CONTENTS

El
Instruction JV\2-01
~~~afi11

Parts list
~ ~ ~

D M.D.O. Engine
A m:51Bf±~•ru1
D Heavy fuel Engine ( I 80 cSt/50°C)
ffi:1U?&~51Bflfl3•ru1 c m:51B ( 1500f.P)
f9"Heavy fuel Eneine (380 ......... 700 cSt/50°C)
{~jf;t?&~51Bflffl•ru1 c m:51B (3500'"'-'7000f.P)

1. Speed 'ISfno. 750rpm 9. F .0. nozzle D Hole dia 0.26

iiM~@l~~ ~HlljM# 7\1l 0.26
D 900rpm
[k(Hole dia 0.28
0 1000rpm
7\il 0.28
2. Direction of revolution Hole dia 0.30
~IU'l@l~)J[EJ 19"'standard (R) 7\1l 0.30
~~ Hole dia 0.32
Reverse (L) '.JC1l 0.32
~~
11. Capacity of L.0. cooler
3. Front P.T.O. 0 With )!'1Ji~i$ff;-t!J~'.g:I: ~Sm'
7 7 :.-- 7 'ilriltr'Z'ffi ~
12m'
11.J 1.J IiX t±l i¥Without
16m'
~

4. Cam shaft ~Solid

10. Inter cooler type 0 DK30 lifDK~l
~~Ri"~Pti1f~~ 0 DK44 0 OK44Hz
fJ L. 'm ~~
D Built-up D 0057 0057Hz
-51-~IJ
12. C.W. pump lifinper dia 170
5. Turbocharger type ff;-~7)<.;f;:,,.-7' ., :,..-....:. 71l 170
®wfi~~~ 0 VTR161 0 VTR214 lnper dia 180
0 VTR201 0 RH183 ., /-"'71l 180
a'i<!iB3 NR15/R

6. Arrange met turbocharger

®wfi~ru:'.11'. [H'Front side

D Rear side
f~'Z'ffi

7. Governor type
~~~1f~~
D UG 10
rM"RH06 ~I\\ '1 "T£ 0
8. F.O. injection pump
~HlljM;f; / 7' O Planger dia 20 voe l>~\S'/
7' 7 / :;; "" ii 20
l9'Planger dia 21
7°7/:/"'71l: 21

NOTE ; Items marked 0 are applied for your diesel engines.

}~ pg J i::p tJ'~*113A..~~j i= ~ffl <!!- n -CL' 0 r~ El -c-9o
 ORDERED BY;
OSHIMA SHIPBUILDING CO., LTD.
1nfJ 5i Jt . 3:: ;
DESTINED FOR ;
Ditto SNo. 10221
~ J... $t;
ENGINE MODEL ; ENGINE NO ; DK520Z0166
5DK - 20 w !l!fll .w. .g ·, DK520Z0167
l1l 00 ]fj it ; 1Jjl{; r.RJ w ._, DK520Z0168
DATE OF MFG; Oct~ 1997
~l§$F.I;

.s td. ti I,.\ Forward

*•~•~i~ffl9~~0&m~~~-c This instruction book deals with the

1. \ t:. t:
;f)> ~ tJ ti. (;f id: s \,
~ \£;$:8{] ~:. t tf fundamental knowledge required for
0 ~ !2J!A: t.: f) 0·e &> ~J °* T tJ• S, +-51-1.~~Jt operation and handling.It is, therefore,
~1~ L., T 1,' t.:: t.:· ~ , '*'
i: J: ~ J ~ 1,' C::!IM Z: ardently requested to follow the working
as well as maintenance instructions,
m'.91:i.~~PJ, •~t=,~t.,*n-c, &m1,\0
r C:. - I j i 0 J-J. C:. /,,, C \, \ f.:: fc ~J t1. (;f, • ~0 so that you may enjoy the utmost
Jt if, -~; i.it ';f l, ,
tY:) *
-c' B )f.iij JE 9 A: ~ ti( i~ durability and satisfactory operation of
our Diesel Engine for many years to
-cJ£$i L, -C \., t.:: t: ~t ~ Z. t t 1T t.;; °*Ta
come.
~-$£~•tt0m~HES~i~ffll
For renewal parts, use our genuine
cr-· ~ 1,' a m~HEB!Jaii .L.:L 9} i fYI! ffl ~ ti. t.::
ones, utherwise we cannot guarantee
~~-•ttu£•0~HU~*"*tl/,,,o
the part quality.
8~0$~c i C::)i:fl.1,' f.:: fc <~(: (j:, :;$: When ordering some parts of the
in: t:cti 1_, -c &>-!> S£~ s J: tfS£=1=-i5-': Diesel Engine, please specify the Type
ct~ -c1,'t.::tc. < e:~'=- ~,-r•~~~t• and No. of Engine, together with names
r~ =i=-i5- i s ~ S tt T ~ ~ J: ? s ~ 1,' 1,' t.:: l of articles and their reference numbers,
°*"to as detailed in this book.
s~~htt, C::~~UT~~C::~MT~ When you give us your order or
-!> J: ? s~1,' 1, \ t.:: L., °*Ta for further information, please contact.

Orders; PARTS SALES DEPT.

Information;
AFTER SALES SERVICE DEPT .

.DAI HATSU DIESEL MFG. CO.,lTD.

7::il.&:m'*'~m1&#S1T 2 Ts 4 ~i4-i5- ~54o 4-14, TOKUl-CHO 2-CHOME, CHUO-KU, OSAKA,
· $a1~*fill?$0 TEL. (06)945-5325 540 JAPAN.
FAX. (06)945-5304~6 FAX. (06)945-5304-6 TLX. 5242723 DAIHAT-J,,C
TEL. (06)945-5327 ·PARTS SALES DEPT. ················· .. ··TEL. (06~5-5325
FAX. (06)945-5304~6 ·AFTER SALES SERVICE DEPT ... ····· ·TEL. (06)945-5326
 T ST R CORDS OF HE DIESEL ENGINE
AT SHOP TRIAL

RECORDS OF SHOP TRIAL

DAil!ATSU D.IESEL IFG. CO., LTD.

r·-·-·-~-·-·-·-·-·- -·-·-·-·-·-·-·-·-~-·-·-·-·-·-·-·-·-·-·-·-·-·-·-·-·-·,
' '
I I

SPECIFICATIONS

FOR

DAIHATSU DIESEL GENERATOR ENGINE

I
·-·-·-·-·J

DAIHATSU DIESEL MFG. CO., LTD.

( 1 6
 The Diesel will be ied with the of
the of the latest issue.

1. Det Norske Veritas (DNV -

2. trial standard (JIS)
3.
The other not in this
on the basis of control
standard.

Diesel to the alternator and

on the fabrication.
The diesel be r installed 's
structure.

which are connected to the

II JIS II.

ied

The be written in
The will be written

All surface will be coated with anti-corrosive

1
s standard, and the fin color of
with customer's instruction in MUNSELL No.
MUNSELL No.

oil :
API CD KOH of TBN, SAE
and

For Same as oil SAE #

31
 with proper external can be
vis cos up to est to the

at 5°C
Residual carbon (wt %)
):
.. Max.
Max.
0.
18
(wt %) .. Max.
5.0
Vanadium ( ): Max.
Water (vol ): Max. 1.0 *1
Ash (wt "/.) : Max. o. 15
Aluminum ( ) : Max. *1
Pou:r (oc) Max.
Flash (oc) Min.
CCAI Less than

Remarks:

*1 : To be eliminated best available method such

The of aluminum and
and 0.2 % before

CCAI Index.

Marine Diesel oil ( of 1.5 -6.o est at c )

Note:

1. of oil at inlet
within the value of Redwood No.1,
in any case.

2. , use
(a) When and while the at
least
(b) load to . (While
c) the below about kW in
(d) hours for the
first time. (
(e) When the

3. Automatic control oil i be

131 ( 6
1.

' s , trunk
air cooler.

Model;
inder bore x stroke; 0 x mm

PS

rpm

Brake-mean pressure;
Mean

Maximum (

Rotation; view from side to

air motor ;
(Remote/Auto. & Manual at local
side)
Cool Jacket,
head,
Exh. valve seat
Fuel nozzle

sea water .oil

air cooler
. oil Piston

Maker; NISHISHIBA Electric Ltd.

kW, Hz, v' 10 ' 0 p.f.

lubrication Self

The numbers of sets: (3)

3 16
2. Construction and

This Daihatsu diesel intake and

exhaust valves with rotators per cool
the crankcase lubr oil, main and shell of aluminum
metal lined thin-shell treatment of
the crankshaft.

At the of the crankshaft end, the end is

and for AC Generator.

The opposite side is refered to as the front side of

where all the and are
Lubr on this side, and it driven
means

bear
structure, which is ion pressure.

The frame has on the both side

be taken out the main and , and other

A intake air duct is located above the on the exhaust

side to from double wall construction to about
effect.

A gear case of monoblock construction with the is formed

in the rear of the to reduce gear vibration and noise.

Also cool are built into this

to
The main to the
and two

The crankshaft is made of , and

the of the crank shaft ls treated in
resistance wear.

torsional vibration
and

liner is made cast iron

its inside

made r so
even under pressure and the

31 6
 shell is made of aluminum it in
It is and
i

The is made cast iron as monoblock

cooled crankcase lubr the connect rod and
inside.

are chromium to have

resistance

iron,
all

head is made cast steel. It has a

fuel nozzle on its and each 2 of intake and
exhaust valves, valve with indicator valve are
around nozzle.
The cool water is corrected in the center the drill
between the exhaust and intake valves the cool

3 6
 Both intake and exhaust valves are mushroom of heat resistance
steel, and are provided with the valve rotators and removable seat r

exhaust is nimonic material and heatresistance

steel.
The exhaust valve seat is water and the treatment of
anti-corrosion is ied for
The intake valve seat cast iron.

rod steel, and it is constructed so

and the end is
hor
with lead
bronze. aluminum
thin shell

with a of Bosch are

inder.

fuel pump is

Fuel the fuel

pumps and heat box in
order to radiation from and

the solenoid valve, the to

every pump's rack takes action oil
delivered from the pump and

with drill hole

is in to a structure.

3 )
3. and

As the start valve is excited s of

pressure of abt.

the s from

Fresh water :
The cool water delivered from the pump driven flows
1nder exhaust valve seat, fuel nozzle, heads
one.
After that the cool is and
to the water

water

sea motor s
the air cooler, oil cooler and escapes
out to the overboard.

on the case cover is the

Lube oil sucked up from the oil sump is sent out and
oil , crank
arm, valve rocker arm,
some oil cooles

in rest,
electric motor driven of continuous is
To the oil cooler and oil excessive
pressure, a relief valve is attached on the oil filter.

3 ( 6
 The
exhaust
to
The exhaust should be so that total
rated is less than mm water column at
An expansion should be
outlet.
number of be and
to absorb thermal exhaust gas duct and to
and from the hull
The cover is the exhaust
manifold in order to

care be when
installed.
1) be directed
air intakes on the
volume for full load;
one (1)
2) F.W. pressure at inder line inlet should be
to 3.5

3) of M.D.O. servise tank should be fitted than 1.6 m

the center of crank shaft for (s)
to start, and invation of air fuel oil line.
F he at

13 6
4.
(each one to be attached to the
(ZEXEL made,

AC 10,

mechanical device

The exhaust drives the the

Model IHI )
With blower side

Tube with fin

cast iron
tube,
tube
Inside of covers are

Tube
Cool 8
cast iron JIS FC200
end cover cast iron JIS
tube JIS
tube end JIS
Inside of end covers are with
: (For ) driven

131 16
 Normal use
6.0

suction s {built in tank)

del 200 mesh, notch

blow off device for
mesh, notch
off device for

* side To
(For H.F.O., M.D.O. tank outlet)

del
(Final filter ) 200 mesh,
blow off device

To be
{Recommended filtration 10

on the rule's

With dev
attached cooler

common bed
e

Attached to the (F.

side)
5 e, with level

Hand ratchet
Steel fabrication insulation

Welded with lube

tank for ine.
Screwed into the common bed

Turbine

15 -
(2

Stainless steel bellows

pump

131 21 6
 consists of gauges
Tachometer Scale 200 - 000 rpm
Fresh water
Scale range 0 - 6
Lub. oil 0 - 10
Scale 0 - 3
Fuel oil 0 - 10
Lub. oil 0 - 10
For Fuel is attached.
stem
Lub. oil; 0° - 100°c
0° - 1
Fresh water; oo -
oo -
0° - l00°C
Exhaust
oo -
Intake air; intake oo -
Fuel ; engine i n l e t - - - - - - - oo -
Sea water ; Air cooler 0° - 100°C

DAIHATSU will and root valves on for

and pressure transmitters of 1
s

Measur Alarm
( )

a)Root valve for transmitter

(1) L.O. inlet (for and 2. l

b
( 1)
{2}
(3)

Remarks)
1. The to be as

PF mm for - L.0. 1 C.W.

- Exh. inlet
H· mm
'
L

31 16 )
6. Accessories auto & remote start and
(each one to be attached to the

1. air
2. Electric motor driven
1. 1
class B
3. Pulse sensor
rloronr; ,.,.., )
_....,,,,,,,,,,,.vv.4.V4.J I

4. Fuel shut down valve(for control and

5. Handle switch, when the lever is located at
tion.
6. switch, to s when the turn bar
in the stand.
1. shut down device at each fuel
pump (for
8. F.O. control
9. Auto. sea water oil

(2.0 ± 0. )
+ 0 %)
- 3
cool .( + 3 oc)
- 2
switch --F.O. from
( level alarm in leaked F.O. tank)
Lub. oil low press.for (2.0 ± 0.1 )
Cool F.W low press. (1.5 ± 0.1 )

*
*

3 16
1.

fuel ( %allowance) under

load. (Provided the is not than 10,
)

wnen full load of the is taken off or,

rated load of the thrown on and followed

will come to;

5 %
10 %
to return to within 1%
state in
no more 5 seconds

the governor motor

more than -1 at no load time about 8 - 12 sec.
+10%

at load and

110 % x 1 Hr.

About 0.8 at
load)

under load.

Below . at

and

131 16 )
8.

(Further details will be in the for

be carried out accord to the

ied classification
The test will be carried out on marine diesel oil.

20 min.
min.
min.
hr.

test
characteristic test
torsional vibration (one )
test

and hot condition.

are to be

9. Tools and Spare Parts

set
set
set
inder bore ) set
Indicator (Max. press. set
tools for set
set
set
set

are to be in with Daihatsu

which the of rules and

131 6
 1
DIESEL AC GENERATOR
TYPE
OUTPUT w
FREQUENCY
M A 5 5
OAIHATSU Ol l MFG. CO ..

C()vfv1()N 0 MASS APPROX. 1790 kg Ori I l035(M30)-1BHoles

ACCE MASS APPROX. 1900 kg
SET TOTAL MASS APPROX. 13240 kg( ORY)
0
10 350 470 470 470 530 540 480 100

ATI
~ 461
956 1725 17
699

512 6

~, *mi~~~j~1m~1mnlii9©t~110
1mn1u 1~1i:L1 9tllZli:fllt 1
1J a:'.
k· Dimension wi ;) are icatea posit on
Rios for conman bed.
Ri I I construction
arranged each Rib
21/222
 1
MA S PART
PISTON&CONNECTING ROD ASSY. 96. 5Kg
CYLINDER LINER ASSY. 66 Kg
CYLINDER HEAD ASSY. 126 Kg
CAMSHAFT ASSY. 140 l(g
LO PUMP ASSY. 37 Kg
CW PUMP ASSY. 35 Kg

5. A PIPE

0 CYL HEAD
.....
0 COVER
ru

0
.....
N
......

\
m
LAST

LO PUMP

1.
TURNING SPACE !RATCHET TYPE)

TURBOCHA E
 1 2 3 4 5 6 7 8 9 10
x
w HISTORY Of DWG. DATE
v Revised N. H JUL. 2. ·97
u
view .. P .. Revised N. H SEP. 5. ·97
(.')

t
s &, 1851
r 935
a
P LO PRIMING PUMP(MOTOR DRIVEN}
0
n CONTROL VALVE BOX
m TURNING BAR HOLDER
I TURNING SAFETY SWITCH LL
k TURNING DEVICE
0
.....
c-
i
l----+-----<--------------1 0 NO. 5CYL CENTER
h LO TANK CLEANING HOLE 0
<:r
g STARTING OPERATION VALVE 0
0
f LEAKED OIL TANK c-
e EXPANSJON JOINT c
d JUNCTION BOX
c LO TANK LEVEL GAUGE
b .SEA II/ATER BUTTERFLY VALVE
a LO BY-PASS FILTER
z FUEL 01L LINE SEAL POT
y
1761
925
"'
I
..

m
w

x
W LO THERMOSTAT VALVE ___ __,
V LEVEL SWITCH(LEAKED Oil TANK)
U THERMAL SWITCH
T PRESSURE SWITCH
S FUEL SHUT DOWN DEVICE(G TYPE)
R RELAY VALVE
Q ,HANDLE SWITCH
P AIR STARTER
0 .FRESH WATER PUMP
N NO. 2 LUB. OIL FILTER
M TURBIN LUB.OIL FILTER
l NO. 3 FUEL Oil FILTER
K SEA WATER VALVE H
s
J
I
H
G
F
GOVERNOR MOTOR
GOVERNOR
GAUGE BOARD
LUB. OIL RELIEF VALVE
LUB. OIL COOLER
--·----<
{'\J

~
.....
. . .I
<:r
(0
.....
I
0
0
<:r
..... '
'
0
: 1-i-
g fr(B
~
,, 'b
N
1==1
\
E LUB. OIL WING PUMP :;ct__ ----i c- 11
p (0 !I
D LUB. OIL PUMP "p L co I /
/

C FUEL OIL RELIEF VALVE

ti
655
--·----< > I ,,,
8 FUEL OIL INJECTION PUMP
A
tn
MARKi N A M E 0 <:r (")
0
lfl (") I <:r
0 0 (0
0 lfl <:r
0 (0
.0 c-
o co
....
0

i
615 775.
I
do
I
6B5
729. 5

40
39
38
37
36 27 18 AIR VENT (TO EXPANSION TANK)
-t---~------------+--+--+--------------+----+---+--------------+--+--+----.:::::::;_----------+-----l
15A 9 BLANK A. l40Al NO. NAME OF PARTS PARTS NO. MATERIAL MASS. cA QTY.
35 26 TURBIN FILTER BLOW OFF DRAIN 010 17 WARMING PORT(WlTH ORIFICE) 15A 8 MIST GAS OUTLET 65A LIST NO. GROUP O
34 STEAM OUTLET (PIPE TRACE) 010 25 LO NO. 2 FILTER BLOW OFF DRAIN 15A 16 FRESH WATER OUTLET 65A 7
PPl10VE
ADK20-0511-3 (10)U004 APRV
BEFORE
33 STEAM INLET (PIPE TRACE} 010 24 15 FRESH WATER INLET BOA 6 STARTING AIR INLET 40A BY &1- ::;;•·-,.,-.-:;,.t::--;,.··"'....... .- v~.
TYPE
.5DK-20
32 23 14 5 CONTROL AIR INLET 010 AFlER
-----r---r---r--------------r--t---+--------------r---i----t--------------t----+
31 CHEMICAL CLEANING (SW SIDElBLANK 25A 22 SEA WATER OUTLET BOA 13 4 LEAKED OIL TANK DRAIN 20A ·'J -~-----,-~--d ~ NAME

30 CHEMICAL CLEANING (LO SIDE>BLANK 25A 21 SEA WATER INLET

---+-
2 9 -----··-·-----·------·----------------- 20
BOA 12
11
3 FUEL OIL OUTLET
2 FUEL OIL INLET
25A
25A
BY
011AWN
. m 5DK20 ARR-FT 4 RH £8 ARRANGEMENT
OF FITTINGS
28 I
t----·--t---1----------------+
19
------·-
10 LUB. 0 IL CHARGE & DISCHARGE PORT tf&. £JOA 1 EXHAUST GAS OUTLET 250A
BY DAIHATSU DIESEL MFG.CO. LTD. I

PARTS NO.
NO. N A M E SIZE NO. N A M E SIZE No. N A M E SIZE NO. N A M E SIZE
DATE OSAKA JAPAN
;\!i~Wtim SNO. 10221/222 OWG. NO.
Q802320410C Hl\B
 1
TE
Revised N. H SEP. 5. ·97

or ain
\II

Thermometer connect ion tor

blower cvrinoo~ .. 0
I I ll!J::,, l =1004:
Expansion ;oint
( 250A x 200A) \
..,.,
~-ii
1 -~
., .. "A ....., _
(i[_
__.......__ _l t - - - i i - - - . . . . . . - . - - - - - - ,

1
T Turl>O ~--~
I
1

c~) J1s1i©m77j~~t~~a~~.
charger
lNOTI } JIS Companion flanges are -----+-+--- ) 1 Air
not SUPPi ed by l TSU. coo I er
I

25
II\

ora n
_£__
27. 2><2.9 STP

1 (010) Steam inlet

20><2.6 STP

From -o.-I-ine
---- -·it><fr-·- - - - - -
1
I
- -::..--7m
JIS A
_FrQlll_fi.GQ.J_n,L ___ ·H><f~--~ fOK-25 NAME OF TS PARTS NO. MATERIAL MASS. c QTY.
UST NO. 0
ADK20-0511-3 ( 10HI005 GROUP APRV
llEfOllf SCAtf TYPE
r~K
~u "O
-c_ <(
AfHll
NAME
PIPING DIAGRAM (1)
OIL &EXHAUST
PA~TS NO.

t! ffi SNO 10221/222 DllG. NO.

 1 3 4 6
HISTORY OWG. DATE
-n- FI ange 1CXJ1 valve (f/ 8
w
111 un i on j oi l><l valve (Union)
-t Bite Joi

. . . ,., . ,. Flexible tube STP Steel pipe Joint CD

(OAIHATSU SUPPLY}
By OAIHATSU CtF Copper Pi oe
BY SHIPYARD ® Press. gauge

(~} JISl•©m7~~V~l~~if~.
(NOTICE) JIS companion flanges are F.O.Cut off Piston
not SUPPi ied bY DAIHATSU.

Pressure regulator u
10x1.6

1 xt. 6 Cl.IP
10x1. 6 Cl.IP

Starting
operation valve ·G1· Type
Fuel shut aown aevice(5V)
&F.o.control oiston(88L)

starting F.O.shut down F.O.control F.O.Shut aown

11agnetic valve 11agnetic valve 11agnetic valve magnetic valve
{88V} 12 (5V) n COOU M (5S}

A
NO. NAME OF PARTS PARTS NO. MATER IA MASS. c QTY.
LIST ltO. 0
ADl<.20-0511-3 (10)U006 GROUP APR\'
1 1 SW TYPE
onlY main oioe SY
AFTU
5DK-20 <(

Parkerizing NAME
PIPING DIAGRAM (2)
BY Hf.
5DK20 P2-03 £8 STARTING AIR
DA IHAT SU DI ESEL MFG. , LTD.
PARTS NO.
OSAU JAPAN
7\!i'Em SNo. 10221/222
0 000 DIG. NO.
Q8333224808 z
 1
Re
60. Sx3. 9 STP
-o- 1 Flange valve
111 un on ioi l><l valve ( ion>
-tit- Bite ioint 11>41 Check valve
111 srectacle f lanoo taJ Cock
0 Banjo joint steel PiPe
..J\IVV- Flexible tube Coooer oioe
<l ROO.icer Press.gauge or ain

\Ihermo valve
BY OAIHATSU
BY SH I PY ARO []1><1
010
--
Mist
,
: 65 ,_
0...

(a) JISl•©m77J~~t~G5~~.
(NOTICE) JIS companion flanges are
~Le.oo!~ __L
oress.
__ , JIS V
not SUPPi led by OAIHATSU. ~
,_
0...
21. 'lx2. SIP
34x3.2 STP
21. 7x2. 8 STP
1 48. 6x3. 7 Slf iming pump
tOxt 8 SIP
Tp
SW valve 48. 6x . 7 STP
Di 1 oan
<with drain Plug) u
Bxt 8 STP

I i TANK)
76.3x5.2 STP
I I
I I
21,, 2x2. 9 STP GENERATOR
'•
,_
Q..

TANK) <fl
t
=
......
="
8x1. 6 STP

CD

sounding PiPe
(LO tank level gauge)
1Sx2.3 SIP

NO. NAME OF PARTS PARTS NO. A

c TY.
llST llO. GROUP Q
ADK20-0511-3 ( 10HI007
SCM.f TYPE l/ ,., r\
1\-Lu <(
NAME
PIPING DIAGRAM (3)
OIL
PARTS t«:l.

llTIG. NO.
t!illffi SNo. 10221/222
8 3 4 3 2 4 2 4 0 B Ri\ B
 1

-u-

o Ban Jo Joint
FI ange(D
~ Flexible tube Copper PiPe (OAIHATSU SUPPLY)
Fi ex-master Press. gauge
~ Butterf Iv valve Thermometer --------~---------------------,
I
T ermo ulb if neces ar 0
BY OAIHATSU 4 COAIHATSU SUPPLY}
I
I
BY SH IPY ARD [}l><l ~ I
I
{a) JISl'®~77JY~i~u~~~.
(NOTICE) JIS comoanion tlanges are
---;;- ~ t
I
not SUPPi ieO by OAIHATSU. 5K-65 I
76. 3><4. 2 STP l
Therma I switch
r-
i

1
15

JIS
Ora in
'"
~
76.3><4.2 STP
I
I
I

'
l
Bxt 8 STP
'Air "' Clocal)
x
----~-~-.S-"3~.8...........ST~P~~~~--------iY--
l 5!-20

---r--t--JiJ>-_
1 - - -..- - _ - - i_:t
,;.;:==~.~.:.+=r

NO. 1

F.W.PUffiP I \ I \
I \ I \
I \ I \
I \ I \
'"ain
20x2.6 STP
SK-15

~
m
SK-BO I
A r I Ox2.6 lP
coo er I
I
1
I t
I
I
I
---------ii--'---------

NO. NAME PARTS p TS NO. ATER IAL MASS. c

A
TY.
UST 110.
ADK20-0511-3 ( 1 0 i:t008 GROUP 0 APRV
BY 3HOiE Sill.£ TYPE r\ I/ ') (\
Ut\-cU
Fresh water D oe AFTU
NAME
Parker z ng BY
PIPING DIAGRAM (4)
COOLING WATER
PARTS NO.

A:! IGm HNO. 10221/222 IJiG. NO.

Q8363242908
 ~S MARK NAME N 0 TE

w
0
0::
<( >-
>- _J
0... 0...
- Q..
:I: ::::>
U"l !fl

et press. IND. &Alarm Below 2.5 kO/at NOrtml

TC Turnin<J safety switch stooct-l>Y Wilen turnino bar useo
cootaet (3-4) ..... 0ff
HS Handle switch Stooct-l>Y At ruooiM POsitioo
contact 12-4) .. OH. 0-2).
PM l. 0. Pr illli J)ijllll) lllOlOf AC 440V. 3fj. 60ttz. 0. 75lW 0
SSL Fuel control oistoo Fuel OC24V. o. ?A FO control in start iM oroeess
• nern: valve control Wl\en so1eno1a 1111.1onet1zea

26W2 63W1 ,...,- ...... , ,-- /-.....,

I TB1 I TB2 i' TB3\
\

..0 Ch
"'
....
I
u
u
I
~
.
I
~
;- ......
.....
-'

TO PRIMING PUMP
CONTROL

BOX

B
RA

the nor!l'6 I rum i oo.

ice a
ine
wir i

A:! liffi SNO. 10221/222

 1

p u Ls E max 1 o om
CONNECT NG
SCREW M3 4-4. 5Dr
NP T I \ I \

0
connection DOD .6.Print modified
\ I \ I
with FG 'f (MOOE Tl
TRIPLE 1

SHIELDED
CABLE I OVER SPEED LAMP
I
9
FG 0
ODDO OVER SPEED OUTPUT

SPEED SWITCH
P ER SOURCE RATED SPEED LAMP
SET • OC24V
PULSE/2REV
ODDO ATED SPEED OUTPUT
1112 OVER SET p LAMP
1113 RATED SET
OW SPEED AMP
11 l 4 LOW SET

1000 HlO l0

DODO LOW SPEED OUTPUT u

OPE
SER. MO.

OVER LOW
SPECJF CATION
~ (1 SPEED OET CT ON
a. N MBER OF DETECTION THREE ETEC ONS (OVE SPEED. RATED SPEED. L SPEED}
. SPEED OE ECTION RANGE 30"'-9999rom
C. N ACT APACITY DC24V 0. 7A wen ductive load
DC100V 0. 2A s used uo to 40%
AC100V 0. 3A f t e eft va ues. >

30 OJ
s 4 9 s NE T ON
S E l FIE ENS A ATS SUPPLY)
p S URCE
Q)Q
±20% 4W
UN W G
<O.C::,
c co
kQ
Q)
......, Q)
(5) 0 OR
cu
· - <D
MUNSEL 7. 58 12
<O Cl
E U) PARTS NO. ATER I AL MASS. A TY.
APRV 0. 6Kg
ME-1
2 2
 ,,

GAS OUTLET

PARTS NO.
--:----
1 B06a3 70111 ift..

2 1 3. a
3 113tZ 2 50A x 300A M 2 30 21. 3
4 114lA 250Ax350A M 12 36 21. 3

1i 13
SPEC I FICA N NAME
400'""5so·c 1
0.03 m2

NO.

M12x1,75

.CO.,J..TD.
OSAKA JAPAN
2
 600 M26xt5 §9

17
 I NS T R UC T I 0 N M NU L

FOR
S P E E D S WI T C H UN I T 2

DAIHATSU· DIES El Mf-G.CO.,LTD.

TECHNICAL DEPARTMENT
OSAKA, JAPAN
TOTAL PAGE 16
BY

ME-107 CHECI<ED BY

No. LT315780FA

28th JUN. 1996 APPROVED BY

5
REVISION
 CONTENTS

1. OUTL NE 1

2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2

3. SPECIFI . .. 3

4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
.c>.
'"'-'

w 5. ION SPEED············ 5

-,,-J
OJ
6. ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
0

7. SETTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8

m
8. I NG AN D '-'LI ,'i1 '\11_ I ON 12
 INE

This consisting of a pulse sensor a

tch unit, is intended to detect the revolving speed of a
rotating object.

Two types units are available. One is equipped with

output, other is not equ E
them detects the revolving speed at arbitrary points.

s all culation is proces by the mi

there are almost no restrictions on the sett or
number i ses. Also, every sett is made at
swi you will feel no trouble at adjustment work.

The equi a wide range of se detection

vi speed of propellers as well as not
to say engine speeds.

1
 91/ 08L9TS11L~

Addition of analogue output

Speed Switch Unit
Tachometer

1----1
Yevefonn
shaping _ 1 - - - - - - - - - 1
,___-;-;D/A
Converter 1----1-----,
4-2DmA 0
Mode setting switch 4-20mA
Display control etc.
D---
CPU
Pulse setting switch

DOD
- - - to control panel
Speed setting switch

DODD
DODD
DOD Relay

Power supply
DODD
DC24V
·---<'r---Voltage lator----Voltage monitor

Fig. l Structure Diagram

 Item

points
detection
detection 3 O to 9, 999 rpm
(restricted the nU1tber of input pulses)
accuracy 0. 5rpm in low speed mode.
0. 3rpm in high speed mode, at speed of l, OOOrpa.

Setting 11ethod Use four-digit switch each speed level.

Response time Detected at every one rotation period.
Hysteresis for : 3% low speed
and 3.1% for regular and over speed.

2 turns by

Special pulse sensor

Display ©2 outputs: 4 to 20 mA
output Load resist. 0-350Q.
®Set speed range for
full scale by switch.
300,400,500,600,800,
1000,1200,1500,1800,
2000,2500,3000,4000,
6000 rpm
Contact Outgut contact Three contacts
output
Contact co11posi tion For 3 contacts. contact 01
(ditto) to OFF
0. 7A or less for 24V DC } (When inductive
capacity 0. 2A or for lOOV DC is used, up to 40%
•' 0. 3A or less for lOOV AC of left •a.u.s~... )
Power Input voltage 24V±20% DC
Power consu11ption 4W
Ambient Working temperature 0 to 55'C
Storage te11perature -20 to 80'C
Atllospbere Must not contain corrosive gases.
Vibrations lG or less, 50Hz
Size 174 X 100 X 36m
Weight 0.6kg
7, 5 BG 7/2 system

3
 4. *I side d ted sq a s Iy f r
spec. of analogue tput addi i
§ 1 ANA TPUT TYPE - - ~ - -
§ 2 DIGI TPUT PE
(A UE O UT N E IPPED

OC24V Ml M2
{ 4 '-2 OmA l

l.- - -- - _,;

1TYPE
I
' J
•
0
I
TESl
--
I
I
I
l•l@l@I@
I I
2
3
4
300
400
soo
l
l
I
I
I
.
I
I
s 600 l
0 6 llOO I I
I
I
I
I
I

"'
r
-I
1
II
1000
1200
I
I
I I I I
(.,.) II l!iOO I I I l
....... A 11100 I
V1 II 2000 I I I I

...J I HlOO 100 lO l

c 2500 l
0 3000 I
":t1 l e 4000 I
l> I I
I F 6000 io\A'
<
m
..._
- --- _J

OAT£
,_.
<D SEii NO.

OVER

30

4 04. 5
 5. l The maximum is restricted the number
pulses as ( F )

(Exampl
If the number of pulses per revolution is 160 then the
maximum speed will be:
864,000 16 O x 2 = 2 , 7 OO rpm

5. 2 on s on low
and set as follows:

30 rpm in low and

60 rpm in h

ID
-.::i

;..-..
U1
-..] 10000
00
0
':tj ..........
> E
c.
!....
'-"
'
,......
IJ)
-0
GI
GI
Q.
Cl)

c:
0
......
0
GI
....
(I)
Cl

E
:::I
E
x
RI
::c

10 100 !000

Number of pulse per one turn

Fig.2 Range of Maximum Detection Revolving Speed

5
6. 1 Detection accuracy

Detection accuracy is the resolution

and it varies w the itself. Ii is also divi
into low or high speed and is i
by the fol lowing equations. (See Fig. 3. )

Let revolving speed as N (rpm), then the resollution

is:
(N / 1369) 2 rpm in low mode, and
(N / 1936) 2 rpm in

In setting, if full scale is to 1,000 rpm

or mode will be low speed. whi if it is set
to 1,200 rpm, mode will be high

2 is

is is ded in the detection speed to ensure

stability of detecting even the
fluctuates.

In
speed when the set speed is reached, and
detection returning is made when
the set speed less hysteresis ls
three are as follows:

ion Speed output return

Divis detection

Low speed set speed 87.5% of set

Regular speed set speed 93. 7% of

6
 1

s::: low speed

0

h speed mode

0.1

O.OJ
IOOO 10000

Revolving speed (rpm)

Fig.3 Accuracy of speed Detection (Resolution Spee

1
 Referr ng the se points as shown in Fig. 4, set
switches f 1 to 16 accordi to the followi procedure.
("Switch" will be abbreviated as• hereafter. )

7. 1 Setting the full scale speed

§ 1 ANALOGUE OUTPUT TYPE (analogue and digital outputs equipped)

Select and set •2• to "F• for Sl16 according to Table2,
depending on th full scale speed to be used.

If Sl16 is set t ·a· or ·1·, the system will enter

the test mode.

§ 2 DIGI PUT E (digital tputs onl

Digi al utput type is not equipped analogue outputs
Set nly ·2· f r 116.

If Sl16 sho ld except ·2· , the system will be no running.

7. 2 Se ing number pulses

Set the number of pulses for two turns according to Table 3.

value setting from to 49 If "O, 0, O"
is sel the setting will be invalid.

If this equ.ipment is used in a turbine, set ten times of

the number of pulses for two turns. Then indication and
output will shown in a 1/10 magnitude.

7. 3 tting output detection s

According to le set the o detection s for

low, regular and over If any of the three s B

are not then set • 99• for t appli le swi

7.4 Adjusting t anal t current

Since this ustment has been made on shJppi normally,

you no further ustment..

On the occasion of us trnent, or if ustment is

meter correction or other reasons, refer to e 1 on
next

8
 Table 1 Procedure ot Output Current Adjustment

.ti>. Remarks

1 Preparation Coof irm power OFF. POW lamp

adjustment Connect ammeter to Ml and M2 output
of the unit.
Put the mode setting switch (SW16)
on the board to "O" to enter
mode.
SW16
0
x x x
x x x
x x x
x x x x
JD
-.::i
l'
'"'3 Turn on power SW itch.
.'
~

,..._.
Cl
-.::i
::0
~

2 Adjustment To adjust Ml output. adjust ZERO Adjustment standard:

current VR(VR3) to 4mA, and SPAN VR(VR2) to 4. 00-20. OOmA ± 02mA
20mA.
"
,..._.
r:J'l
To adjust M2 output. adjust DIF The same as the above.
VR(VRl) to 4mA and 20mA.

3 Turn the power sw

Reinstate wiring and mode to the
before-adjustment state (SV16).
Turn on power switch.

* the locations of switches and control knobs on the board, see Fig.4.

9
 le 2 Unit lection II-scale eed Setting
-
Setting value Full-scale Mode
SW16 speed
0 --- Test mode
1 --- ~

2 300 rpm Low mode

3 400 rpm
4 500 rpm
5 600 rpm
6 800 rpm
7 1000 rpm
8 1200 rpm High
9 1500 rpm
A 1800 rpm
B 2000 rpm
c 2500 rpm
D 3000 rpm
E 4000 rpm
F 6000 rpm

Table 3 Number of Pulses Setting

Sett SW Setting posit

SW13 units digit
SW14 tens t
SW15 hundreds d t

Table 4 Detection Speed Setting

Division Setting SW Setting position

Low SW 1 units digit
SW 2 d
SW 3 hundreds digit
SW 4 thousands digit
Regular SW 5 units digit
speed SW 6 digit
SW 7 digit
SW 8 thousands digit
Over speed SW 9 units digit

10
 0 p N s
0
SW16: mde setting switch
Reset button

[J
•<
VR!
~3
Janalogue output current
Adjus-nt knob for

0
l
SW13 - 15:
0
0) 1 5 14 l 3 Pulse setting switch
..,0
£)
c 1 2 I I 10 9
0
9'9 - 12:
....., ""
..I
8 7 6 5 Over speed setting switch

~
-3
w
1--
01
4 3 2 1 SW5 - 8:
.;i
0
' Regular speed setting switch
;)

©0©© SWl - 4:
POf Oilfl Oilfl OilU low speed setting switch
1C la U IC Ja 2b
1--
)
0

. 4 Location of Setting Switches

11
 ION

1 Installation

When select the place for installation, avoid

where power lines or large ays are located or
places ect to vibrations.

2 on

(1) Unit'
) .Fig. 5 "External ion Diagram"
external connections of the unit.

Fig. 6 "Schematic Connection Diagram"

connections to sensors and unit.

) terminals for wiring firmly screw

to the terminal b

) ng power supply of 24V DC.

connect us
end to up" and the minus end to "N•.

Note that the unit may destroyed, i f a wrong

voltage connected or, the power is
to wrong ls,

(2) Pulse sensor

(a) wiring to unit, to the pulse
sensor, must separated from power cables.

(b) lding wire for pulse sensor

shielding line should not be connected
on the sensor side, but on the unit side, it must
connected to the unit mounting screw. )

(3) Indicator
Use d w output, make a
single end grounding ei on the unit or
)

l 2
POWER SUPPLY
24V , SENSOR I ND I CATOR
+ s + •
* Inside dotted square is only for
~ + - spec. of analogue output addition.
~

0 0
t_sJ
DC24V SENSOR M1 M2
(4"-20mA)

0000

rn m m
OVER RATED LOW

12c 12a 1Zb 13c 13a 13b He Ha l4b

0 0

COM A B COMA B COMA B

'-v--' '--v-' '--v-'
CONTACT FOR CONTACT FOR CONTACT FOR
OVER SPEED REGULAR SPEED LOW SPEED
* Between COM and A is short-circuited when specified speed is
detected.
Between COM and B is short-circuited when specified spedd is
not reached.

Fig.5 ternal Connection Diagram

13
 U8l91t:J/l

r--1 Set to 111111.

Indicator (4-20mA.)
The shielding wire must be
comp.I ete I y i nsu I ated so that Two-core shielding
it will not touch the case. wire is reconmended.
Pulse sensor DPYCS-1. 25
The shielding wire must be
completely insulated so that I
it wi 11 not touch the case. l
t
!
i
Speed Switch Unit (2) j Speed Switch Unit·(2)
Indicator (4-20mA)
SENSOR Ml M2 I
I
r--1 n n
After fixing, do not
apin the body a half
turn or more.
I
Three--core shielding
I
!
! PN
wI re 1nust be used. ,__,_... $~ply here 24V DC.
TPYCS··l.25

Keep away from terminals of

'Po.r 1lnes(start valve,
Field terminal block ...----; shut bff valve, etc.)
(Keep 3 terminals bet111een.) Connect the shielding line
o the unit f xing screw.

Inside the dotted square is an addition for

Three-core shielding
...__ _ wire must be used. two un i t spec•
TPYCS-1.25

Terminals of shielding wire must

be i ndeoendent; must ret be shared
with other shie~ldlng wires.
Avoid laying pawer
I ines together.
Fig. 6 Schematic Connection D agram
 MAINTENANCE INSTRUCTIONS FOR G F2 FILTER

With the engine stopped or filter isolated from the lubricating system by
means of a valve:

1. Remove the cover nuts and washers and Ii ft off the fi Iter body cover.

2. Withdraw the rotor unit including the spindle from the body, allowing the
oil to drain out from the rotor.

3. Remove the rotor lock nut and washer and separate the two parts of the rotor unit.
The spindle and rotor pipes will remain in the lower part of the rotor.

4. Scrape the sludge away from the walls of the rotor and thoroughly wash the
components in paraffin, ensuring that the rotor jets are not blocked.

5. Re-assemble the rotor unit, checking that the 0 rings are in good condition and
replace the rotor in the body.

6. Replace the l:::ody cover and secure with the bolts, nuts and wQshers ensuring that
they are al I tightened down evenly.

/ XJ\.
NOZZLE
 ·03537651
Form P6921
Editions
May,1995

OPERATOR'S MANUAL
for
SERIES ST700 TURBINE-POWERED STARTERS

! WARNING

IMPORTANT INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATING TOOL.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

• maximum
"""''"'r""''.. Series
ST700 Starters at air pressures over the
pressure stamped on the nameplate.
• Always turn off the air or gas supply and
disconnect the air or gas supply hose before
lnstalling,removing or adjusting any
maintenance on this starter.
• After assembling a starter ,always test it in
accordance with the procedures outlined in
this manual. Never install a reassembled
starter that has not been tested in
manual.
• Operate this starters only when properly
installed on the engine.
• Do not lubricate starters with flammable or
volatile liquids such as kerosene or jet fuel.
• For ....,.,..,,..,..,,., nr,.,+.,.,~tir.n do not remove any
labels.
Replace any damaged label.
• Use only recommended Ingersoll-Rand
accessories.

NOTICE

The use of other than rectlac:eriner1t parts may result in safety

pe1rfo1·m~mc:e.i:tnd increased maintenande,and may invalidate all warranties.

is not for customer modification of starters for aot>licatl<ms on which

Ingersoll-Rand was not consulted.

should be made by authorized trained Consutt your nearest

Authorized Servi center.

INGERSOLL-RANDR
ENGINE STARTING SYSTEMS
 WARNING LABEL IDENTIFICATION
I WARNING

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

A WARNING A WARNING
Always wear eye protection

• ®
when operating or Always wear hearing
pertormlng maintenance on protection when operating
this starter. this starter.

A WARNING
A WARNING
Always tum off the air
supply and disconnect the Do not use damaged, frayed
air supply hose before or deteriorated air hoses
lnstalllng, removing or and fittings.
adjusting any accessory on
this starter, or before
performing any maintenance
on this starter.

NOTICE
For natural gas operation, starter main exhaust must be piped away.

To pipe the Drive Housing vent,remove the Drive Housing Plug and replace it with a suitable tubing
line. The tubing must vent at a safe location and must not be interconnected with any other exhaust
lines which might intorduce a back pressure on the Drive Housing Vent

NOTICE
ST900-267 Strainer or is required for all starters used in GAS applications.

2
 CONTENTS

PAGE

11

. . . . .... ... . . . ........ ........ .... .... ............... 1 16

.... . ... . ... ... ....... ......... ............. .. . ... 1

3
 Maintenance Items

1. Maintenance of starter
*

or on

1) starts

2)

1
11. 1
12.
1
1 181
1 1
1 151
1
1

·Wipe

wear is 3

4
 screws sure are

* to

4)

1
*
2. Others : Every 1 year

- 3. Maintenance flow chart

& wear---+

5
 l

SERIES ST700 TURBINE-POWERED STARTERS

34 41 40 38

I ..... II \,.......,_.
~
I 12 \2! \l9 \21/ 32\49\48\52 \41153!35/36/ /59 I IRA

ST7500601
ST7SOGBDI
ST799GBOl ~
~
ST799GBOl
35

$;
m
<!:
'"'~= •&mDi::=::I~""' " ' I (")
""'"" I
rn
(/)
ni
(")
::1
0
6 7 8 24 10 23
16 j
..
,...
26 IMUCCf:f''~~ <!:

ST75060DP09R5l
ST750GODP09L52
ST799GODP09RSl
ST799GODP09L52
40
58

(Dwg.TPA1
 SERIES ST700 TURBINE- ST ARTER (PRE-ENGAGED)

ee

(Dwg.TPA 1273-4)
MAINTENANCE SECTION
PRE-ENGAGED DRIVE

8
 MAINTENANCE SECTION
PRE-ENGAGED DRIVE (Continued)
PART

and ST799GODP09L52
for all other models
Drive

ST750GBDP03L32, ST799GBDP03R31
and ST799GBDP03L32 888158-9

SS825C-9

9
 MAINTENA SECTION
PRE-ENGAGED DRIVE (Continued)

10
 MAINTENANCE SECTION
PRE-ENGAGED DRIVE (Continued)

11
 MA
Starter.
! WARNING
wear eye protection when nn••u.,dir•n
or any maintenance on this starter.
Always turn off the air or gas supply and
disconnect the air or gas supply hose before 2.
instailing,removing or adjusting any accessory remove the Starter
on this starter or before performing any
maintenance on this starter. 3.

-LUBRICATION- rotate it until the ears clear the

Each time a Series ST700 Starter disassembled the
for maintenance or the starter as ears
can be removed from the Motor
to 159.
NOTICE
1.
2.

3.

-DISASSEMBLY-
General Information
1. Do not disassemble the Starter any further than

2.

(Dwg.TP01159)
4.

4.

5
5.

and Drive
these members can be localed
the same relative when the Starter is
reassembled.
6. Do not press any needle
installation. Needle

Disassembly of the Housing Exhaust

Cover,Motor Assembly,and Motor
(Dwg.TP01160)
Housing
If

12
 MAINTENANCE SECTION

(Owg.TPD1164)

162) 8, a bench

6, 9.
Do not remove.

! WARNING
If the Intermediate Gear Case is not
supported on a bench and if the Intermediate
Pinion Retaining Screw is completely
removed, the Intermediate Gear Case and
completely removed,the Intermediate Gear
Case and components could fall causing
injury.
the Intermediate Pinion
Planet Gear Frame A<:<~on,n11
Intermediate Gear Case. Refer
TPD1169.

(Owg.TP01161)

7. the Intermediate Gear Case

it from the Gear
TDPD11

13
 MAINTENANCE SECTION

from the vise and NOTICE

Remove the Rear Gear Case 0-
and Front Gear Case from
the Intermediate Gear Case. only if the Washer or Front Baring Spacer is
11 Remove Planet Gear Frame damaged
from the Intermediate Gear Case.
sleeve that contacts the outer race of the Fron! the Drive
Gear Fame press the Planet Gear
Front Gear Frame Shaft and the Front workbench.
7) from the front end 2. Remove the Drive Pinion ).
the Intermediate gear
Case Refer TP011
NOTICE

Models ending in R25,R31 and R51 have a

left-hand thread. Models ending in L26,l32
and L52 have a thread.
3. Remove the Starter from the vise.
4. Remove the Drive Pinion and the

5. and the

6.
hex inserted

7.
PLANET GEAR FRAME ASSEMBLY
(Dwg.TPD1166-1)
8.
12. remove the Rear Gear
from the Planet Gear
! WARNING
13. Remove the Planet Gear Planet Failure to follow this procedure could result
1 and in injury to personnel.
9. Place the Drive in an arbor press,
14. end up. a load to !he
arbor press to compress the Piston Return
before the Bulkhead
Plane! Gear Frame the front of rn1mn1rAC< .. Acrf air tO

the Planet Gear Frame Shatt Refer to

TP01167 a Bulkhead
Retainer.Use off the arbor press.

NOTICE
Make sure the tensi<>f! of the'sprlng pushes the
Bulkhead out of the Housing befor
removing the Drive H from the arbor
press.
11. Remove the from the Piston.
24 12. Remove the Outer Bulkhead and the
Inner Bulkhead Mm1nrn1x
13. Slide the Drive from the Drive
25

14. off the

Shaft
14
 MAINTENANCE SECTION
Gear Case.
NOTICE
This operation will damage the Piston Seal. NOTICE
Th......,,fn•• a replacement Piston Seal must be
on hand. Do not diassemble the Drive Gear and Clutch
15. Remove the Piston from the Piston. parts of Series ST700 Turbine-Powered
16. the Starters.
Piston so that it rests on If the Drive Shaft is defective, install a new
Clutch the Seal out of the or factory-rebuilt unit.
Piston. 26.

NOTICE 27. Remove the Rear Drive Gear ) from

the Drive Gear.
This operation will damage the Piston Seal.
Therefore, a replacement Piston Seal must be -ASSEMBLY-
on hand. General Instructions
17. 1.

2.

1
20.

21. 4.

22. Press the Rear Drive Shaft

of 5.
a
as follows: suitable solution and with a clean
a. remove the cloth. Sealed or shielded bearings should
small drive shaft Drive never be cleaned. Work grease
Shafi. every open before installation.
6. a film of all
NOTICE before final
b. Press the Rear Drive Shalt 7. Unless otherwise press on the
off
the Drive Shaft stamped end of a needle when
23. the needle in a recess. Use a
24. tool similar to the one shown

Needle Bearing Inserting Tool

Pl.OTTO OF

1
 MAINTENANCE SECTION
Gear Case lnstert the Drive
Place t11e Gear Shaft
rear end of the Drive Gear. 14. Insert the the Drive
2. an arbor press, press the Rear Drive Gear Shaft
the rear end of the Drive Gear. 15. Press the inserted
3. seal the Rear Drive and install the Clutch
Gear Case the
NOTICE
4.
If it is necessary to replace the Drive
5. Housing(40) and drive components, make
sure that the Piston Seal (part number
SSS00-272) has been removed from the rear
of the new Piston(54). The Piston Seal must
be removed to prevent pressure build-up
which will cause moved to prevent of the
PlanetGear Frame Shaft Seal(16). If this
condition occurs, the Piston cannot retract
and the Drive Pinion(63) will renain in
32 engagement with the flywheel, causing
damage to the Starter drive train andJor
Starter motor. To remove the Piston Seal,
insert a screwdriver inside the lip of the Seat
and pry it loose from the Piston.
16. Install the onto the Drive Shaft until
!he Rear Drive Shatt seats into the
Piston.
17. a thin flat blade screw driver to assist in
the Drive Shatt
into the groove ol the
Piston to retain the outer race of the Drive Shalt
(Dwg.TPD1170)
18.
Lubricate !he Drive Gear 8
groove of the Piston.
oz.
Position the Drive an arbor press,
No. 130 Grease.
down and install the Drive
7. Press the Rear Drive Shaft""""'"'""' onto the
Drive Shaft
8. Slide the small retainer convex side
the Drive Shaft Press seal faces away from the Drive
accorcance the 20. a sleeve that contacts the outer race of
the new Retainer. the Front Drive press the
9. Assemble the Drive Gear Drive Gear lock seats. For
the Piston
on
10. in a external illustration on page 1
end down. Place assembled Drive 21. Slide the Piston Return onto the
Shaft Screw Unit into the Drive screwead of the
down. Lubricate !he inside diameter of the Drive Shatt
Drive Shaft with No.130
Grease. 22. Lubricate and insert the Drive Shaft
11 Slide the Drive Gear into the Drive
Shaft 23.
12.
24.
Jaw teeth 25. With the Drive
on

16
 MAINTENANCE SECTION
NOTICE
Drive Pinion Retaining Screw into the end of
Feel the underside of the Drive the Drive Shaft and tighten it to 80 ft-lb
make sure the Drive Shaft passes (108.5Nm) torque for models with "B" and
the Bearing. "C" gear ratios and to 125ft~lb(169.5Nm)
26. install the Bulkhead torque for models with "D",gear ratio.

Assembly of the Intermediate Gear

! WARNING Case, Motor Housing, Motor
Assembly and Housing Exhaust
Make sure the Bulkhead Retainer is
Cover
properiy seated in the Motor Housing a tool of the proper
groove before easing off the arbor press. press the Front Gear Frame 1 into the
Failure to do so will allow mr-,rr1•nP•n\l rear of the Intermediate Gear Place
retained parts to separate when removed on
from the arbor press resulting in injury to 2. a sleeve which contacts the outer of
press the Planet Gear Frame Shaft
27. the rear of the Intermediate Gear
28. Case over the Front Gear Frame Refer
to TPD1172-1.
Drive
29. Position the assembled Gear Case a

The assembled mus! be

30. the assembled Drive

Gear Case and

31

(Dwg.TPD1172-1)
32. wrench with a
hex inserted into NOTICE
Make sure the flat side of the Seal is installed
against the Bearing
33.
3. Install the Rear Gear Case the
and the Pinion
groove at the rear of the Intermediate Gear Case
over the Pinion end of the
and the Front of the Intermediate Case.
Drive Shaft
Coat both with
34. Lubricate the Pinion end the Drive Shaft with
4. Install one Gear Shaft
No.11 Grease and install the

Front
35. the Drive Pinion in a leather-covered or
,...,,,nnr::.r_,v,,,·arc>n vise with the starter
Planet Gear Frame to hold the Gear Shaft
on a workbench.
Washer in vvmuv•
36. onto Drive
NOTICE
Coat the Front Bearing Spacer with Grear
NOTICE lube before installing it. Be careful not to
gouge or scratch the Front ...... ,,.r''"" ::>o,acE!r
Models in R25,R31 and R51 have a
installation as this could result in
models in '-""'"·'-·"" 1e211u11Qe between the Planet Gear Frame and
and l52 have a thread. Install the Gear Case.

17
 MAINTENANCE SECTION
5
and

"'"'3rarc: and
with in Planet Gear Frame and
insert Planet Gear end
the,_,,_,,~~~·

Washer.

(Dwg.TPD11
NOTICE

Qo not move or turn over the Planet Gear Install the Intermediate
Frame until 6 and 7 have been
completed. with the notches and
Movement of the Planet Gear Frame Planet Gear Frame.
Assembly could dislodge assembled 1 Clean the threads of the lntermediarte Pinion
components, making it necessary to repear and 2·3 of
Step 5. Permabond HM 118*** the threads
Install the other Planet Gear Shaft
3mm from the end of the Screw.
Washer over the shaft al the rear of the Planet
to hold
Gear.
7, the proper size
11 . For final
press the Rear Gear Frame on the
Gear Case so the Intermediate Pinion is
shaft al the rear of the Planet Gear Frame.
Reier 167. of a leather-covered or
the Intermediate

24

25

(Dwg.TPD1167)

8. Slide ttie Planet Gear Frame

into the rear of the Intermediate Gear
sure that !he Planet Gears (Dwg.TPD1204)
care so as to not
TOPD1173

18
 MAINTENANCE SECTION

12. Remove the Intermediate Gear the

vise and set a bench.

NOTICE

The Intermediate Gear Case from the vise

and set it on a bench.
the marks on !he Intermediate
Gear Case and Gear Case and a
the Intermediate Gear Case until
it seats in the rear of the Gear Case. Make
sure the lntermediale Pinion meshes with
Drive Gear. Refer to TPD1165.

trademark of Permabond
(Dwg. TPD1161)

14. marks in the Motor with

marks on the lntermediare Gear Case
a the Motor
until seats on the rear of the
Intermediate Gear Case. Refer to
TP01163.

(Dwg.TPD1165)

end of the rotor to

toward the front Refer to TPD1161.

NOTICE (Dwg.TPD1

Tum the Intermediate Pinion so that the

gear on the rotor meshes with the Planet
Gears. Make sure that the rear of the Motor
Assembly is installed flush with the rear of
the Cylinder.

19
 MAINTENANCE SECTION

15. Coat the Exhaust Cover with

lubricant and install the groove on the
Exhaust Cover.
16. the marks on the Exhaust 5
marks on the Motor
a the
Exhaust Cover until it seats.
17. Exhaust Cover on the rear
the Starter
Screw
Use an 8mm hex-head wrench to
of

1 (Owg.TPD1160)

NOTICE
Use Ingersoll-Rand SMB-441 Pipe Sealant on
all plugs.
20. Install the Bottom
Inlet

the side

CAUTION
Do not overfill.
(Owg.TPD1183) Install the side

-TEST AND INSPECTION

PROCEDURE-
1. Clutch Ratcheting : Turn Shaft
NOTICE
hand in the direction of Starter
18. When assembling the exhaust cover to the rotation. The clutch should ratchet with
starter, add 15 ml of Dextron***ll Automatic a action.
Transmission Fluid through the pipe plug 2. Motor and Gearing Freeness: Turn the Drive
hole in the Exhaust Cover. Shaft the direction of Starter
19. Install the Deflector Ri::>t,,1r1inr rotation.The Drive Shaft Pinion tum
Sf"'ir"'"'1"'1 in the hand.
rear of the Exhaust Cover. Refer to
TPD1160. NOTICE

NOTICE Inadvertent application of air pressure to the

"OUT" port will result In Drive
Coat the threads of the Deflector Retaining malfunction(Pinion will fail to retract). ff this
Screw with SMB-441 occurs, loosen Drive Housing Cap
Sealant Screw(38) to vent Gear Case(21 ). Also, loosen
Housing Plugs and {1 to vent Motor.
 MAINTENANCE
Pinion Engagement : Confirm Drive Rotation : low pressure
and observe
move the direction .,,,,.,mr'"'"

outward and air gas escape from the Chamfer on teeth shiould be
the "OUT" Port and of gear tooth.
lo the "IN" Port. Drive Housing FunctiarPre-Engaged Models
Check and make sure no air or gas is es<:aom Only : 1 "IN" of Drive
Measure the dimension from the lace of the five times.Air should exhaust
Drive Shaft lo the face of the each
11. Free Speed (All Models) : install the Starter on

for models motor inlet Free

'""'""''""'"'"'"' should be as Follows:
4. MAXIMUM MINIMUM
"B" ratio
12. Exhaust Deflector Operation : Install
Starter on low air pressure
5. Motor Seals : the exhaust and to motor and observe. Deflector must return to its
.ccviv<>n.;; 1.41 wntlr-n-i'lr,ra•oe to the inlet of normal after of the Starter.
the motor. Immerse the Stasrter for 30 seconds 13. Drive Housing Leakage-Pre-Engaged Models
If Only : "OUT" and
to extend
appear, Drive There should be no
6. Gear Case Seals: 14. Test Pinion Engagement-Pre-Engaged Models
.4 1"~•1 ~~'" lo the inlet of Only : ·our and
the motor. Immerse the Stasrter for 30 seconds needed. In its normal
the distance from the to
the end of the Drive Shaft should be 1-
the Gear Case area or in the shaft seal fn its extended the Drive
the Intermediate Gear If the Starter is Shaft should be 2-7/8" While the Drive Shaft is
bubbles Drive
7. Remove ""'""""' shaft Rear face
hex drive to rotate move back. 1

8. Orientation : Drive must be assembled

lo customer orientation or per <=>n<11ne>i::>n
If orientation is not cn<>l"'ITIL>rl

Check dimension on
 Ingersoll-Rand Service Center

Canada Inc.
51 Worcester Road
Division '"'"'"""'"'• Ontario M9W 4K2
P.0.Box 1776 PHONE: (41 675 5611 2-3-12 Shin-Yokohama
NJ 07938 FAX: (41 675 · 6920 1vnLr"u Yokohama 222
647 6000 PHONE: 45 476 - 7801
647 6007 FAX: ) 45 - 476 - 7806

Southern Sales Office

inner"""-'"'"''"'"' Power Tool Ltd.
Division 42 Benoi Road
111 1nnArs.m1-1-1;:irm Drive 629903
·h<>mhJoo GA 30341 3501 St Charles Blvd. PHONE: 860 6836
PHONE: 936. 6200 Quebec H9H 483 FAX: 862 - 1373
FAX: 936 6202 PHONE: 4) 695 9040
FAX: 695 - 0963 Australia
- Western Sales Office
Power Tool 201-6351 Westminster A.C.N. 004 099 861
Division B.C. V7C 5C7 80 100 Frankston Rd.
5533 E. m1rr>n•" Blvd. 274 0459 ""'"'"'",.'" Vic 3175
CA 90022 FAX: 278 2519 ) 3 . 794 . 1673
FAX: ) 3 - 794 - 7895
FAX: 725 2890 EUROPE I MIDDLE EAST I

Distribution Center Far East

Sales
Power Tool 19th Floor
Division 50 Gloucester Rd.
510 Hester Drive
White TN 37188 ,,..,,.,.,,...,,,Road 527 - 0183
PHONE: 672 - 0321 Wvth1J:J•n<::l'1:::tv1.10 Road 529 - 5976
FAX: 672 - 0601
Manchester M23 9LN
United
Korea
LATIN AMERICA PHONE: 061 902 · 9098 Korea

FAX: 4461 -946-6375

Division TELEX: 667833
730 N.W. 107th Ave.
300 2-565-6815
FL 33172-3107 2 - 565 - 6818
PHONE: 559. 0500
FAX: 559 - 7505
441617 TLS VI
IHI
~h""AJ t'1~~I
EXHAUST GAS TURB0 CHARGER

TYP E RH1 2 3 1 3 3

Instructions for operation

and a i nt enance

Jll tl!!Itl*J\~tt
!s 'kawajima-Harima Heavy Industries Co. ,Ltd
vr,F r' Q J:i! pA· !l!!
1
T r1
t

V01'.-l53
(RHl 2 0 1 S-1)
 FORWARD

lH l r;~~ 7' To make full utilization of the IHI Exhaust-Gas

(7)15l~~ tu inafter briefly called
T\1 ~ "turbocharger"), it s important to comply with
<~ c t procedures for operation and maintenance as
wel a ns r ions contained in his instruc ion
manual.
rat the tu bocharger after reading thro
this in truction mc.:rnal.

CAlJTlO~

1. Order and inquiry

(!)When ordering the parts, clearly ind cate he
following symbols in you o
1
]
RH ...
( ) ~ Serial As stam on the rating
]
Specification plate of
J
Part number
and designation J
l efer to Fig. I)

s per Fig. 2 and parts list t

J ity

(2)Address your order and inq ry to our agenc s

I
serv ce of i c or ine manu urcr
ce stat ions.

2. emptions of liabi ty
In respect of ace dents during the ~ rantt~
period that a recognized as being clearly
a tributable to IH' design or manufacture,
llll w l make epa r fr of charge, but H:
wil assume responsib l t even uuring the
(1) guaran ee per od for the following ace dents.
t: t: Cl) (7)$~
(7)'.iJ::W'J3Z~ ~ (l)Accidents due to t use contrary the
t: t: Cb C) instructions cont ned n this manual
<z) ccidents due to a neglect of period c
~ fl t: f::_ Cl) UJ replacement of weari g parts
(3)Accidents due to the use of pans ether 1.llar:
IHI genuine parts
(4)Accidents due to the use in excess of the
rated capacity

3. c::i!UB~~JH:-::.> ~' T
IC 5119 ~ Mroi, (Z: ~ ZL 3. Communication
T t 1 fJ. t '~ 'J]rj (7) $ i7JJ , i L t::.. G , r;
~ I) Regarding the doubts about his instruction
1 I }-)J i t: ';t :® ~ I) u) l Hl ~ fiJT iz: '- 2: v. o anual, obscure points therein, special cases not
tated therein or any disorder, etc ..
please contact the engine manufacturer or the
nearest lHI business office.
RH1201S-l
 li Il GAS
TURBOCHARGER
TYPE RH
SPEC. c $ D 0 40 ification
H 0~02

Nm ax s
Y3
Tm ax .c Maximum allowable speed
I H I TOKYO JAPAN and maximum allowable
gas temperature

1i 1 . :i@J *fr~~~ .tR

Fig. 1. Rating plate

4. Caution
l) ~iif c (l)Do not touch the turbocharger in operation,
0) -c' i~ because the turbocharger is in a high
tempera re and hi condition.
(2) 1m~1;;;' j ~, tt::1'i51M 6~tL
51 (C. :i@J *fr 1m 0) -:i t::tk~cff%: Lc 2: ~\o (2)Dismantle or remove the turbocharger after
get t ng cold.

2 RH1201S-1
 Ei~ Contents

1. f~-@c ~U~ 1. Construction and function

l. l ir~Hfl m0 tl l. 1 Construction of the turbocharger
l. 2 1 2 Sectional drawing and parts list
l. 3 1 3 Structual drawing

2. i!I! i!f£met& 2. Operation

2. 1 2 Lubricating oil
2. 2 2.2 ration
2. 3 2. 3 Inspection and maintenance

3. 3 Maintenance
3. 1 3. l Cleaning
3. 2 3. 2 Tools
3. 3 3. 3 Disassembling the turbocharger
3. 4 3. 4 Reassembling the t rbocharger

4. ::;r--:~~ 4. Faults
4. 1 ~~ C: 1. toms of faults and possible causes
42 ii& 0) 4. 2 Tak ng the turbocharger out of service

5. Cleaning the compressor in service

Service offices

3 RH1201S-l
1. Construction and function
. 1 Construction of t
The RH12 33 type t consists
essent a ly a m xed flow turb ne and a
rad al flow compressor, assembled as a single

Turbine
gas from the diesel eng ne flows
turbine housing to the turb ne
wheel and provides the rotat ng torque to
the turbine shaft.
Seal ring and heat shie d are provided
~o that gas may not adversely affect the
bearings.

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

(3) Bear ng
A Thrust bearing
nee thrust force is stantly applied
to the turbine shaft, the thrust bearing is
0 rm-c 2 1c ts. V:J , 'm~ i;t ~.:i prov ded to prevent move of the shaft due to
0 T: , 9- t . I 'ffi v) ~ ~ 0C J: VJ ~ thrust force.
oc(i {jf < tJ f) ' liJ 'l('fE~
B. Journal bearing
A floating is employed. ln comparison
with the ordinaly fixed type, a dual oil
f Im is formed on the internal and external
faces of the bearing. The bearing bush
rotates and the sliding speed of each
bearing face is lower than the turbine
shaft speed. resulting in an increase of
ic stabilization.

4 RH 1 2 0 1 S -1
 Sectional draw g d s l is

'
. R ~ ,f?lttfr
sc type of RH 2 133

on

(bearing side)
[) s 3llC PICC
( \
\ j Thru t collar (com pr sso
J Scaling bu h
6 Shaft end hex a r.u 1
1-fv Scai r 1 g (tur ne side)
20 -
30
- 'l
v
:;
J/7 h
rn·
Jn· v·1
~;· IH
)

1
8
8
20
30
-
-

-
8
1
1
z
3
Seal ng (comvressor side)
essor wheel
ressor ho us ng
cssor side cl
Hexagon head bo t
l
1
1
8
8
'
40 1 :;-rv1· 1i- r 1 40 - Seal plate (compressor side) 1
2 1-fvj' v 1 2 Seal plat ( ring s i
50 1 •m5t~~
-
" 1 50 Bearing housing l
- 2
3 'At·17'
!l 3t !Bi1}'Jf
"" l
4
- 2
3
Bearing bush
Snap ring
l
4
- 4 /\~*· H M6 6 4 Hexagon head bolt M6 6
- 5 !ib!i~ 6 6 5 Spring lock washer 6 6
- 6 Ql}'Jf 1 - 6 0 ring
7 ~~tx
- 1 - 7 Beat shield 1
8 l·dt' 'J - 8 no ck pin l
- 9 0 1);7· 1 -
9 0 ring 1
60 - 1 ]0-101 n1; 2 60 1 Floating journal bearing 2
- 2 AJAL/9fv 1 2 Thrust bearing l
70 - 1 ~-t' ')~~ l 70 l Turbine housing l
- 2 ~ - t . I ffilJ tifl .:l fti 8 - 2 Turbine side clamp 8
- 3 /\~;· H M8 8 - 3 Hexagon head Loll
80 - l 1~-g.~ 1 80 Silencer
2 I!& :i6 #ZJ. 1ov 9 1 2 Air f i l t c r
- 3 /\~;· H M8 4 - 3 Hexagon head bolt
- 4 lib1*~ 8 4 l k was

5 R II 1 2 0 1 s -1
 'l. 3 Structura 1 draw ng

RH l 2 3 1 3 3
i g. '3. rue ur draw g 12 3

30 2

30-3 '•

•
80 2
\

J
80 1

40 2

10 5

10 6

50 9

• 506

50 l

/
/

RH1201S-1
2.
2

.1 !\ecommendabl o if l cat
CD
CC. CD

20

0 0

2.
a r

rd ng to L
recommenda ion
r prec ng
the l t
o r

Operat on
r new or overhauled urboc ger. not
following po nts.

6 Ii, 1- 11. 2. 2. 1 Before tak ng into service

2: All p pes have to be fix in a way th
t>io th er are no forces wh ch could deform the
1-:; (}) (}) cas ng.
deformations on the cas ng can feet
« r: (}) {: lL. the bearings.
Lr: 2: l \ 0
All lubricating oil pipes must be cleaned
IL. ~i ';: 7' 71 ~ ho l y before tak ng into servi
rr")r: 2:l\o
7·71 u1· ~il:Bff Ii ~~,JIA D C', 0. 5 - l. O Before starting the engine, always operate
(kg/cm 3 G) ';: L r: 2= i.' a the prelubrication system with inlet o l
pressure 0. 5 - L 0 (kg/cm 2

7 RH1201S-1
 . 2. rs aking nto service
gas, a and oi p pe connec
'o
Oi inlet pressure must be 2 - 5 (kg/cm 2 )
during operation at least 1 (kg/cm 2 )
d ling.
nlet pressure must east
2
) at low load operation n e
s less than 45 and
u is ess han Nmax x0.6)

Before stopp ng engine, d ng must be

at for 5 minutes to carbon ze
the heat from turb ne wheel
impossible, the engine mus
after starting up of priming
pump.

•
Pr ming pump must be operated at least
minutes after stopping the engine.

first 00 ing hours

2. ement u t laced or

8 RH 1 2 0 1 S -1
 2.
of he

n 11

nspcction in erval

item Inspection very E er

points !2 0 hr 2.j 0 4800 hrs.

Check ng of c r

tating cond of r ne sh

Checking of clearance of u b af

Disassembling, cleaning and inspection

Cleaning and inspection of oil fi

.., in accordance with instruction manual f the
~
<.) •
Engine oil change eng ne manufac rer
~1--~~~~~~~~~~~~~~~~~.~~-+-~~~~~-~-~------~-~---~------·~·-------------J
I-< ....
.0 in
::I
~"'
>. Inspection of oil pipe system

Inspection of intake
and exhaust pipe system

9 RII1201S l
 2 . 2 rocedures for
2. 1

ru o ten ng t
ar any dur ng rotat on
here the
does t rotate smoothly, he
turbocharger shoud be ismantled.
, 2. 3
2. . 2. 3 Check ng clearance of turbine shaft
C earanc s ust be measured n accordance
wi h fol owing figure.

A11 ow e x a clearanc s shown as

fa;-;-~~~~----~--~~~~~~~

Lt OJ
Allowable radial clearance is shown as
fol low.

initial clearance allowable

Radial clearance 0. 31 - 0. 45(mm) 0. 58 (mm)

When mea ured clearances are ove

mi ts or when the scoring or
ex ss ve wear is observed on the bearing
surf s. replace t rus and journal
bear ng.

For safety operating, replacing of thrust

and journal bearing every 2 years or
every 16000 hours is recommended, even
though these clearances are allowable.

t Max.
i 0. 58 (mm)

0.06 0.12
(mm)

H !Zl 4. !l!ill~Fa~~ 0.:>~t dl,1J~iJi

Fig 4 Measurement of bearing clearances

10 RH1201S-l
. 3.

·Pressu

pressure at the nlet c

r the ou let of c l tan

11 RH1201S-1
•

12 RH1201S-l
3.

lt

t f;

. 2. . 2

wrenche 0 ·cm
hammer
3. 2. 2 r

r too
etic base
gauge

13 RH 1 2 0 1 S -1
 . 3 sassemb ing the t
Refer to Fig.

t on
rbocharger f rs
reassemb same oca ion
ch s removed.

Remov ng i encer r o Fig. 5-1.

Remove hexagon bolts ).
Remove s l enc er .

. 3. 3 Removing compres hous ng

-Refer to Fig. 5-1.
hexagon head bolts ).
compressor s de clamps.
compressor housing.

i 'J not to the compressor

blades when remov compressor housing.

3.3.4 Pulling out compressor wheel

-Refer to Fig. 5-1.
Ins a l turb ne shaf ocking device to
gas ou let flange of turbine housing.
shaft end nut ).
is left-hand threaded.
out compressor wheel.
s ff c t to pull out hand.
heat compressor wheel even y be ow 100 C.

3 . 5 Removing seal late -Refer to Fig. 5-

Remove hexagon head l s and
3 5 spr ng lock washers.
sing the removed 2 bolts. up seal
L p ate (compressor si bearing si

•
C: with sealing bush .
0 Take care not to the • ring and
. ~fl'? !t fJ. ~ '\ J: -) ' i not to dip in the light oi 1.
2: ~ '\ 0
3. 3. 6 Removing thrust collar and thrust bearing
3. 3. 6 A -Refer to Fig. 5-L
thrust collar side).
0 C2)Using the removed 2 bolts for seal plate,
t' H 2 :;t~1tll L if push up thrust bearing.
'A U9A-~ Ii'()'} To CIDRemove distance piece and thrust collar
]X~D7 ($ffi§t{ll!J) ~Ii'()'}'to (bearing side).

14 RH I 2 0 I S -1
3
\
j •

I I
l l

\I/hen ng
r ng f
no

Do not remove nner snap

inspecti or replace.

and e these beari g parts wi h care to

prevent

15 RH 1 2 0 1 S -1
•

16 RH1201S-l
3. 4
as ng

4.

ing

g
t 7.h , i) :;1 i-
i: -) Tb G i!
SU sn gs ar ,. i
r ng sh groov

' ~)

n gap of r ngs t downwa s.

Take care to prevent damage o floating

3. 4. ''c journal bearing us plier.
. 4.
g e i.v
" Fig. 5
seal (t ne s l
g t g
, 4.

sea ring( essor

r ng in seal sh groov
:;-;1v 1J1f 7· 'dr'C' using seal ring plier.
3t.T 2:~ 1 0
When installing seal ring using plier,
3. 4. 3 ~~1N0%11 5-2 ~~.~T 2: t' always hold seal ring by finger.
'!llS't 1: l!ft~.tN ~ !& fi '1 6 0

. 4. 3 Reassembling heat shield

-Refer to Fig. 5 2.
Install heat shield to bearing hous ng.

17 RH1201S-1
I . 4 4 Reassembl ng turb ne shaft
-Refer fig. 5-2
I fer nstalling sea r ng to urbi
shaft, nstal l turbine shaf to bear ng
housing from turbine s de.

nstal ling turbine shaft. app y

ubricating oil on the shaft.

·Turn gap of seal ring to

· Before installing turbine shaft, ascertain

that there is no foreign in the bearing
housing.
· 9-t· :;-~ 11' ~J: iJ~:£i:~A9Zt:~
9-t· lifil 1J G*-ff.::i. ~lt~l\ ·For saftey inserting of turbine side sea
t:: Lt -9 o ring, vertical installing of turbine shaft
~ <D~l: IH-t. 1{!1!]:; 1C,,~7-t· lfUl is recoamended.
c :bttT T ~ ~ o At inserting of turbine shaft, place the
center of it to the center of turbine shaft.

3. 4 5 t / 0 5-2 ~H.~T ~ ~\ 3. 4. 5 Reassembling turbine housing

• :SJWfMi:[fJLt::
~ '=*Ji
7,: bttT9-
.::i.:k:'.:u o
7- t. I {!lljflj1 ;;UfiU:i J: *'
Ff:J )V ~ ( M8)
I

~ :$(
-Refer to Fig. 5 2.
Install turbine housing to bearing housing
aligning the mark.
Install turbine side clamps and hexagon
head bolts(M8).
Tighten bolts by 230 (kgf·cm).
Apply seizure prevent compound on bolts.
®Install turbine shaft locking device.

. 4. 6 ;J:JJ7, !. ~,I 3. 4. 6 Reassembling thrust collar and thrust

5-1 ~ bearing -Refer to Fig. 5-1.
1· o7nt· -1.Bcr.Y:1. ~7 t. 1•m Insert distance piece and thrust collar
1: F¥A 9 6 o (bearing side) to turbine shaft.
~ 1. 11. r; 7JV~ •w S¥: ~'ft <D 1·1 H · / <D 11: 'c: v tt G:)Set thrust bearing into the knock pin of
T :$11-:Hr 6 o bearing housing.
1.71. rfhi: Ii it G iJ> L ~illlt!tiltl~~:ffi L, *i5 Apply lubricating oil on the thrust
c
iltl/\ ~ '!ll5¥'.~'ff <D*i5iltl/\ ~:b tt T *Jl ii it 6. bearing. Install thrust bearing to bearing
•w
71. ~ t 7 CJ n · v·1 t ffi'D ~ 7 - t · / 'c: F¥;.. 6 , r housing with aligning lubricating hole.
®Insert thrust collar(compressor side) to
1-!v7·v-r<D 11~ 5-1 ~~T~~'o turbine shaft.
iltltJJ VJ ~1-i1-1· v-Hc:F¥A T 6 o
~ 0il~L iltltJJ VJ i::$1N it G nt::1-J¥ 1!11· <D 3. 4. 7 Reassembling seal plate -Refer to Fig. 5-1.
D fl· [OJ ~ 1: ts. 6 J: -5 ';:~A L -c 2: l' o Insert sealing bush in seal plate.
~0 1J;f ~•t!JS¥: (1)~$1c:*Jl:i6Vo Turn gap of seal ring to upwards.
~ (!) ~~' 0 I} I?' iJ> t:l l: ~1, t:: tk ~ i: ts. G ts. ~ \ J: Insert "O" ring in the groove of bearing
-JC.' ~~\o housing not to be twisted.
®iltltJJ VJ ~ *Jli::: ;{, t:· 1-JV1 • v- r~, •mS¥:~ i: ®Install seal plate inserted sealing bush
*Jli::: ti' 0 to bearing housing.
® 11. t PM.~!£- Ff:J *H ( M6) ~ .!1X'. ft U 6 a ®Install spring lock washers and hexagon
f.i%1i~JvJ(j: 110 (kgf·cm) c·9o head bolts(M6).
Tighten bolts by 110 (kgf·cm).

18 RH1201S-1
4

'c

19 RH1201S-!
 < Exhaust gas emperature hi r than normal
or charged air pressure lower than normal
ssible cau
rty filter of s lencer

pressure too

2 noise of tur larger

Po

P P ng
ger

4. 1. ubricating oil pressure too low

rJ) Poss i 1e cause ;
Dir y or c icating o

. 1. 4 Too large lubricating oil consumption

Possible causes ,
br cati g 1 pressure

ng oil piping

4. . 5 Surging of the compressor

Possible causes :
CD!ncrease of the friction resistance
in the ir cooler or filter of
. 1
s1,encer

20 RH 1 2 0 1 S -1
 c 1

ea
d

t'

r a vinyl n e te

water qu should be
ob , bee se r g neon rolled
to urbocharger and gine causes a troubl
ither cha air pressure or exhaust gas
<f 0 emperatur changes after injecting water.
(± 7)<. !<.: {R ~ Ii, 10 If pressure or temperature does not change,
?ti&(<.: ~ t 10 may ly be repeated after 10 minutes.
cr:>i±.7J<. mm~ ')-r b tJ) it> re is no c in performance even
G :tlJJ \ \ ~ l:L :i®fi'. ® J fJ> ti L repeating 3 or 4 times injection, which
< !i t~ fl;~ ® JJ~:t:~I iJ:> ~ ;t G i ® <:: , :i® M5 ttl causes the deposit to be very heavy and hard
~0M L Jn· hit~mm "* t: !i,El~ L -Cl' 2: \ 'o or the compressor wheel to be damaged.
®i±.7J<.ntmi&J>tJ < e: b 1s 0 1;t :imV\®-r:i1 In this case, the compressor wheel should be
:/1~i1UiL, 2:1±-C 2:t'o dismantled for checking or cleaning.
@After injection, the engine should be run
loaded for at least 15 minutes.

21 RH1201S-l
 ~
Lubr1cat1ng 011 outlet
ll!Uili'lli~!1 Hi!P
se12ur·e when u,r •ur lliTT 7~1'
Snap ring RT o11er

-~~tlt5i~~1I~
FJg.5.01sasse 1ng d asse ling
"F 00 ··· G - 2

32

'T 4 ~ 9
TEL
06-281-201

-,~
T lv . l l 5 )
TEL 03-3 34-3648"--'9
PAX 0 534-3636

11930601
 =r'104 2-9 7
TEL 03-3277-4220
FAX 03-3277-4244

,JtmJ.iQIJJ3Rrifr:i€1~~7· Jv- 7°
=ro6o fL~~fiJct19'1:1R:*:.im ¥J i 3- 4
TEL Oll-241-8156
FAX 011-271-5266

!,fUt'1I\;f:Jij[~fi;#l '.7 Jv- 7°

=r98o 1u1f:li1H1rn11R*mr1 -1 2 3 o
TEL 022-227-9711
FAX 022-227-9738

t
1!1~ 'W!f1ij[ !~t~·mt

=r'450 b 6~ifJcf1,f;j(R'.{'1~\3 l 7 3 4
TEL 052-563-0971
FAX 052-586-4723

*flf:,{*;fjifr~*~#l '.7" JV- 7°

=r 564 t:~lZJftll)\EIJrtJ~t:nmr i s - i i
TEL 06-386-5621
FAX 06-380-2435

Lt.%$~fr:i€1Po~7· Jv- 7'

=r133 11:.%m£§!2SJtllJ111l!J i i 2- 5
TEL 082-295-8041
FAX 082-295-0821

~t~E'*Pfii.®*15~7· Jv- 7°
=r'760 fltt~f!J~lt~ll!J 3 - 6
TEL 0878-51-9158
FAX 0878-23-0301

fillfi'GJ.!Jf}~JT~ffit;,t 1· Jv- 7°
=r 815 mfffi.lrfJ]¥j(Rij;\!Jjl 2 - 2 - 5
TEL 092-512-6001
FAX 092-512-6076

H930602
 I H I I HS

3 3 5
TEL 0154-23-4251
FAX 0154-22-4082

l?JiW:I~f*:r\.Q:t±
T 040 tillft'!ili13&llir 3 l 1
TEL 0138-42-1256
FAX 0138-41-5587

1J\ffI*Jft:r\.£:t±
'T290 f-~!J¥l:rfJJJjfFf'J;\$li8 6 6 - 2
TEL 0436-42-0511
FAX 0435-42-0711

tJii~ ¥~:i:t£:Umtlli~~
'T 222 tlii~ rn P.!~ t!E> NJlIRJ l 2 5 6
TEL 045-471-6001
FAX 045-471-6063

; I~:f*itQ:U ·
"f652 f!lfi'SrfJ~f!lf[ZiJ11{::;~1llf l 3 ·- 2 1
TEL 078-681-7421
FAX 078-681-7424

~iMJ {!'§~I~t~itQ:t±
=r 750 ~Mrn:rurt~!IlJ 8 - 4 6
TEL 0832-48-4111
FAX OB 32-48-4112

11930603
Fax :81(3)3286-20

8930604
Turbocharger Control Division
2-9-7, Yaesu, Chuo-ku, 104 JAPAN.
Tel :81(3)3277-4220 Fax :81 3277-1244

Hokkaido Works District Turbocharger Group

13-1, Odor i-N i sh i. Chuo-ku. Sapporo 060 JJ\PJ\N.
Tel .81(11)241-8156 Fax :81(11)271-5266

Tohoku Branch Sales Office Turbocharger Group

1-12-30, Hon-cho, Aoba-ku, Sendai 980 JAPAN.
Tel .81(22)227-9711 Fax :81(22)227-9738

Works District Turbocharger Group

3-17-34, Meieki. Nakamura-ku, 450 JAPAN.
Tel .81(52)563-0971 Fax :81(52)586-4723

Osaka Works District Turbocharger Group

13-11, Toyotsu-cho, Sui ta-shi, Osaka 564 JAPAN.
Tel : 81(6)386-5621 Fax :81(6)380-2435

Hiroshima Works District Turbocharger Group

1-12-5, Yokokawa-cho, Nishi-ku, Hiroshima 733 JAPAN.
Tel : 81(82)295-8041 Fax :81(82)295-0821

Takama t su Br an ch Sa I es Office Turbocharger Group

3-6, Konya-cho, Takamatsu 760 JAPAN.
Tel :81(878)51-9158 Fax :81(878)23-0301

Fukuoka Works District Turbocharger Group

2-2-5, Shiobara, Minami-ku, Fukuoka 815 JAPAN.
Tel :81 (92)512-6001 Fax :81(92)512-6076

ff 930605
 !HJ Turbocharger's Service Agents

BUS AN:Consolidated Maritime neer i ng ! nc.

Korea Express Building, 12il-1. Choryan Busan. KOREA
Tel :82 (51)465-2381 ~3
Fax ·82(51)462-7631
Telex :K 53759

SEOUL :Consolidated Maritime ineering Inc. (Seoul Office)

Room 96. Kwang J l Bui !ding, 11. Mugyo-Dong, Jung-ku. Seoul, KOREA.
Tel :82(2)773-2381~3
Fax 82(2)756-7077

TA I PE I :Dahsan Enterprise Co., Ltd

F. 14-1. No. 85, Sec. 1 Chung Hsiao E. fld .. Taipei, TAIWAN. fl. 0. C.
Tel :886(2)322-4515~6
Fax ·886(2)322-4521

K /\ 0 HS I UNG .Dahsan Enterprise Co .. Ltd. (Kaohsiung Office)

4F .. NO. 21. llua 3rd Road, Kaohsiung, TAIWAN. R. 0. C.
Tel :886 (7) 201-7133~4
Fax :886(7)281-5295

ll930606
NEW YORK: !HJ !NC., Principal Office
280 Park West Building 30th New York. N.Y. 10017, U.S.A.
Tel :1(212)599-8100
Fax :1(212)599-8111
Telex :420539 !HI Ul

D E T R 0 I T : l ll l l n tern at i ona l, l NC.

Top of Troy Building Suite 1110
755 West Big Beaver Road, Troy, Michigan, 48084, U.S. A.
Tel : 1(313)244-9370
Fax :1(313)244-9062

H 0 UST 0 N : IHI Marine Technology, INC.

2400 Augusta Drive, Suite 250, Houston, Texas 77057, U.S. A.
Tel :1(713)974-3040
Fax :1(713)974-4204
Telex :WU 792-395

MEX I C 0 C I TY : !Ill Co., Ltd.

Mexico Representative Office
Paseo de La Ref orma No. C. P 06600 MEXICO. D. F. MEXICO
Tel : 52 (5) 705-0 0393
Fax :52(5)705-0143
Telex : 1771735 ll!l ME

RI 0 DE JANE I RO: Jshikawajima do Brasil Estaleiros S.~

Rua General Gurjao, No. 2 Ponta do Caju Cep-20931

Rio de Janeiro, RJ, BRASIL
Tel :55(21)580-8668
Fax :55(21)580-8826
Telex : 2121336

ROTTERDAM: !HI Marine B.V.

Glashaven IDA, 3011 XH Rotterdam, THE NETHERLANDS
Tel :31(10)411-6406
Fax :31(10)411-6412
Telex :22462 !Ill NL

L 0 ND 0 N : !Ill Europe Ltd.

Floor 9A, No. l Minster Court, Mincing Lane, London EC3R 7AA. ENGLAND
Tel :44(71)626-1010
Fax :44(71)626-0078
Telex :888377 lll!LDN G

H930607
 PAR I S : IHI Co .. Ltd.
Paris Representative Office
35. Avenue Frankl in-!looseve t. 75008-Paris. Fl\ANCE
Tel 33(1)43-59-30-17,43-5 7
33( )42-8 5
: l Hl CO 6414 0 9F

PIRAEUS : IHI Co .. Ltd.

Greece ti ve Office
3rd Floor 7. Akti Miaouli Street. Piraeus. GREECE
Tel 30(1)422-4294
Fax :30(1)422-4297
Telex :212483, 212842 llll GR

L I ER S : HI Co., Ltd.
Bureau de L a son. d' Alger
65, Chemin Cheikh Bachir lbrahimi, E\-Biar, Alger. ALGEl\iA
(Mailing P.OBox llll, BP.102. El--Bar. Alger
Tel : 2 l3 (2) 79-33-99, 79-29-15, 79-00-80
Fax .213(2)79-14-36
Telex :61369 lH CO DZ

OSCO : Hl
Moscow ta ve Of i
MYTNAYA UL.. DOM , KV. 7, MOSCO\\' 7049. RUSSIA
:7 5)230-10 0978
Fax ·7(095)230-2756
Telex :413087 lll!CO SU

TEHRAN : l!ll Co., Ltd.

Tehran Office
No.19, 17th St., Gandhi Ave., IRAN
iling P.0.Box 15875-3486 !RAN
Tel :98 ) 687-358, 687-805
Fax :98(21)888-4281
Telex :223725 !SHI IR

B E I J I N G : lH I Co. , Ltd.
Peking Liaison Off ice
Room 705. China World Trade Center No.1 Jian Guo Men Wai Avenue, Beijing, CHINA
Tel :86(1)505-4997,0408
Fax :86(1)505-4350
Telex :210343 IHIPK

1!930608
TA I PE I : !HI Co .. Ltd.
Taipei Liaison Office
Room 1202. Chia Hsin Bldg. No. Sec. Z. Shan N. Road, Taipei, TAIWAN
Tel :886(2)542-55 5521,5523
Fax ·886(2)542-4362
Telex : 11320 !HICO

H 0 NG K 0 NG : IHI (l!K) Ltd.

!loom 831 Central Building, Pedder Street. HONG KONG
Tel :852-5236287, 5224093---95
Fax ·852-8452497
Telex :73797 !HICO HX

BANG K 0 K : IHI Co .. Ltd.

Representative Office
8th Floor. Thaniya Building 62, Si lorn Road, Bangkok, THAILAND
Tel :66(2)236-3490, 7356, 9099
Fax :66(2)236-7340
Telex :82375 IHICOT!l

KUALA LUMPUR: !HI Co., Ltd.

Kuala Lumpur Office
Letter Box No. 22nd Flr. UBN Tower, 10 Jin. P. Ramlee
50250 Kuala Lumpur. MALAYSIA
Tel :60(3)232-1255, 1271
Fax :60(3)232-1418
Telex :20257 IHI KL

S ING AP 0 RE : Ill! Marine Engineering (Singapore) PTE. Ltd.

11. Jurong Pier Road. Singapore. 2261. SINGAPORE
Tel :65-268-7360
Fax :65-265-0780
Telex :!MES RS37048

J A K A R T A : l ll I Co. . Ltd.
Jakarta Representative Office
Skyline Bui !ding 9th Floor, JL. M. H. Thamrin No. 9, Jakarta, INDONESIA
Tel :62(21)32-2147
Fax :62(21)32-3273
Telex :44175 Ill! JKT

S YD NEY : IHI Engineering Australia Pty. Ltd.

15th Floor, 213-219 Miller Street, North Sydney, N. S. W. 2060, AUSTRALIA
Tel :61 957-4777
Fax :61(2)922-3638
Telex :AA120480 lH!CO

H930609
 FOREWORD
The RHO hydraulic governor is a high
performance variable speed governor for
use with main and auxiliary marine engines,
engines for electric generators and general
power engines.
This service manual describes construction
and operation, repair and maintenance, and
adjustment of the RHD6 and RHD10
hydraulic governors.
The contents of this manual, including
illustrations, drawings and specifications
are the latest available at the time of
printing.
The right is reserved to make changes in
specifications and procedures at any time
without notice.
ZEXEL CORPORATION

CONTENTS
Page Page
OJ FEATURES . . . . . . .. . .. . . . . . . . . . . . . . . . . . 1 (2] DISASSEMBLY . . . . . . . .. . . . . . . . . . . 23
~ SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . .. . . . . . . .. . . . . . 23
@] CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . 6 EXPLODED VIEW . . . . . . . . . . .. . 24
GJ OPERATION . . . . . . . . . . . . . . . .. . .. . . . . . . 8 PART LIST . . . . . . . . ........ 25
ENGINE STARTING . . . . . . . . . . 8 PREPARATION . . . . . . . . . . . . .. . . . 26
NORMAL OPERATION . . . . . . . . . . 9 @] DISASSEMBLY . . . . . .. . . . . . 26
LOAD DECREASE . . . . . . . . . . . . . . . . 10 8 INSPECTION . . . . . ............ 31
LOAD INCREASE . . . . . . . . . . . . . . 11 ~REASSEMBLY . . . 34
ENGINE STOPPING . . . .. . . . . .. . . . 12 ~ ADJUSTMENT 40
AUXILIARY STARTING BOOSTER 13 SPECIAL TOOLS . . . ........ 40
SPEED DROOP MECHANISM . . 14 PREPARATION 40
COMPENSATOR MECHANISM .. 15 OPERATION 43
@] ADDITIONAL DEVICES . . . . .. . . . . . . . . . 16 ADDITIONAL ......... .
GOVERNOR MOTOR . . . .. . .. . . . 16 DJ:] TROUBLESHOOTING . . . . .. . . . . 52
PNEUMATIC CONTROLLER ..... 18 @] PART NUMBER EXPLANATION . . . . 53
HYDRAULIC CONTROLLER . . . . 19
I@] HANDLING . . . . . . . . . . . . . . . . . . . . . . . . 20
GOVERNOR INSTALLATION 20
HYDRAULIC FLUID . . . . . . . . . . . 20
AIR BLEEDING &
COMPENSATION ADJUSTMENT 21
LINKAGE CONNECTIONS ....... .
DAILY INSPECTION . . . . . ..
IN-SERVICE INSPECTION ...... 22

1. The RHO governor has a large controlling
force, despite its compact size.
2. As the hydraulic fluid is contained
governor, piping and sub-tank
are unnecessary when
governor on the engine.
3. As the power piston utilizes a differential
system, the operating force is uniform.
Moreover, it is not necessary to install a
return spring in the fuel control linkage.
When play in the linkage system
excessive, however, it necessary to
install a spring at the end of the system
to absorb this play.
4. The governor is able to rotate in either
direction, and therefore it can be used
without modification on engines which
rotate in the reverse direction.
5. Because the normal operating speed is
: . low, governor endurance is high, and
gearing simple when installing the
governor on low and intermediate speed
engines.
6. The governor has a speed droop
mechanism and a compensator
mechanism, enabling it to be easily and
freely adjusted.
The adjustment range is very wide,
enabling governor use on a wide range of
engines. The governor can also be used
as an isochronous governor with
speed droop .
.•..y'
w FEATURES
The governor b y's high nsile
aluminum alloy casting makes it
extremely lightweight.
8. The governor can be equipped with a
governor motor, pneumatic controller
a hydraulic controller.
9. RHD6 and RHD1 O governors are
interchangeable. For example, if a higher
pressure injection system is required or if
the governor's control force is insufficient
to cope with the demand for increased
engine output, decreased fuel
consumption or the use of lower
fuel oil, then the RHD10 can replace
RHD6.
10. The governor is equipped with a
standardized piping connection to enable
the installation of an auxiliary starting
booster.
11.0f the RHD10 governor's main
components, 80°/o are identical to those
of the RHD6. Almost 100% of the
remote control device's components are
identical to those of the RHD6.
 cg] SPECIFICATIONS

Control force
Output shaft torque
Output shaft operation angle
Power piston diameter
RHD6 RHD10
5.9 J {0.6 kgf·m} 9.8 J {1.0 kgf·m}
9.8 N·m {1.0 kgf·m} 15 N·m {1.5 kgf·m}
35° 40°
Small: ¢ 17. 7; Large: ¢25 Small: ¢ 18.6; Large: ¢27

Controlled speed range Standard rating: 600-2,000 r/min (Normal: 1, 700- 2,000)
High speed rating: 800-2,400 r/min
(Normal: 1,900-2,400)
Maximum allowable speed 2,500 r/min
Compensator Needle valve type
Speed droop adjustment o- approx 10% (rated)
range 4~

Direction of rotation Clockwise & counterclockwise

Hydraulic fluid SAE20W- 40 (Mobiloil)
Dry weight (lever type) 5.5 kg 5.7 kg
Governor drive power Max approx 0.2 kW {0.3 ps}
Applicable engines Low speed: up to approx 1,500 kW Low speed: up to approx 2,200 kW
{2,000 ps} {3,000 ps}
Intermediate speed: up to approx 1,850 kW
{2,500 ps}
High speed: up to approx 2,200 kW High speed: up to approx 2,950 kW
{3,000 ps} {4,000 ps}

Applicable injection pumps PE (all types) PE (all types)

PF1Zx 18 cyl PF1CXX 18 cyl
PF1C, -1CDx 16 (18) cyl PF1WXX 16 cyl
PF1WX 12 (16) cyl PF1GXX 12 cyl ~·
PF1GDX8 cyl PF1DXX8 cyl
PF1DDX6 cyl PF1EXX6 cyl

The main difference between the RHD6 and
the RHD1 O is the power piston. The parts
adjacent to the power piston also differ.
Note:
1. The method of connecting fuel linkages
and the amount of corresponding
resistance differ depending on the size of
the applicable engine and the size and
number of the injection pumps.
Consequently, engines with little friction
loss can be used in high output engine
applications and, conversely, engines
with large friction loss can only be used
in applications equal to or less than those
specified above.
2. Simply because the governor has surplus
control force does not necessarily mean
that stable operation can be ensured.
In order to ensure stable operation and to
prevent the speed from exceeding the
necessary speed, the inertia of the
engine and the drive system should be as
large as possible.

2
type
 [2J SPECIFICATIONS

RHD6 and RHD10 -MCL type governor motors

MC type with governor motor

Approx 8

JIS C3410 250V type

Current
Voltage Cycle Speed consumption Output
Motor 50/60Hz 1,200/1450 r/min 20W 4W
1,200/1450 r/min 20W 4W
DC24V 2,200 r/min 20W 3W
DC100V 2,200 r/min 20W 3W

1/300, 1/375, 1/450, 1/600,

can be determined freely by choosing

from any of the gear heads.
The standard specified time, however, is approximately that
shown below.
Main engines: sec dead slow to rated speed
Engines for generators: 7-9 sec/1 Hz

switch adjustment Standard specification Lower limit: 600 r/min

range Upper limit: 2,000 r/min
Prior shipment, lower limit is set at 600 r/min, and the
(RHD6, 10 upper at 1,600 r/min.
High speed specification Lower limit: 800 r/min
Upper limit: 2,400 r/min
is set at 800 r/min, and the

4
 C1J SPECIFICATIONS

MCL type with governor motor

Speed setting screw
Lower limit switch Upper limit switch

I I
Speed adjuster / \
I (cam) \ Motor
Speed adjusting · \ Gear head
lever \
Friction coupling
I()

<ci I
gj Fork

Approx 148

Pneumatic controller dimensions

5
 increase
Speed decrease

6
 Set

Flyweight assembly

Beanng

Pilot valve

Sleeve

Gasket
 [!] OPERATION

ENGINE STARTING
Control lever High pressure

~·
___.,.._ Fuel decrease hydraulic fluid
- Fuel increase Low pressure
c
hydraulic fluid
Cross section

Power piston
Speeder spring

Gear shaft 0

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

8
 OPERATION

NORMAL OPERATION
Control lever ~~Ill High pressure hydraulic
tiii fluid
- - - Fuel decrease =·=c-=m•
Low pressure
- - - Fuel increase ===fluid

Speed control shaft

Speeder spring ---- Power piston

Regulating valve

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

9
 ffllll High pressure hydraulic

--
Cross section

~ Compensating lower I

Compensating piston

I
LOAD I

lever
 •

[4J OPERATION

ENGINE STOPPING

11111 High pressure hydraulic fluid

Stop side
- Fuel decrease
Control lever
~-~
Cross section

Power piston

Needle

Because the governor's power piston is
moved in the fuel decrease direction by the
high pressure hydraulic fluid above the
power piston, when the control lever is
moved to the stop side the pilot valve is
moved up by the speeder spring.
Terminal lever
Stop
,..-
governor
The high pressure hydraulic fluid in the
bottom of the power piston is then returned
to the governor's hydraulic fluid tank, the
power piston moves down (in the fuel
decrease direction) and the engine can be
forcibly stopped.
The engine can also be stopped by remote
control by a governor motor or pneumatic
Fuel decrease controller. These remote control devices r '
are also installed with a synchronizer to
enable manual engine stopping.
When the engine is not stopped on the
governor side as described above, but is
instead stopped by a handle which
mechanically sets the control rack to the
Rack limit non-injection position, it is necessary to
install a spring in the link system to prevent
excessive force being applied to the
Engine stop handle
governor.
As this governor does not have a load limit
device, it is also necessary to install a
spring as above when it is necessary to
mechanically the load.

12
 C!l OPERATION

AUXILIARY STARTING BOOSTER

Control lever ==""'" High pressure hydraulic fluid

- Fuel decrease

~
c" ~Fuel increase [][l§E§ Low pressure hydraulic

~--~~
Cross section
oom!iMJ Compressed air

Power piston

0~ Gear shaft
Starting compensation
booster Return check valve
Compressed air \._

Air port -

An auxiliary starting booster can be As the governor is simultaneously being

connected to the RHD10 governor when
necessary.
The following explains engine operation at
starting when a booster has been
connected to the governor.
When compressed air is supplied to the
booster piston to facilitate starting, the
piston compresses the spring and the
hydraulic fluid in the chamber opposite the
compressed air is guided through the
discharge side check valve to the chamber
above the power piston.
As the governor at this time is in the
engine starting status, as explained
previously, the hydraulic fluid also flows
through the pilot valve to the chamber
below the power piston.
turned, high hydraulic fluid from
the gear pump is also acting on the top
and bottom chamber of the power piston.
Consequently, hydraulic fluid pressurized
by the booster moves the power piston in
the fuel increase direction faster than
normal, and it arrives at the fuel position
necessary for starting faster than normal.
The booster is an effective means of
assisting starting for engines such as those
for emergency power generators where
mis-starting must be avoided, and in high
output engines where the governor's
surplus output is small.
ZEXEL manufactures boosters especially
for the RHD6 and RHD10

13
 C5J ADDITIONAL DEVICES
The governor can be equipped with a central control room.
governor motor and a pneumatic controller. Their construction and operation are
These facilitate remote engine control from a explained below.
GOVERNOR MOTOR
RHDG and RHD10 - MC type governor motor

Speed screw Stopper Friction coupling Gear head Motor

Gear I

/
Maximum speed setting screw

\
Synchronizer knob

"" Cover

I
Guide screw

The governor motor operates when the
engine speed set switch in the control
room is turned ON.
When the motor operates, the speed
setting screw is rotated by the friction
coupling and gear.
As the speed setting screw is screwed into
the guide screw, this rotation results in
vertical movement.
Because the speed setting screw acts on
the speed adjusting mechanism within the
governor, speed setting screw movement
changes the set load of the speeder spring
to vary engine speed.
The speeder can also be changed
manually in the same way by turning the
synchronizer knob.

16
 Cfil ADDITIONAL DEVICES
RHD6 and RHD10 - MCL type governor motor
(with limit switch)
Speed setting screw

lower limit switch Upper limit switch

Synchronizer knob

Speed adjuster (cam)

Speed adjusting lever

Gear head

Fork Friction coupling

This governor motor enables the electrical
control of the set governor speed's upper
and lower limits through limit switches.
Three types are available for use with
ships' main engines, pumps, and
generators. The control range and speed
setting time di ff er depending on the type
used.
The motor is decelerated by the gear head
which, through the friction coupling, turns
the speed setting screw to slide the speed
adjuster in an axial direction. A pin
protruding from the speed adjuster turns
the speed adjusting lever fixed to the
speed control shaft to vary the set speed.
The upper part of the speed adjuster also
serves as a cam operate the limit
switches and move them within the range
set by the and enable adjustment of
the upper and lower set speeds.
When setting the speed manually, the
motor side synchronizer can be used to
freely vary the speed from the minimum to
the maximum irrespective of limit switch
control.
Also, when an attempt is made to
simultaneously change the set speed by
remote control, the ction coupling
ensures that the speed is first changed on
the engine side to prevent any adverse
effect on the motor.

17
 Diaphragm

Cover

spring.
can also be freely
the same way by
top of the controller.
 I]] ADDITIONAL DEVICES

HYDRAULIC CONTROLLER
Knob /Locknut

Adjusting screw Eye bolt

Air breather

Cap

Spacer

Inner spring
Outer spring
Cylinder

Cover

The hydraulic controller is control The hydraulic controller's piston

engine speed, but utilizes hydraulic displacement is 12
pressure instead of air pressure, and a
piston instead of a diaphragm.

19
 [§:] HANDLING

GOVERNOR INSTALLATION
1. Install the governor vertically to the
3.5
governor drive case. Use the
accompanying gasket at the installation
surface.
2. Ensure the governor gear shaft is not
smaller dia) subjected to a direct radial load, and
that eccentricity and acceleration-gear
play are as small as possible.
Gear shaft spline coupling dimensions
are shown at left. These are the same
for RHD6 and RHD1 O governors.

CAUTION
When handling the governor, ensure the
end of the governor's gear shaft is not
subject to force or impact.

Note:
Although the spline is a standard JIS
square-shaped spline (6 x 13 x 16), the
dimensions shown at left are
recommended to avoid even minute
eccentricity when installing the coupling.
The spline couplings shown at left are
standard ZEXEL spline couplings.

HYDRAULIC FLUID
Hydraulic fluid type Fluid charge Inspection Replacement
The type of hydraulic Approx 1,300 cm3 Check the hydraulic The fluid must initially
fluid used varies With the governor fluid daily. If the be replaced after
depending on the horizontal, fill the charge is less than 1 ,000 hours or 3
governor oil governor with fluid that specified, check months. Thereafter,
temperature during until the level is for leaks. If repair is the fluid must then
normal operation. slightly above the not possible, contact be replaced every
Less than 50°C: middle of the an authorized ZEXEL 3,000 hours or 6
SAE20 governor case service station. months.
50°C-70°C: window.
SAE30 If the fluid charge is
Over 70°C: insufficient, bubbles
SAE40 will form, perform-
ance will decrease,
and fluid deterioration
will be accelerated.

20
 []] HANDLING
AIR BLEEDING AND
COMPENSATION ADJUSTMENT
1. Set the speed droop at the smallest
value possible using the speed droop
adjuster (0-2 on the adjuster scale)
and fully open the compensating needle
valve (3 turns from the fully closed
position).
2. Operate the engine at low speed and
cause the engine to 'hunt' or 'surge' for
approximately 30 seconds to bleed the
air.

3. Stop the engine, set the speed droop to

the setting estimated for the particular
application (determined from the
pertormance diagram) and then restart
the engine.

4. Close the needle valve until 'hunting'

stops.

CAUTION
The above completes air bleeding and
compensation adjustment. If, however,
the speed droop adjustment setting is
changed during engine adjustment,
readjust the needle valve to as open a
position as possible at which stabilized
engine operation Is obtained.

21
 [§] HANDLING
RHD6 type Speed droop adiuster scale LINKAGE CONNECTIONS
-- -- 0 1. a split
---·-- 5 determining secure
10 it using a knock pin, etc.
The linkage must as
direct as possible.
the actual mass

RHD10 type Speed droop adjuster scale The figures left show the
- - 0 recommended relationships for
5 shaft
10 a static

As play the system adversely

affects performance, ensure play Is as
as pO$Sible.

level
DAILY INSPECTION
1. before

IN-SERVICE INSPECTION
1.

22
 C1J DISASSEMBLY

SPECIAL TOOLS
The fallowing special
reassembly of the RHO

Key No Part name Application

1 Case
2 Spanner

3 Screwdriver 376100-2200 i
4 Screwdriver 00-2300 1
5 Pliers 376100-2400 1
6 Spanner 3761 00-2500 1 17
7 Allen wrench 3761 00-2600 i SW 3 mm
8 Allen .U,,.,,
\AIH.
376100-2700 1 SW 5 mm
9 Extractor 3761 1 For

2 3

5 6

7 9

20 28

23
 [Z] DISASSEMBLy

EXPLODED VIEW

105116

24
 [I] DISASSEMBLY

PART LIST
RHO-LC type hydraulic governor

Key No Part name Key No Part name Key No Part name

1 Base 36 Bolt 89 Roll pin
2 Needle roller 50 Flyweight 95 Floating lever
bearing 51 Washer 96 Wire
3 Oil seal 52 Thrust needle roller 104 Gasket
7 Gear shaft bearing 105 Cover
10 0-ring 53 Pilot valve 106 Bolt
11 Housing assembly 108 Maximum speed
13 Sleeve 60 Guide lever setting screw
18 Compensator 61 Pin 109 Nut
assembly 62 Split pin 110 Minimum speed
18/1 Power piston 70 Terminal arm setting screw
18/3 Compensator upper assembly 111 Nut
spring 70/1 Terminal arm 112 Gasket
18/4 Pushrod 7012 Terminal shaft 113 Air breather
18/5 Washer 70/3 Taper pin 118 Needle valve
18/6 Compensator lower 7014 Set screw 119 0-ring
spring 7015 Speed droop 123 Gasket
18/7 Snapring adjuster 124 Screw plug
18/8 Compensator 7016 Washer 130 Gasket
bushing 7017 Lock washer 131 Regulating valve
18/9 0-ring 7018 Screw 135 Indication plate
18/10 Compensator piston 85 Speed control shaft 136 Nail
18/11 Roll pin 86 Collar 137 Indication plate
35 Gasket washer 88 Fork 140 Pointer

Pneumatic controller
Key No Part name Key Part name Key No Part name
105 Pneumatic 105/11 Push rod 105/24 Spring washer
controller 105/12 Piston 105/25 Bolt
105/1 Cover 105/13 Diaphragm 105/26 Eye
105/2 Cylinder 105/14 Plate 105/27 Gasket
105/3 Screw 105/15 Nut 105/28 Eye bolt
105/4 Spring washer 105/16 Cover 105/30 Nut
105/5 Spring seat 105/17 Screw 105/31 Bolt (set screw)
105/6 Nut 105/18 0-ring 105/35 Gasket
105/7 Washer 105/19 Wing nut 105/36 Bolt
105/8 Spring 105/21 Knob (158) Pin
105/9 Spring 105/22 Set screw
105/10 Washer 105/23 Screw

25
 CZJ DISASSEMBLY

PREPARATION
Keep the work bench and During disassembly, put the disassembled
Before starting disassembly, re co parts neatly and sequentially on the work
performance data and the positions of bench, labelling them if necessary to
adjustable parts for later reference. This facilitate later reassembly.
data will facilitate the detection and diagnosis Clean the outside of the governor before
of any governor malfunctions and defects. disassembly.
Cover DISASSEMBLY
Bolts (4)
1. Remove the four bolts using a
screwdriver and then remove the cover
together with the gasket.
2. Tum the governor upside down and
drain the fluid.

3. Remove the two wires connecting the

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

Pilot valve assembly

4. Remove the pilot valve assembly.

t /
CAUTION
Put the pilot valve In clean light oil.

26
 UJ DISASSEMBLY
Terminal arm
5. Remove the two split pins and then
remove the two pins connecting the
terminal arm and the guide lever to the
power piston.

Guide lever

6. Remove the bolts using an alien wrench

(SW 5 mm).

Base 7. Tap the base lightly with a plastic

hammer to separate it from the housing.

Housing

Sleeve" Housing 8. Remove the sleeve from the housing

and the gear shaft from the base.

CAUTION
Put the sleeve in clean light oil.

27
 [Z] DISASSEMBLV
9. Push the power piston down from the
top of the governor and then remove
the compensator bushing and the
compensator assembly.

10. Remove the roll pin securing the fork to

the speed control shaft, and then
Cancel spring
remove the speed control shaft, the
i"\-~1 collars and the fork.
I I
N~: ~
PC, MC, and MCL type governors are
equipped with a cancel spring on the
speed control shaft. Remove the cancel
spring when removing the speed control
shaft.
I
Speed control shaft

Flyweight assembly
11. Remove the flyweight assembly
t together with the thrust needle bearing
Thrust needle
bearing
and the washer from the housing.

Terminal arm Terminal shaft 12. Turn the terminal shaft one half turn and
remove the terminal shaft's two taper
pins. Remove the set screws using an
allen wrench (SW 3 mm), then remove
the terminal shaft and arm.
CAUTION
1. Do not remove the terminal shaft
unless it is not operating smoothly or
It is necessary to replace parts.
Taper pins (2) 2. When replacing the terminal shaft
and arm, they must be replaced as
an assembly.

28
 [I] DISASSEMBLY

Taper pin

Regulating valve 13. Remove the needle valve and regulating

valve (hexagon head, SW 24 mm) and
any other external parts.

The above completes disassembly of main

RHD governor components.
Disassemble other components when
necessary.
The pneumatic controller is the most
commonly equipped additional device.
Disassembly is described below.

Knob PNEUMATIC CONTROLLER

DISASSEMBLY
Locknut 1. Loosen the locknut. Then, loosen the
knob until it can be easily turned.

2. Remove the four bolts using a

screwdriver and then remove the cover.

Bolts {4)

Cover

29
 [1] DISASSEMBLY
3. Remove the diaphragm together
the push rod, and then remove the
springs.

Springs (2)

seat 4. Loosen the locknut and then remove the

t spring seat.

Locknut The above completes disassembly of main

pneumatic controller parts.
Disassemble other parts when necessary.

30
 CID INSPECTION
Record the details of all inspections and REPLACEMENT STANDARDS
repairs.
With parts as those listed below, first
Parts with key numbers 0:
check their external appearance to Replace at disassembly or
determine whether further disassembly is Parts with key numbers marked
necessary.
• Terminal arm assembly Replace every 4 years or 20,000
• Pilot valve assembly In principle, assemblies must be
• Housing assembly when any of their component parts have
• Flyweight assembly been used for 8 years or 40,000 hours.
• Governor motor
Wash all parts thoroughly clean light oil,
and check for wear, dam a e and
Replace any parts
new parts.

Oil seal Gasket

Gear shaft Gasket

0 ring Oil seal

0- ring Oil level gauge

Pin Flyweight

@ Pin Washer

@ Pin [§1] Thrust needle roller bearing

® Gasket [[1] Pin

@ Gasket Floating lever

8 0 ring Regulating valve

If parts other than the above are worn or damaged,

replace those parts with new ones.

31
 CID INSPECTION
I
Gear shaft Base assembly and housing
Sleeve contact surface
contact surface Replace the base if the power piston, gear
Power piston shaft or sleeve contact surfaces are worn
contact surface or damaged.
Replace the housing if the power piston,
gear shaft or sleeve contact surfaces, or
the housing holes are worn or damaged.
Replace the housing if the pressfitted
terminal arm bushings are worn or loose.

Housing holes

Sleeve contact
surface

K,
Power piston
contact surface

Sleeve Gear shaft and sleeve

Pilot port~
Replace the gear shaft if the outside,
spline, oil seal contact surface or gear is
worn or damaged. Replace the sleeve if
Gear
the gear, pilot ports or lands are worn or
damaged.

Gear

Gearshaft

Compensator assembly
compensator Assemble the compensator assembly's
bushing power piston, pushrod and compensator
bushing in the housing and check that they
move smoothly up and down under their
own weight when the housing is moved.
Repair or replace them if they do not move
smoothly.
I CAUTION
If the power piston does not move
smoothly, hunting or excessive speed
droop will prevent engine adjustment.

32
 [j] INSPECTION
Flyweight assembly
~/Flyweight Foreign matter in the flyweight will prevent
smooth flyweight movement.
Check that the flyweight moves smoothly.
Wash the flyweight thoroughly.

Speed control shaft

Power piston, guide lever and terminal
arm
• Replace the guide lever if the pin holes
are worn.
Floating lever Replace the pins if they are worn.
Replace the power piston if the inside is
worn.
• Replace the speed control shaft if it is
bent or the shaft journals are worn.

Terminal arm
Power piston

Regulating valve
Check that the piston moves smoothly.
Spring Repair or replace the piston if it is worn or
does not move smoothly.
\ Other parts
• Check all other parts for cracks,
Pin damage, damaged threads and rust.
Repair or replace them if necessary.
~ • Replace all 0-rings and gaskets.
• Replace springs that are damaged, bent
or rusted.
Regulating valve

33
 [ru REASSEMBLY

Spring seat Governor reassembly is described below.

PNEUMATIC CONTROLLER
(if installed)
1. Screw the locknut onto the spring seat,
then screw the spring seat into the
cylinder.

2. Install the diaphragm and pushrod

together two springs.

(2)

Install the cover and secure it using

bolts.

4. Install the knob and locknut

Locknut

34
 Cfil REASSEMBLY
Regulating valve GOVERNOR ASSEMBLY
1.

When installing the two taper pins in the

terminal shaft, support the terminal arm
and terminal shaft to avoid damaging
bushing pressfitted to the housing.

an adhesive
screws.

Taper pin
Set screw

35
 Cfil REASSEMBLY
5. Install the flyweight assembly, thrust
Flyweight assembly
bearing and washer in the housing.

6. Install the speed control shaft, collars

and fork, and then install the roll pin.
Cancel spring

CAUTION
PC, MC, and MCL governors are
equipped with a cancel spring. Install
the cancel spring when Installing the
speed control shaft.

7. Install the power piston, the

compensator assembly and the
Compensator
bushing compensator bushing.

8. Install the gear shaft in the base, and

Housing the sleeve in the housing.
Gear shaft

36
 CID REASSEMBLY

CAUTION
High pressure fluid
passageway When pressfitting the gear shaft bearing
into the base, pressfit the bearing to
align with the base face, as shown. If
the bearing is pressfltted too deep, the
bearing will block the high pressure fluid
passageway.

Bearing

Gear 9. Install the base to the housing using the

bolts and washers.
CAUTION

" While securing the base to the housing,

check that the gear shaft turns
smoothly. If the gear shaft does not
turn smoothly, the oil delivery gear may
be damaged.

10. Attach the guide lever to the terminal

Terminal arm arm and the power piston using the two
pins and two split pins .

/
. ,,,_,. !
Then, bend the split pins over.

• Gear shaft

Pilot valve assembly 11. Install the pilot valve assembly.

37
 []] REASSEMBLY
1
Floating lever

Floating lever
Wires

Fork
Bend the ends of the .......""'""
them from loosening.

1'
~

38
 []] REASSEMBLY
1

remove

39
 [IQ] ADJUSTMENT

In addition to general tools, the following special tools are necessary for governor
adjustment.
SPECIAL TOOLS
Key no Part name Part no Shape Remarks
1 Driving stand 307610-0050 For driving RHO
governor

2 Adjusting device 307610-1010 For measuring

lever angle

PREPARATION
1. Attach the driving stand to the pump
Hydraulic
tester and install the governor on the
driving stand.
Fill the governor with the specified
amount of hydraulic fluid (approx 1,300
cm3; the fluid should be a little over the
middle level of the gauge).

40
 ITQJ ADJUSTMENT
Terminal arm 2. Move the terminal arm by hand until it
becomes difficult to move to bleed the
air from the governor.

3. Turn the flywheel by hand and check

that the gear shaft can be turned easily,
and that the flyweight turns together.

CAUTION
If the gear shaft does not turn easily, it
will heat up during operation and
adversely affect endurance.

control shaft 4. Set the speed control shaft in the speed

increase position, rotate the gear shaft
and check that the terminal shaft moves
in the fuel increase direction.

Adjusting device 5. Attach the adjusting device to the

driving stand and then attach the
adjusting device lever to the terminal
shaft.

41
 [IQ] ADJUSTMENT

If
shaft may n
decrease direction,
position of

cover.

42
 [IQ] ADJUSTMENT

Speed droop adjuster

r angle

For RHD6

7
(30) 6
al
°'"'
c

'lij
5
4
<D
ti ~ 3
(ij
c "'
~

.$
E c 2
05 i5
!::, 0..

0
2,000 ·10
Governor speed

43
 ITQJ ADJUSTMENT
For RHD6 Speed droop adjustment
1. Temporarily fix the droop adjuster
pointer at the specified position.
(30) 6 2. Operate the governor at N1 r/min and
5 then fix the speed control shaft when
the terminal shaft angle is 30° for the
4
RHD6 or 32° for the RHD10.
3
(10) 2 +----"""-"----+-"--!

o"~----~~~
N1 N2
Governor speed (r/min)

3. Gradually increase governor speed and

further adjust the speed droop adjuster
so that governor speed is N2 r/min
when the terminal shaft angle is
returned to 10° for the RHD6 or 8° for
the RHD10.
Note:
When the speed droop adjuster pointer is
moved toward 0, speed droop decreases.
When the speed droop adjuster is moved
toward 10, speed droop increases.

I CAUTION
Confirm that N2 is within the allowable
speed when the speed droop adjuster is
exactly as specified.
10°

Note:
If the lever attached to the terminal shaft
deviates more than ± 1 ° during high speed
operation (ie, approx 1,800 r/min), check
as follows.
Regular deviation: Check compensator
related parts (housing, base, assembly,
regulating valve). Replace them if
necessary.
Irregular deviation: Check the flyweight
assembly. Replace it if necessary.
Perform the fallowing adjustments with the
governor adjusted as described above.

44
 [ill ADJUSTMENT
For RHD6 Maximum speed setting screw
adjustment
(not necessary on MCL type governors)
1. Operate the governor at N 1 r/min, adjust
the maximum speed setting screw until
the terminal shaft angle is 30 ° for the
RHD6 or 32° for the RHD10, and then
fix the screw using the locknut.

Governor speed (r/min)

Minimum speed setting screw

adjustment
(not necessary on PC, MC or MCL type
governors)
1. With the governor stopped, move the
speed control shaft as far as possible to
the low speed side (0 or less on the
scale), and then temporarily set the
minimum speed setting screw.
2. Operate the governor at N3 r/min and
adjust the minimum speed setting screw
so that the terminal shaft angle does not
exceed 10° (RHD6) or 8° (RHD10).
Then, fix the screw using the locknut.
Compensator chamber high pressure
hydraulic fluid flow
The flow of a large quantity of hydraulic
fluid to the compensator is not desirable.
To check for this, perform the following
test.
1. Fully open the needle valve (approx 3
turns from the fully closed position) and
maintain governor speed at approx
1,000 r/min.
Terminal shaft 2. Fix the speed control shaft so that the
/1
"
(if)
terminal shaft angle is approx 20 ° (4 on
,;;;;/ ~
the scale).
Needle valve

45
 ADJUSTMENT

Speed increase Speed decrease

46
 ±0.5

(terminal

o-
(term Ina

47
 [J]J ADJUSTMENT
Governor motor operation confirmation
(MC type)
1. Specification confirmation
Confirm from the individual standards
that the specifications of individual parts
are correct.
• Motor specification (voltage)
• Condenser capacity
• Speed reduction ratio

2. Operation confirmation (using speed

adjustment knob)
Turn the knob manually, and confirm
that the speed setting screw turns
smoothly over the whole range by
observing speed control shaft pointer
movement.
If it does not move smoothly over the
whole range, loosen the friction coupling
Speed adjustment set screw, adjust the positions of the
bevel gear teeth and recheck screw
movement.

Example 3. Operation confirmation (using the

motor)
Connect the governor motor assembly
Test circuit to the electrical test circuit in
accordance with the particular motor's
specifications, as shown at left.

Friction coupling 4. Operation test

• Turn the governor motor's speed switch
ON in the speed increase direction to
operate the motor.
Then, operate the motor until the fork
contacts the maximum speed setting
screw adjusted above and the friction
coupling is rotating freely.
Maximum speed
setting screw

Fork Speed setting screw

48

Speed setting screw
[]QJ ADJUSTMENT
• Then, turn the switch OFF and then ON
in the speed decrease direction, and
confirm that the speed setting screw
begins moving smoothly.

Fork

Stopper Friction coupling • Operate the governor motor until the

speed setting screw contacts the
stopper and the friction coupling is
rotating freely.

Speed setting screw

setting screw • Then, turn the switch OFF and then ON

in the speed increase direction and
confirm that the speed setting screw
moves smoothly.
CAUTION
During the above operation test, if the
friction coupling rotates freely in other
than the following two cases, check the
alignment of the bevel gear teeth.
• When the maximum speed setting
Fork screw is contacting the fork
• When the speed setting screw is
contacting the stopper

Governor motor operation test and limit

switch adjustment (MCL type)
1. Specification confirmation
Confirm from the individual standards
that the specifications of individual parts
are correct.
• Motor specification (voltage)
• Condenser capacity
• Speed reduction ratio

49
 speed

50
 [IQ] ADJUSTMENT
• Minimum speed limit switch adjustment
Operate the governor at the specified
speed (N3 r/min), and the governor
motor in the speed decrease direction.
Adjust the limit switch's lower limit
position so that the governor motor
stops at a terminal shaft angle of
10±3°
Set the governor speed at 1,500 r/min
and confirm that the governor motor
operates correctly between the upper
and lower operation limits and that the
friction coupling does not rotate freely.

51
 ill] TROUBLESHOOTING

TROUBLESHOOTING
Of the phenomena listed below, some If no engine faults can be found, check the
originate solely in the governor, and some governor.
solely in the engine. As the governor uses many precision
parts, there is a danger of the engine over-
• Faulty starting
running if these parts are incorrectly
• Hunting assembled.
• Insufficient engine output
• Engine will not operate at maximum CAUTION
speed
• Excessive momentary speed droop, or Never attempt to repair the governor on-
inability to control speed site.
First, check the engine for the following Always consult your nearest ZEXEL
faults. If engine faults are found, perform representative.
repairs in accordance with the engine
maker's instructions.
• Compression pressure of cylinder
is extremely uneven
• Excessive play in fuel control and speed
adjustment linkage
• Excessive resistance in injection pump
control rack and fuel control linkage
• Excessive play because of worn
governor drive system gear or rubber
damper
• Relative positions of linkages incorrect
• Dashpot spring in control linkage
bent or damaged

52
 IJ]] PART NUMBER EXPLANATION

MODEL NUMBER
Example: RHO § L C
(1) (2) (3)(4)
(1) Independent type hydraulic governor, manufactured by ZEXEL CORPORATION
(2) Control force (work load)
Indicates 1O times controlling force (work load) in kgf·m.
(3) L: lever type
M: with governor motor
P: with pneumatic controller
(4) C: with compensator
CODE NUMBER
Example: !_Q ~ § § - 0 O 0 0
(1) (2) (3)(4) (5) (6)
10: Assembly part number
58: Hydraulic governor manufactured by the ZEXEL CORPORATION
Type
5: RHO 6 type
6: RHO 10 type
(4) Direction of pump rotation and governor installation position

Direction of pump Governor installation Governor installation

rotation position position
0
1
2
Clockwise
Clockwise
Counterclockwise
Right side
Lett side
Right side
} For pumps

3 Counterclockwise Left side

4 Clockwise
5 Counterclockwise
6 Reversible

Note:
With in-line pumps, the direction of pump rotation is viewed from the pump's drive side.
Governor installation position is viewed from the pump's cover plate side.
9 (5) Remote control device installation
3: LC type without remote control device
4: PC type
MC type
6: MC type
7: MCL type with remote control device
8: MCL type
9: HC type,
others
(6) Characteristic number

53