A02-DK20e Instruction Manual (Maintenance)

DK-20e
INSTRUCTION MANUAL
( MAINTENANCE )
e-V00
٨ Replacement Parts
・Hazards and nonconformities of imitation parts

<Use of imitation parts causes accidents.>
1. Recent engines have compact bodies and high power, and are designed to prevent fuel
deterioration and to reduce NOx discharge. Even if imitation parts are similar in shape
to the genuine parts, the use of imitation parts will degrade the engine performance
because of their fragile materials and low machining accuracy. Since the service life of
such parts is short, the engine must be maintained more frequently.
2. If imitation parts are used for the engines designed in accordance with MARPOL VI, the
certificate (EIAPP) may lose its validity, and operation of the engine may be inhibited.
3. If you use imitation parts, you will not be supplied with parts improved in quality and per-
formance.
4. If imitation parts are used, it may be difficult to make insurance claims for the engine
when any accident occurs.
5. We take no responsibility for the engine in which imitation parts are used.
Daihatsu Diesel supplies reliable engines. Use genuine parts to

operate your engine safely.
http://www.dhtd.co.jp
Head Office 1-30, Oyodo Naka 1-chome, Kita-ku, Osaka, 531-0076 Japan
TEL : 81-6-6454-2393 FAX : 81-6-6454-2686
Tokyo Office 16-11, Nihonbashi 1-chome, , Chuo-ku, Tokyo, 103-0027 Japan

TEL : 81-3-3279-0827 FAX : 81-3-3245-0359
Moriyama Division 45 Amura-cho, Moriyama-city, Shiga, 524-0035 Japan

TEL : 81-77-583-2551 FAX : 81-77-582-5714
Taiwan Office c/o Marine Technical Industries Co., Ltd.

No.14 Tai-Tang RD, Lin-Hai Industrial Zone, Kaohsiung, 812 Taiwan
TEL : 886-7-803-1082 FAX : 886-7-801-9179
Daihatsu Diesel (Europe) Ltd. 5th Floor, Devon House, 58-60 St. Katharine's Way, London E1W 1LB, U.K.
TEL : 44-20-7977-0280 Fax : 44-20-7702-4325
Daihatsu Diesel (AMERICA), Inc. 180 Adams Avenue, Hauppauge, NY 11788, U.S.A.
TEL : 1-631-434-8787/8/9 FAX : 1-631-434-8759
Daihatsu Diesel (ASIA PACIFIC) Pte.Ltd. 128 Pioneer Road, Singapore 639586
TEL : 65-6270-7235 FAX : 65-6270-6236
Daihatsu Diesel (SHANGHAI) Co.,Ltd. Room A Floor 9, Huamin Empire Plaza, No. 726 Yanan Rd (w), Shanghai, China
TEL : 86-21-6225-7876/7 FAX : 86-21-6225-9299
DK-20e 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-20e Z 10-10
CHAPTER
ITEM
CONTENTS DK-20e
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
1.2 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
2.2 Replacement Consumables, Implements and Measuring Instruments 3-2.2
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ITEM
DK-20e 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
3.3 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
4.3 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
5.3 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
Fuel Oil Injection Valve ( ："Operation" 5-4.2 )
4. PISTON AND CONNECTING ROD 4

1. General of Construction 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 Crank Pin Shell 4-4.4
4.5 Replacement of Connecting Rod Bolt 4-4.5
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ITEM
CONTENTS DK-20e
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 Construction 5-1
2. . Replacing Consumables, Implements and Measuring Instruments 5-2
3. Inspection and Maintenance of Cylinder Liner Inner Surface 5-3
4. Extraction of Cylinder Liner 5-4
5. 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
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 Disassembly of Thrust Bearing 6-4.1
4.2 Maintenance of Thrust Bearing 6-4.2
4.3 Assembly of Thrust Bearing 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
4 Inspection of Balance Weight Bolt Tightening Force 7-4
5 Measurement of Crankshaft Deflection 7-5
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DK-20e CONTENTS
8. TIMING GEAR AND CAMSHAFT 8

1. Timing Gears 8-1
1.2 Replacing Consumables, and Implements and Measuring Instruments 8-1.2
1.3 Disassembly of Cam Gear 8-1.3
1.4 Inspection and Maintenance of Timing Gears 8-1.4
1.5 Assembly of Idle Gear 8-1.5
2. Camshaft 8-2
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

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. Mounting of Fuel Oil Injection Pump 9-5
10. VALVE OPERATING DEVICE 10

3. Disassembly of Valve Operating Device 10-3
4. Inspection and Maintenance of Valve Operating Device 10-4
5. Assembly and Fitting of Valve Operating Device 10-5
11. GOVERNOR DRIVING DEVICE 11

3. Disassembly of Governor Driving Dvice 11-3
4. Inspection and Maintenance of Governor Driving Dvice 11-4
5. Assembly of Governor Driving Dvice 11-5
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ITEM
CONTENTS DK-20e
12. INTAKE AND EXHAUST DEVICE 12

1. Outline of Intake and Exhaust Device 12-1
2. Turbocharger 12-2
3. Air Cooler 12-3
3.3 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
2.3 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
3.3 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
14. FUEL OIL SYSTEM 14

1. Outline of Fuel Oil System 14-1
2. Fuel Oil Relief Valve 14-2
2.3 Disassembly of Fuel Oil 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
3.3 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
DK-20e Z 10-10
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ITEM
DK-20e CONTENTS
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
ｏFuel Oil Filter ( ："Operation" 5-4.3 )
15. LUBRICATING OIL SYSTEM 15

1. Outline of Lubricating Oil System 15-1
2. Lubricating Oil Pump 15-2
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
3.3 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
4.3 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
5.3 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
ｏLubricating Oil Filter ( ："Operation" 5-4.3 )
16. COOLING WATER SYSTEM 16

1. Outline of Cooling Water System 16-1
2. Cooling Water Pumps 16-2
2.3 Disassembly of Cooling Water Pump 16-2.3
2.4 Inspection and Maintenance of Cooling Water Pump 16-2.4
2.5 Assembly of Cooling Water Pump 16-2.5
DK-20e Z 10-10
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ITEM
CONTENTS DK-20e
3. Cooling Water Temperature Control Valve 16-3

3.3 Disassembly of Thermostat 16-3.3
3.4 Inspection and Maintenance of Thermostat 16-3.4
3.5 Assembly of Cooling Water Temperature Control Valve 16-3.5
17. ENGINE CONTROL AND PROTECTIVE DEVICE 17

1. Outline of Engine Control and Protective Device 17-1
2. Fuel Oil Shutdown Device (G1 Type) 17-2
2.3 Disassembly of Fuel Oil Shutdown Device (G1 Type) 17-2.3
2.4 Inspection, Maintenance, and 17-2.4
Assembly of Fuel oil Shutdown Device (G1 Type)
2.5 Mounting and Adjustment of Fuel Oil Shutdown Device (G1 Type) 17-2.5
3. Fuel Oil Shutdown Device (J2 Type) 17-3
3.3 Disassembly, Maintenance, and 17-3.3
Assembly of Fuel oil Shutdown Device (J2 Type)
3.4 Mounting and Adjustment of Fuel Oil Shutdown Device (J2 Type) 17-3.4
18. GAUGE BOARD 18

1. Gauge Board 18-1
1.3 Disassembly and Maintenance of Gauge Board 18-1.3
2. Seal Pot (Heavy Fuel Oil Specification) 18-2
DK-20e Z 10-10
CHAPTER
Introduction 0
ITEM
Prior to Start of Engine Maintenance DK-20e 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 under-
stand 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 spend-
ing 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 troubles.
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 personnel
and the engine
DK-20e Z 10-10
CHAPTER
0 Introduction
ITEM
1 DK-20e Prior to Start of Engine Maintenance
(2) If it is found as a result of disassembly or inspection that parts are damaged or end of their service life is
reached, be sure to replace such parts.
(3) For replacement, be sure to use our genuine parts or those specified by us. If the parts used for
replacement are other than our genuine parts or those specified by us, we shall not be held responsible for
their quality.
(4) When it is difficult to take countermeasures or corrective actions at the site, or the required replacing
parts are not prepared, please contact our Service 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 Air motor
4 Control equipment 5 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 trans-
fer 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-20e Z 10-10
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Introduction 0
ITEM
Precautions Pertaining to Maintenance: Safety Precautions DK-20e 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 prevent
the crankshaft from idle turning.
The turning bar should be removed from the flywheel except when the engine is turned.
(3) Before executing the work, wear protection gears such as gloves, hard hat, safety shoes, and safe-
ty 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
(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 strictly prohibited.
䃁 For the sake of preventing pollution, entrust a special waste ddisposal company with the task of dis-
posing the used waste liauid and oil.
DK-20e Z 10-10
CHAPTER
0 Introduction
ITEM Precautions Pertaining to Maintenance: Precautions and
2.2,2.3 DK-20e Confirmation of 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 bolt
and nuts.
(7) Tighten each of the bolts and nuts uniformly with the specified torque (or specified oil pressure).
If it is necessary to apply an agent, such as a lubricant, to the bolts and nuts when tightening them,
never use an aqent 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 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 impracti-
cable during operation.
(2) Turn the engine and prime each fluid to check that there is no problems such as interference of the work-
ing area, and leakage or clogging of each area.
(3) After end of the work, check that the flywheel turning device and the turning bar used are in "disen-
gaged" position
(4) Record the contents of the work executed and parts replaced in the Engine Diary.
DK-20e Z 10-10
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Introduction 0
ITEM
Engine Conforming to NOx Technical Code:
Outline / Parts to be Specified / Engine Setting Value DK-20e 3.1～3.3
0
0-3. Engine Conforming to NOx Technical Code
0-3.1 Outline
(1) The marine diesei 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 discharge
inspection on board.
The engine parameter check method is a method for verifying that the engine components and setting
values conform to the requirements specified in the technical file, and does not require the measurement
of NOx discharge. To the engines that are not conforming to the requirements of the technical file, the
engine parameter check method cannot be applied. For such engines, the measurement of NOx discharge
shall be required.
0-3.2 The parts to be Specified

The technical file states the engine components that can affect the NOx discharge specified in NOx
Technical Code, and shows the identification marks stamped on them, and the user is required to maintain
the technical file for each engine. When replacing any parts shown in the technical file, be sure to use our
genuine parts stamped with the identification marks. In the case that any 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 bv the enaine oarameter 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 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 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:
<ltems set before shipment>

(1) Fuel oil injection timing
DK-20e Z 10-10
CHAPTER
1 Equipment Arrangement and Maintenance Schedule
ITEM
1 DK-20e Equipment Arrangement
1-1 Equipment Arrangement

Exhaust manifold Rocker arm device
Intake and exhaust

valves
Piston
Cylinder head
Fuel oil nozzle
Cylinder Starting valve
liner Indicator-
Intake duct safety valve
Connecing
rod
Fuel oil injection
valve
Valve operating
device
Crank shaft Cam shaft
Engine frame
Engine frame
safty valve Side bolt
Crankpin
shell
Gauge board
Governor
Cam gear
Idle gear
Control lever
Starting air rotary

valve (6, 8DK)
Cooling water pump
Lubricating oil pump
Auxiliary drive gear

Crank gear
Crankshaft Main bearing shell Thrust force receptor
DK-20e Z 10-10
CHAPTER
Equipment Arrangement and Maintenance Schedule 1
ITEM
Equipment Arrangement DK-20e 1
Turbocharger Gauge board Operating lever Governor
Cooling
water pump
Lubricating oil pump Fuel oil feed pump Starting air operation valve Flywheel
Lubricating oil filter Lubricating oil temperature Turbocharger

(Automatic backwashing) control valve
Air cooler
Air cooler
Lubricating oil relief valve Lubricating oil cooler Air motor Ring gear
5DK
(Note) Equipment arrangement may be different according to specifications
DK-20e Z 10-10
CHAPTER
ITEM
2 DK-20e Maintenance Schedule Table
1-2 Maintenance Schedule Table
This table covers the periodic disassembly and maintenance items of the engine. For the items related with
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-20e Z 10-10
CHAPTER
ITEM
Maintenance Schedule Table DK-20e 2
Work Overhaul and maintenance piriod(hr)

㨪
㨪
portion workers x
Hours
1500 3000 6000 12000 24000
2 to
3 mths 6 mths 1 yr. 3 yr.
4 to
5 yr.
1
Crankshaft Deflection measurement 2 x 1.0 ً Separate "Operation"
٤ volume 5-4.5
Balance weight bolt tightening check
Wiring inspection 1 x 0.5 ٤ 7
Inspection by torque wrench 2 x 1.0 ٤ 7
Timing gear Tightening bolt check and retightening 1 x 1.5 ٤ 8-1
Gear tooth contact and backlash inspection 1 x 1.0 ٤ 8-1
Idle gear overhaul and bush inspection
and measurement 1 x 1.5 ٤ 8-1
Cam gear disassembly,inspection,and
Camshaft measurement 3 x 2.0 ٤ 8-2
Camshaft Camshaft bearing disassembly,inspection,
bearing shell and measurement 2 x 1.0 ٤ 8-2
Camgear
Cam gear disassembly and inspection 1 x 1.0 ٤ 8-2
Fuel injection Injection timing check 㧖2 x 1.0 ً ٤ 8-2
pump
Injection pump disassembly and inspection 㧖1 x 2.0 ٤/٧ 9-4
Deflector inspection and replacement ٤ ٧ 9-4
Plunger assembly and delivery valve 9-4
replacement ٧
Spring and spring seat replacement ٧ 9-4
Fuel injection Extraction inspection,cleaning and injection 㧖㧝㨤1.0 ٤ Separate "Operation"
valve pressure adjustment volume
Fuel oil O-ring replacement 2 x 4.0 ٧
piping system ٤
Valve operating Swing arm disassembly,roller and bush 㧖㧝㨤1.0 ٤
device inspection 10
‫ڏ‬Governor Disassembly and inspection Separate Instruction
volume manual
Governor driving Disassembly,inspection and cleaning 1 x 2.0 ٤ 11
device
‫ڏ‬Turbocharger Disassembly,inspection and cleaning Separate Instruction
volume manual
Air cooler Disassembly,inspection cleaning and 2 x 3.0
hydrostatic test ٤ 12-3
Starting air valve Disassembly,inspection and O-ring replacement 1 x 2.0 ٤/٧ 13-2
Starting air rotary 1 x 1.5 ٤ 13-3
valve Disassembly and inspection
‫ڏ‬Air motor Disassembly,inspection and cleaning 2 x 3.0 Separate Instruction
volume manual
Fuel oil relief valve Disassembly and inspection 1 x 1.5 ٤ 14-2
Fuel oil feed pump Disassembly and inspection,bearing
inspection and replacement 1 x 2.0 ٤/٧ 14-3
Lubricating oil Disassembly,inspection and cleaning 2 x 1.5 ٤ 15-2

pump
Bearing and oil seal replacement ٧ 15-2
Lubricating oil Inspection,cleaning and hydrostatic test 2 x 3.0 ٤ 15-3
cooler
Lubricating oil Disassembly and inspection 1 x 1.5 15-4
relief valve ٤
Lubricating oil Disassembly,inspection,cleaning and
temperature 㧝x 1.0 ٤ ٧ 15-5
control valve pellet replacement
Disassembly,inspection and cleaning 2 x 2.0 ٤ 16-2

Cooling water
pump Oil seal,mechanical seal replacement ٧ 16-2
Bearing replacement ٧ 16-2
DK-20e Z 10-10
CHAPTER
ITEM
2 DK-20e Maintenance Schedule Table
Work Overhaul and maintenance piriod(hr)

㨪
㨪
㨪
portion workers x 1500 3000 6000 12000 24000
2 to 4 to
Hours 3 mths 6 mths 1 yr. 3 yr. 5 yr.
Cooling water
temperature Disassembly,inspection,cleaning and
element replacement 1 x 1.0 ٤ ٧ 16-3
control valve
Fuel oil shut- Disassembly,inspection,and O-Ring
down device replacement 1 x 1.0 ٤/٧ 17
Gauges Replacement of pressure gauge rubber

hose and vibration insulating rubber 1 x 1.0 ٧ 18
Inspection of pressure gauge and ٤ (٤)
tachometer (Calibration) 18
Replacement of F.O.pressure gauge
ethylene glycol 1 x 0.5 ٧ 18
(in case of heavy fuel oil specifications)
Pressure damper Accumlator assembly replacement
of main fuel (including the O-Ring) 1 x 0.5 ٧
oil pipe
Notes:
1). The above table shows the standard values of the man-hour as well as the overhaul and main-
tenance period under the conditions of general use of the heavy fuel oil.
In servicing an actual engine, initially set the work man-hour larger, and set the overhaul and
maintenance interval smaller than those shown in the table.
Later reset the work man-hour 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 bearing).
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
maintenance company, of conduct the work under his guidance.
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
1
CHAPTER
2 General Maintenance Items
ITEM
1 DK-20e Preparation before Maintenance Work
2-1 Preparation before Maintenance Work
Make the following preparation before starting the engine disassembly and mainte-
nance work
< Preparation before work >

(1) Set the control handle to the "STOP" position.
(2) Close the air tank main valve.
(3) Close the fuel oil outlet and inlet valves.
(4) Close the lubricating oil outlet and inlet valves.
(5) Close the cooling water outlet and inlet valves.
(6) Open the cooling water inlet pipe drain valve to discharge cooling water in the jacket.
(7) Turn OFF the POWER switch of engine control system.
(8) Open the indicator valve.
DK-20e Z 10-10
CHAPTER
General Maintenance Items 2
ITEM
General Consumables and Materials/General Tools,
Implements, and Measuring Instruments DK-20e 2.1, 2.2
2-2 General Consumables and 2-2.2 General Tools, Implements, and

Materials/General Tools, Measuring Instruments
Implements, and Measuring
Instruments (1). General tools and implements
1 General tools
General consumables, materials, tools, and meas- a Sockets (17x12.7,19x12.7, 24x19, 27x19)
uring instruments to be prepared for the engine
maintenance work are shown below. The con-
b Double-ended spanners (8×10, 11×13, 2
17×19, 22×24, 27×30)
sumables, tools, and measuring instruments spe-
c Offset wrenches (17×19)
cially required for specific works are shown in
d Hex. rod spanners (4, 6, 10, 14)
each individual section.
e Box spanner (19×180, 65×130)
f Adapter (19X12.7)
2-2.1 General Consumables and Materials
g Monkey wrenches
1 Waste cloth h Pliers
2 Washing oil i Snap ring pliers

3 Lubricating oil j Screwdrivers (plus, minus)
4 Grease k Hammers (iron, plastic)
5 Machine oil VG-10 2 Torque wrenches (1000, 4200,14000)
6 Lubricating agent (MOLYKOTE 1000 spray- 3 Ratchet handles (12.7,19)
type) 4 Extention bar (19X400, 12.7X150)
7 High-temperature anti-seizure agent 5 Pipe handle
8 Liquid packing 6 Eye bolts (M10, M12, M16)
9 Silicon rubber 7 Chain block
10 Compound medium size, fine size (for fac- 8 Wire rope for suspension
ing-up) 9 Tap (M10×1.5)
11 Lubricating penetrant
12 Dye testing penetrant (for color check) (2). Measuring instruments

13 Blue paint lead (for confirmation of contact) 1 Calipers
14 Liquid nitrogen or dry ice (for cold-fitting) 2 Thickness gauge
15 Wire (for wire ring) 3 Outside micrometer (mm) (0~25,
16 Wire brush 25~50,50~75, 75~100, 100~125, 150~175,
17 Sandpaper #80 or equivarent 175~200)
18 Oil stone 4 Spherical micrometer (0~25 mm)
19 Anti-corrosive paint (for liner repairing) 5 Cylinder gauge (mm) (10~18, 35~60,
20 Repair agent (for liner repairing) 50~100, 160~250)
21 Lead wire (for measuring instruments for 6 Dial caliper gauge (3~9 mm)
gear backlash, etc.) 7 Dial gauge

22 Adhesive (LOCK-TIGHT 242,243,271) 8 Magnet stand
DK-20e Z 10-10
CHAPTER
ITEM
3 DK-20e Bolt and Nut Tightening Torque, Tightening Oil Pressure
2-3 Bolts and Nut Tightening Torque, Tightening Oil Pressure

Bolt or nut width Tightening torque
Name of bolts and nuts Size across flats or oil pressure Remarks
(mm) (N㨯m) {kgf㨯m}
Hydrauric Oil pressure 54 MPa Studding torque 245 {25}
1 Cylinder head nuts M39 tightening {550 kgf/cট } ‫ڏ‬
2 Crank pin bolt M22 27 196 {20} 㧗 40q ‫ڏ‬
3 Connecting rod bolt M20 27 98 {10} 㧗 20q ‫ڏ‬

Hydrauric Oil pressure 69 MPa To be returned by 1/4 to
4 Side bolt M39 1/2 turn after fully screwing
tightening {700 kgf/cট } on the studding side
Hydrauric Oil pressure 78 MPa Studding torque 245 {25}
5 Main bearing tightening nut M39 {800 kgf/cট }
tightening
Balance weight bolt M30
980 ‫ڏ‬
6 50 {100}
Flywheel bolt M30

1270 ‫ڏ‬
7 41 {130}
8 Generator fitting bolt M30

1080 ‫ڏ‬
41 {110}
9 Idle gear shaft bolt (1) M30 41 196 {20} 㧗 40q ‫ڏ‬
196
10 Idle gear shaft bolt (2) M16 Hole 14 {20} ‫ڏ‬
118
11 Idle gear tightening bolt M14 24 {12}
80
12 Cam gear mounting Power-Rock M10 Hole 8 {8.3} ٠
85
13 Cam bearing positioning pin G1/2 27 {8.7}
Cam bearing upper and lower 88
14 tightening nut M14 22 {9} U-nut
15-1 Aux.machinery drive gear bolt 27 373 ‫ڏ‬

M20 {38}
Aux.machinery drive gear 69 ‫ڏ‬
15-2 Cushion bolt M12 19 {7}
Rocker arm shaft holder 98 ‫ڏ‬
16 thghtening nut M16 24 {10}
Fuel oil injection pump 24 90㨪110 Applied to black stud bolt
17 fitting nut M16 {9㨪11} ‫ڏ‬
18 Fuel oil injection pump
delivery valve tightening bolt M16 Hole 14
137㨪157
{14㨪16} ‫غ‬
Fuel oil nozzle mounting nut --- 196㨪226 ‫غ‬

19 27 {20㨪23}
59 ‫ڏ‬
20 Nozzle holder mouting nut M12 19 {6}
88㨪98
21 Nozzle holder inlet connector M16 19 {9㨪10}
F.O.High-pressure coupling 34㨪44
22 mounting bolt M12 17 {3.5㨪4.5} ‫ڏ‬
DK-20e Z 10-10
CHAPTER
ITEM
Bolt and Nut Tightening Torque, Tightening Oil Pressure DK-20e 3
Bolt or nut width Tigjtening torque or

across flats oil pressure
Name of bolts and nuts Size (N.m) Remarks
(mm) { kgf . m }
Governor drive shaft 59 RHD6
23 M16 22 {6}
tightening nut U-NUT
59
24 Swing arm mounting bolt
Starting valve cover

M16 24 {6}
59
2
25 mounting bolt M12 17 {6}
59
26 Indicator valve mounting nut M12 19 {6}
196
27 Divided cam shaft bolt and nut M16 22 {20}
F.O. feed pump driving gear 215
28 mounting nut M20 32 {21/9}
L.O. pump driving gear 245
29 M22 32 {25}
mounting nut
C.W. pump driving gear 333
30 M27 41 {34}
mounting nut
C.W. pump impeller 147
31 mounting nut M18 36 {15}
32
2 General bolts and nuts M10 17 15 ~ 20 { 1.5 ~ 2 }
M12 19 29 ~ 39 { 3 ~ 4 }
M14 22 34 ~ 49 { 3.5 ~ 5 }

M16 24 49 ~ 69 { 5 ~ 7 }
M18 27 78 ~ 98 { 8 ~ 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 tightening nut and connecting rod bolts after a certain peri-
od of operation. (: 1-1.2 "Maintenance Schedule Table".)
4) Anti-seizure agent should be applied on the threaded parts and seat surfaces around the exhaust
manifold which are subjected to high temperature for the prevention of seizure before tightening.
5) Retighten the bolts used for installation when stopping the engine, and be sure to check the crank-
shaft 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.
䃩 :Apply the lubricating agent (MOLYKOTE 1000 spray type) to the contact surfaces and threaded
areas of the bolt and nuts.
䂔 :Apply the lubricating agent (MOLYKOTE U-paste) to the contact surfaces and threaded areas of
the bolt and nuts.
䂺 :Apply lubricating oil to the threaded portions and contact surfaces.
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-20e Z 10-10
CHAPTER
ITEM
4.1, 4.2 DK-20e General Construction of Hydraulic Jack/Removal of Nut
2-4 Hydraulic Jack

2-4.1 General Construction of
High-pressure
Hydraulic Jack rubber hose C
The hydraulic jack (assy.) A is consisted of a
pairof a hydraulic cylinder and a hydraulic piston. Coupler c
Operate the hydraulic pump B connected with

Air vent plug f
high-pressure hose C to give the rated pulling
power to the bolt by hydraulic pressure. And, in Back-up ring
this condition, turn the nut to tighten or loosen it. Hydraulic
piston a
Tighten and remove the nuts of the following bolts Hydraulic
using a hydraulic jack. cylinder b
O-ring
Cylinder head bolt
Main bearing bolt
Jack handle F Hydraulic
Side bolt jack assy.
A
2-4.2 Removal of Nut Back-up ring

Hydraulic
Remove the nut according to the following proce- jack stand E
dures: Circular nut

(1) Clean the area around the circular nut careful-
ly, and confirm that there is no dirt or foreign Hydrauric Jack
matters on the seat surfaces of the hydraulic
jack stand E and place the hydraulic jack stand.
(2) Place the hydraulic jack assembly on the jack
Neutral
stand, and screw the hydraulic piston a into the Release valve e
Pressurise
bolt. Be minded to screw the hydraulic piston
Return
until it strikes the hydraulic cylinder b .
(3) After confirming that the hydraulic jack are
closely attached to the jack stand, turn back the Changeover lever
hydraulic jack by about 1/2 turn. To Hydrauric jack A
Air vent plug d
(4) Confirm that the valve of coupler c foi con-
Hydrauric gauge
necting the high-pressure hose is not stuck, and
then connect the hydraulic jack and terminal D
Turminal D
and then connect the terminal and hydraulic
pump using a high-pressure hose.
High-pressure Oil level check
(5) Loosen the air vent plug d of the hydraulic hose rod (Supply port)
pump, and release air in the oil tank into the Hydrauric pump B
Coupler
atmosphere.
(6) Check the hydraulic pump oil level, and in case Highdrauric pump
that the level is low, replenish the hydraulic oil.
Hydraulic oil: Machine Oil VG-10
DK-20e Z 10-10
CHAPTER
ITEM
General Construction of Hydraulic Jack/Removal of Nut DK-20e 4.2～4.4
(7) Tighten the release valve e of hydraulic pump. contact with the bottom.
(8) Loosen the air vent plug f of hydraulic jack (4) Strike the jack handle with a hammer, and con-
and operate the hydraulic pump lever to vent the firm that it is securely tightened.
air in the hydraulic cylinder. Tighten the air vent (5) Slowly open the hydraulic pump release
plug after confirming that the air is completely valve,and gradually reduce the oil pressure down
vented.
(9) Operate the hydraulic pump lever to increase
to "0".
(6) Manually loosen the hydraulic, and remove it. 2
the oil pressure up to the specified level. (7) Remove the hydraulic jack stand.
Specified value To be specified in (8) In the case of a bolt equipped with the protec-
each work item. ( : 2-3) tion cap, fit it with the protection cap.
(10) Insert the jack handle F into the hole of the

circular nut through the oblong hole of the
2-4.4 Maintenance of Hydraulic Jack
hydraulic jack stand, and loosen the circular nut
by 5 to 6 holes. (1) Extract the piston from hydraulic cylinder by
(11) Slowly open the release valve of hydraulic striking its lower area with a wooden hammer,and
pump, and gradually reduce the oil pressure pull out the piston from the hydraulic cylinder.
down to "0". (2) Remove the air vent plug.
(12) Manually loosen and remove the hydraulic (3) Wash all the parts using the washing oil, and
jack. check them for scratch.
(13) Remove the hydraulic jack stand. (4) Apply the hydraulic oil to all the parts, and
(14) Remove the circular nut. install the hydraulic piston to the cylinder.
(5) Replace the O-ring and the back-up ring with
new ones.
When operating the hydraulic jack, oil is high-
ly pressurized, and if oil is leaked and sprout-
ed out, it is extremely dangerous. When installing the piston, be careful so that
Therefore, be minded to wear the protective the O-ring and the back-up ring may not be
glass without fail. fitted upside down. Wrong way of fitting will
cause the O-ring to be damaged.
2-4.3 Tightening of Nut
(1) Carefully clean around the bolt, and confirm
< Consumables for hydraulic jacks >
that there is no foreign matters on the seat sur-
face of the nut and jack stand. Then,manually ( : "Parts List")
screw the nut until it gets in contact with the bot- ① Back-up ring (small)4-9.1.1 No.18
tom, and place the jack stand. ② Back-up ring (large) 4.9.1.1 No.19
(2) Install the hydraulic jack, and connect to the ③ O-ring (small) 4.9.1.1 No.506
hydraulic pump according to the same proce- ④ O-ring (large) 4.9.1.1 No.507
dures as those for removal, and increase the oil
pressure up to the specified level by operating
the hydraulic pump lever.
(3) Insert the jack handle through the long hole of
the jack stand, and tighten it until it gets in
DK-20e Z 10-10
CHAPTER
3 Cylinder Head and Valves
ITEM
1.1,1.2 DK-20e Cylinder Head:General Construction/Replacing Consumables
3. Cylinder Head and Valves

Cylinder head (independent): 120 kg
3-1 Cylinder Head
Cylinder head assy, (with valves): 130 kg
3-1.1 General Construction
The cylinder head made of the special cast iron of 3-1.2 Replacing
high strength and high thermal conductivity is Consumables,Implements and
designed to assume the structure of high rigidity,
Measuring Instruments
and hydraulically fastened to the engine frame- (1) Replacing Consumables
rigidly with the four large-diameter bolts via metal- Replace the following parts with the new ones
gasket and cylinder liner. ( : "Parts List")
The combustion surface is of the thick-walled ① Cylinder head gasket 3-15 No.A18
structure provided with the forced cooling through ② O-ring (fuel oil injection valve guide)
the drilled holes. 3-15NO.A30
The intake and exhaust valves consist of the 4- ③ O-ring (Starting valve inlet) 3-15NO.A505
valve system of 2 piece each for intake and ④ O-ring (exhaust valve seat) 3-15NO.A26,27
exhaust, with the valve seat cold-fitted to the cylin- ⑤ CW connection pipe gasket 3-15NO.A56
der head, and with the exhaust valve seal cooled ⑥ Gasket (intake air vent) 3-15NO.B7
by the cooling water. ⑦ Intake air vent seal 3-15NO.B59
The fuel oil injection valve, indicator valve anc ⑧ Gasket (exhaust manifold) 3-29.1 NO.A27
safety valve are mounted on the upper side of the- ⑨ Rubber seal (head cover) 3-21 No.A10
cylinder head, and the starting valve (not providec ⑩ Push rod rubber seal 3-22 No. 14
in case of air-motor type) is mounted on the latera- ⑪ Gasket (1) 34X70 (CW head outlet pipe)
side respectively. 2-1.7
The leaked oil from the fuel oil injection valve as
well as the cooling water (or, cooling oil) of the fuel
oil injection valve, when heavy fuel oil is used, arc
guided into the piping on the fuel oil injection pump
Cap
side throuah the hole.
Stud
Nut
Exhaust valve Fuel oil injection
valve Intake air Starting valve
vent (6,8DK)
Intake valve
Exhaust valve Cylinder head

Gasket
Cylinder safty valve Indicator valve Exhaust valve seat Intake valve
(Option) Intake valve seat
Cylinder Head and Valves
DK-20e Z 10-10
CHAPTER
Cylinder Head and Valves 3
ITEM
Cylinder Head: Implements and Measuring Instruments DK-20e 1.2
(2) Implements and Measuring Instruments

① General tools and measuring instruments
( : 2-2 )
② Nozzle holder extracting implement
③ Hydraulic jack 2 Nozzle Holder Extract 6 Valve Guide Extract
a Jack cylinder Head
Implement Implement
b Tension bolt Head
c Jack stand Head
d Jack handle
④ Hydraulic pump
3
a
a Hydraulic pump
b High-pressure hose (2 m x 6)
c Terminal (4T) 7 Water Cooling
d Male coupler ValveSeat Extracting
Implement
⑤ Cylinder head suspending implement
a Spring disassembling implement-2 b
(for common use) c
b EyeboltM16
d
⑥ Valve guide extracting implement (option] b a
⑦ Water cooling valve seat extracting
implement (option)
⑧ Water cooling valve seat fitting tool
a Water cooling valve seat fitting tool-1
3 Highdrauric Jack
b Water cooling valve seat fitting tool-2
(option) 8 Water Cooling Valve
⑨ Valve seat fitting implement (option) Seat Fitting Tool
a Valve seat fitting implement-1
b Valve seat fitting implement-2 b
d c
5 Cylinder Head Suspending Implement

a
a b
4 Hydrauric Pump 9 Valve Seat Fitting Implement
DK-20e Z 10-10
CHAPTER
ITEM
1.3 DK-20e Removal of Cylinder Head
3-1.3 Removal of Cylinder Head

A F
Remove the cylinder head (top hole) on the
following procedu: C
(1) Remove all the covers.
① Exhaust manifold cover A B
② Heat box cover B
③ Cylinder head cover C
All the parts (the exhaust manifold and the

area around the cylinder head, in particular)
are hot immediately after stopping the engine,
and a burn may be caused if the parts of such
areas are touched with naked hand.
Therefore, be minded to wear safety gloves
during the work and be careful to prevent a
burn. G D
(2) Remove all the piping around the cylinder

head. E
① Nozzle cooling outlet and inlet piping D
② Starting valve pilot air pipe E
③ Cooling water outlet pipe flange F
④ F.O. leaked oil branch pipe G
(3) Remove the F.O. high-pressure joint and inlet
connector, and extract the fuel oil injection valve.
( "Operation" 5-4.2 "Inspection and
Maintenance of Fuel oil injection Valve")
(4) Remove the exhaust manifold mounting bolt.
The exhaust manifold mounting bolt is made

of stainless steel. Be careful not to mix with
other general bolts. I
J
(5) Loosen the mounting nut H , and take out rock- M

er arm device I
( : 3-4 "Rocker Arm Device")
K
(6) Extract the valve retainer tee J and push
rod K
L H
DK-20e Z 10-10
CHAPTER
ITEM
Removal of Cylinder Head DK-20e 1.3
(7) Remove the cylinder head mounting nut L

using the hydraulic jack 3 .
( : 2-4 "Hydraulic Jack")
3-a
a) Mount the tension bolt 3 - b to the head
bolt M ,and fully screw it until it gets in contact 3-c
withthe bottom. 3-b
b) Place the jack stand 3 - c by adjusting its L
M
cut-out part, so as not to let it interfere with the
adjoining cylinder nut. 3-d
5 - a, b
3
c) Mount the hydraulic jack 3 - a to the tension
bolt.
d) Mount the male coupler 4 - d ) to the high-
pressure hose 4 - b , and then connect the
hydraulic pump 4 - a , terminal 4 - c , and
hydraulic jack 3 with a hydraulic hose.
e) Increase the hydraulic oil pressure to the
specified pressure by operating the hydraulic
pump, and remove the cylinder head by loos-
ening the nut using the handle 3 - d .
Mounting of Hydrauric Jack
Hydraulic pump specified oil pressure:
54 MPa {550 kgf/cm2}
3
4-d
f) Confirm the pressure to allow the nut to start-
turning, and check that the cylinder head bolt
is tightened securely to be free from loosening.
4-b
4-c
4-a
4-d
Connection of Hydrauric Hose
DK-20e Z 10-10
CHAPTER
ITEM
1.3 DK-20e Removal of Cylinder Head
(8) Mount the cylinder head suspending implement

5 - a and 5 - b on the upper surface of the 5-b
head, and suspend the cylinder head using a 5-a
chain block and suspending wire rope.
When suspending the cylinder head, be sure

to use the specified suspending implement,
and be minded to strictly observe the use
standard of the wire rope.
1) When suspending the cylinder head, con- Suspension of Cylinder Head

duct the work slowly while confirming that
the head is not caught on anything. Further,
be careful so that the cooling water in the
head may not enter the cylinder. Intake duct cover Cylinder liner cover
2) When lowering down the cylinder head, be
careful not to scratch the lower surface of M
the cylinder head.
(9) Remove cylinder head gasket M , and place a

cover to prevent infiltration of foreign matters into
the cylinder liner and the intake duct.
Intake Duct Cover and Cylinder Liner
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Cylinder Head (Body) DK-20e 1.4
3-1.4 Inspection and Maintenance of (6) Clean the contact surface of the cylinder head
Cylinder Head (Body) gasket.
If necessary, conduct the facing-up of the con-
Since the items mentioned in this section will tact surface.
be the parts to which NOx Technical Code (7) Inspect the inside of the jacket through the
shall be applied, when replacing any of these cooling water outlet hole. If heavy scale deposits
parts, be sure to use the parts provided with are found, remove the plug on the upper
the identification marks. face,and clean the inside.
( :0-3 "Engine Conforming to NOx
Technical Code")
After cleaning, apply the adhesive ( LOCK- 3
TIGHT271 ) on the plug, and then securely tight-
en it.
(1) Before servicing the cylinder head (body), dis-
connect the following attachments. (For the dis-
connecting procedure, refer to the descriptions Cooling water
inlet
of the separate sections.)
① Intake and exhaust valves ( : 3-2)
② Starting valve ( : 3-3)
③ Indicator and safety valves ( : 3-5) Intake port Exhaust
port
④ Intake air pipe vent
⑤ Cooling water head outlet pipe
(2) Observe and inspect the conditions of the car-

bons deposited on the combustion surface and
intake and exhaust ports, in the state that the
attachments are removed.
(3) Completely remove the carbons deposited on
the combustion surface and intake and exhaust,
ports, carefully clean them, and check for the-
cracks by means of color check. Cooling water inlet
Particularly be minded to check the combustion
surface most carefully, since the part is exposed
to the high temperature and high pressure.
Do not use a gas burner to remove carbon.It Plug

Plug
may cause hardening of the O-ring due to
high temperature and deterioration of the
materials due to local heating.
(4) Check if there is corrosion on the intake and

exhaust ports.
(5) Check for the corrosion of the contact surfaces
of the cooling water connecting pipe gasket and
starting air connecting pipe O-ring, and also
check for the leak of gases from the cylinder-
head gasket surface.
Cleaning and Inspection of Head
DK-20e Z 10-10
CHAPTER
ITEM
1.5 DK-20e Cylinder Head: Intake and Exhaust Valve Guides
3-1.5 Intake and Exhaust Valve Guides

a,b
The dimension "C" of the intake valve guide
differs from that of the exhaust valve guide.
C
Intake valve guide C=42 mm Intake and exhaust
valve guide
Exhaust valve guide C=39.5 mm
(1) Measurement of Inner Diameter A,B

Inspect the intake and exhaust valve guides for
corrosion, measure the inner diameters with a
cylinder gauge and record the data.
Calculate the clearance by joining the outer A,a : Intake valve
B,b : Exhaust valve
diameter measurement results of the intake and
exhaust valve stem parts. ( : 3-2.4)
Norn. Size Standard Replacing

(mm) Clearance (mm) limit (mm) Clearance of Valve Guide
A=φ14 a=0.09~0.13 0.3
B=φ14 b=0.09~0.13 0.3 Hammer
(2) Replacement of Valve Guides

When the clearance between the intake and
exhaust valve stems and the intake and exhaust- 23
valve guides is more than the specified replacing 6
limit and the valve guides are found heavily
worn, remove the intake and exhaust valve
guides and replace them with the new ones
according to thefollowing procedure: Valve guide
360
a) Remove the valve guide.

Produce the valve guide extracting implement
6 (option), or produce the extracting imple-
ment as shown in the figure using a round bar,
10
and strike out the valve guide with a hammer,

by inserting such implement into the valve 13
guide.
b) Fit the valve guides.
Fit the valve guides by means of cold-fitting Extraction of Valve Guide
using liquid nitrogen or dry ice.
< Cold-fitting procedure >

In case of liquid nitrogen .......Immerse the If the cooling liquid or cooled-down parts are
parts in the liquid, take out the parts when touched by nakedI hand, frostbite may be
bubbles disappear, and fit it promptly.
caused. Therefore, be minded to wear cotton
In case of dry ice .......Immerse the parts and
arctic gloves during execution of the works.
dry ice in alcohol, take out the parts after
cooling for 20 to 30 minutes, and fit it prompt-
ly.
DK-20e Z 10-10
CHAPTER
ITEM
Cylinder Head: Intake and Exhaust Valve Seats DK-20e 1.6
3-1.6 Intake and Exhaust Valve Seats

Welding rod
(1) Valve Seat Dimensional Measurement
Measure the dimensions of the valve seat
part,and in case that it is worn out heavily
exceeding the replacing limit, replace the Padding welding
exhaust valve with the new one.
(Replacing limit : 3-2.4 (4))
(2) Replacement of Valve Seat

a) Removal of valve seat
3
Remove the valve seats on the following pro-
cedure: Perform the padding welding on the
inner surface of the valve seat, and quench it
with water. By doing this, the valve will contract
and can easily be taken out.
When performing the padding welding, be

Removal of Intake Valve Seat
careful not to damage the combustion surface
or valve guide hole with the spatters.
Further, when removing the valve seat, be
careful not to damage the fitting part of the
Fix using a spanner
head.
b) Valve seat fitting

Cold-fit the valve seat using liquid nitrogen or
dry ice. (The cold-fitting procedure is as same
7
as the one for the valve guide. : 3-1.5)
(3) Replacement of Water Cooling Exhaust

Valve Seat
Replace the water cooling valve seat, in case
that the valve seat part is used exceeding the
correction limit, or every 16000 to 24000 hours
(4 to 5 years).
Be minded to replace the O-ring at the same
time.
a) Removal of Valve Seat
Removal of the valve seat shall be made by
padding welding as same as in the case of the
intake valve seat, or shall be made by using
the valve seat extracting implement 7 (option).
Removal of Exhaust valve Seat
DK-20e Z 10-10
CHAPTER
ITEM
1.6 DK-20e Cylinder Head: Intake and Exhaust Valve Seats
b) Valve seat fitting

As the O-ring is attached to the exhaust valve Water cooling exhaust valve seat
O-ring
seat, fit the valve seat into the cylinder head
using the water cooling valve seat tool, after
cooling and hardening the valve seat with liquid
nitrogen or dry ice on the state that the O-ring is
installed on the valve seat.
(The cold-fitting procedure is as same as in the
case of valve guide. : 3-1.5) 8 - a
< Fitting procedure > Exhaust Valve Seat Cooling Procedure

i) Apply grease to the O-ring at a normal tempera-
ture, and fit the exhaust valve seat,
ii) Heat the water cooling valve seat fitting 65
o
tool 8 - a with boiled water of 70 to 80 C. Round bar
iii) Insert the valve seat into the water-cooling 8 - b
valve seat fitting tool 8 - a .
iv) Cool down the valve seat in the state that it is
inserted in the valve seat fitting implement,
v) Take the valve seat out of the water-cooling
valve seat fitting tool after cooling down it using
a round bar or the water-cooling valve seat fitting
tool 8 - b , and insert the valve seat in the cylin-
der head promptly.Be minded to securely strike Removal of Valve Seat from Tool
down the valve seat using a used valve or the
valve seat fitting implement 9 - a and b
(option).
9 - b
9 - a
Used valve
Fitting of Exhaust Valve Seat
DK-20e Z 10-10
CHAPTER
ITEM
Mounting of Cylinder Head DK-20e 1.7
3-1.7 Mounting of Cylinder Head (9) Attach the rubber cap.

(10) Mount the fuel oil injection valve.
Mount the cylinder head according in the reversed
order of the disassembling procedure as shown in ( : "Operation" 5-4.2)
the followings: (11) Insert the push rod.
(1) Mount the intake and exhaust valve and start- (12) Mount the rocker arm device. ( : 3-4.5)
ing valve in the cylinder head. (13) Mount the indicator valve and safety valves.
( : 3-2.6, 3.5) (14) Insert the fuel oil injection valve inlet connec-
(2) Fit the intake air vent. tor, and tighten it with the specified torque.
(3) Clean the cylinder head and cylinder liner head
gasket contact surface, intake air seal contact Specified Torque:
3
surface, starting air inlet, push rod protection 88~98 N.m { 9~ 10 kgf.m}
tube rubber seal fitting area.
(4) Fit the cylinder head gasket to the upper sur (15) Mount the fuel oil high-pressure coupling, and
face of liner. tighten it with the specified torque.
Specified Torque: 34~44 N.m

Do not apply any anti-seizure agent or lubri- {3.5~4.5 kgf.m}
cant oil to the cylinder head gasket surface.
(5) Apply grease to individual O-ring and the intake All the high-pressure joint of the fuel oil injec-
air seal, and mount them in the specified position system are connected with the metal
tions. touch. Take enough care so that each joint
(6) Mount the cylinder head suspending implement may not be damaged, and so that any foreign
5 on the upper surface of the head, and con- matters may not be caught in them.
firm that there is no foreign matters in the cylin-
der, and install the head. (16) Install the exhaust manifold and each of the
(7) Temporarily attach the exhaust manifold piping around the cylinder head.
mounting bolt, and attach the cylinder head tight- (17) Mount the cylinder head cover, heat box
ening nut. cover, and exhaust manifold cover.
Be careful not to mistakenly attach the cylin-

der head tightening nut with the upper and
lower surface upside-down.
(8) Install the hydraulic jack in the same procedure

as that of disassembling, and tighten it with the
specified hydraulic pressure.
Specified hydraulic pump pressure:

54MPa {550 kgf/cm2}
DK-20e Z 10-10
CHAPTER
ITEM
2.1 DK-20e Intake and Exhaust Valves: General Construction
3-2 Intake and Exhaust Valves

3-2.1 General Construction Valve rotator
The intake and exhaust valves consist of the 4- Valve cotter
valve system with 2 piece each for intake and Stem seal
exhaust, having the valve rotators fitted to the ( Intake valve : Black
Exhaust valve : Gray (
upper areas.
Stem seal are fitted to the upper areas of the Valve spring (outside)
intake and exhaust valve guides, so as to appropri- Valve spring (inside)
ately control the volume of lubricating oil to be sup- Valve spring seat
plied to the stem. Intake valve
Exhaust valve
The intake valve and exhaust valve are identi-

cal and can be used in common for each
other, in case of the diesel fuel oil specifica-
tions.
However, in case of the heavy fuel oil specifi-
Intake Valve and Exhaust Valve
cations, the intake valve and exhaust valve
are same in the shape and dimensions,and
different in the materials, and therefore they
are discriminated by cutting a slit on the upper
part of the exhaust valve. Notched mark Notched mark Notched mark
"S6R" "HNP" "S637T"
When assembling them, be careful not to mis-
Slit
take them with each other.
Intake/exhaust valve (independent):

0.6 kg each
Diesel fuel oil Heavy fuel oil Heavy fuel oil

specification specification specification
The stem seal for the suction valve is black, intake and exhaust valve intake valve
and the stem seal for the exhaust valve is exhaust valve
grey. In this way, the stem seals can be easi- Discrimination Marks of Valves
ly identified from their rubber colors.
In addition, the length of the suction valve
guide differs from that of the exhaust valve
guide.
Carefully assemble the valves.
DK-20e Z 10-10
CHAPTER
ITEM
Intake and Exhaust Valves: Consumables,Implements,
and Measuring Instlruments/Disassembly DK-20e 2.2,2.3
3-2.2 Consumables, Implements, and

(1) Replacing Consumables
Replace the following parts with the new ones:
( : "Parts List")
① Valve stem seal (Intake valve) 3-15 No.A32
② Valve stem seal (Exhaust valve) 3-15 No.A103

3 Valve Facing-Up 4 Valve Facing-Up
3
( : 2-2) Implement Spring
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 Stem seal striking implement
3-2.3 Disassembly of Intake and

Exhaust Valves
When disassembling the intake and exhaust-
valves, disassemble the four valves at the same-
7 Stem Seal Tool 㩷
time using the valve disassembling implement, on
the following procedure:
(1) In order to avoid wrong assembling, be minded

Asembling position of
to put the markings such as the discrimination- intake valve
"I" of Intake valve
marks of intake and exhaust, as well as the Cylinder number
cylinder numbers on the valve head, before
starting the disassembling work.
c
#1 #1
I2 I1
a
#1 #1
E2 E1
"E" of Exhaust valve䇭 Asembling position of

exhaust valve
2 Valve Spring Disassembling Implement Marking Procedure of Intake and Exhaust Valves
DK-20e Z 10-10
CHAPTER
ITEM
Intake and Exhaust Valves: Disassembly, Inspection and
2.3,2.4 DK-20e Maintenance
(2) Mount the valve spring disassembling imple-

Nozzle holder retaining stud
ment-2 2 - b using the nozzle holder retaining
stud on the upper surface of the cylinder.
2-b
(3) Mount the valve spring disassembling imple-
ment-1 2 - a on the rotator body, and screw the
special bolt 2 - c into the valve spring disas-
sembling implement-2.
(4) Turn the special bolt to retain the spring, and-
take out the cotter.
(5) Return the bolt, and take out the disassembling
implement.
(6) Take out the valve rotator and spring.
(7) Pull out the intake and exhaust valves from the
nnmhnstinn rhamher side.
3-2.4 Inspection and Maintenance of 2-c

Intake and Exhaust Valves 2-a
(1) Clean the intake and exhaust valves with wash-

ing oil.
(2) Inspect on the following items: Cotter
① Corrosion of valve head area
② Corrosion or bending of valve stem area
③ Blow-out or pitching of valve seat area
④ Contact conditions of valve seat area and
valve stem area
⑤ Crack or corrosion of valve spring
........Conduct color check depending on the
conditions.
Disassembly of Intake and Exhaust Valves
(3) Measurement of Valve Stem
a) Measure the stem area of the intake and
exhaust valves using outside micrometer, anc
record the data. a,b
b) Calculate the clearance between the sterr
area and valve guide by combining the meas-
urement results of the intake and exhausl
valve guide inner diameters, and in case thai
the value is over the replacing limit, replace the
valve stem of which wear is larger. A,B
The wear amount of the valve stem can be cal-
culated by comparing with the non-sliding A,a : Intake valve
area. B,b : Exhaust valve
Nom. size Standard Replacing

(mm) clearance (mm) limit (mm)
A= φ14 a = 0.09~0.13 0.3
B= φ14 b = 0.09~0.13 0.3
Measurement of Valve Stem
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Intake and Exhaust Valves DK-20e 2.4
(4) Measurement of head thickness and valve

seats of 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.
E
In case that the wear is over the replacing limit,
replace it with a new one.
Norn, size Replacing

(mm) limit (mm)
Intake valve Exhaust valve 3
Intake valve seat area C=5.0 3.5
Exhaust valve seat area E=5.0 3.5 Measurement of Valve Head Thickness
Intake valve seat D=2.0 0.5
Exhaust valve seat F=2.0 0.5
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 D
observe the followings. F
Intake valve seat Exhaust valve seat
1) Set the intake air temperature at a little
higher level.
Measurement of Valve Seat
2) Exhaust combustion gas by means of air
running when the engine is stopped.
(5) Facing-up of intake and exhaust valves

Facing-up of the intake and exhaust valves, the
latter in particular, is one of the most trouble-
some works in the maintenance work.
The care and maintenance period largely
depends on the load factor, the fuel oil used, and
the operating conditions of the engine. Further,
delay in the maintenance of the engine leads to
the acceleration of the wear and tear of the
valves. So, execute facing-up a little earlier
according to the situations.
DK-20e Z 10-10
CHAPTER
ITEM
2.4 DK-20e Inspection and Maintenance of Intake and Exhaust Valves
< Facing-up procedure >

a) Apply lubricating oil to the valve stem, mount
the valve facing-up spring 4 on the valve stem,
3
and insert the valve stem into the cylinder head
valve guide.
Valve
b) Mount the valve facing-up implement 3 to the
valve.
c) Apply compound to the seat area, and carefully
conduct the facing-up.
Use the compound in the order of the medium 4
grade and fine grade.
Medium grade compound ...... Conduct the
facing-up as if to strike.
Fine grade compound ...... Conduct the finish-
ing facing-up as if to press compound against
the seat.
Facing-Up of Intake and Exhaust valve
Finally, wash the seat carefully, and conduci
the oil facing-up.
d) Conduct the blue-lead check of the seal surface
contact conditions after finishing the facing-up.
e) Measure the valve head thickness and the valve
seat dimensions with calipers again, and cofirm
that the measured values do not exceec the use
limit.
(6) Correction of valves
If the valve face scratch is deep and cannot be
corrected with compound, conduct the correction o +15' o
0
120 -15'
120 0
(rough finishing) using a machine or grinding tool
before conducting facing-up. Valve Valve seat
a) Machine the valve seat using the valve seal
cutter (option).
b) Machine the angle of the valve seat to make Correction of Intake Valve,Exhaust Valve,
and Valve Seat
the outside contact to be as shown in the fiau-
re.
If the valve rear face is ground, the valve

strength will be reduced and cause
cracking.Therefore, be minded never to grind
the valve rear face.
DK-20e Z 10-10
CHAPTER
ITEM
Intake and Exhaust Valves: Inspection and Maintenance of
Valve Rotator DK-20e 2.5
3-2.5 Inspection and Maintenance of

Valve Rotator
Rotator body
Since imperfect rotation of the valve rotator largely
Ball race
affects the valve life adversely, be sure to conduct-
the periodical inspection and maintenance.
Coned disc spring
Valve rotator rotational speed: min -1
Retainer
Standard value: 2~4
Replacing limit: 1/2 of initial rotational speed
Circlip 3
Ball
(1) Disconnect the circlip and disassemble the
rotator.
Spring
(2) Wash the individual parts using washing oil,and
Oil hole
check the parts for the following defects:
1 Wear, deformation, and corrosion of ball
2 Break, corrosion, and fatigue of spring
Valve Rotator
3 Compression mark on ball race
4 Corrosion and fatigue of coned disc spring
5 Compression mark on rotator body groove
(3) Replace the defective parts.
(4) Assemble the valve rotator according in the
reverse order of the disassembling procedure.
Assemble the spring in such a manner that it

rests in the oil hole side of the groove of the
rotator body.
DK-20e Z 10-10
CHAPTER
ITEM
Intake and Exhaust Valves: Assembly of Intake and
2.6 DK-20e Exhaust Valves
3-2.6 Assembly of Intake and Exhaust

Valves Stem seal tool 7
(1) Use the stem seal tool 7 to put the stem seal Stem seal
(Intake valve : black, Exhaust valve : gray) on
the upper area of the valve guide, and apply
grease to the Inner periphery.
(2) Insert the valve from the combustion surface
side.
1) Before inserting the valve, be minded to con-

firm the identification mark of the valve head,
and be sure to asemble the valve into the
original position.
2) If the inner periphery of the stem steal is
scratched or damage, it will affect the lubri-
Fitting Stem Seal
cating oil consumption and stain of the valve.
Therefore, be minded to apply lubricating oil
on the valve stem part, and then gradually
insert it.
(3) Assemble the valves in the reverse order of the

disassembling procedure, using the valve disas-
sembling implement.
DK-20e Z 10-10
CHAPTER
ITEM
Starting Valves: General Construction/Replacing Consumables,
Implements, and Measuring Instlements/Disassembly DK-20e 3.1~3.3
3-3 Starting Valve

3-3.2 Replacing Consumables,
The starting valve is a pneumatic valve of pilot-
Instruments
type, and the pilot air from the starting air rotary-
valve works on the starting valve piston, so that (1) Replacing Consumables
the valve opens to allow the flow of starting air into Replace the following parts with
the cylinder. ( : "Parts List")
The starting valve is installed on the F.O. injec-
tion pump side of the cylinder head, and it can be
① Circular gasket
② O-ring
3-18 No.508, 509
3-18 No.506
3
removed in the state of the assembly. If leak has ③ Split pin 3-18NO.503
occurred from the seal of the startingvalve seat
area, the combustion gas flows back into the start-
1 General tools and measuring instruments
ing air main pipe side to cause sticking or damage
( : 2.2)
of the starting air rotary valve, starting air valve,
and so on, and therefore make it a rule to conduct
the inspection and maintenance periodically. 3-3.3 Disassembly of Starting Valve
In case of overheating of the starting air pipe dur-
(1) Remove the starting valve cover a , and
ing operation, the possible cause is gas leak from
extract the starting valve assembly from the
the starting valve, and therefore conduct the
cylinder head.
inspection of the parts. (2) Extract the split pin c , nut d , and starting
valve e .
Starting valve assy. : 1.1 kg (3) Remove the starting valve piston f and
spring g .
Spring g
Piston f
Valve body b
Starting valve e
Nut d
Split pin c
Cover a
Starting Valve
DK-20e Z 10-10
CHAPTER
ITEM
3.4,3.5 DK-20e Inspection, Maintenance, and Assembly of Starting Valve

Starting Valve
(1) Clean the individual parts using washing oil. e
(2) Conduct the following inspections:
① Sticking of the starting valve and starting
valve piston, and the leak of gas from the
seat area b
② Corrosion or scratch of the spring
(3) Apply compound to the seat areas of the start-
ing valve and valve body b , assemble the start-
ing valve and piston into the valve body, and
conduct the facing-up.
(4) Apply blue lead to the starting valve seat area,
and check the contact
Contact range: 75% or more
g
3-3.5 Assembly of Starting Valve f
(1) Assemble the starting valve assembly on the
following procedure:
a) Insert the starting valve into the starting valve c d
body. a
b) Insert the spring and starting valve piston,
Disassembly of Starting Valve
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 into the

cylinder head, and tighten with the bolt after
attachina the cover.
Specified torque: 59 N.m {6 kgf.m}
Be minded to gradually tighten the bolt alter-

nately, and evenly. Uneven tightening will
cause the leaks of the starting air and gas.
DK-20e Z 10-10
CHAPTER
ITEM
Rocker Arm Device: General Construction/Consumables,
Implements, and Measuring Instlements/Disassembly DK-20e 4.1~4.3
3-4 Rocker Arm Device 3-4.2 Replacing

Consumable,Implements,and
3-4.1 General Construction Measuring Instlements
The intake and exhaust valves are driven by the
intake and exhaust cams that are shrunk-fit to the
camshaft, via swing arm, push rod, rocker arm,
( : "Parts List")
and valve retainer tee.
① O-Ring 3-20 No.512
Individual areas of the rocker arm are lubricated
by the system oil fed from the piping on the fuel oil
② Special ring 24 x 12.7 3
injection pump side of cylinder head, through the
(2) Implementsand Measuring Instlements
drilled holes inside the head.
① General tools and measuring instlements
For adjusting procedure of the valve end
clearance, refer to the separate "Operation". ( : 2-2)
( : "Operation" 5-4.1 "Adjusting Valve End
Clearance") 3-4.3 Disassembly of Rocker Arm
Device
Rocker arm assy. : 11.8 kg
(1) Loosen the nut, and disconnect the rocker arm
device assembly.
(2) Remove the valve retainer tee e .
(3) Remove the snap rings h at both ends of the
rocker arm shaft d , and disconnect the rocker
arm a and b of the intake and exhaust valves.
Rocker arm shaft d

Rocker Arm (intake/exhaust) a b "A"
h
Valve retainer tee e k
i
j
2 Special ring 24X12.7
"B"
Push rod g
Rocker arm shaft

holder c
Valve retainer guide f
Rocker Arm Device
DK-20e Z 10-10
CHAPTER
ITEM
4.4,4.5 DK-20e Inspection, Maintenance, and Assembly of Rocker Arm Device

Rocker Arm Device
(1) Clean the Individual parts using washing oil.
(2) Measure the rocker arm shaft diameter with an Bush
outside micrometer, and measure the rocker arm
bush inner diameter with a cylinder gauge, to
calculate the clearance.
If the clearance is over the replacing limit,
D
replace the bush with a new one.
d
D=φ50 d = 0.05-0.14 0.25
* Bush press-fitting force :

14.7~27.5 kN {1500~2800 kgf} Clearance of Rocker Arm Shaft Bush
(3) Inspect the individual parts on the following points:

① Contact conditions of the valve retainer tee
and valve retainer guide f
② Bend, scratch on the end surface, and Presence of scratch,
and contact conditions
abnormal contact of the push rod g
③ Scratch and abnormal contact on the contact
areas "A" and "B" with the valve
④ Scratch, abnormal contact, and wear of the
valve retainer tee j , rocker arm metal fitting
Presence of bending
cap i , and rocker arm screw k
3-4.5 Assembly of Rocker Arm Device

(1) Assemble the rocker arm device assembly.
Pass the intake and exhaust rocker arm through
the rocker arm shaft, and attach a snap ring.
(2) Insert the valve retainer tee into the valve
retainer guide.
(3) Place the rocker arm shaft assy. on the cylinder
head, apply the lubricating agent (MOLYKOTE
1000 spray) to the rocker arm shaft holder tight-
Presence of scratch,
ening nut and bolt, and tighten the nut with the
and contact conditions
specified torque. (use special ring 2 )
Inspection of Push Rod
Specified torque : 98N･m {10kgf･m}
(4) After assembling, adjust the valve end clear-

ance.
( : "Operation" 5-4.1(2) "Adjusting Rocker
Arm Clearance")
DK-20e Z 10-10
CHAPTER
ITEM
Indicator and Safety Valves:General Construction/Replacing
Consumables, Implements, and Measuring Instlements DK-20e 5.1,5.2
3-5 Indicator and Safety Valves

3-5.1 General Construction Close
The indicator valve and the cylinder safety valve
(option) are incorporated in the same valve
body.The indicator valve screw is of "left hand Open
screw",and the valve is opened and closed by the
handle in the directions as shown in the figure.
For the pressure measuring procedure, refer to the
separate manual of the "Operation".
3
( : "Operation" 5-3.1)
Indicator and safety valve assy.: 1.7kg

Opening and Closing of Indicator Valve

Instruments

Replace the following parts with new ones:
b
( : "Parts List")
① Circular gasket 3-19 No.A506, A507-1
No.A507-2
② Straight pin 3-19 No.A504 c

① General tools and measuring instruments Safety valve
( : 2-2) a
② Safety valve testing implements 2 Safety Valve Testing Implement

a Hydraulic pump
b Safety valve test joint
c High-pressure hose
DK-20e Z 10-10
CHAPTER
ITEM
5.3 DK-20e Disassembly of Indicator and Safety Valves
3-5.3 Disassembly of Indicator and

Safety Valves d
c
e
The indicator and safety valve are extremely-
hot during operation. If it may be touched with
naked hands during operation or immediately
k
after the stop, a burn may be caused. Conduct b
the maintenance work after the indicator and
safety valves are cooled down sufficiently. i
(1) Removal of Indicator and Safety Valve

Assembly
Disconnect the flange mounting nut a , and
remove the indicator and safety valve assembly g
from the cylinder head.
f h
(2) Disassembly of Safety Valve
a) Remove the safety valve (independent assy.)
b from the indicator valve body. a
b) Loosen lock nut c and adjusting screw d .
Respectively provide the lock nut, adjusting
screw, and spring retainer e with the match-
marks for the sake of convenience when j
reassembling.
c) Loosen and disconnect the spring retainer. Indicator and Safety Valves
When the spring retainer is taken out while the

spring is in compressed state, the spring will
jump out causing a hazard.
Gradually loosen the spring retainer, and
remove it after confirming that the spring com-
pression is eliminated. The threaded part of the indicator valve h is
of "left-handed screw", and the extracting
(3) Disassembly of Indicator Valve direction is clockwise as viewed from the side
a) Take out hex. Plug f . of the hexagonal plug.
b) Extract the straight pin g , and remove the
indicator valve nut i from the indicator
valve h .
c) Extract the indicator valve using a screwdriv-
er.
DK-20e Z 10-10
CHAPTER
ITEM
Indicator and Safety Valves: Inspection and
Maintenance/Assembly and Adjustment/Mounting DK-20e 5.4~5.6
3-5.4 Inspection and Maintenance of e) Fix the adjusting screw by tightening the lock-
Indicator and Safety Valves nut.
(1) Wash all the disassembled parts using washing
oil to eliminate stains such as carbon. 3-5.6 Assembly and Mounting of
(2) Inspection and maintenance of safety valve Indicator and Safety Valve
a) Check the safety valve outer periphery and
seat for the marks of abnormal contact, scratch (1) Assemble the indicator and safety valve
and sticking. assembly in the reverse order of the disassem-
bling procedure.
b) If scratch or sticking is found, correct the
faulty areas with oil stone, and apply com- When assembling, replace the straight pins of
indicator valve with new ones, and fix them to
3
pound to the seat to perform the facing-up.
the indicator nut by caulking the three places on
(3) Inspection and maintenance of indicator valve
the both sides respectively.
a) Check the indicator valve seat for scratch or
(2) Blow air to the mounting surface of the cylinder
one-sided contact.
head to clean there, and mount the indicator and
b) When scratch is found, correct it using an oil
safety valve assembly while placing the circular
stone and apply compound to the seat to per-
gasket i between them.
form the facing-up.
(3) Apply the lubricating agent "MOLYKOTE 1000
(4) Check the spring for abnormal contact or
spray type" to the threaded part of the mounting
scratch, and when scratch is found, replace the
nut, and tighten the nut after adjusting the direc-
spring with a new one.
tion, so that the indicator valve will not protrude
from the cylinder side surface.
3-5.5 Assembly and Adjustment of
Safety Valve Specified torque: 59 N.m {6.0 kgf.m}
(1) Assembly of safety valve (independent
assy.)
Insert the valve and the spring into the safety
valve body after facing-up, and assemble the Tighten the nuts alternately and uniformly.
lock nut and the adjusting screw to them. Uneven tightening causes the leaks of gases.
(2) Adjustment of Safety Valve
Adjust the valve opening pressure according to
a) Mount the safety valve test joint on the safety High-pressure pipe
valve, and connect them to the hydraulic pump
using a high-pressure pipe.
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. Test joint
Tester side
d) Turn the adjusting screw, and adjust the valve
opening pressure.
Setting pressure: 19.1 MPa｛195 kgf/cm2｝

Safety valve
When the spring is replaced with a new one,
set the value about 10% higher than the Test joint
above value by taking into consideration the
initial fatigue.
Safety Valve Testing Procedure
DK-20e Z 10-10
CHAPTER
ITEM
6.1,6.2 DK-20e Nozzle Holder Guide: Extruction/Cooling
3-6 Nozzle Holder Guide 4) Put the entire nozzle holder guide into liquid
The O-ring of the nozzle holder guide should be nitrogen just as in the state of Figure 2.
replaced for every 16,000~24,000 hours (4~5 Cool it down until the air bubble, that generates
years). when cooling down, completely disappears.
(Required time: about 2 minutes)
The tools can be supplied as optional parts. (5) Install the nozzle holder as shown in Figure 3,
( : "Parts List") and remove the tool 4 by hammering with a
① O-rinq 3-13 No.A30 wooden hammer.
At this time, do not remove the tool 5.
3-6.1 Extraction of the nozzle holder Place a wood, cloth, or the like beneath the tool 4.
guide
< Extracting procedure >
(1) Remove the nozzle holder, and turn the cylin- Snap ring
der head sideways. (Turn it to the state that the Tool 1
O-ring High-torque nut
combustion surface can be seen.)
(2) Remove the snap ring.
(3) Install the tool 1~3 and high-torque nut as
shown in the Figure. Hammering
(4) Tighten the high-torque nut, and extract the
nozzle holder guide.
In case that the nozzle holder guide is difficult to
be extracted, the tool 1 may be hammered with
Nozzle holder guide Tool 3 Tool 2
a wooden hammer from the combustion surface
side. Nozzle holder guide extracting procedure
3-6.2 Cooling of the nozzle holder guide

< Cooltng procedure >
(1) Install the O-ring to the nozzle holder guide.
Adjust to upper end face of
Before installation, make sure that there is not Tool 4 nozzle guide holder
Hammering
any scratch nor tearing on the O-ring.
Tool 4
Be minded to install the O-ring so that it should
not be scratched nor distorted.
(2) Apply grease to the entire circumference of the Grease
O-ring in the state of above Item 1. applied part
O-ring
(3) After warming the tool 4 with hot water (about
80℃) for 2 ~ 3 minutes, install it to the nozzle
holder guide.
Tool 5 Grease
applied part Tool 5
Be minded to carefully install it so that the O- Push in the tool
ring should not be scratched. unit it completly fits in
the fitting part.
Fig.1 Fig.2 Fig.3
Install the tool 5 to the nozzle holder guide, after
applying grease to the entire circumference ol Nozzle holder guide cooling-down procedure
the fitting part.
Installation should be done as shown in the
Figure 2.
DK-20e Z 10-10
CHAPTER
ITEM
Nozzle Holder Guide: Cooling/Fitting DK-20e 6.3
3-6.3 Fitting of the nozzle holder guide

< Fitting procedure >
(1) Wipe off dust, etc. on the seating face and fit-
ting part of the cylinder head with a waste cloth
or the like.
(2) Apply silicone paste to the specified places in
circumferential manner. (It can be applied easily
if a brush or the like is used.)
At this time, do not block the cooling water hole
inside the cylinder head with silicone paste.
3
(3) Apply LOCK-TIGHT 648 to the fitting part of the
cylinder head.
Silicone paste Snap ring installing

※ Be minded to perform the work of the applied part position
above Item (1)~(3) before cooling down the
nozzle holder guide.
Hammering
(4) Install the tool 3 to the nozzle holder guide in
the state that the tool 5 is still attached, and fit in
the cylinder head by hammering.
Tool 3
Tool 5
Cooling
When fitting in, be sufficiently careful so that water hole Nozzle holder guide
the nozzle holder guide should not be ham-
mered in the state that it is tilted. Fitting part and seating face
Further, continue hammering until the nozzle ROCK-TIGHT 648 applied part
holder guide strikes the seating face.
Nozzle holder guide fitting-in procedure
Be careful because the fitting-in of the nozzle
holder guide will be difficult unless this work is
rapidly performed.
(5) Remove the tool 3 and 5.

(6) Install the snap ring to the specified place.
DK-20e Z 10-10
CHAPTER
4 Piston and Connecting Rod
ITEM
1 DK-20e General Construction
4. Piston and Connecting Rod

4-1 General Construction
Piston
The connecting rod is of carbon steel die forging Piston pin

with the large end part being horizontal 3-division
Piston pin bush
type. This structure allows the extraction of the
piston without disassembling the bearing part oi
the crank pin shaft.
The large end divided surfaces (serrated) and
trunk part divided surfaces are angularly fastened Connecting rod
rigidly with 4 bolts B and A , respectively.
Crank pin shell is made of aluminum alloy of high
wear resistance.
Piston pin is of full floating type, and held with the
snap ring. Further, the piston pin push is stepped
Bolt A
so as to allow a wide bearing area on the side,
where explosive force works.
The piston is an assembly of the ductile integral
cast iron product, and special coating is applied tc Crank pin shell
the outer periphery of the skirt.
The piston cooling lubricating oil reaches from the
crankshaft to the cooling cavity in the piston, via
piston pin, through the drilled holes in the
connecting rod trunk part.
The piston rings consist of the 3 compression rings
and 2 oil rings.
In the heavy fuel oil specifications, induction
hardening is conducted to the top and second ring Bolt B
arooves to improve wear resistance. Piston and Connecting Rod
Piston connecting rod assy.: 73 kg

Piston: 18.6 kg
Piston pin: 6.8 kg
Connecting rod assy.: 46 kg
Crank pin bolt: 2 kg
Piston
Clamp ring
Piston pin
Piston and Piston Pin
DK-20e Z 10-10
CHAPTER
Piston and Connecting Rod 4
Replacing Consumables,Implements,and Measuring ITEM
Instlements DK-20e 2
4-2 Replacing Consumables,

Instruments
None

( : 2-2 )
② Piston insertion frame
③ Protection ring extracting implement 4
④ Metal cap fitting and disengaging implement
(option)
⑤ Cylinder liner position gauge
⑥ Cylinder bore gauge 200 - 225
⑦ Piston suspending implement (option) 2 Piton Insertion Frame
4 Metal Cap Fitting and Disengaging Impleme

3 Protection Ring Extracting Implement
5 Cylinder Head Suspending Implement 6 Cylinder Bore Gauge
7 Piston Suspending Implement
DK-20e Z 10-10
CHAPTER
ITEM
3.1 DK-20e Extraction of Piston
4-3 Disassembly of Piston and

Connecting Rod
4-3.1 Extraction of Piston
Extract the piston after removing the cylinder head.
( : 3-1.3 "Removal of Cylinder Head")
In the case of piston extraction only, it is not 3
necessary to disassemble the large end part, and

conduct the extraction work by separating the G
large end part from the small end trunk part. H
If the crankshaft has turned when handling

theparts located in the crank chamber when
extracting the piston, it will cause serious acci-
dents resulting form entanglement and it will
be very dangerous.
Therefore, be sure to conduct turning after
exchanging the signs with coworkers, and
donot fail to put the flywheel turning device in
the"disengage" position, except when the
engine is turned.
Extraction of Protection Ring
< Piston extraction procedure >
(1) Take off the cover on the engine frame side on
the both sides of the cylinder to be overhauled,
and place the piston to the position of about 50〇
before the top dead center.
(2) Place waste cloth on the piston upper surface
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 3 .
a) Spray penetrating lubricant to the protection
ring outer periphery before starting the work, to Tap M10
facilitate easy removal of the protection ring.
b) When extracting the protection ring, gradually
extract it while lightly striking the lower surface
of the extracting implement with a plastic ham- Removal of Carbon from the threaded
mer. Hole for Suspension
(5) Remove the carbon deposited in the piston
suspending threaded hole using a tap (M10X
1.5).
(6) Turn the crankshaft, and place the piston to be
released in the position of 120〇 before the
bottom dead center.
DK-20e Z 10-10
CHAPTER
ITEM
Extraction of Piston DK-20e 3.1
If the big end of the connecting rod of the

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
big end does not turn.
(7) Remove the rotation-stopping wire of the con-

necting rod joint bolt A , and loosen the joint bolt
to extract it.
(8) Mount the eye bolt M10 (for piston suspension)
4
on the upper surface of the piston, suspend it
with the wire rope and chain block, and then
extract the piston.
Extraction of Piston
Cylinder liner cover

Securely tighten the suspending eye bolt
down to the seat surface. Unless securely
tightened to the seat surface, it causes distor-
tion or breakage of the metal fitting (eye bolt),
and is very dangerous.
When suspending the piston, be careful so

that the cylinder liner may not be damaged
being struck by the connecting rod.
(9) Fit a cover on the cylinder liner after extracting

the piston, so that no foreign matters may infil-
trate in the engine.
Cylinder liner cover
(10) Place the piston in the specified place with its
combustion surface facing downward.
(11) Lightly suspend the connecting rod, and
remove the clamp ring E on one side of the pis-
ton pin D using a snap ring pliers.
(12) Extract the piston pin, and remove the piston
D
from the connecting rod.
(13) Remove the piston ring and oil ring. E
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-
sembling the engine. Extraction of Piston Pin
DK-20e Z 10-10
CHAPTER
ITEM
3.2 DK-20e Disassembly of Connecting Rod Large End Part
4-3.2 Disassembly of Connecting Rod

Large End Part
Disassemble the connecting rod large end part-
when the crank pin shell C or crank pin bolt B is
inspected or replaced. When only extraction of the A
piston is intended, disassembly of the connecting
rod large end part is not required. C
When only inspection of the crank pin shell is intend-
ed, the connecting rod large end part can be disas-
sembled with the piston being suspended,and without
removing the cylinder head.
(1) Remove the connecting rod joint bolt A , and
B
suspend the piston and connecting rod small
end side. (Piston extracted or piston suspended)
(2) Turn the crankshaft, and mount the metal cap
fitting and disengaging implement 4 , so that the
large end part is facing sideways.
(3) Remove the rotation-stopping wire of the crank
pin bolt B , and disconnect the bolt using the
socket and extension bar.
4
(4) Take the top and bottom of the large end part
out of the right and left inspection windows
respectively.
(5) Remove the crank pin shell 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. Disassembly of Connecting Rod Large End Part
(6) Mark the disassembled shells with the cylinder
numbers and ID marks, so that the upper and
lower shells can be distinguished from each
other.
< Disassembly of the large end part by sus-

pending the piston >
a) Turn the crankshaft, and place the crank pin
of cylinder to be inspected in the position
where the crank pin bolt can be disassembled.
b) Remove the fuel oil high-pressure joint and

inlet connector, and extract the fuel oil injection
valve.
c) Insert the piston suspending bolt into the
mounting hole of the fuel oil injection valve,
screw it into the threaded hole of the upper
part of the piston, and then fix it.
d) Loosen the crank pin bolt, and remove the
large end cap.
e) Turn the crankshaft, and remove the upper
shell. Piston Suspending Procedure
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Piston DK-20e 4.1
4-4 Inspection and Maintenance of

Piston and Connecting Rod
Piston
1
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. 3
4
( :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.
5
① Conditions of the carbon deposited on the pis- 2
ton, and the lubricating conditions
② Scratch and abnormal contact of the sliding
areas
6
③ Sticking of the piston ring, and conditions of
chrome plating
④ Conditions of the carbon sludge deposited on
the piston underside.
⑤ Abnormal contact of the piston pin and pin Inspection of Piston
boss inner surface
⑥ Abnormal contact of the connecting rod small
end of the piston pin boss
(2) Eliminate the carbon deposited on the upper Color check
part of the piston with a sandpaper of fine mesh.
The piston skirt is specially coated. Do not

sandpaper or buff the surface
Oil hole
(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. Special coating
(5) Blow air to the oil hole of piston pin, and clean
the inside of the hole. Inspection and Maintenance of Piston Parts
DK-20e Z 10-10
CHAPTER
ITEM Inspection and Maintenance of Piston/Inspection and
4.1,4.2 DK-20e Maintenance of Ring
(6) Measurement of dimensions

Measure the dimensions of individual parts, and
10.5
record the results. Calculate the clearance
40
based on the results of measurement, and A a
replace the parts with the new ones, if the clear-
ance is exceeding the replacing limit.
a) Piston outer diameter 75
Measure the four places of the piston outer B b
diameter using an outer micrometer, and
record the results.
Calculate the clearance based on the results of
73
the measurement of the cylinder liner inner
diameter. C1 c1
( : 5-3 "Inspection of the Inside Surface of
Cylinder Liner")
62
Norn, size Standard Replacing c2
(mm) clearance (mm) limit (mm) C2
A=200 a =0.66~0.76
B=200 b =0.12~0.21
Clearance between Piston and Liner
C1=200 c1 =0.10~0.19 0.4
C2=200 c2 =0.10~0.19 0.4
b) Piston pin and piston pin boss

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

A=φ90 a=0.04~0.08 0.15
a

Ring Piston pin
(1) Eliminate the carbon deposited on the piston

rings and oil rings, and wash the rings using A
washing oil.
(2) Since hard-chrome plating is applied to the slid-
ing surfaces of the rings, in case that the ring
surface is exposed due to wear of the plated lay-
ers, or the defects such as crack are found,
replace the ring with a new one, even when it is Clearance between Piston Pin and Pin Boss
still within the specified replacing period.
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Ring DK-20e 4.2
(3) Measure the end clearance of ring.

Measurement of the end clearance using a new
cylinder liner is advisable. C1
Standard clearance Replacing limit C2 Piston ring

(mm) (mm)
C1 = 1.50~1.70 2.5 C3
C2 = 0.90~1.10 1.5
C3 = 0.75~0.95 1.5 B1
C4 = 1.05~1.25 2.0 A1 1st.
B2
C5 = 1.05~1.25 2.0 A22nd. Piston ring
B3
A3 3rd.
(4) Measure the width of the piston ring and oil
ring, and also measure the piston ring groove
B4
A4 Oil ring (upper) : with coil
4
B5
width, and if the clearance is over the replacing A5 Oil ring (lower) : with coil
limit, replace the ring with a new one.
C4
Norn, size Standard Replacing Oil ring (upper)
(mm) clearance (mm) limit (mm) C5
A1 = 5 B1= 0.13~0.17 0.3 Oil ring (lower)
A2 = 5 B2 = 0.09~0.13 0.3
A3 = 5 B3 = 0.08~0.12 0.3 Piston Ring and Oil Ring
A4 = 7 B4 = 0.04~0.08 0.2
A5 = 7 B5 = 0.04~0.08 0.2
When wear of the piston ring groove width is so

excessive, as to require replacement with an
oversize ring, consult our Service Department.
Each ring periphery is edged sharply after a

long-time run of the engine. Therefore, when
disassembling the engine, be sure to wear
safety gloves to prevent injuries.
Even when the wear of the ring is within the

permissible value, replace it with a new one at
every periodical inspection with the interval of
8000~12000 hours (2~3 years).
DK-20e Z 10-10
CHAPTER
ITEM
4.3 DK-20e Inspection and Maintenance of Connecting Rod

Connecting Rod E
(1) Inspect the connecting rod on the following

points, record the results, and repair or replace D
whenever a defect is found.
① Contact conditions of the small end part pis-
ton pin bush D and loosening or positional
deviation of the bush fitting area
② Scratch and fretting on the joint surface of the
trunk part and large end part
③ Dent or peel of the threaded areas and seat
surfaces of the connecting rod joint bolt and
crank pin bolt
④ Conditions of the serrated area Wear and fret-
Mating surface A
ting
(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 E that is C
running through the trunk part, and clean the
parts. Serration
(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.
B
Norn, size Standard Replacing
Inspection and Maintenance of Connecting Rod
A=φ90 a=0.09~0.16 0.3
< Bush replacing method >

a) Take out the bush by striking with a press or
a
hammer.
b) Insert a new bush by pressing or cold-fitting
after confirming the oil hole position of the
bush.
A
< In case of pressing >
Press-fitting force of bush : 8.8~44.1 kN
｛900~4500 kgf｝
< In case of cold-fitting >
Immerse the bush in liquid nitrogen, and take
out the bush when bubbles disappear (in 5 to
10 minutes), and then insert it.
(5) Confirm the tightening torque and matchmarks

of the connecting joint bolt and crank pin bolt. Piston Pin Bush Clearance
DK-20e Z 10-10
CHAPTER
Inspection and Maintenance of Connecting Rod/Inspection ITEM
and Maintenance of Shell DK-20e 4.3,4.4
Connecting joint bolt and crank pin may pro-

duce deviation in the relative position of the 1) Be sure to replace the shell as one set of a
bolt and body due to becoming accustomed pair of the upper shell and the lower one.
after a long period of operation, and therefore
2) When the shell is used for a long time, it
in such a case, be minded to renew the match-
shows reduction of the tension and harden-
mark on the bolt side.
ing of its surface, resulting in crack or peel of
( : 4-4.5 Matchmark Notching Procedure") the shell, even if the wear is; within the
allowance value.Therefore, be minded to
(6) Measure and record the inner diameter of the
replace the shell every 16,000 to 24,000 hr
large end housing in the state that the connect-
ing rod is independently assembled (the state (4 to 5 years).
that the large end part and trunk part are assem-
bled without the shells, and the connecting rod Check for peeling, cavitation, 4
joint bolt and crank pin bolt are tightened with and forein matters
the specified torque), and inspect if there is any
distortion of the shape.
( : 4-5 "Assembly of Piston and Connecting Rod")

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

the crank pin. If the result is over the replacing
limit, replace the shell with a new one.
a

A=φ170 a=0.10~0.19 0.3
Crank Pin Shell Clearance
DK-20e Z 10-10
CHAPTER
ITEM
4.5 DK-20e Replacement of connecting Rod Bolt
4-4.5 Replacement of Connecting Rod

Bolt Bolt side matchmark Body side matchmark
Be minded to replace the crank pin bolt and con-
necting rod joint bolt every 16,000 to 24,000 hrs (4
to 5 years), even when the appearance problem is
not found.
< Bolt replacing procedure > (B) (A)

(1) Check the contact of the bolt head bearing sur-
face with minium or blue paste at torque A. If the
contact is improper, correct the bearing surface B mark
of the connecting rod A mark
Rotating angle
A-torque Angular Tightening Matchmark

Connecting rod joint bolt: 98 N.m {10kgf.m}
Crank pin bolt: 196 N.m {20kgf.m}
Tightening order: 1-4-2-3-1 Engine identification number
Bolt number
(2) Stamp the identification number of the engine
Cylinder number
to be replaced, the cylinder number, and the bolt When replacing the

number on the head part of a new bolt. bolt,be sure to notch
(3) Apply the lubricating agent (MOLYKOTE 1000 the same number as
spray type) on the threaded part and seat sur- that of the old bolt.
face of the bolt, and repeat loosening and tight-
ening 2 to 3 times using a torque wrench, with
the torque of the following table, so as to make Bolt Identification Mark
the parts to be accustomed.
Connecting rod joint bolt: 255N.m {26kgf.m}

Crank pin bolt: 392N.m {40kgf.m}
(4) Notch the matchmark on the following proce-

dure:
a) Apply the lubricating agent on the threaded
area and seat surface of the bolt. MOLYKOTE 1000
spray type
1) Use of the lubricating agents of different

brands causes difference in the bolt axial
tension. Therefore, be sure to use the lubri-
cating agent "MOLYKOTE 1000 spray
type" (genuine parts).
2) MOLYKOTE brings about changes in the Application of Lubricating Agent
frictional force after drying. Therefore,
quickly tighten the bolts after spraying
before it dries.
DK-20e Z 10-10
CHAPTER
ITEM
Replacement of connecting Rod Bolt DK-20e 4.5
b) Tighten the bolt using a torque wrench with A-

torque in the following order:
3 1
A-torque
Connecting rod joint bolt:
98 N.m {10kgf.m}
4 2
Tightening order: 1-4-2-3-1 Embossed seat
Bolt Tightening Order

c) Make a matchmark on each bolt based on the A
mark on the body. 4
DK-20e Z 10-10
CHAPTER
ITEM
5.1 DK-20e Assembly of Connecting Rod Large End Part
4-5 Assembly of Piston and Connecting

Rod
4-5.1 Assembly of Connecting Rod 1
3
Large End Part
4 2
(1) Clean all the parts using washing oil and blow
air to the threaded holes before assembly.
(2) Cleanly wipe off the dirt and oil accumulated on Connecting rod
the inside surface of the large end part housing joint bolt
and the rear surface of the shell. Bolt number
Embossed
Do not apply lubricating oil or grease to the seat
rear surface of the shell. Inclusion of oil will
cause the reduction of adhesion
(3) Adjust the position of the shell claw to the

groove of the large end part housing, and mount
it so that the shell may be positioned at the cen-
ter of the large end part housing.
(4) Strike the shell at its center with hand to fit the
shell tightly to the housing.
(5) Cleanly wipe the crank pin area, and apply
lubricating oil to the inner surface of the shell.
(6) Assemble the large end shell cap using the
shell cap fitting and disengaging implement from
both sides in the same procedure of the disas-
sembling, with enough care so as not to scratch
the crank pin.
Crank pin bolt
4 2
Be sure to install the connecting rod large end
part after matching the cylinder number, so 1
3
that the embossed seat may be in the position
directed toward the front side of the enqine.
Bolt number
(7) Apply the lubricating agent (MOLYKOTE 1000
Assembly of Connecting Rod Large End Part
spray type) on the threaded area and seat sur-
face of the crank pin bolt, and screw the bolt
down to the bottom surface.
Since the bolt number is notched on the

bolt,be minded to mount the bolt in the original
position without fail, not mistaking the assem-
bling position.
DK-20e Z 10-10
CHAPTER
ITEM
Assembly of Connecting Rod Large End Part DK-20e 5.1
(8) Angularly tighten the crank pin bolt on the fol-

lowing procedure, using the socket, extension
3 1
bar, and torque wrench:
a) Evenly tighten the bolt with A-torque, accord-
ing to the tightening order as shown in the fig-
ure on the right. 4 2
b) Confirm that the A mark of the bolt and the
matchmark of the seat surface is matched Embossed seat
Bolt Tightening Order
If the matchmark is not aligned, make a new

matchmark on the bolt.
Bolt side matchmark Body side matchmark 4
When making a new matchmark on a bolt in
use, flatten out the previous mark to avoid
confusion during reassembly, and clearly
make a new matchmark. (B) (A)
c) Angularly tighten the bolt down to the B mark B mark

in the order of 1-4-2-3. A mark
Rotating angle
A-torque: 196N.m {20kgf.m}

〇 Angular Tightening Matchmark
Augular tightening (B mark): +40
If the tightening of bolt is insufficient, it will not

only damage the bearing shell and large end
part serration, but also incur serious accidents
such as the breakage of bolt, and therefore be
minded to securely tighten the bolt.
Matchmark Matching Procedure

(9) Confirm that the matchmark of the bolt is tight-
ened down to the B mark position of the large
end part, and then conduct the rotation stop-
page.
(10) Manually turn the large end part, and confirm
that it rotates lightly.
DK-20e Z 10-10
CHAPTER
ITEM
5.2 DK-20e Assembly of Piston and Connecting Rod
4-5.2 Assembly of Piston and P

Connecting Rod
(1) Wash all the parts and blow air to them before
assembling the piston.
(2) Assemble the piston and the connecting rod. View "P"
a) Insert the connecting rod small end into the
piston, placing the combustion surface of the
piston facing downward, while matching the
embossed seat of the connecting rod lower
part and "F" mark of the piston combustion
surface.
F
Cylinder No.
Notched mark 㵰F㵱

Confirm that the discrimination numbers of the
Embossed seat
large end part and the small end part are iden-
tical.
b) Apply lubricating oil to the piston pin outer

periphery and piston pin boss inside area, Assembly of Piston and Connecting Rod
lightly suspend the connecting rod, and then
insert the piston pin. Ring end
c) Fit the piston pin stopper ring into the groove Ring end
using a snap ring pliers.
(3) Fit the piston insertion frame into the cylinder
liner upper part.
(4) Turn the crankshaft to place the crank pin at Coil
the bottom dead center position.
Coil joint Manufacturing mark
(5) Mount the suspension metal fitting (eye bolt) on
the piston upper part, and suspend the piston notched position
and the connecting rod part.
(6) Assemble the piston ring. Oil ring
Joint
Assemble the piston ring in the position as
shown in the figure, with the manufacturing mark Top ring
facing upward (toward the combustion chamber Piston
Second ring ring
side) so as to ensure the correct assembling
position. Third ring
(7) Assemble the oil ring.
a) Entangle the coil into the piston oil ring Top ring Third ring
groove, and insert the coil joint. Oil ring
(Lower)
b) Assembly the oil ring so that the coil joint
comes on the opposite side of the ring joint
(8) When mounting the piston rings and oil rings, Front F Rear
turn the rings to position them as shown in the
figure so that the ring ends are not aligned.
(Fig.:Piston Ring Mounting Procedure) Oil ring
(Upper) Second ring
(9) Sufficiently apply lubricating oil to the piston,
piston ring, oil ring, piston insertion frame, and 㪘㫉㫉㪸㫅㪾㪼㫄㪼㫅㫋㩷㫆㪽㩷㪩㫀㫅g end
cvlinder liner. Piston Ring Mounting Procedure
DK-20e Z 10-10
CHAPTER
ITEM
Assembly of Piston and Connecting Rod DK-20e 5.2
(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 face toward the engine front side,
and then align the knock of the large end part
and trunk part after slowly lowering the piston.
When assembling the piston to the cylinder

liner, it is advisable to lightly strike the piston-
periphery with a plastic hammer, since it facili-
tates 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
4
piston again.
(11) Apply the lubricating agent (MOLYKOTE 1000

spray type) on the threaded area and seat sur-
face of the connecting rod, and assemble the rod
into the position of the discrimination number. Insertion of Piston
(12) Augularly tighten the connecting rod joint bolt
on the following procedure:
< Bolt tightening procedure >

a) Evenly tighten the bolt with the A-torque 1 3
according to the tightening order as shown in
the figure on the right. 2 4
b) Confirm that matchmark of the bolt and A
mark of the seat surface are matched. B mark
Embossed seat A mark
In case that matcmarks are not matched, Bolt Tightening Order

renew the matchmarking of the bolt
When making a new matchmark on a bolt in

use, flatten out the previous mark to avoid
confusion during reassembly, and clearly
make a new matchmark.
c) Angularly tighten the bolt down to B mark in

the order of 1-4-2-3.
A-torque: 98N.m {10kgf.m}

〇
Angular tightening (B mark) : +20
(13) 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.
Confirmation of Side Motion
DK-20e Z 10-10
CHAPTER
ITEM Assembly of Piston and Connecting Rod/Confirmation of
5.2,5.3 DK-20e Bolt Tightening Force and Retightening
(14) Manually insert the protection ring into the

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

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

Protection ring Notched mark "US"
4-5.3 Confirmation and Retightening of Insertion of Protection Ring
Connecting Rod Bolt Tightening
Force
Confirm the tightening conditions of the crank pin-
bolt and connecting rod joint bolt taking into con-
sideration the initial running-in, and check and
retighten these bolts within 3,000 hr after the initial
operation or the replacement of the bolts.
Afterwards also, be minded to periodically check-
the tightening force within every 6,000 hours.
< Tightening confirmation and retightening

procedure >
(1) Turn the crankshaft to place the crank pin of
the cylinder, which is to be inspected, in the
position where the crank pin rod or connecting Tightening Confirmation of Crank Pin Bolt
rod joint bolt can be inspected.
(2) Remove the rotation stopper wire ring.
(3) Tighten the bolt after setting the torque wrench
to the torque of the following table. If the bolt
does not turn, the tightening force is normal.
(4) In case that the bolt is turned, once loosen the
bolt, and conduct the angular tightening after
renewing thematchmark again.
( : 4-4.5 Matchmark Notching Procedure")

Connecting rod joint bolt:
255 N.m {26kgf.m}
Tightening Confirmation of
Connecting Rod Joint Bolt
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
4
CHAPTER
5 Engine Frame and Cylinder Liner
ITEM
General Construction/Replacing Consumables,
1,2 DK-20e Implements, and Measuring Instruments
5. Engine Frame and Cylinder Liner

5-1 General Construction
The engine frame is of a suspension shell struc-
ture made of cast steel, and has sufficient rigidity
against the explosion pressure.
The main bearing part is hydraulically fastened
securely with the main bearing bolts and side bolts
of large diameters.
The air-intake passage, cooling water assage,and
lubricating oil passage are incorporated in the
engine frame to minimize external piping.
The cylinder liner upper area is provided with the
thin-wall liner protection ring, for the sake of pre-
venting the accumulation of carbon sludge.
The engine frame and the cylinder liner are tightly-
sealed with O-rings at both the top and bottom
part.
Cylinder liner: 67 kg
a d
c b
Instruments

( : "Parts List")
O-ring 3-12 No.9, 501 2 Cylinder Liner Fitting and
(2) Implements and Measuring instruments Disengaging Implement
General tools and measuring instruments
(Refer:2-2)
Cylinder liner fitting and disengaging imple-
ment
3 Cylinder Liner Bore Gauge
Fitting and disengaging implement-1
Nut
Cylinder bore gauge (200 - 225 mm)
Cylinder line position gauge
4 Cylinder Liner Position Gauge
DK-20e Z 10-10
CHAPTER
Engine Frame and Cylinder Liner 5
ITEM
Inspection and Maintenance of Cylinder Liner Inner Surface DK-20e 3

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

a) Observe the conditions of the carbon deposi-
ted on the cylinder liner inner surface.
b) Remove the carbon, and check the inner sur- 5
face for scratch, scuffing, blow-by mark, and
corrosion.
(2) Measure the cylinder liner inner diameter.
Mount the liner position gauge in the state that
the cylinder liner is assembled in the engine
frame, measure the inner diameter with the cylin-
der bore gauge , and record the results.
4
Nom.size Replacing limit Correction limit
(mm) (mm) (mm) 3
D= φ 200 1.0 Uneven wear: 0.3
Measurement of Cylinder Liner Inner Diameter

(3) Measure the protection ring thickness with a
spherical micrometer, and record the results.
Stamp mark "US"
Nom. size (mm) Replacing limit (mm)

_0.25
a=8.7
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 a (Bottom side)
causes problems such as blow-by and Measurement of Protection Ring Thickness
increase in the consumption of lubricating oil,
and therefore when the parts reach or come
close to the use limit, be minded to replace Protect ring thickness of "upper side" and
them in an earlier stage. "bottom side" is deferent.
Please note to measure the protect ring thick-
ness at bottom side.
There is a stamped mark at the upper side as "US".
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Cylinder Liner Inner
3,4 DK-20e Surface/Extraction of Liner
(4) Dressing (de-glazing) of cylinder liner (4) Remove the O-ring

When the piston ring is replaced, or the cylinder
liner inner surface is in the mirror surface condi- It is possible to conduct honing processing in
tion, dress the inner surface. the state that the cylinder liner is assembled in
Conduct the dressing with sandpaper or by hon- the engine frame by using a special honing
ing. machine.
a) Polish the surface with sandpaper (#80) in the As for the details, consult the Service
circumferential direction, so that the surface may Department of Daihatsu Diesel Manufacturing
be marked with the sandpaper mesh. Co., Ltd.
b) In the case of dressing by honing, correct the
uneven wear, and conduct honing, so that the
surface may be 5 to 10μ Rz at the cross-hatch
angle of 40 °.
c) After the end of honing, measure the inner
diameter, and confirm that the inner diameter is
within the replacing limit.
5-4 Extraction of Cylinder Liner
Extract the cylinder liner after removing the cylin- 2-a 2-e 2-d
der head and piston.
( : 3-1.3 "Removal of Cylinder Head") 2-c
( : 4-3.1 "Extraction of Piston")
(1) Before extracting the cylinder liner, confirm that
water in the cylinder jacket is drained completely. Cylinder
(2) Receive dirt, foreign matters, water droplets, head bolt
etc. on a vinyl sheet or the like, so that they may
not drop on the oil pan.
(3) Extract the cylinder liner in the following proce-
dure:
a) Insert the liner fitting and disengaging imple-
ment 2 - a into the cylinder, making the head
bolt as the guide.
O-Ring
b) Mount the implement-2 2 - b to the imple-
ment- 1, and screw the implement until it hits Cylinder liner
againsi the liner lower end surface.
c) Turn the nut 2 - e , and pull up the liner until
the O-ring of the liner lower part is completely
extracted out of the engine frame.
d) Tighten the nut 2 - d , and completely fix the
cylinder liner using the implement-2 2 - b and
the implement-3 2 - c .
e) Pass the wire rope around the liner fitting ano 2-b
disengaging implement-1 2 - a , and suspend
it. Extraction of Cylinder Liner
f) Remove the liner fitting and disengaging
implement.
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Cylinder Liner Outer
Periphery and Engine Frame Jacket DK-20e 5

Cylinder Liner Outer Periphery and
Engine Frame Jacket
H
(1) Remove the scale or silicone rubber accumu- B
lated on the liner outer periphery using a wire
brush or the like.
(2) Subject flange fillet "A" to the color check, and A
inspect if there is any crack.
(3) Inspect the cylinder liner outer periphery "C"
and engine frame jacket "U" for cavitation or cor- C
rosion. If the degree of the defect is minor,
repair the faulty part using a repairing agent.
(4) Inspect the fitting areas "B" and "D", and the
inserting area "E" and "G" of the engine frame
D
5
for corrosion and fretting. I
In case of the corrosion or cavitation is found,

the following possible reasons can be consid-
ered: Inspection of Liner Outer Periphery
1) Cooling water rust preventive agent is not
effectively working.
2) Cooling water pressure is low.
3) Cooling water is mixed with air.
Conduct appropriate cooling water control in E
strict conformance with the Control Standard.
( :"Operation" 6-3 "Control of Cooling
Water")
(5) If the anti-corrosion coating film of the cylinder F

liner outer periphery and the engine frame jacket
is peeled off, conduct touchup painting.
Pale gray-brownish deposit is a film of the rust G

preventive agent that has been used.
Therefore, do not remove it.
Inspection of Engine Frame Jacket
DK-20e Z 10-10
CHAPTER
ITEM
6 DK-20e Mounting of Cylinder Liner
5-6 Mounting of Cylinder Liner

Mount the cylinder liner in the reverse order of
thedismounting procedure:
Circular nut 2 - e 2 - a
(1) Clean the cylinder liner inner and outer sur-
faces, and O-ring grooves.
(2) Fit O-rings to the cylinder liner.
(3) Apply silicone rubber on the flange part outer
periphery "H" of the liner upper part, and also 2 - b
apply it on the O-ring part upper side "I" of the
Cylinder
liner lower part. head bolt
1) Do not apply silicone rubber to the O-ring.

2) After silicone rubber is applied, assemble
the cylinder liner at a little earlier timing
hefnre it dries.
(4) Mount the liner in the following procedure:

a) Mount the liner fitting and disengaging imple-
ment to the liner.Tighten the nut 2 - d , and fix
the liner using the implement-2 2 - b and the
implement-3 2 - c .
b) Pass the wire rope around the liner fitting and
disengaging implement-1 2 - a , suspend it by 2 - c
a chain block, and insert it into the engine
frame.
2 - d
Matching the punch mark of the liner and the
notched line of the engine frame (between the
2 lines), and slowing lower the liner, taking
care so as not to cut the O-ring. Swing the
Mounting of Cylinder Liner
liner, and lower it down until it does not lower
any more with its own weight.
c) Fix the implement-1 2 - a with the circular
nut for head bolt.
d) Remove the nut 2 - d and the implement-
3 2- c .
e) Turn the nut 2 - e anticlockwise direction,
and tighten it until the line is completely
attached to the engine frame.
f) Remove the liner fitting and disengaging
implement 2 - a and 2 - b .
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
5
CHAPTER
6 Main Bearing and Thrust Bearings
ITEM
1 DK-20e General Construction
6. Main Bearing and Thrust Bearing

6-1 General Construction Oil hole Main bearing shell
The main bearings are of a suspension bearing-

Engine
shell structure with the main bearing cap hydrauli- frame
cally fastened rigidly by the main bearing bolt and
the side bolts. Side bolt
The main bearing shells are made of aluminum
alloy of high wear resistance, and the top and bot-
tom bearing shell are positioned by means oi the
claw.
The main bearing lubricating oil will be supplied
through the drilled holes of the engine frame from
the upper bearing shell. Main bearing cap
The thrust bearings are made of aluminum alloy as Main bearing bolt
same as in the case of the main bearing, mounted
at the top and bottom on the both sides of the 1st Main Bearing
wall located on the engine rear side, and forcibly
lubricated through the drilled holes of the engine-
frame
Thrust bearing
Main bearing cap: 33 kg
Main bearing shell
Thrust Bearing
DK-20e Z 10-10
CHAPTER
Main Bearing and Thrust Bearings 6
Replacing Consumables, Implements, and Measuring ITEM
instruments DK-20e 2

Instruments

2 Main Bearing Top Shell Extracting Implement
None
(2) Implements and Measuring Instruments b

( : 2-2)
② Main bearing top shell extracting implement
③ Hydraulic ram assy.
a Hydraulic ram
b Shell cap implement-1
c Shell cap implement-2
d Bolt
c d 6
④ Hydraulic ram receptor metal fitting
a
⑤ Hydraulic jack and hydraulic pump for main
bearing 3 Hydrauric Ram Assy.
a Hydraulic jack
b Jack stand
c Jack handle
d Hydraulic pump
e High-pressure hose
f Terminal (4T)
g Male coupler
4 Hydrauric Ram Receptor Metal Fitting
g f
c e
5 Hydraulic Jack Hydraulic Pump
DK-20e Z 10-10
CHAPTER
ITEM
3.1 DK-20e Disassembly of Main Bearing Shell
6-3 Main Bearing Shell

For disassembly and inspection of the main bear- 5-䌢 5-䌡
ing shell, the bearing shell can be extracted only
by lowering the main bearing shell cap without
removing it completely.
6-3.1 Disassembly of Main Bearing Shell

(1) Remove the covers of the both sides on the
engine frame side of the cylinders at the front
and rear of the main bearing to be disassem-
bled,and set the crank pin on the working side to 5-d
be horizontal on the opposite side.
5-e
(2) Disconnect the side bolt tightening nut using
the hydraulic jack.
( : 2-4 "Hydraulic Jack Operating Method")
a) Mount the jack stand 5 - b and hydraulic jack 5-f
5 - a on the side bolts on the both sides, and Removal of Side Bolt Nut
connect it to the hydraulic pump 5 - d using a
high-pressure hose 5 - e .
b) Operate the hydraulic pump lever to increase
the oil pressure to the specified level, and
loosen the nut using the jack handle 5 - c .
Specified oil pressure: 69 MPa {700 kgf/cm 2}
c) Confirm the oil pressure to cause the nut to

turn, and check the side bolts for loosening.
d) Remove the hydraulic jack and jack stand.
e) Disconnect the side bolt tightening nut.
(3) Remove the main bearing cap tightening nut
5-g 5-b
using the hydraulic jack.
( : 2-4 "Hydraulic Jack Operating Method") 5-e 5-a
a) Mount the jack stand 5 - b and hydraulic jack
5 - a , and connect them to the hydraulic pump
5-f
5 - d using the high-pressure hose 5 - e .
b) Operate the hydraulic pump to increase the oil
pressure to the specified level, and use the
iack handle 5 - c to loosen the nut. 5-d
Specified oil pressure : 78 MPa {800 kgf/cm 2}
c) Check the oil pressure for the nut to begin to

turn, and inspect that the main bearing bolts
are tightened securely to be free from loosen- 5-g
ing.
Removal of Main Bearing Cap Tightening Nu
DK-20e Z 10-10
CHAPTER
ITEM
Disassembly of Main Bearing Shell DK-20e 3.1
d) Remove the hydraulic jack and jack stand.

e) Remove the main bearing cap tightening nut
on one side.
f) Mount the sheil cap implement-1 3 - b on the
end of the main bearing bolt, of which main
bearing cap tightening nut is removed.
To prevent spontaneous fall of the shell

cap,immediately mount the shell cap imple-
ment-1 after removing the main bearing cap
tightening nut on one side.
3-b
(4) Dismount the main bearing cap in the following
procedure:
a) Mount the hydraulic ram receptor metal fitting 4
to the main bearing cap.
b) Mount the metal cap implement-1 3 - b to the
6
main bearing bolt, and fix the metal cap imple-
ment-2 3 - c with the nut N .
c) After fitting the rod end of the hydraulic ram
3 - a into the hydraulic ram receptor metal fit-
ting of the main bearing cap, mount them to
the metal cap implement-2 with the mounting
4
bolt 3 - d
d) Connect the oil feed port "U" of the hydraulic N
ram and the port "A" of the hydraulic pump
changeover valve with the high-pressure hose 3-c 3-b
5 - e
Likewise, connect the oil feed port "D" of the 3-a
hydraulic ram and the port "B" of the hydraulic
pump changeover valve with the high-pressure Mounting of Hydraulic Ram
hose.
e) Operate the hydraulic pump 5 - d and pres-
surize.
Pressurise
Neutral 5-d
Be minded not to increase the hydraulic oil Return
U D
pressure over the value of 19.6 MPa {200
kgf/cm2} A
B
f) Switch the changeover valve to "Return", and
slowly lower the main bearing cap.
5-e
Connection of Hydrauric Ram
DK-20e Z 10-10
CHAPTER
ITEM
3.1 DK-20e Disassembly of Main Bearing Shell
If the changeover valve is switched to

"Return", the hydraulic oil flows from "B" to "D"
and the main bearing cap lowers, and if the
changeover valve is switched to "Pressurize", Claw 2
the oil flows from "A" to "U" and the main bear-
ing cap rises.
In the neutral position, the hydraulic oil does
not flow.
In case that the main bearing cap dose not
lower, if the side bolts on both sides are loos-
ened, it will facilitate to lower the cap.
(5) Remove the main bearing bottom shell from the

cap.
(6) Remove the main bearing top shell in the fol-
lowing procedure:
a) Insert the main bearing top shell extracting
implement② into the crankshaft oil hole.
Be careful so that the main bearing sheli

extracting implement may not come off the oil
hole. Application of grease to the insertion side
of the extracting implement will make it difficult
for the implement to come off Extraction of Main Bearing Shell
(Viewed from the engine front side)
b) Press the main bearing shell extracting imple-
ment against the end face of the main bearing
top shell, turn the crankshaft anticlockwise as
viewed from the engine front side, and then
extract the top shell.
Be careful not to turn the crankshaft in a wrong

direction. The positioning claw is provided on
the main bearing shell, and it will be damaged if
the crankshaft is turned in a wrona direction.
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Main Bearing Shell DK-20e 3.2

Main Bearing Shell
(1) Inspect if there is fretting on the rear surface
and the joint surface of the main bearing shell, Main bearing
and also check if there are seizure mark, peel, upper shell
cavitation, or imbedded foreign matters in the
inner surface. When the degree of the fault is
minor, correct the surface using an oil stone.
The main bearing shell is a thin-wall finished

metal, and provided with appropriate interfer-
ence (crush) and tension, so as to make it tight-
ly fit to the housing surface.
Therefore, do not repair the rear surface and
joint surfaces with a file or scraper.
Main bearing
lower shell
6
1) Long-time use of the shells brings about the
reduction of tension and hardening of the shell Main Bearing Shell
surfaces to cause crack and peel of the shells,
even if the wear is below the allowable value.
Therefore, be minded to replace the shells
every 16,000 to 24,000 hours (4 to 5 years).
2) Be sure to simultaneously replace the top
and bottom shells as one pair set.
(2) Check the seat surface of the tightening nut

and the seat surface of the cap side, and if there
is any roughness on them, correct the part.
(3) If the tightening nut of the disassembled main
bearing bolt is found to be loosened, retighten
the other main bearing bolts as well.
(4) Inspect the main bearing cap joint surface and
the contact surface of the fitting area, to check if
there is any fault such as fretting.
(5) Inspect the crankshaft surface for scratch, and
also check the contact and wear conditions.
DK-20e Z 10-10
CHAPTER
ITEM
3.3 DK-20e Assembly of Main Bearing Shell
6-3.3 Assembly of Main Bearing Shell c) Confirm that the shell is completely mounted.
d) Sufficiently apply lubricating oil to the bottom
(1) Visually check and also check with naked hand
shell inner surface with naked hand.
that the crankshaft journal part is free from the
deposit of foreign matters and scratch.
(2) Clean the shell inner surface and rear surface
Be minded not to apply lubricating oil to the
with washing oil, then carefully wipe off the oil.
back surface of the shell. If the oil is applied,
(3) Assemble the top shell to the engine frame in
the adhesion performance decreases.
a) Check the positions of the top shell claw and
the helical groove In the engine frame, and
push in the top shell from the side noi
equipped with the claw by hand as deeply as
possible.
b) Insert the main top shell extracting implemeni
into the crankshaft oil hole according to the
same procedure as that for disassembly.
c) Turn the crankshaft counterclockwise as
viewed from the engine front side, and push
the top shell into the engine frame, until the top
shell end face fits the main bearing cap joini
surface of the engine frame.
Conduct turning with enough care, so that the

main bearing top shell extracting implement
may not be dislocated from the shell end face.
d) Confirm that the top shell is inserted in the

regular position.
e) Turn the crankshaft anticlockwise as viewed
from the engine front side, and remove the
main bearing top shell extracting implement. Assembly of Main Bearing Shell
(4) Assemble the bottom shell to the main bearing

cap in the following procedure:
a) Visually recheck and also recheck with naked
hand that the crankshaft journal and the main
bearing cap inner surface are free from the
deposit of foreign matters and scratch.
b) Confirm the positions of the bottom shell, the
end face of the main bearing cap, and the
claw. And then, mount the bottom shell to the
main bearina cap.
DK-20e Z 10-10
CHAPTER
ITEM
Assembly of Main Bearing Shell DK-20e 3.3
(5) Assemble the main bearing cap in the reverse a) Tighten the two side bolts of the same main
order of the extracting procedure. bearing at the same time.
a) Match the main bearing cap side face with the b) After tightening the bolts with the specified
engine frame side face, switch the pressure, once return the oil pressure back to
changeovervalve to "Pressurize" (main bearing "0", then increase the oil pressure up to the
cap raising direction), and slowly push up the specified value again to check for the tighten-
main bearing cap until it strikes the joint sur- ing conditions.
face of the upper area engine frame.
b) Spray the lubricating agent (MOLYKOTE
1000 spray type) to the threaded area on the
studding side of the side bolt, and manually
screw the bolt into the threaded hole of the
main bearing cap.
Turn it back by 1/4 to 1/2 turn after the bolt is
screwed down to the bottom.
c) Screw the side bolt tightening nut until it is
completely settled to the bottom.
MOLYKOTE
1000 6
d) Remove the hydraulic ram assembly and
hydraulic ram receptor metal fitting, and manu-
ally screw the tightening nut into the main
bearing bolt.
To prevent the spontaneous falling-off of the

main bearing cap, remove the hydraulic ram Application of Lubricating Agent
after screwing the side bolt.
e) Install the hydraulic jack, and conduct the

hydraulic tightening of the bolts.
The tightening shall be made on the 2 bolts at
the same time.
Specified oil pressure: 78 MPa {800 kgf/cm2}
f) 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 for the tighten-
ing conditions.
(6) Mount the hydraulic jack on the side bolts, and

tighten the bolts hydraulically.
Specified oil pressure: 69 MPa {700 kgf/cm2}
DK-20e Z 10-10
CHAPTER
ITEM
4.1 DK-20e Dismounting of Thrust Bearing
6-4 Thrust Bearing

The thrust bearings are mounted on the front and
rear surfaces of No.1 main bearing (flywheel side). Thrust
bearing
Dismount the thrust bearings at the time of disas- d
sembling the main bearing.
6-4.1 Dismounting of Thrust Bearing

(1) Measure the side clearance of the crankshaft
according to the following procedure before dis-
mounting the thrust bearing:
a) Use the bar to shift the crankshaft toward the
either side, front or back, and place the dial
gauge against the crankshaft.
b) Fully shift the crankshaft toward the opposite
side, and read the value.
D
Side Clearance
When hooking the bar on the crankshaft,hook it
on the crank web, and do not hook the bar on
the balance weight.
(2) The bottom side thrust bearing is mounted on

No.1 main bearing cap with knock pins (1 piece
each on both sides). Therefore, it can be dis-
connected at the same time when the main bear-
ing bottom shell is extracted.
(3) The top side thrust bearing can easily be
extracted when the end face is pushed with hand
The thrust bearings are designed to form a pair

with the top and bottom shells.
Therefore, be careful not to mistake the front
thrust bearing for the rear thrust bearing.
Discriminate them by marking or the like.
Dial gauge
Measurement of Side Clearance
DK-20e Z 10-10
CHAPTER
ITEM
Maintenance and Assembly of Thrust Bearing DK-20e 4.2,4.3
6-4.2 Maintenance of Thrust Bearing

(1) Check the thrust bearing for seizure mark and
imbedded 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
clearance with the crankshaft is exceeding the
replacing limit, replace the thrust bearing with a
new one.
Be sure to replace the thrust bearing as one set
of a pair of the top and bottom shells.

D=92 d=0.13~0.30 0.6
Thrust Bearing
6
6-4.3 Assembly of Thrust Bearing
(1) Carefully clean the thrust bearings and apply
lubricating oil to the bearing surfaces.
(2) Insert the top side thrust bearing. Thrust
bearing
(3) Mount the bottom side thrust bearing to the d
main bearing cap, and assemble them together
as an assembled parts.
(4) Measure the side clearance.
Side Clearance
DK-20e Z 10-10
CHAPTER
7 Crankshaft
ITEM
Crankshaft: General Construction / Consumables,
1, 2 DK-20e Implements, and Measuring Instruments
7. Crankshaft 7-2 Replacing Consumables,

7-1 General Construction Implements, and Measuring
The crankshaft is a high-strength carbon steel Instruments
forged product of one-piece construction, and pro- (1) Replacing Consumables
vided with sufficient rigidity and strength. None
The thrust bearing is processed by induction hard-
ening to increase abrasion resistance. (2) Implements and Measuring Instruments
Two pieces of the balance weight are fitted to each ① General tools and measuring Instruments
cylinder, and they are securely tightened with two ( : 2-2)
pieces of the bolts respectively.
The crank gear is shrink-fitted to the rear side of
the crankshaft to drive the camshaft, and further
the auxiliary drive gear is bolted on the front end to Flywheel
drive the lubricating oil pump and cooling water pump.
Lubricating oil supplied to the main bearing
through the holes of the engine frame reaches the
crank pin metal through the drilled holes in the
crankshaft, and further flows to the piston pin and
piston through the drilled holes in the connecting rod.
The crankshaft is manually turned by the turning
device on the flywheel side.
Crankshaft assy.: 5DK: 1059 kg

6DK: 1287 kg
8DK: 1684 kg
Turning Device
Auxiliary drive gear

Crank gear
Balance weight
Crankshaft
DK-20e Z 10-10
CHAPTER
Crankshaft 7
ITEM
Inspection and Maintenance of Crankshaft DK-20e 3

Crankshaft
In ordinary maintenance, the crankshaft is not dis-
assembled, but inspected and adjusted in the state In case that the following situations has hap-
that it is assembled. pened and if the operation is continued disre-
When it becomes necessary to overhaul the crank- garding any one of them, it may result in
shaft because of the particular reasons such as serious damages or accidents:
seizure of the bearing or abnormal wear of the- ① In case that the engine is operated for a
shaft, consult our Service Department. long time in the dangerous rotation number
range due to torsional vibration
1. Inspection of Crank Pin ② In case that the engine is operated exceed-
Inspect the crank pin when the connecting rod ing the allowable value of the crankshaft
large end part is disassembled. deflection
( : 4-3.2 "Disassembly of Connecting Rod ③ In case that the clearance between the
Large End Part") crankshaft and shell is excessive, or the
crankshaft is unevenly worn out
(1) Check the bearing for scratch and contact con- ④ In case that the shell is burnt (In case of
ditions. minor degree)
If scratch is found, correct it using an oil stone,
and conduct the color check carefully.
7
(2) Measure the shaft diameter, and record the
results.
( : 4-4.4 "Inspection and Maintenance of
Fillet
Crank Pin Shell") Presence of
(3) Subject the fillet to color check. hair crack
In case that the problems such as the ones as
described above are found, carefully conduct the
Fillet
color check with particular attentions.
2. Inspection of Crank Journal

Inspect the crank journal when the main bearing-
shell is disassembled.
(1) Check the bearing for scratch and contact con-
ditions.
(2) Subject the fillet to color check.
In case that the problems such as the ones as
described above are found, carefully conduct the
color check with particular attentions.
Inspection of Crankshaft
When disassembly of the crankshaft is

required as a result of inspection, consult our
Service Department.
DK-20e Z 10-10
CHAPTER
7 Crankshaft
ITEM
Crankshaft: Inspection of Balance Weight Bolt Tightening
4, 5 DK-20e Force / Measurement of Deflection
7-4 Inspection of Balance Weight Bolt

Tightening Force
(1) Inspection of every 4,000 to 6,000 hours
(every year).
Inspect the rotation-stopper wire ring conditions,
and confirm that the balance weight bolt is not
loosened.
(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 the specified torque,
and confirm the tightening force. When the bolt
does not turn, it is sufficiently tightened, and
then conduct the rotation stoppage with the
wiring.
c) In case that the bolt is turned, remove the Balance weight
bolt, apply the lubricating agent (MOLYKOTE Wiring
Balance weight bolt
1000 spray type), and once again tighten the
boll with the specified torque.
d) After tightening, conduct the rotation stoppage Balance Weight Bolt
with wiring.
Specified torque: 980 N･m {100 kgf･m}
7-5 Measurement of Crankshaft

Deflection
1) Measure the crankshaft deflection when the

engine is cold.
2) When the engine is continuously operated
in the state that the crankshaft deflection is
over the limit value, the added stress of the
crankshaft will become excessive, and will
lead to the breakage of the crankshaft in the
worst case. Therefore, adjust the deflection
to a proper value at the time of installation,
and periodically measure the crankshaft Crankshaft deflection measuring procedure:
deflection every 2,000 to 3,000 hours (every ( : "Operation" 5-4.5 "Measurement of
6 months) after the start of operation of the Crankshaft Deflection")
engine, and correct the situation in case thai
the deflection is over the limit value.
DK-20e Z 10-10
CHAPTER
Crankshaft 7
ITEM
MEMO DK-20e
7
CHAPTER
8 Timing Gears and Camshaft
ITEM
1.1 DK-20e General Construction of Timing Gear
8. Timing Gear and Camshaft

High technology is needed to disassemble,
8-1 Timing Gear assemble, and adjust the area around the tim-
ing gear and camshaft.
When the maintenance of such high technol-
The timing gear is arranged on the engine front ogy is needed as the results of the inspection,
side, and the camshaft is driven by the cam gear please contact our Service Department or
D , from the crank gear A located on the crank- agency, and perform suck works under the
shaft rear side, via the idle gear-1 B and idle experienced engineers' guidance.
gear-2 C
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 is fixed to the camshaft by means
of the shaft fastening elemental parts (POWER-
LOCK) E , which makes use of the wedge effect.
D
Lubricating oil is supplied to the idle gear bush
F through the drilled holes of the idle gear shaft
bolt G and idle gear shaft H . E
The gear tooth is lubricated through the oil feed
nozzle.
C
Cam gear : 39 kg
Idle gear assy. : 44 kg H
Cam gear D G
Idle gear-2 C
Idle gear-1 B F
2
2
2
1 Crank gear A
1 1
Engagement of Timing Gear Timing Gears
DK-20e Z 10-10
CHAPTER
Timing Gears and Camshaft 8
ITEM
Timing Gears: Replacing Consumables and
Implements / Disassembly of Idle Gear DK-20e 1.2,1.3
8-1.2 Replacing Consumables, Implements

and Measuring Instruments
x2
Replace the following Consumables with the
x2
new ones:
( : "Parts List") 2 Idle Gear Shaft Implement 3 Spanner 42x25.4
① O-ring 3-6 No.502, 503, 504

① General implements and measuring
instruments ( : 2-2)
② Idle gear shaft implement (option) 4 Hex. Wrench 14x12.7
③ Spanner 41X25.4 (option)
④ Hex. wrench 14X12.7 (option)
8-1.3 Disassembly of Idle Gear

When disassembling the idle gear, the cam gear
is needed to be extracted beforehand so that the
idle gear can be dismounted from the cam gear
8
cover side.
( : 8-2.3 "Disassembly of Camshaft")
(1) Remove the flywheel cover.
(2) Remove the governor and governor driving
b
device.
( : 11-3 "Disassembly of Governor Driving

Device")
(3) Remove the mist pipe on the rear side.
(4) Conduct the following measurement before
disassembling the idle gear:
a) Measure the thrust clearance on the axis
direction of the idle gear, and record the
data.
Standard clearance Replacing limit

(mm) (mm)
b = 0.3 ~ 0.7 0.9
Idle Gear Thrust Clearance
DK-20e Z 10-10
CHAPTER
ITEM
1.3 DK-20e Timing Gears: Disassembly of Idle Gear
b) Measure the backlash between the timing Lead wire

gears, and record the data. A
i ) Bend a lead wire of 0.5 mm diameter along B
the tooth profile, and adhere it using grease.
ii)Slowly turn the engine, and stop turning b
when the lead wire is engaged.
iii) Next, turn the engine in the reverse direc- Backlash b ( = A+B )
tion, and pick up the lead wire to this side.
iv) Measure the thinnest part of the thickness
of the lead wire that is collapsed. (A and B B
as shown in the figure) C
v) Conduct the measurement in the 4 places
per 90° on the large gear wheel, and take
its average value. I
Standard value Replacing

Backlash (mm) limit (mm)
A+B b= 0.2 ~0.3 0.5
(5) Remove the cam gear.

( : 8-2.3 "Disassembly of Cam Gear")
(6) Install the eyebolt to the idle gear-1 B , and
G
support the idle gear-1 by passing the sus-
pending wire around the eyebolt from the mist
exhaust port of the engine frame
(7) Remove the oil feed plug of the idle gear shaft
H L
bolt G , and remove the idle gear shaft bolt
using the spanner 41 x 25.4 ③.
(8) Screw the bolt of the idle gear shaft implement② 2
into the idle gear shaft support-3 I , and remove
the idle gear shaft support-3.
(9) Mount the idle gear shaft implement on the
idle gear shaft support-2 J .
Screw the bolt into the idle gear shaft support
implement, and extract the idle gear shaft sup-
port-2 and idle gear shaft support-4 K at the
same time.
(10) Remove the bolt L with the hole in the idle
gear shaft using the hexagonal wrench ④.
(11) Screw the idle gear shaft bolt into the idle
gear shaft, and extract the idle gear shaft.
(12) Take out the idle gear from the cam gear
cover side of the engine side face, by slowly
L K J
loosening the wire.
Idle Gear Disassembling Procedure
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of Timing Gear DK-20e 1.4

Timing Gear
(1) Wash all the gears and parts using washing oil.
(2) Clean the idle gear shaft oil hole by blowing air.
(3) Check the idle gear-1, -2, and cam gear tooth
surface for contact, pitching, and scratch.
(4) Turn the crankshaft, and check the crank gear
as well, in the same manner as above.
(5) Inspect the tightening conditions of the tighten-
ing bolt N of the idle gear-1 and idle gear-2.
Inspect the bolt tightening conditions under
the specified torque, and in case that the bolt
is loosened, remove the bolt, clean it, and
then tighten it again with the specified torque.
In case that the thread of the bolt is damaged,
replace the bolt with a new one.
Specified torque : 118 N.m {12 kgf.m}
(6) Check the idle gear bush and shaft for the
contact and wear conditions. 8
(7) Measure the outer diameter of the bush con-
tact area of the idle gear shaft using an out-
side micrometer.
(8) Measure the inner diameter of the idle gear
bush using a cylinder gauge.
(9) Calculate the clearance from the results of the
measurement of the idle gear shaft and idle
gear bush, and when the clearance is over the
a
replacing limit, replace the idle gear bush with

a new one.
A
Nom. Size Standard Replacing

A=φ65 a=0.03~0.15 0.25
When it is presumed that the clearance will

be over the replacing limit before the next peri- N
odic maintenance, replace the bush, even if the
clearance is presently within the limit.
Idle Gear Bush Clearance
DK-20e Z 10-10
CHAPTER
ITEM
1.5 DK-20e Timing Gears: Assembly of Idle Gear
8-1.5 Assembly of Idle Gear

Assemble the idle gear according in the reverse B
order of the disassembling procedure.
F 2
(1) Suspend the idle gear assembly with a wire, L C
and move it to the specified place.
(2) Turn the crank shaft, and place the No.1 cylin-
der to the position of the intake top dead center.
(3) Apply grease to the idle gear bush F , and
match the match marks of the idle gear-1 B
and crank gear.
(4) Apply lubricating oil to the idle gear shaft H , insert
it into the idle gear and idle gear shaft support-1
M , and then match the knock pin positions.
G
(5) Apply lubricating agent (MOLYKOTE 1000
spray type) to the thread area and seat surface
of the bolt L with the hole, and tighten it with H
the specified torque using a hexagonal wrench. K J
(6) Assemble the idle gear shaft support-2 J and

B
idle gear shaft support-4 K . M
Mount the idle gear shaft implement 2 and
idle gear shaft support-2, -4 to the idle gear
shaft bolt G . I
Tighten the idle gear shaft bolt until the idle

gear shaft support-2 becomes tightly in con-
tact with the idle gear shaft.
(7) Remove the idle gear shaft bolt and idle gear
shaft implement.
(8) Apply the lubricating agent (MLYKOTE 1000
spray type) to the threaded area and seat sur-
face of the idle gear shaft bolt, mount the idle
gear shaft support-3 I , and angularly tighten F
it with the specified torque using the spanner
41x25.4 ③.
H L
A-torque: 196 N.m {20 kgf.m}
o
Angular tightening (B mark): 40
Idle Gear Disassembling Procedure
DK-20e Z 10-10
CHAPTER
ITEM
Timing Gears: Assembly of Idle Gear DK-20e 1.5
<Cautionary items when assembling the tim-

ing gears>
a) The engagement match marks of the tim- Cam gear
slit
ing gears are notched on the side of each
gear. Be sure to check the engagement
2
2
match marks when assembling the gears
2
without fail.
b) When the match marks of the crank gear
and idle gear are engaged, also have the 1
1
match marks of the cam gear and idle gear 1
engaged at the same time. Engine frame

end face
c) If the slit on the flywheel side of the cam
gear is aligned with the engine end face,
while matching the engagement match
marks on the crank gear side, the match
marks of the cam gear and idle gear will be
engaged. This figure shows the engagement of timing gears
when No.1 cylinder is on the position of the intake
d) Since it is required to determine the oil top dead center
injecting direction of the idle gear oil feed
Matchmarks of Timing Gears
8
nozzle, be careful of the mounting direction
of the nozzle.
The punch mark direction of the nozzle
hexagonal head is the oil injecting direc-
tion. Be minded to conduct the shim Punch mark
adjustment so that the punch mark faces
toward the horizontal direction of the
Oil injecting direction
engine inner side.
Mounting Direction of Oil Feed Nozzle
DK-20e Z 10-10
CHAPTER
ITEM
2.1 DK-20e General Construction of Camshaft
8-2 Camshaft Governor

driving
8-2.1 General Construction device
The camshaft is of one-piece construction made
of carbon steel, and is driven by the cam gear
located on the rear end part.
The governor driving device is provided to the
cam gear upper part, and is directly driven from Cam gear
the cam gear.
The starting air rotary valve is driven from the
camshaft front end via the Oldham's coupling.
The intake and exhaust cams are fixed to the
camshaft by shrink fitting, and these cams are
positioned by the key.
The fuel cam is also fixed to the camshaft by
shrink fitting as in the same manner as the case of
the intake and exhaust cams.
The surface of each cam is carburized. Exhaust cam Camshaft
The cam bearings are provided at the front and Intake cam
rear of the cam gear, and the cam bearings are Fuel oil cam
also provided at the front side of the fuel oil injec-
Camshaft Rear End
tion pump of each cylinder.
The bearing housing between each cylinder is
divided into 2 parts, i.e. the upper and lower sec-
tions, and the cam bearing pin combines the oil Camshaft divided into 2 sections (optional
feed passage.
specification)
( : 8-1 "Timing Gear") The camshaft divided into 2 sections is divided
( : 11 "Governor Driving Device") at the center of the camshaft in relation to the dis-
( : 13-3 "Starting Air Rotary Valve) assembly space, and the connecting flange is
tightened with 10 sets of the bolts and nuts.
Camshaft assy. (excluding cam gear): The outer periphery of the flange is the bearing
5DK : 140 kg part, and the bearing shell is press-fitted into the
6DK : 160kg engine frame.
8DK :210kg
P
View P
Camshaft Divided Into 2 Sections (Option)
DK-20e Z 10-10
CHAPTER
ITEM
Camshaft : Replacing Consumables, Implements and
Measuring Instruments DK-20e 2.2

Instruments
Replace the following parts with the new ones
( : "Parts List")
① O-ring 3-8.7 NO.B509
② O-ring 3-8.1 -8.6 No.B511
③ Circular gasket 3-8.1 -8.6 No.B510

① General implements and measuring
instruments ( : 2-2)
② Camshaft shell extracting implement
....For the camshaft divided into 2 sections
(Option) c a b
a Shell extracting implement-1
b
c
Shell extracting implement-2 2 Camshaft Shell Extracting Implement
8
Bolt
③ Camshaft shell assembling implement
....For the camshaft divided into 2 sections
(Option)
a Shell extracting implement-1
b Shell extracting implement-2
c Shell extracting implement-3
d Shell extracting implement-4
d
④ Fuel oil cam adjusting implement (option)
a Hydraulic pump (Use the one for hydraulic
jack.)
b High-pressure hose (Use the one for
hydraulic jack.)
c Coupler
d Fuel oil cam adjusting handle
c b a
3 Camshaft Shell Assembling Implement
DK-20e Z 10-10
CHAPTER
ITEM
2.3 DK-20e Disassembly of Camshaft
8-2.3 Disassembly of Camshaft

Disassemble the camshaft in the following pro- E
cedure:
(1) Remove the governor, governor driving D
device, starting air rotary valve and its related
parts, and piping.
( : 11-3 "Governor Driving Device")
C
( : 13-3 "Starting Air Rotary Valve")
(2) Remove the gear case on the front side of the
camshaft, cam gear cover on the side of the
camshaft, and cam chamber cover.
B
(3) Take out the cylinder head cover, and remove
the rocker arm device and push rod,
( : 3-4 "Rocker Arm Device")
(4) Remove the fuel oil injection pump and valve A

driving device.
( : 9 "Fuel Oil Injection Pump")
( : 10 "Valve Driving Device")
(5) Before removing the thrust bearing, measure
the thrust clearance of the camshaft.
Placing a dial gauge against the top end of the Thrust Bearing
camshaft, and measure the clearance by mov-
ing the camshaft back and forth.
Standard clearance (mm) Replacing limit (mm)

b = 0.15 0.45
(6) Remove the thrust bearing located on the rear

side of the camshaft in the following procedure:
a) Loosen the bolt, and take out the bearing
cover A . Inner ring
b) Loosen the thrust bearing mounting bolt, and Tightening bolt
remove the thrust bearing B and thrust shell C . F
c) Remove the bearing body D .
Remove the bearing cover, thrust bearing,
and bearing body using the jack bolt.
(7) Remove the POWER-LOCK E mounted on
the cam gear in the following procedure:
Outer ring
a) Confirm that the rotational torque or thrust
load is not applied on the boss and shaft.
b) Gradually loosen he POWER-LOCK tighten-
ing bolt F by dividing into several steps.
c) Remove the POWER-LOCK by screwing
Removal of POWER-LOCK
and tightening the tightening bolt F into the
dismounting threaded hole.
DK-20e Z 10-10
CHAPTER
ITEM
Disassembly of Camshaft DK-20e 2.3
(8) Remove the camshaft positioning pin of the (8) Disassemble the cam bearing, and remove it
camshaft upper part shelf. from the camshaft.
(9) Move the camshaft to the front of the engine (9) Extract the camshaft-R toward the front.
to as much extent as that the disassembling of
the camshaft is possible.
(10) Divide the cam bearing, and remove it from
the camshaft. Reamer bolt
The cam bearing is divided into 2 parts of the
upper and lower sections, and can be disas- Positioning pin
sembled if the reamer bolt is removed.
(11) Move the camshaft to the front of the engine,
and take out the cam gear from the side of the
cam gear chamber.
(12) Extract the camshaft toward the front.
When disassembling the camshaft, be care-

ful not to damage the cam and camshaft.
Disassembly of the camshaft divided into 2

sections
(1) After finishing the works of the above Item (1)
to (8), loosen the nut of the divided parts at
the center of the camshaft, and remove the
tightening bolt. 2 - a 2 - b
8
(2) Move the camshaft-F to the front of the engine
to as much extent as that the cam bearing can
be disassembled.
(3) Disassemble the cam bearing, and take out it 2 - c
from the camshaft.
(4) Extract the camshaft-F toward the front.
(5) Move the camshaft-R toward the rear, and
mount the camshaft shell extracting imple-
ment.
(6) Push in the extracting implement bolt, and
extract the camshaft shell.
(7) Move the camshaft-R to the front of the Camshaft shell
engine to as much extent as that the cam
bearing can be disassembled. Disassembly of Camshaft Shell
Camshaft shell
Camshaft-F Camshaft-R
P
View P Camshaft bearing
Divided
Camshaft Divided Into 2 Sections
DK-20e Z 10-10
CHAPTER
ITEM
2.4 DK-20e Inspection and Maintenance of Camshaft
8-2.4 Inspection and Maintenance of (5) Inspect the wearing, scratch, or peeling condi-
Camshaft tions of the thrust shell.
(6) Maintenance of POWER-LOCK
Since the items mentioned in this section are a) Disassemble the POWER-LOCK by extract-
the parts to which NOx Technical Code shall be ing the bolt, and clean all the parts.
applied, when replacing any of these parts, be b) Thinly apply lubricating oil on all the parts.
sure to use the parts provided with the identifi-
cation marks.
Do not use the oil which contains silicone
( : 0-3 "Engine Conforming to NOx
type or molybdenum type lubricating agent.
Technical Code.")
Use of such an oil decreases the friction
coefficient and allows easier sliding.
(1) Inspect if there is any pitching or peel on each
cam surface.
c) Assemble the camshaft so that the blanked
tap hole of the inner ring and the phase of
When the pitching, peeling, or wearing on the the outer ring slit part do not match.
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 camshaft shell for the wearing,
scratch, or peeling conditions.
(4) Measure the clearance between the camshaft
and the bearing.
a) Measure the outer diameter of each bearing
of the camshaft using an outside micrometer.
b) Assemble the cam bearing incorporating the
shell, and measure the inner diameter of a
A
the bearing using a cylinder gauge.
c) Calculate the clearance from the results of
the measurement, and in case that the
clearance is over the replacing limit, replace
the bearing shell with a new one.

A=φ9O a=0.04~0.12 0.2 Clearance of cam bearing
Clearance of Cam Bearing
DK-20e Z 10-10
CHAPTER
ITEM
Inspection, Maintenance and Assembly of Camshaft DK-20e 2.4,2.5
Inspection and maintenance of the

camshaft divided into 2 sections
As for the bearings of the divided sections, also b
inspect for the wearing, scratch, and peeling condi-
tions of the bearing shell, as same manner as in
the case of the other bearings. B
Measure the bearing clearance, and in case that

the clearance is over the replacing limit, replace
the bearing shell with a new one.
Nom. Size Standard Replacing Camshaft shell

A=φ155 a=0.07~0.19 0.3
Camshaft Shell Clearance
(Position of Camshaft Devided Into 2 Section)
8-2.5 Assembly of Camshaft

Psitioning pin
Assemble the camshaft in the reverse order of
the disassembling procedure.
Adjusting
(1) Clean the boss inner surface of the cam gear screw
and the surface of the camshaft, and thinly
Matchmark 8
apply lubricating oil on them.
(2) Insert the camshaft into the position to as
much extent as that the cam bearing can be
installed.
Adjusting
Insert the cam gear and POWER-LOCK into screw
the camshaft. Adjusting hole
(3) Confirm the match marks of the top and bot-
tom cam bearings, assemble the shell into the Fitting of Camshaft Bearing
housing, and tighten the nut by passing the
reamer bolt.
direction, and toward the front and rear direc-

tions, utilizing the adjusting threaded hole or
the hole of the cam bearing side face.
(4) Move the camshaft and cam bearing to the (6) Install the thrust bearing.
position where the cam bearing positioning pin
holes can be matched.
(5) Attach the circular gasket and O-ring to the
cam bearing positioning pin, and then fit and
install the pin into the cam bearing pin hole.
To fit the pin into the bearing pin hole, move
the cam bearing toward the circumferential
DK-20e Z 10-10
CHAPTER
ITEM
2.5 DK-20e Assembly of Camshaft
(7) Adjust the thrust bearing clearance.

Place the dial gauge against the tip of the
camshaft, move the camshaft back and forth, Clearance 0.15mm
E
and then adjust using the shim so that the
clearance becomes 0.15 mm.
(8) Fix the cam gear to the camshaft using
POWER-LOCK, install the cam gear so that
the clearance between the cam gear and idle
gear-1 B becomes 3 mm.
(9) Tighten the POWER-LOCK in the following
procedure: 3mm
<POWER-LOCK tightening procedure> Shim
a) Lightly push the POWER-LOCK to the speci-

fied position by hand, in the state that the
POWER-LOCK tightening bolt is lightly Mounting of Cam Gear
tightened. Outer ring
Inner ring
b) After inserting the POWER-LOCK to the
specified position, tighten the tightening Mounting bolt F
bolts of 4 places diagonally with about 1/4
torque.
Next, tighten the other tightening bolts in the
same manner.
c) Setting the tightening torque to about 1/2 of
the specified torque, sequentially tighten the
bolts diagonally in the same manner as in
item b).
d) Sequentially tighten all the tightening bolts Mounting of POWER-LOCK
with the specified torque diagonally.
Repeat this procedure a few times, and
confirm the tightening conditions.
3 - d
Specified torque: 80 N.m {8.3 kgf.m}
Camshaft shell
Assembly of the camshaft divided into 2
Nut
sections
(1) Insert the camshaft-R to the position where
the cam bearing can be installed.
Previously insert the cam gear and
POWER-LOCK into the camshaft.
(2) Install the cam bearing.
(3) Move the camshaft-R and cam bearing to 3 - c 3 - b 3 - a
the position where the camshaft shell fitting
implement can be mounted. Mouting of Camshaft Shell
DK-20 A 10-6
CHAPTER
ITEM
Assembly of Camshaft DK-20e 2.6
(4) Mount the camshaft shell and camshaft shell

fitting implement, and press-fit the camshaft
shell by tightening the implement nuts.
Install the camshaft shell, so that the oil
hole is in horizontal position.
When fitting the shell, be careful so that the

shell may not be distorted or damaged.
(5) Insert the camshaft-F to the position where

the cam bearing can be installed, and then
install the cam bearing. Oil hole (2places)
(6) Insert the camshaft-F and camshaft-R into
Camshaft shell
the camshaft shell part, attach the bolts,
and then tighten them with the nuts. Mounting of Camshaft
Attach the 2 reamer bolts diagonally, and
sequentially tighten the nuts diagonally.
Specified torque: 196 N.m {20 kgf.m} 8

(7) Afterwards, assemble the camshaft in the
same procedure as that of the one-piece
construction camshaft.
DK-20e Z 10-10
CHAPTER
ITEM
2.6 DK-20e Camshaft: Inspection of Fuel Oil Cam Timing
8-2.6 Inspection of Fuel Oil Cam

Timing Initial injection
position mark line Tappet slit
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 Mounting position
mark line
Technical Code.")
Read the initial injection angle when the initial

injection line of the fuel oil injection pump and the
fuel oil injection pump tappet line is aligned, from
the scale on the flywheel. Initial Injection Position
DK-20 A 05-03
CHAPTER
ITEM
Camshaft: Adjustment of Fuel Oil Cam Timing
(When Replacing Cam) DK-20e 2.7
8-2.7 Adjustment of Fuel Oil Cam 4 c 4 b 4 a

Timing (When Replacing Cam)

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.
Technical Code")
In case that the cam or camshaft is replaced,

perform the adjustment in the following procedure:
Adjusting handle
(1) Attach the coupler and coupler connector to
the fuel oil cam, and then connect the high-
pressure hose.
(2) Apply the hydraulic pressure of more than Adjustment of Fuel Oil Cam
34.3MPa {350 kgf/cm2} using a hydraulic pump.
The maximum oil pressure is 68.6 MPa {700

kgf/cm2} 8
(3) Adjust the fuel oil cam using the special handle in
the state that the hydraulic pressure is applied.
a) Adjust the fuel oil cam slit referring to the slit
Initial injection
on the intake cam side as the standard. position mark line Tappet slit
b) Read the initial injection angle when the ini-
tial injection line of the fuel oil injection pump
and the fuel oil injection pump tappet line is
aligned, from the scale on the flywheel.
c) Adjust the fuel oil cam again, so that the
angle becomes the initial injection angle
that is specified on the adjustment plate on Mounting position
the inspection window of the engine frame. mark line
When restarting the operation, measure the

maximum combustion pressure, and readjust
the initial injection timing of the fuel oil cam, so
that the deviation among the cylinders is within
Initial Injection Position
0.3 MPa {3 kgf/cm2} at the time of full loading.
However, be minded that the maximum com-
bustion pressure at the time of full loading do
not exceed 15.8 MPa {160 kgf/cm2}.
DK-20e Z 10-10
CHAPTER
ITEM
Camshaft: Adjustment of Fuel Oil Cam Timing
2.7 DK-20e (When Replacing Cam)
<Relationship between the initial injection

angle of the fuel oil cam and the maximum
combustion pressure (Pmax)>
The maximum combustion pressure can be var-
ied by turning the fuel oil cam, and by changing the
initial injection angle, as the followings:
(The rotating direction of the camshaft is as
same as the rotating direction of the engine.)
o Turn the camshaft toward the rotating direc-
tion. (Advance the injection timing.)
......Pmax will be increased.
o Turn the camshaft toward the anti-rotating

direction. (Delay the injection timing.)
......Pmax will be decreased.
Variation standard of Pmax (when fully

loaded)
o
If the initial injection is changed by 1 of the
crank angle, Pmax will be changed by 0.3~0.5
MPa {3~5kgf/cm2}.
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
8
CHAPTER
9 Fuel Injection Device
ITEM
1 DK-20e General of Construction
9 Fuel Oil Injection Device .
9-1 General Construction ( ： " Operation" 5-4.2 "Inspection and

Maintenance of F.O. Injection Valve" )
The F.O. injection pump is a Bosch type, tappet-
incorporated high-pressure single cylinder pump,
Fuel injection pump assembly: 16.8 kg
and the plunger is lubricated with lubricating oil. In
case of heavy fuel oil specification, the pump rack
is assembled with the stop air cylinder.
High-pressure fuel oil is introduced from the
pump outlet into the F.O. injection valve inlet con-
nector C , through the drilled holes of the forged
steel high-pressure joint B , via the joint A with the
spherical surfaces on the both ends.
In case that high-pressure oil has leaked from
the connecting part ranging from the F.O. injection
pump to the F.O. injection valve, such oil will be
recovered through the piping into the leak oil tank
from the leak oil cover D attached on the upper
part of the fuel oil injection pump, and the level
switch will detect the abnormality.
Inlet connector C
F.O.injection valve
F.O. High-pressure joint B
Leak oil cover D
Joint A
F.O.Injection pump
Fuel Oil Injection Device
DK-20e Z 10-10
CHAPTER
Fuel Injection Device 9
ITEM
Replacing Consumables, Implements, and Messuring
Instruments / Disassembly of F.O. Injection Pump DK-20e 2, 3

Implements, and Measuring The injection tinning of the F.O. injection
Instruments pump is readily adjusted for each cylinder.
When disassembling the pump, be minded to
discriminate the pumps according to the fol-
Replace the following parts with the new ones: lowing procedure, so that each of the F.O.
( :"Parts List") injection pumps may not be assembled into a
① O-ring 2-23.2 No.216, 230, 236, 285 wrong cylinder:
② Back-up ring 3-23.2 No.235 1) Describe the engine number and cylinder
③ Gasket 3-23.2 No.261,280 number on the pump body.
2) Attach the tag as one set to the shim {for
④ O-Ring (for high-pressure coupling)
adjusting the base circle) of the mounting
3-24.1.1 No.505
surface, and describe the engine number
3-24.1.2 No. 12, 506 and cylinder number on it.
( : 2-2)
② F.0･ pump spanner 24 B
9
J
2 F.O.Pump Spanner 24
9-3 Disassembly of F.O. Injection Pump

(1) Turn the engine to place the roller of the F.O.
injection pump on the base circle of the fuel oil
cam.
(2) Remove the F.0. high-pressure joint B ,
plunger oil supply piping E , drain pipe F , leak
oil cover D , and rack pin G .
Disconnect the stop air piping (heavy fuel oil
specification) H of each cylinder.
H I
(3) Remove the mounting bolt I of the F.0. injec-
tion pump inlet block. E
(4) Disconnect the pump mounting nut(J) using
the F.O. pump spanner 24 2 .
G
(5) Pass a wire around the F.O. injection pump,
suspend it, and dismount it from the engine. F
DK-20e Z 10-10
CHAPTER
ITEM
4.1 DK-20e Disassembly of F.O. Injection Pump
9-4 F.0. Injection Pump (9) Remove the deflector q .

9-4.1 Disassembly of F.0. injection Pump
The F.O. injection pump is a precision parts in 1) Be minded to handle the plunger and barrel
particular. as one pair. The clearance of the both
Even fine foreign matters will cause sticking or parts are matched, and if wrong combina-
breakage of the plunger and the delivery valve.
tion is made, the parts cannot be used.
Therefore, when disassembling or assembling
2) Be sure to sort the disassembled parts per
the pump, take every possible care to prevent
the infiltration of foreign matters. each pump, so that they do not mix with the
parts of the other cylinders.
(1) Mount the F.O. injection pump on a vice, so
that the tappet d is on the upper side.
(2) Remove the fall-stop pin e by means of the m
bolt (M6×20), while pushing the tappet, and
using a gear puller and the like.
p
n Delivery
valve assy.
Be careful so that the tappet roller may not
jump out due to the spring force. q c Plunger
barrel
(3) Take out the tappet assembly, plate f , spring
b Plunger
seat‘lower g , spring h , plunger b ,
spring seat-upper j , in this sequence. a Pump body
(4) Take out the control sleeve k and contra!
Rack l .
l
(5) Remove the F.0. injection pump from the vice,
turn over the pump upside-down, and mount it
on the vice again.
k
(6) Disconnect the mounting bolt m , and remove
the delivery valve assembly n .
j
Do not disassemble the delivery valve. g

Instead, be minded to replace it as an assembly. h
(7) Remove the positioning screw p . e

f
(8) Turn over the pump again, and extract the
plunger barrel c from the body while receiving
d Tappet assy.
it on the hand.
If extraction is difficult due to too tight fitting,
place a wooden piece against the barrel from F.O. Injection Pump
the opposite side, and strike the wooden piece
with a hammer to extract it.
DK-20e Z 10-10
CHAPTER
ITEM
Inspection and Maintenance of F.O. Injection Pump DK-20e 4.2

F.O. Injection Pump
Plunger barrel
the parts to which NOx Technical Code shall
be applied, when replacing any of these parts,
be sure to use the parts provided with the
identification marks.
Technical Code")
(1) Wash all the disassembled parts with clean Deflector

washing oil, and blow air on them.
(2) Check the plunger, barrel, and deflector for Plunger
the corrosion caused by cavitation.
In case that the degree of corrosion is heavy, Plunger, Barrel, and Deflector
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.
9
(3) Measure the inner and outer diameters of the
tappet, and calculate the tappet clearance.

C= 2 a = 0.03 ~ 0.08 0.25

B
(4) Placing a dial gauge against the tappet roller

surface, and measure the bearing clearance by
moving the roller up and down.
b
C c
B= 28 c = 0.05 ~ 0.08 0.20 Tappet Diameter Clearance and Roller

Bearing Clearance
DK-20e Z 10-10
CHAPTER
ITEM
4.3 DK-20e Assembly of F.O. Injection Pump
9-4.3 Assembly of F.0. Injection Pump

m
p
When assembling the F.O. injection pump, do n
not wear gloves but handle the pump with
naked hands, so as to prevent the deposit of 㩷c
foreign matters or dust on the pump. q
Assemble the F.O. injection pump in the follow- 㩷b

ing procedure:
a
(1) Mount the pump body a on a vice with the
delivery valve side facing upward.
l
(2) Apply grease to the O-ring and the back-up
ring, both of which are newly replaced, and fit
them to the barrel c .
k
(3) Match the barrel positioning bolt hole and the
barrel hole of the pump body for each other,
and insert the barrel into the pump body.
j
(4) Mount the barrel positioning bolt p .
(5) Assemble the delivery vaive assembly n into
the pump body with its knock pin position g h
matched with the pin hole position.
(6) Apply the lubricating agent (MOLYKOTE U- e
paste) to the threaded area and seat surface of f
the bolt m , and tighten the bolts with the speci-
d
fied torque diagonally and uniformly.
Specified torque:
137 ~ 157 N･m ｛14 ~ 16 kgf･m｝
(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 l and the inner surface of the Control rack
Control sleeve k , and assemble them while
matching the control rack teeth with the control
sleeve end teeth (rack 0-mm direction). 30 20 10 0
Be careful since the engine cannot be operat- Assembly of Control Rack and Control Sleeve
ed properly, if the rack is not normally and cor- ( Position of Rack 0 )
rectly engaged with the sleeve. ( Viewed from Pump Tappet Roller Side )
DK-20e Z 10-10
CHAPTER
ITEM
Assembly of F.O. Injection Pump DK-20e 4.3
(9) Assemble the spring seat-upper j , plunger b

, spring h , spring seat-lower g ,
plate f , and tappet assembly d in this Z mark
sequence.
Z
Assemble the plunger so that the "Z" mark on
the lower part faces toward the opposite side of
the rack.
(10) Mount the fall-stop pin e while pushing the
tappet using a gear puller and the like. Plunger Matchmark
When assembling, be careful not to scratch

the tappet or roller.
(11) Mount the deflector q .

(12) After finishing the assembly, confirm that the
rack moves smoothly, and the "0" point position
is matched.
DK-20e Z 10-10
CHAPTER
ITEM
5 DK-20e Mounting of F.O. Injection Pump
9-5 Mounting of F.O. Injection Pump

(1) Check if the fuel oil cam is placed on the posi- Shim
tion of the base circle.
Tappet slit
(2) Install the fuel injection pump on the engine,
and tighten the nut to the specified torque.
Specified torque: 90 ~ 110 N･m

{9.2 ~ 11.2 kgf･m}
(3) Confirm the assembling height of the F.O.

injection pump.
a) When the tappet roller is on the base circle
of the fuel oil cam, confirm that the tappet slit is
matched with the base line slit. Assembling position mark line
b) In case that the adjustment of the assem-
bling height is necessary, adjust it by the shim. Mounting Hight of F.O. Injection Pump
Shim thickness ( :"Parts List")

0.5 mm (Standard) 3-23.1 N0. 11
0.1 mm 3-23.1 No. 12
1.0 mm 3-23.1 No. 13
(4) Apply grease to the O-ing, fit it on leak oil

cover, and assemble them into the F.O. iniec-
tion pump.
(5) Install the F.O. injection high-pressure cou-
pling, and tighten the bolt with the specified
torque.
F.O. High-
Specified torque: 34 ~ 44 N･m Pressure joint
{3.5 ~ 4.5 kgf･m}
(6) Mount the rack pin, and adjust the rack

amount uniformly. O-Ring
( :"Operation" 5-3.1 "Adjustment of the F.O.
Injection Pump Rack Amount")
(7) Mount all the piping.
(8) Check the fuel oil injection timing.
( : 8-2.6 "Inspection and Adjustment of
the Fuel Oil Cam Timing")
(9) After finishing the adjustment, pass the fuel Leak oil cover
oil, and loosen the air vent screw to vent air.
( : "Operation" 4-2.2(5) "Fuel Oil Priming Mounting of F.O. Injection
and Air Vent") High-Pressure Coupling
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
9
CHAPTER
10 Valve Operating Device
ITEM General Construction / Replacing Consumables,
1~3 DK-20e Implements, and Measuring Instruments / Disassembly
10. Valve Operating Device

10-1 General Construction Push rod
The valve operating device is of a swing-arm
type,equipped with the roller follower, and the
valve operating devices for exclusive use of intake
and exhaust are separately provided respectively.
The intake and exhaust cam lift is transmitted to
the intake and exhaust valves from the
roller,through the push rod, rocker arm, and valve
retainer tee, via swing arm pivot (push rod seat). Swing arm
A bearing is press-fitted into the roller, and it turns
Swing arm shaft
around the tappet roller pin which is press-fitted
into the swing arm.
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
Push rod
swing arm shaft, and via the shaft and the drilled- seat
holes inside the arm. 䇭䇭䇭䇭
A ring knock is press-fitted into the shaft, so as to Tappet roller
ensure the parallelism between the roller and cam-
contact surfaces. Tappet roller
pin䇭䇭䇭䇭
Swing arm assy. : 11 kg
Camshaft
10.2 Replacing Consumables, Valve Operating Device

Implements, and Measuring instru-
ments
(1) Replacing Consumables j a
None
(2) Implements and Measuring instruments
i h f c
b
( : 2-2)
e
10.3 Disassembly of Valve Operating
Device
(1) Disconnect the cylinder head cover, and
remove the rocker arm device and the push rod.
(2) Remove the cover on the camshaft side.
(3) Disconnect the bolt a , and remove the swing
arm assembly. d
Mark the engine number and the cylinder num-
ber with magic ink or the like, before removing
the swing arm assembly.
(4) Disconnect the snap ring b , and remove the Swing Arm Assembly
swing arm c and d from the swing arm shaft e .
DK-20e Z 10-10
CHAPTER
Valve Operating Device 10
ITEM
Inspection and Maintenance of Valve Operating Device DK-20e 4

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 infiltrated.
(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
on the outer periphery of the tappet roller f .
(4) Inspect if there is any scratch or abnormal dent on g
the contact surface of the push rod seat g .
(5) Measure the clearance between the roller pin h
Inspection of Swing Arm Shaft and Swing Arm
and tappet roller bush i , placing a dial gauge
against the upper face of the tappet roller, and
moving the tappet roller up and down.

B = φ22 b = 0.07-0.13 0.2
f
10
When the clearance become wider, the valve
end clearance becomes larger, and the valve
opening and closing timing changes, resulting
in the deterioration of the engine performance.
In case that the measurement result of the
clearance is over the replacing limit, replace
the swing arm (with the roller) with a new one.
B b
Clearance Measurement of Tappet Roller Bush
DK-20e Z 10-10
CHAPTER
10 Valve Operating Device
ITEM
5 DK-20e Assembly of Valve Operating Device
10.5 Assembly of Valve Operating

Device
(1) Mount the arm on the arm shaft, matching the Oil hole groove
oil hole of swing arm and the oil hole groove of
swing arm shaft.
Be careful not to mistake when handling the

swing arms each other, since there are two
types of swing arm, one for intake and one for
exhaust. The one with the carved stamp "R" is
for exhaust (flywheel side), and the one with
the notched mark "L" is for intake (front side). Oil hole
Further, before assembling, be minded to con-
firm the cylinder number, so as to preventmis-
taking it with the parts of the other cylinder. Swing Arm Oil Hole
(2) Fix a snap ring.

(3) Match the ring knock j position, then mount
the swing arm assembly on the engine frame.
(4) Tighten the bolt with the specified torque, after
applying lubricating agent (MOLYKOTE 1000)
on the threaded area of bolt and seat surface.
Specified torque : 59 N.m {6 kgf.m}
DK-20e Z 10-10
CHAPTER
Valve Operating Device 10
ITEM
MEMO DK-20e
10
CHAPTER
11 Governor Drive Device
ITEM General Construction / Replacing Consumables,
1,2 DK-20e Implements, and Measuring Instruments
11. Governor Driving Device

In this engine, the following 2 types of governor is
11-1 General Construction applied.
The governor is of a hydraulic type that controls As for the handling of the governor body, refer to a
the rack amount of the F.O. injection pump and the separately provided document.
F.O. injection rate, in accordance with the load and ( : "Governor Instruction Manual")
the revolving speed of the engine via common rod.
The governor driving device is located on the rear- < RHD6........Standard >
side of the engine, and composed of the helical-
gear engaged with the cam gear and a pair of the- Governor: 8kg
bevel gear, and drives the governor via spline cou- Governor driving device assy.: 21 kg
pling.
< UG10........Option >
The governor gear case and the mounting surface-
of the engine frame are sealed with liquid sealant,
Governor: 20 kg
and the adjustment of the bevel gear backlash is
Governor driving device assy.: 22 kg
made by the adjusting shims on the mounting sur-
face of the governor.

Instruments
Replace the following parts with the new ones.
< For RHD6 governor > Governor lever (A) Terminal shaft
( : "Parts List".) Link pin (B)
① O-ring 3-25.1 (6,8DK) № 521, 522
3-22.1 (3,5DK) № 521, 522
② Cover 3-25.1 (6,8DK) № 48
3-22.1 (3,5DK) № 48
③ Bearing 3-25.1 (6,8DK) № 512
3-22.1 (3,5DK) № 512
④ Split pin 3-25.1 (6,8DK) № 532,539
3-22.1 (3,5DK) № 532,539
Common rod
< For UG10 governor >
( : "Parts List".)
① O-ring 3-25.2 (6,8DK) № 23
3-22.2 (3,5DK) № 23
② Bearing 3-25.2 (6,8DK) № 513,514
3-22.2 (3,5DK) № 513,514
③ Split pin 3-25.2 (6,8DK) № 532,539
3-22.2 (3,5DK) № 532,539
Common rod lever

General tools and measuring instruments Governor Link
( : 2-2.)
DK-20e Z 10-10
CHAPTER
Governor Drive Device 11
Disassembly, Inspection, and Maintenance of Governor ITEM
Driving Device DK-20e 3,4
11.3 Disassembly of Governor Driving (C)

Device
(g)
(e)
The construction of governor driving device is basi-
cally same regardless of the types of governor, (h)
and therefore the explanation is made regarding
(f)
Type RHD6 in this section. (b)
(1) Remove the governor lever(A) and link pin (B) (i)
(c)
(2) Remove the oil feed piping of the driving
device. (d) (a)
(3) Remove the governor mounting nut (C), and
(p) (q)
remove the governor.
(4) Remove the governor gear case mounting bolt (k)
(j)
(D), and remove the governor driving device
(l)
assembly.
(5) Measure the backlash between the governor (D)
gear (b) and governor driving gear (c).
Standard clearance Replacing limmit

(mm) (mm)
Backlash 0.3~0.5 0.8
(6) Take out the bolt (e) and remove the governor
base (f).
Governor Driving Device
As the spline coupling (g), governor driving shaft-
2 (h), bearing (i), and governor gear (b) are all
mounted on the governor base, these parts can
be pulled out at the same time.
(7) Remove the cover (k) of the governor driving
shalft-1 (j).
(8) Fit a spanner to the hexagonal area at the end
11
of governor driving shaft-1, and then remove the
nut (l). After that, remove governor driving shaft- 1.
During this removal work, support the governor
driving gear so that the gear cannot fall.
(9) Remove the governor drive gear (c) and (d).

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 shaft-1 (j), -2 (h) and
flange bush (p), (q) for abnormal dent or scratch.
DK-20e Z 10-10
CHAPTER
11 Governor Drive Device
ITEM Inspection, Maintenance, and Assembly of Governor
4,5 DK-20e Driving Device
(4) Calculate the clearance by measuring the gov-

ernor driving shaft outer diameter and flange
bush inner diameter, and in case that the clear-
ance is over the replacing limit, replace the
flange bush with a new one.
< Governor driving shaft-1 > D

Norn, size Standard Replacing d
A = φ30 a = 0.02~0.13 0.15
A
< Governor driving shaft-2 >
a
D=φ14 d = 0.02~0.08 0.10
11-5 Assembly of Governor Driving

Clearance of Flange Bush
Device
(1) Assemble the governor driving device in the
a) Replace the O-ring and bearing with the new
ones, and apply grease to them before assem-
bling.
b) Replace the cover (k) with a new one. Apply
seal bond (silicone type) and insert it into the
hole, and evenly strike it placing a patch, so
that the outer periphery should be adhered
tightly.
(2) After assembling, check the followings: Shim
a) The governor drive gear and governor rotate
smoothly. O-Ring
b) Confirm that backlash is normal, and in case Bearing
that it is not within the specified value, adjust it O-Ring
by inserting the shim between the governor
base and governor gear case. Cover (k)
< For RHD6 Governor > ( : "Parts List")
Shim thickness : 0.1 mm 3-25.1 No.54

0.8 mm 3-25.1 No.55
1.0 mm 3-25.1 No.53
< For UG10 Governor > ( : "Parts List")
Shim thickness : 0.2 mm 3-25.2 No.57

0.5 mm 3-25.2 No.58 Assembly of Governor Driving Device
1.0 mm 3-25.2 No.59
DK-20e Z 10-10
CHAPTER
Governor Drive Device 11
ITEM
MEMO DK-20e
11
CHAPTER
12 Intake and Exhaust System
ITEM
1,2 DK-20e General of Intake and Exhaust Device / Turbocharger
12 Intake and Exhaust Device 12-2 Turbocharger

12-1 General of Intake and Exhaust
System Since the items mentioned in this section are
The high-temperature and high-pressure exhaust the parts to which NOx Technical Code shall be
gases shall be emitted from the cylinder are effec- applied, when replacing any of these parts, be
tively introduced into the turbocharger through the sure to use the parts provide with the identifica-
exhaust manifold, and a part of the exhaust ener- tion marks.
gies will be recovered as intake pressure. ( : 0-3 "Engine Conforming to NOx
The high-temperature air compressed by the tur- Technical Code")
bocharger will be cooled down while passing
through the air cooler, and will be introduced to the
Lubricating oil that lubricates the bearing are
intake duct of the engine frame.
sup-plied to the turbocharger.
The turbocharger and the air cooler is located
The lubricating oil is supplied to the turbocharger,
onthe front part of the engine as standard, howev-
being branched from the engine system oil.
er they can be located on the rear part of the
Further, an orifice is installed at the inlet of the tur-
engine according to the specifications.
bocharger, so as to maintain the lubricating oil
pressure at the appropriate level.
As for the operation, disassembly, and mainte-
nance of the turbocharger, refer to a separately
provided instruction manual.
Orifice
TPS48 : 129 kg
Exhaust air Air cooler
TPS52 : 187 kg
MET18SRC : 180 kg
Air
The turbocharger is very hot just after the

Turbo
charger engine is stopped. Wait until it sufficiently cools
Air pre-filter䇭 down before dismantling it for inspection and
Cooling water
Lubricating oil maintenance.If it must be dismantled before it
Expansion Intake cools down, wear safety gloves, and take care
joint air
not to burn your hands.
Exhaust
Exhaust gas
pipe
Intake pipe
(Integral with
engine frame)
Cylinder head
From another cylinder To another cylinder
Intake and Exhaust Device
DK-20e Z 10-10
CHAPTER
Intake and Exhaust System 12
Air Cooler: General Construction / Replacing Consumables, ITEM
Implements, and Measuring Instruments / Dismounting DK-20e 3.1~3.3
12-3 Air Cooler (6) Remove the air cooler mounting nut (F), bolt
(G) and (H) (Stand alone type), passing a wire
rope around the air cooler and suspending it with
The air cooler is of a fin-tube multi-tubular type a chain block.
with box shape, and is installed to the bracket.
(7) Disconnect the air cooler.
The cooling water inlet and outlet ducts of the air
cooler are equipped with a butterfly valve to adjust (D)
Exhaust manifold cover
the intake air temperature to an appropriate value.
(A) Turbocharger
Model No. of air cooler
DH29, DH39, DH48 : 240 kg
OH52, DH73: 310 kg (C)
DH95: 300 kg
(F)
(B)
Instruments
(G)
Since the replacing consumbales, such as O-ring,
Air cooler
packing, and gasket, vary depending on the
model number of the air cooler, refer to a sepa- (I) Cooling water cock
rately provide parts list. Dismounting of Air Cooler
(Integrated Bracket Type)
( :"Parts List")

Exhaust manifold cover
① General implements and measuring instru- (D)
ments
( :2-2)
(A) 12
Turbocharger
(C)
12-3.3 Dismounting of Air Cooler
(1) Remove the instrument board that is mounted
on the same side as the fuel injection pump of (B)
(F)
the air cooler casing or of its bracket.
(2) Remove the exhaust pipe cover. Remove the
connection bolts (A) from the turbocharger and (H )
the exhaust pipe.
(3) Remove the air cooler cover (B) and air cooler
inlet pipe (C). (G)
(4) Disconnect the exhaust outlet duct (D) and the Air cooler
supercharger.
(I) Cooling water cock
(5) Remove the bolt (E) that joint the cooling water
entrance pipe of air coolert. Dismounting of Air Cooler
(Stand-alone Type)
DK-20e Z 10-10
CHAPTER
12 Intake and Exhaust System
ITEM
3.4~3.5 DK-20e Inspection, Maintenance, and Mounting of Air Cooler
12-3.4 Inspection and Maintenance of 12-3.5 Mounting of Air Cooler

Air Cooler Assembly the air cooler in the reverse order of the
disassembled procedure.
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 iden-
tification marks.
( : "Engine Conforming to NOx Technical
Code")
(1) Remove the water chamber covers 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 coating
again.
(2) Clean the inside of the cooling tube using a
nylon brush.
After brushing, wash it with clean and fresh
water.
(3) Eliminate the stains on the air side by blowing
air on them.
In case the degree of stain is heavy, disconnect
the water chamber, and remove the stain by
immersing the plate-fin tube assembly in neutral
detergent.
After eliminating the stain, wash with clean and
fresh water, and sufficiently dry the assembly
promptly.
To be minded to use the sulphamic acid

cleaning agent.
In order to secure stable engine perform-
ance, air cooler shoud be checked and cleaned
according to the maintenance / cleaning sched-
ule (4,000~6,000 hr)
(4) Inspect the protective zinc, and replace it with a

new one. (In case that the equipment is provided
with the protective zinc.)
( : 5-4.6 "Daily Inspection and Maintenance
of Protective Zinc")
DK-20e Z 10-10
CHAPTER
Intake and Exhaust System 12
ITEM
MEMO DK-20e
12
CHAPTER
13 Starting Air System
ITEM
1 DK-20e Outline of Starting Air System
13. Starting Air System The major components of air system of the air
motor starting type are the air motor, the starting
valve, the pressure regurating valve and starting
13.1 Outline of Starting Air System solenoid valve.
Among these equipment, regarding the pressure
The air starting type is employed to DK-20 regurating valve and starting solenoid valve, over-
engines, the direct starting type by the starting- haul and repair is virtually impossible.
valve is employed to 6.8DK engines, and the air- If those equipments are faulty operation, please be
motor starting type is employed to 5DK engines. replase by assembly.
( : "Operation" 2-2.1 "Starting Air System") As for the air motor, refer to the separately provid-
ed "Instruction Manual".
The high-pressure air of 2.5 to 2.9 MPa {25 to 30 ( : "Instruction Manual of Air Motor")
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.
The major components of direct starting air type
are the starting air valve, starting air rotary valve,
and starting operation valve.
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 ( Direct Starting Type )
DK-20e Z 10-10
CHAPTER
Starting Air System 13
ITEM
Outline of Starting Air System DK-20e 1
Starting push button
Starting solenoid valve

Control air
Air motor
Air vent Ring gear

valve
Starting valve Safty valve
Relief valve
Starting valve Pressure

regurating valve
for emergency
(manual) Air filter
Starting air
Starting Pneumatic System ; Air motor starting type

13
DK-20e A 11-06
CHAPTER
ITEM
Starting Air Valve: General Construction / Replacing
2.1~2.3 DK-20e Consumables and Implements / Disassembly
13-2 Starting Air Valve

The starting air valve is the valve that controls the- When disassembling, carefully perform the
supply of the high-pressure air for starting when work so that the spring will not fly out, because
the engine is being started, and is activated by the- the spring is compressed by the piston.
controlling low-pressure air which is sent from
either the starting operation valve or the starting c) Remove the bolt and disconnect the cylinder g
solenoid valve. d) Take out the stopper ring h , and remove the
key receptor i and the key j .
Starting Valve assembly.: 12 kg e) Disconnect the piston k , and extract the valve
stem l .
13-2.2 Replacing Consumables, f) Take out the split pin m and the nut n , and
Implements, and Measuring remove the valve receptor o , the valve p , and
Instruments the valve retainer q from the valve stem.
g) Remove the union screw r , and take out the
(1) Replacing Consumbales spring s and the check valve t .
( : "Parts List")
① Valve 4-1.1.1 No.B6 d a
② Split pin 4-1.1.1 No.B10.B25
③ O-ring 4-1.1.1 No.B502, B503, B504,
c
No.B505, B506, B507
e
No.B508. B509
④ Circular gasket 4-1.1 No.C516, C517 f
g
(2) Implements and Measuring Instruments h
① General implements and measuring instru-
ments
( : 2-2) j
i
13-2.3 Disassembly of starting valve l k
(1) Disconnect the piping of the starting air outlet q
and inlet and the piping of the control air
inlet,and remove the starting air valve assembly p
from the bracket.
(2) Disassemble the starting air valve according to o
a) Disconnect the mounting bolt, and remove the
upper cover a and lower cover b .
b) Take out the split pin of the valve stem and
n m b
the nut d , and remove the piston e and the
spring f . Starting Air Valve
DK-20e Z 10-10
CHAPTER
ITEM
Inspection, Maintenance, and Assembly of Starting Air Valve DK-20e 2.4~2.5

Starting Air Valve
(1) When rust is found, carefully remove it using a
fine sandpaper.
For the sake of rust-prevention, be minded to

r
perform the draining of the equipment and the
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 k .
(4) Inspect if there is any scratch on the seat sur-
face of the valve p .
on the check valve t and the seat surface.
(6) Inspect if there is any scratch on the spring f
and s . t s
Check Valve
13-2.5 Assembly of Starting Air Valve

(1) Before assembling, thinly apply silicone grease
on the valve, the O-ring, and the sliding part of
the seat surface.
(2) Assemble the staring air valve assembly in the 13
(3) Mount the starting air valve assembly to the
bracket, and install the piping.
Sufficiently flush the piping before installation,

so that dust and drain are completely removed.
Further, be minded that sealant or the like will
not be deposited during the work.
DK-20e Z 10-10
CHAPTER
ITEM
Starting Air Valve: General Construction / Replacing
3.1~3.3 DK-20e Consumables and Implements / Disassembly
13.3 Starting Air Rotary Valve

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
front end of the camshaft via rotary valve coupling
(Oldham's coupling).
Starting air rotary valve assy.: 8.4 kg

Implements, Measuring instru-
ments
( : "Parts List")
① Rotary valve cover gasket 4-1.2 No.A14
② Circular gasket 4-1.2 No. A505, A515

ments d
Starting air inlet
( : 2-2) a
c
f
13-3.3 Disassembly of Starting Air
Rotary Valve
(1) Disconnect each piping of the starting air inlet
and the starting air outlet.
(2) Disassemble the starting air rotary valve on the
a) Remove the mounting bolts, and disconnect
the rotary valve cover a and the circular gas- Flexible cable
ket b .
b) Extract the starting air rotary valve c . g
c) Disconnect the mounting bolts of the rotary
valve seat d , and remove the rotary valve b
e
seal and the gasket e .
d) Remove the rotary valve coupling f .
Lubricating oil inlet
Starting Air Rotary Valve
DK-20e Z 10-10
CHAPTER
ITEM
Inspection, Maintenance, and Assembly of Starting Air
Rotary Valve DK-20e 3.4~3.5
13-3.4 Inspection and Maintenance of 13-3.5 Assembly of Starting Air Rotary

Starting Air Rotary Valve Valve
(1) Wash all the disassembled parts with clean Assemble the starting air rotary valve in the
washing oil, and blow air on them. reverse order of the disassembling procedure.
(2) Inspect the scratch and wearing conditions of (1) Wash the starting air rotary valve and rotary
the rotary valve bush g . valve seat, and apply the lubricating oil to the
Measure the shaft diameter and the bush inner seat surface and shaft area.
diameter of the rotary valve, and calculate the
(2) When inserting the starting air rotary valve into
clearance.
the rotary valve seat, conduct the insertion work
Nom. size Standard Replacing by adjusting the air hole of the starting air valve
(mm) clearance (mm) limit (mm) to the rotary valve seat hole of the cylinder num-
A =φ 28 a = 0.02~0.10 0.20 ber, which is on the explosion process.
When the holes do not match, insert the starting
air rotary valve by turning it 180
When wear of the bush becomes heavy, lubri-
cating oil will infiltrate into the starting air pipe,
making the starting difficult. In such a case, Be careful not to disassemble the rotary valve
replace the bush with a new one. in a wrong way, since it will inhibit the engine to
start.
(3) Inspect if there is any fin or foreign matters
caught on the seat areas of the starting air rotary (3) Install the piping and flexible cable.
valve and the rotary valve.
In case that inclusion scratch is extended over 4 2
the holes of each cylinder, perform the facing-up
Nomally
after grinding and correcting the seat surface. rotating
Further, in case that fin is found, remove it using engine
a file or scraper.
(4) Inspect if the engagement area of the starting
air rotary valve c and rotary valve coupling f ,
and the engagement area of the rotary valve 1 6 13
coupling and camshaft are not worn out, respec-
tively.
Reversely
rotating engine
If the wearing degree of the engagement area
is heavy, the opening and closing timing of the 5 3
starting valve will be delayed, making the start- ( Nomally rotating
engine )
ing difficult.
In such a case, replace the starting air rotary- Rotating direction of rotary valve
valve or rotary valve coupling with a new one.
The above figure shows the positional relationship
of the starting air valve when the No.1 engine is on
the top dead center position of explosion.
Rotary Air Valve Assembling Procedure
DK-20e Z 10-10
CHAPTER
ITEM
4 DK-20e Starting Operation Valve and Handle Switch
13-4 Starting Operation Valve and

Handle Switch
The starting operation valve is an air valve for the Operation lever 0 STOP
purpose of starting from the machine side, and the 10
starting air valve will be actuated by manually 20
operating the pushbutton, so that the low-pressure 30
RUN
air is supplied to the starting air valve. FUEL

NOTCH
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 operation valve

and handle switch. In case that malfunction is
occurred, be minded to replace it as an assembly.
Starting operation valve

Handle switch
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
13
CHAPTER
14 Fuel Oil System
ITEM
1 DK-20e General of Fuel Oil System
14. Fuel Oil System Fuel oil filter

( : "Operation" 5-4.3 "Cleaning Filters")･
14-1 General of Fuel Oil System
Facilities and equipment for pretreatment
The engine is designed on the assumption that
( : Separately supplied "Instruction Manual")
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- < Cautions in disassembling, maintaining
of the engine is particularly important, and the
and reassembling the fuel oil system >
quality of the fuel oil will give a remarkable influ-
1) The parts such as the fuel oil injection pump
ence on the various equipment such as the fuel oil-
and fuel oil injection valve, which are used in
injection pump.
Since not only the individual systems but also the the fuel injection system, are all precision
facility and equipment will also differ depending on parts, and therefore if any dust or foreign
the grade of the oil to be used, be minded to per- matter is mixed in the oil, it will result in the
form appropriate maintenance, inspection, and faults such as seizure.ln case that the equip-
adjustment according to the instruction manuals of ment of the fuel oil system is disassembled,
each facility and equipment. regardless of whether it is the one attached
The major component parts attached to the to the engine or the one to be separately
engine are the fuel oil filterr (When shipped, flush- installed, be particularly careful so that any
ing-filter is installed in the fuel oil filter. Remove it dust or foreign matters will not infiltrate into
after 300-200 hours of operation.), fuel oil relief the inside of the equipment or piping.
valve, fuel oil feed valve, and so on. 2) In case that the fuel oil system is over-
hauled, be sure to perform air bleeding after
As for the inspection and maintenance of the fol- restoration.
lowing equipment, refer to the other sections in this When discharging air, take care not to splash
manual or separately supplied documents. the oil.
( : "Operation" 2-2.2 "Fuel 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 damper pressure Fuel injection
block valve
Filter
Fuel oil
Viscosity feed
controller pump
Inlet connector
Fuel
injection
Heater Filter pump Inlet main pipe
Filter Pressure damper

Waste
Pressure control valve Return main pipe leakage
oil tank
Fuel Oil System
DK-20e Z 10-10
CHAPTER
Fuel Oil System 14
ITEM
Fuel Oil Relief Valve DK-20e 2.1~2.5
14-2 Fuel Oil Pressure Regulating Valve (2) Disassemble the relief valve according to the
14-2.1 General of structure
a) Disconnect the cap nut a , loosen the lock
The fuel oil relief valve is installed on the readend nut b , and completely turn back the adjusting
of the fuel oil main pipe, and the valve oper-ates to screw c .
maintain the pressure at the inlet of the fuel oil Before loosening the adjusting screw, either
injection pump within the appropriate range. put a mark on the tightening position of the
Excessive oil will be returned to the supply sys- adjust- ing screw or keep the record of the
tem through the relief valve. dimension, so that the original position can be
identified when assembling.
b) Loosen and remove the spring retainer d .
The fuel oil pressure depends on the source-
c) Remove the spring seat e , spring f , and
pressure of the supply system, and it alsovaries
relief valve g from the relief valve body h .
depending on the viscosity of the oil.In case of
heavy fuel oil, adjustment is readilymade so g h f e d a
that the pressure stays at an appropriate vis-
cosity and to be within the blue mark range on
the pressure gauge. Therefore, when the pres-
sure is deviated from the specified range during
operation, be minded to first check if the vis-
cosity of the fuel oil is appropri-ate or not
b
before starting to disassemble and inspect the
fuel oil relief valve. c
Fuel Oil Relieve Valve

When heavy fuel oil is used, the oil is heated
to a high temperature (100℃ or more). If the oil 14-2.4 Inspection and Maintenance of
is splashed on the skin, it may be scald. Fuel Oil Relief Valve
Take care not to splash the oil when disassem-
(1) Wash all the disassembled parts with clean
bling.
washing oil, and remove the sludge
14-2.2 Replacement Consumables, on the relief valve, or also check if the valve is
Implements, and Measuring not stuck.
Instruments (3) Inspect if there is any abnormal dent or scratch
(1) Replacement Consumables

on the spring
14
14-2.5 Reassembly of fuel oil pressure
( : "Parts List")
regulating valve
① Circular gasket 4-2.5 No.507, 508, 509
(2) Implements and Measuring instruments Perform the assembly of the relief valve in the
① General implements and measuring reverse order of the disassembling procedure.
Instruments ( : 2-2) (1) Set the adjusting screw to the position of the
marking.
(2) After assembling, drive the engine and check
14-2.3 Disassembly of Fuel Oil Relief if the pressure is within the blue mark
Valve range,and in case that the pressure is out of
(1) Take out the connected piping, and remove the range,adjust the pressure with the adjust-
the relief valve assembly. ing screw.
DK-20e Z 10-10
CHAPTER
14 Fuel Oil System
ITEM
FuelOil Feed OPump: General Construction / Replacing
3.1~3.3 DK-20e Consumables and Implements / Dismounting
14.3 Fuel Oil Feed Pump (4) Loosen the clamping screw of the coupling and
remove the coupling.
14-3.1 General Construction (5) Take out the coupling key.
The fuel oil feed pump is installed on the front part
of engine, and is driven from the auxiliary gear
case via pump driving device.
The feed pump is a trochoid type, and the safety-
cover is incorporated into the upper cover.
Fuel oil feed pump assy. : 24 kg

Instruments
( : "Parts List")
< Fuel oil feed pump >
① O-ring 4-2.1.2 No.200-5, 200-6
② Gasket 4-2.1.2 No.200-7
③ Bearing 4-2.1.2 No.200-1, 200-2
④ Oil seal 4-2.1.2 No.200-3, 200-4
< Fuel oil feed pump driving device >

① Gasket 4-2.2.1 No.7 Coupling Cover Drive shaft
② Plain washer 4-2.2.2 No.503 Fuel oil feed pump
③ Washer with tooth 4-2.2.2 No.505, 506 Kye
④ Split pin 4-2.2.2 No.507

⑤ Oil seal 4-2.2.2 NO.513
⑥ Bearing 4-2.2.2 NO.511, 512

General tools and measuring instruments
( : 2-2)
Positioning pin Pump base

14-3.3 Dismounting of Fuel Oil Feed
Pump Dismounting of Fuel Oil Feed Pump
(1) Disconnect the outlet and inlet 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, carefully watch-
ing the positioning pin.
DK-20e A 11-06
CHAPTER
Fuel Oil System 14
ITEM
Disassembly, Inspection,and Maintenance of Fuel Oil Feed
Pump DK-20e 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,
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
15 17 33 20 27 34
O-ring 34
(10) Pull the oil seal⑰ and bearing⑭ out of the
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. Oil Seal
(12) Remove the spring receiving nut o , and
remove the spring retainer p , spring q , and
safety valve r .
14
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.
s
(3) Check for scratches and wear of the outer rotor
periphery.
(4) Turn the bearing, and check that it can turn Fuel Oil Feed Pump Safty Valve
smoothly without abnormal noise.
DK-20e Z 10-10
CHAPTER
14 Fuel Oil System
ITEM
Inspection, Maintenance and Assembly of Fuel Oil Feed
3.5~3.6 DK-20e 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).
14-3.6 Assembly of Fuel Oil Feed Pump

Reassemble the fuel feed pump in reverse order 19 Snap ring 14 Bearing
to disassemble.
17 Oil seal 33 Collar
㪧㫉㪼㫊㫊㩷㪽㫀㫋
(1) Mount a set of the shaft③, sealing-set (seal
20 Oil seal
case 27 , oil seal⑳, O-ring 34 ), and collar 33 ,
34 O-ring
bearing⑭, and oil seal⑰ in this order using a
hand press or the like, and fit the snap ring⑮. 27 Seal case
(2) Mount the angle plate 29 , and fit the shaft key
⑧ using a hammer and a brass bar.
3 Shaft
(3) Fit the inner key⑨ and inner rotor④.
(4) Mount the shell② provided with the outer rotor 1 Body
⑤ and O-rings 21 , and mount the pipe knock ⑱.
39.5
Take care that the O-rings are not engaged.
(5) Set the pump with the rotor upward, and mount Assembly of Shafy & Bearing Module
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-20e Z 10-10
CHAPTER
Fuel Oil System 14
ITEM
Disassembly, Maintenance, and Assembly of Fuel Oil Feed
Pump Driving Device DK-20e 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)
G Bearing
side
(2) Disconnect the fuel oil feed pump.
( : 14-3.3 "Dismounting of Fuel Oil Feed
Pump") Apply lithium grease
(3) Disconnect the mounting nut, and remove the
F E B
pump drive bearing A . Fuel oil feed pump
(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
bearing, and take out the bearing E and dis-
tance piece F .
(6) Remove the oil seal G .
14-4.2 Maintenance and Assembly of A D C
Fuel Oil Feed Pump Driving

Device
(1) Inspect if there is any wear or pitching on the Fuel Oil Feed Pump Driving Device
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
order of the disassembling procedure.
Specified torque: 215 N.m {21.9 kgf.m}
DK-20e Z 10-10
CHAPTER
15 Lubricating Oil System
ITEM
Outline of Lubricating Oil System / General
1,2.1 DK-20e Construction of Lubricating Oil Pump
15. Lubricating Oil System 15-2 Lubricating Oil Pump

15-1 Outline of Lubricating Oil System 15-2.1 General Construction
The lubricating oil is installed on the front end of The lubricating oil is of a gear type, and all the 5
the engine, and driven by the auxiliary drive gear pieces of the bearings used in the pump are nee-
attached to the crankshaft. dle bearings. Further, a safety valve is incorporat-
The lubricating oil cooler is installed on the ed into the pump cover.
engine,and equipped with a temperature control
valve as an assembly. Lubricating oil pump assy.: 33 kg
The lubricating oil filter is also installed on the
engine, and the lubricating oil relief valve is
installed on the installation base of the engine.
As the filters for the turbocharger and fuel injection
pump, the special filters of a higher precision are
installer!
( : "Operation" 2-2.3 "Lubricating Oil System")
( : "Operation" 5-4.3 "Cleaning Filters")
Rocker arm
Cooler Fuel injection pump
Filter Filter
Temperature
control valve Relief Swing arm
valve
Camshaft
Turbo-
charger
Pump
Safty valve Timming gear

Governor driving gear
Cooling water pump
Base plate of engine Leaked oil tank

Lubricating Oil System
DK-20e Z 10-10
CHAPTER
Lubricating Oil System 15
ITEM
Lubricating Oil Pump: Replacing Consumables,
Implements, and Measuring Instruments / Disassembly DK-20e 2.2,2.3
15-2.2 Replacing (2) Remove the inlet and outlet piping.

Consumables,Implements, and (3) Remove the mounting nut, and take out the
lubricating oil pump assembly.
(4) Assemble the lubricating oil pump on the fol-
(1) Replacing Consumables lowing procedure:
Replace the following parts with the new ones. a) Before disassembling, be minded to mark the-
( : "Parts List") matchmarks on the mating surfaces of the
① Needle bearing 4-3.1.1 No.42 pump body, cover, and so on.
② Oil seal 4-3.1.1 No.526 b) Remove the split pin a and castle nut b ,
③ Split pin 4-3.1.1 No.510 andtake out the gear c and key d .
④ Pump body gasket 4-3.2 No.10 c) Remove the bolt of the pump body cover e
,and take out the pump body cover.
(2) Implements and Measuring Instruments d) Pull out the pump gear f and g from the
① General implements and measuring instru pump body h .
ments e) Remove the snap ring i , and pull out the oil
( :2-2.) seal j .
f) Remove the snap ring k , and pull out the
15-2.3 Disassembly of Lubricating Oil bearing l .
Pump g) Pull out the bearing m from the pump body
and pump body cover.
(1) Before removing the lubricating oil pump, take-
h) Remove the safety valve retainer n , and pull
out the center cover of the auxiliary gear
out the safety valve spring o and safety
case,and measure the backlash of the pump
valve p .
drive gear.
Standard value Replacing limit

(mm) (mm)
j
Bearing side Gear side
Apply
lithium
grease
15
a
n o p m e g f m h
l k i c d b
Lubricating Oil Pump
DK-20e Z 10-10
CHAPTER
ITEM
Inspection, Maintenance, and Assembly of Lublicating
2.4,2.5 DK-20e Oil Pump

Lubricating Oil Pump (3) Install the lubricating oil pump.
In case that the pump drive gear is replaced con-
(1) Wash all the disassembled parts with clean-
firm the backlash.
washing oil.
(4) Connect the inlet and outlet piping.
(2) Inspect the wearing conditions of the toothsur-
face of each gear, and presence of pitting.
Also inspect the peeling conditions of the outer-
periphery and side face, and the presence of
seizure.
(3) Inspect if there is any abnormal wear on the oil
seal sliding surface of the pump gear shaft.
on the pump body, and the inner surface of the
pump body cover.
(5) Inspect the wearing conditions of the toothsur-
face 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 thescratch
degree is light, correct it with oil stone.
15-2.5 Assembly of Lubricating Oil

Pump
(1) Assemble the lubricating oil pump in the
(2) To fit the driving gear c , apply the lubrication

oil to the crown nut, and then tighten the nut with
the specified torque.
If the groove of the crown nut is not aligned with
the hole of the cotter pin, further tighten the nut.
Specified torque: 245 N.m (25 kgf.m)
< Cautions when assembling >

1) Replace the needle bearing and oil seal with
the new ones.
2) Use liquid sealant for the mating surface of
the pump body cover and pump body.
3) Be minded to assemble the pump body
cover after confirming the matchmarks that
have been made when disassembling, so
that oil release hole is situated on the deliv-
ery side without fail.
DK-20e Z 10-10
CHAPTER
ITEM
Lublicating Oil Cooler: General Construction / Replacing
Consumables and Implements / Inspection and Maintenance DK-20e 3.1~3.3
15-3 Lubricating Oil Cooler 15-3.2 Replacing

15-3.1 General Construction Consumables,Implements, and
The lubricating oil cooler is installed on the engine-
body, and the temperature control valve is (1) Replacing Consumables
attached to the lubricating oil outlet. Replace the following parts with the new ones.
The cooling pipe is multi-tubular type, and there ( : "Parts List")
are the tube plates on both sides, and the tube- ① Gasket 4-3.3.1 No.525, 526
plate on one side is fixed type, and the tube plate ② O-ring 4-3.3.1 No.521
on the other side is outer-periphery-slide type, ③ Protective zinc mounting gasket 4-3.3.1 No.61
which absorbs thermal expansion of the tube, and
is sealed with O-ring. (2) Implements and Measuring Instruments
In case that the cooling water is sea water, protec- ① General tools and measuring instruments
tive zinc is attached to the side covers on the both ( : 2-2)
sides.
( : "Operation" 5-4.6 "Inspection and
Replacement of Protective Zinc") 15-3.3 Inspection and Maintenance of
Lubricating Oil Cooler
If sludge is accumulated on the cooling pipe sur-
Lubricating oil cooler 12 m2: 170 kg face of the lubricating cooler, the cooling perform-
16 m : 220 kg ance will drastically be decreased.
Therefore, be minded to conduct the maintenance
according to the maintenance interval specified in
the overhaul and maintenance list.
(1) Removal of lubricating oil cooler
a) Remove the connecting piping of the cooling
water and lubricating oil.
b) Pass a wire rope around the lubricating oil
cooler assembly, and dismount the cooling
water assembly by removing the mounting
bolt, while suspending it with a chain block.
L.O. L.O.
Water Water 15
Side cover䇭B
Tube plate Casing C Tube plate D Side cover A
(Fixed side) (Slide side)
O-Ring E
Lubricating Oil Cooler
DK-20e Z 10-10
CHAPTER
ITEM
Inspection, Maintenance, and Assembly of Lublicating
3.3,3.4 DK-20e Oil Cooler
(2) Cleaning of lubricating Oil Side

Clean the lubricating oil side of the lubricating oil
cooler by means of chemical cleaning, pulling
out the cooling pipe assembly.
a) Remove the bolt and nut, and take out the
cover A and B on the both sides.
b) Pull out the cooling pipe assembly by pushing
it from the slide side (cover A side) to the
fixed side (cover B side).
c) Clean the cooling pipe assembly by immers-
ing it into cleaning liquid.
1) As for the details on the brand of the cleaning

agent, the mixing ratio, heating, postcleaning
treatment, and so on, refer to the instruction
manual of the manufacturer of each cleaning
Cooling Pipe Assembly
agent.
2) Be minded not to add the heat of 150℃ or
more 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
a) Inspect if there is any crack or corrosion on
the inner surface of the cooling pipe.
b) In case that crack or corrosion is found,
replace the cooling pipe with anew one.
As for the replacing method, consult the Cleaning of Cooling Pipe
Service Department of Daihatsu Diesel
Manufacturing Co., Ltd.
c) Replace the O-ring E of the tube plate D
outer periphery, and insert it into the casing C .
15-3.4 Assembly of Lubricating Oil

Cooler
(1) Attach the covers on the both sides.
(2) Conduct the water pressure test in the state of
the cooler assembly, and confirm that there is < Water pressure test >
not leakage from any section of the parts. Water side: 0.6MPa { 6 kgf/cm2}
(3) Install the cooler assembly on the engine, and Lubricating oil side: 1.0 MPa {10 kgf/cm2}
connect the piping.
DK-20e Z 10-10
CHAPTER
ITEM
Lubricating Oil Relief Valve DK-20e 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 lower part block of the lubricating filter.
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 by turning the adjusting screw a , and by
with oil stone, and confirm that the valve can be
changing the spring force of the relief valve,.
moved smoothly.
15-4.2 Replacing
Consumables,Implements, and on the spring.
(1) Replacing Consumables 15-4.5 Assembly of Lubricating Oil
Relief Valve
( : "Parts List") Assemble the relief valve in the reverse order of
① Circular gasket 4-3.5.1 No.532, 533 the disassembling procedure.
(1) Set the adjusting screw to the marking position.
(2) Implements and Measuring Instruments (2) After assembling, operate the engine and
① General implements and measuring instru- check if the pressure is within the blue mark
ments range and in case that the pressure indication is
( : 2-2) out of the range, adjust it with the adjusting
screw.
15-4.3 Disassembly of Lubricating Oil
Relief Valve
(1) Remove the cap b , loosen the lock nut c ,
and fully turn back the adjusting screw a .
Before loosening the adjusting screw, eithermark a
c
the tightening position of the adjusting screw, or
record the dimensions, so that the previous
adjusting position can be identified when assem-
bling.
(2) Take out the spring case d .
b
d e g f h i
Since the spring of the spring case is com-

pressed, be minded to slowly and carefully
Lubricating Oil Relief Valve
15
loosen it.
(3) Take out the spring seat e , spring f and g ,

and relief valve h from the lubricating oi relief
valve body i .
DK-20e Z 10-10
CHAPTER
ITEM
Lublicating Oil Temperature Control Valve: General
5.1,5.2 DK-20e Construction / Replacing Consumables and Implements
15-5 Lubricating Oil Temperature 15-5.2 Replacing

Control Valve: Consumables,Implements, and
15-5.1 General Construction Measuring Instruments
The lubricating oil temperature control vafve is a
kind of the mixing type with 3-direction valves, and
① Gasket S4104100680
the common port "A", high-temperature port "B",
② O-ring Z560101124
and low-temperature port "C" are provided. The
③ Pellet (1) S10400
valve f is opened or closed by the activation of
Note: The controlling temperature of pellet will
the spindle e , which moves out and moves in by
vary depending on the specifications.
expansion or contraction force of the wax of the
Therefore, clearly indicate the controlling tem-
wax pellet d located in the common port "A".
perature of the name plate when issuing
orders.
< 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 indicates the state that
ments
the port "C" is fully closed and the port "B" is fully
opened. ( :2-2)
When the lubricating oil temperature is increased,
the wax in the wax pellet will expand to extend the
spindle, so that the valve f is pushed down to g l m h e
O-Ring
open the port "C",and the lubricating oil tempera-
f
ture in the port "A" can be controlled to be of the
Gasket
specified value. j
In case that the lubricating oil temperature of the
engine inlet has abnomally increased due to failure k
of the pellet,and so on,the temperature can be
decreased by manually screwing the adjusting
screw g as an emergency measure,to push down
the valve f and open the port "C".
C
( : "Operation" 5-3.2 "Manual Adjustment of

B
Lubricating OilTemperature")
Lubricating oil temperature control valve

(DTC50): 13 kg
d
i
A
Lubricating Oil Temperature Control Valve
DK-20e Z 10-10
CHAPTER
ITEM
Lublicating Oil Temperature Control Valve:
Disassembly / Inspection and Maintenance / Assembly DK-20e 5.3~5.5
15-5.3 Disassembly of Lubricating Oil 15-5.5 Assembly of Lubricating Oil

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

As the pellet d Is attached to the valve, pull
out the valve and pellet at the same time.
c) Pull out the spring i .
d) Remove the E-ring j , and take out the
spring k .
e) Take out the pellet from the valve.
f) Remove the cap nut l and lock nut m , and-
pull out the adjusting screw g .

Lubricating Oil Temperature
Control Valve
(1) Clean all the disassembled parts with washing
oil, and remove the scales.
(2) Inspect if there is any scratch on the outer
periphery and end surface of the valve, and con-
firm that the valve moves smoothly.
In case that the degree of scratch is minor,cor-
rect it with oil stone.
on each spring. 15
DK-20e Z 10-10
CHAPTER
16 Cooling Water System
ITEM
Outline of Cooling Water System / General
1,2.1 DK-20e Construction of Cooling Water Pump
16. Cooling Water System line, seawater (in the case of marine use) or clean
water is used.
16.1 Outline of Cooling Water System The jacket line cooling water outlet in the engine is
There are available two types of cooling water sys- provided with a temperature control valve.
tems, a clean water 1-line cooling system and a
clean water-seawater (or clean water) 2-line In the case of a heavy fuel oil engine with cooling
cooling system. nozzle, cooling water is supplied through a branch
・The clean water 1-line cooling system consists from the jacket line.
of a cooler line (low temperature) on which ( : "Operation" 2.2.4 "Cooling Water System")
cooling water is fed by the cooler cooling
water pump (provided on the engine or sepa- 16.2 Cooling Water Pump
rately installed) and a jacket line (high temper- 16.2.1 General Construction
ature) branching from the cooler system on
which cooling water is fed by the jacket cool- The cooling water pump of the jacket system is a
ing water pump (provided on the engine). volute type, and the pump is installed on the front
This cooling system requires one inlet and one of the engine, and is driven by the auxiliary drive
outlet in the engine. gear located on the front end of the crankshaft.
・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 Cooling water pump: 39 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-20e Z 10-10
CHAPTER
Cooling Water System 16
ITEM
Cooling Water Pump: Replacing Consumables,
Implements, and Measuring Instruments / Disassembly DK-20e 2.2,2.3
16.2.2 Replacing
Consumables,Implements and
The screw of the impeller mounting nut b for
(1) Replacing Consumables normal rotation engine is threaded as "left-
Replace the following parts with the new ones. handed" screw. Therefore, be careful of the
( : "Parts List") direction when loosening or tightening the nut
① O-ring 4-4.1 No.522 and screw.
② Circular gasket 4-4.1 No.529
③ Gasket 4-4.2 No.10 c) Remove the rotary part of the mechanical
④ Oil seal 4-4.1 No.520 seal e .
⑤ Mechanical seal 4-4.1 No.49 d) Remove the seal holder f , and take out the-
⑥ Bearing 4-4.1 No.57 fixed part of the mechanical seal.
e) Remove the water-cutting ring g .
(2) Implements and Measuring Instruments f) Remove the cooling water pump gear tighten-
ing nut h , remove the cooling water pump
ments
( : 2-2.2) gear i , and then take out the key j .
g) Pull out the collar k , and take out the snap
ring l .
h) Extract the pump shaft n out of the bearing
16.2.3 Disassembly of Cooling Water case o , together with the ball bearing m .
Pump
i) Take out the oil seal p from the bearing case
(1) Before dismounting the cooling water
pump,remove the cover of the center of the aux-
iliary gear case, and measure the backlash of
the pump drive gear. Impeller side p Bearing side
Standard Replacement limit a

(mm) (mm)
c Apply lithium grease
Notched mark 㵰O"
d m
(2) Disconnect the piping of the pump inlet and outlet. Lubricating l
(3) Remove the tightening nut, and dismount the oil inlet j
cooling water pump assembly.
(4) Disassemble the cooling water pump in thefol-
lowing procedure:
Before disassembling, put matchmarks on the
joint surfaces of the pump body, cover, and so
on.
16
< Cooling water pump disassembling procedure >
n a k i h
a) Remove the mounting nut, and take out the
pump body a .
f g
b) Remove the impeller mounting nut b , remove b e
the impeller c and take out the key d .
Cooling Water Pump
DK-20e Z 10-10
CHAPTER
ITEM
2.4 DK-20e 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 innerdiame- Mouth ring
ter of the mouth ring, and calculate the clearance.
Mouth ring clearance

Standard value Replacement limit
a
(mm) (mm)
a = 0.50~0.56 1.0
In case that the clearance is over the replace-

ment limit, replace the parts, of which wearing
degree is larger.
Clearance between Impeller and Mouth Ring
Excessive wear may degrade the pump effi-
ciency.
(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 coolingwa-
ter pump gear tooth flank and the presence oi
pitching.
(6) Rotate the bearing, and check if it rotates
smoothly, does not make abnormal noise, or is
not worn out.
Replace the bearing at the time of the periodi-

cal inspection of every 8,000 to 12,000 hrs.
(every 2 to 3 years) with a new one, even
when there is no particular abnormalitv on it.
DK-20e Z 10-10
CHAPTER
ITEM
Assembly of Cooling Water Pump DK-20e 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 faces straight upward
To tighten the impeller nut (b) and the (the notched mark "O" facing straight
pump gear nut (h), apply the lubrication oil upward), when the pump is mounted on
to the nuts, and then tighten the nuts with the engine.
the specified torque. 2) Replace the oil seal, mechanical seal,
packing, folded washer, O-ring, etc. with
new ones.
3) Be careful not to assemble the oil seal in
When tightening the pump gear nut (h), fix the wrong direction.
the gear and then tighten the nut so that the 4) Mark the direction of the washer claw on
load (reaction) cannot be applied to the the impeller (refer to Fig. 1).
impeller. 5) Tighten the impeller nut with the specified
torque using a torque wrench.
When tightening the impeller nut, check that
Specified torque: the folded washer does not turn together
Impeller nut: 147 N.m (15 kgf.m) with the nut.
Pump gear nut: 333 N.m (34 kgf.m) 6) Before fitting the pump body, turn the
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).
Notched mark "O"
Mark which way

the claw washer's tongue
16
Fig. 1 Fig. 2
DK-20e Z 10-10
CHAPTER
ITEM
2.5 DK-20e Assembly of Cooling Water Pump
<Caution in handling mechanical seal> "Never allow oily substance

and foreign matters to stick"
1) Do not use any greases. Mating Ring
Seal Ring
2) Do not apply any oils to the sliding sur-
Impeller side
face. If oil or foreign material is on the Bellows
sliding surface, wipe it off the sliding sur-

face using clean cloth moistened with
alcohol or acetone.
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. Apply turbine oil # 32
4) Leave the mechanical seal as it is for 30 "Never use grease."
minutes or more. Installation of the Mechanical Seal
(2) Mount the cooling water pump.

In case that the cooling water pump gear is
replaced, check the backlash.
(3) Connect the cooling water inlet and outlet pip-
ing.
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.
DK-20e Z 10-10
CHAPTER
ITEM
Cooling Water Temperature Control Valve: General Construction /
Replacing Consumables, Implements, and Measuring Instruments DK-20e 3.1,3.2
16-3 Cooling Water Temperature 16-3.2 Replacing

Control Valve Consumables,Implements, and
16-3.1 General Construction Measuring Instruments
The cooling water temperature control valve is a
kind of the mixing type with 3-direction valves as in
① Y-ring S104100650
the case of the lubricating oil temperature control
② O-ring Z560102124ZZ
valve. Consequently, the basic structure, function,
③ O-ring Z560103635ZZ
activation, and handling method is approximately
④ O-ring Z565001300ZZ
identical with those of the lubricating oil tempera-
⑤ Pellet S10400
ture control valve.
Note: The controlling temperature of pellet may
( : "Lubricating Oil Temperature Control
differ depending on the specification.
Valve")
Therefore, be minded to clearly Indicate the-
controlling temperature of the name plate
Cooling water temperature control valve
when issuing orders.
(DTV-65): 20 kg

ments ( : 2-2)
r
g
h
i
j
l
p
m
b
q
f
C port B port
n
o
16
e
d
A port
Cooling Water Temperature Control Valve
DK-20e Z 10-10
CHAPTER
ITEM
Cooling Water Temperature Control Valve: General Construction /
3.3~3.5 DK-20e Replacing Consumables, Implements, and Measuring Instruments
16-3.3 Disassembly of Cooling Water 16-3.4 Inspection and Maintenance of

Temperature Control Valve Cooling Water Temperature
(1) Disconnect the connection piping, and remove Control Valve
the temperature control vaive assembly. (1) Clean all the disassembled parts with washing
(2) Disassemble the cooling water temperature- oil, and remove the scales.
control valve in the following procedure: (2) Inspect if there is not any scratch on the outer
periphery and end surface of the valve, and con-
< Disassembling procedure > firm that the valve moves smoothly.
a) Remove the mounting bolt, and take out the- If the degree of scratch is minor, correct it with oil
cover c . stone.
Since the adjusting screw h and the rod j (3) Inspect if there is not any abnormal dent or
are attached to the cover c , remove them scratch on the cushion spring.
altogether. (4) Insert the shaft into the shaft bush, and inspect
b) Remove the mounting bolt, and take out the- if it moves smoothly.
cover b .
Since the valve f , shaft j , pellet d , and
main spring m are attached to the cover,
remove them altogether. 16-3.5 Assembly of Cooling Water
c) Take out the pellet. Temperature Control Valve
d) Remove the lock nut n and o , take out the-
Assemble the temperature control valve in the
valve from the shaft.
reverse order of disassembling procedure.
Since the main spring is compressed, be

Be minded to replace the pellet every 2 years,
minded to carefully and slowly loosen the nut,
taking into consideration the degradation of
so that the spring may not fly out.
the rubber diaphragm in the inside.
e) Take out the shaft, spring seat p , and main-

spring.
f) Pull out the shaft bush q from the cover.
Take out the cap r , and pull out cushion
spring g and rod j from the adjusting
screw h .
DK-20e Z 10-10
CHAPTER
ITEM
MEMO DK-20e
16
CHAPTER
17 Engine Control and Protective System
ITEM
1 DK-20e Outline of Engine Control and Protective Device
17. Engine Control and Protective

Device
Turning safety switch and solenoid valve
17-1 Outline of Engine Control and .....Disassembling is prohibited, and therefore
Protective Device
replace them as an assembly.
( : "Operation" 2-3 "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 (for speed, temperature, pressure, level, etc.)
maintenance of each equipment, perform the work .....The disassembling of these parts are prohibit-
according to the following procedure. ed, and therefore replace each of them as an
assembly.
(1) Engine Control (Start, Drive, and Stop) Various electric parts
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 .....Incorporated into the fuel oil control device.
( : "Instruction Manual of Governor") (Explained in this section.)
Starting operation valve Governor motor

Turning bar Pulse sensor
63 Starting
Q2 air valve Speed switch

From L.O.

%
(12,13,14)
piping Governor Meter display
(4-20mA)
Turning Stop Control
safety cylinder cylinder Common rod
Starting air
switch
Control air
Control air
rotary valve
Fuel oil shut
down device
Fuel oil injection pump
Stop Operation lever
Starting cylinder
valve Air tank
RUN
To fuel START
oil injection pump
of each cylinder STOP
Control air
0.8MPa
{8kg/cm2} Handle switch (HS)
Stating Fuel oil Fuel oil Fuel oil

sorenoid shut down control shut down
valve solenoid solenoid solenoid
valve valve valve
䇭䇭䋨㪏㪏䌖䋩䇭䇭䋨䋵䌖䋩䋨䋸䋸䌌䋩䇭䋨䋵䌓䋩
Starting and stoppage System of Constant-Speed Engine (Direct Starting Type)
DK-20e Z 10-10
CHAPTER
Engine Control and Protective System 17
ITEM
Outline of Engine Control and Protective Device DK-20e 1
Governor motor
Pulse sensor
Flywheel Starting push button Governor

Speed switch
(12,13,14)

㩿㪏㪏㪭㪀
Meter display
(4-20mA)
Air motor Control air Control cylinder
Stop cylinder Common rod
Air vent
valve
Fuel oil shut
down device
Starting valve
Safty valve Operation lever
Stop cylinder
Turning bar
Relief valve
RUN
Pressure To fuel START
regurating valve oil injection pump
Air filter of each cylinder STOP
Air tank
Turning
safety switch Handle switch (HS)
Starting air
63
Q2
Control air Fuel oil Fuel oil Fuel oil
shut down control shut down
From L.O. piping 0.8MPa
solenoid valve solenoid valve solenoid valve
{8kg/cm2} (5V) (㪏㪏䌌) (5S)
Starting and Stoppage System of Constant-Speed Engine ( Air motor starting type)
63 Starting operation valve

Q2 Pulse sensor
From L.O. Starting air valve Air piston Governor
piping 12
Speed switch
Explosion plate
13
14
C
(12,13,14)
Meter display
(4-20mA)
Starting air Fuel oil shutdown
rotary valve and control device
Common rod
Stop Operation lever

Starting cylinder
Air tank
valve
RUN
Governor boost To fuel START
sorenoid (GVB) oil injection pump
of each cylinder STOP
Control air
0.8MPa Handle switch (HS)
{8kg/cm2}
17
Fuel oil shutdown Fuel oil shutdown
Governor boost air solenoid valve solenoid valve
Governor air (from control handle) (5V) (5S)
(0.1~0.4 MPa (1~4 kg/cm2)
Starting and stoppage System of Variable-Speed Engine

(Direct Starting Type.Engine side Operation)
DK-20e A 11-06
CHAPTER
ITEM
Fuel Oil Shutdown Device (G1 Type): General Construction / Replacing
2.1~2.3 DK-20e Consumables, Implements, and Measuring Instruments / Disassembly
17-2 Fuel Oil Shutdown Device (G1 Type) 17-2.2 Replacing

17-2.1 General construction Consumables,Implements, and
As the fuel oil shutdown device, there are two
types, i.e., G1 Type for the constant-speed engine
(such as a generator engine) and J2 Type for the
( : "Parts List")
variable-speed engine (such as a marine propul-
<G1 type> O-ring
sion engine), and which engine should be used
4-7.1.1 No.505, 506, 507, 508, 509
depends on the purpose of its use and specifica-
tions.
The fuel oil shutdown device (G1 Type) is provided
with a stop cylinder to shut down the fuel oil,and a
ments
fuel control cylinder to control excessive fuel oil
( : 2-2)
injection that are arrenged in tandem,and this shut-
down device shifts the fuel injection pump rack to
either "Stop" position or "Control" position via com- 17-2.3 Disassembly of Fuel Oil
mon rod,by affecting the control air to each posi- Shutdown Device (G1 Type)
tion. (1) Before disassembling, put a mark (matchmark)
to the adjusting place, or keep the record of the
Fuel oil shutdown device (G1 type): 5.5 kg dimensions.
(2) Take out the link pin C , and remove the fork
end B .
(3) Remove the fuel oil shutdown device assembly A
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 shutdown pis-
ton e out of the cylinder a .
c) Extract the control piston f from the opposite
side.
g d f a b B C
Common rod
c e
Fuel Oil Shutdown Device (G1 Type)
DK-20e Z 10-10
CHAPTER
ITEM
Inspection, Maintenance, Assembly, Mounting, and
Adjustment of Fuel Oil Shutdown Device ( G1 Type ) DK-20e 2.4,2.5
17-2.4 Inspection, Maintenance, and 17-2.5 Mounting and Adjustment of

Assembly of Fuel Oil Shutdown Fuel Oil Shutdown Device (G1
Device (G1 Type) Type)
(1) Wash all the disassembled parts with clean- (1) Mount the fuel oil shutdown device assembly to
washing oil, and blow air on them. the engine, and attach the fork end and link
(2) Inspect if there is any abnormal dent or scratch lever.
on the shutdown piston and control piston. At this time, be minded to temporarily adjust the
(3) Inspect if there is any abnormal dent or scratch adjusting bolt g by matching it to the match-
on the cylinder inner surface. mark.
(4) Inspect if there is any scratch on the main (2) Turn the operation lever to "Drive" position, and
spring. supply control air to the control cylinder of the
(5) Inspect if there is any rusting on each fuel oil shutdown device. And, adjust the screw-
parts,which is caused by drain. in position of the fork end, so that the rack scale
(6) Assemble the fuel oil shutdown device assem- indicates the specified position, and fix the link
bly in the reverse order of the disassembling pro- lever.
cedure. (3) Next, supply air to the shutdown cylinder,and
adjust the screw-in position of the adjusting
bolt,so that the rack is at "0" position.
1) Replace all the O-rings with the new ones. If the screwin direction is clockwise,the shutdown
2) When assembling, thinly apply grease to the stroke will be decreased.
sliding surfaces of the O-ring,piston,and so on. (4) When the adjustment of the control stroke and
the shutdown stroke is completed after repeating
(7) After assembling, confirm that every part of the the above steps (2) and (3),fix the fork end and
device operates smoothly. adjusting bolt with the lock nuts.
Lock nut Lock nut Link lever
Adjust bolt Forkl end STOP RUN 17

Mounting and Adjustment of Fuel Oil Shutdown Device (G1 Type)
DK-20e Z 10-10
CHAPTER
ITEM
Fuel Oil Shutdown Device (J2 Type): General Construction / Replacing
3.1~3.4 DK-20e Consumables / Disassembly and Assembly / Mounting and Adjustment
17.3 Fuel Oil Shutdown Device (J2 Type) 17.3.3 Disassembly, Maintenance, and
17.3.1 General construction Assembly of Fuel Oil Shutdown
Device (J2Type)
The fuel oil shutdown device (J2 type) is employed
The assembly, maintenance, and assembly of the
in the air-system type variable-speed engine, and
fuel shutdown device (J2 type) shall be conducted
as in the case of G1 type, the shutdown device is
according to the procedure of G1 type.
composed of a stop cylinder which shuts down the
( : 17-2 "Fuel Oil Shutdown Device (G1 Type)")
fuel, and a control cylinder which controls exces-
sive fuel injection.
The limit value of the control cylinder is variable, 17-3.4 Mounting and Adjustment of
and it shall be varied by the air pressure for opera- Fuel Oil Shutdown Device (J2
tion, and according to the load. Type)
The adjustment of the fuel oil shutdown device (J2
Fuel oil shutdown device (J2 type): 9.5 kg type) shall be conducted by correlating it with the
pressure of operating air.
(1) Mount the fuel oil shutdown device to the
17.3.2 Replacing Consumables, engine, and attach the fork end and link lever by
temporarily adjusting them.
(2) Set the operating lever of the engine to "Drive"
Instruments
position, push the rack indicator needle to the
(1) Replacing Consumables increase direction, adjust the screw-in position of
Replace the following parts with the new ones the fork end, so that the rack amount in the state
( : "Part List") that the link pin is struck against the long-hole
① Mini-Y gasket 4-7.1.2 No.40, 41 part of the link should be the rack amount +2-3
② GLY gasket 4-7.1.2 No.44 mm (Point A in the figure) of the starting
③ O-ring 4-7.1.2 No.37 time,and then fix the link lever.
④ SER scraper 4-7.1.2 No.47 (3) Supply the operating air equivalent to the total
load rack amount (0.4MPa in the figure) to the
(2) Implements and Measuring Instruments rack control piston.
① General implements and measuring instru- In the meantime,confirm that the link pin is not
ments ( : 2-2) struck against the long-hole part of the link.
l k f a b h
m C
B
n
STOP RUN
c e
Fuel Oil Shutdown Device (J2 Type)
DK-20e Z 10-10
CHAPTER
ITEM
Mounting and Adjustment of Fuel Oil Shutdown Device( J2
Type ) DK-20e 3.4
(4) Next, push the rack indicator needle to the (8) When the adjustment of the rack control stroke-
increase direction, and adjust the screw-in posi- and shutdown stroke is completed by repeating
tion of the spring seat, so that the rack amount in the procedure of the above Item (3) to (7), fix the
the state that the link pin is struck against the fork end and adjust bolt with the lock nut.
long-hole part of the link should be the rack
amount +1~2 mm (Point B in the figure) of the
full-loading time. 1) Although hysteresis may be seen between
If the screw-in direction is clockwise, the limit the increase time and decrease time of operat-
rack amount will be decreased. ing air pressure, there is no functional prob-
(5) In case that the rack stopper is set in the full- lems at all.
loaded position, confirm the rack amount to be 2) The adjustment of activating properties of
limited by the clearance between the link long- ) the rack control piston shall be conducted
hole part and link pin. only in the direction of increasing the operat-
(6) After the operating air is decompressed to 0.1 ing air pressure, so that the errors due to
MPa or lower, gradually supply the operating air hysteresis can be minimized.
to the control piston again, and confirm that acti- 3) Since the spring seat is locked not to rotate
vation starting point (Point C in the figure) is by the stopper screw and nylon piece,
within the range of 0.1 ~0.2MPa. adjustment shall be conducted after loosen-
(7) Next, supply the control air to the shutdown pis- ing the stopper screw, and be sure to lock it
ton, and adjust the screw-in position of the again after finishing the adjustment.
adjusting bolt, so that the rack position is "O".
If the screw-in direction is clockwise, the shut-
down stroke will be decreased.
Nylon piece and
Nut stopper screw Activation starting
Adjust bolt Fork end
Spring seat pressure
Lock nut Increase Decrease
STOP RUN
Lock nut Nylon piece and
stopper screw Link lever
Mounting and Adjustment of Fuel Oil Shutdown Device (J2 Type)
Rack stopper B
position
Fuel oil rack scale
Rack control piston

activating position
Starting time A
Load properties of marine
propulsion engine 17
control position
C
0 0.1 0.15 0.2 0.3 0.4
[ D.S. ] [ FULL ]
Operating Air Pressure {MPa}
DK-20e Z 10-10
CHAPTER
Gauge Board
18
ITEM
General Construction/Replacing Consumables, Implements,
1.1～1.3 DK-20e and Measuring Instruments/Disassembly and Maintenance
18 Gauge Board (2) Inspection and Maintenance of Gauge Board

18-1 Gauge Board a) Check the accuracy of each gauge, compar-
ing with the equipment for calibration purpose
or new equipment. In case that any fault is
The gauge board is equipped with a tachometer
found, replace it with a good gauge.
and each pressure gauge (for lubricating oil, fuel
b) Replace the flexible hose with a new one.
oil, intake air, cooling water, etc.), and is supported
by cushion rubber. c) Replace the cushion rubber with a new one.
The tachometer is driven from the front end of
the camshaft via flexible cable, and each pressure
1) It is difficult to repair the defective gauges
gauge is connected from the source valve at the
on site. Therefore, replace them with the
end of piping with flexible hose
new ones, or inquire the specialized maker
for the repair.
2) Heavily deteriorated hoses may break. If
18-1.2 Replacing Consumables, the hoses for fuel oil and lubricating oil
Implements, Measuring Instruments break and high-temperature parts are
splashed with the oil, a fire may occur.
(1) Replacing Consumables Replace such hoses without fail.
Replace the following parts with the new ones. 3) If the elasticity of the cushion rubber is lost,
( : "Parts List") the vibration of the gauge will increase and
the indication fault of the gauge will be
① Flexible hose 4-6.1 No. A20, A21, A24
advanced.
② Cushion rubber 4-6.1 No. A15
Cushion rubber
( ：2-2)
18-1.3 Disassembly and Maintenance Cushion spring
of Gauge Board
Perform the disassembly and maintenance of
the gauge board at the time of the periodic inspec-
tion (every 16,000 to 24,000 hr: every 4 to 5
years), according to the following procedure:
(1) Disassembly of Gauge Board

a) Remove the flexible cable of tachometer from
Flexible hose
the take-out port.
b) Close the source valve of the pressure
gauge, and disconnect the flexible hose.
c) Remove the mounting bolt of cushion rubber
to the bracket, and disconnect the entire
gauge board. Flexible cable Source valve
Gauge Board
DK-20e Z 10-10
CHAPTER
Gauge Board
18
ITEM
Seal Pot DK-20e 2
18-2 Seal Pot ( Heavy fuel oil specifica-

tion)
In case of heavy fuel oil, a seal pot is provided in Fuel oil main pipe
the middle of the fuel oil pressure gauge

piping,and filled with ethylene glycol to replace the
pressure, so that the pressure gauge can be pre- B
vented from malfunction due to the sticking of fuel

oil in the cold condition.
Ethylene glycol will be contaminated and deteri-
a
orated being mixed with fuel oil as time, passes, To remote
C pressure gauge
and therefore be minded to periodically
replace ethylene glycol with new one. c

<Replacing procedure of ethylene glycol> To pressure gauge
b
(1) Close the valve B , C , and D at the seal
pot inlet and outlet, and remove the seal pot A .
(2) Disconnect the inlet side joint c of siphon Seal pot A
tank b , and discharge the fuel oil and ethylene
glycol of the inside.
(3) Wash the inside of the tank.
(4) Fill ethylene glycol until it starts to spill out of Seal Pot
the upper part hole, and then install the joint.
(5) Install the piping to the seal pot.
Although athylene glycol is less toxic to skin

and membrane, it is still dangerous if it was
taken into human body. Therefore, be minded
to take enough care in the handling, and
promptly wash it away when it is deposited on
hand or skin.
18
DK-20e Z 10-10
CHAPTER
Gauge Board
18
ITEM
General Construction/Replacing Consumables, Implements,
1.1～1.3 DK-20 and Measuring Instruments/Disassembly and Maintenance
18 Gauge Board (2) Inspection and Maintenance of Gauge Board

18-1 Gauge Board a) Check the accuracy of each gauge, compar-
ing with the equipment for calibration purpose
or new equipment. In case that any fault is
The gauge board is equipped with a tachometer
found, replace it with a good gauge.
and each pressure gauge (for lubricating oil, fuel
b) Replace the flexible hose with a new one.
oil, intake air, cooling water, etc.), and is supported
by cushion rubber. c) Replace the cushion rubber with a new one.
The tachometer is driven from the front end of
the camshaft via flexible cable, and each pressure
1) It is difficult to repair the defective gauges
gauge is connected from the source valve at the
on site. Therefore, replace them with the
end of piping with flexible hose
new ones, or inquire the specialized maker
for the repair.
2) Heavily deteriorated hoses may break. If
18-1.2 Replacing Consumables, the hoses for fuel oil and lubricating oil
Implements, Measuring Instruments break and high-temperature parts are
splashed with the oil, a fire may occur.
(1) Replacing Consumables Replace such hoses without fail.
Replace the following parts with the new ones. 3) If the elasticity of the cushion rubber is lost,
( : "Parts List") the vibration of the gauge will increase and
the indication fault of the gauge will be
Flexible hose
1 4-6.1 No. A20, A21, A24
advanced.
Cushion rubber 4-6.1 No. A15
2

Cushion rubber
( ：2-2)
18-1.3 Disassembly and Maintenance Cushion spring
of Gauge Board
Perform the disassembly and maintenance of
the gauge board at the time of the periodic inspec-
tion (every 16,000 to 24,000 hr: every 4 to 5
years), according to the following procedure:
(1) Disassembly of Gauge Board

a) Remove the flexible cable of tachometer from
Flexible hose
the take-out port.
b) Close the source valve of the pressure
gauge, and disconnect the flexible hose.
c) Remove the mounting bolt of cushion rubber
to the bracket, and disconnect the entire
gauge board. Flexible cable Source valve
Gauge Board
DK-20 A 05-03
CHAPTER
Gauge Board
18
ITEM
Seal Pot DK-20 2
18-2 Seal Pot ( Heavy fuel oil specifica-

tion)
In case of heavy fuel oil, a seal pot is provided in Fuel oil main pipe
the middle of the fuel oil pressure gauge

piping,and filled with ethylene glycol to replace the
pressure, so that the pressure gauge can be pre- B
vented from malfunction due to the sticking of fuel

oil in the cold condition.
Ethylene glycol will be contaminated and deteri-
a
orated being mixed with fuel oil as time, passes, To remote
C pressure gauge
and therefore be minded to periodically
replace ethylene glycol with new one. c
ċ
<Replacing procedure of ethylene glycol> To pressure gauge
b
(1) Close the valve B , C , and D at the seal
pot inlet and outlet, and remove the seal pot A .
(2) Disconnect the inlet side joint c of siphon Seal pot A
tank b , and discharge the fuel oil and ethylene
glycol of the inside.
(3) Wash the inside of the tank.
(4) Fill ethylene glycol until it starts to spill out of Seal Pot
the upper part hole, and then install the joint.
(5) Install the piping to the seal pot.
Although athylene glycol is less toxic to skin

and membrane, it is still dangerous if it was
taken into human body. Therefore, be minded
to take enough care in the handling, and
promptly wash it away when it is deposited on
hand or skin.
18
DK-20 Z 99-9

A02-DK20e Instruction Manual (Maintenance)

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DK-20e

・Hazards and nonconformities of imitation parts

Daihatsu Diesel supplies reliable engines. Use genuine parts to

Tokyo Office 16-11, Nihonbashi 1-chome, , Chuo-ku, Tokyo, 103-0027 Japan

Moriyama Division 45 Amura-cho, Moriyama-city, Shiga, 524-0035 Japan

Taiwan Office c/o Marine Technical Industries Co., Ltd.

1. EQUIPMENT ARRANGEMENT AND MAINTENANCE SCHEDULE 1

2. GENERAL MAINTENANCE ITEMS 2

3. CYLINDER HEAD AND VALVES 3

2.3 Disassembly of Intake and Exhaust Valves 3-2.3

4. PISTON AND CONNECTING ROD 4

5. Reassembly of Piston and Connecting Rod 4-5

5. ENGINE FRAME AND CYLINDER LINER 5

6. MAIN BEARING AND THRUST BEARING 6

8. TIMING GEAR AND CAMSHAFT 8

9. FUEL OIL INJECTION DEVICE 9

10. VALVE OPERATING DEVICE 10

11. GOVERNOR DRIVING DEVICE 11

12. INTAKE AND EXHAUST DEVICE 12

13. STARTING AIR SYSTEM 13

14. FUEL OIL SYSTEM 14

4. Fuel Oil Feed Pump Driving Device 14-4

15. LUBRICATING OIL SYSTEM 15

16. COOLING WATER SYSTEM 16

3. Cooling Water Temperature Control Valve 16-3

17. ENGINE CONTROL AND PROTECTIVE DEVICE 17

18. GAUGE BOARD 18

0-1 Prior to Start of Engine Maintenance

(1) This manual bears the following safety signs.

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

..."Obligatory acts"= Recommended practice or instruction to be followed to ensure safety of personnel

and the engine

0-2.2 Precautions for Disassembly, Maintenance, and Assembly

(10) Be minded to promptly replenish all the used spare parts.

0-2.3 Check Items after Disassembly, Maintenance, and Assembly

0-3.2 The parts to be Specified

<Parts with identification marks>

0-3.3 Engine Setting Value

<ltems set before shipment>

1 Equipment Arrangement and Maintenance Schedule

1-1 Equipment Arrangement

Intake and exhaust

Crank shaft Cam shaft

Starting air rotary

Cooling water pump

Lubricating oil pump

Auxiliary drive gear

Crankshaft Main bearing shell Thrust force receptor

Turbocharger Gauge board Operating lever Governor

Lubricating oil filter Lubricating oil temperature Turbocharger

1-2 Maintenance Schedule Table

Overhaul and maintenance piriod(hr)

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

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

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

Piston ring replacement 㧖㧝㨤0.5 ٧ 4-4