YC6TDSer

iesMar
ineDi
esel
Engi
ne

Oper
ati
onManual
Pl
easer
eadt
hisoper
ati
onmanual
car
eful
l
ybef
oreuse

Guangxi
Yuchai
Machi
ner
yCo.
,Lt
d.
August2014
 For
ewor
d
Thi
sManualdescr
ibest
hemai
nst
ruct
ure,t
echni
calpar
amet
ers,t
echni
calspeci
fi
cat
ion&dat
aofmai
n
accessor
ies,aswel
lasbasi
coper
ati
onandmai
ntenanceofYC6TD ser
iesmar
inedi
eselengi
neand
i
ncl
udespr
eli
minar
yint
roduct
iont
osomet
ypi
cal
faul
tsandt
roubl
eshoot
ingsol
uti
ons.

Toenabl
ebet
teruseoft
heengi
ne’
shi
ghper
for
manceandt
oensur
eit
ssaf
eoper
ati
on,pl
easer
eadt
his
oper
ati
onmanualcar
eful
l
ybef
oreuse,t
olear
n,under
standandmast
eroper
ati
onandmai
ntenance
r
equi
rement
sofYC6TDser
iesmar
inedi
eselengi
nei
nacor
rectwayandpl
easeal
sopayspeci
alat
tent
ion
t
othe“
precaut
ionsofsaf
eoper
ati
on”bel
ow.

Wi
tht
hecont
inuousdev
elopmentanddemandoft
hesoci
ety
,theengi
newi
l
lbeopt
imi
zedandi
mpr
oved
cont
inuousl
y,wi
thcont
inuousi
ncr
easei
npr
oduct
swi
thv
ari
antdesi
gn;t
hisManualwi
l
lnotbemodi
fi
ed
exceptf
ort
hepar
ti
cul
arl
ysi
gni
fi
cantv
ari
antdesi
gn;t
her
efor
e,i
ntr
oduct
ioni
nthi
sManualmaybe
somewhatdi
ff
erentf
rom t
heact
ualengi
neaf
teracer
tai
nper
iodoft
ime,pl
easet
aket
heact
ualoneas
st
andar
dandpl
easepaydueat
tent
ionandy
ourunder
standi
ngi
shi
ghl
yappr
eci
ated.

Thi
sManualonl
ydescr
ibest
heengi
nesofbasi
cmodel
sindet
ailwi
thoutl
i
stoft
hepr
oduct
sofv
ari
ant
model
s,pl
easepaydueat
tent
ionandy
ourunder
standi
ngi
shi
ghl
yappr
eci
ated.

Guangxi
Yuchai
Machi
ner
yCo.
,Lt
d.r
eser
vest
hei
nter
pret
ati
onr
ightoft
hisManual
.

Pr
ecaut
ionsf
orSaf
eOper
ati
on

1. Thepart
ssuchaslubri
catingoilpressuresensor,wat
ersensorplugandannunci
atorfortoolow
l
ubri
cati
ngoi
lpressur
ear everyimpor t
antandt hoseoutofordermustbeimmediatel
yr epl
aced
toensur
enormaloperat
ion,orthecr ankshaftmaybeburntoutduet olackofoi
lorthecy l
i
nder
headmaybecrackedbyov erheati
ngduet olackofwater.

2. Forrepl
acementofl ubri
cati
ngoi lfi
l
terintheprocessofmai ntenance,thenew lubri
catingoil
fi
lt
ershallbefil
l
edwi ththelubri
cati
ngoilpri
ortoinstal
lati
onandaf tercompleti
onofinstall
ati
on,
theenginemustbest art
edt orunatidlespeed,afterwhichyoushal lgetofftocheckthef il
ter
caref
ull
yt oconfi
rm whetherthereisanyleakage;theleakage,i
fany ,mustbeeliminat
edi nti
me,
ortheauxili
arymovingcomponent sorpart
ssuchascr ankshaftandbearingbushmaybebur nt
outduet olackofoi
l.CF-15W40- C1enhancedov erbasedmar i
neengi neoilofHanhuBrandshal l
beusedf orYC6TDser iesengine.

3. Theengi nemustbemadet orunatidl

espeedf or3~5mi nut
eseveryti
mei ti
sst art
edandit
shallnotst artrunning unt
ilal
ltheinstr
ument sareinnor maloperat
ion.Stepping onthe
acceler
atori n asudden undert hecold st
ateisnotal l
owed,ort heinstr
ument sand the
corr
espondingpar t
smaybedamaged;mov i
ngpartsoftheenginemaybewor nmor equickl
y
andthet ur
bochar germaybedamaged, r
esult
inginshor
teni
ngofservi
celi
feoftheengine.

4. Suddenflameoutforshut
downunderheavy-
loadrunningatahighspeedi snotallowedand
shutdownshallbedoneaft
err
unni
ngatani dlespeedf or3~5mi nut
es,ortur
bochargerand
othermovingpart
smaybedamaged,r
esult
inginshort
eningofser
viceli
feoftheengi
ne.

5. I
ntakepi
pel
i
neshal
lbei
nspect
edr
egul
arl
ytoconf
ir
m whet
hert
her
eisai
rleakageorwhet
hert
heai
r
 cl
eaneri
sbl
ocked;i
ncaseofexi
stenceoft
heabov
ephenomenon,t
hemai
ntenanceshal
lbe
per
for
medi
nti
me,ort
het
urbochar
germaybedamagedandsuchf
aul
tascy
li
nderscor
emaybe
caused;meanwhi
l
e,r
epai
rshal
lber
equi
redi
nti
mebecauset
hev
ehi
clemayonl
yrunatar
elat
ivel
y
l
owspeedduet
olower
edengi
nepower
.

6. Theengi
neshal
lbest
art
edatt
hef
ir
stgeardur
inguse,
other
wiset
heengi
nemayst
all
.

7. I
ncaset
heengi
nei
sfoundi
nabnor
mal
oper
ati
on,
itshal
lbet
reat
edi
nti
me.

8. Whent
heengi
ner
uns,i
tisf
orbi
ddent
ogetcl
oset
other
otat
ingpar
tsandi
tispr
ohi
bit
edt
odi
rect
ly
t
oucht
hehi
gh-
temper
atur
ecomponent
soft
heengi
ne,suchasexhaustpi
peandt
urbochar
ger
;do
notopent
hewat
ert
ankcov
eri
mmedi
atel
yaf
tershut
down,
toav
oidscal
d.

9. Br
eaki
ng-
inmai
ntenanceshal
lbecar
ri
edoutf
ort
heengi
nei
nti
meaccor
dingt
other
equi
rement
sof
t
heuser
’smai
ntenancemanual
.

10.Qual
if
iedanti
-f
reezeli
quidmustbeusedf
ort
hecool
i
ngsy
stem,ort
hef
aul
tincur
redshal
lnot
enj
oythefr
eewar rant
y.

11.Somecomponent softheEuro-
3el ectr
onicall
y-
contr
oll
edengi
ne,especi
all
yt heelect
roni
cunit
pump,areidenti
calorsimi
lartothoseoft heEuro-
2enginei
nappear ance,suchast hefuel
i
nject
or,
fuelf
il
ter,
etc.I
tisf
orbi
ddent orepl
acesuchcomponentsbythoseofot hermodels.

12.I
tispr
ohi
bit
edt
odi
sassembl
eorr
epai
rthepar
tsr
elat
edt
oel
ect
roni
ccont
rol
arbi
tr
ari
l
y.

13.Ar
bit
rar
ypl
ug-
inorpul
l
-outofeachconnect
orassembl
ybyuseri
spr
ohi
bit
ed.

14.I
tisf
orbi
ddent
ofl
usht
heengi
newi
thwat
eroranycl
eani
ngf
lui
d.

15.The accumulat
ed waterdischarge offuelpre-
fi
lt
er,t
he repl
acementofpr
e-f
il
terel
ement
assemblyandfi
nefi
lt
erassembl yshall
becarr
iedoutasspeci
fi
ed.

16.Pri
ortoremovi
ngthebatt
eryanddi
sconnect
ingmai
nswi
tchoft
hebat
ter
y,pl
easeconf
ir
mthat
thei
gnit
ionswi
tchi
soff.

17.Befor
estar
ti
ngtheengi
ne,pleasemakesur
ethatthefaul
tdiagnosi
sswi
tchi
sintheof
fposi
ti
on
andthenst
artandoper
atetheengi
ne.Thef
aultdi
agnosisswitchi
sonl
yforr
eadi
ngtheDTC.

18.Ar
bit
rar
yrepl
acementoft
heexhaustbr
akebut
ter
fl
yval
vei
spr
ohi
bit
ed.

19.Hoi
sti
ngandt r
ansport
ati
onshal
lbeconductedaspertheprecaut
ionsoutsi
dethepacki
ngcase;
t
heplaceforstor
ageofengineshallbeventi
l
ated,dryandcleanwithoutcor
rosi
vesubst
ance;
t
heeffect
ivepr
eservat
ionl
if
eoftheenginei
sindicat
edonthepackingcaseoftheengi
ne.

20.Thenameplateoft heengineincl
udessuchbasicinfor
mati
onoftheengineasrat
edpower,
rat
edspeed,ser
iesnumber, dat
eofmanufact
ureandexecut
ivest
andar
d,et
c.Thenamepl
ateof
YC6TDL-
20islocatedattheoutersi
deofthei
ntakepipe.

21.Engi
nemodelandf act
orynumber(seethefi
gur
ebel
ow)ar
epr
int
edont
hepl
atf
ormi
nthe
middl
eoft
heloweredgeofthecy
li
nderbl
ock.

22.Safety warni
ng incl
udes not
es to user s,crankshaf
ttur
ning,rot
ati
ng dangerand hi
gh
temperatur
edangerwhicharestuckont hecyli
nderheadcover
,cl
utchhousi
ngandsi
deofthe
cyl
inderheadcovercl
osetotheexhaustpipe.
23.Thepackingcaseincludesthef ol
lowi
ngcompul sorydocument
s:oper
ati
onmanual,l
istof
compulsor
ysparepart
s,li
stofcompulsoryt
ool
s,certi
fi
cat
eofqual
it
yandpacki
ngl
i
st.Theuser
shoul
dcheckthem i
ntimeafterunpacki
ng.
 Cont
ent
s
For
ewor
d 2
1 Ov
erv
iew -1-
1.
1 Pr
oductcharact
eri
sti
cs -1-
1.
2 Modelnumbercompositionandi
tsspeci
fi
cmeani
ng -1-
1.
3 Mainscopeofappli
cati
on -1-
2 Techni
cal
Feat
ures -2-
2.
1 Mainper f
ormancepar ameter
sofdieselengi
ne -2-
2.
2 Maintechnicalparameter
sofdieselengi
ne -3-
2.
3 Ti
ghteningtorqueofmai nbolt
,st
udandnutf ordi
eselengi
ne -4-
2.
4 Recommendedv aluesofti
ghteni
ngtorqueforscr
ewplug -7-
2.
5 Recommendedv aluesofti
ghteni
ngtorqueunspeci
fi
edforotherbol
ts -8-
2.
6 Fi
tclear
ance( int
erfer
ence)ofmainparts -8-
3 Basi
cSt
ruct
ureandMai
ntenanceMet
hodsofDi
esel
Engi
ne -11-
3.
1 Cyli
nderblockandcr ankcase -11-
3.
2 Cyli
nderhead -12-
3.
3 Crank-
li
nkmechani sm -14-
3.
4 Valvemechani sm andgeart rai
n -16-
3.
5 Fuelsuppl
ysy stem -19-
3.
6 Lubri
cati
ngsy stem -26-
3.
7 Cooli
ngsy stem -27-
3.
8 Turbochar
gingandi ntercool
ingsyst
em -31-
3.
9 El
ectri
calsystem andi nstruments -34-
3.
10 Ai
rcl
eaner -48-
4 I
nst
all
ati
onofDi
esel
Engi
ne -49-
4.
1 I
nst
all
ati
onenvi
ronment -49-
4.
2 I
nst
all
ati
onandinspect
ionofdi
esel
engi
ne -49-
5 Oper
ati
onandMai
ntenanceofDi
esel
Engi
ne -50-
5.
1 Operati
onofdieselengine -50-
5.
2 Maintenanceofdieselengi
ne -50-
6. CommonFaul
tsandTr
oubl
eshoot
ingMet
hodsofDi
esel
Engi
ne-54
-
6.
1 St
arti
ngfail
ureofdi
eselengi
ne -54-
6.
2 Underpowerofdi
eselengi
ne -54-
6.
3 Abnormalsoundduri
ngrunningofdiesel
engine -55-
6.
4 Bl
acksmokepr oducedduri
ngairexhaust -56-
6.
5 Whit
eandbl uesmokeproducedduringairexhaust -56-
6.
6 Toolowoilpressure -57-
6.
7 Toohighoilpressur
e -57-
6.
8 Highoil
temper at
ureandl
argeoi
lconsumpt
ion -57-
1 Ov
erv
iew
1.
1Pr
oductchar
act
eri
sti
cs
6TDser iesmar i
neengi
nei sanewmodeldesi gnedanddev elopedindependentlybyGuangxiYuchai
Machi nery Co.,Ltd.forthe sat isfaction ofmar ketdemands.Yuchaicar ri
ed outper f
ormance
developmentbyadopt i
ngadv anceddesi gni deasanddesi gnmet hodsandbasedont her i
chpracti
cal
experience,andcarri
edoutreli
abili
tydev elopmentbyr ef
erenceofthemechani caldevel
opmentprogram
ofFEVCompanyi nGermany .Thisser i
esofengi nesi scharacteri
zedbywi depowercov er
age,low
emission,lowf uel
consumption,lownoi se, hi
ghrel
iabil
it
yandstrongmat chi
ngadapt abi
li
ty.
1.
2Model
numbercomposi
ti
onandi
tsspeci
fi
cmeani
ng
Theproductmodelnumberconsi
stsofAr
abi
cnumer
alsandcapi
talEngl
i
shl
ett
ers,
andt
hespeci
fi
c
meani
ngisasfoll
ows:

Codeofappl
i
cat
ion:
C–usedasmar
inepowerengi
neandaux
il
iar
ymar
inegener
ator
;
1.
3Mai
nscopeofappl
i
cat
ion
Thi
smodel ofengineismainlyusedfort
het r
ansportshipsandf i
shingboat sintheinl
andriv
ersand
i
nshoreareas.Itisforbiddentowor kinwaterori nfire.I
tshouldbenot edt ocleantheaircleaner
el
ementundert heenvironmentofsev er
esandwi ndandmuchdust .Thefiltershouldberepl
acedwi th
anOEM fil
terofsamespeci fi
cat
ionincaseofanybr eak.Forotherapplicat
ions, t
heusershouldconsult
YuchaiTechni
calDept.andSer v
iceDept.andtakeeffecti
vemeasur esoruset hecorrespondi
ngspecial
engi
netoensurethenor mal wor
king.

-1-
2 Techni
cal
Feat
ures
2.
1Mai
nper
for
mancepar
amet
ersofdi
esel
engi
ne

Tabl
e2-
1

S/
N Descr
ipt
ion Techni
cal
Par
amet
ers
1 Model YC6TD650L-
C20 YC6TD600L-
C20
2 Type Ver
ti
cal,i
n-l
i
ne, water-
cooled,4-
str
oke
3 Aspir
ation Turbochargingandinter-
cooled
4 Typeofcombust i
onchamber Directi
nject
ion
5 Numberofcy li
nders 6
6 Cyli
nderbor e,mm 152
7 Pi
stonst roke,mm 180
Totaldisplacementofpi
ston,
8 19.
6
L
9 Compr essionrati
o 14∶1
10 Rat
edpower
,kW 478 441

11 Rat
edspeed,
r/mi
n 1800 1500

12 Ov
erl
oadpower
,kW 525.
8 485

13 Ov
erl
oadspeed,
r/mi
n 1858 1545
Specif
ic fuel consumpt ion,
14 ≤225
g/(
kW· h)
Specif
ic oi l consumpt ion,
15 ≤1.
5
g/(
kW· h)
Minimum adj ustabl
e no-l
oad
16 650~700
speed,r/
mi n
Minimum cont i
nuousfull
-l
oad
17 ≤675
speed,r/
mi n
18 Averagepistonspeed,m/s 10.
8 9
19 Meanef
fect
ivepr
essur
e,MPa 1.
6 1.
8

20 Rat
edgov
erni
ngr
ate,
% ≤15
I
nstantaneous speed
21 ±12
di
ffer
ence,%
22 Exhaustsmoke,Bosch ≤3.
2
23 Noi
sel
i
mitLw,
dB(
A) ≤118
I
tcanwor knormall
yunderat r
ansverseincli
nat
ion
of15°,l
ongi
tudi
nalincli
nati
onof5° ,tr
ansv er
se
24 I
ncl
i
nat
ion
osci
ll
ati
onof22.5°andl ongit
udinaloscil
lati
onof
7.
5°
25 Emissi
onlimit
,g/(kw·h) HC: ≤2.
1, CO: ≤8.4, NOx :≤10.8
26 Exhaustt
emper at
ure,℃ ≤550
27 Oilt
emperatur
e,℃ 80~105
28 Powergenerati
onor der 1—5—3—6—2—4

-2-
 29 Di
rect
ionofr
otat
ion Ant
icl
ockwi
se(
viewedf
rom t
hepowerout
putend)

30 Oi
lcapaci
ty,
L 52

31 Cool
i
ngmode Doubl
eci
rcul
ati
onandwat
er-
cool
ed

32 Modeofl
ubr
icat
ion Combi
nat
ionofpr
essur
eandspl
ashi
ng

Oi
lpr
essur
e(i
nnor
mal
33 0.
25~0.
60
oper
ati
on)
,MPa

Oi
ltemper
atur
e(ati
dle
34 ≥0.
1
speed)
,MPa

35 St
artmode El
ect
ri
cst
art(
airst
artopt
ional
)

Out
li
nedi
mensi
ons
36 1987×1130×1600
(
lengt
h×wi
dth×hei
ght
),mm

37 Netwei
ght
,kg 2200

Gear
boxD300AofHangz
houAdv
anceGear
box
38 Adapt
iver
educt
iongearbox
Gr
oupCo.
,Lt
d.
Note:thepr
oductper
for
mancei
sbei
ngi
mpr
ovedunceasi
ngl
yandi
ssubj
ectt
ochangewi
thout
pr
iornot
ice.

2.
2Mai
ntechni
cal
par
amet
ersofdi
esel
engi
ne
1. Valvet i
mi ng(basedoncr ankshaf
tangl
e):
Int
akeadv anceangl e 32°±5°
Int
akel agangl e 48° ±5°
Exhaustadv anceangl e 54° ±5°
Exhaustl agangl e20° ±5°
Note:whenmeasur ingt hetimingphase,adj
usttheintakev al
veclear
ancet
o0.
25±0.
05mm andt
he
ex
haustvalv
ecl earanceto0. 55±0.05mm.
2. Fuel i
njectoropeni ngpr essure: (25±0.5)MPa
3. Cyli
ndercompr essionclearance: (0.639~1.271)mm
4. Idl
espeed: SeeTabl e2- 1
5. Oilpressur e:
Innor mal operation (
0.25~0. 6)MPa
Atidlespeed (
≥0.1)MPa
6. Varioust emper atureranges:
Post
-t
urboex
haustt
emper
atur
e ≤550℃
Oi
ltemper
atur
eofoi
lpan (
80~105)℃
Out
letwat
ert
emper
atur
e ≤95℃
7. Oi
lcapaci
tyofoi
lpan: 52L

-3-
2.
3Ti
ght
eni
ngt
orqueofmai
nbol
t,st
udandnutf
ordi
esel
engi
ne

Tabl
e2-
3

Thr
ead
S/
N I
tem Techni
cal
Condi
ti
ons
Speci
fi
cat
ion

Fi
rstt
ime:
tight
ent
o30N.
m

Secondt
ime:
tight
ent
o90N.
m
Ti
ght
eni
ngt
orqueof
1 M16 Thi
rdt
ime:
tight
ent
o150N.
m
connect
ingr
odbol
t
Four
tht
ime:
tight
ent
o(220~

260)
N.m

Fi
rstt
ime:
tight
ent
o30N.
m

Secondt
ime:
tight
ent
o150N.
m
Ti
ght
eni
ngt
orqueofmai
n
2 M20 Thi
rdt
ime:
tight
ent
o280N.
m
bear
ingbol
t
Four
tht
ime:
tight
ent
o(360~

420)
N.m

Cr
ankshaf
tgy
roscopi
c

momentaf
tert
ight
eni
ngof
3 ≤60N.
m
bol
tsofmai
nbear
ingand

connect
ingr
od

Fi
rstt
ime:
tight
ent
o100N.
m

Ti
ght
eni
ngt
orqueofcy
li
nder Secondt
ime:
rot
atef
or120°
4 M16
headbol
t Thi
rdt
ime:
rot
atef
or90°

Cont
rol
l
ingt
orque:
340-
500Nm

Fi
rstt
ime:
tight
ent
o30N.
m
Ti
ght
eni
ngt
orqueofbol
tsf
or
5 M16 Secondt
ime:
tight
ent
o150N.
m
pul
l
eydamper
Thi
rdt
ime:
tight
ent
o240N.
m

-4-
 Thr
ead
S/
N I
tem Techni
cal
Condi
ti
ons
Speci
fi
cat
ion

Fi
rstt
ime:
tight
ent
o40N.
m

Ti
ght
eni
ngt
orqueoff
lywheel Secondt
ime:
tight
ent
o150N.
m
6 M18
bol
ts Thi
rdt
ime:
tight
ent
o(260~

300)
N.m

Ti
ght
eni
ngt
orqueofbol
tsat M10(
Grade
7 (
50~70)
N.m
f
rontendofcamshaf
t 10.
9)

Ti
ght
eni
ngt
orqueofbol
tsf
or M10(
Grade
8 (
58~71)
N.m
camshaf
tthr
ustpl
ate 10.
9)

Ti
ght
eni
ngt
orqueofoi
lpan M10(
Grade
9 (
50~70)
N.m
bol
ts 10.
9)

Ti
ght
eni
ngt
orqueofgear
10 M12 (
70~90)
N.m
chambercov
erbol
ts

Ti
ght
eni
ngt
orqueofbol
tsf
or M10(
Grade
11 (
50~70)
N.m
bi
gidl
egearshaf
t 10.
9)

Ti
ght
eni
ngt
orqueofbol
tsf
or M10(
Grade
12 (
50~70)
N.m
i
nter
medi
atei
dlegearshaf
t 10.
9)

Ti
ght
eni
ngt
orqueofbol
tsf
or M10(
Grade
13 (
50~70)
N.m
i
dlegearshaf
tofoi
lpump 10.
9)

Ti
ght
eni
ngt
orqueofsi
de
14 M8 (
10~25)
N.m
cov
erpl
atebol
ts

Ti
ght
eni
ngt
orqueofbol
tsf
or M8(
Grade
15 (
20~30)
N.m
f
rontandr
earoi
lseal
seat
s 10.
9)

M10(
Grade
(
50~70)
N.m
Ti
ght
eni
ngt
orqueoff
lywheel 10.
9)
16
cov
erbol
ts M14(
Grade
(
170~200)
N.m
10.
9)

-5-
 Thr
ead
S/
N I
tem Techni
cal
Condi
ti
ons
Speci
fi
cat
ion

Ti
ght
eni
ngt
orqueof
M10(
Grade
17 f
ast
eni
ngbol
tsf
orr
ocker (
65~75)
N.m
10.
9)
ar
m br
acket

Ti
ght
eni
ngt
orqueofwat
er
18 M10 (
40~70)N.
m
pumpbol
ts

Ti
ght
eni
ngt
orqueofst
art
er
19 M12 (
70~90)
N.m
bol
ts

Ti
ght
eni
ngt
orqueoff
uel
20 M10 (
50~70)
N.m
i
nject
orpr
essur
epl
atenut
s

Ti
ght
eni
ngt
orqueofoi
l M6(
Grade
21 (
8~15)
N.m
r
etur
nscr
ewofoi
lret
urnpi
pe 10.
9)

Ti
ght
eni
ngt
orqueofbol
tsf
or M10(
Grade
22 (
50~70)
N.m
char
geradj
ust
ingpl
ate 10.
9)

Ti
ght
eni
ngt
orqueofcar
ryi
ng M10(
Grade
23 (
50~70)N.
m
bol
tsf
orchar
ger 10.
9)

Ti
ght
eni
ngt
orqueofex
haust M10(
Grade
24 (
45~65)
N.m
pi
pebol
ts 10.
9)

Ti
ght
eni
ngt
orqueofi
nlet
25 M10 (
28~40)
N.m
pi
pef
ixi
ngbol
ts

Ti
ght
eni
ngt
orqueof
26 M8 (
15~35)
N.m
t
her
mol
atorbasebol
ts

Ti
ght
eni
ngt
orqueofoi
lfi
l
ter
27 M10 (
28~40)
N.m
basebol
ts

Ti
ght
eni
ngt
orqueof

28 f
ast
eni
ngbol
tsf
orwat
er M8 (
10~25)
N.m

di
schar
gepi
pe

-6-
 Thr
ead
S/
N I
tem Techni
cal
Condi
ti
ons
Speci
fi
cat
ion

Ti
ght
eni
ngt
orqueof
29 M12 (
70~90)
N.m
f
ast
eni
ngbol
tsf
orl
i
fti
ngl
ugs

Ti
ght
eni
ngt
orqueof
30 M10 (
40~60)
N.m
t
urbochar
ger
-ex
haustpi
penut
s

Ti
ght
eni
ngt
orqueofbol
tsf
or
M8(
Grade
31 f
uel
ret
urnpi
peof (
20~30)N.
m
10.
9)
t
urbochar
ger

Ti
ght
eni
ngt
orqueofbol
tsf
or
M10(
Grade
32 f
uel
ret
urnpi
peof (
50~70)
N.m
10.
9)
t
urbochar
ger

Ti
ght
eni
ngt
orqueofbol
tsf
or
33 M12 (
90~120)
N.m
f
uel
inj
ect
ionpumpbr
acket

Ti
ght
eni
ngt
orqueofbol
tsf
or

34 connect
ingpl
ateoff
uel M12 (
90~120)
N.m

i
nject
ionpumpbr
acket

Ti
ght
eni
ngt
orqueofbol
tsf
or M10 (
50~70)
N.m

35 t
ransmi
ssi
onshaf
tassembl
y
M12 (
90~120)
N.m
off
uel
inj
ect
ionpump

Ti
ght
eni
ngt
orqueof
M10(
Grade
36 f
ast
eni
ngbol
tsf
orf
uel (
50~70)
N.m
10.
9)
i
nject
ionpump

Ti
ght
eni
ngt
orqueofbol
tsf
or M12(
Grade
37 (
90~130)
N.m
f
uel
inj
ect
ionpumpgear 10.
9)

Ti
ght
eni
ngt
orqueofex
ter
nal

38 spl
i
nesf
orf
uel
inj
ect
ion M20 (
190~210)
N.m

pumpt
ransmi
ssi
on

-7-
 Thr
ead
S/
N I
tem Techni
cal
Condi
ti
ons
Speci
fi
cat
ion

Ti
ght
eni
ngt
orqueofbol
tsf
or
M8(
Grade
39 t
ransmi
ssi
onshaf
tthr
ust (
20~30)
N.m
10.
9)
washer

Ti
ght
eni
ngt
orqueofoi
l
40 M10 (
50~70)
N.m
cool
erbol
ts

Ti
ght
eni
ngt
orqueoff
ixi
ng
41 M10 (
35~55)
N.m
bol
tsf
orf
uel
inj
ect
ionpump

2.
4Recommendedv
aluesoft
ight
eni
ngt
orquef
orscr
ewpl
ug

Tabl
e2-
4

Thr
ead NPT1/
8 NPT1/
4 NPT3/
8 NPT1/
2 NPT3/
4 NPT1

Ti
ght
eni
ngTor
que
8~14 24~34 47~68 68~95 88~102
(
N.m)

2.
5Recommendedv
aluesoft
ight
eni
ngt
orqueunspeci
fi
edf
orot
herbol
ts

Tabl
e2-
5

Thr
ead Ti
ght
eni
ngTor
que(
N•m)

M6 Gr
ade8.
8:8~12; Gr
ade10.
9:10~15

M8 Gr
ade8.
8:18~24; Gr
ade10.
9:20~30

M10 Gr
ade8.
8:28~45; Gr
ade10.
9:35~55

M12 Gr
ade8.
8:65~90; Gr
ade10.
9:85~100

M14 Gr
ade8.
8:90~110; Gr
ade10.
9:110~130

2.
6Fi
tcl
ear
ance(
int
erf
erence)ofmai
npar
ts

Tabl
e2-
6

(
Uni
t:mm)

-8-
 Fi
tt
ing Fi
tCl
ear
ance
S/
N Fi
tt
ingPar
ts Dr
awi
ngDi
mensi
ons
Pr
oper
ty I
nter
fer
ence

I
ntake v
alv
e seat I
nter
fer
enc
① 0.
072~0.
113
Ф50 /
Ф50
hol
e/i
ntakev
alv
eseat e

Ex
haust v
alv
e seat I
nter
fer
enc
② 0.
056~0.
097
Ф48 /
Ф48
hol
e/ex
haustv
alv
eseat e

Val
ve gui
de hol
e of I
nter
fer
enc
③ 0.
015~0.
044
Ф16 /
Ф16
cy
li
ndercap/
val
vegui
de e

Val
vegui
dehol
e/i
ntake Radi
al
④ 0.
025~0.
062
Ф9.
5 /
Ф9.
5
v
alv
est
em cl
ear
ance

Val
ve gui
de Radi
al
⑤ 0.
040~0.
077
Ф9.
5 /
Ф9.
5
hol
e/ex
haustv
alv
est
em cl
ear
ance

⑥ I
ntakev
alv
e 0.
6±0.
15
Val
vesi
nki
ngdept
h
① Ex
haustv
alv
e 0.
6±0.
15

Val
vet
appethol
e/v
alv
e Radi
al
⑦ 0.
025~0.
089
Ф39 /
Ф39
t
appet cl
ear
ance

Cy
li
nder l
i
ner
/pi
ston Radi
al
⑧ 0.
140~0.
185
Ф152 /
Ф151.
85
ski
rt cl
ear
ance

Camshaf
t bear
ing I
nter
fer
enc
⑨ 0.
040~0.
094
Ф69 /
Ф69
hol
e/camshaf
tbushi
ng e

Camshaf
t bushi
ng
Radi
al
⑩ hol
e/camshaf
t bear
ing 0.
07~0.
14
Ф65 /
Ф65
cl
ear
ance
j
our
nal

Camshaf
t Radi
al
⑪ 0~0.
42
φ20 /
φ20
gear
/camshaf
t cl
ear
ance

Bushi
ng hol
eoft
imi
ng Radi
al
⑫ 0.
05~0.
10
Ф78 /
Ф78
i
dlegear
/i
dlegearshaf
t cl
ear
ance

-9-
 Bushi
ng hol
e of

i
nter
medi
ate i
dle Radi
al
⑬ 0.
05~0.
10
Ф78 /
Ф78
gear
/i
nter
medi
ate i
dle cl
ear
ance

gearshaf
t

Bushi
ng hol
e of i
dle

gear of f
ueli
nject
ion Radi
al
⑭ 0.
05~0.
10
Ф78 /
Ф78
pump/
idl
egearshaf
tof cl
ear
ance

f
uel
inj
ect
ionpump

Hei
ght of pi
ston r
ing
Ax
ial
⑮ gr
oov
e/hei
ght of t
op 3. 0.
08~0.
012
4 /
3.289
cl
ear
ance
compr
essi
onr
ing

Hei
ght of pi
ston r
ing
Ax
ial
⑯ gr
oov
e/hei
ght of t
he 3. 0.
075~0.
115
59 /
3.5
cl
ear
ance
secondoi
lscr
aperr
ing

Hei
ght of pi
ston r
ing
Ax
ial
⑰ gr
oov
e/hei
ghtofoi
lri
ng 5.
05 /
5.0 0.
04~1.
08
cl
ear
ance
component

End cap cl
ear
ance of
Topr
ing:
0.5~0.
8
pi
stonr
ingcompr
essi
ng
⑱ Secondr
ing:
0.8~1.
05
i
nto Ф152 i
nsi
de
Thi
rdr
ing:
0.4~0.
7
di
amet
ergauge

Bear
ing hol
e at
⑲ Ф119
connect
ingr
odbi
gend

Connect
ingr
odbear
ing
⑳ 3.
5
t
hickness

Bear
ing hol
e (
wit
h
Radi
al
21 bear
ing bush) at Ф112 /
Ф112 0.
03~0.
102
cl
ear
ance
connect
ing r
od bi
d

-10-
 end/
connect
ing r
od

j
our
nal

Connect
ingr
odbushi
ng Radi
al
22 Ф61 /
Ф61 0.
01~0.
031
hol
e/pi
stonpi
n cl
ear
ance

Pi
ston pi
n boss Radi
al
23 Ф61 /
Ф61 0.
008~0.
024
hol
e/pi
stonpi
n cl
ear
ance

24 Mai
nbear
inghol
e Ф125
25 Mai
nbear
ingbush 3.
5

Mai
nbear
inghol
e(wi
th
Radi
al
26 bear
ing bush)
/mai
n Ф118 /
Ф118 0.
05~0.
125
cl
ear
ance
j
our
nal

Cr
ankshaf
t t
hrust
Ax
ial
27 f
ace/
crankshaf
t t
hrust 0.
1~0.
29
cl
ear
ance
pl
ate

Camshaf
t t
hrust Ax
ial
28 0.
06~0.
26
pl
ate-
camshaf
t cl
ear
ance

Meshi
ng backl
ash Gear
29 0.
07~0.
25
bet
weengear
s backl
ash

Cl
ear
ance bet
ween

30 i
ntakev
alv
eandr
ocker Cl
ear
ance 0.
25±0.
05

ar
m(atcol
dst
ate)

Cl
ear
ance bet
ween

ex
haust v
alv
e and
31 Cl
ear
ance 0.
55±0.
05
r
ocker ar
m (
at col
d

st
ate)

Pr
otr
usi
on hei
ght of
32 0.
09~0.
15
cy
li
nderl
i
ner

Bushi
ng hol
e of I
nter
fer
enc
33 Ф77 /
Ф77 0.
045~0.
94
t
ransmi
ssi
on shaf
t of e
-11-
 f
uel i
nject
ion

pump/
bushi
ng

Bushi
ng/
transmi
ssi
on
Radi
al
34 shaf
toff
ueli
nject
ion Ф72 /
Ф72 0.
07~0.
14
cl
ear
ance
pump

Tr
ansmi
ssi
on t
hrust
Ax
ial
35 r
ing/
transmi
ssi
on shaf
t 4.
5 /
4.5 0.
3~0.
5
cl
ear
ance
off
uel
inj
ect
ionpump

3 Basi
cSt
ruct
ureandMai
ntenanceMet
hodsofDi
esel
Engi
ne
3.
1Cy
li
nderbl
ockandcr
ankcase
Thecy linderbl ockofYC6TDser i
esengi neisofagant r yst r
uctureandi scastwi t
hHT250gr aycast
i
ron.
Ont heengi nebody ,therear esev ensemi -circularcav itiesofmai nbear ingbl ock,wi t
ht hesame
widthofthemai nbear ingbushesandt het hr
ustpl at eisplacedonbot hsidesoft hef our t
hmai nbear i
ng
block.
Thest ructureofwetcy l
inderlinerisadopt edf ort heengi nebody .Thewal lthicknessoft hecy li
nder
l
ineris11mm andt hei nnersurfaceoft hecy l
inderl inerisofmade- t
o-orderflatr eti
culatepat tern,whi ch
hasgoodef fectsonr unning-i
naccel erationandwear -r
esistingper formance.
Ther earendf aceoft heengi nebodyi sprov idedwi t
hagearchambercov er ,betweenwhi chandt he
enginebody ,LOCTI TE510seal anti sused,i nsteadofaseal i
nggasket .Noseal inggasketi spr ovided
betweent hei nst al
lationsur faceoft hef ly
wheelcov erandt hegearchambercov er.Thegearchamber
andt heflywheelcov erar ecastasawhol e.Thewhol edrivet rainisont her earendoft heengi nebody ,
withstabledr i
v eandsmal limpact .
Therei sacut -thr oughmai noi lgall
eryont her i
ghtwai stoft heengi nebody ,providingoi lforthe
mai nbearingbl ockandt hecool ingj ethooksofsi xpi st
ons;t hereareacut -throughaux il
i
aryoi lgallery
and6upperoi lgaller i
esont hel eftwai st,providingl ubricat i
ngoi landcool i
ngf ort hecy li
nderhead,
rockerarm, camshaf tandgeart r
ain, et
c.
Therei sanout er -
hangingoi lcooleront hel eftsi deoft heengi nebodyandt hef reshwat erfl
ows
throughtheoi lcool ert othemai nwat ercav it
yoft heengi nebody ,whichi sint ernall
ypr ov i
dedwi t
h12
i
nletsofcr oss-flowwat erways.

Fi
g.3-
1 Cy
li
nderBl
ock

Att
hel
owerpar
toft
hecy
li
nderbl
ock,
acasti
ronoi
lpanf
ort
hest
orageofl
ubr
icat
ingoi
li
spr
ovi
ded,

-12-
withalubricatingoilcapacityof52L.
Duri
ngt heinstall
ationoft hemainbear ingbolt,thebeari
ngsurfaceandt hr
eadshouldbeapplied
withengineoi latfir
standbol tscanbet ightenedupwi thbarehands.Withatight
eningtor
queof(360~
420)N.m,t hemai nbear ingbol tshoul
dnotbet ight
enedupatonet ime,butshouldbet i
ght
enedupat
fourti
mesi nturnfrom themi ddletobothends.
Fi
rsttime: ti
ghtent o30N. m
Secondt i
me: t
ightent o150N. m
Thir
dt ime: t
ightento280N. m
Fourtht i
me: ti
ghtent o(360~420)N. m
Note:thecr ankshaftshoul dberotat
edbackatev eryti
meoftighteni
ng,t
ocheckt hefl
exi
bil
i
ty.
Themai nbearingbol t
sar enotall
owedt obeusedr epeat
edl
y!
3.
2Cy
li
nderhead
Thecy li
nderheadof6TD ser i
esmar ineengineisdesi gnedwi t
ht het ypeofoneheadf orone
cyl
inder.Eachcy linderisconnect edwiththeenginebodyby6bol ts,wi t
hgoodseal ingperfor
mance.
Thet aperangl eoft hei ntakevalveandt heint
akev al
veseatr ingi s120°andt hatoftheexhaust
val
veandt heex haustv alv
eseatr ingis90°.
Duet ol argepr et
ighteningf or
ceappl i
edont hecyli
nderheadbol ts,thet i
ght eni
ngtorqueand
sequenceoft hecy li
nderheadbol tsshouldbecont r
oll
edst ri
ctl
ysoast or educedef or
mat i
onand
guaranteer el
iabl esealing.Thet ensi
lefor
ceshoul dbemor ethan130kNaf t ert
hecy l
i
nderheadboltsare
ti
ghtenedup.
Thet i
ght eningsequenceofcy li
nderheadboltsisshowninFi g.2-3:

Fi
g.3-
2 Schemat
icDi
agr
am f
orTi
ght
eni
ngSequenceofMai
nCy
li
nderHeadBol
ts

Aft
erappl yinglubri
cati
ngoiltot hecy l
inderheadbol t
sandt hepr essure-beari
ngsurf
ace,t
ight
ent he
bolt
sinthreet i
mesi ntheordershowni nt hefigure:
Fi
rstti
me: tightento100N. m
Secondt i
me: r
otatefor120°fort hefi
rststep
Thir
dtime: rotatefor90°forthesecondst ep
Aft
ertighteningt hebolt
swi t
ht herotationanglemet hod,t
het orquer angemoni t
oredshouldbe340
~500N. m
Thebol telongationofthecy l
inderheadshoul dbe( 0.6~1. 0)mm af terthecyli
nderheadbolt
sar e
ti
ghtenedupi nsequence.
Note:t
hecy li
nderheadbol t
sar eallowedt ober epeat
edlyusedf or3t i
mesatmost !
Thecylinderheadgasketi sasi ngle-
layersteelgasket,wi
thgoodr esistanceofdamaget ocyl
inder
gasket.

-13-
 1-
Machi nedcomponentsofcyli
nderhead(cyl
inderhead, i
ntakeval
veseat,exhaustval
veseat
,
val
v eguideandbowl typeexpansionplug)
2-Exhaustval
ve; 3- Rotati
nggasket; 4- Valveoilseal
; 5-
Exhaustvalvespr
ing
6-Exhaustvalv
espri
ngseat;7-I
ntakeval
vespr i
ng;8-Valvespri
ngupperseat;9-Val
vecoll
et
10-I
ntakev alv
e

Fi
g.3-
3 St
ruct
ureofCy
li
nderHead

Aφ5hol ei
spr ovidedontheex haustsideofthecy li
nderheadandi ncaseofoi lfl
owfrom t
hishole,
i
tindicat
esthesealingfail
ureofO-ri
ngoft hefueli
njectoronthecy l
inderhead; ori
ncaseofgasblowout
duri
ngt heoperat
ionoft heengine,itindicat
estheseal ingfail
ureoft hef uelinj
ect
orgasketont he
cyl
inderheadandthust heengineshouldbest oppedf ormaintenanceandr eplacement.

φ5hol
e

Fi
g.3-
4 Si
deVi
ewofCy
li
nderHead

3.
3Cr
ank-
li
nkmechani
sm
Cl
earancef i
tisadopt edf orthepistonandt hepi stonpin.Duri
ngt hefi
tti
ng,thesmal lendoft he
connect
ingrodi splacedint hemi ddleofthet wopistonpi ns.I
tshouldbenot edthattheforwardmar k
ontheconnect i
ngr odmustbeconsi st
entwiththefor wardar r
owont hepistontop.Thepi nisputinto
thepinholeandknockedwi thsoftmet alhammerorwoodenhammersl i
ght l
yandt henputintot he
checkri
ng.Af t
erthat,t
hepi stonandt heconnecti
ngr odshoul dbeabletoswingf r
eely
,withoutbl
ockage,
asshowni nFig.3-5.Thent hepistonringisinst
all
ed.Dur i
ngt hei
nstall
ati
onofpi st
onr i
ng,thesurf
ace
wit
hamar kisputupwar ds.Itisbettert
ouseaspeci al serv
icetool
.
-14-
 Eachpistonhast hreepistonr ings.Thef i
rstr i
ngi st heairr i
ng,whi chismai nlyf orseal
ing
hi
gh- t
emperatur
eandhi gh-pr
essuregases.Thi sr ingisat r
apez oi
dalmo- spray
edpenetr ati
ngceramic
fl
exibl
etubbishri
ng,wit
hgoodcy l
inderlineradapt abil
i
t yandhigh-temperaturewearresistanceaswell
asgoodant i-
bondi
ngandr i
ngclampi ngeffect. Thesecondr ingistheoi lscr
aperr
ingwi t
haconical
surf
ace,whichismai nl
yf orseali
nggasesandscr apingoil.Thet hi
rdri
ngi stheoi
lringcomponent ,
whichisthecombinedringandmai nlyforscrapingoi l(
Fig.3-6).

1—Pi
ston
2—Ai
rri
ng
3—Oi
l scr
aper
r
ing
4—Oi
l r
ing
component

Fi
g.3-
6 Mount
ingDi
rect
ionofPi
stonRi
ng

I
n or dert o ensur
e seali
ng perf
ormance,t he ax i
al
cl
earanceand end gap cl ear
anceoft hepist
on rng must Fi
i g.3-
5Pi
stonConnect
ingRodAssembl
y
compl ywi t
ht hev al
uesspecifi
ed inTable2-5i n2. 3.The
measur ementmet hodofendgapcl earance:t
oputt hepi stonring
i
ntot hecy l
inderli
nerhole(canbel eveledbythepi ston),andt o
measur etheclearanceatendoft hemeasuredringwi ththickness
gauge( Fi
g.3-7).

Whent hepist
onr odisassembledint
ot hecylinderl
iner
,thearr
owatthepi
stont
opmustindicat
e
thef
rontendoftheengine.Theopeningofthreepistonri
ngsshould
bestagger
ed(seeFig.3-
8),toensur
eseali
ngper f
ormance. Fi
g.3-
7MeasurementofEnd
GapCl
ear
anceofPi
stonRi
ng

Intheassemblyoft heconnecti
ng rod bolts,the
connecti
ngrodboltsshouldbeablet obetightenedt o
theutmostbyhandsandt hentight
enedupbyat orque
wrench.Theti
ght
eningtor
queoftheconnecti
ngrodbol ts
i
s( 220~260)N. m andtheconnecti
ngrodboltsshoul d
betight
enedupinfourt
imes:
(
30±10)N. mforthefir
stti
me
(90±10)N. mforthesecondt i
me
(150±10)N. mforthet hi
rdti
me
(220~260)N. mf orthefour
thti
me
Aftertighteningup,itshouldbeensur edt
hatt
he
cr
ankshaftrotatesfl
exi
bly
. Fi
g.3-
8Openi
ngDi
rect
ionofPi
stonRi
ng

Thepi
stonistheinternal
-cool
ingoilgaller
ypi st
onandiscooledbyt hepist
oncool ingjethook
j
ett
ingengi
neoil,t
oensur eeffecti
vepistoncoolingtoavoi
doverheati
ng.Thecoolingjethookshould
notbumpagainstthepistonandcr ankshaft
,toensuretheengi
neoi lcanbeaccuratel
yjettedint
othe

-15-
pistonoi lgal l
er y
.
Thef our thgearoft hecr ankshaf tispr ov idedwi thathr ustplatetopr eventthecrankshaftplaying
forwar dandbackwar d, andt hecr ankshaf tax ialcl earancemustbeensur edtobe( 0.
1~0. 29)mm.See
Fig.3-9.
Thef rontoi lsealoft hecr ankshaf tissetont hef rontoilsealseatandt herearoilsealissetont he
rearoi lsealseat .Aspeci alser v
icet oolshoul dbeusedf orpr essingi ntofrontandr earoilseals,to
ensur er el
iablei nstall
at i
onoft heoi lseali npl ace.Whent i
ght eni
ngt hef r
ontandr earoilsealseats,the
boltsar etight enedupasperdi agonal cr ossandt i
ghtenedi nt wotimest o( 10~13)N. m att hefi
rstti
me
andt o( 20~30)N. m att hesecondt ime.Theseal ing
surfaceoft her earoi lseali smat chedwi t
ht het iming
gear .Wheni nstall
ingt her earoi lseal ,t het imi nggear
mustbef ast enedt othebi gendoft hecr ankshaf twi t
h
bolts and at tenti
on shoul d be pai dt ot he cor r
ect
i
nst all
ationoft heO- r
ingbet weent hecr ankshaf tend
faceandt het iminggear ,soast oav oidbr eakoft he
O-ri
ngandoi l l
eakage.
Fort heposi ti
oningassembl yoft hef lywheeland
thet iminggearendf ace,i tshoul dbenot edt okeep
clean and i ntactj ointsur face dur i
ng assembl y.The
fastening bol ts oft he f l
y wheelshoul d be cr ossed
diagonal lyandt i
ghtenedupi n3t imesasr equi redby
Tabl e2-6, withat i
ghteni ngt orqueof( 260~300)N. m.
Thecr ankshaf tpulleydamperi sconnect edwi ththe
crankshaf tbybol ts,whi char ecr osseddi agonal lyand
ti
ght enedupi n3t i
mesasr equiredbyTabl e2- 6,wi t
ha
ti
ght eningt orqueof( 240±10)N. m.
Fig.3-9Measur ementofAx ial
Cl
ear
anceofCr
ankshaf
t
3.
4Val
vemechani
sm andgeart
rai
n
Thev al vemechani sm i scomposedofv alvegroupandv alve
traingr oup.Thev alvegr oupi ncludesv alve,v al
vespr ing,v alve
l
ockcl amp,v alvest em seal ,v al
v egui de,upperseatofv alve
spr i
ng and r otating gasket .The v alve geargr oup i ncludes
camshaf t,tappet ,v alvepushr odcomponent ,rockerar m shaf t
bear i
ng, valver ockerar m component , camshaf tti
mi nggear ,valve
bridgeandot herpar ts.
Amongwhi ch,thel ubricat i
ngoi lisl edf rom theengi nebody
tot her ockerar m shaf tbear ingandt hent ot herockerar m shaf t
hole.Par toft hel ubricat i
ngoi lisi nj
ect edt ot hev al
v ebridgeand
thepushr odnest ,andf i
nallyf l
owst ot het appetandr eturnsto
theoi lpan.
Thecamshaf tisoft hef ul l
-suppor tov erheadt ypest ructure
andt hecamshaf tt i
mi nggeari sposi ti
onedt hroughal ocationpi nandf astenedonthecamshaf tend
surfacebyf ourM8bol ts.Theax i
alcl earanceoft hecamshaf t
i
scont roll
edbyt het hr ustpl ate,whi chi s( 0.06~0. 26)mm,as Fig.3-10Rear-
endDeviceofCamshaft
showni nFi g.3- 10.
Fort hedi sassembl yandassembl yoft hev alvespring,speci aldisassemblyandassemblytoolsof
thev alv espr ingshoul dbeused.
I
nor dert oensur et heser v i
ceper for mance,t hev al
v eandt hev alveseatmustbegroundafterthe
valvei si nstal l
edi ntot hecy l
inderhead, andt hewi dth
ofgr oundv alveseal ingbel tshoul dbeasf ollows:
(1.1~2)mm f ort hei ntakev alve;
(1.1~1. 6)mm f ort heex haustv alve.
Thev alvesi nkageshoul dbecont r
olledst ri
ctl
y .
SeeFi g.3- 11.
Techni cal r
equi r
ement s:
(0.6±0. 15)mm f ori ntakev alvesi nkage;
(0.6±0. 15)mm f orex haustv alvesi nkage.

To ensurethe nor
malworking st
atus oft
he
di
eselengi
ne,theusershoul
dcheckandadjustt
he
Fi
g.3-
11Val
veSi
nkage
-16-
val
v ecl earancer egularl
yasspeci fied.Undert hecol d state,theclear
anceoft hei
ntakev alv
ei s
(0.
25±0. 05)mm.Thecl ear anceoft heex haustv alv
ei s( 0.
55±0.05)mm.Themet hodofchecki
ngand
adjustingt hev alveclearance:t oswi tcht hecr ankshaf ttotheupperdeadcent erofthef
ir
stcyl
inder,to
checkandadj ustthev alvesNo.1, 2,4,5, 8and9, andt henswitchto360°,t
ocheckandadjustvalvesNo.
3,6, 7,10,11and12.
Thev al v
ecl earancecanbeadj ustedt hroughadj usti
ngt heval
veadj ust
mentscrew.Duringt he
adjustment ,l
oosent hel ocknutatf irst,screw inorout
the v alv
e adj ustmentscr ew as r equi r
ed wi th scr ew
dri
v er,andt hencheckt hecl earancebet weent her ocker
arm andt hev alveendwi that hicknessgaugeandt hen
ti
ght enupt hel ocknutaf terrequirement sar esat i
sfied,
andr epeatt hecheck.SeeFi g.3-12fort hecl earance.

Thepost posedgearchamberi sadopt edf ort he

geart rain.Thegearchamberandt hefly
wheelcov erar e
castasawhol e.Fort hepost posedgear ,thedr iveis
stabl eandt hei mpacti ssmal l
.Inaddi ti
on,thepat ented
technol ogy --point
-li
nemeshi nggeari sappl i
edi nt he
geardesi gn,whi ch can r educe t he contactst ress,
i
mpr ovet hecont actf atiguest rengt h,toachi evet he Fig.3-12ClearanceofI ntakeValv eandEx haust
pur poseofef fect
iv enoi ser eduction.Thebi gi dl
egear V al
ve
seti scomposedoft woi dl
egear s,i.
e.onebi gandonesmal l.Thebi gandsmal li
dlegear sarepr essed
toget hert hroughi nt erferencef i
t.Theoi lpumpgearandt heoi lpumpdr iv
egearadoptt hestraightgear
withoutt i
mi ngmar ks.Theoi lpumpgeari sdirect l
yfixedt ot hecrankshaftthroughi nt
erf
er encefit
.
Other sadoptt hehel icalgearwi tht imingmar ks.Ti mingmar ksont hesmal lidlegearcanbeseen
throught heci rcularhol eont hebi gidlegear .Duringassembl y,theassemblymar ksmustbeal igned,to
prev entdi slocati
on whi ch wi l
laf f
ectt he ser vice performance and ev en cause damage t ot he
component s.Mor eov er, t
hebackl ashoft hesmal lidlegearwit hothergearscanbedet ectedthrought he
cir
cul arhol eont hebi gi dlegear .Thebackl ashatt hegearsi deofYC6TDengi negeari srequiredtobe
(0.07~0. 25)mm, asshowni nFig.3- 13.

Fi
g.3-
13GearTr
ain

-17-
3.
5Fuel
suppl
ysy
stem
3.
5.1 Basi
cwor
kingpr
inci
plesoff
uel
inj
ect
ionsy
stem
1 Fuel
inj
ect
ionsy
stem
Theengi neadoptst headvancedel ectronicunitpump( EUP)fuelinject
ionsy stem i nt
hewor l
d,
whichincl
udesl ow-pr
essureandhi gh-
pressurefuelsy stems.Theschemat icdiagram oft hesyst
em i
s
showninFi g.16.Underthecontrolofthecont rol
ler
, t
heEUPpr essuri
zesacer tainamountoff uel(upt
o
160MPa)andr ecei
vesthecontrolcommandf rom thecont r
ollert
hrought hesol enoi
dv al
veont heEUP
todeterminet heopeningorcl osingtime,soast odet erminet hecurr
enti njecti
onpr ocessofeach
cyl
inder
,i.
e.fuelinj
ect
ionpressure,fueli
njecti
onquant ityandfuelinj
ecti
ont imi
ng.

Fi
g.3-
17Schemat
icDi
agr
am ofFuel
Inj
ect
ionSy
stem

2. Lowpr
essur
epi
pel
i
ne
Thel ow pressur eoi lcircuitconsi st
soft hef uelt ank,oi l-
wat ersepar atorandhandoi lpump,f uel
deli
v erypump,f i
nef i
lt
er,EUPassembl y,fuelsuppl ypi pe,f ueltemper atur esensor ,fuelr eturnpi peand
othercomponent s.Itcanbedi videdi ntot hef uelinletsy stem andf uelret urnsy stem aspert hef unct ion
andl ocationoft heoi lci
rcui t
:
Fueli nl
etsy stem:undert heact i
onoft hesuct ionf or ceoft hef ueldel iver ypump, t
hef uelint hef uel
tankf lowst hr
ought heoi l-
wat ersepar atorandECU( thedi eseloilflowst hroughECUt ocoolt heECU)t o
theinl etofthef ueldel i
ver ypump,andt henundert hepr essureoft hef ueldel i
verypump,i tisdel ivered
totheEUPassembl yoi lgalleryt hrought hef i
nef ilter.TheECUassembl yandt hef uelmustbecl ean,
other wiseitwillcausest i
ckingoft heEUPsol enoidv alveandt hepl unger ,poorseal ingandf ueli njector
j
am.Ther ef
ore,thef i
nef i
ltermustsat isfyt hegr ader equi r
ementof( 3~5)m sot hati mpur it
iesi nt he
fuelcanbef i
lt
eredoutcompl etely.Theor et i
caldel iv eryf l
ow off ueldel i
v erypump:( 7~9)L/ mi n,fuel
suppl ypressure: (0.4~0. 6)MPa.
Fuel retur
nsy stem: thef uelr et
urnsy stem consi st soft wopar ts, i
.e.(I)f uelreturnoft hef uel injector,
whichmeanst hatasmal lamountoff uell eakedoutf rom t hef uelinject orf lowst hrought hef uelr eturn
mani foldandr et urnst ot hef uelt ankv i
at hef ueldi stribut or;(I
I)fuelr et ur noft hepr essur eregul ating
valve.I nordert omai ntaint hef uelpr essur ei nt heEUPassembl yoi lgal l
erywi thin0. 4~ 0. 6MPa,a
one-waybal lvalve( pressur er egulatingv alv e)isinst alledatt heout l
etoft heEUPassembl yoi lgal l
ery
andt heopeni ngpr essureoft heone- wayv al veis0.2- 0.3MPa.
3 Lubr
icat
ionci
rcui
tofEUPassembl
y
-18-
 For
cedlubri
cati
onwithengineoilisadoptedf ortheEUPassembl yandt hef
lowdir
ect i
oni
sshown
i
nFig.3-18.Duri
ngtheserviceperi
od,itisnecessaryt ocheckforandmai nt
aint
hecorrectandrel
iabl
e
connect
ionofthecir
cuitwit
houtloosenessandl eakage.Thelubri
cati
ngoilfl
owsthr
ought heci
rcul
ati
ng
syst
em oftheenginetogiv
ef or
cedcoolingtotheEUPassembl y.

Fi
g.3-
18Lubr
icat
ingOi
lPi
pei
nEUPChamber

4 Fuel
inj
ect
or
ThemechanicalP-ty
pefuelinj
ectorisadopt
ed,asshowninFig.3-
19.
Thefuelinj
ectorismai nl
ycomposedoft hehousing,nozzl
emat chingpar t
s,pr
essur
eadjust
ing
spri
ng,etc.Theopeni ngpressureoft hefuelinj
ect
orisdef i
nedaccordingt othepret
ensionofthe
pressur
eadjusti
ngspring.Thepressurecanbeadjustedbychangingt
het hicknessoft
hegasketonthe
spri
ngseat.Theopeningpressureis240~252bar .

Fi
g.3-
19St
ruct
ureofFuel
Inj
ect
or

Dur i
ng t he di sassembl y of t he f ueli nject or,t he
correspondi ngcy li
ndershoul dbei nstall
edt oitspr evious
positi
on.Nomi xingi sal l
owed.Theseal inggasketshoul d
ber eplacedwi t
ht heoneoft hesamet hickness,av oiding
i
mpedanceonnoz z l
epr otrusi onhei ghtorper formanceof
thediesel engi ne.
Due t oi tsf our -
valve st ructure,t he f uelinj ectori s
arrangedatt hecent eroft hecy li
nderf orbet terf ormat ion
andcombust ionofgasmi xtur e.Themi stspr ayshape
and at omi zation off ueli njectorshoul d be nor mal ,
withoutanyf uel dripping. Fi
g.3-20Bot tom Hei
ghtofProtr
uded
Thebot tom hei ghtofpr ot r
udedcy li
ndercov erof Cyli
nderCov erofFuelNozzl
e
fuelnoz zlef ort hisengi nei s3. 2±0.1mm,asshowni n
Fig.3-20.
Attention:Thef uelinjectori smadeofspeci almat eri
alsandpr ocessedwit
hspecialt
echnol
ogy.In
spiteoft heappear ancesi mi lart oar egularf uelinj ector,i
thasdifferentperf
ormanceandcompressive
strength.Ther efore,itmustnotber eplacedwi thar egularonet oav oi
danyaccidentordamagetot he
engine.
War
ning:I
tisf
orbi
ddent
otoucht
hef
uelspr
ayf
rom t
henoz
zlewi
thhandsorot
her
par
toft
hehumanbody
.

5 Ai
rex
haustf
rom oi
lsuppl
ysy
stem
Duringthenormaloper at
ionofthedieselengine,t
hereshoul
dbenoairintheoilsuppl
ysyst
em
pi
pel
ine,other
wisetheengineisdif
fi
cultt
ost ar
t.Foranewengineoranengi
neparkedforalongti
me,
ai
rexhaustshouldbecarr
iedoutbeforest
arti
ng.Themet hodi
stoloosent
hef
ueldischar
geport
softhe

-19-
fuelfi
lt
erinsequenceandkeeppushingt
hemanual
pumpunti
lnobubbl
eiscont
ained,
andt
henlockt
he
dischargeport
.Notethataf
terthecompl
eti
onofai
rex
haust
,themanualpumpshouldber
otat
edtoit
s
normal posi
ti
on(andfast
ened).
6 Hi
gh-
pressur
efuel
pipe
Attent
ion:theEUPengi neisequippedwi t
haspeci alhigh-pressuref
uelpipewhi
chismadeof
specialmat er
ial
sandpr ocessedwithspecialtechnol
ogy.Therefore,itmustnotberepl
acedwi
tha
regul
aronet oav oi
danysafetyacci
dentordamaget otheengi
ne.
7 Fuel
fil
ter
TheEUPenginehasahighrequi
rementonf
uelcl
eanl
i
nessandaspeci
alandef
fi
ci
entt
wo-
stage
f
uel
fil
teri
sadopt
ed,asshowni
nFig.3-
21.

Fi
g.3-
21Schemat
icDi
agr
am ofSpeci
alTwo-
stageFuel
Fil
ter

Thedi eselfilt
erhasapaperf i
lterelementandi sofr otarytype.Thei ntegralfil
terelementoft he
diesel fi
ltershoul dber epl acedr egularlytoav oidinsuffi
cientf uelsupplycausedbyl argeresistancefrom
thefilterel ement .Dur i
ngi tsi nst
all
ation,thefilt
erelementshoul dbef il
ledwithcleandi eseloiltoprevent
airfrom ent eri
ngt hef uelsy stem,whi chcanr esultinthest art
updi f
f i
cult
yandunst ableoper ati
on.And
then, asmal lamountofcl eanengi neoi lshoul dbeusedt ol ubri
catet herubberseal ri
ngbef oreinstall
ing
theint egr alfil
terel ement( itshouldbescr eweddownf or3/ 4~1ci rcl
ewhent hesealr ingbasi call
y
touches t he pedest al
).The r epl
acementper i
od oft he f il
tershoul d be in compl i
ance wi tht he
requirement sfort hemai ntenanceofdi eselenginei n4.2.2.
Wat eraccumul atedi nt hewat ercupoft hef uelprefi
l
t ermustbeobser vedanddi schargedev eryday .
Dur ingt hei nstall
ationoft hefuelf i
lt
er,thenewf il
tershoul dbef i
ll
edwi thcleandi eseloiltoprevent
airfrom ent eri
ngt hef uelsy stem,whi chcanr esultinthest art
updi f
f i
cult
yandunst ableoper ati
on.And
then, asmal lamountofcl eanengi neoi lshoul dbeusedt ol ubri
catet herubberseal ri
ngbef oreinstall
ing
thefilter.
At
tent
ion:
1.
Onl
ytheuseofaqual
i
fiedf
uelf
il
tercanensur
ethecl
eanl
i
nessoft
hef
uelandr
educet
he
engi
nef
ail
ure.Makesur
etouseaf
il
terspeci
all
ydesi
gnedf
ororappr
ovedbyYuchai
;
2.
Car
ryoutmai
ntenancei
nst
ri
ctaccor
dancewi
tht
hemai
ntenancei
nst
ruct
ions;
3.
Yuchaishoul
dnotber
esponsi
blef
orpr
ovi
dingwar
rant
yser
vicesf
ornocompl
i
ancewi
th
t
her
equi
rement
sofI
tem 1andI
tem 2.
8 El
ect
roni
ccont
rol
syst
em
Asthe“ner
vecenter”oftheengine,
theel
ectr
oniccont
rolsystem consi
stsoft
hesensor
,cont
rol
l
er,
act
uat
orandcontr
olharness.SeeFig.3-
22fori
tsschemati
cdiagram.

-20-
 Fi
g.3-
22Schemat
icDi
agr
am ofEl
ect
roni
cCont
rol
Syst
em

9 Sensor
Thesensor sadopt edf ortheel ectroniccont rolsystem oft heEUPengi neofYuchaimai nlyinclude:
crankshaf tsensor ,accel eratorposi ti
onsensor ,camshaf tsensor ,turbochargedpr essure&t emper ature
sensor ,cool i
ngwat ert emper aturesensor ,fueltemper atur
esensor ,oi
控制器lpressure&t emper atur
esensor
andaccel er atorposi tionsensor .
(1) Thecr ankshaf tsensori si nstall
edatt hef r
ontofthegearchamberandt hecamshaf tsensori s
i
nstal ledont hef ueli njectionpump.Thei nstal
lati
onai rgapoft hecr ankshaf tsensorandt hesignalgear
i
s3. 0- 3.5mm andt hatoft hecamshaf tsensori s0. 1-1.
8mm, whi chmustbedet ectedwithaf eel
ergauge
duringt heinst all
at i
on.Thecr ankshaf tsensori susedt opreciselycal culat
et hecrankshaftpositi
on,t he
fuelinj ect
iont i
meandspeed.Thecamshaf tsensori susedf orcy l
inderdet ecti
onandr unningwi thfault
i
ncaseoff ail
ur eoft hecr ankshaf tsensor .
Thecr ankshaf tsensorandt hecamshaf tsensormustbei ncompl iancewithcertainphaser el
at i
on,
soast oensur egoodoper ati
onoft heengi ne.I ncaseoff ail
ureofoneoft heabov esensor s,t he
malf unct i
oni ndi catorl ampwi l
lbeonandr unatt heenginef ail
uremode,soast oensuret heshipcan
runt ot heser v i
cear eaf orr epai
r.SeeFi g.3-23andFi g.3-
24fort heirinstall
ati
onposi t
ions

Fi
g.3-
23Cr
ankshaf
tSpeedSensor Fi
g.3-
24Camshaf
tSpeedSensor

(2) Tur bochargedpressureandt emperaturesensor

Thet urbochargedpr essureandt emperaturesensori susedtomeasur ethei ntakepressureand
i
ntaket emper atur
eoft heengi ne,andcorrectthef uelinj
ecti
onquant i
tyandfuelinjecti
ont i
ming,and
al
sousedf orov erheati
ngpr otect
ion.Thei ntakepr essureandintaket emperaturewi l
lbeusedt o
cal
culatet heairinflow andwi l
lbei nt
egr
atedwi t
ht heintaketemperatur
e.Duringt heinst
all
ationand
-21-
disassemblyofthetur
bochar
gedpressur
eandtemperat
uresensor
,becar
efulnottobreakthepressure
tubeoft hesensorandthesealr
ingshouldbei
nst
all
edinplacetoensur
enol eakageoccurs.SeeFig.
3-25.

Fi
g.3-
25 Tur
bochar
gedPr
essur
eandTemper
atur
eSensor Fi
g.3-
26 Cool
i
ngWat
erTemper
atur
eSensor

(3) Cool ingwat ertemper aturesensor

Thecool ingwat ert emperat uresensori susedf ormoni t
oringoft hecooli
ngwat ertemper atureof
theengine, coldstartandcal culationoft argeti
dlespeed,correcti
onoft hefueli
njecti
onadv anceangl e,
andov erheatingpr ot
ection.Ifthewat ertemperatur
eex ceeds98℃, thecont
roll
erwi l
lcontr
olt heengi ne
toreducei tspowerandent ert het hermalpr ot
ecti
onst at
et oensuret hesafeoper at
ionoft heengi ne.
Thesealandt or
queshoul dbepai dat t
entiontoduringt heinstal
lati
onanddi sassembl yt oprev ent
cooli
ngwat erleakage.SeeFi g.3- 26.
(4) Fuel t
emper aturesensor
Thef ueltemper aturesensori sinst
alledonthefuelinj
ectionpumpandusedf ort r
ansferr
ingsi gnals
toECUt ocal culateandcont rolthef uelinject
ionquanti
ty.SeeFig.3-27.

Fi
g.3-
27Fuel
Temper
atur
eSensor

(5) Oilpressureandt emperatur

esensor
Theoilpressureandt emperaturesensori
sinst
all
edonthemainoi
lgal
leyofthecyl
inderbl
ockand
wi
l
lgivealar
m si gnalwhent heoi
lpressur
eandtemperatur
eist
oolowortoohigh.SeeFi
g.3-28.

Fi
g.3-
28Oi
lPr
essur
eandTemper
atur
eSensor

10 Cont
rol
l
er
Ast he“ brai
n”oft hewhol eel ectr
oni
ccont rolsystem,t hecont roll
erconsistsofhar dwareand
soft
wareandshoul dbei nst all
edataposi ti
onf arawayf rom t hehigh-temperaturezoneoft heengi
ne
andtheshi p.Coll
isi
onandf all
ing-offshoul
dbest ri
ctl
yprohi bi
tedduringi t
soperationandmai nt
enance.
SeeFig.3-29.
Duri
ngt hedisassembl yofcont r
oll
erconnectors,
thel ockingdeviceshouldbepul ledupwardtothe
l
imiti
ngposi tionfir
stl
yandt hent heconnectorsshoul dbeunpl ugged;dur i
ngt heinstal
lat
ionofthe
connectors,theconnect orsshoul dbemai ntai
nedi nthest atewhent heyarer emov edandt hetwo
connectorsshoul dbepl uggedi ntothecontrol
leronebyoneandt hent helockingdev i
ceshouldbe
-22-
pull
eddownwar dti
llt
helockingdev i
cer eachest hel
ockingposit
ion.
Uponanyunpl uggi
ng/pl
ugging- i
ndif
ficult
yofconnectorsdur i
ngt he
di
sassembl y,
theunplugging/pluggi
ng-inoperat
ionshoul
dbest opped t
o
fi
rst
lyinspectwhetherthel ockingdev i
ceispulledinplace,whether
anyf orei
gn objectenterst he connectors,so as to preventany
damaget othecontrol
lerorconnectors.
11 Cont
rol
har
ness
Thecont rolhar
nessisahingeconnect
ingthesensor
,cont
roll
er
andact uatoraswel lasyachtsi
gnalandpowersuppl y.Rel
evant
wiri
nghar nessdiagramsmaybeusedasar efer
enceduri
ngthetest of
thewiri
nghar nessonaship. Fi
g.3-
29Cont
rol
l
er
12 Faul
thandl
i
ngofel
ect
roni
ccont
rol
component
s
Anyi ndividual
sex ceptfortheprofessionalmaintenancepersonnelaut hori
zedbyYuchaishoul dbe
prohibitedf oranyassembl yanddi sassembl yoperati
ons.Incaseofanydamageoft hecr ankshaft
sensor ,camshaf tsensor,turbochargedpr essur
eandt emperat
uresensor ,cooli
ngwat ertemper ature
sensor ,fuelt emperaturesensor,oi lpressureand t emperat
uresensor ,cont rol
lerorhar ness,iti s
necessar ytocont acttheafter-
sal
esser vi
cedepartmentofYuchaif ormai ntenanceandhandl ing.Forall
theel ectroniccont r
olcomponent s,anyper sonex ceptforthepr ofessionalmai nt
enanceper sonnel
authorizedbyYuchaishoul dbepr ohibi
tedforanyassembl yanddi sassembl yoperati
ons,otherwiset he
usershoul dassumer elat
edliabi
li
ti
es.
3.5.2 Met hodoft imi ngsignal assembl yofEUPdi esel engine
Thephaser elat i
onofsi gnalpaneli sshowni nFi g.3- 30:whent hedieselengi nei sint heupperdead
centeroft hef i
rstcy linder ,thecr ankshaf tsensorshoul di ndicatethe36t ht oothaf terthemi ssingt eeth
ofthecr ankshaf tsi gnalpanel( seet hef igur ebel ow f ort het oothnumber )ori ndicatet he210°( crank
angle)posi t
ionaf tert he1stt ooth( asshowni nt hef i
gur ebel ow:210° =360° -150° ).Itshoul dbef i
rstl
y
ensuredt hatwhent hepi stonoft hef i
rstcy l
inderi si ntheupperdeadcent er,t het imingpoi ntershoul d
pointto“ 0”posi tion.
◆ Pr iort ot hei nst allationoft hef ueli nject i
onpumpassembl y,itmustbeensur edt hatt het i
mi ng
mar ksoft hegeart rainhav eaone- to-onecor respondence, i.
e.thereisaone- t
o-onecor respondence
bet weent het imi ngmar ksoft hef ollowi ngi tems:cr ankshaf tti
minggearandi ntermedi atei dlegear ,
intermedi atei dlegearandbi gi dlegear ,bi gi dlegearandcamshaf tt i
mi nggear ,bigi dlegearand
idlegearoff ueli nject i
onpump,i dlegearandgearoff uelinjecti
onpump.Thecamshaf tphaseof
thef ueli nject ionpumpshoul dbeensur edt opr eci selycor r
espondt ot hecr ankshaf tphase.And
then, thef uel inject ionpumpgearshoul dbef ast enedt othef ueli
njecti
onpump.
◆ Thecr ankshaf tspeedsensori si nst all
edbesi det hev i
brati
ondampersi gnalpanelandf acest he
frontendoft hecr ankshaf t.Thev i
brat i
ondamperi smount edont hecr ankshaf tthroughposi t
ioning
byal ocat i
onpi nandt henthe0scal emar koft hev ibrationdampersi gnalpanelshoul dpoi nttot he
cent eroft hespeedsensor .SeeFi g.1- 14.
Dur i
ngt hei nst allationofspeedsensor ,theai rgapbet weent hesensorendsur f
aceandt hesi gnal
panelt eethshoul dbe3. 0~3. 5mm andshoul dbeadj ustedbyuseofagasketi fbeingl esst han
suchv alve.

-23-
 Fi
g.3-
30PhaseRel
ati
onbet
weenCr
ankshaf
tSensorandVi
brat
ionDamperSi
gnal
Panel

3.
5.3 Requi r
ementsonassemblyphaseoffuel
inject
ionpump
Dur
ingact
ualoper
ati
on(
taket
herepl
acementwit
hanewf uelpumpasanex
ampl
e):

Fi
g.3-
31Assembl
ySequenceofFuel
Inj
ect
ionPump

1) Remov et het i
mi ngpi ncov eroft hef uelpumpt ocheckwhet hert hepi ni sintheopeni ng
positionoft heupperdeadcent erandi nst allthenewf uel pumpi nplace.
2) Loosent hedr ivegearoft hef uel pumpi nt
hegearchamber .
3) Car ryoutbar ri
ngt i
lltheupperdeadcent eroft hef i
rstcy li
nder:dr iv
et hecr ankshaftt omake
theupperdeadcent erpoi nterpoi ntt o0posi ti
onoft hesi gnal panel;
4) Remov et hef ir
stcy l
inderheadcov er.Easyr otationoft heex haustpushr odi ndi
catest hatthe
upperdeadcent eroft hef irstcy li
nderi sr eached,other wiser otatet hecr ankshaf tagainfor360°~0°
andr echeckwhet herthepushr odcanber otated.Whet hert heupperdeadcent eroft hefir
stcy li
nderis
reachedcanbeconf i
rmedonl ywhent heupperdeadcent erpoi nterpoi nt
st o0°andt hepushr odoft he
fi
rstcy l
indercanber otated( bothcondi tionsshoul dbesat isfi
edsi mul taneously).Notet hatt heoil
bleedi ngmet hodusedf ort hemechani calpumpshoul dnotbeadopt edf ortheel ectr
oniccont rolpump
toconf i
rmt heupperdeadcent eroft hef irstcy li
nder.
5) Af tert heupperdeadcent eroft hef i
rstcyli
nderi sconf ir
med,sl ightlyrotatethecrankshaf tin
ant i
clockwisedi rect i
on( viewedf rom t hef rontend)t ot hescal eof3° ,andt henr otateitincl ockwise
directiontot hescal eof0° ,soast oel i
mi nat ethegap.
6) Ti ght ent hedr i
vegearoft hef uelpump.Putt het i
mi ngpi noft hef uelpumpbacki ntot hepin
holei nar ever semanner .

-24-
 Fi
g.3-
32Assembl
ySequenceofFuel
Inj
ect
ionPump

3.
6Lubr
icat
ingsy
stem
The l ubr
icati
ng syst
em is used f
orsending clean lubri
cati
ng oi
latsuitable pressur
e and
temperaturet
oeachf ri
cti
onsurf
aceforl
ubri
cat
ionorcooling,r
eali
zi
ngnormaloper
ationofeachpar tof
thedieselengine.SeeFig.3-
21f ori
tsoper
ati
ngprinci
ple.Detail
sofuseoft hedieselengineoilare
showni ntheNotestoUsers.

Fi
g.3-
21Schemat
icDi
agr
am ofLubr
icat
ingOi
lSy
stem

-25-
 Theoi llevelinsidetheoi lpanshoul dbei nspected
regul ar
lytoensur ethati tisbetweent heupperl i
mit
andl owerl i
mi tont heoi lscal e(seeFi g.3-22)andi t
shoul dber eplenishedwhenr unningshor t
.Oi lshould
ber epl
acedev er
y250hour sofcumul ati
veoper ati
on.
The dr ai
ni ntervalshoul d be shor tened undert he
circumst ancesoff requentst art
upsoroper ati
onsat
high speed and gr eatload.The oi lpan hasan oi l
capaci t
yof52L.Adr ai
npl ugi sprovi
dedatt hel ower
par toftheoi lpanf ordrainingoilforoi
l change.

Theoi lfi
lt
erhasapaperf i
lt
erelementandi sof
rot
aryty pe(seeFig.3-23).Itshouldber eplaced
ever
y250hour sofcumul ati
v eoperati
on.Dur i
ng
theinstall
ati
onoft hefil
ter,thenewf i
lt
ershoul d Fi
g.3-
22CheckofOi
lLev
el
befill
edwi thcleanengineoi landt henasmal l
amountofcl eanengineoi lshouldbeusedt o
l
ubricat
et herubbersealringbef or
einstallat
ionthefil
ter
.
Pressur
e
regul
ati
ng
valve

Fi
g.3-
23Oi
lFi
l
ter Fi
g.3-
24By
-passCent
ri
fugal
Oil
Fil
ter

Aby-
passcent ri
fugaloilf
il
terisprov
idedbesidet heoilfil
ter(asshowninFig.3-24)andisprovi
ded
wi
thanoi
lpr essur
eregulati
ngv alv
eoni t
sseat .I
ftheoi lpressureisbeyondtherecommendedr ange,i
t
maybeadjust edthrought hi
sv al
v etoreacht hespeci fi
edr ange.Theoi lpr
essurer angeis0.25~
0.
6MPaduringoperation.Theoilsludgei
nt herotorshouldber emovedevery500hofoper at
ionandthe
cl
eani
ngi
ntervalmaybeex t
endedpr oper
lyift
heoi lsl
udgei sless.
3.
7Cool
i
ngsy
stem
Thefunct
ionofthecool
ingsystem ofYC6TDseriesmarinedieselengi
nei
stoproperl
yandr el
i
ably
coolthepartsandcomponent soperat
inginhightemperatureconditi
onsdur
ingtheoperati
onoft he
engi
ne,soast oensurethattheengineisabletowor katt
hemostsui t
abl
etemperat
urestatusunder
var
iousenvir
onmentalcondi
ti
onsandoper at
ioncondi
ti
ons.

-26-
 Fi
g.3-
25Schemati
cDiagr
am ofOpen Fi
g.3-
26Schemat
icDi
agram ofFr
eshWat
erCool
i
ng
Seawat
erCooli
ngSyst
em System

Thef or cedcl osedci rculat ingwat ercool ingsy st em i sadopt edf orYC6TDser iesengi ne.Qual ifi
ed
ant i
-freez eliqui di susedast hecool ant.
Theopenseawat ercool ingsy stem i sadopt edout sidet heYC6TDser iesmar inedi eselengi ne,as
showni nFi g.3- 25.Thef or cedcl osedci rculatingf reshwat ercool i
ngsy stem isadopt edi nsidet he
engi ne,asshowni nFi g.3- 26.
Theseawat ersuckedf rom t heone- wayv alveatt hebot tom oft heshi pholdi spumpedi nt othe
i
nt ercool ert hr ought heseawat erpumpandt henl edi ntot heseawat er-
freshwat erheatex changerf or
cool i
ngoft hef reshwat eraf t ercool ingoft het urbochar gedai r,andfinall
ydi scharged.SeeFi g.3- 25f or
thewhol epr ocess.
Thef reshwat erpumpedf rom t hef reshwat erpumpf lowst hrought heoilcool eront hedi esel
engi nef oroi lcool ingandt henent erscool i
ngj acketoft hecy li
nderblock.Eachcy linderi sprov idedwi th
aci rculatinghol econnect ingt ot hecool ingj acketandt hef reshwat erenterst hecy l
indercool ingl inerof
thecool i
ngcav i
tyi nt hecy linderbor ev iasuchci rculat i
nghol e.Aftercool ingthecy li
nderbl ockand
cylinderhead,t hecool i
ngwat erf lowst hr ought hecool ingwat ermani f
oldt ot hewat er-coolingex haust
pipeandf inal l
yent erst heseawat er -
freshwat erheatex changerv i
at het hermost at.At hermost ati s
i
nst alledont hesi deoft hewat er-cool ingex haustpi peandcanbeusedt oadj usttheopeni ngaccor ding
tot het emper at ure.Whent hef reshwat ert emper at urei smor ethan( 75±2) C,thet hermost atwi llbe
opened;whent hef reshwat ert emper atur ei smor et han( 85±2)C,thet hermost atwi llbef ullyopened
andt hent hef reshwat erwi l
lent ert hef reshwat ercool ert oflowbackt ot hef r
eshwat erpump.When
thef reshwat ert emper aturei sl esst han( 75±2) C,t hef r
eshwat erwi l
ldirectlyfl
ow t ot hef reshwat er
pumpf orcool ingci r
culat i
onwi t
houtcool ing.

-27-
 Seawater-
fr
esh
water heat Thermostatseatand Water out
let
exchanger ther
mostat manif
old

Water
-cool
ed
ex
haustpipe

Fresh wat
er Oi
lcool
er
pump

Fi
g.3-
27St
ruct
ureofFr
eshWat
erCool
i
ngSy
stem

At her
mostatseati
si nstall
edatthefrontendofthewat er
-cooledex
haustpipeandisinter
nall
y
equippedwithtwoparal
lelthermostatswhi
chshouldnotber emov edeasi
lydur
ingusetopreventany
i
nfluenceonthenormaloperationofthedi
eselengi
ne.SeeFi
g.3-27.
3.7.1 Fr eshwat erpump
Thef unct ionoft hef r
eshwat erpumpi st opr essur izeandpr ovidef low powert othecool antt o
accel erateit sci rculat i
onf lowint hecool i
ngsy stem.
Useandmai nt enanceoff reshwat erpump:
a. Dur inguse,r egul arlycheckwhet hert hetensi onoft hef reshwat erpumpbel tisappr opri
ate.If
thet ensi oni st oosmal l(
tool oose) ,thebel twi llslipagai nstt hebel tpulley,causi ngi nsuffi
cient
ci r
cul atingwat erv olumeandov erhi ghwat ertemper at ur e, andaccel erati
ngt hebel twear .I
ft he
tensi oni st ooheav y( t
oot ight )
,itwi l
laccel erat et hewearoft hewat erpumpbear ingandbel t
andi ncr easepowerconsumpt ion.
b. Appl ycal ci um basegr easeont hewat erpumpbear ingandt ensi onpul l
eybear ingatar egular
inter val of200hour sofoper ation.Donotuset oomuchgr easeeacht i
me.
c. Ther el
iabi lityofwat erpumpst r
uct ur emai nlydependsont hewat erseal .Dur inguse,r egular l
y
checkf orwat erl eakagef rom t hedr ai nhol eatt hel owerpar toft hewat erpump.Anywat er
leakagewhi chusual lyoccur saf tershut -
downr at hert handur ingoper ati
oni ndicatest hatt he
wat erseal i
sdamagedandshoul dber epairedorr eplaced.
3.7.2 Seawat erpump
Theseawat erpumpwi thaf l
ow r angebei ngnol esst han600L/ mi nisr ecommendedf orYC6TD
seriesmar i
nedi esel engine.Thi sdiesel engi neisdel iveredwi thoutaseawat erpump.
I
nfor mat i
onont heuseandmai ntenanceofor dinaryseawat erpumpi sasf oll
ows:
a. Bef or eoper ationoft heseawat erpump,t hepumpchambershoul dbef il
ledwi thcool ing
wat erandt hebel tpul l
eyshoul dber ot atedf orsev eralt ur nst omaket heseal i
ngsur f
acenor mal l
y
ali
gned.I fst icki ngoccur s,thebel tpul l
eyshoul dbedi sassembl edf orinspect i
onandshoul dbe
reusedaf t
ert heel i
mi nat i
onoff ault.Long- ti
mewat erf ailureshoul dnotbeal loweddur i
ngt he
oper ationoft heseawat erpump, soast opr eventdamaget ot hewat erseal unit.
b. I nor dert opr ev entthepi pelineorpumpi mpel l
erf rom bei ngbl ockedbydi rt,whichwi l
l
affectt heuse,af il
terscr eeni si nstalledatt hei nletoft heseawat erpumpandshoul dbecl eaned
regul arly.
c. Af terst arting oft he pump,payat tention t ot he bear ing t emper atur e ofwhi ch t he
t
emper
atur
eri
sei
snotmor
ethan35
Cgener
all
yandt
hemax
imum t
emper
atur
eshoul
dnotex
ceed
75
C.
-28-
 d. Undert henor malcondi tions,addsomegr easef rom t hest raighthy draul i
cgr easeni ppl e
byuseofanoi lgunev er y200hour sofseawat erpumpoper ation, soast oi mpr ovet heser vicel i
f e
oft hebear ing.Donotuset oomuchgr easeeacht ime.
e. Dur i
nguseoft heseawat erpump, incasewat erl eaksf rom t hedr ai
nhol eatt hebot tom oft he
bear ingbody , thewat ersealr ingshoul dber emov edf orinspect ionandr epl aced.Dur i
ngassembl y
oft hewat ersealr i
ng,appl yadr opofspi ndleoi lont hef rictionsur faceoft hest ationar ysealr ing
(butdonotst ai nther ubberpar ts)andt henpusht hewat ersealr i
ngi ntot hebear i
ngbodyi na
par allel way .St riki
ngorskewi spr ohibited.
f. I ncaset heseawat erpumpi sst oppedf oral ongt i
mei ncol dweat her,unscr ewt hedr ai n
plugont hepumpbodyanddr aint heaccumul atedwat erof fi nt hechambert opr ev entf rost
cracki ngoft hepump.
g. Per for m inspect ion and mai nt enance f ort he seawat erpump ev er y 2000 hour s of
oper at ion.Cl eant hebear ingandal lther ot ati
ngcomponent sandr eplacewi thcl eangr ease.
3.7.3 Seawat er-
freshwat erheatex changer
Asshowni nFig.3- 29,t heseawat er-fr
eshwat erheatex changeri sawhol econsi sted ofan
expansi ont ankandaf reshwat ercool erandi tisinst all
edont hef r
ont -
endsuppor toft hedi eselengi ne
(seeFi g.3- 27) ,wi t
hahei ghtsl ight l
yabov et hef r
eshwat erout l
etoft hedi eselengi ne.Thef r
eshwat er
cool ercor ei soft het ube- sheetst ructur e.Theseawat erf l
owsi nt het ubewhi l
et hef r
eshwat erf l
ows
outsi det het ubei nawayofdoubl et ube- passes.Az incbari spr ov i
dedont heendcov er,whi chcan
reducecor r osionont hecool ercomponent scausedbyt heseawat er .Afterusi ngf oraper iodoft ime,a
l
ay erofscal ewi l
lbepr oducedont hesur faceoft hez i
ncbar ,whi chshoul dbecl eanedf requent l
yt o
avoi dl osingt heant i
-corrosi onef fect.Thez incbarwhi chi scor rodedshoul dber eplacedwi thanewone.
Ast heseawat eriscor rosive,itcandamaget hesur faceoft hepr otectivelay er,causecor r
osionand
format ionoff oul i
ngt othet ube, andt husdecr easet heseawat erci rculationar eaandr educet hecool ing
effect .Ther ef or e,thef reshwat ercool erandex pansi ont ankshoul dbecl eanedatr egul ari nterval.
Remov et hei nl etandout l
etendcov ersoft hewat ert ank,t akeoutt hecool ercor e,i mmer sei tint he
wat ercont ai ningdet ergentandt akei toutaf t
er15mi nut es;aftert hat ,cleant hei nsideoft her adiating
pipewi thanon- met al
licbr ushandf l
ushi tthoroughl ywi thwat er.Checkf ort hecor rosionofi nletand
outletendcov er saswel l asz i
ncbar .Alltheseal r
ingsmustber eplaced.

Fi
g.3-
29Seawat
er-
FreshWat
erHeatEx
changer

3.7.
4 Useandmai ntenanceofcool ingsystem
Ast hecool ingsy stem willaff
ectthepowerandf uelconsumpt ionaswel lasreli
abil
ityandser vi
ce
l
ifeofthedi eselengine, maintenanceshouldbecar r
iedoutf orthecoolingsystem asf ol
lowst oensur e
thenormal operation:
a) Cl eansof twat ersuchasr ai
nwat erorsnowwat ershouldbeusedast hecool i
ngwat er.Well
water,springwat erandr i
verwatershouldbeboi ledf orpreci
pit
at i
onbeforeuse,soast opr ev
entscal e
i
ncrustation.Themet hodofsof teneradditi
onmayal sobeadopt edandt hecommonsof tenersincl
ude
sodium bicar bonat e(
sodaash)andsodi um hydrox i
de( causti
csoda) .Addthesoftenerinthehar dwat er
tobepr ocessedatar ati
oof( 0.5~0. 8)gsodi um hy droxi
def or1Lwat er
.Af t
erpr eci
pi t
ati
onoft he
i
mpur it
iesgener ated,takethecleanwat erandinjectitintothecooler.
-29-
 b) Dur i
nguse,paycl oseat tent i
ont othef actwhet hert hecool i
ngwat ertemperat
urei snor mal
andt hewat erv ol
umei nt heex pansi ont ankissuf fi
cient.
c) Checkt het ensionoft hebel ttopreventsl i
ppingcausedbyt ooloosebelt.Meanwhile,regularly
applyapr operamountofgr easet ot hewat erpumpandt het ensionpulleybeari
ngt hr
ought hegr ease
ni
pple.
d) Theant i-f
reezel i
qui dshoul dbeadopt edwhent het emperatureislowert han5 C.Ifno
anti
-freezeliquidisusedf ort hecool er,thecoolingwat erintheengi neandt hecoolershoul
dbedr ained
off(afterthewat ertemper aturei sr educedt o50 C)aftershut-down.Thepr eparati
onproportionoft he
anti
-freezel iquid and t he cor respondi ng f r
eez i
ng pointsar e shown i n Table 3-
1.The v olume of
anti
-freezeliquidi ncreaseswi t
hr isingt emper ature,theref
ore,itshouldbe5%~6%l essthant het otal
capaci t
yoft hecool erwhent heant i
-freez el
iquidisaddedi ntothecool er.

Tabl
e3-
1 Pr
epar
ati
onPr
opor
ti
onofAnt
i-
fr
eez
eLi
qui
d

Freezi Alcohol +water Glycerinum +wat er

Gly
col +wat ermixture
ng mixture mi xtur
e
Point Massf racti
onof Massf ract
ionof Massf racti
onofgl ycol
 C alcohol X100 glycerinum X100 X100
-5 11.3 21 -
-10 19.5 32 28. 4
-15 26.0 43 32. 8
-20 31.0 51 38. 5
e) Thecool ermustbecl eanedr egularl
yt or emov escal e.I
tshoul dber egul
arlycl eanedby
i
njecti
ngaki ndofcl eaningagentt hatispr epar edbyaddi ng750gcaust i
csodaand150gker osene
i
n10Lwat er.Thecl eaningpr ocessi sasf ollows:t heengi neshoul dfirstl
yr unatani ntermedi ate
speedf or5~10mi nbyt aki
ngsuchcl eaningagentascool ant,andt henst opaf terthecl eani ng
agenti sheat ed,andt hecl eani
ngagentshoul dbemai ntainedint hedi eselenginef or10~12h;
aftert
hat ,t
heengi neshoul dbest art
edt orunatani ntermedi at
espeedof5~10mi nanddi schar ge
thecleaningagent ,andt hencleanwat ershoul dbef il
ledbef orebeingdischar gedafteroper ationof
theengineatani ntermedi atespeedf oraper i
odoft i
me.Incaseofal otofwat erscale,repeatt his
processf or2~2t imes.
f) Regul arl
ycheckt heoperationandseal ingcondi ti
onsoft hecool er.Ifthecooleroper ates
abnormal ly,
findoutt hereasonandcar ryoutr epai r.
3.
8Tur
bochar
gingandi
nter
cool
i
ngsy
stem
Theex haustt ur bochar gingt echnol ogyi sadopt edf orallthedi eselengi nesofYC6TDser ies.The
tur
bochar geri sequi ppedwi thaby passv al
ve,whi chcoul def f
ect i
v elyincreaset hel ow- speedt orque,
andsat i
sfyper for mancer equirement sbot hatahi ghspeedandal owspeed.Theoper ati
ngpr i
ncipl
eof
theturbochar gedandi nter-cooleddi esel enginei sshowni nFig.3- 30.
Duringt heoper ationofat urbochar gedengi ne,theex haustf rom t heex haustpi peofengi nei s
conveyedi ntot het ur bineandmakest het ur
bi neandi tscoax ialgascompr essorr otatebyt hef uncti
on
ofthet her malener gyi nt heex haustpr essur e.Inhaledandcompr essedbyt hegascompr essor ,airis
conveyedi ntot hei nt akepi peofengi net hrought hepiping.Thecool edandex pandedex haustf r
om t he
tur
bineisconv ey edi ntot heex haustsy stem ofengi net hrought het urbinecasi ngandi sv ent edintot he
atmospher e.
Compr essi onatai rintakecani ncr easet hedensi tyofai rchar gedi ntothecy li
nderandwi t
hgood
coordi
nat ionoft hef uelsuppl ysy stem,mor ef ueliscombust edsuf f
ici
ently,impr ovingt hepowerand
economi cef f
iciency .
Thet ur bochar gi ngandi ntercool ingr efertot hecool ingofcompr essedai r,tofurtherimpr ov epower
byincreasi ngai rdensi tyandi ncr easingai rint ake.Meanwhi l
e,i tcoul dr educet het emper at ur
eoft he
combust ionchamber .

-30-
 Fi
g.3-
30Schemat
icDi
agr
am ofTur
bochar
gingandI
nter
cool
i
ngSy
stem

3.8.
1 Tur bochar ger
Theoutli
neandst ructur
eoft het ur
bochar gerareshowni nFig.3-31.Thisk i
ndoft ur bochargeri
s
addit
ional
l
yequi ppedwi thacont r
oldev i
ceofby passvalve.Wi t
haccuratecal
i
bration,whent hedevicei
s
opened,apartofex haustisby passedoutwi thoutpassi ngthroughtheturbi
neimpel l
er,
bywhi chtheshaft
speedisrestr
ict
edandt hetur
bochar gingpressurei scontrol
l
ed.Theby passval
veel i
minatesthepossi bi
li
ty
ofexcessi
velyhi
ghai rpressure( over
-boost)i
nt heai ri
ntakepipewhent heengi
ner unsinahi ghspeedora
hi
ghl oad,t
husthecy l
i
nderex plosi
onpr essureiscont r
olledwithi
ntheal l
owedvalueofengi nemechani cal
l
oad.

Fi
g.3-
31TheOut
li
neandSt
ruct
ureoft
heTur
bochar
ger

As a ki
nd ofpreci
si
on machi
ne wit
h hi
gh-speed oper
ation,the turbochar
gershould notbe
di
sassembl
edatwil
landshoul
dbesentt
othemaintenancecenterformaintenanceincaseofanyfaul
t.
At
tenti
onshoul
dbepaidt
othefol
l
owingduri
ngoperati
on:
Pr
iort
obui
l
dingupl
ubr
icat
ingoi
lpr
essur
eoft
heengi
ne,
theengi
nemustbekepti
nidl
i
ng
st
ate.
-31-
 Bef or et heengi nei sst opped,i tst emper at ur eandspeedshoul dber educedf rom t he
max imum v aluesgr adual ly .
Thet ur bochar gershoul dbepr e- l
ubr icat ed.Af tert her eplacementofl ubricat i
ngoi lorany
mai nt enance ( incl udi ng t he r elease ofl ubr icating oi l
),t he t ur bochar gershoul d be
pre- lubr i
cat edandt hecr ankshaf tdi scshoul dbemov edf orsev eralt imespr iort ot he
star tingoft heengi ne.Theengi neshoul dbekepti ni dlingst at ef oracer taint imeaf terthe
star tingandpr iort ot hehi gh- speedoper ation,soast obui ldupt hepr essur ef orent i
r e
circul at ingofl ubr icat ingoi l.
Thest ar tingoft heengi neatl ow t emper at ur emustbeconduct edwi thcaut ions.The
super -lowambi entt emper at ur eorout -of -ser v i
cef oral ongt imecoul daf fectbui lding-up
oft henor malpr essur eandf l
ow r at eofl ubr icatingoi loft heengi ne.I nt hiscase,t he
star tedengi nemustbekepti ni dli
ngst at ef orsev eralmi nutesbef or eent er i
ngt henor mal
oper at ionst ate.
Meanwhi le, long- t i
mei dl i
ngr unni ngoft heengi neshoul dbeav oided.
3.8.2 I nter cool er
The YC6TD ser ies mar ine di eselengi ne i s
equi pped wi th an i nt ercool er .The ai rf rom t he
turbochar gercompr essori sl ed t ot he wat er -air
cool i
ng t ype i nt ercool ert hati si nst alled on t he
platfor m suppor toff lywheelhousi ng byaf ront
pipe,i nsteadofbei ngdi rect lyconv ey edi ntot heai r
i
nt akepi peoft heengi ne.I nt hei nt er cool er ,t he
compr essedai rdensi tyi sf ur theri ncr easedaf ter
cool i
ng,whi chhel pst oi mpr ov et hedi eselengi ne
per f
or mance.
Thest ruct ur eofi nt er cool eri sshowni nFi g.
3-32.
Tur bochar ged ai rpassesar ound t hecopper Fig.3- 32St ruct ur eofI nter cool er
pipe of i nt ercool er and t he seawat er passes
throughi nt hecopperpi pe,andt heex ter nalsur f aceoft hecopperpi pei sequi ppedwi thf inspr ovi
ding
thermaldi ssi pat ion.Thef insandcopperpi pesar econnect edbyex pandedconnect ion.The" heat
transf erhol es"enhanci ngheatt ransf erar esetatt hear easar oundeachpi pehol eandi nt hewi dt h
directionaswel l ast hef insbet weenpi pehol es.Ther ei st hei ni t
ial disturbancest ructur eont hef inedge.
Thesechar act er i
st icsbr inghi gherai rflow v eloci ty,andt he" heatt r
ansf erhol es"enhancet heheat
transf er,leadi ngt ohi ghheatt ransf eref f i
ci ency .Theendcov eri sf i
xedont het ubesheetwi thM10bol ts
andi sseal edwi thgasket s.Thet ight eni ngt or quei st ight enedupi nthreet i
mes( 10- 30-50)N. m.I tbegins
from t hei nter medi ateposi tioni nt hel engt hdi rect ion.Theex haustofi nt er cool ercoul dbeconduct ed
throught hedr ainpl ughol eont heendcov er.
Oper at ionandmai ntenance
Undernor malcondi tions, thegassi deofi nt er cool ershoul dbef reeofdi rt.Gener al l
yt hesi dewat er
needsnomai nt enancei nacl osedci rcul at ing.Cl eant hesi dewat erimmedi at elyi ncaseofcool ingwat er
pollutionduet omi soper at ion.Dur i
ngoper at i
on,t hedr ainpl ugsont hev ent ingendcov ershoul dbe
openedr egul ar ly, tor emov et hecondensedwat erpr oduceddur i
ngoper ati
on.
Whencl eani ngt hei nt er cool er, thewat erst or edi ni nter cool ershoul dbedr ai nedt hr oughwat erpipe
ordr ainpl ug, andt heendcov ershoul dber emov ed.
a. Cl eani ngwi thmechani cal met hod
Thepi peshoul dbecl eanedi ncaseofscal esi nt hepi pedur i
ngmai nt enance.Al lpi pesshoul dbe
cleanedwi thbr ushi nwet tingst atus.Thebr usheddi rtshoul dbeel i
mi natedaf terbr ushing.Thent heend
cov ershoul dbeseal edwi thnewgasket s, andi nst alledaccor dingt ot het ight eningt orquer equirement s
andsequence.
b. Cl eani ngwi thchemi cal met hods
Thechemi calmet hodsshoul dbeusedi ncaseoft heunsat i
sfy i
ngmechani calmet hods( thesame
as t he boi lercl eani ng met hods) .
The chemi calcl eani ng shoul d be conduct ed byt he speci ali
zed
depar tment .Thechemi calcl eani ngshoul dbeconduct edbyt hespeci alizeddepar tment ,soast o
shor tent hecl eani ngpr ocessassoonaspossi bl e,andt hecool ingsy stem shoul dbef reeofr esidues
aftercl eani ng.At tent ion and pr ot ect ion shoul d be pai d and conduct ed t ot he f or mat i
on ofnew
protect i
v el ay eront hepi pe.
c. Repai rofcool ingwat erl eakageofi nt ercool er
Thecommonf aul tofi nt er cool eri swat erl eakage, whi chwi llreducet hedi eselengi nepower ,lower
-32-
thet urbochargingpr essureandi ncr easet heex haustt emper ature.Thepossi bler easonofl eakagei sthe
cor r
osionofpi pesorl eakageofend- pipeswi thout war dex pansi on.Iti sbet tertodi sassembl et he
i
nt ercoolerandputi tont hepr operr ack,t of i
ndt hel eakageposi t i
on.Thedi sassembl ingi ntercooler
shoul dcar r
youtpr essuret estwi thwat er,andt hel eakageposi ti
oncoul dbej udgedbyt hedr ipping
condi ti
ons.Allthepi pesinl eakagepar tshouldcar ryouthy drauli
ct estonebyonei fnecessar y,soast o
fi
ndoutt her ealleakingpi pe,andt heendcov ershoul dber emov edatt hist i
me.I fnecessar y,itis
recommendedt oputt heintercool erintot hewat ertank( dri
nkingwat erqual i
ty),especial
lywhent hereis
l
eakageofout war dex pansionend- pipes, soast of i
ndoutt heleakingpi pe.Appl y0.05MPapr essur eon
thesi dewat er,andbl ow-dryt heint ercoolerwithhi gh-pr essureairafterfinishing.Thel eakingpi pesmust
beex pandedout wardagai n,andt hedef ecti
vepi peshoul dbebl ockedwi thconi caltubepl ug,ofwhi ch
themat eri
alsar ethesamewi tht hoseoft het ubesheet .Thet aperoft hepl ugpi pei s1:25, andt het ube
plugshoul dbeknockedi ntot het woendsofl eakingpi peswi thahammer .Theendcov ershoul dbe
i
nst all
edont hei nt
ercoolerwi t
hnewgasket .Thei nter coolershoul dcarr youtpr essuretestf oratl east
15mi nutes,andt hepi l
otrunoft hei ntercoolershoul dbeconduct edaf t
erinst al
lation.

3.
9El
ect
ri
cal
syst
em andi
nst
rument
s
The el ectr i
calsy stem consi sts of t he
starti
ng sy stem and moni tori
ng sy stem.The
starti
ng sy stem i s composed ofa bat tery,
chargi ng gener ator ,st artermot or,di sconnect
switch and st arti
ng swi tch ( install
ed on t he
i
nst r
umentpanel );whi let hemoni t
oringsy stem
i
scomposedofani nstrumentassembl y.
TheYC6TDser iesmar inedi eselengi nei s
equipped wi th an el ectricalst arti
ng sy stem
(pneumat icst ar t
ingi sopt i
onal ).
Theschemat i
c
diagram ofel ectr i
calst arti
ngsy stem i sshown
i
nFi g.3- 33.
Whenst ar ti
ng,bycl osingt hedi sconnect
switch DK f irst,and t hen pr essing t he
starti
ngswi tchont hei nst r
umentpanel , 1. Char
ginggenerator 2.St ar
termotor 3.Di sconnectswit
ch
currentf lowst hrought hemagnetcoi lMK 4.St
arti
ngswi t
ch( ontheinst
rumentpanel) 5.Bat ter
yset
oft her elayi nsi det hest artermot or ,t o
maket hemagnetactandswi tchont he
Fi
g.3-33Electr
icalSchematicDiagr
am ofStart
ingSystem
starterci rcuit.Whent hest arterr uns,t he
pini
onwi llbepushedoutt obeengaged
witht hef lywheel ringgearoft hedi esel engine,soastost ar
tthedieselengi
ne.
Thewi ri
ngdi agr am oft heel ectri
cal system ofYC6TDser i
esdieselengi
neisshowninFig.3-
34.
3.9.1 St ar ter
Thef unctionofast arteri stoov ercomesuchr esistancesofengi necyli
ndercompr essi on,f ri
ct i
on
andi nert
iaforce, achi evingt hedesi redst art
ingspeedoft hedi eselenginefrom t hestati
onar yst ate, and
reali
zingthei gnition,combust i
onandnor maloper ati
onoft hedi eselengine.Thest r
uctur eofst art
er
mot orisshowni nFi g.3-35.
Thespeci fi
cat ionoft hest arterofYC6TDser iesdi eselengi neis24V,7. 5kW.Thest ruct ur
eoft he
start
eriscomposedoft hreepar t
s:aDCser i
esmot orpr oduci ngtorque;aone- waycl utchengagi ngor
disengagingt hepi nionoft hest arterwi t
ht hef l
ywheelr inggear ;anelectr
omagnet icswitchconnect i
ng
ordisconnect i
ngt heci rcuitbet weent hest arterandbat t
er y.
Mai nt
enanceandser viceofst artermot or
a Checkt hebat terypowerandwhet hert hewi reconnect i
onandt heer ecti
onbol t
sofDC
starteraresecur e;
b. Thest ar tingper i
odf oreacht i
meshoul dnotex ceed10s.Thet i
menecessar yf orasecond
starti
ngaf t
erst art i
ngf ailureshoul dbeatl east1mi nut e.Incaseofst arti
ngf ai
lur
ef ort hreet imes,
starti
ngshoul dbeonl ycar r
iedoutaf tercausesar efoundoutandt r
oubleshoot i
ngisconduct ed.
c. Af tertheengi nei si gnit
edandst arted,t
hest ar tingswi t
chmustbet urnedoffi mmedi ately;
d. Eachcomponentoft heDCst art
ershoul dbeal way skeptcl eananddr y
;
e. TheDCst artershoul dbecheckedandadj ustedannual l
y.

-33-
-34-
Fi
g.3-
34Wi
ri
ngDi
agr
am ofEl
ect
ri
cal
Syst
em
 1.start
erswi t
chcont
actdisc 2.el ectr
omagneticswitchshell 3.el
ect
romagneti
cswitchcoil
4.bondstrapswit
ch 5.mov i
ngcor e
6.retur
nswi tch 7.shift
ingfork 8.eccent r
icscrew 9.dri
vi
ngendcap 10.cast l
enut
11.startershaft 12.one-wayclut
ch 13.ar mature 14.magneti
cpole 15.el
ectr
ical
brush
16.shell

Fi
g.3-
35St
ruct
ureofDCSt
art
er

3.9.
2 ACgener ator
Theint
egratedsili
conrecti
fi
cati
onbr ushl
essgener
ator(
exci
ti
ngtype)i
semploy
edast hechargi
ng
generat
or,wi
thbeltdr i
ve,
ar at
edv ol
tageof28Vandar atedpowerof1500W.Thest
ruct
ureisshownin
Fi
g.3-36.Theelectr
icschematicdiagram i
sshowninFig.3-
37.

Fi
g.3-
36Par
tsDr
awi
ngofI
ntegr
atedSi
l
iconRect
if
icat
ionBr
ushl
essGener
ator

Operati
onandservi
ceofchargi
nggenerator
Thecor r
ectoperat
ionofsili
conrecti
fi
cationgener
atorcouldreducefaul
tsandensur
eal ong
ser
vicelif
e.Anymisuseisli
abl
etocausedamage.Ther ef
ore,at
tent
ionshoul
dbeespeci
all
ypai
dtothe
fol
l
owi ngaspect
sduri
ngoperati
onandmai ntenance:
-35-
 a) Thebat ter ybondst r appol ar itymustbei dent i
calt othegener ator .Thesi li
conr ecti
ficat i
on
ACgener atorempl oy edf orYC6MKser iesdi eselengi nesar eal loft henegat ivebondst rap,sot he
bat ter iesonboar dal somustbeoft henegat ivebondst rap.Ot herwi seoncet hel iv ewi reoft he
bat ter yt ouchest hel ivewi ret ermi naloft hegener ator ,thedi odewi llbebur ntoutast hebat tery
dischar gest hrought hedi ode.
b) Al lt he wi re connect i
ons oft he si li
con
rect ificat iongener at ormustbecor rect .
Gener ally,a gener ator i s equi pped wi thf our
connect ion post s,wi th mar ki ngs and descr iptions
bei ngasf oll
ows:
B+─ ar mat ur econnect ionpost ;
D+─ magnet icf i
el dconnect ionpost ;
W ─ speedmeasur i
ngt ermi nal ;
E─ gr oundi ngconnect i
onpost .
c) Af ter t he engi ne i s shut down, t he
disconnectswi tchshoul dbeswi tchedof ftopr ev ent
the bat teryf rom di schar gi ng t ot he gener at or
ex citingwi ndi ngf oral ongt ime,whi chmaycause
damages t o t he ex citing wi ndi ng and ot her Fig.3-37El ectri
cal Schemat i
c
equi pment . Diagr am ofGener ator
d) Dur ing oper ation oft he gener ator ,iti s not
allowedt ocar ryoutscr apingonB+ar mat ureconnect ion
postwi thascr ewdr i
v erandot hermet alobj ects, forchecki ngonpowergener ationoft hegener ator,
soast oav oi danydamaget ot hegener atorandbur ningofwi r
inghar ness.
e) I ncaseofgener ationf ailur eoft hegener at or,f aultcausesshoul dbef oundoutand
elimi nat edi nt ime,andt hegener at orshoul dnoti noper at i
onf oral ongt i
me.Onedi odesuf fered
from shor tci r
cui tcausesgener at i
onf ail
ur eoft hegener ator,andcont i
nuousoper at i
onr esul tsi n
bur ni ng- outoft heot herpr ev iousl yint actdi odesort hr ee- phasest atorwi ndings.
f) I ti snotal lowedt ocheckt hei nsulat i
onper formanceoft hegener atorwi tha220VAC
vol tagemet erormegohmmet er ,
ot her wiset hebr eakdownanddamagewi ll becausedt ot herect i
fier
diodeduet oanov er-highv oltage.
g) Thet ensi onoft hegener at ort ransmi ssionbel tshoul dbeadj ust edpr oper lyandt hebel t
shoul dnotbet ool ooseort oot ight .Tool oosebel ti spr onet osl i
p,causi ngi nsuf f
icientpower
gener at ion; whi l
et oot i
ghtbel ti spr onet odamaget ot het ransmi ssionbel tandgener atorbear ing.I n
adj ust ment ,bypr essi ngdownt hebel ti nt hemi ddleposi tionwi thahand, thet i
ght nessi sconsi der ed
appr opr iat eift hebel tcoul dbel ower edf or10- 15mm.
h) Cor rectj udgmentshoul dbemadef ort henor maloper ationoft hegener atorchar ging
sy stem.Thebat ter ypr ov i
desagr eatdealofel ectr i
cener gyt ot hest arterwhent hedi eselengi nei s
star ted,whi chcausesar educt i
onoft ermi nalv oltage.Af tert her unni ng ofdi eselengi ne,t he
gener at ori mmedi at elyconduct sboostchar gingt ot hebat teryunt ilthebat teryt ermi nalv oltage
reachest hev oltagel imi toft her egul ator,whi chmeans
thebat t
er yi sf ullychar ged.Av oltmet ermaybeusedt o
bridget wo endsoft hebat t eryt o checkt heout put
vol tageoft hegener ator .
Precaut ions:
☆ As t he gener atori s notequi pped wi tht he
elect rical brushandsl ipr i
ng, thef aul tssuchasunst able
ex citat ioncur rentandf ailureofpowergener ationwi l
l
notbecausedbywear ingandabl at ionoft hesl ipr ing
andel ect ri
calbr ush.Ther efor e,f requentmai ntenance
andser vicear eunnecessar y.Howev er,t hegener ator
shoul dbedi sassembl edf ormai nt enanceatar egul ar
i
nt er valt oensur enor mal ,saf eandr el i
abl eoper ationof
thegener ator.
☆ Theex ter nalpar toft hesi l
icon r ect i
ficat ion
gener at orshoul dbeal way skeptcl eanandat tent ion
shoul d be pai dt o checki ng whet hert he connect ion
-36-
post sar eloose.Thei temsofr egul arov er haul andmai ntenancear easf ol l
ows:
a. Bl ow of ft hedustwi thi nt hegener atorwi thcompr essedai randcl eanoutt her esidualoi l
dirtat tachedonal lpar tswi thgasol i
ne.
b. Checkwhet hert heconduct orson al lt he Fig. 3-38St ruct ureandOut li
neofBat tery
connect ion post s oft he gener atorar ei n good
cont actandf irml yconnect ed.
c. Repl acet hegener atorbear ingi ncaseofanyobv i
ouspl ayorabnor malsound.Appl ygr ade
1~3compl excal cium- sodi um basegr easet ot hegener atorbear ingdur i
ngmai ntenance.
3.9.3 Bat ter y( tobepr ov idedbyt heuser )
Al ltheel ect r
icalequi pmentoft heYC6TDser iesdi eselengi nei ssuppl i
edbyt hebat tery.Thi sser ies
ofdi eselengi nei sequi ppedwi tht wol eadbat ter ies( 12V)wi thacapaci tymor et han195Ah.Maj or
funct ionsoft hebat t
er yi ncludesuppl yingpowert ot heDCmot orwhent hedi eselengi nei sst arted;
suppl yingpowert ot heel ectricequi pmenti ncaseofpowergener at i
onf ail
ureofchar gi nggener atorora
l
owv ol tage;pr ov idingaddi ti
onalpowersuppl ywhenel ectricit
yl oadex ceedst hepowersuppl ycapaci ty
oft hechar gi nggener ator , andpowerst or agef unct ionwhenchar gi ngthebat terybychar ginggener ator
i
ncaseofl owbat terypower ,whi l
et heout putofchar ginggener atorex ceedst hel oadr equired
Gener alst ructur eoft hebat teryi sshowni nFi g.3- 38.Thebat t
eryi scomposedofbat terypl ates,
separ ator s, housi ng, elect r ol
y teandconnect ingst ri
ps.Thewor kingpr i
nciplei sthatt heel ectricener gyi s
transf or medi nt ochemi calener gybyel ect r
olyt ef orst oragedur i
ngbat terychar gi ng;whi l
et hechemi cal
ener gyi st ransf ormedi ntoel ect ri
cener gybyel ect roly t
eandbesentoutdur ingbat terydi schar ging.
Oper at ionandser viceofbat tery:
a. Thebat teryshoul dbef lex i
bl yandf irml yi nst alledi nsidet hemount ingf rame, t
opr eventt he
bat ter ypl at eandhousi ngf rom damageduet ov ibr at i
on;
b. Thewi r
eandt er mi nal postshoul dbef i
rml yconnect edandi ngoodcont act ;
c. Dur ingbat t
er yi nst allation,connectt he“ li
v ewi re”t ermi nalf i
rst ,thenconnectt wobat tery
set si n ser i
es and f inal lyconnectt he “ bond st rap”t ermi nal .Bat ter ydi sassembl yshoul d be
per for medi nt heopposi teor der ;
d. Whenf ill
ingt heel ect rol yte,onl ypur esul fur i
caci danddi st i
ll
edwat ercoul dbeusedand
dr oppi ngofanysundr i
essuchasmet allicconduct orsar enotal l
owedi ntot hebat tery,andt he
bat ter yshoul dbeal way skeptcl ean.Gr ease( pet rol at um)shoul dbeappl iedont het ermi nalpostand
connect ingst ripaf tert heox idesar er emov edf rom t hem,t opr ev entox idat i
onoft het er minalpost
andconnect ingst rip.
e. Checkt heel ect r ol
y tel ev elinsi det hebat ter yr egul arly.Thel evel shoul dbe10~15mm hi gher
thant hebat t
er ypl ateandonl yt hedi st i
lledwat ercoul dbef ill
edi ncaseofi nsuf f
iciency .Thef il
lingof
sul f
ur icaci dsol ut i
oni sal l
owedonl yundert heci r cumst ancet hati tisconf ir
medt hatt hedecl ineof
l
iqui dl ev el isr esul tedf rom spl ashi ngofel ect rolyte.
f. Measur et hedensi tyofel ect rolytewi t
hasuct iondensi met erandmeasur et het emper at ureof
elect rol ytewi that her momet eratt hesamet ime( Fi g.3- 39) .

Tabl
e3-
2El
ect
rol
yteDensi
ty(
20°
C)

Speci
fi
edv
alue(
g/cm3) Ser
vicel
i
mit(
g/cm3)
1.26~1.28 1.15
Foreachincreaseordecr easeoftheelectr
olyt
etemper at ur
efor1° C, theelectr
olyt
edensi t
yshould
3
bereducedori ncreasedby0. 0007g/cm ,bywhi chconv er
siont othest andar ddensit
yv alueat20°Cis
conducted.
Rightaft
erthef i
ll
ingofdi sti
l
ledwaterorhigh-i
ntensit
ydi schargi
ng,t heel ect
roly
tedensi t
yshould
notbemeasur edi mmediately,astheelectr
oly
teisnotuni formlydistri
but ed.Measur ethedi schar
ge
vol
tagewi t
hahi ghratedischargegauge(Fig.3-
40)andt hedischargev oltagei sshowni ntable3-3.

Tabl
e3-
3Di
schar
geVol
tage

Speci
fi
edval
ue(
V) Ser
vicel
imi
t(V)
2.
0 <1.
75
g. Thebatteryshoul
dbef r
equentl
ykepti
nchargestat
einthecoldwint
er,t
oprev
entfr
eezi
ng
ofel
ect
rol
yte,whichmayr esul
tinthehoggingofbatt
eryplat
es,fal
l
ingoffofacti
vemater
ial
sor
cr
ackofthehousi ng.I
nwinter
,thefil
l
ingofelect
rol
yteanddist
il
ledwatershoul
dbecarri
edout
-37-
beforebatter
ychargingorsai l
ing;
h. Theel ectr
olytedensityshouldbeadjust
edasnecessaryi
nsummerandwi nt
er.I
nsummer ,
asmal lamountofel ectroly
temaybesuckedoutf orfi
ll
i
ngofthedist
il
ledwat
er,whil
einwinter
,the
elect
roly
tewithadensi tyof1.4g/ cm3shoul
dbef i
ll
edin;
i
. Thebat teryshoul dbest oredwit
hfullchargeandwit
helectr
olyt
edensi
tycomplyingwith
thespecifi
edrequir
ement sforly
ingidl
efor1-
2mont hs.

Fi
g.3-
39Measur
ingofEl
ect
rol
yteDensi
tyandTemper
atur
eFi
g.3-
40Measur
ingofDi
schar
geVol
tage

3.9.4 Moni t
or i
ngsy stem
Themoni toringsy stem i scomposedofani nstrumentassembl ywhi chi sdividedintothelocal
i
nst rument sandr emot ei nstrument s.Ther emot einstrument sar eoptional,whichisequi ppedfort
he
conv eni enceofr emot econt rolandmoni tori
ngoft her unningcondi t
ionsofdi eselengine.Theuserwho
needst her emot ei nstrumentmustmakear equestwhenor der
ing.
Fort he suppor ti
ng i nst rumentofYC6TD ser ies diesel
engine, t aking t he di esel engi ne moni toring i nstrument
producedbyChongqi ngChuany iSudaEl ectroni cs&Machi nery
Co., Ltdf orex ampl e( requirementofot hert ypei nstrumentmay
best atedwhenor der i
ng) ,theout l
inei sshowni nFig.3- 41.The
moni toringi nst rumenti sintendedt oaut omat i
callydet ectt he
wor king condi t
ions oft he di eselengi ne and per f
or m l i
mit
protect iont ot heel ect ronicequi pmentofdi eselengi ne.The
moni toringi nst rumentconduct st heaut omat icmeasur ement,
digitaldi spl ayandl imi tpr otectionofpar amet erssuchast he
speedofdi eselengi ne,oi lpr essur e,wat ert emper ature,oil
temper at ure,and sends outaudi o-visualal arm si gnal .The
moni toringi nst rumenti sequi ppedwi thast ar tbuttont ost artthe
dieselengi ne.Ref erst o Oper ati
on& Mai nt enanceManualf or Fi
g.3-41CFZ- DTy peDiesel
CFZ- D Type Di eselEngi ne Moni toring I nstrument ,f or the EngineMoni t
or i
ngInstr
ument
oper at i
onandmai ntenanceoft hemoni toringi nstrument .
Al lt
heal armv aluesandshut downout putv aluesar eshowni nt
able3- 4andt abl
e3- 5.

Tabl
e3-
4Par
amet
erSett
ingsofAlar
m Val
ueandShut
downValue,
andAl
arm DelayTi
mef
orToo
Hi
ghWaterTemperat
ure,TooHi
ghOil
Temperat
ure,
TooLowOilPressur
e

Par
amet
erset
ti
ng
S/
N I
tem Shutdown
Al
arm par
amet
ers Al
arm del
ayt
ime(
s)
parameter
s
Too hi gh wat
er
1 97℃ 99℃ 10
temper
atur
e
Too hi
gh oi
l
2 115℃ 117℃ 10
temper
atur
e
-38-
3 Tool owoi lpressure 0. 1MPa 0.07MPa 3
Note:thealar m delayt imest ar
tswhenthepar ameters(suchaswat ert
emper at
ure)det
ect
edby
theenginer eacht heal armv al
ues.Whenthealarm del
ayt i
meisup, al
arm si
gnali
ssendoutift
he
detect
edpar ameters( suchaswat ert
emperature)sti
ll
exceedthealarmv al
ues.Oncethedet
ect
ed
paramet er
sr eacht heshut downv al
ues,theshut downi nstr
uct
ioni ssendoutandshut down
procedureisi mplement ed.

Tabl
e3-
5Par
amet
erSet
ti
ngofSpeed

Dieselengi
nespeed Paramet erset t
ing
Alar
mv alue Shutdownv al
ue
(Mainengi ne:ex ceed15% (Mainengine:ex ceed17%ofthe
Alar
m del
ayt
ime
Rating oftheratedv al
ue rat
edv al
ue
(s)
auxil
i
arymachi ne:exceedauxil
iar
ymachi ne:exceed 10%
8%oft her atedv al
ue) oftheratedvalue)
Main
1725 1755 5
engi
ne
1500
Auxi
li
ary
1620 1650 5
machine
1800 2070 2106 5

Descr
ipt
ionofi
nstr
umentfaul
tli
ghtst
ate
Thestat
esoffaul
tli
ghtar
easfoll
ows:
S/
N St
ate Descr
ipt
ion Remar
ks

1 Faul
tli
ghti
sof
f Thesy
stem i
sfaul
t-
fr
ee

2 Faul
tli
ghti
snor
mal
l
y-on Thesy
stem i
swi
thmi
norf
aul
t

3 Faul
tli
ghti
sbl
i
nki
ng Thesy
stem i
swi
thmaj
orf
aul
t

4 Fl
ashcodeout
put Fl
ash out
putofcur
rentorhi
stor
ical

DTC
Fl
ashcoder
eadi
ngmet
hods:
 Pr
ess&r
eleaset
hef
aul
tdi
agnosi
sswi
tch,
toact
ivat
ethef
lashcodeout
put

mode;

 Faul
tli
ghti
sof
ffor2s;

 Fl
ashout
putofaDTC;

 Pr
ess&r
eleaset
hef
aul
tdi
agnosi
sswi
tchagai
n,t
oout
putt
henex
tDTC;

 Out
putt
hecur
rentorhi
stor
ical
faul
tfl
ashcodei
ntur
n;

 Af
tert
heout
putofal
lfaul
tfl
ashcodes,
conductl
oopout
putuponnex
trequest
;

 Af
tert
heout
putofeachf
lashcode,
thef
aul
tli
ghtr
etur
nst
othest
atebef
ore

f
lashcoder
eadi
ng.
Forex
ampl
e:t
hef
lashcodei
s254,
andt
hef
lashcoder
eadi
ngi
sasf
oll
ows:

-39-
 DTCLi
st

I
SO15031 J1939 Fl
ash Faul
t
S/
N Faul
tdescr
ipt
ion
DTC SPN FMI DTC code l
evel

Bey
ond l
ower l
i
mit of t
hrot
tl
e
1. P0122 91 4 5B000400H 32 Maj
or
si
gnal

Bey
ond upper l
i
mit of t
hrot
tl
e
2. P0123 91 3 5B000300H 32 Maj
or
si
gnal

Bey
ondl
owerl
i
mitoft
hrot
tl
e(5V)
3. P0652 91 1 5B000100H 522 Maj
or
r
efer
encev
olt
age

Bey
ondupperl
i
mitoft
hrot
tl
e(5V)
4. P0653 91 0 5B000000H 522 Maj
or
r
efer
encev
olt
age

5. Unr
easonabl
ethr
ott
lesi
gnal P2135 91 12 5B000C00H 32 Maj
or

6. Thr
ott
lef
aul
tcausi
ngl
i
mphome P2106 91 20 5B001400H 32 Maj
or

Bey
ond l
ower l
i
mit of

7. t
urbochar
ged pr
essur
e sensor P0237 102 4 66000400H 46 Maj
or

si
gnal

Bey
ond upper l
i
mit of

8. t
urbochar
ged pr
essur
e sensor P0238 102 3 66000300H 46 Maj
or

si
gnal

Bey
ond l
ower l
i
mit of
9. P0642 102 1 66000100H 515 Maj
or
t
urbochar
ged pr
essur
e (
5V)
-40-
S/
N Faul
tdescr
ipt
ion I
SO15031 J1939 Fl
ash Faul
t

r
efer
encev
olt
age

Bey
ond upper l
i
mit of

10. t
urbochar
ged pr
essur
e (
5V) P0643 102 0 66000000H 515 Maj
or

r
efer
encev
olt
age

Unr
easonabl
e t
urbochar
ged
11. P0236 102 18 66001200H 46 Maj
or
pr
essur
esi
gnal
-l
ower

Unr
easonabl
e t
urbochar
ged
12. P0236 102 16 66001000H 46 Maj
or
pr
essur
esi
gnal
-hi
gher

Tur
bochar
ged pr
essur
e sensor
13. P0235 102 7 66000700H 46 Maj
or
power
-onf
aul
t

Camshaf
tand cr
ankshaf
tsi
gnal
14. P0016 723 7 D3020700H 144 Maj
or
sy
nchr
oni
zat
ioner
ror

Camshaf
t si
gnal sel
f-
checki
ng
15. P0340 723 8 D3020800H 142 Maj
or
er
ror

16. Camshaf
tsi
gnal
loss P0341 723 2 D3020200H 142 Maj
or

Cr
ankshaf
t si
gnal sel
f-
checki
ng
17. P0335 636 8 7C020800H 143 Maj
or
er
ror

18. Cr
ankshaf
tsi
gnal
loss P0336 636 2 7C020200H 143 Maj
or

19. Openci
rcui
tofsol
enoi
dval
ve1 P1229 651 5 8B020500H 332 Maj
or

20. Openci
rcui
tofsol
enoi
dval
ve2 P1233 652 5 8C020500H 334 Maj
or

21. Openci
rcui
tofsol
enoi
dval
ve3 P1237 653 5 8D020500H 336 Maj
or

22. Openci
rcui
tofsol
enoi
dval
ve4 P1241 654 5 8E020500H 342 Maj
or

23. Openci
rcui
tofsol
enoi
dval
ve5 P1245 655 5 8F020500H 344 Maj
or

24. Openci
rcui
tofsol
enoi
dval
ve6 P1249 656 5 90020500H 346 Maj
or

25. Shor
tci
rcui
tofsol
enoi
dval
ve1 P1230 651 6 8B020600H 332 Maj
or

26. Shor
tci
rcui
tofsol
enoi
dval
ve2 P1234 652 6 8C020600H 334 Maj
or

27. Shor
tci
rcui
tofsol
enoi
dval
ve3 P1238 653 6 8D020600H 336 Maj
or
28. Shor
tci
rcui
tofsol
enoi
dval
ve4 P1242 654 6 8E020600H 342 Maj
or
-41-
S/
N Faul
tdescr
ipt
ion I
SO15031 J1939 Fl
ash Faul
t

29. Shor
tci
rcui
tofsol
enoi
dval
ve5 P1246 655 6 8F020600H 344 Maj
or

30. Shor
tci
rcui
tofsol
enoi
dval
ve6 P1250 656 6 90020600H 346 Maj
or

Bey
ondl
owerl
i
mitofsensor(
5V)
31. P0642 1079 4 37040400H 515 Maj
or
r
efer
encev
olt
ageA

Bey
ondupperl
i
mitofsensor(
5V)
32. P0643 1079 3 37040300H 515 Maj
or
r
efer
encev
olt
ageA

Bey
ond l
ower l
i
mit of bat
ter
y
33. P0562 168 18 A8001200H 41 Maj
or
v
olt
age

Bey
ond upper l
i
mit of bat
ter
y
34. P0563 168 16 A8001000H 41 Maj
or
v
olt
age

Toohi
ghbat
ter
yvol
tagel
i
mit
ing
35. P0560 168 3 9E000300H 41 Maj
or
speed

Bey
ond l
ower l
i
mit of cool
i
ng
36. P0117 110 4 6E000400H 116 Maj
or
wat
ert
emper
atur
esensorsi
gnal

Bey
ond upper l
i
mit of cool
i
ng
37. P0118 110 3 6E000300H 116 Maj
or
wat
ert
emper
atur
esensorsi
gnal

Unr
easonabl
e cool
i
ng wat
er
38. P1116 110 12 6E000C00H 116 Maj
or
t
emper
atur
esensorsi
gnal

Ov
erheat pr
otect
ion of cool
i
ng
39. P0217 110 0 6E000000H 121 Maj
or
wat
ert
emper
atur
e

Cool
i
ngwat
ert
emper
atur
esensor
40. P0115 110 7 6E000700H 116 Maj
or
power
-onf
aul
t

Bey
ond l
ower l
i
mit of i
ntake
41. P0112 105 4 69000400H 15 Maj
or
t
emper
atur
esensorsi
gnal

Bey
ond upper l
i
mit of i
ntake
42. P0113 105 3 69000300H 15 Maj
or
t
emper
atur
esensorsi
gnal

I
ntake t
emper
atur
e sensor
43. P0110 105 7 69000700H 15 Maj
or
power
-onf
aul
t
-42-
S/
N Faul
tdescr
ipt
ion I
SO15031 J1939 Fl
ash Faul
t

Bey
ond l
ower l
i
mit of f
uel
44. P0182 174 4 AE000400H 254 Mi
nor
t
emper
atur
esi
gnal

Bey
ond upper l
i
mit of f
uel
45. P0183 174 3 AE000300H 254 Mi
nor
t
emper
atur
esi
gnal

Unr
easonabl
e f
uel t
emper
atur
e
46. P0181 174 12 AE000C00H 254 Mi
nor
si
gnal

Fuelt
emper
atur
esi
gnalpower
-on
47. P0180 174 7 AE000700H 254 Mi
nor
f
aul
t

Bey
ondl
owerl
i
mitofat
mospher
ic
48. P2228 108 4 6C000400H 34 Mi
nor
pr
essur
evol
tage

Bey
ond upper l
i
mit of
49. P2229 108 3 6C000300H 34 Mi
nor
at
mospher
icpr
essur
evol
tage

Bey
ondl
owerl
i
mitofECUi
nter
nal
50. P0668 1136 4 70040400H 123 Mi
nor
t
emper
atur
evol
tage

Bey
ondupperl
i
mitofECUi
nter
nal
51. P0669 1136 3 70040300H 123 Mi
nor
t
emper
atur
evol
tage

ECU i
nter
nal t
emper
atur
e
52. P0666 1136 7 70040700H 123 Mi
nor
power
-onf
aul
t

Bey
ond l
owerl
i
mitofsol
enoi
d
53. P2147 629 12 75020400H 263 Maj
or
v
alv
edr
ivi
nghi
ghpr
essur
e

Bey
ond upperl
i
mitofsol
enoi
d
54. P2148 629 12 75020300H 263 Maj
or
v
alv
edr
ivi
nghi
ghpr
essur
e

Bey
ond l
ower l
i
mit of t
hrot
tl
e
55. P0222 29 4 1D000400H 33 Maj
or
si
gnal
#2

Bey
ond upper l
i
mit of t
hrot
tl
e
56. P0223 29 3 1D000300H 33 Maj
or
si
gnal
#2

57. Twot
hrot
tl
esi
gnal
srel
evantf
aul
t P2136 29 12 1D000C00H 33 Maj
or
58. Shor
tci
rcui
ttogr
oundofsol
enoi
d P1253 651 4 8B020400H 322 Maj
or
-43-
S/
N Faul
tdescr
ipt
ion I
SO15031 J1939 Fl
ash Faul
t

v
alv
e135hi
gh-
end

Shor
tci
rcui
ttopowersuppl
yof
59. P1254 651 3 8B020300H 322 Maj
or
sol
enoi
dval
ve135hi
gh-
end

Shor
tci
rcui
ttogr
oundofsol
enoi
d
60. P1255 652 4 8C020400H 324 Maj
or
v
alv
e246hi
gh-
end

Shor
tci
rcui
ttopowersuppl
yof
61. P1256 652 3 8C020300H 324 Maj
or
sol
enoi
dval
ve246hi
gh-
end

Shor
t ci
rcui
t t
o gr
ound of
62. P0541 729 4 D9020400H 35 Mi
nor
pr
eheat
err
elay

Shor
tci
rcui
ttopowersuppl
yof
63. P0542 729 3 D9020300H 35 Mi
nor
pr
eheat
err
elay

64. Openci
rcui
tofpr
eheat
err
elay P0543 729 4 D9020400H 35 Mi
nor

65. Openci
rcui
toff
aul
tli
ght P0650 1213 4 BD040400H 362 Mi
nor

Shor
tci
rcui
tto gr
ound off
aul
t
66. P1661 1213 4 BD040400H 362 Mi
nor
l
i
ght

Shor
tci
rcui
ttopowersuppl
yof
67. P1662 1213 3 BD040300H 362 Mi
nor
f
aul
tli
ght

Open ci
rcui
t of engi
ne speed
68. P0654 697 4 B9020400H 226 Mi
nor
out
put

Shor
tci
rcui
ttogr
oundofengi
ne
69. P1673 697 4 B9020400H 226 Mi
nor
speedout
put

Shor
tci
rcui
ttopowersuppl
yof
70. P1674 697 3 B9020300H 226 Mi
nor
engi
nespeedout
put

Open ci
rcui
t of hi
gh wat
er
71. P0655 702 4 BE020400H 261 Mi
nor
t
emper
atur
eli
ght

Shor
tci
rcui
tto gr
ound ofhi
gh
72. P1675 702 4 BE020400H 261 Mi
nor
wat
ert
emper
atur
eli
ghtl
ow-
end
73. Shor
tci
rcui
ttopowersuppl
yof P1676 702 3 BE020300H 261 Mi
nor
-44-
S/
N Faul
tdescr
ipt
ion I
SO15031 J1939 Fl
ash Faul
t

hi
gh wat
er t
emper
atur
e l
i
ght

l
ow-
end

Shor
t ci
rcui
t t
o gr
ound of
74. P2606 703 4 BF020400H 115 Mi
nor
pr
eheat
ingl
i
ghtl
ow-
end

Shor
tci
rcui
ttopowersuppl
yof
75. P2607 703 3 BF020300H 115 Mi
nor
pr
eheat
ingl
i
ghtl
ow-
end

76. Openci
rcui
tofpr
eheat
ingl
i
ght P2608 703 4 BF020400H 115 Mi
nor

77. I
gni
ti
onswi
tchf
aul
t P2533 158 7 9E000700H 532 Mi
nor

78. St
art
ingswi
tchf
aul
t P0512 158 2 9E000200H 533 Mi
nor

79. I
dli
ngcont
actswi
tchf
aul
t P256A 558 7 2E020700H 32 Mi
nor

80. Di
agnosi
srequestswi
tchf
aul
t P25A1 706 7 C2020700H 111 Mi
nor

81. Ser
viceswi
tchf
aul
t P25A2 966 7 C6030700H 212 Mi
nor

82. Oi
l
-wat
ersepar
ati
onswi
tchf
aul
t P2267 707 7 C3020700H 211 Mi
nor

83. Remot
ethr
ott
leswi
tchf
aul
t P0220 969 7 C9030700H 114 Mi
nor

Cr
uise swi
tch gr
oup cascadi
ng
84. P0585 599 12 57020C00H 361 Mi
nor
f
aul
t

Cr
uise swi
tch gr
oup cl
ampi
ng
85. P0578 599 7 57020700H 361 Mi
nor
f
aul
t

Bey
ondl
owerl
i
mitofsensor(
5V)
86. P0652 1080 4 38040400H 522 Maj
or
r
efer
encev
olt
ageB

Bey
ondupperl
i
mitofsensor(
5V)
87. P0653 1080 3 38040300H 522 Maj
or
r
efer
encev
olt
ageB

88. Camshaf
tsi
gnal
EMCi
nter
fer
ence P0344 723 9 D3020900H 142 Maj
or

Cr
ankshaf
t si
gnal EMC
89. P0339 636 9 7C020900H 143 Maj
or
i
nter
fer
ence

Open ci
rcui
t of oi
l
-wat
er
90. P2269 97 4 61000400H 211 Mi
nor
separ
ati
onwar
ningl
i
ght
91. Shor
tci
rcui
ttogr
oundofoi
l
-wat
er P226A 97 4 61000400H 211 Mi
nor
-45-
S/
N Faul
tdescr
ipt
ion I
SO15031 J1939 Fl
ash Faul
t

separ
ati
onwar
ningl
i
ght

Shor
tci
rcui
ttopowersuppl
yof
92. P226B 97 3 61000300H 211 Mi
nor
oi
l
-wat
ersepar
ati
onwar
ningl
i
ght

Engi
neand DCU communi
cat
ion
93. PC100 639 19 7F021300H 611 Mi
nor
f
aul
t

94. Thr
ott
lesi
gnal
clampi
ng P2299 91 7 5B000700H 32 Maj
or

Open ci
rcui
t of st
art
er cont
rol
95. P0615 1675 4 8B060400H 534 Maj
or
r
elay

Shor
tci
rcui
ttogr
oundofst
art
er
96. P0616 1675 4 8B060400H 534 Maj
or
cont
rol
rel
ay

Shor
tci
rcui
ttopowersuppl
yof
97. P0617 1675 3 8B060300H 534 Maj
or
st
art
ercont
rol
rel
ay

Bey
ondl
owerl
i
mitofoi
lpr
essur
e
98. P0522 100 4 64000400H 421 Mi
nor
sensorsi
gnal

Bey
ondupperl
i
mitofoi
lpr
essur
e
99. P0523 100 3 64000300H 421 Mi
nor
sensorsi
gnal

100.Tool
owoi
lpr
essur
eal
arm P0524 100 1 64000100H 422 Mi
nor

Bey
ond l
ower l
i
mit of oi
l
101. P0197 175 4 AF000400H 423 Mi
nor
t
emper
atur
esensorsi
gnal

Bey
ond upper l
i
mit of oi
l
102. P0198 175 3 AF000300H 423 Mi
nor
t
emper
atur
esensorsi
gnal

Unr
easonabl
e oi
l t
emper
atur
e
103. P0195 175 12 AF000C00H 423 Mi
nor
sensorsi
gnal

104.Toohi
ghoi
ltemper
atur
eal
arm P0196 175 1 AF000100H 424 Mi
nor

Engi
ne and r
emot
e di
agnost
ic
105. PD115 1231 19 CF041300H 622 Mi
nor
communi
cat
ionf
aul
t

Not
e:f
ort
hef
aul
tlev
elmar
kedwi
th"
minor
",t
heact
ivat
edf
aul
tli
ghti
snor
mal
l
y-on,whi
l
efort
he
f
aul
tlev
elmar
kedwi
th"
maj
or"
,theact
ivat
edf
aul
tli
ghti
sbl
i
nki
ng.
-46-
Aboutt
hewar
ningmessageset
ti
ngoff
orwat
eri
nfuel
:(t
hewar
ningl
i
ghti
sonasl
ongast
her
eis

wat
er)
.

3.
10 Ai
rcl
eaner
Aircleaneri susedt of il
teroutdustandi mpur it
iesintheai renteri
ngintothedieselengine,soast o
ensureai rcl eannessi nt hecy l
inderandr educewearbet weent hecy li
nderandpi st
on,bet weent he
pist
onassembl yandv alveassembl ycomponent s.Theai rcleanerscreenofYC6TDser iesmar i
nedi esel
enginei smadeofst ainlessst eelwi r
emesh.Thest r
uctureisshowni nFig.3-
42.
Ser vi
cemet hodandpr ecaut i
ons:
Af t
ert heaircl eaneri susedf oracer tai
nperiodoft i
me, thef i
l
terelementwi l
lbecomedi rty,andt he
airi
ntaker esi
stancewi llbei ncreased.Theai rcleanershoul dbecheckedi ncaseofpowerr eductionof
thedi eselengi neoroccur renceofbl acksmoke,hi ghexhaustt emper atur
eanddi ffi
cult
yofst art
ing.
Gener al
ly,aftert her unningof250hofdi eselengine,theaircleanershoul dbecheckedandcl eanedor
repl
acedr egularly.Fortheshi pwi thoutboardairintake,i
tmaybedi sassembl ed.
Itmaybecl eanedwi thker oseneorgasol ine.

Fi
g.3-
42A
-4 i
rCl
7- eaner
4I
nst
all
ati
onofDi
esel
Engi
ne
4.
1Inst
all
ati
onenv
ironment
Theshipcabi
nshouldbeclean,bri
ghtandwit
hgoodventi
lat
ion.Thecabinshoul
dhaveaspaci
ous
pl
aceforr
easonabl
ear r
angementofvari
ouspipel
i
nesandnecessaryaccessor
ies,
toensur
ethenor
mal
oper
ati
onandmaintenanceofdi
eselengine.
4.
2Inst
all
ati
onandi
nspect
ionofdi
esel
engi
ne
4.2. 1 I nst allationofdi esel engi ne, gearbox ,propel l
er( shaf tsy stem)
4.2. 1.1 Thedi eselengi nei sconnect edwi thgearboxr abbet ,andt hef lywheelcov eri sconnect ed
wi thgearcasecov ert hroughr abbet ,whi char ebot hinst all
edont hehul l.Thecoax ialityshoul dbe
checkedbef oreconnect ingwi thpr opel ler,andt heunder -chassi sofdi eselengi neandgearbox
shoul dbel ockedaf terconnect ion.
4.2. 1.2 Whenconnect i
ngt hedi eselengi neandgearboxbyt hewayot hert hanr abbet ,the
coax i
alit
ybet weendi eselengi neandgearboxandendf acer un- outshoul dbecheckedwi thapl ug
gauge.Thedi eselengi neandgearboxshoul dalsobel ockedaf tert heal i
gnmentconnect ionwi th
propel l
er.Thecoax i
al itybet weent hedi eselengi neandgearboxi s≤φ0. 3mm;endf acer un- outis
≤0. 12mm; thecoax ialitybet weengearboxandpr opel l
eri s≤φ0. 1mm; endf acer un- outi s≤0. 1mm.
4.2. 2 Pi pelinei nst al l
ation
4.2. 2.1 Fuelpi pingi nst allat i
on:i ti sr ecommendedt oequi pt hef uelt ankwi thadi eself i
lt
er
addi tionll
y,t oensur et hecl eanl i
nessofdi eself uelent eringi nt ot heengi ne,andi mpr ovet he
reliabili
tyoft heengi ne.Thef uelpi pef rom f uelt ankt of ueli nletoff uelt ransf erpumpi swell
connect ed( thef uell etoff uelt ransf erpumpi sconnect edbyoi ledbol tofM14×1. 5).I fthef uelis
transf erredt ot hedi eself ilterwi thoutpassi ngt hroughf uelt ransf erbump,t hehei ghtoft hefuel
tankt othedi eself i
ltershoul dbeov er1. 5m, andt hei nnerpor edi amet eroff uelt ransf erpi pei snot
l
esst hanφ10.Thei nnerwal loft hef uelpi peshoul dbecl eanedst rictly,andcl eannessshoul dbe
kept .
4.2. 2.2 I nst allationr equi rement sofseawat erpiping:t hedi amet erofi nletandout l
etpi peshoul d
benotl esst hanφ40,andal lt hej oi ntsshoul dbesmoot h.Thesundr yf i
lteringdev iceshoul dbe
prov i
dedbef or et heseawat erpump.Thef low sequenceofseawat erint hei ntercool erandheat
ex changershoul dcompl ywi tht her equi r
ement sspeci fiedi nFi g.3- 25.
4.2. 2.3 I nst allationofai ri nt akepi ping:t heai rcleaneri spr ov idedandcheckedr egul ar l
yf orits
cleanness.At tentionshoul dbepai dt okeepi ngt heai rcleanerdr y .
4.2. 2.4 I nst allationofex haustpi pi ng: checkt hepi pedi amet erofai rinletandout letpi pelineoft he
muf fl
erwhi chshoul dbegr eat ert hant heex haustconnect oroft ur bochar ger ,t oensur esmoot h
ex haust i
ng.Theex haustpi pes( orpost -tur bot ube)andt hemuf flersandot hert ubesonboar d
shoul dbeofex pansi onj oi ntt ransi tion,andt her i
gidconnect ioni snotal lowed.Dur ingconnect i
ng,
theconnect orsmustbeal ignedwi thoutf orcedconnect i
on, ort het ur bochar gerwi llbedamaged.
4.2. 3 I nst allationofseawat erpump
Af t
ert hei nstal l
ationofseawat erpump, thepul l
eygr oov eanddi eselengi neaddi t
ionalpul leygr oove
mustbei nt hesamel ev el
.Thebel ttight nessshoul dbeappr opr iate,andgener al l
yt hebel tdef l
ectionis
10- 15mm underex ternal f
or ceof40- 50N.
4.2. 4 I nst allationoff r
ont -endout put
Thedi eselengi nef ront-endout puti sequi ppedwi thaCt ypef our -groov ebel tpul l
eyf orthedr iveof
seawat erpump.Thecr ankshaf tfree-endconnect sitsout putconnect i
onf l
ange.Theout putt orquei snot
l
esst han65%oft her at edt orque, andi tshoul dbesy mmet ri
cal l
yar rangedwi thhi ght orqueout put .

-48-
5 Oper
ati
onandMai
ntenanceofDi
esel
Engi
ne
5.
1Oper
ati
onofdi
esel
engi
ne
5.1.1 Pr epar at i
onbef or est arti
ngofdi esel engine
5.1.1.1 Checkwhet hert hecool antofheatex changeri ssuf fi
cient,andf illenoughcool antas
requi r
edi ncaseofi nsuf ficiency .
5.1.1.2 Checkt heoi llev eli noi lpan,andaddoi lt othel ev elindi catedont hedi pst icki ncaseof
i
nsuf f
iciency .
5.1.1.3 Checkwhet hert hef ueli nf uelt anki nsuf ficientandaddf uelasr equi redi ncaseof
i
nsuf f
iciency .
5.1.1.4 Checkwhet hereachcomponentofel ectri
calsy st em i snor mal , whet hert hebat terypower
i
ssuf ficient, andf il
lenoughel ect r
ol yt
e.
5.1.1.5 Empt ytheai rfrom t hef uel l
i
newi tht hemanual pump( ifther eisai rinsi det heoi lgal
ler y).
5.1.2 St artingofdi esel engi ne
Tur nt heswi tchcont rollingt hef uelcut -offel ectr
omagnet icv alve( keyswi tch)t ot hest artposi tion,
placet hegear boxhandl et ot heneut r
alposi tion,andpr essdownt hest arti
ngbut ton,t ost artthedi esel
engine.Af tersuccessf ulst ar ting,r eleaset hest arti
ngbut toni mmedi ately.Incaseoff ailuret ost ar tup
for3t imes,st artupshoul donl ybecar riedoutaf tercausesar ef oundoutandt roubl eshoot ingi s
conduct ed.
Not e:Thest artingper iodf oreacht i
meshoul dnotex ceed10s( second) .Thet imeneededf ora
secondst ar t
upaf terstar tingf ailureshoul dbeatl east1mi nut e( mi nute).
5.1.3 Runni ngofdi esel engi ne
Aftert hedi eselengi nei sst arted,successi v
elywar mt heengi nei nal ow speedandi ntermedi ate
speedunderno- load.I tshoul dnotbeoper atedwi t
hloadunt ilt hecool antt emper atureofdi eselengi ne
i
snotl owert han60℃,andt heoi ltemper at ur eisnotl owert han45℃.Payat t
ent i
ont ot hef ol
lowi ng
points.
5.1.3.1 Donotkeept heengi nei dler unni ngf oral ongt ime.
5.1.3.2 Theoi lpr essur eati dl espeedshoul dnotbebel ow0. 1Mpa.
5.1.3.3 Theoi lpr essur e,oi lt emper at ureandout letwat ert emper aturedur ingr unni ngshoul dbe
normal andcompl ywi tht her equi rement sasshowni nabov ei tem 2. 2.
5.1.3.4 Theengi neshoul dbest oppedi mmedi atelyf orchecki ncaseofanyabnor malsoundand
vibration.
5.1.3.5 Checkt heseal i
ngcondi tionsofoi l
,gasandwat er ,andr emov ei ti mmedi atel yincaseof
anyl eakage.
5.1.3.6 Anew orpost -ov erhauldi eselengi nei snotal lowedt ooper ateunderahi ghspeedand
heav y-dut ywor kingcondi tionatt hebegi nni ng.Dur i
ngt hef irst50h( hour s),itshoul dbeoper ated
withar educedpowerandl oadnotmor et han65%, toensur egoodbr eaking- i
n.
5.1.4 Shut -
downofdi esel engi ne
Emer gencyshut downofdi eselengi neshoul dbeav oi ded.Bef oret heengi nei sst opped,t heengi ne
shoul dr unatal owspeedf or( 2-5)mi nutest ocool thediesel engi ne,andt henr unati dlespeedunderno
l
oadf or( 1-3)mi nut es,andt henst opt heengi ne.
I
naddi t
ion, whent heambi entt emper atur eisbel ow5℃, empt ythecool anti nt i
met oav oidf r
eez ing
ofcomponent sift heengi necool anti swat erort heant i-
freez el iqui dforwhi cht henon- freez ingproper t
y
cannotbeensur ed.
5.
2Mai
ntenanceofdi
esel
engi
ne
Thecor r
ect,t
imel
yandcarefulmaintenancecoul
dguar ant
eegoodworki
ngperformanceofthe
dieselengi
neinalongterm,
avoi
df aul
t,r
educewearandprolongthel
if
eti
me.Theusershoul
dmaint
ain
thedieselengi
neaccor
dingt
otherequir
ement si
nthi
ssect
ion.Thespeci
fi
ccl
assi
fi
cati
onisasfol
l
ows:
●Routi
nemai
ntenance(dai
lymaint
enance)
;
●GradeImai
ntenance(
runningf
or50hours);

-49-
●Gr adeI Imai nt enance( runni ngf or150~180hour s) ;
●Gr adeI IImai nt enance( runni ngf or800hour s) .
5.2.1 Rout i
neMai nt enance
5.2.1.1 Checkt hef uel lev el oft hef uel tankandf ill upt hef uel tank;
5.2.1.2 Checkt heengi neoi llev el oft heoi lpanandf i
ll upt heoi lpani ncaseofi nsuf fici ency;
5.2.1.3 Checkandel imi nat ewat erl eakage, oil leakageandai rleakage;
5.2.1.4 Checkal lki ndsofi nst rument s,obser vewhet hert her eadi ngsar ecor rectandr epairor
replacet hedamagedi nst rument st imel y ;
5.2.1.5 Checkt hemount ingst atusofal l theaccessor i
es;
5.2.1.6 Checkt hecool antl ev el ofheatex changerandf i
llupi ncaseofi nsuffici ency ;
5.2.1.7 Keept hedi eselengi necl ean( especi al l
yt heel ect ricalequi pmentshoul dbef reeofoi l
stain).
5.2.2 Gr adeImai nt enance
Besidest her outinemai ntenancei tems,t hef ollowi ngmai nt enancei temsshoul dbeaddedf ort he
diesel engineaf terev er y50hour sofr unni ng.
5.2.2.1 Checkt het ensi onoft hewat erpumpbel tandadj usti tifnecessar y;
5.2.2.2 Checkandadj ustt hecl ear anceoft hei nletv al veandex haustv alve;
5.2.2.3 Checkandr ef ill thebat ter yel ect rolyte;
5.2.2.4 Repl acet heengi neoi l,int hef irstGr adeImai nt enancef oranew machi ne( ordi esel
engi neaf terthewar rant yper iod) ;
5.2.2.5 Cl eant heai rcl eanerandoi linletf il
teroft heoi l tr
ansf erpump;
5.2.2.6 Repl acet hespi n-onf il
terel ementoft heoi lf il
t er,i
ncaseofi nsuf ficientoi lpr essur e( tobe
conduct edatt hesamet i
mewhent heengi neoi l isr epl acedl at er ).
5.2.3 Gr adeI Imai nt enance
Besidest heGr adeImai nt enancei tems,t hef ollowi ngmai nt enancei temsshoul dbeaddedt ot he
diesel engineaf terev er y150hour sofr unni ng.
5.2.3.1 Checkt heopeni ngpr essur eoft hef uel inj ect orandadj usti tifnecessar y ;
5.2.3.2 Checkt headv anceangl eofst aticf uel suppl yandadj usti tifnecessar y;
5.2.3.3 Checkt heseal ingcondi tionsoft hei nl etv al veandex haustv alv e,andgr i
ndt hem i f
necessar y;
5.2.3.4 Checkt hedr ippi ngcondi tionsoft hespi llwayhol esoft hewat erpumpandr eplacet he
wat erseal i
ncaseofsev er edr ippi ng;
5.2.3.5 Checkt het ight eni ngcondi ti
onsofmaj orpar ts,suchasmai nbear ingbol ts,cy l
inderhead
boltsandconnect i
ngr odbol ts, andr et ight ent hem t ot hespeci f i
edt orquei ncaseofl ooseness.
5.2.3.6 Repl acet heengi neoi l;
5.2.3.7 Per for m descal i
ngi ncaseofov er -
temper at ur econdi tion;
5.2.3.8 Cl eant her espi rat orf il
ter .
5.2.4 Gr adeI IImai nt enance
Thegr adeI IImai nt enance( af terev ery800hour sofdi eselengi ner unni ng)i sconduct edf or
checki ngandadj ust i
ngt heengi neassembl y( tobeconduct edwi t
hr ef erencet ot heGr adeI/Gr adeII
mai ntenance)t oel i
mi nat et hef aul tr i
sks.I fser i
ousai rleakageandoi ll eakageoft heengi neandear l
y
wearoft hecy linderbor eoccurandt heoi lpr essur ecannotbeadj ust edt othespeci fiedpr essur e,the
enginemustbedi sassembl ed.I ft heengi ner unsi nnor malcondi ti
on,t hef ollowi ngi t emsmaybe
selectedf ormai nt enanceort het imef orGr adeI IImai nt enancemaybeex tendedappr opr i
at ely.
5.2.4.1 Di smant leandcl eant hecompl et emachi ne:cl eart hecar bondeposi t,oi lst ai nandgum
deposi tandcl eanal l thel ubr i
cat i
ngpi pesandoi l duct s;
5.2.4.2 Checkwearcondi tionsoft hepar t
ssuchasai rv alv e,v alv eseat ,v alv egui depi pe,v alve
spring, valvet appet , pushr odandr ockerar m, gr indandr eplacet hem i fnecessar y ;
5.2.4.3 Checkwearcondi tionsoft hepi stonr ing,cy li
nderbor e,bushi ngf orsmal lendoft he
connect i
ngr odandconnect ingr odshaf thol e,andr eplacet hem i fnecessar yex ceptt hatt he
-50-
cyli
nderboremaybebor edorsl eevedf orrepair;
5.2.
4.4 Checkwearcondi ti
onsoft hemai nbear i
ngbush( includingt hef i
ft
hf l
angedt hr
ustmai n
bearingbush)andr eplacei tifnecessar y;
5.2.
4.5 Checkwearcondi t
ionsoft hegearandt hegearbackl ash,andr eplaceitifnecessary;
5.2.
4.6 Checkat omizationcondi ti
onsoft hefuelinjector
,grindthei njectornoz zlematchingparts
orreplacethei nj
ectorifnecessar y ;
5.2.
4.7 Checkt heoi lpumpgearandoi lpumpbodyandr eplacethem i fnecessar y;
5.2.
4.8 Checkt hegener atorandst art
er,cleanal lthepar tsandbear i
ngsandf i
llupwi thnew
l
ubricati
nggr ease;
5.2.
4.9 Checkbear i
ngcl ear anceoft heturbochargerandr eplacet hetur bochargerifnecessary;
5.2.
4.10Checkwhet hert herei sairleakagei ntheintercoolerandr epairi tifnecessary.
5.2.
5 Pr acticaltechnical mai ntenanceofdi eselengi ne
Conductr outi
nemai ntenanceandcheckt hecool i
ngwat erlevel,oillevelinoilpanandi nj
ect
ion
pumpandt he“ threeleakage”condi ti
onsev eryday.

Tabl
e5-
1
Br
eaki
per

Checkand
Ti
me(
h) 100 200 300 400 500 600 700 800 900 1000 1100 1200
i

maint
enanc
od
ng-

eit
em
in

Ti
me(
Mont
h) 1 2 3 4 5 6 7 8 9 10 11 12

Cl
eant
heengi
neassembl
y △ △ △ △ △ △ △ △ △ △ △ △
Checkandadj ustt hebel t
○ △ △ △ △ △ △ △ △ △ △ △ △
ti
ghtness
Check and cl ean t he air
△ △ △ △ △ △
cl
eanerel ement
Replace t he ai r cl eaner
△ △
el
ement
Check t he accel eration
performance,decel eration
○ △ △ △ △ △ △ △ △ △ △ △ △
performance and ex haust
condi t
ion
Check the cy li
nder
△
compr essionpr essur e
Checkandadj ustt hev alve
○ △ △ △ △
cl
ear ance
Checkt he“ t
hreel eakage”
○ △ △ △ △ △ △ △ △ △ △ △ △
condi t
ionsofengi ne
Checkt hecl eanl i
nessand
△ △ △ △ △ △ △ △ △ △ △ △
surplusofl ubri
cat ingoi l
Replace t
he engine
○ △ △ △ △ △ △
l
ubricat i
ngoi l
Replace t he oi l f i
lt
er
△ △ △ △ △ △
assembl y
Check t
ight ening
condi t
ions oft he cy li
nder ○ △
headbol ts
Cleart hedeposi tsedi ment
○ △ △ △ △ △ △ △ △ △ △ △ △
offuel fi
lt
er

-51-
Check t
he worki
ng
○ △
pr
essureoffuel
inj
ect
or
Checkt
hei
nject
iont
imi
ng △
Check whether t
he fuel
i
njecti
onpumpisinnormal △
operat
ion
Check the funct
ions of
△
ther
mostat
Repl
acet
hef
uel
fil
ter △ △ △ △
Checkwhet herther adiator
△
isinnor mal oper
ati
on
Clean t he engi ne cool i
ng
△
syst em
Check whet her t
he
turbochar geri sin nor mal △
oper ati
on
Clean t he r espi
ratorf il
ter
△ △ △ △ △ △
element
Check and cl ean t he
△
intercoolerinnercav i
ty
Checkandcl eant heheat
△
exchangeri nnercavity
Checkwhet herthejointsof
the el ectri
calsy stem ar e △ △ △ △ △ △ △ △ △ △ △ △
loose
Not e:Thei t
emswi t
h" ○"ar etobef
ini
shedbyt
hewar
rant
yser
vicesst
ati
on.

-52-
6.Common Faul
ts and Tr
oubl
eshoot
ing Met
hods ofDi
esel
Engi
ne
6.
1St
art
ingf
ail
ureofdi
esel
engi
ne

Tabl
e6-
1

Faul
tcauses Tr
oubl
eshoot
ingmet
hods

Checkthest
arti
ngsyst
em andtheengi
nest
art
ingspeed
① Theengi
nespeedi
stool
ow
shoul
dnotbelowert
han110r/min.
Checkwhet hert hej oi ntsoff uellinesar eloose.Unscr ew
theai rbleedscr ew ont hef uelf ilt
erassembl yandf eed
② Ther ei sairi
nf uel suppl ysy stem
fuelwi thamanualpumpt i
llthespi l
ledf ueli swi thout
bubbles.
③ Cl oggingoff uel li
nes Checkwhet hert hef uel supplyl inesar euncl ogged.
Replace t he spi n-on f i
lt
erel ementoft he f uelf i
lter
④ Cl oggingoff uel fil
ter
assembl y .
Checkwhet hert herei sai rleakagei nt hef uelinletpi pe
⑤ No f uelsuppl yori ntermi t
tentf uel
and whet hert he f il
teroft he f ueldel ivery pump i s
suppl yoff ueldeliverypump clogged.
Checkat omi zationcondi ti
onsoft hef ueli njectorand
checkwhet hert he i njection pump pl ungerand out let
⑥ Littlef uelinj
e ctio n,n of uel i
n j
ecti
o nvalvea rew or no r stu cka ndw h ether thep lun ger sp ri
n g
orlowi nj
ectionpr essur e an do utl
e t valves prin ga r efrac t
u red. Chec ka n da d j
u st
theinjectionpr essur et ot hespeci f
iedr angeasshowni n
it
em 2. 2.
Wr ong ci rcui t connect ion orCheck whet hert he ci rcuitconnect ion is cor rectand
⑦ p oorco nta ct reli
able.
Starting Lowbat terypower Charget hebat tery.
sy stem Poorcont actbet ween st arterRepairorr eplacet heel ect r
icbr ush,cl eant hesur faceof
faults car bon brush andt hecommunt atorwi tht heabr asivepaperf orwoodand
communt at or blowi tclean.
Ex cessi ve wear ofRepl acet hepi stonr i
ngandaddcy li
ndersl eev ef orrepai r
⑧ I nsuf fi
cient
pi stonr i
ng asappr opr i
at e.
aver agepr essure Checkt hev alvecl ear ance,ai rti
ghtnessofv alvespr ing,
of compr essedAi rleakageofv alve v alvegui depi peandv alv eseatandgr indthev alveseati n
air caseofpoorai r
tight ness.
⑨ Looseordi r
ty/cor rosivejointsoff uel
Tighten,cleanorr epl ace.
cut-of felectromagnet icv al
v e.
⑩ The coi lv oltage of f uel cut-offThemi nimum v ol t
agei s9V, andr epairorr eplacet hecoi l
electromagnet i
cv alv eist ool ow incaseofi nsuf fi
ciency .
Incor rectadv anceangl eoff uel supply. Checkandadj ust.
6.
2Under
powerofdi
esel
engi
ne

Tabl
e6-
2

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
Checktheaircleanerandi
nletpi
peandcl
eanorr
epl
ace
① Cl
oggi
ngofai
rinl
et
theai
rcleanerelement.
-53-
② Ex cessi vely hi gh ex haust back Checkt hev alv etimingandadj ustitifnecessary:clean
pressur e the exhaus tpipe .
③ I nsuf fi
cient pressur e of
Checkandel imi nateleakageoft heli
nesandj oints.
turbochar gingsy stem
④ Cloggi ng or damage of
Abnor m co mp ressorandt urbi
neai rf
low Cl eanorr eplacet hecompr essorcasing/t
urbinecasing.
al p ass age
oper atio Bear ingf ai
lure Replace.
n of
turboch Car bon deposi t/oilsl udge on
Clean.
arger the turb i
ne/co mp resso r
⑤ Damage and ai r l eakage of
Repairorr eplace.
i
nter cool er
Checkseal i
ngcondi ti
onsoft heoilpipeandj oi
ntsand
⑥ O i
l l
e akag e or cl
o ggi
n go f f
u ell
ines cl
o gging c ond i
tionso ff uelfilt
er,repl
acet h es pi
n-on
fi
lterel
ement .
⑦ Ex cessi ve wear of f uel i nj
ecti
on
Checkandr epl ace.
pumppl unger
⑧ Damageofsmoke- li
mi terdiaphragm Repl ace.
⑨ D ama gea nda i
r l
eak ag eo f vacuum
Replace.
l
ine
Checkt hei nject i
onpr essure,clearthecar bondeposi t
,
⑩ Poorat omi z
at i
onoff uel injector
adjustandr epai r.
⑾ I ncor rectv alvetiming Checkandadj ustthev alv
et i
mi ngandv al
vecl ear
ance.
⑿ A dva nceo r de l
ayo f a dvan cea ngle
Checkandadj ust.
off uel suppl y
⒀ Thehi gh- speedadj ustmentofspeed
Checkandadj ust.
gov ernori st ool ow
Tightenthecy li
nderheadbol ti naccordancewi t
ht he
⒁ Ai
rleakageofcy
li
ndergasket speci
fi
ed t
orque and or
derorr
epl
ace t
he cy
li
nder
gasket
.
⒂ Poorseal i
ngofval
ve Gri
ndorrepl
aceforregr
indi
ng.
⒃ Ov er
heat of t he engine and
Checkandr epai
rtheradiat
or,t
her
mol
atorandadj
ust
excessi
vel
y hi gh engi ne coolantt het
ensi
onoff anbel
t.
temperat
ure
Excessi
ve wearand fr
act
ure ofpi
ston
Repl
ace
ri
ng
6.
3Abnor
mal
sounddur
ingr
unni
ngofdi
esel
engi
ne

Tabl
e6-
3

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
① Cr isp metalknocki ng noise wi t
hin cy
li
nder: Adjustthe st at
ic advance angle off uel
too-earl
yoilinj
ection supply.
② Low and uncl ear knocki ng noi se withi
n Adj ustthe st at
ic advance angle off uel
cyli
nder :
too-l
ateoi l
inject
ion supply.
③ Knocki ng noi se at t he cr ankcase due to Di smantle and check t he bearing bush,
excessive wear of connect i
ng r od bear ng r
i epl
ace iti fnecessaryand mai ntai
nthe
bush/ mainbearingbush specif
iedreasonableclearance.
④ Knocki ngnoi seofcr ankshaftmov ementatidl
e Repl ace t he parts and mai ntain t
he
speedduet oexcessi v
ewearoft hrustmainbearng speci
i f
iedax i
alcl
earance.
-54-
bush
⑤ Nov ibrati
ondampingef
fectduet ot
hedamage Checktheconnect
ingboltanditsdamage
ofvi
brati
ondamper condi
ti
onandrepl
aceiti
fnecessary
.
⑥ Col li
sionbetweenval
veandpi st
on Checkandadj
ustt
hev
alv
eti
ming.
⑦ Excessi ve wearand too large cl
ear
ance of
Checkthebacklashandrepl
acethegeari
n
tr
ansmissiongear.Knocki
ngnoi seattimi
nggear accor
dancewithwearcondit
ions.
chambercov er
Replacet hepiston,addt hecy
li
ndersleeve
⑧ Knocki ng noi se at cy l
i
nder wal l duri
ng
for repai r in accor dance wi t
h wear
operati
on due t o ex cessivel
yl arge clear
ance conditi
ons and mai ntain t
he cy li
nder
betweent hepistonandcy li
nder clear
ance.
Cleart he carbon deposi tand dir
tint he
⑨ Sur geoft ur
bocharger compr essor passage and ex haust gas
passage.
⑩ Coll
ision between rotati
n g par
ts and casi
ng
Replacethet urbochargerassembly.
duetothedamageoft urbochargerbeari
ng
⑾ Lar ge sound at cy li
nder head due t o
Adjustthev al
veclearance.
excessi
v el
ylargevalv
ecl earance
6.
4Bl
acksmokepr
oduceddur
ingai
rex
haust

Tabl
e6-
4

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
① Cl
oggi
ngofai
rinl
et Checkt
heai
rcl
eanerandai
rinl
etl
i
neandcl
eant
hem.
② Poorf
uel
qual
i
ty Repl
acei
twi
tht
hespeci
fi
edf
uel
.
③ I
ncor
recti
nject
ionorv
alv
eti
ming Adj
ustasspeci
fi
ed.
④ Poorat omi zat
ionoff ueli
nject
or Check,
repai
rorr
epl
ace.
⑤ Ex cessi vel
yl arge f uelsupply of
Checkandadj
ustasspeci
fi
ed.
i
njectionpump
⑥ I nsuf fi
cient pressure of
Checkandel
i
minat
eleakageoft
hel
i
nesandj
oint
s.
tur
bochar gingsy st
em
⑦ Abnor mal operati
onoft ur
bocharger Checkandr
epl
acet
heassembl
y.
⑧ Damage and ai r l eakage of
Repai
rorr
epl
ace.
i
ntercool er
⑨ I ncor rect wor ki
ng poi nt of
Readj
ust
.
smoke- li
mi t
er
6.
5Whi
teandbl
uesmokepr
oduceddur
ingai
rex
haust

Tabl
e6-
5

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
① Poor f uelquali
ty and excessi
ve
Repl
acet
hef
uel
.
moi
sture
② The cool i
ng wat
ert emper
atureis Check t
he wor ki
ng t
emper
atur
e oft
her
mol
atorand
t
oolow repl
acei
tifnecessar
y.
③ I ncor
rectval
vetiming ori
njecti
on
Checkandadj
ust
.
t
imi
ng

-55-
④ Low compr ession pr essure and
Checkthepist
onri
ngandcy l
i
ndergasketandr
epl
ace.
i
ncompletecombust i
on
⑤ I ncor
rect mount ing direct
ion of
Checkandreassemble.
pi
stonri
ngandnon- staggeredopeni
ng
⑥ Long- ter
m underl
oadr unning Usetheproperworki
ngspeedandload.
⑦ Wearoft
urbochar
gerseal
i
ngr
ing Checkandr
epl
ace.
⑧ Wearoft
urbochargert
hrustbear
ing Checkandr
eplace.
⑨ Cl
oggi
ngoft urbochar
geroilret
urn
Cl
eanandrepair
.
l
i
ne
6.
6Tool
owoi
lpr
essur
e

Tabl
e6-
6

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
① Thi nni
ng ofengi ne oiloruse of Sel
ectt
hepr operengi
neoilaccor
dingt
othespeci
fi
ed
improperengineoil saf
eoperat
ionprecaut
ionsasshownint
heabove.
② Wear of oi l pump gear or
Repl
acet
hegearandadj
ustt
hecl
ear
ance.
excessi
velyl
argeassembl ycl
ear
ance
③ Cloggi
ngo foil
fil
ter Repl
acet
hespi
n-onf
il
terel
ement
④ Mal functi
onofpr essureregul
ati
ng
Repai
r.
ofoi
lfi
lt
er
⑤ Damageorwearofoi lpumpdr i
ve
Repl
ace.
gear
⑥ Cr ackon t heoilinletpipeofoi l
Repai
randrepl
ace.
pump
⑦ Loosef i
xi
ngboltofoi linl
etpi
peof
Ti
ghtenthebol
tstothespeci
fi
edt
orque.
oi
lpump
⑧ Ex cessiv
ely lar
ge cl ear
ance of
Checkandrepl
ace.
bear
ingbush
6.
7Toohi
ghoi
lpr
essur
e

Tabl
e6-
7

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
① Largeroilvi
scosi
tydue Selecttheengineoilofspeci
fi
edoilgrade,conductlow-
speed
t
o excessi
vel
y low operati
onfi
rstaft
erstar
ti
ngandre-
checkaft
ertheoilt
emperat
ure
t
emper
atur
e becomesnor mal.
② Cloggi
ngofreli
efv
alv
e Checkandcl
ean.

6.
8Hi
ghoi
ltemper
atur
eandl
argeoi
lconsumpt
ion

Tabl
e6-
8

Faul
tcauses Tr
oubl
eshoot
ingmet
hods
① Leakage ofex
ter
naloi
l Checkandr
epai
r.
-56-
pi
pel
i
ne
② Ov erl
oad of di esel
Reducet heload.
engine
③ Use of i mproper oi l
Sel
ectasspeci fi
ed.
grade
④ Jammi ng or excessiv
e
Check,repairandreplaceifnecessar
y.
wearofpi st
onri
ng
⑤ Ex cessiv
e wear of Repl acet hepist
onr ingoff i
nishsiz
eaft
ercy
li
nderbor
ing,oradd
cyli
nderbore cyl
indersleeveforrepair
.
⑥ Ex cessiv
ewearofv ale Checkandr
v eplace.
guidepipeandseali
ngf ai
lur
e
ofv al
verod

-57-