6N18(A)L-V

SERIES

Thank you for purchasing

YANMAR product.
Be sure to read this Operation Manual for
you to use this product safety and correctly.
Even after reading it, carefully keep it, making clear
to all personnel concerned where it’ s kept so that
the operator, mechanic or supervisor will have an I.B.C.No. 08-6N18(A)-V-H-24E
access to it whenever he wants to read or refer to it. 2008.3.13R
　　　　　　　　
 CONTENTS

Page
PREFACE ................................................................................................................................... 0-1
1. Foreword ................................................................................................................................ 0-1
2. Terms & Symbol Marks ......................................................................................................... 0-3
3. Precautions on Safety ............................................................................................................ 0-4
3-1. Basic Precautions ................................................................................................................0-4
3-2. Precautions on Operation ....................................................................................................0-7
(1) Prior to Staring of the Engine .........................................................................................0-7
(2) During a Run ..................................................................................................................0-7
(3) When Stopping the Engine ............................................................................................0-8
3-3. Precautions on Maintenance ................................................................................................0-9
(1) Precautions Prior to Maintenance Servicing ..................................................................0-8
(2) Precautions During Maintenance Servicing .................................................................0-10
(3) Precautions at Completion of Maintenance Servicing .................................................0-11
4. List of Safety Labels ............................................................................................................ 0-12
5. Lifting Procedures for Engine .............................................................................................. 0-13

1. ENGINE DESCRIPTION ....................................................................................................... 1-1

1-1. Engine Specification .............................................................................................................1-1
1-2. Types of Accessories & Attachments ...................................................................................1-3
1-3. Sectional View of the Engine ...............................................................................................1-4
1-4. Engine Outline & Device Arrangement ................................................................................1-5
2. STRUCTURE OF MAJOR PARTS ........................................................................................ 2-1
3. TABLE OF ENGINE STANDARD ADJUSTMENTS .............................................................. 3-1
4. OPERATION .......................................................................................................................... 4-1
4-1. Operational Preparation ..................................................................................................4-1
4-1-1. Lubricating Oil System .........................................................................................4-2
4-1-2. Fuel Oil System ...................................................................................................4-4
4-1-3. Cooling Water System .........................................................................................4-7
4-1-4. Boost Air System .................................................................................................4-7
4-1-5. Starting Air System ..............................................................................................4-8
4-1-6. Control and Protective Devices ............................................................................4-8
4-2. Starting ..........................................................................................................................4-8
1) Starting operation procedures ....................................................................................4-8
2) Corrective actions to be taken in starting failure ..........................................................4-9
3) Checks to be made immediately after starting ...........................................................4-10
4-3. Running .......................................................................................................................4-10
1) Initial Running-in Operation ......................................................................................4-10
2) Steady (Routine) Running ........................................................................................4-10
4-4. Stopping .......................................................................................................................4-13
4-4-1. Stopping in Normal Running ...............................................................................4-13
4-4-2. Emergency Stop ................................................................................................4-14
4-4-3. Disposal After an Emergency Stop .....................................................................4-14
5. FUEL OIL, LUB. OIL & COOLING WATER ........................................................................... 5-1
5-1. Fuel Oil .................................................................................................................................5-1

2002.12.25R F-1
CONTENTS

5-1-1. Quantity Criteria of Fuel Oil ..................................................................................5-1

5-1-2. Quality Criteria of Blended Fuel Oil .......................................................................5-2
5-1-3. Properties of Fuel Oil at the Engine Inlet ..................................................................5-2
5-1-4. How to Find out the Heavy Fuel Oil Heating Temperature .......................................5-5
5-1-5. How to Find out the Viscosity of Blended Oil ............................................................5-6
5-2. Lubricating Oil ................................................................................................................5-7
5-2-1. Choosing the Lub. Oil ..........................................................................................5-7
5-2-2. Control on Lub. Oil ...............................................................................................5-8
1) Control Criteria ..........................................................................................................5-8
2) Oil Change Criteria ....................................................................................................5-8
5-2-3. List of Lub. Oil Brands ..........................................................................................5-9
5-3. Cooling Water (Engine Jacket Water) ............................................................................5-10
5-3-1. Criteria on Cooling Fresh Water .........................................................................5-10
5-3-2. Selection of and Control on Corrosion Inhibitor ...................................................5-10
6. MAINTENANCE CHECKING ................................................................................................. 6-1
6-1. Precautions in Maintenance Checking .............................................................................6-1
6-2. Table of Periodical Checking ...........................................................................................6-2
1) Table of Routine Maintenance Checking .....................................................................6-2
2) Checking Table for Engine Using Marine Diesel Oil .....................................................6-3
3) Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at...) ...............................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 Pressure (Pmax) .............................................6-10
6-3-3. Regulation of Fuel Injection Volume (Rack Scale) .................................................6-11
6-3-4. Adjustment of Fuel Injection Timing ........................................................................6-12
6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure ....................6-13
6-3-6. Adjustment of Suc./Exh. Valve Head Clearance ....................................................6-18
6-3-7. Adjustment of Lub. Oil Pressure .............................................................................6-19
6-3-8. Adjustment of Lub. Oil Temperature .......................................................................6-20
6-3-9. Adjustment of Fuel Oil Pressure .............................................................................6-22
6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valves ...............................6-23
6-3-11. Cleaning of Lub. Oil Bypass strainer ....................................................................6-24
6-3-12. Cleaning of Lub. Oil Strainer .................................................................................6-29
6-3-13. Cleaning of Fuel Oil Filter .....................................................................................6-31
6-3-14. Cleaning of Strainer/Filter Element .......................................................................6-33
6-3-15. Washing of Turbocharger ......................................................................................6-33
6-3-16. Maintenance of Pressure Gauge ..........................................................................6-37
6-3-17. Measurement of Crankshaft Deflection ................................................................6-39
6-3-18. Adjustment of Fuel Injection Pump Pinion Lubricating Volume
(for Engine Using H.F.O.) .....................................................................................6-42
6-3-19. Maintenance of Fuel Oil Seal Pot (for Engine Using H.F.O.) ................................6-42
6-3-20. Check & Replacement of Anticorrosive Zinc ........................................................6-43
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 ..................................................7-4
4) Handling Procedures for Turning Gear Device ............................................................7-4
5) Handling Procedures for hydraulic Jack ......................................................................7-5
7-1. Cylinder Head & Its Accessories ...................................................................................7-10
7-1-1. Cylinder Head ....................................................................................................7-10
7-1-2. Suction & Exhaust Valves ..................................................................................7-15
7-1-3. Suc./Exh. Valve Seat .........................................................................................7-16
7-1-4. Suc./Exh. Valve Guide .......................................................................................7-18
7-1-5. Suc./Exh. Valve Bridge & Its Guide ....................................................................7-19
7-1-6. Valve Rotator .....................................................................................................7-19

2006.6.20R(MET F-2
CONTENTS

7-2. Piston & Connecting Rod ..............................................................................................7-20

7-2-1. Piston & Piston Pin ............................................................................................7-20
7-2-2. Connecting Rod .................................................................................................7-23
7-2-3. Crank Pin Metal .................................................................................................7-24
7-2-4. Connecting Rod Bolt ..........................................................................................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. Main Bearing & Crankshaft ...........................................................................................7-29
7-4-1. Main Bearing .....................................................................................................7-29
7-4-2. Crankshaft .........................................................................................................7-36
7-5. Timing Gear, Camshaft & Suc./Exh. Swing Arm ............................................................7-37
7-5-1. Timing Gear .......................................................................................................7-37
7-5-2. Camshaft ...........................................................................................................7-39
7-5-3. Suc./Exh. Swing Arm .........................................................................................7-40
7-6. Fuel Injection Pump & Pump Driver ...............................................................................7-41
7-6-1. Fuel Injection Pump ...........................................................................................7-41
7-6-2. Fuel Injection Pump Driver .................................................................................7-44
7-7. Governor & Governor Gear ...........................................................................................7-45
7-7-1. Governor ............................(See the separate-vol. manual on hydraulic governor.)
7-7-2. Governor Gear ...................................................................................................7-45
7-7-3. Coupling Adjustment of Governor Gear ..............................................................7-47
7-8. Lub. Oil Pump, Lub. Oil Pressure Regulating Valve & Lub. Oil Cooler ............................7-48
7-8-1. Lub. Oil Pump ....................................................................................................7-48
7-8-2. Lub. Oil Cooler ...................................................................................................7-50
7-9. Cooling Water Pump .....................................................................................................7-52
7-10. Fuel Oil Feed Pump ....................................................................................................7-53
7-11. Suction/Exhaust System .............................................................................................7-54
7-11-1. Boost Air Cooler ...............................................................................................7-54
7-11-2. Exhaust Manifold .............................................................................................7-56
7-11-3. Turbocharger ............................. (See the separate-vol. manual on turbocharger.)
7-12. Air Motor ....................................................................................................................7-57
7-13. Electromagnetic Pickup ...............................................................................................7-58
7-14. Stopping Air Piston .....................................................................................................7-59
8. PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING ................ 8-1
9. TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS ................................................... 9-1
10. CLEARANCES & WEAR LIMITS OF MAJOR PARTS ...................................................... 10-1
11. TROUBLESHOOTING & COUNTERMEASURES ............................................................ 11-1

Parts List & Figure ................................................................................................................... Appended

ATTACHED
Service Manual for the Engine Air Starters
Yanmar Service Networks

2004.3.29R F-3
CONTENTS

MEMO

F-4
PREFACE (Foreword)

PREFACE

Thank you for purchasing a YANMAR Diesel Engine.

1. Foreword
This Operation Manual has been prepared for your safe and effective use of the engine. Read through this
Operation Manual and fully understand the safety precautions and precautions regarding the operation,
checking and servicing before using this engine.

(1) Keep this Operation Manual at a clearly identified place accessible for the operator to refer to it at
any time.
(2) The text and illustrations of this Operation Manual may partly disagree with engines of some speci-
fications.
For such engines, refer to the Engine Specification and Final Document we have submitted you
separately.
Also note that used parts and the content of this Operation Manual description of this engine are
changed without notifying the user beforehand for improving the quality and performances of
engine or for safety.
(3) For the following devices, refer to the corresponding operation manuals separately attached.
Turbocharger
Hydraulic governor
Other attachments of special specifications
(4) In this manual, the numerical values are based on the SI system (International System of Units).
However, the numerical values based on the conventional unit system are also given in brackets.
(5) Replacement parts should be our genuine parts or specified parts. Order a part to your nearest
sales or service agent of Yanmar’s parts. When ordering a part, clearly specify the Part Name (part
description) and Part No., and the Model and manufacture’s Serial No. of the engine.
(6) If you should have lost or damaged this Operation Manual, or if you have any questions and advice,
please contact us or your nearest sales or service agent (shown in the service network list "YAN-
MAR Worldwide Service" appended to this manual).
(7) If you transfer this engine, also transfer this Operation Manual, Final Document and Records of
Shop Trial with the engine to the next owner.
(8) If you use this engine for an application or under service condition other than those specified, or if
you handle it not in accordance with this Operation Manual, an accident or a failure may be caused.
Please contact us or your nearest sales or service agent before changing any technical data of the
engine or modifying the engine after it has been delivered. Never modify the engine without consult-
ing us.

2006.6.23R 0-1 (Volume:14pages)

PREFACE (For safe use of your engine)

For safe use of your engine.

Be sure to abide by -marked DANGERs, WARNINGs and CAUTIONs described in this Manual.
As far as safety is concerned, they are particularly important parts of instructions.

● The following shows the safety marks used for caution indications in this Operation Manual and
safety labels attached to this product and explains their meaning.

It indicates that a danger of possible death or serious injury is very great

when the proper precautions is not followed.

It indicates that there is a danger of resulting in death or serious injury when

the proper precautions is not followed.

It indicates that there is the possibility of resulting in injury or serious

damage to the engine when an advice on safety handling or the
proper precautions is not followed.

● Where the safety labels are posted is shown in page 0 -12.

● The cautions prefixed with the mark in this Operation Manual are especially important for safe
handing of this product. A failure to observe this caution may incur a deterioration of performances or
trouble/accident of this product. Therefore, be sure to observe the items.

0-2
PREFACE (Terms & Symbol Marks)

2. Term & Symbol Marks

1) The major terms used in this Operation Manual are defined as follows:
Front part of engine: Part opposite to the flywheel end
Rear part of engine: Part on the flywheel end
Operating side: Left side as viewed form the flywheel end (fuel injection pump side)
Non-operating side: On the right as viewed from the flywheel end (exhaust pipe side)
CW rotation: Clockwise rotation as viewed from the flywheel end
CCW rotation: Counterclockwise rotation as viewed from the flywheel end
Cylinder No: Assigned in the ascending order from the cylinder nearest to the flywheel end

Non-operating Side
Flywheel

6 5 4 3 21 Generator

Fuel Injection Pump

Operating Side

2) The following symbol marks are used in the safety labels shown in this Operation Manual and
posted on the engine.

(1) Caution marks and signal words

It indicates that a danger of possible death or serious injury is very great

when the proper precautions is not followed.

It indicates that there is a danger of resulting in death or serious

injury when the proper precautions is not followed.
It indicates that there is the possibility of resulting in injury or serious
damage to the engine when an advice on safety handling or the
proper precautions is not followed.

It indicates a handing caution which, if not observed, may incur a deteriora-

tion of performance or a trouble/accident of this product.

(2) Symbol marks

(a)Caution marks (b)Others

Caution Caution on ・・Refer to another page,

on explosion rotating part section or chapter of this
Operation Manual or other
document.
Caution on
Caution on fire
high temperature

Caution on High pressure

hazardous noise air inside

2004.11.25R 0-3
PREFACE (Safety Precautions / Basic Precautions)

An accident may occur if the safety rules are not followed.

3. Precautions on Safety

3-1. Basic Precautions

Strict Observance of the Safety Rules

• When running the engine or servicing it for its maintenance, observe the safety rules, precautions on
safety and work procedures.
• When carrying out a joint work, work according to the predeter-
mined signs. K Before starting
R
WO a work
Way of pre-work arrangement
(1) According to kind of work required
(2) Everyone to contemplate and consider
(3) Everyone to understand well
(4) Fix the most suitable way to work

• Wear the proper protective garment. Don't wear oil

smudged work clothes because they are prone to catch
fire.
• Wear protectors such as helmet, safety goggles, safety
shoes, protective mask, protective glove, life-line, etc.,
depending on the nature of work required. (1) Safety has priority over
all the works.
Safety helmet (2) Safety is more impor-
tant than any other
Be properly clothed
duties.
Life-line (3) It is needless to say
that "Safety First"
Protective glove
means that safety has
priority over working
Safety shoes efficiency.
(4) Safety is the foundation
• When working on the engine, use the specified engine for working efficiency.
tools. Use jigs or tools suitable for particular work because Safety is never contra-
use of a wrong tool causes an injury. dictory to working effi-
ciency.

• While at work, do not jump on and off the engine.

• For working, install a work bench fitted to the size of your engine to secure a good footing. Don't work
in a dangerous position.

0-4
PREFACE (Safety Precautions / Basic Precautions)

No Modification, Please.

• When you want to modify your engine, consult us or your nearest sales
or service agent in advance. Yanmar can not be responsible for an acci- Sealed ?
dent resulting in injury or death or an engine trouble resulted from unau-
thorized modification.
• Your engine and its safety devices have been sealed for the sake of
safety. Don't break or tamper with a seal indiscreetly.
• If a sealing is missing, take a proper step of promptly contacting us or
your nearest sales or service agent for ensuring the proper initial set-
ting.

Observe the precautions for ensuring safety.

Check of Safety Devices

• Check the all the safety devices of your engine have been set normally.
• If a safety device is wrongly used, it leads to a serious accident resulting in injury or death.
• Promptly repair a cover a rotating part, a heat shielding cover for exhaust pipe, a protective cover of
the heating region or the like, if found damaged.
• Never run the engine while the cover of a rotating part is removed. Otherwise dur-
ing operation, your hand, body or clothing may be caught in the rotating part, result-
ing in your injury.

Be Cautious of Handling of a High-temperature or High-pressure Spot.

— Take care not to get burnt. —

• During running and immediately after the engine has stopped, the whole engine is heated. Take care
not to get burnt.
• When changing cooling water, lubricating oil or filter immediately after the engine has
stopped, proceed to work only after the temperature has lowered.
• Do not touch a high-temperature region such as the exhaust pipe or pressure indicator
cock of engine with bare hands.
• Do not touch the heater and heated sections of fuel oil system with bare hands.
• Since the pressure indicator becomes hot, be sure to wear gloves when taking read-
ing.
• If you uncap the radiator or fresh water tank, vapor or hot water may blow up, causing
you to get burnt.
• Stop the engine and wait until the temperature has dropped. Then, wrap the cap with
cloth and slowly loosen it to release the internal pressure. After that, remove the cap.

0-5
PREFACE (Safety Precautions / Basic Precautions)

Be Cautious of Handling of Fuel & Lubricating Oil.

• If fire is brought close to fuel and/or lubricating oil, there is the possibility of catching
fire.
(Particularly the fuel is highly flammable and dangerous.)
• Fire should be strictly prohibited in the engine installed place (engine room).
• Check for leak of fuel oil and lubricating oil. If you find a defective point, repair it and
wipe out leaked fuel or lubricating oil.
• Store the fuel oil and lubricating oil at the specified place and do not allow persons
other than those concerned to handle them.
• Unnecessary flammables in the engine installed place (engine room) may cause fire.
Therefore, store these flammables in another specified place.

NO SMOKING CAUTION:
FLAMMABLES

Ventilate Well.

• Exhaust gas emitted from an engine is dangerous.

Ventilate well to prevent gas intoxication.
• If Exhaust gas is leading, promptly repair such a leaking
point at the exhaust pipe.
• Ventilate well the indoor engine installed place (and/or the
engine room.)
• Take care that the room does not fall short of the air (oxy-
gen) because the turbocharger takes in a great volume of
air.
• While charging the battery, there is danger of
catching fire because hydrogen gas is gen-
erated. • Inhaling exhaust gas is very dangerous.
• When working indoors, sufficiently
• ventilate the room.

Installing of a Fire Extinguisher and First-aid Kit

• Install a fire extinguisher against a possible fire, and check how to use FIRE
EXTINGUISHER
it.
• Fix a safekeeping place for a first-aid kit, and install it there.
• Fix the actions to be taken when fire or an accident has occurred.
• Establish a means of reporting to emergency medical institution such
as an emergency hospital, and have its telephone number written
down.

0-6
PREFACE (Safety Precautions / Precautions on Operation)

Observe the precautions for ensuring safety.

3-2. Precautions on Operation

(1) Prior to Starting of the Engine

Start the Engine after Signaling

• Check if no one is around the engine.

• If someone is found near the engine, give him a sign that the engine will be
started. Only then start it.
• Check the holding capacities of fuel, oil, air, etc.
• Be sure to detach the turning device once the engine is started, and keep
it at it's fixed housing spot.
• Turn on the power supply of the engine protection device before starting up the engine.
• After the engine has been stopped for a long time or after the engine has been serviced, be sure to
start up the engine at the engine side.
• If the rotational speed rises extremely rapidly or if you find an usual sound or fume, immediately set
the start/stop lever in the STOP position to stop the engine.

Check After the Engine Is Started

• Check if pressure values of each instrument/gauge board are normal.

• Check if there are no unusual sound and abnormal heat buildup.
• Check for any leakages of fuel, oil, air, etc., and if a leakage is found, promptly repair.
• Except in case of emergency, apply the load after a warming-up.

(2) During a Run

• Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup.
• Check whether the engine fully shows its proper performances and record the check results. (Refer to
the Records of Shop Trial, then record the check results on the Engine Log.)

Take care not to be caught in a rotating part.

• Never allow your hands, body and clothing to make contact or bring close to any rotat-
ing part.

Take care not to get burnt.

• During running and immediately after 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 clothing to make contact with the turbo-
charger, exhaust manifold, exhaust pipe and/or engine as whole.
• If any abnormality is detected, immediately stop the engine and repair it.

Take care not to get hearing loss.

• Put an ear protection in engine-room during running, because can cause hearing loss.

2003.10.20R 0-7
PREFACE (Safety Precautions / Precautions on Operation)

An accident may occur if the safety rules are not followed.

(3) When Stopping the Engine

• Do not stop the engine simultaneously with load shutoff.

• Except in case of emergency, keep running the engine without load after load shutoff.
• Keep the engine ready for being started up.
• Promptly repair the points that have been troubling during a run.
• Do not open the side cover of crankcase for at least 10 minutes after having stopped
the engine. Otherwise, the entry of external air may result in explosion.

Take care not to get burnt.

• Immediately after 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 clothing to make contact with the turbo-
charger, exhaust manifold, exhaust pipe and engine as a whole.
• If you attempt to drain oil while the engine is still hot, take care not to get burnt with
splash of oil.
• If you disassemble the cooling water system while the engine is still hot, vapor or hot
water may blow out, causing you to get burnt.
Wait until the engine becomes cool, then wrap the disassembling part with cloth or the
like and slowly loosen it.

0-8
PREFACE (Safety Precautions / Precautions on Maintenance)

Observe the precautions for ensuring safety.

3-3. Precautions on Maintenance

(1) Precautions Prior to Maintenance Servicing

Indication of Warnings in Checking and Servicing

• While checking and/or maintenance servicing the engine, post a notice

on a warning indicating board for danger prevention.
• Strive for safety, maintaining a close contact with the respective parties
concerned.
• Strive to prevent a danger from emerging, forbidding other than the par-
ties concerned to enter the engine installed place (and/or the engine
room), for instance.

Immediately After an Engine Stop

• Do not open the side cover of crankcase for at least 10 minutes after having stopped
the engine. Otherwise, entry of external air may result in explosion.

Take care not to get burnt.

• Immediately after 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 clothing to make contact with the turbo-
charger, exhaust manifold, exhaust pipe and engine as a whole.
• If you attempt to drain oil while the engine is still hot, take care not to get burnt with
splash of oil.
• If you disassemble the cooling water system while the engine is still hot, vapor or hot
water may blow out, causing you to get burnt.
• Wait until the engine becomes cool, then wrap the disassembling part with cloth or the
like and slowly loosen it.

Preparation Prior to Working

• Since a working area will be stained/smudged, put it in good order.

• Prepare engine jigs and tools ready to use.
• Prepare oil, genuine parts, waste cloth, wire, etc. according to the nature of work to be done.
• Secure a work bench fitted to the height of the engine.

0-9
PREFACE (Safety Precautions / Precautions on Maintenance)

An accident may occur if the safety rules are not followed.

(2) Precautions During Maintenance Servicing

Check in Course of Work

• For a joint work strive for elimination of a possible danger by keeping

alert to the surroundings.
• Tie such an accessory detached in work to a stable post or spot so that
it will not fall down.
• For a work at a height, put on the safety belt or life-line. OPERATION
MANUAL
• According to the condition of working, wear protectors.
• Be careful of oil stained or smudged protective glove because working
with such a glove might lead to a damage of parts or a personal injury
as your hands are apt to slip.
• Wipe off or mop up spilled fuel or oil at once because, if left alone, it is
dangerous as it causes a slip.
• Prepare a box to accommodate removed parts in advance so that they will not be lost nor damaged.
• If necessary, provide setting marks before disassembling the engine so that you can reassemble it in
the proper reassembling sequence.
• Reassemble the setting marked portions with reference to the setting marks.
• Tighten the bolts and nuts to the specified torque or hydraulic pressure.

Use of the Proper Tools

• Use the specified engine tools to prevent the damage of the respective bolts and nuts of the engine.
• When handling a heavy thing, follow the slinger's instructions.
• In advance of using exclusive tools, check the function of these tools.
• Carefully check for any damages to rubber hose and joints of hydraulic jacks.
• Use the specified lifting gear, hook, rope, etc.; and pay attention to safety when handling a heavy
thing particularly.

Precautions in Use of Fire

• In such works with welder, electrical tools

e and Flammab
and grinder, be careful of sparking.
t ion:Fir les
Since there is the possibility of catching ou
fire, try not to leave combustibles such as
C
fuel, lubricating oil and used waste cloth in
a working area.

0-10
PREFACE (Safety Precautions / Precautions on Maintenance)

Observe the precautions for ensuring safety.

Precautions in Checking the Electrical System

• Shut off the power supply before starting the work. Otherwise, a fire may occur or you
may receive electric shock.
• When checking the battery system, be sure to disconnect the earth cable
(–) terminal. Otherwise, the negative terminal may be short-circuited by mistake,
resulting in fire.
• The strong acid battery electrolyte put on your skin or eyes will cause inflammation. If
the battery electrolyte should be put on your skin or eyes, immediately flush it with
fresh water, then consult a physician.

Precautions for Using Organic Solvent

• Since an organic solvent is highly volatile, liable to be gasified and absorbed by worker through his
breathing as it vaporized, pay close attention to ventilation when handling it.
• Since a highly concentrated organic solvent has the property of dissolving fats and oils and is
absorbed by worker through his skins, be careful of handling it.
• When working with such a solvent, be sure to wear rubber gloves.

(3) Precautions at Completion of Maintenance Servicing

Check of Work Finish

• Check if detached parts have been refitted at the specified spots in the total
number.
• Check if the damaged parts have been replaced with the good ones.
• Return tools, lifting gear, hook, rope, etc. used to the former safekeeping place.
ENG
• Remove fuel and oil from the engine installed place (and/or the engine room). LOG INE
• Keep the engine installed place (and/or the engine room) in order and tidy so
that it will not interfere with daily operation.
• Before starting the engine, check various parts to see if there is no abnormality.
Refer back to 3-2. Precautions on Operation, (1) Prior to Starting of the
Engine.
• Proceed t a load run, and check that the performance does not differ from that
existed prior to the maintenance servicing.
Refer back to 3-2. Precautions on Operation, (2) During a Run.
• As soon as a load run is completed, enter records of performance as well as
KEEP TIDY
the nature of maintenance servicing in your Engine Log. (Keeping of records
and then reporting of work completion)
• Remove such as a standing signboard, and contact the respective parties con-
cerned for reporting the completion of work.

0-11
 4. List of Safety Labels
This page shows where safety labels are posted for safely use of this engine. Carefully read the cautions
shown on the safety labels to prevent accidents.

2002.8.30R
If any safety label is stained, damaged or lost, order it to your nearest Yanmar sales or service agent
(shown in the service network list "YANMAR Worldwide Service" appended to this manual) by clearly
specifying its Part No., and post it.
WARNING

CAUTION

HAZARDOUS NOISE
Can cause hearing loss.
Put on ear protection.
4. List of Safety Labels

146673 07230 141616-07270

0-12
PREFACE (Safety Precautions / List of Safety Labels)
PREFACE (Safety Precautions / Lifting Procedures Engine)

5. Lifting Procedures for Engine

Falling of the engine or generating set during its lifting or carriage is very dangerous if so happened.
In time of a load lifting work, observe the following items in order to prevent an accident:
• Use the lifting wire rope, shackle, etc. that are suitable for lifting weight.
• Choose the wire rope length so that the engine or common bed does not lean to one side during lift-
ing.
• Put a cushioning material such as padding between the wire rope and the engine or driven machine
(generator, for instance) which the wire rope comes into contact with otherwise.
• Choose such a cushioning material as will not be damaged not removed during lifting, then attach it
not to allow its contacts with the engine or driven machine to be damaged.
• Do not enter an area below the lifting load.

Lifting sling attaching points

1) Common bed set

The "Hang up This Point" labels have been
stuck on the common bed. 60
No.6 No.1

HOOK HOOK

Hang up This Point

2) Engine singly

○ Fit the (optionally available) exclusive lifting

slings to cylinder head clamping bolts of the
No. 2 and No. 5 cylinders close to the center of
the engine. 60
○ Haul up the cylinder heads under the specified
No.6 No.1
hydraulic pressure tightened state.
○ Keep the lifting angle of the wire rope within 60
degrees.

3) Driven machines (generator, pump, etc.)

○ For the wire rope attaching points, refer to the

respective Operation Manuals.

0-13
PREFACE

MEMO

0-14
1.　ENGINE DESCRIPTION (Engine Specification)

1. ENGINE DESCRIPTION

1-1. Engine Specification (1/2)

Model Unit 6N18L-DV 6N18L-UV 6N18L-SV 6N18L-EV

Type --- Vertical, water-cooled, 4-cycle diesel engine

Combustion chamber --- Direct injection type

No. of cylinders --- 6

Cylinder bore mm 180

Stroke mm 280

Total cylinder displacement --- 42.75

Compression ratio --- 16.5

Rated speed of revolution min-1(rpm) 720 or 750

Direction of rotation of
--- Counterclockwise as viewed from the flywheel end (XL)
crankshaft

Operating side --- On the left as viewed from the flywheel end

Order of firing --- 1-4-2-6-3-5-1

Supercharging system --- Exhaust gas turbine supercharger (turbocharger) with air cooler

Cooling system --- Dual fresh water line cooling.

Forced lubrication
Lubricating system --- (system oil also used as turbocharger lub.oil)
(system oil also used as rocker arm lub.oil)

Lubricating oil sump sys-

--- Sump incorporated in common bed
tem

Starting system --- Air motor starting

Overall length mm 2,696

Dimen-
Overall width mm 1,315
sions
Overall height mm 1,935

6,500
Mass (of engine singly) kg
(may vary as depending on specification)

Constitution of Model Designation

No. of cylinders
Engine series Configuration of Cylinders
Cyl. bore (in cm)

6 N 18 A L EV
6 5 4 3 2 1 Flywheel
W/O"A": 720 or 750min-1
W/"A": 900 or 1000min-1
Marine auxiliary/Land use
Degree of supercharging

2003.4.17R 1-1 (Volume:6pages)

1.　ENGINE DESCRIPTION (Engine Specification)

1-1. Engine Specification (2/2)

6N18AL- 6N18AL- 6N18AL- 6N18AL- 6N18AL-
Model Unit
HV DV UV SV EV

Type --- Vertical, water-cooled, 4-cycle diesel engine

Combustion chamber --- Direct injection type

No. of cylinders --- 6

Cylinder bore mm 180

Stroke mm 280

Total cylinder displacement l 42.75

Compression ratio --- 16.5

Rated speed of revolution min-1(rpm) 900 or 1,000

Direction of rotation of
--- Counterclockwise as viewed from the flywheel end (XL)
crankshaft

Operating side --- On the left as viewed from the flywheel end

Order of firing --- 1-4-2-6-3-5-1

Exhaust gas turbine supercharger (turbocharger) with

Supercharging system ---
air cooler

Cooling system --- Dual fresh water line cooling.

Forced lubrication
Lubricating system --- (system oil also used as turbocharger lub.oil)
(system oil also used as rocker arm lub.oil)

Lubricating oil sump system --- Sump incorporated in common bed

Starting system --- Air motor starting

Overall length mm 2,696

Dimen-
Overall width mm 1,315
sions
Overall height mm 1,935

6,500
Mass (of engine singly) kg
(may vary as depending on specification)

Constitution of Model Designation

No. of cylinders
Configuration of Cylinders
Engine series
Cyl. bore (in cm)

6 N 18 A L EV
6 5 4 3 2 1 Flywheel
W/O"A": 720 or 750min-1
W/"A": 900 or 1000min-1
Marine auxiliary/Land use
Degree of supercharging

2003.4.17R 1-2
1.　ENGINE DESCRIPTION (Types of Accesories & Attachments)

1-2. Types of Accessories & Attachments

Accessory/Attachment Type Remarks

Supercharger Air-cooled exhaust gas turbine

Boost air cooler Plate finned multitubular

Governor Hydraulic

Fuel injection pump Bosch

Fuel valve Non-cooled perforated

M.D.O.feed pump Gear For marine diesel oil

Heat-insulating, manual back-washing,

Fuel oil filter For engine inlet
duplex, changeover notch wire

Lub.oil pump Gear Pressure regulating valve integrated

Lub.oil cooler Low finned tube multitubular w/automatic temperature control valve

Lub.oil strainer Duplex, changeover notch wire Manual back-washing

Lub.oil by-pass strainer Centrifugal

Lub.oil tank Tank incorporated in common bed

Cooling water pump Centrifugal Cylinder jacket side, cooler side

Lub.oil priming pump Screw

Air motor Turbine

1-3
1.　ENGINE DESCRIPTION (Sectional View of the Engine)

1-3. Sectional View of the Engine

OPERATING SIDE NON OPERATING SIDE

Valve Push Rod Rocker Arm Suc./Exh.Valve

Cyl. Head

Injection Pipe Joint

Protection Ring
Exh. Manifold

Fuel Injection Pump

Piston
Boost Air Boost Chamber

Cyl. Liner
Pump Housing Cover

Swing Arm

Lub. Oil Cooler

Camshaft

Connecting Rod

Lub. Oil Strainer

Crankshaft Cyl. Block

Side Bolt

Main Brg. Bolt

Oil Pan

Mounting Foot

1-4
1.　ENGINE DESCRIPTION (Engine Outline & Device Arrangement)

1-4. (1/2) Engine Outline & Device Arrangement

Operating Side Engine Rear End

Turbocharger Injection Pump Housing Cover Gauge Panel

Fuel Injection Pump

Starting Switch

Start/Stop Lever

Governor

Control Position
Selector Switch

Air Motor

Flywheel
Turning Device
Cam Case Cover

1-4. (2/2)Engine Outline & Device Arrangement

Non-operating Side Engine Front End

Exh. Manifold Cover

Lub. Oil Thermostatic
Valve
Hot Water
Thermostatic Valve

Fuel Filter

Boost Air Cooler

Fuel Oil Pressure

Regulating Valve

Cold Water Pump

(on Cooler Side)
Hot Water Pump
(on Cly. Jacket Side) M.D.O.Feed Pump
Lub. Oil Cooler
Crankcase Safety Valve
Lub. Oil Pressure
Regulating Valve Lub. Oil Bypass Strainer

Lub. Oil Pump Lub. Oil Priming Pump

Lub. Oil Strainer

1998.10.20R 1-5
1.　ENGINE DESCRIPTION

MEMO

1-6
2.　STRUCTURE OF MAJOR PARTS (Outline of Structure)

2. STRUCTURE OF MAJOR PARTS

2-1. Outline of Structure

This engine is designed to be a crankcase integrated, suspension metal structure as shown in the below
sectional view.
For its installation, there are the fixed supporting to fix it directly on the common bed and the antivibration
supporting to fix the mounting foot and generator on the common bed via rubber vibration insulators.

Drawing 2-1.
OPERATING SIDE NON OPERATING SIDE

Valve Push Rod Rocker Arm Suc./Exh.Valve

Cyl. Head

Injection Pipe Joint

Protection Ring
Exh. Manifold

Fuel Injection Pump

Piston
Boost Air Boost Chamber

Cyl. Liner
Pump Housing Cover

Swing Arm

Lub. Oil Cooler

Camshaft

Connecting Rod

Lub. Oil Strainer

Crankshaft Cyl. Block

Side Bolt

Main Brg. Bolt

Oil Pan

Mounting Foot

2-1 (Volume:6pages)
2.　STRUCTURE OF MAJOR PARTS (Structure of Major Parts)

2-2. Structure of Major Parts

1) Cylinder block
Provided with side covers on both the operating side and the non-operating side, the cylinder block is a
duplex wall structure made of casting integrating the boost air manifold (boost air chamber), main lubricat-
ing oil pipe and main cooling water pipe.

2) Cylinder liner
Made of a special cast iron, the cylinder liner has the special thermal treated surface. The inner face is
finished with precision honing. On the upper part of inner diameter of the liner, an anti-polish ring is
mounted.

3) Cylinder head
The cylinder head is of the 4-valve type equipped with two suction valves and two exhaust valves and
arranged with a fuel injection valve at the center. The cylinder head is clamped by tightening four bolts
under the hydraulic pressure.
The exhaust valve seat is water cooled, and the fuel injection valve is mounted with a sleeve.

4) Piston and piston rings

The piston is special cast iron. Its upper parts is cooled by the cocktail shaker method using lubricating oil
that passes through the connecting rod and piston pin. The skirt is provided with special coating.
The piston rings are two compression rings, and their sliding surface is chrome-plated. Besides, there is
one oil ring combined with a coil expander whose sliding surface is also chrome-plated.

5) Connecting rod
The big end of a connecting rod is an obliquely split structure, and its mating surfaces are serrated. The
connecting rod bolts are two tap bolts tightened to the specified angle.

6) Crankshaft and main bearings

A balance weight is attached to each arm of the crankshaft by tightening the balance weight clamping bolts
to the specified angle.
The main bearing is of the suspension metal type. At the flywheel-side timing gear case of the No.1 main
bearing, the No.0 main bearing is provided, and it is attached with thrust metal and journal metal.
Each bearing cap is fixed with two mounting bolts and two side bolts on both the operating side and non-
operating side. The mounting bolts are tightened to the specified hydraulic pressure.(The side bolt of the
No.0 main bearing cap is equipped only on the non-operating side.)

7) Camshaft
The suction/exhaust cam and fuel cam form a monoblock structure with the camshaft. It is split in two at
the bearing part between the No.3 & No.4 cylinders.

8) Fuel injection pump

The fuel injection pump is of the Bosch type. The delivery valve is a pressure equalizing valve, and the
plunger barrel is of the top closed type.
The fuel injection timing is adjusted by means of the adjusting bolt of tappet of pump driving gear.

9) Fuel injection valve

The type using the high viscosity fuel oil is cooled with the cooling water running through the fuel injection
sleeve mounted on the cylinder head. A heat transfer bush (copper) is installed between the fuel injection
nozzle and the injection valve sleeve, thus indirectly cooling the injection nozzle. The engine using the MD
oil does not use the indirect cooling system nor a heat transfer bush. The injection pressure is adjusted
with the spring shoe fastened with the adjusting nut.

10) Starting and stopping devices

The engine is started by an air motor using the compressed air.
To stop the engine, the start/stop lever is set in the STOP position. To stop the engine by the remote oper-
ation, the air piston is actuated to set the rack of fuel injection pump at the non-injection position.
The start/stop lever and turning device are interlocked with the respective switches to prevent starting by
erroneous operation.

2002.8.8R 2-2
2.　STRUCTURE OF MAJOR PARTS (Lubricating Oil System)

2-3. Lubricating Oil System

○ The lubricating oil pump is a gear pump integrating the pressure regulating valve and safety, valve.
○ The lubricating oil strainers are a notch-wire type strainer and a centrifugal bypass strainer.
○ The lubricating oil cooler is a unit structure of the multi-tubular type fitted with an automatic thermo-
static valve and a notch-wire type strainer.
○The priming pump is a motored screw pump and is mounted on the common bed. The delivery pipe
is connected with the inlet side of the notch-wire type strainer.

The lubricating oil discharged from the pump is regulated of its pressure to the specified value by the pres-
sure regulating valve. Then, the lub. oil passes through the cooler and strainer and then enters the main
gallery of the cylinder block. The lubricating oil line is branched at the main gallery. The oil passes through
each part and returns to the oil pan and then the common bed.
Each lub. oil passage franched off from the main gallery is a drilled hole structure, excluding lines leading
to the pressure regulating valve and governor driving gear.
The oil suction part of the pump varies according to the engine installation types. In the case an engine
installed by the fixed supporting, the fixed suction part is the command bed; in the case of antivibration
supporting, it is oil pan.

Drawing 2-2
(Heavy Fuel Oil Spec.)
Fuel Injection Pump Pinion

Swing Arm Brg. Swing Arm Roller Pin

Suc./Exh. Valve Rocker Arm

Fuel Injection Pump Tappet Roller Cam Bearing

(Connecting Rod)
M. Brg. Crank-pin Brg. Piston-pin Brg. Piston

Cooling Water Pump Intermed. Gear

Camshaft Intermed. Gear

Lub. Oil Pump Intermed. Gear

Auto. Thermostatic Valve Turbocharger

Governor Driving Gear Main Gallery

Lub. Oil Cooler

Pressure Regulating
Valve Turbocharger
Lub. Oil Strainer
Paper Element Type

Pump
Engine Main
Lub. Oil Strainer
Notch-wire Type

Bypass Strainer,
Oil Pan Centrifugal

Command Bed

Priming Pump

1999.7.2R 2-3
2.　STRUCTURE OF MAJOR PARTS (Cooling Water System)

2-4. Cooling Water Pipe System

2-4-1. Cooling Water Pipe System (both fresh water line of the mixing type)
The cooling system of this engine is to cool the engine (cylinder liner and cylinder head) with hot fresh
water and the lubricating oil cooler and boost air cooler with cold fresh water. This cooling system is called
the dual fresh water line cooling system of the mixing type.

○ Both the cold water pump and the hot water pump are centrifugal pumps equipped to the frontal
part of the engine. The hot water pump is such a structure to incorporate the check valve directly
to the frontal side gear case through the check valve on the delivery side. (The suction parts of
both pumps are caupled in the gear case.)
○ The temperature of hot water is controlled by the pellet type automatic thermostatic valve.
○ The temperature of cold water is controlled by a thermostatic valve equipped on the fresh water
cooler side.

The cooling water discharged from the cold water pump passes through the boost air cooler and lubricat-
ing oil cooler, and then returns to the fresh water cooler side. However, a part of the cooling water passes
through the cooling water passage in the cylinder block and flows into the cold water suction side through
the automatic thermostatic valve.

The cooling water discharged from the hot water pump returns to the cylinder jacket, cylinder head and
cooling water collecting pipe and then to the automatic thermostatic valve which controls the temperature
of thus returned cooling water.

The cooling water flown into the cylinder head cools the combustion surface and periphery of fuel injection
valve sleeve and then cools the exhaust valve seat. After that, the cooling water flows into the cooling pipe.

Expansion Tank
Drawing 2-3

Check Valve
Hot Water Pump

Automatic Thermostatic Valve

Cold Water Pump

Lub. Oil Cooler Boost Air

Cooler

Cold Water Thermostatic Valve

Fresh Water
Cooler

(Sea Water)

2-4
2.　STRUCTURE OF MAJOR PARTS (Cooling Water System)

2-4-2. Cooling Water Pipe System (cold water line sea water spec.)
1) The cooling system of this engine is to cool the engine (cylinder liner and cylinder head) with hot fresh
water and the lubricating oil cooler and boost air cooler with cold sea water.

○ The cooling system is a dual-line system consisting of the cylinder jacket line and cooler line.
Sea water lines are equipped with a motor-driven centrifugal pump mounted in the marine as the
standard provision.
○ The cooling fresh water pump in the cylinder jacket line, the centrifugal pump is driven via an idle
gear.

2) The cooling sea water discharged from the cold water pump passes through the boost air cooler and
lubricating oil cooler.

3) A bypass valve is provided at the cooling water outlet side of boost air cooler.
Opening the bypass valve decreases the amount of cooling water flowing through the boost air cooler
and raised the boost air temperature.

4) The cooling water discharged from the hot water pump returns to the cylinder jacket, cylinder head and
cooling water collecting pipe and then to the cooling water expansion tank tank.

5) The cooling water flown into the cylinder head cools the combustion surface and periphery of fuel
injection valve sleeve and then cools the exhaust valve seat. After that, the cooling water flows into the
cooling water cooling pipe.

Drawing 2- 4
Fresh (Hot) Water Pump

Fresh (Hot) Water Outlet

(To expansion tank) Automatic Sea Water Valve
(mount in marine)

Fresh Water Inlet

Sea Water Inlet
Lub. Oil Cooler Boost Air
Cooler

Sea Water Pump

(mount in marine)
Sea Water Outlet By-pass Valve

2000.10.6R 2-5
2.　STRUCTURE OF MAJOR PARTS

MEMO

2-6
3.　TABLE OF ENGINE STANDARD ADJUSTMENTS

3. TABLE OF ENGINE STANDARD ADJUSTMENTS

3-1. Assembly Adjustment Values

Item Adjustment Value Remarks
Piston top clearance(A) mm 2.0 ± 0.2
Begins to open(before T.D.C.) 68
Exhaust Valve Suction Valve

deg.
Ends closing(after B.D.C) 50
Valve head clearance(B) mm 0.3 In the cold state
Begins to open(before B.D.C) 68
deg.
Ends closing(after T.D.C) 58
Valve head clearance(B) mm 0.4 In the cold state
Timing/Clearance

B
A

Adjust B after
setting it to zero

Fuel injection pump begins to Refer to Records of Shop

deg. ★
deliver(before T.D.C) Traial.
Injection pressure, fuel injection valve MPa(kgf/cm2) 34.0 ± 0.5(347 ± 5)

3-2. Pressure & Temperature Setting Values

Item Setting Value Remarks
0.49 ～ 0.54(5.0 ～ 5.5) Marine disel oil(M.D.O)
Fuel feed pressure
Refer to Chapter 5,5-1-3 Heavy fuel oil(H.F.O.)
Refer to Records of Shop
Maximum combustion pressure(Pmax) ★ Trial.
0.39 ～ 0.44(4.0 ～ 4.5) Engine inlet(cooler outlet)
Lub. oil pressure
0.1 ～ 0.2(1.0 ～ 2.0) Turbocharger inlet
Values marked with ※ are per-
missible cooling water pres-
Pressure

2
MPa(kgf/cm )
0.15 ～ 0.25/ ※ 0.39 sure of central cooling system
Cooling water pressure(jacket cooling line)
(1.5 ～ 2.5/ ※ 4.0) when the pressurized water
inlet pressure or tank head
pressure are imposed
0.15 ～ 0.25/ ※ 0.39
Cooling water pressure(cooler cooling line)
(1.5 ～ 2.5/ ※ 4.0)
Starting air Starting air tank 2.94(30) Lower limit:1.18(12)
pressure After decompression 0.69 ～ 0.98(7 ～ 10) At the air motor inlet
Cooling water engine outlet temperature 358 ± 4(85 ± 4) At the rated output
Cooling water air cooler inlet temperature Below311(below38)
Temperature

Lub.oil engine inlet temperature(cooler

323 ～ 338(50 ～ 65)
outlet)
K( ℃ )
Exhaust temperature(at each cylinder out- Refer to Records of Shop
let) ★ Trial.
Refer to Records of Shop
Exh.gas turbocharger inlet temp. ★ Trial.

Note: For a star( ★ ) given above, refer to the Records of Shop Trial and enter the obtained value here
because it varies according to the engine specification and output.

2006.12.15R 3-1 (Volume:2pages)

3.　TABLE OF ENGINE STANDARD ADJUSTMENTS

3-3. Protective Device Setting Values

Item Unit Alarm Setting Value Emer.Stop Setting Value

Lub.oil engine inlet pressure 0.34(3.5) 0.29(3.0)

MPa(kgf/cm2)
Lub.oil turbocharger inlet pressure 0.1(1.0) ---

Cooling water engine outlet tem-

K( ℃ ) 368(95) 373(100)
perature

115 ～ 120% of the rated

Rotational overspeed min-1(rmp)
speed

* Lub.oil priming pressure 0.02(0.2) ---

* Differential pressure(lub.oil
0.09(0.9) ---
strainer)

* Differential pressure(fuel.oil filter) 0.09(0.9) ---

* Starting air pressure 0.65(6.6) ---

MPa(kgf/cm2)
* Control air pressure 0.65(6.6) ---

* Cooling water pressure(jacket

0.13(1.3) ---
cooling line)

* Cooling water pressure(cooler

0.13(1.3) ---
cooling line)

* Lub.oil engine inlet(cooler outlet)

K( ℃ ) 348(75) ---
temperature

As for an asterisk(*), for equipment of each item varies as depended on the specification, refer to the Final
Document.

3-4. Holding Volumes of Lubricating Oil and Cooling Water

[Unit: Itr.]
Item Holding Volume Remarks

Engine(incl.inside the cooler, strainer &

35
Lubricating Oil

piping)

Lub.oil sump(common bed tank) * more than 1.0l/ps

Type NZ61, RHD 1.3

* Governor
Type PSG 2.0
Cooling water

Cylinder jacket(fresh water) 75

Cooler 25

As for an asterisk(*), refer to the Final Document as the volume may vary according to the specification.

2006.6.20R(MET 3-2
4.　OPERATION (Operational Preparation)

4. OPERATION

During operation, the diesel engine runs at a high speed. Also, some parts of the engine are hot, and
the compressed air and such pressurized fluids as oil and water are flowing inside it. Therefore, thor-
oughly read the safety precautions before operation, maintenance and inspection to handle the
engine properly not to cause any accidents.
Chapter0, Section 3. Precautions on Safety

4-1. Operational Preparation

Before the initial start of the engine after its installation or before its restart after its overhaul servicing
or a long-term stoppage, sufficiently perform the following inspection and operation preparation in
addition to daily inspection and operational preparation, and make sure there is no abnormality and
the operational preparation has completed.
(1) Make sure no part nor tool has been left in the crankcase.
(2) Check for a part not tightened yet.
(3) If you have disassembled the valve mechanism, check the suction/exhaust valve head clearance.

Chapter 6, 6-3-6. Adjustment of Suc./Exh. Valve Head Clearance

(4) Operate the lubricating oil priming pump, and open the pressure indicator cocks of all the cylinders.
While turning the flywheel, make sure the lubricating oil is dropping from each part of the valve
rocker arm shafts, piston pins, crank pins, main sure bearings and swing arms.
(5) Bleed the air from the lubricating oil strainer.
(6) Bleed the air from the fuel oil filter and inlet pipe of fuel injection pump.
(7) Manually lubricate the governor linkage, and make sure it moves smoothly.

[ Procedures for turning the flywheel ]

Be careful not to allow your body to make contact with a moving part while turning the flywheel.
(Never put you hand into the crankcase.)

4-1 (Volume:14pages)
4.　OPERATION (Lubricating Oil System)

Turn the flywheel by the following procedures:

Turning Gear Device - - - - - - - - Operational spec.

(1) Remove the lock bar, loosen the stopper lock bolt and slightly move the stopper.
(2) Press the turning gear shaft down to the GEAR IN position.
(3) Fit the stopper into the groove B of the gear shaft, and then tighten the stopper lock bolt.
(4) Attach the socket and ratchet handle for turning to the shaft, and then turn the flywheel.
(5) When the turning operation has completed, return the turning gear shaft to the GEAR OUT position.
Then, fit the stopper into the groove A , and tighten the stopper lock bolt.
(6) Attach the lock bar.

Unless the turning gear is the GEAR OUT position, the turning gear engagement/disengagement
switch actures to disable starting. (optional spec)

Drawing 4-1. Turning gear device (Optional spec.)

Turning Gear Shaft Look Bar

GEAR Flywheel
Look Bar OUT
Pos.

Turning Gear
Stopper GEAR IN
A
Pos.
Stopper Lock Bolt
B
Micro Switch

4-1-1. Lubricating Oil System

The piping parts of lubricating oil system are banded with yellow coating.

1) Inspection and oil supply of lubricating oil sump

(1) Open the drain valve, cock or plug of the following oil sumps and devices; and check the drain.
Supply the lubricating oil to the upper limit of oil level gauge or dipstick in each oil sump;
① Engine oil pan or common bed (lubricating system oil sump)
② Governor oil sump
③ Lubricating oil cooler
④ Lubricating oil strainer
(2) Check the properties of lubricating oil; and if it is considerably contaminated of deteriorated, change it.

Chapter 3. Table of Engine Standard Adjustment

Chapter 5, 5-2-2. Control on Lub. Oil

2001.6.15R 4-2
4.　OPERATION (Lubricating Oil System)

Drawing 4-2. Draining&Air Bleeding Points on Non-operating Side Drawing 4-2. Draining & Air Bleeding Points

Lub. Oil Cooler Air Vent Valve

Air Vent Plug

Air Vent Plug

Lub. Oil Strainer

for turbocharger
Drain Plug Chang-over Cock

Lub. Oil Strainer

Drain Plug
Drain Plug

Oil Supplying Points on Operating Side

Hand Lubricating Points

Manually lubricate the governor link and control devices (circled portions)

Drawing 4-4. Governor Device

Control Lever
for Gov. output Governor

Start/Stop Lever Connector

Oil Level Gauge

1st Lever Shaft Remove the top cover
and supply oil to 2 to
3 mm above the cen-
ter of oil level gauge.

Drain Plug

Drawing 4-5. Lub. System Oil

Lub. Oil Dipstic

Lub. Oil Filler System oil sump

1999.7.2R 4-3
4.　OPERATION (Fuel Oil System)

2) Priming of lubricating oil

This engine employs the continuous priming system using a motor-operated pump.

● Keep the control power supply for the motor-operated priming pump of this engine switched ON
always.
● Switch OFF the said power supply in a long-term stoppage of the ship and in a rest and maintenance

servicing of the power installation.

After priming has stopped for two hours or longer, perform priming for about 20 minutes or longer.

Priming pressure: 0.02 ～ 0.20MPa (0.2 ～ 2.0kgf/cm2)

3) Air Bleeding of Lub. Oil Cooler

● If any of the following items arises, start the engine after bleeding air from the lub. oil cooler, operate
the priming pump.
● After priming has stopped for two hours or longer.

● After disassembling & cleaning the lub. oil strainer.

● After changing the lub. oil or disassembling the piping parts of lubricating oil system.

Air Bleeding Procedures

(1) Operate the priming pump.
(2) Open the air bleed valve of the lub. oil cooler.
(3) Discharge the air, and then close the air bleed valve.

● If you cannot operate the motor-operated priming pump, perform air running for about 3 seconds
repeatedly five times.
After starting the engine should be executed the air venting again.

4-1-2. Fuel Oil System

The piping parts of fuel oil system are banded with red coating.

(1) Drain the fuel oil tank and fuel oil filter.
(2) Supply the fuel oil into the fuel oil tank, and check the fuel oil. Then, open or close each valve accord-
ing to the operation conditions.
(3) You use an engine of marine diesel oil (M.F.O) start/stop specifications, turn on the heater for the
heavy fuel oil (H.F.O.) pipe line, and continue heating the H.F.O. until its viscosity becomes proper.

If you use an engine of heavy fuel oil (H.F.O.) start/stop specifications, make sure the fuel oil temper-
ature (viscosity) at the engine inlet is proper.

Chapter 5, 5-1-3. Properties of Fuel Oil at the Engine Inlet

1998.4.21R 4-4
4.　OPERATION (Fuel Oil System)

(4) Bleeding air from oil system

After engine installation, long-term stoppage or overhaul of the engine, bleed air from the fuel oil sys-
tem by the following procedures:

① Open the bypass valve of fuel feed pump.

(Fully turn the bypass valve handle counterclockwise)
② Open the air bleed cock of fuel oil filter to bleed air.

Drawing 4-6 Air Bleeding Points on Frontal Side

8
7

6
Item Name 9
1 Fuel Feed Pump 5
2 Press Regulat. Valve
3 By-pass Handle
4 Chang-over Cock
5 Fuel Filter NO.2
6 Air Bleed Cock
7 Fuel Injection Pump
8 Air Bleed Plug 4
2
9 Drain Cock 3

By-pass Valve
Clockwise for close

③ Loosen the air bleed plugs on the fuel oil pipe mount of each fuel injection pump to bleed air.

Drawing 4-7 Air Bleeding Points on Operating Side

Air Bleed Plug

④ Bleed the air from each fuel injection pump by the following procedures:
● Set the start/stop lever in the RUN position, and push the rack of fuel injection pump to
the injection volume increase direction.
● Attach the priming tools to the pump tappet while the plunger of fuel injection pump is at the

lowermost position.

4-5
4.　OPERATION (Fuel Oil System)

No. Exclusive Tool Description Part No.

① Priming lever 146673-92920

② Lever support 146673-92930

Drawing 4-8 Priming Procedures

Operate

Tappet

● Move up and down the priming lever until you feel a strong resistance.
● Turn the flywheel to bleed the air from all of the cylinders.
⑤ Close the bypass valve.
(Fully turn the bypass valve handle clockwise.)

Fuel Oil Seal Pot Servicing Procedures (for Engine Using H.F.O.)

Seal pots are equipped to the mount for fuel oil pressure gauge and that for the fuel oil differential pressure
indicator (optional) of an engine using the heavy fuel oil (equivalent to 1,500-sec. or higher fuel oil).

Drawing 4-9 Seal Pot Servicing Procedures

Fuel Pressure Gauge

Seal Pot

Pressure
Transmitter

Seal Pot

Differential Pressure
Indicator

2002.5.15R 4-6
4.　OPERATION (Cooling Water System & Boost Air)

(1) Remove the filler plug ① and the air vent plug ② .
(2) Pour ethylene glycol from the filler until it overflow from the air vent plug.
(3) When the seal pot is filled with ethylene glycol, securely tighten the plugs ① & ② .
(4) Remove the plug ③ , and pour ethylene glycol from the filler. When the seal pot is filled with ethylene
glycol, tighten the plug.
(5) Periodically (about every two months) loosen the plug ② and plug ③, and check if the fuel oil does not
overflow.

4-1-3. Cooling Water System

The piping parts of cooling water system are banded with blue coating.

(1) Inspect the cooling water tank, and check whether the cooling water is not contaminated. If the cooling
water is considerably, change it.
(2) Supply the cooling water to the upper limit of water level gauge, and add a proper amount of rust
inhibitor.

Chapter 5, 5-3-2. Brands of Rust Inhibitor & Adding Quantity

(3) Open and close each valve of the cooling water pipe system according to the operation conditions.
(4) If you use an engine of heavy fuel oil (H.F.O.) start/stop specifications, heat the cooling water in the
cylinder jacket side to 65 to 75 ℃ .

When you have replaced the cylinder liner or drawn it out for servicing, remove the cylinder side
cover and make sure no water leaks inside cylinder.

4-1-4. Boost Air System

Open the drain cocks of the following points to drain them.

Drawing 4-10 Boost Air System Draining Points on Non-operating Side

Open

2002.5.15R 4-7
4.　OPERATION (Starting & Control Air System / Starting)

4-1-5. Starting Air System

The piping parts of fuel oil system are banded with white coating.

(1) Drain the starting air reservoir.

(2) Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine (2.2
MPa{22kgf/cm2} or higher).

4-1-6. Control and Protective Devices

(1) Move the start/stop lever from the RUN position to the STOP position and vice versa, and make sure
the rack of fuel injection pump, 1st lever shaft of governor link and connector move smoothly.
(2) Check for excessive play of connector pin.
(3) Set the power switch of protective and alarm devices to the ON position.

Unless the power switch is set in the ON position, the protective and alarm devices do not actuate.

4-2. Starting
This engine is started by an air motor.
Press the START switch. Then, the pilot air solenoid valve directly attached to the air motor will open on
the battery power to start the engine.

During start operation, do not bring your face close to the air motor. Dust adhered at the exhaust port
of air motor may enter your eye, resulting in injury.

Before the initial start of the engine after its installation of before its start after its overhaul or long-term
stoppage, perform air running by the following procedures, and make sure there is no abnormality.
Then, start the engine by the control panel on the engine side. If a large amount of fuel oil, cooling
water or lubricating oil should be entrapped in cylinders, "water hammering" may occur.
● Set the ENGINE/REMOTE operation selector switch in the ENGINE position.

● Open the pressure indicator cocks of all the cylinders.

● Set the start/stop lever in the STOP position.

● Hold the START switch pressing for 2 to 3 seconds to effect air running.

1) Starting operation procedures

Start the engine by the following procedures.

(1) Make sure the turning gear is it the GEAR OUT position.
(2) Make sure the pressure indicator cock is closed.
(3) Set the ENGINE/REMOTE operation selector switch to the ENGINE or REMOTE position correspont-
ing to the control panel to be selected.

2002.5.15R 4-8
4.　OPERATION (Starting)

(4) Set the start / stop lever in the RUN position.

(5) Make sure the pointer of speed control shaft of governor indicates the position of ordinary operation
(rated speed).
(6) Open the starting air reservoir valve and control air valve.
(7) Hold the START switch pressing for 2 to 3 seconds, and make sure of ignition. Only then release the
switch.
Drawing 4-11 Start Operating Procedures

Speed Control Knob

START Switch (for Governor)

Speed Control Shaft

Start/Stop Lever

ENGINE/REMOTE
Operation Selector Switch

Control Air Valve

Set it to the position in which the start/stop lever is fixed respectively in notch when you suit the start/
stop lever to the position of "RUN" or "STOP".

2) Corrective actions to be taken in starting failure

If the engine cannot be properly started, unburnt combustion gas in the flue may be ignited, resulting
in explosion. Therefore, perform air running to discharge the gas from the exhaust gas system before
attempting to restart the engine.

(1) Make sure the flywheel has completely stopped, and then press the START switch.
(2) If the battery power for the START switch has been exhausted (and in case of emergency), press the
manual button of air motor to start the engine.

Use starting control based on the manual button only in emergency because the air motor may rotate
excessively as the control module is not in operation in this case.

Drawing 4-12 Air Motor Manual Button

Air Motor

Pilot Air Solenoid Valve Manual Button

2005.8.25R 4-9
4.　OPERATION (Running)

3) Checks to be made immediately after starting

Check the following items. If any abnormality is found, stop the engine and repair it.
(1) Value indicated by the pressure indicator on the gauge panel
(2) Leak from each piping
(3) Unusual sound and abnormal heat generation of each part

4-3. Running

○ During a run and immediately after the engine stop, never touch the following parts with bare hands.
Otherwise, you may get burnt.
•Turbocharger, Exhaust pipe system, boost air pipe system
•Flue and funnel
○ During a run, never touch any moving part. Otherwise, you may be caught in, resulting in injury.

Keep the control air valve opened during a run.

If you close it, the protective devices cannot actuate.

1) Initial Running-in Operation

To prevent initial abnormal wear of piston rings and cylinder liner, run the engine on marine diesel oil
(M.D.O) for the following period:

(1) For 10 to 20 hours after installation.

(2) For 10 to 20 hours after replacement of piston rings, piston or cylinder liner

2) Steady (Routine) Running

(1) Make sure the pressure of lubricating oil, cooling water and fuel oil has reached the specified value.
(2) Run the engine for about 10 minutes at the rated speed without load to warm it up.
(3) If the engine is used to drive a cargo pump or the like, which requires the control on rotation, run the
engine at the preset idling speed to warm it up.

The critical speed that may cause torsional vibration is within the normal rotation speed range, quickly
avoid it, and set the rotational speed to the rated speed.

2002.5.15R 4-10
4.　OPERATION (Running)

(4) If you continue running the engine with a low load for longer than three hours, observe the following
load factors, otherwise combustion worsens and fouling of the combustion chamber, exhaust pipe,
turbocharger, etc. becomes heavy.

① If fuel oil used is the marine diesel oil (M.D.O), run the engine at 15% or higher load factor.
② If fuel oil used is the heavy fuel oil (H.F.O)
•And if the (optional) boost air temperature controller which heats the boost air in a low load run is
equipped, run the engine at 15% or higher load factor.
•But if the cooling water for the boost air cooler and lub. oil cooler is used jointly with the main
marine engine, run the engine at 20% or higher load factor.

If you want to run the engine at further lower load factor, change over the fuel oil to the M.D.O.

•But if the cooling water for the air cooler and lub. oil cooler is sea water, run the engine at 25% or
higher load factor.

If you want to run the engine at further lower load factor, change over the fuel oil to the M.D.O.

(5) Boost air pressure regulating valve

① To evade the surging generation of the supercharger when the high load is driven (vicinity of the load
of 100%), it equips the boost air pressure regulating valve (6N18AL-E V-type engine)

Drawing 4-12-2 Boost Air Press. Regulating Valve Installation position

Boost Air Press. Regulating Valve

② Adjustment of boost air pressure regulating valve

* Adjust it in the state that opens from the state of all closes 180°(state at shipment).
* Please turn the valve in an open direction and enlarge opening when the supercharger does surg-
ing by the change in the room temperature etc.
* Opening of the valve disc opens from all closes only to 540°.

2005.3.16R 4-11
4.　OPERATION (Stopping in Normal Running)

Adjustment of Boost air temperature

(In the case of sea water cooling)
① Adjust the boost air temperature to 40 to 60 ℃ , operating the cooling water bypass valve handle of
the boost air cooler.

As the bypass valve handle is set in the OPEN side, the cooling water bypassed, and the boost
air temperature rises.

Drawing 4-13 Sea Water By-pass Valve (Boost Air Cooler)

Drain Cock

Close

Open By-pass Valve

② In the case of a high humidity, this is not abnormal although much drain may be produced as the
moisture in the air is condensed.
In this case, run the engine as the drain cock of the boost air cooler kept opened.

(6) If you use an engine of marine diesel oil (M.D.O.) start/stop specifications, observe the following
items:
● If the load factor is less than 20% of the generator rated output, do not switch the fuel oil from the

M.D.O. to the heavy fuel oil (H.F.O.).

● Make sure the H.F.O. at the engine inlet has been heated so that its viscosity becomes proper, and

then switch over the fuel oil from the M.D.O. to the H.F.O.
● The load substantially fluctuates at the incoming and outgoing and loading and unloading of vessel.

For these operations, we recommend you to run the engine on the M.D.O.

Proper viscosity: 11 to 14 cSt (R.W.No.1 55 ～ 65 sec.)

(7) Measure the running performance once a day and record the measurement data.

Chapter 6, 6-3-1. Measurement of Running Performance

2005.3.16R 4-12
4.　OPERATION (Emergency Stop)

4-4. Stopping
4-4-1. Stopping in Normal Running
Except in case of emergency, stop the engine by the following procedures:

1) Preparation of stopping
(1) If you use an engine of marine diesel oil (M.D.O.) start/stop specifications, switch over the fuel oil from
the heavy fuel oil (H.D.O.) to the M.D.O. to prevent the H.F.O. from being stagnant inside the fuel oil
pipes, fuel oil filter, fuel injection pumps when stopping the engine.

As the reference, continue running the engine on the marine diesel oil (M.D.O.) for 20 to 30 minutes
before stopping the engine. However, since the required time depends upon the load applied when
the fuel oil is switched over and the capacity of pipes in the vessel, consult the dockyard where the
engine has been installed.

(2) Shut off the load, and then continue running the engine without load for about 10 minutes.

2) Stopping operation
(1) Set the start/stop lever in the STOP position.

If you use the engine of the remote start/stop specifications, press the STOP switch.

(2) Run the lubricating oil priming pump

(3) Open the pressure indicator cock, and perform air running to discharge the as from the combustion
chambers.
(4) Open or close the valves of each system according to the stopping conditions.

When the cooling water may be frozen under cold weather, or before a long term stoppage, drain the
cooling water from the cylinder jacket side and cooler side.

4-4-2. Emergency Stop

If any of the following problems arises, immediately set the start/stop lever in the STOP position to stop the
engine.

(1) Any of the following alarms has been issued.

● Expressive pressure drop of lub. oil
● Expressive temperature rise of lub.oil

● Expressive tempera rise of cooling water

● Overspeed

(2) An unusual sound has been made.

(3) Heat has generated unusually from a part
(4) Smoke is issued from a bearing or any other moving part.
(5) A pipe of fuel oil, lub. oil or cooling water system has been broken.
(6) The supply of cooling water has stopped, and it is impossible to supply it immediately.
(7) A setscrew or bolt of a moving part is loose or broken.
(8) Moisture is mixed in the lubricating oil.
(9) The boost air pressure has dropped, and the exhaust temperature has excessively risen.
(10) The rack of fuel injection pump has stuck.

If the engine is not stopped by setting the start/stop lever in the STOP position or pressing the STOP
switch, close the fuel oil inlet valve.

2005.3.16R 4-13
4.　OPERATION (Disposal After an Emergency Stop)

4-4-3. Disposal After an Emergency Stop

When repairing the engine or investigating the cause of problem, observe the following items:

Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine.
Entry of fresh air into the engine may cause ignition of oil mist, resulting in explosion.

If you have stopped the engine while it is running on the heavy fuel oil (H.F.O.), immediately dis-
charger the H.F.O. from the fuel oil pipes, fuel oil filter and fuel injection pumps, and displace them
with marine diesel oil (M.D.O.).

If the residual H.F.O. is cooled and its viscosity rises, it becomes impossible to restart the engine.

(1) Set the fuel oil changeover valves at the engine inlet and outlet to the marine diesel oil (M.D.O.)
position.
(2) Open the bypass valve of fuel feed pump.
(3) Open the drain cock of fuel oil filter and drain valve of fuel oil main pipe.
(4) Turn the flywheel to discharge the H.F.O. from the fuel injection pipes and fuel injection valves. (Set
the start/stop lever in the RUN position, and turn the flywheel under the fuel injection status.)

Drawing 4-14 H.F.O. Discharging Points

Fuel Injection Pump

Fuel Oil Filter

Drain Cock

Fuel Oil
Discharg Valve

OPEN

Normal CLOSE
Discharg OPEN

2005.3.16R 4-14
5.　FUEL OIL, LUB. OIL & COOLING WATER (Fuel Oil)

5. FUEL OIL, LUB. OIL & COOLING WATER

5-1. Fuel Oil

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

5-1-1. Quality Criteria of Fuel Oil

Direct burning fuel oil --- 200sec.Oil 1,500sec.Oil 3,500sec.Oil 7,000sec.Oil
Quality Criteria

at 50 ℃ cSt 3～8 < 30 < 180 < 380 < 700

Viscosity
R.W.No.1 at 100°
F sec. 37 ～ 58 < 200 < 1500 < 3500 < 7000

Specific gravity at
< 0.86 < 0.991 < 0.991 < 0.991 < 0.991
15/4 ℃

Flash point ℃ > 60 > 60 > 60 > 60 > 60

Residual carbon mass.% < 0.7 < 10 < 15 < 18 < 22

Sulfur content mass.% < 1.0 < 3.5 <5 <5 <5
Property Ash content mass.% --- < 0.10 < 0.10 < 0.15 < 0.20
critical
value Moisture content vol.% < 0.1 < 0.5 < 1.0 < 1.0 < 1.0

Vanadium ppm --- < 150 < 300 < 500 < 600

Sodium ppm --- < 30 < 40 < 100 < 200

Aluminum ppm --- < 30 < 30 < 30 < 30

(Cetane no. of
Diesel index > 30 > 25 > 20 > 15
> 45)

ISO DBMorDMA RMB10 RME25 RMG35 RMH55

Quality criteria equivalent CIMAC --- CIMAC B10 CIMAC E25 CIMAC G35 CIMAC H55
fuel oil BSI --- (M4) (M6) (M7) M9

JIS M.D.O I.F.O H.F.O.(heavy fuel oil)

Note: M.D.O. = marine diesel oil; I.F.O. = intermediate fuel oil

" Use HFO with the CCAI, (an ignitability index), below 850 as an standard. (However, please note that the
said value was estimated from the past operation data and that the value can vary depending on the future
fuel oil quality.) The use of HFO with CCAI exceeding 850 will cause faulty combustion and aggravate
exhaust color. If such use is inevitable, raise the intake air temperature. This will improve combustion to
an extent. However, raise the intake air temperature carefully in relation with the exhaust temperature,
since this will affect the exhaust temperature and other engine performance."

What is CCAI?
CCAI stands for Calculation Carbon Aromaticity Index, which shows an ignitability index.
The index, in consideration of the relation between aromatic compound content in fuel oil and the
ignitability is used to obtain the aromaticity degree in relation with the fuel oil properties. The larger
the CCAI value, the larger the firing delay for inferior ignitability. In this case, the HFO direct starting
is not possible or exhaust color is aggravated due to faulty combustion.

2008.3.13R 5-1 (Volume:12pages)

5.　FUEL OIL, LUB. OIL & COOLING WATER (Fuel Oil)

5-1-2. Quality Criteria of Blended Fuel Oil

In the case of using a highly viscose fuel oil by blending with marine diesel oil to lower the viscosity of fuel
oil, in addition to the case of direct burning of fuel oil set forth above for its pretreatment, apply the blending
ratio shown in the following table based on the quality criteria on the blended fuel oil, not based on the vis-
cosity criteria.

When blending fuel oil of different production origins, sludge may be separated out, resulting in clog-
ging of fuel oil filters and sticking of fuel injection pumps and fuel injection valves. Pay your attention
to this regard.

Blended fuel oil 200-sec. oil equivalent 1,500-sec. oil equivalent 3,500-sec. oil equivalent
ISO RMB10 RME25 RMG35
Quality criteria on
direct burning CIMAC CIMAC B10 CIMAC E25 CIMAC G35
equivalent fuel oil
BSI (M4) (M6) (M7)
M.D.O.: H.F.O.(1,500-sec.oil)
60 : 40
M.D.O.: H.F.O.(3,500-sec.oil) M.D.O.: H.F.O.(3,500-sec.oil)
Blending ratio(%) 70 : 30 40 : 60
M.D.O.: H.F.O.(7,000-sec.oil) M.D.O.: H.F.O.(7,000-sec.oil)
60 : 40 30 : 70

Note: M.D.O. = marine diesel oil; H.F.O. = heavy fuel oil

Viscosity after blending: 5-1-5. How to Find out the Viscosity of Blended Oil

5-1-3. Properties of Fuel Oil at the Engine Inlet

Impurities contained in the heavy fuel oil (H.F.O.) may cause fuel injection pumps and fuel injection valves
to be damaged, cylinder liners to be excessively worn and exhaust valves and valve seats to be deterio-
rated. Therefore, raise the cleaning effect of pretreatment system to the maximum extent, and also supply
the fuel oil heated to have the proper pressure and viscosity.

Residual oil of a catalytic cracking refining device is sometimes used for industrial low-cost, high-vis-
cosity fuel oil. In this residual oil, there remain fine particles of silica and alumina that are catalysts for
this device.
A low-cost, high-viscosity fuel oil which uses there bases will cause abnormal wear of piston rings,
cylinder lines, fuel injection pumps, fuel injection valves, etc.
Therefore, use a low-cost, high-viscosity fuel oil treated of content less than 0.03 wt. % of ash, mini-
mum of silicon and aluminum and removed of all particles which exceed 3 ～ 5 μin size, utilizing the
F.O. treating apparatus.
Incidentally, the moisture content should be kept at less than 0.2 vol. %.

2002.12.25R 5-2
5.　FUEL OIL, LUB. OIL & COOLING WATER (Fuel Oil)

(1) Recommend properties of heavy fuel oil (H.F.O.) at engine inlet

Moisture content Less than 0.2 vol.%

Content of solid particles Less than 20 ppm
Size of FFC catalytic particle Less than 5μ

(2) Recommended viscosity and pressure of heavy fuel oil (H.F.O.) at engine inlet

Recommended Viscosity Recommended Pressure

Fuel oil
at the Engine Inlet MPa (kgf/cm2)
200-sec. oil 0.20 ～ 0.25 (2.0 ～ 2.5)
1,500-sec. oil 11 ～ 14 cSt 0.40 ～ 0.45 (4.0 ～ 4.5)
3,500-sec. oil (R.W. No.1 55 ～ 65 sec.) 0.45 ～ 0.50 (4.5 ～ 5.0)
7,000-sec. oil 0.65 ～ 0.70 (6.5 ～ 7.0)
M.D.O. 3 ～ 8 cSt 0.50 ～ 0.55 (5.0 ～ 5.5)

Heating temperature: 5-1-4. How to Find out the Heavy Fuel Oil Heating Temperature

2002.12.25R 5-3
5.　FUEL OIL, LUB. OIL & COOLING WATER (Fuel Oil)

Calculation of CCAI

CCAI = D - 81 - 141࡮ loglog (V + 0.85)

D : Density kg/m3 @ 15͠‚ V : Viscosity mm2 /S @ 50͠

V D CCAI
1 800 800

820 810

860
820
2 860
830 The smaller CCAI,
880 the better firing
3 and combustion
840 performance.
4 900
5 850
920 The larger CCAI,
the inferior firing
860 performance.
940 This will cause
10 normal operation
870 to be hard.
960
20
980 880
30
50 1000
890

100 1020
900
200
1040
400 910

1000
920

5000
930
40000
50000

[ Example ]
Obtaining CCAI of HFO with the viscosity of 380cSt @ 50͠ and the density of 985 kg/m3
@ 15͠ from the table above:
Draw a line from the viscosity (V) 380cSt to the density (D) 985 and extend the line to
CCAI column. The fuel oil CCAI in the present example is 846.

2002.12.25R 5-4
5.　FUEL OIL, LUB. OIL & COOLING WATER (Fuel Oil)

5-1-4. How to Find out the Heavy Fuel Oil Heating Temperature
Example: In the case of finding out the heating temperature of 700 cSt (at 50 ℃ ) fuel oil
Find the intersecting point ① corresponding to viscosity of 700 cSt and temperature of 50 ℃ on a
line ② standing for viscosity-temperature relation of 700 cSt (at 50 ℃ ) fuel oil.
On this line ② , locate a point corresponding to the recommend viscosity at the engine inlet, and
then draw a perpendicular ③ from this point to the axis of abscissa (x-axis).
The intersection of this perpendicular with the x-axis indicates the heating temperature required.
(In this case, the temperature is 150 ℃ .)

(1) Prepare a correct viscosity-temperature relation chart according to the properties of fuel oil existing
at the time of its delivery to you.
If the viscosity - temperature line corresponding to your applied fuel oil is not shown, enter the vis-
cosity and temperature of the applied fuel oil on the above chart, item from the intersecting point of
the entered data draw a line in parallel to the nearest drawn viscosity-temperature line, and find out
the heating temperature accordingly.
(2) Set the fuel heating temperature so that the fuel oil viscosity becomes 11 to 14 cSt (55 to 65 sec.) at
the engine inlet to allow some temperature drop in the piping system.

5-5
5.　FUEL OIL, LUB. OIL & COOLING WATER (Fuel Oil)

5-1-5. How to Find out the Viscosity of Blended Oil

Example: In the case of finding out the viscosity of blending (R.W. No.1 at 100° F) 7,000-sec. heavy fuel oil
(H.F.O.) with (R.W. No.1 at 100° F) 40-sec. marine oil (M.D.O.) at the blending ratio of 70:30.
On the left y-axis (axis of ordinate) corresponding to 100 % H.F.O., locate the point ○
A
corresponding to the viscosity (7,000 sec.) of H.F.O.; on the right y-axis corresponding to 100 %
M.D.O., the point ○ B corresponding to the viscosity (40 sec.) of M.D.O. Now draw a straight line
○K to link both located points.
Then, locate the point ○ Y corresponding to the blending ratio of 70 % H.F.O. and 30 % M.D.O. on
the axis of abscissa (x-axis), and draw a perpendicular ① from the point ○ Y to the drawn straight
line ○
K , intersecting at the point ○C . Finally, draw a horizontal line ② from thus found intersecting
point ○C to the left y-axis to find out the viscosity of the blended oil. (In the case, the viscosity at
100° F is about 550 sec.)

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2008.3.13R 5-6
5.　FUEL OIL, LUB. OIL & COOLING WATER (Lub. Oil)

5-2. Lubricating Oil

Selection of the proper lubricating oil is important for a diesel engine. In case of using an inappropriate lub.
oil, sticking of piston ring, seizure and early wear of piston, cylinder liners and bearings, etc. will occur.
Consequently, discreetly select the lubricating oil to be used.

5-2-1. Choosing the Lub. Oil

Depending on properties of fuel oil and conditions of usage of the engine, lub. oil to be selected varies.
Choose lub. oil API Service Grade CE or CD Class.

1) Viscosity
Use an oil shown in the below table.

Frash point Kinematic Viscosity(cSt)

Viscosity Specific ℃ Pour Point Viscosity
Application
(SAE) Gravity (Open (℃) 40 ℃ 100 ℃ Index
Type)

● Marine aux-
30 0.89 > 230 < － 10 105～125 11 ～ 12.5 96 ～ 110
iliary engine

● Marine aux-
iliary engine
40 0.893 > 240 < － 7.5 140～155 14 ～ 15.5 96 ～ 110
● Land use
engine

2) Total Base Number (T.B.N.)

Select a lub. oil based on the values given in the following table for the base number against the sulfur
content including in the fuel used.

Fuel Oil Used Total Base

Redwood No.1 Sulfur Content Number
Viscosity (wt. %) (T.B.N.)
s(100°F) (mgKOH/g)

M.D.O. equivalent <1 9 ～ 15

I.F.O. eq. 200-sec. < 3.5 16 ～ 26

1,500-sec
H.F.O. eq. 3,500-sec. <5 30 ～ 42
7,000-sec

Lub. oil to be applied: 5-2-3. List of Lub. Oil Brands

(1) Avoid blended use of different brands.

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

2002.5.15R 5-7
5.　FUEL OIL, LUB. OIL & COOLING WATER (Lub. Oil)

5-2-2. Control on Lub. Oil

① In case of handling the lubricating oil inside the engine immediately after an engine stop, be careful
not to get burnt.
② Should there be a possibility of lubricating oil to get in your eyes or to stick to your skin during han-
dling of lubricating oil, wear protectors such as safety goggles and rubber gloves.
③ If lubricating oil get in your eyes or stick to your skin, it might cause inflammation. In such case,
flush an affected region with clean water, and then consult a physician, if necessary.
④ Method of disposing waste oil has been provided for in the law. Dispose of waste oil properly
according to the pertinent law. In case you don’t know what to do, inquire of your supplier of lubri-
cationg oil about this matter, and dispose of waste oil accordingly.

1) Control Criteria

Conduct the property analysis of lub. oil used every 500 hours of engine run, and change or make up the
lub. oil as guided by control criteria set forth in the following table.

Item Unit Control Criteria Critical Value of Usage

Flash point(PM method) ℃ > 180 140

Change in viscosity cSt(40 ℃ ) Within new oil ± 15 % New oil ± 25 %

Moisture content vol.% < 0.1 0.2

n-pentane insoluble matter
mass.% < 1.5 2.0
(A method)

Toluene insoluble matter

mass.% < 1.5 2.0
(A method)

Difference between n-
pentane and toluene mass.% --- < 0.5
insoluble matters
Meas. method HCl HClO4 HCl HClO4
Fuel oil used method method method method

M.D.O. 3.0 6.0 1.0 4.0

Total base number mgKOH/g 200-sec. oil 5.0 10.0 3.0 7.0

1,500-sec. oil
12.0 18.0 10.0 15.0
3,500-sec. oil

7,000-sec. oil 12.0 18.0 10.0 15.0

2) Oil Change Criteria

Since oil change criteria vary as depended on conditions of use of the engine, an instance of the criteria
may be set forth as follows although they could not fixed uniformly on base of the time used alone.

(1) Ask your lub. oil supplier to analyze the lub. oil being used and thus to determine whether the oil can
be further used continually or not.

2004.11.25R 5-8
5.　FUEL OIL, LUB. OIL & COOLING WATER (Lub. Oil)

Sample 500 cc of lub. oil at least from the drain plug of lub. oil strainer immediately after stopping the
engine for asking the analysis of lub. oil.

(2) Procuring a spot test kit to learn the remaining total base number, degree of contamination, cleanness
dispersing qualities of lub. oil used, etc. as a simple way of criteria, make the most of using such a
spot test kit.

(3) Should either of the aforementioned criteria be not possible, change the entire volume of lub. oil with
the new one at about 1,500 running hours in the case of constantly holding the oil volume of 1 ltr. /PS
by replenishing with the new oil.

5-2-3. List of Lub. Oil Brands

API Service Grade CE or CD/SAE 30 or 40 Equivalent.
Intermediate fuel oil Heavy fuel oil
Fuel Oil Spec. Marine diesel oil
I. F.O.=(R.W. No.1 at 100°
F) H.F.O.=(R.W. No.1 at 100° F)
Division M.D.O.
200sec. Oil 1,500sec./3,500sec./7,000sec.Oil

Total Base
Number(T.B.N)
9 ～ 15 16 ～ 25 30 ～ 42
Supplier

YANMAR MARINE
YANMAR --- ---
SUPER OIL 30, 40
IDEMITSU DAPHNE MARINE OIL SW30, SW40 DAPHNE MARINE OIL SW30, SW40
DAPHNE MARINE OIL SX30, SX40
KOSAN DAPHNE MARINE OIL MV30, MV40 DAPHNE MARINE OIL SH40

MCL 30, 40
CASTROL TLX Plus 203, 204 CASTROL TLX Plus 303, 304
CASTROL CASTROL MHP153, 154
CASTROL TLX Plus 303, 304 CASTROL TLX Plus 403, 404
SEAMAX EXTRA30, 40

BRITISH BP ENERGOL IC-HFX303, 304

BP ENERGOL DS3-153, 154 BP ENERGOL IC-HFX203, 204
PETROLEUM BP ENERGOL IC-HFX403, 404

DELO 3000 MARINE 30, 40

DELO 1000 MARINE 30, 40
Chevron Tsxaco DELO 2000 MARINE 30, 40 DELO 3400 MARINE 30, 40
TARO 12XD 30, 40
(FAMM, Caltex) TARO 20 DP30, 40 TARO 30 DP30, 40
TARO 16XD 30, 40
TARO 40 XL30, 40

COSMO OIL COSMO MARINE SUPER 30, 40 COSMO MARINE 3025, 4025 COSMO MARINE 3040, 4040

FUJI KOSAN FUKKOL MARINE 312, 412 FUKKOL MARINE 320, 420 FUKKOL MARINE 330, 430

MOBIL GARD 312, 412 MOBIL GARD M330, M430

EXXON MOBIL MOBIL GARD 312, 412
MOBIL GARD M330, M430 MOBIL GARD M340, M440

KYGNUS OIL KYGNUS MARINE DX 30, 40 KYGNUS MARINE DX 330, 340 ---
JAPAN
JOMO MARINE D-13, D-14 JOMO MARINE D-23, D-24 JOMO MARINE D-33, D-34
ENERGY

TOTAL
DISOLA M3015, M4015 AURELIA XL3030, XL4030 AURELIA XL3040, XL4040
Lubmarine

ARGINA S OIL 30, 40 ARGINA T OIL 30, 40

SHELL GADINIA OIL 30, 40
RIMULA FB OIL 30, 40 ARGINA X OIL 30, 40

NIPPON OIL MARINE T103, T104 MARINE T203, T204 MARINE T303, T304

2008.3.13R 5-9
5.　FUEL OIL, LUB. OIL & COOLING WATER (Cooling Water)

5-3. Cooling Water (Engine Jacket Water)

5-3-1. Criteria on Cooling Fresh Water

(1) Use pure water (distilled water) or tap water.
(2) Use the water having the properties shown in the following table.

Recommended Water Quality

Do not use hard water.
pH 298 K (25 ℃） 6.3 ～ 8.0 If hard water is used, scale adheres to
water chambers such as cylinder head and
Total hardness (CaCO3) < 100 ppm cylinder water jackets and may cause an
overheat. Pay your particular attention to
Chlorine ion (Cl-) concentration < 100 ppm
this regard.
M alkalinity 30-100 ppm

Ammonium ion (NH4+) conc. < 0.05 ppm

Sulfate ion (SO4- -) concentration < 100 ppm

Evaporated residue < 400 ppm

5-3-2. Selection of and Control on Corrosion Inhibitor

(1) Add a corrosion inhibitor to cooling fresh water because use of fresh water causes a drop in strength
of parts and the cooling effect through corrosion of water chamber and adhering of scale.
(2) Select a corrosion inhibitor which does not have an adverse effect on parts of the cooling water sys-
tem because parts made of cast iron, carbon steel, brass and bronze, are used in the cooling water
system of an engine.

• In the case where aluminum materials are used in the cooling water system, consult the supplier of
corrosion inhibitor because a kind of corrosion inhibitor to be used differs in this case.
• As to the adding quantity of and concentration control on corrosion inhibitor and addition and han-
dling of supplementary adjuster, obey the criteria set by the supplier of corrosion inhibitor.
• In the case where the concentration of corrosion inhibitor could not be controlled, annually change
the cooling water by the total volume.

① Do not dump cooling water to which the corrosion inhibitor was added directly to the ocean or river.
Since the method of treating the waste liquor has been provided for in the law, such liquid has to
be treated according to instructions given by the supplier of corrosion inhibitor.
② Do not mix different brands of corrosion inhibitor. (In the case where mixing of different brands of
corrosion inhibitor is unavoidable, consult the suppliers of corrosion inhibitor.
③ A corrosion inhibitor is chemical for industrial water treatment use; do not use it in the drinking
water line.
④ When handling, wear rubber gloves and gauze mask to avoid direct contact with hands or other
parts of the body.
⑤ If the chemical accidentally comes in contact with skin, eyes or mouth, wash out thoroughly with
fresh water. If the problem persists, consult a doctor.

2003.10.20R 5-10
5.　FUEL OIL, LUB. OIL & COOLING WATER (Cooling Water)

(3) Recommended brands of corrosion inhibitor

Brands of corrosion inhibitor applicable to the enclosed circuit specification of the cooling water system are
shown in the following table.

Brand Supplier Brand Supplier

Royal Caviruston Antirust

Yanmar Sangyo Co., Ltd. Diesel Guard NB UNITOR & Taiho
*YANMAR Royal Freeze
Industries Co., Ltd
Polycrin I - 109 Rocor NB Liquid

Polycrin I - 175 Kurita Water Industries Ltd. Nalcool 2000

*Kurilex L - 501 *Nalfleet 9 - 111 NALCO Japan Co., Ltd.

Neos PN - 106S Nalfleet 9 - 108

Neos Co., Ltd.
Neos PN - 106 Uniprot PC - 200
Nippon Yuka Kogyo Co., Ltd.
Hi-mol L - 10 Uniprot PC - 300
Taiho Industries Co., Ltd.
Hi-mol AM - 5 Shadan K Otsuka Chemical Co., Ltd.

*Olgard C-601 Organo Co., Ltd. Liquide WT ASHLAND JAPN CO., Ltd

• In the case where the cooling water system is of the enclosed circuit specification, consult the sup-
plier of corrosion inhibitor because some brands drop in the concentration of corrosion inhibitor early.
• Notice a corrosion inhibitor which doubles as an anti-freeze has a low thermal conductivity and may
be overheated during a load running.
• In the case where aluminum materials are in the cooling water system, use a brand of corrosion inhib-
itor asterisked above.

2006.10.16R 5-11
5.　FUEL OIL, LUB. OIL & COOLING WATER

MEMO

5-12
6.　MAINTENANCE CHECKING (Precaution in Maintenance Checking)

6. MAINTENANCE CHECKING

6-1. Precautions in Maintenance Checking

To use an engine always in good order, checking is necessary periodically for trouble prevention. The
period of checking can not be fixed indiscriminately because it is influenced by application of the engine,
conditions of use, quality of fuel oil and lub. oil used, and daily handling circumstance.

• The following tables of checking show the standard checking frequency. Perform the initial overhaul
servicing according to these checking tables. Then, based on the obtained checking (on wear corro-
sion, accumulation of carbon, accumulation of sludge and others), make the most economical check-
ing schedule suitable for your engine, and conform to the specified schedule from the second
checking.
• As for the items whose checking frequency is shown by both the accumulated operation hours and
number of days, schedule the checking at the earlier timing.

6-2. Table of Periodical Checking

(1) For marine service engine
1) Table of Routine Maintenance Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-1.
2) Checking Table for Engine Using Marine Diesel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-2.
3) Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100° F 1,500 ～ 7,000-sec. Equivalent
Fuel Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Table 6-3.
(2) For land service and/or generator engine
In accordance with the Specifications of Checking & Servicing of Diesel Service Generating Set separately
stipulated.

6-3. Routine Maintenance Checking & Adjustment Procedures

6-3-1. Measurement of Running Performance
6-3-2. Measurement of Max. Combustion Pressure (Pmax)
6-3-3. Regulation of Fuel Injection Volume (Rack Scale)
6-3-4. Adjustment of Fuel Injection Timing
6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure
6-3-6. Adjustment of Suc./Exh. Valve Head Clearance
6-3-7. Adjustment of Lub. Oil Pressure
6-3-8. Adjustment of Lub. Oil Temperature
6-3-9. Adjustment of Fuel. Oil Pressure
6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valve
6-3-11. Cleaning of Lub. Oil Bypass Strainer
6-3-12. Cleaning of Lub. Oil Strainer
6-3-13. Cleaning of Fuel. Oil Filter
6-3-14. Cleaning of Strainer Element
6-3-15. Washing of Turbocharger
6-3-16. Maintenance of Pressure Gauge
6-3-17. Measurement of Crankshaft Deflection
6-3-18. Adjustment of Fuel. Injection Pump Pinion Lubricating Volume (for Engine Using H.F.O.)
6-3-19. Maintenance of Fuel. Oil Seal Pot (for Engine Using H.F.O.)
6-3-20. Checking & Replacement of Anticorrosive Zinc

2006.6.20R(MET 6-1 (Volume:44pages)

6.　MAINTENANCE CHECKING (Routing Maintenance Checking)

Table 6-1. Table of Routine Maintenance checking

Nature of Work
Checking Area
Daily Weekly Monthly (or 300-500hrs.)

Starting air tank Pressure check Draining

Checking & lubrication of

Governor gear Gov. oil volume check
linkage system

Check on leak from oil

Fuel feed pump
seal

Fuel oil filter Draining Back-washing (blow-off) Overhaul cleaning

Fuel Oil System

Check on rack scale

Fuel injection position
Pump *Check on pinion lubri-
cating Volume

Injection timing Check on looseness of

adjust bolt lock nuts

Lub. oil cleaning

Common bed
Oil volume check The batch cleaning by Lub. oil property analysis
(or oil pan)
the purifier
Lub. Oil System

Back-washing (blow-off) Overhaul cleaning

Lub. oil strainer Draining
* (2 ～ 3 days) * (10 ～ 15 days)

Lub. oil bypass

--- Overhaul cleaning
strainer

Cooling water Check on leak from

pump mechanical seal

Prefilter washing
Turbocharger
Blower washing

Check that electrical wir-

ing is fastend firmly.
Starting air motor Check that no air leaks
from the air pipe and the
joint.

Each pressure Check on defective indi-

Instrument

gauge cation

Each thermom- Check on defective indi-

eter cation

Check on looseness of
bolts & nuts
Check on leaks of vari-
Engine appearance ous parts
(cooling water, fuel oil,
lub. oil, boost air &
exhaust gas)

Each pipe system Leak check

Note: An asterisk (*) refers to only for engine using heavy fuel oil (H.F.O.)

2003.12.10R 6-2
6.　MAINTENANCE CHECKING (Engine Using Marine Diesel Oil)

Table 6-2. Checking Table for Engine Using Marine Diesel Oil (1/3)

An asterisk (*) given in the following tables refers to the timing of initial check after the initial start or
part replacement. Perform the check from the second time and onward at the ordinary frequency.

Checking & Servicing

Frequency (hrs.)

2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
6 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div. Nature of Service
Checked

Fuel injection
Drawing-out check & adjustment 1,500 ～ 2,000 1st time:500～800hrs
valve
Check & adjustment of the valve head clearance ○
Check of valve spring ○
Cylinder head

Check disassembly & check of valve rotator ○

Disassembly, check & cleaning ○
Cylinder head
Grinding of suc./ehx. valve seat ○
Scale cleaning & hydraulic test of water chamber ○
Replacement of stem seal (Suc./Ehx. Valve) ○
Check of cyl. head bolt tightening force ＊ ○
Drawing-out, cleaning, checking & measurement
of piston ○
Piston
Check & measurement of piston rings ○
Check & measurement of piston pin ○
Check & measurement of piston pin metal ○
Connecting Check & measurement of crank-pin metal ○
rod Check of connecting rod bolt tightening force ○
Change of connecting rod bolts 20,000 hrs.
Inner dia. checking, cleaning & measurement ○
Cyl. liner Drawing-out, check & cleaning of water jacket
part ○
Major Moving Parts

Measurement of crank pin outer dia. & journal ○

Crankshaft
Measurement & adjustment of deflection ○
Disassembly, metal checking & measurement ○
Check on tightening force of main bearing clamp-
Main bearing ○
ing bolts
Check on tightening force of side bolt ○
Check of cam & roller bearing ○
Disassembly & check of fuel pump tappet ○
Camshaft Disassembly, check & measurement of swing arm ○
Drawing-out of crankshaft & bearing check &
measurement ○

Check of tooth bearing & backlash ○

Disassembly of idle gear & check & measurement
Timing gear ○
of bearing
Check of idle gear mounted shaft tightening force ○

2002.10.7R 6-3
6.　MAINTENANCE CHECKING (Engine Using Marine Diesel Oil)

Table 6-2. Checking Table for Engine Using Marine Diesel Oil (2/3)
Checking Servicing
Cycle (hrs.)

2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
3 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div.

Nature of Service
Checked
Major Moving Parts

Fuel feed Check of tooth bearing & backlash ○

pump, lub. oil
pump, & cold
Disassembly, check & measurement
water pump ○
of bearing
driving
intermediate Check of gear mounted shaft tighten-
gear. ing force ○

Change of hydraulic fluid ＊ ○

Gov. Gear

Governor
Disassembly & check ○
Governor driv- Disassembly & check of tooth bear-
ing gear ing & bearing ○

Check of injection timing ○ 1st time: 300 - 500

Fuel injection
Check of deflector & replacement
Fuel Oil System

pump ○
Disassembly, cleaning & check ○
Fuel feed Disassembly & check ○
pump Replacement of oil seal ○
F.O.control &
Replacement of o-ring ○
stop air piston
Change (depended on results of
Lub. oil ○
property analysis)
Disassembly, check, cleaning &
Lub. oil cooler ○
hydraulic test
Thermostatic
Disassembly, check & cleaning ○
valve
Lub. Oil System

Disassembly, check & measurement ○

Lub. oil pump Disassembly & check of pres. reg.
valve & safety valve ○

Change the element

Turbocharger
Change the element of lub. oil 1,000- When the lub. oil
lub. oil
strainer 2,000 pressure dropped by
strainer
0.3MPa(3kgf/cm2)
○
Lub.oil priming ○ 2nd
Bearing of motor 1st &
motor pump sub-
time seq
uent

2005.3.16R 6-4
6.　MAINTENANCE CHECKING (Engine Using Marine Diesel Oil)

Table 6-2. Checking Table for Engine Using Marine Diesel Oil (3/3)
Checking Servicing
Cycle (hrs.)

2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
3 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div.

Nature of Service
Checked

Thermostatic
Disassembly, check & cleaning ○
valve
Cooling Water System

Cooling water Disassembly, check & measurement ○

pump Replacement of mechanical seal ○
Fresh water Disassembly, check, cleaning & hydrau-
cooler lic test ○

Cooling water Change (depended on results of prop-

(Fresh water) erty analysis) ○

Sea water cool- Check of anticorrosive zinc & replace-

ing parts ment (Air cooler & Lub. oil cooler) ○

Turbocharger Disassembly & cleaning ○

Disassembly, check, cleaning & hydrau-
Boost air cooler ○
lic test
Disassemble and clean the muffler ele-
ment. (Clean with neutral detergent.) ○

Remove the starting motor from the

engine and turn the pinion gear manu-
ally, check that it turns smoothly and it ○
emits no abnormal sound.
Disassembly, inspection, cleaning and
Other

Starting air replacement of grease of moving parts.

motor replacement of o-ring, first reduction ○
gear bearing and special grease inside
the reduction gear.
Disassembly, inspection, cleaning and
replacement of grease of moving parts.
replacement of o-ring, 1st & 2nd reduc- ○
tion gear bearings and special grease
inside the reduction gear.
Engine tachome-
Calibration of indication ○
ter
Alarm switch Actuation test ○

2006.6.20R(MET 6-5
6.　MAINTENANCE CHECKING (Engine Using Heavy Fuel Oil)

Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100°
F 1,500 ～ 7,000-sec. Equiv-
alent Fuel Oil) (1/3)

An asterisk (*) given in the following tables refers to the timing of initial check after the initial start or
part replacement. Perform the check from the second time and onward at the ordinary frequency.

Checking & Servicing

Frequency (hrs.)

2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
6 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div. Nature of Service
Checked

Fuel injection
Drawing-out check & adjustment 1,500 ～ 2,000 1st time:500～800hrs
valve
Check & adjustment of the valve head clearance ○
Cylinder head

Check of valve spring ○

Check disassembly & check of valve rotator ○
Disassembly, check & cleaning ○
Cylinder head
Grinding of suc./ehx. valve seat ○
Scale cleaning & hydraulic test of water chamber ○
Replacement of stem seal (Suc./Ehx. Valve) ○
Check of cyl. head bolt tightening force ＊ ○
Drawing-out, cleaning, checking & measurement
of piston ○
Piston
Check & measurement of piston rings ○
Check & measurement of piston pin ○
Check & measurement of piston pin metal ○
Connecting Check & measurement of crank-pin metal ○
rod Check of connecting rod bolt tightening force ○
Change of connecting rod bolts 20,000 hrs.
Inner dia. checking, cleaning & measurement ○
Cyl. liner Drawing-out, check & cleaning of water jacket
○
Major Moving Parts

part
Measurement of crank pin outer dia. & journal ○
Crankshaft
Measurement & adjustment of deflection ○
Disassembly, metal checking & measurement ○
Check on tightening force of main bearing clamp-
Main bearing ○
ing bolts
Check on tightening force of side bolt ○
Check of cam & roller bearing ○
Disassembly & check of fuel pump tappet ○
Camshaft Disassembly, check & measurement of swing arm ○
Drawing-out of crankshaft & bearing check &
measurement ○
Check of tooth bearing & backlash ○
Disassembly of idle gear & check & measurement
Timing gear ○
of bearing
Check of idle gear mounted shaft tightening force ○

2002.10.7R 6-6
6.　MAINTENANCE CHECKING (Engine Using Heavy Fuel Oil)

Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100°
F 1,500 ～ 7,000-sec. Equiv-
alent Fuel Oil) (2/3)
Checking Servicing
Cycle (hrs.)

2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
3 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div.

Nature of Service
Checked

Check of tooth bearing & backlash

Major Moving Parts

Fuel feed ○
pump, lub. oil Disassembly, check & measure-
pump, & cold ment of bearing ○
water pump
driving Check of gear mounted shaft tighten-
intermediate ing force ○
gear.
Change of hydraulic fluid ＊ ○
Gov. Gear

Governor
Disassembly & check ○
Governor driv- Disassembly & check of tooth bear-
ing gear ing & bearing ○

Check of injection timing ○ 1st time: 300 - 500

Fuel injection
Check of deflector & replacement ○
pump
Disassembly, cleaning & check ○
Fuel feed Disassembly & check ○
Fuel Oil System

pump Replacement of oil seal ○

Pressure Check on filling of ethylene glycol ○
gauge seal
pot Change of ethylene glycol ○
Replacement of Accumulator (for
Accumulator Fuel oil line: F.O. Main pipe & Pres- ○ optional part
sure regulating valve.)
F.O.control &
Replacement of o-ring ○
stop air piston
Change (depended on results of
Lub. oil ○
property analysis)
Disassembly, check cleaning, &
Lub. oil cooler ○
hydraulic test
Thermostatic
Disassembly, check & cleaning ○
valve
Lub. Oil System

Disassembly, check & measurement ○

Lub. oil pump Disassembly & check of pres. reg.
valve & safety valve ○

Change the element

Turbocharger
Change the element of lub. oil 1,000- When the lub. oil pres-
lub. oil
strainer 2,000 sure dropped by
strainer
0.3MPa(3kgf/cm2)
○
Lub.oil priming ○ 2nd
Bearing of motor 1st &
motor pump sub-
time seq
uent

2005.3.16R 6-7
6.　MAINTENANCE CHECKING (Engine Using Heavy Fuel Oil)

Table 6-3. Checking Table for Engine Using Heavy Fuel Oil (R.W. No.1 at 100°
F 1,500 ～ 7,000-sec. Equiv-
alent Fuel Oil) (3/3)
Checking Servicing
Cycle (hrs.)

2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
3 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div.

Nature of Service
Checked

Thermostatic
Disassembly, check & cleaning ○
valve
Cooling Water System

Cooling water Disassembly, check & measurement ○

pump Replacement of mechanical seal ○
Fresh water Disassembly, check, cleaning & hydrau-
cooler lic test ○

Cooling water Change (depended on results of prop-

(Fresh water) erty analysis) ○

Sea water cool- Check of anticorrosive zinc & replace-

ing parts ment (Air cooler & Lub. oil cooler) ○

Turbocharger Disassembly & cleaning ○

Disassembly, check, cleaning & hydrau-
Boost air cooler ○
lic test
Disassemble and clean the muffler ele-
Every 6 months
ment. (Clean with neutral detergent.)
Remove the starting motor from the
engine and turn the pinion gear manu-
Every 6 months
ally, check that it turns smoothly and it
emits no abnormal sound.
Disassembly, inspection, cleaning and
Other

Starting air replacement of grease of moving parts.

motor replacement of o-ring, first reduction ○
gear bearing and special grease inside
the reduction gear.
Disassembly, inspection, cleaning and
replacement of grease of moving parts.
replacement of o-ring, 1st & 2nd reduc- ○
tion gear bearings and special grease
inside the reduction gear.
Engine tachome-
Calibration of indication ○
ter
Alarm switch Actuation test ○

2006.6.20R(MET 6-8
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3. Routine Maintenance Checking & Adjusting Procedures

6-3-1. Measurement of Running Performance
Check and record the following engine performances once a day while the load is stable.

(1) Each cylinder internal max. combustion pressure (Pmax)

(2) Each cylinder outlet exhaust gas temperature
(3) Turbocharger inlet exhaust gas temperature
(4) Lub. oil temperature (at the cooler inlet)
(5) Lub. oil temperature (at the engine inlet)
(6) Cooling water temperature (at the engine inlet)
(7) Cooling water temperature (at the engine outlet)
(8) Cooling water temperature (at the air cooler inlet)
(9) Cooling water temperature (at the air cooler outlet)
(10) Cooling water temperature (at the lub. oil cooler outlet)
(11) Boost air temperature
(12) Engine inlet fuel temperature (for engine using H.F.O.)
(13) Each pressure indicated on the gauge panel
(14) Room temperature

Drawing 6-1 (1/2) Running Performance Confirming Points

Operating Side

Fuel Oil Pressure Gauge

Drawing 6-1 (2/2) Running Performance Confirming Points

Non-operating Side Engine Front End

6-9
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Compare readings with corresponding valves given in the Records of Shop Trial or the Records of Transfer
Trial, and if found to be abnormal, carry out an adjustment or servicing required.

Refer to the following items since the engine performance vary according to the room temperature,
water temperature, condiltions of load, etc.
(1) The dispersion of the maximum combustion pressure (Pmax) among cylinders is normal if it is
within 0.5Mpa (5kgf/cm2).
• Pmax may rise considerably as depended on properties of fuel oil. However, in any case, run the
engine to keep Pmax below 17.7Mpa (180kgf/cm2).
• Reflation between the Pmax and the boost air temperature
If the room temperature rises, Pmax falls; conversely, if the room temperature drops, Pmax rises.
There is a tendency of Pmax 0.2 MPa (2kgf/cm2) against the room temperature change 3 ℃ .
(2) Exhaust temperature refers to the corresponding temperature recorded in the Transfer Trial.
• The dispersion of the exhaust temperature among the respective cylinder outlets is normal if it is
within 40 ℃ .
Even if this temperature is found not uniform among cylinders, it is unnecessary to force revising this
non-uniformity if the fuel injection volume and Pmax are found uniform among cylinders.
• Relation between the room temperature and the exhaust temperature.
The exhaust temperature varies at the rate of about twice the room temperature change. Neverthe-
less, use the engine within the limit values, maintaining a good servicing of the engine, etc. and
reducing the load because fouling of turbocharger and suction/exhaust passage, exhaust pressure,
properties of fuel oil, etc. may influence this relation.

6-3-2. Measurement of Max. Combustion Pressure (Pmax)

Wear gloves when taking a measurement because the pressure indicator becomes hot.

(1) Prepare the following exclusive tools:

No. Exclusive Tool Description Part No.

① Pressure indicator cock turning handle 153605 - 92360

② Pressure indicator 137600 - 93751

Drawing 6-2. Pmax Measurement Procedures

Turning Handle
Inserting Hole

Valve
Max. Pressure Indicator Cock

1998.2.27R 6-10
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(2) Open the valve of pressure indicator cock with use of pressure indicator cock turning handle ① , and
lightly race/rev up the engine for two to three times.
(For prevention of dust and foreign matter from intruding into pressure indicator)
(3) Attach the pressure indicator ② , and close its exhaust valve ③ .
(4) Be sure to fully open the valve of pressure indicator cock withe use of turning handle, and close the
indicator cock when the pressure becomes the highest.
(5) After reading out the Pmax, open the exhaust valve of pressure indicator.
(6) Detach the pressure indicator when its needle shows 0 MPa (0 kgf/cm2).

(When the pressure indicator cock is found hard to loosen, use the turning handle.)

(1) Should the dispersion in Pmax among cylinders exceed 0.5MPa(5kgf/cm2), adjust it with the injec-
tion timing of within 1°.
(2) Should the Pmax exceed its limiting value, adjust the injection timing upon examining the engine
performances.

6-3-3. Regulation of Fuel Injection Volume (Rack Scale)

(1) Should the dispersion in exhaust temperature among cylinders exceed 40 ℃ under the serviced
state of the fuel injection valve, adjust the rack of the corresponding fuel injection pump.
(2) Keep the range of dispersion of rack adjustment among cylinders within one scale graduation.

Drawing 6-3. Fuel Injection Volume Regulating Procedures

FUEL VOL.
FUEL DECREASE FUEL INCREASE Fuel Injection Pump
Rack

(1) Loosen the lock nut ① .

(2) Turn the adjusting screw ② as follows:
Clockwise: To increase the injection volume (exhaust temperature rise)
Counterclockwise: To decrease the injection volume (exhaust temperature drop)
(3) Tighten the lock nut.

6-11
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-4. Adjustment of Fuel Injection Timing

If it is necessary to adjust the fuel injection timing as based on the data recorded during a load run, stop
the engine, and adjust the timing according to the following procedures:

1) Procedures for checking the fuel injection timing

(1) Turn the flywheel to align the marked-off line on the body of fuel injection pump with that on the
plunger guide.
(2) The scale graduation pointed out by the flywheel pointer at this time indicates the fuel injection timing.
(The flywheel scale within the range of 0 to 30°from the T.D.C. is graduated in 2°, and outside the
range, 5°.)

2) Adjustment of the injection timing

Do not bring your fingers close to the lock nut nor oil shield plate while turning the flywheel. Other-
wise, your fingers may be caught in, resulting in an injury.

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Single-ended wrench (M24) for adjusting bolt 138603 - 92510

Double-ended wrench 28110 - 220240

Ratchet handle for turning 147673 - 92851

Socket (M24) for turning 42111 - 001850

Drawing 6-4. Fuel Injection Timing Adjusting Procedures

Maked-off Line
Fuel Injection Pump

Oil Shield Plate

(2) Turn the flywheel to position the adjusting bolt ① at the lowermost.
(3) Loosen the lock nut ② .
(4) Turn the flywheel in the direction of engine rotation so as to align the flywheel pointer with the injection
timing (indicated by the flywheel scale) of a cylinder to be adjusted.

Advance the injection timing: Pmax rises.

Delay the injection timing: Pmax drops.

2006.3.31R 6-12
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(5) Turn the adjusting bolt to align the marked-off line on the pump body with that on the plunger guide.
(6) Turn the flywheel to position the adjusting bolt at the lowermost.
(7) Tighten the lock nut.
(Have the adjusting bolt fixed with use of a wrench so as not to allow the bolt to turn together when
lock nut is tightened.)

After having adjusted the injection timing, turn the flywheel in the direction of engine rotation. When
the adjusting bolt has come to its uppermost position, further push up the oil shield plate to make sure
there is allowance for the pump stroke. (Use the fuel pump priming tool.)

Drawing 6-5. Fuel Injection Pump Priming Tool

No. Exclusive Tool Description Part No.

Operate
① Priming lever 146673 - 92920

② Lever support 146673 - 92930

Tappet

6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure

Improper servicing of fuel injection valve greatly affects the fuel combustion and output. However, it is gen-
erally difficult to specify the servicing frequency which depends on such as the fuel oil used and service
load. Therefore, determine the proper servicing frequency based on such as changes of exhaust tempera-
ture and exhaust color.

In the engine using high viscosity fuel oil, the fuel injection nozzle is indirectly cooled. For servicing
and dismantling the fuel valve, refer to Fig. 36-C: Fuel injection maintenance procedure.

1) Drawing-out of a fuel injection valve

(1) Prepare the following exclusive tools:

No. Exclusive Tool Description Part No.

① Body of fuel injection valve drawing-out tool 146673 - 92340

② Drawing-out bolt 146673 - 92330

③ Nut 26732 - 160002

Hexagonal wrench key (M8) 28150 - 080000

Hexagonal wrench key (M6) 28150 - 060000

2000.8.8R 6-13
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Drawing 6-6. Fuel Injection Valve Drawing-out Procedures

Rocker Arm
<Prevent leakage oil in the fuel Shaft Pedestal
injection valve from dropping
in the cylinder liner>
Fuel Valve Tightening Nut
Before the fuel injection valve
slips out, remove the bolt (B) Fuel Valve Guard
(Refer drawing 6-7, p6-15) of
pipe coupling. Leakage oil in
the fuel injection valve can be Nozzle Sleeve
exhausted if it does so.
Additionally, blowing by com-
pressed air can effectively
exhaust the leakage oil.

Case Nut Packing

(2) Remove the clamping bolts ⑤ of fuel injection pipe joint ④ with use of hexagonal wrench key. (Also
remove the bolts on the fuel injection pump side.)
(3) Loosen the cap ⑥ nut of fuel injection pipe ⑦ , and remove it with the fuel injection pipe.
(4) Remove the fuel valve tightening nut.

Handle the injection pipe with care because oil leakage takes place if the spherical surface on either
end of fuel injection pipe is flawed.

(5) Screw the drawing-out bolt ② into the fuel valve guard.
(6) Attach the body of drawing-out tool ① .
(7) Tighten the nut ③ to draw out the fuel valve.
(8) Draw out the case nut packing. (It may be drawn out together with the fuel valve.)

2) Incorporating the valve

After cleaning, check or replacement of the fuel valve and adjustment of fuel injection pressure is finished,
incorporate the fuel valve while observing the following point:

(1) Take care not to damage the tip of nozzle sleeve when clearing the fuel valve mounting hole.
(2) Replace the case nut packing with new one.
(3) First tighten the cap nut ⑥ of fuel injection pipe, and then tighten the fuel valve tightening nut.
(4) Do not make a mistake in the incorporating direction because spherical washers are used to the
injection pipe joint clamping bolts on the fuel injection pump side.
(5) Tighten the clamping bolts of fuel injection pipe joint ④ on the cylinder head side and the fuel injec-
tion pump side alternately and gradually in two or three times.

2006.1.20R 6-14
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

3) Leaked oil check

During a run immediately after servicing of a fuel injection valve, check for oil leaked from the overflow
pipe.
(A) Leaked oil take-off part of the injection pipe and injection pipe joint
(B) Leaked oil take-off part from the nozzle clearance.

Drawing 6-7. Leaked Oil Take-off Parts

Injection Pipe Joint

4) Disassembly & cleaning of a fuel injection valve

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Socket for case nut 146673 - 92260

Single-ended wrench (M41) for pressure regulation 146673 - 92270

Hexagonal wrench key (M8) 28150 - 080000

(2) Clean carbon adhered to the nozzle exterior, and then disassemble the fuel injection valve. (Removal
of carbon is facilitated by soaking the nozzle in the carbon remover or stock solution of cresol.)
(3) First remove the fuel valve guard, and then disassemble the valve sequentially in the ascending order
of numbers shown in the drawing below.

6-15
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Drawing 6-8. Fuel Valve Disassembling Sequence

Fuel Injection Valve Holder Set Bolt

Guard (Flange) Flange

Fuel Injection Valve

Holder Fuel Injection Valve
Holder

O-ring O-ring

O-ring

O-ring
O-ring

(4) Check & servicing of various parts

○ Check for sulfuric acid corrosion on the periphery of nozzle ④ . If found noticeable corroded, replace the
nozzle with a new one.
○ If the nozzle valve has stuck of it does not move smoothly, replace it with a new one.

○ When the stepped wear "A" of valve stop spacer ⑤ exceeds 0.15mm, replace it with a new one.

○ Replace the case nut ③ and O-rings of body of fuel injection valve with the respectively new ones.

○You are recommended to hold spare parts of nozzle, supposing that its average service life is about 2,500

hours.

(5) Reassemble a fuel injection valve in the sequence reverse to disassembly, paying attention to the fol-
lowing paints:

(1) Do not make a mistake in the incorporating direction of the spring seat ⑥ , spring shoe ⑧ and
spring shoe guide ⑨ .
(2) Tighten the case nut to the specified torque using an exclusive socket. Excessively tightening it
may cause the nozzle to malfunction and the straight pin to be broken.

Chapter9. Table or Tightening Torques of Major Bolts

2001.2.28R 6-16
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

5) Injection test & injection pressure regulation

When operating the nozzle tester, be careful not to expose any part of your body to spray from the
injection valve.
If exposed, you would be seriously wounded because the injection pressure is very high at 34MPa
(347kgr/cm2)

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Nozzle tester 737600 - 93110

Injection pipe for nozzle tester 141616 - 93420

Single-ended wrench (M41) for pressure regulation 146673 - 92270

Socket for case nut 146673 - 92260

Double-ended wrench (M41 × M46) 28110 - 410460

Drawing 6-9. Injection Test & Injection Pressure Regulating Procedures

Injection Pipe
for Nozzle Tester

Nozzle Tester

Case Nut

Set the fuel injection valve downwards.

(2) Attach the injection valve to the nozzle tester.

(3) While slowly operating the hand lever of the tester, adjust the screwing-in of the pressure adjusting
nut ① to attain the specified injection pressure.
(4) Quickly operate the hand lever of the tester (at rate of two to three strokes per second), and check the
state of spray. If the hand lever of the tester is operated slowly at this time, fuel oil runs down after the
hand lever is stoked, and you might err in judgment that the nozzle is defective. Thus, pay attention to
this regard.
• Replace such a clogged nozzle or nozzle which gives a streaky injection with the new one.
(5) The nozzle can be used continually if the oil tightness of the seat part maintains a pressure 2.0 MPa
(20kgf/cm2) lower than the specified injection pressure and allows the fuel oil to such an extent of
oozing out from the nozzle tip.

2004.11.25R 6-17
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(1) When replacing the nozzle, remove the case the case nut under the loosened state of the pressure
adjusting nut. If the case nut is loosened under a high state of the injection pressure, the mating
surfaces of nozzle and spacer and the straight pin may be damaged.
(2) Tighten the case nut to the specified torque with use of exclusive socket.

(6) When the injection test and adjustment of injection pressure are finished, tighten the lock nut ② with
an exclusive single-ended wrench. (To prevent the adjusting nut ① from being turned together with
the lock nut, lock it with a double-ended wrench.)

6-3-6. Adjustment of Suc./Exh. Valve Head Clearance

Adjust the suction/exhaust valve head clearance according to the following procedures because the valve
mechanism of this engine is so constructed to retain two suction (or exhaust) valves by means of the T-
shaped valve guard which will be distorted to cause an abnormal wear to the valve guard guide and/or
valve guide unless adjusted to retain two valves simultaneously:

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Feeler gauge, 0.3-mm thick (suction) 28312 - 300750

Feeler gauge, 0.4-mm thick (exhaust) 28312 - 400750

Drawing 6-10. Valve Head Clearance Adjusting Procedures

A B

Valve Guard

(2) Turn the flywheel to bring the cylinder for which the clearance is to be adjusted to assume the T.D.C.
of the compression stroke.

Do not mistake the T.D.C. of overlap for the instructed T.D.C.

6-18
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(3) Loosen the lock nuts ② & ④ , and then loosen the rocker arm adjusting screw ① and valve guard
adjusting screw ③ .
(4) Press down the center of the valve guard from above (so that the clearance  becomes zero under
this condition). Gradually tighten the valve guard adjusting screw ③ so that the clearance 
becomes zero. After the adjustment, lock the adjusting screw ③ not to turn, and securely tighten the
lock nut ④ .
(5) Put a feeler gauge into a clearance  between the rocker arm adjusting screw ① and the valve guard,
and gradually tighten the rocker arm adjusting screw ① until the clearance becomes narrow enough
to permit the feeler gauge to be smoothly drawn out. Then, lock the adjusting screw ① , and tighten
the lock nut ② .
(6) After having securely tightened the lock nut ② , check that the feeler gauge can be smoothly drawn
out.

The valve head clearance of a suction valve and that of an exhaust valve are different. Be careful not
to mistake the clearance of one valve for that of the other.

Valve head clearance: Chapter 3. Table of Engine Standard Adjustments

6-3-7. Adjustment of Lub. Oil Pressure

The lubricating oil pressure regulating valve has been integrated in the lubricating oil pump.
Should the lubricating oil pressure go out of the specified value, adjust it according to the following proce-
dures:

(1) Before adjusting the lub. oil pressure, first clean the lubricating oil strainers.
(2) Run the engine, and then adjust the lubricating oil pressure to the specified value only after the
lubricating oil temperature is stabilized.

Drawing 6-11. Lub. Oil Pressure Adjusting Procedure

(1) Loosen the lock nut ① .

(2) Adjust the screwing-in of the adjusting

bolt ② to regulate the pressure.
Clockwise ... The pressure rises.
Counterclockwise ...
The pressure drops.

(3) Securely tighten the lock nut.

Lub Oil Pump

6-19
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-8. Adjustment of Lub. Oil Temperature

An automatic thermostatic valve has been equipped to the lubricating oil cooler to rise the lubricating oil
temperature in a short time after the engine is started and to maintain the temperature in the proper range
during a run. The lubricating oil temperature varies with a change of the cooling water temperature in each
season and sea aria, a fluctuation in the cooling water flow rate, fouling of the lubricating oil cooler, etc.

The automatic thermostatic valve has been set so that the lubricating oil temperature at the engine inlet
becomes 50 to 65 ℃. However, if the lubricating oil temperature exceeds this range, adjust and check it
according to the following procedures:

1) Adjustment of lubricating oil temperature

Drawing 6-12. Lub. Oil Temperature Adjusting Procedures

Element

Piston

Nameplate

Cover

(1) Remove the cap nut ① , and loosen the lock the lock nut ② .
(2) Check the projecting dimension  of the adjusting bolt ③ .
(3) Screw the adjusting bolt in the direction of an arrow shown on the nameplate, and make sure the tem-
perature drops. (The bolt screwing-in depth must be 17mm or less.)

Should the temperature do not drop even after the above adjustment, fouling of the lubricating oil
cooler, sticking of a piston of malfunction of the element, etc. may be suspected. Investigate the
cause, and restore the engine to the former proper condition.

6-20
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

2) Check of automatic thermostatic valve

Stop the engine discharge the lubricating oil from the lubricating oil cooler, and then check the automatic
thermostatic valve according to the following procedures:

(1) Loosen the bolt ④ shown in Drawing 6 -12, and then detach the cover.
(2) Check if the piston moves smoothly. (If the piston is catching or stuck, restore it to the proper condi-
tion.)
(3) Take out the piston (incorporating the element withe a circlip)
(4) Soak the element in cold water and warm water for 3 to 5 minutes, respectively, and measure the lift
 of element spindle.

Drawing 6-13. Element Checking Procedures

Element

Piston

Spring

Circlip

Element Spindle

Lift of the element spindle (normal part)

Checking Water Temperature Lift 

Cold water of 30 ℃ or less 5 ± 0.1mm

Warm water of 65 ℃ or more Greater than 23mm

(5) If the lift of element spindle does not satisfy the values shown in the above table, replace the element
with the new one.
(6) Adjust the projecting dimension  of the adjusting bolt ③ to 36mm, and then attach the cover.

6-21
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-9. Adjustment of Fuel Oil Pressure

The fuel oil pressure regulating valve is equipped to the end of fuel oil return pipe together with a damper
which absorbs the pulsating pressure inside the return pipe.

Drawing 6-14. Pressure Regulating Valve Equipped Point

Fuel Oil Pressure Gauge

Pressure Regulating Valve

Damper

(1) Before adjusting the fuel oil pressure, first clean the fuel oil filters.
(2) Adjust the fuel oil pressure, taking the tank head pressure into consideration.

Drawing 6-15. Fuel Oil Pressure Adjusting Procedures

Adjusting Screw Fuel Oil Inlet

Fuel Oil Outlet

(1) Turn the pressure adjust screw as follows:

Clockwise ... The pressure rise.
Counterclockwise ... The pressure drops.

6-22
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-10. Checking of Cyl. Jacket Cooling Water Thermostatic Valves

An automatic thermostatic valve has been equipped to cylinder jacket to rise the cylinder jacket cooling
water temperature in a short time after the engine is started and to maintain the temperature within the
proper range during a run.
This automatic valve has been set so that the cooling water at the engine outlet becomes 85 ℃ when the
cold fresh water temperature is 38 ℃ .
When the engine is operated at low load or when heat discharge, the cooing water temperature naturally
drops, but there is no problem of sulfuric corrosion as far as the cooling water temperature at engine outlet
is maintained over 75 ℃ .
Overhaul, and check the thermostatic valve according to the following procedures.

Drawing 6-16. Thermostatic Valve Removing Procedures

Air Bleeder

Throttle Plate (Orifice)

Thermostatic Valve Case

Thermostatic Valve Element

Side Cover

Throttle Plate (Orifice)

Jacket Cooling Water Pump

1) Removal of thermostatic valve elements

(1) Close each valve at the inlet and outlet of the cooling water system, and then discharge the cooling
water from inside the cylinder jacket.
(2) Remove the air bleeder.
(3) Detach the side cover.
(4) Remove the thermostatic valve case, and take out the elements.

Be careful not to drop the thermostatic valve elements.

2006.12.15R 6-23
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

2) Check of thermostatic valve elements

The thermostatic valve is equipped with two elements of different valve opening temperatures.
Check the elements according to the following procedures:

(1) Check for crack of the valve, broken spring and foreign matters caught on the valve seat face.
(2) Soak the elements in cold water and hot water for 2 to 3 minutes, respectively, and measure the valve
lift  .

Drawing 6-17. Element Checking Procedures

Valve Valve Opening Temp. Stamp

Valve lift of the element (normal part)

Checking Water Temperature Lift 

Cold water of 30 ℃ or less 45 ± 1mm

Hot water of 95 ℃ to 100 ℃ Greater than 55 ± 1mm

(3) If the valve lift does not satisfy the values shown in the above table, replace the elements with new
one.

3) Incorporation thermostatic valve elements

Incorporation thermostatic valve element in the sequence reverse to removal.

(1) Do not make a mistake in the element incorporating direction.

(2) Do not forget to incorporate throttle plates at thermostatic valve case inlet and outlet sides.

6-3-11. Cleaning of Lub. Oil Bypass strainer

The lubricating oil system is equipped with a centrifugal bypass strainer in addition to a notch-wire oil
strainer. During a run, keep open a cock at outlet of lub. oil pump to allow the lubricating oil to flow through
the strainer regularly. When any problem has occurred to the bypass strainer, close the cock to stop the oil
flow.

Stop the engine before cleaning the bypass strainer.

If you disassemble the bypass strainer during a run, oil mist may be blown off, causing you to get a
burt.

6-24
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

GF-2type Bypass Strainer

1) Disassembly & cleaning

Disassemble and clean the lub. oil bypass strainer according to the following procedures:

Drawing 6-18. GF-2type Bypass Strainer Disassembling Procedures

Bearing

Spindle

Body
Nozzle

Bearing

Lub. Oil Inlet

Lub. Oil Outlet

(1) Loosen the tightening nut ① of the body cover ② , and then remove the cover ② .
(2) Remove the rotor assembly (spindle, rotor cover ④ and rotor body ⑤ ).
(3) Lock the nozzle section of rotor assembly.

When locking the nozzle section, take care not to flaw the nozzle hole and the spindle bearing.

(4) Loosen the rotor cover tightening nut ③ , and then detach the rotor cover ④ .
(5) Completely remove the sludge adherent to the rotor body ⑤ and inside of rotor cover ④ , and then
wash them.

Completely remove the sludge. Otherwise, the residual sludge may cause an unbalance in rotation,
resulting in a damage to the bearing.

(6) Check for flaws of the bearings of body and body cover.

2) Reassembly

Reassemble the lub. oil bypass strainer in the sequence reverse to disassembly, paying attention to the
following points.

(1) Check for clogging of the nozzle and damage of the nozzle hole before incorporating the rotor
cover.
(2) Incorporate the body cover after incorporating the rotor assembly into the body and making sure it
rotates smoothly.

1999.7.2R 6-25
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

ROC-5type Bypass Strainer

1) Disassembly & cleaning

Disassemble and clean the lub. oil bypass strainer according to the following procedures:
(1) Loosen the bell knob 1/4 turns and remove the bell clamp, then remove the bell housing.
(2) Raise up the turbine assembly to allow the lub. oil to drain from inside, then remove the turbine
assembly.
• Take care not to bend the base shaft.
(3) Loosen the can nut, then turn over the turbine assembly withe the can nut loosely attached.
• If the can nut is too tight to loosen with your hands, insert a bar into the hole of can nut and turn the
bar.
• Take care not to scratch the end surface of bush.
(4) Press down the turbine can, then remove the nut, turbine can and baffle screen.

Drawing 6-19. ROC-5type Bypass Strainer Disassembly Procedures

Bell Knob Turbine Assy. Disassembly of Turbine Assy.

Can nut
Bush
Bell Housing
Turbine Can

Paper Insert Turbine Can

Bell Clamp
Baffle Screen Assy.
O-ring
Can nut
O-ring
Bush
Bush
Base Shaft
Turbine Rotor

Base Bush

Nozzle
Cut-off Valve
[on Opposite Side of Lub. Oil Inlet]

2) Checking and servicing

Sludge whose thickness is 15mm or more may cause abnormal vibration. According to the operation con-
ditions, specify the proper servicing interval.
(1) Insert such a narrow and thin tool as a spatula between the inside wall of turbine can and paper insert
to remove sludge and paper insert.
(2) Clean the turbine can, baffle screen and turbine rotor.
• Completely remove the sludge. Otherwise, abnormal vibration may be caused.
(3) Check for clogging of nozzle.
(4) Replace the O-ring, gasket and paper insert with new ones, respectively.

3) Reassembly

Reassembly the lub. oil bypass strainer in the sequence reverse to disassembly, paying attention to the fol-
lowing points.
○ Tighten the can nut and bell clamp only with your hands and fingers.

○ Attach the turbine assembly to the bell shaft, then make sure that it can be smoothly turned.

○ Tighten the bell clamp, then tighten the can nut 1/4 turns.

1999.7.2R 6-26
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

FM200 type Bypass Filter

This FM200 centrifugal bypass filter should be cleaned at regular intervals ensuring that the thickness of
the dirt deposit inside the rotor does not exceed approximately 35 mm.
The filter assembly is fitted with a cut off valve, which is located in the filter body. This valve is designed to
protect the engine by stopping the supply of lube oil to the filter at start-up and during periods when the oil
pressure is below the valve rating.

1) Disassembly & cleaning

Disassemble and clean the lube oil bypass filter according to the following procedures:

Drawing 6-18-b FM200 type Bypass Filter



  

TQVQTDGCTKPI









 


roter cver
slot 




pin


LUB.OIL
INLET


LUB. OIL 
 OUTLET 
 

ͳ NAME ͳ NAME
 BODY ASSEMBLY  BEARING TUBE
 BODY  STAND TUBE
 SPINDLE  ROTOR COVER
 COVER CLAMP  PAPER INSERT

 COVER ASSEMBLY  CIRCLIP

 COVER NUT  O-RING (ROTOR ASSEMBLY)
 O-RING  ROTOR BODY
 COVER  NOZZLE

 ROTOR ASSEMBLY  O-RING (FILTER BODY)

 ROTOR COVER NUT  CUT OFF VALVE KIT
 STIFFNENER PLATE  FLANGE GASKET

2006.1.20R 6-27
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

(1) Ensure the engine stopped, and the filter has come to a complete stop before proceeding.
(2) Remove the band clamp ④ ,unscrew the cover nut ⑥ and remove the centrifuge cover assembly ⑤ .
(3) Allow the oil to drain out of the rotor assembly ⑨ . Withdraw the rotor assembly vertically upwards
from the spindle.
・At this time, it is noted not to damage an upper and lower rotor bearing.
(4) Secure the rotor assembly ⑨ on the rotor disassembly tool. Unscrew the rotor cover nut ⑩ and sepa-
rate the rotor cover from the rotor body ⑱ .
(5) Remove the stand-tube ⑬ .
(6) Remove sludge deposits from the inside of the rotor cover ⑭ using a spatula, and remove the paper
insert from the rotor cover. Clean the rotor components using a suitable cleaning fluid.

2) Reassembly
(1) Ensure that all rotor components (including the two nozzles located in the rotor body) are thoroughly
cleaned and free from debris before reassembly.

Completely remove the sludge. Otherwise, the residual may cause an unbalance in rotation, resulting
in damage to the bearing.

(2) Fit a new paper insert into the rotor cover, and attach the whole rotor assembly component. And then
tighten with the rotor cover nut ⑩ .
・ Examine the centrifuge body O ring ⑰ for damage and renew if necessary.
・ Inspect rotor bearings for wear and replace bearing tube ⑫ if necessary.
・ Reassemble the rotor assembly ⑨ ensuring that the rotor cover slot and rotor body pin are aligned.
This prevents the unbalance during operation.
(3) Replace the rotor assembly ⑨ on the spindle.
・ Inspect spindle ② for wear and replace filter body assembly ① if necessary.

After replacing the rotor assembly, check the rotor spins freely.

(4) Replace the filter cover assembly ⑮ and fasten the centrifuge cover nut ⑥ hand tight. (Tightening
torque =5 ～ 7 Nm)
・ Examine the filter body O ring for damage and renew if necessary.
(5) Replace the cover clamp ④ and tighten hand tight. (Tightening torque =5 ～ 7 Nm)

The band clamp must be securely fitted during operation of the centrifuge.

(6) With the centrifuge running, check all joints for leaks.

2006.1.20R 6-28
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-12. Cleaning of Lub. Oil Strainer

Engine Main Lubricating Oil Strainer
The lubricating oil strainer is of the manual back-washing, duplex changeover type, and its element are of
the notch-wire type. In a normal run, the lubricating oil passes through both sides (both elements) of the
strainer.
Besides, a differential pressure indicator which detects the oil pressure at the inlet and outlet of the strainer
has been fitted to the lubricating oil cooler so as to detect clogging of the strainer.

When the difference between the oil pressures at the inlet and outlet of the strainer reaches 0.09 MPa
(1kgf/cm2), the differential pressure alarm is issued.

Be careful not to get burnt by touching this strainer because it assumes a high temperature during a
run.

• Should the differential pressure not drop even if back-washing is done, overhaul and clean the
strainer.
• Should the strainer be fouled noticeably, a lub. oil pressure drop alarm may be issued when one side
of this strainer is used. Therefore, check the oil pressure while cleaning the strainer.

1) Back washing (blow-off)

Wash both sides of this strainer, one at a time, according to the following procedures:
(1) Align the red mark of the changeover cock ① with the LEFT (or RIGHT) CHANGE position on the
nameplate.
(2) Loosen the drain plug ② two to three turns.
(3) Carry out the changeover cock with the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds.
(4) Return the changeover cock with the CHANGE position.
(5) Repeat the above operation steps (3) & (4) three or four times.
(6) Tighten the drain plug.
(7) Return the changeover cock to the NORMAL RUN position.

Drawing 6-20. Lub. Oil Strainer Cleaning Procedures

Changeover Cock Nameplate

LEFT CHANGE

22.5

LEFT BLOW-OFF O-ring

NORMAL RUN

Case

1999.7.2R 6-29
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

2) Disassembly & cleaning

When disassembling this strainer during a run, do so one side of the strainer at a time according to the fol-
lowing procedures:
(1) Align the red mark of the changeover cock ① with the LEFT (or RIGHT) CHANGE position.
(2) Loosen the drain plug ② .
(3) Loosen the air vent plug ③ .
(4) Discharge the lubricating oil in the case, loosen the nut ④ , and then detach the blow-off pipe ⑤ .
(5) Loosen the center bolt ⑥ , and remove the case and element.
(6) Clean the removed.

6-3-14. Cleaning of Strainer/Filter Element

3) Incorporation

Incorporation a strainer element in the sequence reverse to disassembly, paying attention to the following
points.

• Do not make a mistake in the element incorporating direction.

• Take care not to permit the O-ring bit in the case.
• When setting the changeover cock in the NORMAL RUN position, shift it slowly. If shifted rapidly, the
oil pressure may temporarily drop before the case is filled with the lubricating oil, causing the lubricat-
ing oil pressure drop alarm to be issued.

Turbocharger Lubricating Oil Strainer

The lubricating oil strainer is of the duplex changeover type and its elements are of the paper type. In a
normal run, the lubricating oil passes through both sides (both elements) of strainer.
Besides, a pressure switch is provided on the outlet side of strainer to detect clogging of the strainer.

When the lub. oil pressure at the outlet of strainer has dropped to 0.3 MPa (3kgf/cm2), replace the ele-
ments of the strainer.
• When the lub. oil pressure at the outlet of strainer has dropped to 0.25 MPa (2.5kgf/cm2), the pres-
sure drop alarm will be issued.
Simultaneously, the relief valve of strainer will open to allow sludge and contaminant in the strainer
to flow to the turbocharger, thereby damaging the bearing. Take care not to let the lub. oil pressure
to drop excessively.
• If the strainer is fouled noticeably, the lub. oil pressure drop alarm may be issued when one side of
this strainer is used. Therefore, keep checking the pressure carefully while operating one side of this
strainer.

Be careful not to get burnt by touching this strainer because it assumes a high temperature during a
run.

1999.7.2R 6-30
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

1) Disassembly & cleaning

If you disassemble the strainer during a run, disassemble and clean on element then the other sequen-
tially.
(1) Align the red mark of the changeover cock with the LEFT (or RIGHT) CHANGE position.
(2) Loosen the air vent plug.
(3) Remove the drain plug, and discharge the lub. oil from the case.
(4) Loosen the center bolt, and remove the case and element.
(5) Replace the element.

Drawing 6-21.

Pressure Gauge
Air Vent Plug
Changeover Cock
Pressure Switch

LEFT CHANGE RIGHT CHANGE

O-ring

NORMAL RUN Case

Relief Valve
Element

Drain Plug
Center Bolt

2) Incorporation

Incorporate a strainer element in the sequence reverse to disassembly, paying the attention to the follow-
ing points.

• Do not make a mistake in the element incorporating direction.

• Take care not permit the O-ring bite in the case.
• When setting the changeover cock in the NORMAL RUN position, shift it slowly. If shifted rapidly, the
oil pressure may temporarily drop before the case is filled with the lubricating oil, causing the lubricat-
ing oil pressure drop alarm to be issue.

6-3-13. Cleaning of Fuel Oil Filter

The fuel oil filter equipped is of the heat-insulating, manual back-washing, duplex changeover type, and its
elements are of the notch-wire type. In a run, the fuel oil passes through both sides (both elements) of this
filter.

Be careful not to get burnt by touching this filter because it assumes a high temperature during a run
on H.F.O.

1999.7.2R 6-31
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

• Should the filter be fouled noticeably, the revolution of the engine may decrease as the fuel oil pres-
sure drops when one side of this filter is used. Therefore, check the fuel oil pressure while cleaning
the filter.
• A positioning notch is provided to the changeover handle. In a blow-off or disassembly, tilt the handle
to align the notch with the knock pin.

1) Back-washing (blow-off)

Wash both sides of this filter, one at a time, according to the following procedures:
(1) Open the drain cock ① .
(2) Hold the changeover handle in the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds, and then
return it to the BOTH SIDES IN USE position.
(3) Repeat the above step (2) three or four times.
(4) Close the drain cock.

Drawing 6-22. Fuel Oil Filter Cleaning Procedures Drawing 6-23.

H.F.O. Filter M.D.O. Filter

BOTH SIDES IN USE BOTH SIDES IN USE

LEFT
BLOW - OFF
80
50 LEFT 90 60
BLOW - OFF

LEFT
DISASSEMBLY

LEFT
DISASSEMBLY

2) Disassembly & cleaning

When disassembly this filter during a run, do so one side of the filter at a time according to the following
procedures:
(1) Tilt the changeover handle ② to the LEFT (or RIGHT) DISASSEMBLY position.
(2) Open the air vent cock ③ .
(3) Open the drain cock ① to discharge the fuel oil.
(4) Remove the circular nut ⑥ .
(5) Remove the element ④ , and clean it.
6-3-14. Cleaning of Strainer/Filter Element

(6) Clean the inside of the filter body.

2003.4.17R 6-32
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

3) Incorporation

Incorporation a filter element in the sequence reverse to disassembly, paying attention to the following
point.

(1) When setting the handle in the BOTH SIDES IN USE position, shift it slowly. If shifted rapidly to the
BOTH SIDES IN USE position, the oil pressure may drop before the filter is filled with the fuel oil.
(2) Open the air vent cock to bleed air.

6-3-14. Cleaning of Strainer/Filter Element

Clean a notch-wire type element of lubricating oil strainer or fuel oil filter according to the following proce-
dures:

Drawing 6-24. Notch-wire Type Element Cleaning Procedures

8/6 Pipe Cock

Smash to about 1mm

(1) Soak the element in the light oil or cleaning fluid to remove the sludge adherent on the surface with a
wire brush.
(2) Prepare a nozzle as shown in the above drawing, and spray the compressed air of 0.3 to 0.5 MPa (3
to 5 kgf/cm2) from the inside of the element.
(3) Lighting the element form its inside, make sure the dirt and foreign matters have been removed.
(4) Check for flaws, wire breakage, corrosion, etc. on the surface of notch wire.

6-3-15. Washing of Turbocharger

1) Washing of Turbocharger Blower
When the blower of turbocharger is fouled, the exhaust temperature may rise, shortening the service life of
fuel injection valves and exhaust valves.
Also, the effect of late washing is lower than that of timely washing. Therefore, record the boost air pres-
sure before and after such a washing, and referring to the recorded data, periodically wash the blower.

(1) Wash the blower during a run of abut 30 ～ 40% load. After washing it, continue a load run for at lest
one hour.
(2) Should the boost air pressure not restored even after washing the blower, overhaul and clean it.

2006.6.20R(MET 6-33
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Drawing 6-25A. Turbocharger Blower Washing Procedures

%QPPGEVKPI*QUG *CPF2WOR

(KNNGT2NWI 014989-00E

(1) Open the drain cock on the outlet side of boost air cooler.
(2) Suck one washing’s usage of the cleaning fluid into a hand pump.

One washing’s usage MET-18 : 0.25

(3) Connect the land pump with the water filler plug, and pour in the cleaning fluid in 4 to 10 seconds.
(4) Repeat the above steps (2) & (3) three of four times.
(5) Pour fresh water of the same quantity as the cleaning fluid into the washer, and carry out washing with
fresh water in the same way above procedures.
(6) After the washing, attach the cap to the water filler plug, and close the drain cock.
(7) If the boost air pressure is not restored, wait next 10 minutes, and then repeat the above washing.

2006.6.20R(MET 6-34
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

2) Solid type cleaning of turbine

Outline of cleaning
With the cleaning method, cereal grains or activated coconut charcoal particles are fed into the turbo-
charger, in front of the turbine, so that these grains or particles, accelerated by gas stream, will hit the tur-
bine nozzles and blades to remove deposits from these components.

(1) Points of care to be observed in installing cleaning device and associated piping
① Air Pipe
Connect the free end of the air pipe to service air supply source of 0.39 ～ 0.88 MPa (4 ～ 9 kgf/cm2) in
pressure, to supply air for the injection of cleaning medium before the turbine.
② Consideration for prevention of clogging of transport pipe (Flexible Rubber Hose)
Connect the Flexible Rubber Hose when cleaning the turbine.
The best is for the transport pipe to be arranged vertically.
Otherwise, provide generous radial of 150 mm or more at bends.
Also, avoid the reduction in pipe diameter at bends.

(2) Cleaning medium (Vegetative cleaning agent quantity)

kind of Particle size Specified Quantity

Cleaning Media (mm) (Once cycle) This media (MARINE GRID #10)
is available from HIKAWA
Walnuts shell MARINE CORP.
1.7 ～ 2.4 0.05 ～ 0.1 liter
Particles

*Use of too much cleaning medium can result in the turbocharger surging. Therefore, use the optimum
quantity of cleaning medium according to the engine operating conditions with due reference to (4).

(3) Cleaning procedure

① Cleaning intervals
As a matter of guide, make it a principle to perform the cleaning once every 200 to 250 hours of oper-
ation.
Adjust the cleaning intervals thereafter in accordance with the decline in turbocharger performance,
i.e., changes in exhaust temperature.
② Engine Load for performance of cleaning.
Since the maximum permissible Engine Load and turbine inlet temperature for the cleaning are as
indicated in table, reduce the engine load below the normal level if the Engine Load and turbine inlet
temperatures at the normal engine load are higher than indicated in the table.

Maximum permissible Engine Load and temp.

before turbine for cleaning

MET-18

Engine Load 50%

Temp. before turbine below 500 ℃

(4) How to perform cleaning

a. The quantity to be used at one time should be 0.05 liter and cleaning should be conducted at a few
times.
b. Should some such sudden change take place in engine operation during injection of the cleaning
medium as, for example, very severe surging, etc., use about 1/2 of the quantity per cleaning for
trial.
Make sure that the engine undergoes stabilized operation, and then repeat the cleaning the same
way. Employ this cleaning method thereafter as a standard practice.
c. In case the exhaust temperature, show no improvements, repeat the process prescribed in (1) ～ (5). If
the repeated cleaning also fails to improve the situation, then open up the turbocharger for cleaning.

2007.8.7R(MET 6-35
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

Perform the cleaning in the following manner

When cleaning only once
(1) Open the valves in the follwing sequence to pass air for one to two minutes for cooling of the clean-
ingdevice.
Valve ③ → ② → ①
(2) Close the valves in the follwing sequence.
Valve ① → ② → ③
(3) Fill the Hopper with the specified quantity of cleaning medium. Be sure to close the cap of the Hopper
without fail.
(4) Open the valves in the follwing sequence to pass air and inject the cleaning medium.
Valve ① → ② → ③
(5) Close the valves in the follwing sequence.
Valve ① → ② → ③

Drawing 6-25B. Outline of cleaning device

Fig shows the cleaning device to be used for the cleaning with cereal grains.

014988-00E

Do not open the turbocharger gas outlet casing drain discharge during the cleaning

2006.6.20R(MET 6-36
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

6-3-16. Maintenance of Pressure Gauge

Glycerin aqueous solution is sealed in a pressure gauge equipped on the gauge panel to prevent wear of
the gear and link mechanism inside the gauge.
Handle a pressure gauge, observing the following items:
(1) When removing the gauge panel or a pressure gauge for its servicing, have the rubber cap of a pres-
sure gauge faced upward.
(If faced sidelong, the sealing liquid will leak through the ventilating hole in the rubber cap.)
(2) Always maintain the sealing liquid at the specified level.

Drawing 6-26. Level of Pressure Gauge Sealing Liquid

Rubber Cap

B
A Minimum liquid level A = 18mm
Higher Liquid level B = 25 26mm

(3) Should the sealing liquid become contaminated or its level drop, detach the rubber cap, and change
the sealing liquid or replenish the pressure gauge with its sealing liquid.
(Sealing liquid (P/#42111-002800) is optionally available.
(4) When a pressure gauge is replaced with the new one, use it after cutting off the navel of the rubber
cap to open a ventilating hole to the gauge.
(If the gauge is not provided with an opened ventilating hole, the indication becomes be out of order.)

Adjustment of Pressure Take-off Main Valve

Check and adjust the operating of a needle valve provided at the piping part of a pressure gauge or
pressure transmitter in order to prevent the damage or malfunction of the pressure gauge and pres-
sure transmitter that are subject to pulsation.
• Fuel pressure main valve: Open 1/4 turn from the completely closed position.
• Other pressure main valve: Open one turn from the completely closed position.

Adjustment of Remote Indicating Pressure

In the case of remote indication of a pressure, a pressure transmitter has been equipped. If the indication
on the remote side has to be adjusted, proceed to the adjustment according to the following procedure:

2006.6.20R(MET 6-37
6.　MAINTENANCE CHECKING (Maintenance Checking&Adjusting Procedures)

[ Adjusting Procedure ] Drawing 6-27. Top Cover

• Detach the top cover from a pressure
transmitter. Screwdriver
• Lightly press a small screwdriver (of
which head is 2mm in diameter)
against the ZERO or SPAN adjust
screw, and turn the screw as the 2mm
Press.Transmitter
need arises.
Adjusting Screw

Test Valve

Connector

• As the screw is turned clockwise, the ZERO ADUJUSTMENT SPAN ADUJUSTMENT

indicated value varies in the direction mA mA
of an arrow shown in the following
graphs. 20 20
Current

Current
4 4

0 Po P P kgf/cm2 0 P P kgf/cm2
Pressure (MPa) Pressure (MPa)

2006.6.20R(MET 6-38
6.　MAINTENANCE CHECKING

6-3-17. Measurement of Crankshaft Deflection

If the crankshaft deflection enlarges excessively, the crankshaft may be broken, resulting in an accident.
Consequently, periodically measure the crankshaft deflection.

(1) Measure the crankshaft defection under the cold state of the engine.
(2) When you have removed of further tightened the engine installation (anchor) bolts, common bed
clamping bolts or driven machine (such as generator) clamping bolts, are disassembled or retight-
ened, measure the crankshaft deflection.
(3) Move the contactor of deflection gauge, and make sure the needle of dial gauge returns to the orig-
inal position.

1) Deflection measuring procedures

(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Deflection gauge 42111 - 000040

Deflection gauge mirror 42111 - 001420

Ratchet handle for turning 147673 - 92851

Socket (M24) for turning 42111 - 001850

(2) Open the pressure indicator cocks of all cylinders.

(3) Turn the flywheel to bring it to the position EB of 30 degrees after the B.D.C.
(4) Fit the deflection gauge, and set the needle of dial gauge in the zero indication.
(5) Slowly turn the flywheel in the rotational direction of the engine, and take and record readings of the
dial gauge at the position E, T, P and PB.

Drawing 6-28. Position for Fitting the Deflection Gauge Drawing 6-29. Deflection Measuring Positions
T

P E
D
L
D/2

PB EB

Crank Pin Position

Deflection Gauge EB 30 after B.D.C. (measuring reference)

E 90 before T.D.C.
D = Diameter of crankshaft of 180mm
L = Width across arms of 98mm T Top Dead Center (T.D.C.)
P 90 after T.D.C.
PB 30 before B.D.C

2006.6.20R(MET 6-39
6.　MAINTENANCE CHECKING

2) Criteria on results of the deflection measurement

The relation between the deflection valve (reading of dial gauge) at each measured position with the refer-
ence taken at the position EB and the crankshaft is as shown in the below table.

Drawing 6-30.

Reading of Dial Gauge ＋ －

Crankshaft
(lower spread) (lower contract)

(1) Should the deflection increase every time it is periodically measured, this is caused by the wear of the
crankshaft and/or main bearings. If the deflection of only a certain cylinder increases suddenly, it is
suspectable that the corresponding main bearing metal is abnormally worn. In these cases, check for
the pertinent parts.
(2) Since the deflection value measured under the hot state of the engine varies as depending on the
temperature existing at the measurement, it cannot be relied on as the reference. However, accord-
ing to out test results, that deflection is roughly 2/10,000 to 3/10,000 × stroke (lower contract).

3) Allowable value of the deflection

Should the crankshaft deflection exceed the allowable value, correct the deflection by redistributing the
installation shims and shaft centers of the engine and driven machine (or outer bearings).

(1) In case of the direct coupling systems  ,  , &  , the normal deflection for the No.1 cylinder is
lower contract.
(2) In case of the direct coupling systems  , adjust the deflection for the No.1 cylinder to lower spread
because the temperature rise of engine bearings becomes larger than that of generator bearings
during a run and thus the shaft center of crankshaft becomes comparatively higher.

Table: Allowable value of the deflection

[Unit:1/100mm] Note: "S" stands for stroke
No.1 Cyl.
Installation
Coupling System Driven Machine T-PB/EB P-E No.2 ～ 6 Cyl.
System
(direction) (direction)

-5.6 ～ +2.8 ± 2.8 ± 2.8

Generator, single- Direct
 (Direct coupling)
side bearing (stationary)
〔　　　 　〕 〔　　　 　〕 〔　　　 　〕
-2S ～ 1S
10,000
± 1S
10,000
± 1S
10,000

-7.5 ～ +2.8 ± 2.8 ± 2.8

 (Bell housing Generator, single- Vibration
coupling) side bearing insulation
〔　　　 　〕 〔　　　 　〕 〔　　　 　〕
-2.7S ～ 1S
10,000
± 1S
10,000
± 1S
10,000

± 2.8 ± 2.8 ± 2.8

Generator, both- Direct
 (Direct coupling)
side bearing (stationary
〔　　　 　〕 〔　　　 　〕 〔　　　 　〕
± 1S
10,000
± 1S
10,000
± 1S
10,000

 (Air clutch & -5.6 ～ +2.8 ± 2.8 ± 2.8

Pump & compres- Direct
flexible cou-
pling)
sor (stationary)
〔　　　 　〕 〔　　　 　〕 〔　　　 　〕
-2S ～ 1S
10,000
± 1S
10,000
± 1S
10,000

2006.6.20R(MET 6-40
6.　MAINTENANCE CHECKING

Drawing 6-31. Driven Machine Direct Coupling Sistem.

Support

Rubber Vibration Insulator

Air Clutch & Flexible

Coupling

2006.6.20R(MET 6-41
6.　MAINTENANCE CHECKING

6-3-18. Adjustment of Fuel Injection Pump Pinion Lubricating Volume (for Engine Using
H.F.O.)
The pinion sleeve of fuel injection pump of an engine using the heavy fuel (equivalent to 3,500-sec. or
7,000-sec. fuel oil) has been lubricated by lub. oil. Adjust the lubricating volume according to the following
procedures:

(1) First run the engine, and then adjust the lubricating volume when the lubricating oil temperature
becomes 55 to 65 ℃ .
(2) Adjust the lubricating volume so that the lubrication becomes 1 dropful per 10 to 12 seconds.

Drawing 6-32. Lubricating Volume Adjusting Procedures

Oil Flow Rate

Regulating Valve

Lubricating Point

(1) Remove the cap nut ① from the lub. oil flow rate regulating valve, and loosen the lock nut ② .
(2) Fully screw in the lub. oil flow rate adjust screw ③ .
(3) Remove the plug ④ on the fuel injection pump side to check the lubricating volume.
(4) Gradually loosen (turn counterclockwise) the adjust screw until the lubricating volume becomes as
specified.
(5) When the lubricating volume has become as specified, securely tighten the lock nut ②, cap nut ① and
plug ④ .

6-3-19. Maintenance of Fuel Oil Seal Pot (for Engine Using H.F.O.)
Maintenance servicing of mentioned in Section 4-1-2. (Page4-6)

2006.6.20R(MET 6-42
6.　MAINTENANCE CHECKING

6-3-20. Check & Replacement of Anticorrosive Zinc

In the case of the fresh & sea water 2-line cooling specification, anticorrosive zincs have been fitted to the
boost air cooler, lub. oil cooler. Check them according to the following procedures:
• In the case where such anticorrosive zinc is found consumed more than 70% of the state retained by
the new article, replace it with the new one.

Fitting Area (Q’ty)

Cooling water inlet/outlet cover (2)

Boost air cooler
Water return cover (2) ･･･ plug type

Inlet side cover (1)

Lub. oil cooler
Outlet side cover (1)

• In the case of continuous use of such anticorrosive zinc, get rid of the oxide layer from the surface of the
zinc to expose the metallic texture.
• The anticorrosive zinc for boost air cooler upper part is of the plug type. Detach the inspection window
cover from the boost air duct, and remove the plug, using a hexagonal wrench key (having the width
across flats of 17mm).

After checking and replacing an anticorrosive zinc and before fitting the inspection window cover,
check that there is no water leakage.

Drawing 6-33. Anticorrosive Zincs Equipped points

Boost air cooler Anticorrosive Zinc Fitting Prosedures
Inspection wind cover
B B
A-Flange Type B-Plug Type

Nut
Flange Plug
Boost air cooler

Packing Packing

Anticrrosive
Anticrrosive Zinc
L Zinc
L
A A D
D

Lub. Oil cooler

Dimensions of Anticorrosive Zincs (in the New-article State)

Flange type Plug type

A A D (mm) 40 25
L (mm) 40 95

2006.6.20R(MET 6-43
6.　MAINTENANCE CHECKING

MEMO

6-44
7.　MAINTENANCE SERVICING

7. MAINTENANCE SERVICING

○ In advance of maintenance and check of the engine, thoroughly read this Operation Manual to
understand the structure of the pertinent part and the nature of work to be performed and to examine
sufficiently the work procedures. If you begin the work without examining the work sufficiently, not
only the labors will be wasted but also accidents or damages of the engine due to misassembly will
be caused.
○ If any part is found to be damaged of not durable for further use (reaching its usage limit) as a result
of check, be sure to replace it. Besides, considering the schedule for next check, replace any part
estimated not to be durable until the next check.
○ If it is difficult to take any countermeasure of action on site, or if the necessary spare part is not avail-
able, consult us or your nearest sales or service agent (shown in the service network list "YANMAR
Worldwide Service" appended to this manual).

7-0. Precautions in Maintenance Servicing

1) Precautions on Safety

To work safely, read the items regarding safety in the following pages:

○ Chapter 0. For Safe Use of Your Engine .... (p.0-2)

○ Chapter 0, 3. Precautions on Safety (pp.0-4 to 0-13)

(1) If the engine runs during disassembly or check, you may be caught in it, resulting in a serious acci-
dent.
☆ Prior to servicing, return the start/stop lever to the STOP position and surely close the valves of the
starting air system to make sure the engine does not turn. Only then, proceed to disassembly or
checking work. (Be sure to changeover the control position selector switch to the ENGINE posi-
tion.)
(2) Before turning the flywheel with the turning device, make sure you do not make a contact withe any
rotating part and that rotation of the engine will not endanger you, your coworkers or other persons
around the engine. Also be sure to give a sign when turning the flywheel.
For usage of the turning device, refer to the following:

Chapter 7-0. 4) Handling Procedures for Turning Device (p. 7-4)

☆ Prevent the self-rotation of crankshaft with the lock bar of the turning device before disassembling
of checking any moving part.
☆ Other than turning the flywheel, return the turning device to the GEAR OUT position.

(3) Be sure to turn off the power switch before handling an electric part. Otherwise, you may receive an
electric shock or fire may be caused.
(4) During welding and grinding, sparks may be spread, resulting in fire. Therefore, do not store such
combustible materials as the fuel oil, lubricating oil and waste cloth at the working site.

7-1 (Volume:60pages)
7.　MAINTENANCE SERVICING (Precautions in Maintenance)

(5) When handling a liquid, strictly observe the following precautions:

☆ Fuel oil and lubricating oil: Flammables . . . . . . . .The lighting of fires is strictly prohibited.
☆ Fresh-water rust inhibitor
and fresh-water antifreezing fluid: Toxic . . . . . . . .Do not drink any of them.
●
Battery fluid When handling the battery fluid, wear rubber
gloves and a mask, if possible, and do not allow
it to make direct contact with your skin.
If it is put o your skin, flush it.
Before discharging it, treat it according to the
instruction manual of the additive manufacturer.
☆ Mercury (thermometer): Poisonous . . . . . . . . . . .Do not drink it. If it is put on your skin, flush it.

(6) According to the condition of working, wear protectors such as gloves, a helmet, safety shoes and
safety goggles.
☆ During a run and immediately after the engine has stopped, the whole engine is heated. Before
working, wear gloves so as not to get burnt.
☆ On the floor of engine room, oil is adherent and slippery. Especially when working at a height
such as on the footboard, sufficiently watch your step not to fall from there.
(7) If you disassemble a strainer/filter of piping joint immediately after the engine has stopped, hot oil or
water may be spout out due to the residual pressure.
Before disassembling a strainer/filter or removing a piping joint, close all valves for external con-
nection to the CLOSE position, and gradually loosen the air vent plug to release the internal pres-
sure. Then wrap the part with cloth or the like to disassemble or remove it.
(8) Note that spring may spring out when disassembling a valve or device which uses one or more
springs.
(9) Do not raise heavy thing forcedly by your hands. Using a chain block, lift it. Also, keep off under the
lifted heavy thing.
For the weight of major part, refer to the following:

Chapter 8, 8-2. Principal Part Mass for Disassembly & Servicing

(10) Use the proper tools. Use an exclusive tool upon understanding its function.
☆ Carefully check for any damages to rubber hose and joints of hydraulic jacks. The high-pressure
oil may spout out from a damaged portion during operation, causing you to get an injury.
For how to use the hydraulic jack, refer to the following:

Chapter 7-0, 5) Handling Procedures for Hydraulic Jack (p. 7-5)

7-2
7.　MAINTENANCE SERVICING (Precautions in Dismantling)

2) Precautions in Dismantling, Servicing & Reassembly

Be sure to observe the following precautions because the performance of the product may be deteriorated
or the machine may break down if you neglect any of the following precautions.

(1) Prepare the necessary tools and spare parts in advance.

As for the exclusive tools, use the specified tools; as for the spare parts, use our genuine parts or
the parts specified by us.
(2) If any part is found to be damaged or not durable for further use as a result of check, be sure to
replace it. Besides, considering the schedule for next check, replace any part estimated not to be
durable until the next check.
Chapter 10. Clearances & Wear Limits of Major Parts

(3) During disassembly, cover any exposed opening with tape or clean cloth so as not to allow foreign
matters to enter it.
Incidentally, do not forget to remove the covering tape or cloth in reassembly.
(4) When disassembling jointed parts, check whether set marks have been stamped or not, and stamp
set marks, if found necessary.
(5) On the major bolts, the cylinder No., bearing No., marking for incorporating position and set mark
have been stamped at the time of manufacture. However, they can not serve as reference for tight-
ening indefinitely because the clamping seat may be worn and the bolts may be stretched in their
use. Using a set mark only as a guide, be sure to tighten each bolt to the specified torque, speci-
fied angle or specified hydraulic pressure.

Chapter 9. Table of Tightening Torques of Major Bolts

Besides, when any of these major bolts has been replaced with a new one, give the same marking as
that of the former on to the new one.

(6) Note that bolts and nuts to be used a the high heated area are made of materials differed from
those used elsewhere but of the same size. If wrong ones are used in reassembly, they become
difficult to be taken out at the next servicing.
(7) When disassembling each section of the engine, carefully check the bolts and nuts that are not
exposed during a run. If such a bolt or nut is loose, investigate the cause, take the proper actions,
and then tighten it.

7-3
7.　MAINTENANCE SERVICING(Precautions at Completion&Handing for Turning Gear)

3) Precautions at Completion of Maintenance Servicing

(1) Turning the flywheel and lubricating oil priming, check for abnormalities in various parts of the
engine.
(2) Be sure to incorporate the removed covers such as covers for rotating parts, heat shielding covers
for exhaust pipe and protective covers for heated region in position.

(3) After having used the turning bar, return it on the set position.
(3)’ After having used the turning device, return it to the GEAR OUT state.

(4) Record the nature of maintenance servicing rendered and replaced parts in the Engine Log.

4) Handling Procedures for Turning Gear Device

(Optional spec.) Drawing 7-1. Turning Device Equipped Point

The turning device is of the gear intermeshing type

and equipped below the air motor on the operating
side. When the turning gear is intermeshing, the
engagement/disengagement switch is actuated,
disabling a start of the engine.

Air Motor

Handle the turning device according to the following

procedures:

① Prepare the exclusive tools for turning.

Exclusive Tool Description Part No. Turning Device

Ratchet handle 147673 - 92851

Socket (M24) 42111 - 001850

② Detach the lock bar, loosen the two stopper lock bolts, and then take off the stopper from the slot  of
turning shaft.
③ Push in the shaft to the GEAR IN position.
④ Fit the stopper in the shaft slot  , and tighten the two lock bolts.
⑤ Attach the socket for turning and ratchet handle to the shaft, and then turn the flywheel.

Before disassembling or checking any moving part engage the turning gear with the flywheel and lock
it with the lock bar to prevent self-rotation of crankshaft.

2001.6.15R 7-4
7.　MAINTENANCE SERVICING (Handling for Hydraulic Jack)

The lock bar is used to prevent the crankshaft from turning itself during an overhaul checking work.
Set the turning gear in the intermeshing state, lock the turning shaft with the stopper, and then tighten
the lock bar.

⑥ After turning work, return the turning gear to the GEAR OUT position, fit the stopper in the slot  , and
then tighten the lock bolts and lock bar.

Drawing 7-2. Turning Device Handling Procedures

Turning Gear Shaft Look Bar

GEAR Flywheel
Look Bar OUT
Pos.

Turning Gear
Stopper GEAR IN
A
Pos.
Stopper Lock Bolt
B
Micro Switch

5) Handling Procedures for hydraulic Jack

Use a hydraulic jack in a work of loosening or tightening the cylinder head tightening nuts and main bear-
ing cap tightening nuts.
Furthermore, simultaneously loosen or tighten the four cylinder head tightening per cylinder or two main
bearing cap tightening nuts per main bearing.

If the hydraulic fluid leaks while the hydraulic jack is being used, the fluid may spout under a high
pressure, resulting in injury. Therefore, be sure to observe the following precautions:
○ Do not use the hydraulic jack with a rubber hose having a flaw or an oil leaking portion.
○ Do not put nor drop a heavy thing on any rubber hose.
○ Do not grip any rubber hose. Do not bring your face close to the jack or branch during a work.

1998.10.20R 7-5
7.　MAINTENANCE SERVICING (Handling for Hydraulic Jack)

Use the following exclusive tools for loosening and tightening each nut.

[Usage]
(1) When assembling the hydraulic jack, be sure to use the sealing tape at the threaded part so that there
will be no leakage.
(2) Connect the hydraulic pump and branch with 3 m long rubber hose.
(3) Connect two 1 m long rubber hoses to the branch.
(4) Use the hydraulic pump placed horizontally.
(5) To operate the hydraulic pump, use it, opening the air valve.
(6) When a hydraulic jack is used for the first time, the rubber hose is filled with the hydraulic fluid. There-
fore, when the hydraulic pressure begins to rise, loosen the air vent plug of hydraulic pump, and then
checking the oil volume, replenish the hydraulic fluid.
(7) If the hydraulic jack does not work even though the hydraulic pressure has risen to the specified
value, loose couples will be the cause.
Loosen the relief valve of hydraulic pump to lower the hydraulic pressure, and then check the con-
nection of couples.

[ Common Tools ]
Drawing 7-3(1/2). Hydraulic Jack Handling Procedures [Common Tools]

No. Exclusive Tool Description Qty.

① Hydraulic pump 1

② Connecting Piece 1 To Branch

③ Gauge damper 1

④ Pressure gauge 1 Air Vent Plug Relief Valve

⑤ Rubber hose, 3 m long 1

⑥ Branch 1

⑦ Rubber hose, 1 m long 4

⑧ Square elbow 2

Coupler, external
⑨ 4
threaded

⑩ Coupler, internal threaded 4

⑪ Hydraulic jack 4

⑫ Spacer 4

⑬ Handle 1

Piston

Body

Back-up Ring

O-ring

Back-up Ring

2003.7.11R 7-6
7.　MAINTENANCE SERVICING (Handling for Hydraulic Jack)

Drawing 7-3 (2/2). Hydraulic Jack Handling Procedures

[Cylinder Head Fitting Procedures] [Main Bearing Cap Fitting Procedures]

Notch Spacer Notch Spacer

(1) Clean the surrounding of cylinder head (or main bearing cap) tightening nuts.

Tighten the cylinder head (or main bearing cap) tightening nuts to their seating with use of the handle.

(2) Fit the spacer.

○ When attaching the hydraulic jack to a cylinder head, be sure to check that the notch of the spacer
fitting surface does not make a contact with the adjacent cylinder head. Otherwise, the spacer and
the cylinder head will be damaged. Only then, raise the hydraulic pressure.
○ When attaching the hydraulic jack to a main bearing, direct the handle insertion hole toward the
crankshaft.

(3) Attach the hydraulic jack to the cylinder head (or main bearing cap) bolt, and screw in the jack until it
adheres to the spacer.

Make sure that there is no differences in level between the piston of hydraulic jack and the end sur-
face of body of the jack.

(4) Connect the hydraulic jack, branch and hydraulic pump with rubber hose (couplers).

1998.10.20R 7-7
7.　MAINTENANCE SERVICING (Handling for Hydraulic Jack)

(5) Loosen the hydraulic jack by one full turn from the state of adhering to the spacer.

Be sure to check that the notch of the spacer fitting surface does not make a contact with the adjacent
cylinder head. Otherwise, the spacer and the cylinder head will be damaged as the accurate tighten-
ing force would not be attained. Only then, raise the hydraulic pressure.

(6) Close the relief valve of hydraulic pump, and operate the pump lever to raise the hydraulic pressure to
the specified value.

Specified hydraulic pressure: 58.8 ± 0.5 MPa (600 ± 5 kgf/cm2)

(7) Insert the handle into the holes of the nut through the hole of spacer, and then turn the nut.

○ When disassembling, loose the nut by seven to eight holes.

○ When tightening, turn the nuts for three to four holes to the fully seated state.

○ If the nut to be removed could not be turned with use of the handle, slowly raise the hydraulic pres-
sure, and then turn the nut.
The hydraulic pressure should not be raised above 63.7 MPa (650 kgf/cm2).
○ When tightening, check if the nut threaded part is not damaged or the couplers are not poorly con-
nected in the case where the number of turns of the nuts is few.

(8) Gradually open the relief valve of hydraulic pump to decrease the hydraulic pressure to the zero.
(9) Screw the hydraulic jack in until it adheres to the spacer, and then discharge the hydraulic fluid from
the jack.
(10) Disconnect the rubber hose of hydraulic jack, branch and hydraulic pump.
(11) Remove the hydraulic jack and spacer.

○ When disassembling, check if the bolts are not loose after removing the tightening nuts.
○ When reassembling, check that set marks of the nuts and bolts are in agreement.

1998.10.20R 7-8
7.　MAINTENANCE SERVICING (Handling for Hydraulic Jack)

[Maintenance Servicing of Hydraulic Jack]

(1) To prevent rusting, apply the lubricating oil to the hydraulic jack, and store it.
(2) Cap each coupler not to allow foreign matters to enter it, and then store it.
(3) As for oil to be sent out from the hydraulic pump, use hydraulic fluid whose viscosity grade is ISO
VG32.

Table of Hydraulic Fluid Brands (Viscosity grade: ISO VG32)

General hydraulic fluid
SUPPLIER Brand
[ Wear resistant hydraulic fluid ]
Tellus Oil C32
SHOWA SHELL
Tellus Oil 32

Super Hiland 32
NIPPON MITSUBISHI OIL
Super Hiland V32

Cosmo Epoch ES32

COSMO OIL
Cosmo Hydro AW32

JOMO Hydrax 32
JAPAN ENERGY ELF
JOMO Hydrax ES32

Daphne Hydraulic Fluid 32

IDEMITSU KOSAN
Daphne Super Hydro 32A

DTE Oil Light, Unipower 32

EXXON MOBIL
DTE 24 Oil, Unipower SQ32

2001.10.R 7-9
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

7-1. Cylinder Head & Its Accessories

Carbon accumulated on the surface of cylinder head exposed to combustion gas hinders combustion and
allows scale to adhere on the cooling water passage, reducing the cooling effect.
Besides, the thermal load during running of an engine may cause the head combustion surface to be
cracked. Therefore, periodically overhaul and clean the cylinder head. (Simultaneously, also remove and
check its accessories.)

7-1-1. Cylinder Head

1) Disassembling preparation

Prepare the following exclusive tools:

(1) Hydraulic pump & hydraulic jack ....... One set
Chapter 7-0, 5) Handling Procedures for Hydraulic Jack (p.7-5)

(2) Cylinder head lifting tool

No. Exclusive Tool Description Part No.

① Lifting tool body 146673 - 92310

② Cap nut 146673 - 92320

③ Eye nut 26620 - 160002

④ Bolt 26116 - 160452

2) Disassembly

Disassemble the cylinder head according to the following procedures:

(1) Close each valve of cooling water inlet and outlet, and drain the cooling water from the cylinder jacket.
(2) Detach the exhaust manifold cover.
Using an eye bolt (P/#26610 - 120002), lift the cylinder head.
(3) Remove the exhaust manifold.
(4) Disconnect the following pipe and accessories from the cylinder head.
Overflow oil pipe, fuel injection pump pinion lub. oil pipe, cooling water connection pipe, pressure
indicator cock, fuel injection pipe joint, fuel injection pipe cap nut and fuel injection pipe.
(5) Detach the bonnet, and remove the rocker arm shaft pedestal, suction/exhaust valve guards and push
rod.
(6) Remove the fuel valve tightening nut.
(7) Remove the protective cap of a cylinder head bolt.
(8) Using the hydraulic jack, remove the cylinder head tightening nut.
Chapter7, 7- 0. 5) Handling Procedures for Hydraulic Jack (p.7-5)

7-10
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

Drawing 7-4. Cylinder Head Disassembling Procedures

Bonnet Suc./Exh. Valve
Rocker Arm
Guard
Shaft Pedestal
Fuel Valve Cooling Water
Fuel Injection Pump
Tightening Nut Connecting Pipe
Pinion Lub. Oil Pipe
Push Rod

Overflow
Oil Pipe Pressure
Indicator Cock

(9) Lock the cylinder head lifting tool onto the fuel valve clamping bolt, and lift the cylinder head straight
up.

Drawing 7-5. Cylinder Head Lifting Procedures

○ Lightly tighten the cap nut ② to an extent that the
body ① does not become rickety.
○ When lifting the cylinder head, be careful not to
damage the hydraulic jack fitting threaded part of
the cylinder head bolt.

(10) Removal of the fuel valve

Remove the cap nuts ② , eye nut ③ and bolt
④ from the cylinder head lifting tool. Then,
attach the fuel valve drawing-out exclusive tool,
Fuel Valve
and draw out the fuel valve. Clamping Bolt

No. Exclusive Tool Description Part No.

⑤ Drawing-out bolt 146673 - 92330

⑥ Nut 26732 - 160002

Drawing 7-6. Fuel Valve Drawing-out Procedures

Attach the lifting tool body ① and drawing-out bolt ⑤

to the fuel valve guard. Tighten the nut ⑥ to draw out Lifting Tool Body
the fuel valve guard.

Fuel Valve Guard

7-11
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

For the maintenance servicing of fuel valve (disassembly, check, adjustment of fuel injection pres-
sure), refer to the following:
Chapter 6-3-5. Checking of Fuel Injection Valve & Adjustment of Injection Pressure

(11) Remove the valve rotators, cotters, valve springs, suction and exhaust valves.

○ The suction and exhaust valves use two cotters, respectively. In reassembly, fit the two cotters as
one pair to the valve to which the cotters have been previously fitted. (If not used the cotters as each
pair, an improper contact at the cotters may cause a breakage to the valves stem.
○ Taking care not to flaw the stem seal lip of a suction/exhaust valve guide, remove the suction and
exhaust valves, respectively.

Lock the cylinder head lifting tool body ① to the fuel valve clamping bolt with the cap nut ② . Remove a
valve rotator with the following exclusive tools.

No. Exclusive Tool Description Part No.

⑦ Rotator retainer 141616 - 92330

⑧ Handle support 146673 - 92360

⑨ Handle 139653 - 92340

⑩ Bolt 146673 - 92350

⑪ Nut 26706 - 120002

Drawing 7-7. Valve Rotator Detaching/Attaching Procedures

Cap Nut

Lifting Tool Body

Fuel Valve
Clamping Bolt
Valve Rotator
Valve Spring

7-12
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

(12) Disassemble the nozzle sleeve once every four years with use of the exclusive tool, check for corro-
sion in the water chamber side, and clean it.

○ Replace the packing and O-rings with new ones.

○ When incorporating the nozzle sleeve, apply Protec grease to the threaded part and packing seating
face, and tighten them to the specified torque.
○ After incorporating them, conduct the hydraulic test.

Test pressure: 0.7 MPa (7 kgf/cm2)

No. Exclusive Tool Description Part No.

⑫ Nozzle sleeve disassembling tool 146673 - 92250

Drawing 7-8. Nozzle Sleeve Disassembling Procedures

O-ring
Nozzle Sleeve

Packing

3) Checking & servicing of cylinder head

○ After having removed the cylinder head, cover the cylinder so as not to allow foreign matters to enter
the boost air chamber.
○ Not to damage the threaded part of a cylinder head bolt, cap it with a protective tube.
○ Do not use any gas burner to eliminate carbon adherent on the combustion surface and at the
exhaust port.
The loose exhaust valve seat and a deteriorated O-ring may cause a water leakage.

7-13
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

(1) Check the state of carbon adherent in the combustion chamber and at the suction and exhaust ports
(for your reference on determining the intervals for subsequent servicing). After clearing, carefully
check for cracks and corrosion.
(2) Check the state of scale in the water jacket part. Depended on the water quality, a lot of scale adheres
even in the water jacket part of a fresh-water cooled engine. Therefore, at least once every two years,
clean the water jacket part with a descaling agent, etc. (For example, Unicon 146 sold by Yanmar can
descale the water jacket part without overhauling the cylinder head while the engine is stopped.)
(3) Especially carefully check for flaws and foreign matters in the socket and spigot part of the cylinder
head fitting surface. If this part has been flawed or contaminated by foreign matters, a blow-bye
occurs during a run.
(4) Conduct the hydraulic test at least once every two years, and check whether water leaks from the
exhaust valve seat mated part.
Also, if the cylinder head is overheated due to a failure of cooling water system, conduct a hydraulic
test.

Test pressure: 0.7 MPa (7 kgf/cm2)

4) Reassembly

Reassemble the cylinder head in the sequence revers to disassembly, paying attention to the following
points:

○ Replace each packing and O-ring with new ones. If you cannot avoid using a packing or an O-ring
again, sufficiently check it for no flaws, deformation and deterioration before using it.
○ Apply the lubricating oil on the suction and exhaust valves, attach the same cotters as those used in
the disassembly to the respective valves, and fit them while taking care not to damage the lip of a
valve guide stem seal.
○ If a head packing of the same dimensions as that used previously is used, the top clearance
becomes the standard value and does not require any particular adjustment.
○ Check for no foreign mattes in the suction and exhaust passages of cylinder head, piston upper part
and boost air chamber of cylinder, and then incorporate the cylinder head.
○ When mounting the cylinder head on the cylinder liner, take care not to flaw the threaded part of a
cylinder head bolt.
○ Apply the grease or lubricating oil on the hydraulic jack fitting threaded part of the cylinder head bolts
to prevent the treaded part from being rusted.
○ Apply the lubricating oil to the head tightening nut. After being tightened, cap them with the protec-
tive caps.

After incorporation of a cylinder head, adjust the suction/exhaust valve head clearance.

Chapter 6, 6-3-6. Adjustment of Suc./Exh. Valve Head Clearance

7-14
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

7-1-2. Suction & Exhaust Valves Drawing 7-9. Markings for Suction&Exhaust Valve
Take care not to confuse the suction and exhaust
valves as they are of the same shape but made of Date of manufacturing
Marking
different materials. 1H37S12S1 S for suc. valve
1H3S12E E for exh. valve
W/Cr-plated stem
(M.D.O. spec.)
180AH3E E for exh. valve
(H.F.O. spec-nimonic)
1) Checking items
(1) Check for sulfuric acid corrosion and bend of the suction/exhaust valve stem, and measure the dimen-
sions.
If the clearance between the suction/exhaust valve stem and the corresponding valve guide exceeds
the usage limit value, replace either the valve or valve guide whichever is worn more than the other.
(2) Check for high-temperature corrosion of the valve poppet.

Correct the valve poppet tip part upon careful checking it because if it becomes too thin, it may be
chipped and the pieces may enter the combustion chamber and turbocharger, causing a secondary
damage. (However, do not grind the combustion surface side of the valve poppet part for this correc-
tion.)

(3) Check the state of blow-bye and carbon biting-in at the valve seat part, and according to the state,
grind the seat face.
(4) Measure the dimensions of the valve seat part. If the dimension have reached the usage limit values,
replace it.
(5) Check for cracks and corrosion of valve springs.

2) Suction/exhaust valve grinding

(1) Perform the initial valve grinding earlier than usual as indicated in Chapter 6, Table of Periodical
Checking. Judging the situation, determine the intervals of subsequent servicing.
(2) Checking the clearance between the valve guide and stem, replace the pertinent part, and then per-
form a valve grinding.

Chapter 10. Clearances & Wear Limits of Major Parts

(3) Apply the proper quantity of grinding compound to the valve to be ground, and elaborately grind the
valve with the specified grinding tool. Finally grind the valve with oil.

Drawing 7-10(1/2). Suc./Exh. Valve Grinding Procedures

Step2: Tighten the nut 1/4 turns. Step1: Make the nut free.
Step6: Loosen the nut 3/4 turns. Step7: Fully tighten the nut (3/4 further after it is seated).

Step3: Tighten the bolts.

Step5: Tighten the bolts. Suc. / Exh. Valve Drawing 7-10(2/2).

Grinding Tool

Holder A Hold Down

Step4: Press the holder B. Spring
Turn
Holder B Suc. / Exh. Valve Suc./Exh. Valve
Grinding Tool

2003.9.10R 7-15
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

(4) If a flaw on the seat face of a suction/

Drawing 7-11. Angle of Suc./Exh. Valve Seat
exhaust valve is so deep that it is
required to be corrected of the flaw by
grinding, finish grinding the valve seat
Suction Seat
part in an angle shown in the figure at
right and the outer periphery of the
d
valve seat part makes contact with the
0
valve (poppet). 120 - 30
+30
120 0
Exhaust Seat
Valve

0
120 - 30

7-1-3. Suc./Exh. Valve Seat

The suction/exhaust valve seat has been shrink fitted to the cylinder head. The exhaust valve seat is of the
cooled type.

1) Checking & servicing

Do not use any gas burner to eliminate carbon adherent on the combustion surface and at the
exhaust port.
Otherwise, the exhaust valve seat may become loose or the O-rings may be deteriorated, resulting in
a water leakage.

(1) Check the state of blow-bye and carbon biting-

Drawing 7-12. Valve Seat Correcting Procedures
in of the valve seat part. According to the
(Rough Finishing)
state, grind the seat face. Since the satellite
has been built on the valve seat face, if a flaw
on it is so deep, correct it with use of a rough
correcting seat cutter (with grinder), and then
grind the valve seat part. (The seat cutter is
optionally available.)

(2) Check for water leakage at the exhaust valve seat mated part.
(If a water leakage is found, replace the valve seat.)
(3) Measure the contact diameter of the valve seat part. If the measurement exceeds the usage limit
value, replace the valve seat with a new one.

7-16
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

2) Replacement of the valve seat

Replace the valve seat according to the following

procedures: Drawing 7-13. Valve Seat Removing Procedures

(1) Removal of the valve seat Iron Plate

Build up the whole circumference of the valve
seat face by arc welding to remove the valve Arc Welding
seat. Valve Seat
If the exhaust valve seat is difficult to remove
because of the O-rings incorporated in it, fur-
ther weld an iron plate to the valve seat, and
hammer out the valve seat through a round
rod driven into the valve guide.

(2) Incorporation of the valve seat

① Check for flaws, hit mark and burr on the valve seat inserting hole of a cylinder head and on the
outer periphery of the valve seat. If found, correct it.
② Measure diameter of the seat valve and the seat valve inserting hole, and confirm the interference.

[ Interference for the Value Seat ] (Unit: mm)

Suction valve seat 0.045 ～ 0.095

0.039 ～ 0.072 (59φpart)

Exhaust valve seat
0.069 ～ 0.102 (67φpart)

③ Heat the whole cylinder head to 40 to 60 ℃ . The appropriate heating is by steam cleaning.
④ Chill the valve seat with liquid carbon dioxide. If liquid carbon dioxide is not available, soak it in the
mixed solution of a small lump (10 kg) of dry ice and alcohol (1.5 lit.) for 1 hour or longer to chill it.

Chill the exhaust valve seat with O-rings incorporated to it. Do not use liquid nitrogen. Otherwise, the
O-rings will be hardened and broken when the valve seat is inserted in the cylinder head.

Drawing 7-14. Exhaust Valve Seat Inserting Procedures

Just before inserting the exhaust valve seat
into its hole of the cylinder head, apply the
seizure inhibitor (spray) and silicone-based
liquid packing (Three-Bond 1211 or its
equivalent) to the inserting hole.

Liquid Packing
: Seizure Inhibitor (spray)

2003.9.10R 7-17
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

⑤Using the suction valve (or exhaust valve), rapidly

Drawing 7-15. Valve Seat Inserting Procedures
insert the valve seat into its hole on the cylinder
head. INSERT
Valve Seat

Take care not to tilt the valve seat. Apply a load

for one to two minutes on the valve seat to avoid
insufficient adhesion to its inserting hole.

After having replaced the exhaust valve seat, be sure to conduct the hydraulic test to make sure no
water leaks from the mated part.

Test pressure: 0.7 MPa (7 kgf/cm2)

7-1-4. Suc./Exh. Valve Guide

The suction/exhaust valve guide has been shrink fitted and inserted and incorporated with the stem seal.

1) Checking & servicing

Drawing 7-16. Valve Guide Removing Procedures
(1) Measure the clearance between the suction/
exhaust valve guide and the valve stem. If
the measurement exceeds the usage limit
value, replace the valve guide or valve.
(2) Replace the stem seal at every servicing. 24 Doubling Rod

2) Removal of the valve guide HAMMER

Draw out the suction/exhaust valve guide by ham-

mering it from the valve side through a stepped
doubling rod.

3) Incorporation of the valve guide

Chill the valve guide with liquid nitrogen, liquid carbon dioxide or the like, and then press fit it.

Interference: 0.001 ～ 0.035 mm

When press-fitting the valve guide, hold the flange part of the valve guide.

7-18
7.　MAINTENANCE SERVICING (Cylinder Head & Its Accessories)

4) Incorporation of the stem seat

Incorporate the stem seal with use of a jig so as not to damage the stem seal lip.

7-1-5. Suc./Exh. Valve Bridge & Its Guide

The valve bridge guide has been shrink fitted in the cylinder head.
If the engine is used under the condition that there is an excessive clearance between the valve bridge and
valve bridge guide, the valve bridge may fall while the suction/exhaust valve is working, causing a malfunc-
tion of the valve, uneven wear of the valve guide or damage of suction/exhaust cam.

1) Checking & servicing

If the clearance between the valve bridge and valve bridge guide exceeds the usage limit value, replace
either the valve bridge or valve guide whichever is worn more than the other.

2) Replacement of the valve bridge guide

Chill the valve bridge guide with liquid nitrogen or liquid carbon dioxide, and then press fit it into the cylin-
der head.

7-1-6. Valve Rotator

Improper rotation of the valve rotator will cause carbon to be bitten in the valve seat part, causing blow-bye
at the seat part and affecting the service life of the valve and valve seat. Therefore, periodically overhaul
and check the valve rotator.

To take out the valve rotator without disassembling the cylinder head, set the piston at the T.D.C. of
the compression stroke, and then remove the valve rotator.
Drawing 7-7. Valve Rotator Detaching/Attaching Procedures (p.7-12)

1) Checking & servicing

Remove the circlip, and check each part. If any of

the following defective parts is found, replace it. Drawing 7-17. Valve Rotator
I
① Wear (at the body groove) and corrosion of Body
Belleville spring Belleville Spring
Spring Shoe
② Wear (deformation) and corrosion of ball I
Circlip
③ Wear and breakage of coil spring
④ Wear of the body groove
Coil Spring

Ball

View I-I
A

7-19
7.　MAINTENANCE SERVICING (Piston & Connecting Rod)

2) Incorporation
① Incorporation the coil springs, balls and Belleville spring in the proper direction.
② After incorporation, make sure of the clearance  .

7-2. Piston & Connecting Rod

The frequency of piston drawing-out check varies according to the daily maintenance, especially the lubri-
cating oil control and load (overload and excessively low load). Therefore, the supervisor is required to
decide the proper frequency. However, the initial overhaul and check should be performed at the time men-
tioned in Chapter 6. From then on, decide the subsequent check schedule according to the overhaul
checking results, an increase of blow-by and an increase in lubricating oil consumption. When the lubricat-
ing oil consumption has become twice the initial value, overhaul and clean the piston, and replace the pis-
ton rings.

7-2-1. Piston & Piston Pin

1) Disassembling preparation

Prepare the following exclusive tools:

[For Disassembling the Connecting Rod Bolt]

Exclusive Tool Description Part No.

Socket wrench for connecting rod bolt 146673 - 92850

Handle 138987 - 92760

Lock nut 239653 - 92770

[For Disassembling the Protection Ring]

No. Exclusive Tool Description Part No.

① Drawing-out plate, protection ring 146673 - 92060

② Liner drawing-out upper implement 146673 - 92010

③ Spacer 139653 - 92040

Eye bolt, piston lifting 26610 - 120002

2006.1.20R 7-20
7.　MAINTENANCE SERVICING (Piston & Connecting Rod)

2) Piston drawing-out

While you are drawing out or incorporating the piston, the crankshaft may turn spontaneously due to
the unbalance. This is dangerous. Securely lock the flywheel not to allow the crankshaft to turn. Mak-
ing sure the crankshaft does not turn spontaneously, proceed to a work.
Chapter 7-0, 4) Handling Procedures for Turning Device (p.7-4)

(1) Set the piston at a position of about 80 to 90°

before the T.D.C. Drawing 7-18. Protection Ring Drawing-out Procedures
(2) Place the protection ring drawing-out tool ① on Cyl. Head
the piston. Tightening Nut

Place the tool so that its outer taper faces toward

the piston and do not allow it to make contact with
Protection Ring
the cylinder liner.

(3) Install the liner drawing-out upper implement ②

and spacer ③ in the cylinder block as shown in Tapered
Drawing 7-18. Afterwards, fix the tools with the Part
cylinder head tightening nut.
(4) Turn the flywheel, and remove the protection ring.
(5) Remove the disassembling tools and protection ring.
(6) Eliminate the carbon from the upper part of cylinder liner.
(7) Set the piston at a position of about 30°after the T.D.C.
(8) Loosen the connecting rod bolts with the specified disassembling tool, and then remove the bolts and
metal cap.
(9) Screw the lifting eyebolt into the piston, and lift it by 20 to 30 mm.
(10) Remove the upper metal, and draw out the piston.

Take care to prevent the connecting rod from making a contact with the crankshaft or cylinder liner.

3) Removal of the piston pin & piston rings

(1) Remove the piston pin circlips with use of pliers (P/#28190 - 000130).

Note that the circlip springs out to cause an injury if the tip of pliers come out of the groove of circlip in
course of removing the circlip.

2006.1.20R 7-21
7.　MAINTENANCE SERVICING (Piston & Connecting Rod)

(2) Draw out the piston pin while holding the connecting rod.
(3) Make two loops from wire, and then remove a piston ring with them.

Wear gloves because the corners of rings will be sharp edged to cause you an injury after a long time
of run.

Be careful not to widen the cut of a ring by more than 40 to 50 mm; otherwise, the ring may be bro-
ken.

4) Checking & servicing

Check the state of carbon adherent on the piston and the state of wear various parts. Refer to these check-
ing results in deciding the subsequent check schedule.

Drawing 7-19.
Penetrate Test for Cracks on Piston
In cleaning of the piston, do not sandpaper the pis-
ton skirt which has been provided with special coat-
ing. (Washing the piston with a carbon removing
agent such as Unicon 146 and Neos is recom-
mended.)

(1) Check the contact of piston skirt and piston hole.

(2) Check the piston by 『Penetrate Test』for cracks
on its top surface and ring groove (outside &
inside).
(3) Remove the piston cooling case cover, and check
for adherent scale. Drawing 7-20. Piston Incorporating Procedures
(4) Measure the dimensions of various piston parts Piston Set Mark Marking on Ring
and of the piston pin.
T
(5) If possible, replace the piston rings with new
ones, considering the time to the next servicing. 2T
(6) If the piston is replaced with the new one, provide
the same set mark on the new one as that on the T

previous one. Cut

Circlip Opening
5) Incorporation of the piston

Incorporate the piston in the sequence reverse to

drawing-out, paying attention to the following points:
(1) Incorporate the perforated piston cooling case Coil Joint
Set Mark
cover on the operating side, apply a proper Piston Cooling Case Cover
screw lock agent (Tokyo Three-Bond Screw Lock (Perforated)
No.1 or its equivalent) on the bolts, and tighten
them to fix the cover.
(2) Incorporate the piston pin circlip with its opening
facing straight down.
(3) Incorporate the piston rings with their marked
sides facing upward and their cuts shifted 120°
from those of adjacent rings.

2001.2.28R 7-22
7.　MAINTENANCE SERVICING (Piston & Connecting Rod)

Piston ring groove plating repaired piston.

If the piston top ring groove have been repaired with Cr-plating, do not use the 3-face Cr-plated top
ring.

(4) Incorporate the oil ring with its coil joint shifted 180°from its cut.
(5) Incorporate the piston and connecting rod, aligning their set marks with each other.

Do not apply the lubricating oil on the rear of crank-pin metals.

(6) Apply the lubricating oil to the piston, cylinder liner and crankshaft.
(7) Set the piston inserting guide (P/#146673 - 92140),
and incorporate the piston.
Drawing 7-21. Piston Reassembling Procedures
(While tapping the piston with a resin hammer,
drive the piston down.)
(8) Tighten the connecting rod bolts.
Piston inserting Guide

If you have restamped the set mark on a connecting

rod bolt, do not mistake the new set mark for the pre-
vious set mark.

Chapter7, 7-2-4. Connecting Rod Bolt (p.7-24)

7-2-2. Connecting Rod

1) Checking & servicing
(1) Check the contact and looseness in fit of piston-pin metals.
(2) Measure the inner diameter of a piston-pin metal. If the measurement exceeds the usage limit value,
replace the piston-pin metal. Remove the piston-pin metal either by hammering it out through a dou-
bling metal or by drawing it out with a press so as not to flaw the metal inserting hole.
To incorporate the piston-pin metal, align oil holes and press fit the metal. After having press fitted,
measure the inner diameter of the metal.
(3) Check for cracks and wear on the serration mating surface of the connecting rod big end.

If a water hammer has occurred or a heavy burnout of the piston has been detected, measure the
bend and inclination of the connecting rod, and dye check for cracks.

Criteria for simple bend check

Draw out the piston-pin metal, detach the oil hole plug on the small end, and try to insert a 10-mm dia.
bar or long drill into this plug hole and to turn the bar or drill.
If the connecting rod is bent, the bar or drill cannot be inserted, or it can be inserted but cannot be
turned.

2002.5.15R 7-23
7.　MAINTENANCE SERVICING (Piston & Connecting Rod)

7-2-3. Crank Pin Metal

1) Checking & servicing

Be sure to replace both the upper and lower crank-pin metals as a pair.

(1) Check the contact on the rear and mating

surface of each metal, and also check for Drawing 7-22. Metal Thickness Measuring Points
cranks, seizure and imbedded foreign mat-
Approx. 40mm A
ters on the sliding surface of each metal.
(2) Incorporate the crank-pin metals to the con-
necting rod, and tighten the connecting rod
bolts to the specified angle. Then, measure B
the inner diameter of the metals. If the mea-
surement exceeds the usage limit value, Approx. 40mm
replace the metals. C
(3) Measure the thickness of the upper and
lower metals. If the difference between the
dimensions  &  and the dimensions  &
 is 0.04 mm or more, replace the metals.
(4) When incorporating the metals to the connecting rod, clean them not to allow biting-in of foreign mat-
ters. Moreover, do not apply the lubricating oil the rear of the metals.

7-2-4. Connecting Rod Bolt

1) Checking & servicing

(1) Checking for hit mark and plucking on the bearing surface and threaded part of each bolt. If any defect
is found, correct it.

(2) When disassembling a connecting rod, be sure to restamp the set mark which has been stamped
on each connecting rod bolt just before the shipment from our shop because the tightening torque
of the bolt varies as depended on accustoming of the bolt threaded part and bearing surface and
the big end serration mated surface.

(3) To prevent the bolts from being broken due to fatigue, replace them about every 20,000 hours even if
their appearance is normal.

2003.9.10R 7-24
7.　MAINTENANCE SERVICING (Piston & Connecting Rod)

2) Reassembling procedures
(1) Be sure to incorporate the bolts at the respectively previous positions.
(2) Before tightening the bolts, apply the lubricating oil to the treated part and Protec grease to the bear-
ing surface.
(3) Tighten the upper and lower bolts gradually in the three steps (approx. 40° , 80°and 120° ), aligning
with the set mark to the point  on the connecting rod.
● Keep the deviation between the set mark of the bolt and the set mark of the connecting rod in less than
2 mm in the bolt tightening direction.

3) Bolt set mark stamping procedures

The connecting rod bolts are tightened to the specified angle. On the connecting rod, the marks indi-
cating the specified angle (120°) are stamped (at two points  &  ).

Stamp a set mark on each bolt according to the following procedures under the condition that the
crank-pin metals are not equipped.

(1) Apply the lubricating oil and Protec grease to each bolt, and screw it to its seating by hand.
(2) Using a torque wrench, tighten the bolt to the seating torque.

After replacing connecting rod bolts or the connecting rod, repeat tightening the bolts by about 90 °
and loosening them three or four times to make the bolts and the connecting rod accustomed each
other.

Seating torque: 49 N ･m (5 kgf ･m)

(3) Stamp a temporary set mark on the side of the

bolt collar, aligning with the set mark at the Drawing 7-23. Connecting Rod Bolt Marks
point  on the connecting rod.
Temporary
(4) Tighten the upper and lower bolts gradually in Set mark
the three steps (approx. 40° , 80°and 120° ),
aligning with the set mark to the point  on the 㧭 120q

connecting rod.
B B
(5) Stamp a set mark on the side of the bolt collar,
aligning with the set mark at the point  on the
120q㧭
connecting rod. Set mark

After replacing connecting rod bolts and the con- Set mark B
necting rod, stamp the same Cylinder No., Bolt
No., etc. as those stamped on the previous ones.

1999.6.25R 7-25
7.　MAINTENANCE SERVICING (Cylinder Block & Cylinder Liner)

7-3. Cylinder Block & Cylinder Liner

7-3-1. Cylinder Block
Excluding some special case such as burnout of the crankshaft, ordinarily removal of the cylinder block is
not necessary. When the cylinder head, piston, cylinder liner, etc., are removed, perform the following
check and servicing:

1) Checking and servicing

(1) Check for loose cylinder head bolts and main bearing cap clamping bolts.

● When replacing a bolt with damaged thread...

Apply a seizure inhibitor (Sumitomo Metal Mining’s Low Call Spray or its equivalent) to the
threaded part on the studded side, and incorporate the new bolt.
Studding torque: 196+490 N ･ m (20+50 kgf ･ m)
● Incorporate the O-ring on the studded side, and apply white paint.

Drawing 7-24. Cylinder Block Checking Points

O-ring

Boost
Air
Chamber

(2) Clean the boost air chamber. If the rust preventive paint applied on its inner surface has peeled off,
repair it. (Epoxy resin paint: Nippon Paint’s Hi-Pon 50 or its equivalent)
(3) Clean the water jacket and cylinder liner fitting part, and check for corrosion.

If a main bearing metal has been burnt out, measure the accuracy of main bearing cap hole.
Straightness: 0.03 mm or less in 1 mm of length
Roundness: 0.02 mm or less

7-3-2. Cylinder Liner

● Periodically measure the inner diameter of cylinder liner because the extent of wear of inner surface of
cylinder liner varies as depended on the control on lubricating oil used, cooling water temperature and
normal load.

Measure the inner diameter of cylinder liner under the condition of being incorporated in the cylinder
block and with use of the inner diameter position measuring implement (P/#42111-002930).

● Periodically draw out the cylinder liner, and check for corrosion of cylinder liner because cooling water
may cause cavitation at the cylinder liner water jacket and erode from the outer surface of cylinder liner.

2003.9.10R 7-26
7.　MAINTENANCE SERVICING (Cylinder Block & Cylinder Liner)

1) Disassembling preparation
(1) Prepare the following exclusive tools:

No. Exclusive Tool Description Part No.

① Spacer 139653-92040

Liner drawing-out upper

② 146673-92010
implement

③ Bolt 137655-92030

④ Washer 22137-240000

⑤ Nut 26732-240002

Liner drawing-out lower

⑥ 146663-92020
implement

⑦ Nut 26732-240002

⑧ Lock nut 26772-240002

(2) When drawing out the cylinder liner, cover the crankshaft with a sheet or the like to prevent water and
foreign matters from entering the crankcase.

2) Disassembly
Remove the cylinder liner according the following procedures:
(1) Attach the exclusive tools in the ascending order of numerals shown in Drawing 7-25.

Attach the aforementioned upper implement ② and the lower implement ⑥ so that their respective
stepped parts face the inner diameter side of the cylinder liner and the lower implement ⑥ in the
direction of the crankshaft.

(2) Adjust the length of protrusion from the lower part of the drawing-out bolt ③ to about 60mm, and lock
the drawing-out bolt ③ with the lock nut ⑧ .
(3) While supporting the cylinder liner to prevent it from making contact with the cylinder, tighten the nut ⑤ .
(4) Fit the cylinder liner in the stepped part on the lower side of the upper implement ② , and lock the cyl-
inder liner with the drawing-out tools.
(5) Attach a wire rope to the upper implement ② , and lift the cylinder liner.
Drawing 7-25. Cylinder Liner Drawing-out Procedures

Abt. 60mm

2003.7.11R 7-27
7.　MAINTENANCE SERVICING (Cylinder Block & Cylinder Liner)

3) Checking & servicing

Do not use sand paper, wire brush, or the like when cleaning the outer periphery of cylinder liner. Oth-
erwise, the heat-treated layer on the surface is removed to cause rusting or corrosion.

(1) If the measurement on the inner diameter of a cylinder liner exceeds the usage limit value or if the
measurement is expected to reach the usage limit value before the next servicing, replace such a cyl-
inder liner.
(2) Check for seizure, streak and corrosion on the sliding surface of cylinder liner.
(3) Dye check the rounded part of collar of cylinder liner for cracks.
(4) Check for corrosion and wear at the part of cylinder liner mated with the cylinder block.

4) Reassembly
(1) Replace the O-rings of cylinder liner. Apply the lubricating oil or silicone oil to new O-rings, and fit
them. Then, eliminate torsion from the O-rings.

Before incorporating the O-rings, stretch them to check whether a crack has developed or not on their
surface due to a change of temperature and humidity, for instance, with time if stored under improper
condition.

(2) Just before incorporating the cylinder liner, apply the silicone-based liquid packing (Three-Bond 1211
or its equivalent) to the upper section of cylinder block. Moreover, apply the lubricating oil to the
mated part of the cylinder liner and block.
(3) Attach the aforementioned exclusive tools ② thru ⑧ to the cylinder liner. Then, aligning the mark
0 (zero) of the cylinder liner and the punched mark of the cylinder (block), incorporate the cylinder
liner into the cylinder, block. (Do not use the spacer ① for this incorporation.)

After having overhauled and serviced the cylinder liner, check for a water leakage form the O-ring part
when filling the water tank with cooling water and when running the engine for testing.

Drawing 7-26. Liquid Packing & Lub. Oil Applying Points

Liquid Packing

Lub. Oil

Lub. Oil

7-28
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

7-4. Main Bearing & Crankshaft

Each throw of the crankshaft is equipped with two balance weights of which shape varies with the service
rotatory speed of a machine driven by the engine.
At the timing gear case behind the journal for the No.1 cylinder, another main bearing is mounted, and fur-
ther at the head, a thrust bearing is incorporated. Thus, this crankshaft is equipped with eight bearings in
total.
The main bearing cap is of the suspension metal structure fixed to the cylinder block with two clamping
bolts (with the tightening nuts tightened to the specified hydraulic pressure) and two side bolts (tightened to
the specified torque).

Side bolts
The side bolts for the datum part (No.0) main bearing cap are equipped only on the non-operating
side. To the No.1, 2, 6 & 7 main bearing caps, side bolts of different lengths are provided to clamp
also the engine supporting feet.

Drawing 7-27. Main Bearing Numbers

Cyl. No. No.6 No.5 No.4 No.3 No.2 No.1

Main brg. cap No. 7 6 5 4 3 2 1 0

Tightening nut On the op. side 71 61 51 41 31 21 11 01
stamped No. On the non-op. side 72 62 52 42 32 22 12 02

7-4-1. Main Bearing

Any main bearing cap cannot be taken out through the cylinder side cover. Check or replace a main bear-
ing metal from the operating side according to the following procedures:

1) Disassembling preparation
(1) Prepare the following exclusive tools:
[For the hydraulic pump & hydraulic jack type]
Chapter7, 7-0. 5) Handling Procedures for Hydraulic Jack (p.7-5)

7-29
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

[Main Bearing Cap Drawing-out Implement]

No. Exclusive Tool Description Part No.

① Body 146673-92100

② Mounting bolt (M10 × 60) 26206-100602

③ Drawing-out bolt 26206-121554

④ Nut 26706-120002

[Main Bearing Cap Holding Implement]

No. Exclusive Tool Description Part No.

⑤ Bolt 146673-92120

⑥ Circular nut 146673-92110

[Upper Metal Detaching/ Attaching Implement]

No. Exclusive Tool Description Part No.

Upper metal detaching/

⑦ 146673-92970
attaching pin

Upper metal inserting

⑧ 146673-92950
implement

(2) To facilitate the check or replacement work, set the piston adjacent to the main bearing to be disas-
sembled at a position about 120°before the T.D.C.

2) Disassembly
(1) Fit a hydraulic jack, and connect it with a hydraulic pump.

Take out t the rubber hose in a direction to facilitate the work.

Drawing 7-28. Hydraulic Jack Fitting Procedusres

Direction of Rotation

120q

Side Bolt Side Bolt

Chapter7, 7-0. 5) Handling Procedures for Hydraulic Jack (p.7-5)

7-30
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

(2) Remove the side bolts from the main bearing to be disassembled.
(3) Loosen the main bearing cap clamping nuts, applying the hydraulic pressure to the hydraulic jack.

If the main bearing cap cannot be drawn out due to its own weight:
○ Loosen the side bolts of the adjacent main bearing caps.
○ Loosen the main bearing cap tightening nuts two to three turns, and then draw out the main
bearing cap using the drawing-out tools.

Lock the drawing-out tool body ① to the main bearing cap bolts with the bolts ② . Then, screw the
bolt ③ to the main bearing cap, and turn the nut ④ to draw out the main bearing cap.

(4) Remove the main bearing cap tightening nuts, and attach the main bearing cap holding implement to
the main bearing cap clamping bolts.

Drawing 7-29. Main Bearing Cap Drawing-out Procedures

Do not remove both tightening nuts simultaneously. Otherwise, the main bearing cap may fall,
resulting in injury.

Screw each circular nut ⑥ into the corresponding holding bolt ⑤ to lock the holding bolt with the corre-
sponding main bearing cap clamping bolt. Adjust the position of circular nuts to make them hold the
main bearing cap.

Drawing 7-30. Main Bearing Cap Holding Procedures

7-31
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

(5) Remove the main bearing lower metal.

(6) Remove the upper metal.

Fit the attaching/ detaching pin ⑦ to the crankshaft oil hole from the no-operating side (so that the
head of attaching/detaching pin lies along the outer periphery of crankshaft). Slowly turn the fly-
wheel in the direction of engine rotation, and draw out the upper metal to the operating side.

Disassembly & Reassembly of No.0 bearing cap

Thrust metals are equipped on both the front and the rear of the datum part (No.0) main bearing cap.
● Remove the lub.oil pump and side bolt on the non-operating side first, and then disassemble the
No.0 bearing cap in the same way as for the No.1 thru 7 main bearing caps.

Drawing 7-31. Metal Drawing-out Procedures

Notch (pawl) Notch (pawl)

3) Checking & servicing

Carefully check and service the main bearing metals. If the clearance between the crankshaft and
the main bearing metals becomes too large, the lubricating oil pressure drops to burn out the metals
and increase the deflection of crankshaft, possibly resulting in serious accidents such as a breakage
of the crankshaft.

(1) Check for hit marks and flaws on the mated and fitted surfaces of main bearing cap with and to the
cylinder block.
(2) Check for hit marks on the mating surface and rear of the main bearing metal, and also check for
flaws, seizures and imbedded foreign matters on their sliding surface.

Do not correct the rear and slicing surface of any main bearing or thrust metal because such a
corrective repair changes the clearance between the metal and the crankshaft.

Drawing 7-32. Thrust Metal Fitted State

Upper Metal, therust
Lub. Oil Pump

Side Bolt

Lower Metal, therust

7-32
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

(3) Check for looseness of main bearing cap clamping bolts.

Studding torque: 196+490 N ･ m (20+50 kgf ･ m)

(4) Measure the clearance between the crankshaft and the metal.

① An accurate method of measuring the clearance is to remove the crankshaft and then to mea-
sure its outer diameter and the inner diameter of a main bearing cap.
② To obtain the clearance without removing the crankshaft, place and about 0.5-mm dia. lead wire
on the sliding surface of main bearing lower metal (along the outer periphery of crankshaft to
prevent the lead wire from slipping with grease, etc.), tighten the main bearing cap tightening
nuts to the specified hydraulic pressure, take out the lead wire, and then measure its thickness.
You can determine the clearance between the crankshaft and metal from this thickness.

(5) If the clearance exceeds the maximum allowable value due to wear of the metal, replace it with the
new one.

When replacing the metal, be sure to replace both the upper and lower metals as a pair.

If the crankshaft is excessively worn (unevenly worn), replace the metals with undersized metals.
Also, it is necessary to rework the crankshaft by polishing it so that it fits with the new undersized metals.

[Thrust metals]
(1) Check for wear and burnout.
(2) If the clearance exceeds the maximum allowable value due to wear, replace both the upper and lower
metals as a pair.

Drawing 7-33. Thrust Clearance Measuring Procedures

Crank Shaft

Dial Gauge

Thrust Metal

① Fix the dial gauge stand to the cylinder block. Put the dial gauge in contact with the crankshaft.
Then, move the crankshaft forward to set the indication of the gauge to zero.
② Move the crankshaft backward. Then, read the value indicated by the gauge. The indicated
value is the thrust clearance.

7-33
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

(3) When incorporating thrust metals, observe the following points:

① Incorporate each one of the upper and lower metals of the frontal and rear parts at the respective
former point, not mistaking one for other.
② Incorporate the upper metal by mating its printed part with the cylinder block side and sliding it
along the crankshaft.
③ Incorporate the lower metal, mating its groove with the crankshaft side.

4) Incorporation of main bearings

Reassemble main bearings in the following sequence:
(1) Turn the flywheel to lower the oil hole in the crankshaft below the center of crankshaft.
(2) Directing the pawl of the upper metal toward the non-operating side, insert the upper metal along the
crankshaft.

Drawing 7-34. Upper Metal Incorporating Procedures

Rounded End Stepped End
Operating Side Non-operating Side

Main Brg. Cap Pawl Hole

Clamping Bolt

Pawl Hole

Pawl

Position the upper metal in the forward-backward direction so that its pawl will mate with the pawl
hole in the cylinder block.

(3) Attach the upper metal inserting implement ③ to the main bearing cap (from which the lower metal is
detached).

Attach the implement, mating its one curved end with the outer periphery of a main bearing cap
clamping bolt on the operating side and aligning the other stepped end with the inner periphery (on
the pawl hole side) of main bearing cap.

(4) Insert the attaching/ detaching pin ⑦ to the crankshaft oil hole on the non-operating side.

Put the head of metal attaching/ detaching pin along and in close contact with the outer periphery of
crankshaft with the proper grease so as not to allow the pin to fall during turning.

(5) Tighten the circular nuts ⑥ of the main bearing cap holding implement until the upper metal inserting
implement ⑧ is about to make contact with the rear of the upper metal.

7-34
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

(6) Slowly turn the flywheel in a direction reverse to the direction of engine rotation.

Make sure the side of pawl of the upper metal is in contact with the side of the metal inserting imple-
ment. If they are not in contact, the pawl does not fit in the pawl hole.

(7) When the pawl of the metal has been aligned with the pawl hole in the cylinder block, continue turning
the flywheel until the metal end aligns with the cylinder block end.
(8) Loosen the circular nuts ⑥ to lower the main bearing cap. Remove the metal attaching/ detaching pin
⑦ and metal inserting implement ⑧ . Then, incorporate the lower metal.
(9) Tighten the circular nuts ⑥ and remove the holding bolts ⑤ . Then, fit main bearing cap tightening
nuts.

Fit the tightening nuts one side a time. When a main bearing cap falls under its own weight, there is a
fear you might be injured.

(10) Tighten the nuts until the main bearing cap makes a close contact with the cylinder block.

If the side bolts of main bearings adjacent to the main bearing involved in disassembly have been
loosened, first tighten the side bolt on the non-operating side, and then the side bolt on the operat-
ing side to the specified torque.

(11) Tighten the side bolt on the non-operating side to half of the specified torque. (Have the bolt on the
operating side removed in advance.)
(12) Tighten the side bolt on the operating side to its seating by hand.
(13) Tighten the main bearing cap tightening nuts to the specified hydraulic pressure.
(14) Tighten the side bolt on the non-operating side to the specified torque.
(15) Tighten the side bolt on the operating side to the specified torque

After incorporating the main bearing, measure the crankshaft deflection.

Chapter 6, 6-3-17. Measurement of Crankshaft Deflection (p.6-34)

7-35
7．MAINTENANCE SERVICING (Main Bearing & Crankshaft)

7-4-2. Crankshaft
The crankshaft requires careful checking and measurement because it may be broken or burnt out if you
continue running under the following states of crankshaft:

① Uneven wear of crankshaft

② Excessive clearance between the crankshaft and main bearing metal due to wear of crankshaft
③ Running exceeding the allowable value of crankshaft deflection
④ Running at critical region of torsional vibration rotatory speed.

1) Disassembling procedures
In either case of removing the crankshaft downward by lifting the engine or removing the crankshaft up
ward by inverting the engine, fit the rope to the No.2 & 5 crank-pin parts, and remove the crankshaft verti-
cally. (The engine lifting tool is optionally available.)

2) Checking & measurement

(1) Check for flaws, improper contact and abnormal wear of the bearings.
(2) Dye the root rounded part of crank arms.
(3) Check for looseness of balance weight clamping bolts.
(4) Measure the dimensions of bearings and check for uneven wear.
(5) Measurement of crankshaft deflection
For measuring procedures, refer to the following:

Chapter 6, 6-3-17. Measurement of Crankshaft Deflection

Drawing 7-35. Crankshaft Bearing Part Measuring Points

In a burnout of the crankshaft bearing part, not only the correction and replacement o main bearing or
thrust metals but also check for hair cracks through measurement of the surface hardness and mag-
netic flaw detection.

Crank shaft surface hardness Should be HS 65 ～ 85.

Hair crack Should not be detected.

7-36
7．MAINTENANCE SERVICING (Timing Gear)

7-5. Timing Gear, Camshaft & Suc./Exh. Swing Arm

7-5-1. Timing Gear
Even under the condition of normal operation, there is a wear of gears. This may cause a pitching wear,
plucking and hair cracks on the tooth surface.
Besides, since the wear is related to noise and vibration periodically check the backlash of gears and con-
tact of tooth surface.
When disassembling the timing gears, measure the backlash of gears, If the measurement exceeds the
allowable value, replace the pertinent gear of bearing with the new one.

A set mark is stamped on the side of crank gear, idle gear A, idle gear B and cam gear. When assembling
the timing gears, set the No.1 (or No.6) cylinder at the B.D.C., and align the set marks.

Drawing 7-36. Timing Gear Set Marks Drawing 7-37. Cam Gear Disassembling Procedures

Governor
Gov. Drive Bevel Gear

Cam Gear Governor Driver

Set Mark Gov. Drive Bevel Gear

Cam Gear
Tachometer Drive Coupling
Idle Gear B
Tachometer Drive Shaft
Idle Gear A
Idle Gear A Idle Gear B

Crank Gear

1) Cam gear

The governor drive bevel gear is incorporated to the cam gear, and they are incorporated to the
camshaft together with the tachometer drive coupling.

Disassemble (or reassemble) the cam gear according to the following sequence with the cover of timing
gear case removed:
(1) Remove the governor and governor driver.
(2) Remove the tachometer drive shaft.
(3) Remove the cam gear clamping bolt and tachometer drive coupling.
(4) Draw out the cam gear toward the flywheel side, and remove the gear through the window of timing
gear case.

7-37
7．MAINTENANCE SERVICING (Timing Gear)

(5) Cam gear clamping procedures

○ Mating the number stamped on the head of cam gear clamping bolt with the number stamped on
the side of cam gear, incorporate the bolt into the gear.
○ When tightening the cam gear clamping bolt, apply the seizure inhibitor (Three-Bond 1910 or its
equivalent) on the bearing surface and threaded part of the bolt, and then tighten the bolt to the
specified torque.

2) Idle gears
Extract the idle gear mounting shaft toward the flywheel side, and then take the idle gears out from the
window of timing gear case.

The idle gears A & B have been shrink fitted.

Drawing 7-38. Idle Gears Disassembling Procedures

Flywheel

Idle Gear
Mtg. Shaft
Support
Idle Gear
Mtg. Shaft

O-ring

(1) Remove the flywheel.

(2) Remove the idle gear mounting shaft support.
(3) Extract the idle gear mounting shaft toward the flywheel side.
(4) Checking
Check for seizure and uneven wear of idle gear shaft bearing and mounting shaft, and measure the
dimensions, If the bearing clearance exceeds the allowable value, replace the bearing or mounting shaft.
(5) When reassembling the idle gear assembly, replace the O-ring of the idle gear mounting shaft.

3) Crank gear Drawing 7-39. Crank Gear Removing Procedures

(1) To facilitate removal of crank gear, drill a hole Drilled Hole
below the bottom land of the gear, and drive a Chisel
chisel into this hole. This will loosen fitting, and Hammer
thus the gear can be easily removed.

Take care not to damage the positioning knock pin.

Crank Gear

(2) Before incorporating the crank gear, put it in the oil bath, and hear the bath to about 150 to 190 ℃ ,
leave the gear in the bath for about 60 minutes, and then take it out of the bath. After that, quickly
insert the crank gear to the crankshaft.
Refrain from heating the crank gear with a burner or the like, otherwise the temperature will rise
excessively to change the structure of the material and to decrease its strength. Instead, use of an oil
bath is recommended for this purpose.

7-38
7．MAINTENANCE SERVICING (Camshaft)

7-5-2. Camshaft
The fuel cam and suction and exhaust cams form a monoblock structure with the camshaft. The camshaft
is split in two at the bearing part between the No.3 & No.4 cylinders and coupled by reamer bolts.
If the engine installation site does not have space enough to extract the camshaft in one piece, split it, and
then draw out two parts from the engine.
Draw out the camshaft toward the front side (the side opposite to the flywheel).

1) Disassembly
Disassemble the camshaft according to the following procedures:
(1) Remove the bonnet, and then rocker arm shaft pedestal and push rod.
(2) Disconnect the fuel injection pipe joint, and then remove the fuel injection pump and fuel injection
pump driver.
(3) Remove the suc./exh. swing arm.
For their removing procedures, refer to the following:
Chapter 7-5-3. Suc./Exh. Swing Arm (p.7-40)
(4) Remove the cooling water pump, fuel oil feed pump and fuel oil filter (together with its mount).
(5) Remove the gear case.

Lift the gear case up with rope. If the gear case falls, an accident may occur.

Since the gear case is positioned with two knock pins, jack it up with M12 bolts to remove it.

(6) Remove the cam gears.

For their removing procedures, refer to the following:
Chapter 7-5-1, 1) Cam gear (p.7-37)

(7) Draw out the camshaft.

2) Checking & servicing

(1) Check for flaws and excessive wear on the fuel, suction and exhaust cams and bearings.
(2) Measure the dimensions of camshaft bearing parts and bearings, and check the clearance between
each bearing and the shaft.
(3) To replace a camshaft bearing by press fitting it, a jig (jack) is necessary.

When incorporating a bearing to the camshaft, put the bearing so that its joint faces upward and its oil
hole is mated with oil hole of camshaft, and press fit the bearing.

Drawing 7-40. Camshaft Coupling Part

Notch Drilled Hole

7-39
7．MAINTENANCE SERVICING (Suc./Exh. Swing Arm)

3) Reassembly
Reassemble the camshaft in the sequence reverse to that of disassembly, paying attention to the follow-
ing points:
(1) Make the camshaft coupling surfaces free from adherent foreign matters and lubricating oil. Then,
align the notch with the drilled hole to reassemble the camshaft.
(2) Tighten U-nuts of the coupling part only after applying the seizure inhibitor (Three-Bond 1910 or its
equivalent) to their threaded part and bearing surface.

Drawing 7-41. Camshaft Bearing Press-fitting Procedures

Oil Hole Joint

Jig

7-5-3. Suc./Exh. Swing Arm

The valve mechanism forcedly lubricates the roller pins by the swing arm system.

1) Disassembly
Remove the rocker arm shaft pedestal and push rods, and disassemble the swing arm assembly accord-
ing to the following procedures:
(1) Remove the cover of cam case. Loosen the swing arm shaft clamping bolts, and remove the arm shaft
and arm together as a set.
(2) Remove the circlips form the arm shaft with use of circlip pliers (P/#28190-000020), and then remove
the swing arms and spacers.

Drawing 7-42. Swing Arm Disassembling Procedures

Spacer Suc. Exh. Push Rod

Swing Arm Shaft

L R
R Push
Rod
Bracket

Circlip Roller

Swing Arm

2003.7.11R 7-40
7．MAINTENANCE SERVICING (Fuel Injection Pump&Pump Driver)

2) Checking & servicing

(1) Check if the roller rotates unsmoothly (is catching) and for flaws on the outer periphery and one-sided
contact of roller.(If any defect is detected, replace the swing arm with the new one by assembly.)
(2) Check for jolting of a push rod. Measure the dimensions of the arm shaft and arm shaft bearing, and if
a measurement exceeds the usage limit value, replace the shaft or the arm.

3) Reassembly
Reassemble the suc./exh. swing arm assembly in the sequence reverse to disassembly.
(1) Check for deformation or missing of collar of swing arm shaft clamping bolt holes.
(2) Incorporate the swing arm shaft so that its set mark "R" is positioned on the right side.
Screw the clamping bolts with the set mark "R" on the right side and with the set marl "L" on the left
side.

Do not make a mistake in this incorporation. If not incorporated properly, the lubricating oil passage is
shut, resulting in burnout of the arm shaft and roller pins.

(3) After having incorporated the rocker arm shaft pedestal, adjust the suc./exh. valve head clearance.
For the adjustment procedures, refer to the following:
Chapter 6, 6-3-6. Adjustment of Suc./Exh. Valve head clearance

7-6. Fuel Injection Pump & Pump Driver

7-6-1. Fuel Injection Pump
Pay full attention to handling of the fuel injection pump in its disassembly & reassembly since it has been
made precisely and even minute foreign matters and hit mark may cause it to be burnt out or its malfun-
cion.

1) Disassembly
(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Socket wrench for pump On the flywheel side 146673-92550

mounting On the anti-flywheel side 146673-92570

Hexagonal wrench key (8 mm) 28150-080000

Hexagonal wrench key (6 mm) 28150-060000

7-41
7．MAINTENANCE SERVICING (Fuel Injection Pump&Pump Driver)

Drawing 7-43. Fuel Injection Pump Removing Procedures

Injection Pipe Joint

(2) Next, remove the fuel injection pump in the following sequence:
Remove the fuel injection pipe joint, overflow oil pipe, fuel oil inlet pipe, fuel oil outlet pipe, and pinion
lub. oil pipe (H.F.O. specification only).
(3) Using the exclusive socket wrenched, loosen the fuel injection pump tightening nuts to remove the pump.
(4) Disassemble the fuel injection pump, paying attention to following points:

○ Be sure to handle the plunger ④ and barrel ⑯ as a pair.

○ When removing the pressure equalizing valve body ⑫ , take care not to lose any parts of
pressure equalizing valve ⑬ .

Drawing 7-44. Fuel Injection Pump Disassembling Procedures

26206-120952 26206-120454
146673-92900
Circlip

26706-120002
: O-ring

Disassemble the fuel injection pump in the ascending sequence of numbers shown in Drawing 7-44.
Invert the pump, and remove the circlip ① with use of the pertinent exclusive tool. Then, remove the
parts ② thru ⑦ .

When taking off the circlip ① from the groove, wrap it with cloth or the like to prevent the circlip from
springing off to inflict you an injury.

2008.3.13R 7-42
7．MAINTENANCE SERVICING (Fuel Injection Pump&Pump Driver)

2) Checking & servicing of fuel injection pump

Wash each part cleanly, and take care not to allow it to be rusted.

(1) Check if the spring of pressure equalizing valve ⑬ is not broken.

(2) Check if the mating surfaces of pressure equalizing valve body ⑫ and barrel ⑯ are free from blow-by
of fuel.
(3) Check for flaws or sludge stuck on the outer periphery of plunger ④ .
(4) Clean the oil hole of barrel and pinion lub. oil hole of the pump body.
(5) If the tip part of deflector ⑩ is dented by corrosion, replace it.
(6) Replace each O-ring with the new one.

3) Reassembly
Reassemble the fuel injection pump in the sequence reverse to disassembly, paying attention to the fol-
lowing points:

Drawing 7-45. Pressure Equalizing Valve Parts Incorporating Sequence

Chamfered

(1) After having incorporated each O-ring, make sure it is not warped.
(2) Apply the lubricating oil to the barrel, and incorporate it to the body.
(3) Incorporate the parts of pressure equalizing valve ⑬ in the ascending sequence of numbers shown in
Drawing 7-45.
(4) Tighten the barrel clamping bolt and pressure equalizing valve body clamping bolt ⑪ evenly in three
steps to the specified torque.
(5) Align the set marks of rack ⑨ , pinion ⑦ and plunger ④ .

Drawing 7-46. Set Marks of Racks, Pinion & Plunger

Rack (red mark on the bottom land)
Pinion (notch on tooth crest)
Pinion (notch groove)
Plunger (punch marked)

(6) When incorporating the circlip ① , push in the plunger guide ② while checking the move of rack ⑨ not
to allow the pinion ⑦ to be damaged by the collar of plunger ④ .
(7) Align the opening of circlip with the notch of the body.

Drawing 7-47. Circlip Incorporating Procedures

Body Notch

Circlip

(8) After reassembling the fuel injection pump, makes sure the rack moves smoothly.

7-43
7．MAINTENANCE SERVICING (Fuel Injection Pump&Pump Driver)

7-6-2. Fuel Injection Pump Driver

The fuel injection pump driver adopts the tappet roller system that forcedly lubricates the roller pin.
Besides, on the body of the pump, the oil hole for lubricating the outer periphery of the roller is provided.

1) Disassembly
Remove the fuel injection pump and then the positioning bolt, After that, remove the driver form the cylin-
der, and disassemble it in the ascending sequence of numbers shown in Drawing 7-48.

Drawing 7-48. Pump Driver Disassembling Sequence

Fuel Injection Pump

O-ring

Positioning Bolt

Guide Ring

O-ring Driver Body

Set Mark "O"

2) Checking & servicing

(1) Check for one-sided contact and flaws on the outer periphery of roller.
(2) Check if the roller rotates smoothly.
(3) Blow the air into the oil hole in the body to check for clogging.
(4) Replace the O-rings shown in Drawing 7-48. with new ones.

3) Reassembly
Reassemble the fuel injection pump driver, paying attention to the following points:
(1) Align the set mark "O" on the body with that on the tappet ⑤ .
(2) Incorporate the oil shield cover ③ with its notch part facing the operating side.
(3) Fully screw in injection timing adjusting bolt ② , and incorporate it in position.
(4) After mounting the fuel injection pump, adjust the injection timing to the specified timing.
For the injection timing adjusting procedures, refer to the following:
Chapter 6, 6-3-4. Adjustment of Fuel Injection Timing (p.6-12)

2002.12.25R 7-44
7．MAINTENANCE SERVICING (Governor & Governor Gear)

7-7. Governor & Governor Gear

7-7-1. Governor
The engines can be equipped with one of the three types of hydraulic governors depending on their speci-
fications. For each governor, refer to its operation manual provided separately.

○ Before removing the governor, record the speed regulation and status of each adjusting point.
○ When removing the governor, do not give an impact to the gear shaft, terminal shaft, speed control
shaft, etc.

7-7-2. Governor Gear

The governor gear is drive via the bevel gear on the camshaft gear side. The governor is driven by the gov-
ernor gear via a spline coupling.

Drawing 7-49A. Type NZ (or RHD) Governor Driver

Spline Coupling

Governor Mount

1) Disassembly

Either of two types of governor gears is applicable to the governor used.

When removing the governor, take it out vertically, paying attention not to flaw the driving shaft spline.

[ In the case of an engine equipped with Type RHD governor ]

(1) Disassemble the governor gear in the ascending sequence of numbers shown in Drawing 7-49A.

○ Loosen the gear tightening nut ② , and remove the parts ③ thru ⑥ to the gear side.
○ Remove the circlip ⑦ with use of circlip pliers. Remove the spline coupling to the governor side.
(The bearings ⑨ & ⑪ are press-fitted to the driving shaft ⑧ .)

2) Checking & servicing

(1) Check the contact of bevel gear tooth surface.
(2) Check the contact and stepped wear of driving shaft spline.

Fit the driving shaft spline with the governor spline, and check if jolting is not excessive.

7-45
7．MAINTENANCE SERVICING (Governor & Governor Gear)

(3) Replace the ball bearings every 8,000 to 10,000 hours even if their appearance is free from abnormality.

When incorporating the ball bearings ⑨ & ⑪ to the driving shaft, press fit them, applying the load to
the inner race of the bearings.

3) Reassembly
Reassemble the governor gear in the sequence reverse to disassembly.

(1) Mount the governor gear, and check the backlash of the bevel gear.

To adjust the backlash, remove the bevel gear ④ from the driving shaft, and adjust the thickness of
adjusting shim ⑥ .

When mounting the governor, let its spline fit with the governor gear spline under the governor own
weight.

[ In the case of an engine equipped with Type SG governor ]

Governor driving gear
Item of importance for disassembly & reassembly
(1) Replace the ball bearing of governor driving gear with the new one by 6,000 ～ 8,000 hours of opera-
tion (about two years) or when they are resulted in abnormal wear.
(2) At the time of attaching the driving gear, confirm the backlash of bevel gear, and adjust the backlash
by regulating the number of shims of bevel gear boss part.
(3) At the time of attaching the governor, check to see that there is no forcing to fitting of governor shaft
and spline coupling.
(4) The backlash of spur gears (A) and (B) should be 0.1 ～ 0.15mm. (Approximately 98 ～ 118N-m (10 ～
12kgf/m) is suggested for spur gear (A) tightening torque.)
(5) Pay attention to the direction of oil seal. (The correct direction is that the oil seal faces downward.)

Drawing 7-49B. Type SG Governor Driver

Governor
(Type SG)

Spline Joint

Ball Bearing

Oil Seal
Spur Gear (A)

Spur Gear (B)

Bevel Gear
Adjusting Shim

2002.12.25R 7-46
7．MAINTENANCE SERVICING (Governor & Governor Gear)

7-7-3. Coupling Adjustment of Governor

Improper coupling of the governor and fuel injection pump may adversely affect the performances of gov-
ernor, disable the engine from stopping and cause the rotational speed to rise excessively. After having
serviced or replaced the fuel injection pump and/or governor, adjust this coupling according to the following
sequence.

(1) Check if the clearance between the coupling rod and the connecting pin on both ends od coupling rod
is not excessive.
(2) Set the start/stop lever in the STOP position.
(3) Make the rack scales of fuel injection pumps of all cylinders set to the same position within the range
of graduation 9 to 10.
(At this time, also make sure the first lever moves smoothly.)

Drawing 7-50. Fuel Injection Pump Rack Adjusting Procedures

Injection Volume
Decrease Increase
Rack
Rack Scale
adjusting screw

Lock nut

1st Lever

1) If the Type NZ (or RHD) governor is equipped

Drawing 7-51. Type NZ (or RHD) Governor Connecting Procedures
Fuel
Governor Lever Decrease Increase

Governor
Output Shaft
Coupling Rod

Start/Stop Lever

95 mm Pointer
Lock Bolt

Coupling Bolt

1st Lever Shaft

2nd Lever

2003.4.17R 7-47
7．MAINTENANCE SERVICING (Lub. Oil Pump & Lub. Oil Press. Reglat. Valve)

(4) Adjust the screwing-in of the 2nd lever coupling bolt so that the distance between the center of the 1st
lever shaft and the center of the coupling rod becomes about 95mm.
(5) Connect the coupling rod to the 2nd lever coupling bolt.
(6) Insert a blade screwdriver into the governor output shaft end, fully turn the shaft in the fuel
DECREASE direction so as to set the pointer at the FUEL "0" indication.
(7) Incorporate the governor lever to the governor output shaft. (Loosen the governor lever lock bolt in
advance.)
(8) Connect the coupling rod to the governor lever. (The governor lever has four holes. Connect the cou-
pling rod with the same hole as connected before disassembly.)
(9) Insert a blade screwdriver into the governor output shaft end, set the pointer to the FUEL "1" indica-
tion, and tighten the governor lever lock bolt.

① Check that both ends of coupling rod are not twisted.

② Alternately setting the star/stop lever in the START and STOP positions, and make sure each rack
scale is set at the graduation 13 (non-injection position) of a less (within the range of graduation 9
to 10) while the lever is set in the STOP position.

7-8. Lub. Oil Pump, Lub. Oil Pressure Regulating Valve & Lub. Oil Cooler
7-8-1. Lub. Oil Pump
The lubricating oil pump is a gear pump of which body is built in incorporates with a pressure regulating
valve and a safety valve. The pump gear and shaft are shrink fitted.

1) Disassembly
(1) Disconnect the suction pipe, delivery pipe and pressure regulating valve pilot pipe from the lub. oil
pump, and then remove the pump.

The pump is positioned with knock pins. Remove the pump by fitting the pump mounting bolts to the
respective disassembling threaded holes  and jacking up the pump.

(2) Disassembly of lubricating oil pump

remove the pump drive gear, and disassemble the pump.

Detach the side cover from the pump. Fit the (M12 × 1.75) bolt at the part  of the driving gear to
lock it. Then, loosen (or tighten) the tightening nut.

Drawing 7-52. Lub. Oil Pump Removing/Disasembling Procedures

Pilot Pipe Knock Pin 㧭
Outlet
Drive Gear

Tightening Nut

Side Cover

Inlet

Pressure Adjusting Bolt

Knock Pin 㧭

7-48
7．MAINTENANCE SERVICING (Lub. Oil Pump & Lub. Oil Press. Reglat. Valve)

(3) Disassembly of the lub. oil pressure regulating valve & safety valve

Be careful of a spring which springs out from the safety valve and/of pressure regulating valve in dis-
assembly to inflict you an injury.
Disassemble the pressure regulating valve after loosening the pressure adjusting bolt.

Drawing 7-53. Pressure Regulating Valve & Safety Valve

Pilot Piston

Safety Valve
Spindle

V-groove
Pressure Reg. Valve

Spring O-ring

Spring Shoe

Lock Nut

Pressure
Adjusting Bolt

2) Checking & servicing

[ Pump body & pump gear ]
(1) Check for flaws and seizure on the tooth surface and side of the pump gear.
(2) Check for flaws and seizure on the pump gear shaft and gear shaft bearing.
(3) Measure the clearance between the pump gear and the pump body at the bearing part. If the mea-
surement exceeds the allowable value, replace either part whichever is worn more than the other.
[ Pressure regulating valve & safety valve ]
(1) Check for flaws on the pilot piston, pressure regulating valve, safety valve and valve springs.
(2) Check the operation of pilot piston, pressure regulating valve and safety valve, and make sure they
operate properly.

Directing the V-groove of pressure regulating valve toward the pilot piston, incorporate the pressure
regulating valve.

3) Reassembly
Reassemble the lubricating oil pump in the sequence reverse to disassembly.

7-49
7．MAINTENANCE SERVICING (Lub. Oil Cooler)

7-8-2. Lub. Oil Cooler

The lub. oil cooler is of the multi tubular type, and chemical cleaning seats that enable cleaning of the oil
cooler without removing it are equipped on the lubricating oil passage side.

1) Chemical cleaning procedures

The hose, pump and the like required for chemical cleaning are not included in the standard provision of
this engine.
(1) Drain the lubricating oil from the oil cooler, rearrange the respective baffle plates ① , ② & ③ at the oil
cooler inlet and outlet.
(2) Remove the round covers from the chemical cleaning seats and connect a hose with each seat. Then,
circulate the cleaning solution.
(3) After having finished cleaning, drain the cleaning solution, and return the baffle plates and round cov-
ers to their former condition.

Drawing 7-54. Chemical Cleaning Procedures

Thermostatic Valve
Bypass Pipe

ԙ
Lub. Oil Cooler

Solution inject Port

Lub. Oil Strainer

To prevent the cleaning solution from being mixed into the lubricating oil, be sure to treat the oil cooler
after chemical cleaning.

2) Disassembly
Drain the lubricating oil from the lub. oil cooler, fix the cooler body with rope, and remove it from the
engine.
(1) Remove the lub.oil strainer.
(2) Remove the caps from the cooling water inlet and outlet.
(3) Remove the lub. oil thermostatic valve.
(4) Remove the cooling water pipe assembly.

7-50
7．MAINTENANCE SERVICING (Lub. Oil Cooler)

3) Checking & servicing

(1) For checking and servicing of lub. oil strainer and lub. oil thermostatic valve, refer to the followings:

Lub. oil strainer: Chapter 6, 6-3-12 (p.6-27)

Thermostatic valve: Chapter 6, 6-3-8 (p.6-20)

(2) Clean the pipe on the cooling water side and lubricating oil side of cooling water pipe assembly.

○ Descale the pipe on the cooling water side with a long-handle brush.
○ For the pipe on the lubricating oil side, cleaning combining washing with such a sludge cleaning
agent as Neos and cleaning with steam is appropriate.

(3) Replace the O-rings at the cooling water inlet and outlet side covers with new ones.

4) Reassembly
Reassemble the lub.oil cooler in the sequence reverse to disassembly, paying attention to the following
points:

(1) Align the set marks of cooling water pipe assembly and lub. oil cooler body when incorporating the
pipe assembly to the cooler body.

Drawing 7-55. Set Marks (on The Cooling Water Outlet Side)
End Plate
Tube
Body

Tube
(Low-fin type)
O-ring

7-51
7．MAINTENANCE SERVICING (Cooling Water Pump)

7-9. Cooling Water Pump

The cooling water pump is a centrifugal pump. The only difference between the high-temperature water
side and the low temperature water side is the direction of cooling water inlet and outlet. The impeller is
incorporated to the shaft by screw tightening.

Note that the thread of impeller and that of impeller tightening nut are reverse handed. When disas-
sembling/reassembling the cooling water pump, be careful of the loosening/tightening direction.

1) Disassembly
Disassemble the pump in the ascending sequence of numbers shown in Drawing 7-56. Remove the
impeller ⑥ with use of the specified exclusive tool (P/#146673-92750).

Drawing 7-56. Cooling Water Pump

Casing
Impeller Attaching/Detaching Procedure

A Exclusive Tool
Incorporation Disassembly

Oil Seal Incorporating

Direction

Remove the ball bearings ⑭ & ⑮ that are press-fitted to the shaft ⑬ together with the shaft.

2) Checking & servicing

(1) Measure the clearance  between the impeller ⑥ and casing. If the measurement exceeds the allow-
able value, replace either part whichever is worn more than the other.
(2) If necessary, replace the mechanical seal ⑦ and oil seal ⑯ .

Do not make a mistake in the incorporating direction.

(3) Replace the ball bearings every 8,000 to 10,000 hours even if their appearance is free from abnormality.

When press-fitting a bearing to the shaft, apply the load on the inner race of the bearing.

3) Reassembly
Reassemble the cooling water pump in the sequence reverse to disassembly, paying attention to the fol-
lowing points:
(1) When incorporating the shaft, be careful not to flaw the lip of oil seal.
(2) Tighten the impeller ⑥ and impeller tightening nut ④ to the specified torque.

7-52
7．MAINTENANCE SERVICING (Fuel Oil Feed Pump)

7-10. Fuel Oil Feed Pump

The fuel oil feed pump is a gear pump. The pump gear on the driving shaft side are coupled to the shaft
through a spline.

1) Disassembly
Disassemble the pump in the ascending sequence of numbers shown in Drawing 7-57.
(1) Remove the ball bearings ⑦ & ⑧ that are press-fitted to the driving shaft ⑥ together with the shaft.
(2) When replacing the oil seal, detach the circlip ⑨ , and draw out the seal toward the driving gear ④
side.
Drawing 7-57. Fuel Oil Feed Pump
ԡ ԣ ԝ Ԧ ԥ Ԡ Ԟ ԝ ԟ Ԝ

Ԙ
ԙ

Oil Seal Incorporating

Direction

Ԣ Ԥ Pump Body

Spline

2) Checking & servicing

(1) Check the contact of the spline fitting part of driving shaft ⑥ and pump gear ⑫ . If the clearance (play)
is too large, replace either part whichever is worn more than the other.
(2) Check the parts of driving shaft ⑥ that make contact with its oil seals ⑭ & ⑯ . Then, if the wear is sub-
stantial, replace the shaft.
(3) If necessary, replace the oil seals.

The oil seals ⑭ & ⑯ are different parts. Do not make a mistake in their incorporating position and
direction.

(4) Replace the ball bearings every 8,000 to 10,000 hours even if their appearance is free from abnormality.

When press-fitting the ball bearing to the shaft, apply the load on the inner race of the bearing.

(5) The bypass valve ⑩ functions also as a safety valve of fuel oil feed pump. During operation, keep the
bypass valve closed.
○ Remove the plug and check the operation of piston.
○ If the fuel leaks from the handle shaft part, replace the O-ring.

Drawing 7-58. Bypass Valve ⑩

Adjusting Screw Handle Shaft

Lock Nut Valve Holder Piston O-ring

7-53
7．MAINTENANCE SERVICING (Suc. & Exh. System/Air Cooler)

3) Reassembly
reassemble the fuel oil feed pump in the sequence reverse to disassembly, pay attention to the following
points:
(1) When incorporating the shaft, be careful not to flaw the lip of oil lip seals.
(2) Apply a thin and uniform film of liquid packing (Three-Bond TB 1201 or its equivalent) on the mating
surfaces of pump cover ⑪ and pump body.
(The thickness of the packing after clamping must be 0.02mm or less.)
(3) Align the hole of spacer ⑮ for oil seal with the over flow oil take-off hole of the body.
(4) Replace the bend washer ② with the new one every time the fuel oil feed pump is disassembled.

7-11. Suction/Exhaust System

7-11-1. Boost Air Cooler
The boost air cooler is a plate finned box structure. It incorporates a duct integrated with the boost air inlet
and outlet pipe, and its connection parts are equipped with V-ring packing.

When servicing the boost air cooler, detach the V-ring on the boost air inlet side, and then remove the
cooler together with the duct.

Drawing 7-59. Boost Air Cooler

Water Return Cover
Duct

V-ring (Inlet)
Boost Air Cooler

Drain Cock Cooling Water Inlet/Outlet Cover

Drawing 7-60. Boost Air Inlet Side V-ring Removing Procedures

Packing Housing

V-ring

Detaching/Attaching Plate

7-54
7．MAINTENANCE SERVICING (Suc. & Exh. System/Air Cooler)

1) Disassembly
Disassemble the boost air cooler, removing its parts according to the following sequence:
(1) Prepare the following exclusive tools:

Exclusive Tool Description Part No.

Packing (V-ring) detaching/attaching tool 146673-92800

Eyebolt (M12) 26610-120002

(2) Remove the boost air cooler thermal insulating plate, thermometer, cooling water pipe and so forth.
(3) Remove the V-ring on the boost air inlet side.

Loosen the packing housing mounting bolts, put the detaching/attaching plate into both sides of the
housing to hold the packing, and then remove the packing together with the housing.

(4) Fit an eyebolt on the top of duct, hold the duct with rope, and remove it toward the non-operating side.
(5) Remove the duct according to the following procedures:

Carefully disassemble the boost air cooler so as not to flaw the V-ring incorporated part, otherwise
this causes a boost air leak.

① Invert the boost air cooler so that the cooling water inlet and outlet caps face upward.
② Unscrew the duct mounting bolts, fit an eyebolt to the cooler, life the cooler, and then remove the duct
from the cooler.

2) Checking & servicing

(1) Clean the air side (plate fin) with steam or soak it in the cleaning fluid, blow the compressed air
against it, and finally wash it in water.

The appropriate cleaning fluid is the following products or their equivalents.

Neos Co.,Ltd: Neos One-1
Kurita Water Industries Ltd.: Emocon 1E55

(2) Remove the water return cover on the cooling water side. Then, clean the cooler interior, brushing
with a long-handle brush.
(3) Check the coating on the inner surface of the duct and inner surface of the cooler side plate. If the
coating has peeled off, repair it with the following paint.

○ Inner surface of duct (heat-resistant silicone paint)

Oshima Kogyo: Pirojin IN Color G2 or its equivalent
○ Inner surface of cooler side plate (silicone epoxy pain)
Oshima Kogyo: Silicone Epoxy ING #2

(4) Check for clogging of a drain hole.

(5) Replace the packings with new ones.

3) Reassembly
Reassemble the boost air cooler in the sequence reverse to disassembly, paying attention to the follow-
ing points.

(1) Fit the V-ring on the boost air outlet side to the cylinder block. After mounting the boost air cooler,
incorporate the V-ring on the boost air inlet side.

7-55
7．MAINTENANCE SERVICING (Suc. & Exh. System/Turbocharger)

7-11-2. Exhaust Manifold

1) Disassembly

Lifting the exhaust manifold cover with use of a lifting use of a lifting eyebolt (P/#26610-100002) and
a chain block or the like, remove the cover.

Disassemble the exhaust manifold while checking whether the steady rest and the clamping bolts are not
loose.
Drawing 7-61. Exhaust Manifold & Expansion Joint

Eye Bolt Stay Rest

Exhaust Manifold Expansion Joint

Be careful not to confuse stainless steel bolts and nuts of exhaust manifold, expansion joint and
steady rest with those made of other material for clamping these parts.

2) Reassembly
(1) Apply the seizure inhibitor to each bolt or nut, and then tighten it.
(2) Checking the mark stamped on the flange of the expansion joint, fit it in the proper incorporating direc-
tion according to the mark.

If the expansion joint is fitted in the reverse direction, carbon is entrapped in the clearance, causing the
expansion joint to be broken in a shorter period.

Drawing 7-62. Exhaust Expansion Joint

Expansion Joint Mark

Gas Flow

7-11-3. Turbocharger
For disassembling and servicing of the turbocharger, refer to the operation manual separately provided for
it.

The turbocharger mount is provided with the boost air and lubricating oil passages. After having
removed the turbocharger, cover the ports of boost air and lubricating oil passages to prevent foreign
matters from entering the turbocharger.

2005.1.21R 7-56
7．MAINTENANCE SERVICING (Air Motor)

7-12. Air Motor

Refer to the attached Service Manual for Engine Air Starters (Model 45M).
Restrict disassembly and repairs of the air motor to disassembly, checking and the following parts replace-
ment of the air inlet housing and the spool valve.
● O-rings of the spool valve and the air inlet housing

● Starting solenoid valve

● Control module

● Pilot air hose

1) Disassembly (of the spool valve)

After removing the air motor, disassemble it in the ascending sequence of numbers given in Drawing 7-64.

When unscrewing a bolt ④ used to fasten the nozzle valve seat ⑤ to the inlet housing, be careful so
that the spool valve does not spring out.

Drawing 7-63. Spool Valve Disassembling Procedures

Spool Valve Air Inlet Housing

O-ring

Pilot Air Hose

O-ring

Standing Solenoid Valve Control Module

2) Maintenance checking
(1) Check the sliding surface and the seat face of the spool valve if they are not flawed not the foreign
matter has not been bittern in.
(2) Check the nozzle/valve seat if the seat face and nozzle part are not damaged.
(3) Replace the O-rings with the new ones.

3) Reassembly
Reassemble the air motor in the sequence reverse to disassembly, paying attention to the following
points:
(1) Apply grease to the sliding surface of the spool valve.
(2) Use sealing tape at the threaded part of the elbow ① of pilot air hose to that the air does not leak from
this part.
(3) Tighten each bolt with the following torques:
● 5 bolts for nozzle/valve seat: 7.2 N-m (0.7 kgf-m)

● 4 bolts for air inlet housing: 19.2 N-m (2 kgf-m)

● 4 bolts for air inlet pipe: 94.9 N-m (9.7 kgf-m)

● 3 bolts for air motor: 136 N-m (13.9 kgf-m)

7-57
7．MAINTENANCE SERVICING (Electromagnetic Pickup)

7-13. Electromagnetic Pickup

This pickup is a sensor to detect the rotational speed of the engine and is mounted near the outer
periphery of the flywheel ring gear.

1) Adjustment on the mounting dimensions

When the pickup is replaced or removed, be sure to adjust the clearance.

If the adjustment on the clearance is found poor, the rotational speed may not be detected, and the
(overspeed) protective device may not actuate.

● Adjust the screwing-in of the pickup so that the clearance between the pickup tip and the outer periph-
ery of the ring gear becomes 1.4 to 2.1 mm.
(Screw in the pickup so that its tip contacts the outer periphery of the flywheel ring gear, and then
loosen by 1 to 1.5 turn.)
● Tighten the lock nut securely.

Drawing 7-64. Electromagnetic Pickup Mounting Procedures

(Junction Box)
Electromagnetic Pickup

Lock Nut

Flywheel Ring gear

1.4㨪2.1 mm

7-58
7．MAINTENANCE SERVICING (Stopping Air Piston)

7-14. Stopping Air Piston

This piston purports to stop the engine when the protective device actuates and in case of remote
stopping, and to control fuel injection volume when engine is started up.
 ,  : stopping (to stop supply of fuel oil) air piston.
 : fuel injection volume controling air piston.

Do not disassemble adjustment nut and adjust bolt in the case where parts replacement is not
needed.
The stroke of the piston has been properly adjusted prior to shipment from out factory, do not readjust it.
When parts replacement is needed, do so with attention paid to the following:
Measure the dimension L1, L2 when disassembly is needed, and set it in the same dimension as the
measured L1, L2 when reassembling this air piston.

1) Disassembly
Disassemble the air piston in the ascending sequence of numbers given in Drawing 7-65.

Drawing 7-65. Stopping Air Piston

Eng. Stop
Control Air Adjust Nut
Eng. Start

L1
Adjust Bolt
A
B L2
Safety System

Eng. Safety Stop

Control Air Eng. Control Stop

Eng. Start Adjust Nut

L1
Adjust Bolt
B C A
L2

2) Reassembly
Reassemble the air piston in the sequence reverse to disassembly.
● Incorporate the piston, applying lubricating oil or lithium series grease to its sliding part.

● Replace the O-ring with the new one.

Conduct such a performance test once in every three months.

● Send the control air into the each air pistons, and confirm the movement of the sopping air piston
adjust nut

7-59
7．MAINTENANCE SERVICING

MEMO

7-60
8.　PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING

8. PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING

Drawing 8-1. Principal Dimensions for Disassembly & Servicing

[Unit: mm]
Cooling Water Outlet Center of Cylinder Dismantling to the Operating Side
Collecting Pipe
879
Piston Cyl. Liner Cyll. Head
Exh. Manifold

1710
1666
225

0
425 Boost Air
1150

1471
137
1115

Cooler
400

15
132

Center of Camshaft 1057

Center of Crankshaft 30
495
Center of Turning Gear Turning Bar
965

Dismantling to the Frontal End Dismantling to the Rear End

Dismantling to the Frontal End Dismantling to the Rear End

2088

2055

1730

1896
1622

Turbocharger

Camshaft Split in Two

Cooling Water Pump

678
Center of No.6 Cyl.
Fuel Feed Pump
707
1178

When Drawing-out en bloc:1988

2004.3.29R 8-1 (Volume:2pages)

8.　PRINCIPAL DIMENSIONS & PART MASS FOR DISASSEMBLY & SERVICING

8-1. Principal Part Mass for Disassembly & Servicing

(1) When hoisting a part, use rope and lifting gear and hook that can withstand the can withstand the
weight of the part.
(2) When disassembling any of the parts prefixed with an asterisk (*) in the following table, use the
attached exclusive tool.

[Unit: kg]
Part Description 6N18L 6N18AL Remarks

* Cylinder head 105

* Piston & connecting rod assy. 42

* Cylinder liner 40

* Air cooler 300 Incl. the casing

Lub. oil cooler 162 Incl. the strainer & thermostatic valve

RH133 63
Turbocharger
RH143 145

Fuel feed pump 16

Lub. oil pump 30

Cooling water pump 35

Air motor 18

Camshaft (split in two) 41 × 2

Camshaft driving gear 15

Intermediate gear assy. 20

* Exhaust manifold cover 45

* Main bearing cap 22

Anti-flywheel end gear case 62

Oil pan 200

Cylinder block 1,496

Crankshaft 760 846 Incl. the balance weight

Flywheel 870 650 Incl. ring gear

2004.3.29R 8-2
9.　TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS

9. TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS

Tighten the major bolts by the specified procedures.

If tightened improperly, a personal injury or damage of device may be caused. Be cautious.

(1) Unless otherwise specified,apply lub.oil on the thread and bearing surface, and then tightening a
bolt or nut.
(2) On the parts prefixed with a star ( ★ ) in the following tables, a match mark is stamped. However,
when tightening any of these parts, do not refer to the macth mark but tighten it to the specified
torque, specified tightening angle or specified hydraulic pressure.

9-1. Hydraulic Peressure Clamping Bolt

Face-to-Face
Screw Specific Hydraulic
Width of
Part Description Dia × Pressure Remarks
Bolt/Nut
Pitch MPa (kgf/cm2)
(mm)

★ Cylinder head tightening nut M33×2.0 Round 58.8 ± 0.5(600 ± 5)

★ Main bearing cap tightening nut M33 ×2.0 Round 58.8 ± 0.5(600 ± 5)

9-2. Angle Clamping Bolts

(1) Before tightening a connecting rod bolt, apply the Protec grease on its bearing surface and lub.oil
on its thread.
(2) Tighten a bolt to the seating tightening torque, then tighten it to the specified angle.

Face-to-Face Seating Specified

Screw Dia. Width of Tightening Tightening
Part Description Remarks
× Pitch Bolt/Nut Torque Angle
(mm) N-m (kgf-m) (deg.)

★ Connection rod bolt M25 × 1.5 32 49(5) 120+3

-0

Balance weight clamping bolt M24 × 2.0 32 49(5) 80+3

-0

2002.7.22R 9-1 (Volume:4pages)

9.　TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS

9-3. Other Major Bolts (Torque Tightening)

(1) Before tightening a flywheel clamping bot or fuel injection valve nozzle sleeve, apply Protec gease
on its thread and bearing surface.
(2) Before tightening a camshaft coupling nut, apply seizure inhibitor (Three-Bond 1910 or its equiva-
lent) on its thread and bearing surface.
(3) The parts prefixed with an asterisk (*) in the following table are provided with an exclusive tool,
respectivery.
(4) Be sure to tighten a part with a torque wrench to the specified torque.

Screw Dia. Face-to-Face Tightening Torque

Part Description Width of Remarks
× Pitch Bolt/Nut (mm) N-m (kgf-m)
Indicator cock tightening nut M12 × 1.75 19 59 ～ 69 6～7
Rocker arm shaft stand clamping bolt M16 × 1.5 24 186 ～ 206 19 ～ 21
M22 × 1.5 157 ～ 167 16 ～ 17 Engine Using MDO
* Fuel injection valve nozzle sleeve 2 grooves
M30 × 1.5 245 ～ 265 25 ～ 26 Engine Using HFO
Fuel injection valve guard tightening
nut M10 × 1.5 17 39 ～ 44 4 ～ 4.5

* Fuel injection valve case nut M28 × 1.5 27 167 ～ 176 17 ～ 18

* Fuel injection valve injection pressure
regulating lock nut M33 × 1.5 41 47 ～ 51 4.8 ～ 5.2
* Fuel injection pipe joint bolt (on cyl. 6
M8 × 1.25 (hex. socket) 20 2
head side)
* Fuel injection pipe joint bolt (on pump 8
side) M10 × 1.5 (hex. socket) 69 7

* Fuel injection pump tightening nut M12 × 1.75 19 74 ～ 83 7.5 ～ 8.5

Fuel injection pump equalizing valve 8
body clamping bolt M10 × 1.5 (hex. socket) 54 ～ 59 5.5 ～ 6.0
Fuel injection pump barrel retaining 8
bolt M10 × 1.5 (hex. socket) 54 ～ 59 5.5 ～ 6.0

Fuel injection pump protector M20 × 1.5 32 49 ～ 59 5.0 ～ 6.0

Fuel injection timing adjust bolt lock 30
nut M22 × 1.5 196 ～ 245 20 ～ 25

Camshaft coupling nut M12 × 1.25 17 88 ～ 98 9 ～ 10 U-nut

Tightening together
Cam gear clamping bolt M14 × 1.5 19 137 ～ 157 14 ～ 16 with tachometer driv-
ing disk
Idle gear shaft clamping bolt M16 × 1.5 24 118 ～ 127 12 ～ 14
Idle gear retainer clamping bolt M12 × 1.75 19 59 ～ 69 6～7
Cooling water pump impeller tightening
nut M16 × 1.5 24 64 ～ 74 6.5 ～ 7.5 Left hand screw
round socket
* Cooling water pump impeller M22 × 2.5 4 points 137 ～ 157 14 ～ 16 Left hand screw
Cooling water pump driving gear tight-
ening nut M24 × 2.0 36 235 ～ 255 24 ～ 26
Cooling water pump idle gear shaft
clamping bolt M16 × 1.5 24 118 ～ 137 12 ～ 14

Main bearing cap side bolt M22 × 1.5 32 343 ～ 382 35 ～ 39

Flywheel clamping bolt M20 × 1.5 24 510 ～ 569 52 ～ 58
Exhaust manifold clamping bolt M12 × 1.75 19 59 ～ 69 6～7
Exhaust expansion joint clamping bolt M12 × 1.75 19 59 ～ 69 6～7
Lub.oil pump driving gear tightening nut M24 × 2.0 36 157 ～ 177 16 ～ 18
Swing arm shaft clamping bolt M16 × 1.5 24 118 ～ 137 12 ～ 14

2003.12.10R 9-2
9.　TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS

9-4. General Bolts

(1) Tighten any bolts other than the major ones according to the following table.
(2) Tighten a part whose clamping section is made of aluminum, tighten it to 80% of the torque shown
in the following table.
(3) The following table is applicable only to the bolts whose Part No. (an 11-digit numeral) shown in the
attached Parts List consists of 2 at its first place and 2, 5 or 6 at its fifth place.

Screw Dia. Face-to-Face Tightening Torque

× Width of Bolt/Nut
Pitch (mm) (mm) N-m (kgf-m)

M6 × 1.0 10 10 ～ 12 (1.0 ～ 1.2)

M8 × 1.25 13 24 ～ 27 (2.4 ～ 2.8)

M10 × 1.5 17 44 ～ 54 (4.5 ～ 5.5)

M12 × 1.75 19 78 ～ 98 (8 ～ 10)

M14 × 1.5 22 123 ～ 152 (12.5 ～ 15.5)

M16 × 1.5 24 206 ～ 245 (21 ～ 25)

M16 × 2.0 24 206 ～ 245 (21 ～ 25)

2002.7.22R 9-3
9.　TABLE OF TIGHTENING TORQUES OF MAJOR BOLTS

MEMO

9-4
10.　CLEARANCES & WEAR LIMITS OF MAJOR PARTS

10. CLEARANCES & WEAR LIMITS OF MAJOR PARTS

(Unit in mm)
Dimension St’d Max. Usage
Item Sketch Clearance Allowance Limit of
Normal Tolerance Assembling Clearance Parts
Time
Inner dia. of cylinder upper +0.029 +0.1
part 0 A1=0.075
φ246 A1=0.25
Outer dia. of cylinder liner -0.075 ～ 0.139
-0.2
upper part 0.110
Inner dia. of cylinder lower +0.029 +0.13
part 0 A2=0.020
φ222 A2=0.2
Outer dia. of cylinder liner -0.020 ～ 0.094
-0.13
lower part 0.065
Cylinder & cylinder liner

Inner dia. of cylinder lower +0.029 +0.13

part 0
B=0.015
φ218 B=0.2
Outer dia. of cylinder liner -0.015 ～ 0.088
-0.13
lower part 0.059
C=1.8
Top clearance 2.0 ± 0.20 C=2.5 －
～ 2.2
Inner dia. of protection ring φ178 ± 0.05 +0.8
D=0.905
～ 1.045 －
Outer dia. of piston head φ177.025 ± 0.02 －
+0.4
+0.030 deflection
Inner dia. of cylinder liner φ180 0 E=0.093 wear of
E=0.3 0.2
～ 0.153
Outer dia. of piston skirt part φ179.892 ± 0.015 -0.2

Radial thick. of piston

F=6.5 ± 0.15 － － ★
rings, No.1 ～ No.2

Radial thick. of oil ring F=5.0 ± 0.25 － － 4.7

-0.065
Width of piston ring, No.1 No.1 -0.2
-0.085 No.1
4.5 G=0.110
Width of piston ring groove, +0.070 G=0.4
Piston piston pin & rings

～ 0.155 +0.3
No.1 +0.045
-0.010
Width of piston ring, No.2 No.2 -0.2
-0.030 No.2
4.0 G=0.055
Width of piston ring groove, +0.070 G=0.4
～ 0.100 +0.3
No.2 +0.045
-0.010
Width of oil ring -0.2
-0.030 H=0.030
6.0 H=0.4
+0.035 ～ 0.065
Width of oil ring groove +0.3
+0.020
Inner dia. of piston pin metal +0.100 +0.17
+0.080 J=0.080
J=0.25
0 ～ 0.113
Outer dia. of piston pin -0.05
-0.013
φ75
Inner dia. of piston pin hole +0.045 +0.15
+0.030 K=0.030
K=0.15
0 ～ 0.058
Outer dia. of piston pin -0.15
-0.013

★ : The 1st ring is to be replaced with the new one when its plated layer is worn out and base metal begins to be
exposed; the 2nd ring, when the taper face is gone.

2003.12.10R 10-1 (Volume:4pages)

10.　CLEARANCES & WEAR LIMITS OF MAJOR PARTS

(Unit in mm)
Dimension St’d Max.
Clearance Allowance Usage Limit
Item Sketch
Normal Tolerance Assembling of Parts
Clearance
Time

Inner dia. of crank pin bear- +0.152 +0.20

ing 0.080
L=0.080
φ145 L=0.25
～ 0.170
deflection
0
Outer dia. of crank pin wear of
-0.025 0.1

+0.189
Inner dia. of main bearing +0.20
+0.120
M=0.120
Crankshaft

φ180 M=0.25 deflection

0 ～ 0.214
Outer dia. of journal wear of
-0.025 0.1
Width of datum part main -0.140 -0.4
bearing -0.200 N=0.140
80 N=0.5
+0.035 ～ 0.230
Width of datum part journal +0.35
0

Refer to
Chapter 6 Maintenance Checking
Deflection － － 6-3-17 Measurement of crankshaft
deflection, 3) Allowable value of the
deflection.

Valve head clearance Refer to Chapter 3 TABLE OF ENGINE

(suc./exh.) － － STANDARD ADJUSTMENTS.
-0.060
Outer dia. of suction valve -0.32
-0.080 R1=0.060
φ14 R1=0.32
Inner dia. of suction valve +0.024 ～ 0.104
+0.26
guide 0
-0.058 Chrome-plated
Outer dia. Chrome-plated -0.32
-0.078 R2=0.058
of exhaust
valve -0.068 ～ 0.102 R2=0.32
Nimonic φ14 -0.35
-0.088 Nimonic R3=0.35
Inner dia. of exhaust valve +0.024 R3=0.068
+0.28
guide 0 ～ 0.112
+0.080
Valve Mechanism

Inner dia. of valve bridge +0.18

+0.060 S=0.014
φ16 S=0.2
Outer dia. of valve bridge +0.046 ～ 0.052
-0.18
guide +0.028
Margin thickness of suc./ T=4.7 ± 0.1 － － 4.3
exh. valve poppet part
Width of suc./exh. valve U= ± 0.2 － － 5.4
seat
Dia. of suc./exh. valve seat
contact part V=φ57 ± 0.1 － － φ58

Outer dia. of rocker arm -0.009 -0.1

shaft -0.034 W=0.029
φ36 W=0.25
Inner dia. of rocker arm +0.085 ～ 0.119
+0.22
bush +0.020
+0.03
Inner dia. of swing arm +0.2
+0.01 X=0.010
φ40 X=0.2
Outer dia. of swing arm 0 ～ 0.069
-0.1
shaft -0.039

2006.10.16R 10-2
10.　CLEARANCES & WEAR LIMITS OF MAJOR PARTS

(Unit in mm)
Dimension St’d Max. Usage
Clearance Allowance
Item Sketch Assembling Limit of
Normal Tolerance Clearance Parts
Time
Outer dia. of camshaft -0.072 -0.17
datum part -0.107
Y=0.072
φ120 Y=0.3
～ 0.197
Inner dia. of camshaft +0.090 +0.17
datum part bearing 0

Thrust clearance of cam- -0.15

Camshaft

shaft datum part -0.20 －

Z=0.200
6 Z=0.5
～ `0.310
Width of camshaft thrust +0.11
collar housing +0.05 －

Outer dia. of camshaft -0.072 -0.17

intermediate part -0.107
a=0.072
φ120 a=0.3
～ 0.197
Inner dia. of camshaft inter- +0.095 +0.17
mediate part bearing 0

Outer dia. of lub. oil pump -0.040

shaft -0.053 －
b=0.040
φ30 b=0.2
Inner dia. of lub. oil pump +0.021 ～ 0.074
+0.15
shaft bush 0

Clearance betw. pump +0.046

－
Lub. oil pump

case & gear 0 c=0.200

φ72 c=0.3
-0.200 ～ 0.296
Outer dia. of gear －
-0.250
6N18L
77 +0.046
Width of pump case 0 －
6N18AL
66 d=0.060
bell mounting
d=0.18
～ 0.136
coupling spec -0.060
Width of pump gear 6N18L －
-0.090
72

Outer dia. of cooling water -0.13

Cooling water pump

-0.6
pump impeller boss -0.18
e1&e2
=0.78 e1&e2
φ94 =1.60
～ 0.87
+0.69
Inner dia. of casing +1.0
0.65

Outer dia. of fuel oil feed -0.020 -0.1

pump shaft -0.041
b=0.020
φ25 b=0.2
～ 0.062
Inner dia. of fuel oil feed E +0.021 +0.1
pump shaft bush 0
Fuel Oil Feed Pump

+0.025
Inner dia. of pump case －
0
c=0.080
D φ48 －
～ 0.130
-0.080
Outer dia. of pump gear －
-0.105

+0.018 d=0.1
Width of pump case －
D E 0 ～ 0.2
12 (Liquid －
F -0.016 packing
Width of pump gear －
-0.034 ≦ 0.02)

2008.4.21R 10-3
10.　CLEARANCES & WEAR LIMITS OF MAJOR PARTS

(Unit in mm)
Dimension St’d Max. Usage
Clearance Allowance
Item Sketch Assembling Limit of
Normal Tolerance Clearance Parts
Time
(Timing gear
& pump f=0.15
－ f=0.5 －
drive gear) ～ 0.25
M=4.5
Gear backlash
(Governor f=0.12
gear) － f=0.3 －
M=3.0 ～ 0.20
Transmission gear

Outer dia. of cam driving -0.030 -0.17

intermediate gear shaft -0.060
g=0.030
φ70 g=0.2
～ 0.090
Inner dia. of the above’s +0.030 +0.14
bush 0

Outer dia. of pump driving -0.030 -0.17

intermediate gear shaft -0.060
h=0.030
φ70 g=0.2
～ 0.090
Inner dia. of the above’s +0.030
+0.14
bush 0

0
Oil shield, flywheel side

Outer dia. of crankshaft －

-0.046

j=0.030
φ220 －
～ 0.446

+0.400
Inner dia. of oil shield －
+0.300

2008.4.21R 10-4
11.　TROUBLESHOOTING & COUNTERMEASURES

11. TROUBLESHOOTING & COUNTERMEASURES

The causes of abnormalities and troubles are diverse, and they break out from compsite factors.
Catching a change in running performance and referring to the record of maintenance and servicing
date and the history of part replacement, locate the cause early and take the proper countermea-
sures.

11-1. Starting Failure

1) Flywheel not turned.
2) Flywheel turned, but ignition not taken place.
11-2. Rotational Speed Dropped Spontaneously.
11-3. Output of Each Cylinder not in Unifomity. (Dispersion of the maximum combustion pressure
and exhaust temperature is large among cylinders.)
11-4. Bad Color of Exhaust Gas
11-5. Lub. Oil Pressure Dropped below the Specified Pressure
11-6. Unusual Sounds Heard (Knocking Occurred) During Operation
11-7. Cooling Water Temperature Too High
11-8. Exhaust Temperatures of All the Cylinders Too High
11-9. Engine Stopped Suddenly

11-1 (Volume:6pages)
11.　TROUBLESHOOTING & COUNTERMEASURES

11-1. Starting Failure

1) Flywheel not turned
Cause Countermeasure
(1) Starting air pressure insufficient Fill the starting air tank with air.
(2) Engagement / disengagement switch actuated Disengage the turning gear.
(Turning gear set at the intermeshing position)
(3) Malfunction of air motor
1.Voltage drop of air motor battery Charge the battery.
2.Malfunction of air motor pilot solenoid valve Press the manual starting push button to
start the engine.
(4) Engagement / disengagement switch actuated. Set the start / stop lever at the RUN posi-
(Start / stop lever set in the STOP position) ton.
(5) Too high viscosity of lubricating oil Warm up the engine or change the cur-
rent lub. oil with a low-viscosity one.
(6) Seizure of moving part
1.Seizure of piston and cylinder liner Check and repair the piston and cylinder
liner, or replace them.
2.Seizure of main bearing and / or camshaft bearing Check and repair the pertinent main
bearing or camshaft or camshaft bearing,
or replace it.

2) Flywheel turned, but ignition not taken place

Cause Countermeasure
(1) Fuel oil not sent under pressure to fuel injection
pump
1.Fuel tank empty Supply the fuel to the fuel tank.
2.Clogging of fuel oil pipe (improper opening and Check the opening and closing status of
closing of each valve) each valve.
3.Clogging of fuel oil filter Clean the filter.
4.Failure of fuel feed pump Check and repair the pump.
5.Air entry through each joint Check and repair each joint, then bleed
air.
(2) Malfunction of sopping air piston Check and repair the air piston.
(3) Defect of fuel injection pump
1.Sticking of plunger and plunger guide Check and repair the plunger or plunger
guide, or replace it.
2.Wear or seizure of plunger guide Replace the plunger.
3.Improper assembling (deviation of match marks) Overhaul and check the pump.
(4) Defect of fuel injection valve
1.Sticking or seizure of needle. Check and repair the needle, or replace
it.
2.Breakage of nozzle spring Replace the nozzle spring.
3.Fuel injection pressure dropped Regulate the pressure.
4.Oil leakage from nozzle excessive Check and clean the mating surfaces of
nozzle and body, or replace the nozzle.
5.Breakage or improper clamping of high-pressure Replace the high-pressure fuel pipe, or
fuel pipe correct clamping.
(5) Malfunction of governor (loose governor link and Check and repair the governor, or
worn spline replace it.
(6) Poor airtightness of suction / exhaust valve
1.No clearance at head of suction / exhaust valve Adjust the valve head clearance.
2.Sticking of suction / exhaust valve Grind or replace the valve.
3.Damage of seat of suction / exhaust valve Grind or replace the valve seat.
(7) Too low cetane number of fuel Use a high- quality fuel oil.

1998.4.21R 11-2
11.　TROUBLESHOOTING & COUNTERMEASURES

11-2. Rotational Speed Dropped Spontaneously

Cause Countermeasure
(1) Clogging of fuel oil filter Clean the filter.
(2) Seizure of moving part (piston, main bearing or tur- Check and repair the pertinent moving
bocharger) part, of replace it.
(3) Air mixed in fuel oil pipe system Check and repair the fuel oil pipe system,
then bleed air.
(4) Moisture content in fuel oil Drain the filter, tank, etc.
(5) Defect of fuel injection pump Check and repair the pump, or replace it.
(6) Defect of fuel injection valve Check and adjust the valve, or replace it.
(7) Malfunction of governor Check and adjust the governor, or
replace it.

11-3. Output of Each Cylinder not in Uniformity. (Dispersion of the

maximum combustion pressure and exhaust temperature is large
among cylinders.)
Cause Countermeasure
(1) Air mixed in fuel oil pipe system Check and repair the fuel oil pipe system,
then bleed air.
(2) Moisture content in fuel oil Drain the filter, tank, etc.
(3) Fuel injection volume not in uniformity among cylin-
ders
1.Nonuniform position of fuel injection pump racks Check the position of fuel injection pump
racks, then adjust it.
2.Sticking or wear of fuel injection pump plunger Check and repair the plunger, or replace
it.
3.Defect of fuel injection valve Check and repair the valve, or replace it.
4.Looseness or damage of fuel injection pipe Check and repair the pipe, or replace it.
5.Sticking of suction / exhaust valve or damage of Check and repair the pertinent valve or
suction / exhaust valve seat valve seat, or replace it.
6.Damage of fuel cam, or damage of suction / Check the fuel cam or suction / exhaust
exhaust cam cam, then repair it, of replace it.

11-4. Bad Color of Exhaust Gas

Cause Countermeasure
(1) Improper injection timing Check and adjust the timing.
(2) Defect of fuel injection valve (fuel injection pressure
Check the valve, then regulate the pres-
drop, sticking of nozzle) sure, or replace it.
(3) Defect of fuel injection pump Check the pump, then repair it, or
replace the pertinent valve sect.
(4) Improper adjustment of suction / exhaust valve Adjust or correct the clearance, or
head clearance or damage of suction / exhaust replace the pertinent valve sect.
valve seat
(5) Sticking of suction / exhaust valve Overhaul the suction / exhaust valve, and
then correct it.
(6) Damage of suction / exhaust cam Replace the camshaft.
(7) Defect of turbocharger
1.Clogging of filter Wash the filter.
2.Fouling of the blower side or turbine side Overhaul and wash the turbocharger /
blower.
(8) Fouling of boost air cooler (too high temperature of Overhaul and clean the air cooler.
boost air)
(9) Shortage of fuel oil Use a high-quality fuel oil.
(10) Overload Reduce the load.

11-3
11.　TROUBLESHOOTING & COUNTERMEASURES

11-5. Lub. Oil Pressure Dropped below the Specified Pressure.

Cause Countermeasure
(1) Looseness of lub. oil pipe and cylinder block oil Check and repair the lub. oil pipe and
hole plug each oil hole plug.
(2) Clogging of lub. oil strainer Overhaul and clean the strainer.
(3) Excessive clearance of crankshaft bearing Check the clearance, then replace the
metal.
(4) Sticking of lub. oil pressure regulating valve or Check the valve and bolt, then repair or
loose adjusting bolt adjust the pertinent part.
(5) Sticking of lub. oil safety valve Check the valve and bolt, then repair it.
(6) Too high temperature of lub. oil
1.Shortage of cooling water volume Check the cooling water pump.
2.Fouling of lub. oil cooler Check the cooler, then over haul and
clean it.
3.Excessive blow-bye (gas leak) into the crank- Check the piston rings and cylinder
case liner.
4.Sticking of piston of lub. oil thermostatic valve Check the piston and element, then
or defect of its element repair or replace the pertinent part.
(7) Air sucked in lub. oil pump (shortage of lub. oil Replenish the lub. oil.
volume)

11-6. Unusual Sounds Heads (Knocking Occurred) During Operation

Cause Countermeasure
(1) Excessive clearance of bearing of crankshaft of Check the clearance, then replace the
camshaft pertinent bearing.
(2) Loose bolts
1.Connecting rod bolts Check the connecting rod and bolts,
then retighten the bolts or replace
them.
2.Flywheel clamping bolts Check the bolts, then retighten them,
or replace them.
(3) Improper adjustment of suction / exhaust valve Check the clearance and bolt, then
head clearance or loose bolt adjust the clearance.
(4) Improper adjustment of fuel injection timing Check the timing, then adjust it.
(5) Fuel injection volume excessive
1.Malfunction of fuel injection pump Check and repair the pump, or replace
it.
2.Defect of fuel injection valve Check and repair the valve, then adjust
it.
(6) Increase of gear backlash or wear of gear bear- Check and adjust the gear or its bear-
ing ing, or replace it.

11-7. Cooling Water Temperature Too High

Cause Countermeasure
(1) Shortage of cooling water volume Check and repair the cooling water
pump.
(2) Sticking or defect of cooling water thermostatic Check or replace the thermostatic
valve valve.

11-4
11.　TROUBLESHOOTING & COUNTERMEASURES

11-8. Exhaust Temperatures of All the Cylinders Too High

Cause Countermeasure
(1) Boost air temperature too high
1.Boost air cooler cooling water temperature too Check the cooling water system, and
high lower the cooling water temperature to
the specified range.
2.Shortage of boost air cooler cooling water vol- Check and repair the cooling water
ume pump.
3.Fouling of boost air cooler (cooling water side & Overhaul and wash the cooler.
air side)
4.Engine room internal temperature too high Check and service the engine room
ventilation equipment.
(2) Boost air pressure too high
1.Clogging of turbocharger filter Wash the filter.
2.Clogging of boost air cooler (air side) Overhaul and wash the cooler.
3.Fouling of turbocharger (turbine side & blower Wash the blower side or overhaul and
side) or its damage wash the turbocharger, or replace it.
4.Rise of back pressure at exhaust port Check and clean the exhaust manifold
and exhaust pipe.
5.Engine room put under a negative pressure Check and service the engine room
ventilation equipment.
(3) Unsuitable properties of fuel oil Judging from the property analysis
results, change the fuel oil if necessary.
(4) Overload Reduce the load.

11-9. Engine Stopped Suddenly

Cause Countermeasure
(1) Protective device switched on
1.Overspeed Check the switch, then repair the
2.Lub. oil pressure drop defective part. If necessary, replace
3.Temperature rise of cooling water excessive the pertinent part.
(2) Governor or governor gear Check the governor and governor gear,
then repair or replace the pertinent
part.
(3) Fuel tank empty Replenish the fuel oil.
(4) Air mixed in fuel oil system Bleed air from the filter and oil pipe.
(5) Clogging of fuel oil filter Overhaul and clean the filter.
(6) Seizure of interlocking part (piston, main bear- Check and repair the pertinent part, or
ing, crank-pin bearing, timing gear, etc.) replace it.

11-5
11.　TROUBLESHOOTING & COUNTERMEASURES

MEMO

11-6
 部　　品　　表 ＰＡＲＴＳＬＩＳＴ

お願い Request
Though this Parts List has been edited to
　この部品表は取扱説明書の付図を兼ねて編集
serve also as the appended figures of the
してありますが、予告なしに部品番号を変更す pertinent. Opefation Manual, any Part No.
thereof is subject to a chamge without notice.
る事があります。このため、部品が必要な場合
Consequently, when you ate in need of a
は御手数ですが、部品名称･部品番号･機関名称 particular Part, kindly place your order of that
Partwuth your nearest YANMAR Parts Selling
（形式）および機関製造番号を明記のうえ最寄
Agent, writing clearly Model and Mfg. No. of
your engine together with Part Name and Part
りのヤンマー部品販売店へ御注文下さい。 No. of the Part in demand.

Example of item & indication necessary at the

部品注文時に必要な記載項目 time of ordering Yanmar engine parts.

機関名称（形式）1 6N18AL-DV Engine Model 6N18AL-DV

機 関 製 造 番 号 3701FSF Engine Mfg. No. 3701FSF
部 品 名 称 ピストン仕組 Part Name Piston Ass'y
部 品 番 号 746674-22011 Part No. 746674-22011
必 要 な 数 量 1 set Q'ty Req'd 1 set

目　　　次 ＩＮＤＥＸ

付図 1 シリンダヘッド仕組 Fig 1 CYLINDER HEAD ASS'Y

付図 2 バルブローテータ仕組 Fig 2 VALVE ROTATOR ASS'Y

付図 3 指圧採取弁仕組 Fig 3 INDICATOR COCK ASS'Y

付図 4 動弁装置 Fig 4 VALVE MECHANISM

付図 5-1 シリンダ側ふた仕組 Fig 5-1 CYLINDER BLOCK SIDE COVER ASS'Y

付図 5-2 シリンダ側ふた仕組 （給油口付） Fig 5-2 CCYLINDER BLOCK SIDE COVER ASS'Y,
with lub. oil filler

付図 5-3 安全弁付シリンダ側ふた仕組 Fig 5-3 CYLINDER BLOCK SIDE COVER ASS'Y,

with safety valve

付図 6 シリンダライナ仕組 Fig 6 CYLINDER LINER ASS'Y

付図 7 主軸受仕組 Fig 7 MAIN BEARING ASS'Y

付図 8 ターニング装置 Fig 8 TURNING DEVICE

付図 9 踏板仕組 Fig 9 PLATFORM ASS'Y

付図 10 カム軸及びカム軸受仕組 Fig 10 CAMSHAFT & BUSH ASS'Y

付図 11 カム軸および潤滑油ポンプ駆動 Fig 11 CAMSHAFT & LUB. OIL PUMP DRIVING

　　　　　　　　中間歯車仕組 IDLE GEAR ASS'Y

2005. 12.22R 6N18(A)L-V

付図 12 冷却水ポンプ駆動中間歯車仕組 Fig 12 COOLING WATER PUMP DRIVING IDLE
GEAR ASS'Y
付図 13 回転計駆動装置仕組 Fig 13 TACHOMETER DRIVING DEVICE ASS'Y

付図 14 給気冷却器仕組 (YPC-37 型) Fig 14 AIR COOLER ASS'Y,

YPC-37 type
付図 15 給気冷却器ケーシング仕組 Fig 15 AIR COOLER CASING ASS'Y

付図16-1 過給機および排気出口管仕組 Fig16-1 TURBOCHAGER & EXHAUST GAS OUTLET

　　　　　　　(RH133-Y型装備） PIPE　ASS'Y,
equipped with RH133-Y type
付図16-2 過給機および排気出口管仕組 Fig16-2 TURBOCHAGER & EXHAUST GAS OUTLET PIPE
　　　　　　　　（RH143-Y型装備） ASS'Y,
equipped with RH143-Y type
付図16-3 過給機ブロワ洗浄装置 Fig16-3 TURBOCHAGER BLOWER WASHER,
(RH133-Y型装備） 　　　RH133-Y type
付図16-4 過給機ブロワ洗浄装置 Fig16-4 TURBOCHAGER BLOWER WASHER,
　　　　　　　　（RH143-Y型装備） 　　　RH143-Y type
付図 17 排気マニホールド仕組 Fig 17 EXHAUST MANIFOLD ASS'Y

付図18-1 クランク軸およびフライホイル仕組 Fig18-1 CRANKSHAFT & FLYWHEEL ASS'Y,

(非胴体直結、片軸受仕様） direct coupling & side bearinng spec.
付図18-2 クランク軸およびフライホイル仕組 Fig18-2 CRANKSHAFT & FLYWHEEL ASS'Y,
　　　　　　　 (非胴体直結、両軸受仕様） direct coupling & both side bearinng spec.

付図18-3 クランク軸およびフライホイル仕組 Fig18-3 CRANKSHAFT & FLYWHEEL ASS'Y ,

(胴体直結仕様） bell mounting spec.
付図 19 ピストンおよび連接棒仕組 Fig 19 PISTON & CONNECTING ROD ASS'Y

付図 20 潤滑油ポンプ仕組 Fig 20 LUBRICATING OIL PUMP ASS'Y

付図21-1 潤滑油冷却器仕組 Fig21-1 LUBRICATING OIL COOLER ASS'Y,

(海水仕様） sea water spec.
付図21-2 潤滑油冷却器仕組 Fig21-2 LUBRICATING OIL COOLER ASS'Y,
(清水仕様） （fresh water spec.)
付図21-3 潤滑油冷却器仕組 Fig21-3 LUBRICATING OIL COOLER ASS'Y,
(Ⅰ系統冷却仕様） coolong of Ⅰline system
付図21-4 潤滑油冷却器仕組 Fig21-4 LUBRICATING OIL COOLER ASS'Y,
(Ⅱ系統冷却仕様） cooling of Ⅱlines system
付図22-1 潤滑油圧力調整弁仕組 Fig22-1 LUBRICATING OIL PRESSURE REGULATING
(低圧型プライミングライン） VALVE ASS'Y,
priming line of low pressure type
付図22-2 潤滑油圧力調整弁仕組 Fig22-1 LUBRICATING OIL PRESSURE REGULATING
(高圧形プライミングライン） VALVE ASS'Y,
priming line of high pressure type
付図23-1 潤滑油こし器仕組 （ノッチワイヤ式） Fig23-1 LUBRICATING OIL STRAINER ASS'Y,
notch-wire type
付図23-2 過給機用潤滑油こし器仕組 （濾紙 Fig23-2 LUBRICATING OIL STRAINER ASS'Y,
式） 【前部駆動なし仕様】 paper element type for turbocharger
【Front side non-driving for separate spec.】

付図23-3 過給機用潤滑油こし器仕組 （濾紙 Fig23-3 LUBRICATING OIL STRAINER ASS'Y,

式） 【前部駆動あり仕様】 paper element type for turbocharger
【Front side driving for separate spec.】

2005.12.22R
6N18(A)L-V
2008.3.13R

15 16 17 18 19 20 等圧弁仕組
ISOBARIC VALVE ASS’Y
21
22

23

Fig. 34 FUEL INJECTION PUMP ASS’Y

24

付図34.　燃料噴射ポンプ仕組
35
9 34 29
31
12 37
11
36
1
10

2
13
14 3

33 27
32 26 32,33
6
25

1
27
40

3
5 28
4 30
8 40
6N18(A)L-V

7 38
39
 1
　 　　　付図58．　　給気圧力調整装置(6N18AL-EV形) 1

Fig.58　Boost Air Pressure Regulating Device (6N18AL-EV Type)

数 量 部 品 番 号
Item 部 品 名 称 Part Name
Quantity Part №

給気圧力調整装置仕組 1set 746673-12150 BOOST AIR PRESSURE REGULATING

VALVE ASS'Y

1 調整弁本体 1 140623-12302 BODY, regulating valve

2 パッキン 1 140623-12312 PACKING
3 特殊フランジ 1 146673-12350 FLANGE
4 調整弁棒 1 137602-12320 REGULATING VALVE ROD
5 ナット M12 1 26706-120002 NUT M12
6 ボルト M10×35 2 26206-100352 BOLT M10×35

7 消音器 1 140623-12341 SILENCER

8 パッキン 1 140623-12190 PACKING
9 ボルト M10×65 2 26206-100652 BOLT M10×65

10 空気室フタ 1 146674-01610 AIR CHAMBER COVER

パッキン 1 146673-01620 PACKING
取付ボルト M12×25 2 26206-120252 BOLT M12×25

2005. 3.16R 6N18AL-EV

 Remove the elbow, loosen two nuts of the solenoid valve, turn
the coil housing (with sealed in black resin) counterclockwise
for loosening and remove it from the (aluminum) valve body.
Loosen the three screws and check that the valve port is not
clogged with impurities. If it is clogged, clean the port and
check the function of the valve again according to the
instruction of ② above.

Fig.1 Module for 24DVC Power Fig.2 Module for 100DVC Power

2006. 2. 13R
Page ATT-2
 Model 6N18(A)L-V
OPERATION MANUAL

History : 17th revision: August, 2004

18th revision: November, 2004
19th revision: January, 2005
20th revision: March, 2005
21st revision: August, 2005
22nd revision: January, 2006
23rd revision: December, 2006
24th revision: March, 2008

Issued by : Quality Assurance Dept.,

Large Power Products Operations Division
Yanmar Co.,Ltd.

Edited by : Yanmar Technical Service Co.,Ltd.