Le ly AWTS MARINE DIESEL ENGINE move. GC X-ETEFOREWORD This service manual outlines procedures for servicing and maintaining Yanmar 6CX-ETE engines to obtain maximum life and performance. It explains about the structure, performance, dis- and re—assembiy procedures, important inspection points, servicing instructions and the wear limit of parts. For a full understanding of this manual, also refer to the Operation Manual and Parts Catalog. Besides reference use at your service shop, this manual can also be used as a text for your service engineers. You should understand the contents of this manual fully to offer accurate and efficient service to your customers. For accurate and efficient work, the following preparations are necessary: 1. Check the service date of your customer @When was the last service? @How many months or hours has the engine been used since the lasteding service? @What was the trouble and what parts were replaced in the last service? @What parts must be replaced in the present service? 2. Preparation of Parts Check the inventory of parts that are necessary for servicing. 3. Preparation of Report Forms Inspection and service check sheets, parts measurement record form, operation test record form. 4, Prepare the servicing tools, measuring devices, containers, eto.3. CONTENTS Specifications ~ 1-1. Major Specification ~ 1-2, Marine Gear =r pete Disassembly and Reassembly 3 2-1. Preparations before Disassembly and Reassembly ~ 3 2-2, Disassembly and Reassembly Toots 4 2:3, Reassembly Procedures “~~ 9 Inspection and Servicing of Major Engine Parts see 32 341. Cylinder Head 32 3-2, Piston and Piston Pin 37 3-3. Connecting Rod ~~ 4 3-4, Cylinder Steeve 42 3-5, Cylinder Block - “4 36. Crankshaft and Main Bearing 3-7. Camshaft and Valve Gear 3-8. Timing Gear - 39. Lube Oil System ~ 310, Cooling Water System 3-11, Fuel Oil System 3-12, Piping Diagram ~~ 3°13. Electrical Equipment - 3-14, Reduction Reversing Gears 3-15. Turbocharger ~~~ 3-16, Front Driving Equipment Periadie Inspection Service Standard ---~~ Adjustment and Set Values Tightening Torque of Major Bolts and Nuts ~1. Specifications 1-1. Major Specification (Without marine gear) ENGINE MODEL NT WKETE Ta Varia, woiersooling, ee diese gine ‘Comberton atom ‘Direct injection ‘Aspiration “Turbocharger with er alee No.of ei bre Svaee = e110 ‘Displacement i 77 Duipui Terentia aposd Hiroe 6/2500 Sormucus | rake esr ates pressure [tal ea Piston spoed wise Des Speciicsons Flywheel ond Mou coting | OULA/CronchaT band Tram 7370 Brake mon effective pressure | baad 68 Piston spoed laa 135 Torsion ration spaed(Miax. Min) rm 30075700275 Storing system Ehoiie starting, BVARW Firing order T2651 Sveti ot | Grankahah Counter cocks {Gremed fom sem} | Propeller shafe Bi-rotation Lub. oif Mex. £ B api Elect 4 nm iro YRS Type THyaravie wer mulch rps Recon Fail rward) i 198 250 roo sat epee con rang] | ram 6 zt ‘00 marine geor [Directions rotten opal sat Clocanige Gouna loci viewad (om San Dry weight fe 180 Luprcatingo [MX n 3 Sepesiy Etective i a7 Hyareuleol pressure tate 26 Fuel ijocton pump incline be Toston fing BO. eh uneven | Teet inecion rae depres Hole ype 640.367 160 Injetion pressure Talla 05 ‘Appice fst Diesel i or light i Cetone value=) Fuel iter Paper element ‘Lobreaion Forze lubrication by geared pimp ‘Lub. ol discharge volume | 07a Tram E7078 Engine ub. | Cub. ol pressure ‘ath 5205 ater Lub. oi ‘API Services grade CO Lu. oi fier SIE Seat pte CR Seo wale pomD Fibber bel typ. ge9r diving ype Freshwate pump Center ype, V-belt driving pe cootine Gooting Fresh wate cooling a Pump discharge volume ‘from Eee. es Fresh wat capesty msise engine | —t = Fresh water cepecity in ub-ten| i Type Garret TW Turbocharger [Cooling Weter cooling Lobrieation Zommon wth engine Type and cenecity Fin tube type 6.60 felt Cooling ‘Saawator oooling ‘Sasa angi SC veroll width X overal eight 7 1607 869004 Piston stoke height installation floor) 77 Engine ry waighie. clutch i 0 NOTE Max. rating: Continuous operation hours at max. Below 0.5 hours AOAS023 $205SP1-2, Marine Gear Tar VERE Reduction and | Type Constant mesh gear with multiple disc clutch reversing oss" ReauctonretedAneea/asern tai | tains | 20a Propallr sme Ahee fer conduc rata) | rom | —Warme | wawiser | roar Ceaea | eran Counce vied a er ane Propeller shaft Changeable(Cockwise/conter-clockwise) Fiarasricor resure ig /i208/2Rrom be oi pressre Bekah 20 8/7rem API Soren gro co Ory wont ta 70 ADALD23 9205SP2. Disassembly and Reassembly 2-1, Preparations before Disassembly and Reassembly 2-1-1 Visual Mark List for Disassembly and Reassembly 1 See Apply liquid w CREB a\G | te > Moasure Clean Bi Olt supply Use torque wrench EI THREE BOND 90.988.058 282 The figure shows the widths across flat of the hexegonal part 2-1-2 Disassembly (Prepare the disassembly tools, measuring dovicos and record forms (2iPrepare the cleaning machine and cleaning cans. (3iPrepare a place for putting parts and parts containers. (4)Extract cooling water and lube oi (5)Put the disassembled parts in order (Return bolts and nuts to their original Positions temporarily to avoid contusion with different bolt and nut types. (Locate the cause of trouble accurately before disassembly, and do not remove or disassemble unnecessary parts. 0A 5023 50083P 2-1-3 Reassembly {1\Clean and inspect the disassembled parts completely, (2iApply clean engine oll to the sliding and rotational parts before installation (3)Replace all gaskets and O-rings. {4\Apply liquid packing to the necessary parts to prevent water or oil leakage. (5)Check and ensure the correct oi! and thrust cleerance during reassembly (linstall the parts according to the alignment marks when they are provided. Take care of the combination of the parts with selective engagement {7/00 not mix up bolts, nuts and washers. Tighten the major bolts and nuts to the specified tightening torque. Take special care when tightening alluminum alloy parts (@)Apply engine oil to the threads and seat of the major bolts and tighten them to the specified tightening torque.2-2. Disassembly and Reassembly Tools Standard tools The following are the standard disassembly and reassembly tooLs: Screw driver Hexagon ber wrench 2,8 changeable lor clutch emergency batt) Name of tool Size Shape Double-heaced wrench x10, 12x14, 19x17 (or removing fuel valve) 19% 22, 28427) Wrench 1,36 Monkey wrench 0 P Double-heed wrench 17x19 = Phiors ° Box wrench 19x12 (fr oy. nea 1350 (18 Pll Oboe) £ Extractor (for tua valve adibatic packing) 127610~92910 - Extractor (Jor remaving tul valve) {peso Cleerence gause (for edusting intke/oshoust ve Hemmar Filter wrench for romoving fiers) seca? outer Turning hendle (Filter wrench) Tools (to be specially ordered) Name of tool Code No Shape Socket (for rod bol) 1a7e0~ 92790 ——)) Extrector for valve guide 127411 - 92160 ees Entretor for fue oi valve T7616 9500 Piston insertion too) e230 40 Piston rings fting/removal ore bol L. Oil pan poioning toot 7. Boi pe) {27610-92700 w 2. Spacers A ? 2 ‘2610-880 N 3. Spacers @ - vere10-92600 ADA8023 9205S?Name of too! Code Na shape Feihaes pane esa (BEES i Space: iBi0-92490 nt ete 080502" oo Gy ‘Automatic timer too! {adiabatic materiel puller > | rsaser=s4200 paralior wisth 24.28 (4-83) ‘Adiabatic material puller 17761082910 (Standard) Protector puller 127696-€2910| ‘Stem seal insertion too! Vaive guide pulter ADAGD2E 05SName of tool Code Na shape Exhaust manifold puller Universal joint Fal vave pall tol 1 | kre 2 t——2— Special tool for ete No Name of tool | Note Emergency bolt span | For tightening the emergency bolton ciutctfature 1 | Gear pul 2 Bearing eperstor For removing bearing: utes together Bere withthe goer puller = 7 a Hydrautietiting ool | For dsessembly of output shalt joint Output shet joint and lege ator ‘ A0AS023 S205SP =Name for using ead pains “Tho sliver grey sami-dry type viscoelastic liquid packing besed on extreme hest-retating CTHREEEONB euxitiory | synthetic rubber end synthetic resin. Agply the packing tothe seal surface and join the pecking): part after servaral minutes when the pecking has become seri-cry. “The white liquid packing based on nylon resin. Brush the packing onthe esl surface and Jpin the part after several minutes when the packing has become semi-dry Be sure to str wal before use White paint ‘Coat the paint on the contastaree with the oylindor body before inserting the oylinger liner to prevent rust and water leekage. (Use the oil type meke-up peint.) Name quantity Code Ne. Note tT 7 t The sivang sealing agent removes ecole | 1 e080 UNIcoN srarao-oreeo | avickly (1-10 hrs) (tha 4) ¥ | Dissolve the agent in 10 parts of water or 3 i feawater (By weight ratio) ang stiri Well. 3 | coumerogent | 1888 ee E | (eouse soa) | agg xa) Scale can be removed by just immersing the i I i disassembled ports. To speed up the treat- 2 — ‘ment, tr the solution. When the cleaning . | performance drops, neutrelize the solution $ | PHtestpaper | sraroo-o4200 | Snd threw it ewer, & i Anti-rust agent ‘Mix the agent in ten parts of fresh water land stir the solution by operating the engine a 74100-04200 for about § minutes, The anti-rust perform ‘ance lasts for about 6 months. Yenmar Super Freeze iT ‘Gen be used Goth es anticireeze in winter and eolant in summer. The performance lasts for 2 yeors. The Super Freeze cen safety be mixed withanti-rust agent Teme. -se | -00 | -150 | -ae | -20 | -we | -ac | 40 Volume ratio wx | ax | gos | asx | ax | asx | sox | 55x ADASG2E 92055PName quantity Code Ne using Has strong performance 10 remove eccumulated carbon Cen safety bo heated to double the cleaning| performance Corrodes almost no metels, including iron peanteareta (Also has entrust effet.) ce ko x 20 75600-02000 tceening soe) To use dissolve 1kg of he agent in 40 liters ot water. When @ cleaning machine is used, use 4-64 solution ond heet in 0 89-80. This will Forthar reise th eect. ‘Soecil cleaning agent for turbocharger sexe 19700-10000 | blower. Needs on water washing wee xt ‘18200-30000 150060 x 6 19200-20000 Meesuring Device Name quantity Code Na using For testing th op tester RCT-2a 988000-088000 ‘AOASO23 S2055P aR2-3. Reassembly Procedures Toole Caution No Item’ Procedure + | cylinder Block Clean the bearing holes com Roverse the cylinder block belore reessembly, ly. T-plug 1/8 | tightening | 0,5Skgf =m torque | Piston Coot- ing Nozzle Install the nozzle correctly according tothe positioning pin. ‘Take care not to over-tighten the nozzle Tightening torque’ 2.0egt-en Check coretully thet there ore no chips or dust in the oil holes of the nozzle body. nozzle installation hole and check nozzle. ‘Check that the nozzle body does not touch the eylindor block Mlustration Oe Cam Shaft | Apply lube cil to the cam cheft journal Insert the cem shatt. Install the theust pate. | Tightening 202 torque 28 beh Mesure the side clearance. Side cleer aa 0.10-0.26mm Installation of com shaft metal Replace the car shaft metal as follows: 1. Apply lube oil 0 the outside circumference TZ | ‘of the cam shett metal end the inside bore (of the block. Aliga the oil hole go thet the joint of the winding metal comes to the unner sice. Overlapping of not less than 2mm will suffice for tho alignment of the oil holee he block end cem shaft metal (Check the alignment efter knocking in the car shat meta.) Hole more than 2mm Insta ion of tho thrust metal A0A5023 9205SPItem Procedure 4 | Gooling Water Passage Cover Install the cooling water passage cover Crentshett ang Mein Bearing ‘The upper bearing (block side) has en oil {gr00v0; no oil greove in the lower bearing The stenderd beering is et the flywheel side (with flange). Apply lube oi to the crank and assemble. Confirm the atignment number on the bearing cap and block. Assemble with the F-mark et the flywheel side. Apply lube oil to the bolt threads and saat eee ond tighten the bolt to the specified tightening torque. Turn menuelty to check that it turns lightly, Measure the side clearance Cap bait tightening torque 0 kahm 0. 185~9, 286mm 98-8 mm | ro Side closrance Cranksha Bearing oi! Measure the side clearance Tool& aution lilustration Fitting the bearing cap, AOASO29 92058? 10Na} Item Procedure Tool& Caution Mlustration 6 | Idle Gear (Lube Pump} ‘Check the gear tide clearance, 0,066-0, 114mm ‘Check the gear backlesh. Gear backlash 0,080, 18mm Install the ite gear 10 the cap. toraue Tightening | 4,52 Oyghim Fitting the idle gear 08023 82055P oiItem Procedure Toole Caution llustration Lube 011 Bump’ Install the lube cil essembly. Install the suction and discharge pines. (Bolt head wiath 12)| gor Tightening torque. 2.5 ‘afm oD oa Check the gear becklath (to the crankshall 7 Backloch for crane gear | 0-12-0.22mm Fitting to the suction pipe Fitting to the Safety valve and dischanger pipe Goor Cate Inetall the bolt for fixing tho fuel pump and the stud bolt for Fixing the seaweter pump to the gear case in advance. Match up the mounting surfaces of the it an Align the positioning pia to the block end install the gear c (Bolt heed width 12) 202 Tightening torque | 2.6" kfm ut off the protruding pecking 011 Pan ring the gaer case level so that the packing it] not Break. (Use the fiting tool.) ee (Bolt head wiath 12) Tightening torque After tightening, cut olf the packing protruding on the wheel housing side. Note ‘Apply THREEBOND to both sides of the packing at the three-face jaint of the gear case and flywheel side. Match up the instelletion faces of the wheel_housing Stop of the joint face at the Flywheel housing si 8.1mm Fit the oil pan useing the tool AU 3 ESP ==Toole 11 | 01 Seat case Deviation ar the il feo! insertion area | 02mm [crankshatt center sual Flywheel housing Tightening torque | Instalt the tube ot! piping (flywheet | housing ~ oil liter} | rn No} Item Procedure eeumanl itlustration 10 | Flywheel | Assemble the flywheel housing according Housing | to the positioning peralle! pin. Press-tit the seal into the oil seal case (with the prass-fiting tool) Note ‘(Apply lube oil ta the outside Up of Y fitting.) Inatall the oll seal case assembly to the flywhee! side with its off escape hole vertical 12 | Engine Foot 12) Plverse the eylinder diock Install the engine foot Reverse the cylinder block AOA 8025 92055PItem 14 | Tappets anc Procedure {Insert the teppets into the cylinder block Tool& Caution Ulustration Clean the outside circumference of the cylinder sleeve completely and insert it rmanuslly into the cylinder block. Note Before inserting the cylinder sleeve, check the cylinder number and the insertion direction. | (Size code is for the cyliner sleove) (ldemica! code for the cylinder block and sleeve) (Make a combination of A, B. C and 0.) (Direct the code side to the anti-operation side.) (Marked in black paint at the anti ‘operation side.) Do not place an the cylinder head face after inserting the eylindor sleov. Be sure to assemble the cylinder sleave manually. (Do not use 8 hammer.) joasure the protrusion of the cylinder Liner protrution | ©03-0.08mm Measure the distortion of the cylinder liner: 150.03mm Cylindricatity (The merk ot the cylinder black side 18 Punched on the head joint Face of the ‘operation side.) Size code is for the cylinder sleeve. Marked in black peint et the anti-operation TBM4 | Piston fitting code Cylinder block fiting code Teppets Case | hoe. cover {Apply ongine cil to the tepests. Move tho tappets manuelly to check that they are inserted smoothly. > Install the tappet case cover ater insert. ing all tappets. oan Topnet Bolt heed wictn 12) | 2 Tightening Torque | 12>! Taat-m 18 | cyiinaer | Clean the sleeve fitting ares of the cytindar i Sleove block completely i AOA8023 92055PToole Na | _ item Caution Procedure Illustration 16 Idle Gear | Install the idle gear shoft. Direct the shett’s oil hole upwards. Tightening |, 208 torque 2.6 atm Install the idle gear. Gear sige | 0, 15-0.35mm Install the carn goar shaft. Gear backlash | 0.08—0. 16mm Mentone: 0,10-0.25mm, Use the puller tool to remove the cam gear. Install the tual pump drive gear Tightening | 5.410 torque 20 kate eu Idle gear 17 | Sea water | Install the sea water pump to the goer c Pump dieecting the oil receiving port upwards. Install the drive gear and tighten the nut 10 the spesitied tightening torque. Drive gear fixing nut| 60 fightesing torque | 14.8" kghm Inetall the fual pump driving beering ease assembly to the gear cose. Gear backlash | 0.08-0. 16mm Motch up the alignment marks of gears at the same time, Fuol pump driving bearing caso AOASD23 92058? =HItem Procedure Took Caution Mustration 8 Piston end Connecting Rod Assemble the connecting rod to the piston. ‘The size code, ML or MS, is provided on the piston head. Match up the code with the correctly code of the cylinder sleeve Distribute the end gaps ofthe piston rings ‘evenly on tho piston. Ingart the piston into the cylinder liner, placing the con. rod alignment mark on the ‘operation side, Apply lube oil Confirm the alignment marks on 1! ‘connecting rod and cap, and install the cap. ‘Apply lube ol to the threed seat fece end tighten the rod bolt to the specified tightening torque. Tighten the bolts by turns evenly 3 times 10 avoid uneven tightening, Tightoning 408 torque 28 hef-m ‘Measure the side claerance etter tigh the bolts. Rood large ond Side clearance | 0: '8-0.35mm Install the cylinder block side cover (An alignment mark is provided on the rod bolt. This is because @ torque wren ‘cennot be used in restricted engine room ‘speces.) = - Goar Case Cover Install the oil see! to the gear case. Note = ‘Apply Tube oil 19 the exterior and hp cf the of! saa! before press-fittng it Inetall the gear cose cover. Note The positioning pia (apring pin) Te provided at the joint face o! the gear case and cylinder block Measure the face deviation of the front ‘tive installation, Face aviation Less than 0.0508 for crack conter Operation side Suc. Code Mark Exh. MUMS. | Assemble the piston and con.rod. ae ( Fitting the gear case cover ADRES 9OESP 16Tore (Align the positioning poraliel pin holes.) Tighten the bolts to the soeeified tightening torque Tightoning torque 207 pgm Measure and chook the flywheel fsce ‘deviation ond centering lovetion daviation. Fece deviation | tess than 0.13mm Follow the instructions below when re- placing the top indiestion plate: 1)Bring the No.1 piston at the fiywhool side to the top position. (Check using the ial gauge.) 2)lnstal aligning the top punched line of ‘the flywheel to the piston top position, 48) The alignment error between the top ‘mark of the indication plate and tho top puncte line of the flywhee! should be ‘within #20 min Na | Item Procedure oe, llustration 20 | Bearing _| instal the sea wator pump drive bearing Cote the V-pulley. cher efter tightening the nut tha breather. | | 21 | Flywhes! | Install the flywhee! (Check the Not cyl.top. ADASO23 9705SP ar aNo) iter Procedure cool Caution | 2 | Install the injection timing adjustment end | turning window covers. | 1) Adjust the injection timing with the | governor control lever at its max. posi | _ thon (pump reck’s max. scale). | 2yatter edjusting the fuel timing. pur Injection alignment mark aligned with | the punched scale on the flange side | _ mounting of the fue! pur. 3)lnstall the turning window cover Tightening | 206 oraue | 8 erm Injection a timing net 23 | Breather Install the breather Mlustration 24 | Cylinder Head) Valve sink: intake 0.2mm, Exhaust 0.2men Install the head gosket according to the positioning pin. Litt the eylindr head lavel and install It according to the positioning pins (spring pins)(4 pes.) Aaply lube oil to the threads end seat of the head bolts and tighten them 3 times 10 ‘the specitied tightening torque in the proper tightening order Tightening |, ,20 Tofaue "| 25° atm procedures for the heed bolts.) Measure tho top clearence lightening order) cam sett side B59 52 oo BA @A BA BAB | Fly 8020 80208 | se $98 0G 9Qe| te pump ae gear side Install the fuel return pipe joint Tightening of the cyl. head ADAG023 8206SP 6Na | Item Procedure Toole Caution Mlustration 25 | Frosh water Tank Install the fresh water tank to the frashwotor pump. Install the stay of the froeh water tank. om 26 | Fresh water he fresh weter pump essembly to Pump the cylinder block Install the thermostat tothe fresh water sump body ‘Thermostat valve oponing tomperature:71° Fullapen it test temperature 85 | | 27 | starting | install ene starting motor to the fywhest | | Motor housing Tightening +08 torque ° helm 28 | Lube 011 Pipe and Lube oi Futter Install the lube oit filter mount to the oylinder block. Install the lubs it filter mount AOAGDG $205SP ayaNo} tem Pocedure Tooré Caution lilustration Install the lube oil piping (Lube ol flter—tywheel housing). Install the lube o!! piping (Lube oil fitter-eylinder block) Insta the filter (install the filter) 28 | Lube oil Cooler Install the oil cooler assembly to the oil ‘cooler mount {install the elbow of the Lube cil pipe filter ‘and union Lube oll pipe to the filter in edvance. ) Install the cooling water piping (220 water pump-Lube oil cooler). |unst@n ine ot! Cooter assematy) eS AOAS023 92055P.Na) Item Procedure Tork toned Mlustration Install the cooting weter piping (LO cooler-Marine gear cooler} Install the coating water piping (Marine geor cooler-intercooler. Install the cooling water piping (intaroooler-teesh water cooler). Install the cooling water piping | (lube oit cooler-tresh water cooler). Do not bend the piping, ce Clutch oooler L.0. cooler 31 | Engine Lift Fixture Install the engine litt fixture, Instail the engine lift fixture ADAG023 92055P. ~ aItem Procedure Mlustration Wire Herness Install the wire herness (engine side) Note. T)Beware of The Feated area of the ‘exhaust and bend pipes as well as the moving parts when wiring. Deter 10 the electircal wiring diagram and ansure coract terminal connections. Install the remote control cable support ‘mount. (Ta be installed to the installation spat at the top of the side cover on the ‘operation side of the block.) Install the Marine gear remote control cab mount. cyLeLock i L S SUCTION MANIFOLO, Cai Huse ot coocer, FIX TO MARINE GEAR canuneet wr orrion LS A0A8023 92055P. -2oNo | Item Tool Caution Illustration Procedure 33 | Direct Coupling of Reversing Gear Reeduction snd| Install the rubber block flenge to the 6 0 ts tor 60x-ETE fe] aie | omer oS al white [Starting motor “s"[@) 0.85 | whi. Black [OW meter-U" 2 Wee [eo swe ees | £etw. —Jetutch Lovsw> [2] 065 [vnue.sive [ew tone. "sw7 [a 068 | Gra Lor” Sw" lal 05 [wnve-nea [ewimersw= fal om [paigm _ |Uiprsameier [s| 0.88 | vo.sinck [oererator'L~ || 6.85 | Grann Blox | B6G8" ee” lel 5 [ras ‘Stervng motor'B° 8) O85 | GrewnsRes | WAIT "Sw" ja| 0 [el fo lol § [eux [o fa] 065 [alverea | teehee lal 005 |aieck ‘fo fos [as ° {Install the cubber block tlange ring to the flywneo input sheft joint of the reduction reversing gears. Apply silicon ait to the eubber block, lift he reduction reversing gear (assembly} | love, and insert it into the ring for | sire ousting Install the reduction clutch A0A8023 $205SP esNe | tem Procedure Tool Caution Mlustration 34 | Fuel Pump Install the fust pump mount to the cylinder block. (Axial deviation TIR within 0.3: deviation | tengle within 30 degrees) (TIR:Total Indicetor Reading) Install the fusl injection pump, install tha 1ubs oi! piping (eylindar block=fual pump), ‘CAUTION: (Do not overtighten tha block or it may "crack-) Union | tightaning torque 0.5- hgh ane Measure Fuel pump mount Assemble the flexible coupling Assemble the Fuel pump Timor and Flexible coupling Titting the Lube oil pipe ADAED29 92055P eaeNa] Item Procedure roo! Caution lllustration 36 | Fus! Injection Vaive and Pipe Put in the protector end adiabetic material ‘and install the fuel injection valve to the covlinder hood. at gem Note 1)Provisionally tighten the tus! injection ‘pipe joint until contacts with the fuel valve s90t (0. tightening torque of 2.5-3,0ka-m. Thon, the fuel injection valve and the fue! injectian pipe joint. 2vApply melyddenura disulfide t0 both the outside and the inside cireumterances of the protector bofore inserting it. Install the fuel injection pipe. Tightening torque’ 3. Seaton Install the fuel return pipe Install the cocker erm case. Packing Protector: 36 | Exoust manifold Install the exhaust manifold. Install the exhaust manifold. 37 | Viscous damper Install the viscous damper. Viscous damper ADASG2S 92065? 28Tore 1)The installation range of the rocker ‘orm shalt mount is 180 degrees. If the mount is installed in reverse thevalre head position will be varied. (See ig. a8 the right.) 2)Check the performance ol the intake! exhaust valve, Fit the push rod to the dentin the teppet. ‘Adjust the bridge valve heed adjust bolt, tnd tighten the set nut. Bridge valve head clearance Int 9, 28mm Exhaust 0. fmm Tightening torque | 2 Okef-m Ingtal! the intake/exhoust rocker orm (assembly) Valve arm | MB bolt Aissy | Tightening forgue” | Mt10 bolt Note When replacing the valve guid, note that the guide is lightly calked (0 he head. (Assemble the push rod, adjust the intake! exhaust vslve bead clearance, and install the rocker arm assembly.) Na] item Procedure Caution llustration 38 | Intake Install the velve bridge Exhoust Rocker Arm | Note (Assembly) Adjust the valve clear: AOASI23 $2065 oppItem Procedure Tool: Caution Hlustration 38 | Cooting Weter 5 the piping between the exhaust oo land the hiter Insisll the piping between the filter and | the injection puma: | Install the feed pump inlet piping Pipe ‘manifold end the tresh water tank i (Freeh Water) Install the piping between the heac snd the | fresh water cooler | | | i 49 | Fuel Piping Install the piping between the feed puma AOAS023 S206SPNa} Item Procedure i Caution ‘oole Mlustration 41 | Fuel return piping 42 | switches of meters Install the fuel retur piping. Fuel return piping lnstall she switches of meters. 7 Penis name Tocation Hydraulic switch (05i9/a) | Cylinder block 1B | Hydravlie switch [Reduction reversing gears I (| Dumper (P14 gral erenion} [Lube ol (lube ol hler=oil housing Durer (°F 1% gaalel ess) Lube oi! ube oi hiter=0 ho Dumper OT Ve vere extesion! eduction reversing gears Tachometer sensor Flywheel housing Fresh water cooler ‘Temperature senzor Tatake meri Lube oil cooler Thermo-switen (1006) Pethedstmanttimcune ot cote] ‘Lube oi sender unt flete il ite rtvnee! tn Cooling moior sender unit | SPR, F eS io ool Exnaust manfoie Flywheel housing | Seal washer Fresh water cooler Mydraulie switch ‘Cube oi ker “8 (Adjust the clearance between the alternator end the mount to 0.05-0.1en by | the eojust shims and tighten.) ‘Adjustment Procedures ‘)instell one en of the adjuster to the ‘rash water cooler side. | 2)Install the other end of the edjuster to the elternetor tentatively. 3)Adjust the pulley with the shims. 4)install the V-belts (2pes.) and edjust the tension with the adjuster. I Bolt(n10x20) Posey \ Tightening torque cover ** XN Flexion sistance neat AOA023 9206SP Tighe7 tem Procedure ante, Illustration 44 | Fresh water | tnstoll the fresh water air venting pipe. venting | | FW Cooler 45 exnaust | Install tne urbocherser mount to the fmaniors, | exnaust menifoid | Exmovet bend | Install the turbocharger. (Installing the | ena tureosheger body) ' Turbocharger | Install the turbocharger cover. {Instelling | the insulator) | Install the lube o'| pipe 0 the turbocharger (nat pipe, Outlet pipe) Install the cooling water pipe. | Instat the exhaust bend. Install the lube oi! pipe A0A8L22 92068P =Na} Item Procedure ~T Took Caution Mlustration 48 | Clutch Bracket Install the clamp bracket Interoooler fand Intake | Connecting Pipe 48 | V-balt cover Install the intercooler. Install the inteke Connecting pipe. (Ducts A.B) ( duct A | duct B Install the V-belt cover. ADASD29 8206SP areaProcedure ilustration A0A8023 8206SP3. Inspection and Servicing of Major Engine Parts Preparations (1Clean all parts completely to remove dust, carbon, oil, scale, etc. (2)Blow compressed air through oil holes to remove dust and check that there’s no packing in the oil holes. (3)Remove carbon from the cylinder head intake/exhaust valve, etc. Take care not to damage these parts when removing the carbon, (4)Put in order the parts that have a definite ‘combination. ‘Standard for Replacing (Repairing) Parts ‘Measure each part end check it according to the| respective inspection procedures. If the part is| defective or exceeds the wear limit, replace it. Also replace any part which is expected to exceed the wear limit by the next inspection| even if it is within the wear limit now. 3-1. Cylinder Head The 3-cylinder integrated type cytinder head has outstanding durability and high rigidity. The unique Yanmar intake port and inteke valve in the cylinder head give superb combustion performance. 3-1-1 Inspection of Cylinder Head (1!Distortion of Combustion Surface Distortion causes head gasket breakage and compression leakage. Check and repair as follows: DClean the cylinder head tace. @Place a straight edge along each of the four sides and each diagonal Measure the clearance between the straight edge and combustion surface with the thickness gauge. om ee area ea Da | oe os allowable limit, either repair or replace the part. ‘AOAB023 S206SP 2(2}Color Check of Combustion Surface “Remove the fuel valve and intake/exhaust valves ‘*Clean the combustion surface and check for the discoloration and distortion. *Check for any cracks with the dyeing flaw detection agent (color check) (Color check) (3llntake/E xhaust Valve Seat ‘*Stellite is welded to the valve seat t 0 boost wear-resistant characteristics. Check the seat surface. If the width is too large, or the surface is too coarse, repair Intake v0" Seat deg, Exhaust 0" Intake | 178 | Seet width ——— - Exhaust 2.12 Volvo Seat Repair Procedures: * Repair the surface roughness of the seat with (Seat width measurement) the seat grinder. Seat repair angle, Stellite weld, Seat width measurement Intake side grinder ~-~-~ Angle 30 degrees Exhaust side grinder ~~~" Angle 45 degrees # The valve seat width is extended after use. — Grind the seat surface with the 70-degree —— a grinder, and finish the seat surface to the Intake wo standard dimension with the 15~degree F grinder Exhaust 4° Note: \ Before repairing the seat surface be sure to check the clearance between the valve and valve guide. If the clearance exceeds the limit, replace the valve or valve guide first. Seat width Seat Stelle weld (Seat repair angle) ADASORS 8r06SP - a‘* Knead the valve compound with oil, and lap the valve with the compound. * Lap the velve with only oil for finishing, No ‘Alter the valve seat repair is completed, clean the valve and cylinder head completely with gas oi! to remove valve compound and grinding powder. 3-1-2 Intake/Exhaust Valve and Valve Guide (Measure the clearance between the intake/exhaust valve stem and valve guide. If the clearance exceeds the limit, replace the valve and valve guide Valve seat ringer Geter Replace the valve seat JN a Measring point Value stern sant (oe) Stendard ™~ dimension Standard Max. | asd t Clearance | allowable [Limit dia, [Pimensional élearance SN tolerance = | Stem out “Bg or) 2 ice dia 08 pee 0.035~0.062 02 ‘anean) = [Valve guide! 7 as © [inside dia. 10.015 se % =0.040 3 a 79 £ [Seda | yg 00 cnn oz = |Valve guide 0 81 5 inside dia 0.015 = Note: The valve stem seal is assembled to the lintake/exhaust valve guide. If this is removed. lonce, this can't be reused. In such cases, replace the part. (2)The intake and exhaust valves have a similar shape. Do not mistake the one for the other: * Intake valve has * S* mark, while the exhaust valve has * E* mark. * Inside of the intake port is cut for the intake valve, (3)Valve Sink After a long use and valve lapping several times, the valve sinks and the combustion performance drops. Measure the valve sink, and repiace the valve and seat if the sink is excessive. (am Standard | Allowable ieletistlia dimension limit Intake 0.20.1 09 Exhaust 0.20.1 og AOASO23 6206SP = 3 (Stem seal) mar Cut point for intake point (Valve sink}3-1-3 Valve Spring (1)Inspection of Valve Spring ioe eae Cee * Check for any flaws or corrosion in the spring ¢ Measure the free length of the spring. # Measure the side fall(to the right angle) of the spring * Measure the spring strength if the tester is available. {nm} ‘Standard | ~ Allowable dimension limit | Side fall - 1a Flat gage Free length 50 49 Compression a (atimm compression) | _ 2.759 8 « 3-1-4 Installation of Cylinder Head oo, a Tighten the head bolts to the specified : tightening torque according to the tightening order. Take care not to distort the cylinder Papin aea head. Tightening Procedures: * Apply lube oil to the threads and seat face of the bolts © Tighten the bolts 4 times in the tightening order. Ist time Tightening " torque ieee 3-1-5 Measurement of Top Clearance (Measuring Procedures *Place 3 pes. of quality fuse (1.5, 10mm length) on the piston head. * Install the head gasket and cylinder head end tighten the bolts to the specified tightening torque. © Turn the crank (in the operational direction) to depress the fuse © Take out the fuse, measure the depression and obtain the average value of the three fuses. Top clearance (How to Place the Fuse) A0A5023 $2085P -s-(Caution): The thickness of the stendard head gasket is 1.5mm. The following gasket is also available for adjustment use. Thiakreas [Farts Tarn | TRH a0 1 amm | 1686-01360 ~ fmm | 127696-01360 3-1-6 Intake/Exhaust Valve and Rocker Arm Mount (1lnspection of Rocker Arm and Mount ‘* Blow compressed air through the oil hole. ‘¢ Repair or replace the damaged or worn part. Measuring the rocker arm bush and rocker arm shaft clearance (mm | Standard . dunension | Shafi outside |” i9,067~19.980 19.90 Bush inside Fe - ars 200 ~70.021 70.083 Oil clearance | 0.020~0.054 3-1-7 Adjustment of Intake/Exhaust Valve Clearance Check the clearance every 300 hours operation and on disassembly and reassembly, and adjust when necessary 2) Adjust while the engine is cool. b)Move the piston to the top dead center of the combustion stroke, ¢)Loosen the valve erm adjust screw and nut, end the adjust screw and the nut at the bridge side d)Press down the valve arm lightly and turn the adjust screw of the valve head ( at bridge side). Tighten it until there is no clearance with the valve head. (Fig. A) e)Lock the adjust screw when the valve head clearance is zero. f)Adjust the clearance between the valve arm and bridge to the specified value, and lock the adjust screw. (Fig.B) g)When the timing gear is disassembled, be sure to check the opening and closing angles for both the intake and exhaust valves. (To check the opening and closing angles, turn the flywheel and read the scale on the flywheel according to the movernent of the push rods A0A8028 92065P - 8 Gasket Spine nee Fost incon valve Cylinder heed (Measuring the valve arm bush)s : Esnauston348 (am) eeceiaaes eee a1 [ Yaenees | antes Tntake | _0nse 00 rovenonltteo? ance Exhaust oa OO (2)When the timing gear is disassembled, be sure to check the opening and closing angles for both the intake and exhaust valve. (To check the opening and closing angles, turn the flywheel and read the scale on the flywheel according to the movement of the push rods.) eee (Valve guide protrusion) | Open | bT.v.c | sss Intake |} 1+ | Close apoc | ats eB.pc | sx bT.D.c Exhaust 3-2. Piston and Piston Pin The piston employs a aluminum alloy casting with low thermal expansion and superior cooling efficiency. The oval piston shape offers smooth movement in the cylinder liner, and the toroidal shaped combustion chamber on the piston crown offers superb stating and combustion performance. The piston ring configuration consists of 3 compression rings and 1 oll ring. The top ring groove is specially processed to boost its wear-resistant characteristics. Each cylinder has a cooling nozzle to cool the inside of the piston, The piston and liner are fitted selectively. 3-2-1 Piston Piston (1) Piston ; “Remove the cerbon on the piston head and combustion surface. (Do not damage the piston while removing the carbon.) Check for flaws and cracks on the combustion surface. (Conduct color checks if necessary.) (2) Cooling Section ‘+ Remove the lube oil sludge from the inside of the cooling section and clean eating sorte (Piston shape) AGA8»023 9206SP — 3 —(3) Piston Outside Dia. and Ring Grooves *Repair or replace if the piston outside circumference and ring grooves are damaged or worn, * Measure the piston dia. at about 30mm from the bottom at a right angle to the piston pin. (mm, Stendard | Allowable dimension _| limit Piston skirt = 0.015 outside 109.925 109.75 (Measuring piston) Cylinder Bora Piston dia Dimensional Dimensional torelance Code Code torelance 110 120% L ke Hy 8 Sh a | oto 988 e110 2888 m ai om ws | 40! +n0 3g § oe Piston outside dia. ID mark: (Q) is only ‘Clearance:0.080~0.100 Spotcoblenstivine toot the ape bor eterna ey (Do not use the part for regular dis~ and re-assembly.) 3-2-2 Piston Pin (1) Fitting of Piston and Piston Pin Apply lube oil to the piston pin hole and insert the pin into the hole slowly. Fitting of piston and piston pin a Piston pin outsi pin dia 46 220" Pi in dia 4635 Pin-Pin hole clearance 0.003~0.028 (2} Measurement of Piston Pin Outside Dia, Measure the outside dia. Replace if worn beyond the limit or if there is excessive step wear. mm. Standard ‘Allowable dimension lienit Piston pin outside | 45. 999~48 977 15.95 dia. ‘AGASOIS 6206SP - 8 (Measuring piston pin position) (Measuring piston pin)3-2-3 Piston Ring (1) Measurement of Piston Ring Measure the width and thickness of the rings as well as the clearance when the rings are inserted into the ring grooves. Replace the ring if it is worn beyound the limit. (em Hing width and] Standard | Standard] Allowable max Fing grove width | dimension | clearance clearance —- ing width f No.t | Ri _ = — ring |Ring groovel bene tel a width t Ring width No.2 a No? ing groove 0.075~0.105 02 width Ring width No.3 if No ing groove 0.050~0.080, 0.15 wwigth ow [Ring width ei fing arsove 0.030~0 060 015 swith (2) Measurement of Ring’s End Gap Insert the piston ring into the cylinder liner (use spare part) as shown in the illustration and fit the ring closely to the piston head to measure the end gap clearence of the ring with the thickness gauge. Measure the clearance at about 60mm from the bottom of the cylinder liner "No. 2_ {moving taor chrome pi No. 3 (whole Parkerising} Ea Teper ender moving taen chrome plates) A) Round cut OS Serre face (SUS nitrides) (SUS nitrdea) ‘Tesi expendsr (Ring cont L ene ie uration) (3) Replacement of Piston Rings *Clean the piston groove completely before replacing the ring. Fit the new ring with the ring fitting/detaching tool. (Do not expand i EL sine (mm) End gap clearance] Standard, Aligweble Piston ring | 0.25~0.45 1s Oil ring 0.25~0.45 18 the end gap too much.) Fit the ring with the maker’s punched mark side up (towards the combustion surface} (Note that there is no maker's punched mark ‘on the oil ring.) © Check that the ring moves lightly after fitting ADAGO2S 9706SP ~ tie un with the maker's(1) Apply lube oil to the piston ring and the entire area of ring groove, and rotate the ring. (2)Distribute the ring end gaps ‘equally along the piston (See illustration at the leit) (3)When distributing the ring ‘end gap positions, place the ‘end gap of the top (No. 1) ring at the intake side. (Avoid the exhaust side in ‘order to prevent the gas entry.) Fitting the coil_ exp: for the oil ring (4) Piston and Con. Rod Assembly ‘* Assemble so that the large valve recess dia ‘on the piston top comes to the right and the small valve recess dia. comes to the left when the con. rod large end’s punched mark side is directed towards you. (Suction ‘S* and exhaust E’ are respectively punched to the large and small valve recess dia.) Insert the piston and con. rod assembly into the cyliner liner with the rod’s punched mark directed to the operation side. (Caution): If the piston is assembled in reverse, the valve interferes with the piston head during operation. AOASI23 9206SP (1) Place the coil’s seam at the ‘opposite side of the ring end gap. (2)Use tge coil protection tube for the ring end gap. Intake side 3 (Gparation side) (Piston and Con. Rod assembly) “03-3. Connecting Rod The connecting rod is made of high strength carbon steel forged iron. The large end is cut slant and fitted with aluminum metal, while the small end employs a double layered copper alloy bush. 3-3-1 Inspection of Connecting Rod {1} Inspection of Serration Conduct a color check for the serrated area of the large end (refer to P.33) to check for any cracks (2) Side Clearance after Assembly Check the side clearance when the con. rod is assembled to the respective crank pin. Also check for any flaws on the thrust surface of both ends mm} Standard ‘Allowable __ dimension _ limit Side gap Tv orenaes 04 3-3-2 Crank Pin Bearing (1) Inspection of Crank Pin Bearing * Check for flaking, fusion, seizure and other damage to the friction surface. If defective, replace the metal Measure the oil clearance of the crank pin with the Plastigauge Measurement by Plastigauge: insert the Plastigauge into the large end cap in the crankshaft direction. ®Tighten the cop to the specitied tightening torque, @Remove the cap and measure the depressed Plastigauge width using the measuring paper. [cam iohening wreve [B= kato ADASOR? 206SP epee (Connecting rod length) (me Sandara Allgwabre dimension limit, 0.04~0.105 0.13 Plastignage (Measurement by Plastigauge)(2) Cautions for Replacing Crank Pin Bearing *Clean both the bearing face and rear face of the bearing completely. ‘*The bearing should be fitted closely to the con. rod and cap. ‘* When assembling the con. rod. match up the large end nos., apply lube oil to the bolt seat face and tighten the bolts evenly. 3-3-3 Piston Pin Bearing (1) Inspection of Piston Pin Bearing © Replace the bearing if it is discolored, worn or damaged (om canara faint Saaton_| “int ee Giicenrarce | vitinouse | om 3-4. Cylinder Sleeve The dry sleeve employing anew material has improved wear-resistant characteristics and higher strength. 3-4-1 Measurement of Sleeve Measure the inside dia. of each cylinder with the cylinder gauge. If worn beyond the limit. replace the sleeve (eam Standard | Allowable dimension fimit 9110338 Gylinder sleeve 007 a inside dia Moots 0.18 on10"3 Cylinder sleove 8 “Cylinder sleeve Gylindeicit AOAS023 S205SP Crank pin metal Part code Standard 127696-23300 (Measuring Piston Pin Metal) Measure A,B.and @,b.¢3-4-2 Insertion of Sleeve Outside dia. and inside dia. div bottom side (non-operation sid jon codes specified in black painton the Cylinder block division 1D mark,A,B,C,or D marked on the top face (at opearation side) (rx vlinder block inside dia Combination | Liner outside dia Glesrance Dimensional logge] Sye2du |Code| Dimensional 114 on Ale A | eit tons : “aR 6114 208 8 os ee ena) fe ol © | atte 20 ens for | 2 D | otis vay 3-4-3 Measurement of Projection Measure the protrusion of the cylinder liner flange from the block surface and check that the following distance is ensured [ Grinder biagearge Te og | hole depth: A. etl 5-000 eee Cylinder liner flange ror thickness: 8 8 36o Cylinder liner protrusion’ 0.08~0.08 ‘Types of gaskat packing for top clearance adjustment AOAE023 92068P Thickness when Yanmar code _|'® punched 1.42007 127695~ 01340 4 1500 127696— 01380 5 207 127695 ~ 01360 16 iste the dimensional code on ‘He lata the OF piston SY SEX Cylinder let WY bloc3-5. Cylinder Block The weight of the cylinder block is reduced by its thin structure, while the ribs are rationally distributed internally and a wave structure is employed for the side wall. This structure boosts the rigidity by far and is instrumental in preventing engine noise from spreading 3-6-1 Inspection for Cracks If the engine has experienced some abnormal accidents such as freezing, falls, etc., check the engine visually. If there may be cracks, inspect the part by color check. If the damage can’t be repaired, replace the part. 3-5-2 Cleaning of Oil Holes Clean each oil hole and ensure its continuity. ‘© Take care not to remove the blind plugs. Dyeing Flaw Detection Agent(Color Check) The aerosol type device, sprays the liquid by pressing the button at the top to detect cracks in metals that are hard to find. 3-5-3 Inspection Procedures Clean the part to be inspected with cleaning agent ‘© Spray the penetration liquid (red) for 5-10 min. (depending on the material) and wait for a while until the liquid penetrates inside. *Clean and remove the red penetration liquid on the surface quickly ‘* Spray the developing liquid (white) thinly and evenly If there are cracks inside, the red penetretion liquid oozes out on the surtace. (Refer to the operation manual of the manufacturer before use.) 3-6. Crankshaft and Main Bearing The crankshaft, mede of precision forged SCM440, has high durebility with the use of aluminum metal for the crank pin end journals. The dynamic imbalance is improved to reduce vibrations. This further enhances the durability The front and rear seal sections, with the optimum finish to the oil seal and the use of special seals, are durable against sea! wear highly effective in preventing oil leakage. AOA8023 62065P - 4 Dysing Flaw ce vpection Agent)3-6-1 Inspection of Crankshaft {1)Color Check of Sheft Check the shaft by cleaning the crankshaft, color check or by magnetic flaw detector. It there are cracks in the shaft or it is excessively damaged, replace the shaft. If the damage is insignificant, repair by grinding (2) Distortion of Crankshaft * Hold both ends of the crankshaft journal with V~blocks. Turn the shaft and measure the Geviation of the center journal with t he dial gauge to check the distortion. If the distortion is excessive, replace the shaft (nm) Standard ‘Allowable __| dimension limit Distortion of crankshaft a oe (3) Outside Die. and Cylindricity of Pin and Journal © Check the pin and journal outside dia. of the crankshaft for biased wear (cylindricity, taper degree). When the wear is within the tolerance, re-grind and adjust within the limit of the outside die. When the outside dia. falls below the limit, replace. an (om) Standard | Allowable dimension | mit Sait outsde 15) e716) 717 dia, cankin | cytinarici o018 008 oil clearance | 0.08~0.105 | 0.19 Shaft outside | 95 o4~95.96 | 95.87 Gent | Feytinariny | 0.98 008 Oil elearence | 0.000.108 | 018 ADASDNS £206SP - 6 t * (Measuring Position of Outside dia. and Cylindricity for Crankshaft Pin and Journal)3-6-2 Side Clearance of Crankshaft ‘Move the crankshaft to one end, place the dial gauge to the crankshaft end face and measure the thrust clearance, or measure the clearance between the standard bearing thrust section and the crankshaft thrust face directly with the thickness gauge. If the clearance exceeds the limit, replace the bearing with the oversized bearing, (mm) ‘Standard Allowable dimension limit Sido clearance | _0.155~0.206 0.33 3-6-3 Inspection of Main Bearing Check for flaking, fusion, seizure and other damege on the contact surface. Replace if the bearing is defective @ Measure the bearing insidé dia., crankshaft outside dia. and oil clearance. If the clearance exceeds the limit. Note: Note the following points when installing the bearing cap to cylinder block. @The upper and lower bearings are not identical @Align the oil hole positions @Assemble the bearing cap with its F mark directed to the flywheel side. @Tighten to the specitied tightening torque, Main bearing in tightening torque 28% 1 kel ADA8023 SC05SP -3-6-4 Crankshaft Oil Seal * The crankshaft is equipped with oil seals at both ends to prevent lube oil leakage. At the flywheel side in particular, the spiral seal is used to prevent oil leakage due to the pumping movement during operation In the case of the oil seal of this type, the viscous pumping movement is lost if grease is applied to the lip. Be sure to apply engine Oil to the lip before reassembly oil sa T Part code No Fiywhed shat) WE 165-8 tatre-oTr82 Dumger | Tes 78-12 | Tewea-o1e0 | When replacing the oil seal, check for any flaws ‘on the oil seal housing, apply engine oil to the outside dia. and lip of the new oil seal and press fit the seal Gcot | Soro | Soscer 80 (Fitting of oil seal) AgAs023 $206SP ae ‘Apply engine oll to the Ip belore reassembly. to Dirgetion of Flyea side ol sel Engine side Flyaheel ioe (Flywheel side oil seal)3-6-5 Measurement of Crankshaft Deflection ‘* For the direct coupling of the engine, be sure to check the crankshaft deflection by the deflection gauge and adjust the deflection with # in the limit 7 3 } $ i : Deflection 2 3 (mm & = Allowable Hie Detrection 0.0128 Datetion gouge Dafrection after leer Direot Coupling . (Doflection gauge fittag position) Measurement Procedures: © Fit the deflection gauge to the cranksheft at a position between the crank arms of the No.! cylinder, free from interference of rod rotations (40mm from the middle of the journal). Turn the engine in its operational direction with 1 shown in the figure at the Fight as the starting point and read the gauge at 1, 2, 3, 4, and& positions shown in the figure © The balance between the max. and min values measured is the deflection value. S.0. (Bottom dead oonter) Defrection gauge (Deflection gauge measuring position) Yanmar part No.95540-000150 ADA8023 $206SP 63-7. Camshaft and Cam Gear The camshaft, equipped with the intake and exhaust valve cams, is made of normalized material, The cams and journals are surface hardened and machined. The polynomial cam with shockless curve reduces cyclical shocks given to the valve seat, resulting in the enhanced durability of the valve seat. 3-7-1 Camshaft and Bearing Check for distortion, journal damage, wear, etc. of the cam shaft. When distortioin, damage or wear is excessive, repair or replace. Camshaft Distortion Carshat distortion or ‘* Measure the height of the cam of the cam- shaft. If it is worn beyond the limit, replace Cam height dimension (mam) 7 Standard ‘Allowable dimension limit Tntake/exhaust | 44 1644.24 a valve cam height *Check the camshaft outside dia. and journal for flaws, wear, etc. If the damage or wear is excessive, replace Dimension of cam shaft and journal (mm. Standard | Allowable dimension iit Gemshah outside 5s o~st.076 | at Gamsheft iournsl | 52.02~52.09 52.15 Oit clearance 0.045~0.140 a2 Measure the side clearance on bearing replacement or disassembly maintenance opportunities. If clearance exceeds the limit, replace the gear side thrust bearing ADAIR 9206SP = Tightonire Te chmshate ‘Thrust bearing (Camshaft side clearance) -# Monsure the clearance olter tightening the mut tothe pected tightening torque (Gkal-m}(mm) Standard | Allowable dimension lienit Side clearance | 0.10~0.25 | 0.38 Thicknass of i thrust bearing | _6.99~7.08 hose 3-7-2 Tappets © The tappet, as shown in the fig. at the right, is rotated during engine operation to provont biased wear. Check the tappet’s contact condition. If there is biased wear or uneven rotation, replace the tappet and repair the cam, Not Before disassembling the cam shaft and| tappet, remember the cylinder nos. and| distinguish between intake and exhaust. QWhen the sliding surface of the tappet to the camshaft is damaged, check the camshaft, 100. Check the outside dia. of the tappet for wear and damage. Replace the tappet if it is defective Tappets and Tappet Guides (oom Standord ‘Allowable aa m fmt qappet outside | 269 o3a~26.96 26.90 Cylinder block Syn 27.00~27 012 2.05 Oil clearance | _0,04~0.082 0.1 3-7-3 Push Rods * Replace the push rod if the distortion exceeds the limit (mm) Standaré Allowable | __ dimension fimit Distortion of | [ Bistorng 0.08 | on Length of | pustrod 289.5~290.5 - ADASD29 8206SP - exnauet (Camshaft and tappet) wWoar (Insertion of tappet)3-8. Timing Gear The helical gear is used for the timing gear. ‘The gear teeth are hardened and polished for higher durability and lower noise. 3-8-1 Inspection of Gears ‘© Inspect the gear face and tooth flank. If there is flaw or wear, replace the gear Measure the backlash of each gear. If the becklash exceeds the limit, replace the working gears as a set. Backlash = (mm) Standard Allowable dimension Himit Backlash of [EEE gsr ee 0.08~0.16 0.3 Note, /mproper backlash not only causes noise, wear, scoring, ete. but also engine malfunction due to improper valve or fuel injection timing. ‘© Replace the bush inside dia, and the mount of the idle gear Bush and shaft outside dia. of idle gear (com) Sianderd] Allowable _ | dimension | “limit Shaft outside | 50.05~50.975 | 50.9 tale gear | Sus" mde TS comer.005 | 61.05 Oit clearance | 0.025~0.075 | 0.12 Shaft outside | 51.950~51.975 | 81.80 {dle gear (Beibrcee | Bush TRB | 5p og0~ap.056 | 52.1 idle gear) 7 shia Oit clearance | 0.055~0.105 | 0.15 3-8-2 Timing Mark The timing merk “” is punched on the side face of each gear--timing gear & gam shaft drive gear, fuel injection pump drive gear & balancer drive gear. Check and align the marks on reassembly. ADASOI3 9206SP = 5 (Measure of backlash) (Measuring idle gear bush inside dia.) (Goar train)3-9. Lube Oil System Engine parts are lubriceted by the forced lubrication system using the gear pump as shown in the lubrication diagram. The hydraulic switch of the system monitors the lube oil condition and warns of eny abnormal condition by sounding the alarm bell end turning on the oi! lamp when the lube oil pressure falls below 1kgf/ cif, 4-9-1 Lube Oi! Diagram Thermostat Lube eit cooker Oil geraly ora Sonar) [Sem Feat ail) [ Cootine sournst | | Shai ome _} [Lsozale crank pin] [ wrin Piston Lbs 4-9-2 Inspection of Parts (1) Lube Oi! Pump. ‘The gear pump usually has no weer. However, when it seizes for to some reason, when the oil pressure can't be raised satisfactorily in spite of the adjustment by the pressure adjust valve, or when the drive shaft (gear) does not turn smoothly, replace the pump as an assembly. Do not disassemble the pump whenever possible, When the reassembly is improper, the pump will seize. If dis— and re-assembly of the pump ere unavoidable, follow the service standard below. ‘A0A5023 9706SP Be ora | ot BOG yoy omar oes my (Lube oi pump) —2- TueLube oi! pump YANMAR code 127895-32000 Engine revolution 2700rpm, pump revolution 2202rpm, Capacity 6978.0 /h laarance: 0018-08840.) clearance: 9.08-0.1( 0.) 4048023 97065P — 8 —(2) Oil Fitter The oil filter uses high performance filtration paper. The lube oil enters into the filter from the outside circumference and goes out from the middle of the filter. The oil filter is equipped with an escape valve to prevent lube oil shortage on the filter element from clogging. If the element clogs during operation, the warning lamp on the instrument panel flickers. Replacement of Filter Element: BO hrs. after installation and every 600 hrs. jopeartion thereafter Replace of Fitter Element Note: Use the accessory standard tool to fit and] remove the filter element. * @Spare filter elements are provided. @When replacing the element, check the used element for any trapped foreign matter. @When fitting the element, contirm that the rubber packing is not disaligned. 5 98 shot Oit Cooter The multi-tubuler type oil cooler cools lube oil flowing on the exterior of the tubes with seawater circulating inside the tubes. The oil e cooler prevens the lube oil temperature from. poe being raised and thus extends the service life of pecking Cever the lube oil When the cooler is disassembled, check the Etorent interior of the cooler cover and tubes carefully and remove scale and rust. | etemen | — cose se Sting ‘Aboty parmence ink for Element) \eeeut $i 2 8 ‘ ) ‘Giserimination. ve opening 1.80, kgf eal iteration aro 4500er4 Fiteration pertormarce:: 20 y AOAS023 92065 - 4