Service Manual 6aym-Ete-Ste PDF

FOREWORD
This service manual describes the construction and functions of the major parts of the 6A YM-
GTE, 6A YM-ETE, 6A YM-STE engine and illustrates the disassembly and assembly procedures
(standard servicing procedures) necessary for maintaining and servicing the engine.
Please read this manual carefully so that you are completely familiar with the construction and
function of each part before you start actual servicing work.
The construction and servicing procedures described in this manual may be slightly modified for
the improvement of quality and performance without prior notice. Please do not hesitate to contact
us if you have any queries or suggestions.
Keep this manual at a specified location to allow reference by the maintenance personnel.
The SI unit system is employed throughout this manual. The numerics within parentheses ( )
show values represented in conventional unit (for reference).
Prepare before you work !
For accurate and efficient service work, check and prepare the following:
1 Check the customer's service ledger
1) When was the machine last serviced?
2) How many months or hours has the machine been used since the previous servicing?
3) What was the previous trouble, and what parts were replaced?
4) Which parts should you replace this time?
2 Prepare the parts
Check the stock of parts which are needed for servicing.
3 Prepare the recording forms such as check sheets, parts measurement record sheet and
operation test record sheet.
4 Prepare the servicing measurement tools, containers, etc.
Marine Propulsion Engine
SERVICE MANUAL Models : 6AYM-GTE Code No. OB6AY-G00201

6AYM-ETE
6AYM-STE
CONTENTS
1. General ............................................................................................................................ 1
1.1 Exterior views .............................................................................................................. 1
1.2 Cross Sectional View .................................................................................................. 2
1.3 Engine specifications .................................................................................................. 3
1.4 Drawings of Engine Outline ........................................................................................ 6
1.5 Piping Diagram ......................................................................................................... 10
1.6 Fuel oil, lubricating oil and cooling water .................................................................. 12
1.6.1 Fuel oil ................................................................................................................. 12
1.6.2 Lubricating oil ...................................................................................................... 12
1.6.3 Cooling Water (Engine Jacket Water) ................................................................. 14
2. Disassembly and reassembly ........................................................................................ 17

2.1 Disassembly and reassembly precautions ................................................................ 17
2.2 Disassembly and reassembly tools ........................................................................... 18
2.2.1 General hand tools .............................................................................................. 18
2.2.2 Special hand tools ............................................................................................... 19
2.2.3 Measuring instruments ........................................................................................ 24
2.2.4 Other material. ..................................................................................................... 26
2.3 Disassembly procedures ........................................................................................... 28
2.4 Reassembly .............................................................................................................. 49
2.5 Wire harness ............................................................................................................. 82
3. Preparation Before Checking and Servicing .................................................................. 85

3.1 Cylinder Head ........................................................................................................... 86
3.1.1 Inspecting the cylinder head ................................................................................ 87
3.1.2 Valve seat correction procedure .......................................................................... 88
3.1.3 Intake/exhaust valves, valve guides .................................................................... 90
3.1.4 Valve springs ....................................................................................................... 92
3.1.5 Valve rotator ........................................................................................................ 93
3.1.6 Nozzle sleeve ...................................................................................................... 93
3.1.7 Assembling the cylinder head ............................................................................. 94
3.1.8 Measuring top clearance ..................................................................................... 95
3.1.9 Intake and exhaust rocker arms .......................................................................... 95
3.1 .10 Push rod ............................................................................................................ 96
3.1.11 Adjustment of valve clearance .......................................................................... 97
3.2 Cylinder block ........................................................................................................... 98
3.2.1 Cylinder block ...................................................................................................... 98
3.2.2 Checking the parts .............................................................................................. 98
3.3 Cylinder liner ............................................................................................................. 99
3.3.1 Measurement of liner ........................................................................................... 99
3.3.2 Insertion of liner ................................................................................................... 99
3.3.3 Measurement of projection ................................................................................ 100
3.4 Piston and piston pins ............................................................................................. 101
3.4.1 Piston ................................................................................................................ 101
3.4.2 Piston pin ........................................................................................................... 102
3.4.3 Piston rings ........................................................................................................ 103
3.5 Connecting rod ........................................................................................................ 105
3.5.1 Inspecting the connection rod ........................................................................... 105
3.5.2 Crank pin metal ................................................................................................. 107
3.5.3 Piston pin bearing .............................................................................................. 108
3.5.4 Assembling piston and connecting rod .............................................................. 108
3.6 Crankshaft and main bearing .................................................................................. 109
3.6.1 Crankshaft ......................................................................................................... 109
3.6.2 Main bearing ...................................................................................................... 112
3. 7 Cam shaft and Tappets ............................................................................................ 113
3.7.1 Camshaft ........................................................................................................... 113
3.7.2 Tappets ............................................................................................................. 115
3.8 Timing gear ............................................................................................................. 116
3.8.1 Inspecting the gears .......................................................................................... 116
3.8.2 Gear timing marks ............................................................................................. 117
3.8.3 Fresh water pump & Alternator driving gear (OFW) .......................................... 117
3.9 Flywheel and housing ............................................................................................. 118
3.9.1 Specifications of flywheel .................................................................................. 118
3.9.2Ringgear ........................................................................................................... 119
3.9.3 Position of top dead center ................................................................................ 119
3.9.4 Dimensions of flywheel ...................................................................................... 120
3.9.5 Dimensions of front P.T.O and mounting flange ............................................... 121
3.10 Fuel injection equipment ....................................................................................... 122
3.10.1 Fuel Oil System ............................................................................................... 122
3.10.2 Fuel injection pump/governor .......................................................................... 122
3. 11 Governor ............................................................................................................... 126
3.11.1 Description ...................................................................................................... 126
3.11.2 Disassembly of Governor ................................................................................ 127
3.11.3 Inspection ........................................................................................................ 134
3.11.4 Assembly ......................................................................................................... 134
3.11.5 Adjustment ...................................................................................................... 139
3.12 Disassembly, Reassembly and Inspection of Fuel injection pump ....................... 140
3.12.1 Disassembly of fuel injection pump ................................................................. 141
3.12.2 Inspection of fuel injection pump ..................................................................... 144
3.12.3 Reassembly of fuel injection pump .................................................................. 146
3.12.4 Adjustment of fuel injection pump ................................................................... 154
3.13 Fuel feed pump ..................................................................................................... 159
3.14 Adjusting the injection timing ............................................................................... 163
3.15 Fuel injection Nozzle ............................................................................................. 164
3.15.1 Functioning of fuel injection nozzle ................................................................. 164
3.15.2 Fuel injection nozzle disassembly ................................................................... 165
3.16 Boost Compensator .............................................................................................. 168
3.16.1 Performance .................................................................................................... 168
3.16.2 Equipment ....................................................................................................... 169
3.17 Troubleshooting of fuel oil system ........................................................................ 170
3.18 Fuel Filter .............................................................................................................. 172
3.18.1 Fuel filter specifications ................................................................................... 172
3.18.2 Fuel Filter inspection ....................................................................................... 172
3.18.3 Water separator ............................................................................................... 173
3. 19 Lubrication system ................................................................................................ 174
3.19.1 Lubrication system .......................................................................................... 174
3.19.2 Lube oil pump .................................................................................................. 175
3.19.3 Oil pressure control valve construction ........................................................... 177
3.19.4 Lube oil filter .................................................................................................... 178
3.19.5 Lube oil cooler ................................................................................................. 180
3.19.6 Piston Cooling Nozzle ..................................................................................... 181
3.19. 7 Gear waste oi I pump (Optional)....................................................................... 182
3.20 Cooling water system ............................................................................................ 183
3.20.1 Cooling water system ...................................................................................... 183
3.20.2 Seawater pump ............................................................................................... 184
3.20.3 Checking and Replacement of Anticorrosive Zincs ......................................... 185
3.20.4 Fresh water pump ........................................................................................... 186
3.20.5 Fresh Water Line ............................................................................................ 188
3.20.6 Fresh Water Cooler ......................................................................................... 189
3.20. 7 Pressure cap and Coolant recovery tank........................................................ 190
3.20.8 Thermostat ...................................................................................................... 193
3.20.9 Seawater System Cleaning ............................................................................. 195
3.20.10 Fresh Water System Cleaning ...................................................................... 195
3.21 Turbocharger ........................................................................................................ 196
3.21.1 Specification .................................................................................................... 196
3.21.2 Construction and function of turbocharger ...................................................... 196
3.21.3 Standards for maintenance and check ............................................................ 198
3.21.4 Periodical checking procedure ........................................................................ 199
3.21.4.1 Periodical checking interval ...................................................................... 199
3.21.4.2 Checking procedure ................................................................................. 199
3.21.5 Disassembly procedure ................................................................................... 200
3.21.5.1 Preparations for disassembly .................................................................... 200
3.21.5.2 Check before disassembly ....................................................................... 200
3.21.6 Disassembly .................................................................................................... 201
3.21.7 Cleaning and checking procedure ................................................................... 204
3.21.7.1 Cleaning .................................................................................................... 204
3.21.7.2 Checking procedure .................................................................................. 206
3.21.8 Reassembling procedure ................................................................................ 208
3.21.8.1 Preparations for reassembly ..................................................................... 208
3.21.8.2 Reassembling procedure .......................................................................... 209
3.21.9 Handling after reassembly .............................................................................. 215
3.21.9.1 Precautions for mounting the turbocharger to the engine ......................... 215
3.21.10 Troubleshooting ............................................................................................. 216
3.21.10.1 Exhaust gas is dense .............................................................................. 216
3.21.10.2 Whitish exhaust gas ............................................................................... 216
3.21.10.3 Too early oil shortage ............................................................................ 217
3.21.10.4 Output drop ............................................................................................ 217
3.21.10.5 Poor follow-up of turbocharger ............................................................... 217
3.21.10.6 Unusual sound or vibration ..................................................................... 217
3.22 Electrical System .................................................................................................. 218
3.22.1 starting motor .................................................................................................. 218
3.22.2 Alternator ......................................................................................................... 222
3.22.3 Wiring Diagram (1 pole type) ........................................................................... 225
3.22.4 Wiring Diagram (1 pole type with Air Heater) .................................................. 226
3.22.5 Wiring Diagram (2 pole type) (Option) ............................................................. 227
3.22.6 Wiring Diagram (2 pole type with Air Heater) .................................................. 228
3.22. 7 Instrument Panel ............................................................................................. 229
3.23 Starting Air Motor (Special order) ......................................................................... 230
3.23.1 Specifications .................................................................................................. 230
3.23.2 Piping Layout. .................................................................................................. 230
3.23.3 Sectional View ................................................................................................. 231
3.23.4 Outline of Consutruction and Its Function ....................................................... 232
3.23.5 Inspection, Maintenance and Adjustment ....................................................... 233
3.23.6 Overhaul .......................................................................................................... 235
3.23. 7 Troubles and Countermeasures ...................................................................... 237
4. Test running ................................................................................................................. 239

4.1 Preliminary precautions .......................................................................................... 239
4.2 Test running procedure ........................................................................................... 239
4.2.1 Check points and precautions during running ................................................... 240
5. Long storage ................................................................................................................ 241

6. Troubleshooting ........................................................................................................... 243
6.1 Preparation before troubleshooting ......................................................................... 243
6.2 Fault-finding chart ................................................................................................... 244
7. Service standards ........................................................................................................ 263

7.1 Engine tuning .......................................................................................................... 263
7.2 Engine body ............................................................................................................ 264
7.2.1 Cylinder head .................................................................................................... 264
7.2.2 Camshaft and gear train .................................................................................... 265
7.2.3 Cylinder block .................................................................................................... 266
8. Maintenance Checking ................................................................................................ 269
8.1 Precautions in Maintenance Checking .................................................................... 269
8.2 Table of Periodical Checking .................................................................................. 269
9. Service Standard ......................................................................................................... 273

10. Tightening Torque for Major Bolts and Nuts .............................................................. 277
10.1 Tightening Torque for Major Bolts and Nuts ......................................................... 277
10.2 Method of Tightening Connecting Rod Nuts
(Tighten the respective nut in three steps) ........................................................... 278
10.3 Method of clamping cylinder head bolts
(Tighten the respective bolts in five steps.) ........................................................... 278
10.4 Method of Tightening Main Bearing tightening bolt (Angular tightening) .............. 280
10.5 Method of clamping side bolts
(after the Clamp them with surface clamping of main bearing bolt of final tight) ... 281
10.6 Standard tightening torque .................................................................................... 282
10.7 Torque for pipe joint bolts ..................................................................................... 282
FOR SAFETY
1. SAFETY LABELS
• Most accidents are caused by negligence of basic safety rules and precautions. For accident
prevention, it is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully understand safety
precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected
accident.
• It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient
consideration for safety is required in addition to the matters marked [A CAUTION) . Especially for
safety precautions in a repair or maintenance job not described in this manual, receive instructions
from a knowledgeable leader.
• Safety marks used in this manual and their meanings are as follows:
DANGER-indicates an imminent hazardous situation which, if

not avoided, WILL result in death or serious injury.
WARNING-indicates a potentially hazardous situation which, if

not avoided, COULD result in death or serious injury.
CAUTION-indicates a potentially hazardous situation which, if

not avoided, may result in minor or moderate injury.
• NOTICE - indicates that if not observed, the product performance or quality may not be
guaranteed.
F-1
2. Safety Precautions
(1) SERVICE AREA
• Sufficient Ventilation
[A WARNING J Inhalation of exhaust fumes and dust particles may be hazardous to ones
health. Running engines welding, sanding, painting, and polishing tasks
should be only done in well ventilated areas.
·Safe I Adequate Work Area

[A CAUTION J The service area should be clean, spacious, level and free from holes in
the floor, to prevent "slip" or "trip and fall" type accidents.
• Clean, orderly arranged place

[A CAUTION J No dust, mud, oil or parts should be left on the floor surface.
[Failure to Observe]
An unexpected accident may be caused.
• Bright, Safely Illuminated Area

[A CAUTION J The work area should be well lit or illuminated in a safe manner. For work
in enclosed or dark areas, a "drop cord" should be utilized. The drop cord
must have a wire cage to prevent bulb breakage and possible ignition of
flammable substances.
• Safety Equipment
[A CAUTION J Fire extinguisher(s), first aid kit and eye wash I shower station should be
close at hand (or easily accessible) in case of an emergency.
F-2
(2) WORK - WEAR (GARMENTS)
·Safe Work Clothing

[A CAUTION J Appropriate safety wear (gloves, special shoes/boots, eye/ear protection,
~'~
head gear, harness', clothing, etc.) should be used/worn to match the task
at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting
OK!!~
clothes around moving machinery. A serious accident may occur if caught
in moving/rotating machinery.
(3) TOOLS
·Appropriate Lifting I Holding

(A WARNING J When lifting an engine, use only a lifting device (crane, jack, etc.) with
sufficient lifting capacity. Do not overload the device. Use only a chain,
cable, or lifting strap as an attaching device. Do not use rope, serious
injury may result.
To hold or support an engine, secure the engine to a support stand, test
bed or test cart designed to carry the weight of the engine. Do not
overload this device, serious injury may result.
Never run an engine without being properly secured to an engine support
stand, test bed or test cart, serious injury may result.
• Appropriate Tools
(A WARNING) Always use tools that are designed for the task at hand. Incorrect usage
~~
of tools may result in damage to the engine and or serious personal injury.
(4) GENUINE PARTS and MATERIALS
·Genuine Parts
[A CAUTION J Always use genuine YANMAR parts orYANMAR recommended parts and
goods. Damage to the engine, shortened engine life and or personal
injury may result.
F-3
(5) FASTENER TORQUE
• Torquing Fasteners
[A WARNING J Always follow the torque values and procedures as designated in the
service manual. Incorrect values, procedures and or tools may cause
damage to the engine and or personal injury.
(6) Electrical
• Short Circuits
[A WARNING J Always disconnect the (-) Negative battery cable before working on the
electrical system. An accidental "short circuit" may cause damage, fire
~
and or personal injury. Remember to connect the (-) Negative battery
cable (back onto the battery) LAST
• Charging Batteries
[A WARNING J Charging wet celled batteries produces hydrogen gas. Hydrogen gas is
~
extremely explosive. Keep sparks, open flame and any other form of
ignition away. Explosion may occur causing severe personal injury.
• Battery Electrolyte
[A WARNING J Batteries contain sulfuric acid. Do NOT allow it to come in contact with
clothing, skin and or eyes, severe burns will result.
(7) WASTE MANAGEMENT

Observe the following instructions with regard to hazardous waste
[A CAUTION J disposal. Negligence of these will have a serious impact on environmental
pollution concerns.
1) Waste fluids such as lube oil, fuel and coolant shall be carefully put
into separate sealed containers and disposed of properly.
2) Do NOT dispose of waste materials irresponsibly by dumping them
into the sewer, overland or into natural waterways.
3) Waste materials such as oil, fuel, coolant, solvents, filter elements and
batteries, must be disposed of properly according to local ordinances.
Consult the local authorities or reclamation facility.
F-4
(8) FURTHER PRECAUTIONS
• Fueling I Refueling
[A WARNING J Keep sparks, open flames or any other form of ignition (match, cigarette,
etc.) away when fueling/refueling the unit. Fire and or an explosion may
J&
result.
• Hot Surfaces.
[A CAUTION J Do NOT touch the engine (or any of its components) during running or
~
shortly after shutting it down. Scalding I serious burns may result. Allow
the engine to cool down before attempting to approach the unit.
a1hllllnbl11u.
• Rotating Parts
[A WARNING J Be careful around moving/rotating parts. Loose clothing, jewelry, ties or
tools may become entangled causing damage to the engine and or
0. severe personal injury.
• Preventing burns from scalding

(A DANGER J 1) Never open the filler cap shortly after shutting the engine down.
Steam and hot water will spurt out and seriously burn you. Allow the
•II
I
., I
engine to cool down before attempt to open the filler cap.
2) Securely tighten the filler cap after checking the cooling water.
Steam can spurt out during engine running, if tightening loose.
• Safety Label Check

(A CAUTION J Pay attention to the product safety label.
A safety label (caution plate) is affixed on the product for calling special
attention to safety.If it is missing or illegible, always affix a new one.
•Do not step on

(A CAUTION J Don't step on engine parts such as part cover, because there is the
possibility of slipping and fall.
ic\
F-5
3. Warning labels
For safe operation, the warning labels should be affixed in the correct place.
Replace the labels with new ones if lost or damaged. Order them from your service agents.
(2) A.111
DANGER
~
(1)
Q
llllll©li\ ')l:lfl=l;I:. !l;i'
l:li"!l©~I:: 2iii'Jf©li\1:1f
•illliili!.ll\jl:::l;l;.:\'--v ·:1 :1Hlllt ltiAH!llll.. "Cl'~~'.
When lifting the engine ,
f,j:L'"t'""F~ L'. e~i;ifJ<~~ Iii! only as shown in
t±J l..f,>!t t:~"t-"'1i!l:*1.65 ~J. diagram.
•Never remove the cap while the

engine is sti I I hot. •Hot water
may spurt out and burn you.
128296-07260
f~ri ~T3 1 4 i:·1
148616-07362
(4)
A WARNING
l±:.
i:::::I (3)
A ff WARNING
l±:.
i:::::I
·~ ~
No. Parts No.
s~
(1) 128296-07260
(2) 148616-07362
· iUicf:lf;I;, t!'-:1t::Pf::'f-¥>m~
(3) 141616-07200 .A;tif,j:L\""C.'( t::~L' • · f9;Jtfl, 10:S:l'llllf;l:lillltfJ:L'"t'l'~L',
. 'Tfl~"t-"'ill:*1.fJt;t. •) a<-t. • lJi:!lliflJ.,f;:J::LJ~~O)il!l:tl.tJ(i!i>LJ;f;"t,

(4) 141616-07210 • Exposed moving parts ·Don't open 10min. after stop
•Can cause injury 141616-07210 ·Can cause injury by explosion
(5) 141616-07220 141616-07200 016017 - OlX
F-6
5
<> A CAUTION
a •
· ~tJgc~ttl:.'~Tg
ilftlh.f.l<if> •J °*T·
• Hot surface
• May cause burn
(4) A : WARN I NG
15-
• i@fi\cpf;I:, t!:'-:it.::L'I::-'¥~~~
A.*1.fJ:L'"C! ( t=.~ L',
• 1rJi~T gaf:!:;ti.f.l<ifi •J i'liT,
• Exposed moving parts
• Can cause injury 141616-07210
016018 -oox
F-7
This Page Intentionally Left Blank
F-8
1. General
1. General
1.1 Exterior views
• Operation Side
Intake manifold
Air cooler
Filler cap
Fuel filter
Governor
Fuel injection pump
Fuel feed pump
Dipstick
Lubricating oil
feeding port
• Non-operation Side
Exhaust manifold Turbocharger
Engine oil cooler
Fresh waler
pump
Lubricating oil
filter
Lubricating oil
bypass filter
Starter
Lubricating oil 016021- OlE
pressure valve
1. General
1.2 Cross Sectional View
Valve Mechanism Supercharging

· 2 intake, 2 exhaust valves ·Air cooled exhaust
·Specially hardened cylinder gas High press. TIC
type tappet
Fuel Injection System

·In-line Pump
Cylinder Block
· Underslung bearing
structure
~l;:==~~~~~~~'~J~i![~J
Q ·castall
in cylinders
one piece for
1
-Y::.~::::;J;gz::~JL~ ·Lubricating oil main
gallery, cam chamber
are integrated
· Horizontal split type
Connecting Rod
·Balancing weights are
integrated to crank
shaft
·Nodular cast iron one
piece piston
Lubricating oil System

·Pump is equipped inside block
·Multi-plates type cooler
·Cartridge type paper filter
016494-00E
2
1. General
1.3 Engine specifications

Engine Principal Particulars
Model Unit 6AYM-GTE 6AYM-ETE 6AYM-STE
Type - Vertical, water-cooled, 4-cycle diesel engine
Combustion chamber - Direct injection type
No. of cylinders - cylinder bore x stroke mm 6-155 x 180
Total cylinder displacement Q 20.38
Ratings - L M H H
Rated output (at flywheel) kW(PS) 670 (911) 610 (829) 555 (755) 485 (659)
Rated engine speed min- 1 1938 1900 1840 1900
1.891 1.776
Brake mean effective pressure MPa(kgf/cm 2 ) 2.036 (20.76) 1.503 (15.33)
(19.28) (18.11)
Mean piston speed m/s 11.63 11.40 11.04 11.40
MPa · m/s 23.67 21.55 19.61 17.14
Power rating (PV value)
(kgf/cm 2 • m/s) (241.4) (219.8) (200) (174.7)
Fuel consumption rate at 100% Load, 205+ 5% 202+ 5% 200+5% 202+ 5%
g/kWh
(when IMO NOx Without
(g/PSh) (151+ 53) (149+ 53) (14?+ 53) (149+ 53)
standards are met) marine gear
g/kWh 0.14-0.82 (0.1-0.6)
Specified lubricating oil consumption
(g/PSh) (at 100% Load)
Compression ratio - 14.33
Crankshaft rotation direction - Counterclockwise, when viewed from the flywheel
Operating side - On the left, when viewed from the flywheel
Firing order - 1-4-2-6-3-5-1
Exhaust gas turbocharger (with an air cooler)
Supercharging system -
TD13
Constant high temperature cooling system
Cooling system -
(with a fresh water cooler)
Volume of cooling fresh water Q 68 (in coolers & jacket)
Lubricating system - Wet sump system, forced lubrication by gear pump
max. : 91 min. : 55 (Standard oil pan)
Capacity of
Q max. : 53 min. : 25 (Shallow oil pan)
lubricating oil sump tank
(in engine piping line : 20)
6 in-line type
Fuel injection system -
Hole type nozzle
Starting system - Electric starting motor DC24V, 7kW
Size of flywheel housing & flywheel - SAE #0 &#18
Overall length mm 2000
Dimensions Overall width mm 1305
Overall height mm 1430.5 (Standard oil pan) 1330.5 (Shallow oil pan)
Engine dry mass
kg 2365
(Without marine gear)
1. The rating shown represents net brake power at the flywheel.
To calculate the power available at the marine gear output flange, a marine gear efficiency of 0.97 must be
taken into account.
2. Cylinder numbers are counted from flywheel side (No.1 ).
3
1. General
6AYM-GTE 6AYM-ETE 6AYM-STE

Model Unit
Without marine gear
Fuel injection pump - YANMAR in-line
b.T.D.C b.T.D.C b.T.D.C
Injection timing (FIC) deg.
20° ± 0.5° 19° ± 0.5° 18° ± 0.5°
Type of injection nozzle Hole type Hole type Hole type
No. of injection hole mm x degree 8 - 00.30 x 160° 8 - 00.30 x 160° 8 - 00.27 x 160°
Fuel - Bore x injection angle + 4 - 00.22 x 90' + 4 - 00.22 x 90' + 4 - 00.22 x 90'
system MP a
Injection pressure 31 ± 0.5 (316 ± 5)
(kgf/cm2)
Packing thickness of
mm 3.0 2.5 2.0
fuel injection valve
Applicable fuel - Diesel fuel oil
Fuel filter - Paper element
Lubrication - Forced lubrication with gear pump
Lube oil
Q/hr./min- 1 15800/hr./2000
discharge volume
Lubrication
system MP a
Lube oil pressure 0.44 - 0.54 (4.5 - 5.5)
(kgf/cm2)
Suction side : Perforated steel plate
Lube oil filter -
Discharge side : Paper element
Seawater pump - Rubber impeller, gear driving type
Fresh water pump - Centrifugal, gear driving type
Cooling - Fresh water cooling
Sea- Rationg(D ' Rationg® ' Rationg(8)
' '
Cooling Q/hr./ water 33000/1938 ' 32000/1900 ' 31000/1840
Pump discharge volume ' '
water min- 1 Fresh- Rationg(D
' '
Rationg(8)
' Rationg® '
system ' '
water 47000/1938 ' 46500/1900 ' 45000/1840
' '
Fresh water capacity of
Q 65
engine water jacket
Fresh water capacity of
Q 1.5
coolant recovery tank
Type - TD13
Turbo-
Cooling - Air cooling
charger
Lubrication - Common with engine
m2 Fin & blads, Fin & blads, Fin & blads,

Type and capacity
Air cooler 21.5 21.5 17.4
Cooling - Seawater cooling
2009.2.25R 4
1. General
Model : GAYM-ETE
Marine gear (YAN MAR product) (option)
Model YXH-240
Rating M,H
Wet multi-disc, hydraulic
Type
(Flange : SAE No.O)
Ahead 1.95 2.27 2.56 3.03 3.48
Reduction ratio
Astern 1.95 2.27 2.56 3.03 3.48
Direction of rotation (Ahead) Clockwise, viewed from sterm
Marine gear mass (kg) 605
Model : GAYM-STE
Marine gear (YAN MAR product) (option)
Model YX-181 YX-180L
Rating M
Wet multi-disc, hydraulic
Type
(Flange : SAE No.O)
Ahead 2.08 2.55 3.03 3.50 4.00 4.54
Reduction ratio
Astern 2.08 2.55 3.03 3.50 4.00 4.54
Direction of rotation (Ahead) Clockwise, viewed from sterm
Marine gear mass (kg) 560 680
5
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017823-00E
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-iiJ
1. General
1.5 Piping Diagram

(1) Cooling Water System
* O.D.76(65A)
S.W.Outlet Pipe _G\1------ -!2::J---t Lub.Oil Cooler
~
t
* l.D.76 Rubber Hose F.W.Pump
Cylinder
--- cP 75
1 lemp. control valve

Detail "A"
J.{set: 75-85°c
~- - - - - Exh.Gas Manifold
Filler.Cap
Set:0.11MPa 1 l.D.38 L=80 Rubber Hose * O.D. 40
I ,_
~
'- Cil
Q) Q)
'-
0)
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0 Q)
0
0
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0 ·-Cii Detail "B"
'- -~
<.( co '-
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__J l:S
F.W.LINE :
* l.D. 76 Rubber Hose
S.W.LINE : - - -
* O.D. 76 (65A)
S.W.lnlet Pipe
Remark: * l.D. 76 Rubber Hose
Pipes & Devices marked * in this drawing are not included in our factory's standard scope of supply. 016090
(2) Lubricating Oil System
Lube Oil Filter
Lube Oil Cooler ---+---1
Oil Gallery
Press. Control - -
Valve
Set : 0.44-0.54 Mpa
'- a..
Ol Q) E
E
'-
~ c
·;::: ,_
Ol :J
Cll 0...
<( .s::: Cil c Cil
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Lube Oil Pump u::
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(/)
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Oil Pan
016091-00E
10
1. General
(3) Fuel oil, Exhaust gas & Air System
-0 -0
J2 ;g
·c: c
Cll Cll
2 2
To Each Valve en Q)
* l.D.5 Rubber Hose Cll

C)
-"'
J!l
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* O.D.6 Fuel Injection Pump
><
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Drain Pipe
Detail"A" Detail"B"
* l.D.15 Rubber Hose
*1.0.15 Rubber Hose Q)

Q_
i:L
3:
0
u::
a:; <J.)
LO > D..
"'""--: 0 0::
ci §l 1i5
~ Detail"D"
*Waler Separator * LL <J.)
(Hull Fitting) C>

LO U""'
"'
ci- -"'
c
0 ~
Fuel Oil System
* u
Exhaust Gas & Air System
20
Model: 6AYM-ETE Model: 6AYM-STE

Detail "C" Detail "C"
Remarks:
1. Pipes & Devices marked * in this drawing are not included in our factory's standard scope of supply.
2. A water separator for fuel oil to be provided in engine inlet line. (between F.O. service tank and engine.)
016092-0lE
11
1. General
1.6 Fuel oil, lubricating oil and cooling water

1.6.1 Fuel oil
The properties of fuel oil applicable to this engine are shown in the following table.
The properties of fuel oil are uncertain and broadly ranged; thus they affect such factors as a smooth run of
the engine, maintenance interval and service life of parts. Consequently, it might be necessary to change the
specifications of engine or add attachment in accordance with the applied fuel oil.
Quantity Criteria of Fuel Oil

Direct burning fuel oil
Quality Criteria
Viscosity at 323K (50 QC ) mm 2/s 3-8
Specific gravity at 288/277K (15/4 QC) <0.86
Flash point K (QC) >333 (> 60)
Residual carbon mass.% <0.7
Sulfur content mass.% <1.0
Property critical Ash content mass.% <0.03
value Moisture content vol.% <0.1
Vanadium ppm -
Sodium ppm -
Aluminum ppm -
Diesel index (Cetane no. o >45)
ASTEM D975 2D
Quality criteria equivalent fuel oil BSl-2869 Class A
JIS (K2205-1-1)
The fuel injection system consists of precision parts and for that reason, do not use fuel oil to which
water and dust are mixed in. If such fuel oil is used, it causes a trouble. Consequently, pay attention to
the following in supply of fuel oil. Besides, as for daily maintenance, carry out draining and maintenance
servicing of fuel oil filter mentioned in Chapter 7.
In time of fuel supply

1) When supplying fuel oil stored in a drum, stand the drum still for longer than one whole day to settle the
impurity, and supply supernatant liquid of the drum to this engine.
2) In the case of supplying fuel oil from a storage tank to the service tank, supply such fuel oil after more than
one whole day elapsed from when fuel oil is supplied to the storage tank.
1.6.2 Lubricating oil

(1) Selection of lubricating oil is very important for a diesel engine. If improper lubricating oil is used or change
of lubricating oil is neglected, it causes sticking of piston rings, seizure or early wear of pistons and cylinder
liners and faster wear of bearings and various other working parts that reduce the durability of the engine.
(2) Choosing the Lub. Oil
Depending on properties of fuel oil and conditions of usage of the engine, lub. oil to be selected varies.
Choose lub. oil API Service Grade CD or CF Class.
12
1. General
1) Specification
Use an oil shown in the below table.
Frash point Kinematic Viscosity (cSt)
Viscosity Specific Pour Point Viscosity
Application QC
(SAE) Gravity (QC) 40QC 100 QC Index
(Open Type)
Marine Propul- 40 0.893 >240 <- 7.5 140-155 14-15.5 96-110

sion engine 15W-40 0.88 >230 <- 30 >100 14-15.5 >140
2) Total Base Number (T.B.N.)
Select a lub. oil based on the values given in the following table for the base number against the sulfur con-
tent including in the fuel used.
Total Base
Fuel Oil Used
Number
Sulfur Content
(T.B.N.)
(wt.%)
(mgKOH/g)
<1 9-15
(1) Avoid blended use of different brands.

(In the unavoidable case of blended use of different brands of lub, consult your lub. oil supplier.)
(2) If lub. oil of a high total base number (T.B.N.) is used when using fuel oil of a low sulfur content,additive
(calcium carbonate) of lub. oil sticks to the high-temperature area together with carbon residue and
causes adverse effects as mentioned below: For that reason, use the proper lub. oil.
• Accumulation of the aforementioned deposits on the combustion chamber hinders sliding of piston
rings and may cause scuffing to the rings, cylinder liners, etc. Besides, they may cause bite-in and
blow-bye if intruded into exhaust valves.
(3) List of Lub. Oil Brands

API Service Grade CD or CF/SAE 40 or 15W-40 Equivalent.
Supplier Brands Supplier Brands
EXXMAR 12TP 40
IDEMITSU DAPHNE MARINE OIL SX40 EXXON
MOBIL GARD 412
KOSAN APOROIL CASTAM WAID 15W-40 MOBIL
DELBACK SUPER 15W-40
MARINE D-154N
CASTROL MHP 40 JAPAN
CASTROL DISOLA M4015
SEAMAX EXTRA 40 ENERGY/ELF
DELSTAR FX 15W-40
MARINE F 15W-40
COSMO MARINE SUPER 40 NIPPON OIL
COSMO OIL MARINE T104
COSMO MARINE SUPER MULTI X15W-40 CORPORATION
DIESEL S-3 15W-40
CHEVRON TAR0-16 XD 40
GADINIA OIL 40
Texaco URSA SUPER PLUS 15W-40 SHELL
RIMULA X 15W-40
(FAMM, Caltex) DELO 1000 MARINE OIL 40
FUKKOL MARINE 412 KYGNUS MARINE DX40
FUJI KOSAN KYGNUS
FUKKOL SUPER MARINES 15W-40 PARN TYPE RV 15W-40
YANMAR MARINE SUPER OIL 40
BRITISH
BP ENERGOL DS3-154 YAN MAR YANMAR HAIPA ROYAL
PETROLEUM
OIL15W-40
13
1. General
1.6.3 Cooling Water (Engine Jacket Water)

(1) Criteria on Cooling Fresh Water
1)Use pure water (distilled water) or tap water.
2)Use the water having the properties shown in the following table.
Recommended Water Quality

pH 298K (25 QC ) 6.5 - 8.0
Do not use hard water.
Total hardness (CaC03 ) <100 ppm If hard water is used, scale adheres to
Chlorine ion (Ci-) concentration <100 ppm water chambers such as cylinder head and
cylinder water jackets and may cause an
M alkalinity 30 - 100 ppm
overheat. Pay your particular attention to
Ammonium ion (NH 4+) cone. <0.05 ppm this regard.
Sulfate ion (So 4- -) concentration <100 ppm
Evaporated residue <400 ppm
(2) Selection of and Control on Corrosion Inhibitor

1)Add a corrosion inhibitor to cooling fresh water because use of fresh water causes a drop in strength of
parts and the cooling effect through corrosion of water chamber and adhering of scale.
2)Select a corrosion inhibitor which does not have an adverse effect on parts of the cooling water system
because parts made of cast iron, aluminum alloy carbon steel, brass and bronze, are used in the cooling
water system of an engine.
Use of antifreeze
In cold regions where cooling water freezes, be sure to add YAN MAR Antifreeze to fresh water cooling
systems.
Method of use:
YAN MAR ANTIFREEZE AGENT
Minimum atmospheric -5 QC -10 QC -15 QC -20 QC -25 QC
temperature
Percentage of antifreeze to
15% 25% 30% 35% 40%
fresh water
• Aluminum materials are used in the cooling water system, consult the supplier of corrosion inhibitor
because a kind of corrosion inhibitor to be used differs in this case.
• As to the adding quantity of and concentration control on corrosion inhibitor and addition and handling
of supplementary adjuster, obey the criteria set by the supplier of corrosion inhibitor.
• In the case where the concentration of corrosion inhibitor could not be controlled, annually change the
cooling water by the total volume.
14
1. General
• Do not dump cooling water to which the corrosion inhibitor was added directly to the ocean or river.
Since the method of treating the waste liquor has been provided for in the law, such liquid has to be
treated according to instructions given by the supplier of corrosion inhibitor.
• Do not mix different brands of corrosion inhibitor. (In the case where mixing of different brands of
corrosion inhibitor is unavoidable, consult the suppliers of corrosion inhibitor.
• A corrosion inhibitor is chemical for industrial water treatment use; do not use it in the drinking water line.
• When handling, wear rubber gloves and gauze mask to avoid direct contact with hands or other parts
of the body.
• If the chemical accidentally comes in contact with skin, eyes or mouth, wash out thoroughly with fresh
water. If the problem persists, consult a doctor.
Recommended brands of corrosion inhibitor
Brands of corrosion inhibitor applicable to the enclosed circuit specification of the cooling water system
are shown in the following table.
Brand Supplier
Kurilex L-501 Kurita Water INdustries Ltd.
Olgard C-601 Organo Co., Ltd.
Nalfleet 9-111 NALCO JAPAN Co., Ltd
Royal Freeze Yanmar Sangyo Co., Ltd.
• In the case where the cooling water system is of the enclosed circuit specification, consult the supplier
of corrosion inhibitor because some brands drop in the concentration of corrosion inhibitor early.
• Notice a corrosion inhibitor which doubles as an anti-freeze has a low thermal conductivity and may be
overheated during a load running.
• As a simplified method of cooling water concentration control, it is suggested to replace the cooling
water (added with rust inhibitor) in total volume with the new one periodically.
15
1. General
16
2. Disassembly and reassembly

2.1 Disassembly and reassembly precautions
(1) Disassembly
1) Prepare the disassembly tools, measuring instruments and recording sheets.
2) Prepare the cleaning machines and cleaning vessel.
3) Provide a space and containers for disassembled parts.
4) Drain the cooling water and lube oil completely out of the engine.
5) Put the disassembled parts in order.
6) The material and dimensions of bolts and nuts differ from each other. To prevent use of wrong bolts or
nuts, put them temporarily in their original position immediately after removal.
7) If trouble is located, first determine the cause of the trouble to prevent removal or disassembly of parts
unrelated to the trouble.
(2) Reassembly
1) Wash and check the parts to be assembled with due care.
2) Apply new engine oil or the specified lubricant to sliding parts and moving parts before assembly.
3) Replace gasket packing, 0-rings, copper packing and other packing with new ones.
4) Use liquid packing, if necessary, to prevent water and oil leakage.
5) Fit each part while checking oil clearance and thrust clearance.
6) Align all marked parts carefully during assembly. When fitting replacement parts, pay attention to their
combination.
7) Do not confuse the bolts, nuts and washers, and tighten the major nuts and bolts to the specified torque.
Take special care not to damage when tightening parts made of aluminum alloy.
8) Apply engine oil to the threads and bearing surfaces of major bolts and tighten them to the specified
tightening torque.
Note:
Use a spanner wrench during disassembly and a torque wrench during assembly.
17
2.2 Disassembly and reassembly tools

The following tools are required when disassembling and reassembling the engine.
Please use them as instructed.
2.2.1 General hand tools

Name of tool Name of tool
Illustration Illustration
code No. code No.
Turning Bar
'.;~o Size (mm)
L: 500
Screw Driver,
Reversible
126410-92720 D: 18
104200-92350
L T: 17
015271-00X
Oil Feeder
28210-000140 Double Ended
Spanner
7 x 8 28110-070080
10 x 13 28110-100130
12 x 14 28110-120140
17 x 19 28110-170190
Tool Box ~ 22 x 24 28110-220240

27 x 30 28110-270300
01527?-00X
Offset Wrench Monkey Wrench

17 x 19 28160-170190 28120-002000
~
Thickness Gauge
Nipper
0.3mm 28312-300750
0.5mm 28312-500750 127610-92760
001414- oox 001?92-00X
Piston ring puller

135410-92140
Cylinder head bolt

oox
clamping tool
001411-
1 - - - - - - - - - - 1 - - - - - - - - - - - - - - i GAUGE. angle
148620-92400
10
I I
.........j :l--
Piston eyebolt
144626-92160 \ M6x1. 0
1----100---"'.,-
016959--00X
Starling Pillar (Shaft type) Starling Pillar (Hole type)

28190-000020 28190-000130
000977-QQX
18
2.2.2 Special hand tools

Connecting rod small end bushing insertion/extraction tool
Dimensions
Material
A B c D E F
-0·2
067 -0.5 052-0.4 5
-0.48 62 100 20 10.8° S45C
Intake and exhaust valve guide insertion tool
lnsenlion tool c
D
008184--00X
Valve guide
Dimensions
Material
A B c D
0·1
030--0.5 015+o. 2 20 ± 0.3 120 S45C
+0.1
Lube oil filter case remover
Fuel injection nozzle extraction tool
013243-00X
19
stem seal insertion tool (for inserting stem seal)
x y
w
c 0.5
G
F H
B
A
J
014283-00X
A B c D E F G H I J K L M N 0
80 56 10 14 3 2 012h7 ci.018) M8 011-0.04 165 60 105 27 15 23 ± 0.1
-0.06
p Q R s T u v w x y
11 034 023 019.6 ± 0.2 017.2±0.1 012H7(+g· 018 ) 025 23 20 1.5
Nozzle sleeve tightening tool
Socket 48-24
R1
D
B c
A
A B c D E F G H I J K L M Material
100 (41) 59 30 10 (028) (033) 031.5 045.5 8.5 9.5 7.8 012.7 S45C
Valve spring suppress tool
20
Cylinder liner extracting tools
Liner puller (Upper)
Cylinder block
(Upper)
Cylinder liner
Liner puller (Lower)
Piston inserting tool
Piston hoist bolt lt-

~~~~
D
A
Part No.144626-92160
A B c
100 40 10
Piston inserting tool ~ ~

1~:· -~1
c
B
A
013239-00X
Part No.148660-92140
A B c
0190.0 0178+0063 0155.0+0()63
21
Camshaft gear extraction tool
A B c D E F G H I J K L M N
M16
145 25 120 60 15 3 045-0.03
-0.06 30 70 020 010 M20 x 1.5 41 Depth
95/105
C2 C2
014286- oox F G
D
B
A
014285 -oox
A B c D E F G H
145.5 125.5 20 3 10 070 045 +o. 3 021
+0.1
Flywheel insertion I extraction tool
ri
009291-00X
A B
020 M20
22
Camshaft insertion tool
w
m
0
ffi
A-A
LI
'
e
b c d
a
a b c d e f g h i j k I m n 0 p
500 80 300 200 150 50 10 19 70 30 48 9 x 40 =360 92 20 50 060
q r s t u v w
069.5_g 1 070 -0.11
-0,08 65 028 +0,05
+0,02 68 010 6 x 10 - 020
Impeller extraction tool
·--..- -5---·
-----------------------------/_L----------------
--
.
f'. »
Part No.133688-92100
A B c D E F
014519
45 12 25 M6 M10 65
Crankshaft oil seal insertion tool
23
2.2.3 Measuring instruments

(1) Application of tools
Instrument Name
No. Description Illustration
(Yanmar code No.)
1 div.···0.01mm To measure bending and

Range
Dial gauge gap of the shaft, surface
0-5mm
distortion, etc.
0-10mm
1 div.···0.01mm To measure positions too

2 Test indicator Range narrow and too deep for
0-0.8mm normal dial indicators.
0014 30-00X
Main bar Sub bar To attach dial

(dia. x length) (dia. x length) indicators to various posi-
3 Magnet stand
12 x 176 10 x 165 tions for easy accurate
14 x 183 12 x 165 viewing
001431-00X
Range (mm)
To measure the O.D. of the
0-25 75-100
4 Micrometer crankshaft, piston, piston
25-50 100-125
pin, 'etc.
50-75 125-150 001432-00X
Range (mm)
~~
To measure the l.D. of the
10-18 50-100
5 Cylinder gauge cylinder liners and bear-
18-35 100-150 ' Z1>
in gs.
35-60 001433-00X
~
1 div.· ··0.05mm To measure outside diam-
6 Vernier calipers Range eter, depth, thickness, !:=
0-150mm width, etc. ~ i
001434--00X
Range (mm) To measure valve sinkage

7 Depth micrometer
0-25mm and liner projection
001435-00X
To measure the inclination

Size of valve springs and
8 Square
100 (mm) squareness of various
parts.
Size Use when measuring the

9 V-block
100 x 50 x 55(mm) bending of a shaft.
24
Instrument Name
No. Description Illustration
(Yanmar code No.)
Use when tightening bolts
Size Range and nuts with specified
(mm) N•m {kgf•m} torques
6-14 3.0-7.8 {31-80}
17, 19,21 3.0-15.7 {31-160} 001005-00X
10 Torque wrench
~-- (Mii)
Range N•m {kgf•cm} 000995-00X
3.9-11.8 {40 - 120} 39.2 -176.4 {400-1,800}

9.8-44.1 {100 - 450} 39.2 -274 {400- 2,800}
To measure oil clearance

between piston rings and
11 Thickness gauge Length 75 x 9 sheets piston grooves or between
shaft couplings during
installation.
001426-00X
To inspect antifreeze solu-

Battery electrolyte
Model tion and electrolyte for
12 tester UFB-N 2 specific gravity, and charg-
(95500-000013)
ing condition.
Pressure gauge:
Nozzle tester
MPa {kgf/cm 2} To inspect spray condition
(737600-93401)
13 0-49 {0-500} and the injection pressure
High pressure pipe
Injection-valve side nut of the fuel injection valve
( 130605-93400)
M16 x 1.5 pusher fitting
14
Deflection gauge
(42221 -000011)
To measure deflection of
crankshaft with crankshaf-
tend. @) 007356-0lX
Penetrant (0.45.e)
Penetrate test
(973100-00FPS)
(for flaw detection)
Developer (0.45£) To be used in detecting
15 Set product
(973100-00FDS) flaws and cracks.
(6 bottles)
Cleaning agent (0.45£)
(973100-FPRDO)
(973100-00FRQ)
000996-00X
25
2.2.4 Other material

Items Usual Contents Features and application
Three Bond Non-drying liquid gasket; solvent less type, easy to remove,
200g
No.1 superior in seawater resistance, applicable to various mating
(1kg also available)
TB1101 surfaces.
Three Bond Non-drying liquid gasket; easy to apply, superior in water resis-
200g
No.2 tance and oil resistance, especially superior in gasoline resis-
TB1102 tance.
Three Bond
Drying film. low viscosity and forming of thin film, appropriate
No.3 150g
for mating surface of precision parts.
Liquid TB1103
gasket Three Bond Semi-drying viscoelastic material, applicable to non-flat surface
200g
No.4 having many indentations and protrusions, superior in heat
TB1104 resistance, water resistance, and oil resistance.
Three Bond
Solvent less type silicone-base sealant, applicable to high tern-
No.10 100g
perature areas (-50 QC to 250 QC )
TB1211
Three Bond
100g Silicone-base, non fluid type, thick application possible.
TB1212
Lock tight Prevention of loose bolts, gas leakage, and corrosion. Torque
200g
TB1401 required to loosen bolt: 10 to 20% larger than tightening torque.
Adhesive Lock tight
SUPER 50g Excellent adhesive strength locks bolt semi-permanently.
TB1330B
Sealing material for threaded parts of various pipes.
Seal Tape 5m round tape
Ambient temperature range: -150 QC to 200 QC
01.92-m dia.:1
02.42-m dia.:1
0-ring of any size can be prepared, whenever required.
0-ring kit 03.12-m dia.:1
(Including adhesive, release agent, cutter, and jig)
03.52-m dia.:1
05.72-m dia.:1
Brand name
(LOWCOL 50g
EP PASTE) For assembly of engine cylinders, pistons, metals, shafts, etc.
lubricant Spray type facilitates application work.
(molybde- Brand name
330g
num (PASTE SPRAY)
di sulfate)
Brand name Prevention of seizure of threaded parts at high temperature.
50g
(MOLYPASTE) Applicable to intake and exhaust valves. (stem, guide, face)
26
Items Usual Contents Features and application

Add antifreeze to fresh water system in cold areas to operate
Anti freeze 2£
engine.
·The cleaning agent removes even carbon adhering to disassem-
bled parts.
Cleaning agent 1 kg x 20
• If a cleaning machine is used, prepare 4 to 6 %mixture of 60 to
80 °C to ensure more effective cleaning.
4£ x 4
Cleaning agent 18£ x 1 Special cleaning agent that requires no water, specially designed
for turbocharger for blower of turbocharger and intercooler.
15 sets : 1,
500cc x 6
It is recommended that the liquid gasket of Three Bond TB1212 should be used for service work.
Before providing service, observe the cautions bellow:
1. Build up each gasket equally.
2. For bolt hole, apply liquid gasket to the inside surface of hole.
3. Conventionally, Three Bond TB1104 (gray) ore Three Bond TB1102 (yellow) is used for paper packing
through the use of only these bonds is not effective.
If convert packing are used, do not use a liquid packing.
27
2.3 Disassembly procedures

Cylinder Block
(1) Drain cooling water
1) Fresh water :
Drain through four cocks located on.
CD Cylinder block
~ Fresh water pump.
@Exhaust manifold (tow cocks).
013819-00X
Fresh Water Pump
/
i
I /~"'(\·
,\
)_
01
Exhaust Manifold
oox
28
2) Sea water Sea Water Pump

CD Drainby removing sea water pump side cove.
000726-01X
(2) Drain lube oil Gear Pump
Put vinyl tube into oil drain hole of the oil pan, and
use draining pump to drain the lube oil.
014359- OOE
(3) Drain fuel oil Fuel Filter

1) Loosen drain plug of fuel filter and fuel water
separator.
2) Loosening round pipe joint accelerates the
draining.
Fuel Water Separator
29
(4) Removing electrical wiring

Remove the wiring from the engine.
• Starter motor • Alternator
• Switch • Sensor
·Others
• C.F.W. Temp. Switch for Alarm (1).

• C.F.W. Temp. Sender (2).
• L.O. Press. Switch for Alarm (4).
• C.W. Level Sensor (3).
• Oil Filter Bypass Valve Switch (7).
• L.O. Temp. Switch for Alarm (5). 013132-0lX
• L.O. Temp. Sender (6).
30
(5) Removing the filter and fuel pipe

1) Remove the fuel pipes (1) (fuel filter - feed pump,
fuel filter - fuel pump and fuel nozzle - fuel filter).
2) Remove the fuel filter assy (2) together with
mount (3) from the engine.
(6) Removing the starting motor

Remove the starting motor (1) from the flywheel
housing.
(7) Removing the breather

1) Remove the rubber hose (2) and remove the
breather pipe (3).
2) Remove the breather (1).
Ol2736-00X
31
(8) Removing the intake manifold

1) Remove the boost compensator inlet rubber hose
(1 ).
2) Remove the boost sensor (2).
3) Remove the intake manifold (3).
(9) Removing the fuel injection pipe

1) Remove the fuel injection pipe support.
2) Loosen the cap nuts on both ends of the fuel
injection pipe and remove the fuel injection pipe.
011440- oox
32
(1 O)Removing the air duct

1) Remove the air duct cover (1) (2).
2) Remove the air duct (turbocharger - intake
manifold).
3) Remove the expansion joint (3).
013159-0lX
( 11 )Removing the turbocharger

1) Remove the cylinder block side expansion pipe
for the turbine lube oil return pipe (1) from the
cylinder block.
2) Remove the turbine lube oil pipe (1) (turbine
inlet).
3) Remove the exhaust bend (3) and support (4).
4) Remove the turbocharger (2).
33
(12)Removing the cooling water pipe

(fresh water)
1) Remove the fresh water pipe (exhaust manifold -
fresh water cooler (1), cylinder head - exhaust
manifold (2)).
2) Remove the fresh water pipe (3) and support (4).
(intake manifold side)
013221-01.X
013222-00X
34
(13)Removing the exhaust manifold

1) Remove the exhaust manifold support (1).
2) Remove the exhaust manifold (2).
(14)Removing the fresh water pump

1) Remove the bolts of cooling water pipe and the
rubber hose (fresh water pump - lube oil cooler).
2) Remove the fresh water pump (1).
012729-00X
(15)Removing the lube oil by-pass filter

1) Remove the by-pass filter (1).
01 ?226-00X
35
(16)Removing the lube oil cooler and lube

oil filter
1) Remove the lube oil filter (1).
2) Remove the cooling water pipe (lube oil cooler -
fresh water cooler).
3) Remove the lube oil cooler (2).
Ol3224-00X
(17)Removing the oil pressure control valve

1) Remove the oil pressure control valve (1).
014035--00X
36
(18)Removing the alternator

1) Remove the V-belt cover (5).
2) Loosen the alternator adjuster bar (3) and
remove the V-belt (4).
3) Remove the alternator (2).
4) Remove the alternator driving unit (1).
012732-00X
(2)
(3)
(4)
oox
37
(19)Removing the fresh water pump and

alternator driving case
1) Remove the lube oil pipe (1 ).
2) Remove the driving case cover (2).
3) Remove the fresh water pump driving gear (3).
4) Remove the case (4).
013227-00X
oox
(20)Removing the fresh water cooler

1) Remove the fresh water cooler (tank) (1).
2) Remove the fresh water cooler mount (2).
(21 )Removing the seawater pump

1) Remove the bend (1) (inlet outlet).
2) Remove the seawater pump (2).
38
(22)Removing the air cooler

1) Remove the support (1).
2) Remove the air cooler (2).
(2)
(1)J<l
01323l-OOX
(23)Removing the fuel injection pipe

1) Remove the fuel return pipe (1).
(Cylinder head outside)
011439- oox
39
(24)Removing the suction/exhaust valve

rocker arm ass'y, and push rod.
1) Remove the bolts for the rocker arm shaft
support. and remove the rocker arm support (1).
2) Remove the valve bridge (2).
3) Pull out the push rods (3).
• Identify the components by cylinder Nos. and
suction/exhaust.
4) Remove the fuel injection pipe (4).
5) Pull out the fuel injection nozzles (5).
• Use fuel injection nozzles special tool.
013232-00X
01?233-00X
(25)Removing the valve rocker arm case

1) Remove the valve rocker case (1).
2) Remove the case packing.
40
(26)Removing the cylinder head

1) Remove the cylinder head bolts (1).
2) Remove the cylinder head (2).
3) Remove the cylinder head gasket.
(27)Removing the fuel injection pump

1) Remove the remote control cable and cable
mount.
2) The matching mark is done to driving joint (1).
3) Remove the fuel pump driving shaft joint coupling
bolts (2).
4) Remove the fuel pump support (3) and then fuel
pump fitting bolts (4).
,...,,-----
Note:
It is good to use the fuel injection pump lifting
up hook (5).
oox
41
(28)Removing the fuel injection pump mount

1) Remove the fuel injection mount (1 ).
2) Remove the shim (2).
(29)Removing the piston and connecting rod

ass'y.
1) Remove the connecting rod bolts and then the
caps.
2) Push up rod and pull out piston rod ass'y (1)
upward
• Identify the components by cylinder Nos.
01 ?247-00X
(30)Removing the cylinder liners.

Pull out liners (1) using cylinder liner special tool.
• Identify the components by cylinder Nos.
42
(31 )Removing the tappets

Take out tappets (1).
• Identify the components by cylinder Nos. and
suction/exhaust.
(32)Removing the flywheel

1) Remove the angle label (1).
2) Loosen the flywheel bolts and remove the
flywheel (2).
• For safer and easier works, use of flywheel lifting
plate is recommended.
Note:
Be careful not to scratch the ring gear.
3) Remove the oil seal case (3).
(33)Removing the viscous damper

1) Remove the viscous damper (1).
012734-00X
43
(34)Removing the viscous damper cover

1) Remove the oil seal case.
• Use installation bolt by putting it into the pull-out
hole.
2) Loosen the viscous damper cover bolts, and
remove the viscous damper cover (1).
• Use pull-out hole.
0132SO-OOX
013251- oox
(35)Removing the engine foot

1) Remove the mounting foot (1).
44
(36)Removing the flywheel housing

1) Remove the flywheel housing (1).
(37)Removing the driving gears

1) Flatten the bend washers, remove nuts, pull out
fuel injection pump driving gears (1) and then
remove the driving unit (4).
2) Flatten the bend washers, remove nuts, and then
pull out the cam gears (2) using cam gear special
tool.
3) Remove the idle gear (3) and mount.
(4)
45
(38)Removing the gear case

1) Remove the gear case (1).
(1)
(39)Removing the idle gear mount

1) Remove the idle gear mount (1).
(1)
(40)Removing the oil pan

1) Remove the oil pan (1) by suing oil out holes.
Note:
Tighten the pull out bolts evenly.
46
(41 )Removing the lube oil pump

1) Remove the lube oil suction pipe (1).
2) Remove the lube oil pump (2).
013255-00X
(42)Removing the camshaft

1) Remove the camshaft thrust metal.
2) Pull out camshaft (1).
Note:
Check that tappets have been removed.
013256- oox
47
(43)Removing the crankshaft

1) Loosen the main bearing cap side bolts and
remove the main bearing cap side bolts (1).
2) Loosen the main bearing bolts and remove the
main bearing bolts (2).
3) Remove the main bearing cap (3) and lower main
bearing metal.
Note:
The thrust metal (lower) is mounted to the base
main bearing cap.
4) Lift up crankshaft to remove.
Note:
•The thrust metal (upper) is mounted to the
standard main bearing.
•Remove the main bearing metal (upper) from
the cylinder block.
Note:
Identify metal caps and main metal by cylinder
Nos. Identify upper and lower parts of main
metals.
011176- oox
(44)Removing the piston cooling nozzle (1)
011402-00X
48
2.4 Reassembly
• Clean all parts
Clean all parts using by the cloth and diesel oil (or
cleaning agent) before reassembly.
Note:
1. If the dust remain with the parts, engine may
cause the seizing or damage.
2. The cleaning agent removes even carbon
adhering to disassembled parts.
(1) Cylinder block

1) Completely clean each oil hole. After cleaning,
check that no scaling remains on cylinder block.
2) Attach cylinder block blind plug.
3) Fit the cover (1) to cylinder block.
(1)
(2) Turning cylinder block upside down
Place a wood block on the floor and put the cylinder
block upside down (with the cylinder head mounting
surface facing down).
Weight of cylinder block : 400 kg
(3) Fitting piston cooling nozzle

Fit each piston cooling nozzle (1). Check that nozzle
end is positioned on piston head side. Also check
that nozzle does not touch cylinder block. Tighten
the nozzle to the specified torque.
N•m (kgf•m)
Tightening torque :
49-59 (5-6)
Pipe joint bolts M16 6 pcs.
Note:
1. Make sure that there is no dust in the nozzle 011402-00X
oil holes and nozzle fitting holes.
49
(4) Fitting camshaft bearing

(1) Pull off the camshaft bushing as follows :
1) Place a metal plate on the bushing and hit it
lightly with a copper hammer until the bushing is
removed.
2) Thoroughly wash the bushing holes of the
cylinder block.
(2) Insert the camshaft bushing as follows :
1)Apply engine oil to the bushing holes in the Joint (Clinch)
cylinder block side and around the bushing
circumference. Press-fit the bushing.
~~~
2) Match the oil holes so that the joint of the
+I
metals are directed upward. L()
iN 4
3)After press-fitting the bushing, measure its
inner diameter to check for distortion. 60°
Detail of oil groove
(mm) 011404-00E
Inner dia. of bush 70 +0.070

after press-fitting +0.020
(5) Camshaft
1) Apply lube oil to bearing of camshaft and then fit
camshaft (1).
2) Fit thrust plate, and secure it by tightening 2 bolts
of M12 x 30mm.
N•m (kgf•m)
Thrust plate tightening torque :
75±5 (7.5±0.5)
Bolt M12 x 30 2 pcs.
Note:
Camshaft metal has two types : 011405-00X
Flywheel side and

front side metal : Width 35 mm, 2 pcs
Other metals : Width 30 mm, 5 pcs
50
(6) Idle gear mount

1) Mount the idle gear bracket (1).
(1)
(Mount it so that the rup J mark comes to the
upper side)
N•m (kgf•m)
Tightening torque : 118±10

M14 x 30 4 pcs. (12 ± 1.0)
011406 -oox
2) Attach cylinder block blind plug (2).

(Flywheel side)
3) Attach cylinder block bend plug (3).
(Front side)
Make sure that there is no dust or foreign matter
inside the main gallery.
011407-00X
(7) Mounting the crankshaft

1) Apply engine oil to each crank journal hole of
cylinder block and each block side main bearing (1 ).
Bearings having an oil groove should be
positioned on upper side (block side).
Fit thrust metal (4) so that oil grooves are
respectively positioned outside.
2) Apply engine oil to each crank pin and crank
journal (2) and fit each journal to main bearing.
3) Fix the bearing side bolt (5).
4) Check that the matching numbers shown on the
bearing cap (3) and cylinder block match.
"AY" embossed on the bearing cap should face
the anti-flywheel before tightening it to the 008173-00X
specified torque.
5) Method of tightening main bearing refer of page
267 and 268.
6) Check that the crankshaft rotates smoothly.
51
7) Measure the side clearance of the crankshaft.
(mm)
Side clearance 0.08-0.229
Oil clearance of crankshaft : (mm)
Crank pin outside dia. 106 -0.04

-0.06
Oil clearance 0.050-0.120
Crank journal outside dia. 134 -0.045

-0.070
Oil clearance 0.045-0.135
Balance weight
Main bearing metal

(intermdeiate)
/~~
((
Thrust metal
(basic side) Main bearing
metal (basic)
014975-00E
52
(8) Lube oil pump

1) Fit the lube oil pump (1).
2) Tighten the bolts for the lube oil pump (1) to the
specified torque.
N•m (kgf•m)
Lube oil pump tightening torque : 45 ± 5
Bolt M10 x 30 4 pcs. (4.5 ± 0.5) (2)
Note:
Three bond 1207 is apply on the cylinder block
lube oil inlet flange face.
3) Check the backlash.
011409- oox
(mm)
I Lube oil pump driving gear 0.15-0.25
(9) Lube oil suction pipe

1) Mount the lube oil suction pipe (1).
N•m (kgf•m)
Lube oil suction pipe
45 ± 5
tightening torque :
(4.5 ± 0.5)
Oll410-00X
( 1O)Gear case
1) Apply Three Bond (TB1212) to the fitting surfaces
of the gear case. (1)
2) Mount the gear case (1) along the dowel pin.
N•m (kgf•m)
Gear case tightening torque : 75 ± 5
Bolt M12 x 30 12 pcs. (7.5 ± 0.5)
53
(11 )Flywheel housing

1) Fit flywheel housing (1) while adjusting position of
2 parallel pms.
Secure housing by tightening bolts listed below :
N•m (kgf•m)
Flywheel housing
tightening torque :
Bolt M10 x 40 21 pcs. 45 ± 5
M10 x 75 4 pcs. (4.5 ± 0.5)
75 ± 5
M12 x 160 1 pcs.
(7.5 ± 0.5)
2) After assembling the flywheel housing to the

cylinder block, measure the following points :
(mm)
Dial gauge
Play at clutch mounting part : A
0.25 or less
Play at surface : B
0.25 or less
Play at oil seal case mounting part : c
0.25 or less
Magnet base 007498-00E
(12)0il seal (Flywheel housing)

1) Fit the oil seal case.
Oil seal case set bolts : M8 x 25 mm, 1 O bolts
2) Item of importance for reassembling the
crankshaft oil seal.
1. Press-fit the lip and sringar to the crankshaft with a
special insertion tool the reassembly of the oil
seal.
2. The insertion tool must 0.5 mm lip side project
from the sringar side.
3. When the oil seal is reassembly, you may 016499-00X
spread the lube oil between the crankshaft and

sringar.
54
(13)0il pan
1) Temporally fit the oil pan (1) to the gear case side
to check the fitting condition.
2) Apply Three Bond (TB1207) to the three fitting
surfaces at the flywheel housing side.
3) After the three surfaces are fitted in place, tighten
the bolts to the specified torque.
N•m (kgf•m)
Oil pan tightening torque : 45 ± 5
Bolt M10 x 30 34 pcs. (4.5 ± 0.5)
( 14)Mount the engine foot

Fit engine foot (1) white adjusting position of 2
parallel pin.
N•m (kgf•m)
Tightening torque :
200 ± 15
(20 ± 1.5)
M16 x 80 8 pcs.
(15)Turn cylinder block upside down

The cylinder block is reversed, and it fixes to the
stand (1).
55
(16)Flywheel
1) Apply engine oil to the threads and contact
surfaces. Use two guide rods (2) (tool) to install
the component.
2) Mount the flywheel (1) along with the knock pin.
3) Tighten the setbolts to the specified torque.
N•m (kgf•m)
Flywheel tightening torque : 481 ± 15
Bolt M20 12 pcs. (49 ± 1.5)
4) Fit the top indication plate.

Bolt M6 x 12 2 pcs.
5) Fit the turning view hole cover.
Bolt M8 x 12 2 pcs.
(17)Cover (Front drive)

1) Apply Three Bond (TB1212) to the three fitting
surfaces of the oil pan (2) and cylinder block (3).
2) Mount the cover (1) along the dowel pin.
N•m (kgf•m)
Gear case tightening torque :
45 ± 5
(4.5 ± 0.5)
Nut M10 1 pcs.
3) After assembling the cover to the cylinder block,

measure the following points.
Center offset of fitting parts : 0.25 or less

Flange surface offset : 0.25 or less
(4)
4) Item of importance for reassembling the
crankshaft oil seal.
1. Press-fit the lip and sringar to the crankshaft with a
special insertion tool the reassembly of the oil
seal. 011424-00X
2. The insertion tool must 0.5 mm lip side project

from the sringar side.
3. When the oil seal is reassembly, you may
spread the lube oil between the crankshaft
and sringar.
56
(18)1dle gear
1) Mount the idle gear (1).
2) Apply engine oil to the bolt threads and contact
surfaces.
N•m (kgf•m)
Idle gear tightening torque : 196 ± 20

Bolt M18 x 30 1 pcs. (20 ± 2)
3) Once the end nut is tightened, be sure to bend

the tongued washer.
4) Fit the idle gear and the crank gear, carefully
matching their marks.
5) Check the backlash of each gear.
(mm)
I Backlash 0.15-0.25
6) Check the side clearance.
(mm)
I Side clearance 0.2-0.4
(19)Cam gear
1) Tighten the cam gear (1) assembly and the bolt to
the specified torque.
2) Make sure the gears aligning mark.
3) Apply engine oil to the bolt thread and contact
surface.
N•m (kgf•m)
Cam gear tightening torque : 294 ± 20

Bolt M20 x 40 1 pcs. (30 ± 2)

the tongued washer.
5) Check the camshaft side clearance.
(mm)
I Side clearance 0.1-0.35
57
(20)Fuel injection pump driving unit

1) Mount the fuel pump driving unit (1) on the gear
case.
N•m (kgf•m)
Fuel pump driving shaft sup-
75 ± 5
port tightening torque :
(7.5 ± 0.5)
(1)
011414- oox
(21 )Fuel injection pump driving gear

1) Mount the fuel injection pump driving gear (2).
2) Tighten the gear fitting plate (1) to the specified
torque.
N•m (kgf•m)
Plate tightening torque : 23 ± 2
M8 x 16 2 pcs. (2.3 ± 0.2)
Note:
Apply Three Bond (TB1401 or TB1324N) to the
bolt threads.
3) Tighten the gear end nut to the specified torque.
4) Apply engine oil to the nut thread, and contact
surface.
N•m (kgf•m)
Idle gear tightening torque : 325 ± 25
Bolt M27 1 pcs. (32.5 ± 2.5)
011415-00X
5) Fit the cam gear and the fuel injection pump

driving gear, carefully matching their marks.
6) Check the backlash with reference to the cam
gear.
(mm)
I Backlash 0.15-0.25

the tongued washer.
58
(22)Cylinder liner
1) Clean the liner fitting grooves in the cylinder
block. (Assemble the 0-rings, taking care not to
distor them).
2) Apply white paint to the 0-rings and press them
in by hand.
Note:
Direct the 11 W 11 mark on the liner's upper
seduce to the control side.
(White paint applied)
01142.S-OOX
3) Check the projection of the liner.
(mm)
I Liner projection 0.03-0.09
59
4) Check and measure the distortion of the liner.

Cylinder gauge
(mm)
Distortion of liner 0.03 or less
----0-ring
----Cylinder liner
007774-00E
5) Cylinder liner identification marks and range of

dimension.
(mm)
Identification
Range of dimension Limit
mark ----- Direction of
crankshaft center
L 155.020-155.030
ML 155.015-155.020 * 155.40
Deflection
MS 155.010-155.015 wear of 0.2
s 155.000-155.010 ~' Piston of too rina .J
Note:
An inside diameter identification mark is
stamped on the liner's upper surface. All the
liners in the engine should preferably have the Center
same identification marks.
* :Indicates the limit at the 1st ring area when
the piston is at T.D.C.
) I
! !
I l About 60mm
' 016500- OOE
60
(23)Piston and connecting rod

1) The piston (1) and the connecting rod (2) should
be assembled so that, when the marking of big
end of the connecting rod faces toward the
worker, suction side on the valve recess on the
upper part of the piston looks rightward and
exhaust side looks leftward. (The recess is
marked with "S" on the suction side and "E" on
the exhaust side.)
2) After assembling the pistons and connecting
rods, insert the pistons into the cylinder liners so
that the "Yanmar" mark of the connecting rods
faces flywheel side. (At this time, the marking
pressed on the connecting rods faces control 011426 -oox
side.)
3) See the piston back of the piston before inserting
the piston and the connecting rod mechanism
and check that the lubricating oil inlet hole is a
cam shaft and the other side (exhaust manifold
side).
4) Mount the connecting rod on the crank pin
(tighten to specified torque as three stage tighten
with PROTEC-grease or PROTEC oil pasted).
Method of Tightening Connecting Rod Nuts

(Tighten the respective nut in three steps)
Tightening torques
N•m (kgf•m)
1st temporary 50 ± 5 (5 ± 0.5)
(Measuring side clearance between
2nd temporary 70 ± 5 (7 ± 0.5) crankshaft and con. rod)
third time 137 ± 5 (14 ± 0.5)
5) Once the rod bolts are duly tightened, check the

large end side clearance.
(mm)
I Side clearance : 0.150-0.324 I
6) Piston identification marks and range of dimension
(mm)
Identification
Range of dimension Limit
mark
L 154.935-154.945
M 154.925-154.935 154.78
s 154.915-154.925
61
7) Applicable combination marks
~
p
L
L
@
ML MS
x
s
x
0
M x @ @ x
s x x 0 @
Combination
@ : Recommended
0 : Acceptable
x : Not acceptable
8) Dimension of piston ring and piston ring groove

(mm)
Standard Wear limit
Groove width 3.630-3.645 3.745

First
Ring width 3.4 70-3.490 3.37
piston
ring Groove and
ring clearance
0.140-0.175 -
Groove width 3.095-3.110 3.21
Second
Ring width 2.970-2.990 2.87
piston
ring Groove and
ring clearance
0.105-0.140 -
Groove width 4.020-4.040 4.14
Oil Ring width 3.970-3.990 3.77

ring
Groove and
ring clearance
0.030-0.070 -
(24)Tappet
Install the suction/Exhaust tappet (1).
(25)Cam cover
Fit the cam cover (1).
N•m (kgf•m)
Cam cover tightening torque : 45 ± 5

Bolt M10 x 22 24 pcs. (4.5 ± 0.5)
62
(26)Cylinder block side cover

Fit the side cover (1 ).
N•m (kgf•m)
Side cover tightening torque : 45 ± 5
Bolt M10 x 22 24 pcs. (4.5 ± 0.5)
(27)Fuel injection pump bracket

1) Mount the fuel injection pump bracket (1) along
the dowel pin.
Adjust shim (3).
(3)~
N•m (kgf•m)
Bracket tightening torque : 1(3)
Stud bolt M16 x 40 2 pcs. 200 ± 15
Nut
M16x160 3 pcs.
M16 5 pcs.
(20 ± 1.5)
~~(3)
2) Mount the fuel injection pump on the fuel pump
bracket.
N•m (kgf•m)
Fuel injection pump
tightening torque : 75 ± 10
Bolt M12 x 115 2 pcs. (7.5 ± 1.0)
M12 x 120 4 pcs.
3) Install the fuel injection pump mounting support (2).
N•m (kgf•m)
Support tightening torque : 75 ± 5
Bolt M12 x 20 4 pcs. (7.5 ± 0.5)
63
4) Centering of fuel pump.

Use the adjusting shim ® for centering the fuel Gauge
pump and driving shaft. Gauge
Thickness of adjusting shim : 0.1, 0.2, 0.3, 0.5 mm.

The margin of error in the coaxiality of the driving
shaft and the pump camshaft should be less than
0.3 mm, and the axial displacement of the
coupling at the pump side and the driving shaft
coupling should be within ± 0.25 mm. Pump installation bed Measuring tool Driving shaft
Note:
1. The driving shaft and pump shaft shall be co-
axial within ± 0.15 mm for peripheral
displacement and ± 0.5 mm for facial
displacement. If not, measure the deflection
and adjust the shim.
2. Place the jig® that is equivalent to the pump
on the installation bed, and then find the
centering with the jig@that is attached to the
driving shaft.
This adjustment is made after securing the
gear case, bearing case, and injection pump
body support properly.
3. When fixing the coupling to the driving shaft, the
axial displacement should be within ± 0.25 mm.
5) Connect the fuel injection pump shaft joint.
(mm)
Deviation of shaft axial
± 0.25 or less
direction
Adjust the fuel injection timing.

(Align the intermediate joint and pointer marker)
N•m (kgf•m)
Shaft joint tightening torque : 98-108
M12 4 pcs. (10-11)
6) Mount and connect the fuel injection pump and

the oiling pipe of the drive oil shaft.
7) Connect the lube oil return pipe.
8) Install the engine stop device.
9) Fit the support of the remote control cable.
64
(28)Cylinder head
1) Clean out the cylinder head bolt holes.
2) Check on the cylinder head surface where it
comes in contact with the block.
3) Coat the head bolt threads with PROTEC oil.
4) Use the positioning pins to line up the head
gasket with the cylinder block.
5) Match up the cylinder head with the head basket
and mount.
6) Tightening of cylinder head bolts.
• Method of tightening cylinder head bolts refer of
page 278 and 279.
Exha~ port
)
0
Suction port
LI\__)
012714-00E
7) Measure the top clearance.
(mm)
I Top clearance 1.56 ± 0.108
007J86 -OOE
(29)Valve rocker arm case

Assemble the valve rocker arm case (1) after
making sure that there is no dust or foreign matter.
N•m (kgf•m)
Bolt M8 x 30 6 pcs.
23 ± 2
M8 x 85 12 pcs.
Tightening (2.3±0.2)
M8 x 105 12 pcs.
torque :
75 ± 5
(7.5±0.5)
011435-00X
65
(30)Valve rocker arm

1) Install the suction/exhaust push rod (1).
2) Install the suction/exhaust valve rocker arm (2).
N•m (kgf•m)
23 ± 2
Suc./exh. (2.3±0.2)
valve
Pipe joint bolt 44 ± 5
rocker arm
M12 x 42 6 pcs. (4.5±0.5)
tightening
torque : 64-84
(6.5-8.5)
011436- oox
0114J7 -oox
(31 )Fuel injection valve

Make sure that there is no dust or foreign matter in
the fuel injection valve mounting hole of the cylinder
head.
1) Install the nozzle packing (2) in the cylinder head.
2) Fit the o-ring (5) on the fuel injection valve (1).
3) Install the fuel injection valve (1).
4) The fuel injection valve (1) is inserted, it fits the fuel
injection valve to the valve rocker arm injection
pipe joint hole, the injection pipe joint (4) is
tightened temporarily, and the fuel injection valve
fitting nut (3) is tightened with the specified torque.
N•m (kgf•m)
Tightening torque :
Nut M14 6 pcs.
N•m (kgf•m)
Injection pipe joint tightening
80 ± 10
torque :
(8 ± 1)
M16 6 pcs.
Note:
1. Be sure to replace the packing (2).
2. Apply silicon oil to the o-ring (5).
66
(32)Fuel oil return pipe

Connect the fuel pipe (1).
011439-00X
(33)Engine lifter
1) Install the lifting fixture (1) for flywheel side.
N•m (kgf•m)
Tightening torque : 200 ± 15
Bolt M16 x 35 4 pcs. (20 ± 1.5)
1) Install the lifting fixture (2) for front side.
N•m (kgf•m)
M16 x 35 3 pcs. (20 ± 1.5)
012711-00X
(34)1ntake manifold
1) Mount the intake manifold (1).
N•m (kgf•m)
Bolt M12x30 24pcs. (7.5 ± 0.5)
2) Fit the automatic drain cock.
67
(35)Fuel oil injection pipe

1) Connect the pipe joints to both ends of the fuel
injection pip (1) with the specified torque.
N•m (kgf•m)
High-press. pipe cap nuts
70 ± 10
tightening torque (Head side):
(7 ± 1)
M25 12 pcs.
N•m (kgf•m)
High-press. pipe cap nuts
60 ± 10
tightening torque (Pump side):
(6 ± 1)
M25 12 pcs. 011440-00X
2) Fix the fuel injection pipe steady-rest on the

intake manifold.
N•m (kgf•m)
Fuel injection pipe steady-
23 ± 2
rest tightening torque :
(2.3 ± 0.2)
(36)Lube oil cooler

Assemble the lube oil cooler (1).
N•m (kgf•m)
Lube oil cooler tightening
torque :
Stud bolt M10 x 40 8 pcs. 45 ± 5
Nut M10 8 pcs. (4.5 ± 0.5)
(37)Lube oil filter

1) Tighten the lube oil filter (2) fully by hand, and
then use a filter wrench to further tighten the filter.
(Turn to the right.)
N•m (kgf•m)
Lube oil filter
tightening torque :
45 ± 5
Stud bolt M10 x 25 3 pcs.
(4.5 ± 0.5)
Nut M10 3 pcs.
012716-00X
68
(38)Lube oil by-pass filter

1) Fit the lube oil by-pass filter (3) on the cylinder
block.
N•m (kgf•m)
Lube oil by-pass filter
tightening torque :
Nut M10 4 pcs. (4.5 ± 0.5)
Ol2717-00X
(39)0il pressure control valve

1) Fit the oil pressure control valve (1).
N•m (kgf•m)
Oil pressure control valve
tightening torque : 45 ± 5
Bolt M10 x 22 2 pcs. (4.5 ± 0.5)
M10 x 50 2 pcs.
012718- oox
(40)Exhaust manifold
Mount the exhaust manifold so that the part to be
fitted with the gasket is positioned as shown in the
figure.
N•m (kgf•m)
Exhaust manifold tightening
75 ± 5
torque :
(7.5 ± 0.5)
Cover tightening torque : 45 ± 5
Bolt M10 x 20 8 pcs. (4.5 ± 0.5)
Bracket tightening torque : 45 ± 5
Bolt M10 x 20 6 pcs. (4.5 ± 0.5)
1) Fit the drain cock.
012719 -oox
69
(41 )Cooling water bend (Cylinder head outlet)

Connect the freshwater bend (1) and tighten the
bolts at cylinder head side and exhaust manifold
side.
N•m (kgf•m)
Tightening torque :
Bolt M10 x 40 6 pcs. 45 ± 5
M10x 50 12 pcs. (4.5 ± 0.5)
M10 x 70 6 pcs.
Ol2720-00X
(42)Fresh water cooler

1) Mount the fresh water cooler bracket (1) to the
cylinder block.
N•m (kgf•m)
75 ± 5
Bolt M12x40 2 pcs.
Freshwater (7.5±0.5)
cooler
120 ± 10
bracket Bolt M14 x 35 2 pcs.
(12 ± 1)
tightening
torque : 200 ± 15
Bolt M16x40 2 pcs.
(20 ± 1.5)
2) Fit the fresh water cooler (2).
N•m (kgf•m)
Fresh water cooler
45 ± 5
tightening torque :
(4.5 ± 0.5)
(43)Freshwater bend
Install the bend (1).
(Exhaust manifold-Fresh water cooler).
70
(44)Air cooler
1) Mount the air cooler (1) to the flywheel housing.
N•m (kgf•m)
Air cooler tightening torque :
45 ± 5
(4.5 ± 0.5)
2) Fit the automatic drain cock (2).

3) Fit the support (3).
N•m (kgf•m)
Support tightening torque :
120 ± 10
Bolt M14 x 25 2 pcs. (1)
(12 ± 1)
4) Install the air duct (4).
N•m (kgf•m)
Air duct tightening torque :
Bolt M8 x 25 4 pcs. 23 ± 2
Bolt M8 x 45 4 pcs. (2.3 ± 0.2)
(2)~
012723-00X
(45)Cooling water pipe (seawater)

1) Install the cooling water pipe (1) and support (2).
2) Install the rubber joint.
N•m (kgf•m)
45 ± 5
(4.5 ± 0.5)
N~ M10 6pcs.
71
(46)Turbocharger and exhaust bend

1) The turbocharger (1) unite with the air duct (2)
and the turbocharger is installed on the exhaust
manifold.
N•m (kgf•m)
Turbocharger tightening
torque : 74 ± 10
Stud bolt M12 x 30 4 pcs. (7.5 ± 1)
U-nut M12 4 pcs.
2) Install the exhaust bend (3) (assembly) and the

support (4).
N•m (kgf•m)
Exhaust bend (ass'y) and
support tightening torque : 75 ± 5
Bolt M12 x 20 4 pcs. (7.5 ± 0.5)
3) Mount the turbocharger's oil pipe (5).
Union M12 1 pcs.

(47)Air duct
1) Install the support (1).
N•m (kgf•m)

45 ± 5
(4.5 ± 0.5)
2) Install the expansion joint (2) and the air duct (3).
N•m (kgf•m)
Tightening torque :
45 ± 5
(4.5 ± 0.5)
Nut M10 16 pcs.
3) Install the air duct (4).
N•m (kgf•m)
Tightening torque :
45 ± 5
(4.5 ± 0.5)
72
(48)Fresh water pump drive case and cover

1) Mount the case (1) along the dowel pin.
N•m (kgf•m)
Case tightening torque : 45 ± 5
Bolt M10 x 28 8 pcs. (4.5 ± 0.5)
2) Install the pump driving gear (2) along the dowel

pin.
N•m (kgf•m)
Fresh water pump driving 012727-00X
75 ± 5
gear tightening torque :
(7.5 ± 0.5)
Bolt M12x20 4pcs.
3) Install the cover (3).
N•m (kgf•m)
Cover tightening torque :
45 ± 5
(4.5 ± 0.5)
012728-00X
(49)Fresh water pump

1) Assemble the driving gear on the fresh water
pump.
N•m (kgf•m)
Driving gear tightening
137 ± 10
torque :
(14 ± 1)
Nut M20 1 pc.
2) Mount the fresh water pump (1).
N•m (kgf•m)
Fresh water pump tightening
45 ± 5 012729-00X
torque :
(4.5 ± 0.5)
3) Fit the drain cock.
73
(50)Seawater pump
1) Mount the seawater pump (1).
N•m (kgf•m)
Seawater pump driving gear
245 ± 10
tightening torque :
(25 ± 1)
Nut M27 1 pcs.
N•m (kgf•m)
Seawater pump
tightening torque :
45 ± 5
(4.5 ± 0.5)
Nut M10 4 pcs.
2) Connect the seawater inlet bend (2).
N•m (kgf•m)
Tightening torque :
45 ± 5
(4.5 ± 0.5)
Bolt M10 x 105 2 pcs
3) Connect the seawater outlet bend (3).
N•m (kgf•m)
Bolt M10 x 35 4 pcs. (4.5 ± 0.5)
74
(51 )Alternator
1) Install the alternator driving device.
(1)Assemble drive shaft, bearing, oil seal, drive
gear and V-pulley into the bearing case.
N•m (kgf•m)
Driving gear tightening
torque : 130 ± 5
V-pulley tightening torque : (13.3 ± 0.5)
Nut M20
V-pulley
Fresh waler pump
017021-00E
(2)Attach driving unit to the fresh water pump

drive cover.
N•m (kgf•m)
Bolt M10 x 30 5 pcs. (4.5 ± 0.5)
2) Fit the alternator hold.
N•m (kgf•m)
45 ± 5
Alternator Bolt M10 x 25 1 pcs.
(4.5 ± 0.5)
tightening
torque : Bolt M12 x 120 1 pcs. 75 ± 5
Nut M12 (7.5 ± 0.5)
75
3) Set the V-belt.
I V-belt size : A28 2pcs.
4) Set the V-belt adjuster.
I Bolt M10 x 40 1 pcs.
5) Install the V-belt cover.

Nut M10 1 pcs.
Lock nut M10 1 pcs.
(52)Rocker arm cover

Fit rocker arm cover (1), and secure it by tightening.
N•m (kgf•m)
Rocker arm cover

6.9 ~ 9.8
tightening torque :
(0.7 ~ 1.0)
Nut M10 6 pcs.
012735-00X
(53)Viscous damper
Mount the viscous damper (1).
N•m (kgf•m)
Viscous damper tightening

245
torque :
(25)
Bolt M20 x 6 pcs.
Ol2734-00X
(54)Breather
1) Mount the breather (1) to the bracket.
N•m (kgf•m)
Tightening torque :
23 ± 2
Bolt M8 x 18 4 pcs.
(2.3 ± 0.2)
Bolt M8 x 16 4 pcs
2) Connect the breather hose (2).

3) Connect the drain pipe (3).
012736-00X
76
(55)Starting motor
Install the starting motor (1).
N•m (kgf•m)
Starting motor tightening
120 ± 10
torque :
(12.0 ± 1.0)
012737-00X
(56)Stopping solenoid
1) Fit motor solenoid (1) front side.
2) Fit remote control cable bracket (2).
N•m (kgf•m)
Bracket tightening torque : 45 ± 5

Bolt M10 x 20 3 pcs. (4.5 ± 0.5)
77
(57)Boost compensator pipe and boost

sensor
Fit boost pipe (1) and boost sensor (2) to intake
manifold and Fuel injection pump.
013157-00X
78
(58)Fuel filter
1) Mount the bracket (1) on the gear case.
N•m (kgf•m)
Bracket tightening torque :
45 ± 5
(4.5 ± 0.5)
Bolt M10 x 28 2 pcs
2) Mount the fuel filter (2).
N•m (kgf•m)
Fuel filter assembly
75 ± 5
tightening torque :
(7.5 ± 0.5)
3) Connect the fuel oil pipe.

(Feed pump - Fuel filter (3))
(Fuel filter - Fuel pump (3))
N•m (kgf•m)
Pipe joint tightening torque : 90-100
Joint bolt M20 4 pcs. (9.2-10.2)
Fuel feed pump

Fuel injection
pump
Fuel filler
016S03-00E
79
(59)Lube oil dipstick

Install the dipstick (1).
(60)Airduct cover
Mount the cover (1) (2) on the air duct.
N•m (kgf•m)
Cover Tightening torque :
N~ M8 9pcs. (2.3 ± 0.2)
Lock nut M8 9 pcs.
01J159- oox
80
(61 )Warning switch

1) Fit cooling water temperature switch (1) to bend.
ON 95 QC± 2 QC
Operating
temperature OFF: 88 QC± 2 QC
2) Fit cooling water level sender unit (2) to bend.

3) Fit cooling water level sensor (3) to fresh water
cooler.
From switch attaching

Operating surface
water level 013132-0lX
Less than 76mm
4) Fit engine lube oil pressure switch (4) to lube oil

cooler.
Operating 0.1 ± 0.020MPa

pressure (1 .0 ± 0.2 kgf/cm 2)
5) Fit engine lube oil temperature switch (5) to lube

oil cooler.
Operating ON : 100 QC± 3 QC

temperature OFF: 95Qc±3Qc
6) Fit engine lube oil sender unit (6).

7) Fit lube oil filter pressure sensor (7) to oil filter.
Operating 0.2 ± 0.03MPa

pressure (2 ± 0.3 kgf/cm 2)
Bypass valve 0.6 ± 0.03MPa

opens (6 ± 0.3 kgf/cm 2)
81
2.5 Wire harness

Assemble the wire harness
(1) Connect each wire according to the identification

marks on the terminals.
(2) Fix the terminals securely.
19
Safety switch
ess ~(Manne gear)
Slop h • m : r
~ Battery switch
11
faohomelemo~oc
3~
2
/-t
LO.Oil press
16
Cooling waler
sender unit
~A~oling water
switch
~ .evel sensor
(Marine gear)
)A
/~~~ 0
(Oil press
switch
I 0.1MPa{1.0 kgf/cm 2}
! ,/1
L--/ i
,~
''fl ~18
15
Eng. Oil pressure
sensor ~ 8
LO.Temp
e
switch
<?"
Wire dia. Wire dia.

No. Wire color Remarks No. Wire color Remarks
mm mm
YW: Oil press. switch
1 0.85 11 2 W: White Starting motor C
Yellow, White o. 1 MPa (1 .Okgf/cm 2 )
YG: L.O. press. switch
2 0.85 12 0.85 G: Green L.O. filter switch
Yellow, Green (Marine gear)
3 0.85 B: Black Tachometer-Sensor - 13 5 R: Red Alternator B
O.B:
4 0.85 Tachometer-Sensor p 14 5 B: Black Alternator E
Orange, Black
YB : Yellow, Black Eng. Oil pressure Sen-
5 0.85 WR : White, Red C.W level sensor 15 0.85
WG : White, Green sor
GB : Green, Black WB:
6 0.85 Boost sensor 16 0.85 C.W sender unit
WG : White, Green White, Black
7 0.85 WL : White, Blue C.W. temp. switch 17 0.85 Lb: Light blue Alternator L
8 - - Rubber joint 18 0.85 Y: Yellow Temp. switch (Eng. oil)
9 5 B: Black - Earth 19 2 W: White Neutral switch of clutch
10 5 R: Red Starting motor B-term
82
Note:
After the disassembly, maintenance and
reassembly, check the following matters.
1. Check that all the bolts and nuts are
tightened to the specified torque and are
provided with specified locks.
2. Give special attention to the bolts and nuts
which cannot be visually checked for
loosening during operation of the engine.
3. Use turning and priming to check that the
engine can be moved normally. Be sure to
remove the turning bar immediately after this
check.
4. Record the maintenance and inspection
works and replaced parts in the service
chart.
83
84
3. Preparation Before Checking and Servicing
Preliminaries
(1) Wash each part with care, and remove dust, carbon deposits, oil, moisture etc.
(2) Blow air through the oil holes to remove deposits to make sure that there are no obstructions in the holes.
(3) Remove carbon sticking to the cylinder head, suction/exhaust valve etc., taking care not to damage the
parts.
(4) Always place parts which belong together in order to avoid confusion.
Standard for parts replacement (including correction)

Measure the dimension of the parts in accordance with the checking procedures. Replace any defective parts
or those parts that exceed the wear limit. Also replace any part which, judging based on past wear limit data,
is likely to exceed the limit before the next service.
85
3.1 Cylinder Head

The cylinder head is independent for each cylinder
of water cooled, intake and exhaust ports crossed-
flow 4-valved construction mounted with 6 bolts.
Special alloy satellite with superior resistance to
heat and wear is fitted on the seats, and the area
between the valves is cooled by a water jet.
Valve
rocker arm
case
86
3.1.1 Inspecting the cylinder head

The cylinder head is subjected to very severe
operating conditions with repeated high pressure,
high temperature and cooling. Thoroughly remove
all the carbon and dirt after disassembly and
carefully inspect all parts.
(1) Distortion of the combustion surface

Carefully check for cylinder head distortion as this
leads to gasket damage and compression leaks.
1) Clean the cylinder head surface.
2) Place a straight-edge along each of the four sides
and each diagonal. Measure the clearance
between the straight-edge and combustion
surface with a feeler gauge.
(mm)
Standard limit
Cylinder head distortion 0.035 or less 0.15
(2) Checking for cracks in the combustion

surface
Remove the fuel injection nozzle, intake and
exhaust valve and clean the combustion surface.
Check for discoloration or distortion and conduct a
color check test to check for any cracks.
010912-00X
(3) Checking the intake and exhaust valve

seats
Check the surface and width of the valve seats.
If seat width is too wide, or if the surface is rough,
correct to the following standards:
Intake 120°
Seat angle
Exhaust goo
(mm)
Seat width Standard Limit
Intake 3.46 3.96
Exhaust 2.48 2.98
87
3.1.2 Valve seat correction procedure

The most common method for correcting
unevenness of the seat surface with a seat grinder
is as follows:
( 1) Use a seat grinder to make the surface

even.
As the valve seat width will be enlarged, first use a
70° grinder, then grind the seat to the standard
dimension 45° by using the seat grinder with a 15°
chamfer.
Intake valve 30 deg.
Seat angle 8
Exhaust valve 45 deg.
Note:
When seat adjustment is necessary, be sure to
check the valve and valve guide. If the
clearance exceeds the tolerance, replace the
valve or the valve guide, and then grind the
seat.
(2) Knead valve compound with oil and

finish the valve seat with a lapping tool.
Lapping tool
Use a rubber cap type lapping tool for valves
without a lapping tool groove slit.
88
(3) Final finishing should be done with oil

only.
Note:
1. Clean the valve and cylinder head with light
oil or the equivalent after valve seat finishing
is completed and make sure that there are
no grindings remaining.
2. Measure valve distortion after valve seat
refinishing has been completed, and replace
the valve and valve seat if it exceeds the
tolerance.
89
3.1.3 Intake/exhaust valves, valve guides
( 1) Wearing and corrosion of valve stem d d

Measure the outside diameter of valve stem.
Replace the valve, ifthe stem is excessively worn or
corroded.
(mm) B
Valve stem
Standard Limit
outside diameter
Intake
10.928-10.950 10.82
Exhaust
Valve measurement position.

A : 68 mm, B : 102 mm
0073S9-00X
(2) Inspection of valve seat wear and

contact surface
Inspect for valve seat scratches and excessive
wear. Check to make sure the contact surface is
normal. The seat angle must be checked and
adjusted if the valve seat contact surface is much
smaller than the width of the valve seat.
Note:
Keep in mind the fact that the intake and
discharge valve have different diameters.
(3) Valve sink

Over long periods of use and repeated lapping,
combustion efficiency may drop.
Measure the sinking distance by depth gauge.
Replace the valve and valve seat if the valve sink
exceeds the tolerance.
(mm) \
Cylinder head
Standard Limit
Valve sink + 0.1- - 0.4 -0.5
90
(4) Valve guide

1) Measuring inside diameter of valve guide.
Measure the inside diameter of the valve guide
and replace it if it exceeds the wear limit.
(mm)
Standard Limit
Valve guide
11.000-11.018 11.12
inside diameter
Intake
Clearance 0.050-0.090 0.2
Exhaust
Note:
The inside diameter standard dimensions are
measured after insertion.
2) Replacing the valve guide Tool
Use the insertion tool and tap valve guide with a
mallet.
Valve guide projection:
The valve guide should project the specified
value from the top of the cylinder head. (See Valve guide
the below figure.)
Cylinder head
Hammer
(5) Valve stem seal Filling tool

The valve stem seals on the intake/exhaust valve
guide cannot be re-used once they are removed. Be Put the guide pin on the fitting tool to
keep the valve stem from falling over.
sure to replace them with new ones.
When assembling the intake/exhaust valves, apply Where spring is attached, be careful
not to let the spring tall off.
an adequate quantity of lube oil on the valve stem
before inserting. Release the upper part to the valve
stem seal from the fitting tool and use
it to push in the shoulder section.
Fit the upper surface of the valve guide
and the valve stem seal so that they
adhere closely together.
When using a hammer or similar tool,
~ attach a positioning stopper to prevent
damage to the stem seal.
(vaves
I tem sea I)
91
3.1.4 Valve springs

( 1) Checking valve springs
1) Check the spring for scratches or corrosion.
2) Measure the free length of the spring.
001509-0lX
3) Measure inclination.
Inclination
(mm)
Limit
Inclination 1.8
001510-00E
'--
(
001511-00X
4) Measure spring tension.

(Inside) (mm)
Valve spring Standard Limit
Free length 57.9 57.7
Length when attached 47.0 46.8
119.86N
Load when attached -
(12.22 kgf)
(Outside) (mm)
Valve spring Standard Limit Spring tension lester
Free length 60.2 60.0

Length when attached 50.0 48.8
216.92 N
Load when attached -
(22.12 kgf)
5) Spring retainer and spring cotter

Inspect the inside face of the spring retainer, the
outside surface of the spring cotter, the contact area
of the spring cotter inside surface and the notch in 001513-0lE
the head of the valve stem. Replace the spring

retainer and spring cotter when the contact area is
less than 70%, or when the spring cotter has been
recessed because of wear.
92
3.1.5 Valve rotator

Check the valve rotator
(1) Remove valve rocker arm chamber during the

operation to check if the valve rotates.
(2) Check the state of the valve rotator at around the
valve rocker arm of the valve head after
disassembly.
(3) Replace the valve rotator if worn excessively.
3.1.6 Nozzle sleeve

1) When assembling, apply lube oil to 0-ring.
2) Fit the sleeve to cylinder head and tighten it.
N•m (kgf•m)
Tightening torque 1s1-161 (16-17) I
Part name Part code
Nozzle sleeve 148620-11770
0-ring 24326-000400
Nozzle sleeve gasket 146673-11870
93
3.1.7 Assembling the cylinder head

Partially tighten the bolts in the specified order and
then tighten to the specified torque, being careful
that the head does not get distorted.
1) Clean out the cylinder head bolt holes.
2) Check on the cylinder head surface where it
comes in contact with the block.
3) Coat the head bolt threads with PROTEC oil.
4) Use the positioning pins to line up the head
gasket with the cylinder block.
5) Match up the cylinder head with the head basket
and mount.
6) When clamping the cylinder head tighten the
respective bolts in five steps as per the following
Table according to the following clamping
sequence give in Drawing.
Table: Tightening torques of cylinder head bolt.

Steps Tightening torque Exha~ port
No.
N•m (kgf•m)
(1) 1st step 98 (10)
(2) 2nd step 471 (48)
All of six bolts are loosened to
(3) 3rd step
the power "O".
(4) 4th step 98 (10) ~
Suction port
150° rotation from state of 4th
(5) 5th step 012714- OOE
step (angle gauge use)
94
3.1.8 Measuring top clearance

(1) Place a high quality fuse (02mm, 1Omm
long) in four positions on the flat part of
the piston head.
(2) Assemble the cylinder head gasket and

the cylinder block and tighten the bolts in
the specified order to the specified
torque.
(3) Turn the crank, (in the direction of

engine revolution), and press the fuse
against the piston until it breaks.
(4) Remove the head and take out the

broken fuse.
(5) Measure thickness of broken fuse at

four positions and calculate the average.
(mm)
Top clearance 1.452-1.668 I
3.1.9 Intake and exhaust rocker arms

The wear of rocker arm and rocker arm bushing
may change opening/closing timing of the valve,
~
~ .!
and may in turn affect the engine performance
according to the extent of the change.
- Rocker arm
/ I shaft
®~"\S;l . ~J,~i'>!cm ~
a/ /~'
Valve bridge
Intake
rocker arm
; 016507-00E
95
( 1) Rocker arm shaft and rocker arm

bushing
Measure the outer diameter of the shaft and the
inner-diameter of the bushing, and replace if wear
exceeds the limit.
(mm)
Standard Limit
Inside dia. of intake and
exhaust rocker arm 32.010-32.065 32.180
bushing
Outside dia of intake and
31.966-31.991 31.880 (Rocker arm hole diameter)
exhaust rocker arm shaft. 001516- OlE
Clearance of rocker arm

shaft and bushing at 0.019-0.099 0.20
assembly
Replace rocker arm bushing if it moves. Replace
entire rocker arm if there is no tightening clearance.
(2) Valve spring

Check the valve spring and replace it if it is corroded
or worn.
(3) Rocker arm and valve top retainer wear

Inspect the contact surface of rocker arm and
replace it if there is abnormal wear or flaking.
(4) Adjusting bolt

Inspect the contact surface of adjusting bolt and
push rod. Replace ifthere is abnormal wear or
flaking.
3.1.10 Push rod

Check the bend.
(mm)
Standard Limit
Bend of push rod 0.1 or less 0.2
96
3.1.11 Adjustment of valve clearance Pressed
( 1) Adjust the valve clearance when the Screw

engine is cool.
(2) Adjust the valve bridge
(3) Adjust the valve clearance

Standard valve clearance (mm)
Intake valve 0.30
Exhaust valve 0.50 Lock nut
(4) Be sure that the opening and closing

Screw
angles for both intake and exhaust
valves are checked when timing gear is
disassembled.
(deg.)
Intake valve open b.TDC. 50° ± 2°
Intake valve closed a.BOC. 40° ± 2°
Exhaust valve open b.BDC. 76° ± 2°
Exhaust valve closed a.TDC. 60° ± 2°
Vale opening diagram

TDC
BOC 016508-00E
97
3.2 Cylinder block

3.2.1 Cylinder block
The cylinder block is a thin-skinned (low-weight),
short skirt type with rationally placed ribs. The side
walls are waver shaped to maximize rigidity for
strength and low noise.
3.2.2 Checking the parts

If your engine which has already encountered such
troubles as freezing, turnover etc., conduct visual
checks carefully before disassembly. If cracking is
suspected, investigate with the color checker.
Replace any part for which the damage is
irreparable.
Flywheel side
Opposite side
of flywheel
98
3.3 Cylinder liner

Since the cylinder liners are cooled in the high
constant temperature cooling by the freshwater,
there is no possibility of abnormal wear of liner due
to over-cooling during low load operation of the
engine. The liners are made of special non-plated
cast iron that has low friction loss. The liner is given
uniform wall thickness to prevent uneven local
thermal expansion. There features provide high ---0-ring
durability to the liners.
(Pistons and liners are fit each other selectively.)
3.3.1 Measurement of liner ---Cylinder liner
Use a dial gauge to measure the cylinder liner.

Measure the inside diameter in the axial direction of
the crankshaft and perpendicularly to the
crankshaft, at the points on the cylinder liner shown
in the table below. If they exceed the limit, replace
the liner. 007774-00E
(mm)
Standard Limit
L 155.020-155.030
Cyl. liner ML 155.015-155.020
155.20 ----- Direction of
inside dia. MS 155.010-155.015 crankshaft center
s 155.000-155.010
Roundness 0.008 or less -
Cylindricity 0.01 O or less -

I Piston of too rina J
3.3.2 Insertion of liner

(1) Remove the rust from contact part of the Center
liner inside the cylinder block.
(2) Fit the rubber packing to the liner, taking

care not to twist it.
I
t
(3) Apply water-proof white paint to the About 60mm
rubber packing.
' 016500
(4) Bring the upper surface of the liner

marked with "W' (hydraulic pressure
mark) to the operation side and insert
into the cylinder.
(5) If it cannot be inserted entirely by hand,

put a padding wood on the liner and tap
lightly.
99
3.3.3 Measurement of projection

Check that the flange of each cylinder is projecting
the top of the cylinder block.
(mm)
c
Cylinder block hole depth : A 14.96-15.0
B A
Cylinder liner flange thickness : B 15.03-15.05
Cylinder liner projection : C 0.03-0.09
C linder liner (Cylinder block)
100
3.4 Piston and piston pins

Pistons are made of a special light alloy with 0 - - 1<t oompce«ioo riog
superior thermal expansion characteristics, and the
top of the piston forms a swirl type combustion
chamber. The opposite face of the piston
combustion surface is oil-jet cooled.
0-- 2od wmprn«ioo ciog
IMPORTANT:
Piston shape differs among engine models. If 0--0ilciog
any incorrect piston is installed, combustion
performance will drop. Be sure to check the
applicable engine model identification mark (l.D
Mark) on the piston to insure use of the correct
part. 0
')~pio.
~CiCClip
121~
Engine ID mark
I occcrn
001
3.4.1 Piston
(1) Piston head and combustion surface
Remove the carbon that has accumulated on the
piston head and combustion surface, taking care
not to scratch the piston. Check the combustion
surface for any damage.
(2) Measurement of piston outside

diameter/inspection
1) Replace the piston if the outsides of the piston or
ring grooves are worn.
2) Measure the outside diameter in the position of A
from the piston bottom in the direction vertical to
the piston pin.
If the piston outside diameter exceeds the limit,
replace the piston with new one.
A 47mm
Piston outside diameter (mm)

Piston
Standard Limit
ID mark
L 154.935-154.945
M 154.925-154.935 154.780
s 154.915-154.925
101
Selective pairing of cylinder liner and piston

Piston must be paired with cylinder liner according
to the below table. The size mark of a piston is
shown on the top surface of the piston and the size
mark of a cylinder liner is shown on the non-
operating side of the cylinder block. The service
parts of pistons are provided.
Application table for Piston and Liner
I~ n
L ML MS s
L @ 0 x x
M x @ @ x
s x x 0 @
Combination
@ : Recommended
0 : Acceptable
x : Not acceptable
(3) Removing the piston

A floating type piston pin is used in this engine. The
piston pin can be pressed into the piston pin hole at
room temperature (coat with oil to make it slide
easily).
006558-00X
3.4.2 Piston pin

Measure the outer diameter and replace the pin if it
is excessively worn.
(mm)
Standard Limit
62.010-
Piston pin hole inside dia. 62.120
62.020
61.971-
Piston pin outside dia. 61.867
61.980
0.030-
Clearance 0.06 Measure al positions a, b and c
0.049
in directions A and B.
a b c
! ! l
t t t
(Piston pin outside diameter)
001520-0JE
102
3.4.3 Piston rings

There are 2 compression rings and 1 oil ring.
Top~in~-
,.-
I
Second rin
(Ring components)
001S22-01E
(1) Measuring the rings.

Measure the thickness and width of the rings, and
the ring-to-groove clearance after installation.
Replace if wear exceeds the limit.
(mm)
Standard Limit
Groove width 3.630-3.645 3.745
Top ring Ring width 3.4 70-3.490 3.370
Clearance 0.140-0.175 0.180
Groove width 3.095-3.110 3.210
Second
Ring width 2.970-2.990 2.870
ring
Clearance 0.105-0.140 0.180
Groove width 4.020-4.040 4.140
Oil ring Ring width 3.970-3.990 3.770
Clearance 0.030-0.070 0.180
I. Thickness • I o16ss4-00E
(2) Measuring piston ring gap

Press the piston ring onto a piston liner and Gap
measure the piston ring gap with a gauge. Press on
the ring about 30mm from the bottom of the liner. Piston ring
(mm)
Standard Limit
Top ring gap 0.40-0.55 1.5
Second ring gap 0.55-0.70 1.5 Piston
Oil ring gap 0.40-0.60 1.5
008089- OOE
103
(3) Replacing the piston rings

Make the punched manufacturer's
1) Thoroughly clean the ring grooves when mark face upward
replacing piston rings.
2) The side with the manufacturer's mark should
face up.
3) After fitting the piston ring, make sure it moves
easily and smoothly.
4) Stagger the piston rings at 180° intervals, making
sure none of them line up with the piston.
5) The oil ring is provided with a coil expander. The
coil expander joint should be opposite (staggered
180°) the oil ring gap.
1st piston ring
2st piston ring
Oil ring
1st piston ring gap

Oil ring gap
~=~~
180°
Joint of coil
expander
016585-00E
104
3.5 Connecting rod Connecting rod

The connecting rod is made of high-strength forged
carbon steel.
The large end with the aluminum metal can be Connecting rod bolt
separated into two and the small end has a 2-layer
copper alloy coil bearing.
Crank pin metal
Connecting rod
(bid end cap)
3.5.1 Inspecting the connection rod
(1) Twist and parallelism of the large and

small ends. Insert the measuring tool
into the large and small ends of the
Parallelism
connecting rod. Measure the extent of
twist and parallelism and replace if they
exceed the tolerance.
(mm)
Standard Limit
Connecting rod 0.03 or less
0.07
twist and parallelism (at 100 mm)
Connecting rod
aligner
Twist measurement using )

( a connecting rod aligner
008285- OOE
105
(2) Checking side clearance of a connecting rod

Fit the respective crank pins to the connecting rod
and check to make sure that the side clearance in
the crankshaft direction is correct.
Standard
Connecting rod
0.150-0.324mm
side clearance
(3) Crank pin metal

Checking of crank pin metal. Check the contact
surfaces for metal removal, fusion, seizure etc. TSize
(mm) Size mark

Classification Size mark Tsize
007S29-01E
Standard STD 2 5-0.005
. -0.019
Crank p_in met_al thickness (T size))
0.25 and under U025 2 525-0.005 ( measuring points
. -0.019
0.5 and under U05 2 75 -0.005
. -0.019 °·
(Housing 0111 +0 022)
106
3.5.2 Crank pin metal
(1) Checking crank pin metal

Check for flaking, melting or seizure on the contact
surface of the crank pin metal.
(2) Measuring crank pin oil clearance

Measure the crank pin outside diameter and the
crank pin metal inside diameter. Calculate the oil
clearance from the measured values.
(Refer to 3.6.1 (3) for measuring the crank pin
outside diameter.)
Replace the crank pin metal if the oil clearance
becomes about the limit dimension of the below
table.
Correct by grinding if unevenly wear, roundness
exceeding the limit or insufficient outside diameter is
found. Also use an undersized metal if necessary.
• Mount the connecting rod on the crank pin (tighten

to specified torque as three stage tighten with
PROTEC-grease or PROTEC oil pasted).
Method of Tightening Connecting Rod Nuts

Tightening torques
N•m (kgf•m)
1st temporary 50 ± 5 (5 ± 0.5)
2nd temporary 70 ± 5 (7 ± 0.5)
Third time 137 ± 5 (14 ± 0.5)
(mm)
Item Standard Limit
Rod metal l.D. 106.010-106.060 106.1
Crank pin O.D. 105.940-105.960 105.85
Metal thickness 2.487-2.5000 -
Clearance 0.050-0.120 0.15
• Other procedure of measuring crank pin oil clearance

1) Use the press gauge (plastic-gauge) for
measuring the oil clearance of the crank pin.
2) Mount the connecting rod on the crank pin and
tighten to specified torque.
3) Remove the connecting rod and measure the
broken plasti-gauge with measuring paper.
107
(3) Precautions on replacement of crank pin metal

1) Wash the crank pin metal.
2) Wash the large end cap, mount the crank pin
metal and make sure that it fits tightly on the large
end cap.
3) When assembling the connecting rod, match up
the large end and large end cap number. Coat
the bolts with engine oil and gradually tighten Alignment mark(Punched mark)
them alternately to the specified torque. Cylinder No.
If a torque wrench is not available, make match
marks on the bolt heads and large end cap (to
indicate the proper torque position) and retighten
the bolts to those positions.
4) Make sure there is no sand, metal cuttings or
other dust in the lube oil, and that the crankshaft
is not scratched. Take special care in cleaning the
oil holes.
OU276-00E
3.5.3 Piston pin bearing

( 1) Measuring piston pin clearance
Excessive piston pin bearing wear may result in
damage to the piston pin or the piston itself.
Measure the piston pin bearing inside diameter and
the piston pin outside diameter. Calculate the oil
clearance from the measured values. (Refer to 3.4.2
for the piston pin.)
(mm)
Standard Limit
Piston pin bearing
62.034-62.049 62.134
inside dia.
Oil clearance 0.054-0.078 0.15
3.5.4 Assembling piston and

Fuel injection
connecting rod pump side
The piston and connecting rod should be

assembled so that the YANMAR mark on the
connecting rod and the maker mark on the piston
top face the same direction. Install the piston and
connecting rod assembly with those marks facing
flywheel side.
Note:
If the piston is installed in opposite direction,
YANMARmark
crankshaft cannot be turned because the piston (Fly wheel side)
hits the cooling nozzle.
014874--00E
108
3.6 Crankshaft and main bearing

The crank pin and crank journal have been
induction hardened for superior durability, and the
crankshaft is provided with for balance weights for Balance weight
optional balance. The crankshaft main bearing is of
the hanger type. The upper metal (cylinder block
side) is provided with an oil groove. There is no oil
groove on the lower metal (bearing cap side). The
bearing cap (location cap) of the flywheel side has a
thrust metal, which supports the thrust load.
• Method of tightening main bearing refer of page
280 and 281. 014974-00E
Main bearing metal

(intermdeiate)
~~
(/
Thrust metal
(basic side) Main bearing
metal (basic)
Thrust metal
(flywheel side)
3.6.1 Crankshaft
( 1) Color checking of crankshaft
Color check after cleaning the crankshaft, and
replace the crankshaft if there is any cracking or
considerable damage.
109
(2) Bending of the crankshaft

Support the crankshaft with V-blocks at both ends of
the journals. Measure the deflection of the center
journal with a dial gauge while rotating the
crankshaft to check the extent of crankshaft
bending.
Deflection
(mm)
007527-QQE
Standard Limit
Crankshaft bend limit
0.018 or less 0.05 1/2
(1/2 the dial gauge reading)
(3) Measuring of crank pin and crank

journal
When the difference between the maximum wear
the minimum wear of these parts (i.e. roundness)
exceeds the limit, grind or replace the crankshaft.
(mm)
Crankshaft Standard Limit
Shaft outside dia. 105.940-105.960 105.85
c
0:: Crankpin 106.010-106.060 106.10
metal inside dia.
Cii Shaft outside dia. 133.930-133.955 133.85

c
I-
:::J Main metal
0
--,
134.000-134.065 134.10
inside dia.
Note:
If re-grinding is performed, use undersize main
metal to adjust the oil clearance to a specified
value.
007528-00X
110
(4) Checking the side clearance of a

crankshaft
After assembling the crankshaft, tighten the main
bearing cap to the specified toque, and move the
crankshaft to one side, placing a dial gauge on one
end of the shaft to measure thrust clearance.
Replace the thrust bearing if it is worn beyond the
limit.
(mm)
Standard Limit
Crankshaft side clearance 0.080-0.229 0.33
111
3.6.2 Main bearing

(1) Inspecting the main bearing
Check for flaking, seizure or burning of the contact
surface and replace if necessary.
(2) Measuring the inner diameter of metal

Tighten the cap to the specified torque and
measure the inner diameter of the metal.
• Method of tightening main bearing refer of page
280 and 281.
(mm)
Standard Limit
Metal inside diameter 134.000-134.065 -
Note:
1) No oil grooves are provided on the lower
bearings (at cap side).
2)Match the matching numbers with those of
the cylinder block.
3)Bring the embossed "AY" mark on the cap to
the front side.
4).Set reference bearings at the flywheel side.
Main Bearing Metal (mm)

TSize
Classification Size mark Tsize
Size mark
Standard STD
-·- 3.o _g_o20
Q)
Q) -0
Cll Cf)
ii 007529
Q)
E Ol
I-
Cll
Q)
Undersize 0.25 u 025 3.125 _8.020
I-
Q) -0
-c Undersize 0.5 U05 3.25_g_ 020
Ero
,.--._
Q) Standard STD 4.o _g_o20
-0
Q) ·u;
(.)-
c Q)
Q) Q)
Undersize 0.25 u 025 4.125 _8.020
I- ..c
~$
Q) >.
0:::5 Undersize 0.5 U05 4.25_g_ 020
007536-00E
112
3. 7 Camshaft and Tappets

3.7.1 Camshaft
The camshaft is normalized and the cam and
bearing surfaces are surface hardened and ground.
The cams have a curve that minimized the repeated
shocks on the valve seats and maximizes valve seat
life.
~r~ Cam gear
Bolt
t::?
Fly wheel side
( 1) Checking the camshaft side clearance Oil clearance Side clearance

Measure the thrust clearance before disassembly.
As the cam gear is shrink-fitted to the cam, be
careful when replacing the thrust bearing.
(mm)
Standard Limit Cam shaft
Camshaft side clearance 0.10-0.35 0.45
Cylinder block
013269-0lE
113
(2) Measure the camshaft height, and

replace the cam if it is worn beyond the
limit.
(mm)
Standard Limit
Intake 59.850-59.950 59.4
Cam height
Exhaust 59.950-60.050 59.5
Height
007709
(3) Camshaft and bearing hole

measurement
Measure the camshaft outside diameter with a
micrometer. The oil clearance shall be calculated by
subtracting the measured camshaft outside
diameter from the inside diameter of the camshaft
bearing or bushing. The camshaft bushing at gear
case side is measured with a cylinder gage after
insertion to the cylinder.
Replace if they exceed the limit or are damaged.
(mm)
Item Standard Limit
Bushing l.D. 70.02-70.07 70.16
Camshaft O.D. 69.91-69.94 69.82
(4) Bending of the camshaft

Support both ends of the camshaft with V-blocks,
place a dial gauge at the central bearing areas and
measure bending. Replace if excessive.
Note:
The reading on the dial gauge is divided by two
to obtain the camshaft bend.
(mm)
I Camshaft bend
Limit
0.05
114
3.7.2 Tappets
( 1) The tappets are offset to rotate during
operation and thereby prevent uneven
wearing. Check the contact of each
tappet and replace if excessively or
unevenly worn.
013540-00X
Tappet
I1
ii
Cam shaft
Ii Offset
Note:
When removing tappets, be sure to keep them
separate for each cylinder and intake/exhaust
valve.
(2) Measure the outer diameter of the

tappet, and replace if worn beyond the
limit.
(mm)
Standard Limit
Tappet stem outside dia. 44.940-44.965 44.90
Tappet guide hole inside
45.000-45.025 45.06
dia. (cylinder block)
Tappet steam and guide
hole oil clearance.
0.035-0.085 -
014926 - oox
(3) Measuring push rods.

Measure the length and bending of the push rods.
Standard Limit
Push rod length 342-343 341.8-343.2
Push rod bend 0.2 or less 0.4
Push rod dia. 15 -
(Push rod bend)

001554-0lE
115
3.8 Timing gear

The timing gear is helical type for minimum noise
and specially treated for high durability.
3.8.1 Inspecting the gears

( 1) Inspect the gears and replace if the
teeth are damaged or worn.
(2) Measure the backlash of all gears that

mesh, and replace the meshing gears
as a set if wear exceeds the limit.
Note:
If backlash is excessive, it will not only result in
excessive noise and gear damage, but also
lead to bad valve and fuel injection timing and a
decrease in engine performance.
(mm)
Standard Limit
Fresh water pump gear
0.12-0.20 0.40
Backlash and alternator gear
Other gear 0.15-0.25 0.40
(3) Idling gear

The bushing is pressure fitted into the idling gear.
Measure the bushing inner diameter and the outer
diameter of the shaft, and replace the bushing or
Idle gear bushing
idling gear shaft if the oil clearance exceeds the
wear limit.
A and B are inscribed on the end of the idling gear.
When assembling, these marks should align with
those on the cylinder block.
mm
Standard Limit
Idle shaft dia. 59.940-59.970 59.83
Idle gear bushing
60.000-60.030 60.14 Idle gear B
inside dia.
016587-00E
Idle shaft and bushing
0.03-0.09 0.2
oil clearance.
(mm)
Standard
Idling gear side clearance 0.2-0.4
116
3.8.2 Gear timing marks

Match up the timing marks on each gear when
assembling.
Idle gear A
Idle gear B
Fuel pump gear
Crankshaft gear
Lub.oil pump
gear
(Gear train)
3.8.3 Fresh water pump & Alternator Cam gear (Front side)
driving gear (OFW)
The fresh water pump and alternator driving gear is
helical type for minimum noise and specially treated
for high durability.
Alternator
driving gear
Fresh waler
pump gear 013274-00E
117
3.9 Flywheel and housing

The function of the flywheel is through inertia, to
rotate the crankshaft in a uniform and smooth
manner by absorbing the turning force created
during the combustion stroke of the engine, and by
compensating for the decrease in turning force
during the other strokes.
The flywheel is mounted and secured by 12 bolts on
the crankshaft end at the opposite end to the gear
case; it is covered by the mounting flange (flywheel
housing) which is bolted to the cylinder block.
The fitting surface for the damper disc is on the
crankshaft side of the flywheel. The rotation of the
crankshaft is transmitted through this disc to the
input shaft of the reduction and reversing gear. The
reduction and reversing gear is fitted to the
mounting flange.
The flywheel's unbalanced force on the shaft center
must be kept below the specified value for the
crankshaft as the flywheel rotates with the
crankshaft at high speed.
To achieve this, the balance is adjusted by drilling
holes in the side of the flywheel, and the
unbalanced momentum is adjusted by drilling holes
in the circumference.
The ring gear is shrink fitted onto the circumference
of the flywheel, and this ring gear serves to start the
engine by meshing with the starter motor pinion.
The stamped letter and line which show top dead
center of each cylinder are positioned on the
flywheel circumference, and by matching these
marks with the arrow mark at the hole of the
flywheel housing, the rotary position of the
crankshaft can be ascertained in order to adjust
tappet clearance or fuel injection timing.
3.9.1 Specifications of flywheel

Outside dia. of flywheel mm 632
Width of flywheel 76
Pitch circle dia. of
mm 138
bolts
Fixing
part of No. of thread holes - 12-021
crankshaft 170-
Fit joint dia. mm
170.04
Center dia. mm 630
Ring gear
No. of teeth - 180
118
3.9.2 Ring gear

When replacing the ring gear due to excessive wear
or damaged teeth, heat the ring gear evenly at its
circumference, and after it has expanded drive it
gradually off the flywheel by tapping it with a
hammer, a copper bar or something similar around
the whole circumference.
(mm)
IShrink range of ring gear o.1s-o.97 I Ring gear
006S72-00E
3.9.3 Position of top dead center

The top dead center is set with the matching marks Flywheel housing
of hole of flywheel housing and of flywheel.
119
w ~
CD
.i::i. ~
(!j
-0
0 Q)
iiJ
3 g:
CD ~
:J
343 Fl wheel en OJ
CD
0 O'
Fl wheel housin :J
-
Ci3
en
0 g
CD
()
::::!! Q"
I '< ~·
:E CQ
~1
.l!l
c
:J"
CD
Q)
~
Q.
Ql
01
CD
(/)
CD
~
0
ZI
;s
()'
s·
0
;::' CQ
J_ __ 0
cri
~o
I'-
~
I\) -s ;z
0
-s
I
Crank shaft center
16-M12 Screws de th 26
12-M16 x 1.5 Screws depth 22
(SAE# O & F.W. # 1B)

w
CD
01
0
3
CD
:J
en
0
266 :J
12-M 10 Screws de th 19
-
en
0
..,
-
0
,_I :J
34
~I
~I
:-u
:-1
0
~I D>
:J
a.
N
0 3
"'"
-e. 0
c:
:J
!:!':
:J ~
(Q
.g:~
::::!!
D>
:J Q)
Tighten torque (Q
iiJ
275 ± 20 N·m CD g:
~
Engine foot OJ
CD
O.F.W.Side O'
Torsional dam er
Ci3
Remove it and
don't remove it
216 0
~
CD
()
12-M20x1 .5 Screws de th 30
Q"
~·
016S89--00E CQ
Q)
~
Q.
(/)
CD
;s
()"
s·
CQ
3.10 Fuel injection equipment

3.10.1 Fuel Oil System
The engine revolutions are transmitted to the
*l.D.5 Rubber Hose
camshaft by the driving gear of the fuel pump.
The feed pump activated by the camshaft rotations *O.D.6
sucks fuel oil from the fuel tank and feeds it to the Drain Pipe
Press.
fuel filter at the pressure of about 0.368-0.48 MPa
Control ...----~
(3.75-4.81 kgf/cm 2). Fuel Filter Valve
* l.D.15 Rubber Hose
The filtered fuel oil is sent to the oil sump in the
pump housing and is pressurized by the plunger.
The fuel oil then flows through the injection pipe and *l.D.15 Rubber Hose
nozzle holder and is injected from the nozzle to (J)
0..
each cylinder. I.{) 0::

~a;
Oc
c:i
* LL~
=
'-"
*Water Separator
(Hull Fitting)
Fuel Oil System
Remarks:
1. Pipes & Devices marked * in this drawing are not included
in our factory's standard scope of supply.
2. A water separator for fuel oil to be provided in engine inlet line.
(between F.O. service tank and engine.)
3.10.2 Fuel injection pump/governor

The Yan mar YPE-1615 fuel injection pump with an
all speed control governor is applied to this engine.
Refer to the service manual of separate volume for Delivery valve
the disassembly and assembly, adjustment holder Delivery valve
procedure of the fuel injection pump and governor
for 6AYM-ETE, 6AYM-STE engines. Fuel oil
chamber
Control rack
Tappet
Camshaft
122
(1) Fuel injection pump specifications
Injection system specifications

General a Rotation direction Clockwise viewed from drive side
b Injection order 1-4-2-6-3-5-1
c Interval deg. 60 ± 0.5
d Drive system Gear
e Lubrication system Forced lubrication
f Fuel cut method Cutting by stop solenoid
Fuel a Cam profile for plunger OS15H230
injection
b Plunger dia./ helix. lead degree mm/deg. 016, clockwise, lead 36.906°
pump
c Lift to port close (No.1 plunger) mm 3.0
d Delivery valve retraction volume mm 3/st 175
e Angleich cutting mm 0.22 x 2
f Delivery valve opening pressure MPa (kgf/cm2) 0.36 (3.63)
g Delivery valve spring constant N/mm (kgf/mm) 3.971 (0.405)
h Damping valve not employed
i Allowable max. pump speed min- 1 1100
j Overflow pressure MPa (kgf/cm2) 0.4 (4.0)
k Allowable pipe inside pressure MPa (kgf/cm2) 90 (918)
Governor a Governor type Electronic control (PGS)
Feed pump a Cam profile type 57H5T
b Fuel delivery cm 2/rev. 11.4
c Delivery pressure MPa (kgf/cm 2) 0.66-0.97 (6.7-9.9)
d Suction head mAq 1.0
123
(2) Feature
The fuel injection pump supplies pressurized fuel to
the injection nozzles through the action of the
plunger.
The plunger reciprocates in the plunger barrel with a
fixed stroke and is lapped for a precise fit. Intake/discharge port
A lead groove is helically cut in the plunger, and this
leads to a connecting groove which rises to the top Plunger barrel
of the plunger.
The integrate plunger barrel, the plunger barrel and
016332-00E
the flange case for the delivery valve holder, equips
a port for intake and discharge.
The injection volume of individual cylinders can
therefore be adjusted by rotating the plunger.
Increase fuel volume
The fuel comes through this port into the plunger
chamber is pressurized by the plunger, opens the
delivery valve, flows to the fuel injection nozzle Connecting groove
Helix ( Lead groove )
through the fuel injection pipe and is injected into
the combustion chamber. Fuel injection ends when
the pressurized fuel has been discharged.
This happens when the lead groove lines up with
the port (as the plunger rises and the pressure in
the fuel injection pipe drops).
Plunger
A fuel leak return hole is provided in the plunger

barrel. This return fuel which leaks through the gap
between the plunger and the barrel to the fuel drain
sump through the drain pipe, preventing dilution of
the lubricant in the cam chamber.
016334-00E
(3) Injection volume control

The fuel control mechanism is shown in following fig.
The T-shaped flange at the bottom of the plunger is
fixed in the grooves of the pinion sleeve, and the
pinion is engaged to the control rack. The plunger
rotates at the same time as the control rack is
moved adjusting the effective stroke and controlling
the injection quantity.
'T' Shaped flange
124
1) Full injection volume position

When the rack is set at maximum setting,
maximum volume of fuel is discharged. Injection
occurs when the top of the plunger lines up with
the intake port in the barrel. At this time, the lead
groove which is positioned at the widest stroke Effective stroke
part lines up with the discharge port, prolonging
the injection time and increasing the volume of
fuel injected.
This setting is normally used for starting and max. 016337
output operation.
2) Half injection volume position

Discharge ends earlier as the rack is moved
towards zero from the maximum setting.
The fuel injection volume is decreased
accordingly.
3) No fuel injection
With the rack set near zero, the intake/discharge
port in the barrel is always open, so no fuel is
pressurized (even though the plunger continues
to reciprocate).
(4) Delivery valve

The delivery valve at the top of the plunger prevents
fuel in the fuel injection pipe from flowing back to the
plunger chamber and sucks up fuel from the nozzle
valve to prevent after-drip.
When plunger lead lines up with the discharge port
of the plunger barrel, the injection pressure drops,
and the delivery valve is brought down by the
delivery valve spring.
At the same time, the suck-back collar (1) blocks off
the fuel injection pipe and the delivery chamber, and
the valve continues descending until the seat (2)
comes in contact with the barrel.
The fuel oil pressure in the fuel injection pipe
"'!
,, I
a
decreases proportionately with the lowering of the Suck-back
valve (due to increased volume). storoke
This accelerates the nozzle to the nozzle valve, and
sucks up fuel from the nozzle to prevent dripping.
The result is a longer nozzle life and improved
combustion efficiency.
125
3.11 Governor
3.11.1 Description
Construction of the governor
Control rack
Governor weight
Control handle
Governor spring 016490-00E
(1) Condition during engine start

When the control lever is pulled to the starting
position, the governor weights are closed by the
governor spring force, the linkage connected to the
shifter moves the rack to the maximum injection
position.
(2) Condition during idle

As the engine starts and the control lever is returned
to the idle position, the spring retainer returns until it
touches to the idle adjusting screw and the governor
spring force is reduced.
The governor weights are opened by the centrifugal
force and pull the control rack to reduce the fuel
injection amount, then they are balanced with the
governor spring force to maintain the idle speed.
126
(3) Condition during maximum speed

When the engine reaches at its maximum speed,
the governor weights balance with the governor
spring force and the rack is controlled to the
appropriate injection amount position, If the engine
load is reduced, the engine speed increases and
the governor weights open. The rack is moved to
reduce the engine speed and the specified engine
maximum speed is maintained. The maximum
injection amount is adjusted by the injection limit
screw. Do not try to adjust the injection limit screw
unless otherwise required since it is sealed.
(4) Condition during engine stop

When the stop lever is turned to the sop position,
the control rack is move to the stop position
regardless of the governor spring force to stop the
engine.
(5) Control handle

The engine can be controlled at the injection pump
by means of the control handle.
3.11.2 Disassembly of Governor

1) Remove the drain plug and drain the lube oil from Draining governor case
the governor case.
"
Drain plug
/
Ol6514-00E
127
2) Remove the spring lever and spring. Spring removal
Spring
016515- OOE
3) Remove the governor case cover bolts and Governor case cover removal
remove the cover while tapping the cover lightly
with a mallet.
016Sl6-00X
4) Remove the C-clips from both ends of the control C-clip removal
lever shaft.
!
/
~) 016517 - oox
128
5) Slide the control lever shaft approx. 20 mm (0.8 0-ring removal

in) by tapping the opposite end lightly and
remove the 0-ring from the shaft groove.
6) Drive the control lever shaft out to the opposite Contrdeverhafumoval

direction.
7) Remove the shifter. Shifter removal
Shifter
129
8) Remove the cotter pin and pin securing link A to Control lever removal
the control lever, then remove the control lever.
Control lever 016521-00E
9) Remove the cotter pin and pin securing link A to Link A removal
the 2nd lever and remove link A.
016522-00E
1O)Remove the thrust bearing and thrust washer. Thbmtrffigoval
016523-00X
130
11 )Hold the drive end of the camshaft using two Holding the camshaft
nuts and a wrench and remove the nut on the
governor end of the camshaft.
016524 -OOE
12)Remove the camshaft spacer from the camshaft. Camshaft spacer removal
13)Remove the governor weight assembly with a Governor weight removal

governor weight puller tool.
016526-00X
131
14)Remove the stop lever spring. Stop lever spring removal
1S)Remove the cotter pin and pin securing link B to Disconnecting the link B
the 2nd lever.
016528- OOE
16)Remove the stop handle. Stop handle removal
016529 -OOE
132
17)Remove the 2nd lever bearing A bolts and tap Driving out bearing A part way
bearing A from the inside until its notches are
released.
Note:
Do not remove bearing A at this time.
18)Drive out the tapper pin securing the stop lever Driving out the taper pin
to the 2nd lever shaft.
19)Remove bearing A from the governor case. Bearing A removal
133
20)Remove the bearing B attaching bolts, 2nd lever 2nd lever shaft removal
shaft, 2nd lever, sleeves A and B, and stop lever.
3.11.3 Inspection
1) Check the governor weight assembly for pin
looseness or wear on the friction portions and
replace it if necessary.
2) Check the thrust washer for wear and replace it if
necessary.
3) Check the inside surface of the shifter for
excessive wear or damage and replace it if
necessary.
4) Check the thrust bearing for wear or damage and
replace it as a set if necessary.
5) Check the governor case oil seal for wear or
damaged and replace it if necessary.
3.11.4 Assembly
1) Install the 0-ring in the groove of 2nd lever shaft 2nd lever bearing B
bearing B and insert the 2nd lever in the bearing B.
0-ring
2nd lever shaft
016534-00E
134
2) Insert the 2nd lever shaft in the governor case 2nd lever shaft installation
and install sleeve B, 2nd lever, sleeve A, stop
lever and bearing A.
Bearing A
I
" Stop lever
0165J5 -OOE
3) Drive the taper pin in the stop lever and set the Driving the taper pin
stop lever to the 2nd lever.
4) Connect link B to the 2nd lever with the pin and

cotter pin.
5) Install the key in the groove in the 2nd lever shaft Stop handle installation
and install the stop handle.
135
6) Install the stop lever spring. Stop lever spring installation
016538- OOE
7) Install the governor weight and spacer and

tighten with the nut.
Torque: 8 kg•m (58 ft-lb)
Note:
• Hold the end of the camshaft with two hex nut
as shown in "Holding the camshaft".
• After tightening the weight, make sure that the
weights move smoothly
8) Install the thrust washer, thrust bearing and Thrust bearing and shifter installation
shifter over the camshaft.
016539-00X
136
9) Connect the control lever to the 2nd lever with Connecting control lever to 2nd lever
link A, pins and cotter pins.
2nd lever-t--t--
Link A-
1O)lnstall the retainers in the holes of the control Alingning the retainers with the shifter
lever fingers and align the retainers with the
shifter groove.
Ol6541-00E
11 )Insert the control lever shaft in the governor case, Control lever shaft installation
install the 0-rings in the grooves of the control
shaft and secure the shaft with the 0-clips.
12)Move the shifter behind and make sure that the

linkage moves smoothly.
Push the shifter all the way in and make sure that
the rack end length from the pump case is
17-19 mm (0.668-0.748 in).
13)1nstall the governor spring.
Control lever
shaft
137
14)Use a new gasket and install the governor case Governor case cover installation
cover.
Cover 016S43-00E
1S)lnstall the control lever spring as shown in Control lever spring installation
"Control lever spring installation".
016S44-00X
138
3.11.5 Adjustment
(1) Rack movement adjustment
1) Pull the control lever fully.
2) Measure the rack end length from the pump
case.
If the injection limit screw is sealed, the rack end
length should be 12-13 mm (0.472-0.512 in).
If the injection limit screw is removed from the
governor case cover, the rack end length should
be 17-18 mm (0.669-0.709 in). Install the injection
limit screw and lock nut to the case cover. With
the control lever is puller fully, adjust the rack end
length to 12-13 mm (0.472-0.512 in) by turning
the injection limit screw. After adjustment, tighten
the lock nut securely and recheck the rack end
length.
3) Pull the stop handle to the stop position and Rack movement inspection
measure the rack end length.
The rack end length should be less than 1mm
(0.039 in).
139
3.12 Disassembly, Reassembly and Inspection of Fuel injection pump
4--:-§
5~
11
10
24-@
23-1.-----,
22--@l>
016546-00X
1. Fuel injection pump body 11. Protector 21. Bushing

2. Delivery valve 12. Fuel pump camshaft 22. Plunger spring seat B
3. 0-ring 13. Bearing 23. Plunger spring
4. Delivery valve spring 14. Bearing 24. Plunger spring seat A
5. Delivery valve assembly 15. Oil seal 25.Control rack
6. Delivery valve 16. Adjusting shims 26. Aux. spring
7. Delivery valve seat 17. Tappet assembly 27. Support
8. Plunger assembly 18. Pin
9. Plunger barrel 19. Roller guide
10. Plunger 20. Roller
140
3.12.1 Disassembly of fuel injection pump

When disassembling the fuel injection pump,
separate the parts for each cylinder and be careful
not to get them mixed up.
Be especially careful to keep the plunger/plunger
barrel, delivery valve/delivery valve seat and other
assemblies separate for each cylinder (the parts of
each assembly must be kept together and put them
back in the same cylinder).
( 1) Preparation
1) Wash off the dirt and grease on the outside of the
pump with cleaning oil (kerosene or diesel oil)
before disassembly.
2) Perform the work in a clean area.
3) Take off the drain plugs and drain the lubrication
oil.
(2) Disassembly
1) Fix the outside of the coupling and remove the
nut.
016548-00X
2) Screw the puller into the nut hole.

Remove the coupling by screwing in the puller
bolt.
Timer puller
016548-00X
141
3) Remove the spring shoe setting screws of all

cylinder.
Setting bolt
4) Loosen the delivery valve holders until they can

be turned by fingers.
016551
5) Remove the plunger barrel tightening nuts.
016552
6) Remove the plunger barrel assembly.

Insert two drivers under the barrel flange.
(Be careful not to damage the surface of the
pump housing.)
Lift up the barrel by prying the driver. Pull out the
barrel by turning it to and fro.
7) Remove and mark the shims to recall the original

Shim---
assembly.
142
8) Remove the plunger and plunger barrel together

with the plunger spring and lower spring retainer.
Barrel
9) Remove the delivery valve holder, delivery valve,
valve spring, valve stopper and 0-ring from the
Straight pin
plunger barrel. r--
cb I
Note:
Mark each part to recall the original Pinion,,.,
'-._/c
assembly.
10) Remove the straight pins securing the spring
0
i
'@
I
shoe to the barrel support, then remove the
I
®
pinion.
frDelWe~v.I"
I
Plunger
. !
~
:)
~)
'~/
~
I
1 Deflector
-.-.;.~
Plunger s p r i n g l ' !
"- L
"-
016570- OOE
11) Remove the rack setting screw and the control

rack.
12) Remove the tappets.
Tappet~
~I
016SS7-00E
13)Remove the fuel feed pump.
Note:
In case of disassembling the fuel feed pump,
see the instructions for fuel feed pump for
details.
143
14) Put the pump body upside down and remove

the hexhollow set bolts that secure the middle
bearing.
15) Remove the cam support and the shims by

prying open the slots in the support with screw
drivers.
16) Remove the camshaft together with the middle

bearing from the drive side.
Note:
Be careful not to damage the governor case
oil seal when removing the camshaft.
016S6l-OOE
3.12.2 Inspection of fuel injection pump
(1) Inspection of plunger

1) Thoroughly wash the plungers, and replace the
plungers that have scratches on the plunger lead
or are discolored.
2) The plunger is in good condition if it slides down 60°
smoothly when it is tilted at about 60°.
Turn the plunger and try this test several times.
If the plunger slides down too quickly or stops
part way, repair or replace it.
012233-00X
144
(2) Inspection of delivery valve

1) Clean the delivery valve well before inspection.
Replace as a set if the collar or seat of the delivery
valve is scratched scored scuffed worn etc.
2) The valve is good if it returns smoothly when
released after being pushed down with your finger.
(While the hole at the bottom of the delivery guide
seat is covered.) Replace it if necessary. Likewise,
the valve should completely close by its own
weight when you take your finger off the hole at
the bottom of the delivery guide sheet.
Note:
When fitting new parts, wash with diesel oil
and perform the above inspection.
(3) Inspection of pump housing

1) Inspect the sliding surface against the tappet
guide for extreme wear. Scratches on the sliding
surface against the roller pin are not a problem.
2) If there are burrs or discoloration, repair or
replace the body as this will lead to dilution of the
lubricant.
(4) Inspection of fuel camshaft and bearings

1) Fuel camshaft
Inspect for scratches or wear of cam surface,
deformation of key grooves and screw on both
ends. Replace it if necessary.
2) Replace the bearings if the outer race surface are
flaked or worn.
Note:
Replace the fuel camshaft and bearings
together.
(5) Inspection of tappet

1) Inspect the surface of the tappet, roller and roller
pin for wear or damage. Replace it if necessary.
2) Measure the clearance between the roller and
pin. Replace them if the clearance exceeds 0.2
mm.
145
(6) Inspection of rack and pinion

Inspect the rack and pinion for wear and burrs on
tooth surface. Replace them if necessary.
(7) Inspection of plunger spring and delivery

valve spring
Inspect the spring for scratches, cracks, breakage,
uneven wear and rust. Replace it if necessary.
(8) Inspection of setting screws

Inspect all setting screws and bolts for wear or
damage. Replace it if necessary.
(9) Inspection of oil seal

Inspect the oil seal lips for wear or damage.
Replace it if necessary.
3.12.3 Reassembly of fuel injection pump

( 1) Preparation
1) After inspection, arrange and clean all parts.
2) Prepare the parts for replacement before starting
assembly.
Note:
Always replace gaskets, packing and 0-rings
with new ones.
(2) Assembly
1) Install the governor case to the pump housing.
2) Fit the bearings to both ends of the camshaft.
Place the pump housing upside down and insert
the camshaft in the housing together with the
middle bearing.
Note:
Apply grease to the middle bearing to
prevent it from falling out before installation.
Coat the camshaft and oil seal with clean
lube oil to prevent damage to the lip of the oil 016605-00E
seal.
146
3) Provisionally tighten the middle bearing with hex,

hollow set bolt.
016559--00E
4) Provisionally install the camshaft support.

Sure to use the standard thickness shim.
Standard thrust clearance of

0.01-0.05 mm
camshaft
Note:
Do not install the 0-ring at this stage.
Coat the camshaft and oil seal with clean
lube oil to protect the oil seal from damage.
Take care that the shims do not stick in the
0-ring grooves.
016609-00E
5) Tighten the camshaft support with four screws. ~
6) Tap both ends of the camshaft with a mallet to

seat the bearings.
Turn the camshaft by hand and feel its rotating
resistance (preload). If it is too heavy, adjust it by
adding shims. Remove the shim if it is too light.
147
7) After adjusting the preload, remove the camshaft

support and install new 0-ring in the groove in the
support.
8) Apply clean lube oil to the 0-rings, pump housing
bore and the camshaft support.
Note:
Be careful not to damage the 0-rings.
9) Securely tighten the hollow set bolts of the middle

bearing.
Note:
Recheck the bearing pre load after tightening
the hollow set bolts, and readjust the pre load
if necessary.
10) Screw in the tappet setting bolts.
11) Align the groove in the tappet with the setting

bolt and insert the tappet. Tappet--e
Setting bolt
016565-00E
148
12) Screw in the spring shoe setting bolts.
13) Insert the rack in the pump housing and align its
ninth division of the scale with the end surface
of the pump housing thread.
Fifth gradation
14) Lock the rack position with a special setting

bolts as shown below.
15) Install new 0-ring in the plunger barrel.
149
16) Insert the plunger barrel in the deflector and

barrel collar. Align the hole in the barrel with the
hole in the collar, then set the straight pin in the Barrel
holes of the barrel and collar to fix them.
Straight pin
17) Insert the pinion in the spring shoe and install
the spring shoe on the barrel collar. Secure the
r--
cb I
spring shoe with the straight pins.
18) Insert the clip ring into the groove in the pinion. Pinion,,.,
'-._/c
19) Install the plunger spring.

20) Hook the neck of the plunger to the spring
i
0
'@
I
I
®
retainer, align the plunger flange with the slots in
frDelWe~v.I"
the pinion and push the plunger until it is locked I
Plunger
by the clip ring on the pinion.
. !
~
:)
~)
'~/
~
I
1 Deflector
Ploogec 'P""'~.•.-.;.~ !
I L_
016570- OOE
21) Place a shim around each stud bolt.
22) Align the grooves in the pinion and spring shoe.
Pinion
Align the groove
tlrnnihID'
l~l
groove Spring shoe
150
23) Align the groove of the spring shoe with the

setting bolt and carefully insert the plunger
barrel assembly in the pump housing bore.
Note:
Apply clean lube oil to the 0-rings and pump
housing bore in order not to damage the 0-
ring.
Do not try to drive in the barrel.
Before inserting the plunger barrel assembly,
turn the camshaft and set the cam to the
position that the tappet comes to the lowest
position.
24) Install the original shims as marked during

Shim-~-
disassembly between the barrel support and
pump housing.
016553- OOE
25) Make sure that all plunger grooves face in the

same direction If they do not, the rack and
pinion engagement will be out of line and will
have to be reassembled.
26) Align the notch of the deflector with the slot in

the plunger barrel and insert the deflector above
the plunger barrel.
151
27) Install the delivery valve seat valve, spring,

stopper and packing then finger tighten the
delivery valve holder. Delivery valve
holder
016578- OOE
28)Align the marks on the barrel support and the

pump housing, then tighten the nuts to the
specified torque.
N•m (kgf•m)
I
Torque 54-64 (5.5-6.5) I
29)Tighten the delivery valve holders to the

specified torque.
N•m (kgf•m)
I
Torque 186-206 (19-21) I
30) Install the fuel feed pump to the pump housing.
Fuel feed pump
152
31) Remove the rack set bolt and install the rack
setting screw securely.
32)Hook a spring scale to the control rack and

measure the sliding force.
I
Sliding force 1472 (150 gf) max.
Excessive sliding force may be caused by the

followings.
• Large resistance at the sliding section of the
plunger assembly.
• Excessive tightening of the delivery valve holder
(distortion of the plunger barrel)
• Damage or particles at the tooth of the control rack
or pinion.
• Damage at the outer periphery of the control rack.
• Damage at the control rack hole in the pump
housing.
In each case, disassemble and repair.
33)Assemble the governor.

34)Fill the pump and governor with clean lube oil.
pump 1500 cc
Oil capacity
governor 250 cc
153
3.12.4 Adjustment of fuel injection pump

Adjust the fuel injection pump after completing
reassembly.
The pump itself must be readjusted with a special
pump tester when you have replaced major parts
such as the plunger assembly, tappet assembly, fuel
camshaft, etc.
( 1) Preparation
Prepare for adjustment as follows.
1) Adjusting nozzle assembly and data sheet of
injection start pressure.
2) Adjusting injection pipe.
mm(in) 012242-00X
Inner dia./outer dia. x length 08 I 2.2 x 760 mm
Minimum bending radius 25 (0.98)
3) Mount the fuel injection pump on the pump tester

platform.
4) Fill the pump and governor with clean lube oil.

oil capacity : pump 1500cc
governor 250cc
016350-00E
5) Connect the fuel oil pipes and operate the pump

tester to purge the air in the line.
6) Set the oil feed pressure from the pump tester to

the injection pump at the pressure specified in the
separate service data sheet.
154
(2) Adjustment of pre-stroke

1) Remove the delivery valve holder of No 6
cylinder.
Remove the delivery valve spring and delivery
valve.
2) Screw the pre-stroke measuring device in the
screw hole on the top of the barrel.
3) Set the control rack to the full load position.
Find the bottom dead center of the plunger while
Pre-stroke measuring
rotating the pump by hand, and set the dial
device
indicator to zero.
016513-00E
4) Slowly rotate the pump in the normal rotation

direction by hand, and measure the plunger lift
until fuel flow from the overflow pipe on the
measuring device stops.
Pre-stroke: See separate service data
5) If the measured pre-stroke is not standard, adjust
by changing the shim thickness between the
flange of the plunger barrel and pump housing.
6) Repeat the above procedure to adjust the pre-
stroke of each cylinder.
7) After adjustment is completed, insert the gasket,
delivery valve, delivery valve holder and spring.
Tighten the delivery valve holder.
N•m (kgf•m)
Delivery valve holder tighten- 186-206
ing torque (19-21)
(3) Adjustment of injection timing

After adjusting the pre-stroke for all cylinders, check
and adjust the injection timing.
1) Set the governor control lever in the operating
position (bring the plunger to the effective
injection range), then turn the camshaft
clockwise, and check the injection starting time
(FID) of No.1 cylinder (start of fuel discharge from
the delivery valve holder).
Cylinder No. Count from drive side
Direction of rotation View from drive coupling side
155
2) Set the tester needle on the flywheel scale in a

position where it is easy to read. and check the
injection timing several times according to the
injection order.
Injection order 1-4-2-6-3-5

Injection interval 60°
Allowable deviation ± 30
3) Readjust the pre-stroke of cylinders that are not

within the allowable deviation (increase of the
adjusting shim thickness makes the injection
timing later, and decrease makes it earlier).
The change in injection timing by the adjusting
shims is as follows.
Adjusting thick- Change of injection timing

ness of shim Cam angle Crank angle
0.1 mm (0.0039 in.) 0.35° 0.7°
mm(in)
Standard 3.0 (0.118)
Thickness 2.5-3.5
of shims Applicable (0.984-1.378)
(t =0.1 mm step)
(4) Plunger pressure test

1) Mount the pressure gauge to the delivery valve
holder of the cylinder to be tested.
98.1 MPa
Max. pressure gauge reading
(1 000 kgf/cm 2)
Connecting screw dimensions M18 x 1.5
2) Set the governor control lever in the stop position,

operate the injection pump at about 200 rpm, and
make sure that the pressure gauge reading is 49
MPa (500 kgf/cm20) or more A11 the time lightly
move the control rack towards fuel increase side.
Replace the plunger if the pressure does not
reach this value.
3) Check to see that oil is not leaking from the
delivery valve holder or fuel injection piping, and
there is no extreme drop in pressure.
156
(5) Delivery valve pressure test

1) Connect a pressure gauge to the delivery valve
holder. (Refer to plunger pressure test.)
Drive the pump at 200 rpm and, moving the control
rack, apply a pressure of 12 MPa (120 kgf/cm 2).
2) Set the control rack to the O mm position and
measure the time required for the pressure to drop
from 1O MPa (100 kgf/cm 2) to 9 MPa (90 kgf/cm 2).
Pressure drop limit 20 seconds minimum
If the pressure drops faster than this, wash the

delivery valve, and retest. Replace the delivery
valve if the pressure drop is not remedied.
(6) Measurement and adjustment of

injection volume
1) Adjustment of injection volume
a) Loosen the two nuts on the plunger barrel flange,
and turn the plunger barrel to the right or left.
b) Measure the injection volume of each cylinder.
Repeat this process until the injection volume
of every cylinder is within the specified limit.
c) After completing the measurements, retighten
the nuts of plunger barrel flange.
N•m (kgf•m)
I Tightening torque
54-64
(5.5-6.5)
d) If match mark is not aligned make a new match Inequality quantity =

mark. Maximum injection quantity - Average injection
of each cylinder quantity
- - - - - - - - - - - - - - - X100
Average injection quantity
157
(7) Adjustment of Exhaust Temperature

(Fuel Injection Volume)
6------
• If the dispersion of exhaust temperature among
the cylinders exceeds 50 °c when the fuel
injection valves are serviced, adjust the exhaust
temperature of each cylinder by moving each
Set mar
barrel support.
• Before adjusting the exhaust temperature, be
sure to stop the engine.
• The deviation between the set mark of barrel
'i
support and that of pump must be within± 5°. Decreasing //
/'to.. Increasing
' ~
1) Remove the fuel injection pipe. Injection volume
• In case of double walled injection pipe.
Loosen the retainer and then remove the injection
pipe.
2) Loosen the barrel support clamping nut one full
turn.
3) Move each barrel support to adjust the position of
set mark.
Counterclockwise: The fuel injection volume increase.
(The exhaust temperature rises.)
Clockwise: The fuel injection volume decreases.
(The exhaust temperature lowers.)
4) Tighten the clamping nut.
158
3.13 Fuel feed pump

(1) Feature
Fuel feed pump is double action piston type with
four check valves. It is installed on the side of the
injection pump and driven by a cam.
The feed pump sucks up fuel from the fuel tank and
Priming pump
sends it to the fuel injection pump through a fuel CMP
filter. It also automatically adjusts the fuel delivery
pressure.
Two oil seals are used on the push rod to prevent
lube oil from mixing with the fuel from entering the
cam chamber.
(2) Double action piston and automatic

pressure control mechanism
When the piston moves upward the pressure in the
upper chamber rises and the pressure in the lower Inlet
chamber becomes negative As to the check valve in
the upper chamber, right vale is closed and left
valve is opened.
Thus, the fuel is delivered to the outlet.
As the pressure in the lower chamber is negative,
left valve in the lower chamber is closed and right
valve is opened, and then fuel flows into the lower
chamber.
When piston moves downward, the pressure in the
lower chamber rises and left check valves are
opened and right valves are closed, and then fuel in Fully lift 016383-00E
the lower chamber is delivered to the outlet.

When the delivery pressure of the fuel pump rises
up to the extent that the pressure at the back of the
piston overcomes the piston spring force, the
movement of the piston is hindered. \ Inlet
Thus, the fuel flow is automatically stopped, and the
fuel pressure is maintained within a fixed range.
Fully down
159
(3) Disassembly of fuel feed pump

1) Remove the piston spring stopper plug and pull
out the piston spring.
2) Remove the piston.
3) Push the tappet from the opposite side of the plug
and remove the snap ring.
4) Remove the tappet and inter spindle.
5) Loosen the screw at the bottom of the priming
pump and remove the priming pump assembly.
6) Remove the inlet and outlet check valve springs
and check valves.
(4) Inspection after disassembly

1) Block the inlet port of the priming pump with your
finger and push in the piston. If the piston returns
by the spring force, the piston does not have
enough negative pressure Always replace the
priming pump as a set.
2) Check the piston spring for cuts, cracks, uneven
wear and rust.
3) If the piston, inter spindle, or tappet assembly is
extremely worn, replace the part.
4) Check the contact surface of the valve and valve
seat for defects.
5) When there is play between a valve seat and
feed pump body, the whole fuel pump body must
be replaced.
6) Clean the filter screen in cleaning solvent and
check it for damage or clogging. Replace it if
damaged.
Note:
Play in the valve seat hinders the opening
and closing of the valve, causing insufficient
fuel supply and abnormal wear of the tappets
and camshaft.
(5) Assembly of fuel feed pump

Assemble in the reverse order of disassembly.
160
(6) Inspection after assembly

1) Air leak test
Inspect the air-tightness of each pipe and packing
etc. Measuring cylinder
Especially check the inlet side because air is
likely to enter due to the negative pressure of the
suction.
2) Leakage from inter spindle seals Tappet
Fuel
Plug the outlet, apply compressed air at 0.29
MPa through the outer port, place the feed pump Plug outlet
in a fuel tank and inspect for leakage from the
inter spindle seals If there are air bubbles,
replace the oil seals, inter spindle or the feed
pump body.
(7) Test of fuel feed pump

1) Setting of the pump
Set the fuel feed pump on the injection pump,
and operate the assembled unit on the pump
tester.
Fuel piping should be provided directly from the
tank, not through the delivery pump of the tester.
2) Suction test for the priming pump

Loosen the handle of the priming pump, and push
the handle at 60 - 100 strokes/minute.
If fuel comes out of the delivery side of the feed
pump after about 30 strokes, the priming pump is
normal. If it takes longer, replace the priming
pump as a set.
Suction head 1m
Within 30 strokes
Suction pipe dia. 8
161
3) Delivery pressure test

The special equipment is necessary to perform
delivery pressure and delivery volume test. Pressure gauge
Operate the injection pump at the specified rpm, 0-0.098 MPa
and read the pressure gauge indicator when

valve B is tightened completely. Tighten the valve
A so that the pressure gauge indicator does not
move when the pressure is applied.
Note:
Do not run the equipment for more than 5
Feed pump
minutes since the fuel injection pump may be
damaged if operated in non-injection
condition.
N•m (kgf•m 2)
0.66-0.97
Delivery pressure
(6.7-9.9)
Pump rpm 600
Replace the piston spring if it is defective.
016387-00X
4) Delivery volume test

Operate the fuel injection pump at the specified
rpm, open valve B until the pressure gauge
indicator shows 0.098 MPa (1 kgf/cm 2), and
measure the delivery rate for one minute.
Delivery volume > 10 Q/min

Back pressure 0.098 MPa (kgf•m 2)
Pump rpm 1000
162
3.14 Adjusting the injection timing

( 1) Checking the injection timing No.6 Injection pipe
1) Disconnect the No.6 fuel injection pipe from the
fuel injection pump.
2) Turn the flywheel manually until the No.6 piston is
about 35° before T.D.C. on the compression
stroke, and then lightly turn the flywheel.
3) Make sure that fuel flows out of the No.6 delivery
holder.
4) The injection timing is read on the scale indicated
by the "1.6T" top mark on the flywheel.
01J488 -OOE
Standard injection 6AYM-GTE 6AYM-ETE 6AYM-STE

timing FID
(before T.D.C.) 20° ± 0.5° 19°±0.5° 18°±0.5°
(2) Adjusting the injection timing

Flywheel housing
1) Align the "1.6T" mark on the flywheel with the
standard injection timing on the crank angle
scale.
2) Loosen the two bolts securing the intermediate
joint and drive shaft coupling.
3) Turn the injection pump shaft slowly until the fuel
flow out of the No.6 delivery holder.
(When turning the pump shaft, use the bolts
securing the intermediate joint and Coupling for
camshaft.)
4) Tighten the two coupling bolts evenly.
007490-00E
Timing adjusting bolls

016?78-00E
163
3.15 Fuel injection Nozzle

When fuel oil pumped by the fuel injection pump
reaches the injection nozzle, it pushes up the nozzle Fuel passage
valve (held down by spring), and is injected into the
combustion chamber at high pressure. Nozzle body
The fuel is atomized by the nozzle to mix uniformly
with the air in the combustion chamber. How well Nozzle valve
the fuel is mixed with high temperature air directly
affects combustion efnciency, engine performance
and fuel economy.
Accordingly, the fuel injection nozzles must be kept
in top. condition to maintain performance and Injection hole
operating efficiency. 014971-00E
Hole type fuel injection nozzle

6AYM-GTE
Engine model
6AYM-ETE
6AYM-STE [m-cap nut
Fuel injection nozzle Ass'y

Type Semi-long type hole-nozzle
t
@
@
@
Operating pres- 31 ± 0.5 MPa
sure (316 ± 5 kgf/cm 2) Adj°'l~ol boll
No. of injection
8 x 0.30 mm 8 x 0.27 mm
holes x injection
hole dia.
Injection angle
4 x 0.22 mm
160°/ go 0
4 x 0.22 mm
160°/ go 0
fJ
<fl N~''' hold"
Valve lift 0.45 ± 0.01 mm 0.40 ± 0.01 mm

0
0
e
3.15.1 Functioning of fuel injection I-- Nozzle spring
nozzle ®:O
Fuel from the fuel injection pump passes through ~
Nozzle valve
the oil port in the nozzle holder, and enters the
Nozzle
nozzle body reservoir. CMP
When oil reaches the specified pressure, it pushes
y.-
Nozzle body
up the nozzle valve (held by the nozzle spring), and
Nozzle nut
is injected through the small hole on the tip of the
nozzle body.
The nozzle valve is automatically pushed down by
the nozzle spring and closed after fuel is injected.
Oil that leaks from between the nozzle valve and
nozzle body goes from the hole on top of the nozzle
spring through the oil leakage fitting and back into
the fuel tank.
(1) Hole type fuel injection nozzles

Nozzle body identification number.
The type of nozzle can be determined from the
number inscribed on the outside of the nozzle body.
Mark
014904-00E
164
3.15.2 Fuel injection nozzle

disassembly
Note:
1. Disassemble fuel injection nozzle in a clean
area as for the fuel injection pump.
2. When disassembling more than one fuel
injection nozzle, keep the parts for each
injection nozzle separate for each cylinder
(i.e. the nozzle for cylinder 1 must be
remounted in cylinder 1).
(1) When removing the injection nozzle

from the cylinder head, remove the high
pressure fuel pipe, fuel return pipe, etc.,
the injection nozzle retainer nut, and
then the fuel injection nozzle.
(2) Put the nozzle in a vise

Note:
Use the special nozzle holder for the hole type
injection nozzle so that the high pressure
mounting threads are not damaged.
(3) Remove the nozzle nut
(4) Remove the inner parts

Note:
Be careful not to lose the spring seat, adjusting
shims or other small parts.
(5) Check and cleaning of fuel injection

nozzle
1) Check the carbon flower deposit around the
injection hole.
2) Check spray condition with nozzle tester
operating the lever 2-3 times per second.
• No sharp angle deviation

• Uniform atmized fuel
• No dipping after stopping
3) Wash the nozzle in clean diesel oil with the

nozzle cleaning kit.
a) Clean off the carbon on the outside of the of the

nozzle body with a brass brush.
b) Clean the nozzle seat with cleaning spray.
c) Clean off the carbon on the tip of the nozzle with
a piece of wood.
d) Clean the nozzle hole with a nozzle cleaning
needle.
015798-00X
165
(6) Inspection of fuel injection nozzle

1) Inspect the nozzle for abnormal scratches or
wear and replace it if the sliding surface or seat is
scratched or abnormally worn.
2) Make sure that the nozzle slides down by itself
when the nozzle is pulled out about half way from
the body and released.
Rotate the nozzle a little, and try again.
Replace the nozzle as a set if there are some
places where it does not slide smoothly.
01490?-00X
166
(7) Reassembly of fuel injection nozzle

1) Install the fuel injection nozzle (A).
2) Install the fuel injection pipe joint (C) to the fuel
injection nozzle (A), (together with the rubber
packing). Fuel injection nozzle
tightening nut (B)
3) Tighten the nozzle tightening nut (B).
N•m (kgf•m)
Tightening torque 121-137(13-14) I
4) Tighten the fuel injection pipe joint (C).
N•m (kgf•m) 0-ring
Tightening torque 10-90 (7-9) I
If the nozzle tightening nut (B) is tightened first,

016375 -OOE
fuel oil may leak into the lube oil.
167
3.16 Boost Compensator

The boost compensator, installed to the injection
pump of the turbocharged engine models, limits the
movement of the fuel control rack with the boost
pressure detection equipment. It optimizes fuel
injection and combustion according to the air
volume inside the cylinder for complete combustion
and higher output.
3.16.1 Performance
Without boost compensator With boost compensator
Rack position and boost

pressure linear diagram
when engine speed is
Rz
raised gradually
c
0
R3
""·u;0 R1
Cl..
.;,::.
'-'
(\l
n:'.
Ro
Boost pressure linear diagram

at quick accelaration
No N2
Idle
Engine speed 003282-00E
1) The solid line shows the rack's moving distance

and the boost pressure when the engine speed is
raised gradually. When the regulator handle is
raised quickly from the idling position (NO) to the
(N1) position, the rack moves from RO to R2 to
attain the engine speed (N1), and injects a large
quantity of fuel. The supply of air, however, is
inadequate due to the follow-up delay of the
turbocharger (i.e. insufficient boost pressure),
and the exhaust turns black.
2) The boost compensator limits the advancing of
the rack and keeps it at R3 position. The rack
starts to move at pressure of PA and reaches to
R2 position when pressure rises up to PB or
more.
In engines with the boost compensator, injection
quantity in the range of rack positions R2 - R3
(shadowed area) is limited and thus black exhaust
is controlled.
168
3.16.2 Equipment
Cancel lever Adjusting screw

Adjust boll
(M8x 1.25)
Fuel
<::_:-::_~
Decreases Increases
Control rack 016J74 -OOE
1) Fine adjustment with the adjust bolt

If you make a fine adjustment to decrease the boost compensation to alter the amount of black smoke and
liner speed start up characteristics when the engine accelerates, turn the adjust bolt on the top of the
case.
• Tightening the adjust bolt increases boost compensation. (Acceleration capacity improves and black
smoke increases.)
• Loosening the adjust bolt decreases boost compensation. (Acceleration capacity declines and black
smoke decreases.)
The bolt can be adjusted only 2 turns (1.25 x 2 =2.5 mm) for decrease or increase. the ratio of the turning
to the change of rack is approximately 1 : 1.
169
3.17 Troubleshooting of fuel oil

system
Before removing fuel injection pump
It is necessary to find out the cause of the trouble
before replacing the defective parts.
The cause of the trouble may not necessarily be in
the pump itself, but may be in the engine or the fuel
oil system.
If the pump is removed prematurely, the cause of
the trouble may never be known.
Before removing the pump from the engine, at least
go through the basic check points given here.
Basic check points

• Check for breaks or oil leaks through out the fuel
system, from the fuel tank to the nozzle.
• Check the injection timings for all cylinders.
Are they correctly adjusted?
Are they too early or too late?
• Check the nozzle spray.
•Check the fuel delivery. Is it in good condition?
Loosen the fuel pipe connection at the injection pump
inlet, and test the operation of the fuel feed pump.
Major faults and troubleshooting

Fault Cause Remedy
1. Engine won't Fuel is not ( 1)No fuel in the fuel tank. Supply
start. delivered from (2) Fuel tank cock is closed. Open
injection pump. (3) Fuel pipe system is clogged. Clean
(4) Fuel filter element is clogged. Replace element
(5) Air is sucked into the fuel due to defective Repair
connections in the piping from the fuel tank
to fuel feed pump.
(6) Defective valve contact of feed pump. Repair or replace
(7) Piston spring of feed pump is broken. Replace
(8) Inter spindle or tappet of feed pump is stuck. Repair or replace
Nozzle does not ( 1) Nozzle valve does not open or close Repair or replace
work. normally.
(2) Nozzle seat is defective. Repair or replace
(3) Case nut is loose. Inspect and tighten
(4) Injection start pressure of nozzle is too low. Adjust
(5) Nozzle spring is broken. Replace
(6) Fuel filter is clogged. Replace element
(7) Excessive oil leaks from nozzle sliding area. Replace nozzle assembly
Injection timing is (1) Injection timing is retarded due to failure of Adjust
defective. the coupling.
(2) Camshaft is excessively worn. Replace camshaft
(3) Roller guide is excessively worn. Adjust or replace
(4) Plunger is excessively worn. Replace plunger assembly
2. Engine starts, but immediately (1) Fuel pipe is clogged. Clean
stops. (2) Fuel filter is clogged. Disassemble and clean, or
replace element
(3) Improper air tightness of the fuel pipe Replace packing, replace pipe
connection or pipe is broken and air is being
sucked in.
(4) Insufficient fuel delivery from feed pump. Repair or replace
170
Fault Cause Remedy

3. Engine's output Defective ( 1) Knocking sounds caused by improper (too Inspect and adjust
is insufficient injection timing, early) injection timing.
and other (2) Engine overheats or emits large amount of Inspect and adjust
failures. smoke due to improper (too late) injection
timing.
(3) Insufficient fuel delivery from feed pump. Repair or replace
Nozzle (1) Case nut is loose. Inspect and tighten
movement is (2) Defective injection nozzle performance. Repair or replace nozzle
defective. (3) Nozzle spring is broken. Replace
(4) Excessive oil leaks from the nozzle. Replace nozzle assembly
Injection pump is ( 1) Max delivery limit bolt is screwed in too far. Adjust
defective. (2) Plunger is worn. Replace
(3) Injection amount is not uniform. Adjust
(4) Injection timings are not even. Adjust
(5) The levers of the governor and the control Repair
rack of the injection pump are improperly
lined up.
(6) Delivery stopper is loose. Inspect and tighten
(7) Delivery packing is defective. Replace packing
(8) Delivery valve seat is defective. Repair or replace
(9) Delivery spring is broken. Replace
4. Idling is rough. ( 1) Movement of control rack is defective.
1) Stiff plunger movement or sticking. Repair or replace
2) Rack and pinion fitting is defective. Repair
3) Movement of governor is improper. Repair
4) Delivery stopper is too tight. Inspect and adjust
(2) Uneven injection volume. Adjust
(3) Injection timing is defective. Adjust
(4) Plunger is worn and fuel injection adjustment Replace
is difficult.
(5) Governor spring is too weak. Replace
(6) Feed pump can't feed oil at low speed. Repair or replace
(7) Fuel supply is insufficient at low speed due Disassemble and clean, or
to clogging of fuel filter. replace element.
5. Engine runs at high speed and cuts (1) The wire or rod of the accelerator is caught. Inspect and repair
out at low speed. (2) Control rack is caught and can't be moved. Inspect and repair
6. Engine does not reach max. rpm. (1) Governor spring is broken or excessively Replace
worn. Replace or repair
(2) Injection performance of nozzle is poor.
7. Loud knocking. (1) Injection timing is too early or too late. Adjust
(2) Injection from nozzle is improper. Fuel drips Adjust
after each injection.
(3) Injection pressure of nozzle is too high. Adjust
(4) Uneven injection volume. Adjust
(5) Engine overheats, or insufficient Repair
compression.
8. Engine emits Black smoke (1) Injection timing is too early. Adjust
too much (2) Intake air volume is insufficient. Inspect and repair
smoke. (3) The amount of injection is uneven. Adjust
(4) Injection from nozzle is improper. Repair or replace
White smoke (1) Injection timing is too late. Adjust
(2) Water is mixed in fuel. Inspect fuel system, and clean
(3) Lube oil comes into the combustion Repair
chamber.
(4) Engine is over cooled. Inspect
171
3.18 Fuel Filter

The fuel filter is installed between the fuel feed
pump and fuel injection pump, and removes dirt/
foreign matter from the fuel pumped from the fuel
tank. The fuel filter element must be changed
periodically. The fuel pumped by the fuel feed pump
goes around the element, is fed through the pores in
the filter and discharged from the center of the
cover. Dirt and foreign matter in the fuel are
deposited in the element.
3.18.1 Fuel filter specifications

Filtering method Filter paper element
Filtering area 15,000 cm 2
Element fitness 8µ
3.18.2 Fuel Filter inspection
(1) Draining the filter:

• Remove the plug at the bottom of the filter and
drain out any water and dirt.
•After draining the filter, reinstall the plug securely.
Service period Every 50 hours
(2) Replacing the element :

• Remove the center filter bolt, then the filter case Case
and element. 0-ring
• Wash the filter case and replace the element and I
Eleme~
0-ring with new ones.
• Do not forget to reinstall the spring and washer. 0-ring
Fasten the center bolt securely.
~-
•Always make sure to bleed the air after the 000729-0lE
element has been replaced.

172
3.18.3 Water separator
(1) Draining the separator:

• Remove the plug at the bottom of the water
separator and drain any water and dirt.
•After draining the separator, reinstall the plug
securely. Center Bolt
(2) Replacing the element :

• Remove the center separator bolt, then the filter
case and element.
• Wash the separator case and replace the element
and 0-ring with new ones.
• Do not forget to reinstall the spring and washer. Drain Plug
Fasten the center bolt securely.
•Always make sure to bleed the air after the
element has been replaced.
173
3.19 Lubrication system

3.19.1 Lubrication system
The lube oil in the pan is pumped up through the
intake filter and intake piping by the lube oil pump,
through the oil cooler to the oil filter bracket.
The lube oil which flows from the oil filter through
the bracket to the oil element is filtered and sent to
the hole of cylinder body. It returns from the main
gallery in the cylinder body to the thermostat.
The lube oil which flows in the main gallery goes to
the crankshaft journal, lubricates the crank pin from
the crankshaft journal, and a portion of the oil is fed
to the camshaft bearings.
Lube oil is sent from the gear case camshaft
bearings through the holes in the cylinder body and
cylinder head to the rocker arm shaft to lubricate the
rocker arm and valves.
Lube oil is also sent the main gallery to the piston
cooling nozzle to cool the piston surface, and is sent
through the intermediate gear bearings and
respective gears.
Lube oil for the fuel injection pump is sent by pipe
from the main gallery to the fuel injection pump.
Part of the lube oil is sent from the main gallery to
the turbocharger in engines fitted with one, and is
then piped back from the turbocharger to the oil pan.
,...__-1 Rocker arm ..,.__ _ _ _---l
.....---iTurbocharger~------1
Lubricating
oil filter
Connecting rod Crankshaft
c
.!!!
(ii
Cl)
Camshaft 6
By-pass filler
Lubricating oil cooler
Idle gear
Pressure
- - - - - - - F u e l injection pump regulator
valve
Oil jet
(for piston)
174
3.19.2 Lube oil pump

(1) Lube oil pump construction
The gear-type lube oil pump is mounted on the Adjusting plate
cylinder block, and the pump is driven by the
crankshaft gear. The lube oil flows from the intake Safety valve (B) ~
filter mounted on the oil pump body through the ~~,
~ \
holes in the cylinder body and engine plate, and out
from the holes in the engine plate and cylinder body
Spring
to the discharge filter.
The lube oil pump is fitted with a pressure safety
~Safety'"'~
valve which maintains the relief pressure at
A : 1 .2-1.4 MPa (12-14 kgf/cm 2).
B : 1 .0-1.2 MPa (10-12 kgf/cm 2).
(A)
A pressure regulating valve is located on cylinder
block behind lube oil cooler.
~Spring
~Adjusting plate
(2) Specifications of lube oil pump

Pump test performance
Delivery 15000 Q/h
Delivery pressure 1.47MPa (15kgf/cm 2)
Pump speed 1689 min- 1
Engine speed 1900 min- 1
175
(3) Lube oil pump disassembly and

reassembly
Removal
CD Drain the engine oil.
~Remove the oil pan.
@ Remove the oil inlet pipe.
@ Remove the oil pump.
Inspection
Remove the oil pump cover and measure the oil
pump gear-to-oil pump body and the gear-to-cover
clearances.
If the measured value exceeds the service limit or if
there is local wear, replace the oil pump assembly.
Gear-to-pump clearance
Standard : 0.20-0.28 mm
Service limit : 0.50 mm
Gear-to-cover clearance
Standard : 0.06-0.12 mm
Service limit : 0.15 mm
Measuring the oil pump gear-to-pump body

clearance.
Measuring the oil pump gear-to-pump cover Straight edge

clearance.
Note:
1. The oil pump should be disassembled only
when oil pressure does not rise sufficiently
even after adjusting with the pressure
regulator valve.
2. When assembling, make sure that the
drive shaft (gear) rotates smoothly.
176
Installation
CD Install the oil pump drive gear on the oil pump.
Note:
1. Tighten the pump bolts temporarily. Rotate
the crankshaft so that the engagement of
the teeth is parallel. Then tighten the
pump bolts.
2. Check the backlash of the drive gear.
Backlash : 0.15-0.25 mm.
~ Use new gasket and attach the oil inlet pipes.

@Use a new gasket and install the oil pan.
Note:
1. Coat the three faced matching corner with
liquid sealant.
2. Tighten after securely matching with the
surface of the cylinder block.
@ Install all drain plugs and pour in the
recommended oil to the upper level.
3.19.3 Oil pressure control valve Cap nut
~
construction
Lube oil travels from oil filter to the lube oil cooler
and sent on to the main gallery of the cylinder body.
Adjust the pressure of the valve located just before Adjusting screw ~~¢$)
~~
the entrance to the main gallery.
When the pressure of the lube oil entering the main
gallery of the cylinder body exceeds the standard,
the pressure control valve piston opens an escape
outlet and allows excess oil to drain into the oil pan.
(1) Regulating pressure

MPa (kgf/cm2)
I Regulating pressure
0.44-0.54
(4.5-5.5)
(2) Oil pressure control valve replacement

The control valve has been adjusted and assembled 013281
at the factory, so it should not be disassembled

without good reason.
If the oil pressure control valve is disassembled due
to spring trouble, etc., mount a pressure gauge on
the oil pressure sender unit mounting washer, and
adjust the pressure with adjusting screw until it is at
the specified value.
177
3.19.4 Lube oil filter

(1) Lube oil filter construction
The lube oil filters are full-flow paper element type,
mounted to the side of the cylinder body with the
lube oil cooler. The cartridge type filter is easy to
remove.
To prevent seizure in the event of the filter clogging,
bypass circuit is provided, in the oil filter bracket.
I Filtration (nominal) 20µ m
CD Lub. oil filter is installed in parallel with the

line, in which a bypass valve is built in.
~ If the filter is clogged, its filtering capacity will
be lost. Unfiltered lube oil will be fed to various
013294- OOE
parts if the pressure loss exceeds 0.2 + 0.03

MPa (2.0 + 0.3 kgf/cm 2 )
@When replacing the oil filter :
1) Remove the filter with the filter wrench.
(Turn to the left.)
2) Before installing the filter, carefully wipe the
installation side and apply lubricating oil to the
packing surface. r-·--·
3) Tighten the lube oil filter fully by hand, and then
use a filter wrench to further tighten the filter.
(Turn to the right.) I
4) Check for oil leakage during operation.
1st time 50 hours

I
Service
period 2nd time and Every 500 hours
after (or every 3 months) 007S4l-OOX
(2) Cleaning of lube oil by-pass filter

The lub. oil system is equipped with a centrifugal by-
pass filter.
Note:
Stop the engine before cleaning the bypass
filter.
If you disassemble the bypass filter during a
run, oil mist may be blown off, causing you to
get burnt.
Disassembly and cleaning

178
1) Disassemble and clean the lub. oil bypass filter

according to the following procedures.
CD Loosen the cap nut and then remove the cover.
~ Loosen the nut and lock nut, remove the rotor
cover and then remove the insulator assembly
and rotor body.
/ 'I
I
O ring
@ Remove the sludge inside the rotor with a
spatula.
Note:
Completely remove the sludge. Otherwise, the
residual sludge may cause an unbalance in
rotation, resulting in damage to the bearing of
spindle shaft.
@Clean the nozzle with a brass wire brush.
Oring--o
@Check each part and 0-rings. If any damage or
excessive wear is found, replace the part.
2) Assembly
Assemble the filter in the sequence reverse to
disassembly while observing the following
precautions.
CD Tighten the nut and lock nut, make sure the
rotor smoothly turns, then attach the cover 01420S-OOE
and tighten the cap nut.

~While operating the filter, make sure oil does
not leak from connected sections. Also, make
sure the filter is not vibrated abnormally.
179
3.19.5 Lube oil cooler

(1) Lube oil cooler construction
The welded plate type is in contact with the inner
surface of the outer plate This forms a fresh cooling
waterway.
The lube oil flows through the outside passageway
and is cooled by the cooling water flowing through
the inner plate.
There are two such pipes, connected side by side,
designed so that the lube oil and water flow in the
opposite directions.
(2) Inspecting for assembly and service

CD Use new packing and 0-ring during assembly.
~When cleaning the cooling water system, use
"WASTn K-1" to remove scales.
@Clean the inside of the water passageway side
with a wire brush to prevent the build-up of
scale.
@ If the rubber hose connection or welds are
corroded, repair or replace the cooler.
@Apply the following water pressure to the
water and lube oil lines to check for any
leakage. Repair or replace the cooler if there
are any leak.
@When tightening bolts, refer to "General Bolt
Tightening Torque Table".
(!)When cleaning the inside of the plate, use a
pressurized air which blow off the inside scale.
Test pressure
Lubricating oil circuit 1.47 MPa (15 kgf/cm 2)
Cooling water circuit 0.39 MPa (4 kgf/cm 2)
180
3.19.6 Piston Cooling Nozzle

(1) Piston cooling nozzle construction
A nozzle made from aluminum die-casting is
mounted on the lower part of cylinder body and oil
from main gallery is sprayed out in a jet from the tip
of this nozzle.
This jet spray cools the piston surface when the
piston goes down.
(2) Inspecting of the piston cooling nozzle

1) Check the nozzle tip hole to see if it is clogged up
with dirt or other foreign matter. And clean.
2) Inspect nozzle mounting to see if it is or may be
damaged due to vibration, etc., and replace it if
necessary.
Piston cooling nozzle
016?71-00E
181
3.19.7 Gear waste oil pump (Optional)

A gear waste oil pump to pump out waste oil during
oil changing is available as an option.
This is a gear type pump. Turning the handle rotates
the gear and pumps out lube oil.
( 1) Construction
Gear waste oil pump
Delivery capacity of one
0.0565 L
revolution
Delivery pressure 0.15MPa (1.5kgf/cm 2)
Suction head 1 m or less
Shaft
Gear
014990-00E
182
3.20 Cooling water system

3.20.1 Cooling water system
This engine uses fresh water cooling system (indirect seawater cooling, fresh water circulation type). This
system ensures a constant temperature of the cooling water regardless of the applied load and can reduce
the clearance between the piston and cylinder liner. Moreover, it reduced thermal distortion of the cylinder
liner and adequate arrangement of oil rings allow less lube oil consumption and eliminate the risk of oil
shortage.
Each part of the engine is cooled as follows :
Seawater pumped up by the seawater pump flows into the fresh water cooler via the air-cooler. After the
fresh water has been cooled, the seawater cools in the reduction reversing gear lube oil cooler. Finally, the
seawater is discharged overboard.
On the other hand, fresh water pumped up by the fresh water pump flows into the lube oil cooler, and cools
the cylinders, cylinder liners and then the cylinder head. The fresh water goes out from the upper part of the
cylinder head and flows into the exhaust manifold passage. The thermostat returns some amount of the
water heated beyond the specified temperature to the fresh water cooler. The returned water is recirculated
by the fresh water pump.
1) Use a new packing.

2) When tightening the collar bolts, refer to "General
Bolt Tightening Torque Table". When attaching a gasket to the cooling water sys-
3) Check the rubber hoses for aging, degradation tem, spray the spray paste on the gasket alone
and crack. If they are defective, replace them. and never allow it to contact the engine.
4) Connect the rubber hoses without stresses and
attach hose clips to them in such a way that When the spray paste is sprayed directly to the
retightening can be easily done. engine, the sticky bond discharged in the cooling
water is attached to the sliding surface of
mechanical seal and catch a foreign matter or the
like floating in the cooling water, resulting in water
leakage.
* O.D.76(65A)
S.W.Outlet pipe ~ -1.:2::::1----i Lub.Oil cooler I
~
* l.D.76 Rubber hose 1 F.W.Pump ____ _J ' 75
~ Cylinder
1 /Temp. control valve Detail "A"
J..(
~ - - -
Set:75-85 °C
- - Exh.Gas manifold
Filler cap
Set:0.11MPa 1 l.D.38 L=80 Rubber hose * O.D. 40
'!:"
F.W. Coolant
recovery lank !
1
0
....
Q)
-
.... Cll
Q)
0
* -8.s:....
Q)
Ol
Q)
C2__ ;
0
u ·- Cll Detail "B"
'-
<(
qE
..c ....
:J 0
_J LI..
~
S.W.LINE : - - - F.W.LINE :
* l.D. 76 Rubber hose
* O.D. 76 (65A)
S.W.lnlel pipe
l.D. 76 Rubber hose
Remark:
Pipes & Devices marked * in this drawing are not included in our factory's standard scope of supply.
016370-0lE
183
3.20.2 Seawater pump

I
The seawater pump has a rubber impeller. The
seawater pump is mounted to the gear case and is --:=======r::==---
/~
Rubber impeller
driven by gear.
014945-00E
(1) Specifications of seawater pump

Performance
Crank shaft speed 1900 min- 1(rpm)
Pump shaft speed 1572 min- 1(rpm)
Delivery capacity 32000 Q/h
0.1 MPa or 100 KPa
Total head
(1.0kgf/cm 2)
(2) Seawater pump Inspection

CD Inspection of rubber impeller Gear
Remove the cover at pump side and then pull out Bearing housing
the impeller. Check the impeller and the pump
body for damage. If it is damaged, replace it.
~ Mechanical seal
If the water that leaks from the drain pipe is too
much, replace the mechanical seal.
@Assembling the seawater pump
1) Apply grease to the seawater pump shaft, the
inside and outside surfaces of the impeller.
2) When fitting the impeller to the pump body, notice
the correct direction of the impeller blades with
respect to the rotation direction of the impeller.
3) Use new 0-rings.
4) Use new packing. Apply sealant (THREEBOND
No. 4 or equivalent) to the packing surface. Wear plate
5) Use new oil seals.
6) Carefully clean the bearings. Seawater pump body Cam part
007543-00E
184
3.20.3 Checking and Replacement of

Anticorrosive Zincs
I Service period Every 500 hours

Anti-corrosive zinc
(1) Replace an anticorrosive zinc with the new one if
anticorrosive zincs mounted on the inlet and
outlet covers or water return covers of the fresh
water cooler and air cooler are found consumed
by more than 1/2 of the original size.
(Exception to this instruction is such an engine to
which anticorrosive zincs are not mounted
according to is conditions of specification.)
(2) At the same time as replacement of the zincs,
thoroughly check for mixing-in or sticking of (Fresh water Cooler)
foreign matter on the interior of cooling water line
and the back of the covers and overhaul clean
them, If found necessary. Anti-corrosive zinc
~
(When mounting an anticorrosive zinc, be careful
of the rubber packing using position.)
! !
>
Anti-corrosive zinc
(Air Cooler)
013300-00E
185
3.20.4 Fresh water pump

(1) Fresh water pump construction
The fresh water pump is a centrifugal (volute) type,
Cover
and circulate water from the fresh water cooler to
the lube oil cooler. Packing
The fresh water pump consists of the pump body, Impeller
impeller, pump shaft, bearing unit and mechanical
seal.
The bearing unit assembled in the pump shaft uses
grease lubricated bail bearings and cannot be
disassembled.
The totally enclosed mechanical seal spring presses
the impeller seal mounted on the impeller side away
from the pump body side. This prevents water from
leaking along the pump shaft.
(2) Precautions for assembly and service

CD Use new packing and oil seals.
~If water leaks, replace the mechanical seal.
@ Before installing the bearing, completely clean
it and apply grease to it.
@The impeller fitting screws are right-handed
screws.
@ Use new 0-rings.
@When tightening collar bolts, refer to "General
Bolt Tightening Torque Table".
(!)The drive gear tightening nuts (thin M20) are
right-handed screws.
@The rotating direction of the impeller is clockwise
(viewed from the drive gear side).
(3) Specifications of fresh water pump

Performance
Crank shaft speed 1900 min- 1(rpm)
Pump shaft speed 2533 min- 1(rpm)
Delivery capacity 46500 Q/h
Total head 11 O kPa (1.1 kgf/cm 2)
186
(4) Fresh Water pump inspection

CD Bearing unit inspection Measuring clearance between impeller and
Rotate the impeller smoothly. If the rotation is not pump body.
smooth or abnormal noise is heard due to
excessive bearing play or contact with other parts,
replace the pump as an assembly.
~ Impeller inspection
Check the impeller blade, and replace if damaged
or corroded, or, if the impeller blade is worn due to
contact with pump case.
@Check the holes in the cooling water and bypass
lines, clean out any dirt or other foreign matter and
repair as necessary.
@ Replace the pump as an assembly if there is
excessive water leakage due to mechanical seal
or impeller seal wear or damage.
@Inspect the fresh water pump body and flange,
clean off scale and rust, and replace if corroded. Measuring clearance between impeller and
@ Measure the clearance between the impeller and body bracket.
the pump body, and the impeller and plate.
Measure the clearance between the impeller and
the pump case by pushing the impeller all the way
towards the body, and inserting and the case.
Measure the clearance between the impeller and
the plate (pump body bracket) by placing a
straight-edge against the end of the pump case
and inserting a thickness gauge between the
impeller and the straight-edge.
(mm)
Clearance Standard Wear limit
Between impeller
0.3-0.9 1.05
and body
187
3.20.5 Fresh Water Line

(1) The fresh water system is circulation
type. Thus carefully check for water
leak. If the fresh water consumption
inside the coolant recovery tank is too
much, check the pipe couplings for
water leak.
CD Fresh water pump - Lube oil cooler
~ Lube oil cooler - Cylinder block
@Cylinder head - Exhaust manifold
@ Exhaust manifold - Fresh water cooler
@ Fresh water cooler - Fresh water pump
014947-0lE
a. Use a new packing and 0-ring.
b. When tightening collar bolts, refer to "General
Bolt Tightening Torque Table". Case cover
@Thermostat
The fresh water cooler is equipped with a
thermostat which keeps the fresh water at
constant temperature.
Stamp
(2) Inspection of thermostat (Opening temperature)
Thermostat
CD Place the thermostat in the vessel filled with water, I
and measure the water temperature while heating
the vessel using an electric heater. If the valve
starts to open at the valve opening temperature
and opens fully at the valve full-opening
temperature, then the thermostat is working
Lift of the element
normally.
(Lift when fully opened : 8 mm)+-_ _..,,.~
Replace if faulty.
~Check the rubber hoses for aging, degradation and
crack. If they are defective, replace them.
@Connect the rubber hoses without stresses and Fresh waler cooler
attach hose clips to them in such a way that
retightening can be easily done.
@When tightening collar bolts, refer to "General Bolt
Valve Valve
YAN MAR Valve
opening full-opening
code lift
temp temp
148616- 71 QC 85QC 8mm A
48200
126634- 76.5 QC 90Qc 8mm B
48180
016365-00E
188
3.20.6 Fresh Water Cooler

The fresh water cooler is multi-pipe type, cooled by
seawater and equipped with a resin coolant
recovery tank. The seawater flowing inside the pipe
core cools the fresh water that passes through the
outside of the core. The thermostat installed inside
the fresh water circuit controls the temperature of
fresh water to ideal point. It is equipped with a
coolant recovery tank that enables a long time of
continuous operation without supplying fresh water.
What to do is only to check the water level in the
coolant recovery tank.
Check the amount of water by checking the water
level inside the coolant recovery tank. The pressure
cap of the fresh water cooler does not need to be
removed. A water level alarm is provided at the
upper part of the fresh water cooler. When the alarm 013302-00X
sensor detects a reduction in water amount, the (Multi-Pipe type cooler, pipe cooler diameter 8/10)
alarm lamp will light and the buzzer sounds.
(1) Precautions for assembly and service

CD The cooling performance may deteriorate due to
scale and rust caused by seawater inside the
pipes. Disassemble and check Use "WASTn K-1"
to remove scale and rust.
~The cooling performance may deteriorate due to
scale and rust caused by fresh water outside the
pipes. Be sure to add an anti-rust agent.
@ To prevent the fresh water from freezing in cold
weather, add antifreeze to the fresh water.
@ Dirts on the pressure cap cause incomplete
closing of the cap and reduction in fresh water. Be
sure to remove dirts and scales from the pressure
cap.
@ Do not remove the pressure cap if the engine is
not cooled enough. For instance during operation
or just after stoppage. This is because hot steam
will spout out through the cap.
@ Use new packing and 0-rings
(!)When tightening collar bolts, refer to "General Bolt
@After assembling the fresh water cooler perform
the multi-pipe water pressure test.
189
3.20. 7 Pressure cap and Coolant

recovery tank
(1) Pressure cap construction
The pressure cap mounted on the fresh water filler
neck incorporates a pressure control valve. The cap
is mounted on the filler neck by placing it on the
locking tab and rotating. The top seal of the cap
seals the top of the filler neck, and the pressure
valve seals the lock seat.
Pressure valve operation Pressure valve spring
(2) Pressure cap pressure control
The pressure valve and vacuum seal both seal the
valve seat when the pressure in the fresh water
system is within the specified value of
0.11 MPa(1.1 kg/cm 2). This seals the fresh water Overflow tube
system.
When the pressure within the fresh water system Pressure valve
exceeds the specified value, the pressure valve
opens, and steam is discharged through the Vacuum valve operation
overflow pipe. When the fresh water is cooled and
the pressure within the fresh water system drops
below the normal value, atmospheric pressure
opens the vacuum valve, and air is drawn in through
the overnow pipe.
The coolant recovery tank (which sill be described
later), keeps the water level from dropping due to
discharge of steam when the pressure valve opens. Vacuum valve Vacuum valve spring oosus-ooE
Action of pressure control valve

Open at 93-123 kPa
Pressure valve
(0.95-1.25 kgf/cm 2)
Open at 5 kPa
Vacuum valve Pressure value
(0.05 kgf/cm 2) or below
008U2-00E
190
(3) Pressure cap inspection

Precautions
Do not open the pressure cap while the engine is
running or right after shutting down because high
temperature steam will be blown out. Remove the
cap only after the water has had a chance to cool
down.
CD Remove scale and rust, check the seat and seat
valve, etc. for scratches or wear, and the spring for
corrosion or settling. Replace if necessary.
Note:
Clean the pressure cap with fresh water as it
will not close completely if it is dirty.
~ Fit the adapter on the tester to the pressure cap.
Pump until the pressure gauge is within the
specified pressure range 93-123kPa (0.95-1.25
kgf/cm 2) and note the gauge reading. The cap is
normal if the pressure holds for six seconds. If the
pressure does not rise, or drops immediately,
inspect the cap and repair or replace as
necessary.
(4) Function of the Coolant recovery tank Filler cap Fresh water tank
The pressure valve opens to discharge steam when
the steam pressure in the fresh water tank exceeds --
93-123kPa (0.95-1.25 kgf/cm 2). This consumes
water. The coolant recovery tank maintains the
water level by preventing this discharge of water. Coolant recovery tank ,.___ _ _ _ _ ____,
The steam discharged into the coolant recovery
tank condenses into watch, and the water level in
the coolant recovery tank rises.
When the pressure in the fresh water system drops
below the normal value, the water in the
coolant recovery tank is sucked back into the fresh
water tank to raise the water back to its original
level.
The coolant recovery tank facilitates long hours of
operation without water replacement and ejected
from the filler neck because the pressure cap does
not need to be removed. 008294-0lE
(5) Specifications of Coolant recovery tank

Overall capacity 3.4 liter
Full scale capacity 1.5 liter
Low scale capacity 0.43 liter
191
(6) Mounting the Coolant recovery tank

CD The coolant recovery tank is mounted at
approximately the same height as the pressure
cap on fresh water tank.
(Allowable difference in height : 300mm (11.8110
in.) or less)
~The overflow pipe should be less than 1,000mm
(39.3701 in) long, and mounted so that it does not
sag or bend.
Note:
Make sure that the overflow pipe of the
coolant recovery tank is not submerged in
bilge. If the overnow pipe is submerged in
bilge, water in the bilge will be siphoned into
the fresh water tank when the water is being
cooled.
(7) Precautions on usage of the Coolant

recovery tank
CD Check the coolant recovery tank when the engine
is cool. Refill with fresh water as necessary to
bring the water level between the low and full
marks.
~Check the overnow pipe and replace if bent or
cracked. Clean out the pipe if it is clogged up.
192
3.20.8 Thermostat
(1) Function of thermostat
The thermostat opens and closes a valve according
to changes in the temperature of the fresh water of
inside the engine, controlling the volume of water
flowing to the fresh water cooler from the cylinder
head, and in turn maintaining the temperature of the
fresh water in the engine at a constant level. The
thermostat is bottom bypass type. It is located in a
position connected with the cylinder head outlet line
to the fresh water cooler. When the fresh water
temperature is low (65-80°cor less), the thermostat
is closed, and fresh water goes from the bypass line
to the fresh water pump intake and circulates in the
engine. When the fresh water temperature is
exceeds the above temperature, the thermostat
opens, and a portion of the water is sent to the fresh
water cooler, the other portion going from the
bypass line to the fresh water pump intake.
The bypass line is closed of as the thermostat valve
opens, and is completely closed when the fresh
water temperature reaches 85°c and 90°c (valve lifts
8 mm), sending all of the water to the heat
exchanger.
No. item Material Measurement

1 Seat C2680R t1
Open valve temperature
2 Attachment frame C2680R t1 Date of manufacture
3 Valve C2680R t 0.8

¢53.6-54.4
(5) ___ _
4 Spring SUS304 02
(6)--__ ---·~--+-------.
5 Stopper C3604B 05.5 (1 )-~ - -- 27
(3)--= -J-__,~~+1-'''\ (below)
6 Piston SUS304 03.8 (2 )------11
(4 )---=-~=-+-,llvr' 33
7 Pellet Ass'y - (7)-----
(8)----::::_,..~~·~----1.
8 Spring SUS304 1.2 (9)-----::::------ i
9 Bass valve C2680R t 0.6 (10)'------
¢ 41.5-43 014995-00E
10 E snap ring SUS304 E7
(2) Thermostat construction

The thermostat used in this engine is of the wax
pellet type, with a solid wax pellet located in a small
chamber.
When the temperature of the cooling water rises,
the wax melts and increases in volume. This
expansion and contraction is used to open and
close the valve.
193
(3) Characteristics of thermostat

Opening temperature 71 QC 76.5 QC
Full open temperature 85QC 90Qc
Valve lift at full open 8 mm or more
Diameter 33 mm
• Valve diameter : 33mm

• Leak hole : Jiggle valve
•Ability:
CD Temperature-Stretch feature
~Amount of water leakage : Cooling water 60 kPa
(0.6 kg/cm 2) at pressure of 1.5L /min. or lower. TEMP{°C) .,,
....J
@Hysteresis : At lift 2 mm within 2.5 QC . T2°C:Valve lift ins ection tern
@ High temperature hysteresis
T1°c:Valve o en tern
At, normal lift within 2.8 QC difference from normal
T1 +1 .5°C:Valve o en ins ection tern
temperature keeping in 135 QC hot water, 1 hour.
01S026-00E
(4) Thermostat inspection Case cover

Remove the thermostat cover on top of the fresh
water cooler out the thermostat. Clean off scale and
rust and inspect, and replace if the characteristics
(performance) have changed, or if the spring is
broken, deformed or corroded. Stamp
(Opening temperature)
Thermostat
I
lift of the element

(lift when fully opened : 8 mm)-1-----!"~
Fresh water cooler
016365-00E
194
(5) Testing the thermostat

CD Put the thermostat in beaker with fresh water. and
heat it on an electric stove. The thermostat is
functioning normally if it starts to open between
71-85Qc, 76.5-90Qc, and opens 8 mm or more at.
Replace the thermostat if it is not functioning
normally. Thermostat
~ Normally, the thermostat should be inspected
every 3000 hours of operation, but, it should be
inspected before this if the cooling temperature
rises abnormally or white smoke is emitted for a
long time after engine starting.
@ Replace the thermostat every 3 years or
6000-9000 hours or operation (whichever comes
first).
0139S3-00E
3.20.9 Seawater System Cleaning
As the engine is used, coolers become fouled, their

cooling effect worsens, and fresh water temperature
becomes abnormally high (above 85 QC
Consequently, eliminate fouling of the seawater
system, coolers in particular. To clean the seawater
system, consult your nearest YANMAR dealer.
3.20.1 O Fresh Water System Cleaning
As the fresh water system becomes dirty naturally,

cooling efficiency worsens, and
fresh water temperature becomes abnormally high
(above 85 QC when the engine is operated for long
time, clean fresh water system periodically. At the
same time, clean the thermostats. As for periodic
servicing, consult your nearest YANMAR dealer.
195
3.21 Turbocharger
3.21.1 Specification
Turbocharger MITSUBISHI HEAVY
maker INDUSTRIES, LTD.(MHI)
Turbine type Radial flow
Blower type Centrifugal
Bearing type Full floating
Lubrication method Outer lubrication
Cooling method AIR cooled
Turbocharger
TD13
model
Applicable engine
6AYM-GTE, 6AYM-ETE, 6AYM-STE
model
3.21.2 Construction and function of turbocharger
, - - - - - - - - - - - - - - - Thrust bearing
~------.. Turbine back plate
Compressor wheel ---~ Shaft & turbine wheel
Air inlet¢ . . Gas outlet
Compressor cover ...__ __, Turbine housing
OU122-00E
196
Signs of rubbing contact

with compressor wheel
16
Vane distortion,
damage,signs of
rubbing contact
on back face and
gas erosion
Signs of rubbing
contact with turbine
wheel and damage
Signs of rubbing contact

with turbine wheel, cracks
and distortion
27 18 17 28
Damage and gas erosion of bearing hole Vane distortion, damage, signs
and distortion of turbine-side flange of rubbing contact on back face,
gas erosion and damage lo ring
grooves
No. Name No. Name No. Name

1 Bolt 11 Oil deflector 21 Snap ring
2 Compressor cover 12 Thrust ring (compressor side) 22 Snap ring
3 0-ring 13 Thrust bearing 23 Bearing
4 Lock nut 14 Thrust ring (turbine side) 24 Snap ring
5 Compressor wheel 15 Bolt 25 Bearing housing
6 Snap ring 16 Turbine housing 26 Lock· plate
7 Insert 17 Shaft & turbine wheel 27 Lock· plate
8 Piston ring 18 Piston ring 28 Lagging
9 Finger sleeve 19 Turbine back plate 29 -
10 0-ring 20 Bearing 30 -
197
3.21.3 Standards for maintenance and check

(1) Standards for maintenance and check
(mm)
Nominal Assembly standard Service limit
Parts or item Remarks
value (standard clearance) (Clearance)
Inside diameter of bearing bores in
30 30.006
bearing housing
Outside diameter 29.876
Bearing Inside diameter 18.050
length 17.440
Diameter of jour-
Shaft & 18 17.996
nals
turbine wheel
Run-out of shaft 0.015
With ring fitted in
End gap of piston ring 0.050-0.25
insert
Clearance between shaft &
0.29-0.91
Turbine wheel and turbine housing
Axial play of shaft & wheel 0.075-0.135
Clearance between turbine back
0.55-1.15
plate and turbine wheel
(2) Tightening torque

Thread Width across Tightening Torque
secured part or component Remarks
Diam.-pitch flats N•m (kgf•m)
Compressor wheel lock nut 11-1.0 19.0 50-54 (5.1-5.5) Apply Molycoat
Bolt 23.5 ± 0.98 (2.4 ± 0.1) to threads
198
3.21.4 Periodical checking procedure

3.21.4.1 Periodical checking interval
Check the entire status and contamination of
turbocharger at regular intervals.
The checking intervals vary depending on the
conditions of use. Perform checking work at the
intervals as shown below according to individual
purposes of use.
Purpose of use Checking intervals

For marine use Every 6 months or Every 12 months or Every 24 months or
Check item 1,500 operating hrs. 2,500 operating hrs. 5,000 operating hrs.
Rotation of turbine shaft 0
Play of turbine shaft 0
Disassembly, cleaning and
0
checking of entire turbocharger
3.21.4.2 Checking procedure
( 1) Checking of rotation of rotor

Check the rotation of the turbine shaft by hearing
whether it produces an abnormal sound or not
during rotation.
When using a listening rod, tap the tip of it closely to
the turbocharger case and pick up the engine speed
gradually.
If a high-pitched sound is heard successively every
2-3 seconds, it means that the rotation of rotor is
abnormal.
When such a symptom is observed, the bearing and
turbine shaft may be in trouble. In such case, the
turbocharger should be replaced or disassembled
and repaired.
199
3.21.5 Disassembly procedure

3.21.5.1 Preparations for disassembly
When assembling and disassembling the turbocharger, the special tools as shown below are necessary
in addition.
Name of tool Purpose of use Remarks
Mounting and dismounting of snap

Pliers
ring of floating bearing
000955-00X
Fixing of compressor wheel

Box wrench
(19 mm x 6sq)
Available in the market
Mounting of turbine housing

Torque wrench (2.4 ± 0.1 kg•cm)
23.5 ± 0.98 N•m for M8 001005 -oox
3.21.5.2 Check before disassembly
( 1) Check that turbine blade wheel and

compressor wheel rotates smoothly.
Wheel do not contact with each other and turbine
shaft.
(2) Measure the play of turbine shaft.

Play of turbine shaft in axial direction
Limit of use : 0.075-0.135 mm
200
3.21.6 Disassembly
( 1) Hold the flange of turbine housing ( 16)
in a vise.
Notes:
Hold the turbine housing securely to prevent it
from moving during disassembling work.
(2) Removal of compressor cover

1) Using a box wrench, remove bolts (1) and lock
plate (26).
2) Using a plastic hammer, lightly tap around on
compressor cover (2) to remove the cover. Also,
remove 0-ring (3) from the bearing housing.
Notes:
Before separating compressor cover (2)
bearing housing (25) and turbine housing (16)
be sure to give a match mark across each joint
with a punch or quick drying ink pen to aid
reassembly.
(3) Removal of compressor wheel

1) Hold the boss of shaft & turbine wheel (17) remove
lock nut (4) securing compressor wheel (5).
Be careful not to bump the compressor wheel

against the compressor cover.
2) While holding the turbine wheel by on hand, turn

compressor wheel (5) back and forth by the other
hand to lift it off the shaft.
201
(4) Removal of snap ring

Using the snap ring pliers, remove snap ring (6).
Hold down the snap ring by hand while pinching

the ring ends with the snap ring pliers, so that the
ring will not fly off just in case the ring ends lip off
the pliers.
(5) Removal of insert, oil deflector and

~(9)
others. 0----(8)
1) Using two screwdrivers, gently lift insert (7) off ~(7)
bearing housing (25).
2) Separate finger sleeve (9) complete with piston ~(10)
ring (8) from insert. ~(11)
3) Remove the following parts from bearing housing ~(12)
(25). ~(13)
(10) 0-ring 1}----(14)

(11) Oil deflector
(12) Thrust ring (compressor side)
(13) Thrust bearing 016367-00X
(14) Thrust ring (turbine side)
(6) Remove of Bolts

Using a box wrench, remove bolts (15), and
displace its installation position.
202
(7) Removal of shaft & turbine wheel

1) Lift bearing housing (25) complete with shaft &
turbine wheel (17) off turbine housing (16) by one
hand holding the shaft and by the other hand
holding the bearing housing.
2) Turn bearing housing (25) upside down (with the
turbine wheel up) and lay it on compressor cover (2).
Under this condition, remove the following parts :
(17) Shaft & turbine wheel

(18) Piston ring
(19) Turbine back plate
(20) Bearing (compressor side)
(8) Removal of snap ring and bearing

~ ------(21)
Lay bearing housing (25) on the bench with the
~
compressor side up, and remove the following ~(22)
parts:
~(23)
(21) Snap ring (compressor side) ~(24)
(22) Snap ring }
(23) Bearing (turbine side)
(25)
(24) Snap ring
Notes:
a) Use the snap ring pliers to remove the snap
rings.
b) When removing the snap ring, be careful not
to damage the inside surface of bearing of
bearing housing and sealing face (turbine
side) of piston ring.
203
3.21.7 Cleaning and checking procedure

3.21.7.1 Cleaning
(1) Checking before cleaning

Before cleaning, visually check the disassembled
parts for any seizure, wear, foreign matters or
carbon deposits.
Closely check for the above-mentioned
abnormalities in case of any trouble, and pinpoint
the cause of trouble at this stage.
Major check items
Check item Position to be checked
1) Turbine shaft, wheel (17) turbine-side piston ring, and
turbine wheel backside.
Carbon deposits
2) Mounts for bearing housing and shroud, and bearing
housing inside wall.
1) Turbine shaft, wheel (17), piston ring (8), (18) (Compressor
and Turbine side).
Lubrication
2) Bearing (20) (23), thrust bearing (13) and thrust ring (12)
(wear, seizure, discoloration, etc.)
(14).
3) Bearing housing, and inner periphery of bearing snap ring.
1) Turbine housing inside wall.
2) Outer periphery of bearing housing, and turbine back plate
mount.
3) Turbine shaft, wheel (17), turbine-side piston ring, and
Oil leak
turbine wheel backside.
4) Compressor cover (2) inside wall.
5) Compressor wheel (5) backside.
6) Finger sleeve (9) surface and piston ring insertion groove.
204
(2) Cleaning procedure

In cleaning the parts, keep the following points in mind.
Section Tools and detergent Cleaning procedure
1. Turbine shaft tools 1) Immerse the turbine shaft in the
1)Washing bucket (500 x 500) washing bucket and heat the
2)Heat source: solution. Do not beat the wheel
steam or gas burner for removal of carbon deposit.
3)Brush 2) Immerse the parts until dirt
2. Detergent: deposits become soft by
carbon remover sold in the penetration of detergent.
market may be used. 3) When the deposits get soft,
1. Turbine shaft remove them with use of a plastic
spatula or bristle brush.
4) Protect the bearing surface of the
turbine shaft and the piston ring
groove from damage during cleaning.
5) Incomplete cleaning will leave
residual deposits which may cause
an imbalance in shaft rotation.
Do not use a wire brush for cleaning.
1. Tools: 1) Apply cleaning fluid to heavily
Same as for cleaning the turbine shaft soiled parts of the turbine housing.
2. Turbine housing
2. Detergent: 2) Use a plastic scraper or a stiff
Same as for cleaning the turbine shaft natural bristle brush to clean.
1. Tools 1) Immerse the parts until dirt
1)Washing bucket deposits become soft by
(500 x 500) penetration of detergent.
3. Compressor cover 2)Brush 2) When the deposits get soft,
2. Detergent remove them with use of a plastic
spatula or bristle brush.
Do not use a wire brush.
1. Wash all the other parts with gas oil.
2. Clean the lube oil passages by blowing compressed air.
4. Others
3. In the cleaning work, pay close attention not to damage the parts and
get them rusted.
Immerse the detergent Give a brush
Coat the engine oil
205
3.21.7.2 Checking procedure
(1) Compressor cover (2).

Check the compressor cover. Make sure there is no
Compressor cover
contact with the compressor wheel, no flaws on the
mating surface, no bruises or cracks and other
damages. Defective compressor cover is to be
replaced with new one.
Compressor wheel
(2) Turbine housing (16).
Check the component for damage from contact with
turbine wheel, exfoliation from deterioration due to
oxidation of casting surface, thermal deformation,
cracks and other damages. Defective turbine housing
is to be replaced with new one.
v
Turbine shaft
(3) Compressor wheel (5).

Check the component for damage from contact, Tocb;oe ho"';og
~
break, corrosion, deformation and other damages.
Defective compressor wheel is to be replaced with
new one.
(4) Turbine shaft (17).

1) Check turbine wheel section for damage from
contact, break, thermal discoloration, deformation 008164-00E
and other damages. Check turbine shaft for bend,

thermal discoloration at the journal section, flaw
from abnormal wear, flaw and wear in piston ring
groove, and other damages.
0
Defective component is to be replaced with new
one.
2) Measure outer diameter of turbine shaft journal
section (A).
Replace the component of which the dimension
exceeds the allowable limit as described below.
Journal O.D. (A) 016364-00E
Limit of use : 17. 996 mm
3) Measure the run-out of the turbine shaft. Replace (7)

the component of which the run-out is 0.015 mm
or over. (8)
(5) Insert (7).

Place a new piston ring (8) in the groove in the
insert, and measure the end gap or the ring. If the
gap exceeds the Standard clearance, replace the
insert.
Item Standard clearance

End gap of piston ring 0.05-0.25 mm
206
(6) Bearing housing (25)

Measure the inside diameter of bearing bores in the
housing. If it exceeds the Service limit, replace the
housing.
Item Service limit

Inside diameter of bearing
30.006 mm
bores in housing (E)
01 ?259-00X
(7) Bearing (20) (23)

(a) Measure the inside diameter of the bearing. If it
exceeds the Service limit, replace the bearing.
B
Item Service limit

Inside diameter of bearing (B) 18.050 mm
013261-00X
(b) Measure the outside diameter of the bearing. If it

is less than the Service limit, replace the
bearing.
Item Service limit

Outside diameter of bearing (C) 29.876 mm
Ol3260-00X
(c) Measure the length of the bearing. If it is less

than the Service limit, replace the bearing.
D
Item Service limit
Length of bearing (D) 17.440 mm
Ol3262-00X
207
3.21.8 Reassembling procedure

3.21.8.1 Preparations for reassembly
(1) When reassembling the turbocharger,

prepare the general and special tools,
fluid sealant (Molykote).
(2) Replace the following parts without fail

before reassembling.
Compressor-side piston ring (8) x 1 pc
Turbine-side piston ring (18) x 1pc
0-ring (large) (3) x 1 pc
0-ring (small) (10) x 1 pc
2 7 6 26 1 10 13 12 20 21 23 25 24 19 16
4 5 8 9 3 14 11 22 15 27 18 17 28
Reassemble sequence
25 -+ 24 -+ 22 -+ Z3 -+ 21 -+ 19 }
2)-+ 14-+ 13-+ 10-+ 12-+ 11
IB-+U f6-+5-+4-+~-+~-+~-+3-+2-+~-+1
9 -1- 8 -1- 7 01?358-00X
Notes:
After installing and overhauled turbocharger of
the engine, crank the engine with the starter to
permit the engine oil to flow to the turbocharger. Replace the compressor wheel or shaft-&-tur-
bine wheel If its vanes are badly distorted or
cracked.
A single blade having minor distortion or
scratching is not the cause for replacement ; in
such a case, never attempt to re-shape the dis-
torted vane.
208
3.21.8.2 Reassembling procedure
(1) Installation of shaft & turbine wheel and

bearings (21) (22) (23) (24) (25)
1) Reassemble the following parts:
(25) Bearing housing

(24) Snap ring }
(23) Bearing (turbine side)
(22) Snap ring
(21) Snap ring (compressor side)
Notes:
a) Use the snap ring pliers to install the snap
rings. After installing each snap ring, make
sure that it can be finger rotated freely.
b) Apply engine oil to the inside and outside
surfaces of bearing.
~Large
2) Lay bearing housing (25) on compressor cover
(2), and install turbine back plate (19).
~Small
3) Install piston ring (18) in the groove formed of End gap
shaft & turbine wheel (17).
(17)
4) When installing shaft & turbine wheel (17)
complete with piston ring to bearing housing (25), (19)
position the piston ring as shown, and insert the

(25)
shaft & turbine wheel into the housing while
rotating it back and forth.
a) When installing the piston ring to the shaft &

turbine wheel, be careful neither to expand the
ring more than is necessary nor to twist its end
gap.
b) After installing the piston ring in its groove,
apply Molykote to it.
c) Piston rings are common to turbine and
compressor sides.
d) Never force the shaft & turbine wheel unless
it is in line with the turbine back plate and bear-
ing housing.
209
(2) After installing shaft & turbine wheel

(17), hold the end of shaft by hand, and
turn it upside down so that its
compressor side is up. Apply engine oil
to the inside and outside surfaces of
bearing (20) and install it on the shaft.
Then, install bearing housing (25) to
turbine housing (16) by tightening bolts
(15) and lock plate (27) temporarily.
(3) Installation of thrust bearing

Apply engine oil to the inside and outside surfaces
of thrust ring (14) and thrust bearing (13), and install
the ring and bearing in place. Position the thrust
bearing by entering the groove pin into the locating (13)
hole.
(4) Installation of 0-ring

Apply engine oil to 0-ring (10), and install it in place.
(10)
(5) Installation of oil deflector

Apply engine oil to both sides of thrust ring (12), and
install it to oil deflector (11 ). Install oil deflector with
its baffle.
210
(6) Reassembly of insert subassembly (7)

1) Reassembly the insert parts in the following
sequence:
(9) Finger sleeve

(8) Piston ring
(7) Insert
a) When installing the piston ring to the finger

sleeve, be careful neither to expand the ring
more than is necessary for installation nor to
twist its end gap.
b) Apply Molykote to the piston ring fitted to the
finger sleeve, and install the sleeve to the insert,
taking care not to damage the ring.
2) Install the insert subassembly to bearing housing

(25).
(7) Installation of snap ring

Using the snap ring pliers install snap ring (6) to
bearing housing (25) with its tapered side facing
upward.
a) Be sure to position the snap ring as specified

above when installing it.
b) Give light hammer blows to the ends of snap
ring through a screwdriver to fit the ring in the
groove in the bearing housing.
c) When giving hammer blows to the snap ring, be
careful not to damage the bearing housing.
211
(8) Measuring of clearance between turbine

wheel and bearing housing
Set up a dial indicator on shaft & turbine wheel (17)
as shown. More the shaft in the axial direction to
measure the clearance. If the clearance is out of the
Standard clearance, disassemble the part, and
investigate for the cause.

Clearance between shaft &
turbine wheel and turbine 0.29-0.91 mm
wheel and turbine housing
(9) Installation of compressor wheel

Install compressor wheel (5), apply Molykote to the
threads of lock nut (4), and tighten the nut to the
specified torque.
Tightening Torque: 50-54 N•m
(5.1-5.5 kgf•m).
Compressor side
(1 O)Measurement of axial play of shaft &

turbine wheel
Set up a dial indicator on shaft & turbine wheel (17)
as shown. Move compressor wheel (5) in the axial
in the axial direction to measure the play. If the play
is out of the Standard clearance, disassembly the
parts, and investigate for the cause.

Axial play of shaft &
0.075-0.135 mm
turbine wheel
oox
212
( 11 )Measurement of clearance between

turbine back plate and turbine wheel
Remove the turbine housing from bearing housing
(25), and install compressor cover (2). Using feeler
gauges, measure the clearance between turbine
back plate (19) and turbine wheel. If the clearance is
out of the Standard clearance, disassemble the
parts, and investigate for the cause.
Notes:
Measure the clearance at the tips of vanes with
two feeler gauges.

Clearance between
turbine back plate and 0.55-1.15 mm
turbine wheel
(12)1nstallation of turbine housing.

1) Install turbine housing (16) to bearing housing
(25), making sure that it is correctly positioned
with respect to the housing.
2) The lock plate is installed, Morykote is spread on

the bolt screw, it tightens a bolt with the specified
torque.
Tightening Torque: 23.5 ± 0.98 N•m
(2.4 ± 0.1 kgf•m).
213
(13)1nstallation of compressor cover

Install compressor cover (2), making sure that it is
correctly positioned with respect to the turbine
housing.
Apply grease to 0-ring (3) when installing it.
(2)
(14)1nstallation of snap ring

Install lock plate (26) and bolts (1) to compressor
cover (2).
214
3.21.9 Handling after reassembly

In mounting the supercharger to the engine or
handling the mounted turbocharger, keep the
following points in mind.
Use particular care to prevent any foreign matters
from coming into the turbocharger.
3.21.9.1 Precautions for mounting the

turbocharger to the engine
Lubrication system
(1) Before mounting to the engine, pour
fresh engine oil from the oil filler port,
and turn the turbine shaft by hand to
lubricate the bearing and thrust bearing.
(2) Clean up the oil inlet pipe and outlet pipe

running from the engine, and check
them for any crush or dust and dirt
remaining in the pipes.
(3) Connect the oil pipes securely to their

connections part not to allow any oil leak
from the connections.
Suction system
( 1) Make sure that there is no rubbish or
foreign matter in the suction system.
(2) Mount the turbocharger securely not to

allow any air leak at the suction air duct
and air cleaner connecting parts.
Exhaust system
( 1) Make sure that there is no rubbish or
foreign matter in the exhaust system.
(2) The bolts and nuts made of heat-

resisting steel are used for the exhaust
system. Do not confuse them with
ordinary bolts and nuts used for other
systems. Apply anti-seizure agent to the
lock bolts and nuts.
(Heat-resisting bolts are use for the
turbine wheel chamber.)
(3) Connect the exhaust pipes securely not

to allow any gas leak at the connections.
215
3.21.10 Troubleshooting
If the turbocharger gets in trouble, it can not perform
as expected and a specified engine power can not
be attained.
In this case, first check up each part of the engine
for any trouble, and when it is confirmed that there
is no problem with the engine, then check the
turbocharger, referring to the tables below, and take
proper measures.
3.21.10.1 Exhaust gas is dense

Insufficient amount of suction air
Possible cause Correction
1) Air cleaner element is clogged. • Replace or clean the element.
2) Air take-in port is blocked up. •Remove obstruction.
3) Air leaks at pipe connection. • Check and repair the pipe.
Turbocharger does not operate

1) Impurities contained in oil precipitate at seal of ·Change the engine oil and disassemble and clean
turbine and hamper smooth rotation of turbine the turbocharger.
shaft.
2) Seizure of bearing • Disassemble and repair the turbocharger.
•Insufficient oil feed or clogging of pipe • Check the engine oil system, and repair the trouble
•Too high oil temperature spot and at the same time change the oil.
•Imbalance in rotating part • Replace or clean the rotating part.
•Insufficient warm-up operation or abrupt stopping • Observe the operating precautions described in
of operation under load operation manual.
(No-load operation)
3) Contact or breakage of turbine wheel or • Check each part of the engine and repair as
compressor wheel required.
•Over-rotation • Disassemble the wheels and remove foreign
•Excessive rise of exhaust gas temperature matters completely and at the same time check
•Entry of foreign matters the air cleaner and the engine and repair as
•Wear of bearing required.
•Wrong reassembly • Disassemble and repair the turbocharger.
• Reassemble the turbocharger.
Effect of exhaust gas resistance

1) Rotating speed does not pick up due to exhaust •Check the pipe connection and repair as required.
gas leak before the turbocharger.
2) Turbocharger fails to increase its speed due to • Repair the pipe to normal state.
deformed or blocked deformation or exhaust gas
pipe.
3.21.10.2 Whitish exhaust gas

1) Oil flows into compressor side or turbine side due ·Repair or replace the pipe.
to clogged or deformed oil return pipe.
2) Piston ring is worn abnormally or broken due to • Dissemble and repair the turbocharger.
excessive bearing abrasion.
216
3.21.10.3 Too early oil shortage

1) Piston ring is worn abnormally or broken due to • Disassemble and repair the turbocharger.
excessive bearing abrasion.
3.21.10.4 Output drop

1) Gas leaks at part (s) in exhaust gas system. • Disassemble and repair the turbocharger.
2) Air leaks at discharge side of compressor.
3) Clogging of air cleaner element. • Clean or replace the element.
4) Turbocharger is contaminated or damaged. • Disassemble and repair or replace the
turbocharger.
3.21.10.5 Poor follow-up of turbocharger

1) Carbon deposits stuck on turbine side (wheel ·Change the engine oil and at the same time
seal) hampers smooth rotation of turbine shaft. disassemble and clean the turbocharger.
2) Incomplete oil combustion. •Check the engine combustion system and restore
its combustion state.
3.21.10.6 Unusual sound or vibration

Unusual sound

1) If gas passage gets too narrow due to blockage • Disassemble and clean the turbocharger.
of nozzle in turbine housing or gas flow speed is
too fast, air discharged from compressor is
blocked and it flows reversely.
(This phenomenon is generally called "surging".)
2) Rotating part is in contact. • Disassemble and repair or replace the
turbocharger.
Unusual vibration

1) Connection between turbocharge and suction or • Check installation state of the turbocharger, and
exhaust pipe or oil pipe is loosened. restore the loose part.
2) Turbine wheel or compressor wheel is broken • Disassemble and repair or replace the
due to trouble with bearing, contact of rotating turbocharger.
part with peripheral part(s) or entry of foreign In the case of entry of foreign matter, remove it
matter. completely.
3) Imbalance in rotating part(s). ·Repair or replace the rotating part(s).
217
3.22 Electrical System

3.22.1 starting motor
( 1) Specifications
1) Body earth
Engine model 6AYM-GTE, 6AYM-ETE, 6AYM-STE
Model No. 0350-702-0424
Nominal output kW I weight kg 7 I 13.4
Rotating direction (as viewed from pinion side) Clockwise
Gear engagement Magnetic shift
Pinion method Electromagnetic shift
Terminal voltage (V) I Amperage (A) 24 I Less than 120
No-load
Rotation speed min- 1 (rpm) More than 4,000
Amprerage (A) I Rotation speed min- 1 (rpm) 800 I More than 880
Restrained load
Torque N•m (kgf•m) More than 72.6 (7.4)
Clutch Roller
Pinion module I No. of teeth 3.5 I 11
No. of teeth for reduction gear (motor side I output side) 11 I 44
2) Earth float
Engine model 6AYM-GTE, 6AYM-ETE, 6AYM-STE
Model No. 0351-702-0130
Nominal output kW I weight kg 7 I 18
Rotating direction (as viewed from pinion side) Clockwise
Gear engagement Magnetic shift
Pinion method Electromagnetic shift
Terminal voltage (V) I Amperage (A) 24 I Less than 100
No-load
Rotation speed min- 1 (rpm) More than 4,000
Amprerage (A) I Rotation speed min- 1 (rpm) 700 I More than 700
Restrained load
Torque N•m (kgf•m) More than 76.5 (7.8)
Clutch
Pinion module I No. of teeth 3.5 I 11
No. of teeth for reduction gear (motor side I output side) 11 I 43
(2) Configuration
Engage switch Coil
218
(3) Output characteristic curves
Body earth Earth float

E N T P E N T p
(V)(min 'Xkg-m)(kW_,_)---.----,---,---,---.,---,..----. (V)(min 'Xkg-m)(kW)
16 28 8000 16 8
14 26 7000 14 7
12 24 6000 12 6
10 20 5000 10 5
8 16 4000 8 4
6 12 3000 6 3
4 8 2000 4 2
2 4 1000 2
0-L---'--'----''-"'---'---'---'---'---'---'--""""-' 0-L---'--'----''--"''--'---'---'---'---'--""""--''--'
0 0 0 0 200 400 600 800 1000 1200 1400 0 0 0 0 200 400 600 800 1000 1200 1400
l(A) OU244-02E I (A) 017758 -OOE
(4) Internal wiring diagram (starter)
Body earth Earth float
Starter relay Starter relay

c .
' 11--'->A--
c -.,.- '
(J) :
15
l:!l
!
Starter
Starter
OU245-00E 017759--00E
219
(5) Servicing standard (starting motor)

Body earth
Item 0350 702 0424
Standard length mm 22
Brush
Wear limit length mm Less than 15
Series coil resistance Q 0.12-0.15
Magnetic switch
Shunt coil resistance Q 0.3-0.5
Maintenance standard mm 44
Outside diameter
Wear limit mm Less than 42
Armature Assembly Repair limit mm Less than 0.1
Deflection
(Commutator) Repair accuracy mm within 0.02
Maintenance standard mm 0.8-0.5
Mica undercut
Repair limit mm Less than 0.2
Armature shaft dia. Deflection mm 44 (limit 42)
Shaft diameter mm 20 (limit 19.9)
Pinion sliding section
Hole diameter mm 20 (limit 20.2)
Standard dimension Shaft diameter mm 35 (limit 34.89)
Gear case Hole diameter mm 35 (limit 35.2)
Bearing hole diameter mm 62 (limit 62.1)
Blanket rear Bearing hole diameter mm 35 (limit 35.1)
220
(6) Troubleshooting
1) Pinion fails to advance when starting switch is closed
Problem Cause Corrective action
Wiring Open or loose battery or switch terminal Repair or retighten
Threaded part connected to pinion section of armature shaft is Repair contacts,
Starting switch
damaged, and the pinion does not move Or replace switch
Threaded part connected to pinion section of armature shaft is
Starter motor Replace
damaged, and the pinion does not move
Magnetic switch Plunger or magnetic switch malfunctioning or coil shorted Repair or replace
2) Pinion is engaged and motor rotates, but rotation is not transmitted to the engine
Starter motor Overrunning clutch faulty Replace
3) Motor rotates at full power before pinion engages ring gear

Starter motor Torsion spring permanently strained Replace
4) Pinion engages ring gear, but starter motor fails to rotate

Wires connecting battery and magnetic switch open or wire Repair, retighten,
Wiring
connecting ground, magnetic switch and motor terminals loose Or replace wire
Pinion and ring gear engagement faulty Replace
Motor mounting faulty Remount
Brush worn or contacting brush spring faulty Replace
Starter motor
Commutator dirty Repair
Armature, field coil faulty Repair or replace
Field coil and brush connection loose Retighten
Contactor contact faulty Replace
Magnetic switch
Contactor contacts pitted Replace
5) Motor fails to stop when starting switch is opened after engine starts
Starter switch Switch faulty Replace
Magnetic switch Switch faulty Replace
221
3.22.2 Alternator
( 1) Specifications
Model 6AYM-GTE, 6AYM-ETE, 6AYM-STE
Type 0213-601-0110
YANMAR part code 144626-77201
Nominal voltage 24V
Nominal output 24V I 25A 600W
Rated amperage 25A
Rated output rotation speed 5000 min- 1 (rpm) (at 28V, 25A)
Rotation speed at the start of charging Less than 900 min- 1 (rpm) (at 27V, OA)
Rotating direction Clockwise and counterclockwise (both direction)
Regulator (Built-in type) l.C regulator
(2) Configuration
Bracket (Front) Ol6493-0lE
(3) Internal wiring diagram
1---------------1
s!
Regulator
!~-------~
i _ , - - - - - - - - - - - - - - - -
Ol6392-00E
222
(4) Standard output characteristics
28V constant
30
~
c
25
20 ~ ---
IJ.)
.....
.....
:::; 15 /
I
(.)
::;
0.. 10
::;
0
5 I
0
J
0 1000 2000 3000 4000 5000
Number of revolution alternator (min- 1
)
016489- OOE
(5) Servicing standard (Alternator)

Type 0213-601-0110
Standard outside dia. mm 37.5
Wear limit mm 35
Slip ring
Standard deflection mm 0-0.03
Limit of correction of deflection mm More than 0.2
Standard mm 19.0
Brush length
Wear limit mm 10.0
Standard pressure g 190-260
Spring pressure of brush 130 or Less
Wear limit g
(18 mm in compressed)
Rotor coil Q Approx. 16-20 (at 20 QC)
Coil resistance Stater coil
Q Approx. 1-1.3 (at 20 QC)
(between 2 phases)
Front side - 6304V
Name of bearings
End side - 6203V
Bearing inside dia. (Standard) mm 25.00-25.03
Front
Wear limit mm More than 52.1
Bracket
Bearing inside dia. (standard) mm 40.000-40.016
End side
Wear limit mm More than 40.1
223
(6) Battery electrolyte level

Battery electrolyte decreases as charging and
discharging are repeated. Check if the electrolyte
level is 10-20 mm above the pole plates. If level is
Insufficient Proper Excessive
low, add distilled water, referring to the figure at
right.
Service period
Every 250 hours
Il
(or every monthly)
Alternator drive belt tension

If tension of the V-belt is too strong, wear and tearof Set bolt
the V-belt are more rapid.
If too weak, V-belt slips and the alternator does not
charge. Check if the belt deflection is 11-12 mm by
pushing the center of the belt between the pulleys
with a finger.
To adjust, adjusting bolts and move the alternator
until the proper belt tension is obtained.
11-12 mm Adjusting boll
Deflection
(Pressed by 98N) Adjusting
013246-00E
Every 500 hours
Service period
(or every 3months)
Cover
Grommet
Stud bolt 12x4.0
Washer 01J581-00E
224
Color coding
R Red Lg Light green
Starter Switch
Black Lb Light blue 1-----------1 1-----------------1
w White Br Brown 30 AC 17 G1 G2 P1 P2 AR
y Yellow Pink GLOW - - u- - - u
!A~--+----r~
L Blue Gr Gray OFF
ON
0
u- ru
:J-f---0
0--0 i M ,--L.J[V~-t--t----,
I', P rocure dB y C ust omer 1°,
G Green Pu Purple
START 0- i i
i ~Batte~J_1{;al1e~ 9 i
0 Orange 'E
! I 1
L~~lL_~top_~ot?!J I---;------------;----
I (DC24V, 240AH) I I
Tacho With
Battery Switc~ L__ ]
-
WBr I
I
I
I
I ~
I
I
~-~Lw..,,1--B I
I
"'C
LI (Not Use) I
I
0
I
Hi .-"~----.----~~~ CD
~
"'C
r;:::------:--
1
I
!
IGN
GND CW. Temp. Switch
Alternator( 600\IV )
B
Earth Boll
-
CD
i YG
L____________________ ~
Charge C.W.Temp. Sender Eng. Oil Temp C.VV. level Sensor Tacho Sensor. Clutch Oil Pressure
E:ng. Oil p. Switch Switch
C.W. Temp.
G.Oilp.
C.W. Level
Eng. Oil Temp WG
Oil F-iller
Instrument panel Oil Filter Bypass Valve Switch

Remarks
1. Battery & cables shown by dotted line to be provided by ship builder.
2
2. Sectional area of battery cables should be 95mm when their total length
2
is less than 5 metres and should be 120mm when their total length is more than 5 metres.
Total cable length shall be ;:;; 10 metres. ( Battery - Starter Motor - Battery)
3. Keep the battery switch [ON] during engine operation.
4. Turn off the battery switch when the quick charger charges the batteries.
5. After engine running, turn off the battery switch.
Detail of Connector( Arrow A-A) Detail of Connector{ ArrowB-B ) Body earth without air heater
I DWG.N0.1 E3-48660-0240
Ol609J-OOE
w ~
I\)
I\) ~
(!j
.i::i. -0
Q)
f-B
~---iH"l
~-~-u
(Not Use) 1-----------------1 § iiJ
g:
f-B ~- ~
Stop Swi;c~ , , - - -
j Procured By Customer ! :J
8 OJ
Fuse
(Q
:i le::l ~:i
3A RB
CD
0 O'
!~-~! D> Ci3
i---r------------r----
I I i
(DC24V,240AH)
..,
(Q
g
© I
I
D>
3
CD
()
Eng. Oil p
C.W.Temp.
G.Oilp.
C.W. Level
Battery Switch 1
I L--
-
~
"'C
§:
CQ
Q)
~
0 Q.
-
CD
'<
"'C
CD
(/)
CD
~·
s·
CQ
Earth Bolt
-
~-
:J"
)>
..,
:::c
--
CD
D>
C.W. Temp Sender Eng. Oil Temp. C.W. Level Sensor Tacho Sendor
..,
CD
Switch
Charge
Eng. Oil p.
C.W. Temp
G.Oilp. ING
C.W. Level
Oil Filter
Remarks Oil Filter Bypass

Instrument panel (Main) 1. Battery & cables shown by dotted line to be provided by ship builder. Valve Switch
2
2. Sectional area of battery cables should be 95mm when their total length
Color coding 2
Detail of Connector (Arrow A-A) Detail of Connector (Arrow 8-8 ) is less than 5 metres and should be 120mm when their total length is more than 5 metres.
R Red Ln Li ht nreen Total cable length shall be ~ 1O metres. ( Battery ...., Starter Motor ,...., Battery )
B Black Lb Li ht blue Starter Switch
w White Br Brown 3. Keep the battery switch [ON] during engine operation.
30 A 17 1 G2 P1 P2 A
y Yellow p Pink GLOW 4. Tum off the battery switch when the quick charger charges the batteries
L Blue Gr Gra" F-F 0 5. After engine running, turn off the battery switch Body earth without air heater
G Green Pu Pumle N
0 Oranae TART
I DWG.NO. I E3-48660-0230
016094-00E
w
I\)
Color coding I\)
R Red Lg Light green
01
w
Black
White
Lb
Be
Light blue
Brown
Starter Switch 1---------L~-1
1--------------------1 §
y
L
Yellow
Blue Ge
Pink
Gray
GLOW i
'A j Procured By Customar j ~-
!
OFF
:J
G Green Pu Purple ON M
i i (Q
i~~·1'
0 Orange START
!E'---4--' 0
l~-~I
L~~~~top_~~~~ i I (DC24V. 240AH) I i D>
LR ---<S5~~~~~~itc~---r---- ..,
(Q
~~~~~~ I I D>
3
WBr
'-l~~~c5£L~st;:Jb:l~
I
Ic
___________.I
I
I
-
I \)
"C
~----'L,,,w_,,f.-IEB 0
-
RG
1~--L"-[-LI (Not Use)
CD
'<
Stop Switch "C
--
WBe
CD
C.W. Temp. Switch Eng. Oil Pressure
Switch Altemator(600W)
B
0
"C
0 B
YG !:!':
0
Charge Tacho Sensor Clutch Oil Pressure

-
:J
~
~
Eng. Oil p.
Switch CD
-0
C.W. Temp Q)
G.Oilp iiJ
C.W. Level g:
Eng. Oil Temp ""''-'--.LI ~
Oil Filter
OJ
CD
O'
Ci3
Instrument panel Oil Filter Bypass Valve Switch 0
~
CD
()
Remarks
1. Battery & cables shown by dotted line to be provided by ship builder.
2
§:
2. Sectional area of battery cables should be 95mm when their total length CQ
2
is less than 5 metres and should be 120mm when their total length is more than 5 metres. Q)
Total cable length shall be ~ 1O metres. ( Battery ......, Starter Motor ....., Battery)
(3P-M) (8P-F) (SP-M) ~
3. Keep the battery switch [ON] during engine operation.
Body earth without air heater Q.
4. Turn off the battery switch when the quick charger charges the batteries.
Detail oi Connector (Arrow A-A) Detail oi Connector (Arrow B-B) (/)
5. After engine running, turn off the battery switch.
I DWG.N0.1 E3-48660-0250 CD
016095-00E ~·
s·
CQ
w ~
I\)
I\) ~
(!j
en -0
Q)
Relay
1--------------------1 § iiJ
g:
j Procured By Customar j
~- ~
:J
(Q OJ
i:~~:i CD
O'
0
! ~--~ ! D> Ci3
I (DC24V, 240AH) I
i----+-------------r----i ..,
(Q
g
© Battery Switch
D>
3
CD
()
v-::-
Wire Harness
LR
I
I
I
I
I
I
IC
-
I \)
"'C
§:
CQ
Q)
~
0 Q.
-
CD
'<
"'C
CD
(/)
CD
~·
s·
CQ
I\)
I\)
00
C.W. Temp. Switch Eng. Oil Pressure
Switch Alternater(600W)
-
~-
:J"
)>
..,
Yo
:::c
--
CD
D>
C.W. Temp. Sender Eng. Oil Temp C.W. Level Sensor Tacho Sensor Clutch Oil Pressure
..,
CD
Switch Switch
Charge
Eng. Oil p.
C.W. Temp.
G.Oilp. WG
C.W. Level
Oil Filter
Instrument panel (Main) Remarks Oil Filter Bypass

1. Battery & cables shown by dotted line to be provided by ship builder. Valve Switch
2
Color coding 2. Sectional area of battery cables should be 95mm when their total length
2
R Red L Liaht areen
is less than 5 metres and should be 120mm when their total length is more than 5 metres
Detail of Connector (Arrow A-A) Detail of Connector (Arrow B-8)
B Black Lb Li ht blue Total cable length shall be ~ 1O metres. { Battery ......, Starter Motor ...... Battery)
i=-.,.i-==--+=+-"""==--1 Starter Switch
w White Br Brown 3. Keep the battery switch [ON] during engine operation
y Yellow p Pink 4. Turn off the battery switch when the quick charger charges the batteries.
L Blue Gr Gra 5. After engine running, turn off the batlety switch.
G Green Pu Pur le
Body earth without air heater
0 Ora nae
I DWG.N0.1 E3-48660-0260
0160%--00E
3.22.7 Instrument Panel
(1) Boost Pressure gauge
( 1) (2) (3) (4) (5) (6) (7) (2) L.O. Pressure gauge
(3) C.W. Thermometer
(4) Tachometer
(5) Buzzer switch
(6) Illumination switch
(7) Slop switch
CLUTGi~
(8) Start switch
OILP. l___~~-j
(9) Buzzer
(10) Clock
(12) (11) (10) (9) (8) (11) Hour meter
(12) OK Monitor
(1) Warning indicators

The instrument panel is provided with the warning
indicator window ("OK" monitor) on its lower left area.
The alarm buzzer goes on if any of the warning
indicators goes on except for the battery charging
indicator.
1) Engine oil pressure warning lamp 4) Cooling water temperature warning lamp
Goes on if engine oil pressure Goes on if abnormally high freshwater
reduction is detected. cooling temperature is detected.
Setting value Setting value : 100 QC
LUB.OIL : 0.05 MPa (0.5 kgf/cm 2) LUB. OIL
PRESS TEMP
000094-00X OOOU0'8-00X
2) Engine oil temperature warning lamp 5) Cooling water low level warning lamp
Goes on if abnormally high engine oil Goes on if abnormally low cooling
temperature is detected. freshwater level is detected.
Setting value : 95 QC
LUB.OIL C. WATER
FILTER TEMP
000097-00X 000093-00X
6)Charging lamp
3) Engine oil filter clog warning lamp This lamp goes off when battery
Goes on if dirt accumulates on the charging has started. The lamp goes
engine oil filter and the clogging is on if the charging is defective. The
detected. BATTERY buzzer does not go on if the alarm
CHARGE lamp goes on.
C. WATER Setting value : 0.2 MPa (2.0kgf/cm 2) 000092-00X
LEVEL The charge lamp is on when the
000096-00X starter switch is at "ON" when engine
is stopped. In such case, the charging
function is not defective.
229
3.23 Starting Air Motor

(Special order)
3.23.1 Specifications
A starting air motor is used to start a diesel engine
as same as an electric starting motor.
The starting air motor specification is shown a table.
THE AM SERIES STARTING AIR MOTOR SPECIFICATION

PERFORMANCE
Operating Total
At Maximum Output Air Con- Max.Torque
Model Air pressure length
MP a Output Revolution Torque sumption. mm
kW min- 1 N-m (m 3/sec) N-m
0.59 7.9 1 890 40 0.22 79

AM500 0.78 10.8 2030 50 0.28 102 410
0.97 13.6 2115 60 0.34 123
3.23.2 Piping Layout

An adequate piping layout to the starting air motor is
shown in a figure below.
Open the starting valve (quick valve or magnet
valve), compressed air (2.94 MPa or 2.45 MPa) in
the reservoir flows via the regulator (air pressure
has been regulated to the pressure range of 0.69
MPa-0.97 MPa), filtered by the filter and go through
the lubricator to the starting air motor.
In the lubricator, lubrication oil is automatically
supplied to the air in state of oil mist.
The compressed air flows in the starting air motor,
drives the motor and flows out from the exhaust
silencer.
Quick valve
Operating air) (Primary air
Air tank
Lubricator
Starting air motor
Air pressure gauge

(Operating air)
~Air filter
230
3.23.3 Sectional View
017816-00E
No. Parts mane No. Parts mane

1 Cylinder 23 Seal/Leaf Spring
2 Rotor 24 Retainer/Leaf Spring
3 Rotor Blade 25 Pinion Shaft
4 Ball Bearing 26 Ball Bearing
5 Washer 27 Circlip
6 Spring/Coned Disc 28 Friction Disc
7 Front Plate 29 Friction Disc
8 End Plate 30 Spring
9 0-Ring 31 Support/Spring
10 End Cover 32 Nut/Torque Adjusting
11 Hexagon Socket Head Cap Bolt 33 Hexagon Socket Set Screw
12 Cross Recessed Head Screw 34 Stopper
13 Retainer/Ball Bearing 35 Return Spring
14 Slotted Head Screw 36 Pinion
18 Mounting Case 37 Stopper/Pinion
19 Ball Bearing 38 Spring Pin
20 Reduction Gear 39 Metal Bush/Pinion Shaft
21 Spacer 40 Front Cover
22 Leaf Spring 41 Slotted Head Screw
231
3.23.4 Outline of Consutruction and Its Function

( 1) Construction
Starting Air Motor is consisted of 5 main parts described below;
1) Motor part
Energy of compressed air is converted to rotation in these parts.
((1) - (9) J
2) Reduction parts
Rotating speed of the motor is reduced in these parts.
((19) - (21) J
3) Missionary parts
Rotating power is transmitted to the engine via these parts.
( (25) (36) - (38) J
4) Shock absorbing parts
When shocking peak torque occurs, these parts protect the engage gears from damage.
( (22) - (24), (26) - (35) J
5) Covers and etc.
((10) - (18), (39) - (41) J
(2) Function
1) Function of Starting Air Motor
Each pressure of the air in reservoir and planed one of the reducing valve is confirmed.
The quick valve (or the solenoid valve) is opened at next.
Compressed air immediately reaches to the lubricator after purified from dirt by the filter.
Lubrication oil mist is automatically injected to compressed air.
Compressed air flows into the cylinder (1) and pushes out blades (3) in slots of the rotor (2), and
simultaneously lets the rotor rotate rapidly.
Revolution of the rotor is transmitted to the pinion shaft (25) via the reduction parts and the shock
absorbing parts.
The pinion (36) does not rotate synchronously to the pinion shaft because of its inertia, pushed forward by
screw of the pinion shaft and engaged with the ring gear.
The pinion comes to end of the pinion shaft, then rotation of the pinion shaft is transmitted to the ring gear
and drives the engine.
When the engine is fired and increased its revolution speed, the pinion is driven by the engine, comes
back, and disengages with the ring gear.
When confirmed the engine being started, close the quick valve and stop air supply to save air
consumption.
In case of remote automatic start, the sequence is designed to close solenoid valve when revolution of the
engine reaches to 400 min- 1 .
2) Function of the torque limiter

The shock absorbing parts of the Starting AIR Motor is constructed same as the Electric Starting Motor's one,
and functioned as same as one.
Normally, torque of the motor is fully transmitted through torque limiter (friction clutch), and drives engine.
In case of over load being tasked to the pinion, friction clutch slips and protects damage of the gears and etc.
232
3.23.5 Inspection, Maintenance and

Adjustment
To use this starting air motor safely, take care of
following descriptions.
Routine lubrication is unnecessary because of
automatic lubrication equipment being attached.
(1) Table of periodic service checkpoints

Carry out serving according to the recommended
schedule in this table below and promptly correct
any defects found.
Periodic inspection schedule

Schedule
Section Items After3000

No. Every Every Every
Daily times/every
a week a month a year
5 years
1 Tightening each part of every instruments 0
Operating
air pressure of the system 0
2 Regulator
Cleaning the screen 0
Purging the drain 0
3 Air filter
Cleaning the element 0
Magnet valve
4 Manual switch 0
for start
Oil level 0
5 Lubricator
Oil flow 0
Air starting
6 Overhaul ~o
motor
Reassemble parts checking and reconditioning

work, then, confirm that there are no other defects
before re-using.
Metal Bush (Pinion Shaft)
017817-00E
233
Usage limits of rotor blade

Nominal Usage limit
No. Model Item dimension (min.size)
(mm) (mm)
Length 120 -0.25
1 -0.40 119.2
(L)
~
Width 24 O.
2 AM500 -0.5 20
(B)
,_______
Thickness 120 -0.15
3 -0.25 4.5
(T)
Symbol of rotor blade dimension
B[ ______________ min. L
'1
min. B
L
017818-00E
(2) Recommended lubrication oil and grease

Use of the lubricating greases and oils.
Lubricating greases and oils Remarks
Environment of
Turbine oils ISO VG32 Don't use spindle oil
Lubricator 5 QC- 60 QC
(exhaust side) Environment of Refrigerating machine oil
Don't use spindle oil
-15 QC - 5 QC ISO VG15
Ball gearing, SHELL "Albania grease #2"
Lithium grease (multipurpose use)
Gear for overhaul
Metal bush for Grease after every 3000 times of use or every 5years
Moricote grease
the pinion shaft (molybdenum disulfide grease)
Be sure the level of oil in the lubricator is between

the upper and lower marks. Add if necessary.
(3) Adjusting of lubricator

The adjusting dome has already been adjusted
when shipped from the factory (one turn back from
the closed condition), therefore, it does not need to
be adjusted. When the engine starts, confirm that oil
is dripping.
234
3.23.6 Overhaul
(1) Disassembling Alignment mark
Normal operation does not require disassembly. If
the air motor fails, disassemble it and replace its
damaged parts.
After 3000 times or more over worked, overhaul is
necessary.
[NOTICE]
Replace all system air pressure before
attempting to work on the starting air motor
system components.
1) Before disassembly, put alignment marks on the (3)
~i
end plate (1 ), the cylinder (2), front plate (3), and
mounting case (4).
2) Remove the mounting case bolts (11-1) and
remove the mounting case (4) by tapping it lightly ..----
~
with a wooden or plastic hammer.
3) Remove the end plate bolts (11-2) and remove I'
Retainer I
Ball bearing
the end plate (1) and rotor (5) from the cylinder
(2) by tapping lightly on the rotor shaft end with a l -~--~--~--~--~--~--~-
(11-3)
'
wooden or plastic hammer. Be careful when the
blade detaches from the rotor groove.
(1)
I
'
4) Remove the front plate bolts (11-3) and then - - - - - - - - - lt--1----., _ _ _ J
remove the front plate (3) .
5) Remove the ball bearing (7) from the front plate
(3). Check the condition of blades (6) and the
cylinder (2) for damage and rust. (5)
(2) Reassembling
Clean and apply lubricating oil to the disassembled
parts. Apply grease to the gears. Recommended
Lube oil is CC class grade and #30 viscosity.
1) Match the alignment marks on respective parts.
2) Install the end plate (3) and rotor (4) on the cyl-
inder (2) .
3) Install the blades (5) in the rotor grooves (1) with
the end plate (3) down. Put the blade (5) outside
and the cylinder inside.
4) Install the front plate and bolts in on carefully.
Make sure the rotor moves smoothly.
5) Press-fit the ball bearing in the front plate and
install the retainer. When press-fitting the ball
bearing in the front plate using a bearing press,
hold the ball bearing inner ring.
6) Install the mounting case.
[NOTICE]
• For overhaul, the 0-rings should be replaced.
• Install the front plate onto the mounting case
017820-0lX
applying a liquid-gasket thinly to end surfaces
of the both parts.
• After assembling the starting air motor, trial
running is limited for 5 seconds or less.
235
(3) Securing the friction plate

If the flywheel does not rotate or rotates at a very
slow rate even though the rotor, blade and cylinder
are assembled correctly, suspect the pinion motion
and friction plate gliding condition. Do the following.
1) Remove the mounting case (1) and front cover
(2).
2) Tap lightly on the pinion shaft (3) while pulling out
the rotating parts.
3) Loosen the lock screw (5) and tighten the torque
adjusting nut (6), until the spring support (4) is in
contact with the friction plate.
4) Tighten the lock screw (5) and crimp the adjusting
nut (6) groove.
[NOTICE]
• If the friction plate is locked up, overhaul or
replace the starting air motor as soon as possible.
236
3.23.7 Troubles and Countermeasures

Item
TROUBLE CAUSE OR INSPECTION COUNTERMEASURES
No.
Check the air pressure and supply air fully to
1. Insufficient quantity of air supply
the air tank
2. Excessive flow resistance of the exhaust Check and remove off the resistance of the
line exhaust line and the exhaust silencer
Regulate the air pressure to operate the reg-
3. Insufficient pressure of air
1 Does not rotate ulating valve
4. Deformation of the blades Refer the Item No. 4
5. Abnormal contact of the moving parts
Reassemble the components
caused by miss-assembling
Overhaul the motor parts
6. Flowing in of dust
Check the air filter
Check the air pressure and supply air fully to
1. Insufficient quantity of air supply
the air tank
2. Excessive flow a resistance of the Check and remove off the resistance of the
exhaust line exhaust line and exhaust silencer
Revolution speed
2 Regulate the air pressure by the regulating
does not enough 3. Insufficient pressure of air
valve
Clean-up the air fitter element
4. Choke of the air filter
Replace the air filter element
5. Lack of lube oil or insufficiency of one Supply oil to the lubricator or adjust oil flow
Abnormal tempera- 1. Insufficient lube oil Supply oil to the lubricator or adjust oil flow
3 lure rise 2. Abnormal contact of the moving parts
(over 40°C of rising) Reassemble the motor parts
2. Abnormal contact of the moving parts
Abnormal wear Reassemble the components
4 and brake of the
blades 3. Rust of inner surface of the cylinder Refer the item No. 5
Overhaul the motor parts
4. Flowing in of dust
Check the air filter
Rust of inner sur- 2. Flowing in of water Purge the drain of the air filter
5
face of cylinder Clean-up the air fitter element
The rotor does not Abnormal contact of the moving parts
6 Reassemble the components
rotate smoothly caused by miss-assembling
1. Insufficient quantity of air supply Check the air pressure and supply air fully
Regulate the air pressure by the regulating
2. Insufficient pressure of air
valve
In sufficient torque
7 3. Abnormal contact of the moving parts
& miss-starting Reassembling
Clean-up the air fitter element
Abnormal wear of Supply oil to the cylinder and gear
1. Lack of lube oil or insufficiency of one
the any parts Supply grease to the bearing
8
(cylinder, bearing, Clean-up the air fitter element
gear) 2. Flowing in of dust
1. Failure of the 0-ring Exchange the 0-ring
Air leakage from 2. Abnormal contact of the moving parts
9 Reassembling to the air tank
assembly caused by miss-assembling
3. Crack in the cylinder or the end-plate Exchange the cylinder or the end-plate
237
238
4. Test running
4. Test running
Perform the test running for an engine as follows
after the maintenance job :
4.1 Preliminary precautions

Before making a test running, make sure of the
following points.
( 1) Warm the engine up.

(2) Remove any precipitation from the F.O.
filter. water separator, and F. 0 tank.
(3) Use only lube oil recommended by
Yan mar.
(4) Be sure to add Long Life Coolant
Antifreeze to cooling fresh water.
(5) Provide good ventilation in an engine
room.
4.2 Test running procedure

1) Supply the fuel oil, lube oil and coolanUwater.
2) Start the engine, and carry out idling operation at
a low speed (600 min- 1) for a few minutes.
3) Run in at the rated speed (no-load) for about five
minutes. Check any water, fuel or lube oil leakage
and existence of abnormal vibration or noise.
Also check the oil pressure, cooling water
temperature and exhaust gas color.
4) Adjust the no-load minimum and maximum
speed.
5) Perform loaded operation as required.
6) Shut down the engine after test running (for about
10 minutes).
Note:
Check the levels of the lube oil and coolanU
water again and add as required.
239
4. Test running
4.2.1 Check points and precautions during running

Step Item Instructions Precautions
Checks before 4) Make sure that the seacock is open. 3) Alarm indicator
operation 5) Make sure there is enough lube oil and coolanU doesn1appearonthe
1 water. display.
6) Operate the electronic control head and check if it
works property.
No load operation; 1) Check the lube oil pressure and coolant 2)
warm up operation temperature on the display. • Fit leaks if any.
2) When the engine starts, check the following: • Check the intake/
•There is no leakage of water, fuel and lube oil. exhaust valves, fuel
• Exhaust gas does not leak. injection nozzle and
2 ·There is no abnormal indication on the display. cylinder head.
•There is no abnormality in seawater discharge, 3) Do not raise the
engine vibration or engine sound. engine speed
3) To warm up the engine, operate at low speed for abruptly.
about 5 minutes, raise the speed to the no-load
rated speed and then to max. speed.
Cruising (load) 1) Do not operate the engine at full load yet, but raise
operation the speed gradually for about 10 minutes until it
reaches the rated speed.
3 2) Make sure that exhaust gas color and temperature
are normal.
3) Check the instrument panel and see if the water
temperature and oil pressure are normal.
Stopping the engine 1) Before stopping the engine, operate it at 600 min- 1 1) Stopping the engine
for about 5 minutes. suddenly during high
2) Raise engine speed to 1 ,800 min- 1 just before speed operation
stopping the engine and idle the engine for about increases the
3-4 seconds. temperature of
4
engine parts.
2) This procedure
prevents carbon from
being deposited on
the valve seats, etc.
Checks after 1) Check again for water and oil leaks. 1) Check the oil seal
stopping the engine 2) Make sure that no nuts and bolts are loose. area.
3) Close the sea cock and fuel cocks. 2) Especially the engine
5
4) When the temperature is expected to fall below installation bolts.
freezing, drain the seawater. 4) Drain from the
5) Turn off the battery switch. seawater pump.
240
5. Long storage
5. Long storage
Observe the following instructions when the
engine is to be stored for a long period without
operation:
1) Do not drain coolanU water in a cold season or
before the long time storage.
[NOTICE]
Negligence of adding anti-freeze will cause the
cooling water remaining inside the engine to be
frozen and expanded to damage the engine
parts.
2) Loosen the V-belt.
3) Perform the nearest periodic inspection before
the storage.
4) Drain or fill the fuel oil fully to prevent
condensation in the fuel tank.
5) Disconnect the battery terminals from the engine,
and store the battery fully charged. Charge the
battery once a month to compensate for the
battery's self discharge.
6) Cover the exhaust pipe, suction inlet, and electric
devices with vinyl sheets to guard against
moisture and dust.
7) Select a well-ventilated location without moisture
and dust for storage.
8) Remove any dirt, grime, or oil on the exterior and
wipe it clean, and apply a coat of antirust oil or
clean oil.
241
5. Long storage
242
6. Troubleshooting
6. Troubleshooting
6.1 Preparation before
troubleshooting
If the signs of a trouble appear, it is important to
lecture on the countermeasure and treatment
before becoming a big accident not to shorten the
engine life.
When the signs of a trouble appear in the engine or
a trouble occurs, grasp the trouble conditions fully
by the next point and find out the cause of sincerity
according to the troubleshooting. Then repair the
trouble, and prevent the recurrence of the trouble.
1) What's the occurrence phenomenon or the

trouble situation?
(e.g. Poor exhaust color)
2) Investigation of the past records of the engine
Check a client control ledger, and examine the
history of the engine.
•Investigate the engine model name and the engine
number. (Mentioned in the engine label.)
Examine the machine unit name and its number in
the same way.
•When was the engine maintained last time?
•How much period and/or time has it been used
after it was maintained last time?
•What kind of problem was there on the engine last
time, and what kind of maintenance was done?
3) Hear the occurrence phenomenon from the
operator of the engine in detail.
SW1 H of the occurrence phenomenon :
the investigation of when (when), where (where),
who (who), what (what), why (why) and how
(how)
•When did the trouble happen at what kind of time?
•Was there anything changed before the trouble?
•Did the trouble occur suddenly, or was there what
or a sign?
•Was there any related phenomenon.
(e.g. Poor exhaust color and starting failure at the
same time)
4) After presuming a probable cause based on the
above investigation, investigate a cause
systematically by the next troubleshooting guide,
and find out the cause of sincerity.
243
6. Troubleshooting
6.2 Fault-finding chart

It is important though systematic having to understand functions of each system and parts of the engine
enough to the fault finding, observing the trouble part carefully when trouble occurs, and
analyzing it pinpoint the cause.
The assumed trouble has been described by the following classification.
Please put the number of [Exterior views] that becomes an object, specify the part position referring to and
the schematic drawing, and treat it to the chart.
Starting Failure
Neither the lamp nor buzzer operate normally when starting

Starting Troubles
switch is made "ON"
Bad Color of Exhaust Gas (White Smoke}
The alarm buzzer rang while engine running and the lube oil
pressure reduction trouble indication lamp
The alarm buzzer rang while engine running and the fresh
water temperature rise trouble indication lamp
The alarm buzzer rang while engine running and the lube oil
temperature rise trouble indication lamp
Running Troubles
Bad Color of Exhaust Gas (White Smoke}
The engine suddenly stops
Insufficient Power Output
Surging is generated
Too great a consumption of lube oil
Too great a consumption of fuel oil

Miscellaneous
Abnormal noise of engine
The lubricating oil is emulsified

015895 -OOE
244
6. Troubleshooting
Cooling waler
Fresh waler cooler lube lever sensor Pressure cap Boost sensor Air cooler lube
Engine harness
Stop motor
Translation harness
Boost compensator Fuel oil filler Fuel waler Fuel hose

separator
0 0
0 0 0
Kingston cock Sea waler filler Instrument panel Starter switch Battery
Remote control handle

016491--00E
245
6. Troubleshooting
Cooling waler Cooling water

Sea waler pump sender unit temp. switch
a\I
Starter relay Lube oil cooler
Engine oil Oil press switch Lube oil filter

pressure sensor pressure sensor
Temp. switch (Engine oil) Lube oil filter
246
6. Troubleshooting
Does starting motor turn?

YES NO
Can the engine be rotated by the hand?

YES NO
Trouble in fuel supply system Trouble of electrical Miscellaneous

system
No. Causes Corrective action Remarks

1 No fuel in a fuel tank and fuel oil cock closed. Add fuel oil and open the fuel cock.
2 Water in fuel oil tank. Remove water from drain and fuel oil system and prime.
3 Clogging of fuel oil pipe. Clean.
4 Air in fuel oil system. Bleed air in the fuel system. 8
5 Clogging of fuel oil filter. Check fuel filter and replace if necessary. 8
The engine stop lever is pulled to the fuel The position of stop cable is adjusted. 6
6
decrease side.
7 Too low cetane number of fuel. Use high quality fuel oil.

1 The battery switch is off. Turn on the battery switch.
2 Battery voltage drop. Charge the battery. 13
3 Faulty of starter or relay. Replace the starter or relay. 19
4 Faulty connection of connected coupler. Repair using sandpaper or replace. 7
5 Cut of harness. Replace. 7
6 Loose of cable terminal. Tighten the terminal. 7

1 Faulty of fuel injection pump. Check and repair or replace.
2 Faulty of fuel injection valve spray. Check and repair or replace.
3 Damaged fuel feeding pump. Check and repair or replace.
4 Edges of ring gear teeth misshapen. Repair or replace.

Damaged of piston, crankshaft, camshaft, Repair or replace.
1 connecting rod, intake/exhaust valves.
turbocharger.
247
6. Troubleshooting
It doesn't turn it off while the charge lamp is driving.

YES NO
Not stopping of the buzzer sound or

nor trouble indication lamp is turned off.
YES NO
Trouble in alternator Defects of short and parts of Loose connection of

circumference. electrical system. electrical system.
015897-00E

1 Engine revolutions are lows. Engine revolutions are raised. 14
2 Loosening of alternator V-belt. Check the tension of V-belt. 5
3 Faulty of the alternator. Replace the alternator. 5
4 Faulty of the lamp. Lamps are replace. 12

Clothes of the harness tear and are Replace the harness.
1 7
short-circuited.
2 The terminal comes off and is short-circuited. lighten the terminal. 7
3 Faulty of the instrument panel. Replace the gauge. 12
Faulty of the sensor and switch. Replace. 2,3,18,
4
20,21,23

Loose connection of connected coupler. It assembles it again detaching the coupler
1 7
once.
Tightening is defective of the harness lighten the terminal.
2 7
terminal.
3 Rivet is defective of the harness terminal. Replace the harness. 7
4 Corrosion of harness terminal. Replace the harness. 7
5 Disconnection of harness terminal. Replace the harness. 7
248
6. Troubleshooting
Is the fuel normal?
YES NO
[ Faulty fuel injection system J Engine movement part Insufficient of [ Miscellaneous J

• Vslve mechanism air volume 015898- OOE

1 Irregular fuel injection timing. Check and adjust the timing
Faulty of fuel injection valve spray. Check, repair or replace.
2
Injection opening is clogged. Clean.
3 Faulty of fuel injection pump. Check, repair or replace.
4 Damaged valve spring in fuel injection valve. Replace.
5 Sticking of valve needle in fuel injection pump. Check, repair or replace.

Seizure of interlocking part. Remove and repair or replace.
1 Piston, Crankshaft, Camshaft, Connecting rod,
Intake/Exhaust valves.
2 Leakage of gas from intake/exhaust valves. Lap valves.
3 Wear of piston rings. Repair and replace.
4 Wear of cylinder liner. Replace the cylinder liner.

1 Clogging of turbocharger filter. Clean or replace. 16
2 Dirty air cooler. Clean. 4

Oil curns.
CD Too great quantity of lube oil. CD Lube oil is adjusted to a proper amount.
1
(2) Oil down from valve stem seals. (2) Replace the valve stem seals.
@Faulty of turbocharger seal ring. @Replace the seal ring.
Poor quality fuel oil. Reduce.with new oil.
2 CD Water mixed in fuel oil.
(2) Too low cetane number of fuel.
3 Too low temperature of boost air. Fit the air heater.
4 Too low temperature of fresh water. Check or replace the thermostat.
249
6. Troubleshooting
Dose the lube oil pressure gauge indicate a nomal value?
YES NO
[ Trouble of electrical system J [ Faulty lube oil system J [ Miscellaneous J ( Shortage of lube oil volume J

1 7
short-circuited.
3 Faulty of the instrument panel. Replace the instrument panel. 12
4 Faulty of lube oil pressure switch. Replace the switch. 20

1 Clogging of lube oil filter. Replace the element. 22
2 Faulty lube oil pressure adjusment valve. Repair.
3 Dirty of lube oil. Replace.

1 1 Faulty of the lube oil pump. Maintenance or replace.
2 Damage to lube oil pump inlet pipe. Repair or replace.
Excess bearing clearance. (Crank pin Replace the bearing.
3
bearing, Main bearing, Camshaft bushing)

1 Shortage of lube oil volume. (engine, clutch) Add the lube oil.
2 Oil leakage from engine and clutch. Is processes it searches for the leaking part.
250
6. Troubleshooting
Is fresh water volume of fresh water tank normal?
YES NO
Trouble of electrical system Faulty of seawater Faulty offresh water Shortage of fresh water
route route volume
015900-00E

1 7
short-circuited.
4 Faulty of fresh water pressure switch. Replace the switch. 18

1 Improper opening and closing of kingston cock. Check the opening and closing status of cock. 10
2 Clogging of kingston cock. Clean the cock. 10
3 Clogging of seawater filter. Clean the filter. 11
Dirty of seawater passage. Clean the seawater passage.
4 1,4
(fresh water cooler, air cooler.

1 Faulty of thermostat. Clean or replace.
2 Dirty of lube oil cooler and fresh water cooler tube. Clean. 1,24

1 Insufficient of fresh water volume. Add the fresh water.
2 Water leakage in freshwater pump. Replace the mechanical seal.
3 Damage of rubber hose. Replace the rubber hose.
4 Loose of draining cock. Tighten firmly.
5 The seal is defective of the piping joint. Tighten firmly or replace packing.
6 Faulty of filler cap. Clean or replace. 2
7 Leakage of gas from head gasket. Replace the gasket packing.
251
6. Troubleshooting
Is lube oil volume of oil pan normal?
YES NO
Trouble of electrical system Faulty of seawater Faulty of lube oil Shortage of lube oil
route route volume
015901-00E

1 7
short-circuited.
4 Faulty of lube oil temperature switch. Replace the switch. 21

1 Improper opening and closing of kingston cock. Check the opening and closing status of cock. 10
2 Clogging of kingston cock. Clean the cock. 10
3 Clogging of seawater filter. Clean the filter. 11
Dirty of seawater passage. Clean the seawater passage.
4 1,4
(fresh water cooler, air cooler.
5 Damaged of rubber impeller in seawater pump. Replace the bobber impeller. 15

1 Faulty of thermostat. Clean or replace.
2 Dirty of lube oil cooler core. Clean. 24

1 Shortage of lube oil volume. Add the lube oil.
2 Too great a quantity of lube oil. Adjust quantity of oil.
3 Oil leakage from engine. Is processes it searches for the leaking part.
252
6. Troubleshooting
Is air quantity?
YES NO
Overloading Faulty fuel injection Engine movement part Air quantity

system ·Valve mechanism insufficient
01S902-00E

1 Damage and dirty of propeller. Repair and replace or clean.
2 Dirty of body of a ship. Clean the body.
3 The travelling figure of the hull is bad. The loading position is changed.
4 Over carry. Review the propeller.
The wick of propeller shaft and the engine Adjust.
5
shifts.
7 The propeller shaft interference the stantube. Repair.

1 Faulty of fuel injection valve spray. Check, repair or replace.
2 Irregular fuel injection timing. Check and adjust the timing.

1
connecting rod, intake/exhaust valves.
2 Damage of turbocharger. Repair or replace.
3 Damage of seat of intake/exhaust valve. Ground or replace the valve seat.

1 The ventilation switch is off. Turn on the ventilation.
2 Faulty of ventilation. Replace the ventilation.
3 Clogged of ventilator. Clean.
4 Dirty of prefilter in the turbocharger. Clean or replace.
5 Dirty of blower in the turbocharger. Clean.
6 Faulty of turbocharger. Repair or replace.
7 Dirty of air cooler. Clean. 4
253
6. Troubleshooting
Is the fuel normal?
YES NO
[ Faulty fuel injection system J Engine movement part Insufficient of [ Miscellaneous J

• Vslve mechanism air volume 015898- OOE

1 Irregular fuel injection timing. Check and adjust the timing
2

3 Wear of piston rings. Repair and replace.
4 Wear of cylinder liner. Replace the cylinder liner.

1 Clogging of turbocharger filter. Clean or replace. 16

Oil curns.
CD Too great aquantity of lube oil. CD Lube oil is adjusted to a proper amount.
1
(2) Oil down from valve stem seals. (2) Replace the valve stem seals.
@Faulty of turbocharger seal ring. @Replace the seal ring.
Poor quality fuel oil. Reduce.with new oil.
4 Too low temperature of fresh water. Check or replace the thermostat.
254
6. Troubleshooting
Can the engine be rotated by the hand?
YES NO
Fuel oil supply system Protective device Miscellaneous

operation

1 No fuel in a fuel tank. Add fuel oil.
Water in fuel oil tank. Remove water from drain and fuel oil system
2
and prime.
3 Clogging of fuel oil pipe. Clean. 8
4 Air in fuel oil system. Bleed air in the fuel system. 8

1 Low lube oil pressure. Check or repair. 20
2 Fresh water temperature is too high. Check or repair. 18

Stop motor operation done by short electric Repair the short part.
1 6,7
wiring.
2 Faulty of fuel injection pump. Repair or replace.
3 Faulty of fuel injection valve spray. Check and repair or replace.

1 connecting rod, intake/exhaust valves.
Damage of turbocharger.
255
6. Troubleshooting
(I) Black smoke has gone out (2) Exhaust temperatures of too high
YES NO
Air quantity Faulty fuel injection Engine movement part Trouble in fuel
insufficient system ·Valve mechanism supply system
015904-00E

1 Damage and dirty of propeller. Repair and replace or clean.
2 Dirty of body of a ship. Clean the body.
3 The travelling figure of the hull is bad. The loading position is changed.
4 Over carry. Review the propeller.
5 The wick of propeller shaft and the engine shifts. Adjust.
7 The propeller shaft interference the stantube. Repair.

1 The ventilation switch is off. Turn on the ventilation.
2 Faulty of ventilation. Replace the ventilation.
3 Clogged of ventilator. Clean.
4 Dirty of prefilter in the turbocharger. Clean or replace. 16
5 Dirty of blower in the turbocharger. Clean.
6 Faulty of turbocharger. Repair or replace.
7 Dirty of air cooler. Clean. 4

1 Faulty of fuel injection valve spray. Check, repair or replace.
256
6. Troubleshooting

1
connecting rod, intake/exhaust valves.
2 Damage of turbocharger. Repair or replace.
3 Damage of seat of intake/exhaust valve. Ground or replace the valve seat.

1 No fuel in a fuel tank and fUel oil cock closed. Add fuel oil and open the fuel cock.
Water in fuel oil tank. Remove water from drain and fuel oil system
2
and prime.
3 Clogging of fuel oil pipe. Clean. 8
4 Air in fuel oil, system. Bleed air in the fuel system. 8
The engine stop lever is pulled to the fuel The position of stop cable is adjusted.
6 6
decrease side.
7 Faulty of fuel feeding pump. Repair or replace.
257
6. Troubleshooting
When the load changes, itis generated.
YES NO
Load change Torqur rich Dirty of intake I Miscellaneous

exhaust system
015905 -OOE

1 Engine stop of load condition. Engine stop the no-load condition.
2 Rapid load change. The rotation is slowly lowered.

1 Rapid turn of full load. Is turns slowly.
2 Dirty bottom of a ship. Clean the bottom of a ship.
3 Bend of propeller. Repair or replace.
2 Dirty of propeller. Clean.

1 Clogging of suction/exhaust pipes. Cleaning.
3 Leakage of gas from suction/exhaust valves. Lap valves.
4 Dirty of silencer in turbocharger. Clean. 16
5 Dirty of the blower side or turbine side. Overhaul and wash the turbocharger I blower.

1 Faulty of fuel injection valve spray. Repair or replace.
2 Distortion of nozzle in turbocharger. Replace.
258
6. Troubleshooting
Do not it leakage outside?
YES NO
Unsuitable of lube oil Engine movement part Miscelaneous Leakage to the outside
·Vslve mechanism OlS906-00E

1 Too high viscosity of lube oil. Reduce. with new oil.
2 Too great a quantity of lube oil in oil pan. Adjust quantity of oil.
3 Too high pressure of lube oil. Check or adjust.

Faulty of cylinder liner. Repair or replace.
1 CD Faulty of roundness.
(2) Worm of cylinder liner.
2 Worn of piston rings. Replace.
3 Faulty positioning of cylinder liner and piston. Replace.
Faulty positioning of intake /exhaust valve and Replace.
4
valve guide.
5 Faulty of valve stem seals. Replace.

1 Worn of seal ring in turbocharger. Replace.
2 Faulty of oil cooler. Repair or replace. 24
3 Faulty of oil seal in fuel feed pump. Replace the oil seal.

1 Lube oil leakage in engine. Is processes it searches for the leaking part.
2 Clogged of breather. Clean the breather.
259
6. Troubleshooting
Do not it leakage outside?
YES NO
Faulty of propeller design Combustion faulty Miscellaneous Leakage to the outside

015907-00E

Increase of slip rate.
1 CD Small of propeller diameter. Repair or replace.
(2) Heavy of propeller.
2 The travelling figure is bad. The buoyancy body is applied to the body of a ship.
3 Dirty the body of a ship. Clean the body of a ship.

Insufficient of air volume.
CD Clogging of turbocharger prefilter. CD Clean or replace.
1 16
(2) Dirty air cooler. (2) Clean or replace.
@ Faulty of turbocharger. @Clean or replace.
2 Faulty of fuel injection valve. Clean or replace.
3 Irregular fuel injection timing. Adjust.
4 Faulty of fuel injection pump. Adjust or replace.

Faulty of nominal compression ratio.
CD Stick of intake/exhaust valve. CD Replace.
1
(2) Faulty of intake/exhaust valve clearance. (2) Adjust.
@ Damage of intake/exhaust valve. @Lap or replace.
2 Worm of piston rings. Replace.
3 Worm of cylinder liner. Replace.

1 Oil leakage from engine. lsprocesses it searches for the leaking part.
Incorporation in the engine oil. Confirmation and replace the fuel injection
2 pump and fuel injection valve and fuel feed
pump.
260
6. Troubleshooting
Knocking is generated?
YES NO
Fuel injection system Engine movement part Miscellaneous

·Vslve mechanism

2

3 Wear of piston rings and cylinder liner. Repair and replace.
4 Faulty of intake/exhaust valve clearance. Adjust.

1 Faulty of thermostat in the fresh water system. Replace the thermostat.
Poor quality fuel oil. Reduce. with new oil.

1 The cover etc. peel off. Repair or replace.
2 Leakage of air from air hose. Tighten firmly or replace.
3 Leakage of exhaust gas. Replace.
261
6. Troubleshooting
Water mixes with oil
Seawater mixing
Seawater mixing.

1 Faulty of mechanical seal in seawater pump. Replace the mechanical seal. 15
2 Clogged drain of seawater pump. Clean the drain hole. 15
3 Faulty of air cooler tube. Replace. 4
Fresh water mixing.

Faulty of mechanical seal in fresh water Replace the mechanical seal.
1
pump.
2 Clogged drain of fresh water pump. Clean the drain hole.
3 Coagulant in the engine. Open the drain cock.
4 Rain water mixing from exhaust duct. -
262
7. Service standards
7.1 Engine tuning
Reference
No. Inspection item Standard Limit
page
Intake 0.3 -
1 Valve clearance mm 3.1.11(3)
exhaust 0.5 -
V-belt tension Used part 11-12 -
2 mm 3.21.2(6)
at 98N (1 Okgf) force New part - -
MP a 31 ± 0.5
3 Fuel oil injection pressure - 3.12
(kgf/cm 2) (316 ± 5)
Engine 65 -
4 Cooling water capacity Coolant Liter
recovery tank
3.4 -
Lube oil capacity (full) 111 Standard oil pan
5 Engine Liter
at rake angle O degree 73 Shallow oil pan
MP a 0.44-0.54
6 Lube oil pressure - 3.18.3(1)
(kgf/cm 2) (4.5-5.5)
MP a 0.1 ± 0.02
7 Oil pressure alarm (ON) - 2.4.(59)
(kgf/cm 2) (1.0 ± 0.2)
Valve opening
temperature
deg.C 71 76.5 -
8
Cooling water I 3.19.5(2)
thermostat 8 or above
Full opening lift mm
(85 and 90 deg.C)
-
Coolant temperature ON 95 ± 2 -
9 deg.C
alarm OFF 88 ± 2 -
2.4.(59)
ON 100 ± 3 -
10 Oil temperature alarm deg.C
OFF 95 ± 3 -
76 from switch
11 Coolant level switch operating level mm
attaching surface
- 2.4.(59)
0.2 ± 0.03
Element ON -
Lube oil filter element MP a (2 ± 0.3)
12 2.4.(59)
bypass valve Bypass valve (kgf/cm 2) 0.6 ± 0.03
opens
-
(6 ± 0.3)
13 Top clearance mm 1.56 ± 0.108 - 3.1.8
263
7.2 Engine body

7.2.1 Cylinder head
(1) Cylinder head
Inspection item Standard Limit Reference page
Combustion surface distortion mm 0.035 or less 0.15 3.1.1 (2)
Valve sink Intake
mm -0.4-+0.1 -0.5 3.1.3(3)
Exhaust
Valve seat angle Intake 120 -
deg. 3.1.1(3)
Exhaust 90 -
(2) Intake/exhaust valve and guide

Intake Guide inside
10.928-10.950 10.92
diameter
Valve stem
11.000-11.018 11.12
outside diameter
Clearance 0.050-0.090 0.2 3.1.3(1)
mm
Exhaust Guide inside 3.1.3(4)
10.928-10.950 10.92
diameter
Valve stem
11.000-11.018 11.12
outside diameter
Clearance 0.050-0.090 0.2
Valve guide Intake
projection mm 19.7-20.3 -
Exhaust 3.1.3(4)
Valve guide driving-in method Cold-fitted -
(3) Valve spring

Free length (intake/exhaust) mm 76.2-77.2 -
3.1.4(1)
Inclination (intake/exhaust) mm - 1.8
(4) Rocker arm and shaft

Arm shaft hole diameter 32.010-32.065 32.180
Shaft outside diameter mm 31.966-31.991 31.880 3.1.9(1)
Clearance 0.019-0.099 0.20
264
7.2.2 Camshaft and gear train

(1) Camshaft
Side clearance 0.10-0.35 0.45 3.7.1(1)
Bending (1/2 the dial gage reading) - 0.04 3.7.1(4)
mm
Cam height Intake 59.85-59.95 59.4
3.7.1(2)
Exhaust 59.95-60.05 59.5
Camshaft and Bushing inside
70.02-70.07 70.16
bearing diameter
Camshaft mm 3.7.1(3)
69.91-69.94 69.82
outside diameter
Clearance 0.08-0.16 0.25
(2) Idle gear shaft and bushing (Cam gear drive)

Idle shaft dia. 59.940-59.970 59.83
Idle gear bushing inside dia. mm 60. 000-60. 030 60.14 3.8.1(3)
(3) Backlash of gear train

Backlash of gear train (other) mm 0.15-0.25 0.40
Back of fresh water pump and mm 0.12-0.20 0.40 3.8.1(2)
alternator gear
265
7.2.3 Cylinder block

(1) Cylinder liner
Liner inside L 155.020-155.030
diameter ML 155.015-155.020
154.800
MS 155.010-155.015
mm 3.3.1
s 155.000-155.010
Liner bore Roundness 0.008 or less -
Cylindricity 0.01 O or less -
(2) Crankshaft
Bending (1/2 the dial gauge reading) 0.018 or less 0.05 3.1.6(2)
Crank pin Metal inside
106.010-106.060 106.150
diameter
Pin outside
105.940-105.960 105.850
diameter
Clearance 0.050-0.120 0.15
mm 3.1.6(3)
Crank journal Metal inside
134.000-134.065 134.100
diameter
Journal outside
133.930-133.955 133.850
diameter
Clearance 0.045-0.135 0.18
(3) Crankshaft thrust bearing

Crankshaft side clearance mm 0.080-0.229 0.33 3.1.6(4)
I
266
(4) Piston and ring

1) Piston

Piston outside diameter L 154.935-154.945
(Measure in the M 154.925-154.935 154.780 3.4.1
direction vertical to the
piston pin.) s 154.915-154.925
Clearance between piston and
liner
Piston diameter measure position mm
(Upward from the bottom end of 47.0 -
the piston)
Piston pin hole inside diameter 62.010-62.020 62.120
Piston pin outside diameter 61.971-61.980 61.867
3.4.2
Clearance between piston pin and
0.030-0.049 0.06
hole
2) Piston ring
Inspection item Standard limit Reference page

Top ring Ring groove width 3.630-3.645 -
Ring width 3.4 70-3.490 3.37
Side clearance 0.140-0.175 0.18
Gap 0.40-0.55 1.5
Second Ring groove width 3.095-3.110 -
ring Ring width 2.970-2.990 2.87
mm 3.4.3
Gap 0.55-0.70 1.5
Oil ring Ring groove width 4.020-4.040 -
Ring width 3.970-3.990 3.77
Gap 0.40-0.60 1.5
267
(5) Connecting rod

1) Rod big end
Side clearance I mm 0.15-0.324 - 3.5.1(2)
2) Rod small end

Item Standard Limit Reference page
Piston pin bushing inside diameter 62.034-62.049 62.134
Piston pin outside diameter mm 61.971-61.980 61.867 3.5.3(1)
Clearance 0.054-0.078 0.15
(6) Tappet
Tappet guide hole inside diameter 45. 000-45. 025 45.06
Tappet stem outside diameter mm 44. 940-44. 965 44.90 3.7.2(2)
Clearance 0.035-0.085 0.15
268
8. Maintenance Checking
8.1 Precautions in Maintenance Checking
To use an engine always in good order, checking is necessary periodically for trouble prevention. The period
of checking can not be fixed indiscriminately because it is influenced by application of the engine, conditions
of use, quality of fuel oil and lub. oil used, and daily handling circumstance.
• The following tables of checking show the standard checking frequency. Perform the initial overhaul
servicing according to these checking tables. Then, based on the obtained checking (on wear
corrosion, accumulation of carbon, accumulation of sludge and others), make the most economical
checking schedule suitable for your engine, and conform to the specified schedule from the second
checking.
• As for the items whose checking frequency is shown by both the accumulated operation hours and
number of days, schedule the checking at the earlier timing.
8.2 Table of Periodical Checking

Servicing of checking
Checking A: Daily (including weekly) Checking E: Semiannually (per 1,500 running hours)
Checking B: Semimonthly (per 100-150 running hours)Checking F: Annually (per 3,000 running hours)
Checking C: Monthly (per 250 running hours) Checking G: Biannually to Three year (per 6,000-9,000 running hours)
Checking D: Trimonthly (per 750 running hours)
KEYS: 0 , checking/cleaning/ flushing/adjustment: @ , parts replacement
*Yan mar or the nearby service agent executes and report Part to be checked shown by the sign, please.
Checking Servicing Cycle

Part to be (by Class.)
Div. Nature of Service Remarks
Checked
A B c D E F G
Fuel injection 1st
pump Check on fuel injection timing time
0 Adjust if required.
0
Replace if found
* Check on deflector 0 worn.
* Disassembly & check of major parts 0
Replacement of plunger and per 8,000 running hrs.
@
* delivery valve
Fuel injection Check on injection pressure & 1st
Replace if found
time
valve atomization condition 0 troubling.
E 0
-
Q)
Cf)
>.
(/)
Removal of carbon
1st
time
0
0
-
6 Disassembly, cleaning & checking @ Replace nozzle.
Q) Replacement of nozzle spring @
:::J
LL
Fuel oil filter Draining 0
Replacement of paper element @ per 500 running hrs.
Fuel tank Check on oil volume 0
Discharge of sediment & moisture
& draining 0
Fuel feed Disassembly & check of major
pump * parts 0
* Replacement of oil seal @
Check on oil leakage from oil seal 0
269

Checked
A B c D E F G
Lub. oil pump * Disassembly & check of major parts 0
* Replacement of pump assembly per 16,000 running hrs.
Oil pan Check on oil volume 0
Exchange of lub. oil
E Light (Gas) oil (Standard oil pan) @ per 500 running hrs.
-Q)
Cf)
>.
(/)
Heavy (Diesel ) oil (Standard oil pan)
Light (Gas) oil (Shallow oil pan)
@
@
per 250
per 300
running
running
hrs.
hrs.
- Heavy (Diesel ) oil (Shallow oil pan) @ per 150 running hrs.
6
..c:i Lub. oil filter Replacement of lubricating oil
:::J
strainer cartridge @ per 500 running hrs.
_J
Lub. oil by-

Cleaning of rotar 0
pass filter
Lub. oil cooler * Disassembly, cleaning & check 0
Suc./exh. valve
Check on oil feeding condition 0
rocker arm
Piston & Draw-out of piston, cleaning of car-
piston pin * bon & measurement 0
* Check of piston/ oil ring groove 0
Check & measurement of piston
* pin hole 0
* Replacement of piston/ oil rings @
* Check & measurement of piston pin 0
Connecting rod Check & measurement of piston
* pin metal 0 per 16,000 running hrs.
Check & measurement of crank pin
* metal 0
Cf)
t: Disassembly & check on connect-
Cll
Cl.. * ing rod bolt 0
Ol
c * Replacement of connecting rod bolt per 16,000 running hrs.
-::;::
0 Cylinder liner Measurement of cylinder liner inner
2: * diameter 0
I-
0
"(ii' Removing & check of water jacket
* part 0
2:
Main bearing * Check of main bearing 0
Check of main bearing clamping
* bolts 0
* Replacement of main bearing per 16,000 running hrs.
* Check of main bearing side bolts 0
Crankshaft Measurement of pin outer
* diameter & check of journal 0
Measurement & adjustment of
* deflection 0
Check & replacement of viscous Replacement per
* damper 0 16,000 running hrs.
270

Checked
A B c D E F G
Cooling water Check on water leakage from
pump mechanical seal 0
(Fresh water) * Replacement of mechanical seal @
0
* Disassembly & check of major parts 0
* Replacement of ball bearing @
* Replacement of impeller & shaft @
E Cooling water Check on water leakage from

0
-
Q)
Cf)
(/)
pump
>. (Sea water) *
mechanical seal
Replacement of mechanical seal @
-~ * Replacement of oil seal @

I-
Q)
Replacement of impeller,
@
* rubber impeller
Ol
c * Replacement of ball bearing @
0
0 Fresh water Disassembly, check, cleaning &
()
cooler * hydraulic test 0
Check of anticorrosive zinc &
0 @
replacement
Thermostat * Disassembly, check & cleaning 0
* Replacement @
Cooling water Check of water volume 0
Exchange 0
E
(].)
u; Governor * Disassembly & check of major parts 0
>-
en
> Governor link Check, adjustment & oiling
0
Cl 0
E Cell motor * Check on wear of brushes 0
-Q)
Cf)
>.
(/)
Battery Electrolyte specific gravity check
Electrolyte level check
0
Ol 0
c
'E Check of terminals 0
ro
Ci5 Replacement per three years
E Cylinder head Check & adjustment of valve head
Cf) & suction/ clearance 0
c
ro exhaust valve Check of valve spring & rotator
..c
()
Q) * rotation 0
~
Check, servicing & replacement of @
Q)
> * valve rotator & stem seal 0
(ii
> Cleaning of carbon of combustion
o6
* chamber 0
-0
ro
Q) Valve & seat replace-
..c Lapping & replacement of
~
Q) * suc./exh. valve 0 ment: per 16,000

-0
c
running hrs.
·-
>- Check of valve guard (bridge),
0 * guide & push rod 0
-0
ro
Q)
:r: Cylinder head
* Cleaning of scale of water jacket 0
>, & valve
0
2009.2.25R 271

Checked
A B c D E F G
Turbocharger Washing of blower filter 0 per 7-10days
E * Replacement of blower filter @
-Q)
Cf)
>.
(/)
* Disassembly & cleaning
Replacement of flowting metal &
0
I- @
Q) * thrust metal
ei Air duct * Replacement of expansion joint
Cll
..c
0
(.)
0 Aircooler * Sweep of core (air side) 0
.c
I-
:::J
* Disassembly & cleaning 0
I-
Check of anticorrosive zinc &
0 @
replacement
~
Cll Camshaft Check of fuel, suction & exhaust

Q)
(9 * cams 0
o6 * Check of camshaft bush per 16,000 running hrs.
¢::'.
Cll
..c Sue./ exh . * Check of roller tappet
Cf)
E tappet
0
Cll
0 Each gear * Check of tooth bearing & backlash 0
Stopping
* Check 0
solenoid
Battery switch * Check 0
Temperature
* Check & replacement 0 @
switch
Pressure
* Check & replacement 0 @
switch
Tachometer * Check on indication & replacement 0 @
Pressure
* Replacement @
gauge
Wire harness Check per 1,000 running hrs.
Each pipe
Check on leakage 0
system
Engine exterior Check on looseness of bolts & nuts 0
~
-
Q)
..c Check on water/ oil/ gas leakage at
various parts 0
0
Alternator 1st 2nd
time time
Check of the V-belt tension 50 500 @
hrs. hrs.
0 0
Check and replacement of viscus damper 0 Check : per 5,000 running hrs.
@ Replacement : per 10,000 running hrs.
Check of remote control cables & replacement 1st
time @
0
0
Check and Replacement of rubber hoses
0 @
(Fuel, lub.oil, cooling water, breather and air line)
Re-tighten hose clips 1st
time
(Lub. oil, cooling water, breather and air line) 50
hrs.
0
0
2009.2.25R 272
9. Service Standard
9. Service Standard
(Unit in mm)
Dimension St'd
Max. Usage
Cl earance Allowance
Item Limit of Sketch
Assembling Clearance Parts
Normal Tolerance Time
Inner dia. of cylinder upper +0.046

part O A=0.025 h
<t> 181 1---0-.0-2-5-----i -o. 101 i
Outer dia. of cylinder liner
upper part -0.055 ··~ f:.A
Inner dia. of cylinder lower +0.040

part O B=0.015
1--------------i 177
~
-~ Outer dia. of cylinder liner

<t>
1---0-.0-1-5-----i -o. 085
-;::: lower part -0.045
~ 1------------+------+------+-----+------+-------i
c h=0.03
~ Bomb of cylinder liner h=0.09
-0.09
o6
~
C=1.452
~ Top clearance 1.56 ± 0.108 -1.668 2.0
c
>,t------------+------+------+-----+------+-------i
0 +0.030
Inner dia. of cyl. liner
+0.4
<t> 155
0
*
Deflection
wear of 0.2
0=2.305
Outer dia. of piston head <t> 152.675 ± 0.015 -2.365
E=0.055
Outer dia. of piston skirt part <t> 154.930 ± 0.015 -0.115
E=0.17 -0.15
No.1 =5.7 No.1=5.38

Radial thick. of piston rings No.2=6.7 ± 0.12 No.2=6.38
Radial thick. of oil ring 3 ± 0.15 2.68

016567-00X
Width of piston ring, No.1 & No.1 =3.5 -0.010 No.1=3.37

No.2 No.2=3.0 -0.030 No.2=2.87
Width of piston ring groove, +0.145 G=0.140

~ No.1 No. 1= 3 ·5 +0.130 -0.175 G=0.18 3.745
.§ 1 - - - - - - - - - - - - + - - - - - - + - - - - - - + - - - - - - - - - l
o6 Width of piston ring groove, +0.110 G=0.105
c No.2 No. 2 = 3 .o +0.095 -0.140 3.21
-~t------------+------+------+-----+------+-------i
c -0.010
.8 Width of oil ring -0.030
3.77
-~ H=0.030
~1--------------i 4 -o. 0 7 0 H=0.18 In I'• ]I
--llH- - +-"'-.tllf-
1---------l
c +0.040
-5l Width of oil ring groove +0.020 4.14
m• "' ·J
~ 1-------------+------+------+-----+------+----~
Inner dia. of piston pin metal
+0.049
+0.034 <1>62.134 Thlr1
J=0.054 016868-00X
J=0.15
1---0-.0-2-0-----< -o. 0 7 8
Outer dia. of piston pin <t> 61.867
-0.029
<1>62
+0.020
Inner dia. of piston pin hole <t> 62.120
+0.010 K=0.030
K=0.06
1---0-.0-2-0-----< -o. 049
Outer dia. of piston pin <t> 61.867
-0.029
*: Indicates the limit at the 1st ring area when the piston is at T.D.C.
273
9. Service Standard
(Unit in mm)
Dimension St'd
Max.
Clearance Usage Limit
Item Allowance Sketch
Normal Tolerance Assembling of Parts
Clearance
Time
Inner dia. of crank pin +0.060
+0.10
bearing +0.010 L = 0.050
<t> 106 L=0.15 f<-9
-0.120 -====
Outer dia. of crank pin
-0.040
-0.060
Deflection
wear of 0.05 I I ~/L
Length of crank pin
+0.074
0 g=0.150
I
'
cit I
66 g = 0.41
Width of connecting rod
big end
-0.150
-0.250
-0.324
'-) \,____,
016869-00X
+0.065
Inner dia. of main bearing
~
ro 134
0 M = 0.045
M = 0.18 ~~j\~N
~i - -
<t>
..c
en -0.045 -0.135 Deflection
~ Outer dia. of journal
c -0.070 wear of 0.08 =
J.e·-- -
~
-
0 Width of datum part main +0.030

52 +0.011
bearing -- C"\
""'
Thickness of thrust bear- -0.055 N = 0.080 -'ilili'
4 N = 0.33
ing -0.105 -0.229 016870-00X
Width of datum part jour- +0.030

60
nal 0
Deflection
Clearance of valve head

Adjusting
value
P=O
-0.018
(cold state)
T = 0.3
(Intake)
Max. allow-
able value
p = 0.036
(cold state)
T = 0.3
(Intake)
ft 016871-00X
''
(Tappet clearance) T = 0.5 T = 0.5

(Exh.) (Exh.) ::s T
Outer dia. of intake valve

-0.050
-0.18 1~ lti
-0.072 v = 0.050 v = 0.2
Inner dia. of intake valve
guide
<t> 11
+0.018
0
-0.090
+0.12 d'*" ~ !!~ u!~ ;'~
;.,, u
; C'.
t·Jl k
~,__v
-0.050 !V
Outer dia. of exhaust valve -0.18
-0.072 v = 0.050 v = 0.2
<t> 11 -0.090
Inner dia. of exhaust valve +0.018
+0.12
guide 0 /(_(x•_,
Outer dia. of valve bridge +0.046 ao
E -0.07
-~ guide +0.028 u = 0.014 Intake = 120 deg.
c
ro
<t> 13 -0.052
u = 0.2 Exh. = 90 deg.
..c +0.080
u Inner dia. of valve bridge +0.18
Q)
+0.060 016872-00X
E Q = 3.9 Q = 3.2
Q)
> Margin thickness of intake/ (In.) (In.)
ro exh. valve poppet part Q =2.25 Q =1.8
> (Exh.) (Exh.)
~I
R = 5.15 R = 5.75
Width of intake/exh. valve (In.) (In.)
seat R=6 R =6.4
(Exh.) (Exh.) Q
s = 051 S= <j>51.5
Dia. of intake/exh. valve (In.) (In.)
±0.1
seat contact part s =<1>50.5 S= <j>51.8
(Exh.) (Exh.)
Outer dia. of rocker arm -0.009 w
-0.12
shaft
~
-0.034 W= 0.019
<1>32 W=0.2
Inner dia. of rocker arm +0.065 -0.099
+0.18
bush +0.010 ' 016874-00X
274
9. Service Standard
(Unit in mm)
Dimension St'd
Max.
Clearance Usage Limit
Item Allowance Sketch
Normal Tolerance Assembling of Parts
Clearance
Time
E
-~
ro
Valve face down (Intake)
- -0.4
t = +0.1
t = -0.5
j ;-~w
..c
Jµ!~
u
w 1------------+-------<r-------<r------+-----+---------<
E
t = +0.1
~ Valve face down (Exh.) t =-0.5
- -0.4 1
~ oox
Outer dia. of camshaft -0.060

datum part
-0.18
-0.090
y = 0.08
rp 70 1--------l -o .16 y = 0.25
Inner dia. of camshaft +0.070 +0.16
datum part bearing +0.020
Thrust clearance of x = 0.10 x = 0.45

camshaft datum part -0.35 016876-00X
~ Outer dia. of camshaft -0.060

-0.18
~
~ intermediate part -0.090
E >-----------~ rp 70 z = 0.08 z = 0.25
ro I-------< -o .16
O Inner dia. of camshaft +0.070 +0.16
intermediate part +0.020 016377-00X
~]
Cam height of intake 59.9 ±0.05 h = 59.4
Cam height of exhaust 60.0 ±0.05 h = 59.5

016378-00X
Outer dia. of lub. oil pump -0.020

shaft
-0.12
-0.033 a= 0.040 ::::0-
rp 30 -0.074 a=0.15
Inner dia. of lub. oil pump +0.041
o.. shaft bush +0.020
E t------------+-------1r-------<1-------+-----+---------i
+0.10
c.J: ~ vva
..d - (
~ Clearance between
b = 0.20 ~~---_L~-:ie
'6 pump case & gear outer -0.28 b = 0.5
,..., ..... _._,
periphery ~ --.. ~
~ 1-------------+-------<f--------<l-------+-----+---------i
::::i
_J +0.030 il--------1
Width of pump case -i~.
0 c = 0.060 ~
70 1--_-0-.0-6-0----l -o. 120 c = 0.15 016879-00X
=
Width of pump gear
-0.090
o._
E I
::::i L....., ' ,.----!
o._
w g = 0.3
I
~ Clearance of blade I~
-0.9 v--~c-g
,~'-
Ol
c
L
0
0 =ll_I __l_ j LL __JL _ ~
016880-00X
0
~
..__
(Timing f=0.15
~
Ol
Gear backlash gear)
-0.25 f = 0.4
c M = 4.5
0 016881-00X
"iii
m t------------+-------<f--------<1-------+-----+-----+--------;
·E Outer dia. of cam driving -0.030
-0.17
~ intermediate gear shaft -0.060 0.030
ro >-----------~ r/)60 -0.090 0.2
i= Inner dia. of the above's +0.030 +0.14
bush 0
275
9. Service Standard
276
10. Tightening Torque for Major Bolts and Nuts

10.1 Tightening Torque for Major Bolts and Nuts
Screw Dia. Face-to-Face Tightening Torque

No. Name of Bolt or Nut x Width of Bolt Remarks
Pitch or Nut (mm) N·m (kgf · m)
1 Cylinder head clamping Item 27 Method of clamping

M21 x 1.5 - - refer to page 10-3
2 Main bearing tightening bolt 30 Method of clamping

M24 x 2 refer to page 10-4
3 Side bolt (main bearing cap) 22 196+ 2 8 (20+5) Method of clamping

M16 x 2 refer to page 10-5
4 Connecting rod bolt tightening nut 19 Method of clamping

M14 x 1.25 137 ± 5 (14 ± 0.5) refer to page 10-2
5 Flywheel clamping bolt M20 x 1.5 24 481 ± 15 (49±1.5)
6 Cam shaft gear tightening bolt M20 x 1.5 30 294 ± 20 (30 ± 2.0)
7 Idle gear clamping bolt M18 x 1.5 27 196 ± 20 (20 ± 2.0)
8 Idle gear support clamping bolt M14 x 1.5 19 118 ± 10 (12±1.0)
9 Rocker arm pipe fitting bolt M12 x 1.75 17 44 ± 5 (4.5 ± 0.5)
10 Rocker arm shaft tightening bolt (A) M12 x 1.75 17 64- 84 (6.5 - 8.5)
11 Rocker arm shaft tightening bolt (B) MS x 1.25 12 23 ± 2 (2.3 ± 0.2)
12 Piston cooling nozzle bolt M16 x 1.5 22 49 - 59 (5-6)
13 Fuel injection valve holder nut M14 x 1.5 22 12r1g (13+6)
14 Nozzle set bolt M14 x 1.5 - 108 ± 5 (11 ± 0.5)
15 Nozzle set nut M28 x 1.5 24 120 ± 10 (12.2±1.0)
16 Fuel injection nozzle sleeve M22 x 1.5 - 15r1g (16+6)
17 Lub. oil pump driving gear clamping nut M24 x 2 36 167 ± 10 (17±1.0)
18 Lub. oil pump set bolt M10 x 1.5 14 44 ± 5 (4.5 ± 0.5)
Fuel injection pump driving gear
19 M27 x 2 41 325 ± 25 (32.5±2.5)
clamping nut
Fuel injection pump driving coupling 9g+1g
20 clamping nut M12 x 1.25 17 (1 o+6l
21 Fuel injection pump camshaft tightening nut M27 x 2 41 343 ± 25 (35 ± 2.5)
22 Viscous damper clamping bolt M20 x 1.5 22 245 (25)
23 Fuel injection pipe nut (pump side) M18 x 1.5 27 60 ± 10 (6 ± 1)
24 Fuel injection pipe nut M25 x 2 35 70 ± 10 (7 ± 1)

(Cylinder head side)
25 Fuel injection pipe joint M16 x 1.5 32 80 ± 10 (8 ± 1)
26 Turbocharger M12 x 1.75 19 74 ± 10 (7.5 ± 1)
27 Fresh water pump impeller M18 x 1.5 - 93 ± 10 (9.5 ± 1)
28 Fresh water pump driving M20 x 1.5 - 137 ± 10 (14 ± 1)
29 Sea water pump driving M27 x 2 - 245 ± 10 (25 ± 1)
30 Fuel injection pump tightening bolt M12 x 1.75 17 75 ± 5 (7.5 ± 0.5)
31 Rocker arm cover nots M10 x 1.5 14 6.9 ~ 9.8 (0.7~1.0)
Note:
1. Be sure to apply lube oil to the contact surface
and thread of bolts and nuts before tightening
them.
2. Do not use molybdenum disulfide lube oil.
277
10.2 Method of Tightening Connecting Rod Nuts

Tightening torques
N·m (kgf · m)
1st temporary 50±5 (5 ± 0.5)
2nd temporary 70 ± 5 (7 ± 0.5)
third time 137 ± 5 (14 ± 0.5)
Apply protective/PROTECT grease or PROTECT oil

to the threaded part of a connecting rod tightening
nut and its seating face.
10.3 Method of clamping cylinder head bolts

(Tighten the respective bolts in five steps.)
(a) Apply PROTECT oil to the threaded part of cylin-
der head bolts.
(b) When clamping the cylinder head tighten the
respective bolts in five steps as per the following Drawing 10-1.
table 10-1 according to the following clamping Order of clamping the cylinder head bolts.
sequence given in Drawing 10-1.
Table 10-1 Tightening torques of cylinder head bolt.

Tightening torques
No. Steps
N•m (kgf•m)
1st
(1) 98 (10)
step
2nd
~
(2) 471 (48)
step
3rd Suction port
(3) Loosen all bolts completely.
step 012714-00E
4th
(4) 98 (10)
step
5th Tighten bolts by further 150° from
(5)
step step 4 position. (angle gauge use)
278
(c) Angle Tightening Box

Prepare 27 mm box equipped with an indicator
needle for angle tightening.
*Install the needle so that it comes on the top of

the bolt ridge.
washer thickness.
*Sketch of the Box : *Install the needle so

Bolts are hexagonal or dodecagonal bolts. In that it comes on the
top of the bolt ridge.
either case, install the needle so that it comes on
the top of the bolt ridge.
017762-00E
(d) How to Use the Angle Gauge and Angle Tighten-

ing Box
1) After tightening the bolt with snug torque
(1 O kgf•m), select an optional head bolt ridge.
(Turn the bolt by 150° and mark the position with
a marker at a place easy to see.)
2) Align the selected bolt ridge with the box needle
and install.
3) Place the angle gauge on the head top face.
4) In consideration of the play of the box, with
pressing the angle gauge on the face to the
tightening direction, align the angle gauge "O"
position to the box needle.
5) Mark a line on the head top face with a pencil at
150° position of the angle gauge.
(It is recommended to mark the area of 150°
position with a white marker in advance.)
*In order to minimize the error of the tightening
angle, the marked line should be as fine as
possible.
6) Remove the angle gauge.
7) Tighten the 6 bolts uniformly, Two and half bolt ridges distances marks 150 degrees.
(with approx. 25 kgf•m torque.) Accordingly, ii is recommended to mark the area between
the 2nd and 3nd ridges clockwise (lightening direction)
8) Check that the selected bolt ridge top aligns with from th'"'"'"' ridg\h a whit' mackec lo ad'"""
the box needle position and tighten the bolt until
the needle comes to align with the marked line on
the head top face. (It is recommended to set the
torque wrench at about 45 kgf•m in advance.)
Example of Head Bolt Marking

OOE
279
10.4 Method of Tightening Main Bearing

tightening bolt (Angular tightening)
(a) Apply protective/PROTECT grease or PRO-
TECT oil to threaded part of a main bearing tight-
ening bolt and its seating face.
(b) When clamping the main bearing tighten the
respective bolts in three steps as per the follow-
ing table 10-2 according to the following clamp-
ing sequence given in Drawing 10-2.
Table 10-2
Steps Tighten the bolt Tightening torque and angle
Surface clamping torque of 49 ± 5 N·m
1st step Operating and Non-operating side
(5 ± 0.5 kgf · m)
Tighten the side bolts the following table 10-3 according.
2nd step Operating side bolt angle 30 deg.
3rd step Non-operating side bolt angle 50 deg.
4th step Operating side bolt angle 68 deg. ± 2 deg (final)
5th step Non-operating side bolt angle 68 deg. ± 2 deg (final)
Drawing 10-2.
Main bearing lightening bolt

1<U49N·m ~
,.,,,- ' Side bolt
(Non-operating side)
Odeg (Non-operation side)
3rd/50deg
Main bearing cap

5th (final)
68deg±2deg
016512 -OOE
280
10.5 Method of clamping side bolts

(after the Clamp them with surface
clamping of main bearing bolt of final tight)
(a) Apply PROTECT grease or PROTECT oil to the
threaded part and seat of side bolts.
Table 10-3
Tightening torque
Steps Tighten the bolt
N•m (kgf•m)
1st
Operating side bolt 68.5 (7)
step
2nd
Non-operating side bolt 147 (15)
step
3rd
Operating side bolt 195+200 (20+ 2 .g)
step
4th
Non-operating side bolt 195+200 (20+ 2 .g)
step
· It assembles it so that mark (AY) of coming to the

surface of become a front side.
· Please assemble the bolt to the same location.
· Please give it as the same to above-mentioned
(10.4) and (10.5) procedure when you use a
factory shipment and the same bolt. However,
please tighten even the combination mark
alternately about the main guide bearing
tightening bolt based on the combination mark.
Please shift in well-set selfish with the
combination mark after tightening is completed,
and make it to 0.5 mm or less.
281
10.6 Standard tightening torque

Thread diameter mm M6 M8 M10 M12 M14 M16
1.5 1.5
pitch mm 1.0 1.25 1.5 1.75
(2.0) (2.0)
Width across flat mm 10 12 14 17 19 24
N•m 10 ± 1 23 ± 2 45 ± 5 75 ± 5 120 ± 10 200 ± 15
Tightening torque
(kgf•m) (1.0±0.1) (2.3 ± 0.2) (4.5 ± 0.5) (7.5 ± 0.5) (12 ± 1.0) (20 ± 1.5)
Note:
Use 80% of the torque for bolts made of aluminum
or aluminum alloys.
Do not apply oil on bolts, nuts or washers.
10.7 Torque for pipe joint bolts

Thread diameter mm M8 M12 M14 M16 M18 M20 M22
pitch mm 1.25 1.25 1.5 1.5 1.5 1.5 1.5
Width across flat mm 14 17 19 22 24 27 30
Carbon 12-17 25-35 40-50 50-60 70-80 90-100 150-200
Tightening steel N•m (1.2-1. 7) (2.5-3.6) (4.1-5.1) (5.1-6.1) (7.1-8.2) (9.2-10.2) (15.2-20.4)
torque Free-cutting (kgf•m) 8-12 18-25 27-34 34-41 48-55 62-69 98-137
brass (0.8-1.2) (1.8-2.5) (2.8-3.5) (3.5-4.2) (4.9-5.6) (6.3-7.0) (10.0-14.0)
Note:
Do not apply oil on bolts.
282
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Domestic Office
YANMAR CO.JI.TD.
•Yanmar (Head office)
1-32, Chayamachi, Kita-ku, Osaka 530-8311, Japan
•Yanmar Marine System CO., LTD.

3-1, 5-Chome, Tsukaguchi-Honmachi, Amagasaki,
Hyogo 661-0001, Japan
Country Code: 81
Phone: 06-6428-0426 Fax: 06-6428-0485
•Marine Operations Dept.
• Production Dept.
Tsukaguchi Plant
Market Service Group
3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki,
Hyogo, Japan 661-0001
Country Code: 81
Phone: 6-6428-3137 Fax: 6-6421-5549
Overseas Office
[Al Yanmar Eurpope B.V. (YEU)
Brugplein 11, 1332 BS Al mere-de Vaart, Netherlands
Country Code: 31
Phone: 036-5493200 Fax: 036-5493209
lliJ Yanmar Asia (Singapore) Corp.Pte.Ltd. (YASC)
4 Tuas Lane, Singapore 638613
Country Code: 65
Phone: 6595-4200 Fax: 6862-5189
[9 Yanmar America Corp. (YA)
(Marine Business Unit)
101 International Parkway
Adairsville, GA30103, U.S.A.
Country Code: 1
Phone: 770-877-9894 Fax: 770-877-9009
User's record
Date of purchase
Place of purchase (Name of dealer)

Marine Propulsion Engine
&AYM-GTE
MODEL &AYM-ETE
&AYM-STE
SERVICE MANUAL
YANMAR CO.,LTD.
1st Edition : June 2004
2nd Revision : January 2007
3rd Revision : April 2008
4th Revision : June 2008
5th Revision : February 2009
Issued by : Marine Operations Dept.

Edited by: Yanmar Technical Service Co., Ltd.
YANMAA
OB6AY-G00201
PRINTED IN JAPAN
YANMAR CD.1LTD.

Service Manual 6aym-Ete-Ste PDF

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FOREWORD

Prepare before you work !

Marine Propulsion Engine

SERVICE MANUAL Models : 6AYM-GTE Code No. OB6AY-G00201

2. Disassembly and reassembly ........................................................................................ 17

3. Preparation Before Checking and Servicing .................................................................. 85

4. Test running ................................................................................................................. 239

5. Long storage ................................................................................................................ 241

7. Service standards ........................................................................................................ 263

9. Service Standard ......................................................................................................... 273

DANGER-indicates an imminent hazardous situation which, if

WARNING-indicates a potentially hazardous situation which, if

CAUTION-indicates a potentially hazardous situation which, if

·Safe I Adequate Work Area

• Clean, orderly arranged place

• Bright, Safely Illuminated Area

·Safe Work Clothing

·Appropriate Lifting I Holding

(4) GENUINE PARTS and MATERIALS

(7) WASTE MANAGEMENT

0. severe personal injury.

• Preventing burns from scalding

• Safety Label Check

•Do not step on

•Never remove the cap while the

. 'Tfl~"t-"'ill:*1.fJt;t. •) a<-t. • lJi:!lliflJ.,f;:J::LJ~~O)il!l:tl.tJ(i!i>LJ;f;"t,

Fuel injection pump

Fuel feed pump

Exhaust manifold Turbocharger

Engine oil cooler

1.2 Cross Sectional View

Valve Mechanism Supercharging

Fuel Injection System

Lubricating oil System

1.3 Engine specifications

6AYM-GTE 6AYM-ETE 6AYM-STE

m2 Fin & blads, Fin & blads, Fin & blads,

'""' "'" "'"'

View from Upper

"' "''- "'

--- -1.. N0.1 CY~ - - - -1 ~ ~

View from Upper 6AYM-STE:S!andard oilpan

Flywheel Housing & Flywheel

"'"' "' "'"' --1. N0.1CY-;:---1.

6AYM-STE:Shallow oilpan (j)

1.5 Piping Diagram

1 lemp. control valve

(2) Lubricating Oil System

Lube Oil Filter

Lube Oil Cooler ---+---1

(3) Fuel oil, Exhaust gas & Air System

* l.D.5 Rubber Hose Cll

* l.D.15 Rubber Hose

*1.0.15 Rubber Hose Q)

(Hull Fitting) C>

Model: 6AYM-ETE Model: 6AYM-STE

1.6 Fuel oil, lubricating oil and cooling water

Quantity Criteria of Fuel Oil

In time of fuel supply

1.6.2 Lubricating oil

Marine Propul- 40 0.893 >240 <- 7.5 140-155 14-15.5 96-110

(1) Avoid blended use of different brands.

(3) List of Lub. Oil Brands