.

6 8DK-28e
INSTRUCTION MANUAL
( OPERATION )

e-V00
 Solemnly    Declare 
Recently we found some companies to pretend to be our agent units, such as 
sales  of  AnQing  Daihatsu  diesel  engine  spare  parts.  Here,  we  solemnly  declare: 
we did not set up any spare parts sales company alone, also not authorized any 
company  to  carry  out  the  Daihatsu  diesel  engine  spare  parts  sales.  Our  spare 
parts only by technical services direct sales, wish masses of customers properly 
identify!   
Through  our  investigation  and  pretend  to  be  on  the  market  sales  of  diesel 
engine  spare  parts  are  imitations,  without  Daihatsu  and  our  company 
recognition,  also  did  not  pass  strict  inspection,  product  performance  and  the 
differences  with  the  technical  requirements,  using  them  will  have  a  negative 
effect  on  diesel  engine.  To  ensure  normal  operation  of  diesel  engine  and  user 
interests,  it  is  strongly  recommended  that  users  through  our  technical  service 
department  or  Japan's  Daihatsu  purchasing  spare  parts.  Using  any  imitation 
parts of diesel engine is fault, we do not assume responsibility. At the same time, 
our  company  also  will  go  through  legal  channels  to  protect  the  name  of  our 
company  sales  of  AnQing  Daihatsu  diesel  engine  spare  parts  rights.  Any     
company  should  not  sale  in  the  name  of  our  company  AnQing  Daihatsu  diesel 
engine spare parts. 
Using imitation parts will cause great harm to diesel engine: 
1  The  part  of  companies  organize  to  product  after  surveying  and  mapping 
production  of  pure  diesel  engine  parts,  such  as  on  the  key  size,  precision, 
performance, heat treatment process, but they unable to grasp the production of 
product performance and less than the pure standard spare parts service life. 
2 Part of the company directly purchase parts from our supplier spare parts sales, 
without  strict  inspection  quality  assurance  processes,  nonconforming  product 
without control. 
3  Part  of  the  company  to  enter  the  market  at  low  price  in  the  technological 
process,  production  materials,  quality  management  costs,  reducing  product 
quality standards. 
4  If  imitation  parts  are  used  for  the  engines  designed  in  accordance  with 
MARPOL  Ⅵ  ,  the  certificate  (EIAPP)  may  lose  its  validity,  and  operation  of  the 
engine may be inhibited 
5 If you use the imitation spare parts, when a failure occurs, we do not assume 
any  liability  to  them,  and  it  is  difficult  to  obtain  the  insurance  claim  of  diesel 
engine. 
In addition, the operation of the diesel engine after a period of time after, the 
moving  parts  may  be  wear,  tighten  bolts  loose  because  of  vibration,  the 
combustion  chamber  components  may  be  carbon  deposition,  if  not  treated  in 
time  will  affect  the  normal  operation  of  diesel  engine.  According  to  Japan's 
Daihatsu specification, DC, DK series diesel engine must be every 2 ~ 3 years on a 
maintenanceto cylinder head, piston, cylinder liner, connecting rod, main bearing, 
CAM shaft overhaul and other major parts. 
 Our  company  as  a  diesel  engine  manufacturers,  has  a  rich  experience,  skills, 
enrich  the  after‐sales  service  team.  Guarantee  the  normal  operation  of  diesel 
engine and meet the demand of users is our after‐sale serving 
 
Our spare parts sales contact information: 
Email address: acdspare@126.com 
Fax: 0556‐5307388 
Telephone: 0556‐5307184      0556‐5307177    0556‐5307389 
 
Contact our after‐sales service: 
At home                                                                                At abroad 
E‐mail: afterserviceanqing@126.com                  Email: interserviceaq@126.com 
Fax: 0556‐5307465                                                Fax: 0556‐5307465 
Telephone: 0556‐5307275                                    Telephone: 0556‐5307179 
 
Our machine sales contact information: 
Email address: aq_daihatsu@126.com 
Fax: 0556‐5209643 0556‐5209644 
Telephone: 0556‐5307180 0556‐5307182 
 
 
 
 
 
 

 
 DK-28e INSTRUCTION MANUAL (OPERATION)
CHAPTER

Introduction 0
General 1
General Construction 2
Eegine Adjustment Standards 3
Operation 4
Inspection and Maintenance 5
Fuel Oil, Lubricating Oil, Cooling Water 6
Troubleshooting and Countermeasures 7
䃁 As for the disassembly, maintenance, assembly, and the parts to be
replaced, refer to the separately provided INSTRUCTION MANUAL
(MAINTENANCE) and PARTS LIST.

䃁 Keep this Instruction Manual and the related documents (drawings, materials, etc.) in
the specified place so that the persons engaged in operation of the engine can refer to
them whenever necessary, and in case that the supervisor of the engine is changed, be
minded that these documents, along with the duties, shall be transferred to the succes-
sor without a fall.

DK-28e Z 11-06
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ITEM
CONTENTS DK-28e

Chapter 0 INTRODUCTION 0
1. Before Running Daihatsu Diesel Engine 0-1
2. Basic Information on Safety Operation 0-2
2.1 Safety Precautions 0-2.1
2.2 Safety Signs and Symbol Marks 0-2.2
2.3 Indication of Warning: Warning Labels 0-2.3
2.4 Indication of Warning: Warning Label Positions 0-2.4
3. Engine Conforming to NOx Technical Code 0-3
3.1 Outline 0-3.1
3.2 The parts to be Specified 0-3.2
3.3 Engine settings 0-3.3
4. General Information 0-4
4.1 Notation of Engine Types 0-4.1
4.2 Definition of Terms 0-4.2
4.3 Units 0-4.3

Chapter 1 GENERAL 1
1. Engine Specifications 1-1
2. Auxiliary Equipment 1-2
3. Engine Outline and Equipment Layout 1-3

Chapter 2 GENERAL CONSTRUCTION 2

1. Engine 2-1
1.1 Engine Frame, Cylinder Liner, and Main Bearing 2-1.1
1.2 Crankshaft and Bearing 2-1.2
1.3 Camshaft and Timing Gear 2-1.3
1.4 Piston and Connecting Rod 2-1.4
1.5 Cylind Head 2-1.5
1.6 Fuel Injecti Divice 2-1.6
1.7 Valve Operating Divice 2-1.7
1,8 Fuel Control Divice 2-1.8
1.9 Intake and Exhaust System 2-1.9

2. Piping Systems 2-2

2.1 Starting Pneumatic System 2-2.
2.2 Fuel Oil System 2-2.2
2.3 Lubricating Oil System 2-2.3
2.4 Cooling Water System 2-2.4
2.5 Nozzle Cooling System 2-2.5

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ITEM

DK-28e CONTENTS

3. Controlling Engine Operation : Protective Device 2-3

3.1 Starting Control 2-3.1
3.2 Stoppage Control 2-3.2
3.3 Engirie Protection System 2-3.3

Chapter 3 ENGINE ADJUSTMENT STANDARDS 3

1. Operating Specifications 3-1
2. Valve Setting Values 3-2

Chapter 4 OPERATION 4
1. Precautions for Operation 4-1
1.1 In case of Starting 4-1.1
1.2 In caase of Operation 4-1.2
1.3 In caase of Stoppage 4-1.3
2. Preparation for Operation 4-2
2.1 Preparation for Daily Operation 4-2.1
2.2 Preparation for Initial Starting after Installation and 4-2.2
Starting after Extended Disuse or Overhaul
3. Starting 4-3
3.1 Starting Procedure 4-3.1
3.2 Inspection and Check Items Immediately after Starting 4-3.2
4. Operation 4-4
4.1 Running-in 4-4.1
4.2 Warming-up and Connecting Load to the Engine 4-4.2
4.3 Operation with Load (Normal Operation)） 4-4.3
4.4 Operation Using Heavy Fuel Oil (for Heavy Fuel Oil Engines) 4-4.4
4.5 Allowable Operating Range 4-4.5
5. Special Operation 4-5
5.1 Low-load Operation 4-5.1
5.2 Operation with Air Cooler Cut-off 4-5.2
5.3 Non-Turbocharger Operation 4-5.3
5.4 Operation with Reduced Number of Cylinders 4-5.4
6. Stoppage 4-6
6.1 Normal Stoppage 4-6.1
6.2 Emergency Stop 4-6.2
6.3 Long-term Shutdown 4-6.3

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ITEM
CONTENTS DK-28e

Chapter 5 INSPECTION AND MAINTENANCE 5

1. Precautions for Inspection and Maintenance 5-1
1.1 Safety Precautions 5-1.1
1.2 Cautionary Items When Finishing Inspection and Maintenance 5-1.2
2. Inspection and Maintenance Item Table 5-2
3. Measurements and Adjustments 5-3
3.1 Maximum Explosion Pressure Exhaust Temperature 5-3.1
3.2 Pressure and Temperature of Each Part 5-3.2
4. Inspection and Maintenance 5-4
4.1 Inspecting Parts on and around Intake and Exhaust Valves, 5-4.1
and Adjusting Valve End Clearance
4.2 Inspection and Maintenance of Fuel Injection Valve 5-4.2
4.3 Cleaning Filters 5-4.3
4.4 Cleaning Turbocharger Blower 5-4.4
4.5 Cleaning Turbocharger Turbine Side 5-4.5
4.6 Measuring Crankshaft Deflection 5-4.6
4.7 Inspecting and Replacing Protective Zinc 5-4.7

Chapter 6 FUEL OIL, LUBRICATING OIL, COOLING WATER 6

1. Fuel Oil Characteristics and Control 6-1
1.1 Selecting Fuel Oil 6-1.1
1.2 Fuel Oil Characteristics and Control 6-1.2
2. Lubricating Oil Characteristics and Control 6-2
2.1 Selecting Lubricating Oil 6-2.1
2.2 Lubricating Oil Characteristics and Control 6-2.2
3. Cooling Water Characteristics and Control 6-3
3.1 Cooling Fresh Water (Raw Water) 6-3.1
3.2 Corrosion Prevention Agent 6-3.2

Chapter 7 TROUBLESHOOTING AND COUNTERMEASURES 7

1. Precautions for Troubleshooting 7-1
2. Troubleshooting and Countermeasures 7-2
2.1 When Starting is difficult 7-2.1
2.2 When Engine Revolution is Not Smooth 7-2.2
2.3 Insufficient Output 7-2.3
2.4 When Exhaust Gas Temperature (Te) or Maximum Explosion 7-2.4
Pressure(Pmax) is Abnormal

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DK-28e CONTENTS

2.5 When Exhaust Gas Shows Abnormal Color 7-2.5

2.6 Abnormal Noise / Abnormal Vibration 7-2.6
2.7 When Engine Stops Suddenly 7-2.7
2.8 Unable to Stop Engine 7-2.8
2.9 Overspeed 7-2.9
2.10 Low Lubricating Oil Pressure 7-2.10
2.11 High Lubricating Oil Temperature 7-2.11
2.12 Low Cooling Water Pressure (Jacket Line) 7-2.12
2.13 High Cooling Water Temperature (Jacket Line) 7-2.13

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Introduction
0
ITEM
Before Running Daihatsu Diesel Engine DK-28e 1

0. Introduction
1) Only skilled operators who have carefully read and fully understood the instruction
manual should operate, inspect and service this machine.
0
Operation, inspection or servicing by persons inadequately familiar with the machine
may result in personal injury, equipment damage or environmental hazard.
(2) No responsibility shall be assumed whatsoever for product damage or any associated
fires, oil spills or other environmental hazards, personal injuries, property damage or
economic losses caused by the use of non-genuine parts or operation, inspection or
servicing that deviates from the instruction manual.
(3) We shall repair new parts or replace any flawed parts made or sold by us, however no
compensation shall be provided for damage to any equipment not of our manufacture
or cargo, or personnel, fire-fighting, towing or other expenses arising from the use of
such flawed parts or fowled fuel, lubricant, cooling water or other medium.
(4) This instruction manual is subject to change without notice.

0-1. Before Running Daihatsu Diesel Engine

This instruction manual describes the proper operation procedure of the DK-28 engine,
its daily maintenance and inspection procedure, and other necessary information on the
engine.
To maintain the engine in good operating condition and ensure that it provides the
specified performance, be sure to read through this manual and become sufficiently
familiar with the proper procedures before operating the engine.
Do not use your engine for applications or under the conditions other than those it is
designed for.
Be sure to observe the procedures described in this manual. Improper practices can
cause damage to the engine or result in injuries or fatal accidents.

(1) Each piece of the information enclosed in the square box is an important safety precautions
and provided as a warning or caution.
(2) The features and structure of your engine may be different from those provided in this manual depend-
ing on the specifications of the engine delivered. In this case, the engine specifications anc final docu-
ments supplied separately have priority over this manual.
(3) For the details on the following machine or device, see their instruction manual supplied with this manu-
al:
1) Turbocharger 2) Governor 3) Control equipment
4) Other special devices
(4) Be sure to use the genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the parts
list.
We will not guarantee the proper operation of the engine unless such parts are used.
For replacement of the parts or service on your engine, contact our Parts Sales Department, Service
Department branch office, or the nearest DAIHATSU DIESEL MFG.Co.,Ltd provided on the cover
page.
Be sure to provide us with the "type and number of your engine" when contacting us.
(5) To prevent environmental contamination, do not dispose of waste products, liquids, etc. thoughtlessly.
Be sure to entrust the disposal of such waste products, liquids, etc. to the authoriqed waste disposal
company.

DK-28e Z 11-06
CHAPTER
Introduction
0
ITEM
Basic Information on Safety Operation:
2.1 DK-28e Safety Precautions

0-2. Basic Information on Safety Operation

0-2.1 Safety Precautions

The diesel engine uses flammable oil. It has the high-speed rotational parts, the parts that
become extremely hot, or the parts that will be under high pressure fluid during operation.
Improper handling of the engine can result in serious injuries or fatal accidents. Be sure to
observe the safety precautions provided in this manual

(1) Beware of Rotational Parts

This engine has the high-speed rotational parts.

Inadvertent contact of human body or objects with such parts can cause the person to get
caught in the engine, or cause the chips of objects to fly in all directions.
(a) Never attempt to touch the rotational parts such as the flywheel and couplings during operation. Also,
be sure to place the protective cover in place before operation.
(b) Before starting operation, check that no personnel is around the engine. Warn any nearby personnel
by signaling that the engine is about to start operation.

(2) Beware of Hot Parts

The engine parts are very hot during and immediately after operation. Touching them with bare
hands or skin can cause burns. Note that the exhaust manifold, turbocharger, indicator valve
periphery, cylinder head, air cooler inlet, and heated heavy fuel oil pipes become extremely hot.
(a) Never attempt to touch any part of the engine with bare hand or skin during or immediately after
operation.
(b) Be sure to wear safety gloves or other protective gear when conducting measurement or inspection
(c) Allow the engine to sufficiently cool down before performing inspection or maintenance work.

(3) Prevent Oil from Catching Fire

Fuel oil or lubricating oil coming in contact with extremely hot parts of the machine may
catch fire.
(a) Be attentive to oil leakage during operation. If any leakage is found, immediately stop the engine and
eliminate the leakage.
(b) Strictly observe the "Causion:Flammables" sign when adding fuel oil or lubricating oil.

If the engine is stopped due to failure or defect failure, be sure to eliminate

the cause of defect and restore it to the normal operating condition before
resuming the engine operation.

DK-28e Z 11-06
 CHAPTER
Introduction
0
ITEM
Basic Information on Safety Operation:
Safety Signs and Symbol Marks DK-28e 2.2

0-2.2 Safety Signs and Symbol Marks

This instruction manual and warning labels affixed to the engine carry one of the following safety signs
and symbol marks: 0
(1) Safety Signs and "Signal words"

："Warning": Precaution related to safety of personnel (Potential hazard which could result in death or serious injury)

："Caution": Precaution related to safety of personnel (Potential hazard which may result in minor or moderate injury)

："Precautions for handling": Information on handling of the engine to prevent damage

："Prohibition": Prohibited practice that can affect the safety of personnel and the engine

："Obligatory acts": Recommended practice or instruction to be followed to ensure safety of personnel and the engine
(2) Symbol Marks
(a) Warning Signs b．Prohibition Signs

：General warning ：Non-specific general prohibition

：Flammable → Fire ：No Smoking

：Explosive → Explosion or Bursting ：Naked fire forbidden

：Poisonous → Poisoning ：Do Not Touch

：Voltage → Electric Shock (c) Signs for Obligatory Acts

：High temperature → Burn ：Wear Eye Protection Gear (safety goggles, etc.)

：Rotational/Moving Part → Getting Caught ：Wear Head Protection Gear (hard hat, etc.)

：Edge → Cut ：Wear Ear (Noise) Protection Gear (ear plugs, etc.)

：High-Pressure Fluid Jet → Injury ：Wear Hand Protection Gear (safety gloves, etc.)

：High Location → Fall ：Wear Foot Protection Gear (safety shoes, etc.)

(d) Others

：Refer to other pages in this manual or other

documents

DK-28e Z 11-06
CHAPTER
Introduction
0
ITEM
Basic Information on Safety Operation:
2.3 DK-28e Indication of Warning: Warning Labels

0-2.3 Indication of Warning: Warning Labels

The warning labels shown below, are used on the DAIHATSU DIESEL MFG. CO., LTD.

㩿㪈㪀 㩿㪉㪀 㩿㪊㪀

㩿㪋㪀 㩿㪌㪀

㩿㪍㪀 㩿㪎㪀 㩿㪏㪀 㩿㪐㪀

㜞ᚲߢߩ૞ᬺߪ‫⿷ޔ‬రߦᵈᗧ
ߒ‫ޔ‬ᱜߒ޿૞ᬺᆫ൓ߢⴕ߁ߎߣ
ࠪ࡝ࡦ࠳ࡋ࠶࠼਄ߥߤ㜞ᚲߦ‛
ࠍ⟎߆ߥ޿ߎߣ
$GUWTGHQQVKPICPFYQTM
RQUVWTGQPJKIJRNCEG
&QPQVRNCEGQDLGEVUQP
E[NKPFGTJGCFQTJKIJRNCEG

㩿㪈㪇㪀 㩿㪈㪈㪀 㩿㪈㪉㪀 㩿㪈㪊㪀 㩿㪈㪋㪀

DK-28e Z 11-06
 CHAPTER
Introduction
0
Basic Information on Safety Operation: Indication of Warning: ITEM
Warning Label Positions DK-28e 2.4

0-2.4 Indication of Warning: Warning Label Positions

For safety, the warning labels shown below are affixed to the engine. The numbers carried by labels cor-
respond to those given on Item 2.3 of Chapter 0. 0
If a label is broken or falls, replace it with a new label, and make arrangement so that it may be visible
clearly at any time.

DK-28e Z 11-06
CHAPTER
Introduction
0
ITEM
Engine Conforming to NOx Technical Code:
3.1-3.3 DK-28e Outline / Parts to be Specified / Engine Setting Values

0-3. Engine Conforming to NOx Technical Code

0-3.1 Outline
(1) The marine diesel engines to which the 13th rule "Nitrogen Oxides (NOx)" in Supplement VI "Rules to
Prevent Air Pollution by Ships" to MARPOL73/78 Treaty applies should conform to NOx Technical Code.
(2) The engines conforming to NOx Technical Code are authorized as an engine group or an engine family,
and it is allowed to apply the engine parameter check method to them, when receiving the NOx dis-
charge inspection on board.
The engine parameter check method is a method for verifying that the engine components and setting
values conform to the requirements specified in the technical file, and does not require the measurement
of NOx discharge. To the engines that are not conforming to the requirements of the technical file, the
engine parameter check method cannot be applied. For such engines, the measurement of NOx dis-
charge shall be required.

0-3.2 Parts to be Specified

The technical file states the engine components that can affect the NOx discharge specified in NOx
Technical Code, and shows the identification marks stamped on them, and the user is required to main-
tain the technical file for each engine. When replacing any parts shown in the technical file, be sure to use
our genuine parts stamped with the identification marks. In the case that any parts without the identifica-
tion mark is used, it shall be regarded as nonconformance to the requirements of the technical file, and in
such a case, inspection by the engine parameter check method cannot be applied.
The followings are the parts that have the identification marks specified in the technical file. When
replacing any of these parts, be sure to check the identification marks.（ ："Technical file"）
<Parts with identification marks>
1) Cylinder head
2) Piston
3) Turbocharger
4) Air cooler
5) Cam shaft
6) Fuel injection pump
7) Fuel injection pump plunger
8) Fuel injection valve
9) Fuel injection valve nozzle

0-3.3 Engine Setting Value

The engines conforming to NOx Technical Code are adjusted to conform to the specifications before
shipment. After shipment, they should not be adjusted to such a manner that the setting values specified
in the technical file may be deviated.
If any change is made in the manner that may deviate from the settings specified in the technical file, it
shall be considered to be nonconformance to the requirements of the technical file, and the inspection by
the engine parameter check method cannot be applied.
The followings are the items that have been set to conform to NOx Technical Code:
<Items set before shipment>
(1) Fuel injection timing

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Introduction
0
ITEM
General Information:
Notation of Engine Type, Definition of Terms, and Units DK-28e 4.1-4.3

0-4． General Information

0-4.1 Notation of Engine Type 0

6, 8 DK (M) - 28 e (F) (L)

 Number of cylinders
 Name of series
 Marine propulsion engine
 Cylinder bore (cm)
 Engine conforming to NOx Technical Code-Secondary Regulation (Tier II)
 Front end drive
 Reverse rotation

0-4.2 Definition of Terms

Definitions of the terms used in this manual are as follows:
 Rear side of engine: Output end side (flywheel side)


 Front side of engine: Opposite side to the output end
Front  Exhaust side
side 
 Exhaust side: Exhaust manifold side (on the right when 

seen from the output end) 
 Pump side: Fuel injection pump side (on the left when Normal
seen from the output end) rotation
(Rightward
rotation)
 Normal rotation (rightward rotation): Clockwise rotation
when seen from the output end
 Reverse rotation (leftward rotation): Counterclockwise
rotation when seen from the output end.
Pump side
 Front end drive: Output to be taken from the engine front
Reverse rotation Rear side
 Cylinder and journal numbers 1, 2, 3,----starting from the (Leftward rotation)
output end

0-4.3 Units
Basically, SI units are used on the engine and in this manual. Note that figures in { } are reference
values given in the conventional uinits.

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DK-28e Z 11-06
CHAPTER
General
1
ITEM
1, 2 DK-28e Engine Specifications and Auxiliary Equipment

1-1 Engine Specifications

Model 6DK-28e 8DK-28e
Type Vertical water-cooling direct injection type 4-cycle diesel engine
Number of cylinders 6 8
Cylinders bore mm 280
Piston stroke mm 390
Engine speed min-1
Output kW
Ignition sequence 1-2-4-6-5-3 1-3-2-5-8-6-7-4
Rotating direction Clockwise when seen from the flywheel
Turbocharging method Turbocharged by exhaust gas turbine equipped with air cooler
Starting method Compressed air (Starting valve type)
Jacket Fresh water
Cooling method
Cooler Fresh (or Sea) water
Note : (1) Both the ignition sequence and the rotation direction show the data in case of the normal
rotation.
(2) Since the engine speed and the output, which are marked with , differ depending upon
the specifications, be minded to enter the data after referring to the "Engine Specifications"
and "Test Run Record"

1-2 Auxiliary Equipment

Auxiliary / equipment Type Remarks
Turbocharger Radial turbine type
Air cooler Multi-tubular type
Governor Hydraulic type
Fuel injection pump Bosch type
Fuel oil valve Bosch type
Fuel oil feed pump Gear type / Trochoide type According to specification.

Fuel oil filter Notch wire, duplex type

Lubricating oil pump Gear type
Lubricating oil cooler Multi-tubular type
Lubricating oil filter Auxiliary engine: Auto back-wash type
Main engine: Notch wire, duplex type
Lubricating oil filter for turbocharger Main engine: Notch wire, duplex type To be applied in case of MET type
Auxiliary engine: Common base plate
Lubricating oil tank incorporated
Main engine: Dry type or wet type
Cooling water pump Centrifugal type
Note : The data given in the above table show those in case of the standard specifications.
Therefore, the data of your engine may differ from those shown in this table, and in such a case
be minded to refer to the "Engine Specifications".

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DK-28e Z 11-06
 CHAPTER
General
1
ITEM
Engine Outline and Equipment Layout DK-28e 3

1-1 Engine Outline and Equipment Layout

Fuel oil relief
valve
Operation lever Fuel oil shut down
Seal pot device
Gauge board
1

Starting
operation
valve

Governor

Fuel oil feed pump

Lubricating oil pump
Cooling water pump
(Jacket line) Starting air valve Fuel oil filter
Lubricating oil filter

Turbo charger Turbocharger lubricating oil

filter ( for MET ) Turbo charger

Lubricating
oil filter
Air cooler Air cooler
Lubricating
oil filter

Main Engine Auxiliary Engine

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DK-28e Z 11-06
CHAPTER
General Construction
2
ITEM
1.1-1.5 DK-28e Engine

2-1 Engine 2-1.4 Piston and Connecting Rod

2-1.1 Engine Frame, Cylinder Liner, The piston is an integral casted type made of
and Main Bearing ductile cast iron or the compound type of special
alloy steel crown and ductile cast iron skirt,, and is
The frame is a monoblock structure made of
cooled down by the lubricating oil that is trans-
castiron, and the upper section of the frame forms
ferred from the connecting rod via piston rod.
a cooling jacket, together with the cylinder liner.
The connecting rod is form-turned forged prod-
The main bearing is a suspension type, and
mounted to the engine frame with 2 mounting bolts uct with the large end, which is horizontally split
and 2 side bolts. into three parts, to allow overhaul of the piston
without disassembling the bearing unit.
Intake air, lubricating oil, and each cooling water
channel,and the timing gear case are incorporated
in the engine frame. 2-1.5 Cylinder Head
A frame safety valve is provided to the cover on
The cylinder head is of a highly rigid structure
the engine frame side.
made of special cast iron, and is hydraulically
secured to the piston with 4 bolts.
2-1.2 Crankshaft and Bearing Four valve system is employed having 2 intake
The crankshaft is a high-strength carbon steel valves and 2 exhaust valves, and a water cooling
forged product of one-piece construction,and pro- valve seat, which is directly attached to the cylin-
vided with suffcient rigidity and strength. der head, is installed for each exhaust valve.
The flywheel is provided at the rear end (output The indicator valve and cylinder safety valve are
side) of the crankshaft. The crank gear for driving
installed on the upper face of the cylinder head, and
the camshaft as well as the component drive gear
the starting valve is located on the side of the head.
for driving various pumps are provided at the front
end of the crankshaft.
The main bearing and crank pin bearing have a Exhaust manifold Intake and exhaust
Rocker arm valves
thin-walled, two-piece structure, and a thrust metal Push rod
is attached to the front and rear end of the No.1 Cylinder head
bearing located at the rear end. Fuel oil injection
valve
Fuel oil injection
pump
2-1.3 Camshaft and Timing Gear
The camshaft is located on the left side of the Intake duct
engine (when seen from the output side).
The intake cam, exhaust cam, and fuel cam are Piston
incorporated to the camshaft,and it is a unit type Valve operating
Cylinder liner device
divided for each portion of 2 cylinders.
Cooling water Cam shaft
Each unit is connected to the flange section that
passage
combines the sliding section with the bearing. Lubricating oil
passage Engine frame
The cam gear for driving the camshaft is installed
Connecting rod
on the front side of the engine, and the cam gear is
driven from the crank gear via the idle gear. Crank pin shell Crank shaft
On the rear side of the engine,the drive coupling
of the starting rotary valve is installed.
Engine base plate
(lubricating oil tank)

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General Construction
2
ITEM
Engine DK-28e 1.6-1.9

2-1.6 Fuel Injection Device 2-1.9 Intake and Exhaust Systems

The fuel injection pump is a Bosch-type high
pressure pump and a tappet-incorporated mono-
lithic type. It is provided with a closed-type plunger
barrel and isobaric valve, and plunger lubrication is
employed.
Also, the high-pressure oil inlet coupling, which
is a horizontal-insertion type, is connected to the
fuel injection pump via high-pressure coupling
made of forged steel.
2-1.7 Valve Operating Device
The intake and exhaust valves are driven by the
force transferred from the camshaft via swing arm,
push rod. and rocker arm.
The turbocharger and air cooler are mounted on
the rear end of the engine (for main engine) or are
mounted on the front end of the engine (for auxil-
iary engine).
The standard specification of the turbocharger
vary according to the engine type, output, and
specification of each order.
( : "Instruction Manual of Turbocharger")
The exhaust manifold and air intake duct are
2
installed on the same side of the engine, and the
intake duct is incorporated in the engine frame.

2-1.8 Fuel Control Device

The governor is installed on the front of the
engine, and is driven by the cam gear.
The control lever is located near the gauge
board on the front side of the engine, together with
the starting valve.

Starting valve

Governor
Starting
operation
valve

Cam gear

Idle gear

Crank gear Starting air

rotary valve

Thrust metal

DK-28e Z 11-06
CHAPTER
General Construction
2
ITEM
2.1 DK-28e Piping Systems:Starting Pneumatic System

2-2 Piping Systems

Piping systems and related equipment vary depending on the engine applications, type of
fuel used, and specifications.
This section describes the typical piping systems of standard specifications. For more
details, refer to the piping systems included in the final documents.

2-2.1 Starting Pneumatic System
The starting operation of engine is made by the
pilot starting valve system activated by com-
pressed air.
When the push button for the starting operation
valve is pressed, control air will flow to the starting
air valve to open the main valve, and the com-
pressed air reaches to the starting valve of each
cylinder.
Meanwhile, the compressed air branched off from
the main starting air pipe is sequentially supplied
to each cylinder by the starting air rotary valve
according to the ignition order, and opens the
starting valve of each cylinder.
The compressed air sent through the main starting
air pipe effects the piston, causing the engine to
start its rotation.
The starting operation valve and starting air valve
are installed on the front side of the engine, and
the starting air rotary valve on the rear side of the
engine, and the starting air rotary valve is driven
from the rear end of the camshaft.
Note that a safety valve and a check valve are
installed in the main air pipe for prevention of the
reversed flow of combustion air.
In case that the engine is started remotely or auto-
matically, the starting operation will be made by
means of the solenoid valve, allowing control air to
reach the starting operation valve.
( : "Starting Method")

Engine starting solenoid valve Starting operation valve

( For remote and
auto starting )

Safety plug
Starting air rotary valve

Starting ( Cylinder head )

air valve
Check valve Starting valve
Control air Starting air

Air tank

Starting Air System ( Pilot-Starting Valve Type )

DK-28e Z 11-06
 CHAPTER
General Construction
2
ITEM
Piping Systems : Fuel Oil System DK-28e 2.2

2-2.2 Fuel Oil System High pressure oil fed by the fuel injection pump
Fuel oil system vary depending on the grade of is introduced into the fuel injection valve connector
the oil used, and a typical example of the fuel oil from the cylinder head side via high-pressure pip-
system for heavy fuel oil is as shown below. ing coupling.
When heavy fuel oil is used, oil must be heated In case of heavy fuel oil specification, nozzle
and kept at a constant temperature to maintain the cooling is provided to prevent the formation of car-
oil viscosity suitable for injection. bon flower.
Oil heated by the heater and pressurized by the ( : 2-2.4 "Cooling Water System")
fuel feed pump is transferred to the fuel injection When diesel fuel oil is used, heating or heating
pump via filter. Surplus of oil is returned to the inlet insulation of oil as well as nozzle cooling are not 2
side of the oil feed pump via pressure regulating required.
valve (relief valve), and is then circulated again.
The oil pipe is provided with various heat insulat-
ing arrangement such as steam trace or ragging,
and is kept at a constant temperature.
The lubrication of the fuel injection pump is
made by means of fuel oil circulation system, and
the plunger is lubricated by means of forced-feed
lubrication system using lubricating oil.
( : 2-2.3 "Lubricating Oil System")

Heavy fuel oil supply system Air separator

Fuel injection valve leakage main pipe

Heavy
fuel Diesel
oil fuel Fuel high-pressure block
tank oil leakage oil main pipe
Accumulator
tank

Fuel high-
pressure Fuel injection
block valve
Filter

Fuel oil
Viscosity feed
controller pump
Pressure Inlet connector
damper Fuel
Filter injection
Heater pump Inlet main pipe

Filter Pressure damper

Waste
Pressure control valve Return main pipe leakage
oil tank
Fuel Oil System (Auxiliary Engine)

DK-28e Z 11-06
CHAPTER
General Construction
2
ITEM
2.3 DK-28e Piping Systems : Lubricating Oil System

2-2.3 Lubricating Oil System

The lubricating oil system is as shown below.
Lubricating oil transferred to the lubricating oil
cooler from the lubricating oil pump is regulated to
reach the specified temperature and pressure, by
means of the automatic temperature control valve
(hereinafter referred to as temperature control
valve) and relief valve respectively, and the
lubricating oil is transferred to the oil channel of the
engine frame from the cooler via filter.
Then, from this oil channel, the lubricating oil is
supplied to the piston through the holes of the con-
necting rod via each main bearing shell and crank
pin shell.
Lubricating oil is also supplied to the camshaft,
valve-operating swing arm, fuel injection pump,
various gears, and around the locker arm.
The lubricating pump is of a gear type provided
with a safety valve, and is installed on the front
side of the engine, to be driven from the crank-
shaft.
The lubricating oil filter is a notch-wire duplex
type (Main engine) or a auto back-wase type
(Auxiliary engine).
Lubricating oil is supplied to the turbocharger
and fuel injection pump via each special lubricating
oil filter respectively.
Lubricating oil, that has circulated through and
has lubricated each part, returns to the base plate
of the engine (oil tank).

Rocker arm

Lubricating oil cooler Lubricating oil cooler

Fuel oil injection pump

Filter Filter
Filter
Relief Swing arm
valve
Temperature Temperature Camshaft bearing
control valve Relief control valve
valve

Filter
Lubricating Lubricating
oil pump oil pump
Turbo Timing gear
charger Turbo
Safety Safety charger Governor driving gear
valve valve Cooling water pump

Engine base plate ( oil tank ) Engine base plate ( oil tank ) Leaked and waste
oil tank
Main Engine Auxiliary Engine

Lubricating oil system

DK-28e Z 11-06
 CHAPTER
General Construction
2
ITEM
Piping Systems : Cooling Water System DK-28e 2.4

2-2.4 Cooling Water System
The cooling water system can be a fresh-water
simplex system cooling method or can be a fresh-
/sea-water (or fresh-water) duplex system method.
(1) Fresh-water simplex cooling
This cooling method consists of a cooler system
(low temperature), where the cooling water sup-
plied from the low temperature line to the engine is
pressured and sent by a cooler cooling-water
pump (built-in or separately installed), and a jacket
system (high temperature), where the cooling
water diverging from the cooler system is pres-
sured and sent by a jacket cooling-water pump
(built-in).
Pressured and sent by the cooler system cool-
ing-water pump, the cooling water passes the
lubricating oil cooler to the air cooler before going
back to the low temperature line.
Pressured and sent by the jacket cooling-water
pump, the cooling water goes into the engine's
jacket, cools down each component, and then
meets the cooler system's flow before going back
to the low temperature line.
(2) Duplex system cooling
This consists of a jacket system and a cooler
system. In the jacket system, the cooling water is
fresh water. In the cooler system, the cooling water
2
is seawater (for watercraft) or fresh water.

Head tank

Air cooler Jacket line

outlet main pipe

Lubricating Temperature
oil cooler control valve

Cooling water pump Diesel

Coolinjg water pump engine
(Cooler line)
(Jacket line)

To low temperature
From low temperature water line
water line
Cooling Water System
(Fresh water one line system)

Head tank

Fresh water cooler

Air cooler
Jacket line
outlet main pipe

Temperature
Lubricating control valve
oil cooler

Cooling water pump Diesel

Coolinjg water pump
(Cooler line) engine
(Jacket line)

Cooling Water System (two lines system)

(fresh water-fresh water or fresh water-sea water)

e
DK-28e Z 11-06
CHAPTER
General Construction
2
ITEM
Piping Systems : Cooling Water System / Nozzle
2.4,2.5 DK-28e Cooling System

The jacket system makes a circulation system. 2-2.5 Nozzle Cooling System
After cooled down by the freshwater cooler, the
cooling water is pressured and sent by the jacket The engines that use heavy fuel oil is recom-
cooling-water pump and goes into the engine's mended to be equipped with nozzle cooling sys-
jacket, where the cooling water cools down each tem.
component before passing through the exit mani-
fold and going back to the freshwater cooler. The Nozzle ends need to be cooled to prevent car-
engine (or the fresh-water cooler) is equipped with bon flower, which forms at ends of fuel injection
a cooling-water temperature adjustment valve valve nozzles while the fuel oil is hot. The cooling
between the exit and the entrance, which main- water passes in the nozzles to cool them down
tains the cooling water at a prescribed tempera-
ture.
The cooling water in the cooler system is pres-
sured and sent by the cooler system pump, passes
through the lubricating oil cooler, the air cooler,
and fresh-water cooler before discharged.

Valve
Outlet main pipe

Valve Orifice
Inlet main pipe

Jacket line
fresh water pump
Fuel nozzle Jacket cooling

Nozzle Cooling System (Cooling Nozzle)

DK-28e Z 11-06 e

General Construction
Engine Operation Control, Protective Device:
Starting Control
2-3 Engine Operation Control and Protective Device
Control and protective devices such as the starting air valve and stoppage cylinder are activat-
ed by low-pressure control air.
This section describes a system generally used for the power station that is remotely con-
trolled for starting and stopping. The engine that is actually delivered may differ from the exam-
ples shown in this section depending on the specifications, and therefore refer to the final docu-
ments, which are separately provided, for the details.
As for the starting air system (high pressure), refer to the previous section 2-2.1.
2-3.1 Starting Control
(1) For generator
a) Remote Control
i) In case of starting the engine by remote control,
the control lever must always be set to "RUN"
position. The handle switch (HS) will be turned
"ON" at this state, and if the turning safety switch
(TC) is also turned "ON", the engine will be on
standby and ready for operation.
ii) The starting solenoid (88V) is powered, excit-
ed, and activated by a start command, so that
control air flows into the starting air valve via
starting operation valve, and the starting air
reaches the starting valve as the main valve is
opened.
iii) Meanwhile, the same start command allows
the fuel control solenoid (88L) to activate, caus-
ing control air to flow into fuel regulating cylinder,
and allows the common rod to be held in posi-
tion, so that the fuel injection amount is con-
trolled not to be excessive at the time of starting.
iv) When the engine reaches the specified rota-
tion speed, the low-speed relay (14) is activat-
ed, canceling the start command and resetting
the protective circuit, so that the engine is set
to operating state.
b) Automatic Starting
When the engine is started automatically, the
engine solenoid is activated in response to the
start command issued automatically in the speci-
fied sequence, so that the control air flows into the
CHAPTER
2
ITEM
DK-28e 3.1
starting air valve and the engine starts its rotation. 2
c) Engine side starting (local starting)
In case of starting the engine from the engine
side (locally), select the operation mode to the
"LOCAL" (engine side) position, and if the push
button of the starting operation valve is
pressed, control air will flow into the starting air
valve.
(2) For marine propulsion engine
a) Engine side starting (local starting)
i) In case of starting the engine from the engine
side (locally), the changeover valve on the
engine must be set to the local side, and the
control lever must be changed to "START"
position from "STOP "position.
ii) When the push button of the starting operating
valve is pressed, control air flows into the start-
ing valve, and starting air (high pressure) flows
into the starting valve as the main valve of the
starting air valve is opened.
iii) When the engine reaches the specified rota-
tion speed, the low-speed relay (14) is activat-
ed, so that the start command is canceled.
iv) When the idle rotation speed becomes stable,
turn the operation lever to "RUN" position from
"START" position. At this state, the handle
switch (HS) will be turned to "ON", and the pro-
tective circuit will be formed so that the operat-
ing state is ready.
v) When the changeover valve on the engine is
DK-28e Z 11-06
CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device:
3.1 DK-28e Starting Control

switched to the remote control side, the engine
operating condition by the control handle of the
bridge will be ready.
b) Remote starting (starting from the bridge)
i) When the operation lever is set to "RUN" posi-
tion, the handle switch (HS) will be turned
"ON".
Then, by turning the safety switch (TC) to "ON",
the engine will be on standby position for start-
ing,
ii) When the control handle of the bridge is set to
"NEUTRAL" position, the engine will be on
standby position for starting.
iii) By a start command, the starting solenoid
(88V) will be powered, excited, and activated,
and control air will flow into the starting valve
via the starting operation valve, so that the
main valve is opened and starting air flows into
the starting valve.
iv) When the engine rotation is reached the
specified speed, the low-speed relay (14) will
be activated, the start command will be can-
celed, and the protective circuit will be formed
so that the engine will be on standby position
for starting.

Turning bar Fuel shutdown device

63 Pulse sencor
Q2 Stoppage cylinder Control cylinder

From L.O. piping Starting air valve Speed switch

(12, 13, 14)

Turning safety Meter display

switch Explosion plate (4-20mA)
To fuel injection
Starting rotary pump of each cylinder Fuel oil injection pump
Starting air

valve
Stoppage Common rod
cylinder
Operation lever
Starting valve Governor motor RUN
START
STOP
Air tank Governor
Starting switch

To Starting solenoid Handle switch (HS)

(88V)

Control air
0.8 MPa
{8 kgf/cm2}
Starting Fuel shutdown Fuel control Fuel shutdown
solenoid solenoid solenoid solenoid
(88V) (5V) (88L) (5S)
Starting and Stoppage System (Generator use . Remote control)

DK-28e Z 11-06
 CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device:
Starting Control DK-28e 3.1

63 Turning bar Starting operation valve

Q2 F.O. Control cylinder
Pulse sencor

From L.O. piping Starting air valve Fuel shutdown and

control device Speed switch
(12, 13, 14)
Turning safety Explosion Meter display
switch plate
To fuel injection (4-20mA)
Starting air pump of each cylinder Fuel oil injection pump
Starting rotary
valve Common rod
Operation lever
Starting valve Stoppage
cylinder
RUN
START
STOP
2
Air tank
Governor

Handle switch (HS)

Governor boost solenoid

)8
Control air
0.8 MPa
{8 kgf/cm2}
Governor boost air
Governor air
Fuel control Fuel shutdown Fuel shutdown Fuel control (From control handle)
piston solenoid solenoid solenoid solenoid 0.1 ~ 0.4 MPa {1 ~ 4 kgf/cm2}
(88F) (5S) (5V) (88L)

Starting and Stoppage System (Marine propulsion . Engine side control)

DK-28e Z 11-06
CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device:
3.1 DK-28e Starting Control

2-3.2 Stoppage Control 2-3.3 Engine Protection System

The fuel shutdown solenoid (5V) is activated by
a stoppage command, causing control air to flow
into the fuel shutdown device, so that the common
rod is turned toward stoppage direction, and then
the engine is stopped.
Note that the fuel control cylinder above
described is the monolithic type assembled with
the fuel shutdown device.
(1) Against the errors that may be led to serious
accidents or failures, alarm is issued and emer-
gency stop is made.
Each abnormal operation data or value is
detected by a switch or sensor, and the fuel
shutdown solenoid is activated by an emergency
stoppage command, so that the engine is imme-
diately stopped.
(2) Depending the specifications, the dual safety
system will be provided. In such a case, in
addition to the normal engine stoppage, control
air is flowed into the stoppage air cylinder
attached to the fuel injection pump to stop the
engine.
(3) In case of the marine propulsion engine air
control system, when the forward clutch of the
reduction gear is engaged, the governor boost
solenoid will be activated by the movement of
the control handle, causing the governor boost
air to reach the governor so that the decrease of
the engine rotation speed can be prevented.
Further, the engine rotation speed is controlled
by governor air via the governor, and at the
same time the governor air reaches the F.O.
control cylinder to control the rotation speed of
the common rod so that the excessive supply of
fuel injection can be restrained.

DK-28e Z 11-06
 CHAPTER
General Construction
2
ITEM
Engine Operation Control, Protective Device:
Stoppage Control/Engine Protection System DK-28e 3.2,3.3

Alarm and Stoppage Items (Examples)

Detection item Alarm Shutdown Location Remarks

Overspeed 12 Cam gear

Decrease of lubricating Combined use with
oil pressure 63Q2 Engine inlet issuing command
Increase of fresh cooling Combined use with
water temperature TRWH 26W2 Engine outlet issuing command
Decrease of turbocharger
lubricating oil pressure 63QT Turbocharger inlet
Increase of lubricating oil
temperature TRQ Engine inlet Combined use with
issuing command 2
Increase of exhaust Combined use with
temperature TRTI Turbocharger inlet issuing command
Oil leakage from high-pressure 33F Tank level of leaked or
fuel oil pipe coupling waste oil
Decrease of lubricating Engine lubricating oil tank
oil level 33QL

Marked : Required

Oil leakage from

high-pressure fuel oil pipe Level switch Pressure switch
Level switch (33QL)
(33F) 㪍㪊
㪨㪉
from L.O. pipe
Lubricating oil
Fuel oil leakage

GM 88V 5V 88L 5S TS HS TC 63Q2 26W2 63QT 33F 63AS COS START33QL 63QD PTQ PTWH
4 1 4 1 PI PI
M 3 2 3 2
+ - S TRQ TRWH TRTI
B R 1 2 1 2 1 2 1 2 1 2 3 E 4 2 1 4 3 1 3 1 2 4 1 2 3 1 2 2 2 3 1 2 1 2 3 4 2 2 3 1 2 1 2 1 2

B R 1 2 1 2 1 2 1 2 1 2 3 E SC 4 2 1 3 4 1 2 1 4 1 3 2 2 1 3 1 2 3 4 2 2 1 2 1 2 1 2 A B B A B B A B B
11
10

12
13

15
14

16

20
18
19
17

34

36
21

33
24

26
22
23

30

32

35
28
29
27
25

31
3

8
7
2

9
5
4
1

6
‫ޓ‬1
‫ޓ‬2

42

46
40
41

43
38

44

48
45
37

47
39

49

(+) (-) (+) (-) (+) (-) (+) (-) (+) (-) (S)(R)

Speed pickup abnormal

1 2 Speed relay Power Analog output
Down Up DC24V 4-20mA
(R)
FG P N + S - M+ M-
Power
AC110V R Speed switch unit
- + 60Hz㧘1Ǿ (Daihatsu supply)
4 3 2 1 S 12 13 14 14㧸
Governor speed
Control unit
(Daihatsu supply) Sb Sc 12a 12c 13a 13c 14a 14c 14La14Lc

Control panel

Engine Protection System (Example)

DK-28e Z 11-06
CHAPTER
Engine Adjustment Standards
3
ITEM

1 DK-28e Operating Specication

3-1 Operating Specification

Item Normal value Alarm setting value

(emergency stop value) Remarks air

Starting air 2.0 ~ 3.0 1.5

Air tank
{20 ~ 30} {15}
0.6 ~ 0.9 0.6
Control air Air tank {6.0}
{6.0 ~ 9.0}
Varies depending on
Intake air Air intake duct the engine output
Pressure MPa {kgf/cm2}

Diesel fuel oil

0.2 ~ 0.3 {2 ~ 3}
Fuel oil Engine inlet
Heavy fuel oil
0.5 ~ 0.6 {5 ~ 6}
Engine inlet 0.40 ~ 0.50 0.25 (0.2)
(filter outlet) {4.0 ~ 5.0} {2.5 (2.0)}
Lubricating oil
Turbocharger 0.06 ~ 0.15 In case of MET
inlet (filter outlet) {0.6 ~ 1.5} turbocharger
Jacket line 0.25 ~ 0.35 Consider static and
(jacket inlet) {2.5 ~ 3.5} dynamic pressure
Cooling water
Cooling line 0.1 ~ 0.2 due to tank head and
(cooler inret) {1 ~ 2} pipe resistance

Inlet air Air intake duct 45 ~ 55

Cylinder outlet 480

Exhaust gas Turbocharger inlet 580

Temperature oC

Turbocharger outlet 480

Lubricating oil Engine inlet

(cooler outlet) 50 ~ 60 65
Cooling water

Engine inlet 65 ~ 70 80
Jacket line
(fresh water) Engine outlet 70 ~ 75 85 (90)

Cooler line Engine inlet ~ 32

notes : (1) As far the alarm setting value and emergency stop value, each item of the pressure represents
the lower limit value, and each item of the temperature represents the upper limit value.
(2) Manometer, thermometer, and alarm/emergency stop device will be provided depending on the
individual specifications.
(3) The actual data found on each engine may differ from those shown in the above table, and
therefore refer to the Test Run Record Table (included in the final documents) for the details.

DK-28e Z 11-06
 CHAPTER
Engine Adjustment Standards
3
ITEM
Valve Setting Values DK-28e 2

3-2 Valve setting values

Item Adjustment value Remarks

(design value)
o
Generator (60 )
Opening start angle
(befor top dead center)
Marine Propulsion (75o) C
Intake valve

Closing end angle (35o) B

(after bottom dead center)
A

Valve end clearance "A" 0.5mm

3
Opening start angle o
(55 )
(before bottom dead center) (1) Valve end clearance data
represents the clearance available
Exhaust valve

when the engine is cold.

(2) Adjust valve end clearance "A" and

Closing end angle
(after top dead center)
Valve end clearance "A"
o "B" shown above such that it
(50 ) becomes equal to "0" first.
Then, adjust value end clearance
"C" such that it becomes equal to the
value given in this table.
0.5mm

Opening start angle

Starting air

(4o)
(before top dead center)
valve

Closing end angle (130o)

(after top dead center)
Pumping start angle by
fuel injection pump
(before top dead center)
Fuel oil injection valve opening pressure
(adjustment value)
Maximum combustion pressure
May vary depending on the engine
output and specifications. Refer to
the Test Run Record Table (included
in the final documents).
34.4MPa
{350kgf/cm2}
May vary depending on the engine
output and specifications. Refer to
the Test Run Record Table (included
in the final documents).

Cylinder safety valve opening pressure 19.2MPa

(adjustment value) {195kgf/cm2}

e
DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
1.1,1.2 DK-28e Precautions for Operating Engine

4-1．Precautions for Operating Engine

4-1.1 Precautions for Starting
(1) Conduct preparations before start of the operation of engine, such as the inspection of oil, water,
and air levels, as well as proper operation of the valves without fault, and be minded to start opera-
tion only after it has been confirmed that all the conditions are ready for the start of engine.
(2) It is extremely dangerous to start the operation of engine with the turning bar inserted in the fly-
wheel. Be minded to remove the bar and store it in a specified place after turning is completed.
(3) Confirm that there are no working staff around the engine. When anyone is around the engine, be
minded to send a signal and confirm safety before starting the operation of engine.

4-1.2 Precautions for Operation

(1) After the starting engine, inspect the following items, and confirm that the engine is in a good and
removal operating for. In case that any defect is found, immediately stop the engine, so that the
causes of the defect can be investigated and the measures for recovery can be taken.
 Any abnormal data of the engines, such as inadequate lubricating oil pressure, inadequate

exhaust temperature, etc.

 Abnormal sound, excessive heating, etc.

 Any leakage from piping. (Particularly, leaks from oil piping will result in fire.)

Be minded never to attempt to resume the operation of engine, until the causes of the problem
or defect are found and eliminated, and the engine is restored to normal operating conditions.
(2) Inadvertent contact of the body of working staff or objects with the rotary parts (e.g. flywheel and
coupling) will result in dangerous accidents such as that the staff may be caught up or the chips of
the objects caught may fly out in all directions. Therefore, be minded that both person or object
may not touch the rotary parts.
Further, ensure that the protective covers of the rotary parts are always attached without fall.
(3) During the operation of engine, particularly the following parts are extremely hot, and therefore
there is a danger of burn if touched with bare hands or skin. Be minded to wear safety gloves or
protective gears whenever maintenance or inspection works are conducted.
After the completion of the work, restore the lagging, heat covers, combustible oil splash preven-
tive means (FN tape) and protective covers that have been removed for maintenance and inspec-
tion.
 Exhaust manifold

 Turbocharger

 Air cooler inlet pipe

 Cylinder head

 Indicator valve

 Fuel injection pump and high-pressure coupling

 Fuel oil filter and fuel oil pipe (in case of heavy fuel oil)

DK-28e Z 11-06
 CHAPTER
Operation
4
ITEM
Precautions for Operating Engine DK-28e 1.3

4-1.3 Precautions for Stoppage

(1) Make sure that the engine is stopped after load is taken off the engine, except in the case of
emergency.
(2) In case that the engine is stopped in emergency stop, be minded never attempt to resume the
operation until the causes of the problems is found and eliminated, and the engine is restored.
(3) Do not open the crankcase for at lease 10 minutes after the engine is stopped and fully cooled
down. Otherwise, there is a danger of explosion since the inflammable mist gas in the crankcase
may catch fire.
(4) The engine immediately after it is stopped is still extremely hot like during the operation, and there
is a danger of burn. Therefore, be minded to wear the protective gears whenever inspection or
maintenance works is conducted without fail.

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
2.1 DK-28e Preparation for Daily Operation

4-2．Preparation for Operation

It is essential to keep the engine in "Operable Conditions" whenever the engine is being
operated. Therefore, be sure to perform pre-operation inspections before the starting of
engine, and take proper corrective actions and countermeasure whenever any problem is
found, to confirm that the engine is in normal conditions for operation, before starting the
operation of engine.
If the engine is started without pre-operation inspections or preparations, it will cause not
only the troubles when starting the engine but also result in a sudden stop or damaging acci-
dents.

4-2.1 Preparation for Daily Operation 4) Reduction gear (In case of marine propul-
sion engine)
The number of the inspection items required- ( : Separately provided "Reduction Gear
before starting the operation varies depending Instruction Manual")
on how long the engine has been out of oper-
ation.
 Daily starting: Short period of disuse (within

one month)
 Initial starting after a long period of disuse,

or after overhaul or maintenance. Upper limit

The daily starting procedures is described in
this section. As for the latter (initial starting), Lower limit

refer to the following section.

( : 4-2.2 "Preparation for Initial Starting")

(1) Inspection before Operation

a) Inspection and Feeding of Lubricating Oil
Check the oil level of the oil tank, and feed
new oil to the upper limit level of the oil gauge.
Further, in case that the lubricating oil is
found inadequate after examination, proceed
with makeup or replace the entire amount of
Oil port Oil port
the lubricating oil.

( : 6-2 "Lubricating Oil Characteristics and

Control) Level gauge
1) Separately installed lubricating oil tank or
engine lubricating oil tank
2) Governor
Lubricating oil level : 1.3L (RHD10)
: 1.5L (UG10)
3) Generator (In case of self-lubricating type)
( : Separately provided "Generator RHD10 UG10
Instruction Manual")
Inspection of Governor Lubricating Oil Level

DK-28e Z 11-06
 CHAPTER
Operation
4
ITEM
Preparation for Daily Operation DK-28e 2.1

b) Inspection, lubrication, and Operation

Check around the Fuel Regulation System
Manually lubricate the bearing and sliding
parts of pins, after checking for any loose or
missing levers, link pins, and bolts around the
governor common rod, stoppage system, and
fuel injection pump rack.
Set the operation lever to "STOP" position
and confirm that the rack scale is "O", and
then alternately move the lever to STOP" and
"RUN" positions, to confirm that the common
rod and pump rack moves smoothly.

c) Draining of Condensed Water from Intake

Air Inlet Duct
Open the drain cock of the intake air inlet
duct, and drain the condensed water out.
Confirm draining the condensed water or
discharging the air during engine running.

Drain cock
Open
4
Close

Engine frame

Engine frame drain cock position

Always keep the drain cock of 。the engine

frame inlet air duct open about 60 (2/3), after
draining the condensed water by fully operat-
ing the drain cock.
In case that the humidity is high and the
cooling water temperature of the air cooler is
low, a large amount of condensed water will
accumulate, any may cause corrosion or
abnormal wear on various parts flowing into
the cylinder and may cause serious accident
as the case may be.

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
2.1 DK-28e Preparation for Daily Operation

d) Draining Condensed Water from, and Supply Some of the examples are shown as fol-
of Air to Air Tank lows.
In case of automatically supplying air, first Since the layout positions of the piping sys-
drain the condensed water out of the starting tems and valves differ depending on each
air tank and starting air control tank, and then engine, refer to the each piping diagrams of
confirm that air pressures in these tanks is the final documents for the details.
above the lower limit value.
[Examples]
In case of manually supplying air (including
1) Valves for fuel oil inlet pipe and return pipe:
manual staring of the air compressor), supply
"Open"
air to the upper limit value.
2) Valves for cooling water (jacket and cooler),
Item Upper limit Lower limit
inlet pipe, and outlet pipe: "Open"
3) Valves for starting air pipe: "Closed" ("Open"
3.0 MPa 2.0 MPa
Starting air only when starting operation)
{30 kgf/cm2} {20 kgf/cm2}
4) Valves for operation air pipe: "Open"
0.9 MPa 0.6 MPa 5) Valves for pipe coupling parts provided for
Control air
{9 kgf/cm2} {6 kgf/cm2} emergency, priming, cleaning, etc.: "Closed"

e) Checking and Feeding of Fresh Cooling

Water If the screw-tightening valves are used on
Check the level of fresh cooling water, and the state of half-open, the valve handle may
if the level is at the lower limit, supply fresh be turned during operation and the opening
water up to the upper limit, and at the same degree may be changed, causing malfunc-
time add a proper amount of the additive. tions.
Therefore, the valves should be fully turned
Further, in case that each properties of toward either "Open" or "Close" position, and
water has reached the limit level, replace the should be locked tightly.
entire amount of water. In case that the valves must necessarily be
( : 6-3 "Cooling Water Characteristics and left half open for the sake of flow adjustment,
Control") be sure to secure the valve handles with wire
ring and the like, and fix them to prevent their
f) Draining of Fuel Oil and Supply of Oil loosening and turning.
First drain fuel oil out of the fuel oil service
tank, and then check the oil level and supply
oil up to the upper limit of the level gauge.
g) Confirmation of the Clutch Being "Neutral"
(in case of the clutch-mounted engine)
In case of the engines such as the marine
propulsion engine, make sure that the clutch
is in "Neutral" position.
h) Opening and Closing of valves
Repeat "Fully open" and "Fully close" oper-
ation of the valves on the piping system 2 to
3 times to confirm that the valves move
smoothly, and then set the valves to "RUN"
position.

DK-28e Z 11-06
 CHAPTER
Operation
4
ITEM
Preparation for Daily Operation DK-28e 2.1

(2) Standby Preparation (Engine on standby) [Turning ]

Before entering the operation of engine, conduct
the following preparations:
a) Priming with Lubricating Oil
Start the motor-driven lubricating oil priming
pump (or, reserve pump) 5 minutes before
starting the operation of engine, and confirm
that there is no oil leaks from various parts of
the piping.
<Work Proceduro
i) Conduct priming with lubricating oil.
ii) Set the operating lever to the "STOP" position.
----> This action prevents fuel oil from injecting,
iii) "Fully open" the indicator valve,
iv) Conduct turning 1 to 2 times, and confirm that
the engine rotates smoothly.

1) Unless turning is not conducted at the time

of priming of the engine, lubricating oil will
not sufficiently be supplied to each par of
the crank pin shells and piston sliding sec-
tion, and consequently the shells and pis- Close
tons may be damaged.
Further, lubricating oil will drop off from the
valve stem section into the combustion cham-
ber, and a large amount of while smoke may
be generated at the time of starting the engine.
4
2) Perform turning of the engine after con-
firming that the lubricating oil pressure is Open
established.

b) Turning or Air Running

Conduct turning or air running to discharge
the dusts or water drops that has collected in
Indicator Valve
the cylinder while the engine is stopped.
Further, when the engine is started after the
inspection of various parts of the engine, or
after a long period of disuse of the engine,
conduct turning before air running to confirm
the safety.

In case that a large amount of water or oil is

accumulated in the cylinder due to the leak-
age from the cylinder head or fuel injection
valve, there is a possibility of serious acci-
dents such as bending damage of the con-
necting rod by water hammer.
When conducting turning or air running, if
water or oil has gushed out of the indicator
valve, immediately stop the starting of engine,
so that the causes can be investigated and
the countermeasure can be prepared and
taken.

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
2.1 DK-28e Preparation for Daily Operation
<Air Running (abbreviated as Air Run.)>
<Work Procedure>
i ) Conduct priming with lubricating oil.
ii) Set the operation lever to "STOP" position.
iii) "Fully open" the indicator valve.
iv) Open the starting air valve and control air
valve, and press the push button for the start-
ing operation valve. Then, starting air flows into
the starting air valve, and the engine starts its
rotation.
v) Keep pressing the push button for 3 to 4 sec-
onds, (for air run)
vi) Release the push button. Then, the starting air
valve closes, and the engine stops its rotation.
If the engine starts its rotation during the
inspection of the inside of the engine or rotary
parts, it is extremely dangerous since the
working staff may be caught up or the objects
that has been caught up may fly out in all
directions.
When conducting air run, strictly observe the
following items:
1) Confirm that the turning device or turning
bar is set "OFF".
2) Send a signal to coworkers and confirm
safety before starting to press the push but-
ton of the starting operation valve.
Do not fully open the starting air valve during
air run, keeping the opening at about 1/3, and
carefully conduct air running at low speed.
If air run is conducted at high speed by fully
opening the starting air valve, it will not only
expend air uselessly, but also will result in
serious accidents such as aggravation of the
defects if any defect had been caused.
DK-28e Z 11-06
When repeating air running on the air motor
starting type system, make sure that the fly-
wheel is stopped to prevent damage to the air
motor and the ring gear.
c) Heating of Fuel Oil (when heavy fuel oil is
used.)
In case that heavy fuel oil is used, heating shall
be made according to the following items:
i ) Turn on the fuel oil heating device,
ii) Operate the motor-driven oil feed pump.
( :6-1 "Fuel Oil Characteristics and
Control")
Heated heavy fuel oil is extremely hot
(100℃ or more), may cause burn if you touch
the piping or equipment on the fuel oil system.
Therefore, in case of handling the equipment
of fuel oil system that carriers heat oil, be sure
to wear safety gloves and never touch them
with bare hands.
d) Turning "ON" of Protective and Alarm
Circuit
Turn "ON" the protective and alarm circuit on
the monitor panel, and confirm that the warning
lam is lit up.
e) Operation of Motor-Driven Pumps
In case that the engine is equipped with the
motor-driven cooling water pump and fuel oil
feed pump, start the pumps 5 minutes before
the starting of engine, and confirm that there is
no oil leaks from various parts of piping.
 CHAPTER
Operation
4
ITEM
Preparation for Initial Starting After A Long Period of
Disuse, and Ovehaul or Maintenance DK-28e 2.2

4-2.2 Preparation for Initial Starting and the elements of the filters:
After A Long Period of Disuse 1) Starting air filter and control air filter
and Overhaul or Maintenance 2) Fuel oil filter ( 5-4.3 "Cleaning Filters")
Since the engine is not ready for immediate 3) Lubricating oil filter ( 5-4.3 "Cleaning
starting of operation after a long period of disuse, Filters")
and overhaul or maintenance, it is particularly nec-
4) Lubricating oil filter for turbocharger
essary to thoroughly conduct the preparations for
5) Centrifugal lubricating oil bypass filter
operation.
6) Cooling water filter
Before the preparation for daily operation, con-
duct the following preparation works ( :4-2.1):
(1) Inspection of Crankcase and Cylinder Liner,
and Supply of Oil
a) Inspection of the Inside of Crankcase
Open the side cover of the engine frame, and
check and ensure that tools, waste clothes, for-
eign matters such as desiccants are not left
behind, and that there is no rusting on the cylin-
der liners, crankshaft, and so on. 4
b) Supplying Lubricating Oil to Cylinder Liner
After a long period of disuse, the various parts
of engine are not covered with sufficient amount
of lubricating oil. Particularly around the cylin-
der, lubricating oil cannot be supplied sufficient-
ly with priming alone, and therefore supply lubri-
cating oil on the following procedure:
i ) Conduct turning to allow the pistons to
move upward, and apply lubricating oil on
the lower part of the cylinder liners by a
spray device and the like.
ii) Sequentially conduct the above procedure
to each cylinder.

(2) Inspection of Connections and Joints

Inspect again the external connections or
joints to confirm that there is no connections that
has been forgotten to be tightened, or loosened
joints. If combustible oil splash preventive
means (FN tape) has been removed from joints,
newly treat the joints in the same manner after
the completion of the work.
(3) Opening, Cleaning, and Cleansing of Filters
Dust or foreign objects, that had been collected
into piping during transportation, and outfitting or
installation, is accumulated in the filters of the
engine inlet.
Open the following filters, and cleanse the inside
(4) Priming with Lubricating Oil and Exhausting
Air
Conduct priming with lubricating oil and exhaust-
ing air on the following procedure:
a) Operate the lubricating oil priming pump for
about 5 minutes, and during this period conduct
turning 2 to 3 times by opening the indicator
valve, so that it can be confirmed that no fuel
oil, lubricating oil, and water do not flow out of
the indicator valve.
b) At the same time, open the each cover and
check the dripping-down conditions of lubricat-
ing oil from each part.

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
Preparation for Initial Starting After A Long Period of
2.2 DK-28e Disuse, and Ovehaul or Maintenance

1) Engine frame: Main bearing, crank pin, (6) Cleaning of Turbocharger Pre-Filter
piston (cooling chamber), and piston pin Dust or debris are collected in the pre-filter of
2) Cam case: Cam bearing, swing arm, and the turbocharger during transportation, outfitting,
tappet and installation, causing the filter to be stained or
3) Cylinder head: Rocker arm and valve retain- damaged.
ing tee
Therefore, clean it or replace it with a new one
c) Operate the priming pump, open the air vent
valve for lubricating oil filter, and drain lubricat- before starting the operation.
ing oil until air bubbles in the oil are completely Air vent
valve
vanished. Take care not to splash the oil.
d) Check that there is no oil leakage from various
parts of the piping during priming. O S O S
(5) Priming with Fuel Oil and Exhausting Air
Conduct priming with fuel oil and exhausting air
bubbles on the following procedure:
i) Operate the fuel oil feed pump (in case of the engine
equipped with a motor-driven oil feed pump).
ii) Open the fuel oil inlet valve, after confirming that
the operation lever is set to "STOP" position.
iii) Open the air vent valve of the fuel oil filer, and
drain oil until air bubbles in oil are completely
vanished.
iv) Open the air vent valve of the fuel injection Exhaousting Air of
pump, and drain oil until air bubbles in oil are Notch-Wire Filter
completely vanished.
Air vent plug
v) After completely removing air bubbles, secure-
ly tighten the air vent plug.

The heavy fuel oil is heated to a high

temperature (100℃ or more).
Touching the splashing oil may scald your
hands. If high-temperature parts are splashed
with the oil, a fire may occur. Take care not to
splash the oil when discharging air.

Exhausting Air of
Pre-filter Fuel Injection Pump
(7) Checking the covers are fitted
Check that the lagging for high-temperature
parts (exhaust pipe, turbocharger, etc.), exhaust
pipe cover and heat box cover that were
removed for disassembly and servicing have
been restored as they were.
Check that the joints that were once discon-
nected are provided with combustible oil splash
preventive means (NF tape).
Turbocharger

DK-28e Z 11-06 Exhaousting Air of

Notch-Wire Filter
 CHAPTER
Operation
4
ITEM
Starting Procedure DK-28e 3.1

4-3 Starting

Inadvertent contact of working staff or

objects with the rotary parts is extremely dan-
gerous since the person may be caught up or
the object that has been caught up may fly out
in all directions.
Therefore, strictly observe the following
items when starting the operation.
1) Confirm that the protective covers of rotary
parts are mounted in normal state, and that
the rotary parts are free of any obstacle.
(2) Remote Starting (Manual and Push Button
2) Confirm that the turning device or turning
Starting)
bar is set to "OFF".
<Work Procedure>
3) Send a signal to a coworker if there is any,
and confirm safety before starting the oper- i ) Switch the starting mode to the remote mode
ation of engine. (from monitor chamber) from local mode (from
engine side).
4-3.1 Starting Procedure ii) Set the operating lever to "RUN" position. 4
iii) Open the starting air valve and control air
(1) Starting from Engine Side (Locally)
valve, after confirming that "READY" indicator
Starting procedure can be classified into the
lamp has lit up.
three types; engine side starting (local starting),
iv) Press the starting push button.
remote starting, and automatic starting, and which
of these should be employed depends on the v) Confirm that "RUN" indicator lamp on the panel
has lit up as the rotation speed of the engine
specifications. However, local starting (starting
has reached the specified rate, and each pres-
from engine side) by manual operation should
sure has reached the specified value.
always be employed after a long period of disuse
vi) Close the starting air valve.
or after overhaul or maintenance.
(Leave the control air valve "OPEN" as it is.)
<Work Procedure>
i) Open the starting valve and control air valve. (3) Automatic Starting
In case of automatic starting, the engine starts
ii) Set the operation lever to "START" position.
automatically by the starting command based on
iii) Press the push button for the starting opera- preset starting conditions, such as the overload
tion valve. conditions of power shutdown or other engines (in
iv) If the rotation speed of the engine has rapidly case of plural engines), and therefore it is essential
increased and starting has been established that the engine should always be kept in operable
along with continuous ignition sounds, release conditions.
the push button. Engines should be kept in the following con-
v) After confirming that the rotation speed of the ditions at all times:
engine has reached the specified speed, and 1) Starting mode: "AUTO"
each pressure has reached the specified value, 2) Operation lever position: "RUN"
set the operating lever to "RUN" position. 3) Starting air valve and control air valve:
vi) Close the starting air valve. "OPEN"
(Leave the control air valve "Open" as it is.)

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
Starting Procedure / Inspection and Check Items
3.1,3.2 DK-28e Immediately After Starting

(4) Corrective Measure In Case of Faulty

Starting
In case that the engine has failed to start or has
not started smoothly, take corrective measures by
referring to a separately provided section.
( : 7 "Trouble Shooting and Countermeasures")

In case that the engine has repeatedly failed

to start in an extremely cold weather while the
engine is still in cold condition, the unburnt
mist of fuel oil may remain in the exhaust
manifold, having a possibility of catching fire
or explosion being caused by high-tempera-
ture combustion gas.
When starting failure has been repeated, con-
duct air running and exhaust the unburnt mist in
the exhaust manifold, before restarting the engine.
(3) Abnormal Sound
4-3.2 Inspection and Check Items Carefully listen to the sound of the following
Immediately After Starting engine parts, and check if there is any abnormal
Check the following items immediately after sound or not:
starting. 1) Cylinder head and surrounding parts (intake
When any abnormal error has been found, and exhaust valves)
immediately stop the engine and take proper 2) Crankcase
measures. 3) Crankcase and timing gear and auxiliary
drive gear
( : 7 "Trouble Shooting and Countermeasure")
4) Turbocharger

(4) Exhaust Temperature

After conducting overhaul or maintenance of
the sliding parts or rotary parts, be sure to
once stop the engine and check that there is
no error or failure by hand-touching.
Check the exhaust temperature of each cylinder,
and confirm that all the cylinders are properly
burnt (at 200oC or more).

(1) Engine Rotation Speed
Confirm that the engine rotation speed (the
number of idle rotation speed, in case of the
marine propulsion engine) has reached the speci-
fied rotation speed, and hunting (swinging of
tachometer) is not occurred.
(5) Gas Leakage from Starting Valve
If gas has leaked from the starting valve, the
starting air main pipe becomes hot.
Check if the starting air main pipe is not heated
or not by lightly touching the pipe.

(2) Pressure Reading of Each Parts
Confirm that the indicator of pressure reading,
for the manometer with blue mark, is within the
blue mark, showing the pressure is within the
specified value.
(6) Leakage and Loosening of Each Part
Check if the bolts and nuts of installation part or
connecting part are not loosened, and if oil, water,
or qas is not leaked.

DK-28e Z 11-06

Operation
Running-in Operation
4-4．Operation
4-4.1 Running-in Operation
When the engine is started for the first time or
immediately after replacement of the parts, such
as the cylinder liners and piston, since the sliding
parts of the engine are not yet sufficiently ready to
work smoothly or freely, failure such as abnormal
wear or seizure of the sliding parts may occur, if
the load is abruptly applied in the stage of such
conditions.
Conduct the running-in operation to ensure
smooth and free working of the sliding parts on the
following procedure, before entering normal opera-
tion:
(1) Initial Running-In Operation
It will substantially affect the engine perform-
ance, especially the combustion performance and
consequently the consumption efficiency of lubri-
cating oil, whether the piston and oil rings move
smoothly and freely, or not. Further, it is assumed
that they will be decided by the initial operation of
a few hours.
When the cylinder liner, piston, piston ring, and
sliding parts around cylinder are replaced, be sure
to conduct running-in operation in accordance to
the figure shown below.
( : Fig. 4.1 "Initial Running-In Pattern")
(2) Operating Conditions during
Running-ln Operation
Be sure to operate the engine during the run-
ning- in period under the following conditions:
1) Load: 80% or less
2) Fuel oil to be used: Diesel fuel oil
Note: For the engines of heavy fuel oil specifi-
cation, be minded to use diesel fuel oil during
the running-in period.
3) Lubricating oil to be used shall comply with the
fuel oil to be used.
Note that in case of the engine with heavy fuel
oil specification, lubrication oil for heavy fuel oil
CHAPTER
4
ITEM
DK-28e 4.1
can be used from the start of engine driving,
notwithstanding the above prescriptions of 2).
4) Running-in period is 150 hours.
(3) Inspection Items during Initial
Running-ln Operation
To detect the potential problems and eliminate
the causes to previously prevent such problems,
particularly heed cautions to the following items:
1) Abnormal sound
2) Partial heating
3) Leakage from connection parts, and loosening
of screws
4) Explosion pressure, exhaust temperature,
irregular exhaust color: Abnormal burning of
fuel
5) Excessive consumption of lubricating oil:
Improper working of liners and rings
4
(4) Inspection and Works after
Completion of Running-ln Operation
At the time when the running-in operation is
completed, conduct the following inspection works
and confirm that there is not any abnormality
before entering the normal and regular operation
of engine:
1) Inspection of foreign matters and stains in the
crankcase
2) Visual inspection of the inner surface of the
cylinder liner
3) Inspection and cleaning of the element of each
filter
4) Remove the flushing filter attached to the ele-
ment of the fuel oil filter.
Be minded never to perform the operation of
engine using heavy fuel oil, while the flushing
filter is attached.
DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
4.1 DK-28e Running-in Operation

Load
㩿㩼㪀 Shutdown
100 60 min
Continuous
Operation

75 30 min

60 min Shutdown 15 min 15 min

50

STEP1 STEP2 STEP3

25 30 min 15 15 min
Check Check
Preparaitio
Start(Manual) Start (Manual)
0
0 30 60 90 0 30 60 90 0 㪊㪇 㪍㪇
TIME(min)

Fig. 䋴.䋱䇭
䋱䇭Initial
Initial Running-In Pattern

DK-28e Z 11-06

Operation
Warming-Up and Connecting Load to the Engine DK-28e
4-4.2 Warming-Up and Connecting
Load to the Engine
In case that the engine is started while it is still in
a cold state, first perform the warm-up operation,
except for the case of emergency, and gradually
onnect the load after the engine has sufficiently
been warmed up.
If the load is hastily connected while the various
parts of the engine are still cold and not yet in the
conditions for proper fuel combustion and lubrica-
tion, malfunctions such as faulty combustion,
excessive wear of the sliding parts, and seizure
may be caused.
(1) Warming-up Operation of Engine
a) Use diesel fuel oil for warming-up opera-
tion
Be sure to use diesel fuel oil for warming up
the engine, even in case of the engine with
heavy fuel oil specification.
b) No load (Idle operation in case of warming
up the marine propulsion engine)
First operate under no load or light load,
and connect the load after jacket cooling
water and lubricating oil temperature has
increased.
Load
(%)
(Normal load)
75
50
25
No load
5 10 15
Fig. 4.2 Load Connection Pattern
CHAPTER
4
ITEM
4.2
Be minded to perform no-load operation on
for warming-up operation, and restrain the
duration of no-load operation within 10 min-
utes.
Running the engine under no-load for long
hours will result in malfunctions such as faulty
combustion and collection of carbons in the
combustion chamber.
(2) Connecting Load to the Engine
The lower the engine temperature (temperatures
of jacket cooling water and lubricating oil) is, the
longer time it is needed to connect the load.
The standard load connection time is shown in
the figure below.
( : Fig. 4.2 "Load Connection Pattern")
In case of the marine propulsion engine (direct
connection by propeller), be minded to gradually
increase the rotation speed, since the load will
4
increase according to the rotation speed.
When increasing the rotation speed, be
minded to quickly let it pass the dangerous
running speed zone (the red mark zone on the
tachometer), under which torsional vibration
may cause damages.
Running the engine within this zone for long
hours may cause the breakage of the crank-
shaft.
䌴 䋺 40°䌃 䌴 䋺 15°䌃
t: Jacket cooling water and lubricating oil
temperature at startup
20 25 30 35 40 Time(min)
DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
4.3 DK-28e Operation with Load (Normal Operation)
4-4.3 Operation with Load (Normal
Operation)
Inspect the running conditions of the engine and
measure the operating performance data in regular
intervals, during the continuous operation with load
(including period of the running-in operation).
In case that any problem is found as the results
of the inspection and measurement, take proper
measures such as adjustment or repair of the
defective parts. (Refer to a separately provided
section for the details.)
( : 5-3 "Measurement and Adjustment")
( : 7 "Troubleshooting and Countermeasures")
(1) Inspection of Operating Conditions
<Check ltems>
1) Abnormal sound
2) Partial overheat
3) Leakage from connections and looseness of
the screws
4) Abnormal combustion pressure, exhaust
temperature, and exhaust color
------ Abnormal combustion
5) Excessive consumption of lubricating oil
------ Damaged cylinder liner and ring
During the operation of engine, particularly the
following parts become extremely hot, and
touching these parts with bare hands or skin
may cause burns.
Therefore, be minded to use the protective
gears such as safety gloves when working on
them.
 Exhaust manifold
 Turbocharger
 Air cooler inlet pipe
 Cylinder head
 Indicator valve
 Fuel oil system equipment and piping
(in case of heavy fuel oil)]
(2) Measuring Performance Data
a) Measure the operating performance data at
least once every day, when the load variation is
less and the load is stable.
DK-28e Z 11-06
b) Compare each of the measured data with the
data obtained when the engine was newly
introduced, and judge if there is any problem
and check the degree of deterioration.
( : "Test Run Record Table" in the final
documents)
<Measurement ltems>
1) Room temperature
2) Load (output)
3) Rotation speed
------In case of variable-speed engine
4) Maximum combustion pressure (each cylin-
der)
5) Intake air temperature (turbocharger inlet)
6) Exhaust temperature (outlet of each cylin-
der)
7) Intake air pressure (engine inlet)
8) Lubricating oil pressure (engine inlet)
9) Lubricating oil pressure for turbocharger
(Turbocharger inlet)
10) Cooling water pressure (engine inlet)
11) Fuel oil pressure (engine inlet)
------In case of heavy fuel oil specification
12) Inlet air temperature (engine inlet)
13) Lubricating oil temperature (engine inlet)
14) Cooling water temperature (engine inlet and
outlet)
15) Fuel oil temperature (engine inlet)
------In case of heavy fuel oil specification
16) Reading on fuel injection pump rack scale
(3) Regular inspection and Maintenance
Conduct inspection and maintenance of the vari-
ous parts of engine regularly.
(Refer to a separately provided section for the
details.)
( : 5 "Inspection and Maintenance")
(4) Operation Records
After completion of the inspection and measure-
ment, keep the records of the works performed for
adjustment or repair in the log book.

Operation
Operation with Load (Normal Operation) /
Operation using Heavy fuel Oil
Operation records are very important docu-
ments when understanding the conditions of
engine and tracing the history of the inspec-
tion or maintenance that has been performed.
Keep and store them carefully, and when the
supervisor is changed, be sure to transfer the
records to the successor without fail.
4-4.4 Operation Using Heavy Fuel Oil
(in case of Heavy Fuel Oil Engines)
Heavy fuel oil is lower in its quality and higher in
its viscosity than diesel fuel oil. When using heavy
fuel oil, proper operation control, such as switching
to the operation using diesel fuel oil depending on
load conditions, is required, in addition to proper
fuel oil and lubricating oil control (Refer to a sepa-
rate section).
(
(
: "6-1 "Fuel Oil Characteristics and Control")
: "6-2 "Lubricating Oil Characteristics and
Control")
(1) Operation with Diesel Fuel Oil
Be minded to use heavy fuel oil only under sta-
ble load conditions, and be sure to use diesel fuel
oil in the following cases:
a) During Running-ln Operation Period (150
hours)
1 Immediately after installation
2 After replacement of the sliding parts
around cylinder (e.g. liner, piston, and
piston ring)
( : 4-4.1 "Running-ln Operation")
b) During Starting or Warming-Up Operation
( : 4-3 "Starting")
( : 4-4.2 "Warming-Up Operation")
c) During Idling or Low-Load Operation
When the engine is operated under low load,
the compressed air temperature in the cylinder
and fuel injection pressure of fuel oil is low, and
therefore if the heavy fuel, of which combustion
quality is lower than that of diesel fuel oil, is
used, combustion will become unstable, result-
CHAPTER
4
ITEM
DK-28e 4.3,4.4
ing in undesirable conditions, such as worsen-
ing of the exhaust smoke, sticking of the ring,
and so on. In case of the connection of the load
that is below the lower limit described in the
engine specification, be minded to use diesel
fuel oil.
d) In Case Load Variation Is Heavy
1) When entering or leaving port
2) When weather is rough and stormy
3) When cargo is being loaded or unloaded
e) Before Stopping Engine
( : "4-6 "Stoppage")
(2) Switching Fuel Oil Types
o
Heavy fuel oil is normally heated up to 80 C to
o o
90 C in the service tank, and 100 C or more at the
engine inlet, and the temperature difference is
larger as compared with that of diesel fuel oil (non-
heated), and therefore if fuel oil is suddenly
switched between these oils, it may cause mal-
4
functions such as sticking of the fuel injection
pump, vapor lock, and so on.
a) Slowly switch from diesel fuel oil to heavy fuel
oil, so that the rate of change in the fuel oil tem-
o
perature at the engine inlet is between 5 C and
o
10 C per minute.
( : Fig.4-3 Switching Pattern from Diesel
Fuel Oil to Heavy Fuel Oil")
b) Maintain the viscosity (temperature) of heavy
fuel oil at the engine inlet at the specified value.
c) Do not raise the temperature of diesel fuel oil
o
beyond the flashing point (60 C is the standard
point.)
d) To prevent the generation of vapor, maintain
the pressure of fuel oil at the specified value.
Further, remove the air bubbles in fuel oil in the
various equipment of the fuel oil system
(heater, filter, tank, etc.) from time to time, so
that the generation of vapor can be prevented.
If high-temperature parts are splashed with
the oil, a fire may occur. Take care not to
splash the oil when discharging air.
DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
4.4 DK-28e Operation using Heavy Fuel Oil

e) Confirm that the heat traces on piping and

equipment is properly functoning.
In case that emergency stop is made during
the operation with heavy fuel oil, immediately
The fuel oil is heated, and the filter and the switch the fuel oil to diesel fuel oil, move the
piping are at high-temperatures. If touched motor-driven pump, and perform flushing of
with bare hands or skin, it may cause a burn. the fuel oil system.
Therefore, be minded not to directly touch the If the engine is cooled down with the heavy
exposed metallic parts such as the valves and fuel oil left unchanged, the oil will be solidified
cocks, and wear the protective gear such as
and the operation will be prohibited.
safety gloves when working on them.

Switching from Diesel Fuel Oil to Heavy Fuel Oil Switching from Heavy Fuel Oil to Diesel Fuel Oil

Viscosity at Viscosity at
㪍㪇㩷㫋㫆㩷㪎㪇㩷㫊㪼㪺㪃㩷㪩㪮㩷㪥㫆㪅㪈 㪍㪇㩷㫋㫆㩷㪎㪇㩷㫊㪼㪺㪃㩷㪩㪮㩷㪥㫆㪅㪈
engine inlet engine inlet
Fuel oil temperature

Fuel oil temperature

at engine inlet

at engine inlet

Temperature of heavy fuel oil Temperature of

heavy fuel oil Changing temperature:
5 to 10 oC/min

Temperature of Temperature of
diesel fuel oil diesel fuel oil
Operation

Operation

Switching from Switching from

diesel fuel oil to Heavy Fuel Oil Operation with
heavy fuel oil
Operation with Operation with Operation with to Diesel Fuel Oil diesel fuel oil
diesel fuel oil heavy fuel oil heavy fuel oil (warming up)
Check items

Check items

Check heavy fuel oil Check that load is stable Check that load is stable Check heavy fuel oil
supply equipment (above lower load limit) (above lower load limit) supply equipment
for proper operation during switching during switching for proper operation

Note: 1. Since the pretreatment of fuel oil differs depending on the use purpose of the engine, the operating method suitable to
each system is necessary.
2. The diesel fuel oil temperature when switching on heated condition shall be 60͠or more.

Fig. 4.3 S witching P attern from Diesel F uel O il to Heavy F uel

DK-28e Z 11-06
 CHAPTER
Operation
4
ITEM
Allowable Operating Range DK-28e 4.5

4-4.5 Allowable Operating Range (In case (1) In case of Fixed Pitch Propeller (FPP)
of Marine Propulsion Engines) The fixed pitched propeller is generally
designed by including the sea margin, which has
In case of the marine propulsion engine, the
taken into consideration the fouled hull surface, in
load changes in accordance with the marine
addition to the absorbed horsepower due to the
characteristics, and according to the changes in
marine characteristics.
the rotation speed.
In case that fouling of the hull surface has
The allowable operating range and recommend-
advanced, increasing the resistance, and has
ed operating range within the marine characteris-
exceeded beyond the sea margin, the absorbed
tics are shown in the figure below.
horsepower increases to such an extent that the
When actually operating, be minded to select a excessive torque occurs even if the rotation speed
proper rotation speed and engine torque (Pme, to is maintained constant. Therefore, always heed
be judged based on the reading on the rack scale), cautions to the rotation speed and the reading on
and keep operating within the recommended oper- the rack scale to prevent excessive torque.
ating range as far as possible, to prevent being
Further, particularly be careful when the
overloaded.
absorbed propeller horsepower suddenly increas-
Note that the lower load limit is normally 30% es, for example when in stormy weather and so
when usina heavv fuel oil. and if the load to be on, since this will often cause the excessive torque
connected is lower than this limit valve, use diesel to occur, eventually leading to surging of the tur-
fuel oil. bocharger. 4
( : Fig.4.4 "Allowable Operating Range")
As for the output characteristics of the engine to
be actually operated, refer to "Test Run Record
Table" included in the seperately provided final
documents.

100

Propeller design point

85
80
Output (%)

Allowable operating range

G

2O Recommended continuous
/'2
㧑 $ OG normal operating range
60  / ' 2
2
$
㧑 P-curve : Marine propeller
characteristic curve

40 M-curve M-curve : Curve with sea margin

P-curve taken into consideration
㪊㪇㩷䋦
Allowable range of
short-time operation
20 on diesel fuel oil in the
case of standard
㪈㪇㩷䋦 specifications

50 60 70 80 90 95 100 105 Revolution (%)

Idling speed
Fig. 4.4 Allowable Operation Range

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
4.5 DK-28e Allowable Operating Range

(2) In case of Changeable Pitch Propeller (CPP)

The changeable pitch propeller is capable of
changing its propeller pitch (blade angle), while
maintaining the engine rotational speed constant,
and is thereby capable of changing the absorbed
horsepower. Therefore, this propeller has a merit
that the rotational speed and load can be changed
according to the conditions of the other auxiliary
machinery driven by the marine propulsion engine,
and the hull resistance.
However, since the changeable pitch propeller
tends to run under excessive torque to as much
extent as it has a larger freedom of its operation,
be minded to operate the engine properly prevent-
ing the excessive torque, by always grabbing the
load conditions.

DK-28e Z 11-06
 CHAPTER
Operation
4
ITEM
Low-Load Operation and Operation with Air Cooler Cut-Off DK-28e 5.1,5.2

4-5 Special Operation 4-5.2 Operation with Air Cooler Cut-Off

4-5.1 Low-Load Operation In case that the defects such as breakage of the
Since running the engine with a low load lower fine tube in the air cooler or water leakage from a
than a certain limit can lead to unfavorable com- caulked sections is found, and the repairing cannot
bustion conditions such as the reduction of intake
air pressure and blowing-back of exhaust air, if the be performed quickly, an emergency measure can
engine is operated under such conditions for long be taken by cutting off the air cooler on the follow-
hours, it may result in the various malfunctions ing procedure:
such as fouling of the turbocharger and combus-
tion chamber, faulty combustion, and so on.
Therefore, be sure to minimize the low-load (1) Preparation for Operation
operation to a shorter period of time as much as
a) Stop water supply to the cooler cooling system,
possible, and in case that the engine must be
inevitably run under a low load for long hours, be and draw out the water from the air cooler.
sure to observe the following conditions: b) Insert the shielding plate R into the flange part
(1) Low-Load Limit of the air cooler cooling water inlet pipe and
The low toad limit varies depending on each outlet pipe.
specification. Confirm the low load limit described
c) "Fully open" the bypass valve of the air cooler.
on the specification supplied with the engine.
d) Operate the cooler cooling water pump, and
(2) Use of Diesel Fuel Oil
In case of the heavy fuel oil specification, be
sure to switch it to diesel fuel oil.
confirm that no water is leaking from the flange
packing area.
4
(3) Increase of Intake Air Temperature
To improve the combustion conditions, increase
the intake air temperature and adjust to as a high-
er level as possible, within the following limit:
o
 Intake air: 75 C or less

 Exhaust air temperature (cylinder outlet):

400 oC or less
( : 5-3.2 (2) "Measurement and
Adjustment: Intake Air Temperature")

(4) Cleaning of Turbocharger

Properly increase the number of times of clean-
ing the turbocharger according to necessity.

The turbocharger is at a high-temperature

during operation and just after the engine is
stopped. If you touch it with bare hands dur-
ing cleaning, you may burn your hands. Wear
safety gloves without fail.
(5) Intermittent High Load Operation
If the load is switched to a high load (60 % or
(2) Operating Conditions
a) The fuel oil to be used is diesel fuel oil.
b) Restrain the output as low as possible, refer-
ring to the following values as the standard:
 Pme (average effective pressure):

more) for about 30 minutes during a continuous 0.8MPa {8 kgf/cm2}

low-load operation, it will have an effect to restrain
or reduce the fouling of the combustion chamber,  Exhaust air temperature
as well as the intake and exhaust air systems. (at cylinder outlet): 400 oC (Max 450 oC)

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
5.3 DK-28e Non-Turbocharger Operation
4-5.3 Non-Turbocharger Operation
In case of the marine propulsion engine, a non-
turbocharger operation implement (turbocharger
blind plate) is provided, so that operation in emer-
gency can be made even when the turbocharger
has been damaged. (The generator is optional.)
The non-turbocharger operation procedure is as
the followings:
( : "Turbocharger Instruction Manual")
(1) Preparation for Operation
<ln case of MET-SR>
a) Remove the cooling water inlet and outlet
pipes, lubricating oil inlet and outlet pipes, and
mist drawing-out pipes out of the turbocharger
b) Remove the turbocharger out of the engine.
c) Remove the gas inlet casing according to the
Turbocharger Instruction Manual.
d) Install the non-turbocharger operation imple-
ment to the gas inlet casing as shown in the fig-
ure on the right.
e) install the gas inlet casing to the engine.
f) Remove the intake connecting pipe (bellows),
and install the air strainer so as not to inhale
dust through the air inlet section of the air cool-
(2) Prerequisites for Operation
DK-28e Z 11-06
er inlet pipe.
g) Close the cooling water inlet and outlet pipes,
as well as the lubricating oil inlet and outlet
pipes.
<ln case of TPS>
a) Stop the lubricant supply to the engine.
b) Remove the turbocharger out of the engine.
c) Remove the gas inlet casing according to
the Turbocharger Instruction Manual.
d) Install the non-turbocharger operation
implement to the gas inlet casing as shown
in the figure on the right.
e) Install the gas inlet casing to the engine.
f) Remove the intake connecting pipe (bel-
lows), and install the air strainer so as not
to inhale dust through the air inlet section of
the air cooler inlet pipe.
g) Start the lubricant supply to the engine. At
this time, verify that any lubricant does not
leak from the non-supercharged operational
tool and the supercharger support base.
During operation or immediately after stop-
ping the engine, the turbocharger is extremely
hot, and if the turbocharger is touched with
bare hands or skin, it may cause burns.
Therefore, perform the disassembly work
after the turbocharger is completely cooled
down.
If it must be removed before it cools down,
wear safety gloves, and remove it taking care
not to burn your hands.
a) The fuel oil to be used is diesel fuel oil.
b) Restrain the output as at a lower level as pos-
sible, referring to the following values as the
standard:
 Pme (average effective pressure):
0.44 MPa {4.5 kgf/cm2}
 Exhaust air temperature (at cylinder outlet):
400 oC (Max 450 oC)
 CHAPTER
Operation
4
ITEM
Operation with Reduced Number of Cylinder DK-28e 5.4

4-5.4 Operation with Reduced Number

of Cylinders
Adoption of the operation with the reduced num-
ber of cylinders impose such problems as the tor-
sional vibration of the shaft system as well as the
external vibration of the engine, and therefore this
operation should be limited as a secondary meas-
ure to be used only in emergency.
The operation with the reduced number of cylin-
ders may be conducted in various cases such as
the case of only reducing the fuel oil, or the case in
which the operating parts are needed to be
removed. Further, since the prohibited items for
the operation vary depending on each case, be
sure to inquire our company for the working
procedures, cautionary items on the operation, and
so on, obtain the necessary instructions, and
strictly observe them, when the operation with the
reduced number of cylinders is conducted.
4
<Prerequisites for Operation>
a) The fuel oil to be used is diesel fuel oil.
b) The output shall be as below:
(total No. of cylinders) -(No. of reduced cylinders)x70%
(total No. of cylinders)
However, the output may be reduced according
to the turbocharger surging or exhaust air tem-
perature in each case.
c) Exhaust air temperature: 400 oC (Max 450 oC}

Be attentive of external vibration of the

engine and the gear sound, and if any abnor-
mality is found, immediately stop the engine. If
the engine is kept operating disregarding such
abnormality, serious accidents may be
caused.

DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
6.1 DK-28e Normal Stoppage

Stoppage
4-6.1 Normal Stoppage
(1) Preparations for Stoppage
a) In case that heavy fuel oil is used, switch the
fuel oil to diesel fuel oil 30 minutes before stop-
ping the engine.
b) Immediately before stopping the engine, stari
the operation of lubricating oil priming pump.
c) Confirm that the starting air pressure is at 2.0
MPa {20 kgf/cm2} or more.
(The preparation for the next round of starting)

(2) Stoppage
a) Conduct the stoppage operation on the follow-
ing procedure:
(3) After Stoppage
a) Operate both the lubricating oil priming pump
[In case of local operation]
and cooling fresh water pump for about 20 min-
Shift the operation lever to "STOP" position. utes, and cool down the engine and
Then, fuel oil injection will be shut off by means
of the common rod, and the engine will be
stopped.
The turbocharger continues to run at a high
speed even after the engine is stopped.
[In case of remote control] Lubrication of the turbocharger provided with
i) Press the "STOP" push button on the control this engine is made using the system oil, and
panel. therefore if the supply of lubricating oil is
Then, the fuel oil injection solenoid valve will stopped immediately after the engine is
be activated to operate the fuel shutdown stopped, it may damage the bearing.
device, and the engine will be stopped.
ii) Shift the operating lever to "STOP" position
b) Fully open the indicator valve to conduct air
running for 3 to 4 seconds, and exhaust the
b) After stoppage operation, be attentive of any combustion gas out of the combustion cham-
abnormal sound in the engine and turbocharg- ber.
er, and confirm that there is not any abnormal c) Close the valves on all the systems.
sound.

In case that the engine does not stop even when

the stoppage operation is conducted, forcibly stop
the engine on the following procedure:
1) Forcibly set the rack of the fuel injection
pump to "0".
2) Fully close the valve of the fuel oil inlet main
pipe.

DK-28e Z 11-06

Operation
Emergency Stop
4-6.2 Emergency Stop
(1) When Emergency Stop Is Required.
Immediately stop the engine when any of the fol-
lowing abnormalities is found:
1) Announcement of "Emergency" or "Alarm"
( Activation of the protective device ---
* operating lever to "STOP" position after the
Automatic stop)
 Overspeed
* b) In case that the operation had been made
*  Decrease of lubricating oil pressure
*  Suspension of water supply/increase of
cooling water temperature
 Increase of exhaust air temperature
 Other alarming (depending on each specifi-
cation)
2) Abnormal sound
3) Heating of the bearings or other moving parts, or
generation of smokes, or abrupt increase of mist.
4) Loosening or falling-off of the governor, com-
mon rod rink, each lever around the fuel injec-
tion pump, link pin, or bolt.
5) Deterioration of fuel oil or lubricating oil, or
damage of the cooling water pipe.
6) Abrupt increase or decrease of rotation speed.
7) Abrupt increase of lubricating oil temperature.
8) Water supply disabled due to suspension of
cooling water supply
In case that the engine is overheated due to
suspension of water supply, do not hastily
supply cooling water.
If cooled down abruptly, each part of the
engine may be deformed, resulting in malfunc-
tion or accidents.
9) Mixing of water into lubricating oil
10) Abrupt increase of exhaust air temperature
11) Abrupt decrease of the turbocharger rotation
speed or intake air pressure
12) Generation of abnormal sound in the propeller
or the stern shaft system
--------In case of the marine propulsion engine
13) Breakage or loosening of the bolts of each
section
CHAPTER
4
ITEM
DK-28e 6.2
(2) Measures after Emergency Stop
In case that the engine is stopped by activation
of the protective device or stopped automatically,
take the following measures:
a) In case that the engine is stopped by remote
operation or stopped automatically, set the
engine is stopped.
using heavy fuel oil, immediately switch the fuel
oil to diesel fuel oil, operate the motor-driven oil
feed pump, and conduct flushing of the fuel oil
system. (However, this procedure does not
apply when the fuel oil pipe is broken.)
Further, conduct turning of the engine, and
exhaust the heavy fuel oil remaining in the fuel
injection pump or fuel valve.
In case that the engine is stopped during the 4
operation using heavy fuel oil and the engine
is cooled down without changing the fuel oil,
heavy fuel oil in the equipment of the fuel oil
system (e.g. pump, filter, etc.) and piping will
not only solidify to prohibit restarting, but also
incur substantial labor to clean and cleanse
after the accident.
c) Disconnect the load off the engine, and return
the operating lever, each valve, and the state of
all other equipment to "STOP" position.
In case that an emergency stop is conduct-
ed, be minded not to restart the engine until
the cause is determined, the countermeasures
are taken, and recovery is completed.
In case that the engine is started without
removing the cause of the abnormality, the
malfunction may be aggravated and serious
accidents may be caused.
DK-28e Z 11-06
CHAPTER
Operation
4
ITEM
6.2,6.3 DK-28e Emergency Stop / Long-Term Shutdown

crankshaft several times while conducting prim-

ing with the lubricating oil.
Be minded not to open the crank case for at After turning, securely close the indicator valve.
least 10 minutes after the engine is stopped
c) Open the covers for the crank and cam cases
and is completely cooled down.
as well the cylinder head, and spray rust-pre-
If the crank case is opened immediately after
ventive oil to the internal parts.
the engine is stopped, flammable mist in the
d) Insert the moistureproof agent such as sil-
crank case may catch fire and explode.
icagel into the crank case, according to the
Particularly be careful when a large amount
ambient air conditions (e.g. weather and
of mist is generated due to overheat or seizing
humidity) and other necessity.
of the engine.
Be minded never to let flames or sparks e) Place the cover on outside air opening part of
approach the crank case even after it is the exhaust air pipe and the mist pipe.
opened. f) Cover the engine with a sheet, and carefully
cover the electric equipment with particular
attention to prevent collection of dust on them.
4-6.3 Long-Term Shutdown
In case that the operation of engine is suspend-
ed for a long term (one month or more), take the
preservation measures (mainly, anti-rusting meas-
ure) on the following procedure:

(1) Shutdown within 3 Months

a) Fully open the indicator valve once every
week, and conduct turning of the crankshaft
several times while conducting priming with
lubricating oil.
In this case, stop the crankshaft at a position
different from that before turning.
After turning, securely close the indicator valve.
b) In case that there is a risk of freezing in
extremely cold season, be minded to remove
cooling water from the engine.

(2) Shutdown beyond 3 Months--Measures for

A Long-Term Storage
In case that the operation of engine is suspend-
ed for 3 months or more, the following measures
for a long-term storage is required:

a) Remove cooling water from the engine.

b) Add rust-preventive oil to lubricating oil, open
the indicator valve, and conduct turning of the

DK-28e Z 11-06
 CHAPTER
Operation
4
ITEM
Long-Term Shutdown DK-28e 6.3

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

1.1 DK-28e Precautions for Inspection and Maintenance

5-1. Precautions for Inspection and Maintenance

When conducting the inspection and maintenance works of engine, be minded to read this
manual carefully, understand the structure of the related parts and the work contents, carefully
examine the working procedures, and prepare the consumable parts and tools in advance,
before starting these works.
If the works are conducted without previous and sufficient examinations, it will not only lead to
the expense of useless labors, but also result in failure or damage of the engine due to mistaken
assembling, and further in personal accidents.Be sure to replace all the damaged parts, or the
parts that have reached replacing limit, both of which have been so found after the results of
inspections.
In case that replacing these parts are difficult on site, or the necessary parts are not readied,
inform the Parts Sales Department, Service Department, Daihatsu Diesel Manufacturing Co., Ltd.
or the nearest branch office or shop, and take proper actions.

5-1.1 Safety Precautions

(1) Do not open the crank case side cover for at least 10 minutes after the engine is stopped and is
completely cooled down. While the engine is overheated, there is a danger that oil mist may
catch fire and explode if new air is flowed into the crank case when it is opened.

(2) If the engine is rotated during disassembly or inspection works, it may impose serious dangers
such as caught-up accidents and so on.
Be minded to start these works, after returning the operating lever to "STOP" position, securely
closing the starting air valve, and confirming that the engine is not running.
When conducting the turning of engine, be minded to start it after confirming that nothing is in
contact with the rotational parts, and no danger is imposed on coworkers by the rotation of
engine, and after sending the signal to them.
Perform a proper preventive measures to prevent the crankshaft from freely turning.

(3) Be minded to wear the protective gears such as safety glove, helmet, safety shoes, safety gog-
gles, according to the circumstances.
During the operation of engine and immediately after stopping the engine, the engine parts, partic-
ularly exhaust manifold, turbocharger, parts round the cylinder are extremely hot. Therefore, be
sure to wear safety gloves, and proceed the works taking care not to incur burns.
The engine room floors and the surrounding areas are slippery due to oils stuck on them.
Therefore, be minded to start the works after sufficiently wiping off the oils stuck on floors or shoe
soles. Particularly when working on a high-rise places such as on the foot-step board, pay
enough attentions to the periphery of your feet, so that falling-off accidents should not happen.

(4) When disassembling the piping systems, "Close" all the valves of the external connection parts,
gradually warm up the air vent plug, and start the disassembly after removing residual pressure.
Immediately after stopping engine, when disassembling the filters and connection parts of piping
systems, you may burn on your skin on a injected high temperature oil or water of residual pres-
sure. If high temperature parts are splashed with the fuel oil or the lubricating oil, a fire may
occur. Take utmost care when disassembling them.

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Precautions for Inspection and Maintenance DK-28e 1.1,1.2

(5) When disassembling the spring-loaded devices such as the regulation valves, proceed the works
paying careful attentions, since there is a risk that the springs may fly out and injury accidents
may occur.

(6) Be minded to use wire rope and chain block when suspending the heavy-weight parts or equip-
ment, and do not try to forcibly raise these parts or equipment by physical force. Further, be
minded not to approach the areas immediately under the suspended parts or equipment.
(7)When handling the electric parts, be sure to cut off the power source.

(8) When handling the liquids, be minded to strictly observe the following items:
Flammable liquids such as fuel oil and lubricating oil, the sources of fire, e.g.: The source of fires
such as flames or sparks are strictly prohibited.
Poisonous substances such as rust-preventive agent for fresh water, anti-freeze solution for fresh
water, mercury (thermometer): Drinking is prohibited, and if any of these has stuck on hands or
skin, immediately wash it off.
Poisonous substance or substance which generate flammable gas, such as battery liquids:
Drinking is prohibited, and if any of these has stuck on hands or skin, immediately wash it off, and
the source of fires such as flames or sparks are strictly prohibited.
䃁 For the sake of preventing environmental contamination, be minded to entrust the disposal and
treatment of the waste oils and liquids to the authorized special waste disposing company.

5
5-1.2 Cautionary Items When Finishing Inspection and Maintenance

(1) Restore the lagging or heat-preventive covers, combustible oil splash preventive means (FN tape)
and protective covers, that have been removed for inspection and maintenance, to each original
position.

(2) After the completion of assembling, confirm that there is no abnormality in each part, by conduct-
ing the turning of engines and the priming with each corresponding oil.
After checking the parts during turning, close the reducing valve without fail.

(3) After the completion of working, return the turning equipment and turning bar, that have been
used, to "OFF" position.

(4) Record the work contents of the inspection and maintenance that have been performed, and the
replaced parts in the daily report respectively.

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

2 DK-28e Inspection and Maintenance Item Table

5-2. Inspection and Maintenance Item Table

This table shows the inspection and maintenance work items (basically, those to be performed within 6
months). As for the work items concerning the regular overhaul and maintenance after the long-term opera-
tion, refer to the corresponding sections of "Maintenance" version, which is separately provided.
（ 䂾 ：Normal, 䂥 ：Initial operation and 1st operation after overhaul, 䃂 ：Initial operation after installation, overhaul,
and maintenance, 䃁 ：Replacement）

before operation
Intervals (Hours)
Ref.

1000-1500
Parts to be

2000-3000
3 months

6 months
Inspection
Remarks

300-500
Monthly
Descriptions

Weekly
Daily
inspected

Engine appearance Check loose parts and leaks. 䂾 䂾

P i p i n g s y s t e m Check loose parts and leaks. 䂾 䂾
Cylinder head cover Check internally. (Valve end clearance, rotator) 䂥 䂾 5-4.1
Including when
Cylinder head Check and tightn head bolt. 䂥 overhauling
Fuel injection pump Remove and check valve. Clean and adjust it. 䂥 䂾 5-4.2
Including when
Connecting rod Check and tighten connecting rod bolt. 䂥 overhauling
Cylnder liner Visually check internal surface. 䃂 䂥 䂾
Crankshaft Measure and adjust deflection. 䂥 䂾 5-4.6
Camshaft Check cam and roller. 䂥 䂾
Governor Check and supply hydraulic oil. 䂾 䂾 䃁 4-2.1 䃁 Replace hydraulic oil.
Fuel control link Check movement and supply oil. 䂾 䂾 4-2.1
Clean filter. 䃂 䃩䂾 4-2.2 䃩150-200 hr
Turbocharger Clean blower. 䃩䂾 5-4.4 䃩150-200 hr
Clean turbine. 䃩䂾 5-4.5 䃩200-250 hr
Starting rotary valve Drain water. 䃂 䂾
Check pressure. 䂾 䂾 4-2.1
Starting air tank
Drain water. 䃂 䂾 4-2.1
Lubricate pump rack. 䃂 䂾 4-2.1
Fuel injection pump
Check reading on rack scale. 䂾 5-3.1
Drain water. 䂾 䂾
Fuel oil filter Clean by blowing-off. 䂾 5-4.3
Overhaul, check, and clean filter. 䃂 䂥 䂾 5-4.3
Drain water. 䂾 䂾
Main engine Clean by blowing-off. 䂾 5-4.3 Notch-wire filter
Lubricating oil filter

Overhaul, check, and clean filter. 䃂 䂥 䂾 5-4.3

Auxiliary engine ( Refer to the separate manual. ) Automatic back-washing filter"
Drain water. 䂾 䂾
Turbocharger Clean by blowing-off. 䂾
䃂 䃩䂥 5-4.3 䃩Supply grease to
Overhaul, check, and clean filter. driving section
Fuel injection pump Overhaul, check, and clean filter. 䃂 䂥 䂾 2-2.1
Check oil level and supply oil. 䂾 䂾 4-2.1
Lubricating oil tank
Analyze and examine oil. 䃂 䂾 6-2
Lubricating oil
temperature control valvel Overhaul, check, and clean valve. 䂾 5-3.2
Fresh water filter Overhaul, check, and clean filter. 䃂 䂾
Check water level, and supply water. 䃂 䂾
Fresh water tank
Check water quality. 䃂 䂾 6-3
For air cooler; Check and replace. 䂾 5-4.7
Protactive zinc
For lubricating oil cooler; Check and replace. 䂾 5-4.7
gauge board Check thermometer and pressure gauge. 䂾
Controlling and
protective device Check and confirm movement. 䃂 䂾
Note : This table shows the standard inspection intervals for inspection and maintenance to be conducted under normaru
operating conditions when heavy fuel oil is used. Determine the most adequate interval of inspection and maintenance,
in accordance with the operating conditions and insupection results.

e
DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment: Maximum Combustion
Pressure and Exhaust Air Temperature DK-28e 3.1

5-3. Measurement and Adjustment

5-3.1 Maximum Combustion Pressure Since the indicator valve is extremely hot
and Exhaust Temperature during the operation of engine, there is a dan-
Maximum combustion pressure and exhaust ger of burns if it is touched by bare hands.
temperature serve as the important indicators for Therefore, be sure to wear safety gloves
knowing the engine combustion conditions and the when handling the valve.
changes according to the elapse of time.
Normally, the decrease of the engine perform-
ance can be indicated by the following irems. Indicator (A)
Exhaust valve (E)
Decrease of the maximum combustion pressure
Increase of the exhsust temperature
Lock nut (D)
Conduct the measurement with the interval of
Indicator catch (C)
once a week or so, and record the resuits, so that
the tendency of the change can be identified and
the data can be used as the judgment materials
when determining the interval of the adjustment. Close

(1) Maximum Combustion Pressure

(hereinafter referred to as Pmax)
a) Pmax
Open
Pmax is determined by load, and varies
depending on the factors such as the fuel oil
viscosity, intake air pressure, and intake air
temperature. Odinarily, however, this adjust- 5
ment is not necessary. Wrench for
Pmax varies according to the initial fuel injec- indicator valve
tion pumping angle, however, it is readily
adjusted and set at an optimum value at the
Safty valve Indicator valve (B)
time of shipment from our factory.
The fuel cam is fixed to the camshaft by shrink
fitting, and therfore, ordinarily, it cannot be
adjusted.

Since the items mentioned in this section will
be he items, to which the engine setting value
specified in Nox techical code shall be
applied, do not make any change that may
deviate from the setting value.
（ ：0-3 "Engine Conforming to Nox Tec
hical Code"）
Be sure to "Fully open" or "Fully close" both
the indicator valve and the exhaust valves are
used.
If these valves are used on the "Half-open"
state, high-temperature gas will flow into the
threaded parts of the valve, and the screws
may be seized.

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment: Maximum Combustion
3.1 DK-28e Pressure and Exhaust Air Temperature

b) Measuring Pmax (3) Adjustment of Reading on Fuel Injection

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

Maximum value (when fully loaded):

17.7 MPa {180 kgf/cm2}
Difference between cylinders:
0.6 MPa {6 kgf/cm2}
Rack lever

(2) Exhaust Temperature

The exhaust temperature at each cylinder out- Lock nut (B)
let slightly varies from one cylinder to another
Rack link
depending on the factors such as the effect of
other cylinders as well as the distance to the tur-
bocharger inlet.
The exhaust temperature can be adjusted by Common rod
increasing or increasing the reading on the fuel
injection pump rack, however, the adjustment is Decrease
ordinarily unnecessary as long as the difference Ajjusting
between cylinders is within the following value. screw (A)
Increase
Difference between cylinders: 40℃ or less
Adjusting of Rack

e
DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DK-28e 3.2

5-3.2 Pressure and Temperature of
Each Part
The pressure and temperature of lubricating oil,
fuel oil, and cooling water, etc. are controlled by
the relief valve, so that they should be proper val-
ues being within each specified value during the
operation of engine, however, when actually
operating the engine, the pressure and tempera-
ture of these fluids may not be within the speci-
fied and proper values.
In such a case, readjust the setting values of
the valves, and perform the operation within the
specified proper range.
(1) Intake Air Pressure
Since the intake air pressure changes in accor-
dance with load, each pressure when the engine
was new (or, after adjustment) becomes a refer-
ence value.
The more the turbocharger is fouled, the more
the intake air will decrease, resulting in the deteri-
oration of the engine performance (e.g. increase
of the exhaust air temperature and increase of
the fuel consumption rate), and therefore regular-
ly conduct the blower cleaning and prevent the
progress of fouling.
fore be minded to adjust and keep the tempera-
ture to be within the specified proper range, as far
as possible.
When the intake air temperature is too low, it
causes abnormal or excessive wear of the cylin-
der liner, intake air valve, etc., since the water
drops is formed by the dew condensation.
Further, if the intake air temperature is too high, it
damages the parts around the combustion cham-
ber such as the exhaust valve, since the exhaust
air temperature will increase. (Exhaust air tem-
perature varies in proportion to the intake air tem-
perature, and also varies in the rate of approxi-
mately 2 times the change of the suction air tem-
perature of the turbocharger.)
<Intake Air Adjusting Procedure>
The intake air adjustment can be made by chang-
ing the cooling water flow rate in the air cooler.
i ) Operate the handle of the bypass valve (A),
and change the opening angle of the valve.
Open the bypass valve. (Handle facing side-
ways) → Increase of temperature
Close the bypass valve (Handle facing
downward) → Decrease of temperature

（ ：5-4.4 "Cleaning Turbocharger Blower"）

ii ) Be attentive to changes of the intake air tem-
perature, and open the bypass valve so as to
5
be within the proper range, and adjust the
angle.
The turbocharger is at a high-temperature
during operation and just after the engine is
stopped. If you touch it with bare hands dur-
ing cleaning, you may burn your hands. Wear
safety gloves without fail.

It is impossible to completely remove the

fouls even when cleansed by blower cleaning,
and to prevent the deterioration of engine per-
formance by the elapse of time, however, if
the cleaning is neglected, fouling will acceler-
ate, resulting in worsening of the engine per-
formance, and as the result it will be required
to disassemble and clean the turbocharger
much earlier than when the cleaning is period-
ically conducted.

(2) Intake Air Temperature

Proper temperature: 45-55℃ (at full load)

Intake air, that is either higher or lower than the

specified range, will affect the engine, and there-

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
3.2 DK-28e Pressure and Temperature of Each Part

<Lubricating Oil Pressure Adjusting

Procedure>
1) In case of changing the orifice (B), be atten- When adjusting the lubricating oil pressure, use
tive to the temperature and pressure the adjusting screw on the lubricating oil regulat-
changes of the rated equipment such as the ing valve.
lubricating oil cooler connected to the same
i ) Remove the screw cap (A), of the relief valve,
cooling water channel as well.
and loosen the lock nut (B).
2) Do not totally close the orifice (B).
ii ) Turn the adjusting screw (C), and adjust the
pressure.
In case that the intake air does not fall within
the proper range even when the bypass valve is Clockwise turning (tightening)
fully opened and the entire amount of cooling → Increase of pressure
water is flowed into the air cooler, it is required to Counterclockwise turning (loosening)
disassemble and adjust the air cooler since the
→ Decrease of pressure
fouling of the air cooler can be considered.
iii) Be attentive to changes of the pressure, and
（ ：12-3 "Air Cooler, "Maintenance Manual）
confirm that the pressure has entered within
the blue mark range.
(3) Lubricating Oil Pressure iv) Tighten the lock nut (B).and attach the cap (A).
Proper range of engine inlet lubricating oil
pressure (Blue mark range of manometer):
0.4 ~ 0.55 MPa {4 ~ 5 kgf/cm2}
Proper range of turbocharger inlet lubricating
oil pressure (Blue mark range of manometer):
0.06 ~ 0.15 MPa {0.6 ~ 1.5 kgf/cm2} Cap (A)

Lubricating oil pressure changes in accordance Decrease Increase

with the changes in the viscosity and temperature
of lubricating oil. Lock nut (B)
Adjusting screw (C)
When the engine is started in extremely cold
weather, and the temperature of the lubricating oil
is still low and the viscosity is high, the pressure T/C Valve
reading may go up beyond the blue mark range,
however, it does not impose any problem if the
reading falls back within the blue mark range
when the engine is warmed up.
In case that the pressure reading is beyond or
under the blue mark range, adjust the pressure
on the following procedure:
Relief

Lubricating oil pressure decreases when the

filter is fouled. Be sure to perform the adjust-
ment of pressure after the filter is cleaned Engine
well.
（ ：5-4.3 "Cleaning Filters"） Lubricating OIl Pressure Adjusting procedure

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DK-28e 3.2

Use range: 30 - 60℃ (Cooler outlet)

In case that the lubricating pressure does Since the oil temperature changes according
not change even when the adjustment screw
to the load, be minded to set the oil tempera-
is turned, there is the possibilities of sticking of
ture at a rather lower level, so that it will not
the relief valve, suction of air, pump failure,
and so on, and therefore investigate the caus- exceed the limit when heavily loaded.
es of the trouble.

(4) Lubricating Oil Temperature


 
Proper range: 50 - 60℃ (cooler outlet) 
 
 
Lubricating oil temperature is controlled to
remain within the proper range of temperature by
the automatic temperature control valve installed
at the lubricating oil cooler outlet.

a) Lubricating Oil Temperature Control Valve

The temperature control valve is an automatic
bypass valve, that changes the flow rate of lubri-
cating oil passing through the cooler, according to
its temperature, and when the engine is started
while it is still in cold state, this valve rapidly rais- 

es the lubricating oil by letting the oil bypass
through the cooler, and when the engine is oper-
5
ated normally, this valve maintains the lubricating
oil to be within the suitable range of the specified (5) Cooling Water Pressure
value.
In case that the lubricating oil does not fall with-
Proper range: 0.25 ~ 0.35 MPa
in the proper range, for example, because the
{2.5 ~ 3.5 kgf/cm2}
cooling water (secondary water) temperature is
different from the design temperature, the temper- Jacket cooling water pressure substantially
ature of lubricating oil can be adjusted by the changes depending on the external conditions
adjusting screw of the temperature control valve. such as the cooling water expansion tank head,
However, in case that the actual temperature is pipe resistance, and so on.
o
exceeding the correctable range (about 5 C) and When cooling water pressure is too low, it will
the adjustment is impossible, contact us for con- cause corrosion of the engine frame or cylinder
sultation on the problem. liner, and therefore adjust the cooling water pres-
sure at the engine outlet using the valve or orifice,
b) Manual Adjustment-Emergency Measures so that the pressure should be proper during the
In case that the temperature control valve has operation of engine.
become faulty and the temperature control has
become impossible, the engine can continuously
be operated by performing the emergency meas-
ures on the following procedure.
（ ：Separately provided "Instruction Manual
of Temperature Control Valve"）

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
3.2 DK-28e Pressure and Temperature of Each Part

(6) Cooling Water Temperature iii) Closely watch the change of the pressure,
and confirm that the pressure reading is within
the proper range.
Proper range: 70 ~ 75℃ (engine outlet)
iv) Tighten the lock nut (B), and attach the screw
cap (A).
a) Warming-Up Operation
When jacket cooling water temperature is too
low, it will cause faulty combustion or the corro-
sion or wear of the parts around the combustion
chamber, and therefore be minded to start the
operation of engine with load after raising the
cooling water temperature by warming-up
operation.
（ ：4-4.2 "Warming-Up Operation"）

b) Temperature Control
Cooling water temperature is controlled to
remain within the proper range by the tempera-
ture control valve installed between the jacket
cooling water inlet and outlet pipe {fresh water
cooler inlet and outlet pipe). 
This temperature control valve is an automatic 

bypass valve that is functionally identical with the
lubricating oil temperature control valve.  
 

（ ： 5-3.2(4) "Lubricating Oil Temperature")



(7) Fuel Oil Pressure


 

a) Engine using Heavy Fuel Oil
When using heavy fuel oil, the pressure of
heavy fuel oil must be adjusted to be within the
following range, so that generation of vapor due When the engine with heavy fuel oil specifica-
to heating-up of the fuel oil can be prevented: tion is operated by diesel fuel oil, the fuel oil pres-
sure does not decrease since the fuel oil cannot
Proper range: 0.5 - 0.6 MPa {5-6 kgf/cm2} be pressurized as in the heavy fuel oil supply line,
however, the adjustment of the fuel oil pressure is
not required if the pressure is above the following
<Fuel Oil Pressure Adjusting Procedure>
value.
Adjustment of fuel oil pressure can be made by
the pressure adjusting screw of the fuel oil relief 0.2 MPa {2 kgf/cm2}
valve.
i ) Remove the screw cap (A) of the relief valve,
and loosen the lock nut (B). b) Engine using Diesel Fuel Oil
ii) Turn the adjusting screw (C), and adjust the
pressure. Proper range: 0.2 - 0.3 MPa {2-3 kgf/cm2}
Clockwise turning (tightening)
→ Increase of pressure In case of diesel fuel oil specification, the pres-
sure adjustment procedure is the same as in case
Counterclockwise turning (loosening)
of heavy fuel oil specification, since the same
→ Decrease of pressure type of the fuel relief valve is used in both cases.

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Measurement and Adjustment:
Pressure and Temperature of Each Part DK-28e 3.2

(8) Fuel Oil Temperature ... When Using Heavy .

Fuel Oil
Heavy fuel oil must be heated so as to make its
viscosity suitable for injection, before the oil is sup-
plied to the engine.

Proper viscosity (engine inlet) dynamic

viscosity: 14 ± 1.5 mm2/s

Since the temperature appropriate for proper

viscosity varies depending on the properties (vis-
cosity) of heavy fuel oil, be minded to keep the
proper viscosity referring to the following figure as
the standard:
（ ：Fig. 6-1.1 "Fuel Oil Viscosity /Temperature
Curve"）
In case that the viscosity controlle (automatic
viscosity regulator) is installed to the engine, con-
trol the fuel oil viscosity in accordance with instruc-
tion manual, and be minded to carefully keep the
manual.
（ ：4-4.4 "Operation Using Heavy Fuel Oil"）

（ ：6.1 "Fuel Oil Characteristics and Control"）

5
Heated fuel oil is extremely hot. Touching it
or metallic parts of the oil carrying equipment
with bare hands or skin can cause burns.
Be sure to wear protective gear such as
safety gloves when handling oil or the oil
carrying equipment.

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM
Inspection Parts around Intake Nd Exhaust Vlves, and
4.1 DK-28e Adjusting valve End Clearance

5-4．Inspection and Maintenance Further, the valve system of this engine is 4-

5-4.1 Inspecting Parts around Intake
and Exhaust Valves, and
Adjusting Valve End Clearance
(1) Replacing Consumables, Implements, and
Measuring Instruments
a) Replacing Consumables （ "Parts List"）
1) Head cover rubber seal 3-20 No.6
b) Implements and Measuring Instruments
1) General tools
( ："Implements List" in the final documents)
valve type, having 2 intake valves and 2 exhaust
valves, and a single valve holder tee is provided to
simultaneously push down both pairs of intake and
exhaust valves, and therefore unless the valve end
clearance of each pair of both intake and exhaust
valves is equal, the valve pushing force will be
unbalanced, resulting in abnormal wear or damage
of the valve holder tee and the guide parts.
Exhaust valve
rocker arm
Inlet valve
rocker arm

(2) Inspecting Parts around Intake and Exhaust

Valves
Both intake and exhaust valves are the parts
that are exposed to the most severe conditions
among all other parts of the engine. Therefore, be
minded to periodically inspect these valves, and
confirm that both valves operate normally.
a) Confirm that there is no abnormal operating
sounds in both the intake and exhaust valves Push rod
during the operation of engine.
b) Check the following points on these valves Valve End Clearance Adjusting Procedure
removing the cylinder head cover when the
engine is stopped.
i ) Lubricating conditions of the rocker arm and
push rods
ii ) Lubricating and sludge collecting conditions of
the intake and exhaust valve cotters, and
valve rotators
iii) Sludge collecting conditions around the valve
spring
iv) Rotating conditions of the valve rotators
( ："Inspection and Maintenance of Vatve
Rotators", Maintenance Manual)
v) Valve end clearance
<Valve End Clearance Adjusting Procedure>
(3) Adjusting Valve End Clearance
Since valve end clearance decreases due to the i ) Place the cylinder in the explosion stroke, and
wear of the valve seat part, and therefore be mind- close the intake and exhaust valves.
ed to periodically inspect and adjust it. ii) Loosen the lock nuts of the adjusting screws
When the valve end clearance is too small, it will (A) and (B) and turn back the adjusting screw
cause improper setting of the valve on its seat dur- (A) and (B).
ing the operation of engine due to thermal expan- iii) Closely fit the valve end "A", place the dial
sion of the valve itself and push rod, resulting in gauge against the valve holder tee, and tighten
burning of the seat.

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspecting Parts around Intake Nd Exhaust Vlves, and Adjusting
valve End Clearance / Inspection of Fuel Oil Injection Valve DK-28e 4.1,4.2

the adjusting screw (A) until the scale pointer b) Implements and Measuring Instruments
swings, so that it can be confirmed that the 1) General tools and measuring instruments
valve ends "A" and "B" are both closely fit at
the same time. ( ：Final Documents）
iv) ) Engage a spanner around the hexagonal 2) Nozzle holder extracting implement
head of the adjusting screw (A) and tighten the 3) Fuel oil injection testing device
lock nut while paying attention so that the 4) Nozzle cleaning implement
screw and the nut do not slip and turn.
v) Insert a thickness gauge of the specified thick- (2) Extracting Fuel Oil Injection Valve
ness into the clearance "C" on the top part of Extraction of the fuel oil injection valve can be
the valve holder tee, and adjust the clearance conducted on the following procedure:
using the adjusting screw (B).
<Extracting Procedure>
Proper clearance: 0.5 mm ( : In case of heavy fuel oil specification)
(for both intake and exhaust valves) i ) Remove the cylinder head cover and heat
box cover (upper side only)
ii ) Close the valve of the nozzle cooling water,
5-4.2 Inspecting and Maintenance of and drain the water completely
Fuel Injection Valve
Since the conditions of the fuel injection valve
substantially affect the performance of engine
operation, be minded to periodically inspect it and
conduct the maintenance.
However, in case that remarkable changes have
been found in the maximum combustion pressure, Bolt (F) Nut (D)
5
exhaust temperature, exhaust color, and so on, be O-ring
minded to conduct immediate inspection and main- O-ring
tenance, regardless of the standard inspection and
maintenance period.
Bolt (E)
Since the items mentioned in this section will O-ring
be the parts to which NOx Technical Code Fuel injection
High-pressure valve (A)
shall be applied, when replaacing any of these Circular gasket (G)
fuel coupling (B)
parts, be sure to use the parts provided with Inlet connector (C)
the identification marks.
( :0-3 "Engine Conforming to NOx Bolt (F)
Technical Code"）

(1) Replacing Consumables, Implements, and Bolt (E)

Measuring Instruments High-pressure
fuel coupling (B)
a ) Replacing Consumables （ :"Parts List"）
1) Circular gasket 3-18.1 No.508
2) O-ring 3-18.1 No.12
3 ) O-ring 3-18.1 No.510
4) O-ring 3-18.1 No.511
(Heavy fuel oil)
5) O-ring 3-18.1 No.512

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.2 DK-28e Inspecting and Maintenance of Fuel Injection Valve

iii) Loosen the bolts (E) and (F), and remove

the fuel high-pressure block (B).
Nozzle holder
iv) Remove the inlet connector (C). extracting
v) Remove the tightening nut (D) using a box implement (2)

wrench.
vi) Extract the fuel oil injection valve (A)
using a fuel oil injection extracting imple-
ment.
vii) Remove the circular gaske (G).

1)Be careful so that the circular packing (G)

may not be left behind in the cylinder head.
2)After removing the high-pressure fuel cou- Nozzle Holder Extracting Procedure
pling and fuel injection valve, be minded to
place the cover both on the coupling part of
the fuel oil injection pump and on the inser-
tion part of the cylinder head.

(3) Injection Test

Conduct a fuel injection test of the fuel injection
valve, to check if the opening pressure and the
spraying conditions of the fuel injection valve is in
proper and normal state.
Conduct the fuel injection test using the fuel
Special gasket
injection test device (3) installed to the engine.
Joint PT3/8
a) Inspecting Valve Opening Pressure
i ) Install the fuel injection valve on the injection test
device, after removing the carbon stuck on the High-pressure
hose
tip of the injection valve, and cleaning the tip. Tester side
ii) Connect the test pump and the fuel injection
valve using a high-pressure hose for testing. Female
coupler
iii) Quickly operate the test pump lever several
times, and drain the air until the valve starts
injection of the fuel as the pressure indicating
scale swings.
Mail coupler
iv) Slowly turn the test pump lever (once every
second, or so), check the pressure reading Nozzle holder joint
(the pressure, that has once increased gradu- Test pump side
ally, suddenly starting to decrease due to Nozzle holdder joint
opening of the valve).
Injection Test Procedure
Normal pressure: 27.4 ~ 29.4 MPa
{280 ~ 300 kgf/cm2}

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspecting and Maintenance of Fuel Injection Valve DK-28e 4.2

Screw driver
b) Adjusting Valve Opening Pressure
When reassembling the fuel injection valve Cap nut (a)
after conducting the maintenance work by extract-
ing the valve out of the engine, and when the noz-
zle is replaced with a new one, adjust the valve Adjusting
pressure on the following procedure. screw (b) Lock nut (c)

Since the items mentioned in this section will

be the parts to which engine setting value
specified in NOx Technical Code shall be con-
firmed, do not make any change that may
deviate from the setting values.
( :0-3 "Engine Conforming to NOx Technical Code"）

Pressure Adjusting Procedure

<Valve Opening Pressure Adjustment
Procedure>
Setting pressure:34.3 MPa {350 kgf/cm2}
i ) Remove the cap nut (a).
Be minded to set the pressure of the fuel
ii) Loosen the lock nut (c) for the adjusting screw (b). injection valve at a rather higher level, taking
iii) Adjust the pressure to the specified pressure into consideration the initial accustoming, in
by turning the adjusting screw using a screw- case that a new injection valve is introduced.
driver, while conducting the injection of the fuel -------30.4 MPa {310 kgf/cm2}
oil, as in the same procedure as in case of the
fuel oil injection test. Needle valve 5
Screwing-in adjusting screw ------ High
Turning-back of adjusting screw --- Low Fuel
iv) Tighten the lock nut (c).
Blank
Nozzle paper
c) Inspecting Fuel Oil Injection
Inspect the fuel oil injecting conditions on the
following procedure:
i ) Quickly operate the test pump lever several
Normal Injection
times (2 to 3 times every second), and inspect
the fuel oil injecting conditions. (Let the fuel oil
injected against a blank paper so that the con-
ditions can be better inspected.)
Check if the cutting-off of injection is good
or not. --- Injection sound
Check if injection is evenly and clearly (A) Clogged nozzle (B) Improper (C) Droopy nozzle
sprayed. needle valve action
Check if injection is not bar pattern, nor Abnormal Injection
dripping down..
ii) Check if there is no dripping-down of fuel oil
from the tip of the nozzle after the injection Be minded not to approach your face or
test. hands near the fuel spray during testing.
If the high-pressure fuel has hit your face or
hands, it will cause injuries.

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.2 DK-28e Inspecting and Maintenance of Fuel Injection Valve

(4) Disassembling and Inspecting Nozzle

In case that a remarkable decrease of the valve Retaining nut (f) Hammer
opening pressure, faulty injection of fuel oil, or
dripping-down of fuel oil after injection is found as Nozzle (e)
the results of the fuel injection test, conduct disas- Patch
sembling, cleaning, and inspection on the following
procedure:

a) Disassembling the Nozzle

i ) Remove the cap nut (a).
ii) Loosen the adjusting nut (b).
iii) Fix the holder housing (d) in a vise, and loosen Vice
the retaining nut (f).
iv) Extract the needle valve out of the Nozzle (e). Extracting
v) Extract the nozzle out of the retaining nut by Holder housing (d) needle valve
striking with a hammer, while placing a pipe-
type patch on the nozzle so as not to damage
the injection hole of nozzle.

Nozzle cleaning
implement
If the retaining nut is turned while the adjust-
ing nut is still tightened, it will damage the
nozzle or nozzle holder parts.
In case that heavy fuel oil is used, the retain-
ing nut and nozzle may be stuck together with
carbon accumulated on them.
If the nut is loosened in this state, the nozzle
will turn together with the nut, and may dam- Nozzle Cleaning Procedure
age the nozzle, or the knock pin of spacer,
and therefore first lubricate the nut with gas
oil, and then carefully loosen the nut by strik-
ing the nozzle with a hammer, while placing a 1) Since the nozzle and needle valve is a pair
patch on the nozzle. functioning together, be minded not to
replace either of them separately.
2) Do not try to reuse a faulty nozzle by wrap-
ping, but be sure to replace it with a new
b) Inspecting Nozzle
one.
i ) Clean the nozzle nut and needle valve with gas
oil.
ii) Clean the nozzle hole using a nozzle cleaning
implement (4).
iii) Push in and push out the needle valve with
your hand, and check the movement.
Check if the movement is smooth or not.
Check if the movement is too loose.

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspecting and Maintenance of Fuel Injection Valve DK-28e 4.2

(5) Assembling Fuel Oil Injection Valve
Assemble the fuel oil injection valve in the
reverse order of the disassembling procedure.
i ) Clean each of the disassembled parts with
clean gas oil, and insert each of them back
into the holder housing (d).
ii) Put the spacer and the knock pin of nozzle
together, and install them into the holder hous-
ing.
iii) Apply the lubricating agent (Molykote U paste)
on the holder housing thread, the seating face
of the retaining nut (f), and the outer periphery
of the nozzle, and screw the retaining nut into
the holder housing by your hand.
iv) Loosen the adjusting nut (b).
v) Tighten the retaining nut (f) with the specified
torque.
Specified torque: 353 ~ 382 N.m
{ 36 ~ 39 kgf.m }
hole of the cylinder head, after confirming that
the old gasket is not left behind in the guide
hole.
iv) Fit the O-ring of the nozzle holder flange (Q),
and apply grease on the O-ring.
v) Insert the nozzle holder flange into the inlet
connector (L), and apply lubricating oil to the
thread, then tighten them with the specified
torque after screwing them into the holder
housing.
v) Screw in the inlet connector with hand, and
tighten it with the specified torque.
Specified torque: 49 ~ 59 N.m
{ 5 ~ 6 kgf.m }
vi) Attach the high-pressure fuel coupling and O-
rings on the cylinder head side and fuel injec-
tion pipe side, tighten the high-pressure fuel
coupling tightening bolt (E) and (F) with the
specified torque.

Specified torque: 59 N.m

Be careful not to tighten the retaining nut
with the torque over the specified value, since
it may cause the sticking of the needle valve
{ 6 kgf.m }
5
of the nozzle. vii) Attach the O-rings on the cylinder head side
of the high-pressure fuel coupling and on the
vi) Set the fuel oil injection valve on the injection fuel oil injection pump side, and apply the lubri-
test device, and adjust the valve opening
cating agent (Molykote 1000 spray) to the
pressure.
thread surfaces of the high-pressure fuel cou-
（ ： 5-4.2 (2) "Fuel Injection Test"）
pling tightening bolt (G) and (H), then tighten
them with the specified torque.
(6) Mounting Fuel Oil Injection Valve
Mount the fuel injection valve to the cylinder
Specified torque
head in the reverse order of the extracting proce-
Tightening bolt (E): 59 N.m {6 kgf.m}
dures.
Tightening bolt (F): 74 N.m {7.5 kgf.m)
i) Apply heat-resistant agent on the O-rings, and
attach them to the holder housing (d).
ii) Apply grease on the circular gasket, and fit it to
the holder housing (d). (To prevent the circular
gasket from falling off into the guide hole of the
cylinder head.)
Apply heat-resistant agent on the circular gasket,
and attach it to the holder housing.
iii) Insert the fuel oil injection valve into the guide

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.3 DK-28e Cleaning Filters

5-4.3 Cleaning Filters be minded to periodically conduct blow-off clean-

ing. In case that the oil pressure does not
Fuel oil filters and lubricating oil filters have very
increase even after the blow-off cleaning has been
important roles, i.e., removing foreign matters or conducted, overhaul the filter and then clean it.
sludge in oil and keeping the oil clean, and maintaining
the normal operation of the various parts of engine. a) Replacing Consumables
Therefore, it is important to periodically overhaul [ For fuel oil ] ( :"Parts List")
and clean, so that filtering capabilities can be
1) Gasket 4-2.3.1 No. 174 (Diesel fuel oil)
maintained.
2) Gasket 4-2.3.1 No.144 (Diesel fuel oil)
The notch-wire duplex type filter is used as the
3) Element gasket 4-2.3.1 No.260 (Diesel fuel
filter for fuel oil, for engine lubricating oil (applied in
oil)
the case of main engine) and for turbocharger
lubricating oil. 4) Gasket 4-2.3.1 No. 106 (Heavy fuel oil)
An automatic backwash cleaning filter is used as 5) Gasket 4-2.3.1 No.267 (Heavy fuel oil)
the filter for engine lubricating oil (applied in the 6) Element gasket 4-2.3.1 No.266 (Heavy fuel
case of auxiliary engine).
oil)
Y-type filtyer are used as the filter for lubricating
oil of the fuel injection pump.
[ For lubricating oil ] ( :"Parts List")
However, which type should be used depends (Main plopulsion engine)
on the specification of each engine, and please
1) Gasket 4-3.4.1 No.168
refer to the Engine Specification.
2) O-Ringt 4-3.4.1 No.149
（ : Seperately provided "Engine
3) Element gasket 4-3.4.1 No.246
Specification"）

(1) Notch-Wire Duplex Type Filter [ For turbocharger ] ( :"Parts List")

The notch-wire duplex type filter is normally 1) Gasket 4-3.5.1 No.173
used as both-side-parallel application. 2) Gasket 4-3.5.1 No.143
Since both the fuel oil pressure and lubricating
3) Element gasket 4-3.5.1 No.260
oil pressure decreases if the filter has been fouled,
Air vent valve (D)

b) Blow-Off Cleaning
In case of blow-off cleaning, deposits can be
removed by reversely flowing the fluid through the
Case (C) element on one side, and this type of cleaning
has no cleaning effect when the element is sub-
stantially clogged, and therefore be minded to
Handle (A) conduct the blow-off cleaning in an earlier state,
while the fouled degree of filter is still light. (The
cleaning should be conducted at least once a
week.)

Drain cock (B)

Notch-Wire Type Filter

e
DK-28e Z 11-06
P
 CHAPTER
Inspection and Maintenance
5
ITEM
Cleaning Filters Notch-Wire Type Filter
DK-28e 4.3

<Blow-Off Cleaning Procedure>

Filters used on both sides "P
P"
i ) Open the drain cock (B) at the bottom part of fil-
ter. At this time, be careful so that waste oil may
not scatter or overflow out of the drain cock. 90 90
Blow-off on Blow-off on
ii) Turn the selector cock handle (A) (usually, set left filter "Q
Q" 60 60 right filter "Q
Q"
to "Used on both sides (P)" position ) to the
o
"Blow-off" position (Q) (about 60 ), and quickly
Left filter Right filter
conduct the operation to return the handle to shut off shut off
the previous position (within 0.5 - 1 sec.) Handle A
iii) Repeat this operation 2 - 3 times. C1 Blow-off
C1
iv) Conduct the above same procedure on the other side. C1
C3
C3
v) Close the drain cock. C3

E1 E2 E1 E2 E1 E2

Conduct the blow-off cleaning quickly.

Further, do not place the lever on the middle
position, but quickly move to the specified C2 C2 C2
position (knock position). When both filters Blow-off on One side shut off
are used right filter
If too much time has been taken in blow-off E1,E2


Right and left elements
cleaning and switching the lever positions, the C1


Selector cock inlet hole Interlock
C2


Selector cock outlet hole
pressure will decrease, and may activate the C3


Selector cock blow-off and draining hole
alarm or emergency stop.

c) Overhaul and Cleaning of Filters

Be minded to conduct the overhaul and cleaning
of filters when the engine is stopped, as far as pos-
Tightening nut (E)
sible. Be sure to wear the safety gloves when Element (F)
operating the filters, and be careful so as not to let Air vent valve
high-temperature oil splash on your skin or clothes. (D)

When using the heavy fuel oil, the fuel oil is

heated up and consequently the filter and the
piping are extremely hot. Therefore, when Case (C)
Gasket (I)
handling the filter, be sure to wear the safety
Gasket (J)
gloves, and be cautious so that the high-tem-
Air vent
perature oil may not splash on the skin or pipe
Drain cock (B)
clothes.
Housing
(G)
i ) Turn the selector handle (A) to the "Close"
o
position (R) (90 ) on the side to be overhauled.
ii) Open the drain cock (B), loosen the air vent valve
(D) at the top of the Case (C), and discharge oil. Knock (H) Cock raising bolt
Handle (A)
iii) Loosen the tightening nut (E), remove the case
(C), and then take out the element (F). Filter Overhaul Procedure

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.3 DK-28e Cleaning Filters

iv) Clean the element with washing oil or gas oil, (2) Y-Type Filter
and conduct blow-off cleaning from the inside. a) Overhaul and Cleaning
v) Clean each of the parts overhauled, and clean the
i ) Remove the plug.
grooves for case gasket of the filter housing (G).
ii) Remove the strainer.
d) Assembly and Restoration iii) Clean the strainer with washing oil or gas oil
i ) Attach the gasket (I) to the element (F), and
attach the gasket (J) to the filter housing (D). b) Mounting
ii) Put the spring (K) on the element, and place the case When mounting the Y-type filter, be minded to
(C) on the top of the spring, and screw the nut (E) mount it with the plug side facing downward, so
into the case while holding the case with your hand.
that sludge may be accumulated in the strainer.
iii) Close the drain cock (B).
iv) Shift the handle (A) to "Blow-off" position "Q".
v) When the filter is overhauled and cleaned while
the engine is stopped, conduct priming and fill
the case with oil.
vi) Close the air vent valve (D), after oil has been let
overflow and air bubbles have completely van-
Inlet Outlet
ished from the oil flowing out of the air vent pipe.
vii) Return the handle to "Both sides used position (P)".
viii) Check if there is any oil leakage from the gas-
ket sections.

Confirm that the knock (H) of the handle (A) Plug

Strainer
is engaged in its position.
If the knock is not properly engaged in the Disassembling Y-type Filter
position, the handle will be overturned by
vibration during the operation of engine, and it
may incur oil spill-out accidents.
(3) Automatic Back-Wash Filter (Lubricating oil)
(Auxiliary Engine)

1) Check conditions of the sludge collected on The lubrication oil filter for auxiliary engine is an
the element. automatic reverse flow filter with a sludge collector
and does not require daily opening and cleaning.
Particularly in case of the lubricating oil filter,
But, the sludge collector requires daily opening
it metallic particles are found, investigate the
and cleaning.
causes and take the coutermeasures.
2) When the element is damaged, or when the ( : "Handling Manual of the Filters" separate-
element is excessively fouled and clogging ly provided)
cannot be removed even by cleaning,
replace the element with a new one.
3) Since the gasket and O-ring are easily be
damaged, be very careful in handling these
parts. Particulaly, the heavy fuel oil filter tends
to be deteriorated in high-temperature condi-
tions, and therfore be mined to replace the fil-
ter every time the overhaul is conducted.

DK-28e Z 11-06 e
 CHAPTER
Inspection and Maintenance
5
ITEM
Cleaning Turbocharger Blower DK-28e 4.4

5-4.4 Cleaning Turbocharger Blower iv) Operate the syringe to inject cleaning liquid.
If the fouled degree of the turbocharger blower v) When 3 to 5 minutes has passed after the
has progressed, the efficiency of the turbocharger injection of cleaning liquid, inject fresh water of
will decrease and the operating performance of the same amount on the same procedure.
engine will be worsened. Particularly when heavy
fuel oil is used, the turbocharger blower tends to Type of Filling amount Filling time
be fouled in faster degree, and therefore be mind- turbocharger (cc) (sec)
ed to conduct blow-off cleaning and restrain the
MET26SR 1000 20䱊40
progress of fouling.
MET30SR 1000 20䱊40
(1) Interval of Cleaning
Clean the blower when intake air pressure has TPS57D 400 4䱊10
decreased 10% at the same load, or at least TPS61D 400 4䱊10
every 150 to 200 hours of operation.
(2) Load during Cleaning
Make sure that the engine shall be operated [Injection Amount and Injecting Time]
under the load of 75% or higher, and continue the
vi) In case that there is no change in intake air
loaded operation for 1 hour or more after cleaning.
pressure before and after the cleaning, repeat
cleaning after 10 minutes.
Type of Turbocharger rotation speed
turbocharger ( min-1 ) 䃁 In case that intake air pressure does not
MET26SR 15,000䱊19,000 change over when the cleaning is repeatedly
conducted, conduct the overhaul and clean-
MET30SR 15,000䱊19,000 ing of the whole of turbocharger.
TPS57D （ ：Separately provided "Turbocharger
Instruction Manual"）
5
TPS61D

The turbocharger is at a high-temperature

during operation and just after the engine is
(3) Cleaning Liquid stopped. If you touch it with bare hands dur-
Be sure to use the specified cleaning liquid. In ing cleaning, you may burn your hands.
case that the specified cleaning liquid is not avail-
Wear safty gloves without fail.
able, use fresh water. (Note that cleaning effect
is inferior with fresh water.)

Connect here
Syringe (A) Filling pipe (B)
Be minded never to use gas oil or any other
flammable liquid for cleaning, since these liq-
uids will be the cause of fire.
Socket
(4) Cleaning Method
Cleaning of the turbocharger blower can be
made using the cleaning device that is supplied
together with the engine.
i ) Pour cleaning liquid into the blower syringe (A).
ii) Connect the syringe socket to the filling pipe
(B) that is connected the turbocharger inlet side.
iii) Fully open the drain cock of the air intake duct. Turbocharger

Turbocharger Blower Cleaning Procedure

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.5 DK-28e Cleaning Turbocharger Turbine Side

5-4.5 Cleaning Turbocharger Turbine Side [Maximum allowable turbocharger rotation

speed and exhaust temperature when cleaning]

Turbocharger Max. Allowable Turbocharger inlet

The turbocharger is at a high-temperature
model rotation speed exhaust temperature
during operation and just after the engine is MET26SR 27,400 min-1
o
500 C or less
stopped. If you touch it with bare hands during o
MET30SR 22,500 min-1 500 C or less
cleaning, you may burn your hands. Wear
safely gloves without fail.
(3) Cleaning Liquid
Use the specified cleaning liquid as shown
< In case of Turbocharger Model "MET"
below.
(Cleaning solid matter) >
Husk of walnut: Diameter of grain: 1.7 to 2.4
If staining of the turbocharger turbine side pro-
mm {Marine grid #10)
gresses, engine performance will be worsened due
Grain (rice, wheat, etc): Diameter of grain:
to decrease of the efficiency as in the case of the
1.7 to 2,4 mm
blower side. Particularly, it tends to be more
䃁 Close the drain hole of the turbocharger gas
stained in'case of heavy fuel oil specification, peri-
outlet casing while cleaning.
odically clean the turbine side, and restrain the
progress of staining. (4) Cleaning Method
When cleaning the solid matter in the turbine,
a) Procedure for one time cleaning
charge vegetable solid particle in front of the tur-
bine, and remove the adhered matters on the tur- i) After opening the valve (B), open the valve (A)
bine nozzle or turbine rotor blade by the impact and cool the equipment by passing air for 1 to 2
force produced by the vegetable solid particle minutes.
accelerated by the exhaust gas. ii) Close the valve (A), and close the valve (B).
iii) Fill the specified use amount of vegetable solid
(1) Interval of Cleaning cleaning agent into the tank, and securely tight-
Conduct the cleaning with the interval of 200 to en the cap of the tank.
250 hours in the initial stage, since the effect of
iv) Open the valve (A) and (B) in this order, and
cleaning will be lost if the layers of the accumulat-
charge the cleaning agent with air pressure.
ed matters have become thick.
v) Close the valve (B) and (A) in this order.
As for the cleaning interval after the initial clean-
ing, properly increase or decrease depending on
the factors such as the exhaust temperature, Various purpose air
0.4-0.5MPa Tank
intake air pressure, and the degree of performance {4-5kgf/cm2}
decrease of the turbocharger rotation speed.

(2) Load during Cleaning

Perform cleaning by making the load of engine (A)
to be 75 to 85% as the standard. Although it is
possible to perform cleaning at a low load of (B)
around 50%, cleaning liquid may sometime be
accumulated at the gas outlet casing, and there-
fore avoid the cleaning of such a low load as far as
possible.
The maximum allowable rotation speed of the
turbocharger when cleaning is performed is as
shown in the following table, and therefore in case
that the normal load value is higher than these,
decrease the load. Turbine Rotor Blade Cleaning Procedure

DK-28e Z 11-06

Inspection and Maintenance
Cleaning Turbocharger Turbine Side
b) Repeated cleaning
i) In case that a sudden change, such as surging,
has occurred in the engine when charging the
cleaning agent, try the cleaning by using a half
of the specified use amount of solid cleaning
agent for single time cleaning, and perform the
cleaning after confirming that there is no more
sudden change in the engine.
Afterwards, make this method as the standard.
ii) After finishing the cleaning, repeat the above
the procedure of Item a), if no particular change
is not found in the performance values such as
the exhaust temperature, intake air pressure,
and turbocharger rotation speed. In case that
any change is not found even after the cleaning
has been repeated, it is necessary to perform
the overhaul and cleaning.
[Specified use amount of solid cleaning agent]
Turbocharger Max. Allowable Turbocharger inlet

model
MET26SR
rotation speed exhaust temperature
27,400 min-1
o
500 C or less
o
MET30SR 22,500 min-1 500 C or less
（ ： "Instruction Manual of Turbocharger")
< In Case of Turbocharger Model "TPS" (pour-
ing water washing)>
As the pouring water washing method of the
supercharger, fresh water is sprayed in front of the
turbine from the pouring water nozzle on the super-
charger. Thus, the extraneous matter is removed
through the difference of the cooled turbine nozzle
eith fresh water, turbine blade and the thermal
expansion extraneous matter.
(1) Washing interval
Since the washing effect is reduced when the
deposit layer becomes thick, apply the washing
every approx. 200 hours.
(2) Load during washing
Apply the washing at such a load as the exhaust
temperature of the cylinder outlet is 350 to
CHAPTER
5
ITEM
DK-28e 4.5
350oC. As the exhaust temperature is lower,
the washing effect decreases. As it is higher,
the turbine nozzle or similar part may be dam-
aged.
Take special care for the exhaust tempera-
ture.
(3) Fresh water for washing
As the fresh water for washing, use the fresh
water which does not include any additives.
Never use any seawater.
(4) Washing method
i) Connect the hoses of the pressure gauge and
the check-valve hose to the pipe connected to
the exhaust pipe,
ii) Open the check valve, fill the water into the
pipe and hose up to the nozzle, and close the
check valve,
iii) Fully open the valve in the nozzle on the
exhaust pipe,
iv) Observing the pressure gauge, slowly open
the check valve to gain the water valve of 0.45
to 0.45 MPa (4.5 to 7.0 kgf/cm2)
v) Continue pouring water 15 to 30 seconds.
vi) Apply the washing three times. Here, provide
5
the interval shown in the table below after
washing of one time.
vii) Close the valve, loosen the hose connection.
Disassemble the manometer and the hose
with valve.
viii) To dry the supercharger, run it applox. 10
minutes at the same load.
ix) If any variation is not observed on the per-
formance values of the exhaust temperature,
charge pressure, supercharger revolution
speed and so on, repeat the procedure above
after completion of the washing. If any variation
is not observed after repetition of several times,
it is necessary to open and clean it.
Turbocharger model Interval time (minutes)
TPS57 3
TPS61 5
（ ： "Operating Manual for Turbocharger")
DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.6 DK-28e Measuring Crankshaft Deflection

5-4.6 Measuring Crankshaft Deflection
If the crankshaft deflection exceeds its limit,
the stress to be applied to the crankshaft will
become excessive, and it will result in the
breakage of crankshaft if the excess of deflec-
tion is too large.
Therefore, adjust the crankshaft deflection to
a proper value when being installed, and peri-
odically measure the deflection, so that it can
be corrected whenever it is over the limit
value.
iii) Install the deflection gauge to the position as
shown in the Figure.
iv) Set the reading on the gauge scale to +20 at
the position "B" in the Figure. (To make clear
the positive and negative directions.)
v) Slowly turn the engine in the normal direction
of rotation, and measure the reading on the
scale when the crankshaft is at the angle of
"B", "C", "D", "E", and "A" respectively, of
which data shall be recorded.

(1) Replacing Consumables and Measuring

Instruments
a) Replacing Consumables （ ："Parts List"）
1) O-ring 3-2 No.9

b) Implements and Measuring Instruments

1) General tools （ ："Implement List" in the
final documents）
2) Deflection gauge
3) Mirror

(2) Conditions for Measuring Deflection

a) Deflection of the crankshaft varies according to
the temperature, and therefor be sure to
measure it when the engine is in cold state.
b) Before measurement, push the contact piece
of the deflection gauge with a finger, and con-
firm that both the contact piece and dial
gauge return to the original positions
correctly.
c) In case of the marine engine, since the deflec-
tion varies according to the loaded cargo con-
ditions, be minded to record the conditions of
loaded cargo, draft, temperature, and so on,
at the same time.

(3) Measuring Deflection

<Measurement procedure>
i ) Open the indicator valve, and conduct turning
the crankshaft.
o
ii) Place the crank pin at the point of 30 (position
"B") past the bottom dead center.

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Measuring Crankshaft Deflection DK-28e 4.5

(4) Calculating Deflection (d)

Calculate the deflection values as based on the
measured values and in accordance with the fol-
lowing formula, and record the calculated values:
Ａ＋Ｂ O
Vertical (V) deflection: dv = D - 30
２
Horizontal (H) deflection: dH = C - E
Positive/negative deflection: Open down- D
C E
ward (+), closing downward (-) B A
Top dead center
A, B, C, D, and E represent the measured val-
ues respectively at each corresponding position Deflection Measuring Position
shown in the figure on the right.

(5) Correction Limit for Deflection

a) The correction limit shall apply to whichever is
Seen from flywheel side
larger of dV and dH as shown in the following
O
table. A 30
O
30 B

(Unit : mm)
E C
Adjusted value Allowable limit Direction
(One-side bearing
In case of direct

0.041 or less 0.116

5
connection :

D (Top dead center)

generator)

1 2.8
x Stroke x a x Stroke x a
10,000 10,000
(Both-side bearing

Dial Gauge Reading

In case of direct

0.041 or less 0.116

connection :
generator)

1 2.8
x Stroke x a x Stroke x a
10,000 10,000
connection with
In case of direct

0.124 or less 0.165

coupling:
flexible

3 4
x Stroke x a x Stroke x a
10,000 10,000
Note: Measurement poit revised value a=1.06

b) Deflection varies depending on the connection

method (direct connection or flexible coupling)
between the crankshaft and drive equipment,
however, usually, the deflection becomes
maximum at the crank throw that is closest to
the flywheel.
Adjust the drive equipment using the adjust-
ing shim or chock liner, so that the deflection
falls within the limited values as shown in the
above table.
The deflection of the crankshaft shall be rep-
resented by the value when the engine is cold,
and since the values measured when the
engine is warm sometimes differ significantly
depending on the measurement conditions, be
minded not to use the value measured when
the engine is warm as standard.

DK-28e Z 11-06
CHAPTER
Inspection and Maintenance
5
ITEM

4.6 DK-28e Measuring Crankshaft Deflection

<Reference> There is a possibility that the measurement

Deflection in warm condition results of the deflection in the warm conditions

In case of the directly connected generating differ from the real value due to the reasons that

engine, the deflection in the warm conditions gen- the engine temperature may suddenly increase

erally tends to vary as compared to the values in after the engine is stopped, and due to the effects

the cold conditions. of the thermal expansion owing to the tempera-

This is because the temperature increase of the ture difference of the crankshaft. Be careful of

engine base is larger than the temperature this fact.

increase of the generator to be directly connect-

ed, so that the crankshaft core relatively increas-
es, the deflection varies towar direction
(downward closing), and thereby the difference
manifests itself as the deflection difference
between the cold and warm conditions.
Like this, in case of the directly connected gen-
erating engine, the deflection difference between
the cold and warm conditions differs depending
on the bearing dimensions and temperature dif-
ference of the engine and generator, so that the
adjustment is impossible, and it will be the value
unique to the generating device.
Consequently, in case of the generating engine,
the adjustment is made with the target of the con-
ditions near to + side upper limit (downward
opening) of the specified value in the cold condi-
tions.
The measured value of the deflection value in
the warm conditions varies according to the tem-
perature, and the different values tend to be
obtained every time the measurement is conduct-
ed, however, based on the actual measurement
results of our company, the value is approximate-
ly 3 to 4/10,000 x stroke and within the range of
(downward closing).

DK-28e Z 11-06
 CHAPTER
Inspection and Maintenance
5
ITEM
Inspection and Replacing Protective Zinc DK-28e 4.7

5-4.7 Inspecting and Replacing b) Replacement and Mounting

Protective Zinc i ) Remove the rust or scale from the mounting
surfaces of the protective zinc and the mounted
In case that sea water is used as the cooling
flange to expose the metallic surface, and
water in the cooleig system, a protective zinc is
securely mount the protective zinc to the flange
provided in each cooler.
in such a way that the both parts are closely in
Conduct periodical inspection and replacement
contact each other.
of the parts on the following procedure:
ii) In case that the protective zinc is reused,
(1) Replacing Consumables, Implements, and shave scale off the surface of the protective
zinc and expose the zinc surface.
Measureing Instruments
a) Replacing Consumbables
Lubricating cooler （ ："Parts List"）
Air cooler （ ："Parts List"）

b) Implements, and Measureing Instruments

1) General tools
（ ："Implement List" in the final documents）

(2) Locations of Protective Zinc and Inspection

Interval
Front and rear covers for lubricating cooler ---
----Every 3 months
Front and rear covers for air cooler-----Every
5
6 months

Efficiency of the protective zinc substantially

varies depending on the purity. Therfore, be
minded to use the genuine parts supplied by
Daihatsu Diesel Manufacturing. Co., Ltd.

(3) Inspection and Replacement

a) Inspection
i ) Remove the mounting flange for protective zinc.
ii) Replace the protective zinc of which volume is
reduced more than 50% (20% by dimension)
as compared to the original shape.
iii) On the contrary, in case that the protective
zinc is rarely worn out, the following failures
may be suspected:
Faulty condition on the mounting surface
Purity failure of zinc

DK-28e Z 11-06
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
1.1 DK-28e Selection Fuel Oil

6-1 Fuel Oil Characteristics and Control

How well the fuel oil characteristics is controlled will greatly affect the smooth operation of
engine, maintenance intervals, as well as the working life of various parts.
When supplying the fuel oil, it is required not only to confirm the characteristics referring to
the characteristics analysis table, but also to conduct the control of the oil in accordance with
each characteristics.
Particularly when using heavy fuel oil, conduct the preprocessing of fuel oil, the control of
viscosity (temperature), and the control of lubricating oil without fail, so that troubles arising
from fuel oil can be prevented.

6-1.1 Selection Fuel Oil

The standard characteristics of the fuel oil appli- Therefore, be minded to check the characteris-
cable to this engine is as shown in a separate tics analysis values of the fuel oils after each deliv-
table. ery, and try to avoid using the fuel oil of which
characteristics is excessively different from those
（ ： Table 6-1.1 "Standard Fuel Oil shown in the standard characteristics table.
Characteristics")
Commercially available fuel oils are considerably
different in the characteristics, and even the same
type of the fuel oil may show a greatly different
characteristics depending on the location and peri-
od of supply.

1. The engine specification varies depending
on the types of the fuel oil to be used. Be
minded to confirm the type of the fuel oil
referring to the specification of engine, and
do not use the oil of which grade is lower
than that shown in the specification.
In case that the fuel oil of lower grade is
used, troubles may be incurred on the oper-
ation of engine, due to the faulty combus-
tion, troubles on the fuel oil system equip-
ment, premature wearing of the parts, and
so on.
2. Avoid using the fuel oil by mixing with the
other oils whose production of origin is dif-
ferent. In case that fuel oil is mixed the oil
with inferior affinity, a large amount of
sludge may be generated, causing troubles
on the operation of engine.
Residual oils resulting from operation by
FCC method (catalytic cracking method) are
often mixed in fuel oils recently.
The mixed oils, such as this, contain rigid
alumina silica (catalyst particles), and will
cause abnormal wear of the various parts of
engine, particularly the parts of the fuel injec-
tion system.
Remove the solid particles by fully utilizing
the existing fuel oil pretreatment equipment,
and by intensifying the cleaning of fuel oil.
In case that the removal of the solid parti-
cles cannot sufficiently be made with the
existing fuel oil pretreatment equipment, the
reinforcement of the cleaning equipment will
be required, and when such reinforcement is
not possible, it may be required to change the
current fuel oil to the oil of a better quality.

DK-28e Z 11-06

Control of Fuel Oil, Lubricating Oil, and Cooling Water
Fuel Oil Characteristics and Control
6-1.2 Fuel Oil Characteristics and Control
(1) Heavy Fuel Oil
Since heavy fuel oil contains more carbon
residue and impurities, and is higher in its viscosity
as compared to diesel fuel oil, heavy fuel oil can-
not be used as the fuel oil for diesel engine, when
it is in the state of bunker fuel oil.
Therefore, it will be a prerequisite to use heavy
fuel oil that the oil must properly be preprocessed
before being supplied to engine (including the
removal of impurities by cleaning, and the assur-
ance of proper viscosity by heating).
a) Cleaning Fuel Oil
Water, and solid contents such as vanadium,
sodium, alumina, and silica, contained in heavy
fuel oil accelerate the corrosion and wear of the
various parts of fuel injection system and fuel com-
bustion chamber system, substantially affecting
and reducing the working life of these parts.
For the purpose of removing such impurities, the
fuel oil preprocessing equipment, such as the cen-
trifugal separator and precision filters, are
installed. Since these equipment will not exhibit the
efficiencies unless each equipment is properly
handled, be minded to operate each equipment in
accordance with the corresponding instruction
manual.
( ：Instruction Manual" for each equipment")
Since waste fuel or sludge will be the
causes of environmental contamination or
pollution, be sure to entrust the treatment of
these to the authorized waste disposal com-
pany, not directly handling or disposing these
matters on your own.
b) Handling Fuel Oil
Since the viscosity of heavy fuel oil is very high,
it is required to heat the oil, so that a proper vis-
cosity for fuel injection can be obtained.
Since the heating temperature varies depend-
ing on the viscosity of fuel oil, heat the oil and
obtain the proper viscosity, by referring to the fuel
CHAPTER
6
ITEM
DK-28e 1.2
oil viscosity/temperature curve on a separate
page as the standard.
In case that a viscontroller (automatic viscosity
regulator) is installed on the engine, control the
fuel oil viscosity to its proper value according to
the attached instruction manual.
( ：Fig. 6-1.1 "Fuel Oil Viscosity/Temperature
Curve")
* Proper viscosity for fuel oil (engine inlet)
Kinematic viscosity: 14 ± 1.5 mm2/s.
If the temperature control of fuel oil is
improper, and the fuel oil with high viscosity
has been supplied to engine, it will not only
incur faulty combustion, but also will result in
the accidents such as the clogged or dam-
aged fuel oil filter, and the breakage of fuel
injection system parts.
(2) Diesel Fuel Oil
a) Water tends to extract and separate out of
diesel fuel oil, and further diesel fuel oil tends to
generate a large amount of sludge when mixed
with the oil of different base oil.
Daily conduct the draining-off of the precipita-
tion tank and setting tank, so that water or
sludge does not flow into the engine.
To remove water or sludge, the centrifugal sep-
6
arator is an effective device.
b) Diesel fuel oil, that has been cut back by using
the gas oil refined by FCC method, may incur
faulty start of ignition, and this tendency is par-
ticularly obvious in case of low sulfur diesel oil
for land vehicles, due to its low cetane number,
if the environmental conditions, such as ambient
temperature or water temperature, are unfavor-
able.
In such a case, special measures will be
become necessary to improve starting capability
and combustibility of engine, and in such occa-
sions, contact our company for consultation.
DK-28e Z 11-06
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
1.2 DK-28e Fuel Oil Characteristics and Control

(3) Gas Oil (4) Kerosene Oil

Although gas oil does not contain few impurities,
it may cause problems on ignition when the gas oil
is refined by FCC method, just like in the case with
diesel fuel oil, and therefore be minded to pay par-
ticular attentions to the cetane number of gas oil.
Further, since gas oil is low in its viscosity and is
inferior in its lubricity, it may cause abnormal wear
on the sliding parts of the fuel oil injection system,
and therefore be minded to conduct the inspection
of the fuel injection pump and fuel injection valve in
the earlier stage than usual.
As a countermeasures to prevent environmental
contamination (air pollution), there may by a case
in which kerosene oil may be used.
Since kerosene oil is further lower in its cetane
number and is lower in its viscosity than gas oil,
it is required to carry out a special arrangement on
the engine, and therefore contact our company for
consultation before using the oil.

Table 6-1.1 Fuel Oil Standard Characteristics

General call Diesel fuel oil note 1) Heavy fuel oil note 2)
JIS (K2205 type 1) (K2205 type 3)
Type of fuel oil
ISO-F (DMA) RMA10 RME25 RMG35 RMH55
CIMAC A10 E25 G35 H55
Density (15 oC) g/cm3 max 0.890 0.975 0.991 0.991 0.991
Kinematic viscosity
cSt max 3.0 - (50 oC) 10/40 25/180 35/380 55/700
100/50 oC
Viscosity
RW#1 100 oF sec max 30 - 50 300 1500 3500 7000
o
Flash point C min 60 60 60 60 60
o
Pour point C max 0 6 30 30 30
Carbon residue wt % max 0.2 10 15 18 22
Ash wt % max 0.01 0.1 0.10 0.15 0.20
Water vol % max 0.1 0.5 1.0 1.0 1.0
Sulfer wt % max 1.5 3.5 5.0 5.0 5.0
Vanadium mg/mg max 150 200 300 600
Sodium mg/mg max 50 50 50 50
Aluminum + silica mg/mg max 80 80 80 80
Cetane number note 3) min 40
CCAI value note 4) max 850 850 850 850

Notes : 1) Since there are a wide range of the standard values for diesel fuel characteristics, the recommended
values are shown in the above table.
2) heavy fuel oil characteristics represent the values of "Residual marine fuel oil" proposed in CIMAC
(1990).
3) Cetane number represent the calculated values based JIS K 2280-1996.
4) CCAI (Calculated Carbon Aromatic Index) value is calculated by the following formula, and indicates
the reference value for starting capability.
CCAI value = 1000 D -141 Log Log (VK + C) - 81
D: Density g/cm3 (15 oC), VK: Viscosity cSt (50 oC), C: Constant (0.85 for heavy fuel oil)

DK-28e Z 11-06
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Fuel Oil Characteristics and Control DK-28e 1.2

Table 6-1.2 Standards for Clean fuel Oil

Component Standards

Water 0.2 vol. % or less

Solid Content 50 mg/kg or less

particles
Size 5 m or less

Vanadium combines with sodium and so

forth and makes an alloy, which is highly cor-
rosive and advances high temperature corro-
sion (vanadium attack).
Moreover, moisture advances corrosion on
components in the fuel injection system.
When, in particular, seawater intrudes, such
corrosion accelerates because the above-
mentioned high temperature corrosion also
occurs. You must use the fuel oil cleaning
device and try to remove seawater and solid
substance as much as you can. 6

DK-28e Z 11-06
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
1.2 DK-28e Fuel Oil Viscosity-Temperature Curve

1000F 500C
9000
7000 Trace 1 Gas oil
curve 3 mm2/s @500C

5000 " 2 MDF 6.2 " "

4000 Rw#1
" 3 TFO 30 " "
3000 11 4 60
10000
" " " "
2000 10 " 5 " 80 " "
1500 6 120
(

" " " "

9
mm2 / S

5000
" 7 " 180 " "
1000
800 8 8 280
" " " "
)

600 7 " 9 MFO 380 " "

Kinematic Visconsity

500 2000
" 10 " 500 " "
400 1500
6 11 700
300
250 1000
5
200
150 4 500

100
80
3
60
50 200
40
30
25 100
20

14 15 65

10 2 50
8
6 40
5
1
4
3

2 30
-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Temperature ( 0 C)

Fig. 6-1.1Fuel Oil Viscosity / Temperature Curve

Example) We find the temperature, under which heavy fuel oil of 380mm2/s can be heated, so as to obtain
the proper viscosity of 14mm2/s at the engine inlet.
To find this temperature, tracing the curve No. 9 downward, and from the point that intersects
kinematic viscosity 14mm2/s, goes down vertically to obtain 130℃.
Note: 1. The viscosity temperature characteristics of fuel oil may slightly differ depending on the original
place of production or its refining process, and therefore confirm the viscosity with a viscome-
ter, and determine the proper value when actually operating the engine.
2. Kinematic viscosity 1cSt = 1 mm2/s

DK-28e Z 11-06
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Selection and Control Lubricating Oil DK-28e 2.1,2.2

6-2 Lubricating Oil Characteristics and Control

Lubricating oil only plays an extremely important roles for engine, not only lubricating the
sliding parts but also cooling the various parts, ensuring air tightness, acting as a detergent-
dispersant, or acting as a neutralizing acids.
For the purpose of maintaining the engine in proper conditions and assuring the smooth
operation, it is indispensable to select suitable lubricating oil brands taking into consideration
the use purpose of engine, the fuel oil to be used, the load to be connected, etc., and to con-
duct an appropriate control of the lubricating oil.

6-2.1 Selecting of Lubricating Oil 6-2.2 Control of Lubricating Oil

(1) Engine system oil
As the system oil for engine, high-grade lubricat-
ing oil (CD of API service category, or higher) for
diesel engine shall be used.
Select the lubricating oil of the suitable grade,
according to the quality of the fuel oil to be used.
The recommended lubricating brands as shown
in a separate table.
（ : Table 6-2.1 "Recommended Lubricating
Oil Brands"）
(1) Cleaning of Lubricating Oil
Since fine dust or combustion residue from the
combustion chamber enter and mix in the lubricat-
ing oil, a centrifugal separator is installed to the
engine, to eliminate such foreign matters, in addi-
tion to the filters attached to engine. Use such
equipment in correct manner, referring to the
instruction manual of each manufacturer.

Do not conduct cleaning by injecting water

Be minded to use the lubricating oil of the
same brand, not mixing the lubricating oil
with the oil of any other brand.
If the lubricating oil is mixed with the oil of
different brand, the additives contained in the
both oils react for each other, and this may
result in the degradation of the lubricating oil.
(2) Lubricating Oils for Other Equipment
In case that separate lubricating system is
employed apart from the engine lubricating sys-
tem, as in the case of the governor, air motor, gen-
erator, etc., be minded to refer to the instruction
manual of each equipment.
（ : "Instruction Manual of each equipment"）
into lubricating oil.Mixing water into lubricat-
ing oil will cause degradation of the lubricat-
ing oil, such as the emulsification of oil, the 6
decrease of total base number, and the
increase of insoluble substances.
(2) Control of Lubricating Oil Characteristics
Periodically conduct the sampling and analysis
of lubricating oil (every 500 hours), and in case
that the analyzed value of the lubricating oil char-
acteristics has reached the control standard value,
immediately consult the lubrication oil manufactur-
er, so that the replacement or makeup can be
carried out.
（ : Table 6-2.2 "Lubricating Oil Control
Standards"）

DK-28e Z 11-06
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
2.2 DK-28e Lubricating Oil Characteristics and Control

a) Sampling Procedure <Information to be Attached to Sample

i ) Collect samples from the air vent pipe of the fil- Receptacle>>
ter during the operation of engine.
If the samples are collected from the drain 1) Name of your company and your name
cock, the analyzed value of the characteristics 2) Model number of engine
may show a different value due to the mixing of
3) Engine number
sludge or solid deposits.
ii ) The minimum amount of sampling shall be 500 4) Data and location of sampling
cm3. 5) The amount of time the engine is operated
iii) Attach on the sampling receptacle with the 6) Lubricating oil brand
label indicating the information as shown on the
7) The total operation time and quantity of
right.
lubricating oil
b) Lubricating Oil Control Standards 8) Replenishment record (Data and quantity of
The lubricating oil control standards are as replenishment)
shown in the Table 6-2.2 below.
Of all the lubricating oil control standards, the
total base number and n-pentane insoluble are
particularly important for the purpose of checking
1) Total Base Number (TBN)
the degradation degree of lubricating oil.
Total base number represents the quantity
of potassium hydroxide (KOH) that corre-
Table 6-2.2
sponds to the quantity of acid required to
Lubricating OIl Control Standards (System oil)
neutralize the base component contained in
Diesel Heavy 1 g of lubricating oil, and is indicated by the
Fuel oil used fuel oil fuel oil unit of mgKOH/g.Total base number indi-
Total base cates the lubricating oil capabilities to pre-
mgKOH/g 3 or more 10 or more
number 1) vent the corrosion due to sulfuric acid gener-
Total base ated from sulfur contained in fuel oil, and
mgKOH/g 5 or more 15 or more
number 2) other acids, and further it indicates the capa-
bilities of lubricating oil to clean and disperse
Kinematic mm2/S +30% or less / -20%
Viscosity
o
(@ 40 C) or more of new oil the fouled sections in the engine.

o
Flash point C 180 or higher 2) Insoluble (= n-pentane soluble)

Water Insoluble is fouling substance that do not

vol. % 0.3 or less dissolve in oil, and the main component is
content
soot which is a product of combustion, and
n-pentane
wt. % 2.5 or less 4) calcium sulfate which is a neutralized prod-
insoluble 3)
uct.Since these substances do not dissolve
Notes:
1) The TBN (Total Base Number) represents the values measured even in n-pentane which is a solvent, n-pen-
according to ASTM D4739, JIS K2501 (Hydrochloric acid method). tane insoluble serves as an index to indicate
2) The TBN (Total Base Number) represents the values measured
according to ASTM D2896, JIS K2501 (Perchloric acid method).
the degradation and fouling degree of lubri-
3) Insoluble represents the values measured according to cating oil.
ASTM D893B.
4) In case that the measure value rapidly increased or exceeded 1.5,
measure toluene insoluble according to the ASTM D893B,
and in case of [ n-pentane insoluble - toluene insoluble ] > 0.5,
replace the lubricating oil.

DK-28e Z 11-06
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Recommended Lubricating Oil Brands DK-28e 2.2

Table 6-2.1 Recommended Lubricating Oil Brands

Kind of fuel oil Gas oil or Up to 200 Sec. Up to 1500 Sec. Up to 7000 Sec.
Diesel oil R.W. No.1 R.W. No.1 R.W. No.1

Class II Class III Class IV Class V

Supplying or Supplying or Supplying or Supplying or
Name of company
Replacing oil Replacing oil Replacing oil Replacing oil

BP ENERGOL BP ENERGOL BP ENERGOL BP ENERGOL

BP DL-MP40 IC-HF253 IC-HF303 IC-HF303
CASTROL MLC30 CASTROL TLX203 CASTROL TLX303 CASTROL TLX303

DELO 1000 Marine DELO 2000 Marine DELO 3000 Marine DELO 3000 Marine
CHEVRON Oil SAE30 Oil SAE30 Oil SAE30 Oil SAE30
TEXACO
TARO XD SAE30 TARO DP SAE30 TARO DP SAE30

EXXMAR 12TP30 EXXMAR 30TP30 EXXMAR 30TP30 EXXMAR 30TP30

EXXONMOBIL MOBILGARD 312 MOBILGARD 330 MOBILGARD 330 EXXMAR 40TP30
MOBILGARD 330
MOBILGARD M330 MOBILGARD M330
MOBILGARD M330

GULF GULF VERITAS GULF VERITAS GULF VERITAS

DPO30 SERECT30 SERECT30

PETROBRAS MARBRAX MARBRAX MARBRAX MARBRAX

CCD310 CCD320 CCD330 CCD330

SHELL GADINIA 30 ARGINA S30 ARGINA T30 ARGINA T30

RUBIA S SAE30 RUBIA ST SAE30 HAM SAE30 HAM SAE30

TOTAL
TOTAL

FINA DISOLA M3015 HAM SAE40
AURELIA 3030
AURELIA 3030 AURELIA 3030 6

Note:(1) This table shows lubricating oils classified as SAE40. Be sure to use lubricating oils classified as
SAE30 only when the minimum ambient temperature is 20℃ or less.
We recommend that multigrade oil (SAE10W-30 or 5W-30) be used in extremely cold locations
(minimum ambient temperature: 5℃ or less).
(2) Be sure to consult with oil manufacturers before selecting the lubricating oil proper brand that
best suits the fuel oil and operating conditions.

DK-28e Z 11-06
CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Cooling Fresh Water (Raw Water) and Corrosion
3.1,3.2 DK-28e Prevention Agent

6-3 Cooling Water Characteristics and Control

Always use fresh water as cooling water in the cylinder jacket system and add cor-
rosion prevention agent to cooling water to maintain cooling effect and prevent cor-
rosion due to scale bonded on the piping surface.
Improper cooling water control can cause localized heating of the jacket line parts
due to corrosion or scale, resulting in excessive wear on or damage to the jacket line
parts.

6-3.1 Cooling Fresh Water (Raw Water)
As cooling fresh water (raw water), be minded to
use the soft water that meets water quality stan-
dards shown in Table 6-3.1 below, or the water to
which softening processing has been adminis-
tered.
6-3.2 Corrosion Prevention Agent
(1) As corrosion prevention agent, we recom-
mend the agent which is nitrous acid type.
(2) Commercially available brands in Japan are
shown in Table 6-3.2.
When using them, carefully read the manufac-
turer's instruction manual, and properly use
the agent in accordance with the use standard
as well as the control standard.

Table 6-3.1 Fresh Water (Ran Water) Quality Standards

Effect (reference)
Item Standards
Corrosion Scale

o
PH (25 C) 6.5 to 8.5 (neutral)
Tortal hardness
100 mg/kg Max.
(CaCO3 PPM)
Chlorine ion
100 mg/kg Max.
(Concentration:Cl-1)
M-alkalinity (PH4.8) 150 mg/kg Max.
Sulfate ion
100 mg/kg Max.
(Concentration:SO4-2)
Total iron (Fe) 0.3 mg/kg Max.

Silica (SiO2) 50 mg/kg Max.

Ammonium ion
0.05 mg/kg Max.
(Concentration:NH4)
Evaporation residue 400 mg/kg Max.

DK-28e Z 11-06
 CHAPTER
Control of Fuel Oil, Lubricating Oil, and Cooling Water
6
ITEM
Corrosion Prevention Agent and Control of Cooling
Water DK-28e 3.2,3.3

Table 6-3.2 Brands of Commercially Available Corrosion Prevention Agents

Brand Name Manufacturer Constituent Amount to added (ppm)

DEWT-NC 3,000~4,500
Drew Chemical Corp. (USA) Nitrite
MAXIGARD 20,000~22,000
COOLTREAT 101
Hauseman Marine Chemical (USA) Nitrite 1,250~5,000
COOLTREAT 102
CWT DIESEL 102 VECOM B.V. Nitrite 1,250~5,000

6-3.3 Control of Cooling Water

(1) As cooling water, be minded to use fresh (2) Controlling Fresh Water with PH Value
water added with corrosion prevention agent, Measure the PH value of cooling water once
from the stage of very first beginning, without every week, using a PH value, and in case that
fail. the value has exceed the standard value speci-
fied by the manufacturer, discharge 10 to 20% of
the cooling water to add new water.
Corrosion prevention agent is poisonous
and toxic substance. Therefore, be minded
(3).Replace the entire amount of cooling water
never to drink the cooling water that is added
once every year or 2 years.
with corrosion prevention agent.
Further, regarding the handling of the cool-
ing water added with corrosion prevention
Be minded never to directly discharge the
agent, be sure to wear the protective gears
cooling water, which are added with corro-
such as rubber gloves and masks, so that
your hands or skin do not directly touch the
sion agent, into sea or river, without ade-
quate processing.
6
cooling water.
When disposing the cooling water, be sure
If the corrosion prevention agent has acci-
to conduct the water examination, to ensure
dentally touched your skin or entered your
that the COD concentration of cooling water
eyes or mouth, immediately wash them with
is diluted to be within the specified value.
fresh water sufficiently.

6･8DK-28 A 02-11
CHAPTER
7 Troubleshooting and Countermeasures
ITEM
1 DK-28e Precautions for Troubleshooting

7．Troubleshooting and Countermeasures

Defect or failure of the engine is caused not only by faulty or improperly adjusted engine
parts, but also by faulty equipment, improper operation and maintenance work, in addition to
the courses attributable to fuel oil characteristics. More often than not, each engine problem is
caused by two or more causes that are interrelated. Therefore, it is impossible to provide the
descriptions of the countermeasure for every single defect or failure.
This chapter describes the defects and problems that are frequently found on engines, as
well as the generally probable causes and countermeasures for such defects and problems.
If your engine has a defect or failure that is not described in this section, or if you cannot dis-
cover the causes after inspection, contact our Service Department.

7-1 Precautions for Troubleshooting

(1) Take proper measures immediately when you find a defect or problem.
If any of the following defects and failures is found, stop the engine for inspection. Never attempt to
restart the engine until you find the cause, take proper measures, and restore the engine to the normal
operating conditions. Resuming operation without taking proper measures may rapidly aggravate the
defect or failure, resulting in injuries or accidents.

1 Activation of protective device: "Alarm", "Emergency Stop"

Overspeed, low lubricating oil pressure, high cooling water temperature, etc.
2 Abnormal sounds (specially mechanical sounds), abnormal vibrations
3 Overheating of the engine
4 Abnormal increase of exhaust temperature or maximum explosion pressure, or abnormal decrease
of exhaust temperature or maximum explosion pressure
5 Defective parts on or around the engine control (governor, control device), or protective device,
loosened link, or detachment of link
6 Damage to piping or joint bolts (specially fuel and lubricating oil systems)

(2) Inspect, disassemble, and adjust the engine correctly according to the instruction manual. To prevent
accidents, never neglect "Safety Precautions".

(3) Be sure to use the genuine parts of DAIHATSU DIESEL MFG. CO., LTD. or those specified in the parts
list. We will not thereafter guarantee the proper operation of the engine unless such parts are used.
If you are out of the spare parts for servicing, immediately control us for replenishment.

Instruments such as tachometers, thermometers, and pressure gauge may provide

incorrect indication even if the engine is running normally.
Inspect the instruments on a daily basis to make sure their indication is correct.
Replace any defects instrument. Always use correct indications as an index for
determining the engine conditions.

DK-28e Z 11-06
 CHAPTER
Troubleshooting and Countermeasures 7
ITEM
When Starting is Difficult DK-28e 2.1

7-2 Troubleshooting and Countermeasuresuntermeasures]

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CHAPTER
7 Troubleshooting and Countermeasures
ITEM
2.2,2.3 DK-28e When Engine Revolution is Not Smooth/Insufficient Output

DK-28e Z 11-06
 CHAPTER
Troubleshooting and Countermeasures 7
ITEM
When Exhaust Gas Temperature or
Maximum Combusion Pressure is Abnormal DK-28e 2.4

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CHAPTER
7 Troubleshooting and Countermeasures
ITEM
2.5 DK-28e When Exhaust Gas Shows Abnormal Color

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 CHAPTER
Troubleshooting and Countermeasures 7
ITEM
Abnormal Noise / Abnormal Vibration DK-28e 2.6

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CHAPTER
7 Troubleshooting and Countermeasures
ITEM
2.7 DK-28e When Engine Stops Suddenly

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 CHAPTER
Troubleshooting and Countermeasures 7
ITEM
When Unable to Stop Engine / OverSpeed DK-28e 2.8,2.9

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CHAPTER
7 Troubleshooting and Countermeasures
ITEM
2.10,2.11 DK-28e Low Lubricating Oil Pressure/High Lubricating Oil temperature

DK-28e Z 11-06
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Troubleshooting and Countermeasures 7
ITEM
Low Cooling Water Pressure (Jacket Line) /
High Cooling Water Temperature (Jacket Line) DK-28e 2.12,2.13

DK-28e Z 11-06
 .
6 8DK-28e
INSTRUCTION MANUAL
( MAINTENANCE )

e-V00
 Solemnly    Declare 
Recently we found some companies to pretend to be our agent units, such as 
sales  of  AnQing  Daihatsu  diesel  engine  spare  parts.  Here,  we  solemnly  declare: 
we did not set up any spare parts sales company alone, also not authorized any 
company  to  carry  out  the  Daihatsu  diesel  engine  spare  parts  sales.  Our  spare 
parts only by technical services direct sales, wish masses of customers properly 
identify!   
Through  our  investigation  and  pretend  to  be  on  the  market  sales  of  diesel 
engine  spare  parts  are  imitations,  without  Daihatsu  and  our  company 
recognition,  also  did  not  pass  strict  inspection,  product  performance  and  the 
differences  with  the  technical  requirements,  using  them  will  have  a  negative 
effect  on  diesel  engine.  To  ensure  normal  operation  of  diesel  engine  and  user 
interests,  it  is  strongly  recommended  that  users  through  our  technical  service 
department  or  Japan's  Daihatsu  purchasing  spare  parts.  Using  any  imitation 
parts of diesel engine is fault, we do not assume responsibility. At the same time, 
our  company  also  will  go  through  legal  channels  to  protect  the  name  of  our 
company  sales  of  AnQing  Daihatsu  diesel  engine  spare  parts  rights.  Any     
company  should  not  sale  in  the  name  of  our  company  AnQing  Daihatsu  diesel 
engine spare parts. 
Using imitation parts will cause great harm to diesel engine: 
1  The  part  of  companies  organize  to  product  after  surveying  and  mapping 
production  of  pure  diesel  engine  parts,  such  as  on  the  key  size,  precision, 
performance, heat treatment process, but they unable to grasp the production of 
product performance and less than the pure standard spare parts service life. 
2 Part of the company directly purchase parts from our supplier spare parts sales, 
without  strict  inspection  quality  assurance  processes,  nonconforming  product 
without control. 
3  Part  of  the  company  to  enter  the  market  at  low  price  in  the  technological 
process,  production  materials,  quality  management  costs,  reducing  product 
quality standards. 
4  If  imitation  parts  are  used  for  the  engines  designed  in  accordance  with 
MARPOL  Ⅵ  ,  the  certificate  (EIAPP)  may  lose  its  validity,  and  operation  of  the 
engine may be inhibited 
5 If you use the imitation spare parts, when a failure occurs, we do not assume 
any  liability  to  them,  and  it  is  difficult  to  obtain  the  insurance  claim  of  diesel 
engine. 
In addition, the operation of the diesel engine after a period of time after, the 
moving  parts  may  be  wear,  tighten  bolts  loose  because  of  vibration,  the 
combustion  chamber  components  may  be  carbon  deposition,  if  not  treated  in 
time  will  affect  the  normal  operation  of  diesel  engine.  According  to  Japan's 
Daihatsu specification, DC, DK series diesel engine must be every 2 ~ 3 years on a 
maintenanceto cylinder head, piston, cylinder liner, connecting rod, main bearing, 
CAM shaft overhaul and other major parts. 
 Our  company  as  a  diesel  engine  manufacturers,  has  a  rich  experience,  skills, 
enrich  the  after‐sales  service  team.  Guarantee  the  normal  operation  of  diesel 
engine and meet the demand of users is our after‐sale serving 
 
Our spare parts sales contact information: 
Email address: acdspare@126.com 
Fax: 0556‐5307388 
Telephone: 0556‐5307184      0556‐5307177    0556‐5307389 
 
Contact our after‐sales service: 
At home                                                                                At abroad 
E‐mail: afterserviceanqing@126.com                  Email: interserviceaq@126.com 
Fax: 0556‐5307465                                                Fax: 0556‐5307465 
Telephone: 0556‐5307275                                    Telephone: 0556‐5307179 
 
Our machine sales contact information: 
Email address: aq_daihatsu@126.com 
Fax: 0556‐5209643 0556‐5209644 
Telephone: 0556‐5307180 0556‐5307182 
 
 
 
 
 
 

 
DK-28e INSTRUCTION MANUAL (MAINTENANCE)
CHAPTER

CHAPTER 0 INTRODUCTION 0
CHAPTER 1 EQUIPMENT ARRANGEMENT AND MAINTENANCE SCHEDULE 1
CHAPTER 2 GENERAL MAINTENANCE ITEMS 2
CHAPTER 3 CYLINDER HEAD AND VALVES 3
CHAPTER 4 PISTON AND CONNECTING ROD 4
CHAPTER 5 ENGINE FRAME AND CYLINDER LINER 5
CHAPTER 6 MAIN BEARING AND THRUST BEARING 6
CHAPTER 7 CRANKSHAFT 7
CHAPTER 8 TIMING GEAR AND CAMSHAFT 8
CHAPTER 9 FUEL OIL INJECTION DEVICE 9
CHAPTER 10 VALVE OPERATING DEVICE 10
CHAPTER 11 GOVERNOR DRIVING DEVICE 11
CHAPTER 12 INTAKE AND EXHAUST DEVICE 12
CHAPTER 13 STARTING AIR SYSTEM 13
CHAPTER 14 FUEL OIL SYSTEM 14
CHAPTER 15 LUBRICATING OIL SYSTEM 15
CHAPTER 16 COOLING WATER SYSTEM 16
CHAPTER 17 ENGINE CONTROL AND PROTECTIVE DEVICE 17
.
CHAPTER 18 GAUGE BOARD 18
DK-28e Z 11-06
 CHAPTER

ITEM
CONTENTS DK-28e

0. INTRODUCTION 0
1. Prior to Start of Engine Maintenance 0-1
2. Precautions Pertaining to Maintenance 0-2
2.1 Safety Precautions 0-2.1
2.2 Precautions for Disassembly, Maintenance, and Assembly 0-2.2
2.3 Check Items after Disassembly, Maintenance, and Assembly 0-2.3
3. Engine Conforming to NOx Technical Code 0-3
3.1 Outline 0-3.1
3.2 The Parts to be Specified 0-3.2
3.3 Engine Setting Value 0-3.3

1. EQUIPMENT ARRANGEMENT AND MAINTENANCE SCHEDULE 1

1. Equipment Arrangement 1-1
2. Maintenance Schedule Table 1-2

2. GENERAL MAINTENANCE ITEMS 2

1. Preparation before Maintenance Work 2-1
2. General Consumables and Materials/General Tools, Implements, and Measuring Instruments 2-2
2.1 General Consumables and Materials 2-2.1
2.2 General Tools, Implements, and Measuring Instruments 2-2.2
3. Bolts and Nut Tightening Torque, Tightening Oil Pressure 2-3
4. Hydraulic Jack 2-4
4.1 General Construction 2-4.1
4.2 Removal of Nut 2-4.2
4.3 Tightening of Nut 2-4.3
4.4 Maintenance of Hydraulic Jack 2-4.4

3. CYLINDER HEAD AND VALVES 3

1. Cylinder Head 3-1
1.1 General Construction 3-1.1
1.2 Replacing Consumables, Implements and Measuring Instruments 3-1.2
1.3 Removal of Cylinder Head 3-1.3
1.4 Inspection and Maintenance of Cylinder Head (Body) 3-1.4
1.5 Intake and Exhaust Valve Guides 3-1.5
1.6 Intake and Exhaust Valve Seats 3-1.6
1.7 Mounting of Cylinder Head 3-1.7
2. Intake and Exhaust Valves 3-2
2.1 General Construction 3-2.1
2.2 Replacement Consumables, Implements and Measuring Instruments 3-2.2

DK-28e Z 11-06
CHAPTER

ITEM

DK-28e CONTENTS

2.3 Disassembly of Intake and Exhaust Valves 3-2.3

2.4 Inspection and Maintenance of Intake and Exhaust Valves 3-2.4
2.5 Inspection and Maintenance of Valve Rotators 3-2.5
2.6 Assembly of Intake and Exhaust Valves 3-2.6
3. Starting Valve 3-3
3.1 General Construction 3-3.1
3.2 Replacing Consumables, Implements and Measuring Instruments 3-3.2
3.3 Disassembly of Starting Valve 3-3.3
3.4 Inspection and Maintenance of Starting Valve 3-3.4
3.5 Assembly of Starting Valve 3-3.5
4. Rocker Arm Device 3-4
4.1 General Construction 3-4.1
4.2 Replacing Consumables, Implements and Measuring Instruments 3-4.2
4.3 Disassembly of Rocker Arm Device 3-4.3
4.4 Inspection and Maintenance of Rocker Arm Device 3-4.4
4.5 Assembly of Rocker Arm Device 3-4.5
5. Indicator and Safety Valve 3-5
5.1 General Construction 3-5.1
5.2 Replacing Consumables, Implements and Measuring Instruments 3-5.2
5.3 Disassembly of Indicator and Safety Valve 3-5.3
5.4 Inspection and Maintenance of Indicator and Safety Valve 3-5.4
5.5 Assembly and Adjustment of Safety Valve 3-5.5
5.6 Assembly and Mounting of Indicator and Safety Valve 3-5.6
6. Nozzle Holder Guide 3-6
6.1 Extraction of Nozzle Holder Guide 3-6.1
6.2 Cooling of Nozzle Holder Guide 3-6.2
6.3 Fitting-ln of Nozzle Holder Guide 3-6.3
䂾 Fuel Injection Valve ( ：5-4.2 in "Operation Manual")

4. PISTON AND CONNECTING ROD 4

1. General of Structure 4-1
2. Replacing Consumables, Implements and Measuring Instruments 4-2
3. Disassembly of Piston and Connecting Rod 4-3
3.1 Extraction of Piston 4-3.1
3.2 Disassembly of Connecting Rod Large End Part 4-3.2
4. Inspection and Maintenance of Piston and Connecting Rod 4-4
4.1 Inspection and Maintenance of Piston 4-4.1
4.2 Inspection and Maintenance of Ring 4-4.2
4.3 Inspection and Maintenance of Connecting Rod 4-4.3
4.4 Inspection and Maintenance of Crankpin Shell 4-4.4
4.5 Replacement of Connecting Rod Bolt 4-4.5

DK-28e Z 11-06
 CHAPTER

ITEM
CONTENTS DK-28e

5. Reassembly of Piston and Connecting Rod 4-5

5.1 Assembly of Connecting Rod Large End Part 4-5.1
5.2 Assembly of Piston and Connecting Rod 4-5.2
5.3 Confirmation and Retightening of Connecting Rod Bolt 4-5.3

5. ENGINE FRAME AND CYLINDER LINER 5

1. General of Structure 5-1
2. . Replacing Consumables, Implements and Measuring Instruments 5-2
3. Inspection and Maintenance of Cylinder Liner Inner Surface 5-3
4. Extraction of Cylinder Liner 5-4
5. Inspection and Maintenance of Cylinder Liner Outer Periphery and 5-5
Engine Frame Jacket
6. Mounting of Cylinder Liner 5-6

6. MAIN BEARING AND THRUST BEARING 6

1. General Construction 6-1
2. Replacing Consumables, Implements and Measuring Instruments 6-2
3. Main Bearing Shell 6-3
3.1 Disassembly of Main Bearing Shell 6-3.1
3.2 Inspection and Maintenance of Main Bearing Shell 6-3.2
3.3 Assembly of Main Bearing Shell 6-3.3
4. Thrust Bearing 6-4
4.1 Dismounting of Thrust Bearing 6-4.1
4.2 Maintenance of Thrust Bearings 6-4.2
4.3 Assembly of Thrust Bearings 6-4.3

7. CRANKSHAFT 7
1. General Construction 7-1
2. Replacing Consumables, Implements, and Measuring Instruments 7-2
3. Inspection and Maintenance of Crankshaft 7-3
3.1 Inspection of Crankpin 7-3.1
3.2 Inspection of Crank Journal 7-3.2
3.3 Inspection of Balance Weight Bolt Tightening Force 7-3.3
3.4 Inspection of Rear Part Oil Cut Clearance 7-3.4
4. Measurement of Crankshaft Deflection 7-4

8. TIMING GEAR AND CAMSHAFT 8

1. Timing Gears 8-1
1.1 General Construction 8-1.1
1.2 Replacing Consumables, and Implements and Measuring Instruments 8-1.2
1.3 Disassembly of Cam Gear 8-1.3

DK-28e Z 11-06
CHAPTER

ITEM

DK-28e CONTENTS

1.4 Disassembly of Idle Gear 8-1.4

1.5 Inspection and Maintenance of Timing Gears 8-1.5
1.6 Assembly of Cam Gear 8-1.6
1.7 Assembly of Idle Gear 8-1.7
1.8 POWER-LOCK operating procedure 8-1.8
2. Camshaft 8-2
2.1 General Construction 8-2.1
2.2 Replacing Consumables, Implements, and Measuring Instruments 8-2.2
2.3 Disassembly of Camshaft 8-2.3
2.4 Inspection and Maintenance of Camshaft 8-2.4
2.5 Assembly of Camshaft 8-2.5
2.6 Inspection of Fuel Oil Cam Timing 8-2.6
2.7 Adjustment of Fuel Oil Cam Timing (When replacing cam) 8-2.7

9. FUEL OIL INJECTION DEVICE 9

1. General Construction 9-1
2. Replacing Consumables, Implements and Measuring Instruments 9-2
3. Disassembly of Fuel Oil Injection Pump 9-3
4. Fuel Oil Injection Pump 9-4
4.1 Disassembly of Fuel Oil Injection Pump 9-4.1
4.2 Inspection and Maintenance of Fuel Oil Injection Pump 9-4.2
4.3 Assembly of Fuel Oil Injection Pump 9-4.3
5. Fuel Oil Injection Pump Tappet 9-5
5.1 Disassembly of Fuel Oil Injection Pump Tappet 9-4.1
5.2 Inspection and Maintenance of Fuel Oil Injection Pump Tappet 9-4.2
5.3 Assembly of Fuel Oil Injection Pump Tappet 9-4.3
6. Mounting of Fuel Oil Injection Pump and Fuel Oil Injection Pump Tappet 9-6
7. Adjustment of Maximum Combustion Pressure 9-7
8. Priming of Fuel Oil injection Pump 9-8

10. VALVE OPERATING DEVICE 10

1. General Construction 10-1
2. Replacing Consumables, Implements and Measuring Instruments 10-2
3. Disassembly of Valve Operating Device 10-3
4. Inspection and Maintenance of Valve Operating Device 10-4
5. Assembly of Valve Operating Device 10-5

11. GOVERNOR DRIVING DEVICE 11

1. General Construction 11-1
2. Replacing Consumables, Implements and Measuring Instruments 11-2
3. Disassembly of Governor Driving Dvice 11-3

DK-28e Z 11-06
 CHAPTER

ITEM
CONTENTS DK-28e

4. Inspection and Maintenance of Governor Driving Dvice 11-4

5. Assembly of Governor Driving Dvice 11-5

12. INTAKE AND EXHAUST DEVICE 12

1. Outline of Intake and Exhaust Device 12-1
2. Turbocharger 12-2
3. Air Cooler 12-3
3.1 General Construction 12-3.1
3.2 Replacing Consumables, Implements and Measuring Instruments 12-3.2
3.3 Dismounting of Air Cooler 12-3.3
3.4 Inspection and Maintenance of Air Cooler 12-3.4
3.5 Mounting of Air Cooler 12-3.5

13. STARTING AIR SYSTEM 13

1. Outline of Starting Air System 13-1
2. Starting Air Valve 13-2
2.1 General Construction 13-2.1
2.2 Replacing Consumables, Implements, and Measuring Instruments 13-2.2
2.3 Disassembly of Starting Valve 13-2.3
2.4 Inspection and Maintenance of Starting Air Valve 13-2.4
2.5 Assembly of Starting Air Valve 13-2.5
3. Starting Air Rotary Valve 13-3
3.1 General Construction 13-3.1
3.2 Replacing Consumables, Implements and Measuring Instruments 13-3.2
3.3 Disassembly of Starting Air Rotary Valve 13-3.3
3.4 Inspection and Maintenance of Starting Air Rotary Valve 13-3.4
3.5 Assembly of Starting Air Rotary Valve 13-3.5
4. Starting Operation Valve and Handle Switch 13-4
4.1 1 General Construction 13-4.1

14. FUEL OIL SYSTEM 14

1. Outline of Fuel Oil System 14-1
2. Fuel Oil Relief Valve 14-2
2.1 General Construction 14-2.1
2.2 Replacing Consumables, Implements and Measuring Instruments 14-2.2
2.3 Disassembly of Fuel Oil Pressure Relief Valve 14-2.3
2.4 Inspection and Maintenance of Fuel Oil Relief Valve 14-2.4
2.5 Assembly of Fuel Oil Relief Valve 14-2.5
3. Fuel Oil Feed Pump 14-3
3.1 General Construction 14-3.1
3.2 Replacing Consumables, Implements, and Measuring Instruments 14-3.2

DK-28e Z 11-06
CHAPTER

ITEM

DK-28e CONTENTS

3.3 Dismounting of Fuel Oil Feed Pump 14-3.3

3.4 Disassembly of Fuel Oil Feed Pump 14-3.4
3.5 Inspection and Maintenance of Fuel Oil Feed Pump 14-3.5
3.6 Assembly of Fuel Oil Feed Pump 14-3.5
4. Fuel Oil Feed Pump Driving Device 14-4
4.1 1 Disassembly of Fuel Oil Feed Pump Driving Device 14-4.1
4.2 Maintenance and Assembly of Fuel Oil Feed Pump Drive Device 14-4.2
䂾 Fuel Oil Filter ( ：5-4.3 in "Operation Manual")

15. LUBRICATING OIL SYSTEM 15

1. Outline of Lubricating Oil System 15-1
2. Lubricating Oil Pump 15-2
2.1 General Construction 15-2.1
2.2 Replacing Consumables, Implements and Measuring Instruments 15-2.2
2.3 Disassembly of Lubricating Oil Pump 15-2.3
2.4 Inspection and Maintenance of Lubricating Oil Pump 15-2.4
2.5 Assembly of Lubricating Oil Pump 15-2.5
3. Lubricating Oil Cooler 15-3
3.1 General Construction 15-3.1
3.2 Replacing Consumables, Implements and Measuring Instruments 15-3.2
3.3 Inspection and Maintenance of Lubricating Oil Cooler 15-3.3
3.4 Assembly of Lubricating Oil Cooler 15-3.4
4. Lubrication Oil Relief Valve 15-4
4.1 General Construction 15-4.1
4.2 Replacing Consumables, Implements and Measuring Instruments 15-4.2
4.3 Disassembly of Lubricating Oil Relief Valve 15-4.3
4.4 Inspection and Maintenance of Lubricating Oil Relief Valve 15-4.4
4.5 Assembly of Lubricating Oil Relief Valve 15-4.5
5. Lubricating Oil Temperature Control Valve 15-5
5.1 General Construction 15-5.1
5.2 Replacing Consumables, Implements and Measuring Instruments 15-5.2
5.3 Disassembly of Lubricating Oil Temperature Control Valve 15-5.3
5.4 Inspection and Maintenance of Lubricating Oil Temperature Control Valve 15-5.4
5.5 Assembly of Lubricating Oil Temperature Control Valve 15-5.5
( : "Operation" 5-3.2 "Manual Adjustment of Lubricating Oil Temperature")

16. COOLING WATER SYSTEM 16

1. Outline of Cooling Water System 16-1
2. Cooling Water Pumps 16-2
2.1 General Construction 16-2.1
2.2 Replacing Consumables, Implements and Measuring Instruments 16-2.2
2.3 Disassembly of Cooling Water Pump 16-2.3

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 CHAPTER

ITEM
CONTENTS DK-28e

2.4 Inspection and Maintenance of Cooling Water Pump 16-2.4

2.5 Assembly of Cooling Water Pump 16-2.5
3. Cooling Water Temperature Control Valve 16-3

17. ENGINE CONTROL AND PROTECTIVE DEVICE 17

1. Outline of Engine Control and Protective System 17-1
2. Fuel Oil Shutdown Device (G2 Type) 17-2
2.1 General Construction 17-2.1
2.2 Replacing Consumables, Implements, and Measuring Instruments 17-2.2
2.3 Disassembly of Fuel Oil Shutdown Device (G2 Type) 17-2.3
2.4 Inspection, Maintenance, and 17-2.4
Assembly of Fuel oil Shutdown Device (G2 Type)
2.5 Mounting and Adjustment of Fuel Oil Shutdown Device (G2 Type) 17-2.5
3. Fuel Oil Shutdown Device (H2 Type) 17-3
3.1 General Construction 17-3.1
3.2 Replacing Consumables, Implements, and Measuring Instruments 17-3.2
3.3 Disassembly of Fuel oil Shutdown Device (H2 Type)
3.4 Maintenance, Assembly, Mounting and Adjustment of 17-3.4
Fuel Oil Shutdown Device (H2 Type)
4. Fuel Oil Shutdown Device (J2 Type) 17-4
4.1 General Construction 17-4.1
4.2 Replacing Consumables, Implements, and Measuring Instruments 17-4.2
4.3 Disassembly of Fuel oil Shutdown Device (J2 Type) 17-4.3
4.4 Maintenance, Assembly of Fuel Oil Shutdown Device J2 Type) 17-4.4
4.5 Mounting and Adjustment of Fuel Oil Shutdown Device (J2 Type) 17-4.5

18. GAUGE BOARD 18

1. Gauge Board 18-1
1.1 General Construction 18-1.1
1.2 Replacing Consumables, Implements, and Measuring Instruments 18-1.2
1.3 Disassembly and Maintenance of Gauge Board 18-1.3
2. Seal Pot (Heavy Fuel Oil Specification) 18-2

DK-28e Z 11-06
 CHAPTER
Introduction
0
ITEM
Prior to Start of Engine Maintenance DK-28e 1

0
0 Introduction

(1) Only skilled operators who have carefully read and fully understood the instruction
manual should operate, inspect and service this machine.
Operation, inspection or servicing by persons inadequately familiar with the machine
may result in personal injury, equipment damage or environmental hazard.
(2) No responsibility shall be assumed whatsoever for product damage or any associated
fires, oil spills or other environmental hazards, personal injuries, property damage or
economic losses caused by the use of non-genuine parts or operation, inspection or
servicing that deviates from the instruction manual.
(3) We shall repair new parts or replace any flawed parts made or sold by us, however no
compensation shall be provided for damage to any equipment not of our manufacture
or cargo, or personnel, fire-fighting, towing or other expenses arising from the use of
such flawed parts or fowled fuel, lubricant, cooling water or other medium.
(4) This instruction manual is subject to change without notice.

0-1 Prior to Start of Engine Maintenance

Before the maintenance work is performed, please read this Manual sufficiently, fully
understand the structure of the parts concerned, and understand well the contents of the
work in advance, and fully understand the working procedure and then start the work.
Execution of the work without sufficient advance understanding will not only result in
spending useless labors but also lead to the troubles and damages of the engine due to
wrong assembly, and personal accidents as well.
Strictly avoid use of the engine for a purpose other than the original purpose of the use
of engine, or on the conditions that are different from the specified conditions or handling
against the descriptions given herein, since such operation will cause accidents or trou-
bles.
Please be advised that the descriptions of this manual may be changed without notice.

(1) This manual bears the following safety signs:

These symbol marks indicate the important descriptions concerning safety. Be fully careful, and conduct
the work with the motto of "Safety First".

："Warning" = Precaution related to the safety of personnel (Potential hazard which could result in
death or serious injury)
："Caution" = Precaution related to the safety of personnel (Potential hazard which may result in
minor or moderate injury)

："Notice" = Information on handling of the engine to prevent damage

："Prohibition" = Prohibited practice that can affect the safety of personnel and the engine

："Obligatory acts" = Recommended practice or instruction to be followed to ensure safety of per-

sonnel and the engine.

DK-28e Z 11-06
CHAPTER
Introduction
0
ITEM

1 DK-28e Prior to Start of Engine Maintenance

(2) If it is found as a result of disassembly or inspection that the parts are damaged or end of their service
life is reached, be sure to replace such parts.

(3) For replacement, be sure to use our genuine parts or those specified by us. If the parts used for
replacement are other than our genuine parts or those specified by us, we shall not be held responsible
for their quality

(4) When it is difficult to take countermeasures or corrective actions at the site, or the required replacing
parts are not prepared, please contact our Service Department, Parts Sales Department, branch office or
service agent to take appropriate actions.
At that time, be sure to inform us or our agent of the engine type and the engine number.

(5) For handling of the following equipment, refer to the Individual Instruction Manuals attached separately.
1) Turbocharger 2) Governor 3) Control equipment
4) Ancillary equipment of special specifications

(6) Keep this Instruction Manual and the related documents (drawings, materials, etc.) in the specified
place at all times for ready reference by the persons engaged in the operation and maintenance of
engine at any time, and at the same time, when the engine supervisor is changed, the predecessor is
requested to transfer his duties to the successor completely.

(7) To prevent public pollution, do not dispose of the replaced scrapped parts or waste liquid without per-
mission but entrust the disposition to an authorized professional disposal company.

DK-28e Z 11-06
 CHAPTER
Introduction
0
ITEM
Precautions Pertaining to Maintenance: Safety Precautions DK-28e 2.1

0
0-2 Precautions Pertaining to Maintenance
0-2.1 Safety Precautions
(1) After stop of the engine, do not open the crankcase side cover for at least 10 minutes, until the
engine cools down sufficiently. If fresh air should flow into the engine, while the engine is not
cooled down, explosion may occur igniting on the oil mist.
(2) Revolution of the engine during the disassembly or inspection work will cause great hazards such
as injury resulting from entanglement.
Before starting the disassembly or inspection work, put the control handle position back to the
"STOP" position, securely close the valves on the starting-air system, extract starting air on
the engine side, and confirm that the engine will not revolve.
Be sure to turn OFF the control power.
When turning the engine, be sure to check that the rotary section is free from contact with
other sections, and that turning of the engine does not bring about hazards to the co-workers
or persons in vicinity, and conduct turning with signs exchanged between the workers.
When moving sections of the engine is disassembled or inspected, take the measures to pre-
vent the crankshaft from idle turning.
Put the flywheel turning device back to the "disengage" position except for execution of fly-
wheel turninq.
(3) Before executing the work, wear protection gears such as gloves, hard hat, safety shoes, and
safety goggles depending on the applicable situations.
While the engine is operating, and just after the engine is stopped, particularly the exhaust
pipe, turbocharger, cylinder heads and parts around them are hot. When servicing them,
wear safety gloves to avoid burns.
(4) The engine room floor and the surroundings are slippery as a result of the deposit of oil. Wipe off
oil on the floor and the shoe soles. When the work is intended at a high place such as on a step
board, particularly be careful of your footing to prevent falling accidents.
(5) When disassembling each pipeline, set all the valves in the external connections to the "CLOSE"
position, and gradually loosen the air vent plug to release the remaining pressure in advance.
If each filter and the joint area of piping system are disassembled immediately after the engine is
stopped, high-temperature oil or water may spout out under residual pressure, and may cause
burn accidents.
Contact of the splashing hot oil with any high-temperature part may cause a fire. Take utmost care
not to splash the oil.
(6) When the spring-incorporated valves or devices are disassembled, conduct the assembly work
very carefully, since the spring may jump out to cause an injury to the worker.
(7) Do not lit heavy parts and equipment forcibly with physical strength. Use wire ropes and chain
blocks to lit them. Also do not walk up to under lifted things.
Concerning the wire ropes used to lift the parts, select a normal one free from break or twist of the
element wire, and of the specified dimensions conforming to the applicable weight.
(8) When inspecting and disassembling an electrical product, be sure to turn OFF the POWER switch,
and put up a sign of "Under Construction".
(9) When handling a liquid, strictly observe the following instructions:
Fuel oil, lubricating oil: Inflammable ･･････Naked flames are strictly prohibited.
Fresh water corrosion inhibitor, fresh water anti-freeze, mercury (thermometer) = Poisonous
････････Drinking is prohibited. Wash away, if deposited on the skin.
Battery electrolyte = Poisonous ･･････Drinking is prohibited. Wash away, if deposited on the
skin. Naked flames are strictly prohibited.
◎ For the sake of preventing pollution, entrust a special waste disposal company with the task
of disposing the used waste liauid and oil

DK-28e Z 11-06
CHAPTER
Introduction
0
ITEM
Precautions Pertaining to Maintenance: Precautions/Check
2.2,2.3 DK-28e for Disassembly, Maintenance and Assembly

0-2.2 Precautions for Disassembly, Maintenance and Assembly

(1) Prepare the replacing parts, tools and measuring instruments in advance. As for the tools, be minded to
use those specified, and concerning the replacing parts, use our genuine parts or those specified by us.
(2) Gaskets, O-rings, split pins and wire ring wires must be replaced with the new parts after every disas-
sembly. Prepare the new parts according to the extent of disassembly.
(3) Block the openings resulting from disassembly with tape or clean cloth to prevent infiltration of foreign
matters.
After restoration, be sure to remove such tape or cloth.
(4) ) Place disassembled parts in neat order for prevention of the damage or loss, and for improvement of
the assembly working efficiency.
(5) Be sure to assemble the parts provided with the assembling position marks or matchmarks, such as the)
cylinder numbers and the bearing numbers, to their original positions.
Further, when these parts are replaced, be sure to provide the new parts with the same marks as those
provided on the old parts.
(6) Materials of the bolts and nuts used in high-temperature sections such as the exhaust manifold are heat-
resistant. When reassembling the engine, therefore, be careful not to confuse them with ordinary bolts
and nuts.
(7) Tighten the main bolts and nuts uniformly with the specified torque (or specified oil pressure).
If it is necessary to apply an agent, such as a lubricant, to the bolts and nuts when tightening them,
never use an agent other than the specified ones.
(8) When parts are required to be measured during maintenance, perform the measurement correctly, and
arrange the results of the measurement as the data for the reference on later days.
(9) After the completion of the work, restore the lagging of the exhaust pipe and the turbocharger, the
exhaust pipe cover and the parts shielding heated parts, such as the heat box, if they have been
removed for disassembly and servicing. Newly treat the disconnected joints with combustible oil splash
preventive means (FN tape) after the completion of the work.
(10) Be minded to promptly replenish all the used spare parts.

0-2.3 Check Items after Disassembly, Maintenance and Assembly

(1) Check that all the bolts and nuts are free from loosening, and that specified lock washers are inserted
securely. Particularly be careful when checking the inside of the engine where visual inspection is
impracticable during operation.
(2) Turn the engine and prime each fluid to check that there is no problems such as interference of the
working area, and leakage or clogging of each section.
(3) After completion of the work, check that that the flywheel turning device and the turning bar that have
been used are in "disengaged" position.
(4) Record the contents of the work executed and the parts replaced in the Engine Diary.

DK-28e Z 11-06
 CHAPTER
Introduction
0
Engine Conforming to NOx Technical Code: ITEM
Outline / Parts to be Specified / Engine Setting Value DK-28e 3.1～3.3

0
0-3 Engine Conforming to NOx Technical Code

0-3.1 Outline
(1) The marine diesel engines, to which the 13th rule "Nitrogen Oxides (NOx)" in Supplement VI "Rules to
Prevent Air Pollution by Ships" to MARPOL73/78 Treaty is applied should conform to NOx Technical
Code.
(2) The engines conforming to NOx Technical Code are authorized as an engine group or an engine family,
and it is allowed to apply the engine parameter check method to them, when receiving the NOx dis-
charge inspection on board.
The engine parameter check method is a method for verifying that the engine components and the set-
ting values conform to the requirements specified in the technical file, and does not require the measure-
ment of NOx discharge. To the engines that are not conforming to the requirements of the technical file,
the engine parameter check method cannot be applied. For such engines, the measurement of NOx dis-
charge shall be required.

0-3.2 The Parts to be Specified

The technical file states the engine components that can affect the NOx discharge specified in NOx
Technical Code, and shows the identification marks stamped on them, and the user is required to maintain
the technical file for each engine. When replacing any parts shown in the technical file, be sure to use our
genuine parts stamped with the identification marks. In the case that any parts without the identification
mark is used, it shall be regarded as nonconformance to the requirements of the technical file, and in such a
case, inspection by the engine parameter check method cannot be applied.

The followings are the parts that have the identification marks specified in the technical file. When replac-
ing any of these parts, be sure to check the identification marks.( ："Technical File")

<Parts with identification marks>

1) Cylinder head 2) Piston 3) Turbocharger
4) Air cooler 5) Fuel oil cam 6) Fuel oil injection pump
7) Fuel oil injection pump plunger 8) Fuel oil injection valve 9) Fuel oil injection valve nozzle

0-3.3 Engine Setting Value

The engines conforming to NOx Technical Code are adjusted to conform to the specifications before ship-
ment. After shipment, they should not be adjusted to such a manner that the setting values specified in the
technical file may be deviated. If any change is made in the manner that may deviate from the setting val-
ues specified in the technical file, it shall be considered to be nonconformance to the requirements of the
technical file, and the inspection by the engine parameter check method cannot be applied.

The followings are the items that have been set to conform to NOx Technical Code:

<Items set before shipment>

(1) Fuel oil injection timing

e
DK-28e Z 11-06
CHAPTER
1 Equipment Arrangement and Maintenance Schedule
ITEM
1 DK-28e Equipment Arrangement

1. Equipment Arrangement and Maintenance Schedule

1-1 Equipment Arrangement

Cylinder head
Intake and exhast valves
Starting valve
Exhaust pipe Rocker arm device
Indicator, Safety valve

Fuel oil injection valve

Fuel oil injection pump

Piston

Intake duct
Rocker arm divice
Cylinder liner Camshaft

Connecting rod Engine frame

Crank pin shell Crank shaft

Governor
Governor
driving device

Cam gear Starting air

rotary valve
Idle gear

Crank gear Thrust bearing

Auxiliary drive Main bearing shell

gear

DK-28e Z 11-06
 CHAPTER
Equipment Arrangement and Maintenance Schedule 1
ITEM
Equipment Arrangement DK-28e 1

1-1 Equipment Arrangement

Fuel oil relief

valve 1
Operation lever Fuel oil shut down
Seal pot device
Gauge board

Starting
operation
valve

Governor

Fuel oil feed pump

Lubricating oil pump
Cooling water pump
(Jacket line) Starting air valve Fuel oil filter
Lubricating oil filter

Turbo charger Turbocharger lubricating oil

filter ( for MET ) Turbo charger

Lubricating
oil filter
Air cooler Air cooler
Lubricating
oil filter

Main Engine Auxiliary Engine

(Note) Equipment arrangement may vary according to each specification.

e DK-28e Z 11-06
CHAPTER
1 Equipment Arrangement and Maintenance Schedule
ITEM
2 DK-28e Maintenance Schedule Table

2. Maintenance Schedule Table

This table covers the periodic disassembly and maintenance items of the engine. For the items related
with daily maintenance and inspection, refer to a separate volume.( ："Operation")
(◯：Periodical inspection, ▲：The 1st inspection after the initial operation, and after overhaul and
maintenance, ◎：Replacement.)

Overhaul and maintenance piriod(hr)

Work
Overhaul and man-hour 1000 2000 4000 8000 16000 Reference

㨪
㨪
maintenance Work contents No. of Remarks
portion workers x 1500 3000 6000 12000 24000
2 to 4 to
Hours 3 mths 6 mths 1 yr. 3 yr. 5 yr.

Cylinder head Checking and retightening cylinder head bolt 㧖㧞㨤0.20 ً ٤ 3-1

Overhaul of cylinder head (top hole) 㧖㧞㨤1.0 ٤ 3-1

Cylinder head inspection and cleaning 㧖㧝㨤1.5 ٤ 3-1

Intake and exhaust valve disassembly,
inspection and facinf-up 㧖㧝㨤2.0 ٤ 3-2

Valve rotaitor disassembly and inspection 㧖㧝㨤1.0 ً ٤ 3-2

Valve spring and cotter inspection 㧖㧝㨤0.25 ً ٤ 3-2

Starting valve disassembly and inspection 㧖㧝㨤1.0 ٤ 3-3

Rocker arm disassembly and inspection 㧖㧝㨤1.0 ٤ 3-4

Indicator and safety valve
disassembly and inspection 㧖㧝㨤1.5 ٤ 3-5
Exhaust valve seat and O-ring
replacement 㧖㧝㨤2.0 ٧ 3-1
Jacket opening for removal of scale 㧖㧝㨤1.0 ٤ 3-1
Piston extraction (including connec-
Piston ting rod small end part) 㧖㧞㨤1.0 ٤ 4-3

Piston inspection,cleaning and measurement 㧖㧝㨤0.5 ٤ 4-4

Piston ring replacement 㧖㧝㨤0.5 ٧ 4-4

Piston pin inspection and measurement 㧖㧝㨤0.25 ٤ 4-4

Piston pin bush inspection 㧖㧝㨤0.25 ٤ 4-4

Protection ring Extraction,inspection,cleaning and measurement 㧖㧝㨤0.25 ٤ 4-3 5-3
Connecting rod Connecting rod bolt inspection and retightening 㧖㧞㨤1.0 ً ٤ 4-5
Crankpin bearing overhaul inspection,
and bearing shell replacement 㧖㧞㨤1.5 ٤ ٧ 4-4

Crankpin inspection and measurement 㧖㧝㨤0.5 ٤ 4-4

Connecting rod bolt inspection and replacement 㧖㧞㨤1.0 ٤ ٧ 4-5

Cylinder liner Cylinder liner inner surface inspection, ٤ 5-3
and measurement 㧖㧝㨤1.0
Cylinder liner extraction 㧖㧞㨤2.0 ٤ 5-4
Inspection on jacket side and 㧖㧝㨤1.0
replacement of O-ring ٤ ٧ 5-5
Main bearing Main bearing bolt tightening check 㧖㧞㨤0.5 ٤ 6-3
Disassembly and inspection of main
bearing,Replacement of bearing shell 㧖㧞㨤2.0 ٤ ٧ 6-3

DK-28e Z 11-06
 CHAPTER
Equipment Arrangement and Maintenance Schedule 1
ITEM
Maintenance Schedule Table DK-28e 2

Overhaul and maintenance period (hr)

Work
Overhaul and 1000 2000 4000 8000 16000 Referrence
man-hour
maintenance Work contents

䌾
No.of Remarks
portion workersx
Hours
1500 3000 6000 12000 24000
3 mths 6 mths 1 yr. 23 yt r.o 4 to
1
5 y r.
Crankshaft Deflection measurment 䋲䌸1.0 䂥 䂾 Separate "Operation"
volume 5-4.6
Balance weight bolt tightening check
䋰 Wiring inspection 䋱䌸0.5 䂾 䋷-䋳
䋰 Inspection by torque wrench 䋲䌸3.0 䂾 䋷-䋳
Tightening bolt check and retightening 䋲䌸2.0 䂾 䋸-䋱
( Idle gear and idle gear shaft)
Timing gear Gear tooth contact and backlash inspection 䋱䌸0.5 䂾 䋸-䋱
Idle gear overhaul and bush inspection and
measurement 䋱䌸1.0 䂾 䋸-䋱
Cam gear Cam gear disassembly and inspection 䋲䌸2.0 䂾 䋸-䋲
Camshaft Cam shaft disassembly, inspection, and 䋳䌸3.0 䂾 䋸-䋲
measurment
Camshaft bearing Camshaft bearing shell disassembly, 䋲䌸1.0 䂾 䋸-䋲
shell inspection , and measurement
Fuel oil injection Injection timing check 䋪䋲䌸1.0 䂥 䂾 䋸-䋲
pump 䋪䋱䌸2.0
Disassembly and inspection 䂾 䋹-䋴
O-ring replacement 䃁 䋹-䋴
Deflector inspection and replacement 䃁 䋹-䋴
Plunger assembly replacement 䃁 䋹-䋴
Delivery valve replacement 䃁 䋹-䋴
Spring replacement 䃁 䋹-䋴
Fuel oil tappet Tappet spring replacement 䃁 䋹-䋵
Fuel oil injection Extruction inspection, cleaning and injection Separate "Operation"
valve pressure adjustment 䋪䋱䌸1.0 䂾 /䃁 volume 5-4.2
Fuel oil high Inspection, O-ring replacement 䋪䋱䌸0.5 䂾 /䃁 Separate "Operation"
pressure joint volume 5-4.2
Fuel oil O-ring replacement 2䌸4.0 䂾 䃁
piping system
Valve operating Swing arm disassembly, roller and bush 䂾
device inspection 䋪䋱䌸1.0 10
䃩 Governor Disassembly and inspection Separate Instruction
volume manual
Governor driving Disassembly, inspection and cleaning 䋱䌸2.0 䂾 11
device 䋰 Bearing, O-ring replacement
䂾/䃁 11
Disassembly, inspection and cleaning Separate Instruction
䃩Turbocharger volume manual
Air cooler Disassembly, inspection, cleaning and 䋲䌸3.0 䂾 12-3
hydrostatic test
Starting air valve Disassembly, inspection and O-ring replacement 䋱䌸2.0 䂾/䃁 13-2
Starting air rotary Disassembly and inspection 䋱䌸1.5 䂾 13-3
valve
Starting air pipe Disassembly and inspection 䋱䌸0.5 䂾 13-3
safety valve
Fuel oil relief valve Disassembly and inspection 䋱䌸1.5 䂾 14-2
Fuel oil feed pump Disassembly, inspection and cleaning 䋱䌸2.0 䂾 14-3
䋰 Oil seal and mechanical seal replacement
䃁 14-3
䋰 Bearing replacement 䃁 14-3
Lubricating oil Disassembly, inspection and cleaning 䋲䌸1.5 䂾 15-2
pump
䋰 Bearing and oil seal replacement
䃁 15-2
Lubricating oil Disassembly, inspection, cleaning and 䋲䌸3.0 䂾 15-3
cooler hydrostatic test
Lubricating oil Disassembly and inspection 䂾 15-4
relief valve 䋱䌸1.5
Lubricating oil Disassembly, inspection, cleaning and 䋱䌸1.0 䂾/䃁 15-5
temp. control valve pellet replacement

DK-28e Z 11-06
CHAPTER
1 Equipment Arrangement and Maintenance Schedule
ITEM
2 DK-28e Maintenance Schedule Table

Overhaul and maintenance period (hr)

Work
man-hour 1000 2000 4000 8000 16000 Referrence

㨪
Work contents No.of Remarks
workersx 1500 3000 6000 12000 24000
Hours 3 mths 6 mths 1 yr. 2 to 4 to
3 y r. 5 y r.
Cooling water Disassembly, inspection and cleaning 㧖㧞㨤2.5 ٤ 16-2
pump
㧜 Oil seal, mechanical seal replacement ٧ 16-2
㧜 Bearing replacement ٧ 16-2
Cooling water Disassembly, inspection,cleaning and 㧝㨤1.0
temp. control valve element replacement ٤ ٧ 16-3
Fuel oil shutdown Disassembly, inspection,and O-ring ٤٧
replacement 㧝㨤1.0 17
device
Replacement of pressure gauge rubber
hose and vibration insulating rubber ٧ 18
㧝㨤1.0
Inspection of pressure gauge and
tachometer (Calibration) ٤
٤ 18
Replacement of F.O. pressure gauge
ethylene glycol 㧝㨤0.5 ٧ 18
(In case of heavy fuel oil specifications)
Pressure damper
Accumulator assembly replacement
of main fuel oil
(including the O ring) 㧝㨤0.5 ٧
pipe

Notes:
1. The above table shows the standard values of the man-hour as well as the overhaul and maintenance
period under the conditions of general use of the heavy fuel oil.
In servicing an actual engine, initially set the work man-hour larger, and set the overhaul and mainte-
nance interval smaller than those shown in the table.
Later reset the work man-hour as well as the overhaul and maintenance interval to the most appropriate
values, according to the operating conditions, work environment, and the results of the overhaul.
2. The work man-hour is based on the standard values for the experienced workers who are also skilled in
restoration. Therefore, please plan to have extra times for those with in experience.
3. The mark "★" given in the work-hour column indicates the man-hour per unit (one cylinder or one bear-
ing). When the number of the objects is "n" pieces, multiply the value by "n".
4. Have the work marked with "☆" executed by a professional technician of the manufacturer or mainte-
nance company, of conduct the work under his guidance.

DK-28e Z 11-06
 CHAPTER
Equipment Arrangement and Maintenance Schedule 1
ITEM
MEMO DK-28e

1
CHAPTER
General Maintenance Items
2
ITEM
1 DK-28e Preparation before Maintenance Work

2 General Maintenance Items

2-1 Preparation before Maintenance Work

Make the following preparation before starting the engine disassembly and maintenance work

<Preparation before work>

(1) Set the control handle to the "STOP" position.
(2) Close the air tank main valve.
(3) Close the fuel oil outlet and inlet valves.
(4) Close the lubricating oil outlet and inlet valves.
(5) Close the cooling water outlet and inlet valves.
(6) Open the cooling water inlet pipe drain valve to discharge cooling water in the jacket.
(7) Turn OFF the POWER switch of engine control system.
(8) Open the rindicator valve.

DK-28e Z 11-06
 CHAPTER
General Maintenance Items
2
ITEM
General Consumables and Materials / General Tools,
Implements, and Measuring Instruments DK-28e 2.1,2.2

2-2 General Consumables and b) Double-ended spanners (7X8, 8×10, 13×

Materials / General Tools, 17, 19×22, 24×27, 30×32, 36X41,
Implements, and Measuring 46X50)
Instruments c) One-ended spanner (65)
d) Offset wrenches (27×30)
General consumables, materials, tools, and
e) Hex. rod spanners (19)
measuring instruments to be prepared for the
engine maintenance work are shown below. The f) Hex. rod heads (LC×1808, LCX1810, 2
consumables, tools and measuring instruments LCX1814)
specially required for specific works are shown in g) Ring heads (27X2800RH, 36X2800RH)
each individual section. h) Box spanner (19×300, 24×300)
i) Monkey wrenches
2-2.1 General Consumables and Materials j) Pliers
1) Waste cloth k) Snap ring pliers
2) Washing oil l) Screwdrivers (plus, minus)
3) Lubricating oil m) Hammers (iron, plastic)
4) Grease
5) Machine oil VG-10 2) Torque wrenches (450CL, 1800CL,
6) Lubricating penetrant (Cray 5-56) 5600QLK, 21000QLE)
7) Sandpaper #80 and or equivalent 3) Ratchet handles (LQ4080, 2800QH)
8) Wire brush
4) Extension bars (12.7X250, 19X400,
9) Wire (for wiring)
25.4X400)
10) Lead wire (measuring instruments for gear
5) Spinner handle (12.7X300)
backlash, etc.)
11) Lubricating agent (MOLYKOTE 1000 spray, 6) Turning bar (34x 1500)
MOLYKOTE 1000 paste type, MOLYKOTE 7) Eye bolts (M10, M12, M16)
1000 U-paste type) 8) Chain block
12) Silicon rubber 9) Wire rope for suspension
13) Compound medium size, fine size (for facing- 10) Tap (M12X1.75)
up) 11) Oil dispenser
14) Dye testing penetrant (for color check)
15) Blue paint lead (for confirmation of fitting) (2) Measuring instruments
16) Liquid sealant (THREE BOND 1215) 1) Calipers
17) Adhesive (ROCK-TIGHT 243, 271) 2) Thickness gauge
18) High-temperature anti-seizure agent 3) Outside micrometer (mm)
(MOLYKOTE G Rapid, Sumokon paste) (0-25, 25-50, 50-75, 75-100, 125-150, 150-
19) Liquid nitrogen, dry ice, or alcohol 175, 175-200, 225-250, 275-300)
20) Oil whetstone 4) Spherical micrometer (0-25 mm)
5) Cylinder gauge (mm)
(18-35,35-60, 50-150, 160-250, 250-400)
2-2.2 General Tools, Implements, and 6) Dial caliper gauge (6-18 mm)
Measuring Instruments 7) Dial gauge
8) Magnet stand
(1) General tools and implements
1) General tools
a) Sockets (19X12.7, 24 X 12.7, 27X12.7,
32X19, 36X19, 36X25.4, 55X25.4)

DK-28e Z 11-06
CHAPTER
General Maintenance Items
2
ITEM

3 DK-28e Bolt and Nut Tightening Torque, Tightening Oil Pressure

2-3 Bolts and Nut Tightening Torque, Tightening Oil Pressure

Bolt or nut Tightening torque or

Names of bolts and nuts Size width oil pressure Remarks
across flats
(mm) (N.m) {kgf.m}

Cylinder head bolts Hydraulic Oil pressure 83.4 MPa ‫ڏ‬

1 M48 tightening {850 kgf/cm2} Studding torque 294 {30}
Hex. hole:19 Oil pressure 83.4 MPa ‫ ڏ‬Studding torque
2 Connecting rod bolt-1 M42 Hydraulic {850 kgf/cm2}
tightening 29-39{3.0-4.0}
o
3 Connecting rod bolt-2 M24 36 196 {20}+25 ‫ڎڏ‬

4 Piston crown bolt M16 24 147 {15} ‫ ڏ‬Studding torque 103 {10.5}
Hex. hole:19 Oil pressure 58.9 MPa ‫ ڏ‬To be returned by 1/4 to 1/2
5 Side bolt M42 Hydraulic {600 kgf/cm2}
turn after complete screwing
tightening on the studding side.

6 Main bearing bolt Hydraulic Oil pressure 88.3 MPa Studding torque 294 {30}
M48 tightening {900 kgf/cm2}
o
7 Balance weight bolt M36 55 490 {50} + 35 ‫ڎڏ‬

8 Flywheel reamer bolt M39 60 1470 {150} + 30o ‫ڎڏ‬

Aux. machinery drive gear 117 {12} ‫ڎڏ‬

9 mounting bolt M16 24

10 Swing
bolt
arm shaft mounting M20 30 138 {14} ‫ڎڏ‬

Idle gear-1,2 tightening

11 bolt M24 36 490 {50} ‫ڎڏ‬

Idle gear shaft mounting M22 32 392 {40} ‫ڎڏ‬

12 bolt

13 Camshaft
and nut
tightening bolt M20 27 373 {38}

14 Cam gear mounting bolt M20 27 314 {32} ‫ڎڏ‬

Camshaft thrust receptor
15 mounting bolt M10 17 39 {4.0} ‫ڎڏ‬

16 Rocker arm shaft assy. M20 30 196 {20} ‫ڎڏ‬

mounting nut
Fuel oil injection pump M16 Hex. hole:14 ‫غ‬
17 delivery valve mounting bolt 157~177 {16~18}

Fuel oil injection nozzle

18 Retaining M40 36 353~382 {36~39} ‫غ‬
nut Operation 5-4.2
Pump side
Hex. hole:10 74 {7.5} ‫ڎڏ‬
19 Fuel oil high-pressure M12
coupling mounting bolt Head side 19 59 {6.0} Operation 5-4.2
M12

59 {6.0} ‫ڎڏ‬
20 Nozzle holder retainer nut M14 22
Operation 5-4.2

DK-28e Z 11-06
 CHAPTER
General Maintenance Items
2
ITEM
Bolt and Nut Tightening Torque, Tightening Oil Pressure DK-28e 3

Bolt or nut Tightening torque or

width oil pressure Remarks
Names of bolts and nuts Size across flats (N m)
(mm) (kgf m)
Operation
21 Inlet connector M18 27 49-59 {5.0-6.0} ٟ 5-4.2
Fuel oil tappet adjusting 294
22 lock nut M22 32
{30} ٟ
Starting valve cover
23 mounting bolt M12 19
59
{6.0} ‫ڎڏ‬
2
Starting valve end hexagon 98
24 (Fixing piston) M14 13 ‫ڎڏ‬
{10}
Indicator and safety valve 59
25
tightening nut M12 19
{6.0}
‫ڎڏ‬
Governor drive gear power 81
26 lock M10 Hex. hole:8 {8.3} ٟ Use of MOLYKOTE is prohibited.
Exhaust outlet block M16 157-176 To be applied with high-temperature
27 mounting bolt 24 seizing preventive agent.
{16-18}
Safety valve spring cap. 637
28 L.O.pump M52 65
{65}
‫ڎڏ‬
L.O.pump drive gear 735 ‫ڎڏ‬
29 tightening nut M39 60 {75}
30 General bolts and nuts M10 17 15-20 {1.5-2.0}
M12 19 29-39 {3.0-4.0}
M14 22 34-49 {3.5-5.0}
M16 24 49-69 {5.0-7.0}
M18 27 78-98 {8.0-10 }
Notes:
1) Main bolts and nuts should be tightened according to the above table without fail.
2) Bolts and nuts must be tightened uniformly in a diagonally and alternating sequence.
3) Be sure to check for loose cylinder head bolt and connecting rod bolts after a certain period of opera-
tion. : 1-2 "Maintenance Schedule Table".)
4) Anti-seizure agent should be applied on the threaded arears and seat surfaces around the exhaust
manifold, which are subjected to high temperature, for the prevention of seizure before tightening.
5) Retighten the bolts used for installation after stopping the engine, and be sure to check the crankshaft
deflection after retightening.
6) Torque wrenches used for tightening should be inspected periodically.
7) The symbol marks used in this table signifies the following:
: The tightening hydraulic pressure and torque specified on the name plate attached on the engine
shall have priority.
 : Apply lubricating agent (MOLYKOTE 1000 spray) to the threaded areas (including studding areas).
 : Apply lubricating agent (MOLYKOTE 1000 spray) to the contact surfaces (seating faces).

: Apply lubricating agent (MOLKOTE U paste) to the contact surfaces and threaded areas.
 : Apply the lubricating oil to the threaded areas and contact surfaces.
8) The bolts applied with the adhesive (ROCK-TIGHT 243) cannot be reused after disassembling.
Therfor, replace them with new ones. At the time of restoration, clean carefully the female screw side
by passing the tap through

If any agent other than the specified products is applied, the friction force of the threaded portions
changes, and the bolts are tightened excessively or insufficiently. As the result of this, the bolts may be
broken or loosened, thereby causing serious damage to the engine.

DK-28e Z 11-06
CHAPTER
General Maintenance Items
2
ITEM
Hydraulic Jack:General Construction / Removal of Nut
4.1, 4.2 DK-28e

2-4 Hydraulic Jack (2) Screw the hydraulic jack (assy.) (A) into the
bolt, and then screw the hydraulic piston (a)
until the hydraulic cylinder closely contact on
2-4.1 General Construction of the jack stand.
Hydraulic Jack Further, be minded to screw the hydraulic pis-
The hydraulic jack (assy.) (A) is consisted of a ton until it strikes the hydraulic cylinder.
pair of a hydraulic cylinder and a hydraulic piston. (3) After confirming that the hydraulic jack are
Operate the hydraulic pump (B) connected with closely contacted on the jack stand, turn back
the high-pressure hose (C) to give the rated the hydraulic jack assy. by about 1/2 turn.
pulling power to the bolt by hydraulic pressure. (4) Confirm that the valve of the coupler (C) for
And, in this condition, turn the nut to tighten or connecting the high-pressure hose is not
loosen it. stuck, and then connect the hydraulic jack and
Tighten or remove the nuts of the following bolts the terminal (D), and the terminal and the
by using a hydraulic jack. hydraulic pump using a high-pressure hose.
(5) Loosen the air vent plug (d) of the hydraulic
pump, and release air in the oil tank into the
 Cylinder head bolt atmosphere.
 Main bearing bolt
(6) Check the hydraulic pump oil level, and in case
 Connecting rod bolt-1 that the level is low, replenish the hydraulic oil.
 Side bolt

Hydraulic oil: Machine oil VG-10

2-4.2 Removal of Nuts

Remove the nuts in according to the following
procedure:
(1) Clean the area around the circular nut careful-
ly, and confirm that there is no dirt or foreign
matters on the seat surfaces of the hydraulic
jack stand (E) or hydraulic cylinder (b), and High-pressure hose (C)
place the hydraulic jack stand.
Coupler (c)
Air vent plug (f)
Hydraulic piston (a)
Hydraulic
cylinder (b) Ball

Backup ring

Hydraulic
O-rings jack
assembly
Backup ring (A)

Bolt

Jack handle (F)

Jack stand (E)
Circular nut

Structure of Hydraulic Jack

DK-28e Z 11-06
 CHAPTER
General Maintenance Items
2
ITEM
Hydraulic Jack:Removal of Nut DK-28e 4.2

(7) Tighten the release valve (e) and air vent plug
of hydraulic pump.
(8) Loosen the air vent plug (f) of hydraulic jack,
and operate the hydraulic pump lever to vent
the air in the hydraulic cylinder. Tighten the air
vent plug after confirming that the air is com-
pletely vented.
(9) Operate the hydraulic pump lever to increase
the oil pressure up to the specified level.
Specified value ....... To be specified in
each work item.
( ： 2-3 "Bolt and Nut Tightening Oil
Pressure")
Hydraulic pump resistance pressure:
98.1 MPa {1000 kgf/cm2}
High-pressure hose resistance pressure:
98.1 Mpa {1000kgf/cm2}
(10) Insert the jack handle (F) into the hole of the
circular nut through the oblong hole of the
hydraulic jack stand, and loosen the circular nut
by 5 to 6 holes.
(11) Slowly open the release valve of hydraulic
pump, and gradually reduce the oil pressure
down to "0". 2
(12) Manually loosen and remove the hydraulic
jack assembly.
(13) Remove the hydraulic jack stand.
(14) Remove the circular nut.
When operating the hydroulic jack, oil is
highly pressurized, and if oil is leaked and
sprouted out, it is extreamely dangerous.
Therefor, be minded to wear the protective
glass without fail.

Nutral Release valve (e)

Pressure
Switch lever
Return

to hydraulic jack (A) Oil pressure gauge

Air vent plug (d)

Terminal (D)

High-pressure Oil level stick

hose
Coupler Hydrauric pump (B)

Connection with Hydraulic Pump

DK-28e Z 11-06
CHAPTER
General Maintenance Items
2
ITEM
4.3,4.4 DK-28e Hydraulic Jack:Tightening of Nut

2-4.3 Tightening of nut 2-4.4 Maintenance of Hydraulic Jack

(1) Carefully clean around the bolt, and confirm
that there is no foreign matters on the seat sur- (1) To extract the hydraulic piston from the
face of the nut and jack stand. Then, manually hydraulic cylinder, strike its lower area with a
screw the nut until it gets in contact on the bot- wooden hammer, and pull it out from the
tom, and place the jack stand hydraulic cylinder.
(2) Install the hydraulic jack, and connect to the (2) Remove the air vent plug.
hydraulic pump according to the same proce- (3) Wash all the parts using washing oil, and
dures as those for removal, and increase the oil check them for scratch.
pressure up to the specified level by operating (4) Apply the hydraulic oil to all the parts, and
the hydraulic pump lever. assemble the hydraulic piston to the cylinder.
(3) Insert the jack handle through the long hole of
(5) Replace the O-ring and the back-up ring with
the jack stand, and tighten it until it gets in con-
new one.
tact on the bottom.
(4) Strike the jack handle with a hammer, and
confirm that it is securely tightened.
When installing the piston, be careful so
(5) Slowly open the hydraulic pump release valve,
that the O-ring and the back-up ring may not
and gradually reduce the oil pressure down to "0"
be fitted upside down. Wrong way of fitting will
(6) Increase the oil pressure to the specified value
cause the O-ring to be damaged.
again. Then, strike the jack handle with a ham-
mer by the force similar to that applied previous-
ly to retighten the circular nut, and confirm that <Consumables for hydraulic jack>
the circular nut does not show any increase in
the angle (i.e. does not turn any further). ( :"Parts List")
(7) When the circular nut shows an increase in a) For cylinder head bolt
the angle, repeat the above procedures (retight- 1) O-ring (large) 4-7.4.1 No.505
ening of the circular nut at the specified oil pres- 2) O-ring (small) 4-7.4.1 No.504
sure R reduction of the oil pressure to "0" R 3) Back-up ring (large) 4-7.4.1 No.9
retightening of the circular nut at the specified
4) Back-up ring (small) 4-7.4.1 No.8
oil pressure) 2-3 times, and confirm that the cir-
cular nut does not show any increase in the b) For main bearing bolt
angle any more.
1) O-ring (large) 4-7.4.2 No.505
(8) Remove the hydraulic jack stand by loosen-
2) O-ring (small) 4-7.4,2 No.504
ing with your hand.
(9) Remove the hydraulic jack stand. 3) Back-up ring (large) 4-7.4.2 No.9
(10) In the case of the bolt equipped with the pro- 4) Back-up ring (small) 4-7.4.2 No.8
tection cap on the thread, fit it with the protec-
tion cap. c) For connecting bolt-1 and side bolt
1) O-ring (large) 4-7.4.3 No.508
2) O-ring (small) 4-7.4.3 No.507
3) Back-up ring (large) 4-7.4.3 No,28
4) Back-up ring (small) 4-7.4.3 No.29

DK-28e Z 11-06
 CHAPTER
General Maintenance Items
2
ITEM
MEMO DK-28e

2
CHAPTER
3 Cylinder Head and Valves
ITEM

1.1 DK-28e Cylinder Head:General Construction

3. Cylinder Head and Valves
3-1 Cylinder Head
3-1.1 General Construction
The cylinder head made of the special cast iron
of high strength and high thermal conductivity is
designed to assume the structure of high rigidity,
and hydraulically fastened to the engine frame
rigidly with four large-diameter bolts via metal gas-
ket and cylinder liner.
The combustion surface is of the thick-walled
structure provided with the forced cooling through
the drilled holes.
The intake and exhaust valves consist of the 4-
valve system of 2 piece each for intake and
exhaust, with the valve seat cold-fitted to the cylin-
der head, and with the exhaust valve seat cooled-
by the cooling water.
The fuel oil injection valve, indicator, and safety-
valve are mounted on the upper surface of the
cylinder head, and the starting valve is mounted on
the side of the fuel oil injection pump, and the
exhaust outlet block is mounted on the exhaust
side, respectively.
Induction of high-pressure fuel oil into the fuel oil
injection pump is made by so-called side-injecting
type, and the leaked oil from the fuel oil injection
valve as well as the cooling water of the fuel oil
injection valve, when heavy fuel oil is used, are
guided into the piping on the fuel oil injection
pump side through the hole.
Cylinder head (independent): 250 kg
Cylinder head assy, (with valves): 280 kg

Indicator/
safety valve Intake valve

Intake rocker arm

Fuel injection valve
Exhaust rocker arm

Exhaust outlet block

Cooling water head
outlet block Exhaust valve

Cooling water
exhaust outlet pipe
Cap

Cylinder head bolt

Stem seal
Nut (Intake valve)

Stem seal
(Exhaust valve) Starting valve
Valve guide

Cooling water
guide pipe
Starting air
Cylinder head gasket Exhaust valve Intake valve guide pipe

Construction of Cylinder Head

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Cylinder head: Replacing consumables, Implements, and
Measuring Instruments DK-28e 1.2

3-1.2 Replacing Consumables, 5) Hydraulic pump

Implements, and Measuring a) Hydraulic pump
Instruments b) High-pressure hose (5m x 2.05m x 4)
c) Terminal (4T)
(1) Replacing Consumables d) Terminal (2T)
Replace the following parts with the new ones.
( : "Parts List")
1) Cylinder head gasket 3-13 No. 18
2) Exhaust outlet gasket 3-13 No.28
3) O-ring (fuel oil injection valve guide) 3-13 No.21 3
4) O-ring (exhaust valve seat) 3-13 No.22
5) O-ring (exhaust valve seat) 3-13 No.40
6) O-ring (exhaust outlet cooling water guide
pipe) 3-13 No.537
7) O-ring (cylinder head cover) 3-20 N0.6
8) O-ring (cooling water guide pipe) 3-12 No.16
9) O-ring (starting air guide pipe) 3-12 N0.504 2) Nozzle Holder Extracting Implement
10) O-ring (push rod protecting tube) 3-22 NO.B501
11) O-ring (high-pressure fuel oil coupling)
3-18.1 No.12 䋨䋱䋩
12) O-ring (fuel oil injection valve body) 3-18.1 N0.510
13) O-ring (fuel oil injection valve body)
AFO : 3-18.1 No.512 䋨䋲䋩
CFO : 3-18.1 No.511
14) O-ring (cooling water outlet main pipe) 䋨䋳䋩
2-5 N0.A564
15) 0-ring (cooling water head outlet block)
2-5 NO.A568
16) Intake vent seal 3-I No.46
17) Exhaust manifold gasket 3-25 NO.A50 3) Special box 4) Hydrauric Jack
18) Circular gasket (retaining nut) 3-18.1 No.508 spanner 22
19) Circular gasket 10 (for piping )
Z665010000ZZ
䋨䋳䋩
20) Gasket (1) 20X58 (cooling water exhaust
outlet pipe) Z541102058AZ

(2) Implements and Measuring Instruments 䋨䋲䋩

1) General tools and measuring instruments

( : 2-2)
2) Nozzle holder extracting implement 䋨䋴䋩
3) Special box spanner 22 (for Nozzle holder 䋨䋱䋩
retaining nut)
4) Hydraulic jack
a) Hydraulic jack assy.
b) Jack stand
c) Jack handle
5) Hydrauric Pump

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM
Cylinder head: Replacing consumables, Implements, and
1.2 DK-28e Measuring Instruments

6) Cylinder head suspending implement
a) Cylinder head suspending implement
(Common use. with the valve spring disas-
sembling implement)
b) Eye bolt M16
7) Valve guide extracting implement (option)
8) Exhaust valve seat extracting implement
9) Intake valve fitting implement
a) Intake valve seat fitting implement-1 (option)
b) Intake valve seat fitting implement-2 (option)
(Common use with the valve guide extracting
implement of above 7)
10) Exhaust valve seat fitting implement
a) Exhaust valve seat fitting implement
b) Exhaust valve seat fitting implement-2
(option)
(Common use with the valve guide extracting
implement of above 7)
11) Exhaust valve seat cold-fitting implement
12) Special single-ended ring wrench 24
(Exhaust manifold head mounting nut)

(2)

(1)

6) Cylinder Head Suspending Implement 7) Valve Guide 8) Exhaust Valve

Extracting Implement Extracting Implement

㪚㫆㫄㫄㫆㫅㩷㫌㫊㪼㩷
㩷㩷㩷㩷㩷㩷㩷㫎㫀㫋㪿㩷㪈㪇㪀㪑㪸㪀

㪈㪈㪀

㪚㫆㫄㫄㫆㫅㩷㫌㫊㪼 㪚㫆㫄㫄㫆㫅㩷㫌㫊㪸
㩷㫎㫀㫋㪿㩷㪹㪀㪑㪎㪀
㫎㫀㫋㪿㩷㪹㪀㪑㪎

11) Exhaust Valve Seat

Cold-Fitting Implement
㩿㪈㪀
㪸㪀

9) Intake Valve Seat 10) Exhaust Valve Seat 12) Special Single-ended
Fitting Implement Fitting Implement Ring Wrench 24

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Removal of Cylinder Head DK-28e 1.3

3-1.3 Removal of Cylinder Head

Remove the cylinder head (top hole jon the fol- 㩿㪘㪀 㪝㫌㪼㫃㩷㫆㫀㫃㩷㫀㫅㫁㪼㪺㫋㫀㫆㫅㩷㫍㪸㫃㫍㪼
lowing procedure: 㪠㫅㫃㪼㫋㩷㪺㫆㫅㫅㪼㪺㫋㫆㫉
㩿㪚㪀
(1) Remove all the covers 㪟㫀㪾㪿㪄㫇㫉㪼㫊㫊㫌㫉㪼
㪝㪅㪦㪅㩷㪺㫆㫌㫇㫃㫀㫅㪾
1) Exhaust the manifold cover (A)
㩿㪙㪀
2) Heat box upper cover (B)
3) Cylinder head cover (C)
3
㪜㫏㪿㪸㫌㫊㫋
㫄㪸㫅㫀㪽㫆㫃㪻
All the parts (the exhaust manifold and the
㩿㪢㪀
area around the cylinder head, in particular)
are hot immediately after stopping the engine,
and a burn may be caused if the parts of such
areas are touched with naked hand.
Removal of Each Cover
Therefore, be minded to wear safety gloves
during the work and be careful to prevent a
burn.

(2) Remove all the piping around the cylinder head.

1) Nozzle leak piping (D)
2) Nozzle cooling inlet piping (E)
3) Nozzle cooling outlet piping (F)
4) Starting valve pilot air pipe (G)
5) Cooling water outlet main pipe flange (1) (H)
6) Lubricating oil inlet piping (for feeding oil to
the rocker arm) (l) 㩿㪟㪀 㩿㪝㪀
7) High-pressure fuel oil leak piping (J)

(3) Remove the high-pressure F.O. manifold cou- 㩿㪞㪀

pling and inlet connector, and extract the fuel oil
injection valve using the implement 2) and 3).
( : "Operation" 5-4.2 "Inspection and
Maintenance of Fuel oil injection Valve") 㩿㪜㪀
(4) Remove the exhaust manifold mounting bolt (K) 㩿㪡㪀
㩿㪛㪀
using a special single-ended ring wrench 24 of
㩿㪠㪀
above 12).

The exhaust manifold mounting bolt is made

of stainless steel. Be careful not to mix with
Removal of Each Piping
other general bolts.

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

1.3 DK-28e Removal of Cylinder Head

(5) Loosen the mounting nut (L), and take out the d) Confirm the pressure to allow the nut to start
rocker arm assy.(M). turning, and make sure that the cylinder head
( :3-4.3 "Disassembly of Rocker Arm bolt is tightened securely so as not to be loos-
Device") ened.
(6) Extract the valve retainer tee (N) and push
rod (D). 㩿㪥㪀 㩿㪤㪀
(7) Remove the cylinder head mounting nuts (P)
using the hydraulic jack of above 4), the nuts at
four places at the same time.
㩿㪧㪀 㩿㪣㪀
( : 2-4 "Hydraulic Jack")
a) Place the jack stand (4)-(b) by adjusting the 㩿㪦㪀
cut-out part of the jack stand so as not to
interfere with the adjacent cylinder.
b) Mount the hydraulic jack assy. (4)-(a) to the
head bolt (Q).
c) Connect the terminal (5)-(c), (d) and the
hydraulic pump (5)-(a) with the high-pressure
hose (5)-(b).
Increase the hydraulic oil pressure to the speci-
fied pressure by operating the hydraulic pump,
Removal of Rocker Arm
and remove the cylinder head by loosening
the nut (P) using the jack handle (4)-(c).

Hydraulic pump specified oil pressure:

83.4 MPa {850 kgf/cm2}

㪫㫆㩷㪫㪼㫉㫄㫀㫅㪸㫃㩷㩿㪉㪫㪀
㪫㫆㩷㪫㪼㫉㫄㫀㫅㪸㫃㩷㩿㪉㪫㪀
㩷㪫㪼㫉㫄㫀㫅㪸㫃㩷㩿㪋㪫㪀㩷㩿㪌㪀㪄㩿㪺㪀
㪟㫐㪻㫉㪸㫌㫉㫀㪺㩷㫁㪸㪺㫂㩷㪸㫊㫊㫐
㩿㪋㪀㪄㩿㪸㪀

㩿㪨㪀
㪡㪸㪺㫂㩷㫊㫋㪸㫅㪻
㩿㪋㪀㪄㩿㪹㪀
㪡㪸㪺㫂
㪿㪸㫅㪻㫃㪼㩷
Terminal (4T) (5)-(c) 㩿㪋㪀㪄㩿㪺㪀
Terminal (2T)
(5)-(d) 㩿㪧㪀
High-pressure hose
(5)-(b)
Hydrauri pump (5)-(a)

Connection of High-Pressure hose Mounting of Hydrauric Jack

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Removal of Cylinder Head DK-28e 1.3

(8) Mount the cylinder head suspending implement 㪚㫆㫆㫃㫀㫅㪾㩷㫎㪸㫋㪼㫉

(6) on the upper surface of the head, and sus- 㪼㫏㪿㪸㫌㫊㫋
㫆㫌㫋㫃㪼㫋㩷㫇㫀㫇㪼 㪚㫆㫆㫃㫀㫅㪾㩷㫎㪸㫋㪼㫉㩷㪿㪼㪸㪻
pend the cylinder head using a chain block and 㩷㩷㫆㫌㫋㫃㪼㫋㩷㪹㫃㫆㪺㫂
suspending wire rope with the exhaust outlet
block (mono-structure with the intake vent) 㪜㫏㪿㪸㫌㫊㫋 㩿㪍㪀㪄㩿㪸㪀㪃㩿㪹㪀
㫆㫌㫋㫃㪼㫋㩷㪾㪸㫊㫂㪼㫋
being attached.

㪜㫏㪿㪸㫌㫊㫋
㫆㫌㫋㫃㪼㫋㩷㪹㫃㫆㪺㫂
When suspending the cylinder head, be sure 3
to use the specified suspending implement,
and be minded to strictly observe the use 㩿㪪㪀
standard of the wire rope.

㩿㪩㪀
㪚㫐㫃㫀㫅㪻㪼㫉㩷㪿㪼㪸㪻㩷㪹㫆㫃㫋
1) When suspending the cylinder head, con-
duct the work slowly so as not to damage
㩿㪫㪀
the screws of the cylinder head.
Further, be careful so that the cooling water 㪪㫋㪸㫉㫋㫀㫅㪾㩷㪸㫀㫉
in the head may not enter the cylinder. 㪺㫆㫅㫅㪼㪺㫋㫀㫅㪾㩷㫇㫀㫇㪼
2) When lowering down the cylinder head, be
㪣㫀㫅㪼㫉㩷㫊㫌㫇㫇㫆㫉㫋㩷
careful not to scratch the lower surface of 㪽㫉㪸㫄㪼
the cylinder head and O-ring contact sur-
face (cooling water guide pipe and starting
air guide pipe). 㪚㫆㫆㫃㫀㫅㪾㩷㫎㪸㫋㪼㫉㩷㪺㫆㫅㫅㪼㪺㫋㫀㫅㪾㩷㫇㫀㫇㪼

(9) Remove cylinder head gasket (R), the exhaust 㪪㫌㫊㫇㪼㫅㫊㫀㫆㫅㩷㫆㪽㩷㪺㫐㫃㫀㫅㪻㪼㫉㩷㪿㪼㪸㪻

manifold gasket (4)-(S), and the intake vent
seal (T), and place a cover to the prevent infil-
tration of foreign matters into the cylinder liner
and the intake duct.
㪚㫆㫍㪼㫉

㪚㫐㫃㫀㫅㪻㪼㫉㩷㫃㫀㫅㪼㫉

㪚㫆㫍㪼㫉

㪠㫅㫋㪸㫂㪼㩷㪻㫌㪺㫋 㪣㫀㫅㪼㫉㩷㫊㫌㫇㫇㫆㫉㫋㩷㪽㫉㪸㫄㪼

Dust Cover

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

1.4 DK-28e Inspection and Maintenance of Cylinder Head (Body)

3-1.4 Inspection and Maintenance of starting air connecting pipe O-ring, and also
Cylinder Head (Body) check for the leak of gases from the cylinder
head gasket surface.
(6) Clean the contact surface of the cylinder head
Since the items mentioned in this section will
gasket.
be the parts to which NOx Technical Code
If necessary, conduct the facing-up of the con-
shall be applied, when replacing any of these
tact surface by applying compound on the con-
parts, be sure to use the parts provided with
tact surface. (GRINDING TOOL : OPTION)
the identification marks.
(7) Inspect the inside of the jacket through the
( : 0-3 "Engine Conforming to NOx
cooling water outlet hole. If heavy scale deposits
Technical Code")
are found, remove the plug on the upper face,
(1) Before starting the maintenance work of the and clean the inside.
After cleaning, apply the adhesive (ROCK-
cylinder head (body), disconnect the following
TIGHT 271) on the plug, and then securely tight-
attachments. (For the disconnecting procedure,
en it.
refer to the descriptions of the separate sec-
tions.)
1) Intake and exhaust valves ( :3-2.3) Cooling water inlet
2) Starting valve ( :3-3.3)
3) Indicator and safety valves ( :3-5.3)
4) Cooling water exhaust outlet pipe Exhaust port
5) Cooling water head outlet block
6) Exhaust outlet block
(2) Observe and inspect the conditions of the car- Combustion
surface
bons deposited on the combustion surface and Intake port
the intake and exhaust ports in the state that the
attachments are removed.
(3) Completely remove the carbons deposited on Cooling water
the combustion surface and the intake and inlet
exhaust ports, carefully clean them, and check
Inspection of Cylinder Head
for the cracks by means of color check.
Particularly be minded to check the combustion
surface most carefully, since the part is exposed
Cooling water outlet
to the high temperature and high pressure.

Do not use a gas burner to remove carbon. It Plug

may cause hardening of the O-ring due to Plug
high temperature and deterioration of the
materials due to local heating.

(4) Check if there is corrosion on the intake and

exhaust ports.
(5) Check for the corrosion of the contact surfaces
of the cooling water connecting pipe gasket and
Cleaning of Cylinder Head Jacket

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Cylinder Head: Intake and Exhaust Valve Guides DK-28e 1.5

3-1.5 Intake and Exhaust Valve Guides

The dimensions of the intake valves guide is as a, b
same as that of the exhaust valve guide.
(1) Measurement of Inner Diameter Intake and
exhaust valve guides
Inspect the intake and exhaust valve guides for
corrosion, measure the inner diameters with a
cylinder gauge and record the data. A, B

Calculate the clearance by joining the outer

diameter measurement results of the intake and 3
exhaust valve stem parts. ( : 3-2.4 A, a : Intake valve
"Inspection and Maintenance of Intake and B, b : Exhaust valve
Exhaust Valves")

Nom. Size Standard Replacing

(mm) Clearance (mm) limit (mm)
A= 2O a=0.09~0.16 0.30
B= 2O b=0.09~0.16 0.30 Clearance of Valve Guide

(2) Replacement of Valve Guides

When the clearance between the intake and
exhaust valve stems and the intake and exhaust
valve guides is more than the specified replacing
limit and the valve guides are found heavily
Hammer
worn, remove the intake and exhaust valve
guides and replace them with the new ones
according to the following procedure:
a) Remove the valve guide.
Insert the valve guide extracting implement (7), (7)
and strike out the valve guide with a hammer.
b) Fit the valve guide (new one).
Fit the valve guides by means of cold-fitting
using liquid nitrogen or dry ice.

<Cold-fitting procedure>
In case of liquid nitrogen ------ Immerse the
parts in the liquid, take out the parts when bub-
bles disappear, and fit it promptly.
In case of dry ice ------- Immerse the parts and
dry ice in alcohol, take out the parts after cool-
ing for 20 to 30 minutes, and fit it promptly.
Valve guide

Extraction of Valve Guide

If the cooling liquid or cooled-down parts are
touched by naked hand, frostbite may be
caused. Therefore, be minded to wear cotton
arctic gloves during execution of the works.

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

1.6 DK-28e Cylinder Head: Intake and Exhaust Valve Seats

3-1.6 Intake and Exhaust Valve Seats a) Removal of Valve Seat

When removing the valve seat, slowly extract it
(1) Valve Seat Dimensional Measurement
so as not to damage the head fitting part using
Measure the dimensions of the valve seat part,
the exhaust valve seat fitting implement (8).
and in case that it is worn out heavily exceeding
the replacing limit, replace the exhaust valve
with the new one.

Nom. Size Replacing

D F
(mm) Limit (mm)
Intake valve seat Exhaust valve seat
Intake valve seat D = 3.0 1.5
Exhaust valve seat F = 5.5 4.5 Demensions of Valve Seat Section

(2) Replacement of Intake Valve Seat Welding rod

a) Removal of the valve seat Padding welding
Remove the valve seat on the following proce-
dure:
Perform the padding welding on the inner sur-
face of the valve seat, and quench it with water.
By doing this, the valve will contract and can Removal of Intake Valve Seat
easily be taken out.

When performing the padding welding, be

(9)-(b)
careful not to damage the combustion surface
(9)-(a)
or valve guide hole with the spatters.
Further, when removing the valve seat, be
careful not to damage the fitting part of the
head. Intake valve
seat
b) Valve seat fitting Used valve

i) Cold-fit the valve seat using liquid nitrogen or

dry ice. The cold-fitting procedure is as same
as the one for the valve guide. ( : 3-1.5)
Fitting of Intake Valve Seat
ii) Securely strike down using the used valve or
the intake valve seat fitting implement (9)-(a).
Fix using a spanner
(3) Replacement of Water Cooling Exhaust
Valve Seat (8)
Replace the water cooling valve seat, in case
that the valve seat part is used exceeding the
correction limit, or every 16,000 to 24,000 hours
(4 to 5 years).
Be minded to replace the O-ring at the same Exhaust
valve seat
time.

Removal of Exhaust Valve Seat

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Cylinder Head: Intake and Exhaust Valve Seats DK-28e 1.6

b) Valve seat fitting

Since the 0-ring is fitted to the exhaust valve seat, (11) Exhaust valve seat O-ring
fit the valve seat into the cylinder head using the
exhaust valve seat cold-fitting implement (11), in
the state that the O-ring is installed on the valve
seat, after the valve seat is cooled down and
hardened with liquid nitrogen or dry ice.
The cold-fitting procedure is as same as in the Cooling of Exhaust Valve Seat
case of the valve guide. ( : 3-1.5) 3
<Fitting procedure>
i) Apply grease to the O-ring at a normal temper-
ature, and fit the exhaust valve seat.
ii) Heat the exhaust valve seat chilling tool (11) in (10)-(a) <Dismouting>
<Mounting>
o
hot water of 70~80 C.
iii) Insert the valve seat into the exhaust valve
seat chilling tool (11).
iv) Cool down the valve seat as it is inserted into
the exhaust valve seat chilling tool (11).
Exhaust valve seat (11)
v) Take the valve seat out of the exhaust valve
seat chilling tool (11) after cooling, insert the Mounting and Dismounting of Valve Seat
valve seat into the cylinder head promptly, and into / out of Cold-Fitting Implement
drive it down securely using a used valve or a
driving tools (10)-(a),(b)

(10)-(b)
Used valve
(10)-(a)

Exhaust
valve seat

Fitting of Exhaust Valve Seat

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM
1.7 DK-28e Mounting of Cylinder Head
3-1.7 Mounting of Cylinder Head
Mount the cylinder head according in the
reversed order of the disassembling procedure as
shown in the followings:
<Work procedure>
(1) Mount the intake and exhaust valves and the
starting valve to the cylinder head.
( : 3-2.6, 3.5)
(2) Fit the exhaust outlet block and the cooling
water head outlet block, and connect the cool-
ing water exhaust outlet pipe. (Before fitting,
clean the gasket and the contact surface of O-
ring, and apply grease to O-ring.
(3) Clean the cylinder head and the contact sur-
face of the cylinder liner head gasket, the con-
tact surface of the intake air seal, and the fit-
ting sections {cooling water inlet, starting air
inlet, and push rod protecting tube) of O-ring.
Sufficiently clean the upper surface of the
cylinder head so that dirt or thread dust should
not be mixed in the lubricating oil, since the
surface is the return passage of the oil that
has lubricated the rocker arm device.
(4) Fit the cylinder head gasket to the upper sur-
face of the liner.
Do not apply any anti-seizure agent or lubri-
cant oil to the cylinder head gasket surface.
(5) Apply grease to individual 0-ring and the
intake air seal, and mount them in the speci-
fied positions.
(6) Mount the cylinder head suspending imple-
ment (6) on the upper surface of the head, and
suspend the cylinder head.
(16) Mount the indicator and the safety valve.
DK-28e Z 11-06
Be sure to suspend the cylinder head horizon-
tally, and be careful so that cooling water
should not enter the inside of the cylinder.
(7) Make sure that there is no foreign matters
inside the cylinder.
(8) Gradually lower the suspended cylinder so as
not to damage the screws of the cylinder head
and the O-ring for the guide pipes of cooling
water and starting air, and install the cylinder
head after confirming that each guide pipe is
securely fitted to the head.
(9) Apply grease to the exhaust manifold mount-
ing bolt, and temporarily attach the exhaust
manifold.
(10) Carefully clean the thread of the cylinder
head, the thread and seating face of the cylin-
der head tightening bolt, and the nut fitting sur-
face of the cylinder head, and attach the nut
after confirming that there is no dirt or foreign
matters on them.
Be careful not to mistakenly attach the cylin-
der head tightening nut with the upper and
lower surface upside-down.
(11) Install the hydraulic jack in the same proce-
dure as that of disassembling, and tighten it
with the specified hydraulic pressure, the four
places at the same time.
Specified hydraulic pump pressure:
83.4 MPa {850 kgf/cm2}
(12) After removing the hydraulic jack, attach the
rubber cap to the thread of the bolt.
(13) Assemble the fuel oil injection valve.
( : "Operation" 5-4.2)
(14) Insert the push rod.
(15) Mount the rocker aim device. (Ref. : 3-4.5)
( : 3-5.6)
 CHAPTER
Cylinder Head and Valves 3
ITEM
Mounting of Cylinder Head DK-28e 1.7

(17) Insert the fuel oil injection valve inlet con-

nector from the side, and tighten it with the
specified torque.

Specified Torque : 49 ~ 59 N.m

{5.0 ~ 6.0 kgf.m}

(18) Mount the high-pressure fuel oil coupling,

apply lubricating oil (MOLYKOTE 1000 spray)
to the thread and seating face of the mounting
3
bolt, and tighten it with the specified torque.

Specified Torque: N.m {kgf.m}

Pump side 74 {7.5}
Head side 59 {6.0}

1) All the high-pressure couplings of the fuel

oil injection system are connected with the
metal touch. Take enough care so that each
joint may not be damaged, and so that any
foreign matters may not be caught in them.
2) Tighten the bolts alternately and step by
step so that the bolts should not fall down.

(19) Install the exhaust manifold and each of the

piping around the cylinder head.
(20) Mount the cylinder head cover, the heat box
cover, and the exhaust manifold cover (cylin-
der head side).

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

2.1 DK-28e Intake and Exhaust Valves: General Construction

3-2 Intake and Exhaust Valves

3-2.1 General Construction
The intake and exhaust valves consist of the 4-
valve system with 2 piece each for intake and
exhaust, having the valve rotators fitted to the
upper areas.
O-ring is fitted to the inner periphery groove of
the upper areas of the intake and exhaust valve
guides so as to adequately control the lubricating
oil amount to be supplied to the stem section.
The intake valve and exhaust valve are made
of different materials, and the discrimination
mark is attached on the upper area of each
valve.
When assembling them, be careful not to mis-
take them with each other.
Intake / exhaust valve (independent):
1.8 kg each

Valve cotter Valve rotator

Stem seal (IN)
Stem seal (EX)

Spring seat Valve spring (outside)

Valve spring (inside)

Valve guide

Intake valve
Exhaust valve

Construction of Intake Exhaust Valves

Main propulsion engine &
Auxiliary engine (Diesel fuel Auxiliary engine (Heavy fuel
oil specification) oil specification)
Intake valve Exhaust valve Intake valve Exhaust valve

ST S637T HNP

Without notched mark Notched mark "ST" Notched mark㶆䌓䋶䋳䋷䌔㶆 Notched mark㶆䌈䌎䌐㶆

Discrimination Marks of Valves

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Intake and Exhaust Valves: Consumables, Implements,
and Measuring Instruments / Disassembly DK-28e 2.2,2.3

3-2.2 Consumables, Implements, and c)

Measuring Instruments
(1) Replacing Consumables
a)
Replace the following parts with the new ones
( : "Parts List")
1) Stem seal (IN) 3-13 No.102 b)
2) Stem seal (EX) 3-13 No.103

(2) Implements and Measuring Instruments 3

1) General tools and measuring instruments
( : 2-2) 2) Valve Spring Disassembling Implement
2) Valve spring disassembling implement
a) Valve spring disassembling implement-1
b) Valve spring disassembling implement-2
c) Special bolt
3) Valve facing-up implement
4) Valve facing-up spring
5) Valve seat cutter (option)
6) Valve seat grinding implement (option)
7) Valve stem seal special tool

3)
3-2.3 Disassembly of Intake and
Exhaust Valves
When disassembling the intake and exhaust
4)
valves, disassemble the two valves at the same
time using the valve disassembling implement
on the following procedure:

(1) In order to avoid wrong assembling, be mind-

ed to put the markings such as the discrimina-
tion marks of intake and exhaust, as well as
the cylinder numbers on the valve head, before 3) Valve Facing-up Implement and (4) Spring
starting the disassembling work.

"E" of exhaust valve Cylinder No. Assembling position

of exhaust valve

#1 #1
E2 E1

#1 #1
I2 I1

"I" of intake valve Assembling position

of intake valve
7) Valve Stem Seal Special Tool
Marking Procedure (Example)

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM
Intake and Exhaust Valves: Disassembly, Inspection and
2.3,2.4 DK-28e Maintenance

(2) Mount the valve spring disassembling imple-

ment-2 (2)-(b) using the nozzle holder retainer Nozzle holder retaining stud
stud bolt on the upper surface of the cylinder
(2)-(a)
head.
(3) Mount the valve spring disassembling imple-
ment-1 (2)-{a) on the rotator body on the diag- (2)-(b)
onal position, and screw the special bolt (2)-(c)
into the valve spring disassembling implement-
2. (2)-(c)

(4) Screw the special bolt to push the valve

spring, and take out the cotter.
(5) Turn back the special bolt.
(6) Next, place the valve disassembling imple-
ment-1 on the valve rotator body, screw the (2)-(c)
Valve rotator
special bolt to push the valve spring, and take Cotter (2)-(a)
out cotter.
(7) Turn back the special bolt, and take out the
disassembling implement.
(8) Take out the valve rotator and the valve
spring.
(9) Draw out the intake and exhaust valves from
the combustion chamber side.
(2)-(b)
3-2.4 Inspection and Maintenance of Valve
spring Intake and exhaust valves
Intake and Exhaust Valves Disassembly of Valve Spring
(1) Clean the intake and exhaust valves with
washing oil.
(2) Inspect on the following items:
1) Corrosion of the valve head area
2) Corrosion or bending of the valve stem area
3) Blow-out or pitching of the valve seat area
4) Contact conditions of the valve seat area
and the valve stem area
5) Crack or corrosion of the valve seat area
and the valve spring c c.Conduct color
check depending on the conditions.

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Inspection and Maintenance of Intake and Exhaust valves DK-28e 2.4

(3) Measurement of Valve Stem

a) Measure the stem area of the intake and a, b
exhaust valves using an outside micrometer,
and record the data.
b) Calculate the clearance between the stem Intake and
exhaust valve guides
area and the valve guide by combining the
measurement results of the intake and A, B
exhaust valve guide inner diameters, and in
case that the value is over the replacing limit,
A, a : Intake valve
B, b : Exhaust valve
3
replace the valve stem of which wear is larger.
The wear amount of the valve stem can be
calculated by comparing with the non-sliding
area.

Nom. Size Standard Replacing

(mm) clealance (mm) limit (mm)
Measurement of Valve Stem
A= 2O a=0.09~0.16 0.30
B= 2O b=0.09~0.16 0.30

(4) Measurement of the head thickness and

valve seats of the intake and exhaust valves.
Measure the head thickness of the intake and
exhaust valve seat areas, and the valve seat
dimensions with calipers, and record the
results.
In case that the wear is over the replacing limit,
replace it with a new one.

Nom. Size replacing

(mm) limit (mm)
㪚 㪜
Intake valve seat area C=7.5 6.5 Intake valve Exhaust valve
Exhaust valve seat area E= 7.5 6.0
Intake valve seat D=3.0 1.5 Thickness of valve head
Exhaust valve seat F=5.5 4.5

When corrosion of the valve stem and wear of

the intake valve seat is remarkable, a possible
cause is low-temperature corrosion.
For the prevention of such corrosion, strictly
observe the followings.
1)Set the intake air temperature at a little high- D F
er level. Intake valve seat Exhaust valve seat
2) Exhaust combustion gas by means of air
Dimension of valve seat
running when the engine is stopped.

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

2.4 DK-28e Inspection and Maintenance of Intake and Exhaust valves

(5) Facing-up of the intake and exhaust valves b) Machine the angle of the valve seat so that it
Facing-up of the intake and exhaust valves, becomes outside contact, as shown in the figure.
the latter in particular, is one of the most trou-
blesome works in the maintenance work. The
care and maintenance period largely depends If the valve rear face is ground, the valve
on the load factor, the fuel oil used, and the strength will be reduced and cause cracking.
operating conditions of the engine. Further, Therefore, be minded never to grind the valve
delay in the maintenance of the engine leads rear face.
to the acceleration of the wear and tear of the
valves.
So, execute facing-up a little earlier according (3)
to the situations.

<Facing-up procedure>
a) Apply lubricating oil to the valve stem, mount
the valve facing-up spring (4) on the valve (4)
stem, and insert the valve stem into the cylin-
der head valve guide.
b) Mount the valve facing-up implement (3) to
the valve. Valve guide
c) Apply compound to the seat area, and careful-
ly conduct the facing-up. Use the compound in
the order of the medium grade and fine grade.
Medium grade compound ..... Conduct the Valve
facing-up as if to strike.
Fine grade compound ..... Conduct the fin-
ishing facing-up as if to press compound
against the seat. Facing-Up of Valve
Finally, wash the seat carefully, and conduct
the oil facing-up.
d) Conduct the blue-lead check of the seat sur-
face contact conditions after finishing the fac- Intake and exhaust valves
ing-up.
e) Measure the valve head thickness and the
valve seat dimensions with calipers again, and
make sure that the measured values do not
Back face
exceed the use limit.
(6) Correction of the valves
If the valve face scratch is deep and cannot be
o 㪂㪊㪇㩾
corrected with compound, conduct the correc- 120 㪂㪈㪌㩾
tion (rough finishing) using a machine or grind-
ing tool before conducting facing-up.
o 㪇 o 㪇
120 㪄㪈㪌㩾 120 㪄㪈㪌㩾
<Procedure of correction> Intake valve seat Exhaust valve seat
a) Machine the valve seat using the valve seat cut-
ter (option). Correction of Valve and Valve Seat

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Intake and Exhaust Valves: Inspection and Maintenance of
Valve Rotator / Assembly of Intake and Exhaust Valves DK-28e 2.5,2.6
3-2.5 Inspection and Maintenance of
㪩㫆㫋㪸㫋㫆㫉㩷㪹㫆㪻㫐
Valve Rotator
Since imperfect rotation of the valve rotator 㪦㫀㫃㩷㪿㫆㫃㪼
largely affects the valve life adversely, be sure to 㪭㪸㫃㫍㪼㩷㪩㫆㫋㪸㫋㫆㫉㩷㪘㫊㫊㫐㪅
conduct the periodical inspection and mainte- 㪙㪸㫃㫃 㪩㫆㫋㪸㫋㫆㫉㩷㪹㫆㪻㫐
nance.
Valve rotator Standard Replacing limit 㪪㫇㫉㫀㫅㪾
(min'1) 2~4 l /2 of initial 㪪㫇㫉㫀㫅㪾
rotational speed

(1) Disconnect the circlip and disassemble the

rotator.
㪙㪸㫃㫃 3
(2) Wash the individual parts using washing oil, 㪙㪸㫃㫃㩷㫃㪸㪺㪼
and check the parts for the following defects:
1) Wear, deformation, and corrosion of ball
2) Break. corrosion, and fatigue of spring 㪩㫆㫋㪸㫋㫆㫉㩷㪺㫆㫅㪼㪻㩷
㪻㫀㫊㪺㩷㫊㫇㫉㫀㫅㪾
3) Compression mark on ball race
4) Corrosion and fatigue of the coned disc spring
5) Compression mark on the body groove of the 㪩㫆㫋㪸㫋㫆㫉㩷㫊㫇㫉㫀㫅㪾
rotator 㫉㪼㪺㪼㫇㫋㫆㫉
(3) Replace the defective parts.
(4) Assemble the valve rotator according in the 㪚㫀㫉㪺㫃㫀㫇
reverse order of the disassembling procedure.

㪜㫏㫇㫃㫆㪻㪼㪻㩷㪧㪸㫉㫋㫊㩷㫆㪽㩷㪭㪸㫃㫍㪼㩷㪩㫆㫋㪸㫋㫆㫉
Assemble the spring in such a manner that it
rests in the oil hole side of the groove of the
rotator main body.

3-2.6 Assembly of Intake and Exhaust

Valves
(1) Install the valve stem seal on the top part of the
valve guide by means of the valve stem seal Stem seal special tool
special tool (7), and apply grease to the inner cir- Stem seal
cumference (lip).
Knock the special tool, and hit to
the stepped part of the valve guide
The stem seal for the suction valve is gray,
and the stem seal for the exhaust valve is
green. In this way, the stem seals can be
easily identified from their rubber colors.
Carefully assemble the valve stem seals.

(2) Insert the valve from the combustion chamber

side.

1) Before inserting the valve, be minded to

confirm the identification mark of the valve
head, and be sure to assemble the valve
into the original position.
2) A flaw given to the inner circumference of Fitting of the Valve Stem Seal
the stem seal (lip) during its installation may
cause increase in consumption of the lubri- (3) Assemble the valves in the reverse order of the
cating oil or fouling of the valve. Apply oil to disassembling procedure, using the valve disas-
the stem and slowly insert the valve. sembling implement

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM
Starting Valve: General Construction / Replacing
3.1,3.2 DK-28e Consumables, Implements, and Measuring Instlements

3-3 starting Valve 3-3.2 Replacing Consumables,

Implements, and Measuring
3-3.1 General Construction
Instruments
The starting valve is a pneumatic valve of pi lot
type, and the pilot air from the starting air rotary (1) Replacing Consumables
valve works on the starting valve piston, so that Replace the following parts with new ones:
the valve opens to allow the flow of starting air into
( : "Parts List")
the cylinder.
1) Starting valve gasket 3-17 No.9
The starting valve is installed on the F.O. injec-
2) O-ring 3-17 No.506
tion pump side of the cylinder head, and it can be
3) Circular gasket 3-17 No.509
removed in the state of the assembly.
4) Split pin 3-17 No.503
If leak has occurred from the sea! of the starting
valve seat area, the combustion gas flows back
(2) Implements and Measuring Instruments
into the starting air main pipe side to cause stick-
1) General tools and measuring instruments
ing or damage of the starting air rotary valve, start-
( : 2-2)
ing air valve, and so on, and therefore make it a
2) Adapter
rule to conduct the inspection and maintenance
periodically.
In case of overheating of the starting air pipe
during operation, the possible cause is gas leak
from the starting valve, and therefore conduct the
inspection of the parts.

Starting valve assy. : 2.8 k9

2) Adapter

Spring (g) Circular gasket (j)

Startying valve piston (e) O-ring (i)
Starting valve (f) Starting valve Mounting
body (b) bolt (k)
Starting valve
gasket (h)
Nut (d)

Split pin(c)

Starting
valve cover (a)

Seat section
Starting air

Pilot air
Construction of Starting Valve

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Starting Valve: Disassembly, Inspection, and Maintenance DK-28e 3.3,3.4

3-3.3 Disassembly of starting Valve

(1) Remove the starting valve cover (a), and
extract the starting valve assembly from the 㪟㪼㫏㪅㩷㫇㪸㫉㫋
cylinder head. (f)
(2) Extract the split pin (C).
(3) Fix the hex. part of the tip of the starting
(h)
valve, and remove the nut (d). (i)
(4) Disassemble the starting valve piston (e) and
the starting valve (f). (b) 3
As the starting valve piston and the starting
(j)
valve are connected with the screws, first fit
the adapter to the hole of end face of the start-
ing valve piston, and fix it with a vise. @Next,
loosen the hex. part of the tip of the starting
valve while pressing the starting valve body (b)
against the adapter side, and take out the
starting valve.
(5) Draw out the starting valve piston and the (g)
spring (g). (e)
(d)

3-3.4 Inspection and Maintenance of (c) (a)

starting Valve
(1) Clean the individual parts using washing oil. (k)
(2) Conduct the following inspections:
㪛㫀㫊㪸㫊㫊㪼㫄㪹㫃㫐㩷㪸㫅㪻㩷㪘㫊㫊㪼㫄㪹㫃㫐㩷㫆㪽㩷㪪㫋㪸㫉㫋㫀㫅㪾㩷㫍㪸㫃㫍㪼
1) Sticking of the starting valve and starting
valve piston, and the leak of gas from the
seat area
2) Corrosion or scratch of the spring
(3) Assemble the starting valve to the piston, and
conduct the facing-up after applying compound
to the valve and the valve body seat areas
(4) Apply blue lead to the starting valve seat
area, and check the contact.

Contact range : 75% or more

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

3.5 DK-28e Assembly of Starting Valve

3-3.5 Assembly of Starting Valve

(1) Assemble the starting valve assembly on the
following procedure:
a) Insert the starting valve into the starting
valve body.
b) Fit the adapter (2) to the hole of the starting
valve piston end face, and fix it with a vice.
c) Apply lubricating agent (MOLYKOTE 1000
spray) to the thread of the starting valve, and
screw the starting valve piston.
d) Tighten the hexagonal part of the tip of the
starting valve with the specified torque while
pressing the starting valve against the
adapter side.

Special torque : 98 N.m {10 kgf.m}

e) Take out the adapter, tighten the nut, and clamp

it with the split pin.

Be careful since tightening of the starting

valve nut with excessive torque will break the
threads¡
The split pin is made of stainless steel. Do
not to mistake it with the one made of ordinary
materials.

(2) Assemble the starting valve assembly to the cylin-

der head according to the following procedure. 㪭㫀㪺㪼 㪘㪻㪸㫇㫋㪼㫉
a) Fit the gasket (h) and O-ring (i) to the start-
ing valve body, apply grease to the O-ring
㪘㫊㫊㪼㫄㪹㫃㫐㩷㫆㪽㩷㪪㫋㪸㫉㫋㫀㫅㪾㩷㪭㪸㫃㫍㪼
and the mounting hole of the starting valve,
and then insert into the cylinder.
b) Assemble the circular gasket (i) to the start-
ing valve body, and fit the starting valve
cover. Be minded to gradually tighten the bolts alter-
nately, and evenly. Uneven tightening will
c) Apply lubricating oil (MOLYKOTE 1000
cause the leaks of the starting air and gas.
spray) to the mounting bolt (k), and tighten it
with the specified torque.

Specified torque: 59 N.m {6.0 kgf.m}

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Rocker Arm Device: General Construction / Consumables,
Implements, and Measuring Instlements / Disassembly DK-28e 4.1~4.3

3-4 Rocker Arm Device 3-4.2 Replacing Consumables,

Implements, and Measuring
3-4.1 General Construction Instruments
The intake and exhaust valves are driven by the (1) Replacing Consumables
intake and exhaust cams of the unit-type camshaft, None
via the swing arm, push rod, rocker arm, and valve (2) Implements and Measuring Instruments
retainer tee. 1) General tools and measuring instruments

Individual areas of the rocker arm are lubricated

by the system oil fed from the piping 0n the fuel oil
( : 2-2)
2) Special ring 30X19
3
injection pump side of cylinder head, through the
drilled holes inside the head. 3-4.3 Disassembly of Rocker Arm Device
(1) Loosen the nut tightening the rocker arm shaft
For adjusting procedure of the valve end clear-
holder (c), and disconnect the rocker arm shaft
ance, refer to the separate "Operation".
assembly.
( : "Operation" 5-4.1 gAdjusting Valve End
(2) Pull out the valve retainer tee assy. (e) from
Clearance")
the valve retainer guide.
(3) Remove the snap rings (h) at both ends of the
Rocker arm assy. : 27 kg
rocker arm shaft (d), and disconnect the rocker
arm (a) and (b) of the intake and exhaust valves.
(4) Remove the clip (f), and separate the valve
end cap (g).

Rocker arm Snap ring (h) Rocker arm

Rocker arm screw (i) (intake/exhaust) (a),(b)
shaft (d)

Push rod
Clip (f) retaining metal (j)

Valve end cap (g)

Valve retainer tee (e)

Nut
"B"

"A"
Intake and exahust
valves
Rocker arm shaft holder(c) Push rod
Valve retainer guide

Construction of Rocker Arm Device

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

4.4,4.5 DK-28e Inspection, Maintenance, and Assembly of Rocker Arm Dvice

3-4.4 Inspection and Maintenance of

Rocker Arm Device
(1) Clean the individual parts using washing oil.
(2) Measure the rocker arm shaft outside diameter
with an outside micrometer, and measure the Rocker arm bush
rocker arm bush inner diameter with a cylinder
gauge to calculate the clearance.
If the clearance is over the replacing limit,
replace the bush with a new one. D
d Rocker arm shaft
Nom. Size Standard Replacing
(mm) clearance {mm) limit (mm)
D= 65 d=0.04~0.12 0.30

* Bush press-fitting force : 12.7~ 23.5 kN

{1300~2400kgf } Inspection of Rocker Arm Device
(3) Inspect the individual parts on the following
points:
1) Contact conditions of the valve retainer tee Presence of scratch,
and the valve retainer guide sliding part and contact conditions
2) Bend, scratch on the end surface, and abnor-
mal contact of the push rod
3) Scratch and abnormal contact on the contact
areas "A" and "B" with the valve
4) Scratch, abnormal contact, and wear of the Push rod
rocker arm screw (i), valve end cap (g), and
Presence of bending
push rod retaining metal (j).

3-4.5 Assembly of Rocker Arm Device

(1) Assemble the rocker arm device assembly.
a) Fit the valve end cap to the rocker arm screw,
and fix it with a clip.
b) Pass the intake and exhaust rocker arm
through the rocker arm shaft, and attach a
snap ring.
(2) Insert the valve retainer tee assy. into the
Presence of scratch,
valve retainer guide. and contact conditions
(3) Place the rocker arm shaft assy. on the cylin-
der head, apply lubricating oil (MOLYKOTE 1000 Inspection of Push Rod
spray) to the rocker arm shaft holder tightening
nut and bolt, and tighten the nut with the speci-
fied torque, using the special ring 30X19.

Specified torque: 196 N.m {20 kgf.m}

(4) Adjust the valve end clearance after finishing

the assembling¥
( : "Operation" 5-4.1 "Adjusting Valve End


30X19
Clearance")

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Indicator and Safety Valves: General construction / Replacing
Consumables, Implements, and Measuring Instlements DK-28e 5.1,5.2

3-5 Indicator and Safety Valves Close

3-5.1 General Construction

The indicator valve and the cylinder safety valve Open
are incorporated in the same valve body.
The indicator valve screw is of "left hand screw",
and the valve is opened and closed by the han-
dle in the directions as shown in the figure. 3) (Box spanner 19)
3
For the pressure measuring procedure, refer to
the separate manual of the "Operation".
( : "Operation" 5-3.1 "Maximum Combustion 1) Opening and Closing of Indicator Valve
Pressure")

Indicator and safety valve assy. : 1.7 kg a)

Joint
3-5.2 Replacing Consumables, c)
Implements, and Measuring
Instruments
(1) Replacing Consumables
Replace the following parts with new ones:
( : "Parts List")
d)
1) Circular gasket 3-19 NO.504
2) Circular gasket 3-19 NO.505 e)
3) Straight pin 3-19 NO.503
b)

(2) Implements and Measuring Instruments Safety valve

1) General tools and measuring instruments

( : 2-2)
2) Safety Valve Testing Implement
2) Safety valve testing implements
a) Hydraulic pump (common use for nozzle test)
b) Safety valve test joint
c) High-pressure hose
d) Male coupler
e) Female coupler
3) Box spanner 19

3) Box Spanner 19

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

5.3 DK-28e Disassembly of Indicator and Safety Valves

3-5.3 Disassembly of Indicator and

Safety Valves
The threaded part of the indicator valve (H) is
of "left-handed screw", and the extracting
The indicator and safety valve are extremely direction is clockwise as viewed from the side
hot during operation. If it may be touched with of the hexagonal plug.
naked hands during operation or immediately
after the stop, a burn may be caused.
Conduct the maintenance work after the indi-
cator and safety valves are cooled down suffi-
ciently.

(1) Removal of indicator and Safety Valves

Assembly
Disconnect the flange (A) tightening nut, and (D)
remove the indicator and safety valves assembly (C)
from the cylinder head.
(E)

(2) Disassembly of Safety Valve

a) Remove the safety valve (independent assy.)
from the indicator valve body (K). (B) (K)
b) Loosen lock nut (C) and adjusting screw (D).
Respectively provide the lock nut, adjusting
(I)
screw, and spring retainer (E) with the match
marks for the sake of convenience when
reassembling.
c) Loosen and disconnect the spring retainer.
(G)

(F) (H)
When the spring retainer is taken out white
the spring is in compressed state, the spring
will jump out causing a hazard.
Therefore, gradually loosen the spring retain- (A) Nut
er, and remove it after confirming that the
spring compression is eliminated.

(3) Disassembly of Indicator Valve

a) Take out hex. Plug (F). (J)
b) Extract the straight pin (G), and remove the indi- Indicator and SAfety Valves
cator valve nut ( I ) from the indicator valve (H).
c) Extract the indicator valve using a screwdriver.

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Indicator and Safety Valves: Inspection and Maintenance /
Assembly and Adjustment DK-28e 5.4,5.5

3-5.4 Inspection and Maintenance of

Indicator and Safety Valves Setting pressure : 19.2 MPa {195 kgf/cm2}
When the spring is replaced with a new one,
(1) Wash all the disassembled parts using wash-
set the value about 10% higher than the
ing oil to eliminate stains such as carbon.
above value by taking into consideration the
(2) Inspection and maintenance of the safety
initial fatigue.
valve
a) Check the safety valve outer periphery and
e) Fix the adjusting screw by tightening the lock
seat area for the marks of abnormal contact,
scratch, and sticking.
nut.
3
b) lf scratch or sticking is found, correct the faulty
areas with oil stone, apply compound to the
seat area, and perform the facing-up.
(3) Inspection and maintenance of the indicator
valve (2)-(c)
a) Check the indicator valve seat for scratch or
one-sided contact.
b) When scratch is found, correct it using an oil
stone, apply compound to the seat area, and
perform the facing-up.
,QKPVPT3/8
(4) Check the spring for abnormal contact or
㪪㫇㪼㪺㫀㪸㫃㩷㪾㪸㫊㫂㪼㫋
scratch, and when scratch is found, replace the 6GUVGTUKFG
spring with a new one.

3-5.5 Assembly and Adjustment of (2)-(d)

Safety Valve
(2)-(e)
(1) Assembly of Safety Valve (independent assy.)
(2)-(a)
Insert the valve and the spring into the safety
(2)-(b)
valve body after facing-up, and assemble the
lock nut and the adjusting screw to them.

(2) Adjustment of Safety Valve 㪪㪸㪽㪼㫋㫐㩷㫍㪸㫃㫍㪼

Adjust the valve opening pressure according to
㪪㪸㪽㪼㫋㫐㩷㫍㪸㫃㫍㪼㩷㫊㫀㪻㪼
the following procedure:
a) Mount the safety valve test joint (2)-(b) on the
safety valve, and connect them to the hydraulic 㪪㪸㪽㪼㫋㫐㩷㪭㪸㫃㫍㪼㩷㪫㪼㫊㫋㫀㫅㪾
pump (2)-(a) using a high-pressure pipe (2)-(c).
b) Screw the adjusting screw up to the match
mark position using a hex. rod spanner.
c) Operate the hydraulic pump lever to increase
the pressure, and read the valve opening pres-
sure.
d) Turn the adjusting screw, and adjust the valve
opening pressure.

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

5.6 DK-28e Assembly and Mounting of Indicator and Safety Valve

3-5.6 Assembly and Mounting of

Indicator and Safety Valve
(1) Assemble the indicator and safety valve
assembly in the reverse order of the disassem-
bling procedure.
When assembling, replace the straight pins of the
indicator valve with new ones, and fix them to
the indicator nut by caulking the three places on
the both sides respectively.
(2) Blow air to the mounting surface of the cylinder
head to clean there, and mount the indicator and
safety valve assembly while placing the circular
gasket (J) between them.
(3) Apply the lubricating agent "MOLYKOTE 1000
spray type" to the threaded part of the mounting
nut, and tighten the nut with the specified torque
after adjusting the direction so that the indicator
valve should not protrude from the cylinder side
surface, and the indicator valve nut can be han-
dled easily.

Specified torque: 59 N.m {6.0 kgf.m}

Tighten the nuts alternately and uniformly.

Uneven tightening causes the leaks of gases.

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
Nozzle Holder Guide: Extraction / Cooling DK-28e 6.1,6.2

3-6 Nozzle Holder Guide Cool it down as long as the generated bubbles
disappear during cooling. (Time required :
3-6.1 Replacing Consumables and Approx. 2 minutes)
Implements (5) Installing it as shown in Fig. 3, hit it with the
(1) Replacing Consumables wooden hammer to remove the insert tool 1. At
this time, do not remove the insert tool 2.
( : "Parts List")
Lay the wood, cloth or similar under the insert
1) O-ring 3-13 NO.21
tool 1.
Nozzle holder guide 0-ring should be replaced
every 16,000 to 24,000 hours (4 to 5 years).
(2) Implements (optional parts)
3
1) Extract tool 1
2) Insert tool 1
3) Insert tool 2
4) Insert tool 3

3-6.2 Extraction of Nozzle Holder Guide

O-ring Snap ring
<Extraction procedure> Extract tool 1
(1) Remove the nozzle holder, and turn the cylin-
der head sideways (so that the combustion sur-
face can be seen.)
(2) Remove the snap ring by using the snap ring Hammering
flyer.
(3) Hit the insert toot l with the hammer to remove
Nozzle holder guide
the nozzle holder guide.
Nozzle Holder Guide Extraction Procedure
3-6.3 Cooling of Nozzle Holder Guide
<Cooling procedure>
(1) Attach the o ring to the nozzle holder guide.
Before attaching the o ring, verify that it is not Insert tool 1
Adjust to the upper end surface
injured or torn. of nozzle holdrer guide
When attaching the O ring, prevent it from being Insert tool 1
Hammering
injured or twisted.
(2) Coat the grease on the whole circumference of O-ring
the o ring in the state (1).
(3) After warming the insert tool l at the hot water
o
(approx. 80 C) 2 to 3 minutes, attach it to the Grease
nozzle holder guide. applied
part
Attach the O-ring, taking care to prevent injuring it.
After coating the grease on the whole circumfer- O-ring
ence of the fitting area of the insert tool 2 which Insert tool 2
the o ring is attached, attach it to the nozzle ( Push in until completely fit
Insert tool 2 into the fitting part )
holder guide. The attaching illustration is as
shown in Fig. 2.
Fig.1 Fig.2 Fig.3
(4) In the state shown in Fig. 2, dip the whole noz-
zle holder guide in the liquefied nitrogen.
Nozzle Holder Guide Cooling Procedure

DK-28e Z 11-06
CHAPTER
3 Cylinder Head and Valves
ITEM

6.3 DK-28e Nozzle Holder Guide : Fitting-In

3-6.4 Fitting-in of Nozzle Holder Guide

<Fitting-in procedure>
(1) Wipe off dirt or dust on the seating face and
the fitting area of the cylinder head. ROCK-TIGHT 648 applied part
(2) Apply silicon paste on the specified place in a
Silicone paste applied part
circumferential shape. (Use of a brush or the like
Snap ring installed position
will facilitate the work.)
O-ring
At this time, do not block the cooling water hole
of the inside of the cylinder head. Hammering
(3) Apply ROCK-TIGHT 648 to the fitting part of
the cylinder head.
Insert tool 3
* Finish the works of above 1 to 3 before
cooling the nozzle holder guide. Nozzle holder guide
Cooling water hole Insert tool 2
(4) Attach the insert tool 3 to the nozzle holder
Fitting part and seating face
guide, and fit it into the cylinder head with the
hammer. Nozzle Holder Guide Fitting-In Procedure
Before attaching it, coat grease on the whole cir-
cumference of the fitting area of the insert tool 3
(with O-ring).
When fitting it, take sufficient care to prevent hit-
ting it in when the nozzle holder guide is inclined.
Moreover, hit it with the hammer as far as the
nozzle holder guide comes into contact with the
seat. Take care that it becomes difficult to fit
the nozzle guide holder unless the work is quick-
ly done.
[ If any flange is provided on the insert tool 3, fit
it using the stud bolts which install the nozzle
holder. If the insert tool 3 is moreover provided
with the positioning pin, align the pin to the
groove of the nozzle holder guide. ]
(5) Remove the insert tool 2 to 3.
(6) Install the snap spring to the specified position.

DK-28e Z 11-06
 CHAPTER
Cylinder Head and Valves 3
ITEM
MEMO DK-28e

3
CHAPTER
4 Piston and Connecting Rod
ITEM

1 DK-28e General Construction

Monoblock Composite Monoblock Composite
4. Piston and Connecting Rod piston piston piston piston
Piston Piston
4-1 General Construction crown
The connecting rod is of carbon steel die forging
with the large end part being horizontal 3-division
type. This structure allows the extraction of the pis-
ton without disassembling the bearing part of the Piston
crank pin shaft. skirt
The large end divided surfaces (serrated) sur-
Piston pin (D) Connecting
faces are rigidly fastened hydraulically with the 2 Nozzle rod
stud bolts (B), and the trunk divided surfaces are Piston pin bush (F)
angularly tightened with the 4 bolts (A).
Connecting
The crank pin shell(C) is made of aluminum rod bolt-2 (A)
alloy of high wear resistance.
The piston pin (D) is of full floating type, and its
axial direction is held with the snap ring (E).
Serration
Further, the piston pin push (F) is stepped so as
to allow a wide bearing area on the side where
combustion forces affect.
The piston can be a monoblock cast component
made of ductile cast iron, or can be a composite
component consisting of a piston crown made of
Circular nut
special alloy steel and a piston skirt made of duc- Crank pin shell (C)
tile cast iron. They are used depending on the pur- Connecting rod bolt-1 (B)
poses and the outputs of engines. Both of these
Piston and Connecting Rod
pistons have a special coating applied on the
external circumference of the piston skirt.
Moreover, some pistons, including the ones for
heavy fuel oil and for main engines, have a top
ring groove and a second ring groove coated with
chrome plating. This improves abrasion resistance
performance.
The piston cooling lubricating oil reaches from
the crankshaft to the cooling cavity in the piston,
via piston pin, through the drilled holes of the con- Momoblock Composite
piston piston
necting rod trunk part.
Piston crown
In addition to this, the monoblock cast piston is Piston
cooled on the backside by way on the nozzle at
the top of the small end of the connecting rod. Piston ring Piston ring
The piston rings comprise three compression
Oil ring
rings and two oil rings for the monoblock piston or Oil ring
one oil ring for the composite piston.
Piston
crown bolt
Piston type Monoblock Composite
Piston connecting Piston skirt
rod assy. : 214 kg 232.5 kg
Piston assy : 68 kg 82 kg Clamp ring (E)
Piston pin : 18.58 kg 19 kg Piston pin (D)
Connecting rod assy. : 128 kg 127 kg
Crank rod bolt-1 : 3.3 3.3 kg kg Piston and Piston Pin

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Replacing Consumable, Implements and
Measuring Instruments DK-28e 2

4-2 Replacing Consumables,

Implements, and Measuring
Instruments
(1) Replacing Consumables None

(2) Implements and Measuring Instruments

1) General tools and measuring instruments
( : 2-2)
2) Hydraulic jack and hydraulic pump
3) Piston Insertion Frame
(common use for the side bolt) 4
a) Hydraulic jack assy.
b) Jack stand
c) Jack handle
d) Hydraulic hose
e) High-pressure hose
f) Terminal (2T)
3) Piston insertion frame
4) Protection ring extracting implement
4) Protection Ring Extracting Implement
5) Metal cap fitting and disengaging implement
6) Piston suspending implements (option)
a) Piston supporting bolt
b) Piston supporting plate

5) Metal Cap Fitting and

e) Disengaging Implement
a) f)

a)
b)
d)
b)
c)

6) Piston Suspending Implement

a) Piston Supporting Bolt
2) Hydrauric Jack and Hydraulic Pump b) Piston Supporting Plate

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

3.1 DK-28e Extraction of Piston

4-3 Disassembly of Piston and

Protection ring (G) Carbon
Connecting Rod Waste clot

4-3.1 Extraction of Piston Liner support

Cylinder liner (H)
frame
Extract the piston after removing the cylinder head.
( : 3-1.3 "Removal of Cylinder Head")
In case of the piston extraction only, it is not
necessary to disassemble the large end part, and Piston
conduct the extraction work by separating the
large end part from the small end trunk part.

If the crankshaft has turned when handling the

parts located in the crank chamber when Removal of Carbon on the Upper Part of Cylinder liner
extracting the piston, it will cause serious acci-
dents resulting form entanglement and it will Plastic hammer (4)
be very dangerous.
Therefore, be sure to conduct turning after
exchanging the signs with coworkers, and do (G)
not fail to put the flywheel turning device in the
"disengage" position, except when the engine
is turned. (H)

≪Piston extraction procedure≫

(1) Take off the cover on the engine frame side on
the both sides of the cylinder to be overhauled,
and place the piston to the position of about 50°
before the top dead center.
(2) Place waste cloth on the piston upper surface Extraction of Protection Ring
to facilitate easy removal of carbon.
(3) Remove the carbons deposited on the upper
areas of the protection ring(G) and cylinder
liner(H) with sandpaper or the like.
(4) Extract the protection ring located in the upper
area of the cylinder liner using the protection ring
extracting implement (4).
a) Tap on the entire circumference of the protec-
tion ring with a plastic hammer.
b) Spray penetrating lubricant (KURE 5-56, etc.)
to the clearance between the cylinder liner and
the protection ring.
c) Attach the protection ring extracting imple-
ment, and gradually extract the ring while light-
ly striking the lower surface of the extracting Tap
M12X1.75
implement with a plastic hammer.
(5) Remove the carbon deposited in the piston sus- Removing of Carbon in The Piston
Suspending Threaded Hole
pending threaded hole using a tap (M12X1.75)

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Extraction of Piston DK-28e 3.1

(6) Turn the crankshaft, and place the piston to be

released in the position of the bottom dead cen- Connecting rod
bolt-2 (A)
ter. Ratchet head

If the big end of the connecting rod of the Torque wrench

cylinder that has been disassembled turns
during turning operation, it may get into con-
tact with the frame and may be damaged.
Slowly turn the crankshaft, taking care that the Socket
big end does not turn.

(7) Remove the rotation-stopping wire of the con-

4
necting rod joint bolt-2(A), and loosen the con-
necting rod bolt-2 to extract it. Removal of Connecting Rod Bolt-2
(8) Mount the piston suspending fitting (eye bolt
M12) on the upper part of the piston, suspend it Piston suspending fitting
with the wire rope and chain block, and then (eyebolt M12)
extract the piston and the connecting rod small
end side.
(9) Attach the piston suspending fitting metal (eye
bolt M12) to the upper part of the piston, sus- Piston
pend it with a wire rope or chain block, and
extract the piston and the connecting rod small
end side.

Securely tighten the suspending eye bolt Connecting rod

small end side
down to the seat surface. Unless securely
tightened to the seating face, it causes distor-
tion or breakage of the metal fitting (eye bolt),
and is very dangerous.

Extraction of Piston

When suspending the piston, be careful so Cover

that the inner surface of the cylinder liner may Cylinder liner
Liner support
frame
not be damaged being struck by the connect-
Cover
ing rod.

(10) Fit the cover on the cylinder liner after extract-

ing the piston, so that no foreign matters may
Intake
infiltrate in the engine. duct
(11) Place the piston in the specified place with its
combustion surface facing downward. Dust Cover

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM
Extraction of Piston / Disassembly of
3.1, 3.2 DK-28e Connecting Rod

(12) Lightly suspend the connecting rod, and

remove the clamp ring (E) on one side of the pis-
ton pin using a snap ring pliers.
Connecting rod
(13) Extract the piston pin (D), and remove the small end side
connecting rod small end side from the piston.
(14) Remove the piston ring and oil ring. Piston
Clamp ring (E)
Piston pin (D)

Since the periphery of each ring is edged

sharply after a long-time operation of the
engine, be sure to wear safety gloves and
take care not to suffer injuries when disas- Snap ring pliers

sembling the engine.

Extraction of Piston

4-3.2 Disassembly of Connecting Rod

Large End Part Connecting rod
Ratchet head bolt-2 (A)
Disassemble the connecting rod large end part
when the crank pin shell(C) or crank pin bolt-1(B)
is inspected or replaced. When only extraction of Torque wrench

the piston is intended, disassembly of the connect-

ing rod large end part is not required.
When only inspection of the crank pin shell is
intended, the connecting rod large end part can be Socket
disassembled by suspending the piston without
removing the cylinder head.

≪Disassembly procedure of the connecting

rod large end part≫ (In case of without the Removal of Connecting Rod Bolt-2
extraction of piston)
(1) Remove the connecting rod bolt-2(A), and sus-
pend the piston and the connecting rod small Circular nut (J)
end side. (Piston extracted or piston suspended)
(2) Turn the crankshaft, and place the large end
part at the place near the inspection window of
the engine frame setting it sideways.
Connecting
rod bolt-1
(B)

Disassembly of Connecting Rod Large End Part

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Disassembly of Connecting Rod Large End Part DK-28e 3.2

(3) Simultaneously loosen the connecting rod bolt- (9) Mark the disassembled shells with the cylinder
1 (B) and the circular nut(J) using a hydraulic numbers and ID marks, so that the upper and
lower shells can be distinguished from each
jack. ( :2-4 "Hydraulic Jack")
other.
a) Place the hydraulic jack stand (2)-(b), attach
the hydraulic jack assy.(2)-(a) to the connect-
ing rod bolt-1, and then connect the terminal
(2T)(2)-(f) and the hydraulic pump(2)-(d) with
the high-pressure hose(2)-(e).
b) Raise the hydraulic pressure to the specified
(2)-(b)
pressure by operating the hydraulic pump (2)-(c)
lever, and loosen the circular nut using the jack
handle(2)-(c).
(2)-(a) 4
(2)-(f)
Specified oil pressure: (2)-(d)
83.4 MPa {850 kgf/cmz}

c) Confirm the hydraulic oil pressure at which the

nut starts to turn, and inspect if there is not any
(2)-(e)
loosening of the tightening.
d) Remove the hydraulic jack assy., and the jack Disassembly of Connecting Rod Large End Part
(Connecting of Hydrauric Jack and Hydrauric Pump)
stand.
(4) In the state that the large end part is set side-
ways, insert the metal cap fitting and disengag-
ing implement (5) into the underside of the large
end part.
(5) Slowly turn the crankshaft until the large end
part lightly contacts with the metal cap fitting and
disengaging implement. Connecting rod bolt-1
threaded part
(6) Loosen the circular nut with your hand, and Large end Crank pin Large end cap
trunk side
remove it. (C)
(7) Take out the top and bottom of the large end
(C)
part from the right and left inspection windows
respectively.

When taking out the trunk side of the large (5)

end, be careful so as not to damage the
screws of the connecting rod bolt-1 and the
crank pin.
Removal of Connecting Rod Large End Part
(Top and Bottom)
(8) Remove the crank pin shell(C) from the large
end part. Place wooden piece against the claw
side of the bearing shell, and strike it lightly.
Then, the bearing shell can be removed easily.

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

3.2 DK-28e Disassembly of Connecting Rod Large End Part

≪Disassembly of the large end part by

suspending the piston≫
(1) Turn the crankshaft, and place the crank pin of
the cylinder to be inspected in the position of the (6)-(b)
(6)-(a)
bottom dead center.
(2) Loosen and extract the connecting rod bolt-2.
(3) Turn the crankshaft, and place the crank pin of
the cylinder to be inspected in the position of the
top dead center.
(4) Remove the high-pressure fuel oil coupling and
the inlet connector, and extract the fuel oil injec
tion valve.

( : "Operation" 5-4.2 "Extraction of Fuel Oil

Injection Valve")
(5) Install the piston support plate (6)-(b) of the pis-
ton suspending implement to the mounting hole
of the fuel oil injection valve.
(6) Screw the piston support bolt (6)-(a) into the
thread hole of the piston upper part, and fit it with
the nut.
(7) As for the works after here, disassemble in
accordance with the Item (2) to (10) of ≪
Disassembling procedure of connecting rod
large end part≫ (In case of without piston) in the Suspension of Piston
Chapter 4-3.2.

1) When turning at the time of separating the

small end trunk part and the large end part,
the trunk part will swing when the flange
surface of the connecting rod trunk part
separates from the large end part.
Therefore, be careful so as not to injure
yourself.
2) Be careful so that the connecting rod
should not strike and damage the cylinder
liner.

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Inspection and Maintenance of Piston DK-28e 4.1

4-4 Inspection and Maintenance of (5) Blow air to the oil hole of the piston pin, and
Piston and Connecting Rod clean the inside of the hole.

4-4.1 Inspection and Maintenance of

Piston

Since the items mentioned in this section will

be the parts to which NOx Technical Code
shall be applied, when replacing any of these
parts, be sure to use the parts provided with
the identification marks.
( : 0-3 "Engine Conforming to NOx
Technical Code")
4
(1) Inspection of individual parts
Inspect the individual parts of the piston, and
record the conditions.
1) Conditions of the carbon deposited on the
combustion surface and top land of the piston,
and lubricating conditions of the sliding area.
2) Scratch and abnormal contact of the sliding
areas
3) Sticking of the piston ring, and conditions of Combusion surface
chrome plating, abnormal contact, and pres- Piston Ring Groove Top land
ence of wear
Pin boss
4) Conditions of the carbon sludge deposited on
Oil hole
the piston back side and the bottom of the ring
Skirt part
groove.
5) Abnormal contact of the piston pin and pin
boss inner surface Piston
Piston pin
6) Abnormal contact of the piston pin boss and
Retaining Ring
the connecting rod small end support part "P"
Inspection and Maintenance of Piston Parts
(2) Eliminate the carbon deposited on the upper
part of the piston with a sandpaper of fine mesh.

Since special coating is applied to the piston

skirt area, do not use sandpaper on the parts.

(3) Clean the piston and the piston ring using

washing oil.
(4) Clean the piston combustion surface carefully,
and perform thorough inspections for crack by
means of color check.

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

4.1 DK-28e Inspection and Maintenance of Piston

(6) Do not separate the piston crown from the skirt

portion as long as no carbon sludge is deposit-
㪉 㪊
ed on it.
Follow the following procedure when it is nec-
essary to do so.
㪋 㪈

<<Procedure to Detach the Piston Crown>>

Sequence to Loose the Fastening Nuts
(1) Put the piston on the appropriate place on the (View "P")
top.
(2) Loosen and remove the tightening nuts in the 䌐
sequence shown in the right figure. Read the Nut
torque at which each of the nuts begins loosen- Washer
ing to make certain that it has not loosened.

Release torque : 147 N.m {15 kgf.m}

Piston Skirt

(3) Separate the piston crown from the piston

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

Piston Crown
Bolt
Release torque : 103 N.m {10.5 kgf.m}
Piston Crown

Separation of the Piston Crown

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Inspection and Maintenance of Piston DK-28e 4.1

(7) Measurement of dimensions

Measure the dimensions of individual parts,
and record the results. Calculate the clearance
based on the results of measurement, and Piston
replace the parts with the new ones, if the
clearance is exceeding the replacing limit.
a) Piston outer diameter
Measure the three places of the piston outer

a
diameter using an outer micrometer, and record
Piston pin
the results. In case that the measured value
exceeds the replacing limit, replace the parts 4

A
with a new one.
"P"
Standard clearance Replacing limit
(mm) (mm)
A = φ280 - 0.50
B = φ280 - 0.50
C = φ280 - 0.50

Clearance between Piston Pin and Pin Boss

Piston
180

㧭
75 75

Measurement Position of Piston

b) Piston pin and piston pin boss

Measure the piston pin outer diameter and the
piston pin boss inner diameter, and replace the
one with larger wear.

Nom. Size Standard Replacing

(mm) clearance (mm) limit (mm)
A = φ125 a = 0.08~0.11 0.20

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

4.2 DK-28e Inspection and Maintenance of Ring

4-4.2 Inspection and Maintenance of C1

Ring 1 st.(top㧕
C2
(1) Eliminate the carbon deposited on the piston
2nd. Piston ring
rings and oil rings, and wash the rings using C3
washing oil. 3rd.
(2) Since hard-chrome plating is applied to the slid- C4

ing surfaces of the rings excepting on the oil Oil ring (upper)
C5 (Momoblock piston)
ring, in case that the ring surface is exposed due
to wear of the plated layers, or the defects such Oil ring (lower)
as crack are found, replace the ring with a new
one, even when it is still within the specified Composite Momoblock
replacing period. piston piston
(3) Measure the end clearance of the ring. B1
B1
Measurement of the end clearance using a new A1 1 st. B2
A1 1 st.

cylinder liner is advisable. B2

B3
A2䇭2nd. Piston
A2䇭2nd. ring
Piston A3 3rd.
ring
B3 B4
Standard clearance placing limit A3 3rd.
(mm) (mm) A4 Oil ring (upper)
B5 䋺without coil
C1=2.10～2.40 3.0 B5
A5 Oil ring (lower)
A5 Oil ring 䋺with coil
C2=1.30～1.60 2.0 䋺with coil
C3=1.00～1.30 2.0
C4=1.05～1.35 2.5 Clearance of Rings
C5=1.40～1.70 2.5

: Monoblock piston
◎ When wear of the piston ring groove width is
(4) Measure the width of the piston ring and oil so excessive, as to require replacement with
ring, and also measure the piston ring groove an oversize ring, consult our Service
width, and if the clearance is over the replacing Department.
limit, replace the ring with a new one.

Nom, size Standard Replacing Each ring periphery is edged sharply after a
(mm) clearance (mm) limit (mm) long-time run of the engine. Therefore, when
M/C disassembling the engine, be sure to wear
A1＝ 6 / 7 B1＝0.13～0.17 0.30 safety gloves to prevent injuries.
A2＝ 6 / 6 B2＝0.08～0.13 0.30
A3＝ 6 / 6 B3＝0.08～0.13 0.30
A4＝ 10 / - B4＝0.11～0.16 0.30 Even when the wear of the ring is within the
A5＝ 10 / 10 B5＝0.06～0.11 0.20 permissible value, replace all the rings with
M: Monoblock Piston
the new ones at every periodical inspection
C: Composit Piston with the interval of 8,000 -12,000 hours (2-3
years).

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Inspection and Maintenance of Connecting Rod DK-28e 4.3

4-4.3 Inspection and Maintenance of
Connecting Rod
(1) Inspect the connecting rod on the following
points, record the results, and repair or replace
whenever a defect is found.
1) Contact conditions of the small end part piston
pin bush(F) and loosening or positional devia-
tion of the bush fitting area
2) Scratch and fretting on the joint surface of the
trunk part and large end part
3) Dent or peeling-off of the threaded areas and
seat surfaces of the connecting rod bolt-1 and
(2) Clean the serrated area, and inspect the area
for scratch by means of color check.
(3) Blow air to the oil hole and nozzle that is run-
ning through the trunk part, and clean the parts.
(4) Measure the piston pin bush inner diameter,
calculate the clearance by combining it with the
results of measurement of the piston pin outer
diameter, and replace the piston bush with a
new one, in case that the wear is exceeding the
replacing limit.
4

㪸
the connecting rod bolt-2
4) Conditions of the serrated area : Wear and
fretting

㪘
5) Dent or peeling-off of the contact surface of
the circular nut of the large end part
6) Dent or peeling-off of the threaded areas and
bearing surface of the circular nut(J) of the con
necting bolt-1

(F) Piston pin bush
Joint surface

Trunk part Oil hole

Nozzle
Nom. Size Standard Replacing
(mm) clearance(mm) limit(mm)
A=φ125 a=0.14 ~ 0.17 0.30

Large end part Large end part ≪Bush replacing method≫

(trunk side) (large end cap)
Oil hole Joint surface Serration a) Take out the bush by striking with a press or
hammer.
b) Insert a new bush by pressing or cold-fitting
after confirming the oil hole position of the
bush.

<ln case of pressing>

Press-fitting force of bush : 10.7 ~ 32.3 kN
{1100 ~ 3300 kgf}
<In case of cold-fitting>
Inspection and Maintenance of Connecting
Rod Parts Immerse the bush in liquid nitrogen, and take
out the bush when bubbles disappear (in 5 to
10 minutes), and then insert it.

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM
Inspection and Maintenance of Connecting Rod
4.3,4.4 DK-28e / Inspection and Maintenance of Crank Pin Shell

(5) Confirm the tightening torque and matchmarks

of the connecting rod bolt-2.
1) Be sure to replace the shell as one set of a
●The connecting rod bolt-2 may produce devia-
tion in the relative position of the bolt and body pair of the upper shell and the lower one.
due to becoming accustomed after a long peri- 2) When the shell is used for a long time, it
od of operation, and therefore in such a case, shows reduction of the tension and harden-
be minded to renew the positioning mark on ing of its surface, resulting in crack or peel
the bolt side. of the shell, even if the wear is within the
( : 4-4.5 " Notching Procedure of Positioning allowance value. Therefore, replace the
Mark") shell with a new one after use for 20,000 hr
(6) Measure and record the inner diameter of the (4 to 5 years).
large end housing in the state that the connect-
ing rod is independently assembled (the state
that the large end part and trunk part are assem-
bled without the shells, and the connecting rod
bolt-1 and the connecting rod bolt-2 are tight- Presence of siezing mark, peeling-off, cavitation,
ened with the specified value), and inspect if and embeded foreign matters
there is any distortion of the shape.
( : "Assembly of Piston and Connecting
Rod")

4-4.4 Inspection and Maintenance of

Crank Pin Shell
(1) Inspect if there is no fretting on the crank pin
shell rear surface and the joint surface, and also
inspect the inner surface for the seizure mark,
peel, cavitation, or any imbedded foreign mat-
ters. When such defects are of light degree,
repair the crank pin shell using an oil stone. Presence of fretting
Inspection of Crank Pin Shell
The shell is the thin-wall finished metal, and is
provided with appropriate interference (crush) Connecting rod
and tension so as to closely fit to the housing large end part
surface. Therefore, do not correct the rear sur-
Crankpin bearing
face and joint surfaces with a file or scraper.
Crank pin
(2) Wash the shell, and measure the thickness of
the shell using a spherical micrometer, and
record the results. A
Calculate the clearance from the measurement
results of the inner diameter of the large end
housing, thickness of the shell, and the diameter
of the crank pin. If the result is over the replacing a
limit, replace the shell with a new one.

Nom, size Standard Replacing

(mm) clearance (mm) limit (mm)
A=φ235 a=0.17 ~ 0.26 0.30
Clearance of Crank Pin Shell

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Replacement of Connecting Rod Bolt DK-28e 4.5

4-4,5 Replacement of Connecting Rod

Bolt

Be minded to replace the connecting rod bolt-

1 and connecting rod bolt-2 every 16,000 to
24,000 hrs (4 to 5 years), even when the
appearance problem is not found.
B mark Positioning mark,
bolt side
(1) Replacement of Connecting Rod BoIt-2
a) Use the red lead or blue paint lead to check A mark
the contact of the bolt head seat surface with
"A" torque, and correct the seat surface of the
Rotation angle
4
Body side mark
connecting rod, in case that there is any fault
Angular ightenig Positioning Mark
or problem.

A-torque: 196 N.m {20 kgf.m}

b) Stamp the identification number of the engine Engine identification Bolt number
number
to be replaced, the cylinder number, and the
Cylinder number When replacing the
bolt number on the head part of the new bolts. bolt, be sure to notch
䋱 the same number as
c) Apply the lubricating agent (MOLYKOTE 1000
䋱 䋱 that of the old bolt
spray type) on the threaded part and seat sur-
face of the bolt, and repeat loosening and
tightening 2 to 3 times using a torque wrench,
with torque 490 N.m, so as to make the parts Identification Mark of Bolt Head Part
to be accustomed. Then notch the positioning (Example)
mark on the bolt according to the following
procedure.

≪Notching procedure of positioning mark≫

a) Apply the lubricating agent (<MOLYKOTE
1000 spray) on the threaded area and seat
surface of the connecting rod bolt-2,

1) Use of the lubricating agents of different

MOLYKOTE 1000
brands causes difference in the bolt axial spray
tension. Therefore, be sure to use the lubri-
Connecting rod bolt-2
cating agent "MOLYKOTE 1000 spray type"
(genuine parts).
2) MOLYKOTE brings about changes in the
frictional force after drying. Therefore,
quickly tighten the bolts after spraying
before it dries. Application of Lubricating Agent

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

4.5 DK-28e Replacement of Connecting Rod Bolt

䌁 mark
b) Tighten the bolt using a torque wrench with A- 䌂 mark
torque in the following order. 䋳 䋱

A-torque: 196 N.m {20 kgf.m}

Tightening order: 1-4-2-3-1 䋴 䋲

㪜㫄㪹㫆㫊㫊㪼㪻㩷㫊㪼㪸㫋 㪚㫆㫅㫅㪼㪺㫋㫀㫅㪾㩷㫉㫆㪻㩷㪹㫆㫃㫋㪄㪉
c) Notch the positioning mark on the bolt by
adjusting with the "A" mark on the body side. Bolt Tightening Order

After the notching of positioning mark on the

bolt, tighten angularly the bolt according to the
procedure of 4-5.2 "Bolt tightening procedure".

(2) Replacement of Connecting Rod Bolt-1 To notch

positioning mark
The connecting rod bolt-1 is a stud of large
diameter. Stud and extract it by means of the 㪙 㪘
hexagonal hole of the head part and the hexag-
Notching of Positioning Mark on The Bolt
onal rod spanner.
a) Stamp the identification number of the engine
to be replaced, the cylinder number, and the
bolt number on the head part of the new bolts
(nut side).
MOLYKOTE 1000
b) Apply lubricating agent(MOKYKOTE 1000 spray
spray) to the thread of the studded side of the
Connecting rod bolt-1
bolt.
c) After cleaning the thread hole of the large end
part, blow air and screw the bolt with your Studded side

hand.
d) Attach the hexagonal rod spanner to the
Application of Lubricating Agent to the Bolt
hexagonal hole of the head part, and normally Threaded Part (Studded Side)
assemble it after repeatedly tightening and
loosening with the specified torque 3 to 4 times Connecting rod bolt-1
to make it accustomed. 1 2

Bolt number
Specified torque: 29 ~ 39 N.m
{3.0 ~ 4.0 kgf.m}

Embossed seat

Replacement of Connecting Rod Bolt-1

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Assembly of Connecting Rod Large End Part DK-28e 5.1

4-5 Assembly of Piston and Connecting

Rod
4-5.1 Assembly of Connecting Rod
Large End Part
(1) Clean all the parts using washing oil, and blow
air to the threaded holes before assembly.
(2) Stud the connecting rod bolt-1 with the speci-
fied torque.
( : 4-4.5'(2) "Replacement of Connecting
Rod Bolt-1")
Since the numbers are notched on the bolt
and nut, be sure to assemble the parts Into
the original bolt holes so as not to mistake the
assembling positions.
Be sure to install the connecting rod large end
part after matching the cylinder number, so
that the embossed seat may be in the position
directed toward the front side of the engine.
(8) Screw the circular nut of the connecting rod
bolt-1 down to the bottom with your hand.
(9) Install the hydraulic jack in the same procedure
of disassembling, and tighten the two at the
same time with the specified oil pressure.
( : 2-4 "Hydraulic Jack") 4
Specified oil pressure: 83.4 MPa
{850 kgf/cm2}

(3) Cleanly wipe off the dirt and oil accumulated on

the inside surface of the large end part housing
and the rear surface of the shell.
Do not apply lubricating oil or grease to the
rear surface of the shell. Inclusion of oil will
cause the reduction of adhesion.
(10) Make sure that the large end part turns lightly
(4) Adjust the position of the shell claw to the
groove of the large end part housing, and mount
it so that the shell may be positioned at the cen-
ter of the large end part housing.
(5) Strike the shell at its center with your hand to fit
If tightening of the bolts is Insufficient, it will
not only damage the bearing shell and the
serration of the large end part, but also incur
major accidents such as breakage of the
bolts. Therefore, be sure to tighten each bolt
securely.
by turn it with your hand.
3 1
4 2
Bolt number

the shell tightly to the housing.

(6) Cleanly wipe the surface of the crank pin, and
apply lubricating oil to the inner surfaces of the ID stamp
Embossed
crank pin and the shell. seat
(7) Assemble the large end part using the shell cap
fitting and disengaging imp!ement(5) from both
sides in the same procedure of the disassem-
bling with enough care so as not to damage the
screws of the crank pin and the connecting rod
Bolt number
bolt-1. Connecting rod
bolt-1
2 1

Assembly of Connecting Rod Large End Part

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

5.2 DK-28e Assembly of the Piston (Composite Piston)

4-5.2 Assembling of the Piston

(Composite Piston)
Assemble the piston crown and the piston skirt
according to the following procedure when they
have been dismantled. Wash them and blow them  
by air before starting the assembling..
(1) Embed the piston crown bolts in the piston
crown. The embedding work should be effected 

according to the following procedure.
a) Remove dust, oil and any other foreign matters
stuck to the piston crown and the threads of the Sequence of Tightening of the Tightening Nuts
bolts. (View "P")
b) Apply blue paint lead to the tip of each bolt to 
be embedded.
Nut
c) Embed the bolt with the specified torque, then
Washer
remove it to see contact condition by means of
the blue paint lead applied to the tip of the bolt.
Correct the bolt when the contact is not satis- Piston Skirt
factory.
d) Apply lubricant (Molykote 1000 Spray) to the
thread to be embedded.
e) Embed the bolt with the specified torque.

Specified torque : 103 N.m {10.5 kgf.m}

O-ring
f) Make certain that the bolt is embedded perpen- Piston Crown
dicularly to the surface of the piston crown in Bolt
which the bolt is embedded after the bolt has
Spring Pin
been tightened with the specified torque.
Piston Crown
(2) Fit the o-ring on the piston skirt. Assembling of the Piston
(3) Set the piston skirt on the piston crown making Crown and the Piston Skirt
certain that position of the spring pin in the pis-
ton crown is correct.
(4) Check adaptation to and contact with each
mating parts of the washers, the nuts and bolts.
The procedure is as described below.
a) Remove dust, oil and any other foreign matters
stuck to the contact surfaces of the washers,
the nuts, the bolts and the piston skirt.
b) Apply blue paint lead to the spherical part of
the washers and the seating surfaces of the
bolts.
c) Tighten the nuts with the initial torque as speci-
fied below in the sequence of 1 " 2 " 3 " 4
as shown in the illustration.

Specified torque : 103 N.m {10.5 kgf.m}

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Assembly of the Piston (Composite Piston) DK-28e 5.2

d) Tighten the nuts with the specified torque as

Piston Crown Bolt
specified below in the sequence of 1 " 2 " 3 Marking
" 4 as shown in the illustration

Specified torque : 147 N.m {15 kgf.m}

e) Make marks as shown in the illustration with

paint or some other on the tip of the bolts and
on the bosses on the piston skirt, and then
loosen the nuts about 50o (the sequence of
loosening is the same as for detachment of the
piston crown).
f) Again tighten the nuts with the "specified 4
torque" in the sequence of 1 " 2 " 3 " 4 as
shown in the illustration.
g) Loosen and remove the nuts to check contact
of the spherical part of the washers, the seating
surfaces of the nuts. Make certain by means of
the marks that the bolt does not turn with the Pin Boss of the Piston Crown
nut at the same time.
(5) Finally tighten the bolts. Work procedure is as
Marking on the Piston Crown
described below.
a) Remove blue paint lead applied to the spheri-
cal part of the washers, the seating surfaces of
the nuts and the surface of the skirt contacting
with the washers. Erase the marks on the tips
of the bolts and the skirt.
b) Apply lubricant (Molykote 1000 Spray) to the
a

spherical part of the washers, seating surfaces

of the nuts and threads of the bolts.
c) Tighten the nuts with the "initial torque" in the
sequence of 1 " 2 " 3 " 4 as shown in the
illustration.
d) Tighten the nuts with the "specified torque" as
specified below in the sequence of 1 " 2 " 3 Detail "D"
" 4 as shown in the illustration.
e) Loosen the nuts about 50o (the sequence of
loosening is the same as for detachment of the
piston crown), and then again tighten the nuts
with the "specified torque" in the sequence of 1
" 2 " 3 " 4 as shown in the illustration.
(6) Measure the clearance between the piston
crown and the piston skirt. If the clearance is D
beyond the limit, replace a new one.

Standard clearance Replacing limit

(mm) (mm) Clearance between
a=0.14~0.19 0.10 Piston Crown and Piston Skirt

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

5.3 DK-28e Assembly of Piston and Connecting Rod

4-5.3 Assembly of Piston and Piston

Connecting Rod combusion
surface

F
(1) Wash all the parts, and blow air to them before
Notched
assembling the piston. Embossed seat mark "F"
(2) Assemble the piston and the connecting rod.
Connecting
a) Insert the connecting rod small end into the rod trunk
piston, placing the combustion surface of the part flange
piston facing downward, while matching the
embossed seat of the connecting rod trunk Connecting rod
trunk part
part flange and "F" mark of the piston combus- Piston pin
Piston clamp ring
tion surface.
Snap ring pliers
Piston pin

Confirm that the discrimination numbers of the

large end part and the small end part are identical.

b) Apply lubricating oil to the piston pin outer Assembly of Piston and
periphery and piston pin boss inside area, Connecting Rod Trunk Part
lightly suspend the connecting rod, and then
insert the piston pin.
c) Fit the piston pin stopper ring into the groove
using a snap ring pliers. Ring end
Ring end
(3) Fit the piston insertion frame into the cylinder
liner upper part.
(4) Turn the crankshaft to place the crank pin at Coil
Coil joint
the bottom dead center position of the cylinder to Manufacturing mark
notched position
which the piston is assembled.
(5) Mount the suspending metal fitting (eye bolt Joint Oil ring
M12) on the piston upper part, and suspend the 1st ring 䋨top ring䋩
piston and the connecting rod part.
2nd ring
(6) Assemble the piston ring.
3rd ring
Assemble the piston ring in the position as
Oil ring ......"M" only
shown in the figure, with the manufacturing (without coil)
mark facing upward (toward the combustion Oil ring
(with coil)
chamber side) so as to ensure the correct
C: Composite piston
assembling position. M: Momoblock piston
㪫op ring
(7) Assemble the oil ring. 3rd ring
Oil ring (M)
a) Entangle the coil into the piston oil ring (without coil)
groove, and insert the coil joint.
Front F Rear
b) Assemble the oil ring so that the coil joint
comes on the opposite side of the ring joint Oil ring (C)
(with coil)
(8) Deviate the positions of each ring as shown in Oil ring (M)
2nd ring
the figure on the right, so that the piston ring and (without coil)
㪘㫉㫉㪸㫅㪾㪼㫄㪼㫅㫋㩷㫆㪽㩷㪩㫀㫅g end
oil ring joint may not be on a straight line.
Construction and Assembly of Rings

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Assembly of Piston and Connecting Rod DK-28e 5.3

(9) Sufficiently apply lubricating oil to the piston, Eye bolt M12
piston ring, oil ring, piston insertion frame, and
cylinder liner.
(10) Check the cylinder number, insert the piston
into the cylinder liner, so that "F" mark on the
piston top surface and the embossed seat of the
connecting rod will face toward the engine front
side, and then align the knock of the large end
part and trunk part after slowly lowering the pis- Embossed
seat
ton. Oil dispenser

Lubricating oil
4
1) When assembling the piston to the cylinder
liner, it is advisable to lightly strike the pis-
ton periphery with a plastic hammer, since it
facilitates easy lowering of the piston.
In case that the piston is fitted too tightly, do
not dare to forcibly lower the piston, but
once suspend the piston and then try to
insert the piston again.
Application of Lubricating Oil When
2) Be careful no to damage the cylinder liner Assembling Piston
inner surface with the flange part of the con-
necting rod trunk part.
Eye bolt M12
(11) Confirm that the knock is securely fitted, and Piston insertion frame
then remove the eye bolt M12 and the piston
insertion frame.
Piston

Connecting
rod trunk part

Knock pin

Connecting
rod large
end part

Insertion of Piston

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM

5.3 DK-28e Assembly of Piston and Connecting Rod

(12) Apply lubricating oil (MOLYKOTE 1000 spray)
on the threaded area and the seat surface of the
connecting rod-2, and assemble the bolt into the
position of I.D. number,
While handling the bolts, use caution to keep
the bolts and the thread part of the connecting
rod free from dent scratches and dust.
(14) Confirm that side motion is seen in the con-
necting rod large end part, and conduct the rota-
tion stoppage by wiring if there is no abnormality.
䌁 mark
䌂 mark
䋳 䋱

(13) Angularly tighten the connecting rod bolt-2 on 䋴 䋲

the following procedure:
㪜㫄㪹㫆㫊㫊㪼㪻㩷㫊㪼㪸㫋 㪚㫆㫅㫅㪼㪺㫋㫀㫅㪾㩷㫉㫆㪻㩷㪹㫆㫃㫋㪄㪉
≪Bolt tightening procedure≫
Bolt Tightening Order
Replace connecting rod bolt-2 with a new one
every 16,000 to 24,000 thousand hours (4 to 5
years).
To replace the bolt, follow the procedure in
section 4-4.5.

a) Evenly tighten the bolt with the A-torque

according to the tightening order (1-4-2-3-1) as
shown in the figure on the right.
b) Confirm that the positioning mark of the bolt Positioning
and A mark of the seat surface are matched. mark
㪙 㪘
Tigtening
㫆
When a positioning mark does not align with the 㪂㩷㪉㪌
A-mark, remake a positioning mark on the bolt.
Connecting Rod Bolt Angular Tightening
When remaking a positioning mark, deform
the old mark. Then, hammer out a new mark
distinctively to prevent you from mistakenly
using the old mark while reassembling.

c) Anguraly tighten the bolt until the positioning mark

on the head of the bolt meets the B torque mark
on the connecting rod. in the order of 1-4-2-3-1.

･ A-torque: 196 N.m {20 kgf.m)

･ Angular tightening (B mark): +25°

A serious accident such as bolt breakage may

result if the bolts are insufficiently tightened.
After tightening the bolts to the positions of the
B-marks, make sure that the positioning marks
on the bolts are aligned with the positions of
the B-marks or are a little beyond the B-marks.

Confirmation of Connecting Rod Side Motion

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Assembly of Piston and Connecting Rod DK-28e 5.3

(15) Manually insert the protection ring into the

cylinder liner, making the notched mark "US"
side facing upward, and taking care not to tilt the
ring.

4
US

Protection ring "US" Stamp

Insertion of Protection Ring

When the piston and the connecting rod are

disassembled, be sure to conduct a test run of
the engine after restoration, to sufficiently
check that they are free from problems
through touching and the like, Then, enter into
the normal operation,

DK-28e Z 11-06
CHAPTER
4 Piston and Connecting Rod
ITEM
Confirmation of Connecting Rod Bolt
5.4 DK-28e Tightening Force and Retightening

4-5.4 Confirmation of Connecting Rod (1) Tightening Confirmation of the Connecting

Bolt Tightening Force, and
Retightening
If the tightening force of the bolt is insufficient,
it will incur serious accidents such as break-
age of the bolt. Therefore, be minded to
securely tighten the bolt.
Check the tightening conditions of the connect-
ing rod bolt-1 and connecting rod bolt-2 and
retighten them within 3,000 hr after initial opera-
tion, overhaul, maintenance after installation or
bolt replacement, in consideration of initial run-in,
and check the tightening force periodically (every
less than 6,000 hr) after that.
Rod Bolt-1
a) Turn the crankshaft to place the crank pin of
the cylinder, which is to be inspected, in the
o
position of 40 ( before the top dead center.
b) Install the hydraulic jack to the bolts on both
sides, and tighten with the specified oil pressure.
( : 4-5.1 "Assembly of Connecting Rod
Large End Part")
( : 2-4 "Hydraulic Jack")
Specified oil pressure:
83.4 MPa {850 kgf/cm2}
c) If the angle of the circular nut has advanced
(i.e. further turned), retighten the nut.

㪋㪇

(2)-(b)

(2)-(a)
(2)-(f)
(2)-(d)

(2)-(e)
Retightening of Connecting Rod Bolt-1

DK-28e Z 11-06
 CHAPTER
Piston and Connecting Rod 4
ITEM
Confirmation of Connecting Rod Bolt
Tightening Force and Retightening DK-28e 5.4

(2) Tightening Confirmation of the Connecting

Rod Bolt-2
a) Turn the crankshaft to place the crank pin of
the cylinder, which is to be inspected, in the
position of the bottom dead center.
b) Remove the rotation stopper wire ring.
c) Tighten the bolt after setting the torque
wrench to 490N.m. If the bolt does not turn, the
tightening force is normal.
d) In case that the bolt is turned, once loosen the
bolt, and conduct the angular tightening after
renewing the positioning mark on the bolt
4
again.
( : 4-5.2 "Bolt Tightening Procedure")

Tightening Order of Bolts

Connecting
rod bolt-2
Ratchet head

Torque wrench

Socket

Retightening of Connecting Rod Bolt-2

DK-28e Z 11-06
CHAPTER
5 Engine Frame and Cylinder Liner
ITEM
General Construction/Replacing Consumables,
1,2 DK-28e Implements, and Measuring Instruments

5. Engine Frame and Cylinder Liner

5-1 General Construction
Liner support frame Protection ring Cylinder liner
The engine frame is of a suspension shell struc-
ture made of cast steel, and has sufficient rigidity
against the explosion pressure.
O-ring
The main bearing part is hydraulically fastened secure- Intake duct
ly with the main bearing bolts and side bolts of large
Cooling water O-ring
diameters. The air-intake passage, cooling water pas-
passage
sage, and lubricating oil passage are incorporated in Engine
the engine frame to minimize external piping. frame

The cylinder liner upper flange area is of thick-wall

Lubricating
structure and cooled forcibly through the drilled oil passage
holes for the sake of reducing thermal load, and its
cooling water is guided to the cylinder head Side bolt
through the liner support frame attached around
the upper outer periphery.
Further, the inner periphery of the cylinder upper
area is provided with the thin-wall liner protection Main bearing bolt
ring, for the sake of preventing the accumulation of
carbon sludge.
Engine Frame and Cylinder Liner
The engine frame and the cylinder liner are tightly
sealed with O-rings at both the top and bottom part.

Cylinder liner : 165 kg

5-2 Replacing Consumables,

Implements, and Measuring Instruments
Replace the following parts with the new ones: e) a)
(1) Replacing Consumables
( : "Parts List")
d)
1) O-ring 3-12 No.15
2) Liner support
2) O-ring 3-12 No.503 frame implement
(2) Implements and Measuring Instruments c)

1) General tools and measuring instruments

( : 2-2) 4) Cylinder liner
2) Cylinder liner support frame implement bore gauge
3) Cylinder liner fitting and disengaging implement
b)
a) Fitting and disengaging implement-1
"c" "d"
b) Fitting and disengaging implement-2
"a" "b"
c) Fitting and disengaging impfement-3
d) Nut-1 3) Cylinder liner fitting 5) Cylinder liner
and disengaging position gauge
e) Nut-2 implement
4) Cylinder bore gauge {275 - 300 mm)
5) Cylinder liner position gauge

DK-28e Z 11-06
 CHAPTER
Engine Frame and Cylinder Liner 5
ITEM
Inspection and Maintenance of Cylinder Liner Inner
Surface DK-28e 3

5-3 Inspection and Maintenance of P-S direction F-A direction

Cylinder Liner Inner Surface
Conduct the inspection and maintenance of the
cylinder liner (hereafter to be referred as liner)
inner surface in the state that the cylinder liner is
assembled in the engine frame, after overhauling
the cylinder head and piston.
( : 3-1.3 "Removal of Cylinder Head")
( : 4-3.1 "Extraction of Piston")
(1) Visual Inspection Liner support frame (4) (5)
a) Observe the conditions of the carbon Measurement of Cylinder Liner
deposited on the cylinder liner inner surface. Inner Diameter
b) Remove the carbon, and check the inner
surface for scratch, scuffing, blow-by mark,
(5) (4) Cylinder liner 5
and corrosion.
c) Check the outer surface of the protection ring
and liner inserting area for corrosion and fretting. "a"
(2) Measure the inner diameter of the cylinder liner.
"b"
Mount the liner position gauge (5) in the state
that the cylinder liner is assembled in the engine
frame, measure the inner diameter with the cylin-
"c"
der bore gauge (4), and record the results.

Nom. size Replacing (Correction)

(mm) limit (mm) "d"
B=φ280 +1.0 (Uneven wear: 0.3)

(3) Measure the protection ring thickness with a

spherical micrometer, and record the results.
Measurement Procedure of
Nom. size (mm) Replacing limit (mm) Cylinder Liner Inner Diameter
a=10.2 -0.25

Stamp mark "US"

Wear of the cylinder liner and protection ring
inner diameters depends on the quality of the
fuel oil used, control of lubricating oil, and
cooling water temperature. Progress of wear
causes problems such as blow-by and
increase in the consumption of lubricating oil,
and therefore when the parts reach or come
close to the use limit, be minded to replace
a (Bottom side)
them in an earlier stage.
Measurement of Protection Ring Thickness

DK-28e Z 11-06
CHAPTER
5 Engine Frame and Cylinder Liner
ITEM
Inspection and Maintenance of Cylinder Liner Inner
3,4 DK-28e Surface / Extraction of Liner

(4) Dressing (de-glazing) of cylinder liner
When the piston ring is replaced, or the cylinder
liner inner surface is in the mirror surface condi-
tion, dress the inner surface.
Conduct the dressing with sandpaper or by hon-
ing.
a) Polish the surface with sandpaper (#80) in
the circumferential direction, so that the sur-
face may be marked with the sandpaper
mesh.
b) In the case of dressing by honing, correct
the uneven wear, and conduct honing, so
that the surface may be 5 to 10μRz at the
cross-hatch angle of 30°.
c) After the end of honing, measure the inner
diameter, and confirm that the inner diameter
is within the replacing limit.
and disengaging implement-1 (3)-(a) should
be even with the upper end surface of the
cylinder head bolt.
d) Turn the nut (3)-(d), and draw up the support
frame until the O-ring on the lower side is
completely dislocated.
e) Suspend the support frame by passing the
wire rope around the fitting and disengaging
implement-1(3)-(a)
It is possible to conduct honing process-
ing in the state that the cylinder liner is
assembled in the engine frame by using a
special honing machine.
As for the details, consult the Service
Department of Daihatsu Diesel
Manufacturing Co., Ltd.

5-4 Extraction of Cylinder Liner

Extract the cylinder liner after removing the cylin-
der head and piston.
( : 3-1.3 "Removal of Cylinder Head")
( : 4-3.1 "Extraction of Piston")
(1) Before extracting the cylinder liner, confirm that
water in the cylinder jacket is drained complete-
ly.
(2) Receive dirt, foreign matters, water droplets,
etc. on a vinyl sheet or the like, so that they
may not drop on the oil pan.
(3) Remove the cylinder support frame (hereafter (3) - (a)
to be referred as support frame) in the following
procedure: Circular nut
a) Remove the support frame mounting bolt
(2)
using a hexagonal rod spanner.
Cylinder head bolt
b) Install the support frame implement (2) on
the upper surface of the support frame. Liner support frame
c) Install the cylinder liner fitting and disengag-
ing implement-1 (3)-(a) and the nut (3)-(d)
using the cylinder head bolt and the circular (3) - (d)
nut according to the procedure as shown in Removal of Liner Support Frame
the Figure.
At this time, adjust the position of the circular
nut so that the upper surface of the fitting

DK-28e Z 11-06
 CHAPTER
Engine Frame and Cylinder Liner 5
ITEM
Extraction of Cylinder Liner DK-28e 4

(4) Extract the cylinder liner.

a) Screw the circular nut into the 2 cylinder
bolts.
b) Install the nut (3)-(d) and the fitting and dis-
engaging implement-1 (3)-(c) to the cylinder
liner fitting and disengaging implement-1 (3)-
(a), and insert them into the cylinder. At this
time, adjust the height of the fitting and dis-
engaging implement-1 (3)-(a) as in the same (3) - (e)
manner of Item (3)-(c).
(3) - (a)
c) Install the fitting and disengaging implement-
1 (3)-(b) to the fitting and disengaging imple-
ment-1 (3)-(a), and screw them until they
strikes the lower surface of the liner.
Circular nut

Cylindr
5
d) Turn the nut (3)-(e) of the center upper part, head bolt
and draw up the liner until the O-ring of the (3) - (d)
liner lower part is completely extracted out of
the engine frame.
e) Tighten the nut (3)-(d), and completely fix the (3) - (c)

liner with the fitting and disengaging imple-

ment-1 (3)-(b) and the fitting and disengag- Cylindr liner
ing implement-1 (3)-(c).
(3) - (b)
f) Pass the wire rope around the fitting and dis-
engaging implement-1 (3)-(a), and suspend
the liner.
(5) Remove the O-ring.
Extraction of Cylinder Liner

DK-28e Z 11-06
CHAPTER
5 Engine Frame and Cylinder Liner
ITEM
Inspection and Maintenance of Cylinder Liner Outer Periphery
5 DK-28e Support Frame Inner Periphery, and Engine Frame Jacket

5-5 Inspection and Maintenance of
Cylinder Liner Outer Periphery, Liner
Support Frame Inner Periphery, and
Engine Frame Jacket
(6) Clean the contact surface with the cylinder
head gasket on the liner upper surface.
If necessary, apply compound to the gasket sur-
face, and conduct facing-up.
(Facing-up implement: Option)

(1) Remove the scale on the cooling water contact

face "O", the cooling water drilled hole "P", "P2",
and the support frame inner periphery "R" using
the wire brush or the like.
(2) Subject the flange fillet "QL", the vicinity of the
cooling water drilled hole "P", and the shelf cor-
ner "QF" of the engine frame to color check, and 㪣㫀㫅㪼㫉㩷㫊㫌㫇㫇㫆㫉㫋㩷㪽㫉㪸㫄㪼 㪚㫐㫃㫀㫅㪻㪼㫉㩷㫃㫀㫅㪼㫉
inspect if there is any crack. P1
Y
(3) Inspect the Mner outer periphery "O", the sup- R X
Y O
port frame inner periphery "R", and the jacket X
V
"U" of the engine frame for cavitation and corro- QF S
Y
sion. If the degree of the defect is minor,
P2 QL
repair the part using a repairing agent.
(4) Inspect the fitting areas ("X", "S", and "T" of the
liner, "Y" of the support frame, and "V" and "W"
U O
of the engine frame) for corrosion and fretting.

㪜㫅㪾㫀㫅㪼㩷㪽㫉㪸㫄㪼
In case of the corrosion or cavitation is found, the
following possible reasons can be considered:
W
1) Cooling water rust preventive agent is not T
effectively working.
2) Cooling water pressure is low.
3) Cooling water is mixed with air.
Conduct appropriate cooling water control in Inspection and Maintenance of Liner Outer
strict conformance with the Control Periphery, Support Frame Inner Periphery and
Engine Frame Jacket
Standard.
( : "Operation" 6-3 "Control of Cooling
Water")

(5) If the anti-corrosion coating film of the cylinder

liner outer periphery and the engine frame jack-
et is peeled off, conduct touchup painting.

Pale gray-brownish deposit is a film of the rust

preventive agent that has been used.
Therefore, do not remove it.

DK-28e Z 11-06
 CHAPTER
Engine Frame and Cylinder Liner 5
ITEM
Mounting of Cylinder Liner DK-28e 6

5-6 Mounting of Cylinder Liner

Mount the cylinder liner in the reverse order of (3) - (a)
the dismounting procedure:
(1) Clean the cylinder liner inner and outer sur-
(3) - (b)
faces, and O-ring grooves.

about
145
(2) Fit O-rings to the cylinder liner. (6 places)
(3) Mount the liner in the following procedure:
a) Screw the fitting and disengaging implement-2
(3)-(b) to the cylinder liner fitting and disengag- Cylinder liner
ing implement-1 (3)-(a) down to the position as
shown in the Figure, and insert the liner.
b) Fit the fitting and disengaging implement-
1(3)-(c), and securely fix the liner by tighten- 㪞
ing the nut (3)-(d).
c) Pass the wire rope around the fitting and dis- 5
engaging implement-1 (3)-(a), and suspend
the liner.
d) Insert the fitting and disengaging implement- (3) - (c)
1(3)-(b), in which the nut (3)-(d) is screwed, (3) - (d)
into the cylinder head bolt.
Mounting of Cylinder Liner Fitting and
Disengaging Implement
1) Do not apply silicone rubber to the O-ring.
2) After silicone rubber is applied, assemble
the cylinder liner at an earlier timing before
it dries up. Notched mark "F"
(3) - (e) Circular nut
O-ring
e) Insert the liner into the engine frame.
Turn the notched line (with "F" notched (3) - (a)
mark) on the side of the liner upper part
(3) - (b)
toward the front of the engine, slowing lower 䌆
the liner while adjusting with the notched line
(between the 2 lines) of the engine frame, Notched line
and then pass the fitting and disengaging
implement-1 (3)-(a) through the cylinder
head bolt.
Cylinder liner

When inserting, be careful so that the thread

of the cylinder head bolt should not be dam-
aged, and the O-ring should not be cut. Engine frame

f) Swing the liner, and fix the fitting and disen-

gaging implement-1(3)-(a) with the circular
nut at the point when it dose not lower with (3) - (c)
its empty weight any more. At this time,
adjust the height of the 2 circular nuts so that (3) - (d)
the line should not fall down.
g) Remove the nut (3)-(d) and the fitting and Assembly of Cilinder Liner
disengaging impiement-1(3)-(c).

DK-28e Z 11-06
CHAPTER
5 Engine Frame and Cylinder Liner
ITEM

6 DK-28e Mounting of Cylinder Liner

h) Turn the nut (3)-(e) anticlockwise direction,

and tighten it until the liner is closely
attached to the engine frame.
i) Remove the fitting and disengaging imple- (2)
ment-1 (3)-(a) and the fitting and disengag-
Liner support frame
ing implement-1 (3)-(b).

(4) Mount the Support Frame

a) Apply grease to the O-ring and the support
frame inner surfaces {upper and lower O-ring Mounting Of Liner Support Frame
contact surfaces).
b) Install the support frame to the support
frame implement (2), and suspend it with a
wire rope,
c) Slowly lower the support frame with the push
rod through hole directed toward the fuel oil
injection pump side, and lower it until it does (3) - (a)
not lower with its empty weight any more Circular nut
after passing it through the cylinder head bolt. Cylinder
head bolt (3) - (d)

(2)
Liner support
When inserting, be careful so that the thread frame
of the cylinder head bolt should not be dam- Knock pin
aged, and the O-ring should not be cut.

d) Insert the fitting and disengaging implement-

1(3)-(b) to which the nut (3)-(d) into the cylin- Assembly of Liner Support Frame
der head bolt.
e) Screw the circular nut into the cylinder head
bolt. At this time, adjust the height of the 2
bolts so that the support frame should not fall
down.
f) Turn the nut (3)-(d), and tighten it until the
support frame is closely attached to the
engine frame.
g) Confirm that the positioning knock (exhaust
side) is securely fitted.
h) Remove the circular nut, the fitting and dis-
engaging implement-1(3)-(a), and the sup-
port frame implement (2).
i) Tighten the support frame mounting bolt
evenly using the hexagonal rod spanner.

DK-28e Z 11-06
 CHAPTER
Engine Frame and Cylinder Liner 5
ITEM
MEMO DK-28e

5
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM

1 DK-28e General Construction

6. Main Bearing and Thrust Bearing

6-1 General Construction

The main bearings are of a suspension bearing

shell structure with the main bearing cap hydrauli- Main bearing shell
Oil hole
cally fastened rigidly by the main bearing bolt and
the side bolt. Engine
The fitting part between the main bearing cap and frame
the engine frame is of tightening fitting.
The main bearing shells are made of aluminum Side bolt
alloy of high wear resistance, and the lower bear-
ing shell are positioned by means of the claw.
The main bearing lubricating oil is supplied through
the drilled holes of the engine frame from the
upper bearing shell.
The thrust bearing is made of aluminum alloy as
same as in the case of the main bearing, and it is Main bearing cap
mounted on the top and bottom of the both sides Main bearing bolt
of the 1st wall located on the engine rear side. The
lubricating oil is forcibly supplied through the main Main Bearing
bearing shell.

Main bearing cap: 69 kg

Crank shaft

Main bearing shell

Thrust bearing

Thrust Bearing

DK-28e Z 11-06
 CHAPTER
Main Bearing and Thrust Bearings 6
Replacing Consumables, Implements, and Measuring ITEM

instruments DK-28e 2

6-2 Replacing Consumables,

Implements, and Measuring
(1) Replacing Consumables
None
(2) Implements and Measuring Instruments
1) General tools and measuring instruments
( : 2-2)
2) Main bearing top shell extracting implement
3) Hydraulic ram assy. for main bearing 2) Main Bearing Upper Shell Extracting
a) Hydraulic ram (1) Implement
b) Shell cap implement (2)
c) Hydraulic jack mounting implement-2
d) Main bearing cap implement (2) d)
e) Special bolt
4) Main bearing cap implement (3)
c)
6
5) Main bearing cap implement (1)

a) e) b)

4) Main Bearing CapImplement (3) 3) Main Bearing Hydrauri Ram Assy.

5) Main Bearing Cap Implement(1)

DK-28e Z 11-06
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM Replacing Consumables, Implements, and Measuring
2 DK-28e instruments

6) Hydraulic jack for main bearing

a) Hydraulic jack assy.
b) Jack stand
c) Jack handle
7) Hydraulic jack for side bolt
(common use with the connecting rod bolt-1)
a) Hydraulic jack assy.
b) Jack stand
a)
c) Jack handle (common use with 6-c)
b) c)
8) Hydraulic pump and high-pressure hose
a) Hydraulic pump
b) High-pressure hose
c) Terminal (2T)
9) Main bearing cap support implement
a) Cap support implement (1) 6) Hydrauric Jack for Main Bearing
b) Cap support implement (2)

a)

b)
c)

7) Hydrauric Jack for Side Bolt

b)
c)

a)

a)

b)

9) Main Bearing Cap Support Inplement 8) Hydrauric Pump and High- Pressure Hose
‫ޓ‬

DK-28e Z 11-06
 CHAPTER
Main Bearing and Thrust Bearings 6
ITEM
Disassembly of Main Bearing Shell DK-28e 3.1

6-3 Main Bearing Shell

For disassembly and inspection of the main bear-
ing shell, the bearing shelf can be extracted only
by lowering the main bearing shell cap without
removing it completely.
Fitting of the main bearing cap and the engine
frame is of tightening fitting. Therefore, never
remove the main bearing cap from the engine
frame when lowered the main bearing cap
downward. (If removed, it will be extremely dif-
ficult to assemble it again.)
(2) Disconnect the side bolt tightening nut using
the hydraulic jack.
( : 2-4 "Hydraulic Jack Operating Method")
a) Mount the jack stand (7)-b and the hydraulic
jack assy. (7)-(a) on the side bolts of the both
sides, and connect it to the hydraulic pump(8)-
(a) with a high-pressure hose(8)-(b).
b) Operate the hydraulic pump lever to increase
the oil pressure to the specified level, and
loosen the nut using the jack handle (7)-(c).
Specified oil pressure: 58.9 MPa {600 kgf/cm2}

c) Confirm the oil pressure to cause the nut to

6-3.1 Disassembly of Main Bearing Shell
(1) Remove the covers of the both sides on the
engine frame side of the cylinders at the front
and rear of the main bearing to be disassem-
bled, and set the crank pin on the working side
for disassembly and inspection to be horizontal.
(Refer to the Figure below.)
turn, and check if the tightening is not loos- 6
ened.
d) Remove the hydraulic jack assy. and jack
stand.
e) Remove the side bolt tightening nut, and
loosen and draw out the side bolt.

Working side

(8)-(b) (8)-(a)
(7)-(c)

(7)-(b) (7)-(a) (8)-(c)

Removal side bolt nut

DK-28e Z 11-06
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM
3.1 DK-28e Disassembly of Main Bearing Shell
(3) Remove the main bearing cap{c) tightening nut
using the hydraulic jack.
( : 2-4 "Hydraulic Jack")
a) Screw the main bearing cap implement (3),4)
into the main bearing cap (A).
b) Connect the high-pressure hose (8)-(b) to the
main bearing hydraulic ram assy.(3), and con-
nect it with the hydraulic pump (8)-(a) accord-
ing to the following procedure.
● Feed port "D" of the hydraulic ram (1)-
hydraulic pump changeover valve port "B"
(Return)
● Feed port "U" of the hydraulic ram (1)(3)-(a) -
hydraulic pump changeover valve port "A"
(Pressurize)
c) Screw the main bearing cap implement (2)(3)-
(b) into the main bearing cap implement(3)
with your hand, and fix the hydraulic ram (1).
d) Install the shell cap implement (2)(3)-(b) to the
hydraulic ram (1) with the special bolt (3)-(e).
e) Install the hydraulic jack mounting implement-
2 (3)-(c) to the right and left arms of the shell
cap implement (2), and place the main bearing
hydraulic jack assy.(6)-(a) and the jack stand
(6)-(b) on it.
f) Turn the changeover valve of the hydraulic
pump to "Pressurize", and slowly operate the
hydraulic pump lever to pressurize.
Do not raise the oil pressure to the value high-
er than 29.4 MPa {300 kgf/cm2}
g) Change the changeover valve of the hydraulic
pump to "Return", and slowly raise the shell
cap implement (2).
Neutral
Return Pressurize (8)-(a)
㪬 㪛
B
A 3
(8)-(b)
(3)-(a)
Connection of Hydrauric Ram
DK-28e Z 11-06
h) When the hydraulic jack assy, is raised up to
the main bearing bolt, stop the operation of the
hydraulic pump and screw the main bearing
bolt using the hydraulic jack assy.
i) After screwing the hydraulic jack assy., rotate
the shell cap implement (2) to a proper direc-
tion so that the hydraulic jack assy., and the
hydraulic jack mounting implement should not
interfere each other.
j) Connect the hydraulic pump to the hydraulic
jack assy, with the high-pressure hose.
k) Raise the oil pressure to the specified pres-
sure by operating the hydraulic pump lever,
and loosen the main bearing cap tightening nut
(C) using the jack handle (6)-(c).
( : 2-4 "Hydraulic Jack")
Specified oil value: 88.3 MPa {900 kgf/cm2}
I) Confirm the hydraulic oil pressure at which the
nut starts to turn, and inspect if there is no
loosening of the tightening.
m) Remove the high-pressure hose from the
hydraulic jack assy.
n) Rotate the shell cap implement (2), and place
the right and left hydraulic jack mounting
implements directly below the hydraulic jack
assy.
A
C 4
B
6 b
d
6 a
3 e 3 c
3 a 3 b
Mounting of Bearing Cap Implement
 CHAPTER
Main Bearing and Thrust Bearings 6
ITEM
Disassembly of Main Bearing Shell DK-28e 3.1

o) Dislocate the hydraulic jack assy. by turning it,

and place the hydraulic jack on the hydraulic
jack mounting implement-2. In order to prevent spontaneous failing-off of
p) Slowly operate the hydraulic pump lever after the main bearing cap, install the main bearing
changing the changeover valve of the cap implement (1) immediately after removing
hydraulic pump to 「Pressurize」, lower the the main bearing cap tightening nut on one
shell cap impiement (2), and then remove the side.
hydraulic jack assy, and the jack stand from
s) Remove the other main bearing cap tightening
the main bearing bolt.
nut, and install the main bearing cap imple-
Further, rotate the arm of the shell cap imple-
ment (1) to it as well.
ment (2) to a proper direction so as not to
impede the works afterwards.
q) Remove the main bearing cap tightening nut
on one side.
r) Install the main bearing cap implement (1), 5)
to the end of the removed main bearing bolt. 6

Main bearing cap

Main bearing bolt

(5)

Mounting of Main Bearing Cap

DK-28e Z 11-06
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM

3.1 DK-28e Disassembly of Main Bearing Shell

(4) Dismount the main bearing cap in the following

procedure. In order to prevent spontaneous falling-off of
a) Remove the shell cap implement (2)(3)-(b) the main bearing cap, install the main bearing
from the hydraulic jack mounting implement- cap support implement immediately after
2(3)-(c). removing the main bearing cap implement (1)
b) Adjust the top and bottom position of the on one side.
hydraulic ram by operating the hydraulic
pump(8)-(a), fit the shell cap implement (2)(3)-
(b) into the main bearing cap(1), 5), and then
fit it with the nut(M). Main bearing
cap (A)
c) Turn the changeover valve to 「Return」, and
lower the main bearing cap(A) by slowly oper-
ating the hydraulic pump lever.

lf the changeover valve is turned to "Return",

the hydraulic oil flows from "B" to "D" so that
the main bearing cap lowers, and if the Main bearing
Nut seating bolt (B)
changeover valve is turned to "Pressurize", face
㩿㪌㪀㪄㩿㪸㪀
the hydraulic oil flows from "A" to "U" so that
Stepped area 㩿㪌㪀㪄㩿㪹㪀
the main bearing cap rises. 㩿㪊㪀㪄㩿㪸㪀 㩿㪊㪀㪄㩿㪹㪀 㩿㪌㪀㪄㩿㪺㪀
Hydraulic oil does not flow when the
changeover valve is at the neutral position. Lowering of Main Bearing Cap (1)
When the cap does not lower, it can be low-
ered easily by loosening the side bolts on the
both side.

d) Stop the operation of the hydraulic pump as Main bearing

soon as the nut seating face of the main bear- bolt (B)
ing cap has struck the stepped area of the
main bearing cap implement (1),5).
e) When disassembling and inspecting the other
main bearing shell at the same time, remove
the hydraulic ram according to the following
procedure.
Main bearing
i) Loosen the nut (M), rotate the shell cap imple- cap (A)
ment (2) (3)-(b), and then remove the main (5)
bearing cap implement (1), 5 on one side. (3)-(b)
ii) Securely screw the main bearing cap imple- (3)-(a)
ment (2) (9)-(b) into the end of the removed
main bearing bolt, and fix it with the support Lowering of Main Bearing Cap (2)
implement (1) (9)-(a).

DK-28e Z 11-06
 CHAPTER
Main Bearing and Thrust Bearings 6
ITEM
Disassembly of Main Bearing Shell DK-28e 3.1

iii) Remove the other main bearing cap imple-

ment (1) as well, and fix the main bearing cap
implement (9) to it, then fit it. Main bearing
bolt (B)
iv) Remove the hydraulic ram assy.(3) from the
main bearing cap (A).

(5) Remove the main bearing lower shell from the

cap.
If you place a wooden piece against the end face
of the shell, and lightly strike it, it can easily be
removed. (9)-(a)
(6) Remove the main bearing upper shell accord- (9)-(b)
ing the following procedure. Mounting of Cap Support Implement
a) Insert the main bearing upper shell extracting
implement (2) into the oil hole of the crank
shaft. 6
Be careful so that the main bearing shell
extracting implement may not come off the oil
hole. Application of grease to the insertion
side of the extracting implement will make it
Upper shell (2)
difficult for the implement to come off.

b) Press the main bearing shell extracting imple-

ment against the end face of the upper shell,
and extract the upper shell by turning the crank
shaft.

When extracting, be careful so as not to incur

injury by receiving the upper shell in your
hand. Lower shell

Extraction of Main Bearing Shells

DK-28e Z 11-06
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM

3.2 DK-28e Inspection and Maintenance of Main Bearing Shell

6-3.2 Inspection and Maintenance of and tighten the nut with the specified oil pres-
Main Bearing Shell sure.

(1) Inspect if there is fretting on the rear surface Specified oil pressure: 88.3 MPa {900 kgf/cm2}
and the joint surface of the main bearing shell,
and also check if there are seizure mark, peel,
cavitation, or imbedded foreign matters in the Presence of siezing scar,
inner surface. When the degree of the fault is peeling-off, cavitation,
embedded foreign matters
minor, correct the surface using an oil stone. Main bearing upper shell

The main bearing shell is a thin-wall finished

metal, and provided with appropriate interfer-
ence (crush) and tension, so as to make it
tightly fit to the housing surface.
Therefore, do not correct the rear surface and
joint surfaces with a file or scraper.

(2) Clean the main bearing shell, and measure the

thickness with spherical micrometer, then record Presence of fretting
Main bearing lower shell
the result.
In case that wear of the shell is significant, and Inspection of Main Bearing Shell
the clearance of the crank journal is over the
replacing limit, replace the parts with the new
ones.
The measurement of the clearance between the
shell and the crank journal shall be performed Lead
according to the following procedure. wire
a) Lower the main bearing cap at the measured
position downward in accordance with Hydrauric Hydrauric
Hydrauric
Disassembling of Main Bearing Shell ( : 6- jack ram jack
3.1)
b) Push up the crank shaft webs at the 2 places
on the both sides of the measuring point or the (Center main bearing)
balance weight with the hydraulic jack. (At this
time, fit the dial gauge to the webs at the 2
places to be pushed up, and slowly apply the
oil pressure until the indicator of the dial gauge
does not move any more.)
c) After confirming that the measured journal has
struck the upper shell using the dial gauge, Hydrauric
Hydrauric
place a small piece of 0.5 mm soft lead wire ram jack
under the lower shell.
(directly under the lower metal.)
d) Assemble the main bearing cap according to (Mainn bearings on both sides)
Assembly of Main Bearing Shell ( : 6-3.3), Clearance Measurement of Main Bearing Shell

DK-28e Z 11-06
 CHAPTER
Main Bearing and Thrust Bearings 6
ITEM
Assembly of Main Bearing Shell DK-28e 3.2

e) Lower the main bearing cap in accordance

with Disassembling of Main Bearing Shell
( :6-3.1), take out the lead wire, and then
measure the thickness using a spherical
micrometer.

Nom. Size Standard clearance Replacing limit

(mm) (mm) (mm)

B
B=φ25O =0.13-0.22 0.30

b
1) Be sure to simultaneously replace the top
and bottom shells as one pair set.
Clearance of Main Bearing Shell
2) Long-time use of the shells brings about the
reduction of tension and hardening of the
shell surfaces to cause crack and peeling-
6
off of the shells, even if the wear is below
the allowable value. Therefore, be minded
to replace the shells every 16,000 to 24,000
hours (4 to 5 years).

(3) Check the seat surface of the tightening nut

and the seat surface of the cap side, and if there
is any roughness on them, correct the part. Joint face
(4) If the tightening nut of the disassembled main
bearing bolt is found to be loosened, retighten
the other main bearing bolts as well.
(5) Inspect if there is not fretting or other fault on
the joint faces of the main bearing caps as well
as the contact face of the fitting part. Fitting part Fitting part
(6) Inspect the scratch on the crank shaft surface
Inspection of Fitting Part and Contact Face
as well as the contact and wear conditions.

DK-28e Z 11-06
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM

3.3 DK-28e Assembly of Main Bearing Shell

6-3.3 Assembly of Main Bearing Shell
(1) Visually check and also check with your naked
hand if the crankshaft journal part is free from
the deposit of foreign matters and scratch.
(2) Clean the shell inner surface and rear surface
with washing oil, then carefully wipe off the oil.
Be minded not to apply lubricating oil to the
back surface of the shell. If oil is applied, the
adhesion performance will be decreased.
a) Visually recheck and also recheck with your
naked hand that the crankshaft journal and the
main bearing cap inner surface are free from
the deposit of foreign matters and scratch.
b) Confirm the positions of the lower shell, the
end face of the main bearing cap, and the
claw. And, then mount the lower shell to the
main bearing cap.
c) Confirm that the shell is completely mounted.
d) Sufficiently apply lubricating oil to the lower
shell inner surface with your naked hand.

(3) Assemble the upper shell in the following pro- Upper shell
cedure.
a) Observe the joint face since the upper shell
has no claw, and set the upper shell in such
(2)
manner that the claw trace of the lower shell
should face toward the front side of the engine,
and it should be positioned in the center of the
shell housing width of the engine frame.
b) Push in the upper shell as far as it can be
pushed in.
c) Insert the main bearing upper shell extracting Lower shell
implement into the oil hole of the crank shaft in Assembly of Mainbearing Upper Shell
the same procedure of disassembling.
d) Turn the crank shaft, and push in until the end
face of the upper shell and the cap joint face of
the engine frame meet.
Engine frame

Upper shell
Conduct turning with enough care, so that the
main bearing top shell extracting implement 1.5 1.5
6.5 6.5
may not be dislocated from the shell end face.

e) Make sure that the upper shell is inserted into Lower shell
the normal position. (Check the dimensions
shown in the Figure on the right.)
f) Turn the crank shaft in reverse direction, and Main bearing
cap
remove the main bearing upper shell extracting
implement. Center bearing Standard bearing
(4) Assemble the lower shell to the main bearing
cap in the following procedure. Confiemation of Main Bearing Shell
Assembling Positions

DK-28e Z 11-06
 CHAPTER
Main Bearing and Thrust Bearings 6
ITEM
Assembly of Main Bearing Shell DK-28e 3.3

(5) Assemble the main bearing cap in the reverse
order of the extracting procedure.
a) Match the main bearing cap side face with the
engine frame side face, switch the changeover
valve to 「Pressurize」 (main bearing cap
raising direction), and slowly push up the main
bearing cap until it strikes the joint surface of
the upper area engine frame.
b) Spray the lubricating agent (MOLYKOTE
h) Remove the main bearing hydraulic jack assy.
i) Turn the main bearing cap implement(2)(3)-(d)
at the end of the hydraulic ram piston with your
hand, and separate the hydraulic ram piston
and the main bearing cap implement(3),4).
(6) Mount the hydraulic jack (7)-(a),(b) on the side
bolts, and tighten the bolts hydraulically.
Specified oil pressure: 58.9 MPa {600 kgf/cm }
2

1000 spray type) to the threaded area on the

a) Tighten the 2 side bolts of the same main
studded side of the side bolt, and screw the
bearing at the same time.
bolt into the threaded hole of the main bearing
b) After tightening the bolts with the specified
cap with your hand.
pressure, once return the oil pressure back to
Turn it back by 1/4 to 1/2 turn after the bolt is
screwed down to the bottom. 「0」, then increase the oil pressure up to the
c) Screw the side bolt tightening nut until it is
specified value again to check the tightening 6
conditions.
completely settled to the bottom.
d) Remove the main bearing cap imple-
ment(3)(5), and screw the main bearing cap
tightening nut(C) into the main bearing bolt
until it strikes the bottom with your hand.

To prevent the spontaneous falling-off of the

main bearing cap, remove the main bearing cap
implement(1),5) after screwing the side bolt.

e) After lowering the hydraulic ram piston by

MOLYKOTO 1000 spray
turning the changeover valve of the hydraulic
pump to 「Pressurize」, place the main bear- Side bolt
ing hydraulic jack(6)-(a),{b) on the right and left
arms of the shell cap implement(2)(3)-(b).
f) Tighten the bolts hydraulically by installing the Studded side
main bearing hydraulic jack as in the case of
removing the main bearing cap tightening nut. Application of Lubricating Agent to the
Tighten the 2 bolts at the same time. Threaded Area of Bolt (studded side)

Specified oil pressure: 88.3 MPa {900kgf/cm2}

g) After tightening the bolt with the specified

pressure, once return the oil pressure back to
"0", then increase the oil pressure up to the
specified value again to check the tightening
conditions.

DK-28e Z 11-06
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM

4.1 DK-28e Dismounting of Thrust Bearing

Crank web
6-4 Thrust Bearing
The thrust bearings are mounted on the front and
rear surfaces of No.1 main bearing (flywheel side).
Dismount the thrust bearings at the time of disas-
sembling the main bearing.

6-4.1 Dismounting of Thrust Bearing

Magnet stand Dial gauge
(1) Measure the side clearance of the crankshaft
according to the following procedure before Measurement of Side Clearance
dismounting the thrust bearing:
Upper thrust bearing
a) Use the bar to shift the crankshaft toward the
either side, front or back, and place the dial
gauge against the crankshaft.
b) Fully shift the crankshaft toward the opposite
side, read the value, and compare it with the
thrust bearing replacing limit value.

When hooking the bar on the crankshaft, hook

it on the crank web, and do not hook the bar
on the balance weight.

(2) The lower side thrust bearing is mounted on Lower thrust bearing Knock pin
No.1 main bearing cap with the knock pins (2 Dismounting of Thrust Bearing (Back side)
pieces each on both sides). Therefore, it can be
disconnected at the same time when the main 2nd wall 1st wall
bearing lower shell is extracted.
(3) The upper side thrust bearing can easily be Upper thrust
bearing
extracted when the end face is pushed with your
hand.

The thrust bearings are designed to form a

pair with the upper and lower shells.
Therefore, be careful not to mistake the front
thrust bearing for the rear thrust bearing.
Discriminate them by marking or the like.

Lower thrust
bearing

Dismounting of Thrust Bearing (Side face)

DK-28e Z 11-06
 CHAPTER
Main Bearing and Thrust Bearings 6
ITEM
Maintenance and Assembly of Thrust Bearing DK-28e 4.2,4.3

6-4.2 Maintenance of Thrust Bearing

(1) Check the thrust bearing for seizure mark and
embedded foreign matters. If the defect is of
minor degree, repair the defect using an oil
stone.
(2) Measure the thrust bearing thickness using an
outside micrometer, and record the results.
(3) When the thrust bearing wear is heavy, and the
side clearance with the crankshaft is exceeding
the replacing limit, replace the thrust bearing
with a new one.
Knock hole Knock hole
Be sure to replace the thrust bearing as one set
of a pair of the upper and lower shells. Thrust Bearing

Nom. Size Standard clearance

(mm) (mm)
Replacing limit
(mm)
6
D=124 d=0.20~0.39 0.60
d

6-4.3 Assembly of Thrust Bearing

(1) Carefully clean the thrust bearings and apply
lubricating oil to the bearing surfaces.
(2) Insert the upper side thrust bearing.
(3) Mount the lower side thrust bearing to the main
bearing cap, and assemble the thrust bearing
together with the main bearing cap.
(4) Measure the side clearance, and make sure
that it is within the replacing limit.

Side Clearance

DK-28e Z 11-06
CHAPTER
Crankshaft
7
ITEM
General Construction / Consumables, Implements,
1 ,2 DK-28e and Measuring Instruments

7. Crankshaft

7-1 General Construction 7-2 Replacing Consumables,

Implements, and Measuring
The crankshaft is a high-strength carbon steel
Instruments
forged product of one-piece construction, and pro-
vided with sufficient rigidity and strength. (1) Replacing Consumables
Two pieces of the balance weight are fitted to None
each cylinder, and they are securely tightened with (2) Implements and Measuring Instruments
two pieces of the bolts respectively. (1) General tools and measuring instruments
The crank gear is shrink-fitted to the front side of ( : 2-2)
the crankshaft to drive the camshaft, and further the
auxiliary drive gear to drive the lubricating oil pump
and cooling water pump is bolted on the crank gear.
Lubricating oil supplied to the main bearing
through the holes of the engine frame reaches the
Flywheel
crank pin shell through the drilled holes in the
crankshaft, and then cools the piston through the
drilled holes in the connecting rod.
An oil cut plate is bolted to the inside of the cou-
pling flange located at the output shaft end, so as
to prevent the leak of oil from the shaft end.
The crankshaft is manually turned by the turning
device on the flywheel side.

Crankshaft assy.: 6DK: 3000 kg

8DK: 3500 kg Turning Device
(varies depending on specification)

Auxiliary drive gear Oil cutting plate

Crank gear

Balance weight

Crank shaft Balance weight bolt

Crankshaft

DK-28e Z 11-06
 CHAPTER
Crankshaft
7
ITEM
Inspection and Maintenance of Crankshaft: Inspection of Crank Pin DK-28e 3, 3.1

7-3 Inspection and Maintenance of

Crankshaft (3) Subject the fillet and bearing oil hole area to
color check.
In ordinary maintenance, the crankshaft is
In case that the problems such as the ones as
not disassembled, but inspected and adjust-
described above are found, carefully conduct the
ed in the state that it is assembled.
color check, including the bearing area for hair
When it becomes necessary to overhaul the
crack with particular attentions.
crankshaft because of the particular reasons
such as seizure of the bearing or abnormal
wear of the shaft, consult our Service
Department.

In case that the following situations has hap-

pened and if the operation is continued disre-
garding any one of them, it may result in seri-
ous damages or accidents. In that case,
please check them carefully.
1) In case that the engine is operated for a
long time in the dangerous rotation speed
range due to torsional vibration. 7
2) In case that the engine is operated
exceeding the allowable value of the crank-
shaft deflection.
3) In case that the clearance between the
crankshaft and shell is excessive, or the
Oil hole
crankshaft is unevenly worn out.
4) In case that the shell is burnt. (In case of
minor degree)

7-3.1 Inspection of Crank Pin

Inspect the crank pin when the connecting rod-
large end part is disassembled.
( : 4"3-2 "Disassembly of Connecting Rod
Large End Part")
(1) Check the bearing area for scratch and contact
conditions. Fillet

If scratch is found, correct it using an oil stone, Measurement of Crank Pin Shaft Diameter
and conduct the color check carefully.
(2) Measure the shaft diameter, and record the
results.
( : 4-4.4 "Inspection and Maintenance of
Crank Pin Shell")

Nominal size D = 235 mm

DK-28e Z 11-06
CHAPTER
Crankshaft
7
ITEM
Inspection of Crank Journal / Inspection of Balance
3.2,3.3 DK-28e Weight Bolt Tightening Force

7-3.2 Inspection of Crank Journal

Inspect the crank journal when the main bearing
shell is disassembled.
( : 6-3.1 "Disassembly of the main bearing
shell")
(1) Check the bearing for scratch and contact con-
ditions.
(2) Subject the fillet and bearing oil hole area to
color check.
In case that the problems such as the ones as
described above are found, carefully conduct the
color check, including the bearing area for hair
crack with particular attentions.
Fillet Fillet

When disassembly of the crankshaft is

required as the result of inspection, consult
our Service Department.

7-3.3 Inspection of Balance Weight Bolt

Tightening Force

If the bolt teightening force is insufficient, it Oil hole

may result in serious accidents during opera-
tion. Therefore, be minded to perform
inspection without fail. Wiring Balance weight bolt

(1) Inspection of every 4,000 to 6,000 hours Inspection of Crank Journal

(every year).
Inspect the rotation-stopper wire ring conditions,
and confirm that the balance weight bolt is not
loosened by hammering.
(2) Inspection of every 16,000 to 24,000 hours
(4 to 5 years)
Inspect the balance weight bolt tightening condi-
tions in the following procedure:
a) Remove the rotation-stopper wire ring.
b) Set the torque wrench to 1570 N.m, and con-
firm the tightening force.
c) When the bolt does not turn, it is sufficiently
tightened, and then conduct the rotation stop-
page with the wiring.

DK-28e Z 11-06
 CHAPTER
Crankshaft
7
ITEM
Inspection of Balance Weight Bolt Tightening Force DK-28e 3.3

d) In case that the bolt is turned, once remove the

bolt, and conduct the angular tightening accord-
ing to the following procedure.
㪊㪌 㫆
i) Check the contact face with the balance
weight bolt as well as the joint face with the A mark
crank shaft, and if stepped wear or fretting is
found, correct the part with a file. Positioning mark B mark
of bolt
ii) Carefully check the balance weight for
roughening of the seating face and crushing
of the thread, and if the damage is significant,
replace the bolt with a new one.
iii) Apply the lubricating agent (MOLYKOTE
1OOO spray type) on the thread and seating Balance weight bolt
face of the bolt.
iv) Set the torque wrench to the A torque, and
tighten it.

㪊㪌 㫆
A torque: 490 N.m { 50 kgf.m} Balance weight
7
v) Notch the positionig mark on the bolt head
and A torque mark on the balance weight.
vi) Notch the B torque mark on the balance Angular Tightening of Balance Weight Bolt
weight side of the position 35o advanced from
the A torque mark.
vii) Anguraly tighten the bolt until the positionig
mark on the head of the bolt meets the B
torque mark on the balance weight.

Anguraly tightening (B mark) : +35o

viii) Conduct the rotation stoppage by wiring.

DK-28e Z 11-06
CHAPTER
Crankshaft
7
ITEM
Inspection of Rear Part Oil Cut Clearance / Measurement
3.4, 4 DK-28e of Deflection

7-3.4 Inspection of Rear Part Oil Cut

Clearance
Rear part oil cut plate
Measure and check the clearance between the
rear part oil cut plate and the flywheel coupling

d
outer periphery using a clearance gauge, without
disassembling the main bearing shell, and the
obtained data shall be used as a guide value for
the wear of the main bearing shell.

Nominal size Standard clearance

E
(mm) (mm)
E= 485 d=0.30~0.45

d
7-4 Measurement of Crankshaft
Deflection Coupling

Crank shaft
1) Measure the crankshaft deflection when Inspection of Rear Part Oil Cut Clearance
the engine is cold.
2) When the engine is continuously operated
in the state that the crankshaft deflection is
over the limit value, the added stress of the
crankshaft will become excessive, and will
lead to the breakage of the crankshaft in
the worst case. Therefore, adjust the
deflection to a proper value at the time of
installation, and periodically measure the
crankshaft deflection every 2,000 to 3,000
hours (every 6 months) after the start of
operation of the engine, and correct the sit-
uation in case that the deflection is over the
limit value.

䃁 Crankshaft deflection measuring procedure:

( : "Operation" 5-4.6 "Measurement of
Crankshaft Deflection")

DK-28e Z 11-06
 CHAPTER
Crankshaft
7
ITEM
MEMO DK-28e

7
CHAPTER
Timing Gears and Camshaft
8
ITEM

1.1 DK-28e General Construction of Timing Gear

8. Timing Gear and Camshaft through the drilled holes of the idle gear shaft (E)
via drilled holes on the engine frame.
8-1 Timing Gear The sealing surface of the auxiliary drive gear
8-1.1 General Construction mounting cover (J) forming the timing gear housing
is sealed with liquid sealant.
The timing gear is arranged on the engine front
side, and the camshaft is driven by the cam gear
Cam gear gear shaft assy. : 68 kg
(D), from the crank gear (A) located on the crank-
Cam gear : 46 kg
shaft front side, via the idle gear-1(B) and idle
gear-2(C). Idle gear assy. : 150 kg
Auxiliary drive gear : 26 kg
All the gears are helical gears made of high-
strength alloy steel, and the cam gear tooth sur-
faces are carburized and hardened.
The cam gear (D) is fixed to the camshaft by the
High technology is needed to disassemble,
bolt with the cam gear shaft (R) in between.
assemble, and adjust the area around the tim-
Further, the governor drive gear (Z) is fixed to
ing gear and camshaft.
the cam gear shaft (R) by means of the shaft fas-
When the maintenance of such high tech-
tening elemental parts (POWER-LOCK) (F) which
nology is needed as the results of the inspec-
makes use of the wedge effect.
tion, please contact our Service Department
The idle gear shaft (E) is a carbon steel forged
or agency, and perform suck works under the
product and rigidly mounted on the engine frame
experienced engineers' guidance.
with 6 bolts.
Lubricating oil is supplied to the idle gear bush (H)

Oil feednozzle

(D)
(Z)
(D)
(R)
(F)

(B)
(K)
(E)
(H)
(C) (C)

(B)

(J)
(A)

(A)

Aux. drive

Area Around Timing Gear

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
Timing Gear:Consumables, Implements and
Measuring Instrements / Disassembly of Cam Gear DK-28e 1.2,1.3

8-1.2 Replacing Consumables, (7) After confirming that piping and wiring do not
Implements and Measuring impede the mounting or dismounting of the aux-
Instruments iliary gear cover(J), remove the cover.

(1) Replacing consumables

Replace the following parts with new ones: The mounting surface of the auxiliary gear
cover to the engine frame is sealed with liquid
( :"Parts List")
sealant without using the gasket.
1) Gasket for timing gear side cover 3-2 No.A12
Screw the bolt into the thread hole for the
2) Gasket-2 for timing gear
jack, and carefully take out without applying
side cover 3-2NO.A13
forcible power.
3) O-ring 3-6 No.507
4) Pump gear case gasket 3-8 No.A10
(8) Loosen the wiring, and take out the auxiliary
5) Cam bearing gasket 3-7 NO.B15
drive gear from the crank gear(A).
(2) Implements and measuring instruments
1) General implements and measuring instruments
( :2-2)

8-1.3 Disassembly of cam gear

(1) Remove all of the auxiliary parts mounted to
the auxiliary gear mounting cover(J) such as
the lubricating oil pump and the cooling water
8
pump, as well as the related piping and wiring.
(Q)
However, the fuel oil pump and the nozzle cool-
ing oil pump should be removed in the state that
they are mounted in the oil pump gear case. Thrust shell
When disassembling the idle gear, the cam
(P)
gear is needed to be extracted beforehand so
that the idle gear can be dismounted from the (M)
cam gear cover side.
(R)
(2) Remove the timing gear side cover(K). In case
that the tachometer sensor is attached, remove
it in the first place. OIl pump gear case
(3) Take out the mounting bolt of the cam bearing
cover(M),and remove the cover.
(4) Measure the thrust clearance "D" of the camshaft.
(A)
Temporarily fit the cam bearing(2){Q) to the
auxiliary gear mounting cover(J) at the time of
(J)
the measuring according to the {Item 8-.3(9)}.
(5) Remove the camshaft thrust receptor(P) from
the cam gear shaft{R).
Aux. drive gear
(6) Screw the bolt into the screw hole for the jack,
Deassembly of Idle Gear
and draw out the cam bearing(2)(Q) together
with the thrust shell.

DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM

1.3 DK-28e Timing Gear : Disassembly of Cam Gear

(9) Before disassembling the idle gear, conduct Thrust shell

d
the following measurement.
a) Measure the thrust clearance "d" on the axial (R)
direction of the camshaft, and the thrust clear-
ance "e" on the axial direction of the idle gear (Y)

using the clearance gauge respectively, and

record the data.

Standard Replacing limit

clearance (mm) (mm)
(P)
Cam gear b=0.20 ~ 0.45 0.55
Idle gear e=0.3 ~ 0.6 0.8
(Q)
(J)

b) Measure the backlash between the timing Thrust Clearance of Camshaft

gears, and record the data.
i) Bend a lead wire of 0.5 mm diameter along the
tooth profile, and adhere it using grease.
(O)
ii) Slowly turn the engine, and stop the turning at
(N)
the point where the lead wire is caught.
iii) Next, turn the engine in the reverse direction, (E)

and take out the lead wire to this side.

iv) Measure the thickness {thinnest part) of the
lead wire that is collapsed by the both sur-
(C)
faces of the tooth. (A and B as shown in the
figure)
v) Conduct the measurement of the 4 places per (B)
90o on the large gear, and make its average
value as the backlash "b".

Thrust Clearance of Idle Gear

Standard value Replacing limit
Backlash (mm) (mm)
(A + B) b=0.2 ~ 0.3 0.5

(10) Loosen the wiring, take out the bolt(N), and

Lead wire
then remove the idle gear shaft retainer(O).
(11) Draw out the idle gear-1, -2 assy.(B),(C) to 㪘 㪙
the front direction by suspending them with the
wire rope. 㪹
(12) In case of removing the idle gear shaft(E)
when necessary, perform the work after disas- Backlash b (= A + B )
sembling the cam gear.

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
Inspection and Maintenance of Timing Gear DK-28e 1.4

8-1.4 Disassembly of Cam Gear
Disassembling of the idle gear should be
performed on the following procedure after
disassembling the parts around the auxiliary
gear cover on the front side of the engine as
well as the idle gear.
( : 8-1.3 "Disassembly of Idle Gear")
(1) Remove the governor and the governor drive
device as well as the related parts and the wiring.
( : 11-3 "Disassembly of Governor Driving
Device")
(2) Remove the governor driving gear (Z).
a) Make sure that rotational torque or thrust load
is not applied on the governor driving gear (Z).
b) Slowly loosen the tightening bolts of the
POWER-LOCK (F) tightening the governor
driving gear (Z) using the hexagonal rod head
and the torque wrench from the mounting win-
dow of the timing gear side cover (K) of the
engine frame.
Since POWER-LOCK is the parts of precision,
and therefore wrong handling may damage it.
When mounting or dismounting, carefully
d) Remove the cam gear shaft(R) and the fitting
part of the cam gear shaft, and suspend the
cam gear(D) and the cam gear shaft(R) as
one set to the front side of the engine frame
while adjusting the tension of the 2 wire ropes.
e) Remove the wire rope on the mounting hole
side of the governor driving device, and lower
the gear and the gear shaft to the specified
position.
f) Take out the cam gear(D) and the cam gear
shaft(R).
Matchmarks are provided on the cam gear
and the cam gear shaft. When disassembling,
record the matchmarks position, and be sure
to match the original positions when assem-
bling.
( : 8-2.6 "Inspection of Fuel Oil Timing")
(D)
(Z)
(F)
(R)
8
Hex. rod head
Engine frame

perform the work according to a separately Torque wrench

Mounting window of
provided operating procedure. timing gear side cover (K)
( : 8-1.8 "POWER-LOCK operating pro-
cedure") Disassembly of Governor Driving Gear

c) Draw out the governor driving gear (Z) and

Governor driving device
the POWER-LOCK (F) from the cam gear mounting hole
(D) Engine frame
shaft (R).
(3) Draw out the cam gear (D).
(R) (I)
Camshaft
a) Pass a wire rope through the 2 holes of the
rim of the cam gear (D) from the mounting
hole of the governor driving device on the Fitting part
engine frame, and lightly suspend it with a Disassembly of Cam Gear (1)
chain block. Governor driving device
b) At the same time, pass wire rope through the mounting hole
Engine frame
same hole of the rim of the cam gear (D) from (D)

the front side of the engine frame, and lightly

suspend it with a chain block. Camshaft
(R)
c) Loosen the wiring, and take out the cam gear
mounting bolt (l).
Disassembly of Cam Gear (2)

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CHAPTER
Timing Gears and Camshaft
8
ITEM

1.5 DK-28e Inspection and Maintenance of Timing Gear

8-1.5 Inspection and maintenance of (10) Confirm the tightening condition of the
timing gear mounting bolt of the idle gear shaft(E).
When the bolt turns, remove the bolt and
(1) Wash all the gears and parts using washing oil.
replace it with a new one, and after cleaning
(2) Clean the oil hole of the idle gear shaft(E) by the female thread side, apply lubricating agent
blowing air. {Prevent flying-out of foreign mat- (MOLYKOTE 1000 spray) to the seating face
ters with waste cloth or the like.)
and the thread of the bolt,and then tighten it
(3) Check the idle gear-1(B), -2(C), and the tooth again with the specified torque.
surface of the cam gear(D) for contact, pitch-
ing, and scratch.
Specified torque: 392N-m {40 kgf-m}
(4) Turn the crankshaft, and check the crank
gear(A) as well, in the same manner as above. (11) Maintain the POWER-LOCK.
(5) Inspect the tightening conditions of the tighten- ( : 8-1.8 "POWER-LOCK Operating
ing bolt of the idle gear-1(B) and idle gear-2(C). Procedure")
Inspect the bolt tightening conditions with the
specified torque, and in case that the bolt is
loosened, remove the bolt and replace it with a
new one, and after cleaning the female thread
side, apply lubricating agent (MOLYKOTE 1000 (B) (E)
spray) to the seating face and the thread of the
bolt, and then tighten it again with the specified (C)
torque.
Oil hole

Specified torque: 490 N-m {50 kgf-m} (H)

(6) Check the idle gear bush (H) and shaft (E) for Tightening bolt
contact and wear conditions.
(7) Measure the outer diameter of the sliding area
Idle gear shaft
of the idle gear shaft(E) with the bush using an mounting bolt
outside micrometer
Inspection and Maintenance of Idle Gear
(8) ) Measure the inner diameter of the idle gear
bush(H) using a cylinder gauge.
(B)
(9) Calculate the clearance from the measurement (E)
results of the idle gear shaft(E) and the idle gear (C)
(H)
bush(H), and when the clearance is over the
replacing limit, replace the idle gear bush(H)
with a new one.
㪘

Nom. size Standard clearance Replacing limit

(mm) (mm) (mm)
㪸

A= 165 a=0.07 - 0.26 0.3

Clearance of Idle Gear Bush

When it is presumed that the clearance will
be over the replacing limit before the next
periodic maintenance, replace the bush, even
if the clearance is presently within the limit.

DK-28e Z 11-06
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Timing Gears and Camshaft
8
ITEM
Timing Gear : Assembly of Idle Gear DK-28e 1.6

8-1.6 Assembly of Cam Gear
Assemble the cam gear on the following procedure.
( : 8-1.3 "Disassembly of Idle Gear")
(1) Fit the cam gear, of which boss inner surface
is applied with lubricating oil, into the cam gear
shaft (R).
Be sure to match the matchmarks of the
cam gear and the cam gear shaft to the origi-
nal positions recorded before disassembling.
( : 8-2.6 "Inspection of Fuel Oil Timing")
(10) Press the governor driving gear shaft(Z)
against the cam gear shaft(R), and make sure
that there is no failing-down.
(11) After confirming that POWER-LOCK(F) is
securely fitted into the specified position, tight-
en the POWER-LOCK(F) using the hexagonal
rod head and the torque wrench.
( : 8-1.8 "POWER-LOCK Operating
Procedure")
POWER-ROCK specified tightening
torque : 81 N-m {8.3 kgf-m}

(2) Pass a wire rope through the 2 holes of the

cam gear (D) rim, and suspend it together with
the cam gearshaft (R) using a chain block.
(3) Move to the front side of the engine frame,
and pass a wire rope through the same hole of
the rim of the cam gear (D) from the mounting
hole of the governor driving device on the
engine frame, and lightly suspend it with a 8
chain block.
(4) Move the cam shaft (D) and the shaft (R) to
the front end of the camshaft while adjusting
the tension of the 2 ropes.
(5) After adjusting the fitting position of the knock
pin, securely fit the gear shaft (R) into the
camshaft.
(6) Once again confirm that the matchmarks of
the cam gear (D) and the cam gear shaft (R)
are matched to the original positions.
(7) Apply lubricating agent (MOLYKOTE 1000
spray) to the thread and seating face of the
cam gear mounting bolt (l), and tighten the bolt
with the specified torque.

Specified torque: 314 N-m {32 kgf-m}

(8) After removing the 2 wire ropes, conduct the

wiring for rotation stoppage of the cam gear
mounting bott (l).
(9) Insert the governor driving gear (R), in which
the POWER-ROCK (F) is fitted, into the cam
gear shaft (R).

DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM

1.7 DK-28e Timing Gear : Assembly of Idle Gear

8-1.7 Assembly of idle gear
Assemble the idle gear according in the reverse
order of the disassembling procedure.
(1) Turn the crank shaft, and place the No.1 cylin-
der on the intake top.
(6) Install the auxiliary drive gear to the crank
gear(A).
a) Apply the lubricating agent (MOLYKOTE 1000
spray) to the seating face and the thread of the
bolt, and tighten it with the specified torque.

(2) Suspend the idle gear assy.(B),(C) with a wire

rope, and insert it into the shaft(E).
Apply lubricating oil to the idle gear bush(H)
and the shaft, and match the matchmarks of
the idle gear-1(B) and the crank gear (A) to
insert them into the shaft.
(3) At the same time, confirm that the match-
marks of the idle gear-1(C) and the cam gear
(D) are matched from the rim hole of the idle
gear-1(B).
(4) install the idle gear shaft retainer(O), and perform
the rotation stoppage of the bolt(N) with wiring.
(5) Measure the thrust clearance "e" of the idle
gear, and confirm that the result is within the
specified value.
( : 8-1.3 "Disassembly of Idle Gear")
Specified torque: 117 N-m {12 kgf-m}
b) Perform the stoppage of the bolt by wiring.
<Cautions when assembling the timing
gears>
1)The engagement marks of the timing gear
are notched on the side face of each gear.
Therefore, when assembling, be sure to
confirm the engagement marks.
2) When the matchmarks of the crank gear
and the idle gear are engaged, let the
matchmarks of the cam gear and the idle
gear engage at the same time.

Specified thrust clearance:

e = 0.30 - 0.60 mm

Idle gear-2 (C)

(D)
Rim window
(C)
(E)
(H)

(N)
Cam gear (D)
㪉
㪉

(O)
㪉 Engaging mark
(C) and (D) (B)

Idle gear-1 (B)

㪈 Aux. drive
㪈 㪈 gear
Engaging mark
(A) and (B) (A)

Crank gear (A)

Matchmarks of Timing Gear Assembly of Idle Gear

DK-28e Z 11-06

Timing Gears and Camshaft
Timing Gear : Assembly of Idle Gear
(7) Install the governor driving device as well as
the related parts and the piping.
( : 11-5 "Assembly of Governor Driving
Device")
(8) Clean the mounting surface of the auxiliary
gear mounting cover (J), and install it on the
engine frame after applying liquid sealant.
(9) Assemble the front end part of the cam gear
shaft (R).
a) Assemble the thrust shell to the front and rear
of the cam bearing (2)(Q).
Assemble the thrust shell with the surface,
where oil collecting process is performed,
directed outward.
b) Apply lubricating oil to the sliding surface of
the thrust shell, the inner surface of the cam
bearing (2)(Q), and the periphery of the cam
shaft (R) end.
c) Attach the gasket to the cam bearing (2)(Q),
carefully fit it into the cam gear shaft(R) so as not
to damage the thrust shell and the bearing bush
inner surface, and then temporarily fix it to the
auxiliary gear mounting cover(J) with the bolt.
Confirm that the lubricating oil drain hole
( 10 mm x 4 places) of the cam bearing (2) is
at the underside
d) Clean the contact surface side of the cam
shaft thrust receptor (P), and confirm that
there is no dent and the like.
Apply lubricating oil to the contact surface,
and apply lubricating agent (MOLYKOTE
1000 spray) to the seating face and the thread
of the mounting bolt, then tighten the cam
gear shaft (R) with the shim (Y) (without shim
for standard) at the time of disassembling in
between with the specified torque.
Specified torque: 39 N-m {4.0 kgf-m}
CHAPTER
8
ITEM
DK-28e 1.7
e) Measure the thrust clearance "d" of the
camshaft using a clearance gauge, and con-
firm that the result is within the specified
value.
( : 8-1.3 "Disassembly of Idle Gear")
Specified thrust clearance:d=0.20-0.45 mm
In case that the thrust clearance "d" is
smaller than the value before disassembling,
or dispersion is found depending on the posi-
tion, once again adjust the governor driving
device by loosening the POWER-LOCK.
f) Remove the temporarily tightened bolt of the
cam bearing(2)(Q), attach the gasket to the
cam bearing cover(M), and then normally
tighten the bolt.
(10) Install the timing gear side cover(K). 8
Since the right-angle joint part of the side
cover gasket is likely to leak oil, use together
with liquid sealant.
(11) Install the auxiliary parts such as the lubricat-
ing oil pump, the cooling water pump, and the
pump gear case to the auxiliary gear mounting
cover(J), and also install the related piping as
well as the wiring.
Thrust shell
(oil collector)
Cam gear shaft (R)
Assembly of
Cam Bearing (2)
Lubricating oil drain hole ( 10 mm㧕
DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM

1.8 DK-28e POWER-ROCK Operating Procedure

8-1.8 POWER-LOCK Operating Procedure
The POWER-LOCK used to fix the cam gear to
the crankshaft is an elemental parts to fasten the
boss to the shaft by making use of wedge effect.
The POWER-LOCK is a precision parts, and
wrong handling may damage it. Therefore, mount
and dismount is most carefully in strict confor-
mance with the following procedure.
(1) Dismounting of POWER-LOCK
a) Check that any rotational torque or thrust load
is applied on the boss and the shaft.
after the tightening bolt is loosened, insert the
bolt sufficiently applied with lubricating oil or
grease to the thread of the dismounting hole,
and slowly and alternately tighten it on the
diagonal line. (As the rotational angle of the
bolt per one time, it is recommended to be
about 30o)
If the bolt is carelessly tightened in a hurry,
it may damage the thread. Therefore, be sure
to perform the work carefully according to the
procedure.

e) When the tightened state is released, hold the

When the boss and the shaft are under
application of a load, if the tightening bolt is
loosened, the lock will be released, and the
bolts may rotate and fly out causing a danger-
ous situation.
b) Before disassembling, tighten the tightening
bolt with the specified torque, and check if
there is any increase in the angle (to further
rotate) of the bolt. (Check of loosening)
c) Gradually loosen the tightening bolt in 2 to 3
states, and then remove it. (Disregarding the
sequence is acceptable.)
d) if the bolt is fixed on the tightened state even
drawing bolt, and draw it out as it is.
(2) Maintenance of POWER-LOCK
a) Draw out all the tightening bolts, and perform
the disassembly.
b) Clean each parts with washing oil, and thinly
apply lubricating oil to all the parts.
Never use the lubricating agent including
the silicon type or the molybdenum type lubri-
cating oil or grease. If such a type of oil or
grease is used, the frictional coefficient
decreases and slippage tends to occur.

Taper ring (a) Outer lace Taper ring (b)

Tightening bolt
Boss

Shaft

Inner lace

Construction of POWER-LOCK

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
POWER-ROCK Operating Procedure DK-28e 1.8

(3) Temporary assembly of POWER-LOCK
Temporarily assemble the POWER-LOCK to
facilitate the easier insertion of it into the shaft and
the boss in the following procedure.
a) Assemble the taper ring(a) and (b) as well as the
inner lace and outer lace as shown in the figure.
At this time, match the drilled hole of the taper
ring(a) and the screw hole of the taper ring(b).
b) Lightly and evenly screw all the tightening
bolts by rotating 2 to 3 turns.
bolts on diagonal lines in the same manner as
the above Item c).
e) Set the tightening torque to the specified
torque, and tighten the bolts in the same man-
ner as the above Item d).
f) Finally, sequentially tighten all the bolts with
the specified torque in clockwise direction
once again, and make sure that the tightening
of the bolts are securely performed after
repeating the tightening until the bolts do not
rotate any more.

(4) Assembly of POWER-LOCK

Assemble POWER-LOCK on the following pro- Tightening the bolts with the torque exceed-
cedure.
ing the specified torque will cause the bolts to
a) Wipe off the dust on the boss inner face and be damaged. Also, tightening the bolts with
the shaft surface, and thinly apply lubricating the torque below the specified torque will
oil or grease.
cause the bolts to be loosened.
b) Insert the POWER-LOCK into boss in the
Therefore, be sure to tighten the bolts with
state that the tightening bolt is lightly tight-
the specified torque always.
ened. At this time, lightly push it with your
hand to the position where the end face of the
boss and the end face of the POWER-LOCK
outer lace meet.
Governor gear
locking lig (optional)
8
1) When fitting the POWER-LOCK into the
specified position, lightly push it with your
hand. When it is difficult to fit, loosen and
push the tightening bolt. Never strike it
Hex. rod head
with a hammer or the like.
2) Assemble the boss into the specified posi-
tion, and perform the work by providing an
Torqe wrench
adequate support so that it should not
incline with its empty weight. Assembly of
POWWER-LOCK

1
The special tool for locking the governor 7 11
gear is available as an optional part. 13 5

c) After inserting it into the specified position,

tighten the tightening bolts into the 4 places 4 9
on diagonal lines with 1/4 of the specified
torque. 10 3
Subsequently, tighten the other bolts on diag-
6 8
onal lines as in the same manner. 2
12
d) Set the tightening torque to 1/2 of the speci-
fied torque, and sequentially tighten the Tightening Order of Bolts

DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM
Camshaft: General Construction / Replacing
2.1,2.2 DK-28e Consumables, Implements, and Measuring Instruments

8-2 Camshaft ( : 8-1 "Timing Gear")

( : 11 "Governor Driving Device")
8-2.1 General Construction
( : 13-3 "Starting Air Rotary Valve")
The camshaft is of one-piece construction made
of carbon steel, and is the unit type divided for
<6DK> <8DK>
every 2 cylinders.
Each unit is tightened with the 12 bolts respec- *Cam gear shaft, gear shaft assy. 300 kg 385 kg
(excluding cam gear)
tively, and the outer periphery of the joint part com-
*Cam gear shaft 22k g 22 kg
bines the shaft section.
The cam gear shaft is tightened to the front end *Cam shaft 1 unit 110 kg 110 kg
(For last cylinder)
part, and the cam gear to drive the cam shaft, the
thrust shell to restrict the axial movement of the
8-2.2 Replacing Consumables,
camshaft, and the governor driving gear to drive the
governor are provided. The governor driving gear
Implements, and Measuring
and the cam gear are fixed with the POWER-LOCK. Instruments
The starting rotary valve is driven from the end (1) Replacing Consumables
side of the camshaft via the rotary valve coupling. Replace the following parts with the new ones.
The surface of each cam is carburized. ( : "Parts List")
The cam bearings are provided on the front and 1) Rotary valve body gasket 3-9 No.15
rear of the cam gear as well as on the walls 2) Rotary valve base gasket 3-9 No.20
between each cylinder, and the bearing shell is 3) Circular gasket 3-9 No.513
directly installed into the engine frame hydrauiically. 4) Cam shaft bolt 3-7 No.A27
The drilled hole provided in the center of the 5) Special nut 3-7 No.A2
camshaft is the oil feed passage to each cam
bearing. (2) Implements and Measuring Instruments
1) General implements and measuring instru-
ments ( : 2-2)

Fuel oil injection

pump
Governor driving Camshaft bolt Cam bearing
Governor
device
Governor driving Camshaft
gear Fuel oil injection
pump tappet
Cam gear Rotary valve base

Starting air rotary

valve
Cam gear
shaft
Thrust shell Exhaust cam
Fuel oil cam
POWER-LOCK
Intake cam
Camshaft front end Camshaft rear end

Construction of Camshaft

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
Disassembly of Camshaft DK-28e 2.3

8-2.3 Disassembly of Camshaft (3) Remove the camshaft side cover.

Disassemble the camshaft in the following
procedure:
<Disassembly of the cam gear shaft>
(1) The disassembling of the cam gear shaft
should be performed at the same time when
the cam gear is disassembled.
( : 8-1.4 "Disassembly of cam gear")
<Disassembly of the camshaft>
The procedure of the camshaft disassembling is
described on the premise that the cam gear
and the cam gear shaft are readily disassem-
bled.
(1) Remove each piping connected to the starting
air rotary valve, and remove the starting air
rotary and the rotary valve base.
(4) Remove the high-pressure fuel oil coupling,
the fuel oil injection pump, and the fuel oil injec-
tion pump tappet.
( : 9-3 "Removal of F.O. Injection Pump and
F.O. Injection Pump Tappet")
(5) Remove the valve operating device.
( : 10-3 "Disassembly of Valve Operating
Device")
(6) Loosen and take out the nut on one side of
the bolts tightened to the camshaft from the
window of the camshaft side. (The nut on the
opposite side may be left as it is.)
(7) After confirming that there is no obstacle in
extracting the camshaft, sequentially draw out
the camshaft one by one unit toward the front
side or rear side of the engine.

( : 13-3 "Disassembly of Rocker Arm

Device")
When disassembling the camshaft, be care-
(2) Remove the cylinder head cover, and take out
the rocker arm device and the push rod. ful so that the cam and the cam bearing shell
should not be damaged by using a pad wood
8
( : 3-4.3 "Disassembly of Rocker Arm
or the like.
Device")

High-pressure fuel
oil coupling
Rocker arm device Camshaft side cover
and push rod
Fuel oil injection
pump and tappet

Governor and
governor driving device

Timing gear side cover

Aux. gear mounting

cover

Cooling water pump

Starting air rotary valve

Lubricating oil pump

Rotary valve base

Disassembly of Camshaft

DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM

2.4 DK-28e Camshaft: Inspection and Maintenance of Camshaft

8-2.4 Inspection and Maintenance of
Camshaft
Since the items mentioned in this section
are the parts to which NOx Technical Code
shall be applied, when replacing any of these
parts, be sure to use the parts provided with
the identification marks.
( : 0-3 "Engine Conforming to NOx
Technical Code.")
(1) Inspect if there is any pitching or peeling-off
on each cam surface.
When the pitching, peeling, or wearing on
the cam surface is excessive, it is necessary
to replace the cam with a new one.
When the damage is of light degree, the
cam service life can be extended to some
degree by conducting the surface treatment.
Therefore, consult our Service Department.
(2) Inspect if the cam is not slid.
(3) Check the bearing sliding area of the
camshaft for scratch and contact conditions. If
there is any scratch, correct it with a oil stone.
(4) Check the camshaft shell for wearing, scratch,
or peeling-of conditions.
(5) Measure the clearance between the bearing
sliding area of the camshaft and the cam bear-
ing shell.
<Replacing method of the cam bearing shelf>
i) It is recommended to slowiy draw out the shell
by pressing since there is a possibility to dam-
age the shell housing inner surface of the
engine frame. (Extraction force: 17.6 to 41.1
KN {1800 to 4200 kgf})
ii) Insert the shell into the engine frame by cold-
fitting with the oil holes (4 places) of the new
cam bearing shell directed upward.
The cold fitting procedure is as same as that
of the valve guide. ( : 3-1.5)
(6) Inspect the condition of wear as well as pres-
ence of scratch or peeling-off of the thrust shell.
a) Correct the minor wear with oil stone.
b) When the wear is significant and the thrust
clearance is over the replacing limit, replace
the thrust shelf with a new one.
Standard Replacing
clearance (mm) limit (mm)
Thrust
clearance d=0.20 - 0.45 0,55
(7) Since adhesive is attached on the cam shaft
bolt and the nut for tightening the camshaft,
replace them with the new parts.
Cam bearing shell (3) Cam bearing shell (2) Cam bearing shell (1)
b

a) Measure the outer diameter of each bearing

c

sliding area of the camshaft using an outside

A
C

micrometer.
b) Measure the inner diameter of the can bear-
ing shell using a cylinder gauge in the state
that each cam bearing shell is assembled on Cam gear shaft Cam gear Cam shaft
the engine frame.
Clearance of Cam Bearing
c) Calculate the clearance from the results of the
measurement, and in case that the clearance
Oil hole
is over the replacing limit, replace the cam
bearing shell with a new one.
Engine frame

Nom. size Standard Replacing

(mm) clearance (mm) limit (mm)
A= 185 a = 0.09 - 0.25 0.35
B= 185 b = 0.09 - 0.25 0.35
Cam bearing shell
C= 85 c = 0.09 - 0.15 0.25
Assembly of Cam Bearing Shell

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
Camshaft: Assembly of Camshaft DK-28e 2.5

8-2.5 Assembly of camshaft
Assemble the camshaft in the reverse order of
the disassembling procedure.
(1) Clean the nut seating face of the camshaft,
and make sure that there is no dent or peeling-
off. In case of fault, correct the part.
Since adhesive is attached on the bolt hole
and nut seating face of the camshaft, carefully
clean the part.
(5) After confirming the discrimination notches (as
shown in the figure below) on the flange part of
each unit, sequentially insert the camshaft for
every unit while paying attention so as not to
damage the cam bearing shell(1).
(6) Securely fit the fitting part by matching to the
knock pin position.
(7) Apply lubricating agent (MOLYKOTE 1000
spray) to the seating face of the nut for tighten-
ing the camshaft, and apply adhesive (ROCK-
TIGHT 243) to the thread, and tighten the bolts
on diagonal lines with the specified torque.

(2) Carefully clean the bolt hole of the camshaft

and the joint face, and blow air on them. Specified torque: 373 N-m {38 kgf-m}

(3) Pass the camshaft bolt for tightening through

the flange part (bearing part) of the camshaft.
(4) After confirming that there is no dust or foreign
matters on the camshaft surface, apply lubricat-
ing oil on the bearing part and the inner sur-
face of the camshaft shell(1). 8

Identification mark (I.D. mark)

For 7,8 cylinder For 5,6 cylinder For 3,4 cylinder For 1,2 cylinder
E6283 E6282 E6281
Normal rotation engine E628M3 E628M2 E628M1
䋶䌄䌋 E628M3A E628M2A E628M1A
E628L3 E628L2 E628L1
Reverse rotation engine E628L3A E628L2A E628L1A
E8284 E8283 E8282 E8281
Normal rotation engine E828M4A E828M3A E828M2A E828M1A
䋸䌄䌋
Reverse rotation engine E828L4A E828L3A E828L2A E828L1A

䋶䌄䌋 6 5 2 1
I.D. mark I.D. mark I.D. mark
䋸䌄䌋 8 7 2 1

Front end side (gear side) Rear end side

Identification Mark of Camshaft

DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM
Camshaft: Inspection and Adjustment of Fuel
2.6 DK-28e Oil Cam Timing

8-2.6 Inspection and Adjustment of Fuel

Cam gear Cam gear shaft
Oil Cam Timing
Camshaft
Since the items mentioned in this section
are the parts to which engine value specified
in NOx Technical Code shall be confirmed, do
not make any change that may deviate from Scale
(cam gear boss part)
the setting values.
( : 0-3 "Engine Conforming to NOx
Technical Code.")

In case that the cam gear shaft or the camshaft Notched line
(cam gear shaft flange part)
is disassembled, perform the inspection on the fol-
Confirmation of Matchmarks of Cam gear and
lowing procedure. Cam Gear Shaft
(1) Remove the timing gear side cover on the
side of the front of the engine.
(2) Confirm that the notched line provided on the
outer periphery of the cam gear shaft flange
part is agreed with the marking position of the
scale notched on the cam gear boss part (last
wall side) recorded before disassembly.
( : 8-1-4 "Disassembly of Cam Gear")
Fuel oil injection pump body
( : 8-1.6 "Assembly of Cam Gear")
(3) Slowly turn the crank shaft, and read the injec-
Guide plunger
tion start angle when the static injection stating notched line "Y"
position notched line "x" of the fuel oil injection Static injection
pump and the notched line "y" of the guide start position
notched "X"
plunger is agreed, on the scale on the flywheel.
Pump mounting
(4) Confirm that the reading shows the injection mark line position
start angle indicated on the adjustment plate on notched line "Z"

the inspection window of the engine frame.

(5) Fit the timing gear side cover.

Injection Start Position

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
Camshaft: Adjustment of Fuel Oil Cam Timing
(When Replacing Camshaft) DK-28e 2.7

8-2.7 Adjustment of Fuel Oil Cam
Timing (When Replacing Cam)
Since the items mentioned in this section
are the parts to which engine value specified
in NOx Technical Code shall be confirmed, do
not make any change that may deviate from
the setting values.
( : 0-3 "Engine Conforming to NOx
Technical Code.")
In case that the camshaft or the cam gear is
replaced, conduct the timing adjustment according
to the following procedure.
Here, we describe the procedure to adjust the
fuel oil injection timing of the entire cylinders by
relatively moving the cam gear and the camshaft.
(1) Remove the timing gear side cover on the
side of the front of the engine.
(2) Release the wiring, and loosen the cam gear
mounting bolt.
(3) Confirm that the notched line provided on the
outer periphery of the cam gear shaft flange
part is within the range of the scale notched on
the cam gear boss part (last wall side).
(4) When the notched line provided on the cam
gear shaft flange part is agreed with the center
notched line (longer notched line) on the scale
of the cam gear boss part, the setting is made
so that the fuel oil injection start angle becomes
the reference value. Adjust by normally or
reversely turning the crank shaft so that the
injection start angle indicated on the adjust-
ment plate of each engine can be obtained by
making it as a reference.
The variation of the injection start angle
depending on the rotational direction of the
cam gear is as shown in the figure below.
The injection angle varies by 2o of the crank
angle per one scale.
The movement range of the cam gear shaft
notched line should be within the scale of the
cam gear boss part.
If the range exceeds the scale, interference
between the intake and exhaust valves and
8
the piston as well as the push-up of the fuel oil
injection pump wilf occur, and in case of
extremity, it may damage the piston and the
fuel oil injection pump.

Cam gear Cam gear shaft (5) After adjusting the timing, tighten the cam
gear mounting bolt with the specified torque.
Cam gear Camshaft
mounting bolt
Specified torque: 314 N-m {32 kgf-m}

o o
Reference value +4 Reference value - 4
(crank angle) Scale (crank angle) Scale
(Cam gear part) (Cam gear part)
Referance value Referance value
(crank angle) (crank angle)

o
Notched line o
Notched line
Referance value - 4 (Cam gear syaft Referance value + 4 (Cam gear syaft
(crank angle) flange part) (crank angle) flange part)

In case of normal rotation engine In case of reverse rotation engine

Camshaft Notched Lines (Timing Adjustment)

DK-28e Z 11-06
CHAPTER
Timing Gears and Camshaft
8
ITEM
Camshaft: Adjustment of Fuel Oil Cam Timing
2.7 DK-28e (When Replacing Camshaft)

(6) Slowly turn the crank shaft, and read and con-
firm the injection start angle when the static
injection stating position notched line "X" of the
fuel oil injection pump and the notched line "Y"
of the guide plunger is agreed, on the scale on
the flywheel.
(7) Confirm this on all the cylinders as in the
same manner as above, and when fault is
found, readjust it by loosening the cam gear
(1) In case of lifting and lowering the F.O. tappet
adjusting screw:
( : 9-7 "Adjustment of Maximum
Combustion Pressure")
a) Against the pump mounting mark line position
notched line "Z" of the fuel oil injection pump
body, move the notched line "Y" of the guide
plunger as the following:
 Raise (to advance the fuel injection timing)

mounting bolt again. In case of a special cylin- ------------Pmax will be increased.

der, adjust on the fuel oil injection pump of the  Lower (to delay the fuel injection timing)

very cylinder. ------------Pmax will be decreased.

In case that the adjustment is impossible
within the range of the scale of the cam gear
boss part, there may be a possibility that
engagement of the cam gear and the idle gear
is wrong.
Reconfirm the matchmarks to check if each
gear is correctly engaged each other.]
b) Variation amount of the rotational angle of the
F.O. tappet and the Pmax:
o
 About 0.4 MPa {4 kgf/cm2} at 60 (rotation)
o
 About 0.2 MPa {2 kgf/cm2} at 30 (rotation)
(2) In case of varying the cam gear scale:
( : 8-2.7(4))
If it is slid one scale of the cam gear {2o at the
crank angle) against the notched line of the cam
gear shaft, variation will be about 0.9 to 1.0 MPa {9
to 10kgf/cm2}.

Fuel oil injection pump body

When restarting the operation, measure the
maximum combustion pressure, and readjust Guide plunger
the injection start timing of the fuel oil cam so notched line "Y"
that the dispersion between the cylinders Static injection
start position
should be within 0.6 MPa {6 kgf/cm2} at the notched "X"
time of full load.
Pump mounting
However, be careful so that the maximum mark line position
notched line "Z"
combustion pressure does not exceed 17.7
Fuel oil tappet adjusting screw
MPa {180 kgf/cm2} at the time of full load.
( : 9"7 "Adjustment of Maximum
Combustion Pressure")
Pmax Adjustment By
Fuel Oil Tappet Adjusting Screw
(8) Perform the rotation stoppage of the cam gear
mounting bolt by wiring.
Cam gear Cam gear shaft
(9) Fit the timing gear side cover.
Camshaft

<Relationship between the initial injection

angle of the fuel oil cam and the maximum
Scale
explosion pressure (Pmax)>-------Standard value (cam gear boss part)
at the time of fulf load
By changing the initial injection angle, the maxi-
mum explosion pressure (Pmax) will be varied as
shown below. Notched line
(cam gear shaft flange part)

Pmax Adjustment By Cam Gear Scale

DK-28e Z 11-06
 CHAPTER
Timing Gears and Camshaft
8
ITEM
MEMO DK-28e

8
CHAPTER
9 F.O. Injection Device
ITEM

1 DK-28e General Construction

9. Fuel Oil (F.O.) Injection Device In case that high-pressure oil has leaked from the
connecting part ranging from the fuel oil injection
9-1 General Construction
pump to the fuel oil injection valve, such oil will be
The fuel oil injection pump (A) is a Bosch type, tap-
induced into the drilled hole on the cylinder side
pet-incorporated high-pressure single cylinder
through the drilled hole for detecting leaked oil
pump, and the plunger is lubricated with lubricating
installed in the high-pressure fuel oil coupling, and
oil. In case of heavy fuel oil specification, the
then will be recovered through the piping into the
pump rack is assembled with the stop air cylinder.
leak oil tank so that the error is detected by the
This fuel oil injection pump is installed on the fuel
level switch.
oil injection pump tappet (B).
The adjusting screw for adjusting the injection tim- ( : "Operation" 5-4.2 "Inspection and
ing is incorporated in the fuel oil injection pump Maintenance of Fuel Oil Injection Valve")
tappet.
High-pressure fuel oil is introduced from the pump F.O. injection pump assy.: 30 kg
outlet into the fuel oil injection valve inlet connector F.O. injection pump tappet assy.: 33 kg
(E), through the drilled holes of the forged steel
high-pressure fuel oil coupling (D), via the joint (C)
with the spherical surfaces on the both ends.

(E) (D)

(C)

(A)

F.O.tappet
adjusting screw
(B)

Fuel Oil Injection Device

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
ITEM
Replacing Consumables, Implements, and Measuring Instlements DK-28e 2

9-2 Replacing Consumables, Delivery valve

Implements, and Measuring
Instruments
(1) Replacing Consumables Plunger barrel
Replace the following parts with the new ones:
Deflector
( :"Parts List")
1) O-ring 3-22 No.511 Rack
2) Blind cover gasket 3-22 No. 19 Plunger
3) Special stopper screw 3-22 No.20 Control
sleeve
4) O-ring 3-23 No.213, 218, 221
5) Backup ring 3-23 No.219, 223
6) Gasket 3-23 No.246
7) Gasket 3-23 No.251, 256, 261
(For heavy fuel oil specification)

(2) Implements and Measuring Instruments F.O. Injection

1) General tools and measuring instruments pump tappet

( : 2-2)
2) Pmax adjusting implement
3) F.O. priming handle
4) Special spanner 9
5) Spinner handle
Fuel Oil Injection Pump and
Fuel Oil Injection Pump Tappet

2) Pmax Adjusting Tool

3) F.O. Priming Handle 4) Special Spanner 5) Spanner Handle

DK-28e Z 11-06
CHAPTER
9 F.O. Injection Device
ITEM Disassembly of F.O. Injection Pump and F.O. Injection
3 DK-28e Pump tappet

9-3 Disassembly of F.O, Injection Pump

and F.O. Injection Pump Tappet
(D)
(1) Turn the engine to place the roller of the F.O.
injection pump tappet on the base circle of the
fuel oil cam. (E)

(2) Remove the fuel oil high-pressure coupling (D), (F)

fuel oil injection pump inlet and outlet pipe (E),
plunger oil feed piping (G), drain pipe(H), and
rack pin(l).
Disconnect the stop air piping(J) (heavy fuel oil
specification) of each cylinder.
(3) Remove the pump mounting nut (K) using the
socket and the spinner handle.
(4) Pass a wire rope around the fuel oil injection
pump to suspend it, and remove it out of the
engine.
(5) Remove the leaked oil pipe (L) of the fuel oil
(G) (I)
injection plump tappet, and draw out the fuel oil
injection pump tappet.
(K)

The injection timing of the fuel oil injection

pump is adjusted for each cylinder in the state
of the combination of both the fuel oil
injection pump and fuel oil injection pump tap-
pet.
Discriminate the pumps according to the fol-
lowing procedure, and be careful so as not to
assemble the fuel oil injection pump into a
wrong cylinder.
1) Describe the engine number and the cylin- (N) (J)
der number on the fuel oil injection pump
and fuel oil injection pump tappet. (L)
2) In case that the fuel oil pump plush rod of
the fuel oil injection pump tappet is drawn
out, be careful so as not to assemble into a
wrong cylinder.
3) Do not loosen the fuel oil tappet adjusting
screw of the fuel oil injection pump tappet
except for the time when adjusting the injec-
tion timing. Piping Around Fuel Oil Injection

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
ITEM
Disassembly of F.O. Injection Pump DK-28e 4.1

9-4 F.O, Injection Pump (7) Turn over the pump again, and extract the
plunger barrel (k) from the body while receiving it
9-4.1 Disassembly of F.O. Injection
on your hand.
Pump
If extraction is difficult due to too tight fitting,
place a wooden piece against the barrel from the
The F.O. injection pump is a precision parts in opposite side, and strike the wooden piece with
particular. a hammer to extract it.
Even fine foreign matters will cause sticking or
breakage of the plunger and the delivery
valve.
Therefore, when disassembling or assembling
the pump, take every possible care to prevent
the infiltration of foreign matters.
(c) (b)
(1) Mount the F.O. injection pump on a vice, so
that the guide plunger (b) comes on the upper (d)
side. (e)
(a)
(2) Remove the snap ring (c) using a screw driver
or the like while pressing the guide plunger using
a gear puller or the like. (f)

Be careful so that the guide plunger should

not jump out due to the spring force. (l)
(g)
9
(m)

Be careful so that the guide plunger should

(k)
not be damaged.

(3) Take out the guide plunger (b), spring seat- (n)
upper (d), spring (e), plunger (f), and spring seat-
lower (g), sequentially. (j)
(4) Take out the fuel oil injection pump from the
vice, turn over the pump upside-down, and
mount it on the vice again. (i)
(5) Remove the mounting bolt (h), and take out the
delivery valve assy.(i).
(h)

Do not disassemble the delivery valve. 㪛㫀㫊㪸㫊㫊㪼㫄㪹㫃㫐㩷㫆㪽㩷㪝㫌㪼㫃㩷㪦㫀㫃㩷㪠㫅㫁㪼㪺㫋㫀㫆㫅㩷㪧㫌㫄㫇

When replacing, be minded to replace it as an
assembly.

(6) Remove the positioning screw (i).

DK-28e Z 11-06
CHAPTER
9 F.O. Injection Device
ITEM Disassembly, Inspection, and Maintenance of F.O.
4.1,4.2 DK-28e Injection Pump

Be minded to handle the plunger and barrel as

one pair. The clearance of the both parts are
matched, and if wrong combination is made,
the parts cannot be used.
Plunger barrel
(8) Remove the control sleeve (l) and the control
rack (m).
(9) Remove the deflector (n).

Be sure to sort the disassembled parts per

each pump, so that they do not mix with the
parts of the other cylinders.

Plunger
Deflector
9-4.2 Inspection and Maintenance of
F.O. Injection Pump Plunger, Barrel, and Deflector

Since the items mentioned in this section are

the parts to which NOx Technical Code shall
be applied, when replacing any of these parts,
be sure to use the parts provided with the
identification marks.
( : 0-3 "Engine Conforming to NOx
Technical Code")]

(1) Wash all the disassembled parts with clean

washing oil, and blow air on them.
(2) Check the plunger, barrel, and deflector for the
corrosion caused by cavitation.
In case that the degree of corrosion is significant,
replace the parts with the new ones.

Replace the plunger assembly, the delivery

valve assembly, and the spring every 16,000
to 24,000 hr (4 to 5 years) with the new ones,
even in case that there is no particular prob-
lems.

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
ITEM
Assembly of F.O. Injection Pump DK-28e 4.3

9-4.3 Assembly of F.O. Injection Pump
When assembling the F.O. injection pump, do
not wear gloves but handle the pump with
your naked hands, so as to prevent the
deposit of foreign matters or dust on the
pump.
(9) Assemble the spring seat-upper (g), plunger (f),
spring (e), spring seat-lower (b), and guide
plunger(b) in this sequence.
Assemble the plunger so that the "Z" mark on
the lower part faces toward the opposite side of
the rack.
(h)

(1) Mount the pump body (a) on a vice with the

delivery valve side facing upward. (i)
(j)
(2) Apply grease to the O-ring (o) and the back-up
ring (p), both of which are newly replaced, and fit (k)
them to the plunger barrel (k). (n)
(3) Match the barrel positioning bolt hole and the
plunger barrel hole of the pump body for each (p)
other, and insert the plunger barrel into the pump (o)
body.
(m)
(4) Mount the barrel positioning bolt (j).
(5) Assemble the delivery valve assembly (i) into (g) (l)
the pump body.
(6) Apply the lubricating agent (MOLYKOTE U- (f)
paste) to the threaded and the seating face of
(a) 9
the bolt(h), and tighten the bolts with the speci-
(b)
fied torque diagonally and uniformly. (e)

Specified torque: 157~177 N.m (d) (c)

{16~18 kgf.m} Assembly of Fuel Oil Injection Pump

(7) Remove the pump body from the vice, and turn
over the body to mount it on the vice again.
Control sleeve
(8) Apply grease to the gear tooth surface of the
control rack (m) and the inner surface of the con-
trol sleeve (l), and assemble them by matching
Control rack
the control rack teeth with the control sleeve end
teeth (rack 0-mm direction).

Be careful since the engine cannot be operat-

ed properly, if the rack is not normally and cor-
rectly engaged with the sleeve. Assembly of Control Rack and Control Sleeve
(Position of Rack 0)
(Viewed from Pump Guide Plunger Side)

DK-28e Z 11-06
CHAPTER
9 F.O. Injection Device
ITEM

4.3 DK-28e Assembly of F.O. Injection Pump

(10) Mount the snap ring (c) while pushing the

guide plunger using a gear puller or the like.

When assembling, be careful not to damage

䌚
the guide plunger.
㵱䌚㵱mark

(11) Mount the deflector (n). Matchmarks of Plunger

(12) After finishing the assembly, confirm that the
rack moves smoothly, and the confirm the posi-
tion of the "0" point.

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
Disassembly, Inspection, and Maintenance of F.O. ITEM
Injection Pump Tappet DK-28e 5.1,5.2

9-5 F.O. Injection Pump Tappet

9-5.1 Disassembly of F.O. Injection
Pump Tappet (i)
(1) Remove the O-ring(b) of the F.O. pump
base(a). (c)
(2) Draw out the F.O. pump push rod(c). (a)
(3) Place the roller(e) on the F.O. injection pump
tappet, and fix it to a vice.
(h)
(4) Remove the stopper screw(f) while pressing
the tappet(d) using the gear puller or the like,
and draw out the tappet. (b)

Be careful so that the tappet should not fly

(f)
out.

(5) Draw out the tappet spring(g) and the tappet

(g)
spring seat(h).
(d)
9-5.2 Inspection and Maintenance of
the F.O. injection pump tappet
(1) Clean all the disassembled parts with washing
oil, and blow air.
9
Assembly of Fuel Oil Injection Pump Tappet (e)
(2) Inspect if there is not any scratch or peeling-off
on the outer periphery sliding surface of the tap- Disassembly of F.O. Injection Pump Tappet
pet (d) and the inner periphery sliding surface of
F.O. pump base(a), as well as any abnormal
contact.
If the fault is minor, correct the part with oil stone
or the like.
(3) Inspect if there is not any scratch or peeling-off
on the tappet(d) and the contact surface of the
tappet spring (g) on the F.O. pump base{a).
(4) Confirm if there is a crack on the tappet.
Also check if the outer spring and the inner
spring is not contacted.

Even when there is not any particular abnor-

mality on the tappet spring (both inside and
outside), replace the spring with a new one for
every 16,000 to 24,000 hours (4 to 5 years).

DK-28e Z 11-06
CHAPTER
9 F.O. Injection Device
ITEM

5.2 DK-28e Inspection, and Maintenance of F.O. Injection Pump Tappet

(5) Check if there is not any abnormality on the

surface of the roller (e), and also check for
scratch or peeling-off.
If the fault is minor, correct the part with oil stone
or the like.

When there is scratch on the surface of the

roller, if the roller is used on that condition, be
careful as it will not only damage the roller but
also damage the fuel oil cam.

(6) Inspect if there is not any abnormal contact as

well as any scratch or peeling-off on the sliding
area of the F.O. pump push rod (c) and the slid-
ing area of F.O. pump base (a) side.
If the fault is minor, correct the part with oil stone
or the like.
(7) Inspect if there is not any scratch or peeling-off
on the head area of the F.O. tappet adjusting
screw (i).
If there is a fault, correct the part with oil stone or
the like.
(8) Inspect if there is not any peeling-back on the
corner area of the stopper screw groove on the
outer periphery of the tappet (d).
If there is any peeling-back, correct the part with
a fine-mesh sand paper.
(9) Measure the outer diameter of the tappet and
the inner diameter of the F.O. pump base, and
calculate the tappet clearance.

Nom. Size Standard clearance Replacing limit

(mm) (mm) (mm)
B

C=φ80 a=0.03~0.10 0.20

(10) Place the dial gauge on the roller surface of

b

the tappet roller, and measure the bearing clear-

ance by moving the roller up and down.
A a
Nom. Size Standard clearance Replacing limlt
(mm) (mm) (mm)
B=φ40 b=0.03~0.12 0.20 Tappet Clearance and Roller Bearing Cleara

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
ITEM
Assembly of F.O. Injection Pump Tappet DK-28e 5.3

9-5.3 Assembly of F.O. Injection Pump

(e)
Tappet
(1) Install the F.O. pump base (a) to a vice so that
the roller side comes on the upper side.
(2) Assemble the tappet spring seat(h) and the
tappet spring (inside and outside)(g). (d)
(3) Apply lubricating oil to the tappet(d), and
(g)
assemble it to the F.O. pump base, and screw
the stopper screw{f) while pressing the tappet
using a gear puller or the like. (f)
(4) After confirming that the stopper screw(f) is not
protruded out of the F.O. pump base periphery,
caulk the outer periphery of the stopper screw.
(b)

After caulking the stopper screw, make sure (h)

that the tappet moves up and down smoothly.
(a)
(5) Remove the F.O. pump base from the vice, and
(c)
fit O-ring(b) to it.
(6) Apply lubricating oil to the sliding face of the
(i)
F.O. pump bush rod (c), and insert it into the
F.O. pump base.
Assembly of Fuel Oil Injection Pump Tappet
9

DK-28e Z 11-06
CHAPTER
9 F.O. Injection Device
Άᢱྃ኿ࡎࠑࡦࡈࠑ㧘ࡎࠑࡦࡈࠑ࠲ࡋࠑ࠶࠻ߩขઃ
ITEM

6 DK-28e Mounting of F.O. Injection Pump and F.O. Injection Pump Tappet

9-6 Mounting of F.O. Injection Pump

and F.O. Injection Pump Tappet

(1) Check if the fuel oil cam is placed on the posi-

tion of the base circle. (b)
(2) After applying grease to the O-ring(b) of the
F.O. pump base, and insert it into the engine
frame.
(3) Mount the F.O. injection pump on the F.O.
injection pump base, and tighten it using the
pump mounting nut.

1) Since a heavy load from the fuel oil cam is

applied on the roller of the F.O. injection
pump tappet, pay utmost attention to the
parallelism of the fuel oil cam and the roller.
2) Confirm that the roller is completely mount- 㪙㪸㫊㪼㩷㪺㫀㫉㪺㫃㪼
ed on the profile of the fuel oil cam (the
state that the end of the roller is not protrud-
㪤㫆㫌㫅㫋㫀㫅㪾㩷㫆㪽㩷㪝㪅㪦㪅㩷㪠㫅㫁㪼㪺㫋㫀㫆㫅㩷㪧㫌㫄㫇㩷㪸㫅㪻㩷㪧㫌㫄㫇㩷㪫㪸㫇㫇㪼㫋
ed out of the fuel cam).

(4) Confirm the height of the F.O. tappet adjusting

screw(t) of the fuel oil injection pump tappet.
When the roller of the fuel oil injection pump tap-
pet is placed on the base circle of the fuel cam,
confirm that the guide plunger notched mark "Y"
and the pump mounting mark line position
Static injection start position
notched line "Z" of the fuel oil injection pump
body is agreed. When they are no agreed,
change and adjust the F.O. tappet adjusting
height.

≪Mounting adjustment procedure of the fuel

oil injection pump≫ Pump mounting mark
line position notched line 㵱䌚㵱

When adjusting, perform the work in the state Guide plunger

䇭䇭notched line 㵱䌙㵱
that the fuel oil injection pump tappet roller is
F.O. injection pump body
placed on the base circle of the fuel cam.
Adjusting screw (i)
a) Remove the fuel oil injection pump tappet cover
(a).
b) Fit the Pmax adjusting implement 2) into the Mounting Adjustment of F.O. Injection Pump
F.O. pump push rod (c).

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
ITEM
Mounting of F.O. Injection Pump and F.O. Injection Pump Tappet DK-28e 6

c) Loosen the lock nut (n).

d) Turn the F.O. injection pump adjusting
screw(m), and confirm that the guide plunger
notched mark "Y" of the fuel oil injection pump
and the pump mounting mark line position 㨅
notched line "Z" of the fuel oil injection pump
㨆
body is agreed.
e) Tighten the lock nut with the specified torque.
(m)
Specified torque: 294 N.m {30 kgf.m} (n)
(C)
f) Fit the fuel oil injection pump tappet cover (a).

(5) Apply grease to O-ring, and install it to the fuel

oil injection pump. (a) (2)
(6) Install the joint (C) and the high-pressure fuel
oil coupling (D), and tighten the bolts (F) and (G) 㪤㫆㫌㫅㫋㫀㫅㪾㩷㪘㪻㫁㫌㫊㫋㫄㪼㫅㫋㩷㪧㫉㫆㪺㪼㪻㫌㫉㪼㩷㫆㪽㩷㪝㪅㪦㪅㩷
with the specified torque. 㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪠㫅㫁㪼㪺㫋㫀㫆㫅㩷㪧㫌㫄㫇
( : "Operation" 5-4.2 "Mounting of Fuel
Oil Injection Valve")

Specified torque
Bolt (F) : 74 N.m {7.5 kgf.m} 9
Bolt (G) : 59 N.m {6 kgf.m}

(7) Install the rack pin, and adjust the rack amount. (G) (D) (F)

( : "Operation" 5-3.1 "Adjustment of Fuel

(C)
“Oil Injection Pump Rack Amount")
(8) Install each piping. O-ring
(9) Confirm the fuel oil injection timing.
( : 8-2.6 "Inspection of Fuel Oil Cam
Timing")
( : 9-7 "Adjustment of Maximum
Combustion Pressure」)

(10) Flow fuel oil after finishing the maintenance

work, and vent air by loosening the air vent
screw.
Mounting of High-Pressure Fuel Oil Coupling
( : "Operation" 4-2.2 "Priming and Air
Vent of Fuel Oil")

DK-28e Z 11-06
CHAPTER
9 F.O. Injection Device
ITEM

7 DK-28e Adjustment of Maximum Combustion Pressure

9-7 Adjustment of Maximum

Combustion Pressure
In case that guide plunger notched line
Since the items mentioned in this section are "Y"position is adjusted to be on the upper
the parts to which engine value specified in side against the mounting mark line notched
NOx Technical Code shall be confirmed, do line "Z" position, be care since the fuel oil
not make any change that may deviate from injection pump plunger will push up the deliv-
the setting values. ery valve.
( : 0-3 "Engine Conforming to NOx Adjusting screw left turn (push-up side)
Technical Code.") Within 240°
Adjusting screw right turn Within 150°
After installing the fuel oil injection pump, if the
maximum combustion pressure (Pmax) of each
cylinder disperse 0.6 Mpa {6kgf/cm2} or more as
the engine is operated, adjust the Pmax according
to the following procedure.
(1) When adjusting Pmax, use the position, where
the guide plunger notched line "Y" of the fuel oil
injection pump and the pump mounting mark line
position notched tine "Z" of the fuel oil injection
pump body is agreed, as a reference.
(2) Move the plunger up and down by turning the
F.O. pump tappet adjusting screw (i), and adjust
the Pmax.
When adjusting the adjusting screw, perform the
work in the same procedure as that of the pump
mounting height adjustment.

The variation of the rotational angle of the F.O.

pump tappet adjustment screw and the combus-
tion pressure is as follows.

F.O. pump tappet adjusting Variation of Pmax

screw rotational angle
60° 0.4 MPa {4kgf/cm2}
30° 0.2 MPa {2kgf/cm2}

DK-28e Z 11-06
 CHAPTER
F.O. Injection Device 9
ITEM
Priming of Fuel Oil Injection Pump DK-28e 8

9-8 Priming of Fuel Oil Injection Pump

When replacement of the fuel oil injection pump

or the maintenance work of the fuel oil system
such as cleaning of the fuel oil filter, etc., perform
priming of the fuel oil injection pump, and vent air
of the fuel oil injection pump.
( : "Operation" 4-2.2 "Priming and Air
Vent of Fuel Oil")

Perform priming of the fuel oil injection pump

according to the following procedure.
(1) Remove the fuel oil injection pump tappet
cover (a).
(2) Install the F.O. pump push rod (c) by using
F.O. priming hand!e (3) as the fulcrum point of
(3)
the F.O. pump base groove.
(3) Perform priming in the state that the fuel oil
rack of the fuel oil injection pump is pushed in by
your hand (the fuel oil rack is set) until you feel a
resistance in the handle.
When you do not feel a resistance when priming, 9
once again vent air of the fuel oil injection pump.
(4) Once again perform priming in the state that
(a) (c)
the fuel oil rack of the fuel oil injection pump is (b)
"0", and make sure that there is no resistance.
(5) Remove the F.O. priming handle, and place the 㪧㫉㫀㫄㫀㫅㪾㩷㫆㪽㩷㪝㫌㪼㫃㩷㪦㫀㫃㩷㪠㫅㫁㪼㪺㫋㫀㫆㫅㩷㪧㫌㫄㫇
cover.

DK-28e Z 11-06
CHAPTER
10 Valve Operating Device
ITEM General Construction / Replacing Consumables,
1~3 DK-28e Implements, and Measuring Instruments / Disassembly

10. Valve Operating Device

Cylinder head
10-1 General Construction
The valve operating device is of a swing-arm type,
equipped with the roller follower, and is used in
common for both the intake and exhaust. Push rod
The intake and exhaust cam lift is transmitted to
the intake and exhaust valves from the roller,
through the push rod, rocker arm, and valve retain- Push rod block
er tee, via the swing arm pivot (push rod seat).
The bearing bush is press-fitted into the roller, and Push rod seat
it turns around the tappet roller pin which is press- Swing arm
fitted into the swing arm.
Swing arm shaft
The swing arm support and roller bearing lubricat-
ing oil are supplied from the drilled holes of the
engine frame, through the bolt which fixes the
swing arm shaft, and via the shaft and the drilled
holes in the arm.
The ring knock is press-fitted into the shaft, so as Cam shaft cover
to ensure the parallelism between the roller and Tappet roller pin
the cam contact surfaces.

Swing arm assy.: 22 kg Tappet roller

Cam shaft
10.2 Replacing Consumables,
Device䇭
Valve Operating Device䇭
Implements, and Measuring instru-
ments
(1) Replacing Consumables
None
(2) Implements and Measuring Instruments
1) General tools and measuring instruments

10.3 Disassembly of Valve Operating

Device (c)
(1) Disconnect the cylinder head cover, and
remove the rocker arm device and the push rod.
(2) Remove the cover on the camshaft side. (h)
(3) Disconnect the bolt(a), and remove the swing
arm assembly.
Mark the engine number and the cylinder num-
ber with magic ink or the like, before removing
(d) (b) (a)
the swing arm assembly.
(4) Disconnect the snap ring(b), and remove the
Swing Arm Assy.
swing arm(c) from the swing arm shaft(d).

DK-28e Z 11-06
 CHAPTER
Valve Operating Device 10
ITEM
Inspection and Maintenance of Valve Operating Device DK-28e 4

10-4 Inspection and Maintenance of

Valve Operating Device
(1) Clean all the parts using washing oil.

Lubricating holes are provided in each of the

individual parts, and therefore be careful so
that no dust or foreign matters will be infiltrat-
ed into these holes.

(2) Inspect if there is any scratch or abnormal dent

on the swing arm shaft and the swing arm sliding
surface.
(3) Inspect if there is any scratch or abnormal dent
g
on the outer periphery surface of the tappet
roller(f).
(4) Inspect if there is any scratch or abnormal dent Inspection of Swing Arm Shaft and Swing Arm
on the contact surface of the push rod seat(e).
(5) Measure the clearance between the tappet
roller pin and the tappet roller bush(g), by press-
ing a dial gauge to the upper face of the tappet
roller(f), and by moving the tappet roller up and
down.
f
Nom. Size Standard clearance Replacing limit
(mm) (mm) (mm) 10
B=φ26 b=0.01~0.10 0.20

If the clearance becomes wider, the valve end

clearance becomes larger, and the valve
opening and closing timing changes, it will
result in the decrease of the engine perform-
ance. B b
In case that the measurement result of the
clearance is over the replacing limit, replace
the swing arm (with the roller) with a new one.

Clearance Measurement of Tappet Roller Bush

DK-28e Z 11-06
CHAPTER
10 Valve Operating Device
ITEM

5 DK-28e Assembly of Valve Operating Device

10.5 Assembly of Valve Operating

Device
(1) Mount the swing arm on the arm shaft, by Oil hole groove
matching the oil hole of the swing arm and the oil
hole groove of the swing arm shaft.

Confirm the cylinder number before assem-

bling so as not to mistake it with other parts.

(2) Fix a snap ring.

(3) Match the ring knock (h), then mount the swing Oil hole
arm assembly on the engine frame.
(4) Tighten the bolt with the specified torque.
Swing Arm Oil Hole
Specified torque: 138 N.m {14 kgf.m}

DK-28e Z 11-06
 CHAPTER
Valve Operating Device 10
ITEM
MEMO DK-28e

10
CHAPTER
11 Governor Drive Device
ITEM General Construction / Replacing Consumables,
1,2 DK-28e Implements, and Measuring Instruments

11. Governor Driving Device In this engine, the following 2 types of the governor
are applied.
11-1 General Construction
As for the handling of the governor body, refer to a
The governor is of a hydraulic type that controls
separately provided document.
the rack amount of the F.O. injection pump and the
F.O. injection rate, in accordance with the load and ( : "Governor Instruction Manual")
the revolving speed of the engine via the common
rod. <RHD10>
The governor driving device is located on the front Governor :5.7 kg
side of the engine, and composed of a couple of Governor driving device assy. :14 kg
the bevel gear driven by the camshaft, and it
drives the governor via the spline coupling. <UG10>
The governor base is positioned on the engine Governor :20 kg
frame by the pin, and the mounting surfaces of the Governor driving device assy.: 19 kg
governor base and the engine frame are sealed
with the gasket.
Backlash adjustment of the bevel gear can be
made by adjusting the mounting position of the
governor base and the engine frame, however,
usually such an adjustment is not necessary.

11-2 Replacing Consumables, Governor

Implements, and Measuring
(1) Replacing Consumables (C)
Replace the following parts with the new ones
<For RHD10 governor> ( : "Parts List")
1) Bearing 3-24.1 NO.B525
2) Split pin 3-24.1 NO.B515
3) Taper pin 3-24.1 N0.B517
4) Governor base gasket 3-24.1 No.B20 (B)

<For UG10 governor> ( : "Parts List")

1) Bearing 3-24.2 NO.B525
(A)
2) Split pin 3-24.2 No.B515
3) Taper pin 3-24.2 No.B518
Governor Link
4) Governor base gasket 3-24.2 No.B20
5) Governor mounting gasket 3-24.2 No.B16

(2) Implements and Measuring Instruments

1) General tools and measuring instruments
( : 2-2)

DK-28e Z 11-06
 CHAPTER
Governor Drive Device 11
Disassembly, Inspection, and Maintenance of Governor ITEM
Driving Device DK-28e 3,4

11-3 Disassembly of Governor Driving

Device
The construction of the governor driving device is
Governor
basically same regardless of the types of the gov- (j)
ernor, and therefore the explanation is made
regarding Type RHD10 in this section. (i)
(D)
(1) Remove the governor lever(B) and the link (h)
pin (C).
(2) Remove the oil feed piping of the governor driv- (f)
(g)
ing device.
(3) Remove the governor mounting nut, and
(c)
(b)
remove the governor.
(4) Remove the side cover on the side of the (e)
engine, and measure the backlash of the gover-
nor gear(b) and the governor driving gear (c). (d)

Standard clearance Replacing limit

(mm) (mm)
Backlash 0.2 ~ 0.6 0.8

(5) Take out the governor base mounting bolt (D),

and remove the governor driving device
assy.(A). Governor Driving Device
(6) Take out the split pin (d) and the nut (e), and
remove the governor gear (b).
Also, take out the key.
(7) Draw out the governor driving shaft (f), and
take out the bearing (g) and the distance (h).
11
(8) Draw out the taper pin (i), and take out the
spline coupling (j).

11-4 Inspection and Maintenance of

Governor Driving Device
(1) Clean all the disassembled parts with washing
oil.
(2) Inspect each gear surface for abnormal wear
and scratch.
(3) Inspect the governor driving shaft (f) for abnor-
mal dent or scratch.
(4) Inspect the spline coupling (j) for abnormal
wear and scratch.

DK-28e Z 11-06
CHAPTER
11 Governor Drive Device
ITEM

5 DK-28e Assembly of Governor Driving Device

11-5 Assembly of Governor Driving

Device
(1) Assemble the governor driving device in the
reverse order of the disassembling procedure.

Replace the bearing with a new one, and apply

grease when assembling.

(2) Confirm that the governor driving gear and the

governor moves lightly after finishing the assem-
bling.

DK-28e Z 11-06
 CHAPTER
Governor Drive Device 11
ITEM
MEMO DK-28e

11
 CHAPTER
Intake and Exhaust System
12
ITEM

1, 2 DK-28e Outline of Intake and Exhaust Device / Turbocharger

12. intake and Exhaust Device 12-2 Turbocharger

12-1 Outline of Intake and Exhaust
Device
The high-temperature and high-pressure
exhaust gases emitted from the cylinder are effec-
tively introduced into the turbocharger through the
exhaust manifold, and a part of the exhaust ener-
gies is converted into, and recovered as, the intake
pressure by the turbocharger.
The high-temperature air compressed by the tur-
bocharger is cooled down while passing through
the air cooler, and is introduced to the intake duct
of the engine frame.
The turbocharger and the air cooler can be
located either at the rear end of the engine or at
the front end of the engine.
Turbocharger
Orifice
Air cooler
Exhaust
Air
Since the items mentioned in this section
are the parts, to which NOx Technical Code
shall be applied, when replacing any of these
parts, be sure to use the parts provide with the
identification marks.
( : 0-3 "Engine Conforming to NOx
Technical Code")
Lubricating oil that lubricates the bearing and
cooling water that cools the bearing base are sup-
plied to the MET turbocharger.
The lubricating oil is supplied to the turbocharger
being branched from the engine system oil
through a special filter. Further, an orifice is
installed at the inlet of the turbocharger so as to
maintain the lubricating oil pressure at the appro-
priate tevei.
As for the operation, disassembly, and mainte-
nance of the turbocharger, refer to a separately
provided instruction manual.

Turbocharger MET26SR : 310 kg

MET30SR : 500 kg
MET30SRC : 730 kg
Expansion Pre-filter
joint Lubricating oil Cooling TPS254 : 300 kg
water
Cooling water Intake TPS254 : 512 kg

Intake
manifold
Exhaust gas

Exhaust (Integrated
manifold with engine
frame) The turbocharger is very hot just after the
engine is stopped. Wait until it sufficiently
Cylinder cools down before dismantling it for inspection
head and maintenance.If it must be dismantled
From other cylinder To other cylinder
before it cools down, wear safety gloves, and
Intake and Exhaust Device take care not to burn your hands.

DK-28e Z 11-06
 CHAPTER
Intake and Exhaust System
12
ITEM
Air Cooler: General Construction / Replacing Consumables,
Implements and Measuring Instruments DK-28e 3.1-3.3

12-3 Air Cooler 12-3.2 Replacing Consumables,

Implements and Measuring
12-3.1 General Construction Instruments
The air cooler is of a fin-tube multi-tubular type (1) Replacing Consumables
with a box shape, and is installed by the insertion Replace the following parts with the new ones.
method into the bracket containing the intake
( : "Parts List")
duce, and therefore it is possible to remove the air
[3-29.1] [3-29.2] [3-29.3]
cooler without disconnecting the turbocharger and
1) Gasket:I/C inlet No.B30 No.B30
the intake air inlet duct.
2) Gasket:T/C
The cooling water inlet and outlet ducts of the air No.B73 No.B73 No.B59
blower outlet
cooler are equipped with a butterfly valve to adjust 3) Gasket:I/C
No.B74 No.B74
the intake air temperature to an appropriate value. inlet pipe
4) Gasket:I/C No.B219 No.B219 No.B219
5) O-ring No.B227 No.B227 No.B229
Air cooling system: 500 ~ 550 kg
No.C550 No.C550 No.C550
6) Circular gasket No.B514 No.B514 No.B514
No.B559 No.B559

(2) Implements and Measuring Instruments

1) General implements and measuring
㫏㩷㪊 instruments ( : 2-2)
2) Inter-cooler support(1) {Option)
3) Inter-cooler support(2) (Option)
4) Inter-cooler support(3) (Option)
5) Nylon brush
6) Neutral detergent
2) Inter-cooler support(1)
12
㫏㩷㪋

3) Inter-cooler support(2)

㫏㩷㪏
㫏㩷㪏

4) Inter-cooler support(3)

DK-28e Z 11-06
CHAPTER
Intake and Exhaust System
12
ITEM

3.4,3.5 DK-28e Dismounting of Air Cooler

12-3.3 Dismounting of aircooler

(1) Remove the cooling water inlet and outlet
ducts.
(2) Remove the seal flange mounting bolt(A), and
remove the seal flange(B) and the O-ring(C).
(3) Disconnect the air cooler mounting bolt(D).
(6) Draw out the air cooler.
If the air cooler is drawn out about 2/3, attach
the eye bolt to the 4 places of the screw hole
(M20) for suspending the upper surface, and
draw out the air cooler while suspending it.

(4) Install the inter-cooler support(1) and the inter- (7) Remove the inter-cooler support.

cooler support(2) to the air cooler bracket.

(5) Install the inter-cooler support(3) to the inter-
cooler support(1) and the inter-cooler sup-
port(2).

Clearance should not be made.

Inter-cooler bracket Turbocharger

Inter-cooler body

(D)

(A)

(E) (F) (C) (B)

Inter-cooler support

Dismounting Procedure of Air Cooler

DK-28e Z 11-06
 CHAPTER
Intake and Exhaust System
12
ITEM
Inspection, Maintenance and Mounting of Air Cooler DK-28e 3.3,3.5

12-3.4 Inspection and Maintenance of

Air Cooler
Since the items mentioned in this section
are the parts, to which Nox Technical Code
shall be applied, when replacing any of these
parts, be sure to use the parts provided with
the identification marks
( : "Engine Gonforming to NOx Technical
Code")
12-3.5 Mounting of Air Cooler
(1) Install the water chamber cover (E) and (D) on
the both sides.
(2) Attach the gasket (G).
(3) Suspend the air cooler, insert it into the brack-
et from the exhaust manifold side, and then fix
it with the bolt (D).

(1) Remove the water chamber covers (E) and

(F) on the both sides, and eliminate the scales
deposited on them.
In case that coating of the inside surfaces is
peeled off, repair the part or conduct the coat-
ing again.
(2) Clean the inside of the cooling tube using a
nylon brush.
After brushing, wash it with clean and fresh water.
(3) Eliminate the stains on the air side by blowing
air on them.
In case the degree of stain is significant, dis-
connect the water chamber, and remove the
stain by immersing the plate-fin tube assembly
in sulphamic acid.
After eliminating the stain, wash with clean and
fresh water, and sufficiently dry the assembly
promptly.
<Cautions when inserting>
Sealing on the air side is made on the con-
tact surface of the air cooler body and the
bracket.
When inserting the body, firmly press the
cooler body against the bracket, and be care-
ful so as not to make any clearance on the
contact surface.
In case that the silicone rubber adhered on
the contact surface is damaged, be minded to
repair it beforehand.
.
(4) Replace the O-ring (C) with a new one, and
attach the seal flange (B).
(5) Install the cooling water inlet and outlet ducts.
12

To be minded to use the sulphamic acid

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

(4) Inspect the protective zinc, and replace it with

a new one. (In case that the equipment is pro-
vided with the protective zinc.)
( : "Operation" 5-4.7 "Inspection and
Replacement of Protective Zinc")

DK-28e Z 11-06
CHAPTER
13 Starting Air System
ITEM

1 DK-28e Outline of Starting Air System

13. Starting Air System

13.1 Outline of Starting Air System
The major components of the air starting system
are the starting air valve, the starting air rotary
valve, and the starting operation valve.
The high-pressure air of 2.5 to 3.0 MPa {25 to 30
kgf/cm2} is used as the starting air, and the low-
pressure air of 0.8 MPa {8 kgf/cm2} is used as the
controlling air.

( : "Operation" 2-2.1 "Starting Air System".)

Engine starting solenoid valve Starting operation valve

( For remote and
auto starting )

Safety plug
Starting air rotary valve

Starting ( Cylinder head )

air valve
Check valve Starting valve
Control air Starting air

Air tank

Starting Air System ( Pilot-Starting Valve Type )

DK-28e Z 11-06
 CHAPTER
Starting Air System 13
ITEM
Starting Air Valve: General Construction / Replacing Consumables,
Implements, and Measuring Instlements / Disassembly DK-28e 2.1~2.3

13-2 Starting Air Valve

13-2.1 General Construction
The starting air valve is the valve that controls the
supply of the high-pressure air for starting when
the engine is being started, and is activated by the
controlling low-pressure air which is sent from
either the starting operation valve or the starting
solenoid valve.
Starting air valve assy.: 16 kg
13-2.2 Replacing Consumables,
Implements, and Measuring
Instruments
(1) Replacing Consumables
Replace the following parts with the new ones.
( :" Parts List".)
When disassembling, carefully perform the work
so that the spring should not fly out, because
the spring is compressed by the piston.
c) Remove the bolt, and disconnect the cylin-
der (g).
d) Take out the stopper ring (h), and remove the
key receptor (i) and the key.
e) Disconnect the piston (j), and extract the valve
stem (k).
f) Take out the split pin (l) and the castle nut (m),
and remove the valve receptor (n), the valve
(o), and the valve retainer (p) from the valve
stem (k).
g) Remove the union screw (q), and take out the
spring (r) and the check valve (s).

1) Valve 4-1.1.1 No.B6

(a) (c)
2) Split pin 4-1.1.1 No.B25
(d)
3) O-ring 4-1.1.1 No.B502~B509
(e)
(k)
(2) Implements and Measuring Instruments
(f)
1) General implements and measuring
Instruments ( : 2-2) (g)
(h)

(i)
13-2.3 Disassembly of Starting Air
Valve
(j)
13
(1) Disconnect the piping of the starting air inlet
and outlet and the piping of the control air inlet
and outlet, and remove the starting air valve (p)
assembly from the bracket. (o)
(2) Disassemble the starting air valve according to
the following procedure:
a) Disconnect the mounting bolt, and remove the (n)
upper cover(a) and the lower cover(b).
(m)
b) Take out the split pin(c) and the nut(d) of the
valve stem, and remove the piston(e) and the (l) (b)
spring (f).

Starting Air Valve

DK-28e Z 11-06
CHAPTER
13 Starting Air System
ITEM

2.4,2.5 DK-28e Inspection, Maintenance, and Assembly of Starting Air Valve

13-2.4 Inspection and Maintenance of

Starting Air Valve
(1) When rust is found, carefully remove it using a
fine-mesh sandpaper.

For the sake of rust-prevention, be minded to (q)

perform the draining of the equipment and the
(s)
piping without fail, at the time of daily mainte-
nance.

(2) Wash all the disassembled parts with clean

washing oil, and blow air on them.
(3) Inspect if there is any abnormal dent or scratch
on the piston(e) and (j). (r)
(4) Inspect if there is any abnormal dent or scratch
on the check valve(s) and the seat surface.
(5) Inspect if there is any scratch on the spring (f)
Check Valve
and (r).

13-2.5 Assembly of Starting Air Valve

(1) Before assembling, thinly apply silicone grease
on the valve, the O-ring, and the sliding area of
the seat surface.
(2) Assemble the staring air valve assembly in the
reverse order of the disassembling procedure.
(3) Mount the starting air valve to the bracket, and
install the piping.

Sufficiently flush the piping before installation

so that dust and drain can be completely
removed. Further, be careful so that sealant or
the like should not be adhered during the
work.

DK-28e Z 11-06
 CHAPTER
Starting Air System 13
ITEM
Starting Air Rotary Valve: General Construction /
Replacing Consumables and Implements / Disassembly DK-28e 3.1~3.3

13.3 Starting Air Rotary Valve

13-3.1 General Construction
The starting air rotary valve is the valve that dis-
tribute pilot air, which is used to actuate the start-
ing valve, to each cylinder according to the explo-
sion sequence, and this valve is driven from the
rear end of the camshaft on the rear end of the
engine via the rotary valve coupling (Oldham’s
coupling).

Starting air rotary valve assy.:24 kg

13-3.2 Replacing Consumables,

Implements, Measuring instru-
ments
(1) Replacing Consumables
Replace the following parts with the new ones.

( :"Parts List")
1) Rotary valve body gasket 3-9 N0.15
2) Circular gasket 3-9 NO.509, 513

(i) (g)
(2) Implements and Measuring Instruments (c) (b)
1) General implements and measuring
Instruments ( :2-2)

13-3.3 Disassembly of Starting Air

Rotary Valve 13
a

(1) Disconnect each piping of the starting air inlet

A

and the starting air outlet.

(2) Remove the mounting bolts, and disconnect
the rotary valve cover (b) and the circular gasket
(c).
(3) Extract the starting air rotary valve (d).
(d)
(4) Remove the bolt, and take out the rotary valve
body (e), the rotary valve body gasket (f), and
the shim (j). (f) (e) (h)
(j)
(5) Remove the rotary valve coupling (g). (k)
(6) Remove the rotary valve base (k).
Starting Air Rotary Valve

DK-28e Z 11-06
CHAPTER
13 Starting Air System
ITEM
Inspection, Maintenance, and Assembly of Starting Air
3.4,3.5 DK-28e Rotary Valve

13-3.4 Inspection and Maintenance of 13-3.5 Assembly of Starting Air Rotary

Starting Air Rotary Valve Valve
(1) Wash all the disassembled parts with clean Ass emble the starting air rotary valve in the
washing oil, and blow air on them. reverse order of the disassembling procedure.
(2) Inspect the scratch and wearing conditions of (1) Wash the starting air rotary valve and the rotary
the rotary valve bush (h). valve body, and apply lubricating oil to the seat
Measure the shaft diameter and the bush inner surface and the shaft area.
diameter of the rotary valve, and calculate the (2) When inserting the starting air rotary valve into
clearance. the rotary valve body, conduct the insertion work
by matching the air hole of the rotary valve to the
Norn. size Standard Replacing limit valve body hole of the cylinder number which is
(mm) (mm) (mm) on the explosion stroke.
B=038 = 0.01 ~ 0.10 0.20 When the holes do not match each other, insert
the starting air rotary valve by turning it 180°.

When wear of the bush becomes significant,

lubricating oil will infiltrate into the starting air Be careful not to disassemble the rotary valve
pipe, making the starting difficult. In such a in a wrong way, since it will inhibit the engine
case, replace the bush with a new one. to start.

(3) Inspect if there is any fin or foreign matters (3) Install the piping
caught on the seat areas of the starting air rotary
valve and the rotary valve body.
6DK 8DK
In case that inclusion scratch is extended over
the holes of each cylinder, perform the facing-up
after grinding and correcting the seat surface.
4 1
Further, in case that fin is found, remove it using
3 1
7 3
a file or scraper. 5 2
(4) Inspect if the engagement area(i) of the starting 6 2
6 4
air rotary valve(d), the rotary valve coupling(g), 8 5
and the camshaft are not worn out, respectively.
Rotating direction Rotating direction
of rotary valve of rotary valve
If the wearing degree of the engagement area Note) The above figure shows the positional relationship
of the rotary air valve when the No.1 engine is on
is significant, the opening and closing timing the top dead center of explosion.
of the starting valve will be delayed, making
Rotary Air Valve Assembling Procedure
the starting difficult.
In such a case, replace the starting air rotary
valve or the rotary valve coupling with a new one.

DK-28e Z 11-06
 CHAPTER
Starting Air System 13
ITEM
Starting Air Operation Valve and Handle Switch DK-28e 4.1

13-4 Starting Air Operation Valve and

Handle Switch
Handle switch
13-4.1 General Construction
Starting air operation valve
The starting air operation valve is an air valve for
the purpose of starting from the machine side, and
the starting air valve will be actuated by manually
operating the pushbutton so that the low-pressure Operation lever
air is supplied to the starting air valve.
The handle switch is a limit switch, which is actuat-
ed interlocking with the control lever, and when the
control lever is set to the drive position, the switch
is turned ON and a protective circuit is formed.

Do not disassemble the starting air operation Starting Air Operation Valve and Handle Switch
valve and the handle switch. In case that mal-
function is occurred, be minded to replace it
as an assembly.

13

DK-28e Z 11-06
CHAPTER
Fuel Oil System
14
ITEM

1 DK-28e Outline of Fuel Oil System

4. Fuel Oil System  Fuel oil filter

14-1 Outline of Fuel Oil System
Facilities and equipment for pretreatment
This engine is designed on the assumption that
the driving shall be performed using heavy fuel oil.
In case of heavy fuel oil, appropriate pretreat-
ment of the fuel oil before feeding at the entrance
of the engine is particularly important, and the
quality of the fuel oil will give a remarkable influ-
ence on the various equipment such as the fuel oil
injection pump.
Since not only the individual systems but also
the facility and equipment will also differ depending
on the grade of the oil to be used, be minded to
perform appropriate maintenance, inspection, and
adjustment according to the instruction manuals of
each facility and equipment.
The major component parts attached to the
engine are the fuel oil filter, fuel oil relief valve, fuel
oil feed valve, and so on.
As for the inspection and maintenance of the fol-
lowing equipment, refer to the other sections in this
manual or separately supplied documents.
( ："Operation" 2-2.2 "Fuel Oil System")
( ："Operation" 5-4.3 "Cleaning Filters")

( ：Separately supplied "Instruction Manual")
<Cautions in disassembling, maintaining and
reassembling the fuel oil system>
1) The parts such as the fuel oil injection pump
and fuel oil injection valve, which are used in
the fuel injection system, are all precision
parts, and therefore if any dust or foreign
matter is mixed in the oil, it will result in the
faults such as seizure.In case that the equip-
ment of the fuel oil system is disassembled,
regardless of whether it is the one attached
to the engine or the one to be separately
installed, be particularly careful so that any
dust or foreign matters will not infiltrate into
the inside of the equipment or piping.
2) In case that the fuel oil system is over-
hauled, be sure to perform air bleeding after
restoration.
When discharging air, take care not to splash
the oil.

Heavy fuel oil supply system Air separator

Fuel injection valve leakage main pipe

Heavy
fuel Diesel
oil fuel Fuel high-pressure block
tank oil leakage oil main pipe
Accumulator
tank

Fuel high-
pressure Fuel injection
block valve
Filter

Fuel oil
Viscosity feed
controller pump
Pressure Inlet connector
damper Fuel
Filter injection
Heater pump Inlet main pipe

Filter Pressure damper

Waste
Pressure control valve Return main pipe leakage
oil tank
Fuel Oil System (Auxiliary Engine)

DK-28e Z 11-06

Fuel Oil System
Fuel Oil Relief Valve: General Construction / Replacing Consumables,
Implements and Measuring Instruments / Disassemblly
4-2 Fuel Oil Pressure Regulating Valve
14-2.1 General Construction
The fuel oil relief valve is installed on the rear
end of the fuel oil main pipe, and the valve oper-
ates to maintain the pressure at the inlet of the fuel
oil injection pump within the appropriate range.
Excessive fuel oil will be returned to the supply
system through the relief valve.
The fuel oil pressure depends on the source
pressure of the supply system, and it also
varies depending on the viscosity of the oil.
In case of heavy fuel oil, adjustment is readi-
ly made so that the pressure stays at an appro-
priate viscosity and to be within the blue mark
range on the pressure gauge. Therefore, when
the pressure is deviated from the specified
range during operation, be minded to first
check if the viscosity of the fuel oil is appropri-
ate or not before starting to disassemble and
inspect the fuel oil relief valve.
When heavy fuel oil is used, the oil is heated
to a high temperature (100℃ or more). If the
oil is splashed on the skin, it may be scald.
Take care not to splash the oil when disassem-
bling.
Fuel oil relief valve assy. : 2.5kg
14-2.2 Replacement Consumables,
Implements and Measuring
Instruments
(1) Replacement Consumables
Replace the following parts with the new ones.
( ："Parts List")
1) Circular gasket 4-2.4 No.507, 509, 522
(2) Implements and Measuring instruments
1) General implements and measuring
Instruments ( ： 2-2 )
CHAPTER
14
ITEM
DK-28e 2.1-2.3
14-2.3 Disassembly of Fuel Oil Relief Valve
(1) Take out the connected piping, and remove
the relief valve assembly.
(2) Disassemble the relief valve according to the
following procedure:
a) Disconnect the cap nut (a), loosen the lock
nut (b), and completely turn back the adjusting
screw (c).
Before loosening the adjusting screw, either
put a mark on the tightening position of the
adjusting screw or keep the record of the
dimension, so that the original position can be
identified when assembling.
b) Loosen and remove the spring retainer (d).
c) Remove the spring seat (e), spring (f), and
relief valve (g) from the relief valve body (h).
(g) (e) (a)
(h) (f) (d)
(b)
(c)
Fuel Oil Relieve Valve
14-2.4 Inspection and Maintenance of
Fuel Oil Relief Valve
(1) Wash all the disassembled parts with clean
washing oil, and remove the sludge.
(2) Inspect if there is any abnormal dent or
scratch on the relief valve, or also check if the
valve is not stuck.
(3) Inspect if there is any abnormal dent or
14
scratch on the spring.
14-2.5 Assembly of Fuel Oil Relief Valve
Perform the assembly of the relief vale in the
reverse order of the disassembling procedure.
(1) Set the adjusting screw to the position of the
marking.
(2) After assembling, drive the. engine and check if
the pressure is within the blue mark range, and
in case that the pressure is out of the range,
adjust the pressure with the adjusting screw.
DK-28e Z 11-06
CHAPTER
Fuel Oil System
14
ITEM
Fuel Oil Feed Pump: General onstruction / Replacing
3.1-3.3 DK-28e Consumablesand Implements / Dismounting

14.3 Fuel Oil Feed Pump
We explain about the fuel oil feed pump for
heavy fuel oil specification as the following.
14-3.1 General Construction
The fuel oil feed pump is installed on the front
side of the engine, and it is driven from the auxil-
iary gear case via the pump driving device.
The pump is a trochoid type, and the safety
valve is incorporated in installed in the upper part
cover.
14-3.3 Dismounting of Fuel Oil Feed
Pump
(1) Disconnect the inlet and outlet piping of the
fuel oil feed pump.
(2) Take out the coupling cover.
(3) Remove the bolts, and disconnect the fuel oil
feed pump from the pump base while carefully
watching the positioning pin.
(4) Loosen the clamping screw of the coupling,
and remove the coupling.
(5) Take out the coupling key.

Fuel oil feed pump assy. : 4.7 kg (6DK)

: 5.1 kg (8DK)

14-3.2 Replacing Consumables,

Implements, and Measuring
Instruments
(1) Replacing Consumables
Replace the following parts with the new ones:
( : "Parts List")

<Fuel oil feed pump>

1) O-ring 4-2.1 No.200-5, 200-6
2) Gasket 4-2.1 No.200-7
3) Bearing 4-2.1 No.200-1, 200-2 Coupling Cover Drive shaft
4) Oil seal 4-2.1 No.200-3, 200-4 Fuel oil feed pump
Kye

<Fuel oil feed pump driving device>

1) Flange gasket 4-2.2 No.7
2) Plain washer 4-2.2 No.503
3) Washer with tooth 4-2.2 No.505, 506
4) Split pin 4-2.2 No.507
5) Oil seal 4-2.2 No.513
6) Bearing 4-2.2 No.511, 512

(2) Implements and Measuring Instruments Positioning pin Pump base

1) General tools and measuring instruments Dismounting of Fuel Oil Feed Pump
( : 2-2)

DK-28e Z 11-06
 CHAPTER
Fuel Oil System
14
ITEM
Disassembly, Inspection and Maintenance of Fuel Oil
Feed Pump DK-28e 3.4,3.5

14-3.4 Disassembly of Fuel Oil Feed 13 1 Safty valve 2 5 4 9 16

Pump
(1) Before disassembling the fuel feed pump, 6
make match marks on the mating surfaces of the 32
pump body and cover. 7
(2) Loosen the bolt t , and remove the safety
valve. 8 10
(3) Loosen the bolt 23 , and remove the top cover
⑦ and 3-diam ring 22 . 23
(4) Remove the snap ring⑲, and remove the bolts
⑯,bolt 30 and nut 31 which secure the bearing
housing⑥. 19
(5) Pull the bearing housing⑥ and bearing⑩ out of 3
the shaft③. 22
(6) Draw out the pipe knock⑱, and remove the
14
shell②, and outer rotor⑤.
12
(7) Remove the inner rotor④, and draw out the
inner key⑨.
(8) Remove the shaft key⑧ with a hammer and a 30 29 18 21 31
brass bar, and remove the angle plate 29 .
(9) Remove the snap ring⑮, and pull the shaft③, Fuel Oil Feed Pump
oil seal⑰, bearing⑭, and collar 33 out of the
body① using a hand press or the like. Then,
draw out a set of the seal case 27 , oil seal⑳, and
O-ring 34
(10) Pull the oil seal⑰ and bearing⑭ out of the 15 17 33 20 27 34
shaft③.
(11) Remove the cap l of the safety valve, loosen
the lock nut m , and loosen the adjusting screw
n.
Before loosening the adjusting screw, mark the
adjusting screw tightening position, or record the
size.
(12) Remove the spring receiving nut o , and Oil Seal
remove the spring retainer p , spring q , and
safety valve r .

14
14-3.5 Inspection and Maintenance of
Fuel Oil Feed Pump l n m o p q r t
(1) Clean the disassembled parts with clean wash
oil, and blow air on them.
(2) Check for wear, cavitation and pitching of the
inner rotor and outer rotor tooth surfaces.
(3) Check for scratches and wear of the outer rotor s
periphery.
(4) Turn the bearing, and check that it can turn
smoothly without abnormal noise. Fuel Oil Feed Pump Safty Valve

DK-28e Z 11-06
CHAPTER
Fuel Oil System
14
ITEM
Inspection, Maintenanceand Assembly of Fuel
3.4,3.5 DK-28e Oil Feed Pump

(5) Check that the safety valve and safety valve

spring are free from abnormal contact and
scratches and they do not stick.

Even if the bearing does not show any abnor-

mality, replace it with a new one in the periodic
maintenance every 12,000 to 16,000 hours (4
years).

19 Snap ring 14 Bearing

14-3.6 Assembly of Fuel Oil Feed Pump 17 Oil seal 33 Collar

㪧㫉㪼㫊㫊㩷㪽㫀㫋
Reassemble the fuel feed pump in reverse order 20 Oil seal
to disassemble. 34 O-ring
(1) Mount a set of the shaft③, sealing-set (seal 27 Seal case
case 27 , oil seal⑳, O-ring 34 ), and collar 33 ,
bearing⑭, and oil seal⑰ in this order using a
hand press or the like, and fit the snap ring⑮. 3 Shaft
(2) Mount the angle plate 29 , and fit the shaft key
1 Body
⑧ using a hammer and a brass bar.
39.5

(3) Fit the inner key⑨ and inner rotor④.

(4) Mount the shell② provided with the outer rotor
⑤ and O-rings 21 , and mount the pipe knock ⑱.
Assembly of Shafy & Bearing Module
Take care that the O-rings are not engaged.

(5) Set the pump with the rotor upward, and mount
the bearing housing⑥ based on the pipe knock
⑱.
Press fit

(6) Press the bearing⑩ into the housing, and fit 10 Bearing

the snap ring⑲. 5 Outer rotor 6 Bearing

hausing
(7) Secure the bearing housing⑥ on the body①
21 O-ring 18 Dowel Pipe
with the hexagon socket head cap screws⑯, 30 ,
and nut 31 . 4 Inner rotor
2 Body
Tightening torque: 29.5 N.m {3 kgf.m}

(8) Fit the 3-diam ring 22 , and mount the top cover 9 Inner key
⑦ with the bolt 23 .

Tightening torque: 12.2 N.m {1.25 kgf.m}

38.5

(9) Fit the safety valve assembly with the bolt (t).

Tightening torque: 12.2 N.m {1.25 kgf.m}

Assembly of Rotor Side

DK-28e Z 11-06
 CHAPTER
Fuel Oil System
14
ITEM
Disassembly, Maintenance and Assembly of
Fuel Oil Feed Pump DK-28e 4.1,4.2

14-4 Fuel Oil Feed Pump Driving

Device
If the oil seal is installed upside-down, oil will
14-4.1 Disassembly of Fuel Oil Feed
leak. Therefore, be careful not to mistake the
Pump Driving Device
assembling direction.
(1) Before starting to disassemble the driving
device, take out the center cover of the auxiliary
drive gear case, and measure the backlash of
the pump drive gear.

Standard value Replacing limit

(mm) (mm)
Backlash 0.3~0.5 0.8

(2) Disconnect the fuel oil feed pump.

( : 14-3.3 "Dismounting of Fuel Oil Feed
Pump")
(3) Disconnect the mounting nut, and remove the
pump drive bearing A .
(4) Remove the nut B , and pull out the pump drive
gear C form the drive shaft D .
Then, take out the key.
(5) Pull out the drive shaft from the pump drive G Bearing
bearing, and take out the bearing E and dis- side
tance piece F .
(6) Remove the oil seal G .
Apply lithium grease
Fuel oil feed pump F E B
14-4.2 Maintenance and Assembly of
Fuel Oil Feed Pump Driving
Device
(1) Inspect if there is any wear or pitching on the
tooth surface of the pump drive gear, 14
(2) Inspect if there is any distortion or crack in the
coupling rubber.
(3) Rotate the bearing, and inspect if it rotates
smoothly or if there is any abnormal sound.
(4) Assemble the driving device in the reverse
A D C
order of the disassembling procedure.

Specified torque: 215 N.m {21.9 kgf.m}

Fuel Oil Feed Pump Driving Device

DK-28e Z 11-06
CHAPTER
15 Lubricating Oil System
ITEM
Outline of Lubricating Oil System / General Construction of
1,2.1 DK-28e Lubricating Oil Pump

15. Lubricating Oil System

15-1 Outline of Lubricating Oil System 15-2 Lubricating Oil Pump
The lubricating oil is installed on the front end of
15-2.1 General Construction
the engine, and it is driven by the auxiliary drive
The lubricating oil is of a gear type, and all the 5
gear attached to the crankshaft.
pieces of the bearings used in the pump are nee-
The temperature control valve is installed to the
dle bearings. Further, a safety valve is incorporat-
lubricating oil cooler as an assembly.
ed into the pump cover.
The lubricating oil filter is also installed on the
engine.
Lubricating oil pump assy.
The lubricating oil relief valve is assembled on the
6DK : 100 kg
outlet block of the lubricating oil filter, or it is
8DK : 110 kg
installed to the piping on the filter inlet side.
As the filters for lubricating oil of the turbocharger
(Main propulsion engine) and the fuel injection
pump, the special filters of a higher precision are
installed respectively.

( : "Operation" 2-2.3 "Lubricating Oil System")

( : "Operation" 5-4.3 "Cleaning Filters")

Rocker arm

Lubricating oil cooler Lubricating oil cooler

Fuel oil injection pump

Filter Filter
Filter
Relief Swing arm
valve
Temperature Temperature Camshaft bearing
control valve Relief control valve
valve

Filter
Lubricating Lubricating
oil pump oil pump
Turbo Timing gear
charger Turbo
Safety Safety charger Governor driving gear
valve valve Cooling water pump

Engine base plate ( oil tank ) Engine base plate ( oil tank ) Leaked and waste
oil tank
Main Engine Auxiliary Engine

Lubricating oil system

DK-28e Z 11-06
 CHAPTER
Lubricating Oil System 15
ITEM
Lubricating Oil Pump: Replacing Consumables,
Implements, and Measuring Instruments / Disassembly DK-28e 2.2,2.3

15-2.2 Replacing Consumables, (2) Remove the inlet and outlet piping.
Implements, and Measuring (3) Remove the mounting nut, and take out the
Instruments lubricating oil pump assembly.
(1) Replacing Consumables (4) Assemble the lubricating oil pump on the fol-
Replace the following parts with the new ones lowing procedure:
Before disassembling, be minded to mark the
( : "Parts List".)
matchmarks on the joint surfaces of the pump
1) Needle bearing 4-3.1 No.A34
body, the cover, etc.
2) Oil seal 4-3.1 No.A526
a) Remove the split pin and the castle nut (a),
3) Split pin 4-3.1 No.A513
and take out the gear (b) and the key (c).
4) Circular gasket 4-3.1 No.A529
b) Remove the bolt of the pump body cover (d),
5) LO. Pump body gasket 4-3.1 No.B10
and take out the pump body cover.
(2) Implements and Measuring Instruments
c) Pull out the pump gear (e) and (f) from the
General implements and measuring instruments
pump body (g).
d) Remove the snap ring (h), and pull out the oil
15-2.3 Disassembly of Lubricating Oil seal (i).
Pump e) Remove the snap ring(j), and pull out the
(1) Before removing the lubricating oil pump, take
bearing (k) from the pump body and the pump
out the inspection window covers on the front
body cover.
side of the engine and on the exhaust side, and
f) Remove the safety valve retainer (l), and pull
measure the backlash of the pump drive gear.
out the safety valve spring (m) and the safety
valve (n).
Standard value Replacing limit
(mm) (mm)
Backlash 0.4 ~ 0.6 0.8

(e) (g)
(d)
(m) (l)
(c) (b)

(a)

(n)

15

Bearing Gear (k)

side side
(j)
(f) (j) (i)
(i) (h)

Oil sel assembly Lubricating Oil Pump

DK-28e Z 11-06
CHAPTER
15 Lubricating Oil System
ITEM

2.4,2.5 DK-28e Inspection, Maintenance, and Assembly of Lubricating Oil Pump

15-2.4 Inspection and Maintenance of b) To fit the driving gear b , apply the lubrication
Lubricating Oil Pump oil to the crown nut a , and then tighten the nut
(1) Wash all the disassembled parts with clean with the specified torque.
washing oil. If the groove of the crown nut is not aligned
(2) Inspect the wearing conditions of the tooth surface with the hole of the cotter pin, further tighten
of each gear, and presence of pitting. the nut.
Also inspect the peeling conditions of the outer
Specified torque : 735 N.m {75 kgf.m}
periphery and side face, and the presence of seizing.
(3) Inspect if there is any abnormal wear on the oil
seal sliding surface of the pump gear shaft. (2) Install the lubricating oil pump.
(4) Inspect if there is any abnormal dent or scratch In case that the pump drive gear is replaced,
on the pump body, and the inner surface of the confirm the backlash.
pump body cover. (3) Connect the inlet and outlet piping.
(5) Inspect the wearing conditions of the tooth surface
of the drive gear(c), and the presence of pitting.
(6) Inspect if there is any scratch or trace of stick-
ing on the safety valve. In case that the scratch
degree is light, correct it with oil stone.

15-2.5 Assembly of Lubricating Oil

Pump
(1) Assemble the lubricating oil pump in the
reverse order of the disassembling procedure.

<Cautions when assembling>

1) Replace the needle bearing and oil seal
with the new ones.
2) Use liquid sealant for the joint surfaces of
the pump body cover and the pump body.
3) Be minded to assemble the pump body
cover after confirming the matchmarks that
have been made when disassembling, so
that oil release hole is situated on the deliv-
ery side without fail.

When assemble the safety valve, tighten the

safety valve retainer (l) with the specified torque.

Specified torque : 637 N.m {65 kgf.m}

DK-28e Z 11-06
 CHAPTER
Lubricating Oil System 15
ITEM
Lublicating Oil Cooler: General Construction / Replacing
Consumables and Implements DK-28e 3.1~3.3

15-3 Lubricating Oil Cooler 15-3.2 Replacing Consumables,

15-3.1 General Construction Implements, and Measuring
The lubricating oil cooler is installed on the com- Instruments
mon base plate as an assembly with the tempera- (1) Replacing Consumables
ture control valve, or it is installed separately. Replace the following parts with the new ones:
The cooling pipe is a multi-tubular type. ( : "Parts List")
In case that the cooling water is sea water, protec- 1) Gasket 4-3.2 No. 6, 12, 18, 20
tive zinc is attached to the side covers on the both 2) O-ring 4-3.2 No. 502
sides.

( : "Operation" 5-4.6 "Inspection and (2) Implements and Measuring Instruments

Replacement of Protective Zinc") 1) General tools and measuring instruments

( : 2-2)
Lubricating oil cooler
8DK (40 m2) : 441 kg

L.O.
Casing Side cover (B)
Side cover (A)

C.W. 15

Lubricating Oil Cooler

DK-28e Z 11-06
CHAPTER
15 Lubricating Oil System
ITEM

3.3,3.4 DK-28e Inspection, Maintenance, and Assembly of Lubricating Oil Cooler

15-3.3 Inspection and Maintenance of In case that crack or corrosion is found, replace
Lubricating Oil Cooler the cooling pipe with a new one.
If sludge is accumulated on the cooling pipe sur-
face of the lubricating cooler, the cooling perform- 䃁 As for the replacing method, consult the
ance will drastically be decreased. Service Department of Daihatsu Diesel
Therefore, be minded to conduct the maintenance Manufacturing Co., Ltd.
according to the maintenance interval specified in
the overhaul and maintenance list. 15-3.4 Assembly of Lubricating Oil
(1) Removal of lubricating oil cooler
Cooler
(1) Replace the gaskets with the new ones, and
a) Remove the connecting piping of the cooling
attach the covers on the both sides.
water and lubricating oil.
(2) Conduct the water pressure test in the state of
b) Pass a wire rope around the lubricating oil
the cooler assembly, and confirm that there is no
cooler assembly, and dismount the cooling
leak from any section of the parts.
water assembly by removing the mounting bolt
(3) Install the cooler assembly on the engine, and
while suspending it with a chain block.
connect each piping.
(2) Cleaning of lubricating Oil Side
Clean the lubricating oil side of the lubricating oil <Water pressure test>
shall be performed by combining the special Water side : 0.6 MPa { 6 kgf/cm2}
cleaning liquid and the steam for heating. Lubricating oil side : 1.0 MPa {10 kgf/cm2}
Connect the cleaning liquid tank and the lubricating
oil inlet and outlet of the lubricating oil cooler, and
start the cleaning by circulating pump cleaning liquid.
After removing dirt, perform the post-cleaning
treatment.

1) As for the details on the brand of the clean-

ing agent, the mixing ratio, heating, post- Cooling Pipe Assembly
cleaning treatment, and so on, consult or
inquire the maker of each cleaning liquid.
2) Do not apply the heat of more than 150°C
to the cooler.

(3) Cleaning of cooling water side

Remove sludge accumulated on the cooling pipe
inner surface using a cleaning brush for small
tube in the state that the covers on the both
sides are removed.
(4) Inspection and maintenance
Inspect if there is any crack or corrosion on the
inner surface of the cooling pipe.
Cleaning of Cooling Pipe

DK-28e Z 11-06
 CHAPTER
Lubricating Oil System 15
ITEM
Lubricating Oil Relief Valve DK-28e 4.1~4.5

15-4 Lubricating Oil Relief Valve 15-4.4 Inspection and Maintenance of

15-4.1 General Construction Lubricating Oil Relief Valve
(1) Clean all the disassembled parts with fresh
The lubricating oil relief valve is incorporated into
washing water, and remove sludge.
the loutlet block of the lubricating filter, or it is
installed to the piping of the filter inlet side. (2) Inspect if there is any abnormal dent or scratch
Surplus lubricating oil will be returned into the oil on the relief valve, or if the relief valve is not
pan or into the oil tank on the engine base plate. stuck.
The adjustment of lubricating oil pressure can be If the degree of the damage is minor, correct it
made by turning the adjusting screw{a) and by with oil stone, and confirm that the valve can be
changing the spring force.
moved smoothly.
(3) Inspect if there is any abnormal dent or scratch
15-4.2 Replacing Consumables,
Implements, and Measuring on the spring.
Instruments
(1) Replacing Consumables
15-4.5 Assembly of Lubricating Oil
Replace the following parts with the new ones. Relief Valve
( :"Parts List") Assemble the relief valve in the reverse order of
Auxiliary Engine Main Engine the disassembling procedure.
1) Gasket 4-3.3 No.45 4-3.4.3 No.42 (1) Set the adjusting screw to the marking position.
2) Circular (2) After assembling, operate the engine, and
gasket 4-3.3 No.510 4-3.4.3 No.528
check if the pressure is within the blue mark
3) Gasket 4-3.3 No.513
range, and in case that the pressure indication is
out of the range, adjust it with the adjusting
(2) Implements and Measuring Instruments
General implements and measuring instruments screw.
( ::2-2)

15-4.3 Disassembly of Lubricating Oil

Relief Valve
(1) Remove the cap (b), loosen the lock nut (c), and (g)
fully turn back the adjusting screw (a).
Before loosening the adjusting screw, either mark
the tightening position of the adjusting screw, or (f)
record the dimensions so that the previous adjusting
position can be identified when assembling.
(2) Take out the spring case (d).
(i)
(e)
15
Since the spring of the spring case is com- (h) (a)
pressed, be minded to slowly and carefully
loosen it. (c)
(d)

(3) Take out the spring seat (e), spring (f) and (g), (b)
and relief valve (h) from the lubricating oil relief
Lubricating Oil Relief Valve
valve body (i).

DK-28e Z 11-06
CHAPTER
15 Lubricating Oil System
ITEM
5.1 DK-28e General Construction of Lubricating Oil Temperature Control Valve
15-5 Lubricating Oil Temperature
Control Valve
15-5.1 General Construction
The lubricating oil temperature control valve is a
kind of the mixing type with 3-direction valves,
and the common port "A", high-temperature port
"B", and low-temperature port "C" are provided.
The valve (f) is opened or closed by the activa-
tion of the spindle (e), which moves out and
moves in by expansion or contraction force of
the wax of the wax pellet (d) located in the com-
mon port "A".
<Explanation of activation>
The figure shows the case that the lubricating oil
temperature of the port "A", which is connected to
the engine inlet, is low, and it indicates the state
"C" is fully closed and the port "B" is fully opened.
When the lubricating oil temperature is increased,
the wax in the wax pellet will expand, and the spin-
dle extends upward. At this time, since the rod
DK-28e Z 11-06
upper part (j) cannot move upward clue to being
pressed by the cushion spring (g), its reacting
force pushed down the valve(f) to open the port
"C", and the lubricating oil temperature in the port
"A" can be controlled to be within the specified
value.
The cushion spring (g) will be compressed and
prevent the damage of the pellet, when the spindle
further extends upward in the state that the port
"B" is fully closed.
In case that the lubricating oil temperature of the
engine inlet has abnormally increased due to fail-
ure of the pellet, etc. the temperature can be
decreased by screwing the adjusting screw (h)
with your hand, as an emergency measure, to
push down the valve (f), to open the port "C", and
then to decrease the temperature.
( : "Operation" 5-3.2 "Manual Adjustment of
Lubricating Oil Temperature")
Lubricating oil temperature control valve
(DTV 80): 20 kg
 CHAPTER
Lubricating Oil System 15
ITEM
Lublicating Oil Temperature Control Valve: Replacing Consumables /
Disassembly / Inspection and Maintenance / Assembly DK-28e 5.2~5.5

15-5.2 Replacing Consumables, e) Take out the shaft (l), the spring seat (p), and
Implements, and Measuring the main spring (m).
Instruments f) Draw out the shaft bush (q) from the cover.
(1) Replacing Consumables g) Remove the cap (r), and draw out the cushion
Replace the following parts with the new ones. spring (g) and the rod (j) from the adjusting
1) O-ring Z560102124ZZ screw (h).
Z560103635ZZ
Z560214531ZZ 15-5.4 Inspection and Maintenance of
2) Y-ring S104100650 Lubricating Oil Temperature
3) Gasket Z565001300ZZ Control Valve
Z565003400ZZ (1) Clean all the disassembled parts with washing
4) Pellet (2) S10400 oil, and remove the scales.
Note: The controlling temperature of the pellet (2) (2) Inspect if there is any scratch on the outer
will vary depending on the specifications. periphery and the end surface of the valve, and
Therefore, clearly indicate the controlling confirm that the valve moves smoothly.
temperature of the name plate when issuing In case that the degree of scratch is minor, cor-
your orders. rect it with oil stone.
(2) Implements and Measuring Instruments (3) Inspect if there is any abnormal dent or scratch
General implements and measuring instruments on the main spring and the cushion spring.
( : 2-2) (4) Insert the shaft into the shaft bush (q), and
check if the shaft moves smoothly.
15-5.3 Disassembly of Lubricating Oil
Temperature Control Valve 15-5.5 Assembly of Lubricating Oil
Temperature Control Valve
(1) Remove each connection piping, and dismount
Assemble the control valve in the reverse order of
the temperature control valve.
the disassembling procedure.
(2) Disassemble the temperature control valve on
the following procedure:
a) Remove the bolt, and take out the cover (i). 1) Apply grease on the sliding area of the
As the adjusting spring (h) and the rod (j) are valve.
attached to the cover, draw out them at the 2) Replace the pellet every 2 years, taking
same time.
into consideration the deterioration of the
b) Remove the mounting bolt, and take out the
rubber diaphragm in the inside.
cover (k).
As the valve (f), the shaft (l), the pellet (l), and 15
the main spring (m) are attached to the cover,
draw out them at the same time.
c) Pull out the pellet (d).
d) Remove the lock nut (n) and (o), and take out
the shaft (I).

Since the spring (i) is compressed, be minded

to slowly and carefully loosen the bolt, so that
the spring may not fly out.

DK-28e Z 11-06
CHAPTER
16 Cooling Water System
ITEM
Outline of Cooling Water System / General Construction of
1,2.1 DK-28e Cooling Water Pump

16. Cooling Water System
16.1 Outline of Cooling Water System
There are available two types of cooling water sys-
tems, a clean water 1-line cooling system and a
clean water-seawater (or clean water) 2-line
cooling system.
・The clean water 1-line cooling system consists
of a cooler line (low temperature) on which
cooling water is fed by the cooler cooling water
pump (provided on the engine or separately
installed) and a jacket line (high temperature)
branching from the cooler system on which
cooling water is fed by the jacket cooling water
pump (provided on the engine). This cooling
system requires one inlet and one outlet in the
engine.
・The two-line cooling system consists of a jacket
line and a cooler line. On the jacket line, clean
water is used as cooling water, and, on the cooler
line, seawater (in the case of marine use) or clean
water is used.
The jacket line cooling water outlet in the engine is
provided with a temperature control valve.
In the case of a heavy fuel oil engine with cooling
nozzle, cooling water is supplied through a branch
from the jacket line.
( : "Operation" 2.2.4 "Cooling Water System")
16.2 Cooling Water Pump
16.2.1 General Construction
The cooling water pump of the jacket system is a
volute type, and the pump is installed on the front
of the engine, and is driven by the auxiliary drive
gear located on the front end of the crankshaft.
Cooling water pump : 40 kg

Head tank

Air cooler Jacket line

outlet main pipe
Temperature
Lubricating control valve
oil cooler
From cooling

To cooling
nozzle

nozzle

Cooling water pump Diesel

Coolinjg water pump engine
(Cooler line)
(Jacket line)

To low temperature
From low temperature water line
water line
Cooling Water System
(Fresh water one line system)

Head tank
Fresh water cooler

Air cooler
Temperature C.W. main outlet pipe
contrl valve (Jacket line)
From fuel oil nozzle

To fuel oil nozzle

Lubricating
oil cooler

Cooling water pump Engine

(Cooler line) Cooling water pump
(Jacket line)
Fresh water cooler
Cooling Water System
(Fresh Water-Sea Water or Fresh Water-Fresh Water)

DK-28e Z 11-06
 CHAPTER
Cooling Water System 16
ITEM
Cooling Water Pump: Replacing Consumables,
Implements, and Measuring Instruments / Disassembly DK-28e 2.2,2.3

16-2.2 Replacing Consumables,

Implements, and Measuring
Instruments The screw of the impeller mounting nut (c)
(1) Replacing Consumables for normal rotation engine is threaded as
Replace the following parts with the new ones: "left- handed" screw. Therefore, be careful of
( : "4-4.1 "Parts List") the direction when loosening or tightening
the nut and screw.
1) Circular gasket No. A526, A527,
No. A528, A543 c) Remove the rotary part of the mechanical
2) Oil seal No. A519 seal (f).
3) Mechanical seal No. A44 d) Remove the seal holder (g), and take out the
4) Bearing No. A57, A58 fixed part of the mechanicai seal.
5) Pump body gasket No. A42 e) Remove the water-cutting ring (h).
f) Remove the cooling water pump gear mount-
6) Bearing stopper gasket No. A55
ing nut (i), and cooling water pump gear (j).
7) Flange gasket No. B10
g) Take out the key (k).
8) Special claw awasher No. A49, A50 h) Remove the bolt, and remove the bearing
caps (l) and (q).
(2) Implements and Measuring Instruments Remove the oil seal (p).
1) General implements and measuring instruments i) Extract the pump shaft (n) out of the bearing
( : 2-2) case (o), together with the ball bearing (r).
j) Remove the ball bearing (m) from the bearing
case (o).
16-2.3 Disassembly of Cooling Water
Pump
(1) Before dismounting the cooling water pump,
(d) (g)
remove the exhaust side cover of the auxiliary (q)
gear case, and measure the backlash of the
pump drive gear. (r) (n) (l) (k)

Standard Replacement limit

(mm) (mm)
<Backlash> 0.4 ~ 0.6 0.8

(2) Disconnect the piping of the pump inlet and

outlet.
(3) Remove the tightening nut, and dismount the
cooiing water pump assembly from the engine.
(4) Disassemble the cooling water pump assy, in (i)
the following procedure: (c)
Before disassembling, put matchmarks on the
joint surfaces of the pump body, cover, and so
(o) (m) ( j ) 16
on.
Impeller Bearing
(b) (e) (a) (f) (h)
a) Remove the pump body mounting nut, and side side
take out the pump body (a) and pump body
(p)
cover (b). Oil seal assembling direction
b) Remove the impeller mounting nut (c), remove
the impeller (d), and take out the key (e). Cooling Water Pump

DK-28e Z 11-06
CHAPTER
16 Cooling Water System
ITEM

2.4 DK-28e Inspection and Maintenance of Cooling Water Pump

16-2.4 Inspection and Maintenance of

Cooling Water Pump
(1) Wash all the disassembled parts with washing
oil, and remove the scales.
(2) Measure the clearance "a" between the Impeller
impeller and the mouth ring.
Measure the outer diameter of the mouth ring
inserting part of the impeller and the inner diam- Mouth ring
eter of the mouth ring, and calculate the clear-
ance.

< Mouth ring clearance=a >

a
Standard value (mm) Replacement limit (mm)
a = 0.48 ~ 0.60 1.0

In case that the clearance is over the

replacement limit, replace the parts, of
which wearing degree is larger.
Excessive wear may degrade the pump
Clearance between Impeller and Mouth Ring
efficiency,

(3) Check if there is any corrosion or cavitation on

the impeller.
(4) Check if there is any corrosion or cavitation on
the casing, or the reduction in thickness of the
casing due to these defects.
(5) Check the wearing conditions of the cooling
water pump gear tooth surface and the presence
of pitching.

In case that the gear is worn out heavily and

the backlash is over the replacement limit,
replace the gear with a new one.

(6) Rotate the bearing, and check if it rotates

smoothly, it does not make abnormal noise, or it
is not worn out.

Replace the bearing at the time of the peri-

odical inspection of every 8,000 to 12,000
hrs. (every 2 to 3 years) with a new one,
even
when there is no particular abnormality on it.

DK-28e Z 11-06
 CHAPTER
Cooling Water System 16
ITEM
Assembly of Cooling Water Pump DK-28e 2.5

16-2.5 Assembly of Cooling Water

Pump
< Cautions when assembling the cooling
(1) Assemble the cooling water pump assembly in water pump >
the reverse order of the disassembling proce-
dure. 1) Be minded to perform the assembling in
such a manner that the lubricating oil inlet
of the bearing case (o) faces straight
To tighten the impeller nut (c) and the upward, when the pump is mounted on
pump gear nut (i), apply the lubrication oil to the engine.
the nuts, and then tighten the nuts with the 2) Replace the oil seal, mechanical seal,
specified torque. packing, folded washer, O-ring, etc. with
new ones.
3) Be careful not to assemble the oil seal in
the wrong direction.
When tightening the pump gear nut (i), fix 4) Mark the direction of the washer claw on
the gear and then tighten the nut so that the the impeller (refer to Fig. 1).
load (reaction) cannot be applied to the 5) Tighten the impeller nut (c) with the speci-
impeller. fied torque using a torque wrench.
When tightening the impeller nut, check that
the folded washer does not turn together
Specified torque: with the nut.
Impeller nut: 147 N.m (15 kgf.m) 6) Before fitting the pump body (a), turn the
Pump gear nut: 275 N.m (28 kgf.m) impeller with your hand, and check that the
impeller can rotate smoothly and there is a
play (0.1 to 0.7 mm) in the axial direction.
Also check that deflection is 0.05 mm or
less on the outer surface of the impeller
(refer to Fig. 2).

Mark which way

the claw washer's tongue

16

Fig.1 Fig. 2

DK-28e Z 11-06
CHAPTER
16 Cooling Water System
ITEM
Assembly of Cooling Water Pump / Cooling Water Temperature
2.5, 3 DK-28e Control Valve

16-3 Cooling Water Temperature

Control Valve
<Caution in handling mechanical seal>
1) Do not use any greases. Structure of the cooling water temperature con-
trol valve is entirely same as that of the lubricating
2) Do not apply any oils to the sliding sur-
oil temperature control valve, but only the materi-
face. If oil or foreign material is on the
als of the components are different (anti-corrosive
sliding surface, wipe it off the sliding sur-
materials.)
face using clean cloth moistened with
( : 15-5 "Lubricating Oil Temperature Control
alcohol or acetone.
Valve")
3) Apply a thin coat of turbine oil #32, or
equivalent oil, to the inner surface of the
mechanical seal and the shaft, and then fit
the mechanical seal.
4) Leave the mechanical seal as it is for 30
minutes or more.

(2) Mount the cooling water pump.

In case that the cooling water pump gear (j) is
replaced, check the backlash.
(3) Connect the cooling water inlet and outlet pip-
ing and bearing oiling piping.

If the flange surfaces cannot be fitted

tightly due to the distortion of piping, correct
the distortion of the piping before connect-
ing. If the distorted piping is forcibly connect-
ed, the pump bearing may be damaged.

"Never allow oily substance

and foreign matters to stick"
Mating Ring
Seal Ring
Impeller side

Bellows

Apply turbine oil # 32

"Never use grease."
Installation of the Mechanical Seal

DK-28e Z 11-06
 CHAPTER
Cooling Water System 16
ITEM
MEMO DK-28e

16
CHAPTER
17 Engine Control and Protective Device
ITEM

1 DK-28e Outline of Engine Control and Protective Device

17 Engine Control and Protective . Turning safety switch and solenoid valve
Device Disassembling is prohibited, and therefore
replace them as an assembly.
17-1 Outline of Engine Control and . Fuel oil control device
Protective Device
Incorporated into the fuel oil shutdown device.
Although the engine control and protective device
(Explained in this section.)
differ depending on the use application of the
engine and the delivery specifications, the com-
(2) Engine Protective Device
posing equipment that are common to each sys-
. Various switches and various sensors
tem are as shown below. As for the inspection and
maintenance of each device, perform the works (for speed, temperature, pressure, level, etc.)
according to the following procedure. The disassembling of these parts are prohibit-
ed, and therefore replace each of them as an
( : "Operation" 2-3 "Engine Control and
assembly.
Protective Device") . Various electric parts
(1) Engine Control (Start, Drive, and Stop) System
The disassembling of these parts are prohibit-
. Starting air valve, starting air operation valve,
ed, and therefore replace each of them as an
and handle switch
assembly.
( : 13 "Starting Air System") . Fuel oil shutdown device
. Governor Refer to the separately provided
Incorporated into the fuel oil control device.
manual. (Explained in this section.)
( : "Instruction Manual of Governor")

Starting operation valve

Fuel shutdown device
Stoppage cylinder Control cylinder Pulse sencor
Turning bar

Starting air valve Speed switch

(12, 13, 14)
Turning safety Explosion plate Meter display
switch (4-20mA)
To fuel injection
Starting rotary pump of each cylinder Fuel oil injection pump
Starting air

valve
Stoppage Common rod
cylinder
Operation lever
Starting valve Governor motor RUN
START
STOP
Air tank Governor

63
Q2

From L.O. piping

Handle switch (HS)

Control air
0.8 MPa
{8 kgf/cm2}
Starting Fuel shutdown Fuel control Fuel shutdown
solenoid solenoid solenoid solenoid
(88V) (5V) (88L) (5S)
Starting and Stoppage System (Generator use . Remote control)

DK-28e Z 11-06
 CHAPTER
Engine Control and Protective Device 17
ITEM
Outline of Engine Control and Protective Device DK-28e 1

63 Turning bar Starting operation valve

Q2 F.O. Control cylinder
Pulse sencor

From L.O. piping Starting air valve Fuel shutdown and

control device Speed switch
(12, 13, 14)
Turning safety Explosion Meter display
switch plate
To fuel injection (4-20mA)
pump of each cylinder Fuel oil injection pump
Starting air

Starting rotary
valve Common rod
Operation lever
Starting valve Stoppage RUN
cylinder START
STOP
Air tank
Governor

Handle switch (HS)

Governor boost solenoid

)8
Control air
0.8 MPa
{8 kgf/cm2}
Governor boost air
Governor air
Fuel control Fuel shutdown Fuel shutdown Fuel control (From control handle)
piston solenoid solenoid solenoid solenoid 0.1 ~ 0.4 MPa {1 ~ 4 kgf/cm2}
(88F) (5S) (5V) (88L)

Starting and Stoppage System (Marine propulsion . Engine side control)

17

DK-28e Z 11-06
CHAPTER
17 Engine Control and Protective Device
ITEM
Fuel Oil Shutdown Device (G2 Type): General Construction /
2.1~2.3 DK-28e Replacing Consumables and Implements / Disassembly

17-2 Fuel Oil Shutdown Device (G2
Type)
17-2.1 General construction
The fuel oil shutdown device (G2 type) is used for
the constant-speed engine (such as a generator
engine) as the fuel oil shutdown and control devices.
This fuel oil shutdown device is provided with a
stop cylinder to shut down the fuel oil, and a fuel con-
trol cylinder to control excessive fuel oil injection that
are arranged in tandem, and the shutdown device
shifts the fuel injection pump rack to either "Stop"
position or "Control" position via the common rod
and by affecting the control air to each piston.
Fuel oil shutdown device (G2 type) : 7.0 kg
17-2.3 Disassembly of Fuel Oil
Shutdown Device (G2 Type)
(1) Before disassembling, put the marks (match-
marks) to the adjusting place, or keep the record
of the dimensions.
(2) Take out the link pin(C), and remove the fork
end (B).
(3) Remove the fuel oil shutdown device assembly
from the engine.
(4) Disassemble the fuel oil shutdown device
assembly in the following procedure:
a) Remove the bolts, and take out the cover-1
(b) and the cover-2 (c).
b) Extract the main spring (d) and the shutdown
piston (e) out of the cylinder(a).
c) Extract the control piston (f) from the opposite
side.

17-2.2 Replacing Consumables,

Implements, and Measuring
Instruments
(1) Replacing Consumables
Replace the following parts with the new ones:

( : "Parts List".)
1) O-ring 4-6.1 No.505, 506, 507, 508, 509
(2) Implements and Measuring Instruments
General implements and measuring instruments
( : 2-2)

Common rod

(g) (d) (f) (a) (b) (B) (C)

(c) (e)

Fuel Oil Shutdown Device ( G2 Type )

DK-28e Z 11-06

Engine Control and Protective Device
Inspection, Maintenance, Assembly, Mounting, and
Adjustment of Fuel Oil Shutdown Device ( G2 Type )
17-2.4 Inspection, Maintenance, and
Assembly of Fuel Oil Shutdown
Device (G2 Type)
(1) Wash all the disassembled parts with clean
washing oil, and blow air on them.
(2) Inspect if there is any abnormal dent or scratch
on the shutdown piston and the control piston.
(3) Inspect if there is any abnormal dent or scratch
on the cylinder inner surface.
(4) Inspect if there is any scratch on the main
spring.
(5) Inspect if there is any rusting due to drain on
each parts.
If rust is found, carefully remove it.
(6) Assemble the fuel oil shutdown device assem-
bly in the reverse order of the disassembling pro-
cedure.
1) Replace all the O-rings with the new ones.
2) When assembling, thinly apply grease to the
sliding surfaces of the O-ring, piston, and so on.
(7) After assembling, confirm that every part of the
device operates smoothly.
Lock nut
Adjusting bolt (g)
Mounting and Adjustment of Fuel Oil Shutdown Device ( G2 Type )
CHAPTER
17
ITEM
DK-28e 2.4,2.5
17-2.5 Mounting and Adjustment of
Fuel Oil Shutdown Device (G2
Type)
(1) Mount the fuel oil shutdown device assembly to
the engine, and attach the fork end and the link
lever.
At this time, be minded to temporarily adjust the
adjusting bolt (g) by matching it to the match-
marks.
(2) Turn the operation lever to "Drive" position,
and supply control air to the control cylinder of
the fuel oil shutdown device. And, adjust the
screw-in position of the fork end so that the rack
scale indicates the specified position, and then
fix the link lever.
(3) Next, supply air to the shutdown cylinder, and
adjust the screw-in position of the adjusting bolt
so that the rack is on the "0" position.
(If the screw-in direction is clockwise, the shut-
down stroke will be decreased.)
(4) When the adjustment of the control stroke and
the shutdown stroke is completed after repeating
the above steps (2) and (3), fix the fork end and
the adjusting bolt with the lock nuts.
Lock nut Link lever
17
Fork end (B)
STOP RUN
DK-28e Z 11-06
CHAPTER
17 Engine Control and Protective Device
ITEM
Fuel Shutdown Device (H2 Type): General Construction / Replacing Consumables /
3.1~3.4 DK-28e Disassembly, Maintenance, Assembly, Mounting and Adjustment

17.3 F.O. control cylinder 17.3.3 Disassembly of F.O. control

17.3.1 General construction
The F.O. control cylinder is used in the variable
speed engine (the main engine, etc.).
The F.O. control cylinder is installed to control
excessive fuel injection, and this cylinder will shift
the fuel injection pump rack to the fuel control posi-
tion via the common rod by supplying governor air
to the control piston.
F.O. control cylinder: 10 kg
17-3.2 Replacing consumables, imple-
ments and measuring instru-
ments
(1) Replacing consumables
Replace the following parts with the new ones
cylinder
(1) Remove the F.O. control cylinder from the
engine.
(2) Before disassembling, put a mark (a match
mark) to the adjusting bolt and the spring seat,
or keep the record of the dimension.
(3) Disassemble the F.O. control cylinder accord-
ing to the following procedure.
a) Loosen the lock nut (b), and remove the
adjusting bolt (a).
b) Loosen the set screw (c), and remove the
spring seat (d).
c) Extract the main spring (e) and the piston (f)
out of the control cylinder (g).

( : "Parts List")
1) Mini-Y gasket 4-6.3 No. 23
2) GLY gasket 4-6.3 No. 24
3) Gasket 4-6.3 No. 513

(2) Implements and measuring instruments

1) General implements and measuring instru-
ments ( : 2-2)

(d) (c) (e) (g) (f) (b) (a)

F. O. Control Cylinder

DK-28e Z 11-06

Engine Control and Protective Device
Fuel Shutdown Device (J2 Type): General Construction / Replacing
Consumables / Disassembly, Maintenance, Assembly, and Mounting
17.3.4 Inspection, maintenance and
assembly of F.O. control cylinder
(1) Clean all the disassembled parts with clean
washing oil, and blow air on them.
(2) Check if there is any abnormal dent and
scratch on the piston.
(3) Check if there is any abnormal dent and
scratch on the cylinder inner surface.
(4) Check if there is any scratch on the main
spring.
(5) Check if there is any rusting owing to drain on
each parts. In case that any rust is found,
carefully remove it.
(6) Assemble the F.O. control cylinder in the
reverse procedure of that for disassembly.
Replace the Y-ring with a new one.
Before assembling, thinly apply grease to the
sliding part of the Y-ring, piston, and so on.
(7) After assembling, check that all the parts
move smoothly.
Rack stopper position
Fuel rack
graduation
Control position at starting
[D.S.]
Operating air pressure [MPa]
Adjustment or Fuel Oil Control Cylinder
CHAPTER
17
ITEM
DK-28e 4.1~4.4
17.3.5 Fitting and adjustment of F.O.
control cylinder
(1) Install the F.O. control cylinder to the engine.
At this time, set the adjusting bolt and the
spring seat to the match mark position.
(2) Confirm that the fuel oil injection quantity
(under approx. 1/3 of the load) is sufficient to
start the engine (starting time control position),
in the state that governor air is supplied to the
control piston.
If case that the engine cannot be started, adjust
the injection quantity with the adjusting screw.
(3) While the engine is operating, the link lever
changes according to the main engine load
characteristics in the range from approx. 1/3 of
the load to the full load, and then adjust the
main spring force moving the spring seat so
that the clearance with the adjusting screw tip
is 0.5 to 2 mm.
(4) After the completion of adjustment, fix the lock
nut of the adjusting screw and the set screw of
the spring seat.
Rack control piston
operating characteristics
Main propulsion engine
load charactaristics
[SLOW] [HALF] [FULL]
17
DK-28e Z 11-06
CHAPTER
Gauge Board
18
ITEM
General Construction/Replacing Consumables, Implements,
1.1~1.3 DK-28e and Measuring Instruments / Disassembly and Maintenance

18 Gauge Board 18-1.3 Disassembly and Maintenance

18-1 Gauge Board of Gauge Board
Perform the disassembly and maintenance of
18-1.1 General Construction the gauge board at the time of the periodic inspec-
The gauge board is equipped with a tachometer tion (every 16,000 to 24,000 hours: every 4 to 5
and each pressure gauge (for lubricating oil, fuel years), according to the following procedure:
oil, intake air, cooling water, etc.), and is supported
(1) Disassembly of Gauge Board
by cushion rubber.
a) Remove the flexible cable of tachometer from
The tachometer is driven from the front end of
the take-out port.
the camshaft via the flexible cable, and each pres-
sure gauge is connected from the source valve on b) Close the source valve of the pressure
the end of the piping with the flexible hose. gauge, and disconnect the flexible hose.
c) Remove the mounting bolt of the cushion
spring to the bracket, and disconnect the
18-1.2 Replacing Consumables,
entire gauge board.
Implements, Measuring Instruments
(2) Inspection and Maintenance of Gauge Board
(1) Replacing Consumables
a) Check the accuracy of each gauge by compar-
Replace the following parts with the new ones.
ing with the equipment for calibration purpose
( : "Parts List") or with the new equipment. In case that any
1) Flexible hose 4-5 No. A21~A25 fault is found, replace it with a good gauge
(2) Implements and Measuring Instruments b) Replace the flexible hose with a new one.
( ：2-2)

Cushion spring Cushion spring

Flexible hose

Flexible hose

Tachometer cable

Camshaft front end

tachometer take-out port

Gauge board

DK-28e Z 11-06
 CHAPTER
Gauge Board
18
ITEM
Gauge Board: Disassembly and Maintenance of Seal Pot DK-28e 2

1) It is difficult to repair the defective gauges

on site. Therefore, replace them with the
Fuel oil main pipe
new ones, or inquire the specialized maker
for the repair.
2) Heavily deteriorated hoses may break. If
the hoses for fuel oil and lubricating oil break (B)
and high-temperature parts are splashed
with the oil, a fire may occur. Replace such
hoses without fail. To pressure gauge
3) If the elasticity of the cushion rubber is lost, (a)
the vibration of the gauge will increase and (C) To remote
the indication fault of the gauge will be pressure gauge
advanced. (c)

㩿㪛㪀

(b)

18-2 Seal Pot Seal pot (A)

In case of heavy fuel oil, a seal pot is provided in
the middle of the fuel oil pressure gauge piping,
and filled with ethylene giycol to replace the pres-
sure so that the pressure gauge can be prevented
from malfunction due to the sticking of fuel oil in a Seal Pot
cold season.
Ethylene giycol will be contaminated and deteri-
orated being mixed with fuel oil as time passes,
and therefore be minded to replace ethylene giycol
with the new one for every 4,000 to 6,000 hours Although ethylene glycol is less toxic to your
skin and membrane, it is still dangerous if it
(once every year).
was taken into human body. Therefore, be
minded to take enough care in the handling,
and promptly wash it away if it is deposited on
<Replacing procedure of ethylene glycol> your hand or skin
(1) Close the valve (B), (C) and (D) of the seal pot
inlet and outlet, and remove the seal pot (A).
(2) Disconnect the inlet side joint (c) of the siphon
tank (b), and discharge the fuel oil and ethylene
glycol from the inside.
(3) Wash the inside of the tank.
(4) Fill ethylene glycol until it starts to spill out of
the upper part hole, and then install the joint.
(5) Install the piping to the seal pot. 18

DK-28e Z 11-06
 パーツリスト
PARTS LIST

6.8DK-28e
低質燃料油
HEAVY FUEL OIL

e-V00
 Solemnly    Declare 
Recently we found some companies to pretend to be our agent units, such as 
sales  of  AnQing  Daihatsu  diesel  engine  spare  parts.  Here,  we  solemnly  declare: 
we did not set up any spare parts sales company alone, also not authorized any 
company  to  carry  out  the  Daihatsu  diesel  engine  spare  parts  sales.  Our  spare 
parts only by technical services direct sales, wish masses of customers properly 
identify!   
Through  our  investigation  and  pretend  to  be  on  the  market  sales  of  diesel 
engine  spare  parts  are  imitations,  without  Daihatsu  and  our  company 
recognition,  also  did  not  pass  strict  inspection,  product  performance  and  the 
differences  with  the  technical  requirements,  using  them  will  have  a  negative 
effect  on  diesel  engine.  To  ensure  normal  operation  of  diesel  engine  and  user 
interests,  it  is  strongly  recommended  that  users  through  our  technical  service 
department  or  Japan's  Daihatsu  purchasing  spare  parts.  Using  any  imitation 
parts of diesel engine is fault, we do not assume responsibility. At the same time, 
our  company  also  will  go  through  legal  channels  to  protect  the  name  of  our 
company  sales  of  AnQing  Daihatsu  diesel  engine  spare  parts  rights.  Any     
company  should  not  sale  in  the  name  of  our  company  AnQing  Daihatsu  diesel 
engine spare parts. 
Using imitation parts will cause great harm to diesel engine: 
1  The  part  of  companies  organize  to  product  after  surveying  and  mapping 
production  of  pure  diesel  engine  parts,  such  as  on  the  key  size,  precision, 
performance, heat treatment process, but they unable to grasp the production of 
product performance and less than the pure standard spare parts service life. 
2 Part of the company directly purchase parts from our supplier spare parts sales, 
without  strict  inspection  quality  assurance  processes,  nonconforming  product 
without control. 
3  Part  of  the  company  to  enter  the  market  at  low  price  in  the  technological 
process,  production  materials,  quality  management  costs,  reducing  product 
quality standards. 
4  If  imitation  parts  are  used  for  the  engines  designed  in  accordance  with 
MARPOL  Ⅵ  ,  the  certificate  (EIAPP)  may  lose  its  validity,  and  operation  of  the 
engine may be inhibited 
5 If you use the imitation spare parts, when a failure occurs, we do not assume 
any  liability  to  them,  and  it  is  difficult  to  obtain  the  insurance  claim  of  diesel 
engine. 
In addition, the operation of the diesel engine after a period of time after, the 
moving  parts  may  be  wear,  tighten  bolts  loose  because  of  vibration,  the 
combustion  chamber  components  may  be  carbon  deposition,  if  not  treated  in 
time  will  affect  the  normal  operation  of  diesel  engine.  According  to  Japan's 
Daihatsu specification, DC, DK series diesel engine must be every 2 ~ 3 years on a 
maintenanceto cylinder head, piston, cylinder liner, connecting rod, main bearing, 
CAM shaft overhaul and other major parts. 
 Our  company  as  a  diesel  engine  manufacturers,  has  a  rich  experience,  skills, 
enrich  the  after‐sales  service  team.  Guarantee  the  normal  operation  of  diesel 
engine and meet the demand of users is our after‐sale serving 
 
Our spare parts sales contact information: 
Email address: acdspare@126.com 
Fax: 0556‐5307388 
Telephone: 0556‐5307184      0556‐5307177    0556‐5307389 
 
Contact our after‐sales service: 
At home                                                                                At abroad 
E‐mail: afterserviceanqing@126.com                  Email: interserviceaq@126.com 
Fax: 0556‐5307465                                                Fax: 0556‐5307465 
Telephone: 0556‐5307275                                    Telephone: 0556‐5307179 
 
Our machine sales contact information: 
Email address: aq_daihatsu@126.com 
Fax: 0556‐5209643 0556‐5209644 
Telephone: 0556‐5307180 0556‐5307182 
 
 
 
 
 
 

 
 CHAPTER
部品目次（低質燃料油）
ITEM
PARTS CONTENTS ( HEAVY FUEL OIL ) 6･8DK-28e

目　 　 　 次
CONTENTS
0. 機関外形　 機器配置図
ENGINE OUTLINE AND EQUIPMENT

-1. 機関外形　 機器配置図

ENGINE OUTLINE AND EQUIPMENT

-2. 機関断面図
SECTION OF ENGINE

1. NOxテクニカルコード適合機関
ENGINE CONFORMING TO NOx TECHNICAL CODE

2. 配管系統図
PIPING SYSTEM

-1. 配管規格部品の記号表示
GRAPHICAL SYMBOLS OF PIPING STANDARD PARTS

-2. 始動空気配管
STARTING AIR PIPING

-3. 燃料油配管
FUEL OIL PIPING

-4.1.1 潤滑油配管（後端過給、ＴＰＳ）
LUBRICATING OIL PIPING(REAR TURBOCHARGER,TPS)

-4.1.2 過給機潤滑油配管（後端過給、TPS57）　
TURBOCHARGER LUBRICATING OIL PIPING(REAR T/C, TPS57)

-4.1.3 過給機潤滑油配管（後端過給、TPS61)
TURBOCHARGER LUBRICATING OIL PIPING(REAR T/C, TPS61)

4.2.1 潤滑油配管(前端過給、ＴＰＳ）
LUBRICATING OIL PIPING, TURBOCHARGER LAYOUT-FRONT TURBOCHARGER

-4.2.2 過給機潤滑油配管（前端過給、ＴＰＳ）
TURBOCHARGER LUBRICATING OIL PIPING(FRONT TURBOCHARGER,TPS)

-4.3 潤滑油冷却器配管
LUBRICATING OIL PIPING （LUBRICATING OIL COOLER)

-4.4 ＣＷポンプ＆ギヤ潤滑油配管
C.W. PUMP & GEAR LUBRICATING OIL PIPING

-5.1 冷却水配管（後端過給、ＴＰＳ）
COOLING WATER PIPING(REAR TURBOCHARGER,TPS)

-5.2 冷却水配管(前端過給、ＴＰＳ）
COOLING WATER PIPING(FRONT TURBOCHARGER,TPS)

-5.3 冷却水配管（空気冷却器)
COOLING WATER PIPING(INTER COOLER)

-6. 燃料漏油戻し配管
FUEL OIL PIPING (LEAK OIL RETURN)

6･8DK-28e Z 11-06
CHAPTER
部品目次（低質燃料油）
ITEM

6･8DK-28e PARTS CONTENTS ( HEAVY FUEL OIL )

-7. 温度計
THERMOMETER

-8. ノズル冷却水配管
NOZZLE COOLING WATER PIPING

3. 機関主要部品
MAIN PARTS

-1.1 架構（主機関用）
ENGINE FRAME(FOR PLOPULSION USE)

-1.2 架構（発電機関用）
ENGINE FRAME(FOR GENERATOR USE)

-2. 架構側蓋，盲蓋
ENGINE FRAME SIDE ＆ BLIND COVER
-3. 架構安全弁(EVA)
ENGINE FRAME SAFETY VALVE(EVA)
-4. 油受
OIL ＰＡN
-5. クランク軸，バランスウエイト，フライホイル ＆ 主軸受
CRANKSHAFT，BALANCEWEIGHT，FLYWHEEL＆ MAIN BEARING
-6. アイドルギヤ
IDLE GEAR
-7.1 カム軸，カム軸受（８ＤＫ）
CAMSHAFT＆ CAMSHAFT BEARING(8DK)
-7.2 カム軸，カム軸受（６ＤＫ）
CAMSHAFT＆ CAMSHAFT BEARING(6DK)

-8. 補機駆動ギヤ
AUXILIARY DRIVING GEAR
-9. 起動回転弁
STARTING AIR ROTARY VALVE
-10. コモンロッド
CONTROL ROD
-11.1 ピストン ＆ 連接棒（発電機関用）
PISTON ＆ CONNECTING ROD(FOR GENERATOR USE)
-11.2 ピストン ＆ 連接棒（主機関用）
PISTON ＆ CONNECTING ROD(FOR PLOPULSION USE)

-12. シリンダライナ
CYLINDER LINER
-13. シリンダヘッド
CYLINDER HEAD
-14. 吸気弁
INTAKE VALVE
-15. 排気弁
EXHAUST VALVE

6･8DK-28e Z 11-06
 CHAPTER
部品目次（低質燃料油）
ITEM
PARTS CONTENTS ( HEAVY FUEL OIL ) 6･8DK-28e

-16. 弁腕
ROCKER ARM
-17. 起動弁
STARTING AIR VALVE
-18.1 燃料噴射装置
FUEL INJECTION DEVICE
-18.2 燃料噴射装置(ノズルホルダ)
FUEL OIL INJECTION DEVICE (FUEL OIL NOZZLE HOLDER)
-18.3 燃料噴射装置(無冷却ノズル)
FUEL OIL INJECTION DEVICE (NON-COOLING)

-18.4 燃料噴射装置(ノズルホルダ、無冷却ノズル)
FUEL OIL INJECTION DEVICE (NOZZLEHOLDER, NON-COOLING)
-19. 指圧器、安全弁
INDICATOR ＆ SAFETY VALVE
-20. シリンダヘッドカバ
CYLINDER HEAD COVER

-21. 吸、排気弁タペット ＆ プッシュロッド

INTAKE, EXHAUST TAPPET ＆ PUSH ROD

-22. 燃料噴射ポンプタペット
FUEL OIL INJECTIONPUMP TAPPET

-23. 燃料噴射ポンプ
FUEL OIL INJECTION PUMP

-24.1 ガバナ駆動装置（ＲＨＤ）
GOVERNOR DRIVING DEVICE (RHD）

-24.2 ガバナ駆動装置（ＵＧ）
GOVERNOR DRIVING DEVICE (UG）

-24.3 ガバナ取付（EAR）
GOVERNOR FITTING (EAR）

-25.1 ガバナ リンク（ＲＨＤ）

GOVERNOR LINK (RHD）

-25.2 ガバナリンク（ＵＧ）
GOVERNOR LINK (UG）

-25.3 ガバナリンク（EAR）
GOVERNOR LINK (EAR）

-26. 操縦装置
OPERATING DEVICE

-27.1 排気管(８ＤＫ,前端過給，排気入口１つ口）
EXHAUST MANIFOLD (8DK,FRONT T/C, GAS INLET 1ENTRY）

-27.2 排気管(８DK，後端過給，排気入口２つ口）
EXHAUST MANIFOLD (8DK, REAR T/C, GAS INLET 2ENTRY）

-27.3 排気管(6DK，前端過給，排気入口１つ口）
EXHAUST MANIFOLD (6DK, FRONT T/C, GAS INLET 1ENTRY）

6･8DK-28e Z 11-06
CHAPTER
部品目次（低質燃料油）
ITEM

6･8DK-28e PARTS CONTENTS ( HEAVY FUEL OIL )

-27.4 排気管(６DK，後端過給，排気入口２つ口）
EXHAUST MANIFOLD (6DK, REAR T/C, GAS INLET 2ENTRY）

-28.1 排気管カバー(８ＤＫ,前端過給，排気入口１つ口）
EXHAUST MANIFOLD COVER (8DK,FRONT T/C, GAS INLET 1ENTRY）

-28.2 排気管カバー(８ＤＫ,後端過給，排気入口２つ口）
EXHAUST MANIFOLD COVER (8DK, REAR T/C, GAS INLET 2ENTRY）

-28.3 排気管カバー(6DK，前端過給，排気入口１つ口）
EXHAUST MANIFOLD COVER (6DK, FRONT T/C, GAS INLET 1ENTRY）

-28.4 排気管カバー(６ＤＫ,後端過給，排気入口２つ口）
EXHAUST MANIFOLD COVER (6DK, REAR T/C, GAS INLET 2ENTRY）

-29.1 過給機，空気冷却器取付（８DK，前端過給，排気入口１つ口）
TURBOCHARGER, AIRCOOLER FITTING (8DK, FRONT T/C, GAS INLET 1ENTRY）

-29.2 過給機，空気冷却器取付（８DK，後端過給，排気入口２つ口）
TURBOCHARGER, AIRCOOLER FITTING (8DK, REAR T/C, GAS INLET 2ENTRY）

-29.3 過給機(MET)，空気冷却器取付（6DK，後端過給，排気入口2つ口）
TURBOCHARGER(MET), AIRCOOLER FITTING (6DK, REAR T/C, GAS INLET 2ENTRY）

-30. ヒートボックス
HEAT BOX

4. 機関付属機器
INSTRUMENT & ACCESSORIES

-1. 起動空気系統
STARTING AIR SYSTEM
-1.1.1 始動弁、操作弁
STARTING AIR VALVE ＆ STARTING AIR CONTROL VALVE
-1.1.2 始動弁取付
STARTING AIR VALVE FITTING
-1.1.3 操作弁取付
STARTING AIR OPERATION VALVE FITTING

-1.1.4 スイッチボックス取付
SWITCH BOX FITTING

-1.2 起動空気管安全栓
SAFETY PLUG , STARTING AIR PIPE
-2. 燃料系統
FUEL OIL SYSTEM
-2.1. 燃料送油ポンプ (TYPE B)
FUEL OIL FEED PUMP (TYPE B)
-2.2. 燃料送油ポンプ 駆動装置 (TYPE B)
FUEL OIL PUMP DRIVING DEVICE (TYPE B)
-2.3.1 燃料ロキ
FUEL OIL FILTER

6･8DK-28e Z 11-06
 CHAPTER
部品目次（低質燃料油）
ITEM
PARTS CONTENTS ( HEAVY FUEL OIL ) 6･8DK-28e

-2.3.2 燃料ロキ取付
FUEL OIL FILTER & FITTING
-2.4 燃料調圧弁
FUEL OIL RELIEF VALVE

-2.5.1 レベルスイツチボツクス
LEVEL SWITCH BOX

-2.5.2 レベルスイツチボツクス（リ－ドスイツチ付）
LEVEL SWITCH BOX (WITH LEAD SWITCH)

-2.6 チエツクバルブ
CHECK VALVE

-3. 潤滑油系統
LUBRICATING OIL SYSTEM

-3.1.1 潤滑油 ポンプ（８ＤＫ）

LUBRICATING OIL PUMP(8DK)

-3.1.2 潤滑油 ポンプ（６ＤＫ）

LUBRICATING OIL PUMP(6DK)

-3.2 潤滑油冷却器
LUBRICATING OIL COOLER

-3.3 潤滑油調圧弁
LUBRICATING OIL RELIEF VALVE

-3.4.1 潤滑油ロキ（主機関用）
LUBRICATING OIL FILTER(FOR MARINE PROPULSION USE)

-3.4.2 潤滑油ロキ（補機関用）
LUBRICATING OIL FILTER(FOR GENERATOR USE)

-3.4.3 潤滑油ロキ取付（主機関用)
LUBRICATING OIL FILTER & FITTING (FOR MARINE PROPULSION USE)

-3.4.4 潤滑油ロキ取付（補機関用)
LUBRICATING OIL FILTER & FITTING (FOR GENERATOR USE)

-3.4.5 スラッジコレクタ
SLUDGE COLLECTOR

-3.5.1 過給機（TPS）潤滑油ロキ
TURBOCHARGER (TPS) LUBRICATING OIL FILTER

-3.5.2 過給機（TPS）潤滑油ロキ取付（後端過給)
TURBOCHARGER (TPS) LUBRICATING OIL FILTER FITTING (REAR TURBOCHARGER)

-3.5.3 過給機（MET）潤滑油ロキ
TURBOCHARGER (MET) LUBRICATING OIL FILTER

-3.5.4 過給機（MET）潤滑油ロキ取付（後端過給)
TURBOCHARGER (MET) LUBRICATING OIL FILTER FITTING (REAR TURBOCHARGER)

6･8DK-28e Z 11-06
CHAPTER
部品目次（低質燃料油）
ITEM

6･8DK-28e PARTS CONTENTS ( HEAVY FUEL OIL )

-4. 冷却水系統
COOLING WATER SYSTEM

-4.1 冷却水 ポンプ

COOLING WATER PUMP

-5. 計器板
GAUGE BOARD

-5.1 計器板（ガバナ：ＲＨＤ＆ＥＡＲ）
GAUGE BOARD(GOVERNOR:RHD&EAR)

-5.2 計器板（ガバナ：ＵＧ）
GAUGE BOARD(GOVERNOR:UG)

-6. 保護装置
PROTECTIVE DEVICE

-6.1 G2 燃料遮断、抑制装置
FUEL OIL SHUTDOWN & CONTROL PISTON DEVICE G2 TYPE

-6.2 燃料遮断、抑制装置取付
FUEL OＩＬ SHUTDOWN DEVICE FITTING

-6.3. FOコントロールシリンダ
FUEL OIL CONTROL CYLINDER

-6.4 パルスセンサ－，（アンプ一体）
PULSE SENSOR(WITH AMPLIFIER)

-6.5 シ－ルポツト取付
SEAL POT FITTING

-7. 機関 要具, 工具
TOOLS & IMPLEMENT

-7.1 タ－ニング装置
FLYWHEEL TURNING DEVICE

-7.2.1 ブロワ－洗浄装置（MET）
BLOWER CLEANING PARTS (MET)

-7.2.2 ブロワ－洗浄装置（TPS）
BLOWER CLEANING PARTS (TPS)

-7.3 油圧ラム（吊下式）
OIL PRESS. RAM (HANGER TYPE)

-7.4.1 油圧ジャッキ（ヘッド）
OIL PRESS. JACK (HEAD)
-7.4.2 油圧ジャツキ（軸受）
OIL PRESS. JACK (CAP)

-7.4.3 油圧ジャツキ（ロツド・サイドボルト）
OIL PRESS. JACK (ROD/SIDE BOLT)

-7.5.1 機関吊り上げ要具（6DK）
ENGINE LIFTING TOOL (6DK)

-7.5.2 機関吊り上げ要具（8DK）
ENGINE LIFTING TOOL (8DK)

6･8DK-28e Z 11-06
 CHAPTER
部品目次（低質燃料油）
ITEM
PARTS CONTENTS ( HEAVY FUEL OIL ) 6･8DK-28e

6･8DK-28e Z 11-06
CHAPTER
0 機関外形、機器配置図
ITEM
1 6･8DK-28e ENGINE OUTLINE AND EQUIPMENT

Άᢱྃ኿ࡐࡦࡊቶ
F.O.INJECTION PUMP ROOM

⸘ེ᧼
GAUGE BOARD
ᠲ૞࡟ࡃ࡯
CONTROL LEVER
ᆎേᠲ૞ᑯ
STARTING AIR
CONTROL VALVE
ࠟࡃ࠽
GOVERNOR
ᆎേᑯ
STARTING AIR Άᢱ⺞࿶ᑯ
VALVE F.O.RELIEF
VALVE
Άᢱᴤߎߒེ
F.O.FILTER

಄ළ᳓ࡐࡦࡊ ‫ޓ‬ẢṖᴤࡐࡦࡊ
L.O.PUMP
㧔ࠫࡖࠤ࠶࠻♽㧕
C.W.PUMP(for JACKET)

ㆊ⛎ᯏ
TURBOCHARGER

ㆊ⛎ᯏ↪ẢṖᴤߎߒེ㧔ਥᯏ㑐↪㧕
L.O.FILTER for TURBOCHARGER (for PROPULSION USE)

ẢṖᴤߎߒེ㧔ਥᯏ㑐↪㧕
L.O.FILTER (for PROPULSION USE)

ⓨ᳇಄ළེ ‫ޓ‬ẢṖᴤࡐࡦࡊ
AIR COOLER L.O.PUMP

ࡈ࡜ࠗࡎࠗ࡞
ࠬ࡜࠶ࠫࠦ࡟ࠢ࠲
FLYWHEEL SLUDGE COLLECTOR
‫ޓ‬ẢṖᴤࡐࡦࡊ ẢṖᴤߎߒེ㧔⵬ᯏ㑐↪㧕
L.O.PUMP L.O.FILTER (for GENERATOR USE)

6･8DK-28e Z 11-5
 CHAPTER
機関断面図 0
ITEM
SECTION OF ENGINE 6･8DK-28e 2

ឃ᳇▤ ᑯ⣨ ๆ䊶ឃ᳇ᑯ
EXHAUST PIPE ROCKER ARM INTAKE,EXHAUST VALVE

䊒䉾䉲䊠䊨䉾䊄
PUSH ROD

䉲䊥䊮䊓䉾䊄
CYLINDER HEAD

Άᢱྃ኿ᑯ
F.O.INJECTION DEVICE

ๆ᳇䉻䉪䊃
INTAKE DUCT Άᢱྃ኿䊘䊮䊒
F.O.INJECTION
䇭䇭 PUMP
䊏䉴䊃䊮
PISTON

䉲䊥䊮䉻䊤䉟䊅 േᑯⵝ⟎
CYLINDER LINER VALVE OPERATING DEVICE

಄ළ᳓ㅢ〝
C.W. PASSAGE 䉦䊛ゲ
CAMSHAFT
ẢṖᴤㅢ〝
L.O. PASSAGE
᨞᭴
ㅪធ᫔ ENGINE FRAME
CONNECTING ROD
䉪䊤䊮䉪䊏䊮䊜䉺䊦
CRANKPIN
䇭䇭䇭 METAL 䉪䊤䊮䉪ゲ
CRANK SHAFT

ᴤฃ
OIL PAN

⸘ེ᧼
GAUGE BOARD

ᠲ૞࡟ࡃ࡯
CONTROL LEVER

ࠟࡃ࠽
GOVERNOR

ࠞࡓࠡࡗ
CAM GEAR

⿠േ࿁ォᑯ
ࠕࠗ࠼࡞ࠡࡗ STARTING AIR
IDLE GEAR ROTARY VALVE
ផജฃ
THRUST METAL
⵬ᯏ㚟േࠡࡗ
AUXILIARY GEAR ਥゲฃࡔ࠲࡞
MAIN METAL
ࠢ࡜ࡦࠢࠡࡗ
CRANK GEAR

6･8DK-28e Z 11-5
CHAPTER
1 NOxテクニカルコード適合機関
ITEM
1-1,1-2 6･8DK-28e ENGINE CONFORMING TO NOx TECHNICAL CODE
1-1 NOｘテクニカルコード適合機関
1-1.1 概要
(1 ) MARPOL73／78条約の付属書Ⅵ 「船舶か
らの大気汚染防止のための規則」の第13規則
「窒素酸化物（NOｘ）二次規制」が適用され
る舶用ディーゼルエンジンは、NOｘテクニカ
ルコードに適合する必要があります。
(2)NOｘテクニカルコード適合機関は、エン
ジングループまたはエンジンファミリーと
して認定をうけており、船上でのNOｘ排出
量確認検査は、エンジンパラメータチェック
法を適用することができます。
エンジンパラメータチェック法とは、エン
ジン構成部品、設定値がテクニカルファイ
ル記載事項を満足していることを検証する
方法であり、NOｘ排出量の計測を行う必要
はありません。テクニカルファイル記載事項
を満足していない場合は、エンジンパラメータ
チェック法を適用することができず、NOｘ排
出量計測が必要となります。
1-1.2 規定対象部品
テクニカルファイルには、NOｘテクニカルコ
ードに規定されたNOｘ排出量に影響を及ぼすエ
ンジン構成部品とその部品の識別刻印が記載され
ており、エンジンごとにテクニカルファイルの保
管が義務付けられています。テクニカルファイル
に記載の部品を交換するときは、必ず識別刻印の
ある弊社純正部品をご使用ください。万一、識別刻
印のない部品が使用されている場合は、テクニカル
ファイル記載事項の不適合となり、エンジンパラメ
ータチェック法による検査は適用できません。
6･8DK-28e Z 11-06
1-1 Conforming to NOx Technical Code
1-1.1 Outline
(1) The marine diesel engine to which the 13th
rule “ Nitrogen Oxides (Nox)Secondary
Regulations” in supplement VI “Rules to Prevent
Air Pollution by Ships” to MARPOL73/78 Treaty
applies should conform to Nox Technical Code.
(2) The engine conforming to Nox Technical Code
are authorized as engine group or an engine fami-
ly, and it is allowed to apply the engine parameter
check method to them, when receiving the Nox
discharge inspection on board.
The engine parameter check method is a method
for verifying that the engine components and set-
ting values conform to the requirements specified
in the technical file, and does not require the
measurement of Nox discharge. To the engines
that are not conforming to the requirements of the
technical file, the engine parameter check method
cannot be applied. For such engine, the measure-
ment of Nox discharge shall be required.
1-1.2 The parts to be Specified
The technical file states the engine components
that can affect the Nox discharge specified in Nox
Technical Code, and shows the identification
marks stamped on them, and the user is required
to maintain the technical file for each engine.
When replacing any parts shown in the technical
file, be sure to use our genuine parts stamped
with the identification marks. In the case that
any parts without the identification mark is used, it
shall be regarded as nonconformance to the
requirements of the technical file, and in such a
case, inspection by engine parameter check
method cannot be applied.
A C
 CHAPTER
NOxテクニカルコード適合機関 1
ITEM
ENGINE CONFORMING TO NOx TECHNICAL CODE 6･8DK-28e 1.2

テクニカルファイルに記載されている識別刻印
のある部品は、以下の通りです。部品交換時には
識別刻印を確認の上、ご使用ください。
（ ：「テクニカルファイル」）
The followings are the parts that have the identifi-
cation marks specified in the technical file. When
replacing any of these parts, be sure to check
identification marks.
( :“Technical file “)

《識別刻印付部品》 <parts with identification marks>

1. シリンダヘッド 1. Cylinder head
2. ピストン 2. Piston
3. 過給機 3. Turbocharger
4. 空気冷却器 4. Air cooler
5. 燃料カム 5. Fuel cam
6. 燃料噴射ポンプ 6. Fuel injection pump
7. 燃料噴射ポンププランジャ 7. Fuel injection pump plunger
8. 燃料噴射弁 8. Fuel injection valve
9. 燃料噴射弁ノズル 9. Fuel injection valve nozzle

A C
6･8DK-28e Z 11-06
CHAPTER
2 配管部品の図式記号表示
ITEM GRAPHICAL SYMBOL, PART NAME
1.1 6･8DK-28e AND PART NUMBER OF PIPING

6･8DK-28e Z 11-06
 CHAPTER
配管部品の図式記号表示 2
GRAPHICAL SYMBOL, PART NAME ITEM

AND PART NUMBER OF PIPING 6･8DK-28e 1.2

6･8DK-28e Z 11-06
CHAPTER
2 配管部品の図式記号表示
ITEM GRAPHICAL SYMBOL, PART NAME
1.3 6･8DK-28e AND PART NUMBER OF PIPING

6･8DK-28e Z 11-06
 CHAPTER
配管部品の図式記号表示 2
GRAPHICAL SYMBOL, PART NAME ITEM

AND PART NUMBER OF PIPING 6･8DK-28e 1.4

6･8DK-28e Z 11-06
CHAPTER
2 配管部品の図式記号表示
ITEM GRAPHICAL SYMBOL, PART NAME
1.5 6･8DK-28e AND PART NUMBER OF PIPING

6･8DK-28e Z 11-06
 CHAPTER
配管部品の図式記号表示 2
GRAPHICAL SYMBOL, PART NAME ITEM

AND PART NUMBER OF PIPING 6･8DK-28e 1.6

6･8DK-28e Z 11-06
CHAPTER
2 配管部品の図式記号表示
ITEM GRAPHICAL SYMBOL, PART NAME
1,7 6･8DK-28e AND PART NUMBER OF PIPING

6･8DK-28e Z 11-06
 CHAPTER
配管部品の図式記号表示 2
GRAPHICAL SYMBOL, PART NAME ITEM

AND PART NUMBER OF PIPING 6･8DK-28e 1.8

6･8DK-28e Z 11-06
CHAPTER
2 配管部品の図式記号表示
ITEM GRAPHICAL SYMBOL, PART NAME
1.9 6･8DK-28e AND PART NUMBER OF PIPING

6･8DK-28e Z 11-06
 CHAPTER
配管部品の図式記号表示 2
GRAPHICAL SYMBOL, PART NAME ITEM

AND PART NUMBER OF PIPING 6･8DK-28e 1.10

6･8DK-28e Z 11-06
CHAPTER

ITEM
2 始動空気配管
2 6･8DK-28e STARTING AIR PIPING

A C
6･8DK-28e Z 11-5
 CHAPTER

始動空気配管 ITEM
2
STARTING AIR PIPING 6･8DK-28e 2
(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)

 
 

 

 

 


A C 6･8DK-28e Z 11-5
CHAPTER

ITEM
2 始動空気配管
2 6･8DK-28e STARTING AIR PIPING
(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)

6･8DK-28e Z 11-5 A C
 CHAPTER

メモ ITEM
2
MEMO 6･8DK-28e

**-** Z **-**
 ITEM
CHAPTER
2

3 6･8DK-28e

6･8DK-28e Z 11-5
F.O. OUTLET
90(10K) 128 126 4 A 124 90(10K)
1/2 1/2 56 130 129 127 125 HEAT BOX 56
T
44 F.O. INLET
609 1/2 44
90
燃料油配管

B 119
1/4
90 1/4 13 UNION SEAL POT NEEDLE
1/2 VALVE VALVE
C D E P
44
FUEL OIL PIPING

3/4 DANPNER 3/8x1/4

3/8 1/4x1/4
1 6
8
118

44

LAGGING

C
 CHAPTER

燃料油配管 ITEM
2
FUEL OIL PIPING 6･8DK-28e 3
(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
A Ref.4-2.3.1 ＦＯロキ F.O. FILTER 1 1
B Ref.4-2.4 オイルチョウアツベン OIL RELIEF VALVE 1 1
C Ref.3-23 ＦＯフンシャポンプ F.O. INJECTION PUMP 6 8
D Ref.3-18.1 ＦＯコウアツブロック F.O. HIGH PRESS. BLOCK 6 8
E Ref.3-18.1 ノズルホルダー NOZZLE HOLDER 6 8

4 E288670040 ブロック:FO:ロキデグチ BLOCK 1 1

13 A245073490 サ-モセンサ-ザ THERMO SENSOR BLOCK 1 1
56 E288670560 ユニオンネジ UNION SCREW 24 32
90 AE01086029 ミャクトリー PULSE ABSORBER 2 2
118 E288675180 FOカン:シユカンイリグチ-2 F.O. PIPE :MAIN INLET-2 1 1

119 E288675190 FO.カン:ロキデグチ F.O. PIPE: FILTER OUTLET 1 1

124 E288675240 FOカン:ロキイリグチ F.O. PIPE: FILTER INLET 1 1
125 E288675250 FO.カン:イリグチシユカン-6D F.O. INLET MAIN PIPE-6D 1
126 E288675260 FO.カン:イリグチシユカン-8D F.O. INLET MAIN PIPE-8D 1
127 E288675270 FOデグチシユカン:(CS)-6D F.O. OUTLET MAIN PIPE:(CS)-6D 1

128 E288675280 FOデグチシユカン:(CS)-8D F.O. OUTLET MAIN PIPE:(CS)-8D 1

129 E288675290 FOカン:フンシヤポンプイリグチ F.O. PIPE:FUEL INJECTION INLET 6 8
130 E288675300 FOカン:フンシヤポンプデグチ F.O. PIPE:FUEL INJECTION OUTLET 6 8

609 Z560103135DZ Oリング O-RING 1 1

C 6･8DK-28e Z 11-5
 ITEM
CHAPTER
2

145
Mist Gas (9)8X1/8
B1 (9)6X1/4 (1)8X1/4
4.1.1 6･8DK-28e

151 58 45 100 99 (8)8 98 43 44 90 144 637 146

6･8DK-28e Z 11-5
676 97
149 145

145

(3)10X3/8

TURBO
CHARGER Drain 6x1/8
G L.O.TANK
1 2 3 4 6 7 8
(9)10X1/4
560

150 (9)10X1/4 135,136 165

4 48 40
121 564 130
44 P 11
(1)6x1/8 18 49 A
(5)10x1/4
1/4 85
0x44 130 Blow off
D 31 41
44
F 150
TURBOCHARGER,TPS)

Drain
8 Blow off
44
潤滑油配管 (後端過給、TPS)

C 85 0x44
B
0x44 126 Drain
44
F
Drain Blow off
LUBLICATING OIL PIPING (REAR

A
C
 潤滑油配管 (後端過給、TPS) CHAPTER
2
LUBLICATING OIL PIPING (REAR ITEM
TURBOCHARGER,TPS) 6･8DK-28e 4.1.1
(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
A Ref. 4-3.1 ＬＯポンプ L..O. PUMP 1 1
B Ref. 4-3.2 ＬＯクーラ L..O. COOLER 1 1
C Ref. 4-3.4.3 ＬＯチョウアツベン L.O. RELIEF VALVE 1 1
D Ref. 4-3.4.1 ＬＯロキ L.O. FILTER 1 1
F Ref. 4-3.5.1 ＬＯロキ(T/C) L.O. FILTER(T/C) 1 1
G E292370020 シドウベントリツケプレート FITTING PLATE;S.A. VALVE 1 1

4 E288770040 シユカンデグチ FLANGE;MAIN PIPE OUTLET 1 1

8 A245073490 サ-モセンサ-ザ BLOCK;SENSOR 1
11 E288770110 セッシュ:チユウケイ RELAY JOINT 1 1
18 E288770180 LOチユウケイブロツク BLOCK ,L.O.CONNECTING 1 1
31 E288770310 LOカン;ロキデグチ-3 L.O. PIPE(3); FILTER OUTLET 1 1

40 E288770400 LOカン(4);ポンプイリグチ L.O. PIPE(4); PUMP INLET 1

41 E288770410 LOカン(4);ポンプデグチ L.O. PIPE(4); PUMP OUTLET 1
43 E288770430 LOカン;ヘツドイリグチ-1 L.O. PIPE; HEAD INLET-1 5 7
44 E288770440 LOカン;ヘツドイリグチ-2 L.O. PIPE; HEAD INLET-2 5 7
45 E288770450 LOカン;ヘツドイリグチ-3 L.O. PIPE; HEAD INLET-3 1 1

48 E288770480 LOカン(1);チユウケイブロツク L.O. PIPE(1); CONNECTING BLOCK 1 1

49 E288770490 LOカン(2);チユウケイブロツク L.O. PIPE(2); CONNECTING BLOCK 1 1
58 E288770580 LOカン:カイテンベン L.O. PIPE; ROTARY VALVE 1 1
90 AE02092007 フィルター:Yガタ Y-FILTER 1 1
97 E288770970 L.O.カン-2;フンシヤポンプ L.O. PIPE-2; INJECTION PUMP 1 1

98 E288770980 L.O.カン-3;フンシヤポンプ L.O. PIPE-3; INJECTION PUMP 4 6

99 E288770990 L.O.カン-4;フンシヤポンプ L.O. PIPE-4; INJECTION PUMP 5 7
100 E288771000 L.O.カン-5;フンシヤポンプ L.O. PIPE-5; INJECTION PUMP
121 E288771210 LOカン:T/Cロキイリグチ-RT2 L.O. PIPE;T/C FILTER INLET-RT2 1 1
126 E288771260 LOカン;T/Cロキイリグチ-RT3 L.O. PIPE;T/C FILTER INLET-RT3 1

130 E288771300 LOカン;T/Cロキ IN，TPS-M L.O. PIPE;T/C FILTER INLET-TPS-M 1

135 E288771350 カラ-;ブロツク COLLAR BLOCK 1 1
136 E288771360 ブロツク;シユカンイリグチ BLOCK;MAIN PIPE INLET 1 1
144 E288771440 LOカン;フンシヤポンプ-6 L.O. PIPE-6; INJECTION PUMP 1 1
145 E288771450 LOカン;フンシヤポンプ-7 L.O. PIPE-7; INJECTION PUMP 1 1

146 AG01546004 チェックベン CHECK VALVE 1 1

149 E288775050 LOカン:カムジクチュウユ　 1 L.O. PIPE;CAMSHAFT OILING-1 1 1
150 E288775070 LOカン:カムジクチュウユ　 2 L.O. PIPE;CAMSHAFT OILING-2 1 1
151 E288775090 ツギボルト BANJO PLUG 1 1

560 Z560206531ZZ Oリング O-RING 1 1

564 Z560206531ZZ Oリング O-RING 1 1

B1 E289370010 ミストパイプ MIST PIPE 1 1

A C 6･8DK-28e Z 11-5
CHAPTER
2 過給機潤滑油配管 (後端過給、TPS57)
ITEM TURBOCHARGER LUBLICATING OIL
4.1.2 6･8DK-28e PIPING (REAR T/C,TPS57)

625 59

130
P
129

505

128

755,754 TURBO-CHARGER
T/C MOUNT
755,754,140 TPS57D
No.1
Cyl.
759

755,754
755,754,140
To Gen. 741
60
749,758
505 123,743,748

142
127
501
Drain
Blow off

501 141 126

757,756,755,753,139 122,743,748,749,758

A C
6･8DK-28e Z 11-5
 過給機潤滑油配管 (後端過給、TPS57) CHAPTER
2
TURBOCHARGER LUBLICATING OIL ITEM
PIPING (REAR T/C,TPS57) 6･8DK-28e 4.1.2

番号 パーツコード 部品名称 Name of Parts 数量

Number Parts Code Quartity
59 E288970590 パッキン GASKET 1
60 E288970600 オリフィス ORIFICE 1
122 E288975220 ブラケット BRACKET 1
123 E288975230 ブラケット BRACKET 1
126 E288975260 T/C LOイリグチカン-1 T/C INLET L..O. PIPE-1 1

127 E288975270 T/C LOイリグチカン-2 T/C INLET L..O. PIPE-2 1

128 E288975280 T/C LOイリグチカン-3 T/C INLET L..O. PIPE-3 1
129 E288975290 T/C LOイリグチカン-4 T/C INLET L..O. PIPE-4 1
130 E288975300 T/C LOデグチカン-1 T/C OUTLET L..O. PIPE-1 1
131 E288975310 T/C LOデグチカン-2 T/C OUTLET L..O. PIPE-2 1

139 E288975390 ブラケット BRACKET 1

140 E288975400 ブラケット BRACKET 2
141 E288975410 T/C LOデグチカン-3 T/C OUTLET L..O. PIPE-3 1
142 E288975420 T/C LOデグチカン-4 T/C OUTLET L..O. PIPE-4 1

501 Z541203044AZ パッキン GASKET 2

502 X200010028ZZ ボルト BOLT 4
505 Z501302200AZ JISパッキン JIS GASKET 3
625 Z541105080AZ パッキン GASKET 1
741 Z501305000AZ JISパッキン JIS GASKET 1

743 X200016042ZZ ボルト BOLT 2

748 Z300010000ZZ ヒラザガネ FLAT WASHER 4
749 X220010000ZZ ナット NUT 4
753 X200012022ZZ ボルト BOLT 1
754 X200016050ZZ ボルト BOLT 2

755 Z260101500ZZ Uボルト U-BOLT 3

756 Z300010000ZZ ヒラザガネ FLAT WASHER 6
757 X220010000ZZ ナット NUT 6
758 Z260104000ZZ Uボルト U-BOLT 2
759 Z541206065AZ パッキン GASKET 3

A C 6･8DK-28e Z 11-5
CHAPTER
2 過給機潤滑油配管 (後端過給、TPS61)
ITEM TURBOCHARGER LUBLICATING OIL
4.1.3 6･8DK-28e PIPING (REAR T/C,TPS61)

P
809,808 641

175


650
176 807

View " P " 638,637

621

173

172
645
806,805
804
60,505
54
177

174 171 801

803,802 501

A C
6･8DK-28e Z 11-5
 過給機潤滑油配管 (後端過給、TPS61) CHAPTER
2
TURBOCHARGER LUBLICATING OIL ITEM
PIPING (REAR T/C,TPS61) 6･8DK-28e 4.1.3

番号 パーツコード 部品名称 Name of Parts 数量

Number Parts Code Quartity
54 E288975800 LOカン:T/Cデグチ-61R2 L.O. PIPE:T/C OUTLET-61R2 1
60 E288970600 オリフイス ORIFICE 1
171 E288975750 LOカン T/C イリグチ:TPS61-R3 L.O. PIPE:T/C INLET-61R3 1
172 E288975760 LOカン T/C イリグチ:TPS61-R4 L.O. PIPE:T/C INLET-61R4 1
173 E288975770 LOカン T/C デグチ:TPS61-R3 L.O. PIPE:T/C OUTLET-61R3 1

174 E289971600 ブラケツト;T/C LOカン;1 BRACKET 2

175 E289971620 ブラケツト;T/C LOカン;3 BRACKET 1
176 E289971630 ブラケツト;T/C LOカン;4 BRACKET 1
177 E289971640 ブラケツト;T/C LOカン;5 BRACKET 2

501 Z541203044AZ パッキン GASKET 1

505 Z501302200AZ JISパッキン JIS GASKET 2
621 Z501302200AZ JISパッキン JIS GASKET 1
637 X570002000ZZ ロッカクプラグ HEX. PLUG 1
638 Z565001300EE マルパッキン GASKET 1

641 Z541106092AZ パッキン GASKET 1

645 Z501306000AZ JISパッキン JIS GASKET 1
650 Z501305000AZ JISパッキン JIS GASKET 1
801 X200012025ZZ ボルト BOLT 2
802 Z260101500ZZ Uボルト U-BOLT 2

803 X220010000ZZ ナット NUT 4

804 X200016050ZZ ボルト BOLT 2
805 Z260305000ZZ Uボルト U-BOLT 2
806 X220010000ZZ ナット NUT 4
807 X200016050ZZ ボルト BOLT 2

808 Z260101500ZZ Uボルト U-BOLT 2

809 X220010000ZZ ナット NUT 4

A C 6･8DK-28e Z 11-5
 ITEM
CHAPTER
2
(9)6x1/4 90
(8)8 (9)8x1/8 (1)8x1/4 144
Mist Gas 146
637
145 100 98 99 44 43 97 145
58
676 (3)10x3/8
4.2.1 6･8DK-28e

151

6･8DK-28e Z 11-5
B1 TURBO L.O. TANK
CHARGER
149 E
Drain 6x1/8

45 1 2 3 4-6 5or7 6or8 (9)10x1/4 145(JIS)

150 1/4 (9)10x1/4 135,136

11
44

To Gen. 4 H A
P 48
8 121 (1)6x1/8 18 49 230
582,583 145(JIS)
1/4 228
234
239,689
232 145
D 60(JIS) 105
B
160 681
TURBOCHARGER,TPS)

680 682
162 163
165 166
潤滑油配管 (前端過給、TPS)

161 164
to T/C 234

228 Relief

A
LUBLICATING OIL PIPING (FRONT

230
"H"

C
Engine in
 潤滑油配管 (前端過給、TPS) CHAPTER
2
LUBLICATING OIL PIPING (FRONT ITEM
TURBOCHARGER,TPS) 6･8DK-28e 4.2.1
(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
A Fig. 4-3.1.2 ＬＯポンプ L.O. PUMP 1 1
B Fig. 4-3.2 ＬＯクーラ L.O. COOLER 1 1
D Fig. 4-3.4 ＬＯロキ（ジドウギャクセン） L..O. FILTER(AUTOBACK WASH) 1 1
E E292370020 シドウベントリツケプレート FITTING PLATE;S.A. VALVE 1 1

4 E288770040 シユカンデグチ FLANGE;MAIN PIPE OUTLET 1 1

8 A245073490 サ-モセンサ-ザ BLOCK;SENSOR 1 1
11 E288770110 セッシュ:チユウケイ RELAY JOINT 1 1
18 E288770180 LOチユウケイブロツク BLOCK ,L.O.CONNECTING 1 1
43 E288770430 LOカン，ヘツドイリグチ-1 LOカン;ヘツドイリグチ-1 5 7

44 E288770440 LOカン，ヘツドイリグチ-2 LOカン;ヘツドイリグチ-2 5 7

45 E288770450 LOカン，ヘツドイリグチ-3 LOカン;ヘツドイリグチ-3 1 1
48 E288770480 LOカン(1);チユウケイブロツク L.O. PIPE(1); CONNECTING BLOCK 1 1
49 E288770490 LOカン(2);チユウケイブロツク L.O. PIPE(2); CONNECTING BLOCK 1 1
58 E288770580 LOカン:カイテンベン LOカン:カイテンベン 1 1

90 AE02092007 フィルター:Yガタ:YS-10(3/8) フィルター:Yガタ 1 1

97 E288770970 L.O.カン-2，フンシヤポンプ L.O.カン-2;フンシヤポンプ 1 1
98 E288770980 L.O.カン-3，フンシヤポンプ L.O.カン-3;フンシヤポンプ 4 6
99 E28877099A L.O.カン-4，フンシヤポンプ L.O.カン-4;フンシヤポンプ 5 7
100 E288771000 L.O.カン-5，フンシヤポンプ L.O.カン-5;フンシヤポンプ 1 1

121 E288771210 LOカン:T/Cロキイリグチ-RT2 L.O. PIPE;T/C FILTER INLET-RT2 1 1

144 E288771440 LOカン;フンシヤポンプ-6 L.O. PIPE-6; INJECTION PUMP 1 1
145 E288771450 LOカン;フンシヤポンプ-7 L.O. PIPE-7; INJECTION PUMP 1 1
146 AG01546004 チェックベン CHECK VALVE 1 1
149 E288775050 LOカン:カムジクチュウユ　 1 L.O. PIPE;CAMSHAFT OILING-1 1 1

150 E288775070 LOカン:カムジクチュウユ　 2 L.O. PIPE;CAMSHAFT OILING-2 1 1

151 E288775090 ツギボルト BANJO PLUG 1 1
160 AE02077005 キャップ CAP 1 1
161 E294175010 LOチョウアツベン VALVE 1 1
162 C037540050 バネウケ RETAINER;VALVE SPRING 1 1

163 C037540070 ケース:バネ VALVE SPRING CASE 1 1

164 C037570201 バネ SPRING 1 1
165 C037570400 バネ SPRING 1 1
166 C037570450 ガスケツト GASKET 1 1
228 E288775280 ブロック:LOチョウアツベン BLOCK;OIL RELIEF VALVE 1 1

230 E288775300 LOシュカンイリグチ L.O. MAIN INLET PIPE 1 1

A C 6･8DK-28e Z 11-5
CHAPTER
2 潤滑油配管 (前端過給、TPS)
ITEM LUBLICATING OIL PIPING (FRONT
4.2.1 6･8DK-28e TURBOCHARGER,TPS)
(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
232 E288775320 LOロキイリグチカン L.O.FILTER INLET PIPE 1 1
234 E288775340 LOチョウアツベンモドリカン L.O. RELIEF VALVE RETURN PIPE 1 1
236 E288775360 ロキデイリグチ: FILTER IN-OUTLET 2 2
239 E288775390 ブラケット:LOチョウアツベンモドリカン BRACKET 1 1

560 Z560206531ZZ Oリング O-RING 1 1

564 Z560206531ZZ Oリング O-RING 1 1

B1 E289370010 ミストパイプ MIST PIPE 1 1

6･8DK-28e Z 11-5 A C
 CHAPTER

メモ ITEM
2
MEMO 6･8DK-28e

**-** Z **-**
CHAPTER
2 過給機潤滑油配管 (前端過給、TPS)
ITEM TURBOCHARGER LUBLICATING OIL
4.2.2 6･8DK-28e PIPING (FRONT T/C,TPS)

69
148
696
773

T/C MOUNT
160
692 149
771

TURBO
CHARGER
170,783,798,799
690
769 169,791,797,798

158 P
696
147 773
779 165, 782,783,784,785
162
793,792,791,167
150 790.789,786,784,783,157
60,766
C B 168,791,792,793
156,783,784,786,789,790

146
690
A
761 145 164, 781,783,784,785

A C
6･8DK-28e Z 11-5
 過給機潤滑油配管 (前端過給、TPS) CHAPTER
2
TURBOCHARGER LUBLICATING OIL ITEM
PIPING (FRONT T/C,TPS) 6･8DK-28e 4.2.2
(1)････TPS61 (2)････TPS57
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
A Ref.4-3.4.1 LO ロキ 1 1
B Ref.4-3.3 LO チョウアツベン 1 1
C E294175020 LO ロキ ブラケット 1 1

60 E288970600 オリフイス ORIFICE 1 1

69 E288975690 T/C LOデグチカン:57-1 L.O.PIPE;T/C OUTLET -57 1
145 E288975450 T/C LOイリグチカン:-F1 L.O.PIPE;T/C INLET-F1 1 1
146 E288975460 T/C LOイリグチカン:-F2 L.O.PIPE;T/C INLET-F2 1 1
147 E288975470 T/C LOイリグチカン:-F3-61 L.O.PIPE;T/C INLET-F3-61 1

148 E288975480 T/C LOデグチカン:61F-1 L.O.PIPE;T/C OUTLET -61-F1 1

149 E288975490 T/C LOデグチカン:61F-2 L.O.PIPE;T/C OUTLET -61-F2 1
150 E288975500 T/C LOデグチカン:61F-3 L.O.PIPE;T/C OUTLET -61-F3 1
156 E289971650 ブラケツト;T/C LOカン-1 BRACKET;T/C L.O.PIPE-1 1
157 E289971660 ブラケツト;T/C LOカン-1 BRACKET;T/C L.O.PIPE-1 1

158 E288975580 T/C LO イリグチカン:FT-TPS57 L.O.PIPE;T/C INLET-FT-57 1

160 E288975600 T/C LO デグチカン:FT-TPS57 L.O.PIPE;T/C OUTLET-FT-57 1
162 E288975620 T/C LO デグチカン:FT-TPS57 L.O.PIPE;T/C OUTLET-FT-57 1
164 E288975640 ブラケット:T/C イリグチカン:1 BRACKET;T/C L.O.INLET PIPE-1 1 1
165 E288975650 ブラケット:T/C イリグチカン:2 BRACKET;T/C L.O.INLET PIPE-2 1 1

167 E289971500 ブラケット:T/C LOカン:OUT1 BRACKET;T/C L.O.PIPE-OUT-1 1

168 E289971510 ブラケット:T/C LOカン:OUT2 BRACKET;T/C L.O.PIPE-OUT-2 1
169 E289971520 ブラケツト;T/C LOカン:OUT3 BRACKET;T/C L.O.PIPE-OUT-3 2
170 E288975710 ブラケット:T/C LOカン:デグチ BRACKET;T/C L.O.PIPE-OUT 2

690 Z541203044AZ パッキン GASKET 1 2

692 Z541105080AZ パッキン GASKET 1
696 Z501205000AZ JISパッキン JIS GASKET 2
761 Z541207585AZ パッキン GASKET 1 1
766 Z501302200AZ JISパッキン JIS GASKET 2 2

769 Z501202200AZ JISパッキン JIS GASKET 1

771 Z541106092AZ パッキン GASKET 1
773 Z541206065AZ パッキン GASKET 2
779 Z501206000AZ JISパッキン JIS GASKET 1 1
781 Z260102000ZZ Uボルト U-BOLT 1 1

782 Z260101500ZZ Uボルト U-BOLT 1 1

A C 6･8DK-28e Z 11-5
CHAPTER
2 潤滑油冷却器配管
ITEM LUBRICATING OIL PIPING (LUBRI-
4.3 6･8DK-28e CATING OIL COOLER)

543,544 123 552 552

128 603
L.O.OUTLET

3
L.O.INLET

128

528 THERMOSTAT VALVE 506 125 510

530,531 523 121

503
523
604

604

C.W. C.W.

A C
6･8DK-28e Z 11-5
 潤滑油冷却器配管 CHAPTER
2
LUBRICATING OIL PIPING (LUBRI- ITEM
CATING OIL COOLER) 6･8DK-28e 4.3

番号 パーツコード 部品名称 Name of Parts 数量

Number Parts Code Quartity
3 E288870030 サ-マルスイツチザ SEAT;THERMAL SWITCH 1
121 E288875210 LOクーラハイカン L.O. PIPE 2
123 E288875230 LOクーラハイカン:DTVデグチ L.O. PIPE; DTV OUTLET 1
125 E288875250 ブラケット:LOクーラハイカン:DTVデグチ BRACKET ; L.O.PIPE 1
128 E288875280 ブロック:LOクーラデイリグチ BLOCK 2

503 Z541209110AZ パッキン GASKET 1

506 Z541209110AZ パッキン GASKET 2
510 Z541206065AZ パッキン GASKET 2
523 Z541209110AZ パッキン GASKET 2
528 Z541206065AZ パッキン GASKET 2

530 X570004000ZZ ロッカクプラグ HEX. PLUG 1

531 Z565002100EE マルパッキン GASKET 1
543 Z565002700EE マルパッキン GASKET 1
544 X570006000ZZ ロッカクプラグ HEX. PLUG 1
552 Z541209110AZ パッキン GASKET 3

603 Z501309000AZ JISパッキン JIS GASKET 3

604 Z506309000AZ 10Kパッキン JIS10K GASKET 2

A C 6･8DK-28e Z 11-5
 ITEM
CHAPTER
2

10X1/4 8X1/8
4.4 6･8DK-28e

6･8DK-28e Z 11-5
500, 2 5 6
GOVERNOR
10X10X1/4
2 ,500
4
1,500 OIL PUMP GEAR CASE
& GEAR )

7 10X1/4
8X1/4
10X1/4
1/4
6X1/4 LAST
Cyl.

C
c

8
6X1/8 FRAME
from
A BLOCK,L.O.CONNECTING

WITH C.W. PUMP

潤滑油配管 (ＣＷポンプ＆ギヤ注油)

A
C
LUBLICATING OIL PIPING (C.W.PUMP
 潤滑油配管 (ＣＷポンプ＆ギヤ注油) CHAPTER
2
LUBLICATING OIL PIPING (C.W.PUMP ITEM
& GEAR ) 6･8DK-28e 4.4
(1)･･CWポンプ付 WITH C.W. PUMP (2)･CWポンプ無 WITHOUT C.W. PUMP
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
A Ref.4-4.1 CW ポンプ C.W.PUMP 1
C E292370020 SA カイテンベントリツケイタ FITTING PLATE; S.A.ROTARY VALVE 1 1

1 E289770010 トクシユツギボルト SPECIAL BANJO BOLT 1

2 E408700100 LOノズル L.O. NOZZLE 2 2
4 E289770040 LOカン，アイドルギヤ-1 L.O. PIPE; IDLE GEAR-1 1 1
5 E289770050 LOカン，アイドルギヤ-2 L.O. PIPE; IDLE GEAR-2 1 1
6 E289770060 LOカン，ガバナダイ L.O. PIPE; GOVERNOR MOUNT 1 1

7 E289770070 LOカン，ポンプギヤケ-ス L.O. PIPE; PUMP GEAR CASE 1

8 E289770080 LOカン，CWポンプ-1 L.O. PIPE; C.W. PUMP-1 1

500 Z565001700EE マルパッキン GASKET 4 2

A C 6･8DK-28e Z 11-5
 ITEM
CHAPTER
2

AIR VENT AIR VENT

5.1 6･8DK-28e

60 8 60

6･8DK-28e Z 11-5
8
756,755 83 23 1/2 155
20 1 21 66 564 76 19 3/4 165

3/4 C.W. OUTLET

117,573 60
1/2 9
 
555 201 568
B 65

 6 1/4 3/4 1/2 155 1/4 3/4 1/2

8

145 (JIS) C.W. INLET

54
65
17 165
70,71
DRAIN A
165
C.W. INLET Without C.W. Pump
TURBOCHARGER TPS)
冷却水配管 (後端過給、TPS)
COOLING WATER PIPING (REAR

A
C
 冷却水配管 (後端過給、TPS) CHAPTER
2
COOLING WATER PIPING (REAR ITEM
TURBOCHARGER TPS) 6･8DK-28e 5.1
(1)CWP付-6DK (2)CWP付-8DK (3)CWPなし-6DK (4)CWPなし-8DK
With C.W. PUMP-6DK With C.W. PUMP-8DK Without C.W. PUMP-6DK Without C.W. PUMP-8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2) (3) (4)
A Ref.4-4.1 ＣＷポンプ PUMP 1 1
B E285670260 ブロック BLOCK:EXHAUST GAS OUTLET 6 8 6 8

1 E289070010 CWデグチシユカンフランジ(1) FLANGE(1):C.W.OUTLET MAIN PIPE 10 14 10 14

6 E289070060 CWデグチシユカンフランジ(3) FLANGE(3):C.W.OUTLET MAIN PIPE 3 3 3 3
8 Y011110154ZZ タマガタベン FLANGED GLOBE VALVE 2 2 2 2
9 E289070090 CWカン:ブロツク:2 BLOCK-2:C.W.PIPE 1 1 1 1
17 E289070170 CWカン，シユカンイリグチ C.W.PIPE:MAIN INLET 1 1

19 E289070190 CWデグチシユカン-9 C.W.OUTLET MAIN PIPE-9 1 1 1 1

20 E289070200 CWデグチシユカン-1 C.W.OUTLET MAIN PIPE-1 1 1 1 1
21 E289070210 CWデグチシユカン-2 C.W.OUTLET MAIN PIPE-2 5 7 5 7
23 E289070230 CWデグチシユカン-RT C.W.OUTLET MAIN PIPE-RT 1 1 1 1
49 E289070490 CWデグチシユカンフランジ(6) FLANGE(6):C.W.OUTLET MAIN PIPE 1 1 1 1

54 E289070540 CWカン，シユカンイリグチ(2) C.W.PIPE:MAIN INLET(2) 1 1

60 A586500100 CWデグチシユカン-RT C.W.OUTLET MAIN PIPE-RT 1 1
66 E289070660 CWカン:ハイキデグチ-2 C.W.PIPE:EX OUTLET-2 6 8 6 8
70 E289070700 CWカン，ポンプイリグチ C.W.PIPE:PUMP INLET 1 1
71 E289070710 ササエ，CWカン，ポンプイリグチ SUPPOTER:C.W.PIPE PUMP INLET 1 1

76 E289070760 CWカン:ヘツドデグチ:3 C.W.PIPE:CYL..HEAD OUTLET-3 6 8 6 8

83 E289070830 CWデグチカン，エアヌキ-RT C.W.OUTLET PIPE:AIR VENT-RT 1 1 1 1
117 C015200030 オリフイス ORIFICE 1 1 1 1
201 E289075010 オリフィス ORIFICE 6 8 6 8

555 Z560107557ZZ Oリング O-RING 1 1 1 1

564 Z560107557ZZ Oリング O-RING 12 16 12 16
568 Z560104435ZZ Oリング O-RING 6 8 6 8
573 Z560107557ZZ Oリング O-RING 1 1 1 1
755 Z540200044ZZ フランジ FLANGE 1 1 1 1

756 Z541203044AZ パッキン GASKET 1 1 1 1

A C
6･8DK-28e Z 11-5
 ITEM
CHAPTER
2

AIR VENT 60
5.2 6･8DK-28e

6･8DK-28e Z 11-5
18 8 60 508 ,509
87
1/2

3/4

19 76 564

66
21 1
20
130

C.W. OUTLET
9 85 3/4

1/2
B 201 568 555
573,117
6
1 8 1/4 3/4 1/2
155

65 145(JIS)

54
TURBOCHARGER TPS)

70
A
冷却水配管 (前端過給、TPS)

DRAIN
C.W. INLET
165

A
COOLING WATER PIPING (FRONT

C
 冷却水配管 (前端過給、TPS) CHAPTER
2
COOLING WATER PIPING (FRONT ITEM
TURBOCHARGER TPS) 6･8DK-28e 5.2
(1)････6DK (2)･･･8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
A Ref.4-4.1 C.W. ポンプ COOLING WATER PUMP 1 1
B E285670260 ブロック BLOCK 6 8

1 E289070010 CWデグチシユカンフランジ(1) FLANGE(1) 10 14

6 E289070060 CWデグチシユカンフランジ(3) FLANGE(3) 3 3
8 Y011110154ZZ タマガタベン GLOBE VALVE 2 2
9 E289070090 CWカン:ブロツク:2 BLOCK(2); C.W. PIPE 1 1
18 E289070180 CWデグチシユカン-FT C.W. OUTLET MAIN PIPE-FT 1 1

19 E289070190 CWデグチシユカン-9 C.W. OUTLET MAIN PIPE-9 1 1

20 E289070200 CWデグチシユカン-1 C.W. OUTLET MAIN PIPE-1 1 1
21 E289070210 CWデグチシユカン-2 C.W. OUTLET MAIN PIPE-2 5 7
49 E289070490 CWデグチシユカンフランジ(6) FLANGE(6);C.W. OUTLET MAIN PIPE 1 1
54 E289070540 CWカン，シユカンイリグチ(2) C.W. PIPE; MAIN INLET(2) 1 1

66 E289070660 CWカン:ハイキデグチ-2 C.W. PIPE ;EX. OUTLET(2) 6 8

70 E289070700 CWカン，ポンプイリグチ C.W. PIPE; PUMP INLET 1 1
71 E289070710 ササエ，CWカン，ポンプイリグチ BRACKET;C.W. PIPE; PUMP INLET 1 1
76 E289070760 CWカン:ヘツドデグチ:3 C.W. PIPE; CYLINDER HEAD OUTLET 6 8
87 E289070870 CWデグチカン，エアヌキ-FT C.W. OUTLET PIPE;AIR VENT-FT 1 1

117 C015200030 オリフィス ORIFICE 1 1

201 E289075010 オリフィス ORIFICE 6 8

508 Z540200044ZZ フランジ FLANGE 1 1

509 Z541203044AZ パッキン GASKET 1 1
555 Z560107557ZZ Oリング O-RING 1 1
564 Z560107557ZZ Oリング O-RING 12 18
568 Z560104435ZZ Oリング O-RING 6 8

573 Z560107557ZZ Oリング O-RING 1 1

A C 6･8DK-28e Z 11-5
CHAPTER
2 冷却水配管 (空気冷却器)
ITEM COOLING WATER PIPING (INTER-
5.3 6･8DK-28e COOLER)

2
2
10
10 5 5
502
502

C.W. INTER- C.W. INTER-

COOLER OUTLET COOLER OUTLET

C.W. INTER- 502 502 C.W. INTER-

COOLER INLET COOLER INLET

FOR RT FOR FT
WITH FLEXIBLE HOSE

2
2
9
9 4 4

C.W. INTER- C.W. INTER-

COOLER OUTLET COOLER OUTLET

C.W. INTER- 165 165 C.W. INTER-

COOLER INLET COOLER INLET

FOR RT FOR FT
WITHOUT FLEXIBLE HOSE

A C
6･8DK-28e Z 11-5
 冷却水配管 (空気冷却器) CHAPTER
2
COOLING WATER PIPING (INTER- ITEM
COOLER) 6･8DK-28e 5.3
(1)･･フレックスホース付　 WITH FLEX.HOSE (2)･フレックスホースなし　 WITHOUT FLEX.HOSE
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)
2 C062000015Z バタフライベン-L-100A BUTTERFLY VALVE-L-100A 2 2
4 E289170040Z CWカン:I/Cイリグチ-SW1 C.W.PIPE:I/C INLET-SW1 1
5 E289170050Z CWカン:I/Cイリグチ-SW2 C.W.PIPE:I/C INLET-SW2 1
9 E289170090Z CWカン:I/Cデグチ-SW1 C.W.PIPE:I/C OUTLET-SW1 1
10 E289170100Z CWカン:I/Cデグチ-SW2 C.W.PIPE:I/C OUTLET-SW2 1

502 Z599040165ZZ フレックスマスター FLEX MASTER 2

A C 6･8DK-28e Z 11-5
CHAPTER

ITEM
2 燃料漏油戻し配管
6 6･8DK-28e FUEL OIL PIPING (LEAK OIL RETURN)

5
(9)15X3/8
(9)15X3/8
38
58

57

6･8DK-28e Z 11-5 C
 CHAPTER

燃料漏油戻し配管 ITEM
2

FUEL OIL PIPING (LEAK OIL RETURN) 6･8DK-28e 6

(1)････6DK (2)････8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2)

3 3

$# ! "#$#   !  

! 
 
!
  
$" ! "#$"   
!  

C 6･8DK-28e Z 11-5
 F.O. FILTER

ITEM
A503,A5
CHAPTER

T
2
F.O. INLET
TURBOCHARGER

B501,B2

.
B6 B501,B4
T
7 6･8DK-28e

6･8DK-28e Z 11-5
C.W. OUTLET
温度計

TURBOCHARGER

B2,B501
B5,B501 B6
T
T
THERMOMETER

C.W. OUTLET
FOR NOZZLE COOLING

C
INLET
 CHAPTER

温度計 ITEM
2
THERMOMETER 6･8DK-28e 7
(1)･後 T/C-6DK (2)･後 T/C-8DK (3)･前 T/C-6DK (4)･前 T/C-8DK
ARANGE,RT-6DK ARANGE,RT-8DK ARANGE,FT-6DK ARANGE,FT-8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2) (3) (4)
A1 Y241004000 オンドケイ　 １００Ｃ　 ｘ　 １／２－Ｌ THERMOMETER 100Cx1/2L 2 2 2 2
A2 Y231004000 オンドケイ　 1００Ｃ　 ｘ　 １／２Ｐ THERMOMETER 100CX1/2P 5 5 5 5
A5 Y282004110 オンドケイ　 2００Ｃ　 ｘ　 １／２ THERMOMETER 200Cx1/2 1 1 1 1

A503 Z565002100EE マルパッキン GASKET 8 8 8 8

B2 Y265204180 オンドケイ　 ５２０Ｃ THERMOMETER 520C 1 1 1 1

B4 Y236204180 オンドケイ　 ６２０Ｃ THERMOMETER 620C 2 2
B5 Y266204180 オンドケイ　 ６２０Ｃ THERMOMETER 620C 1 1
B6 Y265204320 オンドケイ　 ５２０Ｃ THERMOMETER 520C 6 8 6 8

B501 Z565002100ZZ マルパッキン GASKET 9 11 8 10

C 6･8DK-28e Z 11-5
CHAPTER

ITEM
2 ノズル冷却水配管
8 6･8DK-28e NOZZLE COOLING WATER PIPING

C
6･8DK-28e Z 11-5
 CHAPTER

ノズル冷却水配管 ITEM
2
NOZZLE COOLING WATER PIPING 6･8DK-28e 8
(1)･後 T/C-6DK (2)･後 T/C-8DK (3)･前 T/C-6DK (4)･前 T/C-8DK
ARANGE,RT-6DK ARANGE,RT-8DK ARANGE,FT-6DK ARANGE,FT-8DK
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2) (3) (4)
1 E289570010 ブロツク BLOCK 1 1 1 1
3 E289570030 オリフイス ORIFICE 1 1 1 1
4 E289570040 ブロツク BLOCK 1 1 1 1
46 E289570460 レイキヤクイリグチシユカン-6D NOZZLE; C.W. INLET MAIN PIPE-6D 1 1
47 E289570470 レイキヤクイリグチシユカン-8D NOZZLE; C.W. INLET MAIN PIPE-8D 1 1

49 E289570490 レイキヤクエダカン，イリグチ NOZZLE; C.W.F.W.BRANCH PIPE 6 8 6 8

50 E289570500 レイキヤクエダカン，デグチ NOZZLE; C.W.BRANCH PIPE 6 8 6 8
52 E289570520 レイキヤクデグチシユカン-6D NOZZLE; C.W.OUTLET MAIN PIPE-6D 1 1
53 E289570530 レイキヤクデグチシユカン-8D NOZZLE; C.W.OUTLET MAIN PIPE-8D 1 1
55 E289570550 レイキヤクデグチカン-1 NOZZLE; C.W.OUTLET PIPE-1 1 1

60 E289570600 1/2 ボ-ルバルブ BALL VALVE 2 2 2 2

61 E289570610 レイキヤクカン NOZZLE; C.W. PIPE 2 2 2 2
62 E289570620 レイキヤクイリグチカン NOZZLE; C.W. INLET PIPE 1 1 1 1
63 E289570630 レイキヤクデグチカン NOZZLE; C.W. OUTLET PIPE 1 1 1 1
66 E289575040 ノズルレイキャクカンイリグチ:FT-1 NOZZLE; C.W. INLET PIPE-FT-1 1 1 1 1

67 E289575030 ノズルレイキャクカンイリグチ:FT-2 NOZZLE; C.W. INLET PIPE-FT-2 1 1 1 1

68 E289570680 レイキヤクデグチカン-FT-1 NOZZLE; C.W. OUTLET PIPE-FT-1 1 1

C
6･8DK-28e Z 11-5
CHAPTER
3 架構(主機関用）
ITEM
1.1 6･8DK-28e ENGINE FRAME(FOR PLOPULSION USE)

1
2
3 3

523
512 10,3
509
27,26
523
512
511
570
523
512

530 102
529
B 3

B508 B11
B510 B507
B503
B502 571

B501 B503
B501

B510

B500 B500
B500 B10 B503,B509
Front View

A C
6･8DK-28e Z 11-5
 CHAPTER
架構(主機関用） 3
ITEM
ENGINE FRAME(FOR PLOPULSION USE) 6･8DK-28e 1.1
(1)････6DK (2)････8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
901 カコウ　 ＡＳＳＹ：ＢＴツキ６ＤＫ ENG. FRAME ASSY. WITH BT-6DK 1
902 カコウ　 ＡＳＳＹ：ＢＴツキ８ＤＫ ENG. FRAME ASSY. WITH BT-8DK 1
903 アブラキリフタ　 ＡＳＳＹ OIL CUT COVER ASSY. 1 1

3 E280270030 カコウ:P-6CYL ENG.FRAME-P-6CYL 1

6 E280270060 メインメタルキヤツプ(キジユン) MAIN METAL CAP(REAR) 1* 1*
7 E280270070 メインメタルキヤツプ MAIN METAL CAP 6* 8*
10 E280270100 カコウ:P-8CYL. ENG.FRAME-P-8CYL. 1
14 E280270140 ボルト:シリンダヘツド BOLT 24 32

16 E280270160 メタルキヤツプボルト METAL CAP BOLT 14 18

17 E280270170 サイドボルト SIDE BOLT 14 18
18 E325270070 マルナツト CIRCULAR NUT 14 18
19 E325670200 マルナツト CIRCULAR NUT 14 18
24 E280270240 トクシユスタツド SPECIAL STUD 24 32

26 E280270251F フタ:アブラキリ:1 COVER-1 1 1

27 E280270252F フタ:アブラキリ:2 COVER-2 1 1
30 E280270300 キヤツプ CAP 14 18
46 E280270460 キユウキベンドシ-ル SEAL 6 8
102 E280275030 ロッカクプラグ HEX. PLUG 6 8

505 X210012050ZZ スタッド STUD 16 16

506 X341010030ZZ ノックボルトASSY KNOCK BOLT ASSY. 2 2
508 X200012028ZZ ボルト BOLT 18 18
509 X200012060ZZ ボルト BOLT 2 2
510 X200012050ZZ ボルト BOLT 12 12

511 X200012150ZZ ボルト BOLT 1 1

512 X220012000ZZ ナット NUT 4 4
513 X341010030ZZ ノックボルトASSY KNOCK BOLT ASSY. 1 1
519 X210012050ZZ スタッド STUD 8 12
521 X210016072ZZ スタッド STUD 48 64

522 X210012054ZZ スタッド STUD 18 24

523 Z315012000ZZ ハツキザガネ WASHER 38 38
525 X210012043ZZ スタッド STUD 5 5
528 X210012063ZZ スタッド STUD 9 9
529 X570003000ZZ ロッカクプラグ HEX. PLUG 1 1

530 Z565001700EE マルパッキン GASKET 1 1

A C
6･8DK-28e Z 11-5
CHAPTER
3 架構(主機関用）
ITEM
1.1 6･8DK-28e ENGINE FRAME(FOR PLOPULSION USE)
(1)････6DK (2)････8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
532 Z571506000ZZ テーパプラグ TAPER PLUG 6 8
534 Z336010025ZZ ダンツキピン STEPPED PIN 6 8
536 X213027210ZZ オシボルト JACK BOLT 6 8
543 Z565002700EE マルパッキン GASKET 6 8

545 X200012028ZZ ボルト BOLT 4 4

546 Z540200065ZZ フランジ FLANGE 1 1
547 Z541206065AZ パッキン GASKET 1 1
565 Z560104235ZZ Oリング O-RING 24 32
570 X345114035ZZ リーマボルト REAMER BOLT 1 1

571 Z571503000ZZ テーパプラグ TAPER PLUG 1 1

B10 E283170091 カバー:ホキギヤ:ブンカツーシタ COVER 1 1

B11 E283170092 カバー:ホキギヤ:ブンカツーウエ COVER 1 1

B500 X200012045ZZ ボルト BOLT 11 11

B501 X200012045ZZ ボルト BOLT 4 4
B502 X345114025ZZ リーマボルト REAMER BOLT 2 2
B503 X220012000ZZ ナット NUT 22 22
B508 X210012043ZZ スタッド STUD 5 5

B509 X210012078ZZ スタッド STUD 1 1

B510 X210012093ZZ スタッド STUD 4 4

注 記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3 架構(補機関用）
ITEM
1.2 6･8DK-28e ENGINE FRAME(FOR GENERATOR USE)

4
5
6 6

523
512
509
87,86
523
512
511
570
523
512
100
563

62

530 102
529
5
B 3
8
B508 B20
B510 B507

571

B501

B510

B504
B500 506 B503,B509
Front View 101,564

Front View

A C
6･8DK-28e Z 11-5
 CHAPTER
架構(補機関用） 3
ITEM
ENGINE FRAME(FOR GENERATOR USE) 6･8DK-28e 1.2
(1)････6DK (2)････8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
904 カコウ　 ＡＳＳＹ：ＢＴツキ６ＤＫ ENG. FRAME ASSY. WITH BT-6DK 1
905 カコウ　 ＡＳＳＹ：ＢＴツキ８ＤＫ ENG. FRAME ASSY. WITH BT-8DK 1
906 アブラキリフタ　 ＡＳＳＹ OIL CUT COVER ASSY. 1 1

6 E280270060 メインメタルキヤツプ(キジユン) MAIN METAL CAP(REAR) 1* 1*

7 E280270070 メインメタルキヤツプ MAIN METAL CAP 6* 8*
14 E280270140 ボルト:シリンダヘツド BOLT 24 32
16 E280270160 メタルキヤツプボルト METAL CAP BOLT 14 18
17 E280270170 サイドボルト SIDE BOLT 14 18

18 E325270070 マルナツト CIRCULAR NUT 14 18

19 E325670200 マルナツト CIRCULAR NUT 14 18
24 E280270240 トクシユスタツド SPECIAL STUD 24 32
30 E280270300 キヤツプ CAP 14 18
46 E280270460 キユウキベンドシ-ル SEAL 6 8

54 E280270540 カコウ:A-6CYL. ENG.FRAME-A-6CYL. 1

60 E280270600 カコウ:A-8CYL. ENG.FRAME-A-8CYL. 1
86 E280270851B フタ:アブラキリ:コモンベッド-1 COVER-1 1 1
87 E280270852B フタ:アブラキリ:コモンベッド-2 COVER-2 1 1
100 E280271000 HTボルト HT BOLT 2 2

101 E328750311 シ-ルワツシヤ SEAL WASHER 4 4

102 E280275030 ロッカクプラグ HEX. PLUG 6 8

505 X210012050ZZ スタッド STUD 16 16

506 X341010030ZZ ノックボルトASSY KNOCK BOLT ASSY. 2 2
508 X200012028ZZ ボルト BOLT 18 18
509 X200012060ZZ ボルト BOLT 2 2
511 X200012150ZZ ボルト BOLT 1 1

512 X220012000ZZ ナット NUT 4 4

513 X341010030ZZ ノックボルトASSY KNOCK BOLT ASSY. 1 1
519 X210012050ZZ スタッド STUD 8 12
521 X210016072ZZ スタッド STUD 48 64
522 X210012054ZZ スタッド STUD 18 24

523 Z315012000ZZ ハツキザガネ WASHER 38 38

525 X210012043ZZ スタッド STUD 5 5
528 X210012063ZZ スタッド STUD 9 9
529 X570003000ZZ ロッカクプラグ HEX. PLUG 1 1

A C
6･8DK-28e Z 11-5
CHAPTER
3 架構(補機関用）
ITEM
1.2 6･8DK-28e ENGINE FRAME(FOR GENERATOR USE)
(1)････6DK (2)････8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
530 Z565001700EE マルパッキン GASKET 1 1

532 Z571506000ZZ テーパプラグ TAPER PIN 6 8

534 Z336010025ZZ ダンツキピン STEPPED PIN 6 8
536 X213027210ZZ オシボルト JACK BOLT 6 8
540 X205030200ZZ HTボルト HT BOLT 18 22
541 X341016050ZZ ノックボルトASSY KNOCK BOLT ASSY. 2 2

543 Z565002700EE マルパッキン GASKET 6 8

545 X200012028ZZ ボルト BOLT 4 4
546 Z540200065ZZ フランジ FLANGE 1 1
547 Z541206065AZ パッキン GASKET 1 1
562 X200012055ZZ ボルト BOLT 12 12

563 X200012140ZZ ボルト BOLT 2 2

564 X205022060ZZ HTボルト HT BOLT 4 4
565 Z560104235ZZ Oリング O-RING 24 32
570 X345114035ZZ リーマボルト REAMER BOLT 1 1
571 Z571503000ZZ テーパプラグ TAPER PLUG 1 1

B20 E283170200 カバー:ホキギヤ:イツタイ COVER 1 1

B503 X220012000ZZ ナット NUT 16 16

B504 X200012050ZZ ボルト BOLT 15 15
B505 X570010000ZZ ロッカクプラグ HEX. PLUG 1 1
B506 Z565003400EE マルパッキン GASKET 1 1
B507 X210012046ZZ スタッド STUD 8 8

B508 X210012043ZZ スタッド STUD 5 5

B509 X210012078ZZ スタッド STUD 1 1
B510 X210012093ZZ スタッド STUD 4 4

注 記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3 架構側蓋、盲蓋
ITEM
2 6･8DK-28e ENGINE SIDE COVER &BLIND COVER

A3,A2
A12

A C
6･8DK-28e Z 11-5
 CHAPTER
架構側蓋、盲蓋 3
ITEM
ENGINE SIDE COVER &BLIND COVER 6･8DK-28e 2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
A2 E280370020 フタ SIDE COVER 1 1
A3 E280375020 フタ SIDE COVER 1 1
A4 E280370040 カバー SIDE COVER 2 3 2 3
A5 E280370050 カバー SIDE COVER 10 13 10 13
A9 E280370090 Oリング O-RING 12 16 12 16

A11 E280370110 カムジクソクフタ SIDE COVER 3 4 3 4

A12 E280370120 タイミングギヤソクフタパツキン GASKET 1 1 1 1
A13 E280370130 タイミングギヤソクフタパツキン-2 GASKET 1 1 1 1
A14 AE01003009 ナット FLANGE NUT 18 24 18 24
A15 AE02003004 ナット FLANGE NUT 48 64 48 64

A23 E280370230 Oリング O-RING 3 4 3 4

A500 X220012000ZZ ナット NUT 9 9 9 9

A501 X200012065ZZ ボルト BOLT 6 6 6 6

B1 E280470010 キユウキダクトフタ-F COVER-F 1 1

B2 E280470020 キユウキダクトパツキン-F GASKET-F 1 1
B3 E280470030 キユウキダクトフタ-R COVER-R 1 1
B4 E280470040 キユウキダクトパツキン-R GASKET-R 1 1
B6 E280470060 メクラフタ-3 BLANK COVER-3 6 8 6 8

B7 E280470070 メクラフタパツキン-2 GASKET-2 6 8 6 8

B8 AE02002019 カバー:キュウキ:1 COVER-1 3 4 2 3
B9 E280470090 メクラフタ-7 BLANK COVER-7 1 1
B10 AE02002020 ガスケット:キュウキ:1 GASKET-1 3 4 3 4

B500 X200022035ZZ ボルト BOLT 12 12 12 12

B502 X200012025ZZ ボルト BOLT 36 48 36 48
B504 X200012025ZZ ボルト BOLT 24 32 24 32
B506 Z540200065ZZ フランジ FLANGE 1 1 2 2
B507 Z541206065AZ パッキン GASKET 1 1 2 2

B508 X200012020ZZ ボルト BOLT 4 4 8 8

B510 Z508090000ZZ JISフランジトク FLANGE 1 1
B511 Z501209000AZ JISパッキン GASKET 1 1
B512 X200016030ZZ ボルト BOLT 4 4

A C
6･8DK-28e Z 11-5
CHAPTER
3 架構安全弁（ＥＶＡ）
ITEM
3 6･8DK-28e ENGINE FRAME SAFETY VALVE (EVA)

5 9 8

505 12

501

502

506

A C
6･8DK-28e Z 11-5
 CHAPTER
架構安全弁（ＥＶＡ） 3
ITEM
ENGINE FRAME SAFETY VALVE (EVA) 6･8DK-28e 3
(1)･･･6DK (2)･･･8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
5 AE02075001 アンゼンベン-EVA SAFETY VALVE-EVA 4 5
8 A598100080 トリツケイタ SETTING PLATE 4 5
9 AE02075002 ガスケット GASKET 4 5
12 A598100120 ガスケット GASKET 4 5

501 X200010060ZZ ボルト BOLT 24 30

502 X200008025ZZ ボルト BOLT 24 30
505 Z310010000ZZ バネザガネ SPRING WASHER 24 30
506 Z300008000ZZ ヒラザガネ FLAT WASHER 24 30

A C
6･8DK-28e Z 11-5
CHAPTER
3 油受
ITEM
4 6･8DK-28e OIL PAN

A C
6･8DK-28e Z 11-5
 CHAPTER
油受 3
ITEM
OIL PAN 6･8DK-28e 4

A C
6･8DK-28e Z 11-5
CHAPTER
3 クランク軸, バランスウエイト,フライホイル& 主軸受
ITEM CRANKSHAFT, BALANCE WEIGHT,FLY-
5 6･8DK-28e WHEEL& MAINBEARING

A C
6･8DK-28e Z 11-5
 CHAPTER
クランク軸, バランスウエイト,フライホイル& 主軸受 3
CRANKSHAFT, BALANCE WEIGHT,FLY- ITEM

WHEEL& MAINBEARING 6･8DK-28e 5

(1)･･･6DK (2)･･･6DKM (3)･･･8DK (4)･･･8DKM

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3) (4)
901 クランクジクＡＳＳＹ－６ＤＫ CRANKSHAFT ASSY. -6DK 1
902 クランクジクＡＳＳＹ－6ＤＫM CRANKSHAFT ASSY. -6DKM 1
903 クランクジクＡＳＳＹ－8ＤＫ CRANKSHAFT ASSY. -8DK 1
904 クランクジクＡＳＳＹ－8ＤＫM CRANKSHAFT ASSY. -8DKM 1

A3 E280670030 クランクギヤ CRANKSHAFT GEAR 1 1 1 1

A8 E280670080 クランクジク －６Ｄ CRANKSHAFT -6D 1 1
A9 E280670090 クランクジク －８Ｄ CRANKSHAFT -8D 1 1
A13 E280670130 トメネジ SET SCREW 6 6 6 6
A21 E280670210 クランクジクアブラキリ－Ｒ CRANKSHAFT -R 1 1 1 1

A22 E280670220 クランクジクアブラキリ－Ｌ CRANKSHAFT -L (1) (1) (1) (1)

A502 X200012020 ボルト BOLT 10 10 10 10

B2 E280870020 バランスウエイトボルト BALANCE WEGHT BOLT 24 24 32 32

B5 E280870050 バランスウエイト BALANCE WEGHT 12
B7 E280870070 バランスウエイト BALANCE WEGHT 16 16
B8 E280870080 バランスウエイト BALANCE WEGHT 12
B12 E280870120 ダンツキピン PINE 12 12 16 16

C1 E28097 フライホイール FJYWHEEL 1 1 1 1

C6 E280970060 フライホイールリーマボルト REAMER BOLT; FLYWHEEL 8 8 8 8
C8 E280970080 フライホイールシシン TIMING POINTER 1 1 1 1
C12 E260985020 フライホイールナット NUT; FLYWHEEL 16 16 16 16

C501 X200012038 ボルト BOLTL 2 2 2 2

C503 X320006070 ワリピン SPLIT PIN 16 16 16 16

D1 E280770010 メインメタル MAIN BEARING SHELL 7 7 9 9

D5 E280770050 スラストメタル THRUST BEARING 2 2 2 2

D501 Z335008020ZZ ヘイコウピン STRAIGHT PIN 4 4 4 4

A C
6･8DK-28e Z 11-5
CHAPTER
3 アイドルギヤ
ITEM
6 6･8DK-28e IDLE GEAR

10

A C
6･8DK-28e Z 11-5
 CHAPTER
アイドルギヤ 3
ITEM
IDLE GEAR 6･8DK-28e 6

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 アイドルギヤ　 ASSY IDLE GEAR ASSY. 1

1 E283570010 アイドルギヤジクオサエ SUPPORTER 1

3 E283570030 アイドルギヤブシュ IDLE GEAR BUSH 1
4 E283570040 アイドルギヤジク IDLE GEAR SHAFT 1
7 E283570070 アイドルギヤ（１） IDLE GEAR (1) 1
8 E283570080 アイドルギヤ（２） IDLE GEAR (2) 1

10 AE02036009 ボルト BOLT 6

12 E283570120 トクシュボルト SPECIAL BOLT 6

500 X200112024ZZ ボルト BOLT 6

501 Z336012030ZZ ダンツキピン STEPPED PIN 2
502 Z336016040ZZ ダンツキピン STEPPED PIN 1
507 Z560103035ZZ Oリング O-RING 1

A C
6･8DK-28e Z 11-5
CHAPTER
3 カム軸 , カム軸受(8DK)
ITEM
7.1 6･8DK-28e CAM SHAFT , CAM SHAFT BEARING(8DK)

901
902
903

A156 A2
A180
A185

A50

A502
A510

A153
A177
A155,A154 A182
A179,A178
A184,A183

A C
6･8DK-28e Z 11-5
 CHAPTER
カム軸 , カム軸受(8DK) 3
ITEM
CAM SHAFT , CAM SHAFT BEARING(8DK) 6･8DK-28e 7.1
(1)･･8DK-28 (2)･･8DKM-28 (3)･･8DKM-28L

号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3)
901 カムジクASSY8e:110 CAMSHAFT ASSY 8e-110 1
902 カムジクASSY8e:125 CAMSHAFT ASSY 8e-125 1
903 カムジクASSY8eL:125 CAMSHAFT ASSY 8eL-125 1

A2 E281170020 Uナツト U-NUT 72 72 72

A4 E281170040 カムギヤ CAMSHAFT GEAR 1 1 1
A9 E281170090 ジク:カムギヤ SHAFT:CAMGEAR 1 1 1
A25 E281170250 トクシユボルト SPECIAL BOLT 12 12 12
A27 E281170270 カムジクボルト CAMSHAFT BOLT 36 36 36

A28 E281170280 トクシユヒラザガネ SPECIAL FLAT WASHER 12 12 12

A34 E281170340 カムジクスラストウケ THRUST RETAINER 1 1 1
A35 AE02011060 ジョイント:カイテンベン COUPLING 1 1 1
A37 E281170370 シム SHIM 1 1 1
A38 E281170380 シム-2 SHIM-2 1 1 1

A50 AE02011085 ヘイコウピン STRAIGHT PIN 4 4 4

A153 E281175530 カムジク:8e1-110 CAMSHAFT:8e1-110 1
A154 E281175540 カムジク:8e2-110 CAMSHAFT:8e2-110 1
A155 E281175550 カムジク:8e3-110 CAMSHAFT:8e3-110 1
A156 E281175560 カムジク:8e4-110 CAMSHAFT:8e4-110 1

A177 E281175770 カムジク:8e1-125 CAMSHAFT:8e1-125 1

A178 E281175780 カムジク:8e2-125 CAMSHAFT:8e2-125 1
A179 E281175790 カムジク:8e3-125 CAMSHAFT:8e3-125 1
A180 E281175800 カムジク:8e4-125 CAMSHAFT:8e4-125 1
A182 E281175820 カムジク:8eL1-125 CAMSHAFT:8eL1-125 1

A183 E281175830 カムジク:8eL2-125 CAMSHAFT:8eL2-125 1

A184 E281175840 カムジク:8eL3-125 CAMSHAFT:8eL3-125 1
A185 E281175850 カムジク:8eL4-125 CAMSHAFT:8eL4-125 1

A501 X205010030ZZ HTボルト HT BOLT 4 4 4

A502 X200112025ZZ ボルト BOLT 6 6 6
A505 Z335608016ZZ ヘイコウピン STRAIGHT PIN 1 1 1
A508 Z321012100DZ ハリガネ WIRE 1 1 1
A510 Z321012050DZ ハリガネ WIRE 1 1 1

B1 E281270010 カムジクウケ CAMSHAFT BEARING SHELL 8 8 8

B2 E281270020 カムジクメタル（２） CAMSHAFT BEARING SHELL(2) 1 1 1
B3 E281270030 カムジクメタル（３） CAMSHAFT BEARING SHELL(3) 1 1 1

A C
6･8DK-28e Z 11-5
CHAPTER
3 カム軸 , カム軸受(8DK)
ITEM
7.1 6･8DK-28e CAM SHAFT , CAM SHAFT BEARING(8DK)
(1)･･8DK-28 (2)･･8DKM-28 (3)･･8DKM-28L

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3)
B8 AE02012007 スラストメタル THRUST BEARING 2 2 2
B10 E281270100 カムジクウケ（２） CAMSHAFT BEARING 1 1 1

B12 E281270120 カムジクウケフタ CASE 1 1 1

B15 E281270150 カムジクウケパッキン GASKET 2 2 2
B17 AE01045005 フレキトリツケフターＦＣＤ HOLDER 1 1 1
B18 AE01045014 ポンプタイパッキン GASKET 1 1 1

B500 X200012050ZZ ボルト BOLT 6 6 6

B501 X200008018ZZ ボルト BOLT 2 2 2
B504 Z335608016ZZ ヘイコウピン STRAIGHT PIN 4 4 4
B505 Z336008025ZZ ダンツキピン STEPPED PIN 2 2 2

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3 カム軸 , カム軸受(6DK)
ITEM
7.2 6･8DK-28e CAM SHAFT , CAM SHAFT BEARING(6DK)

906
906
907
907
908
908

A142
A142 A2
A2
A171
A171
A175
A175
A50
A50

A502
A502
A510
A510

A140
A140
A169
A169
A141
A141 A173
A173
A170
A170
A174
A174

A C
6･8DK-28e Z 11-5
 CHAPTER
カム軸 , カム軸受(6DK) 3
ITEM
CAM SHAFT , CAM SHAFT BEARING(6DK) 6･8DK-28e 7.2
(1)･･6DK-28 (2)･･6DKM-28 (3)･･6DKM-28L

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3)
906 カムジクASSY6e:110 CAMSHAFT ASSY 6e-110 1
907 カムジクASSY6e:125 CAMSHAFT ASSY 6e-125 1
908 カムジクASSY6eL:125 CAMSHAFT ASSY 6eL-125 1

A2 E281170020 Uナツト U-NUT 48 48 48

A4 E281170040 カムギヤ CAMSHAFT GEAR 1 1 1
A9 E281170090 ジク:カムギヤ SHAFT:CAMGEAR 1 1 1
A25 E281170250 トクシユボルト SPECIAL BOLT 12 12 12
A27 E281170270 カムジクボルト CAMSHAFT BOLT 24 24 24

A28 E281170280 トクシユヒラザガネ SPECIAL FLAT WASHER 12 12 12

A34 E281170340 カムジクスラストウケ THRUST RETAINER 1 1 1
A35 AE02011060 ジョイント:カイテンベン COUPLING 1 1 1
A37 E281170370 シム SHIM 1 1 1
A38 E281170380 シム-2 SHIM-2 1 1 1

A50 AE02011085 ヘイコウピン STRAIGHT PIN 3 3 3

A140 E281175400 カムジク:6e1-110 CAMSHAFT:6e1-110 1
A141 E281175410 カムジク:6e2-110 CAMSHAFT:6e2-110 1
A142 E281175420 カムジク:6e3-110 CAMSHAFT:6e3-110 1
A169 E281175690 カムジク:6e1-125 CAMSHAFT:6e1-125 1

A170 E281175700 カムジク:6e2-125 CAMSHAFT:6e2-125 1

A171 E281175710 カムジク:6e3-125 CAMSHAFT:6e3-125 1
A173 E281175730 カムジク:6eL1-125 CAMSHAFT:6eL1-125 1
A174 E281175740 カムジク:6eL2-125 CAMSHAFT:6eL2-125 1
A175 E281175750 カムジク:6eL3-125 CAMSHAFT:6eL3-125 1

A501 X205010030ZZ HTボルト HT BOLT 4 4 4

A502 X200112025ZZ ボルト BOLT 6 6 6
A505 Z335608016ZZ ヘイコウピン STRAIGHT PIN 1 1 1
A508 Z321012100DZ ハリガネ WIRE 1 1 1
A510 Z321012050DZ ハリガネ WIRE 1 1 1

B1 E281270010 カムジクウケ CAMSHAFT BEARING SHELL 6 6 6

B2 E281270020 カムジクメタル（２） CAMSHAFT BEARING SHELL(2) 1 1 1
B3 E281270030 カムジクメタル（３） CAMSHAFT BEARING SHELL(3) 1 1 1
B8 AE02012007 スラストメタル THRUST BEARING 2 2 2
B10 E281270100 カムジクウケ（２） CAMSHAFT BEARING 1 1 1

A C
6･8DK-28e Z 11-5
CHAPTER
3 カム軸 , カム軸受(6DK)
ITEM
7.2 6･8DK-28e CAM SHAFT , CAM SHAFT BEARING(6DK)
(1)･･6DK-28 (2)･･6DKM-28 (3)･･6DKM-28L

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3)
B12 E281270120 カムジクウケフタ CASE 1 1 1
B15 E281270150 カムジクウケパッキン GASKET 2 2 2
B17 AE01045005 フレキトリツケフターＦＣＤ HOLDER 1 1 1
B18 AE01045014 ポンプタイパッキン GASKET 1 1 1

B500 X200012050ZZ ボルト BOLT 6 6 6

B501 X200008018ZZ ボルト BOLT 2 2 2
B504 Z335608016ZZ ヘイコウピン STRAIGHT PIN 4 4 4
B505 Z336008025ZZ ダンツキピン STEPPED PIN 2 2 2

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3 補機駆動ギヤケース
ITEM
8 6･8DK-28e AUXILIARY DRIVING GEAR CASE

A C
6･8DK-28e Z 11-5
 CHAPTER
補機駆動ギヤケース 3
ITEM
AUXILIARY DRIVING GEAR CASE 6･8DK-28e 8

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

A C
6･8DK-28e Z 11-5
CHAPTER
3 起動回転弁
ITEM
9 6･8DK-28e STARTING AIR ROTARY VALVE

A C
6･8DK-28e Z 11-5
 CHAPTER
起動回転弁 3
ITEM
STARTING AIR ROTARY VALVE 6･8DK-28e 9
(1)･･6DK-28 (2)･･6DK-28L (3)･･8DK-28 (4)･･8DK-28L

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3) (4)
1 AE02013010 タイ:カイテンベン:6D ROTARY VALVE BODY-8D 1 1
2 AE02013002 タイ:カイテンベン:8D ROTARY VALVE BODY-8D 1 1
5 AE02013003 カバー:カイテンベン COVER 1 1 1 1
8 AE02013006 カイテンベン ROTARY VALVE 1 1
9 E321370090 キドウカイテンベン-2 ROTARY VALVE -2 1 1

11 AE02013007 シム:カイテンベン SHIM 1 1 1 1

12 E281370120 カイテンベンダイ MOUNT 1 1 1 1
14 E281375010 ブッシュ:カイテンベン BUSH 1 1 1 1
15 AE02013008 ガスケット:カイテンベンタイ GASKET 2 2 2 2
18 AE02013004 ジョイント:カイテンベン COUPLING 1 1 1 1

20 E281370200 カイテンベンダイパツキン GASKET 1 1 1 1

501 X200012035ZZ ボルト BOLT 6 6 6 6

503 X220012000ZZ ナット NUT 7 7 7 7
509 Z565001300EE マルパッキン GASKET 2 2 2 2
510 X570002000ZZ ロッカクプラグ HEX. PLUG 2 2 2 2
513 Z565008500ZZ マルパッキン GASKET 1 1 1 1

517 Z336008025ZZ ダンツキピン STEPPED PIN 3 3 3 3

A C
6･8DK-28e Z 11-5
CHAPTER
3 コモンロッド
ITEM
10 6･8DK-28e COMMON ROD

A C
6･8DK-28e Z 11-5
 CHAPTER
コモンロッド 3
ITEM
COMMON ROD 6･8DK-28e 10
(1)････6DK (2)････8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
2 E281670020 コモンロツドジクウケ(1) CONTROL ROD BEARING (1) 2 3
3 E321670030 コモンロツドジクウケ(2) CONTROL ROD BEARING (2) 2 2
5 E281670050 コモンロツド-6DK CONTROL ROD -6DK 1
6 E281670060 コモンロツド-8DK CONTROL ROD -8DK 1
10 E281670100 ラツクレバ RACK LEVER 6 8

11 AE01016006 クラツチ：ラツクレバ- RACK LEVER CLUTCH 6 8

12 AE01016007 ホルダ：ネジリバネ HOLDER 8 10
13 E321650251 ネジリバネ RETURN SPRING 6 8
16 AE01016009 ピン：ラツクリンク RACK LINK PIN 12 16
17 E281670170 ラツクリンク RACK LINK 6 8

19 AE01016011 ベアリング：スフエリカルプレイン SPHERICAL PLAIN BEARING 12 16

20 AE01016012 デイスタンス DISTANCE 6 8
21 AE01016013 ヒラザガネ SPECIAL FLAT WASHER 12 16
22 E321670330 トクシユボルト SPECIAL BOLT 6 8
25 E641600190 コモンロツドストツパ STOPPER 2 2

29 E321670280 スフエリカルプレンベアリング SPHERICAL PLAIN BEARING 2 2

30 E401600320 スナツプリング SNAP RING 2 2

501 Z451460050ZZ ベアリング BEARING 2 3

502 Z412004700ZZ スナツプリング SNAP RING 2 3
505 X200012035ZZ ボルト BOLT 2 3
506 X200012030ZZ ボルト BOLT 4 6
507 X200012055ZZ ボルト BOLT 4 4

508 X220012000ZZ ナツト NUT 4 4

509 Z315012000ZZ ハツキザガネ TOOTHED LOCK WASHER 4 4
512 Z415005040ZZ スプリングピン SPRING PIN 6 8
513 Z212010035ZZ アナツキボルト BOLT 6 8
514 Z315010000ZZ ハツキザガネ TOOTHED LOCK WASHER 6 8

515 X220308000ZZ ナツト NUT 6 8

516 X250108016ZZ ロツカクトメネジ HEX. SET SCREW 8 10
517 X227006000ZZ Uナツト U-NUT 12 16

A C
6･8DK-28e Z 11-5
CHAPTER
3 ピストン & 連接棒（発電機関用）
ITEM
11.1 6･8DK-28e PISTON& CONNECTING ROD(GENERATOR USE)

901
901

902
902
A21
A21
A19
A3
A3 A19
A20
A20
A22 A31
A22 A31
A23
A23
AA
DETAIL"A"
DETAIL"A"
A27
A27

A29
A29
A10
A10 903
903
A501
A501

905

B7
B22
B22 B12
B3
B3 B7
B10
B1
B10 B12
B6
B1 B505
B6
B15
B505

B15

905

C
6･8DK-28e Z 11-5
 CHAPTER
ピストン & 連接棒（発電機関用） 3
ITEM
PISTON& CONNECTING ROD(GENERATOR USE) 6･8DK-28e 11.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

901 ピストンASSY PISTON ASSY. 1

902 ピストンリング　 ASSY PISTON RING ASSY. 1
903 ピストンピン　 ASSY PISTON PIN ASSY. 1
905 レンセツボウ　 ASSY CONNECTING ROD ASSY. 1

A3 E285170030 ピストン PISTON 1

A10 E285170100 ピストンピン PISTON PIN 1 ＊
A19 E285170190 ピストンリング(2) PISTON RING(2) 1
A20 E285170200 ピストンリング(3) PISTON RING(3) 1
A21 E285170210 ピストンリング(1) PISTON RING(1) 1

A22 E285100220 オイルリング OIL RING 1

A23 E285170230 オイルリンク OIL RING 1
A27 E285170270 ピストンピントメワ SNAP RING 2
A29 M140600100 ケーニックエキスパンダ PLUG 4 ＊
A31 E285170310 プラグ PLUG 4

A501 X251214014ZZ トメネジ SET SCREW 2 ＊

B1 E565270010 クランクピンメタル CRANK PIN BEARING 1

B3 E285270030 ピストンピンブッシュ PISTON PIN BUSH 1
B6 E285270060 レンセツボウボルト-1 BOLT-1 2
B7 E285270070 レンセツボウボルト-2 BOLT-2 4
B10 E565270100 レンセツボウ CONNECTING ROD 1

B12 E205250080 トクシュヘイコウピン SPECIAL STRAIGHT PIN 2

B15 E325670200 マルナット CIRCULAR NUT 2
B22 E205250150 ノズル NOZZLE 1

B505 Z335006016ZZ ヘイコウピン STRAIGHT PIN 1

( /CYL)

注 記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

C
6･8DK-28e Z 11-5
CHAPTER
3 ピストン & 連接棒（主機関用）
ITEM
11.2 6･8DK-28e PISTON& CONNECTING ROD(PROPULSION USE)

906
906

A502 907
A502 907

A119
A112 A119
A112
A19
A19
A114 A20
A114 A20
A23
A503 A23
A503
A116
A116
A115
A A115 DETAIL"A"
A DETAIL"A"
A27
A27

A29
A29
A118
A118 908
A113 908
A113

910
910

B103
B103

B501,B7
B501,B7

B102 B12
B102 B12
B1
B1 B6
B6
B505
B505
B15
B15

6･8DK-28e Z 11-5 C
 CHAPTER
ピストン & 連接棒（主機関用） 3
ITEM
PISTON& CONNECTING ROD(PROPULSION USE) 6･8DK-28e 11.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
906 ピストンＡＳＳＹ PISTON ASSY. 1
907 ピストンリングＡＳＳＹ PISTON RING ASSY. 1
908 E285175100 ピストンピンＡＳＳＹ PISTON PIN ASSY. 1
910 レンセツボウＡＳＳＹ CONNECTING ROD ASSY. 1

A19 E285170190 ピストンリング PISTON RING 1

A20 E285170200 ピストンリング PISTON RING 1
A23 E285170230 オイルリング OIL RING 1
A27 E285170270 ピストンピントメワ SNAP RING 2
A29 M140600100 ケ-ニツクエキスパンダ PLUG 4 ＊

A112 E285175120 ピストンクラウン PISTON CROWN 1

A113 E285175130 ピストンタイ PISTON BODY 1
A114 E285175140 ボルト:ピンストンクラウン BOLT 4
A115 E285175150 ナット:クラウンボルト NUT 4
A116 E285175160 ディスタンス:クラウンボルト DISTANCE 4

A118 E285175180 ピストンピン:ブンカツ PISTON PIN 1 ＊

A121 E285175210 ピストンリング:(1) PISTON RING 1

A502 Z415010025ZZ スプリングピン SPRING PIN 1

A503 Z560223057DZ Oリング O-RING 1

B1 E285270010 クランクピンメタル CRANK PIN BEARING 1

B6 E285270060 レンセツボウボルト-1 BOLT-1;CONNECTING ROD 2
B7 E285270070 レンセツボウボルト-2 BOLT-2;CONNECTING ROD 4
B12 AE02052008 ピン PIN 2
B15 E325670200 マルナツト CIRCULAR NUT 2

B102 E285275020 レンセツボウ CONNECTING ROD 1 ＊

B103 E285275030 ブッシュ:ピストンピン PISTON PIN BUSH 1

B501 Z321018020ZZ ハリガネ WIRE 2

B505 Z335006016ZZ ヘイコウピン STRAIGHT PIN 1

( /CYL)

注 記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

C
6･8DK-28e Z 11-5
CHAPTER
3 シリンダライナ
ITEM
12 6･8DK-28e CYLINDER LINER

901
901

7 9 5
7 9 5
8
8 16
16 501
504 501
504

15
15
2
2

503
503

A C
6･8DK-28e Z 11-5
 CHAPTER
シリンダライナ 3
ITEM
CYLINDER LINER 6･8DK-28e 12

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 シリンダライナASSY CYLINDER LINER ASSY. 1

2 E285070020 シリンダライナ CYLINDER LINER 1

5 E285070050 ライナシジワク HOLDER,CYL.LINER 1
7 E285070070 プロテクトリング PROTECT RING 1
8 E285070080 ＳＡレンラクカン S.A.CONNECTOR 1
9 E285070090 ＣＷレンラクカン C.W.CONNECTOR 4

15 E285070150 Ｏリング O-RING 3

16 E280230350 Ｏリング O-RING HT 4

501 Z212012070ZZ アナツキボルト HEX.SOCKET BOLT 4

503 Z560732357ZZ Ｏリング O-RING 3
504 Z560103035ZZ Ｏリング O-RING 1
( /CYL)

A C
6･8DK-28e Z 11-5
CHAPTER
3 シリンダヘッド
ITEM
13 6･8DK-28e CYLINDER HEAD

909
908
909
908

525
525
26 519 15 16 32
26 519 15 16 32

517
517
43
516, 521 43
516, 521 505
28 24, 513 505
21
28 24, 513 13
21
Fuel 13
nozzle non-cooling type
Fuel nozzle non-cooling type

34 533 17 20 101 103 7 102 14 519 15 16 32

34 533 17 20 101 103 7 102 14 519 15 16 32

36

538, 539 36 , 520

515

538, 539 520

515, 517
3
517
33 3
25
33 505
526 25
505
21
526
21 12
12 nozzle cooling type
Fuel
537 30 40 22 10 518 6 18
Fuel nozzle cooling type
537 30 40 22 10 518 6 18

C
6･8DK-28e Z 11-5
 CHAPTER
シリンダヘッド 3
ITEM
CYLINDER HEAD 6･8DK-28e 13
(1)･･･燃料ノズル冷却仕様 FUEL NOZZLE COOLING TYPE : ( NC )
(2)･･･燃料ノズル無冷却仕様 FUEL NOZZLE NON COOLING TYPE : ( NNC)
番号 部品番号 部品名称 Name of Parts 数量Quantity
Number Parts number (1) (2)
908 シリンダヘッド（ＮＣ）；ベンナシ CYLINDER HEAD ASSY. (NC) ; WITHOUT V. 1
918 シリンダヘッド（ＮＣ）；ベンツキ CYLINDER HEAD ASSY. (NC) ; WITH V. 1
909 シリンダヘッド（ＮＮＣ）；ベンナシ CYLINDER HEAD ASSY. (NNC) ; WITHOUT V. 1
919 シリンダヘッド（ＮＮＣ）；ベンツキ CYLINDER HEAD ASSY. (NNC) ; WITH V. 1

3 E285675040 シリンダヘッド CYLINDER HEAD 1 *

6 E285670060 キュウキベンシート SEAT; INTAKE VALVE 2 2
7 E285670070 ベンオサエガイド GUIDE; VALVE YOKE 2 2
10 E285670100 ハイキベンシート（メテコ） SEAT(METCO); EX.VALVE 2 2
12 E285670120 ノズルホルダガイド GUIDE; NOZZLE HOLDER 1

13 E265680500 ノズルホルダガイド ＷＪ GUIDE WJ; NOZZLE HOLDER 1

14 E285670140 ベンワンジクウケスタッド STUD; HOLDER ROCKER ARM SHAFT 4 4
15 E285670150 スタッド STUD 1 1
16 E285670160 ノズルホルダスタッド STUD; NOZZLE HOLDER 1 1
17 E325270070 マルナット CIRCULAR NUT 4 4

18 E285670180 シリンダヘッドパツキン GASKET; CYL.HEAD 1 1

20 E285670200 キヤップ CAP 4 4
21 E405600310 Ｏリング O-RING 2 2
22 E285670220 Ｏリング O-RING 2 2
24 AE02056014 トクシュプラグ SPECIAL PLUG 4 4

25 M125610130 ワンガタプラグ SEALING CAP 5 5

26 E285670260 ハイキデグチブロック BLOCK; EX.GAS OUTLET 1 1
28 E285670280 ハイキデグチパッキン GASKET; EX.GAS OUTLET 1 1
30 E285670300 CWハイキデグチブロック C.W.CONNECTOR; EX.GAS OUTLET 1 1
32 AE02056021 スタッド STUD 2 2

33 E180210140 HTスタッド H.T. STUD 3 3

34 E285670340 HTナット HT NUT 3 3
36 H150103400 ワンガタプラグ SEALING CAP 8 8
40 E285670400 Ｏリング O-RING 2 2
43 E285675060 シリンダヘッド（ムレイキヤク） CYLINDER HEAD 1*

101 E285675010 ベンガイド VALVE GUIDE 4 4

102 E285675020 バルブステムシール IN SEAL; VALVE STEM (IN) 2 2
103 E285675030 バルブステムシール EX SEAL; VALVE STEM (EX) 2 2
(/CYL)

C
6･8DK-28e Z 11-5
CHAPTER
3 シリンダヘッド
ITEM
13 6･8DK-28e CYLINDER HEAD
(1)･･･燃料ノズル冷却仕様 FUEL NOZZLE COOLING TYPE : ( NC )
(2)･･･燃料ノズル無冷却仕様 FUEL NOZZLE NON COOLING TYPE : ( NNC)
番号 部品番号 部品名称 Name of Parts 数量Quantity
Number Parts number (1) (2)
505 Z412006500ZZ スナップリング SNAP RING 1 1
513 Z565004200ZZ マルパッキン GASKET 4 4
515 X570001000ZZ ロッカクプラグ HEX.PLUG 2 2
516 X570006000DZ ロッカクプラグ HEX.PLUG 1 1
517 Z571501000ZZ テーパプラグ TAPER PLUG 4 4

518 Z571503000ZZ テーパプラグ TAPER PLUG 6 6

519 Z571503000ZZ テーパプラグ TAPER PLUG 2 2
520 Z565001000ZZ マルパッキン GASKET 2 2
521 Z565002700ZZ マルパッキン GASKET 1 1
525 X205016180ZZ HTボルト HT BOLT 2 2

526 X205016060ZZ HTボルト HT BOLT 1 1

533 Z335606014ZZ ヘイコウピン STRAIGHT PIN 1 1
537 Z560102235DZ Ｏリング O-RING 1 1
538 X570012000ZZ ロッカクプラグ HEX.PLUG 2 2
539 Z565004200ZZ マルパッキン GASKET 2 2
(/CYL)

注　 　 記
Remarks

(1) *印部品の単体販売は不可
Parts (Signal *) cannot be purchased by itself.
(2) シリンダヘッド（ベンツキ）には、吸・排気弁、起動弁、指圧器安全弁を含む：3-14、3-15、3-17、3-19を参照ください。
CYLINDER HEAD ASSY.; WITH V.(VALVES) INCLUDE IN. & EX. VALVES and INDICATOR & SAFETY VALVE. :
Ref. 3-14, 3-15, 3-17, 3-19

C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3 吸気弁
ITEM
14 6･8DK-28e INTAKE VALVE

C
6･8DK-28e Z 11-5
 CHAPTER
吸気弁 3
ITEM
INTAKE VALVE 6･8DK-28e 14

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 キユウキベン　 ＡＳＳＹ-2 INTAKE VALVE ASSY.-2 2

2 E285770020 キユウキベン INTAKE VALVE 2

6 E285770060 バルブロ－テ－タ VALVE ROTATOR 2
8 E285770080 コツタ VALVE COTTER 2
10 E285770100 ベンバネ VALVE SPRING 2
11 E285770110 ベンバネ VALVE SPRING 2

12 E285770120 ベンバネシ－ト SEAT,VALVE SPRING 2

201 E285772010 ホンタイ BODY 1 ＊

202 E285772020 サラバネ CONED DISC SPRING 1
203 E285772030 リテ－ナ RETAINER 1
207 E285772070 コイルバネ COIL SPRING 7
209 E225802050 トメワ CIRCLIP 1

211 E285772110 ボ－ル BALL 7

212 E285772120 ボ－ルレ－ス BALL RACE 1
(/CYL)

注記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

C
6･8DK-28e Z 11-5
CHAPTER
3 排気弁
ITEM
15 6･8DK-28e EXHAUST VALVE

C
6･8DK-28e Z 11-5
 CHAPTER
排気弁 3
ITEM
EXHAUST VALVE 6･8DK-28e 15

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 ハイキベンASSY-2 EXHAUST VALVE ASSY.-2 2

3 E285870030 ハイキベン EXHAUST VALVE 2

6 E285770060 バルブロ－テ－タ VALVE ROTATOR 2
8 E285770080 コツタ VALVE COTTER 2
10 E285770100 ベンバネ VALVE SPRING 2
11 E285770110 ベンバネ VALVE SPRING 2

12 E285770120 ベンバネシ－ト SEAT,VALVE SPRING 2

201 E285772010 ホンタイ BODY 1 ＊

202 E285772020 サラバネ CONED DISC SPRING 1
203 E285772030 リテ－ナ RETAINER 1
207 E285772070 コイルバネ　 COIL SPRING 7
209 E225802050 トメワ CIRCLIP 1

211 E285772110 ボ－ル BALL 7

212 E285772120 ボ－ルレ－ス BALL RACE 1
(/CYL)

注記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

C
6･8DK-28e Z 11-5
CHAPTER
3 弁腕
ITEM
16 6･8DK-28e ROCKER ARM

901

12 504 
505 508 503 5 902

24
14
9
18
2
506
502

10
903

1
16
4
20

28

500

A C
6･8DK-28e Z 11-5
 CHAPTER
弁腕 3
ITEM
ROCKER ARM 6･8DK-28e 16

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 ベンワン　 ASSY ROCKER ARM ASSY. 1
902 ベンワン（ブッシュツキ） ROCKER ARM (WITH BUSH) 2
903 ベンオサエティ（シートツキ） T. VALVE YOKE (WITH SEAT) 2

1 E285970010 ベンワンジクホルダ HOLDER, ROCKER ARM 1

2 E285970020 ベンワン ROCKER ARM 2
4 E285970040 ベンオサエテイ T.VALVE YOKE 2 ＊
5 E285970050 ベンワンジク ROCKER ARM SHAFT 1 ＊
9 E285970090 ベンワンブツシユ BUSH, ROCKER ARM 2

10 E285970100 プツシユロツドシート（ウエ） PUSH ROD SEAT (UPPER) 2

12 E285970120 ベンワンネジ SCREW, ROCKER ARM 2
14 E285970140 ベンタンキヤツプ VALVE END CAP 2
16 E285970160 ベンオサエシ－ト(1) SEAT(1), VALVE YOKE 2
18 E285970180 ベンオサエネジ ADJUSTING SCREW, VALVE YOKE 2

20 E285970200 ベンオサエシ－ト(2) SEAT(2), VALVE YOKE 2

24 E285970240 クリツプ CLIP 2
28 E285970280 ＬＯチヨウセイネジ L.O. ADJUSTING SCREW 1

500 X220020000ZZ ナツト NUT 4

502 X251206008ZZ トメネジ SET SCREW 6
503 X251210012ZZ トメネジ SET SCREW 1
504 X251206006ZZ トメネジ SET SCREW 2
505 X220818000ZZ ナツト NUT 2

506 X220820000 ナツト NUT 2

508 Z411006500 スナツプリング（ジク） SNAP RING 2
(/CYL)

注記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

A C
6･8DK-28e Z 11-5
CHAPTER
3 起動弁
ITEM
17 6･8DK-28e STARTING AIR VALVE

A C
6･8DK-28e Z 11-5
 CHAPTER
起動弁 3
ITEM
STARTING AIR VALVE 6･8DK-28e 17

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AE 02060005

AE 02060006

A C
6･8DK-28e Z 11-5
CHAPTER
3 燃料噴射装置
ITEM
18.1 6･8DK-28e FUEL OIL INJECTION DEVICE

14
14
3-18.2

3-18.2

504
504 Ref.3-18.2
Ref.3-18.2
77

501
501
22
511
511
512
512

510
510

508
508

AA
66

11
11
99 12
12
33 Section
Section"A-A"
"A-A"
506
506
12
12
11
AA

901
901

6･8DK-28e Z 11-5 C
 CHAPTER
燃料噴射装置 3
ITEM
FUEL OIL INJECTION DEVICE 6･8DK-28e 18.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 F.OコウアツカンブロックASSY. BLOCK ASSY,F.O.INJECTION 1

1 E286270010 Ｆ．Ｏ．コウアツカン BLOCK,F.O.INJECTION 1 ＊

2 E286270020 HTボルト HT-BOLT 2

3 E286270030 コウアツカン　 ジヨイント JOINT,INJECTION PIPE 1

6 E286270060 ノズルホルダオサエ CLAMP,NOZZLE HOLDER 1
7 E286270070 ノズルホルダオサエ（２） CLAMP(2),NOZZLE HOLDER 1

9 AE02062021 ボ－ル BALL 1

11 E206250110 プラグ PLUG 1
12 E286270120 Ｏリング O RING 3
14 E286270140 ノズルホルダ（レイキヤク）ASSY. NOZZLE HOLDER(COOLING TYPE)ASSY. 1

501 X205012055ZZ ＨＴボルト HT BOLT 2

504 X220014000ZZ ナツト NUT 2
506 X251206006ZZ トメネジ SET SCREW 1
508 Z565002520ZZ マルパツキン GASKET 1
510 Z560204531DZ Ｏリング O RING 1

511 Z560206031DZ Ｏリング O RING 2

512 Z560205531DZ Ｏリング O RING 1
(/CYL)

注記
Remarks
＊印部品の単体販売は不可
Parts(Signa*) cannot be purchased by itself.

C
6･8DK-28e Z 11-5
CHAPTER
3 燃料噴射装置（ノズルホルダ）
ITEM FUEL OIL INJECTION DEVICE
18.2 6･8DK-28e（FUEL OIL NOZZLE HOLDER）

6･8DK-28e Z 11-5 C
 CHAPTER
燃料噴射装置（ノズルホルダ） 3
FUEL OIL INJECTION DEVICE ITEM
（FUEL OIL NOZZLE HOLDER） 6･8DK-28e 18.2
(1)･･･φ0.48×10 (2)････φ0.52×9 (3)････φ0.52×10
番号 パーツコード 部品名称 Name of Parts 数量Quantity
Number Parts Code (1) (2) (3)
27 E286270270 ノズルホルダASSY. NOZZLE HOLDER ASSY. 1
30 E286270300 ノズルホルダASSY. NOZZLE HOLDER ASSY. 1
36 E286270360 ノズルホルダASSY. NOZZLE HOLDER ASSY. 1

14 E286270140 ノズルホルダ NOZZLE HOLDER 1 1 1

20 E286270200 ノズルＤＬＦ１４０ＵＢ４８１０ NOZZLE DLF140UB４８１０ 1
23 E286270230 ノズルＤＬＦ１４０ＵＢ５２９ NOZZLE DLF140UB５２９ 1
33 E286270330 ノズルＤＬＦ１４０Ｕ５２１０ NOZZLE DLF140U５２１０ 1

300 E286273000 タイ　 　 　 　 　 　 　 　 　 　 　 　 　 　 BODY,N.H. 1* 1* 1*

302 E286273020 ピン　 　 　 　 　 　 　 　 　 　 　 　 　 　 PIN 1 1 1
303 E326253030 プツシユロツド　 　 　 　 　 　 　 　 　 PUSH ROD 1 1 1
304 E326203050 ピン　 　 　 　 　 　 　 　 　 　 　 　 　 　 PIN 4 4 4
305 E326253050 スプリングシ－ト　 　 　 　 　 　 　 　 SPRING SEAT 1 1 1

307 E286273070 バネ　 　 　 　 　 　 　 　 　 　 　 　 　 　 SPRING,NOZZLE 1 1 1

308 E286273080 チヨウセイ　 ネジ　 　 　 　 　 　 　 　 ADJUSTING SCREW 1 1 1
310 E326253100 スペ－サ　 　 　 　 　 　 　 　 　 　 　 　 SPACER 1 1 1
312 E326273120 キヤツプナツト　 　 　 　 　 　 　 　 　 CAPNUT 1 1 1
313 E226950310 ナツト　 　 　 　 　 　 　 　 　 　 　 　 　 NUT 1 1 1

319 E326273190 リテ－ナ－ナツト　 　 　 　 　 　 　 　 RETAINER NUT 1 1 1

320 E286273200 コネクタ－　 　 　 　 　 　 　 　 　 　 　 INLET CONNECTOR 1 1 1
513 Z567001402CC ガスケット GASKET 2 2 2
（ / CYL ）

注記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

C 6･8DK-28e Z 11-5
CHAPTER

ITEM
3 燃料噴射装置 （無冷却ノズル）
18.3 6･8DK-28e FUEL OIL INJECTION DEVICE (NON-COOLING)

16
16
3-18.4ෳᾖ
504 3-18.4

504 Ref.3-18.2
Ref.3-18.2
7
7
501
501
2
2 511
511
512
512
510
510

508
508

A
A
6
6

11
11 12
9 12
9
3 Section "A-A"
506 3 Section "A-A"
506 12
1 12
1 A
A

901
901

6･8DK-28e Z 11-5 C
 CHAPTER

燃料噴射装置 （無冷却ノズル） ITEM

3
FUEL OIL INJECTION DEVICE (NON-COOLING) 6･8DK-28e 18.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 FOコウアツブロックASSY F.O. INJECTION BLOCK ASSY. 1

1 E286270010 F.O.コウアツカン F.O. INJECTION BLOCK 1

2 E286270020 HTボルト HT-BOLT 2
3 E286270030 コウアツカンジョイント INJECTION PUPE JOINT 1
6 E286270060 ノズルホルダオサエ NOZZLE HOLDER CLAMP 1
7 E286270070 ノズルホルダオサエ(2) NOZZLE HOLDER CLAMP (2) 1

9 AE02062021 ボール BALL 1

11 E206250110 プラグ PLUG 1
12 E286270120 Oリング O-RING 3
16 E286270160 ノズルホルダ (ムレイキャク) ASSY NOZZLE HOLDER (NON-COOLING) ASSY. 1

501 X205012055ZZ HTボルト HT-BOLT 2

504 X220014000ZZ ナット NUT 2
506 X251206006ZZ トメネジ SET SCREW 1
508 Z565002520ZZ マルパッキン GASKET 1
510 Z560204531DZ Oリング O-RING 1

511 Z560206031DZ Oリング O-RING 2

512 Z560205531DZ Oリング O-RING 1
（ / CYL ）

注記
Remarks

印部品の単体販売は不可。
Parts (Signal ) cannot be purchased by itself.

C 6･8DK-28e Z 11-5
CHAPTER

ITEM
3 燃料噴射装置 （ノズルホルダ、無冷却ノズル）
18.4 6･8DK-28e FUEL OIL INJECTION DEVICE (NOZZLE HOLDER, NON-COOLING)

28
28
40
40

16
16
309
309

306 21
306 21
39
39

21
21
39
39

6･8DK-28e Z 11-5 C
 CHAPTER

燃料噴射装置 （ノズルホルダ、無冷却ノズル） ITEM

3
FUEL OIL INJECTION DEVICE (NOZZLE HOLDER, NON-COOLING) 6･8DK-28e 18.4
燃料噴射弁／F.O. NOZZLE (1)････φ0.48×10 (2)････φ0.52×10
番号 部品番号 部品名称 Name of Parts 数量Quantity
Number Parts number (1) (2)
28 E286270280 ノズルホルダ(ムレイキヤク)ASSY NOZZLE HOLDER (NON-COOLING TYPE) ASSY. 1
40 E286270400 ノズルホルダ(ムレイキヤク)ASSY NOZZLE HOLDER (NON-COOLING TYPE) ASSY. 1

16 E286270160 ノズルホルダ(ムレイキヤク) NOZZLE HOLDER (NON-COOLING TYPE) 1 1

21 E286270210 ノズル DLL145UE4810 NOZZLE DLL145UE4810 1
39 E286270390 ノズル DLL145UE5210 NOZZLE DLL145UE5210 1
302 E286273020 ピン PIN 1 1
303 E326253030 プッシュロッド PUSH ROD 1 1

304 E326203050 ピン PIN 4 4

305 E326253050 スプリングシート SPRING SEAT 1 1
306 E266283060 タイ BODY 1 1
307 E286273070 バネ SPRING 1 1
309 E266283090 チョウセイネジ ADJUSTING SCREW 1 1

310 E326253100 スペーサ SPACER 1 1

312 AE01062025 キャップナット CAPNUT 1 1
313 AE01062015 ナット NUT 1 1
319 E326273190 リテーナーナット RETAINER NUT 1 1
320 E286273200 コネクター INLET CONNECTOR 1 1

513 Z567001402CC ガスケット GASKET 2 2

（ / CYL ）

注記
Remarks

印部品の単体販売は不可。
Parts (Signal ) cannot be purchased by itself.

C
6･8DK-28e Z 11-5
CHAPTER
3 指圧器, 安全弁
ITEM
19 6･8DK-28e INDICATOR & SAFETY VALVE

14

901

902

8 901
502

13

12
10

䋹
505
11
503
5

505

7
2
1
4
505
6 501

504

A C
6･8DK-28e Z 11-5
 CHAPTER
指圧器, 安全弁 3
ITEM
INDICATOR & SAFETY VALVE 6･8DK-28e 19

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 00026-026 指圧器ＡＳＳＹ（安全弁付） ASSY., INDICATOR (with SAFETY VALVE) 1
902 00026-027 安全弁ＡＳＳＹ ASSY., SAFETY VALVE 1

1 00026-001 タイ BODY 1
2 00026-002 シアツキベン INDICATOR VALVE 1
3 00026-003 フランジ FLANGE 1
4 00026-004 ロッカクプラグ HEX. PLUG 1
5 00026-005 アンゼンベン SAFETY VALVE 1

6 00026-006 ジク SHAFT 1
7 00026-007 ナット NUT 1
8 00026-008 トメネジ SET SCREW 1
9 00026-009 バネ SPRING 1
10 00026-010 セッシュ JOINT 1

11 00026-011 タイ BODY 1
12 00026-012 オサエ CLAMP 1
13 00026-013 シート SEAT 1
14 00026-028 カバー COVER 1

501 X220012000ZZ ナット NUT 2

502 X220308000ZZ ナット NUT 1
503 Z335004020ZZ ヘイコウピン STRAIGHT PIN 1
504 Z565001700ZZ マルパッキン GASKET 1
505 Z565002300ZZ マルパッキン GASKET 4

( /CYL)

A C
6･8DK-28e Z 11-5
CHAPTER
3 シリンダヘッドカバ
ITEM
20 6･8DK-28e CYLINDER HEAD COVER

A C
6･8DK-28e Z 11-5
 CHAPTER
シリンダヘッドカバ 3
ITEM
CYLINDER HEAD COVER 6･8DK-28e 20

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 E286370010 シリンダヘツドカバ(1) "COVER,CYLINDER HEAD" 1
5 AE01063002 ノブ：シリンダヘツドカバ KNOB 2
6 E286370060 Oリング O-RING 1
7 AE02063004 ジク：ハンドル SHAFT 2

501 X210010055ZZ スタツド M10X1.5X55 STUD 1

505 Z415004024ZZ スプリングピン 4X24 SPRING PIN 2
( /CYL)

A C
6･8DK-28e Z 11-5
CHAPTER
3 吸, 排気弁タペット & プッシュロッド
ITEM
21 6･8DK-28e INTAKE,EXHAUST TAPPET & PUSH ROD

901

B2

B501

B9

A11 A2
B501

902

A9

A3

A12

A20

A7

A5
501 A505 A502

A6

6･8DK-28e Z 11-5 A C
 CHAPTER
吸, 排気弁タペット & プッシュロッド 3
ITEM
INTAKE & EXHAUST TAPPET & PUSH ROD 6･8DK-28e 21

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 キュ、ハイキベンタペットASSY IN.EX.TAPPET ASSY. 1
902 タペットローラ　 ASSY TAPPET ROLLER ASSY. 2

A2 E286670020 スウイングア－ム SWING ARM 2

A3 E266600040 タペツトロ－ラブシユ TAPPET ROLLER BUSH 2
A5 E566670050 ジク，スイングアーム SHAFT,SWING ARM 1
A6 E286670060 ボルト，スウイングタペツトジク　 BOLT,SWING TAPPET SHAFT 2
A7 E286670070 リングノツク RING,KNOCK 2

A9 E266600100 タペツトロ－ラ TAPPET ROLLER 2 ＊

A11 E286670110 プツシユロツドシ－ト SEAT,PUSH ROD 2
A12 E286670120 タペツトロ－ラピン PIN,TAPPET ROLLER 2
A20 AE01066017 ケーニックエキスパンダ KOENIC EXPANDER 2

A501 X251206008ZZ トメネジ SET SCREW 2

A502 X251210012ZZ トメネジ SET SCREW 1
A505 Z411005500ZZ スナツプリング SNAP RING 2

B2 E286870020 プツシユロツド PUSH ROD 2

B9 E286870090 プツシユロツドホゴツツ PROTECTIVE TUBE,PUSH ROD 2

B501 Z560204531ZZ Ｏリング O RING 4

（/ CYL.）

注記
Remarks
＊印部品の単体販売は不可
Parts(Signa＊）cannot be purchased by itself.

A C
6･8DK-28 A 05-1
CHAPTER
3 燃料噴射ポンプタペット
ITEM
22 6･8DK-28e FUEL OIL INJECTION PUMP TAPPET

A C
6･8DK-28e Z 11-5
 CHAPTER
燃料噴射ポンプタペット 3
ITEM
FUEL OIL INJECTION PUMP TAPPET 6･8DK-28e 22

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 ＦＯポンプタペツトASSY. F.O.PUMP TAPPET ASSY. 1

1 E286770010 ＦＯポンプダイ　 　 　 　 　 　 　 　 　 MOUNT,F.O.PUMP 1

4 E326770040 ＦＯタペツトロ－ラブツシユ　 　 　 F.O. TAPPET ROLLER BUSH 1
7 E326770070 ＦＯポンププツシユロツドシ－ト　 SEAT, F.O. PUMP PUSH ROD 1
8 E326770080 ＦＯタペツト　 　 　 　 　 　 　 　 　 　 F.O. TAPPET 1
9 E286770090 ＦＯポンププツシユロツド　 　 　 　 PUSH ROD,F.O.PUMP 1

10 E326770100 ＦＯタペツトロ－ラピン　 　 　 　 　 F.O. TAPPET ROLLER PIN 1

11 E326770110 ＦＯタペツトロ－ラ　 　 　 　 　 　 　 F.O. TAPPET ROLLER 1
12 E326770120 ＦＯタペツトチヨウセイネジ　 　 　 ADJUSTING SCREW, F.O. TAPPET 1
15 E326770150 ＦＯタペツトバネウケ　 　 　 　 　 　 SEAT, F.O. TAPPET SPRING 1
17 E326770170 Ｕ　 ナツト　 　 　 U-NUT 1

18 E286770180 メクラフタ　 　 　 　 　 　 　 　 　 　 　 COVER 1

19 E286770190 メクラフタパツキン　 　 　 　 　 　 　 GASKET 1
20 E326770300 トクシユトメネジ SPECIAL SCREW 1
26 E326770260 タペツトバネ TAPPET SPRING 1
27 E326770270 タペツトバネ TAPPET SPRING 1

500 X200006012ZZ ボルト　 BOLT 4

503 X220018000ZZ ナツト　 　 　 NUT 4
511 Z560209531ZZ Ｏリング　 　 　 　 　 　 　 　 O RING 1
（ /CYL )

A C
6･8DK-28e Z 11-5
CHAPTER
3 燃料噴射ポンプ
ITEM
23 6･8DK-28e FUEL OIL INJECTION PUMP

13
3

229

237, 238

View "P"
220

215

218, 219

204, 209
245, 246
213
210

221, 223
235
251
234 250 226
252 225
50 40 30
255
STOP 230
P 202
256
227

260, 261 231

6･8DK-28e Z 11-5 C
 CHAPTER
燃料噴射ポンプ 3
ITEM
FUEL OIL INJECTION PUMP 6･8DK-28e 23
1･･主機 ,陸用 Propulsion,Stationary 2･･補機 Auxiliary

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
3 E286470030 ＦＯフンシャポンプ　 ＡＳＳＹ F.O. INJECTION PUMP ASSY 1
13 E286470130 ＦＯフンシャポンプ　 ＡＳＳＹ F.O. INJECTION PUMP ASSY 1

202 E2864720２0 ポンプハウジング HOUSING; PUNP 1* 1*

204 E286472040 プランジヤＡＳＳＹ PLUNGER ASSY. 1
209 E286472090 プランジヤＡＳＳＹ PLUNGER ASSY. 1
210 E286472100 デフレクタ DEFLECTOR 2 2
213 E326472130 Ｏリング O RING 2 2

215 E286472150 デリベリバルブ DELIVERY VALVE 1 1

218 E326472180 Ｏリング O RING 1 1
219 E326472190 バツクアツプリング BACKUP RING 2 2
220 E326472200 ボルト BOLT 6 6
221 E326472210 Ｏリング O RING 3 3

223 E326472230 バツクアツプリング BACKUP RING 2 2

225 E326472250 プランジヤスプリング SPRING; PLUNGER 1 1
226 E326472260 スプリングシ－ト（ウエ） SPRING SEAT 1 1
227 E326472270 スプリングシ－ト（シタ） SPRING SEAT 1 1
229 E206452660 ポインタ POINTER 1 1

230 E326472300 プランジヤガイド GUIDE; PLUNGER 1 1

231 E326472310 スナツプリング SNAP RING 1 1
234 E326472340 コントロ－ルラツク CONTROL RACK 1 1
235 E326472350 コントロ－ルスリ－ブ CONTROL SLEEVE 1 1
237 E266402360 シム SHIM 1 1

238 E206452680 ボルト BOLT 1 1

245 E326472450 セツトスクリユウ SET SCREW 1 1
246 E326472460 ガスケツト GASKET 1 1
250 E326472500 シリンダ CYLINDER 1 1
251 E326472510 ガスケット GASKET 1 1

252 E326472520 アイ EYE 1 1

255 E326472550 アイボルト EYE BOLT 1 1
256 E326472560 ガスケット GASKET 2 2
260 E286472600 プラグ PLUG 2 2
261 E286472610 ガスケット GASKET 2 2
(/CYL.)

注記
Remarks
*印部品の単体販売は不可
Parts (Signal *) cannot be purchased by itself.

C 6･8DK-28 A 04-12
CHAPTER
3 ガバナ駆動装置 (RHD)
ITEM
24.1 6･8DK-28e GOVERNOR DRIVING DEVICE (RHD)

A C
6･8DK-28e Z 11-5
 CHAPTER
ガバナ駆動装置 (RHD) 3
ITEM
GOVERNOR DRIVING DEVICE (RHD) 6･8DK-28e 24.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AE01045015

A C
6･8DK-28e Z 11-5
CHAPTER
3 ガバナ駆動装置 (UG)
ITEM
24.2 6･8DK-28e GOVERNOR DRIVING DEVICE (UG)

A C
6･8DK-28e Z 11-5
 CHAPTER
ガバナ駆動装置 (UG) 3
ITEM
GOVERNOR DRIVING DEVICE (UG) 6･8DK-28e 24.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AE 01045017

AE01045016

A C
6･8DK-28e Z 11-5
CHAPTER
3 ガバナ取付 (EAR)
ITEM
24.3 6･8DK-28e GOVERNOR FITTING (EAR)





A C
6･8DK-28e Z 11-5
 CHAPTER
ガバナ取付 (EAR) 3
ITEM
GOVERNOR FITTING (EAR) 6･8DK-28e 24.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
A

B532 Z310010000ZZ 
 SPRING WASHER 4

A C
6･8DK-28e Z 11-5
CHAPTER
3 ガバナリンク (RHD)
ITEM
25.1 6･8DK-28e GOVERNOR LINK (RHD)

A C
6･8DK-28e Z 11-5
 CHAPTER
ガバナリンク (RHD) 3
ITEM
GOVERNOR LINK (RHD) 6･8DK-28e 25.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AE01046019
AE01046020 
FORK END
AE01046021
AE01046022
AE01046023

AE01046024

A C
6･8DK-28e Z 11-5
CHAPTER
3 ガバナリンク (UG)
ITEM
25.2 6･8DK-28e GOVERNOR LINK (UG)





 



A C
6･8DK-28e Z 11-5
 CHAPTER
ガバナリンク (UG) 3
ITEM
GOVERNOR LINK (UG) 6･8DK-28e 25.2
(1)････UG10 (2)････UG25

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
2 E284670020 レバ-，コモンロツド CONTROL ROD LEVER 1 1
6 E324600390 ガバナレバ(UG8) GOVERNOR LEVER (UG8) 1
8 E284670080 レンケツカン CONECTION ROD 1 1
11 E324600500 ガバナリンクバネウケ SPRING SEAT 1 1
12 E284670120 レンケツカンジク，UG8 SHAFT 1 1

14 AE01046019 ナット NUT 1 1

15 AE01046020 ホークエンド FORK END 1 1
18 AE01046021 スフエリカルプレインベアリング SPHERICAL PLAIN BEARING 1 1
19 AE01046022 ロッドエンド ROD END 1 1
21 AE01046023 リンクピン LINK PIN 1 1

22 AE01046024 リンクピン LINK PIN 1 1

24 E284670240 バネ SPRING 1 1
43 E284675010 レバ:ガバナ:UG-25 GOVERNOR LEVER (UG-25) 1

500 X200010020ZZ ボルト BOLT 1

501 Z315010000ZZ ハツキザガネ TOOTHED LOCK WASHER 1 1
504 X200010032ZZ ボルト BOLT 1 1
505 Z315010000ZZ ハツキザガネ TOOTHED LOCK WASHER 1 1
506 Z415005040ZZ スプリングピン SPRING PIN 1 1

508 X225110000ZZ キクナット CASTLE NUT 1 1

509 Z300010000ZZ ヒラザガネ FLAT WASHER 1 1
510 Z320002025ZZ ワリピン SPLIT PIN 1 1
511 X220310000ZZ ナット NUT 1 1
514 X225110000ZZ キクナット CASTLE NUT 1 1

515 Z300010000ZZ ヒラザガネ FLAT WASHER 1 1

516 Z320002025ZZ ワリピン SPLIT PIN 1 1
530 X200010025ZZ ボルト BOLT 1

A C
6･8DK-28e Z 11-5
CHAPTER
3 ガバナリンク (EAR)
ITEM
25.3 6･8DK-28e GOVERNOR LINK (EAR)

A C
6･8DK-28e Z 11-5
 CHAPTER
ガバナリンク (EAR) 3
ITEM
GOVERNOR LINK (EAR) 6･8DK-28e 25.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
11 E324600500 ガバナリンクバネウケ SPRING SEAT 1
14 AE01046019 ナット NUT 1
16 E264680150 レンケツカンナツト NUT 1
18 AE01046021 スフエリカルプレインベアリング SPHERICAL PLAIN BEARING 1
19 AE01046022 ロッドエンド ROD END 1

21 AE01046023 リンクピン LINK PIN 1

27 E284670270 レバ-，コモンロツド，EAR-20 COMMONROD LEVER (EAR-20) 1
30 E284670300 レンケツカンジク，EAR-20 SHAFT(EAR-20) 1
31 E284670310 リンクピン，EAR-20 LINK PIN(EAR-20) 1
32 E284670320 レンケツカン，EAR-20 CONECTION ROD(EAR-20) 1

33 E284670330 バネ SPRING 1
34 E284670340 ピン PIN 1
35 E284670350 レバ:ヒジヨウヨウ EMERGENCY LEVER 1
36 E284670360 メイバン NAME PLATE 1
37 E284670370 ブラケット BRACKET 1

38 E287270370 ノブ NOB 1
39 AE01046013 ノブ NOB 1
41 E180610040 ダンツキピン STEPPED PIN 1
42 E284670420 メイバン NAME PLATE 1

504 X200010032ZZ ボルト BOLT 1

505 Z315010000ZZ ハツキザガネ TOOTHED LOCK WASHER 1
506 Z415005040ZZ スプリングピン SPRING PIN 1
508 X225110000ZZ キクナット CASTLE NUT 1
509 Z300010000ZZ ヒラザガネ FLAT WASHER 2

510 Z320002025ZZ ワリピン SPLIT PIN 1

511 X220310000ZZ ナット NUT 1
514 X225110000ZZ キクナット CASTLE NUT 1
515 Z300010000ZZ ヒラザガネ FLAT WASHER 1
516 Z320002025ZZ ワリピン SPLIT PIN 1

520 X210008029ZZ スタッド STUD 1

523 X200008040ZZ ボルト BOLT 1
524 X220008000ZZ ナット NUT 1
526 X245203005ZZ ナベコネジ MACHINE SCREW 4
527 X245203005ZZ ナベコネジ MACHINE SCREW 2

529 X200012145ZZ ボルト BOLT 2

A C
6･8DK-28e Z 11-5
CHAPTER
3 操縦装置
ITEM
26 6･8DK-28e OPERATING DEVICE

901,902

A17,

A16,

Detail of Load pointer

A C
6･8DK-28e Z 11-5
 CHAPTER
操縦装置 3
ITEM
OPERATING DEVICE 6･8DK-28e 26
(1)･･ガバナ GOVERNOR (RHD,UG) (2)･･ガバナ GOVERNOR (EAR)

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
901 ソウサレバサブASSY(RHD,UG) CONTROL LEVER SUB ASSY.(RHD,UG) 1
902 ソウサレバサブASSY(EAR) CONTROL LEVER SUB ASSY.(EAR) 1

A1 E287570010 レバ LEVER 1
A3 E287570030 オシボウ PUSH ROD 1
A4 E287570040 ピン PIN 1 1
A5 E287570050 レバジククラツチ CLUTCH 1 1
A7 E284600291 バネ SPRING 1 1

A9 E641600190 コモンロツドストツパ STOPPER 2 2

A11 E287570110 ブラケット BRACKET 1 1
A16 E287570160 レバ:EAR LEVER(EAR) 1
A17 E287570170 オシボウ:EAR PUSH ROD(EAR) 1

A501 Z451460050ZZ ベアリング BEARING 1 1

A502 Z412004700ZZ スナップリング:アナ SNAP RING 1 1
A505 Z415005040ZZ スプリングピン SPRING PIN 1 1
A507 X200012055ZZ ボルト BOLT 3 3
A508 X220012000ZZ ナット NUT 3 3

A509 Z315012000ZZ ハツキザガネ TOOTHED LOCK WASHER 3 3

A510 X200010040ZZ ボルト BOLT 1 1
A511 Z315010000ZZ ハツキザガネ TOOTHED LOCK WASHER 1 1

B2 AE01046003 ボルト：ラツクストツパ BOLT 1 1

B7 AE02132001 シシン：フカケイ LOAD POINTER 1 1
B12 E293270120 フカケイシシンレバ LEVER 1 1
B14 E293270140 フカケイメモリバン LOAD SCALE PLATE 1 1

B501 X200008038ZZ ボルト BOLT 1 1

B502 X200006010ZZ ボルト BOLT 2 2
B505 X220308000ZZ ナツト NUT 1 1
B507 X245103006ZZ プラスマルコネジ SCREW 6 6
B508 X250106010ZZ ロツカクトメネジ HEX.SET SCREW 1 1

B510 Z315008000ZZ ハツキザガネ TOOTHED LOCK WASHER 1 1

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管（８ＤＫ,前端過給,排気入口1つ口)
ITEM EXHAUST MANIFOLD (8DK,FRONT TUR-
27.1 6･8DK-28e BOCHARGER, GAS INLET 1 ENTRY)

A504 A530 A531 A63

A68 A64 A73 A60 A76 A135

㧼
A561
A560

B23

B523 A520, A521

A50 A518, A519

B22
B522 A522, A523

Section "A=A"

View "P"

A C
6･8DK-28e Z 11-5
 排気管（８ＤＫ,前端過給,排気入口1つ口) CHAPTER
3
EXHAUST MANIFOLD (8DK,FRONT TUR- ITEM

BOCHARGER, GAS INLET 1 ENTRY) 6･8DK-28e 27.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

901 ハイキカンＡＳＳＹ EXHAUST MANIFOLD ASSY. 1

A50 E282170500 ハイキカンパッキン（４） EXHAUST MANIFOLD GASKET (4) 8

A60 E282170600 ベローズ２００ＡＸ１３６ BELLOWS 200AX136 4
A63 E282170630 Ｔ／Ｃハイキイリグチガスケット GASKET: T.C. EXHAUST INLET 1
A64 E282170640 ハイキカンパッキン（５） EXHAUST MANIFOLD GASKET (5) 9
A68 E282170680 メクラフタ　 ３５０ CAVER 350 1

A73 E282170730 ハイキカン（ＦＴ）－２００Ａ－８０ EXHAUST MANIFOLD (FT)-200A-80 3

A76 E282170760 Ｔ／Ｃ　 イリグチカン（ＦＴ）－ＭＥＴ３０ T.C. INLET PIPE (FT)-MET30 1
A135 E282171350 Ｔ／Ｃイリグチカン－ＴＰＳ６１ T.C. INLET PIPE -TPS61 1

A504 X205016040ZZ ＨＴボルト HT BOLT 32

A518 X570006000DZ ロッカクプラグ HEX. PPLUG 1
A519 Z565002700ZZ マルパッキン GASKET 1
A520 X570004000DZ ロッカクプラグ HEX. PPLUG 1
A521 Z565002100ZZ マルパッキン GASKET 1

A522 X570010000DZ ロッカクプラグ HEX. PPLUG 1

A523 Z565003400ZZ マルパッキン GASKET 1
A530 X205020065ZZ ＨＴボルト HT BOLT 54
A531 X220020000DZ ナット NUT 54
A560 X205020075ZZ ＨＴボルト HT BOLT 6

A561 X220020000DZ ナット NUT 6

B22 E282270220 ハイキカンブラケット８Ｄ（２） EXHAUST MANIFOLD BRACKET 8D (2) 4

B23 E282270230 ハイキカンブラケットＦＴ EXHAUST MANIFOLD BRACKET FT 1

B522 X200012025ZZ ボルト BOLT 10

B523 X200012020DZ ボルト BOLT 10

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管（８DK,後端過給,排気入口２つ口)
ITEM EXHAUST MANIFOLD (8DK,REAR TUR-
27.2 6･8DK-28e BOCHARGER, GAS INLET 2 ENTRY)

A508, A566 A508, A564, A565

B503, B511, B513
A508, A565
A120 A129 A123 A16
A567
A127 A122 A508 B45

A128 A15 A19 A503 A137

A121 A557 A137, A558

B32

A126 B53 B51

B36 B35
A125 B52 B50
A110 B502, B503 A124 B503, B507, B508
B503, B512

B56 A4

B503, B512 A520, A521

A518, A519 B38 A504

B34
B43 B503, B512 A50 B503, B512

B503, B512 B45

B44 B501
B30
A5 B55
B37 B503
B503, B515
B516, B517 B57

View "P" Section "A-A" Detail "B"

A C
6･8DK-28e Z 11-5
 排気管（８DK,後端過給,排気入口２つ口) CHAPTER
3
EXHAUST MANIFOLD (8DK,REAR TUR- ITEM
BOCHARGER, GAS INLET 2 ENTRY) 6･8DK-28e 27.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

902 ハイキカンＡＳＳＹ EXHAUST MANIFOLD ASSY. 1

A4 E282170040 Ｔ／Ｃノズル－１，ＴＰＳ６１－７０ T/C NOZZLE-1: TPS61-70 1

A5 E282170050 Ｔ／Ｃノズル－２，ＴＰＳ６１－７０ T/C NOZZLE-2: TPS61-70 1
A15 E282170150 ベローズ　 １５０ＡＸ１４０ BELLOWS 150AX140 12
A16 E282170160 メクラフタ２４０ COVER 240 4
A19 E282170190 ハイキカンパッキン（２） EXHAUST MANIFOLD GASKET (2) 30

A50 E282170500 ハイキカンパッキン（４） EXHAUST MANIFOLD GASKET (4) 8

A110 E262180290 Ｔ／Ｃガスケツト １３０Ｘ１８５ T/C GASKET 130X185 2
A120 E282171200 ハイキカン，ＰＬＳ－１（８ＲＴ） EXHAUST MANIFOLD: PLS-1(8RT) 2
A121 E282171210 ハイキカン，ＰＬＳ－２（８ＲＴ） EXHAUST MANIFOLD: PLS-2(8RT) 2
A122 E282171220 ハイキカン，ＰＬＳ－３（８ＲＴ） EXHAUST MANIFOLD: PLS-3(8RT) 2

A123 E282171230 ハイキカン，ＰＬＳ－４（８ＲＴ） EXHAUST MANIFOLD: PLS-41(8RT) 2

A124 E282171240 ハイキカン，ＰＬＳ－５（８ＲＴ） EXHAUST MANIFOLD: PLS-5(8RT) 1
A125 E282171250 ハイキカン，ＰＬＳ－６（８ＲＴ） EXHAUST MANIFOLD: PLS-6(8RT) 1
A126 E282171260 ハイキカン，ＰＬＳ－７（８ＲＴ） EXHAUST MANIFOLD: PLS-7(8RT) 1
A127 E282171270 ハイキカン，ＰＬＳ－８（８ＲＴ） EXHAUST MANIFOLD: PLS-8(8RT) 1

A128 E282171280 ハイキカン，ＰＬＳ－９（８ＲＴ） EXHAUST MANIFOLD: PLS-9(8RT) 1

A129 E282171290 ハイキカン，ＰＬＳ－１０（８ＲＴ） EXHAUST MANIFOLD: PLS-10(8RT) 1
A137 E282171370 キュウメンザガネ SPHERICAL WASHER 12

A503 X205014050ZZ HTボルト HT BOLT 104

A504 X205016040ZZ HTボルト HT BOLT 32
A508 X220014000DZ ナット NUT 180
A518 X570006000DZ ロッカクプラグ HEX. PLUG 2
A519 Z565002700ZZ マルパッキン GASKET 2

A520 X570004000DZ ロッカクプラグ HEX. PLUG 2

A521 Z565002100ZZ マルパッキン GASKET 2
A557 X205014055ZZ HTボルト HT BOLT 16
A558 X205014065ZZ HTボルト HT BOLT 12
A564 X205014050ZZ HTボルト HT BOLT 13

A565 X205014055ZZ HTボルト HT BOLT 31

A566 X205014060ZZ HTボルト HT BOLT 4
A567 X205016055ZZ HTボルト HT BOLT 8

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管（８DK,後端過給,排気入口２つ口)
ITEM EXHAUST MANIFOLD (8DK,REAR TUR-
27.2 6･8DK-28e BOCHARGER, GAS INLET 2 ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

B30 E282270300 ハイキカンブラケツト１，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 1: PLS-8D 3

B32 E282270320 ハイキカンブラケツト２，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 2: PLS-8D 1
B34 E282270340 ハイキカンブラケツト３，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 3: PLS-8D 4
B35 E282270350 ハイキカンブラケツト４，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 4: PLS-8D 1
B36 E282270360 ハイキカンブラケツト５，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 5: PLS-8D 1

B37 E282270370 ハイキカンブラケツト６，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 6: PLS-8D 1

B38 E282270380 ハイキカンブラケツト７，ＰＬＳ－８Ｄ EXHAUST MANIFOLD BRAKET 7: PLS-8D 8
B43 E282270430 Ｔ／Ｃノズルササエ－１ T/C NOZZLE SUPPORT-1 1
B44 E282270440 Ｔ／Ｃノズルササエ－２ T/C NOZZLE SUPPORT-2 1
B45 E282270450 ハイキカンベロ－ズブラケツト BRAKET: EXHAUST PIPE BELLOWS 3

B50 E282270500 ハイキカンブラケツト１１，ＰＬＳ－８ EXHAUST MANIFOLD BRAKET 11: PLS-8D 1

B51 E282270510 ハイキカンブラケツト１２，ＰＬＳ－８ EXHAUST MANIFOLD BRAKET 12: PLS-8D 1
B52 E282270520 ハイキカンブラケツト１３，ＰＬＳ－８ EXHAUST MANIFOLD BRAKET 13: PLS-8D 1
B53 E282270530 ハイキカンブラケツト１４，ＰＬＳ－８ EXHAUST MANIFOLD BRAKET 14: PLS-8D 1
B55 E202651030 サラバネ DISK SPRING 16

B56 E282270560 ハイキカンブラケツト，ＴＰＳ１－Ｐ EXHAUST MANIFOLD BRAKET TPS1-P 1

B57 E282270570 ハイキカンブラケツト，ＴＰＳ２－Ｐ EXHAUST MANIFOLD BRAKET TPS2-P 1

B501 X200012035DZ ボルト BOLT 4

B502 X200012025DZ ボルト BOLT 11
B503 Z300012000ZZ ヒラザガネ FLAT WASHER 70
B507 X200012030DZ ボルト BOLT 4
B508 X220012000DZ ナット NUT 4

B511 X205012050ZZ ＨＴボルト HT BOLT 2

B512 X205012020ZZ ＨＴボルト HT BOLT 45
B513 X220012000DZ ナット NUT 2
B515 X200012020DZ ボルト BOLT 2
B516 X200016025DZ ボルト BOLT 2

B517 Z300016000ZZ ヒラザガネ FLAT WASHER 2

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3
排気管（６ＤＫ,前端過給,排気入口1つ口)
ITEM EXHAUST MANIFOLD (6DK,FRONT TUR-
27.3 6･8DK-28e BOCHARGER, GAS INLET 1 ENTRY)

A543
A68 A64 A73 A60 A73 A64 A75 A67 A78 A65 A539

A P

B22 B22 A504 B22 B23

A

A531 A530

A521 A519 A523

A520 A518 A522
B523
B522 A50

Section " A - A " View " P "

A C
6･8DK-28e Z 11-5
 排気管（６ＤＫ,前端過給,排気入口1つ口) CHAPTER
3
EXHAUST MANIFOLD (6DK,FRONT TUR- ITEM

BOCHARGER, GAS INLET 1 ENTRY) 6･8DK-28e 27.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
904 ハイキカンＡＳＳＹ． EX.MANIFOLD ASSY. 1

A50 E282170500 ハイキカンパツキン　 　 　 　 　 　 GASKET 6

Ａ60 E282170600 ベロ－ズ　 　 　 　 　 BELLOWS 2
A64 E282170640 ハイキカンパツキン　 　 　 　 　 　 GASKET 5
A65 E282170650 Ｔ／Ｃイリグチパツキン GASKET 1
A67 E262180140 ハイキカンパツキン　 　 　 　 　 　 GASKET 1

A68 E282170680 メクラフタ　 　 　 　 　 　 　 　 　 　 　 BLANK FLANGE 1

A73 E282170730 ハイキカン（ＦＴ）　 　 EX.MANIFOLD(FT) 2
A75 E282170750 Ｔ／Ｃ　 イリグチカン－ＦＴ T/C INLET PIPE-FT 1
A78 E282170780 ベロ－ズ（ＦＴ）　 BELLOWS(FT) 1

A504 X200016040DZ ボルト BOLT 24

A515 Z315016000ZZ ハツキザガネ　 　 　 　 TOOTHED LOCK WASHER 24
A518 X570006000DZ ロツカクプラグ　 　 　 　 　 　 HEX.PLUG 1
A519 Z565002700ZZ マルパツキン　 　 　 　 　 　 　 　 　 　 GASKET 1
A520 X570004000DZ ロツカクプラグ　 　 　 　 　 　 　 　 HEX.PLUG 1

A521 Z565002100ZZ マルパツキン　 　 　 　 　 　 　 　 　 　 GASKET1 1

A522 X570010000DZ ロツカクプラグ　 　 　 　 　 　 　 　 　 　 HEX.PLUG 1
A523 Z565003400ZZ マルパツキン　 GASKET 1
A530 X205020065ZZ ＨＴボルト　 　 HT BOLT 36
A531 X220020000DZ ナツト　 　 　 　 　 　 　 　 NUT 36

A532 Z315020000ZZ ハツキザガネ　 　 　 　 　 　 　 　 TOOTHED LOCK WASHER 36

A539 X220010000DZ ナツト　 　 　 　 　 　 　 　 NUT 8
A540 Z315010000ZZ ハツキザガネ　 　 　 　 　 　 　 　 TOOTHED LOCK WASHER 8
A543 X205010055ZZ ＨＴボルト　 　 HT BOLT 8

B22 E282270220 ハイキカンブラケツト－８Ｄ　 　 BRACKET-8D 3

B23 E282270230 ハイキカンブラケツト－ＦＴ　 　 　 　 　 BRACKET 1

B522 X200012025ZZ ボルト　 　 　 　 BOLT 8

B523 X200012020DZ ボルト　 　 　 　 BOLT 8

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管（6DK,後端過給,排気入口２つ口)
ITEM EXHAUST MANIFOLD (6DK,REAR
27.4 6･8DK-28e TURBOCHARGER, GAS INLET 2 ENTRY)

A50

A504

B502 A15
A508 A19 A503

View "Q"

A507 A22
A502
A-518 , A-519 A520, A521 Q
A70 A44 A45 A43 B26 A6 A41 A41 A6 A16 A43

A71
A507 B6 A43
A-544 B502,B503 B505, B509 B25

A C
6･8DK-28e Z 11-5
 排気管（6DK,後端過給,排気入口２つ口) CHAPTER
3
EXHAUST MANIFOLD (6DK,REAR ITEM
TURBOCHARGER, GAS INLET 2 ENTRY) 6･8DK-28e 27.4

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

903 ハイキカンＡＳＳＹ－２Ｅ（ＲＴ） EXHAUST MANIFOLD ASSY.-2E（RT) 1

Ａ6 E282170060 ハイキカン EXHAUST MANIFOLD 2

Ａ15 E282170150 ベローズ BELLOWS 4
Ａ16 E282170160 メクラフタ BLANK COVER 2
Ａ19 E282170190 ハイキカンパッキン GASKET; EXHAUST MANIFOLD 15
Ａ22 E282170220 タービンイリグチパッキン GASKET; T/C INLET 2

Ａ41 E282170410 ハイキカン EXHAUST MANIFOLD 2

Ａ43 E282170430 ハイキカン EXHAUST MANIFOLD 3
Ａ44 E282170440 ハイキカン EXTHAUST MANIFOLD 1
Ａ45 E282170450 ハイキカン EXTHAUST MANIFOLD 1
Ａ50 E282170500 ハイキカンパッキン GASKET; EXHAUST MANIFOLD 6

Ａ70 E282170700 Ｔ／Ｃイリグチカン T/C INLET PIPE 1

Ａ71 E282170710 Ｔ／Ｃイリグチカン T/C INLET PIPE 1

Ａ502 X205012045ZZ ＨＴボルト HT BOLT 6

Ａ503 X205014050ZZ ＨＴボルト HT BOLT 90
Ａ504 X200016040DZ ボルト BOLT 24
Ａ507 X220012000DZ ナット NUT 18
Ａ508 X220014000DZ ナット NUT 90

Ａ518 X570006000DZ ロッカクプラグ HEX.PLUG 2

Ａ519 Z565002700ZZ マルパッキン GASKET 2
Ａ520 X570004000DZ ロッカクプラグ HEX.PLUG 2
Ａ521 Z565002100ZZ マルパッキン GASKET 2
Ａ522 X570010000DZ ロッカクプラグ HEX.PLUG 2

Ａ523 Z565003400ZZ マルパッキン GASKET 2

Ａ544 X210012060DZ スタッド STUD 6

Ｂ6 E282270060 ハイキカンササエ SUPPORTER; EX. MANIFOLD 5

Ｂ25 E282270250 ハイキカンブラケット BRACKET; EX. MANIFOLD 1
Ｂ26 E282270260 ハイキカンブラケット BRACKET; EX. MANIFOLD 1

Ｂ502 X200012025DZ ボルト BOLT 14

Ｂ503 Z300012000ZZ ヒラザガネ FLAT WASHER 10
Ｂ505 X220016000ZZ ナット NUT 4

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管カバ-（８ＤＫ,前端過給,排気入口1つ口)
ITEM EXHAUST MANIFOLD COVER(8DK,FRONT
28.1 6･8DK-28e TURBOCHARGER, GAS INLET 1 ENTRY)

74 71 75 72 75 72 75 72

564, 565 130

548, 549

A B

132 551, 552

A
65 66 66 67 B 558, 559 557

540, 541 546, 547 543 136 138 131

84 128 85
83 556 555
129
82 538
133
536 137
554
525 561, 562
View "P" Section "A-A" Section "B-B" View "Q"

A C
6･8DK-28e Z 11-5
 排気管カバ-（８ＤＫ,前端過給,排気入口1つ口) CHAPTER
3
EXHAUST MANIFOLD COVER(8DK,FRONT ITEM

TURBOCHARGER, GAS INLET 1 ENTRY) 6･8DK-28e 28.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

65 E282570650Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1

66 E282570660Z ハイキカンカバ COVER: EXHAUST MANIFOLD 2
67 E282570670Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1
71 E282570710D ハイキカンカバ COVER: EXHAUST MANIFOLD 1
72 E282570720C ハイキカンカバ COVER: EXHAUST MANIFOLD 3

74 E282570740A ハイキカンカバ COVER: EXHAUST MANIFOLD 1

75 E282570750A ハイキカンカバ COVER: EXHAUST MANIFOLD 3
82 E282570820Z ハイキカンカバブラケツト BRACKET: EXHAUST MANIFOLD COVER 5
83 E282570830A ハイキカンカバブラケツト BRACKET: EXHAUST MANIFOLD COVER 3
84 E282570840A ハイキカンカバブラケツト BRACKET: EXHAUST MANIFOLD COVER 1

85 E282570850A ハイキカンカバブラケツト BRACKET: EXHAUST MANIFOLD COVER 1

128 E282571280Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1
129 E282571290Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1
130 E282571300Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1
131 E282571310Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1

132 E282571320Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1

133 E282571330Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1
136 E282571360Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1
137 E282571370A ハイキカンカバ COVER: EXHAUST MANIFOLD 1
138 E282571380Z ハイキカンカバ COVER: EXHAUST MANIFOLD 1

525 X200012030ZZ ボルト BOLT 20

536 X200012035ZZ ボルト BOLT 16
538 X200012025ZZ ボルト BOLT 16
540 X200012045ZZ ボルト BOLT 24
541 Z300012000ZZ ヒラザガネ FLAT WASHER 24

543 X200012045ZZ ボルト BOLT 16

546 X200012025ZZ ボルト BOLT 24
547 Z300012000ZZ ヒラザガネ12 FLAT WASHER 24
548 X200006012ZZ ボルト BOLT 4
549 X220006000ZZ ナット NUT 4

551 X200006014ZZ ボルト BOLT 5

552 X220006000ZZ ナット NUT 5
554 X200012025ZZ ボルト BOLT 2
555 X200012025ZZ ボルト BOLT 3
556 X200012025ZZ ボルト BOLT 2

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管カバ-（８ＤＫ,前端過給,排気入口1つ口)
ITEM EXHAUST MANIFOLD COVER(8DK,FRONT
28.1 6･8DK-28e TURBOCHARGER, GAS INLET 1 ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

557 X200012020ZZ ボルト BOLT 2

558 X200012025ZZ ボルト BOLT 6
559 Z300012000ZZ ヒラザガネ FLAT WASHER 6
561 X200012025ZZ ボルト BOLT 2
562 X220012000ZZ ナット NUT 2

564 X200012020ZZ ボルト BOLT 4

565 Z300012000ZZ ヒラザガネ FLAT WASHER 4

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3
排気管カバ-（８ＤＫ,後端過給,排気入口２つ口)
ITEM EXHAUST MANIFOLD COVER(8DK,REAR
28.2 6･8DK-28e TURBOCHARGER, GAS INLET 2 ENTRY)

319 593, 594

322 591, 592

316
A

P Q

A
321 601 317
596, 597 161
185 574 201 162 163 164

593, 594 320 589, 590 571, 572 167 562 546, 547 175
570
199 168
318 183
181
324 540 169
595 541
323 184
180 182
543
536 544
562
598 538
525 599
600
178 573 538

View "P" Section "A-A" View "Q"

A C
6･8DK-28e Z 11-5
 排気管カバ-（８ＤＫ,後端過給,排気入口２つ口) CHAPTER
3
EXHAUST MANIFOLD COVER(8DK,REAR ITEM

TURBOCHARGER, GAS INLET 2 ENTRY) 6･8DK-28e 28.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

161 E282571610A ハイキカンカバー　 ８ＤＫＭ－１ EXHAUST MANIFOLD CAVER 8DKM-1 1

162 E282571620A ハイキカンカバー　 ８ＤＫＭ－２ EXHAUST MANIFOLD CAVER 8DKM-2 1
163 E282571630A ハイキカンカバー　 ８ＤＫＭ－３ EXHAUST MANIFOLD CAVER 8DKM-3 1
164 E282571640A ハイキカンカバー　 ８ＤＫＭ－４ EXHAUST MANIFOLD CAVER 8DKM-4 1
167 E282571670Z ハイキカンカバー　 ８ＤＫＭ－５ EXHAUST MANIFOLD CAVER 8DKM-5 4

168 E282571680B ハイキカンカバー　 ８ＤＫＭ－６ EXHAUST MANIFOLD CAVER 8DKM-6 4

169 E282571690Z ハイキカンカバー　 ８ＤＫＭ－７ EXHAUST MANIFOLD CAVER 8DKM-7 4
175 E282571750Z ハイキカンカバー　 ８ＤＫＭ－１０ EXHAUST MANIFOLD CAVER 8DKM-8 1
178 E282571780Z ハイキカンカバブラケツト　 ８Ｍ－１ BRACKET: EXHAUST MANIFOLD CAVER 8M-1 5
180 E282571800A ハイキカンカバブラケツト　 ８Ｍ－３ BRACKET: EXHAUST MANIFOLD CAVER 8M-3 1

181 E282571810A ハイキカンカバブラケツト　 ８Ｍ－４ BRACKET: EXHAUST MANIFOLD CAVER 8M-4 1

182 E282571820Z ハイキカンカバブラケツト　 ８Ｍ－５ BRACKET: EXHAUST MANIFOLD CAVER 8M-5 1
183 E282571830B ハイキカンカバブラケツト　 ８Ｍ－６ BRACKET: EXHAUST MANIFOLD CAVER 8M-6 3
184 E282571840B ハイキカンカバブラケツト　 ８Ｍ－７ BRACKET: EXHAUST MANIFOLD CAVER 8M-7 2
185 E282571850Z カバ＆キキトリツケイタ BRACKET: CAVER & EQIOPMENT 4

199 E282571990Z カバブラケット　 ６１Ｄ－ＲＴ CAVER BRAKET 61D-RT 1

201 E282572010A ハイキカンカバブラケット　 ８Ｍ－８ BRACKET: EXHAUST MANIFOLD CAVER 8M-8 1
316 E282575160Z ハイキカンカバー　 ８Ｍ－Ｒ－１ EXHAUST MANIFOLD CAVER 8M-R-1 1
317 E282575170Z ハイキカンカバー　 ８Ｍ－Ｒ－２ EXHAUST MANIFOLD CAVER 8M-R-2 1
318 E282575180Z ハイキカンカバー　 ８Ｍ－Ｒ－３ EXHAUST MANIFOLD CAVER 8M-R-3 1

319 E282575190Z ハイキカンカバブラケット　 ８Ｍ－Ｒ－１ BRACKET: EXHAUST MANIFOLD CAVER 8M-R-1 1

320 E282575200A ハイキカンカバブラケット　 ８Ｍ－Ｒ－２ BRACKET: EXHAUST MANIFOLD CAVER 8M-R-2 1
321 E282575210Z ハイキカンカバブラケット　 ８Ｍ－Ｒ－３ BRACKET: EXHAUST MANIFOLD CAVER 8M-R-3 1
322 E282575220A ハイキカンカバブラケット　 ８Ｍ－Ｒ－４ BRACKET: EXHAUST MANIFOLD CAVER 8M-R-4 1
323 E282575230Z ハイキカンカバブラケット　 ８Ｍ－Ｒ－５ BRACKET: EXHAUST MANIFOLD CAVER 8M-R-5 1

324 E282575240A ハイキカンカバブラケット　 ８Ｍ－Ｒ－６ BRACKET: EXHAUST MANIFOLD CAVER 8M-R-6 1

525 X200012030ZZ ボルト BOLT 20

536 X200012035ZZ ボルト BOLT 31
538 X200012025ZZ ボルト BOLT 22
540 X200012045ZZ ボルト BOLT 24
541 Z300012000ZZ ヒラザガネ FLAT WASHER 24

543 X200012045ZZ ボルト BOLT 24

544 Z300012000ZZ ヒラザガネ FLAT WASHER 24
546 X200012025ZZ ボルト BOLT 9
547 Z300012000ZZ ヒラザガネ FLAT WASHER 9
562 X220012000ZZ ナット NUT 9

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管カバ-（８ＤＫ,後端過給,排気入口２つ口)
ITEM EXHAUST MANIFOLD COVER(8DK,REAR
28.2 6･8DK-28e TURBOCHARGER, GAS INLET 2 ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

570 X200012025ZZ ボルト BOLT 6

571 X200012045ZZ ボルト BOLT 24
572 Z300012000ZZ ヒラザガネ FLAT WASHER 24
573 X200012030ZZ ボルト BOLT 8
574 X200012035ZZ ボルト BOLT 24

589 X200012025ZZ ボルト BOLT 9

590 Z300012000ZZ ヒラザガネ FLAT WASHER 9
591 X200012025ZZ ボルト BOLT 7
592 Z300012000ZZ ヒラザガネ FLAT WASHER 7
593 X200012020ZZ ボルト BOLT 5

594 Z300012000ZZ ヒラザガネ FLAT WASHER 5

595 X200012025ZZ ボルト BOLT 4
596 X200012025ZZ ボルト BOLT 6
597 Z300012000ZZ ヒラザガネ FLAT WASHER 6
598 X200012030ZZ ボルト BOLT 2

599 X220012000ZZ ナット NUT 2

600 Z300012000ZZ ヒラザガネ FLAT WASHER 2
601 X200016020ZZ ボルト BOLT 2

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3
排気管カバ-（６ＤＫ,前端過給,排気入口1つ口)
ITEM EXHAUST MANIFOLD COVER(6DK,FRONT
28.3 6･8DK-28e TURBOCHARGER, GAS INLET 1 ENTRY)

74 71 75 72 75 72

564,565 548,549
B
134
A

P Q

132
A B
65 66 67 558,559 557 551,552

136 135 139

540,541 546,547 543
84 128 85
83 555

538 129
556
536 133
82 554
137 561,562
525
View "P" Section "A-A" Section "B-B" View "Q"

A C
6･8DK-28e Z 11-5
 排気管カバ-（６ＤＫ,前端過給,排気入口1つ口) CHAPTER
3
EXHAUST MANIFOLD COVER(6DK,FRONT ITEM

TURBOCHARGER, GAS INLET 1 ENTRY) 6･8DK-28e 28.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

65 E282570650 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1

66 E282570660 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
67 E282570670 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
71 E282570710 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
72 E282570720 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 2

74 E282570740 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1

75 E282570750 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 2
82 E282570820 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 4
83 E282570830 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 2
84 E282570840 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 1

85 E282570850 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 1

128 E282571280 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
129 E282571290 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
132 E282571320 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
133 E282571330 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1

134 E282571340 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1

135 E282571350 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
136 E282571360 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
137 E282571370 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1
139 E282571390 ﾊｲｷｶﾝｶﾊﾞ COVER，EX.MANIFOLD 1

525 X200012030ZZ ﾎﾞﾙﾄ BOLT 16

536 X200012035ZZ ﾎﾞﾙﾄ BOLT 12
538 X200012025ZZ ﾎﾞﾙﾄ BOLT 12
540 X200012045ZZ ﾎﾞﾙﾄ BOLT 18
541 Z300012000ZZ ﾋﾗｻﾞｶﾞﾈ FLAT WASHER 18

543 X200012045ZZ ﾎﾞﾙﾄ BOLT 12

546 X200012025ZZ ﾎﾞﾙﾄ BOLT 24
547 Z300012000ZZ ﾋﾗｻﾞｶﾞﾈ FLAT WASHER 24
548 X200006012ZZ ﾎﾞﾙﾄ BOLT 4
549 X220006000ZZ ﾅﾂﾄ NUT 4

551 X200006014ZZ ﾎﾞﾙﾄ BOLT 5

552 X220006000ZZ ﾅﾂﾄ NUT 5
554 X200012025ZZ ﾎﾞﾙﾄ BOLT 2
555 X200012025ZZ ﾎﾞﾙﾄ BOLT 3
556 X200012025ZZ ﾎﾞﾙﾄ BOLT 2

A C
6･8DK-28e Z 11-5
CHAPTER
3
排気管カバ-（６ＤＫ,前端過給,排気入口1つ口)
ITEM EXHAUST MANIFOLD COVER(6DK,FRONT
28.3 6･8DK-28e TURBOCHARGER, GAS INLET 1 ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

557 X200012020ZZ ﾎﾞﾙﾄ BOLT 2

558 X200012025ZZ ﾎﾞﾙﾄ BOLT 6
559 Z300012000ZZ ﾋﾗｻﾞｶﾞﾈ FLAT WASHER 6
561 X200012025ZZ ﾎﾞﾙﾄ BOLT 2
562 X220012000ZZ ﾅﾂﾄ NUT 2

564 X200012020ZZ ﾎﾞﾙﾄ BOLT 4

565 Z300012000ZZ ﾋﾗｻﾞｶﾞﾈ FLAT WASHER 4

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3
排気管カバ-（６ＤＫ,後端過給,排気入口２つ口)
ITEM EXHAUST MANIFOLD COVER(6DK,REAR
28.4 6･8DK-28e TURBOCHARGER, GAS INLET 2 ENTRY)

116 113 117 114

Q
P

109 110 111

124 546,547
540,541 119 122
125 126
120

538
543

536
525 64

View "P" Section "A-A" View "Q"

A C
6･8DK-28e Z 11-5
 排気管カバ-（６ＤＫ,後端過給,排気入口２つ口) CHAPTER
3
EXHAUST MANIFOLD COVER(6DK,REAR ITEM

TURBOCHARGER, GAS INLET 2 ENTRY) 6･8DK-28e 28.4

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

64 E282570640 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 4

109 E282571090 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1
110 E282571100 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1
111 E282571110 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1
113 E282571130 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1

114 E282571140 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 2

116 E282571160 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1
117 E282571170 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 2
119 E282571190 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1
120 E282571200 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1

122 E282571220 ﾊｲｷｶﾝｶﾊﾞ COVER ，EX.MANIHOLD 1

124 E282571240 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 1
125 E282571250 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 2
126 E282571260 ﾊｲｷｶﾝｶﾊﾞﾌﾞﾗｹﾂﾄ BRACKET，EX.MANI.COVER 1

525 X200012030ZZ ﾎﾞﾙﾄ BOLT 16

536 X200012035ZZ ﾎﾞﾙﾄ BOLT 12
538 X200012025ZZ ﾎﾞﾙﾄ BOLT 12
540 X200012045ZZ ﾎﾞﾙﾄ BOLT 12
541 Z300012000ZZ ﾋﾗｻﾞｶﾞﾈ FLAT WASHER 12

543 X200012045ZZ ﾎﾞﾙﾄ BOLT 12

546 X200012025ZZ ﾎﾞﾙﾄ BOLT 18
547 Z300012000ZZ ﾋﾗｻﾞｶﾞﾈ FLAT WASHER 18

A C
6･8DK-28e Z 11-5
CHAPTER
過給機、空気冷却器取付（８ＤＫ、前端過給,、排気入口１つ口)
3
ITEM TURBOCHARGER AIRCOOLER FITTING
29.1 6･8DK-28e (8DK,FRONT T/C,GAS INLET 1 ENTRY)

A536
A88
A583
A525, A529
A506
A107
A505 View "P"
B73
A109
B505, B506
A531, A524

A578
B545, B543 C550
A556
B546, B544
C549
B72
B510
B524
A205 Detail "B"
B

A519 C3 B215

A526, A530 A89 A94 A508 TUBOCHARGER

B136,
B138, B218

A106 B508

B542, B543
A582
B522
P A579, A
A580, A581

A102

A564 A563 B227

A78 B219 B525

B514, B517 B
B520
Detail "A"
A
B522 B533, B534, B535 B510

A C
6･8DK-28e Z 11-5
 過給機、空気冷却器取付（８ＤＫ、前端過給,、排気入口１つ口) CHAPTER
3
TURBOCHARGER AIRCOOLER FITTING ITEM
(8DK,FRONT T/C,GAS INLET 1ENTRY) 6･8DK-28e 29.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
A78 E282370780 サラバネ CONICAL WASHER 12
A88 E282370880 Ｔ／Ｃデグチダクト DUCT: T/C OUTLET 1
A89 E282370890 Ｔ／Ｃハイキデグチガスケット GASKET: T/C OUTLET 1
A94 E282370940 ボルト BOLT 2
A102 E282371020 Ｔ／Ｃダイ MOUNT: T/C 1

A106 E282371060 ディスタンス DISTANCE 4

A107 E282371070 ブラケット１ BRACKET 1 1
A109 E282371090 ブラケット２ BRACKET 2 2
A205 E282375050 ブラケット BRACKET 1

A505 Z560103035DZ Ｏリング O-RING 1

A506 Z560207031DZ Ｏリング O-RING 1
A508 Z300024000ZZ ヒラザガネ FLAT WASHER 2
A519 X220016000ZZ ナット NUT 2
A524 Z565001300EE マルパッキン GASKET 2

A525 Z565002100ZZ マルパッキン GASKET 3

A526 Z565002700ZZ マルパッキン GASKET 2
A529 X570004000DZ ロッカクプラグ HEX. PLUG 3
A530 X570006000DZ ロッカクプラグ HEX. PLUG 2
A531 X570002000ZZ ロッカクプラグ HEX. PLUG 2

A536 X220012000DZ ナット NUT 8

A556 X200016030ZZ ボルト BOLT 4
A563 X200016035ZZ ボルト BOLT 6
A564 X200016030ZZ ボルト BOLT 2
A578 X200016055ZZ ボルト BOLT 4

A579 Z300016000ZZ ヒラザガネ FLAT WASHER 4

A580 X205016040ZZ ＨＴボルト HT BOLT 2
A581 X220016000DZ ナット NUT 2
A582 X205016028ZZ ＨＴボルト HT BOLT 2
A583 X205012080ZZ ＨＴボルト HT BOLT 4

A C
6･8DK-28e Z 11-5
CHAPTER
過給機、空気冷却器取付（８ＤＫ、前端過給,、排気入口１つ口)
3
ITEM TURBOCHARGER AIRCOOLER FITTING
29.1 6･8DK-28e (8DK,FRONT T/C,GAS INLET 1ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

B72 E282670720 カバー COVER 1

B73 E282670730 ブロワデグチガスケット GASKET: BLOWER OUTLET 1
B136 E282671360 Ｉ／Ｃイリグチフランジ FLANGE: I/C INLET 1
B138 E282671380 Ｉ／Ｃイリグチガスケット GASKET: I/C INLET 1
B215 E282675150 Ｉ／Ｃブラケット BRACKET: I/C 1

B218 E282675180 ダクト DUCT 1

B219 E282675190 Ｉ／Ｃパッキン GASKET: I/C 1
B227 E262385350 Ｏリング O-RING 1

B505 X200016060ZZ ボルト BOLT 6

B506 X220016000ZZ ナット NUT 6
B508 X200016050ZZ ボルト BOLT 4
B510 X200022050DZ ボルト BOLT 16
B514 Z565002100EE マルパッキン GASKET 2

B517 X570004000ZZ ロッカクプラグ HEX. PLUG 2

B520 X200016120ZZ ボルト BOLT 12
B522 X200016105ZZ ボルト BOLT 2
B524 X200016040ZZ ボルト BOLT 22
B525 X200016035ZZ ボルト BOLT 22

B533 X340010032ZZ ノックボルト KNOCK BOLT 2

B534 Z300008000ZZ ヒラザガネ FLAT WASHER 2
B535 X220308000ZZ ナット NUT 2
B542 X200012016ZZ ボルト BOLT 2
B543 Z310012000ZZ バネザガネ SPRING WASHER 8

C3 C04560 エアクーラ（仕様により異なる） AIR COOLER (Depend on spec.) 1

C549 C045605490 シールフランジ SEAL FLANGE 1

C550 C045605500 Ｏリング O-RING 1

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e

A C
CHAPTER
過給機、空気冷却器取付（８ＤＫ、後端過給,、排気入口２つ口)
3
ITEM TURBOCHARGER AIRCOOLER FITTING
29.2 6･8DK-28e (8DK,REAR T/C,GAS INLET 2ENTRY)

TURBOCHAGER A508 A94 A536

A505 (INLET) A89 A564
A506 (OUTLE
(OUTLET) A510, A515
A78
A207
A86
A582 Detail "A"
A111
A572, A579, A580, A581
A573
A112
A502 P
A
B
A91
A518, A519, A520
B525
C3
A525, A529
A526, A530
B558,, B559
B219 A113
B514, B517
B533
B534
B510 B521 B531 B535 B505, B506

B77 B73
B74

B227

B222

B508
C549

C550 A516

B54

Detail "B" B30

B221 B514, B517
B524
View "P"

A C
6･8DK-28e Z 11-5
 過給機、空気冷却器取付（８ＤＫ、後端過給,、排気入口２つ口) CHAPTER
3
TURBOCHARGER AIRCOOLER FITTING ITEM
(8DK,REAR T/C,GAS INLET 2ENTRY) 6･8DK-28e 29.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

A78 E282370780 サラバネ CONICAL WASHER 12

A86 E282370860 T/Cダイ MOUNT: T/C 1
A88 E282370880 T/Cデグチダクト DUCT: T/C OUTLET 1
A89 E282370890 T/Cハイキデグチガスケット GASKET: T/C OUTLET 1
A91 E282370910 T/Cデグチカンブラケット-1 BRACKET: T/C OUTLET DUCT 1

A94 E282370940 ボルト BOLT 2

A111 E282371110 ブラケット-ウエ BRACKET UPPER 1
A112 E282371120 ブラケット-シタ BRACKET LOWER 1
A113 E282371130 ブラケット BRACKET 1

A502 X200016040ZZ ボルト BOLT 6

A505 Z560103035DZ Oリング O-RING 1
A506 Z560207031DZ Oリング O-RING 1
A508 Z300024000ZZ ヒラザガネ FLAT WASHER 2
A510 X205022080ZZ HTボルト HT BOLT 16

A515 X220022000ZZ ナット NUT 16

A516 X200012030ZZ ボルト BOLT 4
A518 X200016060ZZ ボルト BOLT 2
A519 X220016000ZZ ナット NUT 2
A520 Z300016000ZZ ヒラザガネ FLAT WASHER 4

A525 Z565002100ZZ マルパッキン GASKET 3

A526 Z565002700ZZ マルパッキン GASKET 2
A529 X570004000DZ ロッカクプラグ HEX. PLUG 3
A530 X570006000DZ ロッカクプラグ HEX. PLUG 2
A536 X220012000DZ ナット NUT 12

A564 X200016030ZZ ボルト BOLT 2

A572 Z565001300EE マルパッキン GASKET 2
A573 X570002000ZZ ロッカクプラグ HEX. PLUG 2
A579 Z300016000ZZ ヒラザガネ FLAT WASHER 4
A580 X205016040ZZ HTボルト HT BOLT 2

A581 X220016000DZ ナット NUT 2

A582 X205016028ZZ HTボルト HT BOLT 2

A C
6･8DK-28e Z 11-5
CHAPTER
過給機、空気冷却器取付（８ＤＫ、後端過給,、排気入口２つ口)
3
ITEM TURBOCHARGER AIRCOOLER FITTING
29.2 6･8DK-28e (8DK,REAR T/C,GAS INLET 2ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

B30 E282670300 I/Cイリグチガスケット GASKET: I/C INLET 1

B54 E282670540 I/Cイリグチカン I/C INLET PIPE 1
B73 E282670730 ブロワデグチガスケット GASKET: BLOWER OUTLET 1
B74 E282670740 I/Cイリグチカンガスケット GASKET: I/C INLET PIPE 1
B77 E282670770 I/Cイリグチカンフランジ FLANGE: I/C INLET PIPE 1

B219 E282675190 I/Cパッキン GASKET: I/C 1

B221 E282675230 I/Cブラケット BRACKET: I/C 1
B222 E282675260 I/Cダクト DUCT: I/C 1
B227 E282670300 Oリング O-RING 1

B505 X200016060ZZ ボルト BOLT 6

B506 X220016000ZZ ナット NUT 6
B508 X200016050ZZ ボルト BOLT 6
B510 X200022050DZ ボルト BOLT 16
B514 Z565002100EE マルパッキン GASKET 2

B517 X570004000ZZ ロッカクプラグ HEX. PLUG 2

B521 X200016150ZZ ボルト BOLT 12
B524 X200016040ZZ ボルト BOLT 22
B525 X200016035ZZ ボルト BOLT 22
B531 X200016040ZZ ボルト BOLT 24

B533 X340010032ZZ ノックボルト KNOCK BOLT 2

B534 Z300008000ZZ ヒラザガネ FLAT WASHER 2
B535 X220308000ZZ ナット NUT 2
B558 X570002000ZZ ロッカクプラグ GASKET 1
B559 Z565001300EE マルパッキン 1

C3 C04560 エアクーラ（仕様により異なる） AIR COOLER (Depend on spec.) 1

C549 C045605490 シールフランジ SEAL FLANGE 1

C550 C045605500 Ｏリング O-RING 1

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
過給機（ＭＥＴ）、空気冷却器取付（６ＤＫ、後端過給,、排気入口２つ口)
3
ITEM TURBOCHARGER(MET) AIRCOOLER FITTING
29.3 6･8DK-28e (6DK,REAR T/C,GAS INLET 2ENTRY)

A515,A510
A526,A530
TURBOCHAGER A562

A525,A529
View " C "

A2 A525,A529

A65
A546 C549

A547 C550
B
A55
A563
C3
B
B219

B525 B517,B514
B521 B531 B510 B533,B534,B535
C
View " P "
B59
A B74

B225
B78

B229

B508 B558,B559
B54
B517,B514

B30
View " A "
B524 B224

A C
6･8DK-28e Z 11-5
 過給機（ＭＥＴ）、空気冷却器取付（６ＤＫ、後端過給,、排気入口２つ口) CHAPTER
3
TURBOCHARGER(MET) AIRCOOLER FITTING ITEM
(6DK,REAR T/C,GAS INLET 2ENTRY) 6･8DK-28e 29.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
A2 E282370020 ハイキデグチカン-30SR GAS OUTLET DUCT-30SR 1
A55 E282370550 T/Cブラケツト30SR-RT(2E) T/C BRACKET 30SR-RT(2E) 1
A65 E282370650 フランジパツキン GASKET 1

A510 X205022080ZZ HTボルト HT BOLT 16

A515 X220022000ZZ ナット NUT 16
A525 Z565002100ZZ マルパッキン GASKET 2
A526 Z565002700ZZ マルパッキン GASKET 1
A529 X570004000DZ ロッカクプラグ HEX. PLUG 2

A530 X570006000DZ ロッカクプラグ HEX. PLUG 1

A546 X205012035ZZ HTボルト HT BOLT 12
A547 X200020040ZZ ボルト BOLT 2
A562 X205020095ZZ HTボルト HT BOLT 2
A563 X200016035ZZ ボルト BOLT 5

B30 E282670300 ガスケット GASKET 1

B54 E282670540 I/C イリグチカン-117S I/C INLET DUCT-117S 1
B59 E262380140 フランジパツキン FLANGE GASKET 1
B74 E282670740 ガスケット GASKET 1
B78 E282670780 フランジ FLANGE 1

B219 E282675190 パッキン GASKET 1

B224 E282675280 I/C ブラケット;DHB151 I/C BRACKET;DHB151 1
B225 E282675300 ダクト:I/C(DHB151) DUCT;I/C(DHB151) 1
B229 E262385330 Oリング O-RING 1

B508 X200016050ZZ ボルト BOLT 6

B510 X200022050DZ ボルト BOLT 16
B514 Z565002100EE マルパッキン GASKET 2
B517 X570004000ZZ ロッカクプラグ HEX. PLUG 2
B521 X200016150ZZ ボルト BOLT 12

B524 X200016040ZZ ボルト BOLT 22

B525 X200016035ZZ ボルト BOLT 22
B531 X200016040ZZ ボルト BOLT 24
B533 X340010032ZZ ノックボルト KNOCK BOLT 2
B534 Z300008000ZZ ヒラザガネ FLAT WASHER 2

B535 X220308000ZZ ナット NUT 2

B558 X570002000ZZ ロッカクプラグ HEX. PLUG 1
B559 Z565001300EE マルパッキン GASKET 1

A C
6･8DK-28e Z 11-5
CHAPTER
過給機（ＭＥＴ）、空気冷却器取付（６ＤＫ、後端過給,、排気入口２つ口)
3
ITEM TURBOCHARGER(MET) AIRCOOLER FITTING
29.3 6･8DK-28e (6DK,REAR T/C,GAS INLET 2ENTRY)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

C3 C0456 エアクーラ(仕様により異なる) AIR COOLER(Depend on spec.) 1

C549 C045605490 シールフランジ SEAL FLANGE 1
C550 C045605500 Ｏ　 リング O-RING 1

A C
6･8DK-28e Z 11-5
 CHAPTER
メモ 3
ITEM
MEMO 6･8DK-28e
CHAPTER
3 ヒートボックス
ITEM
30 6･8DK-28e HEAT BOX

33
22

A C
6･8DK-28e Z 11-5
 CHAPTER
ヒートボックス 3
ITEM
HEAT BOX 6･8DK-28e 30
(1,2)ガバナ(GOVENOR)RHD.UG, (3,4)ガバナ(GOVERNOR)EAR (1)･･6DK (2)･･8DK (3)･･6DK (4)･･8DK

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2) (3) (4)
2 E287270020 カバー:ヒ-トボツクス:マエ COVER,HEAT BOX,FRONT 1 1
3 E287275010 カバー:ヒートボックス:マエ-EAR-20 COVER,HEAT BOX,FRONT(EAR20) 1 1
4 E287270040 ポンプシツカバ(ウシロ) COVER (REAR),HEAT BOX 1 1 1 1
13 E287270130 サイドカバ-1，ヒ-トボツクス HEAT BOX COVER,SIDE-1 2 3 2 3
14 E287270140 サイドカバ-2，ヒ-トボツクス HEAT BOX COVER,SIDE-2 1 1 1 1

20 E287270200 カバー:ポンプシツ:シタ-1 COVER(UNDER-1),HEAT BOX 1 1 1 1

21 E287270210 カバー:ポンプシツ:シタ-2 COVER(UNDER-2),HEAT BOX 1 1 1 1
22 E287270220 カバー:ポンプシツ:シタ-3 COVER(UNDER-3),HEAT BOX 1 1
25 E287270250 ブランクカバー、1 BLANK COVER-1 1 1 1 1
26 E287270260 ブランクカバー、2 BLANK COVER-2 1 1 1 1

29 E287270290 カバ-ササエ、ヒ-トボツクス SUPPORTER,HEAT BOX COVER 2 3 2 3

30 E287270300 ノブトリツケボルト BOLT,SETTING COVER KNOB 6 8 6 8
37 E287270370 ノブ KNOB 12 16 12 16

501 X200012030ZZ ボルト BOLT 4 4 4 4

503 X200012030ZZ ボルト BOLT 2 2 2 2
504 X200012035ZZ ボルト BOLT 3 3 3 3
505 X570002000ZZ ロッカクプラグ HEX.PLUG 2 2
506 X200010015ZZ ボルト BOLT 4 6 4 6

507 Z300010000ZZ ヒラザガネ FLAT WASHER 2 3 2 3

508 Z415002014ZZ スプリングピン SPRING PIN 6 8 6 8
510 X200010020ZZ ボルト BOLT 6 8 6 8
535 X200012025ZZ ボルト BOLT 3 3 3 3
536 X220012000ZZ ナット NUT 4 4 4 4

537 X200012060ZZ ボルト BOLT 3 3 3 3

538 X220012000ZZ ナット NUT 3 3 3 3
540 X200012025ZZ ボルト BOLT 3 3 3 3
541 X220012000ZZ ナット NUT 4 4 4 4
542 X200012060ZZ ボルト BOLT 3 3 3 3

543 X220012000ZZ ナット NUT 3 3 3 3

545 X200012045ZZ ボルト BOLT 2 4 2 4
546 X220012000ZZ ナット NUT 2 4 2 4
548 X200012025ZZ ボルト BOLT 2 2
549 X220012000ZZ ナット NUT 4 4

554 X200010014ZZ ボルト BOLT 4 4 4 4

555 X200010014ZZ ボルト BOLT 4 4 4 4

A C
6･8DK-28e Z 11-5
CHAPTER
4 始動弁, 操作弁,電気式始動スイッチ
ITEM STARTING AIR VALVE , STARTING AIR OPERATION
1.1.1 6･8DK-28e VALVE & ELECTRICAL STARTING SWITCH

D A

A-1
A-2

D1

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
始動弁, 操作弁,電気式始動スイッチ 4
STARTING AIR VALVE , STARTING AIR OPERATION ITEM
VALVE & ELECTRICAL STARTING SWITCH 6･8DK-28e 1.1.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
A S108509010 シドウソウサベン STARTING OPERATION VALVE 1

A1 S108500010 マニュアルバルブ MANUAL VALVE 1

A2 S108500020 ホゴカバ PROTECTION COVER 1

B S108709010 シドウベン MAIN AIR STARTING VALVE 1

B1 S108700010 ホンタイ S.A. VALVE BODY 1

B2 S108700020 シタフタ COVER 1
B5 S108700050 ベンボウ VALVE SHAFT 1
B6 S108700060 バルブ VALVE 1
B7 S108700070 バルブウケ SEAT, VALVE 1

B8 S108700080 バルブオサエ COVER, VALVE 1

B9 S108700090 ミゾツキナット HEXAGON SLOTTED & CASTLE NUT 1
B10 S108700100 ワリピン SPLIT PIN 1
B13 S108700130 ピストン　 Ａ PISTON A 1
B14 S108700140 キー KEY 1

B15 S108700150 キーウケ RETAINER, KEY 1

B16 S108700160 トメワ STOP RING 1
B19 S108700190 シリンダ CYLINDER 1
B20 S108700200 ウエフタ COVER 1
B23 S108700230 ピストン　 Ｂ PISTON B 1
1
B24 S108700240 ミゾツキナット HEXAGON SLOTTED & CASTLE NUT 1
B25 S108700250 ワリピン SPLIT PIN 1
B26 S108700260 バネ SPRING 1
B29 S108700290 ボルト BOLT 8
B30 S108700300 ボルト BOLT 4
1
B34 S108700340 メタル METAL 1
B35 S108700350 トメワ STOP RING 1
B38 A226570290 ジドウシドウベンメイバン LABEL, MAIN AIR STARTING VALVE 1
B51 S108600510 フィルタ FILTER 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 始動弁, 操作弁,電気式始動スイッチ
ITEM STARTING AIR VALVE , STARTING AIR OPERATION
1.1.1 6･8DK-28e VALVE & ELECTRICAL STARTING SWITCH

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
B502 Z560206531ZZ Ｏリング O-RING 2
B503 Z560103435ZZ Ｏリング O-RING 1
B504 Z560101524ZZ Ｏリング O-RING 1
B505 Z560101124ZZ Ｏリング O-RING 1
B506 Z560104935ZZ Ｏリング O-RING 1

B507 Z560205031ZZ Ｏリング O-RING 1

B508 Z560101024ZZ Ｏリング O-RING 1
B509 Z560001418ZZ Ｏリング O-RING 1
B519 Z310012000ZZ バネザガネ SPRING WASHER 8
B520 Z310008000ZZ バネザガネ SPRING WASHER 4

C S109609110 シドウベンフゾクキキ ACCESSORIES, S.A. VALVE 1

C92 C040340210 チェックバルブ CHECK VALVE 1

C93 C040340220 ユニオンネジ UNION SCREW 1
C94 C040370342 バネ SPRING 1

C512 X570004000ZZ ロッカクプラグ HEX. PLUG 1

C516 Z565002100ZZ マルパッキン GASKET 1
C525 Z565004200ZZ マルパッキン GASKET 2
C529 X555004120ZZ セッシュザ JOINT SEAT 1

D NN00046002 スイッチボックス SWITCH BOX 1

D1 X245204020ZZ プラスナベコネジ PLUS PAN MACHINE SCREW 4

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
メモ 4
ITEM
MEMO 6･8DK-28e
CHAPTER
4 始動弁取付
ITEM

1.1.2 6･8DK-28e STARTING AIR VALVE FITTING

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

始動弁取付 4
ITEM
STARTING AIR VALVE FITTING 6･8DK-28e 1.1.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 操作弁取付
ITEM

1.1.3 6･8DK-28e STARTING AIR OPERATION VALVE FITTING

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

操作弁取付 4
ITEM
STARTING AIR OPERATION VALVE FITTING 6･8DK-28e 1.1.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 スイッチボックス取付
ITEM

1.1.4 6･8DK-28e SWITCH BOX FITTING

101

Ref.4-1.1.1
SWITCH BOX
START&CHANGE OVER
(NN00046002)

BRACKET:F.O.INLET PIPE

COVER:AUX.GEAR

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

スイッチボックス取付 4
ITEM
SWITCH BOX FITTING 6･8DK-28e 1.1.4

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
101 E292375010 ブラケット BRACKET 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 起動空気管安全栓
ITEM

1.2 6･8DK-28e SAFETY PLUG,STARTING AIR PIPE

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

起動空気管安全栓 4
ITEM
SAFETY PLUG,STARTING AIR PIPE 6･8DK-28e 1.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 NN00160001 セッシュ:アンゼンセン JOINT,SAFETY PLUG 1
2 NN00160002 フクロナット:アンゼンセン CAP NUT,SAFETY PLUG 1
5 NN00160003 バクレツバン:アンゼンセン BURSTING PLATE,SAFETY PLUG 1
7 NN00160004 オリザガネ TAB WASHER 1

502 Z567001800BZ ガスケット GASKET 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 燃料送油ポンプ （TYPE B）
ITEM

2.1 6･8DK-28e FUEL OIL FEED PUMP (TYPE B)

5 , 6, 7, 8

Detail "A"
200
200-4 200-5

200-3 200-2 200-6 200-1 200-7

A

(A) (C)
6･8DK-28 A 06-3
 CHAPTER

燃料送油ポンプ （TYPE B） 4
ITEM
FUEL OIL FEED PUMP (TYPE B) 6･8DK-28e 2.1
(1)(3)････正転用 NORMAL ROTATION (2)(4)････逆転用 REVERSE ROTATION
(1)(2)････6DK (3)(4)････8DK
番号 部品番号 部品名称 Name of Parts 数量 Quantity
Number Parts number (1) (2) (3) (4)
5 C034400050 オイルポンプ, 212HWT031１ OIL PUMP, 212HWT031 1
6 C034400060 オイルポンプ, 212HWTR031 OIL PUMP, 212HWTR031 1
7 C034400070 オイルポンプ, 216HWT031 OIL PUMP, 216HWT031 1
8 C034400080 オイルポンプ, 216HWTR031 OIL PUMP, 216HWTR031 1
200 C034402000 シールキット, HWTVB SEAL KIT, HWTVB 1 1 1 1

200-1 ボールベアリング BALL BEARING (1)* (1)* (1)* (1)*

200-2 ボールベアリング BALL BEARING (1)* (1)* (1)* (1)*
200-3 オイルシール OIL SEAL (1)* (1)* (1)* (1)*
200-4 オイルシール OIL SEAL (1)* (1)* (1)* (1)*
200-5 O リング O-RING (1)* (1)* (1)* (1)*
200-6 O リング O-RING (2)* (2)* (2)* (2)*
200-7 トップカバーパッキン TOP COVER GASKET (2)* (2)* (2)* (2)*

REMARKS; PARTS(SIGNAL*) CANNOT BE PURCHASED BY ITSELF.

* 印部品の単品販売は不可。

(A) (C) 6･8DK-28 A 06-3

CHAPTER
4 燃料送油ポンプ駆動装置 (TYPE B)
ITEM

2.2 6･8DK-28e FUEL OIL FEED PUMP DRIVING DEVISE (TYPE B)

F.O. FEED PUMP

7 513 4 511
512 509
2 12 13
514 507

16

501,505
,

500
510

10,11 14 504,515 502,506,516 3 508 15 6 1 503 9

View:"P"

16

6･8DK-28 A 06-3 (A) (C)

 CHAPTER
燃料送油ポンプ駆動装置 (TYPE B) 4
ITEM
FUEL OIL FEED PUMP DRIVING DEVISE (TYPE B) 6･8DK-28e 2.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 A596800010 クドウジク, FOソウユポンプ DRIVING SHAFT, F.O. FEED PUMP 1
2 A596800020 カバー, チェーンカップリング COVER, COUPLING, F.O. FEED PUMP 1
3 A596800030 ブラケット, FOソウユポンプ BRACKET, F.O. FEED PUMP 1
4 E211350020 ディスタンス, クドウジク,FOP DISTANCE, DRIVING SHAFT, F.O. FEED PUMP 1
6 E211350060 FOポンプクドウギヤ　 Ｚ＝３７ F.O. PUMP DRIVING GEAR Z=37 1

7 E203150130 ガスケット GASKET 2

9 E211350270 ザツキキクナット CASTLE NUT WITH SEAT 1
10 E211350291 シム SHIM 4
11 E211350292 シム SHIM 4
12 A596800120 メイバン, カップリングカバー NAME PLATE, COUPLING COVER 1

13 A596800130 キー SUNK KEY 1

14 A596800060 ローラーチェーンカップリング ROLLER CHAIN COUPLING 1
15 E291370090 ディスタンス, ブラケット,FOP" DISTANCE, BRAKET, F.O. FEED PUMP 1
16 E291370100 ユニオンネジ, FOソウユポンプ UNION SCREW, F.O. FEED PUMP 2

500 X200008045Z ボルト BOLT 4

501 X220008000Z ナット NUT 4
502 X220012000Z ナット NUT 6
503 Z300020000Z ヒラザガネ FLAT WASHER 1
504 Z315006000Z ハツキザガネ TOOTHED LOCK WASHER 4

505 Z315008000Z ハツキザガネ TOOTHED LOCK WASHER 4

506 Z315012000Z ハツキザガネ TOOTHED LOCK WASHER 6
507 Z320004040Z ワリピン SPLIT PIN 1
508 Z310006000Z バネザガネ SPRING WASHER 4
509 Z400007018Z キー KEY 1

510 Z415004030Z スプリングピン SPRING PIN 2

511 Z451163060Z ベアリング BEARING 1
512 Z451162060Z ベアリング BEARING 1
513 Z461406212S オイルシール OIL SEAL 1
514 Z412006200Z スナップリング SNAP RING 1

515 Z212006010Z アナツキボルト HEX. SOCKET BOLT 4

516 X210012066Z スタッド STUD 6

(A) (C) 6･8DK-28 A 06-3

CHAPTER
4 燃料ロキ
ITEM

2.3.1 6･8DK-28e FUEL OIL FILTER

6･8DK-28e Z 11-5 (A)

(A) (C)
(C)
 CHAPTER

燃料ロキ 4
ITEM
FUEL OIL FILTER 6･8DK-28e 2.3.1
3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

(A) (A)
(C) (C) 6･8DK-28e Z 11-5
CHAPTER
4 燃料ロキ
ITEM

2.3.1
3 6･8DK-28e FUEL OIL FILTER

号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

6･8DK-28e Z 11-5 (A)

(A) (C)
(C)
 CHAPTER
メモ 4
ITEM
MEMO 6･8DK-28e
CHAPTER
4 燃料ロキ取付
ITEM

2.3.2 6･8DK-28e FUEL OIL FILTER FITTING

523

6･8DK-28e Z 11-5 (A)

(A) (C)
(C)
 CHAPTER

燃料ロキ取付 4
ITEM
FUEL OIL FILTER FITTING 6･8DK-28e 2.3.2
3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

2
2

523 Z560206531ZZ

RING 4

(A) (A)
(C) (C) 6･8DK-28e Z 11-5
CHAPTER
4 燃料調圧弁
ITEM

2.4 6･8DK-28e FUEL OIL RELIEF VALVE

17

6･8DK-28e Z 11-5 (A) (C)

(A) (C)
 CHAPTER

燃料調圧弁 4
ITEM
FUEL OIL RELIEF VALVE 6･8DK-28e 2.4

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 NN00017001 タイ:チョウアツベン-1 BODY,OIL RELIEF VALVE 1
2 NN00017002 オサエ:バネ CAP,VALVE SPRING 1
3 NN00017003 シート:バネ SEAT,SPRING 1
5 NN00017004 チョウアツベン RELIEF VALVE 1
8 NN00017006 フクロナット CAP NUT 1

10 NN00017007 チョウセイネジ ADJUSTING SCREW 1

17 NN00017008 バネ SPRING 1

500 X220312000ZZ ナット NUT 1

507 Z565001300EE マルパッキン GASKET 4
509 Z565003400EE マルパッキン GASKET 1
511 X570002000ZZ ロッカクプラグ HEX. PLUG 2
521 X570006000ZZ ロッカクプラグ HEX. PLUG 2

522 Z565002700EE マルパッキン GASKET 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 レベルスイッチボックス
ITEM

2.5.1 6･8DK-28e LEVEL SWITCH BOX

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

レベルスイッチボックス 4
ITEM
LEVEL SWITCH BOX 6･8DK-28e 2.5.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 NN00058001 ボックス:レベルスイッチ LEVEL SWITCH BOX 1
5 NN00058002 フタ:レベルスイッチボックス COVER,LEVEL SWITCH BOX 1
6 NN00058003 フタ BLANK PLATE 1
8 NN00058008 カンビヒン:ドレンカン:1 DRAIN PIPE-1 1
9 NN00058009 カンビヒン:ドレンカン:2 DRAIN PIPE-2 1

500 Z310006000ZZ バネザガネ SPRING WASHER 3

501 X200006008ZZ ボルト BOLT 3
502 X200006010ZZ ボルト BOLT 3
503 X200012025ZZ ボルト BOLT 2
505 X200010022ZZ ボルト BOLT 4

506 X200010035ZZ ボルト BOLT 4

507 X220010000ZZ ナット NUT 4
508 Z500302800ZZ JISフランジ JIS FLANGE 1
509 Z501302800AZ JISパッキン JIS GASKET 2
515 X545203000ZZ ツギボルト BANJO PLUG 1

516 Z565001700EE マルパッキン GASKET 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 レベルスイッチボックス（リードスイッチ付）
ITEM

2.5.2 6･8DK-28e LEVEL SWITCH BOX (WITH LEAD SWITCH)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

レベルスイッチボックス（リードスイッチ付） 4
ITEM
LEVEL SWITCH BOX (WITH LEAD SWITCH) 6･8DK-28e 2.5.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 NN00058001 ボックス:レベルスイッチ LEVEL SWITCH BOX 1
5 NN00058002 フタ:レベルスイッチボックス COVER,LEVEL SWITCH BOX 1
8 NN00058008 カンビヒン:ドレンカン:1 DRAIN PIPE-1 1
9 NN00058009 カンビヒン:ドレンカン:2 DRAIN PIPE-2 1

500 Z310006000ZZ バネザガネ SPRING WASHER 3

501 X200006008ZZ ボルト BOLT 3
503 X200012025ZZ ボルト BOLT 2
505 X200010022ZZ ボルト BOLT 4
506 X200010035ZZ ボルト BOLT 4

507 X220010000ZZ ナット NUT 4

508 Z500302800ZZ JISフランジ JIS FLANGE 1
509 Z501302800AZ JISパッキン JIS GASKET 2
515 X545203000ZZ ツギボルト BANJO PLUG 1
516 Z565001700EE マルパッキン GASKET 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 チェックバルブ
ITEM

2.6.1 6･8DK-28e CHECK VALVE

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

チェックバルブ 4
ITEM
CHECK VALVE 6
6･8DK-28e 2.6.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AG01020007

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油ポンプ(8DK)
ITEM

3.1.1 6･8DK-28e LUBRICATING OIL PUMP(8DK)

929,930 A A

Outlet
L

A51 View "P"

(2) 8DK-28L

Outlet

A A
Section "A-A" R

A49 A529 A50 View "P"

(1) 8DK-28

A25 A34 A514 B10 B2

A509 A526

A515
A502
P A518

A513

A46 A11 A47 A10 A30 A1 A528 A15

A67

B501

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

潤滑油ポンプ(8DK) ITEM
4
LUBRICATING OIL PUMP(8DK) 6･8DK-28e 3.1.1
(1)･･正転 NORMAL ROTATION (2)･･逆転 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
929 C036790290 LO ﾎﾟﾝﾌﾟ ASSY L.O. PUMP ASSY 1
930 C036790300 LO ﾎﾟﾝﾌﾟ ASSY L.O. PUMP ASSY 1

A1 C036710010 ポンプジクウケ PUMP BEARING 1 1

A10 C036710100 ポンプタイ PUMP BODY 1 1
A11 C036710110 ポンプタイフタ COVER, PUMP BODY 1 1
A15 C036730150 ポンプモトギヤ PUMP DRIVING GEAR 1
A25 C036730240 ポンプウケギヤ PUMP DRIVING GEAR 1 1

A30 C036740300 デイスタンス DISTANCE PIECE 1 1

A34 G003100440 ニ－ドルベアリング NEEDLE BEARING 5 5
A46 C036740460 スタツド STUD 4 4
A47 AE02106011 スタツド STUD 2 2
A49 C036740490 アンゼンベン SAFETY VALVE 1 1

A50 C036640230 アンゼンベンバネオサエ CAP, SAFETY VALVE SPRING 1 1

A51 C036670371 バネ SPRING 1 1
A67 C036730670 ポンプモトギヤ PUMP DRIVING GEAR 1

A502 Z300039000ZZ ヒラザガネ FLAT WASHER 1 1

A509 X220016000ZZ ナツト NUT 6 6
A513 Z320005070ZZ ワリピン SPLIT PIN 1 1
A514 Z335010025ZZ ヘイコウピン STRAIGHT PIN 4 4
A515 Z400012031ZZ キ－ KEY 1 1

A518 X225639000ZZ キクナツト CASTLE NUT 1 1

A526 Z461507212SB オイルシ－ル OIL SEAL 1 1
A528 Z412007200ZZ スナツプリング SNAP RING 7 7
A529 Z665052000ZZ マルパツキン GASKET 1 1

B2 E270580020 ポンプギヤ PUMP GEAR 1 1

B10 E290500100 ＬＯ　 ポンプタイパツキン GASKET, L.O. PUMP 1 1

B501 X220012000ZZ ナツト NUT 8 8

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油ポンプ(6DK)
ITEM

3.1.2 6･8DK-28e LUBRICATING OIL PUMP(6DK)

A A
925,926
Outlet
L

A51 View "P"

(2) 6DK-28L

Outlet

A A
Section "A-A" R

A49 A529 A50 View "P"

(1) 6DK-28

A21 A34 A514 B10 B2

A509 A526

A515
A502
P A518

A513

A43 A11 A41 A7 A30 A1 A528 A17

A69

B501

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

潤滑油ポンプ(6DK) ITEM
4
LUBRICATING OIL PUMP(6DK) 6･8DK-28e 3.1.2
(1)･･正転 NORMAL ROTATION (2)･･逆転 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
925 C036790250 LO ﾎﾟﾝﾌﾟ ASSY L.O. PUMP ASSY 1
926 C036790260 LO ﾎﾟﾝﾌﾟ ASSY L.O. PUMP ASSY 1

A1 C036710010 ポンプジクウケ PUMP BEARING 1 1

A7 C036710070 ポンプタイ PUMP BODY 1 1
A11 C036710110 ポンプタイフタ COVER, PUMP BODY 1 1
A17 C036730170 ポンプモトギヤ PUMP DRIVING GEAR 1
A21 C036730210 ポンプウケギヤ PUMP DRIVING GEAR 1 1

A30 C036740300 デイスタンス DISTANCE PIECE 1 1

A34 G003100440 ニ－ドルベアリング NEEDLE BEARING 5 5
A40 C036740430 スタツド STUD 4 4
A41 C036740402 スタツド STUD 2 2
A43 C036740430 スタツド STUD 4 4

A49 C036740490 アンゼンベン SAFETY VALVE 1 1

A50 C036640230 アンゼンベンバネオサエ CAP, SAFETY VALVE SPRING 1 1
A51 C036670371 バネ SPRING 1 1
A69 C036730690 ポンプモトギヤ PUMP DRIVING GEAR 1

A502 Z300039000ZZ ヒラザガネ FLAT WASHER 1 1

A509 X220016000ZZ ナツト NUT 6 6
A513 Z320005070ZZ ワリピン SPLIT PIN 1 1
A514 Z335010025ZZ ヘイコウピン STRAIGHT PIN 4 4
A515 Z400012031ZZ キ－ KEY 1 1

A518 X225639000ZZ キクナツト CASTLE NUT 1 1

A526 Z461507212SB オイルシ－ル OIL SEAL 1 1
A528 Z412007200ZZ スナツプリング SNAP RING 7 7
A529 Z665052000ZZ マルパツキン GASKET 1 1

B2 E270580020 ポンプギヤ PUMP GEAR 1 1

B10 E290500100 ＬＯ　 ポンプタイパツキン GASKET, L.O. PUMP 1 1

B501 X220012000ZZ ナツト NUT 8 8

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油冷却器
ITEM

3.2 6･8DK-28e LUBRICATING OIL COOLER

900

16 12,11 18,17 3
2 4-1

4-2
4-5 4-3 1
9
17,18 8 6 501 4-4,4-6 14 501 5 502
11,12

20 19 500

View " A "

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

潤滑油冷却器 4
ITEM
LUBRICATING OIL COOLER 6･8DK-28e 3.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

900 NN00452052 オイルクーラ ASSY. OIL COOLER ASSY. 1

1 NN00452053 ケーシング CASE 1

2 NN00452006 カバ (A) COVER (A) 1
3 NN00452008 カバ (B) COVER (B) 1
4-1 NN00452054-1 チューブプレート (A) TUBE SHEET (A) 1
4-2 NN00452054-2 チューブプレート (B) TUBE SHEET (B) 1

4-3 NN00452054-3 フィンチューブ FIN TUBE 278

4-4 NN00452054-4 ディスタンスパイプ DISTANCE PIPE 1
4-5 NN00452054-5 バッフルプレート BUFFLE PLATE 7
4-6 NN00452054-6 ロッド ROD 4
5 NN00452013 リング RING 1

6 NN00452014 パッキン GASKET 2

8 NN00452015 ボルト BOLT 12
9 NN00452016 ボルト BOLT
11 NN00452017 プラグ PLUG 6
12 NN00452018 パッキン GASKET 6

14 NN00452020 スタンド STAND 2

16 NN00452055 メイバン NAME PLATE 1
17 NN00452024 プラグ PLUG 4
18 NN00452025 パッキン GASKET 4
19 NN00452026 イタ BLIND PLATE 2

20 NN00452028 パッキン GASKET 2

500 X200016035ZZ ボルト BOLT 8

501 X220016000ZZ ナット NUT 24
502 Z560230057ZZ Oリング O RING 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油調圧弁
ITEM

3.3 6･8DK-28e LUBRICATING OIL RELIEF VALVE

45

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

潤滑油調圧弁 4
ITEM
LUBRICATING OIL RELIEF VALVE 6･8DK-28e 3.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
911 C037590110 オイルチヨウアツベン ASSY. OIL RELIEF VALVE 1

3 C037510030 チヨウアツベンタイ RELIEF VALVE BODY 1

5 C037540050 バネウケ RETAINER:VALVE SPRING 1
6 C037540060 ベン VALVE 1
7 C037540070 ケース:バネ VALVE SPRING CASE 1
8 AE02077005 キャップ CAP 1

13 C037570151 バネ SPRING 1
21 C037570201 バネ SPRING 1
45 C037570450 ガスケツト GASKET 1

501 X200012030ZZ ボル BOLT 4

503 X222312000ZZ コガタナット NUT 1
507 X251512070ZZ トメネジ SET SCREW 1
510 Z565002700EE マルパッキン GASKET 1
512 Z540200072ZZ フランジ FLANGE 1

513 Z541206072AZ パッキン GASKET 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油ロキ（主機関）
ITEM LUBRICATING OIL FILTER (FOR MARINE
3.4.1 6･8DK-28e PROPULSION USE)

49

6･8DK-28 A 08-9 (A) (C)

 CHAPTER
潤滑油ロキ（主機関） 4
LUBRICATING OIL FILTER (FOR MARINE ITEM
PROPULSION USE) 6･8DK-28e 3.4.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
13 CO6O7OO130 ロキ FILTER 1

103 C060901850 ロキホンタイ FILTER BODY 1

108 C060901860 キリカエコック COCK 1
110 Y529000025 パッキンシート PACKING SEAT 1
114 Y529000034 パッキン（コック） PACKING (COCK) 1
119 Y529000049 オサエフタ COCK COVER 1

123 Y529000059 ハンドル HANDLE 1

126 Y529000065 ナット（ハンドル） NUT (HANDLE) 1
131 Y529000073 バネ（トメセン） SPRING (NOTCH BAR) 1
135 Y529000080 トメセン NOTCH BAR 1
140 Y529000088 スタッド（フタ） STUD (COVER) 2

143 Y529000093 ナット（フタ） NUT (COVER) 2

144 Y529000093 ナット（フタ） NUT (COVER) 4
147 Y529000100 ボルト（フタ） BOLT (COVER) 2
149 C060701490 Ｏリング（ロキケース） O-RING (CASING) 2
157 C060701570 ジク SHAFT 2

162 C060701620 ケース CASING 2

164 Y529000149 バネ（ロキケース） SPRING (CASING) 2
168 C060701660 Ｏリング（シメツケナット） O-RING (CAP NUT) 2
176 C060701760 シメツケナット CAP NUT 2
178 Y529000178 パッキン（ベンザ） PACKING (VALVE SEA) 2

183 Y529000184 ベンザ VALVE SEAT 2

187 Y529000189 パッキン（カンセッシュ） PACKING (CONNECTOR) 4
191 Y529000195 カンセッシュ CONNECTOR 2
195 Y529000200 パッキン（フクロナット） PACKING (SLEEVE NUT) 2
199 Y529000207 フクロナット SLEEVE NUT 2

203 Y529000211 クウキヌキセン AIR PLUG 2

306 C060702060 スタッド（ロキトリツケ） STUD 4
210 C060702100 バネザガネ（ロキトリツケ） SPRING WASHER 4
229 C060702290 ヒラザガネ FLAT WASHER 1
240 C060700240 エレメントＡＳＳＹ ELEMENT ASSY. 2

246 C060702460 エレメントパッキン PACKING 2

247 C060702470 アイボルト EYE BOLT 2
284 C060702240 フルラインアップ FILLING-UP ASSY. 1
285 C060702850 メイバン NAME PLATE 1
286 C060702860 クイコミツギテ PIPE FITTING 1

287 C060702870 ニップル NIPPLE 1

288 C060702880 バルブ VALVE 1

(A) (C) 6･8DK-28 A 08-9

CHAPTER
4 潤滑油ロキ（補機関）
ITEM LUBRICATING OIL FILTER (FOR GENERA-
3.4.2 6･8DK-28e TOR USE)

23
13 10
5
37
63
77 3B
38,46
34,68
3A
42 40,48
15
17
16
Section " A - A " 42 11 14 47 41 25
Detail " Y "
Z 38 37 35,69
9 83
6 70
2
81
31
30 60 66
1 71 82
27
56
23 79
24
18 75,42
Detail " Z "

52
53 8
44
57
4
28 35,69
55 7
62
61
27
35,69
55
Y
A A

28
35,69

22 26
65
43 21 12

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
潤滑油ロキ（補機関） 4
LUBRICATING OIL FILTER (FOR GENERA- ITEM
TOR USE) 6･8DK-28e 3.4.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
900 E294175340 L.Oロキ FILTER ASSY. 1

1 E294175090 ハウジング HOUSING 1

2 E294175100 カバー COVER 1
3A E294175110 アーム:フラッシング ARM 1
3B AE02141008 プラグ PLUG 2
4 AE02141009 LOカン:ジョイニングチューブ L.O. PIPE ; JOINING TUBE 1
1
5 E294175120 プレート:シーブ:シタ PLATE ; LOWER 1
6 E294175130 プレート:シーブ:ウエ PLATE ; UPPER 1
7 NN00496008 フィルター:エレメント:マルガタ30μｍ FILTER;ELEMENT 48
8 E294175150 フィルター:シーブ FILTER;SIEVE 1
9 E294175160 プレート:カバー PLATE;COVER 1

10 AE02141016 ジク:フラッシングカナルシャフト SHAFT ; FRESHING CANAL 1

11 NN00496011 ハウジング:タービン HOUSING ; TURBINE 1
12 AE02141018 フランジ:フランジファスニング FLANGE 1
13 E294175180 ギヤ GEAR 1
14 NN00496012 タービンインペラ TURBINE IMPELLER 1

15 AE02141021 ギヤ:ツースドホイール GEAR ; TOOTHED WHEEL 1

16 AE02141022 ブッシュ BUSH 1
17 AE02141023 ブッシュ BUSH 1
18 AE02141024 バルブ VALVE 6
21 E294175200 ノズル NOZZLE 1

22 AE02141026 バネ:プレッシャスプリング SPRING 1

23 E294175210 ベアリング:フカミゾタマガタ BEARING 2
24 E294175220 インジケータ:サアツ INDICATOR ; PRESS. DIFFERENCE 1
25 AE02141029 ボルト:スロッテッドチーズヘッド BOLT ; SLOTTED CHEESE HEAD 1
26 AE02141030 ピン PIN 1

27 AE02141031 スプリングピン SPRING PIN 3

28 E294175230 アングルベン ANGLE VALVE 2
30 E294175240 スタッド STUD 8
31 E294175250 ナット NUT 8
34 NN00496022 ロッカクプラグ HEX. PLUG 1

35 AE02141036 ロッカクプラグ HEX. PLUG 5

37 AE02141038 ボルト:スロッテッドチーズヘッド BOLT ; SLOTTED CHEESE HEAD 6
38 AE02141039 ボルト:スロッテッドチーズヘッド BOLT ; SLOTTED CHEESE HEAD 6
40 AE02141040 ソケットヘッドボルト SOCKET HEAD BOLT 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油ロキ（補機関）
ITEM LUBRICATING OIL FILTER (FOR GENERA-
3.4.2 6･8DK-28e TOR USE)

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
41 AE02141041 ボルト BOLT 1

42 AE02141042 ソケットヘッドボルト SOCKET HEAD BOLT 10

43 AE02141043 ソケットヘッドボルト SOCKET HEAD BOLT 4
44 E294175270 ソケットヘッドボルト SOCKET HEAD BOLT 2
46 AE02141045 バネザガネ SPRING WASHER 3
47 AE02141046 ザガネ:ディスク WASHER;DISC 1

48 AE02141047 ザガネ WASHER 1

52 E294175280 ブラケット:インジケータ "BRACKET,INDICATOR" 1
55 AE02141048 セッシュ JOINT 2
56 AE02141049 セッシュ JOINT 2
57 AE02141050 LOカン:チューブ L.O. PIPE ; TUBE 1

60 E294175290 Oリング O-RING 1

61 E294175300 Oリング O-RING 1
62 E294175310 Oリング O-RING 2
63 NN00496030 Oリング O-RING 96
65 AE02141055 Oリング O-RING 1

66 AE02141056 Oリング O-RING 1

68 E294175320 ガスケット GASKET 1
69 AE02141058 ガスケット GASKET 5
70 AE02141059 ガスケット GASKET 1
71 AE02141060 Oリング O-RING 1

75 AE02141061 バネザガネ SPRING WASHER 3

77 AE02141063 ナット NUT 1
79 AE02141064 ソケットヘッドボルト SOCKET HEAD BOLT 1
80A AE02141065 メイバン:ラベルIN NAME PLATE;LABEL IN 1
80B AE02141066 メイバン:ラベルOUT NAME PLATE;LABEL OUT 1

80C AE02141067 メイバン:ネームプレート NAME PLATE 1

81 E294175330 ブッシュ:コンプリートディスプレー BUSH;COMPLETE DISPLAY 1
82 NN00496035 カバー:テンションリング COVER ; TENSION RING 1
83 AE02141070 ガラスキャップ:インスペクショングラス GLASS CAP ; INSPECTION GLASS 1

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
メモ 4
ITEM
MEMO 6･8DK-28e
CHAPTER
4 潤滑油ロキ取付（主機関）
ITEM LUBRICATING OIL FILTER FITTING (FOR
3.4.3 6･8DK-28e MARINE PROPULSION USE)

42

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
潤滑油ロキ取付（主機関） 4
LUBRICATING OIL FILTER FITTING (FOR ITEM
MARINE PROPULSION USE) 6･8DK-28e 3.4.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
2 C060700130 ロキ FILTER 1
4 E274180050 LOロキ&チヨウアツベンタイ L.O.FILTER & RELIEF VALVE BODY 1
6 E294170060 ブラケツト-RT BRACKET-RT 1
10 E294170100 LO ロキブラケツトパツキン GASKET:L.O.FILTER BRACKET 1
13 E294170130 ウケザラ，LOロキ SAUCER 1

15 C037540050 バネウケ RETAINER:VALVE SPRING 1

16 E294175010 ベン VALVE 1
17 C037540070 ケース:バネ: CASE:VALVE SPRING 1
18 AE02077005 キャップ CAP 1
20 C037570400 バネ SPRING 1

21 C037570201 バネ SPRING 1
42 C037570450 ガスケツト GASKET 1
201 C060700240 エレメントASSY ELEMENT ASSY. 2

503 X200012160ZZ ボルト BOLT 8

506 X200012035ZZ ボルト BOLT 6
514 X200012105ZZ ボルト BOLT 4
515 Z540200085ZZ フランジ FLANGE 2
516 Z541207585AZ パッキン GASKET 2

517 X200012032ZZ ボルト BOLT 8

519 Z501209000AZ JISパッキン JIS GASKET 2
522 Z580103000ZZ ドレンコック DRAIN COCK 1
525 X222312000ZZ コガタナット NUT 1
526 X251512070ZZ トメネジ SET SCREW 1

528 Z565002700EE マルパッキン GASKET 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 潤滑油ロキ取付（補機関）
ITEM LUBRICATING OIL FILTER FITTING (FOR
3.4.4 6･8DK-28e GENERATOR USE)

539

539 533

533

307
View " P "

308

538 536,537 538

P

535

530

531,532
534
530
303
531,532 304 302 507

10
B 304

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
潤滑油ロキ取付（補機関） 4
LUBRICATING OIL FILTER FITTING (FOR ITEM
GENERATOR USE) 6･8DK-28e 3.4.4

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
Ref.4-3.4.2 LOロキ L.O.FILTER 1
Ref.4-3.4.5 スラッジコレクタ SLUGE COLLECTOR 1

10 E294170100 LO ロキブラケツトパツキン GASKET,L.O.FILTER BRACKET 1

302 E294175020 ブラケット:LOロキ BRACKET,L.O.FILTER 1
303 E294175030 ブラケット:スラッジコレクタ BRACKET,SLUGE COLLECTOR 1
304 E294175040 ブラケット:スラッジコレクタ BRACKET,SLUGE COLLECTOR 1
307 E294175070 LOロキギャクセンカン L.O.FILTER WASHING PIPE 1

308 E294175080 LOロキギャクセンカン L.O.FILTER WASHING PIPE 1

334 E294175340 LOロキ L.O.FILTER 1

507 X205012040ZZ HTボルト HT BOLT 6

530 X200012035ZZ ボルト BOLT 4
531 X200012045ZZ ボルト BOLT 4
532 Z300012000ZZ ヒラザガネ FLAT WASHER 4
533 X200010022ZZ ボルト BOLT 8

534 X200012040ZZ ボルト BOLT 4

535 Z560104235ZZ Oリング O-RING 1
536 X200012028ZZ ボルト BOLT 5
537 Z300012000ZZ ヒラザガネ FLAT WASHER 5
538 Z501304300AZ JISパッキン JIS GASKET 2

539 Z501203500AZ JISパッキン JIS GASKET 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 スラッジコレクタ
ITEM

3.4.5 6･8DK-28e SLUDGE COLLECTOR

91

100 97 95 102 93 92 94

95

IN
OUT

98 99
104
72

101

96

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

スラッジコレクタ 4
ITEM
SLUDGE COLLECTOR 6･8DK-28e 3.4.5

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

91 AE02141091 スラッジコレクタ：1.12.2 SLUDGE COLLECTOR ; 1.12.2 1

72 AE02141072 エレメントASSY：フィルタエレメント ELEMENT ASSY. ; FILTER 1

92 AE02141092 ザガネ WASHER 2
93 AE02141093 ソケットヘッドボルト SOCKET HEAD BOLT 2
94 AE02141094 Oリング O-RING 1
95 AE02141095 プラグ PLUG 2

96 AE02141096 プラグ PLUG 1

97 AE02141097 ゲージ PRESS. GAUGE 1
98 AE02141098 バルブ VALVE 1
99 AE02141099 ガスケット GASKET 1
100 AE02141100 ボルト BOLT 4

101 AE02141101 ブッシュ BUSH 1

102 AE02141102 バネ SPRING 1
104 AE02141104 リング：クワッド RING ; QUAD 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 過給機（ＴＰＳ）潤滑油ロキ
ITEM TURBOCHARGER (TPS) LUBRICATING OIL
3.5.1 6･8DK-28e FILTER

9
160 174 179 192 199 206 209
202

195

188

154
263
261
260

144

140
137

225
221

141 149 101 193 190 191

123 130
212,215,218

134

243,240,126
118 113 109 105

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
過給機（ＴＰＳ）潤滑油ロキ 4
TURBOCHARGER (TPS) LUBRICATING OIL ITEM
FILTER 6･8DK-28e 3.5.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
9 C060605010 ロキ FILTER 1

101 Y529000002 ロキホンタイ FILTER BODY 1

105 Y529000012 キリカエコック SWITCHING COCK 1
109 Y529000022 パッキンシート PACKING SEAT 1
113 Y529000030 パッキン（コック） GASKET (COCK) 1
118 Y529000043 オサエフタ COCK COVER 1

123 Y529000054 ハンドル HANDLE 1

126 Y529000063 ナット（ハンドル） NUT (HANDLE) 1
130 Y529000071 バネ（トメセン） SPRING (NOTCH BAR) 1
134 Y529000078 トメセン NOTCH BAR 1
137 Y529000084 スタッド（フタ） STUD (COVER) 2

140 Y529000092 ナット（フタ） NUT (COVER) 2

141 Y529000097 ボルト（フタ） BOLT (COVER) 2
144 Y529000105 パッキン（ロキケース） GASKET (CASING) 2
149 C060505030 ジク SHAFT 2
154 Y529000136 ケース CASING 2

160 Y529000149 バネ（ロキケース） SPRING (CASING) 2

174 Y529000155 パッキン（シメツケナット） GASKET (CAP NUT) 2
179 Y529000163 シメツケナット CAP NUT 2
188 Y529000178 パッキン（ベンザ） GASKET (VALVE SEAT) 2
190 C060501900 ボールベン BALL VALVE 1

191 C060501910 クイコミツギテ BITING UNION JOINT 1

192 Y529000184 ベンザ VALVE SEAT 2
193 Y529000242 ニップル NIPPLE 1
195 Y529000189 パッキン（カンセッシュ） GASKET (CONNECTOR) 4
199 Y529000194 カンセッシュ CONNECTOR 2

202 Y529000200 パッキン（フクロナット） GASKET (SLEEVE NUT) 2

206 Y529000207 フクロナット SLEEVE NUT 2
209 Y529000211 クウキヌキセン AIR PLUG 2
212 Y529000216 スタッド（ロキトリツケ） STUD 4
215 Y529000223 バネザガネ（ロキトリツケ） SPRING WASHER 4

218 Y529000228 ナット（ロキトリツケ） NUT 4

221 Y529000233 プラグ（ドレン） PLUG 1
225 Y529000238 パッキン GASKET 1
240 Y529000260 ザガネ（ハンドル） WASHER (HANDLE) 1
243 Y529000267 バネザガネ（ハンドル） SPRING WASHER (HANDLE) 1

260 Y529000306 エレメントパッキン GASKET 2

261 C060502610 エレメントパッキン GASKET 2
263 C060502630 エレメントASSY. ELEMENT ASSY. 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 過給機（ＴＰＳ）潤滑油ロキ取付（後端過給）
ITEM TURBOCHARGER (TPS) LUBRICATING OIL
3.5.2 6･8DK-28e FILTER FITTING (REAR TURBOCHARGER)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
過給機（ＴＰＳ）潤滑油ロキ取付（後端過給） 4
TURBOCHARGER (TPS) LUBRICATING OIL ITEM
FILTER FITTING (REAR TURBOCHARGER) 6･8DK-28e 3.5.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

 

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 冷却水ポンプ
ITEM

4.1 6･8DK-28e COOLING WATER PUMP

A539 928
927

B10

A505, A506 A541, A542, A543

A42
A42 A501, A509

A13, A55
A7
A504, A506 A43, A527

A536

A57 A58 A14

A511
A502,A509

A44 A514
A38, A39
A33 , A34

A49 A50

A28, A29

A23
B2
A528, A533
A25 , A26

A527, A532
B501
A519

A18, A19 A526, A531 A8 A5 A37 A36 , A527

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

冷却水ポンプ ITEM
4
COOLING WATER PUMP 6･8DK-28e 4.1
(1)････正転 NORMAL ROTATION (2)････逆転 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)

927 C038590270 CWポンプＡＳＳＹ（Ｒ） C.W. PUMP ASSY. (R) 1

928 C038590280 CWポンプＡＳＳＹ（Ｌ） C.W. PUMP ASSY. (L) 1

A5 C038510051 シールホルダ－ＦＣ MECHANICAL SEAL HOLDER-FC 1 1

A7 C038510070 ジクウケケ-ス BEARING CASE 1 1
A8 C038510081 ポンプタイ－ＦＣ PUMP BODY-FC 1 1
A11 C038510111 ポンプタイフタ－ＦＣ PUMP BODY COVER-FC 1 1
A13 C038110120 ベアリングオサエ(ポンプガワ) BEARING STOPPER (PUMP SIDE) 1 1

A14 C038500140 ベアリングオサエ(ギヤガワ) BEARING STOPPER (GEAR SIDE) 1 1

A18 C038520160 ハネグルマ（Ｒ） IMPELLER-R 1
A19 C038520170 ハネグルマ（Ｌ） IMPELLER-L 1
A23 C038520190 マウスリング MOUTH RING 2 2
A25 C038120220 ミズキリリング（Ｒ） CUT RING-R 1

A26 C038120230 ミズキリリング（Ｌ） CUT RING-L 1

A28 C038340250 ポンプジク（Ｒ） PUMP SHAFT-R 1
A29 C038340260 ポンプジク（Ｌ） PUMP SHAFT-L 1
A33 C038800400 ハネグルマ ナット－Ｒ IMPELLER NUT-R 1
A34 C038800410 ハネグルマ ナット－Ｌ IMPELLER NUT-L 1

A36 C038140320 ドレンカンソケット JOINT ; DRAIN PIPE 1 1

A37 C038140330 ドレンカンオサエ RETAINER ; DRAIN PIPE 1 1
A38 C038340340 トクシュナツト （Ｒ） SPECIAL NUT-R 1
A39 C038340350 トクシュナツト （Ｌ） SPECIAL NUT-L 1
A42 C038570420 ポンプタイパッキン GASKET ; PUMP BODY 2 2

A43 C038800580 トクシュセッシュザ SPECIAL JOINT SEAT 1 1

A44 C038770440 メカニカルシール MECHANICAL SEAL 1 1
A49 C038800660 トクシュツメツキザガネ SPECIAL CLAW WASHER 1 1
A50 C038370420 トクシュツメツキザガネ SPECIAL CLAW WASHER 1 1
A55 C038500550 ベアリングオサエパッキン GASKET ; BEARING STOPPER 1 1

A57 C038500570 ベアリング BEARING 1 1

A58 C038500580 ベアリング BEARING 1 1

A501 X200010020DZ ボルト BOLT 4 4

A502 X200010022ZZ ボルト BOLT 4 4
A504 X210010040DZ スタッド STUD 12 12
A505 X210010043DZ スタッド STUD 12 12
A506 X220010000JZ ナット NUT 24 24

(A) (C) 6･8DK-28e Z 11-5

CHAPTER

ITEM
4 冷却水ポンプ
4.1 6･8DK-28e COOLING WATER PUMP
(1)････正転 NORMAL ROTATION (2)････逆転 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)

A509 Z318210000ZG シタツキザガネ TONGUED WASHER 8 8

A511 Z335603008JZ ヘイコウピン STRAIGHT PIN 1 1
A514 Z400007025DZ キー KEY 2 2
A519 Z461355511TC オイルシール OIL SEAL 1 1
A526 Z565001700EE マルパッキン GASKET 3 3

A527 Z565002100EE マルパッキン GASKET 4 4

A528 Z565002700EE マルパッキン GASKET 3 3
A531 X570003000JZ ロッカクプラグ HEX. PLUG 3 3
A532 X570004000ZZ ロッカクプラグ HEX. PLUG 1 1
A533 X570006000ZZ ロッカクプラグ HEX. PLUG 2 2

A536 Z571501000JZ テーパプラグ TAPER PLUG 1 1

A539 Z580203000ZZ ドレンコック DRAIN COCK 1 1
A541 Z545106020ZZ ツギワ BANJO 1 1
A542 X545202000ZZ ツギボルト BANJO PLUG 1 1
A543 Z565001300EE マルパッキン GASKET 2 2

B2 E290170020 ポンプギヤ PUMP GEAR 1 1

B10 E283300120 フランジパッキン GASKET 1 1

B501 X220012000ZZ ナット NUT 6 6

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
メモ 4
ITEM
MEMO 6･8DK-28e
CHAPTER
4 計器板（ガバナ：ＲＨＤ ｏｒ ＥＡＲ）
ITEM

5.1 6･8DK-28e GAUGE BOARD(GOVERNOR:RHD or EAR)

A533 A27(Right), A28(Left) A532 A29

A26
A26
A530,
A531
A533
A29
A532

Detail "B" Detail "A"

B503

B12
B503
B33
B36
B503 B504
B504
B34
B35 B503

Detail "C" Detail "D"

A8
A
B3,B502 B5,B502
A6 C503,C502,C5
C503,C501,C4
B6,B502

B A10,
B502,B4 A515

B502,B9

A528, A21,A23,A24 D
A529 C
B31
A14
B11

A525 C6,A3

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

計器板（ガバナ：ＲＨＤ ｏｒ ＥＡＲ） ITEM

4
GAUGE BOARD(GOVERNOR:RHD or EAR) 6･8DK-28e 5.1
(1)････正転　 NORMAL ROTATION (2)････逆転　 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
A3 E213050450 ケッソクバンド INSULOCK 2 2
A6 E293070060 ブラケット BRACKET 1 1
A8 E213050330 ケイキバン -6 GAUGE BOARD -6 1 1
A10 AE01130005 フタ COVER 1 1
A14 E293070140 コックダイ COCK HOLDER 1 1

A21 NN00015001 ホース HOSE 1 1

A23 NN00015004 ホース HOSE 1 1
A24 NN00015005 ホース HOSE 2 2
A25 NN00015006 ホース HOSE 1 1
A26 E273085020 バネ SPRING 4 4

A27 E273085030 ブラケット BRACKET 1 1

A28 E273085040 ブラケット BRACKET 1 1
A29 E273085050 ヒラザガネ FLAT WASHER 4 4

A515 X245204008ZZ プラスナベコネジ + PAN MACHINE SCREW 3 3

A525 X200016030ZZ ボルト BOLT 4 4
A528 X200012030ZZ ボルト BOLT 2 2
A529 X220012000ZZ ナット NUT 2 2
A530 X200006014ZZ ボルト BOLT 2 2

A531 X220006000ZZ ナット NUT 2 2

A532 Z212003015ZZ アナツキボルト HEX. SOCKET BOLT 4 4
A533 Z212003012ZZ アナツキボルト HEX. SOCKET BOLT 4 4

B3 NN00469002 ゲージ PRESS. GAUGE 1 1

B4 NN00469015 ゲージ PRESS. GAUGE 1 1
B5 NN00469021 ゲージ PRESS. GAUGE 1 1
B6 NN00469022 ゲージ PRESS. GAUGE 1 1
B9 NN00469017 ゲージ PRESS. GAUGE 1 1

B11 Y012350085ZZ ニードルバルブ NEEDLE VALVE 2 2

B12 Y142030300ZA ダンプナー DAMPNER 1 1
B31 Y012360085ZZ ニードルバルブ NEEDLE VALVE 3 3
B33 AE01130010 セッシュ JOINT 1 1
B34 AE01130012 フクロナット CAP NUT 1 1

B35 AE01130011 セッシュ JOINT 1 1

B36 AE01130009 セッシュ JOINT 4 4

(A) (C) 6･8DK-28e Z 11-5

CHAPTER

ITEM
4 計器板（ガバナ：ＲＨＤ ｏｒ ＥＡＲ）
5.1 6･8DK-28e GAUGE BOARD(GOVERNOR:RHD or EAR)
(1)････正転　 NORMAL ROTATION (2)････逆転　 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
B502 X245204008ZZ プラスナベコネジ + PAN MACHINE SCREW 15 15
B503 Z665006000ZZ マルパッキン GASKET 6 6
B504 X230303000ZZ トクシュナット SPECIAL NUT 4 4

C4 NN00016003 カイテンケイ TACHMETER 1

C5 NN00016004 カイテンケイ TACHMETER 1
C6 NN00016008 フレキケーブル FLEX. CABLE 1 1

C501 X220004000ZZ ナット NUT 4 4

C503 X245204014ZZ プラスナベコネジ + PAN MACHINE SCREW 4 4

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
メモ 4
ITEM
MEMO 6･8DK-28e
CHAPTER
4 計器板（ガバナ：UG）
ITEM

5.2 6･8DK-28e GAUGE BOARD(GOVERNOR:UG)

A533 A27(Right), A28(Left) A532 A29

A26
A26
A530,
A531
A533
A29
A532

Detail "B" Detail "A"

B503

B12
B503
B33
B36
B503 B504
B504
B34
B35 B503

Detail "C" Detail "D"

A8
A
B3,B502 B5,B502
A13 C503,C502,C5
C503,C501,C4
B6,B502

B A10,
B502,B4 A515

B502,B9

A528, A21,A22,A24,A25 D
A529 C
B31
A14
B11

A525 C7,A3

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

計器板（ガバナ：UG） ITEM
4
GAUGE BOARD(GOVERNOR:UG) 6･8DK-28e 5.2
(1)････正転　 NORMAL ROTATION (2)････逆転　 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
A3 E213050450 ケッソクバンド INSULOCK 2 2
A8 E213050330 ケイキバン -6 GAUGE BOARD -6 1 1
A10 AE01130005 フタ COVER 1 1
A13 E293070130 ブラケット BRACKET 1 1
A14 E293070140 コックダイ COCK HOLDER 1 1

A21 NN00015001 ホース HOSE 1 1

A22 NN00015002 ホース HOSE 1 1
A24 NN00015005 ホース HOSE 2 2
A25 NN00015006 ホース HOSE 1 1
A26 E273085020 バネ SPRING 4 4

A27 E273085030 ブラケット BRACKET 1 1

A28 E273085040 ブラケット BRACKET 1 1
A29 E273085050 ヒラザガネ FLAT WASHER 4 4

A515 X245204008ZZ プラスナベコネジ + PAN MACHINE SCREW 3 3

A525 X200016030ZZ ボルト BOLT 4 4
A528 X200012030ZZ ボルト BOLT 2 2
A529 X220012000ZZ ナット NUT 2 2
A530 X200006014ZZ ボルト BOLT 2 2

A531 X220006000ZZ ナット NUT 2 2

A532 Z212003015ZZ アナツキボルト HEX. SOCKET BOLT 4 4
A533 Z212003012ZZ アナツキボルト HEX. SOCKET BOLT 4 4

B3 NN00469002 ゲージ PRESS. GAUGE 1 1

B4 NN00469015 ゲージ PRESS. GAUGE 1 1
B5 NN00469021 ゲージ PRESS. GAUGE 1 1
B6 NN00469022 ゲージ PRESS. GAUGE 1 1
B9 NN00469017 ゲージ PRESS. GAUGE 1 1

B11 Y012350085ZZ ニードルバルブ NEEDLE VALVE 2 2

B12 Y142030300ZA ダンプナー DAMPNER 1 1
B31 Y012360085ZZ ニードルバルブ NEEDLE VALVE 3 3
B33 AE01130010 セッシュ JOINT 1 1
B34 AE01130012 フクロナット CAP NUT 1 1

B35 AE01130011 セッシュ JOINT 1 1

B36 AE01130009 セッシュ JOINT 4 4

(A) (C) 6･8DK-28e Z 11-5

CHAPTER

ITEM
4 計器板（ガバナ：UG）
5.2 6･8DK-28e GAUGE BOARD(GOVERNOR:UG)
(1)････正転　 NORMAL ROTATION (2)････逆転　 REVERSE ROTATION

番号 部品番号 部品名称 Name of Parts 数量Quantity

Number Parts number (1) (2)
B502 X245204008ZZ プラスナベコネジ + PAN MACHINE SCREW 15 15
B503 Z665006000ZZ マルパッキン GASKET 6 6
B504 X230303000ZZ トクシュナット SPECIAL NUT 4 4

C4 NN00016003 カイテンケイ TACHMETER 1

C5 NN00016004 カイテンケイ TACHMETER 1
C7 C061501935 フレキケ-ブル FLEX. CABLE 1 1

C501 X220004000ZZ ナット NUT 4 4

C503 X245204014ZZ プラスナベコネジ + PAN MACHINE SCREW 4 4

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
メモ 4
ITEM
MEMO 6･8DK-28e
CHAPTER
4 G2 燃料遮断、抑制装置
ITEM FUEL OIL SHUTDOWN & CONTROL PISTON
6.1 6･8DK-28e DEVICE G2 TYPE

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
G2 燃料遮断、抑制装置 4
FUEL OIL SHUTDOWN & CONTROL PISTON ITEM
DEVICE G2 TYPE 6･8DK-28e 6.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 燃料遮断、抑制装置取付
ITEM

6.2 6･8DK-28e FUEL OIL SHUTDOWN DEVICE FITTING

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

燃料遮断、抑制装置取付 4
ITEM
FUEL OIL SHUTDOWN DEVICE FITTING 6･8DK-28e 6.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
A S107909010 G2ガタＦ０シャダンソウチ F.O. SHUT DOWN DEVICE G2 1

5 E296070050 シャダンソウチブラケット "BRACKET,SHUTDOWN DEVICE " 1

8 E296070080 ＦＯシャダンレバ "LEVER,F.O.SHUTDOWN" 1
10 E296070100 ＦＯシャダンリンク "LINL,F.O.SHUTDOWN" 1

500 X200010020ZZ ボルト BOLT 4

501 Z300010000ZZ ヒラザガネ FLAT WASHER 4
502 X200012030ZZ ボルト BOLT 4
505 X220312000ZZ ナット NUT 1
506 Z420012120ZZ ホークエンド FORK END 1

509 Z300012000ZZ ヒラザガネ FLAT WASHER 1

510 Z425112032ZZ リンクピン LINK PIN 1
511 Z320003020ZZ ワリピン SPLIT PIN 1
514 Z300012000ZZ ヒラザガネ FLAT WASHER 1
515 Z425112032ZZ リンクピン LINK PIN 1

516 Z320003020ZZ ワリピン SPLIT PIN 1

519 Z415005040ZZ スプリングピン SPRING PIN 1
520 X200010035ZZ ボルト BOLT 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 ＦＯコントロールシリンダ
ITEM

6.3 6･8DK-28e FUEL OIL CONTROL CYLINDER

502

23
513
2

507

508
515

4 24

504

12
8

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER
ＦＯコントロールシリンダ 4
ITEM
FUEL OIL CONTROL CYLINDER 6･8DK-28e 6.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

901 S105709010AZ ＦＯコントロールシリンダーＡＳＳＹ FUEL OIL CONTROL CYLINDER ASSY 1

2 S105700020ZA シリンダ CYLINDER 1

4 S105700040AZ ピストン PISTON 1
5 S105700050ZA バネウケ SPRING RETAINER 1
7 A374940050ZZ アジャストボルト ADJUST BOLT 1
8 S105000420ZA ナイロンピース NYLONPIESE 1

12 S105700122ZZ ピストンピンバネ SPRING, PISTON 1

23 S105700230ZZ ミニＹパッキン Y PACKING 1
24 S105700240ZA GL Yパッキン GL Y PACKING 1

502 X220308000ZZ ナット NUT 1

504 X251106008ZZ トメネジ SET SCREW 1
507 Z545108010ZZ ツギワ BANJO 1
508 X545201000ZZ ツギボルト BANJO PLUG 1
513 Z565001000ZZ マルパッキン GASKET 2

515 Z571501000ZZ テーパプラグ TAPER PLUG 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 パルスセンサ（アンプ一体）
ITEM

6.4 6･8DK-28e PULSE SENSOR (WITH AMPLIFIER)

901

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

パルスセンサ（アンプ一体） 4
ITEM
PULSE SENSOR (WITH AMPLIFIER) 6･8DK-28e 6.4

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

901 NN00006019 パルスセンサ PULSE SENSOR 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 シールポット取付
ITEM

6.5 6･8DK-28e SEAL POT FITTING

501

504

505 2

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

シールポット取付 4
ITEM
SEAL POT FITTING 6･8DK-28e 6.5

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

A NN00003001 シールポット SEAL POT 1

2 E297370020 シールポットブラケット BRACKET,SEAL POT 1

501 X200012020ZZ ボルト BOLT 2

504 Z260105000ZZ Ｕボルト U-BOLT 1
505 X220010000ZZ ナット NUT 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 ターニング装置
ITEM

7.1 6･8DK-28e FLYWHEEL TURNING DEVICE

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

ターニング装置 4
ITEM
FLYWHEEL TURNING DEVICE 6･8DK-28e 7.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

901 ターニングソウチ　 ASSY. FLYWHEEL TURNING DEVICE ASSY. 1

A1 NN00056001 ダイ FULCRUM 1
A4 NN00056002 ジク:フォークレバー FORK LEVER SHAFT 1
A5 NN00056003 ジク:ツメツキレバー CLAW LEVER SHAFT 1
A6 NN00056004 プッシュロッド PUSH ROD 2
A7 NN00056005 ガイド:プッシュロッド GUIDE PLATE (PUSH ROD) 1

A8 AE01046010 ストッパ STOPPER 1

A9 NN00056006 ガイド:ストッパ GUIDE STOPPER 1
A10 AE01046011 ノブ KNOB 1
A16 NN00056007 レバ:フォーク FORK LEVER 1
A17 NN00056008 レバ:ツメツキ CLAW LEVER 1

A22 NN00056009 バネ SPRING 2

A23 NN00056010 バネ SPRING 1

A501 X200008018ZZ ボルト BOLT 2

A504 Z330006050ZZ テーパピン TAPER PIN 1
A505 Z330008080ZZ テーパピン TAPER PIN 1

B7 C001470070 ターニングバー TURNING BAR 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 ブロワー洗浄装置(MET)
ITEM

7.2.1 6･8DK-28e BLOWER CLEANING PARTS (MET)

B902

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

ブロワー洗浄装置(MET) 4
ITEM
BLOWER CLEANING PARTS (MET) 6･8DK-28e 7.2.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
901 AE01199117 ブロワシリンジ BLOWER SYRINGE 1
905 AE02199094 ブロワシリンジハイカン（MET） PIPING: BLOWER SYRINGE(MET) 1

A3 AE01199064 シリンジ SYRINGE 1

A4 AE01199065 ホースニップル HOSE NIPPLE 1
A5 AE01199066 ソケット SOCKET 1
A8 A506470150 メイバン LABEL,BLOWER SYRINGE 1

B3 AE01199067 プラグ PLUG 1

B9 AE01199068 ビニールホース VINYL HOSE 1

B503 Z584001500ZZ ホースバンド HOSE BAND 2

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 ブロワー洗浄装置(TPS)
ITEM

7.2.2 6･8DK-28e BLOWER CLEANING PARTS (TPS)

A901 B902

A4, A1 A3 B4 B502 B5

A2

B502

B6

B503

B501

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

ブロワー洗浄装置(TPS) 4
ITEM
BLOWER CLEANING PARTS (TPS) 6･8DK-28e 7.2.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

A901 AE01199117 ブロワシリンジ BLOWER SYRINGE 1

B902 AE02199094 ブロワシリンジハイカン（TPS） PIPING: BLOWER SYRINGE(TPS) 1

A1 AE01199064 シリンジ SYRINGE 1

A2 AE01199065 ホースニップル HOSE NIPPLE 1
A3 AE01199066 ソケット SOCKET 1
A4 A506470150 メイバン LABEL,BLOWER SYRINGE 1

B4 AE01199067 プラグ PLUG 1

B5 AE02199092 ビニールホース VINYL HOSE 1
B6 AE02199093 パイプ PIPE 1

B501 Z565001700EE マルパッキン GASKET 1

B502 Z584001500ZZ ホースバンド HOSE BAND 2
B503 Z588610000JZ クイコミユニオン BITING UNION 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 油圧ラム（吊下式）
ITEM

7.3 6･8DK-28e OIL PRESS.RAM (HANGER TYPE)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

油圧ラム（吊下式） 4
ITEM
OIL PRESS.RAM (HANGER TYPE) 6･8DK-28e 7.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
1 E299470070 シリンダ，ユアツラム CYLINDER 1
5 E299470050 ピストン PISTON 1
8 E299470080 シリンダカバ- COVER,CYLINDER 1
10 E659400100 メインメタルキヤツプヨウグ (1) PULLER,MAIN METAL CAP-1 1
11 E659400110 メインメタルキヤツプヨウグ (2) PULLER,MAIN METAL CAP-2 1

12 E659400120 メインメタルキヤツプヨウグ (3) PULLER,MAIN METAL CAP-3 1

22 E299470220 バツクアツプリング T2 P26 BACK UP RING 1
24 E659400240 バツクアツプリング T2 P39 BACK UP RING 3
29 AE01199026 PCHS:メスカプラ SOCKET COUPLING 2
36 E299470351 メタルキヤツプヨウグ(1)-1 PULL PIECE 1-1 2

37 E299470352 メタルキヤツプヨウグ(1)-2 PULL PIECE 1-2 2

38 E219450063 メタルキヤツプヨウグ(1)-3 PULL PIECE 1-3 2
40 E299470400 メタルキヤツプヨウグ(2) PULL PIECE 2 1
42 E299470420 ユアツジヤツキトリツケヨウグ-1 SETTING TOOL,HYDRAU.JACK-1 2
43 E299470430 ユアツジヤツキトリツケヨウグ-2 SETTING TOOL,HYDRAU.JACK-2 2

45 AE01199107 ボルト:トクシュ SPECIAL BOLT 2

503 X220022000ZZ ナット NUT 2

505 X220324000ZZ ナット NUT 2
507 X251206006ZZ トメネジ SET SCREW 2
516 Z411002000ZZ スナップリング SNAP RING 2
518 Z560102635ZZ Oリング O-RING 1

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 油圧ジャッキ（ヘッド）
ITEM

7.4.1 6･8DK-28e OIL PRESS. JACK (HEAD)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

油圧ジャッキ（ヘッド） 4
ITEM
OIL PRESS. JACK (HEAD) 6･8DK-28e 7.4.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AE02195010
AE 01195011

AE01199026

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 油圧ジャッキ（軸受）
ITEM

7.4.2 6･8DK-28e OIL PRESS. JACK (CAP)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

油圧ジャッキ（軸受） 4
ITEM
OIL PRESS. JACK (CAP) 6･8DK-28e 7.4.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

AE02195010
AE 01195011

AE01199026

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 油圧ジャッキ（ロッド & サイドボルト）
ITEM

7.4.3 6･8DK-28e OIL PRESS. JACK (ROD / SIDE BOLT)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

油圧ジャッキ（ロッド＆サイドボルト） 4
ITEM
OIL PRESS. JACK (ROD / SIDE BOLT) 6･8DK-28e 7.4.3

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity
6A02195010
6A 0119902E

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 機関吊上げ用具（６ＤＫ）
ITEM

7.5.1 6･8DK-28e ENGINE LIFTING TOOL (6DK)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

機関吊上げ用具（６ＤＫ） 4
ITEM
ENGINE LIFTING TOOL (6DK) 6･8DK-28e 7.5.1

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

(A) (C) 6･8DK-28e Z 11-5

CHAPTER
4 機関吊上げ用具（８ＤＫ）
ITEM

7.5.2 6･8DK-28e ENGINE LIFTING TOOL (8DK)

6･8DK-28e Z 11-5 (A) (C)

 CHAPTER

機関吊上げ用具（８ＤＫ） 4
ITEM
ENGINE LIFTING TOOL (8DK) 6･8DK-28e 7.5.2

番号 部品番号 部品名称 Name of Parts 数量

Number Parts number Quantity

(A) (C) 6･8DK-28e Z 11-5