Professional Documents
Culture Documents
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.
TEL: 06
6454-2346
FAX.
06
6454-2680
http://www.dhtd.co.jp
Chapter 0
Introduction
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
The Crankshaft
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Chapter 14
Chapter 15
Chapter 16
Chapter 17
Chapter 18
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
DC-23 Z 05-12
CHAPTER
Contents
ITEM
DC-32
Chapter 0 Introduction
1.
0-1
2.
0-2
0-2.1
0-2.2
0-2.3
3.
0-3
0-3.1
0-3.2
0-3.3
1.
1-1
2.
1-2
1.
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.
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
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
DC-23 Z 05-12
CHAPTER
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.
3-3
3-3.1
3.3
3.4
3.5
5.
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
3-5.1
3-5.2
3-5.3
3-5.4
3-5.5
3-5.6
7.
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
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
1.
4-1
2.
4-2
3.
4-3
4-3.1
4-3.2
4.
4-4
4-4.1
4-4.2
4-4.3
4.5
5.
4-4.4
4-4.5
4-5
4-5.1
4-5.2
4-5.3
4-5.4
1.
5-1
2.
5-2
3.
5-3
4.
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.
5-6
7.
5-7
1.
6-1
2.
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.
6-4
6-4.1
6-4.2
6-4.3
DC-23 Z 05-12
CHAPTER
ITEM
DC-32
Contents
1.
7-1
2.
7-2
3.
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
8-2.2
8-2.3
8-2.4
8-2.5
8-2.6
1.
9-1
2.
9-2
3.
9-3
4.
5.
DC-23 Z 05-12
9-4
9-4.1
9-4.2
9-4.3
9-5
CHAPTER
Contents
ITEM
DC-32
10
1.
10-1
2.
10-2
3.
10-3
4.
10-4
5.
10-5
11
1.
11-1
2.
11-2
3.
11-3
4.
11-4
5.
11-5
12
1.
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
DC-32 Z 05-12
CHAPTER
ITEM
Contents
DC-32
Chapter 13 The Starting Air System
1.
13
13-1
2.
13-2
13-2.1
13-2.2
13-2.3
13-2.4
13-2.5
3.
13-3
13-3.1
13-3.2
13-3.3
3.4
3.5
13-3.4
13-3.4
4.
14-1
14-2
14-2.1
14-2.2
14-2.3
2.4
2.5
14-2.4
14-2.5
14
1.
13-4
13-4.1
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.
15-3
15-3.1
15-3.2
15-3.3
15-3.4
15-3.5
15-3.6
15-3.7
4.
15-4
15-4.1
15-4.2
15-4.3
15-4.4
15-4.5
5.
15-5
15-5.1
15-5.2
15-5.3
15-5.4
15-5.5
3.
16
16-1
16-2
16-2.1
16-2.2
16-2.3
2.4
2.5
16-2.4
16-2.5
16-3
16-3.1
16-3.2
16-3.3
16-3.4
16-3.5
DC-32 Z 05-12
CHAPTER
ITEM
DC-32
Contents
2.
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
DC-32
Introduction
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
: "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
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
DC-32 Z 05-12
CHAPTER
0
ITEM
3.1,3.2 DC-32
Introduction
Engines Conforming to
The NOx Technical Code :
DC-32 Z 05-12
CHAPTER
Introduction
Engines Conforming to
The NOx Technical Code :
ITEM
3.3
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
1 DC-32
ITEM
1-1
Piston
Cylinder Liner
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
ITEM
Turbocharger
Governor
1
Turbocharger
Control
Handle
Intercooler
Lubricating
Oil Cooler
DC-32 Z 05-12
CHAPTER
2 DC-32
ITEM
Component to be
serviced
involving
dismantling of
the engine
and/or the
component
Cylinder Head
Piston
Protect Ring
Connecting Rod
Cylinder Liner
Main Bearing
Reference
20.25
Note
3-1
21.75
3-1
12.5
3-2
13.0
3-2
11.0
3-2
10.25
3-2
11.0
3-3
11.0
3-4
11.5
3-5
12.0
12.0
3-1
22.0
4-3
12.0
4-4
10.5
4-4
10.25
4-4
10.25
4-4
10.25
4-3 /5-3
22.0
23.0
10.5
21.0
12.0
23.0
5-4
11.0
/
5-5
/
5-6
2000
4-5
21.0
23.0
DC-32 Z 05-12
3-1
4-4
4-4
/4-7
4-4
5-3
6-3
6-3
CHAPTER
1
ITEM
Component to be
serviced
involving
dismantling of
the engine
and/or the
component
Crankshaft
DC-32
Measurement of deflection
2000
Reference
Note
A manual
separately
provided
Operation
Manual
10.5
7-3
23.0
7-3
10.5
8-1
21.0
8-1
22.0
8-1
10.5
8-1
13.0
8-1
Cam Gear
24.0
8-2
8-2
8-2
Timing Gear
Camshaft
35.0
Camshaft Bearing
22.0
21.0
12.0
Replacement of O-Rings
/
8-2
9-4
11.0
Valve Train
11.0
9-4
9-4
A manual
separately
provided
10
A manual
separately
provided
12.0
11
A manual
separately
provided
Turbocharger
Intercooler
24.0
Starting Valve
12.0
/
13-2
11.5
13-3
14-2
11.5
Replacement
11.0
Lubricating
Hydraulic pump
21.5
15-2
/
15-2
24.0
Instruction
Manual
12-3
Instruction
Manual
11
/
Replacement of Bearings
Operation
Manual
10
Bushings
Governor
9-4
9-4
15-3
A manual
separately
provided
11.5
Lubricating Oil
Thermostat Valve
11.0
Instruction
Manual
15-3
15-5
DC-32 Z 05-12
CHAPTER
2 DC-32
ITEM
Component to be
serviced
involving
dismantling of
the engine
and/or the
component
Cooling Water
Pump
22.5
Cooling Water
Bypass Valve
Cooling Water
Thermostat Valve
Fuel Oil Control
Cylinder
(Fuel Cut-off/Fuel
Limiting Device)
Instruments
11.0
10.5
11.0
11.0
proof
16-2
16-2
/
16-2
16-3
/
Note
17-2.3
18
()
18
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
MEMO
1
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
1 DC-32
ITEM
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
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.
3.
4.
5.
6.
7.
8.
9.
ITEM
DC-32 2.1,2.2
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
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)
M56
Tighten by Oil
Pressure
M56
Name of Bolt/Nut
36
Note
M52
Tighten by Oil
Pressure
M52
Socket 22
M30
Tighten by Oil
Pressure
M30
Socket 12
M52
Tighten by Oil
Pressure
M52
M56
M56
M39
M39
24
196
M20
30
294
M22
32
392
M36
55
1666
M20
30
225
M20
30
225
M24
36
441
M22
32
294
Apply oil
Do not use Molykote
M24
36
343
Apply oil
Do not use Molykote
M22
32
392
M20
27
373
M20
27
373
10
DC-32 Z 05-12
36
Tighten by Oil
Pressure
Tighten by Oil
Pressure
CHAPTER
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
Note
M24
36
490
Apply oil
Do not use Molykote
M12
19
49
M20
27
343
16
19
M24
32
588
20
M30
41
882
21
M20
30
265
M14
Socket 12
137 - 157
M16
24
177 - 196
M42
46
373 - 403
M24
Socket 19
196
M20
24
147
M14
22
88
M14
26
M16
24
127
27
M16
13
127
M12
19
39
M12
19
59
M18
27
196
M18
13
147
M16
24
118
M10
Socket 8
39
M20
30
225
25
32
49
(thread)
DC-32 Z 05-12
CHAPTER
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)
Note
M20
13
245
(Thread)
M20
30
440
(Stud) Bolt
M24
17
440
(Thread)
Nut
M24
36
780
M16
24
137
M18
27
216
M20
30
294
M16
24
147
M12
19
59
M22
32
177
M16
24
118
M12
Socket 10
69
30
127
M20
30
127
(Thread)
M20
30
127
M42
65
1470
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
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
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
ITEM
Coupler (iii)
O-ring
DC-32 Z 05-12
Hydraulic Jack
Assembly (a)
Jack Handle(f)
Backup Ring
Circular Nut
Neutral
Depressurize
Pressurize
Shift Lever
To the Hydraulic Jack (a)
Oil Pressure Gauge
Terminal (d)
Oil Level Gauge Bar
(Filler Mouth)
High Pressure
Hose (c)
Coupler
CHAPTER
2
ITEM
Hydraulic Jack :
DC-32
4.2
Coupler (iii)
Hydraulic Jack
Assembly (a)
Backup Ring
Jack Handle (f)
Circular Nut
DC-32 Z 05-12
CHAPTER
ITEM
Coupler (iii)
Hydraulic
Cylinder (ii)
Hydraulic Jack
Assembly (a)
O-ring
Backup Ring
Joint Bolt (g)
Jack Stand (e)
Jack Handle(f)
DC-32 Z 05-12
Circular Nut
CHAPTER
2
ITEM
DC-32 4.3,4.4
DC-32 Z 05-12
CHAPTER
2
ITEM
: "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
CHAPTER
MEMO
2
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
Intake Valve
Indicator & Safety Valve
Cap
Cylinder Head Bolt
Circular Nut
Exhaust Distance
Piece
Cylinder Head
Gasket
Exhaust Valve Seat
Exhaust Valve Seat
Intake Valve
Exhaust Valve
Push Rod Block Gasket
Starting Valve
CHAPTER
(2)
3
ITEM
DC-32
1.2
(1)
(3)
(4)
(1)
DC-32 Z 05-12
CHAPTER
ITEM
(1) (2)
(3)
(4)
(2)
(1)
(2)
(3)
(1)
(1) (2)
DC-32 Z 05-12
CHAPTER
(2)
3
ITEM
DC-32
1.2
(1)
(2)
(2)
(1)
(6)-1
(3)
(4)
(3)
(6)-2
Pin
(5)
(1)
(5)
(3)(4)
DC-32 Z 05-12
CHAPTER
ITEM
(B2)
Inlet
Connector
Fuel Oil High
Pressure Block
(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.
DC-32 Z 05-12
Exhaust
Manifold
Exhaust
Manifold Bolt
(b)-(1)
(b)-(2)
Cap
(H)
(b)-(3)
Fuel Oil Injection Valve Holding Flange
CHAPTER
3
ITEM
DC-32
1.3
(c)-(1)
(c)-(3)
(c)-(4)
(H)
(d)-(3)
(d)-(2)
(d)-(4)
(d)-(1)
DC-32 Z 05-12
CHAPTER
ITEM
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)
DC-32 Z 05-12
CHAPTER
3
ITEM
DC-32
1.4
: 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
Inlet of the
starting air
: 3-4.3)
: 3-5.3)
: 3-6.3)
: 3-7.3)
Plug
DC-32 Z 05-12
CHAPTER
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)
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
Hammer
(h)-(1)
Replacement Limit
DC-32 Z 05-12
A, B
Valve Guide
CHAPTER
3
ITEM
Cylinder Heads :
DC-32
Stem Seal
1.5
DC-32 Z 05-12
CHAPTER
3
ITEM
Valve Seats
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
D
Intake Valve Seat
Measurement of Dimensions
of the Valve Seats
Fix by a wrench
(j)-(2)
(j)-(4)
j)-(1)
(j)-(4)
Intake Valve Seat
(j)-(3)
Exhaust Valve Seat
Used valve
(i)-(1)
DC-32 Z 05-12
(i)-(2)
CHAPTER
3
ITEM
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)
O-ring
3
Chilling of the Exhaust Valve Seat
Pushing out
Fitting in
(i)-(3)
Exhaust Valve Seat
(k)-(2)
(i)-(3)
Used valve
(h)-(1)
DC-32 Z 05-12
CHAPTER
ITEM
Holder Guides
1. Gasket
2. O-ring
2-16
2-16
No.22
No.507
Snap Ring
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
<<Procedure of Chilling>>
Nozzle Holder
Guide Chilling Tool -1
Hammering
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
Figure 2
Figure 3
CHAPTER
3
ITEM
Holder Guides
DC-32
1.7
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
Installing location
of the snap ring
Area on which silicon
paste is to be applied
Locating Pin
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
DC-32 Z 05-12
CHAPTER
ITEM
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
CHAPTER
3
ITEM
DC-32
1.8
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
3
ITEM
of the Structure
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
Exhaust Valve
Intake Valve
Exhaust Valve
Seat
Intake
Valve Seat
DC-32 Z 05-12
Intake
Valve
CHAPTER
(3)
(2)
3
ITEM
DC-32 2.2,2.3
(1)
(2)
(3)
(1)
3
(d) Valve Finishing Spring
(1) (2)
#1
#1
E2
E1
#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.
Assembled position
of the intake valve
(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
ITEM
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
E
Intake Valve
Exhaust Valve
(mm)
(mm)
A = 22.5 a = 0.09 - 0.17
b = 0.09 - 0.17
B = 22
(mm)
0.3
0.3
DC-32 Z 05-12
D
Intake Valve Seat
F
Exhaust Valve Seat
Measurement of Dimensions
of the Valve Seats
CHAPTER
3
ITEM
and Maintenance
DC-32
2.4
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)
+15'
0
Intake Valve
0
-15'
Backside of the
Valve Head
+15'
0
Exhaust Valve
0
-15'
Corrective Machining/Grinding
of the Valve/the Valve Seat
DC-32 Z 05-12
CHAPTER
Standard
3-5
Service limit
Ball
DC-32 Z 05-12
Spring
CHAPTER
3
(b)-(1) Special Ring Nut
(b)-(3) Eyebolt M 12
(b)-(2)
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
Tightening Nut
Rocker Arm Shaft Holder (A)
DC-32 Z 05-12
CHAPTER
ITEM
Standard Clearance
(mm)
(mm)
D = 80
d = 0.04 - 0.13
Service limit
(mm)
0.30
(b)-(2)
(b)-(3)
(b)-(1)
Bushing
Rocker Arm Shaft
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).
DC-32 Z 05-12
CHAPTER
3
ITEM
DC-32
3.5
Flaws and
Contact Marks
Push Rod
Bend
Flaws and
Contact Marks
Flaws and
Contact Marks
Rocker Arm
Rocker Arm Cap (I)
Push Rod Seat
Inspection of the
Rocker Arm Cap
Flaws and
Contact Marks
DC-32 Z 05-12
CHAPTER
3
ITEM
Starting Valve
Piston (E)
O-ring (J)
Starting Valve
Gasket (H)
Mounting Bolt (M)
Starting Valve Lid (A)
Starting Valve Nut (C)
Starting air
O-ring (K)
Pilot air
DC-32 Z 05-12
CHAPTER
3
ITEM
DC-32 4.3,4.4
Hexagonal part
(D)
(H)
(J)
(B)
(K)
(L)
(I)
(G)
(E)
(C)
(A)
(M)
DC-32 Z 05-12
CHAPTER
3
ITEM
Assembling
Starting Valve
Starting Valve
Disassembling Tool
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
CHAPTER
Open
(1)
Joint
(3)
2-21
No.504
2. Gasket
2-21
No.505
3. Straight Pin
2-21
No.503
(4)
(5)
(2)
Safety Valve
DC-32 Z 05-12
CHAPTER
ITEM
(D)
(C)
(E)
(K)
(B)
(I)
(G)
(H)
(F)
(A)
Nut
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)
CHAPTER
3
ITEM
DC-32 5.4,5.5
(b)-(3)
Joint PT 3/8
Special Gasket Pump side
(b)-(4)
(b)-(5)
(b)-(2)
DC-32 Z 05-12
CHAPTER
ITEM
DC-32 Z 05-12
and Installation
CHAPTER
ITEM
DC-32 6.1,2,3
3-4.1
3-4.1
3-4.1
No.506
No.507
No.508
O-ring (E)
Special
Flange (C)
Mounting
Bolts (F)
O-ring (D)
Cylinder Head Outlet of the
Cooling Water Pipe (A)
O-ring (H)
Orifice (G)
DC-32 Z 05-12
CHAPTER
3
ITEM
6.4,6.5 DC-32
DC-32 Z 05-12
CHAPTER
3
ITEM
DC-32 7.1,2,3
Intake Manifold
(head inlet) (A)
Dowel
Pin (C)
Mounting Bolt (E)
Cylinder Head
Intake Manifold
(head inlet)
Eye Bolt M 12
Pushing Bolt to
separate the flange
from the cylinder head
DC-32 Z 05-12
CHAPTER
ITEM
DC-32 Z 05-12
CHAPTER
MEMO
3
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
ITEM
of the Structure
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)
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
CHAPTER
4
ITEM
(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)
DC-32 Z 05-12
CHAPTER
ITEM
(1)
(4)
(3)
(2)
(4)
(4)
(1)
(3)
(2)
(2)
TO
(1)
(1)
(2)
DC-32 Z 05-12
CHAPTER
4
ITEM
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)
Tapping Handle
Tap (M16 x 2.0)
DC-32 Z 05-12
CHAPTER
ITEM
of the Piston
(A)
(d)-(2)
(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")
DC-32 Z 05-12
(d)-(1)
CHAPTER
4
ITEM
3.1
4
Lid (for the cylinder liner)
Dust-proof Lid
(l)-(4)
Piston Pin (D)
(l)-(1)
(l)-(3)
(l)-(2)
50
35
136
Wooden Bolster
Wooden Bolster
DC-32 Z 05-12
CHAPTER
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).
(c)-(3)
(c)-(2)
(c)-(1)
(d)-(2)
(d)-(3)
(d)-(1)
DC-32 Z 05-12
(C)
(g)-(2)
(g)-(1)
(C)
(g)-(3)
CHAPTER
4
ITEM
DC-32
3.2
(k)-(3)
50
(k)-(1)
(k)-(4)
DC-32 Z 05-12
CHAPTER
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).
DC-32 Z 05-12
CHAPTER
4
ITEM
DC-32
4.1
(1)
Top Land
(3)
(5)
(2)
4
Checking of Condition
of the Piston
Oiling Hole
Piston Skirt
DC-32 Z 05-12
CHAPTER
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.
P
Nut
Washer
O-ring
Piston Crown
Bolt
Piston Crown
DC-32 Z 05-12
CHAPTER
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
DC-32
200
0.095 - 0.135
Replacement Limit(mm)
0.25
A = 150
Piston
Pin Boss
Nominal Diameter(mm)
Piston Pin
DC-32 Z 05-12
CHAPTER
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.
C1
No. 1 (Top) Ring
C2
Compression
Rings
No. 2
C3
No. 3
a = 0.15 - 0.19
b = 0.12 - 0.16
b = 0.12 - 0.16
d = 0.05 - 0.11
0.3
0.3
0.3
0.3
DC-32 Z 05-12
No. 2
Compression
Rings
No. 3
A=7
B=7
C=7
D = 10
Oil Ring
C c
C4
A a
B b
Oil Ring
CHAPTER
4
ITEM
4.3
A = 150
a = 0.09 - 0.19
0.35
Circular
Nuts (K)
Oiling Holes
Mating Surfaces
Oiling Hole
DC-32 Z 05-12
CHAPTER
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.
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
0.35
Fretting
DC-32 Z 05-12
CHAPTER
4
ITEM
DC-32
4.5
Bolt Number
4
Molykote 1000
Spray
Thread to be
Embedded
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
Bolt Number
Crankpin Bolt
DC-32 Z 05-12
CHAPTER
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.
DC-32 Z 05-12
Mark to identify
the forward
direction
Punched identification
marks such as the
cylinder number
Circular Nut
Crankpin Bolt
1 Bolt Number
CHAPTER
4
ITEM
Assembling :
Assembling of Pistons
DC-32
5.2
P
Nut
Washer
Piston Skirt
O-ring
Piston Crown
Bolt
Spring Pin
Piston Crown
DC-32 Z 05-12
CHAPTER
ITEM
Assembling of Pistons
DC-32 Z 05-12
CHAPTER
4
ITEM
DC-32
5.3
(l)
Piston
Marks
Joint
No. 1 Ring
(Top Ring)
No.2 Ring
No. 3 Ring
Oil Ring
(with an coiledexpander)
DC-32 Z 05-12
CHAPTER
ITEM
Oiler
Lubricating Oil
Oiler
Lubricating
Oil
Cylinder Number
Position of the "P" stamped on the top surface of the piston crown
DC-32 Z 05-12
CHAPTER
4
ITEM
DC-32
5.3
2
1
(View "P")
P
Connecting Rod Joint Bolt
Marks
Cylinder Liner
Connecting
Rod Joint
Bolt
Dowel
Pin
Protect Ring
DC-32 Z 05-12
CHAPTER
4
ITEM
2
1
Sequence of Attaching
the Hydraulic Jack
1
2 or 2 1
DC-32 Z 05-12
CHAPTER
MEMO
4
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
ITEM
1 DC-32 The Engine Frame and Cylinder Liners : Outline of the Structure
5
Cylinder Liner
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
CHAPTER
(5)
5
ITEM
(1)
(4)
(3)
5
(2)
"a" "b"
"c"
"d"
(2)
(3)
(1)
DC-32 Z 05-12
CHAPTER
5
ITEM
(c)
D = 320
a = 11.5
Direction P-S
Direction A-F
"b"
"c"
"d"
(d)
- 0.30
DC-32 Z 05-12
CHAPTER
5
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
4 DC-32
ITEM
DC-32 Z 05-12
Cylinder Head
Tightening Nut
Cylinder
Head Bolt
(A) (b)-(1)
(b)-(4)
(b)-(3)
Cylinder Liner
Holder
O-rings
Center Shaft
(b)-(2)
CHAPTER
B2
C
G
H
J
DF
B1
DL
K
L
DC-32
F
E A D
Inspection and
Maintenance :
5
ITEM
(e)-(2)
(e)-(3)
(e)-(1)
DC-32 Z 05-12
CHAPTER
ITEM
Cylinder Liner
Holder
O-ring
Engine Frame
Cooling Water Inlet Pipe
(b)-(5)
(b)-(1)
DC-32 Z 05-12
(b)-(2)
"G"
"F"
Cylinder Liner
(b)-(3)
(b)-(4)
CHAPTER
5
ITEM
DC-32
(A)
(b)-(5)
(b)-(1)
(b)-(2)
Cylinder
Head Bolt
Cylinder Liner
(b)-(3)
(b)-(4)
DC-32 Z 05-12
CHAPTER
7 DC-32
ITEM
5-7
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)
(d)
(c)
View Q
Piston
Cylinder Liner
View P
CHAPTER
5
ITEM
DC-32 Z 05-12
CHAPTER
ITEM
of the Structure
Oil Hole
Main Bearing
Side Bolt
Engine Frame
Main Bearing
Weight of ;
The main bearing cap
(for a middle journal)
: 135 kg
: 144 kg
:
:
Crankshaft
5 kg
2 kg
Main Bearing
(for a middle journal)
Main Bearing
(for the base journal)
Thrust Bearings
DC-32 Z 05-12
CHAPTER
6
ITEM
(2)
6
(1)
(2)
(3)
(3)
(2)
(1)
(2)
DC-32 Z 05-12
CHAPTER
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.
(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.
(f)-(2)
95
(e)-(2)
()-(3)
(e)-(1)
DC-32 Z 05-12
(f)-(1)
CHAPTER
6
ITEM
DC-32
3.1
(g)
Main Bearing Cap
Tightening Nut (C)
(f)-(2)
(f)-(1)
(c)-(3)
(c)-(2)
(c)-(4)
(c)-(1)
DC-32 Z 05-12
CHAPTER
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.
(g)
(f)-(2)
(f)-(1)
(c)-(3)
(c)-(4)
(c)-(2)
(c)-(1)
(h)
(f)-(2)
(f)-(1)
(c)-(3)
(c)-(4)
(c)-(1)
(h)
(g)
DC-32 Z 05-12
CHAPTER
6
ITEM
DC-32
3.1
Locating
Protrusion
(b)
Upper Bearing Metal
Crankshaft
Lower
Bearing Metal
DC-32 Z 05-12
CHAPTER
ITEM
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
Main Bearing
Surfaces
at the
closed gap
Fitted
area
Fitted
area
CHAPTER
Main Bearings
Assembling and Installation of
and Thrust Bearings : the Main Bearing
ITEM
DC-32
3.3
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.
DC-32 Z 05-12
CHAPTER
ITEM
DC-32 Z 05-12
CHAPTER
6
ITEM
DC-32
4.1
Crank Web
Dial Gauge
Dowel Pin
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
DC-32 Z 05-12
CHAPTER
6
ITEM
Main Bearings
4.2,4.3 DC-32 and Thrust Bearings : Maintenance and Installation of Thrust Bearings
Replacement Limit
(mm)
(mm)
d = 0.30 - 0.51
0.80
(mm)
D = 168
Locating hole
for a dowel pin
D
d
DC-32 Z 05-12
CHAPTER
MEMO
6
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
The Crankshaft
7
ITEM
of the Structure
6DC : 4050 kg
8DC : 5495 kg
Balance Weight
Crankshaft
DC-32 Z 05-12
CHAPTER
The Crankshaft
ITEM
DC-32
7.2
(1)
(2)
(3)
7
(c) Hydraulic Jack L for Tighten the
Balance Weight
(3)
(1)
(2)
(2)
(1)
(3)
DC-32 Z 05-12
CHAPTER
The Crankshaft
ITEM
of Crankpins
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).
DC-32 Z 05-12
Oil Hole
Fillet
CHAPTER
The Crankshaft
ITEM
DC-32 3.2,3.3
Fillet
When its dismantling is found necessary as the result of the inspection, please consult with the Service Division of DAIHATSU.
7
Oil
Holes
Balance Weight
Balance Weight Tightening Nut
Balance Weight Tightening Bolt
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
DC-32 Z 05-12
Crankshaft
CHAPTER
The Crankshaft
MEMO
7
ITEM
DC-32
DC-32 Z 05-12
CHAPTER
ITEM
of the Structure
Weight of ;
36 kg
Cam Gear
75 kg
87 kg
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
DC-32 Z 05-12
129 kg
(G)
CHAPTER
8
ITEM
DC-32
1.2
DC-32 Z 05-12
CHAPTER
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
DC-32 Z 05-12
CHAPTER
Camshaft
Idle gear
Replacement limit
(mm)
d = 0.15 - 0.20
e = 0.30 - 0.60
(mm)
0.40
0.80
Standard value
Replacement limit
(mm)
(mm)
b= 0.20 - 0.33
0.60
ITEM
DC-32
1.3
(P)
(O)
(F)
(B)
(C)
(Q)
Backlash b (= A+ B)
(b)
(F)
DC-32 Z 05-12
CHAPTER
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")
B)
Standard value
Replacement limit
(mm)
(mm)
b = 0.20 - 0.33
0.6
DC-32 Z 05-12
Camshaft
(E)
(S)
Engine Frame
Hexagonal
Wrench
Torque Wrench
Matching Mark
(R) (notched line)
Detachment of the
Governor Driving Gear
(D)
Engine
Frame
(R)
Camshaft
CHAPTER
8
ITEM
DC-32
1.4
(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
(S)
(Z)
(R)
(D)
Engine
Frame
: section 8-1.4 D)
(E)
(R)
Camshaft
DC-32 Z 05-12
CHAPTER
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)
(D)
Engine
Frame
(E)
Camshaft
DC-32 Z 05-12
CHAPTER
Standard Clearance
(mm)
A = 200
(mm)
a = 0.10 - 0.31
Replacement Limit
(mm)
0.40
1.5
(C)
(B)
(G)
DC-32
8
ITEM
(F)
Fastening
Bolt
(Q)
DC-32 Z 05-12
CHAPTER
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.
Cam Gear
Shaft (E)
Thrust Metal
(oil retaining recess)
Lubricating Oil Drain Hole
Cam Bearing Case
DC-32 Z 05-12
CHAPTER
8
ITEM
DC-32
1.7
(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)
(N)
(H2)
Distance
Piece
DC-32 Z 05-12
CHAPTER
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.
DC-32 Z 05-12
CHAPTER
8
ITEM
of the Structure
DC-32
2.1
<6DC>
590kg
Camshaft Assembly
<8DC>
725kg
(with the cam gear shaft. the cam gear and the governor driving gear)
115kg
115kg
139kg
139kg
Governor
Governor Driving Device
Fuel cam
Camshaft Bearing
Camshaft
Intake Cam
Exhaust Cam
DC-32 Z 05-12
CHAPTER
ITEM
(3)
(1)
(2)
DC-32 Z 05-12
CHAPTER
8
ITEM
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.
Camshaft
Cover
Intercooler
Cam Gear Cover
Valve Train
Cooling Water Pump
Lubricating
Oil Pump
Gear Case
DC-32 Z 05-12
CHAPTER
8
ITEM
Standard Clearance
Thrust clearance (axial play)
Replacement Limit
(mm)
d = 0.15 - 0.20
(mm)
0.40
Camshaft Bearing 3
Cam Gear Shaft
Camshaft Bearing 2
Camshaft Bearing 1
Nominal Diameter
Standard Clearance
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")
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
Thrust Metals
DC-32 Z 05-12
CHAPTER
8
ITEM
of the Camshaft
DC-32
2.5
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
Rear end
DC-32 Z 05-12
CHAPTER
ITEM
DC-32 Z 05-12
CHAPTER
8
ITEM
DC-32
2.6
Cam Gear
Cam Gear Shaft
Distance Piece
Camshaft
Scribed Line
(on the boss of the cam gear)
Dial
(on 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
DC-32 Z 05-12
CHAPTER
ITEM
of the Structure
Weight of;
(E)
(D)
(C)
(B)
(A)
DC-32 Z 05-12
CHAPTER
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
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)
DC-32 Z 05-12
CHAPTER
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.
(D)
(B)
(J)
(I)
(A)
(H)
(F)
(G)
(A)
(J)
(G)
(K)
(H)
Shims
(b)-(3)
(b)-(2)
(b)-(1)
(J)
DC-32 Z 05-12
CHAPTER
9
ITEM
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)
DC-32 Z 05-12
CHAPTER
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).
DC-32 Z 05-12
Flange
Upper surface of
the Plunger Barrel
CHAPTER
9
ITEM
The Fuel Injection System : Inspection and Maintenance of Fuel Injection Pumps
DC-32
4.2
Deflector
Plunger
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
(mm)
B = 45
Standard Clearance
(mm)
b = 0.06 - 0.10
Replacement Limit
(mm)
0.20
Nominal Diameter
DC-32 Z 05-12
CHAPTER
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
Pump Housing
Backup Ring
O-ring
Backup Ring
DC-32 Z 05-12
CHAPTER
9
ITEM
Plunger Barrel
DC-32
4.3
Molykote 1000
9
Thread Hole
Flange
DC-32 Z 05-12
CHAPTER
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.
7
5
Plunger Barrel
Delivery Valve
Spring
Discharge
Valve
Delivery Valve
Spring
Spring Seat
Return
Valve
3
5
6
4
Pin (2 pcs.)
Sequence of Tightening of
the Socket Head Bolts
DC-32 Z 05-12
CHAPTER
9
ITEM
DC-32
4.3
Deflector
O-ring
Control Rack
Stand
Control Sleeve
Control Rack
Control Sleeve
DC-32 Z 05-12
CHAPTER
ITEM
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
DC-32 Z 05-12
CHAPTER
9
ITEM
(E) (P)
(L)
(O)
(Q)
(R)
(D)
(C)
(B)
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
ITEM
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
No.3
No.5
DC-32 Z 05-12
Valve Train
Camshaft
CHAPTER
10
ITEM
DC-32
3,4
(A)
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)
DC-32 Z 05-12
CHAPTER
10
ITEM
Nominal diameter
Replacement limit
(mm)
B = 35
(mm)
b = 0.03 - 0.11
(mm)
0.2
(E)
(G)
(F)
(E)
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.
DC-32 Z 05-12
Oiling Groove
(D)
(B)
(A)
CHAPTER
MEMO
10
ITEM
DC-32
10
DC-32 Z 05-12
CHAPTER
ITEM
Weight of ;
Governor
Control Lever
Terminal Shaft
Governor Link
DC-32 Z 05-12
CHAPTER
Backlash
Standard backlash
Replacement limit
(mm)
0.1 0.15
(mm)
0.3
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)
DC-32 Z 05-12
11
CHAPTER
ITEM
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
DC-32 Z 05-12
Weight of ;
3-3.2
No.
3-3.2
No.
: 2-2)
Intercooler
Flexible Joint
Exhaust Gas
Flexible
Joint
CHAPTER
12
ITEM
The Intercooler :
Intercooler
DDB207XBLF :
980 kg
2-30
No.9
No.29
No.28
No.8
Engine Frame
12
(J)
Turbocharger
Turbocharger Bracket
(E)
(F)
No.32
"Parts List")
(c)
: 2-2)
(C)
(I)
(E)
(A)
(B)
(G)
(I)
(D)
Intercooler
DC-32 Z 05-12
CHAPTER
12
ITEM
DC-32 Z 05-12
12-3.5
CHAPTER
MEMO
12
ITEM
DC-32
12
DC-32 Z 05-12
CHAPTER
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
Starter Push
Button
CHAPTER
Weight of ;
3-1.3
No.3
2.Split Pin
3-1.3
No.7
3.O-rings
3-1.3
No.503 - 510
(C)
(D)
(H)
(I)
(S)
(Q)
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
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)
DC-32 Z 05-012
CHAPTER
13
ITEM
2.4,2.5 DC-32 The Main Air Starting Valve : Inspection and Maintenance/Assembling
13-2.4
13-2.5
(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.
DC-32 Z 05-12
CHAPTER
13
13-3.4
(mm)
A = 30
13-3.2
ITEM
Replacement limit
(mm)
(mm)
= 0.01 - 0.10
0.20
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
3-1.4
No.8
3-1.4
No.9
3-1.4
No.505.506
3-1.1
No.510.511
(K)
(E)
(H) (D)
13-3.3
(B)
(I)
(G)
(L)
(C)
(M)
(F)
(J)
(N)
DC-32 Z 05-012
13
CHAPTER
13
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.
13-3.5
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
13
ITEM
The Starter Push Button and the Handle Switch : Outline of the Structure
DC-32
4.1
Governor
Handle Switch
Control Handle
Starter Push Button
13
DC-32 Z 05-012
CHAPTER
14
ITEM
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
Leaked Waste
Oil Tank
CHAPTER
14
The Fuel Oil Outline of the Structure/Consumable Replacement Parts, Special Tools and
Relief Valve : Measuring Instruments/Dismantling/Inspection and Maintenance/Assembling
14-2.2
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
ITEM
14-2.4
14-2.5
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
(B)
(C)
DC-32 Z 05-12
CHAPTER
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)
Rocker Arm
Turbocharger
Filter
Lubricating Oil Cooler
Piston
Camshaft
Relief
Valve
Filter
Thermostat
Valve
Sludge
Collector
Timing Gears
Pump
Safety
Valve
DC-32 Z 05-12
CHAPTER
15-2.3
Dismantling of the
Lubricating Oil Pump
15-2.2
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
Backlash
Replacement limit
(mm)
(mm)
0.3 - 0.6
0.8
DC-32 Z 05-12
15
CHAPTER
15
ITEM
(H)
(F)
(J)
(R)
(L)
(K)
(D)
(E)
(C)
(B)
(P)
(A)
(N) (M)
(L)
Side of the
needle bearing
(Q)
Lithium grease
Installation direction of the oil seal
15-2.4
(S)
15-2.5
Assembling of the
Lubricating Oil Pump
DC-32 Z 05-12
(G)
(V)
(W)
CHAPTER
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 ;
15-3.2
470kg
970kg
15-3.3
Detachment of the
Lubricating Oil Cooler
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
(c)
(C)
(A)
15
(1)
(2)
(E) (F)
(B)
DC-32 Z 05-12
CHAPTER
15
ITEM
Dismantling of the
Lubricating Oil Cooler
15-3.5
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.
Example of the
marking
(by a marker pen
or some other)
(F2)
DC-32 Z 05-12
(E)
(F1)
(d)
(b)-(1)
(G)
(J)
(H)
(L)
(K)
(b)-(2)
CHAPTER
15
ITEM
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.
3.6
(b)-(1)
(d)
(E)
(L)
(K)
(b)-(2)
G
B
BG
15
DC-32 Z 05-12
CHAPTER
15
ITEM
15-3.7
Honeycomb-like Structure
(F)
(b)-(1)
(G)
(E)
(L)
(K)
(b)-(2)
(d)
Attaching the Eye
Bolts M16 (c)
(d)
(b)-(2)
(E)
(F)
391
(G)
DC-32 Z 05-12
(K)
CHAPTER
(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 ;
15-4.2
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
3-3.12
3-3.12
No. 7
No. 505
15-4.3
Dismantling of the
Lubricating Oil Relief Valve
(G)
(H)
(F)
15
(D)
(E)
(A)
(C)
(B)
DC-32 Z 05-12
CHAPTER
15
ITEM
4.4,4.5 DC-32 The Lubricating Oil Relief Valve : Inspection and Maintenance/Assembling
15-4.4
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.
DC-32 Z 05-12
CHAPTER
DC-32 5.1,5.2
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
3-3.13
No.503,504,505
2. Gaskets
3-3.13
No.506,507
3. Pellet
3-3.13
No.4
(O)
(G)
(Y1)
(R)
14.5
15-5.2
15
ITEM
(Z3)
(T)
(S)
(Y2)
(V)
(N)
(J)
(K)
(P)
(H)
(Z2)
(L)
(U)
(Z1)
(E)
(M)
Weight of ;
(F)
B
(W)
(X)
A
(D)
DC-32 Z 05-12
15
CHAPTER
15
ITEM
Dismantling of the
Lubricating Oil Thermostat
Valve
Dismantling/Inspection and
Maintenance/Assembling
15-5.4
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
Assembling of the
Lubricating Oil Thermostat
Valve
CHAPTER
MEMO
15
ITEM
DC-32
15
DC-32 Z 05-12
CHAPTER
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
Head Tank
(hydraulic pressure)
Bypass Valve
Lubricating Oil Cooler
Intercooler
Jacket System
Cooling Water Pump
Cooler System
Cooling Water Pump
Thermostat
Valve
Thermostat
Valve
CHAPTER
16
ITEM
DC-32 2.2,2.3
16-2.3
Backlash
Standard backlash
Replacement limit
(mm)
(mm)
0.3 - 0.6
0.8
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
Bolt
(T)
(J)
(B)
(E)
(D)
(N)
(K)
(H)
Plug
(L)
(G)
(F)
(M)
(Q1)
(O)
(P)
(Q2)
(C)
(S)
(Y)
(U)
(R)
DC-32 Z 05-12
16
CHAPTER
16
ITEM
(mm)
a = 0.44 - 0.56
(mm)
1.0
Mouth Ring
Standard clearance
Impeller
(radial clearance)
16-2.4
and Maintenance
DC-32 Z 05-12
CHAPTER
16
ITEM
2.5
Oil Seal
Impeller side
Gear
side
Seal Ring
Bellows
Impeller side
16-2.5
DC-32
16
DC-32 Z 05-12
CHAPTER
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
16-3.1
16-3.2
DC-32 Z 05-12
40
(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)
(L)
(C)
(J)(K)
Gear Case
CHAPTER
16
ITEM
16-3.3
Dismantling/Inspection and
Maintenance/Assembling and Installation DC-32 3.3 - 3.5
16-3.4
16-3.5
A. Assembling of the bypass valve is to be effected in the reverse sequence of that for the dismantling.
DC-32 Z 05-12
16
CHAPTER
17
ITEM
(
: "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)
Starter Lever
(for emergency use)
Cylinder Head
Starting Valve
Main Starting Air Valve
Main
Starting
Air Valve
Pulse Sensor
12
13
14
C
Fuel Injection
Pump
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
Weight of ;
17-2.2
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
17-2.3
(A)
(B)
(C)
(F)
Control Cylinder
(E)
Governor Lever
O-ring
17
Common Rod
DC-32 Z 05-12
CHAPTER
17
ITEM
(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.
For Fuel
Cut-off
Lock Nut
(I)
(Q) (G1)
(P)
(M)
(V) (Z)
For Fuel
Cut-off
For Fuel
Limiting
(U) (T)
(G4) (F)
(R)
(E)
Lock Nut
(S)
(X2)
(T)
(X1)
DC-32 Z 05-12
CHAPTER
17-2.6
Lever
For fue
cut-off
For fue
cut-off
For fuel
limiting Lock Nut
Common Rod
DC-32 Z 05-12
17
CHAPTER
18
ITEM
18-1.2
Consumable Replacement
Parts, Special Tools and
Measuring Instruments
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.
Gauge Board
Bracket
3-6.1.2 No.513
18-1.3
DC-32 Z 05-12
Vibration
Isolating
Spring
Hose
Needle Valve
Flexible Cable
Gauge Board
CHAPTER
18
ITEM
Seal Pot
DC-32
(B)
(a)
(C)
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