YANMAR-6N18(A)L-V Manual (ЧН 18 28)+

W'UMAB
D',EsiELE Utr',NE
M a r i n eA u x i l i a r yE n g i n e
6Nf8(AlL-\/sE'rrEs
,/
t/
//''-
OPERATION
]YIANUAL
Be sureto readthis OperationManualfor you to use
this productsafelyandcorrectly.
Evenafter readingit, carefullykeep it, makingclearto
all personnelconcemedwhere it is kept so that the
operator,mechanicor supervisorwill havean accessto it
wheneverhe wantsto reador referto it.
\-
@YANMAI
2003.12.10R
Ea,.,LTD.
YArMAB
6]||8(A)L-lf
CONTENTS
Page
....0-1
PREFACE
. . . . . . . . . . . . . .0
. .-.1. .
1. Foreword
0-3
..............
2. Terms& SymbolMarks
on Safety
3. Precautions
3-1.BasicPrecautions
3-2.Precautions
on Operation
( 1 )P r i otro S t a r i nogf t h eE n g i n e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(2)During
a Run
(3)WhenStopping
theEngine
................
3-3.Precautions
on Maintenance
(1) Precautions
................
Priorto Maintenance
Servicing
(2) Precautions
Servicing
DuringMaintenance
(3) Precautions
Servicing
at Completion
of Maintenance
0-4
..................
.................0-4
.....0-7
................0-7
...................0-7
................0-8
....0-9
............0-8
........0-10
...........0-11
O-12
..................
4. Listof SafetyLabels
....0-13
for Engine
5. LiftingProcedures
EE S C R I P T I O. N
.........
1 . E N G T ND
1-1.EngineSpecification
& Attachments
1-2.Typesof Accessories
1-3.SectionalView
of theEngine...............
................
& Device
Anangement
1-4.EngineOutline
. . . . . . . . . . . . . . .1. .-.1. . .
...........1-1
......1-3
....14
......1-5
...,,...,...,,.2.1
OF MAJORPARTS
2. STRUCTURE
........
3 . T A B L EO F E N G I N E
S T A N D A RA
DD J U S T M E N T.S
. . . . . . . . . . . . .3. .-.1.
4. oPERATION
...............
4-1.OperationalPreparation
...........
4-1-1.Lubricating
Oilsystem
4 - 1 - 2F. u e l O i l s y s t e m
................;.
4 - 1 - 3C
. o o l i nW
g a t eS
r ystem
4-1-4.BoostAir System
4-1-5.Starting
Air System
4-1-6.Controland
Protective
Devices
4-2.Starting
procedures
1) Starting
operation
2) Conectiveactionsto be takenin startingfailure
3) Checksto be madeimmediately
afterstiarting
4 - 3 .R u n n i n g. . . . . . . . . . . . . .
'1)lnitialRunning-in
Operation
(Routine)
Running
2) Steady
4 - 4 .S t o p p i n.g. . . . . . . . . . . . . .
4-4-1.Stopping
in NormalRunning
4-4-2.Emergency
Stop....,.....
Stop..........
4-4-3.Disposal
Afteran Emergency
.................4-1
..............4'1
.................4'2
.........44
.................4'7
.......4-7
....4-8
....4-8
.............4-8
............4-8
....4-9
.....4'10
..............4-10
..............4-10
...............4-10
.............4-12
.......4-12
..............4-13
.....4'13
5 . FUELOIL,LUB.OIL& COOLINGWATER
5 - 1 .F u e l O i .l . . . . . . . . . . .
2002.12.25R
F-1
... 5.1
....................5-1
CONTENTS
YAX'',AF
5 - 1 - 1Q. u a n t i tCy r i t e r ioaf F u e l O i l. . . . . . . . . . . .
5-1-2.Quality
Criteria
of Blended
FuelOil
5-1-3.Properties
of FuelOilat the Enginelnlet
5-1-4.Howto FindouttheHeavyFuelOilHeating
Temperature
5-1-5.Howto FindouttheViscosity
of Blended
Oil ............
5-2.Lubricating
Oil
5 - 2 - 1C. h o o s i nt gh eL u b .O i l
5-2-2.Control
on Lub.Oil ............
3) Control
Criteria
4) OilChange
Criteria
5-2-3.Listof Lub.OilBrands
5-3.Cooling
Water(EngineJacketWater)
5-3-1.Criteria
on Cooling
FreshWater
5-3-2.Selection
of andControlon Corrosion
Inhibitor
6ilT8(A)L.Y
...............5-1
................5-2
.........5-2
..................5-5
.........5-6
....5-T
.................5-7
..........5-g
...............S-g
..........5-g
.................S-9
...5-10
...................5-10
..............S-10
6 . M A I N T E N A N CCEH E C K I N G
......6-1
6-1.Precautions
in Maintenance
Checking
.......................6-1
6-2.Tableof Periodical
Checking
..................6-2
1)Tableof Routine
Maintenance
Checking
...............6-2
2) Checking
Tablefor EngineUsingMarineDieselOit .............
......................6-3
3) Checking
Tablefor EngineUsingHeavyFuetOit(R.W.No.1at...)
............6-6
6-3.Routine
Maintenance
Checking
& Adjusting
Procedures
.............6-9
6-3-1.Measurement
of Running
Performance
..............
.............6-9
6-3-2.Measurement
of Max.Combustion
(Pmax)
Pressure
.....6-10
6-3-3.Regulation
of Fuellnjection
Votume(RackScale)
..........6-11
6-3-4.Adjustment
of FuelInjection
Timing
.............6-12
6-3-5.Checking
of FuelInjection
Valve& Adjustment
of lnjectionPressure...................6-13
6-3-6.Adjustment
of Suc./Exh.
ValveHeadCtearance
.............6-19
6-3-7.Adjustment
of Lub.OilPressure
...................6-19
6-3-8.Adjustment
of Lub.OilTemperature
..........
..6-20
6-3-9.Adjustment
of FuelOilPressure
...................6-22
6-3-10.Checking
of Cyl.JacketCoolingWaterThermostatic
Valves
..........6-23
6-3-1
1.Cleaning
of Lub.OilBypassstrainer
...........6-24
6-3-12.Cleaningof Lub.Oil Strainer
....6-27
6-3-13.
Cleaning
of FuelOilFilter
........6-29
6-3-14.
Cleaning
of Strainer/Filter
Element...............
...............6-31
6-3-15.
Washing
of Turbocharger
Blower
..............6-31
6-3-16.
Maintenance
of Pressure
Gauge
...............6-32
6-3-17.
Measurement
of Crankshaft
Deflection
............
............6-34
6-3-18.Adjustment
of FuelInjectionPumpPinionLubricating
Volume
( f o rE n g i n e
U s i n gH . F . O) . . . . . . . .
...........6-37
6-3-19.
Maintenance
of FuetOitSealPot(forEngineUsingH.F.O.)..............................6-37
6-3-20.Check& Replacement
of Anticorrosive
Zinc .........
........6-3g
7. MAINTENANCE
SERVICING
.,...7-1
7-0.Precautions
in Maintenance
Servicing
.....7-1
1) Precautions
on Safety
......7-1
2) Precautions
in Dismantling,
Servicing
& Reassembly
............
....................7-3
3) Precautions
at Completion
of Maintenance
Servicing
.............74
4) Handling
Procedures
for TurningGearDevice
......7-4
5) Handling
Procedures
for hydrautic
Jack..........
......7-s
7-1.Cylinder
Head& ltsAccessories
.........
..7-10
7-1-1.Cylinder
Head
.........7-10
7-1-2.Suction& Exhaust
Valves
..........7-15
7-1-3.Suc./Exh.
ValveSeat .........
........7-16
7-14.Suc./Exh.
ValveGuide
...............7-1g
7-1-5.Suc./Exh.
ValveBridge& ttsGuide
..............7-19
7-1-6.ValveRotator
...........7-19
2002.12.25R
F-2
CONTENTS
YA}//'',AR 61II8(A)L-Y
7-2.Piston& Connecting
Rod
....7-20
7-2-1.Piston& PistonPin ...........
........7-20
7 - 2 - 2 . C o n n e c tR
i nogd. . . . . . . . . . .
..............7-Zg
7-2-3.CrankPinMetal
......7-24
7-24. Connecting
RodBolt
.................,7-24
7-3.Cylinder
Block& Cylinder
Liner.........
...7-26
7-3-1.Cylinder
Block
.........7-26
7-3-2.Cylinder
Liner
.........7-26
7-4.MainBearing
& Crankshaft
..............
.....7-29
7-4-1.MainBearing
..........7-29
7-4-2.Crankshaft
.........
.....7-36
7-5.TimingGear,Camshaft
& Suc./Exh.
SwingArm ..........
..............7-37
7 - 5 - 1T. i m i n g
Gear
.............7-37
7-5-2.Camshaft
...........
......7-39
7-5-3.Suc./Exh.
SwingArm ..........
.......7-40
7-6.FuelInjection
Pump& PumpDriver
.......7-41
7 - 6 - 1F. u e l n j e c t i oPnu m p. . . . . . . .
...........7-41
7 - 6 - 2 . F u Ienl j e c t i oPnu m pD r i v e .r . . . . . . . . . . . . . .
............7-44
7-7.Governor
& Governor
Gear
...................7-45
7-7-1.Governor..........
(Seethe separate-vol.
manualon hydraulicgovernor.)
7-7-2.Governor
Gear
........7-45
7-7-3.Coupling
Adjustment
of Governor
Gear .........
.................7-47
7-8.Lub.OilPump,Lub.OilPressure
Regulating
Vatve& Lub.OitCooter
..........7-49
7 - 8 - 1L. u b O
. ilPump
..........7-48
7-8-2.Lub
O.i l C o o l e r
.........7-50
7-9.Cooling
WaterPump
...........7-52
7 - 1 0F
. u e l O iFl e e dP u m p
..........7-53
7-11.Suction/Exhaust
System
...7-54
7-11-1.
BoostAirCooler
.....7-54
7 - 1 1 - 2E. x h a u sMt a n i f o l d
....................7-56
7-11-3.
Turbocharger
..............
(Seethe separate-vol.
manualon turbocharger.)
7 - 1 2A
. i M o t o r. . . . . . . .
..................7-57
7-13.Electromagnetic
Pickup
.....7-Sg
7-14.Stopping
AirPiston
..........7-59
8. PRINCIPAL
DIMENSIONS
& PARTMASSFOR DESASSEMBLY
& SERVICING..............8-1
9. TABLEOF TIGHTENING
TORQUESOF MAJORBOLTS
10. CLEARANCES
& WEARLIMITSOF MAJORPARTS
1 1 . T R O U B L E S H O O T I&
NG
COUNTERMEASURES
PartsList& Figure
..................
1O-1
,.....11-1
. Appended
ATTACHED
ServiceManualfor the EngineAir Starters
YanmarServiceNetworks
2002.12.25R
...............9-1
F-3
PREFACE(Foreword)
YAnrrAn 6Illg(A)L-Y
PREFACE
Thankyou for purchasinga YANMARDieselEngine.
1. Foreword
This OperationManualhas beenpreparedfor yoursafeandeffectiveuse of the engine.Readthorough
regardingthe operaand precautions
the safetyprecautions
this OperationManualandfully understand
beforeusingthisengine.
tion,checkingandservicing
placeaccessible
for the operatorto referto it at
(1) Keepthis OperationManualat a clearlyidentified
anytime.
Manualmaypartlydisagreewithenginesof somespeci(2) The textand illustrations
of thisOperation
fications.
and FinalDocumentwe have submittedyou
For such engines,referto the EngineSpecification
separately.
Also note that this OperationManualis subjectto changefor improvingthe qualityand performancesof engineor for safety.
manualsseparatelyattached.
operation
(3) For the followingdevices,referto thecorresponding
Turbocharger
Hydraulicgovernor
of specialspecifications
Otherattachments
Systemof Units).
(4) In this manual,the numerical
valuesare basedon the Sl system(lnternational
given
in brackets.
are
also
unit
system
conventional
on
the
numericalvalues
based
However,the
your nearest
part
parts.
to
parts
a
Order
or specified
(5) Replacementpartsshouldbe our genuine
salesor serviceagentof Yanmar'sparts.Whenorderinga part,clearlyspecifythe PartName(part
SerialNo.of the engine.
and PartNo.,andthe Modelandmanufacture's
description)
Manual,or if you haveanyquestionsand advice,
(6) lf you shouldhavelostor damagedthisOperation
"YANpleasecontactus or yournearestsalesor serviceagent(shownin the servicenetworklist
to thismanual).
MARWorldwideService"appended
(7) lf you transferthis engine,alsotransferthis OperationManual,FinalDocumentand Recordsof
ShopTrialwiththe engineto the nextowner.
(8) lf you usethis enginefor an application
or underserviceconditionotherthanthosespecified,or if
Manual,an accidentor a failuremaybe caused.
you handleit not in accordance
withthisOperation
your
agent
beforechanginganytechnicaldataof the
or
service
nearestsales
Pleasecontactus or
Nevermodifythe enginewithoutconsulttheengineafierit hasbeendelivered.
engineor modifying
ing us.
0-l (Volume:14pages)
safe useof your engine)
PREFACEFoT
YATITUAB 6]II8(A)L-Y
For safe use of your engine.
WARNINGsand CAUTIONsdescribedin this Manual.
Be sureto abideby A -markedDANGERs,
particularly
importantparts of instructions.
are
they
As far as safetyis concerned,
Manualand
in thisOperation
showsthesafetymarksusedfor cautionindications
o Thefollowing
product
meaning.
their
and
explains
to this
safetylabelsattached
l\onruoenIt indicates that a danger of
possible death or serious injury is very great
when the proper precautions is not followed.
WARNING It indicatesthat there is a danger of resulting in death or serious
is notfollowed.
injury whentheproperprecautions
CAUTION It indicatesthat there is the possibilityof resultingin injuryor serious
damage to the engine when an advice on safety handlingor the
proper precautions is not followed.
r Wherethesafetylabelsare postedis shownin pageO-12.
for safe
marf in this OperationManualare especiallyimportant
with the A
o The cautionsprefixed
performances
or
of
handingof this product.A failureto observethis cautionmay incura deterioration
of thisproduct.Therefore,be sureto observethe items.
trouble/accident
0-2
& SymbolMarks)
PREFAC(Terms
YANM,AN 6]IT8(AL-Y
2. Term& SymbolMarks
1) The major terms used in this Operation Manual are defined as follows:
Front part of engine: Part oppositeto the flywheel end
Rearpartof engine: Part on the flywheelend
Operatingside:
Left side as viewed form the flywheelend (fuel injectionpump side)
Non-operating
side: On the rightas viewedfrom the flywheelend (exhaustpipe side)
CWrotation:
CCWrotation:
No:
Cylinder
Clockwise
rotationas viewedfromthe flywheelend
Counterclockwise
rotationas viewedfromthe flywheelend
Assigned
in the ascending
orderfromthe cylindernearestto theflywheel
end
Non-operatingSide
F
Fuel InjectionPump
OperatingSide
2) The following symbol marks are used in the safety labels shown in this Operation Manual and
posted on the engine.
(1)Cautionmarksand signalwords
l\onrucen It indicates that a danger of possible death or serious injury is very great
when the proper precautions is not followed.
l\wnnulruc It indicatesthat there is a danger of
resultingin death or serious
injury whenthe properprecautions
is not followed.
l\clunont
It indicatesthat there is the possibilityof resultingin injuryor serious
damageto the engine when an advice on safety handling or the
proper precautions is not followed.
l_\
lt indicates a handing caution which, if not observed, may incur a deterioration of performance or a trouble/accident of this product.
(2)Symbolmarks
(a)Caution
marks
(b)Others
ru
Caution
on explosion
Cautionon
rotatingpart
Cautionon fire
Cautionon
high temperature
Cautionon
hazardousnoise
0-3
. Refer to anotherpage,
sectionor chapterof this
OperationManualor other
document.
/ BasicPrecautions)
PREFAC(SafetyPrecautions
YAttroAB 6lll8(A)L-v
WARNINGAn accident may occur if the safetyrules are not followed.
3. Precautionson Safety
3-1.Basic Precautions
Strict Observanceof the SafetyRules
. When runningthe engineor servicingit for its maintenance,
observethe safetyrules,precautionson
safetyandworkprocedures.
. Whencarryingout a joint work,workaccordingto the predeterminedsigns.
Way of pre-workarrangement
(1) Accordingto kindof work required
(2) Everyoneto contemplate
and consider
(3) Everyoneto understand
well
( ) Fixthe mostsuitableway to work
. Wear the proper protectivegarment. Don't wear oil
smudgedwork clothesbecausethey are proneto catch
fire.
. Wear protectorssuch as helmet,safety goggles,safety
shoes, protectivemask, protectiveglove, life-line,etc.,
dependingon the natureof workrequired.
When workingon the engine,use the specifiedengine
tools.Usejigs or toolssuitablefor particularworkbecause
useof a wrongtoolcausesan injury.
%
f
sarewFrRsr
(1) Safety has priorityover
all the works.
(2) Safety is more important than any other
duties.
(3) lt is needless to say
"Safety First"
that
means that safety has
priority over working
efficiency.
(4) Safetyis the foundation
for working efficiency.
Safety is never contradictory to working efficiency.
. While at work, do not jump on and off the engine.
. For working,installa work bench fitted to the size of your engineto securea good footing.Don't work
in a dangerousposition.
0-4
PREFAC(Safety Precautions/ Basic Precautions)
YA)rruAn 6Ill8(A)L-V
I\CAUTION
Yanmarcannotbe responsible
for an accior serviceagentin advance.
fromunauin injuryor deathor an enginetroubleresulted
dentresulting
thorizedmodification.
. Yourengineand its safetydeviceshave been sealedfor the sake of
safety.Don'tbreakor tamperwitha sealindiscreetly.
. lf a sealingis missing,takea properstepof promptlycontacting
us or
your nearestsalesor serviceagentfor ensuringthe properinitialsetting.
A
ro*osoFF!
I \ W A R N IN GObserve the precautions for ensuring safety.
Check of Safety Devices
. Checkthe all the safetydevicesof your enginehave been set normally.
. lf a safetydeviceis wronglyused,it leadsto a seriousaccidentresultingin injuryor death.
. Promptlyrepaira cover a rotating part, a heat shieldingcover for exhaust pipe, a protectivecoverof
the heatingregionor the like,if found damaged.
. Neverrun the enginewhilethe coverof a rotatingpartis removed.Otherwise
dur-
mwAr-,rc-l ingoperation,
part,resultyourhand,bodyor clothingmaybe caughtin therotating
ingin yourinjury.
f---r'--..l
|
, { . J l
t.tYl
ItVtl
l\caunoru
Spot
or High-pressure
Be Cautiousof Handlingof a High-temperature
- Take care not to get burnt. . Duringrunningand immediatelyafterthe enginehas stopped,the wholeengineis heated.Takecare
not to get burnt.
1-a--_-_::-t . When changing cooling water, lubricatingoil or filter immediatelyafter the enginehas
qfry
stopped,proceedto work only after the temperaturehas lowered.
. Do not touch a high-temperatureregion such as the exhaustpipe or pressureindicator
cock of enginewith bare hands.
. Do not touch the heater and heated sectionsof fuel oil systemwith bare hands.
. Since the pressure indicatorbecomes hot, be sure to wear gloves when taking reading. lf you uncap the radiatoror fresh water tank, vapor or hot water may blow up, causing
you to get burnt.
. Stop the engineand wait untilthe temperaturehas dropped.Then, wrap the cap with
cloth and slowly loosen it to releasethe internalpressure.After that, removethe cap.
0-5
PREFAC(SafetyPrecautions/ BasicPrecautions)
YANM,AB 6NI8(A)L'Y
f\oarucen
Be Cautious of Handling of Fuel & LubricatingOil.
Z6-o_,**-l
\-
. lf fire is broughtcloseto fuel andior lubricatingoil, there is the possibilityof catching
Ilfe.
(Particularlythe fuel is highly flammable and dangerous.)
. Fire shouldbe strictlyprohibitedin the engineinstalledplace(engineroom).
. Check for leak of fuel oil and lubricatingoil. lf you find a defectivepoint,repairit and
wipe out leakedfuel or lubricatingoil.
. Store the fuel oil and lubricatingoil at the specifiedplace and do not allow persons
otherthan thoseconcernedto handlethem.
. Unnecessaryflammablesin the engineinstalledplace(engineroom) may cause fire.
Therefore,store theseflammablesin anotherspecifiedplace.
. If Exhaustgas is leading,promptlyrepair such a leaking Ventilatewell to preventgas intoxication.
pointat the exhaustpipe.
. Ventilatewell the indoor engine installedplace (and/orthe
engineroom.)
- )- r^\
. Take care that the room does not fall short of the air (oxylr
gen) becausethe turbochargertakes in a great volumeof
air.
i?--)^Fl*
.+ --+Tf
<,4..)r-l- '^\
'drA
(l ( )<d
f-A;"'n*-l
M
. Whilechargingthe battery,
thereis dangerof
catchingfire becausehydrogengas is gen. Inhaling
exhaustgas is verydangerous.
erated.
. Whenworkingindoors,sufficiently
ventilate
the room.
FIHE
it.
. Fix a safekeepingplace for a first-aidkit, and installit there.
. Fix the actionsto be taken when fire or an accidenthas occurred.
. Establisha means of reportingto emergencymedicalinstitutionsuch
as an emergency hospital,and have its telephonenumber written
down.
EXTINGUISHER
-
-e-
lt
lt
r t
r
r
-
-
FIRST-AIDKIT
0-6
on Operation)
PREFACE(SafetyPrecautions/Precautions
vAnnAB
61ll81a)L-yr
WARNINGObservethe precautionsfor ensuringsafety.
3-2.Precautionson Operation
(1)Priorto Startingof the Engine
Startthe EngineafrerSignaling
. Check if no one is aroundthe engine.
. lf someoneis foundnearthe engine,give him a signthatthe enginewill be
started.Only then start it.
. Check the holdingcapacitiesof fuel, oil, air, etc.
. Be sure to detach the tuming device once the engine is started,and keep
f
sorewFrRsr
it at it'sfixedhousingspot.
. Turnon the powersupplyof the engineprotection
up theengine.
devicebeforestiarting
. Afterthe enginehas beenstoppedfor a longtimeor afterthe enginehas beenserviced,be sure to
startup theengineat theengineside.
. lf the rotationalspeedrisesextremelyrapidlyor if you findan usualsoundor fume,immediately
set
leverin the STOPpositionto stopthe engine.
the starUstop
GheckAfter the Enginels Started
. Checkif pressurevaluesof eachinstrumenVgauge
boardare normal.
. Checkif thereare no unusualsoundandabnormal
heatbuildup.
. Checkfor any leakagesof fuel,oil,air,etc.,andif a leakageis found,promptlyrepair.
. Exceptin caseof emergency,
applythe loadaftera warming-up.
(2)Duringa Run
. Keepwatchingthe pressureandtemperature
or checkfor unusualsoundandabnormalheatbuildup.
. Checkwhethertheenginefullyshowsits properperformances
and recordthecheckresults.(Referto
the Recordsof ShopTrial,thenrecordthe checkresultson the EngineLog.)
f-A* ""*l
Takecare not to be caught in a rotating part.
. Neverallowyourhands,.body
andclothingto makecontactor bringcloseto any rotating part.
Takecare not to get burnt.
mcArntolrl
tA*"""il]
2003.10.20R
. During running and immediatelyafter the engine has stopped,the whole engine is
heated. Therefore, take care not to get burnt.
. Take care not to allow your hands, body and clothingto make contactwith the turbocharger,exhaust manifold,exhaustpipe and/orengine as whole.
. lf any abnormalityis detected,immediatelystop the engine and repair it.
Takecare not to get hearing loss.
. Putan ear protection
duringrunning,becausecancausehearingloss.
in engine-room
0-7
Precautions
/ Precautions
on Operation)
PREFAC(Safety
,AXMAE
6NtB1a)L-yz
f\wnnrulrucAn accidentmay occur if the safety rules are not followed.
(3) When Stopping the Engine
.
.
.
.
Do not stopthe enginesimultaneously
with load shutoff.
Exceptin caseof emergency,keep runningthe enginewithoutload after load shutoff.
Keepthe enginereadyfor beingstartedup.
Promptlyrepairthe pointsthat have been troublingduringa run.
. Do not open the side cover of crankcasefor at least 10 minutesafter havingstopped
the engine.Otherwise,the entryof externalair may resultin explosion.
m"*"*1
M
M
l-A;.,fi]
Take care not to get burnt.
. lmmediatelyafterthe enginehas stopped,the whole engineis heated.Therefore,take
care not to get burnt.
Takecare not to allowyour hands,body and clothingto make contactwith the turbocharger,exhaustmanifold,exhaustpipe and engineas a whole.
. lf you attemptto drain oil while the engine is still hot, take care not to get burnt with
splashof oil.
. lf you disassemblethe coolingwater systemwhile the engine is still hot, vapor or hot
watermay blow out, causingyou to get burnt.
Waituntilthe enginebecomescool,then wrap the disassemblingpartwith clothor the
likeand slowlyloosenit.
0-B
Precautions
/ Precautions
on Maintenance)
PREFACqSafety
'AI,IUAR
6lllg{AL-V
O bservethe precautionsfor ensuringsafety.
l\wnnrurruc
3-3.Precautionson Maintenance
(1) PrecautionsPrior to MaintenanceServicing
lndication of Warnings in Checking and Servicing
. Whilecheckingand/ormaintenanceservicingthe engine,post a notice
on a warningindicatingboardfor dangerprevention.
. Strivefor safety,maintaininga close contact with the respectiveparties
concerned.
. Striveto preventa dangerfrom emerging,forbiddingotherthan the parties concernedto enter the engine installedplace (and/orthe engine
room),for instance.
A
KEEPour!
A
,* woRKrNG
lmmediately After an Engine Stop
m;-G*-.t
M
m*fi* I
ffi
. Do not open the side cover of crankcasefor at least 10 minutesafterhavingstopped
the engine.Otherwise,entry of externalair may resultin explosion.
Take care not to get burnt.
. lmmediatelyafterthe enginehas stopped,the whole engineis heated.Therefore,take
care not to get burnt.
Takecare not to allow your hands, body and clothing to make contactwith the turbocharger,exhaustmanifold,exhaustpipe and engineas a whole.
. lf you attemptto drain oil while the engine is still hot, take care not to get burntwith
splashof oil.
. lf you disassemblethe coolingwater systemwhile the engine is stillhot,vapor or hot
watermay blow out, causingyou to get burnt.
. Wait untilthe enginebecomescool,then wrap the disassemblingpartwith clothor the
like and slowlyloosenit.
Preparation Prior to Working
.
.
.
.
put it in good order.
Sincea workingareawill be stained/smudged,
Prepareenginejigs and tools readyto use.
Prepareoil,genuineparts,waste cloth,wire, etc. accordingto the natureof work to be done.
Securea work benchfittedto the heightof the engine.
\,
0-9
on Maintenance)
/ Precautions
PREFAC(SafetyPrecautions
tO"-O"
6X|8(A)L-Yz
l\WARNTNG An accident may occur if the safety rules are not followed.
(2) Precautions During MaintenanceServicing
Gheck in Course of Work
. For a jointwork strivefor elimination
of a possibledangerby keeping
alertto the surroundings.
. Tie suchan accessorydetachedin workto a stablepostor spotso that
it willnotfall down.
. Fora workat a height,puton the safetybeltor life-line.
. Accordingto the conditionof working,wearprotectors.
. Be carefulof oil stainedor smudgedprotective
glovebecauseworking
parts
injury
or a personal
glove
of
lead
to
a
damage
might
withsucha
your
apt
to
slip.
handsare
as
. Wipeoff or mopup spilledfuel or oil at oncebecause,
if leftalone,it is
it
a
sliP.
dangerous
as causes
. Preparea boxto accommodate
removedpartsin advanceso thattheywillnotbe lostnordamaged.
it in
. lf necessaryprovidesettingmarksbeforedisassembling
the engineso thatyoucan reassemble
sequence.
theproperreassembling
. Reassemble
the settingmarkedportionswithreferenceto the settingmarks.
. Tightenthe boltsand nutsto the specifiedtorqueor hydraulicpressure.
Useof the ProperTools
.
.
.
.
.
Use the specifiedenginetools to preventthe damage of the respectiveboltsand nuts of the engine.
When handlinga heavything,followthe slinger'sinstructions.
In advanceof usingexclusivetools,checkthe functionof thesetools.
Carefullycheck for any damagesto rubberhose and jointsof hydraulicjacks.
Use the specified lifting gear, hook, rope, etc.; and pay attentionto safety when handling a heavy
thing particularly.
%
n
B
Z,,R\
t\2.1
V
A
toots
Precautions in Use of Fire
rA;'{GER-I
. In such works with welder, electricaltools
and grinder,be carefulof sparking.
Since there is the possibilityof catching
fire, try not to leave combustiblessuch as
fuel, lubricatingoil and usedwasteclothin
a workingarea.
ttu
0-l 0
tl"^rnables
oootronflo
Precautions
/ Precautions
on Maintenance)
PREFACESafety
l\wenunc
yAmUAB
61118(A)L-yz
Observethe precautionsfor ensuringsafety.
l\onrucen
Precautionsin Gheckingthe ElectricalSystem
-a
-._::-t
I /I\ DANGER I
rr.i)-=j:::::j_J
. Shutoff the powersupplybeforestartingthework.Otherwise,
a fire mayoccuror you
mav receive elgctric shock.
. When checkingthe batterysystem,be sure to disconnectthe earth cable
(-) terminal.Othenruise,
the negativeterminalmay be short-circuitedby mistake,
resultingin fire.
. The strong acid batteryelectrolyteput on your skin or eyes will cause inflammation.lf
the battery electrolyteshould be put on your skin or eyes, immediatelyflush it with
fresh water,then consulta physician.
Precautionsfor Using Organic Solvent
. Since an organicsolventis highlyvolatile,liableto be gasifiedand absorbedby workerthroughhis
when handlingit.
breathingas it vaporized,pay closeattentionto ventilation
. Since a highly concentratedorganic solvent has the propertyof dissolvingfats and oils and is
absorbedby workerthroughhis skins,be carefulof handlingit.
. When workingwith such a solvent,be sure to wear rubbergloves.
A
*=or PRorEcroRs
(3) Precautions at Gompletion of Maintenance Servicing
Check of Work Finish
. Check if detached parts have been refitted at the specifiedspots in the total
number.
. Check if the damaged parts have been replacedwith the good ones.
. Returntools, liftinggear, hook, rope,etc. used to the formersafekeepingplace.
. Removefuel and oil from the engineinstalledplace(and/orthe engineroom).
. Keep the engine installedplace (and/orthe engineroom)in orderand tidy so
that it will not interferewith daily operation.
. Beforestartingthe engine, check variousparts to see if there is no abnormality.
Refer back lo 3-2. Precautions on Operation, (1) Prior to Starting of the
Engine.
. Proceedt a load run, and check that the performancedoes not differfrom that
existedpriorto the maintenanceservicing.
Refer back to 3-2. Precautionson Operation,(2) Duringa Run.
. As soon as a load run is completed,enter recordsof performanceas well as
the natureof maintenanceservicingin your EngineLog. (Keepingof records
and then reportingof work completion)
. Remove such as a standingsignboard,and contactthe respectivepartiesconcerned for reportingthe completionof work.
0-11
PREFACESafetyPrecautions/ List of Safety Labels)
6]|I8(A)L-V
YAM'AN
4. List of SafetyLabels
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PREFACqsafetyPrecautions/ LiftingProceduresEngine)
YA}'NAR
6I[T8(A)L'V
5. Lifting Proceduresfor Engine
WARNING
Fallingof the engineor generatingset duringits liftingor carriageis very dangerousif so happened.
ln time of a load liftingwork, observethe followingitems in order to preventan accident:
. Use the liftingwire rope,shackle,etc. that are suitablefor liftingweight.
. Choosethe wire rope lengthso that the engineor commonbed does not lean to one side duringlifting.
. Put a cushioningmatedalsuch as paddingbetweenthe wire rope and the engineor drivenmachine
(generator,for instance)whichthe wire rope comes into contactwith otherwise.
. Choosesuch a cushioningmaterialas will not be damagednot removedduringlifting,then attachit
not to allowits contactswith the engineor drivenmachineto be damaged.
. Do not enteran area belowthe liftingload.
Lifting sling attaching points
1) Common bed set
The "Hang up This Point"labelshave been
stuckon the commonbed.
2) Enginesingly
o Fit the (optionallyavailable)exclusive lifting
slings to cylinderhead clamping bolts of the
No. 2 and No. 5 cylinderscloseto the centerof
the engine.
o Haul up the cylinderheadsunderthe specified
hydraulicpressuretightenedstate.
o Keep the liftingangle of the wire rope within 60
degrees.
3) Driven machines(generator,pump, etc.)
o For the wire rope attachingpoints, refer to the
respectiveOperationManuals.
0-13
1.
Specification)
ENGINEDESCRIPTION(Engine
YAmuAa 6tr€l(AlL-V
1 . E N G I N ED E S C R I P T I O N
1-1.EngineSpecification(1121
Unit
Model
Type
6N181-DV I 6N181-UV I 6N181-SV I 6N1BL-EV
4-cycledieselengine
Vertical,water-cooled,
Directinjectiontype
Combustionchamber
No. of cylinders
o
Cylinderbore
mm
180
Stroke
mm
280
42.75
Totalcylinderdisplacement
16.5
Compressionratio
Rated speed of revolution
minj(rpm)
Directionof rotationof
crankshaft
720or 750
Counterclockwiseas viewedfrom the flywheelend (XL)
Operatingside
On the left as viewedfrom the flywheelend
Order of firing
1-4-2-6-3-5-1
e ri t)ha i rc o o l e r
E x h a u sgta st u r b i n seu p e r c h a r g( et ur r b o c h a r gw
Superchargingsystem
Dualfreshwaterline cooling.
Coolingsystem
Forcedlubrication
(systemoil also usedas turbochargerlub.oil)
(systemoil also usedas rockerarm lub.oil)
Lubricating
system
Lubricating
oilsumpsystem
in commonbed
Sump incorporated
Air motorstarting
Startingsystem
Dimensions
Overalllenoth
mm
2,696
Overallwidth
mm
1, 3 1 5
Overallheight
mm
1,935
kg
6,500
(mayvaryas depending
on specification)
Mass(of enginesingly)
Constitutionof Model Designation
J- No. of cylinders
I
f Engineseries
t
t
|
|
;- Cyl. bore (in cm)
i-]
of Cylinders)
IConfiguration
="1
EINL,'
lb_lH-t
WO"A":ZZOor 750min-1
_l
I
M'A': 900or 1000min-1
I
Marine auxiliary/Landuse J
I
I
I
@o@@@o
Flywheel
Degreeof superchargingJ
2003.4.17R
1-1 (Volume:6pages)
1.
(EngineSpecification)
ENGINEDESCRIPTION
!'A}/,TUAN6NT8(A)L'V
(212)
1-1.EngineSpecification
Unit
Model
6N18ALHV
6N18ALDV
6N18ALUV
6N 18AL.
SV
6N18ALEV
Vertical,water-cooled,4-cycle d iesel eng ine
Type
Direct injectiontype
Combustionchamber
No. of cylinders
Cylinderbore
mm
180
Stroke
mm
280
0
42.75
Totalcylinderdisplacement
ratio
Compression
16.5
Ratedsoeed of revolution
900or 1,000
min-1(rpm)
Directionof rotationof
crankshaft
Counterclockwiseas viewed from the flywheelend (XL)
On the left as viewed from the flywheelend
Operatingside
1-4-2-6-3-5-1
Order of firing
(turbocharger)
with
Exhaustgasturbinesupercharger
air cooler
Supercharging
system
Dual freshwater line coolino.
Coolingsystem
Forced lubrication
(systemoil also used as turbochargerlub.oil)
(systemoil also used as rockerarm lub.oil)
Lubricating
system
Sump incorporatedin common bed
Lubricating
oil sumpsystem
Startingsystem
Dimensions
Air motor stariing
Overalllength
mm
Overallwidth
mm
Overallheight
mm
'1,935
kg
6,500
(mayvaryas depending
on specification)
Mass (of enginesingly)
2,696
'1,315
Constitution
of ModelDesignation
No. of cylinders
Engineseries
I
f
[Configurationof Cylinders)
5-
I
I
J-
cyl.bore(incm)
EEtrEE-tr
wlo-'n.
z-zo
orF.in-iT
@@@@@o
Flywheel
l-
W/'A":900or 1000min-1
|
Marineauxiliary/Landuse J
|
I
Degree of stiperchargingJ
2003.4.17R
1-2
(Typesof Accesories
& Attachments) vAn''Aa
1. ENGINEDESCRIPTION
6;518(A)L'yz
1-2.Typesof Accessories& Attachments
Accessory/Attachment
Supercharger
Boostair cooler
Governor
pump
Fuelinjection
Fuelvalve
M.D.O.feedpump
Fueloilfilter
Lub.oilpump
Lub.oilcooler
Lub.oilstrainer
Lub.oilby-passstrainer
Lub.oiltank
Coolingwaterpump
Lub.oilprimingpump
Air motor
Remarks
Type
exhaustgas turbine
Air-cooled
Platefinnedmultitubular
Hydraulic
Bosch
perforated
Non-cooled
For marinedieseloil
Gear
Heat-insulating,
manualback-washing,
notchwire
duplex,
changeover
Forengineinlet
Gear
Pressureregulatingvalveintegrated
Lowfinnedtubemultitubular
valve
control
temperature
dautomatic
notchwire
Duplex,changeover
Manualback-washing
Centrifugal
Tankincorporatedin common bed
Centrifugal
Screw
Turbine
1-3
jacketside,coolerside
Cylinder
1.
of the Engine)
ENGINEDESCRIPTION(SectionalView
YAI{/IOAB 6][I8(A)L-V
1-3.SectionalView of the Engine
OPERATING
SIDE
NON-OPERATING
SIDE
ValvePush Rod
Suc./Exh.Valve
Cyl. Head
Exh.Manifold
Pump HousingCover
Swing Arm
Lub.Oil Cooler
Camshaft
ConnectingRod
MainBrg.Bolt
OilPan
Mounting
Foot
1-4
Outline& DeviceArrangement)
1. ENGfNEDESCRIPTION(Engine
VanM,aB 6lf|8(A)L-Y7
1-4.(112)EngineOutline& DeviceArrangement
EngineRearEnd
Turbocharger
Fuel InjectionPump
StartingSwitch
StarVStopLever
Governor
Control Position
Selector Switch
Air Motor
Cam Case Cover
TurningDevice
1-4.(2|2)EngineOutline& DeviceArrangement
EnqineFrontEnd
ino Side
Exh. ManifoldCover
Lub.OilThermostatic
Valve
HotWater
ThermostaticValve
FuelFilter
BoostAir Cooler
Fuel Oil Pressure
RegulatingValve
Cold WaterPump
(on CoolerSide)
Hot WaterPump
(on Cly.JacketSide)
Lub.Oil Cooler
Lub.Oil Pressure
Valve
Regulating
Lub.OilPump
Crankcase SafetyValve
',
Lub.Oil Bypass Strainer
Lub.Oil PrimingPump
Lub. Oil Strainer
1998.10.20R
1-5
Pump
M.D.O.Feed
2.
STRUCTUREOF MAJOR PARTS(Outlineof Structure)
YA]{/TUAR6]II8(A)L-Y
OF MAJORPARTS
2. STRUCTURE
2-1. Outlineof Structure
This engine is designedto be a crankcaseintegrated,suspensionmetalstructureas shown in the below
sectionalview.
there are the fixed supportingto fix it directlyon the commonbed and the antivibration
For its installation,
supportingto fix the mountingfoot and generatoron the commonbed via rubbervibrationinsulators.
Drawing2-1.
SIDE
NON-OPERATING
SIDE
OPERATING
ValvePush Rod
RockerArm
Suc./Exh.Valve
Cyl.Head
InjectionPipe Joint
ProtectionRing
Exh. Manifold
Fuel InjectionPump
Piston
BoostAir BoostChamber
' Cyl. Liner
PumpHousing
Cover
SwingArm
Lub.Oil Cooler
Camshaft
Rod
Connecting
Lub.Oil Strainer
Crankshaft
Cyl.Block
MainBrg
Oil Pan
MountingFoot
2-1 (Volume:6pages)
2.
of MajorParts)
STRUCTUREOF MAJORPARTS(Structure
YAN',,AB 6]|T8(A}L'Y
2-2.Structureof MajorParts
1) Cylinder block
Providedwith side coverson both the operatingside and the non-operatingside, the cylinderblock is a
duplexwall structuremadeof castingintegratingthe boostair manifold(boostair chamber),main lubricating oil pipeand maincoolingwaterpipe.
2) Cylinder liner
Made of a specialcast iron,the cylinderlinerhas the specialthermaltreatedsurface. The innerface is
finishedwith precisionhoning.On the upper part of inner diameterof the liner, an anti-polishring is
mounted.
3) Cylinder head
The cylinder head is of the 4-valve type equipped with two suction valves and two exhaust valves and
arrangedwith a fuel injectionvalve at the center.The cylinderhead is clamped by tighteningfour bolts
underthe hydraulicpressure.
The exhaustvalveseat is watercooled,and the fuel injectionvalve is mountedwith a sleeve.
4) Piston and piston rings
The pistonis specialcast iron.lts upperpartsis cooledby the cocktailshakermethodusing lubricatingoil
that passesthroughthe connectingrod and pistonpin. The skirtis providedwith specialcoating.
The pistonrings are two compressionrings,and their slidingsurfaceis chrome-plated.Besides,there is
one oil ringcombinedwith a coil expanderwhose slidingsurfaceis also chrome-plated.
5) Connecting rod
The big end of a connectingrod is an obliquelysplit structure,and its matingsurfacesare serrated.The
connectingrod boltsare two tap boltstightenedto the specifiedangle'
6) Grankshaft and main bearings
A balanceweightis attachedto eacharm of the crankshaftby tighteningthe balanceweightclampingbolts
to the specifiedangle.
The main bearingis of the suspensionmetaltype. At the flywheel-sidetiminggear case of the No.1 main
bearing,the No.Omainbearingis provided,and it is attachedwith thrustmetaland journalmetal.
Each bearingcap is fixed with two mountingbolts and two side bolts on both the operatingside and nonoperatingside. The mountingboltsare tightenedto the specifiedhydraulicpressure.(Theside bolt of the
side.)
No.0 mainbearingcap is equippedonlyon the non-operating
7) Gamshaft
The suction/exhaustcam and fuel cam form a monoblockstructurewith the camshaft. lt is split in two at
the bearingpart betweenthe No.3& No.4cylinders.
8) Fuelinjectionpump
The fuel injectionpump is of the Boschtype. The deliveryvalve is a pressureequalizingvalve, and the
plungerbarrel is of the top closedtype.
The fuel injectiontimingis adjustedby means of the adjustingbolt of tappet of pump driving gear.
9) Fuel injection valve
The type usingthe highviscosityfuel oil is cooledwith the coolingwater runningthroughthe fuel injection
sleevemountedon the cylinderhead.A heat transferbush (copper)is installedbetweenthe fuel injection
nozzleand the injectionvalve sleeve,thus indirectlycoolingthe injectionnozzle.The engine using the MD
oil does not use the indirectcoolingsystemnor a heat transferbush. The injectionpressureis adjusted
with the spring shoe fastenedwith the adjustingnut.
10) Starting and stopping devices
The engineis startedby an air motorusingthe compressedairTo stop the engine,the starVstoplever is set in the STOP position.To stop the engine by the remote operposition.
ation,the air pistonis actuatedto set the rack of fuel injectionpump at the non-injection
The starUstoplever and turningdevice are interlockedwith the respectiveswitchesto prevent starting by
erroneousoperation.
2002.8.8R
2-2
2.
OilSystem)
STRUCTUREOF MAJORPARTS(Lubricating
YANTUAE 6]II8(A)L'Y
2-3.LubricatingOil System
oil pumpis a gear pump integratingthe pressureregulatingvalve and safety,valve.
O The lubricating
O The lubricatingoil strainersare a notch-wiretype strainerand a centrifugalbypass strainer.
type fittedwith an automaticthermooil cooleris a unitstructureof the multi-tubular
O The lubricating
staticvalve and a notch-wiretype strainer.
OThe primingpumpis a motoredscrewpumpand is mountedon the commonbed. The deliverypipe
is connectedwith the inlet side of the notch-wiretype strainer.
The lubricatingoil dischargedfrom the pump is regulatedof its pressureto the specifiedvalue by the pressure regulatingvalve.Then,the lub. oil passesthroughthe cooler and strainerand then entersthe main
galleryof the cylinderblock.The lubricatingoil line is branchedat the main gallery.The oil passesthrough
each partand returnsto the oil pan and then the commonbed.
Each lub. oil passagefranchedoff from the main galleryis a drilledhole structure,excludinglines leading
to the pressureregulatingvalveand governordrivinggear.
The oil suctionpart of the pump varies accordingto the engine installationtypes. In the case an engine
installedby the fixed supporting,the fixed suction part is the command bed; in the case of antivibration
supporting,it is oil pan.
Drawing 2-2
(HeavyFuel Oil Spec.
Fuel InjectionPump Pinion
Swing Arm RollerPin
Fuel lnjectionPumpTappetRoller
(ConnectingRod)
Auto. ThermostaticValve
Governor
DrivingGear
MainGallery
Lub. Oil Cooler
Turbocharger
Lub. Oil Strainer
Paper ElementType
EngineMain
Lub. Oil Strainer
Notch-wireType
BypassStrainer,
Centrifugal
CommandBed
PrimingPump
1999.7.2R
2-3
2.
STRUCTUREOF MAJOR PARTS(CoolingWater System)
YANM,AB G]ll8(All.-v
2-4. CoolingWaterPipe System
2-4-1. CoolingWaterHpe System(both freshwater)ineof the mixingtype)
The coolingsystem of this engine is to coof the engine (cylinderliner and cylinderhead) with hot fresh
waterand the lubricatingoil coolerand boost air coolerwith coldfreshwater.This coolingsystemis called
the dual fresh water line coolingsystemof the mixingtype.
O Both the cold water pump and the hot water pump are centrifugalpumpsequippedto the frontal
part of the engine.The hot water pump is such a structureto incorporatethe checkvalvedirectly
to the frontalside gear case throughthe check valve on the deliveryside. (The suctionparts of
both pumpsare caupledin the gear case.)
O The temperatureof hot water is controlledby the pellettype automaticthermostaticvalve.
O The temperatureof cold water is controlled by a thermostaticvalve equippedon the fresh water
coolerside.
The coolingwater dischargedfrom the cold water pump passesthroughthe boostair coolerand lubricating oil cooler,and then returns to the fresh water cooler side. However,a part of the coolingwater passes
throughthe coolingwater passagein the cylinderblockand flows intothe cold watersuctionside through
the automaticthermostaticvalve.
The coolingwater dischargedfrom the hot water pump returnsto the cylinderjacket,cylinderhead and
coolingwater collectingpipe and then to the automaticthermostaticvalvewhich controlsthe temperature
of thus returnedcoolingwater.
The coolingwater flown into the cylinderhead cools the combustionsurfaceand peripheryof fuel injection
valvesleeveand then coolsthe exhaustvalve seat.Afterthat,the coolingwaterflowsintothe coolingpipe.
Tank
Exoansion
Drawing2-3
I
I
I
4l
'j:-i!
, ai - - - CheckValve
a
HotWaterPump
I
I
I
AutomaticThermostaticValve
ColdWater Pump
I
i
.i.
- - -. {i
li
F1i i
;
-a---
i
Fresh
Water
cooler
.t-t
ColdWaterThermostaticValve
I
i
I
I
(SeaWater)
2-4
2.
STRUCTUREOF MAJORPARTS(CoolingWaterSystem)
YA'//'UAE 6TI8(A)L'V
2-4-2.CoolingWaterPipeSystem(coldwaterlineseawaterspec.)
1) The coolingsystemof this engineis to cool the engine(cylinderlinerand cylinderhead)with hot fresh
water and the lubricatingoil coolerand boostair coolerwith cold sea water.
o The coolingsystemis a dual-linesystemconsistingof the cylinderjacketlineand coolerline.
Sea water lines are equippedwith a motor-drivencentrifugalpump mountedin the marineas the
standardprovision,
o The coolingfresh water pump in the cylinderjacketline,the centrifugalpump is drivenvia an idle
gear.
2) The coolingsea water dischargedfrom the cold water pump passesthroughthe boostair coolerand
lubricatingoil cooler.
3) A bypass valve is providedat the coolingwater outletside of boost air cooler.
Openingthe bypassvalve decreasesthe amountof coolingwaterflowingthroughthe boostair cooler
and raisedthe boostair temperature.
4) The coolingwater dischargedfrom the hot water pump returnsto the cylinderjacket,cylinderhead and
coolingwater collectingpipe and then to the coolingwaterexpansiontank tank.
5) The cooling water flown into the cylinder head cools the combustionsurface and peripheryof fuel
injectionvalve sleeveand then cools the exhaustvalveseat.After that,the coolingwaterflows into the
coolingwater coolingpipe.
Drawing2- 4
Fresh(Hot)Water Pump
Fresh (Hot)Water Outlet
(Toexpansiontank)
AutomaticSea Water Valve
FreshWater lnlet
By-passValve
SeaWaterOutlet
2000.10.6R
2-5
Sea Water Pump
(mountin marine)
3. TABLEoF ENGINESTANDARD
ADJUSTMENTS
yermee
6J|!B(A)L-V
3. TABLEOF ENGINESTANDARD
ADJUSTMENTS
3-1.AssemblyAdjustmentValues
Item
Pistontop clearance(A)
z
Beginsto open(before
T.D.C.)
E
Ends closing(afterB.D.C)
Valve head clearance(B)
s
@
Beginsto open(before
B.D.C)
I
Ends closing(afterT.D.C)
Valveheadclearance(B)
u
AdjustmentValue
mm
Remarks
2.0 + 0.2
68
deg.
50
0.3
68
58
mm
deg.
o.4
mm
q)
In the cold state
ln the coldstate
o
o
q)
o
.E
tr
Adjust B after
setting it to zero
pumpbeginsto
Fuelinjection
deliver(before
T.D.C)
Injectionpressure,fuel injectionvalve
deg.
*
Referto Recordsof Shop
Traial.
MPa(kgf/cmz) 34.0-r-0.5(347-f 5)
3-2. Pressure& TemperatureSettingValues
Item
SettingValiie
Remarks
0 . 4 9 - 0 . 5 4 ( 5 . 0 - 5 . 5 ) Marinediseloil(M.D.O)
Referto Chapter5,5-1-3 Heavyfuel oil(H.F.O.)
Fuelfeedpressure
Maximum
pressure(Pmax)
combustion
*
Refer to Records of Shop
Trial.
0 . 3 9 - 0 . 4 4 ( 4 . 0 - 4 . 5 ) Engineinlet(cooler
outlet)
O . 2 5 - 0 . 4 4 ( 2 . 5 - 4 . 5 )Turbocharger
inlet
Valuesmarked
withX areper.
E
missible
cooling
waterpresMPa(kgf/cm2)
C"
0
.
1
5
0
.
2
5
l
X
0
.
3
9
sure
of
central
cooling
system
waterpressure(jacket
o Cooling
coolingline
- 2 . 5 t N 4 . 0 ) whenthepressurized
(
1
.
5
E
water
(L
inletpressure
or tankhead
pressure
areimposed
0.15-0.25lX0.39
Coolingwaterpressure(cooler
coolingline
( 1 . 5- 2 . 5 t N 4 . 0 \
Startingairtank
Startingair
2.94(30)
Lowerlimit1.18(12)
pressure
Afierdecompression
0 . 6 9 - 0 . 9 8 ( 7 - 1 0 ) At the air motorinlet
Coolingwaterengineoutlettemperature
358+4(85+4)
Coolingwaterair coolerinlettemperature
Below311(below38)
Lub.oil Dressure
o
(E
L
Lub.oilengine inlettemperature(cooler
outlet)
o)
o.
Exhausttemperature(at
eachcylinderoutE le0
P
Exh.gasturbocharger
inlettemp.
323-338(50-65)
K('C )
*
*
Referto Recordsof Shop
Trial.
Referto Recordsof Shoo
Trial.
Note:Fora star( * ) givenabove,referto the Recordsof ShopTrialand enterthe obtainedvalue here
becauseit variesaccording
to theenginespecification
and output.
200't.2.28R
3-1 (Volume:2pages)
YANM,AN 6]|I8(A)L-Y
TABLE OF ENGINESTANDARDADJUSTMENTS
3.
3-3.ProtectiveDeviceSetting Values
AlarmSettingValue
Unit
Item
0.34(3.s)
Lub.oilengineinletpressure
Lub.oilturbochargerinletpressure
MPa(kgf/cm2)
Coolingwaterengineoutlettemoerature
Rotationaloverspeed
* Lub.oilprimingpressure
0.02(o.2)
. Differential
pressure(lub.oil
strainer)
0.0e(o.e)
* Differentialpressure(fuel.oilfilter)
0.oe(0.e)
MPa(kgf/cm2)
373(100)
of the rated
115- 120o/o
sDeed
min-'(rmp)
. Startingair pressure
* Controlair pressure
0.2e(3.0)
0.25(2.5)
368(e5)
K ( " C)
Emer.Stop
SettingValue
0.65(6.6)
0.65(6.6)
. Coolingwaterpressure(acket
coolingline)
- Coolingwaterpressure(cooler
0 . 1 3 (.13 )
0.13(1.3)
coolingline)
. Lub.oilengineinlet(cooler
outlet)
temperature
348(75)
K ( " C)
As for an asterisk("),for equipmentof each item varies as dependedon the specification,refer to the Final
Document.
3-4.HoldingVolumesof LubricatingOil and CoolingWater
Unit:ltr.
HoldingVolume
Item
o
thecooler,strainer&
Engine(incl.inside
piping)
35
morethan1.lLlos
bedtank)
Lub.oilsump(common
" Governor
J
'
Remarks
TypeN261,RHD
1.3
TypePSG
2.0
water)
Cylinderjacket(fresh
75
Cooler
25
As for an asterisk(*),referto the FinalDocumentas the volumemay vary accordingto the specification.
1998.5.29R
3-2
4.
Preparation)
OPERATION(Operational
YADt',,An 6]||8(A)L-Y
4. OPERATION
Duringoperation,the dieselengineruns at a high speed.Also,some partsof the engineare hot, and
the compressedair and such pressurizedfluidsas oil and waterare flowinginsideit. Therefore,thoroughly read the safety precautionsbefore operation,maintenanceand inspectionto handle the
engineproperlynot to cause any accidents.
fLLfi Chapter0,Section3. Precautionson Safety
4-1. OperationalPreparation
Beforethe initialstart of the engine after its installationor beforeits restartafter its overhaulservicing
or a long-termstoppage, sufficientlyperform the following inspectionand operationpreparationin
additionto daily inspectionand operationalpreparation,and make sure there is no abnormalityand
the operationalpreparationhas completed.
(1) Make sure no part nor tool has been left in the crankcase.
(2) Checkfor a part not tightenedyet.
valveheadclearance.
(3) lf you havedisassembledthe valve mechanism,checkthe suction/exhaust
flll llCtrapter6, 6-3-6.Adjustmentof Suc./Exh.ValveHeadClearance
indicator
cocksof allthecylinders.
(4)Operatethelubricating
oil primingpump,andopenthe pressure
fromeachpartof the valve
oil is dropping
Whileturningthe flywheel,makesurethe lubricating
arms.
pins,
and
swing
pins,
main
bearings
piston
sure
crank
rockerarmshafts,
oilstrainer.
(5)Bleedtheairfromthe lubricating
pump.
(6)Bleedtheairfromthefueloil filterandinletpipeof fuelinjection
and makesureit movessmoothly.
(7)Manually
thegovernorlinkage,
lubricate
I Proceduresfor turningthe flywheel]
Be careful not to allow your body to make contact with a moving part while turning the flywheel.
(Neverput you hand into the crankcase.)
4-1 (Volume:14pages)
4.
OPERATION(LubricatingOil System)
YAxi'An
6X!8(A)L-Y
Drawingzt-2.Draining&Air
BleedingPointson Nonoperating
Silde Drawing4-2. Draining & Air Bleedingpoints
Lub.Oil Cooler
AirVentValve
AirVent Plug
AirVentPlug
Chang-over
Cock
Drain Plug
DrainPlug
OilSupplying Points on OperatingSide
Hand Lubricating Points
Manually lubricatethe governorlink and controldevices(circledportions)
Drawing4-4.GovernorDevice
Control Lever
for Gov. output
StarVStop
Lever
Governor
Connector
l i
Oil Level Gauge
1st LeverShaft
Remove the top covel
and supply oil to 2 to
3 mm above the center of oil level gauge.
DrainPlug
Lub.Oil Filler(Systemoil sump)
1999.7.2R
4-3
(Lubricating
OilSystem)
4. OPERATION
YAr/'UAB 6TII8(A)L-V
Turn the flywheel by the following procedures:
Turning Gear Device - - - - - - - - Operationalspec.
(1) Removethe lock bar,loosenthe stopperlock boltand slightlymovethe stopper.
(2) Pressthe turninggear shaftdownto the GEAR lN position.
(3) Fit the stopper into the groove B of the gear shaft,and then tightenthe stopper lock bolt.
(4) Attach the socket and ratchethandlefor turningto the shaft, and then turn the flywheel.
(5) When the turningoperationhas completed,returnthe turninggear shaftto the GEAR OUT position.
Then, fit the stopperintothe grooveA, and tightenthe stopperlock bolt.
(6) Attach the lock bar.
Unless the turning gear is the GEAR OUT position,the turning gear engagemenVdisengagement
switch actures to disablestarting.(optionalspec)
Drawing 4-1 Turning gear device (Optionalspec.)
r-l
TurningGear
L-._l
r N' Ti'
'rt
/41
B
4-1-1.LubricatingOil System
The piping parts of lubricatingoil systemare bandedwith yellow coating.
1) Inspection and oil supply of lubricatingoil sump
(1) Open the drain valve,cock or plugof the followingoil sumpsand devices;and checkthe drain.
Supplythe lubricatingoil to the upperlimitof oil levelgaugeor dipstickin each oil sump;
systemoil sump)
@ Engineoil pan or commonbed (lubricating
Governor
oil
sump
@
@ Lubricatingoil cooler
@ Lubricatingoil strainer
contaminated
of deteriorated,changeit.
(2) Checkthe propertiesof lubricating
oil;and if it is considerably
lLl_flChapter 3. Tableof EngineStandardAdjustment
fl | fltGhapter5. 5-2-2.Control on Lub. Oil
2001.6.15R
4-2
4.
OPERATION(LubricatingOil System)
YAxi'An
6X!8(A)L-Y
Drawingzt-2.Draining&Air
BleedingPointson Nonoperating
Silde Drawing4-2. Draining & Air Bleedingpoints
Lub.Oil Cooler
AirVentValve
AirVent Plug
AirVentPlug
Chang-over
Cock
Drain Plug
DrainPlug
OilSupplying Points on OperatingSide
Hand Lubricating Points
Manually lubricatethe governorlink and controldevices(circledportions)
Drawing4-4.GovernorDevice
Control Lever
for Gov. output
StarVStop
Lever
Governor
Connector
l i
Oil Level Gauge
1st LeverShaft
Remove the top covel
and supply oil to 2 to
3 mm above the center of oil level gauge.
DrainPlug
Lub.Oil Filler(Systemoil sump)
1999.7.2R
4-3
4.
OPERATION(FuelOil SYstem)
YANJUAB 6NI8(A)L'V
2) Primingof lubricatingoil
pump.
primingsystemusinga motor-operated
Thisengineemploysthe continuous
o Keep the control power supply for the motor-operatedpriming pump of this engine switchedON
always.
o SwitchOFF the said powersupplyin a long-termstoppageof the ship and in a restand maintenance
servicingof the powerinstallation.
Afterpriminghas stoppedfor two hoursor longer,performprimingfor about20 minutesor longer.
pressure:
0.02- 0.20MPa(0.2- 2.0kgf/cm2)
Priming
3) Air Bleeding of Lub. Oil Cooler
airfromthe lub.oilcooler,operate
itemsarises,startthe engineafterbleeding
r lf anyof thefollowing
theprimingpump.
r Afterpriminghasstoppedfor two hoursor longer.
& cleaningthelub.oil strainer.
r Afterdisassembling
oil system.
the pipingpartsof lubricating
the lub.oil or disassembling
o Afterchanging
Air Bleeding Procedures
(1) Operatethe primingpump.
(2) Openthe air bleedvalve of the lub. oil cooler.
(3) Dischargethe air,and then closethe air bleedvalve.
o lf you cannotoperatethe motor-operatedpriming pump, performair runningfor about 3 seconds
repeatedlyfive times.
Afterstartingthe engineshouldbe executedthe air ventingagain.
4-1-2.FuelOil System
Thepipingpartsof fueloilsystemarebandedwithredcoating.
(1)Drainthefueloiltankandfueloilfilter.
(2)Supplythefueloil intothefueloiltank,andcheckthefueloil.Then,openor closeeachvalveaccordconditions.
ingto theoperation
turn on the heaterfor the
specifications,
(3) Youusean engineof marinedieseloil (M.F.O)starUstop
proper.
becomes
pipeline,andcontinueheatingtheH.F.O.untilitsviscosity
heavyfueloil(H.F.O.)
make sure the fuel oil temperlf you use an engineof heavyfuel oil (H.F.O.)starUstopspecifications,
proper.
ature(viscosity)at the engine inletis
fLl-[lChapter5, 5-1-3.Propertiesof FuelOil at the EngineInlet
1998.4.21R
4-4
4.
OPERATION(FuelOilSYstem)
YAN',,AB 6]|I8(A)L-Y
(4)Bleeding
airfromoilsystem
long-termstoppageor overhaulof the engine,bleedair from the fuel oil sysAfterengineinstallation,
tem by the followingprocedures:
O Open the bypassvalveof fuel feed pump.
(Fullyturn the bypassvalve handlecounterclockwise)
the air bleedcock of fuel oil filterto bleedair.
Open
@
Drawing 4-6 Air Bleeding Points on Frontal Side
Iten
1
z
Name
Fuel Feed Pumo
Press Reoulat.Valve
Bv-oassHandle
4
5
6
8
9
Chano-overCock
Fuel Filter (NO.2)
Air BleedCock
Fuel lniectionPump
Air BleedPlug
Drain Cock
By-passValve
(Clockwisefor close)
@ Loosenthe air bleedplugson the fuel oil pipe mountof each fuel injectionpumpto bleedair.
Drawing 4-7 Air Bleeding Points on Operating Side
'if-\ixi
Air BleedPlug
f-
@ Bleedthe air from each fuel injectionpump by the followingprocedures:
o Set the starVstopleverin the RUN position,and push the rackof fuel injectionpumpto
the injectionvolumeincreasedirection.
r Attachthe primingtools to the pumptappetwhilethe plungerof fuel injectionpump is at the
lowermostposition.
4-5
4.
SYstem)
OPERATION(FuelOil
No.
ExclusiveToolDescription
YAT{/TUAB6III8(A)L-V
PartNo.
O
Priminglever
146673-92920
@
Leversupport
146673-92930
Drawing 4-8 Priming Procedures
r Move up and down the primingleveruntilyou feel a strongresistance.
r Turn the flywheelto bleedthe air from all of the cylinders.
@ Closethe bypassvalve.
(Fullyturn the bypassvalve handleclockwise.)
Fuel Oil Seal Pot Servicing Procedures(for Engine Using H.F.O.)
Seal potsare equippedto the mountfor fuel oil pressuregaugeand that for the fuel oil differentialpressure
to 1,500-sec.or higherfuel oil).
indicator(optional)of an engineusingthe heavyfuel oil (equivalent
Drawing 4-9 Seal Pot Servicing Procedures
Seal Pot
2002.s.15R
4-6
4.
WaterSystem& BoostAir)
OPERATION(Cooling
YA'j,'frAB 61II8(A}L'V
(1) Removethe fillerplugO and the air vent plug@ .
(2) Pour ethyleneglycolfrom the filleruntilit overflowfromthe air vent plug.
(3) When the seal pot is filledwith ethyleneglycol,securelytightenthe plugsO & @ .
(4) Removethe plug @, and pour ethyleneglycolfromthe filler.When the seal pot is filledwith ethylene
glycol,tightenthe plug.
(5) Periodically(abouteverytwo months)loosenthe plug@ anOplug @, and check if the fuel oil does not
overflow.
4-1-3.CoolingWaterSystem
The piping partsof coolingwatersystemare bandedwith blue coating.
(1) Inspectthe coolingwatertank,and checkwhetherthe coolingwateris not contaminated.lf the cooling
changeit.
water is considerably,
(2) Supply the coolingwater to the upper limit of water level gauge, and add a proper amount of rust
inhibitor.
[LLilCnapter 5, 5-3-2.Brandsof RustInhibitor& AddingQuantity
(3) Open and closeeach valveof the coolingwaterpipe systemaccordingto the operationconditions.
heat the coolingwater in the
(4) lf you use an engineof heavyfuel oil (H.F.O.)starVstopspecifications,
jacket
cylinder
sideto 65 to 75'C .
When you have replacedthe cylinderliner or drawn it out for servicing,remove the cylinderside
cover and make sure no waterleaksinsidecvlinder.
4-1-4.BoostAir System
Open the drain cocksof the followingpointsto drainthem.
Drawing4-10 Boost Air System Draining Points on Non-operatingSide
2002.5.15R
4-7
4.
OPERATION(Starting& ControlAir System / Starting)
YADIM,AB 61118(A)L-V
Air System
4-1-5.Starting
The pipingpartsof fuel oil system are bandedwith white coating.
(1) Drainthe startingair reservoir.
(2) Make sure that the pneumaticpressurein the air reservoiris high enough to start the engine (2.2
MPa{22kgf
I cm2}or higher).
Devices
4-1-6.Controland Protective
(1) Movethe starUstopleverfromthe RUN positionto the STOP positionand vice versa,and makesure
the rackof fuel injectionpump, 1st levershaftof governorlink and connectormove smoothly.
(2) Checkfor excessiveplay of connectorpin.
(3) Set the powerswitchof protectiveand alarm devicesto the ON position.
Unlessthe powerswitch is set in the ON position,the protectiveand alarm devices do not actuate.
4-2.Starting
Thisengineis startedby an air motor.
Pressthe STARTswitch.Then,the pilotair solenoidvalvedirectlyattachedto the air motorwillopenon
the batterypowerto startthe engine.
Duringstartoperation,
do not bringyourfacecloseto the air motor.Dustadheredat the exhaustport
in injury.
of air motormayenteryoureye,resulting
Before the initialstart of the engine after its installationof before its start after its overhaulor longterm stoppage,performair runningby the followingprocedures,and make sure there is no abnormality.Then,startthe engineby the controlpanelon the engineside. lf a largeamountof fuel oil,cooling
"waterhammering"may occur.
wateror lubricating
oil shouldbe entrappedin cylinders,
operationselectorswitchin the ENGINEposition.
o Set the ENGINE/REMOTE
pressure
indicatorcocksof all the cylinders.
o Openthe
e Set the starUstoplever in the STOP position.
o Hold the STARTswitch pressingfor 2 to 3 secondsto effect air running.
1) Starting operation procedures
Start the engineby the followingprocedures.
(1) Makesurethe turninggear is it the GEAR OUT position.
(2) Make sure the pressureindicatorcock is closed.
(3) Set the ENGINE/REMOTE
operationselectorswitchto the ENGINEor REMOTEpositioncorresponting to the controlpanelto be selected.
2002.5.15R
4-8
4.
YATJ',,AB 6I|I8(A)L-Y
OPERATION(Starting)
(4) Set the start/ stop leverin the RUN position.
(5) Make surethe pointerof speedcontrolshaftof governorindicatesthe positionof ordinaryoperation
(ratedspeed).
(6) Open the startingair reservoirvalveand controlair valve.
(7) Hofdthe STARTswitchpressingfor 2Io 3 seconds,and make sure of ignition.Only then releasethe
switch.
Drawing 4-11Start Operating Procedures
v\/v
@@@
SpeedControlKnob
(for Governor)
Speed ControlShaft
ENGINE/REMOTE
OperationSelectorSwitch
ControlAir Valve
2) Corrective actions to be taken in starting failure
gasin thefluemaybe ignited,resulting
combustion
started,
unburnt
lf the enginecannotbe properly
gas
fromthe exhaustgas systembefore
perform
discharge
the
running
to
Therefore,
air
in explosion.
to restarttheengine.
attempting
(1) Make surethe flywheelhas completelystopped,and then pressthe STARTswitch.
(2) lf the batterypower for the STARTswitch has been exhausted(and in case of emergency),press the
manualbuttonof air motorto startthe engine.
Use startingcontrolbasedon the manualbuttononly in emergencybecausethe air motor may rotate
excessivelyas the controlmoduleis not in operationin this case.
Drawing 4-12 Air Motor Manual Button
2002.5.15R
4-9
4.
OPERATION(Running)
YAr/'UAB 6]|I8(A)L-V
3) Checks to be made immediately after starting
Checkthe followingitems.lf any abnormalityis found,stop the engine and repairit.
(1)Valueindicatedby the pressureindicatoron the gaugepanel
(2) Leakfrom each piping
(3) Unusualsoundand abnormalheatgenerationof each part
4-3.Running
partswithbarehands.
aftertheenginestop,nevertouchthefollowing
o Duringa runandimmediately
youmaygetburnt.
Otherwise,
.Turbocharger,
Exhaustpipesystem,boostair pipesystem
.Flueandfunnel
youmay be caughtin,resulting
in injury.
o Duringa run,nevertouchanymovingpart.Otheruvise,
Keepthecontrolairvalveopenedduringa run.
devicescannotactuate.
lf youcloseit, the protective
1) Initial Running-inOperation
To preventinitialabnormalwear of pistonrings and cylinderliner,run the engineon marinedieseloil
(M.D.O)for the followingperiod:
(1) For 10 to 20 hoursafterinstallation.
(2) For 10 to 20 hoursafterreplacementof pistonrings,pistonor cylinderliner
2) Steady (Routine)Running
(1) Makesure the pressureof lubricatingoil, coolingwater and fuel oil has reachedthe specifiedvalue.
(2) Run the enginefor about 10 minutesat the ratedspeedwithoutload to warm it up.
(3) lf the engineis used to drive a cargo pump or the like,which requiresthe controlon rotation,run the
engineat the presetidlingspeedto warm it up.
The criticalspeedthat may causetorsionalvibrationis withinthe normalrotationspeedrange,quickly
avoid it, and set the rotationalspeed to the rated speed.
2002.5.15R
4-10
4.
OPERATION(Running)
YANTOAB 6]II8(A)L-\/
(4) lf you continuerunningthe enginewith a low load for longerthan three hours,observethe following
load factors,othenrvise
combustionworsensand foulingof the combustionchamber,exhaustpipe,
turbocharger,etc. becomes heavy.
or higherloadfactor.
@ ff fuel oil used is the marinedieseloil (M.D.O),run the engineat 15o/o
@ lf fuel oil used is the heavyfuel oil (H.F.O)
.And if the (optional)boost air temperaturecontrollerwhich heatsthe boostair in a low load run is
or higherload factor.
equipped,run the engineat 15o/o
.But if the coolingwater for the boost air cooler and lub. oil cooler is used jointlywith the main
marineengine,run the engineat2oo/oor higherload factor.
lf youwantto runtheengineat furtherlowerloadfactor,changeoverthefueloilto theM.D.O.
.But if the coolingwater for the air coolerand lub. oil cooleris sea water,run the engineat25o/oor
higherload factor.
lf you want to run the engineat furtherlower load factor,changeoverthe fuel oil to the M.D.O.
Adjustment of Boost air temperature
(ln the case of sea water cooling)
oC operatingthe coolingwater bypassvalve handleof
,
e Adjust the boost air temperatureto 40 to 60
the boostair cooler.
As the bypassvalve handle is set in the OPEN side, the coolingwaterbypassed,and the boosti
air temperaturerises.
Drawing 4-13 Sea Water By-pass Valve (Boost Air Gooler)
@ In the case of a high humidity,this is not abnormalalthoughmuch drainmay be producedas the
moisturein the air is condensed.
ln this case,run the engineas the draincock of the boostair coolerkeptopened.
2000.6.26R
4-11
4.
(Stoppingin NormalRunning)
OPERATTON
YAX]UAB 6I|I8(A}L-V
(5) lf you use an engine of marine diesel oil (M.D.O.) starUstopspecifications,observe the following
items:
o lf the load factor is less than 20% of the generatorrated output, do not switch the fuel oil from the
M.D.O.to the heavyfuel oil (H.F.O.).
r Make sure the H.F.O.at the engineinlethas been heatedso that its viscositybecomesproper,and
then switchover the fuel oilfrom the M.D.O.to the H.F.O.
fluctuatesat the incomingand outgoingand loadingand unloadingof vessel.
o The load substantially
For these operations,we recommendyou to run the engineon the M.D.O.
Properviscosity:11 to 14 cSt (R.WNo.1 55 - 65 sec.)
data.
(6)Measurethe runningperformance
oncea dayandrecordthemeasurement
of RunningPerformance
6, 6-3-1.Measurement
ILL-UIChapter
4-4,Stopping
4-4-1.Stoppingin NormalRunning
stopthe engineby thefollowingprocedures:
Exceptin caseof emergency,
1) Preparationof stopping
(1)lf youusean engineof marinedieseloil (M.D.O.)
switchoverthefueloilfrom
starVstop
specifications,
frombeingstagnantinsidethefueloil
to the M.D.O.to preventtheH.F.O.
the heavyfueloil (H.D.O.)
pumpswhenstopping
pipes,fueloilfilter,fuelinjection
theengine.
As the reference,continuerunningthe engineon the marinedieseloil (M.D.O.)for2O to 30 minutes
before stopping the engine. However,since the requiredtime depends upon the load applied when
the fuel oil is switchedover and the capacityof pipes in the vessel, consultthe dockyardwhere the
enginehas been installed.
(2)Shutoffthe load,andthencontinue
runningtheenginewithoutloadfor about10 minutes.
2) Stoppingoperation
(1) Setthe starUstop
leverin the STOPposition.
lf you use the engine of the remotestarUstopspecifications,pressthe STOP switch.
(2) Runthe lubricating
oil primingpump
(3) Openthe pressureindicatorcock,and performair runningto dischargethe as from the combustion
chambers.
(4)Openor closethe valvesof eachsystemaccordingto thestoppingconditions.
When the cooling water may be frozen under cold weather,or beforea long term stoppage,drain the
coolingwater from the cylinderjacket side and cooler side.
2000.6.26R
4-12
4.
OPERATION(EmergencyStoP)
YAD/,'',AN 6]|T8(A}L-Y
Stop
4-4-2.Emergency
lf any of the followingproblemsarises,immediatelyset the starUstoplever in the STOP positionto stop the
engine.
(1) Any of the followingalarmshas been issued.
o Expressivepressuredrop of lub. oil
o Expressivetemperaturerise of lub.oil
o Expressivetemperarise of coolingwater
o Overspeed
(2) An unusualsoundhas been made.
(3) Heat has generatedunusuallyfrom a part
(4) Smoke is issuedfrom a bearingor any othermovingpart.
(5) A pipe of fuel oil, lub.oil or coolingwatersystemhas been broken.
(6) The supplyof coolingwaterhas stopped,and it is impossibleto supplyit immediately.
(7) A setscrew or bolt of a movingpart is looseor broken.
(B)Moistureis mixedin the lubricating
oil.
(9) The boostair pressurehas dropped,and the exhausttemperaturehas excessivelyrisen.
(10)The rack of fuel injectionpump has stuck.
lf the engine is not stoppedby settingthe starVstoplever in the STOP positionor pressingthe STOP
switch,closethe fuel oil inletvalve.
4-4-3.DisposalAfteran Emergency
Stop
the causeof problem,observethe followingitems:
When repairingthe engineor investigating
Do not open the side coverof crankcasefor at least10 minutesafterhavingstoppedthe engine.
in explosion.
of oil mist,resulting
Entryof freshairintotheenginemaycauseignition
2000.6.26R
4-13
4.
OPERATION(DisposalAfteran EmergencyStop)
YA'IJUAN 6]|I8(A)L'V
lf you have stoppedthe engine while it is running on the heavy fuel oil (H.F.O.),immediatelydischargerthe H.F.O.from the fuel oil pipes,fuel oil filter and fuel injectionpumps,and displacethem
with marinedieseloil(M.D.O.).
lf the residualH.F.O.is cooledand its viscosityrises,it becomesimpossibleto restartthe engine.
(1) Set the fuel oil changeovervalvesat the engine inlet and outletto the marinedieseloil (M.D.O.)
position.
(2) Openthe bypassvalveof fuel feed pump.
(3) Openthe draincock of fuel oil filterand drain valve of fuel oil main pipe.
(4) Turn the flywheelto dischargethe H.F.O.from the fuel injectionpipes and fuel injectionvalves.(Set
the starVstopleverin the RUN position,and turn the flywheelunderthe fuel injectionstatus.)
Drawing4-14 H.F.O.Discharging Points
2000.6.26R
4-14
5.
FUELOlL, LUB. OIL & COOLINGWATER(FuelOil)
YAnruAB 6Ill8(A)L-V
5. FUELOIL,LUB.OIL& COOL'NGWATER
5-1.FuelOil
The propertiesof fuel oil applicableto this engine are shown in the followingtable.
The propertiesof fuel oil are uncertainand broadlyranged;thus they affectsuch factorsas a smoothrun of
the engine, maintenanceintervaland service life of parts. Consequently,it might be necessaryto change
the specificationsof engine or add attachmentin accordancewith the appliedfuel oil.
5-1-1.Quantity
Criteriaof FuelOil
il
"C
200sec.Oil1 ,500sec.Oil
3,500sec.Oil
7,000sec.Oil
3-8
<30
< 190
< 380
< 700
37-58
< 200
< 1500
< 3500
< 7000
< 0.86
< 0.991
< 0.991
< 0.991
< 0.991
>60
>60
>60
>60
>60
Residualcarbon mass.%
< 0.7
<10
<15
<19
<22
Sulfurcontent
mass.%
< 1.0
< 3.5
<5
<5
<5
Ash content
mass.%
< 0.10
< 0.'10
< 0.15
< 0.20
< 0.5
< 1.0
< 1.0
< 1.0
at 50
cSt
Viscosity
R.W.No.1
at 100'F sec.
Specificgravityat
1514"C
"c
Flashpoint
Property
critical
value
< 0.1
Moisturecontent
vol.o/o
Vanadium
ppm
< 150
< 300
< 500
< 600
Sodium
ppm
<30
<40
< 100
<200
Aluminum
ppm
<30
<30
<30
<30
>30
>25
>20
>15
(Cetaneno. of
,45)
Dieselindex
rso
Quatitycriteriaequivalent
fueloil
DBMoTDMA R M B l O
RMG35
RMH55
crMAc810 crMAcE25 ctMAcG35 crMAcH55
CIMAC
BSI
JIS
RME25
(M4)
M.D.O
(M6)
r.F.o
(M7)
M9
H.F.O.(heavy
fuel oil)
Note:M.D.O.= marinedieseloif;l.F.O.= intermediate
fuefoil
" UseHFOwiththe CCAI,(anignitability
pleasenotethatthe
index),below850as an standard.(However,
saidvaluewasestimated
fromthe pastoperationdataandthatthe valuecanvarydepending
on thefuture
fueloil quality.)The use of HFOwith CCAIexceeding850 will causefaultycombustion
and aggravate
exhaustcolor.
lf suchuse is inevitable,raisethe intakeair temperature.Thiswill improvecombustion
to
'However,
an extent.
raisethe intakeair temperature
carefullyin relationwith the exhausttemperature,
sincethiswillaffectthe exhausttemperature
and otherengineperformance."
Whatis CCAI?
CCAIstandsfor Calculation
index.
QarbonAromaticity
lndex,whichshowsan ignitability
The index,in consideration
of the relationbetweenaromaticcompoundcontentin fuel oil and the
ignitability
is usedto obtainthe aromaticitydegreein relationwith the fuel oil properties.The larger
theCCAIvalue,the largerthe firingdelayfor inferiorignitability.In thiscase,the HFOdirectstarting
is notpossibleor exhaustcoloris aggravated
dueto faultycombustion.
2002.12.25R
5-1 (Volume:12pages)
Oil)
5. FUELOtL,LUB.OtL& COOLING
WATER(Fuel
YATTT',AR6XI8.A,L'V
5-1-2.QualityCriteriaof BlendedFuelOil
In the caseof usinga highlyviscosefueloil by blendingwithmarinedieseloil to lowerthe viscosityof fuel
oil, in additionto thecaseof directburningof fueloil setforthabovefor its pretreatment,
applythe blending
ratioshownin thefollowingtablebasedon thequalitycriteriaon the blendedfueloil, not basedon the viscositycriteria.
Whenblendingfueloil of differentproduction
origins,sludgemaybe separated
out,resultingin cloggingof fuel oil filtersand stickingof fuelinjectionpumpsandfuelinjectionvalves.Payyourattention
to this regard.
Blendedfuel oil
200-sec.oil equivalent 1,500-sec.
oilequivalent 3,500-sec.
oil equivalent
rso
criteria
on
Quality
directburning
CIMAC
fueloil
equivalent
BSI
RMBlO
RME25
RMG35
crMA c8 1 0
crMAcE25
crMAcG35
(M4)
(M6)
(M7)
Blendingratio(%)
M.D.O.:
H.F.O.(7,O0O-sec.oil)
M.D.O.:
H.F.O.(7,000-sec.oil)
60:40
30:70
Note:M.D.O.= marinedieseloil; H.F.O.= heavyfueloil
Viscosityafterblending:[m
5-1-5.Howto Find out the Viscosityof BlendedOil
5-1-3.Properties
of FuelOil at the EngineInlet
lmpuritiescontainedin the heavyfueloil (H.F.O.)
maycausefuelinjectionpumpsandfuel injectionvalves
to be damaged,cylinderlinersto be excessively
wornand exhaustvalvesandvalveseatsto be deteriorated.Therefore,raisethe cleaningeffectof pretreatment
systemto the maximumextent,and alsosupply
thefuel oil heatedto havethe properpressureandviscosity.
Residualoil of a catalyticcrackingrefiningdeviceis sometimes
usedfor industrial
low-cost,high-viscosityfuel oil. In thisresidualoil,thereremainfine particlesof silicaandaluminathatare catalystsfor
this device.
A low-cost,high-viscosity
fuel oil whichusestherebaseswill causeabnormalwear of pistonrings,
cylinderlines,fuel injectionpumps,fuelinjectionvalves,etc.
Therefore,usea low-cost,high-viscosity
fueloil treatedof contentlessthan0.03wt. % of ash,minimumof siliconand aluminumand removedof all particleswhichexceed3 - 5 U in size,utilizingthe
F.O.treatingapparatus.
lncidentally,
the moisturecontentshouldbe keptat lessthan0.2vol.o/o.
2002.12.2sR
5-2
Oil)
5. FUELolL, LUB.olL & coOLlNGWATER(Fuel
.\,
yAnrrAF
6l||8{A)L-v/
properties
at engineinlet
(1) Recommend
of heavyfueloil (H.F.O.)
Moisturecontent
Less than 0.2vol.o/o
Lessthan20 ppm
Contentof solidparticles
Size of FFC catalyticparticle
Lessthan5tr
(2) Recommendedviscosityand pressureof heavyfuel oil (H.F.O.)at engineinlet
Fueloil
Viscosity
Recommended
at the Enginelnlet
0.20- 0.25(2.0- 2.5)
200-sec.oil
oil
1,500-sec.
oil
3.500-sec.
11- 14cSt
(R.W.No.1 55 - 65 sec.)
0.40- 0.45(4.0- 4.5)
0.45- 0.50(4.5- 5.0)
0.65- 0.70(6.5- 7.0)
7.000-sec.
oil
M.D.O.
Pressure
Recommended
MPa(kgf/cm2)
3-8cSt
0.50- 0.55(5.0- s.5)
Heatingtemperature,
Iml5-1-4. How to Find out the HeavyFuelOil HeatingTemperature
2002.'t2.25R
5-3
oil)
5. FUELOlL,LUB.OIL& COOLINGWATER(Fuel
vADtM,Aa 6Ill8(AlL-v/
Calculationof CCAI
C C A |= D - 8 1 - 1 4 1. l o g l o g ( V + 0 . 8 5 )
D : Densitykg/m3@ 15'C, V : Viscositymm2/S @ 50"C
ccAl
V
-1
- 800
810
820
-2
830
;3
840
- 4
850
5
860
940
960
870
..a'
.980
880
1000
890
1020
The largerCCAI,
the inferiorfiring
performance.
Thiswillcause
normaloperation
to be hard.
900
1040
910
920
930
IExample]
ObtainingCCAIof HFOwiththe viscosityof 380cSt@ 50'c andthe densityof 985 k9/m3
@ 15'Cfromthe tableabove:
Drawa linefromthe viscosity(V) 380cStto the density(D) 985 and extendthe lineto
CCAIcolumn.Thefuel oil CCAIin the presentexampleis 846.
2002.12.25R
5-4
5.
FUELOlL, LUB.OIL & COOLINGWATER(FuelOil)
YA}'NAB
6]|I8(A}L.Y
5-1-4.Howto Findout the HeavyFuelOil HeatingTemperature
Example:In thecaseof findingoutthe heatingtemperature
of 700cSt (at 50 'C ) fueloil
pointO corresponding
Findtheintersecting
to viscosityof 700cSt and temperature
of 50'C on a
line@ standingfor viscosity-temperature
relationof 700 cSt (at 50 "C ) fueloil.
On thisline@, locatea pointcorresponding
to therecommend
viscosity
at theengineinlet,and
point
thendrawa perpendicular
from
this
to
(x-axis).
the
axis
of
abscissa
@
Theintersection
of thisperpendicular
withthex-axisindicates
the heatingtemperature
required.
"C
(ln thiscase,thetemperature
is 150 .)
100'F
6At
I J^s^e^c)
R.Il.No.1 100'F
75
cu
40
30
,i
Q)
o
L
Reconmended
viscosity
at engrne
Inlet
o
o
10.0
9.0
8.0
i.0
=
=
0.
I
a
o)
+J
cJ)
;
c)
e
.t
.:
o
()
o
;
o
o
q)
;
80
90
r00
100'F(37.8'c)
110
120 130 140 1
E n g i n ei n l e t F . 0 . t e m p
("C)
Temoerature
(1) Preparea correctviscosity-temperature
relationchartaccordingto the propertiesof fueloil existing
at thetimeof its deliveryto you.
lf theviscosity- temperature
lineconesponding
to yourappliedfuel oil is not shown,entertheviscosityandtemperature
of the appliedfueloil on the abovechart,itemfromthe intersecting
pointof
theentereddatadrawa linein parallelto the nearestdrawnviscosity{emperature
line,andfindout
the heatingtemperature
accordingly.
(2)Setthefuelheatingtemperature
so thatthefueloil viscositybecomes11to 14 cSt(55to 65 sec.)at
theengineinletto allowsometemperature
dropin the pipingsystem.
5.
FUELOlL, LUB.OIL & COOLINGWATER(FuelOil)
YAIJ',,AB 6ilI8(A)L'Y
5-1-5.Howto Findout the Viscosityof BlendedOil
heavyfueloil
Example:In the caseof findingout the viscosityof blending(R.W.No.1at 100'F)7,000-sec.
(H.F.O.)
ratioof 70:30.
at theblending
with(R.W.No.1at 100'F)40-sec.marineoil (M.D.O.)
to 100 o/oH.F.O.,locate
the point @ correOn the left y-axis(axisof ordinate)corresponding
(7,000
y-axis
to 100 %
sec.) of H.F.O.;on the right
corresponding
spondingto the viscosity
(40 sec.)of M.D.O.Nowdrawa straightline
M.D.O.,the point@ corresponding
to the viscosity
@ to tint<bothlocatedpoints.
ratioof 70 o H.F.O.
Then,locatethe point@ corresponding
to theblending
and30 % M.D.O.on
the axisof abscissa(x-axis),and drawa perpendicular
O fromthe pointe to the drawnstraight
line@ , intersecting
at the point@ . Finally,drawa horizontal
line@ fromthusfoundintersecting
point(O to the lefty-axisto find out the viscosityof the blendedoil. (ln the case,the viscosityat
100"Fis about550sec.)
Lorqlality Fuel0il
R.W.No.1 at 100"F
<i
q)
o
ct
gt
6
l!
o
o
o
=
=
.A
€)
+,
6'
E,
.:qt
qt
o
o
o
6
;
ci
(D
q>
o
o
o
r-
o
o
o
o
(0
o
o
lr
t!
o
!o
o.j
o
o
:
N
N
o
-
6D
q
ci
ci
o
ci
v)
-
-
cEt
-
3l
*tarine
" " Dieset
" " . oit
" . t.. 'D.0.
. - -0
10
20
30
40
50
60
70
80
90
100
Havy
Oil H.F.0.100
Fuel
90
B0
70
60
50
40
30
20
l0
0
B l e n d i n gR a t i o ( % )
5-6
5.
Oil)
FUELOlL, LUB.OIL & COOLINGWATER(Lub.
YA}'MAN 6]II8(A)L-Y
5-2.LubricatingOil
Selectionof the proper lubricatingoil is importantfor a dieselengine.In case of using an inappropriatelub.
oil, stickingof pistonring, seizure and early wear of piston,cylinderlinersand bearings,etc. will occur.
discreetlyselectthe lubricating
Consequently,
oilto be used.
5-2-1.Choosing
the Lub.Oil
Depending
on properties
of fuel oil and conditions
of usageof the engine,lub.oil to be selectedvaries.
Chooselub.oilAPIServiceGradeCE or CDClass.
1) Viscosity
Usean oil shownin the belowtable.
Application
Viscosity Specific
(sAE)
Gravity
Frash point
'c
(OpenType)
Viscosity(cSt)
PourPoint Kinematic
Viscosity
(r)
"c
Index
40
100'c
O Marineauxiliaryengine
30
0.89
> 230
<-10
105- 125 1 1 - 1 2 . 5 9 6 - 1 1 0
O Marineauxiliaryengine
O Landuse
engine
40
0.893
> 240
< - 7.5
140- 155
14- 15.5 9 6 - 1 1 0
2) TotalBaseNumber(T.B.N.)
Selecta lub.oil basedon the valuesgivenin thefollowing
tablefor the basenumberagainstthe sulfur
contentincluding
in thefuelused.
FuelOilUsed
RedwoodNo.1
Viscosity
s(100'F)
SulfurContent
(vvt.%)
TotalBase
Number
(r.B.N.)
(msKOH/s)
M.D.O.equivalent
< 1
9-15
l.F.O.eq. 200-sec.
< 3.5
16-26
<5
30-42
1,500-sec
H.F.O.eq. 3,500-sec.
7,000-sec
Lub.oilto beapplieo,
lffi]
5-2-9.Listof Lub.Oil Brands
(1) Avoid blendeduse of differentbrands.
(ln the unavoidablecase of blended use of differentbrandsof lub, consultyour lub. oil supplier.)
(2) lf 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-temperaturearea together with carbon
residue and causes adverse effectsas mentionedbelow:For that reason,use the proper lub. oil.
o Accumulationof the aforementioneddepositson the combustionchamberhinders slidingof piston
rings and may cause scuffingto the rings,cylinderliners,etc. Besides,they may cause bite-in and
blow-byeif intrudedinto exhaust valves.
2002.5.15R
5-7
Oil)
WATER(Lub.
5. FUELOtL.LUB.OIL& COOLING
YANMAR 6]II8(AL-V
5-2-2.Controlon Lub.Oil
afteran enginestop,be careful
oil insidethe engineimmediately
the lubricating
O ln caseof handling
notto get bumt.
oil to get in youreyesor to stickto yourskinduringhanof lubricating
@ Shouldtherebea possibility
protectors
wear
such
as safetygogglesand rubbergloves.
lubricating
oil,
dlingof
In suchcase,
oil get in youreyesor stickto your skin,it mightcauseinflammation.
@ lf tubricating
physician,
if necessary.
flushan affectedregionwithcleanwater,and thenconsulta
of waste oil properly
provided
Dispose
in
the
law.
for
has
waste
oil
been
of
disposing
tUetnod
@
accordingto the pertinentlaw.In caseyou don'tknowwhatto do, inquireof yoursupplierof lubricationgoil aboutthis mattetanddisposeof wasteoil accordingly.
1) ControlCriteria
Conductthe propertyanalysisof lub.oil usedevery500 hoursof enginerun,and changeor makeup the
lub.oil as guidedby controlcriteriasetforthin the followingtable.
ofUsage
CriticalValue
ControlCriteria
Item
Unit
Flashpoint(PMmethod)
'c
> 180
140
Changein viscosity
cSt(40"C)
Wthin new oil -! 15 o/o
New oil + 25 o/o
Moisturecontent
vol.o/o
< 0.1
0.3
n-pentaneinsolublematter
(A method)
mass.%
< 1.5
2.0
Tolueneinsolublematter
(A method)
mass.%
< 1.5
2.0
Differencebetween npentianeand toluene
insolublematters
mass.%
< 0.5
HCt04
method
M.D.O.
3.0
6.0
1.0
4.0
200-sec.oil
5.0
10.0
3.0
7.0
12.4
18.0
10.0
15.0
12.0
18.0
10.0
15.0
Fueloilused \
Totalbase number
mgKOH/g
HCtO4
HCI
method method
HCI
method
\letnoa
1,500-sec.
oil
oil
3.500-sec.
7.000-sec.oil
2) OilChangeCriteria
Sinceoil changecriteriavaryas dependedon conditionsof use of the engine,an instanceof the criteria
maybe setforthas followsalthoughtheycouldnotfixeduniformlyon baseof the time usedalone.
(1)Askyourlub.oil supplierto analyzethe lub.oil beingusedand thusto determinewhetherthe oil can
befurtherusedcontinually
or nol
2003.10.20R
5-8
Oil)
WATER(Lub.
5. FUELOlL,LUB.OIL& COOLING
YANMAB 61IT8(AL-Y
Sample500 cc of lub.oil at leastfrom the drainplug of lub. oil strainerimmediatelyafterstoppingthe
of lub.oil.
enginefor askingtheanalysis
cleanness
(2) Procuring
a spottestkitto learnthe remainingtotalbasenumber,degreeof contamination,
sucha
most
of
using
make
the
qualitiesof lub.oil used,etc. as a simpleway of criteria,
dispersing
spottest kit.
(3) Shouldeitherof theaforementioned
criteriabe not possible,changethe entirevolumeof lub.oil with
holdingthe oil volumeof 1 ltr./PS
the newoneat about1,500runninghoursin the caseof constiantly
withthe newoil.
by replenishing
5-2-3.Listof Lub.Oil Brands
API ServiceGradeCE or CD/SAE30 or 40
Marinedieseloil
M.D.O.
FuelOilSpec
Division
TotalBase
Number(LB.N)
fuel oil
lntermediate
No.1at 100"F)
1.P.O.=(R.W.
200sec.Oil
16-25
9-15
Heavyfueloil
No.1ai 100"F)
'-1.P.6.=1R.W.
1,500sec./3,500sec./7,000sec.Oil
3O-42
Supplier
YANMAR
YANMARMARINE
SUPEROIL40
IDEMITSU
KOSAN
OILSX3O,
SX4O
DAPHNE
MARINE
SW4O
MARINE
OILSW3O,
MARINE
OILSW3O,
SW4O DAPHNE
DAPHNE
OILSH4O
MARINE
MV4O DAPHNE
DAPHNE
MARINE
OILMV3O.
CASTROL
MCL30,40
MHP3O,40
CASTROL
SEAMM EXTRA3O,40
CASTROL1LX203,204
BRITISH
DS}153,154
BPENERGOL
PETROLEUM
MARINE
DELO1OOO
OIL30.40
CASTROLTX303, 304
CASTROLTX403, 404
304
204 BP ENERGOLIC-HFX3O3.
BP ENERGOLIC.HFX2O3,
MARINE
OIL30,40
DELO3OOO
MARINE
OIL30,40
DELO34OO
TARO30 DP30,40
ChevronTsxaco
TARO
XD1230,40
(FAMM,Caltex)
MARINE
OIL30,40
DELO2OOO
TARO20 DP30,40
cosMootL
COSMO
MARINE
SUPER30.40
3025,4025 cosMo MARINE3040.4040
cosMo MARTNE
FUJIKOSAN
FUKKOL
MARINE
312.412
FUKKOLMARINE32O,420
330,430
FUKKOLMARINE
MOBILGARD 312,412
MOBILGARD 330,430
MOBILGARD330,430
MOBILGARDUO,44O
EXXMAR30 TP3O,40
EXXMAR40 TP3O,40
TARO
XD1630,40
MOBIL
GARD312,412
EXXONMOBIL
EXXMAR12TP3O.40
KTGNUS
OIL
KYGNUSMARINEDX 30. 40
JAPAN
D.13.D-14
JOMOMARINE
ENERGY/ELF Dtsou M3015.4015
KTGNUSMARINEDX330,340 KYGNUSMARINEEX330.440
JOMOMARINED.23,D-24
AURELTA
3030,4030
JOMOMARINED-33,D-34
AURELIAXT 3040,4MO
CHEVRON
MARINEOIL30.40
DELO1OOO
MARINEOIL30,40
DELO2OOO
MARINEOIL30.40
DELO3OOO
SHELL
OIL30,40
GADINIA
RIMULACT OIL 30, 40
RIMULA
OIL30,40
RIMULAOIL30,40
RIMULA
FB OIL30,40
ARGINAT OIL30,40
ARGINAX OIL30.40
2003.10.20R
5-9
\A/bter)
WATER(Cooling
5. FUELOlL,LUB.OIL& COOLING
YADTWAB 61118(A}L-V
5-3.Cooling Water (EngineJacket Water)
5-3-1.Criteriaon CoolingFreshWater
(1) Use pure water (distilledwater) or tiapwater.
(2) Use the water having the propertiesshown in the followingtable.
WaterQuality
Recommended
pH 298 K (25"c)
6 . 3- 8 . 0
Total hardness(CaCO3)
< 1 0 0p p m
Chlorineion (Cl-)concentration
< 100ppm
M alkalinity
30-100ppm
Ammonium
ion(NH4*)conc.
< 0.05 ppm
-)
Sulfate ion (SOa- concentration
< 1 0 0p p m
residue
Evaporated
< 400 ppm
Do notusehardwater.
lf hard water is used. scale adheresto
waterchamberssuchas cylinderheadand
cylinderwaterjacketsand may causean
overheat.Pay your particularattentionto
thisregard.
5-3-2.Selectionof and Controlon CorrosionInhibitor
(1)Add a corrosioninhibitorto coolingfreshwaterbecauseuseof freshwatercausesa dropin strength
of partsandthe coolingefiectthroughcorrosionof waterchamberandadheringof scale.
(2) Selecta conosioninhibitorwhichdoes not havean adverseeffecton partsof the coolingwatersystem becauseparb madeof castiron,carbonsteel,brassand bronze,are usedin the coolingwater
systemof an engine.
. In the casewherealuminummaterialsare usedin the coolingwatersystem,consultthe supplierof
corrosioninhibitorbecausea kindof corrosioninhibitorto be useddiffersin thiscase.
. As to the addingquantityof and concentration
controlon corrosioninhibitorand additionand handlingof supplementary
adjuster,obeythe criteriaset by the supplierof corrosioninhibitor.
. In the casewherethe concentration
annuallychange
of conosioninhibitorcouldnot be controlled,
the coolingwaterby the totalvolume.
@ Do notdumpcoolingwaterto whichthe corrosioninhibitorwasaddeddirectlyto theoceanor river.
Sincethe methodof treatingthe wasteliquorhas beenprovidedfor in the law,suchliquidhasto
givenby the supplierof conosioninhibitor.
be treatedaccordingto instructions
@ Do not mix differentbrandsof corrosioninhibitor.(ln the casewheremixingof differentbrandsof
conosioninhibitoris unavoidable,
consultthe suppliersof conosioninhibitor.
A
corrosion
inhibitor
is
chemical
for industrialwatertreatmentuse;do not use it in the drinking
@
waterline.
@ \fvtrenhandling,wear rubberglovesand gauzemaskto avoiddirectcontactwith handsor other
partsof the body.
with
comesin contactwith skin,eyesor mouth,washout thoroughly
O tt tne chemicalaccidentally
fteshwater.lf the problempersists,consulta doctor.
2003.10.20R
5-10
Water)
WATER(Cooling
5. FUELOlL,LUB.OIL& COOLING
YAr.nM
6]|!8(AL-V
(3) Recommended
brandsof corrosioninhibitor
of the coolingwatersystemare
inhibitorapplicable
to the enclosedcircuitspecification
Brandsof corrosion
shownin thefollowingtiable.
Brand
Antirust
RoyalCaviruston
* YANMARRoyal Freeze
Polycrin
l- 109
Brand
Supplier
YanmarSangyo
Co.,Ltd.
DieselGuardNB
Nalcool2000
Kurilex
L-222
*Nalfleet9-111
Hi-molAM- 5
* OlgardC-601
NALCOJapanCo., Ltd.
Nalfleet9 - 108
Neos PN - 106S
Hi-molL - 10
UNITOR& Taiho
Co..Ltd.
lndustries
Ltd. Rocor NB Liquid
Kurita\AhterIndustries
Polycrinl - 175
Neos PN - 106
Supplier
Neos Co.. Ltd.
UniprotPC - 200
Taiholndustries
Co.,Ltd.
OrganoCo., Ltd.
UniprotPC - 300
YukaKogyo
Co.,Ltd.
Nippon
ShadanK
Co..Ltd.
OtsukaChemical
LiquideWT
ASHI.ANDJAPNCO.,Ltd
. In the casewherethe coolingwatersystemis of the enclosedcircuitspecification,
consultthe supplierof conosioninhibitorbecausesomebrandsdropin the concentration
of corrosioninhibitorearly.
. Noticea corrosioninhibitorwhichdoublesas an anti-freezehas a low thermalconductivity
and may
be overheated
duringa loadrunning.
. In thecasewherealuminummaterialsare in the coolingwatersystem,usea brandof corrosion
inhibitorasterisked
above.
2003.10.20R
5-11
Checking)yeraren
in Maintenance
CHECKING(Precaution
6. MAINTENANCE
€tl8(A)L-V
CHECKING
6. MAINTENANCE
6-1.Precautionsin MaintenanceChecking
for troubleprevention.The
To use an enginealwaysin good order,checkingis necessaryperiodically
of the engine,
by application
becauseit is influenced
periodof checkingcan not be fixedindiscriminately
circumstance.
quality
daily
handling
and
oil
and
lub.
oil
used,
of
fuel
of use,
conditions
. The followingtables of checkingshow the standardcheckingfrequency.Performthe initialoverhaul
servicingaccordingto these checkingtables.Then, based on the obtainedchecking(on wear corrosion, accumulationof carbon, accumulationof sludge and others),make the most economicalchecking schedule suitable for your engine, and conform to the specified schedule from the second
checking.
. As for the items whose checkingfrequencyis shown by both the accumulatedoperationhours and
numberof days,schedulethe checkingat the earliertiming.
6-2.Tableof PeriodicalChecking
(1) Formarineserviceengine
. SeeTable6-1.
Checking
1) Tableof RoutineMaintenance
.
. SeeTable6-2.
.
.
.
Diesel
Oil
2) CheckingTablefor EngineUsingMarine
Equivalent
Tablefor EngineUsingHeavyFuelOil (R.W.No.1at 100"F1,500 7,000-sec.
3) Checking
. . SeeTable6-3.
FuelOil)
(2) Forlandserviceand/orgeneratorengine
Setseparately
of DieselServiceGenerating
& Servicing
of Checking
withthe Specifications
tn accordance
stipulated.
6-3.RoutineMaintenanceChecking& AdjustmentProcedures
of RunningPerformance
6-3-1.Measurement
Pressure(Pmax)
of Max.Combustion
6-3-2.Measurement
of FuelInjectionVolume(RackScale)
6-3-3.Regulation
of FuellnjectionT'iming
6-3-4.Adjustment
of InjectionPressure
of
6-3-5.Checking FuelInjectionValve& Adjustment
of Suc./Exh.ValveHeadClearance
6-3-6.Adjustment
of Lub.Oil Pressure
6-3-7.Adjustment
of Lub.OilTemperature
6-3-8.Adjustment
of Fuel.Oil Pressure
6-3-9.Adjustment
Valve
6-3-10.Checkingof Cyl.JacketCoolingWaterThermostatic
of Lub.Oil BypassStrainer
6-3-11.Cleaning
6-3-'12.
Cleaningof Lub.Oil Strainer
of Fuel.Oil Filter
6-3-13.Cleaning
of StrainerElement
Cleaning
6-3-14.
Blower
6-3-15.Washingof Turbocharger
of PressureGauge
6-3-16.Maintenance
Deflection
of Crankshaft
6-3-17.Measurement
Volume(forEngineUsingH.F.O.)
lnjection
PumpPinionLubricating
of
Fuel.
Adjustment
6-3-18.
of Fuel.OilSealPot(forEngineUsingH.F.O.)
6-3-19.Maintenance
Zinc
of Anticorrosive
6-3-20.Checking& Replacement
1999.7.2R
6-1 (Volume:38pages)
(Routing
Checking) yAmoAB
6. MAINTENANCE
Maintenance
CHECKING
6N|8([)L-Y
Table6-1.Tableof RoutineMaintenance
Natureof Work
CheckingArea
Weekly
Daily
Startingair tank
Pressurecheck
Governorgear
Gov.oilvolumecheck
Monthly(or 300-500hrs.)
Draining
Checking& lubricationof
linkagesystem
leak from oil
pump Check on
Fuelfeed
seal
E Fueloilfilter
Draining
Back-washing (blow-off)
o
o
U)
o
o
Check on rack scale
position
Fuel injection
Pump
*Checkon pinionlubricating Volume
LL
Checkon loosenessof
lock nuts
Injectiontiming
adjustbolt
E
c)
o
U)
Lub.oil cleaning
The batchcleaningby
the ourifier
Lub.oil propertyanalysis
Lub.oilstrainer Draining
Back-washing (blow-off)
*(2-3days)
Overhaulcleaning
* ( 1 0- 1 5 d a y s )
Lub.oil bypass
strainer
Overhaulcleaning
Commonbed
(or oil pan)
Oilvolumecheck
o
-ci
J
cleaning
Overhaul
Coolingwater
pump
Check on leak from
mechanicalseal
Prefilterwashing
Turbocharger
Blowerwashing
Check that electricalwiring is fastend firmly.
Startingair motor
o
E
L
o
Check that no air leaks
from the air pipe and the
joint.
Eachpressure Check on defectiveindigauge
cation
Eachthermom- Check on defectiveindication
A?AT
Checkon loosenessof
bolts & nuts
Check on leaks of variEngineappearance ous parts
(coolingwater,fuel oil,
lub. oil, boostair &
exhaustgas)
Eachpipesystem
Leak check
Note:An asterisk(") refersto only for engineusing heavyfuel oil (H.F.O.)
2003.12.10R
6-2
(EngineUsingMarineDieselOil)
6. MAINTENANCE
CHECKING
151118(A)L-yr
vAnry;Aa
Table6-2.CheckingTablefor EngineUsingMarineDieselOil (1i3)
-a-
An asterisk(*) given in the followingtables refersto the timing of initialcheck after the initial start or
part replacement.Performthe check from the secondtime and onward at the ordinaryfrequency.
Checking& Servicing
Frequency(hrs.)
Div.
Partto Be
Checked
Natureof Service
rr)
hcl
I
I
o
o_
N
E
o
o
E
(o
o-
rr)
I
*
g
>
I
o
o_
c!
I
o
o
o
od
o
d
>
r)
I
o
u
b
N
Fuel injection
Drawing-outcheck & adjustment
valve
Check& adjustmentof the valve head clearance
(U
o
L
o)
:
o
1,s00- 2,000
o
o
o
Check of valve spring
& checkof valverotator
Checkdisassembly
Disassembly,
check& cleaning
Cylinderhead
valveseat
Grinding
of suc./ehx.
o
o
o
o
o
o
o
o
o
o
o
testof waterchamber
Scalecleaning& hydraulic
Replacementof stem seal (Suc./Ehx.Valve)
Checkof cyl. head bolt tighteningforce
*
Drawing-out,cleaning,checking& measurement
of piston
Piston
Check& measurement
of pistonrings
Check& measurement
of pistonpin
Check& measurementof pistonpin metal
Connecting
rod
1st time:500-800hrs
metal
Check& measurement
of crank-pin
Checkof connectingrod bolt tighteningforce
Changeof connecting
rodbolts
20.000hrs.
o
Innerdia.checking,
cleaning& measurement
Cyl.liner
g,
o
o,
't
Crankshaft
Drawing-out,
check& cleaningof waterjacket
part
o
o
Measurement
of crankpinouterdia.& journal
Measurement
& adjustmentof deflection
o
o
o
o
Disassembly,
metalchecking
& measurement
L
o
'6'
Checkon tighteningforce of main bearingclampMain bearing
ing bolts
Checkon tighteningforce of side bolt
Checkof cam& rollerbearino
Disassembly
& checkof fuelpumptappet
Camshaft
Disassembly,
check& measurement
of swingarm
o
o
o
Drawing-out
of crankshaft& bearingcheck&
measurement
Check of tooth bearing & backlash
'l'iming
gear
2002.10.7R
Disassembly
of idlegear& check& measurement
of bearing
Checkof idlegearmountedshafttightening
force
6-3
o
o
o
o
(EngineUsingMarineDieselOil)
6. MAINTENANCE
CHECKING
Table6-2.
Tablefor
7ANJ2AB 6Ill8(AL-l/
MarineDieselOil
Partto Be
Checked
Fuelfeed
Checkof toothbearing& backlash
pump,lub.
oil
pump,& cold
Disassembly,
check& measurewaterpump
mentof bearing
driving
intermediate Checkof gearmountedshafttightgear.
eningforce
Change of hydraulicfluid
Disassembly
& checkof toothbearing & bearing
1sttime:300- 500
Checkof deflector& replacement
Replacement
of o-ring
Change(depended
on resultsof
propertyanalysis)
Disassembly,
check& cleaning
Disassembly
& checkof pres.reg.
valve& safetyvalve
Change the elementof lub. oil
strainer
2002.5.15R
6-4
Changetheelement
Whenthelub.oil
pressuredroppedby
0.3MPa(3kgf/cm2)
6.
UsingMarineDieselOil)
CHECKING(Engine
MAINTENANCE
Table6-2.
Tablefor E
MarineDieselOil
Partto Be
Checked
check& cleaning
Disassembly,
Disassembly,
check,cleaning& hydraulic test
Sea water cooling parts
on resultsof propChange(depended
ertyanalysis)
zinc& replaceCheckof anticorrosive
ment(Aircooler& Lub.oil cooler)
& cleaning
Disassembly
Disassembly,
check,cleaning& hydraulic test
Disassembleand clean the mufflerelement. (Clean with neutraldetergent.)
Startingair
motor
Removethe startingmotorfromthe
engineandturnthe piniongearmanually,checkthatit turnssmoothlyand it
sound.
emitsno abnormal
cleaning
and
inspection,
Disassembly,
replacement
of greaseof movingparts.
of o-ring,firstreduction
replacement
gearbearingandspecialgrease
inside
the reductiongear.
inspection,
cleaning
and
Disassembly,
parts.
grease
moving
of
replacement
of
replacement
of o-ring,1st& 2nd reducandspecialgrease
tiongearbearings
insidethe reductiongear.
Calibration
of indication
2002.5.15R
6-5
YADTM,AB6Ill8(A)L-V
MAINTENANCECHECKING(EngineUsingHeavy FuelOil)
6.
YADIM,AB 6Ill8(A)L-Y
EquivTablefor EngineUsingHeavyFuelOil(R.W No.1at 100'F1,500- 7,000-sec.
Table6-3.Checking
(1/3)
alentFuelOil)
An asterisk(.) givenin the followingtablesrefersto the timingof initialcheckafterthe initialstartor
partreplacement.
Performthe checkfromthe secondtimeandonwardat the ordinaryfrequency.
Checking& Servicing
Frequency(hrs.)
o
o
6-
Div.
Partto Be
Checked
N
I
Natureof Service
I
o
oo
c;
E
o
oro
I
o
6i
o
o
E
s-
,i
I
o
o
o
cl
I
o
o
o<o
g
e
@
o
I
o
N
Fuelinjection
check& adjustment
Drawing-out
valve
o
(D
:
O
1.500- 2,000
Check & adjustmentof the valve head clearance
Checkof valve spring
Checkdisassembly& checkof valve rotator
Disassembly,check& cleaning
Cylinderhead
Grindingof suc./ehx.valveseat
o
Piston
Connecting
rod
Cyl.liner
o
E
(L
o,
o
o
o
o
o
testof waterchamber
Scalecleaning& hydraulic
Valve)
of stemseal(Suc./Ehx.
Replacement
Check of cyl. head bolttighteningforce
Crankshaft
o
20,000hrs.
o
cleaning
& measurement
Innerdia.checking,
Drawing-out,
check& cleaningof waterjacket
part
of crankpinouterdia.& journal
Measurement
Check of idle gear mountedshaft tighteningforce
6-6
o
o
o
o
o
o
o
o
Check & measurementof crank-pinmetal
Check of connectingrod bolt tightening force
Change of connectingrod bolts
& measurement
metalchecking
Disassembly,
forceof mainbearingclampCheckon tightening
Main bearing
ing bolts
Checkon tighteningforceof sidebolt
Checkof cam& rollerbearing
Disassembly
& checkof fuelpumptappet
Camshaft
of swingarm
check& measurement
Disassembly,
& bearingcheck&
Drawing-out
of crankshaft
measurement
Checkof toothbearing& backlash
Disassembly
of idlegear& check& measurement
Timinggear
of bearing
2002.10.7R
rr
& measurement
checking
Drawing-out,
cleaning,
of piston
of pistonrings
Check& measurement
of pistonpin
Check& measurement
of pistonpin metal
Check& measurement
Measurement& adjustmentof deflection
lst time:500-800hrs
o
o
o
o
o
o
o
o
o
o
o
o
o
6. MAINTENANCE
CHECKING(Engine
UsingHeavyFuetOit)
YA}'MAR 6J|T8,A,L.Y
Table6-3.Checking
Tablefor EngineUsingHeavyFuelOil(R.W.No.1at 100'F1,500- 7,000-sec.
EquivalentFuel
Partto Be
Checked
Checkof toothbearing& backlash
Fuelfeed
pump,lub.oil Disassembly,
check& measurepump,& cold mentof bearing
waterpump
driving
Checkof gearmountedshafttightintermediate eningforce
gear.
Changeof hydraulicfluid
Disassembly
& checkof toothbearing & bearing
1sttime:300- 500
Checkof deflector& replacement
Disassembly,
cleaning& check
Checkon fillingof ethyleneglycol
Replacement
of Accumulator
(for
Fueloilline:F.O.Mainpipe& Pressureregulating
valve.)
F.O.control&
stopair pis- Replacement
of o-ring
ton
Change(depended
on resultsof
propertyanalysis)
Disassembly
& checkof pres.reg.
valve& safetyvalve
Changethe elementof lub. oil
strainer
2002.5.15R
6-7
Changethe element
Whenthe lub.oil
pressuredroppedby
0.3MPa(3kgtlcm2)
6.
UsingHeavy Fuel Oil)
MAINTENANCECHECKING(Engine
YAMUAB 6]|T8(A)L-Y
EquivTable6-3.CheckingTablefor EngineUsingHeavyFuelOil (R.W.No.1at 100"F1,500- 7,000-sec.
alentFuel
Checking Servicing
Cycle(hrs.)
Partto Be
Checked
Disassembly,
check& cleaning
Coolingwater
(Freshwater)
Disassembly,
check,cleaning& hydraulic test
on resultsof propChange(depended
ertyanalysis)
Check of anticorrosivezinc & replacement (Air cooler & Lub. oil cooler)
Startingair
motor
Disassembly,
check,cleaning& hydraulictest
Disassemble
andcleanthe mufflerelement.(Cleanwithneutraldetergent.)
Removethe startingmotorfrom the
engineandturnthepiniongearmanually,checkthat it turnssmoothlyand it
emitsno abnormalsound.
inspection,
cleaningand
Disassembly,
replacement
of greaseof movingparts.
replacement
of o-ring,firstreduction
gearbearingandspecialgrease
inside
the reductiongear.
Disassembly,
inspection,
cleaningand
replacement
of greaseof movingparts.
replacement
of o-ring,1st& 2nd reductiongearbearingsandspecialgrease
insidethe reductiongear.
2002.5.15R
6-8
Procedures)
CHECKING(MaintenanceChecking&Adjusting
6. MAINTENANCE
1ANMAB
6tt8(A)L't/
6-3.RoutineMaintenanceGhecking& AdjustingProcedures
of RunningPerformance
6-3-1.Measurement
oncea daywhilethe loadis stable.
Checkand recordthefollowingengineperformances
(Pmax)
pressure
(1) Eachcylinderinternalmax.combustion
(2) Eachcylinderoutletexhaustgastemperature
(3)Turbocharger
inletexhaustgas temperature
(atthecoolerinlet)
(4) Lub.oiltemperature
(at the engineinlet)
(5) Lub.oil temperature
(at the engineinlet)
(6) Coolingwatertemperature
(at the engineoutlet)
(7) Coolingwatertemperature
(at the air coolerinlet)
(8) Coolingwatertemperature
(at the air cooleroutlet)
(9) Coolingwatertemperature
(at the lub.oil cooleroutlet)
(10)Coolingwatertemperature
(11)Boostairtemperature
(forengineusingH.FO.)
(12)Engineinletfueltemperature
indicated
on thegaugepanel
(13)Eachpressure
(14)Roomtemperature
PerformanceConfirmingPoints
Drawing6-1(1121Running
SideI
lOperating
Gauge
FuelOil Pressure
PerformanceGonfirmingPoints
Drawing6-1(2121Running
Side
EnqineFrontEnd
yatrmeR
6. MAINTENANCECHECKING(MaintenanceChed<ingMdjustingProcedures)
6X|8(AL-I/
valvesgiveninthe Recordsof ShopTrialor the Recordsof Transfer
Comparereadingswithcorresponding
or servicingrequired.
Trial,and if foundto be abnormal,carryoutan adjustment
vary accordingto the roomtemperature,
Referto the followingitemssincethe engineperformance
condiltions
of load,etc.
watertemperature,
(1) The dispersionof the maximumcombustionpressure(Pmax)amongcylindersis normalif it is
within0.SMpa(Skgf/cm2).
. Pmax may rise considerably
of fuel oil. However,in any case, run the
as dependedon properties
engineto keepPmaxbelow17.7Mpa(180kgf/cm2).
. Reflationbetweenthe Pmaxandthe boostair temperature
drops,Pmax rises.
if the roomtemperature
rises,Pmaxfalls;conversely,
lf the room temperature
3"C.
change
(2kgf/cm2)
room
temperature
againstthe
Thereis a tendencyof Pmax0.2 MPa
recordedin the TransferTrial.
temperature
(2) Exhausttemperature
refersto the corresponding
. The dispersionof the exhausttemperature
amongthe respectivecylinderoutletsis normalif it is
within40"C.
to forcerevisingthis
is foundnotuniformamongcylinders,it is unnecessary
Evenif this temperature
among
cylinders.
found
uniform
Pmax
are
if thefuelinjectionvolumeand
non-uniformity
. Relationbetweenthe roomtemperature
andthe exhausttemperature.
change.Neverthevariesat the rateof abouttwicethe roomtemperature
The exhausttemperature
good
the
engine,etc. and
of
a
servicing
less,use the enginewithinthe limitvalues,maintaining
passage,
exhaustpressure,
and suction/exhaust
reducingthe loadbecausefoulingof turbocharger
propertiesof fueloil,etc.mayinfluence
thisrelation.
(Pmax)
Pressure
of Max.Combustion
6-3-2.Measurement
becausethe pressureindicatorbecomeshot.
Weargloveswhentakinga measurement
(1) Preparethe followingexclusive
tools:
No.
ToolDescription
Exclusive
PartNo.
O
cockturninghandle
Pressureindicator
153605- 92360
@
Pressureindicator
137600- 93751
Drawing6-2.PmaxMeasurementProcedures
@
Max.PressureIndicatorCock
1998.2.27R
6-10
6.
MAfNTENANCE
CHECKING(MaintenanceChecking&AdjuslingProcedures)
venry1,aA 6tf8(Al|.-!/
(2) Openthe valveof pressureindicator
cockwithuseof pressureindicatorcockturninghandleO , and
lightlyrace/revup the enginefor twoto threetimes.
(Forprevention
of dustandforeignmatterfromintrudingintopressureindicator)
pressure
(3) Attachthe
indicator@ , andcloseitsexhaustvalve@ .
(4) Be sureto fullyopenthe valveof pressureindicatorcockwitheuseof turninghandle,and closethe
indicator
cockwhenthe pressurebecomesthe highest.
(5) Afterreadingoutthe Pmax,opentheexhaustvalveof pressureindicator.
(6) Detachthe pressureindicatorwhenits needleshows0 MPa(0 kgf/cm2).
(Whenthe pressureindicatorcockis foundhardto loosen,usethe turninghandle.)
(1) Should the dispersionin Pmax among cylindersexceed 0.5MPa(5kgflcmz),
adjust it with the injection timingof within1" .
(2) Shouldthe Pmax exceedits limitingvalue,adjustthe injectiontiming upon examiningthe engine
performances.
Volume(RackScale)
of FuelInjection
6-3-3.Regulation
(1) Shouldthe dispersionin exhausttemperatureamong cylindersexceed40'C under the serviced
state of the fuel injectionvalve,adjustthe rack of the correspondingfuel injectionpump.
(2) Keep the rangeof dispersionof rack adjustmentamong cylinderswithin one scale graduation.
Drawing6-3.FuellnjectionVolumeRegulatingProcedures
FUELVOL.
Pump
FUELINCREASEFuelInjection
FUELDECREASE._
(1) LoosenthelocknutO.
(2) Turnthe adjusting
screw@ as follows:
rise)
volume(exhausttemperature
Toincreasethe injection
Clockwise:
drop)
Todecreasetheinjectionvolume(exhausttemperature
Counterclockwise:
(3) Tlghtenthe locknut.
6-11
yanrtaa
CHEOKfNG{MaintenanceChed<ingMdjustingPrccedur*)
6. MA,NTENANCE
6tt8lA)L-!7
Timing
of FuelInjection
6-3-4.Adjustment
lf it is necessaryto adjust the fuel injectiontiming as based on the data recordedduring a load run, stop
the engine,and adjustthe timing accordingto the followingprocedures:
1) Procedures for checking the fuel injection timing
(1) Turn the flywheel to align the marked-offline on the body of fuel injectionpump with that on the
plungerguide.
(2) The scale graduationpointedout by the flywheel pointer at this time indicatesthe fuel injectiontiming.
(The flywheelscale within the range of -r 10 to 30"from the T.D.C.is graduatedin 2", and outsidethe
range,5'.)
2) Adjustment of the injection timing
Do not bringyour fingersclose to the lock nut nor oil shield plate while turning'theflywheel.Otherwise, your fingers may be caught in, resultingin an injury.
(1) Preparethe followingexclusivetools:
PartNo.
ToolDescription
Exclusive
wrench(M24)tor adjustingbolt
Single-ended
138603-92510
Double-endedwrench
28110- 220240
Ratchethandlefor turning
147673 - 92851
Socket(M24)tor turning
421't1- 001850
Drawing6-4.Fuel InjectionTiming Adjusting Procedures
oiistrietapnte
(2)Turnthe flywheeltopositionthe adjustingboltO at the lowermost.
(3)Loosenthelocknut@.
(4)Turntheflywheelin the directionof enginerotationso as to aligntheflywheelpointerwiththe injection
by the flywheelscale)of a cylinderto be adjusted.
timing(indicated
Advancethe injectiontiming: Pmaxrises.
Pmaxdrops.
Delaythe injectiontiming:
6-12
6. MAINTENANCE
Checking&Adjusling
Procedures)
CHECKING(Maintenance
vANruAB
6Ill8(AL-l/
(5)Turnthe adjustingboltto alignthe marked-off
lineon the pumpbodywiththaton theplungerguide.
(6)Turnthe flywheelto positionthe adjustingboltat the lowermost.
(7)Tighten
thelocknut.
(Havethe adjustingboltfixedwith use of a wrenchso as not to allowthe boltto turntogetherwhen
locknutis tightened.)
After having adjusted the injection timing, turn the flywheel in the direction of engine rotation. When
the adjustingbolt has come to its uppermostposition,further push up the oil shieldplateto make sure
there is allowancefor the pump stroke. (Use the fuel pump primingtool.)
Drawing6-5.Fuel lnjectionPump PrimingTool
No. ExclusiveToolDescription
O
Priminglever
@ Leversupport
Part No.
146673- 92920
J--,i
146673- 92930
{---'I-.l
@
6-3-5.Checkingof FuelInjectionValve& Adjustmentof lnjectionPressure
lmproperservicingof fuelinjectionvalvegreatlyaffectsthefuelcombustion
andoutput.However,
it is generallydifiicultto specifythe servicingfrequencywhichdependson suchas the fuel oil usedand service
load.Therefore,
determine
the properservicingfrequencybasedon suchas changesof exhausttemperatureandexhaustcolor.
In the engineusinghighviscosityfuel oil, the fuel injectionnozzleis indirectlycooled.Forservicing
procedure.
anddismantling
thefuelvalve,referto Fig.36-C:Fuelinjectionmaintenance
1) Drawing-outof a fuel injectionvalve
(1)Preparethefollowingexclusivetools:
No.
Exclusive
ToolDescription
PartNo.
O
Bodyof fuel injectionvalvedrawing-outtool
146673- 92340
@
Drawing-outbolt
146673 - 92330
@
Nut
26732- 160002
Hexagonalwrench key (M8)
28150- 080000
Hexagonal
wrenchkey (M6)
28't50- 060000
2000.8.8R
6-13
6. MAINTENANCECHECKING(MaintenanceChecking&AdjuslingProcedure)
6Ill8(AlL-!/
vAnruAA
Drawing6-6.FuellnjectionValveDrawing-outProcedures
@
RockerArm
ShaftPedestal
Fuel ValveTighteningNut
@
Fuel ValveGuard
€/
Nozzle Sleeve
Case Nut Packing
(2) Remove the clamping bolts @ of fuel injectionpipejoint @ with use of hexagonalwrench key. (Also
remove the bolts on the fuel injectionpump side.)
(3) Loosen the cap @ nut of fuel injectionpipe @, and removeit with the fuel injectionpipe.
(4) Remove the fuel valve tighteningnut.
Handle the injectionpipe with care becauseoil leakagetakes place if the sphericalsurface on either
end of fuel injectionpipe is flawed.
(5) Screwthe drawing-out
bolt@ intothefuelvalveguard.
(6)Attachthe bodyof drawing-out
toolO .
(7)Tightenthe nut@ to drawoutthefuelvalve.
(8) Drawout the casenut packing.(lt maybe drawnouttogetherwiththefuelvalve.)
2) lncorporatingthe valve
of fuelinjectionpressureis finished,
of thefuelvalveandadjustment
checkor replacement
Aftercleanir.rg,
thefollowingpoint:
incorporate
the fuelvalvewhileobserving
(1) Takecarenotto damagethetip of nozzlesleevewhenclearingthe fuelvalvemountinghole.
(2) Replacethe casenut packingwithnewone.
(3) Firsttightenthe cap nut@ of fuelinjectionpipe,andthentightenthe fuelvalvetighteningnut.
(a) Do not makea mistakein the incorporating
directionbecausesphericalwashersare usedto the
joint
pipe
fuel
injectionpumpside.
bolts
on
the
clamping
injection
pipe
(5)Tightenthe clampingboltsof fuelinjection joint@ on the cylinderheadsideand the fuel injecandgraduallyin two or threetimes.
tion pumpsidealternately
6-14
CHECKING(MaintenanceCheckingMdjuslingProcedures)
6. MAINTENANCE
yartne
6Nl8(AlL-l/
3) Leaked oil check
During a run immediatelyafter servicing of a fuel injectionvalve, check for oil leakedfrom the overflow
pipe.
(A) Leaked oil take-off part of the injectionpipe and injectionpipejoint
(B) Leaked oil take-off part from the nozzle clearance.
Drawing 6-7. Leaked Oil Take-off Parts
I F,,t
PipeJoint
, Injection
I
4) Disassembly & cleaning of a fuel injection valve
(1) Preparethe followingexclusivetools:
PartNo.
ExclusiveToolDescription
Socketfor casenut
146673 - 92260
wrench(M41)for pressureregulation
Single-ended
146673- 92270
Hexagonalwrench key (M8)
28150- 080000
(2) Cleancarbonadheredto the nozzleexterior,and thendisassemble
valve.(Removal
thefuelinjection
of carbonis facilitatedby soakingthe nozzlein the carbonremoveror stocksolutionof cresol.)
(3) Firstremovethe fuelvalveguard,andthendisassemble
order
thevalvesequentially
in theascending
of numbersshownin the drawingbelow.
6-15
6.
Procedures)
MAfNTENANCECHECKING(lilaintenanceChecking&Adjusling
vADtJy,A;; 6Ill8(A)L-l1/
Drawing&8. FuelValveDisassembling
Sequence
Fuel InjectionValve
Guard (Flange)
HolderSet Bolt
Flange
Fuel InjectionValve
Holder
Fuel InjectionValve
Holder
O-ring
O-ring
O-ring
@
o
\U
@
@
16\
@
@
@
O-ring
@
@
@
@
O-ring
@
\?
(4) Check& servicingof variousparts
corroded,replacethe
of nozzle@ . lf foundnoticeable
o Checkfor sulfuricacidcorrosionon the periphery
nozzlewith a newone.
replaceit witha newone.
o lf the nozzlevalvehasstuckof it doesnotmovesmoothly,
"A"
o Whenthe steppedwear of valvestopspacer@ exceeds0.1Smm,replaceit witha newone.
valvewiththe respectively
newones.
o Replacethe casenut@ and O-ringsof bodyof fuelinjection
to holdsparepartsof nozzle,supposingthat its averageservicelife is about
o You are recommended
2,500hours.
payingattentionto the fol(5) Reassemble
a fuelinjectionvalvein the sequencereverseto disassembly,
lowingpaints:
(1) Do not makea mistakein the incorporatingdirection
of the springseat @ springshoe @ and
springshoeguide@.
(2) Tightenthe case nut to the specifiedtorqueusingan exclusivesocket.Excessively
tighteningit
maycausethe nozzleto malfunction
andthestraightpinto be broken.
[EQlCf,apterg. Tableor TighteningTorquesof MajorBolts
2001.2.28R
6-16
Procedurcs)
Checking&Adjus{ing
6. MAINTENANCE
CHECKING(Maintenanoe
yAry4oAn
6X!8(A)L-I/
5) Injectiontest & injectionpressureregulation
When operatingthe nozzle tester,be careful not to expose any part of your body to spray from the
injectionvalve.
lf exposed,you would be seriouslywounded because the injectionpressure is very high at 34MPa
(347kgr/cm2)
(1) Preparethe followingexclusivetools:
PartNo.
Exclusive
ToolDescription
Nozzletester
737600- 93110
Injectionpipefor nozzletester
1416't6 - 93420
Single-ended
wrench(M41)for pressureregulation
146673 - 92270
Socketfor case nut
146673 - 92260
Double-endedwrench(M41 x M46)
Drawing6-9.InjectionTest& lnjectionPressureRegulatingProcedures
NozzleTester
Set the fuel injectionvalvedownwards.
(2) Attachthe injectionvalveto the nozzletester.
(3) Whileslowlyoperating
the handleverof the tester,adjustthe screwing-in
of the pressureadjusting
pressure.
nutO to aftainthespecifiedinjection
(4) Quicklyoperatethe handleverof thetester(at rateof two to threestrokespersecond),and checkthe
stateof spray.lf the handleverof thetesteris operatedslowlyat thistime,fueloil runsdownafterthe
Thus,payattentionto
handleveris stoked,andyoumighterrinjudgmentthatthe nozzleis defective.
this regard.
. Repfacesucha cloggednozzleor nozzlewhichgivesa streakyinjectionwith the new one.
(5) The nozzlecan be usedcontinually
if the oil tightnessof the seatpartmaintainsa pressure2.0 MPa
(20kgf/cm2)
lowerthanthe specifiedinjectionpressureand allowsthe fuel oil to such an extentof
oozingoutfromthe nozzletip.
2001.10.24R
6-17
CHECKING(MaintenanceCheckingMdjustingProcedures)
6. MAINTENANCE
vAnruA3 61118(A)L-t/
stateof the pressure
(1)Whenreplacing
the nozzle,removethe casethe casenutunderthe loosened
adjustingnut. lf the case nut is loosenedundera highstateof the injectionpressure,the mating
surfacesol nozzleand spacerand the straightpin maybe damaged.
(2)Tlghtenthecasenutto the specifiedtorquewith useof exclusivesocket.
(6) When the injectiontest and adjustmentof injectionpressureare finished,tightenthe lock nut @ with
an exclusivesingle-endedwrench. (To preventthe adjustingnut @ from being turned togetherwith
the lock nut, lock it with a double-endedwrench.)
of Suc./Exh.ValveHeadClearance
6-3-6.Adjustment
becausethevalve
valveheadclearanceaccordingto the followingprocedures
Adjustthe suction/exhaust
to retaintwo suction(or exhaust)valvesby meansof the Tmechanism
of this engineis so constructed
shapedvalveguardwhichwill be distortedto causean abnormalwear to the valveguardguideand/or
valveguideunlessadjustedto retaintwo valvessimultaneously:
(1) Preparethefollowingexclusivetools:
Part No.
ToolDescription
Exclusive
Feelergauge,0.3-mmthick(suction)
28312- 300750
Feelergauge,0.4-mmthick(exhaust)
28312- 400750
Drawing 6-10. Valve Head Clearance Adjusting Procedures
O
@
@
iA
@
B
t
ValveGuard
hlll--u"
luii-
ll,-
(2) Turn the flywheelto bring the cylinderfor which the clearanceis to be adjustedto assumethe T.D.C.
of the compressionstroke.
Do not mistakethe T.D.C.of overlap for the instructedT.D.C.
6-1I
Procedures)
Checking&Adjusting
6. MAINTENANCE
CHECKING(Maintenance
ynrmae
6ill8{AlL-l7
(3) Loosenthe lock nuts @ & @ , and then loosenthe rockerarm adjustingscrewO and valveguard
adjusting
screw@.
(4) Pressdownthe centerof the valveguardfrom above(sothatthe clearance@ becomeszerounder
this condition).Graduallytightenthe valve guard adjustingscrew @ so that the clearance@
lockthe adjustingscrew@ notto turn,andsecurelytightenthe
becomeszero.Afterthe adjustment,
locknut@ .
screwOandthevalveguard,
(5) Puta feelergaugeintoa clearance
@ betweenthe rockerarmadjusting
and graduallytightenthe rockerarmadjustingscrewO untilthe clearancebecomesnarrowenough
to permitthe feelergaugeto be smoothlydrawnout.Then,lockthe adjustingscrewO , and tighten
thelocknut@.
(6) Afterhavingsecurelytightenedthe locknut @ , checkthat thefeelergaugecan be smoothlydrawn
out.
The valve head clearanceof a suctionvalve and that of an exhaustvalve are different.Be carefulnot
to mistakethe clearanceof one valve for that of the other.
Valveheadclearance: lffiCtrapter
3. Tableof EngineStandardAdjustments
6-3-7.Adjustment
of Lub.Oil Pressure
The lubricatingoil pressureregulatingvalve has been integratedin the lubricatingoil pump.
Should the lubricatingoil pressurego out of the specifiedvalue, adjust it accordingto the followingprocedures:
(1) Beforeadjustingthe lub.oil pressure,
oilstrainers.
firstcleanthe lubricating
(2) Run the engine,and then adjustthe lubricatingoil pressureto the specifiedvalueonly afterthe
is stabilized.
lubricating
oil temperature
Drawing6-11.Lub. Oil PressureAdjusting Procedure
!
(1)LoosenthelocknutO.
(2)Adjustthe screwing-in
of the adjusting
bolt@ to regulatethe pressure.
... Thepressurerises.
Clockwise
...
Counterclockwise
Thepressuredrops.
(3) Securelytightenthe locknut.
o
@
6-19
CHECKING(MaintenanceChecking&AdjustingProcedures)
yaAltIUAn 6lll8(AlL-l/
6. MAINTENANCE
of Lub.Oil Temperature
6-3-8.Adjustment
An automaticthermostaticvalve has been equippedto the lubricatingoil cooler to rise the lubricatingoil
temperaturein a short time after the engine is startedand to maintainthe temperaturein the proper range
during a run. The lubricatingoil temperaturevarieswith a changeof the coolingwater temperaturein each
season and sea aria,a fluctuationin the coolingwater flow rate,fouling of the lubricatingoil cooler,etc.
The automaticthermostaticvalve has been set so that the lubricatingoil temperatureat the engine inlet
oC.However,if the lubricatingoil temperatureexceeds this range, adjust and check it
becomes 50 to 65
accordingto the followingprocedures:
1) Adjustment of lubricating oiltemperature
AdjustingProcedures
Drawing6-12.Lub. Oil Temperature
- +l r
{'r
i i
t{
Element
Piston
A
\a
A
o
(1)RemovethecapnutO, andloosenthelockthelocknut@.
(2) Checkthe projecting
dimension@ of the adjustingbolt@.
and makesurethe tem(3) Screwthe adjustingboltin the directionof an arrowshownon the nameplate,
peraturedrops.(Theboltscrewing-in
depthmustbe 17mmor less.)
foulingof the lubricatingoil
do not drop evenafterthe aboveadjustment,
Shouldthe temperature
be
piston
may
suspected.lnvestigatethe
of malfunction
of the element,etc.
cooler,stickingof a
proper
condition.
cause,and restorethe engineto the former
6-20
6.
Procedures)
MAINTENANCE
CHECKING(MaintenanceChecking&Adjusling
vAn77,AE 1$X|$(A)L-I/
2) Checkof automaticthermostaticvalve
oil cooler,and thencheckthe automatic
oilfromthe lubricating
Stopthe enginedischargethe lubricating
valveaccording
to thefollowingprocedures:
thermostatic
(1) Loosenthe bolt@ shownin Drawing6 -12,andthendetachthe cover.
(lf the pistonis catchingor stuck,restoreit to the propercondi(2) Checkif the pistonmovessmoothly.
tion.)
(3) Takeout the piston(incorporating
theelementwithea circlip)
and measurethe lift
(a) Soakthe elementin coldwaterandwarmwaterfor 3 to 5 minutes,respectively,
@ of elementspindle.
Drawing 6-13. Element Checking Procedures
Piston
Spring
Circlip
ElementSpindle
Liftof the elementspindle(normalpart)
CheckingWaterTemperature
Coldwaterof 30"Corless
Warmwaterof 65'Cormore
Lift@
5 + 0.1mm
Greaterthan23mm
(5) lf the lift of elementspindledoes not satisfythe values shown in the above table, replacethe element
with the new one.
(6) Adjust the projectingdimension@ of the adjustingbolt @ to 36mm, and then attachthe cover.
6-21
CHECKING(MaintenanceChecking&AdjustingProcedures)
6. MAfNTENANCE
6nl8{A}L-l/
VaXnaA
of FuelOil Pressure
6-3-9.Adjustment
valveis equippedto the end of fuel oil returnpipetogetherwitha damper
Thefueloil pressureregulating
whichabsorbsthe pulsatingpressureinsidethe returnpipe.
Drawing6-14.PressureRegulatingValveEquippedPoint
Gauge
FuelOil Pressure
Valve
PressureRegulating
(1) Beforeadjusting
thefueloil pressure,firstcleanthe fueloil filters.
(2)Adjustthefueloil pressure,
takingthe tankheadpressureintoconsideration.
Drawing6-15.Fuel Oil PressureAdjusting Procedures
Fuel Oil lnlet
FuelOil Outlet
(1)Turnthe pressureadjustscrewas follows:
rise.
Thepressure
Clockwise...
... Thepressuredrops.
Counterclockwise
6-22
Procedures)
yAMuAn
CHECKING(MaintenanceChecking&Adjusting
6. MAINTENANCE
6Ill8(AlL-l/
Valves
6-3-10.Checkingof Cyl.JacketCoolingWaterThermostatic
An automaticthermostaticvalve has been equipped to cylinder jacket to rise the cylinderjacket cooling
water temperaturein a short time after the engine is started and to maintainthe temperaturewithin the
proper range during a run. The coolingwater temperaturevaries with the load conditionsand the cooling
water (cold fresh water) temperatureat the boost air cooler inlet. This automaticthermostaticvalve has
been set so that the coolingwater at the engine outlet becomes 85'C when the cold fresh water tempera'C. However,if this coolingwater temperatureis not within the rangefrom 80'C to gO'C as for
ture is 38
your guide,overhaulcheck the thermostaticvalve accordingto the followingprocedures:
Drawing6-16.ThermostaticValveRemovingProcedures
Air Bleeder
ThrottlePlate(Orifice)
Thermostatic Valve Case
ValveElement
Thermostatic
Side Cover
Throttle Plate (Orifice)
Jacket CoolingWater Pump
1) Removalofthermostaticvalve elements
the cooling
(1) Closeeachvalveat the inletand outletof the coolingwatersystem,andthendischarge
jacket.
waterfrominsidethe cylinder
(2) Removethe air bleeder.
(3) Detachthe sidecover.
(4) Removethethermostatic
valvecase,andtakeout the elements.
valveelements.
Be carefulnotto dropthe thermostatic
6-23
P'oeduras)
Checking&Adjusting
6. MAINTENANCE
CHECKING(Maintenance
17A,rJf,An 6Ill8(A)L-t/
2) Gheckof thermostaticvalve elements
valveopeningtemperatures.
valveis equippedwithtwoelementsof different
The thermostatic
Checkthe elementsaccordingto thefollowingprocedures:
(1) Checkfor crackof the valve,brokenspringandforeignmatterscaughton the valveseatface.
and measurethe valve
(2) Soakthe elementsin coldwaterandhotwaterfor 2 to 3 minutes,respectively,
tift@.
Drawing 6-17. Element Ghecking Procedures
ValveOpeningTemp.Stamp
Valveliftof the element(normalpart)
CheckingWaterTemperature
Cold water of 30'C or less
Hotwaterof 95"Cto 100"C
Lift@
45 + 1mm
than55 + 1mm
Greater
(3) lf the valvelift does not satisfythe valuesshownin the abovetable,replacethe elementswith new
one3) Incorporationthermostaticvalve elements
valveelementin the sequencereverseto removal.
Incorporation
thermostatic
(1) Do not makea mistakein the elementincorporating
direction.
valvecaseinletand outletsides.
(2) Do notforgetto incorporate
throttleplatesat thermostatic
6-3-11.Cleaningof Lub.Oil Bypassstrainer
The lubricatingoil systemis equippedwith a centrifugalbypassstrainerin additionto a notch-wireoil
oil to flowthrough
strainer.Duringa run,keepopena cockat outletof lub.oil pumpto allowthe lubricating
problem
to stopthe oil
close
the
cock
hasoccurredto the bypassstrainer,
the strainerregularly.
Whenany
flow.
Stopthe enginebeforecleaningthe bypassstrainer.
lf you disassemble
the bypassstrainerduringa run,oil mistmaybe blownoff,causingyou to get a
burt.
6-24
Proceduresl
Checking&Adjusling
CHECKING(Maintenance
6. MAINTENANCE
vann4.p
6Ill8(AlL-t/
GF-2typeBypassStrainer
1) Disassembly & cleaning
Disassembleand clean the lub. oil bypassstraineraccordingto the followingprocedures:
Drawing6-18.GF-2typeBypassStrainerDisassemblingProcedures
I
Lub. Oil Outlet
(1) Loosenthe tighteningnut@ of the bodycover@ , andthenremovethecover@ .
(2) Removethe rotorassembly(spindle,rotorcover@ androtorbody@ ).
(3) Lockthe nozzlesectionof rotorassembly.
When lockingthe nozzle section,take care not to flaw the nozzlehole and the spindlebearing.
(4) Loosenthe rotorcovertightening
nut@ , andthendetachthe rotorcover@ .
(5) Completelyremovethe sludgeadherentto the rotorbody @ and insideof rotorcover @ , and then
washthem.
the residualsludgemay causean unbalancein rotation,
Completelyremovethe sludge.Otherwise,
resultingin a damageto the bearing.
(6) Checkfor flawsof the bearingsof bodyandbodycover.
2) Reassembly
payingattentionto the
Reassemble
the lub. oil bypassstrainerin the sequencereverseto disassembly,
followingpoints.
(1) Check for clogging of the nozzle and damage of the nozzle hole before incorporatingthe rotor
cover.
(2) lncorporatethe body cover after incorporatingthe rotor assemblyinto the body and making sure it
rotates smoothly.
1999.7.2R
6-25
Procedures)
Checking&Adjusting
CHECKING(Maintenance
6. MAfNTENANCE
vaxnap
6tl8(Al|.-l/
BypassStrainer
ROC-Stype
& cleaning
1) Disassembly
andcleanthe lub.oil bypassstraineraccordingto the followingprocedures:
Disassemble
(1) Loosenthe bellknob1/4turnsand removethe bellclamp,thenremovethe bellhousing.
(2) Raiseup the turbineassemblyto allowthe lub. oil to drainfrom inside,then removethe turbine
assembly.
. Takecarenotto bendthe baseshaft.
(3) Loosenthecannut,thenturnoverthe turbineassemblywithethe can nut looselyattached.
. lf the cannutis tootightto loosenwithyourhands,inserta bar intothe holeof can nut andturnthe
bar.
. Takecarenotto scratchthe endsurfaceof bush.
(4) Pressdowntheturbinecan,thenremovethe nut,turbinecan and bafflescreen.
Drawing6-19.ROG-stypeBypassStrainerDisassemblyProcedures
of TurbineAssy.
Disassembly
BellKnob
Bush
Bell Housing
TurbineCan
PaperInsert
TurbineCan
Bell Clamp
O-ring
i
L-----'eusn
;
14-
TurbineRotor
l @
- i.
i' _ - _ _\F<--_____,-----\
I
l- - - - -s-Z-
aot0
\
ausn
Nozzle
c ut-off Varve
Sideof Lub.OilInlet]
[onOpposite
2) Checkingand servicing
Accordingto the operationconis 1Smmor moremay causeabnormalvibration.
Sludgewhosethickness
ditions,specifytheproperservicinginterval.
(1) Insertsucha narrowandthintoolas a spatulabetweenthe insidewallof turbinecanand paperinsert
to removesludgeandPaPerinsert.
(2) Cleanthe turbinecan,bafflescreenand turbinerotor.
. Completely
maybe caused.
abnormalvibration
removethe sludge.Otherwise,
(3) Checkfor cloggingof nozzle.
(4) ReplacetheO-ring,gasketand paperinsertwith newones,respectively.
3) Reassembly
payingattentionto thefolthelub.oilbypassstrainerin the sequencereverseto disassembly,
Reassembly
lowingpoints.
o Tightenthe cannutandbellclamponlywithyourhandsandfingers.
o Attachthe turbineassemblyto the bell shaft,then makesurethat it catt be smoothlytumed.
o Tightenthe bellclamp,thentightenthe can nut 1/4turns.
1999.7.2R
6-26
yANruAn 6Ill8(A)L-l/
6. MAfNTENANCECHECKING(MaintenanceChecking&Adjus{ingProcedures)
of Lub.Oil Strainer
6-3-12.Cleaning
EngineMainLubricatingOil Strainer
type,and its elementare of
duplexchangeover
oil straineris of the manualback-washing,
Thelubricating
oil passesthroughbothsides(bothelements)of the
type.ln a normalrun,the lubricating
the notch-wire
strainer.
pressureindicatorwhichdetectsthe oil pressureat the inletandoutletof thestrainer
a differential
Besides,
oil coolerso as to detectcloggingof the strainer.
hasbeenfittedto the lubricating
When the differencebetweenthe oil pressuresat the inlet and outlet of the strainerreaches0.09 MPa
(1kgf/cm2),
the differentialpressurealarm is issued.
duringa
Be carefulnotto get burntby touchingthis strainerbecauseit assumesa hightemperature
run.
. Should the differentialpressure not drop even if back-washing is done, overhaul and clean the
strainer.
. Shouldthe strainerbe fouled noticeably,a lub. oil pressuredrop alarm may be issuedwhen one side
of this straineris used.Therefore,check the oil pressurewhile cleaningthe strainer.
1) Backwashing(blow-off)
Washbothsidesof thisstrainer,one at a time,accordingto thefollowingprocedures:
cock O with the LEFT(or RIGHT)CHANGEpositionon the
(1) Alignthe red markof the changeover
nameplate.
(2)Loosenthedrainplug@ twoto threeturns.
(3) Carryoutthe changeover
cockwiththe LEFT(or RIGHT)BLOW-OFFpositionfor 1 to 2 seconds.
(4) Returnthechangeover
cockwiththe CHANGEposition.
(5) Repeattheaboveoperationsteps(3) & (4) threeor fourtimes.
(6)Tightenthe drainplug.
(7) Returnthechangeover
cockto the NORMALRUNposition.
Drawing6-20.Lub. Oil StrainerCleaningProcedures
Changeover Cock Nameplate
@
LEFrCHANGEI-2257
\
LLEFT BLOW.OFF-
NORMALRUN
@
o
@
@
1999.7.2R
6-27
Prccedures)
Checking&Adjusting
CHECKING(Maintenance
6. MAINTENANCE
vA)trUAn
1$tl8(1[)L-l/
2) Disassembly& cleaning
thisstrainerduringa run,do so onesideof the strainerat a timeaccordingto thefolWhendisassembling
lowingprocedures:
(1) Alignthe red markof the changeover
cockO withtheLEFT(or RIGHT)CHANGEposition.
plug
(2) Loosenthe drain
@.
(3) Loosentheairventplug@.
(4) Dischargethe lubricating
oil in the case,loosenthe nut@ , anOthendetachthe blow-offpipe@ .
(5) Loosenthe centerbolt@ , and removethe caseand element.
(6)Cleanthe removed.
Element
of Strainer/Filter
flflle-s-f l. Gleaning
3) lncorporation
Incorporationa strainerelement in the sequence reverseto disassembly,payingattentionto the following
ooints.
. Do not makea mistakein the elementincorporating
direction.
. Takecarenotto permitthe O-ringbit in the case.
. Whensettingthe changeover
cockin the NORMALRUNposition,shiftit slowly.lf shiftedrapidly,the
oil,causingthe lubricatdropbeforethe caseis filledwiththe lubricating
oil pressuremaytemporarily
ingoil pressuredropalarmto be issued.
TurbochargerLubricatingOil Strainer
typeand its elementsare of the papertype.I n a
The lubricatingoil straineris of the duplexchangeover
of strainer.
oil passesthroughbothsides(bothelements)
normalrun,the lubricating
Besides,a pressureswitchis providedon the outletsideof strainerto detectcloggingof the strainer.
replacetheeleWhenthe lub.oil pressureat theoutletof strainerhasdroppedto 0.3MPa(3kgf/cm2),
mentsof the strainer.
. Whenthe lub.oil pressureat the outletof strainerhasdroppedto 0.25MPa(2.5kgficm2),
the pressuredropalarmwill be issued.
in the strainer
the reliefvalveof strainerwill opento allowsludgeandcontaminant
Simultaneously,
therebydamagingthe bearing.Takecarenotto let the lub.oil pressure
to flow to the turbocharger,
to drop excessively.
. lf the straineris foulednoticeably,
the lub. oil pressuredropalarmmaybe issuedwhenone sideof
whileoperating
one sideof this
is
used.
Therefore,
keep
checkingthe pressurecarefully
this strainer
strainer.
duringa
Be carefulnot to get burntby touchingthis strainerbecauseit assumesa hightemperature
run.
1999.7.2R
6-28
6.
Procedures)
MAINTENANCECHECKING(Mainienance
Checking&Adjusting
yANI;AB
6f,|f$(Al|--\/
1) Disassembly & cleaning
lf you disassemblethe strainerduringa run, disassembleand clean on elementthen the other sequentially.
(1) Align the red mark of the changeovercock with the LEFT (or RIGHT)CHANGEposition.
(2) Loosenthe air vent plug.
(3) Removethe drain plug, and dischargethe lub. oil from the case.
(4) Loosenthe centerbolt,and removethe case and element.
(5) Replacethe element.
Drawing 6-21.
AirVentPlug
LEFT CHANGE-
ChangeoverCock
- RIGHT CHANGE
O-ring
NORMALRUN
Element
2) Incorporation
payingthe atientionto the followlncorporate
a strainerelementin the sequencereverseto disassembly,
ingpoints.
. Do not make a mistakein the elementincorporating
direction.
. Take care not permitthe O-ring bite in the case.
. When settingthe changeovercock in the NORMALRUN position,shiftit slowly.lf shiftedrapidly,the
oil pressuremay temporarilydrop beforethe case is filledwith the lubricatingoil, causingthe lubricating oil pressuredrop alarm to be issue.
6-3-13.Cleaningof Fuel Oil Filter
duplexchangeovertype, and its
manualback-washing,
The fuel oil filterequippedis of the heat-insulating,
passes
through both sides (bothelements)of this
elementsare of the notch-wiretype. In a run, the fuel oil
fllter.
duringa run
thisfilterbecauseit assumesa hightemperature
Be carefulnotto get burntby touching
on H.F.O.
1999.7.2R
6-29
6. MAINTENANCE
(Maintenance
CHECKING
Checking&Adjusting
Procedures)
yAI(;y,Ag- (i11tfl(Al|.-\/
. Should the filter be fouled noticeably,the revolutionof the engine may decreaseas the fuel oil pressure dropswhen one side of this filteris used.Therefore,check the fuel oil pressurewhile cleaning
the filter.
. A positioningnotchis providedto the changeoverhandle.In a blow-offor disassembly,
tilt the handle
to alignthe notchwiih the knockpin.
1) Back-washing (blow-off)
Wash both sides of this filter,one at a time, accordingto the followingprocedures:
(1) Openthe draincockO.
(2) Hold the changeoverhandlein the LEFT (or RIGHT)BLOW-OFFpositionfor 1 to 2 seconds,and then
returnit to the BOTHSIDESlN USE posiiion.
(3) Repeat the above step (2) three or four times.
(4) Closethe draincock.
Drawing 6-22. Fuel Oil Filter Cleaning Procedures
Drawing 6-23.
H.F.O.Filter
M.D.O.Filter
BOTH SIDESIN USE
BOTHSIDESIN USE
LET
I
DISASSEMBLY
2) Disassembly& cleaning
When disassemblythis filterduringa run, do so one side of the filter at a time accordingto the following
procedures:
(1) Tilt the changeoverhandle@ to tne LEFT (or RIGHT) DISASSEMBLYposition.
(2) Open the air vent cock @ .
(3) Open the draincock O to dischargethe fuel oil.
(4) Removethe circularnut @ .
(5) Removethe element@, and cleanit.
Element
fl[lls-s-f +. Cleaningof Strainer/Filter
(6) Clean the insideof the filter body.
2003.4.17R
6-30
(Maintenance
Procedures)
Checking&Adjusting
6. MAINTENANCE
CHECKING
vexnAn
6Ill8([)L-Y
3) Incorporation
payingattentionto the following
a filter elementin the sequencereverseto disassembly,
lncorporation
point.
(1) When settingthe handlein the BOTHSIDES lN USE position,shiftit slowly.lf shiftedrapidlyto the
BOTH SIDES lN USE position,the oil pressuremay drop beforethe filter is filled with the fuel oil.
(2) Open the air vent cock to bleedair.
Element
6-3-14.Cleaningof Strainer/Filter
Clean a notch-wiretype elementof lubricatingoil straineror fuel oil filter accordingto the followingprocedures:
Drawing6-24.Notch-wireTypeElementCleaningProcedures
ffir
8/6 0 Pipe
Cock
I L J I r
\ ^-l-L
\=:7^T
-
Smashto about1mm
on the surfacewitha
(1)Soakthe elementin thelightoil or cleaning
fluidto removethe sludgeadherent
wirebrush.
air of 0.3 to 0.5 MPa(3
(2) Preparea nozzleas shownin the abovedrawing,andspraythe compressed
fromthe insideof the element.
to 5 kgf/cm2)
(3) Lightingthe elementformits inside,makesurethedirtandforeignmattershavebeenremoved.
(4) Checkfor flaws,wirebreakage,
corrosion,
etc.on thesurfaceof notchwire.
Blower
6-3-15.Washingof Turbocharger
When the blower of turbochargeris fouled,the exhausttemperaturemay rise, shorteningthe servicelife of
fuel injectionvalves and exhaustvalves.
Also, the effect of late washing is lower than that of timelywashing.Therefore,record the boost air pressure before and after such a washing,and referringto the recordeddata, periodicallywash the blower.
(1) Washthe blowerduringa runof abutT5o/o
or moreload.Afterwashingit, continuea loadrunfor at
lestone hour.
(2) Shouldthe boostair pressurenotrestoredevenafierwashingthe blower,overhauland cleanit.
(3) Freshwateralonedoesnothavethe effectof cleaningthe blower.Forwashingthe blower,usethe
cleaningfluid (P/#137616-18400).
6-31
Procedures)
yAMuAB
Checking&Adjus{ing
CHECKING(Maintenane
6. MAINTENANCE
6rl8(AL-Y/
Drawing6-25.TurbochargerBlowerWashingProcedures
HandPump
Hose
Connecting
(1) Open the drain cock on the outlet side of boost air cooler.
(2) Suck one washing'susageof the cleaningfluid into a hand pump.
TypeRH133:0.15ltr.
usage
Onewashing's
TypeRH143:0.2 ltr.
(3)Connectthehandpumpwiththewaterfillerplug,andpourin thecleaningfluidin 4 to 10 seconds.
(4)Repeatthe abovesteps(2) & (3)threeof fourtimes'
(5)Pourfreshwaterof thesamequantityas the cleaningfluidintothe washer,and carryoutwashingwith
freshwaterin the sameway aboveprocedures.
(6)Afterthe washing,attachthe capto thewaterfillerplug,and closethe draincock.
(7) lf the boostair pressureis notrestored,wait next10 minutes,andthen repeatthe abovewashing.
of PressureGauge
0-0-1.Maintenance
Glycerinaqueoussolutionis sealedin a pressuregaugeequippedon the gaugepanelto preventwearof
insidethegauge.
thegearandlinkmechanism
gauge,
thefollowingitems:
pressure
observing
Handlea
panel
gauge
or a pressuregaugefor its servicing,havethe rubbercapof a presth(1)Whenremoving
suregaugefacedupward.
the sealingliquidwill leakthroughthe ventilatingholein the rubbercap.)
(lf facedsidelong,
(2)Alwaysmaintain
the sealingliquidat the specifiedlevel.
correct
2002.12.25
6-32
Checking&Adjusling
Procedures)
6. MAINTENANCE
CHECKING(Maintenance
VeXnaa
6X|8(A)L-I/
Drawing6-26.Levelof PressureGaugeSealingLiquid
Minimumliquidlevel@ = 18mm
HigherLiquidlevel @ = 25-26mm
(3) Shouldthe sealingliquid becomecontaminatedor its level drop, detach the rubbercap, and change
the sealingliquidor replenishthe pressuregaugewith its sealingliquid.
(Sealing liquid(Pltt42111-002800)is optionallyavailable.
(4) When a pressuregauge is replacedwith the new one, use it after cutting off the navel of the rubber
cap to open a ventilatinghole to the gauge.
(lf the gauge is not providedwith an opened ventilatinghole, the indicationbecomesbe out of order.)
Adjustmentof PressureTake-offMainValve
Checkand adjusttheoperatingof a needlevalveprovidedat the pipingpartof a pressuregaugeor
pressuretransmitter
of the pressuregaugeand presin orderto preventthe damageor malfunction
thataresubjectto pulsation.
suretransmitter
. Fuefpressuremainvalve:Open114tumfromthe completely
closedposition.
. Otherpressuremainvalve:Openoneturnfromthe completely
closedposition.
Adjustment of Remote Indicating Pressure
of a pressure,a pressuretransmitterhas beenequipped.lf the indicatio't
In the caseof remoteindication
accordingto the followingprocedure:
on the remotesidehasto be adjusted,proceedto the adjustment
IAdjustingProcedure
]
. Detachthe top coverfroma pressure
transmitter.
. Lightlypressa smallscrewdriver
(of
which head is 2mm in diameter)
againstthe ZERO or SPAN adjust
screw,and turn the screw as the
needarises.
Drawing 6-27.
Screwdriver
Press.Transmitter
Adjusting Screw
TestValve
Connector
. As the screwis turnedclockwise,
the
indicated
valuevariesin the direction
of an arrow shownin the following
graphs.
ZEROADU..'USTMENT
'o1
'ol
='otr
E"l
/
8^+/,,
'o(!.....r.....,
0
1997.9.1R
SPANADUJUSTMENT
P o ' P P ' kgf/cm2
Pressure (MPa)
6-33
0
P'
P
Pressure
kgf/cmz
(MPa)
Prooedures)
CHECKING(lrrlaintenanceCfred<ing&Arljusting
6. MAINTENANCE
vAnIrAR
(Blll8(AlL-Y7
6-3-17.Measurementof CrankshaftDeflection
may be broken,resultingin an accident.
the crankshaft
lf the crankshaftdeflectionenlargesexcessively,
periodically
measurethe cnnkshaftdeflection.
Consequently,
(1) Measurethe crankshaftdefectionunderthe coldstateof the engine.
(anchor)bolts,commonbed
(2) \Mren you haveremovedof furthertightenedthe engineinstrallation
or retightclampingboltsor drivenmachine(suchas genentor)clampingbolts,aredisassembled
ened,measurethe crankshaftdeflection.
(3) Movethe contactorof deflectiongauge,andmakesuretheneedleof dialgaugereturnsto the originalposition.
{) Deflectionmeasuringprocedures
(1) Preparethefollowingexclusivetools:
PartNo.
ExclusiveToolDescription
Deflectiongauge
42111- 000040
Deflectiongaugeminor
42111-001420
Ratchethandlefor turning
147673- 92851
Socket(M24)for turning
42111- 001850
(2) Openthe pressureindicatorcocksof all cylinders.
(3)Turnthe flywheelto bringit to the positionEB of 30 degreesafterthe B.D.C.
(4) Fitthe deflectiongauge,and set the needleof dialgaugein thezeroindication.
directionof the engine,and takeand recordreadingsof the
(5) Slowlytum the flywheelin the rotiational
dialgaugeat the positionE, T, P and PB.
Drawing6-28. Positionfor Fitting the DeflectionGauge
Drawing6-29.DeflectionMeasuringPositions
CrankPin Position
Deflection Gauge
reference)
EB : 30' afterB.D.C.(measuring
E : 90" beforeT.D.C.
T : TopDeadCenter(LD.C.)
P :90" afterT.D.C.
PB : 30' beforeB.D.C
D = Diameterof crankshaftof 180mm
L = Widthacrossarns of 98mm
2003.7.11R
6-34
6. MAINTENANCE
CHECKING(tulainbnanceChed<ing&A{uslirg
Prooedures)
yfr,Jum
1$Ill$([}L-Y
2) Criteria on results of the deflection measurement
The relationbetweenthe deflectionvalve(readingof dial gauge)at each measuredpositionwith the referencetakenat the positionEB andthe crankshaft
is as shownin the belowtable.
6-30.
+
Readingof Dial Gauge
Crankshaft
(lowerspread)
(lowercontract)
(1) Shouldthe deflectionincreaseeverytimeit is periodically
measured,
thisis causedby the wearof the
crankshaftand/ormain bearings.lf the deflectionof onlya certaincylinderincreasessuddenly,it is
suspectable
thatthe corresponding
mainbearingmetalis abnormally
wom. In thesecases,checkfor
the pertinentparts.
(2) Sincethe deflectionvaluemeasuredunderthe hot stateof the enginevariesas dependingon the
temperature
existingat the measurement,
it cannotbe reliedon as the reference.However,accordingto outtest results,thatdeflectionis roughly?10,000to 3/10,000x stroke(lowercontract).
3) Allowablevalue of the deflection
Shouldthe crankshaftdeflectionexceedthe allowablevalue,correctthe deflectionby redistributing
the
installation
shimsand shaftcentersof theengineanddrivenmachine(orouterbearings).
A
( 1 )ln caseof the directcouplingsystems@ , @ , & @ , the normaldeflection
for the No.1cylinderis
lowercontract.
(2) ln caseof the directcouplingsystems@ , adjustthe deflection
for theNo.1cylinderto lowerspread
becausethe temperature
rise of enginebearingsbecomeslargerthanthat of generatorbearings
duringa runand thusthe shaftcenterof crankshaft
becomescomparcilively
higher.
Table:Allowablevalue of the deflection
nit 1/1
CouplingSystem
Driven Machine
InstallationSystem
No.
T-PB/EB
(direction)
-5.6- +2.8
Note:"S" standsfor s stroke
cvl.
P.E
(direction)
No.2- 6 Cyl.
+ 2.8
+ 2.9
Generator,
single- Direct
@ lDirectcoupling) sidebearing
(stationary) r - 2 s - 1 s l
r ils
@ (eetthousing
coupling)
| -rrs )
l-lo=,d6-o
J
r +1s )
t-1o"oooJ
+ 2.9
+ 2.8
I lopoo J
@ (Airclutch&
flexiblecoupling)
2003.9.10R
+
2.8
Direct
-rrs l
l
,
(stationary
[-ro,ooo ,l
-5.6- +2.8
Pump& compres- Direct
(stationary) r - 2 s - 1 s)
sor
t-10^ooo
J
6-35
r i1s
l
LTo-^ooo-JL-TdFd-o
J
+ 2.8
Generator,
single- Vibration
sidebearing
insulation
Generator,
both@ (Directcoupling) sidebearing
l
[ 'rrs )
th;mo-J
1- 2.8
I r-rs )
t 1o,oooJ
+ 2.8
'l
r +1s
t 1o^ooo
.l
+ 2.8
| *rs l
[ld,o6-o J
(Maintenance
CheckingMdjusling
Procedures)
CHECKING
6. MAINTENANCE
vextnaa
Drawing6-31.DrivenMachineDirectCouplingSistem.
Insulator
RubberVibration
6-36
6N|8(A)L-I/
(Maintenance
Procedures)
Checking&Adjusting
6. MAfNTENANCECHECKING
UeXnan
1$tl!([)L-t/
Volume(for EngineUsing
of FuellnjectionPumpPinionLubricating
6-3-18.Adjustment
H.F.O.)
to 3,500-sec.
or
The pinionsleeveof fuelinjectionpumpof an engineusingthe heavyfuel (equivalent
volume
accordingto thefollowing
7,000-sec.
fueloil)hasbeenlubricated
by lub.oil. Adjustthe lubricating
procedures:
(1) Firstrunthe engine,and thenadjustthe lubricating
volumewhenthe lubricating
oil temperature
55to 65'C.
becomes
(2)Adjustthelubricating
volumeso thatthe lubrication
becomes1 dropfulper 10 to 12 seconds.
Drawing6-32.LubricatingVolumeAdjusting Procedures
o ( 9 @
Oil Flow Rate
RegulatingValve
'.-: :
[1 i
_------t-
,
I
r
t
.-----:-.
..,'- t9, )
I
:
t*r-r-'-.rb':
'i-----'
l
l--L\-rl
./
LubricatingPoint
(1)RemovethecapnutO fromthe lub.oilflow rateregulatingvalve,and loosenthe lock nut@.
(2)Fullyscrewin thelub.oilflowrateadjustscrew@.
(3) Removethe plug@ on thefuelinjectionpumpsideto checkthe lubricating
volume.
(4) Graduallyloosen(turncounterclockwise)
the adjustscrewuntilthe lubricatingvolumebecomesas
specified.
(5)Whenthelubricating
volumehasbecomeas specified,securelytightenthe locknutO, capnutO and
@
.
Plug
6-3-19.Maintenance
of FuelOil SealPot (for EngineUsingH.F.O.)
in Section4-1-2.(Page4-6)
Maintenance
servicing
of mentioned
2002.5.15R
6-37
Procedures)
6. MAfNTENANCECHECKING(MaintenanceChecking&Adjus{ing
1ANUAB
61118(A)L-t/
Zinc
of Anticorrosive
6-3-20.Check& Replacement
zincshavebeenfittedto the
anticorrosive
In the caseof the fresh& seawater2-linecoolingspecification,
procedures:
boostair cooler,lub.oil cooler.Checkthemaccordingto thefollowing
. ln the casewheresuchanticorrosive
of the stateretainedby
zinc is foundconsumedmorethan70o/o
the newarticle,replaceit withthe newone.
FittingArea (Q'ty)
Boostair cooler
cover(2)
CoolingwaterinleVoutlet
'"
plugtype
(2)
Waterreturncover
Lub.oilcooler
Inletsidecover(1)
Outletsidecover(1)
. ln the caseof continuous
zinc,getridof the oxidelayerfromthesurfaceof the
useof suchanticorrosive
zincto exposethe metallictexture.
window
. The anticorrosive
zincfor boostair coolerupperpartis of the plugtype.Detachthe inspection
(having
width
the
key
wrench
plug,
hexagonal
a
using
remove
the
duct,
and
air
from
the
boost
cover
acrossflatsof 17mm).
zinc and beforefittingthe inspectionwindowcover,
After checkingand replacingan anticorrosive
checkthatthereis no waterleakage.
Drawing6-33.AnticorrosiveZincs Equippedpoints
Znc FittingProsedures
lBoostair coolerI
Insoectionwind cover
IB-PlugType)
lA-FlangeType)
'{;7;'"
Boostair cooler
ePPackins
@.-
v
q-
I
Plug
Packing
Anticrrosive
Zinc
K
Fr]-'.
[Q---Anticnosive
rFE-,I
r D l
, D l
I Lub.Oilcooler I
Strate)
Zincs(in the New-article
Dimensions
of Anticonosive
dD (mm)
L (mm)
1999.6.25R
6-38
Flange type
Plug type
40
40
25
95
7.
YANM,AB 61II8(A)L-V
MAINTENANCESERVICING
SERVICING
7. MAINTENANCE
Manualto
readthis Operation
and checkof the engine,thoroughly
O In advanceof maintenance
performed
to
examine
and
work
to
be
part
of
pertinent
nature
the
and
of
the
the
structure
understand
not
sufficiently,
work
the
examining
without
you
work
procedures.
the
lf
begin
work
sufiicientlythe
will
misassembly
due
to
engine
of
the
or
damages
also
accidents
wasted
but
will
be
onlythe labors
be caused.
itsusagelimit)as a result
O lf any partis foundto be damagedof notdurablefor furtheruse(reaching
check,replaceany part
for
next
schedule
the
of check,be sureto replaceit. Besides,considering
estimatednotto be durableuntilthe nextcheck'
sparepartis notavailof actionon site,or if the necessary
O lf it is difficultto takeanycountermeasure
"YANMAR
able,consultus or yournearestsalesor serviceagent(shownin the servicenetworklist
WorldwideService"appendedto this manual).
7-0.Precautionsin MaintenanceServicing
1) Precautionson Safety
Toworksafely,readthe itemsregardingsafetyin thefollowingpages:
0. ForSafeUseof YourEngine....(p.0-2)
tffitO Chapter
O Chapter0, 3. Precautionson Safety(pp.04 to 0'13)
in a seriousaccior check,youmaybe caughtin it, resulting
(1) lf the enginerunsduringdisassembly
dent.
leverto the STOPpositionandsurelyclosethevalvesof the
* Priorto servicing,returnthe starUstop
or
doesnot turn.Onlythen,proceedto disassembly
the
engine
make
sure
startingair systemto
posiENGINE
the
position
switch
to
selector
the
control
(Be
to
changeover
sure
checkingwork.
tion.)
(2) Beforeturningthe flywheelwiththe turningdevice,makesureyoudo notmakea contactwitheany
or otherpersons
rotatingpartandthat rotationof the enginewill notendangeryou,yourcoworkers
aroundthe engine.Alsobe sureto givea signwhenturningtheflywheel.
For usageof the turningdevice,referto thefollowing:
flillctrapter
7-{t.4) HandlingProceduresfor TurningDevice(p. 74)
withthe lockbarof the turningdevicebeforedisassembling
of crankshaft
* Preventthe self-rotation
of checkingany movingPart.
* Otherthanturningthe flywheel,returntheturningdeviceto the GEAROUTposition.
you mayreceivean
(3) Be sureto turnoffthe powerswitchbeforehandlingan electricpart.Otherwise,
electricshockor fire maybe caused.
do not storesuch
(4) Duringweldingand grinding,sparksmaybe spread,resultingin fire.Therefore,
working
site.
at
the
waste
cloth
and
oil
oil,
lubricating
fuel
as
the
materials
combustible
7-1 (Volume:60pages)
7.
in Maintenance)
MAINTENANCESERVICING(Precautions
YATJ'',AB 61II8(A)L-V
(5)Whenhandlinga liquid,strictlyobservethefollowingprecautions:
. . . . . . .Thelighting
of firesis strictlyprohibited.
oil:Flammables.
* Fueloilandlubricating
rustinhibitor
*' Fresh-water
.Do notdrinkany of them.
antifreezing
fluid:Toxic.
andfresh-water
. Batteryfluid
Whenhandlingthe batteryfluid,wearrubber
glovesanda mask,if possible,
anddo notallow
it to makedirectcontactwith yourskin.
lf it is puto yourskin,flushit.
Beforedischarging
it, treatit accordingto the
instruction
manualof the additivemanufacturer.
Poisonous
....
.Donotdrinkit. lf it is puton yourskin,flushit.
* Mercury(thermometer):
(6) Accordingto the conditionof working,wearprotectorssuchas gloves,a helmet,safetyshoesand
safetygoggles.
afterthe enginehasstopped,the wholeengineis heated.Before
* Duringa runand immediately
working,wearglovesso as notto get burnt.
* On the floorof engineroom,oil is adherentand slippery.Especiallywhen workingat a height
sufficiently
watchyourstepnotto fall fromthere.
suchas on thefootboard,
(7) lf youdisassemble
afterthe enginehasstopped,hotoil or
a strainer/filter
of pipingjointimmediately
watermaybe spoutoutdueto theresidualpressure.
or removinga pipingjoint,closeall valvesfor externalconBeforedisassembling
a strainer/filter
nectionto the CLOSEposition,andgraduallyloosenthe air vent plugto releasethe internalpresor removeit.
sure.Thenwrapthe partwithclothor the liketo disassemble
(8) Notethat springmay springout whendisassembling
a valveor devicewhich usesone or more
springs.
(9) Do not raiseheavythingforcedlyby yourhands.Usinga chainblock,lift it. Also,keepoff underthe
liftedheavything.
Fortheweightof majorpart,referto thefollowing:
EllCnapter
8, 8-2.PrincipalPartMassfor Disassembly& Servicing
(10)Usethe propertools.Usean exclusive
tooluponunderstanding
its function.
joints
of hydraulicjacks.The high-pressure
* Carefullycheckfor anydamagesto rubberhoseand
oil mayspoutoutfroma damagedportionduringoperation,
causingyouto get an injury.
jack,referto the following:
Forhowto usethe hydraulic
for Hydraulic
Jack(p.7-5)
lffilCnapter 7.0,5) HandlingProcedures
7-2
7.
(Precautions
in Dismantling)
MAINTENANCESERVICING
YA}/,TUAE 6TI8(A)L-Y
2) Precautions
in Dismantling,
Servicing& Reassembly
Be sureto observethefollowingprecautions
becausethe performance
of the productmay be deteriorated
or the machinemaybreakdownif you neglectany of the followingprecautions.
(1) Preparethe necessary
toolsandsparepartsin advance.
As for the exclusivetools,usethe specifiedtools;as for the spareparts,use our genuinepartsor
the partsspecifiedby us.
(2) lf anypartis foundto be damagedor not durablefor furtheruse as a resultof check,be sureto
replaceit. Besides,considering
the schedulefor nextcheck,replaceany partestimatednotto be
durableuntilthenextcheck.
& WearLimitsof MajorParts
lffilCfrapter 10.Clearances
(3) Duringdisassembly,
coveranyexposedopeningwithtapeor cleanclothso as notto allowforeign
mattersto enterit.
Incidentally,
do notforgetto removethe coveringtapeor clothin reassembly.
jointedparts,checkwhetherset markshavebeenstampedor not,and stamp
(4)Whendisassembling
set marks,if foundnecessary.
positionand set mark
(5) On the majorbolts,thecylinderNo.,bearingNo.,markingfor incorporating
havebeenstampedat thetimeof manufacture.
However,
theycan notseryeas referencefor tighteningindefinitely
becausethe clampingseatmay be worn and the boltsmay be stretchedin their
use.Usinga set markonlyas a guide,be sureto tighteneach boltto the specifiedtorque,specifiedangleor specifiedhydraulicpressure.
fl[lJjCft"pter 9. Tableof TighteningTorquesof Major Bolts
Besides,whenanyof thesemajorboltshasbeenreplacedwith a newone,givethe samemarkingas
thatof theformeron to the newone.
(6) Notethat boltsand nutsto be useda the high heatedarea are madeof materialsdifferedfrom
thoseusedelsewherebut of the samesize.lf wrongonesare usedin reassembly,
they become
difficultto be takenoutat the nextservicing.
(7) Whendisassembling
eachsectionof the engine,carefullycheckthe boltsand nuts that are not
exposedduringa run.lf sucha boltor nut is loose,investigate
the cause,takethe properactions,
andthentightenit.
7-3
7. MAINTENANCE
SERV161116(PrecautionsatCompletion&HandingforTumingGear)
Y,A,tl'AB 6lfl8(A)L-vZ
3) Precautionsat Gompletionof MaintenanceServicing
(1) Turningthe flywheeland lubricatingoil priming,checkfor abnormalities
in variouspartsof the
engine.
(2) Be sureto incorporate
the removedcoverssuchas coversfor rotatingparts,heatshieldingcovers
for exhaustpipeand protectivecoversfor heatedregionin position.
(3)Afterhavingusedthe turningbar,returnit on the set position,
(3)'Afterhavingusedthe turningdevice,returnit to the GEAROUTstate.
(4) Record the natureof maintenanceservicingrenderedand replacedparts in the EngineLog.
4) Handling Proceduresfor Turning Gear Device
(optionalspec')
Drawing 7-1. Turning Device Equipped Point
The turningdeviceis of the gear intermeshing
type
and equippedbelowthe air motoron the operating
side.Whenthe turninggear is intermeshing,
the
engagemenUdisengagement
switch is actuated,
disablinga startof the engine.
Handlethe turningdeviceaccordingto the following
procedures:
O Preparethe exclusivetoolsfor turning.
ExclusiveToolDescription
PartNo.
Ratchethandle
147673- 92851
Socket (M24)
421't1- 001850
TurningDevice
@ Detachthe lockbar,loosenthe two stopperlock bolts,and thentakeoffthe stopperfromthe slot@ of
turningshaft.
@ Pushin the shaftto the GEARlN position.
@ fit tne stopperin the shaftslot@, and tightenthe two lock bolts.
@ Attachthe socketfor turningand ratchethandleto the shaft,andthenturntheflywheel.
Beforedisassembling
or checkingany movingpartengagethe turninggearwiththeflywheelandlock
prevent
it with the lockbarto
self-rotationof crankshaft.
2001.6.15R
7-4
7.
MAINTENANCESERVICING(Handlingfor HydraulicJack)
UA}/iTAAE6]|I8(A}L-Y
The lockbar is usedto preventthe crankshaft
fromturningitselfduringan overhaulcheckingwork.
Setthe turninggearin the intermeshing
state,locktheturningshaftwiththe stoppelandthentighten
thelockbar.
@ nfterturningwork,returnthe turninggearto the GEAROUTposition,fit the stopperin the slot@ , and
thentightenthe lockboltsand lockbar.
Drawing7-2.Turning DeviceHandlingProcedures
Stopper Lock Bolt
Micro Switch
5) Handling Proceduresfor hydraulic Jack
Use a hydraulicjack in a work of looseningor tighteningthe cylinderhead tighteningnuts and main bearing cap tighteningnuts.
Furthermore,simultaneouslyloosen or tighten the four cylinderhead tighteningper cylinderor two main
bearingcap tighteningnuts per main bearing.
lf the hydraulic
jack is beingused,the fluidmayspoutundera high
fluidleakswhilethe hydraulic
pressure,resultingin injury.Therefore,be sureto observethefollowingprecautions:
jack witha rubberhosehavinga flawor an oil leakingportion.
O Do not usethe hydraulic
O Do not put nor dropa heavythingon any rubberhose.
O Do not gripany rubberhose.Do not bringyourfacecloseto thejackor branchduringa work.
1998.10.20R
7-5
MAINTENANCESERVICING(Handlingfor HydraulicJack)
7.
YA]truAB 6Ill8(AL-V
eachnut.
andtightening
toolsforloosening
exclusive
Usethefollowing
IUsage]
partsothatthere
jack,besureto usethesealing
tapeatthethreaded
(1)\Men assembling
thehydraulic
will be no leakage.
(2) Connectthe hydraulicpumpand branchwith3 m longrubberhose.
(3) Connecttwo 1 m longrubberhosesto the branch.
pumpplacedhorizontally.
(4) Use the hydraulic
(5)To operatethe hydraulicpump,useit, openingthe air valve.
jack is usedfor thefirsttime,the rubberhoseis filledwiththe hydraulicfluid.There(6)\A/hena hydraulic
fore,whenthe hydraulicpressurebeginsto rise,loosenthe air vent plugof hydraulicpump,andthen
fluid.
the hydraulic
checkingthe oil volume,replenish
jack
(7) lf the hydraulic
does not work eventhoughthe hydraulicpressurehas risento the specified
value,loosecoupleswill be the cause.
Loosenthe reliefvalveof hydraulicpumpto lowerthe hydraulicpressure,and then checkthe connectionof couples.
I CommonTools]
HydnulicJack HandlingProcedures
Dnwing7-3(1121.
[CommonTools]
No. ExclusiveToolDescription otv.
@
o
pump
Hydraulic
1
@
@
ConnectingPiece
1
To Branctr
@
Gauge damper
1
@
Pressuregauge
1
@
Rubberhose,3mlong
1
@
Branch
1
@
Rubberhose,
l mlong
4
@
Squareelbow
2
o
Coupler,external
threaded
4
@
Coupler,intemalthreaded
4
@
Hydraulicjack
4
@
Spacer
4
@
Handle
I
2003.7.11R
j@
AirVentPlug
Relief Valve
-ffF-
7-6
@
7.
MAINTENANCESERVICING(Handlingfor HydraulicJack)
Drawing7-3 (2121.
HydraulicJack HandlingProcedures
[CylinderHeadFiftingProceduresl
YAnr',An 6lll8(A)L-V
[MainBearingGapFifting Proceduresl
(1) Cleanthe surroundingof cylinderhead (or main bearingcap) tighteningnuts.
Tightenthe cylinderhead (or mainbearingcap)tighteningnuts to theirseatingwith use of the handle.
(2) Fitthe spacer.
jackto a cylinderhead,be sureto checkthatthe notchof the spacer
the hydraulic
O Whenattaching
fittingsurfacedoesnot makea contactwith the adjacentcylinderhead.Otherwise,
the spacerand
pressure.
the cylinder
headwillbe damaged.
Onlythen,raisethe hydraulic
jack to a main bearing,directthe handleinsertionhole towardthe
O Whenattachingthe hydraulic
crankshaft.
(3) Attach the hydraulicjack to the cylinderhead (or main bearing cap) bolt, and screw in the jack until it
adheresto the spacer.
Makesurethatthereis no differences
in levelbetweenthe pistonof hydraulicjack and the end surfaceof bodyof thejack.
jack,branchandhydraulic
(4)Connectthehydraulic
pumpwithrubberhose(couplers).
1998.10.20R
7-7
7.
MAINTENANCESERVICING(Handlingfor HydraulicJack)
YATTM,AB61II8(A}L.V
jack by one full turnfromthe stateof adheringto the spacer.
(5) Loosenthe hydraulic
Be sureto checkthatthe notchof the spacerfittingsurfacedoesnot makea contactwiththeadjacent
cylinderhead.Otherwise,
the spacerand the cylinderheadwill be damagedas the accuratetighteningforcewouldnot be attained.Onlythen,raisethe hydraulicpressure.
(6) Close the reliefvalve of hydraulicpump, and operatethe pump lever to raisethe hydraulicpressureto
the specifiedvalue.
Specifiedhydraulicpressure:58.8 + 0.5 MPa (6OOr- 5 kgflcm2)
(7) Insertthe handleintothe holesof the nut throughthe hole of spacer,and then turn the nut.
loosethe nut by sevento eightholes.
O Whendisassembling,
turnthe nutsfor threeto four holesto the fullyseatedstate.
O Whentightening,
O lf the nutto be removedcouldnot be turnedwith use of the handle,slowlyraisethe hydraulicpressure,andthenturnthe nut.
The hydraulicpressureshouldnot be raisedabove63.7MPa (650kgf/cm2).
checkif the nut threadedpartis not damagedor the couplersare not poorlyconO Whentightening,
nectedin the casewherethe numberof turnsof the nutsis few.
(8) Graduallyopenthe reliefvalveof hydraulicpumpto decreasethe hydraulicpressureto thezero.
jack in untilit adheresto the spacer,and then discharge
(9) Screwthe hydraulic
the hydraulicfluidfrom
jack.
the
jack,branchand hydraulic
(10)Disconnect
pump.
the rubberhoseof hydraulic
jack and spacer.
(11) Removethe hydraulic
O When disassembling,check if the bolts are not loose after removingthe tighteningnuts.
O When reassembling,check that set marks of the nuts and bolts are in agreement.
1998.10.20R
7-8
(Handling
for Hydraulic
7. MAINTENANCE
Jack)
SERVICING
.\--
6!f|8(A)L-vz
rr"-.r
IMaintenanceServicingof HydraulicJackl
jack,andstoreit.
(1)To preventrusting,applythe lubricating
oil to the hydraulic
(2) Capeachcouplernotto allowforeignmattersto enterit, andthenstoreit.
(3) As for oil to be sentout fromthe hydraulicpump,use hydraulicfluidwhose viscositygradeis ISO
VG32.
Tableof Hydraulic Fluid Brands
SUPPLIER
Brand
: ISO
t @J
Generalhydraulic
fluid
Tellus
OilC32
SHOWASHELL
TellusOil32
SuperHiland32
N I P P O NM I T S U B I S H I O I L
SuperHilandV32
cosMoorL
JAPANENERGYELF
CosmoEpochES32
CosmoHydroAW32
JOMOHydrax32
JOMOHydraxES32
IDEMITSU
KOSAN
DaphneHydraulic
Fluid32
DaphneSuperHydro32A
EXXONMOBIL
DTEOil Light,Unipower
32
DTE24Oil, Unipower
SQ32
2001.10.R
7-9
I
(CylinderHead& lts Accessories)vAMuAa
SERVICING
7. MAINTENANCE
6iltl|(A)L-Y/
7-1.CylinderHead& lts Accessories
gas hinderscombustion
and
on the surfaceof cylinderheadexposedto combustion
Carbonaccumulated
passage,
effect.
reducing
the
cooling
allowsscaleto adhereon the coolingwater
Besides,the thermalload duringrunningof an enginemay causethe headcombustionsurfaceto be
alsoremoveand
periodically
overhauland cleanthe cylinderhead.(Simultaneously,
Therefore,
cracked.
checkits accessories.)
Head
7-1-1.Cylinder
1) Disassembling preparation
Preparethe followingexclusivetools:
(1) Hydraulicpump& hydraulicjack .......One set
(p.7'5)
fffilCfrapter 7-0,5) HandlingProceduresfor HydraulicJack
head
No.
tool
ExclusiveTool Description
Part No.
O
Liftingtool body
146673- 92310
@
Capnut
146673- 92320
@
Eyenut
26620- 160002
@
Bolt
26116 - 160452
2) Disassembly
the cylinderheadaccordingto the followingprocedures:
Disassemble
('1)Closeeachvalveof coolingwaterinletand outlet,anddrainthe coolingwaterfromthecylinderjacket.
(2) Detachthe exhaustmanifoldcover.
the cylinderhead.
Usingan eye bolt(Pl#26610- 120002)1,lift
(3) Removethe exhaustmanifold.
fromthe cylinderhead.
(4) Disconnect
the followingpipeandaccessories
Overflowoil pipe,fuel injectionpumppinionlub. oil pipe,coolingwaterconnectionpipe,pressure
indicatorcock,fuel injectionpipejoint,fuel injectionpipecap nutandfuelinjectionpipe.
valveguardsandpush
suction/exhaust
(5)Detachthe bonnet,and removethe rockerarm shaftpedestal,
rod.
(6) Removethefuelvalvetighteningnut.
(7) Removethe protectivecap of a cylinderheadbolt.
jack, removethe cylinderheadtighteningnut.
(8) Usingthe hydraulic
(p.7'5)
E[lCfrapter 7-0,5 HandlingProceduresfor HydraulicJack
7-10
\
(CylinderHead& ltsAccessories),.r-r"
7. MAINTENANCE
SERVICING
6NlO(AlL-Yz
Drawing 7-4. Gylinder Head Disassembling Procedures
RockerArm
Shaft Pedestal
Push Rod
Pressure
Indicator
Cock
(9) Lock the cylinderhead lifiing tool onto the fuel valve clampingbolt, and lift the cylinderhead straight
up.
Drawing7-5.CylinderHeadLifting Procedures
O Lightlytightenthe capnut@ to an extentthatthe
bodyO doesnot becomerickety.
O Whenliftingthe cylinderhead,be carefulnot to
jack fittingthreadedpartof
damagethe hydraulic
the cylinderheadbolt.
(10)Removalof
thefuelvalve
Removethe cap nuts @ , eye nut @ and bolt
@ from the cylinderhead lifting tool. Then,
attachthe fuelvalvedrawing-out
exclusivetool,
and drawoutthefuelvalve.
No.
ExclusiveToolDescriotion
@
Drawing-out
bolt
146673- 92330
@
Nut
26732- 160002
@
@
O
@
Fuel Valve
ClampingBolt
PartNo.
Drawing76. FuelValveDrawing-out
Procedures
Attachthe liftingtoolbodyO anddrawing-out
bolt@
to the fuelvalveguard.Tightenthe nut@ to drawout
thefuelvalveguard.
FuelValveGuard
7-11
(CylinderHead& ltsAccessories)yAnMAB
SERVICING
7. MAINTENANCE
(6N18(A)L-Y/
check,adjustmentof fuel injectionpresservicingof fuel valve(disassembly,
For the maintenance
sure),referto the following:
of InjectionPressure
fl[llCnapter 6-3-5.Checkingof FuellnjectionValve& Adjustment
(11) Removethe valve rotators,cotters,valve springs,suctionand exhaustvalves.
O tne suctionand exhaustvalves use two cotters,respectively.In reassembly,fit the two cotters as
one pair to the valve to which the cottershave been previouslyfitted. (lf not used the cottersas each
pair,an impropercontactat the cottersmay cause a breakageto the valves stem.
O Taking care not to flaw the stem seal lip of a suction/exhaustvalve guide, remove the suction and
exhaustvalves, respectively.
Lock the cylinderhead liftingtool body O to tne fuel valve clampingbolt with the cap nut @ . Remove a
valve rotatorwith the followingexclusivetools.
PartNo.
No.
ToolDescription
Exclusive
@
Rotatorretainer
- 92330
141616
@
Handlesupport
146673- 92360
@
Handle
139653-92340
@
Bolt
146673- 92350
@
Nut
26706- 120002
Drawing 7-7. Y alve Rotator Detachi ng/Attachi n g Proced u res
A
ar'
CapNut@
LiftingToolBodyO
FuelValve
Bolt
Clamping
1-12
Head& lts Accessories)rar-or
7. MAINTENANCE
SERVICING(Cylinder
6ltl8(A)L-Yl
(12)Disassemble
the nozzlesleeveonceeveryfouryearswithuseof the exclusivetool,checkfor corrosionin thewaterchamber
side.andcleanit.
O Replacethe packingand O-ringswith new ones.
O When incorporatingthe nozzlesleeve,apply Protecgreaseto the threaded part and packing seating
face, and tightenthem to the specifiedtorque.
O After incorporatingthem, conductthe hydraulictest.
Testpressure:0.7MPa(7 kgf/cm2)
No.
ExclusiveTool Description
Part No.
@
Nozzlesleevedisassembling
tool
146673 - 92250
Drawing7-8.NozzleSleeveDisassemblingProcedures
NozzleSleeve
3) Checking & servicing of cylinder head
O After havingremovedthe cylinderhead,cover the cylinderso as not to allow foreign mattersto enter
the boostair chamber.
O tttotto damagethe threadedpart of a cylinderhead bolt, cap it with a protectivetube.
O Oo not use any gas burner to eliminatecarbon adherent on the combustion surface and at the
exhaust port.
The loose exhaustvalve seat and a deterioratedO-ring may cause a water leakage.
7-13
(CylinderHead& lts Accessories) vAnMAR
7. MAINTENANCE
SERVICING
(6l|l|'(A)L-v
(1) Checkthe stateof carbonadherentin the combustion
chamberand at the suctionand exhaustpo;ts
(for your referenceon determiningthe intervalsfor subsequentservicing).
Afterclearing,carefully
checkfor cracksand corrosion.
(2)Checkthe stateof scalein the waterjacketpart.Dependedon the waterquality,a lot of scaleadheres
evenin thewaterjacketpartof a fresh-water
cooledengine.Therefore,
at leastonceeverytwoyears,
cleanthewaterjacketpartwith a descalingagent,etc.(Forexample,Unicon146soldby Yanmarcan
descalethe waterjacketpartwithoutoverhauling
the cylinderheadwhilethe engineis stopped.)
(3) Especiallycarefullycheckfor flaws and foreignmattersin the socketand spigotpartof the cylinder
headfittingsurface.lf this part has been flawedor contaminated
by foreignmatters,a blow-bye
occursduringa run.
(4) Conductthe hydraulictest at leastonce everytwo years,and checkwhetherwaterleaksfromthe
exhaustvalveseatmatedpart.
Also,if the cylinderheadis overheateddue to a failureof coolingwatersystem,conducta hydraulic
test.
Test pressure: 0.7 MPa (7 kgf/cm2)
4) Reassembly
Reassemblethe cylinder head in the sequence revers to disassembly,paying attentionto the following
points:
O Replaceeachpackingand O-ringwith newones.lf you cannotavoidusinga packingor an O-ring
again,sufficiently
checkit for no flaws,deformation
and deterioration
beforeusingit.
Apply
the lubricating
oil on the suctionandexhaustvalves,attachthe samecottersas thoseusedin
O
the disassembly
to the respectivevalves,and fit themwhiletakingcarenotto damagethe lip of a
valveguidestemseal.
O lf a head packingof the same dimensionsas that used previouslyis used,the top clearance
becomesthe standardvalueand doesnot requireany particularadjustment.
O Checkfor no foreignmattesin the suctionandexhaustpassagesof cylinderhead,pistonupperpart
andboostair chamberof cylinder,and thenincorporate
the cylinderhead.
O Whenmountingthe cylinderheadon the cylinderliner,takecare notto flawthe threadedpartof a
cylinderheadbolt.
jackfittingthreadedpartof thecylinderheadbolts
oil on the hydraulic
O Applythegreaseor lubricating
to preventthe treadedpartfrom beingrusted.
oil to the headtighteningnut.Afterbeingtightened,capthemwiththe protecO Applythe lubricating
tivecaps.
Afterincorporation
of a cylinderhead,adjustthe suction/exhaust
valveheadclearance.
EfllCfrapter 6, 6-36. Adjustmentof Suc./Exh.ValveHeadClearance
7-14
7. MAINTENANCE
Head& lts Accessories)YA'//',AB 6TIT8(AIL-Y
SERVICING(Cylinder
7-1-2.Suction& ExhaustValves
Takecare not to confusethe suctionand exhaust
valvesas theyare of the sameshapebut madeof
differentmaterials.
Drawing7-9.Markingsfor Suction&Exhaust
Valve
, Dateof manubcturing
Markins
//l
1H37S12S1
i___71S tor suc.vatve
1H3s12Ei:::::::l Eforexh.vatve
WCr-platedstem /
(M.D.O.spec.) I
180AH3Ei::::--::j E tur exh.valve
(H.F.O.spec-nimonic)
1)Gheckingitems
(1) Checkfor sulfuricacidcorrosionandbendof the suction/exhaust
valvestem.andmeasurethedimensions.
lf the clearancebetweenthe suction/exhaust
valvestemandthe corresponding
valveguideexceeds
the usagelimitvalue,replaceeitherthe valveor valveguidewhicheveris wom morethanthe other.
(2) Checkfor high-temperature
conosionof the valvepoppet.
Correctthe valvepoppettip part uponcarefulcheckingit becauseif it becomestoo thin,it may be
chippedand the piecesmay enterthe combustionchamberand turbocharger,
causinga secondary
damage.(However,
do not grindthe combustion
surfacesideof the valvepoppetpartfor thiscorrection.)
(3) Checkthe stateof blow-byeand carbonbiting-inat the valveseatpart,and accordingto the state,
grindthe seatface.
(4) Measurethe dimensions
of the valveseatpart.lf the dimensionhavereachedthe usagelimitvalues,
replaceit.
(5) Checkfor cracksand corrosionof valvesprings.
2) Suction/exhaustvalve grinding
(1) Performthe initialvalve grindingearlierthan usual as indicatedin Chapter6, Tableof Periodical
Checking.Judgingthe situation,determinethe intervalsof subsequent
servicing.
(2) Checkingthe clearancebetweenthe valveguideand stem,replacethe pertinentpart,and thenperforma valvegrinding.
_
& WearLimitsof MajorParts
[EElCnapter10.Clearances
(3) Applythe properquantityof grindingcompoundto the valveto be ground,and elaborately
grindthe
valvewiththe specifiedgrindingtool.Finallygrindthe valvewithoil.
Drawing7-10(1121.
Suc./Exh.ValveGrinding Procedures
Step2:Tightenthe nut 1/4tums.
Stepl: Makethe nutfree.
Step3:Tightenthe bolts.
Step5: Tighten the
Suc. / Exh. Valve
Grinding Tool
Drawing7-10(2J21.
Hold Down
Step4:Pressthe holderB.
HolderB
2003.9.10R
Spring
Suc. / Exh. Valve
7-15
Suc./Exh.Valve
GrindingTool
(CylinderHead& ltsAccessories)v'ADrIfrAn 6||l8(AlL-YZ
7. MAfNTENANCESERVICING
($ lf a flaw on the seat face of a suction/
exhaust valve is so deep that it is
required to be corrected of the flaw by
grinding,finish grindingthe valve seat
part in an angle shown in the figure at
right and the outer periphery of the
valve seat part makes contactwith the
valve (poppet).
Drawing7-11.Angle of Suc./Exh.ValveSeat
seall
tfsuction
,E-l-,
r__:r
-1-
--
tzo'-rZ/
-)-
nExhaustseAT]
i-------*-7>
t]
it_
l"l--_--_______\"(
4--.'-_
rzo.-rl--.-)
7-1-3.Suc./Exh.ValveSeat
The suction/exhaustvalve seat has been shrinkfittedto the cylinderhead. The exhaustvalve seat is of the
cooledtype.
1) Checking & servicing
Do not use any gas burner to eliminatecarbon adherenton the combustionsurface and at the
exhaust port.
Othenryise,
the exhaustvalve seat may becomeloose or the O-ringsmay be deteriorated,resultingin
a water leakage.
(1) Checkthe stateof blow-byeand carbonbitingDrawing 7-12.Valve SeatCorrecting Procedures
in of the valve seat part. Accordingto the
{RoughFinishing)
state,grind the seat face. Sincethe satellite
has beenbuilton the valveseatface,if a flaw
on it is so deep,correctit with useof a rough
correctingseat cutter(withgrinder),and then
grindthe valve seat part.(The seat cutteris
optionally
available.
)
(2) Checkfor waterleakageat the exhaustvalveseatmatedpart.
(lf a waterleakageis found,replacethevalveseat.)
(3) Measurethe contactdiameterof the valveseat part.lf the measurement
exceedsthe usagelimit
value,replacethe valveseatwitha newone.
7-16
7.
Head& lts Accessories) ylAxruAp
MATNTENANCE
SERVICING(Cylinder
61111p(Al-yz
2) Replacementof the valveseat
Replacethe valve seat accordingto the following
Drawing7-13.ValveSeat RemovingProcedures
procedures:
(1) Removalof thevalveseat
Build up the wholecircumference
of the valve
seat iace by arc weldingto removethe valve
seat.
lf the exhaustvalveseat is difficultto remove
becauseof the O-ringsincorporated
in it, further weld an iron plateto the valveseat,and
hammerout the valve seat througha round
rod drivenintothevalveguide.
lron Plate
Arc Welding
Valve Seat
(2) lncorporation
of thevalveseat
O Checkfor flaws,hit markand burron the valveseatinsertinghole of a cylinder head and on the
outerperiphery
of the valveseat.lf found,conectit.
@ Measurediameterof the seat valve and the seat valve insertinghole. and confirm the interference.
for theValueSeat]
I Interference
Suctionvalveseat
Exhaustvalveseat
(Unitmm)
0.045- 0.095
0.039- 0.072(59dpart)
0.069- 0.102(676part)
"C
heatingis by steamcleaning.
@ Heatthewholecylinderheadto 40 to 60 . Theappropriate
Cnitt
the
valve
seat
with
liquid
carbon
dioxide.
lf
liquid
carbon
dioxideis not available,soakit in the
@
(10
(1.5
mixedsolution
lump
kg)
ice
of a small
of dry andalcohol lit.)for t houror longerto chillit.
Chillthe exhaustvalveseatwithO-ringsincorporated
to it. Do not useliquidnitrogen.Otherwise,
O-ringswill be hardened
and brokenwhenthevalveseatis insertedin the cylinderhead.
Drawing7-14.ExhaustValveSeatInsertingProcedures
Just beforeinserting
the exhaustvalveseal
into its holeof the cylinderhead,applythe
seizureinhibitor(spray)and silicone-based
liquid packing (Three-Bond1211 or ib
equivalent)to the insertinghole.
ff
2003.9.10R
7-17
: SeizureInhibitor(spray)
(CylinderHead& lts Accessories)vA,t',An
7. MAINTENANCE
SERVICING
6lll81a)L-yz
@Usingthesuctionvalve(orexhaustvalve),rapidly Drawing7-15.Valve
SeatlnsertingProcedures
insertthe valveseat into its holeon the cylinder
head.
INSERT
Valve Seat
Take care not to tilt the valve seat. Apply a load
for one to two minuteson the valve seat to avoid
insufficientadhesionto its insertinohole.
Afterhavingreplacedthe exhaustvalveseat,be sureto conductthe hydraulictestto makesureno
waterleaksfromthe matedpart.
Testpressure:0.7MPa(7 kgf/cm2)
7-14. Suc./Exh.
ValveGuide
Thesuction/exhaust
valveguidehasbeenshrinkfittedand insertedand incorporated
withthe stemseal.
1) Checking& servicing
Drawing 7-16.Valve Guide Removing Procedures
(1) Measurethe clearancebetweenthe suctioni
exhaustvalveguideand the valvestem. lf
the measurement
exceedsthe usage limit
value,replace
thevalveguideor valve.
(2)Replacethe stemsealat everyservicing.
2) Removalof the valve guide
Drawoutthe suction/exhaust
valveguideby hammeringit from the valve side througha stepped
doubling
rod.
3) Incorporationof the valve guide
Chillthevalveguidewithliquidnitrogen,liquidcarbondioxideor the like,andthenpressfit it.
Interference:
0.001- 0.035mm
Whenpress-fitting
the valveguide,holdthe flangepartof the valveguide.
7-18
(QylinderHead& lts Accessories) yAmuAB
SERVICING
7. MAINTENANCE
(6lf18(A)L-UZ
4) Incorporationof the stem seat
Incorporate
the stemsealwith use of a jig so as notto damagethe stemseallip.
ValveBridge& lts Guide
7-1-5.Suc./Exh.
The valve bridgeguide has been shrinkfitted in the cylinder head.
lf the engine is used under the conditionthat there is an excessiveclearancebetweenthe valve bridgeand
valve bridgeguide,the valve bridge may fall while the suction/exhaustvalve is working,causinga malfunction of the valve, unevenwear of the valve guide or damage of suction/exhaustcam.
1) Checking & servicing
lf the clearancebetweenthe valve bridge and valve bridge guide exceedsthe usage limit value, replace
eitherthe valve bridgeor valve guide whicheveris worn more than the other.
2) Replacementof the valve bridge guide
Chillthe valve bridgeguidewith liquidnitrogenor liquidcarbondioxide,and then pressfit it into the cylinder head.
7-1-6.ValveRotator
lmproperrotationof thevalverotatorwill causecarbonto be bittenin thevalveseatpart,causingblow-bye
overhaul
at the seatpartand affectingthe servicelife of the valveand valveseat.Therefore,periodically
andcheckthe valverotator.
To take out the valve rotatorwithout disassemblingthe cylinder head, set the piston at the T.D.C.of
the compressionstroke,and then removethe valve rotator.
fl[ll
Procedures(p.7'121
Orawing7-7.VatveRotatorDetaching/Attaching
1) Ghecking & servicing
Remove the circlip, and check each part. lf any of
the followingdefectiveparts is found, replaceit.
Drawing7 -17. Yalve Rotator
l+
@ Wear (at the body groove) and corrosion of
Bellevillespring
@ Wear (deformation)and corrosionof ball
@ Wear and breakageof coil spring
@ Wear of the body groove
7-19
Body
Belleville
Spring
SpringShoe
Circlip
(Piston& Connecting
Rod)
SERVICING
7. MAINTENANCE
YAnnAn 61118(A)L-V
2) lncorporation
springin the properdirection.
the coilsprings,ballsand Belleville
@ Incorporation
makesureof the clearance
@.
@ Rfterincorporation,
7-2. Ptston & ConnectingRod
the lubriespecially
to the dailymaintenance,
checkvariesaccording
The frequencyof pistondrawing-out
low load).Therefore,the supervisoris requiredto
catingoil controland load (overloadand excessively
at thetimementhe initialoverhaulandcheckshouldbe performed
However,
decidethe properfrequency.
checkscheduleaccordingto the overhaul
tioned in Chapter6. From then on, decidethe subsequent
Whenthe lubricatoil consumption.
checkingresults,an increaseof blow-byand an increasein lubricating
has becometwicethe initialvalue,overhaulandcleanthe piston,and replacethe pising oil consumption
ton rings.
7-2-'1.Piston& PistonPin
1) Disassemblingpreparation
Preparethefollowingexclusivetools:
[For Disassemblingthe ConnectingRod Boltl
PartNo.
ExclusiveToolDescription
Socketwrenchfor connectingrod bolt 146673- 92850
Handle
138987- 92760
Locknut
239653- 92770
[For Disassembling the Protection Ring]
No.
ExclusiveToolDescription
PartNo.
O
plate,protection
ring
Drawing-out
146673- 92030
@
Linerretainingimplement
- 92010
146673
@
Spacer
139653-92040
Eye bolt, piston lifting
26610- 120002
7-20
(Piston& Connecting
7. MAINTENANCE
SERVICING
Rod)
YANJUAN 61II8(A)L.Y
2) Piston drawing-out
Whileyou are drawingoutor incorporating
the piston,the crankshaft
mayturn spontaneously
due to
the unbalance.
Thisis dangerous.
Securelylocktheflywheelnotto allowthe crankshaft
to turn.Making surethe crankshaft
proceedto a work.
doesnotturnspontaneously,
ilillCft"pter
7-0,4) HandlingProceduresfor TurningDevice(p.74)
(1) Set the pistonat a positionof about 80 to 90'
before the T.D.C.
(2) Place the protectionring drawing-outtoolO on
the piston.
Drawing
7-18.Protection
RingDrawing-out
Procedures
Cyl.Head
Tightening
Nut
@
@
Place the lool so that its outer taper faces toward
the piston and do not allow it to make contactwith
the cylinderliner.
(3) Attach the liner retainingimplement@ and
spacer@,and lockthemwith the cylinderhead
tighteningnut.
(4) Turn the flywheel, and remove the protection
O
Protection Ring
Tapered
Part
nng.
(5) Removethe disassembling
toolsandprotection
ring.
(6) Eliminatethe carbonfromthe upperpartof cylinderliner.
(7)Setthe pistonat a position
of about30'aftertheT.D.C.
(8) Loosenthe connecting
rodboltswiththe specified
disassembling
tool,andthenremovethe boltsand
metalcap.
(9) Screwthe liftingeyeboltintothe piston,and liftit by 20 to 30 mm.
(10)Removethe uppermetal,anddrawoutthe piston.
Take care to preventthe connectingrod from makinga contactwith the crankshaftor cylinder liner.
3) Removalof the piston pin & piston rings
- 000130).
(1) Removethe pistonpin circlipswithuseof pliers(Pl#28190
Notethatthe circlipspringsoutto causean injuryif thetip of plierscomeout of thegrooveof circlipin
courseof removingthe circlip.
7-21
7.
MAINTENANCESERVICING(Piston& ConnectingRod)
YA}'J,,AE 61II8(A}L-Y
(2) Drawoutthe pistonpinwhileholdingthe connecting
rod.
(3) Maketwoloopsfromwire,andthenremovea pistonringwiththem.
Wearglovesbecausethe cornersof ringswill be sharpedgedto causeyou an injuryaftera longtime
of run.
Be carefulnotto widenthe cut of a ring by morethan40 to 50 mm; otherwise,the ringmay be broken.
4) Checking & servicing
Check the stateof carbonadherenton the piston and the state of wear various parts. Referto these checking resultsin decidingthe subsequentcheckschedule.
Drawing7-19.
the pisIn cleaning
of the piston,do notsandpaper
provided
has
with
which
been
special
coatton skirt
ing. (Washingthe pistonwith a carbonremoving
agent such as Unicon146 and Neos is recommended.)
Penetrate Test for Cracks on Piston
(1) Checkthecsntactof pistonskirtand pistonhole.
(2) Checkthe pistonby fiPenetrate
TestJfor cracks
on its top surfaceand ring groove (outside&
inside).
(3) Removethe pistoncoolingcasecover,and check
Drawing7-20.PistonIncorporatingProcedures
for adherentscale.
(4) Measurethe dimensionsof variouspistonparts
andof thepistonpin.
(5) lf possible,replacethe piston rings with new
ones,considering
the timeto the nextservicing.
(6) lf the pistonis replacedwiththe newone,provide
the sameset markon the newoneas that on the
previousone.
5) Incorporationof the piston
Incorporatethe piston in the sequencereverseto
payingattentionto thefollowingpoints:
drawing-out,
(1) Incorporatethe perforatedpistoncoolingcase
cover on the operatingside, apply a proper
screwlockagent(TokyoThree-BondScrewLock
No.1or its equivalent)
on the bolts,and tighten
themto fix the cover.
(2) Incorporate
the pistonpin circlipwith its opening
facingstraightdown.
(3) Incorporatethe pistonrings with their marked
sidesfacingupwardand their cuts shifted120'
fromthoseof adjacentrings.
2001.2.28R
7-22
(Piston& Connecting
7. MAINTENANCE
Rod)
SERVICING
Y/ANM,AB 6TI8(AL-V
Pistonringgrooveplatingrepairedpiston.
lf the pistontop ringgroovehavebeenrepairedwith Cr-plating,do not use the 3-faceCr-platedtop
ring.
(4)Incorporate
the oilringwithitscoiljointshifted180'fromits cut.
(5)Incorporate
the pistonandconnecting
rod,aligning
theirset markswitheachother.
apply the lubricatingoil on the rear of crank-pinmetals.
(6)Applythe lubricating
oilto thepiston,cylinderlinerandcrankshaft.
- 92140),
(7)Setthe pistoninsertingguide(P/#146673
and incorporatethe piston.
Drawing7-21.PistonReassembling
Procedures
(While tapping the piston with a resin hammer,
drive the pistondown.)
(8) Tightenthe connectingrod bolts.
PistoninsertingGuide
lf you haverestamped
the set markon a connecting
rodbolt,do notmistakethe newset markfor the previousset mark.
RodBolt(p.7-2al
ilffif Cn"p1rlr7-24.Gonnecting
7-2-2.Connecting
Rod
1)Checking& servicing
(1)Checkthe contactand loosenessin fit of piston-pinmetals.
(2)Measurethe innerdiameterof a piston-pinmetal.lf the measurement
exceedsthe usagelimitvalue,
replacethe piston-pinmetal.Removethe piston-pinmetaleitherby hammering
it out througha doublingmetalor by drawingit outwitha pressso as notto flaw the metalinsertinghole.
To incorporate
the piston-pinmetal,alignoil holesand pressfit the metal.Afterhavingpressfitted,
measurethe innerdiameterof the metal.
(3)Checkfor cracksandwearon the serrationmatingsurfaceof the connectingrodbigend.
lf a waterhammerhas occurredor a heavyburnoutof the pistonhas beendetected,measurethe
bendand inclination
of the connecting
rod,and dye checkfor cracks.
Criteriafor simple bend check
Drawoutthe piston-pin
metal,detachthe oil holeplugon the smallend,andtry to inserta 10-mmdia.
baror longdrillintothisplugholeandto turnthe baror drill.
lf the connecting
rod is bent,the bar or drillcannotbe inserted,or it can be insertedbut cannotbe
turned.
2002.5.15R
7-23
7. MAINTENANCE
(Piston& Connecting
SERVICING
Rod)
YAnr',AE 6Ill8(A)L-V
7-2-3.CrankPin Metal
1) Checking& servicing
Be sure to replaceboth the upper and lower crank-pinmetalsas a pair.
(1) Checkthe contacton the rear and mating
surfaceof each metal, and also checkfor Drawing 7-22. MetalThickness Measuring Points
cranks,seizureand imbeddedforeignmatterson the slidingsurfaceof each metal.
(2) lncorporate
the crank-pinmetalsto the connectingrod, and tightenthe connectingrod
boltsto the specifiedangle.Then, measure
the innerdiameterof the metals.lf the measurementexceedsthe usage limit value,
Approx.40mm
replacethe metals.
@
(3) Measurethe thicknessof the upper and
lower metals.lf the differencebetweenthe
dimensions
@ & O and the dimensions
@&
is
O.O+
mm
or
more,
replacethe metals.
@
(4) \Mten incorporating
the metalsto the connecting
rod,cleanthemnotto allowbiting-inof foreignmatters.Moreover,
do not applythe lubricating
oil the rearof the metals.
7-24. Connecting
Rod Bolt
1) Checking& servicing
(1) Checkingfor hit markand pluckingon the bearingsurhceandthreadedpartof eachbolt.lf any defect
is found,conectit.
(2) \A/hendisassembling
a connectingrod,be sureto restampthe set markwhichhas beenstamped
on eachconnectingrod boltjust beforethe shipmentfromour shopbecausethe tighteningtorque
of the boltvariesas dependedon accustoming
of the boltthreadedpartand bearingsurfaceand
the bigend senationmatedsurface.
(3) To preventthe boltsfrom beingbrokendue to fatigue,replacethemaboutevery20,000hoursevenif
theirappearance
is normal.
2003.9.10R
7-24
7.
MAINTENANCESERVICING(Piston& ConnectingRod)
YAN'',AN 6TI8(A)L-Y
2) Reassemblingprocedures
(1) Be sureto incorporate
previouspositions.
the boltsat the respectively
(2) Beforetightening
the bolts,applythe lubricating
oilto the treatedpartand Protecgreaseto the bearing surface.
(3)Tightenthe upperand lowerboltsgraduallyin the threesteps(approx.40',80'and 120'),aligning
withthesetmarkto the point@ on the connecting
rod.
O Keepthe deviationbetweenthe set markof the boltand the set markof the connecting
rod in lessthan
2 mmin the bolttightening
direction.
3) Bolt set mark stampingprocedures
Theconnecting
rodboltsare tightenedto the specifiedangle.On the connecting
rod,the marksindicatingthespecified
angle(120")arestamped(attwo points@ & @ ).
A
Stampa set mark on each bolt according to the following proceduresunder the conditionthat the
crank-pin
metalsare not equipped.
(1) Applythe lubricatingoil and Protecgreaseto each bolt,and screw it to its seatingby hand.
(2) Using a torquewrench,tightenthe bolt to the seating torque.
Afterreplacingconnecting
rod boltsor the connectingrod, repeattighteningthe boltsby about 90'
andloosening
themthreeor four times to make the bolts and the connectingrod accustomedeach
other.
Seatingtorque:49 N .m (5 kgf .m)
(3) Stampa temporaryset markon the sideof the
bolt collar,aligningwith the set mark at the
point@ on theconnecting
rod.
(4) Tightenthe upperand lowerboltsgraduallyin
the threesteps(approx.40', 80" and 120'),
aligningwiththeset markto the point@ on the
rod.
connecting
(5) Stampa set markon the sideof the boltcollar,
aligningwiththeset markat the point@ on the
rod.
connecting
Afterreplacingconnecting
rod boltsand the connectingrod, stampthe same CylinderNo., Bolt
No.,etc.as thosestampedon the previousones.
1999.6.25R
7-25
Drawing 7-23. Connecting Rod Bolt Marks
Block& CylinderLiner) vArrruAg
7. MAfNTENANCESERVICING(Cylinder
6Ill8(AL-yz
7-3.CylinderBlock & CylinderLiner
7-3-1.CylinderBlock
Excludingsomespecialcasesuchas bumoutof the crankshaft,
ordinarilyremovalof the cylinderblockis
not necessary.\Men the cylinderhead,piston,cylinderliner,etc.,are removed,performthe following
checkand servicing:
1) Checkingand servicing
(1) Checkfor loosecylinderheadboltsandmainbearingcapclampingbolts.
o Whenreplacinga boltwithdamagedthread...
Apply a seizure inhibitor(SumitomoMetal Mining'sLow Call Spray or its equivalent)to the
threadedparton the studdedside,andincorporate
the newbolt.
Studding
torque:196*4E
N . m (20*fikgf. m)
o lncorporate
the O-ringon the studdedside,and applywhitepaint.
Drawing7-24.Cylinder Block GheckingPoints
(2) Cleanthe boostair chamber.lf the rust preventivepaintappliedon its innersurfacehas peeledofr,
repairit. (Epoxyresinpaint NipponPaint'sHi-Pon50 or its equivalent)
(3) Cleanthe waterjacketand cylinderlinerfittingpart,andcheckfor corrosion.
lf a mainbearingmetalhasbeenburntout,measuretheaccuracyof mainbearingcap hole.
Straightness:
0.03 mm or lessin 1 mm of length
Roundness:
0.02mm or less
7-3-2.CylinderLiner
measurethe innerdiameterof cylinderlinerbecausethe extentof wearof innersurfaceof
o Periodically
cylinderlinervariesas dependedon the controlon lubricating
and
oil used,coolingwatertemperature
normalload.
Measurethe innerdiameterof cylinderlinerunderthe condition
in the cylinder
of beingincorporated
(Pl#42111-002930).
blockandwith use of the innerdiameterpositionmeasuring
implement
draw out the cylinderliner,and checkfor corrosion
r Periodically
of cylinderlinerbecausecoolingwater
maycausecavitationat the cylinderlinerwaterjacketanderodefromthe outersurfaceof cylinderliner.
2003.9.10R
7-26
(CylinderBlock& CylinderLiner) vAmuAB
7. MAfNTENANCESERVICING
15lllg(All-yz
I ) Disassemblingpreparation
(1) Preparethe followingexclusivetools:
PartNo.
No.
ExclusiveToolDescription
O
Spacer
139653-92040
@
Linerdrawing-out
upper
implement
146673-92010
@
Bolt
137655-92030
@
\Ahsher
22137-240000
o
Nut
26732-240002
@
lower
Linerdrawing-out
implement
146663-92020
@
Nut
26732-240002
@
Locknut
26772-240002
(2)\Mrendrawingoutthecylinderliner,coverthecrankshaft
with a sheetor the liketo preventwaterand
foreignmattersfromenteringthe crankcase.
2) Disassembly
Removethe cylinderlineraccording
thefollowingprocedures:
(1)Attachthe exclusivetoolsin theascending
orderof numeralsshownin Drawing7-25.
Attrachthe aforementioned
upperimplement@ and the lowerimplement@ so that their respective
steppedpartsfiacethe innerdiametersideof the cylinderlinerand the lowerlmplement@ in the
directionof the crankshaft.
(2) Adjustthe lengthof protrusion
bolt@ to about60mm,and lock
fromthe lowerpartof the drawing-out
the drawing-out
bolt@ withthe locknut@.
(3) \A/frilesupportingthecylinderlinerto preventit frommakingcontiact
withthe cylinder,tightenthe nut@ .
(4) Fit the cylinderlinerin the steppedparton thelowersideof the upperimplement@ , and lockthe cylinderlinerwiththe drawing-out
tools.
(5)Attacha wire ropeto the upperimplement
@ , andliftthe cylinderliner.
Drawing7-25.CylinderLinerDrawing-outProcedures
@
@
@
@
o
2003.7.11R
7-27
(CylinderBlock& CylinderLiner) yA,rMAn
7. MAINTENANCE
SERVICING
15;5l81a)L-yz
Do notusesandpaper,wirebrush,or the likewhencleaningthe outerperipheryof cylinderliner.Otherwise,the heat-treated
layeron the surfaceis removedto causerustingor conosion.
(1) lf the measurement
on the innerdiameterof a cylinderlinerexceedsthe usagelimitvalueor if the
is expectedto reachthe usagelimitvaluebeforethe nextservicing,replacesucha cylmeasurement
inderliner.
(2)Checkfor seizure,streakand corrosionon the slidingsurfaceof cylinderliner.
(3) Dyecheckthe roundedpartof collarof cylinderlinerfor cracks.
(4)Checkfor corrosion
andwearat the partof cylinderlinermatedwiththe cylinderblock.
4) Reassembly
(1) Replacethe O-ringsof cylinderliner.Applythe lubricating
oil or siliconeoil to new O-rings,and fit
them.Then,eliminate
torsionfromthe O-rings.
Beforeincorporating
theO-rings,stretchthemto checkwhethera crackhasdevelopedor noton their
surfacedueto a changeof temperature
and humidity,for instance,withtime if storedunderimproper
condition.
(2)Just beforeincorporating
the cylinderliner,apply the silicone-based
liquidpacking(Three-Bond1211
or its equivalent)to the upper section of cylinder block. Moreover, apply the lubricatingoil to the
mated part of the cylinderliner and block.
(3) Attachthe aforementionedexclusivetools @ thru @ to the cylinder liner.Then, aligningthe mark
0 (zero) of the cylinder liner and the punched mark of the cylinder (block), incorporatethe cylincier
liner into the cylinder,block. (Do not use the spacer O for this incorporation.)
After havingoverhauledand servicedthe cylinderliner,checkfor a water leakageform the O-ringpart
when fillingthe water tank with coolingwater and when runningthe engine for testing.
Drawing7-26.Liquid Packing& Lub. Oil Applying Points
7-28
7. MAINTENANCESERVICING(MainBearing& Crankshaft)
YAx'',An 6lltg(A)L-v
74. MainBearing& Crankshaft
Eachthrowof the crankshaftis equippedwith two balanceweightsof whichshapevarieswiththe service
rotatoryspeedof a machinedrivenby the engine.
At thetiminggearcasebehindthejournalfor the No.1cylinder,
anothermainbearingis mounted,
andfurtherat the head,a thrustbearingis incorporated.
Thus,thiscrankshaftis equippedwitheightbearingsin
total.
The mainbearingcap is of the suspensionmetalstructurefixedto the cylinderblockwith two clamping
bolts(withthetighteningnutstightenedto the specifiedhydraulicpressure)and two sidebolts(tightened
to the specified
torque).
Sidebolts
The sideboltsfor the datumpart(No.O)mainbearingcap are equippedonlyon the non-operating
side.Tothe No.1,2,6 & 7 mainbearingcaps,sideboltsof differentlengthsare provided
to clamp
alsotheenginesupporting
feet.
Drawing 7-27. Main Bearing Numbers
Cyl. No. No.6 No.s No.4 No.3 No.2 No.1
+
Mainbrg.capNo.
Tightening
On theop.side
nut
stampedNo. Onthe non-op.side
t
7
71
72
+
t
6
61
62
t
5
51
52
+
t
4
41
42
+
?
3
31
32
+
t
2
21
22
+
t i
1
0
11 01
12 02
74-1. MainBearing
Anymainbearingcapcannotbe takenout throughthe cylindersidecover.Checkor replacea mainbearingmetalfromthe operatingsideaccordingto the followingprocedures:
I ) Disassemblingpreparation
(1)Prepare
thefollowing
exclusive
tools:
jacktype]
pump& hydraulic
[Forthe hydraulic
for Hydrautic
Jack(p.Z-S)
lffilCftapterT-0.5) HandlingProcedures
7-29
7. MAINTENANCESERVICING(MainBearing& Crankshafl)
YAxMAn 6Ilt8(A)L-\'
lmplement]
[MainBearingCapDrawing-out
No.
ExclusiveToolDescription
O
Body
146673-92100
@
Mounting
bolt(M10 x 60)
26206-100602
o
Drawing-out
bolt
26206-121554
@
Nut
26706-120002
PartNo.
[MainBearingCap Holdinglmplement]
No.
ExclusiveToolDescriotion
o
Bolt
146673-92120
@
Circularnut
146673-92110
PartNo.
Attachinglmplement]
[UpperMetalDetaching/
No.
ExclusiveToolDescriotion
O
Uppermetaldetaching/
attachingpin
146673-92970
@
Uppermetalinserting
implement
146673-92950
PartNo.
(2) To facilitatethe checkor replacement
work,set the pistonadjacentto the mainbearingto be disassembledat a positionabout120' beforethe T.D.C.
2) Disassembly
jack,andconnectit witha hydraulic
(1) Fita hydraulic
pump.
Takeoutt the rubberhosein a directionto facilitatethework.
Drawing7-28.HydraulicJack Fitting Procedures
Side Bolt
Side Bolt
lffilCf."pter7-O. 5) HandlingProceduresfor HydraulicJack (p.7-5)
7-30
7. MAINTENANCESERVICING(MainBearing& Crankshaft)
YAliloAB
61118(A)L-Y
(2) Removethe side boltsfromthe mainbearingto be disassembled.
(3)Loosenthemainbearingcapclamping
jack.
pressure
nuts,applying
thehydraulic
to the hydraulic
lf the main bearing cap cannotbe drawn out due to its own weight:
C Loosenthe side boltsof the adjacentmain bearingcaps.
C Loosenthe main bearingcap tighteningnuts two to threeturns, and then draw out the main
bearingcap usingthe drawing-outtools.
Lock the drawing-outtool body O to tfre main bearingcap boltswith the bolts @. Then, screw the
bolt @ to the main bearingcap, and turn the nut @ to draw out the main bearingcap.
(4) Removethe main bearingcap tighteningnuts,and attachthe main bearingcap holdingimplementto
the main bearingcap clampingbolts.
Drawing 7-29. Main Bearing Cap Drawing-out Procedures
Do not removebothtightening
nutssimultaneously.
Otherwise,
the mainbearingcap mayfall,
resultingin injury.
Screweachcircularnut @ intothe corresponding
holdingbolt@ to lockthe holdingboltwiththe correspondingmainbearingcap clampingbolt.Adjustthe positionof circularnutsto makethem hold the
mainbearingcap.
Drawing 7-30. Main Bearing Cap Holding Procedures
A
a,
7-31
SERVICING(MainBearing& Crankshaft)
7. MAINTENANCE
YANIUAE (BilI8(A)L'V
(5) Removethe mainbearinglowermetal.
(6) Removethe uppermetal.
side (sothatthe
detachingpin @ to the crankshafioil holefrom the no-operating
Fitthe attaching/
periphery
pin lies alongthe outer
Slowlyturn the flyof crankshaft).
headof attaching/detaching
wheelin the directionof enginerotation,and drawoutthe uppermetalto the operatingside.
Disassembly & Reassembly of No.0 bearing cap
on boththefrontandthe rearof the datumpart(No.0)mainbearingcap.
Thrustmetalsareequipped
the
sidefirst,andthendisassemble
o Removethe lub.oilpumpandsidebolton the non-operating
No.0bearingcapin thesamewayas for the No.1thru7 mainbearingcaps.
Drawing7-31.MetalDrawing-outProcedures
Notch(pawl)i i
II:O
Notch (pawl)
3) Checking& servicing
Carefullycheckand servicethe mainbearingmetals.lf the clearancebetweenthe crankshaftand
oil pressuredropsto burnoutthe metals
the mainbearingmetalsbecomestoo large,the lubricating
possiblyresultingin seriousaccidentssuchas a breakage
of crankshaft,
and increasethe deflection
of the crankshaft.
(1) Checkfor hit marksand flawson the matedand fittedsurfacesof mainbearingcap with and to the
cylinderblock.
(2) Checkfor hit markson the matingsurfaceand rear of the main bearingmetal,and also checkfor
foreignmatterson theirslidingsurface.
flaws,seizuresandimbedded
Do notcorrectthe rearandslicingsurfaceof any mainbearingor thrustmetalbecausesucha
repairchangesthe clearancebetweenthe metalandthe crankshaft.
corrective
7-32
(MainBearing& Crankshaft)
7. MAINTENANCE
SERVICING
YAtr,'UAN 6]IT8(A)L'Y
(3) Checkfor looseness
of mainbearingcapclampingbolts.
Studding
torque:
196*48
N . m (20*fikgf. m)
(4) Measurethe clearancebetweenthe crankshaftand the metal.
the clearanceis to removethe crankshaftand thento meaO An accuratemethodof measuring
sureitsouterdiameter
andthe innerdiameterof a mainbearingcap.
placeand about0.5-mmdia.leadwire
withoutremovingthe crankshaft,
@ To obtainthe clearance
on the slidingsurfaceof main bearinglower metal(alongthe outerperipheryof crankshaft
to
preventthe leadwire from slippingwith grease,etc.),tightenthe main bearingcap tightening
nutsto thespecifiedhydraulicpressure,
take out the leadwire,and then measureitsthickness.
Youcandetermine
the clearancebetweenthe crankshaft
and metalfromthisthickness.
(5) lf the clearance
exceedsthe maximumallowablevaluedue to wear of the metal,replaceit withthe
newone.
When replacingthe metal,be sure to replaceboth the upper and lower metals as a
lf the crankshaft
is excessively
worn(unevenly
worn),replacethe metalswith undersizedmetals.
Also,it is necessary
to reworkthe crankshaft
by polishingit so that it fitswiththe new undersized
metals.
[Thrustmetals]
(1)Checkforwearandburnout.
(2) lf the clearance
exceedsthe maximumallowablevaluedueto wear,replaceboththe upperandlower
metalsas a pair.
Drawing7-33.Thrust ClearanceMeasuringProcedures
Crank Shaft
Dial Gauqe
O Fix the dialgaugestandto the cylinderblock.Putthe dialgaugein contactwith the crankshaft.
Then,movethe crankshaft
forwardto set the indication
of the gaugeto zero.
@ Movethe crankshaftbackward.Then, read the value indicatedby the gauge.The indicated
valueis thethrustclearance.
7-33
(MainBearing& Crankshaft)
7. MAINTENANCE
SERVICING
YA)r',,An 61118(A)L-V
(3)Whenincorporating
thrustmetals,observethe followingpoints:
eachoneof the upperand lowermetalsof thefrontalandrearpartsat the respective
@ Incorporate
formerpoint,not mistakingone for other.
the uppermetalby matingits printedpartwiththe cylinderblocksideand slidingit
@ Incorporate
alongthe crankshaft.
the lowermetal,matingits groovewiththe crankshaft
@ lncorporate
side.
4) Incorporationof main bearings
Reassemble
mainbearingsin the followingsequence:
(1) Turnthe flywheelto lowerthe oil holein the crankshaft
belowthe centerof crankshaft.
(2) Directingthe pawlof the uppermetaltowardthe non-operating
side,insertthe uppermetalalongthe
crankshaft.
Drawing7-34.UpperMetalIncorporatingProcedureg
RoundedEnd
SteppedEnd
MainBrg.Cap
ClampingBolt
Non-operatingSide
Pawl Hole
Pawl Hole
@
@
@
Positionthe uppermetalin the forward-backward
directionso that its pawlwillmatewith the pawl
holein the cylinderblock.
(3)Attachthe uppermetalinsertingimplement@ to the mainbearingcap (fromwhichthe lowermetalis
detached).
Attachthe implement,matingits one curvedend withthe outerperipheryof a mainbearingcap
clampingbolton the operatingsideand aligningthe othersteppedendwiththe innerperiphery(on
the pawlholeside)of mainbearingcap.
(4) Insertthe attaching/
detachingpin @ to the crankshaft
oil holeon the non-operating
side.
Putthe headof metalattaching/detachingpin alongandin closecontactwiththeouterperipheryof
crankshaft
withthe propergreaseso as notto allowthe pinto fallduringturning.
(5)Tightenthe circularnuts@ of the mainbearingcap holdingimplementuntitthe uppermetalinserting
implement@ is aboutto makecontactwiththe rearof the uppermetal.
7-34
(MainBearing
& Crankshaft)
7. MAINTENANCE
SERVICING
YAmoAn 61ll8(A)L-Y
(6) Slowlyturntheflywheelin a directionreverseto the directionof enginerotation.
Make sure the side of pawl of the upper metal is in contactwith the side of the metal insertingimplement. lf they are not in contact,the pawl does not fit in the pawl hole.
(7)Whenthe pawlof the metalhasbeenalignedwiththe pawlholein thecylinderblock,continueturning
the flywheeluntilthe metalend alignswiththe cylinderblockend.
(8) Loosenthe circularnuts@ to lowerthe mainbearingcap.Removethe metalattaching/
detachingpin
implement
thelowermetal.
@ and metalinserting
@. Then,incorporate
(9) Tightenthe circularnuts @ and removethe holdingbolts@ . Then,fit mainbearingcap tightening
nuts.
Fit the tighteningnuts one side a time. When a main bearingcap falls under its own weight, there is a
fear you might be injured.
(10)Tightenthe nutsuntilthe mainbearingcapmakesa closecontact
withthecylinderblock.
lf the side bolts of main bearingsadjacentto the main bearinginvolvedin disassemblyhave been
loosened,first tighten the side bolt on the non-operatingside, and then the side bolt on the operating side to the specifiedtorque.
(11)Tightenthe sidebolt on the non-operating
sideto halfof the specified
torque.(Havethe bolton the
operatingsideremovedin advance.)
('12)Tightenthe sidebolton the operatingsideto its seatingby hand.
pressure.
(13)Tightenthe mainbearingcaptighteningnutsto the specifiedhydraulic
(14)Tightenthe sidebolton the non-operating
sideto thespecified
torque.
(15)Tightenthe sidebolton the operatingsideto the specified
torque
Afterincorporating
the mainbearing,measurethe crankshaft
deflection.
ru
(p.6-34)
Chapter6, 6-3-17.Measurement
of Crankshaft
Deflection
7-35
(MainBearing& Crankshaft)
7. MAINTENANCE
SERVICING
YAMUAN 6IIT8(A)L-Y
74-2. Crankshaft
The crankshaft
requirescarefulcheckingand measurement
becauseit may be brokenor burntout if you
continuerunningunderthe followingstatesof crankshaft:
O Unevenwearof crankshafi
clearance
betweenthe crankshaft
and mainbearingmetaldue to wearof crankshaft
@ Excessive
valueof crankshaft
deflection
the allowable
@ Runningexceeding
of torsionalvibration
rotatoryspeed.
@ Runningat criticalregion
I ) Disassemblingprocedures
In eithercaseof removingthe crankshaft
downwardby liftingthe engineor removingthe crankshaftup
vertiwardby inverting
the engine,fit the ropeto the No.2& 5 crank-pinparts,and removethe crankshaft
available.)
cally.(Theengineliftingtoolis optionally
2) Checking& measurement
(1)Checkforflaws,improper
contactandabnormal
wearof the bearings.
(2) Dyethe rootroundedpartof crankarms.
(3) Checkfor looseness
of balanceweightclampingbolts.
(4) Measurethedimensions
of bearingsandcheckfor unevenwear.
(5) Measurement
of crankshaft
deflection
procedures,
Formeasuring
referto thefollowing:
of CrankshaftDeflection
lEEl Cn"pter6, 6-3-17.Measurement
Drawing7-35.GrankshaftBearingPart MeasuringPoints
A
In a burnoutof thecrankshaft
bearingpart,not onlythe correction
and replacement
o mainbearingor
thrustmetalsbutalsocheckfor haircracksthroughmeasurement
of the surfacehardnessand magneticflawdetection.
Crankshaftsurfacehardness
Shouldbe HS 65 - 85.
Haircrack
Should not be detected.
7-36
(TimingGear)
7. MAINTENANCE
SERVICING
YATJTUAB6NI8(A}L.I'
7-5.TimingGear,Gamshaft& Suc./Exh.SwingArm
7-5-1.TimingGear
Even under the conditionof normaloperation,there is a wear of gears. This may cause a pitchingwear,
pluckingand hair crackson the tooth surface.
Besides,since the wear is relatedto noise and vibrationperiodicallycheck the backlashof gears and contact of tooth surface.
When disassembling
the timinggears,measurethe backlashof gears, lf the measurementexceedsthe
allowablevalue, replacethe pertinentgear of bearingwith the new one.
A set mark is stampedon the side of crankgear,idle gear A, idle gear B and cam gear.When assembling
the timinggears,set the No.1 (or No.6)cylinderat the B.D.C.,and alignthe set marks.
Drawing 7-36. Timing Gear Set Marks
Drawing 7-37. Cam Gear Disassembling Procedures
r'--l
Gov. Drive Bevel Gear
Governor
Governor
Driver
Cam Gear
Gov.DriveBevelGear
CamGear
T
ldle Gear B
Tachometer
DriveCoupling
Tachometer
DriveShaft
ldle GearA
ldle GearA
ldle Gear B
-' -]
t
I
CrankGear
1) Camgear
The governordrivebevelgearis incorporated
to the cam gear,and they are incorporated
to the
camshafttogetherwiththetachometer
drivecoupling.
(or reassemble)
Disassemble
the camgearaccordingto the followingsequencewith the coverof timing
gearcaseremoved:
(1) Removethe governorandgovernordriver.
(2) Removethetachometer
driveshaft.
(3) Removethe camgearclampingboltandtachometer
drivecoupling.
(4) Drawout the camgeartowardthe flywheelside,and removethe gearthroughthe windowof timing
gearcase.
7-37
7. MAINTENANCESERVICING(TimingGear)
YANNAN 6]|I8(A}L'Y
(5) Cam gear clampingprocedures
O Mating the number stamped on the head of cam gear clamping bolt with the numberstampedon
the side of cam gear, incorporatethe bolt into the gear.
O When tighteningthe cam gear clamping bolt, apply the seizure inhibitor(Three-Bond1910 or its
equivalent)on the bearing surface and threaded part of the bolt, and then tighten the bolt to tire
specifiedtorque.
2) ldle gears
Extract the idle gear mounting shaft toward the flywheel side, and then take the idle gears out from the
windowof timinggear case.
The idlegearsA & B havebeenshrinkfitted.
Drawing7-38.ldle GearsDisassemblingProcedures
(1) Removethe flywheel.
(2) Removethe idle gear mountingshaft support.
(3) Extractthe idle gear mountingshaft toward the flywheelside.
(4) Checking
Check for seizure and uneven wear of idle gear shaft bearingand mountingshaft,and measurethe
dimensions,lf the bearingclearanceexceedsthe allowablevalue,replacethe bearingor mountingshaft.
(5) When reassemblingthe idle gear assembly,replace the O-ring of the idle gear mountingshaft.
3) Crankgear
Drawing7-39.CrankGearRemovingProcedures
(1) To facilitateremovalof crankgear,drill a hole
Drilled Hole
belowthe bottomlandof the gear,and drivea
chiselintothis hole.Thiswill loosenfitting,and
thusthe gearcan be easilyremoved.
knockpin.
Takecarenotto damagethe positioning
CrankGear
"C
(2) Beforeincorporating
the crankgear,put it in the oilbath,and hearthebathto about150to 190 ,
leavethe gear in the bathfor about60 minutes,and thentake it out of the bath.Afterthat,quickly
insertthe crankgearto the crankshaft.
will rise
Refrainfrom heatingthe crankgear with a burneror the like, otherwisethe temperature
excessively
to changethe structureof the materialandto decreaseitsstrength.Instead,useof an oil
for this purpose.
bathis recommended
7-38
7. MAINTENANCESERVICING(Camshaft)
YANM,AN 61II8(A)L.Y
7-5-2.Camshaft
Thefuel cam and suctionand exhaustcamsforma monoblock
structure
withthe camshaft.
The camshaft
is splitin two at the bearingpartbetweenthe No.3& No.4cylindersandcoupledby reamerbolts.
lf the engineinstallation
sitedoesnot havespaceenoughto extractthe camshafiin onepiece,splitit, and
thendrawout two partsfromthe engine.
Drawout the camshafttowardthe frontside(thesideoppositeto theflywheel).
1) Disassembly
Disassemble
the camshaftaccordingto the followingprocedures:
(1) Removethe bonnet,andthenrockerarmshaftpedestaland pushrod.
(2) Disconnectthe fuel injectionpipejoint, and then removethe fuel injectionpumpand fuel injection
pumpdriver.
(3) Removethe suc./exh.swingarm.
Fortheirremovingprocedures,
referto the following:
ru
Chapter7-5-3.Suc./Exh.
SwingArm (p.ZaO)
(4) Remove the coolingwater pump, fuel oil feed pump and fuel oil filter (togetherwith its mount).
(5) Removethe gear case.
Liftthe gearcaseup with rope.lf the gearcasefalls,an accidentmayoccur.
Sincethe gearcaseis positioned
withtwo knockpins,jack it up withM12boltsto removeit.
(6) Removethecamgears.
Fortheirremovingprocedures,
referto the following:
ru
Chapter
7-5-1,1)
Camgear(p.7-37)
(7) Drawout the camshaft.
2) Checking& servicing
(1) Checkfor flawsand excessivewearon the fuel,suctionandexhaustcamsandbearings.
(2) Measurethe dimensionsof camshaftbearingpartsand bearings,and checkthe clearancebetween
eachbearingandthe shaft.
(3)Toreplacea camshaftbearingby pressfittingit, a jig (jack)is necessary.
n\
/
Whenincorporating
a bearingto the camshaft,putthe bearingso thatitsjointfacesupwardand itsoil
holeis matedwithoil holeof camshaft,and pressfit the bearing.
Drawing740. GamshaftCouplingPart
7-39
(Suc./Exh.
SwingArm)
7. MAINTENANCE
SERVICING
YANTUAE 6]II8(AL'Y
3) Reassembly
Reassemblethe camshaftin the sequencereverseto that of disassembly,paying attentionto the following points:
(1) Make the camshaftcoupling surf;acesfree from adherentforeign matters and lubricatingoil. Then,
align the notchwith the drilled hole to reassemblethe camshaft.
(2) Tighten U-nutsof the couplingpart only afterapplyingthe seizureinhibitor(Three-Bond1910 or its
equivalent)to their threadedpart and bearingsurface.
Drawing7-41.CamshaftBearingPress-fittingProcedures
Joint
7-5-3.Suc./Exh.SwingArm
forcedlylubricates
the rollerpinsby the swingarmsystem.
Thevalvemechanism
1) Disassembly
the swingarm assemblyaccordRemovethe rockerarmshaftpedestaland pushrods,anddisassemble
procedures:
ing to the following
(1) Removethecoverof camcase.Loosentheswingarmshaftclampingbolts,and removethe arm shaft
and armtogetheras a set.
andthen remove
(2) Removethe circlipsformthe arm shaftwithuseof circlippliers(P/#28190-000020),
the swingarmsandspacers.
Drawing742. SwingArm DisassemblingProcedures
Suc.
Exh.
PushRod
Swing Arm Shaft
:-,c..
(--@
tl
r!.:
'I
t
i\\
rl
2003.7.11R
7-40
(Fuellnjection
Pump&Pump
Driver)vAnMAn
7. MAINTENANCE
SERVICING
6Nt8(AlL-yz
2) Checking & servicing
(1) Check if the roller rotatesunsmoothly(is catching)and for flaws on the outer peripheryand one-sided
contact of roller.(lfany defect is detected,replacethe swing arm with the new one by assembly.)
(2) Check for jolting of a push rod. Measurethe dimensionsof the arm shaft and arm shaft bearing,and if
a measurementexceedsthe usagelimitvalue,replacethe shaftor the arm.
3) Reassembly
Reassemblethe suc./exh.swing arm assemblyin the sequencereverseto disassembly.
(1) Checkfor deformationor missingof collarof swingarm shaftclampingbolt holes.
(2) Incorporatethe swing arm shaft so that its set mark "R" is positionedon the right side.
"L" on the lefi
Screw the clampingbolts with the set mark "R" on the rightside and with the set marl
side.
A
properly,
is
Do notmakea mistakein thisincorporation.
lf notincorporated
thelubricating
oilpassage
in burnoutof the armshafiandrollerpins.
shut,resulting
(3) After having incorporatedthe rocker arm shaft pedestal,adjustthe suc./exh.valve head clearance.
For the adjustmentprocedures,refer to the following:
iffil
Cfrapter6, 6-3-6.Adjustmentof Suc./Exh.Valveheadclearance
7-6.Fuel InjectionPump & PumpDriver
7-6-1.FuelInjection
Pump
Payfull attentionto handlingof the fuel injectionpumpin its disassembly
& reassembly
sinceit has been
madepreciselyand evenminuteforeignmattersand hit markmaycauseit to be burntout or its malfuncion.
1) Disassembly
(1) Preparethefollowing
exclusive
tools:
ExclusiveToolDescription
Socket wrench for pump
mounting
PartNo.
On the flywheelside
146673-92550
On the anti-flywheel
side
146673-92570
Hexagonalwrench
key(8 mm)
28150-080000
Hexagonalwrench
key(6 mm)
28150-060000
7-41
(FuelInjectionPump&Pump
Driver)yzANry,AR 6;518(A)L-yz
7. MAINTENANCE
SERVICING
Drawing7.43.FuelInjectionPumpRemovingProcedures
(2) Next,removethefuelinjectionpumpin the followingsequence:
Removethe fuelinjectionpipejoint,overflowoil pipe,fueloil inletpipe,fueloil outletpipe,and pinion
lub.oil pipe(H.F.O.
specification
only).
pumptightening
(3)Usingtheexclusive
nutsto removethe pump.
wrenched,
loosenthefuelinjection
socket
(4) Disassemble
thefuelinjectionpump,payingattentionto followingpoints:
C Be sureto handlethe plunger@ andbarrel@ as a pair.
valvebody@ , tate carenotto loseany partsof
C Whenremovingthe pressureequalizing
pressure
valve@.
equalizing
Drawing7-4. Fuel InjectionPump Disassembli ng Procedures
@
@
x
@
x
@
x
26206-120952
146673-92900
x
@
@
\!)
26206-120454
Circlip
@
o
@
@
@
@
@
O
26706-120002
Disassemble
the fuelinjectionpumpin the ascendingsequenceof numbersshownin Drawing744.
Invertthe pump,and removethe circlipO with use of the pertinentexclusivetool.Then, removethe
parts@ thru@.
Whentakingoff the circlip@ fromthe groove,wrapit withclothor the liketo preventthe circlipfrom
springingoffto inflictyouan injury.
(FuelInjectionPump&Pump
7. MAINTENANCE
Driver)vAnMAn
SERVICING
6lll816)L-yz
2) Checking& servicingof fuel injectionpump
Washeachpartcleanly,andtakecarenotto allowit to be rusted.
(1) Checkif thespringof pressureequalizing
valve@ is not broken.
(2) Checkif the matingsurfacesof pressureequalizing
valvebody@ and barrel@ arefreefromblow-by
of fuel.
(3) Checkfor flawsor sludgestuckon the outerperipheryof plunger@ .
(4)Cleantheoilholeof barrelandpinionlub.oil holeof the pumpbody.
(5) lf the tip partof deflector@ is dentedby corrosion,
replaceit.
(6) ReplaceeachO-ringwiththe newone.
3) Reassembly
payingattentionto the folReassemble
thefuelinjectionpumpin the sequencereverseto disassembly,
lowingpoints:
Drawing7.45.PressureEqualizingValveParts IncorporatingSequence
@
@
@
ii
il
i1*-@
tl
Chamfered
- - -'-\[E*-O
H-H
(1)Afterhavingincorporated
eachO-ring,makesureit is notwarped.
(2)Applythe lubricating
oil to the barrel,and incorporate
it to the body.
(3) Incorporate
thepartsof pressureequalizing
valve@ in the ascendingsequenceof numbersshownin
Drawing7-45.
(4) Tightenthe barrelclampingboltand pressureequalizing
valvebodyclampingbolt @ evenlyin three
stepsto the specified
torque.
(5)Alignthe set marksof rack@ , pinionO and plunger@ .
Drawing746. Set Marksof Racks,Pinion & Plunger
Rack(redmarkon the bottomland)
Pinion (notch on tooth crest)
Pinion (notch groove)
Plunger(punch marked)
(6)Whenincorporating
the circlipO , pushin the plungerguide@ whilecheckingthe moveof rack@ not
to allowthe pinionO to ne damagedby the collarof plunger@ .
(7)Alignthe openingof circlipwiththe notchof the body.
Drawing 747. Circlip IncorporatingProcedures
(8)Afterreassembling
thefuelinjectionpump,makessurethe rackmovessmoothly.
7-43
7. MAINTENANCE
SERVICING(FuelInjectionPump&Pump
Driver)y,arm^,
|iillg(A)L-Yz
7-6-2.FuelInjectionPumpDriver
The fuel injectionpump driver adoptsthe tappet roller systemthat forcedlylubricatesthe roller pin.
Besides,on the bodyof the pump,the oil holefor lubricating
the outerperiphery
of the rolleris provided.
1) Disassembly
Removethe fuel injectionpumpandthenthe positioning
bolt,Afterthat,removethedriverformthe cylinder,and disassemble
it in the ascendingsequenceof numbersshownin Drawing748.
Drawing748. Pump Driver DisassemblingSequence
Fuel InjectionPump
-- -\
--{
:'.--
':l-4-7\f='!
j,-.,
I
--i'--:1
A
,.@
2) Checking& servicing
(1) Checkfor one-sidedcontactandflawson the outerperipheryof roller.
(2) Checkif the rollerrotatessmoothly.
(3) Blowthe air intothe oil holein the bodyto checkfor clogging.
(4) Replacethe O-ringsshownin Drawing7-48.with newones.
3) Reassembly
Reassemble
the fuel injectionpumpdrivel payingattentionto the followingpoints:
(1)Alignthe set mark"O" on the bodywiththat on the tappet@ .
(2) lncorporate
the oil shieldcover@ withits notchpartfacingthe operating
side.
(3) Fullyscrewin injectiontimingadjustingboltO, and incorporate
it in position.
(4)Aftermountingthe fuel injectionpump,adjustthe injectiontimingto thespecifiedtiming.
Forthe injectiontimingadjustingprocedures,
referto the following:
ru
Chapter6, 6-34.Adjustmentof FuelInjectionTiming(p.6-i2)
2002.12.25R
7-44
7. MAINTENANCE
SERVICING(Governor& GovernorGear)
vAntfrAR 6X|8(A)L-Y
7-7. Governor & Governor Gear
7-7-1.Governor
governors
The enginescan be equippedwith one of the threetypesof hydraulic
depending
on theirspecifications.Foreachgovernor,referto its operationmanualprovidedseparately.
O Beforeremovingthe governor,recordthe speedregulation
andstatusof eachadjustingpoint.
O Whenremovingthe governor,do notgivean impactto thegearshaft,terminalshaft,speedcontrol
shaft,etc.
7-7-2.GovernorGear
The governor gear is drive via the bevel gear on the camshaftgear side. The govemor is driven by the
governorgear via a splinecoupling.
Drawing749A. Type NZ (or RHD)GovernorDriver
ltsr
lr.fl,--n
tJ-t-/
[I:n-l
l_ -_ -
|
.':r
t.ebl
I
.--i-'--ij
|
:
r-:A]J
I
i
__
Sptine
GovernorMount
\u
@
@
@
Q'
@
16\
@
@
@
o
1) Disassembly
Eitherof two typesof governorgearsis applicable
to the governorused.
payingattentionnotto flawthedrivingshaftspline.
Whenremovingthe governor,
takeit out vertically,
I In the case of an engineequippedwith TypeRHDgovernorI
(1) Disassemble
the governorgearin the ascendingsequenceof numbersshownin Drawing749A.
O Loosenthe geartighteningnut@ , and removethe parts@ tnru@ to tnegearside.
O Removethe circlip@ with useof circlippliers.Removethe splinecouplingto thegovernorside.
(ThebearingsO & @ are press-fitted
to the drivingshaft@.)
2) Ghecking& servicing
(1) Checkthe contactof bevelgeartoothsurface.
(2) Checkthe contactand steppedwearof drivingshaftspline.
Fit the driving shaft spline with the governor spline,and check if jolting is not excessive.
7-45
(Governor
7. MAINTENANCE
& Governor
Gear)
SERVICING
YAttrtAn 6lll8(AlL-Y
(3) Replacethe ballbearings
every8,000to 10,000hoursevenif theirappearance
is freefromabnormality.
Whenincorporating
the ballbearingsO & @ to the drivingshaft,pressfit them,applyingthe toadto
the innerraceof the bearings.
3) Reassembly
Reassemble
the governorgearin thesequencereverseto disassembly.
(1) Mountthe governorgear,andcheckthe backlashof the bevelgear.
To adjust the backlash,remove the bevel gear @ from the driving shafi, and adjust the thickness of
adjustingshim@.
Whenmountingthe governor,let itssplinefit with the govemorgearsplineunderthe governorown
weight.
I In the case of an engineequippedwith TypeSG governor]
Governordriving gear
Item of importancefor disassembly& reassembly
(1) Replacethe ballbearingof governordrivinggearwiththe newone by 6,000- 8,000hoursof operation (abouttwo years)or whentheyareresultedin abnormalwear.
(2) At the timeof attachingthe drivinggear,confirmthe backlashof bevelgear,and adjustthe backlash
by regulating
the numberof shimsof bevelgearbosspart.
(3) At the timeof attachingthe governor,
checkto see thatthereis no forcingto fittingof governorshaft
andsplinecoupling.
(4)Thebacklash
of spurgears(A)and(B)shouldbe 0.1- 0.15mm.(Approximately
(1098 - 1'18N-m
l2kgflm)is suggested
for spurgear(A)tightening
torque.)
(5) Payattentionto the directionof oilseal.(Thecorrectdirectionis thatthe oil sealfacesdownward.)
Drawing7498. TypeSG GovernorDriver
SpurGear(A)
SpurGear(B)
BevelGear
2002.12.25R
7-46
7. MAINTENANCE
SERVICING(Governor& GovernorGear)
y/A}TIUAB 6ilIE}(A)L'l'
7-7-3.Coupling
Adjustment
of Governor
lmproper couplingof the governorand fuel injectionpump may adversely affect the performancesof governor, disablethe engine from stopping and cause the rotational speed to rise excessively.After having
servicedor replacedthe fuel injectionpumpand/orgovernor,adjustthis couplingaccordingto the following
sequence.
(1) Checkif the clearancebetweenthe couplingrod and the connectingpin on both ends od couplingrod
is not excessive.
(2) Set the starUstoplever in the STOP position.
(3) Make the rack scalesof fuel injectionpumpsof all cylindersset to the same positionwithin the range
of graduation9 to 10.
(At this time, also make sure the first lever moves smoothly.)
Drawing 7-50.Fuel lnjection Purnp Rack Adjusting Procedures
1) lf the Type NZ (or RHD)governor is equipped
Drawing 7-51.Type NZ (or RHD) Governor Connecting Procedures
Govemor Lever
Fuel
Decrease Increase
I
\
F\.
)@,
Coupling
fl\
I Govemor
I OutputShaft
StarVStooLever
Lock Bolt
Coupling
2003.4.17R
7-47
Yalue)
OilPump
OilPress.
Reglat.
&Lub.
7. MAINTENANCE
SERVICING(Lub.
y163y,ps1s6Nl8(AlL-t/
(a) Adjustthe screwing-inof the 2nd lever couplingbolt so that the distancebetweenthe centerof the 1st
lever shaft and the center of the couplingrod becomes about 95mm.
(5) Connectthe couplingrod to the 2nd lever coupling bolt.
(6) lnsert a blade screwdriver into the governor output shaft end, fully turn the shaft in the fuel
'0" indication.
DECREASEdirectionso as to set the pointerat the FUEL
(7) Incorporatethe governor lever to the governor output shaft. (Loosenthe governorlever lock bolt in
advance.)
(8) Connectthe couplingrod to the governor lever. (The governor lever has four holes.Connectthe coupling rod with the same hole as connectedbefore disassembly.)
"1" indica(9) lnserta bladescrewdriverinto the governoroutput shaft end, set the pointerto the FUEL
O Cneckthatbothendsof couplingrodare nottwisted.
and makesureeachrack
settingthe star/stopleverin the STARTand STOPpositions,
@ Alternately
(within
position)of a less
9
the rangeof graduation
13 (non-injection
scaleis setat thegraduation
to 10)whilethe leveris set in the STOPposition.
e e g u l a t i nVga l v e& L u b .O i lC o o l e r
7 - 8L
, u b .O i lP u m p L, u b .O i lP r e s s u r R
7-8-1.Lub.Oil Pump
with a pressureregulating
The lubricatingoil pump is a gear pump of which body is built in incorporates
valve and a safetyvalve.The pump gear and shaft are shrink fitted.
1) Disassembly
(1) Disconnectthe suctionpipe, deliverypipe and pressureregulatingvalve pilot pipe from the lub. oil
pump,and then removethe pump.
The pump is positionedwith knockpins. Removethe pump by fittingthe pump mountingboltsto the
respectivedisassembling
threadedholes@ and jacking up the pump.
(2)Disassembly
of lubricating
oil pump
pump
gear,
thepump.
removethe
drive
and disassemble
Detachthe side coverfrom the pump. Fit the (M12 x 1.75)bolt at the part @ of the drivinggear to
lockit. Then, loosen(or tighten)the tighteningnui.
Procedures
Drawing7-52.Lub. Oil Pump Removing/Disasembling
Pilot Pioe
Knock Pin
t
PressureAdjustingBolt
7-48
7. MAINTENANCE
yatve)
sERVlclNG(Lub.
oitpump&
Lub.
oitpress.
Regtat.
yaslplg
6ilt8(A)L-Y
Disassembly
of the lub.oil pressureregulatingvalve& safetyvalve
Be carefulof a spring which springsout from the safety valve and/of pressure
assemblyto inflictyouan injury.
Disassemble
the pressureregulating
v alveafterloosening
the pressureadjustingbolt.
Drawing 7-53. Pressure Regulating Valve & Safety Valve
Pilot Piston
Spindle
V-groove
Reg. Valve
Spring
2) Checking& servicing
I Pumpbody& pumpgear]
(1) checkfor flawsandseizureon the toothsurfaceand sideof the pumpgear.
(2)checkfor flawsandseizureon thepumpgearshaftandgearshaftbearing.
(3) Measurethe clearancebetweenthe pumpgear and the pumpbodyat the bearingpart.lf the measurementexceedsthe allowablevalue,replaceeitherpartwhicheveris wornmorethantheother.
Pressure
regulating
valve& safetyvalve]
I
(1) Checkfor flawson the pilotpiston,pressureregulating
valve,safetyvalveandvalvesp6ngs.
(2) Checkthe operationof pilotpiston,pressureregulatingvalveand safetyvalve,and makesurethey
operateproperly.
Directingthe V-grooveof pressureregulatingvalvetowardthe pilotpiston,incorporate
the pressure
regulating
valve.
3) Reassembly
Reassemblethe lubricatingoil pump in the sequence reverseto disassembly.
7-49
(Lub.OilCooler)
7. MAINTENANCE
SERVICING
YA}'TOA'| 6TI8.A'L.Y
7-8-2.Lub.Oil Cooler
The lub. oil cooleris of the multitubulartype,and chemicalcleaningseatsthat enablecleaningof the oil
coolerwithoutremovingit areequippedon the lubricating
oil passageside.
1) Chemicalcleaningprocedures
The hose,pumpandthe likerequiredfor chemicalcleaningare not includedin the standardprovisionof
thisengine.
(1) Drainthe lubricating
oilfromthe oil cooler,rearrange
the respective
baffleplatesO , @ & @ at the oil
coolerinletandoutlet.
(2) Removethe roundcoversfromthechemicalcleaningseatsand connecta hosewitheachseat.Then,
circulate
the cleaning
solution.
(3)Afterhavingfinishedcleaning,drainthe cleaningsolution,and returnthe baffleplatesand roundcovers to theirformercondition.
Drawing7-54.ChemicalCleaningProcedures
ThermostaticValve
Topreventthe cleaningsolutionfrombeingmixedintothelubricating
oil,be sureto treatthe oil cooler
afterchemicalcleaning.
2)Disassembly
Drainthe lubricatingoil from the lub. oil cooler,fix the coolerbodywith rope,and removeit from the
engine.
(1)Removethelub.oilstrainer.
(2) Removethe capsfromthe coolingwaterinletandoutlet.
(3) Removethe lub.oilthermostatic
valve.
(4) Removethe coolingwaterpipeassembly.
7-50
7. MAINTENANCESERVICING(Lub.OilCooler)
YAfl/'AAB 61II8(A)L-Y
3) Ghecking& servicing
(1) For checkingandservicingof lub.oil strainerand lub.oil thermostatic
valve,referto the followings:
lffilluU. oilstrainer:Chapter6, 6-3-12(p.6-2tl
Thermostaticvalve:Chapter6, 6-3-8(p.6-20)
(2)Cleanthepipeon thecoolingwatersideandlubricating
oil sideof cootingwaterpipeassembly.
O Descalethe pipe on the coolingwaterside with a long-handlebrush.
C For the pipe on the lubricatingoil side, cleaningcombiningwashingwith such a sludgecleaning
agent as Neos and cleaningwith steam is appropriate.
(3) Replacethe O-ringsat the coolingwater inlet and outletside coverswith new ones.
4) Reassembly
Reassemblethe lub.oilcoolerin the sequencereverseto disassembly,payingattentionto the following
points:
(1) Align the set marks of coolingwater pipe assemblyand lub. oil coolerbody when incorporating
the
pipe assemblyto the cooler body.
Drawing 7-55. Set Marks (on The Cooling Water Ouflet Side)
fUOe
End Plate
A
lt ll
i
-K
-\'1{#
-iL./;
\\_\J_
\-- \
7-51
(Cooling
WaterPump)
7. MAINTENANCE
SERVICING
uAt ruAE 61118(A)L-l/
7-9.CoolingWaterPump
water
The coolingwaterpumpis a centrifugalpump.The only differencebetweenthe high-temperature
waterside is the directionof coolingwater inletand outlet.The impelleris
sideand the low temperature
incorporated
to the shaftby screwtightening.
Notethatthe threadof impellerand that of impellertighteningnut are reversehanded.Whendisasthe coolingwaterpump,be carefulof the loosening/tightening
direction.
sembling/reassembling
1) Disassembly
Disassemblethe pump in the ascending sequence of numbers shown in Drawing 7-56. Remove the
impeller@ with use of the specifiedexclusivetool (P/#146673-92750).
Drawing7-56.CoolingWaterPump
Casing
Procedure
lmpellerAttaching/Detaching
ExclusiveTool
a
Incorporation Disassembly
@
a,
a,
/ ' A \ \
\ V )
\:-,/
@
o
Oil SealIncorporating
Direction
Removethe ballbearings@ & @ thatare press-fitted
to the shaft@ togetherwiththe shaft.
2)Checking& servicing
(1)Measuretheclearance@ betweenthe impeller@ and casing.lf the measurement
exceedstheallowablevalue,replaceeitherpartwhicheveris wornmorethanthe other.
(2)lf necessary
replacethe mechanical
seal@ andoil seal@.
Do notmakea mistakein the incorporating
direction.
(3)Replace
theballbearingsevery8,000to 10,000hoursevenif theirappearance
is freefromabnormality.
Whenpress-fitting
a bearingto the shaft,applythe loadon the innerraceof the bearing.
3) Reassembly
payingattentionto the folReassemble
the coolingwaterpumpin the sequencereverseto disassembly,
lowingpoints:
(1)Whenincorporating
the shaft,be carefulnotto flawthe lip of oil seal.
(2)Tightenthe impeller@ and impellertighteningnut@ to the specifiedtorque.
7-52
7. MAINTENANCE
SERVICING(FuelOilFeedPump)
YAN''AB
6TI8(A)L-Y
7-10.FuelOil FeedPump
Thefuel oil feed pumpis a gear pump.The pumpgear on the drivingshaftsideare coupledto the shafi
througha spline.
1) Disassembly
Disassemble
thepumpin theascending
sequence
of numbersshownin Drawing
7-57.
(1) Removethe ballbearings@ & @ thatare press-fitted
to the drivingshafi@ togetherwiththeshaft.
(2)Whenreplacing
the oil seal,detachthe circlipO , and drawoutthesealtowardthe drivinggear@
side.
Drawing 7-57. FuelOil Feed Pump
Oil Seal Incorporating
Direction
2) Ghecking& servicing
(1)Checkthecontactof the splinefittingpartof drivingshaft@ andpumpgear@ . lf the ctearance
(ptay)
is too large,replaceeitherpartwhicheveris wornmorethanthe other.
(2)Checkthe partsof drivingshaft@ thatmakecontactwith itsoil seals@ & @ . Then,if thewearis substantial,replacethe shaft.
(3) lf necessaryreplacethe oil seals.
The oilseals@ & @ are differentparts.Do not makea mistakein theirincorporating
positionand
direction.
(4)Replacethe ballbearingsevery8,000to 10,000hoursevenif theirappearance
is freefromabnormality.
Whenpress-fitting
the ballbearingto the shaft,applythe loadon the innerraceof the bearing.
(5)The bypassvalve@ functionsalsoas a safetyvalveof fueloil feedpump.Duringoperation,
keepthe
bypassvalveclosed.
O Removethe plugand checkthe operationof piston.
O lf thefuelleaksfromthe handleshaftpart,replacethe O-ring.
Drawing7-58.BypassValve@
AdjustingScrew
Lock Nut
HandleShaft
ValveHolder
7-53
(Suc.& Exh.System/Air
Cooler)
7. MAINTENANCE
SERVICING
Y/ADtruAn6]|r8(AlL-V
3) Reassembly
payattentionto the following
reassemble
the fuel oil feed pumpin the sequencereverseto disassembly,
points:
(1) Whenincorporating
the shaft,be carefulnotto flawthe lip of oil lip seals.
(2) Applya thin and uniformfilm of liquidpacking(Three-Bond
TB 1201or its equivalent)
on the mating
pump
pump
body.
surfacesof
cover@ and
(Thethickness
mustbe 0.02mmor less.)
of the packingafterclamping
(3)Alignthe holeof spacer@ for oil sealwiththe overflowoil take-offholeof the body.
(4) Replacethe bendwasher@ withthe newoneeverytimethefueloil feedpumpis disassembled.
7 -11.Suction/ExhaustSystem
7-11-1.
BoostAir Cooler
The boost air cooler is a plate finned box structure.lt incorporatesa duct integratedwith the boost air inlet
and outlet pipe, and its connectionparts are equippedwith V-ringpacking.
When servicingthe boost air cooler,detachthe V-ringon the boost air inlet side; and then remove the
cooler togetherwith the duct.
Drawing7-59.BoostAir Cooler
WaterReturnCover
Drain Cock
CoolingWater InleVOutletCover
Drawing7-50.Boost Air Inlet SideV-ringRemovingProcedures
PackingHousing
V-ring
Detaching/AttachingPlate
7-54
(Suc.& Exh.System/Air
7. MAINTENANCE
Cooler)
SERVICING
YAI/IM,AB 6]II8(A}L.V
1) Disassembly
Disassemble
the boostair cooler,removingits partsaccording
to the followingsequence:
(1) Preparethe followingexclusive
tools:
ExclusiveToolDescription
Part No.
Packing (V-ring) detaching/attaching
tool
146673-92800
Eyebolt(M12)
26610-12000
(2) Remove the boostair coolerthermalinsulatingplate,thermometer,coolingwater pipe and so forth.
(3) Remove the V-ringon the boostair inlet side.
Loosen the packinghousingmountingbolts, put the detachingiattachingplate into both sides of the
housingto hold the packing,and then removethe packingtogetherwith the housing.
(4) Fit an eyebolt on the top of duct, hold the duct with rope,and removeit toward the non-operatingside.
(5) Remove the duct accordingto the followingprocedures:
part,otherwise
Carefullydisassemble
the boostair coolerso as not to flawthe V-ringincorporated
thiscausesa boostair leak.
O Invertthe boostair coolerso thatthe coolingwaterinletand outletcapsfaceupward.
@ Unscrewthe ductmountingbolts,fit an eyeboltto the cooler,lifethe cooler,andthen removethe duct
fromthe cooler.
2) Checking& servicing
(1) Cleanthe air side(platefin)with steamor soakit in the cleaningfluid,blowthe compressed
air
against,it, andfinallywashit in water.
The appropriate
cleaningfluidis thefollowingproductsor theirequivalents.
NeosCo.,Ltd:NeosOne-1
KuritaWaterIndustries
Ltd.: Emocon1E55
(2) Removethe waterreturncoveron the coolingwaterside.Then,cleanthe coolerinterior,brushing
witha long-handle
brush.
(3) Checkthe coatingon the innersurfaceof the ductand innersurfaceof the coolerside plate.lf the
coatinghas peeledofi, repairit withthefollowingpaint.
O Innersurfaceof duct(heat-resistant
siliconepaint)
OshimaKogyo:PirojinlN ColorG2 or itsequivalent
O Innersurfaceof coolersideplate(siliconeepoxypain)
OshimaKogyo:Silicone
EpoxyING#2
(4)Checkfor clogging
of a drainhole.
(5) Replacethe packingswithnewones.
3) Reassembly
Reassemble
the boostair coolerin the sequencereverseto disassembly,
payingattentionto the followingpoints.
(1) Fit the V-ringon the boostair outletsideto the cylinderblock.Aftermountingthe boostair cooler,
incorporate
theV-ringon the boostair inletside.
7-55
7. MAINTENANCE
SERVICING(Suc.& Exh.System/Turbocharger)
yzexnaa
6lll8(All-yz
7 -11-2. ExhaustManifold
1)Disassembly
Liftingthe exhaustmanifoldcover with use of a liftinguse of a liftingeyebolt (Pl#26610-100002)and
a chain blockor the like. remove the cover.
Disassemble
theexhaustmanifoldwhilecheckingwhetherthe steadyrest and the clampingboltsare not
loose.
Drawing7-61.ExhaustManifold& ExpansionJoint
ExhaustManifold
StayRest
Expansion
Joint
Be careful not to confuse stainless steel bolts and nuts of exhaust manifold, expansionjoint and
steadyrest with those made of other materialfor clampingthese parts.
2) Reassembly
(1)Applytheseizureinhibitor
to eachboltor nut,andthentightenit.
joint,fit it in the properincorporating
(2) Checking
themarkstampedon theflangeof the expansion
directionaccording
to the mark.
jointis fittedin the reversedirection,carbonis entrappedin the clearance,
lf the expansion
causingthe
jointto be brokenin a shorterperiod.
expansion
Drawing7-62.ExhaustExpansionJoint
7-11-3.
Turbocharger
providedfor
Fordisassembling
andservicingof the turbocharger,
referto the operationmanualseparately
it.
The turbocharger
mountis providedwith the boostair and lubricatingoil passages.After having
removedtheturbocharger,
coverthe portsof boostair and lubricating
oil passagesto preventforeign
mattersfromenteringthe turbocharger.
7-56
7. MAINTENANCESERVICING(AirMOTOT)
YANMAN 6]II8(A)L'Y
7-12.Air Motor
Refer to the attachedServiceManualfor EngineAir Starters(Model 45M).
Restrictdisassemblyand repairsof the air motorto disassembly,checkingand the followingparts replacement of the air inlet housingand the spoolvalve.
o O-ringsof the spoolvalveand the air inlethousing
o Startingsolenoidvalve
o Controlmodule
o Pilotair hose
1) Disassembly(of the spoolvalve)
After removingthe air motor,disassembleit in the ascendingsequenceof numbersgiven in Drawing7-64'
When unscrewinga bolt @ used to fastenthe nozzlevalve seat @ to tne inlet housing,be careful so
that the spool valve does not springout.
Drawing7-63.SpoolVatveDisassemblingProcedures
StandingSolenoidValve
ControlModule
checking
2) Maintenance
(1) Checkthe slidingsurfaceand the seatfaceof the spoolvalveif they are not flawednot the foreign
matterhasnotbeenbitternin.
(2) Checkthe nozzlelvalve
seatif theseatfaceand nozzlepartare not damaged.
(3) Replacethe O-ringswiththe newones.
3) Reassembly
payingattentionto the following
Reassemblethe air motorin the sequencereverseto disassembly,
points:
(1)Applygreaseto the slidingsurfaceof the spoolvalve.
(2) Usesealingtapeat thethreadedpartof theelbowO of pilotair hoseto thatthe air doesnot leakfrom
this part.
torques:
(3) Tighteneachboltwiththe following
o 5 boltsfor noalelvalveseat:7.2N-m(0.7kgf-m)
o 4 boltsfor air inlethousing:19.2N-m(2 kgf-m)
r 4 boltsfor air inletpipe:94.9N-m(9.7kgf-m)
r 3 boltsfor air motor:136 N-m(13.9kgf-m)
7-57
(Electromagnetic
Pickup)
7. MAINTENANCE
SERVICING
YANM,AB 6NI8.A,L-Y
7 -13.ElectromagneticPickup
This pickupis a sensorto detectthe rotationalspeedof the engineand is mountednearthe outer
periphery
of the flywheelringgear.
1) Adjustment on the mounting dimensions
When the pickup is replacedor removed, be sure to adjust the clearance.
lf the adjustment
on the clearanceis foundpoor,the rotationalspeedmay not be detected,and the
protective
(overspeed)
devicemay not actuate.
of the pickupso thatthe clearancebetweenthe pickuptip andthe outerperipho Adjustthe screwing-in
eryof theringgearbecomes1.4to 2.1 mm.
(Screwin the pickupso that its tip contactsthe outer peripheryof the flywheelring gear,and then
loosenby 1 to 1.5turn.)
o Tightenthe locknutsecurely.
Drawing7-64.ElectromagneticPickup Mounting Procedures
1.4-21 mm
7-58
7. MAINTENANCESERVICING(StoppingAir Piston)
YA}/,'y'AB 6NI8(A)L-Y
7-14.StoppingAir Piston
This pistonpurportsto stop the enginewhenthe protectivedeviceactuatesand in caseof remote
stopping,andto controlfuelinjectionvolumewhenengineis startedup.
(tostopsupptyof fuetoit)air piston.
@, @: stopping
fuel
injection
volumecontroling
@:
air piston.
Do not disassembleadjustmentnut and adjust bolt in the case where partsreplacement
is not
needed.
Thestrokeof thepistonhasbeenproperlyadjustedpriorto shipment
fromoutfactorydo notreadjust
it.
when partsreplacement
is needed,do so withattentionpaidto thefollowing:
Measurethedimension
L1, L2 whendisassembly
is needed,andsetit in th-esamedimension
as the
measured
L1,L2 whenreassembling
thisair piston.
1) Disassembly
Disassemble
theair pistonin the ascendinq
sequence
of numbers
givenin Drawing
7-65.
Drawing7-65.StoppingAir Piston
2) Reassembly
Reassemble
the air pistonin the sequencereverseto disassembly.
o lncorporate
the piston,applyinglubricating
oil or lithiumseriesgreaseto itsslidingpart.
o Replacethe O-ringwiththe new one.
Conductsucha performance
test oncein everythreemonths.
o Sendthe controlair intothe eachair pistons,and confirmthe movementof the soppingair piston
adjustnut
7-59
&SERVICING
FORDESASSEMBLY
& PARTMASS
DIMENSIONS
8. PRINCIPAL
YA,r',,An 6Ill8(A)L-V
& SERVICING
FORDESASSEMBLY
MASS
& PART
DIMENSIONS
8. PRINCIPAL
& Servicing
for Disassembly
Drawing8-1.PrincipalDimensions
CoolingWater Outlet
CollectingPipe
Centerof Cylinder
[Unit:mm]
Side
to theOperating
Dismantling
Piston
Exh. Manifold
CYl.Liner
CYll.Head
Center of Camshaft
I
Centerof Crankshaft
Centerof TurningGear
Dismantlingto the FrontalEnd
Dismantlingto the FrontalEnd
to the Rear End
Dismantling
to the Rear End
Dismantling
N
Camshaft(Splitin Two)
CoolingWater PumP
Fuel Feed PumP
Centerof No.6 Cyl
(WhenDrawing-outen bloc:1988)
B-1 (Volume:2pages)
& SERVICING
DIMENSIONS
& PARTMASSFORDESASSEMBLY
8. PRINCIPAL
YiANTV/,AB6]II8(AL-V
& Servicing
PartMassfor Disassembly
B-1Principal
(1) When hoistinga part,use rope and liftinggear and hook that can withstandthe can withstandthe
weightof the part.
(2) When disassembling
any of the parts prefixedwith an asterisk(.) in the followingtable, use the
attachedexclusivetool.
Part Description
Remarks
6N18AL
6N1BL
" Cylinderhead
105
. Piston& connecting
rodassy.
42
. Cylinderliner
40
" Air cooler
300
Incl.the casing
Lub.oilcooler
162
Incl.the strainer& thermostaticvalve
RH133
bJ
RH143
145
Turbocharger
Fuelfeedpump
to
Lub.oil pump
30
waterpump
Cooling
35
Air motor
18
4 1x 2
Camshaft(splitin two)
Camshaftdrivinggear
15
gearassy.
Intermediate
* Exhaust
manifold
cover
20
45
* Main bearingcap
22
Anti-flywheelend gear case
62
Oilpan
200
1,496
Cylinderblock
Crankshaft
760
846
Incl.the balanceweight
Flywheel
870
650
Incl.ring gear
B-2
9. TABLEOFTIGHTEN]NG
TORQUESOF MAJORBOLTS
YAD//',,AE6I|I8(AIL-V
9. TABLEOF TIGHTENING
TORQUESOF MAJORBOLTS
Tightenthe major bolts by the specifiedprocedures.
lf tightenedimproperly,a personalinjury or damage of device may be caused. Be cautious.
(1) Unlessotherwisespecified,apply
lub.oilon the threadand bearingsurface,and thentightening
a
boltor nut.
(2) On the partsprefixedwitha star ( * ) in the followingtables,a matchmarkis stamped.However,
whentighteningany of theseparts,do not referto the macthmark but tightenit to the specified
torque,specified
tighteningangleor specifiedhydraulicpressure.
9-1.HydraulicPeressureGlampingBolt
Screw
Dia x
Pitch
Face-to-Face
Widthof
BolUNut
(mm)
SpecificHydraulic
Pressure
MPa(kgf/cm2)
* Cylinderheadtighteningnut
M33x 2.0
Round
58.8+0.5(600+5)
* Main bearingcap tighteningnut
M33x 2.0
Round
58.8 .4-0.5(600 + 5)
PartDescription
Remarks
9-2.Angle ClampingBolts
A
(1) Beforetightening
a connectingrod bolt,applythe Protecgreaseon its bearingsurfaceand lub.oil
on itsthread.
(2)Tightena boltto the seatingtighteningtorque,thentightenit to the specifiedangte.
ScrewDia.
x Pitch
Face-to-Face
Width of
BolUNut
(mm)
* Connection
rodbolt
M25 x 1.5
32
4e(5)
120:E
Balanceweightclampingbolt
M24 x 2.0
32
4e(5)
8o:8
PartDescription
2002.7.22R
Seating
Specified
Tightening Tightening
Remarks
Torque
Angle
N-m (kgf-m)
(deg.)
9-1 (Volume:4pages)
9.
TABLE OF TIGHTENINGTORQUESOF MAJORBOLTS
6]II8(A}L-Y
YA}'',AB
9-3.Other MajorBolts (TorqueTightening)
(1) Before tighteninga flywheel clamping bot or fuel injectionvalve nozzlesleeve,apply Protecgease
on its thread and bearing surfiace.
(2) Beforetighteninga camshaftcouplingnut, apply seizureinhibitor(Three-Bond1910 or its equivalent) on its thread and bearing surface.
(3) The parts prefixedwith an asterisk (") in the followingtable are providedwith an exclusivetool,
respectivery.
(4) Be sure to tightena part with a torque wrench to the specifiedtorque.
Part Descriotion
Torque
ScrewDia. Face-to-Face Tightening
Width of
X Pitch BolVNut(mm)
(kgf-m)
N-m
Remarks
Indicatorcock tighteningnut
M12x1.75
19
Rockerarm shaftstandclampingbolt
M 1 6x 1 . 5
24
" Fuelinjectionvalve nozzlesleeve
M22x 1.5
Fuelinjectionvalve guardtightening
nut
* Fuel injectionvalvecase nut
M 1 0x 1 . 5
pumpprotector
Fuelinjection
M20x '1.5
32
Fuelinjectiontimingadjustbolt lock
nut
M22x 1.5
30
196- 245 2 0 - 2 5
Camshaftcouplingnut
M12x1.25
17
Cam gear clampingbolt
M 1 4x 1 . 5
19
ldle gear shaftclampingbolt
M 1 6x 1 . 5
24
I - 1 0 U-nut
Tiqhteninq
tooether
driv137- 157 1 4 1 6 wih tachdmeler
ingdisk
14
118- 127 t z
ldle gear retainerclampingbolt
M12x1.75
waterpumpimpeller
tightening
Oooling
M 1 6x 1 . 5
1ut
19
59-69
24
64-74
2 grooves
M 3 0x 1 . 5
17
59-69
6-7
186- 206 1 9 - 2 1
157- 167 1 6 - 1 7 EngineUsingMDO
245-265
25-26
39-44
4-4.5
EngineUsingHFO
27
167- 176 1 7 1 8
M 2 8x 1 . 5
* Fuelinjectionvalveinjectionpressure
41
4 7 - 5 1 4.8.- 5.2
M 3 3x 1 . 5
regulatinglock nut
" Fuel injectionpipejoint bolt (on cyl.
o
2
20
M 8 x 1 . 2 5 (hex. socket)
headside)
. Fuelinjectionpipejoint bolt (on pump
8
7
69
M 1 0x 1 . 5 (hex.socket)
side)
" Fuelinjedionpumptighteningnut
19
7 4 - 8 3 7.5- 8.5
M12x1.75
8
Fuelinjectionpump equalizingvalve
M 1 0x 1 . 5 (hex. socket) 5 4 - 5 9 5.5- 6.0
bodyclampingbolt
8
Fuelinjectionpump banel retaining
M 1 0x 1 . 5 (hex.socket) 5 4 - 5 9 5.5- 6.0
bolt
. Coolingwater pumpimpeller
M22x 2.5
Flywheelclamping
bolt
6-7
6.5- 7.5 Left hand screw
M22x 1.5
M 2 0x 1 . 5
235-255 2 4 - 2 6
24
118- 137 1 2
32
343- 382 3 5 - 3 9
510- 569 5 2 - 5 8
24
19
Lub.oilpumpdrivinggeartighteningnut M24x 2.0
36
24
2003.12.10R
88-98
36
Exhaustmanifoldclampingbolt
M12x1.75
joint
Exhaustexpansion
clampingbolt M12x1.75
Swingarm shaftclampingbolt
5.0- 6.0
roundsocket
Left hand screw
4 points 137 157 1 4 - 1 6
Coolingwater pumpdrivinggear tightM24 x 2.0
eningnut
Coolingwater pump idlegear shaft
M 1 6x 1 . 5
clampingbolt
Mainbearingcap side bolt
49-59
19
M 1 6x 1 . 5
9-2
59-69
14
6-7
6-7
59-69
157 177 1 6 - 1 8
118- 137 1 2 - 1 4
9.
TABLE OF TIGHTENINGTORQUESOF MAJORBOLTS
YA)traAB 611!8(A)L-V
9-4.GeneralBolts
(1) Tightenany boltsotherthan the majorones accordingto the followingtable.
(2) Tightena part whose clampingsectionis made of aluminum,tightenit to 80% of the torqueshown
in the followingtable.
(3) The followingtable is applicableonlyto the boltswhosePart No. (an 11-digitnumeral)shown in the
attached Parts List consistsof 2 at its first place and 2,5 or 6 at its fifth place.
Screw Dia.
x
Pitch (mm)
Face-to-Face
Width of BolUNut
(mm)
N-m
(kgf-m)
M6 x 1.0
10
10-12
( 1 . 0- 1 . 2 )
M8 x 1.25
13
24-27
(2.4- 2.8)
M 1 0x 1 . 5
17
44-54
(4.5- 5.s)
M12 x 1.75
19
78-98
(8 - 10)
M 1 4x 1 . 5
22
123- 152
(12.5- 15.5)
M 1 6x 1 . 5
24
206 - 245
(21 - 25)
M16x 2.0
24
206 - 245
(21 - 25)
2002.7.22R
TighteningTorque
9-3
10. CLEARANCES
& WEARL|MTTS
OFMAJORPARTS
]'ArrruAB 61118(AL-l/
10.CLEARANCES
& WEARLIMITSOF MAJORPARTS
(Unitin mm)
Dimension
Item
Innerdia.of cylinderupper
part
Outerdia.of rylinderliner
upperpart
Sketch
sfd
Max.
Clearance Allowance
Assembling
Normal Tolerance
Clearance
Tlme
6246
Innerdia. of cylinderlower
part
Outer dia. of cylinderliner
lower part
o
=
o
Innerdia. of cylinderlower
part
Outer dia. of cylinderliner
lower part
co
o Top clearance
:
0222
Innerdia.of protection
ring
Outerdia. of pistonhead
Innerdia. of cylinderliner
Outerdia.of pistonskirtpart
o218
-0.020
0.065
+0.029
0
B=0.015
- 0.088
-0.015
0.059
+ 0.20
4178
+ 0.05
6177.025 + 0.02
C=1.8
- t-z
+0.13
M=0.2
-0.13
+0.13
B=0.2
-0.13
C=2.5
+0.8
D=0.905
- 1.O45
+0.030
0
E=0.093
- 0.153
6179.892 -|-0.015
-0.2
+0.4
deflec{ion
wear of
d 180
E=0.3
o.2
-0.2
F=6.5
+ 0.15
*
Radialthick.of oil ring
F=5.0
+ o.25
4.7
Width of pistonring groove,
No.1
od
\Mdth of pistonring,No.2
\Mdthof pistonringgroove,
No.2
4.5
4.O
Width of oil ring
.9
n
A2=0.020
- 0.094
+0.1
Radialthick.of piston
rings,No.1,- No.2
3t
o
+0.029
0
2.0
Width of pistonring,No.1
o)
+0.029
0
A1=0.075
- 0 . 1 3 9 A1=0.25
-0.075
0.110
Usage
Limitof
Parts
6.0
Width of oil ring groove
pinmetal
Innerdia.of piston
Outerdia.of pistonpin
Innerdia. of pistonpin hole
Outer dia. of pistonpin
475
-0.065
-0.085
+0.070
+0.045
-0.010
-0.030
+0.070
+0,045
-0.010
-0.030
+0.035
+0.020
+0.100
+0.080
0
-0.013
+0.045
+0.030
0
-0.013
No.1
G=0.110
- 0.155
No.1
G=0.4
No.2
G=0.055
- 0.100
No.2
G=0.4
H=0.030
.- 0.065
+n?
-0.2
+0.3
-0.2
H=0.4
+0.3
J=0.080
- 0 . 1 1 3 J=0.25
K=0.030
- 0.058
-0.2
+0.17
-0.05
+0.15
K=0.15
-0.15
* : The 1stringis to be replacedwiththe new onewhenits platedlayeris worn out and basemetalbeginsto be
exposed;
the2ndring,whenthetaperfaceis gone.
2003.12.10R
10-1 (Volume:4pages)
10. CLEARANCES
& WEARLIMITSoF MAJoR PARTS
yermaa
6ttB(A)L-Y
(Unitin mm)
st'd
Max.
Limit
Clearance Allowance Usage
Normal Tolerance Assembling Clearance of Parts
Tlme
Dimension
Item
Sketch
+0.152
0.080
Innerdia.of crankpinbearIng
L=0.080
- 0.170 L=0.25
6145
o
-g
Outer dia. of crank pin
bearing
-0.025
lnner dia. of main bearino
+0.189
+0.120
U
0 180
Outerdia.of journal
Width of datum part main
80
\Mdth of datum partjournal
0
-0.025
deflection
wear of
0.1
+0.20
M=0.120
- 0.214 M=0.25
deflection
wear of
0.1
-0.140
,0.200 N=0.140
- 0.23O N=0.5
+0.035
n
-o.4
+0.35
Deflection
Referto
Checking
Chapter6 Maintenance
of crankshaft
6-3-17Measurement
deflection,
3) Allowablevalueof the
deflection.
Valveheadclearance(suc./
exh.)
Q=0.3i0.4
Outer dia. of suctionvalve
014
Innerdia.of suctionvalve
guide
Outerdia. Chrom+plated
of exhaust
valve
Nimonic
014
lnner dia. of exhaustvalve
guide
E Inner dia. of valve bridge
.9
(E
+0.2O
o
o
Outer dia. of valve bridge
guide
o
Margin thicknessof suc./
exh. valve poppet part
s \Mdthof suc./exh.valve
seat
Dia.of suc./exh.
valveseat
contactpart
o16
\=
Chrorn+plated
R2=0.058
- 0.102 R2=0.32
R3=0.35
Nimonic
+0.024 R3=0.068
- 0.112
0
+0.080
+0.060 S=0.014
- 0.052 S=0.2
+0.046
: # '{
-0.32
+0.26
-0.32
-0.35
+0.28
+0.18
-0.18
T4.7
+ 0.1
4.3
(.f=
-r 0.2
5.4
+ 'y = e 5 7
+ 0.1
458
-0.009
-0.034
-0.1
036
lnner dia. of rocker arm
bush
lnnerdia.of swingarm
2003.12.10R
R1=0.060
- 0.104 R1=0.32
+0.028
Outerdia. of rockerarm
shaft
Outerdia.of swingarm
shafi
-0.060
-0.080
+0.024
0
-0.058
-0.078
-0.068
-0.088
Q=0.3/0.4
o40
10-2
W=0.029
- 0 . 1 1 9 W=0.25
+0.085
+0.020
+0.03
+0.01
0
-0.039
X=0.010
- 0.069
+0.22
+O.2
X=0.2
-0.1
YANIUAE {6XT8(A)L'Y
10. CLEARANCES& WEAR LIMITSOF MAJORPARTS
(Unitin mm)
sfd
Max.
Usage
Clearance Allowance Limitof
Assembling
Tolerance
Clearance Parts
Time
Dimension
Item
Sketch
Normal
Outerdia.of camshaft
datumpart
o
U'
tz
0 120
Inner dia. of camshaft
datum part bearing
Thrust clearanceof camshaft datum part
0
-0.15
-0.20
o
thrust
Widthof camshaft
tv
collarhousing
Outer dia. of camshaft
intermediateoart
Inner dia. of camshaftintermediatepartbearing
Outer dia. of lub.oil pump
shaft
a 120
030
Innerdia.of lub.oil pump
shaftbush
+0.11
+0.05
-0.072
-0.107
+0.095
0
Z=0.200
-'0.310
a=0.072
- 0.197
-0.040
-0.053 b=0.040'
- 0.074
+0.021
072
Outer dia. of gear
+0.046
0
c=0.200
- 0.296
-0.200
-0.250
-0.17
+0.17
Z=0.5
-0.17
a=0.3
+0.17
b=0.2
+0.15
U
Clearancebetw.pump case
& qear
-i
-0.072
-0.107 Y=0.072
- 0.197 Y=0.3
+0.090
c=0.3
6 N 1 8 1 +0.046
0
77
6N18AL
d=0.060
66
,- 0.136 d=0.18
bellmounling
-0.060
coudingspec
-0.090
6N181
Widthof pumpcase
J
Width of pump gear
72
E
-0.13
-0.18
Outerdia.of coolingwater
pumpimpeller
boss
e1&e2
=0.78
- 0.87
o
(!
3
=
-0.6
694
e1&e2
=0.16
+0.69
0.65
Innerdia.of casing
+1.0
C)
Gear backlash
(u
()
fludnggear&
pump
drive
serr)
M=4.5
f=0.15
- 0.25
f=0.5
(Governor
gear)
M=3.0
f=0.12
- 0.20
f=0.3
-0.030
-0.060
'6 Outer dia. of cam driving
gear shaft
.9, intermediate
(t
(U
F
070
Inner dia. of the above's
bush
-o.17
g=4.2
+0.14
-0.030
-0.060
Outer dia. of pumpdriving
intermediategear shaft
A7o
Inner dia. of the above's
bush
2001.6.15R
g=0.030
- 0.090
+0.030
0
10-3
h=0.030
- 0.090
+0.030
0
-0.17
g=0.2
+0.14
& WEARLlMlrsoF MAJORPARTS
10' CLEARANCES
uAnnAn
Gilr8(AL-V
(Unitin mm)
sfd
Usage
Max.
Clearance Allowance Limitof
Normal Tolerance Assembling Clearance Parts
Time
Dimension
Item
q)
E
'6
Sketch
0
-0.046
Outerdia.of crankshaft
(l)
o
=
j=0.030
- 0.446
4220
a=
-i
p
vt
o
+0.400
+0.300
lnnerdia.of oil shield
10-4
V
& COUNTERMEASURES
11. TROUBLESHOOTING
yArtMAF
(Elf l8(AlL-Y
& COUNTERMEASURES
11. TROUBLESHOOTING
The causes of abnormalitiesand troublesare diverse,and they break out from compsite factors'
CatchinEa changein runningperformanceand referringto the recordof maintenanceand servicing
date and the historyof part replacement,locate the cause early and take the proper countermeasures.
11-1. Starting Failure
1) Flywheelnot turned.
2) Flywheelturned, but ignition not taken place.
11-2. RotationalSpeed Dropped Spontaneously'
11-3. Output of Each Gylinder not in Unifomity.(Dispersion of the maximum combustion pressure
and exhaust temperatureis large among cylinders')
11-4. Bad Golor of Exhaust Gas
11-5. Lub. Oil PressureDropped below the Specified Pressure
11-6. UnusuatSounds Heard (Knocking Occurred) During Operation
11-7. Cooling WaterTemperatureToo High
11-8. Exhaust Temperaturesof All the Cylinders Too High
11-9. Engine Stopped SuddenlY
l1-1 Nolume:Opages)
11
& COUNTERMEASURES
TROUBLESHOOTING
YANMAB 6I|I8(A)L-Y
11-1.StartingFailure
not turned
1
Cause
(1) Startingair pressureinsufficient
(2) Engagement
switchactuated
/ disengagement
position)
gearset at the intermeshing
(Turning
(3) Malfunction
of air motor
l.Voltagedrop of air motorbattery
of air motorpilotsolenoidvalve
2.Malfunction
(4) Engagement/ disengagement
switchactuated.
(Start/ stop leverset in the STOP position)
(5) Toohighviscosityof lubricatingoil
Countermeasure
Fillthe startingair tankwithair.
Disengagethe turninggear.
Chargethe battery.
Pressthe manualstartingpushbuttonto
startthe engine.
Set the start/ stop leverat the RUNpositon.
Warmup the engineor changethecurone.
rentlub.oilwitha low-viscosity
(6) Seizureof movingpart
l.Seizureof pistonand cylinderliner
Checkand repairthe pistonandcylinder
liner,or replacethem.
2.Seizure
of mainbearingand / or camshaftbearing Checkand repairthe pertinentmain
bearingor camshaftor camshaftbearing,
or replaceit.
2l
turned.but
not tal(en
Countermeasure
Cause
( 1 )Fuel oil not sent under pressureto fuel injection
pump
Supplythe fuelto thefueltank.
1.Fueltankempty
2.Cloggingof fuel oil pipe (improperopeningand Checkthe openingand closingstatusof
eachvalve.
closingof each valve)
Cleanthe filter.
3.Cloggingof fuel oil filter
pump
Checkandrepairthe pump.
4.Failureof fuel feed
Checkandrepaireachjoint,thenbleed
5.Airentrythrougheachjoint
air.
Checkand repairtheair piston.
(2) Malfunctionof soppingair piston
(3) Defectof fuel injectionpump
Checkand repairthe plungeror plunger
l.Stickingof plungerand plungerguide
guide,or replaceit.
Replacethe plunger.
2.Wearor seizureof plungerguide
(deviation
of matchmarks) Overhauland checkthe pump.
assembling
3.lmproper
(4) Defectof fuel injectionvalve
l.Stickingor seizureof needle.
Checkand repairthe needle,or replace
it.
Replacethe nozzlespring.
2.Breakageof nozzlespring
pressure
Regulatethe pressure.
dropped
3.Fuelinjection
Checkand cleanthe matingsurfacesof
4.Oil leakagefrom nozzleexcessive
nozzleand body,or replacethe nozzle.
fuelpipe,or
or improperclampingof high-pressureReplacethe high-pressure
5.Breakage
correctclamping.
fuel pipe
(5) Malfunctionof governor(loose governor link and Checkand repairthe governor,or
replaceit.
wornspline
(6) Poorairtightnessof suction/ exhaustvalve
at headof suction/ exhaustvalve Adjustthe valveheadclearance.
1.Noclearance
Grindor replacethe valve.
2.Stickingof suction/ exhaustvalve
Grindor replacethe valveseat.
3.Damageof seat of suction/ exhaustvalve
Usea high-qualityfueloil.
(7) Toolow cetanenumberof fuel
1998.4.21R
11-2
11. TROUBLESHOOTING
& COUNTERMEASURES
YA}IIUAB
6]T8(A)L-Y
11-2.RotationalSpeedDroppedSpontaneously
Cause
('l) Cloggingof fueloil filter
(2) Seizureof movingpart (piston,main bearingor turbocharger)
(3)Air mixedin fueloil pipesystem
(4) Moisturecontentin fuel oil
(5) Defectof fuel injectionpump
(6) Defectof fuel injectionvalve
(7) Malfunction
of governor
Countermeasure
Cleanthe filter.
Checkand repairthe pertinentmoving
part,of replaceit.
Checkand repairthefueloil pipesystem,
thenbleedair.
Drainthe filter,tank,etc.
Checkand repairthe pump,or replaceit.
Checkand adjustthe valve,or replaceit.
Checkand adjustthe governor,or
replaceit.
11-3,Output of Each Gylinder not in Uniformity.(Dispersionof the
maximum combustion pressure and exhaust temperature is large
amongcylinders.)
Countermeasure
Cause
(1)Airmixedin fueloilpipesystem
Checkand repairthefueloil pipesystem,
thenbleedair.
Drainthe filter,tank,etc.
(2) Moisturecontentin fuel oil
(3) Fuelinjectionvolumenot in uniformityamongcylinders
positionof fuelinjection
pumpracks Checkthe positionof fuel injectionpump
l.Nonuniform
racks,then adjustit.
Checkand repairthe plunger,or replace
2.Sticking
or wearof fuel injectionpumpplunger
it.
Checkand repairthe valve,or replaceit.
3.Defectof fuel injectionvalve
pipe
Checkand repairthe pipe,or replaceit.
4.Looseness
or damageof fuel injection
S.Stickingof suction/ exhaustvalve or damageof Checkand repairthe pertinentvalveor
valveseat,or replaceit.
suction/ exhaustvalveseat
Checkthe fuel cam or suction/ exhaust
fuel
or
damage
of
suction
/
cam,
6.Damageof
cam,then repairit, of replaceit.
exhaustcam
11-4.BadGolorof ExhaustGas
Countermeasure
Cause
(1) lmproperinjection
and
adjust
the timing.
Check
timing
(2) Defectof fuelinjectionvalve(fuelinjectionpressure Checkthe valve,then regulatethe pressure,or replaceit.
drop,stickingof nozzle)
(3) Defectof fuel injectionpump
Checkthe pump,then repairit, or
replacethe pertinentvalvesect.
(4) lmproperadjustmentof suction / exhaust valve Adjustor correctthe clearance,or
head clearanceor damaqe of suction/ exhaust replacethe pertinentvalve sect.
valveseat
the suctioni exhaustvalve,and
(5) Stickingof suction/ exhaustvalve
Overhaul
then correctit.
(6) Damageof suction/ exhaustcam
Replacethe camshaft.
(7) Defectof turbocharger
Washthe filter.
l.Cloggingof filter
/
Overhauland wash the turbocharger
2.Fouling
of the blowersideor turbineside
blower.
(8) Foulingof boostair cooler(too hightemperatureof Overhauland cleanthe air cooler.
boostair)
fuel oil.
(9) Shortage
Usea high-quality
of fueloil
Reducethe load.
(10)Overload
11-3
11"
& COUNTERMEASURES
TROUBLESHOOTING
YA}T,',AB 6]II8(AL-Y
11-5.Lub. Oil PressureDroppedbelowthe SpecifiedPressure.
Countermeasure
Cause
Checkand repairthe lub.oil pipe and
eachoil hole plug.
Overhauland cleanthe strainer.
Checkthe clearance,then replacethe
metal.
(4) Stickingof lub. oil pressureregulatingvalve or Checkthe valveand bolt,thenrepairor
adjustthe pertinentpart.
loose adjustingbolt
Checkthe valveand bolt,then repairit.
(5) Stickingof lub. oil safety valve
(1) Loosenessof lub. oil pipe and cylinderblock oil
hole plug
(2) Cloggingof lub. oil strainer
(3) Excessiveclearanceof crankshaftbearing
(6)Too high temperatureof lub. oil
l.Shortageof coolingwatervolume
2.Foulingof lub. oil cooler
Checkthe coolingwaterpump.
Checkthe cooler,thenover haul and
clean it.
3.Excessive blow-bye (gas leak) into the crank- Checkthe pistonringsand cylinder
liner.
case
valve
Checkthe pistonand element,then
4.Stickingof pistonof lub. oil thermostatic
repairor replacethe pertinentpart.
or defect of its element
(7) Air sucked in lub. oil pump (shortageof lub. oil Replenishthe lub.oil.
volume)
11-6.UnusualSoundsHeads(KnockingOccurred)DuringOperation
Countermeasure
Cause
(1) Excessiveclearanceof bearingof crankshaftof Checkthe clearance,then replacethe
pertinentbearing.
camshaft
(2) Loose bolts
l.Connectingrod bolts
Checkthe connectingrod and bolts,
then retightenthe boltsor replace
them.
Checkthe bolts,thenretightenthem,
bolts
2.Flywheel
clamping
or replacethem.
of suction/ exhaustvalve Checkthe clearanceand bolt,then
(3) lmproperadjustment
adjustthe clearance.
headclearanceor loosebolt
Checkthe timing,thenadjustit.
timing
(4) lmproperadjustment
of fuelinjection
(5)Fuelinjectionvolumeexcessive
pump
of fuelinjection
l.Malfunction
Checkand repairthe pump,or replace
it.
Checkand repairthe valve,then adjust
2.Defectof fuelinjectionvalve
it.
gear
bear- Checkand adjustthe gear or its bear(6) lncreaseof gear backlashor wear of
ing,or replaceit.
ing
11-7.CoolingWaterTemperatureToo High
Countermeasure
Checkandrepairthecoolingwater
(1) Shortageof coolingwatervolume
pump.
(2) Sticking or defect of cooling water thermostatic Checkor replacethethermostatic
valve.
valve
Cause
11-4
11.
!-
TROUBLESHOOTING
& COUNTERMEASURES
YAn'''An 6Ifl8(A)L-V
11-8.ExhaustTemperaturesof All the CylindersToo High
Countermeasure
Cause
(1) Boostair temperaturetoo high
l.Boost air cooler cooling water temperaturetoo Checkthe coolingwatersystem,and
lower the coolingwater temperatureto
high
the specifiedrange.
2.Shortageof boost air cooler coolingwater vol- Checkand repairthe coolingwater
pump.
ume
3.Foulingof boostair cooler (coolingwaterside & Overhauland washthe cooler.
air side)
Checkand servicethe enoineroom
4.Engineroom internaltemperaturetoo high
ventilationequipment.
(2) Boostair pressuretoo high
Wash the filter.
l.Cloggingof turbochargerfilter
Overhauland washthe cooler.
2.Cloggingof boostair cooler (airside)
3.Foulingof turbocharger(turbineside & blower Washthe blowerside or overhauland
wash the turbocharger,or replaceit.
side)or its damage
port
pressure
Checkand cleanthe exhaustmanifold
4.Riseof back
at exhaust
and exhaustpipe.
Checkand servicethe enoineroom
5.Engineroom put under a negativepressure
ventilationequipment.
(3) Unsuitablepropertiesof fuel oil
Judgingfrom the propertyanalysis
results,changethe fuel oil if necessary.
(4)Overload
Reducethe load.
11-9.Engine Stopped Suddenly
Countermeasure
Cause
(1) Protective
deviceswitchedon
l.Oversoeed
1 Checkthe switch,then repairthe
part. lf necessary replace
drop
2.Lub.oil pressure
i defective
---L
pertinent
part.
the
riseof coolingwaterexcessive
3.Temperature
(2)Governor
Checkthe governorand governorgear,
or governorgear
then repairor replacethe pertinent
part.
(3)Fueltankempty
Replenishthe fuel oil.
( ) Air mixedin fueloilsystem
Bleedair from the filterand oil pipe.
(5)Clogging
Overhauland cleanthe filter.
of fueloil filter
part (piston,mainbear-Checkand repairthe pertinentpart,or
(6) Seizureof interlocking
replaceit.
ing,crank-pin
bearing,timinggear,etc.)
11-5