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    M-33 Diesel Generator Engine Manual

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    Jibu George Thomas
    The document is a list of plans and documents for a diesel generator engine for a shipbuilding company, requiring customer signature upon receipt and return of the documents. It includes approval plans, working plans, and finish plans for the engine. The customer is asked to confirm the documents, receive them, and return the document list with their signature.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    M-33 Diesel Generator Engine Manual

    Uploaded by

    Jibu George Thomas
    5K views847 pages
    The document is a list of plans and documents for a diesel generator engine for a shipbuilding company, requiring customer signature upon receipt and return of the documents. It includes approval plans, working plans, and finish plans for the engine. The customer is asked to confirm the documents, receive them, and return the document list with their signature.

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    M-33 DIESEL GENERATOR ENGINE MANUAL

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    The document is a list of plans and documents for a diesel generator engine for a shipbuilding company, requiring customer signature upon receipt and return of the documents. It includes approval plans, working plans, and finish plans for the engine. The customer is asked to confirm the documents, receive them, and return the document list with their signature.

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    M-33 Diesel Generator Engine Manual

    Uploaded by

    Jibu George Thomas
    The document is a list of plans and documents for a diesel generator engine for a shipbuilding company, requiring customer signature upon receipt and return of the documents. It includes approval plans, working plans, and finish plans for the engine. The customer is asked to confirm the documents, receive them, and return the document list with their signature.

    Copyright:

    Attribution Non-Commercial (BY-NC)
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    Close this Document

    By rakesh at 3:54 pm, 11/10/07

    Search
    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
    >ai :> l! : > i:
    1°1
    -
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    = ; n;: [ L : ;
    .. .. ..
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    -
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    ... ... ...
    .. .. ..
    5/02 /
    . . .
    5 .; o i.z .i
    . . .
    5ioz i
    . .. ..
    .. . .
    ..-. ... ...
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    - .. .. ...
    ... ... ...
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    -- .. .. ..
    . . .
    -:-_:.
    ... ... ...
    -:-.-. ..-:- . .
    .. .. ...
    -:-:-
    .. .. ..
    . . .
    .. .. ..
    -- .. .. ..
    .. .. ..
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    ... ... ...
    -... .... ....
    . . .
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    .. .. ..
    . . .
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    -. .. ..
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    . .
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    +.-+. .
    . . .
    - .* . -. ;-
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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

    -1
    '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
    I'
    ,i

    I REG I S T E R E D
    945
    1230
    2085
    -I--

    I
    I
    855
    >
    SPACE FOR WITHDRAWAL
    OF ROTOR
    , STRAIGHT AXIALLY 2000 rnm
    45' WITH THE AXIS 1 6 0 0 mrn

    SPACE FOR REMOVING


    THE AIR FILTER
    r--
    I
    -
    DIRECTION OF ROTATION

    j THERMOMETER
    (ALCOHOL TYPE)

    I
    II II

    @ 3 2 DRILL 8HOLES

    SPACE FOR'REMOVING
    THE BEARING BRACKET

    ADJUSTING PLATES

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


    W
    (ADJUSTING BOLT)
    (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 "


    TOTAL ~ ~ ' = 3 4 6 krn2(WITHOUT
    g~ SHAFT)
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    - 2-68520564
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    103 OIL RING NON-DR IVEN S lDE

    - 4-43361 7610
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    I I 1O P - ~ ~ O ~ W - ~ ~ O V - ~ O H Z - O . ~ P F - ~ ~ O A
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    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) '
    ( W
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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)

    !
    !
    1
    H1 H2

    220V AC SOURCE
    SPACE HEATER
    SEARCH COlL
    CIRCUIT
    220V AC SOURCE
    SPACEHEATER
    -
    ~~~~~ COIL 22OV AC SOURCE
    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

    w
    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


    foot -Refer to fig. 5-1
    @Remove exhaust housing.
    @Remove turbine side foot.
    Before removing turbine side foot, insert
    a support under turbocharger.
    3. 3. 6 ln.bvi)%$Dl$.$$ L - !$a
    5-1 %!gF 3 L \
    09-t' ?$bBliZEa%?-t' ?$~f~kbt:oji./r. 3. 3. 6 Pulling out compressor wheel
    l~@i$1?6. -Refer to fig. 5-1
    O$lbltrE (Ml2) &fl@b%~ Olnstall turbine shaft locking device t o
    +DR. S d M t v E liZ%Y. T%DTC&ST gas outlet flange of turbine. housing.
    $L \ o @Remove shaft end hexagon nut (M12).
    @1?7' blt3$%%@60 This nut is left-hand threaded.
    127' b,14t3Slaf&fl1 9 hiBil%fJ%@kk. %$ @Pull out compressor wheel.
    % 100 ('c)E~TDZET%$K@&T~> G When i t is difficult to pull out by hand.
    %81? T F S L \ o 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&[email protected]'& 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 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 .
    I +b I B i t e j o i n t 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 0 1 ~ a n i oj o i n t I I cock I J o i n t ($
    I-'++ F l e x i b l e t u b e 1 STP 1 S t e e l 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

    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
    1 HS I Handle s n i t c h
    I
    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
    PM 1 1 . 0 . P r i m i n g v u o v n o t o r 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
    n
    0
    -
    7
    C
    5
    z
    li

    DWG. No. K S 2 0 0 5 0 4 1
    -
    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

    -
    z
    0
    -
    k
    "
    E
    rL
    E
    s vl
    0
    a
    m
    w

    E
    -
    z
    3
    re
    =
    3
    n
    LL

    $E
    0

    SHIP INSTNLATION

    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
    -'"""
    ~ ~
    /
    " 1 ~
    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
    z m $
    U1
    E17ATTACHED
    8
    E
    D
    5
    :
    : a
    w
    w
    "7
    L,
    E
    L

    5
    6
    =
    %
    L

    .>"
    ENGINE

    sE
    SHEET 14..

    - ? 2
    FOR L.O.
    PRIMING PUMP STIIRTER
    E~1 z ?
    NORMAL CLOSE
    FOn ENCINC CONTROL ROOM CONSOLE
    2 I
    u
    -"*"
    ~
    -
    0

    25.JLL.05
    -0"A.H
    /
    ~ 7 ~

    "'"'"ED ""W"
    MAIN DIESEL GENERATOR ENGINE
    LOCAL CONTROL P A N E L
    SEQUENCE DIAGRAM

    1 (- 7)
    1
    """ "%$ WO."..

    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

    I---- -- -- -- - -- -- P ~-
    R D,
    SC&E i i

    - -

    I t

    WrO
    -

    EM'CY THERMOSTATE
    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
    / S
    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
    , -.

    t--

    NP=SPARE BOX

    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 .

    1000 c c

    LEVER STROKE

    ,lai

    I I t I ., ,.
    I I U K - Z- U

    @a
    -

    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
    ~ 3 9 0 3 3 3 5 4 0 Z~
    When rubber hrxe i s connected. l
    f "7 75 -1 I

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


    7
    /----
    Stopper valve

    (DAIbATS!J SUPPLY1 1 Set / Shio

    Hose connection \ ~ o s econnection


    ( 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

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    & 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.

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    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
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    & ADDRESS
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    No. I 08200

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    & 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.

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    T O O L 1 PAGE
    O X No.
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    PAGE
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    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
    After zsscn~blinga ST400 Starter, nlways lesl it in
    accordance the procedures outlined in this m a n u a l .
    ; i t air pressures over the pressure rating stamped Never i ~ ~ s t nal lreassembled s t a r l e r t h a t has not
    on the nanwplate. Use supply lines of adequale size been tested in accordance with the procedures
    as directed in the instnllation i~lslructionsin this 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 7. To reniove the Housing Cover (I I), slowly loosen [he
    maintenance on this starter. four Housing Cover Bolls (12) while holding the
    Always turn off the a i r supply and disconnect the air Housing Cover (1 I) in place.
    supply before inslalling, rcnlo\,ing or adjusting any 8. Slide tlic Liner Assembly (9) O U I ofllic Housing.
    accessory on this starter o r before perrorming any 9. Rcmove 111eReturn Spring (8)
    n~ainlenanceon this starter. ASSEMBLY
    DISASSEMBLY General Instructions

    General Information I . Always press on the inner ring of a ball-lype bearing


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


    fixture. Apply 90 psig lo lhc slnrlcr motor. Minimum
    IVhcn 90 psig air pressure is applied to the starter, frcc spccd is 2,500 RPM.
    the Drivc Pillion will be rulalil~g81 2,800 rpnl and 3. Confirm O v e r r ~ ~ n n i nofg Clutch: Turn lhc Drive
    Drivc Shaft a n d Drivc Pinion will move forward Pinion by hand in the direction of rotation. The
    1.25". Keep face and hands away from rollling clulch should ralchct srnoolhly.
    Drive Pinion. 4. Confirm Drive Rotation: Turn lhe Drive Pinion by
    1. Orienhtion: Mounting Flangc must be oricnlcd pcr hand in the direction opposile of rotation. Thc clutch
    111ccustomer's order or engineering drawing. If should not ra~chet.
    orientation is not specified by cuslonler, standard
    orientation will be supplied.
    lngersoll-Rand Service Center

    UNITED STATES- CANADA ASIA


    Markelin!g/Sales/Service Production Equipmenl Group Japan
    Headquarlers Ingersoll-Rand Canada Inc. Ingersoll-Rand Japan, Lld.
    Ingersoll-Rand Power Tool 51 Worcesler Road Shin-Yokohama Square
    Division Rexdale, Ontario M9W 4K2 Bldg.5F
    P.0.Box 1776 PHONE: (416) 675 - 561 1 2-3-12 Shin-Yokohama
    Liberly Corner, NJ 07938 FAX: (416) 675 - 6920 Kohoku.ku, Yokohama 222
    PHONE: (908) 647 - 6000 PHONE: (81) 45 - 476 - 7801
    FAX: (908) 617 - 6007 Regional Offices FAX: (81) 45 - 476 - 7806
    1430-5555 Calgary Trail, N.W.
    Soutllern Sales Oflice Calgary, Alberla. T ~ 5P9
    H Singapore
    Ingersoll-Rand Power Tool PHONE: (403) 438 - 5039 Ingersoll-Rand S.E.A.Ple Ltd.
    Division FAX: (403) 437 - 3145 42 Benoi Road
    11 1 lngersoll-Rand Drive Singapore 629903
    Chamblee. GA 30341 3501 Sl. Charles Blvd. PHONE: (65) 860 - 6836
    PHONE: (404) 936 - 6200 Kirkland, Quebec H 9 H 4 5 3 FAX: (65) 862 - 1373
    FAX: (404) 936 - 6202 PHONE: (514) 695 - 9040
    FAX: (514) 695 - 0963 Auslralia
    Weslern Sales Olfice Ingersoll-Rand Auslralia.Lld.
    Ingersoll-Rand Power Tool 201-6351 Weslminsler Highway A.C.N. 004 099 861
    Division Richmond, B.C. V7C 5C7 8 0 - 100 Frankslon Rd.
    5533 E. Olympic Blvd. PHONE: (604) 274 - 0459 Dandenong, Vic 3175
    Commerce. CA 90022 FAX: (604) 278 - 2519 PHONE: (61) 3 - 794 - 1 6 7 3
    PHONE: (21 3) 725 - 2826 FAX: (61) 3 - 794 - 7 8 9 5
    FAX. (21 3) 725 - 2890 EUROPE IMIDDLE E A S T /
    AFRICA Hong Kong
    Distribution Cenler Ingersoll-Rand Sales Ingersoll-Rand Far East
    Ingersoll-Rand Power Tool Cornpany.Lld. 19th Floor Malaysia Bldg.
    Division Trallord House 50 Gloucesler Rd.
    510 Hesler Drive P.0.Box 2 3 Hong Kong
    While House. TN 37188 Soulhmoor Road PHONE: (852) 527 - 0183
    PHONE: (615) 672 - 0321 Wylhenshawe Road FAX: (852) 529 - 5976
    - FAX: (61 5) 672 - 0601 Manchesler M23 9LN
    United Kingdom Korea
    LATIN AMERICA PHONE: 061 . 9 0 2 . 9098 Ingersoll-Rand Korea
    Ingersoll-Rand Power Tool FAX: 4461 - 946 - 6375 13lh Floor Haekwang Bldg.
    Division TELEX: 667833 158 - 13, Samsung - Dong
    730 N.W. 107lh Ave. Kangnam - ku. Seoul
    Suile 300 PHONE: (82) 2 - 565 - 681 5
    Miami. FL 33172-3107 FAX: (82) 2 - 5 6 5 - 681 8
    PHONE: (305) 559 - 0500
    FAX: (305) 559 - 7505
    TELEX: 441617 TLS VI
    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 =Note:
    valve from the Receiver o r before This valve normally design to be activated
    attempting t o perform any maintenance with its 3ways solenoid pilot valve can be
    o n the Starter Relay Valve. activated directly with the manual actuated
    Never attempt t o remove the cap andlor control.
    the housing cover until air pressure has This valve can also drive inertia or pre-
    been bleed of. If this i s done while engaged ST400 series Starter.
    there i s pressure i n the piping, internal Its own master regulator pressure control
    parts of the valve will b e blown out with the air pressure on the outlet to the starter.
    considerable force. Rated ooeratina conditions :
    IF OUTLET PRESSURE IN EXCESS OF
    THE REGULATOR PRESSURE SETTING Inlet pressure : 0.1 to 3.0 MPa
    COULD CAUSE DOWNSTREAM (1 to 30 kgf/cd)
    EQUIPEMENT TO RUPTURE OR Outlet pressure : 0 to 1.0 MPa
    MALFUCTION, INSTALL A PRESSURE (0 to 10 kgflcm')
    RELIEF DEVICE DOWNSTREAM OF THE Temperature : -20 to 80'C. With dewpoint
    4EGULATOR. THE RELIEF PRESSURE less than air temperature below 0°C.
    CO?ILD AND FLOW CAPACITYOF THE Fluid : Air compressed
    RELIEF DEVICE MUST SATISFY
    REQUIREMENTS.

    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
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    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 I Cause I Countermeasure
    1 Display/LED does n o t light The power is n o t supplied Turn on the power supply
    I
    w e r supply mis-wired. Redo wiring work.
    I
    s-wired t o pulse sensor Redo wiring work.
    I
    Contact signal does n o t output ong set value Redo the setting work.

    The meter does n o t work .ong wiring l ~ e d owiring work

    ~ l s esensor attaching gap Fix within the range of I t o 2 turn


    appropriate return from the rotor.
    It can be checked if it is detected
    during operation of pulse sensor by
    the meen LEO.
    II --

    i s unit or pulse sensor failure


    -'2,Y
    -I
    Check if either t h e unit or sensor is

    !----
    I Meter indication swings during
    constant rotation.
    Icontact output turns off sometimes.
    h e sensor attaching gap
    appropriate
    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
    mseness in pulse sensor lock nut Retighten
    I
    ~ l s esensor failure l ~ e p l a c ethe pulse sensor with a new
    one.
    oise influence Contact the person in charge of
    enaineering
    mseness, omission of wiring Redo wiring work.

    c o r r e c t speed switch set value Redo the setting work


    measurement

    I
    Contact output differs from the nalogue adjustment defect (Only for Make adjustment by analogue settint
    revolution speed detected by the Be phenomenon of meter reading (Correctable UD t o f 9.9%)
    contact output. sing different from the actual
    ~easurement)
    ulse sensor attaching gap Fix within the range of 1 to 2 turn
    appropriate return from the rotor.
    It can be checked if i t is detected
    during operation of pulse sensor by
    JL

    -w-
    nalogue output load resistance Lower the load resistance
    xceeds 500R
    ORDERED BY DDC
    @ S * &
    DEST l NED FOR HUDONG SHIPYARD HNO. HI 3 9 0 ~
    A %
    DK520Z1378
    ENGINE MODEL DK52021379
    & M % z €
    5 ~ ~ - 2 0
    DK520Z1380
    g&*a NOV-05

    1. NO. o f Cylinders [Wf%31 11. Nozzle cooling [/Xlb;$M]


    0 3 0 5 0 6 Oa OWWMDO) 6 0WMWater) E
    O )0w i o u t ( ~ ~ o%)
    W ~ ~ M D %
    2. Speed [@i?4HE&l
    720rnin-1.750rnin-1 900min-1 1000rnin-1 12. F.O. injection nozzle [EHG&N#Fl
    Hole size niZ q 0.26 x 1( 0 0.28 x 10
    3. Direction of revolution [##El~&z~l m0.30Xl( 00.32xlO
    Standard(R) E% qReverse(U 3%
    13. Starting system [EZhzZl
    4. Front P.T.0 [95>9881iiil%BfiB!&] 1 7 ~ 0 M
    ~E ~
    #
    valve
    Wii(Solid) %(-#I Air motor 17'5-9
    O W ~ ( B U ~ ~6U (f)Sl)
    P) 0 ST499 ~ ~ 7 5 0
    awiout %
    14. F.O. shutdown device [i%%gSl
    5. Cam shaft [hL881] I 3 ~ i ~ ~ t
    % 0 ~ 17
    1 ~2
    OSolid Ei@ qB U ~ ~ U931
    P
    15. Capacity o f LO. Cooler [7d;#$h%M%SPl
    6. Turbocharger type [S%@%Z] n6.4m' U 8 m ' 0 1 2 d n 1 6 d
    0 ~ ~ 1 8 3 RH203 ~ ~ 1 4 3
    0 ~ ~ 1 6 03 ~ ~ 1 3 3 16. Inter cooler type [Z%%M#%~I
    DK25 ~ ~ 2 5 ~ .XB
    2 = BOX TYPE
    7. Arrangement turbocharger [jB!f$&EE] DK~O ~ D K ~ O H Z -&El
    a ~ r o n tside 8% Rear side

    8. Turbocharger system [S@ZZ]


    DSP o ~ y n a m i cpres. WE

    9. Governor type [%%@%Zt]


    OUGIO 0RHDG
    lo. F.O. iriection pump [RH@&iK/Yl 17. C.W. pump [;$M7kiK>Y1
    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
    Tokyo Office. 2-10. 2chomo. N:hanoasni-Honcho.Chu~ku,To~y0,103-W23 Japan
    TEL81-3-3279-0627 FAX 81-3-3245-0395
    Sydney Gillce. PO.Box 519. North Sydney N.S.W.2060 Australia
    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, In 3DK engine, the balancing shaft is installed for
    preventing vibration.
    and Main Bearing
    The balancing shaft is supported to the crankshaft
    The frame is a monoblock structure made of cast with 4 thin-walled metal and 2 automatic core-
    iron, and the upper section of the frame forms a adjusting bearing, and is driven by the auxiliary
    cooling jacket, together with the cylinder liner. gear located on the front side of the engine.
    T h e main bearing is a suspension type, and
    mounted to the engine frame with 2 mounting bolts 2-1.5 Piston and Connecting Rod
    and 2 side bolts.
    Intake air, lubricating oil, and each cooling water The piston is an assembly type made Of 'pecia'
    channel, and the timing gear case are incorporated alloy steel with ductile cast iron, and is cooled
    in the engine frame. down by the lubricating oil that is transferred from
    A frame safety valve is provided to the cover on the connecting rod via piston rod.
    the engine frame side. The connecting rod is form-turned forged product
    with the large end, which is horizontally split into
    2-1.2 Crankshaft and Bearing three parts, to allow overhaul of the piston without
    disassembling the bearing unit.
    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 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 2-1.8 Valve Operating Device


    The cylinder head is of a highly rigid structure The intake and exhaust valves are driven by motion
    made of special cast iron, and is hydraulically transferred from the camshaft via swing arm, push
    secured to the piston with 4 bolts. rod. and rocker arm.
    Four valve system is employed having 2 intake
    valves and 2 exhaust valves, and a water cooling 2-1.9 Fuel Control Device
    valve seat, which is directly attached to the cylinder
    head, is installed for each exhaust valve. The governor is installed on the rear of the engine,
    The indicator valve and cylinder safety valve are and is driven by the cam gear.
    installed on the upper face of the cylinder head, The control lever is located near the qauqe
    - - board
    and the starling valve is located on the side of the on the front side of the engine, together with the
    head. Note that 3.5DK engine has no starting starting valve.
    valve since it is motor starting type. &
    2-1.10 intake and Exhaust System @?$
    b A.33,.

    2-1.7 Fuel Injection Device


    The turbocharger and air cooler are mounted on
    The fuel injection pump is a Bosch-type high the front end of the engine.
    pressure pump and a tappet-incorporated The standard specification of the turbocharger is
    monolithic type. It is provided with a closed-type non-cooling and forced-feed lubrication, however
    plunger barrel and isobaric valve, and plunger the specifications may vary according to the engine
    lubrication is employed. type, output, and specification of each order.
    Also, the high-pressure oil inlet coupling, which is a
    horizontal-insertion type, is connected to the fuel
    (a: "Instruction Manual of Turbocharger")
    The exhaust manifold and air intake duct are
    injection pump via high-pressure coupling made of installed on the same side of the engine, and the
    forged steel. 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 opens the starting- valve of each cylinder.
    system, and direct starting system is employed for The compressed air sent through the main
    6.8DK, and air motor starting system is employed starting air pipe effects the piston, causing the
    for 3.5DK. engine to start its rotation.
    The starting operation valve, starting air valve,
    (1) Direct Starting Type and starting air rotary valve are installed on the
    Starting operation is made by means of the front side of the engine, and starting air rotary
    piloted ignition system using compressed air. valve is driven from the front end of the camshatl.
    When the push button for the starting operation Note that a safety valve and a check valve is
    valve is pressed, control air flows to the starting installed in the main air pipe for prevention of the
    a i r valve t o open the main valve, and the reversed flow of combustion air.
    compressed air reaches to the starting valve of In case that the engine is started remotely or
    each cylinder. automatically, the starting operation is made b y
    Meanwhile, the compressed air branched off means of the solenoid valve, allowing control air
    from the main starting air pipe is sequentially to reach the starting operation valve.
    supplied to each cylinder by the starting air ( : "Starting Method")
    rotary valve according to the ignition order, and

    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 Consequently, the air motor is driven by the main
    Starting operation of the engine is made by air air, and the engine starts its rotation.
    motor system using compressed air. In case of starting from the engine side (locally), if
    In case of remote starling or automatic starling, if the starting operation valve i s pressed.
    the stating push button ol the engine control decompressed pilot air opens the main circuit of
    board or operation board (monitoring board) is the starter relief valve, and decompressed air
    pressed, the starter relief valve provided with pushes out the pinion gear of air motor.
    pressure control function (monolithic type Note that a strainer is provided between the air
    incorporated with relief valve) activates, and the tank and relief valve for protection of the air
    decompressed air pushes out the pinion gear of motor.
    the air motor. The relief valve and air motor are installed on the
    When the pinion gear is engaged with the wheel base plate of the engine.
    gear attached to the flywheel, the main air circuit
    of the air motor opens.
    (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. with a safety valve, and is installed on the front side
    Lubricating oil transferred to the lubricating oil of the engine, to be driven from the crankshaft.
    cooler from the lubricating oil pump is regulated to The lubricating oil filter is a notch-wire duplex type,
    reach the specified temperature and pressure, by and blow-off cleaning during operation is possible
    means of the automatic temperature control valve with this filter.
    (hereinafter referred to as temperature control Lubricating oil is supplied to the turbocharger and
    valve) and relief valve respectively, and the fuel injection pump via each special lubricating oil
    lubricating oil is transferred to the oil channel of the filter respectively.
    engine frame from the cooler via filter. Then, from Lubricating oil, that has circulated through and has
    this oil channel, the lubricating oil is supplied to the lubricated each part, returns to the base plate of
    piston through the holes of the connecting rod via the engine (oil tank).
    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

    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 (2) Cooler Llne
    line (primary water) and the cooler line (secondary Cooling water in the cooler line is forcibly fed by
    water), and normally the jacket line is used for a special pump exclusive for cooler line, which is
    fresh water, and the cooler line is used for sea separately installed, to the air cooler, lubricating
    water (in case of use for vessels) as the standard oil cooler, and fresh water cooler, and is then
    application. 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 In case of the special specification using diesel fuel
    uses heavy fuel oil. oil, the cooling system is of independently feeding
    In order to prevent the formation of the carbon system, and the nozzle cooling pump is installed on
    flower that occur on the nozzle tip of the fuel the front parl of the engine. The oil reaches the
    injection valve when fuel oil temperature i s fuel injection valve from the cooling pump through
    intensely heated, cooling of the nozzle tip i s the inlet main pipe to cool the nozzle tip. After
    required, and therefore the nozzle cooling using cooling, the oil returns to the outlet main pipe, and
    cooling water or diesel fuel oil is carried out. then returns to the diesel fuel tank through the relief
    As the standard specification, cooling water is valve and temperature control valve. This is the
    employed. forced-feed circulation syslem.
    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.

    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) d) When the engine reaches the specified
    a) In case of starting the engine by remote rotation speed, the low-speed relay ( 1 4 ) i s
    control, the control lever must always be set lo activated, canceling the start command and
    "RUN" position. The handle switch (HS) will be resetting the protective circuit, so that the
    turned "ON" at this state, and if the turning engine is set to operating state.
    safety switch (TC) is also turned "ON", the
    engine will be on standby and ready for (2) Automatic Starting
    operation. When the engine is started automatically, the
    b) In case of directly starting the engine, the engine solenoid is activated in response to the
    starting solenoid (88V) is powered, excited, start command issued automatically in t h e
    and activated by a start command, so that specified sequence, so that the control air flows
    control air flows into the starting air valve via into the starting air valve and the engine starts its
    starting operation valve, and the starting air rotation.
    reaches the starting valve as the main valve is Further, in case of air motor starting system, the
    opened. solenoid valve of the starter relief valve i s
    Further, in case of air motor starting system, activated b y a start command, a n d
    the solenoid valve of the starter relief valve is decompressed air flows into the air motor, so that
    activated b y a start command, and the the engine starts its rotation.
    decompressed air reaches the air motor to
    push the pinion gear. (3) Engine Side Starting (Local starting)
    When the pinion gear is engaged with the In case of starting the engine from the engine
    wheel gear, the main air circuit of the air motor side (locally), the operation mode must be set to
    will be opened. "LOCAL" position, and in case of direct starting
    c) Meanwhile, the same start command allows system, if the push button of the starting
    the fuel control solenoid (88L) to activate, operation valve is pressed, control air flows into
    causing control air to flow into fuel regulating the starting air valve, and starling air flows into
    cylinder, and allows the common rod to be held the cylinder.
    in position, so that the fuel injection amount is Further, in case of air motor starting system, i f
    controlled not to be excessive at the time of the push button of the starting operation valve is
    starling. 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) b) Remote Starting (Starting from the bridge)
    i ) In case of starting the engine from the i ) When the engine is to be started remotely
    engine side (locally), the changeover valve on (starting from the bridge), set the control
    the engine must be set to the local side, and handle of the bridge to "NEUTRAL" position,
    the control lever must be changed to and set the operating lever to " R U N position.
    "START position from "STOP" position. At Then, the handle switch (HS) will be turned
    this state, the handle switch (HS) will be "ON", and the turning safety switch (TC) will
    turned to "ON", and the protective circuit will also be turned to "ON", so that the engine is
    be released. on standby position for starting.
    i i ) When the push button of the starting ii ) The starting solenoid (88V) is powered,
    operating valve is pressed, control air flows excited, and activated by a start command.
    into the starting valve, and starting air (high and control air flows into the starting valve via
    pressure) flows into the starting valve as the starting operation valve, so that the main
    main valve of the starting air valve is opened. valve is opened, and starting air flows into the
    iii) When the engine reaches the specified starting valve.
    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.

    Pulse sensor

    Starting and Stoppage System (Marlne propulsion engine side)


    General Construction
    Engine Control, protective Device :
    Controlling Engine StoppageIEngihe Protective Device I DK-20 13.2,3.31
    ITEM

    2-3.2 Stoppage Control 2-3.3 Engine Protection System


    (1) For Generator (1) As for the errors that may be led to serious
    The fuel shutdown solenoid (5V) is activated by a accidents or failures, alarm is issued a n d
    stoppage command, causing control air to flow emergency stop is made.
    into the fuel shutdown device, s o that the Each abnormal operation data or value is
    common rod is turned toward stoppage direction, detected b y a switch or sensor, and the fuel
    and then the engine is stopped. shutdown solenoid is activated by an emergency
    In case of stopping the engine from the engine stoppage command, s o that the engine is
    side (locally), turn the operating lever to "STOP immediately stopped.
    position. (2) Depending the specifications, the dual safety
    Note that the fuel control cylinder above system will be provided. In such a case, in
    described is the monolithic type assembled with addition to the normal engine stoppage, control
    the luel shutdown device. air i s flowed into the stoppage air cylinder
    attached to the fuel injection pump to stop the
    (2) For Marine propulsion engine engine.
    The fuel shutdown solenoid (5s) is activated by a (3) When the forward clutch of the reduction gear is
    stoppage command, causing control air to flow engaged, the governor boost solenoid is
    into the stoppage cylinder, so that the rack of the activated by movement of the control handle,
    fuel injection pump is moved toward the stoppage causing the governor air boost to reach the
    direction, and then the engine is stopped. governor, so that the reduction of the engine
    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)

    Table 2.3-1 Alarm and Stoppage Items (Examples)

    I Detection item I Alarm I Shutdown I Location ( Remarks I


    I Overspeed I I I Cam gear I I

    % Marked : Option
    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
    ITEM
    Valve Setting Values DK-20 2

    3-2 Valve Setting Values

    Adjustment value Remarks


    Item
    (design value)
    I I

    Opening start angle


    (before top dead center)
    (30' )

    Closing end angle


    (after bottom dead center) (35' )

    --
    Valve end clearance "C- 1 0.31mm
    (Valve end clearance
    adjusting procedure)
    Opening start angle
    (before bottom dead center) (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,
    Closing end angle adjust valve end clearance "C"
    (after top dead center) such that it becomes equal to the
    value given in this table.
    - I
    Valve end clearance -C' 0.31mm
    --
    In case of direct starting system,
    ! -
    !
    -
    May vary depending on the engine

    I
    Pumping start angle by
    fuel injection pump output and specifications. Refer to
    the Test Run Record Table (included i n
    (before to^ dead center) the final documents).

    uel oil injection valve opening pressure 29.4MPa


    (adjustment value)
    May vary depending on the engine
    output and specifications. Refer to
    Maximum combustion pressure
    I the Test Run Record Table (included in
    the final documents).

    Zylinder safety valve opening pressure 19.1MPa


    (adjustment value) 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, In case of automatically supplying air, first drain
    and drain the condensed water out. the condensed water out of the starting air tank
    and starting air control tank, and then confirm
    1. Close 2. Open that air pressures in these tanks is above the
    1) Drain cock of engine frame inlet air duct lower limit value.
    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) [Turning ]
    Before entering the operation of engine, conduct <Work Procedure>
    the following preparations: i ) Conduct priming with lubricating oil.
    ii ) Set the operating lever to "STOP" position.
    a) Priming with Lubricating Oil
    (Do not inject fuel oil.)
    Start the motor-driven lubricating oil priming
    iii) Set the indicator valve to "Fully open"
    pump (or, reserve pump) 5 minutes before
    position.
    starting the operation of engine, and confirm
    N) Conduct turning 1 to 2 times, and confirm that
    that there is no oil leaks from various parts of
    the engine rotates smoothly.
    the piping.

    [Priming 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 DK-20

    [Air Running (abbreviated as Air Run.)]


    <Work Procedure> Do not fully open the starting air valve during
    i ) Conduct priming with lubricating oil. air run, keeping the opening at about 113, and
    ii) Set the operation lever to " S T O P position carefully conduct air running at low speed.
    iii) "Fully open" the indicator valve. If air run is conducted at high speed by fully
    opening the starling air valve, it will not only
    iv) Open the starting air valve and the control air
    valve, and press the push button forthe start- expend air uselessly, but also will result in seri-
    ing operation valve. Then, starting air flows ous accidents such as aggravation of the
    into the stsrting air valve, and the engine defects if any defect had been caused.
    start its rotation.
    In case of air motor starting system, operate c) Heating of Fuel Oil (when heavy fuel oil is
    the solenoid of the starter relief valve. Then, used.)
    pilot air flows into the air motor, and the In case that heavy fuel oil is used, heating
    engine starts its rotation. shall be made according to the following items:
    v) Keep pressing the push button for 3 to 4 sec- i ) Turn on the fuel oil heating device.
    onds. (for air run) ii) Operate the motor-driven oil feed pump
    . .
    vi) Release the push button. Then, the starting
    ( : 6-1 "Fuel Oil Characteristics and
    air valve closes, and the engine stops its
    rotation. Control")
    In case of air motor starting system,stop the
    operationof the solenoid. Then, the air motor Heated heavy fuel oil i s extremely h o t
    stops, and the engine stops its rotation.
    (100% or more), may cause burn i f you touch
    the piping or equipment on the fuel oil system.
    If the engine starts its rotation during the Therefore, in case of handling the equipment of
    inspection of the inside of the engine or rotary fuel oil system that carriers heat oil, be sure to
    parts, it is extremely dangerous since the wear safety gloves and never touch them with
    working staff may be caught up or the objects bare hands.
    that has been caught up may fly out in all
    directions. d) Turning "ON" of Protective and Alarm
    When conducting air run, strictly observe the Circuit
    following points. Tum "ON" the protective and alarm circuit on
    1) Confirm that the turning device or turning the monitor panel, and confirm that the warning
    bar is set "OFF". lam is lit up.
    2) Send a signal to coworkers and confirm
    safety before starting to press the push but-
    ton of the starting operation valve. e) Operation of Motor-Driven Pumps
    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
    lamp has lit up.
    three types; engine side starting (local starting),
    iv) Press the starting push button.
    remote starting, 'and automatic starting, and
    v ) Confirm that "RUN" indicator lamp on the
    which of these should be employed depends on
    panel has lit up as the rotation speed of the
    the specifications. However, local starting
    engine has reached the specified rate, and
    (starling from engine side) by manual operation
    each pressure has reached the specified value.
    should always be employed after a long period of
    v i ) Close the starting air valve.
    disuse or after overhaul or maintenance.
    (Leave the control air valve "OPEN" as it is.)
    <Work Procedurer
    i ) Open the starting valve and control air valve. (3) Automatic Starting
    ii ) Set the operation lever to "START" position. In case of automatic starting, the engine starts
    iii) Press the push button for the starting automatically by the starting command based on
    operation valve. preset starling conditions, such as the overload
    N) Ifthe rotation speed of the engine has rapidly
    conditions of power shutdown or other engines
    increased and starting has been established (in case of plural engines), and therefore it is
    along with continuous ignition sounds, release essential that the engine should always be kept
    the push button. in operable conditions
    v ) After confirming that the rotation speed of the Engines should b e kept in the following
    engine has reached the specified speed, and conditions at all times:
    each pressure has reached the specified @Starling mode: "AUTO"
    value, set the operating lever to "RUN" @Operation lever position: "RUN"
    position. 8 Starting air valve and control air valve:
    vi) Close the starting air valve. "OPEN
    (Leave the control air valve "Open" as it is.)
    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 Check the exhaust temperature of each cylinder,
    the sliding parts or rotary parts, be sure to once and confirm that all the cylinders are properly
    stop the engine and check that there is no error burnt (at 200°C or more).
    or failure by hand-touching.
    (5) Gas Leakage from Starting Valve
    (1) Engine Rotation Speed If gas has leaked from the starting valve, the
    Confirm that the engine rotation speed (the starting air main pipe becomes hot.
    number of idle rotation speed, in case of the Check il the starting air main pipe is not heated
    marine propulsion engine) has reached the or not by lightly touching the pipe.
    specified rotation speed, and hunting (swinging of
    tachometer) is not occurred. (6) Leakage and Loosenlng of Each Part
    Check il the bolts and nuts of installation part or
    (2) Pressure Reading o f Each Parts
    connecting part are not loosened, and if oil,
    Confirm that the indicator of pressure reading, for
    water, or gas is not leaked.
    the manometer with blue mark, is within the blue
    mark, showing the pressure is within the specified
    value.
    Operation

    DK-20 Running-In Operation


    4-4 Operation (3) lnspection Items during Initial Running-In
    Operation
    4-4.1 Running-In Operation To detect the potential problems and eliminate
    When the engine is started for the first time or the causes to previously prevent such problems,
    immediately after replacement of the parts, such particularly heed cautions l o the following items:
    as the cylinder liners and piston, since the sliding @Abnormal sound
    parts of the engine are not yet sufliciently ready to @ Partial heating
    work smoothly or freely, failure such as abnormal @ I from connection parts, and loosening
    Leakage
    wear or seizure of the sliding parts may occur, if of screws
    the load is abruptly applied in the stage of such @ Explosion pressure, exhaust temperature.
    conditions. irregular exhaust color: Abnormal burning of
    Conduct the running-in operation to ensure smooth fuel
    a n d free working of the sliding parts o n the @ Excessive consumption of lubricating oil:
    following procedure, before entering normal Improper working of liners and rings
    operation:
    (4) lnspection and Works after Completion of
    (1) Initial Running-In Operation Running-In Operation
    I t will substantially a f f e c t the engine At the time when the running-in operation is
    p e r f o r m a n c e , especially the combustion completed, conduct the following inspection
    performance and consequently the consumption works and confirm that there is no abnormalities,
    efficiency of lubricating oil, whether the piston before entering the normal and regular operation
    and oil rings move smoothly and freely, or not. of engine:
    Further, it is assumed that they will be decided @ lnspection of foreign maHers and stains in the
    b y the initial operation of a few hours. crankcase
    When the cylinder liner, piston, piston ring, and @ Visual inspection of the inner surface of the
    sliding parts around cylinder are replaced, be cylinder liner
    s u r e to conduct running-in operation i n @ lnspection and cleaning of the element of
    accordance to the figure shown below. each filter
    (a : Fig. 4.1 "Initial Running-In Pattern") @ Remove the flushing filter attached to the
    element of the fuel oil filter.
    (2) Operating Conditions d u r i n g Running-In
    Operation L l
    Be sure to operate the engine during the running-in Be minded never to perform the operation of
    period under the following conditions: engine using heavy fuel oil, while the flushing
    Load: 80% or less filter is attached.
    @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.
    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
    Be minded to perform no-load operation on
    to the Engine
    for warming-up operation, and restrain the
    In case that the engine is started while it is still in a duration of no-load operation within 10
    cold state, first perform the warm-up operation, minutes.
    except for the case of emergency, and gradually Running the engine under no-load for long
    connect the load after the engine has sufficiently hours will result in malfunctions such as faulty
    been warmed up. combustion and collection of carbons in the
    If the load is hastily connected while the various combustion chamber.
    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 The lower the engine temperature (temperatures
    combustion, excessive wear of the sliding parts,
    of jacket cooling water and lubricating oil) is, the

    -
    and seizure may be caused. longer time it is needed to connect the load.
    The standard load connection time is shown in
    (1) Warming-up Operation of Engine
    the figure below.
    a) Use diesel fuel oil f o r warming-up
    operation
    (m: Fig. 4.2 "Load Connection Pattern")
    In case of the marine propulsion engine (direct
    Be sure to use diesel fuel oil for warming up
    connection by propeller), be minded to gradually
    the engine, even in case of the engine with
    increase the rotation speed, since the load will
    heavy fuel oil specification.
    increase according to the rotation speed.

    b) 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 A

    Operation with Load (Normal Operation) DK-20


    4-4.3 Operation with Load (Normal introduced, and judge if there is any problem
    and check the degree dl deterioration.
    Operation)
    Inspect the running conditions of the engine and
    (m : "Test Run Record Table" in the final
    documents)
    measure the operating performance data in regular
    intervals, during the continuous operation with load <Measurement Items,
    (including period of the running-in operation). Q) Room temperature
    In case that any problem is found as the results ol @Load (output)
    the inspection and measurement, take proper @ Rotation speed
    measures such as adjustment or repair of the ......In case of variable-speed engine
    defective parts. (Refer to a separately provided @Maximum combustion pressure (each
    section.) cylinder)
    (a:
    (a 5-3"Measurement and Adjustment")
    : 7 "Troubleshooting and Countermeasures")
    @ Intake air temperature (turbocharger inlet)
    @Exhaust temperature (outlet of each cylinder)

    (1) lnspection of Operating Conditions


    a Intake air pressure (engine inlet)
    @ Lubricating oil pressure (engine inlet)
    <Check Hems, @Cooling water pressure (engine inlet)
    @ Abnormal sound @ Fuel
    l oil pressure (engine inlet)
    @ Paltial overheat ...... In case of heavy fuel oil specification
    @Leakage from connections and looseness of 0Inlet air temperature (engine inlet)
    screws @Lubricating oil temperature (engine inlet)
    @ A b n o r m a l combustion pressure, exhaust @Cooling water temperature (engine inlet and
    temperature, and exhaust color outlet)
    ......Abnormal combustion @Fuel oil temperature (engine inlet)
    @ Excessive consumption of lubricating oil ...... In case of heavy fuel oil specification
    ...... Damaged cylinder liner and ring @ Reading on fuel injection pump rack scale

    (3) Regular inspection and Maintenance


    During the operation of engine, particularly Conduct inspection and maintenance o f the
    the following parts become extremely hot, various parts of engine regularly.
    and touching these parts with bare hands or (Refer to a separate\y provided section.)
    skin may cause burns.
    Therefore, be minded to use the protective
    (a : 5 "Inspection and Maintenance")

    gears such as safety gloves when working on (4) Operation Records


    them. After completion of the inspection a n d
    0 Exhaust manifold
    measurement, keep the records of the works
    0 Turbocharger
    performed on adjustment or repair i n the log
    0 Air cooler inlet pipe
    book.
    OCylinder head
    0 Indicator valve
    OFuel oil system equipment and piping (in Operation records are very important
    case of heavy fuel oil)] documents when understanding t h e
    conditions of engine and tracing the history of
    ( 2 ) Measuring Performance Data the inspection or maintenance that has been
    a) Measure the operating performance data at performed.
    least once every day, when the load variation is Keep and store them carefully, and when the
    less and the load is stable. supervisor is changed, be sure to transfer the
    b) Compare each of the measured data with the records to the successor without fail.
    data obtained when the engine was newly
    ' l

    Operation
    -
    Operation Using Heavy Fuel Oil

    4-4.4 Operation Using Heavy Fuel Oil d) In Case Load Variation i s Heavy
    (in case of Heavy Fuel Oil @ When entering or leaving port
    Specification Engine) @ When weather is rough and stormy
    @ When cargo is being loaded or unloaded
    Since heavy fuel oil is lower in its quality and
    higher in its viscosity as comperared with diesel e) Before Stopping Engine
    fuel oil, it is required to carry out an appropriate
    ( : 4.6"Stoppage")
    operation control, such as operating the engine by
    changing to diesel fuel oil depending on the load
    (2) Switching Fuel Oil Types
    conditions, in addition an appropriate control of the
    Heavy fuel oil is normally heated up to 80 to
    fuel oil and lubricating oil, when this type of oil is to
    90°C in the service tank, and 100°C or more at
    be used. the engine inlet, and the temperature difference
    Further, the starting and stopping the engine, is larger as compared with that of diesel fuel oil
    when heavy oil is used, is only allowed on the (non-heated), and therefore if fuel oil is suddenly
    engine of the heavy-fuel-oil starting-and stopping switched between these oils, it may cause mal-
    specification. functions such as sticking of the fuel injection
    pump, vapor lock, and so on.
    ( : 6.1 "Fuel Oil Characteristics and Control")
    a) Slowly switch from diesel fuel oil to heavy fuel
    ( a ' 6.2 "Lubricating Oil Characteristics and oil, so that the rate of change in the fuel oil tem-
    perature at the engine inlet is between 5 and
    Control'?
    IC'C per minute.
    (1) Operation with Diesel Fuel Oil ( : Fig. 4.3 "Switching Pattern from Diesel
    Be minded to use heavy fuel oil only under Fuel Oil to Heavy Fuel Oil")
    stable load conditions, and be sure to use diesel b) Maintain the viscosity (temperature) of heavy
    fuel oil in the following cases: fuel oil at the engine inlet at the specified value
    c) Do not raise the temperature of diesel fuel oil
    a) During Running-In Operation Period(l50 hours) beyond the flashing point (60% is the standard
    @) Immediately aHer installation point).
    @ AHer replacement of the sliding parts around d) To prevent the generation of vapor, maintain
    cylinder (e.g. cylinder liner, piston, and piston the pressure of fuel oil at the specified value.
    ring)
    -. Further, remove the air bubbles in fuel oil in
    ( a : 4.4.1"Running-In operationv) 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-
    b) During Starting or Warming-Up Operation ed.

    ( : 4.3 "Starting")
    I.\
    ( : 4.4.2 "Warming-Up Operation") If high-temperature parts are splashed with
    the oil, a fire may occur. Take care not to
    c ) During idling o r Low-Load Operation splash the oil when discharging air.
    When the engine is operated under low load, e) Confirm that the heat traces on piping and
    the compressed air temperature in the cylinder equipment is properly functioning.
    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 The fuel oil is heated, and the filter and the
    used, combustion will become unstable, result- piping are at high-temperatures. If touched
    ing in undesirable conditions, such as worsening with bare hands or skin, it may cause a bum.
    o f the exhaust smoke, sticking of the ring, and Therefore, be minded not to directly touch the
    s o on. In case of the connection of the load that exposed metallic parts such as the valves and
    is below the lower limit described in the engine cocks, and wear the protective gear such as
    specification, be minded to use diesel fuel oil. 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 (1) In case 01 Fixed Pitch Propeller (FPP)
    changes i n accordance with the marine The fixed pitched propeller is generally designed
    characteristics, and according to the changes in by including the sea margin, which has taken into
    the rotation speed. consideration the fouled hull surface, in addition
    The allowable operating range and recommended to the absorbed horsepower due to the marine
    operating range within the marine characteristics characteristics.
    are shown in the figure below. In case that fouling of the hull surface h a s
    When actually operating, be minded to select a advanced, increasing the resistance, and has
    proper rotation speed and engine torque (Pme, to exceeded beyond the sea margin, the absorbed
    be judged based on the reading on the rack scale), horsepower increases to such an extent that the
    a n d keep operating within the recommended excessive torque occurs even if the rotation
    operating range as far as possible, to prevent speed is maintained constant. Therefore, always
    being overloaded. heed cautions to the rotation speed and the
    Note that the lower load limit is normally 30% when reading on the rack scale to prevent excessive
    u s i n g heavy f u e l oil, a n d i f the load to b e torque.
    connected is lower than this limit value, use diesel Further, particularly be careful when t h e
    fuel oil.
    (a : Fig.4.4 "Allowable Operating Range")
    As for the output characteristics of the engine to be
    absorbed propeller horsepower suddenly
    increases, for example when in stormy weather
    and so on, since this will often cause t h e
    actually operated, refer to "Test Run Record excessive torque to occur, eventually leading lo
    Table' included in the separately provided final surging of the turbocharger.
    documents.

    100

    Propeller design point


    85
    -s
    -- 80
    Allowable operating range

    -
    2
    m Recommended continuous
    normal operating range
    a

    I
    60
    P -curve : Marine propeller
    characteristic curve
    M-curve : Curve win sea margin
    taken Into consideration

    Allowable range of
    20 short-lime operation

    Revolutions (%)
    Idling speed

    Fig.4.4 Allowable Operating Range


    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,


    as well as the intake and exaust air systems. '.
    4-5.1 Low-Load Operation
    Since running the engine with a low-load lower 4-5.2 Operation with Air Cooler Cut-Off
    than a certain limit can lead to unfavorable com-
    bustion conditions such as the reduction of intake In case that the defects such as breakage of the
    air pressure and blowing-back of exhaust air, if the fine tube in the air cooler or water leakage from a
    engine is operated under such conditions for long caulked sections is found, and the repairing cannot
    hours, it may result in the various malfunctions be performed quickly, an emergency messure can
    such as fouling of the turbocharger and combus- be taken by cutting off the air cooler on the follow-
    tion chamber, faulty combustion and so on. ing procedure:
    Therefore, be sure to minimize the low-load
    operation to a shorter period of time as much as (1) Low-Load Limit
    possible, and in case that the engine must be a) Stop water supply to the cooler cooling system,
    inevitably run under a low-load for long hours, be and draw out the water from the air pipe.
    sure to observe the following conditions:
    b) Insert a shielding plate A into the flange part of
    (I)Low-Load Limit the air cooler cooling water inlet pipe and outlet
    The low-load limit varies depending on each pipe.
    specification. Confirm the l o w load limit c) "Fully open" the bypass valve of the air cooler.
    described on the specification supplied with the
    engine. d) Operate the cooler cooling water pump, and
    confirm that no water is leaking from the flange
    (2) Use of Diesel Fuel Oil packing area.
    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 Snlelduig plate @
    the intake air temperature and adjust to as a high-

    ..
    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 DK-20 5.3,5.4

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


    In case of the marine propulsion engine, a non- of Cylinders
    turbocharger operation implement (turbocharger Adoption of the operation with the reduced num-
    blind plate ) is provided, so that operation in emer- ber of cylinders impose such problems as the tor-
    gency can be made even ehwn the turbocharger sional vibration of the shaft system as well as the
    may have been damaged. ( The generator is opti- external vibration of the engine, and therefore this
    nal.) operation should be limited as a secondary meas-
    The non-turbocharger operation procsdure is as ure to be used only in emergency.
    the followings: In case of 3DK and 5Dk engines, the operation
    with the reduced number of cylnders is prohibited
    (1) Preparation f o r Operation due to the axternal vibration of engine.
    Install the non-turbocharger operation implement The operation with the reduced number of cylin-
    in accordance with the Turbocharger Instruction ders may be conducted in various cases such as
    Manual 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
    During operation or immediately after stop- sure to inquire our company for the working proce-
    dures, cautionary items on the operation, ansd so
    ping the engine, the turbocharger is extremely
    on, obtain the necessary instructions, and strictly
    hot, and if the turbocharger is touched with observe them, w h e n t h e operation w i t h the
    bare hands or skin, it may cause burns. reduced number of cylinders is conducted
    p+y
    J N 8-4
    Therefore, perform the disassembly work
    after the turbocharger is completely cooled <Preparation f o r Operatiom
    down. a) The fuel oil to be used is diesel fuel oil..
    If it must be removed before it cools down, b) The output shall be as below:
    wear safety gloves, and remove it taking care (No. of cylinders)-(No. of reduced cylinders)
    X 70%
    not to burn your hands. Votal number of cylinders)
    HoweverJhe outpui may be reduced accord-
    ing to the turbochager sursing or exhaust air
    (2) Prerequisites for Operation
    temperature in each case.
    a) The fuel oil to be used is diesel fuel oil c) Exhaust temperature : 450'C or less
    b) Restrain the output as a lower level as possi-
    (each cylinder outlet)
    ble, referring to the following values asthe stan-

    .
    dard:
    Pme(average effective pressure): Be attentive of the external vibration o f

    . 0.44MPa (4.5 kgf/cm2)


    Exaust air temperature (cylinder outlet):
    400 "C or less
    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. (3) After Stoppage
    following procedure: a) Operate both the lubricating oil priming pump
    and cooling fresh water pump for about 2 0
    [In case of local operation] minutes, and cool down the engine a n d
    Shift the operation lever to "STOP" position. turbocharger.
    Then, fuel oil injection will be shut off by means
    of the common rod, and the engine will be u
    stopped. The turbocharger continues to run at high
    speed even after the engine i s stopped.
    [In case of remote control] Lubrication of the turbocharger provided with
    i ) Press the "STOP" push button on the control this engine is made using the system oil, and
    panel. therefore if the supply of lubricating oil is
    Then, the fuel oil injection solenoid valve will stopped immediately after the engine is
    be activated to operate the fuel shutdown stopped, it may damage the bearing.
    device, and the engine will be stopped.

    .
    ii ) Shift the operating lever to "STOP" position.
    b) Fully open the indicator valve to conduct air
    b) After stoppage operation, be attentive of any running for 3 to 4 seconds, and exhaust the
    abnormal sound i n the engine a n d combustion gas out of the combustion
    turbocharger, and confirm that there is not any chamber.
    abnormal sound. 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 as well the cylinder head, and spray rust-
    least 10 minutes after the engine is stopped preventive oil to the internal parts.
    and is completely cooled down. d ) Insert the moistureproof agent such as
    If the crank case is opened immediately after silicagel into the crank case, according to the
    the engine is stopped, flammable mist in the ambient air conditions (e.g. weather and
    crank case may catch fire and explode. humidity) and other necessity.
    Particularly be careful when a large amount e) Place the cover on outside air opening part of
    of mist i s generated due t o overheat or the exhaust air pipe and the mist pipe.
    seizing of the engine. 1 ) Cover the engine with a sheet, and carefully
    Be minded never to let flames or sparks cover the electric equipment with particular
    approach the crank case even after it is attention to prevent collection of dust on them.
    opened.

    4-6.3 Long-Term Shutdown


    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 Pump Rack
    warming-up operation of engine has been In case that the exhaust temperature differs from
    completed and the load has become stable. those of other cylinders in excess of the range
    During measurement, the measured values specified in the above (2),for example, when the
    may change due to such factors a s the fuel injection plunger or the fuel injection valve
    occurrence of the load fluctuation. In such a nozzle is replaced, adjust the fuel injection
    case, perform the measurement again to amount by increasing or decreasing the reading
    obtain a stable data. on the rack scale.
    (a : "Test Run Record" included in the final
    documents) <Rack Adjusting Procedure>
    The reading on the rack scale can be increased
    <Measuring Procedure> or decreased by adjusting screw @ of the fuel
    i ) Open the indicator valve @ with a special injection pump rack lever.
    wrench for indicator valve before installing the i ) Loosen the lock nut @.
    indicator @, and close the indicator valve alter . ii ) Turn the adjusting screw A and change the
    lightly releasing it 1 or 2 times. reading on the rack scale.
    ii ) Install the indicator to the indicator catch 0, Clockwise turning "Increase" (Increase of
    and securely lock it by turning the lock nut @. exhaust air temperature)
    ii ) Close the exhaust valve @ of the indicator. a Counterclockwise turning "Decrease"
    iv) Open the indicator valve. (Decrease of exhaust air temperature)
    v ) Check the reading of .the pressure on the i i ) Confirm that the exhaust air temperature is
    indicator. within the specified value.
    vi ) Close the indicator. N) Securely tighten the lock nul.
    vii) Open the exhaust valve of the indicator, and
    remove the indicator after indicating reading * Difference between cylinders: 1.5 mm or
    has become "0".

    *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 DK-20 3.2

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

    I\ Bypass valve@
    It is impossible to completely remove the
    fouls even when cleansed by blower cleaning,
    and to prevent the deterioration of engine per-
    formance by the elapse of time, however, if the
    cleaning is neglected, 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. en
    (2) lntake Air Temperature I l i . !. I-

    * Proper temperature: 45-55C (at full load) Cuulirig water ilileI


    .....,.
    C~ulirlgwatel uu[lt!t
    lntake air, that is either higher or lower than'the
    specified range, will affect the engine, and there-
    Air Cooler Bypass Valve
    fore be minded to adjust and keep the tempera-
    1 Ins~ectionand Maintenance 1

    In case that the intake air does not fall within the Counterclockwise turning (loosening)
    proper range even when the bypass valve is fully Decrease of pressure
    opened and the entire amount of cooling water is ii ) Be attentive to changes of the pressure, and
    flowed into the air cooler, it i s required to confirm that the pressure has entered within
    disassemble and adjust the air cooler since the the blue mark range.
    fouling of the air cooler can be considered. iv) Tighten the lock nut @, and aHach the cap @.
    ( a 12-3 "Air Cooler" in the Instruction
    Manual, "Maintenance Version") 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 Further, in case that nozzle cooling is conducted
    Heavy Fuel Oil using fresh water, it is not required to regulate
    Heavy fuel oil must be heated so as to make its both the pressure and temperature, since jacket
    viscosity suitable for injection, before the oil is cooling water is used in such a case.
    supplied to the engine.
    b) Nozzle Cooling Oil Temperature
    * Proper viscosity (engine inlet) dynamic
    viscosity: 1 4 k 1 cSt
    1 I
    ..... When Using Heavy Fuel Oil
    *Proper range: 50-60°C 1
    Since the temperature appropriate for proper
    viscosity varies depending on the properties Nozzle cooling oil temperature is regulated by
    (viscosity) of heavy fuel oil, be minded to keep the temperature control valve.
    the proper viscosity referring to the following This temperature control valve is the same type
    figure as a standard: as the one used for regulating lubricating oil. As
    (a: Fig.6-1.1 "Fuel Oil Temperature Curve")
    In case that the viscontroller (automatic viscosity
    for the regulating procedure, refer to the <
    Adjusting Procedure > of (4) Lubricating Oil
    regulator) is installed to the engine, control the Temperature.
    fuel oil viscosity in accordance with instruction In case that nozzle cooling oil temperature is too
    manual, and be minded to carefully keep the low, it will cause sulfated corrosion on the tip part
    manual. of the fuel injection valve nozzle, and in case that
    ( rn : 4-4.4 "Operation Using Heavy Fuel Oil") the temperature i s too high, it will c a u s e
    ( a: 6-1 "Fuel Oil Characteristics and generation of carbon flower on the nozzle.
    Control")

    (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 valves, and a single valve holder tee is provided
    to simultaneously push down both pairs of intake
    5-4.1 Inspecting Parts around lntake and and exhaust valves, and therefore unless the
    Exhaust Valves, and Adjusting Valve valve end clearance of each pair of both intake
    End Clearance and exhaust valves is equal, the valve pushing
    force will be unbalanced, resulting in abnormal
    (1) Replacing Consumables, Implements, and
    wear or damage of the valve holder tee and the
    Measuring lnstruments
    a) Replacing Consumables (a
    @ Head cover rubber seal No.DI0
    : 'Parts List")
    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 *Setting pressure: 29.4 MPa (300 kgflcm')
    after conducting the maintenance work by Be minded to set the pressure of the fuel
    extracting the valve out of the engine, and injection valve at a rather higher level,
    when the nozzle is replaced with a new one. taking into consideration the initial working
    adjust the valve pressure on the following adjustment, in case that a new injection
    procedure: valve is introduced.
    ...... 30.4 MPa (310 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-


    I
    periphery of the nozzle, and screw the rings o n the cylinder head side and f u e l
    retaining nut into the holder housing by hand. injection pipe side, tighten the high-pressure
    iv) Loosen the adjusting nut a. fuel coupling tightening bolt @ and @ with the
    v ) Tighten the retaining nut with the specified specified torque.
    torque.
    *Specified torque: 34-45 N.m
    *Specified torque: 196-226 N.rn (3.5-4.5 kg1.m)
    {ZO-23 kgf.m)

    Be careful not to tighten the retaining nut with


    the toque over the specified value, since it
    may cause the sticking of the needle valve 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
    -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
    iv) Clean the element with washing oil or gas oil, clogging cannot b e removed e v e n by
    and conduct blow-off cleaning from inside. cleaning, replace the element with a new
    v ) Clean each of the parts overhauled, and one.
    clean the case gasket grooves of the filter 3) Since the gaskets and O-rings are easily
    housing @. be damaged, be very careful in handling
    these parts. Particularly, the heavy fuel oil
    <Assembly and Restoration> filter tends to be deteriorated i n high-
    i ) Attach the gasket @ to the element 0, and' temperature conditions, and therefore be
    attach the gasket @ to the filter housing @. minded to replace the filter every time the
    ii ) Put the spring @ on the element, and place overhaul is conducted.
    the case 0 on the top of the spring, and screw
    the nut @ into the case while holding the case
    with hand. (2) Y-Type Filter
    iii ) Close the drain cock @. a) Overhaul and Cleaning
    iv) Shift the handle @ to "Blow-off" position. i ) Remove the plug.
    v ) When the filter is overhauled and cleaned ii ) Remove the strainer.
    during the engine being stopped, conduct ir ) Clean the strainer with washing oil or gas oil.
    priming and fill the case with oil.

    -
    vi) Close the air vent valve @, after the oil has d) Mounting
    b e e n let overflow and air bubbles have When mounting the Y-type filter, be minded to
    completely vanished from the oil flowing out of mount it with the plug side facing downward, so
    air vent pipe. that sludge may be accumulated in t h e
    vii) Return the handle to "Both sides used" (P) strainer.
    position.
    hi) Check if there is any oil leakage from the
    gasket sections.
    - 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 DK-20 4.4

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


    made using the cleaning device that is supplied
    If the fouled degree of the turbocharger blower
    together with the engine.
    has progressed, the efficiency of the turbocharger
    will decrease and the operating performance of i ) Pour cleaning liquid into the blower syringe a.
    engine will be worsened. Particularly when heavy ii) Connect the syringe socket to the filling pipe
    fuel oil is used, the turbocharger blower tends to @ that is connected the turbocharger inlet side.
    be fouled in faster degree, and therefore be mind- iii) Fully open the drain cock of the air intake duct.
    ed to conduct blow-off cleaning and restrain the iv) Operate the syringe to inject cleaning liquid.
    progress of fouling.
    v) When 3 to 5 minutes has passed afler the
    (1) Interval o f Cleaning injection of cleaning liquid, inject fresh water of
    Clean the blower when intake air pressure has the same amount on the same procedure.
    decreased 10% at the same load, or at least [Injection A m o u n t a n d Injecting Time]
    every 150 to 200 hours of operation. vi)) In case that there is no change in intake air
    (2) Load during Cleaning
    Make sure that the engine shall be operated
    under the load of 75% or higher, and continue the
    Type of
    tur-bocharger
    I injection 1 Injecting
    alnount (L) time (sec)
    loaded operation for 1 hour or more afler cleaning. I

    (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.

    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
    Turbocharger Blower Cleaning Procedure hands. Wear safety gloves without fail.

    (4) Cleaning Method


    Inspection and Maintenance

    4.5 DK-20 Cleaning Turbocharger Turbine

    5-4.5 Cleaning Turbocharger Turbine @ after water is fed for 5 minutes, close the..
    nozzle @ to discharge drain at a rate of about
    A 0.1 llmin.
    The turbocharger is at a high-temperature ix) After the completion of water cleaning, close
    during operation and just after the engine is the nozzle @.
    stopped. If you touch it with bare hands during
    x) Make sure that no drain is discharged, and
    cleaning, you may burn your hands. Wear
    safety gloves without fail. close the drain cock @ .
    xi) After water cleaning, keep the engine running
    <Turbocharger type "RH" (water washing)> for about 5 to 10 minutes under the same load.
    (Applicable 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
    m Keep a close watch on the turbine during
    can be removed by the mechanical effect of collo-
    sion of water drops and the dissolving effect. water injection. Take care that the injection
    Part of the water evaporates, and the remaining. rate is not too high or the drain pipe is not
    water is discharged through the drain hole in the clogged with removed deposit.
    gas outlet duct. Even if drainage is not observed, do not feed
    water for 7 minutes or more.
    (1) Frequency of cleaning After the completion of cleaning, remove the
    Clean the turbine every 250 hours. connected hoses.
    (2) Engine running conditions during cleaning
    ( : Separately provided "Turbocharger
    Clean the turbine after &"ing the engine for Instruction Manual")
    about 20 minutes or more at a power at which a
    turbocharger inlet gas temperature of 300 to 350°C
    is obtained

    (3) Cleaning procedure


    i ) Connect the water injection tube @ 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 charge pressure, supercharger revolution


    washing)> speed and so on, repeat the procedure above
    As the pouring water washing method of the after completion of the washing. If any varia-
    supercharger, fresh water is sprayed in front of tion is not observed after repetition of several
    the turbine from the pouring water nozzle on the times, it is necessary to open and clean it.
    supercharger. Thus, the extraneous matter is
    removed through the difference of the cooled 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
    ( a : "Operating Manual for Supercharger")

    every approx. 200 hours. <Turbocharger type "VTR" (Water cleaning)>


    As the procedure of the water cleaning method
    (2) Load during washing
    Apply the washing at such a load as the of turbine, inject fresh water from watering nozzle
    exhaust temperature of the cylinder outlet is 300 located on the exhaust pipe to the front of the tur-
    to 350°C. Asthe exhaust temperature is lower, the bine, remove the adhered matters on the turbine
    washing effect decreases. As it is higher, the tur- nozzle, turbine rotor blade, etc. by the impact
    bine nozzle or similar part may be damaged. force of the water drops accelerated by the
    Take special care for the exhaust temperature. exhaust gas and the solution force of water.
    A part of the fresh water will evaporate, and the
    (3) Fresh water for washing
    remaining will be discharged from the drain hole
    As the fresh water for washing, use the fresh
    water which does not include any additives. of the turbine chamber. Do not evaporate the
    Never use any seawater. fresh water entirely.

    (4) Washing method (1) Interval of cleaning


    Conduct the cleaning with the interval of 200 to
    i ) Connect the hoses of the pressure gauge and
    250 hours in the initial stage, since the effect of
    the check-valve hose to the pipe connected to cleaning will be lost if the layers of the accurnulat-
    the exhaust pipe. ..
    ed matters have become thick.
    ii) Open the check valve, fill the water into the . , As for the cleaning interval after the initial
    pipe and hose up to the nozzle, and close the cleaning, properly increase or decrease depend-
    check valve. ing on the factors such as the exhaust tempera-
    iii) Fully open the valve in the nozzle on the ture, intake air pressure, and the degree of per-
    exhaust pipe. formance decrease of the turbochager rotation
    speed.
    iv) Observing the pressure gauge, slowly open
    the check valve to gain the water valve of (2) Load during Cleaning
    0.45 to 0.7 MPa (4.5 to 7.0 kgWcm2) The maximum allowable rotation speed of the
    v) Continue pouring water 25 to 30 seconds. turbocharger when cleaning is performed is as
    shown in the following table, and therfore in case
    vi) Apply the washing three times. Here, provide
    that the normal load value is higher than these,
    the interval shown in the table below after decrease the ioad.
    washing of one time.
    vii) Close the valve, loosen the hose connection. [Turbocharger Rotaition Speed and Exhaust
    Disassemble the manometer and the hose Temperature]
    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,
    ,
    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.


    Installation position shall be approximately on
    the identical line with the outer diameter of the
    I journal, and shall be on the intersecting point
    on the center line of the crank arm.
    If the crankshafl deflection exceeds its limit,
    the stress to be applied to the crankshaft will iv) Set the reading on the gauge scale to +20 at
    become excessive, and it will result in the the position "B" in the Figure. (To make clear
    breakage of crankshafl if the excess of deflec- the positive and negative directions.)
    tion is too large. v) Slowly conduct turning of the engine in the nor-
    Therefore, adjust the crankshaft deflection to mal direction of rotation, and measure the
    a proper value when being installed, and peri- reading on the scale when the crankshafl is at
    odically measure the deflection, so that it can the angle of " B . "C","D", "E, and "A" respec-
    be corrected whenever it is over the limit value. 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 Bottoms oils resulting from operation by FCC
    on the types of the fuel oil to be used. Be method (catalytic cracking method) are often
    minded to confirm the type of the fuel oil mixed in fuel oils recently.
    referring to the specification of engine, and The mixed oils, such as this, contain rigid
    do not use the oil of which grade is lower alumina silica (catalyst particles), and will
    than that shown in the specification. cause abnormal wear of the various parts of
    I n case that the fuel oil of lower grade is used. engine, particularly the parts o f the fuel'
    troubles may be incurred on the operation of injection system.
    engine, due to the faulty combustion, Remove the solid particles by fully utilizing the
    troubles on the fuel oil system equipment, existing luel oil pretreatment equipment, and
    premature wearing of the parts, and so on. by intensifying the cleaning of fuel oil.
    2) Avoid using the fuel oil by mixing with the In case that the removal of the solid particles
    other oils whose production of origin is cannot sufliciently be made with the existing
    different. In case that fuel oil is mixed the oil fuel oil pretreatment equipment, the
    with inferior affinity, a large amount of sludge reinforcement of the cleaning equipment will be
    may be generated, causing troubles on the required, and when such reinforcement is not
    operation of engine. 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
    ITEM
    Fuel Oil Characteristics and Control DK-20 1 9

    6-1.2 Fuel Oil Characteristics and Control on the viscosity of fuel oil, heat the oil and obtain
    the proper viscosity, by referring to the fuel oil
    (1) Heavy Fuel Oil
    viscosity/temperature curve on a separate page
    Since heavy fuel oil contains more carbon residue
    as a standard.
    and impurities, and is higher in its viscosity as
    In case that a viscontroller (automatic viscosity
    compared to diesel fuel oil, heavy fuel oil cannot
    regulator) is installed on the engine, control the
    be used as the fuel oil for diesel engine, when it is
    fuel oil viscosity to its proper value according to
    in the state of bunker fuel oil.
    the attached instruction manual.
    Therefore, it will be a prerequisite to use heavy fuel
    Fig.6-1.1 "Fuel Oil ViscosityiTemperature
    oil that the oil must properly be preprocessed
    QJICurveu
    before being supplied to engine (including the
    removal of impurities by cleaning, and the - A
    assurance of proper viscosity by heating).
    L l
    'Proper viscosity for fuel oil (engine inlet)
    Kinematic viscosity: 14+ 1 mm2/S
    a) Cleaning Fuel Oil
    If the temperature control o l fuel oil i s
    Water, and solid contents such as vanadium,
    improper, and the fuel oil with high viscosity
    sodium, alumina, and silica, contained in heavy
    has been supplied to engine, it will not only
    fuel oil accelerate the corrosion and wear of the
    incur faulty combustion, but also will resull in
    various parts 6f fuel injection system and fuel
    the accidents such as the clogged o r
    combustion chamber system, substantially
    damaged fuel oil filter, and the breakage of
    affecting and reducing the working life of these
    fuel injection system parts.
    parts,
    For the purpose of removing such impurities, the
    fuel oil preprocessing equipment, such as the (2) Diesel Fuel Oil
    ~ ~

    centrifugal separator and precision filters, are a) Water tends to extract and separate out of
    installed. Since these equipment will not exhibit diesel fuel oil, and further diesel fuel oil tends
    the efficiencies unless each equipment is to generate a large amount of sludge when
    properly handled, be minded to operate each mixed with the oil of different base oil.
    equipment in accordance with the corresponding Daily conduct the draining-off of the
    instruction manual. precipitation tank and settling tank, so that
    a "Instruction Manual" for each equipment water or sludge does not flow into the engine.
    To remove water or sludge, the centrifugal

    -u
    Since waste fuel or sludge will be the causes
    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
    of environmental contamination or pollution,
    be sure to entrust the treatment of these to faulty start or ignition, and this tendency is
    particularly obvious in case of low sulfur diesel
    the authorized waste disposal company, not
    directly handling or disposing these matters oil for land vehicles, due to its low cetane
    on your own. number, if the environmental conditions, such
    as the ambient temperature or water
    temperature, are unfavorable.
    b) Heating Fuel Oil In such a case, special measures will be
    Since the viscosity of heavy fuel oil is vety high, become necessary to improve starting
    it is required to heat the oil, so that a proper capability and combustibility of engine, and in
    viscosity for fuel injection can be obtained. such occasions, contact our company for
    Since the heating temperature varies depending consultation.
    . _,
    I
    ,

    Control of Fuel Oil, Lubricating Oil, and Cooling Water


    ITEM
    1 2 DK-20 Fuel Oil Characteristics and Control
    (3) Gas Oil (4) Kerosene 011
    Although gas oil does not contain few impurities, it As a countermeasures to prevent environmental
    may cause problems on ignition when the gas oil is contamination (air pollution), there may a case in
    refined by FCC method, just like the case with which kerosene oil may be used.
    diesel fuel oil, and therefore b e minded to pay Since kerosene oil is further lower in its cetane
    particular attentions to the cetane number of gas number and is lower in its viscosity than gas oil, it
    oil. is required to carry out a special arrangement on
    Further, since gas oil is low in its viscosity and is the engine, and therefore contact our company for
    inferior in its lubricity, it may cause abnormal wear consultation before using the oil.
    on the sliding 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.

    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 (1)
    . . Cleaning.of Lubricating .Oil
    As the system oil for engine, high-grade lubricating Since fine dust or combustion residue from the
    oil (CD of API service category, or higher) for combustion chamber enter and mix in the
    diesel engine shall be used. lubricating oil, a centrifugal separator is installed to
    Select the lubricating oil of the suitable grade. the engine, to eliminate such foreign matters, in
    according to the quality of the fuel oil to be used. addition to the filters attached to engine. Use such
    The recommended lubricating brands are shown in equipment in correct manner, referring to the
    a separate table. instruction manual of each manufacturer.
    Table 6-2.1 "Recommended Lubricating Oil
    Brands" $\
    Do not conduct cleaning by injecting water into
    : Be minded to use the lubricating oil of the
    lubricating oil.
    Mixing water into lubricating oil will cause
    same brand, not mixing the lubricating oil with degradation of the lubricating oil, such as the
    the oil of any other brand. emulsification of oil, the decrease of total base
    If the lubricating oil is mixed with the oil of number, and the increase of insoluble
    different brand, the additives contained in the substances.
    both oils react for each other, and this may
    result in the degradation of the lubricating oil.
    (2) Control of Lubricating- Oil Characteristics
    Periodically conduct the sampling and analysis of
    (2) Lubricating Oils for Other Equtpment
    ~ ~
    lubricating oil (evely 500 hours), and in case that
    In case that separate lubricating system is the analyzed value of the lubricating oil
    employed apart from the engine lubricating characteristics has reached the control standard
    system, as in the case of the governor, air motor, value, immediately consult the lubricating oil
    turbocharger, generator, deduction gear, etc., be manufacturer, so that the replacement or makeup
    minded to refer to the instruction manual of each
    equipment.
    "Instruction Manual of each equipmen"
    ,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 (Information to b e Attached to Sample
    i ) Collect samples from the air vent pipe of the Receptacle)
    filter during the operation of engine.
    If the samples are collected from the drain Name of your company and your name
    cock, the analyzed value of the 3 Model number of engine
    characteristics may show a diflerent value 3 Engine number
    due to the mixing of sludge or solid a Date and location of sampling
    deposits. 9 The amount of time the engine i s
    ii ) The minimum amount of sampling shall be operated
    500 cm3. 5 ) Lubricating oil brand
    iii) Attach on the sampling receptacle with the The total operation time and quantity of
    label indicating the information as shown on lubricating oil
    the right. 8 Replenishment record (Date and quantity
    of replenishment)
    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 1) Total B a s e N u m b e r (TEN)
    total base number and n-pentane insoluble are Total base number represents the quantity of
    particularly important for the purpose of checking potassium hydroxide (KOH) that corresponds
    the degradation degree of lubricating oil. to the quantity of acid required to neutralize
    the base component contained in 1 g of
    Table 6-2.2 lubricating oil, and is indicated by the unit of
    Lubricating Oil Control Standards (System oil) 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 visconsity I I
    c ~ t + 30% or less / -20%
    or more of new oil I
    indicates the capabilities of lubricating oil to
    clean and disperse the fouled sections in the
    engine.
    1 Flash point 1 "C 1 180°C or higher I 2) Insoluble ( = n-pentane soluble) ,
    Water vol.% 0.3 or less .Insoluble i s fouling substance that do not
    content
    dissolve in oil, and the main component is

    I n-pentane
    insoluble
    2.5 or less
    I soot which is a product of combustion, and
    calcium sulfate which i s a neutralized
    Note: 1) The total base number represents the product.
    values measured according to ASTM D664,
    JIS K2501 (hydrochloric acid method). Since these substances do not dissolve even
    ..... TEN (Total Base Number) in n-pentane which is a solvent, n-pentane
    2) n-pentane insoluble represents the values
    measured according to ASTM D893B. insoluble serves as an index to indicate the
    In case that the measured value has quickly degradation and fouling degree of lubricating
    increased. or has surpassed 1.5, measure oil.
    the insolubles of toluene with the same
    method, and in case ol n-pentane insolubles
    - toluene insolubles L 0.5, replace the
    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 (1) As corrosion prevention agent, we recommend
    use the soft water that meets water quality the agent which is nitrous acid type.
    standards shown in Table 6-3.1 below, or the. (2) Commercially available brands in Japan are
    water to which softening processing has been shown in Table 6-3.2.
    administered 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
    1 --
    Control of Fuel Oil, Lubricating Oil, and Cooling Water
    ITEM
    Cooling Fresh Water (Raw Water) and Corrosion
    Prevention Agent DK-20 W 3 . 3
    Table 6-3.2 Brands of Cornrnercially Available Corrosion Prevention Agents
    -

    Brand Name Manufacturer Constituent Amount to added (ppm)

    DEW-NC 3,000 - 4,500


    Drew Chemical Corp. (U.S.A.) Nitrite
    MAXIGARD 20,000 - 22.000

    C W DIESEL 102 VECOM B.V. Nitrite 1.250 - 5,000

    6-3.3 Control of Cooling Water


    (1) As cooling water, be minded to use fresh water (2) Controlling Fresh Water with PH Value
    added with corrosion prevention agent, from the Measure the PH value of cooling water once
    stage of very first beginning, without fail. 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
    Corrosion prevention agent is poisonous and 20 % of the cooling water to add new water.
    toxic substance. Therefore, be minded never
    to drink the cooling water that is added with (3) Replace the entire amount of cooling water
    corrosion prevention agent. once every year or 2 years.
    Furlher, regarding the handling of the cooling
    water added with corrosion prevention agent,
    be sure to wear the protective gears such as Be minded never to directly discharge the
    nrbber gloves and masks, so that your hands cooling water, which are added with corrosion
    or skin do not directly touch the cooling water. agent, into sea or river, without adequate
    If the corrosion prevention agent has processing.
    accidentally touched your skin or entered your When disposing the cooling water, be sure to
    eyes or mouth, immediately wash them with conduct the water examination, to ensure that
    fresh water sufficiently. 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. 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
    Dalhatsu Dlesel (Europe) Ltd. 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
    Dalhalsu Dlesel (AMERICA), lnc. 180 Adams Avenue,Hauppauge.NY 117BB.U.S.A.
    TEL:l-631-434.87871819 FAX:1-631-434-8759
    Dalhatsu Dlesel (ASIA PACIFIC) PIe.Ltd. 128 Pioneer Road Singapore 639586
    TEL:65-6270-7235 FAX:65-6270-6236
    Dalhatsu Dlesel (SHANGHAI) Co..Lld. Suile 3004 Nan Zheng Building 580 Nan Jing West Road Shanghai. China
    TEL:86.21-5234-1228-9 FAX:86-21.5234-1062
    Dalhntsu Dlesel Pam Servloe Co.,Ltd. 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 DK-20

    (7) Tighten the release valve@ of hydraulic pump. contact with the bottom.
    (8) Loosen the air vent plug @ of hydraulic jack , (4) Strike the jack handle with a hammer, and
    and operate the hydraulic pump lever to vent the confirm that it is securely tightened.
    air in the hydraulic cylinder. Tighten the air vent (5) Slowly open the hydraulic pump release valve.
    plug after confirming that the air is completely and gradually reduce the oil pressure down to
    vented. "0"
    - ~ %&$$
    $@$
    (9) Operate the hydraulic pump lever to increase (6) Manually loosen the hydraulic, and remove it.
    (7) Remove the hydraulic jack stand.
    @$$!
    za.n'T
    the oii pressure up to the specified level.
    (8) In the case of a bolt equipped with the
    Specified value.. ....To be speclfled In protection cap, fit it with the protection cap.
    each work item. ( a : 2-3)

    (10) Insert the jack handle @ into the hole of the 2-4.4 Maintenance of Hydraulic Jack
    circular nut through the oblong hole of the
    hydraulic jack stand, and loosen the circular nut (1) Extract the piston from hydraulic cylinder by
    by 5 to 6 holes. striking its lower area with a wooden hammer,
    (11) Slowly open the release valve of hydraulic a n d pull out the piston from the hydraulic
    pump, and gradually reduce the oil pressure cylinder.
    down to "0". (2) Remove the air vent plug.
    (12) Manually loosen and remove the hydraulic (3) Wash all the parts using the washing oil, and
    jack. check them for scratch.
    (13) Remove the hydraulic jack stand. (4) Apply the hydraulic oil to all the parts, and
    (14) Remove the circular nut. install the hydraulic piston to the cylinder.
    (5) Replace the O-ring and the back-up ring with
    new ones.
    When operating the hydraulic jack, oil is
    highly pressurized, and if oil is leaked and
    sprouted out, it is extremely dangerous. When installing the piston, be careful so that
    Therefore, be minded to wear the protective the O-ring and the back-up ring may not be
    glass without fail. fitted upside down. Wrong way of fitting will
    cause the O-ring to be damaged.

    2-4.3 Tightening of Nut


    (Consurnables for hydraulic jacks)
    (1) Carefully clean around the bolt, and contirm
    that there is no foreign matters on the seat
    (m: "Parts List" )
    @ Back-up ring (small) 9-1.1 No.18
    surface of the nut and jack stand. Then, @Back-up ring (large) 9-1.1 No.19
    manually screw the nut until it gets in contact @ O h g (small) 9-1.1 No.506
    with the bottom, and place the jack stand. @O-ring (large) 9-1.1 No.507
    (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
    ,

    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 (6) Clean the contact surface of the cylinder head
    Cylinder Head (Body) gasket.
    Ifnecessary, conduct the facing-up of the contact
    Since the items mentioned in this section will surface.
    be the parts to which NOx Technical Code (7) Inspect the inside of the jacket through the
    shall be applied, when replacing any of these' cooling water outlet hole. If heavy scale deposits
    parts, be sure to use the parts provided with are found, remove the plug on the upper face,
    the identification marks. and clean the inside. ggp
    ( a : 0-3 "Engine Conforming to NOx
    Technical Code")
    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


    injection system are connected with t h e
    I
    positions. metal touch. Take enough care so that each
    ( 6 ) Mount the cylinder head suspending implement joint may not be damaged, and so that any
    @ on the upper surface of the head, and confirm foreign matters may not be caught in them.
    that there is no foreign matters in the cylinder,
    and install the head. (16) Install the exhaust manifold and each of the
    ( 7 ) Temporarily attach the exhaust manifold piping around the cylinder head.
    mounting bolt, and attach the cylinder head (17) Mount the cylinder head cover, heat box
    tightening nut. 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 (2) Implements and Measuring Instruments
    into the starling air main pipe side to cause sticking a General tools and measuring instruments
    or damage of the starting air rotaly valve, starting ( 0 : 2-2)
    air valve, and so on. and therefore make it a rule to
    conduct the inspection a n d maintenance
    periodically.
    3-3.3 Disassembly of Starting Valve
    In case of overheating of the starting air pipe
    during operation, the possible cause is gas leak (1) Remove the starting valve cover @, and extract
    from the starling valve, and therefore conduct the the starting valve assembly from the cylinder
    inspection of the parts. head.
    (2) Extract the split pin 0, nut @, and starting
    Starting valve assy. : 1.1 kg 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 3-4.2 Replacing Consumables,
    Implements, and Measuring
    The intake and exhaust valves are driven by the
    Instruments
    intake and exhaust cams that are shrunkfit to the
    camshaft, via swing arm, push rod, rocker arm, (1) Replacing Consumables
    and valve retainer tee. Replace the following parts with the new ones:
    Individual areas of the rocker arm are lubricated by ( a: "Parts List")
    @O-ring 3-20 No.512
    the system oil fed from the piping on the fuel oil
    injection pump side of cylinder head, through the
    drilled holes inside the head. (2) Implements and Measuring lnstruments
    For adjusting procedure of the valve end @General tools and measuring instruments
    clearance, refer to the separate "Operation". ( Q) : 2-2)
    (m : "Operation" 5-4.1 "Adjusting Valve End
    Clearance")
    3-4.3 Disassembly of Rocker Arm Device
    Rocker arm assy. : 11.8 k g (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 The threaded part of the indicator valve @ is
    a) Take out hex. Plug @. of "left-handed screw", and the extracting
    b) Extract the straight pin @, and remove the direction is clockwise as viewed from the side
    indicator valve nut @ from the indicator valve of the hexagonal plug.
    0.
    c ) Extract the indicator valve using a screwdriver
    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
    barrel as one pair. The clearance of the
    The F.O. injection pump is a precision parts in
    both parts are matched, and if wrong
    particular.
    combination is made, the parts cannot be
    Even fine foreign matters will cause sticking or
    breakage of the plunger and the delivery valve. used.
    Therefore, when disassembling or assembling 2) Be sure to sort the disassembled p a r k per
    the pump, take every possible care to prevent each pump, so that they do not mix with the
    the infiltration of foreign matters. 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 12-2 Turbocharger


    12-1 General of lntake and Exhaust
    System Since the items mentioned in this section are
    the parts to which NOx Technical Code shall be
    T h e high-temperature and high-pressure applied, when replacing any of these parts, be
    exhaust gases shall be emitted from the cylinder sure to use the parts provide with the identifica-
    are effectively introduced into the turbocharger tion marks.
    through the exhaust manifold, and a part of the
    exhaust energies will be recovered as intake pres-
    (a : 0 - 3 "Engine Conforming to N O x
    Technical Code")
    sure.
    The high-temperature air compressed by the tur-
    Lubricating oil that lubricates the bearing and
    bocharger will be cooled down while passing
    through the air cooler, and will be introduced to the cooling water that cools the bearing base are sup-
    intake duct of the engine frame. plied to the turbocharger.
    The turbocharger and the air cooler is located o n The lubricating oil is supplied to the turbocharger
    the front part of the engine as standard, however through a special filter, being branched from the
    they can be located on the rear part of the engine engine system oil. Further, an orifice is installed at
    according to the specifications. 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.
    f roln allnllicr cyltu:dcr I ri iaoolll(~cy(ifidrr

    lntake a n d E xhaust Device


    ,,-
    co

    Intake and Exhaust Device


    Air Cooler: General ConstructionIReplacing Consumables,
    Implements, and Measuring Instru'mentslDisrnounting DK-20 irk3.3
    12.3 Air Cooler
    12.3.1 General Construction 12-3.3 Dismounting of Air Cooler
    The air cooler is of a fin-tube mulii-tubular type (1) Remove the cooling water inlet and outlet duct
    with box shape, and is installed to the bracket. @.
    The cooling water inlet and outlet ducts of the air (2) Remove the air cooler cover @ andIair cooler
    cooler are equipped with a butterfly valve to adjust inlet duct @.
    the intake air temperature to an appropriate value. (3) Disconnect the exhaust outlet duct @, and the
    turbocharger.
    Model No. of air cooler (4) Remove the air cooler mounting bolt @ and 0,
    DK25, DH31 : 150 k g passing a wire rope around the air cooler and
    DHB31 : 234 k g suspending it with a chain block.
    DK30, DH29, DH39, DH48 : 240 k g (5) Disconnect the air cooler.
    DH52, DH73 : 310 k g
    DH95 : 300 kg

    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 major components of air system of the air
    motor starting type are the starter, relay valve (with
    The air starting type i s employed to DK-20 the regulator), and starling operation valve.
    engines, the direct starting type by the starling Among these equipment, regarding the starter,
    valve is employed to 6.8DK engines, and the air relay valve, and starting operation valve, the
    motor starling type is employed to 3.5DK engines. overhaul and repair i s virtually impossble.
    (0: "Operation" 2-2.1 "Starling Air System") Therefore, be minded to activation is faulty.
    The high-pressure air of 2.5 to 2.9 MPa 125 to 30 As for the air motor, refer to the separately
    kgflcm2) is used as the starting air, and the iow- provided "Instruction Manual".
    pressure air of 0.8 MPa 18 kgf/cm2) is used as the : "Instruction Manual of Air Motor")
    (
    controlling air.
    The major components of direct starting air type
    are the starling air valve, starling air rotary valve,
    and starting operation valve.

    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


    ( : "Operation" 5-4.3 "Cleaning Filters")
    14-1 General of Fuel Oil System
    The engine is designed on the assumption that Facilities a n d equipment for pretreatment
    the driving shall be performed using heavy fuel oil. (a : Separately supplied "Instruction Manual")
    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 reassembling the fuel oil system>
    injection pump. 1) The parts such as the fuel oil injection pump
    and fuel oil injection valve, which are used in
    Since not only the individual systems but also
    the fuel injection system, are all precision
    the facility and equipment will also differ depending
    parts, and therefore if any dust or foreign
    on the grade of the oil to be used, be minded to
    matter is mixed in the oil, it will result in the
    perform appropriate maintenance, inspection, and
    faults such as seizure.ln case that the equip-
    adjustment according to the instruction manuals of
    ment of the fuel oil system is disassembled,
    each facility and equipment.
    regardless of whether it is the one attached
    T h e major component parts attached to the to the engine or the one to be separately
    engine are the fuel oil filter, fuel oil relief valve, fuel installed, be particularly careful so that any
    oil feed valve, and so on. dust or foreign matters will not infillrate into
    As for the inspection and maintenance of the fol- the inside of the equipment or piping.
    lowing equipment, refer to the other sections in this 2) In case that the fuel oil system is over-
    manual or separately supplied documents. hauled, be sure to perform air bleeding afle~
    a
    ( : "Operation" 2-2.2 "Fuel Oil System") 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 (2) Disassemble the relief valve according to the
    following procedure:
    14-2.1 General of structure
    a) Disconnect the cap nut @ , loosen the lock
    The fuel oil relief valve is installed on the read
    end of the fuel oil main pipe, and the valve oper- nut @ , and completely turn back the adjusting
    ates to maintain the pressure at the inlet of the fuel screw @.
    oil injection pump within the appropriate range. Before loosening the adjusting screw, either put
    Excessive oil will be returned to the supply sys- a mark on the tightening position of the adjust-
    tem through the relief valve. ing screw or keep the record of the dimension,
    so that the original position can be identified
    when assembling.
    The fuel oil pressure depends on the source b) Loosen and remove the spring retainer @ .
    pressure of the supply system, and it also C) Remove the spring seat @, spring 0,
    and
    varies depending on the viscosity of the oil.ln
    case of heavy fuel oil, adjustment is readily
    relief valve @ from the relief valve body @.
    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.

    Fuel Oil Relieve 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. 14-2.4 Inspection arld Maintenance of
    Take care not to splash the oil when disassem- Fuel Oil Relief Valve
    bling.
    (1) Wash all the disassembled parts with clean
    washing oil, and remove the sludge
    14-2.2 Replacement Consumables, (2) Inspect if there is any abnormal dent or scratch
    Implements, and Measuring on the relief valve, or also check if the valve is
    not stuck.
    lnstruments
    (3) Inspect if there is any abnormal dent or scratch
    (1) Replacement Consumables on the spring
    Replace the following parts with the new ones.
    (a : "Parts List") 14-2.5 Reassembly of fuel oil pressure
    regulating valve
    1) Circular gasket 4-2.5 No.507.508. 509
    (2) Implements and Measuring instruments Perform the assembly of the relief valve in the
    reverse order of the disassembling procedure.
    1) General implements and measuring
    lnstruments ( a : 2-2 ) (1) Set the adjusting screw to the position of the
    marking.
    14-2.3 Disassembly of Fuel Oil Relief Valve (2) Afler assembling, drive the engine and check
    if the pressure is within the blue mark range,
    (1) Take out the connected piping, and remove and in case that ihe pressure is out of ihe range,
    the relief valve assembly. 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 ITEM

    , Consumables and Implernentsllnspection and Maintenance DK-20 3.1-3.3


    15-3 Lubricating Oil Cooler 15-3.2 Replacing Consumables,
    Implements, and Measuring lnstrurnents
    15-3.1 General Construction
    (1) Replacing Consumables
    The lubricating oil cooler is installed on the engine
    Replace the following pads with the new ones.
    body, and the temperature control valve is
    ( Q:"Parts Listv)
    attached to the lubricating oil outlet.
    @ Gasket 4-3.3.1 No.525, 526
    The cooling pipe is multi-tubular type, and there
    @O-ring 4-3.3.1 No.521
    are the tube plates on both sides, and the tube
    @ Protective zinc mounting gasket 4-3.3.1 No.61
    plate on one side is fixed type, and the tube plate
    on the other side is outer-periphery-slide type, (2) Implements and Measuring Instruments
    which absorbs thermal expansion of the tube, and General tools and measuring instruments
    is sealed with O-ring. (QJ : 2-2)
    In case that the cooling water is sea water,
    protective zinc is attached to the side covers on
    the both sides. 15-3.3 Inspection and Maintenance of
    (a: "OperationM5-4.6 "Inspection and
    Replacement of Protective Zinc")
    Lubricating Oil Cooler
    If sludge is accumulated on the cooling pipe
    surface of the lubricating cooler, the cooling
    Lubricating oil cooler performance will drastically be decreased.
    6.4 m2: 123 k g Therefore, be minded to conduct the maintenance
    8 m2: 136 kg according to the maintenance i n t e ~ aspecified
    l in
    12 m': 170 kg 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 Cooler


    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 Temperature Control Valve
    (1) Take out each connection piping, and dismount Assemble the control valve in the reverse order of
    the temperature control valve. the disassembling procedure.
    (2) Disassemble the temperature control valve on
    the following procedure:
    a) Remove the bolt, and take out the cover @. 1) Apply grease on the sliding part of the
    valve.
    Lil 2) Replace the pellet every 2 years, taking
    Since the spring @ i s compressed, be into consideration the deterioration of the
    minded to slowly and carefully loosen the rubber diaphragm in the inside.
    bolt, so that the spring may not fly out.

    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 Cooling Water Temperature Control
    (1) Disconnect the connection piping, and remove
    Valve
    the temperature control valve assembly. (1) Clean all the disassembled parts with washing
    (2) Disassemble the cooling water temperature oil, and remove the scales.
    control valve in the following procedure: (2) Inspect if there is not any scratch on the outer
    periphery and end surface of the valve, a n d
    (Disassembling procedure) confirm that the valve moves smoothly.
    a) Remove the mounting bolt, and take out the If the degree of scratch is minor, correct it with oil
    cover @. stone.
    Since the adjusting screw 0and the rod a (3) Inspect if there is not any abnormal dent or
    are attached to the cover @, remove them scratch on the cushion spring.
    altogether. (4) Insert the shaft into the shaft bush, and inspect
    b) Remove the mounting bolt, and take out the if it moves smoothly.
    cover @.
    Since the valve @, shaft a,
    pellet @, and
    main spring @ are attached to the cover,
    16-3.5 Assembly of Cooling Water
    remove them altogether.
    Temperature Control Valve
    c) Take out the pellet.
    d) Remove the lock nut @ and @, take out the Assemble the temperature control valve in the
    valve from the shaft. 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) 17-2.2 Replacing Consumables,
    Implements, and M e a s u r i n g Instruments
    17-2.1 G e n e r a l construction
    (1) Replacing Consumables
    As the fuel oil shutdown device, there are two
    Replace the following park with the new ones.
    types, i.e., G1 Type tor the constant-speed engine
    ( Q: "Parts List")
    (such as a generator engine) and J2 Type for the
    <G1 type> O-ring
    variable-speed engine (such a s a marine
    4-7.1.1 No.505.506, 507, 508, 509
    propulsion engine), and which engine should be
    used depends on the purpose of its use and
    (2) Implements and Measuring instruments
    specifications.
    @General implements and measuring instruments
    The fuel oil shutdown device ( G I Type) is provided
    ( Q : 2-2)
    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 17-2.3 D i s a s s e m b l y o f Fuel Oil Shutdown
    shutdown device shifts the fuel injection pump rack . D e v i c e (GI Type)
    to either "Stop" position or "Control" position via
    (1) Before disassembling, pul a mark (matchmark)
    common rod, by affecting the control air to each
    to the adjusting place, or keep the record of the
    piston.
    dimensions.
    (2) Take out the link pin 0, and remove the fork
    I Fuel oil shutdown device ( G l type) : 5.5 k g 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
    /

    d b b b
    Fuel Oil Shutdown Device ( G I Type)
    Engine Control and Protective Device I

    17-2.4 Inspection, Maintenance, and 17-2.5 Mounting and Adjustment of Fuel


    Assembly of Fuel Oil Shutdown Device Oil Shutdown Device (GI Type)
    6 1 Type) (1) Mount the fuel oil shutdown device assembly to
    (1) Wash all the disassembled parts with clean the engine, and attach the fork end and link
    washing oil, and blow air on them. lever.
    (2) lnspect if there is any abnormal dent or scratch At this time, be minded to temporarily adjust the
    on the shutdown piston and control piston. adjusting bolt @ by matching it t o the
    (3) lnspect if there is any abnormal dent or scralch matchmark.
    on the cylinder inner surface. (2) Turn the operation lever to "Drive" position, and
    (4) lnspect if there is any scratch on the main supply control air to the control cylinder of the
    spring. fuel oil shutdown device. And, adjust the screw-
    (5) lnspect if there is any rusting on each parts, in position of the fork end, so that the rack scale
    which is caused by drain. indicates the specified position, and fix the link
    (6) Assemble t h e fuel oil shutdown device \ever.
    assembly in the reverse order of the (3) Next, supply air to the shutdown cylinder, and
    disassembling procedure. 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
    1) Replace all the O-rings with the new ones. shutdown stroke will be decreased.
    2) When assembling, thinly apply grease to (4) When the adjustment of the control stroke and
    the sliding surfaces of the O-ring, piston, the shutdown stroke is completed after repeating
    and so on. the above steps (2) and (3), fix the fork end and
    adjusting bolt with the lock nuts.
    (7) After assembling, confirm that every par1 of the
    device operates smoothly.

    Fork end
    \

    STOP RUN

    Mounting and Adjustment of Fuel Oil Shutdown Device (GI Type)


    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 ITEM

    TYpe) DK-20 3.4

    (4) Next, push the rack indicator needle to the (8) When the adjustment of the rack control stroke
    increase direction, and adjust the screw-in and shutdown stroke is completed by repeating
    position of the spring seat, s o that the rack the procedure of the above Item (3) to (7),fix the
    amount in the state that the link pin is struck fork end and adjust bolt with the lock nut.
    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.
    u
    1) Although hysteresis may be seen between
    If the screw-in direction is clockwise, the limit the increase time and decrease time o f
    rack amount will be decreased. operating air pressure, there is n o
    (5) In case that the rack stopper is set in the full- functional problems at all.
    loaded position, confirm the rack amount to be 2) The adjustment of activating properties of
    limited by the clearance between the link long- the rack control piston shall be conducted
    hole part and link pin. only in the direction of increasing t h e
    (6) After the operating air is decompressed to operating air pressure, so that the errors
    0.1 MPa or lower, gradually supply the operating due to hysteresis can be minimized.
    air to the control piston again, and confirm that 3) Since the spring seat is locked not t o
    activation starting point (Point C in the figure) is rotate by the stopper screw a n d nylon
    within the range of 0.1 -0.2MPa. piece, adjustment shall be conducted after
    (7) Next, supply the control air to the shutdown loosening the stopper screw, and be sure
    piston, and adjust the screw-in position of the to lock it again after finishing t h e
    adjusting bolt, so that the rack position is "0. adjustment.
    If the s c r e w - i n direction is clockwise, the
    shutdown stroke will be decreased.

    Nylon piece and


    Nut stopper screw
    Adjust bolt \ / Fork end Activation startina
    pressure
    -
    Increase Decrease

    I I
    Stopper screw and Link lever
    nylon piece
    iock nu1 Mounting and Adjustment of Fuel Oil Shutdown Device (J2 Type)

    Rack stopper
    posilion / / / / / / / / / / / / / / /k'
    -m
    1
    $
    U

    -0m
    Rack control piston
    .- aclivaling properties
    -m
    3
    LL
    Load properlies of marine
    propulsion engine
    Slarling time control
    position

    0 0.1 0.15 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-


    ing with the equipment for calibration purpose
    18-1.1 General Construction
    or new equipment. In case that any fault is
    The gauge board is equipped with a tachometer found, replace it with a good gauge.
    and each pressure gauge (for lubricating oil, fuel
    b) Replace the flexible hose with a new one.
    oil, intake air, cooling water, etc.), and is supported
    by cushion rubber. 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
    site. Therefore, replace them with the new
    end of piping with flexible hose ones, or inquire the specialized maker for the
    repair.
    2) Heavily deteriorated hoses may break. lfthe
    18-1.2 Replacing Consumables, hoses for fuel oil and lubricating oil break and
    Implements, Measuring Instruments high-temperature parts are splashed with the
    oil, a fire may occur. Replace such hoses
    (1) Replacing Consumables without fail.
    Replace the following parts with the new ones. 3) If the elasticity of the cushion rubber is lost,
    ( : "Parts List") the vibration of the gauge will increase and
    the indication fault of the gauge will be
    @ Flexible hose 4 - 6 . i No. A20. A21, A24
    advanced.
    @ Cushion rubber 4-6.1 No. A15
    (2) Implements and Measuring lnstruments 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
    -

    *0
    EEEEBa"aCnHTE!Fd3& LF&a%%,%iB%
    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
    ni!*!=a
    ~ ~ 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 L O . PIPE. CYL. HEAD INLET
    LO A>. Z>T39'i>77F - RT L.O. PIPE. THERMO. VALVE OUTLET-RT
    h>?WI-1. LOP 7 7 1 - R T PlPE SUPPOTER-1. L.O.P. OUT PIPE.RT
    LO A>, LOP 7 9 1 - 1 - R T 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)

    View " P "


    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 = /
    pK)
    : ~ ~ / : ~t-17: Q - A (:*~,a7 ~
    LUBRICATING OIL COOLER (FRESH WATER)

    View "" P "


    , -

    ik%#%l;~i$%(I&&)
    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

    ;Hi#;aaE% & +@kt (#%$B$E)- a)(-kt


    LUBRICATING OIL RELIEF VALVE &
    5DK-20 FILTER FITTING (REAR T/C) WITH COVER
    , .
    'B!'W~E#
    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 The contents of the manual. including
    performance variable speed governor for use illustrations. drawings and specifications were
    with main and auxiliary marine engines. engines the latest available at the time of printing.
    for electric generators and general power The right is reserved to make changes in
    engines. specifications and procedures at any time
    This service manual describes the construction without notice.
    and operation. repair and maintenance. and
    adjustment of the RHD6 and RHDIO hydraulic Bosch K.K.
    governors.
    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
    7 Qk ,
    /
    FEATURES

    1. The RHD governor has a large controlling 7. The governor body's high tensile aluminum
    force, despite its compact size. alloy casting makes it extremely lightweight.
    2. As the hydraulic fluid is contained in the 8. The governor can be equipped with a
    governor, piping and sub-tank installation governor motor, a pneumatic controller and
    are unnecessary when installing the a hydraulic controller.
    governor on the engine. 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
    3. As the power piston utilizes a differential interchangeable. For example, if a higher
    system, the operating force is uniform. pressure injection system is required or if
    Moreover, it is not necessary to install a the governor's control force is insufficient to
    return spring in the fuel control linkage. cope with the demand for increased engine
    When play in the linkage system is output, decreased fuel consumption or the
    excessive, however, it is necessary to install use of lower quality fuel oil, then the RHDIO
    a spring at the end of the system to absorb can replace the RHD6.
    this play. 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
    4. The governor is able to rotate in either standardized piping connection to enable
    direction, and therefore it can be used the installation of an auxiliary starting
    without modification on engines which rotate booster.
    in the reverse direction. 11. O f t h e R H D I O g o v e r n o r ' s m a i n
    5. Because the normal operating speed is low, components, 80% are identical to those
    governor endurance is high, and gearing is of the RHD6. Almost 100% of the remote
    simple when installing the governor on low control device's components are identical
    and intermediate speed engines. to those of the RHD6.
    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.
    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 SAE20W-40 (Mobiloil)
    3ry weight (lever type) 5.5 kg 15.7 kg
    Sovernor drive power 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
    Applicable engines
    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 applications and, conversely, engines with
    RHDIO is the power piston. The parts adjacent large friction loss can only be used in
    to the power piston also differ. applications equal to or less than those
    Note: specified above.
    1. The method of connecting fuel linkages and 2. Simply because the governor has surplus
    the amount of corresponding resistance control force does not necessarily mean that
    differ depending on the size of the applicable stable operation can be ensured.
    engine and the size and number of the In order to ensure stable operation and to
    injection pumps. prevent the speed from exceeding t h e
    Consequently, engines with little friction loss necessary speed, the inertia of the engine
    c a n be used i n high output 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 zear shafl

    The above figure shows a cutaway view of the pump (RHD6: 1. I 8 MPa {I2 kfglcm2}, RHDI 0:
    RHD6 hydraulic governor. 1.47 MPa (15 kgf/cm2})and returns excess fluid
    The governor is installed directly on the engine. to the gear pump's intake side.
    Engine crankshaft speed is increased using a The gear pump has four check valves so that
    suitable gear ratio, and is then transmitted to governor performance does not vary, even when
    the governor gear shaft. This rotation is the governor rotates in the reverse direction.
    transmitted to the hydraulic governor's gear The gear pump's driven gear and the sleeve are
    pump, which pressurizes the hydraulic fluid. unified. One end of the sleeve is connected lo
    The gear pump pumps hydraulic fluid from the the governor flyweight. The pilot valve inside
    governor's hydraulic fluid tank in through the low the sleeve is moved up and down in response
    pressure side of the regulating valve, and to the flyweight's centrifugal force to control the
    delivers the high pressure hydraulic fluid to the flow of hydraulic fluid to the power piston,
    pilot valve. The regulating valve also regulates reacting promptly to variations in engine load to
    the pressure of the fluid pressurized by the gear rotate the terminal shaft.
    CONSTR CTlON7P
    Air breather

    Flyweight assembly
    Thrust needle roller bearing

    Lower compensating spring

    Compensating piston
    Compensating bushing

    Gear shaft
    P-RHDRdO

    The flyweight's centrifugal force is transmitted mechanism which enables high stabilized
    to the pilot valve by the thrust needle roller output.
    bearing. The speeder spring's force is always The power piston is operated by the hydraulic
    acting against the flyweight's centrifugal force. fluid to move in both the fuel increase and fuel
    The set force of the speeder spring can be decrease directions. The power piston rotates
    changed by moving the control lever. the terminal shaft via the guide lever and the
    The flyweight assembly is an oil damper type terminal arm to directly control fuel injection
    assembly. When sleeve rotation is transmitted quantity.
    to t h e flyweight, the oil acts to absorb In addition to having a larger diameter power
    u n n e c e s s a r y high frequency rotation piston, the RHDIO is equipped with a piping
    fluctuations and enable stable output. connection to enable the connection of an
    The power piston, which controls the fuel auxiliary starting booster to the top of the power
    injection quantity to the engine, is a simple piston.
    79i / j
    OPERATION

    NGlNE STARTING
    Control lever -
    - Fuel decrease
    Fuel increase
    a
    , High pressure
    hydraulic fluid

    - Low pressure
    hydraulic fluid
    uCross section
    \ I

    /
    Gear shaft
    +
    When the engine is stopped, the flyweight is move, the pressurized hydraulic fluid passage
    pushed down and closed by the force of the and the passage to the power piston are open,
    speeder spring. Consequently, the pilot valve and the hydraulic fluid pressurized by the gear
    is in its lowermost position. pump is delivered through the pilot valve to the
    When the control lever is then moved in the fuel top and bottom of the power piston.
    increase direction, the engine is rotated by Because the ratio of the areas of the power
    compressed air, etc, the gear pump is operated piston subject to hydraulic pressure is 1 2 , the
    through the gear shaft and the hydraulic fluid is power piston is immediately moved up (in the
    pressurized. fuel increase direction) to move the output shaft
    Because the flyweight is pushed down by the side lever in the fuel increase direction through
    speeder spring and the pilot valve does not the system of links and facilitate engine starting.
    BOO
    OPERATION

    NORMAL OPERATION
    Control lever
    High pressure
    hydraulic fluid
    Low pressure
    \?I hydraulic fluid
    Cross section
    .

    , Power piston

    When the control lever is moved in the speed is pulled up. At the position where the speeder
    increase direction, the speeder spring is spring force and the flyweight's centrifugal force
    compressed by the speed control shaft. When balance, the high pressure hydraulic fluid
    the speeder spring force exceeds the flyweight's passage and the bottom power piston passage
    centrifugal force, the pilot valve is moved down. are closed by the pilot valve land. Because of
    Because of this, the high pressure hydraulic fluid this, the power piston maintains this position and
    passage and the top and bottom power piston a constant stable speed is maintained.
    passages open, and the high pressure hydraulic At this time, excess hydraulic fluid overflows
    fluid pressure moves the power piston in the through the regulating valve and is returned to
    fuel increase direction to increase engine speed. the gear pump's intake side to maintain a stable
    As the engine speed increases, the flyweight's hydraulic fluid pressure to the pilot valve.
    centrifugal force increases and the pilot valve
    9
    OPERATION

    LOAD DECREASE
    Control lever

    ~ e e d lvalve
    i

    When engine load decreases, and governor compensating spring in the power piston.
    rotation has increased, the flyweight's centrifugal Because of this, the negative pressure
    force increases and moves the pilot valve up. generated in the compensator chamber relieves
    This opens the center pilot port so that the the upward movement of the pilot valve.
    hydraulic fluid in the bottom of the power piston momentarily applying a force in the downward
    returns to the governor's hydraulic fluid tank. direction.
    Consequently, the power piston is moved down The compensating effect ends when hydraulic
    (in the fuel decrease direction) by the high fluid from the governor chamber flows in through
    pressure hydraulic fluid in the top of the cylinder the needle valve for a fixed period to restore
    and the speed is decreased to the previous the negative pressure in the compensator
    balanced condition. chamber to atmospheric pressure.
    W h e n the power piston moves down, it Consequently, when the pilot port is closed by
    compresses the speeder spring through the t h e s p e e d d r o o p mechanism and t h e
    speed droop mechanism's floating lever, the compensator mechanism, the power piston and
    pilot valve moves down, and the land moves to the terminal shaft stop at a new position where
    a position where it closes the pilot port. the fuel necessary to operate the engine at
    When the power piston moves down, its normal no-load speed is supplied when the
    downward movement is also transmitted to the engine load is cut.
    compensating pushrod and piston through the
    @?;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 compensating piston is drawn up by the lower
    exactly opposite to that at load decrease. compensating spring, and the compensator
    Thus, the pilot valve moves down, high pressure chamber pressure becomes positive.
    hydraulic fluid flows into the chamber below the Because of this, the speed at which the pilot
    power piston, and the power piston moves valve moves down is relieved as this pressure
    upward in the fuel increase direction to increase is applied in an upward direction.
    the engine speed and return it to the previous The compensating effect ends when the
    balanced condition. hydraulic fluid flows from the governor chamber
    When the power piston moves up, the speeder in through the needle valve for a fixed period to
    spring is moved upward by the speed droop restore the pressure in the compensator
    mechanism through the floating lever. chamber to atmospheric pressure.
    Consequently, the pilot valve also moves In this way, the pilot valve returns to its regular
    upward until the pilot valve land closes the pilot position and the engine is maintained at the new
    port. 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 The high pressure hydraulic fluid in the bottom
    i n the fuel decrease direction by the high of the power piston is then returned to the
    pressure hydraulic fluid above the power piston, governor's hydraulic fluid tank, the power piston
    when the control lever is moved to the stop side moves down (in the fuel decrease direction) and
    the pilot valve is moved up by the speeder the engine can be forcibly stopped.
    spring. The engine can also be stopped by remote
    control by a governor motor or pneumatic
    rerrninal lever 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 As the governor is simultaneously being turned,
    to the RHDIO governor when necessary. The high pressure hydraulic fluid from the gear pump
    following explains engine operation at starting is also acting on the top and bottom chambers
    when a booster has been connected to the of the power piston.
    governor. Consequently, hydraulic fluid pressurized by the
    When compressed air is supplied to the booster booster moves the power piston in the fuel
    piston to facilitate starting, the piston increase direction faster than normal, and it
    compresses the spring and the hydraulic fluid arrives at the fuel position necessary for starting
    in the chamber opposite the compressed air is faster than normal.
    guided through the discharge side check valve The booster is an effective means of assisting
    to the chamber above the power piston. starting for engines such as those for emergency
    As the governor at this time is in the engine power generators, where mis-starting must be
    starting status, as explained previously, the avoided, and high output engines where the
    hydraulic fluid also flows through the pilot valve governor's surplus output is small.
    to the chamber below the power piston. Boosters are manufactured especially for the
    RHD6 and RHD10 governors.
    c,
    &=,s E'

    OPERATION

    SPEED DROOP MECHANISM


    Speed droop adjuster
    Terminal am1

    a Full load maximum


    U)
    m
    C
    C
    LU

    Time until

    Power piston
    Speed droop (%) = No load maximum speed (N,) -full load maximum speed (N)
    x I00
    Full load maximum speed (N)
    P.RHORQ1

    With the speed droop mechanism, speed droop Conversely, when the load increases, power

    the speed droop adjuster.


    -
    can be varied freely from 0% 10% by adjusting piston movement in the fuel increase direction
    extends the speeder spring so that the engine
    When the speed control shaft position is fixed speed is maintained at a speed a little lower
    using the control lever, and the engine speed is than that when the engine speed was originally
    maintained at a speed suitable for a fixed load, balanced.
    should the load decrease, the power piston is Consequently, by adjusting the speed droop
    moved in the fuel decrease direction (ie, down) adjuster scale, the link lever ratio is changed
    to prevent an excessive speed increase. and, as the speeder spring's set force can be
    With this power piston movement, the speed changed, speed droop can be set freely.
    droop adjuster attached to the terminal arm turns Speed droop (stabilizing droop)
    and pivots the floating lever in a clockwise When load is cut at full-load maximum speed
    direction around the wire A to compress the (N), the speed will increase and then stabilize
    speeder spring and apply a new set load. at no-load maximum speed (NJ.
    Because the speeder spring's set load is Speed droop is the no-load maxrnurn speed ( N),
    increased, the pilot valve is again moved down expressed as a percentage of the full-load
    to a position where it closes the pilot port, the maximum speed (N).
    flyweight's centrifugal force and the speeder Momentary droop
    spring are balanced at an engine speed a little When the load is cut at full-load maximum speed
    higher than the initial balanced condition, and (N), the maximum speed (N,) attained while -the
    this engine speed is maintained. speed is stabilizing expressed as a percentage
    of the full-load maximum speed (N) is referred
    to as the momentary droop.
    B 06
    OPERATION

    COMPENSATOR MECHANISM
    Upper compensating spring

    Lower compensating spring

    Compensating chamber

    Needle valve
    P-RHDR-011

    The compensator mechanism is used to prevent In other words, providing the compensating
    hunting, which generally more easily occurs spring with a set load and varying the rate at
    when speed droop is decreased. which negative pressure is generated by power
    T h e compensator mechanism's upper piston movement can improve stability by
    compensating spring and lower compensating preventing hunting, and improve response (ie,
    spring are both assembled with a set load. the speed at which the power piston moves in
    When engine speed increases and the power the fuel increase direction) by minimizing
    piston has moved in the fuel decrease direction momentary droop.
    (ie, down), the power piston and pushrod and Conversely, when engine speed decreases, the
    the compensating piston first move down power piston moves up. As the lower
    together. Because of this, the pressure in the compensating spring has a set force, however,
    compensating chamber becomes negative. the compensating piston also initially moves up,
    When this negative pressure falls below a and the compensating chamber pressure
    certain value, as it overcomes the upper spring's becomes positive. When this positive pressure
    set load and compresses the spring, the amount exceeds a certain level, the s p r i n g i s
    of compensating spring movement becomes compressed and the rate at which the positive
    relatively less than the amount of power piston pressure is generated is slowed. When the
    movement (the rate that negative pressure is compensating chamber pressure becomes
    generated becomes less than power piston positive, the lower pilot valve chamber pressure
    movement). As the compensating chamber is also becomes positive, and the pilot valve is
    connected to the lower pilot valve chamber, the pushed up to close the pilot port.
    lower pilot valve chamber pressure also Because of this, excessive power piston
    becomes negative, and the pilot valve works to movement and therefore hunting c a n be
    move down against the flyweight's centrifugal prevented.
    force and close the previously open pilot port. Closing the needle valve increases the pressure
    Because of this, power piston movement in generated in the compensating chamber, and
    response to engine fluctuations can be slowed thus increases the compensator effect, so that
    to a certain extent and hunting prevented. 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 Because the speed setting screw acts on the
    speed set switch in the control room is turned speed adjusting mechanism within the governor,
    ON. speed setting screw movement changes the set
    When the motor operates, the speed setting load of the speeder spring to vary engine speed.
    screw is rotated by the friction coupling and gear. The speed can also be changed manually in
    As the speed setting screw is screwed into the the same way by turning the synchronizer knob.
    guide screw, this rotation results in vertical
    movement.
    -
    RHD6 and RHDIO MCL type governor motor
    (with limit switches)

    ~rictio'ncoupling

    Fork

    This governor motor enables electrical control The upper part of the speed adjuster also serves
    of the set governor speed's upper and lower as a cam to operate the limit switches and move
    limits through limit switches. them within the range determined by the slot to
    Three types are available for use with ships' enable adjustment of the upper and lower set
    main engines, pumps, and generators. The speeds.
    control ranges and speed setting times differ When setting the speed manually, the motor side
    depending on the type used. synchronizer can be used to freely vary the
    The motor is decelerated by the gear head speed from the minimum to the maximum
    which, through the friction coupling, turns the irrespective of limit switch control.
    speed setting screw to slide the speed adjuster Also, when an attempt is m a d e to
    in an axial direction. A pin protruding from the simultaneously change the set speed by remote
    speed adjuster turns the speed adjusting lever control, the friction coupling ensures that the
    fixed to the speed control shaft to vary the set speed is first changed on the engine side to
    speed. 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 The pushrod acts on the speed adjusting link
    engine speed. mechanism in the governor to change the set
    When air at a specified pressure is supplied to load of the speeder spring.
    the pneumatic controller, the air pressure acts The engine speed can also be freely changed
    on the diaphragm and plate, compressing the manually in the same way by turning the knob
    spring and pushing the pushrod down. 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. During disassembly, put the disassembled parts
    Before starting disassembly, record neatly and sequentially on the work bench,
    performance data and the positions of labelling them if necessary to facilitate later
    adjustable parts for later reference. This data reassembly.
    will facilitate the detection and diagnosis of any Clean the outside of the governor before
    governor malfunctions and defects. 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


    Wires
    to the floating lever and then remove the
    floating lever.

    P-RHDR.

    4. Remove the pilot valve assernbly.


    Pilot valve assembly
    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. REPLACEMENT STANDARDS
    With parts such as those listed below, first check Parts with key numbers marked 0:
    their external appearance to determine whether Replace at disassembly or every 2 years
    further disassembly is necessary. Parts with key numbers marked :
    Terminal arm assembly Replace every 4 years or 20,000 hours
    Pilot valve assembly
    Housing assembly In principle, assemblies must be replaced when
    Flyweight assembly any of their component parts have been used
    Governor motor assemblv for 8 years or 40,000 hours.
    Wash all parts thoroughly in clean light oil, and
    check for wear, damage and scratches.
    Replace any parts that cannot be reused with
    nebyparts.

    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


    (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 Speed control shan I Compensator chamber high pressure
    hydraulic fluid flow
    / The flow of a large quantity of hydraulic fluid to
    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
    Terminal shaft 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


    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
    1 O Air pressure (MPa (kgf/cm2)) 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)


    Connect the governor motor assembly t o the
    electrical test circuit in accordance with the
    Test electrical circuit Governor rnolor assembly particular motor's specifications, as shown
    Motor I 1 at left.
    Black

    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

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