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DC-32

INSTRUCTION MANUAL
( MAINTENANCE )

Replacement Parts
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
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.

Inquiry and Order


Order ; Parts sales

Daihatsu Diesel Parts Service Co.,Ltd.


12-34, Tanaka-cho, Ibaraki, Osaka, 567-0025 Japan
TEL:81-72-621-3482 FAX:81-72-621-3484

Inquiry ; Service Department

TEL: 06

6454-2346

FAX.

06

6454-2680

Or, get in touch with our offices listed below.

DAIHATSU DIESEL MFG. CO.,LTD.


Osaka Head Office.

http://www.dhtd.co.jp

1-30, Oyodo Naka 1-chome, Kita-ku, Osaka, 531-0076 Japan


TEL:81-6-6454-2393 FAX:81-6-6454-2686
45 Amura-cho, Moriyama-city, Shiga, 524-0035 Japan
Moriyama Factory.
TEL:81-77-583-2551 FAX:81-77-582-5714
2-10, 2-chome, Nihonbashi-Honcho, Chuo-ku, Tokyo, 103-0023 Japan
Tokyo Office.
TEL:81-3-3279-0827 FAX:81-3-3245-0395
P.O. Box 519, North Sydney N.S.W. 2060 Australia
Sydney Office.
TEL:61-2-9923-1155 FAX:61-2-9923-1532
16th Floor, Wisma Antara Bldg., Jl. Medan Merdeka, Selatan No.17, Jakarta-Pusat, Indonesia
Jakarta Office.
TEL:62-21-384-8411 FAX:62-21-384-8412
Unit 1010 Herrera Tower Herrera Corner Valero Sts., Salcedo Village, Makati City 1226 Philippines
Manila Office.
TEL:63-2-753-3211 63-2-817-1279/1285 FAX:63-2-845-0691
No.14 Tai-Tang RD, Lin-Hai Industrial Zone, Kaohsiung, 812 Taiwan
Taiwan Office.
(c/o Marine Technical Industries Co., Ltd.) TEL:886-7-803-1082 FAX:886-7-801-9179
7th Floor, Peninsular House, 36 Monument Street, London EC3R 8LJ, U.K.
Daihatsu Diesel (Europe) Ltd.
TEL:44-20-7626-4600 FAX:44-20-7626-6020
180 Adams Avenue, Hauppauge, NY 11788, U.S.A.
Daihatsu Diesel (AMERICA), Inc.
TEL:1-631-434-8787/8/9 FAX:1-631-434-8759
Daihatsu Diesel (ASIA PACIFIC) Pte.Ltd. 128 Pioneer Road, Singapore 639586
TEL:65-6270-7235 FAX:65-6270-6236
Daihatsu Diesel (SHANGHAI) Co.,Ltd. Suite 3004 Nan Zheng Building 580 Nan Jing West Road Shanghai, China
TEL:86-21-5234-1228~9 FAX:86-21-5234-1062
Daihatsu Diesel Parts Service Co.,Ltd. 12-34, Tanaka-cho, Ibaraki, Osaka, 567-0025 Japan
TEL:81-72-621-3482 FAX:81-72-621-3484

DC-32 Instruction Manual (Maintenance)


CHAPTER

Chapter 0

Introduction

Chapter 1

Configuration of Components and Accessories,


and Maintenance Intervals

Chapter 2

General Matters of Maintenance

Chapter 3

Cylinder Heads and Valves

Chapter 4

Pistons and Connecting Rods

Chapter 5

The Engine Frame and Cylinder Liners

Chapter 6

Main Bearings and Thrust Bearing

Chapter 7

The Crankshaft

Chapter 8

The Timing Gear and the Camshaft

Chapter 9

The Fuel Injection System

Chapter 10

The Valve Driving Train

Chapter 11

The Governor Driving Train

Chapter 12

The Intake and Exhaust Systems

Chapter 13

The Starting Air System

Chapter 14

The Fuel Oil System

Chapter 15

The Lubricating Oil System

Chapter 16

The Cooling Water System

Chapter 17

The Engine Control and the Protective System

Chapter 18

The Gauge Board

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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CHAPTER

Contents

ITEM

DC-32

Chapter 0 Introduction
1.

Matters to be Remembered Before Maintenance Operation

0-1

2.

Matters to be Attended in Relation to Maintenance


2.1 Matters to be Attended for Safety
2.2 Matters to be Attended for Dismantling, Maintenance and Assembling
2.3 Items to be Checked After Dismantling, Maintenance and Reassembling

0-2
0-2.1
0-2.2
0-2.3

3.

Engines Conforming to The NOx Technical Code


3.1 Summary
3.2 Parts Subject to The Regulations
3.3 Calibrated Parameters of The Engine

0-3
0-3.1
0-3.2
0-3.3

Chapter 1 Configuration of Components and Accessories, and Interval of Their Maintenance

1.

Configuration of Components and Accessories

1-1

2.

Table of Maintenance Intervals

1-2

Chapter 2 General Matters of Maintenance

1.

Preparation That Has to be Made Before Starting of The Maintenance Work

2-1

2.

General Consumable Goods, Materials, General Tools, Special Tools and Measuring Instruments

2-2
2-2.1
2-2.2

2.1
2.2
3.
4.

General Consumable Goods and Material


General Tools, Special Tools and Measuring Instruments

Tightening Torque or Oil Pressure for The Bolts and The Nuts
Hydraulic Jack
4.1 Basic Structure and Functions of the Hydraulic Jack
4.2 Unscrewing of the Nuts
4.3 Tightening of the Nuts
4.4 Maintenance of the Hydraulic Jack

Chapter 3 Cylinder Heads and Valves


1.

Cylinder Heads
1.1 Outline of the Structure
1.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
1.3 Detaching of the Cylinder Head
1.4 Inspection and Maintenance of the Cylinder Head (unit)
1.5 Intake/Exhaust Valve Guides
1.6 Intake/Exhaust Valve Seats
1.7 The Nozzle Holder Guide
1.8 Assembling and Installing of the Cylinder Head

2-3
2-4
2-4.1
2-4.2
2-4.3
2-4.4

3
3-1
3-1.1
3-1.2
3-1.3
3-1.4
3-1.5
3-1.6
3-1.7
3-1.8

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ITEM

Contents

DC-32
2.

Intake/Exhaust Valves
2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
2.3 Detachment of the Intake/Exhaust Valves
2.4 Inspection and Maintenance of the Intake/Exhaust Valves
2.5 Inspection and Replacement of the Valve Rotator
2.6 Assembling of the Intake/Exhaust Valve Assembly

3-2
3-2.1
3-2.2
3-2.3
3-2.4
3-2.5
3-2.6

3.

Valve Rocker Arm Assembly


3.1 Outline of the Structure
3.2 Consumable Replacement Parts, Special Tools and Measuring Instruments

3-3
3-3.1

3.3
3.4
3.5

Dismantling of the Valve Rocker Arm Assembly


Inspection and Maintenance of Components of the Valve Rocker Arm Assembly
Assembling of the Valve Rocker Arm Assembly

z Fuel Injection Valve (


4.

5.

Indicator & Safety Valve

5.3
5.4
5.5
5.6
6.

3-4
3-4.1
3-4.2
3-4.3
3-4.4
3-4.5
3-5

Outline of the Structure

3-5.1

Consumable Replacement Parts, Special Tools and Measuring Instruments


Dismantling of the Indicator & Safety Valve
Inspection and Maintenance of the Indicator & Safety Valve
Assembling and Adjustment of the Safety Valve
Assembling and Installation of the Indicator & Safety Valve

3-5.2
3-5.3
3-5.4
3-5.5
3-5.6

The Cylinder Head Outlets of the Cooling Water Piping


6.1 Outline of the Structure
6.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
6.3
6.4
6.5

7.

: [Operation Manual] 5-4.2)

Starting Valve
4.1 Outline of the Structure
4.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
4.3 Disassembling of the Starting Valve
4.4 Inspection and Maintenance of the Starting Valve
4.5 Assembling of the Starting Valve
5.1
5.2

3-3.2
3-3.3
3-3.4
3-3.5

Detachment of the Cylinder Head Outlet of the Cooling Water Piping


Inspection and Maintenance of the Cylinder Head Outlet of the Cooling Water Piping
Installation of the Cylinder Head Outlet of the Cooling Water Piping

The Intake Manifold


7.1 Outline of the Structure
7.2 Consumable Replacement Parts, Special Tool and Measuring Instruments
7.3 Detachment of the Intake Manifold (Head Inlet)
7.4 Inspection and Maintenance of the Intake Manifold (head inlet)
7.5 Installation of the Intake Manifold (head inlet)

DC-23 Z 05-12

3-6
3-6.1
3-6.2
3-6.3
3-6.4
3-6.5
3-7
3-7.1
3-7.2
3-7.3
3-7.4
3-7.5

CHAPTER

Contents

ITEM

DC-23

Chapter 4 Pistons and Connecting Rods

1.

Outline of the Structure

4-1

2.

Consumable Replacement Parts, Special Tools and Measuring Instruments

4-2

3.

Dismantling of the Piston and Connecting Rod Assembly


3.1 Pulling-out of the Piston
3.2 Dismantling of the Big End of the Connecting Rod

4-3
4-3.1
4-3.2

4.

Inspection and Maintenance of the Piston and the Connecting Rod


4.1 Inspection and Maintenance of the Piston
4.2 Inspection and Maintenance of the Piston Rings
4.3 Inspection and Maintenance of the Connecting Rod
4.4 Inspection and Maintenance : Inspection and Maintenance of the Crankpin Bearing

4-4
4-4.1
4-4.2
4-4.3

4.5
5.

Replacement of the Connecting Rod Bolts

Assembling of the Piston and the Connecting Rod


5.1 Assembling of the Large End of the Connecting Rod
5.2 Assembling of the Piston
5.3 Assembling of the Piston and the Connecting Rod
5.4 Checking and Retightening of the Connecting Rod Bolt

4-4.4
4-4.5
4-5
4-5.1
4-5.2
4-5.3
4-5.4

Chapter 5 The Engine Frame and Cylinder liners

1.

Outline of the Structure

5-1

2.

Consumable Replacement Parts, Special Tools and Measuring Instruments

5-2

3.

Inspection and Maintenance of the Inside Surface of the Cylinder Liner

5-3

4.

Pulling-out of the Cylinder Liner

5-4

5.

Inspection and Maintenance of the Outer Surface of the Cylinder Liner, the Inner
Surface of the Cylinder Liner Holder and the Fitted Area of the Engine Frame

5-5

6.

Installation of the Cylinder Liner

5-6

7.

Detachment and Installation of the Cylinder Unit

5-7

Chapter 6 Main Bearings and Thrust Bearings

1.

Outline of the Structure

6-1

2.

Consumable Replacement Parts, Special Tools and Measuring Instruments

6-2

3.

Main Bearings
3.1 Dismantling of the Main Bearing
3.2 Inspection and Maintenance of the Main Bearing
3.3 Assembling and Installation of the Main Bearing

6-3
6-3.1
6-3.2
6-3.3

4.

The Thrust Bearings


4.1 Detachment of the Thrust Bearings
4.2 Maintenance of the Thrust Bearings
4.3 Installation of the Thrust Bearing Metals

6-4
6-4.1
6-4.2
6-4.3

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ITEM

DC-32

Contents

Chapter 7 The Crankshaft

1.

Outline of the Structure

7-1

2.

Consumable Replacement Parts, Special Tools mad Measuring

7-2

3.

Inspection and Maintenance of the Crankpin


3.1 Inspection of the Crankpin
3.2 Inspection of the Crank Journal
3.3 Checking of the Tightening Torque of the Balance Weight Tightening Bolts
3.4 Clearance Between the Oil Cut Cover and the Crankshaft

4. . .Measurement of Deflection of the Crankshaft

Chapter 8 Timing Gears and the Camshaft

7-3
7-3.1
7-3.2
7-3.3
7-3.4
7-4

1.

Timing Gears
1.1 Outline of the Structure
1.2 Consumable Replacement Parts , Special Tools and Measuring Instruments
1.3 Detachment of the Idle Gears
1.4 Detachment of the Cam Gear
1.5 Inspection and Maintenance of the Timing Gears
1.6 Installation of the Cam Gear
1.7 Installation of the Idle Gears

8-1
8-1.1
8-1.2
8-1.3
8-1.4
8-1.5
8-1.6
8-1.7

2.

The Camshaft
2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments

8-2
8-2.1

2.3
2.4
2.5
2.6

Dismantling and Detachment of the Camshaft


Inspection and Maintenance of the Camshaft
Assembling of the Camshaft
Checking of the Fuel Injection Timing

Chapter 9 The Fuel Injection System

8-2.2
8-2.3
8-2.4
8-2.5
8-2.6

1.

Outline of the Structure

9-1

2.

Consumable Replacement Parts, Special Tools and Measuring Instruments

9-2

3.

Detachment of the Fuel Injection System

9-3

4.

5.

The Fuel Injection Pump


4.1 Dismantling of the Fuel Injection Pump
4.2 Inspection and Maintenance of the Fuel Injection Pump
4.3 Assembling of the Fuel Injection Pump
Installation of the Fuel Injection Pump

DC-23 Z 05-12

9-4
9-4.1
9-4.2
9-4.3
9-5

CHAPTER

Contents

ITEM

DC-32

Chapter 10 The Valve Train

10

1.

Outline of the Structure

10-1

2.

Consumable Replacement Parts, Special Tools and Measuring Instruments

10-2

3.

Dismantling of the Valve Train

10-3

4.

Inspection and Maintenance of the Valve Train

10-4

5.

Assembling and Installation of the Valve Train

10-5

Chapter 11 The Governor Driving Device

11

1.

Outline of the Structure

11-1

2.

Consumable Replacement Parts, Special Tools and Measuring Instruments

11-2

3.

Detachment and Dismantling of the Governor

11-3

4.

Inspection and Maintenance of the Governor Driving Device

11-4

5.

Assembling of the Governor Driving Device

11-5

Chapter 12 The Intake and Exhaust System

12

1.

Outline of The Intake and Exhaust System

12-1

2.

Turbocharger

12-2

3.

The Intercooler
3.1 Outline of the Structure
3.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
3.3 Detachment of the Intercooler
3.4 Inspection and Maintenance of the Intercooler
3.5 Installation of the Intercooler

12-3
12-3.1
12-3.2
12-3.3
12-3.4
12-3.5

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ITEM

Contents

DC-32
Chapter 13 The Starting Air System
1.

Outline of the Starting Air System

13
13-1

2.

The Main Air Starting Valve


2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
2.3 Dismantling of the Main Air Starting Valve
2.4 Inspection and Maintenance of the Main Air Starting Valve
2.5 Assembling of the Main Air Starting Valve

13-2
13-2.1
13-2.2
13-2.3
13-2.4
13-2.5

3.

The Starting Air Rotary Valve


3.1 Outline of the Structure
3.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
3.3 Dismantling of the Starting Air Rotary Valve

13-3
13-3.1
13-3.2
13-3.3

3.4
3.5

13-3.4
13-3.4

4.

Inspection and Maintenance of the Starting Air Rotary Valve


Assembling of the Starting Air Rotary Valve

The Starter Push Button and the Handle Switch


4.1 Outline of the Structure

Chapter 14 The Fuel Oil System


1.
2.

Outline of the Fuel Oil System

14-1
14-2
14-2.1
14-2.2
14-2.3

2.4
2.5

14-2.4
14-2.5

Inspection and Maintenance of the Fuel Oil Relief Valve


Assembling of the Fuel Oil Relief Valv
: [Operation Manual] 5-4.3)

Chapter 15 The Lubricating Oil System


2.

14

The Fuel Oil Relief Valve


2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
2.3 Dismantling of the Fuel Oil Relief Valve

zFuel Oil Filter (

1.

13-4
13-4.1

Outline of the Lubricating Oil System


The Lubricating Oil Pump
2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
2.3 Dismantling of the Lubricating Oil Pump
2.4 Inspection and Maintenance of the Lubricating Oil Pump
2.5 Assembling of the Lubricating Oil Pump

DC-32 Z 05-12

15
15-1
15-2
15-2.1
15-2.2
15-2.3
15-2.4
15-2.5

CHAPTER

Contents

ITEM

DC-32

3.

The Lubricating Oil Cooler


3.1 Outline of the Structure
3.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
3.3 Detachment of the Lubricating Oil Cooler
3.4 Dismantling of the Lubricating Oil Cooler
3.5 Inspection and Maintenance of the Lubricating Oil Cooler
3.6 Assembling of the Lubricating Oil Cooler
3.7 Installation of the Lubricating Oil Cooler

15-3
15-3.1
15-3.2
15-3.3
15-3.4
15-3.5
15-3.6
15-3.7

4.

The Lubricating Oil Relief Valve


4.1 Outline of the Structure
4.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
4.3 Dismantling of the Lubricating Oil Relief Valve
4.4 Inspection and Maintenance of the Lubricating Oil Relief Valve
4.5 Assembling of the Lubricating Oil Relief Valve

15-4
15-4.1
15-4.2
15-4.3
15-4.4
15-4.5

5.

The Lubricating Oil Thermostat Valve


5.1 Outline of the Structure
5.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
5.3 Dismantling of the Lubricating Oil Thermostat Valve
5.4 Inspection and Maintenance of the Lubricating Oil Thermostat Valve
5.5 Assembling of the Lubricating Oil Thermostat Valve

15-5
15-5.1
15-5.2
15-5.3
15-5.4
15-5.5

zLubricating Oil Filter (

: [Operation Manual] 5-4.3)

Chapter 16 The Cooling Water System


1.
2.

3.

16

Outline of the Cooling Water System

16-1

Cooling Water Pumps


2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
2.3 Dismantling of the Cooling Water Pump

16-2
16-2.1
16-2.2
16-2.3

2.4
2.5

16-2.4
16-2.5

Inspection and Maintenance of the Cooling Water Pump


Assembling of the Cooling Water Pump

The Cooling Water Bypass Valve


3.1 Outline of the Structure
3.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
3.3 Dismantling of the Cooling Water Bypass Valve
3.4 Inspection and Maintenance of the Cooling Water Bypass Valve
3.5 Assembling and Installation of the Cooling Water Bypass Valve

16-3
16-3.1
16-3.2
16-3.3
16-3.4
16-3.5

DC-32 Z 05-12

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ITEM

DC-32

Contents

Chapter 17 The Engine Control and Protective System


1.
2.

Outline of the Engine Control and Protective System


The Fuel Control Cylinder
2.1 Outline of the Structure
2.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
2.3 Detachment of the Fuel Control Cylinder
2.4 Dismantling of the Fuel Control Cylinder
2.5 Inspection, Maintenance and Assembling of the Fuel Control Cylinder
2.6 Installation and Adjustment of the Fuel Control Cylinder

Chapter 18 The Gauge Board


1.

2.

The Gauge Board


1.1 Outline of the Structure
1.2 Consumable Replacement Parts, Special Tools and Measuring Instruments
1.3 Dismantling and Maintenance of the Gauge Board
The Seal Pot (for the heavy oil engine models)

DC-32 Z 05-12

17
17-1
17-2
17-2.1
17-2.2
17-2.3
17-2.4
17-2.5
17-2.6

18
18-1
18-1.1
18-1.2
18-1.3
18-2

CHAPTER

Introduction

0
ITEM

Matters to be Remembered Before Maintenance Operation


0

DC-32

Introduction

0-1 Matters to be Remembered Before Maintenance Operation


Maintenance operators shall carefully read this manual, be fully acquainted with the structure of the
component to be maintained and with the work of the maintenance and well consider the procedure of the
work before starting the maintenance work.
If a maintenance operator starts the work without enough understanding of the work, an engine failure or damage to the engine due to incorrect assembling may happen to induce an accident resulting in
human injury or death as well as waste of the efforts.
Users shall always avoid utilization of the engine for a purpose or with an operating condition other
than its intended ones and also handling not following this manual since such things might cause an accident or a failure.
Users and maintenance operators are requested to understand that the contents of this manual may
be changed without any advance notice.

A. The following safety signs and symbols are used in this manual. Where any of the symbol is attached to
a remark, it means that the remark is so important in term of safety that the user or the maintenance
operator should be very attentive to safety of the work keeping "safety first" in mind.
: "Warning" = Warning related to safety of a human body
: "Caution" = Warning related to safety of a human body

Possibility of a serious accident

Possibility of a medium or light danger of an accident

: "Handle With Care" = Attention should be paid to prevent the engine or the component from being damaged
: "Prohibited" = An action prohibited in relation to safety.
: "Compulsory Action" = Recommendation or direction of an action in relation to safety.
B. Always replace such a part as is found damaged or has reached the service limit in an inspection.
C. The genuine part or the designated part shall be used for replacement of a part. When a part other than
the genuine one or the designated one is used, DAIHATSU can not assume responsibility for its quality.
D. If a trouble can not be solved on the spot, or a necessary replacement part is not available, contact with
Daihatsu Diesel Parts Service Co., Ltd., Service Division of Daihatsu Motor Co., Ltd. or a Branch of
Daihatsu (the address is listed on the top of this manual) to take an appropriate measure.
When contacting with Daihatsu, be sure to clearly specify the engine type and number.
E. For handling of the following components or units, each operation manual to be separately provided shall
be referred to.
- The turbocharger
- The governor
- Control devices
- Other accessories having specialized specifications
F. This manual and related written materials (drawings, data, etc.) shall be always placed at the designated
place where they are always available to the operators of the engine and maintenance operators and
shall be assuredly transferred to the successor whenever the person in charge of the engine is replaced.
G. A replaced part or waste liquid to be disposed shall not be carelessly disposed but its disposal shall be
entrusted to a specialized contractor.

DC-32 Z 05-12

CHAPTER

0
ITEM

Introduction
Matters to be Attended

2.1 DC-32 in Relation to Maintenance:

Matters to be Attended for Safety

0-2 Matters to be Attended in Relation to Maintenance


0-2.1 Matters to be Attended for Safety
A. Do not open the engine frame side cover for at least 10 minutes until the engine cools enough
after its stoppage. There is a risk that oil mist may be ignited to explode when fresh air flows into an
overheated engine.
B. Rotation of the engine during inspection or maintenance presents such a very dangerous situation
that an accident that something is caught between some parts of the engine.
- Start the work after shifting the control lever back to the "STOP" position, assuredly closing the
valves in the starting air system, vent the starting air in the engine and finally making certain that
the engine would not rotate.
- Switch off the power supply for the engine control system.
- When the turning of an engine is effected, make certain that nothing will touch the rotating part
and the co-worker will not be exposed to any danger due to the engine rotation and finally send a
signal to that person to warn of start of the turning.
- Take a measure to prevent unintentional rotation of the crankshaft.
- Make certain that the switch of the turning motor is in the OFF position.
C. Wear protective gears such as safety gloves, a safety helmet, safety shoes and safety glasses as
appropriate during the work.
- Some part of the engine, especially the exhaust manifold, the turbocharger, the cylinders and
the surrounding of them become hot during operation or immediately after stop. Wear safety
gloves to prevent a burn during the work.
D. Since oil sticks to the floor of the engine room or surroundings of the engine making them slippery,
wipe well the floor and the soles of the shoes before starting the work. Especially for work at a high
place, e.g. on a step, watch for your feet with enough attention to prevent a fall.
E. When disassembling each of the piping systems, "close" all the valves that are connected to
something outside the engine and gradually loosen the air bleed plug to release the residual pressure before starting the disassembling work.
If a joint of each filter or a piping system is disassembled immediately after stop of the
engine, hot oil or water spout out by the residual pressure may cause a burn.
And since scattered fuel oil or lubricating oil may cause a fire when it touches a hot part of
the engine, pay enough attention to scattered oil.
F. Since an ejected spring may injure a person working with a device such as a control valve in which
a spring is incorporated when such a device is disassembled, carry out such work with care.
G. Do not lift a heavy part or a device by human power but do it by means of wire ropes and a chain
block. And do not let any person go under a lifted load.
Use such wire ropes in a good condition as conforms to the specifications meeting the load
requirement and without breakage or a kink and strictly follow the work standards.
H. Switch off the power supply when inspecting or disassembling an electric device or its component
and stand a sign board "Under Repair".
I. When handling a liquid, follow the following instructions.
- Fuel oil/Lubricating oil = Inflammable material .......... No fire shall be brought in.
- Rust preventive oil/Antifreezer for fresh water/Mercury (thermometer) = Poisonous
..........Do not drink any of them. Wash it out when stained by any of them.
- Battery electrolyte = Poisonous/Generating inflammable gas
..........Do not drink. Wash it out when stained by it. No fire shall be brought in.
 Entrust disposal of waste oil and waste water to a subcontractor specialized in waste treatment to
prevent pollution to the environment.

DC-32 Z 05-12

Introduction
Dismantling / Assembling/Matters to be
Matters to be
Attended for Maintenance : Attended and Checked for Assembling

CHAPTER

0
ITEM

DC-32 2.2,2.3

0-2.2 Matters to be Attended for Dismantling, Maintenance and Assembling


A. Spare parts, tools and measuring instruments should be prepared before starting the maintenance work.
Use specified tools and DAIHATSU genuine parts or designated parts to replace the currently installed
parts.
B. Since such parts as gaskets, o-rings, split pins, wire cables for the wiring need to be replaced every time
when the engine or the assembly is dismantled, they should be prepared depending on the scope of dismantling before starting the maintenance work.
C. Block any opening made due to dismantling with a tape or clean cloth to prevent foreign matters from
entering in the engine or the dismantled component. And do not forget to remove it after the maintenance
or the repair is completed.
D. Classify and put in order the components of the dismantled part to prevent them from suffering from flaws
and being missed as well as for efficient work when they are reassembled.
E. For a part having a stamped mark or a match mark of the cylinder number, the bearing number, always
reinstall it on the original place. When any of them is replaced, stamp on the new part the same mark as
that on the replaced part.
F. Since bolts and nuts that are used in a hot place such as the exhaust manifold are made from heat resistant materials, attention should be paid not so as to misuse general purpose ones for them.
G. Evenly tighten each of the bolts and nuts for which the tightening torque (or the oil pressure) is specified.
And do not apply other lubricant than specified one when it is required for tightening.
H. For a part requiring measurement for the maintenance or the repair, assuredly effect measurement and
keep the data in a orderly manner for information to be used in the future.
I. Always restore lagging for the exhaust manifold or the turbocharger, and other parts to insulate hot part
of the engine such as the exhaust manifold cover and the heat box that were detached for disassembling
and/or maintenance to the original places after the work is finished. And renew the treatment and the
material used on the part of a detached joint to prevent inflammable oil from scattering (e.g. FN tape).
J. Replenish consumed spare parts as soon as possible.

0-2.3 Items to be Checked After Dismantling, Maintenance and Reassembling


A. Make certain that all the bolts and nuts are not loosened and firmly locked.
Pay special attention to the places in the engine where visual inspection is difficult during the time when
the engine is operated.
B. Effect the turning and the priming of each fluid after assembling of the engine, and make certain that no
interferences between moving parts and others nor leakage from various points have been detected.
C. Make certain after the work is finished that the turning motor switch has been turned OFF.
D. Record work contents effected and parts replaced in the engine control log book.

DC-32 Z 05-12

CHAPTER

0
ITEM

3.1,3.2 DC-32

Introduction
Engines Conforming to
The NOx Technical Code :

Summary/Parts Subject to The Code

0-3 Engines Conforming to The NOx Technical Code


0-3.1 Summary
A. Marine diesel engines to which the article 13 "Nitrogen Oxides (NOx)" of the attachment VI "Regulations
to Prevent Air Pollution From Ships" to the MARPOL 73/78 Treaty is applied are required to conform to
the NOx Technical Code.
B. Since the engines conforming to the NOx Technical Code are to be certified for an engine family or
group, this method of engine-parameter check can be used for verification of NOx exhaust emission on
board.
This method is a method to verify that the engine components and their calibrated parameters satisfy the contents entered in the technical file, and therefore, measurement of the exhaust
emission of NOx is not required. In case that they do not satisfy the contents entered in the technical file, the method can not be used but an actual measurement test of NOx is required.

0-3.2 Parts Subject to The Regulations


The technical file specifies the components of an engine and their stamped identification marks
that may affect exhaust emission of NOx specified in the NOx Technical Code. The technical file is legally
required to be kept with each engine. When a part specified in the technical file is replaced, the genuine
part provided by DAIHATSU that bears the stamped identification mark shall be used. If a part that does
not bear the stamped identification mark should be used, it would constitute inconformity to the contents
entered in the technical file and the engine-parameter check method can not be used.
The following components are those specified in the technical file required to have the stamped
identification marks. A part with the appropriate mark shall be used whenever replacing such a part making certain that the stamped identification mark is the proper one. (
: "Technical File")
<< Components to Have Stamped Identification Marks >>
1. Cylinder Head
2. Piston
3. Turbocharger
4. Intercooler
5. Fuel Cam
6. Fuel Injection Pump
7. Fuel Injection Pump Plunger
8. Fuel Injection Valve
9. Fuel Injection Valve Nozzle

DC-32 Z 05-12

CHAPTER

Introduction
Engines Conforming to
The NOx Technical Code :

Calibrated Parameters of The Engine DC-32

ITEM

3.3

0-3.3 Calibrated Parameters of The Engine


Since the engines that meet the NOx Technical Code are to be calibrated before their shipment so
that they meet the applicable regulations, such an alteration as changes the calibration out of the range
specified in the technical file shall not be effected after their shipment. If an alteration out of the range
specified in the technical file should be made, it would constitute inconformity to the contents specified in
the technical file and the engine-parameter check method can not be used.

The following items are those specified in the code so that the engine may conform to the NOx
technical code.
<<Parameters to be Calibrated Before The Shipment>>
1. Fuel Injection Timing
2. Fuel Injection Valve Opening Pressure

DC-32 Z 05-12

CHAPTER

Configuration of Components and Accessories, and Interval of Their Maintenance

1 DC-32

Configuration of Components and Accessories

ITEM

Configuration of Components and Accessories, and Interval of Their Maintenance

1-1

Configuration of Components and Accessories


Exhaust Manifold

Intake Valve, Exhaust Valve


Valve Rocker Arm Assembly
Fuel Injection Valve

Piston
Cylinder Liner

Cylinder Head, Starting


Valve, Indicator & Safety Valve
High Pressure Fuel Block
Fuel Injection Pump
Valve Train

Intake Duct

Camshaft
Engine Frame

Connecting Rod

Crankshaft

Engine Frame
Safety Valve
Crank Pin Bearing

Side Bolt

Crankshaft
Main Bearing
Cam Gear
Idle Gear
Cooling Water
Pump
Lubricating
Hydraulic pump
Auxiliary Machinery
Driving Gear
Crank Gear

DC-32 Z 05-12

Flexible Coupling
Thrust Bearing

CHAPTER

Configuration of Components and Accessories, and Interval of Their Maintenance

Configuration of Components and Accessories DC-32

ITEM

Turbocharger

Governor

1
Turbocharger

Control
Handle

Intercooler

Cooling Water Pump


Lubricating Hydraulic pump
Lubricating Oil Thermostat Valve

Lubricating
Oil Cooler

12 Engine Frame Safety Valve

Lubricating Oil Cooler


Lubricating Oil Relief Valve

DC-32 Z 05-12

CHAPTER

Configuration of Components and Accessories, and Interval of Their Maintenance

2 DC-32

Table of Maintenance Intervals

ITEM

1-2 Table of Maintenance Intervals


The following table lists up the parts and work to be regularly dismantled and maintained. For the daily
maintenance and inspection, refer to another manual separately provided. (
: "Operation Manual")
(z : Periodic maintenance, S : The first maintenance after starting of the engine operation or the maintenance involving dismantling of the engine and/or the component,  : Replacement)
Intervals of Dismantling /Maintenance

Component to be
serviced
involving
dismantling of
the engine
and/or the
component
Cylinder Head

Piston

Protect Ring
Connecting Rod

Cylinder Liner

Labor Hours 1000


Work to be Effected

Main Bearing

4000 8000 16000

Reference

-1500 -3000 -6000 -12000 -24000


[Number of
Operators
Every Every
2-3
4-5
Time(hr)] 3 months 6 months Annually years years

Inspection and retightening of Cylinder Head Bolts

20.25

Dismantling of Cylinder Heads (Top hole)

Note

3-1

21.75

3-1

Inspection and maintenance of Cylinder Heads

12.5

3-2

Dismantling, inspecting and finishing of Intake/Exhaust Valves

13.0

3-2

Dismantling and inspecting of Valve Rotators

11.0

3-2

Inspection of Valve Springs and Valve Cotters

10.25

3-2

Dismantling and inspecting of Starting Valves

11.0

3-3

Dismantling and inspecting of Valve Rocker Arm Assemblies

11.0

3-4

Dismantling and inspecting of Indicator and Safety Valves

11.5

3-5

Replacement of Exhaust Valve Seats and O-Rings

12.0

Disassembling of Jackets and removing of scale

12.0

3-1

22.0

4-3

Inspection, cleaning and measurement of Pistons

12.0

4-4

Replacing of Piston Rings

10.5

4-4

Inspection and measurement of Piston Pins

10.25

4-4

Inspection of Piston Pin Bushes

10.25

4-4

Detachment, inspection, cleaning and measurement

10.25

4-3 /5-3

Inspecting and retightening of the Connecting Rod Bolts

22.0

Dismantling and inspecting of Crank Pin Bearings/


Inspecting of Bearing Metals

23.0

Inspection and measurement of Crank Pins

10.5

Inspecting and replacing of Connecting Rod Bolts

21.0

Inspection and measurement of internal surfaces of


Cylinder Liners

12.0

Taking-out of Cylinder Liners

23.0

5-4

11.0

/

5-5

Inspection, cleaning and measurement/Replacing O-Rings 11.0

/

5-6

Taking-out of Pistons (including the small end of the connecting rod)

Inspection of the holder side (jacket side)/Replacing O-Rings


Cylinder Liner Holder

2000

4-5

Inspecting and tightening of Main Bearing Bolts

21.0

Dismantling and inspecting of Main Bearings/


Replacing of Bearing Metals

23.0

DC-32 Z 05-12

3-1

4-4
4-4

/4-7

4-4
5-3

6-3

6-3

CHAPTER

Configuration of Components and Accessories, and Interval of Their Maintenance

1
ITEM

Table of Maintenance Intervals

Intervals of Dismantling /Maintenance

Component to be
serviced
involving
dismantling of
the engine
and/or the
component
Crankshaft

DC-32

Labor Hours 1000


Work to be Effected

Measurement of deflection

2000

4000 8000 16000

Reference

-1500 -3000 -6000 -12000 -24000


[Number of
Operators
Every
Every
2-3
4-5
years
Time(hr)] 3 months 6 months Annually years
21.0

Note

A manual
separately
provided

Operation
Manual

Inspection of tightening of Balance Weight Bolts


Inspection by a hammering test
Inspection by means of the hydraulic jack
Inspection of tightening of the Crank Gear and the
Auxiliary Machinery Driving Gear

10.5

7-3


23.0

7-3

Inspection of the Wiring

10.5

8-1

Inspection by means of a torque wrench

21.0

8-1

Inspecting and retightening of Tightening Bolts

22.0

8-1

Inspection of contact and backlash of Gears


Taking-out and inspecting of the Idle Gear/
Inspection and measurement of the Bushing

10.5

8-1

13.0

8-1

Cam Gear

Dismantling and inspecting of the Gear

24.0

8-2

8-2

8-2

Timing Gear

Camshaft

Taking-out, inspecting and measuring of the camshaft

35.0

Camshaft Bearing

Inspection and measurement of the camshaft bearings

22.0

Fuel Injection Pump

Inspecting of the fuel injection timing


Dismantling and inspecting of Fuel Injection Pumps

21.0
12.0

Replacement of O-Rings



/


Inspection and replacement of Deflectors

8-2
9-4

Replacement of Plunger Assemblies and Delivery Valves


Replacement of Tappet Springs
Fuel Injection Valve

Inspection and cleaning/Adjustment of the injection pressure

11.0

Valve Train

Dismantling of Swing Arms/Inspection of Tappet Rollers and

11.0

Dismantling and inspecting

Governor Driving Train

Dismantling, inspecting and cleaning

9-4
9-4
A manual
separately
provided




10
A manual
separately
provided

12.0

11
A manual
separately
provided

Turbocharger

Disassembling, inspecting and cleaning

Intercooler

Disassembling, inspecting, cleaning and a water pressure test

24.0

Starting Valve

Disassembling and inspecting/Replacement of O-Rings

12.0

 /

13-2

Starting Air Rotary Valve

Disassembling and inspecting

11.5

13-3

Fuel Relief Valve

14-2

Disassembling and inspecting

11.5

Replacement

11.0

Lubricating
Hydraulic pump

Dismantling, inspecting and cleaning

21.5

15-2

 /

15-2

Lubricating Oil Cooler Dismantling and washing

24.0

Instruction
Manual

12-3

Pulse Absorber Assemblies

Inspection and replacement of Bearings and Oil Seals

Instruction
Manual

11

/

Replacement of Bearings

Operation
Manual

10

Bushings

Governor

9-4
9-4

15-3
A manual
separately
provided

Lubricating Oil Filter

Dismantling and washing

Lubricating Oil Relief Valve

Dismantling and inspecting

11.5

Lubricating Oil
Thermostat Valve

Dismantling, inspecting and cleaning/Replacing of the Pellet

11.0

Instruction
Manual

15-3

15-5

DC-32 Z 05-12

CHAPTER

Configuration of Components and Accessories, and Interval of Their Maintenance

2 DC-32

Table of Maintenance Intervals

ITEM

Component to be
serviced
involving
dismantling of
the engine
and/or the
component
Cooling Water
Pump

Intervals of Dismantling /Maintenance


Labor Hours 1000 2000 4000 8000 16000 Reference
Work to be Effected

Dismantling, inspecting and cleaning

-1500 -3000 -6000 -12000 -24000


[Number of
Operators
Every
Every
2-3
4-5
years
Time(hr)] 3 months 6 months Annually years

22.5




Inspection and replacement of Oil Seals and Mechanical Seals

Cooling Water
Bypass Valve
Cooling Water
Thermostat Valve
Fuel Oil Control
Cylinder
(Fuel Cut-off/Fuel
Limiting Device)
Instruments

Dismantling, inspecting and cleaning/Replacement of O-Rings

11.0

Dismantling, inspecting, cleaning and replacing

10.5

Dismantling and inspecting/Replacing of


O-Rings and Seals\

11.0

Pressure Gauge Hose

11.0

Inspection of Pressure Gauges and Tachometers Calibration

proof

16-2

Inspection and replacement of Bearings

16-2

 /


16-2
16-3

 /

Note

17-2.3

18

()

18

Seal Pot (for the heavy oil model)


Replacement of ethylene glycol

10.5

18

Note : 1. The labor hours and the intervals of maintenance involving dismantling of the engine and/or the
component indicated in the above table represent typical ones under the usual conditions of operation
with heavy oil. In the actual case, expect the more labor hours than the indicated ones and effect the
shorter intervals of maintenance involving dismantling of the engine and/or the component than the
indicated ones. And establish the labor hours and the intervals of maintenance involving of the engine
or the component most suitable to the engine based on the operational conditions of the engine, the
work conditions and the experience in the maintenance actually effected involving dismantling.
2. Since the labor hours indicated in the above table represent those including restoration effected by
skilled technicians, do not make a tight schedule for the maintenance during the period when the technicians are not accustomed to the maintenance work.
3. The labor hours to which a mark is attached represent those for maintenance of one unit (one
cylinder, one journal etc.). Therefore, multiply the indicated labor hours by n when n units need to be
maintained.
4. The maintenance work to which a @ mark is attached should be effected by specialized technician
of the manufacture or a contractor specialized in the maintenance or under their instruction.

DC-32 Z 05-12

CHAPTER

Configuration of Components and Accessories, and Interval of Their Maintenance

MEMO

1
ITEM

DC-32

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

1 DC-32

Preparation That Has to be Made Before Starting of The Maintenance Work

ITEM

General Matters of Maintenance

2-1 Preparation That Has to be Made Before Starting of The Maintenance Work
The following preparation should be made before starting of dismantling of the engine and the maintenance work.
<<Pre-work Preparation>>
(1) Shift the control lever to the "STOP" position.
(2) Shut off the main valve installed on the air reservoir.
(3) Shut off the main valves at the inlet and the outlet of the fuel system.
(4) Shut off the main valves at the inlet and the outlet of the lubricating oil system.
(5) Shut off the main valves at the inlet and the outlet of the cooling water system.
(6) Open the drain valve for cooling water of the lubricating oil cooler case to discharge cooling water
in the jackets.
(7) Suspend the power supply for the engine control system.
(8) Open the indicator valves fitted on the cylinder heads.

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

General Consumable Goods, Materials, General


Tools, Special Tools and Measuring Instruments
2-2 General Consumable Goods,
Materials, General Tools,
Special Tools and Measuring
Instruments
General consumable goods, materials, general tools, Special Tools and measuring instruments that are necessary for maintenance of the
engine are as follows. Special consumable parts,
tools and measuring instruments to be used for
each maintenance work are indicated in a section
describing the procedure of each maintenance
work.

2-2.1 General Consumable Goods


and Material
1.
2.
3.
4.
5.
6.

Cotton waste
Washing oil
Lubricating oil
Grease
Machine oil VG-10
Lubricant (Molykote 1000 spray, Molykote
1000 paste, Molykote U paste)
7. High temperature seizure preventive lubricant
(Molykote G Rapid, SMOCON Paste)
8. Liquid sealer (Three Bond 1215)
9. Silicon rubber
10. Abrasive compounded (Medium roughness
and fine roughness) (for finishing of valves)
11. Lubricating penetrant (KURE5-56)
12. Dye flaw detecting penetrant (for color checking)
13. Blue Paint Lead (for confirmation of contact)
14. Liquid nitrogen or dry ice, and alcohol (for
shrinkage fitting)
15. Steel wire (for wiring)
16. Wire brush
17. Sandpaper #80 and other abradants
18. Oilstone
19. Corrosion preventive coating (for repair of the
cylinder liner)
20. Amending materials (for repair of the cylinder
liner)
21. Lead wire (for measurement of gear backlash
and others)
22. Adhesive (Loctite271, 962T and 243)

2-2.2 General Tools, Special Tools


and Measuring Instruments
A.General Tools and Special Tools
1. General Tools and Outfits
(a) Sockets (13 x 12.7, 19 x 12.7, 22 x 12.7,
24 x 12.7, 27 x 12.7, 30 x 12.7, 30 x 19,
32 x 19, 36 x 19, 41 x 25.4)

2.
3.
4.
5.
6.
7.
8.
9.

ITEM

DC-32 2.1,2.2

(b) Open-end wrenches (13 x 17, 19 x 22, 24


x 27, 30 x 32, 36 x 41, 46 x 50)
(c) Single-end wrenches (8, 10, 55, 60, 65)
(d) Box-end combination wrench (19 x 22)
(e) Hexagonal-bar wrenches (5, 6, 8, 10)
(f) Hexagonal-bar heads (LCX1808,
LCX1810, LCX1812)
(g) Ring heads (special 27 x 19, 36 x 19)
(h) Box wrench (19 x 180)
(i) Hexagonal-bar sockets (19 x 19, 22 x 19)
(j) Adapter (19 x 12.7, 25.4 x 19)
(k) Adjustable angle wrench
(l) Cutting pliers
(m)Snap ring pliers (CS3B special)
(n) Screw drivers (Phillips and normal types)
(o) Hammers (iron and plastic)
Torque wrenches (LC180N, CL420N x 22D,
N10000QLK)
Ratchet Heads (LQ4080, 2800QH)
Extension bars (12.7 x 200, 12.7 x 600, 19 x
400)
Eyebolts (M10 x 1.5, M12 x 1.75, M16 x 2,
M18 x 2.5, M24 x 3)
Chain block
Slinging wire rope
Tap M16 x 2, Tapping handle
Oiler

B. Measuring Instruments
1. Vernier Caliper
2. Filler gauges
3. Outside Micrometer (mm) (0 - 25, 25 - 50, 75 100, 125 - 150, 150 - 175, 200 - 225, 300 325, 350 - 375)
4. Spherical Micrometer (0 - 25 mm)
5. Cylinder Gauges (mm) (18 - 35, 35 - 60, 50 150, 160 - 250, 250 - 400)
6. Dial Caliper Gauge (6 - 18 mm)
7. Dial Gauge
8. Magnetic Stand

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

ITEM

3 DC-32 Tightening Torque or Oil Pressure for The Bolts and The Nuts
2-3 Tightening Torque or Oil Pressure for The Bolts and The Nuts
Screw
Diameter

Width Across
Flats of
Bolt/Nut (mm)

Cylinder Head Tightening Nut

M56

Tighten by Oil
Pressure

Cylinder Head (Stud) Bolt

M56

Name of Bolt/Nut

36

Tightening Torque/Oil Pressure


(N.m)

Note

Oil pressure : 83MPa


490

(on the thread)

M52

Tighten by Oil
Pressure

M52

Socket 22

M30

Tighten by Oil
Pressure

Connecting Rod Joint (Stud) Bolt

M30

Socket 12

Side Bolt Tightening Nut

M52

Tighten by Oil
Pressure

Side (Stud) Bolt

M52

Main Bearing Cap Tightening Circular Nut

M56

Main Bearing (Stud) Bolt

M56

Balance Weight Circular Nut

M39

Balance Weight (Stud) Bolt

M39

24

196

(on the thread)

Gear Case Mounting Bolt

M20

30

294

(on the thread and the seating surface)

Idle Gear Shaft Tightening Bolt

M22

32

392

Punch a match mark on the bolt head to identify the position.

Engine Frame Holding-down Bolt

M36

55

1666

Oil Pan Mounting Bolt


(inside the Engine Frame)

M20

30

225

(On the gear case located on


the engine front end)

M20

30

225

11 Rocker Arm Shaft Holder Tightening Nut

M24

36

441

(on the thread and the seating surface)

12 Valve T Yoke Adjusting Screw Locknut

M22

32

294

Apply oil
Do not use Molykote

13 Rocker Arm Screw Locknut

M24

36

343

Apply oil
Do not use Molykote

14 Idle Gear (1) and (2) Tightening Bolt

M22

32

392

15 Camshaft Joint Bolt


(at the end wall)

M20

27

373

M20

27

373

2 Connecting Rod Large End Tightening Nut


Crankpin (Stud) Bolt
3 Connecting Rod Circular Nut

10

(at the intermediate wall


(nuts on both sides))

DC-32 Z 05-12

36
Tighten by Oil
Pressure

Oil pressure : 76MPa


294
Oil pressure : 90MPa
98

(on the thread)

Oil pressure : 59MPa


Screw back 1/4 ~ 1/2 turn
(on the thread)
from fully screwed-up position

Oil pressure : 88MPa


490

Tighten by Oil
Pressure

(on the thread)

(on the thread)

Oil pressure : 93MPa

(on the thread and the seating surface)


(on the thread and the seating surface)

Apply the Loctite 242.

(on the thread and the seating surface)


Punch a match mark on the bolt head to identify the position.

(on the thread and the seating surface)


(seating surface)
on the thread : Loctite243

CHAPTER

General Matters of Maintenance

2
ITEM

Tightening Torque or Oil Pressure for The Bolts and The Nuts

Name of Bolt/Nut

Screw
Diameter

Width Across
Flats of
Bolt/Nut (mm)

DC-32

Tightening Torque/Oil Pressure


(N.m)

Note

Swing Arm Shaft Mounting Bolt

M24

36

490

Apply oil
Do not use Molykote

17 Camshaft Thrust Collar Mounting Bolt

M12

19

49

(thread and seating surface)

18 Cam Gear Mounting Bolt

M20

27

343

(thread and seating surface)

16

19

Crank Gear/Spacer Tightening Bolt

M24

32

588

(thread and seating surface)

20

Aux. Driving Gear Tightening Bolt

M30

41

882

(thread and seating surface)

21

Fuel Injection Pump Mounting Nut

M20

30

265

(thread and seating surface)

M14

Socket 12

137 - 157

(thread and seating surface)

M16

24

177 - 196

(thread and seating surface)

Fuel Nozzle Mounting Cap Nut

M42

46

373 - 403

(thread and seating surface)

24 Fuel Oil High Pressure Block Mounting Bolt


(pump side)

M24

Socket 19

196

(thread and seating surface)

(cylinder head side)

M20

24

147

(thread and seating surface)

Nozzle Holder Holding Nut

M14

22

88

(thread and seating surface)

Nozzle Holder (Stud) Bolt

M14

26

Starting Valve Lid Tightening Bolt

M16

24

127

(thread and seating surface)

27

Starting Valve End Hexagonal Head

M16

13

127

(thread and seating surface)

Starting Valve Tightening Nut

M12

19

39

(thread and seating surface)

28 Indicator & Safety Valve Tightening Nut

M12

19

59

(thread and seating surface)

29 Piston Crown Tightening Nut

M18

27

196

Spherical seating surface of the distance piece

Piston Crown (Stud) Bolt


Governor Drive Gear
30 (driven side) Tightening Nut
Governor Drive Gear
31 (drive side) Tightening Bolt

M18

13

147

(thread and seating surface)

M16

24

118

(thread and seating surface)

M10

Socket 8

39

(thread and seating surface)

M20

30

225

(thread and seating surface)

22 Fuel Injection Delivery Valve Tightening Bolt


Tightening Bolt (1)
Tightening Bolt (2)
23

25

32

Turbocharger Bracket Mounting Bolt

49

(thread)

(thread and seating surface)

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

2
ITEM

3 DC-32 Tightening Torque or Oil Pressure for The Bolts and The Nuts

Screw
Diameter

Name of Bolt/Nut

Width Across
Flats of
Bolt/Nut (mm)

Tightening Torque/Oil Pressure


(N.m)

Note

Turbocharger Mounting Nut


(Stud) Bolt
Turbocharger
TPL 65
Nut

M20

13

245

(Thread)

M20

30

440

(Thread and seating surface)

(Stud) Bolt

M24

17

440

(Thread)

Nut

M24

36

780

(Thread and seating surface)

M16

24

137

(Thread and seating surface)

Exhaust Manifold Mounting Bolt


Cylinder Head Side

M18

27

216

(Thread and seating surface)

Exhaust pipe to Exhaust pipe

M20

30

294

(Thread and seating surface)

Turbocharger (TPL65,69) Intake Pipe

M16

24

147

(Thread and seating surface)

Turbocharger (MET33MA) Intake Pipe

M12

19

59

(Thread and seating surface)

35 Intercooler Mounting Bolt

M22

32

177

(Thread and seating surface)

36 Intercooler Cover Mounting Nut

M16

24

118

(Thread and seating surface)

Intercooler Cover Mounting Nut

M12

Socket 10

69

(Thread and seating surface)

30

127

(Thread and seating surface)

M20

30

127

(Thread)

38 Lubricating Oil Cooler Mounting Bolt

M20

30

127

(Thread and seating surface)

39 Flywheel Reamer Bolt Tightening Nut

M42

65

1470

(Thread and seating surface)

M10

17

15 - 20

M12

19

29 - 39

M14

22

34 - 49

M16

24

49 - 68

M18

27

78 - 98

33

Turbocharger
TPL 69

Turbocharger MET33MA
34

37 Lubricating Oil Cooler Mounting Block


M20
Block Tightening Nut
Block Mounting Bolt

40 General Bolts and Nuts

Note : 1. Always effect tightening the important bolts and nuts in accordance with specified values in this
table.
2. Tighten bolts and nuts diagonally and alternately along the diagonal line so that the bolts and nuts
may be evenly tightened.
3. For the cylinder head tightening nuts (item No. 1 in the above table) and the bolts of the connecting
rods (items no. 2 and 3), inspect their tightening torque after the engine has been operated for a
given time. (
1-2 "List of maintenance Intervals")

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

2
ITEM

Tightening Torque or Oil Pressure for The Bolts and The Nuts

DC-32

4. Apply seizure preventive material on the threads and seating surfaces that are located around the
exhaust manifold and may become hot.
5. Effect retightening of the holding-down bolts when the engine is stopped and never forget to measure deflection of the crankshaft after the retightening.
6. Periodically check accuracy of the torque wrenches.
7. Each of the symbol marks used in this manual represents each of the following meaning.
* : The tightening torque or oil pressure indicated on the name plate attached on the engine should
prevail.
@ : Apply a lubricant (Molykote 1000 spray).
: Apply a lubricant (Molykote U paste)
8. A bolt coated by an adhesive (Loctite 243) can not be reused once detached.
Replace it by new one. The female threads should be retapped and completely washed before
restoration of the fastened parts.

If a coating material other than specified one should be used, tightening torque of the bolt would
be too much or too weak resulting in breakage or loosening of the bolt that may cause serious damage
to the engine.

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

ITEM

4.1,4.2 DC-32 Hydraulic Jack : Outlines of the Hydraulic Jack/Unscrewing of Nuts


2-4 Hydraulic Jack
2-4.1 Basic Structure and Functions
of the Hydraulic Jack
The hydraulic jack assembly (a) consists of
a pair of cylinder and piston.
Oil pressure generated in the hydraulic
pump (b) and added on the jack through the high
pressure hose (c) connected to the pump gives a
given tensile force to the bolt. And the nut is tightened or unscrewed with the bolt pulled with the
tensile force.
The hydraulic jacks are roughly classified
into three types
The <Type-I> jack, the <Type-II> jack or the
<Type-III> jack is used for the side bolt with no
joint bolt nor jack stand, for the connecting rod
joint bolts, the main bearing bolts and the balance
weight bolts with no joint bolt but with the jack
stand or for the cylinder head bolts, the crankpin
bolts with a joint bolt respectively.

High Pressure Hose (c)

Air Bleed Plug (vi)

Coupler (iii)

Hydraulic Piston (i)


Hydraulic
Cylinder (ii)

O-ring

2-4.2 Unscrewing of the Nuts


Unscrewing of the nuts should be effected
as described below.
<Hydraulic Jack ...... Type-I>
A.Clean around the circular nut with care and
make certain that no dust nor foreign matters
are attached on the hydraulic jack assembly
and especially the seating surface of the
hydraulic cylinder (ii), and then screw the
hydraulic jack on the bolt.
B.Screw the hydraulic piston (i) on the bolt until
the hydraulic cylinder completely contacts the
seating surface of the part fastened. And also
screw the hydraulic piston (i) until it completely
contact the upper surface of the hydraulic cylinder.
C.Check the contact between the hydraulic cylinder and the hydraulic piston, and then turn back
the hydraulic jack assembly about a half turn.
D.Make certain that the valve of the high pressure
hose joint coupler (iii) are not stuck and then
connect the hydraulic jack and the terminal (d),
and the terminal and the hydraulic pump by the
high pressure hoses.
E. Loosen the air bleed plug (vi) of the hydraulic
pump to make the inside of the oil tank open to
the atmospheric pressure.
F. Check oil level of the hydraulic pump and
replenish with the working oil when the level is
lower than the specified one.
Working oil : Machine oil VG-10

DC-32 Z 05-12

Hydraulic Jack
Assembly (a)
Jack Handle(f)
Backup Ring

Circular Nut

Structure of the Hydraulic Jack <Type-I>

Neutral
Depressurize

Pressurize

Release Valve (v)

Shift Lever
To the Hydraulic Jack (a)
Oil Pressure Gauge

Air Bleed Plug (iv)

Terminal (d)
Oil Level Gauge Bar
(Filler Mouth)

High Pressure
Hose (c)
Coupler

Hydraulic Pump (b)

Connections With the Hydraulic Pump

CHAPTER

General Matters of Maintenance

2
ITEM

Hydraulic Jack :

Unscrewing of the Nuts

DC-32

4.2

G.Close the release valve (v) and the air bleed


plug of the hydraulic pump.
H.Loosen the air bleed plug (iv) of the hydraulic
jack to bleed air in the hydraulic cylinder by
moving up and down the hydraulic pump lever.
Tighten the air bleed plug after making certain
that air is completely bled.
I. Raise oil pressure by moving up and down the
hydraulic pump lever.
J. Insert the jack handle (f) in a hole of the circular
nut through the oblong hole in the hydraulic
cylinder and turn the handle around an angle
corresponding to 5 - 6 holes to loosen the circular nut.
K.Gradually open the release valve of the
hydraulic jack to gradually lower the oil pressure to zero "0".
L. Loosen and detach the hydraulic jack by hand.
M.Detach the circular nut.
Type-II>
<Hydraulic Jack
A.Clean around the circular nut with care and
make certain that no dust nor foreign matters
are attached on the seating surface of the jack
stand (e), and then put the jack stand on the
bolt to be loosened.
B.Screw the hydraulic jack (a) on the bolt (screw
the piston (i) on the bolt until the oil pressure
cylinder (ii) completely contacts the jack stand).
C.Check the contact between the hydraulic cylinder and the hydraulic piston, and then turn back
the hydraulic jack assembly about a half turn.
D.Effect the same work as described in D to H of
the section <Hydraulic Jack Type-I>
E. Insert the jack handle (f) in a hole of the circular
nut through the oblong hole in the jack stand
and turn the jack handle around the angle corresponding to 5 - 6 holes to loosen the circular
nut.
F. Gradually open the release valve of the
hydraulic pump to gradually lower the oil pressure to zero "0".
G.Loosen and detach the hydraulic jack assembly
by hand.
H.Detach the jack stand.
I. Unscrew and remove the circular nut.

High Pressure Hose (c)

Coupler (iii)

Air Bleed Plug (vi)


Backup Ring
Hydraulic Piston (i)
Hydraulic
Cylinder (ii)
O-ring
Hydraulic Jack
Stand (e)

Hydraulic Jack
Assembly (a)

Backup Ring
Jack Handle (f)
Circular Nut

Structure of the Hydraulic Jack <Type-II>

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

ITEM

4.2,4.3 DC-32 Hydraulic Jack : Unscrewing and Tightening of the Nuts


<Hydraulic jack ... Type-III>
A. Clean around the circular nut with care and
make certain that no dust nor foreign matters
are attached on the seating surface of the jack
stand (e).
B. Screw the joint bolt (g) on the bolt until the head
of the bolt lightly contacts the bottom of the hole
in the joint bolt.
C. Put the jack stand on the part fastened.
D. Effect the work as described in B to H in the
section <Hydraulic jack Type-II>
E. To be followed by unscrewing of the joint bolt.
F. Unloosen and remove the circular nut.

High Pressure Hose (c)


Air Bleed Plug (vi)

Coupler (iii)

Hydraulic Piston (i)

Hydraulic
Cylinder (ii)

Hydraulic Jack
Assembly (a)

O-ring

Specified Values .... Each of them is specified


for each work in the previous table.
(
: 2-3 "Tightening Oil Pressure for Bolts
and Nuts")

Backup Ring
Joint Bolt (g)
Jack Stand (e)

Jack Handle(f)

1. Pressure resistance of the hydraulic pump


and the high pressure hoses is 100 MPa. Do
not raise the oil pressure exceeding this
value to avoid dangerous situation.
2. Leaking and gushing-out of oil highly pressurized during operation of the hydraulic jack
is dangerous. Always wear the safety glasses when effecting this work.

2-4.3 Tightening of the Nuts


<Hydraulic Jack ... Type-I>
A.Clean the seating surface of the fastened part
under the circular nut as well as the seating surface of the circular nut and the bottom surface
of the hydraulic cylinder with care and screw
the circular nut on the bolt until the seating surface of the circular nut lightly contacts the surface of the fastened part.
B.Set the hydraulic jack assembly on the bolt and
connect it to the hydraulic pump in the same
manner as that for unscrewing of the nut, and
raise the oil pressure to the specified one by
moving up and down the lever.

DC-32 Z 05-12

Circular Nut

Structure of the Hydraulic Jack <Type-III>

CHAPTER

General Matters of Maintenance

2
ITEM

Hydraulic Jack : Tightening of the Nuts/Maintenance of the Hydraulic Jack

C.Insert the jack handle in a hole of the circular


nut through the oblong hole in the hydraulic
cylinder and tighten it by hand until the circular
nut lightly contacts the part to be fastened.
D.Knock the jack handle with a hammer to check
the tightening condition.
E. Gradually open the release valve of the
hydraulic pump to gradually lower the oil pressure to zero "0".
F. Again raise the oil pressure to the specified one,
and then knock the jack handle with the same
force as described in the item D above with a
hammer to retighten the circular nut and make
certain that the circular nut does not turn (be
tightened) more.
G.If the circular nut should turn in the tightening
direction, repeat the same operation described
in the item F above (retighten the circular nut
with the specified oil pressure, lower the oil
pressure to zero and then retighten the circular
nut with the specified oil pressure) a few times
and make certain that the circular nut does not
turn in the tightening direction any more.
H.Loosen the hydraulic jack by hand and remove
it.
I. Do not forget to attach the protecting cap on the
bolt on which the thread protecting cap has to
be attached.
<Hydraulic Jack ... Type-II>
A.Clean the part of fastened parts under the circular nut as well as the seating surface of the circular nut and the bottom surface of the jack
stand with care and screw the circular nut on
the bolt until the seating surface of the circular
nut lightly contacts the seating surface of the
fastened part.
B.Put the jack stand on the part to be fastened.
C.Effect the work as described in B to H in the
section <Hydraulic Jack ... Type-I>.
D.Remove the jack stand.
E. Do not forget to attach the protecting cap on the
bolt on which the thread protecting cap has to
be attached.

DC-32 4.3,4.4

faces of the circular nut and the jack stand with


care and screw the circular nut on the bolt until
the seating surface of the circular nut lightly
contacts the seating surface of the part to be
fastened after making certain that no foreign
matters are attached on the seating surfaces.
B.Screw the joint bolt (g) on the bolt.
C.Effect the work as described in B to H in the
section <Hydraulic Jack Type-I>
D.Remove the hydraulic jack assembly, the jack
stand and the joint bolt in this sequence.
E. Attach the protecting cap on the bolts on which
the thread protecting cap has to be attached.

2-4.4 Maintenance of the Hydraulic


Jack
A.Knock the bottom part of the hydraulic jack with
a plastic hammer or some other tool to push it
out from the hydraulic cylinder.
B.Detach the air bleed plug.
C.Wash each of the components with a washing
oil and inspect whether or not there is any flaw
on them.
D.Apply the working oil on each of the components, and assemble the hydraulic piston and
the hydraulic cylinder.
E. Replace each of the o-rings and the backup
rings by new one.

Do not confuse the upper side with the


lower side or vice versa of the o-rings and the
backup rings. An o-ring would be broken if it is
installed upside down.

<Hydraulic Jack ... Type-III>


A.Clean the seating surface of the fastened part
under the circular nut as well as the seating sur-

DC-32 Z 05-12

CHAPTER

General Matters of Maintenance

2
ITEM

4.4 DC-32 Hydraulic Jack : Maintenance


<<Consumable Parts of the Hydraulic Jack>>
(

: "Parts List")

A. For the Cylinder Head Bolts and the Main Bearing Bolts
1. Ring
3-9.1
No. 22
2. Ring
3-9.1
No. 23
3. O-Ring
3-9.1
No. 503
4. O-Ring
3-9.1
No. 504
B. For the Crankpin Bolts and Side Bolt
1. Ring
3-9.2
No. 14
2. Ring
3-9.2
No. 15
3. O-Ring
3-9.2
No. 503
4. O-Ring
3-9.2
No. 504
C. For the Connecting Rod Joint Bolts
1. Ring
3-9.3
2. Ring
3-9.3
3. O-Ring
3-9.3
4. O-Ring
3-9.3

No. 33
No.33
No. 503
No. 504

D. For the Balance Weight Bolts (for Shorter one, and Longer one)
1. Ring
3-9.4
No. 9
2. Ring
3-9.4
No. 27
3. O-Ring
3-9.4
No. 503
4. O-Ring
3-9.4
No. 504

DC-32 Z 05-12

of the Hydraulic Jack

CHAPTER

General Matters of Maintenance

MEMO

2
ITEM

DC-32

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves


ITEM
Outline of the Structure/Consumable Replacement
1.1,1.2 DC-32 Cylinder Head : Parts, Special Tools and Measuring Instruments
3

Cylinder Heads and Valves

3-1 Cylinder Heads


3-1.1 Outline of the Structure
The cylinder head is made of high tensile
special cast iron having high thermal conductivity
and has a very rigid structure. It is firmly installed
on the engine frame by four bolts having a large
diameter via the metal gasket and the cylinder liner
by means of the hydraulic jack.
The gasket has a structure to seal combustion gas as well as cooling water.
Part of the cylinder head facing the combustion chamber has a thick structure of which center
part is forcedly cooled through a drilled hole to
make it unnecessary for the fuel injection nozzle to
be cooled for the heavy oil burning engines.
The cylinder head has four valves, two for
intake and the same number for exhaust. The
valve seats are fitted in the cylinder head by
means of shrinkage fitting and the exhaust valve
seats are cooled by water.
The fuel injection valve and the indicator &
safety valve, and the starting valve are installed on
the upper part and the side of the cylinder head
respectively.
Introduction of highly pressurized fuel oil is
effected by what is called cross feed configuration
and the high pressure block at the outlet of the fuel
injection pump and the fuel injection valve are connected via the inlet connector.
Each of the fuel oil leaked from the fuel oil
Intake Manifold
(Cylinder Head Inlet)

Intake Valve
Indicator & Safety Valve

injection valve and the highly pressurized fuel oil


system is returned to the receiving tank for the
returned fuel oil via each independent piping connected with the engine frame.

Weight of a Cylinder Head


(one unit only)
:430 kg
Weight of a Cylinder Head Assembly
(with valves)
:460 kg

3-1.2 Consumable Replacement Parts, Special


Tools and Measuring Instruments
A. Consumable Replacement parts
The following parts should be replaced by
the new ones.
(
: "Parts List")
1. Gasket
2-16
No. 16
2. Gasket (for the cylinder head cover) 2-17
No. 7
No. 12
3. Gasket (for the push rod block) 2-22
4. Gasket (for the exhaust manifold) 2-16
No. 9
5. O-ring (for the cylinder liner) 2-13
No. 4
No. 506, 508
6. O-ring (for the push rod block) 2-22
7. O-ring (for the fuel injection valve) 2-25
No. 505, 506
8. O-ring (for the high pressure block) 2-25
No. 503, 504
9. O-ring (for the FW outlet pipe flange) 3-4.1 No. 507, 508
10. Gasket (for the fuel injection valve) 2-25
No. 507
11. Seal (for the cylinder head cover) 2-17
No. 3
12. Seal (for the intake manifold (head inlet)) 2-1
No. 18

Cap
Cylinder Head Bolt

Circular Nut
Exhaust Distance
Piece

Cooling Water Outlet Pipe

Fuel Injection Valve


Exhaust Valve

Cylinder Head
Gasket
Exhaust Valve Seat
Exhaust Valve Seat
Intake Valve
Exhaust Valve
Push Rod Block Gasket

Cylinder Head and Valves


DC-32 Z 05-12

Push Rod Block

Starting Valve

CHAPTER

Cylinder Heads and Valves


Outline of the Structure/Consumable Replacement
Cylinder Head :
Parts, Special Tools and Measuring Instruments
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Cylinder Head Hanger
(1) Base
(2) Eyebolt M24
(c) Hydraulic Jack (to be also used for the main
bearings)
(1) Hydraulic Jack Assembly (with a socket
coupling)
(2) Hydraulic Jack Bolt
(3) Jack Stand
(4) Jack Handle
(d) Hydraulic Pump
(1) Hydraulic Pump
(2) High Pressure Oil Hose 2 m long (5 pcs.
with a male coupler)
(3) Terminal 4T
(4) Female Coupler (2 pcs.)

(2)

3
ITEM

DC-32

1.2

(1)

(3)
(4)

(c) Hydraulic Jack


(2)

(1)

(b) Cylinder Head Hanger

(d) Hydraulic Pump

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves


Outline of the Structure/Consumable Replacement
1.2 DC-32 Cylinder Head : Parts, Special Tools and Measuring Instruments
3

ITEM

(e) Nozzle Holder Puller


(1) Base
(2) Spacer
(3) Hanger Bolt
(4) Fixing Bolt
(f) Cylinder Head Finishing Tool (Optional)
(to be used also for the cylinder liner)
(1) Cylinder Head and Cylinder Liner
Finishing Tool -1
(2) Cylinder Head and Cylinder Liner
Finishing Tool -2
(3) Bolt
(g) Valve Stem Seal Special Tool
(1) Exhaust Valve Stem Seal Special Tool
(2) Intake Stem Valve Seal Special Tool
(h) Valve Guide Pushing-out Tool
(1) Exhaust Valve Guide Pushing-out Tool
(2) Intake Valve Guide Pushing-out Tool
(i) Intake Valve Seat Fitting Tool
(1) Exhaust Valve Guide Pushing-out Tool
[(h)-(1) is to be used also for this purpose]
(2) Intake Valve Guide Pushing-out Tool[(h)(2) is to be used also for this purpose]
(3) Valve Seat Fitting Tool
(j) Valve Seat Puller
(1) Valve Seat Puller-1
(2) Valve Seat Puller-2
(3) Exhaust Valve Seat Puller
(4) Intake Valve Seat Puller
(5) Special Nut

(1) (2)

(3)

(4)

(2)

(1)

(e) Nozzle Holder Puller

(2)
(3)

(1)

(f) Cylinder Head Finishing Tool

(1) (2)

(h) Valve Guide Pushing-out Tool

DC-32 Z 05-12

(g) Valve Stem Seal Special Tool

CHAPTER

Cylinder Heads and Valves


Outline of the Structure/Consumable Replacement
Cylinder Head :
Parts, Special Tools and Measuring Instruments
(k) Exhaust Valve Seat Cooling Tool
(1) Exhaust Valve Seat Fitting Tool [(i)-(1) is
used also for this purpose]
(2) Exhaust Valve Seat Cooling Tool
(m) Nozzle Holder Guide Special Tool
(1) Nozzle Holder Guide Taking-out Tool
(2) Nozzle Holder Guide Cooling Tool-1
(3) Nozzle Holder Guide Cooling Tool-2
(4) Nozzle Holder Guide Fitting Tool
(5) Special Pliers
(6) O-ring-1, 2

(2)

3
ITEM

DC-32

1.2

(1)

(2)

(k) Exhaust Valve Seat Cooling Tool

(2)

(1)

(6)-1
(3)

(4)

(3)

(i) Valve Seat Fitting Tool


(2)

(6)-2

Pin

(5)
(1)
(5)

(3)(4)

(m) Nozzle Holder Guide Special Tool


(j) Valve Seat Puller

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

1.3 DC-32 Cylinder Head : Detaching

of the Cylinder Head

3-1.3 Detaching of the Cylinder Head


The following is the description of procedure
to detach the cylinder head (the top hole).

Fuel Injection Valve


(B1)

A. Detach the following covers.


z Exhaust Manifold Cover (A)
z Cylinder Head Cover (B1), (B2)
z Heat Box Cover (C)

(B2)
Inlet
Connector
Fuel Oil High
Pressure Block

(A) Cooling Water


Outlet Pipe

(C)
Since these parts (especially for the
exhaust manifold and the parts installed near
the cylinder head) are hot for a while immediately after stop of the engine, touching with
them with bare skin may cause a burn.
Wear safety gloves whenever working
with them to prevent a burn.
B. Detach the flange of the cooling water outlet
located on the upper part of the cylinder head.
C. Detach the fuel oil high pressure block and the
inlet connector. Detach the fuel injection valve
holding nut and the flange, then take out the
fuel injection valve by means of the nozzle
holder puller. (
: 5-4.2 "Inspection and
Maintenance of the Fuel Injection Valve" of
"Operation Manual")
D. Detach the exhaust manifold fixing bolt.
E. Detach the cylinder head lubricating oil leak
pipe.

The exhaust manifold fixing bold


is made from alloy metal. Be careful not to mix
other general type bolts for it.
F. Detach the rocker arm shaft holder tightening
nuts, then detach the rocker arm assembly.
(
: 3-3.3 "Dismantling of The Rocker Arm
Assembly)
G. Taking-out the T. Valve Yoke and the Push
Rods.
H. Detach the Cylinder Head Bolt Caps.
I. Install the Fuel Injection Valve Holding Flange
and attach the Cylinder Head Hangers (b)-(1)
and (b)-2 on the fuel injection valve holding
bolts.

DC-32 Z 05-12

Exhaust
Manifold
Exhaust
Manifold Bolt

Detaching of the Covers, the Cooling Water


Outlet Pipe and the Exhaust Manifold Joint

(b)-(1)

(b)-(2)

Cap

(H)
(b)-(3)
Fuel Oil Injection Valve Holding Flange

Attaching of the Cylinder Head Hanger

CHAPTER

Cylinder Heads and Valves

3
ITEM

Cylinder Head : Detaching

of the Cylinder Head

J. Detach four Cylinder Head Tightening Nuts (H)


at the same time by means of the hydraulic jack
(c).(
: 2-4 "Hydraulic Jack")
(1) Put the jack stands (c)-(3) in such a manner
that the i notched part of each of them may be
directed to the direction with which nothing may
interfere with the neighboring cylinder head.
(2) Screw each of the joint bolts on a cylinder
head bolt. (Effect this on all four bolts)
(3) Set the hydraulic jack (c)-(2) on the joint bolt
(c)-5.
(4) Attach a male coupler on each of the high
pressure hoses (d)-(2) and connect the
hydraulic pump (d)-(1), the terminal 4T (d)-(3)
and the hydraulic jack assemblies by means of
the high pressure hoses as indicated in the
illustration on the right.

DC-32

1.3

(c)-(1)
(c)-(3)
(c)-(4)

(H)

Cylinder Head Bolt

Installation of the Hydraulic Jack

(5) Raise the oil pressure to the specified one by


operating the hydraulic pump and loosen the
nut (H) by means of the jack handle.

Specified oil pressure : 84 MPa


(6) Check the oil pressure at which the nut begins
loosening to find whether or not any of the nuts
has been loosened.

(d)-(3)

(d)-(2)

(d)-(4)

(d)-(1)

Attaching of the High Pressure Hoses

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

1.3 DC-32 Cylinder Head : Detaching

of the Cylinder Head

K. Check fixing condition of the cylinder head


hanger (b) on the cylinder head and sling the
cylinder head by means of a chain block and
slinging wires.

Falling of the cylinder head during slinging presents a very dangerous situation.
Always use the designated slinging device and
fittings and follow the service standards of the
wire ropes.
(F)
(G)
1. Slowly sling the cylinder head not to give flaw
to the threads of the cylinder head bolts. Also
pay attention not to let cooling water in the
cylinder head penetrate into the cylinder.
2. Be attentive not to give any flaw on the bottom surface of the cylinder head when
removing and storing it in the designated
place.

(E)

(J)
(I)

(D)







L. Detach the cylinder head gasket (F), o-ring (E),


the intake seal (D), the starting air connecting
pipe o-rings (G) and (I) and the push rod gasket
(J), and cover the cylinder liner, the intake duct
and other fluid passages with clean cloth or
tape to prevent foreign matters from penetrating.

Slinging of The Cylinder Head


Lid (for the intake manifold)

Lid (for the cylinder liner)

Dust Proofing Lids

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

3
ITEM

Cylinder Head : Inspection and Maintenance of the Cylinder Head Unit

DC-32

1.4

3-1.4 Inspection and Maintenance of


the Cylinder Head (unit)
Since the parts described in this section
are subject to the regulation of the NOx
Technical Code, always use a part on which
the identification is stamped. (
: 0-3
"Engines Conforming to NOx Technical Code")
A. Detach the following assembled parts before
starting the maintenance of the cylinder head
(unit). (For the procedure to detaching, refer to
other sections as follows).
1. Intake and Exhaust Valves (
2. Starting Valve (

: 3-2.3)

Inlet of the
cooling water

Surface of the
combustion chamber
Exhaust port

Intake Port
Indicator &
Safety
Valve Hole

Fuel Oil
Leaking Hole

Starting air hole


Inlet of the lubricating oil

Inlet of the
starting air

Push Rod Hole

Inlet of the starting pilot air

: 3-4.3)

3. Indicator & Safety Valve (


4. Cooling Water Outlet Pipe (
5. Intake Manifold (Head Inlet) (

: 3-5.3)

Cleaning and Inspection of the Cylinder Head

: 3-6.3)
: 3-7.3)

B. Observe and inspect the inside surface


exposed to combustion gas and carbon deposit
on the intake port and the exhaust port of them
as they are detached.
C. Effect color check to check to find a crack if any
after removing carbon deposit on the surface
exposed to combustion gas and on the intake
port and the exhaust port, and clean them with
care. Since the surface exposed to combustion gas and the inside surface of each port
near the combustion chamber are exposed to
high temperature and pressure, check them
with special care.

A gas burner should not be used for


removal of carbon deposit. It may cause hardening of o-rings and degradation of materials
due to partial heating up.
D. Check the intake and exhaust ports to find corrosion on them if any.
E. Check the sealing surfaces around the passage
holes of fluids (e.g. the contact surface with the
cooling water sealing o-ring) to find internal corrosion if any.
F. Check the sealing surface to find gas leakage
from the sealing surface contacting with the
cylinder head gasket if any.

Color check of the Surface


of the Combustion Chamber

Plug

Cleaning of the Cylinder Head Jacket

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves


ITEM
Inspection and Maintenance of the Cylinder
1.4,1.5 DC-32 Cylinder Head : Heads (unit)/Intake and Exhaust Valve Guides
3

G. Clean the sealing surface mating with the cylinder head gasket. Finish the surface when necessary. (the finishing tool is optional)
H. Inspect the scale deposited in the jacket
through the outlet of the cooling water. When
too much scale is found in the jacket, remove
the plug installed on the side to clean the
inside. Apply a adhesive, Loctite 271 on the
threads of the plug and firmly tighten the plug
after cleaning.

(f)-(2)
(f)-(3)
(f)-(1)

3-1.5 Intake/Exhaust Valve Guides


Shape of the intake valve guide and the
valve stem seal resemble those of the exhaust but
the diameter of the former is different from that of
the latter. The collar of the exhaust valve guide is
grooved. There is a protrusion for identification on
the intake valve stem seal.

Finishing of the Surface of the


Cylinder Head Mating With the Gasket
a, b
Intake/Exhaust Valve Guides

A. Measurement of I.D. (inside diameter)


Remove the valve stem seals fitted
on the upper end of the intake/exhaust valve
guides, then check them to find corrosion
inside the valve guides if any, and measure
the IDs by means of a cylinder gauge and
record the results.
Also measure the ODs of the valve
stems of the intake/exhaust valves and calculate the clearance using the results together
with the IDs already measured.
(
: 3-3.4 " Inspection and Maintenance of
Intake/Exhaust Valves")
Nominal Diameter

Standard Clearance

(mm)
A = 22.5

(mm)
a = 0.09 - 0.17

(mm)
0.35

B = 22

b = 0.09 - 0.17

0.35

Valve Stem
A. a : Intake Valve
B. b : Exhaust Valve

Valve Guide Clearance

Hammer

(h)-(1)

Replacement Limit

B. Replacement of Valve Guide and Valve Stem


Seal
When wear of an intake/exhaust
valve guide is so much that the clearance
between the valve guide and the valve stem
has exceeded the service limit, remove the
valve guide according to the following procedure and replace it by a new one.

DC-32 Z 05-12

A, B

Valve Guide

Pushing-out of a Valve Guide

CHAPTER

Cylinder Heads and Valves

3
ITEM

Cylinder Heads :

Intake/Exhaust Valve Guides

DC-32

A valve stem seal should be replaced by


new one once it is detached from the valve
guide.

Valve Stem Seal


Special Tool (g)

(1) Detach the valve stem seal.

Stem Seal

1.5

(2) Push out the valve guide.


Insert the valve guide pushing-out tool
(h) or a tool as shown in the figure on the right
that is made from a rod into the valve guide
and push it out by knocking it with a hammer.

(3) Fit a valve guide (new one) into the cylinder


head.
Effect it by shrinkage fitting using liquid
nitrogen or dry ice.
<<Procedure of Shrinkage Fitting>>
z

When using liquid nitrogen;


Immerse the part in the liquid and take
it out when bubbles stop coming out, then fit it
in the cylinder head as soon as possible.

Fitting of the Valve Stem Seal

When using dry ice;


Immerse dry ice and the part in alcohol
for 20 - 30 minutes, then take it out and fit it in
the cylinder head as soon as possible.

Touching the chilling liquid or cooled


part by a bare hand may cause frostbite.
Always wear cotton gloves for protection
against frostbite during the work.

(4) Fit a valve stem seal on the valve guide.


Fit the stem seal by means of the
valve stem seal special tool (g). Lightly knock
the end of the stem seal special tool with care
not to give any flaw to the valve stem seal.

The valve guide and the valve stem


seal for the intake valve are not the same as
those for the exhaust valve. Make certain that
right parts are going to be assembled when
effecting assembling.

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

3
ITEM

1.6 DC-32 Cylinder Heads : Intake/Exhaust

Valve Seats

3-1.6 Intake/Exhaust Valve Seats


A. Measurement of Dimensions of the Valve

Seats
Measure dimensions "D" and "F" of the
valve seats and replace such one of which wear
exceeds the service limit by new one.
Nominal Dimension

Replacement limit

(mm)
D = 5.0
F = 7.5

(mm)
2.5
6.5

Intake Valve Seat


Exhaust Valve Seat

D
Intake Valve Seat

2. Fitting the intake valve seat in the cylinder


head
(1) Effect the fitting by shrinkage fitting using liquid nitrogen or dry ice. Procedure of the shrinkage fitting is the same as that for the valve
guide. (
: 3-1.5)

Exhaust Valve Seat

Measurement of Dimensions
of the Valve Seats
Fix by a wrench
(j)-(2)

B. Replacement of a Valve Seat


An intake/exhaust valve seat should be
replaced when the dimension "D" or "F" exceeds
the correction limit or every 16,000 -24,000
hours (4 - 5 years) of operation.
The o-rings of the valve seat should be
also replaced at the same time.
1. Removal of a Valve Seat
Both for the intake and exhaust valve
seats, use the valve seat puller (j), and gradually
pull it out not to give any flaw to the mating part
of the cylinder head.

(j)-(4)
j)-(1)

(j)-(4)
Intake Valve Seat

(j)-(3)
Exhaust Valve Seat

Pulling out of the Valve Seat

Used valve

(i)-(1)

(2) Assuredly fit the valve seat in the cylinder


head by means of a used valve or the valve
seat fitting tools (i)-(3) and (h)-(2).
3. Fitting the exhaust valve seat in the cylinder
head
Since o-rings are fitted on the exhaust
valve seat, use the exhaust valve seat in the tool
(k)-(2) and fit the valve seat in the cylinder head
after chilling and hardening the valve seat with
the o-rings installed using liquid nitrogen or dry
ice. Procedure of the shrinkage fitting is the
same as that for the valve guide. (
: 3-1.5)

DC-32 Z 05-12

(i)-(2)

Fitting an Intake Valve


Seat in the Cylinder

CHAPTER

Cylinder Heads and Valves

3
ITEM

Cylinder Heads : Intake/Exhaust

Valve Seats

DC-32

1.6

<<Procedure of Fitting>>
(1) Coat the o-rings with grease and install them
on the exhaust valve seat at the room temperature.

(k)-(2)

Exhaust Valve Seat

O-ring

(2) Heat the exhaust valve seat chilling tool (k)-(2)


o
in hot water of 70 - 80 C.
(3) Insert the exhaust valve seat in the tool (k)-(2)
by means of an used valve or the valve seat fitting tool (i)-(3).
(4) Chill the exhaust valve seat as set in the tool
(k)-(2).
(5) Take out the exhaust valve seat from the tool
(k)-(2) by means of the tool (i)-(3) after the
valve seat is chilled, and fit it in the cylinder
head as soon as possible.
(6) Assuredly knock the valve seat in the cylinder
head using the tools (h)-(1) and (i)-(3).

3
Chilling of the Exhaust Valve Seat
Pushing out

Fitting in
(i)-(3)
Exhaust Valve Seat

(k)-(2)

Setting the Exhaust Valve Seat in the Chilling


Tool (k)-(2) and Taking it out of the Tool

(i)-(3)
Used valve
(h)-(1)

Fitting the Exhaust Valve


Seat in the Cylinder Head

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

1.7 DC-32 Cylinder Heads : Nozzle


3-1.7 The Nozzle Holder Guide
The o-rings of the nozzle holder ring should
be replaced every 16,000 - 24,000 hours (4 - 5
years). The special tool can be provided as optional one. (
: "Parts List")

Holder Guides

(5) Lay the completed unit as shown on the figure


3 and detach the chilling tool 1 by knocking the
tool by a wooden hammer as shown on the figure 3. Do not remove the chilling tool 2 at this
time.
Lay wood or cloth under the chilling tool 1.

1. Gasket
2. O-ring

2-16
2-16

No.22
No.507
Snap Ring

Nozzle Holder Guide


Pushing-out Tool (1)

O-ring

<<Procedure of Pushing-out>>
(1) Detach the nozzle guide holder and lay the
cylinder head on its side (to make the combustion chamber visible).

Hammering

(2) Detach the snap ring by means of the special


pliers (m)-(5).
(3) Push out the nozzle guide holder by hammering the pushing-out tool 1.

Nozzle Holder Guide

Procedure to Push out the Nozzle Holder Guide

<<Procedure of Chilling>>
Nozzle Holder
Guide Chilling Tool -1

(1) Install the o-rings on the nozzle holder guide.


Check the o-rings to find flaws or torn surfaces
if any before their installation.

Align with the upper surface


of the nozzle holder guide

(2) Apply grease on the o-rings as they are


installed as described in the above.

Hammering

(3) Install the o-rings on the nozzle holder guide


after warming the chilling tool 1 in hot water
(about 80oC) for a few minutes.
Install the o-rings with care paying attention not to give any flaw. Fit the chilling tool 2 in
the nozzle holder guide after applying grease
on the whole fitting circumference of the tool
with the o-rings installed. Figure 2 shows the
completed unit with the chilling tool 2 installed
in the nozzle holder guide.
(4) Immerse the nozzle holder guide complete as
shown on the figure 2 in the liquid nitrogen vessel.
Chill the completed unit until bubbles generated during chilling do not appear any more
(for about 2 minutes).

DC-32 Z 05-12

Area to
which grease is
to be applied

O-ring

Area to which
grease is to
be applied

Nozzle Holder
Guide Chilling
Tool -2

Push it in until it is completely


fitted in the mated part
O-ring
Figure 1

Figure 2

Figure 3

Procedure to Chill the Nozzle Holder Guide

CHAPTER

Cylinder Heads and Valves

3
ITEM

Cylinder Heads : Nozzle

Holder Guides

DC-32

1.7

<<Procedure to Fit the Nozzle Holder Guide


in the Cylinder Head>>
(1) Wipe out dust or other foreign matters on the
mating surface of the cylinder head with waste
cloth or other appropriate material.
(2) Apply silicon paste on the appropriate area of
the cylinder head in a circular pattern (it is easily effected by a brush).

Be careful not to block the holes for cooling water inside the cylinder head with the silicon paste.
Area on which Loctite
684 is to be applied

(3) Apply Loctite 648 on the area of the cylinder


head in which the nozzle holder guide is fitted.

Installing location
of the snap ring
Area on which silicon
paste is to be applied
Locating Pin

* Processes (1) - (3) should be effected


before the nozzle holder is chilled.
(4) Attach the fitting tool on the nozzle holder
guide and knock it in the cylinder head by
hammering. Apply grease all around the mating
surface of the fitting tool (with o-rings) before
setting the tool on the nozzle holder guide.
Be well attentive so that the nozzle holder guide may not lean against the hole in the
cylinder head during fitting work. And effect the
hammering until the nozzle holder guide
becomes contacted.
Remember that this fitting work of the
nozzle holder guide may become difficult if the
work is not quickly effected. (Effect the fitting
work making use of the nozzle holder guide fixing stud bolt. In case that a locating pin is provided for the fitting tool, engage the pin with the
groove in the nozzle holder guide.)

Hammering

O-ring
O-ring
Area on which grease
is to be applied
Nozzle Holder Guide
Nozzle holder
guide fitting tool

Nozzle holder
guide chilling tool -2

Procedure to Fit the Nozzle Holder


Guide in the Cylinder Head

(5) Remove the chilling tool-2 and the fitting tool.


(6) Install the snap ring on the appropriate position.

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

1.8 DC-32 Cylinder Heads : Assembling and Installing of Cylinder Heads


3-1.8 Assembling and Installing of
the Cylinder Head
Assembling and installing of the cylinder
head is to be effected in the reverse sequence of
its detachment and dismantling.
A. Installing the intake and exhaust valves, the
starting valve, the indicator & safety valve, the
cooling water outlet pipe, the intake manifold
(head inlet) and the exhaust manifold joint pipe
on or in the cylinder head.
(

: 3-2.6 "Assembling of the Intake/Exhaust Valves")

: 3-4.5 "Assembling of the Starting Valve")

: 3-5.6 "Assembling of the Indicator & Safety Valve")

: 3-6.5 "Assembling of the Cooling Water Outlet Pipe")

: 3-7.5 "Assembling of the Intake Manifold (Head Inlet)")

B. Clean well the mating surfaces of the cylinder


head gasket, the cylinder head o-rings, the
intake manifold seal, the starting air intake oring, the push rod block gasket, etc.

Since the return oil having lubricated the


rocker arm system is running in the upper part
of the cylinder head, completely clean the cylinder head not to let dust or waste threads mix in
the lubricating oil.
C. Install the new cylinder head gasket and the orings on the upper surface of the cylinder liner
and the new push rod block gasket on the
upper surface of the push rod block.
D. Apply grease on the starting air intake pipe oring and the intake seal, and install them on the
appropriate location.

1. Do not apply seizure preventive oil or lubricating oil on the surface of the cylinder head
mating with the cylinder head gasket.
2. For the push rod block gasket, make certain
that the surface on which the manufacturer's
name is printed faces upward, and install it
making use of the starting air intake pipe as
the location guide.
E. Attach the cylinder head hanger (e) on the
cylinder head, and sling the cylinder head.

DC-32 Z 05-12

Always horizontally sling the cylinder


head with care to prevent cooling water in the
jacket from penetrating in the cylinder.
F. Make certain that no foreign matters are left
inside the cylinder.
G. Slowly lower the cylinder hung up not to give
any flaw to the threads of the cylinder head
bolts, and see that the starting air inlet pipe also
functioning as a location guide for the cylinder
head is properly fitted in the cylinder head and
also that the intake sealing is smoothly inserted
in the intake manifold, then finally install the
cylinder head.
H. Apply seizure preventive oil (Molykote 1000
spray) on the threads and the seating surface
of the exhaust manifold tightening bolts, insert
the exhaust joint gasket between the exhaust
manifold and the exhaust joint, and tentatively
tighten the bolts.
I. Thoroughly clean threads of the cylinder head
bolts, threads and seating surfaces of the cylinder head tightening nuts and the surfaces of the
cylinder head mating with the cylinder head
tightening nuts. Check that no dust or foreign
matters are left there, and then screw the tightening nuts until they lightly touch the cylinder
head.

Do not install the cylinder head tightening nuts upside down.


J. Attach the hydraulic jack in the same procedure
as that used for detachment of the cylinder
head to tighten the 4 bolts with the specified
torque at the same time.
Specified oil pressure : 83 MPa
K. Attach the rubber caps on the threads of the
bolts after removing the hydraulic jack.
L. Install the fuel injection valve. (
: "5-4.2
"Inspection and Maintenance of the Fuel
Injection Valve" in the "Operation Manual")
M. Insert the push rods.
N. Install the rocker arm assembly. (
: 3-3.5
"Assembling of the Rocker Arm
Assembly")

CHAPTER

Cylinder Heads and Valves

3
ITEM

Cylinder Heads : Assembling and Installing of Cylinder Heads

DC-32

1.8

O. Insert the inlet connector in the cylinder head in


the sideways direction seeing that the direction
of the nozzle holder is correct.

Since a inlet connector other than the


specific one for the cylinder may cause oil leakage due to insufficient adaptation to the mating
part, always use the inlet connector specific to
each cylinder.

P. Install the o-rings coated with grease on the


high pressure fuel block.
Q. Install the high pressure fuel block.
Apply a lubricant (Molykote 1000 spray) on
threads and seating surfaces of the mounting
bolts and tighten them with the specified torque
adjusting their position in relation with the fuel
injection pump.
Specified torque : 147 N.m (cylinder head side)
: 196 N.m (fuel injection pump side)

1. Connections of the joints in the high pressure fuel oil system are all metal to metal
ones.
Be attentive enough not to give any flaw to
the contact surface of each joint and not to
catch foreign matters between the joints.
2. Tighten the bolts alternately and gradually,
and pay attention so that the bolt may be
screwed without leaning.
R. Tighten the exhaust manifold tightening bolts.
S. Tighten the special flange of the cooling water
outlet pipe with the mounting bolts.
T. Install the cylinder head cover, the heat box
cover and the exhaust manifold cover.

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

3
ITEM

2.1 DC-32 Intake/Exhaust Valves : Outline

of the Structure

3-2 Intake/Exhaust Valves


3-2.1 Outline of the Structure

Though the shapes and dimensions of


the intake and the exhaust valves resemble
each other, the material of the former is different from that of the latter being identified by the
identification mark stamped on the top part of
the valves. Be attentive not to install a wrong
valve.

This engine has 2 intake and 2 exhaust


valves, i.e. 4 valves, and each of valves is
equipped with a valve rotator at the upper part.
Each of the intake and exhaust valve guides
is equipped with a stem seal to control quantity of
lubricating oil to be fed to the stem.

Weight of the intake or exhaust valve


(without any fittings) : 2.8 kg for each

Stamp Stamp
IN
S6

Valve Rotator

Stamp
1237T

Stamp
HNP

Valve Cotter
Valve Spring
Stem Seal
Intake Exhaust
Valve
Valve
For Diesel Oil

Valve Guide

Exhaust
Valve

For Heavy Oil

Valve Identification Mark

Exhaust Valve
Intake Valve

Exhaust Valve
Seat
Intake
Valve Seat

Structure of the Intake/Exhaust Valves

DC-32 Z 05-12

Intake
Valve

CHAPTER

Cylinder Heads and Valves


Consumable Replacement Parts, Special Tools
Intake/Exhaust Valves :
and Measuring Instruments/Detachment
3-2.2 Consumable Replacement
Parts, Special Tools and
Measuring Instruments

(3)

A. Consumable Replacement Parts


The following parts should be replaced by
new once they are detached. (
: "Parts List")
1. Stem Seal (Intake)
2-18
No.3
2. Stem Seal (Exhaust)
2-19
No.3

(2)

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Special tools for the valve spring
(1) Plate
(2) Base
(3) Special Bolt
(c) Valve Finishing Tool
(d) Spring for Valve Finishing
(e) Valve Seat Cutter (optional)
(f) Valve Seat Grinding Tool (optional)
(g) Special tools for the valve stem seal (1) and
(2)

3
ITEM

DC-32 2.2,2.3

(1)
(2)
(3)
(1)

(c) Valve Finishing Tool

3
(d) Valve Finishing Spring
(1) (2)

(b) Valve Spring


Special Tool

(g) Valve Stem Seal


Special Tool

E for Exhaust Cylinder Number Assembled position


of the exhaust valve
Valve

3-2.3 Detachment of the


Intake/Exhaust Valves

#1

#1

E2

E1

Detachment of the intake and the exhaust


valves should be effected for all the 4 valves at the
same time by means of the special detachment
tool.

#1
I2

#1
I1

A. Mark identifications on the valve head to differentiate the valves by type, i.e. intake or exhaust
and by the cylinder number before starting the
detachment.
B. Take out the valve spring by means of the tool
for the valve spring (b).
(1) In case that the nozzle holder is installed,
detach the nuts from the nozzle holder holding
bolts fitted on the upper surface of the cylinder
head. In case that the nozzle holder is already
detached, put the nozzle holder on the original
place.
(2) Fit the plate (b)-(1) directly on the valve rotator
and screw the foot of the base (b)-(2) in the
nozzle holder holding bolt through the upper
part of the plate.
(3) Screw the special bolt (b)-(3) through the base
until it contacts the plate by hand.

I for Intake Valve

Assembled position
of the intake valve

Procedure of the marking (an example)


(b)-(3)
Valve Rotator

(b)-2)
(b)-(1)

Intake/Exhaust
Valve Spring
Valve Stem Seal
Intake/Exhaust
Valves

Nozzle Holder
Holding Bolt
Nozzle Holder
Retainer
Nozzle Holder

Detachment of the
Intake/Exhaust Valves
DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

2.3,2.4 DC-32 Intake/Exhaust Valves : Detachment/Inspection and Maintenance


(4) Screw up the special bolt deeper to push the
intake/exhaust valve spring and take out the
valve cotters.
(5) Turn back the special bolt and detach the
valve spring special tool.
(6) Take out the valve rotator and the
intake/exhaust spring.
C. Push out the intake/exhaust valve towards the
combustion chamber.

3-2.4 Inspection and Maintenance of


the Intake/Exhaust Valves
A. Wash the intake/exhaust valves with washing
oil.
B. Inspect the valves about the following items.
(1) Corrosion of the valve head
(2) Corrosion and bend of the valve stem
(3) Pitting on the valve face due to leaked gas
(4) Contact of the valve face with the valve seat
and of the stem with the valve guide
(5) Crack on the valve face and the
intake/exhaust valve spring. Effect color check
if it is considered necessary judging from
appearance of the corrosion.
C. Measurement of the Valve Stem
(1) Measure diameters of the intake/exhaust
valve stems by an outside micrometer and
record the results.
(2) For each combination of the intake/exhaust
valves and the intake/exhaust valve guides,
calculate the clearance between the
intake/exhaust valve stems and the
intake/exhaust valve guides using the measurement of outside diameters of the
intake/exhaust valve stem together with measurement of the internal diameter of the
intake/exhaust valve guide. When a result
exceeds the service limit, replace the appropriate valve or the stem of which wear is larger.
Wear of the valve stem can be obtained
by measuring a diameter of contacting part of a
valve stem and that of non-contacting part of
the same valve stem and comparing both
results.
Nominal Diameter

Nominal Diameter

Replacement limit

(mm)
Intake Valve : seating portion C = 10.0
Exhaust Valve : seating portion E = 10.0
Intake Valve Seat D = 5.0
Exhaust Valve Seat F = 7.5

(mm)
9.0
8.5
2.5
6.5

a, b
Intake/Exhaust Valve Guides
A, B
Valve Stem
A. a : Intake Valve
B. b : Exhaust Valve

Valve Guide Clearance

E
Intake Valve

Exhaust Valve

Thickness of the Valve Face

Standard Clearance Replacement limit

(mm)
(mm)
A = 22.5 a = 0.09 - 0.17
b = 0.09 - 0.17
B = 22

(mm)
0.3
0.3

D. Measurement of Thickness of the


Intake/Exhaust Valve Heads and Dimensions of
Intake/Exhaust Valve Seats
Measure thickness of the intake/exhaust
valve heads and dimensions of the
intake/exhaust valve seat by means of a vernier
caliper and record the results.

DC-32 Z 05-12

When wear exceeds the replacement


limit, replace the appropriate valve and/or the
valve seat by new one.

D
Intake Valve Seat

F
Exhaust Valve Seat

Measurement of Dimensions
of the Valve Seats

CHAPTER

Cylinder Heads and Valves

3
ITEM

Intake/Exhaust Valves : Inspection

and Maintenance

When corrosion of the valve stem or


wear of the intake valve seat is found too
much, the possible cause is low-temperature
corrosion. Follow the recommendation for prevention as described below.
1. Adjust the setting of the intake air temperature somewhat higher.
2. When the engine is stopped, effect air running to scavenge combusted gas.
E. Finishing of the Intake/Exhaust Valves
Finishing of intake/exhaust valves, especially for the exhaust valves is a time-consuming task among maintenance work. The interval
of the maintenance much depends on the operational conditions of the engine such as load
rate and fuel used, and delayed maintenance
may accelerate worsening of flaws of the
valves. Therefore, effect the finishing in early
time as the condition of the engine requires.
<<Procedure of the Finishing>>
(1) Apply oil to the valve stem and attach the special spring for valve finishing, then insert the
valve into the valve guide installed in the cylinder head.
(2) Install the valve on the valve finishing tool (c).
(3) Apply abrasive compound to the valve seat,
and then elaborately finish the valve.
Use an abradant compound of medium
fineness followed by a fine one.
z For a medium fine compound Effect the finishing by repeated tapping action.
z For a fine compound Effect the finishing
with pressure on the tool.
z Finally wash the valve completely and carry
out the last finishing with oil.
(4) After completion of the finishing work, check a
contact mark on the valve face with blue paint
lead to make certain that the contact is set at
the outer part of the valve face.
(5) Measure dimensions of "C", "E" of the valve
head and "D" and "F" of the valve seat again
with a vernier caliper to make certain that they
have not exceeded the service limits.
F. Corrective Machining/Grinding
When a dent in the valve seat is so deep
that it can not be removed by the finishing with
an abrasive compound, the valve seat should
be subject to corrective machining or grinding
by a cutting machine or the valve seat grinding
tool (f) (an optional tool) to effect rough finishing.

DC-32

2.4

<<Procedure for the Corrective


Machining/Grinding>
(1) The valve seat should be machined by the
seat cutter (e) (an optional tool).
(2) Each angle of the valve face and the contact
surface of the valve seat should be worked as
shown on the following figures to cause contact
with the mating part at the outer circumferential
area.

3
Since machining of back part of
the valve head may weaken the valve strength
to cause breakage of the valve, never cut or
grind that part.
Valve Finishing Tool (c)-(1)

Valve Finishing Tool (c)-(2) (3)


Intake Valve Seat
Special Spring for
Valve Finishing (d)

Exhaust Valve Seat


Intake Valve
Exhaust Valve
Valve Guide
Valve Guide

Finishing of the Intake/Exhaust Valves


Backside of the
Valve Head

+15'
0

Intake Valve

0
-15'

Intake Valve Seat

Backside of the
Valve Head

+15'
0

Exhaust Valve

0
-15'

Exhaust Valve Seat

Corrective Machining/Grinding
of the Valve/the Valve Seat

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves


ITEM
Inspection and Maintenance of the Valve Rotator
2.5,2.6 DC-32 Intake/Exhaust Valves : /Assembling of Intake/Exhaust Valve Assemblies
3

3-2.5 Inspection and Replacement of


the Valve Rotator

Valve Rotator Body

Since insufficient rotation of the valve rotator


may affect life of the valve, periodically inspect it
and replace the valve rotator assembly when it has
reached its service limit.
Valve Rotator

Standard

Rotation speed (min-1)

3-5

Ball Race (PCHS)

Coned Disk Spring


Retainer
Circlip

Service limit

1/2 of the initial rotation speed

Ball

3-2.6 Assembling of the


Intake/Exhaust Valve Assembly
A. Install the valve stem seal on the top part of the
valve guide by means of the valve stem seal
special tool (g), and apply grease to the inner
circumference (lip).
B. Insert the valve from the combustion chamber
side.
C. Assemble the valve assembly in the reverse
sequence of disassembling by means of the
valve spring special tool (b).

1. Identify the identification marks "I" (Intake)


and "E" (Exhaust) stamped on the surface of
the combustion chamber of the cylinder head
and install each of the valves in the original
place according to the identification mark
marked on the valve head when they are disassembled. (since the shape and the dimensions of the intake valve resemble those of
the exhaust valve , be especially attentive
not to install wrong one.)
2. A flaw given to the inner circumference of the
stem seal (lip) during its installation may
cause increase in consumption of the lubricating oil or fouling of the valve. Apply oil to
the stem and slowly insert the valve.

DC-32 Z 05-12

Spring

Valve Rotator Assembly

Valve Stem Seal


Special Tool (g)
Stem Seal

Fitting of the Valve Stem Seal

CHAPTER

Cylinder Heads and Valves


3
ITEM
Outline of the Structure/Consumable Replacement
Valve Rocker Arm Assemblies:
DC-32 3.1,3.2
Parts, Tools and Measuring Instruments
B. Special Tools and Measuring Instruments

3-3 Valve Rocker Arm Assembly


3-3.1 Outline of the Structure

(a) General Tools and Measuring Instruments


(
: 2-2)

The intake/exhaust valves are moved by the


intake/exhaust cams on the unit type camshaft via
the swing arms, the push rods, the rocker arms
and the T valve yokes.
Each component of the valve rocker arm
assembly is lubricated by lubricating oil fed
through the engine frame, the push rods and a
drilled hole in the cylinder head without any piping
outside the engine.
For adjustment of the valve clearance, refer
to the "Operation Manual" separately provided.
(
: 5-4.1 III "Adjustment of the Valve
Clearance" of the "Operation Manual")

(b) Rocker Arm Shaft Holder Special Tool


(1) Special Ring Nut
(2) Special Extension Bar
(3) Eyebolt M 12

3
(b)-(1) Special Ring Nut

Rocker Arm Shaft Assembly : 50.0 kg


(including the rocker arms, the rocker arm
shaft and the rocker arm holder)

3-3.2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments

(b)-(3) Eyebolt M 12

(b)-(2)

A. Consumable Replacement Parts


None

Special Extension Bar


5 Rocker Arm Screw (J)
Snap Ring (D)

Intake Valve Rocker Arm (E)


Exhaust Valve Rocker Arm (F)

Clip (G)
Rocker Arm Cap (I)
T Valve Yoke
Screw

Push Rod
Seat (K)

Push Rod

Bushing
T Valve Yoke
Assembly (B)
T Valve Yoke (H)

Intake/Exhaust Valve

T Valve Yoke Guide

Tightening Nut
Rocker Arm Shaft Holder (A)

Structure of the Valve Rocker Arm Assembly

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

3.3,3.4 DC-32 Valve Rocker Arm Assemblies : Dismantling/Inspection and Maintenance


3-3.3 Dismantling of the Valve Rocker
Arm Assembly

A. Wash each component with washing oil.


B. Measure the outside diameter of the rocker arm
shaft (C) by an outside micrometer and the
internal diameter of the bushing by a cylinder
gauge, and calculate the clearance between
them. When a clearance exceeds the service
limit, replace the bushing by a new one.
Nominal Diameter

Standard Clearance

(mm)
(mm)
D = 80
d = 0.04 - 0.13

Service limit

(mm)
0.30

* Fitting force for the bushing : 14 - 30 kN

(b)-(2)

(b)-(3)

(b)-(1)

Rocker Arm Shaft Holder (A)


Rocker Arm Shaft (C)

Detachment of the Rocker Arm Shaft

Bushing
Rocker Arm Shaft

3-3.4 Inspection and Maintenance of


Components of the Valve
Rocker Arm Assembly

Rocker Arm

A. Detach the rocker arm shaft holder (A) tightening nuts by means of the rocker arm shaft holder special tool followed by detachment of the
rocker arm shaft assembly (consisting of the
rocker arm, the shaft, and the holder) from the
cylinder head.
B. Pull out the T valve yoke assembly (B) from the
T yoke guide.
C. Write the identification mark and the cylinder
number on the intake/exhaust valve rocker
arms.
D. Remove both snap rings (D) installed at the end
of the rocker arm shaft (C), and detach the
intake/exhaust valve rocker arms (E) and (F).
E. Remove the clip (G) and detach the valve end
cap (I).

C. Inspect each component for the following items.


(1) Loosening of the bushing, flaws to the internal
surface and unusual contact marks. (in case
that the part is to be continuously used)
(2) Contact marks of the sliding part of the T
valve yoke and the T valve yoke guide.
(3) Bend of the push rod, flaws of the end of the
push rod and unusual contact marks of the
push rod
(4) Flaws of and unusual contact marks on the
contacting surfaces "A" and "B" of the T valve
yoke assembly (B) with the intake/exhaust
valves.

DC-32 Z 05-12

Clearance Between the Rocker


Arm Shaft and the Bushing
(5) Flaws, unusual contact marks and wear of the
contact surface "C" of the rocker arm cap and
the T valve yoke, the contact surface of the end
of the rocker arm screw (J) and the rocker arm
cap, also the contact surface of the push rod
and the push rod seat (K)

CHAPTER

Cylinder Heads and Valves

3
ITEM

Valve Rocker Arm Assemblies: Assembling

DC-32

3-3.5 Assembling of the Valve Rocker


Arm Assembly
A. Assembling of the Rocker Arm Shaft Assembly
Fit the rocker arm cap (I) on the rocker arm
screw (J) and lock it by the clip (G). Let the
rocker arm shaft (C) go through the
intake/exhaust valve rocker arms (E) and (F),
and install the snap ring (D) on it.

3.5

Flaws and
Contact Marks

Push Rod

Bend

Assemble the rocker arm after identifying


the identification mark on the rocker arm.

B. Insert the T valve yoke assembly (B) in the T


valve yoke guide.
C. Install the rocker arm shaft assembly (B) on the
cylinder head and tighten the rocker arm shaft
holder (A) tightening nuts with the specified
torque with the threads and the seating surfaces of the nuts coated by a lubricant
(Molykote 1000 spray).
Specified torque : 441 N.m

Flaws and
Contact Marks

Inspection of the Push Rod


Rocker Arm Screw (J)

D. Adjust the valve clearance after completion of


assembling. (
: 5-4.1 III "Adjustment of the
Valve Clearance" of the "Operation Manual")

Flaws and
Contact Marks
Rocker Arm
Rocker Arm Cap (I)
Push Rod Seat

Inspection of the
Rocker Arm Cap

Flaws and
Contact Marks

Inspection of the Push Rod Seat

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

3
ITEM

Outline of the Structure/Consumable Replacement


4.1,4.2 DC-32 Starting Valve: parts, Special Tools and Measuring Instruments
3-4.2 Consumable Replacement
Parts, Special Tools and
Measuring Instruments

3-4 Starting Valve


3-4.1 Outline of the Structure
The starting valve is an air valve to utilize
pilot air that is fed from the starting air rotary valve
and moves the piston of the starting valve to open
the valve inducing starting air in the cylinder.
The starting valve is installed on the same
side of the cylinder head as that on which the fuel
injection pump is installed and can be detached as
an assembly.
Since a malfunction of its seat for sealing
function allows combusted gas to flow backward to
the starting air main system causing damage to
and stick of the starting valve piston, the starting
air rotary valve and/or the starting valve, periodically effect its inspection and maintenance.
Since overheating of the starting air pipe
hints gas leakage from the starting valve, an
inspection is required.

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Gasket (for the starting valve) 2-20
No.6
2. O-ring
2-20
No.503
3. O-ring
2-20
No.504
4. O-ring
2-20
No.505
5. Gasket
2-20
No.506
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Starting Valve Disassembling Tool

Weight of the starting valve : 2.4 kg

(b) Starting Valve


Dismantling Tool
Starting Valve Spring (G)
Starting Valve (D)
Starting Valve
Body (B)

Starting Valve
Piston (E)

O-ring (J)

Starting Valve
Gasket (H)
Mounting Bolt (M)
Starting Valve Lid (A)
Starting Valve Nut (C)

Special Gasket (I)


O-ring (L)
Seating surface

Starting air

O-ring (K)
Pilot air

Structure of the Starting Valve

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

3
ITEM

Starting Valve : Dismantling /Inspection and Maintenance


3-4.3 Disassembling of the Starting
Valve
A. Detach the starting valve lid (A) and pull the
starting valve assembly out of the cylinder
head.
B. Fix the hexagonal part at the end of the starting
valve and detach the nut (C).
C. Attach the tip of the starting valve dismantling
tool in the pin hole at the end of the starting
valve piston (E).
D. Since the starting valve piston and the starting
valve are fastened by the screw threads, fix the
end of the starting valve dismantling tool by
means of a vice. Then, unscrew the starting
valve by turning the hexagonal part at the end
of the starting valve to detach it with the starting
valve body (B) being pushed against the dismantling tool.
E. Take out the starting valve piston and the
spring (G).

DC-32 4.3,4.4

Hexagonal part
(D)
(H)

(J)
(B)
(K)
(L)
(I)

(G)
(E)
(C)
(A)
(M)

3-4.4 Inspection and Maintenance of


the Starting Valve

Disassembling and Assembling


of the Starting Valve

A. Wash each component with washing oil.


B. Inspect them in terms of the following items.
(1) Stick of the starting valve or the starting valve
piston and gas leakage from the seat.
(2) Corrosion and flaws of the spring
C. Install the starting valve on the piston and apply
a abrasive compound on the seating surfaces
of the valve and valve body to effect finishing.
D. Apply blue paint lead to the seating surface of
the starting valve to check the contact.
Contact area : 75 % or more

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

3
ITEM

4.5 DC-32 Starting Valves :

Assembling

3-4.5 Assembling of the Starting


Valve
A. The components of the starting valve should be
assembled in accordance with the procedure as
described below.
(1) Insert the spring and the starting valve piston
in the starting valve body.
(2) Attach the starting valve disassembling tool to
the hole of the end of the starting valve piston
and fix them by means of a vice or some other
device.
(3) Apply a lubricant (Molykote 1000 spray) to the
threads of the starting valve and screw the
valve in the starting valve piston.
(4) Tighten the starting valve at the hexagonal
part with the specified torque pushing the starting valve body against the disassembling tool.
Specified torque : 127 N.m
(5) Detach the disassembling tool and tighten the
nut with the specified torque.
Specified torque : 39 N.m

Starting Valve

Starting Valve Body

Starting Valve Piston

Starting Valve
Disassembling Tool

Fix by means of a vice


Remember that over-torque may break
the nut of the starting valve.

B. Install the starting valve assembly on the cylinder head according to the procedure as
described below..
(1) Install the gasket (H), and the o-rings (J), (K)
and (L), apply grease to the o-ring and the hole
in the cylinder head that receives the starting
valve and then insert the valve in the cylinder
head.
(2) Install the special gasket (I) on the starting
valve body and attach the starting valve cover.
(3) Apply a lubricant (Molykote 1000 spray) to the
mounting bolts (M) and tighten them with the
specified torque.
Specified torque : 127 N.m

DC-32 Z 05-12

Assembling of the Starting Valve

The mounting bolts should be evenly


tightened gradually and alternately. Uneven
tightening may cause leakage of the starting air
and/or the combusted gas.

CHAPTER

Cylinder Heads and Valves


3
ITEM
Indicator & Safety Valves : Outline of the Structure/Consumable Replacement
DC-32 5.1,5.2
Parts, Special Tools and Measuring Instruments
3-5 Indicator & Safety Valve
Close

3-5.1 Outline of the Structure


The indicator valve and the safety valve are
integrated in one valve body. The screw of the
indicator valve is left-handed one and the direction
of valve opening or closing is as shown in the figure. For the procedure of pressure measurement,
refer to the "Operation Manual" separately provided. (
: 5-3.1 "Measurement of the Maximum
Explosion Pressure" of the "Operation Manual")

Weight of the Indicator & Safety Valve : 1.7 kg

Open

(c) Box Spanner 19

Opening and Closing of the Indicator Valve

(1)
Joint

3-5.2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments

(3)

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Gasket

2-21

No.504

2. Gasket

2-21

No.505

3. Straight Pin

2-21

No.503

(4)
(5)
(2)

B. Special Tools and Measuring Instruments

Safety Valve

(a) General Tools and Measuring Instruments


(
: 2-2)
(b) Safety Valve Testing Tools
(1) Hydraulic pump (the same one for testing
of the nozzle)
(2) Safety Valve Testing Joint
(3) High Pressure Hose
(4) Socket Coupler
(5) Male Coupler

(b) Safety Valve Testing Device

(c) Box Spanner 19

(c) Box spanner 19

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

5.3 DC-32 Indicator & Safety Valves : Dismantling


3-5.3 Dismantling of the Indicator &
Safety Valve
The indicator & safety valve becomes
hot when the engine is operated. Since touching it with bare hand during engine operation or
immediately after its stop may cause a burn,
effect maintenance work after the engine
becomes cooled enough.
A. Detachment of the Indicator & Safety Valve
Assembly
Unscrew the flange (A) tightening nuts to
detach the indicator & safety valve assembly
from the cylinder head.
B. Dismantling of the Safety Valve
(1) Take out the safety valve (unit assembly) from
the indicator valve body (K).
(2) Loosen the lock nut (C) and the adjusting
screw (D). Put matching marks on the lock nut
(C) and the spring clamp (E) to align the mating
parts when they are reassembled.

(D)
(C)
(E)

(K)

(B)

(I)

(3) Loosen and detach the spring clamp.


If the spring clamp should be removed
with the spring compressed, the spring may
dangerously ejected. Gradually loosen the
spring clamp and remove it after making certain
that compression of the spring has decreased
almost to zero.

(G)
(H)

(F)

(A)

Nut

C. Dismantling of the Indicator Valve


(1) Remove the hexagonal plug (F).
(2) Pull out the straight pin (G) and remove the
indicator valve nut (I) from the indicator valve
(H).
(3) Push out the indicator valve by means of a
screw driver.

The screw of the indicator valve is lefthanded one and clockwise turning viewed from
the hexagonal plug is the direction to loosen
the valve.

DC-32 Z 05-12

(J)

Indicator & Safety Valve

CHAPTER

Cylinder Heads and Valves


Inspection and Maintenance/Assembling
Indicator & Safety Valve :
and Maintenance of the Safety Valve
3-5.4 Inspection and Maintenance of
the Indicator & Safety Valve
A. Wash the disassembled components and
remove fouling such as carbon deposit.
B. Inspection and Maintenance of the Safety Valve
(1) Inspect whether or not there is a trace of
abnormal partial contact flaw or sticking on
the outer circumference of the safety valve or
the seating surface.
(2) When any flaw or a trace of sticking is found,
rectify it by means of a oil stone and effect finishing with the seat face to which abrasive
compound is applied.
C. Inspection and Maintenance of the Indicator
Valve
(1) Inspect whether or not there is a flaw or a
trace of partial contact on the seating surface of
the indicator valve.
(2) When any flaw is found, rectify it by means of
a oil stone and effect finishing with the seating
surface to which abrasive compound is applied.
D. Inspect whether or not there is a trace of abnormal contact or a flaw on the spring. When a
flaw is found, replace it by new one.

3-5.5 Assembling and Adjustment of


the Safety Valve
A. Assembling of the Safety Valve (unit assembly)
Insert the valve and the spring in the
safety valve body and install the spring clamp,
the lock nut and the adjusting screw after
effecting finishing.
B. Adjustment of the Safety Valve
Adjust the valve opening pressure
according to the procedure as described below.
(1) Couple the safety valve testing joint (b)-(2)
with the safety valve, and connect it with the
hydraulic pump (b)-(1) via the high pressure
hose (b)-(3).
(2) Screw the adjusting screw with the hexagonal
bar spanner until the matching marks align
each other.
(3) Moving up and down the hydraulic pump lever
to raise the oil pressure and read the valve
opening pressure.
(4) Turn the adjusting screw to adjust the valve
opening pressure.

3
ITEM

DC-32 5.4,5.5

(5) Fix the adjusting screw and tighten the lock


nut.

(b)-(3)

Joint PT 3/8
Special Gasket Pump side

(b)-(4)
(b)-(5)
(b)-(2)

Safety Valve side


Pressure setting : 21.1 MPa
Set the oil pressure higher than the
above figure by somewhat 10 % to compensate
the initial permanent set in fatigue of the spring.

Testing of the Safety Valve

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

5.6 DC-32 Indicator & Safety Valve : Assembling


3-5.6 Assembling and Installation of
the Indicator & Safety Valve
A. Assemble the indicator & safety valve in the
reverse sequence of that for the disassembling.
In this assembling work, the straight pin for the
indicator valve should be replaced by new one
and the both ends should be riveted on the indicator valve nut at three points per each end to
fix it to the nut.
B. Blow the seating surface of the cylinder head
by air to clean it and install the indicator & safety valve assembly on the cylinder head with the
gasket (J) installed between them.
C. Adjust the direction of the valve assembly so
that the indicator valve may not protrude from
the side of the cylinder head and also the indicator valve nut may be easily handled, and
tighten the nuts with the specified torque after
applying a lubricant (Molykote 1000 spray) to
the nuts.
Specified torque : 59 N.m

Tighten the nuts alternately and evenly.


Uneven tightening may cause leakage of the
combusted gas.

DC-32 Z 05-12

and Installation

CHAPTER

Cylinder Heads and Valves


Cylinder Head Outlets of
the Cooling Water Piping:

Outline of the Structure/Consumable Replacement


Parts, Special Tools and Measuring

ITEM

DC-32 6.1,2,3

3-6 The Cylinder Head Outlets of


the Cooling Water Piping
3-6.1 Outline of the Structure
The cylinder head outlet of the cooling water
piping is made of cast iron in which an orifice that
regulates flow of the cooling water is built in and
has a boss for a thermometer and another threaded boss used for its slinging.
Another cylinder head outlet of the cooling
water piping (B) and the special flange (C) are provided between the neighboring cylinders to facilitate connecting and detaching of them.

Weight of the cooling water piping


assembly : 13 kg

3-6.2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced with
new ones when maintenance is effected.
(
: "Parts List")
1. O-ring
2. O-ring
3. O-ring

3-4.1
3-4.1
3-4.1

No.506
No.507
No.508

Cylinder Head Outlet of the


Cooling Water Piping (A)

O-ring (E)

Special
Flange (C)

Mounting
Bolts (F)

Cylinder Head Outlet of the


Cooling Water Piping (B)

O-ring (D)
Cylinder Head Outlet of the
Cooling Water Pipe (A)

O-ring (H)

Orifice (G)

Cylinder Head Outlet Cooling


Water Piping Assembly

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

Eye Bolt M10

3-6.3 Detachment of the Cylinder


Head Outlet of the Cooling
Water Piping
A. Screw the eye bolt M10 in the tapped hole for
slinging located on the cylinder head outlet of
the cooling water piping (A).
B. Loosen and detach the mounting bolts (F) and
detach the special flange (C) together with the
cylinder head outlet of the cooling water piping
(B) from the cylinder head outlet of the cooling
water piping (A).
C. Loosen and detach the mounting bolts of the
cylinder head outlet of the cooling water piping
(A).
D. Hook the wire rope on the eye bolt and slowly
sling the cylinder head outlet of the cooling
water piping (A), then detach it from the wire
rope.
E. Detach the orifice (G) and the o-ring (H).
F. Detach the o-rings (D) and (E) from the special
flange (C).

Detachment of the Cylinder Head


Outlet of Cooling Water Piping

Orifices and o-rings are easily fall off. Be


attentive so that they may not be missed.

DC-32 Z 05-12

CHAPTER

3
ITEM

6.4,6.5 DC-32

Cylinder Heads and Valves


Cylinder Head Outlets of
the Cooling Water Piping :

3-6.4 Inspection and Maintenance of


the Cylinder Head Outlet of the
Cooling Water Piping
A. Wash each component and remove scale in the
cooling water passage.
B. Inspect the following items.
(1) Corrosion and flaws of the cooling water passage in the cylinder head outlet of the cooling
water piping and the grooves for the o-rings.
(2) Corrosion and flaws of the cooling water passage, the area to be fitted in the cylinder head
outlet of the cooling water piping and the
groove for the o-ring in the special flange.

3-6.5 Install the cylinder head outlet


of the cooling water piping by
the reverse process of that for
its detachment.
A. Apply grease to the o-ring and install it on the
special flange (C).
B. Mount the special flange on the cylinder head
outlet of the cooling water piping (B).
C. Fit the orifice in the cylinder head outlet of the
cooling water piping (A).
D. Apply grease to the o-ring and install it in the
cylinder head outlet of the cooling water piping.
E. Blow the mating surface of the cylinder head
and deliberately clean it, and then mount the
cylinder head outlet of the cooling water piping
on the cylinder head.
F. Mount the cylinder head outlet of the cooling
water piping (B) on the cylinder head outlet of
the cooling water piping (A) by the mounting
bolts (F).

Tighten the nuts alternately and evenly.


Uneven tightening may cause water leakage.

DC-32 Z 05-12

Inspection and Maintenance


/InstallationInstruments /Detachment

CHAPTER

Cylinder Heads and Valves


Outline of the Structure/Consumable Replacement Parts,
Intake Manifolds : Special Tools/Measuring Instruments/Detachment

3
ITEM

DC-32 7.1,2,3

3-7 The Intake Manifold


3-7.1 Outline of the Structure
Mounting
Bolt (D)

Tapped Hole for


the Pushing Bolt

Intake Manifold
(head inlet) (A)

Dowel
Pin (C)
Mounting Bolt (E)

Cylinder Head

The intake manifold (cylinder head inlet) is


an intermediate component that connects the
intake manifold in the engine frame and the cylinder head. It is attached on the intake manifold via
a special rubber seal that facilitate their assembling.
The cylinder head can be installed on the
engine with the intake manifold being mounted.

Weight of the intake manifold : 21 kg

3-7.2 Consumable Replacement


Parts, Special Tool and
Measuring Instruments

Intake Manifold
(head inlet)

Special Rubber Seal (B)

Intake Manifold (cylinder head inlet)

A. Consumable Replacement Parts


1. Seal (for the intake manifold) 2-1
No.18
(special rubber seal)
(
: "Parts List")
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)

3-7.3 Detachment of the Intake


Manifold (Head Inlet)

Eye Bolt M 12
Pushing Bolt to
separate the flange
from the cylinder head

A. Screw the eye bolt M12 in the tapped hole for


slinging located in the intake manifold and the
bolt M 12 in the tapped hole used for disassembling in the flange on the cylinder head.
B. Hook the wire rope on the eye bolt and unscrew
and remove the mounting bolts with the intake
manifold being slung.
C. Screw up the pushing bolt to separate the
flange from the cylinder head.

Detachment of the Intake


Manifold (head inlet)

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

ITEM

7.4,7.5 DC-32 Intake Manifolds (head inlet) :Inspection and maintenance/Installation


3-7.4 nspection and Maintenance of
the Intake Manifold (head inlet)
A. Check stain in the air passage in the intake
manifold (head inlet).

Stain in the air passage hints how bad


back fire has been.
When the stain is found conspicuous,
investigate whether or not the engine is operated at the low load for a prolonged time or combusted gas has leaked through the valve, and
then take necessary measures.
B. Wash the intake manifold (head inlet).
C. Inspect corrosion of the air passage.
D. Inspect corrosion, flaws, deformation and
degradation of quality of the special rubber
seal.

3-7.5 Installation of the Intake


Manifold (head inlet)
The intake manifold (head inlet) should be
installed in the reverse sequence of that for
detachment.
A. Apply liquid sealer to the surface of the flange
of the intake manifold (head inlet) that is to be
mated with the cylinder head.
B. Blow by air and deliberately clean the mating
surface of the cylinder head.
C. Position the intake manifold (head inlet) locating it by the dowel pin and screw up the mounting bolts to tighten the intake manifold (head
inlet) while slinging it.

DC-32 Z 05-12

CHAPTER

Cylinder Heads and Valves

MEMO

3
ITEM

DC-32

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

1 DC-32 Pistons and Connecting Rods : Outline

of the Structure

4. Pistons and Connecting Rods


4-1 Outline of the Structure
The connecting rod is made of carbon steel
and formed by closed die forging. Its large end has
three-piece structure horizontally parted. Owing to
this structure, the piston can be taken out without
dismantling the crankpin bearing.
The serration treated upper and lower parts
parted at the mating surface in the large end portion of the connecting rod are tightened with two
crankpin bolts (B) while the rod part and the large
end part are tightened with four connecting rod
joint bolts (A) by means of the hydraulic jack.
The connecting rod is also supported by the
lower part of a boss of the piston for the piston pin.
The crank pin bearing (C) is made of a high
abrasion resistant aluminum alloy.
The piston pin (D) is completely floating, and
its axial movement is limited by snap rings (E).
The piston pin bushing (F) is of a stepped
shape to provide as large a bearing area as possible for the side to receive explosion pressure.
The piston is a composite type consisting of
a special alloy steel crown and a ductile cast iron
skirt of which outer circumference is specially coated. Also for the engines using heavy fuel oil, the
grooves for the top and the second piston rings are
hardened by induction heating to improve abrasion
resistance.
The lubricating oil to cool the piston is fed to
the cooling cavity in the piston through the
crankpin, a drilled hole in the connecting rod and
the piston pin.
The piston rings consist of three compression rings and one oil ring, four in total. The surface of the compression and the oil rings sliding on
the surface of the cylinder liner is chrome plated to
improve their abrasion resistance.

Crown
Mounting Bolt

Piston (G)

Piston Pin
Bushing (F)
Piston Pin (D)

Connecting Rod
Joint Bolt (A)

Connecting
Rod (L)

Crankpin
Bearing (C)
Serration
Circular
Nut (K)
Crankpin
Bolt (B)

Piston pin and Connecting Rod


Piston Crown
Piston Rings (H)
Oil Ring (I)
Piston Skirt
Piston Crown
Mounting Bolt
Piston Pin (D)

Snap Ring (E)

Weight of ;
Piston and Connecting Rod Assembly : 322 kg
Piston Assembly (not including the pin) : 90 kg
Piston Pin
: 29.5 kg
Connecting Rod Assembly : 202.5 kg

DC-32 Z 05-12

Circular Nut (J)

Piston and Piston pin

CHAPTER

Pistons and Connecting Rods


Consumable Replacement Parts, Special
Pistons and Connecting Rods :
DC-32
Tools and Measuring Instruments

4
ITEM

4-2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following part should be replaced when
maintenance is effected.
1.
O-ring
2-14
No.8

(1)

(2)
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Hydraulic Jack (for the connecting rod joint
bolts)
(1) Hydraulic Jack Assembly
(2) Jack Stand
(3) Jack Handle
(c) Hydraulic Jack (for the crankpin bolts)
(1) Hydraulic Jack Assembly
(2) Joint Bolt
(3) Jack Stand
(4) Jack Handle (the same one as (b)-(3))
(d) Hydraulic Pump
(1) Hydraulic Pump
(2) High Pressure Hose (3 pieces with a male
coupler for each)
(3) Terminal (2T) (with a socket coupler)
(e) Piston Inserting Frame
(3)

(3)

4
(b) Hydraulic Jack
(for the connecting rod joint bolts)

(1)

(3)

(4)
(2)

(2)

(c) Hydraulic Jack (for the crankpin bolts)


(1)

(d) Hydraulic Pump

(e) Piston Inserting Frame

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods


Consumable Replacement Parts, Special
2 DC-32 Pistons and Connecting Rods : Tools and Measuring Instruments
4

ITEM

(f) Protect Ring Special Tool


(1) Protecting Ring Special Tool #1
(2) Protecting Ring Special Tool #2
(3) Protecting Ring Special Tool #3
(4) Plane Washer
(g) Connecting Rod Large End
Disassembling/Assembling Tool
(1) Connecting Rod Disassembling Tool (1)
(2) Eye Bolt M10
(h) Cylinder Liner Measuring Point Locating Tool
(i) Cylinder Bore Gauge (250 mm - 450 mm)
(j) Ring Gauge (320 mm)
(k) Piston Suspending Tool (optional)
(1) Piston Holding Bolt
(2) Piston Holding Plate
(3) Piston Hanger Bolt
(4) Piston Holding Block
(l) Piston Pin Special Tool
(1) Piston Pin Special Tool-1
(2) Piston Pin Special Tool-2
(3) Piston Pin Special Tool-3
(4) Eye Bolt M10
(m) Piston Ring Installation/Detachment Tool
(optional)

(h) Cylinder Liner Measuring


Point Locating Gauge

(i) Cylinder Bore Gauge

(j) Ring Gauge


(3)

(1)
(4)
(3)
(2)

(4)
(4)

(1)

(3)
(2)

(2)

(k) Piston Suspending Tool

(i) Piston Pin Special Tool

(f) Protect Ring Special Tool

TO

(1)

(2) To be used for the top ring

The right grip


(1)

(1)

(2)

The left grip

(g) Connecting Rod Large End


Disassembling/Assembling Tool

DC-32 Z 05-12

(m) Piston Ring Installation/Detachment Tool

CHAPTER

Pistons and Connecting Rods

4
ITEM

Detachment /Dismantling : Pulling-Out


4-3 Dismantling of the Piston and
Connecting Rod Assembly
4-3.1 Pulling-out of the Piston
Pulling-out of the piston should be effected
after detachment of the cylinder head.
(
: 3-1.3 "Detachment of the Cylinder
Head")
It is not necessary to dismantle the large
end of the connecting rod when pulling-out of the
piston is the only purpose of the work but just
detachment of the rod portion from the large end is
required.

In the operation of piston pulling-out,


rotation of the crank shaft during handling of a
part in the engine frame may cause a dangerous accident in which part of a human body or
some other object is caught between the
engine parts.
The turning shall be effected after
sending a signal to the co-worker and the turning device shall be "disengaged" except when
the turning is carried out.
<<Procedure for Pulling-out of the Piston >>
A. Detach the engine frame side covers on both
sides of the cylinder from which the piston is
going to be pulled out, and carry out the turning
to bring the piston to 50oBTDC.
B. Put cotton waste over the upper surface of the
piston to facilitate collection of removed carbon
deposits.
C. Remove carbon deposits stuck to the protect
ring (M) and the upper part of the cylinder liner
(N) with sandpaper or some other tools.
D. Pull out the protect ring fitted on the upper part
of the cylinder liner by means of the protect ring
special tool (f).
(1) Lightly knock all around the protect ring with a
plastic hammer.
(2) Spray lubricating penetrant (e.g. KURE 5-56)
in the gap between the cylinder liner and the
protect ring.
(3) Attach the protect ring special tool (f) and
gradually pull out the protect ring with the protect ring special tool (f)-(3) being turned. (When
the pulling-out is not easy, pull out the protect
ring while evenly knocking the protect ring with
a plastic hammer.)
E. Remove carbon deposits stuck to the tapped
hole for pulling-up of the piston by means of a
tap (M16 x 2.0).

of the Piston DC-32

Protect Ring (M)


Cylinder Liner (N)

3.1

Carbon
Cotton
Waste

Piston (G)

4
Removal of carbon deposits stuck to
the upper part of the cylinder Liner
(f)-(3)
(f)-(2)
(M)
(N)
(f)-(1)

Pulling-out of the Protect Ring

Tapping Handle
Tap (M16 x 2.0)

Removal of carbon deposits stuck to


the hole for pulling-up of the Piston

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

3.1 DC-32 Detachment /Dismantling : Pulling-Out

of the Piston

F. Attach the eye bolt M16 (for pulling up of the


piston) to the upper part of the piston and hook
a wire rope on it.
The eye bolt M16 should be screwed
up until its flanged head contacts the piston. If
eye bolt should be screwed half way, a dangerous situation such as coming-off of the bolt and
breakage of the piston may be presented
G. Effect the turning of the crank shaft to bring the
piston to 105oBTDC.

Sequence According to Which the Hydraulic


Jack is to be Attached :1 2 or 2 1
(b)

(A)
(d)-(2)

When effecting the turning of the crank


shaft, slowly do it with care so that a large end
that has been already dismantled may not
touch the engine frame.

(d)-(3)

(d)-(2)
H. Loosen the circular nuts on the connecting rod
joint bolts (A) by means of the hydraulic jack for
the connecting rod (b).
When unscrewing the circular nuts,
unscrew a pair of two diagonally located ones
at each time. Read the oil pressure at which
each nut began to be loosened and check
whether or not the nut was tightened enough
when it was tightened.
(
: 2-4 Hydraulic Jack")

Specified oil pressure : 90 MPa


I. Effect the turning of the crank shaft to bring the
piston to be pulled out to the BDC.
J. Detach the circular nut (A), and pull up the piston by means of wire ropes and a chain
block to pull out the piston together with the
small end portion of the connecting rod.

Detachment of the Circular Nuts on


the Connecting Rod Joint Bolts
Eye Bolt M16
Piston (G)
Small-end Portion of
the Connecting Rod (L)
Connecting Rod
Joint Bolt (A)

Be attentive so that the connecting rod


may not scratch or dent the inner surface of the
cylinder liner or thread of the connecting rod
joint bolt when slinging the piston.
K. Attach the piston pin special tool on the piston
pin while the piston is hanged up.

Pulling-out of the Piston

DC-32 Z 05-12

(d)-(1)

CHAPTER

Pistons and Connecting Rods

4
ITEM

Detachment /Dismantling : Pulling-Out

of the Piston DC-32

3.1

L. Provide a wooden bolster and put the piston on


it on its side.
Lid (for the intake duct)

When putting the piston on the bolster,


be attentive not to scratch or dent the surface
of the cylindrical part of the piston.

M. Put lids on the cylinder liner as well as the


intake duct to prevent foreign matters from penetrate in the engine.
N. Detach one of the snap rings (E) fitted on the
upper side of the piston pin by means of the
snap ring pliers.
O. Pull out the piston pin (D) and separate the
small end portion of the connecting rod from the
piston.
P. Put the piston with its combustion chamber side
facing upward on the designated place.
Q. Detach the piston rings and the oil ring by
means of the piston ring installation/detachment
tool (m). However, replace the right side grip by
another one (m)-(2) when detaching the top
ring.

4
Lid (for the cylinder liner)

Dust-proof Lid

(l)-(4)
Piston Pin (D)
(l)-(1)

(l)-(3)

Snap Ring (E)


Snap Ring
Pliers

(l)-(2)

50

35

136

Since the edge of circumference of


each piston ring becomes sharp after a prolonged engine operation, wear safety gloves
and be careful not to be cut while detaching or
dismantling the piston.

Wooden Bolster

Wooden Bolster

Pulling-out of the Piston Pin

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

3.2 DC-32 Dismantling : Dismantling of the Big End of the Connecting Rod
4-3.2 Dismantling of the Big End of
the Connecting Rod
It is necessary to dismantle the big end of
the connecting rod when inspecting and/or replacing the crankpin bearing (C) or the crankpin bolt
(B). It is not necessary to do so when pulling out
the piston.
And the big end of the connecting rod can
be dismantled without detaching the cylinder head
with the piston being suspended when intending to
inspect just the crankpin bearing.
<<Procedure for Dismantling of the Big End of
the Connecting Rod>>
(In case that the piston is pulled out)
A. Pull out the piston together with the small end
portion of the connecting rod according to the
"Procedure for Piston Pulling-out".
(
: 4-3.1 "Pulling-out of the Piston" or
"Suspension of the Piston" to be later
described")
B. Effect the turning of the crankshaft to bring the
crankpin to 93oBTDC and direct the big end
portion sideways.
C. Loosen two circular nuts (K) on the crankpin
bolts (B) at the same time by means of the
hydraulic jack (c). (
: 2-4 "Hydraulic Jack")
(1) Put the jack stand (c)-(3) on the big end portion of the connecting rod, screw up the joint
bolt (c)-(2) on the crankpin bolt and attach the
hydraulic jack assembly (c)-(1) to the joint bolt
(c)-(2), then connect the hydraulic pump (d)-(1)
with the hydraulic jack via the high pressure
hoses (d)-(2).
(2) Move the lever of the hydraulic pump up and
down to raise oil pressure to the specified one
and loosen the circular nuts using the jack handle (c)-(4).

Since the big end portion is prone to


fall off, the circular nut should not be removed
from the bolt.

(c)-(3)
(c)-(2)
(c)-(1)
(d)-(2)
(d)-(3)
(d)-(1)

Dismantling of the Big End Portion of the Connecting Rod


(How to Connect the Hydraulic Pump with the Hydraulic Jack)

Connecting Rod Joint Bolt (A)


Thread of the Crankpin Bolt (B)
Crankpin
Large End Cap
(g)-(3)

Specified oil pressure : 76 MPa


(3) See the oil pressure at which the circular nut
began to move to make certain that the circular
nut did not loosen.
(4) Detach the hydraulic jack assembly, the joint
bolt and the jack stand.

DC-32 Z 05-12

(C)
(g)-(2)

(g)-(1)

(C)

(g)-(3)

Taking-out of the Large End (upper and lower)


of the Connecting Rod

CHAPTER

Pistons and Connecting Rods

4
ITEM

Dismantling : Dismantling of the Large End of the Connecting Rod

D. Put the connecting rod large end assembling


and dismantling tool (g)-(1) across the inspection window located on the engine frame and fix
it on the inspection window lower bolt.
E. Slowly effect the turning of the crankshaft until
the connecting rod large end assembling and
dismantling tool (g)-(1) is contacted.
F. Attach the connecting rod large end assembling
and dismantling tool (g)-(2) on the connecting
rod joint bolt (A) and fix it by means of the circular nuts (J).
G. Attach the eye bolt M10 (g)-(3) on the connecting rod large end cap.
H. Loosen and remove the circular nut (K) on the
crankpin bolt by hand.
I. Take out each of the upper and the lower portion
of the large end through the left inspection window and the right one respectively.

DC-32

3.2

(k)-(3)

Be attentive not to damage the thread


of the crankpin bolt (B) and the crankpin when
taking out the rod portion of the large end.
(k)-(2)

J. Detach the crankpin bearing (C) from the large


end. The bearing metal will be easily detached
by light tapping on the bearing metal on a locating protrusion with a wooden block.
K. The cylinder number and the position of the
metal, upper or lower should be written on the
detached bearing metals for identification.

50

<<Dismantling of the Large End with the Piston


Being Suspended>>
(1) Effect the turning of the crankshaft to bring the
crankpin of the crankshaft to be inspected to
105oBTDC.
(2) Loosen the circular nuts on the connecting rod
joint bolts (A) in accordance with the procedure
described in 4-3.1G.
(3) Effect the turning of the crankshaft to bring the
crankpin to the BDC. and remove the circular
nuts.
(4) Detach the high pressure fuel block and the
inlet connector, and then pulling out the fuel
injection valve.
(
: 5-4.2 "Pulling-out of the Fuel Injection
Valve" of the "Operation Manual")

(k)-(1)

(k)-(4)

Suspending of the Piston

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

3.2 DC-32 Dismantling : Dismantling of the Large End of the Connecting Rod
(5) Screw the piston suspending bolt (k)-(3) in the
tapped hole in the piston and pull up the piston
so that the clearance between the flange of the
connecting rod and the flat surface of the balance weight is 50 mm, and then insert the piston support block (k)-(4).
(6) Put the flange of the connecting rod on the
piston support block (k)-(4) and replace the piston hanger bolt with the piston support bolt (k)(1).
(7) Lift the piston a little from the piston support
block by means of the piston support bolt (k)(1) to remove the piston support block.
(8) When the work processes descried above
have completed, dismantle the piston in accordance with the procedure described in the
items B to K of this chapter 4-3.2 <<Procedure
for Dismantling of the Large End Portion of the
Connecting Rod>> (in case that the piston is
pulled out).

Be attentive to prevent the connecting


rod from hitting the cylinder liner producing
flaws on it.

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

4
ITEM

Inspection and Maintenance : Inspection and Maintenance of the Piston

4-4 Inspection and Maintenance of


the Piston and the Connecting
Rod
4-4.1 Inspection and Maintenance of
the Piston

DC-32

4.1

Surface facing the combustion


chamber

(1)
Top Land
(3)
(5)

Since these parts are subject to the


NOx Technical Code, always use a part that
has the identification stamp when replacing it.
(
: 0-3 "Engines Conforming to the NOx
Technical Code")
A. Inspection of Major Part of the Piston
Inspect the following major part of the piston
and record the results.
(1) Carbon deposits stuck to the surface of the
piston facing the combustion chamber and to
the top land, and lubricating condition of the
sliding portion.
(2) Flaws and unusual contact marks on the sliding portion
(3) Piston ring stick, peeling off of the chrome
plating, unusual contact marks and wear
(4) Condition of carbon sludge stuck to the inside
surface of the piston and the bottom of the ring
grooves
(5) Partial corrosive wear of the ring grooves
(6) Unusual contact marks on the piston pin and
on the internal surface of the piston pin boss
(7) Unusual contact marks on the piston pin boss
and on the connecting rod small end supporting
portion
B. Remove carbon deposits stuck to the upper
part of the piston by means of fine sandpaper.

Do not use sandpaper on the piston


skirt because the piston skirt is coated with a
special material or method.
C. Wash the piston and the piston rings with washing oil.
D. Thoroughly clean the surface of the piston facing the combustion chamber and effect color
check to inspect cracks on the piston with care.
E. Blow the oil feeding holes in the piston by air to
clean the inside of the piston.

(2)

4
Checking of Condition
of the Piston
Oiling Hole

Inspection and Maintenance of the Piston Pin


Surface facing the combustion chamber (color check)
Top Land

Piston Skirt

Inspection and Maintenance


of the Major Part of the Piston

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

4.1 DC-32 Inspection and Maintenance : Inspection and Maintenance of the Piston
F. Do not separate the piston crown from the skirt
portion as long as no carbon sludge is deposited on it.
Follow the following procedure when it is
necessary to do so.

2 3

4 1
<<Procedure to Detach the Piston Crown>>
(1) Put the piston on the appropriate place on the
top.
(2) Loosen and remove the tightening nuts in the
sequence shown in the right figure. Read the
torque at which each of the nuts begins loosening to make certain that it has not loosened.

Sequence to Loose the Fastening Nuts


(View "P")

P
Nut
Washer

Release torque : 196 N.m


Piston Skirt
(3) Separate the piston crown from the piston
skirt with care not to damage the piston crown
bolts that are screwed in the piston crown.
(4) Detach the o-ring fitted on the piston skirt.
(5) Loosen and pull out the piston crown bolts.

O-ring
Piston Crown
Bolt
Piston Crown

Release torque : 147 N.m

Separation of the Piston Crown

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

4
ITEM

Nominal Diameter(mm)
A = 320

Replacement Limit(mm)
-0.5

B = 320

-0.5

C = 320

-0.5

4.1

80

B
120

G. Measurement of the Major Dimensions


Measure the major dimensions of the piston and record them.Calculate the clearances
and replace the part that exceeds the replacement limit with new one.
(1) Outside Diameter (O.D.) of the Piston
Measure the O.D. at three specified positions on the piston and record the results.
Calculate the clearances from the results
together with the measurements of the inside
diameter (I.D.) of the cylinder liner.
(
: 5-3 "Inspection of the Inside Surface of the
Cylinder Liner")

DC-32

200

Inspection and Maintenance : Inspection and Maintenance of the Piston

Position to be Measured on the Piston


(2) Piston Pin and Piston Pin Boss
Measure the O.D. of the piston pin and
the I.D. of the piston pin boss and replace
either one of which wear is larger.

0.095 - 0.135

Replacement Limit(mm)

0.25

A = 150

Standard Clearance (mm)

Piston
Pin Boss

Nominal Diameter(mm)

Piston Pin

Clearance Between the Piston Pin


and the Piston Pin Boss

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

4
ITEM

4.2 DC-32 Inspection and Maintenance : Inspection and Maintenance of the Piston
4-4.2 Inspection and Maintenance of
the Piston Rings
A. Remove carbon stuck to the piston rings and
the oil ring, and wash them with washing oil.
B. Since the sliding surface of a piston ring is
hard-chrome plated, replace the piston ring of
which plated layer has been worn out to the
base metal or when any irregularity such as a
crack is found on its surface with new one even
when the wear is within the replacement limit.
C. Measurement of the Piston Ring Closed Gap.
It is recommended that the piston ring closed
gap should be measured for each of the piston
rings by putting it in the ring gauge (j) or a new
cylinder liner.

Replace all the piston rings with new


ones on every periodic maintenance of 8000 to
12000-hour (2 to 3 years) engine operation even when the service limits are not
exceeded.

C1
No. 1 (Top) Ring

C2

Compression
Rings

No. 2

C3
No. 3

Standard Gap (mm)

a = 0.15 - 0.19
b = 0.12 - 0.16
b = 0.12 - 0.16
d = 0.05 - 0.11

Replacement Limit (mm)

0.3
0.3
0.3
0.3

 In case that wear of the width of any piston ring


is so much that the piston ring is required to be
replaced with oversized one, please contact the
Service Division of DAIHATSU.
Since the edge of circumference of
each piston ring becomes sharp after a prolonged engine operation, wear safety gloves
and be careful not to be cut when handling the
piston.

DC-32 Z 05-12

No. 2

Compression
Rings

No. 3

A=7
B=7
C=7
D = 10

No. 1 (Top) Ring

Nominal Width (mm)

Oil Ring

C c

D. Measure the width of each of the piston rings


and of the ring grooves and replace the ring or
the piston with new one when it exceeds the
replacement limit.

C4

A a

Replacement Limit (mm)


3.5
3.5
3.5
3.5

B b

Standard Gap (mm)


C1 = 2.4 - 2.7
C2 = 2.0 - 2.3
C3 = 1.6 - 1.9
C4 = 1.6 - 1.9

Oil Ring

Clearances of the Piston Rings

CHAPTER

Pistons and Connecting Rods

4
ITEM

Inspection and Maintenance :

Inspection and Maintenance of Connecting Rods DC-32

4-4.3 Inspection and Maintenance of


the Connecting Rod
A. Inspect the following items and record the
results, and repair or replace the appropriate
ones that are found faulty.
(1) Contact marks on the piston pin bushing (F)
installed in the small end and loosening or displacement out of its normal position of the fitted
portion of the bushing
(2) Flaws and fretting on the mating surfaces of
the rod portion and the large end portion of the
connecting rod
(3) Flaws or dents on the threads of the connecting rod bolts (A) and the crankpin bolts (B) produced by something hitting it and peeling happened on them
(4) Condition of the serrations ... wear and fretting
(5) Flaws or dents on the surfaces of the connecting rod contacting with the circular nuts (J) and
(K) produced by something hitting them and
peeling happened on them
(6) Flaws or dents on the threads of the circular
nuts (J) and (K) and on the seating surfaces
produced by something hitting them and peeling happened on them
B. Clean the serrations and effect the color checking to make certain that no flaws are produced
on them.
C. Blow the oiling hole drilled through the connecting rod to clean it.
D. Measure the I.D of the piston pin bushing. And
calculate the clearance between the piston pin
and the bushing from the results of the measurement together with the measurements of the
O.D. of the piston pin, and replace one exceedSerrations
Mating Surfaces
Large End (Large End Cap)
Large End Portion
(Rod Portion)

4.3

ing its replacing limit with new one when the


replacing limit is exceeded.
Nominal Diameter (mm) Standard Clearance (mm)

A = 150

a = 0.09 - 0.19

Replacement Limit (mm)

0.35

<<Procedure for Replacement of the


Bushing>>
(1) Push out the bushing by means of a press or
a hammer and take it out.
(2) Insert a new bushing by shrinkage fitting making it adapted to the shape of the connecting
rod.
<When using a press>
Fitting force for the bushing : 19 - 57 kN
<When using shrinkage fitting>
Immerse the bushing in liquid nitrogen, and
take it out when bubbles disappear (after 5 10 minutes) and fit it in the connecting rod.
E. Measure the I.D. of the large end housing of the
connecting rod assembly (the large end portion
and the rod portion are assembled with the connecting rod joint bolts and crankpin bolts being
tightened with the specified torque respectively
but with the crank pin bearing yet to be assembled) and record the result to check its deformation.
(
: 4-5 "Assembling of the Connecting Rod")
Crankpin Bolts (B)

Circular
Nuts (K)

Oiling Holes
Mating Surfaces

Connecting Rod Joint Bolts (A)


Piston Pin Bushing (F)

Oiling Hole

Circular Nuts (J)

Inspection and Maintenance of


Major Part of the Connecting Rod

Clearance Between I,D. of the Piston Pin Bushing


and the O.D. of the connecting Rod (small end)

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

4
ITEM

4.4 DC-32 Inspection and Maintenance : Inspection and Maintenance of Crankpin Bearings
4-4.4 Inspection and Maintenance of
the Crankpin Bearing
A. Inspect the bearing to find whether or not fretting on the outside surface or the closed gap
between the metals, a trace of seizure, peeling,
and a trace of cavitation on the inside surface,
and sunken foreign matters in the surface are
found. When a flaw or a dent is not deep, rectify
it by an oil stone.

A trace of a seizure, peeling,


a trace of cavitation
and a sunken foreign matter

The bearing is a thin completed component for which an appropriate tightening margin (crush) and expanding force (tension) are
provided to maintain full contact with the large
end of the connecting rod, therefore, don not
effect correction of the outside or the inside
surface by a file or a scraper.
B. Wash the bearing, measure the thickness by a
spherical micrometer and record the result. And
calculate the clearance between the bearing
and the large end housing using the measurements of the I.D. of the large end housing, the
thickness of the bearing and the O.D. of the
crankpin to replace the bearing with new one
when the replacement limit to the clearance is
exceeded.

A = 310

a = 0.19 - 0.29

Connecting Rod
(large end)
Crankpin Bearing
Metals
Crankpin

Replacement Limit (mm)

0.35

Standard Clearance (mm)

Crankpin Bearing Metals

Nominal Diameter (mm)

Fretting

1. Always replace metals of a bearing by a pair


of the new upper and lower metals at the
same time.
2. Replace the bearing metals every 20,000
hours of operation (4 - 5 years) even when
the wear is within the allowable limit because
prolonged operation of an engine may cause
a crack or peeling to the bearing metals due
to reduction of the tightening margin or to
hardening of the inside portion of the metals.

DC-32 Z 05-12

Clearance of the Crankpin Bearing

CHAPTER

Pistons and Connecting Rods

4
ITEM

Inspection and Maintenance : Replacement of the Connecting Rod Bolts

4-4.5 Replacement of the Connecting


Rod Bolts
Replace the connecting rod joint bolts and
the crankpin bolts with new ones every 16,000 24,000 hours (4 - 5 years) even if there are no
apparent irregularities with them.
<<Procedure for Replacement of the Bolts>>
(1) Check the contact of the seating surface of
the circular nuts by means of red lead primer or
blue paint lead, and correct the seating surface
of the connecting rod when the contact is not
good.
(2) Punch the engine identification number, the
cylinder number and the bolt number of the bolt
to be replaced on the head of the new bolt.
(3) Apply lubricant (Molykote 1000 Spray) to the
embedded thread of the stud bolts.
(4) Wash the tapped holes in the large end and
blow them by air, and then screw the bolts by
hand.
(5) Attach a hexagonal bar head on the head of
each of the connecting rod joint bolts and the
crankpin bolts and repeat its tightening and
loosening for three to four times with the specified torque by means of a torque wrench to
adapt the thread of the bolt to the thread of the
tapped hole, and then finally tighten it.

DC-32

4.5

Bolt Number

Engine Identification Number


Cylinder Number
1
1

Punch the same


numbers as those
of the bolts replaced

An Example of Identification Numbers on the Bolt Head (nut side)

4
Molykote 1000
Spray

Thread to be
Embedded

Application of Lubricant to Thread


(to be embedded) of a Bolt
3

Bolt Number

2
4
Head With a Hexagonal Bar Torque Wrench
Connecting Rod
Joint Bolt

<<Specified Torque>>
For the connecting rod joint bolt 98 N.m
For the crankpin bolt
294 N.m
A Mark to Identify the Forward Direction

Replacement of the Connecting Rod Joint Bolt


1) Always use the lubricant, Molykote 1000
Spray (genuine one) since the axial tension
generated in a bolt with a lubricant of a brand
may be different from that with another lubricant of a different brand.
2) Since the friction co-efficient of Molykote will
be changed when it becomes dry, tighten a
bolt as soon as possible after the Molykote is
sprayed on it before it becomes dry.

Head With a Hexagonal Bar Torque Wrench

Bolt Number

Crankpin Bolt

A Mark to Identify the


Forward Direction

Replacement of the Crankpin Bolt

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

5.1 DC-32 Assembling : Assembling of the Large End of the Connecting Rod
4-5 Assembling of the Piston and
the Connecting Rod
4-5.1 Assembling of the Large End of
the Connecting Rod
A. Wash each of the components with washing oil
and blow each of the tapped holes by air before
starting of assembling.
B. Embed the connecting rod joint bolts and the
crankpin bolts with the appropriate specified
torque.
(
: 4-4.5 "Replacement of the Connecting Rod
Bolts")
Embed each of the bolts in the right
original tapped hole referring to the number
punched on the bolt.

I. Attach the hydraulic jack in the same procedure


as for the detachment, and tighten the two nuts
at the same time.
(
: 2-4 "Hydraulic Jack")
Specified oil pressure : 76 MPa

Since incomplete tightening of the


bolts may not only cause damage to the bearing and the serrations at the large end but also
result in a serious accident such as breakage
of the bolts, tighten them completely.
J. Lightly turn the large end by hand to make certain that it smoothly turns.

C. Wipe out dust and oil from inside surface of the


large end housing and the outside surface of
the bearing.
Number of the Bolt

Do not apply any lubricant nor grease


on the outside surface of the bearing. Good
contact may be hindered by in-between oil.
D. Install the crankpin bearing aligning the locating
protrusion of the crankpin bearing and the
groove of the large end housing to center the
bearing in the large end housing.
E. Tap the central part of the crankpin bearing by
hand to obtain good contact of the bearing with
the large end housing.
F. Wipe out the surface of the crankpin and apply
lubricant to the crankpin and the inside surface
of the crankpin bearing.
G. Install the large end from both sides, the rod
portion and the large end cap, by means of the
connecting rod dismantling tool in the same
way as for its dismantling with care not to damage the crankpin, the threads of the connecting
rod joint bolts and the crankpin bolts
Always assemble the large end of the
connecting rod so that the number on the rod
portion and the mark to identify the forward
direction may agree with those on the cap portion respectively.
H. Screw in the circular nut for the crankpin bolt by
hand until it just contacts the cap.

DC-32 Z 05-12

Mark to identify
the forward
direction

Connecting Rod Joint Bolt


Circular Nut

Punched identification
marks such as the
cylinder number

Circular Nut
Crankpin Bolt

1 Bolt Number

Assembling of the Large


End of the Connecting Rod

CHAPTER

Pistons and Connecting Rods

4
ITEM

Assembling :

Assembling of Pistons

DC-32

5.2

4-5.2 Assembling of the Piston


Assemble the piston crown and the piston
skirt according to the following procedure when
they have been dismantled. Wash them and blow
them by air before starting the assembling..
A. Embed the piston crown bolts in the piston
crown. The embedding work should be effected
according to the following procedure.
(1) Remove dust, oil and any other foreign matters stuck to the piston crown and the threads
of the bolts.
(2) Apply blue paint lead to the tip of each bolt to
be embedded.
(3) Embed the bolt with the specified torque, then
remove it to see contact condition by means of
the blue paint lead applied to the tip of the bolt.
Correct the bolt when the contact is not satisfactory.
(4) Apply lubricant (Molykote 1000 Spray) to the
thread to be embedded.
(5) Embed the bolt with the specified torque.

Specified torque : 147 N.m


(6) Make certain that the bolt is embedded perpendicularly to the surface of the piston crown
in which the bolt is embedded after the bolt has
been tightened with the specified torque.
B. Fit the o-ring on the piston skirt.
C. Set the piston skirt on the piston crown making
certain that position of the spring pin in the piston crown is correct.
D. Check adaptation to and contact with each mating parts of the washers, the nuts and bolts.
The procedure is as described below.
(1) Remove dust, oil and any other foreign matters stuck to the contact surfaces of the washers, the nuts, the bolts and the piston skirt.
(2) Apply blue paint lead to the spherical part of
the washers and the seating surfaces of the
bolts.
(3) Tighten the nuts with the initial torque as
specified below in the sequence of 1  2  3
 4 as shown in the illustration.

Sequence of Tightening of the Tightening Nuts


(View "P")

P
Nut
Washer

Piston Skirt

O-ring
Piston Crown
Bolt
Spring Pin
Piston Crown

Assembling of the Piston


Crown and the Piston Skirt

Initial torque : 98 N.m

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

5.2 DC-32 Assembling :

Assembling of Pistons

(4) Tighten the nuts with the specified torque as


specified below in the sequence of 1  2  3
 4 as shown in the illustration

Piston Crown Bolt


Marking

Specified tightening torque : 196 N.m


(5) Make marks as shown in the illustration with
paint or some other on the tip of the bolts and
on the bosses on the piston skirt, and then
loosen the nuts about 90o (the sequence of
loosening is the same as for detachment of the
piston crown).
(6) Again tighten the nuts with the "specified
torque" in the sequence of 1  2  3  4 as
shown in the illustration.
(7) Loosen and remove the nuts to check contact
of the spherical part of the washers, the seating
surfaces of the nuts. Make certain by means of
the marks that the bolt does not turn with the
nut at the same time.
E. Finally tighten the bolts. Work procedure is as
described below.
(1) Remove blue paint lead applied to the spherical part of the washers, the seating surfaces of
the nuts and the surface of the skirt contacting
with the washers. Erase the marks on the tips
of the bolts and the skirt.
(2) Apply lubricant (Molykote 1000 Spray) to the
spherical part of the washers, seating surfaces
of the nuts and threads of the bolts.
(3) Tighten the nuts with the "initial torque" in the
sequence of 1  2  3  4 as shown in the
illustration.
(4) Tighten the nuts with the "specified torque" as
specified below in the sequence of 1  2  3
 4 as shown in the illustration.
(5) Loosen the nuts about 90o (the sequence of
loosening is the same as for detachment of the
piston crown), and then again tighten the nuts
with the "specified torque" in the sequence of 1
 2  3  4 as shown in the illustration.

DC-32 Z 05-12

Pin Boss of the Piston Crown

Marking on the Piston Crown

CHAPTER

Pistons and Connecting Rods

4
ITEM

Assembling : Assembling of Pistons and Connecting Rods

DC-32

5.3

4-5.3 Assembling of the Piston and


the Connecting Rod
A. Wash each of the components and blow them
by air.
B. Assemble the piston and the rod portion of the
connecting rod.
(1) Fit one of the piston pin snap rings in one of
the grooves (in the opposite side of the
positioning mark) by means of the snap
ring pliers.
(2) Put the piston on the wooden bolster on its
side where the snap ring is fitted, and insert the
small end of the connecting rod into the piston
aligning the mark on the flange of the rod portion of the connecting rod and another mark on
the pin boss of the piston skirt.

Snap Ring Pliers


Piston Pin
Eye Bolt M16

(l)

Piston

Marks

Piston Pin Snap Ring

Assembling of the Piston Pin and the


Rod Portion of the Connecting Rod

Make certain that the identification


number on the small end agrees with that on
the large end.
(3) Attach the piston pin special tool (I) on the piston, apply lubricant to the outer surface of the
piston pin and the inside of the piston pin boss,
lift the small end of the connecting rod a little to
align the piston pin and the bore of the piston
pin boss, and then insert the piston pin.
(4) Fit the piston pin snap ring in the groove by
means of the snap ring pliers.
C. Fit the piston inserting frame (e) in the upper
part of the cylinder liner.
D. Turn the crankshaft to bring the crankpin for the
cylinder where the piston is to be inserted to the
BDC.
E. Assuredly attach the eye bolt M16 on the piston
head to hang up the piston and the rod portion
of the connecting rod.
F. Detach the piston pin special tool.
G. Install the piston rings by means of the piston
ring installing and detaching tool (m).
However, the right grip of the piston ring
installing and detaching tool should be replaced
with another one (m)-(2) when the top ring is fitted.
H. The piston rings should be installed on the position as indicated in the right figure with the
manufacture's mark of the rings being faced
upward paying attention to install them on the
right places.

Closed Gap of a Piston Ring


Closed Gap of
a Piston Ring
Coiled Oil Ring
Expander
Connecting Point of
the Coiled Expander

Position Where the


Maker Mark is Stamped
Oil Ring

Joint
No. 1 Ring
(Top Ring)
No.2 Ring
No. 3 Ring

Oil Ring
(with an coiledexpander)

Configuration of the Rings and Their Assemblage

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

ITEM

5.3 DC-32 Assembling : Assembling of Pistons and Connecting Rods


I. Install the Oil Ring
(1) Put the expander coil into the oil ring groove
and insert the joint.
(2) Adjust the position of the expander so that the
joint of the expander may be positioned in the
groove at the place opposite to the closed gap.
J. Move the piston and oil rings so that the closed
gaps may differ in their relative positions in the
groove 90o each other.
K. Apply enough amount of lubricant to the piston,
the piston rings, the oil ring, the piston inserting
tool and the cylinder liner by an oiler.
L. See the cylinder number and make certain
again that the numbers on the piston pin boss
of the piston skirt, the rod portion of the connecting rod and the large end portion of the
connecting rod are the same one. And position
the piston so that the marks face the front of the
engine making certain that the "P" mark on the
top surface of the piston crown comes to the
side near to the injection pump.
M. Insert the piston in the cylinder liner and slowly
bring it down letting the dowel pins fitted in the
holes in the large end and the holes in the rod
portion of the connecting rod align in a row.

Oiler

Eye Bolt M16


Piston
Piston Ring
Oil Ring

Lubricating Oil

Mark to identify the


forward direction
Oiler
Lubricating Oil

Piston Inserting Tool


Cylinder Liner
Cylinder Liner Holder

Oiler

Lubricating
Oil

Application of Lubricating Oil When the Piston is Installed


1) Lightly knocking the surrounding area of the
piston with a plastic hammer facilitates the
piston going down into the cylinder when
inserting the piston in the cylinder liner.
When the piston does not smoothly go down,
do not force it to do so but firstly hung it up
and then try to insert it again.
2) Be careful so that the flange of the rod portion of the connecting rod may not damage
the inside surface of the cylinder liner and
the threads of the connecting rod joint bolts.

The marks shall appear on the same side of the components.


Positions of the marks on the
piston and the connecting rod

Cylinder Number
Position of the "P" stamped on the top surface of the piston crown

N. Make certain that the dowel pin is completely


fitted in the mating holes, and then detach the
eye bolt M16 attached on the piston head.
O. Slowly turn the crankshaft to bring the crankpin
to 105oBTDC.

DC-32 Z 05-12

Mark "P" stamped on the top surface of the piston crown


Flywheel
Positions of marks on the piston
and the connecting rod

Direction of installation of the


connecting rod (alignment mark)

CHAPTER

Pistons and Connecting Rods

4
ITEM

Assembling : Assembling of Pistons and Connecting Rods


P. Diagonally tighten the connecting rod joint
bolts, two at a time by means of the hydraulic
jack as shown in the right illustration.
(
: 2-4 "Hydraulic Jack")

DC-32

5.3

2
1

Sequence of Attaching the Hydraulic Jack 1 2 or 2 1


Specified oil pressure :90 MPa

(View "P")

Q. Make certain that there is side play between the


large end of the connecting rod and the crankshaft.
R. Insert the protect ring into the cylinder liner by
hand with care not to let the protect ring get
slant.

Begin the service operation of the


engine after carrying out the trial run of the
engine, making certain by touching or other
means that no irregularity has been detected
after the completed restoration when disassembling the piston and the connecting rod.

P
Connecting Rod Joint Bolt

Marks

Sequence of the Tightening

Cylinder Liner

Flange of the Rod


Portion of the
Connecting Rod

Checking of the Side Play Between the


Connecting Rod and the Crankshaft

Connecting
Rod Joint
Bolt

Dowel
Pin

Large End of the


Connecting Rod

Insertion of the Piston

Protect Ring

Insertion of the Protect Ring

DC-32 Z 05-12

CHAPTER

4
ITEM

Pistons and Connecting Rods

5.4 DC-32 Assembling : Checking and Retightening of Connecting Rod Bolts

4-5.4 Checking and Retightening of


the Connecting Rod Bolt
Always retighten the bolts since insufficient tightening force of a bolt may result in a
serious accident such as breakage of the bolt
while being driven.

2
1

Sequence of Attaching
the Hydraulic Jack
1
2 or 2 1

Tightening condition of the connecting rod


joint bolts and the crankpin bolts should be
checked and the bolts should be retightened at the
end of the first service operation after its installation, considering the initial running-in, after maintenance that involves dismantling of the engine or
within 3000 hours after replacement of the bolt.
Thereafter, periodically (every 6000 hours) check
the tightening force.
A. Effect the turning of the crankshaft to bring the
crankpin of the cylinder to be inspected to such
a position as enables the connecting rod joint
bolts or the crankpin bolts to be inspected as
shown below.
For the connecting rod joint bolts : 105oBTDC
For the crankpin bolts :
65oBTDC

Retightening of the Connecting Rod Joint Bolts

B. Attach the hydraulic jack to tighten the bolts


with the specified torque.
Tighten two crankpin bolts at the same
time and also tighten two of the connecting rod
joint bolts diagonally located at the same time.
(
: 4-5.1 "Assembling of the Large End of
the Connecting Rod")
(
: 4-5.3 "Assembling of the Piston and the
Connecting Rod")
(
: 2-4 "Hydraulic Jack")
C. When any nut is turned more in the tightening
direction, retighten the nut.

Retightening of the Crankpin Bolts

DC-32 Z 05-12

CHAPTER

Pistons and Connecting Rods

MEMO

4
ITEM

DC-32

DC-32 Z 05-12

CHAPTER

The Engine Frame and Cylinder liners

ITEM

1 DC-32 The Engine Frame and Cylinder Liners : Outline of the Structure
5

The Engine Frame and


Cylinder liners

Cooling Water Inlet Pipe

Cylinder Liner

5-1 Outline of the Structure


The engine frame is made of cast iron and
has a hanger metal type structure having enough
rigidity to resist the explosion pressure.
The main bearing is firmly tightened by
means of the hydraulic jack with the main bearing
cap bolts and the side bolts each of which has a
large diameter
The air intake, the inlet of cooling water, and
the passage of lubricating oil are integrated in the
engine frame, so the structure with less exposed
piping can be realized owing to this structure.
An oil cut plate is fitted on the flywheel side
of the number one wall in the engine frame to prevent oil from leaking from the back end of the
crank shaft, and moreover the engine frame is
equipped with an oil cut cover having a multi-stage
structure to shake oil off to surely seal the engine
frame.
The engine frame safety valves each of
which has a large capacity are installed on the side
covers located on the exhaust manifold side.
Cooling of the cylinder liners is effected only
for their upper part to decrease cooling loss, while
forced cooling making use of the drilled holes in
the thick part of the liner is adopted to lessen the
thermal load.
The cylinder liner holder fitted on the upper
part of the engine frame constitutes the cooling
water jacket between it and the cylinder liner to
feed cooling water to the drilled holes in the cylinder liner.
Sealing of the cylinder liner, the cylinder
liner holder and the engine frame are assuredly
provided for by three o-rings.
The cylinder liner is fixed at three areas, the
cylinder liner holder (the part on which o-rings are
fitted), the upper part of the engine frame (the part
on which an o-ring is fitted) and the lower part of
the engine frame. And the thin protect ring is fitted
on the inside wall of the cylinder liner to prevent
sludge from being accumulated.

Weight of the cylinder liners : 305 kg

DC-32 Z 05-12

Protect Ring

O-rings
Passage of
Cooling Water

Cylinder Liner
Holder
O-rings

Engine
Frame

Intake
Duct

Passage
of
Lubricating
Oil

Side
Bolt

Main Bearing Cap

Main Bearing Bolt

The Engine Frame and the Cylinder Liner

CHAPTER

The Engine Frame and Cylinder liners


Consumable Replacement Parts,
The Engine Frame
and Cylinder Liners : Special Tools and Measuring Instruments DC-32
5-2 Consumable Replacement
Parts, Special Tools and
Measuring Instruments

(5)

5
ITEM

(1)

A. The following parts should be replaced

with new ones when maintenance is


effected.
(
: "Parts List")
1. O-ring
2-13
No.5
2. O-ring
2-13
No.502,503
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Cylinder Liner Special Tools
(1) Special Tool-1
(2) Special Tool-2
(3) Special Tool-3
(4) Nut M42
(5) Eye Bolt M16
(c) Cylinder Bore Gauge (250 - 400 mm)
(d) Cylinder Liner Positioning Gauge
(e) Cylinder Liner Finishing Tool (optinal)
(This is used also for finishing of the cylinder
head.)
(1) Tool-1 for finishing of the cylinder head and
the cylinder liner
(2) Tool-2 for finishing of the cylinder head and
the cylinder liner
(3) Bolts
(f) Cylinder Liner Detachment Tool
(1) Eye Bolt M18

(4)

(3)

5
(2)

(b) Cylinder Liner Special Tools

(c) Cylinder Bore Gauge

"a" "b"

"c"

"d"

(2)

(d) Cylinder Liner Positioning Gauge

(3)
(1)

(e) Cylinder Liner Finishing Tool

DC-32 Z 05-12

CHAPTER

The Engine Frame and Cylinder liners


Inspection and Maintenance of the
The Engine Frame
3 DC-32 and Cylinder Liners : Inside Surfaces of Cylinder Liners

5
ITEM

5-3 Inspection and Maintenance of


the Inside Surface of the
Cylinder Liner

(c)

Inspection and maintenance of the inside


surface of the cylinder liner (abbreviated as the
liner) should be effected as the liner is left to be
installed on the engine frame after the cylinder
head and the piston are detached.
(
: 3-1.3 "Detachment of the Piston",
4-3.1 "Pulling-out of the Piston")
A. Visual Inspection
(1) See condition of carbon deposits stuck to the
inside surface of the cylinder liner.
(2) Remove carbon and check scratches, scuffing, traces of blow-by, corrosion, etc. on the
inside surface of the liner.
(3) Check corrosion and fretting on the outer surface of the protect ring and the fitted area of the
cylinder liner.
B. Measurement of I.D. of the Cylinder Liner
Attach the cylinder liner positioning gauge (d) in
the liner with it being fitted in the engine frame
at room temperature, and then measure the I.D.
by means of a cylinder bore gauge (c) in two
directions (P-S and A-F) and at four points ("a"
- "d") for each direction and record the results.
Nominal Diameter (mm)

D = 320

a = 11.5

Direction P-S

Direction A-F

(d) "a" (c)

"b"

"c"

"d"

Replacement (correction) Limit (mm)

+ 1.2 (partial wear : 0.4)

C. Measure thickness of the protect ring by means


of a spherical micrometer and record the result.

Nominal Diameter (mm)

(d)

Measurement of I.D. of the Protect Ring

Replacement Limit (mm)

- 0.30

Measurement of Thickness of the Protect Ring

DC-32 Z 05-12

CHAPTER

The Engine Frame and Cylinder liners


The Engine Frame
and Cylinder Liners :

Inspection and Maintenance of the


Inside Surfaces of Cylinder Liners

5
ITEM

DC-32

Wear of the inner surfaces of the liner


and the protect ring depends on quality of fuel
oil used, control of lubricating oil, temperature
of cooling water, etc. The worsened wear may
cause blow-by, increase in lubricating oil consumption and some other problems, therefore,
replace one of which wear has reached or is
reaching the replacement limit as soon as possible.
D. Roughening of the Cylinder Liners (Deglazing)
When any of the piston rings is replaced
or the inner surface of a cylinder liner becomes
too smooth like a mirror surface, effect roughening of the inner surface of the liner.
Roughening should be effected by
means of sandpaper or honing.
(1) Abrade the inner surface of the cylinder liner
with sandpaper (#80) so that the sanding mark
may circularly run.
(2) In case that honing is used, correct the partial
wear, and then effect honing so that 5 - 10 Rz
may be produced with cross hatch angle of 30o
- 40o.
(3) Measure the I.D. when the honing is completed and make certain that it is within the
replacement limit.

It is possible to effect honing with the


cylinder liner being fitted in the engine frame by
means of a special honing machine.
For the detail, please consult with the
Service Division of DAIHATSU.

DC-32 Z 05-12

CHAPTER

The Engine Frame and Cylinder liners

4 DC-32

The Engine Frame


and Cylinder Liners :

ITEM

5-4 Pulling-out of the Cylinder


Liner
A. Make certain that water in the jacket has been
completely drained before effecting pulling-out
of the cylinder liner.
B. Prepare a vinyl sheet or some others to prevent
dust, foreign matters, water drops, etc. from
falling into the bottom of the engine frame.
C. Pull out the cylinder liner.
(1) Attach the nut (b)-(4) and the special tool-3
(b)-(3) on the center shaft of the special tool-1
(b)-(1), insert them in the cylinder as a unit with
the cylinder head bolt being used as the guide
and then fix the unit with the tightening nuts.
(2) Attach the special tool-2 (b)-(2) to the center
shaft of the special tool-1 (b)-(1) with the surface of the special tool-2 (b)-(2) where "U" is
stamped being faced upward and screw it up
until it contacts the lower end of the cylinder
liner.
(3) Pull up the cylinder liner by turning the nut (A)
on the center of the upper surface of the special tool-1 (b)-(1) until the o-rings on the cylinder liner completely get rid of the engine frame
and the cylinder liner.
(4) Screw up the nut (b)-(4) to completely fix the
cylinder liner by means of the special tool-2 (b)(2) and the special tool-3 (b)-(3).
(5) Loosen and remove the cylinder head tightening nut.
(6) Attach a wire rope to the eye bolts M18 (b)-(5)
fixed on the special tool-1 (b)-(1) to hang up the
cylinder liner together with the cylinder liner
special tool (b).
D. Detach the o-rings.
E. Detach the cylinder liner holder (abbreviated as
the liner holder) from the upper part of the
engine frame by means of the hang up bolt
M18.

DC-32 Z 05-12

The Engine Frame and Cylinder Liners

Cylinder Head
Tightening Nut
Cylinder
Head Bolt

(A) (b)-(1)

(b)-(4)
(b)-(3)

Cylinder Liner
Holder

O-rings
Center Shaft

(b)-(2)

Pulling-out of the Cylinder Liner

Eye Bolt M18

Detachment of the Cylinder Liner Holder

CHAPTER

The Engine Frame and Cylinder liners


Inspection and Maintenance of the Outer Surfaces of Cylinder Liners, the
Surfaces of Cylinder Liner Holders and the Fitted Area of the Engine Frame

5-5Inspection and Maintenance of


the Outer Surface of the Cylinder
Liner, the Inner Surface of the
Cylinder Liner Holder and the
Fitted Area of the Engine Frame

The following causes are considered


possible to cause corrosion or cavitation corrosion.
1. The cooling water rust prevention agent is
not effective.
2. Pressure of the cooling water is too low.
3. Air is mixed in the cooling water.
Follow the control standards to effect
proper control of the cooling water.
(
: 6-3 "Control of Cooling Water" of the
"Operation Manual")

B2
C
G

H
J

DF

B1

DL

K
L

A. Remove scale and silicon rubber on the cooling


water-contacting surface "A" of the outer surface of the liner, the drilled holes for cooling
water "B1" and "B2" and the inner surface of the
liner "C" with a wire brush or some other tool.
B. Effect a color check on the flange fillet "DL", the
corner of shelf of the engine frame "DF", the
surrounding area of the drilled hole for cooling
water "B1" and the drilled hole on the upper part
for cooling water "B2" to check whether or not
any crack has been developed.
C. Check whether or not cavitation corrosion or
other corrosion is found on the outer surface of
the liner "A" and the inner surface of the liner
holder "C". When the corrosion if any is not
deep, amend it with a repair kit.
D. Check whether or not fretting or corrosion
develops on the fitted areas ("D", "E" and "L" of
the liner, "F", "G", and "H" of the holder and "I",
"J" and "K" of the engine frame).

DC-32

F
E A D

Inspection and
Maintenance :

5
ITEM

Inspection and Maintenance of the Outer


Surface of the Cylinder Liner,the Inner
Surface of the Cylinder Liner Holder and
the Jacket Area of the Engine Frame.

(e)-(2)
(e)-(3)
(e)-(1)

E. Amend the rust prevention paint that coats the


outer surface of the liner "A" and the inner surface of the holder "C" when it is peeled off.
Since a grayish brown deposit is a film
produced by use of a rust prevention agent, it
should not be removed.
F. Clean the upper surface of the liner contacting
the cylinder head gasket and the other surface
contacting the upper surface of the engine
frame. For the upper surface of the liner contacting the cylinder head gasket, finish the surface applying abradant compound when necessary. (The finishing special tool (e) : Optional)

Finishing of the Surface of the


Cylinder Liner Contacting the Gasket

DC-32 Z 05-12

CHAPTER

The Engine Frame and Cylinder liners

ITEM

6 DC-32 Inspection and Maintenance : Installation of Cylinder Liners


5-6 Installation of the Cylinder
Liner
Installation of the cylinder liner is to be
effected in the reverse sequence of that for its
detachment.
A. Clean the outer and inner surfaces of the cylinder liner holder, the grooves for the o-rings, the
groove for the o-ring on the cooling water inlet
pipe, the upper surface of the engine frame
contacting the liner holder and the groove for
the o-ring.
B. Fit the o-rings on the cooling water inlet pipe
and the upper surface of the engine frame.
C. Install the liner in the liner holder in accordance
with the following procedure.
(1) Attach the eye bolt M18 on the cylinder liner
holder, hook a wire rope on it to hang it up.
(2) Make certain that the cylinder head bolts and
the cooling water inlet pipe are in the proper
positions and put liner holder on the engine
frame aligning the notched lines on the upper
part of the liner holder and on the engine
frame.

Cylinder Liner
Holder

O-ring

Engine Frame
Cooling Water Inlet Pipe

Installation of the Cylinder Liner Holder

(b)-(5)
(b)-(1)

Be attentive not to damage threads of


the cylinder head bolts nor to cut the o-ring
when inserting the liner.
D. Clean the inner and outer surfaces of the liner
and the grooves for the o-rings.
E. Fit the o-rings on the liner.
F. The liner is to be installed in accordance with
the following procedure.
(1) Screw the special tool-2 (b)-(2) on the center
shaft of the special tool-1 (b)-(1) until the special tool-2 reaches the position shown in the
right illustration with the "U" stamped on the
special tool-2 (b)-(2) being faced upward, and
then insert the combined tool in the liner.
(2) Fit the special tool-3 (b)-(3) on the center shaft
of the special tool-1 (b)-(1) and tighten the nut
(b)-(4) to firmly fix the liner.
(3) Hook a wire rope on the eye bolts M16 (b)-(5)
and hang up the liner by means of a chain
block.
(4) Apply appropriate amount of silicon rubber to
the upper side of the uppermost o-ring fitted on
the liner (area "F") and the whole circumference of the area "G" of the liner.

DC-32 Z 05-12

(b)-(2)

"G"

"F"

Cylinder Liner

(b)-(3)
(b)-(4)

Installation of the Cylinder


Liner Special Tools
1. Do not apply silicon rubber to the o-rings
2. Install the parts to which silicon rubber is
applied as soon as possible before the silicon rubber becomes dry.

CHAPTER

The Engine Frame and Cylinder liners

5
ITEM

Inspection and Maintenance : Installation of Cylinder Liners


(5) Insert the liner in the engine frame.
Position the liner so that the stamped
mark on the side upper surface of the liner
can be seen from the side on which the fuel
injection pump is fitted, and then slowly bring
the liner down letting the cylinder head bolts
go through the special tool-1 (b)-(1) with the
center of two notched lines on the side upper
surface of the liner and the center of the other
two notched lines on the liner holder may
align.

Be attentive when inserting the liner


not to damage threads of the cylinder head
bolts nor to cut the o-rings.
(6) Rock the liner and fix the special tool-1 (b)-(1)
with the cylinder head tightening bolts when the
liner does not go down any more by gravity
force.
(7) Detach the nut (b)-(4) and the special tool-3
(b)-(3), and screw the nut (A) located at the
center of the upper part of the special tool-1
(b)-(1) until the liner fully contact the engine
frame.

DC-32

(A)
(b)-(5)
(b)-(1)
(b)-(2)
Cylinder
Head Bolt

Cylinder Liner

(b)-(3)

(b)-(4)

Installation of the Cylinder Liner

DC-32 Z 05-12

CHAPTER

The Engine Frame and Cylinder liners

7 DC-32

The Engine Frame


and Cylinder Liners :

ITEM

5-7

Detachment and Installation of Cylinder Units

Detachment and Installation of


the Cylinder Unit

The engine is structured so that the cylinder


head, the cylinder liner, the cylinder liner supporting frame, the piston and the rod portion of the
connecting rod may be detached and installed as
an assembly cylinder to cylinder.
A. Special Tools and Measurement Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Cylinder Unit Suspending Tool (optional)
(1) Base

(c) Cylinder Liner Holder Fixing Tool

(d) Rod Portion of the Connecting


Rod Fixing Tool (optional)

(2) Distance Piece

(3) Eye Bolt M36


(4) Plane Washer
(c) Cylinder Liner Holder Fixing Tool (optional)
(d) Rod Portion of the Connecting Rod Fixing
Tool (optional)
B. Detachment of the Cylinder Head Unit
(1) Loosen and remove the cylinder head tightening nuts in accordance with the same procedure as that for detachment of the cylinder
head, and then fix the cylinder liner and the
liner holder on the cylinder head by means of
the cylinder liner holder fixing tool (c) (at 4
points)
(
: 3-1.3 "Detachment of the Cylinder Head)
(2) Turn the crankshaft to bring the piston to be
pulled out to 105 BTDC, remove the circular
bolts on the connecting rod joint bolts, and then
again turn the crankshaft to bring the piston to
the TDC.
(
: 4-3.1 "Pulling-out of the Piston")
(3) Attach the fixing tool for the rod portion of the
connecting rod (d) to fix the rod portion of the
connecting rod.
(4) Check the condition in which the cylinder
hanger tool (b) is attached and sling the unit by
means of the slinging wire rope.
Remove the push rod block with the
cylinder liner holder being almost touch the
push rod block to pull out the unit.

DC-32 Z 05-12

(b)-(3)

(b)-(4)
(b)-(1)

(b)-(2)

(c)

Cylinder Liner
Holder

Cylinder Liner
Piston

Rod Portion of
the Connecting
Rod

(d)

P
(c)

Rod Portion of the Connecting Rod

(d)

(c)

View Q

Piston

Cylinder Liner

View P

Suspending the Cylinder Unit

CHAPTER

The Engine Frame and Cylinder liners


The Engine Frame
and Cylinder Liners :

5
ITEM

Detachment and Installation of Cylinder Units DC-32

C. Installation of the unit is to be effected in the


reverse sequence of that for its detachment.
(

: 3-1.8 "Installation of the Cylinder Head"


4-5.1 "Assembling of the Connecting Rod"
4-5.3 "Assembling of the Piston and the
Connecting Rod"
5-6 "Installation of the Cylinder liner")

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings

ITEM

1 DC-32 Main Bearings and Thrust Bearings : Outline


6

of the Structure

Main Bearings and Thrust


Bearings

Oil Hole

Main Bearing

6-1 Outline of the Structure


The main bearing housing is a hanger metal
type and the main bearing cap is firmly fastened
with the main bearing cap bolts as well as the side
bolts tightened by means of the hydraulic jack.
The main bearing metals are made of high
abrasion resistant aluminum alloy and each of the
upper and the lower metals is positioned by a
locating protrusion.
Lubricating oil is fed to the main bearing
from the upper bearing housing through the drilled
hole in the engine frame.
The thrust bearing metals are also made of
the same aluminum alloy that is used for the main
bearing metals and are fitted on the upper and the
lower of both sides of the number one wall located
near the rear end of the engine. Lubricating oil is
fed through the main bearing.

Side Bolt
Engine Frame

Main Bearing Bolt


Main Bearing Cap

Main Bearing

Number Two Wall

Weight of ;
The main bearing cap
(for a middle journal)

: 135 kg

The main bearing cap


(for the base journal)

: 144 kg

The main bearing


The thrust bearing

:
:

Crankshaft

Number One Wall


Thrust Bearings

5 kg
2 kg

Main Bearing
(for a middle journal)

Main Bearing
(for the base journal)

Thrust Bearings

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings


Consumable Replacement Parts,
Main Bearings and Thrust Bearings : Special Tools and Measuring Instruments DC-32

6
ITEM

6-2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
None
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Pin for the Main Bearings
(c) Main Bearing Cap Special Tool
(1) Hydraulic Ram
(2) Hydraulic Jack Fitting Tool
(3) Nut
(4) Stopper
(d) Hydraulic Jack for the Main Bearing (to be
used also for the cylinder head bolts)
(1) Hydraulic Jack Assembly
(2) Jack Stand
(3) Jack Handle
(e) Hydraulic Jack for the Side Bolts (to be used
also for the crankpin bolts)
(1) Hydraulic Jack Assembly
(2) Jack Handle (the same tool as (d)-(3))
(f) Hydraulic Pump
(1) Hydraulic Pump
(2) High Pressure Oil Hose, 2 m (3 pcs., with a
male coupler)
(3) Terminal, 2T (2 pcs., with a socket coupler)
(g) Main Bearing Cap Connecting Bolt
(h) Main Bearing Cap Holding Tool

(b) Pin for the Main Bearings


(3)
(4)

(2)

6
(1)

(c) Main Bearing Cap Special Tool


(1)

(2)
(3)

(g) Main Bearing


Cap Connecting Bolt

(3)

(d) Hydraulic Jack for


the Main Bearings
(1)

(2)

(1)
(2)

(f) Hydraulic Pump

(e) Hydraulic Jack


for the Side Bolts

(h) Main Bearing


Cap Holding Tool

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings

6
ITEM

3.1 DC-32 Main Bearings and Thrust Bearings : Dismantling of Main Bearings
6-3 Main Bearing
For usual dismantling and inspection of the
main bearing, the main bearing cap need not to be
completely detached. They can be effected with
the main bearing cap just being lowered.

(2) Move the lever of the hydraulic pump up and


down to raise the oil pressure to the
specified one, and loosen the nuts by means of
the jack handle (e)-(2).

Specified oil pressure : 59 MPa

6-3.1 Dismantling of the Main


Bearing
A. Detach both engine frame side covers for the
cylinders next to the main bearing to be dismantled, and then bring the crankpin located in
front of or behind the where the dismantling and
o
inspection is effected to 95 BTDC. (see the
illustration below.)
B. Loosen and detach the side bolt tightening nuts
by means of the hydraulic jacks.
(
: 2-4 "Hydraulic Jack)
(1) Attach the hydraulic jack assemblies (e)- (1) to
both of the side bolts and connect the
hydraulic jacks to the hydraulic pump (f)-(1)
with the high pressure hoses (f)-(2) via the terminal 2T.

(3) See the torque at which each nut begins loosening in order to check whether or not
any of the nuts has been loosened.
(4) Detach the hydraulic jack assemblies.
(5) Loosen and detach the nuts, and then loosen
and pull out the side bolts.

The side from which


the work is effected.

(f)-(2)

95

(e)-(2)

()-(3)

(e)-(1)

Detachment of the Side Bolt Tightening Nuts.

DC-32 Z 05-12

(f)-(1)

CHAPTER

Main Bearings and Thrust Bearings

6
ITEM

Main Bearings and Thrust Bearings : Dismantling of Main Bearings


C. Loosen and detach the main bearing cap tightening nuts (C) by means of the hydraulic jacks.
(
: 2-4 "Hydraulic Jack")
(1) Attach each of the main bearing cap connecting bolts (g) to the main bearing cap (A).
(2) Attach the high pressure hoses (f)-(2) to the
main bearing cap special tool (c) and connect
the hoses to the hydraulic pum (f)-(1) as
described and illustrated below.
z The oil feeding hole on the upper part of the
hydraulic ram ~ the port "B" of the hydraulic
pump shift valve
z The oil feeding hole on the lower part of the
hydraulic ram ~ the port "A" of the hydraulic
pump shift valve
(3) Fit the lower flange of the hydraulic ram for
the main bearing cap (c)-(1) in the hydraulic
ram holding base on the bottom part of the
engine base located just under the main bearing cap.
(4) Put each of the hydraulic jack assemblies (d)(1) for the main bearings and each of the jack
stands (d)-(2) on each of the left and the right
arms of the hydraulic jack fitting tool (c)-(2).
(5) Shift the hydraulic pump shift lever to
"Pressurize" and slowly move the hydraulic
pump lever to raise the hydraulic piston.
(6) Stop moving the hydraulic pump lever when
the hydraulic jacks for the main bearings are
raised to touch the main bearing bolts, and
then screw up each of the hydraulic jacks on
each of the main bearing bolts.

DC-32

3.1

(7) After screwing up the hydraulic jacks, rotate


the hydraulic jack fitting tool to such a direction
that each of the hydraulic jacks and the
hydraulic jack fitting tool may not interfere each
other.
(8) Connect the hydraulic pump to the hydraulic
jacks for the main bearings with the high pressure hoses.
(9) Move the hydraulic pump lever up and down
to raise the oil pressure to the specified one
and loosen the main bearing cap tightening
nuts (c) by means of the jack handle.
(
: 2-4 "Hydraulic Jack")

Specified oil pressure :88 MPa


(10) See the torque at which each of the nuts
begins to loosen to check whether or not the
nut has loosened.
(11) Detach the high pressure hoses from the
hydraulic jacks for the main bearings.
(12) Rotate the hydraulic jack fitting tool so that
the left and the right arms come just under
each of the hydraulic jacks for the main bearings.
(13) Turn and detach each of the hydraulic jacks
for the main bearings and put each of them on
each of the arms of the hydraulic jack fitting
tool.

Main Bearing Bolt (B)

(g)
Main Bearing Cap
Tightening Nut (C)

Main Bearing Cap (A)

(f)-(2)

(f)-(1)

(c)-(3)

(c)-(2)

(c)-(4)
(c)-(1)

Installation of the Main Bearing Cap Special Tool


and the Hydraulic Jacks

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings

ITEM

3.1 DC-32 Main Bearings and Thrust Bearings : Dismantling of Main Bearings
(14) Shift the shift valve of the hydraulic pump to
"Return", and then slowly move the hydraulic
pump lever up and down to lower the piston in
the hydraulic ram and detach the hydraulic
jacks from the main bearing bolts.
And rotate the arms of the hydraulic jack fitting
tool to the proper direction so that they may not
interfere with some other object when again
raising the piston of the hydraulic ram.
(15) Detach one of the main bearing cap tightening nuts.
(16) Attach one of the main bearing holding tools
(h) to the tip of one of the main bearing bolts of
which nut has been detached.

Attach the main bearing cap holding


tool immediately after one of the main bearing
cap tightening nuts is detached to prevent the
main bearing cap from falling off due to gravity
force.
(17) Detach the other main bearing cap tightening
nut and attach the main bearing cap holding
tool to the main bearing.

Main Bearing Bolt (B)

(g)

(f)-(2)

(f)-(1)
(c)-(3)
(c)-(4)
(c)-(2)
(c)-(1)

(h)

Attaching of the Main Bearing Cap Holding Tool

(f)-(2)

(f)-(1)

(c)-(3)
(c)-(4)
(c)-(1)

(h)
(g)

Lowering of the Main Bearing Cap

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings

6
ITEM

Main Bearings and Thrust Bearings : Dismantling of Main Bearings


D. Lower the main bearing cap in accordance with
the following procedure.
(1) Shift the shifting valve of the hydraulic pump
to "Pressurize" and slowly move the hydraulic
pump lever up and down to raise the piston in
the hydraulic ram.
(2) Turn the nut (c)-(3) of the main bearing cap
special tool by hand to screw it in the main
bearing cap connecting bolt when the end of
the hydraulic ram touches the main bearing cap
connecting bolt (g).
Install the stopper (c)-(4) on the hydraulic jack
fitting tool (c)-(2).
(3) Shift the shift valve of the hydraulic pump to
"Return", and slowly move the hydraulic pump
lever to lower the main bearing cap.
(4) Stop moving the hydraulic pump lever when
the nut of the main bearing cap special tool
touches the stopper (c)-(4).

DC-32

3.1

1. Be careful not to mistake the direction of the


turning. The main bearing metal has a locating protrusion that will be broken if the crankshaft is rotated in the reverse direction.
2. When taking out the metal, receive it by a
hand in order to prevent it from being damaged.

Locating
Protrusion

(b)
Upper Bearing Metal

Crankshaft

Do not raise the oil pressure exceeding 29.5 MPa.


E. Remove the lower bearing metal from the main
bearing cap.
It can be easily removed by light knocking of
the end surface of the bearing metal with a
wooden block.
F. Remove the upper bearing metal in accordance
with the procedure as described below.
(1) Insert the pin (b) for the main bearing in an oil
hole in the crankshaft.

Lower
Bearing Metal

Removal of the Upper Bearing Metal


(viewed from the front end of the engine)

Be attentive not to let the pin for the


main bearing fall off from the oil hole. Grease
applied to the portion in which the pin is to be
inserted can prevent the pin from easily falling
off.
(2) Turn the crankshaft anticlockwise viewed from
the front end of the engine to remove the upper
bearing metal as the pin for the main bearing is
contacted with the side (the side not having a
locating protrusion) of the upper bearing metal.

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings


Inspection and Maintenance
Main Bearings
3.2 DC-32 and Thrust Bearings : of Main Bearings
6

ITEM

6-3.2 Inspection and Maintenance of


the Main Bearing

Upper Bearing Metal


A trace of a seizure,
peeling, a trace of
cavitation and a
sunken foreign matter

A. Inspect the main bearing metals to find whether


or not fretting on the outside surface or the
closed gap between the metals, a trace of
seizure, peeling, or a trace of cavitation on the
inside surface, or sunken foreign matters in the
surface is found. When a flaw or a dent is not
deep, rectify it by an oil stone.

The main bearing metal is a thin finished component for which an appropriate
tightening margin (crush) and expanding force
(tension) are provided to maintain full contact
with the bearing housing, therefore, do not
effect correction of the outside or the mating
surface of the closed gap by a file or a scraper.

1. Replace the bearing metals every 16,000 24,000 hours of operation (4 - 5 years)
because prolonged operation of an engine
may cause a crack or peeling to the bearing
metals due to reduction of the tightening
margin or to hardening of the inside portion
of the metals even if the wear is not much.
2. Always replace metals of a bearing by a pair
of the new upper and lower metals at the
same time.
B. Inspect the seating surfaces of the tightening
nuts and the bearing caps, and rectify roughened surface if any.
C. When any loosening is found with a main bearing cap tightening nut of a main bearing that
has been dismantled, retighten the nuts of other
main bearings as well.
D. Inspect whether or not any irregularity such as
fretting is found on the mating surface or the fitted surface of the main bearing cap.
E. Inspect flaws, marks of contact and condition of
wear on the surface of the crankshaft.
For measurement of wear and checking of wear conditions, please consult with the
Service Division of DAIHATSU.

DC-32 Z 05-12

Checking of Fretting

Lower Bearing Metal

Main Bearing

Surfaces
at the
closed gap
Fitted
area

Fitted
area

Inspection of Contact Marks on the


Fitted Area and Surface at the Closed Gap

CHAPTER

Main Bearings and Thrust Bearings

Main Bearings
Assembling and Installation of
and Thrust Bearings : the Main Bearing

ITEM

DC-32

3.3

6-3.3 Assembling and Installation of


the Main Bearing
A. Make certain visually and by touching by bare
hands that no foreign matters stick to and no
flaws are on the crank journal.
B. Clean the inside and the outside surfaces of the
main bearing metals with washing oil and then
wipe them down with care.

Do not apply lubricating oil to the outer


surface of the main bearing metals. Oil existing
in the clearance lowers good contact of the
bearing with the housing.
C. Fit the upper bearing metal in the engine frame
according to the procedure as described below.
(1) See the positions of the locating protrusion on
the upper bearing metal and of the slit in the
engine frame, then push the side of the metal
in the engine frame with the side having no protrusion being faced forward as long as it can be
pushed into by hand.
(2) Insert the pin (b) for the main bearing in the oil
hole in the crankshaft according to the same
procedure that used on its dismantling.
(3) Turn the crankshaft clockwise viewed from the
front end of the engine and push the upper
bearing metal until its side and the surface of
the engine frame mating with the main bearing
cap become flat.

Do not apply lubricating oil to the outer


surface of the lower metal and the inner surface of the main bearing cap. Oil existing in the
clearance lowers good contact of the bearing
with the cap.
(3) Make certain that the main bearing metals
have completely inserted and sit on the right
place.
(4) Apply enough quantity of lubricating oil to the
inner surface of the lower metal by bare hands.
(b)
Crankshaft

Upper Metal

6
Locating
Protrusion

Lower Metal
Turn the crankshaft with care so that
the pin for the main metal may not get out of
the end surface of the metal.

Fitting of the Upper Metal


(viewed from the front end of the engine)

(4) Make certain again that the upper metal has


been inserted and sits on the right place.
(5) Turn the crankshaft anticlockwise viewed from
the front end of the engine to take out the pin
for the main metal.
D. Fit the lower metal in the main bearing cap
according to the procedure as described below.
(1) Make certain again by touching by bare hands
that no foreign matters stick to and no flaws are
on the crank journal and the inner surface of
the main bearing cap.
(2) See the positions of the end surfaces of the
lower metal, the main bearing cap and the
locating protrusion, then fit the lower metal in
the main bearing cap.

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings


Assembling and Installation of
Main Bearings
3.3 DC-32 and Thrust Bearings : the Main Bearing
6

ITEM

E. Install the main bearing cap in the reveres


sequence of that for the detachment.
(1) Make the side surface of the main bearing cap
and the side surface of the engine frame flat,
and slowly push up the main bearing cap until
its upper surface touches the surface of the
engine frame above it with the shift valve of the
oil pressure pump being shifted to "Pressurize"
(direction to push the main bearing cap
upward).
(2) Apply lubricant (Molykote 1000 Spray) to
thread of each side bolt to be embedded and
screw it in the tapped hole in the main bearing
cap by hand until the tip of the bolt touches the
bottom of the hole. Then, unscrew the bolt 1/4 1/2 turn.
(3) Screw each of the nuts for the side bolts on
the bolt until its seating surface just touches the
seating surface of the engine frame.
(4) Detach the main bearing cap holding tool (h)
and screw up each of the main bearing cap
tightening nuts on the main bearing bolt by
hand.
(5) Turn the nut (c)-(3) on the top end of the
hydraulic ram piston by hand to separate the
hydraulic ram piston from the main bearing cap
joint bolt (g).
Detach the main bearing cap holding
tool and separate the hydraulic ram piston from
the bearing cap joint bolt after having screwed
the side bolts in the engine frame to prevent
the main bearing cap from falling off.

(6) Lower the hydraulic ram piston with the shift


valve of the hydraulic pump being shifted to
"Return", then put the hydraulic jacks for the
main bearing (d)-(1) and the jack stands (d)-(2)
on the right and the left arms of the hydraulic
jack fitting tool (c)-(2).
(7) Tighten the nuts by means of the hydraulic
jack installed in the same way that is used for
detachment of the main bearing cap tightening
nuts. Tightening should be simultaneously
effected for the two nuts.

Specified oil pressure : 88 MPa


(8) After normally effecting the tightening, return
the oil pressure to "0", then again raise the oil
pressure to the specified one to check the condition of tightening.
F. Attach the hydraulic jacks to the side bolts to
tighten the bolts making use of oil pressure.

Specified oil pressure :59 MPa


(1) Tightening of the two side bolts for a main
bearing shall be simultaneously effected.
(2) After normally effecting the tightening, return
the oil pressure to "0", then again raise the oil
pressure to the specified one to check the condition of tightening.

Installation of the Main Bearing


Cap Tightening Nuts

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings


Main Bearings
and Thrust Bearings :

6
ITEM

Detachment of Thrust Bearings

6-4 The Thrust Bearings

DC-32

4.1

Crank Web

The thrust bearings are installed on the front


and the rear sides of the No.1 main bearing (nearmost one to the flywheel).
Detachment of the thrust bearings should be
effected with the main bearing being detached.
(
: 6-3.1 "Dismantling of the Main Bearing")

6-4.1 Detachment of the Thrust


Bearings
A. Before detaching the thrust bearings, measure
the side play of the crankshaft according to the
following procedure.
(1) Put a dial gauge on the crankshaft with the
crankshaft being pushed to either side of the
front or the rear of the engine by means of a
bar.
(2) Read the value on the dial gauge with the
crankshaft being pushed against the other side
to compare the replacement limit of the thrust
bearings.

Dial Gauge

Measurement of the Side Play


Upper Thrust Bearing

Push the crankshaft by a bar put on


the crank web (not on the balance weight).
B. The lower thrust bearings are attached to the
No. 1 main bearing cap by means of a dowel
pins (one for each side), so it can be detached
at the same time when the lower main bearing
metals are detached.
C. Each of the upper thrust bearings can be easily
detached by pushing the side face by hand.

Dowel Pin

Lower Thrust Bearing

Detachment of the Thrust Bearings (front view)


The Second Wall

The No. 1 Wall


Upper Thrust
Bearing

For the thrust bearings, an upper bearing metal and a lower one are paired up, so
identify them something such as a mark to prevent either one from being paired with a wrong
one.

Lower Main
Bearing Metal

Lower Thrust
Bearing

Detachment of the Thrust Bearings (side view)

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings

6
ITEM

Main Bearings
4.2,4.3 DC-32 and Thrust Bearings : Maintenance and Installation of Thrust Bearings

6-4.2 Maintenance of the Thrust


Bearings
A. Check them whether or not there is a trace of
seizure or foreign matters sunken in the material on the thrust bearing. Rectify any flaw or dent
with an oil stone when it is not so deep.
B. Measure thickness of the thrust bearings with
an outside micrometer and record the results.
C. When wear of a thrust bearing metal is so much
that clearance (d) between the thrust bearings
and the side play of the crankshaft exceeds the
replacement limit, replace the thrust bearing
metals by new ones.
When effecting replacement of the thrust bearing metals, replace a pair of the upper and the
lower ones by new ones at the same time.
Nominal Width

Standard Side Play

Replacement Limit

(mm)

(mm)

d = 0.30 - 0.51

0.80

(mm)
D = 168

Locating hole
for a dowel pin

Thrust Bearing Metals

6-4.3 Installation of the Thrust


Bearing Metals
A. Deliberately clean the thrust bearing metals and
apply lubricant to surfaces of the metals.
B. See that the identification mark is the right one,
and insert the upper one.
C. See that the identification mark is the right one
and install the lower one in the main bearing
cap and install it as assembled with the main
bearing cap.
D. Measure the side play (d) and make certain that
it is within the replacement limit.

D
d

Side Play (Clearance)

DC-32 Z 05-12

CHAPTER

Main Bearings and Thrust Bearings

MEMO

6
ITEM

DC-32

DC-32 Z 05-12

CHAPTER

The Crankshaft

7
ITEM

7.1 DC-32 The Crankshaft : Outline


7. The Crankshaft
7-1 Outline of the Structure
The crankshaft is made of special steel and
manufactured by the RR integral forging having
enough rigidity and strength. Two balance weights
are mounted for each cylinder with two bolts tightened by means of the hydraulic jack.
On the front end of the crankshaft are
mounted the crank gear to drive the cam shaft and
the auxiliary machinery gear by the mounting bolts
to drive the lubricating oil pump and the cooling
water pump.

of the Structure

Lubricating oil fed to the main bearings


reaches the crankpin bearings through drilled
holes in the crankshaft and finally flows through
the drilled holes in the connecting rods to cool the
pistons.
On the inside of the coupling flange located
at the output end is mounted the oil cut plate by
the bolts to prevent oil from leaking from the shaft
end.
Turning of the crankshaft is effected by the
electrically operated turning device connected with
the flywheel side of the crankshaft.
Weight of ;
Crankshaft Assembly
(including the balance weights, the crank
gear and the aux. machinery gear)

6DC : 4050 kg
8DC : 5495 kg

Aux. Machinery Gear


Oil Cut Plate
Crank Gear

Balance Weight

Crankshaft

DC-32 Z 05-12

CHAPTER

The Crankshaft

Consumable Replacement Parts,


The Crankshaft : Special Tools mad Measuring Instruments

ITEM

DC-32

7.2

7-2 Consumable Replacement


Parts, Special Tools mad
Measuring Instruments
A. Consumable Replacement Parts
None
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Hydraulic jack S for Tightening of the Balance
Weight
(1) Hydraulic Jack Assembly S
(2) Jack Stand S
(3) Jack Handle
(c) Hydraulic Jack L for Tightening of the Balance
Weight
(1) Hydraulic Jack Assembly L
(2) Jack Stand L
(3) Jack Handle
(d) Hydraulic Pump and High Pressure Hose
(1) Hydraulic Pump
(2) High Pressure Hose, 2 m long (3 pcs., with
a male coupler)
(3) Terminal 2T (with a socket coupler)

(1)

(2)

(3)

7
(c) Hydraulic Jack L for Tighten the
Balance Weight

(3)
(1)

(2)

(2)

(1)

(3)

(b) Hydraulic Jack S for Tighten the


Balance Weight

(d) Hydraulic Pump and High Pressure Hoses

DC-32 Z 05-12

CHAPTER

The Crankshaft

ITEM

3.1 DC-32 Inspection and Maintenance : Inspection

of Crankpins

7-3 Inspection and Maintenance of


the Crankpin
On the normal maintenance, the crankshaft
is to be inspected and maintained as installed in
the engine without its dismantling.
When dismantling of the engine is necessary due to a special reason such as seizure of a
bearing or unusual wear of the shaft, please consult with the Service Division of DAIHATSU.

When the user encounters the following situation, continued engine operation may
cause serious damage to the engine or an accident. The user should inspect the engine with
special care.
1. When operating the engine for a long time in
the critical revolution range due to torsional
vibration.
2. When operating the engine with deflection of
the crankshaft exceeding its allowable limit.
3. When oil clearance between the crankshaft
and a bearing metal has become too much
or partial wear has happened with the crankshaft.
4. When a bearing metal is broken (when the
breakage is not serious).

7-3.1 Inspection of the Crankpin


Inspection of the crankpin should be effected when the big end of the connecting rod is dismantled.
(
: 4-3.2 "Dismantling of the Big End of the
Connecting Rod")
A. Inspect the bearings in terms of flaws and condition of the contact.
When a flaw is found, rectify it with an oil stone
and effect a deliberate color check.
B. Measure the O.D. of the shaft and record the
results.
(
: 4-4.4 "Inspection and Maintenance of the
Crankpin")
Nominal diameter of the shaft = 275 mm
C. Effect color checks of the fillet portions and oil
holes on the shaft.
When an unusual condition as described above
happens, inspect the shaft including the sliding
surfaces of the bearings with special care as to
whether or not a hair crack is found.

DC-32 Z 05-12

Oil Hole

Fillet

Measurement of the O.D. of the Crankpin

CHAPTER

The Crankshaft

Inspection and Inspection of Crank Journals


nspection and Maintenance : and Tightening Torque of the Bolts
7-3.2 Inspection of the Crank Journal
Inspection of the crank journal should be
effected when the main bearing is dismantled.
(
: 6-3.1 "Dismantling of the Main Bearing")
A. Inspect the bearings in terms of flaws and condition of the contact.
B. Effect color checks of the fillet portions and oil
holes on the shaft.
When an unusual condition as described above
happens, inspect the shaft including the sliding
surfaces of the bearings with special care as to
whether or not a hair crack is found.

ITEM

DC-32 3.2,3.3

Specified oil pressure :93 MPa


(2) Make certain that the balance weight tightening nuts does not advance (turn to the direction
of tightening) under the specified oil pressure
being applied. If any nut should advance, return
the oil pressure to "0", then again raise the oil
pressure to the specified one to check the condition of tightening.
Fillet

Fillet

When its dismantling is found necessary as the result of the inspection, please consult with the Service Division of DAIHATSU.

7-3.3 Checking of the Tightening


Torque of the Balance Weight
Tightening Bolts
Always check the tightening torque of
the bolts and nuts since insufficient tightening
torque of a bolt or a nut may result in a serious
accident such as breakage of the bolt during
the engine operation.

7
Oil
Holes

Inspection of the Crank Journal

A. Periodic inspection to be effected every 4,000 6,000 hours (one year)


Make certain by inspection around the seating
surfaces for the balance weight tightening nuts
and hammering of the nuts that they have not
loosened.

Do not apply hammering to the


threads of the bolts.
B. Periodic inspection to be effected every 16,000
- 24,000 hours (4 - 5 years)
Effect inspection of the tightening torque of the
balance weight tightening bolts and retighten
them.
(1) Attach the hydraulic jacks to the both bolts
and apply the specified oil pressure to the
hydraulic jacks.
(
: 2-4 "Hydraulic Jack")

Balance Weight
Balance Weight Tightening Nut
Balance Weight Tightening Bolt

Inspection of the Balance Weight Bolts

DC-32 Z 05-12

CHAPTER

The Crankshaft
ITEM
Inspection of Clearance Between the Oil Cut Cover and the
3.4,4 DC-32 Crankshaft and Measurement of Deflection of the Crankshaft
7

7-3.4 Clearance Between the Oil Cut


Cover and the Crankshaft

Oil Cut Cover

Standard Clearance (mm)


d = 0.30 - 0.50
E

Nominal Diameter (mm)


E = 555

Measure the clearance between the I.D. of


the oil cut cover located in the rear part of the
engine and the crankshaft with the filler gauge to
obtain rough data on the wear as the main bearings are not dismantled.

1. Measurement of deflection shall be effected


in the cold state.
2.Continued operation of the engine with
deflection of the crankshaft exceeding the
allowable limit may cause breakage of the
crankshaft in the extreme case due to too
much stress in the crankshaft. The deflection
shall be not only properly adjusted on its
installation but also shall be measured every
2,000 - 3,000 hours (6 months) after starting
the service operation and correct the deflection when its allowable limit is exceeded.

<<Procedure to Measure Deflection of the


Crankshaft>>
(
: 5-4.5 "Measurement of Deflection of the
Crankshaft" of the "Operation Manual")

DC-32 Z 05-12

Crankshaft

7-4 Measurement of Deflection of


the Crankshaft

Inspection of Clearance Between the


Oil Cut Cover and the Crankshaft

CHAPTER

The Crankshaft

MEMO

7
ITEM

DC-32

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

ITEM

1.1 DC-32 Timing Gears : Outline

of the Structure

(G) from the oil hole in the engine frame through


the drilled hole in the idle gear shaft (F).
Also, lubricating oil is sprayed on the teeth
flanks of the gear from the oil spray nozzle fitted
on the bottom plane of the governor supporting
mount (J).
The sealing surfaces of the gear case (H)
that constitutes the timing gear chamber and of the
cam gear case (I) are sealed with liquid sealant.

8. Timing Gears and the


Camshaft
8-1 Timing Gears
8-1.1 Outline of the Structure
The timing gears are installed at the front
end of the engine and the camshaft is driven by
the crank gear (A) via the idle gear No. 1 (B), the
idle gear No.2 (C) and finally the cam gear (D).
Each gear is a helical gear made of highstrength alloy steel and its teeth flanks are carburized and quenched.
The cam gear (D) is supported by the journals at both sides of the gear to relief bending
stress on the camshaft, and it is mounted on the
camshaft by the bolts as well as the cam gear
shaft (E) that constitutes the front journal.
The thrust metals are fitted on the cam gear
shaft bearing to bear thrust loaded on the
camshaft. Lubricating oil is fed to the cam gear
shaft bearing and the thrust metals through the
end part of the camshaft through drilled hole in the
camshaft.
The idle gear shaft (F) is made of carbon
steel and firmly mounted on the engine frame with
the mounting bolts.
Lubricating oil is fed to the idle gear bushing

Weight of ;

Cam Gear Shaft

36 kg

Cam Gear

75 kg

Idle Gear Assembly


Idle Gear Shaft

87 kg

Aux. Machinery Gear

55 kg

Dismantling, assembling and adjustment of the timing gear train and the camshaft
requires a high level technique.
When such services are required,
please contact the Service Division of DAIHATSU or the service agent of DAIHATSU and
effect the service under instruction of a skilled
technician.

(I)

(J)

(E)
(D)
(C)

(F)

(B)
(A)
Aux. Machinery
Gear
(H)
Distance
Piece

Timing Gear Train

DC-32 Z 05-12

129 kg

(G)

CHAPTER

Timing Gears and Camshaft

Consumable Replacement Parts, Special


Timing Gears : Tools and Measuring Instruments

8
ITEM

DC-32

1.2

8-1.2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced
when maintenance is effected.
(
: "Parts List")
1. O-ring (for the lubricating oil pump) 3-3.10 No.511
2. O-ring (for the cooling water pump) 3-4.2
No.517
3. O-ring (for the cam gear shaft bearing)2-8
No.503
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Idle gear shaft hanging tool

(b) Idle Gear Shaft Hanging Tool

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

ITEM

1.3 DC-32 Timing Gears and the Camshaft : Detachment of the Idle Gears
8-1.3 Detachment of the Idle Gears
Detachment of the idle gears is to be effected as the gear case and the accessories fitted in
the gear case are detached.
A. Detach all the accessories (the cooling water
pump, lubricating oil pump, the intercooler, the
governor, etc.) fitted in the gear cases (H1) and
(H2) and the related piping and wiring.
B. Detach the sensor for the tachometer fitted in
the cam gear cover (I) and then the cam gear
cover.
C. Unscrew the fixing bolts for the cam gear bearing cover (L) and remove the cover.
D. Measure thrust clearance "d" of the camshaft.
When effecting measurement described in the
section 8-1.3 (J), the cam gear bearing case
should be tentatively fixed on the gear case
(H1).
E. Detach the collar (M) bearing the thrust on the
camshaft from the cam gear shaft (E).
F. Screw a bolt in the tapped hole for the hydraulic
jack to pull out the cam bearing case (K)
together with the thrust bearings.
G. Make certain that the piping or the wiring does
not hinder detachment of the gear cases (H1)
and (H2) and then detach the gear case.

(H1)
Thrust
Bearing
(K)
(L)
(M)
(E)

(A)

(N)

Distance
Piece

(H2)
Aux. Machinery
Gear

The surfaces of the gear cases and


the cam gear cover mating with the engine
frame are sealed with liquid sealant, without
use of packing.
Separate them not forcibly with care

Detachment of the Idle Gears


d

H. Untie the tying wire on the aux. machinery gear


tightening bolts (N). Screw the eye bolts M12 in
the two tapped holes in the aux. machinery
gear and pass a wire rope through them while
lifting the gear a little to unscrew and detach the
aux. machinery gear tightening bolts, and finally
detach the aux. machinery gear from the distance piece.

Thrust Clearance of the Camshaft

DC-32 Z 05-12

CHAPTER

Timing Gears and Camshaft

Timing Gears and the Camshaft : Detachment of the Idle Gears


I. Effect the following measurement before
detachment of the idle gears.
1. Measure the axial play of the camshaft "d" and
that "e" of the idle gears with a filler gauge and
record the results.

Camshaft
Idle gear

Standard axial play

Replacement limit

(mm)
d = 0.15 - 0.20
e = 0.30 - 0.60

(mm)
0.40
0.80

2. Measure backlash of the timing gears and


record the results.
(a) Bend a lead wire ( 0.5 mm) along the curve
of a tooth flank of a gear and attach it to a tooth
with grease.
(b) Slowly turn the engine to have the lead wire
be caught between the gear teeth and then
stop the turning.
(c) Then, turn the engine in the reverse direction
and take out the lead wire towards the tester.
(d) Measure the thickness of the lead wire
crushed between the teeth (the thinnest part).
(A and B in the illustration)
o
(e) Measure the thickness every 90 at the circumference of a gear, four points in total and take
the average for the backlash "b".
Backlash
(A+B)

Standard value
Replacement limit
(mm)
(mm)
b= 0.20 - 0.33
0.60

(f) Untie the tying wire of the bolts (O) to unscrew


and remove the bolts and detach the idle gear
clamp (P).
(g) Screw the eye bolts M12 in the two tapped
holes in the idle gear-1 (B) and pass a wire
rope through them while lifting the gear a little
to pull out the idle gear-1 (B) and the idle gear2 (C) towards the front of the engine.
(h) When detachment of the idle gear shaft (F) is
required, do it after detachment of the cam
gear. Unscrew and detach the bolts after untying the tying wire of the bolts (Q).
(i) Attach the idle gear shaft hanging tool (optional) (b) to the idle gear shaft and take out the
idle gear shaft from the engine frame while
slinging the tool with the wire.

ITEM

DC-32

1.3

Be careful not to let the idle gear fall


off and injure the foot of the operator when it
leaves the engine frame. (Do this work with
care using a pulling bolt or some other to hold
it.)
e

(P)
(O)

(F)

(B)
(C)

(Q)

Axial Play of the Idle Gear


Lead wire
b

Backlash b (= A+ B)

(b)

(F)

Detachment of the Idle Gear Shaft

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

1.4 DC-32 Timing Gears and the Camshaft : Detachment of the Cam Gear
8-1.4 Detachment of the Cam Gear
Detachment of the cam gear is to be effected as the gear case and the accessories fitted in
the gear case are detached in the same manner
that is used for detachment of the idle gears.
(
: 8-1.3 "Detachment of the Idle Gears")

For detachment of the cam gear, it can


be taken out sideways with the gear case being
left on the engine if the cam gear cover and
some others are removed.
However, it is recommended to effect
the work with the gear case being detached in
consideration of operability and safety of such
work as taking-out of the cam gear, its installation, measurement of backlash and of making
certain that the gears are engaged as the proper marks are aligned.
A. Remove the governor, the governor driving
train and related parts and piping.
(
: 11-3 "Detachment and Dismantling of the
Governor"'
B. Detach the gear case in accordance with the
procedure described in 8-1.3.
C. Measure and record the backlash before starting detachment of the cam gear.
(
: Section J.2. of 8-1.3)
Backlash
(A

B)

Standard value
Replacement limit
(mm)
(mm)
b = 0.20 - 0.33
0.6

D. Detach the governor driving gear (Z).


(1) Make certain that no rotational torque nor
thrust force are added on the governor driving
gear (Z).
(2) Gradually loosen the mounting bolts (S) that
fasten the governor driving gear on the
camshaft in several steps by means of a
hexagonal head and a torque wrench.
(3) Pull out the governor driving gear from the
cam gear shaft (E).
E. Detach the cam gear (D).
(1) Remember the positions of notched matching
lines on the camshaft and the cam gear.

DC-32 Z 05-12

Since performance of the engine may


be changed if the gears are engaged as the
matching marks do not align, align the matching marks in the same status as before their
detachment when assembling them.
(
: 8-2.6 "Inspection of the Fuel Injection
Timing")
(2) Passing a wire rope through the hole of the
rim of the cam gear (D) and the eye bolt M12
attached on the tip of the cam gear shaft (E), a
little lift the cam gear by means of a chain
block, and finally loosen and detach the cam
gear mounting bolts (R).
(D)
(Z)

Camshaft

(E)
(S)
Engine Frame

Hexagonal
Wrench
Torque Wrench

Matching Mark
(R) (notched line)

Detachment of the
Governor Driving Gear
(D)
Engine
Frame

Eye Bolt M12


(E)

(R)

Camshaft

Detachment of the Cam Gear

CHAPTER

Timing Gears and the Camshaft

8
ITEM

Timing Gears and the Camshaft : Detachment of the Cam Gear

DC-32

1.4

(3) Manipulate the wire rope to detach the cam


gear (D) together with the cam gear shaft (E)
and hang them down on the designated place.

Be careful not to let the cam gear fall


off and injure the operator or someone during
its transportation.

(J)
(H)
(K) (Y)

(D)

Engine
Frame

(M)
(4) Detach the cam gear shaft (E) from the cam
gear (D).
G. In case that the cam gear (D) is detached as
the gear case is left on the engine.
(1) Detach the governor driving device from the
gear case.
(2) Detach the cam bearing cover (L) and loosen
the bolt on the tip of the cam gear shaft, then
detach the collar (M).
(3) Screw the jack bolt M12 in the tapped hole in
the cam case (K) to separate the part of the
cam bearing case where o-rings are fitted from
the gear case.
(4) Remove the jack bolt and screw the eye bolt
M12 in the cam case to remove the cam shaft
case from the gear case, a little lift the cam
case by means of a wire rope, and then detach
the cam case from the gear case.
(5) Detach the governor driving gear (Z).
(

Camshaft

(L) (X) (E)

(S)
(Z)

(R)

Camshaft Bearing Case

(D)

Engine
Frame

: section 8-1.4 D)

(6) Pass a wire rope through the governor driving


device installing hole on the gear case and two
holes in the cam gear rim and lightly suspend
the cam gear by means of a chain block.
(7) Attach two eye bolts to the tip of the cam gear
shaft and pass a wire rope through them, and
also pass another wire rope through the hole in
the governor driving gear mounting flange of
the cam gear shaft, then lightly suspend it by
means of a chain block.
(8) Untie the tying wire to detach the cam gear
mounting bolts (R).

(E)

(R)

Camshaft

Eye Bolt M12

Detachment of the Cam Gear

(with the gear case being mounted on the engine frame)

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

ITEM

1.4 DC-32 Timing Gears and the Camshaft : Detachment of the Cam Gear
(9) Pull out the cam gear shaft (E) fitted in the
camshaft from the camshaft and separate the
cam gear shaft from the cam gear.
(10) Bring the cam gear shaft in the forward direction out of the engine by means of the cam
gear shaft hanging tool while adjusting the wire
rope.
(11) Bring the cam gear out from the cam gear
cover (I) by means of the cam gear hanging
tool while loosening the wire rope.

(D)

Engine
Frame

Camshaft

(E)

(R)

Eye Bolt M12

Detachment of the Cam Gear

(with the gear case being mounted on the engine frame)

(D)
Engine
Frame

Eye Bolt M12

(E)

Detachment of the Cam Gear

Camshaft

(with the gear case being mounted on the engine frame)

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft


Inspection and Maintenance of
Timing Gears and the Camshaft :
Timing Gears

Specified torque : 392 N.m


H. Check contact marks and wear of the idle gear
bushing (G) and the idle gear shaft (F).
I. Measure the O.D. of part of the idle gear shaft
sliding on the bushing with an outside micrometer.
J. Measure the I.D. of the idle gear bushing with a
cylinder gauge.
K. Calculate clearance between the idle gear shaft
and the idle gear bushing based on the results
of measurement. Replace the idle gear bushing
when the clearance exceeds the replacement
limit.
Nominal Diameter

Standard Clearance

(mm)
A = 200

(mm)
a = 0.10 - 0.31

Replacement Limit

(mm)
0.40

1.5

When the clearance is expected to


exceed the replacement limit before the next
periodic inspection, replace the bushing even if
the current clearance is within the standard
one.
L. Check tightening condition of the idle gear shaft
mounting bolts (Q) (in case that the idle gear
shaft is not detached).
Untie the tying wire and tighten two bolts with
the specified torque.
(1) When the bolt does not turn any more, the
tightening is proper. Tie again the heads of the
bolts with the tying wire to lock the bolts.
(2) When any of the bolts turns, unscrew and
remove the bolt and clean it. Also blow the
female threads to clean them with care. Then,
apply lubricant (Molykote 1000 Spray) to the
female threads and the seating surfaces, and
finally retighten the bolts with the specified
torque.

Specified torque : 392 N.m

(C)
(B)
(G)

A. Wash each gear and component with washing


oil.
B. Remove sealant adhered to the mating surfaces of the gear case (H) and the engine
frame with care.
C. Blow the oil holes on the idle gear shaft (F) by
air and clean the shaft (in case that the idle
gear shaft is detached).
D. Blow the oil hole in the cam gear shaft (E) by
air and clean it.
E. Check contact marks, pitting and flaws on the
teeth flanks of each of the idle gear-1 (B), idle
gear-2 (C) and the cam gear (D).
F. Turn the crankshaft to check the crank gear (A)
on the same items as described above.
G. Check the tightening condition of the tightening
bolts of the idle gear-1 (B) and the idle gear-2
(C).
Check the tightening condition with the specified torque being added. When they are found
loosened, replace any bolt loosened by new
one. And completely clean the male threads of
them, apply lubricant (Molykote 1000 Spray) to
the seating surfaces and threads of the bolts,
and then tighten them with the specified torque.
Finally tie the bolts with the tying wire to lock
the bolts.

DC-32

8-1.5 Inspection and Maintenance of


the Timing Gears

8
ITEM

(F)

Fastening
Bolt
(Q)

Clearance (Radial Play)


Between the Idle Gear Bushing and the Shaft

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

ITEM

1.6 DC-32 Timing Gears and the Camshaft : Installation of the Cam Gear
8-1.6 Installation of the Cam Gear
Installation of the cam gear is to be effected
in the reverse sequence of that for its detachment.
(
: 8-1.4 "Detachment of the Cam Gear")
A. Fit the cam gear shaft (E) in the cam gear (D)
with the bolt holes being aligned.
B. Hang up the cam gear together with the cam
gear shaft with a wire rope and fit them onto the
camshaft.

Be careful not to let the cam gear shaft


fall off from the cam gear and injure the operator or someone during its transportation.
C. Align the match marks (notched line) of the cam
gear and the cam gear shaft as they were
aligned before their separation. (Or align the
match marks drawn when they were separated.)

Always align the match marks of the


cam gear and the cam gear shaft as they were
aligned before their separation.
(
: 8-2.6 "Checking of the Fuel Injection
Timing")
D. Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surfaces of the cam
gear bolts (R), and then tighten the bolts diagonally with the specified torque.

Specified torque : 343 N.m


E. Detach the wire rope, and then tie the cam gear
bolts with the tying wire to lock the bolts.
F. Install the governor driving gear (Z) on the cam
gear shaft and alternately tighten the mounting
bolts (S) with care to screw them up straight.
G. Apply lubricant to the outer surface of the cam
gear shaft.
H. In case that the gear case (H) is installed on the
engine frame,
(1) Fit the o-rings and the thrust metals on the
cam shaft bearing case (K).

Install the thrust metals so that the


side on which oil retaining recesses are made
may face outwards.
(2) Apply lubricating oil to the inner surface (inner
surface of the bearing) and the sliding surfaces
of the thrust metals.
(3) Fit the same shim (Y) that is fitted when the
assembly was dismantled on the cam bearing
case, and then fit it onto the cam gear shaft (E)
with deliberate care not to damage the thrust
metals and the inner surface of the bearing
bushing, and then temporarily mount it by the
bolts.
Make certain that the drain holes (
19 mm x 2) to discharge lubricating oil face
downwards.
(4) Clean the contact surface of the collar (M) that
is subjected to thrust force and make certain
that no flaws due to hitting by something exist
on the surface. Install it on the end of the cam
gear shaft as the same shim (X) that is fitted
when they were dismantled is put between the
collar and the cam bearing case.
(5) Measure the axial play (d) of the camshaft
with a filler gauge to make certain that it is within the specified range.
(
: 8-1.3 "Detachment of the Idle Gear")
Specified axial play d = 0.15 - 0.20 mm
(6) Remove the bolts temporarily tightened and
finally tighten the cam bearing cover.

Cam Gear
Shaft (E)

Thrust Metal
(oil retaining recess)
Lubricating Oil Drain Hole
Cam Bearing Case

Assembling of the Cam Bearing

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

Timing Gears and the Camshaft : Installation of Idle Gears


8-1.7 Installation of the Idle Gears
Installation of the idle gears is to be effected
in the reverse sequence of that for its detachment.
(
: 8-1.3 "Detachment of the Idle Gears")
A. Clean by air the threads tapped in the engine
frame in which the idle gear mounting bolts are
screwed.
B. Fit the idle gear shaft (F) in the engine frame
paying attention not to let it fall off.
C. Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surfaces of the idle
gear shaft mounting bolts (Q) and tighten them
with the specified torque.

DC-32

1.7

H. Fit the idle gear assembly onto the idle gear


shaft (F) as the matching marks on the idle
gear-1 (B) and the idle gear shaft (F) are
aligned.
I. Also, see through the hole of the rim portion of
the idle gear-1 that the matching marks on the
idle gear-2 (C) and the cam gear (D) align.
J. Install the idle gear clamp (P) on the idle gear
shaft as the bolt holes of both parts are aligned.
K. Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surfaces of the idle
gear mounting bolts (O) and tighten them with
the specified torque.

Specified torque : 49 N.m

Specified torque : 392 N.m


D. Lock the bolts (Q) with tying wire.
E. Turn the crankshaft to bring the piston of the
No. 1 cylinder to the top of the intake stroke.
F. Hang up the idle gear assembly (B) and (C) by
a wire rope and move it to the given place.
G. Apply lubricant to the sliding part of the idle
gear bushing (G) and the idle gear shaft (F).

K. Lock the bolts (O) with the tying wire.

Idle Gear-2 (C)


(H1)
Window on
the Rim

(D)
(E)

(G)

(B)
Cam Gear (D)
Matching Marks on
(C) and (D)

Idle Gear-1(B)
Matching Marks on
(A) and (B)

(P)
(F)
(O)
(C)
(Q)
(A)

Crank Gear (A)


Aux. Machinery
Gear

Matching Marks on the Timing Gears

(The above illustration shows how the components


are engaged each other when the piston of the No. 1
cylinder is brought to the top in the intake stroke.)

(N)
(H2)

Distance
Piece

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

ITEM

1.7 DC-32 Timing Gears and the Camshaft : Installation of Idle Gears
L. Measure the axial play (e) of the idle gears to
make certain that they are within the specified
range.
Specified axial play e = 0.3 - 0.5 mm
M. Attach the aux. machinery gear on the crankshaft.
(1) Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surfaces of the aux.
machinery gear mounting bolts and tighten
them with the specified torque.

Specified torque : 882 N.m


(2) Lock the bolts with tying wire.

<<Matters to be Attended on Installation of


the Timing Gears>>
1. Matching marks of the timing gears are
stamped on the side of each gear. See the
matching marks whenever effecting their
assembling.
2. Align the matching marks of the cam gear
and one of the idle gears at the time when
those of the crank gear and the other idle
gear are aligned.
N. Clean the mating surfaces of the gear cases
(H1) and (H2), then apply liquid sealant to them
and install them on the engine frame.
O. Install the parts to be fitted on the front end of
the cam gear shaft (E).
(
: Section D of 8-1.6)
P. Install the governor, the governor driving device
and the related parts and piping.
(
: 11-5 "Installation of the Governor
Assembly")
Q. Clean the mating surface of the cam gear cover
(I), apply liquid sealant to it and then install it on
the engine frame.
R. Install the tachometer sensor.
S. Install the aux. machinery such as the lubricating oil pump and the cooling water pump on the
gear case (H2), and also install all the related
piping and the wiring.

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

The Camshaft : Outline

of the Structure

DC-32

2.1

A drilled hole in the center of the camshaft


constitutes an oil passage to feed lubricating oil to
each bearing.

8-2 The Camshaft


8-2.1 Outline of the Structure
The camshaft is an assembled type in
which the intake and the exhaust cams and the
fuel cams are integrated consisting of units
each of which works for every two cylinders.
Each unit is fastened with the neighboring unit(s) by the bolts and the nuts and its
outer surface is also used as one of the bearings of the camshaft.
On the front end are fitted the cam
gear to drive the camshaft, the thrust metals to
limit the axial movement of the camshaft, the
governor driving gear to drive the governor and
the coupling to drive the tachometer.
The starting air rotary valve is driven
by the camshaft via a joint fitted on the rear end
of the camshaft.
The camshaft bearings are built in the
walls between the cylinders and directly fitted in
the engine frame by shrinkage fitting.

: 8-1 "Timing Gears")

: 11 "Governor Driving Device")

: 13-3 "Starting Air Rotary Valve")

<6DC>
590kg

Camshaft Assembly

<8DC>
725kg

(with the cam gear shaft. the cam gear and the governor driving gear)

115kg

Cam Gear Shaft Assembly

115kg

(with the cam gear and the governor driving gear)

139kg

One unit of the Camshaft

139kg

Governor
Governor Driving Device

Fuel Injection Pump

Governor Driving Gear (Z)

Fuel Injection Pump Tappet

Starting Air Rotary


Valve Mount

Cam Gear (D)

Fuel cam

Cam Gear (E)


Thrust Metals

Camshaft Bearing
Camshaft

Intake Cam
Exhaust Cam

Camshaft Connecting Bolt


Camshaft Joint Nut

Starting Air Rotary Valve

Rear end of the Camshaft

Front end of the Camshaft

Structure of the Camshaft

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft


Consumable Replacement Parts, Special
2.2 DC-32 The Camshaft : Tools and Measuring Instruments
8

ITEM

8-2.2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced
when maintenance is effected.
(
: "Parts List")
1. Gasket
3-1,4
No.9
(for the starting air rotary valve body)
2. Gasket
3-1,4
No.8
(for the starting air rotary valve body)
3. Gasket
3-1,4
No.506
4 Camshaft Bolt
2-7
No.15
5 Special Nut
2-7
No.16
6 O-ring
2-8
No.503
(for the cam gear shaft bearing)

(b) Special Ring Head 27 x 19

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Special Ring Head 27 x 19
(c) Camshaft Puller (optional)
(1) Puller-1
(2) Puller-2
(3) Bolt

(3)

(1)

(2)

(c) Camshaft Puller


(optional)

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

The Camshaft : Dismantling and Detachment of the Camshaft DC-32


8-2.3 Dismantling and Detachment of
the Camshaft
Usually the camshaft is detached as the
gear case is removed. However, it can be pulled
out with the gear case being left on the engine
frame when the cam gear has been already
removed.
(
: 8-1.4 "Detachment of the Cam Gear")
This manual describes the necessary work
to detach the camshaft when the cam gear and the
cam gear shaft have been already detached but
the gear case is still left on the engine frame.
(Given that the governor, the governor driving device, the governor gear case and the related
parts and piping have been already removed.)
(
: 11-3 "Detachment of the Governor Driving
Device")
A. Remove the various piping connected to the
starting air rotary valve and then detach the
starting air rotary valve and the starting air
rotary valve mount.
(
: 13-3 "Starting Air Rotary Valve")
B. Detach the camshaft cover mounted on the
side of the engine frame.
C. Remove the cylinder head cover and then
detach the rocker arm assemblies and the push
rods.

D.

E.
F.

G.

2.3

(
: 3-3.3 "Dismantling of the Rocker Arm
Assembly")
Remove the high pressure fuel block mounting
bolts and then detach the high pressure fuel
block and the fuel injection pump. (
: 9-3
"Detachment of the Fuel Injection Pump")
Detach the valve train.
(
: 10-3 "Dismantling of the Valve Train")
Loosen and remove one of the two nuts for the
camshaft connecting bolts that join the unit with
the neighboring unit of the camshaft by means
of the special ring head 27 x 19 (b) that is
inserted through a window on the camshaft
cover.
After making certain that there are no obstacles
to hinder pulling out of the camshaft unit, pull
out the camshaft towards the front end or the
rear end unit by unit.
This work is not necessary when there is
enough space in front of the engine to enable
the camshaft to be pulled out as assembled.

Pull out the camshaft with care by


using wooden bolsters or some others not to
damage the surfaces of the cams or the inner
surfaces of the camshaft bearings.

Turbocharger overnor and Governor Driving Device


Rocker Arm Assembly and Push Rods
High Pressure Fuel Block
Fuel Injection Pump Cylinder Head

Camshaft
Cover

Intercooler
Cam Gear Cover
Valve Train
Cooling Water Pump
Lubricating
Oil Pump
Gear Case

Dismantling of the Camshaft

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

2.4 DC-32 The Camshaft : Inspection and Maintenance of the Camshaft

A. Inspect pitting and peeling on each of the cams.

When pitting, peeling or wear of the


cam surface is very bad, it is necessary to
replace the camshaft by new one.
In case that the damage is not so critical, the service life may be extended to a certain extent by a surface treatment. Please contact with the Service Division of DAIHATSU.

Standard Clearance
Thrust clearance (axial play)

Replacement Limit

(mm)
d = 0.15 - 0.20

(mm)
0.40

F. Since adhesive is stuck to the camshaft bolts


and the nuts, replace them by new ones.

Camshaft Bearing 3
Cam Gear Shaft
Camshaft Bearing 2

Camshaft Bearing 1

Nominal Diameter

Standard Clearance

B. Inspect flaws and contact marks on the sliding


surfaces of the camshaft bearings. The flaws, if
any, should be rectified by an oil stone.
C. Inspect the condition of wear of the inner surfaces of the bearings and whether or not any
flaw or peeling is found on them.
D. Measure oil clearance between the sliding part
of each bearing journal and the bearing of the
camshaft.
(1) Measure the O.D. of the sliding part of each
bearing journal with an outside micrometer.
(2) Measure the I.D. of each bearing with a cylinder gauge as the bearing is fitted in the engine
frame.
(3) Calculate the clearance based on the measurements and replace the bearing when the
clearance exceeds the replacement limit.

Since the parts described in this section are subject to the regulation of the NOx
Technical Code, always use a part on which
the identification is stamped.
(
: 0-3 "Engines Conforming to NOx
Technical Code")

<<Procedure to Replace the Camshaft


Bearing>>
(1) Attach the camshaft bearing puller (c) to the
engine frame and slowly screw the bolt (c)-(3)
in the puller body with care not to damage the
bearing housing in the engine frame to pull out
the bearing.
(2) Fit the new bearing in the engine frame by
means of shrinkage fit while aligning the oil
holes in both of the engine frame and the bearing. Procedure for the shrinkage fit is the same
one that is used for the valve guide.
(
: 3-1.5 B "Replacement of the Valve
Guide")
E. Inspect the condition of wear, flaws and peeling
of the thrust metals for the camshaft.
(1) When the damage is not critical, rectify it by
an oil stone.
(2) When the wear is so bad that the axial play
"b" exceeds the replacement limit, replace the
thrust metals by new ones.
(
: 8-1.3 J "Axial Play of the Camshaft")

8-2.4 Inspection and Maintenance of


the Camshaft

Replacement Limit

(mm)
A = 216

(mm)
a= 0.13 - 0.23

(mm)
0.40

B = 216

b= 0.13 - 0.23

0.40

C = 92

c= 0.10 - 0.18

0.30

Camshaft
Cam Gear
Governor Driving Gear

Camshaft Connecting Bolt

Thrust Metals

Oil Clearance and Axial Play of the Camshaft Bearings

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

The Camshaft : Assembling

of the Camshaft

8-2.5 Assembling of the Camshaft


Assembling of the camshaft is to be effected
in the reverse sequence of that for dismantling.
(
: 8-2.3 "Dismantling of the Camshaft")

Make certain that the camshaft to be


assembled is the right one by its punched identification mark before starting the assembling.
Especially when the camshaft is replaced one,
always do this checking.
A. Wash dismantled components such as the
camshaft with washing oil.

Since adhesive may stick on the bolt


holes and the seating surfaces of the nuts for
the camshaft, clean up them with care.
B. Clean the surfaces contacting the camshaft
connecting nuts and see that no flaws or dents
due to hitting by something are found. Rectify
the damaged surfaces if any.
C. Deliberately clean the camshaft bolt holes and
the surfaces to be mated with the neighboring
camshaft unit(s) and blow them by air.

DC-32

2.5

D. Insert each of the camshaft connecting bolts


that fasten the camshaft units together into the
hole in the camshaft flange (functioning also as
the bearing).
E. Make certain that no dust or foreign matters are
left on the surfaces of the camshaft, and then
apply lubricating oil to the bearing journals and
the inner surfaces of the camshaft bearings.
F. See that the identification marks punched on
the camshaft between each exhaust cam located nearer to the front end of the engine and the
intake cam of a camshaft unit (see the following
illustration) are correct ones, and then insert the
camshaft units with care unit by unit avoiding
damage to the camshaft bearings.
G. Assuredly fit the fitting part of the camshaft unit
into the mating part with the dowel pin and mating holes being aligned.
H. Apply lubricant (Molykote 1000 Spray) and
adhesive (Loctite 243) to the seating surfaces
of the camshaft connecting nuts and the
threads respectively, and then diagonally tighten them with the specified torque by means of
the special ring head 27 x 19 (b) and a torque
wrench.

Specified torque : 373 N.m

Punched identification mark


For No. 7 and 8 cylinders For No. 5 and 6 cylinders For No. 3 and 4 cylinders For No. 1 and 2 cylinders

6DC
8DC

8.4

6
8

Punched
5
identification
7
mark

Scribed
lines

Intake cam
Exhaust cam
Distance piece
Front end

6.3

6.2

6.1

8.3

8.2

8.1

Punched
identification
mark

Punched
1
identification
mark

Fuel pump cam

Stamped Identification Marks on the Camshaft

Rear end

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

ITEM

2.5 DC-32 The Camshaft : Checking of the Fuel Injection Timing


I. Install the cleaned cam gear(D) and the
cleaned cam gear shaft (E) on the front end of
the camshaft (on the front most unit) and apply
lubricant (Molykote 1000 Spray) to the threads
and the seating surfaces of the cam gear bolts
(R), and then diagonally tighten the bolts with
the specified torque.
(
: 8-1.6 "Installation of the Cam Gear")

Specified torque : 343 N.m

Align the match marks on the


camshaft and the cam gear in the same aligning state as before their detachment. (Or align
match marks that were marked before detachment.)
(
: 8-2.6 "Checking of the Fuel Pump Cam
Timing")
J. Effect the work as described in the section 81.6 E and install the cam bearing case on the
gear case.
K. Install the valve train.
(
: 10-5 "Assembling and Installation of the
Valve Train")
L. Install the fuel injection pump and connect the
high pressure fuel block with the bolts.
(
: 9-5 "Installation of the Fuel Injection
Pump")
Insert the push rods and install the rocker arm
assembly.
M. Install the cylinder head cover.
(
: 3-3.5 "Assembling of the Rocker Arm
Assembly")
N. Install the gear case to be mounted on the front
end of the engine, the governor driving device
fitted in the gear case, the governor, the lubricating oil pump, the cooling water pump and
other accessories and the related parts and piping.
(
: 8-1.7 "Installation of the Idle Gears")
(

: 11-5 "Assembling of the Governor Driving


Device")
O. Install the camshaft cover.
P. Install the starting air rotary valve and the piping that are located around the rear end of the
engine.

DC-32 Z 05-12

CHAPTER

Timing Gears and the Camshaft

8
ITEM

The Camshaft : Checking of the Fuel Injection Timing


8-2.6 Checking of the Fuel Injection
Timing

DC-32

2.6

Cam Gear
Cam Gear Shaft

Since the engine parameters that may


be adjusted in accordance with the instruction
described in this section are to be
checked with the certified engine parameters in
accordance with the NOx Technical Code, do
not change any of these parameters in such a
manner that its value deviates from the certified
range of adjustment.
(
: 0-3 "Engines Conforming to the NOx
Technical Code")

Distance Piece

Camshaft

When the cam gear, the cam gear


shaft or the camshaft is detached, dismantled
and/or replaced, check the injection timing in
accordance with the following procedure.
A. Remove the cam gear cover fitted on the side
of the gear case and the camshaft cover
fitted on the side of the engine frame.
B. Make certain that the scribed line on the periphery of the boss of the cam gear points the
scribed line on the periphery of the distance
piece fitted on the end part of the camshaft as
they aligned before detachment. (Or that the
matching marks that were marked before
detachment align after assembling of them too.)
(
: 8-1.4 "Detachment of the Cam Gear")
(
: 8-1.6 "Installation of the Cam Gear")
C. Slowly turn the crankshaft to read the crankshaft angle of beginning-of-delivery on the dial
marked on the flywheel that represents the time
when the position mark "X" on the fuel injection
pump housing to indicate the beginning of delivery points to the scribed line "Y" on the fuel
injection tappet.
D. Make certain that the value obtained as
described above is the same angle of beginning
of delivery that is indicated on the name plate
attached to the engine frame side cover.
E. Check all the cylinders in the same manner as
described above. if a specific cylinder should
shows incorrect angle of beginning-of-delivery,
check the fuel injection pump of the cylinder.
(
: 9-5 "Installation of the Fuel Injection
Pump")
F. Install the cam gear cover and the camshaft
cover.

Scribed Line
(on the boss of the cam gear)

Dial
(on the distance piece)

Checking of the Positions of the Matching


Marks of the Cam Gear and the Distance Piece

Indication
line "X"
indicating the
position of
beginningof-delivery

Fuel Injection
Pump

Tappet Roller
Indication
line "Z"
indicating
installation
position
Scribed line "Y"
on the tappet

Fuel Cam
Camshaft

Position of Beginning-of -Delivery

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

ITEM

1 DC-32 The Fuel Injection System : Outline


9

of the Structure

When highly pressurized fuel should leak


from a certain joint in the passage from the fuel
injection pump to the fuel injection valve, the
leaked fuel will be recovered in the leak oil tank
through the drilled hole, fuel high pressure block
(D), the cylinder head, the push rod block, the
engine frame, and the main oil passage, and also
the high pressure line leak detector and leakage is
detected by the level switch.
(
: 5-4.2 "Inspection and Maintenance of the
Fuel Injection Valve" of the "Operation Manual")

The Fuel Injection System

9-1 Outline of the Structure


The fuel injection pump (A) is a Bosch type
having a single cylinder to be highly pressurized
with an integrated tappet.
The plunger is lubricated with lubricating oil.
Highly pressurized fuel oil is delivered from
the discharging port on the upper part of the pump
to the high pressure fuel block (D) that is made of
forged steel via high pressure fuel joint (C) of
which both ends have spherical structures, and
then introduced to the inlet connector (E) of the
fuel injection valve system fitted on the side of the
cylinder head through the drilled hole in the block.

Weight of;

Fuel Injection Pump Assembly : 65 kg

(E)
(D)
(C)
(B)
(A)

Fuel Injection System

DC-32 Z 05-12

CHAPTER

The Fuel Injection System


Consumable Replacement Parts, Special
The Fuel Injection System :
Tools and Measuring Instruments
9-2 Consumable Replacement
Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced
when maintenance is effected.
(
: "Parts List")
1. Gasket (for the camshaft cover)
2. O-ring (for the high pressure block)
3. O-ring (for the high pressure block)
4. O-ring (for the high pressure block)
5. O-rings (for the tappet)
6. O-rings (for the tappet)
7. O-ring (for the fuel oil block)
8. Gasket (for the plunger oiling pipe)

2-2
2-25
2-25
2-25
2-22
2-22
3-2.1

No.5
No.503
No.504
No.504
No.4,14
No.4,14
No.38

3-3.3

No.507

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Fuel Injection Pump Hanging Tool
(1) Fuel Injection Pump Hanging Tool
(2) Hexagon Head Bolt M24
(3) Eye Bolt M16

Delivery Valve
Assembly

9
ITEM

DC-32

Flange Tightening
Bolt
Plunger Assembly

Plunger
Chamber
Oil Retaining
Chamber
Deflector

Outlet of
Lubricating Oil

Plunger
Block
(Barrel)
Plunger

Inlet of
Lubricating Oil
Control
Sleeve

Control
Rack
Spring
Seat

Plate

Pump
Housing

Pin
Snap Ring

Plunger
Spring

Tappet Assembly
Spring
Seat

(3)
(2)

The Fuel Injection Pump and the Tappet


(1)

(b) Fuel Pump Hanging Tool

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

ITEM

3 DC-32 The Fuel Injection System : Detachment of the Fuel Injection Pump
9-3 Detachment of the Fuel
Injection System
A. Remove the camshaft cover fitted on the side of
the engine frame.
B. Turn the engine to position the tappet roller of
the fuel injection pump (A) so that it may rest on
the base circle of the fuel cam.
C. Remove the high pressure fuel block (D), the
high pressure fuel joint (C) and high pressure
fuel joint cover (B).
D. Detach the rack link pin (F).
E. Detach the fuel injection pump leak pipe (G)
and the plunger oiling pipe (H).
F. Loosen and detach the mounting nuts for the
fuel main pipe block (J) and separate it from the
fuel injection pump.
G. Detach the injection pump tightening nuts (K)
by means of a box spanner.
H. Attach the fuel injection pump hanging tool (b)
to the upper part of the fuel injection pump to
hang up the pump and take it out from the
engine.
I. Detach the fuel injection pump hanging tool.

Injection timing of each of the fuel


injection pumps is adjusted exclusively for a
specific cylinder for which it works. Identify
those detached in such a manner as described
below and pay attention to prevent a wrong one
from being installed.
1. Stamp the appropriate engine serial number
and the cylinder number on the fuel injection
pump housing and the high pressure fuel
flange.
2. The shims to be used on the mounting surface (for adjustment of base circle) should be
grouped cylinder by cylinder and a tag
should be attach to each group of shims and
the engine serial number and the cylinder
number should be entered in the tag.

(D)
(B)
(J)

(I)

(A)
(H)
(F)
(G)

(A)
(J)

(G)

(K)

(H)

Shims
(b)-(3)
(b)-(2)
(b)-(1)
(J)

Detachment of the Fuel Injection Pump

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

9
ITEM

The Fuel Injection System : Dismantling of the Fuel Injection Pump

9-4 The Fuel Injection Pump


9-4.1 Dismantling of the Fuel
Injection Pump
The fuel injection pump is a delicate
component that is very precisely manufactured.
Even a microscopic foreign matter
may cause stick of or damage to such parts as
the plunger and the delivery valve.
Pay the most closest attention so that
any foreign matters may not attach to or penetrate into the parts when effecting their dismantling or assembling.
(1) Hold the fuel injection pump between the jaws
of a vise with the tappet assembly (a) facing
upward.
(2) Push the tappet into the plunger barrel by
means of a gear puller or some other tool until
the outside end of the tappet reaches a position
deeper in the plunger barrel than the position of
the pin (b), and detach the snap ring at the pin
(b), then screw a bolt (M6 x 20) in the pin (b) to
remove the pin.
(3) Slowly loosen the gear puller and remove it.

Since force of the plunger spring (e) is


added on the tappet, slowly loosen the puller to
prevent the tappet from being ejected.
(4) Slowly take out the tappet assembly (a)
together with the plunger (c) and the spring
seat (d).
(5) Remove the plunger spring (e).
(6) Remove the control sleeve (f) together with
the spring seat (g) and the plate, and then pull
out the control rack (h).
(7) Detach the fuel injection pump from the vise
and hold it again between the jaws of the vise
as the pump's top and bottom being turned
over.
(8) Remove the deflector (l).
(9) Draw scribed lines on the delivery valve and
the flange (n). (to prevent misassembling)
(10) Remove the socket head bolts.

Delivery Valve
Assembly (k)
Flange (n)

DC-32

4.1

Flange Tightening
Bolt (m)
Plunger Assembly

Plunger
Chamber
Oil Retaining
Chamber
Deflector
(l)

Plunger
Block (i)
Plunger (c)

Inlet of
Lubricating Oil

Outlet of
Lubrication Oil

Control
Sleeve (f)
Control
Rack (h)

Plate

Spring
Seat (g)

Plunger
Spring (e)
Pin (b)
Snap Ring

Pump
Housing (j)

Tappet
Assembly (a)

Spring
Seat (d)

Fuel Injection Pump

Socket Head Bolt


Scribed Lines
Flange Tightening
Bolt

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

ITEM

4.1 DC-32 The Fuel Injection System : Dismantling of the Fuel Injection Pump
(11) Remove the flange tightening bolts (m).
(12) Remove the flange (n).
(13) Remove the delivery valve holder and take
out the delivery valve assembly (k).

1) Replace the delivery valve as an assembly


status at the same time when replacing the
plunger assembly.
2) Since the lower surface of the delivery valve
holder and the upper surface of the plunger
barrel are machined and finished very precisely to seal highly pressurized oil, pay
attention not to damage the surfaces when
handling them.
(14) Pulling out the plunger block (i).
When it is too tight to easily pull out, push
it out by knocking the opposite end with a hammer with a plastic bar or a wooden block being
put on the knocked side of the plunger block.

1) The plunger (c) and the plunger block (i)


should be handled as a pair. Selective
matching is used for these two parts, so a
specific plunger can not be used with other
plunger block than paired one, and vice
versa.
2) Dismantled parts of a pump should be classified pump by pump to prevent them from
being mixed with those of the other pumps.

DC-32 Z 05-12

Flange

Delivery Valve Holder

Upper surface of
the Plunger Barrel

CHAPTER

The Fuel Injection System

9
ITEM

The Fuel Injection System : Inspection and Maintenance of Fuel Injection Pumps

DC-32

4.2

9-4.2 Inspection and Maintenance of


the Fuel Injection Pump
Plunger Barrel
Since the engine parameters that may
be adjusted in accordance with the instruction
described in this section are to be
checked with the engine parameters certified in
accordance with the NOx Technical Code, do
not change any of these parameters in such a
manner that its value deviates from the certified
range of adjustment.
(
: 0-3 "Engines Conforming to the NOx
Technical Code")
(1) Wash each of components dismantled with
washing oil and blow it by air.
(2) Check whether or not there is cavitation corrosion on the plunger, the plunger block (barrel)
and the deflector.
When the cavitation corrosion is too bad,
replace the component with new one.

Deflector
Plunger

The Plunger, The Barrel and The Deflectors

Replace the plunger assembly, delivery valve assembly and the plunger spring
every 16,000 - 24,000 hours (4 - 5 years) even
when no irregularities are found.

Standard Clearance

Replacement Limit

(mm)
C = 100

(mm)
c = 0.04 - 0.13

(mm)
0.25

(4) Touch the tip of a dial gauge to the surface of


the tappet roller and measure the bearing
clearance while the roller is moved up and
down.
Nominal Diameter

(mm)
B = 45

Standard Clearance

(mm)
b = 0.06 - 0.10

Replacement Limit

(mm)
0.20

Nominal Diameter

(3) Measure the I.D. of the tappet and calculate


the tappet clearance.

Tappet Clearance and Roller Bearing Clearance

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

ITEM

4.3 DC-32 The Fuel Injection System : Assembling of the Fuel Injection Pump
9-4.3 Assembling of the Fuel
Injection Pump

Grease

Handle the components with bare


hands without gloves when assembling the fuel
injection pump so that any foreign matters or
dust may not stick to them.
Assembling of the fuel injection pump
should be effected in the reverse sequence of that
for dismantling.
(1) Hold the pump housing (j) between the jaws of
a vise as the end of the pump housing on
which the delivery valve is fitted faces upwards.
(2) Thinly apply grease to the part of the pump
housing (j) with which the o-rings fitted on the
plunger block (barrel) contact.
(3) Lightly bend each of the backup rings inwards
with care not to break it so that it may closely
contact with the groove of the plunger block. (to
prevent the backup ring from being broken)

Pump Housing

Application of Grease to the Inside of the Housing


To the upper side

To the upper side

To the upper side

To the lower side

(4) Fit the o-rings (new parts) and the backup


rings on the plunger block (i) and thinly apply
grease to them. Fit the backup rings in such a
manner that the closed gap of a backup ring is
positioned 180 apart from the closed gap of
the other backup ring.
Closed gap

(5) Push the o-ring and the backup rings against


one side of the groove as shown in the illustration. (to prevent the backup ring from being
broken)

Backup Ring
O-ring

Backup Ring

Points of Fitting of the Backup Rings and the O-rings

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

9
ITEM

The Fuel Injection System : Assembling of the Fuel Injection Pump

(7) Insert the plunger block into the pump housing


while making certain that the set screw hole in
the plunger barrel and the hole in the pump
housing align.
(8) Apply Molykote 1000 to the threads and the
seating surfaces of the flange tightening bolts
(m).
(9) Install the flange on the upper surface of the
plunger barrel so that the holes in the flange
and the tapped holes in the pump housing may
be aligned, and insert and screw the two flange
tightening bolts and slowly tighten them alternately while inserting the plunger barrel into the
pump housing. Loosen the two flange tightening bolts.
(10) Screw the socket head bolts in the plunger
barrel (two bolts). Turn the plunger barrel by
means of the socket head bolts to align the
hole in it for the set screw and the hole in the
plunger housing. And then, remove the socket
head bolts.
(11) Put the set screw in the hole.

Plunger Barrel

DC-32

4.3

Hole for the set screw


Position of the hole in which
the set screw is inserted

Alignment of the Plunger Block and the Pump Housing

Parts of the bolt to which


Molykote 1000 is to be applied

Molykote 1000

Application of Molykote 1000


Specified Torque : 15 - 20 N.m

9
Thread Hole

Flange

Socket Head Bolt (2 pcs.)


Position of the hole
for the Set Screw
Position of the
hole in which the
set screw is
inserted

Insertion of the Plunger Block

Adjustment of the position of the Plunger Block

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

9
ITEM

4.3 DC-32 The Fuel Injection System : Assembling of the Fuel Injection Pump
(12) Diagonally and alternately tighten the flange
tightening bolts in the sequence as shown in
the right illustration with the tightening torque
being gradually increased up to the specified
torque.

Specified torque : 177 - 196 N.m


(13) Install the delivery valve spring and the
return spring in the plunger barrel, and fit the
discharge valve, delivery valve spring and the
spring seat in the return valve.
(14) Fit the locating pins in the holes located on
the upper surface of the plunger barrel, and
install the delivery valve holder in the plunger
barrel aligning the pins and the holes in the
delivery valve holder.
(15) Apply Molykote 1000 to the threads and the
seating surfaces of the socket head bolts, and
alternately and evenly tighten the socket head
bolts as shown in the illustration below to fasten the delivery valve holder. And make certain
that the scribed line on the delivery valve holder is at the same level as the upper surface of
the flange, then finally tighten the bolts with the
specified torque.

7
5

Plunger Barrel

Delivery Valve
Spring
Discharge
Valve
Delivery Valve
Spring

Spring Seat

Return
Valve

Specified torque : 137 - 157 N.m

Installation of the Delivery Valve

Delivery Valve Holder

3
5

6
4

Pin (2 pcs.)

Sequence of Tightening of
the Socket Head Bolts

Installation of the Delivery Valve Holder

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

9
ITEM

The Fuel Injection System : Assembling of the Fuel Injection Pump

(16) Fit the o-ring (new part) in the groove of each


deflector (l), thinly apply grease to the o-rings
and tighten the deflectors to the pump housing.

DC-32

4.3

Deflector

Specified torque : 118 - 137N.m


(17) Detach the fuel injection pump from the vise,
turn it over and then again hold it between the
jaws of the vise. Apply grease to the control
rack (h) and insert it into the pump housing.
(18) Engage the end part of the gear teeth of the
control sleeve (f) with the end part of the gear
teeth of the control rack (h), and insert the control sleeve (f) into the pump housing.
(19) Install the upper spring seat (g) on the outer
surface of the control sleeve (f) and install the
plunger spring (e) on it.
(20) Install the plunger (c) on the lower spring
seat (d).
(21) Insert the plunger (c) into the plunger block
(i) with the flange of the plunger being fitted in
the cut of the control sleeve (g). Insert the
plunger with "Z" mark on its flange facing the
opposite side of the side on which the control
rack is fitted.
(22) Insert the tappet in the pump housing with its
guide being mated in the groove in the pump
housing.
(23) Install the pin (b) and the snap ring while
pushing the tappet by means of a gear puller or
some other tool.
(24) Make certain after completion of the assembling that the rack smoothly moves and that the
zero point is positioned on the correct point.

O-ring

Installation of the Deflector

Control Rack

Stand

Insertion of the Rack

Control Sleeve
Control Rack

Insertion of the Control Sleeve


Plunger
Flange
portion

Control Sleeve

"Z" match mark

A Match Mark on the Plunger

Insertion of the Plunger and the Tappet

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

ITEM

5 DC-32 The Fuel Injection System : Installation of Fuel Injection Pumps


9-5 Installation of the Fuel Injection
Pump
A. Make certain that the tappet roller sits on the
base circle of the fuel cam.
B. See the cylinder number and install the shim(s)
on the fuel injection pump mounting stud bolt.
C. Attach the fuel injection hanging tool (b) to the
fuel injection pump (A) and hang it up by wire
rope to set the fuel injection pump on the
mounting position of the engine frame.
D. Tighten the pump tightening nuts (K) by means
of a box wrench.
Pump Housing

Specified torque : 265 N.m

Shims

Make certain that the tappet roller contacts with the cam profile with its whole width
(end of the roller does not protrude from the
fuel cam).
E. See the height of the fuel injection pump as
installed.
(1) Make certain that the scribed line "Y" on the
tappet just and the installation position reference line "Z" on the pump housing aligns each
other when the tappet roller sits on the base
circle of the cam.
(2) When adjustment of the height is necessary,
do it with the shims (the standard height : 0.5
mm).
Put the scribed line "Y" above the installation
position reference line "Z": Decrease number
(thickness) of shims  Injection timing is
advanced.
Put the scribed line "Y" below the reference line
"Z" : Increase number (thickness) of the shims
 Injection timing is retarded.

Cylinder Head
"X" indicating the position
of static point of injection start

Installation position
reference line "Z"

Camshaft

Scribed line "Y"


on the Tappet

Height of the Fuel Injection Pump as Installed


Thickness of the Shim (
: "Parts List")
0.1 mm
3-23.1
No.12
0.5 mm
3-23.1
No.13

Effect the adjustment when the tappet


roller sits on the base circle of the fuel cam.

DC-32 Z 05-12

CHAPTER

The Fuel Injection System

9
ITEM

The Fuel Injection System : Installation of Fuel Injection Pumps DC-32


F. Paste the o-rings (Q) and (R) to which grease is
applied to the high pressure fuel joint cover (B),
and then install it on the fuel outlet of the fuel
injection pump.
G. Insert the high pressure fuel joint (C) into the
high pressure fuel joint cover (B).

(E) (P)

(L)

(O)

Install the high pressure fuel joint on


the same position of the high pressure fuel joint
cover where it was originally installed according
to the identification mark on it.
H. On the high pressure fuel block (D) install the oring (P) to which grease is applied.
I. Install the high pressure fuel block (D).
Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surfaces of the mounting bolts (L) and (O), and alternately tighten
them with the specified torque while adjusting
the positions so that the fuel block may be well
fitted to both of the cylinder head and the fuel
injection pump.
(
: 5-4.2 "Installation of the Fuel Injection
Valve" of the "Operation Manual")

(Q)
(R)

(D)

(C)
(B)

Installation of the High Pressure Block

Specified torque
Cylinder Head side
Fuel Injection Pump side

:
:

147 N.m
196 N.m

J. Install the rack link pin (F) and equalize the rack
amount through the fuel injection pumps.
(
: 5-3.1 "Adjustment of Pump Rack Amount
of the Fuel Injection Pump" of the "Operation
Manual")
K. Fix the main fuel pipes (I) and (J) with the
mounting bolts.
L. Install the fuel injection pump leak pipe (G) and
the plunger oiling pipe (H).
M. Check the fuel injection timing.
(
: 8-2.6 "Inspection of the Fuel Injection
Timing")
N. Install the camshaft cover.
O. Effect oil priming after completion of the installation and also air bleeding by
loosening the deflectors.
(
: 4-2.2 (5) "Priming and Air-Bleeding of
Fuel Oil" of the "Operation Manual")

DC-32 Z 05-12

CHAPTER

The Valve Train


Outline of the Structure/Consumable Replacement
1,2 DC-32 The Valve Train : Parts, Special Tools and Measuring Instruments
10

ITEM

10 The Valve Train


Cylinder Head

10-1 Outline of the Structure


The valve train mechanism has two swing
arms per cylinder each of which has a roller follower (tappet roller) and both the intake and the
exhaust systems have this mechanism in common.
Lifts of the intake and exhaust cams are
transmitted to the intake and the exhaust valves
respectively via the tappet rollers, the swing arms,
the push rods, rocker arms and the T yokes.
The bearing bushing is press-fitted in the
tappet roller and pivots on the tappet roller pin that
is press-fitted in the swing arm.
Lubricating oil is fed to the pivot of the swing
arm and the tappet roller shaft via drilled hole in
the engine frame, the swing arm shaft fixing bolt
and the drilled holes through the swing arm shaft
and the swing arm.
A ring knock is press-fitted in the shaft to
maintain parallelism between the tappet roller and
the contact surface of the cam.

Push Rod
Push Rod
Block
Push Rod
Seat

Swing Arm
Camshaft Cover

Camshaft Cover
Tappet Roller Pin

Weight of ;
Swing Arm Assembly : 27.5 kg
Tappet Roller

10-2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
1. Seal (for the cylinder head cover) 2-17
2. Gasket (for the camshaft cover) 2-2

No.3
No.5

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

DC-32 Z 05-12

Valve Train

Camshaft

CHAPTER

The Valve Train

10
ITEM

The Valve Train : Dismantling, Inspection and

DC-32

Maintenance of the Valve Train

3,4

10-3 Dismantling of the Valve Train

A. Remove the cylinder head cover and detach


the rocker arm assembly and the push rods.
B. Detach the camshaft cover installed on the side
of the engine frame.
C. A little lift the center of the swing arm shaft by
means of a wire rope.
D. Detach the swing arm shaft bolts (A), and slowly remove the swing arm assembly from the
engine frame.

Remember that the swing arm rotates


on the swing arm shaft when the tappet roller of
the swing arm gets lost contact with the
camshaft and carefully handle it.

Swing Arm Assembly


E. Write the engine serial number and the cylinder
number on the parts concerned with a marker
pen.
F. Remove the snap ring (B) and detach the swing
arm (C) from the swing arm shaft (D).

10-4 Inspection and Maintenance of


the Valve Train

(A)

A. Wash each component with washing oil.

10

(D)
Pay attention to prevent dust or foreign
matters from penetrating in the oil holes of the
parts.
B. Check whether or not any flaw or unusual contact mark is found on the sliding parts of the
swing arm shaft (D) and the swing arm (C).
C. Check whether or not any flaw or unusual contact mark is found on the outer surface of the
tappet roller (E).
D. Check whether or not any flaw or unusual contact mark is found on the push rod seat (surface
contacting with the push rod) of the swing arm
(C).
E. Put the tip of a dial gauge on the upper surface
of the tappet roller (E) and measure the radial
clearance between the tappet roller pin (F) and
the tappet roller bushing (G) with the tappet
roller being moved up and down.

(B)

(B)
(C)

Push Rod Seat

Inspection of the Swing Arm Shaft


and the Swing Arm

DC-32 Z 05-12

CHAPTER

The Valve Train

10
ITEM

Inspection and Maintenance/


4,5 DC-32 The Valve Train : Assembling of the Valve Train

Nominal diameter

Standard axial clearance

Replacement limit

(mm)
B = 35

(mm)
b = 0.03 - 0.11

(mm)
0.2

(E)

Too much axial clearance causes


increase in the valve clearance to change the
valve timing and to result in deterioration of the
engine performance.
When measurement exceeds the
replacement limit, replace the swing arm
(together with the roller) by new one.

10-5 Assembling and Installation of


the Valve Train
A. Install the swing arm on the swing arm shaft
with the oil holes of the swing arm (C) and the
swing arm shaft (D) being aligned.

(G)

(F)

(E)

Measurement of Radial Play of


the Tappet Roller Bushing

Oiling Hole
(C)
See that the cylinder number written
on the parts is correct one before assembling
to prevent a part of the other cylinder from
being assembled by mistake.
B. Install the snap ring (B).
C. Install the swing arm assembly on the engine
frame while aligning the ring knock and the
mating hole of the engine frame.

A hole is tapped in the side of the


seating surface for the bolt (A) of the swing arm
shaft for directional identification. See that it is
located on the right side (rearwards of the
engine).
D. Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surfaces of the swing
arm shaft bolts (A) and tighten them with the
specified torque.

Specified torque : 490 N.m

DC-32 Z 05-12

Oiling Groove

(D)

Oiling Holes in the Swing Arm


(C)

(B)
(A)

Tapped Hole for


Identification

Installation of the Swing Arm Shaft

CHAPTER

The Valve Train

MEMO

10
ITEM

DC-32

10

DC-32 Z 05-12

CHAPTER

The Governor Driving Device


The Governor Outline of the Structure/Consumable Replacement
1,2 DC-32 Driving Device : Parts, Special Tools and Measuring Instruments
11

ITEM

11 The Governor Driving Device

Weight of ;

Governor (UG 40)


: 45 kg
Governor Driving Device Assembly : 25 kg

11-1 Outline of the Structure


This governor is a hydraulic type governor
and controls amount of fuel to be injected through
control of displacement of the rack in the fuel injection pump via the common rod corresponding to
variation of the load and the engine rpm.
The governor driving device that is fitted on
the front end of the engine consists of a pair of
bevel gears driven by the camshaft, and drives the
governor via spline coupling.
Since the governor mount is mounted on the
gear case with a pin locating the position after
backlash of the bevel gears has been adjusted in
the factory, adjustment of the backlash is not to be
effected in a usual inspection or maintenance.
Each of mating surfaces between the gear
case and the governor mount and between the
governor mount and the mounting surface of the
governor is sealed with a gasket.
How to handle the governor itself, refer to
another manual provided.
(
: "Instruction Manual for the Governor")

11-2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Gasket (for the governor fitting)
2-27 No.11
2. Gasket (for the governor mount) 2-27 No.12
3. Bearing
2-27 No.501
4. Split Pin
2-27 No.506
5. Gasket (for the governor oiling pipe) 3-3.5 No.502
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instrument
(
: 2-2)

Governor Lever (A)


Link Pin (B)

Governor

Control Lever

Terminal Shaft

Common Rod Lever


Common Rod

Governor Link

DC-32 Z 05-12

CHAPTER

The Governor Driving Device


The Governor Detachment and Dismantling/Inspection
Driving Device : and Maintenance/Assembling
11-3 Detachment and Dismantling of
the Governor
A. Detach the governor Lever (A) and the link pin
(B) that are connected to the governor.
B. Detach the governor oiling pipe.
C. Detach the governor booster pipe.
D. Remove the governor mounting nuts (C) and
detach the governor.
E. Remove the cover installed on the cam gear
side and feel how the backlash between the
governor driving gear (F) and the governor driven gear (G) is.

Backlash

Standard backlash

Replacement limit

(mm)
0.1 0.15

(mm)
0.3

F. Remove the governor mount mounting bolts (D)


and detach the governor driving device assembly.
G. Remove the split pin (K) and the nut (L), and
detach the governor driven gear (G) and then
take out the key.
H. Pull out the governor driving shaft (M), and take
out the bearing (P) and the distance piece (Q).
I. Pull out the taper pin (N) and take out the spline
coupling (O).
J. Detach the governor driving gear (F) when necessary.
(
: 8-2.3 "Dismantling and Detachment of the
Camshaft")

11-4 Inspection and Maintenance of


the Governor Driving Device
A. Wash each of the dismantled parts with washing oil.
B. Assuredly remove liquid sealant stuck to the
parts with care not to damage their surfaces.
C. Check whether or not any unusual wear or flaw
is found on the tooth-flanks of the drive and
driven gears.
D. Check whether or not any fretting is found on
the portion of the governor driven gear (G) on
which the bearings are fitted.
E. Check whether or not any unusual wear or flaw
is found on the tooth-flanks of the spline coupling (O).

11
ITEM

DC-32

3,4,5

Governor
(C)

(D)

(F)

(Q)
(M)

(O)
(E)
(N)
Oiling hole for
the governor
driving device

(P)

(G)
(L)
(K)

Governor Driving Device

11-5 Assembling of the Governor


Driving Device
A. Assembling of the governor driving device is to
be effected in the reverse sequence of that for
the dismantling.
(1) The bearings should be replaced by new ones
and be installed as grease is applied to them.
(2) The gaskets fitted between the mating surfaces of the gear case and the governor mount,
and between the mating surfaces of the governor mount and the governor should be replaced
by new ones when effecting the assembling.
B. Check the following items after the assembling.
(1) Make certain before the governor mount
assembly is installed on the gear case that the
governor driven gear smoothly rotates.
(2) Check by feeling of the hand after the governor mount assembly is installed on the gear
case while aligning the pin and the mating hole
whether or not the backlash is within the normal range.

DC-32 Z 05-12

11

CHAPTER

The Intake and Exhaust System


Outline of the Intake and Exhaust
The Intake and
1,2 DC-32 Exhaust System : System/Turbocharger
12

ITEM

12 The Intake and Exhaust


System
12-1 Outline of The Intake and
Exhaust System
High temperature and high pressure
exhaust gas emitted from the cylinders is introduced to the turbocharger through the exhaust
manifold, and part of its energy is transferred to
the intake pressure and thus recovered by the turbocharger.
High temperature air compressed by the turbocharger is passed through the intercooler to be
cooled and introduced to the intake duct arranged
in the engine frame.
The turbocharger and the intercooler are
installed on the front end of the engine.
The exhaust manifold and the intake duct
are located in the same side of the engine and the
intake duct is integrated in the engine frame.

12-2 The Turbocharger


Since each of the parts referred to in
this section is subject to the regulation of the
NOx Technical Code, always use a part on
which the identification is stamped.
(
: 0-3 "Engines Conforming to NOx
Technical Code")

Turbocharger

Exhaust
Manifold

Lubricating Oil
Cooling Water

Pre-Air
Filter

Cooling Water
Bypass Valve
Intake
Air

Cooling
Water
Intake Manifold
(integrated in the
engine frame)

Exhaust
Gas

From other
cylinders

Cylinder Head

To other
cylinders

The Intake and Exhaust System

DC-32 Z 05-12

Weight of ;

Turbocharger : TPL65 : 296 kg

12-2.1 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Gasket (for the inlet of lubricating oil)

3-3.2

No.

2. Gasket (for the outlet of lubricating oil)

3-3.2

No.

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(

: 2-2)

Intercooler

Flexible Joint
Exhaust Gas

Flexible
Joint

Lubricating oil is fed to the turbocharger to


lubricate its bearings.
The lubricating oil is the same one as the
system oil of the engine and is returned to the gear
case after it has lubricated the bearings.
For its handling, dismantling and maintenance, refer to other instruction manual separately
provided.

The turbocharger becomes very hot


for some period of time immediately after the
engine stops, so wait until it is enough cooled
and detach it when it is necessary for its
inspection and/or maintenance.
In case that it has to be detached
during the time when it is still hot, always wear
safety gloves and work with it very carefully to
avoid a burn.

CHAPTER

The Intake and Exhaust System

12
ITEM

The Intercooler :

Outline of the Structure/Consumable Replacement Parts,


DC-32 3.1 - 3.3
Special Tools and Measuring Instruments/Detachment
12-3.3

12-3 The Intercooler


12-3.1

Outline of the Structure

The intercooler is a multi-fin-tubular type


box-shape device and installed on the gear case.
The intercooler has a two-stage cooling system (in such a manner that cooling water flows
through only the high temperature side when the
load is light while it flows through both of the high
temperature and the low temperature when the
load is heavy), and the cooling water is controlled
by cooling water bypass valve corresponding to
the load (boost pressure).
Weight of ;

Intercooler

DDB207XBLF :

980 kg

12-3.2 Consumable Replacement


Parts, Special Tools and
Measuring Instruments
A. Consumable Replacement Parts
The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Intercooler (I/C) Gasket

2-30

No.9

3. I/C Inlet Duct Gasket

No.29

4. Rubber Seal (I/C Cooling Water Outlet)

No.28

6. Consumable parts used inside the I/C (

A. Remove the I/C inlet duct cover (A).


B. Detach the flexible joint (C).
C. Attach the eye bolt M16 to the I/C inlet duct
(B), pass the wire rope through it and loosen
the mounting bolts (D) to detach the duct while
lifting the duct a little.
D. Attach the eye bolt M16 to the I/C outlet duct
(E), pass the wire rope through it and remove
the mounting bolts (G) and the bracket (F) while
lifting the duct a little, and finally detach the
duct.
E. Remove the turbocharger and the turbocharger
mounting bracket.
F. Attach the eye bolt M24 (c) to the upper part of
the intercooler, pass the wire rope through it
and detach the intercooler mounting bolts (I)
while lifting the intercooler by means of a chain
block.
G. Detach the intercooler from the gear case and
bring it down on the designated place.

Falling off of an object during hanging


up presents very dangerous situation.
Assuredly screw up the eye bolt until the seating surface of the eye bolt completely contact
the surface of the object to be hung up and
strictly follow the operation standards for the
wire rope.

No.8

2. Blower Outlet Gasket

5. O-ring (for the connecting duct)

Detachment of the Intercooler

Engine Frame

12

(J)

Turbocharger
Turbocharger Bracket

(E)
(F)

No.32
"Parts List")

(c)

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(

: 2-2)

(C)

(I)

(b) Eye Bolt M16


(c) Eye Bolt M24

(E)

(A)

(d) Nylon Brush

(B)

(e) Neutral Cleanser


(f) I/C Puller (optional)

(G)

(I)

(D)
Intercooler

Detachment of the Intercooler

DC-32 Z 05-12

CHAPTER

12

The Intake and Exhaust System

ITEM

3.4,3.5 DC-32 The Intercooler : Inspection and Maintenance/Installation


12-3.4

Inspection and Maintenance


of the Intercooler

Since each of the parts referred to in this


section are subject to the regulation of the NOx
Technical Code, always use a part on which
the identification is stamped.
(
: 0-3 "Engines Conforming to NOx
Technical Code")

The intercooler shall be detached from the


engine whenever its maintenance is carried
out. If the maintenance is effected with the
intercooler being installed on the engine, the
removed scale may be allowed to flow into the
engine causing its malfunction due to wrong
maintenance.

A. Remove the water chamber covers on both


sides to remove scale stuck to the chamber.
B. Clean the inside the cooling pipes with nylon
brush. Wash the inside of the pipes with fresh
water after brushing.
C. Eliminate the stains on the air side by blowing
air on them.
In case the degree of stain is significant, disconnect the water chamber, and remove the
stain by immersing the plate-fin tube assembly
in sulphamic acid.
After eliminating the stain, wash with clean and
fresh water, and sufficiently dry the assembly
promptly.

To be minded to use the sulphamic acid


cleaning agent.
In order to secure stable engine performance,air cooler should be checked and cleaned
according to the maintenance / cleaning schedule ( 4000~6000 hr ).

DC-32 Z 05-12

12-3.5

Installation of the Intercooler

Clean the cooling water inlet and the outlet on


the gear case for the intercooler (4 locations), and
attach the rubber seal, then install the intercooler
in the reverse sequence of that for its detachment.

CHAPTER

The Intake and Exhaust System

MEMO

12
ITEM

DC-32

12

DC-32 Z 05-12

CHAPTER

The Starting Air System

13
ITEM

1 DC-32 The Starting Air System : Outline of the Starting Air System
13 The Starting Air System
13-1 Outline of the Starting Air
System
Starting of the engine is effected by compressed air controlled by the pilot and the starting
air valve.
Air used to rotate the engine is highly pressurized to 2.0 - 3.0 MPa while air used to control
the system is pressurized to lower pressure of 0.6
- 0.9 MPa.
The engine control lever, the starter push
button and the main air staring valve are installed
at the front end of the engine while the starting
rotary valve is installed at the rear end of the
engine. And a check valve and a safety valve are
installed at the outlet of the starting air valve to
protect the engine in case that reverse flow of
combusted gas happens.
Pushing of the local starter push button or

another starter push button on the console (monitoring panel) activates the control air magnetic
valve to introduce the control air into the main air
starting valve making the main valve open to let
the compressed air reach the starting valve at the
cylinder head.
On the other hand, compressed air
branched from the main starting air pipe is sent
from the starting air rotary valve to each cylinder in
accordance with the designed ignition sequence to
open the starting valve and to push the piston
down finally causing rotation of the engine.
In case of automatic starting, the control
magnetic valve is opened in accordance with programmed sequence to start the engine.
In such an emergency as loss of the power
supply, engine can be started in such a procedure
that a lever is fitted on the upper part of the main
air starting valve to directly open the main air starting valve. (
: 4.3.1 "Starting Method" of the
"Operation Manual")

Cylinder Head

Starting Air
Rotary Valve

Starting
Valve

Starting Lever
(for emergency use)

Control Air
Main Air
Starting Valve

Main Starting Air Piping


Safety Plug
Check Valve

Starting Air Reservoir

Starting Air System

Starter Push
Button

CHAPTER

The Starting Air System


The Main Air Outline of the Structure/Dismantling/Consumable
Starting Valve : Replacement Parts, Special Tools and Measuring
13-2 The Main Air Starting Valve
13-2.1

Weight of ;

Main Air Starting Valve Assembly : 25kg

Dismantling of the Main Air


Starting Valve

A. Detach the piping connected to the starting air


inlet and the outlet and to the control air inlet,
then detach the main air starting valve assembly from the heat box front cover.
B. Dismantling of the main air starting valve is to
be effected in accordance with the procedure
as describe below.
(1) Detach the mounting bolts (A) and remove the
upper cover (B).
(2) Remove the split pin (C) and the nut (D) on
the valve shaft and detach the piston (E) and
the spring (F).

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected,
(
: "Parts List")
1.Valve

3-1.3

No.3

2.Split Pin

3-1.3

No.7

3.O-rings

3-1.3

No.503 - 510

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

(C)
(D)

Since the piston compresses the


spring, effect this work with care not to let the
spring be ejected when dismantling the valve.

(H)
(I)
(S)
(Q)

(3) Remove the cylinder (G).


(4) Remove the snap ring (H) and then detach the
key retainer (I) and the key.
(5) Detach the piston (J) and pull out the valve
shaft (K).
(6) Remove the split pin (L) and the nut (M) and
then detach the valve seat (N), the valve (O)
and the valve clamp (P) from the valve shaft
(K).
(7) Remove the cover (Q) and take out the spring
(R) and the check valve (S).

DC-32 2.1 - 2.3

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

Outline of the Structure

The main air starting valve is a valve operated by low pressure control air sent from the starting magnetic valve and controls feeding of pressurized starting air to the engine during starting of
the engine.

13-2.3

13-2.2

13
ITEM

(A)
(B)

(E)
(F)
(G)

13

(R)

(J)

(K)
(P)
(O)
(N)
(M)

Main Air Starting Valve Assembly (L)

DC-32 Z 05-012

CHAPTER

13

The Starting Air System

ITEM

2.4,2.5 DC-32 The Main Air Starting Valve : Inspection and Maintenance/Assembling
13-2.4

Inspection and Maintenance


of the Main Air Starting Valve

(1) When rust grows, completely remove it with


fine sandpaper.
Assuredly drain water from the appropriate devices and piping on the daily maintenance to prevent them from being rusted.
(2) Wash each dismantled parts with clean washing oil and blow it by air.
(3) Check whether or not any unusual contact
mark or flaw is found on the pistons (E) and (J).
(4) Check whether or not any unusual contact
mark or flaw is found on the check valves (S)
and (R) and seating surface of the valve body.
(5) Check whether or not any flaw is found on the
springs (F) and (R).

13-2.5

Assembling of the Main Air


Starting Valve

(1) Lightly apply silicon grease to the valve, orings, seating surfaces and other sliding parts
before starting the assembling.
(2) Assemble the main air starting valve in the
reverse sequence of that for its dismantling.
(3) Install the main air starting valve on the heat
box front cover and then mount the piping.

Completely flash the piping before its


installation to remove dust and residual water
to be drained. Pay attention not to let sealant or
any others stick to the parts during the work.

DC-32 Z 05-12

CHAPTER

The Starting Air System

13

Outline of the Structure/Consumable Replacement parts, Special Tools


The Starting
Air Rotary Valve : and Measuring Instruments/Dismantling/Inspection and Maintenance

13-3 The Starting Air Rotary Valve


13-3.1 Outline of the Structure
The starting air rotary valve is a valve to distribute the pilot air to each of the starting valves of
the cylinders to activate them according to the
sequence of ignition and is driven via the rotary
valve coupling (Oldham's coupling) attached on
the rear end of the camshaft located at the rear
end of the engine.
Weight of ;

Starting Air Rotary Valve : 24 kg

13-3.4

DC-32 3.1 - 3.4

Inspection and Maintenance


of the Starting Air Rotary
Valve

(1) Wash each of the dismantled parts and blow


each of them by air.
(2) Inspect the conditions of the rotary valve
bushing (H) in terms of flaws and wear.
Measure the O.D. of the rotary valve shaft and
the I.D. of the bushing to calculate the radial
clearance between them.
Nominal diameter

(mm)
A = 30

13-3.2

ITEM

Standard radial play

Replacement limit

(mm)

(mm)

= 0.01 - 0.10

0.20

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following part should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Gasket (for the rotary valve body)

3-1.4

No.8

2. Gasket (for the rotary valve body)

3-1.4

No.9

3. Gaskets (for the rotary valve body)

3-1.4

No.505.506

4. Gaskets (for the piping)

3-1.1

No.510.511

Too much wear of the bushing may


allow lubricating oil to penetrate into the starting air pipe to make the starting difficult. In
such a case, replace the bushing by new one.

(K)
(E)

(H) (D)

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

Dismantling of the Starting


Air Rotary Valve

(1) Remove the piping connected to the inlet and


the outlet of the starting air.
(2) Remove the mounting bolts (L) and detach the
rotary valve cover (B) and the gasket (C).
(3) Pull out the rotary valve (D).
(4) Remove the bolts (M) and detach the rotary
valve body (E), the rotary valve body gasket (F)
and the shim (J).
The knock pin on rotary valve body (E) is for
positioning. It is located on the upper part only.
(5) Take out the rotary valve joint (G).
(6) Detach the rotary valve mount (K).

13-3.3

(B)

(I)
(G)

(L)
(C)
(M)
(F)
(J)
(N)

Starting Air Rotary Valve

DC-32 Z 05-012

13

CHAPTER

13

The Starting Air System

ITEM

3.4,3.5 DC-32 The Starting Air Rotary Valve : Inspection and Maintenance/Assembling
(3) Check whether or not any burr on the rotary
valve or the seat of the rotary valve body, or a
flaw made by foreign matters caught between
the rotary valve and the rotary valve body is
found. When the flaw reaches a hole connected to a cylinder, rectify it by machining and finishing, and remove a burr by a file or a scraper
when it is found.
(4) Check whether or not wear is found on the
rotary valve (D), or the fitting part of the rotary
valve joint (G) and the camshaft (I) the both
parts are engaged or fitted each other.

Too much wear of the fitting part may


cause retardation of the valve timing resulting
in difficult starting of the engine. In such a case,
replace the rotary valve or the rotary valve joint
by new one.

13-3.5

Assembling of the Starting


Air Rotary Valve

Assembling of the starting air rotary valve is


to be effected in the reverse sequence of that for
dismantling.
(1) Wash the rotary valve and the rotary valve
body, then apply lubricating oil to the seating
surfaces and the shaft.
(2) When inserting the rotary valve into the rotary
valve body, effect it so that the air hole of the
rotary valve and the air hole in the valve body
for the cylinder in the ignition stroke may be
aligned. When both holes can not be aligned,
rotate the rotary valve 180 degrees, then again
try to insert the rotary valve.

Since misinstallation of the rotary


valve causes impossibility of engine start,
assemble it with care.
(3) Install the piping.

DC-32 Z 05-12

No4
No7
No6
No8

Direction of the
engine revolution

No1
No3
No2
No5
The Procedure for Assembling of the Rotary Valve

CHAPTER

The Starting Air System

13
ITEM

The Starter Push Button and the Handle Switch : Outline of the Structure

DC-32

4.1

13-4 The Starter Push Button and


the Handle Switch
13-4.1

Outline of the Structure

When the starter push button is manually


operated, the control air magnetic valve is actuated to allow the low pressure control air to be introduced in the main starting air valve to let the main
air starting valve operate.
The handle switch is a limit switch linked
with the control lever. The control lever shifted to
the operation position turns the switch on.

Governor
Handle Switch
Control Handle
Starter Push Button

Do not dismantle the starting control


valves and the handle switch. When any of
them gets incapable to work well, replace it by
the assembly.

The Starter Push Button and The Handle Switch

13

DC-32 Z 05-012

CHAPTER

Fuel Oil System

14
ITEM

1 DC-32 The Fuel Oil System : Outline

manual or the instruction manual separately provided.


(
: 2-2.2 "Fuel Oil System" of the "Operation
Manual")
- Fuel Oil Filter
(
:5-4.3 "Washing of the Fuel Oil Filter" of the
"Operation Manual")
- Various equipment and accessories for pre-treatment
(
: "Instruction Manual" separately provided)

14 Fuel Oil System


14-1 Outline of the Fuel Oil System
Though the fuel oil system varies depending
on the grade of fuel to be used, the following
schematic diagram presents a typical example for
heavy oil.
For heavy oil, appropriate pre-treatment of
the oil as far as the inlet of the engine is so important that service lives of devices such as the fuel
injection pump highly depend on its performance.
Since sub-systems, equipment and accessories may be changed depending on the grade of
fuel oil to be used, appropriate maintenance and
inspection should be effected in accordance with
instruction manuals for the actually used equipment and accessories.
In case that heavy oil is used, the fuel oil is
heated by the heater, pressurized by the delivery
pump and sent to the fuel injection pump through
the filter. Surplus of the fuel oil is returned to the
inlet of the fuel delivery pump via the relief valve
installed in the engine, and the fuel oil is thus circulated.
Highly pressurized fuel oil sent from the fuel
injection pump is introduced to the inlet collector of
the fuel injection valve from the side of the cylinder
head via the high pressure fuel block.
For the inspection and maintenance of the
following equipment, refer to other section of this
Heavy Oil Feeding System

of the Fuel Oil System

<<Attention to be paid to on Dismantling,


Maintenance and Assembling of the Fuel Oil
System>>
1. Components and parts of the fuel injection
system such as the fuel injection pump and
the fuel injection valve are products of precision manufacturing, so are liable to malfunction such as seizure with existence of dust or
foreign matters. When dismantling any
equipment or device of the fuel system,
whether left in the engine or stored in other
place, pay special attention so that any dust
or foreign matters may not penetrate inside
the equipment, the device or the piping.
2. When the fuel system is opened to the
atmosphere, always effect air bleeding after
restoration of the system. When effect air
bleeding, pay attention not to let oil be dispersed.

Diesel Oil Feeding System


Air Separator
Fuel Injection Valve Main Return Pipe

Heavy
Oil Tank

Diesel
Oil Tank
Leaked Fuel Main Pipe

Accumulator

High Pressure
Fuel Block

Inlet Connector

Filter

Viscorator

Fuel Delivery
Pump
Fuel Injection
Valve

Heater

Filter

Fuel Injection
Pump
Main Inlet Pipe

Damper
Main Return Piping
Relief Valve

Fuel Oil System


DC-32 Z 05-12

Leaked Waste
Oil Tank

CHAPTER

Fuel Oil System

14

The Fuel Oil Outline of the Structure/Consumable Replacement Parts, Special Tools and
Relief Valve : Measuring Instruments/Dismantling/Inspection and Maintenance/Assembling

14-2 The Fuel Oil Relief Valve


14-2.1 Outline of the Structure
The fuel oil relief valve is integrated in the
fuel inlet block that is installed on the lower part of
the gear case located under the fuel injection
pump to keep the fuel pressure at the inlet of the
fuel injection pump constant. Surplus of the fuel oil
is returned to the fuel feed system via the relief
valve.
Pressure of the fuel oil depends on the
pressure of the supply source as well as viscosity of the fuel oil.
In case that heavy oil is used, the
pressure is adjusted so that the pressure may
fall in the blue range of the pressure gauge with
the proper viscosity. Therefore, when the pressure runs off the targeted range during engine
operation, check whether or not the viscosity is
in the proper range before starting dismantling
of the fuel oil relief valve for inspection.

In case that heavy oil is used, since


o
the fuel oil is heated (to more than 100 C), and
touching with the dispersed oil may cause a
burn, pay attention not to let the oil be dispersed when effecting its dismantling.
Weight of ;

Fuel Block Assembly : 26 kg

14-2.2

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1.
Gaskets
3-2.3 No.509,512
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)

ITEM

DC-32 2.1 - 2.5

Make a mark on the point of the screw


to which the adjusting screw is screwed up or
record this dimension before loosening the
screw to identify the original position of adjustment when assembling the valve again.
(2) Loosen and remove the cap (D).
(3) Take out the spring seat (E), the spring (F)
and the relief valve (G) from the fuel inlet block
(H).

14-2.4

Inspection and Maintenance


of the Fuel Oil Relief Valve

A. Wash each of the dismantled parts with clean


washing oil to remove the sludge.
B. Check whether or not any unusual mark of contact or flaw as well as a trace of sticking is
found on the relief valve.
C. Check whether or not any unusual mark of contact or flaw is found on the the spring and the
spring seat.

14-2.5

Assembling of the Fuel Oil


Relief Valve

Assembling of the relief valve is to be effected in the reverse sequence of that for dismantling.
A. Set the adjusting screw at the position marked
before dismantling.
B. Run the engine when assembling is completed,
then check whether or not the pressure falls in
the blue range of the gauge, and adjust the
pressure by means of the adjusting screw when
the pressure runs off the range.
(H)

14

(G)
(F)

(E)
(D)

(A)

14-2.3

Dismantling of the Fuel Oil


Relief Valve

Dismantling of the relief valve is to be effected in the procedure as described below.


(1) Remove the cap nut (A), and loosen the nut
(B) to enable the adjusting screw (C) to be fully
unscrewed.

(B)
(C)

Fuel Oil Relief Valve Assembly

DC-32 Z 05-12

CHAPTER

The Lubricating Oil System

15
ITEM

1 DC-32 The Lubricating Oil System : Outline of the Lubricating Oil System
15 The Lubricating Oil System
15-1 Outline of the Lubricating Oil
System
Pressure and temperature of lubricating oil
sent to the lubricating oil cooler from the lubricating
oil pump are regulated by means of the thermostat
valve and the pressure relief valve respectively so
that the pressure and the temperature may be the
designed ones, and then the oil is fed to the main
oil passage in engine frame through the lubricating
oil filter. The oil branches from this main passage
and lubricate the parts as shown below. (Fuel
injection pump and turbocharger are shortened to
FIP and T/C respectively.)
Main passage  Main Bearings  Crank Pin
Journals  Connecting Rods
(drilled holes)  Pistons
Main passage  Camshaft (drilled holes) 
Camshaft Bearings  Rocker Arms
 Swing Arms  FIP Tappets
 Filter (for FIPs)  FIP Plungers
Main passage  Governor Driving Device 
Governor Driving Gear
Main passage  Filer (for T/C)  T/C
Main passage  Idle Gear Bushing
Main passage  Timing Gears, Aux.
Machinery Gear (oiling the tooth flanks)

The lubricating oil pump is a gear pump with


a safety valve, installed in the gear case located
on the front end of the engine and driven by the
aux, machinery gear fitted on the crankshaft.
The lubricating oil cooler is of a plate type
and is installed on the lubricating oil unit block.
The thermostat valve is directly mounted on
the lubricating oil unit block and the relief valve
and the lubricating oil filter are directly on the
engine frame.
The lubricating oil filter is an automatic
reverse flow filter and its elements are always
cleaned during engine operation.
Another filter that filters finer particles is provided exclusively for the lubricating oil for the fuel
injection pump.
(
: 2-2.3 "Lubricating Oil System" of the
"Operation Manual")
(
: 5-4.3 "Washing of the Filter" of the
"Operation Manual")

Rocker Arm

Fuel Injection Pump


Swing Arm

Turbocharger

Filter
Lubricating Oil Cooler
Piston
Camshaft
Relief
Valve

Filter

Thermostat
Valve

Sludge
Collector

Timing Gears

Pump

Governor Driving Device

Safety
Valve

Aux. Machinery Gear

Main Bearing, Crankshaft

Engine Base Plate (Oil Pan)

DC-32 Z 05-12

Lubricating Oil System

Governor Driving Gear

CHAPTER

The Lubricating Oil System


15
ITEM
The Lubricating Outline of the Structure/Consumable Replacement Parts,
DC-32 2.1 - 2.3
Oil Pump :
Special Tools and Measuring Instruments/Dismantling
15-2 The Lubricating Oil Pump
15-2.1

Outline of the Structure

The lubricating oil pump is installed on the


gear case..
The lubricating oil pump is a gear pump and
all the eight bearings are needle bearings. And a
safety valve is integrated in the pump cover.
Weight of ;

15-2.3

Dismantling of the
Lubricating Oil Pump

A. Detach the piping for the lubricating oil pump


and the lubricating unit block, and the suction
piping.
B. Check backlash between the pump driving gear
(D) and the aux. machinery gear by touch
through the window on the gear case before
taking out the lubricating oil pump assembly.

Lubricating Oil Pump Assembly : 125 kg


Standard backlash

15-2.2

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: Parts List)
1. Split Pin
3-3.10
No. 506
2. O-ring
3-3.10
No. 511
3. Oil Seal
3-3.10
No. 14
4. Needle Bearing
3-3.10
No. 8
5. Needle Bearing
3-3.10
No. 9
6. Gasket
3-3.10
No. 17
7. Gasket
3-3.1
No. 507

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

Backlash

Replacement limit

(mm)

(mm)

0.3 - 0.6

0.8

C. A little lift the lubricating oil pump assembly by


a wire rope, detach the mounting nuts and then
take out the lubricating oil pump from the gear
case.
D. Dismantling of the lubricating oil pump is to be
effected according to the following procedure.
(1) Remove the split pin (A), the castle nut (B)
and the washer (C), then detach the pump driving gear (D) and the key (E).
(2) Loosen and detach the bolts fastening the
pump cover (F), then remove the pump cover.
(3) Pull out the pump driving gear shaft (G) and
the pump gear shaft (driven side) (H) from the
pump body (J).
(4) Detach the snap ring (K) and pull out the oil
seal (L).
(5) Alternately loosen the safety valve spring
clamping bolts and remove them, then remove
the safety valve spring clamp (M).

Alternately loosen the safety valve


spring clamping bolts. Or, the spring force may
break the components.
(6) Pull out the safety valve spring (N) and the
safety valve (P).
(7) Remove the O-ring (R).

DC-32 Z 05-12

15

CHAPTER

The Lubricating Oil System

15
ITEM

2.4,2.5 DC-32 The Lubricating Oil Pump : Inspection and Maintenance/Assembling

(H)

(F)

(J)

(R)

(L)

(K)
(D)
(E)
(C)
(B)

(P)

(A)

(N) (M)
(L)

Side of the
needle bearing

Side of the driving


gear

(Q)
Lithium grease
Installation direction of the oil seal

15-2.4

(S)

Lubricating Oil Pump (U)

Inspection and Maintenance


of the Lubricating Oil Pump

A. Wash each of the dismantled parts with clean


washing oil.
B. Check whether or not any unusual wear is
found on the surface of the shaft portion of the
pump gear (G) on which the lip of the oil seal
slides.
C. Check whether or not any unusual wear or a
pressure mark is found on the surface of the
shaft portion of the pump gear (G) or of the
pump (driven) gear (H) on which the needle
bearings roll.
D. Inspect each of the pump gears in terms of
wear and pitting of the tooth flanks and peeling
or seizure of the peripheries and the sides.
E. Check whether or not any unusual contact mark
or flaw is found on the pump body (J) and the
inner surface of the cover (F).
F. Inspect the pump driving gear (D) in terms of
wear and pitting of the tooth flanks.
G. Check whether or not any flaw or trace of sticking is found on the safety valve (P). When the
flaw, if any, is a light one, rectify it with an oil
stone.

15-2.5

Assembling of the
Lubricating Oil Pump

A. Assembling of the lubricating oil pump is to be


effected in the reverse sequence of that for dismantling.
<<Attention to be paid in the Assembling>>
1. Replace the needle bearings and the oil seal
by new ones.

DC-32 Z 05-12

(G)
(V)

(W)

2. Pay attention to the installation direction of the


oil seal and apply lithium grease to the lips of it
when installing it.
3. Apply a liquid sealant to the mating surfaces of
the pump body and the pump cover.
4. Position and install the pump cover with its two
dowel pins being fitted in the locating holes.
Apply lubricant (Molykote 1000 Spray) to the
seating surfaces and the threads of the pump
cover mounting nuts and then tighten them with
the specified torque.

Specified torque : 140 N . m


5. Apply grease to the o-ring (R) and then install
on the pump body.
Apply lubricant (Molykote 1000 Spray) to the
seating surface and the thread of the pump
driving gear tightening nut and then tighten it
with the specified torque.

Specified torque : 735 N . m


6. After completion of the assembling, rotate the
pump driving gear (D) by hand to make certain
that it smoothly rotates.
B. Install the lubricating oil pump on the gear case.
C. Install the piping.

CHAPTER

The Lubricating Oil System


15
ITEM
The Lubricating Outline of the Structure/Consumable Replacement Parts,
DC-32 3.1 - 3.3
Oil Cooler :
Special Tools and Measuring Instruments/Detachment
15-3 The Lubricating Oil Cooler
15-3.1

Outline of the Structure

The lubricating oil cooler as well as the thermostat valve is mounted on the lubricating oil unit
block located near the gear case.
The lubricating oil cooler is a plate type cooler for which a special pattern is pressed on the
metal plate that is designed to obtain the maximum
heat transfer efficiency and the plates are laminated and fixed by bolts to present compactness to
the cooler.
Weight of ;

Lubricating Oil Cooler Assembly


Lubricating Oil Cooler & Lubricating Unit Block

15-3.2

470kg
970kg

15-3.3

Detachment of the
Lubricating Oil Cooler

(1) Loosen the cover mounting bolts and remove


the cover-1 (A).
(2) Firmly screw the eye bolts M16 in the upper
tapped holes from which the bolts are removed.
(3) Pass a wire rope through the eye bolts M16
and remove the cooler mounting bolts (B) and
detach the cooler assembly from the lubricating
oil unit block while a little lifting the cooler by
means of a chain block.
(4) Detach the o-ring (C), and lay the cooler
assembly on the designated place with its
mounting surface being faced downwards.
(5) Detach the eye bolt M16.

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. O-ring
3-3.6 No.513
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)
(b) Guide Bar Assembly (2 pcs.)
(1) Guide Bar
(2) Special Bolt
(c) Eye Bolt M16
(d) Stud Bolt (exclusively for maintenance)

(c)

(C)

(A)

15
(1)
(2)
(E) (F)

(b) Guide Bar

(B)

Detachment of the Lubricating Oil Cooler

DC-32 Z 05-12

CHAPTER

15

The Lubricating Oil System

ITEM

3.4,3.5 DC-32 The Lubricating Oil Cooler : Dismantling/Inspection and Maintenance


15-3.4

Dismantling of the
Lubricating Oil Cooler

(1) Detach the movable cover mounting bolts (F1)


and (F2).
(2) Attach the guide bar (b) and the stud bolt that
are prepared for maintenance (d).
(3) Detach the movable cover (G), the end plate
(J) and the laminated plates (H) in this
sequence.

Wear safety gloves to avoid injuries


due to sharp edges of the plates.

Make marks on the fixed cover (K), the


lid and each plate to identify the correct
sequence and direction of installation.
Recorded code letters will facilitate the work
when they are reassembled.
In case that some plates stick each
other, slowly separate each plate from the
other so that the gasket may be left on the
plate to which the gasket was attached.
Since the method to attach the gasket
varies plate to plate, recording of the code letters will facilitate replacement of the gasket.

15-3.5

Inspection and Maintenance


of the Lubricating Oil Cooler

1. A brush made of other material than stainless steel such as steel wool and carbon
steel shall not be used.
2. When washing the object with diluted nitric
acid, pay enough attention to corrosion
resistance of the plate and the gasket, and
assuredly effect neutralization and rinsing
after washing with the diluted nitric acid. (For
concentration and temperature of the nitric
o
acid, 4 weight percent and 60 C or lower are
recommended.)
3. Do not use hydrochloric acid nor sulfuric
acid.

B. Replacement of the Plate


When replacing a plate due to damage to it,
replace the damaged plate only by new one. At
such a time, pay attention to direction of the plate.
(The direction is to be decided corresponding to
the shape of the gasket used.)

Example of the
marking
(by a marker pen
or some other)

(F2)

DC-32 Z 05-12

(E)
(F1)

Deliberately clean sludge deposited on the


water facing surfaces of the plates since it will
reduce cooling efficiency very much.
A. Washing of the Plates
- Wash them with water using a brush of fiber
such as nylon or a stainless steel wire brush
with care not to damage the gaskets (washing
by a water jet with water pressure of about 5
MPa will be more effective).
- Precipitates containing oxides or calcium compounds will be removed by a soft brush and
nitric acid solution of 2 - 5 % concentration.
- Precipitates containing oil will be removed by a
soft brush and light oil.

(d)

(b)-(1)

(G)
(J)
(H)

(L)
(K)
(b)-(2)

Dismantling of the Lubricating Oil Cooler

CHAPTER

The Lubricating Oil System

15
ITEM

The Lubricating Oil Cooler : Assembling


15-3.6

DC-32

Assembling of the
Lubricating Oil Cooler

(1) Clean the surfaces of the gaskets before stating the assembling.
(2) Attach the guide bar assembly (b) and the
stud bolts for maintenance (d) to the fixed
cover (K).
(3) In case that the stud bolts (E) are detached,
clean the male threads of the stud bolts and the
female threads of the fixed cover, apply adhesive (Loctite 271) to the threads of the stud
bolts and the seating surfaces of the nuts (L),
and then put the nuts on the stud bolts and
tighten them.
(4) Apply adhesive (3M's EC-776) to the grooves
of the gaskets that were recorded on detachment of the plates, install the gaskets and dry
them up with light pressure added by means of
the plate or some other suitable plate.
Make certain that the gaskets are properly
positioned and the adhesive has got dry.
(5) As to the plates, mount the plates on the
guide bar (b)-(1) making use of the guides plate
by plate in accordance with the marking made
on dismantling paying attention so that they
may be installed in the correct direction while
seeing the code letter on the upper right of
each plate.

Make certain that the following instructions are followed.


1. The sequence of installation is : the fixed
cover (K)  the starting plate B  Plates
(code G  C  E  B  G  C  E  B 
65th plate B  G  B G  Back Plate
(with a half gasket)  Movable Cover with
the surface to which the gasket is attached
being faced downwards.
2. After completion of the assembling, see that
the plates are assembled like honeycomb.

3.6

(b)-(1)
(d)

(E)

(L)

(K)
(b)-(2)

Installation of the Guide Cover


The 66th Plate
The 65th Plate
The 64th Plate

The 5th Plate


The 4th Plate
The 3rd Plate
The 2st Plate
The 1st Plate

G
B

Movable Cover (G)


G

BG

The 103rd Plate


The 102nd Plate
The 101st Plate
The 100th Plate

Fixed Cover (K)

15

(6) Pass the guide bar (b)-(1) through the hole in


the movable cover (G) and lay the cover over
the end plate.
When maintenance of the lubricating
oil cooler is required, please consult with the
Service Division of DAIHATSU or its service
agent.

Installation of the Plates

DC-32 Z 05-12

CHAPTER

The Lubricating Oil System

15
ITEM

3.6,3.7 DC-32 The Lubricating Oil Cooler : Assembling


(6) Apply lubricant (Molykote 1000 Spray) to the
threads and the seating surface of the nuts (F)
and diagonally and evenly tighten the stud bolts
for maintenance (d) so that the distance
between the fixed cover (K) and the movable
cover (G) may be 391 mm.
(7) Diagonally and evenly tighten the stud bolts
(E).
(8) Detach the guide bar assembly (b) and the
stud bolts for maintenance (d).

15-3.7

Installation of the Lubricating


Oil Cooler

(1) Apply grease to the o-rings (C) and fit them on


the fixed cover (K).
(2) Firmly attach the eye bolts M16 to the tapped
holes in the end surface of the fixed cover (K)
and also in the end surface of the movable
cover (G) (on both of which scribed letter marks
of "T" are stamped) that are prepared for the
cover (A) mounting bolts.
(3) Pass a wire rope through the eye bolts M16,
and then install the cooler on the lubricating oil
unit block with the cooler mounting bolts (B)
while a little lifting the cooler by means of a
chain block.
(4) Detach the eye bolts M16.
(5) Install the cover (A).
(6) After the running of the engine, make certain
that no oil or water leakage is detected at each
part of the cooler.
Lubricating Oil Unit Block
(C)

Honeycomb-like Structure

Seeing of the Formation of the Plates


Application of Molykote 1000 Spray

(F)

(b)-(1)

(G)

(E)

(L)
(K)
(b)-(2)

Installation of the Movable Cover


(b)-(1)

(d)
Attaching the Eye
Bolts M16 (c)

(d)

(b)-(2)

(E)
(F)

391

(G)

Scribed mark "T"


(B)
Lubricating Oil Cooler Assembly

Installation of the Lubricating Oil Cooler

DC-32 Z 05-12

(K)

Fastening of the Plates

CHAPTER

The Lubricating Oil System


15
ITEM
The Lubricating Outline of the Structure/Consumable Replacement Parts,
DC-32 4.1 - 4.3
Oil Relief Valve : Special Tools and Measuring Instruments/Dismantling
15-4 The Lubricating Oil Relief Valve
15-4.1

Outline of the Structure

This valve is a relief valve located between


the lubricating oil filter and the inlet on the engine
frame, and fitted on the engine frame.
Surplus of the lubricating oil of which pressure has been regulated is returned to the oil
reservoir in the engine frame.
Pressure of the lubricating oil can be adjusted by turning the adjusting bolt (A) to change the
spring force.
(
: 5-3.2 "Procedure for Adjustment of the
Lubricating Oil Pressure" of the "Operation
Manual")

Since the case compressed the spring,


sudden detachment of the case will let the
spring be dangerously ejected. Slowly loosen it
while covering the relief valve with a sheet of
cotton waste or some other.

(3) Take out the spring seat (E), the spring (F)
and the valve (G) from the valve body (H).
The screw M6 located at the center of the
valve facilitates its taking-out.

Weight of ;

Lubricating Oil Relief Valve : 13 kg

15-4.2

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A.Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Gasket
2. Gasket

3-3.12
3-3.12

No. 7
No. 505

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

15-4.3

Dismantling of the
Lubricating Oil Relief Valve

A. Remove the connected piping and take out the


relief valve assembly.
B. Dismantling of the relief valve is to be effected
in accordance with the procedure as described
below.
(1) Remove the cap (B), loosen the lock nut (C) to
fully unscrew the adjusting bolt (A).
Make a mark on a thread of the bolt or
record the length of the bolt above the lock nut
indicating the adjusted position of the bolt
before loosening it.
(2) Loosen and remove the case (D).

(G)

(H)

(F)

15
(D)
(E)
(A)
(C)

(B)

Lubricating Oil Relief Valve

DC-32 Z 05-12

CHAPTER

15

The Lubricating Oil System

ITEM

4.4,4.5 DC-32 The Lubricating Oil Relief Valve : Inspection and Maintenance/Assembling
15-4.4

Inspection and Maintenance


of the Lubricating Oil Relief
Valve

A. Wash each of the dismantled components with


clean washing oil to remove the sludge.
B. Check whether or not any unusual contact mark
or flaw is found on the periphery of the valve or
the inner surface of the valve body where the
valve slides and also whether or not the valve is
stuck. Rectify the flaw, if any, with an oil stone
when the flaw is not deep, then make certain
that the valve smoothly moves.
C. Check whether or not any unusual contact mark
or flaw is found on the spring.

15-4.5

Assembling of the
Lubricating Oil Relief Valve

Assembling of the relief valve is to be effected in the reverse sequence of that for dismantling.

1. Set down the adjusting bolt at the depth


already marked.
2. After completion of the assembling, run the
engine to check whether or not pressure of the
lubricating oil falls in the blue range indicated
on the gauge, and adjust it by means of the
adjusting bolt when necessary.

DC-32 Z 05-12

CHAPTER

The Lubricating Oil System


The Lubricating Oil Outline of the Structure/Expandable Replacement
Thermostat Valve : Parts, Special Tools and Measuring Instruments

The illustration on the right shows the status


of the valve where the port "C" is fully closed and
the port "B" is fully opened when the temperature
of the lubricating oil at the port "A" that is connected to the oil inlet of the engine is low.
As the temperature of the lubricating oil
rises, wax in the pellet (D) expands to push up the
rod (E) and to push down the valve (F) opening the
port "C" so that the temperature may be controlled
to keep the temperature of the lubricating oil in the
port "A" within the specified one.
In case that the temperature of the lubricating oil at the inlet of the engine unusually rises due
to malfunction of the pellet (D) or some other reason, the temperature can be lowered by an emergency measure that the adjusting screw (R) is
screwed up by hand to push the valve (F) down
forcing the port "C" to open.
(
: 5-3.2 "Manual Adjustment of the
Temperature of Lubricating Oil" of the "Operation
Manual")

DC-32 5.1,5.2

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
1. O-rings

3-3.13

No.503,504,505

2. Gaskets

3-3.13

No.506,507

3. Pellet

3-3.13

No.4

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

(O)

(G)
(Y1)
(R)

14.5

The unit of the lubricating thermostat valve


is inserted and installed in the lubricating unit
block.
The lubricating oil thermostat valve is one
with the mixing type three-way cock that is provided with the common port "A", the hot port "B" and
the cold port "C". Expansion or shrinkage of wax in
the wax pellet (D) located in the common port "A"
pushes the spindle (E) up or lets it be lowered to
open or close the valve (F).
<<Mechanism of the Operation>>

15-5.2

Initial set length

15-5 The Lubricating Oil Thermostat


Valve
15-5.1 The Lubricating Oil
Thermostat Valve

15
ITEM

(Z3)

(T)
(S)
(Y2)

(V)

(N)

(J)
(K)
(P)

(H)
(Z2)

(L)
(U)

(Z1)
(E)

(M)
Weight of ;

(F)

Lubricating Oil Thermostat Valve Assembly : 14 kg

B
(W)
(X)

A
(D)

Lubricating Oil Thermostat Valve

DC-32 Z 05-12

15

CHAPTER

15
ITEM

5.3 - 5.5 DC-32


15-5.3

The Lubricating Oil System


The Lubricating Oil
Thermostat Valve :

Dismantling of the
Lubricating Oil Thermostat
Valve

A. Remove the bolts and detach the thermostat


valve assembly from the lubricating oil unit
block.
B. Dismantling of the thermostat valve is to be
effected in accordance with the procedure as
described below.
(1) Remove the bolts (P) and detach the case
(H).

Since the case compresses the spring,


sudden detachment of the case will let the
spring be dangerously ejected. Slowly loosen
and remove it with care.

Dismantling/Inspection and
Maintenance/Assembling
15-5.4

A. Wash each of the dismantled parts with clean


washing oil to remove the sludge.
B. Check whether or not any unusual contact mark
or flaw is found on the periphery of the valve or
the inner surface of the valve body (U) on which
the valve slides and whether or not the valve is
stuck.
Rectify the flaw, if any, with an oil stone when
the flaw is not deep and make certain that the
valve smoothly moves.
C. Check whether or not any unusual contact mark
or flaw is found on each of the springs.

15-5.5
(2) Pull out the rod (E) from the shaft (J).
(3) Pull out the valve (F) together with the pellet
(D), the shaft (J), the bushing (M), the spring
(K) and the spring seats (L) and (N).
(4) Loosen the screw portion of the pellet (D) and
take it out from the shaft (J).
(5) Loosen the nut (W) and the lock nut (X), and
detach the valve (F) from the shaft (J).
(6) Pull out the bushing (M), the spring seats (L)
and (N) and spring (K) from the shaft (J).
(7) Remove the cap (O) and pull out the adjusting
screw (R) together with the spring seat (G)
from the guide (T).
(8) Loosen the spring seat (G) and pull out the
spring (S) and the stopper (V).
(9) Detach the o-rings (Z1), (Z2) and (Z3) and the
gaskets (Y1) and (Y2).

DC-32 Z 05-12

Inspection and Maintenance


of the Lubricating Oil
Thermostat Valve

Assembling of the
Lubricating Oil Thermostat
Valve

Assembling of the thermostat valve is to be


effected in the reverse sequence of that for dismantling.

1. Apply grease to the o-rings and fit them on


the adjusting screw and the valve body..
2. Apply grease to the sliding part of the valve.
3. Replace the pellet every 8,000 - 12,000
hours (2 - 3 years) in consideration of deterioration of the rubber diaphragm inside the
pellet.

CHAPTER

The Lubricating Oil System

MEMO

15
ITEM

DC-32

15

DC-32 Z 05-12

CHAPTER

The Cooling Water System

16
ITEM

1,2.1 DC-32 The Cooling Water System : Outline/Outline of the Cooling Water Pump
16 The Cooling Water System
16-1 Outline of the Cooling Water
System
The cooling water system consists of two
independent circulation systems, that is, the jacket
system (hot water system) and the cooler system
(cold water system) for both of which fresh water is
specified as the standard working fluid.
The air cooler is a two-stage type, hot one
and cold one, and the system is equipped with a
bypass valve at the cooling water inlet located in
the cold system to automatically cut off the flow of
cooling water during engine operation with a light
load as well as starting of the engine.
The cooling water pumps of the jacket system and the cooler system are installed on the
front end of the gear case of the engine side by
side.
(
: 2-2.4 "Cooling Water System" of the
"Operation Manual")
A. The Jacket System
This system is a cooling water circulation
system where the cooling water is pressurized by
and sent out from the cooling water pump in the
jacket system, entering into the cylinder jacket of
the engine, and is returned to the fresh water cooler via the main outlet manifold and the intercooler
after the water has cooled each part of the engine.
Temperature of the cooling water is kept
constant by means of the thermostat valve.
Head Tank

B. The Cooler System


This system is a cooling water circulation
system where the cooling water is pressurized by
and sent out from the cooling water pump in the
cooler system, entering into the lubricating oil cooler via the intercooler, and is returned to the fresh
water cooler.
Temperature of the cooling water is kept
constant by means of the thermostat valve.

16-2 Cooling Water Pumps


16-2.1

Outline of the Structure

The cooling water pumps are the volute


pumps. The pump for the jacket system and that
for the cooler system are of the same type. They
are installed on the front side of the gear case side
by side and driven by the aux. machinery gear fitted on the front end of the crankshaft.
Weight of ;

Cooling Water Pump Assembly : 114 kg

Head Tank

(hydraulic pressure)
Bypass Valve
Lubricating Oil Cooler

Intercooler

Jacket System
Cooling Water Pump
Cooler System
Cooling Water Pump
Thermostat
Valve

Fresh Water Cooler

Thermostat
Valve

Fresh Water Cooler

The Cooling Water System


DC-32 Z 05-12

CHAPTER

The Cooling Water System


Consumable Replacement Parts, Special Parts
The Cooling Water Pump :
and Measuring Instruments/Dismantling

16
ITEM

DC-32 2.2,2.3

6-2.2 Consumable Replacement


Parts
A. Consumable Replacement Parts
The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. O-rings
3-4.2
No.516,517
2. Special Claw Washer
3-4.2
No.15
3. Mechanical Seal
3-4.2
No.16
4. Split Pin
3-4.2
No.510
5. Bearings
3-4.2
No.11,12
6. Oil Seal
3-4.2
No.512
7. O-rings
3-4.2
No.14,518
B. Special Tool and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2.2)

16-2.3

Dismantling of the Cooling


Water Pump

A. Check by feeling the backlash between the


pump gear (D) and the aux. machinery gear by
means of a screw driver inserted through the
plug hole at the center of the pump body (A)
from which the plug is detached and pushing
the tip of the pump shaft (B) (or by holding and
moving the impeller (C) by hand with the pump
body being detached) before detaching the
cooling water pump assembly.

Backlash

Standard backlash

Replacement limit

(mm)

(mm)

0.3 - 0.6

0.8

B. Remove the mounting nuts and detach the


cooling water pump assembly.
C. Dismantling of the cooling water pump is to be
effected in accordance with the procedure as
described below. Make a match mark on the
mating surfaces of the pump body (A) and the
bearing case (E) before starting the dismantling.

<<Procedure for Dismantling>>


(1) Remove the mounting bolts, and then detach
the pump body (A).
(2) Flatten the tongue of the claw washer (F),
then loosen and remove the impeller nut (G).

The screw of the impeller nut is "lefthanded". Pay attention to the direction of loosening or tightening. (The letters of "L" are
stamped on the opposite sides of the hexagon
head.)
(3) Remove the impeller (C), then detach the key
(H).
(4) Remove the rotating part of the mechanical
seal (J).
(5) Pull out the split pin (K), then loosen and
detach the pump gear nut (L).
(6) Detach the washer (M), the pump gear (D)
and the key (K) from the pump shaft (B) in this
sequence.
(7) Remove the bolts (O), then the bearing holder
(P).
(8) Pull out the pump shaft (B) together with the
bearings (Q1) and (Q2) from the bearing case
(E).
(9) Take out from the bearing case (E) the fixed
part of the mechanical seal (J) and the o-ring
(R), and the oil seal (S) towards the impeller
side and the gear side, respectively.
(10) Detach the o-rings (T), (U), (V) and (W).

(W)
(A)

Mounting Nut (V)

Mounting
Bolt

(T)

(J)

(B)
(E)

(D)
(N)
(K)

(H)

Plug
(L)

(G)
(F)

(M)
(Q1)
(O)
(P)
(Q2)

(C)
(S)
(Y)

(U)

(R)

Cooling Water Pump

DC-32 Z 05-12

16

CHAPTER

The Cooling Water System

16
ITEM

2.4 DC-32 The Cooling Water Pump : Inspection


Inspection and Maintenance
of the Cooling Water Pump

A. Wash each of the dismantled components with


washing oil to remove the scale.
B. Measure the clearance "a" between the
impeller and the mouth ring (Y). Measure the
O.D. of portion of the impeller facing the mouth
ring and the I.D. of the mouth ring, then calculate the clearance.
Clearance between the mouth ring and the impeller
Replacing limit

(mm)
a = 0.44 - 0.56

(mm)
1.0

Mouth Ring

Standard clearance

Impeller

(radial clearance)

16-2.4

and Maintenance

When the clearance exceeds the


replacement limit, replace by new one either of
the parts of which wear is larger.
Too much clearance lowers the efficiency of the pump.
C. Check whether or not any corrosion or cavitation corrosion is found on the impeller.
D. Check whether or not any corrosion or cavitation corrosion is found on surfaces of the cooling water passages in the pump body and the
bearing case as well as any reduction of thickness due to such corrosion.
E. Check wear and pitch of the tooth flanks of the
pump gear.

When the wear or the backlash


exceeds the replacement limit, replace the gear
by new one.
F. Check whether or not the bearings smoothly
rotate, any abnormal noise is heard and any
part of them is worn.

Replace the bearings by new ones


every 8,000 - 12,000 hours (2-3 years) periodic
maintenance even if no irregularities are found.

DC-32 Z 05-12

Clearance Between the Impeller and the Mouth Ring

CHAPTER

The Cooling Water System

16
ITEM

The Cooling Water Pump : Assembling


Assembling of the Cooling
Water Pump

A. Assembling of the cooling water pump is to be


effected in the reverse sequence of that for the
dismantling.

B. Mount the cooling water pump assembly on the


gear case. Check the backlash when the pump
gear is replaced.

<<Attention to be paid when assembling


the cooling water pump>>
1. Tighten the impeller nut and the pump gear
nut with the specified torque.
<Specified Torque>
Impeller
:
137 N.m
(Attention! The screw is left-handed.)
Pump Gear Nut :
294 N.m
2. Replace the oil seal, the mechanical seal,
the split pin, the gasket, the claw washer and
the o-rings by new ones.
3. Apply grease to the o-rings, then install
them.
4. For the o-ring (R), first put it in the bearing
case, then insert the pump shaft. And fit the
fixed part of the mechanical seal in the bearing case after making certain that the o-ring
is inserted as far as the stepped part of the
shaft and does not touch the bearing case.
5. Be careful so that the oil seal may not be
installed in the wrong direction. Apply lithium
grease to the lip, then install it.
6. Apply lithium grease to balls of the bearings,
then install them.
7. Do not apply lubricating oil to the sliding surfaces of the mating ring and the seal ring.
When oily substance or foreign matters are
found on the surfaces, wash them with alcohol or acetone. Grease shall not be applied
to the mechanical seal.
8. Rotate the impeller by hand to make certain
before installing the pump body that the
impeller smoothly rotates.
9. Assemble the pump body and the bearing
case with match marks on them being
aligned.

2.5

Oil Seal

Impeller side
Gear
side

Apply lithium grease

Assembling of the Oil Seal

Never allow oily substance


and foreign matters to stick
Mating Ring

Seal Ring
Bellows

Impeller side

16-2.5

DC-32

16

Apply turbine oil # 32


"Never use grease."

Installation of the Mechanical Seal

DC-32 Z 05-12

CHAPTER

The Cooling Water System


ITEM
The Cooling Water Outline of the Structure/Consumable Replacement
3.1,3.2 DC-32 Bypass Valve :
Parts, Special Tools and Measuring Instruments
16

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

Outline of the Structure

The cooling water bypass valve is inserted in the


side of the gear case (the side to which the
exhaust manifold is installed) and connected to the
outlet passage of cooling water for the intercooler.
The cooling water bypass valve is a valve that
cuts off the supply of cooled water of the cooler
system to the intercooler and let the water bypass
it to allow the intake air to be heated by the cooling
water of the jacket system when the engine is
operated with a light load, and is controlled by the
sensed boost pressure operating the hydraulic piston.
(
: 2-2.4 "Cooling Water System" of the
"Operation Manual")

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
1. O-rings
3-4.3
No.507 - 511
2. Split Pin
3-4.3
No.506
3. Gaskets
3-4.3
No.512,513
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)

Initial Set Length

16-3.1

16-3.2

<<Mechanism of the Operation>>


The illustration on the right shows a status
of the valve during the time when the engine is
operated with a heavy load. The cooling water discharged from the cooling water pump flows to the
lubricating oil cooler through the intercooler. And
part of the cooled water bypasses the intercooler
and flows to the lubricating oil cooler.
When the boost pressure is lower than the
set pressure, the magnetic valve is actuated to let
the lubricating oil flow in the valve and the
hydraulic pressure push the piston (A) down to
compress the spring (B) and finally to move the
valve (C) to seat on the gear case side.
By these movements, the outlet passage of
the intercooler is blocked and the outlet passage of
the cooling water pump is fully opened at the same
time to let the cooling water bypass the intercooler
and flow to the lubricating oil cooler.
Adjustment of the air intake temperature is
to be effected by screwing up of the adjusting
screw (D) (loosening and tightening of the locknut
(E) should be assuredly done) to open the valve
adjusting the flow rate of the cooling water.
Weight of ;

Cooling Water Bypass Valve Assembly : 22 kg

DC-32 Z 05-12

40

16-3 The Cooling Water Bypass


Valve

(D)
(E)
(P)

(V)
(T)

(K)
(J)

Inlet of the
lubricating
oil to cause
bypassing

(U)
(B)

(H)
The drain hole

(F)

(A)
(Q)

(S)

(Y)
(W)
(Z)

From the cooling


water tank

(L)
(C)

To the lubricating oil cooler

(J)(K)
Gear Case

From the intercooler

Cooling Water Bypass Valve

CHAPTER

The Cooling Water System

16
ITEM

The Cooling Water Bypass Valve :

16-3.3

Dismantling/Inspection and
Maintenance/Assembling and Installation DC-32 3.3 - 3.5

Dismantling of the Cooling


Water Bypass Valve

A. Detach the connected piping for bypass valve


lubricating oil.
B. Remove the bolts and detach the bypass valve
assembly from the gear case.
C. Dismantling of the bypass valve is to be effected in accordance with the procedure as
described below.
Make match marks across the mating line of
the body (Y) and the case (H) before starting
dismantling.

<<Procedure for the Dismantling>>


(1) Remove the bolts and take out the case (H).
Since the adjusting screw (D) is installed on the
case (H), it can be taken out together with the
case at the same time.
(2) Remove the split pin (J) and the castle nut (K)
that are installed on the piston (A), then detach
the piston (A) and the spring (B).

Since the castle nut compresses the


spring, gradually loosen it with care. Its sudden
removal dangerously causes ejection of the
spring.
(3) Pull out the valve (C) together with the shaft
(L) towards the direction opposite.
(4) Remove the split pin (J) and the castle nut (K)
that are installed on the valve (C) and detach
the valve from the shaft (L)
(5) Detach the lock nut (E) from the case (H), and
then pull out the adjusting screw (D).

Measure and record the length of the


adjusting screw protruding from the upper surface of the guide (P) and always set the adjusting screw so that the same length may be
restored when reassembled.
(6) Take out the guide (P) from the case (H).
(7) Take out the o-rings (Q) - (W).

16-3.4

Inspection and Maintenance


of the Cooling Water Bypass
Valve

A. Check traces of water and oil leakage from the


drain hole of the body (Y) before starting the
washing, and carefully inspect whether or not
any deformation or cut of the o-ring (S), (T), (U)
or (W) or any irregularity such as a flaw and
partial wear on the contact surfaces of the mating parts exists if any trace is found.
B. Wash each of the dismantled parts with washing oil to remove the scale.
C. Check whether or not any hardening or deformation of the valve or flaw on the valve face is
found and replace it by new one if any flaw is
found.
D. Inspect the periphery of the shaft and the inner
surface of the bushing (2) as to whether or not
any unusual mark of contact, a flaw or a trace
of sticking exists.
When the flaw is a slight one, rectify it with an
oil stone and make certain that the shaft
smoothly moves.
E. Check whether or not any mark of unusual contact or a flaw is found.

16-3.5

Assembling and Installation


of the Cooling Water Bypass
Valve

A. Assembling of the bypass valve is to be effected in the reverse sequence of that for the dismantling.

1. Apply grease to the o-rings, and then install


them.
2. Apply grease to the sliding portion of the
shaft.
3. Put the shim that was fitted before the dismantling on the adjusting screw, and screw it
until the upper surface of the shim and the
end surface of the joint becomes flat, then
tighten the cap nut.
4. Assemble them aligning the match marks on
the body and the cover.
B. Install the bypass valve assembly on the gear
case.
(Make certain that it was installed with the drain
hole being directed downwards.)
C. Make certain after effecting engine running that
water or oil leakage from the drain hole is not
detected.

DC-32 Z 05-12

16

CHAPTER

The Engine Control and Protective System

17
ITEM

1 DC-32 The Engine Control and Protective System : Outline


17 The Engine Control and
Protective System

(
: "Instruction Manual for the Governor"
separately provided)
- The Turning Safety Switch
This switch shall not be dismantled. It should
be replaced by its assembly.
- The Fuel Cut-off Device (tandem cylinder)
This device is integrated in the fuel limiting
device. (to be explained in this chapter)

17-1 Outline of the Engine Control


and Protective System
Though the engine control and protective
system varies depending on the engine model
actually delivered to the customer, the common
components among the models are as shown
below.Inspection and maintenance of each component should be effected in accordance with the
procedure as described below.
(
: 2-3 "Engine Control/Protective Device" of
the "Operation Manual")

B. The Engine Protective System


- Switches and Sensors (engine rpm., temperature, pressure, level, etc.)
They shall not be dismantled and each of them
should be replaced by its assembly.
- Electrical Components
They shall not be dismantled and each of them
should be replaced by its assembly.
- The Fuel Limiting Device (tandem cylinder)
This device is integrated in the fuel limiting
device. (to be explained in this chapter)

A. The Engine Control System (Engine starting,


Engine Operation and Engine Stop)
- The Main Starting Air Valve, The Starter Push
Button, The Handle Switch
(
: 13 "The Starting Air System)
- The Governor

Starter Lever
(for emergency use)

Cylinder Head
Starting Valve
Main Starting Air Valve

Starting Air Rotary Valve

Main
Starting
Air Valve
Pulse Sensor

12
13
14
C

Fuel Control Cylinder

Speed Switch 63 Pressure Switch


Q2
(12, 13, 14)
from the lubricating
Indication on
oil piping
the meter dial
Turning Safety
Switch (TC)

Fuel Injection
Pump

Starter Push Button


(to 88V)

Starting Air

Common Rod
Starting Air
Reservoir
Control Lever

Governor Motor

RUN

START
STOP

Turning Motor
Governor
Handle Switch
(HS)

Flywheel

Controlling Air

DC-32 Z 05-12

Starting and
Stopping System
Starter Magnetic
Valve (88V)
Fuel Limiting Magnetic Fuel Cut-off
Fuel Cut-off
Valve (88L)
Magnetic Valve (5S) Magnetic Valve (5V)

CHAPTER

The Engine Control and Protective System


17
ITEM
The Fuel Control Outline of the Structure/Consumable Replacement Parts, Special
Cylinder :
Tools and Measuring Instruments/Detachment and Dismantling DC-32 2.1 - 2.3
17-2 The Fuel Control Cylinder
17-2.1

Outline of the Structure

The fuel control cylinder and the magnetic


valves are mounted on the front upper part of the
engine.
The fuel control cylinder incorporates two
cylinders in tandem, one is the fuel cut-off cylinder
and the other is the fuel limiting cylinder to hold
back too much quantity of fuel to be injected. The
control air operates each of the pistons to shift the
fuel injection pump rack to the position of "stop" or
"hold" via the common rod.
In the cylinder to cut off the fuel are incorporated two cylinders in tandem, one is for the usual
stop of the engine and the other is for emergency
stop. In an emergency, the control air moves both
cylinders at the same time to assuredly stop the
engine.

Weight of ;

Fuel Control Cylinder Assembly : 3 kg

17-2.2

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. O-ring
3-7.1.1
No.95
2. Gaskets
3-7.1.1
No.93,97
B. Special Tools and Measuring Instruments
(a) General Tools and Measuring Instruments
(
: 2-2)

17-2.3

Detachment of the Fuel


Control Cylinder

A. Remove the fuel cut-off pipe 5V (A), the fuel


cut-off pipe 5S (B) and the fuel limiting pipe 88L
(C).
B. Make match marks across the bracket (D) and
the fuel control cylinder assembly before starting the detachment of the fuel control cylinder
assembly.
C. Loosen the bolts and detach the fuel control
cylinder assembly from the bracket (D).

(A)

(B)

(C)

(F)

Control Cylinder
(E)

Governor Lever

O-ring

17
Common Rod

Detachment of the Fuel Control Cylinder

DC-32 Z 05-12

CHAPTER

The Engine Control and Protective System

17
ITEM

2.4 DC-32 The Fuel Control Cylinder : Dismantling


17-2.4

(8) Pull out the bearing (J2) at the near side to the
stroke adjusting cap (stopper) (F), then pull out
the bearing (L), the piston (H3) and the rods
(G3) and (G4).
(9) Detach the o-ring (Z),then gaskets (V) and
(W) from each shaft.

Dismantling of the Fuel


Control Cylinder

Dismantling of the fuel control cylinder


assembly is to be effected in accordance with the
procedure as described below.
(1) Measure and record the distance "a" between
the fitting metal (retainer) (E) and the fuel control cylinder and the distance "b" between the
stroke adjusting cap (stopper) (F) and the fuel
control cylinder before starting dismantling of
the fuel control cylinder assembly.
(2) Remove the lock nut and detach the fitting
metal (retainer) (E).
(3) Remove the lock nut and detach the stroke
adjusting cap (stopper) (F).
(4) Remove the hexagon socket bolts (S) and (T),
then detach the foot metal (retainers) (X1) and
(X2) and the stopper plate (U). Separate the
control cylinder assembly into three parts.
(5) Remove the ring (R) and pull out the bearings
(l), (J1), (J2), (K1) and (K2) from the cylinder.
(6) Pull out the piston (H2) and the rod (G2) situated at the center of the cylinder from the cylinder.
(7) Pull out the spring seat (P) and the spring (K)
situated at the near side to the metal fitting (E),
then pull out the piston (H1) and the rod (G1).

For Fuel
Cut-off
Lock Nut

(I)

(Q) (G1)

(P)

(M)

(V) (Z)

For Fuel
Cut-off

(J1) (G2) (N)

For Fuel
Limiting

(G3) (O) (H3) (L)

(U) (T)

(G4) (F)

(R)

(E)

Lock Nut
(S)

(X2)

(H1) (K1) (W)

(T)

(H2) (K2) (J2)

(X1)

Dismantling of the Fuel Control Cylinder

DC-32 Z 05-12

CHAPTER

The Engine Control and Protective System


17
ITEM
Inspection, Maintenance and
The Fuel Control Cylinder :
Assembling/Installation and Adjustment DC-32 2.5,2.6
17-2.5

Inspection, Maintenance and


Assembling of the Fuel
Control Cylinder

A. Wash each of the dismantled parts with clean


washing oil and blow them by air.
B. Check whether or not any unusual contact
mark, hardening, deformation and flaw is found
on the o-ring (Z) and the gaskets (V) and (W).
C. Check whether or not any unusual contact mark
or corrosion is found on the inner surface of the
cylinder.
D. Check whether or not any unusual contact mark
or flaw is found on the pistons, rods and bearings.
E. Check whether or not any corrosion is found on
the spring.
F. Check whether or not each of the parts is rusted due to water to be drained left in the cylinder. Remove rust with care if any.
G. Assembling of the fuel cut-off device assembly
is to be effected in the reverse sequence of that
for the dismantling.

1. Replace all the o-rings and the gaskets by


new ones.
2. Thinly apply grease to the sliding surfaces of
the o-rings, gaskets and other parts before
installing them.
3. Since the pistons, the rods, the cylinders, the
bearings and some others are resemble in
the shape each other in the group having the
similar name, pay attention not to install
wrong one.
4. Assemble the control cylinder so that the
dimensions "a" and "b" may be restored to
those before dismantling.

17-2.6

Installation and Adjustment


of the Fuel Control Cylinder

A. Install the fuel control cylinder with the match


marks being aligned.
B. Install the each piping.
C. Shift the engine control lever to the "Run" position to send control air to the fuel limiting cylinder of the fuel control cylinder and make certain
that the rack scale is positioned at the specified
point.
When the position is not at the specified one,
adjust the position by loosening the nut
attached on the end portion of the rod and turning the stroke adjusting cap.
D. Next, introduce air into the fuel cut-off cylinder
and check whether or not the "0" point of the
rack is properly calibrated.
If the "0" position of the rack is not properly calibrated, loosen the lock nut and effect the
adjustment by turning the fitting metal (retainer)
(the cut-off stroke is reduced as the fitting metal
(retainer) is turned clockwise).
E. Repeat the processes C and D to complete the
adjustment of the fuel limiting stroke and the
fuel cut-off stroke, then fix the metal fitting
(retainer) and the stroke adjusting screw (stopper) by the lock nut.

H. Make certain that each moving part moves


without any problem such as drag after assembling.

Metal Fitting Lock Nut

Lever

Fuel Control Cylinder

Stroke Adjusting Cap (Stopper)

For fue
cut-off

For fue
cut-off

For fuel
limiting Lock Nut

Common Rod

Installation and Adjustment of the Fuel Control Cylinder

DC-32 Z 05-12

17

CHAPTER

18

The Gauge Board

ITEM

1.1 - 1.3 DC-32

The Gauge Board :

Outline of the Structure/Consumable Replacement Parts, Special


Tools and Measuring Instruments/Inspection and Maintenance

18 The Gauge Board


18-1 The Gauge Board
18-1.1 Outline of the Structure
The gauge board is installed on the rear end
of the engine so that it may be viewed from the
part of the engine where the fuel injection pump is
installed.
On the gauge board are mounted the
tachometer and pressure gauges (for lubricating
oil, fuel, intake air and cooling water) and the
board is suspended by the spring to isolate vibrations.
The tachometer is driven by the flexible
cable connected to the rear end of the camshaft
and each of the pressure gauges is connected to
the needle valve fitted on the end of the piping via
a hose.

18-1.2

Consumable Replacement
Parts, Special Tools and
Measuring Instruments

A. Consumable Replacement Parts


The following parts should be replaced by
new ones when maintenance is effected.
(
: "Parts List")
1. Hoses
3-6.1.2 No.21,31 - 35
2. Vibration Isolating
3-6.1.2 No.8, 9
Springs
3. Gasket

B. Inspection and Maintenance of the Gauge

Board
(1) Carry out precision check of each of the
meters and gauges by means of the calibration
device or comparison with the indication of the
new meter or gauge.
Replace the meter or gauge by new one when
the current one is found defective.
(2) Replace the hoses by new ones.
(3) Replace the vibration isolating springs by new
ones.

1. It is difficult to repair a defective instrument on


the spot. Replace it by new one or entrust the
repair to the manufacturer specialized in the
device.
2. A deteriorated hose has possibility to be broken. Since fuel oil or lubricating oil that is dispersed from a broken hose may cause a fire if
it touches a hot spot, always replace such a
hose by new one.

Gauge Board

Bracket

Vibration Isolating Spring

3-6.1.2 No.513

B. Special Tools and Measuring Instruments


(a) General Tools and Measuring Instruments
(
: 2-2)

18-1.3

Dismantling and Maintenance


of the Gauge Board

Dismantling and maintenance of the gauge


board should be effected every time of periodic
maintenance (every 16,000 - 24,000 hours/4 - 5
years).
A. Dismantling of the Gauge Board
(1) Remove the flexible cable for the tachometer
from the connecting hole.
(2) Close the needle valves for the pressure
gauges and detach the hoses.
(3) Remove the mounting bolts to mount the
vibration isolating springs on the bracket and
detach the whole gauge board.

DC-32 Z 05-12

Vibration
Isolating
Spring
Hose

Needle Valve
Flexible Cable

Gauge Board

CHAPTER

The Gauge Board

18
ITEM

The Gauge Board :

Seal Pot

DC-32

18-2 The Seal Pot (for the heavy oil


engine models)
In case that heavy oil is used for the fuel,
the engine is equipped with the seal pot that is
installed in the piping to the fuel pressure gauge to
prevent the gauge from sticking due to the cold
fuel resulting in faulty gauging. The seal pot is
filled with ethylene glycol that substitutes the
heavy oil in terms of working fluid of which pressure is measured.
Periodically replace the ethylene glycol in
the seal pod since it is contaminated and deteriorates for a prolonged period of time due to fuel oil
mixed in it.

Fuel Inlet Block-1

(B)

(a)
(C)

<<Replacing of the Ethylene Glycol>>


(1) Close the inlet and outlet valves (B), (C) and
(D).
(2) Remove each piping and the U bolt, then
detach the seal pod (A) from the bracket.
(3) Detach the inlet joint (c) located at the inlet of
the siphon tank (b), then discharge fuel oil and
ethylene glycol in the seal pod.
(4) Wash the inside of the siphon tank.
(5) Fill the seal pod with ethylene glycol until it
spills out of the hole located at the upper surface (about 130 cc), then install the joint.
(6) Mount the seal pot on the bracket and connect
the piping to it.

To the remote
pressure gauge

(c)
(D) To the
pressure
gauge
(b)

(A)
Seal Pot

Seal Pot

Though ethylene glycol is a weak poison to human skin and mucous membrane, it is
dangerous if swallowed. Carefully handle it and
wash it away when it sticks to the hand or the
skin.

18
DC-32 Z 05-12

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