement of Connecting Rod Bolt IDK-20 1 ITEM

4.51

b) Tighten the bolt using a torque wrench with A-

I
torque in the following order:

A-torque
Connectlng rod lolnt bolt:
98 N.m {lo kgf.m)
Crank pin bolt: 196 N.m (20 l(gf.m)
Tightening order: 1-4-2-3-1
~mbo&edseat
c) Notch the "A' mark on the bolt.
Bolt Tightening Order

u When renew the notching of "A' mark, be

minded to clearly notch the new "A' mark
after erasing the old mark, so that the new
mark may not be mistaken with the old mark
when reassembling.
 Piston a n d Connecting Rod
-
DK-20 Assembly of Connecting Rod Large End Part

4-5 Assembly of Piston and

Connecting Rod
4-5.1 Assembly of Connecting Rod Large
End Part
(1) Clean all the parts using washing oil and blow
air to the threaded holes before assembly.
(2) Cleanly wipe ofi the dirt and oil accumulated on Connecting rod 'Bolt number
the inside surface of the large end part housing
and the rear surface of the shell.

Do not apply lubricating oil or grease to the

rear surface of the shell. Inclusion of oil will
cause the reduction of adhesion.
Embossed
seat
(3) Adjust the position of the shell claw to the
groove of the large end part housing, and mount
it so that the shell may be positioned at the
center of the large end part housing.
(4) Strike the shell at its center with hand to fit the

-
shell tightly to the housing.
( 5 ) Cleanly wipe the crank pin area, and apply
lubricating oil to the inner surface of the shell.
(6) Assemble the large end shell cap using the
shell cap fitting and disengaging implement from
b o t h sides i n the same procedure of the
disassembling, with enough care so as not to 1
Crank pin bolt
scratch the crank pin.

Be sure to install the connecting rod large

end part after matching the cylinder number,
so that the embossed seat may be in the
position directed toward the front side of the Bolt number
engine.
I
Assembly of Connecting Rod Large End Part
(7) Apply the lubricating agent (MOLYKOTE 1000
spray type) o n the threaded area and seat
surface of the crank pin bolt, and screw the bolt
down to the bottom surface.

Since the bolt number is notched on the bolt,

be minded to mount the bolt in the original
position without fail, n o t mistaking the
assembling position.
 Piston and Connecting Rod

Assembly of Connecting Rod Large End Part

(8) Angularly tighten the crank pin bolt on the

following procedure, using the socket, extension
bar, and torque wrench:
a ) Evenly tighten the bolt with A-torque,
according to the tightening order as shown in
the figure on the right.
b) Confirm that the A mark of the bolt and the A
mark of the seat surface is matched.
/
Embossed seat

In case that A marks are not matched, renew Bolt Tightening Order

c) Angularly tighten the bolt down to the B mark Boll side rnalchrnark Body side rnalchmark
\ A
in the order of 1-4-2-3-1.

A-torque : 196N.m (20 kgf.m)

Augular tightening (B mark) : +40°
(B mark equivalent torque :
392 N.m (40 kgf.m)

If the tightening of bolt is insufficient, it will

not only damage the bearing shell and large
end part serration, but also incur serious
accidents such as the breakage of bolt, and
therefore be minded to securely tighten the
bolt.

(9) Confirm that the matchmark of the bolt is

tightened down to the B mark position of the
large end part, and then conduct the rotation
stoppage.]
(10) Manually turn the large end part, and confirm
that it rotates lightly.
Matchmark Matching Procedure
 < ,

Piston and Connecting Rod

DK-20 Assembly of Piston and Connecting Rod

4-5.2 Assembly of Piston and

Connecting Rod
(1) Wash all the parts and blow air to them before
assembling the piston.
(2) Assemble the piston and the connecting rod.
a) Insert the connecting rod small end into the
piston, placing the combustion surlace of the
piston facing downward, while matching the
embossed seat of the connecting rod lower part
and " F markof the piston combustion surface.

Confirm that the discrimination numbers of

the large end part and the small end part are
identical.

b) Apply lubricating oil to the piston pin outer

periphery and piston pin boss inside area,
lightly suspend the connecting rod, and then
inseri the piston pin.
c ) Fit the piston pin stopper ring into the groove
using a snap ring pliers. Embossed seal
(3) Fit the piston insertion frame into the cylinder
liner upper part. Assembly of Piston and Connecting Rod
(4) Turn the crankshaft to place the crank pin at
the bottom dead center position.
(5) Mount the suspension metal fitting (eye bolt) on Ring end.
the piston upper part, and suspend the piston \I Ring end,
and the connecting rod part.
(6) Assemble the piston ring.
Assemble the piston ring i n the position as
shown in the figure, with the manufacturing mark
facing upward (toward the combustion chamber
side) so as to ensure the correct assembling Manufacturing mark
notched posilion
position.
(7) Assemble the oil ring.
a) Entangle the coil into the piston oil ring
groove, and insert the coil joint.
b) Assembly the oil ring so that the coil joint
comes on ihe opposite side of the ring joint Piston
(8) Deviate the positions of each ring by go0, so
that the piston ring and oil ring joint may'not be Third ring j
7,-
o n a straight line.
(9) Sufficiently apply lubricating oil to the piston,
piston ring, oil ring, piston insertion frame, and
cylinder liner.
 Piston and Connecting Rod

Assembly of Piston and Connecting Rod

-
(10) Check the cylinder number, insert the piston
into the cylinder liner, so that 'F" mark on the
piston top sutiace and the embossed seat of the
connecting rod face toward the engine front side,
and then align the knock of the large end part
and trunk part after slowly lowering the piston.

When assembling the piston to the cylinder

liner, it is advisable to lightly strike the piston
periphery with a plastic hammer, since it
facilitates easy lowering of the piston.
In case that the piston is fitted too tightly, do
not dare to forcibly lower the piston, but once
suspend the piston and then try to insert the
piston again. Insertion of Piston

(11) Apply the lubricating agent (MOLYKOTE 1000

spray type) on the threaded area and seat
surface of the connecting rod, and assemble the mark
rod into the position of the discrimination number. mark
(12) Augularly tighten the connecting rod joint bolt
on the following procedure:

(Bolt tightening procedure)

/
a) Evenly tighten the bolt with the A-torque Embossed seat
according to the tightening order as shown in
Bolt Tighteni'ng Order
the figure on the right.
b) Confirm that A mark of the bolt and A mark of
the seat surface are matched.

In case that A marks are not matched, renew

the marking according to the procedure of 4-4.5

c ) Angularly tighten the bolt down to B mark in

the order of 1-4-2-3-1.

A-torque: 98 N.rn {lOkgf.m)

Angular tightening (B mark) : f20"
(B mark equivalent torque :
255 N.m (26 kgf.m)

(13) Confirm that side motion is seen in the

connecting rod large end part, and conduct the
rotation stoppage by wiring if there is no
abnormality. Confirmation of Side Motion
 Piston and Connecting Rod
Assembly of Piston and Connecting RodIConfirmation of
DK-20 Bolt Tightening Force and Retightening

(14) Manually insert the,protection ring into the

cylinder liner, making the notched mark "US"
side facing upward, and taking care not to tilt the
ring.

When the piston and the connecting rod are

disassembled, be sure to conduct a test run
of the engine after restoration, to sufficiently
check that they are free from problems
through touching and the like. Then, enter
into the normal operation. I I
Protection ring Notched mark 'US'
Insertion of Protection Ring
4-5.3 Confirmation and Retightening of .
Connecting Rod Bolt Tightening Force
Confirm the tightening conditions of the crank pin
bolt and connecting rod joint bolt taking into
consideration the initial running-in, and check and
retighten these bolts within 3,000 hr after the initial
operation or the replacement of the bolts.
Afterwards also, be minded to periodically check
the tightening force within every 6,000 hours.

(Tightening confirmation and retightening

procedure)
(1) Turn the crankshaft to place the crank pin of
the cylinder, which is to be inspected, in the -.._I

position where the crank pin rod or connecting

rod joint bolt can be inspected. Tightening Confirmation of Crank Pin Bolt
(2) Remove the rotation stopper wire ring.
(3) Tighten the bolt after setting the torque wrench
to the B mark equivalent torque. If the bolt does
not turn, the tightening force is normal.
(4) In case that the bolt is turned, once loosen the
bolt, and conduct the angular tightening after
renewing the A mark again.
(a : 4-4.5 " A Mark Notching Procedure")

B mark equlvalent torque

0 Crank pin bolt : 392 N.m (40 kgf.m)

Connecting rod joint bolt :

255 N,m {26 kgf,m)
Tightening Confirmatlon of
Connecting Rod Joint Bolt
- \

Piston and Connecting Rod

ITEM
Memo DK-20
 hq?-

Engine Frame and Cylinder Liner

ITEM General ConstructionlReplacing Consurnables,
1, 2 DK-20 Implements, and Measuring Instruments

5. Engine Frame and Cylinder Liner

5-1 General Construction

The engine frame is ol a suspension shell structure
made of cast steel, and has sufficient rigidity
against the explosion pressure.
The main bearing part is hydraulically lastened
securely with the main bearing bolts and side bolts
of large diameters.
The air-intake passage, cooling water passage.
and lubricating oil passage are incorporated in the
engine frame to minimize external piping.
The cylinder liner upper area is provided with the
thin-wall liner protection ring, for the sake of
preventing the accumulation of carbon sludge.
The engine frame and the cylinder liner are tightly
sealed with O-rings at both the top and bottom
part.

Cylinder liner : 67 k g

5-2 Replacing Consumables,

Implements, and Measuring
Instruments
(1) Replacing Consumables
( a : "Parts List")
O-ring 3-12 N0.9. 501
@ Cylinder Liner Fitting and
Disengaging Implement
(2) Implements and Measuring lnstruments
General tools and measuring instruments
(Q: 2-2)
@ Cylinder liner fitting and disengaging
implement
@ Fitting and disengaging implement-1 @ Cylinder Liner Bore Gauge
@ Fitting and disengaging implement-2
@ Fitting and disengaging implement-3
@ Nut
@Cylinder bore gauge (200 - 225 mm)
@Cylinder line position gauge

@ Cylinder Liner Positlon Gauge

-
Engine Frame and Cylinder Liner

Inspection and Maintenance of Cylinder Liner lnner Surface DK-20

5-3 lnspection and Maintenance of

Cylinder Liner lnner Surface
Conduct the inspection and maintenance of the
cylinder liner (hereafter to be referred as liner)
inner surface in the state that the cylinder liner is
assembled in the engine frame, after overhauling
the cylinder head and piston.
(
(
a:
a 3-1.3 "Removal of Cylinder Head")
: 4-3.1 "Extraction of Piston")

(1) Visual lnspection

a) Observe the conditions of the carbon
deposited on the cylinder liner inner surface.
b) Remove the carbon, and check the inner
surface for scratch, scuffing, blow-by mark,
and corrosion.
(2) Measure the cylinder liner inner diameter.
Mount the liner position gauge @ in the state that
the cylinder liner is assembled in the engine
frame, measure the inner diameter with the
cylinder bore gauge 0, and record the results.

Nom. size Replacing limit Correction limit

-
(mm) (mm) (mm)
D= d 200 1.O Uneven wear: 0.3

(3) Measure the protection ring thickness with a

spherical micrometer, and record the results.

Nom. size (mm) Replacing limit (mm)

Measurement of Cylinder Liner lnner Dlameter
a = 8.7 - 0.25

Wear of the cylinder liner and protection ring

inner diameters depends on the quality of the
fuel oil used, control of lubricating oil, and
cooling water temperature. Progress of wear
causes problems such as blow-by and
increase in the consumption ol lubricating oil,
and therefore when the parls reach or come
close to the use limit, be minded to replace
them in an earlier stage.
Measurement of Protection Ring Thlckness
 Engine Frame and Cylinder Liner
ITEM Inspection and Maintenance of Cylinder Liner Inner
3, 4 DK-20 SurfacelExtraction of ~ i n e r

(4) Dressing (de-glazing) of cylinder liner (4) Remove the O-ring.

When the piston ring is replaced, or the cylinder
liner inner surface is in the mirror surface It is possible to conduct honing processing in
condition, dress the inner surface. the state that the cylinder liner is assembled
Conduct the dressing with sandpaper or by in the engine frame by using a special honing
honing. machine.
a) Polish the surface with sandpaper (#80) in the As for the details, consult the Service
circumferential direction, so that the surface Department of Daihatsu Diesel
may be marked with the sandpaper mesh. Manufacturing Co., Ltd.
b ) In the case of dressing by honing, correct the
uneven wear, and conduct honing, so that the
surface may be 5 to 10p Rz at the cross-hatch
angle of 40".
c) After the end of honing, measure the inner
diameter, and confirm that the inner diameter-
is within the replacing limit

5-4 Extraction of Cylinder Liner

Extract the cylinder liner after removing the
cylinder head and piston.
(a
(a : 3-1.3 "Removal of Cylinder Head")
: 4-3.1 "Extraction of Piston")
(1) Before extracting the cylinder liner, confirm that
water in the cylinder jacket is drained completely.
(2) Receive dirt, foreign matters, water droplets,
etc. on a vinyl sheet or the like, so that they may
not drop on the oil pan.
(3) Extract the cylinder liner in the following
procedure:
a ) Insert the liner fitting and disengaging
implement @-@ into the cylinder, making the
head bolt as the guide.
b) Mount the implement-2 0-@ to the implement-
1, and screw the implement until it hits against
the liner lower end surface.
c) Turn the nut @-a, and pull up the liner until
the O-ring of the liner lower part is completely
extracted out of the engine frame.
d) Tighten the nut @-a, and completely fix the
cylinder liner using the implement-2 @-a and
the implement-3 @-@.
e) Pass the wire rope around the liner fitting and
Extraction o l Cylinder Liner
disengaging implement-1 @@,and suspend it.
f ) Remove the liner fitting and disengaging
implement.
 Engine Frame and Cylinder Liner
ITEM
lnspection and Maintenance of Cylinder Liner Outer
Periphery and Engine Frame Jacket DK-20 5

5-5 lnspection and Maintenance of

Cylinder Liner Outer periphery and
Engine Frame Jacket
(1) Remove the scale o r silicone rubber
accumulated on the liner outer periphery using a
wire brush or the like.
(2) Subject flange fillet " A to the color check, and
inspect if there is any crack.
(3) lnspect the cylinder liner outer periphery " C
and engine frame jacket "U" for cavitation or
corrosion. If the degree of the defect is minor,
repair the faulty part using a repairing agent.
(4) lnspect the fitting areas "B" and "Dm,and the
inserting area " E and "G"of the engine frame for
corrosion and fretting.

u In case of the corrosion or cavitation is

found, the following possible reasons can be
considered: I
1) Cooling water rust preventive agent is not
effectively working. lnspection of Liner Outer Periphery
2) Cooling water pressure is low.
3) Cooling water is mixed with air.
Conduct appropriate cooling water control
in strict conformance with the Control
Standard.
0:
( "Operation" 6-3"Control of Cooling
Water")

(5) If the anti-corrosion coating film of the cylinder

liner outer periphery and the engine frame jacket
is peeled off, conduct touchup painting.

Pale gray-brownish deposit is a film of the

rust preventive agent that has been used.
Therefore, do not remove it.

lnspection of Engine Frame Jacket

 I

Engine Frame and Cylinder Liner

DK-20 Mounting of Cylinder Liner

5-6 Mounting of Cylinder Liner

Mount the cylinder liner in the reverse order of the
dismounting procedure:
Circular nut @@ p@

(1) Clean the cylinder liner inner and outer

surfaces, and O-ring grooves.
(2) Fit O-rings to the cylinder liner.
(3) Apply silicone rubber on the flange part outer
periphery "H" of the liner upper part, and also
apply it on the O-ring part upper side "I" of the
liner lower part.

2) After silicone rubber is applied, assemble

the cylinder liner at a little earlier timing
before it dries.

(4) Mount the liner in the following procedure:

a) Mount the liner fitting and disengaging
implement to the liner.
Tighten the nut @-a,
and fix the liner using the
implement-2 @@and the implement-3 00.
b) Pass the wire rope around the liner fitting and
disengaging implement-1 @@, suspend it by
a chain block, and insert it into the engine
frame.
Mounting of Cylinder Liner
Matching the punch mark of the liner and the
notched line of the engine frame (between the
2 lines), and slowing lower the liner, taking
care so as not to cut the O-ring.
Swing the liner, and lower it down until it does
not lower any more with its own weight.
c) Fix the implement-1 @-@ with the circular nut
for head bolt.
d) Remove the nut @-a and the implement-3
00.
e) Turn the nut @@anticlockwise direction, and
tighten it until the line is completely altached to
the engine frame.
f ) Remove the liner fitting and disengaging
implement @-a and @-@.
Engine Frame and Cylinder Liner
ITEM
Memo DK-20
 Main Bearing and Thrust Bearing
ITEM

1 DK-20 General Construction

6. Main Bearing and Thrust Bearing

6-1 General Construction Main bearing shell

The main bearings are of a suspension bearing

Engine
shell structure with the main bearing cap kame
hydraulically fastened rigidly by the main bearing
bolt and the side bolts.
The main bearing shells are made of aluminum
ide bolt
alloy of high wear resistance, and the top and
bottom bearing shell are positioned by means of
the claw.
The main bearing lubricating oil will be supplied
through the drilled holes of the engine frame from
the upper bearing shell.
The thrust bearings are made of aluminum alloy as
Main bearing cap
same as in the case of the main bearing, mounted
at the top and bottom on the both sides of the 1st
wall located on the engine rear side, and forcibly
lubricated through the drilled holes of the engine Main Bearing
frame.

1 Main bearing cap : 33 kg

I

"
Main bearing shell

Thrust Bearing
 kyo
Main Bearing and Thrust Bearing
ITEM
Replacing Consumables, Implements, and Measuring
Instruments DK-20 2

6-2 Replacing Consumables,

Implements, and Measuring
lnstruments
(1) Replacing Consumables
None @ Main Bearing Top Shell Extracting Implement

(2) Implements and Measuring lnstruments

@ General tools and measuring instruments
a( : 2-2)
@ Main bearing top shell extracting implement
@ Hydraulic ram assy.
@Hydraulic ram
@Shell cap implement-1
@Shell cap implement-2
@ Bolt
@ Hydraulic ram receptor metal fitting
@ Hydraulic jack and hydraulic pump for main
bearing @ Hydraulic Ram assy.
@ Hydraulic jack
@Jack stand
@Jack handle
@Hydraulic pump
@ High-pressure hose
a Terminal (4T)
@Male coupler @ Hydraulic Ram Receptor Metal Fitting

@ Hydraulic Jack and Hydraulic Pump

 Main Bearing and Thrust Bearing

DK-20 Disassembly of Main Bearing Shell

6-3 Main Bearing Shell

F o r disassembly and inspection of the main
bearing shell, the bearing shell can be extracted
only by lowering the main bearing shell cap without
removing it completely.

6-3.1 Disassembly of Main Bearing Shell

(1) Remove the covers of the both sides on the
engine frame side of the cylinders at the front
and rear of the main bearing to be disassembled,
and set the crank pin on the working side to be
(To the lefl)
horizontal on the opposite side.
(2) Disconnect the side bolt tightening nut using ,@@
the hydraulic jack.
(a : 2-4 "Hydraulic Jack Operating Method")
a) Mount the jack stand 0-@ and hydraulic jack
0-@ on the side bolts on the both sides, and
connect it to the hydraulic pump @-a
using a
Removal of Side Bolt Nut
high-pressure hose 8-@.
b) Operate the hydraulic pump lever to increase
the oil pressure to the specified level, and
loosen the nut using the jack handle 0-0.

Specified oil pressure: 69 MPa {700 kgf/crnz)

c ) Confirm the oil pressure to cause the nut to

turn, and check the side bolts for loosening.
d) Remove the hydraulic jack and jack stand.
e) Disconnect the side bolt tightening nut.
(3) Remove the main bearing cap tightening nut
using the hydraulic jack.
( m:2-4 "Hydraulic Jack Operating Method")
a) Mount the jack stand 06 and hydraulic jack
@-@, and connect them to the hydraulic pump
@@ using the high-pressure hose @-@.
b ) Operate the hydraulic pump to increase the oil
pressure to the specified level, and use the
jack handle 0-0 to loosen the nut.

=oli pressure : 78 MPa (800 kgf/cm2) I

c ) Check the oil pressure for the nut to begin to
turn, and inspect that the main bearing bolts
are tightened securely to b e f r e e from Removal of Main Bearing Cap Tightening Nut
loosening.
 '/ -

Main Bearing and Thrust Bearing

Disassembly of Main Bearing Shell

d) Remove the hydraulic jack and jack stand. I

e) Remove the main bearing cap tightening nut !! / i
on one side.
1) Mount the shell cap implement-1 0-@ on the
end of the main bearing bolt, of which main
bearing cap tightening nut is removed.

To prevent spontaneous fall of the shell cap,

~mmediatelymount the shell cap implement-1
after removing the main bearing cap

(4) Dismount the main bearing cap in the following

procedure:
a) Mount the hydraulic ram receptor metal fitting
@ t o the main bearing cap.
b) Mount the metal cap implement-1 0 4 3to the
main bearing bolt, and fix the metal cap
implement-:! 0-0 with the nut 0.
c) Alter fitting the rod end of the hydraulic ram
0-@ into the hydraulic ram receptor metal
fitting of the main bearing cap, mount them to
the metal cap implement-2 with the mounting
bolt@-a.
d) Connect the oil feed port "U" of the hydraulic
ram and the port "A" of the hydraulic pump
changeover valve with the high-pressure hose
m.
Likewise, connect the oil feed porl "DMof the
hydraulic ram and the port "B" of the hydraulic Mounting of Hydraulic Ram
pump changeover valve with the high-pressure
hose.
e) Operate the hydraulic pump @-a and
pressurize.

Be minded not to increase the hydraulic oil I f

pressure over the value of 19.6 MPa (200

- -
f ) Switch the changeover valve to "Return", and
slowly lower the main bearing cap. Connection of Hydraulic Ram
 1 - -
Main Bearing and Thrust Bearing
ITEM
I I
1 DK-20 Disassembly of Main Bearing Shell

I I the changeover valve is switched to "Return", Claw

the hydraulic oil flows from "8" to "D" and the
main
bearing cap lowers, and if the changeover
valve is switched to "Pressurize", the oil llows
from "A" to "U" and the main bearing cap rises.
*In the neutral position, the hydraulic oil does
not flow.
-In case that the main bearing cap dose not
lower, i f the side bolts on both sides are
loosened, it will facilitate to lower the cap.

(5) Disconnect the main bearing bottom shell from

the cap.
(6) Disconnect the main bearing top shell in the.
following procedure:
a) Insert the main bearing top shell extracting
implement aA into the crankshaft oil hole.

Be careful so that the main bearing shell Extraction of Main Bearing Shell
extracting implement may not come off the (Viewed from the engine front side)
oil hole. Application of grease to the
insertion side of the extracting implement will

-
make it difficult for the implement to come
on.

b) Press the main bearing shell extracting

implement against the end face of the main
bearing top shell, turn the crankshaft
anticlockwise as viewed from the engine front
side, and then extract the top shell,

Be careful not to turn the crankshaft in a

wrong direction. The positioning claw is
provided on the main bearing shell, and it will
be damaged if the crankshaft is turned in a
wrong direction.
 Main Bearing and Thrust Bearing
ITEM
Inspection and Maintenance of Main Bearing Shell DK-20 3.2

6-3.2 lnspection and Maintenance of

Main Bearing Shell
(1) Inspect if there is fretting on the rear surface Main bearing
and the joint surface of the main bearing shell. upper shell
and also check if there are seizure mark, peel.
cavitation, or imbedded foreign matters in the
inner surface. When the degree of the fault is
minor, correct the surface using an oil stone.

;
The main bearing shell is a thin-wall finished
metal, and provided with appropriate
interference (crush) and tension, so as to
make it tightly fit to the housing surface. Main bearing
Therefore, do not repair the rear surface and lower shell
joint surfaces with a file or scraper.
Main Bearing Shell

u 1) Long-time use of the shells brings about

the reduction of tension and hardening of
the shell surfaces to cause crack and peel
of the shells, even if the wear is below the
allowable value. Therefore, be minded to
replace the shells every 16,000 to 24,000
hours (4 to 5 years).
2) Be sure to simultaneously replace the top
and bottom shells as one pair set.

(2) Check the seat surface of the tightening nut

and the seat surface of the cap side, and if there
is any roughness on them, correct the part.
(3) If the tightening nut of the disassembled main
bearing bolt is found to be loosened, retighten
the other main bearing bolts as well.
(4) lnspect the main bearing cap joint surface and
the contact surface of the fitting area, to check if
there is any fault such as fretting.
(5) lnspect the crankshaft surface for scratch, and
also check the contact and wear conditions.
 Main Bearing and Thrust Bearing
ITEM
3 3 DK-20 Assembly of Main Bearing Shell

6-3.3 Assembly of Main Bearing Shell c) Confirm that the shell is completely mounted.
d) Sufficiently apply lubricating oil to the bottom
(1) Visually check and also check with naked hand
shell inner surface with naked hand.
that the crankshaft journal part is free from the
deposit of foreign matters and scratch.
(2) Clean the shell inner surlace and rear surface
Be minded not to apply lubricating oil to the
with washing oil, then carefully wipe off the oil.
back surface of the shell. If the oil is applied.
(3) Assemble the top shell to the engine frame in
the adhesion performance decreases.
the following procedure:
a) Check the positions of the top shell claw and
the helical groove in the engine frame, and
push in the top shell from the side not
equipped with the claw by hand as deeply as
possible.
b) Insert the main top shell extracting implement
into the crankshaft oil hole according to the
same procedure as that for disassembly.
c ) Turn the crankshaft counterclockwise as
viewed from the engine front side, and push
the top shell into the engine frame, until the top
shell end face fits the main bearing cap joint
surface of the engine frame.

Conduct turning with enough care, so that

the main bearing top shell extracting
implement may not be dislocated from the
shell end face.

d) Confirm that the top shell is inserted in the

regular position. Assembly 01 Main Bearing Shell
e) Turn the crankshaft anticlockwise as viewed
from the engine front side, and remove the
main bearing top shell extracting implement.

(4) Assemble the bottom shell to the main bearing

cap in the following procedure:
a) Visually recheck and also recheck with naked
hand that the crankshaft journal and the main
bearing cap inner surface are free from the
deposit of foreign matters and scratch.
b) Confirm the positions of the bottom shell, the
end face of the main bearing cap, and the
claw. And then, mount the bottom shell lo the
main bearing cap.
 Main Bearing and Thrust Bearing

Assembly of Main Bearing Shell DK-20 "EM3.3

(5) Assemble the main bearing cap in the reverse a) Tighten the two side bolts of the same main
order of the extracting procedure. bearing at the same time.
a) Match the main bearing cap side face with the b ) After tightening the bolts with the specified
engine frame side face, switch the changeover pressure, once return the oil pressure back to
valve to "Pressurize" (main bearing cap raising "OM,then increase the oil pressure up to the
direction), and slowly push up the main bearing specified value again to check for t h e
cap until it strikes the joint surface of the upper tightening conditions.
area engine frame.
b) Spray the lubricating agent (MOLYKOTE 1000
spray type) to the threaded area o n the
studding side of the side bolt, and manually
screw the bolt into the threaded hole of the
main bearing cap.
Turn it back by 114 to 112 turn aHer the bolt is
screwed down to the bottom.
c) Screw the side bolt tightening nut until it is
completely settled to the bottom.
d) Remove the hydraulic ram assembly and
hydraulic ram receptor metal fitting, and
manually screw the tightening nut into the main
bearing bolt.

To prevent the spontaneous falling-off of the

Application of Lubricating Agent
main bearing cap, remove the hydraulic ram
aHer screwing the side bolt.

e) Install the hydraulic jack, and conduct the

hydraulic tightening of the bolts.
The tightening shall be made on the 2 bolts at
the same time.

Specified oil pressure: 78 MPa (800 kgf/cml)

1 ) After tightening the bolt with the specified

pressure, once return the oil pressure back to
"On, then increase the oil pressure up to the
specified value again to check for the
tightening conditions.

(6) Mount the hydraulic jack on the side bolts, and

tighten the bolts hydraulically.

Specified oil pressure: 69 MPa (700 kgt/cm2)

 Main Bearing and Thrust Bearing
ITEM
4.1 DK-20 Dismounting of Thrust Bearing

6-4 Thrust Bearing

The thrust bearings are mounted on the front and
rear surfaces of No.1 main bearing (flywheel side).
Dismount the thrust bearings at the time of
disassembling the main bearing.

6-4.1 Dismounting of Thrust Bearing

(1) Measure the side clearance of the crankshaft
according to the following procedure before
dismounting the thrust bearing:
a) Use the bar to shift the crankshaft toward the
either side, front or back, and place the dial
gauge against the crankshaft.
b) Fully shift the crankshaft toward the opposite
side, and read the value. bd kd
Thrust Bearing
When hooking the bar on the crankshaft,
hook it on the crank web, and do not hook
the bar on the balance weight.

(2) The bottom side thrust bearing is mounted on

No.1 main bearing cap with knock pins (1 piece
each o n both sides). Therefore, it can be
disconnected at the same time when the main
bearing bottom shell is extracted.
(3) The top side thrust bearing can easily be
extracted when the end face is pushed with
hand.

The thrust bearings are designed to form a

pair with the top and bottom shells.
Therefore, be careful not to mistake the front
thrust bearing for the rear thrust bearing.
Discriminate them by marking or the like.

Measurement of Side Clearance

 Main Bearing and Thrust Bearing

Maintenance and Assembly of Thrust Bearing

6-4.2 Maintenance of Thrust Bearing

(1) Check the thrust bearing for seizure mark and
imbedded foreign matters. If the delect is of
minor degree, repair the defect using an oil
stone.
(2)Measure the thrust bearing thickness using an
outside micrometer, and record the results.
(3)When the thrust bearing wear is heavy, and the
clearance with the crankshaft is exceeding the
replacing limit, replace the thrust bearing with a
new one.
Be sure to replace the thrust bearing as one set
of a pair of the top and bottom shells.

Nom. size Standard Replacing Thrust Bearing

(mm) clearance (mrn) limit (mm)
D=92 d=0.13-0.30 0.6

6-4.3 Assembly of Thrust Bearing

(1) Carefully clean the thrust bearings and apply
lubricating oil to the bearing surfaces.
(2)Insert the top side thrust bearing.
(3)Mount the bottom side thrust bearing to the
main bearing cap, and assemble them together
as an assembled parts.
(4) Measure the side clearance.

Side Clearance
 -

Crankshaft and Balancer Shaft

ITEM Crankshaft: General Construction/Consumables,
1.2 DK-20
1.I, Implements, and Measuring Instruments

7. Crankshaft and Balancer Shaft

7-1 Crankshaft 7-1.2 Replacing Consumables,

Implements, and Measuring
7-1.1 General Construction
lnstrurnents
The crankshaft is a high-strength carbon steel RR
(1) Replacing Consumables
forged product of one-piece construction, and
None
provided with sufficient rigidity and strength.
The thrust bearing is processed by induction
(2) Implements and Measurlng Instruments
hardening to increase abrasion resistance.
Two pieces of the balance weight are fined to each
a General tools and measuring instrurnenls
( Q : 2-2)
cylinder, and they are securely tightened with two
pieces of the bolts respectively.
The crank gear is shrink-fitted to the rear side of
the crankshaft to drive the camshaft, and further,
the auxiliary drive gear is bolted on the front end to
drive the lubricating oil pump and cooling water
pump.
Lubricating oil supplied to the main bearing
through the holes of the engine frame reaches the
crank pin metal through the drilled holes in the
crankshatl, and further flows to the piston pin and
piston through the drilled holes in the connecting
rod.
The crankshaft is manually turned by the turning
device on the flywheel side.

Crankshalt assy.: 3DK : 740 k g

5DK : 1059 k g
6DK : 1287 k g
Turning Device

puxiliary Drive G e a ~ Crank gear

Crankshaft
 Crankshaft and Balancer Shaft
ITEM
Inspection and Maintenance of Crankshaft DK-20 1.3

7-1.3 lnspection and Maintenance of :

In case that the following situations has
Crankshaft
happened and if the operation is continued
In ordinary maintenance, the crankshaft is not
disregarding any one of them, it may result in
disassembled, but inspected and adjusted in the
serious damages or accidents:
state that it is assembled.
@ In case that the engine is operated for a
When it becomes necessary to overhaul the
long time in the dangerous rotation number
crankshaft because of the particular reasons such
range due to torsional vibration
as seizure of the bearing or abnormal wear of the
@ I n case that the engine is operated
shaft, consult our Service Department.
exceeding the allowable value of the
crankshaft deflection
1. lnspection of Crank Pin
@ In case that the clearance between the
lnspect the crank pin when the connecting rod crankshafl and shell is excessive, or the
large end part is disassembled. crankshaft is unevenly worn out
(a : 4-3.2 "Disassembly of Connecting Rod
Large End Part")
@ In case that the shell is burnt (In case of
minor degree)

(1) Check the bearing for scratch and contact

conditions.
If scratch is found, correct it using an oil stone,
and conduct the color check carefully.
(2) Measure the shaft diameter, and record the Presence ol
hair crack
results.
(a: 4-4.4 "lnspection and Maintenance of
Crank Pin Shell")
(3) Subject the fillet to color check.
In case that the problems such as the ones as
described above are found, carefully conduct the
color check with particular attentions.

2. lnspection of Crank Journal

lnspect the crank journal when the main bearing
shell is disassembled.
(1) Check the bearing for scratch and contact
conditions.
(2) Subject the fillet to color check.
In case that the problems such as the ones as lnspection of Crankshatl
described above are found, carefully conduct the
color check with particular attentions.

When disassembly o f the crankshaft is

required as a result of inspection, consult our
 Crankshaft and Balancer Shaft
ITEM Crankshaft: Inspection of Balance Weight Bolt Tightening
1.4,l.S DK-20 ForcelMeasurernent of Deflection

7-1.4 lnspection of Balance Weight Bolt

Tightening Force
(I) lnspection o f every 4,000 t o 6,000 h o u r s
(every year).
Inspect the rotation-stopper wire ring conditions.
and confirm that the balance weight bolt is not
loosened.
(2) lnspection of every 16,000 t o 24,000 hours
(4 t o 5 years)
Inspect the balance weight bolt tightening
conditions in the following procedure:
a) Remove the rotation-stopper wire ring.
b) Set the torque wrench to the specified torque,
and confirm the tightening force.
When the bolt does not turn, it is sufficiently
tightened, and then conduct the rotation .
stoppage with the wiring.
c ) In case that the bolt is turned, remove the bolt,
/'
Wiring
Balance weighl boll
Balance weighl

apply the lubricating agent (MOLYKOTE 1000

Balance Weight Bolt
spray type), and once again tighten the bolt
with the specified torque.
d) Atter tightening, conduct the rotation stoppage
with wiring.

Specified torque: 980 N. m { I 0 0 kgf . m)

7.15 Measurement of Crankshaft

Deflection

s 1) Measure the crankshaft deflection when the

engine is cold.
2) When the engine is continuously operated in
the state that the crankshaft deflection is
over the limit value, the added stress of the
crankshaft will become excessive, and will
lead to the breakage of the crankshaft in the
worst case.
Therefore, adjust the deflection to a proper
value at the time of installation, and
periodically measure the crankshaft
deflection every 2,000 to 3.000 hours (every
6 months) after the start of operation of the
OCrankshaft deflection measuring procedure:
engine, and correct the situation in case that
the deflection is over the limit value.
(a: "Operation" 5-4.5 "Measurement of
Crankshaft Deflection")
7.2 Balancer Shaft 7-2.2 Replacing Consumables,
Implements, Measuring Instruments
7-2.1 General Construction
(1) Replacing Consumables
In 3DK engine, the balancer shaft is provided for
Replace the following parts with the new ones:
the purpose of controlling vibration.
The balancer weight is provided on the front side
( a
a
: "Parts List")
Automatic core-adjusting bearing 3-8 No.5
and rear side of the balancer shaft, and is
@O-ring 3-8 No.507
supported in the crank case with 4 thin-wall shells
@Gasket 3-8 No.16
and 2 automatic core adjusting bearing, and is
@Gasket 3-8 No.17
driven by the auxiliary drive gear
. located on the
front side of the engine.
(2) Implements and Measurlng Instruments
@ General tools and measuring instruments
( IQI:2-2)
Balancer shaft assy. : 131 k g
@ Bearing retainer
@Jack bolt
@Jack bolt
@Plate washer

@ Bearing Retainer . @ Jack Bolt

Aulomalic core-adjusting
Balancer shafl Balancer weigh
Thin-wall shell

\
B a l a n c e r weight R
ri
Auxiliary drive gear

Balancer Shafl Assembly

 Crankshaft and Balancer Shafi
ITEM
1 /
2.3 DK-20 Inspection and Maintenance of Balancer Shaft

7-2.3 lnspection and Maintenance of

Balancer Shaft
In ordinary inspections, balancer shaft is not
disassembled, however replace the automalic
core-adjusting bearings on the both sides at every
16,000 to 24,000 hours (4 to 5 years) with the new
ones.

(Replacing procedure of automatic core-

adjusting bearing)
1. Removal of bearing
(1) Remove the bearing housing cover-F @ on the
front side.
(2) Disconnect the mounting bolt of the bearing
housing-F @, mount the jack bolt (M12) to the
shaft housing-F and evenly tighten it, and then
remove the bearing @ and bearing housing-F.
(3) Remove the bearing @ from the bearing
housing-F.
(4) Attach the bearing housing-F and bearing
housing cover-F again, and fix the balancer shafi
with the jack bolt (M14) 8.
( 5 ) Remove the bearing housing cover-R @ on the
rear side, and remove lhe bearing slopper @ by
loosening the bolt @.
(6) Mount the jack bolt (M12) on the bearing
housing-R @ and evenly tighten it, and then
remove the bearing 0and bearing housing-R.
( 7 ) Remove the bearing 0 from the bearing
housing-R.

2. Assembling of Bearing
(1) Adjust the jack bolt @ of the bearing housing
cover-F @ and, and fix it at the place where "a"
on the rear side of the balancer shaft is 1 to 1.5
mm.
(At this moment, the distance between the faces
of the bearing housing-R @ and balancer shaft is
17.5 to 18 mm.)
(2) Put the bearing @ into the bearing housing-R
0, and tighten the jack bolt 8 until the bearing
hits the shoulder of the bearing housing-R, while
Placing the bearing retainer @ on it.
 I

Crankshaft and Balancer Shaft

ITEM

.
Inspection and Maintenance of Balancer Shaft DK-20 2.3

(3) Remove the jack bolt @ and bearing housing-F

@ on the front side, and tighten the jack bolt @
on the rear side until it does not turn any more, to
change the clearance "a" to 0.
(4) Screw the bearing @ on the front side into the
balancer shafi using the bearing retainer @ and
jack bolt @, on the state that the bearing is
attached with the bearing retainer @ on the rear
side and jack bolt @.
(5) When the jack bolt on the front side does not
turn any more, remove the jack bolt and bearing
retainer on the front side and rear side.
( 6 ) Mount the bearing stopper @ on the rear side
to the balancer shaft using the bolt 0, and attach
the bearing housing cover4 @.
( 7 ) Attach the bearing housing cover-F @ of the
front side.
 Timing Gear and Camshaft
.
ITEM
1 1 DK-20 General Construction of Timing Gear

8. Timing Gear and Camshaft

High technology is needed to disassemble,
8-1 Timing Gear assemble, and adjust the area around the
timing gear and camshaft.
8-1.1 General Construction
When the maintenance of such high
The timing gear is arranged on the engine front technology is needed as the results of the
side, and the camshaft is driven by the cam gear inspection, please contact our Service
@, from the crank gear @ located o n the Department or agency, and perform suck
crankshaft rear side, via the idle gear-1 @ and idle works under the experienced engineers'
gear-2 0. guidance.
All the gears are helical gears made of high-
strength alloy steel, and the c a m gear tooth
surfaces are carburized and hardened.
The cam gear is fixed to the camshaft by means of
the shaft fastening elemental parts (POWER-.
LOCK) @, which makes use of the wedge effect.
Lubricating oil is supplied to the idle gear bush @
through the drilled holes of the idle gear shaft bolt
@ and idle gear shaft @.
The gear tooth is lubricated through the oil feed
nozzle.

Cam gear : 39 k g
Idle gear assy. : 44 k g

Engagement of Timing Gears Timing Gears

 Timing Gear and Camshaft
Timing Gear: Replacing Consumabes and
ImplementsIDisassembly of Idle Gear I DK-20 I1.2,1.31
ITEM

8-1.2 Replacing Consumables,

Implements and Measuring instruments
(1) Replacing Consumables
Replace the following Consumables with the new
ones:
(&Q : "Pads Listn)
@O-ring 3-6 N0.502, 503, 504 @ Idle Gear Shaft Implement @ Spanner 41 x 25.4

(2) Implements and Measuring Instruments

@ General implements and measuring
instruments (m : 2-2)
@ ldle gear shaft implement (option)
@Spanner 41 X25.4 (option) @
Hex.I
Wrench 1 4 X 12.7
@ Hex. wrench 14X 12.7 (option)

8-1.3 Disassembly of ldle Gear

When disassembling the idle gear, the cam gear is
needed to be extracted beforehand so that the idle
gear can be dismounted from the cam gear cover
side.
( &Q : 8-2.3"Disassembly of Camshaft")

(1) Remove the flywheel cover.

(2) Remove the governor and governor driving
device.
(a:
Device")
11-3 "Disassembly of Governor Driving

(3) Remove the mist pipe on the rear side.

(4) Conduct the following measurement before
disassembling the idle gear:
a) Measure the thrust clearance on the axis
direction of the idle gear, and record the data.

Standard clearance Replacing limit

b = 0.3 - 0.7
ldle Gear Thrust Clearance
 >

Timing Gear and Camshaft

ITEM
1 3 DK-20 Timing Gear: Disassembly of Idle Gear

b) Measure the backlash between the timing Lead wire

gears, and record the data. / .

i ) Bend a lead wire of 0.5 mm diameter along

the tooth profile, and adhere it using grease.
ii ) Slowly turn the engine, and stop the turning
at the point where the lead wire is caught.
iii) Next, turn the engine i n the reverse Backlash b (= A + B)
direction, and pick up the lead wire to this
side. -
. p
iv) Measure the thinnest part of the thickness
of the lead wire that is collapsed. (A and B
as shown in the figure)
v ) Conduct the measurement in the 4 places
per 90'on the large gear wheel, and take its
average value.

I Backlash
A+B
Standard value

b = (0.2 -) 0.3

( 5 ) Remove the cam gear.

Replacing
limit (mm)
0.5 1
( a: 8-2.3 " ~ i s a s s e m bofl ~Cam Gear")
( 6 ) Install the eyebolt to the idle gear-1 @, and
support the i d l e g e a r - 1 by passing the
suspending wire around the eyebolt from the
mist exhaust port of the engine frame
( 7 ) Remove the oil feed plug of the idle gear shaft
bolt 0, and remove the idle gear shaft bolt using
the spanner 41 x 25.4 0.
(8) Screw the bolt of the idle gear shaft implement
@ into the idle gear shaft support-3 0, and
remove the idle gear shaft support-3.
(9) Mount the idle gear shaft implement on the idle
gear shaft support-2 0.
Screw the bolt into the idle gear shaft support
implement, a n d extract the idle gear shaft
support-2 and idle gear shaft support-4 @ at the
same time.
(10) Remove the bolt with the hole in the idle
gear shaft using the hexagonal wrench @.
(11) Screw the idle gear shaft bolt into the idle gear
shaft, and extract the idle gear shaft.
(12) Take out the idle gear from the cam gear 4
cover side of the engine side face, by slowly
loosening the wire. Idle Gear Disassembling Procedure
 Timing Gear and Camshaft
ITEM
Inspection and Maintenance of Timing Gear DK.20 1.4

8-1.4 lnspection and Maintenance of

Timing Gear
(1) Wash all the gears and parts using washing oil.
(2) Clean the idle gear shaft oil hole by blowing air.
(3) Check the idle gear-1. -2, and cam gear tooth
surface tor contact, pitching, and scratch.
(4) Turn the crankshaft, and check the crank gear
as well, in the same manner as above.
(5) lnspect the tightening conditions of the
tightening bolt @ of the idle gear-1 and idle gear-
2.
lnspect the bolt tightening conditions under the
specified torque, and in case that the bolt is
loosened, remove the bolt, clean it, and then
tighten it again with the specified torque.
In case that the thread of the bolt is damaged,
replace the bolt with a new one.

I Specified torque : 118 N.m {I2 kg1.m) I

( 6 ) Check the idle gear bush and shaft for the
contact and wear conditions.
( 7 ) Measure the outer diameter of the bush contact
area of the idle gear shalt using an oulside
micrometer.
(8) Measure the inner diameter of the idle gear
bush using a cylinder gauge.
(9) Calculate the clearance from the results of the
measurement of the idle gear shaft and idle gear
bush, a n d when the clearance i s over the
replacing limit, replace the idle gear bush with a
new one.

Nom. size Standard Replacing

clearance (mm) limit (mrn)
A= $ 6 5 a=0.0-0.15

When it is presumed that the clearance will

be over the replacing limit before the next
periodic maintenance, replace the bush,
even if the clearance is presently within the
limit.
Idle Gear Bush Clearance
 , -
Timing Gear and Camshatt

DK-20 Timing Gear : Assembly of ldle Gear

8-1.5 Assembly of ldle Gear

Assemble the idle gear according in the reverse
order of the disassembling procedure.

(1) Suspend the idle gear assembly with a wire,

and move it to the specified place.
(2) Turn the crank shaft, a n d place the No.1
cylinder to the position of the intake top dead
center.
(3) Apply grease to the idle gear bush 0, and
match the matchmarks of the idle gear-1 @ and
crank gear.
(4) Apply lubricating oil to the idle gear shaft @I,
insert it into the idle gear and idle gear shaft
support-1 @, and then match the knock pin'
positions.
(5) Apply lubricating agent (MOLYKOTE 1000
spray type) to the thread area and seat surface
of the bolt a with the hole, and tighten it with the
specified torque using a hexagonal wrench.

I Specified torque: 196 N. m (20 kgf. m) I

( 6 ) Assemble the idle gear shaft supporl-2 @ and
idle gear shaft support-4 0.
Mount the idle gear shaft implement @ and ldle
gear shaft support-2, -4 to the idle gear shaft bolt
0.
Tighten the idle gear shaft bolt until the idle gear
shaft support-2 becomes tightly in contact with
the idle gear shaft.
( 7 ) Remove the idle gear shaft bolt and idle gear
shaft implement.
(8) Apply the lubricating agent (MLYKOTE 1000
s p r a y type) t o the threaded area and seat
surface of the idle gear shaft bolt, mount the idle
gear shaft support-3 0, and angularly tighten it
with the specified torque using the spanner 41 X
25.4 0.

A-torque: 196 N . m {20 kgf . m) ldle Gear Assembling Procedure

Angular tightening (6 mark): 40"
B mark equivalent torque:
588 N . m (60 k g f . m )
-

-
Timing Gear and Camshaft

Timing Gear : Assembly of Idle Gear

[Cautionary items when assembling the

liming gears)
3 ) The engagement matchmarks of the
timing gears are notched on the side of
each gear.
engagement
Be sure to check the
matchmarks
assembling the gears without fail.
when
\

DK-20
ITEM
1.5

b) When the matchmarks of the crank gear

and idle gear are engaged, also have the
matchmarks of the cam gear and idle gear
engaged at the same time.
c) If the slit on the flywheel side of the cam
gear is aligned with the engine end face,
while matching the engagement
matchmarks on the crank gear side, the
matchmarks of the cam gear and idle gear
will be engaged. This figure shows the engagement of timing gears
d) Since it is required to determine the oil when No.1 cylinder is on the position of the intake
injecting direction of the idle gear oil feed top dead center.
nozzle, be careful of the mounting direction
of the nozzle. Matchmarks of Timing Gears

--
The punch mark direction of the nozzle
hexagonal h e a d i s the oil injecting
direction. Be minded lo conduct the shim
adjustment so that the punch mark faces
toward the horizontal direction of the Oil injecling direclion
engine inner side.

Mounting Direction of Oil Feed Nozzle

 97 1
Timing Gear and Camshaft
ITEM
2 1 DK-20 General Construction of Camshaft

8-2 Camshaft
8-2.1 General Construction
The camshaft is of one-piece construction made of
carbon steel, and is driven by the cam gear
located on the rear end part.
The governor driving device is provided to the cam
gear upper part, and is directly driven from the cam
gear.
The starting air rotary valve is driven from the
camshaft front end via the Oldham's coupling.
The intake and exhaust cams are fixed to the
camshaft by shrink fitting, and these cams are
positioned by the key.
T h e fuel cam is also fixed to the camshaft by
shrink fitting as in the same manner as the case of '
the intake and exhaust cams.
The surface of each cam is carburized.
The cam bearings are provided at the front and
rear of the cam gear, and the cam bearings are
a l s o provided at the front side of the fuel oil
injection pump of each cylinder.
The bearing housing between each cylinders is
divided into 2 parts, i.e. the upper and lower
sections, and the cam bearing pin combines the oil Camshaft Rear End
feed passage.
a
(
a
(
: 8-1 "Timing Gear")
: 1 1 "Governor Driving Device")
QCamshaft divided into 2 sections (optional

a
( : 13-3 "Starting Air Rotary Valve")
specification)
The camshaft divided into 2 sections is divided
at the center of the camshaft in relation to the
Camshaft assy. (excluding cam gear) :
disassembly space, and the connecting flange
3DK : 96 k g
is tightened with 10 sets of the bolts and nuts.
5DK : 140 k g
The outer periphery of the flange is the bearing
6DK: 160 k g
part, and the bearing shell is press-fitted into
8DK: 210 k g
the engine frame.

Camshaft Divided Into 2 Sections (Option)

-
Timing Gear and Camshaft
ITEM
Camshaft : Replacing Consumabes, Implements, and
Measuring Instruments DK-20 2.2

8-2.2 Replacing Consumables,

Implements, and Measuring
lnstruments
(1) Replacing Consumables
Replace the following pads with the new ones.
( a : "Park List")
O-ring 3-8.7No.6509
@ O-ring 3-8.1 - 8.6 No.6511
-
@Circular gasket 3-8.1 8.6 No.8510

(2) Implements and Measuring Instruments

General implements and measuring
instruments(a : 2-2)
@ Camshaft shell extracting implement
.....For the camshaft divided into 2 sections
(Option)
@ Shell extracting implement-1
@Shell extracting implement-2
@ Bolt
@ Camshaft shell assembling implement
..... For the camshaft divided into 2 sections @ Camshaft Shell Extracting Implement
(Option)
@Shell assembling implement-1
@ Shell assembling implement-2
@Shell assembling implement-3
@ Shell assembling implement-4
@ Fuel oil cam adjusting implement (option)
@ Hydraulic pump (Use the one for hydraulic
jack.)
@ High-pressure hose (Use the one for
hydraulic jack.)
@Coupler
@Fuel oil cam adjusling handle

@ Camshaft Shell Assembling Implement

 Timing Gear and Camshaft
ITEM

2 3 DK.20 Disassembly of Camshaft

8-2.3 Disassembly of Camshaft

Disassemble t h e camshaft i n the following
procedure:

(1) Remove the governor, governor driving device,

starting air rotary valve and its related parts, and
piping.
a:
( 11-3 "Governor Driving Device")
a:
( 13-3 "Starting Air Rotary Valve")
(2) Remove the gear case on the front side of the
camshaft, cam gear cover on the side of the
camshaft, and cam chamber cover.
(3) Take out the cylinder head cover, and remove
the rocker arm device and push rod.
(m : 3-4 "Rocker Arm Device")
(4) Remove the fuel oil injection pump and valve
driving device.
( a : 9 "Fuel Oil Injection Pump")
a:
( 10 "Valve Driving Device")
(5) Before removing the thrust bearing, measure
the thrust clearance of the camshaft. I l l
Placing a dial gauge against the top end of the
camshaft, and measure the clearance by moving Thrust Bearing
the camshaft back and forth.

Standard clearance(mm) Replacing limit(mm)

b = 0.15 0.45

(6) Remove the thrust bearing located on the rear

side of the camshaft in the following procedure:
a) Loosen the bolt, and take out the bearing
cover @.
b) Loosen the thrust bearing mounting bolt, and
remove the thrust bearing @ and thrust shell
0.
c ) Remove the bearing body @.
Remove the bearing cover, thrust bearing, and
bearing body using the jack bolt.
(7) Remove the POWER-LOCK @ mounted on the
cam gear in the following procedure: Removal of POWER-LOCK
a) Confirm ihat the rotational torque or thrust
load is not applied on the boss and shaft.
b) Gradually l o o s e n the POWER-LOCK
tightening bolt @ by dividing into several steps.
C ) Remove the POWER-LOCK by screwing and
tightening the tightening bolt @ i n t o the
dismounting threaded hole.
 11 79
Timing Gear and Camshaft
ITEM
Disassembly of Camshaft DK-20 2.3

(8) Remove the camshaft positioning pin of the (8) Disassemble the cam bearing, and remove it
carnshaft upper part shelf. from the camshaft.
(9) Move the carnshaft to the front of the engine to (9) Extract the camshaft-R toward the front.
as much extent as that the disassembling of the
carnshaft is possible.
(10) Divide the cam bearing, and remove it from
the camshaft. Reamer boll
The cam bearing is divided into 2 parts of the
upper a n d lower sections, a n d can be
disassembled if the reamer bolt is removed.
(11) Move the camshaft to the front of the engine,
and take out the cam gear from the side of the
cam gear chamber.
(12) Extract the camshaft toward the front.

When disassembling the camshall, be

careful not to damage the cam and camshaft.

ODisassembly of the camshaft divided into 2

sections
(1) After finishing the works of the above Item (1)
to (a), loosen the nut of the divided parts at the
center o f the camshalt, and remove the
tightening bolt.
(2) Move the camshaft-F to the front of the engine
to as much extent as that the cam bearing can
be disassembled.
(3) Disassemble the cam bearing, and take out it
from the camshaft.
(4) Extract the camshaft-F toward the front.
(5) Move the c a m s h a f t 4 toward the rear, and
mount the camshaft shell extracting implement.
(6) Push in the extracting implement bolt, and
extract the carnshaft shell.
(7) Move the camshaft4 to the front of the engine
to as much extent as that the cam bearing can \
be disassembled. Camshatl shell

\ \
Cam bearing Camshaft shell
Camshatl Divided Into 2 Sections
 Timing Gear and Camshaft
ITEM
2.41 I
DK-20 lnspection and Maintenance of Camshaft

8-2.4 lnspection and Maintenance of ( 5 ) lnspect the wearing, scratch, or peeling

Camshaft conditions of the thrust shell.
(6) Maintenance of POWER-LOCK
a) Disassemble the POWER-LOCK by extracting
Since the items mentioned in this section are
the bolt, and clean all the parts.
the parts to which NOx Technical Code shall
b) Thinly apply lubricating oil on all the parts.
be applied, when replacing any of these parts,
b e sure to use the parts provided with the
identification marks.
Do not use the oil which contains silicone
( 0: 0-3 "Engine Conforming to NOx
type or molybdenum type lubricating agenl.
Technical Code.")
Use of such an oil decreases the friction
coeflicient and allows easier sliding.
(1) lnspect if there is any pitching or peel on each
cam surface.
c) Assemble the camshaft so that the blanked
tap hole of the inner ring and the phase of the
outer ring slit part do not match.
When the pitching, peeling, or wearing on the
cam surface is excessive, it is necessary to
replace the cam with a new one.
When the damage is of light degree, the cam
service life can be extended to some degree
b y conducting the surface treatment.
Therefore, consult our Service Department.

(2) Inspect if the cam is not slid.

(3) Check the camshaft shell for the wearing,
scratch, or peeling conditions.
(4) Measure the clearance between the camshaft
and the bearing.
a) Measure the outer diameter of each bearing of
the camshaft using an outside micrometer.
b) Assemble the cam bearing incorporating the
shell, and
measure the inner diameter of the bearing using
a cylinder gauge.
c) Calculate the clearance from the results of the
measurement, and in case that the clearance
is over the replacing limit, replace the bearing
shell with a new one.

Norn. size Standard Replacing

limit (mm)
\
(mm) clearance (mm) Clearance of cam bearing
A=+90 a=0.04-0.12 0.2
Clearance of Cam Bearing
 Timing Gear and Camshaft

Inspection, Maintenance, and Assembly of Camshaft DK-20 2.4 , 2.5

Olnspectlon and maintenance of the camshaft

divided into 2 sections
As for the bearings of the divided sections, also
inspect for the wearing, scratch, and peeling
conditions of the bearing shell, as same manner
as in the case of the other bearings.
Measure the bearing clearance, and in case that
the clearance is over the replacing limit, replace
the bearing shell with a new one.

Nom. size Standard Replacing

clearance (mm) limit (rnm)
A= $155 a=0.07-0.19

8-2.5 Assembly of Camshaft

Assemble the camshaft in the reverse order ol the Posilioning pin
I
disassembling procedure.
(1) Clean the boss inner surface of the cam gear
and the surface of the camshaft, and thinly apply
lubricating oil on them.
(2) Insert the camshatt into the position to as much
extent as that the cam bearing can be installed.
Insert the cam gear and POWER-LOCK into the
camshaft.
(3) Confirm the matchmarks of the top and bottom
cam bearings, assemble the shell into the
housing, and tighten the nut b y passing the
reamer bolt.
(4) Move the camshaft and cam bearing to the ~ d j u s l i nhole
~

position where the cam bearing positioning pin

holes can be matched.
(5) Attach the circular gasket and O-ring to the
cam bearing positioning pin, and then fit and
install the pin into the cam bearing pin hole.
To fit the pin into the bearing pin hole, move the
cam bearing toward the circumferential direction,
and toward the front and rear directions, utilizing
the adjusting threaded hole or the hole of the
cam bearing side face.
(6) Install the thrust bearing.
 Timing Gear and Camshaft

DK.20 Assembly of Camshaft

( 7 ) Adjust the thrust bearing clearance.

Place the dial gauge against the tip o f the
camshaft, move the camshaft back and forth,
a n d then adjust using the shim so that the
clearance becomes 0.1 5 mrn.
(8) Fix the c a m gear t o the camshaft using
POWER-LOCK. Install the cam gear so that the
clearance between the cam gear and idle gear-1
@becomes 3 mm.
(9) Tighten the POWER-LOCK in the following
procedure:

(POWER-LOCK tightening procedure)

a ) Lightly p u s h the POWER-LOCK to the
specified position by hand, in the state that the.
POWER-LOCK tightening bolt i s lightly
tightened.
b) After inserting the POWER-LOCK to the
specilied position, tighten the tightening bolts
of 4 places diagonally with about 114 torque.
Next, tighten the other tightening bolts in the
same manner.
c ) Setting the tightening torque to about 112 of
the specified torque, sequentially tighten the
bolts diagonally in the same manner as in Item
b).
d) Sequentially tighten all the tightening bolts
with the specified torque diagonally. Repeat
this procedure a few times, and confirm the Mounting of POWER-LOCK
tightening conditions.

Specified torque: 80 MPa {8.3 kgf. m)

o ~ s s e m b l yo f t h e c a m s h a f t d i v i d e d i n t o 2
sections
(1) Insert the camshaft-R to the position where the
cam bearing can be installed. Previously insert
t h e c a m gear a n d POWER-LOCK into the
camshaft.
(2) Install the cam bearing.
(3)Move the camshaft-R and cam bearing to the
p o s i t i o n where the camshaft shell fitting
implement can be mounted.
 Timing Gear and Camshaft

Assembly of Camshaft DK-20 "'"2.5

(4) Mount the camshaft shell and camshaft shell

fitting implement, and press-fit the camshaft shell
by tightening the implement nuts.
Install the camshaft shell, so that the oil hole is in
horizontal position.

When press-fitting the shell, be careful so

that the shell may n o t be distorted or
damaged.

( 5 ) Insert the camshaft-F to the position where the

cam bearing can be installed, and then install the
cam bearing.
( 6 ) Insert the camshaft-F and camshaft-R into the
camshalt shell part, attach the bolts, and then
tighten them with the nuts.
Attach the 2 reamer bolts diagonally, and
sequentially lighten the nuts diagonally.
( 7 ) Aftefwards, assemble the camshaft in the same
procedure as that of the one-piece construction
camshaft.
 Timing Gear and Camshaft
ITEM
2.6 DK-20 Camshaft: Inspection of Fuel Oil Cam Timing

8-2.6 lnspection of Fuel Oil Cam Timing

Since the items mentioned in this section are Initial injeclion

position mark line Tappet slit
the parts to which engine value specified in
NOx Technical Code shall be confirmed, do
not make any change that may deviate from
the setting values.
( m: 0-3 "Engine Conforming to NOx
Technical Code.")

Read the initial injection angle when the initial

injection line of the fuel oil injection pump and the
fuel oil injection pump tappet line is aligned, from
the scale on the flywheel.

Initial Injection Position

Timing Gears and Camshaft

CamshafkAdjustment of Fuel Oil Cam Timing

(When Replacing Cam)

8-2.7 Adjustment of Fuel Oil Cam

Timing (When Replacing Cam)

Since the items mentioned in this section are

the parts to which engine value specified in
NOx Technical Code shall be confirmed, do not
make any change that may deviate from the
setting values.

( : 0-3 "Engine Conforming to NOx Technical

Code")

In case that the cam or camshafl is replaced,

perform the adjustment in the following procedure:
(IAttach
) the coupler and coupler connector to
the fuel oil cam, and then connect the high-
pressure hose.
(2) Apply the hydraulic pressure of more than
34.3MPa (350 kgf/cm2) using a hydraulic pump.
Adjustment of Fuel Oil Cam

The maximum oil pressure is 68.6 MPa (700

(3) Adjust the fuel oil cam using the special han-
dle in the state that the hydraulic pressure is Initia! injection
applied. pos~lmnmark line Tappet slil

a) Adjust the fuel oil cam slit referring to the slit

\ /
on the intake cam side as the standard.
b) Read the initial injection angle when the ini-
tial injection line of the fuel oil injection pump
and the fuel oil injection pump tappet line is
aligned, from the scale on the flywheel.
c) Adjust the fuel oil cam again, so that the
angle becomes the initial injection angle that
is specified on the adjustment plate on the
inspection window of the engine frame.

A When restarting the operation, measure the Initial Injection Position

maximum combustion pressure, and readjust
the initial injection timing of the fuel oil cam, so
that the deviation among the cylinders is within
0.3 MPa (3 kgflcm') at the time of full loading.
However, be minded that the maximum com-
bustion pressure at the time of full loading do
not exceed 15.8 MPa (160 kgflcm').
 Timing Gear and Camshaft
Camshaft: Adjustment of Fuel Oil Cam Timing
DK-20 (when Replacing Cam)

(Relationship betweenthe initial injection

angle of the fuel oil cam and the maximum
combustion pressure (Pmax))
The maximum combustion pressure can be
varied by turning the fuel o i l cam, and by
changing the initial injection angle, as the
followings:
(The rotating direction of the camshaft is as
same as the rotating direction of the engine.)
0 Turn the camshaft toward the rotating
direction. (Advance the injection timing.)
.... . Pmax will be increased.
OTurn the camshaft toward the anti-rotating
direction. (Delay the injection timing.)
. . .. .Pmax will be decreased.

Variation standard of Pmax (when fully

loaded)
If the initial injection is changed by l o of the
crank angle, Pmax will be changed by 0.3-
0.5 MPa (3-5 kgf/cm2).
Timing Gear and Camshaft
ITEM
Memo DK-20
 F.O. lnjection Device
ITEM
1 DK-20 General Construction ,

9. F.O. lnjection Device

9-1 General Construction ( m: "Operation" 5-4.2 "Inspection and

Maintenance of F.O. lnjection Valve")
The F.O. injection pump is a Bosch type, tappet-
incorporated high-pressure single cylinder pump,
and the plunger is lubricated with lubricating oil. In
case of heavy fuel oil specification, the pump rack
I F.O. injection p u m p assy. : 16.8 kg I
is assembled with the stop air cylinder.
High-pressure fuel oil is introduced from the pump
outlet into the F.O. injection valve inlet connector
@, through the drilled holes of the forged steel
high-pressure coupling @, via the joint @ with the
spherical surfaces on the both ends.
In case that high-pressure oil has leaked from the
connecting part ranging from the F.O. injection
pump to the F.O. injection valve, such oil will be
recovered through the piping into the leak oil tank
from the leak oil cover @ attached on the upper
part of the fuel oil injection pump, and the level
switch will detect the abnormality.

F.O. High-pressurejoint @
!i
I
I
-,
F.O. injection valve

.-. .- 7 .

..-. .-..-..-..-..- ..
.

-. -..-..-
,

F.O. injection pump

Fuel Oil lnjection Device

9-2 Replacing Consumables, (2) Implements and Measuring lnstruments
Implements, and Measuring @ General tools and measuring instruments
lnstruments a( : 2-2)
@ F.O. pump spanner 24
(1) Replacing Consumables
Replace the following park with the new ones:
(m: "Parts List")
@ O-ring 2-23.2 No.216, 230, 236, 285
@ Back-up ring 3-23.2 No.235
@ Gasket 3-23.2 No.261,280
@ O-ringI(for high-pressure coupling)
3-24.1.1 N0.505
3-24.1.2 N0.12, 506 @ F.O. Pump Spanner 24

9-3 Disassembly of F.O. Injection Pump

(1) Turn the engine to place the roller of the F.O.
injection pump on the base circle of the fuel oil
cam.
(2) Remove the F.O. high-pressure joint @,
plunger oil supply piping @, drain pipe @, leak
oil cover @, and rack pin 0.

-
Disconnect the stop air piping (heavy fuel oil
specification) of each cylinder.
(3) Remove the mounting bolt @ of the F.O.
injection pump inlet block.
(4) Disconnect the pump mounting nut @ using the
F.O. pump spanner 24 @.
(5) Pass a wire around the F.O. injection pump,
suspend it, and dismount it from the engine.

The injection timing of the F.O. injection

pump is readily adjusted for each cylinder.
When disassembling the pump, be minded to
discriminate the pumps according to the
following procedure, so that each of the F.O.
injectior, pumps may not be assembled into a
wrong cylinder:
1) Describe the engine number and cylinder
number on the pump body.
2) Attach the tag as one set to the shim (for
adjusting the base circle) of the mounting
surlace, and describe the engine number
and cylinder number on it.
 F.O. lnjection Device

DK-20 Disassembly of F.O. lnjection Pump

9-4 F.O.lnjection Pump (9) Remove the deflector @.

9-4.1 Disassembly of F.O. lnjection Pump

u1) Be minded to handle the plunger and
The F.O. injection pump is a precision parts in
particular.
Even fine foreign matters will cause sticking or
breakage of the plunger and the delivery valve.
Therefore, when disassembling or assembling
the pump, take every possible care to prevent
the infiltration of foreign matters.
barrel as one pair. The clearance of the
both parts are matched, and if wrong
combination is made, the parts cannot be
used.
2) Be sure to sort the disassembled p a r k per
each pump, so that they do not mix with the
parts of the other cylinders.

(1) Mount the F.O. injection pump on a vice, so

that the tappet @ is on the upper side.
(2) Remove the fall-stop pin @ by means of the
bolt (M6X20), while pushing the tappet, and
using a gear puller and the like.

Be careful so that the tappet roller may not

jump out due to the spring force.

(3) Take out the tappet assembly, plate 0,

spring
seat-lower @, spring @, plunger @, spring seat-
upper@, in this sequence.
(4) Take out the control sleeve @ and control rack
a.
(5) Remove the F.O. injection pump from the vice,
turn over the pump upside-down, and mount it on
the vice again.
( 6 ) Disconnect the mounting bolt 0,and remove
the delivery valve assembly @.

Do not disassemble the delivery valve.

Instead, b e minded t o replace it as a n
assembly.

( 7 ) Remove the positioning screw @.

(8) Turn over the pump again, and extract the
plunger barrel @from the body while receiving it
o n the hand.
If extraction is difficult due to too tight fitting,
place a wooden piece against the barrel from the
opposite side, and strike the wooden piece with a F.O. lnjection Pump
hammer to extract it.
 F.O. lnjection Device
ITEM
Inspection and Maintenance 0f;F.O. Injection Pump DK-20 4.2

9-4.2 lnsoection and Maintenance of F.O.

Injection Pump

Since the items mentioned in this section are Plunger barrel

the parts to which NOx Technical Code shall
be applied, when replacing any of these parts,
be sure to use the parts provided with the
identification marks.
a:

-
( 0-3 "Engine Conforming to NOx
Technical Code')

(1) Wash all the disassembled parts with clean

washing oil, and blow air on them.
(2) Check the plunger, barrel, and deflector for the
corrosion caused by cavitation.
In case that the degree of corrosion is heavy,
replace the parts with the new ones.
Plunger, Barrel, and Deflector

Replace the plunger assembly, the delivery

valve assembly, and the spring every 16,000
to 24,000 hr (4 to 5 years) with the new ones,
even i n case that there is n o particular
problems.

(3) Measure the inner and outer diameters of the

tappet, and calculate the tappet clearance.

Nom. size Standard Replacing

clearance (mm) limit (mm)
C= $72 a =0.03-0.08

(4) Placing a dial gauge against the tappet roller

surface, and measure the bearing clearance by
moving the roller up and down.

Nom. size Standard Replacing

(mm) clearance (mm) limit (mm)
B= # 2 8 c=O.O5-0.08 0.20 Tappet Diameter Clearance and Roller
Bearing Clearanc
 . - ,

F.O.Injection Device
ITEM
4.3 DK-20 Assembly of F.O. Injection Pump

9-4.3 Assembly of F.O. Injection Pump

When assembling the F.O. injection pump, do

not wear gloves but handle the pump with
naked hands, so as to prevent the deposit of
foreign matters or dust on the pump.

Assemble the F.O. injection pump in the following

procedure:
(1) Mount the pump body @ on a vice with the
delivery valve side facing upward.
(2) Apply grease to the O-ring and the back-up
ring, both of which are newly replaced, and fit
them to the barrel @.
(3) Match the barrel positioning bolt hole and the
barrel hole of the pump body for each other, and
insert the barrel into the pump body.
(4) Mount the barrel positioning bolt @.
(5) Assemble the delivery valve assembly @ into
t h e pump body with its knock pin position
matched with the pin hole position.
(6) Apply the lubricating agent (MOLYKOTE U-
paste) to the threaded area and seat surface of
t h e bolt 0, and tighten the bolts with the
specified torque diagonally and uniformly.

Specified torque:
1 3 7 - 1 7 N . m {14-16 kgf.m) I
(7) Remove the pump body from the vice, and turn
over the body to mount it on the vice again.
(8) Apply grease to the gear tooth surface of the
control rack @ and the inner surface o l the
control sleeve 0,and assemble them while
matching the control rack teeth with the control
sleeve end teeth (rack 0-mm direction).

Be careful since the engine cannot be

Assembly of Control Rack and Control Sleeve
operated properly, if the rack is not normally
(Position of Rack 0)
and correctly engaged with the sleeve.
(Viewed from Pump Tappet Roller Side)
 F.O. lnjection Device

Assembly of F.O. lnjection Pump

(9) Assemble the spring seat-upper 0, plunger @,

spring @, spring seat-lower @, plate 0, and
tappet assembly @ in this sequence.
Assemble the plunger so that the "2"mark on the
lower part faces toward the opposite side of the
rack. Plunger Matchmark
(10) Mount the fall-stop pin @ while pushing the
tappet using a gear puller and the like.

When assembling, be careful not to scratch

the tappet or roller.

(11) Mount the deflector @.

(12) After finishing the assembly, conlirm that the
rack moves smoothly, and the " 0 poinl position
is matched.
 Fuel lnjection Device
1
51 DK-20 l~ountingof F.O. injection pump I
9-5 Mounting of Fuel lnjection Pump
(1) Check if the fuel oil cam is placed on the posi- Shim !
tion of the base circle.
(2) Install the fuel injection pump on the engine,
and tighten the nut to the specified torque.

Specified torque: -
90 110 N m
-
{9.2 11.2 kgfm)

(3) Confirm the assembling height of the F.0

injection pump.
a) When the tappet roller is on the base circle of
the fuel oil cam, confirm that the tappet slit is
matched with the base line slit. Assembling position mark line
b) In case that the adjustment of the assembling Mounting Heght of F.0, lnjection Pump
height is necessary, adjust it by the shim.
-

I Shim thickness (a"Parts List")

:
0.5 mm (Standard) 3-23.1 No. 11
0.1 mm 3-23.1 No. 12
1.0 mm 3-23.1 No. 13

(4) Apply grease to the O-ring, fit it on leak oil

cover, and assemble them into the F.O. injec-
tion pump.
(5) Install the F.O. injection high-pressure cou-
pling, and tighten the bolts with the specified
torque.

I Specified torque: -
34 44 N.m
-
(3.5 4.5 kgf-m) 1
(6) Mount the rack pin, and adjust the rack
amount uniformly.
( : "Operation" 5-3.1 "Adjustment of the
F.O. lnjection Pump Rack Amount")
( 7 ) Mount all the piping.
(8) Check the fuel oil injection timing. Leak oil cover
( a : 8-2.6 "Inspection and Adjustment of
the Fuel Oil Cam Timing")
Mounting of F.O. lnjection
High-pressure Coupling
(9) After finishing the adjustment, pass the fuel
oil, and loosen the air vent screw to vent air.
( : "Operation" 4-2.2(5) "Fuel Oil Priming
and Air Vent")
F.O. Injection Device

Memo DK-20
 I I Valve Operating Device I

10. Valve Operating Device

10-1 General Construction
The valve operating device is of a swing-arm type,
equipped with the roller follower, and the valve
operating devices for exclusive use of intake and
exhaust are separately provided respectively.
The intake and exhaust cam lift is transmitted to
the intake and exhaust valves from the roller,
through the push rod, rocker arm, and valve
retainer tee, via swing arm pivot (push rod seat).
A bearing is press-fitted into the roller, and it turns
around the tappet roller pin which is press-fitted
into the swing arm.
T h e s w i n g a r m support and roller bearing
lubricating oil are supplied from the drilled holes of
the engine frame, through the bolt which fixes the
swing arm shaft, and via the shaft and the drilled
holes inside the arm. --
A ring knock is press-fitted into the shaft, so as to
ensure the parallelism between the roller and cam Push rod.
seal
contact surfaces.
Roller-

I Swing arm assy. : 11 kg

I
Swing arm shaft
10.2 Replacing Consumables, Implements,
and Measuring instruments
Valve Operaling Device
(1) Replacing Consurnables
None
(2) Implements and Measuring Instruments
a General tools and measuring instruments
a
( : 2-2)

10.3 Disassembly of Valve Operating Device

(1) Disconnect the cylinder head cover, and
remove the rocker arm device and the push rod.
(2) Remove the cover on the camshaft side.
(3) Disconnect the bolt @, and remove the swing
arm assembly.
M a r k the engine number and the cylinder
n u m b e r with magic ink or the like, before
removing the swing arm assembly.
(4) Disconnect the snap ring @, and remove the
swing arm @ and @ from the swing arm shalt @. Swing Arm Assy,
 ,
Valve Operating Device

I Inspection and Maintenance of Valve Operating Device I DK-20 I I It M

10-4 lnspection and Maintenance of

Valve Operating Device
(1) Clean all the parts using washing oil.

Lubricating holes are provided in each of the

individual parts, and therefore be careful so
that n o dust or foreign matters will b e
infiltrated.

(2) lnspect if there is any scratch or abnormal dent

on the swing arm shaft and the swing arm sliding
surface.
(3) lnspect if there is any scratch or abnormal dent
on the outer periphery of the tappet roller @. Inspection of Swing A r m Shalt and Swing Arm
(4) lnspect if there is any scratch or abnormal dent
on the contact surface of the push rod seat @.
(5) Measure the clearance between the roller pin
@ and tappet roller bush @, placing a dial gauge
against the upper face of the tappet roller, and
moving the tappet roller up and down.

Nom. size Standard Replacing

clearance (mm) limit (mm)
B = .# 22 b = 0.07-0.13

$\
When the clearance become wider, the valve
end clearance becomes larger, and the valve
opening and closing timing changes,
resulting in the deterioration of the engine
performance.
In case that the measurement result of the
clearance is over the replacing limit, replace
the swing arm (with the roller) with a new
one.

Clearance Measurement of Tappet Roller B u s h

 /

Valve Operating Device

DK-20 Assembly of Valve Operating Device

10.5 Assembly of Valve Operating

Device
(1) Mount the arm on the arm shaft, matching the
oil hole ol swing arm and the oil hole groove of
swing arm shaft.

Be careful not to mistake when handling the

swing arms each other, since there are two
types of swing arm, one for intake and one
for exhaust. The one with the cawed stamp
"R" is for exhaust (flywheel side), and the
one with the notched mark "L" is for intake
Swing Arm Oil Hole
(front side).
Further, before assembling, be minded to
confirm the cylinder number, so as to prevent
mistaking it with the parts of the other
cylinder.

(2) Fix a snap ring.

(3) Match the ring knock @.position, then mount
the swing arm assembly on the engine frame.
(4) Tighten the bolt with the specified torque, after
applying lubricating agent (MOLYKOTE 1000) on
the threaded area of bolt and seat surlace.

I Specified torque : 59 N. m (6 kgf. m)

I
Valve Operating Device
ITEM
Memo DK-20
 Governor Driving Device
General ConstructionlReplacing Consumables,
DK-20 Implements, and Measuring Instruments

11. Governor Driving Device

11-1 General Con~truction In this engine, the following 2 types of governor is

applied.
The governor is of a hydraulic type that controls
As lor the handling of the governor body, refer to
the rack amount of the F.O. injection pump and the
a separately provided document.
F.O. injection rate, in accordance with the load and
the revolving speed of the engine via common rod.
( a: "Governor Instruction Manual")

The governor driving device is located on the rear

side of the engine, and composed of the helical
gear engaged with the cam gear and a pair of the
Governor : 8 k g
bevel gear, and drives the governor via spline
Governor driving device assy. : 21 kg
coupling.
The governor gear case and the mounting surface
of the engine frame are sealed with liquid sealant.
and the adjustment of the bevel gear backlash is
made by the adjusting shims on the mounting
surface of the governor.
Governor : 20 kg
Governor driving device assy. : 22 k g
1
11-2 Replacing Consumables,
Implements, and Measuring
Instruments
Govern1
(1) Replacing Consumables
Lir
Replace the following parts with the new ones.

(For RHD6 governor)

(a
@
: "Parts Listn.)
O-ring 3-25.1 No.522
@ Cover 3-25.1 N0.48
@ Bearing 3-25.1 No.512
O Split pin 3-25.1 No.532, 539

(For UGlO governor)

( a:
@O-ring
"Parts List".)
3-25.2 No.523
@Bearing 3-25.2 No.513, 514
@Split pin 3-25.2 No.532, 539

(2) Implements and Measuring Instruments ,Common rod lever

General tools and measuring instruments
( 0 : 2-2.) Governor Link
 .

Governor Driving Device

Disassembly, Inspection, and Maintenance of Governor
Driving Device

11.3 Disassembly of Governor Driving

Device
The construction of governor driving device is
basically same regardless of the types of governor,
and therefore the explanation is made regarding
Type RHD6 in this section.
(1) Remove the governor lever@ and link pin @.
(2) Remove the oil feed piping of the driving
device.
(3) Remove the governor mounting nut 0, and
remove the governor.
(4) Remove the governor gear case mounting bolt
@, and remove the governor driving device
assembly.
(5) Measure the backlash between the governor
gear @ and governor driving gear @.

Standard clearance Replacing limit

(mm) (mm)
Backlash 0.3-0.5 0.8

(6) Take out the bolt @ and remove the governor

base @.
As the spline coupling @, governor driving shaft-
2 @, bearing @, and governor gear @ are all
mounted on the governor base, these pans can
be pulled out at the same time.
( 7 ) Remove the covers @ on both sides of the
governor driving shalft-1 0.
(8) Insert a hexagonal-bar spanner into the Governor Driving Devlce
hexagonal hole of the end part of the governor
driving shaft-1, remove the nut 0, and then pull
out the governor shalt-1.
Be minded to hold the governor gear with hand
so that it may not fall down.
(9) Remove the governor drive gear @ and @.

11-4 Inspection and Maintenance of

Governor Driving Device
(1) Clean all the disassembled pads with washing
oil.
(2) Inspect each gear surlace for abnormal wear
and scratch.
(3) lnspect the governor shaft-1 0, - 2 @ and
llange bush @. @ I
for abnormal dent or scratch.
 Governor Driving Device
Inspection, Maintenance, and Assembly of Governor
DK-20 Driving Device

(4) Calculate the clearance by measuring the

governor driving shaft outer diameter and flange
bush inner diameter, and in case that the
clearance is over the replacing limit, replace the
flange bush with a new one.

<Governor driving shaft-I>

Nom. size Standard Replacing
(mm) clearance (mm) limit (mm)
A=$22 a = 0.01 -0.10 0.15
<Governor driving shaft-2>
Nom. size Standard Replacing
(mm) clearance (mm) limit (mm) Clearance of Flange Bush
D=$14 d = 0.01 -0.08 0.13

11-5 Assembly of Governor Driving Device

(1) Assemble the governor driving device in the
reverse order of the disassembling procedure.
a) Replace the O-ring and bearing with the new
ones, and a p p l y grease to them before
assembling.
b) Replace the cover @ with a new one. Apply
seal bond (silicone type) and insert it into the
hole, and evenly strike it placing a patch, so
that the outer periphery should be adhered
tightly.
(2) Atter assembling, check the followings:
a) The governor drive gear and governor rotate
smoothly.
b) Confirm that backlash is normal, and in case
that it is not within the specified value, adjust it
by inserting the shim between the governor
base and governor gear case.

(For RHD6 Governor) (a: "Parts List")

0.8 mm 3-25.1 No.55

1.O mm 3-25.1 N0.53

(For UGlO Governor) ( a: "Paris List")

Assembly of Governor Driving Device

0.5 mm 3-25.2 No.58
1.0 mm 3-25.2 No.59
Governor Driving Device
ITEM
Memo DK-20
 lntake and Exhaust Device
1. 2 DK-20 General of Intake and Exhaust DevicelTurbocharger
12 lntake and Exhaust Device
12-1 General of lntake and Exhaust
System
T h e high-temperature and high-pressure
exhaust gases shall be emitted from the cylinder
are effectively introduced into the turbocharger
through the exhaust manifold, and a part of the
exhaust energies will be recovered as intake pres-
sure.
The high-temperature air compressed by the tur-
bocharger will be cooled down while passing
through the air cooler, and will be introduced to the
intake duct of the engine frame.
The turbocharger and the air cooler is located o n
the front part of the engine as standard, however
they can be located on the rear part of the engine
according to the specifications.
f roln allnllicr cyltu:dcr I ri iaoolll(~cy(ifidrr
lntake a n d E xhaust Device
12-2 Turbocharger
Since the items mentioned in this section are
the parts to which NOx Technical Code shall be
applied, when replacing any of these parts, be
sure to use the parts provide with the identifica-
tion marks.
(a : 0 - 3 "Engine Conforming to N O x
Technical Code")
Lubricating oil that lubricates the bearing and
cooling water that cools the bearing base are sup-
plied to the turbocharger.
The lubricating oil is supplied to the turbocharger
through a special filter, being branched from the
engine system oil. Further, an orifice is installed at
the inlet of the turbocharger, so as to maintain the
lubricating oil pressure at the appropriate level.
As for the operation, disassembly, and mainte-
nance of the turbocharger, refer to a separately
provided instruction manual.
Turbocharger (except the exhausl duct)
RH123, RH133 : 37 kg
RH143, RH163 : 115 kg
RH183, RH203 : 214 kg
TPS 48 129 kg
TPS 52 187 kg
A
The turbocharger is very hot just after the
engine is stopped. Wait until it sufficiently
cools down before dismantling it for inspection
and maintenance.lf it must be dismantled
before it cools down, wear safety gloves, and
take care not to burn your hands.
 ,,-
co

Intake and Exhaust Device

Air Cooler: General ConstructionIReplacing Consumables,
Implements, and Measuring Instru'mentslDisrnounting
12.3 Air Cooler
12.3.1 General Construction
The air cooler is of a fin-tube mulii-tubular type
with box shape, and is installed to the bracket.
The cooling water inlet and outlet ducts of the air
cooler are equipped with a butterfly valve to adjust
the intake air temperature to an appropriate value.
Model No. of air cooler
DK25, DH31 : 150 k g
DHB31 : 234 k g
DK30, DH29, DH39, DH48 : 240 k g
DH52, DH73 : 310 k g
DH95 : 300 kg
DK-20 irk3.3
12-3.3 Dismounting of Air Cooler
(1) Remove the cooling water inlet and outlet duct
@.
(2) Remove the air cooler cover @ andIair cooler
inlet duct @.
(3) Disconnect the exhaust outlet duct @, and the
turbocharger.
(4) Remove the air cooler mounting bolt @ and 0,
passing a wire rope around the air cooler and
suspending it with a chain block.
(5) Disconnect the air cooler.

12-3.2 Replacing Consumables,

Implements, and Measuring
lnstruments
(1) Replacing Consumables
Since the replacing consumbales, such as O-
ring, packing, and gasket, vary depending on the
model number of the air cooler, refer to a
separately provide park list.
( : "Parts List")

(2) Implements and Measuring lnstruments

a General implements and measuring
instruments
( Q.J : 2-2)

Dismounting of Air Cooler

 5-Q '

ITEM
1 /
Intake and Exhaust Device

3 5 DK-20 Inspection, Maintenance, and Mounting of Air Cooler

II
12.3.4 Inspection andMaintenance of Air
Cooler

Since the items mentioned in this section are

the parts, to which Nox Technical Code shall
be applied, when replacing any of these parts,
b e sure to use the parts provided with the
identification marks.
(a
Code")
: "Engine Conforming to NOx Technical

(1) Remove the water chamber covers on the both

sides, and eliminate the scales deposited on
them.
I n case that coating of the inside surfaces is
peeled ofl, repair the parl or conduct the coating
again.
(2) Clean the inside of the cooling tube using a
nylon brush.
After brushing, wash it with clean and fresh
water.
(3) Eliminate the stains on the air side by blowing
air on them.
In case the degree of stain is heavy, disconnect
the water chamber, and remove the stain by
immersing the plate-fin tube assembly in neutral
detergent.
After eliminating the stain, wash with clean and
fresh water, and sufficiently dry the assembly
promptly.
(4) Inspect the protective zinc, and replace it with a
new one. (In case that the equipment is provided
with the protective zinc.)
a
( : 5-4.6 "Daily Inspection and Maintenance
of Protective Zinc")

12-3.5 Mounting of Air Cooler

Assembly the air cooler in the reverse order of the
disassembling procedure.
Intake and Exhaust Device
lTEM
Memo DK-20
 Starting Air System
ITEM
1 DK-20 Outline of Starting Air System

13. Starting Air System

13.1 Outline of Starting Air System
The air starting type i s employed to DK-20
engines, the direct starting type by the starling
valve is employed to 6.8DK engines, and the air
motor starling type is employed to 3.5DK engines.
(0: "Operation" 2-2.1 "Starling Air System")
The high-pressure air of 2.5 to 2.9 MPa 125 to 30
kgflcm2) is used as the starting air, and the iow-
pressure air of 0.8 MPa 18 kgf/cm2) is used as the
controlling air.
The major components of direct starting air type
are the starling air valve, starling air rotary valve,
and starting operation valve.
The major components of air system of the air
motor starting type are the starter, relay valve (with
the regulator), and starling operation valve.
Among these equipment, regarding the starter,
relay valve, and starting operation valve, the
overhaul and repair i s virtually impossble.
Therefore, be minded to activation is faulty.
As for the air motor, refer to the separately
provided "Instruction Manual".
: "Instruction Manual of Air Motor")
(

Engine starting solenoid valve Starting operation valve

(For remote and auto stalling)

air rotary valve

I
I
(Cylinder head)

Stalling valve

L
control air

Air tank

Starting Air System (Direct Starting Type)

 (0 C(

Starting Air System 1

ITEM
Outline of Starting Air System DK-20 1

Starting air

'
Starting Air System (Air Motor Starting Type)
13-2 Starting Air Valve
When disassembling, carefully perform the
13-2.1 General Construction work so that the spring will not f l y out,
The starting air valve is the vaive that controls the because the spring is compressed by the
supply of the high-pressure air for starting when
the engine is being started, and is activated by the
controlling low-pressure air which is sent from c) Remove the bolt and disconnect the cylinder
either the starting operation valve or the starting @.
solenoid valve. d) Take out the stopper ring 0, and remove the
key receptor @ and the key 0.
Starting valve assy. : 12 k g e) Disconnect the piston 0, and extract the valve
stem a.
1 ) Take out the split pin @ and the nut 0, and
remove the valve receptor @, the valve @, and
13-2.2 Replacing Consumables, the valve retainer @ from the valve stem.
Implements, and Measuring g) Remove the union screw 0, and take out the
Instruments spring @ and the check valve @.
(1) Replacing Consurnbales
Replace the following parts with the new ones
(a
@Valve
: "Parts List")
4-1.1.1 No.86
@Split pin 4-1.1.1 No.810, 825
O O-ring 4-1.1.1 No.8502, 8503, 8504,
No.B505,8506, 8507
No.8508, 8509
@ Circular gasket 4-1.1 No.C516. C517

(2) Implements and Measuring Instruments

@ General implements and measuring
instruments
(a : 2-2)

13-2.3 Disassembly of starting valve

(1) Disconnect the piping of the starting air outlet
and inlet and the piping of the control air inlet,
and remove the starting air vaive assembly from
the bracket.
(2) Disassemble the starting air valve according to
the following procedure:
a) Disconnect the mounting bolt, and remove the
upper cover @ and lower cover @.
b ) Take out the split pin of the valve stem and d b b
the nut @, and remove the piston @ and the
spring @. Starting Alr Valve
 Starting Air System

[ Inspection, Maintenance, and Assembly of Starting Air Valve I DK-20 12y4, 2.5 1
13-2.4 Inspection and Maintenance of
Starting Air Valve
(1) When rust is found, carefully remove it using a
fine sandpaper.

f L l
For the sake of rust-prevention, be minded to
perform the draining of the equipment and
the piping without fail, at the time of daily
maintenance.

(2)Wash all the disassembled parts with clean

washing oil, and blow air on them.
(3) lnspect il there is any abnormal dent or scratch
on the piston @ and 0.
(4) lnspect if there is any scratch on the seat
surface of the valve @.
(5) lnspect if there is any abnormal dent or scratch
on the check valve @ and the seat surface.
(6) lnspect il there is any scratch on the spring @ 6
and 0.
Check Valve

13-2.5 Assembly of Starting Air Valve

(1) Before assembling, thinly apply silicone grease
on the valve, the O-ring, and the sliding part of
the seat surface.
(2)Assemble the staring air valve assembly in the
reverse order of the disassembling procedure.
(3) Mount the starting air valve assembly to the
bracket, and install the piping.

Sufficiently flush the piping before

installation, so that dust a n d drain are
completely removed. Further, be minded
that sealant or the like will not be deposited
during the work.
13.3 Starting Air Rotary Valve
13-3.1 General Construction
T h e starting air rotary valve is the valve that
distribute pilot air, which is used to actuate the
starting valve, to each cylinder according to the
explosion sequence, and this valve is driven from
the front end of the camshaft via rotary valve
coupling (Oldham's coupling).

I Starling air rotary valve assy. : 8.4 k g I

13-3.2 Replacing Consumables,
Implements, Measuring instruments
(1) Replacing Consumables
Replace the following parts with the new ones.
( a:"Parts Listu)
@ Rotary valve cover gasket 4-1.2 No.Al4
@Circular gasket 4-1.2 No. A505, A515

(2) Implements and Measuring Instruments

@General implements and measuring
instruments
(a: 2-2)

13-3.3 Disassembly of Starting Air

Rotary Valve
(1) Disconnect each piping of the starting air inlet
and the starting air outlet.
(2) Disassemble the starting air rotary valve on the
following procedure:
a) Remove the mounting bolts, and disconnect
the rotary valve cover @ and the circular
gasket @.
b) Extract the starting air rotary valve @.
C) Disconnect the mounting bolts of the rotary
valve seat @, and remove the rotary valve seat
and the gasket @.
d) Remove the rotary valve coupling @.

Starling Air Rotary Valve

 Starting Air System
Inspection, Maintenance, and Assembly of Starting Air ITEM
Rotary Valve DK-20 3.4,3.5

13-3.4 Inspection and Maintenance of 13-3.5 Assembly of Starting Air Rotary

Starting Air Rotary Valve Valve
(1) Wash all the disassembled parts with clean Assemble the starting air rotary valve in the
washing oil, and blow air on them. reverse order of the disassembling procedure.
(2) lnspect the scratch and wearing conditions of (1) Wash the starting air rotary valve and rotary
the rotary valve bush @. valve seat, and apply the lubricating oil to the
Measure the shaft diameter and the bush inner seat surface and shaft area.
diameter of the rotary valve, and calculate the (2) When inserting the starting air rotary valve into
clearance. the rotary valve seat, conduct the insertion work
by adjusting the air hole of the starting air valve
Nom. size Standard Replacing to the rotary valve seat hole of the cylinder
clearance (mm) limit (mm) number, which is on the explosion process.
a = 0.02-0.10 When the holes do not match, insert the starting
air rotary valve by turning it 180(.

When wear of the bush becomes heavy.

Be careful not to disassemble the rotary
lubricating oil will infiltrate into the starting air
valve in a wrong way, since it will inhibit the
pipe, making the starting difficult. In such a
engine to start.
case, replace the bush with a new one.

(3) Install the piping and flexible cable.

(3) lnspect if there is any fin or foreign matters
caught on the seat areas of the starting air rotary
valve and the rotary valve.
In case that inclusion scratch is extended over
the holes of each cylinder, perform the lacing-up
after grinding and correcting the seat surface.
Further, in case that fin is found, remove it using
a file or scraper.
(4) lnspect if the engagement area of the starting
air rotary valve @ and rotary valve coupling a,
and the engagement area of the rotary valve
coupling and camshaft are not worn out,
respectively.
engine)
Rolating direction 01 rolary valve
If the wearing degree of the engagement
area is heavy, the opening and closing timing The above figure shows the posilional relationship
of the starting valve will be delayed, making ot the slarling air valve when the No.1 engine is on
the starting difficult. the lop dead center position ol explosion.
In such a case, replace the starting air rotary
Rotary Air Valve Assembling Procedure
valve or rotary valve coupling with a new
. one.
L
 J /

Starting Air System

DK-20 Starting Operation Valve and Handle Switch

13-4 Starting Operation Valve and

Handle Switch
The starling operation valve is an air valve for the
purpose of starting from the machine side, and the
starting air valve will be actuated by manually
operating the pushbutton, so that the low-pressure
air is supplied to the starting air valve.
T h e handle switch is a limit switch, which is
actuated interlocking with the control lever, and
when the control lever is set to the drive position,
the switch is turned ON and a protective circuit is
formed.

D o not disassemble the starting operation

valve and handle switch. In case that
malfunction is occurred, be minded to replace
it as an assembly.
Starting Air System
ITEM
Memo DK-20
 Fuel Oil System

DK-20 General of Fuel Oil System

14. Fuel Oil System Fuel oil filter

14-1 General of Fuel Oil System
The engine is designed on the assumption that
the driving shall be performed using heavy fuel oil.
In case of heavy fuel oil, appropriate pretreat-
ment of the fuel oil before feeding at the entrance
of the engine is particularly important, and the
quality of the fuel oil will give a remarkable influ-
s
:Cautions in disassembling, maintaining and
ence on the various equipment such as the fuel oil
injection pump.
Since not only the individual systems but also
the facility and equipment will also differ depending
on the grade of the oil to be used, be minded to
perform appropriate maintenance, inspection, and
adjustment according to the instruction manuals of
each facility and equipment.
T h e major component parts attached to the
engine are the fuel oil filter, fuel oil relief valve, fuel
oil feed valve, and so on.
As for the inspection and maintenance of the fol-
lowing equipment, refer to the other sections in this
manual or separately supplied documents.
a
( : "Operation" 2-2.2 "Fuel Oil System")
( : "Operation" 5-4.3 "Cleaning Filters")
Facilities a n d equipment for pretreatment
(a : Separately supplied "Instruction Manual")
reassembling the fuel oil system>
1) The parts such as the fuel oil injection pump
and fuel oil injection valve, which are used in
the fuel injection system, are all precision
parts, and therefore if any dust or foreign
matter is mixed in the oil, it will result in the
faults such as seizure.ln case that the equip-
ment of the fuel oil system is disassembled,
regardless of whether it is the one attached
to the engine or the one to be separately
installed, be particularly careful so that any
dust or foreign matters will not infillrate into
the inside of the equipment or piping.
2) In case that the fuel oil system is over-
hauled, be sure to perform air bleeding afle~
restoration.
When discharging air, take care not to splash
the oil.

:uai oi! injoilion 'va!w

relurn oi! main pipe
Giesci
fuel
Fuel Oil System
Fuel Oil Relief Valve
14-2 Fuel Oil Pressure Regulating Valve
14-2.1 General of structure
The fuel oil relief valve is installed on the read
end of the fuel oil main pipe, and the valve oper-
ates to maintain the pressure at the inlet of the fuel
oil injection pump within the appropriate range.
Excessive oil will be returned to the supply sys-
tem through the relief valve.
The fuel oil pressure depends on the source
pressure of the supply system, and it also
varies depending on the viscosity of the oil.ln
case of heavy fuel oil, adjustment is readily
made so that the pressure stays at an appropri-
ate viscosity and to be within the blue mark
range on the pressure gauge. Therefore, when
the pressure is deviated from the specified
range during operation, be minded to firs1
check if the viscosity of the fuel oil is appropri-
ate or not before starting to disassemble and
inspect the fuel oil relief valve.
When heavy fuel oil is used, the oil is heated
to a high temperature (100°C or more). If the
oil is splashed on the skin, it may be scald.
Take care not to splash the oil when disassem-
bling.
14-2.2 Replacement Consumables,
Implements, and Measuring
lnstruments
(1) Replacement Consumables
Replace the following parts with the new ones.
(a : "Parts List")
1) Circular gasket 4-2.5 No.507.508. 509
(2) Implements and Measuring instruments
1) General implements and measuring
lnstruments ( a : 2-2 )
14-2.3 Disassembly of Fuel Oil Relief Valve
(1) Take out the connected piping, and remove
the relief valve assembly.
(2) Disassemble the relief valve according to the
following procedure:
a) Disconnect the cap nut @ , loosen the lock
nut @ , and completely turn back the adjusting
screw @.
Before loosening the adjusting screw, either put
a mark on the tightening position of the adjust-
ing screw or keep the record of the dimension,
so that the original position can be identified
when assembling.
b) Loosen and remove the spring retainer @ .
C) Remove the spring seat @, spring 0,
and
relief valve @ from the relief valve body @.
Fuel Oil Relieve Valve
14-2.4 Inspection arld Maintenance of
Fuel Oil Relief Valve
(1) Wash all the disassembled parts with clean
washing oil, and remove the sludge
(2) Inspect if there is any abnormal dent or scratch
on the relief valve, or also check if the valve is
not stuck.
(3) Inspect if there is any abnormal dent or scratch
on the spring
14-2.5 Reassembly of fuel oil pressure
regulating valve
Perform the assembly of the relief valve in the
reverse order of the disassembling procedure.
(1) Set the adjusting screw to the position of the
marking.
(2) Afler assembling, drive the engine and check
if the pressure is within the blue mark range,
and in case that ihe pressure is out of ihe range,
adjust the pressure with the adjusting screw.
14.3 Fuel Oil Feed Pump
14-3.1 General Construction 14-3.3 Dismounting of Fuel Oil Feed
The fuel oil feed pump is installed on the front part Pump
of engine, and is driven from the auxiliary gear (1) Disconnect the outlet and inlet piping of the fuel
case via pump driving device. oil feed pump.
The feed pump is a trochoid type, and the safety (2) Take out the coupling cover.
cover is incorporated into the upper cover. (3) Remove the bolts and disconnect the fuel oil
feed pump from the pump base, carefully
Fuel oil feed pump assy. : 24 kg watching the positioning pin.
(4) Loosen the clamping screw of the coupling and
remove the coupling.
14-3.2 Replacing Consumables, (5) Take out the coupling key.
Implements, and Measuring
lnstruments
(1) Replacing Consumables Coupling, Cover
Replace the following parts with the new ones:
( : "Parts List")
(Fuel oil feed pump)
@ O-ring 4-2.1 No.205, 206
@Gasket 4-2.1 No.235,236, 297, 298
@Mechanical seal 4-2.1 No.238
@ Bearing 4-2.1 No.232, 233

(Fuel oil feed pump driving device)

@ Gasket 4-2.2 No.20
@ Plain washer 4-2.2 No.507
@Washer with tooth 4-2.2 No.508, 509, 510
@ Split pin 4-2.2 No.511
@Oil seal 4-2.2 N0.519
@ Bearing 4-2.2 No.518

(2) Implements and Measuring Instruments

General tools and measuring instruments Posilioning pin Pump base
( a: 2-2)
Dismounting of Fuel Oil Feed Pump
 Fuel Oil System
Disassembly, Inspection, and Maintenance of Fuel Oil Feed
Pump

14-3.4 Disassembly of Fuel Oil Feed Pump

(1) Before disassembling the fuel oil feed pump, be
minded to mark the matchmarks on the pump
body, the cover, and so on.
(2) Remove the piping ol the ring joint 0.
(3) Remove the bolt and nut, and take out the seal
cover @.
(4) Take out the mechanical seal @ from the seal
cover.
(5) Remove the bolt, and take out the bearing
cover @.
(6) Remove the bolt, and take out the side cover @
and bearing @.
( 7 ) Take out the rotary part of the mechanical seal.
(8) Take out the outer rotor @ and rotor housing
@. Fuel Oil Feed Pump
(9) Pull out the inner rotor@ and shaft a.
Carefully handle the parts so as not to bend the
shaft.
(10) Take out the bearing a and collar @I.
(11) Remove the safety valve cap 0, loosen the
lock nut 0,and then loosen the adjusting screw
0-
Before loosening the adjusting screw, be minded
either to mark the tightening position of the
adjusting screw, or to record the dimensions.
(12) Take out the connector @, and remove the
spring retainer @, spring @, and safety valve a.
Fuel Oil Feed Pump Safety Valve
14-3.5 Inspection and Maintenance of
Fuel Oil Feed Pump Fixed part

(1) Clean all the disassembled parts with fresh

washing oil, and blow air on them for drying.
(2) lnspect the wearirig conditions of the inner rotor
a n d outer rotor tooth surfaces, cavitation.
pitching, and so on.
(3) lnspect the scratch and wearing conditions of
the outer periphery of outer rotor.
(4) Rotate the bearing, and check if it rotates
smoothly or if there is not any abnormal sound.
( 5 ) Inspect if there is any abnormal dent on the
safety valve and safety valve spring, and also if
there is not any sticking.
Mechanical Seal
 Fuel Oil System
Inspection, Maintenance, and Assembly of Fuel Oil Feed
DK-20 Pumn

Even in case that no particular fault is found

in the bearing, be minded to replace it with a
new one a t the time of the periodical
inspection, which shall be pelformed every
12,000 to 16,000 hours (4 years).

14-3.6 Assembly of Fuel Oil Feed Pump

(1) Anach the inner rotor @ to the shaft 0, and
install them into the casing @.
a
(2) Install the collar @ and bearing to the shaft.
(3) lnsert the pipe knock into the casing, attach the
rotor housing @, and then mount the outer rotor
0.
(4) Insert the mechanical seal rotary part into the
Seal ring Set screw
shaft. \ \

a) Apply lubricating oil to the inner surface of the \ Drive ri?g groove \
gasket and shaft.
b) Mount the collar, and fix the shaft by
tightening the set screw.
When inserting the collar leg into the drive ring
groove, be minded to slowly and carefully
insert it, so that the gasket will not be peeled
Insertion of Mechanical Seal Rotary Part
off.
( 5 ) Attach the side cover @ with short bolt, insert
the bearing @, and then install the bearing cover
(6) lnsert the fixed part of the mechanical seal into
the seal cover @.
(7) Attach the seal cover to the main body.
Temporarily tighten 2 short bolts and 2 long
bolts, and then securely tighten all the bolts alter
confirming that it can be rotated lightly by hand.
(8) Install the safety valve.
(9) Install the piping of ring joint, and attach the
drive key.
(10) lnstall the coupling, and mount the fuel oil
feed pump on the pump base.
(11) Attach the pump inlet and outlet piping
-
Fuel Oil System
Disassembly, Maintenance, and Assembly of Fuel Oil Feed
Pump Driving Device

14-4 Fuel Oil Feed Pump Driving

Device
14-4.1 Disassembly of Fuel Oil Feed
Pump Driving Device
(1) Before starting to disassemble the driving
device, take out the center cover of the auxiliary Apply lithium grease
drive gear case, and measure the backlash of
the pump drive gear.

Standard value Replacing limit

Backlash 0.3-0.5

(2) Disconnect the fuel oil feed pump.

(a:
Pump")
14-3.3 "Dismounting of Fuel Oil Feed

(3) Disconnect the mounting nut, and remove the

pump drive bearing @.
(4) Remove the nut @, and pull out the pump drive
gear @ form the drive shaft @.
b b b
Then, take out the key. Fuel Oil Feed Pump Driving Device
(5) Pull out the drive shaft from the pump drive
bearing, and take out the bearing @ and
distance piece @.
(6) Remove the oil seal @.

14-4.2 Maintenance and Assembly of

Fuel Oil Feed Pump Driving Device
(1) Inspect if there is any wear or pitching on the
tooth surface of the pump drive gear,
(2) Inspect if there is any distortion or crack in the
coupling rubber.
(3) Rotate the bearing, and inspect if it rotates
smoothly or if there is any abnormal sound.
(4) Assemble the driving device in the reverse
order of the disassembling procedure.

I1 the oil seal is installed upside-down, oil will

leak.
'
Therefore, be careful not to mistake the
assembling direction.
 Lubricating Oil System

15. Lubricating Oil System

15-1 Outline of Lubricating Oil System 15-2 Lubricating Oil Pump

The lubricating oil is installed on the front end of 15-2.1 General Construction
the engine, and driven by the auxiliary drive gear
The lubricating oil is a gear type, and all the
attached to the crankshaft.
pieces of the bearings used in the pump are needle
The lubricating oil cooler is installed on the engine,
bearings. Further, a safety valve is incorporated
and equipped with a temperature control valve as
into the pump cover.
an assembly.
T h e lubricating oil filter is also installed on the
engine, and the lubricating oil relief valve is Lubricating oil pump assy. : 33 k g
installed on the installation base of the engine.
As the filters for the turbocharger and fuel injection
pump, the special filters of a higher precision are
installed.
(a
a:
(
: "Operation" 2-2.3 "Lubricating Oil System")
"Operation" 5-4.3"Cleaning Filters")

Safe

I I u
Engine base plate (oil lank) Leaked and waste
oil tank
Lubricating Oil System
15-2.2 Replacing Consumables, (2) Remove the inlet and outlet piping
Implements, and Measuring Instruments (3) Remove the mounting nut, and take out the
lubricating oil pump assembly.
(1) Replacing Consumables
(4) Assemble the lubricating oil pump on the
Replace the following parts with the new ones
following procedure:
( Q:"Parts List".)
a) Before disassembling, be minded to mark the
@ Needle bearing 4-3.1.1 No.42
matchmarks on the mating surfaces of the
0Oil seal 4-3.1 .I N0.526
pump body, cover, and so on.
@ Split pin 4-3.1 .1 No510
b) Remove the split pin @ and castle nut @, and
@ Pump body gasket 4-3.2 No.10
take out the gear @ and key @.
c) Remove the bolt of the pump body cover @,
(2) Implements and Measuring lnstruments
and take out the pump body cover.
@ General implements and measuring instruments
d) Pull out the pump gear @ and @from the
( Q : 2-2.)
pump body @.
e) Remove the snap ring 0, and pull out the oil
seal 0.
15-2.3 Disassembly of Lubricating Oil
f ) Remove the snap ring 0, and pull out the
Pump a.
bearing
(1) Before removing the lubricating oil pump, take g) Pull out the bearing @ from the pump body
out the center cover of the auxiliary gear case, and pump body cover.
and measure the backlash of the pump drive h) Remove the safety valve retainer 0, and pull
gear. out the safety valve spring @ and safety valve
@.

Backlash 0.3- 0.5

Bearing
side , -m 0
side
:ear

Lubricating Oil Pump

 *

Lubricating Oil System

ITEM Inspection, Maintenance, and Assembly of Lubricating Oil
2.4,2.5 DK-20 pump

15-2.4 Inspection andMaintenance of

Lubricating Oil Pump
(1) Wash all the disassembled parts with clean
washing oil.
(2) lnspect the wearing conditions ol the tooth
surface of each gear, and presence ol pitting.
Also inspect the peeling conditions ol the outer
periphery and side face, and the presence of
seizure.
(3) lnspect if there is any abnormal wear on the oil
seal sliding surface of the pump gear shaft.
(4) lnspect if there is any abnormal dent or scratch
on the pump body, and the inner surface of the
pump body cover.
( 5 ) lnspect the wearing conditions of the tooth
surface of the drive gear a, and the presence of
pitting.
( 6 ) lnspect i f there is any scratch or trace of
sticking on the safety valve. In case that the
scratch degree is light, correct it with oil stone.

15-2.5 Assembly of Lubricating Oil Pump

(1) Assemble the lubricating oil pump in the
reverse order of the disassembling procedure

(Cautions when assembling)

1) Replace the needle bearing and oil seal
with the new ones.
2) Use liquid sealant for the mating surface
of the pump body cover and pump body.
3) Be minded to assemble the pump body
cover after confirming the matchmarks that
have been made when disassembling, so
that oil release hole is situated on the
delivery side without fail.

(2) Install the lubricating oil pump.

In case that the pump drive gear is replaced,
confirm the backlash.
(3) Connect the inlet and outlet piping.

Lubricating Oil System
Lubricating Oil Cooler: General ConstructionIReplacing
, Consumables and Implernentsllnspection and Maintenance
15-3 Lubricating Oil Cooler
15-3.1 General Construction
The lubricating oil cooler is installed on the engine
body, and the temperature control valve is
attached to the lubricating oil outlet.
The cooling pipe is multi-tubular type, and there
are the tube plates on both sides, and the tube
plate on one side is fixed type, and the tube plate
on the other side is outer-periphery-slide type,
which absorbs thermal expansion of the tube, and
is sealed with O-ring.
In case that the cooling water is sea water,
protective zinc is attached to the side covers on
the both sides.
(a: "OperationM5-4.6 "Inspection and
Replacement of Protective Zinc")
Lubricating oil cooler
6.4 m2: 123 k g
8 m2: 136 kg
12 m': 170 kg
Lubricating Oil Cooler
<-
ITEM
DK-20 3.1-3.3
15-3.2 Replacing Consumables,
Implements, and Measuring lnstrurnents
(1) Replacing Consumables
Replace the following pads with the new ones.
( Q:"Parts Listv)
@ Gasket 4-3.3.1 No.525, 526
@O-ring 4-3.3.1 No.521
@ Protective zinc mounting gasket 4-3.3.1 No.61
(2) Implements and Measuring Instruments
General tools and measuring instruments
(QJ : 2-2)
15-3.3 Inspection and Maintenance of
Lubricating Oil Cooler
If sludge is accumulated on the cooling pipe
surface of the lubricating cooler, the cooling
performance will drastically be decreased.
Therefore, be minded to conduct the maintenance
according to the maintenance i n t e ~ aspecified
l in
the overhaul and maintenance list.
(1) Removal of lubricating oll cooler
a) Remove the connecting piping of the cooling
water and lubricating oil.
b) Pass a wire rope around the lubricating oil
cooler assembly, and dismount the cooling
water assembly by removing the mounting bolt.
while suspending it with a chain block.
 Lubricating Oil System
Inspection, Maintenance, and Assembly of Lubricating Oil
DK-20 cooler

(2) Cleaning of lubricating Oil Side

Clean the lubricating oil side of the lubricating oil
cooler by means of chemical cleaning, pulling out
the cooling pipe assembly.
a) Remove the bolt and nut, and take out the
cover @ and @ on the both sides.
b ) Pull out the cooling pipe assembly by pushing
it from the slide side (cover @ side) to the fixed
side (cover @ side).
c ) Clean the cooling pipe assembly by immersing
it into cleaning liquid.

: 1) As for the details on the brand of the

cleaning agent, the mixing ratio, heating, Cooling Pipe Assembly
postcleaning treatment, and so on, refer to
the instruction manual of the manufacturer
of each cleaning agent.
2) Be minded not to add the heat 01 1 5 0 " ~
or
more to the cooler.

(3) Cleaning of cooling water side

Remove sludge accumulated on the cooling pipe
inner surlace using a cleaning brush for small
tube, in the state that the covers on the both
sides are removed.
(4) Inspection and maintenance
a) Inspect if there is any crack or corrosion on
the inner surface of the cooling pipe.
b ) In case that crack or corrosion is found,
replace the cooling pipe with a new one.
O A s for the replacing method, consult the
Service Department of Daihatsu Diesel Cleaning of Cooling Pipe
Manufacturing Co., Ltd.
c ) Replace the O-ring @ 01 the tube plate @
outer periphery, and insert it into the casing @.

15-3.4 A s s e m b l y o f Lubricating Oil Cooler

(1) Attach the covers on the both sides.
(2) Conduct the water pressure test in the state of (Water pressure test)
the cooler assembly, and confirm that there is Water side : O.6MPa {6 kgf/crna)
not leakage from any section of the p a r k Lubricating oil side : 1.OMPa { l o kgflcm')
(3) Install the cooler assembly on the engine, and
connect the piping.
 Lubricating Oil System
ITEM
Lubricating Oil Relief Valve DK-20 4.1-4.5

15-4 Lubricating Oil Relief Valve 15-4.4 Inspection and Maintenance of

Lubricating Oil Reliet Valve
15-4.1 General Construction
(1) Clean all the disassembled parts with lresh
The lubricating oil relief valve is incorporated into
washing water, and remove sludge.
the lower part block of the lubricating filter.
(2) lnspect if there is any abnormal dent or scratch
Surplus lubricating oil will be returned into the oil
on the relief valve, or it the relief valve is not
pan or into the oil tank on the engine base plate.
stuck.
The adjustment of lubricating oil pressure can be
If the degree of the damage is minor, correct it
made by by turning the adjusting screw a, and by
with oil stone, and confirm that the valve can be
changing the spring force of the relief valve,.
moved smoothly.
(3) Inspect if there is any abnormal dent or scratch
on the spring.
15-4.2 Replacing Consumables,
Implements, and Measuring lnstruments
(1) Replacing Consumables 15-4.5 Assembly of Lubricating Oil Relief
Replace the following parts with the new ones Valve
(a : "Parts Listn)
6)Circular gasket 4-3.5.1 No.532, 533
Assemble the relief valve in the reverse order of
the disassembling procedure.
(1) Set the adjusting screw to the marking position.
(2) Implements and Measuring lnstruments
(2) After assembling, operate the engine and check
@ General implements and measuring instruments
(a: 2-2)
if the pressure is within the blue mark range, and
in case that the pressure indication is out of the
range, adjust it with the adjusting screw.

15-4.3 Disassembly of Lubricating Oil

Relief Valve
(1) Remove the cap 0, loosen the lock nut 0,
and
fully turn back the adjusting screw @.
Before loosening the adjusting screw, either
mark the tightening position of the adjusting
screw, or record the dimensions, so that the
previous adjusting position can be identified
when assembling.
(2) Take out the spring case @I.

Since the spring of the spring case is Lubricating Oil Relief Valve
compressed, b e minded to slowly a n d
carefully loosen it.

(3) Take out the spring seat @, spring @ and @,

and relief valve @ from the lubricating oil relief
valve body a.
 Lubricating Oil System
Lubricating Oil Temperature Control Valve: General
DK-20 ConstructionlReplacing Consumables and Implements

15-5 Lubricating Oil Temperature

Control Valve:
15-5.1 General Construction 15-5.2 Replacing Consumables,
The lubricating oil temperature control valve is a
Implements, and Measuring Instruments
kind of the mixing type with 3-direction valves, and (1) Replacing Consurnables
the common port "A", high-temperature port "B", Replace the following pads with the new ones.
and low-temperature port "C" are provided. The @ Gasket S4104100680
valve a is opened or closed by the activation of @ O-ring Z56OlOll24
the spindle @, which moves out and moves in by 8Pellet (1) S10400
expansion or contraction force of the wax of the Note: The controlling temperature of pellet will
wax pellet @ I in the common port " A .
located vary depending on the specifications.
Therefore, clearly indicate the controlling
(Explanation of activation) ternperature of the name plate when issuing
The figure shows the case that the lubricating oil. orders.
ternperature of the port " A , which is connected to
the engine inlet, is low, and indicates the state that (2) Implements and Measuring lnstruments
the port "C"is fully closed and the port "6" is fully @ General implements and measuring instruments
opened. ( QJ : 2-2)
When the lubricating oil ternperature is increased,
the wax in the wax pellet will expand to extend the
spindle, so that the valve @ is pushed down to
o p e n the port " C " , and the lubricating oil
temperature in the pod "A" can be controlled to be
of the specified value.
In case that the lubricating oil temperature of the
engine inlet has abnormally increased due to
failure of the pellet, and so on, the temperature can
be decreased by manually screwing the adjusting
screw @, as an emergency measure, to push
down the valve and open the port "C".
(a : "Operation" 5-3.2"Manual Adjustment of
Lubricating Oil Temperature")

Lubricating oil temperature control valve

(DTV50) : 13 k g

Lubricating Oil Temperature Control Valve

 Lubricating Oil System
Lubricating Oil Temperature Control Valve:
Disassemblyllnspection and MainfenanceIAssembly

15-5.3 Disassembly of Lubricating Oil 15-5.5 Assembly of Lubricating Oil

Temperature Control Valve
(1) Take out each connection piping, and dismount
the temperature control valve.
(2) Disassemble the temperature control valve on
the following procedure:
a) Remove the bolt, and take out the cover @.
Lil
Since the spring @ i s compressed, be
minded to slowly and carefully loosen the
bolt, so that the spring may not fly out.
Temperature Control Valve
Assemble the control valve in the reverse order of
the disassembling procedure.
1) Apply grease on the sliding part of the
valve.
2) Replace the pellet every 2 years, taking
into consideration the deterioration of the
rubber diaphragm in the inside.

b) Dismount the valve @.

As the pellet @ is attached to the valve, pull
out the valve and pellet at the same time.
c) Pull out the spring @.
d) Remove the E-ring 0, and take out the spring
0.
e) Take out the pellet from the valve.
f) Remove the cap nut @ and lock nut 0,and
pull out the adjusting screw @.

15-5.4 Inspection and Maintenance of

Lubricating Oil Temperature Control Valve
(1) Clean all the disassembled parts with washing
oil, and remove the scales.
(2) lnspect if there is any scratch on the outer
periphery and end surface of the valve, and
confirm that the valve moves smoothly.
In case that the degree of scratch is minor,
correct it with oil stone.
(3) lnspect if there is any abnormal dent or scratch
on each spring.
 Cooling Water System
ITEM Outline of Cooling Water SystemlGeneral Construction of
1, 2.1 DK-20 cooling water pump

16. Cooling Water System

16.1 Outline of Cooling Water System 16.2 Cooling Water Pump
The cooling water system is divided into a jacket 16.2.1 General Construction
system for cooling the engine, and a cooler system
The cooling water pump of the jacket system is a
for cooling the air cooler and lubricating oil cooler.
volute type, and the pump is installed on the front
As the standard specifications, the jacket system
of the engine, and is driven by the auxiliary drive
cooling water pump is attached on the engine, and
gear located on the front end of the crankshaft.
t h e cooler system cooling water pump is
separately installed.
The engine outlet of the jacket system cooling
water is equipped with a temperature control valve.
I Cooling water pump : 39 kg
I
In case of heavy fuel oil specifications, the fuel oil
injeclion valve is water-cooled, and cooling water
is supplied as branched from the jacket system.
.
(a : "Operation" 2.2.4 "Cooling Water System")

Nozzle cooling system

(Unnecessary in case ol diesel fuel
(Remove RH133) oil specilications)

J-7 Head lank

' Turbocharger
-?
1

Fresh water cooler

. . .m ......... m' V
Jacket syslem
fresh water
pump

Cooling Water System

 5
Cooling Water System
ITEM
Cooling Water Pump: Replacing Consumables,
Implements, and Measuring lnstrumentslDisassembly DK-20 2.2,2.3

16.2.2 Replacing Consumables,

Implements and Measuring lnstruments The screw of the impeller mounting nut @ for
normal rotation engine is threaded as "left-
(1) Replacing Consumables
handed" screw. Therefore, be careful of the
Replace the following parts with the new ones
(a: "Parts List")
O-ring 4-4.1 No.522
direction when loosening or tightening the nut
and screw.

@ Circular gasket 4-4.1 No.529 c) Remove the rotary part of the mechanical seal
@Gasket 4-4.2 No.10
@.
@ Oil seal 4-4.1 No.520 d) Remove the seal holder 0, and take out the
@Mechanical seal fixed parl of the mechanical seal.
(For normal rotation engine) 4-4.1 No.49 e) Remove the water-cutting ring @.
(For reverse rotation engine) 4-4.1 No.50 f ) Remove the cooling water p u m p g e a r
@ Bearing 4-4.1 No.514 tightening nut 0, remove the cooling water
pump gear 0, and then take out the key 0.
(2) Implements and Measuring Instruments g) Pull out the collar 0,and take out the snap
@ General implements and measuring instruments ring 0.
J
(?
Q : 2-2.2) h) Extract the pump shaft @ out of the bearing
case @, together with the ball bearing @.
i)Take out the oil seal @ from the bearing case.
16.2.3 Disassembly of Cooling Water
Pump
(1) Before dismounting the cooling water pump,
remove the cover of the center of the auxiliary
gear case, and measure the backlash of the
pump drive gear.

Standard Replacement limit

Backlash 0.3-0.5

(2) Disconnect the piping of the pump inlet and

outlet.
(3) Remove the tightening nut, and dismount the
cooling water pump assembly.
(4) Disassemble the cooling water pump in the
following procedure:
Before disassembling, put matchmarks on the
joint surfaces of the pump body, cover, and so
on.

(Cooling water pump disassembling procedure)

a) Remove the mounting nut, and take out the
pump body @.
b) Remove the impeller mounting nut @, remove Cooling Water Pump
the impeller 0,
and take out the key @.
 >

Cooling Water System

ITEM
2 4 DK-20 Inspection and Maintenance of Cooling Water Pump

16.2.4 Inspection andMaintenance of

Cooling Water Pump
(1) Wash all the disassembled parts with washing
oil, and remove the scales.
(2) Measure the clearance "a" between the
impeller and the mouth ring.
Measure the outer diameter of the mouth ring
inserting part of the impeller and the inner
diameter of the mouth ring, and calculate the
clearance.

Mouth ring clearance

Standard value(mm) Replacement limit(mm)
a = 0.50-0.56 1.O

I n case that the clearance i s over the Clearance between Impeller and Mouth Ring
replacement limit, replace the pads, of which
wearing degree is larger.
Excessive wear may degrade the pump
efficiency.

(3) Check if there is any corrosion or cavitation on

the impeller.
(4) Check if there is any corrosion or cavitation on
the casing, or the reduction in thickness of the
casing due to these defects.
( 5 ) Check the wearing conditions of the cooling
water pump gear tooth flank and the presence of
pitching.
( 6 ) Rotate the bearing, and check if it rotates
smoothly, does not make abnormal noise, or is
not worn out.

Replace the bearing a t the time of the

periodical inspection of every 8,000 l o
12,000 hrs. (every 2 to 3 years) with a new
one, even when there is no particular
abnormality on it.
 Cooling Water System

Assembly of Cooling Water Pump DK-20 ITEM 2.5

16.2.5 Assembly of Cooling Water Pump

(1) Assemble the cooling water pump assembly in
the reverse order of the disassembling
procedure.

Tightening torque of impeller

mounting nut: 147 N. m (15 kgf. m)

7/\
:Cautions when assembling the cooling
water pump)
1) Be minded to perform the assembling in
such a manner that the lubricating oil inlet
of the bearing case faces straight upward
(the notched mark " 0 " facing straight
upward), when the pump is mounted on
the engine.
2) Replace the oil seal, mechanical seal,
gasket, and O-rings with the new ones.
3) Be careful not to assemble the oil seal in a
wrong direction.
4) Do not apply lubricating oil to the carbon
of the mechanical seal.
5) Before mounting the pump body, turn the
impeller by hand and confirm that it rotates
smoothly.

(2) Mount the cooling water pump.

In case that the cooling water pump gear is
replaced, check the backlash.
(3) Connect the cooling water inlet and outlet
piping.

: If the flange surfaces cannot be fitted tightly

due to the distortion of piping, correct the
distortion of the piping before connecting. If
the distorted piping is forcibly connected, the
pump bearing may be damaged.
16-3 Cooling Water Temperature 16-3.2 Replacing Consumables,
Control Valve Implements, and Measuring Instruments
16-3.1 General Construction (1) Replacing Consumables
Replace the following parts with the new ones:
The cooling water temperature control valve is a @ Y-ring S104100650
kind of the mixing type with 3-direction valves as in @ O-ring 256010212422
the case of the lubricating oil temperature control @O-ring 256010363522
valve. Consequently, the basic structure, function, @O-ring Z565001300U
activation, and handling method is approximately
@ Pellet S10400
identical with those of the lubricating oil Note: The controlling temperature of pellet may
temperature control valve.
(a
Valve")
: "Lubricating Oil Temperature Control
differ depending on the specification.
Therefore, be minded to clearly indicate the
controlling temperature of the name plate when
issuing orders.

I Cooling water temperature control valve

(DTV-65) : 20 kg (2) Implements and Measuring lnstruments
@ General implements and measuring
instruments (m:2-2)

A pod
Cooling Water Temperature Control Valve
 Cooling Water System
Cooling Water Temperature Control Valve:
Disassemblyllnspection and MainfenancelAssembly

16-3.3 Disassembly of Cooling Water 16-3.4 Inspection and Maintenance of

Temperature Control Valve
(1) Disconnect the connection piping, and remove
the temperature control valve assembly.
(2) Disassemble the cooling water temperature
control valve in the following procedure:
(Disassembling procedure)
a) Remove the mounting bolt, and take out the
cover @.
Since the adjusting screw 0and the rod
are attached to the cover @, remove them
altogether.
b) Remove the mounting bolt, and take out the
cover @.
Since the valve @, shaft a,
pellet @, and
main spring @ are attached to the cover,
remove them altogether.
c) Take out the pellet.
d) Remove the lock nut @ and @, take out the
valve from the shaft.
Cooling Water Temperature Control
Valve
(1) Clean all the disassembled parts with washing
oil, and remove the scales.
(2) Inspect if there is not any scratch on the outer
periphery and end surface of the valve, a n d
confirm that the valve moves smoothly.
If the degree of scratch is minor, correct it with oil
stone.
a (3) Inspect if there is not any abnormal dent or
scratch on the cushion spring.
(4) Insert the shaft into the shaft bush, and inspect
if it moves smoothly.
16-3.5 Assembly of Cooling Water
Temperature Control Valve
Assemble the temperature control valve in the
reverse order of disassembling procedure.

Since the main spring is compressed, be Be minded to replace the pellet every 2 years,
minded to carefully and slowly loosen the taking into consideration the degradation of the
nut, so that the spring may not fly out. rubber diaphragm in the inside.

e) Take out the shaft, spring seat @, and main

spring.
f ) Pull out the shaft bush @from the cover.
Take out the cap 0, and pull out cushion
spring @ and rod from the adjusting screw
0.
 5-3 \
Engine Control and Protective Device
ITEM

1 DK-20 Outline of Engine Control and Protective Device

17. Engine Controland Protective

Device

17-1 Outline of Engine Control and .Turning safety switch and solenoid valve
Protective Device ..... Disassembling is prohibited, and therefore
(m: "Operation" 2-3 "Engine Control and
replace them as an assembly.
8 Fuel oil control device
Protective Device") ..... lncorporated into the fuel oil shutdown
Although the engine control and protective device device. (Explained in this section.)
differ depending on the use application of the
engine and the delivery specifications, the (2) Engine Protective Device
composing equipment that are common to each 0Various switches and various sensors
system are as shown below. As for the inspection (for speed, temperature, pressure, level, etc.)
and maintenance of each equipmenl, perform the . . . . . The disassembling of these parts are
work according to the following procedure. prohibited, and therefore replace each of them
as an assembly.
(1) Engine Control (Start, Drive, and Stop) System Various electric parts
Starting air valve, starter relay valve, starting air .....The disassembling- of these parts are
operation valve, and handle switch
(a:
Governor
13 "Starting Air System")
prohibited, and therefore replace each of them
as an assembly.

(a: "Instruction Manual of Governor")

0 Fuel oil shutdown device

..... lncorporated into the fuel oil control device.

(Explained in this section.)

3ovemar mot Pulse sensor

Turning bar Starling operation valve

Speed switch

Meler display
(4.20rnA)

Turning salety Slop cylinder Control cylinder

swilch Slarting air \ \ L ~ a m r n o rod
n
rotary valve Fuel oil
shutdown device

1 A \ ,Fuel oil injection pump

solenoid valve (SV) solenoid valve ( 5 s )

Slaning solenoid Fuel oil conlrol
valve (88V) ~ o l e n ~ i d v a(BBL)
lv~

Start and Stop System of Constant-Speed Engine (Direct Starting Type)

Engine Control and Protective Device
ITEM
Outline of Engine Control and Protective Device DK-20 1

Start and Stop System of Constant-Speed Engine (Air Motor Starting Type)

Pulse sensor

Governor air (From operali

Start and Stop System of Variable-Speed Engine (Direct Starting Type)

17-2 Fuel Oil Shutdown Device (GIType)
17-2.1 G e n e r a l construction
As the fuel oil shutdown device, there are two
types, i.e., G1 Type tor the constant-speed engine
(such as a generator engine) and J2 Type for the
variable-speed engine (such a s a marine
propulsion engine), and which engine should be
used depends on the purpose of its use and
specifications.
The fuel oil shutdown device ( G I Type) is provided
with a stop cylinder to shut down the fuel oil, and a
fuel control cylinder to control excessive fuel oil
injection that are arranged in tandem, and this
shutdown device shifts the fuel injection pump rack .
to either "Stop" position or "Control" position via
common rod, by affecting the control air to each
piston.
I Fuel oil shutdown device ( G l type) : 5.5 k g
d b
Fuel Oil Shutdown Device ( G I Type)
17-2.2 Replacing Consumables,
Implements, and M e a s u r i n g Instruments
(1) Replacing Consumables
Replace the following park with the new ones.
( Q: "Parts List")
<G1 type> O-ring
4-7.1.1 No.505.506, 507, 508, 509
(2) Implements and Measuring instruments
@General implements and measuring instruments
( Q : 2-2)
17-2.3 D i s a s s e m b l y o f Fuel Oil Shutdown
D e v i c e (GI Type)
(1) Before disassembling, pul a mark (matchmark)
to the adjusting place, or keep the record of the
dimensions.
(2) Take out the link pin 0, and remove the fork
I end @.
(3) Remove the fuel oil shutdown device assembly
@from the engine.
(4) Disassemble the fuel oil shutdown device
assembly in the following procedure:
a) Remove the bolts, and take out the cover-l@
and the cover-2 0.
b) Extract the main spring @ and shutdown
piston @out of the cylinder @.
c) Extract the control piston @ from the opposite
side.
Common rod
/
b b
 Engine Control and Protective Device
17-2.4 Inspection, Maintenance, and
Assembly of Fuel Oil Shutdown Device
6 1 Type)
(1) Wash all the disassembled parts with clean
washing oil, and blow air on them.
(2) lnspect if there is any abnormal dent or scratch
on the shutdown piston and control piston.
(3) lnspect if there is any abnormal dent or scralch
on the cylinder inner surface.
(4) lnspect if there is any scratch on the main
spring.
(5) lnspect if there is any rusting on each parts,
which is caused by drain.
(6) Assemble t h e fuel oil shutdown device
assembly in the reverse order of the
disassembling procedure.
1) Replace all the O-rings with the new ones.
2) When assembling, thinly apply grease to
the sliding surfaces of the O-ring, piston,
and so on.
(7) After assembling, confirm that every par1 of the
device operates smoothly.
Mounting and Adjustment of Fuel Oil Shutdown Device (GI Type)
I
17-2.5 Mounting and Adjustment of Fuel
Oil Shutdown Device (GI Type)
(1) Mount the fuel oil shutdown device assembly to
the engine, and attach the fork end and link
lever.
At this time, be minded to temporarily adjust the
adjusting bolt @ by matching it t o the
matchmark.
(2) Turn the operation lever to "Drive" position, and
supply control air to the control cylinder of the
fuel oil shutdown device. And, adjust the screw-
in position of the fork end, so that the rack scale
indicates the specified position, and fix the link
\ever.
(3) Next, supply air to the shutdown cylinder, and
adjust the screw-in position of the adjusting bolt,
so that the rack is at "0" position.
If the screw-in direction is clockwise, the
shutdown stroke will be decreased.
(4) When the adjustment of the control stroke and
the shutdown stroke is completed after repeating
the above steps (2) and (3), fix the fork end and
adjusting bolt with the lock nuts.
Fork end
\
STOP RUN
 I Enaine Control and Protective Device I

17.3 Fuel Oil Shutdown Device (J2 Type) 17.3.3 Disassembly, Maintenance, and
Assembly of Fuel Oil Shutdown Device
17.3.1 General construction
(J2 Type)
The fuel oil shutdown device (J2 type) is employed
The assembly, maintenance, and assembly of the
in the air-system type variable-speed engine, and
fuel shutdown device (J2 type) shall be conducted
as in the case of G I type, the shutdown device is
according to the procedure of G1 type.
composed of a stop cylinder which shuts down the
fuel, a n d a control cylinder which controls
(m: 17-2 "Fuel Oil Shutdown Device (GI Type)")

excessive fuel injection.

The limit value of the control cylinder is variable,
17-3.4 Mounting and Adjustment of Fuel
a n d it shall be varied by the air pressure for
Oil Shutdown Device (52 Type)
operation, and according to the load.
The adjustment of the fuel oil shutdown device (J2

I Fuel oil shutdown device (J2 type) : 9.5 kg I

type) shall be conducted by correlating it with the
pressure of operating air.
(1) Mount the fuel oil shutdown device to the
engine, and attach the fork end and link lever by
17.3.2 Replacing Consumables, temporarily adjusting them.
Implements, and Measuring lnstruments (2) Set the operating lever of the engine to "Drive"
position, push the rack indicator needle to the
(1) Replacing Consumables
increase direction, adjust the screw-in position of
Replace the following parts with the new ones.
( a: "Parts List")
@ Mini-Y gasket 4-7.1.2 No.40, 41
the fork end, so that the rack amount in the state
that the link pin is struck against the long-hole
parl of the link should be the rack amount +2-3
@ GLY gasket 4-7.1.2 No.44
mm (Point A in the figure) of the starting time,
@ O-ring 4-7.1.2 N o 3 7
and then fix the link lever.
@ SER scraDer 4-7.1.2 No.47
(3) Supply the operating air equivalent to the total
load rack amount (0.4MPa in the figure) to the
(2) Implements and Measuring lnstruments
rack control piston.
@ General implements and measuring
In the meantime, confirm that the link pin is not
instruments (0: 2-2)
struck against the long-hole part of the link.

Fuel Oil Shutdown Device (J2 Type)

 Engine Control and Protective Device
Mounting and Adjustment of Fuel Oil Shutdown Device (52
TYpe)
(4) Next, push the rack indicator needle to the
increase direction, and adjust the screw-in
position of the spring seat, s o that the rack
amount in the state that the link pin is struck
against the long-hole part of the link should be
the rack amount +1 - 2 mm (Point B in the
figure) of the full-loading time.
If the screw-in direction is clockwise, the limit
rack amount will be decreased.
(5) In case that the rack stopper is set in the full-
loaded position, confirm the rack amount to be
limited by the clearance between the link long-
hole part and link pin.
(6) After the operating air is decompressed to
0.1 MPa or lower, gradually supply the operating
air to the control piston again, and confirm that
activation starting point (Point C in the figure) is
within the range of 0.1 -0.2MPa.
(7) Next, supply the control air to the shutdown
piston, and adjust the screw-in position of the
adjusting bolt, so that the rack position is "0.
If the s c r e w - i n direction is clockwise, the
shutdown stroke will be decreased.
Nut
Adjust bolt
I I
Stopper screw and Link lever
nylon piece
iock nu1 Mounting and Adjustment of Fuel Oil Shutdown Device (J2 Type)
Rack stopper
posilion / / / / / / / / / / / / / /
-m
1
$
U
-0m
.-
-m
3
LL
Slarling time control
position
0 0.1 0.15
ITEM
DK-20 3.4
(8) When the adjustment of the rack control stroke
and shutdown stroke is completed by repeating
the procedure of the above Item (3) to (7),fix the
fork end and adjust bolt with the lock nut.
u
1) Although hysteresis may be seen between
the increase time and decrease time o f
operating air pressure, there is n o
functional problems at all.
2) The adjustment of activating properties of
the rack control piston shall be conducted
only in the direction of increasing t h e
operating air pressure, so that the errors
due to hysteresis can be minimized.
3) Since the spring seat is locked not t o
rotate by the stopper screw a n d nylon
piece, adjustment shall be conducted after
loosening the stopper screw, and be sure
to lock it again after finishing t h e
adjustment.
Nylon piece and
stopper screw
\ / Fork end Activation startina
pressure
-
Increase Decrease
/k'
Rack control piston
aclivaling properties
Load properlies of marine
propulsion engine
0.2 0.3
 Gauge Board

General ConstructionlReplacing Consumables, Implements,

DK-20 and Measuring lnstrumentslDisassembly and Maintenance

18 Gauge Board (2) Inspection and Maintenance of Gauge Board

18-1 Gauge Board a) Check the accuracy of each gauge, compar-

18-1.1 General Construction
The gauge board is equipped with a tachometer
and each pressure gauge (for lubricating oil, fuel
oil, intake air, cooling water, etc.), and is supported
by cushion rubber.
ing with the equipment for calibration purpose
or new equipment. In case that any fault is
found, replace it with a good gauge.
b) Replace the flexible hose with a new one.
c) Replace the cushion rubber with a new one.

The tachometer is driven from the front end of

the camshaft via flexible cable, and each pressure
c1) It is difficult to repair the defective gauges on
gauge is connected from the source valve at the
end of piping with flexible hose
18-1.2 Replacing Consumables,
Implements, Measuring Instruments
(1) Replacing Consumables
Replace the following parts with the new ones.
( : "Parts List")
@ Flexible hose 4 - 6 . i No. A20. A21, A24
@ Cushion rubber 4-6.1 No. A15
(2) Implements and Measuring lnstruments
site. Therefore, replace them with the new
ones, or inquire the specialized maker for the
repair.
2) Heavily deteriorated hoses may break. lfthe
hoses for fuel oil and lubricating oil break and
high-temperature parts are splashed with the
oil, a fire may occur. Replace such hoses
without fail.
3) If the elasticity of the cushion rubber is lost,
the vibration of the gauge will increase and
the indication fault of the gauge will be
advanced.
Cushion rubber

Cusliion spring
18-1.3 Disassembly and Maintenance
of Gauge Board
Perform the disassembly and maintenance of
the gauge board at the time of the periodic inspec-
t i o n (every 16.000 to 24,000 hr: every 4 to 5
years), according to the following procedure:

(1) Disassembly of Gauge Board

a) Remove the flexible cable of tachometer from
Flexible hose
the take-out port.
b) Close the source valve of the pressure
gauge, and disconnect the flexible hose.
c) Remove the mounting bolt of cushion rubber
to the bracket, and disconnect the entire
gauge board. U 11 Flexible/cable iource valrw

Gauge Board
18-2 Seal Pot (Heavy fuel oil
specification)
In case of heavy fuel oil, a seal pot is provided in Fuel oil main pipe

F
the middle of the fuel oil pressure gauge piping,
and lilled with ethylene glycol to replace the
pressure, s o that the pressure gauge can be
prevented from malfunction due to the sticking of
fuel oil in the cold condition.
Ethylene glycol w i l l be contaminated and
deteriorated being mixed with fuel oil as time
passes, and therefore be minded to periodically
replace ethylene glycol with new one.

(Replacing procedure of ethylene glycol)

(1) Close the valve @, 0, and @ at the seal pot
inlet and outlet, and remove the seal pot @.
(2) Disconnect the inlet side joint @ of siphon tank
@, and discharge the fuel oil and ethylene glycol
of the inside.
(3) Wash the inside of the tank.
(4) Fill ethylene glycol until it starts to spill out of
Seal Pot
the upper part hole, and then install the joint.
( 5 ) Install the piping to the seal pot.

Although ethylene glycol is less toxic to skin

and membrane, it is still dangerous i f it was
taken into human body. Therefore, be
minded to take enough care in the handling,
a n d promptly wash it a w a y when it is
deposited on hand or skin.
 I Regarding replacement parts for Daihatsu Diesel engine
Hazards and nonconformitiesof imitation parts
<Use of imitation parts causes accidents.>
1. Recent engines have compact bodies and high power, and are designed to prevent fuel deterioration
and to reduce NOx discharge. Even if imitation parts are similar in shape to the genuine parts, the
use of imitation parts will degrade the engine performance because of their fragile materials and low
machining accuracy. Since the service life of such parts is short, the engine must be maintained more
frequently.
2. If imitation parts are used for the engines designed in accordance with MARPOL VI, the certificate
(EIAPP) may lose its validity, and operation of the engine may be inhibited.
3. If you use imitation parts, you will not be supplied with parts improved in quality and performance.
4. If imitation parts are used, it may be difficult to make insurance claims for the engine when any
accident occurs.
5. We take no responsibility for the engine in which imitation parts are used.

Daihatsu Diesel supplies reliable engines.

Use genuine parts to operate your engine safely.

I lnauiw and Order I

Order ; Parts sales D a i h a t s u D i e s e l P a r t s S e r v i c e Co.,Ltd.
12-34, Tanaka-cho, Ibaraki, Osaka, 567-0025 lapan
TEL:B1-72-621-3482 FAX:81-72-621-3484

Inquiry ;Service Department ------------..-

DAIHATSU DIESEL MFO.CO.,LTD. Osaka Head Oflice.
1-30, Oyodo Nakal -chome, Kila-ku, Osaka, 531-0076 Japan
TEL:81-6-6454-2346 FAX:81-6-M54-2680-1

Or, get in touch with our offices listed below.

DAIHATSU DIESEL MFG.CO.,LTD.O

Osaka Head Office. 1-30. Oyodo Nakal-chome. Kila-ku. Osaka. 531-0076 Japan
TEL:816-6454-2393 FAX:81-66454-2686
Morlyarna Factory. 45 Amura-cho.Moriyamacity,Shiga.5240035 Japan
TEL:81-77-583-2551FAX:81-77-582.5714
Tokyo Office. 2-10. Z-cho~ne,N.honDasn~.HonchoCh~Ok~.Tonyo,l03.0023 Japan
TEL 81-3.3279.0627 FAX'81.3-3245-0395
Sydney Onice. P.O.Box519. North Sydney N.S.W.2060Australia
TEL:61-2.9923-1155 FAX:61-2-9923-1532
Jakarta Office. 161h Flmr.Vvisma Antara Bldg., JI. Medan Merdnka.Selatan No.17.Jakarta-Pusat,lndonesia
TEL:62-21-384-8411 FAX:62-21-38443412
Manila Offlce. Unll 1010 Herrera T o ~ e Herrera
r Corner Va ero Sts.. Sakedo Val age Makatl City 1226 Pn 1:pp'nes
TEL'63.2.753-3211 63-2-817-127911285 FA%63-2-845.0691
Taiwan Onlce. No.14 Tai-Tang RD. Lin-Hai lnduslrial Zone, Kaohsiung. 812 Taiwan
(do Marine Technical Industries Co.. Lld.) TEL:886-7-803-1082 FAX:886-7.801-9179
Daihalsu Dlesel (Europe) Ltd. 7th Floar. Peninsular H o u s e 3 Monument Slree1,London EWR BW, U.K.
TEL:44-20-7626-4600FAX:44-20-7626.6020
Oslhatsu Diesel (AMERICA), lnc. 180 Adams Avenue.Hauppauge.NY 11788.U.S.A.
TEL:1-631-434-87871819 FAX:l-631-434-8759
Dalhatsu Dlesel (ASIA PACIFIC) Pte.Ltd. 128 Pioneer Road Singapore 639586
TEL:65-6270-7235 FAX:65-6270-6236
Dalhatsu Dlesel (SHANGHAI) Co.,Ltd. Suite 3004 Nan Zheng Building 580 Nan Jing Wesl Road Shanghai. China
TEL:86-21-5234.1228-9 FAX:M-21-5234-1062
Dalhnlsu Dlesel Part3 Setvlae Co.,Ltd. 12-34, Tanaka-cho, Ibaraki. Osaka, 567-0025 Japan
TEL:81-72-621-3482FAX:81-72-621-3484
I PARTS LIST I
3%€I ;% (iE%a%H) ITEM
PARTS CONTENTS (HEAVY FUEL OIL) 5DK-20

B ;A
CONTENTS

1. &M9+H%M
ENGINE OUTLINE

2. B?E%%H
PlPlNG SYSTEM
EE3EOI03S?%83&U:3E%%
3ESF
GRAPHICAL SYMBOL, PART NAME AND PART NUMBER OF PlPlNG PART
EWJ?ZEE
STARTING AIR PlPlNG
H'EE
FUEL OIL PlPlNG
%&mm&E
(WKflf6)
LUBRICATING OIL PlPlNG (FRONT TIC)
BBBrnE r&%B%)
LUBRICATING OIL PlPlNG (REAR TIC)
%3l7KE@(E%&Wi)
COOLING WATER PlPlNG (FRONT T/C)
%M7J(RE~&%fl@)
COOLING WATER PlPlNG (REAR TIC)
/XJl%EiMEE
NOZZLE COOLING WATER PlPlNG
/ XJVZSEQEE
NOZZLE COOLING OIL PlPlNG
fRkmHfi2YrnE
FUEL OIL lNJECTlON PUMP PlPlNG
RS%$!dEEM
ARRANGEMENT OF PROTECTIVE ZINC

\IT OF THERMOMETER

IE (SIDE VIEW)
- 1.2 %@ ma)
ENGINE FRAME (FRONT VIEW)
- 1. 3 %% r&E)
ENGINE FRAME (REAR VIEW)
- 2. %%RllZ
ENGINE SIDE COVER
- 3. %#Zf#?
ENGINE FRAME SAFETY VALVE
 a I H':
'
clBm €I;2 (iE%@IL,iM)
ITEM

5DK-20 PARTS CONTENTS (HEAVY FUEL OIL)

74 F'lbffl
IDLE GEAR
i f 4 J b $ > Y @ g Z CE~KIL&ZI/XIK%~?J~~%)
OIL PUMP GEAR CASE (F.W. NOZZLE COOLENG SYSTEM)
;;T4lbit\'>YE~Z (AEi&!lX6/Xlbm"M{f&.)
OIL PUMP GEAR CASE (D.O. NOZZLE COOLENG SYSTEM)
(-%%I
CAMSHAFT (ONE-BLOCK TYPE)
LlL@ (f38J%)
CAMSHAFT (BUILT-UP TYPE)
BL\I&%33M
DETAIL OF CAMSHAFT REAR END
/XlKfiBBfi>YBB%E
NOZZLE COOLING OIL PUMP DRIVING DEVICE
9 7 7 9 % & 1T77X3I-f b
CRANKSHAFT & BALANCE WEIGHT
9529a & z m
CRANKSHAFT & MAIN BEARING
774fi4-11/
FLYWHEEL
9'J 7974T
CYLINDER LINER
YXby
PISTON
zCONNECTING
tz @z ROD
9lJy9-y
CYLINDER HEAD
81 5 8
EXHAUST VALVE
$2 5% 8
INTAKE VALVE
tEEE . Sf#
INDICATOR & SAFETY VALVE
a#zE
VALVE OPERATING DEVICE
21~79-9 ~fi)~-
CYLINDER HEAD COVER
%3 , !%5%5'flY t-
INTAKE & EXHAUST TAPPET
- 20, 1 iK#R43fi2I&M
FUEL OIL INJECTION PUMP FITTING
- 2 0 . 2 !%HDa43%2Y
FUEL OIL INJECTION PUMP
I PARTS CONTENTS (HEAVY FUEL OIL) SDK-20

% H W E ~ O Y ~
FUEL OIL INJECTION BLOCK
%+~@~@S~(;$~JXJL)
F 0 INJECTION DEVICE(CO0LING NOZZLE)
%H@%~ZE(%;%WXJL)
F.O. INJECTION DEVICE(N0N-COOLING NOZZLE)
f i i i t B E i @ Z ( R H D 6)
GOVERNOR DRIVING DEVICE (RHD 6)
h'iit%Xi%i$g(UG 10)
GOVERNOR DRIVING DEVICE (UG 10)
2=E>OYF
CONTROL ROD
~~~i \>Fh
CONTROL HANDLE
WG3
LOAD GAUGE
t j i \ . t 1 J > 9 ( R H D 6)
GOVERNOR LlNK (RHD 6)
?ii<+J>9(UG 10)
GOVERNOR LlNK (UG 10)
+%W$ ( K % B % )
EXHAUST MANIFOLD (FRONT TIC)
4RZ!!$(@UB%)
EXHAUST MANIFOLD (REAR TIC)
#Z-?$hii-(%?%S%)
EXHAUST MANIFOLD COVER (FRONT TIC)
Wi$hii-(@?%B%)
EXHAUST MANIFOLD COVER (REAR TIC)
S % # ( K % B % : RH133). %!W;$M#(DHBZ)H!~~;~
TURBOCHAGER (FRONT TIC : RH133) &INTERCOOLER (DHB TYPE) FITTING
B%$$(@%B%: RHl33). ~%$&l%KXt;f
TURBOCHAGER (REAR TIC : RH133) &INTERCOOLER FITTING
a+mma%: RH143). g ~ ; $ ~ + m i +
TURBOCHAGER (FRONT TIC : RH143) &INTERCOOLER FITTING
a m ( @ e % a % :RH143) zzmam~+
TURBOCHAGER (REAR T ~ C: RH143) & INTERCOOLER FITTING
ZZ;?i%ll%(DH31)-%1k
INTERCOLER (DH31)-SEA WATER
Z%$H%(DH29)-%.7k
INTERCOLER (DH29)-SEA WATER
gS;+2ll%(DH39HZ)-;S7k
INTERCOLER (DH39HZ)FRESH WATER
~%$&D%-DHB~~ (Z7k). D H B ~ I H Z ( % ~ ~ )
INTERCOLER-DHB31(SEA WATER), DHB31HZ(FRESH V1IATER)
SZ;$&P#;;CDH29)-%7k
INTERCOLER (DH29)-SEA WATER
 milBil(iEB%#;B>
5 ~ ~ 4 PARTS
0 CONTENTS (HEAVY FUEL OIL)

-30. '~~@$$$>~Y-f~h~i-
FUEL OIL INJECTION PUMP SIDE COVER
-31. f'k &
STEP BOARD
4. &Ml*EB%
INSTRUMENT 8 ACCESSORIES
.@%2W%%
STARTING AIR SYSTEM
H&35Eazg
TACHOMETER DRIVING DEVICE
175-9 & rp*-mj*
AIR MOTOR B AIR MOTOR FITTING

%H%%
FUEL OIL SYSTEM
F
'%%>
3
'it?
i (TYPE A)
FUEL OIL FEED PUMP (TYPE A)
EPMiFh%>? (TYPE B)
FUEL OIL FEED PUMP VYPE 6)
?
>' %
i%
!t%
i sEagg
gYPE A)
FUEL OIL PUMP DRlVlN DEVICE (TYPE A)
E#ZiFh*/? %EZhZE
?!
ppE
FUEL OIL PUMP DRlVlN DEVl E (TYPE B)
EHO+
FUEL OIL FILTER
Ew+rQl;fm - * )
FUEL OIL FILTER F I n I N G (WITHOUT COVER)
Ew%E#
FUEL OIL RELIEF VALVE
RBiFh%%
LUBRICATING OIL SYSTEM
T%i%Fh %>?
LUBRICATING OIL PUMP
Td#a *>?HQt*
LUBRICATING OIL PUMP F l n l N G
%
d
)k7
(3
lW
f&
ld
LUBRICATING OIL COOLER (SEA WATER)
iM;Bih;+M%(;3k)
LUBRICATING OIL COOLER (FRESH WATER)
IM&+IO+
LUBRICATING OIL FILTER
.*#
;rd:g,.:@,ee$,r & o+rw(aa%aw-h/c--s
LUBRICATING OIL RELIFE VALVE 8 FILTER FllllNG (FRONT TIC)-WITHOUTCOVER
Mi@X%IE# & n+HQt*(@9%Bk%)-h/C-%
LUBRICATING OIL RELIFE VALVE B FILTER FITTING (REAR TIC)-WITHOUT COVER
ird;RihaE# & n + r ~ i * ( a 3 % a % ) - h / w *
LUBRICATING OIL RELIFE VALVE B FILTER FITTING (FRONT TIC)-WITHCOVER
: 23% & O+Hxt*(iYi~%iB%)-h/f-t+
ip;l:a:&=ar
,~1,
LUBRICATING OIL RELIFE VALVE 8 FILTER FITTING (REAR TIC)-WITH COVER
ff a
&a R X (tE!SEBt%H) ITEM
PARTS CONTEATS (HEAVY FUEL OIL) 5DK-20

- 3.6 B$GW%%&0+
TURBOCHARGER LUBRICATING OIL FILTER
- 3.7.1 a%EBaBaoT4!7.{*(g&ai$) - hl<-%
TURBOCHARGER LUBRICATING OIL FILTER FITTING (FRONT T/C) - WITHOUT COVER
- 3. 7 . 2 a$GB;@;Bj&o+m{*
r&~%af$)
. BIG-%
TURBOCHARGER LUBRICATING OIL FILTER F I ~ ~ I N(REAR
G T/C) -WITHOUT COVER
- 3 . 7 .3 B@%aMlaoT&f*(S&fiI%) - h)C-fq
TURBOCHARGER LUBRICATING OIL FILTER FITTING (FRONT T/C) - WITH COVER
- 3. 7. 4 a+$%w,%&o+&.Iriq
~?.J%B%)
- h)<-iq
TURBOCHARGER LUBRICATING OIL FILTER FITTING (REAR T/C) -WITH COVER
- 4. ;w~17xm
COOLING WATER SYSTEM
- 4. 1 %M7J<iWY
- 70A
COOLING WATER PUMP - 7 0 A
- 4 2 ;~~,WYYHW
COOLING WATER PUMP FITTING
- 5. 1 X~L%Bm%E
NOZZLE COOLING OIL SYSTEM
-5.1 lx.)v+D;&2;&*YY
NOZZLE COOLING OIL PUMP
- 5 2 /;Ol/;$Miaitt'JYE6J
NOZZLE COOLING OIL PUMP F l n l N G
- 5.3 lXJK$W,Q%E%
NOZZLE COOLING OIL RELIEF VALVE
- 6. 8 % #E
GAUGE BOARD
- 6. 1 3 E @ C$%B$6)- I/C : D H g
GAUGE BOARD (FRONT T/C) - I/C D H TYPE
-6 2 3E+,k(K%Bi,$: RH133) - I/C : D H B g
GAUGE BOARD (FRONT T/C : RH 1 3 3 ) - I/C DHB TYPE
6. 3 3E#i ~@%B%fi)
GAUGE BOARD (REAR T/C)
- 7. IZZsGB
PROTECTIVE DEVICE
- 7. 1 $%HEW.Nl%lJSE
FUEL SHUTDOWN 6 CONTROL PISTON
- 7. 2 $~W&!&.tl%llgE&N
fr

FUEL SHUTDOWN & CONTROL PISTON FITTING

- 8. B$S@,%YXB
TURBOCHARGER CLEANING DEVICE
. 8. 1 707-%%3EB - T/C : R H 1 3 3
BLOWER CLEANING PARTS - T/C : R H 1 3 3
- 8.2 707-$%3%S - T/C : RH 143
BLOWER CLEANING PARTS - T/C : R H 1 4 3
 d n n R ;2
b I=I ,H'' 2
(iEE~@IJ,,,,H)
5DK-20 PARTS CONTENTS (HEAVY FUEL OIL)

- 9. I
TOOLS -
R

- 3 l J 2 9 4 F)
9. 1 . 1 % E ~ T ~ Y( + ~
OIL PRESS JACK (CYLINDER HEAD)
- 9. 1 . 2 % ~ E ~ T ( X~
~ ~YL $
+T>YY)
OIL PRESS JACK (METAL CAP)
-9.2 %EE7L\
OIL PRESS RAM
@M9+flZM
ITEM
ENGINE OUTLINE 5DK-20
 1-1. Engine Conforming to NOx
Technical Code

1-1.1 Outline

(1) The marine diesel engines to which the 13th

rule "Nitrogen Oxides (NOx)" in Supplement VI
"Rules to Prevent Air Pollution by Ships" to
MARPOL73R8 Treaty applies should conform to
NOx Technical Code.

(2)NOX Y 9 3 1 ) b X - FSf%Ml$. I292 (2) The engines conforming to NOx Technical

9)b-7%fc1$123>775 Y - & LGZE Code are authorized as an engine group or an
E5lf Tdj'0. R61TD NOx %E3f 6$3@B engine family, and it is allowed to apply the
I$\ 1 2 3 2 1 r 7 % - 9 F ~ ~ 9 E E i @ R T 6 engine parameter check method to them, when
receiving the NOx discharge inspection on
C&~TS*T,
board.
12321c7%-9?1~~9~z&l$. 129 The engine parameter check method is a
2m!aE. SElim793J)b774Jbmt method for verifying that the engine components
SmE%ZLTL)&ZtE@ZT6E%T50, and setting values conform to the requirements
NOx R E ~ S ~ ~ ~ U E E 0 J X~ tSi ~
LZ I ~ ? ~ specified in the technical file, and does not
?9
3 3 J b 7 74)bE?BSRE%Z LTL)%L)Ef?i require the measurement of NOx discharge. To
12. 1>321c7%-9?1Yg%iEi@R!f6 the engines that are not conforming to the
E & % ~ requirements of the technical file, the engine
Z t b T 3 F . NOx ~ ~ ~ E S B I I V Z I %
To parameter check method cannot be applied.
For such engines, the measurement of NOx
discharge shall be required.

1-1.2 The parts to be Specified

The technical file states the engine components

that can affect the NOx discharge specified in NOx
Technical Code, and shows the identification
marks stamped on them, and the user is required
to maintain the technical file for each engine.
When replacing any parts shown in the technical
file, be sure to use our genuine parts stamped with
the identification marks. In the case that any park
without the identification mark is used, it shall be
regarded as nonconformance to the requirements
of the technical file, and in such a case, inspection
by the engine parameter check method cannot be
applied.
 NOX f 9=;hll/I- FBeBH
ENGINE CONFORMING TO NOX TECHNICAL CODE 5 ~ ~ ~ 1.2
2 0

~ ~ ~ ~ J L , ~ T . ~ I L , I L E ? @ Z ~ Y I T L \ The
~ ~ ~f o E
l l oIwJi n~g s~ are
E ~ the
D parts that have the
6 %BG~@B?jILIZ$Ell identification marks specified in the technical file.
E D PER < TYLL When replacing any of these parts, be sure to
check the identification marks.
(a : "Technical file")

<Parts with identification marks>

Cylinder head
@ Piston
@ Turbocharger
@ Air cooler
@ Fuel cam
@ Fuel injection pump
a Fuel injection pump plunger
@ Fuel injection valve
@ Fuel injection valve nozzle
 a 0 b 0
~ZE~Ba"aDH3~Z~dj'&UpBnn%%,cllJ~n%E
ITEM GRAPHICAL SYMBOL, PART NAME
1.1 5DK-20 AND PART NUMBER OF PIPING PART

E43ze
Graphical symbol
j4x
Size NC
*-1 m
n
se
Parts number / 10rE18X Name of parts

Union assy. 8 x %
1 Jnion screw 8
8XM 2 Sasket 13
3 Union nut 8
4 UNion nipple 8

Union assy. l o x %
1 Union screw 10
lox% 2 Sasket 17
3 Union nut 10
4 UNion nipple 10

Union assy. 12x%

1 Union screw 12
12X% 2 Gasket 21
3 Union nut 12
4 UNion nipple 12

Union assy. 15x M

1 Union screw 15
15XH 2 Gasket 21
3 Union nut 15
4 UNion nipple 15

Union assy. 18XM

1 Union screw 20
18XM 2 Gasket 21
3 Union nut 18
4 UNion nipple 18
- ~

Union assy. 2 0 x X
1 Union screw 20
20XX 2 Gasket 21
3 Union nut 18
4 UNion nipple 20

Union assy. 20X%

1 Union screw 22
2OxM 2 Gasket 27
3 Union nut 18
4 UNion nipple 20

Union assy. 2 2 x X
1 Union screw 25
22X% 2 Gasket 27
3 Union nut 22
4 UNion nipple 23
 ,
Bi! E n B a a ~ H 3 i Z ~ 8 & ~*n B a a %* %a, ~ B a a S ~
0 0

GRAPHICAL SYMBOL, PART NAME

AND PART NUMBER OF PIPING PART 5DK-20

M 3 Z E v-fx $UESE
NC Parts BBG8tZ Name of parts
Gra~hicalsvmbol Size number

Union assy. 35X 1%

1 Union screw 35
5X1M 2 Gasket 42
3 Union nut 35
4 Union nipple 35

1 Union screw 30
2 Gasket 34
28x1
3 Union nut 25
4 Union nipple 28

Flat union assy. 15X M

1 Flat union screw 15
2 Oring PI5
15XM
3 Gasket 21
4 Flat union nut 15
5 Flat union nipple 15

X551018040ZZ 779 bI=jS>ASSY. 18x% Flat union assy. 18xX

1 X55122000022 77Y b i z 9 20 Flat union screw 20
2 25601020242Z O'J >9 P20 0 ring P20
18XK
3 256500210022 7 J b l P +>
~ 21 Gasket 21
4 X55131800022 7 7 ~ b 1 ~18b Flat union nut 18
5 X55111800022 7 7 ~ b ' Y l T 18 Flat union nipple 18

Flat union assy. 20x%

1 Flat union screw 22
2 0 ring P20
20XX
3 Gasket 27
4 Flat union nut 18
5 Flat union nipple 20

X551022060Z2 7 7 b l~= k > A S S Y . 22X% Flat union assy. 22x%

1 X55122500022 7 7 ~ 25 Flat union screw 25
2 Z5601026352Z O'J >3 P26 0 ring P26
22X%
3 256500270022 ? I ~ I Y Y * > 27 Gasket 27
4 X55 l325OOOZZ 77 'Y b t:,' b 25 Flat union nut 25
5 X55 1 122000ZZ 7 7 v b YlX 22 Flat union nipple 22

Flat union assy. 28x 1

1 Flat union screw 28
2 0 ring P26
28x 1
3 Gasket 34
4 Flat union nut 25
5 Flat union nipple 28
 U .*' ~0B a a %*~ , ~ B a a S F
R!E~BaOaCnH3ZFifj'&
GRAPHICAL SYMBOL, PART NAME
5DK-20 AND PART NUMBER OF PIPING PART

M S 6 E T Name of parts
Graphical symbol

Hex. plug M
Gasket 10

Hex. plug !A
Gasket 13

Hex. plug %
Gasket 17

Hex. plug %
Gasket 2 1

Hex. plug 34,

Gasket 27

Hex. plug 1
Gasket 34
iESEE~B~~DQSEZ~~~'&~~"~B~",~%,EBEBZ
II 0

GRAPHICAL SYMBOL, PART NAME

AND PART NUMBER OF PIPING PART
-
M Z Z S T-tX Name of parts
Graphical symbol Size

Banjo assy. 6 x M
Banjo plug Y
i
Gasket 10
Banio 6 x M

'YY7 ASSY. 6XM Banio assy. 6 x M

'Y+%Jb b % Banjo plug %
?IbIYvSY 13 Gasket 13
'YY7 6XM Banjo 6 x M

'YY7 ASSY. 8x!4 Banio assy. 8 x %

'YY%Jbb !4 Banjo plug Ya
?lblYY*> 10 Gasket 10
Y Y 7 8X% Banjo 8 xM

Y Y 7 ASSY. 8 X X Banjo assy. 8 x M

J M Banjo plug M
?JbIYv*> 13 Gasket 13
Y Y 7 8XM Banjo 8 x M

'YY7 ASSY. 10XX Banjo assy, lOxM

YY%lbb % Banjo plug M
?bY+> 13 Gasket 13
'YY7 10XY Banjo l o x %

'YY7 ASSY. 10x36 Banjo assy. 10x36

'YYiKJb b % Banjo plug 36
Y + > 17 Gasket 17
Y Y 7 ?OX% Banjo 10x36

Y Y 7 ASSY. 12XH Banjo assy, l 2 x Y

'Y+iKJb b % Banio plug %
?lblY~=kY 13 Gasket 13
'YY7 1 2 x x Banjo 1 2 x X

X54611203022 Y Y 7 ASSY. 12x% Banio as%. 12 x %

1 X54520300022 'YYiKJbb % Banjo plug %
2 256500170022 ?JbIYv+Y 17 Gasket 17
3 254511203022 'YY7 12x36 Banjo 1 2 x Y

1 X5461 1503022 Y Y 7 ASSY. 15x36 Banjo assy. 15x 36

' X54520300022 ' Y Y ~ I b % Banjo plug 36
256500170022 7 1 ! 1 l P ~ i > 17 Gasket 17
25451 1503022 ' Y f 7 15x36 Banjo 15x36

X54611504022 'YY7 ASSY. l 5 X f i Banjo assy. 15x%

X54520400022 'YY%Jb b fi Banio plug Y2
2565002100Z2 ?lblYv+> 21 Gasket 2 1
26451 15000Z2 'YY7 15X% Banjo 1 5 x X
 RZEEBa"aCnBSiZ%dj'&U.'EBE%%,*clRaaS% 0

ITEM GRAPHICAL SYMBOL, PART NAME

1.5 5DK-20 AND PART NUMBER OF PIPING PART

E4itze lo. B[r.",B% BBG".% ~ a m eof parts

Graphical symbol Parts number

X546118040ZZ 'Yf9 ASSY. 18X% Banjo assy 18xY2

1 X545204000zz ' Y f * l b b Y2 Banio plug Y
2
2 Z5650021OOZZ 7IblPv+Y 21 Gasket 21
3 Z545118040ZZ Y f 7 18X% Banjo 18x Y
2
- ~

X546120040ZZ 'YY9 ASSY. 20XY2 Banjo assy. 20X%

1 X545204000zz ' Y f f i l b b Yz Banio plug Y2
2 Z5650021OOZZ 7 l b / W * > 21 Gasket 21
3 Z545120040ZZ ' Y f 9 20X% Bank 20x %

1 X545210000ZZ Y Y * l b b 1 Banio plug 1

2 X665034OOOZZ 7JbIW * Y 34 Gasket 34
3 z545120100zz ' Y f 9 20x 1 Banio 20x 1

X546122040ZZ 'Y/Y7 ASSY. 22XM Banio assy. 22xM

1 X545204000zz 'YY*lbb Y2 Banio plug Yz
2 Z5650021OOZZ 7 l b J P ~ ~ * > 21 Gasket 21
3 z54512204ozz Y Y 9 22XH Banjo 22xH

Banio assy 28x ;

Banio plug 1
Gasket 34
Banio 28x 1

Special banjo plug M 18x31

Gasket 18
Banio 15xM18

Banio plug 20
Gasket 24
Banjo 20

Special banjo plug M18x36

Gasket 18
Banio 20xMl8
~ZEEBa"aCnM3EZ%dj'&UE8aOa%%,EBaOaBF
GRAPHICAL SYMBOL, PART NAME
AND PART NUMBER OF PIPING PART 5DK-20

wsze j4 x %BES% Name of parts

Size 0. 88 .". B 8
Graphical symbol Parts number

X54621080822 f i i i * ' Y + 9 ASSY. Yax8x8 Double banio assy. M x 8 x 8

I X54540100022 ?IY*'Y+ifr'lb b Ys Double banjo plug M
! 256501000022 71biYY*> 10 .' Gasket 10
4 2545108010ZZ ' Y f 9 8xM Banjo 8 X M

X54622080822 f i i i * ' Y Y 9 ASSY. %x8x8 Double banio assy. M x 8 m

I X54540200022 hii*'Y+ifr'lb I- !4' Double banjo plug Yi
1 256500130022 7 1 l / I Y ~ * > 13 Gasket 13
,4 254510802022 'Y+9 8XX Banjo 8 x X

X54622081022 2 i i * ' Y Y 9 ASSY. WX8XlO Double banjo ashy. H x 8 x l 0

1 X5454020002Z fiY+'Y+ifr'lb k X Double banib plug M
! 256500 130022 7 l b I Y ~ 3 Y 13 Gasket 13
3 254510802022 'Y+9 8XYi Banjo 8 X M
1 25451 1002022 'Yr7 lox% Banjo l o x %

X5462210102Z h Y * ' Y + 7 ASSY. KXIOX10 Double banjo assy. Kx10X10

1 X54540200022 hiiit'Y+-'if;ll/ I- M Double banio plug Yi
! Z5650013002Z 7 l b l P ~ 3 > 13 Gasket 13
,4 25451 10020ZZ 'Y+7 1OXK Banjo l O x M

X54624 182222 h t t * ' Y Y 9 ASSY. '/2XBX22 Double banio assy. M x B x 2 2

1 X54540406522 h Y * ' Y f if(ll/t- %X65 Double banio plug %x65
2 256500210022 7 1 b 1 Y ~ 3 > 21 Gasket 2 1
3 25451 1804022 Y + 9 1 8 X H Banjo 1 8 x M
4 254512204022 ' Y f 7 2 2 X X Banjo 22 X %

X54624202222 h Y * ' Y f 7 ASSY. 'AX20X2: Double banjo assy. MX 20 x 2 2

1 X54540406522 hY*'YYifr'lb k YzX65 Double banjo plug % x 6 5
2 256500210022 7 I b I Y v + Y 21 Gasket 2 1
3 254512004022 'Y+9 20X% Banjo 2OXX
4 2545122040Z2 'Y+9 22X% Banjo 2 2 X %
 fr n
nzE~BEaHsFzedj'ckU.'DBnfl%n,~BE~~
GRAPHICAL SYMBOL, PART NAME
5DK-20 AND PART NUMBER OF PIPING PART

msze
Graphical symbol
9 4 x Yo.! 31.4
-Size Parts number
1 g A?. . Name of parts

JIS gasket (1) 18

Bolt M10X 1 5 x 3 2
055 Bolt M10x 1.5X20
Nut M10X 1.5

Gasket (1) 20x58

Bolt M10X 1.5X32
Bolt MlOX 1.5X20
Nut M10X 1.5

Gasket (1) 35x60

Bolt M10x 1 5 x 4 0
Bolt M10X 1 5 x 2 5
Nut M10X 1.5

Gasket ( 1 ) 35x62
Bolt M10X 1.5X35
Bolt M10x 1.5X22
Nut M i O x l . 5

Gasket (1) 34x70

Bolt M12X1.75X45
Bolt M12x1.75X28
Nut M12X1.75

Gasket ( 1 ) 50x80
Bolt M12X 1.75X45
Bolt M12X1.75X28
Nut M12X 1.75

Gasket (1) 60x92

Bolt M12X1.75X45
Bolt M12X 1.75X28
Nut M12X1.75

Gasket (1) 30x60

Bolt M l 0 x 1.5X35
Bolt M10X 1.5X22
Nut M10X 1.5

Gasket (1) 2 8 x 5 8
Bolt M10x 1.5X32
Bolt M10X 1.5X20
Nut M10X 1.5

Gasket (1) 42x75

Bolt M10X 1.5X40
Bolt MIOX 1.5X25
Nut M10X 1.5
mi?, *E
A* 0
m B
* r=r
n n ~ ~ ~ &rr'mBnn%@,mBanSE
S ! ~ 8
* 0

GRAPHICAL SYMBOL, PART NAME

AND PART NUMBER OF PIPING PART 5DK-20

w s z e VI'X 8!3Ese E B G a n Name of parts

Graphical symbol Size Parts number

Sasket (2) 40x54

Bolt M12X1.75X45
Bolt M12X1.75X28
Nut M12X1.75

Gasket (2) 45x60

Bolt M12X l.75X4O
Bolt M12x l.75x28
Nut M12X 1.75

Gasket (2) 60x65

Bolt M12X 1.75X45
Bolt M 12x 1 . 7 5 ~ 2 8
Nut M12x1.75

Gasket (2) 75x85

Bolt M12x 1.75X55
Bolt M12x 1 . 7 5 ~ 3 5
Nut M12X1.75

Gasket (2) 90x96

Bolt M12X1.75X55
Bolt M12X 1.75X35
Nut M12X 1.75

JIS IVY+> (2) 80 JIS Gasket (2) 80

I M12X1.75X55 Bolt M12X 1.75X55
Zlbb M12x1.75X35 Bolt M12X 1.75X35
f b M12X1.75 Nut M12X 1.75

JIS Gasket (2) 60

Bolt M12X l.75X55
Bolt M12X1.75X35
Nut M12X1.75

JIS ICY*> (2) 60 JIS Gasket (2) 60

I b M12X l.75X4O Bolt M12x 1.75X40
I M12X1.75X28 Bolt M12X 1.75X28
t~b M12X1.75 Nut M12X 1.75

JIS Gasket (2) 80

Bolt M12x 1 . 7 5 ~ 4 0
Bolt M12X l.?5X28
Nut M12x 1.75
 -

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GRAPHICAL SYMBOL, PART NAME
5DK-20 AND PART NUMBER OF PIPING PART

Mit.:?z
G r a ~ h i c asvmbol
l
94x
Size
BEESF
Parts number
I BEE%% Name of parts

Z501302200AZ JIS I P s + > (3) 22 JIS Gasket (3) 22

X200010032ZZ * l b b MlOX15X32 Bolt M10x 1 5 x 3 2
X200010020ZZ *Jbb MlOX15X20 Bolt M10X 1.5X20
X220010000ZZ t- M10X1.5
t-:, Nut M10X15

Z501302800AZ JIS IT,:, 3> (3) 28 JIS Gasket (3) 28

X200010032ZZ f i l b b MlOX1.5X32 Bolt M10X 1 5 x 3 2
X200010020ZZ *]kt- MlOX1.5X20 Bolt M10X 1 5 x 2 0
X220010000ZZ f ~ t M10X1.5
- Nut M10X 1.5

Z501303500AZ JIS JPv+> (3) 35 JIS Gasket (3) 35

X200010032ZZ ilfJl,b M10X 1.5X32 Bolt M10X 1 5 x 3 2
X200010020ZZ i%Jbb MlOX1.5X20 Bolt M10X 1.5X20
X220010000ZZ f ,: I- M10X 1.5 Nut M10X 1.5

JlS Gasket (3) 43

Bolt M12X1.75X38
Bolt M12X1.75X25
Nut M12X1.75

JIS Gasket (3) 50

Bolt M12X1.75X38
Bolt M12X1.75X25
Nut M12X1.75

Z501306000AZ JIS lPs+> (3) 60 JIS Gasket (3) 60

X200012042ZZ filb t- M12X 1.75X42 Bolt M12X1.75X42
X200012028ZZ fill, l- M12X 1.75X28 Bolt M12X1.75X28
X220012000ZZ f v b M12X 1.75 Nut M12X1.75

JIS Gasket (3) 80

Bolt M12X1.75X42
Bolt M12X1.75X28
Nut M12X1.75

JIS Gasket (3) 90

Bolt M16X2.0X45
Bolt M16X2.0X30
Nut M16X2.0

JIS Gasket (3) 115

Bolt M16X20X50
Bolt M16X2.0X35
Nut M16x2.0
iRz* L Y*~0
EclBim~H3S!Edj'& BangKL~BfiBE
GRAPHICAL SYMBOL, PART NAME
AND PART NUMBER OF PIPING PART

M X Z Y f-fX Name of parts

Graphical symbol Size

10K Gasket 35
Bolt M12X2.0X42
Bolt M12X2.0X32
Nut M16X2.0

IOK JPv+> 25 10K Gasket 25

I M12X1.75X42 Bolt M12X 1.75X42
I b M12x 175x28 Bolt M12X 175x28
f~ b M12X1.75 Nut M12x1.75
 c/6&
i

ITEM GRAPHICAL SYMBOL, PART NAME

1.11 5DK-20 AND PART NUMBER OF PIPING PART

3 z e 74x Name of parts

Graphical symbol Size

Flange (2) OX 44
Gasket (2) 30x44
Bolt MlOX1.5X40

Nut M10x 1.5

Flange (2) 0 x 5 4
Gasket (2) 30x54
Bolt M12X 1.75X40

Nut M12X1.75

Flange (1) 0 x 6 5
Gasket (1) 6 0 x 6 5
Bolt M12X175X45

Nut M12X1.75

Flange (2) O X 150

Gasket (2) 130X 150

Bolt M22X2.5X45

Flange (1) 0 x 5 8
Gasket (1) 2 0 x 5 8
Bolt M10X 1.5X30

Nut M10X1.5

Flange (1) 0 x 6 0
Gasket (1) 3 0 x 6 0

Bolt M l O x 1.5X22
B Z&* *0
k mBnaaH3EZZbj'&UmBan%%,EBES%
0

GRAPHICAL SYMBOL, PART NAME ITEM

AND PART NUMBER OF PIPING PART 5DK-20 1.I2
-
IWX1:?29 94 x 3ES9 Name of parts
Graphical symbol Size Parts number

941%1=8> ( 1 ) X58810601OZZ Biting union (1) 6 X X

Biting union (1) X588206010ZZ (2) 6x%
X588306OlOZZ (3) 6 X X
X5884O6OlOZZ (4) 6 x 5
X588506010ZZ 4 (5) 6 X M

9-f152=3>(2)
(2)
Biting union

X58810802OZZ
X58820802OZZ
943s1=8> (3)
Biting union (3) X588308020ZZ
X58840802OZZ
X58850802OZZ

X588llOOlOZZ Biting union (1) lox&

X588Z1001OZZ 4 (2) 10x5
X588310010ZZ 4 (3) I O X Y ~
X58841001OZZ 'I (4) l0XYe
X588510010ZZ 'r
(5) 10XX
94353=3> (4)
(4)
Biting union X5881 10020ZZ Biting union (1) lox%
X588210020ZZ 'I (2) lOXM
X58831002OZZ (3) 10XN
X588410020ZZ (4) 10xx
X58851002OZZ (5) lOXM

3iting union (1) lox%

2 lox%
(3) lox%
9-f151=*> (5)
Biting union (5) 'I (4) 10x94
4 (5) lox%

3iting union (1) 10x8

(2) lox%
'r (3) 10XK
y
(4) lox%
4 (5) IOXY,

5DK-20 Z 99-3
 fi 0
B?E~BE"aHZ~~E8&O~bnnB%,~BE%~
ITEM GRAPHICAL SYMBOL, PART NAME
1.13 5DK-20 AND PART NUMBER OF PIPING PART

Bre%?e 3 .". s e Name of parts

Graphical symbol Parts number

3iting union (1) 1 1X %

94351=z> ( 1 )
Biting union ( 1 ) + (2)llX%
n (3)11X%
4 (4)11X3
4 (5)11X3

3iting union (1) 1 2 X X

n (2) 1 2 X X
n (3) 1 2 X X
r (4) l 2 x X
34751=8> (2) 4 (5) 12x14
Biting union (2)
Biting union ( 1) 12X 3
4 (2) 12X%
/I (3) 12x34
n (4) 12x%
4 (5) 1 2 x 3

Biting union (1) 14X%

4 (2) l 4 x X
4 (3) l 4 x %
4 (4) 1 4 X X
n (5) 14X1A

Biting union (11 1 4 x 3

r (2) 14X%
4 (3) 14X%
+ (4) 14x3
4 (5) 14X%

Biting union (1) 1 4 X H

n (2) 14X%
4 (3) 14X%
n (4) 1 4 X g
r (5) l 4 X %

Biting union (1) 1 5 x 3

a (2) l 5 X %
4 (3) 15X%
94J51=$> (5) r (4) 15X%
Biting union (5)
r (51 15X%

Biting union ( 1) 15X K

r (2) 15X%
0 (3) 15X%
a (4) 15X%
4 (5)15X!4
I AND PART NUMBER OF PIPING PART I ~ D K - 2 01 1.141

M ; C Z . v-rx BBE8.M; Name of parts

Graphical symbol Size Parts number

94151=z> (1) Biting union (1) 16xX

Biting union (1) 4 (2) 16X!4
(3) 16X%
4 (4) 16XH
4 (5) 16X%

Biting union (1) 18X3%

4 (2) l a x %
4 (3) 18x56
4 (4) 1 8 ~ %
9<1xl=z>(2)
Biting union (2) 'I (5) 18X%

Biing union (1) 18xH

4 (2) 18XH
4 (3) 1 8 x 8
4 (4) 18X%
~r (5) 1 8 x 8

Biting union (1) 20X3A

'I (2) 20xM
94151=z> (3)
Biting union (3) b (3) 20X%
b (4) 20x%
+ (5) 2 0 x 3 ~

Biting union (1 22x%

4 (2) 22XH
4 (3)2 2 x x
4 (4) 2 2 x g
'I (5) 2 2 x 8
94151=z> (4)
Biting union (4) Biting union (1) 22xM
(2) 22X%
Ir (3) 22x%
'I (4) 22x%
+ (5) 22xM

Biting union (1) 25xM

'I (2) 25XM
(3) 25xM
943s2=z> (5)
Biting unlon (5) 'I (4) 25X%
~r (5) 25x%

Biting union (1) 28x%

'I (2) 28X%
'I (3) 28X%
'I (4) 2 8 ~ %
'I (5) 28X%
 $'L?
* %0, ~ B n n B E
mi2 isp B a a ~ ~ 3 Z Z ~ d j ' & Ua. "0~ B a a %
ITEM GRAPHICAL SYMBOL, PART NAME
1.15 5DK-20 AND PART NUMBER OF PIPING PART

IWssze YI'X * m
an se
UU
Name of parts
Graphical symbol Size Parts number

Z5881281OOZZ Biting union (1) 2 8 x 1

94152=*> (1)
Biting union (1) X588228 1OOZZ + (2) 28X 1
X588328 1OOZZ (3) 28X 1
X58842810022 a (4) 28X 1
X588528iOOZZ 4 (5) 2 8 x 1

Biting union (1) 30X 1

4 (2) 30X 1
4 (3) 3 0 x 1
4 (4) 30X 1
+ (5) 3 0 x 1
94151=*> ( 2 )
Biting union (2) Biting union (1) 34X 1
a (2) 3 4 x 1
n (3) 34X 1
4 (4) 34X 1
+ (5) 34X 1

Biting union (1) 34X 1%

(2) 3 4 X l %
4 (3)34X1%
4 (4) 34X1%
9 (5) 3 4 x 1 %
943z1=7t> (3)
Biting union (3)
Biting union ( i ) 35X 1%
+ (2)35XI!A
4 (3)35Xl!A
4 (4) 3 5 X l X
4 (5)35X1!4

Biting union (1) 38X 1%

4 (2)38X1%
4 (3138~1%
4 (4) % X I %
9475IL=*> (4)
Biting union (4) (5)38X1!4

Biting union (1) 40X 1%

(2) 4OXl%
a (3)40X1!4
o (4) 4 0 X l M
(5)40X1%

Biting union ( 1) 42X 1%

4 (2)42Xl%
+ (3)42X1%
94Zls1=a> (5)
Biting union (5) + (4)42XlM
.;. (5)42~1%

Biting union (1) 42X 1%

+ (2) 42X1%
4 (3)42X1%
4 (4) 4 2 ~ 1 %
+ (5) 4 2 ~ 1 %
 <6
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~ ~ B
* 0 *
a n ~ H S ~ Z ~ d j ' & U ~ B n n % ~ , ~ B a n ~ ~
GRAPHICAL SYMBOL, PART NAME
AND PART NUMBER OF PIPING PART 5DK-20 1.16

- - ~

M S Z F tf<x BUEf F Name of parts

GraDhicai svmboi Size Parts number

B~tingunion (9) 6X!4

Biting union (9) 8xYe

91'751=*> (9)
Biting union (9)
Biting union (9) 8XX

Biting union (9) l o x %

Biting union (9) lox%

Biting union (9) 12XX

Biting union (9) 1 2 ~ %

Biting union (9) 15x%

Biting union (9) 15Xx

Biting union (9) 8x!4

Control air
 me
EE&sdZE
STARTING AIR PIPING 5DK-20
L

se
Number
3ESE
Parts number 3sgfi Name of Parts .aQuantity
Ref. 4-7.1 FUEL SHUTDOWN DEVICE. G1 TYPE
Ref. 4-1.2 AIR MOTOR
E21555 MAGNETIC VALVE FITT. & PIPING
Ref. 4-1.2 REGULATOR& RELAYVALVE
S108509010 STARTING OPERATION VALVE
E2 1 2 8 5 SPLIT FLANGE

E208551000 SUPPORT. STRAINER IN & OUTLET

E208551010 S.A. PIPE. RR100-F30 lNCET
E208551020 S.A. PIPE. A/M INLET
E208551060 IN. &OUTLET PIPE. STRAINER
E208551090 SUPPORT. S.A. MAIN PIPE30

E208551160 BOLT
E208552090 JOINT
E208552200 S.A. PIPE. RR100 OUTLET-50
E208552210 S.A. PIPE. OP. VALVE INLET-5D
E208552140 S.A. PIPE. OP. VALVE INLET-2

E208552150 STRAINER
€208552220 S.A. PIPE. OP. VALVE OUTLET-50
E208552230 S.A. PIPE. RR 1 0 0 INLET-50

E215550010 MAGNETIC VALVE BOARD

E215550020 MAGNETIC VALVE BOX
E215550210 S.A. PIPE. F.O. CONTROL PISTON 2
E215550220 S.A. PIPE, F.O. CONTROL PISTON 3
E215550420 S.A. PIPE. F.O. SHUTDOWN DEVICE 3

E215550440 S.A. PIPE. F.O. SHUTDOWN DEVICE 5

€215550530 S.A. PIPE. F.O. CUT-4
E215550550 S.A. PIPE. F.O. CUT 6
E215550620 S.A. PIPE. F.O. CUT 1 3
 /

%*%!ii!E
FUEL OIL PIPING 5DK-20

s5 g0.".se
Number Parts number Name of Parts BiB
Quant~ty

A Ref. 3 - 2 1 . 2 /XJbfiJbg NOZZLE HOLDER

Ref. 3 - 2 0 . 2 F.O. 7>9?it;>l F.O. INJECTION PUMP
C Ref. 4-2.5 F.O. 9 s 37'Y<> F.O. RELIEF VALVE
D Ref. 4-2.3 F.O. O+ F.O. FILTER
E Ref. 4-2.1 F.O. i K > l F.O. PUMP
F 2 4 J b F s 37'?4> OIL RELIEF VALVE

A7 C034000220 9-Jb7Y9V SEAL WASHER

A1 2 YO1 3 1 6 0 2 0 4 +V9997~94)/ CHECK GROVE VALVE
A1 4 E208650140 FO h)/.0*4 'i9F F O . PIPE. FILTER INLET
A1 8 E208650180 FO h > T Y I - 1 SUPPORT-1. F.O. PIPE
A1 9 E208650190 h)/;.fVI PIPE SUPPORTER

A20 E208650200 h)/;fYI PIPE SUPPORTER 8

A23 E2066.50230 FO %I)/. O t - ? 9 F - C - 2 F O . PIPE. FILTER OUTLET-C-2 1
A24 E208650240 FO h>,~ I ~ I Y ~ I J ~ F - C F.O. PIPE. MAIN PIPE INLET-C 1
A27 E208650270 FO 4 ' J 9 F 9 l % I > - 5 O K F.O. INLET MAIN PIPE-5OK 1
A28 E208650280 FO 1 9 A > ( 4 I J T F - 1I F.O. BRANCH PIPE (INLET-]) 4

A29 E208650290 FO I 9 B > ( 4 'J 9 F ~ 2 1 F.O. BRANCH PIPE (INLET-21 1

A30 E208650300 3-Jb7'Y9? SEAL WASHER 2
A33 E208650330 FO Y T F 9 2 h Y - 5 0 K F.O. OUTLET MAIN PIPE-5OK 1
A34 €208650340 FO I 9 h Y ( Y 9 F ) F.O. BRANCH PIPE (OUTLET) 5
A39 E208650390 FO NH ? 1 - 9 % 4 l W l h > - 5 0 F.O. N H LEAK OIL MAIN PIPE-SO 1

A40 E208650400 FO I 9 h Y ~ N H (031) F.O. BRANCH PIPE-NH (LEAK OIL) 5

A41 E 2 0 8 6 5 0 4 10 FO a)/. NH IJ -991h>TTF F.O. PIPE. NH LEAK MAIN PIPE OUTLET 1
A43 E208650430 FO 4 'J 9 F h Y 3 7 T ' Y b-C BRACKET-C. F.0, INLET PIPE 1
A45 E208650450 7b F%.FO 0+?9F%IY-C SUPPORTER. F.O. FILTER OUTLET-C 1
A46 E208650460 FO I 9 % I > - F S ( 0 3 1 - 1 ) F.O. BRANCH PIPE-FS (LEAK OIL-1I 4

A47 E208650470 FO I 9 h ) / - F S ( 0 3 2 - 2 ) F.O. BRANCH PIPE-FS (LEAK OIL-2) 1

A51 E208650510 1J-9%4>iT-f7 (F0IP)-50 F.O. LEAK MAIN PIPE (F.0.I.P)-5D 1
A52 E208650520 FO I 9 B > - F O I P ( 0 3 1 ) F.O. BRANCH PIPE-F.0.I.P (LEAK OIL) 5
A55 E208650550 FO h>,i k > l - P J T F - C F.O. PIPE. F.O. PUMP INLET-C 1
A56 E208650560 FO h>,f i > 7 ? 9 ? - C F O . PIPE. F.O. PUMP OUTLET-C 1

A57 E208650570 FO hI/.F 3 3 P ' Y f i 7 7 9 F F.O. PIPE. RELIEF VALVE

A59 E208650590 1 0 ' Y 9 FO-3 BLOCK. F.O.3
A60 E208650600 30Y9 FO-4 BLOCK. F.0.-4
A61 E2086506l0 70'99 FO-1 BLOCK. F O - 1
A62 E228650860 b9917723 SPECIAL FLANGE

A64 A245012010 *131iz~91 (11 BLOCK. L O . PIPE 1

A66 E208650660 FO h 7 . 0 + ? 9 F C . l F.O. PIPE. FILTER OUTLET-C. I 1
A1 07 E268180020 ?7+2/ib-7 ACCUMULATOR I
A1 08 E268180060 0 1JY9 0 RING I
~1 1 5 ~208651150 7+>9. FO 7 4 > - 5 0 ~ - ~ LAGGING. F.O. LINE6OK.C I

O-RING
O-RING
 'RHBZE
FUEL OIL PIPING
S;~~'~JLLAI~X~YF @......(q @......%
LEVEL SWITCH. LEAK OIL TANK With Without
SE BE.".SE BB.".8% Name of Parts mQuantity
Number Parts number 010
BLOCK. L.O. PlPE
F.O. LEAK RETURN MAIN PIPE (50)
F.O. LEAK RETARN PlPE
F.O. PIPE. FRAME (FRONT)
FO. PIPE. FILTER LEAK

F.O. PIPE. FILTER BROW OFF

F.0, INJECTION PlPE LEAK (ED) 1
F.0, INJECTION PlPE LEAK (6D) 2
F.O. INJECTION PlPE LEAK (5D) 1
F.O. PIPE, NOZZLE LEAK (50)

F.O. PIPE. PLUNGER LEAK (50)

F.O. PIPE. FRAME (REAR) 5 D

PlPE SUPPORTER
 Detail "V"
for GOVERNOR UGlO

Detail "V"
for GOVERNOR RHD6

A 4 8 (lor L.O. COOLER 8mmi)

A 4 6 (for L.O. COOLER 12mm2)
 2 '

;H;B;mBL!E (ZC%B$$)
LUBRICATING OIL PIPING (FRONT T/C) 5DK-20

Ref. 4-3.1 L.O. 327 L.O. PUMP

Ref. 4-3.3 L.O. 9-5 L.O. COOLER
Ref. 4-3.6 T / C L.O. U+ T I C L.O. FILTER
Ref. 4 - 3 . 4 L.O. O+ L.O. FILTER
Ref. 3-4 PI' F J b C f l IDLE GEAR
Ref. 3 - 5 %4Jb3>3'4 FJMV IDLE GEAR. OIL PUMP
ClI'>9it;>7 3/4FC WING PUMP 3/4FC
Ref. 3-1.1 L.O. J X J L L.O. NOZZLE
Ref. 3-1.3 L.O. J X J L (2) L.O. NOZZLE (2)
Ref. 4-4.1 C.W. 377 C.W. PUMP
%>3334> THERMOSTAT VALVE
Ref.4-1.1 *47>?49 F 9 Y 9 F TACHOMETER DRIVING DEVICE
SX b3+1\4A> MIST PlPE
Ref. Sparate manual 9--z3?-3t TURBOCHARGER

A2 E208750020 'YTiKJb b BANJO PLUG

A3 €208750030 LO 9 - 5 t l ' Y 3 1 BLOCK. L O . COOLER
A5 E208750050 YO'Y9 BLOCK
A1 1 E208750110 LO * l l 9 2 t 2 " 3 1 ( 3 ) L.O. BLOCK (3)
A20 E208750200 a > / ( > F-3, b 3 3 4 Y 7 ? h > PIPE CLIP-3. FRAME INLET PIPE

A21 E208750210 B > J U F-4. h334 U7?71> PIPE CLIP-4. FRAME INLET PIPE
A26 E208750260 7739 ( b 9 ) SPECIAL FLANGE
A27 E208750270 LO 3 l t 1 3 / % 9 5 7 5 > W 3 0 BRANK FLANGE. L . 0 MAIN PIPE-80
A28 E208750280 LO 3 1 h ' J % 9 7 7 3 > 3 BRANK FLANGE. L O . MAIN PIPE
A29 E208750290 LO 3 1 7 1 3 / % 9 5 7 5 > 3 t j X 9 ' Y b GASKET. L.O. MAlN PlPE FLANGE

A30 E208750300 LO F 1 3 9 4 7 0 Y 9 L.O. CONNECTING BLOCK

A33 E228700230 /<'3*>( b 9 ) SPECIAL PACKING
A37 E268700111 b 9 3 X Wb SPECIAL BOLT
A39 E208750390 LO h>.LOP 7 7 F - 6 0 L O PIPE. PUMP OUTLET-60
A46 E208750460 LO a>. J < 4 l < X - (2) L.O. PIPE. BY-PASS-(2)

A48 E208750480 LO b>,JC41TX- (1) L O . PIPE. BY-PASS-(1)

A50 E208750500 LO A>. 0 + 4 ' J 7 F - 6 0 L.O. PIPE. FILTER INLET-60
A5 1 E208750510 LO a>. 0 * 7 7 S . 6 0 L O . PIPE. FILTER OUTLET-60
A56 E208750560 LO by. 9-577F (2) 5 0 L.O. PIPE. COOLER OUTLET (2) 50
A57 E208750570 LO b>.7 L / - L 4 ' J T S (50) FT L.O. PIPE. FRAME INLET (5D) FT

A60 E208750600 LO A>. 9-5777 (1) 50 L.O. PIPE. COOLER OUTLET ( I ) 5 0

A61 E208750610 LO a>,i C 0 7 4 FJbqt7 L.O. PIPE. PUMP IDLE GEAR
A62 E208750620 LO a>. f i > 7 Y t 7 L O . PIPE. PUMP GEAR
A63 E208750630 LO by, F l 9 9 4 Y O ' Y 9 L . 0 PIPE. CONNECTING BLOCK
A65 E208750650 LO a>. 7 4 F I b Y t 7 9 9 L O . PIPE, IDLE GEAR SHAFT
 -

xFli#;aBzE (imBG)
ITEM
4.1 5DK-20 LUBRICATING OIL PIPING (FRONT TIC)
B&a%m%Bs @......8m' @ ......12",2
CAPACITY of L.O. COOLER
SG BBSW 3S8% Name of Parts =Quantity
Number Parts number 0 10
I
LO. PIPE, TIMING GEAR (1) 1
L.O. PIPE. TIMING GEAR (2) 1
L.O. PIPE. CAM SHAFT BEARING 1
L.O. PIPE. CYL. HEAD INLET 5
L.O. PIPE. COOLER INLET-FT 1

L.O. PIPE. THERMO. VALVE OUTLET FT 1

NOZZLE. OILLING GEAR 2
L.O. PIPE. C.W. PUMP DRIVING GEAR 1
LO. PIPE. L.O. PUMP DRIVING GEAR 1

BANJO PLUG 1
L.O. PIPE, C.W. PUMP 1
L.O. PIPE. GOVERNOR
L.O. PIPE. GOVERNOR (UG8) 1
L.O. PIPE. GOVERNOR (UG8)-2 1

L.O. PIPE. FILTER INLET (NR15)

SPECIAL GASKET
FLANGE. L.O. INLET
BANJO
L.O. PIPE. T/C INLET RH 1 6 3 - 1

L.O. PIPE. T/C OUTLET RH163-1

L.O. PIPE. TIC OUTLET R H I 6 3 - 2
L.O. PlPE SUPPORT. T/C OUTLET
L.O. PIPE. T/C INLET (RH133)
L.O. PIPE, T/C OUTLET RH 133-1

LO a)/,TIC 7 9 F RH133-2 L.O. PIPE. T/C OUTLET R H I 33-2

LO a>. T/C +9F RH 133-3 L.O. PIPE. TIC OUTLET RH133-3
LO a?. T/C 4LJ7F R H I 33-1 L.O. PIPE, TIC INLET RH133-1
LO a>. TIC 4 LJ 9 F RH 12 3 - 2 L.O. PIPE. T/C INLET RH123-2
LO A>?J?JI,T/C +94 (1) L.O. PlPE SUPPORT. T/C OUTLET (1)

GAUGE PIPE. RH 133-FT1

GAUGE PIPE. RH 133-FT2
GAUGE PIPE. RH 163-FT 1
GAUGE PIPE. RH 163-FT2
LAGGING (1). T/C. L.O. PlPE

LAGGING (2). T/C, L.O. PlPE

LAGGING (3). T/C, L.O. PlPE
 $%B;&n2E
(ZK,B%3
LUBRICATING OIL PIPING (FRONT T/C) 5DK-20

nn
Be &&% Name of Parts a'lrt
Number Parts number Quantity

01 1 € 2 0 9 15 0 1 1 0 LO jI2. LOP Y 9 3 3 2 - 1 (6DG) L O PIPE. L.O.P. SUCTION-1 (60G) 1

014 E2091501 40 LO a>. LOP Y 9 9 3 3 / - 2 (6DG) L.O. PIPE. L.O.P. SUCTION-2 (60G) 1

El 1 A5841001 1 0 LO B Y . PR. P ? 9 ? L.O. PIPE. PRIMING PUMP OUTLET

El2 A5841001 2 0 LO PR. P41J7T-1-RT L.O. PIPE. PRIMING PUMP INLET-1-RT
El3 A 5 8 4 1 0 0 1 30 LO 217.PR. P 4 1J7F-2-RT L.O. PIPE. PRIMING PUMP INLET-2-RT
 I! (lor D.O. NOZZLE A 6 2 Ifor D.O. NOZZLE COOLING SYSTEM1

Detail "V"
for GOVERNOR UG I0

Detail "V"
for GOVERNOR RHD6
Mirl gar
 J

;B;B;aazE (f@~%B%)
ITEM
LUBRICATING OIL PIPING (REAR T/C) 5DK-20 4.2
&q:F*.AaEG&*
, I ! %
0......8",Z @...... 12",2
CAPACITY of L.O. COOLER
SF %U.'.SF Name of Parts XlrPQuantity
Number P a n s number 0 10
Ref. 4 - 3 . 1 L.O. it;>7 L.O. PUMP
Ref. 4-3.3 L.O. 7-5 L.O. COOLER
Ref. 4-36 T/C L.O. O+ T I C L.O. FILTER
Ref. 4-3.4 L.O. D j i L.O. FILTER
Ref. 3 - 4 7'4 FJb+? IDLE GEAR
Ref. 3-5 Z 4 J b X 2 7 7 4 PJb*? IDLE GEAR. OIL PUMP
9423iK27 3/4FC WING PUMP 314FC
Ref. 3-1.1 L.O. I X J b L.O. NOZZLE
Ref. 3-1.3 L O . J XJb (2) L.O. NOZZLE ( 2 )
Ref. 4-4.1 C.W. 827 C.W. PUMP
325F3342 THERMOSTAT VALVE
Ref. 4-1.1 h472949 F 9 Y 9 F TACHOMETER DRIVING DEVICE
S X b3+1[4?l> MIST PlPE
Ref. Sparate manual P-iti'Ft-3r TURBOCHARGER

A2 E208750020 'Y+ZlL b BANJO PLUG

A3 E208750030 LO 9 - 7 e ' Y g l BLOCK. L O . COOLER
A5 E208750050 TOY9 BLOCK
A1 l E208750110 LO + - l 9 1 i z Y 3 1 ( 3 ) L.O. BLOCK (3)
A26 E208750260 7539 ( b 9 ) SPECIAL FLANGE

A27 E208750270 LO 3 1 A > S 9 5 7 5 > 9 - 8 0 BRANK FLANGE. L O . MAIN PIPE-80 1

A28 E208750280 LO 3 1 A > S 9 5 7 7 > 3 BRANK FLANGE. L.O. MAIN PIPE 1
A29 E208750290 LO 3 l A 2 % 9 5 7 5 > 9 9 j X 9 ' Y b GASKET. L.O. MAIN PIPE FLANGE 1
A30 E208750300 LO 1 1 9 9 4 7 0 Y 9 L O . CONNECTING BLOCK 1
A33 E228700230 JW+> (b9) SPECIAL PACKING 1

A37 E26870011 1 b991iKIbb SPECIAL BOLT 4

A46 E208750460 LO A>. l < - f J U - (2) L O . PIPE. BY-PASS-(2)
A48 E208750480 LO a>. J < 4 1 < X - (1) L.O. PIPE. BY-PASS-(] 1
A61 E208750610 LO a>, ,X>774 Fib+? L O . PIPE. PUMP IDLE GEAR 1
A62 E208750620 LO B Y , fi>745? L.O. PIPE. PUMP GEAR 1

L O . PIPE. CONNECTING BLOCK

L O . PIPE. IDLE GEAR SHAFT
L.O. PIPE. TIMING GEAR (I)
L.O. PIPE. TlMlNG GEAR (2)
L.O. PIPE. CAM SHAFT BEARING

LO a>. 4 ' Y F
'I 'J9F
LO A>. Z>T39'i>77F - RT
h>?WI-1. LOP 7 7 1 - R T
LO A>, LOP 7 9 1 - 1 - R T
L O . PIPE. CYL. HEAD INLET
L.O. PIPE. THERMO. VALVE OUTLET-RT
PlPE SUPPOTER-1. L.O.P. OUT PIPE.RT
PIPE. L.O.P. OUTLET-] -RT

!%harks
% 1 .-..-,i@7klL$&/ZK,"B{t# F.W. Nozzle cooling system
X2......ABi*l:$5/XJb;%in(t4S D.O. Nozzle cooling system
 ;M;G:Qn?E
( ~ ~ ~ ~ ~
LUBRICATING OIL PIPING (REAR T/C)
/TI
I I
0......SrnZ
.B:*:,&yJ,~~# @..-...1 Zrn'
CAPACITY of L.O. COOLER
a%
Number
$B.".S%
Parts number
Name of Parts XPiQuantitV
010
I
LO hl/. 9-?-PIT?-RT L.O. PIPE. COOLER INLET-RT 1
LO B Y . O M IJ9F (RT) 1.0.PIPE. FILTER INLET (RT) 1
LO h Y . 7 b-A4 ?)9?-RT L O . PIPE. FRAME INLET-RT 1
LO h Y . ?3$?'Yr;YlJ-9-2RT L.O. PIPE. RELIEF V. RETURN-2-RT 1
NOZZLE. OILLING GEAR 2

L.O. PIPE. C.W. PUMP ORlVlNG GEAR

L.O. PIPE. L.O. PUMP DRIVING GEAR

82 E208750020 Y+%h t- BANJO PLUG 1

85 E208950050 LO hy.C.W. % Y l L.O. PIPE. C.W. PUMP 1
8 14 E208950140 LO h Y , f j l T f L.O. PIPE. GOVERNOR
8 15 E208950150 LO h Y . f j l W (UG8) L.O. PIPE. GOVERNOR (UG8) 1
B 16 E208950160 LO ?I>. fj!V (UG8)-2 L.O. PIPE. GOVERNOR (UG81-2 1

4=133+2~91(3) BLOCK. OIL JOINT (3)

?I>!<> F-2. T/C O W LIT? PlPE CLIP-2. T/C FILTER INLET
LO b3/75.9':, b-TC L.O. PlPE BRACKET-T/C
h>lW F-3,h 3 9 4 V 5 J F h Y PlPE CLIP-3. FRAME INLET PlPE
LO h Y . 04=4LIT?-1 (RT1 5 0 L.O. PIPE. FILTER INLET-1 (RT) 5 0

LO h)/.0 + 4 J T ? - 3 (RT) L.O. PIPE. FILTER INLET3 (FIT)

LO ?I>. O++"JTF (5RT) L.O. PIPE. FILTER INLET (5RT)
LO ?I)/. T/C .('JT?-1 L.O. PIPE. T/C INLET-]
t-991!T\Y*> SPECIAL GASKET
LO I ' L I T T 7 5 2 3 L.0, INLET FLANGE

BANJO
FLANGE BLOCK
L.O. PIPE. T/C INLET RH163-2
L.O. PIPE. T/C OUTLET RH163-3
L.O. PIPE. T/C OUTLET RH163-4

L.O. PIPE. T/C INLET-2 RH133

L.O. PIPE. T/C OUTLET RH 133-1
L.O. PIPE, T/C OUTLET RH 1 3 3 - 2
GAUGE PIPE, RH133-RT
GAUGE PIPE. RH163-RT

GAUGE PIPE. T/C-RT-50

GAUGE PIPE. T/C-RT
 :flyR:@@z=
,i, ,
'
€i(t&G%E%)
ITEM
LUBRICATING OIL PIPING (REAR T/C) 5DK-20 4.2
TURBOCHARGER
TYPE
m
Number Parts number ""' Name of Parts BBQuantity
01 0
LAGGING (1). T/C. L.O. PIPE 1 1
LAGGING (2). T/C. L.O. PIPE 1 1
LAGGING (3). T/C. L O PIPE 1

BB
Quantity

E209150110 LO b>. LOP V93El>.l (60G) L.O. PIPE. L.O.P. SUCTION-1 (6DG) 1
E209150140 LO by. LOP Y 9 3 3 Y - 2 (60G) L.O. PIPE. L.O.P. SUCTION-2 (6DG) 1

A584 1001 1 0 LO A>. PR. P 7 9 T L.O. PIPE. PRIMING PUMP OUTLET 1

A5841 0 0 12 0 LO b2. PR. P 4 1 J 9 T - 1 - R T L.O. PIPE. PRIMING PUMP INLET-1-RT 1
A5841 0 0 13 0 LO h>.PR. P41JTT-2-RT L . 0 PIPE. PRIMING PUMP INLET.2-RT 1
 0 4 4 x 2 2 (lor R H 1 4 3 )

Detail "V"
(for SEA WATER)

Detail "V"
(for FRESH WATER)

(AIR MANIFOLD) AIRBLOW OFF I DRAIN

(IIC SIDE COVER) I (AIR MANIFOLD)
DRAIN
(IIC AIR CASE)
;$%P7kPEE(EC%f%)
COOLING WATER PIPING (FRONT T/C) 5DK-20
FZ @...-..OH3 1. OH29. OH39HZ @....-OH83 1 . D H 8 3 1HZ
3LER TYPE
-
*.Um8%
n
Name of Parts Bf ntity
P a r t s number 0Qua
1 -0
Ref. 4-4.1 C.W. i 3 7 C.W. PUMP 1
Ref. Separate manual 9-iKfv-3? TURBOCHARGER 1
Ref. 3 - 2 9 <>9-9-7 INTER COOLER 1
Ref. 4-3.3 L.O. 9-5 L.O. COOLER 1

BUTTERFLY VALVE 1
C.W. PIPE. I/C OUTLET-FT 1
C.W. PIPE. L.O. COOLER 0UTLET.FT 1
C.W. PlPE 5 . L O . COOLER OUTLET-FT 1
SUPPORT. C.W. PlPE L O / C OUTLET-FT 1

C.W. PIPE. C.W. PUMP INLET 1

C.W. PIPE. FRAME INLET-FT 1
C.W. PIPE. MAlN PIPE DRAIN 1
C.W. OUTLET MAlN PIPE. 5 0 K 1
BLOCK-2. C.W. PlPE 1

FLANGE0 GLOBE VALVE 1

FLANGEDGLOBEVALVE 1
SPECIAL FLANGE 1
SUPPORT. C.W. PUMP INLET PiPE 1
SUPPORT. C W FRAME INLET PIPE-Fl 1

SUPPORT. C.W. DRAIN PIPE-FT 1

SUPPORT I.OUTLET PIPE-5DFT
SUPPORT 2. OUTLET PIPE-5DFT
SUPPORT 3. OUTLET PIPE-SOFT 1
SUPPORT. C.W. OUTLET PIPE-50 1

SUPPORT-1. C W OUTLET PlPE 1

SUPPORT4. OUTLET PIPE-5DFT 1
SUPPORT5. OUTLET PIPE-SOFT 1

CW a>. T/C 41J7?+3H163FTl C W PIPE. T/C INLET-RHl63FT1

CW ?I>. T/C 4 1 J i F - R H 1 6 3 F T 2 C.W. PIPE. T/C INLET-RH163FT2
CW B Y . T/C 7 7 T . R H 1 4 3 - 1 C.W. PIPE. T/C OUTLET-RH143-1

0......$@*
@..,,..if$,K
SEA WATER FRESH WATER
W&3uantity

ORIFICE
ORIFICE
ITEM

5.1 5DK-20 COOLING WATER PIPING (FRONT T/C)

SF
Number
-
*&&%
P a r t s number 8BEgm Name of P a r t s BB
Quantity

Dl X €21895 CW * > - I . IVC 7 4 I J i F CW. PIPE-'. I/C INLET A N 0 OUTLET 1

06 X E21895 CW 7l2-2. i/C 7 4 IJ 9 F C.W. P I P E 2 I/C INLET A N 0 OUTLET 1
Dl6 E218950160 t t i f ~ i - LONG NUT 4

E l0 E206150100 CW a>. P.,Y F79F (RH3) C.W. PIPE. CYLINDER HEAD OUTLET (RH3) 1

%Ell3.",ld~~E$l~d~WiXB.
Parts (Signal X ) depend on specification
 AIR BLOW OFF
$60 1I5A
7 !T

- T
Detail "V"

g
(for SEA WATER)

DI

- T
Detail "V"
(for FRESH WATER)
 ;?ia7NBzE (GMfE%)
COOLING WATER PIPING (REAR T/C) 5DK-20

S%
Number
gb.".Z&e
Parts number g".".ga Name of Parts
at
Quantity

A Ref. 4-4.1 C.W. i K 2 7 C.W. PUMP

B Ref. Separate manual 9-%??-ijr TURBOCHARGER
C Ref. 3-29 429-9-5 INTER COOLER
0 Ref. 4-33 L.O. 9-5. L.O. COOLER

BUTTERFLY VALVE
C.W. PIPE. I/C OUTLET-RT
C.W. PIPE. L.O. COOLER INLET-RT
C.W. PIPE. L O . COOLER OUTLET-RT
SUPPORT. C.W. PlPE L.O./C INLET-RT

C.W. PIPE. C.W. PUMP INLET

C.W. PIPE. FRAME INLET-RT
C.W. OUTLET MAlN PIPE. 5DK
8LOCK-2. C.W. PlPE
FLANGED GLOBE VALVE

SUPPORT. C.W. PUMP INLET PlPE

SUPPORT. C.W. OUTLET PIPE-5D
SUPPORT 1. OUTLET PIPE-5DRT
SUPPORT 2. OUTLET PIPE-5DRT
SUPPORT 3. OUTLET PIPE-5DRT

a+amse 0-----RHI
33 0 . - - . . - ~ ~ 1 4 3
TURBOCHARGER TYPE
=Quantity

FLANGED GLOBE VALVE

SUPPORT. MAlN PlPE DRAIN OUTLET-RT
CW ?I>. FLY-RT C.W. PIPE. MAIN PIPE DRAIN-RT 1
CW a>.T/C 4 LJ 7 F - R H 1 6 3 - 2 CW. PIPE. T/C INLET-RH163-2 1
CW a>. T/C 4 1
J 7 F - R H 1 63.3 C.W. PIPE. T/C INLET-RH163-3 1

CW A>. T/C 7 7 F - R H 1 4 3 - 2 C.W. PIPE. T/C OUTLET-RH143-2 I

0......;@,k @. .....;&K
SEA WATER FRESH WATER

ORIFICE
ORIFICE
 I COOLING WATER PIPING (REAR T/C)
SY
Number
SO.".S9
P a r t s number
-
=~ 1 1 n ~ 8 . M ; Name of P a r t s
am
Quantity

Dl X €21895 CW ?I>-1. I/C T4lJ7T C.W. PIPE-1. I/C INLET A N 0 OUTLET 1

D6 X €21895 CW ?I‘/-2. I/C 7 4 ?I9T C.W. PIPE-2. I/C INLET A N 0 OUTLET 1
Dl6 E218950160 ftjf\~b LONG NUT 4

E l0 E206150100 CW B Y . ".,Y F??f (RH3) C.W. PIPE. CYLINDER HEAD OUTLET (RH3) 1

Xc.E0.%.".l~lft51:&~Rt6B
P a r t s (Signal X ) depend on specification
+03,,
(For No.1-5)
 Jx1L/;*%P7Kn2E
NOZZLE COOLING WATER PIPING 5DK-20

Number
EEESY
Parts number
Name of Parts a%
Quantity

Ref. 3-21.2 NOZZLE HOLDER

Ref. 4-4.1 C.W. PUMP

E209550070 GASKET I
YO21310154 SCREWED GLOBE VALVE 2
E208650200 PIPE SUPPORTER 8
E209550210 SUPPORTER. N/C PIPE 3
E209550300 COOLING WATER BRANCH PIPE (IN) 5

E209550330 L/-f*fl9X-fI953> (OUT) COOLING WATER BRANCH PIPE (OUT) 5

E209550360 N/C FW 3 1 f i > - 5 0 K N/C F.W. MAIN PIPE-5DK 1
E229950420 15tT'Y 1- BRACKET 1
E229950430 U itilb b U-BOLT 1
E209550500 3=7f>i?y93 UNION JOINT 2

E209550520 N/C F.W. INLET PlPE

E209550530 N/C F.W. OUTLET PlPE
 J Xl l/;$5DSEBBZE
NOZZLL- 700LING OIL PIPING 5DK-20

SF
Number
2l3.".SF
Parts number g8Eg'
Name of Parts at
Quantity

Ref. 4-5.1 OIL PUMP

Ref. 3 - 2 1.2 NOZZLE HOLDER
THERMOSTAT VALVE
Ref. 4-5.3 OIL RELIEF VALVE

E209550070 GASKET
E229950090 PlPE SUPPORTER
E229950100 PlPE SUPPORTER
E209550130 N/C PIPE.PUMP INLET (R-1)
E209550140 N/C PIPE.MAIN PlPE INLET

E209550150 N/C PIPE.MAIN PlPE OUTLET

YO11110254 FLANGED GLOBE VALVE
E208650200 PlPE SUPPORTER
E209550210 SUPPORTER. N/C PlPE
€209550240 N/C. IN. OUTLET MAIN PIPE-50K

E209550290 COOLING OIL BRANCH PlPE (IN)

E209550320 COOLING OIL BRANCH PlPE (OUT)
 - -

lRHPBH%2 YniE
ITEM

7 5DK-20 FUEL OIL INJECTION PUMP PIPING

 J

r
,
1RNDB4d%2YnzE
FUEL OIL INJECTION PUMP PIPING 5DK-20

se su.".se
Number P a r t s number
n -
.Um8VJ Name of P a r t s
81
Quantity

Ref. 3-20.2 F.O. $77 F.O. INJECTION PUMP 5

Ref. 2-3 (NO.A39) F.O. N H Y - 9 b 4 J b 3 l h 2 F.O. NH LEAK OIL MAlN PlPE 1
Ref. 2 - 3 (No.A20) a > b V l : PlPE SUPPORTER 8
Ref. 2 - 2 ?23<>1\4hY MAG. VALVE PIPING 1Set
(No.B.53, B 5 5 . 8 6 2 )

S.A. MAlN PIPE. F.O. SHUTDOWN-5D 1

GASKET 1
S.A. PIPE. F.O. PUMP INLET-1 5
S.A. PIPE. F.O. PUMP INLET-2 5
PlPE SUPPORTER. F.O. PUMP 3

L O . PIPE-1. F.O. PUMP 1

L.O. PIPE-2. F.O. PUMP 1
L.O. PIPE-3. F.O. PUMP 3
L O . PIPE-4. F.O. PUMP 1
L.O. PIPE-5. F.O. PUMP 1

L O . PIPE-6. F.O. PUMP 4

BLACKET-4. STRAINER 1
Y-FILTER 1

PlPE SUPPORTER 3
{zg$gggdiJzgl3y
ARRANGEMENT OF PROTECTIVE ZINC
 /,
f%%%$daZfiSZj
ITEM
ARRANGEMENT OF PROTECTIVE ZlNC 5DK-20 8
FZ;%aEff$% D - . - - - O H 3 1 @..---OH29 0 - . - - - - O H 8 3 1
INTER COOLER TYPE
3ES5 BSQuantity
Number P a r t s number Name of Parts 01 0 10
A Ref. 3-29.1 479-9-5 OH31 INTER COOLER OH31 1
8 Ref. 3-29.2 479-9-5 OH29 INTER COOLER O H 2 9 1
C Ref. 3 - 2 9 . 4 4>9-9-5 OH831 INTER COOLER O H 8 3 1 1
D Ref. 4-3.3 L.O. 9-5 L.O. COOLER 1 1 1

A31 C048420310 $99397I> (A) ZINC PROTECTOR (A) 4 3

A32 C048420320 $993 9717 (8) ZINC PROTECTOR (8) 2 2
A33 C048420330 $993971> (A) ZINC PROTECTOR (A) 3
A99 C048470990 lr7+>
(4) GASKET (4) 4 3
A1 00 C 0 4 8 4 7 1 000 (5)
I<,Y+> GASKET (5) 2 2

A101 C048471010 1(7+>(4) GASKET (4) 131

et
Quantity

864 C037400320 I I PACKING. ZINC PROTECTOR 4

865 C045170020 ik37I> PROTECTOR ZINC 4
ITEM
9 5DK-20 ARRANGEMENT OF THERMOMETER
 3 1 '
%%WBZEH
ITEM
ARRANGEMENT OF THERMOMETER 5DK-20 9

se 3.".s4 Name o f Parts %Quantity

'dm
Number P a r t s number

Ref. 4-2.1 F.O. $77 F.O. P U M P

Ref. 4-2.3 F.O. 0, F.O. FILTER
Ref. Separate manual 9-iK3t-3t- TURBOCHARGER
Ref. 3 - 2 9 -f>9-9-5. INTER C ~ O L E R
Ref. 4-4.1 C.W. i K > l C.W. P U M P
Ref. 4-3.3 L.O. 9-5 L.O. COOLER
Ref. 4-3.4 L.O. 0, L.O. FILTER

Y23 I 0 0 3 1 4 0 37 KT4 1OOCX3/8P THERMOMETER 1OOCX3/8P 2

Y232014150 37 KT4 2 0 0 C X 1/2P-100 THERMOMETER 2 0 0 C X 1/2P- 1 0 0 1
Y241004000 37 KT4 1OOCX 1/2-L THERMOMETER 1OOC x 1 /2L 1
Y231 0 0 4 0 0 0 87 KT4 1OOCx 1 / 2 P THERMOMETER 1OOCx 1/ 2 P 2
Y 2 3 10 0 4 0 0 0 87 KT4 1OOCX 1/ 2 P THERMOMETER 1OOCX 1/ 2 P 1

Y231004000 7 2 7 K94 1OOCX 1 / 2 P THERMOMETER 1 OOCx 1/2P 1

2 5 6 5 0 0 17 0 0 2 2 ?IbIC'Y+7 GASKET
2 5 6 5 0 0 2 1 OOZZ ?lblW+7 GASKET

Y215004160 87 KT4 5OOCx 1 / 2 x 1 6 2 THERMOMETER 5 0 0 C x 1/ 2 x 1 6 2 1

Y215004240 87 KT4 5OOCx 1/ 2 X 2 4 2 THERMOMETER 5 0 0 C X 1/ 2 X 2 4 2 5
%@ (fF!ml)
ENGINE FRAME (SIDE VIEW)
 ,

%# mi)
ENGINE FRAME (SIDE VIEW) 5DK-20

SF sB.".BE Name of Parts Bf

Number Parts number 8uo"oga Quantity

ENGINE FRAME ASSY.-50. W/BOLT

BOWL TYPE PLUG

SPECIAL PLUG
C.W. CONNECTOR
PIN
COVER-1. INTAKE MANIFOLD

GASKET-1, INTAKE MANIFOLD LID

GEAR CASE LID
GASKET.GEAR CASE LID
GASKET. AUX. GEAR CASE SIDE COVER
L.O. NOZZLE

ENGINE FRAME60

BOLT
BOLT
BOLT
FLANGE
GASKET

GASKET
STUD
STUD
STUD
STUO

STUD
STEPPED PIN
TAPER PLUG
TAPER PLUG
TAPER PLUG

TAPER PLUG
O-RING
KNOCK BOLT ASSY.
STUO
STEPPED PIN

HEX.PLUG
GASKET
HEXPLUG
GASKET
I ENGINE FRAME (FRONT VIEW) I
 ,

%B (Em)
ENGINE FRAME (FRONT VIEW) 5DK-20

Z&% E!%%SF Name of Parts

Number Parts number Quantity

ENGINE FRAME ASSY.-5D. W/BOLT

HEAD BOLT
MAIN BEARING BOLT
SIDE BOLT
CIRCULAR NUT
CAP

MAIN METAL CAP

HT BOLT
HT BOLT
STUD
STUD
STUD

GASKET
SPECIAL PLlG
BOLT
STUD
ITEM
1.3 5DK-20 ENGINE FRAME (REAR VIEW)
 u -

848 ( ~ ~ ~ )
ENGINE FRAME (REAR VIEW) 5DK-20

S% 8U.".S4 Name of Parts at

Number Parts number EU.".b% Quantity

ENGINE FRAME ASSY.-50. W/BOLT

BOWL TYPE PLUG

LID-2, INTAKE MANIFOLD
GASKET-2. INTAKE MANIFOLD LID
MAIN METAL CAP(REAR)
L.O. NOZZLE

BOLT
GASKET
SPECIAL NUT
STUD
STUD
NUT

COVER-1. REAR SlDE

COVER-2. REAR SlDE
GASKET. REAR SlDE COVER

BOLT
FLAT WASHER
BOLT
BOLT
NUT

Z 3 0 0 0 10 0 0 0 2 2 K7Yfi;( FLAT WASHER

X341010030ZZ /'Y9ZJb b ASSY KNOCK BOLT ASSY

Remarks
XEP3&OY@HEIZ5BJ
Parts (Signal %) cannot be purchased by itself.
i-

%Em!ES
ENGINE SIDE COVER

I Section "A-A"

I
Ref. 3-3

I i Section " B -6"

 %~~REs
ENGINE SlDE COVER 5DK-20

SF
Number
SUESF
Parts number Name of Parts
at
Quantity

SlDE COVER (1)

SIDE COVER (21
SIDE COVER (4)
SIDE COVER (7)
CAM GEAR COVER

GASKET. SlDE COVER (4)

GASKET. SlDE COVER ( 5 )
GASKETCAM GEAR COVER
O-RING
GASKET. SIDE COVER (7)

FLANGE NU1

BOLT
BOLT
BOLT
BOLT
BOLT

NUT
5DK-20 ENGINE FRAME SAFETY VALVE
 %$ZS*X
ENGINE FRAME SAFETY VALVE 5DK-20

SF *m Bnn o S 4 BH
Number P a r t s number gE'88J Name of P a r t s Quantity

0 0 3 15 9 0 0 1 0 hII3P>t?>"r> ASSY. ENGINE FRAME SAFETY VALVE ASSY. 1

SEAT. SAFETY VALVE

SAFETY VALVE
COVER. SAFETY VALVE
SAFETY VALVE SHAFT
RETAINER. SAFETY VALVE

SPRING 1

BOLT
BOLT
O-RING
O-RING
O-RING
ITEM
4 5DK-20 IDLE GEAR

10,
[Remark]
Make arrangement for the
following a tool when
decompose of the idle gear
Optional tool
Parts number : E 2 1 9 9 5 9 1 1 0
Name of Parts :
REMOVER, IDLE GEAR SHAFT
 74 F J W V
ITEM
IDLE GEAR 5DK-20 4-

%9
Number
-
*&08F
Parts number Name of Parts am
Quantity

IDLE GEAR ASSY:SD

IDLE GEAR (2)

IDLE GEAR (1)-TF
BUSH.IDLE GEAR
SUPPORTER (1), IDLE GEAR SHAFT
SUPPORTER (2). IDLE GEAR SHAFT

SUPPORTER (3), IDLE GEAR SHAFT

SUPPORTER (4), IDLE GEAR SHAFT
IDLE GEAR SHAFT
BOLT. IOLE GEAR SHAFT
BOLT. IDLE GEAR

KNOCK PIN, IDLE GEAR

STEPPED PIN
O-RING
O-RING
O-RING
HEX. SOCKET BOLT
 637
a d m n m @ z s ( i g 7 ~&a
1 ~I x~~;wttta
ITEM OIL PUMP GEAR CASE
5.1 5DK-20 (F.W. NOZZLE COOLENG SYSTEM)
SF 3ES4 BS
Number Parts number gBEgn Name of Parts Quantity

jrr(Jbit;>7~?'9- ASSY.-C.W. OIL PUMP GEAR CASE ASSY:C.W. 1

4 9 - Y b GASKET, OIL PUMP GEAR CASE I

if4Jbit;>Wt79-X OIL PUMP GEAR CASE I

BOLT
BOLT
NUT
KNOCK BOLT ASSY.
 Section "A-A"
....................................
 34)b$2YG$S(A9;QlC&~/X~b;%~P{k$%)
OIL PUMP GEAR CASE
(D.O. NOZZLE COOLENG SYSTEM)

S% 80SZ&? n a
~80088 Name of P a r t s a*
Number Parts number Quantity

X4JbiKY7Y*?-X ASSY.-DO. OIL PUMP GEAR CASE ASSY:D.O. 1

OIL PUMP GEAR CASE

IDLE GEAR. OIL PUMP
PUMP IDLE GEAR SHAFT
NUT. PUMP IDLE GEAR SHAFT
BUSH. PUMP IDLE GEAR

GASKET. OIL PUMP GEAR CASE

BLANK FLANGE
GASKET

80LT
BOLT
BOLT
NUT
KNOCK BOLT ASSY.

O-RING
O-RING
 LII
T l (-I*@)~ ~ ~
ITEM

6.1 5DK-20 CAMSHAFT (ONE-BLOCK TYPE)

 - ,

fiLs$tl (-4*%)
ITEM
CAMSHAFT (ONE-BLOCK TYPE) 5DK-20 6.1

ftf e gSEs4 Name of Parts BtQuantity

Number P a r t s number 3Ega 0 10
1
ah39 ASSY.-5D-1 CAMSHAFT ASSY .-SD-1 1
A L 3 9 ASSY.-5D-3 CAMSHAFT ASSY.-5D-3
BL39 ASSY.50-8 CAMSHAFT ASSY.-SD-8 1
~ ~ ASSY.-50-10
3 9 CAMSHAFT ASSY.-50-1 o

CAMSHAFT - 50 W D . 0 .
CAMSHAFT - 50 (R)-C.W.
EXHAUST CAM (90.1 ) - 2 8 5
EXHAUST CAM ( 9 0 . 2 ) - 2 8 5
EXHAUST CAM ( 9 0 . 3 ) - 2 8 5

INTAKE CAM (90.1 ) - 2 4 5

INTAKE CAM (90.21-245
INTAKE CAM ( 9 0 . 3 2 4 5
F.O. CAM-1 (90.1 )
F.O. CAM-1 (90.2)

F.O. CAM-1 (90.3)

F.O. CAM-2 (90.1 )
F O . CAM-2 (90.2)
F.O. CAM-2 (90.3)

A504 2 4 0 0 0 15 0 4 0 2 2 +- KEY 10

88 E201250080 BL3999 CAM SHAFT BEARING SHELL 6

831 E201250310 Ah3939 (31) BEARING. CAM SHAFT (UPPER) 6
832 E201250320 hL3999 (99) BEARING. CAM SHAFT (LOWER) 6
833 E201250330 Y>,hL3999 ~1 P N C A M SHAFT BEARING-1 6
834 E261210080 'J - 7 * I b b REAMER BOLT 12

8510 2 5 6 5 0 0 2 1 OOZZ 7IWW+> GASKET

651 1 25601 l2524ZZ 0 Y>7 O-RING
8520 X227014000ZZ UY'Y b U-NUT

mz
Remarks

X 1 .....,AUal;b6/XlK&Mt*i% 0.0. Nozzle cooling system

X2.~....i&7Kl:b&/XIb%M~f~ F.W. Nozzle cooling system
 ;bLa (.ffmJ>
ITEM

6.2 5DK-20 CAMSHAFT (BUILT-UP TYPE)

 r ,

&L\%I (%m3 ITEM

CAMSHAFT (BUILT-UP TYPE) 5DK-20 6.2

SF 8B.".SF Name of Parts W f Quantity

Number P a r t s number BBWgn 0 I @
CAMSHAFT ASSY.-50-2
CAMSHAFT ASSY.-50-4
CAMSHAFT ASSY.-50-9
CAMSHhFT ASSY.-50-1 1
CAMSHAFT SUB.-ASSY.-5D

CAMSHAFT - 5 0 ( 8 4 R
CAMSHAFT - 5 0 (8-U) F-C.W.
CAMSHAFT. 5 0 (B-U) F-0.0.
CAMSHAFT BOLT-2
U.NUT

CAMSHAFT BOLT-1
EXHAUST CAM ( 9 0 1 ) - 2 8 5
EXHAUST CAM (90.2)-285
EXHAUST CAM(90.3)-285
INTAKE CAM ( 9 0 . 1 ) - 2 4 5

INTAKE CAM (90.2)-245

INTAKE CAM (90.3)-245
F.O. CAM- 1 (90.1)
F.O. CAM.1 (90.2)
F.O. CAM-1 (90.3)

F.O. CAM-2 (90.1)

F.O. CAM-2 (90.2)
F.O. CAM-2 (90.3)

KEY

CAM SHAFT BEARING SHELL

BUSH. CAM SHAFT. 5.0.
BEARING. CAM SHAFT (UPPER)
BEARING. CAM SHAFT (LOWER)
PIN. CAM SHAFT BEARING-1

REAMER BOLT

GASKET
O-RING
UNUT

ZE
Remarks
 t-J L$hf&C%SBi$rn
ITEM

6.3 5DK-20 DETAIL OF CAMSHAFT REAR END

Detail " D "

Ref. 3-6.1-2
 '-1 -
f i LLhf&c%gB;$$l
DETAIL OF CAMSHAFT REAR END 5DK-20

a7 3Eae BBE".B% Name of Parts

aft
Number Parts number Quantity

CAM GEAR
POWER LOCK

STRAIGHT PIN

BEARING CASING
CAP
PRESSURE PLATE
CAM SHAFT BEARING SHELL (1)

THRUST METAL, CAM SHAFT

SHlM (1)
SHlM (2)
SHlM (4)
SHlM (5)

BOLT
HT BOLT
STRAIGHT PIN
O-RING
 / Xl l/X?i2PSEB%278FagE
ITEM NOZZLE COOLING OIL PUMP DRIVING
6.4 SDK-20 DEVICE
 97,!@EbgS
1Xj b~$%D%blt
NOZZLE COOLING OIL PUMP DRIVING
DEVICE 5DK-20

Be
Number
%3SS
Parts number gB'g.M; Name of Parts itm
Quantity

1 E203750010 9 F9+.?Y949 SIDE PLATE

2 C263700160 9 F9+?ZX DRIVING GEAR BOSS
3 C263700100 9'>33>1(?3- t- SEAT. CUSHION SPRING
4 E263710221 SPRING "
5 €203750050 9'Y33>1(>9? HOLDER.CUSHION SPRING

6 E223700120 BlTf 7 F9+J;.fYI RETAINER. GOVERNOR GEAR 1

7 E223700100 f j l c f 9 F 9 + W ,Y t- NUT. DRIVING GEAR 1
8 E223700150 KJ9IY%Y+Yfj? SPECIAL CLAW WASHER 1
9 E203750090 i W 7 9 F9+? GEAR. PUMP DRIVING 1

KEY
HEX. SOKCET BOLT
 4~
5'55/5'$b & /T55/5(913'b
ITEM

7.1 5DK-20 CRANKSHAFT 6 BALANCE WEIGHT

 - -
b
95>9$h& /C75/5(314
ITEM
CRANKSHAFT & BALANCE WEIGHT 5DK-20 7.1

Se %K.".S9 Name of Parts W0

1Q
Number Parts number gu.".gm

95 >93'3 ASSY.-SD-1 CRANKSHAFT ASSY.-SD-1 1

95>932 ASSY.-SD-2 CRANKSHAFT ASSY.-SD-2

E200650040 W 9 I;9+t. (274) AUX. MACHINERY DRIVING GEAR (274) 1

E200650050 *+9 I;3+17 (271 ) AUX. MACHINERY DRIVING GEAR (271)
E160680070 %'Y+t!> PIN
E200650080 ik+9 F9+? blJ'Y?%Jb b BOLT. AUX.MACH1NEP.Y GEAR
E200650090 9779Y17-TF CRANK GEAR-TF

E200650460 977939 - 5DK CRANKSHAFT - 5DK

SET SCREW
SET SCREW

E200850020 IC772914 bZJb b BALANCE WEIGHT BOLT

€20085 7 1 4b I BALANCE WEIGHT (Depend on sppc.)
E280870120 9><Y+t!Y PIN

232 1 0 2 3 4 0 0 Z Z il9fjZ WIRE

 9529$h& &$hS
ITEM
7.2 5DK-20 CRANKSHAFT 6 MAIN BEARING
 95299Ill is &$Ill53
CRANKSHAFT & MAlN BEARING

BE EBEB4 n a
.Bn&t& Name of Parts am
Number Parts number Quantity

A46 €200650460 952959 - 5 0 K CRANKSHAFT - 5 0 K I

MAlN BCARING SHELL

THRUST BEARING

8501 2 3 3 5 0 0 8 0 1 6ZZ A433t3 STRAIGHT PIN 2

 754fi4-AJ
FLYWHEEL 5DK-20

SF EUZ%% Name of Parts Bf Quantity

Number Parts number s"'g' @ I @
1 E20095 7 4 4 - I FLYWHEEL (Depend on spec.) 1 1
13 E200950130 774ik4-JL99Y-1 FLYWHEEL POINTER.1 1
28 E200950280 774di4 -1LiKJL b FLYWHEEL BOLT 12 12
30 E200950300 l\'Y?Y+ t-IJsY?iKJL t- GEN. FITTING BOLT 8 8
35 E200950350 774ik4-JL99Y-3 FLYWHEEL POINTER-3 1

BOLT
WIRE
WIRE
9 IJ 29549-
CYLINDER LINER
 9!J=/954t
CYLINDER LINER

SF
Number
BB.".se
Parts number Name of Parts
em
Quantity

90 1 1JIJ )/5'74* ASSY. CYLINDER LINER ASSY. 1

CYLINDER LINER
PROTECT RING
O-RING

O-RING
Detail "A"
 ex t-2
PISTON 5DK-20

SF %.".SF * m z9.m
Number Parts number duogm Name of Parts Quantity

PISTON ASSY.
PISTON RlNG ASSY.
PISTON PIN ASSY.

PISTON RlNG (3)

PISTON RlNG (2)
OIL RlNG
PISTON RING (11
PISTON-6

SNAP RING. C-TYPE

PISTON PIN
KONlC EXPANDER

m?!
Remarks
%€D1PDYRfi%l2-
Parts (Signal W cannot be purchased by itself.
 C "

@%@
ITEM

12 5DK-20 CONNECTING ROD

 2EB@
ITEM
CONNECTING ROD 5DK-20 12

SF
Number
EU.".SF
P a r t s number
n -
mUm%J Name of Parts Rff
Quantity

bYizYiti'3 ASSY. CONNECTING ROD ASSY.

b>*'YX9 (9Y9-7') ASSY. CONNECTING ROD SUB-ASSY

E205250010 972!7t!>>71L CRANKPIN BEARING SHELL

E205250040 t 3 b>t!>Y>X PISTON PIN BUSH
E205250060 97Y9CYiK1L b CRANKPIN BOLT
E205250070 bYiz'YiK9'Yf f iKIb b ROO CONNECTING BOLT
E205250080 b991'bi19YY SPECIAL STRAIGHT PIN

CONNECTING ROD
NOZZLE

WIRE
STRAIGHT PIN

i*:?
Remarks
X€!IIG~LBEEI~T~
Parts (Signal X) cannot be purchased by itself
 I

3lJ2 g ~ t y
ITEM

13 5DK-20 CYLINDER HEAD

 L37-
=
J IJ - ~ g 4 y
ITEM
CYLINDER HEAD 5DK-20 13
.

SF EE.".W BE.".".gn Name of Parts

Em
Number Parts number Quantity

9lJ>r/-Y F ASSY. < > 3-Cj -2 CYLINDER HEAD ASSY. W/OUT VALVE-C-2 1
9IJ29-Y F ASSY. <>YS-C.2 CYLINDER HEAD ASSY. WITH VALVE-C-2 1
9'J>9-Y F (93)ASSY.9 CYLINDER HEAD SUB-ASSY.8 1

<>%idF VALVE GUIDE

$-13*<>V SEAT, INTAKE VALVE
flXf?Kt?idF GUIDE. VALVE YOKE
1\4*<>V (ST3 SEAT. E.X. VALVE (METCO)
/ Xlbfilb9%id F GUIDE. NOZZLE HOLDER

X9YF STUD
?Jbj'Y b CIRCULAR NUT
3 l J > 9 4 ' Y FICY+> GASKET. CYLINDER HEAD
32fj9179 BOWL TYPE PLUG
7>fj9177 BOWL TYPE PLUG

XJb b (1). l X J b i K l b 9 BOLT (1). NOZZLE HOLDER

iKJb b (2). l X l b i k J b 9 BOLT (2). NOZZLE HOLDER
0 'J>7 ( 3 Y 3 3 O-RING (SI)
0 'J>7 ( 7 Y Y ) O-RING (FLUORO)
+t"7 CAP

0 l J Y 7 (7'YY) O.RING (FLUORO)

lTlb1X~L3-lb VALVE STEM SEAL
3 9 > 9 4 ' Y F-C-50 CYLINDER HEAO-C-50
cw L>?~?I>IW+> GASKET. C.W. CONNECTOR

STUO
STRAIGHT PIN
STUD
SNAP RING
TAPER PLUG (5)

TAPER PLUG (5)

TAPER PLUG (5)
SPECIAL PLUG (3)
HEX. PLUG
GASKET

GASKET 2
( /CYL.)

Remarks
(I 1 msmwnmmq.
Parts (Signal 3%) cannot be Purchased by itself.
(2) No.908 3 ' J > 9 + , ~ F ASSY. (^r>'Y+) 1L12G. Biz#, %EESP#EBG : 3-14. 3.15. 3-16%g?!BTZLI
CYLINDER HEAO ASSY. WITH VALVES) INCLUDE IN. 6 EX. VALVES and INOICATOR 6 SAFETY VALVE : Ref. 3-14, 3-15. 3-1 6.
 21J>y\\y
CYLINDER HEAD

ST guwse * n
Name of Parts as
Number Parts number uunmga Quantity

82 E202050020 +39+fi>'X> F BEN0,INTAKE MANIFOLD

87 E202050070 fiX?'Y b . +39+71><>F GASKET.INTAKE MANIFOLD BEND
B9 €202050090 +33+4> F9-Jb SEAL.INTAKE MANIFOLD BEND

BOLT
BOLT
HF z 3
EXHAUST VALVE
 ITEM
EXHAUST VALVE 5DK-20 14

se EB.".se n m
Name of Parts an
Number Parts number munm8a Quantity

EXHAUST VALVE ASSY:l

EXHAUST VALVE- I
SEAT, VALVE SPRING
VALVE COTTER
VALVE ROTATOR
VALVE SPRING (INNER)

VALVE SPRING (OUTER)

STEEL BALL
BALL RACE
ClRCLlP
COIL SPRING

COEND DISK SPRING

RETAINER
BODY

%ED%.".cr)Y@WScEldF~
Parts (Signal x) cannot be purchased by itself.
 d3 6
a - b
?ha XL I-F
ITEM

15 5DK-20 INTAKE VALVE

 4-a
4:JCl XL A-
ITEM
INTAKE VALVE 5DK-20 15

SF
Number
3ES9
Parts number 3Egm Name of P a r t s am
Quantity

INTEAKE VALVE ASSY.-1

VALVE-2
SEAT. VALVE SPRING
VALVE COTTER
VALVE ROTATOR
VALVE SPRING (INNER)

VALVE SPRING (OUTER)

STEEL BALL
BALL RACE
ClRCLlP
COIL SPRING

COEND DISK SPRING

RETAINER
BODY

XEO3~OX!!@&El.iT~
Parts (Signal X ) cannot be purchased by itself
 LJ 9
ITEM
tazE5, s*+F
16 5DK-20 INDICATOR & SAFETY VALVE
 EES, 82%
ITEM
INDICATOR & SAFETY VALVE 5DK-20 16

SF
Number
HESF
Parts number
n m
&&$3 Name of Parts
M
O Y antity
Q
o
962 E206959620 977+P>t2>rC> (2) ASSY. INDICATOR & SAFf3Y VALVE (2) ASSY. 1,
963 E206959630 P > e > < > ASSY. SAFETY VALVE ASSY. 1
966 E206959660 9PY+-P>V>rC> (2C) ASSY, INDICATOR & SAFETY VALVE (2C) ASSY. 1
967 E206959670 7>e>rC> ASSY. (C) SAFETY'VALVE ASSY. (C) 1

BLOCK, INDICATOR VALVE

VALVE. INDICATOR
FLANGE, INDICATOR VALVE
SPECIAL HEX. PLUG
SAFETY VALVE

SHAFT-2. INDICATOR VALVE

NUT. INDICATOR VALVE
SET SCREW
SPRING
INDICATOR CONNECTOR

BODY. SAFETY VALVE

SPRING RETAINER
SPRING SEAT
SPRING

NUT
NUT

STRAIGHT PIN
GASKET
GASKET
GASKET
ITEM
17 5DK-20 VALVE OPERATING DEVICE
 , ,

a%%E ITEM
VALVE OPERATING DEVICE 5DK-20 17

s4 *DEn&%
CI

Number Parts number Name of Parts Quantity

4 7 7 2 ASSY. ROCKER ARM ASSY.

I \ 5 ) IN. & EX. VALVE ROCKE ARM (WITH BUSH)
47Z'YIE?i (5-b Y S ) T. VALVE YOKE (WITH SEAT)

HOLDER. ROCKER ARM

IN. & EX. VALVE ROCKER ARM
T, VALVE YOKE
SHAFT. ROCKER ARM
ADJUSTING SCREW. VALVE YOKE

METAL PIECE ROCKER ARM

SEAT. VALVE YOKE
SCREW. ROCKER ARM
SEAT (1). VALVE YOKE
CAP. ROCKER ARM METAL PIECE

BUSH. ROCKER ARM

L . 0 ADJUSTING SCREW

NUT
NUT
NUT
SET SCREW
SET SCREW

ltY1Y>7 ( 3 7 ) SNAP RING (SHAFT)

0 Y27 O-RING

Parts (Signal X) cannot be purchased by itself. Please order sub assy.

(2) 901<3/73/ ASSY. I#.3-18. 8 9 , h.:,FfiIT-itfJb t.$%bj.
ROCKER ARM ASSY. include No.89. BOLT. HEAD COVER in 3 - 1 8
 3 IJ 2 9 ~ 1 F~J)(-
y
ITEM

18 5DK-20 CYLINDER HEAD COVER

- 6 c[7
pIJ=/y,'/\y Fa)\"-
ITEM
CYLINDER HEAD COVER 5DK-20 18

SE
Number
BB.".Se
Parts number EBEgw Name of Parts
m
Quantity

COVER (21.CYLINDER HEAD

SHAFT. HEAD COVER KNOB
KNOB. CYLINDER HEAD COVER
RUBBER SEAL. HEAD COVER

SPRING PIN

BOLT. HEAD COVER

2Ez
Remarks
%EnB[lo"olb3- 1 7 . 9 0 1 . <>7> ASSY. IZ5ER6
Parts (Signal %I i i includid in ROCKER ARM ASSY. : Ref. 3-1 7.
 D ! = #%94Yt-
INTAKE & EXHAUST TAPPET SDK-20 . 19

$&% /<-*XI4
Number Parts Code %%%% Name of Parts
-
&lx
Quartitv

IN. EX. ++I-ASSY. IN. EX. TAPPET ASSY.

0-3 ASSY. ROLLER ASSY.

SWING ARM(L)
SWING ARM(R)
SHAFT. SWING TAPPET
BOLT. SWING TAPPET SHAFT
RING KNOCK

PUSH ROD
BUSH:TAPPET ROLLER
SEAT. PUSH ROD
PIN. TAPPET ROLLER
RUBBER SEAL. PUSH ROD

TAPPET ROLLER
KOENIC EXPANDER

SET SCREW
TAPER PLUG
SNAP RING(SHAFT)

P a
Remarks

# EP%6&".3#&%lbFJ
Parts(Signal#)cannot be purchased by itself.
 2 7$jltd
I%W+UB~~%
FUEL OIL INJECTION PUMP FITTING
 EHnBgdS 2 YEWq
ITEM
FUEL OIL INJECTION PUMP FITTING 5DK-20 20.1 -

!ST %3?&?Z Name of Parts kit

Number Parts number sZgn Quantity

F.O. PUMP
SHIM 0.6.F.O. PUMP
SHiM 0.1.F 0.PUMP
SHIM 1.0.F 0.PUMP

501 X2200 1600022 7 . Y b NUT 3

( 1CYL.I
 FUEL OIL INJECTION PUMP

Mark Dosition

S ) I ~ B I : ~ O ~ E T ~ M : : ~ ~ &BYfflEZEEDl.
B~L@. BUSZ%LT<TiZLI. Example of Mark
Note) Different parts are used depending on the specifications.
D NP-PFR1W V 2 0 0 A 0 3 N 4
Check the identification mark before ordering parts.
- 7 ' .'

EH@5f;f$=/Y
ITEM
FUEL OIL INJECTION PUMP 5DK-20 20.2.

a??
Number
BB.".SF
Parts number Name of Parts m
Quantity

F.O. il;>Y-C21 TG-L42D F.O.PUMP-C21TG-L42D

HOUSING PUMP
PLUNGER ASSY.-21
DEFLECTOR
O-RING
DELIVERY VALVE ASSY.

O-RING
BOLT
BACK U P RlNG
O-RING
TAPPET

PIN
SPRING PLUNGER
SPRING SEAT
SPRING SEAT
PLATE

CONTROLRACK
PLUG
GASKET
CONTROL SLEEVE
POINTER

SHIM
BOLT
BACK UP RlNG
SET SCREW
GASKET

O-RING

ZZ
Remarks

xErJa~D&~mzlxTw
Parts (Signal X ) cannot be purchased by itself
RW2iEIO Y 9
FUEL OIL INJECTION BLOCK
 RNEE70 ~9
FUEL OIL INJECTION BLOCK

€$.".SF Name of Parts am

Number Parts number gB.".ga Quantity

7 E206250070 3399 CONNECTOR 1

O-RING
GASKET
NUT
ITEM

21.1 -2 5DK-20 FUEL OIL INJECTION BLOCK

L 1
View " B"
Ref. 3-21.1.1
-

%HWEIn Y 9
FUEL OIL INJECTION BLOCK

Se &K.".ST Name of P a r t s %R
Number Parts number 8K.".ga Quantity

90 1 F.O. 33J'YfJ> ASSY. F.0, INJECTION BLOCK. ASSY. 1

I E206250010 FO 3 9 P ' Y B Y BLOCK. F.O. INJECTION

3 E206250030 397"YjI7334Yb JOINT. INJECTION PIPE
4 E206250040 ,tfJ!~b BOLT
5 E206250050 O91jIJC COVER. LEAK OIL
6 E206250060 13Jbb BOLT

BALL
PLUG
O-RING

O-RING
SET SCREW

% E P % B ~ ( n ~ W ~ % I ~No.901.
T E T , F.O. 3 3 7 ' Y b Y ASSY 0 ; F Z E i B Q Z V .
Parts (Signal %) cannot b e purchased by itself. Please order F.O. INJECTION BLOLK ASSY. ( N o 9 0 1 ).
 ENDE~TSB(%@/X)L)
ITEM
21.2 5DK-20 F.O. INJECTION D N l C E (COOLING NOZZLE)

Note) Different parts are used depending on the specifications.

Check the identification mark before ordering parts.
 RH@%SE($i%DIX')L)
F. 0. INJECTION DEVlCE(COOL1NG NOZZLE) 5 ~ ~ ~212-2 0
F.O.Nozzle Hole dia -
%* 1 <-YZl-F im,%% Name of Parts &&!I itity
Number Parts Code 111 (2)
-
/ ~ J L ~ ~ J L ~ - D L FASSY.
~BIO NOZZLE HOLDERDLFZ810 ASSY.
/;(IL~JL~-DLF~OIO ASSY. NOZZLE HOLDER DLF3010 ASSY. 1

NOZZLE HOLDER 1
NOZZLE-DLF140TE2810
NOZZLE-DLF140TE3010 1
BODY,N.H. x
PIN,NOZZLE DOWEL 4

PUSH ROD 1
SPRING SEAT 1
SPRING,NOZZLE 1
ADJUSTING SCREW 1
NUT 1

CAPNUT 1
GASKET 2
SPACER 1
RETAINING NUT 1
INLET CONNECTOR 1

O-RING 3
O-RING 1

(ICYL)

Remarks
XEP~EKJ~S~*ESI~FJ
Parts(Signa1.X)cannot be purchased by itself.
 EHm44zB(%;*a/X/L)
F.O. INJECTION DEVICE(N0N-COOLING NOZZLE)

5%) ~ H E I ~ & ~ Z WEZ Z @ ~~ ? L?T I~~~

. %Z
~ ~% LSC < ~
~: Z L~L ~ ~Example
~ ~ of Mark
~
Note) Different Darts are used depending on the specifications. 0 NP-DLLl40TE281ON1
Check the identification mark before ordering parts.
 F.O.Nozzle Hole dia
1 G.73-F
Number Parts Code %FA%% Name of Parts %%k111
!uanty
i 1 (2)

40 E206250400 / ~ I L 7 k l L 7 - ~ ~ L 2 8ASSY.
10 NOZZLE HOLDEROLU810 ASSY. 1
41 E206250410 / ~ I L ~ ~ ~ L ~ - D L ASSY.L ~ O ~ O NOZZLE HOLDER DLWOlO ASSY. 1

44 E206250440 /XIL;~;ILY.DLL NOZZLE HOLDER,DLL 1 1

46 E206250460 /XlL-~~~140~~2810 NOZZLE-DLL140TE2810 1
47 E206250470 /~lL-DLL140TE3010 NOZZLE-DLL140TE3010 1
206 AE01062021 t5, / x J L 3 - ? Z l L PIN,NOZZLE DOWEL 4 4
207 AE01062011 ?Y-jloyt-' PUSH ROD 1 1

208 AE01062022 XT1J>?>-I- SPRING SEAT 1 1

209 AE01062023 /XILX;P'J>Y SPRING.NOZZLE 1 1
212 E206252120 /XIL~~JL~~~?'?-,DLL BODY,N.H.,DLL 1% 1 X
213 E206252130 75vX'i4>929'J~.DLL ADJUSTING SCREW,DLL 1 I
216 AE01062015 fYI- NUT 1 1

CAPNUT 1 1
GASKET 2 2
SPACER 1 1
RETAINING NUT 1 1
INLET CONNECTOR 1 1

503 Z560105035DZ 0 'I>T O-RING 3 1 3

(ICYL)

Remarks
X E P ~ ~ ~ ~ t * P ~ % I ~ ~ E J
Parts(Signa1 x)cannot be purchased by itself.
u

tj'l \ ; ' t , 3 E ~ (RHD

~ E 6)
GOVERNOR DRIVING DEVICE (RHD 6)
 ~1 ~ t % E E % E E (RHD 6)
ITEM
GOVERNOR DRIVING DEVICE (RHD 6) 5DK-20 22.1

SE %.".Be Name of Pans Bm

Number Parts number %B.".88 0
GOVERNOR GEAR CASE (RHO)
MOUNT, GOVERNOR (RHO)
GOVERNOR DRIVING GEAR-1 (221 )
GOVERNOR DRIVING GEAR-) (229)
GOVERNOR ORlVlNG GEAR-2 (229)

fil<t+'? (221) GOVERNOR GEAR ( 2 2 1)

4+? (225)
fil <f GOVERNOR GEAR (225)
fiI<f9 F 9 3 9 . 1 (RHO) GOVERNOR DRIVING SHAFT-] (RHD)
BlW9 FC739-2 (RHO) GOVERNOR DRIVING SHAFT-2 (RHD)
77Y?Y'Y9Il FLANGE BUSH

FLANGE BUSH
COUPLING. DRlVlNG SHAFT
CAP (RCA)
SHlM (RHD)
SHlM (RHO)

SHlM (RHO)
SHIM. GOVERNOR GEAR CASE
SHIM. GOVERNOR GEAR CASE

U-NUT
BOLT
BOLT
STUD
NUT

BEARING
KEY
KEY
TAPER PIN
O-RING

KNOCK BOLT ASSY. ( I )

 ww

ITEM
a/Tt3E~SE(UG 10)
22.2 5DK-20 GOVERNOR DRIVING DEVICE (UG 1 0 )
 a)ct5ISbEE (UG 10)
ITEM
GOVERNOR DRIVING DEVICE (UG 1 0 ) 5DK-20 22.2

SF *.B.W
C1

Number Parts number 3BEga Name of Parts WQuantity

01 0
3 E204550021 f j 1 W f - P 9 - X - l (UGB) GOVERNOR GEAR CASE-1 (UGB) 1
4 E204550022 f j l W f W - X - 2 (UGB) GOVERNOR GEAR CASE-2 (UGB) 1
14 E204550140 f j l W 3 F3Yt7-UGB (229) GOVERNOR DRIVING GEAR-UGB (229) 1 1
19 E204550190 f j l W 3 F 9 ft7-4 ( 2 2 7 ) GOVERNOR DRIVING GEAR-4 (227) 1
20 E204550200 fjlW3 F 9 ft7-5 (224) GOVERNOR DRIVING GEAR-5 (224) I

25 E204550250 1 J l Wf P ( 2 2 0 ) GOVERNOR GEAR (220) 1

26 E204550260 fjl(ff-P(Z24) GOVERNOR GEAR (224) 1
33 E204550330 f j l W 9 F 3 9 9 (UGB) GOVERNOR DRIVING SHAFT (UGB) 1 1
34 E204550340 1JlCf 9 F 9 9 9 ; f Y I RETAINER. GOV. DRIVING SHAFT I , I
40 E204550400 75797Y31 FLANGE BUSH 2 2

SHlM (UGB)
SHlM (UGB)
SHlM (UGB)
DISTANCE-1
DISTANCE-2

74- 1 E204550731 fjlTf+'-P?-X9L SHIM, GOVERNOR GEAR CASE 1 1

74-2 E204550733 fjIlf$??-X9A SHIM. GOVERNOR GEAR CASE 1 1

505 X20001203022 X l b i- BOLT

510 X21001006722 X7YF STUD
51 1 X 2 2 0 0 1 OOOOZZ T'Y b NUT
5 13 2451 16909022 <P?l)/7 BEARING
514 245116911OZZ <YlJ)/7 BEARING

523 256010363522 0 lJ77 O-RING

524 X341 1 0 8 0 3 0 2 2 /'Y97Klbi-T ASSY. (1) KNOCK BOLT ASSY. (1
530 X2050 1002522 HT X l b b HT BOLT
533 X 2 0 0 0 0 8 0 16 2 2 itflb b BOLT
534 2 5 7 1 5 0 1 00022 T-lV57 TAPER PLUG

535 2 5 7 1 5 0 100022 F-ICZ7 TAPER PLUG 1 1

I€>OY F
CONTROL ROD
 II=E>UY F
CONTROL ROD 5DK-20

ST BBEW Name of P a r t s a&

Number P a r t s number BBEgG Quantity

HEATBOX COVER (FRONT)

HEATBOX COVER (REAR)
CONTROLROOSTANO
C O N T R ~ LROO BEARING (2)
SPHERICAL PLAIN BEARING

CONTROL ROD-50K
RACK LEVER
RACKLEVERCLUTCH
HOLDER. RETURN SPRING
RETURN SPLING. RACK LEVER

RACK LlNK PIN

RACK LlNK
SPHERICAL PLAIN BEARING
LlNK PIN DISTANCE
SPECIAL FLAT WASHER

BEARING
SNAP RING (HOLE)
BOLT
STRAIGHT PIN
BOLT

TOOTHED LOCK WASHER

HEX. SET SCREW
HEX. SET SCREW
NUT
SPRING PIN

U-NUT
BOLT
SNAP RING (HOLE)
 Riw\2 FllJ
ITEM

24.1.1 5DK-20 CONTROL HANDLE

3-24.1.29R Q
Ref. 3-24.1. 2
+
 Ern/\'/F h
ITEM
CONTROL HANDLE 5DK-20 24.1 .I

SE %%SF Name of Parts xp.

Number Parts number 3Egn Quantity

SHAFT. STOP LEVER

HOLDER. STOP LEVER SHAFI
STOP LEVER

SNAP RING (SHAFT)

BOLT
BOLT
SPRING PIN
TOOTHED LOCK WASHER
1%
Em)uF h
CONTROL HANDLE

View " P

View "Q"
3-24.1, 1 B E
Ref. 3-24.1, 1
 EM)\2 F h
CONTROL HANDLE

#3%
Number
BBZS%
Parts number '"' Name of Parts BS
Quantity

C272000040 5 ' Y g X b'Y1 <XJbb BOLT. RACK STOPPER

€204650070 YgTbl<- CONTROL LEVER
€2046501 1 0 Zl€>U'Y FblC- CONTROL LOO LEVER
COO 1 3 4 0 0 5 0 X b>Yl( STOPPER
COO 13 4 0 0 7 0 /7 KNOB

SPRING
HANDLE GRIP
HANDLE STOPPER
NAME PLATE (1). GOVERNOR LEVER
NAME PLATE (3). GOVERNOR LEVER

NUT
TOOTHEDLOCKWASHER
STUD
BOLT
SPRING PIN

SPRING PIN
TOOTHED LOCK WASHER
NUT
+ PAN MACHINE SCREW
RIVET
L.6 8
B zt
LOAD GAUGE
 669
a jEj it ITEM
LOAD GAUGE 5DK-20 24.2

SF %GS Name of Parts tm

Number Parts number gKza' Quantity

13 E204650130 392bI(- LOAD POINT LEVER

16 E204650160 7h94%€'J>I<Y LOAD SCALE PLATE

HEX. SET SCREW

SPRING PIN
+ PAN MACHINE SCREW
tj')C
t J! 23 (RHD 6)
GOVERNOR LINK (RHD 6)
 67 I
tj'!CstIJ 29 (RHD 6)
ITEM
GOVERNOR LlNK (RHD 6) 5DK-20 25.1

ST
Number
3EiST
P a r t s number guEg8J Name of Parts am , .
Quantity

E2046503lO L > ? ' Y f i Y (RHO) CONNECTION ROD (RHO)

E204650330 L/>?'YA>Y9 (RHO) SHAFT. CONNECTION ROD (RHO)
E204650370 T'Y b NUT
E204650380 L/>Y'YfiYYY b NUT. CONNECTION ROD
E204650410 ;(7IYAJl~,lL4>~771J 7 9 SPHERICAL PLAIN BEARING

ROD END
LlNK PIN
LlNK PIN
GOVERNOR LEVER-RHO
CONTROL ROD LEVER-RHD

SPRING

FLAT WASHER
CASTLE NUT
SPLIT PIN
NUT
FLAT WASHER

CASTLE NUT
SPLIT PIN
TAPER PIN
BOLT
SPRING PIN
 t j ' l c t I J 2 9 (UG 10)
ITEM
25.2 5DK-20 GOVERNOR LINK (UG 10)
 tj'l C
t IJ 95' (UG 10)
GOVERNOR LlNK (UG 10)

se ~ ~ s e
Number Parts number Nams of Parts Bf
Quantity

CONNECTION ROD (UG8)

SHAFT. CONNECTION ROD (UG8)
NUT
NUT. CONNECTION ROD
SPHERICAL PLAIN BEARING

ROD END
LlNK PIN
LlNK PIN
GOVERNOR LEVER-UG8
CONTROL ROD LEVER-UG8

SPRING

FLAT WASHER
CASTLE NUT
SPLIT PIN
NUT
FLAT WASHER

CASTLE NUT
SPLIT PIN
BOLT
SPRING PIN
BOLT
H -s
h E g~winfi#a
U A U \

EXHAUST MANIFOLD (FRONT T/C)

#EE (imiEm)
EXHAUST MANIFOLD (FRONT T/C)

-
ntity
0
-
EXHAUST MANIFOLD ASSY.-53-1
EXHAUST MANIFOLD ASSY.-50-2 1

GASKET. EXHAUST MANIFOLD 5

BELLOWS 1
EYE FLANGE, EX. MANIFOLD (OSP) 1
GASKET. EX. MANIFOLD (DSP) 7
BELLOWS. 2L-5C 1

SUPPORT-1. EX. MANIFOLD (DSPI-RT 2

.
EX. MANIFOLD-I 120XO.B-FT 2
EX. MANIFOLD-2. 120XO.B-FT 1
T/C INLET PIPE. RH 1 63-FT 1
GASKET. T/C INLET (RH163) 1

SUPPORT-1. EX. MANIFOLD (DSP)-FT 1

SUPPORT-2. EX. MANIFOLD (DSP)-FT 2
T/C INLET PIPE. RH 133-FT
GASKET, T/C INLET (RH133)

HT BOLT 20
HT BOLT 12
NUT 12
HT BOLT 4
NUT 4

HT BOLT
NUT
BOLT 6
HT BOLT 6
BOLT 4

NUT 4
HT BOLT
HT BOLT 16
NUT 16
E (f~~%BiG)
EXHAUST MANIFOLD (REAR T/C)
EXHAUST MANIFOLD (REAR T/C)

EXHAUST MANIFOLD ASSY.-50-3 1

EXHAUST MANIFOLD ASSY.-50-4

GASKET. EXHAUST MANIFOLD 5

EX. MANIFOLD-1, 120xO.B-RT 2
EX. MANIFOLD-2, 1 2 0 x 0 . 8 - R T 1
BELLOWS 2
EYE FLANGE. EX. MANIFOLD (DSP) 1

GASKET. EX. MANIFOLD (DSP) 7

BELLOWS. 2L-5C 1
SUPPORT-1. EX. MANIFOLD (DSP)-RT 3
SUPPORT-2. EX. MANIFOLD (DSP)-RT 3
GASCKET. T/C INLET (RH 1 6 3 )

T/C INLET PIPE. RH163-RT

GASCKET. TIC INLET (RH133) 1
T/C INLET PIPE. RH 133-RT 1

HT BOLT
HT BOLT
NUT
HT BOLT
NUT

X2O5O 1 OO45ZZ HT XJL t- HT BOLT

X 2 2 0 0 1OOOODZ 7-Yb NUT
X 2 0 0 0 12 0 2 0 z z MIL b BOLT
X2O5O 1 2 0 2 0 2 2 HT iKlL t- HT BOLT
X2000 12025ZZ MJL t- BOLT

X 2 2 0 0 I2 0 0 0 z z ?'Y t- NUT
-X205012030ZZ HT MIL t- HT BOLT
X2O5O l 6 0 6 O Z Z HT MIL t- HT BOLT
X 2 2 0 0 16 0 0 0 D Z f 'Y t- NUT
ITEM
#zEa 1 l'-
(EC%2i!$$)
27.1 5DK-20 EXHAUST MANIFOLD COVER (FRONT T/C)

View " P " Section " A-A " View " Q "
 -

#ZEA ) c- (i@%%i$E) ITEM

EXHAUST MANIFOLD COVER (FRONT T/C) 5 ~ ~ - 2 27.1
0
i!%%11?3 a . - - - R H 1 3 3 @.--.-RHI 43
TURBOCHARGERTYPE
SF 88.".SY Name of Parts EtPQuantity
Number Parts number 01 0
I

191 E202251910 1 \ 4 + h > h l < - 7 , OSP~FT EX. MANI. COVER-7. OSP-FT 1

192 E202251920 /\4;fh>hlC-8. OSP-FT EX. MAN1 COVER-8. DSP-FT 1
193 E202251930 / \ 4 + a > h 1 < - 9 . DSP-FT EX. MAN1 COVER8. DSP-FT 1
199 E202251990 l\-l+h>hlC-15. DSP-FT EX. MANICOVER- 1 5 . DSP-FT 1
202 E202252020 I\-f+h>h1F16. OSP-FT EX. MANI. COVER. 16. OSP-FT I

205 E202252050 1\4+h>alC-Y91-1, OSP BRACKET. EX. MANI. COVER-1. OSP 4

206 E202252060 I\4+h>hlC-YYI-2. OSP BRACKET. EX. MANI. COVER-2, OSP 1
208 E202252060 1\4+h>hlC-991-4. DSP BRACKET. EX. MANI. COVER-4. OSP
209 E202252090 I\4+-A>h1C-9YI-5. OSP BRACKET. EX. MANI. COVER-5. OSP I
233 €202252330 1 \ 4 * h > A I C - 2 0 . DSP-FT EX. MANI. COVER-20. OSP-FT I

234 E202252340 1\4'+A>hlF2 1 . OSP-FT EX. MAN1 COVER-21. DSP.FT I

235 E202252350 1 \ 4 + A > h / F 2 2 . OSP-FT EX. MAN1 COVER-22. DSP-FT 1
236 E202252360 l\-l+b>131\-23. OSP-FT EX. MANI. COVER-23. OSP-FT I
239 E202252390 I\-f+h>hl~-Yf1-7, DSP BRACKET. EX. MANI. COVER-7. OSP I
240 E202252400 1\4+A>f?lC-9YI-8. OSP BRACKET. EX. MAN1 COVER-6. OSP I

24 1 E2022524 1 0 1\4*h>hI<-tfY1-9. OSP BRACKET. EX. MAN1 COVER-9. OSP

BOLT
FLAT WASHER
BOLT
BOLT
BOLT

BOLT
FLAT WASHER
BOLT
FLAT WASHER
BOLT

FLAT WASHER
BOLT
FLAT WASHER
BOLT
FLAT WASHER

BOLT
FLAT WASHER
BOLT
FLAT WASHER
BOLT

632 230001200022 t7tffj3 FLAT WASHER

View " P " Section "A-A"
 #MEfi1c- (fg~%a#E)
ITEM
EXHAUST MANIFOLD COVER (REAR T/C) 5 ~ ~ ~ 27.2
2 0

-
!SF BB.".!S9 itity
Number Parts number SUE%iVJl %
E202252050 I \ 4 + B > A I C - Y Y I - 1 . OSP BRACKET. EX. MANI. COVER-1. OSP 4
E202252090 1\4+A>AIC-Y'31-5. DSP BRACKET. EX. MANI. COVER5. DSP 1
EZO2252 1 0 0 1\4+h>hlC-YYI6. DSP BRACKET. EX. MANI. COVER-6. DSP 1
E202252210 l \ 4 + B > B l F 7 . OSP-RT EX. MANI. COVERJ. DSP-RT 1
E202252220 l \ 4 + h > B l F 8 . OSP~RT EX. MANI. COVER-8. OSP-RT 1

E202252230 I \ 4 + A > A 1 W DSP-RT EX. MANI. COVER-9. OSP-RT 1

E202252240 I\<+A>A1T-lO. OSP-RT EX. MAN1 COVER-1 0. DSP-RT 1
E202252250 l \ 4 + B > h 1 ~ - 1 1 . OSP-RT EX. MANI. COVER-1 1. DSP-RT 1
E202252260 1\4+13>131F12. DSP-RT EX. MANI. COVER-1 2. DSP.RT 1
E202252280 l \ 4 = F B > A l < - 1 4 . OSP-RT EX. MANI. COVER-14. DSP.RT 1

E202252290 l\4+?I>Bl<-15. DSP-RT EX. MANI. COVER-1 5. OSP-RT

E202252300 l \ 4 + B ) / B l < - l 6 . DSP-RT EX. MANI. COVER-16 . DSPFIT 1
E202252310 l\4+B>?IlF17. DSP-RT EX. MANI. COVER-17, DSP-RT 1
E202252390 l \ 4 + B Y B l < - ' 3 Y I - 7 . DSP BRACKET. EX. MANI. COVER-7. DSP 1
E202252400 1 \ 4 = F B > b I C - 7 7 1 - 8 , OSP BRACKET. EX. MANI. COVER-8. DSP 1

E202252410 1\4+h>hlC-Y'3I.S. OSP BRACKET. EX. MANI. COVER-9. DSP 1

BOLT 8
FLAT WASHER 8
BOLT 2
BOLT 2
BOLT 2

BOLT 2
FLAT WASHER 2
BOLT 5
FLAT WASHER 5
BOLT 6

FLAT WASHER 6
BOLT 6
FLAT WASHER 6
BOLT 5
FLAT WASHER 5

BOLT 2
FLAT WASHER 2
BOLT 6
FLAT WASHER 6
BOLT 2

FLAT WASHER 2
1 3-29.4S8.8 Ref. 3-29.4
 /\{*I
P i

S$E&(K%B$E : RH 1331, ?Z;~2P%(DHB32)B!KI

TURBOCHARGER (FRONT T/C : RH 133) 6
INTERCOOLER (DHB TYPE) FITTING

se gsizse
Number Parts number
*
&&&
El
Name of Parts
WR
Quantity

E200250320 +13+fi>79tjX?'Y b-2 GASKET-2, INTAKE MANIFOLD LID

E202650550 I/C f j X 9 , ~b (OK-25) I/C GASKET (OK-25)
E202650910 I/C 4 LJ7Fh>. RHl33-FT I/C INLET DUCT. RH 133-FT
E202650920 707F7S75>5RH133 FLANGE:'BLOWWER OUTLET-RH133
E l62600180 T/C 7 7 S h > l r , ~ * > T/C OUTLET DUCT PACKING

E202650970 I/C A]<-. RH123 I/C COVER. RH123

BOLT
FLAT WASHER
O-RING
BOLT
NUT

BOLT
NUT
BOLT

E202350200 l\.I*F9Sh> (RH 133) GAS OUTLET DUCT (RH 1 3 3 )

E l62300200 9-C>7991C'Y+> GASKET. TURBIN OUTLET
E202350310 1\4+?9TA>99I-RH 123 SUPPORT. GAS OUTLET DUCT-RH 1 2 3

X570004000DZ O'YA9159 HEX. PLUG

2 5 6 5 0 0 2 1OOZZ 7IblW+> GASKET
X570006000DZ O'YA9759 HEX. PLUG
256500270022 7JblC,Y*> GASKET
X21001205002 Z9YF STUD

NUT
BOLT
BOLT

E20245 5J-iti'Ft~-5?
({t&lcb!lSf&25) TURBOCHARGER (Depend on spec.)
 % ( : R H 1 3 3 ) , z*"'na
m m #@{q
ITEM TURBOCHARGER (REAR T/C : R H 13 3 ) &
28.2 ~ D K - ~ INTERCOOLER
O FITTING

13-29,]S8,8
Ref. 3-29.1
 $ 6(
: RH 133), ~ % ; % ~ # W Y I
TURBOCHARGER (REAR T/C : RH 133) & ITEM
INTERCOOLER FITTING 5DK-20 28.2.

SF 3ESZ Name of Parts am

Number Parts number Quantity

€200250320 *19+bY79fj;(Y':,Yb-2 GASKET-2, INTAKE MANIFOLD LID

E202650550 I/C 8 X V . y b (DK.25) I/C GASKET (DK-25)
E202650920 70777F7-5Y3-RH133 FLANGE. B L O W E R OUTLET-RH133
E202650940 7429YX DISTANCE
E l6260018 0 T/C 77F;h?I<~+'/ T/C OUTLET DUCT PACKING

E202651000 I/C 1 5 . 9 , y b. RH133-RT I/C BRACKET. RH 133-RT

E202651020 I/C 4 LJ7F;hY. RH133-RT I/C INLET DUCT. RH 133-RT

X200016030ZZ ZJb b BOLT

X200016030DZ ZJb b BOLT
23 1 0 0 1 6 0 0 0 Z Z lG'-VLl3 SPRING WASHER
X 2 0 0 0 1 6 1OOZZ ZJb b BOLT
X210010043ZZ XTYF STUD

X 2 2 0 0 1 OOOOZZ f 'Y b NUT

Z560108057DZ 0 LlY7 O-RING
X200008045ZZ ZJb b BOLT
X220008OOOZZ ZJL b BOLT
X2000 1604522 $lL b BOLT

E202350260 I\4*75'SfiY (RH133) GAS OUTLET DUCT (RH 133)

E l62300200 9-t377FIPY+Y GASKET. TURBIN OUTLET
E202350300 l\4??5'F;hY99I-RH 133 SUPPORT. GAS OUTLET DUCT-AH133

X5700040000Z 0Y;h9177 HEX. PLUG

2 5 6 5 0 0 2 1 OOZZ 7hlWV~ GASKET
X5700060OODZ O'Yf3915.7 HEX. PLUG
Z5650027OOZZ 7 J b l WWJ GASKET
~210012050~ zX ~ FY STUD

NUT
BOLT
BOLT
NUT

€20245 9-it;??-Fjr (k%ILACIRf&&) TURBOCHARGER (Depend on spec.)

1 I
28.31 5DK-20 INTERCOOLER FITTING

3-29.5. ~ ~ ~ 1 . 6 s e 5
Ref. 3-29.5,3-29.6
 B$%%(Z%iWS
: RH 143),2%;$8%&{g
TURBOCHARGER (FRONT T/C : RH 143) &
INTERCOOLER FITTING

se
Number
-
*d o n % $
Parts number ""' Name of Parts t4.H
Quantity

A31 E2026503 10 I/C fjX?'> I- (OK30) I/C GASKET (OK-30) 1

A32 E200250320 +l9+713/77fjX?'Y b-2 G A S K E T 2 INTAKE MANIFOLD LIO 1
A66 E202650660 I/C 4 I I 9 S h > RHl63-OSP I/C INLET DUCT, RH163-OSP 1
A67 E202650670 I/C h1C- RH163-OSP-FT I/C COVGR, RH163-OSP-FT 1
A68 E202650680 7077977729 RH163 FLANGE. B L O W E R OUTLET. R H 1 6 3 1

A69 E202650690 ~ O ~ ~ ! J F I T , Y RH
+ >1 6 3 GASKET. B L O W E R OUTLET, R H 1 6 3 1

A549 2560 1 1125702 0 II29 O-RING

A555 X 2 0 0 0 1 OO55ZZ iKlb I- BOLT
A556 X 2 2 0 0 1 OOOOZZ +'> I- NUT
A567 X200012016ZZ i t i h I- BOLT
A569 Z30001200022 k7Yfj;f FLAT WASHER

BOLT
BOLT

823 E202350230 1 \ 4 + 7 9 7 b 2 (RH163) GAS OUTLET DOCT (RH 163) 1

824 E202350240 l\4+?9?I < , ~ + (RH
2 163) GASKET. GAS OUTLET DOCT (RH163) 1
836 E202350360 1159,~ I- RH143-163 BRACKET. RH 143-1 63 1

HEX. PLUG
GASKET
HEX. PLUG
GASKET
BOLT

BOLT
NUT
NUT
BOLT

C E20245 '/-~St.-ijt. (MKADRiX8) TURBOCHARGER (Depend on spec.) 1

 & ( : RH 1431, ~ % % P % @ ~ Y I
TURBOCHARGER (REAR T / C : R H 1 4 3 ) 6
1 I
28.41 5DK-20 INTERCOOLER F I ~ I N G

/3-29.2. 3-29.3SR
Ref. 3-29.2.3-29.3
 ... ,, .

(RH 143),I~XL~TJ%PWJ~~
**.A

TURBOCHARGER (REAR T/C : RH 143) 6 ITEM

INTERCOOLER FITTING 5DK-20 28.4

se *&rS4
m
a n #an
Number Parts number mEnnga Name of Parts Quantity

I/C GASKET (DK30)

GASKET-2. INTAKE MANIFOLD LID
GASKET. BLOWER OUTLET-VTR1 6 1
I/C BRACKET-2 (RT)
FLANGE. BLOWER OUTLET-VTR 16 0

GASKET.BLOWER OUTLET-RH 16 3
I/C BRACKET-RH 163-RT
I/C INLET DUCT-RH163-RT
BLOWER OUTLET PIPE. RH163-RT

STUD
NUT
BOLT
BOLT
NUT

X200010050zz iKJb i- BOLT

X 2 2 0 0 1oooozz fY i- NUT
X200016040ZZ XJb i- BOLT
X200016055ZZ XJb i- BOLT
2560 1 1 l 2 5 7 O Z 0 ?I29 O.RING

BOLT
SPRING WASHER
BOLT
NUT

GAS OUTLET DUCT ( f l H l 6 3 )

GASKET. GAS OUTLET DUCT (RH 163)

HEX. PLUG
GASKET 2 1
HEX. PLUG
GASKET
HEX. PLUG

GASKET
BOLT
BOLT
NUT

E20245 9 - I d TURBOCHARGER (Depend on spec.)

 ( $ 2: RH 143), TiZ;$2PSI&!id
ITEM TURBOCHARGER (REAR T/C : RH 143) &
28.5 5DK-20 INTERCOOLER FITTING
 S 8 R (f8lS$::: RH 143), 2Z;%PEIQlg
TURBOCHARGER (REAR T/C : RH 1 4 3 ) &
INTERCOOLER FITTING

Fs EB.".S% Name of Parts E

m
Number P a r t s number Quantity

I/C GASKET (DK30)

GASKET-2. INTAKE MANIFOLD 110
GASKET. BLOWER OUTLET-VTR1 6 1
I/C BRACKET-2 (RT)
FLANGE. BLOWER OUTLET-VTRI 6 0

GASKET.BLOWER OUTLET-RHI 63
I/C BRACKET-RH 163-RT
I/C INLET DUCT-RH 163-RT
BLOWER OUTLET PIPE. RH 163-RT

STUD
NUT
BOLT
BOLT
NUT

BOLT
NUT
BOLT
BOLT
O-RING

BOLT
SPRING WASHER
BOLT
NUT

GAS OUTLET DUCT (RH163)

GASKET. GAS OUTLET DUCT (RH163)

HEX. PLUG
GASKET
H E X PLUG
GASKET
HEX PLUG

GASKET
BOLT
BOLT
NUT

TURBOCHARGER (Depend on spec.)

 J

ITEM
m""a#
~ ~ 1 (DH3 1 ) - i@7N
- n

29.1 5DK-20 INTERCOOLER (DH3 1) - SEA WATER

 '2

*-'a
r X L mP(DH31) - &7H
ITEM
INTERCOOLER (DH31 ) - SEA WATER 5DK-20 29.1
~...9-JL,1$+32-T43/9 @-..?87[/>3-T4)/7 @.*871/: /?.
Tar epoxy coating Neoprene coating e lir
Neopren-
Be
Number
*.b%4
m

Parts number g"'8a

Name of Parts
4
x1
(

INTER COOLER (DH31-25)

INTER COOLER (OH31 -25)-NC
INTER COOLER (OH31 -25)-NL

SlDE COVER (A) DK25-TC

SlDE COVER (8) DK25-TC
ZINC PROTECTOR (A)
STUD BOLT
FIN TUBE (DH3 1-25)

TUBE PLATE
HEAD (A). ZINC PROTECTOR
GASKET (11
GASKET (2)
GASKET (3)

ICY+'/ (4) GASKET (4)

9-927 FRAME
Y-f Fhl T- (A) DK25-NC SiOE COVER (A) OK25-NC
Lf-f FBI C- (A) OK25-NL SlDE COVER (A) DK25.NL
Y-f FhiT- (8) DK25-NC SIDE COVER (8) DK25-NC

SlDE COVER (B) DK25-NL

BOLT
U-NUT
NUT
SPRING WASHER
DRAIN COCK

DRAIN COCK
 *-so.
rXLm
ITEM
29.2 5DK-20 INTERCOOLER (DH29) - SEA WATER
 --
(DH29)
r*"*?$I%
XLm - j@7k
ITEM
INTERCOOLER (DH29) - SEA WATER 5DK-20 29.2

INTER COOLER (DH29-27)

INTER COOLER (DH29-27)-NC
INTER COOLER (DH29-27)-NL

TI'F%V- (A) DK27-TC SlDE COVER (A) DK27-TC

TI'MI<-(01 DK27-TC SlDE COVER (8) DK27-TC
fi333971Y (8) ZlNC PROTECTOR (8)
iK9339717 (A) ZlNC PROTECTOR (A)
X 9 ' Y FZJL t- STUD BOLT

FIN TUBE (DH29-27)

TUBE PLATE
HEAD (8). ZlNC PROTECTOR
HEAD (A), ZlNC PROTECTDR
GASKET (1)

GASKET (2)
GASKET (3)
GASKET (5)
GASKET (4)
GASKET (8)

OVAL FLANGE (1 )
FRAME
SlDE COVER (A) DK27-NC
SIDE COVER (A) DK27-NL
SlDE COVER (8) DK27-NC

SlDE COVER (8) DK27-NL

BOLT
BOLT
BOLT
U-NUT
NUT

Z5715010000Z TAPER PLUG

2 3 1 0 0 1 OOOOZZ SPRING WASHER
23 100 12 0 0 0 Z Z SPRING WASHER
Z310008000ZZ SPRING WASHER
Z580201000ZZ DRAIN COCK

DRAIN COCK
 *-.A
XXLITI 5 % (DH39HZ) - S7k
ITEM

29.3 5DK-20 INTERCOOLER (DH39HZ) - FRESH WATER

 /,
*-'a
35iLt-n BE (DH39HZ) - E7J(
ITEM
INTERCOOLER (DH39HZ) - FRESH WATER 5 ~ ~ ~ 29
2.30

%F
Number
EB.".SF
Parts number gB'88
Name of Parts %a
Quantity

INTER COOLER (DH39HZ-30)

SlDE COVER (A)

SlDE COVER (8)
STUD BOLT
FIN TUBE (DH39-30)
TUBE PLATE

GASKET ( 1 )
GASKET (2)
GASKET (3)
GASKET (8)
OVAL FLANGE (1 )

FRAME

BOLT
U-NUT
TAPER PLUG
SPRING WASHER
DRAIN COCK

DRAIN COCK
 ." -
~~~~ZrJs- DHB3 1 (&rf<), DHB3 1 HZ(3W)
XXLJTI
ITEM INTERCOOLER - DHB3 1 (SEA WATER),
29.4 5DK-20 DHB3 1HZ (FRESH WATER)
 6-99
*""glIS
1131-n - DHB31 (237J<), D H B 3 l HZ(1E7B)
INTERCOOLER - DHB3 1 (SEA WATER), ITEM
DHB3 1HZ (FRESH WATER) 5DK-20 29.4-
-
-
ity
HB31HZ
IDI
INTER COOLER (DHB31)-TC
INTER COOLER (DHB31 HZ) 1
INTER COOLER (DHB31 )-NC
INTER COOLER (DHB31)-NL

I/C FRAME. DHB31 1

SlDE COVER (A) 0HB.TC
SlDE COVER (0) DHB-TC
HEAD (A). ZlNC PROTECTOR
ZlNC PROTECTOR (A)

STUD BOLT
FIN TUBE (OH31 -25) 1
TUBE PLATE
GASKET (1) 2
GASKET (3) 1

GASKET (4)
GASKET (5)
GASKET (0) 1
STUD BOLT 32
FIN TUBE 2

fi3939PIYh,P ~ (B) HEAD (B) ZlNC PROTECTOR

f i 9 9 3 9 7 7 I Y (B) ZlNC PROTECTOR ( 0 )
Y 4 FBI<- (A) OHBHZ-TC SlDE COVER (A) DHBHZ-TC 1
Y 4 FBI<- (5) DHBHZ-TC SlDE COVER (8) DHBHZ-TC 1
Y 4 F?llq- (A) DHB-NC SlOE COVER (A) DHB-NC

Y 4 F?ll<- (8) DHB-NC SIDE COVER (8) DHB-NC

94 FBI<- (A) DHB-NL SlOE COVER (A) DHB-NL
9 4 FBlC- (8) OHB-NL SlOE COVER (5) DHB-NL

X200010025ZZ $lb b BOLT

X227012000ZZ U Y Y ~ U-NUT '32
X 2 2 0 0 1 OOOOZZ f ,Y t- NUT
2 3 1 0 0 1 OOOOZZ i<3+ftj3 SPRING WASHER
X200010025ZZ GJLi- BOLT

23 1 0 0 1 OOOOZZ lC3tftj3 SPRING WASHER

Z5802020002Z Fb>3~9 DRAIN COOK 2
 *r=.a.
% (DH29) - S 7 K
ITEM
29.5 5DK-20 INTERCOOLER (DH29) - SEA WATER
 !2u
m
' *.&
(DH29)- j@7k
INTERCOOLER (DH29) - SEA WATER
ITEM

5DK-20 29.5
~-..9-~mit;+~q-?.i'~'7 @...jp7fll/;)3-?477 O.-fp7fYL~'/
Tar epoxy coatlng Neoprene coating Neoprene
.....
S=3
Number
EE.".S?
Parts number -
Name of Parts ??
INTER COOLER. DH29-TC
INTER COOLER. DH29-NC
INTER COOLER. DH29-TL

STUD BOLT
GASKET (5)
HEAD. ZlNC PROTECTOR (8)
ZlNC PROTECTOR (B)
i/C FRAME D H 2 9 . 3 9

FIN TUBE (DH29-27)

GASKET (1 )
TUBE PLATE D H 2 9
GASKET (2)
GASKET OH29

'34 F h l < - (A) DK30-TC SlDE COVER (A) DK30-TC

'3-4 Fa/<- (A) OK30-NC SIDE COVER (A) DK30-NC
'34 Fa/<- (A) DK30-NL SIDE COVER (A) OK30-NL
'34Fa/<- (8) DH29-TC SlDE COVER (8) DH29-TC
'34 I%/<- (8) DH29-NC SlDE COVER (8) DH29-NC

'31' Fa/<- (B) DH29-NL SlDE COVER (8) DK29-NL

i K 3 9 3 9 7 1 ' J (A) ZlNC PROTECTOR (A)
iK39397'12fi7 F (A) HEAD. ZlNC PROTECTOR (A)
IT9*7 (4) GASKET (4)

BOLT
U-NUT
DRAIN COCK (2)
BOLT
NUT

SPRING WASHER
SPRING WASHER
TAPER PULG
ITEM
29.6 5DK-20 INTERCOOLER (DH39HZ) - FRESH WATER

0
AIR
 (DH39HZ)
*""i$%
rm1-n - S7k
INTERCOOLER (DH39HZ) - FRESH WATER 5 ~ ~ 4 29.6
ITEM
0

sz
Number
SU.".S%
Parts number
* m
.UOO%$J Name of Parts am
Quantity

INTER COOLER. OH39HZ-TC

STUD BOLT
I/C FRAME D H 2 9 . 3 9
FIN TUBE (DH39-30)
GASKET (1)
TUBE PLATE

GASKET (2)
GASKET (3)
SIDE COVER (A)
SIDE COVER ( 0 ) DK39HZ-TC

U-NUT
DRAIN COCK (2)
TAPER PULG
1R*4nBg$%2YY4Fa)(-
FUEL OIL INJECTION PUMP SIDE COVER

Section "A - A"

 1RHPB8j%2YY4FLIII-
FUEL OIL INJECTION PUMP SIDE COVER 5 ~ ~ 4 0

Se
Number
88ZS4
Parts number Name of Parts m
Quantity

HEAT BOX COVER (LOWER) - 2

HEAT BOX COVER (LOWER) -4
FRONT COVER.HEAT BOX
KNOB. CVLlNOER HEAD COVER
PLASTIC CROSS KNOB

SHAFT KNOBU.HEAT BOX

SUPPORT. HEAT BOX FRONT COVER
HEAT BOX COVER (UPPER) -1
HEAT BOX COVER (UPPER) -2

BOLT
BOLT
BOLT
BOLT
BOLT

X200010012zz BOLT
2 3 0 0 0 1 oooozz FLAT WASHER
2 2 1 2 0 10 0 3 5 z z HEX. SOCKET BOLT
z415004024zz SPRING PIN
X200012020zz BOLT

X 2 0 0 0 1 20 1 B Z Z BOLT
ITEM

31 5DK-20 STEP BOARD

u
Detail "A"
 ri &!
STEP BOARD 5DK-20

se 3Ese
Number Parts number gBEgM; Name of Parts
XP1
Quantity

STEP BOARD-5D
CUSHION RUBBER
BRACKET.STEP BOARD-30

BOLT
BOLT
BOLT
+ FLAT MACHINE SCREW
NUT

5 16 Z 3 0 0 0 1 OOOOZZ k5!ffj? FLAT WASHER 18

a$zEt,5Fags
TACHOMETER DRIVING DEVICE

!I CAMSHAFT
I
 H$ZFt$EQZE
ITEM
TACHOMETER DRIVING DEVICE 5DK-20 1.1

we 3.".S? t3.H
Number Parts number Name of Pans Quantity

COUPLING 1
HOLDER. TACHOMETER FLEX 1

BOLT
O-RING
O-RING
IF'€-9 & IF'€-9@!$
AIR MOTOR & AIR MOTOR FITTING
I AIR MOTOR & AIR MOTOR FllTlNG
SZ Name of Parts tit
Number Parts number ggsgfi Quantity

3 €212850030 175-9779.9 b BRACKET. AIR MOTOR 1

9 €212850090 IJ79ft7 RING GEAR 1
12 € 2 1 2 8 5 0 1 20 1 7 F - 9 7 5 9 , ~b 2 i X 9 , ~
b GASKET. AIR MOTOR BRACKET 1
13 €212850130 175-9 AIR MOTOR 1
17 E212850170 ~77'Y4Y'Y+~Jl,-IUbY RELAYVALVE &REGULATORVALVE 1

30 €21 2 8 5 0 3 0 0 71J753/5 SPPRIT FLANGE 1

HT BOLT
NUT
HT BOLT
NUT
 !k%$%%TEb%>y
(TYPE A)
~ D K - ~ FUEL
O OIL FEED PUMP (TYPE A)
 %$%%%l%>y
(TYPE A)
FUEL OIL FEED PUMP (TYPE A)

u
#T %&#%
Number Parts number
%&%a Name of Parts a,
-
Quantity

OIL PUMP TKGK-2-6D2

O-RING
O-RING
SHAFT
SHAFT COLLAR
INNER ROTOR

OUTER ROTOR
COUPRIN KEY
BALL BEWRING
BALL BEARING
JOINT PACKING

JOINT PACKING
MECHANICAL SEAL
COLLAR
KNOCK PIN
VALVE BOX

CONNECTER
SAFETYVALVE
VALVE SPRING
SPRING CARRIER
ADJUST SCREW

LOCK NUT
HEXAGON NUT
HEXAGON BOLT
HEXAGON BOLT
HEXAGON BOLT

HEXAGON BOLT
HEXAGON BOLT
CAP
SOCKET HEAD CAP SCREW
BEARING COVER

ROTOR HOUSING
BRACKET
PACKING
PACKING
RING JOINT

ROTOR KEY
CASING
SIDE COVER
SEAL COVER
PIPE NOCK
 I ' ,
%+%%b$>~ (TYPE 6)
~ D K - ~ OFUEL OIL FEED PUMP (TYPE B)

Detail: " A %
 !b%#%%b$>y
(TYPE B)
FUEL OIL FEED PUMP (TYPE B) 5DK-20 2.1.2

%hi
b

Number
D
3nns-i
n

Parts number
SF&%
( I ) . . - . i E & H NORMAL ROTATION

Name of Parts
-
( 2 ) . . . - 2 & % REVERSE ROTATION

s ~ ~ u a n t i t ~
( I ) / (2)

C034400020 *-f'IL%>?, 206HWT031 OIL PUMP, 206HWT031 1

C034400090 *-fIL%>?, ZOGHWTR031 OIL PUMP, 206HWTR031 1

C034402000 5 - HVVNB SEALKIT. H W B

BALL BEARING
BALL BEARING
OIL SEAL
OIL SEAL
O-RING

REMARKS; PARTS(S1GNAL') CANNOT BE PURCHASED BY ITSELF

*EP%.".~&%EZl;t+3~
 1

#!#%%#>3%Ei%%B
(TYPE A)
2.2.1 ~ D K - 2 0 FUEL OIL PUMP DRIVING DEVICE (TYPE A)

I-..7
I
!

OIL PUMP TLGK-2-6D2 20 i

 ! ' I

#H%;'EIVK~~!@G@~E
(TYPE A)
FUEL OIL PUMP DRIVING DEVICE (TYPE A) ~ D K - 2 0 2.2.1
(I)..-
-720,750 rprn (2). ".900rpm
e+ 3XgW Name of Parts %!%uantity
Number Parts number I I (21

DRIVING SHAFT, F . 0 FEED PUMP

DISTANCE.PIECE
F.O. PUMP DRIVING GEAR Z=34
F.O. PUMP DRIVING GEAR Z=37
COVER COUPLING

SHlM 0.1
SHlM 0.2
COUPLING
COUPLING RUBBER
HEX. SOCKET SET SCREW

HEX. SOCKET SET SCREW

GASKET
BRACKET, F O . FEED PUMP .
CASTLE NUT WITH SEAT. M20x1.5

BOLT
BOLT
NUT
NUT
FLAT WASHER

TOOTHED LOCK WASHER

TOOTHED LOCK WASHER
TOOTHED LOCK WASHER
SPLIT PIN
KEY

KEY
SPRING PIN
BEARING
OIL SEAL
SNAP RING
 /' u

E H Z G E ~ $ > ~ R % S B F Y PB)
E
~ D K - ~ FUEL
O OIL PUMP DRIVING DEVISE (TYPE B)
SF- sm#~
0 I

Ell&%%
..
Name of Parts
. .
-
@-uantity
Number Parts number " 1 121
l S J

DRIVING SHAFT, F.O. FEED PUMP 1

COVER, COUPLING. F.O. FEED PUMP 1
BRACKET, F.O. FEED PUMP 1
DIST- DRMffiSHbFT,F O FEEDPUMP 1

F.O. PUMP DRlVlNG GEAR Z=34

F.O. PUMP DRIVING GEAR Z=37

GASKET
"UNION SCREW, F.O. FEED PUMP"
CASTLE NUT WITH SEAT
SHlM

SHlM
"NAME PLATE, COUPLING COVER
SUNK KEY
ROLLER CHAIN COUPLING

BOLT
NUT
NUT
FLAT WASHER
TOOTHED LOCK WASHER

TOOTHED LOCK WASHER

TOOTHED LOCK WASHER
SPLIT PIN
KEY
SPRING PIN

BEARING
BEARING
OIL SEAL
SNAP RING
HEX. SOCKET BOLT
FUEL OIL FILTER
 r -

RHn=F
FUEL OIL FILTER 5DK-20

sz
Number Parts number
Name of Parts XPt
Quantity

FILTER

FILTER BODY
COCK
O-RING
O-RING
PACKING. COCK COVER

COCK COVER
HANDLE
HANDLE
SPRING (NOTCH BAR)
NOTCH BAR

PACKING (CASING)
SHAFT
CASING
SPRING (CASING)
CAP NUT

PACKING (CONNECTOR)
CONNECTOR
PACKING (SLEEVE NUT)
SLEEVE NUT
AIR PLUG

VALVE
ELEMENT ASSY. (200ME)
PLUG
COVER
GASKET

LAGGING
ITEM

2.4 5DK-20 FUEL OIL FILTER FITTING (WITHOUT COVER)

I FUEL OIL FILTER FITTING (WITHOUT COVER)
se %BEST Name of Parts %!m
Number Parts number Quantity

8 C060800010 O+ FILTER I
10 E2 1 4 3 5 0 100 3 ! ~ Y 5 .FO O + (C3500) SAUCER. F.O. FILTER (C3500) I
11 E2 1 4 3 5 0 1 10 1W+>. FO O$ (C3500) GASCKET. F . 0 FILTER (C3500) I
28 E2 1 4 3 5 0 2 8 0 FO 0 + 7 5 ! T ' Y b-C (3500) BRACKET. F.O. FILTER (C3500) I
202 Y529000301 I b % > b A S S Y (ZOOME) ELEMENT ASSY. (200ME) 2

BOLT
BOLT
DRAIN COCK
g$*qaE#
FUEL OIL RELIEF VALVE
 I -
ENBE#
FUEL OIL RELIEF VALVE
0 1 .O-20kg/cm2 ({f%S%M)
Relief press. 0.10-0.20MPa (Refer t o specification)
BE 3ESq Name of Parts XPWZ!uantity
Number Parts number 0
C034509030 F. 0.43 3 7YL;'J ASSY. (S - 3) F. 0. RELIEF VALVE ASSY. (S - 3 ) 1

C034500010 ?397'Y<>91' - 1 BODY - 1. OIL RELIEF VALVE 1

C034500020 /W.bYI CAP. VALVE SPRING 1
C034000030 IW3- b SPRING SEAT 1
C034040010 F3 3 7 " Y d ' J RELIEF VALVE 1
C034500080 7 9 0 t . b~ CAP NUT 1

ADJUSTING SCREW
SPRING (1.6)

NUT
GASKET
GASKET
GASKET
HEX. PLUG

X570004OOOZZ O~fi9779 HEX. PLUG 2

 /

;MjBimaY
LUBRICATING OIL PUMP

42 501
Section "A- A"
 ;m;m2 Y
LUBRICATING OIL PUMP 5DK-20

se *&&em

Number P a r t s number ""' Name of P a r t s BH

Quantity

C034790090 L.O. $27 ASSY. V 1 4 3 R L.O. PUMP ASSY. V 1 4 3 R

L.O. PUMP COVER ( V 1 8 4 )

L.O. PUMP BODY (V143)
L.O. PUMP DRIVING GEAR N 1 4 3 )
L.O. PUMP DRIVEN GEAR (V143)
SAFETY VALVE

RETAINER. SAFETY VALVE SPRING

CAP. SAFETY VALVE SPRING
FLAT WASHER
BEARING
SPRING

BOLT
CASTLE NUT
SPLIT PIN
KEY
TAPER PLUG

Z 6 6 5 O l OOOOZZ 7'hlWT> GASKET

266503400022 7'JW CY4Y GASKET
X67OOl 0 0 0 0 2 2 O>Yh9759 HEX. PLUG
2 4 6 1 3 5 5 5 1 1SC $-flb3-lb OIL SEAL
2 4 1 200550022 XT'Y7LJ>9 SNAP RING

SNAP RING
STRAIGHT PIN
1

iHjBSEB%2 7@iq
LUBRICATING OIL PUMP FITTING
 iB;B;EB7tt=/Ymkt
LUBRICATING OIL PUMP FITTING

se 3FJse
Number Parts number sDEgW Name of Parts XPPQuantity
010
5 €2 10550050 LO i1;>7$t7 (234) L O . PUMP GEAR (234) 1,
6 E210550060 LO M 7 7 Y t 7 ( 2 3 7 ) L.O. PUMP GEAR (237) 1
10 E203150130 h ' X T Y t- GASKET 1 1

502 X22001200022 fY b NUT 6 6

 (El7K)
~~~~~~;~~~
LUBRICATING OIL COOLER (SEA WATER)

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 2 1

EMmS%%D(%
Z7N
ITEM
LUBRICATING OIL COOLER (SEA WATER) !~DK-~(J3.3.1
I
ST 3ESe Name of P a r t s
Number P a r t s number BLIGgn I

OIL COOLER (F-8)

OIL COOLER (F-12)
OIL COOLER (F-8)-NC
OIL COOLER (F-12)-NC
OIL COOLER (F-8)-NL
OIL COOLER (F-12)-NL

SHELL (1 )
SHELL (2)
SlOE COVER (1)
SlDE COVER (2)
TUBE PLATE (3)

TUBE PLATE (4)

LOW FIN TUBE (1)
LOW FIN TUBE (2)
SPACER-] (F-8)
SPACER-1 (F-12)

SPACER-2 (F-8)
SPACER-2 (F-12)
STAY BOLT (2)
STAY BOLT (31
BUFFLE PLATE

GASKET (11. TUBE PLATE

GASKET (2). TUBE PLATE
JOINT SEAT
JOINT SEAT
ROTATING ELBOW

PACKING. ZlNC PROTECTOR

PROTECTIVE ZlNC
FLANGE. PROTECTIVE ZlNC
SlDE COVER (1)-NC
SlDE COVER (2)-NC

SlOE COVER (1 )-NL

SlDE COVER (2)-NL

BOLT
BOLT
BOLT
BOLT
BOLT

STUD
STUD
NUT
NUT
 O . . . ~ - J L I ~ + Z - T - ~ ~ ~@ . i z ; f l L / Y ? - 7 4 M ~.-izjfxo54-~9
Tar epoxy coating Neoprene coating Neoprene lining
I BM Quantity
s=
Number
3SSE
Parts number sb'gG
Name of Parts 1 12ma
8m2
01 Q l 1 @ 1 ( ? ) [ @ I G J
I I I I I
5 21 25602200572Z 0 1J29 O.RING 2 2 2 2 2 2
525 256500270022 711.1C'Y+2 GASKET l l l l l l
526 Z66503OOOOZZ 7JW ('Y+2 GASKET 2 2 2 2 2 2
530 X570006OOOZZ O5Y*9l79 HEX.PLUG 1 1 1 I 1 1
533 Z580102000ZZ FL/>?Y9 DRAIN COCK 1 1 1 1 1 1

534 2 5 8 0 1040002Z FL/23Y9 DRAIN COCK )I 11 I ] 1 1 11 I

I = /
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LUBRICATING OIL COOLER (FRESH WATER)

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LUBRICATING OIL COOLER (FRESH WATER) 5 ~ ~ ~3.23.20
&yw*--aEsg
, m .....Bm2 @......1zm2
CAPACITY of L.O. COOLER
S% El.".&% Name of Parts
X4.Ouantity
Number parts number 0 0
914 C041090140 8-fJb9-5 (F-8) F.W. OIL COOLER (F-B) F.W. 1
915 C041090150 84Jb9-5 (F.12) F.W. OIL COOLER (F-12) F.W. 1

1 C041010010 9-9>5'(1) SHELL (1)

2 C041010020 9-3>5'(2) SHELL (2)
7 C041010070 9 4 F L U - (1) SlOE COVER (1)
8 C041010080 9 4 F h l b (2) SIDE COVER (2)
14 C041070140 F l - Y T b - t.(3) TUBE PLATE (3)

15 C041070150 Fl-7jb- t. (4) TUBE PLATE (4) 1

21 C04 1 0 7 0 2 01 0-7-f>Fl-7 (1) LOW FIN TUBE (1) 118
22 C041070202 0-74??2-7(2) LOW FIN TUBE (2)
36 C041070360 X f l - 7 - 1 (F.8) SPACER-1 (F-8) 24
37 C041070370 X<-7.1 (F-12) SPACER-] (F-12)

SPACER-2 (F.8)
SPACER.2 (F-12)
STAY BOLT (2)
STAY BOLT (3)
BUFFLE PLATE

GASKET (1 ). TUBE PLATE 1

GASKET (2). TUBE PLATE 2
JOINT SEAT 1
JOINT SEAT 1
ROTATING ELBOW I

64 C037400320 I b J ' Y 7 Y PACKING. ZINC PROTECTOR 4 4

66 C0371 1 0 2 4 0 ..
i K 3 7 1 > 7 7 - JY FLANGE. PROTECTIVE ZINC 4 4

BOLT
BOLT
BOLT
BOLT
BOLT

STUD
STUD
NUT
NUT
O-RING

GASKET
GASKET
HEX.PLUG
DRAIN COCK
DRAIN COCK
 irn~B3la0=F
LUBRICATING OIL FILTER

I..
 , -
iH%%EB
.
0
LUBRICATING OIL FILTER 5DK-20

ST %B.".S% Name of Parts %m

Number Parts number Quantity

FILTER

FILTER BODY
COCK
PACKING SEAT
PACKING (COCK)
COCK COVER

HANDLE
NUT (HANDLE)
SPRING (NOTCH BAR)
NOTCH BAR
STUD (COVER)

NUT (COVER)
BOLT (COVER)
PACKING (CASING)
SHAFT
CASING

SPRING (CASING)
PACKING (CAP NUT)
CAP NUT
PACKING (VALVE SEATI
VALVE SEAT

PACKING (CONNECTOR)
CONNECTOR
PACKING (SLEEVE NUT)
SLEEVE NUT
AIR PLUG

STUD
SPRING WASHER
NUT
PLUG
PACKING

NIPPLE
CONNECTER
VALVE
SLEEVE NUT
SLEEVE

WASHER (HANDLE)
SPRING WASHER (HANDLE)
NAME PLATE
ELEMENT ASSY. (200ME)
PACKING
I I
3.5.1 15DK-20 FILTER FITTING (FRONT TIC) WITHOUT COVER

P View "P"

Section "A-A"
L..... 2
 H%EEIE# & CI +Hj&l (TdB@) - h 1 l'-E
LUBRICATING OIL RELIEF VALVE &
FILTER FllTlNG (FRONT T/C) WITHOUT COVER 5DK-20 3.5.1

Se
Number
BBEW
Parts number 8EEg@ Name of Parts
m
Quantity

F33?'!JY3/ ASSY. L.O. RELIEF VALVE ASSY.

FILTER
SAUCER. L.O. FILTER
BRACKET. L.O. FILTER (Fn
GASKET. SIDE COVER (5)
BODY, RELIEF VALVE

RETAINER. VALVE SPRING

VALVE
VALVE SPRING CASE
CAP
SPRING

SPRING

HT BOLT
BOLT
BOLT
NUT
BOLT

FLANGE
GASKET
GASKET
DRAIN COCK
BOLT

FLANGE
GASKET
BOLT
NUT
SET SCREW

GASKET
GASKET
SPECIAL PLUG
GASKET
HEX.PLUG

GASKET
O-RING
Section "A-A"
 iB%3Q8E#& EI (f&fi$BG)- h l t-%
LUBRICATING OIL RELIEF VALVE &
FILTER FITTING (REAR T/Cl WITHOUT COVER 5DK-20 3.5.2

S9 EEGS9 Name of Parts Y

m
Number Parts number gEsg8 Quantity

L.O. RELIEF VALVE ASSY.

FILTER
SAUCER, L.O. FILTER
BRACKET. L O . FILTER (RT)
GASKET. SIDE COVER (5)
SlDE COVER (5)

BODY. RELIEF VALVE

RETAINER. VALVE SPRING
VALVE
VALVE SPRING CASE
CAP

SPRING
SPRING

BOLT
BOLT
NUT
BOLT
FLANGE

GASKET
GASKET
DRAIN COCK
HT BOLT
NUT

FLANGE
GASKET
BOLT
NUT
SET SCREW

GASKET
GASKET
SPECIAL PLUG
GASKET
HEX. PLUG

GASKET
O-RING
..............................................

Section "A-A"
............................................. 8
 8mmEElE# & 0*&tq (rGag) - a1 l'-tYt
LUBRICATING OIL RELIEF VALVE &
FILTER FITTING (FRONT T/C) WITH COVER 5DK-20

63%
Number
BBESE
Parts number
n -
nhagm Name of Parts
am
Quantity

3 3 9 7 Y n f Y ASSY. L.O. RELIEF VALVE ASSY.

FILTER
SAUCER. L.O. FILTER
BRACKET. L.O. FILTER (FTI
GASKET. SIDE COVER (5)
COVER-1. L O . FILTER

WING BOLT
COVER-2. L.O. FILTER
BODY. RELIEF VALVE
RETAINER. VALVE SPRING
VALVE

VALVE SPRING CASE

CAP
SPRING
SPRING

HT BOLT
BOLT
BOLT
BOLT
NUT

FLANGE
GASKET
GASKET
BOLT
DRAIN COCK

BOLT
FLANGE
GASKET
BOLT
NUT

X25I51207OZZ b%*3 SET SCREW

2 5 6 5 0 0 6 1 OOZZ 71blW*> GASKET
Z56500270OZZ 7JblW+> GASKET
X5722420002Z b99175.7 SPECIAL PLUG
2565004200ZZ 7JblW*> GASKET

HEX.PLUG
GASKET
O-RING
 -I

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LUBRICATING OIL RELIEF VALVE &
5DK-20 FILTER FITTING (REAR T/C) WITH COVER
 , .
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I*// - h/C-N
& LI+$j7(3(@$$fig)
LUBRICATING OIL RELIEF VALVE &
FILTER FITTING (REAR T/C) WITH COVER 5DK-20 3.5.4

S% EB.".R Name of Parts RR

Number Parts number gB.".gn Quantity

? 3 3 P ' Y Y > ASSY. L.O. RELIEF VALVE ASSY.

FILTER
SAUCER. L.O. FILTER
BRACKET. L.O. FILTER (RT)
GASKET. SIDE COVER (5)
SlOE COVER (5)

COVER-1. L.O. FILTER

WING BOLT
COVER-2. L.O. FILTER
BODY. RELIEF VALVE
RETAINER, VALVE SPRING

VALVE
VALVE SPRING CASE
CAP
SPRING
SPRING

BOLT
BOLT
BOLT
NUT
FLANGE

GASKET
GASKET
BOLT
DRAIN COCK
HT BOLT

NUT
FLANGE
GASKET
BOLT
NUT

SET SCREW
GASKET
GASKET
SPECIAL PLUG
GASKET

HEX. PLUG
GASKET
O-RING
 +
S#EEH;#5@ 0
TURBOCHAGER LUBRICATING OIL FILTER
 B$GBiR3B3EB0 *
TURBOCHAGER LUBRICATING OIL FILTER ~ D K - ~ O
-

SF *&Jse
m XII.QuantiW
Number Parts number gllsga Name of Parts 010
FILTER
FILTER

FILTER BODY
COCK
PACKING SEAT
PACKING (COCK)
COCK COVER

HANDLE 1 1
NUT (HANDLE) 1 1
SPRING (NOTCH BAR) 1 1
NOTCH BAR 1 1
STUD (COVER) 2 2

140 Y529000092 f Y t- (77) NUT (COVER)

143 Y529000104 IT,>+> (O+?-XI PACKING (CASING)
148 Y529000114 39 SHAFT
153 Y529000133 9-X CASING
159 Y529000148 I<> (0+9-XI SPRING (CASING)

173 Y529000154 I<-Y*> ( 3 % ' Y ? f - ~ b) PACKING (CAP NUT) 2 2

178 Y529000162 Y%Y?f9 b CAP NUT 2 2
182 Y529000170 IT-Y*> (1?-3+) PACKING (AIR PLUG) 2 2
185 Y529000174 1?-3* AIR PLUG 2 2
2 12 Y529000216 27-9F (O* b U Y ? ) STUD 4 4

2 15 Y529000223 /W!ffia ( n + k l J ~ ? ) SPRING WASHER

2 18 Y529000228 f ,Y t- ( 0 + t-1J5Y?) NUT
224 Y529000237 /<Y+> PACKING
228 Y529000241 =~7h NIPPLE
232 Y529000250 X I J - 7 7 , ~t- SLEEVE NUT

236 Y529000255 XY-Y SLEEVE 1 1

240 Y529000260 tfB> ( I \ > FJL) WASHER (HANDLE) 1 1
243 Y529000267 I<>tftj? ( I \ > Fib) SPRING WASHER (HANDLE) 1 1
246 Y529000272 Fx94%4lW NAME PLATE 1 1
259 C060502590 I b % > t- ASSY-280ME ELEMENT ASSY. (280ME) 2

260 Y529000306 1 b % > t-lt,~*> PACKING

262 C060502620 I L / % ? i - ASSY-350ME (20UMl ELEMENT ASSY.-350ME (20UM) 2
 -1 \ 7
- I T-E
0+mkt (KI$%fa$$)
a$~giHjE;@
TURBOCHAGER LUBRICATING OIL FILTER
5DK-20 FITTING (FRONT T/C) - WITHOUT COVER
 a#ER;B:B;Q +mkt (KG%B#E) -L
I 1 l'-E
TURBOCHAGER LUBRICATING OIL FILTER
FITTING (FRONT T/C) - WITHOUT COVER 5DK-20
iEi%#!%iY @.-.-..RHI 3 3 0-...--RH1 43
TURBOCHARGERTYPE
s4 *u.".se Name of Parts XPPQuantity
Number Parts number g8.".gn 010
E214950010 LO 0 * - N R 1 5 9 ' Y b-1 BRACKET-1. L O . FILTER 1 1
A 2 4 5 0 12 2 7 0 O*@'Y93 PIPING BLOCK
C060500013 O* FILTER
C06050001 4 O* FILTER "
E294970070 3Yf7. LO O* SAUCER. L.O. FILTER

C060502590 Ib%> b ASSY-2BOME ELEMENT ASSY.-280ME

C060502620 Ib%> b ASSY-350ME (20UM) ELEMENT ASSY.-350ME (20UM)

BOLT
BOLT
GASKET
FLANGE
GASKET

BOLT
BOLT
DRAIN COCK
 B$sB;m;H;a +mkt ( ~ ~ - A~1 l'-%!
~ ~ $ ~
TURBOCHAGER LUBRICATING OIL FILTER
5DK-20 FITTING (REAR T/C) - WITHOUT COVER
 a*EmH;#;a *mkl @;%a$$) - a1r-!%
TURBOCHAGER LUBRICATING OIL FILTER
FITTING (REAR T/C) - WITHOUT COVER
m$&%%
TURBOCHARGERTYPE
@......RHl 3 3 @...-.RHl 4 3

SF %.".SF *&&t&
n
Name of P a r t s
BmQuantity
Number P a r t s number 0 0
2 E214950020 LO 0 + 1 5 ? ' Y b-TC (RT) BRACKET. T/C L 0. FILTER (RT) 1. 1
7 A24501 2 2 7 0 O+e'Y32 PIPING BLOCK 1 1
10 C060500013 0+ FILTER I
11 C060500014 0+ FILTER ' 1
20 E294970070 99Y5.. LO O+ SAUCER. L 0 FILTER 1 1

201 C060502590 I L S Y b ASSY-2BOME ELEMENT ASSY.28OME 2

202 C060502620 I L S Y b ASSY-350ME (20UM) ELEMENT ASSY-350ME (20UM) 2

BOLT
BOLT
GASKET
FLANGE
GASKET

BOLT
BOLT
DRAIN COCK
I FllTlNG (FRONTT~C)- WITH COVER 1 5DK-20 1 3.7.31
i%%k%?f 0 . - - - R H 1 33 @......RHl 4 3
TURBOCHARGER TYPE
S3 %B.".ZE Name of Parts BQQuantitv
Number Parts number aBEgn 01 0
1 € 2 1 4 9 5 0 0 10 LO O+-NR13T5Y b.1 BRACKET-1. LO. FILTER 1 1
7 A24501 2 2 7 0 O+@>Y33 PIPING BLOCK 1 1
10 C060500013 0+ FILTER 1
11 C060500014 0+ FILTER " 1
21 €21 4 9 5 0 2 10 3TT3. LO O$ SAUCER. L.O. FILTER 1 1

23 €21 4 3 5 0 2 0 0 Fs 3it;lb b WING BOLT 6 6

25 €21 4 9 5 0 2 5 0 2lC-1. T/C LO O+-FT COVER-1. T/C L.O. FILTER-FT 1 1
26 E214950260 2lr-2. TIC LO O+FT COVER9. T/C L.O. FILTER-FT 1
27 E214950270 21C-3. T/C LO O+-FT COVER-3. T/C L.O. FILTER-FT 1 1
201 C060502590 I t / > > t- ASSY-2BOME ELEMENT ASSY.-280ME 2

202 C060502620 IL/>> b ASSY-350ME (20UM) ELEMENT ASSY.-350ME (20UM)

BOLT
BOLT
1
GASKET
FLANGE
GASKET

BOLT
BOLT
DRAIN COCK
STUD
 ; ( l l C-i$
-2
TURBOCHAGER LUBRICATING OIL FILTER
5DK-20 FITTING (REAR T/C) - WITH COVER
FITTING (REAR T/C) - WITH COVER

E214950020 LO 0 1 1 5 9 ' Y b-TC (RT) BRACKET. T/C L . 0 FILTER (RT)

A 2 4 5 0 12 2 7 0 OSe'Y3l PIPING BLOCK
C060500013 O+ FILTER
C060500014 0+ FILTER "

E2 1 4 9 5 0 1 50 ?I](-I. T/C LO o+-RT COVER-1. TIC L O . FILTER-RT

E214950160 A](-2. T/C LO O+-RT COVER-2. T/C L.O. FILTER-RT

E214950170 AJr-3. T/C LO O+-RT COVER-3. TIC L.O. FILTER.RT
E214950210 39tf5, LO O+ SAUCER. L.O. FILTER
E214350200 $3 3 X J b b WING BOLT
C060502590 Ib%> b ASSY-2BOME ELEMENT ASSY.-280ME

BOLT
BOLT
GASKET
FLANGE
GASKET

X 2 0 0 0 10 0 2 8 Z Z Xlb b BOLT
X200010070ZZ *lb b BOLT
Z580203OOOZZ FbYIY9 DRAIN COCK
X 2 0 0 0 0 6 0 1 OZZ itiJb b BOLT
'A2P7K%=/ Y - 7 0 A
ITJ

COOLING WATER PUMP - 7 0 A

 "B7k%=/Y
ITJ - 70A
COOLING WATER PUMP - 7 0 A 5DK-20
0--EK, @...9K,
NORMAL ROTATION REVERSE ROTATION
as B.".S4 * rn Name of Parts
Number P a r t s number &8% 1

C.W. X 2 Y F70AR170 C.W. PUMP ASSY. F70AR170

C.W. $27' F 7 0 A L I 70 C.W. PUMP ASSY. F7OALl70
C.W. X 2 7 F70AR160 C.W. PUMP ASSY. F7OARl60
C.W. X 2 l F70AL160 C.W. PUMP ASSY. F7OAL1 GO

BEARING CASE
PUMP BODY (2) 70A-R-FC
PUMP BODY (2)70A-L-FC
MECHANICAL SEAL HOLDER-FC
IMPELLER (R)-160

IMPELLER (L)- 1 6 0
IMPELLER (R)-170
IMPELLER (L)-170
MOUTH RlNG
NUT (R), IMPELLER

NUT (L), IMPELLER

PUMP SHAFT-R
PUMP SHAFT-L
MECHANICAL SEAL
MECHANICAL SEAL

CUT RlNG
SPECIAL NUT
SPECIAL WASHER
COLOR

STUD
NUT
NUT
STRAIGHT PIN
KEY

KEY
SNAP RlNG
BEARING
OIL SEAL
O-RING

DRAIN COCK
2 5 7 1 5 0 1 OOOJZ TAPER PLUG
X570003OOOJZ HWPLUG
GASKET
CLAW WASHER
.,-

COOLING WATER PUMP FITTING

 -Aa17J<%
IT1 2 YrniYt
COOLING WATER PUMP FITTING 5DK-20

Z&Z %;".Bq Name of Parts RSQuantity

Number Parts number 8E'g@ 010
1
C.W. PUMP GEAR (223)
C W PUMP GEAR (226)
GASKET

NUT
1xIl/;$aSmzm%=/Y
NOZZLE COOLING OIL PUMP

Section "A-A"
I NOZZLE COOLING OIL PUMP
SE SBSBE Name of Parts Ha
Number Parts number gEEg4; Quantity

b < J b i t i > l ASSY. V06L-18 OIL PUMP ASSY. VOGL-1 8

COVER.PUMP BODY
PUMP BODY
RELIEF VALVE
CAPSAFETY VALVE SPRING
PUMP DRIVING GEAR SHAFT

PUMP DRIVEN GEAR SHAFT

PUMP BUSH (2)
PUMP BUSH (1)
GASKET. CHECK VALVE BODY
OIL CUT RING (2)

BLANK PLATE
SPRING

BOLT
BOLT
NUT
CLAW WASHER
STRAIGHT PIN

KEY
SNAP RING
BEARING
OIL SEAL
BANJO

BANJO PLUG
OIL SEAL
GASKET
GASKET
TAPER PLUG
 X~L;WISEQ~Y~~;~
NOZZLE COOLING OIL PUMP FITTING
 / Xl i/;f;a;a$3aKt
=/
NOZZLE COOLING OIL PUMP FITTING

SF 3ESF Name of Parts BR

Number Parts number gBEg.M; Quantity

GEAROIL PUMP
GASKETPUMP BODY

504 X200008018ZZ iKlb b BOLT 4

/ XIL/;$%PSQflE#
NOZZLE COOLING OIL RELIEF VALVE
 7 p-9
/ X')L;%BSh3E#
NOZZLE COOLING OIL RELIEF VALVE 5DK-20

as Bsse Name of Parts ax

Number Parts number 3'g8J Quantity

OIL RELIEF VALVE ASSY. 1

RELIEF VALVE BODY

RELIEF VALVE
SPECIAL WELDING SEAT
CAP NUT
ADJUSTING SCREW

SPRING CASE
SPRING

NUT
FLAT WASHER
BANJO
GASKET
GASKET
Et#$E (SGSG)- l/C DH@
GAUGE BOARD (FRONT T/C) - I/C : DH TYPE
 I

St%& (ZGag) - l/C DH3!

GAUGE BOARD (FRONT T/C) - I/C : DH TYPE 5 ~ ~ ~ 2 0
i&GtRl%z @......RHl 33 @.-,.RH143
TURBOCHAGERTYPE
se
Number
BE=
Parts number Name of Parts

E2 13 0 5 0 0 7 0 94+JW-6 GAUGE BOARD-6

C047070240 Z 9 9 Y j L (I) CUSHION RUBBER (1)
C047070250 94+1<Y b 9 3 I U W SPECIAL SPRING. GAUGE BOARD
€21 3 0 5 0 1 80 94*1W759'Y b-L BRACKET-L:GAUGE BOARD
E213050190 94+1W759Y b-R BRACKET-R. GAUGE BOARD

C012400011 it-X HOSE

C012400012 iti-X HOSE
E2 1 3 0 5 0 2 2 0 Y-illVblYY1 SUPPORT. GAUGE VALVE
E213050230 94*1<YiKIb b BOLT. GAUGE BOARD
C012400013 it-X HOSE

€2 1 3 0 5 0 2 6 0 94+JW159.:, b74X9YX DISTANCE. GAUGE BOARD BRACKET

E213050290 7'4X9YX DISTANCE
E213050300 74X9YX DISTANCE

X 2 0 0 0 0 6 0 1 OZZ ZJb b BOLT

X200006016ZZ 8th b BOLT
X200010020zz Zlb b BOLT
X20000602OZZ Zlb b BOLT
X220006OOOZZ +Yb NUT

NUT
NUT
SPECIAL NUT
FLAT WASHER
SPLIT PIN

GASKET
BOLT
BOLT
BOLT
BOLT

X200012025ZZ ZJb b BOLT

C061500851 ?347>94 70 (2) 2:l RlOOO TACHOMETER 70 (2) 2:l R 1 0 0 0

C061500921 %14?)/9470 (2) 2.1 R 1 5 0 0 TACHOMETER 70 (2) 2.1 R 1 5 0 0
C06 1 5 0 1933 7b*!~-YJb FLEX. CABLE

X2200040002Z +Yb NUT

X245204014ZZ +YKX&9 + P A N MACHINE SCREW 4 4
 Et#$k (ZCgSE) - l/C : D H g
GAUGE BOARD (FRONT T/C) - I/C : DH TYPE

se BEse
Number Parts number Name of Parts BMQwnt'itv
@ I @
I
60 PRESS. GAUGE. 0 1/4U3-00
6 0 PRESS. GAUGE. 0 1 /4U6-00
60 PRESS. GAUGE. 0 1 / 4 U 1 0 - 4 0
6 0 PRESS. GAUGE. 0 1 /4U10-50
6 0 PRESS. GAUGE. 0 1 /4U10-23

60 PRESS. GAUGE, D 1/4U6-24

DAMPNER
NEEDLE VALVE
NAME PLATE-ST1
JOINT

COCK CONNECTOR
JOINT
CUP NUT

+ PAN MACHINE SCREW

GASKET
 W#& (i$5%%4%: RH133) - l/C : DHBg
GAUGE BOARD (FRONT T/C : DH133) -
I/C : DHB TYPE 5DK-20

se
Number
%8.".?SF
Parts number Name of Parts BM
Quantity

GAUGE BOARD-6
CUSHION RUBBER (1 )
SPECIAL SPRING, GAUGE BOARD
BRACKET-L.%AUGE BOARD
BRACKET-R. GAUGE BOARD

HOSE
HOSE
BOLT. GAUGE BOARD
HOSE
DISTANCE

SUPPORT. GAUGE VALVE

BOLT
BOLT
BOLT
BOLT
NUT

NUT
NUT
SPECIAL NUT
FLAT WASHER
SPLIT PIN

GASKET
BOLT
BOLT

C061500851 ;h4?>?4 7 0 (2) 2: 1 R1000 TACHOMETER 7 0 (2) 2: 1 R1000 1

C061500921 ;h47>?4 7 0 (2) 2.1 R1500 TACHOMETER 7 0 (2) 2.1 R1500 1
CO61501933 7b*?-71b FLEX. CABLE 1 1

NUT
+ PAN MACHINE SCREW
' I --
it#@ : RH 133) - I/C : DHBE!
(Z$%aG
GAUGE BOARD (FRONT T/C : DH133) -
0 : DHB TYPE
5 ~ ~ - 2 I/C

6 0 PRESS. GAUGE. 0 1/ 4 U 3 - 0 0
60 PRESS. GAUGE. D 1/ 4 U 6 - 0 0
60 PRESS. GAUGE. 0 1 /4U10-40
60 PRESS. GAUGE. 0 1 /4U 1 0 - 5 0
60 PRESS. GAUGE. 0 1 /4U 1 0 - 2 3

60 PRESS. GAUGE. D 1/4U6-24

OAMPNER
NEEDLE VALVE
NAME PLATE-ST1
JOINT

COCK CONNECTOR
JOINT
CUP NUT

+ PAN MACHINE SCREW

GASKET
 ,,

=t%&
D (f&%Bi$Z)
GAUGE BOARD (REAR T/G) 5DK-20

SF 88SEF4 8KE8VJ Name of Parts

Brn
Number Parts number Quantity

BOLT. GAUGE BOARD

GAUGE BOARD-6
BRACKET. GAUGE BOARD
SUPPORT. GAUGE VALVE
CUSHION RUBBER (1 I

SPECIAL SPRING. GAUGE BOARD 2

HOSE 2
HOSE 2
HOSE 2

X 2 0 0 0 0 6 0 1 OZZ filb i- BOLT

X200006016ZZ SJb b BOLT
X200006016ZZ SJb b BOLT
X220006OOOZZ TYb NUT
X220006000ZZ T 5 Yb NUT

NUT
SPECIAL NUT
FLAT WASHER
SPLIT PIN
GASKET

BOLT
BOLT
NUT

TACHOMETER 70 (a
2:1 R 1 0 0 0 I
TACHOMETER 70 (2) 2: 1 R 1500 1
FLEX. CABLE I 1

NUT
+ PAN MACHINE SCREW

B.auantiW

Y703093000 6 0 T - 3 D1/4U3-00 0 PRESS. GAUGE 0 1/ 4 U 3 - 0 0

Y703096000 6 0 T - 3 D l /4U6-00 6 0 PRESS. GAUGE 0 1/ 4 U 6 - 0 0
Y703001040 60 7 - 3 D 1 / 4 U I O - 4 0 60 PRESS. GAUGE. 0 1 / 4 U 1 0 - 4 0
Y703001050 60 Y -3 D l /4U 1 0 - 5 0 60 PRESS. GAUGE. 0 1 / 4 U 1 0 - 5 0 1
Y703001023 6 0 T - 9 D1/4U 10-23 6 0 PRESS. GAUGE. 0 1 / 4 U 1 0 - 2 3 1
 WSJi (@%a%)
2 0 BOARD (REAR T/C)
5 ~ ~ ~GAUGE
O..---.iE7RlX&/XIb%M O-.....AEE@lLb&/XIb%B
F.W. NOZZLE COOLING 0.0. NOZZLE COOLING
SF %K,o,Se * n
Name of Parts DQuanti
Number Parts number mBnog% @ I @
I
C10 Y703096024 60 T-3 D1/4U6-24 6 0 PRESS. GAUGE. D 1 /4U6-24 1 1
C1 1 Y 142030300 927f - DAMPNER 1 1
C12 YO1 2 3 5 0 0 8 5 Z- F l b l O b 7 NEEDLE VALVE 5 6
C14 YA506471750 T-f*%41<2-STl NAME PLATE-ST 1 1
C25 E213650250 e'Y93 JOINT 4 5

COCK CONNECTOR
JOINT
CUP NUT

+ PAN MACHINE SCREW

GASKET
 . jlp%ugg
$$$+qg%gE
FUEL SHUTDOWN 6 CONTROL PISTON
 HgwgE #lp$#gg -
FUEL SHUTDOWN & CONTROL PISTON 5DK-20

S% *&.mBe xp..
Number P a r t s number gBzafi Name of P a r t s Quantity

FUEL SHUTDOWN DEVICE G1

CYLINDER
SHUTDOWN PISTON
CONTROL PISTON
ADJUST BOLT
COVER.?

COVER-2
LABEL. FUEL SHUTDOWN DEVICE
MAIN SPRING
AIR FILTER

BOLT
SPECIAL NU1
O-RING
O-RING
O-RING

O-RING
O-RING
 $$#Eg@g jfp$?@Emiq
FUEL SHUTDOWN 6 CONTROL PISTON
5DK-20 FITTING
 g$#qm&gjg #lp$,qgjsQg{q
FUEL SHUTDOWN 6 CONTROL PISTON
FITTING 5DK-20

?SS 8EES9 Name of Parts @.H.

Number Parts number Ouantlty

S107809010 G l f S 9 F.O. 3 1 . 9 Y Y 3 ' f F.O. SHUTDOWN DEVICE G1 N P E 1

A333790010 fi7aX-fyY OVER LOAD INDICATOR 1
L510009010 itiEF231%-9 POTENTIOMETER 1

E2 16050020 7 4 > Y 9 F Y 5 T 5 Yb G f l 9 BRACKET.F.0. SHUTDOWN DEVICE-G 1

E216050090 FO 9?9'/L/)<-. G f j 9 LEVER. F.O. SHUTDOWN-G 1
E216050100 FO 9?929;/9-Gfl9 LINK. F.O. SHUTDOWN DEVICE I
E201650050 3 € Y O Y F 9 9 W (2) CONTROL ROD BEARING (2) 1
E216050150 X7ILlhJb7b><7lJ>9 SPHERICAL PLAIN BEARING 1

BOLT
BOLT
TOOTHEOLOCKWASHER
SPRING PIN
SPRING PIN

SNAP RING
NUT
TOOTHED LOCK WASHER
BOLT
BOLT

E2 16450030 h7hT>9Y*77tr~ t- BLACKET. OVER LOAD DETECTOR 1

E296400090 blc- LEVER 1

BOLT
NUT
BOLT
HEX. SET SCREW
SPRING PIN

E215150010 i K ? Y 9 3 % - 9 3 7 T ~ i. (GI) BRACKET (G 1 ). POTENTIOMETER 1

E2 16050080 F.0. > ? 9 Y b l < - LEVER. F.O. SHUTDOWN 1
E295 150060 i K ? Y 3 3 9-9blc- (2) LEVER (2). POTENTIOMETER 1
E2 1 5 1 5 0 0 7 0 U'/9 LINK 1

NUT
BOLT
BOLT
BOLT
SPRING PIN

FLAT WASHER
LlNK PIN
SPLIT PIN
SPRING PIN
SF
Number
888.ES9
Parts number 8K'gw Name of Parts
alp
Quantity

BOLT
FLAT WASHER
LINK PIN
SPLIT PIN
SPRING PIN
ITEM

8.1 5DK-20 BLOWER CLEANING PARTS - T/C : R H 1 3 3

 2'07-%fgS - T/C : RH 133
BLOWER CLEANING PARTS - T/C : RH 133 50~40

se
Number
BB.".SF
Parts number aEg@ Name of Parts Pi*
Quantity

C044090010 ASSY
1073?13/3 BLOWER SYRINGE ASSY.

SYRINGE
HOSE NIPPLE
SOCKET
NAME PLATE. BLOWER SYRINGE

PLUG
VINYL HOSE
JOINT PIECE (RU)

HOSE BAN0
u 7 - T C RH 143
BLOWER CLEANING PARTS - T/C : RH 143
 7 7 - T C : RH 143
BLOWER CLEANING PARTS - T/C : RH143

SF *&&E
m

Number P a r t s number Name of P a r t s XQuantity

.r(

C044090010 7073 Y 23 ASSY BLOWER SYRINGE ASSY.

SYRINGE
HOSE NIPPLE
SOCKET
NAME PLATE. BLOWER SYRINGE

PLUG
CLUMP
VINYL HOSE
PlPE

X546110030JZ '9373ASSY BANJO ASSY.

Z584OOl5OOZZ fi-XD F HOSE BAND
2 5 8 5 1 1OOO3ZZ t 1 2 l P lF PlPE SUPPORTER
$JjE3?y+ ( 9 9 2 9 4 y p)
OIL PRESS JACK (CYLINDER HEAD)
 :QE9-py+ ( 9 Y 2 9 - y F)
OIL PRESS JACK (CYLINDER HEAD)

SF %ES% am
Number Parts number gBzga Name of Parts Quantity

5 E219550050 9,,y+X9> F - ~ FY JACK STAND-HEAD

7 E219550070 3?,~+9IJ>9 JACK CYLINDER
9 E219550080 ~ ? , Y + Y Xb> JACK PISTON
9 E219550090 L Y I < U Z Ib~ TENSION BOLT
15 E339500140 3 ? , ~ + 1 \ > FJb JACK HANDLE

BACK-UP RlNG
BACK-UP RlNG
SOCKET COUPLING

HEX. SET SCREW

BALL
O-RING
O-RING
;QJwT Y * (%5'wFT ~ 7 )
OIL PRESS JACK (METAL CAP)
 % E ~ ? Y = (%9WF?~71
F
OIL PRESS JACK (METAL CAP)

SF 3ESe Name of Parts E

m
Number Parts number 'n'gm Quantity

6 E219550060 ijt3Y+X9>F-+t,~f JACK STAND-CAP

7 E219550070 ijf ,~*3'J79 JACK CYLINDER
8 E219550080 ~ ~ , Y +k C
7 X JACK PISTON
15 E339500140 3f>~+l\Y FJL JACKHANDLE
18 E219550180 1<~~977~1'J77 BACK-UP RING

BACK-UP RlNG
SOCKET COUPLING

HEX. SET SCREW

BALL
O-RING
O-RING
 3QESL
OIL PRESS. RAM

Detail "A" Detail "B"

 78
3
SQE7lA
OIL PRESS. RAM

SE %8ES4
Number P a r t s number 3Eg8J Name of Parts Quantity
CYLINDER. OIL PRESS. RAM
SPECIAL BOLT
PISTON. OIL PRESS, RAM
PLUG. C~LINOER
PULL PIECE (1 )

PULL PIECE (2)

SOCKET COUPLING
PULL PIECE (3)
DUST SEAL
BACK-UP RlNG

BACK-UP RING
PULL PIECE. OIL PRESS. RAM

SET SCREW
O-RING
O-RING
BOLT
 Pub. No. EE74E-11015

CONSTRUCTION & OPERATION

REPAIR & MAINTENANCE
 WARNINGS
The following definitions and warning signs are used in this service manual.
These are extremely important to safe operation.
Important points are described to prevent bodily injury and property damage.
They must be fully understood before beginning governor maintenance.

Improper maintenance can result in injury and property damage.

1
MEANINGS OF MARKS
The following marks are used in this service manual to facilitate correct governor
maintenance.

I Advice Procedures that must be performed to enable the best possible governor I I
maintenance.
Note Information assisting in the best possible governor maintenance.
 FOREWORD
The RHD hydraulic governor is a high
performance variable speed governor for use
with main and auxiliary marine engines. engines
for electric generators and general power
engines.
This service manual describes the construction
and operation. repair and maintenance. and
adjustment of the RHD6 and RHDIO hydraulic
governors.
The contents of the manual. including
illustrations. drawings and specifications were
the latest available at the time of printing.
The right is reserved to make changes in
specifications and procedures at any time
without notice.
Bosch K.K.
Sales Automotive Aftermarket Division

CONTENTS
Page Page
DISASSEMBLY ...................................23
FEATURES ......................
.............. 1
SPECIAL TOOLS .................................. 23
SPECIFICATIONS ................................ 2
EXPLODED VIEW ................................ 24
CONSTRUCTION ................................. 6 PART LIST ......................................... 25
PREPARATION ....................................26
OPERATION ....................................... 8
DISASSEMBLY .....................................26
ENGINE STARTING ...............................8
NORMAL OPERATION ..........................9 INSPECTION ................................... 31

.
LOAD INCREASE .................................
ADJUSTMENT ..................................
ENGINE STOPPING .............................
AUXILIARY STARTING BOOSTER ..... SPECIAL TOOLS ..................................
SPEED DROOP MECHANISM ............. PREPARATION .................................. .
COMPENSATOR MECHANISM ........... OPERATION TEST ...............................
ADDITIONAL DEVICES ........................
ADDITIONAL DEVICES ......................
TROUBLESHOOTING ........................
GOVERNOR MOTOR ...........................
PNEUMATIC CONTROLLER ...............18 PART NUMBER EXPLANATION ....... 56
HYDRAULIC CONTROLLER ................ 19
HANDLING .........................................20
GOVERNOR INSTALLATION .............. 20
HYDRAULIC FLUID ..............................20
AIR BLEEDING &
COMPENSATION ADJUSTMENT ........ 21
LINKAGE CONNECTIONS ...................22
DAILY INSPECTION.............................22
IN-SERVICE INSPECTION .................. 22

1. The RHD governor has a large controlling
force, despite its compact size.
2. As the hydraulic fluid is contained in the
governor, piping and sub-tank installation
are unnecessary when installing the
governor on the engine.
3. As the power piston utilizes a differential
system, the operating force is uniform.
Moreover, it is not necessary to install a
return spring in the fuel control linkage.
When play in the linkage system is
excessive, however, it is necessary to install
a spring at the end of the system to absorb
this play.
4. The governor is able to rotate in either
direction, and therefore it can be used
without modification on engines which rotate
in the reverse direction.
5. Because the normal operating speed is low,
governor endurance is high, and gearing is
simple when installing the governor on low
and intermediate speed engines.
6. T h e g o v e r n o r h a s a s p e e d d r o o p
mechanism and a compensator
mechanism, enabling it to be easily and
freely adjusted.
The adjustment range is very wide, enabling
governor use on a wide range of engines.
The governor can also be used as an
isochronous governor with 0% speed droop.
7 Qk ,
/
FEATURES
7. The governor body's high tensile aluminum
alloy casting makes it extremely lightweight.
8. The governor can be equipped with a
governor motor, a pneumatic controller and
a hydraulic controller.
9. R H D 6 a n d R H D I O g o v e r n o r s a r e
interchangeable. For example, if a higher
pressure injection system is required or if
the governor's control force is insufficient to
cope with the demand for increased engine
output, decreased fuel consumption or the
use of lower quality fuel oil, then the RHDIO
can replace the RHD6.
10. T h e g o v e r n o r is e q u i p p e d w i t h a
standardized piping connection to enable
the installation of an auxiliary starting
booster.
11. O f t h e R H D I O g o v e r n o r ' s m a i n
components, 80% are identical to those
of the RHD6. Almost 100% of the remote
control device's components are identical
to those of the RHD6.
 f 71

SPECIFICATIONS

Zontrol force 15.9 J {0.6 kgf. m) .

19.8 J { I .O kgf m)
Iutput shaft torque . .
9.8 N m { I .0 kgf m} 15N-m(1.5 kgf-m}
Iutput shaft operation angle 135" 140'
'ewer piston diameter I small: # 17.7; Large: # 25 1 small: # 18.6; Large: # 27
I Standard rating: 600-2,000 rlmin
(Normal: 1,706-2,000 rlmin)
;ontrolled speed range
High
- speed
. rating: 800-2,400 rlmin
I (Normal: 1,goo--2,400 rlmin)
Vlaxirnum allowable speed 12,500 rlmin
zompensator Needle valve type
Speed droop adjustment
ange
1 O-approx 10% (rated)

3irection of rotation I Clockwise 8 counterclockwise

iydraulic fluid
3ry weight (lever type)
Sovernor drive power
Applicable engines
SAE20W-40 (Mobiloil)
5.5 kg 15.7 kg
I Max approx 0.2 kW ( 0 . 3 ~ ~ )
Low speed: up to approx Low speed: up to approx
1,500 kW (2,000 ps} 2,200 kW {3,000 ps}
Intermediate speed: up to
approx 1,850 kW {2,500 ps}
High speed: up to approx High speed: up to approx
2,200 kW {3,000 ps} 2,950 kW (4.000 DS)

PE (all types) PE (all types)

P F I Z x I 8 cvl PFICX x 18 cyl
PFIC, - 1 ~ d 16 x (18) cyl PFIWX x 16 cyl
Applicable injection pumps PFIW 6, cvl
PFIGXx12cyl
P F I D X x 8 cyl
P F I E X x 6 cyi
I

The main difference between the RHD6 and the
RHDIO is the power piston. The parts adjacent
to the power piston also differ.
Note:
1. The method of connecting fuel linkages and
the amount of corresponding resistance
differ depending on the size of the applicable
engine and the size and number of the
injection pumps.
Consequently, engines with little friction loss
c a n be used i n high output engine
applications and, conversely, engines with
large friction loss can only be used in
applications equal to or less than those
specified above.
2. Simply because the governor has surplus
control force does not necessarily mean that
stable operation can be ensured.
In order to ensure stable operation and to
prevent the speed from exceeding t h e
necessary speed, the inertia of the engine
and the drive system should be as large as
possible.
The figure below shows the RHD6 hydraulic governor (lever type). The RHDIO has a special plug
(piping connection) for auxiliary starting booster installation located below the center of the name
plate.
HD6 and RHD10-MC, -MCL type governor motors
MC type with governor motor

Approx 118
I j 29

JIS C3410 250V type

0
2

Current
Voltage Cycle Speed
consumption
AC IOOV 50160 Hz 1,20011,450 rlrnin
AC220V 50160 Hz 1,20011,450 rlmin
Motor
DC24V 2,200 rlmin
DC 100V 2,200 rlmin
Gear head 1118, 1/30, 1150, 1/75, 11100, 11150, 11300, 11375, 11450, 11600,
(speed reduction ratio) 11900, 111500
The speed setting time can be determined freely by choosing from
any of the above gear heads.
Speed setting time The standard specified time, however, is approimately that shown below.
Main engines: 20-25 sec dead slow to rated speed
Engines for generators: 7-9 secll Hz
Standard specification
Lower limit: 600 rlmin
Upper limit: 2,000 rlmin
Prior to shipment, the lower limit is set at 600 rlmin, and the upper at
Limit switch adjustment
1,600 rlmin.
range
High speed specification
(RHD6, 10 -MCL)
Lower limit: 800 rlmin
Upper limit: 2,400 rlrnin
Prior to shipment, the lower limit is set at 800 rlmin, and the upper at
2.000 rlmin.
MCL type with governor motor
Speed sening screw
\
Lower limit sw,ititch upperlimit switch
 73 ->
CONSTRUCTION
Gear pump
The above figure shows a cutaway view of the
RHD6 hydraulic governor.
The governor is installed directly on the engine.
Engine crankshaft speed is increased using a
suitable gear ratio, and is then transmitted to
the governor gear shaft. This rotation is
transmitted to the hydraulic governor's gear
pump, which pressurizes the hydraulic fluid.
The gear pump pumps hydraulic fluid from the
governor's hydraulic fluid tank in through the low
pressure side of the regulating valve, and
delivers the high pressure hydraulic fluid to the
pilot valve. The regulating valve also regulates
the pressure of the fluid pressurized by the gear
zear shafl
pump (RHD6: 1. I 8 MPa {I2 kfglcm2}, RHDI 0:
1.47 MPa (15 kgf/cm2})and returns excess fluid
to the gear pump's intake side.
The gear pump has four check valves so that
governor performance does not vary, even when
the governor rotates in the reverse direction.
The gear pump's driven gear and the sleeve are
unified. One end of the sleeve is connected lo
the governor flyweight. The pilot valve inside
the sleeve is moved up and down in response
to the flyweight's centrifugal force to control the
flow of hydraulic fluid to the power piston,
reacting promptly to variations in engine load to
rotate the terminal shaft.

Air breather
Flyweight assembly
Thrust needle roller bearing
Gear shaft
The flyweight's centrifugal force is transmitted
to the pilot valve by the thrust needle roller
bearing. The speeder spring's force is always
acting against the flyweight's centrifugal force.
The set force of the speeder spring can be
changed by moving the control lever.
The flyweight assembly is an oil damper type
assembly. When sleeve rotation is transmitted
to t h e flyweight, the oil acts to absorb
u n n e c e s s a r y high frequency rotation
fluctuations and enable stable output.
The power piston, which controls the fuel
injection quantity to the engine, is a simple
CONSTR CTlON7P
Lower compensating spring
Compensating piston
Compensating bushing
P-RHDRdO
mechanism which enables high stabilized
output.
The power piston is operated by the hydraulic
fluid to move in both the fuel increase and fuel
decrease directions. The power piston rotates
the terminal shaft via the guide lever and the
terminal arm to directly control fuel injection
quantity.
In addition to having a larger diameter power
piston, the RHDIO is equipped with a piping
connection to enable the connection of an
auxiliary starting booster to the top of the power
piston.
 79i / j
OPERATION
NGlNE STARTING
Control lever
\ I
/
Gear shaft
+
When the engine is stopped, the flyweight is
pushed down and closed by the force of the
speeder spring. Consequently, the pilot valve
is in its lowermost position.
When the control lever is then moved in the fuel
increase direction, the engine is rotated by
compressed air, etc, the gear pump is operated
through the gear shaft and the hydraulic fluid is
pressurized.
Because the flyweight is pushed down by the
speeder spring and the pilot valve does not
-
- Fuel decrease
Fuel increase
a
, High pressure
hydraulic fluid
- Low pressure
hydraulic fluid
uCross section
move, the pressurized hydraulic fluid passage
and the passage to the power piston are open,
and the hydraulic fluid pressurized by the gear
pump is delivered through the pilot valve to the
top and bottom of the power piston.
Because the ratio of the areas of the power
piston subject to hydraulic pressure is 1 2 , the
power piston is immediately moved up (in the
fuel increase direction) to move the output shaft
side lever in the fuel increase direction through
the system of links and facilitate engine starting.

NORMAL OPERATION
Control lever
\?I
.
When the control lever is moved in the speed
increase direction, the speeder spring is
compressed by the speed control shaft. When
the speeder spring force exceeds the flyweight's
centrifugal force, the pilot valve is moved down.
Because of this, the high pressure hydraulic fluid
passage and the top and bottom power piston
passages open, and the high pressure hydraulic
fluid pressure moves the power piston in the
fuel increase direction to increase engine speed.
As the engine speed increases, the flyweight's
centrifugal force increases and the pilot valve
BOO
OPERATION
High pressure
hydraulic fluid
Low pressure
hydraulic fluid
Cross section
, Power piston
is pulled up. At the position where the speeder
spring force and the flyweight's centrifugal force
balance, the high pressure hydraulic fluid
passage and the bottom power piston passage
are closed by the pilot valve land. Because of
this, the power piston maintains this position and
a constant stable speed is maintained.
At this time, excess hydraulic fluid overflows
through the regulating valve and is returned to
the gear pump's intake side to maintain a stable
hydraulic fluid pressure to the pilot valve.
 9
OPERATION
LOAD DECREASE
Control lever
~ e e d lvalve
i
When engine load decreases, and governor
rotation has increased, the flyweight's centrifugal
force increases and moves the pilot valve up.
This opens the center pilot port so that the
hydraulic fluid in the bottom of the power piston
returns to the governor's hydraulic fluid tank.
Consequently, the power piston is moved down
(in the fuel decrease direction) by the high
pressure hydraulic fluid in the top of the cylinder
and the speed is decreased to the previous
balanced condition.
W h e n the power piston moves down, it
compresses the speeder spring through the
speed droop mechanism's floating lever, the
pilot valve moves down, and the land moves to
a position where it closes the pilot port.
When the power piston moves down, its
downward movement is also transmitted to the
compensating pushrod and piston through the
compensating spring in the power piston.
Because of this, the negative pressure
generated in the compensator chamber relieves
the upward movement of the pilot valve.
momentarily applying a force in the downward
direction.
The compensating effect ends when hydraulic
fluid from the governor chamber flows in through
the needle valve for a fixed period to restore
the negative pressure in the compensator
chamber to atmospheric pressure.
Consequently, when the pilot port is closed by
t h e s p e e d d r o o p mechanism and t h e
compensator mechanism, the power piston and
the terminal shaft stop at a new position where
the fuel necessary to operate the engine at
normal no-load speed is supplied when the
engine load is cut.
 @?;5-./
OPERATION

LOAD INCREASE

\
Control lever
qFloatiy lever -
-
,GJ2
Fuel decrease
Fuel increase
I
.High pressure
hydydr1ic ,,,,id
Low pressure
hvdraulic fluid
0 cioss section

Speeder spring
,Power piston

/
Needle valve
P-RHDRdl8

When the engine load increases, engine speed As t h e p o w e r p i s t o n m o v e s u p , t h e

decreases and the governor's operation is
exactly opposite to that at load decrease.
Thus, the pilot valve moves down, high pressure
hydraulic fluid flows into the chamber below the
power piston, and the power piston moves
upward in the fuel increase direction to increase
the engine speed and return it to the previous
balanced condition.
When the power piston moves up, the speeder
spring is moved upward by the speed droop
mechanism through the floating lever.
Consequently, the pilot valve also moves
upward until the pilot valve land closes the pilot
port.
compensating piston is drawn up by the lower
compensating spring, and the compensator
chamber pressure becomes positive.
Because of this, the speed at which the pilot
valve moves down is relieved as this pressure
is applied in an upward direction.
The compensating effect ends when the
hydraulic fluid flows from the governor chamber
in through the needle valve for a fixed period to
restore the pressure in the compensator
chamber to atmospheric pressure.
In this way, the pilot valve returns to its regular
position and the engine is maintained at the new
power piston position.
 03
OPERATION

:NGINE STOPPING
High pressure
hydraulic fluid
L o w pressure
hydraulic fluid
Cross section

,Power piston

/
Needle valve

Because the governor's power piston is moved
i n the fuel decrease direction by the high
pressure hydraulic fluid above the power piston,
when the control lever is moved to the stop side
the pilot valve is moved up by the speeder
spring.
rerrninal lever
The high pressure hydraulic fluid in the bottom
of the power piston is then returned to the
governor's hydraulic fluid tank, the power piston
moves down (in the fuel decrease direction) and
the engine can be forcibly stopped.
The engine can also be stopped by remote
control by a governor motor or pneumatic
controller. These remote control devices are
also installed with a synchronizer to enable
manual engine stopping.
When the engine is not stopped on the governor
side as described above, but is instead stopped
by a handle which mechanically sets the control
rack to the non-injection position, it is necessary
to install a spring in the link system to prevent

\
Hydraulic governor
Engine stop handle
I excessive force being applied to the govern or.
As this governor does not have a load limit
P.RHDR-OI2 device, it is also necessary to install a spring as
above when it is necessary to mechanically limit
the load.
 Control lever High pressure

\ 3. --c Fuel decrease

Fuel increase
- hydraulic fluid
Low pressure
hydraulic fluid
Cross section
compressed air

+\ Gear shaft

Compressedair
,
'Iarting
boosler
npensarlon
,Return check ;
1

valve P-RHDR41

An auxiliary starting booster can be connected
to the RHDIO governor when necessary. The
following explains engine operation at starting
when a booster has been connected to the
governor.
When compressed air is supplied to the booster
piston to facilitate starting, the piston
compresses the spring and the hydraulic fluid
in the chamber opposite the compressed air is
guided through the discharge side check valve
to the chamber above the power piston.
As the governor at this time is in the engine
starting status, as explained previously, the
hydraulic fluid also flows through the pilot valve
to the chamber below the power piston.
As the governor is simultaneously being turned,
high pressure hydraulic fluid from the gear pump
is also acting on the top and bottom chambers
of the power piston.
Consequently, hydraulic fluid pressurized by the
booster moves the power piston in the fuel
increase direction faster than normal, and it
arrives at the fuel position necessary for starting
faster than normal.
The booster is an effective means of assisting
starting for engines such as those for emergency
power generators, where mis-starting must be
avoided, and high output engines where the
governor's surplus output is small.
Boosters are manufactured especially for the
RHD6 and RHD10 governors.
 c,
&=,s E'
OPERATION
SPEED DROOP MECHANISM
a Full load maximum
U)
m
C
C
LU
Time until
Speed droop (%) = No load maximum speed (N,) -full load maximum speed (N)
Full load maximum speed (N)
With the speed droop mechanism, speed droop
the speed droop adjuster.
-
can be varied freely from 0% 10% by adjusting
When the speed control shaft position is fixed
using the control lever, and the engine speed is
maintained at a speed suitable for a fixed load,
should the load decrease, the power piston is
moved in the fuel decrease direction (ie, down)
to prevent an excessive speed increase.
With this power piston movement, the speed
droop adjuster attached to the terminal arm turns
and pivots the floating lever in a clockwise
direction around the wire A to compress the
speeder spring and apply a new set load.
Because the speeder spring's set load is
increased, the pilot valve is again moved down
to a position where it closes the pilot port, the
flyweight's centrifugal force and the speeder
spring are balanced at an engine speed a little
higher than the initial balanced condition, and
this engine speed is maintained.
Speed droop adjuster
Terminal am1
Power piston
x I00
P.RHORQ1
Conversely, when the load increases, power
piston movement in the fuel increase direction
extends the speeder spring so that the engine
speed is maintained at a speed a little lower
than that when the engine speed was originally
balanced.
Consequently, by adjusting the speed droop
adjuster scale, the link lever ratio is changed
and, as the speeder spring's set force can be
changed, speed droop can be set freely.
Speed droop (stabilizing droop)
When load is cut at full-load maximum speed
(N), the speed will increase and then stabilize
at no-load maximum speed (NJ.
Speed droop is the no-load maxrnurn speed ( N),
expressed as a percentage of the full-load
maximum speed (N).
Momentary droop
When the load is cut at full-load maximum speed
(N), the maximum speed (N,) attained while -the
speed is stabilizing expressed as a percentage
of the full-load maximum speed (N) is referred
to as the momentary droop.

COMPENSATOR MECHANISM
Upper compensating spring
Compensating chamber
Needle valve
The compensator mechanism is used to prevent
hunting, which generally more easily occurs
when speed droop is decreased.
T h e compensator mechanism's upper
compensating spring and lower compensating
spring are both assembled with a set load.
When engine speed increases and the power
piston has moved in the fuel decrease direction
(ie, down), the power piston and pushrod and
the compensating piston first move down
together. Because of this, the pressure in the
compensating chamber becomes negative.
When this negative pressure falls below a
certain value, as it overcomes the upper spring's
set load and compresses the spring, the amount
of compensating spring movement becomes
relatively less than the amount of power piston
movement (the rate that negative pressure is
generated becomes less than power piston
movement). As the compensating chamber is
connected to the lower pilot valve chamber, the
lower pilot valve chamber pressure also
becomes negative, and the pilot valve works to
move down against the flyweight's centrifugal
force and close the previously open pilot port.
Because of this, power piston movement in
response to engine fluctuations can be slowed
to a certain extent and hunting prevented.
B 06
OPERATION
Lower compensating spring
P-RHDR-011
In other words, providing the compensating
spring with a set load and varying the rate at
which negative pressure is generated by power
piston movement can improve stability by
preventing hunting, and improve response (ie,
the speed at which the power piston moves in
the fuel increase direction) by minimizing
momentary droop.
Conversely, when engine speed decreases, the
power piston moves up. As the lower
compensating spring has a set force, however,
the compensating piston also initially moves up,
and the compensating chamber pressure
becomes positive. When this positive pressure
exceeds a certain level, the s p r i n g i s
compressed and the rate at which the positive
pressure is generated is slowed. When the
compensating chamber pressure becomes
positive, the lower pilot valve chamber pressure
also becomes positive, and the pilot valve is
pushed up to close the pilot port.
Because of this, excessive power piston
movement and therefore hunting c a n be
prevented.
Closing the needle valve increases the pressure
generated in the compensating chamber, and
thus increases the compensator effect, so that
response can be further slowed.
The governor can be equipped with a governor Their construction and operation are explained
motor and a pneumatic controller. below.
These facilitete remote engine control from a
central control room.
GOVERNOR MOTOR
-
RHD6 and RHDIO MC type governor motor

/
Guide screw

The governor motor operates when the engine
speed set switch in the control room is turned
ON.
When the motor operates, the speed setting
screw is rotated by the friction coupling and gear.
As the speed setting screw is screwed into the
guide screw, this rotation results in vertical
movement.
Because the speed setting screw acts on the
speed adjusting mechanism within the governor,
speed setting screw movement changes the set
load of the speeder spring to vary engine speed.
The speed can also be changed manually in
the same way by turning the synchronizer knob.
 -
RHD6 and RHDIO MCL type governor motor
(with limit switches)
Fork
This governor motor enables electrical control
of the set governor speed's upper and lower
limits through limit switches.
Three types are available for use with ships'
main engines, pumps, and generators. The
control ranges and speed setting times differ
depending on the type used.
The motor is decelerated by the gear head
which, through the friction coupling, turns the
speed setting screw to slide the speed adjuster
in an axial direction. A pin protruding from the
speed adjuster turns the speed adjusting lever
fixed to the speed control shaft to vary the set
speed.
~rictio'ncoupling
The upper part of the speed adjuster also serves
as a cam to operate the limit switches and move
them within the range determined by the slot to
enable adjustment of the upper and lower set
speeds.
When setting the speed manually, the motor side
synchronizer can be used to freely vary the
speed from the minimum to the maximum
irrespective of limit switch control.
Also, when an attempt is m a d e to
simultaneously change the set speed by remote
control, the friction coupling ensures that the
speed is first changed on the engine side to
prevent any adverse effect on the motor.
PNEUMATIC CONTROLLER

Plate
wing
n 7
nut

Maximum speed

0 N, (idling)
Governor speed (rlmin)
(DS = dead slow)

The pneumatic controller is used to control
engine speed.
When air at a specified pressure is supplied to
the pneumatic controller, the air pressure acts
on the diaphragm and plate, compressing the
spring and pushing the pushrod down.
The pushrod acts on the speed adjusting link
mechanism in the governor to change the set
load of the speeder spring.
The engine speed can also be freely changed
manually in the same way by turning the knob
on the top of the controller.
 $Yo
ADDITIONAL DEVICES

HYDRAULIC CONTROLLER

The hydraulic controller is used to control engine The hydraulic controller's piston displacement
speed, but utilizes hydraulic pressure instead is 12 cm3.
of air pressure, and a piston instead of a
diaphragm.
 HANDLING

GOVERNOR INSTALLATION
1. Install the governor vertically to the governor
drive case. Use the accompanying gasket
at the installation surface.
2. Ensure the governor gear shaft is not
subjected to a direct radial load, and that
eccentricity and acceleration-gear play are
as small as possible.
1 + 13.2 Gear shaft spline coupling dimensions are
(spline smaller dla)
shown at left. These are the same for RHD6
and RHDIO governors.

When handling the governor, ensure the end

of the governor's gear shaft is not subjectto
force or impact.
Note:
Although the spline is a standard JIS square-
shaped spline (6 x 13 x 16), the dimensions
shown at left are recommended to avoid even
minute eccentricity when installing the coupling.
The spline couplings shown at left are standard
~osc~ h u t o m o t i v e ~ ~ s t espline
m s couplings.

Hydraulic fluid type Fluid charge Inspection Replacement

The type of hydraulic Approx 1,300 cm3. ,heck the hydraulic The fluid must initially
fluid used varies With the governor fluid daily. If the be replaced after
depending on the horizontal, fill the :harge is less than 1,000 hours or 3
governor oil governor with fluid until that specified, check months. Thereafter,
temperature during the level is slightly for leaks. If repair is the fluid must then be
normal operation. above the middle of lot possible, contact replaced every 3,000
Less than 50" C : the governor case an authorized Bosch hours or 6 months.
SAE20 window. hutomotive Systems
50" C-70" C : If the fluid charge is station.
SAE30 insufficient, bubbles
Over 70" C : will form, performance
SAE40 will decrease, and
fluid deterioration will
be accelerated.
 $1
HANDLING

Speed droop adjuster AIR BLEEDING AND COMPENSATION

ADJUSTMENT
1. Set the speed droop at the smallest value
possible using the speed droop adjuster (0
- 2 on the adjuster scale) and fully open
the compensating needle valve (3 turns from
the fully closed position).
2. Operate the engine at low speed and cause
t h e engine to ' h u n t ' or ' s u r g e ' f o r
approximately 30 seconds to bleed the air.
/
Needle valve P-RHDR.02

Speed droop adjustel

3. Stop the engine, set the speed droop to the
setting estimated for the particular
application (determined from t h e
performance diagram) and then restart the
engine.

4. Close the needle valve until 'hunting' stops.

Advice
The above completes air bleeding and
compensation adjustment. If, however, the
speed droop adjustment setting is changed
during engine adjustment, readjust the
needle valve to as open a position as
possible at which stabilized engine operation
is obtained.
 w3
HANDLIN'G

RHD6 type Speed droop adjuster scale

..~
..---~~-
LINKAGE CONNECTIONS
0
-.- 1. Use a split tightening type lever. After
5
---- 10 determining the correct position, secure it
7 - 35 using a knock pin, etc.
-%30 rach
FUIIID~ ~
- 6 I poYUon 2. The linkage must be as simple and direct
E" 5'-
s25
as possible. Minimize resistance and the
-
C
.E 3
e
b 4 F 2 0
-
"7
I5
actual mass of the linkage.
a
2 -.& I 0 No load rack

0-
E
1: I- e 5
0
500 1,000 1.500 2.000
I
1 pwi~on
Xrjecaon

~kpos'''o
Governor speed (rlmin)
P-RHDR024

RHDIO type
Speed droop adjuster scale 3. The figures at left show the recommended
...-.~
- - - 0- ~
relationships for connections between the
terminal shaft angle and the injection pump
for a static governor.
Advice
As play i n the link system adversely affects
performance, ensure play is a s small as
possible.

fi]
Governor speed (rlmin) P - R H D R ~ ~ ~

Oil level DAILY INSPECTION

-
1. Check the fluid level daily before beginning
operation.
If the level is below the middle of the gauge,
add fluid to the governor.
2. Check that the governor mounting bolts are
not loose and that there are no faults in the
0000 linkage connections from the governor
-ZEXBL. terminal shaft to the injection pumps' control
rack.
P-RHORd26

IN-SERVICE INSPECTION
1. Check the governor temperature. The
temperature should generally increase to
-
approx 60 " C after 30 40 min of high
speed engine operation. If the ambient
temperature is high, the temperature may
increase to 80 " C after continued h igh
speed operation (over 1,800 rlmin).
Temperatures over 100" C are abnormal.
2. Check for abnormal noises.
3. Wipe any fluid from the outside of t h e
P.RHDRQ27
governor and check that no fluid leaks during
operation.
;
1
-
'I
- 22 -
4 -
.. . ~
 I(y
DlS SSEMBLY

SPECIAL TOOLS
The following special tools (in addition to general tools) are required for disassembly and reassembly
of the RHD hydraulic governor.
Kev No 1 Part name 1 Part number / Application
1 Case For tools
2 Spanner For removing/installing regulating valve
(SW22mm,24mm)
3 Screwdriver For removinglinstalling cover bolts
4 Screwdriver For speed droop adjuster adjustment
5 Pliers For removing split pins
6 Spanner For removinglinstalling plug (SW17mrn)
7 Allan wrench SW3mm
8 Allan wrench SW5mm
9 Extractor For removing pin
 %IS"
DISASSEMBLY

EXPLODED VIEW
 %I/
, DISASSEMBLY

PART LIST
RHD-LC type hydraulic governor

Part name Part name Part name

Base Bolt Roll pin

Needle roller Flyweight Floating lever
bearing Washer Wire
Oil seal Thrust needle roller Gasket
Gear shaft bearing Cover
O-ring Pilot valve Bolt
Housing assembly Maximum speed
Sleeve Guide lever setting screw
Compensator Pin Nut
assembly Split pin Minimum speed
Power piston Terminal arm setting screw
Upper compensating assembly Nut
spring Terminal arm Gasket
Pushrod Terminal shaft Air breather
Washer Taper pin Needle valve
Lower compensating Set screw O-ring
spring Speed droop Gasket
Snapring adjuster Screw plug
Compensator Washer Gasket
bushing Lock washer Regulating valve
O-ring Screw lndication plate
Compensating piston Speed control shaft Nail
Roll pin Collar lndication plate
Gasket washer Fork Pointer

Pneumatic controller

Part name Key No Part name Part name

Pneumatic controller 105112 Piston Bolt

Cover 105/13 Diaphragm Eye
Cylinder 105114 Plate Gasket
Screw 105115 Nut Eye bolt
Spring washer 105116 Cover Nut
Spring seat 105117 Screw Bolt (set screw)
Nut 105118 O-ring Gasket
Washer 105/19 Wing nut Bolt
Spring 105121 Knob Pin
Spring 105122 Set screw
Washer 105123 Screw
Pushrod 105124 Spring washer
PREPARATION
Keep the work bench clean and tidy.
Before starting disassembly, record
performance data and the positions of
adjustable parts for later reference. This data
will facilitate the detection and diagnosis of any
governor malfunctions and defects.
Wires
P-RHDR.
Pilot valve assembly
During disassembly, put the disassembled parts
neatly and sequentially on the work bench,
labelling them if necessary to facilitate later
reassembly.
Clean the outside of the governor before
disassembly.
DISASSEMBLY
1. Remove the four bolts using a screwdriver
and then remove the cover together with the
gasket.
2. Turn the governor upside down and drain
the fluid.
3. Remove the two wires connecting the fork
to the floating lever and then remove the
floating lever.
4. Remove the pilot valve assernbly.
Advice
Put the pilot valve i n clean light oil.
 w \ >

DISASSEMBLY

~erminalarm 5. Remove the two split pins and then remove

the two pins connecting the terminal arm and
the guide lever to the power piston.

I P-RHDR- 032

I 6. Remove the bolts using an allan wrench

(SW 5 mm).

I P-RHDR. 033

7. Tap the base lightly with a plastic hammer

to separate it from the housing.

Sleeve
8. Remove the sleeve from the housing and
the gear shaft from the base.
Advice
Put the sleeve i n clean light oil.

P-RHDR
 %\?I
DISASSEMBLY

9. Push the power piston down from the top of

Compensator bushing the governor and then remove the
compensator bushing and the compensator
assembly.

P-RHDR- 03

10. Remove the roll pin securing the fork t o

the speed control shaft, and then remove
the speed control shaft, the collars and the
fork.
Note:
PC, MC, and MCL type governors are equipped
with a cancel spring on the speed control shaft.
Remove the cancel spring when removing the
speed control shaft.

11. Remove the flyweight assembly together

with the thrust needle roller bearing and
the washer from the housing.

.
12. Turn one terminal shaft one half turn and
Terminal a m Terminal shafls (2)
remove the terminal shafts' taper pins.
Remove the set screws using an allan
wrench (SW 3 mm), then remove the
terminal shafts and arm.
Advice
1. Do not remove the terminal arm assembly
unless it is not operating smoothly or it
is necessary to replace parts.
2. When replacing the terminal shafts and
arm, they must be replaced as an
P-RHDR- O3! assembly.
 9 <&"
[fl DISASSEMBLY

Taper pin

P-RHDR. M(

Regulating valve 13. Remove the needle valve and regulating

valve (hexagon head, SW 24 mm) and any
other external parts.
The above completes disassembly of main RHD
governor components.
Disassemble o t h e r components w h e n
necessary.
The pneumatic controller is the most commonly
equipped additional device.
Disassembly is described below.

PNEUMATIC CONTROLLER
DISASSEMBLY
1. Loosen the wing nut. Then, loosen the knob
until it can be easily turned.

P-RHDR- M:

2. Remove the four bolts using a screwdriver

and then remove the cover.
 g 'L)
DISASSEMBLY

3. Remove the diaphragm together with the

pushrod, and then remove the two springs.

4. Loosen the nut and then remove the spring

seat seat.

The above completes disassembly of main

pneumatic controller parts.
Disassemble other parts when necessary.
Record the details of all inspections and repairs.
With parts such as those listed below, first check
their external appearance to determine whether
further disassembly is necessary.
Terminal arm assembly
Pilot valve assembly
Housing assembly
Flyweight assembly
Governor motor assemblv
Wash all parts thoroughly in clean light oil, and
check for wear, damage and scratches.
Replace any parts that cannot be reused with
nebyparts.
REPLACEMENT STANDARDS
Parts with key numbers marked 0:
Replace at disassembly or every 2 years
Parts with key numbers marked :
Replace every 4 years or 20,000 hours
In principle, assemblies must be replaced when
any of their component parts have been used
for 8 years or 40,000 hours.

Oil seal @ Gasket

Gear shaft @ Gasket
O-ring 11117 Oil seal
@ O-ring 111181 Oil level gauge
@ pin Flyweight
@ Roll pin Washer
@ Wire Thrust needle
@ Gasket roller bearing
@ Gasket Pin
@ O-ring Floating lever
11311 Regulating valve
If parts other than the above are worn or
damaged, replace them with new ones.
P-RHDR. 04
 Sleeve contact surface Gear shaft contact Base assembly and housing
\ surface Replace the base if the power piston, gear shaft
Power piston or sleeve contact surfaces are worn or damaged.
contact surface
Replace the housing if the power piston, gear
shaft or sleeve contact surfaces, or the housing
holes, are worn or damaged.
Replace the housing if the pressfitted terminal
arm bushings are worn or loose.
.
,
,-.

I Bushings (2)

I P-RHOR- M B I

Gear shaft and sleeve

Replace the gear shaft if the outside, spline, oil
seal contact surface or gear is worn or damaged.
Replace the sleeve if the gear, pilot ports or
Gear lands are worn or damaged.

Gear shaft Spline P-RHOR-

M

Compensator bushing
Compensator assembly
Assemble the compensator assembly's power
piston, pushrod and compensator bushing in the
housing and check that they move smoothly up
and down under their own weight when the
housing is moved.
Repair or replace them if they do not move
smoothly.
Note:
If the power piston does not move smoothly,
hunting or excessive speed droop will prevent
engine adjustment.
 Flyweight assembly
Flyweight
/ Foreign matter in the flyweight will prevent
smooth flyweight movement.
Check that the flyweight moves smoothly.
Wash the flyweight thoroughly.

Speed control shaft Power piston, guide lever and terminal arm
\
Replace the guide lever if the pin holes are
worn.
Replace the pins if they are worn.
Replace the power piston if the inside is
worn.
Replace the speed control shaft if it is bent
or the shaft journals are worn.

Regulating valve
I Washer I Check that the piston moves smoothly.
Repair or replace the piston if it is worn or does
not move smoothly.

Other parts
Check all other parts for cracks, damage,
damaged threads and rust.
Repair or replace them if necessary.
Replace all O-rings and gaskets.
Replace springs that are damaged, bent or
Regulating valve
P-RHDR.~~~ rusted.
 $'?&.,
INSPECTION

GOVERNOR MOTOR BRUSH

INSPECTION (MC, MCL TYPES)
Advice
lnspection applies only to direct current (DC)
type motors. The following i s not necessary
for alternating current (AC) motors.

Brush inspection intervals

Brush inspection intervals are shown 'below.

Brush
P-RHDR- 10
1 part name 1 lnspection
interval
Replacement
interval

or less

Note:
Overall length of new brushes: 10 mm
Brush inspection
I Remove brush (one side) I

+ Confirm overall length

Overall length is
4 mm or less
NO

+
1 Remove motor and 1
replace both brushes original position

Brush removal
1. Remove the screw and then remove the
cover.

Cover Screw P-RHDR-

;
 INSPECTION

2. Loosen and then remove the cap.

-. . P-RHDR- 10;

3. Remove the brush from the motor.

Advice
Do not stretch the brush spring during
removal.

4. Measure the overall length of the brush.

Advice
When overall brush length still exceeds
the wear limit of 4 mm, reverse the
removal procedure to reinstall the brush.
(Inspection is complete.)
When overall brush length is 4 mm or
less, continue with the following steps.
(Replace both brushes at the same time.)

&sh
P-RHDR- 10'

Motor removal
1. Loosen the screw and then remove the
knob.
Note:
Screw: SW3
 %
i-
~7
INSPECTION

Screws (4) 2. Remove the screws and then remove the

motor horizontally.

Advice
Harness The motor is connected t o a harness. Do
not pull the harness excessively.

P-RHDR- 11

Brush replacement
1. Remove the knob-side brush using the same
procedure as above.
2. Replace both brushes with new ones and
then reinstall the motor <--d k n c b by
reversing the removal procedure. -
Advice
When reinstalling the motor, install the
motor so that the side with the nameplate
is facing up.
Tighten diagonally opposed motor fixing
screws (4) gradually and evenly.
Tightening torque: 2 2.2 N m --
(0.2 0.22 kgf m) .
Brush part numbers
I Part name I RBAJ Dart no. I Remarks I
Brush
158901-4500 1 For DC24V
1589014600 1 For DClOOV
 Governor reassembly is described below.
PNEUMATIC CONTROLLER
(if installed)
1. Screw the locknut onto the spring seat, then
screw the spring seat into the cylinder.

I P-RHDR- 05

I' 2. Install the diaphragm and pushrod together

with the two springs.

3. Install the cover and secure it using the four

bolts.

I P-RHDR- 051

I 4. Install the knob and wing nut.

 REASSEMBLY
52-3

Regulating valve GOVERNOR ASSEMBLY

--
1. Install the regulating valve.
Tightening torque: 25 29 N rn
(2.5 3.0 kgf rn}.

2. Install the terminal shafts and arm. Align

each terminal shaft's and terminal arm's
taper hole.
Coat the taper pins with an adhesive and
install the taper pins.

When installing the two taper pins in the

terminal shafts, support the terminal arm and
terminal shafts to avoid damaging the
bushings pressfitted to the housing.

3. Coat the set screws with an adhesive and

Taper pin
t screw --
install the two set screws.
Tightening torque: 3.9 4.9 N m
(0.4 0.5 kgf m)

4. Caulk the two taper pins after final tightening.

Terminal shafls (2)

I P-RHDR- 06[
 62-7
REASSEMBLY

5. lnstall the flyweight assembly, thrust needle

+ FlyweigJt assembly
roller bearing and washer in the housing.

P-RHDR- 06

6. lnstall the speed control shaft, collars and

fork, and then install the roll pin.
Advice
PC, MC, and MCL governors are equipped
with a cancel spring. lnstall the cancel
spring when installing the speed control
shaft.

7. lnstall the power piston, the compensator

assembly and the compensator bushing.

Sleeve
\ Housing
1 8. lnstall the gear shaft in the base, and the
sleeve in the housing.
 4JP %
,

REASSEMBLY

High pressure fluid Advice

passageway When pressfitting the gear shaft bearing into
/ the base, pressfit the bearing to align with
the base face, as shown. If the bearing is
pressfitted too deep, the bearing will block
the high pressure fluid passageway.

aligns with base end face

I P-RHDR- 065

9. Install the base to the housing using the bolts

and gasket washers.

{I
--
Tightening torque: 10 15 N m
.O 1.5 kgf m).
While securing the base t o the housing,
check that the gear shaft turns smoothlv.
If the gear shaffdoes not turn smoothly,-the
oil delivery gear may be damaged.

P-RHOR- 066

10. Attach the guide lever to the terminal arm

Terminal arm and the power piston using the two pins
and two split pins.
Then, bend the split pins over.

Pins

11. Install the pilot valve assembly.

P i 1 7 assembly
 a3 l
REASSEMBLY

Floating lever 12. Install the floating lever and secure it to

the fork and pilot valve using the two wires.
wir+4$g'

Advice
Wires Floating lever Bend the ends of the wires to prevent them
from loosening.

P-RHDR-07

Connector 13. After assembling the governor's inner

\ components, thoroughly wash the inside
,C o m p r e s s e d ail and then install the cover using the bolts.
49kPa (0.5 kgf/crn2]
Air tightness test
-1 Before filling the governor with hydraulic
Light oil fluid, remove the air breather and install the
connector, gaskets and eye bolt. Then,
supply compressed air at 49 kPa (0.5 kgfl
cm2}to the governor through the connector,
and immerse the governor in light oil.
-2 Operate the speed control shaft and check
I P-RHOR-07 that no air leaks from the governor. If air
leaks, repair the governor.
Advice
If the governor is equipped with an o v e f l 0 ~
valve, seal i t using a blind plug.
If the governor i s equipped with booster
connections, remove them and seal the
openings with blind plugs.
Remove the blind plugs and reinstall all
components after adjustment.
 332
REASSEMBLY

14. Remove the connector, gaskets and eye

bolt.
Reinstall the air breather, then remove the
cover.
 -
ADJUSTMENT

In addition to general tools, the following special tools are necessary for governor adjustment.
SPECIAL TOOLS

Part name Part No Shape 1 Remarks

For driving RHD

]riving stand
governor

For measuring lever

4djusting device
angle

PREPARATION
1. Attach the driving stand to the pump tester
and install the governor on the driving stand.
Fill the governor with the specified amount
of hydraulic fluid (approx 1,300 cm3;the fluid
should be a little over the middle of the
gauge).
 % 3il
ADJUSTMENT

2. Move the terminal arm by hand until it

I Terminal arm
/
becomes difficult to move to bleed the air
from the governor.

Flywheel 3. Turn the flywheel by hand and check that

! > , I / the gear shaft can be turned easily, and that
the flyweight turns together.
Note:
If the gear shaft does not turn easily, it will heat
up during operation and adversely affect

, ~
endurance.
8
- ~ ..-.\A
Il.i-
m ./ .. Remove the lever after operating the
9;;
,
,," i'_ _
8-, ,/

flywheel.
-
~, , I, ,- .
P.RHDR475I 6perating the test bench without removing
the lever can cause serious injury and
Speed Increase dlrecson 'pee' damage the test bench.

4. Set the speed control shaft in the speed

increase position, rotate the gear shaft and
check that the terminal shaft moves in the
fuel increase direction.

~errninalshaft P - R ~ D R ~ ~

Adjusting device lever Adjusting device

5. Attach the adjusting device to the driving
/ stand and then attach the adjusting device
lever to the terminal shaft.
1 S~eed
decrease direction I 6. Set the speed control shaft in the speed
decrease position, rotate the gear shaft and
check that the terminal shaft moves in the
Fuel de
direction fuel decrease direction.
Note:
If the cover is installed, the terminal shaft may
not return in the fuel decrease direction,
depending on the set position of the speed
control shaft.
7. Install the governor cover.
Terminal shaft P-RHORU78

Speed control shafl Warming-up operation

Run the governor at 1,000 rlmin for 20 mins and
check that no fluid leaks.
Air bleeding
Fully open the needle valve (approx 3 turns from
the fully closed position) and run the governor
at 1,000 rlmin. Operate the speed control shaft
so that the power piston moves through its full
stroke.
Do this at least 10 times to bleed all air from the
governor's hydraulic system.

0 position Stop position Speed cpntrol shaft Terminal shaft pointer adjustment
1. Run the governor at approx 1,000 rlmin and
move the speed control shaft to the stop
position.
2. In the above condition, align the terminal
shaft side pointer with the indication plate's
(fuel side) 0 position and fix it using the
screw.

~errninalshaft

Adjusting device lever 3. This position is the terminal shaft angle's 0

position. Align the adjusting device's 0
position with this position.
 ADJUSTMENT -a
(:;3

4. Run the governor at approx 600 rlmin (with

the needle valve fully open, ie, returned 3
turns from the fully closed position) and turn
the speed control shaft. Check that the
terminal shaft moves easily from 0 "
" (RHDIO: 0 " -40 ' ) when the power
- 35

piston moves through its full stroke.

At this time, check that the terminal shaft
-
operating torque is 9.8 N rn { I kgfm} for
-
the RHDG or 14.7 N m { I .5 kgfm) for the
RHDIO using a spring balance attached to
Terminal shaft P.RHDROB: the adjusting device.

OPERATION TEST
The operation test is the same for LC, PC, MC,
and MCL type governors.
Perform the operation test with the needle valve
fully open.
Speed control shaft pointer angle adjustment
1. Remove the governor cover and set the
droop adjuster pointer at the specified value.

For RHDG 2. Run the governor at 2,000.,, rlmin and

secure the speed control shaft at the position
(A) where the terminal shaft angle is 30 "
- 7
(ie, 6 on the scale). Then, align the speed
control shaft pointer at 8 (on scales
-
graduated from 0 8) and tighten the
screw.
Note:
-1 On PC, MC and MCL governors, the terminal
-0 shaft is fixed (at A) by a knob.
2.000 -10
Governor speed (rlmin)

-2 On RHDIO governors, when the terminal

shaft angle is 32" (ie, 8 on the scale), align
the speed control shaft pointer at 1 0 using
the screw.
 q,2 7
ADJUSTMENT

Speed droop adjustment

1. Temporarily fix the droop adjuster pointer at
the specified position.
2. Operate the governor at N, rlmin and then
fix the speed control shaft when the terminal
shaft angle is 30 " for the RHDG or 32 "
for the RHDIO.

Governor speed (rlrnin)

3. Gradually increase governor speed and

further adjust the speed droop adjuster so
that governor speed is N, rlmin when the
terminal shaft angle is returned to 10 for
the RHD6 or 8 " for the RHDIO.
Note:
When the speed droop adjuster pointer is moved
toward 0, speed droop decreases.
When the speed droop adjuster is moved toward
10, speed droop increases.
Advice
Confirm that N, is within the allowable speed
when the speed droop adjuster is exactly as
specified.
Note:
If the lever attached to the terminal shaft deviates
more than + 1 " during high speed operation
(ie, at approx 1,800 rlmin), check as follows.
Regular deviation: Check compensator related
parts (housing, base, assembly, regulating
valve). Replace them if necessary.
Irregular deviation: Check the flyweight
assembly. Replace it if necessary.
Perform the following adjustments with the
governor adjusted as described above.
 Maximum speed setting screw adjustment
(not necessary on MCL type governors)
1. Install the governor cover.
Operate the governor at N, rlmin, adjust the
maximum speed setting screw until the
terminal shaft angle is 30 " for the RHD6
or 32 " for the RHDIO, and then fix the
screw using the locknut.

0
N, N,
Governor speed (rlmin)

Minimum speed setting screw adjustment

I Speed control shan
/ The flow of a large quantity of hydraulic fluid to
Terminal shaft
(not necessary on PC, MC o r MCL type
governors)
1. With the governor stopped, move the speed
control shafl as far as possible to the low
speed side (0 or less on the scale), and then
temporarily set the minimum speed setting
screw.
2. Operate the governor at N, rlrnin and adjust
the minimum speed setting screw so that
the terminal shafl angle does not exceed
10 " (RHD6) or 8 " (RHDIO). Then, fix
the screw using the locknut.
I Compensator chamber high pressure
hydraulic fluid flow
the compensator is not desirable.
To check for this, perform the following test.
1. Fully open the needle valve (approx 3 turns
from the fully closed position) and maintain
governor speed at approx 1,000 rlmin.
2. Fix the speed control shaft so that the
terminal shafl angle is approx 20 " (4 on
the scale).
 $3 9'
ADJUSTMENT

Terminal shaft 3. Fully close the needle valve and check that
" , the terminal shaft does not move more than
1 ' in the 0 direction.
Advice
If the terminal shaft moves more than 1" in
the 0 direction, check for the following.
Clearance between the sleeve and base.
The base-housing contact surfaces may
not be even, or may be scratched.
The needle valve escape ports ( # 0.4 and
# 0.8) and the base escape ports ( # 1.5)
may be blocked.
The compensator bushing O-ring may be
damaged.

Governor control confirmation

Spring balance
Under the following conditions, operate the
Fuel increase / Fuel decrease
speed control shaft to move the terminal shaft
in the fuel increase direction (RHD6: 0 "
; RHD 10: 0 " - 4 0 "
- 35
) a n d in the fuel
RHDIO: 40 ' -
decrease direction (RHD6: 35 " + 0 ' .
0 " ) and check that the leve;
resistance is as specified.
Measurement conditions
Governor speed: 600 rlmin
Needle valve position: fully open
/ \
Speed control shaft ~ ~shan ~ ~ i R~(see fig~ at left):
l 100 mm
P-RHDR-09
Note :
If the lever resistance is not as specified, replace
the following parts.
Regulating valve assembly
Check for openings or leaks in the gear
pump or hydraulic fluid system and replace
faulty or damaged parts.
Reverse operation
The RHD governor is constructed so that
identical performance is obtained whether it is
operating clockwise or counterclockwise.
To confirm this, operate the governor in the
reverse direction and check governor control as
described above under the exact s a m e
conditions and procedures, and check that
performance is as specified.
 ADJUSTMENT

ADDITIONAL DEVICES
Pneumatic controller adjustment
1. Before adjustment, check that the outer and
inner springs' distinguishing colors are as
specified.
2. Temporarily position the manual knob as
shown at left and connect a compressed air
-
source capable of supplying 0 0.49 MPa
(0-5 kgflcrnZ}to the eye bolt.
Note :
Perform the following adjustments and
confirmations based on the individual test
standards.
3. Point I adjustment

1,680 -
Example:
-
0.37 MPa
(3.8 kgflcm2}
30 & 0.5

(speed) (air pressure) (terminal shaft

1 O Air pressure (MPa (kgf/cm2))
angle)
Operate the governor at 1,680rlrnin and adjust
the spring seat so that the terminal shaft angle
is 3 0 * 0 - 5 " when 0.37 MPa {3.8 kgf/cm2} air
pressure is supplied. Then, secure the spring
seat using the nut.
Advice
When adjusting point I , return the air
pressure t o 0 a n d the manual speed
adjusting knob t o its original position t o
prevent diaphragm damage.
4. Point II adjustment
Example:
1,055 - 0.16 MPa -
{I.6 kgflcm2)
(Approx 16.5)

(speed) (air pressure) (terminal shaft

angle)
Operate the governor at 1,055rlmin and confirm
that the terminal shaft angle is 16.5" when 0.16
MPa {I .6kgflcmz} air pressure is supplied.
5. Point adjustment
Example:
700 - 0-
(speed) (air pressure)
8.5+j5
(terminal shaft
angle)
Operate the governor at 700 rlmin and adjust
the manual speed adjustment knob so that the
terminal shaft angle is 8+l-=" at an air pressure
of 0. Then, secure the knob using the wing nut.
 Wt'
ADJUSTMENT

Governor motor operation confirmation

(MCtype)
1. Specification confirmation
Confirm from the individual standards that
the specifications of individual parts are
correct.
Motor specification (voltage)
Condenser capacity
Speed reduction ratio

2. Operation confirmation (using speed

adjustment knob)
Turn the knob manually, and confirm that
the speed setting screw turns smoothly over
the whole range by observing speed control
shaft pointer movement.
If it does not move smoothly over the whole
range, loosen the friction coupling set screw,
adjust the positions of the bevel gear teeth
and recheck screw movement.

3. Operation confirmation (using the motor)

Test electrical circuit Governor rnolor assembly
Motor I 1 at left.
Black
Connect the governor motor assembly t o the
electrical test circuit in accordance with the
particular motor's specifications, as shown

Speed decrease

Friction coupling 4. Operation test

I
Turn the governor motor's speed switch ON
in the speed increase direction to operate
the motor.
Then, operate the motor until the fork
contacts the maximum speed setting screw
adjusted above and the friction coupling is
rotating freely.

~oik S p e e d getting screw P-RHDR-09

 ADJUSTMENT %Lit

I
Speed sening screw

/ 1 0 Then, turn the switch OFF and then ON in

the speed decrease direction, and confirm
that the speed setting screw begins moving
smoothly.

I Stopper

/
Friction coupling
/ 1 Operate the governor motor until the speed
setting screw contacts the stopper and the
friction coupling is rotating freely.

Speed setting screw P.RHORK

Speed sening screw Then, turn the switch OFF and then ON in
/ the speed increase direction and confirm
that the speed setting screw moves
smoothly.
Advice
During the above operation test, i f the friction
coupling rotates freely in other than t h e
following two cases, check the alignment of
the bevel gear teeth.
When the maximum speed setting screw
is contacting the fork
When t h e s p e e d s e t t i n g s c r e w i s
contacting the stopper
Governor motor operation test and limit
switch adjustment (MCL type)
1. Specification confirmation
Confirm from the data sheet that the
specifications of individual parts are correct.
Motor specification (voltage)
Condenser capacity
Speed reduction ratio
 3L-l 3
ADJUSTMENT

2. Operation confirmation
(using the manual speed adjustment knob)
Confirm operation as described below
before adjusting the terminal shaft side
pointer.
Operate the knob manually and confirm that
the speed setting screw rotates smoothly
over the full range.
If it does not move smoothly in some places,
check the installation of the holder or the
speed setting screw.

3. Governor motor operation test

(limit switch adjustment)
Test electrical circuit Governor rnolor assembly Connect the governor motor assembly to the
Motor 1 1 electrical test circuit in accordance with the
particular motor's specifications, as shown
at left.
Then, adjust each limit switch.

For RHDG Maximum speed limit switch adjustment

Operate the governor at the specified speed
(N, rlmin), and the governor motor i n the
'- speed increase direction.
Adjust the limit switch's upper limit position
so that the governor motor stops a t the
terminal shaft angle of 30k3" for the RHD6
or 3
2
'
" for the RHDIO.

Governor speed (rlrnin)

Minimum speed limit switch adjustment
Operate the governor at the specified speed
(N, rlmin), and the governor motor in the
speed decrease direction.
Adjust the limit switch's lower limit position
so that the governor motor stops at the
terminal shaft angle of for the RHD6
or 8*3' for the RHDIO.
Set the governor speed at 1,500 rlmin and
confirm that the governor motor operates
correctly between the upper and lower
operation limits and that the friction coupling
does not rotate freely.
TROUBLESHOOTING
Of the phenomena listed below, some originate If no engine faults are found, check the governor.
solely in the governor, and some solely in the As the governor uses many precision parts, there
engine. is a danger of the engine overrunning if these
Faulty starting parts are incorrectly assembled.
Hunting
Insufficient engine output
Engine will not operate at maximum speed Never attempt t o repair the governor on-site.
Excessive momentary speed droop, or A l w a y s c o n s u l t y o u r nearest B o s c h
inability to control speed ~ u t o m o t i v esystems representative.
First, check the engine for the following faults.
If engine faults are found, perform repairs in
accordance with t h e engine maker's
instructions.
Compression pressure of each cylinder is
extremely uneven
Excessive play in fuel control and speed
adjustment linkage
Excessive resistance in injection pump
control rack and fuel control linkage
Excessive play because of worn governor
drive system gear or rubber damper
Relative positions of linkages incorrect
Dashpot spring in fuel control linkage bent
or damaged
 PART NUMBER EXPLANATION

MODEL NUMBER
Example: RHD 6 C C
(1) (2) (3) (4)
(1) Independent type hydraulic governor, manufactured by Bosch Automotive Systems
Corporation
(2) control force (work load)
Indicates 10 times the controlling force (work load) in kgfm.
(3) L: lever type
M: with governor motor
P: with pneumatic controller
(4) C: with compensator
Note:
No symbol 'C' indicates that a compensator is not used.

CODE NUMBER
Example: 1 0 5 8 5 5 - 000
(1) (2) (3)(4) (5) (6)
(1) 10: Assembly part number
(2) 58: Hydraulic governor manufactured by Bosch Automotive Systems Corporation
(3) Type
5: RHD6 type
6: RHDlO type
(4) Direction of pump rotation and governor installation position

I Direction of pump
rotation
Governor installation
position
Remarks

0 Clockwise
1 Clockwise
2 Counterclockwise
3 Counterclockwise
4 Clockwise
Right side
Left side
Right side
Left side
-
IFor in-line pumps

5 Counterclockwise -
6 Reversible -
Note:
With in-line pumps, the direction of pump rotation is viewed from the pump's drive side,
Governor installation position is viewed from the pump's cover plate side.
(5) Remote control device installation
3: LC type without remote control device
4: PC type
5: MC type
6: MC type
with remote control device
7: MCLtype
8: MCLtype
9: HC type, others
(6) Characteristic number