OPERATION MANUAL

VANMAR CD.,LTD.
MM-5
All Rights Reserved, Copyright YANMAA CO.,l.TD.
 YAN MAR &NYl&L·W

INTRODUCTION

Thank you for purchasing a YANMAR engine.

•This Operation Manual covers the necessary precautions for the safe and effective use of your engine.
Thoroughly read the Operation Manual and make sure that you fully understand it to use the product
correctly and in the best possible way.
For special engine specifications (e.g. engines with a turbocharger or a hydraulic governor), please
refer to the applicable operation manuals.
•The numerical values in this manual are based on the SI system (International System of Units).

() • Only use genuine YANMAR replacement parts or other specified parts.

• Order parts from your nearestYANMAR sales or service agent. When you order a part, clearly specify:
- The part name
- The part number
- The engine model
- The serial no. of the engine.
• If you use this engine for a purpose or under service condition other than those specified, or if you
handle it not in accordance with this Operation Manual, an accident or a failure can occur. If you
want to change or modify the engine after it has been delivered, contact us or your nearest sales
agent. DO NOT make any modifications yourself.

•Keep this Operation Manual at a clearly identified place so that the operator can refer to it at any time.

•If you transfer this engine, also transfer this Operation Manual, the Final Document and Records of
Shop Trial with the engine to the next owner.

•When. this manual is lost or damaged, promptly contact us or your nearest sales or service agent to
order a replacement Operation Manual.

•Also note that the contents of this Operation Manual can change without prior notification to improve
the quality and performance of the engine and improve safety. The text and illustrations of this
Operation Manual may partly disagree with engines of some specifications.

•If you have questions or comments about this manual, please contact YANMAR or your sales or
service agent.
 YANMAR GNYIGL-W

Terms & Symbols

The major terms used in this Operation Manual are defined as follows:
Note: The front of the engine: Opposite the flywheel side
The back of the engine: The flywheel side
Operation side: On the left side as viewed from the flywheel side (fuel injection pump side)
Non-operation side: On the right side as viewed from the flywheel side (exhaust pipe side)
Tum right: Clockwise rotation as viewed from the flywheel side
Tum left: Counterclockwise rotation as viewed from the flywheel side
Cylinder number: Counted from the flywheel side (1, 2, 3, ... )

Non-operating Side Flywheel

r-----h
, Generator : •
.. ti
'------
Operating Side Fuel Injection Pump oueu-oo•

The following symbol marks are referred to throughout this Operation Manual.

m
~
Refer to another page, section or chapter of this Operation
Manual or other document.
 YANMAR 6NY16L·W

CONTENTS

(Page)

FOR YOUR SAFETY ......................................................................................................... 0-1

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

Engine Specification ................................................................................................... 1-1
Attachments ........................ ~ ....................................................................................... 1-2

MAJOR PARTS ................................................................................................................. 2-1

Structure Outline ......................................................................................................... 2-1
Engine External View & Equipment Layout................................................................ 2-2
Major Parts .......... ...... ............. .. ...... ......... ...... ....... ............ .. ........................................ 2-3
Lubricating Oil System................................................................................................ 2-4
Cooling Water System·······································································:························ 2-5
Fuel Oil System .... ......... .. ...... .. .... ... .. ..... ...... .. ...... .. .. .... ... .. .... .... .. ....... ......... .... ....... .. ... 2-6
Start Air System .......................................................................................................... 2-7

TABLE OF ENGINE STANDARD ADJUSTMENTS ........................................................... 3-1

Assembly Adjustment Values ..................................................................................... 3-1
Pressure and Temperature Settings ........................................................................... 3-1
Protective Device Settings ............. :............................................................................ 3-2
Holding Volumes of Lubricating Oil and Cooling Water .............................................. 3-2

ENGINE OPERATION ........................................................... :........................................... 4-1

Inspection and Preparatio'n before Engine Start ......................................................... 4-1
Engine Start ................................................................................................................ 4-7
Operation ................................ ~................................................................................... 4-9
Engine Stop ................................................................................................................ 4-9

FUEL OIL, LUBRICATING OIL & COOLING WATER ....................................................... 5-1

Fuel Oil ....................................................................................................................... 5-1
Lubricating Oil ............................................................................................................. 5-2
Cooling Water (Engine Jacket Water) .................................................·. .. ...... ......... ... . . 5-5
/

MAINTENANCE INSPECTION .......................................................................................... 6-1

Precautions for the Maintenance Inspection .............................................................. 6-1
Periodical Inspections ................................................................................................. 6-2
How to Do Routine Maintenance Inspections and Adjusting...................................... 6-5
 YANMAR 6NY16L·W

MAINTENANCE ...................................................................... .-.......................................... 7-1

Maintenance Precautions ........................................................................................... 7-1
Cylinder Head and Accessories .... ....... ... .. ......... ............. .......... ................................. 7-3
Piston and Connecting Rod ...................................................................................... 7-10
Cylinder Block and Cylinder Liner ............................................................................ 7-16
Main Bearing and Crankshaft................................................................................... 7-18
Timing Gear, Camshaft & Intake/Exhaust Tappet .................................................... 7-28
Fuel Injection Pump and Governor........................................................................... 7-30
Lubricating Oil Pump and Lubricating Oil Cooler. ..................................................... 7-39
Cooling Water Pump . ... .. ... ... .. .. ....... ..... ....... .. ......... .. ......... .. .... .. .. .. ..... .... .. ................ 7-41
Intake/Exhaust System .............. :.............................................................................. 7-43
Freshwater Cooler.................................................................................................... 7-43

PRINCIPAL DIMENSIONS & MASS FOR DISASSEMBLY & SERVICING ........................................ 8-1
Principal Dimensions for Disassembly & Servicing ............. ·....................................... 8-1 \.~ __/

Mass of Major Parts.................................................................................................... 8-2

TIGHTENING TORQUES FOR BOLTS AND NUTS ......................................................... 9-1

Angle clamping bolt ................................. ,.................................................................. 9-1
Other Major Bolts and Nuts ........................................................................................ 9-1
Regular Bolts and Nuts ............................................................................................... 9-5
Pipe Joint Bolt............................................................................................................. 9-5

CLEARANCE AND WEAR LIMITS OF MAJOR PARTS .................................................. 10-1

TROUBLESHOOTING & COUNTERMEASURES ........................................................... 11-1

Parts List

Ya'nmar's Worldwide Service Network

FOR YOUR SAFETY YANMAR &NYl&L·W

FOR YOUR SAFETY

We are confident that you will be fully satisfied with this product if you use it as described in this manual.
But in the case that you do not obey all instructions, serious accidents and damage (e.g. burns, injuries
and fire) can occur.
Thorough.ly read this manual and make sure that you fully understand its contents.

About Safety Decals

This manual and the engine have safety decals. These. are important safety ~ymbols and warnings that .
are necessary to operate this product safely.
The meaning of the safety decals is as follows.

This safety alert symbol appears with most safety statements. It means attention, become
alert, your safety is involved! Please read and obey the message that follows the safety
alert symbol.

This indicates great danger of death or serious injury if you do

not obey the precautions.

This indicates danger of death or serious injury if you do not

obey the precautions.

This indicates danger of injury if you do not obey the

precautions.

This indicates danger of damage to the engine, personal property

and/or disruption of normal engine operation.

0-1 (14 pages)

-FOR YOUR SAFETY YANMAR. 6NY16L.•W

Safety Hazards

• Basic Precautions

Precautions Against Fire

• Double-check that the type of fuel is correct before you refuel.
• Never refuel with the engine running.
• Wipe up all spilled fuel.
• Store the fuel oil and lubricating oil at the specified place
and make sure that only authorized personnel handle them.
• Remove all flammable material that is not necessary near
the engine or in the engine room. It can cause fire. Put it
NO SMOKING
back in the specified location.
• Do not store or put oils and other easily ignitable
substances near the engine. They can catch fire.
• Do not bring cigarettes, matches and lighters near
flammable materials.

Check the Safety Devices

• Make sure that all the safety devices of the
engine are set correctly.
Incorrect operation of a safety device can
cause personal injury.
• Make sure that the covers of rotating engine
parts, heat shielding covers for the exhaust
pipe and protective covers of hot engine parts
are not damaged.
Repair them immediately if you find any damage.
• Never remove the cover of rotating engine parts.
If your clothing, hands or other body parts are
caught, this can cause injury.

Good Airflow
• Make sure that the engine room has good airflow.
• NEVER block ventilation devices (e.g. windows,
vents, ventilators) in the engine room.
The engine room must have good airflow
during operation.
• It is very dangerous tO breathe exhaust gas.
• Immediately repair all leaks of exhaust gas.
• Be careful that the room has good airflow because
the turbocharger needs a lot of air (oxygen).
• The battery makes hydrogen gas when it charges.
The gas is very flammable. Ventilate well.

0-2
FOR YOUR SAFETY YAHMAR 6NYl6L·W

Precautions Against Burns

• The whole engine is very hot during operation and after engine stop.
Take care not to get burned.
• Do not touch the heater of the fuel system with bare hands.
Do repairs and servicing after the engine has cooled.
• Do not touch hot parts (e.g. the exhaust pipe or pressure indicator
cock) with bare hands. Wear gloves when you take a measurement.

_.,. • Do not open the cap of the radiator or freshwater tank while the
engine is hot. Steam or hot water can come out and burn you.
Stop the engine and wait until it is cool. Then slowly turn the cap
I
n I · and release the pressure. Then remove the cap.
• Exchange cooling water, lubricating oil and filters after the engine ·
has cooled.

0-3
FOR YOUR SAFETY YANMAR 6NYl6L·W

Obey the Safety Rules

• When you operate or service the engine, obey
all safety rules, precautions and work proce-
Safety+ first
dures.
(1) Safety measures have the highest
priority among all work tasks.

(2) Safety· measures are more important

than any other work task.

(3) ·safety first" means that work

efficiency comes second after safety.

(4) Safety is the basis of efficient work.

Safety and efficiency do not
contradict each other.

(5) Safety begins with a tidy workplace.

• When you work in a team, decide on hand

signs.

• Wear correct work clothes.

Don't wear oily work clothes. They can catch
fire.

• Wear protective gear that is appropriate to your

task.
E.g. helmet, safety goggles, safety shoes,
protective mask, protective gloves, life-line.

• Use the appropriate tools for the task and the

engine-specific special tools. Using the wrong
tools can result in injury.

• Do all tasks in the correct body position.

Use a work bench that matches the size of the
engine. Make sure that you have good footing.

• Do not climb on top of the engine.

0-4
 FOR YOUR SAFETY VAHMAR 6NY16L·W

Install a Fire Extinguisher and First-aid Kit

FIRE
• Make sure that you understand where the fire extinguisher is and how to EXTINGUISHER

operate it. Keep it accessible.

• Decide on a place for a first-aid kit and keep it accessible.

[ ~ FIRST-AID KIT

• Decide on safety procedures in case of fire or an accident and keep them

accessible.
• Decide where and how to report an emergency and keep the telephone
number accessible.
(
\..

. 0-5
FOR YOUR SAFETY YAflMAR. &NYl&L·W

Precautions for Engine Operation

• At Engine Start

Carefully Check the Following:

• Nobody is near the engine.
If somebody is present, give a signal and make sure that the person is safe
before you start the engine.
• The amount of fuel oil, lubricating oil and air.
• Make sure that you remove the turning bar. Keep it in its designated place.
+
SAFETY FIRST

• Before you start the engine, turn on the power of the protective devices.
. . .
• After a long engine stop or servicing, make sure that you start the engine on the
engine side.
• If anything unusual occurs (e.g. the engine rotation suddenly increases, unusual
sounds or smoke), immediately set the start/stop handle to STOP and stop the
engine.

• After Engine Start

Carefully Check the Following:

• The pressure shown on all gauges is correct.
• There are no unusual sounds or unusual heat.
• There are no leaks of fuel oil, lubricating oil or air. If you find a leak, repair it immediately.
• Do not apply load to the engine without a warm-up run unless in an emergency.

• During Operation

Do Not Get Caught in the Engine

• Never let your hands, body or clothing make contact or come close to any rotating
part.
If you get caught in the front power take-off shaft, V-belt or propeller shaft, injury
can result.
• Never operate the engine without the the cover of rotating parts.
• Before you start the engine, make sure that no tools or rags are near the engine.
Precautions Against Noise
• Wear ear plugs in the engine room to prevent hearing loss .

•
Precautions Against Alcohol or Drug Abuse and Overwork
• Never operate the engine while you are under the influence of alcohol or drugs.
• Never operate the engine when you feel tired, unwell or otherwise physically unfit.
There is always the risk of unexpected incidents.

0-6
 FOR YOUR SAFETY YANMAR 6NY16L·W

~m,1:iz1~9~~~Z!§~,,~/:::t'···
Precautions Against Burn Injury
• During operation and immediately after the engine stops, all of the engine is very
hot. Be careful that you do not get burned.
• Make sure that you (e.g. your hands, body and clothing) do not touch the
turbocharger, exhaust manifold, exhaust pipes or engine body. There is a risk of
burn injury.

Carefully Check the Following:

• The pressure and temperature, and that there are no unusual sounds or unusual heat.
•The engine operates to satisfactory standards. Record the performance values.
(Refer to the Records of Shop Trial/Factory Test Table and record the values in the engine log.)
• If you find anything unusual, immediately stop the engine and repair it.
(

• After Engine Stop

• Do not stop the engine at the same time as you shut off load, unless in an emer-
gency.
• Continue to run the engine without load.
• Always keep the engine ready for an engine start.
• The whole engine is very hot after engine stop. Take care not to get burned.
• Do not open the side cover of the crankcase for at least 10 minutes after the engine
stops. Fresh air that rushes in can cause an explosion.

'":·~!!Mi::
Precautions Against Burn Injury
•The whole engine is very hot during operation and after engine stop. Take care not
to get burned.
• Make sure that you (e.g. your hands, body and clothing) do not touch the
turbocharger, exhaust manifold, exhaust pipes or engine body. There is a risk of
burn injury.
• When you drain oil from the hot engine, make sure that you do not get burned by
splashes or spray of oil.
• When you disassemble the cooling water system of a hot engine, hot steam or
water can blow out and burn you.
Wait until the engine becomes cool, then wrap the part that you want to remove
with cloth and slowly loosen it.

0-7
FOR YOUR SAFETY YANMAR 6NY16L-W

Precautions when Servicing

Do Not Modify This Product.

• If you want to do a modification, consult YAN MAR or your sales or service
agent in advance.
• YAN MAR is not responsible for injury or 9.amage that is the result of not
approved modification.
• To ensure safe engine operation, the fuel injection volume control and the
engine speed control are sealed.
In case that the seal is removed, the engine life decreases drastically. This is
due to deterioration and increased wear on the sliding and rotating par.ts of
the engine. As a result, consumption of lubricating oil and fuel increases.
This causes seizure and damage on all parts. Never remove the seals.
If a seal is missing, immediately contact YAN MAR or your nearest sales or
service agent to return the engine to its original condition.
Removing a seal voids your warranty.

Precautions before Servicing

•Warning Notices during Inspection and Servicing

• Put a warning notice when you do an inspection or servicing of the engine.

• Communicate well with other personnel and cooperate for safety. [fil KEEP ON.) .
• Forbid unauthorized personnel to enter the engine room.

[fil1N WORK)
• After Engine Stop
.···~

I
\, ·- /

Precautions Against Burn Injury

• Immediately after the engine stops, all of the engine is very hot. Be careful that you
do not get burned.
• Make sure that you (e.g. your hands, body and clothing) do not touch the turbo-
charger, exhaust manifold, exhaust pipes or engine body. There is a risk of burn
injury.
• When you drain oil from the hot engine, be careful that you do not get burned by
the oil (including small drops of oil).
• When you disassemble the cooling water system of a hot engine, hot steam or
water can come out and burn you.
Wait until the engine becomes cool. Then put the part that you want to remove in
waste cloth. Slowly loosen it.

0-8
FOR YOUR SAFETY YAN MAR &NYl&L·W

• Preparation before Servicing

• Before you disassemble or inspect a moving part, prevent the crankshaft from sudden rotation.
To do so, engage the turning gear with the flywheel and lock it with the lock bar.
• Use a lock bar to prevent the crankshaft from suddenly rotating during overhaul. Engage the
turning gear and lock the crankshaft with a stopper. Then tighten the lock bar.

• Keep the engine room in good order. The work area gets dirty easily.
• Prepare all engine-specific tools and other tools.
• Prepare all necessary tools for your task (e.g. lubricating oil, genuine parts, waste cloth and wire).
• Prepare a workbench that has the correct height for the engine.
• Carefully examine the wire rope before you start your work. Do not use the wire rope if it has one of the
defects shown in this table.

Do not use wire rope that looks like this:

More than 10% of
Breakage the wire is broken
within 1 twist.
The diameter has
Wear decreased more
than 7% of the
nominal diameter.

Torsion The wire is twisted.

The wire has a lofof Deformation Corrosion

Deformation deformation or
corrosion.
x
Damaged The loop end is Unraveled
wire end unraveled or worn by
the stopper.
~x
~--~-

019607-0lEOl

0-9
FOR YOUR SAFETY YANMAR &NYl&L-W

Precautions while Servicing

• Checks during Work

• When you do work as a team, carefully examine the area around you to pre-
vent any dangers.
• Keep all removed parts safely and make sure that they do not fall. OPERATION
• Put on a safety belt when you do work in a high area. MANUAL

• Put on the protective gear that is applicable for your task.

• Be careful when you hold items with dirty gloves. The items can fall and cause
damage or injury.
• If fuel or lubricating oil spills, clean the area immediately. You can fall.
• Prepare a box to store removed parts so that you do not lose or damage them.
• Before you remove a part, think about h~w you will install it again.
Before you remove a part, think about how you installed it.
• Obey all match marks.
• Tighten all bolts and nuts to the specified torque or hydraulic pressure.
• Oil leaks from a hydraulic jack are dangerous. The hydraulic fluid is under high
pressure and can cause injury. Obey the following precautions:
• Do not use rubber hoses with flaws or oil leaks.
• Do not put or drop heavy things on the rubber hose.
• Do not squeeze the rubber hose. Do not bring your face close to the jack
or branch.

• Use the Applicable Tools

• Use the applicable tools to prevent damage to the bolts and nuts of
the engine.
• When you work with heavy objects, obey the instructions of the
slinger (the person who loads the object on the crane).
• Make sure that you understand how to use the special tools before
you use them.
• Carefully examine the rubber hose and the joints of the hydraulic
jack for damage.
• Use the applicable lifting gear and be very careful when you do work
with heavy things.

0-10
FOR YOUR SAFETY YANMAR &NYl&L-W

• When You Work with Fire

Be Careful that Battery Fluid Does Not

Come in Contact with Your Skin or Eyes.
• Battery fluid is a strong add and causes
inflammation.
• If you get it on your skin or eyes, immediately flush
the area with a lot of fresh water. Get medical aid.

Make Sure that You Know Where the Fire

Extinguisher is and How To Operate It.

Precautions after Servicing

•Checks after Task Completion:

• All removed parts are installed again in their correct position.

• All damaged parts are replaced.
• All tools (including lifting gear and wires) are back at their correct location.
• All lubricating oil is removed from the engine room.
• The engine room is clean. Nothing prevents you from your routine work.
• Before you start the engine, make sure that all parts are in a good condition.
• Start the engine and look for leaks of fuel, lubricating oil, cooling water or air.
• Start a load run and check that the engine performance is the same as
before servicing. If you find an unusual difference, immediately stop the KEEP TIDY
engine. Adjust or repair the engine.

• When the load run is finished, record the performance values and the con-
tents of your servicing in the engine log. (First finish the records, then report
that you are finished with your work.)
• Remove the warning notices. Tell all related personnel that your work is com-
plete.

0-11
FOR YOUR SAFETY YANMAR &NY16L·W

• When You Inspect the Electrical System

Before You Start Work

• Disconnect the power source. You can get burned or suffer an electric shock.
•When you do a check of the battery system, make sure that you disconnect the
grounding cable(-) terminal.
You can cause a short circuit and a fire.

Be CarefUI that Battery Fluid Does Not Come in Contact with Your Skin
or Eyes.
• Battery fluid is a strong acid and causes inflammation.
• If you get it on your skin or eyes, immediately flush the area with a lot of fresh
water. Get medical aid.

• When You Use Organic Solvents

• Organic solvent can turn into a gas easily. It is dangerous to breathe the gas.
Make sure that the area where you use this solvent has sufficient airflow.
• Because organic solvent in high concentration can dissolve fats, it is absorbed by the skin.
This is dangerous. Put on protective gear when you use such a solvent.

0-12
 FOR YOUR SAFETY YANMAR 6NY16L-W

Location of Safety Decals (Labels)

• These are the locations of the safety decals (labels). Carefully read all safety decals to prevent accidents.
• If a safety decal is dirty or missing: Find the part number and send an order for a new safety decal to
your YANMAR sales agent. (Refer to the service network list "YANMAR Worldwide Service" in the
appendix of this manual.) Attach the new safety decal.

Part Unit Numbers

Part Name
Japanese - English Attached

1 141616-07210 Safety decal (moving part hazard) 2

2 141616-07250 Safety decal (pressure cap hazard) 1
3 141616-07220 Safety decal (high temperature hazard) 2
4 141616-07230 Safety decal ("Handle with care") 1
5 141616-07200 Safety decal (blow-by explosion hazard) 1
6 141616-07240 Safety decal ("Handle with care") (English) 1

1 2 3
,,
'1 All tc
WARNfNiG
Am; Pl
DANDER
A :;t
CAUTION
a
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6 5 4 3
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a
o~~t~~~o~h~~ r~~ ~;~~;~~ n"~~~~al
8 OOIDllllL't:.. fi!*:l:O:tlJD1.'t:.t:.<t:r>. ft.~0:'3111.t
before starting operation. llllt41'TflJ.btft?"C(t,:a1.'.
OFailure to lollow the Instructions In 011:111Hlat.t < llN~ti1:$f!L'{ t:;!L\
the operallon manual can lead to · D1?t::lltl:L'r:. A1t•ur=maaar:11fl•»t.,LJe1".
serious Injury. •11WlllPl8t.t<EI.._,, Rfl'JIML"Cti-&.:flJll<t.:'.;!L'.
o~r~~~P~~·~ 0~ropur':!et~; :~fol~8e ~1o;,,f~~aty ·11t!G.~W&~~-Lf':Jl&t:.Dtt~.:!t:St
the engine. <t.:'.;!L'•
ONever touch exposed moving parts during ·1'l!ll.1091111Wllltlf'•"FF~< .. otalalil:t:.. elUllllDA~JllAIDtitB:l!L. "C < t.:;!L'• liilllU!
operation. You may be hurt. ~1108't'tl..,V. illilflr:. lfiltiefl't:fll.t\.Q:L'.t'51:L."C
OWear gloves when Inspecting during or •1illilL\C:J:IJIH<7l10t<1fl;IJt'f', · <!bgl:l"ltc'<!Tg
Immediately after operation. You may be • Don'I op•n 10mln. •flu stop· (f:::;!L'• ll!ntl'!;!li:T.
burned. O"°lt~l!Jil~nl>'J. &liil'lll!Ulfll&ttl:. lllEIUllf,
• C1n uu11 Injury by 11.ploalon • Hot surface
OCheck that no luel Is leaking during , ..111a-01200 i!C8VC411114tl~1"f1Jl&r:. ¥-&t•JDL. "C <t.:a:~'.
operation. Fuel leeks may cause llres. 01<JZID$'t'tl..,Y.i16~.E"~ce~&IDE"•n~ ·May caus! 1 ~-
Olf disassembling lllters, beware ol hot
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~~uspri:~~ngedb~r~~dr.e~:fua~s~r~~=u~~8saure Hliil>llt.ce!llfitlltt1:. 60 c•11Jmt£ffll?llftl1,
llrst by loosening the air-vent plug D.!£1:..tVilill.IDftf*IJ«<ttlL. ~ttEO'J$-f";h.b(tlLJf:1".
before disassembly. Dlli!:>',~tlltJ, IUJ£1111!L"C6'off~"C<t;~<•.
OReturn turning equipment to "otr after
Inspection and maintenance. Otllil' • 4ta0>tr=. f!Jlll..f':9-.:.:.<~lf~il-.:.:.-'/1(­
OContact Yanmar 11 the safety plate and/ ~1""•" 0Jttl1l:.RL."C(t.:;!L\
or operation manual Is lost or damaged.
YAHMAR YAHMAR

014840· OlXOl

0-13
FOR YOUR SAFETY VANMAR 6NY16L-W

Lifting the Engine

Do not let the engine or generator fall when you lift it. It is very dangerous.
To prevent an accident, obey these precautions when you lift the engine.
• Use a wire rope and shackles that are applicable to the engine weight.
• Use a wire rope with the correct length. The engine qr !=Ommon b~d must not tilt to one side.
• Put a padding (e.g. a wooden block) between the wire rope and the engine or a driven machine.
• Do not go into the area below the lifted item.

Installation Location for Lifting Tools ·

• Common Bed Set

The correct location for lifting is marked on the
common bed with labels ("Lifting Position").

Lifting Position . .
Hang up This P~nl
014501-00E

• Engine Body
Keep the lifting angle of the wire rope within
60°.

014500-00EOO

• Driven Machines (e.g. Generator, Pump)

For the correct locations to attach the wire rope,
refer to the operation manuals of the driven
machine.

0-14
ENGINE DESCRIPTION YANMAR 6NY16L-W

ENGINE DESCRIPTION

Engine Specification

Engine Model Unit 6NY16L-HW I 6NY16L-DW I 6NY16L-UW I 6NY16L-SW I 6NY16L-EW

Type - Vertical, water-cooled, 4-cycle diesel engine
Number of cylinders - 6
Cylinder bore x stroke mm 160 x 200
Displacement Q 24.127
Compression ratio - 14.24
Specified engine rotation
min- 1 1000, 1200
speed
Direction of crankshaft
rotation
- Left as viewed from the flywheel side

Operation side - Left as viewed from the flywheel side

Firing order - 1-4-2-6-3-5-1
Type of turbocharger - Exhaust gas turbine turbocharger (with air cooler)
Freshwater-seawater dual
Freshwater: Cylinder, lubricating oil cooler
Type of cooling - system cooling ( Seawater: Air cooler, freshwater cooler
)
(with freshwater cooler)
Forced lubrication by internal pump
Type of lubrication - Auxiliary equipment (turbocharger, rocker arm): engine lubricating oil, used combined
Fuel injection pump: special oil
Type of lubricating oil sump - Wet sump incorporated in the common bed
Type of starting - Pressurized air
Overall
mm 1996
length .
Engine Overall
mm 1085
dimensions width
Overall
mm 1532
height
Mass (of engine only) kg 2880

•Engine Model Naming

No. of Cylinders
(Configuration of Cylinders)
Engine Series

B1GJ~L~ra )':f I
Degree of Turbocharging 015636-00E
(HW-DW-UW-SW-EW) ou010-01•00

1-1. (2 pages)
ENGINE DESCRIPTION YANMAR &NY1&L-W

Attachments

Accessories & Devices Format Remarks

Forced lubrication with engine
Turbocharger Air-cooled exhaust gas turbine
lubricating oil
Charge air cooler ·Plate-finned, multi-tubular
Force lubricated independently with
Governor Automated or oil pressure
fuel injection pump special oil
Force lubricated independently with
Fuel injection pump lnline Bosch
fuel injection pump special oil
Fuel injection valve Uncooled, multi-hole
Fuel feed pump Piston
Manual backwashing, duplex
Fuel filter
changeover, notch wire
Lubricating oil pump Gear (cog wheel) Integrated safety valve
Lubricating oil cooler Low-finned tube, multi-tubular
Manual backwashing, duplex
Lubricating oil filter
changeover, notch wire
Lubricating oil bypass filter Centrifugal
Cooling water pump Swirl
Lubricating oil priming pump Manual wing pump
Freshwater cooler Multi-tubular With automatic thermostat

1-2
 MAJOR PARTS YANMAR &NYl&L·W

MAJOR PARTS

Structure Outline
As shown in the sectional view below, the structure of this engine is an integrated crankcase with hanging
bearings.
When installing the engine, fix it with the engine brackets to the engine bed.

Figure 2-1

Rocker Arm

EF5¥ ,a,,
Cylinder Head

Piston

Cylinder Liner

Piston Cooling
Nozzle

Boost Air
Chamber
_,/

Connecting Rod

Side Bolt___);;Y~
Crankshaft
Mounting F o o t _ /

Oil Pan
014450-00EOl

2-1 (8 pages)
MAJOR PARTS YAN MAR &NYl&L·W

Engine External View & Equipment Layout

Figure 2-2

•·@@iij&ii• Lubricating Oil Pump

Fuel Oil Gauge Control Lubricating Oil Air Cooler for Fuel Injection Pump
Filter Panel Valve Bypass Filter

Governor Governor Fuel Injection Lubricating Oil Lubricating Oil Fuel Feed Pump
Motor Pump Tank for Fuel Strainer for Fuel
Injection Pump Injection Pump 020401-00EOl

•§t.!ij iof;J&liiMt\MiiM
0

Lubricating Oil Pressure Lubricating Oil Lubricating Oil

Regulating Valve Cooler Filter

Freshwater Lubricating Oil Priming Motor Pump

Pump Pump

2-2
 ------------

MAJOR PARTS YANMAR &NY1&L·W

Major Parts

• Cylind~r Block
The crank case has covers on the operation side and non-operation side. The air intake manifold (air
intake chamber), main lubricating oil passage and main cooling water passages are cast into a single
block. The block has a double-wall structure.

• Cylinder Liner
The cylinder liner is made of a special cast iron. The outer surface has an anti-corrosive coating. The
inner surface has a precision honing.

• Cylinder Head
The cylinder head has 2 intake and 2 exhaust valves. The fuel injection valve is in the middle.
The cylinder head is installed with 6 bolts that are tightened to a specified torque.
The installation part of the fuel injection valve is fitted with a sleeve.

( \
; • Piston and Piston Rings
The piston is made of a special cast iron. The top is cooled by lubricating oil that is injected from the
piston cooling nozzle. The skirt has a special coating.
There are three piston ring set has three compression rings. They are chrome-plated on the sliding
surface. There is one oil ring. It is combined with a coil expander. It is chrome-plated on the sliding
surface.

• Connecting Rod
The large end of the connecting rod is split diagonally and the joint faces come together in a serration
joint.
The connecting rod has 2 push bolts. It is tightened by angle-tig.htening.

• Crankshaft and Main Bearing

The crankshaft has integrated balance weights.
The main bearing is a hanging bearing. A thrust bearing is attached to the No. 1 main bearing.
( '-,
I , All main bearing caps are fixed with 2 mounting bolts and 2 side bolts from the operation side and non-
operation side. The main bearing caps are tightened by angle-tightening.

•Camshaft
The intake/exhaust cams are integrated into the shaft.

• Fuel Injection Pump

The fuel injection pump is an inline Bosch pump with an integrated governor.

• Fuel Injection Valve

The fuel injection valve is not cooled.

• Start/stop Mechanism
The engine is started by pressurized air direct-entry.
To stop the engine from the operation side, move the stop lever of the governor to the stop position. To
stop the engine remotely, actuate the air piston and move the rack of the fuel injection pump to the non-
injection position.

2-3
MAJOR PARTS YANMAR · &NY1&L·W

Lubricating Oil System

•The lubricating oil pump is a cogwheel pump with an integrated safety valve.
• The lubricating oil filter is a notch-wire-type centrifugal bypass filter.
• The lubricating oil cooler is multi-tubular.
• An electric pump or manual wing pump are installed as a priming pump.
• The fuel injection pump and governor are force lubricated independently with special oil.

The lubricating oil that is discharged by the pump flows through the lubricating oil cooler and filter, and
then enters the main gallery of the cylinder block. There it is adjusted to the specified oil pressure by the
pressure control valve.
From the main gallery, the oil lines divide to all parts of the engine and flow back to the oil pan and
common bed.

Figure 2-3

( \
' I
\ __ )
Main Bearings Crank Pin Bearings

Suction/Exhaust Valve
Pressure Regulating Valve Rocker Arms

---------,
I
I Main Gallery
~:---1~-------~
- 1------..
I
I
Pump Intermediated Gear 1-+--i
I
I
Camshaft lnermediate Gear """""4---
1
I rt 1t-.......,~---'"""---lllh
I
I
I 'i 11-r-n---r--l
' I
I
Lube Oil Pum~-!'Tt1'iirrr 1 : Lube Oil Cooler
Lube Oil Filter
I I I
1· I
l--J----------l--i-------------- __________,
pi ' '
~-----------------------------------
Oil Pan .
___,,
Common Bed
Wing Pump

Governor
~---.----~
------·:
I
I
I
I
Fuel Injection Pump --1 :

'_ '
I I

Lube Oil Pump :

: :
.-----~--___,_ _,: ::
L...__ _ _ _ __ _ J_ _ _ _ _ !
020403-00E

2-4
 MAJOR PARTS YANMAR &NYl&L-W

Cooling Water System

The engine is cooled by a freshwater-seawater dual system cooling. The freshwater cooler is directly
attached to the engine.
• The freshwater pump is a centrifugal (volute) pump.
• The seawater pump is a motor-driven centrifugal pump.
• An automatic pellet-type thermostat controls the temperature of the freshwater. It is installed inside the
thermostat casing of the freshwater cooler.
•The seawater bypass valve (optional) controls the temperature of the intake.air. It adjusts the seawater
flow rate of the air cooler.

Freshw~ter System (Continuous Line: "' )

The cooling water flows from the freshwater cooler to the lubricating oil cooler, freshwater pump, cylinder
jacket, cylinder head and exhaust manifold. Then it flows back to the freshwater cooler, where the
automatic thermostat adjusts the freshwater temperature to its specified value.
(__) Seawater System (Dotted Line: - - - - -. )
The cooling water flows from the the seawater pump to the below parts and is discharged to the outside
of the ship.
Freshwater cooler ---+ air cooler ---+ outside

Figure 2-4

Boost Air Cooler

•
Outside Marine

Sea Water Pump

Fresh Water Pump Lube Oil Cooler 014453~00E

2-5
MAJOR PARTS YANMAR 6NY16L.·W

Fuel Oil System

The fuel oil flows from the tank through the inlet-side filter to the fuel feed pump that is installed on the
fuel injection pump. Then it flows through the outlet-side filter from the fuel injection pump to the fuel
injection valve.
The pressure control valve adjusts the pressure of the surplus fuel. The fuel flows back to the inlet-side of
the fuel feed pump.
The fuel feed pump is a piston-type pump with a manual priming pump.

Figure 2-5

Fuel Injection Valve

:,.-·-\
\ __ j

Pressure Regurating Valve

Fuel Tank 014454-00E

2-6
MAJOR PARTS YANMAR &NY1&L-W

Start Air System

• Control Valve
The check valve opens when you move the lever of the control valve in the START position. When the
check valve opens, the start air flows to the air starting valves of all cylinders and to the distributor valve.
From there, the air flows according to the firing order to all cylinders and the air starting valves open. The
engine starts turning. The air inside the cylinder is compressed by the piston and becomes hot. At this
point, the injected fuel ignites and the engine starts.
When the lever of the control valve is in the RUN position, the control valve is closed and the start air is
cut off.
You can conduct an air running without fuel injection if you set the stop handle of the cover to STOP and
move the lever of the control valve to RUN.

Figure 2-6

I Starting Valve I Cylinder Head

u

IDistributing Valve I
Starting Air Reservoir

014455-00E

• Check Valve
The check valve sends the high-pressure air from the start air reservoir to the distributor valve and the air
starting valve. A control valve opens and closes the start air reservoir.

• Distributor Valve
The distributor valve is on the back end of the camshaft. It sends high-pressure air from the check valve
to the air starting valves of all cylinders. It sends the air through a notch part that is actuated by specific
angles of the crank and the firing order.

• Air Starting Valve

The air starting valve is on the side of all cylinder heads. It is opened by high-pressure air from the
distributor valve. It sends high-pressure air into the cylinder according to the firing order.

2-7
MAJOR PARTS YA.NMAR &NY1&L-W

[Memo]

/~
( ___,,, )
,...._

2-8
TABLE OF ENGINE STANDARD ADJUSTMENTS
YAHMAR 6NY16L·W

TABLE OF ENGINE STANDARD ADJUSTMENTS

Assembly Adjustment Values

Item Unit Adjustment Value Remarks

Piston top clearance (A) mm 1.5 to 1.8
50
deg
40
Valve head clearance (B) mm 0.3 Engine is cold

1ii Open (before B.D.C.) 60

::iaJI------------~ deg
~ ~ Closed (after T.D.C.) 60
x >1--------------t-----t---------~-----------i
w Valve head clearance (B) mm 0.4 Engine is cold

Q)

~
(,)
c
Ill
....
Ill
Q)
0
....
0
Cl
c
.E
i=

014827-00X

ci Begins to open (before T.D.C.) 4

c
t: Q)
Ill 2
1ii ~ Closed (after T.D.C.) 130
~ deg

Fuel injection pump begins to deliver Refer to the "Records

(before T.D.C.) of Shop Trial".
Injection pressure (fuel injection valve) MPa 27.4± 0.5

Pressure and Temperature Settings

Item Unit Adjustment Value Remarks

Fuel supply pressure 0.2 to 0.25 -
Q)
....
::J
Lubricating oil pressure 0.49 to 0.59 -
en
en Cooling water pressure (cylinder jacket) MPa 0.15 to 0.25 -
....
Q)

0. Cooling water pressure (cooler system) 0.05 to 0.15 -

Start-air reservoir pressure 2.45 or 2.94 Lower limit: 1.2
Cooling water engine outlet temperature
(cylinder jacket)
71to85 -
Q)
....
::J Cooling water temperature at air cooler inlet
iii 32 or less Planned value
....
Q)
a.
(seawater) oc
E Lubricating oil temperature at engine inlet 75 to 85 -
~
Exhaust gas temperature at turbocharger Refer to the "Records
inlet of Shop Trial".
-

3-1 (2 pages)
TABLE OF ENGINE STANDARD ADJUSTMENTS YANMAR 6NY16L·W

Prot~ctive Device Settings

Item Unit Alarm Settings Emergency Stop Settings

Lubricating oil pressure 0.44 0.39
MPa
Differential pressure at lubricating oil filter 0.2 -
Cooiin'g water temperature (freshwater) 95 100
·c
Lubricating oil temperature 95 -
Rotational overspeed min- 1 - 112 to 115 % of rated speed

Note: All items vary with the specification. Refer to the delivered specification papers.

Holding Volumes of Lubricating Oil and Cooling Water

Unit: Q
Item Holding Volume Remarks
Engine (inside cylinder) 30
Cl
c: Oil pan 105 Auxiliary tank: > 1.36 Q/kW
~
·c ·5 Lubricating oil cooler 7
(.)

.0
_,
::J Fuel injection pump cam case 1.5
Special tank
Fuel injection pump lubricating oil tank 8.0
Cl .... Enige (cylinder jacket) 33
.5 2
0 ro Freshwater cooler 27
0
(.) :s:
Lubricating oil cooler 4

3-2
 ENGINE OPERATION YANMAR 6NY16L·W

ENGINE OPERATION

'. C::-~.~;t.~~:~iE~f~i;·,;~!£§[j.2'~,,,;i,L~.J]~~~~i~~,f~·l:f:!~;~it:;fi
• During operation, the diesel engine runs at high speeds. Some parts of the engine are very hot.
Compressed air and pressurized fluids (e.g. oil and water) flow through the engine. Thoroughly
read the safety precautions before operation, maintenance and inspection and operate the
engine correctly to prevent accidents.

W "FOR YOUR SAFETY" on page 0-1

Inspection and Preparation before Engine Start

Do this inspection and preparation in addition to the daily inspection and preparation before the first
\. engine start after installation, servicing or a long engine stop. Start the engine only after you completed
this preparation and you made sure that there are no defects.

• Make sure that you do not leave any parts or tools in the crankcase.
• Make sure that you tightened all parts.
• If you disassembled the valve mechanism, check that the clearance of the intake and exhaust valve
heads is correct.

!WJ "Adjusting the Clearance of the Intake/Exhaust Valve Heads" on page 6-22

• Operate the lubricating oil priming pump and open the pressure indicator cocks of all cylinders. Turn
the flywheel and make sure that drops of lubricating oil fall down from the rocker-arm shafts, piston
pins, crank pins, main bearings and swing arms.
• Release the air from the lubricating oil filter.
• Release the air from the fuel oil filter and the inlet pipe of the fuel injection pump.
• Manually lubricate the governor linkage. Make sure that it moves easily.

• Be careful that your body does not touch any moving parts when you turn the flywheel.
(Never put your hand into the crankcase.)
• After you finish turning, put the turning bar back to its specified location.

Turning the Flywheel

Before you turn the flywheel, align the decompression shaft with the DECOMPRESSION side according
to the following instructions.
• When set to DECOMPRESSION, the intake valve opens and the flywheel is easier to turn.
1. Loosen the lock bolts of the decompression shaft caps.
2. Turn the decompression shaft completely in the anti-clockwise direction to move it in the DECOM-
PRESSION position.

After you finish the turning, turn the decompression shaft completely in the clockwise direction to
move it in the .RUN position. Tighten the lock bolts of the decompression shaft caps.

4-1 (10 pages)

ENGINE OPERATION YAHMAR· 6NY-16L·W

Figure 4-1 How to Se.t the Decompression Shaft

7' :::i ;.; :1 '1!I ill: Iii

DECOMP.SHAFT POSITION
7':::i ;.;:1 iUli
DECOMP. RUN

00
Lock Bolt Decamp. Shaft Retainer

Push Rod (Suction)

(
Decamp. Shaft 014456-DOE

• Lubricating Oil System

• The pipes of the lubricating oil system have a yellow coating.

Inspecting and Filling the Lubricating Oil Reservoir

1. Open the following drain valves, cocks or plugs of all oil reservoirs and and devices. Drain these
parts.
2. Fill all oil reservoirs with oil. Fill to the top limit of the oil level gauge or the dipstick.
• Engine oil pan and hull-fitted auxiliary tank (The filler for the oil pan is on the side cover of cylin-
der no. 2 on the operation side.}
• Lubricating oil cooler
• Lubricating oil filter
• Lubricating oil tank for the governor and the fuel injection pump
3. Check the properties of the lubricating oil. If the lubricating oil is very contaminated or deterio-
rated, change it.

W ''TABLE OF ENGINE STANDARD ADJUSTMENTS" on page 3-1

!WJ "Handling the Lubricating Oil" on page 5-2

Figure 4-2 Locations for Oil Filling (Operation Side)

Lube Oil Supply Port

Starting Air Distributing Valve

Lube Oil Dipstick for Lube Oil Supply Port Lube Oil Dipstick
Fuel Oil Injection Pump for Fuel Oil Injection Pump 020407-00E

4-2
 ENGINE OPERATION
YANMAR &NYl&L·W

Priming the Lubricating Oil

• If an electric priming pump is attached
Before engine start, do a priming with the electric priming pump for 3 to 4 minutes.

Figure 4·3 How to Prime the Lubricating Oil (Electric Pump)

Priming Motor Pump 020405-DOE

• If a wing pump is attached

While turning the flywheel, .move the switch cock handle of the wing pump to PRIMING and operate
the handle for 5 minutes.
When you finish priming, move the switch cock handle to RUN/SCAVENGE OIL.

Figure 4-4 How to Prime the Lubricating Oil (Wing Pump)

Wing Pump Changeover Cock

Changeover Cock Handle

/
\ ___,,
Priming

Lube Oil Wing Pump

020406-00E

4.3
ENGINE OPERATION YANMAR &NYl&L·W

• About the fuel injection pump lubricating oil

Loosen the handle of the priming pump on the special tank. Move it up and down to do the priming.
When you are finished, securely tighten the priming pump handle.

Figure 4-5 Priming the Lubricating Oil of the Fuel Injection Pump

/
!

Operate up
and down

CJ

020404-006

4-4
ENGINE OPERATION YANMAR 6NYl6L·W

• Fuel Oil System

• The pipes of the fuel oil system have a red coating.
1. Drain the fuel tank and fuel oil filter.
2. Fill the fuel oil into the fuel tank. Check the fuel oil. Open or close all valves according to the oper-
ation conditions.
3. Release the air from the fuel oil system.

• Release air from the fuel oil system after engine installation, long-term stoppage or engine mainte-
nance. Obey these instructions:
1. Open the air vent cock of the fuel oil filter.
2. Loosen the air vent plug of the fuel injection pump again.
3. Loosen the priming pump handle of the fuel feed pump and move it up and down.

Figure 4·6 How to Release Air from the Fuel Oil System

Air Vent Cock

Fuel Oil Filter

Handle

Fuel Feed Pump

014459-00EOl

After you release the air, securely tighten the priming pump handle.
A loose handle during operation causes fuel leaks.

4. Make sure that the fuel oil is cut off.

Move the stop handle of the governor in the STOP position, tum the flywheel and make sure that
the fuel injection valves make no sound.

4-5
ENGINE OPERATION YANltllAR &NYl&L·W

• Cooling Water System

• The pipes of the cooling water system have these color coating: blue for the freshwater system, green
for the seawater system.

• Make sure that you use soft water (tab water) for the freshwater system. Add corrosion inhibitor to pre-
vent ineffective cooling due to water scale and rust.
See below for corrosion inhibitors.

!IWJ "Selecting and Controlling the Corrosion Inhibitor" on page 5-5

• If you replaced the cylinder liner or removed it for servicing, remove the cylinder side cover and make
sure that there are no water leaks inside the cylinder.

1. Remove the cap of the freshwater cooler. Fill water until it overflows from the tiller.
·Freshwater system capacity: approx. 64 l
2. Open and close each valve of the cooling water pipe system according to the operation condi-
(1
\ __ __,/
tions.
3. Open the cock on the top of the air cooler and release the air.

• Start Air System

• The piping of the start air system is banded with white coating.
1. Drain the air reservoir.
2. Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine
(1.2 MPa or higher).
3. Loosen the drain cocks of the air intake chamber and drain it.
The drain plug is on the back side of the lubricating oil bypass tilter.

Figure 4-7 Air Intake Chamber Drain Plug

Lube Oil Bypass Filter

4-6
 ENGINE OPERATION YANMAR 6NYl6L·W

Engine Start

Before the first start after installation, servicing or a long engine stop, obey the following procedures and
make sure that there are no defects. Then start the engine. A large amount of fuel oil, cooling water or
lubricating oil in the cylinders can cause water hammering.
1. Align the decompression shaft to DECOMP of all cylinders. Turn the flywheel until cylinder no. 1 is
in a position of 25° before the top of compression.
2. Put only the decompression shaft of cylinder no. 1 in the RUN position. Slowly turn the flywheel. If
you can turn to the top of the compression without feeling a bump, the cylinder is not defective.
3. Do the same check on all cylinders in firing order.
If you feel a bump and cannot turn to the top of compression, that cylinder is defective. Disassem-
ble the cylinder head, find the cause and fix it.

• How to Start the Engine

Obey these instructions to start the engine.
1. Open the start air reservoir and all valves of the air control system.
2. Move the control valve lever to START. If ignition occurs, move it to RUN.
•If an oil-pressure governor is installed, move the stop handle to RUN.
3. Move the speed handle of the governor to the rated speed.
•If a mechanical governor is installed
• When operating from the engine side, push in the handle and operate.
• When operating remotely, pull out the handle.
4. Close the valves of the air pipe system and the start air reservoir.

Figure 4-8 How to Start the Engine

\I START I
' ,,

Stop Valve
I When equipped with hydraulic governor I
RUN STOP

Stop Lever '

0144U-OOE

4-7
ENGINE OPERATION YANMAR 6NY16L-W

-~~I~!,§~f!il~("
• If the engine does not start correctly, unburned combustion gas in the flue can ignite and
cause an explosion. Before you restart the engine, do an air running and discharge the gas
from the exhaust gas system.
• How to do an air running
Keep the stop lever (or handle) in the STOP position. Move the control lever to the START
position. This way, only start air is supplied.

• Checks after Engine Start

Do these checks. If you find any defects, stop the engine and do the necessary repairs.
• Check that the pressure values on the instrument panel are correct.
• Check all pipes for leaks.
• Check for unusual sounds and unusual heat.

After you fill lubricating oil or cooling water for the first time or replace it, operate the engine for
approximately 5 minutes and then stop it again. Check the levels of the lubricating oil and the cooling
water and fill again. The levels are lower than before because of the oil and water that was send through
the engine.

4-8
ENGINE OPERATION YANMAR &NYl&L-W

Operation

• NEVER touch the following parts with your bare hands when the engine is running or when the
engine has just stopped. There is a risk of burn injury.
• Turbocharger, exhaust pipe system, intake pipe system, indicator cocks
• Flue and funnel
• NEVER touch a moving part during engine operation. You can get caught and hurt.

•Regular (Routine) Operation

1. Make sure that the pressure of the lubricating oil, cooling water and fuel oil is the specified value.
2. Run the engine for about 10 minutes without load at the rated speed to warm it up.
3. If you use the engine to drive a device that requires controlled rotation (e.g. cargo pump), run the
engine at the preset idling speed to warm it up.

While the engine speed increases from idling speed to the rated speed, critical torsional vibration can
occur. In that case, set the engine to the rated speed and let it pass quickly through the critical
rotation speed.

• Running-in
After replacing the piston, piston rings, cylinder or liner, do a running-in operation. This prevents seizure
and unusual wear.
• Quickly pass through the critical rotation range where torsional vibration occurs.
• Operate the engine at the below speeds under no load for 10 minutes, and under load for 20 minutes.
• 500 min-1 .
1
• Rated speed x 0.6 min·
• Rated speed x 0.8 min· 1
• Rated speed x 0.9 min- 1
• Rated speed min- 1

Engine Stop
• Normal Engine Stop
Except in an emergency, obey these instructions to stop the engine.
1. Run the engine without load for approximately 10 minutes.
2. Set the start/stop handle to STOP.
• If the engine operates on remote start/stop, press the STOP switch.
3.After engine stop, turn the flywheel and release gas from the combustion chambers.
4. After engine stop, make sure that you operate the lubricating oil priming pump and sufficiently
cool all parts.
At that time, tum the flywheel and listen for unusual sounds.
5. Open or close the valves of all circuits as it is specified·for engine stops.
• Drain the cooling water from the cylinder block, cylinder heads and all coolers if the cooling
water can freeze due to cold weather or before a long engine stop.

4-9
ENGINE OPERATION YANMAR &NYl&L·W

• Emergency Stop

.1'·!(~·~'.;§~'~[i§~:!
If any of the following problems arises, immediately decrease the engine speed and then move
the stop lever to the STOP position to stop the engine.
• One of these alarms operates:
• Unusual decrease of lubricating oil pressure
• Unusual increase of lubricating oil temperature
• Unusual increase of cooling water temperature
• Overspeed
• Unusual noise and vibration
• Unusual heat
• Smoke from a bearing or other moving part
• A broken pipe of the fuel oil system, lubricating oil system or cooling water system
• The supply of cooling water stopped and cannot be resumed immediately
• A loose or broken bolt or setscrew of a moving part
• Water in the lubricating oil
• The intake air pressure decreases and the exhaust temperature increases a lot
• The rack of the fuel injection pump is stuck
• The exhaust temperature of one cylinder is 40 °C higher or lower than the average temperature
of all cylinders. (There is risk of misfiring and torsional vibration.)

If you move the stop lever to STOP or press the stop switch and the engine does not stop, close the fuel
oil inlet valve.

• After an Emergency Stop

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

Do not open the cap of the freshwater cooler immediately after engine stop. It is dangerous,
because hot steam or water can come out.
Wait until the engine becomes cool. Then put the cap in waste cloth. Slowly loosen it.
After filling water, tighten the cap securely.

After an emergency stop, do not open the side cover of the crankcase for 10 minutes or more after
the engine stop. Fresh air that enters the engine can ignite oil mist and result in an explosion.

4-10
 FUEL OIL, LUBRICATING OIL & COOLING WATER
VANMAR &NYl&L·W

FUEL OIL, LUBRICATING OIL & COOLING WATER

Fuel Oil
The fuel oil for this engine is marine diesel oil as specified in Japanese Industrial Standard (JIS) K-2205
Category 1 Number 2 (marine diesel oil).
The property range of the JIS is wide. Because the quality of fuel has an effect on smooth engine opera-
tion, maintenance intervals and service life of engine parts, the following properties are recommended.

Properties of Marine Diesel Oil

Residue Ash Sulfur Water Flash

Viscosity Cetane Pour Point Density
Carbon Content Content Content Point
mm 2/s Number oc oc kg/m 3
{mass%) {mass%) {mass%) {vol%)
(at 40 °C) (at 15 °C)
>45 > -10 <0.3 < 0.01 < 1.0 < 0.1 > 60
2 to 11 < 900

(_.. Remark: JIS Category 1 Number 2 is equivalent to ASTM D975 DIESEL FUEL OIL No. 4-D and BS2869
CLASS B1.

• Extreme viscosity can cause seizure on the plunger and the barrel of the fuel injection pump. Check the
viscosity of the bunkered fuel by the basis of the viscosity chart. Adjust .the filled fuel to a minimum of
1.8 mm2/s at engine inlet. If you cannot maintain a minimum viscosity of 1.8 mm 2/s at engine inlet, we
recommend that you install a fuel oil cooler or chill cooler to the MGO/MFO system.
• The fuel injection mechanism is made of precision parts. Do not use fuel oil that is contaminated with
water or dirt, because it can cause defects.
• Obey the following precautions when you fill fuel oil.
• When filling from barrels, let the barrels rest for one day of more· so that 9ontaminants can settle.
Fill fuel oil from the top of the barrel.
• When filling from the storage tank to the service tank, let the fuel oil in the storage tank rest for one
day or more.
• Do filter servicing and draining as part of your regular maintenance .

.W "MAINTENANCE INSPECTION" on page 6-1

5-1 (6 pages)
FUEL OIL, LUBRICATING OIL & COOLING WATER YANMAR 6NY16L-W

Lubricating Oil
Selection of the correct lubricating oil is important for a diesel engine. An inappropriate lubricating oil
causes seizure and early wear of the pistons, cylinder liners and bearings and sticking of the piston rings.
Select the lubricating oil carefully.

• .Selecting the Lubricating Oil

• Select a lubricating oil with an API service grade of CE or CD based on the values of the below table.
• The viscosity should be SAE 30 or SAE 40.

Flash Point Pour Kinematic Viscosity Total Base Number

Viscosity Specific mm 2/s (cSt) Viscosity
Engine (Open Type) Point mgKOH/g
(SAE) Gravity Index
oc •c 40 •c 100 •c (T.B.N.)

Marine aux- 30 0.89 > 230 > -10 105 to 125 11to12.5 96 to 110 9 to 15
iliary engine 40 0.893 > 240 < -7.5 140 to 155 14 to 15.5 96 to 110 9 to 15

• The commonly sold fuel brands with an API service grade of CE or CD are indicated in "List of Lubricat-
ing Oil Brands" on page 5-4.

• Do not mix different brands.

(If you cannot avoid mixing different brands of lubricating oil, consult your lubricating oil supplier.)
• Use the correct lubricating oil. If the fuel oil has low sulfur content and the lubricating oil has a high total
base number, additives (calcium carbonate) in the lubricating oil and carbon residue will stick to hot
engine parts.
If these particles collect in the combustion chamber, they prevent the piston rings from moving freely.
This results in scuffing of the piston rings and cylinder liners. The particles also cause bite-in and
blow-by in the exhaust valves.

• Handling the Lubricating Oil .

\'--j
• If you handle the lubricating oil inside the engine immediately after an engine stop, be careful
not to get burned.
• Put on protective clothing (e.g. safety goggles and rubber gloves) if lubricating oil can get into
your eyes or stick to your skin.
• If lubricating oil enters your eyes or sticks to your skin, it can cause inflammation. Wash the
affected region with clean water. If an unusual reaction occurs, consult a doctor.

• Hbw to handle waste oil is stipulated by law. Make sure that you dispose all oils correctly and lawfully.
If you are not sure how to handle the oil, consult with your oil dealer.

5-2
 FUEL OIL, LUBRICATING OIL & COOLING WATER YANMAR 6NYl6L·W

Control Standards
Make an analysis of the properties of the lubricating oil every 500 hours of engine operation. Change or
make-up the lubricating oil according to the standards in this table.

Item Unit Control Standard Usage Limit

Flash point (PM method) oc > 180 140
Viscosity change (40 °C) mm 2/s (cSt) New oil: within ±15 % New oil: ±25 %
Water content vol% < 0.1 0.2
N-pentane insoluble content (A
mass% < 1.5 2.0
method)
Toluene insoluble matter (A
mass% < 1.5 2.0
method)
Difference between N-pentane
insoluble matter and toluene insol- mass% - < 0.5
uble matter
Total base num- HCI method > 3.0 1.0
( ber mgKOH/g
\
(T.B.N.) HCI04 method > 6.0 4.0

Oil Change Standards

If only one criteria or limit of the check items is not met, change the whole amount of oil. Use your own
judgment when you schedule and perform oil changes. The standards cannot be decided on operating
time alone and vary depending on the operating conditions of the engine.
• Ask your lubricating oil supplier to make an analysis of the lubricating oil and decide whether you can
continue using the oil or not.

• For the analysis, take an oil sample of 500 cc or more. Take it from the drain plug of the lubricating oil filter
immediately after engine stop.
• If you change the whole amount of oil, make sure that no oil remains iii the oil cooler or inside the filter.

(
• Ask the lubricating oil maker for a spot test kit. Use it to find the remaining total base number, degree of
contamination and cleaning dispersion.
• If you cannot make a decision about one of the above items, change the whole amount of oil according
to the change time in the below table.

Complete Oil Change

Specification Lubricating Oil Sump Capacity (Liter)
Time (Hours)
Wet sump in the engine oil
Standard specification Approx. 500 105
pan

Optional specification Sump incorporated in com- Approx. 1500 550

5-3
FUEL OIL, LUBRICATING OIL & COOLING WATER YANMAR· 6NY16L·W

• List of Lubricating Oil Brands

API Service Grade CE or CD

c.~
YANMAR SANGYO
SAE30

YAN MAR MARINE SUPER OIL 30

SAE40

YAN MAR MARINE SUPER OIL 40

IDEMITSU KOSAN DAPHNE MARINE OIL SX 30 DAPHNE MARINE OIL SX 40
EXXON MOBIL MOBIL GARD 312 MOBIL GARD 412
CASTROL MHP 153 CASTROL MHP 154
CASTROL SEAMAX EXTRA 30 SEAMAX EXTRA 40
MCL30 MCL40
CHEVRON DELO 1000 MARINE 30 DELO 1000 MARINE 40
(CALTEX, TEXACO) TARO 12XD 30 TARO 12 XD40
KYGNUS OIL KYGNUS MARINE DX 30 KYGNUS MARINE DX 40
COSMO OIL COSMO MARINE SUPER 30 COSMO MARINE SUPER 40
SHELL GADINIA OIL 30 GADINIA OIL 40
JAPAN ENERGY JOMO MARINE D13 JOMO MARINE D14
TOTAL Lubmarine DISOLA M3015 DISOLA M4015
FUJI KOSAN FUKKOL MARINE 312 FUKKOL MARINE 412
BRITISH PETROLEUM B.P.ENERGOL DS3-153 B.P.ENERGOL DS3-154
NIPPON OIL MARINE T103 MARINE T104

5-4
 FUEL OIL, LUBRICATING OIL & COOLING WATER YANMAR &NYl&L·W

Cooling Water (Engine Jacket Water)

• Cooling Freshwater Standards

• Use pure (distilled) water or tap water.
• Use water with the properties shown in the table.

• Do not use hard water.

• If you use hard water, scale collects in water channels (e.g. cylinder head and cylinder water jackets)
and can cause overheat. Be careful.

Recommended Water Quality

pH 298K (25 °C) 6.5 to 8.0
Total hardness (CaC0 3 ) < 100 ppm
Chlorine ion (CQ) < 100 ppm
(
M alkalinity 30 to 100 ppm

Ammonium ion (NH+4 ) < 0.05 ppm

Sulfate ion (S04 4) concentration < 100 ppm

Evaporation residue < 400 ppm

• Selecting and Controlling the Corrosion Inhibitor

• Add a corrosion inhibitor to the cooling freshwater. Even freshwater causes corrosion and scale on the
water channels. This results in weak parts and less cooling effect.
• Some parts of the cooling water system are made of cast iron,.carbon steel, brass and bronze. Select a
corrosion inhibitor that has no negative effect on these parts.

• Do not discharge cooling water with corrosion inhibitor into the sea or rivers. This can cause
environmental pollution. How to handle waste liquids is stipulated by law, and such liquids
must be treated according to the instructions given by the supplier of the chemical.
• Do not mix different brands.
(If you must mix different brands of lubricating oil, consult your lubricating oil supplier.)
• Corrosion inhibitors are water treatment chemicals for industrial use. Do not use them in the
drinking water system.
• When you handle corrosion inhibitors, wear rubber gloves and a gauze mask to avoid contact
with your hands or other body parts.
• If the corrosion inhibitor accidentally comes in contact with skin, eyes or mouth, flush the area
thoroughly with fresh water. Seek treatment from a doctor if the affected area shows an unusual
reaction after you washed it.

5-5
FUEL OIL, LUBRICATING OIL & COOLING WATER YANMAR 6NYl6L·W

• If th~ cooling water system contains aluminum materials, consult the supplier of corrosion inhibitor. You
must use a different kind of corrosion inhibitor.
• Obey the standard recommended by the supplier of the corrosion inhibitor about:
• The amount of corrosion inhibitor that you add
• Controlling the concentration
• Adding an adjustment agent
• Handling the corrosion inhibitor.
• If you cannot control the concentration of corrosion inhibitor, change all the cooling water once a year.

• Recommended brands of corrosion inhibitor

Find corrosion inhibitors that are applicable to the enclosed circuit specification of the cooling water sys-
tem in this table.

Brand Supplier Brand Supplier

Royal Caviruston DIESEL GUARD NB UNITOR
YANMAR Sangyo Co., Ltd.
YANMAR Royal Freeze* ROCOR NB LIQUID Taiho Industries Co., Ltd.
Polycrin 1-1 09 NALCOOL 2000
Kurita Industries Co., Ltd.
Polycrin 1-175 Nalfleet 9-111 * NALCO Japan Co., Ltd.
(Koei Co., Ltd.)
Kurilex L - 501 * Nalfleet 9-108
Neos PN-106S Uniprot PC-200
Neos Co., Ltd. Nippon Yuka Kogyo Co., Ltd.
Neos PN-106 Uniprot PC-300
Hi-mol L-10 Shadan K Otsuka Chemical Co., Ltd.
Taiho Industries Co., Ltd.
Hi-mol AM-5 LIQUIDE WT ASHLAND JAPAN Co., ltd.
Olgard C-601 * Organo Co., Ltd.

• If the cooling water system is an ·enclosed circuit specification, consult the supplier of the corrosion
inhibitor. The concentration decreases earlier for some brands.
• Be careful with corrosion inhibitors that are also anti-freeze agents. They have low thermal conductivity
and can overheat during a load run.
• If the cooling water system contains aluminum materials, use a corrosion inhibitor with an asterisk(*).

5-6
 MAINTENANCE INSPECTION YANMAR 6NYl6L-W

MAINTENANCE INSPECTION

Precautions for the Maintenance Inspection

Check the engine periodically to maintain good engine operation and prevent defects. The inspection
periods depend on the operation conditions and the quality of the fuel oil and lubrication oil. It is difficult to
recommend a fixed inspection schedule.

• The following inspection table show the standard inspection frequency for each fuel in use. Perform the initial
servicing according to this table. Then schedule the subsequent inspections based on the results of the initial
inspection (wear, corrosion, carbon deposits, sludge deposits) for the most economic schedule.
• If an engine part has two inspection periods (operating hours and number of days), schedule the
inspection at the earlier time.

Periodical Inspections
Routine maintenance inspections .............................................................................. Table 6-1
Periodical inspections .................................................................................................Table 6-2
How to Do Routine Ma.intenance Inspections and Adjustments
Measuring the Operating Performance ...................................................................... 6-5 Page
Cleaning the Fuel Oil Filter. ........................................................................................ 6-6 Page
Cleaning of the Lubricating Oil Filter .......................................................................... 6-8 Page
Cleaning the Element ................................................................................................. 6-9 Page
Adjusting the Lubricating Oil Pressure ..................................................................... 6-10 Page
Cleaning the Lubricating Oil Bypass Filter ............................................................... 6-11 Page
Lubricating Oil Filter of the Fuel Injection Pump ........................... ·.·· ......................... 6-12 Page
Lubricating Oil Pump of the Fuel Injection Pump ..................................................... 6-13 Page
Checking the Fuel Injection Valve and Adjusting the Injection Pressure .................. 6-14 Page
Turbocharger Blower Cleaning (Fill Water) .............................................................. 6-17 Page
.r -,.. Inspection and Replacing the Anti-cprrosive Zinc (Zinc Anode) ............................... 6-18 Page
Inspection of the Thermostats for the Cylinder Jacket Cooling Water ...................... 6-19 Page
Maintenance of the Pressure Gauges ...................................................................... 6-20 Page
Adjusting the Pressure Transmitter ................... : ...................................................... 6-21 Page
Adjusting the Clearance of the Intake/Exhaust Valve Heads ................................... 6-22 Page
Adjusting the Fuel Injection Trming .......................................................... ,................ 6-23 Page
Adjusting the Exhaust Gas Temperature (Fuel Injection Volume) ............................ 6-24 Page
Measuring the Crankshaft Deflection ....................................................................... 6-25 Page
Maximum Combustion Pressure (Pm ax) Measurement... ........................................ 6-28 Page

6-1 (28 pages)

MAINTENANCE INSPECTION YANMAll' &NYl&L·W

Periodical Inspections
Tble 6-1 Table of Routine Maintenance Inspections

Inspection Interval Task

250 hours 400 to 500 hours
Daily (2 to 3 days *)
lnspe,ction Part (or 1 week) (or 1 month)
Pressure check
Fuel air reservoir
Draining*
- -
Fuel oil tank Oil amount check, draining - -
Fuel feed pump Oil seal leak check - -
=E
0 Q) Disassembly and
men
:J >-
Fuel oil filter Air bleeding * Back-washing (blow-off)
cleaning
LL VJ
Rack scale position
Fuel injection pump - check
-
Complete change of
Oil pan (wet sump)
Oil amount check - lubricating oil
Common bed (dry sump) Lubricating oil analysis
Draining Disassembly and
·5 Lubricating oil filter Back-washing (blow-off)
giE Air bleeding * cleaning
+: Q)
co..,
0 VJ Lubricating oil bypass Disassembly and
·- >-
.0 VJ filter
- cleaning
-
:J
_J
Lubricating oil tank of the Complete change of
fuel injection pump
- lubricating oil
-
Lubricating oil filter of the Disassembly and
fuel injection pump
Turn the handle.
cleaning
-
....
Q)

iii E
Cooling water pump Mechanical seal leak check - -
~ Q)
C>..,
c VJ Corrosion inhibitor
·-
0 >-
0
VJ Cooling water pump Water amount check - concentration
l>
measurement
- Filter cleaning -
Turbocharger Blower cleaning
- (fill water)
-
I VJ
:J ..,
.... c
All pressure gauges Check for wrong indications. - -
iii Q)
.E E All thermometers Check for wrong indications. - -
Check bolts and nuts for
looseness.
Engine appearance Check all parts for leaks. - -
(cooling water, fuel oil, air,
exhaust gas)
Check all pipe systems for leaks. - -
Regarding tasks for inspection intervals of more than 1000 hours or 3 months, see Table 6-2.

6-2
 MAINTENANCE INSPECTION YANMAR 6NYl6L·W

Tble 6-2 Periodical Inspections/Maintenance Table (1/2)

U: Perform tasks marked with a star as instructed by a specialized engineer of the manufacturer or the
maintenance provider.
* Inspections marked with this symbol are the first inspection after the first engine start or after you
replace a part. Do the inspection at the normal frequency from the second time on.
Inspection and Servicing Frequency
(In Hours)
(:'

-
0 Inspection 3months 6months 1 month 3months 5months
Cl Task Remarks
Q)
ca part or or or or or·
(.)
1000 to 2000 to 4000 to 8000 to· 16000 to
1500 h 2500 h 5000 h 10000 h 20000 h
Fuel injection Disassembly, cleaning and pressure
1500 to 2000 1st time: 500 h to 800 h
valve adjustment
Inspection and adjustment of valve head
0
clearance, inspection of valve spring
-0
ctl
Q)
C[1eck the valve bridge guide for looseness. 0
.c Disassembly and inspection of the valve rotator 0
Qj
( -0
.E Cylinder head
>.
Disassembly, inspection and cleaning 0
(.)
Grinding of the intake/exhaust valve seat 0
Scale cleaning and hydraulic test of the water
0
chamber
Inspection of the cylinder head bolt tightening
force
. 0
Removal of the piston, cleaning, inspection and
0
measurement
Piston
Inspection and measurement of the piston rings 0
Inspection and measurement of the piston pin 0
Inspection and measurement of the piston pin
0
bearing
Inspection and measurement of the crank pin
Connecting 0
bearing
rod
Inspection of the tightening force of the
connecting rod bolt
. b
Replacing the connecting rod bolts 20,000 hours
Inspection, cleaning and measurement of the
0
inner diameter
Cylinder liner
Removal, inspection and cleaning of the water
Ill
t::
0
ctl jacket
Q.
Cl Crank pin outer diameter measurement,
c: 0
·~ Crankshaft uoumal check
E Measurement and adjustment of the deflection 0
....
0
"(ij" Disassembly, inspection of the bearing and
:2 0
measurement
Main shaft Inspection of the tightening force of the main
bearing bolt
. 0
Inspection of the tightening force of the side bolt 0
Inspection of contact of the cam and tappet 0
Disassembly and inspection of the intake/
0
Camshaft exhaust air tappet
Crankshaft removal, bearing inspection and
0
measurement
Inspection of tooth contact and backlash 0
Gear disassembly, inspection and
Timing gear 0
measurement of the shaft bearing
Idle gear.
Inspection of the tightening force of the gear
0
mounted shaft

6-3
MAINTENANCE INSPECTION YAN MAR &NY16L-W

Table 6·2 Periodical Inspections/Maintenance Table (2/2)

Inspection and Servicing Frequency

(In Hours)
~
0
Cl
Inspection 3months 6months 1 months 3months Smonths
Q) Task Remarks
70 Part or or or or or
0 1000 to 2000 to 4000 to 8000 to 16000 to
1500 h 2500h SOOOh 10000 h 20000 h
~ -.:t: Disassembly and inspection 0
Q)
Cl
....
g Governor
lo Lubricating oil change (oil pressure governor) . 0
>
0
C!>
1st time: 300 to 500
Inspection of the injection timing 0
~ Fuel injection hours
(/)
~pump Deflector inspection and replacing 0
·a --:.- Disassembly, inspection and adjustment 0
Qi
::I Fuel feed Disassembly and inspection 0
u.
pump Replacing the oil seal 0
(depending on the
Common bed
Complete change of lubricating oil properties
(dry sump)
analysis)
E Lubricating oil Disassembly, inspection, cleaning and
2(/) cooler 0
hydraulic test
>-
(/)
lubricating oil
0 Disassembly, inspection and measurement 0
oi pump
c:
~ Pressure
0 Disa~sembly and inspection 0
:§ control valve
::I
_J Lubricating oil
pump of the
Disassembly and inspection 0
fuel injection
pump
Thermostat Disassembly, inspection and cleaning 0
E Cooling water Disassembly, inspection and measurement 0
Q)
pump Replace the mechanical seal. 0
i
~ Freshwater Disassembly, inspection, cleaning and
2IO cooler 0
hydraulic test
3: .
gi Cooling water
Replace. 0
0 (freshwater)
0
(.) Seawater Inspection and replacing the anti-corrosive zinc
0
cooling parts (zinc anode)
E Air starting
Q) Disassembly, inspection and grinding 0
iii valve
>-
(/)
.... Check valve Disassembly, inspection and grinding 0
"Cij
t::: Distributor
IO Disassembly and inspection 0
Ci5 valve
.... Turbocharger. Disassembly and cleaning 0
"Cij
Q)
-" Disassembly, inspection, cleaning and
.l9 Air cooler 0
.E hydraulic test
Erygine
gauge inspection 0
tachometer
lo
£ Alarm switch actuation test 0
0
Intermediate, periodic inspection,
Rubber parts V-belt and 0-ring replacement
maintenance replacememnt

6-4
MAINTENANCE INSPECTION YANMAR &NYl&L·W

How to Do Routine Maintenance Inspections and Adjusting

• Measuring the Operating Performance

Check and record these engine properties once a day when the load is stable.
CD All pressure values on the gauge panel
® Intake air temperature (air cooler outlet)
@ Exhaust gas temperature at turbocharger inlet
©Lubricating oil temperature (cooler inlet)
® Lubricating oil temperature (engine inlet)
® Freshwater temperature (engine inlet)
0 Freshwater temperature (engine outlet)
@ Cooling water temperature (air cooler inlet)
® Maximum combustion pressure (Pmax) *
@> Exhaust gas temperature of all cylinder outlets *
*Instruments marked.with an asterisk are optional orders.

Figure 6-1 Operating Performance Check Locations

6-5
MAINTENANCE INSPECTION YANMAR 6NY16L·W

C~eck the engine performance. Compare the values with the Records of Shop Trial or the Records of
Transfer Trial. If you find anything unusual, do the necessary adjustment and servicing of the engine.

Refer to the following items because the engine performance varies according to the room temperature,
water: temperature and load conditions.
• For the correct exhaust temperature, refer to the Transfer Trial record.
•.The difference of the exhaust temperature among cylinder outlets is normal if it is within 40 °C. It is
not necessary to repair this difference, if the fuel injection volume and Pmax are equal among
.cylinders.
• If the difference of the exhaust temperature at cylinder outlet is more than 40 °C, but within ± 40
°C of the average exhaust temperature at cylinder outlet, the combustion is unbalanced.
• Stop the engine and do the appropriate maintenance.
If the difference of the exhaust temperature at cylinder outlet of one cylinder is more than 40 °C
higher or lower than the average exhaust temperature at cylinder outlet, misfiring can occur and
cause torsional vibrations. Immediately stop the engine. Find the cause and repair it.
• Relationship between room temperature and exhaust temperature
The exhaust temperature changes at about twice the rate as the room temperature. But
contamination of the turbocharger and the intake/exhaust passage, exhaust pressure and
properties of fuel oil can have an effect on this relation. Do maintenance, reduce load and use the
engine within its limits.
• A difference in maximum combustion pressure (Pmax) of 0.5 MPa or lower between cylinders is normal.
~ Pmax can increase considerably as depended on properties of fuel oil. Keep it below 14.7 MPa.
• Relationship between Pmax and intake air temperature
If the room temperature increases, the Pmax decreases. If the room temperature decreases, the
Pmax increases. If the room temperatures changes by 3 °C, the Pmax changes by O~ 1 MPa.

Tble 6·3 Turbocharger Inlet Exhaust Gas Temperature Limit

(Under Rated Output and Room Temperature of 25 °C)

Unit: 0
c
Engine
1200 Revolutions 1000 Revolutions
Specifications
6NY16L-HW 440 420
6NY16L-DW 470 455
6NY16L-UW 490 470
6NY16L-SW 510 500
6NY16L-EW 530 530

•Cleaning the Fuel Oil Filter

The fuel oil strainer is a manual back-washing, duplex changeover filter. It has notch wire elements.
During engine operation, the fuel oil passes through the elements on both sides.

• If the filter is very dirty and only one side is used, the pressure decreases and the engine rotation slows
down. Check the oil pressure while you do back-washing (blow-off) and disassembly and cleaning dur-
ing operation.
• In case of a blow-off or during disassembly, align the changeover handle with its positioning notch hole.

6-6
MAINTENANCE INSPECTION YANMAR &NYl&L·W

Back-washing (Blow-off)
Wash both sides of this filter, one at a time, and obey these instructions:
1 . Open the drain cock.
2. Hold the changeover handle in the LEFT (or RIGHT) BLOW-OFF position for 1 to 2 seconds.
Then return it to BOTH SIDES IN USE.
3. Repeat step 2 for three or four times.
4. Close the drain cock.

Figure 6-2 How to Clean the Fuel Oil Filter

IBOTH SIDES IN USE I Air Vent Cock

Changeover Lever

LEFT BLOW-OFF

Packing

Notch hole 014463-00B

Disassembly and Cleaning

When you disassemble the filter during engine operation, do so one side at a time and obey the following
instructions.
1. Move the changeover handle to LEFT (or RIGHT) DISASSEMBLY.
2. Open the air vent cock.
3. Open the drain cock and drain the fuel oil.
4. Remove the element and clean it.

IWJ "Cleaning the Element" on page 6-9

Installing
Install the filter element in the reverse sequence of disassembly. Obey these instructions:

• When you shift the switch cock to BOTH SIDES IN USE, move it slowly. If you do it quickly, the oil pres-
sure can decrease until the filter is filled with fuel oil.
• Open the air vent cock and release the air.

6-7
MAINTENANCE INSPECTION YANMAR &NYl&L-W

•Cleaning of the Lubricating Oil Filter

The lubricating oil strainer is a manual back-washing, duplex changeover filter. It has notch wire elements.
During engine operation, the fuel oil passes through the elements on both sides. A pressure switch
detects if the filter is clogged. It is on the outlet side of the filter (optional).
• When the difference between the oil pressure at the inlet and outlet of the filter reaches 0.2 MPa, the
differential pressure alarm operates .

. iL~:•.. ."~,·~~~~]}g,~~~;,~
Be careful of burns.The filter becomes hot during engine operation.

• If the pressure is not restored after a backwash cleaning, disassemble and clean the oil filter.
• If the filter is very dirty and only one side is used, the lubricating oil pressure drop alarm can sound.
Check the oil pressure while you do back-washing (blow-off) and disassembly and cleaning during
operation.

Figure 6-3 How to Clean the Lubricating OilFfilter

Changeover Cock

Air Vent Plug

~y~~~~~--·'RIGHTCHANGEI
(

0-ring

Element
Case
Center Bolt

Blow-off Pipe 014464-006

Back-washing (Blow-off)
Wash both sides of this filter, one at a time, and obey these instructions:
1. Move the red mark of the switch cock to LEFT (OR RIGHT) EXCHANGE on the engine name
plate.
"

2. Loosen the drain plug for 2 to 3 turns ..

3. Move the switch cock for 1 to 2 seconds to RIGHT (OR LEFT) SIDE BLOW-OFF.
4. Move the switch cock back to EXCHANGE.
5. Repeat steps 3 and 4 for three or four times.
6. Close the drain plug.
7. When you set the switch cock to NORMAL RUN, shift it slowly.

6-8
 MAINTENANCE INSPECTION YANMAR &NY16L-W

Disassembly and Cleaning

When you disassemble the filter during engine operation, do so one side at a time and obey the following
instructions.
1. Move the red mark of the switch cock to RIGHT (LEFT) EXCHANGE.
2. Loosen the drain plug.
3. Loosen the air vent plug.
4. Drain the lubricating oil from the case. Loosen the nut. Remove the blow-off pipe.
5. Loosen the centerbolt. Remove the case and the element.
6. Clean the element.

i.WJ "Cleaning the Element" on page 6-9

Installing
Install the filter element in the reverse sequence of disassembly. Obey these instructions:

(-\
\_j • Make. sure that you install the elements in the correct direction.
• Make sure that the 0-ring of the case does not get caught.
•When you set the switch cock to NORMAL RUN, shift it slowly. If shifted rapidly, the oil pressure can
decrease temporarily until the case fills with lubricating oil. This causes the lubricating oil pressure drop
alarm to operate.

• Cleaning the Element

Clean the notch wire elements of the lubricating oil filter or fuel oil filter and obey these instructions:

Figure 6-4 How to Clean the Notch Wire Elements

~i \ 8/60Pipe
~ Cock

1..Soak the elements in light oil or cleaning fluid. Remove all sludge from the front side of the
element with a wire brush.
2. Blow the element from the inside with compressed air. Use an air pressure of 0.3 to 0.5 MPa.
Refer to the figure.
3. Illuminate the element from the inside and check that you removed all dirt and unwanted material.
4. Check the surface of the notchwire for damage, broken wire and corrosion.

6-9
MAINTENANCE INSPECTION YAHMAR GNYIGL·W

• Adjusting the Lubricating Oil Pressure

If the lubricating oil pressure is not within the specified value, adjust it and obey these instructions:

• Clean the lubricating oil filter before you adjust the pressure.
• Run the engine. Wait for the lubricating oil temperature to stabilize. Adjust the pressure to the specified
value.

Figure 6-5 How to Adjust the Lubricating Oil Pressure

Lubricating Oil Pump

014465-00EOl

1. Remove the cap nut CD. Loosen the locknut@.

2. Screw the adjusting bolt @ in or out to adjust the pressure.
Clockwise (right): Increase pressure.
Counter-clockwise (left): Decrease pressure.
3. Tighten the locknut and cap nut securely.

6-10
MAINTENANCE INSPECTION YANMAR &NYl&L·W

•Cleaning the Lubricating Oil Bypass Filter

The lubricating oil system has a centrifugal bypass oil filter in addition to a notch wire oil filter.
During engine operation, keep open a cock at the outlet of the lubricating oil pump. This allows the lubri-
cating oil to flow through the filter regularly. If the bypass filter has a defect, close the cock and stop the oil
flow.

::;t:j\P}i''!l"~~I~~!?~i!l~N!.:
Stop the engine before you clean the bypass filter.
If you disassemble the bypass filter during engine operation, oil mist can come out and burn you.

Disassembly and Cleaning

Figure 6·6 How to Disassemble the Bypass Filter

Cover Cap Nut Nut Lock Nut

Rotary Cover

Spindle Shaft
0-ring

Rotor Body
0-ring
Insulator Assembly

Nozzle

014466-00B

Disassemble and clean the lubricating oll bypass filter and obey these instructions:
1. Loosen the cap nut. Remove the cover.
2. Loosen the nut and the locknut. Remove the rotor cover. Remove the insulator assembly and the
rotor body.
3. Remove the sludge inside the rotor with a spatula. Clean the inside.
• Completely remove all sludge ..Residue sludge can cause an unbalance in rotation. This results
in damage to the spindle bearing.
4. Clean the nozzle with a brass wire brush.
5. Inspect all parts and 0-rings. Replace them if you find damage or wear.

Assembling
Install the filter element in the reverse sequence of disassembly. Obey these instructions:
1. Tighten the nut and locknut. Make sure that the rotor moves smoothly. Install the cover. Tighten
the cap nut.
2. Operate the filter and make sure that there are no oil leaks from the coupling parts.
Also make sure that there are no unusual vibrations.

6-11
MAINTENANCE INSPECTION YANMAR 6NY16L-W

• Lu~ricating Oil Filter of the Fuel Injection Pump

Turn the handle of the lubricating oil filter (auto-cleaner) of the injection pump at least once a day. Disas-
semble and clean it every 250 hours.

Figure 6-7 Lubricating Oil Filter of the Fuel Injection Pump

Handle Air Vent Plunge

Element
(Wash it after removing the fouling
by turning the handle)

}
/

Drain Plug 020408-00E:

If the oil signal of the lubricating oil filter o the fuel injection pump turns red, the oil supply is low. Check
the oil amount, fill oil and inspect the filter.

6-12
MAINTENANCE INSPECTION YAN MAR GNYIGL-W

• Lubricating Oil Pump of the Fuel Injection Pump

The fuel injection pump lubricating oil system is indicated in Figure 6-8.

Figure 6-8 Fuel Injection Pumpllubricating Oil System

Fuel Oil Injection Pump

Return Pipe ii t

Oil Signal

Lube Oil Strainer

020525-00E

Figure 6-9 Lubricating Oil Pump

Plug

Intake Valve

Piston Oil Seal 020526-00E

Handling
1. At initial operation or after a lubricating oil change, push the manual. lubricating oil priming pump
several times. When the suction pipe is filled with lubricating oil, start the engine and check that
the oil signal operates. (If the lubricating oil circulates during operation, the oil signal is green.)
2. lfthe circulation of the lubricating oil is not good, check the intake valve, delivery valve and spring
for damage. Replace any damaged part.
3. Do an overhaul approximately once every year.

6-13
MAINTENANCE INSPECTION YANMAR &NY1&L-W

• Checking the Fuel Injection Valve and Adjusting the Injection Pressure
lncorre.ct servicing of the fuel injection valve greatly affects the combustion and output. It is difficult to
specify the servicing interval, because it depends on the fuel oil and service load. Examine the change of
exhaust temperature and exhaust color and schedule the servicing interval accordingly.

Removing the Fuel Injection Valve

Use the following special tools.

No. Special Tool Part No.

CD Body of the fuel injection valve drawing-out tool 152623-92171
@ Drawing-out bolt 138613"92181
@ Nut 26706-100002

Figure 6-10 How to Remove the Fuel Valve

Double walled Pipe Retainer

(8)
[Injection Valve side]

(D)

~)
[Injection Pump side]

Fuel Injection Valve

(A) Fuel lnjecton Valve Guard

(B) Spherical Washer
(C)·lnjecton Pipe Joint
(D) Double walled Pipe Retainer

Nozzle Mounting Nut Packing

014467-01600

1 . Remove the fuel injection pipe.

When you remove the covered injection pipe , loosen the pipe retainer and then loosen the
injection pipe joint and the cap nut.
·2. Remove the fuel valve bridge.
3. Install the removal·tool <D and screw the removal bolt (~}into the cap nut.
4. Tighten the nut @ and remove the fuel injection valve.
5. Remove the packing of the nozzle tightening nut. (It can come out together with the fuel injection
valve.)

6-14
 MAINTENANCE INSPECTION YAHMAR &NYl&L·W

Installing the Fuel Injection Valve

After cleaning, inspection or replacement of the fuel valve and adjustment of the fuel injection pressure,
install the fuel injection valve. Obey these instructions:

• Replace the nozzle tightening nut packing with a new one.

• Make sure that you install the spheric washer in the correct direction.

Disassembling and Cleaning the Fuel Injection Valve

1. Remove carbon from the outside of the nozzle. Disassemble it in the sequence shown in the
figure. (Soak the valve in carbon remover or Cresol stock solution to make cleaning easier.)

Figure 6-11 How to Disassemble the Fuel Injection Valve

I
\

@
Body of Fuel Injection valve

®
(J)

®
@

014828-00E

2. Inspection and servicing of all parts

•Check for sulfuric acid corrosion on the outer circumference of the nozzle@. If it has a lot of
corrosion, replace the nozzle with a new one.
•If the nozzle valve is stuck or if it does not move easily, replace it with a new one.
•When the stepped wear "A" of the valve stop spacer® is more than 0.15 mm, replace it with a
new one.
•~eplace the 0-rings of the fuel injection valve with new ones.
•The average service life of the nozzle is about 2,500 hours. We recommend that you have a
spare nozzle in stock.
3. Reassemble the cooling water pipe assembly in the sequence reverse to disassembly and obey
these instructions:

• Make sure that you install the spring seat ® and spring retainer ® in the correct direction.
• Tighten the nozzle tightening nut to the specified torque with the special socket (133614-92200)
and a torque wrench.
If you tighten it too much, the nozzle can malfunction or the straight pin can break.
Tightening torque: 157 to 177 N·m

6-15
MAINTENANCE INSPECTION YANMAR &NY16L·W

Injection Test and Adjusting the Injection Pressure

• When you operate the nozzle tester, make sure that you do not get in contact with spray from
the injector. The very high injection pressure will cause injury.
• Make sure that fuel injection valve points down.

Figure 6-12 How to Do an Injection Test and Adjust Injection Pressure

Pressure Regulating Screw

Lock Nut

\j

Nozzle Testre

1. Install the fuel injection valve to the nozzle tester.

2. Set the nozzle tester to the specified injection pressure. To do so, slowly operate the hand lever of
the nozzle tester and tum the pressure adjusting screw.
Specified injection pressure: 27.4 ± 0.5 MPa
If you operate the hand lever of the tester slowly, fuel oil can leak. Do not think that the nozzle is
defective.
3. Quickly operate the hand lever of the tester (at rate of two to three strokes per second) and
examine the spray.
Replace the nozzle with a new one if it is clogged or if it injects in streaks even if you move the
handle bar quickly.
4. Check if the seat is oiltight: Apply a pressure of 1.96 MPa lower than the specified injection
pressure for 2 to 3 seconds. If the fuel oil comes out from the nozzle tip only a little bit, the nozzle
can be used again.

When you replace the nozzle, loosen the pressure adjusting screw. Remove the nozzle tightening
nut. Do not loosen the nozzle tightening nut under high injection pressure. It can cause damage to
the straight pin and to the mating surfaces of the nozzle and the spacer.

5.After you complete the injection test and adjust the injection pressure, tighten the pressure
adjusting screw with a locknut, so that it does not tum together with the screw.

6-16
 MAINTENANCE INSPECTION YANMAR 6NY16L-W

• Turbocharger Blower Cleaning (Fill Water)

When the blower of the turbocharger is dirty, the exhaust temperature increases. This shortens the ser-
vice life of the fuel injection valves and exhaust valves. The effectiveness of the compressor decreases, if
you clean it too late. Record the boost air pressure before and after a cleaning. Schedule regular cleaning
intervals according to these records.

• Clean the compressor during a run of about 75 % load or more. After you clean it, continue the load run
for 1 hour or more.
• If the boost air pressure does not improve after you clean the compressor, disassemble and clean it.
• Use cleaning fluid (137616-18400). Cleaning with only water has no effect.

Figure 6-13 How to Clean the Turbocharger Blower

( \
Washing Hose Hand Pump
\
' -

Turbochager Blower
Water Filling Port

014469-00E

1. Open the drain cock of the boost air chamber.

2. Fill cleaning fluid (0.15 Q) into a hand pump.
3. Connect the cleaning hose to the filler of the turbocharger. Fill in about 4 to 10 seconds.
( 4.Add the same amount of freshwater in the same way.
5. Repeat steps 2 to 4 three or four times.
6. If the boost air pressure does not improve, wait 1O minutes and repeat the cleaning.
7. Close the drain cock after the cleaning.

6-17
MAINTENANCE INSPECTION YANMAR GNYIGL·W

• lnspe~tion and Replacing the Anti-corrosive Zinc (Zinc Anode)

The charge air cooler and freshwater cooler have zinc anodes. Check them and obey these instructions:

Tble 6-4 Installation Locations

Cooling water in/outlet cover (2)

Air cooler
Water return cover (2)
Cooling water in/outlet cover (4)
Freshwater cooler
Water return cover (2)

• If the zinc anode is worn to 30 % of its original dimensions, replace it with a new one.
Zinc anode dimensions (new part) 0D x L =40 x 40 (mm)
• If you decide not to replace the zinc anode, remove the oxide layer until the metal surface is fully
visible.

Figure 6-14 Installing the Anti-corrosive Zinc (Zinc Anode)

CITJ j
/Flange

=----
rrr;::..,l'l......;::~1,..,,Ir

~ Anti-oo"o'''" Zloo
Packing

014470-00E

After you check and replace a zinc anode, check that there is no water leakage.

6-18
MAINTENANCE INSPECTION YAN MAR 6NY16L·W

• Inspection of the Thermostats for the Cylinder Jacket Cooling Water

The freshwater cooler has an automatic thermostat. It increases the temperature of the cooling water in
the cylinder jacket for a short time after engine start. It maintains the temperature within the correct range
during operation.
The cooling water temperature varies according to the load conditions and the cooling water temperature
(seawater temperature) at the freshwater cooler inlet. If the seawater temperature is 32 °C, the tempera-
ture at engine outlet is set to 70 °C to 80 °C. If the cooling water temperature is not stable, do an overhaul
of the thermostat according to the following instructions.

Removing the Thermostat Elements

1. Close all valves at the inlet and outlet of the cooling water system.· Drain the cooling water from
the freshwater cooler.
2. Remove the element from the thermostat case.

Figure 6-15 How to Remove the Thermostat

Thermostatic Valve Case

Thermostatic Valve Element Fresh Water Cooler

014471-00E

Checking the Thermostat Elements

There are 4 elements. Check the elements and obey these instructions:
1. Check for cracks in the valve, breakage of the spring and bite-in of unwanted material on the
valve seat surface.
2. Soak the elements in cold water and hot water for 2 to 3 minutes each. Measure the valve lift (A).

Figure 6-16 How to Check the Elements

l In Cold water l In hot water

®
®

014472-00E

6-19
MAINTENANCE INSPECTION YANMA'R GNYIGL·W

Tble 6-5 Valve Lift of the Elements (Normal Pa'rt)

Water temperature when

Lift A
checking
Cooling water: < 30 °C 33mm
Hot water: 95 °C to 100 °C 44 mm or more

3. If the valve lift is different from the table, replace the element with a new one.

• Maintenance of the Pressure Gauges

The pressure gauges on the instrument panel are filled with a glycerol-water solution. This prevents wear
of the gear and link mechanism inside the gauge.
Obey the below instructions when you handle the pressure gauge.
1.. Make sure that the rubber cap of the pressure gauge points up when you remove the gauge panel
or the pressure gauge for servicing.
(If you hold the gauge sideways, the sealing liquid will leak from the air hole in the rubber cap.)
2. Always maintain the specified level of the sealing liquid.

Figure 6-17 Level of the Sealing Liquid for the Pressure Gauge

Maximum liquid level @=18mm

Higher liquid level @=25-26mm
014473·00E

3. If the sealirig liquid becomes contaminated, change the sealing liquid. If the level of the sealing
liquid decreases, refill the pressure gauge with sealing liquid. (Sealing liquid (part number 42111-
002800) is sold separately). \
4. When you replace.the pressure gauge with a new one, cut the navel of the rubber cap to open a
vent hole. (The gauge cannot operate correctly without an air hole.)

Adjusting the Pressure Take-off Main Valve

Check the opening of the needle valve at the piping of the pressure transmitter or pressure gauge. Adjust
it if necessary. Surging (pulsation) causes damage and malfunction of the pressure gauge and pressure
transmitter.
•Fuel pressure main valve: Open 1/4 turn from the fully closed position.
•Other pressure valves: Open 1 turn from the fully closed position.

6-20
 MAINTENANCE INSPECTION YAHMAR 6NY16L·W

• Adjusting the Pressure Transmitter

The device has a pressure transmitter to indicate the pressure remotely. If you need to make adjustments
on the remote side, obey these instructions.

How to Adjust
1. Remove the top cover from the pressure transmitter.
2. Turn the ZERO or SPAN adjust screw with a small screwdriver (2 mm). Apply light pressure to the
screw.
• If you turn the screw clockwise (to the right}, the indicator moves in the direction of the arrow in
the figure.

Figure 6-18 How to Adjust the Pressure Transmitter

Screwdriver
Top Cover

(~)

Pressure Transmitter

111111111

Connector

IZERO adjustment I I SPAN adjustment I

mA mA

r>
\ ___ J
20 20
Current Current

4 4
0 Po' P P' kgf/cm2 0 P' P kgf/cm2
Pressure Pressure
014474·008

6-21
MAINTENANCE INSPECTION · 'YANMAR 6NY1&L·-w

• Adjusting the Clearance of the Intake/Exhaust Valve Heads

The valve mechanism can operate 2 intake or exhaust valves at the same time through a T-shaped valve
bridge. It is necessary to adjust the valve head clearance to avoid problems with the valve bridge (such
as unusual wear on the valve bridge guide and the valve guide). Obey these instructions when you adjust
the valve head clearance:
• The valve head clearance of an intake valve and an exhaust valve are different. Make sure that you
use the correct clearance.
Intake valve: 0.3 mm
Exhaust valve: 0.4 mm

Figure 6·19 How to Adjust the Valve Head Clearance

CD
®'---.. . .~~~==T9""'-J

Decamp.Shaft 014475-00E

1. Align the decompression shaft of the cylinder head to DE COMP.

Alternatively, open the pressure indicator cock (optional).
2. Turn the flywheel and move the relevant cylinder to top dead center of the compression stroke.

Do not mistake this position with the top dead center of the overlap stroke.

3. Loosen the lock nuts @ and ©. Loosen the adjust screw of the rocker arm <D and the adjust
screw of the valve bridge @.
4. Press down the center of the valve bridge.
(In this position, the clearance (A) is 0.)
5. Tighten the adjust screw of the valve bridge so that the clearance (8) becomes 0. After you adjust
the clearance, lock the adjust screw@ so that it does not turn. Securely tighten the lock nut©.
6. Insert a feeler gauge into the clearance between the rocker arm and the valve bridge. Tighten the
adjust screw of the rocker arm CD, but make sure that you can pull out the feeler gauge easily.
Then tighten the locknut @ and lock the adjust screw 1.
?.After you tighten the locknut@, check again that you can pull out the feeler gauge easily.

6-22
MAINTENANCE INSPECTION YAN MAR 6NY16L·W

• Adjusting the Fuel Injection Timing

The fuel injection pump is set to the fuel injection timing match mark of cylinder no. 6.

Figure 6-20 How to Adjust the Fuel Injection Timing

Drive Shaft Joint

Flywheel TOP Mark

/ 014476-008

1. Slowly turn the flywheel in the turning direction. Align the match marks of the camshaft bearing of
the fuel injection pump and the intermediate power take-off shaft coupling.
2. Loosen the clamping bolt of the power take-off shaft coupling .
3. Align the TOP mark of cylinder no. 6 of the flywheel to the scale of the flywheel angle label
(specified injection timing).
4. Tighten the bolt of the power take-off shaft coupling.

6-23
'MAINTENANCE INSPECTION YANMAR 6NY16L·W

•Adjusting the Exhaust Gas Temperature (Fuel Injection Volume)

• If the difference in exhaust temperatures between the cylinders is more than 50 °C (and you serviced
the fuel injection valve}, adjust it with the barrel support of the fuel injection pump.
• Stop the engine before you adjust the fuel injection volume.
• The distance between the match mark of the barrel support and the match mark on the pump body
must be fess than ±5°.

When you remove the covered injection pipe , loosen the pipe retainer and then loosen the injection pipe
joint and the cap nut.

j 1njection Valve Side I I Injection Pump Side I

Double Walled
Pipe Retainer
Double Walled Injection Pipe Joint
Pipe Retainer

014477-00E
014478-00E

Figure 6-21 How to Adjust·the Exhaust Temperature (Fuel Injection Volume)

Barrel Support

Set Mark
Decreasing ~../'·
!~
014479-00E

1. Loosen the barrel support tightening nut for 1 tum.

2. Move the match mark of the barrel support.
Tum right: Increase the injection amount (exhaust temperature increases)
Tum left: Decrease the injection amount (exhaust temperature decreases)
3. Tighten the .tightening nut.

6-24
MAINTENANCE INSPECTION YAHMAR 6NY16L·W

• Measuring the Crankshaft Deflection

Measure the deflection of the crankshaft (the opening and closing of the crank arm) to find wear of the
main bearings.
Measure the deflection at regular intervals. If the crankshaft deflection becomes unusually large, the
crankshaft can break.

• Measure the crankshaft defection when the engine is cold.

• Measure the crankshaft deflection every time you remove or tighten:
• The engine installation (anchor) bolts
• The common bed clamp bolts
• The clamp bolts of driven equipment (such as a generator).
• Move the contact of the deflection gauge. Make sure that the needle of the dial gauge returns to the
original position.

How to Measure Deflection

• You cannot measure cylinders no. 2 and no. 5.
1. Align the decompression shaft of all cylinder heads to DE COMP.
2. Turn the flywheel to 30 degrees after bottom dead center. This is the EB position.
3. Install the deflection gauge and set the needle of the dial gauge to O (zero).
Figure 6·22 Installation Locations for the Deflection Gauge

D .--
D/2'

Deflection Gauge

=
D Crankjoumal diameter: 135mm
L = Crank arms width : 69mm 014480-00E

4. Slowly turn the flywheel in the direction of engine rotation. Record the readings of the dial gauge
at the crankpin positions E, T, P and PB.

Figure 6-23 Deflection Measurement Locations

EB : 30° after B.D.C (measuring reference)

E : go· before T.D.C
T : T.D.C
Calculating crankshaft deflection
P : go• after T.D.C • Vertical deflection =T-EB
P B : 30° before s.o.c· or T-PB
• Horizontal deflection = P-E

Crank Pin Position 014481-00E

6-25
MAINTENANCE INSPECTION YANMAR 6NY16L-W

Analyzing the Results of the Deflection Measurement

Measure the vertical deflection by calculating the difference between T and PB or EB. The horizontal
deflection is calculated by the difference between P and E.
The relation between the deflection readings at each crankpin position and the open and closed positions
of the crank arms are defined below.

Reading of the Dial Gauge + -

Crankshaft ~ ~ 017780-00X 017781-00X

(bottom opened) (bottom closed)

• If the deflection increases every time it is measured; the crankshaft or the main bearings are probably
worn. If the deflection increases suddenly in only one cylinder, the corresponding main bearing proba-
bly has unusual wear. In these cases, check the relevant parts.
• If the deflection is measured when the engine is hot, the results will vary largely depending on the
engine temperature at the time of the measurement. The measurement is not reliable.
According to our test results, that deflection is roughly 2/10,000 to 3/10,000 x stroke (bottom closed).

Permitted Value of the Deflection

The permitted value of deflection varies with the coupling method of the driven equipment.
The permitted values for each coupling method is shown in the table on the next page.

• For direct couplings on generators with single-sided bearings, deflection occurs depending on the
mass of the flywheel and generator. Therefore a "bottom-closed" deflection at the measuring position T
is normal.
• For direct couplings on generators with bearings on both sides, the temperature of the engine shaft
bearings increases more than the temperature of the generator shaft bearings during operation. The
crankshaft center rises. Therefore, change the deflection at the measuring position T to "bottom-
opened".
• If a radiator is attached, adjust the tension of the V-belt and then measure the deflection.
• If a' flexible coupling is used, adjust the face deflection of the coupling on the flywheel and driven equip-
ment side. Then measure the deflection.

How to Correct the Deflection

If the crankshaft deflection is more than permitted, repair the deflection. Consider the installation shims
and the center of the crankshaft of the engine and driven machines (or outer bearings).

6-26
 MAINTENANCE INSPECTION YANMAR 6NY16L·W

Tble 6-6 Permitted Value of the Deflection

Unit: 1/100 mm (''S" stands for stroke)

Coupling Driven Calculation

No.1 cyl. No. 3, 4, 6 cyl.
Method Machine Method

Mounting Generator
(T-PB, T-EB) ± 2.0
flange (bearings on
both sides)
(P-E) (± 1/10,000). s
direct coupling

-4.0 to +2.0
Generator (T-PB, T-EB)
Single-layer (-1/5,000 to +1/10,000) • S
(bearing on
method (A) ± 2.0
one side) (P-E)
(± 1/10,000). s
-8.0 to +2.0 ± 2.0
Multi-layer (T-PB, T-EB)
method
Generator (-1/2,500 to +1/10,000) • S (± 1/10,000). s
(bearing on
(laminate) ± 3.0
one side) (P-E)
(B) (± 1.5/10,000). s

Generator -6.7 to +2.0

(T-PB, T-EB)
(bearings on (-1/3,000 to +1/10,000) • S
Flexible cou-
both sides)
piing (C) ± 3.0
Normal (P-E)
implement (± 1.5/10,000). s

(~)

Coupling

~-
(A) ( B) ( C)
a a
a) Flywheel
b) Single plate
c) Laminate
d) Flexible coupling a e

~
e) Clutch

014S62·00E

6-27
MAINTENANCE INSPECTION YANMAR &NYl&L·W
I
• Maximum Combustion Pressure (Pmax) Measurement
The indicator cock and pressure indicator are optional.

Put on gloves when you take a measurement. The pressure indicator is hot.

Use the following special tools.

Special Tool Part No.

Pressure indicator 14 7673-93753

Figure 6-24 How to Measure the Pmax

Pressure Indicator

Exhaust Valve

I Pressure Indicator Cock I OH482-00E

1. Open the pressure indicator cock and lightly rev the engine 2 or 3 times.
(This prevents dirt and unwanted material from collecting in the pressure indicator.)
2. Install the pressure indicator. Close the exhaust valve of the pressure indicator.
3. Make sure that you fully open the pressure indicator cock. Close the indicator cock when the
pressure is at the maximum.
4. After you read the Pm ax, open the exhaust valve of the pressure indicator.
5. Remove the pressure indicator when the needle shows 0 MPa.
(If you cannot loosen the pressure indicator easily, use the turning handle.)

6-28
 MAINTENANCE YAN MAR 6NY16L-W

MAINTENANCE

• Before you do servicing or an inspection of the engine, thoroughly read this Operation Manual to
understand the structure of the relevant parts and the nature of your task. Obey all instructions. If you
do not obey all instructions, you waste your work time and you can cause accidents or engine damage.
• Replace all parts that are damaged or that reached their usage limit. Also replace all parts that reach
their usage limit before the next inspection.
• If you cannot solve or repair a problem on site, or if you do not have the necessary part in storage, con-
sult us or your nearest sales or service agent. (Refer to the service network list "YAN MAR Worldwide
Service" in the appendix of this manual.)

Maintenance Precautions
• Safety Precautions
Please read these precautions to operate the engine safely.

W "FOR YOUR SAFETY" on page 0-1

• Stop the engine before you disassemble it or do an inspection. If it runs, you can get caught and seriously hurt.
Before you start your task:
• Move the start and stop handle to STOP.
• Close the valves of the starting air system.
• Make sure that the engine does not rotate. Move the select switch of the operating station to ENGINE.
• Before you turn the engine (flywheel):
•Always give a sign that you will turn the engine.
• Make sure that the rotation of the engine is not dangerous for you, your coworkers or other
persons around the engine.
· • Make sure that you do not touch any rotating parts.
• Before you do work on an electric part, make sure that you turn off the power switch. Otherwise you
can cause electric shock or fire;
• When you weld or grind, sparks can cause a fire. Do not store combustible materials (e.g. the fuel oil,
lubricating oil and waste cloth) at the work site.
r--~\ • When you use a liquid, strictly obey these instructions.
~~
1
· • Fuel oil and lubricating oil: Flammable (fire not permitted)

• Freshwate'r rust inhibitor and freshwater anti-freezing fluid: Toxic (do not drink)
When you work with it, put on rubber gloves and a mask. Make sure that it does not touch your
skin. When you touch it, clean the exposed area. When you discharge it, obey the instruction
manual of the manufacturer when you dispose of it.
• Mercury (thermometer): Toxic (do not drink) When you touch it, clean the exposed area.
• Put on the correct protective gear for your task (e.g. gloves, helmet, safety shoes and safety goggles).
• The whole engine is very hot during operation and after engine stop. Put on gloves to prevent bum injury.
• The floor of the engine room and the engine is slippery with oil. Watch your step, especially
when you work at a height (e.g: step board).
• When you disassemble a filter or a piping joint immediately after engine stop, the residual pressure can
cause hot oil or water to come out. Close all valves that connect to the outside. Gradually loosen the air
vent plug and release the internal pressure. Then hold the part with a cloth and disassemble il
• When you disassemble a valve or a device that has a spring, the spring can suddenly come out. Be careful.
• Do not try to lift heavy items by hand. Lift them with a chain block. Do not enter the area below the lifting load.
For the weight of major parts, refer to the relevant chapter.

W "PRINCIPAL DIMENSIONS & MASS FOR DISASSEMBLY & SERVICING" on page 8-1
• Use the correct tools. Make sure that you understand how to operate the special tools before you use them.

7-1 (44 pages)

MAINTENANCE YANMAR &NYl&L-W

• Pr~cautions when Disassembling, Servicing & Reassembling

• Prepare the necessary tools and spare parts in advance.

Use the specified special tools. Use only genuine YANMAR parts or parts that are specified by YAN-
MAR.
• Replace all parts that are qamaged 9r t.hat reac.hed their usage limit. Al,so '!!Pia~~ all par:ts. that reach
' ,,, ' , , .

their usage limit before the next inspection.

W "CLEARANCE AND WEAR LIMITS OF MAJOR PARTS" on page 10-1

• Put a cover (e.g. tape or clean cloth) on all openings to prevent unwanted material from entering.
Do not forget to remove the tape or cloth when you reassemble the part.
• When you disassemble jointed parts, make sure that the parts have a match mark. If not, make a
match mark.
• Major bolts are stamped at the factory with match marks that align with the cylinder number and bear-
ing number to indicate the installation location. But do not rely on these match marks. They can
change during operation because the tightening surface can become thinner and the bolts can become
longer. When you tighten these parts, disregard the match mark and tighten them with the specified
tightening torque and angle.

W "TIGHTENING TORQUES FOR BOLTS AND NUTS" on page 9-1

If you replace a major bolt, make the same mark on the new one.
• The bolts and nuts that are used in hot areas of the engine are made of a special material. If you reas-
semble the wrong bolts and nuts, they will be difficult to' remove at the next servicing.
• Check all parts of the engine and especially. bolts and nuts that you cannot see during operation, for
looseness. If a part is loose, find the cause, fix the problem .and tighten the part.

• Precautions after Servicing

• Check all parts of the engine for defects when you turn the flywheel or do a.priming of the lubricating
oil.
• Put back the covers for rotating parts, the heat-shielding cover for the exhaust pipe and other
protection covers for hot areas of the engine.

• Put the turning bar back to its specified location.

• Make a record in the engine log of the servicing and replaced parts.

7-2
 MAINTENANCE YANMAR GNYIGL·W

Cylinder Head and Accessories

Carbon can collect on the surface of the cylinder head that is exposed to combustion gas. This has a
negative effect on combustion. If scale collects in the cooling water passages, this has a negative effect
on cooling. Disassemble and clean these parts at regular intervals.

• Cylinder Head

How to Disassemble
1. Remove the bonnet, support of the rocker arm shaft, intake/exhaust valve bridge and push rod.
Do not forget pipes at locations that are difficult to see.
2. Remove the fuel injection pipe and fuel injection valve.

m "Checking the Fuel Injection Valve and Adjusting the Injection Pressure" on page 6-14

3. Remove the intake/exhaust valve rocker arm.

4. Remove the exhaust manifold.
If you do not disassemble the engine completely, remove the cylinder bolts only as needed.
5. Remove the push rod.
6. Remove the exhaust thermometer.
7. Loosen and remove the cylinder head tightening nuts.
8. Remove the cylinder head. (see the figure for lifting tools)

Figure 7-1

t
- - - i - - Cyl.Head
Lifting Tool

('
\
"--" /

014502-00E

7-3
MAINTENANCE YANMAR &NYl&L·W

Important Points for Overhaul and Assembly

1. Check for carbon buildup in the combustion chamber and the intake/exhaust ports. (Schedule
subsequent servicing depending on the amount of carbon buildup.) After cleaning, carefully
check for cracks.
2. Check the water jacket for scale. Clean with a descaling agent if necessary. Clean the water
jacket at least one time in 2 years. A lot of scale can collect depending on the water quality, even
on a freshwater cooler.
3. If the fitting surface of the cylinder head is damaged, blow-by can occur during operation. Check
these parts very carefully.
4. If you use a head gasket of the initial dimensions, the standard top clearance is the same and
adjustment is not necessary.
5. After you clean all parts, it is necessary to carefully lean holes. But completely cover all such parts
to prevent dirt from entering and clogging.
6. After you remove the nozzle sleeve, replace the barrel packing and 0-rings with new, genuine
parts. Apply a screw lock agent to the threads. Tighten to a torque of 235 N·m.

Figure 7-2

0-ring

Copper packing

Thread part
014503-00E

7. When you install the cylinder head, apply Protec grease to the tightening nut threads and bearing
surfaces.

W "How to Tighten the Cylinder Head Tightening Nuts" on page 9-4

7-4
 MAINTENANCE YAHMAR GNYIGL-W

• How to Remove and Install the Intake/Exhaust Valve Guide, Exhaust Valve and
Valve Rotator

How to Disassemble
1. Install the valve spring detaching/attaching tool to the cylinder heads as indicated in the figure.
2. Press the handle of the detaching/attaching tool into the direction of the arrow in the figure.
Remove the cotter (detent).
When you disassemble the valve spring or the valve rotator with the cylinder head installed, set
the piston of that cylinder to top dead center. Perform the above steps 1 and 2.

Figure 7.3 How to Remove and Install the Intake/Exhaust Valve Spring

Suc./Exh. Valve Spring

Detaching/Attaching
Tool

014505-00E

Important Considerations for Overhaul and Assembly

1. When you remove the valve spring, check the valve spring for cracks and corrosion.
2. There are 2 cotters on every intake/exhaust valve. When re-assembling, install them together to
the same valve. If you install different cotter keys, bad contact can cause damage to the valve
stem.
3. When you remove the valve rotator, disassemble the rotator and inspect the inside.
How to distinguish intake valves and exhaust valves: The valves have a symbol on the bottom
.. '1 side .

Figure 7-4

0
=1120° for suction valve
90° for exhaust valve

I
Stamp S for suction valve
E for exhaust valve
014506-00E

7.5
MAINTENANCE YANMAR &NY1&L-W

Handling the Stem Seal

When Assembling
1. When assembling, make sure that you apply lubricating oil to the seal lip, valve stem and inner
diameter of the valve guide.
2. Obey these instructions when you install the stem seal to prevent damage to the stem seal lip.
1- Do not apply too much force to the lip when you tap the seal into the valve guide.
2- To move the valve shaft through the seal, momentarily remove the coil spring and install it
again.
When Disassembling
Remove the coil spring of the stem seal. Then remove the valve shaft.

Grinding the Intake/Exhaust Valve

1. Do the first valve grinding early. Examine the state of the valve and schedule the servicing
(~
' '
accordingly. \~j

!WJ "Periodical Inspections" on page 6-2

2. Before grinding, check the wear on the valve guide and the clearance of the valve stem. Refer to
table "CLEARANCE AND WEAR LIMITS OF MAJOR PARTS" on page 10-1 and replace parts as
necessary.
3. The contact face of the valve seat (seat ring) has a stellite welding. When you correct a deep flaw,
grind the valve seat with a seat cutter (with grinder) for rough corrections. (The seat cutter is
available as an option.)
4. Measure the dimensions of the. valve seat and the seat ring. If the seat wear is more than the
wear limit indicated in Chapter 10, replace the valve seat with a new one.
Carefully check the valve head tip. If it becomes too thin, it can be damaged and pieces cause
secondary damage in the combustion chamber and the turbocharger. Adjust the valve head tip if
necessary.
5.Apply the correct quantity of grinding compound to the valve. Carefully grind the intake/exhaust
valve with the grinding tool. Do the last grind with oil. (=)
Figure 7-5 Figure 7-6 How to Correct the Intake/Exhaust Valve
Seat (Rough Correction)

Hold down

Electric Drill

Seat Cutter
(w/Grinder)

Weak Spring

014752-00E 014753-00E

7-6
 MAINTENANCE YANMAR 6NYl6L·W

How to Replace the Valve Guide and Valve Seat (Seat Ring)
Make sure that you do not cause damage to the insertion hole of the cylinder head. The valve guide and
valve seat are shrink-fitted.
If you apply liquid nitrogen, the insertion is easier.

Figure 7-7 How to Remove the Valve Guide Figure 7-8 How to Remove the Valve Seat

cP 21
If the entire circumference of
valve seat part is built up by arc
Valve Rod welding, the valve seat shrinks
due to welding distorison and
can be easily removed.

Valve Guide 014754-00E

( .
014755-00E

1 . Before inserting the seat ring, measure the outer diameter of the seat ring and the inner diameter
of the insertion hole. Check that the interference is between 0.047 mm and 0.085 mm.
2. If you use liquid nitrogen for the insertion of the valve guide and the valve seat, put the valve
guide or the valve seat into the liquid nitrogen. Just after defoaming, quickly take the parts out of
the liquid nitrogen and insert them. To make sure, you can lightly hit the parts after insertion to fit
them into the correct location.
If you cannot use liquid nitrogen: Fill approximately 1.5 liter of alcohol and 10 kg of dry ice (in 10
to 30 chunks) into a thermos bottle (with a stainless internal). Cover the parts in dry ice and cool
them for approximately 1 hour. Then, insert the cooled valve guide or valve seat.
3. To make sure that the seat ring is straight (and not inclined), cool it sufficiently and hit it lightly
with an old valve stem.

Figure 7-9 How to Insert the Seat Ring

Valve Seat Hammer

(Seat Ring) Worn-out Valve

014756-008

7-7
MAINTENANCE YAN MAR &NYl&L-W

Valve Bridge and Valve Bridge Guide

Check the valve bridge and valve bridge guide. Do the same check as for the guide of the intake/exhaust
valves. If necessary, replace them with new ones.
Too much clearance between the valve bridge and the valve bridge guide can cause them to fall when
operated. This can cause a defect and damage to the intake/exhaust cam due to uneven stress.

Valve Rotator (Intake/Exhaust)

If the valve rotator stops turning, valve blow-by can happen easier. If engine rotations becomes bad,
disassemble the machine and fix the problem as soon as possible. You can remove the valve rotator
without disassembling the cylinder head.

WJ "How to Remove and Install the Intake/Exhaust Valve Guide, Exhaust Valve and Valve
Rotator" on page 7-5

•Important Considerations for Overhaul and Assembly

1. Check the coil spring and Belleville spring for corrosion.
2. Check the groove, ball and Belleville spring for wear. \
Examine the ball in the groove and how much it sticks out. If it sticks out more than the wear
groove of the Belleville spring, you can continue to use it.
3. Replace parts that have corrosion or wear.
4. Install the ball and the spring in the direction of the mark.

Figure 7-10

Body

Ball
~~....-Belleville Spring

Spring Shoe
Circlip

'\
}
Pressure

7-8
 MAINTENANCE YANMAR &NYl&L·W

Air Starting Valve (Automatic)

If the air starting valve is stuck or if the valve is not air tight, air from the check valve or the distributor
valve can flow back and cause damage or a valve to get stuck. Check them carefully and grind if
necessary.
Do the check and grinding when you do the regular inspection of the intake/exhaust valve. When you
find a defect, you can remove a single air starting valve without disassembling the cylinder head.

•Important Considerations for Overhaul and Assembly

1. Disassemble the air starting valve in the order shown in the figure. Assemble it in the opposite
order.
2. When you install the air starting valve, replace the gaskets and the 0-rings with new ones.
3. The air starting valve has an inlet hole for the start air. Align it to the air hole of the cylinder head.
4. When you install the air starting valve, apply seizure inhibitor (Molykote) to the outer
circumference of the valve.
Figure 7-11 How to Disassemble the Air Starting Valve (Order)

/ "-,
~-1
\ I
,,

2-~
3-©
6--·~

1:j·~
11
12

Air Inlet Hole

014758-00E

Control Valve (Automatic)

Vibration of the piston and engine body can cause unusual wear. To prevent this, apply Maly paste (by
Sumico Lubricant Co., Ltd.) all around the sliding surfaces of the piston and the engine body.

Figure 7-12 Control Valve

From solenoid
valve piston & pump

' Piston Body Packing

Assemble after applying

Rockole paste (Sumi-ko lubricating additive)
014159-00E

7-9
MAINTENANCE YAN MAR &NYl&L·W

Piston and Connecting Rod

How often you remove and check the piston depends on the daily maintenance, especially the control of
lubric~ ting oil and load (i.e. overload and very low load). The supervisor must decide the correct
1

frequency.
Do the first overhaul as shown in Chapter 6. Examine the results of that inspection, the increase of blow-
by and the increase in lubricating oil consumption, and schedule the subsequent inspections accordingly.
When the consumption of lubricating oil becomes twice the initial value, disassemble and clean the piston
1

1
and re place the piston rings.

Figure 7-13

"a"

Approx.
1---+----+++--I~=-_.__ 80 mm

Box Spanner 014760-00EOl

Figure 7-14 How to Lift and Insert the Piston

Piston Inserting Tool

7-10
MAINTENANCE YANMAR &NYl&L·W

Removing the Piston

1. Remove the carbon from the combustion chamber on the top of the cylinder liner (marked "a" in
the figure).
2. Set the piston to 70° after top dead center. (The piston top will be 80 mm below the top face of the
liner.)

Lock the flywheel.

If you do not lock the flywheel carefully, the crankshaft can turn spontaneously due to
unbalance when you remove a piston. This is dangerous.

3. Loosen the 2 connecting rod bolts with a special box wrench (socket wrench). Completely remove
one of these bolts.
4. Remove the other bolt together with the connecting rod bolt and connecting rod cap.
5. Set the piston to 30° after top dead center. (The piston top will be 18 mm below the top face of the
liner.)
6. Install the piston lifting piece (eye bolt) to the piston head.
7. Remove the piston and connecting rod. Make sure that the connecting rod does not touch the
piston cooling nozzle.

Inserting the Piston and Important Considerations

1 . Set the piston to approximately 30° after top dead center. Lock the flywheel.
2. Then, insert the piston by obeying the steps for removal in opposite order, but obey the following
instructions.
1- Use the piston insertion tool.
2-Attach the piston rings so that their openings are staggered by 120° and 60°.
3- Tum the connecting rod so that the cap and opening of the large end faces the operation side.
4-Apply lubricating oil to the sliding parts of the ring and cylinder liner.
5-When you insert the piston, make sure that the large end of the connecting rod does not touch
the piston cooling nozzle at the bottom of the cylinder liner. Be careful that the end of the pis-
ton insertion tool does not get caught in the oil rings. Apply lubricating oil to the sliding surface
of the bearing. Make sure that there is no lubricating oil on the back of the bearing.

7-11
MAINTENANCE YAN MAR &NY1&L-W

• Piston and Piston Pin

Important Considerations when Disassembling and Assembling the Piston and

Connecting Rod
1 . Remove the piston pin circlip.
2. Soak the piston and the connecting rod together as an assembly in heated oil (approximately 80
°C). When they are heated and expanded, remov~ t~e pis~on pin. Now the ass~mbly is
disassembled into three parts: piston, piston pin and connecting rod. If the piston is already
heated, it is not necessary to heat it in an oil bath to remove the piston pin.
When you re-assemble, it is necessary to heat the parts again to prevent wear on the piston and piston pin.
3. To install and remove the piston rings and oil ring, make loops from wire. Use them to make the
ring openings wider.
4. The oil ring has a coil expander. Turn them so that the joint of the coil is 180° apart from the oil
ring opening (see the figure).
5. Check the cooling chamber on the back of the piston head for scale. If you find scale, remove it
thoroughly. For example, soak the part in cleaning oil and then blow it with compressed air.
6. When you measure the piston, do a color check for cracks in the piston head and the ring grooves.

Figure 7-15

Figure 7-16 How to Detach and Attach the Ring

..-ir-:'T-1-..+--Spreading Dimension:
About30 mm

IOil Ring I Ping Joint I Operation Side I

/ 2nd.Ring 3rd.Ring

1st.Ring Oil.Ring
INon-Operation Side I
014764-00E

7-12
MAINTENANCE YAN MAR GNYIGL·W

Figure 7-17 Parts for the Piston Color-check

Penetration test zoon

Figure 7-18 Disassemblign the Piston and Connecting Rod

Ring Stamp

1st ri TT
Inspection
Date Stamp 2nd J:::=J T2
3rdI) T3

Oil~
Piston

lOperating Side j

Set Mark

7-13
MAINTENANCE YANMAR- GNYIGL·W

Figure 7-19 Top View of the Cylinder Inside

I Non-Operation Side Cylinder Liner

Piston Cooling
Crank Shaft
Nozzle

IOperation Side I Crank Pin

014767-00E

7. When you install the connecting rod to the piston, make sure that you align the match mark. If
you replace the piston with a new one.• make the same match mark as on the old .piston.
8. When installing the piston ring, turn the rings so that the match marks point up.

Connecting Rod
• Inspection and Servicing
1. The mating surfaces of the cap on the large end of the connecting rod are serrated. When you do
a scheduled inspection, check the mating surfaces for wear due to cracks and loose bolts.
2. Check the mating parts of the small ·end of the connecting rod and the piston pin bearing for
looseness and cracks.
3. Measure the inner diameter of the piston pin bearing. If the measurement is more than the wear
limit (see Chapter 10), replace the piston pin bearing with a new one.
Press-fit the piston pin bearing. To remove the piston pin bearing, use a suitable metal piece and
hit it or push it out with a press.
After press-fitting the piston pin bearing, measure the inner diameter. Check that the. roundness is
within 0.02 mm.
If the roundness is larger, replace the piston pin bearing with a new one.
4. If water hammering occurs or the piston has a lot of seizure, measure the bend and inclination of
the connecting rod.

Figure 7-20 Connecting Rod

Evaluation Standards for Bending of the Connecting Rod

Pitch Between the Large and Small End: L = 350 mm ± 0.05 mm

7-14
MAINTENANCE YAHMAR &NY16L-W

Crank Pin Bearing

•Inspection and Servicing
1. Check the sliding surface of the crank pin bearing for cracks.
2. Install the crank pin bearing to the connecting rod. Tighten the connecting rod bolt to the match
mark. Measure the inner diameter of the bearing. If the inner diameter is more than the usage
limit, replace the bearing with a new one.
3. Measure the thickness of the top and bottom bearings. If the difference between a and b (as
shown in the figure) is 0.04 mm or more, replace the bearings.

Figure 7-21 Crank Pin Bearing

Approx.
40mm
Ila"

"b" 014769-00E

4. Make sure that you replace the top and bottom bearings as a pair. {The top and·bottom have
identical shapes.)
5. When you install a bearing, clean the back of the bearing. Install it wit_hout applying oiL
6. When you install a bearing, check that the mating part of the bearing pawl (the groove) has no
burrs and is correctly installed.

Connecting Rod Bolt

•Inspection and Servicing
1. Check for hit marks and plucking on the bearing surface of each bolt. Repair all defects.
2. Be sure to stamp a new match mark each time you disassemble a connecting rod. Each bolt is
stamped with a match mark when it leaves the factory. But the tightening torque of the bolt varies
depending on. break-in between the bolt thread, the bearing surface and serration on the large
end of the connecting rod.
3. Replace the connecting rod bolts with new ones approximately every 20,000 hours. If you find
seizure on the piston, replace the connecting rod bolts of that cylinder with new ones. A lot of
force can be exerted on the bolts.

• How to Make a Bolt Match Mark

W "TIGHTENING TORQUES FOR BOLTS AND NUTS" on page 9-1

• How to Tighten a Bolt

ilWJ "TIGHTENING TORQUES FOR BOLTS AND NUTS" on page 9-1

7-15
MAINTENANCE YANMAR &NYl&L·W

Cylinder Block and Cylinder Liner

Cylinder Block
It is not necessary to disassemble the cylinder block during scheduled inspection, unless you remove the
crankshaft. Nevertheless, check the inside of the jacket every 2 years.

•Important Considerations for Inspections

1. Clean the water jacket and water chamber for corrosion. Check the condition of the mating part of
the cylinder liner.
2. When you disassemble the cylinder block, make sure that you align the match mark of the timing
gear when you re-assemble.
3. Check if the cylinder head bolt tightening nuts are loose. Tighten them if necessary.
4. The stud torque for the cylinder head tightening bolt is 70 % of the tightening torque for the nuts.

Cylinder Liner
•Important Considerations for Inspections
1. Remove the liner at regular intervals and check it for corrosion. Cooling water can cause cavita-
tion on the cylinder liner jacket. This results in erosion from the outer surface of cylinder liner.
2. Measure the inner diameter of the liner at regular intervals. The amount of wear on the inner
surface depends on:
• The control of the lubricating oil
• The temperature of the cooling water
·The regular working load.
Make the measurement with the liner inside the cylinder block.

When you remove the liner, put the bottom part of the liner removal/insertion tool in a right angle to
the crankshaft. Make sure that it does not touch the piston cooling nozzle.

Figure 7-22 How to Remove the Cylinderlliner

Drawing-out ~ ' Insertion

Cyl.Liner
Drawing-ouU
Inserting Tool .

Spacer (for Drawing-out)

Lower Piece 014770-00E

7-16
 MAINTENANCE YAN MAR &NY1&L-W

• Important Considerations when Installing the Cylinder Liner

1. Clean the liner hole of the cylinder block.
2. Replace the liner packing with a new one. Stretch the rubber packings and check for cracks.
3. Apply anti-corrosive epoxy resin paint (SOC coat #402 by Dai Nippon Toryo Co., Ltd. or
equivalent) to the area B on the outer circumference of the liner.
4. Install a rubber packing to the liner. Make sure that there are no twists. Apply silicone oil to the
area C.
5. Align the match mark of the cylinder liner to the match mark of the cylinder block.
6. Install the liner rubber packing as shown on the figure below.

Figure 7-23 How to Apply Paint to the Cylinder Liner Figure 7-24 Installation Sequence for the Lliner
Rubber Packing

~~~=:;--0-ring

•Packing (black)

B Epoxy Resin Paint

(SOC COAT #402)
lo be coated once
by brushing (about I Packing (black)
40 µm thickness) •Packing (black~ b rk
lue ma
Packing (black) ·
C To be coated just 014772-00E
before insertion of
cyl.liner. (silicone oil)
0147'71-01£00

( '\

"'·· )

7-17
MAINTENANCE YANMAR. &NYl&L·W
'

Main Bearing and Crankshaft

Main Bearing and Oil Pan

•Inspection and Servicing
1. This engine has an oil pan. But it is possible that the cleaning does not reach all corners when
you clean it during regular oil changes. Remove the oil pan once every couple of years and clean
the inside.
2. If the paint on the inside is damaged, clean it with thinner, degrease and re-apply the paint.
3. If the crankshaft has unexpected seizure, check the dimensions of the main bearing hole of the
cylinder block.
Straightness: less than 0.03 mm per 1 meter length
Roundness: less then 0.02 mm
4. During overhaul inspections:
• Check the main bearing cap for knocking.
• Check the oil hole of the cylinder block for cracks.
5. Make sure that the clamping bolt of the main bearing cap is tight. If necessary, apply a screw lock
agent and tighten it.
The stud torque for the main bearing tightening bolt is 70 % of the tightening torque for the nuts.

Main Bearing and Thrust Bearing

• Inspection
1. Check the clearance between the main bearings and the crankshaft at regular intervals. If the
clearance is too large, a lot of lubricating oil escapes and the lubricating oil pressure decreases.
This causes damage and cracks.
2. Remove the main bearings. Check the sliding surface for cracks.
3. This is the correct method to measure the dimensions: Remove the crankshaft from the cylinder
block. Tighten the main bearing cap to the specified to"rque. Measure the inner diameter of the
bearing.
4. If the clearance is too large due to wear on the bearing, replace the bearing with a new one.
5. If you replace the bearing with a new one, but the clearance stays too large, use a genuine
)
undersized bearing (inner diameter}.
In that case, it is necessary to polish the crankshaft so that it fits the undersized bearings.
6. Measure the thickness of the main bearings. If the difference between a and b (as shown in the
figure} is 0.04 mm or more, replace the bearings.
7. Check the thrust bearings for wear and seizure. The thrust bearings are installed to the bearing
that is nearest to the flywheel.
. 8. When you replace the main bearings or thrust bearings, replace the top and bottom bearings m
as a pair.
Measure the clearance of the thrust bearing.

7-18
 -- ~--- ----------

MAINTENANCE YAN MAR &NY1&L-W

Figure 7-25 Main Bearings

Approx.
40mm
_Approx.
40mm
"a"
'
"b" 014773-00E

Figure 7-26 How to Measure the Clearance of the Thrust Bearing

N0.1
Main bearing

Thrust Metal

Dial Gauge

Push the crankarm

Magn'et bese
<D- __ ... ~e~ the dial gag~ to
indicate zero point.
-----@ Indicated valuve of dial
gage is thrust gap.
014774-0.0E

7-19
MAINTENANCE YANMAR &NY16L-W

How to Remove and Install Main Bearings

•Removing
1~. Loosen the tightening nuts of the main bearing cap bolt.
2. Loosen the side bolts of the main bearing caps. Every bearing has a side bolt.
3. Install the main bearing cap drawing-out tool to the clamping bolt.

Figure 7-27 How to Remove the Main Bearin,g Caps

Tool
\ -j

Main Bearing Cap

Side Bolt

B
Detaching/Attaching Tool 014775-00E

Do not remove the tightening nuts on both sides at the same time. The main bearing cap can
fall and cause injury.

4. Screw the drawing-out bolt D to the main bearing cap. Turn the nut C. Draw out the main bearing
cap until it is free.
5. Remove bolt B. Remove the main bearing cap and the main bearing together with the tool from
the engine.

7-20
MAINTENANCE YANMAR &NYl&L-W

• Removing the Top Main Bearings

1. Put the drawing-out tool into the oil hole of the crankshaft.
2. Slowly turn the flywheel counter-clockwise as seen from the flywheel side. Stop turning when the
top bearing is completely out the housing. Remove the bearing.

Figure 7-28 How to Remove the Top Bearing

Oil Hole

Drawing-out
Tool

014716-00E

How to Make a Nut Match Mark

When you replace a bearing or a tightening nut or during disassembly, make sure that you apply a new
match mark. The bolts have a factory match mark, but the tightening force of a-bolt changes after it is
tightened to a seat.

Make a match mark on each nut with the main bearings not installed. Obey the below instructions.
1. Apply lubricating oil to the bolt. Apply Protec grease to the nut seating face.
2. Tighten to the seating torque with a torque wrench.
Seating torque: 49 N·m
3. Align the 0° position of an angle gauge to the match mark of the main bearing cap. Make a match
mark on the side of the nut collar at 105°.

7-21
MAINTENANCE YA'NMAR &NYl&L-W

Figure 7-29

014777-00E

Installing the Main Bearings

1. Check the bearings for damage and buildup of dirt.
Check for hit marks and plucking on the bearing surface and thread of each nut. Repair all
defects.

Do not mistake the top and bottom bearings .. The top bearing has an oil groove.

2. Insert the bearing removal tool into the oil hole of the crankshaft. Turn the crankshaft until the tool
disappears in the housing.
3. Carefully check the relationship of the fitting position between the top bearing ,pawl and the
housing pawl. Insert the one without a pawl into t~e housing first. (Push in manually by
approximately 1/4.)
4. Install the bearing insertion tool (guide).
5. Slowly and carefully turn the crankshaft to the right. Insert the bearing.
(Make sure that the bearing pawl and the insertion tool guide are aligned.)
6. Turn until the bearing and the housing match and the bearing is completely settled. Then stop
turning.
7. Turn the crankshaft back a little. Remove the bearing insertion tool and the bearing removal tool.

7-22
 MAINTENANCE YAHMAR &NYl&L·W

Figure 7-30 How to Insert the Top Main Bearings

Operating Drawing -out

Side Tool

groove
(for pawl passing)

014778-00E

/'

Tightening the Main Bearing Cap

1. Align the bearing pawl to the fitting position of the main bearing cap pawl.
2. Align the match marks of the main bearing cap and the cylinder block and install.
3. Install the drawing-out tool to the main bearing cap. (See Figure 7-31.)
4. Screw the bolt D into the main bearing cap. Turn the nut C. When the main bearing cap is settled
in the specified position (when the mating surfaces are aligned), remove the special tools.
5. Tighten the tightening nut of the main bearing cap to the specified torque of 49 ± 5 N·m.

J
Install the tightening nuts on one side, then on the other side. The main bearing cap can fall
and cause injury.

( Figure 7-31 How to Install the Main Bearings Figure 7·32 Tightening the Main Bearing Cap

D 014779-00X

7-23
MAINTENANCE
YANMAR 6NY16L·W

6. Tighten the side bolt on the operation side to half the specified torque.
123 N·m (Remove the bolt on the non-operation side.)
7. Tighten the side bolt on the non-operation to the specified torque of 49 N·m.
8. Tighten until the match mark of the main bearing cap tightening nuts align with the match mark of
the main bearing cap. Obey the instructions below.
•Operation side: approximately 40°
•Non-operation side: approximately 80°
•Operation side: up to the match mark
•Non-operation side: up to the match mark
9. Tighten the side bolt on the operation side to the specified torque.
245 ± 10 N·m
10. Tighten the side bolt on the non-operation to the specified torque.

Crankshaft
Disassemble the crankshaft at regular intervals. The following conditions can occur:
•Uneven wear of the crankshaft
•Too much clearance of the main bearing (due to wear of the crankshaft)
•Cracks caused by too much crankshaft deflection
•Hair cracks caused by crankshaft seizure due to lack of oil
•Cracks caused by torsional vibration at normal speeds
If the crankshaft or the main bearings have seizure, replace the bearings. Also, check the crankshaft
for hair cracks:
• Measure the surface hardness.
• Do a magnetic check for deep flaws.

Evaluation
Crankshaft surface hardness HS 75to HS 90
Hair cracks Not permitted

•Important Considerations for Disassembly and Assembly

1. Clean carefully including the oil hole during disassembly.
2. During maintenance, protect the engine from seawater and other materials that cause rust.
Rust can cause cracks.
3. When you install, align the knock pin of the crankshaft and the flywheel. Insert it by hitting it lightly.
4. Before you install the flywheel clamping bolt, check the bolt thread for defects. Apply seizure
inhibitor (e.g. Molycote) to the bolt thread.
5. Measure the crankshaft deflection during installation.

7-24
 MAINTENANCE YANMAR 6NY16L·W

Replacing the Oil Seal at the Front End of the Crankshaft

Replace the oil seal every one or two years during regular maintenance. Obey the following instructions.
1. If a front power take-off shaft is attached to the front, remove it and its coupling.
2. Remove the oil seal housing together with the oil seal.
3. Replace the oil seal with a new one, even if it is still usable.
If there is an oil leak before the next scheduled maintenance, the replacement work can be labor-
intensive.

•Important Considerations for Installing

1. Install the oil seal with the oil seal lib turned to the inside.
· 2.Apply lithium·grease to the oil seal lib.
3. To make sure that the whole circumference of the oil seal is inserted evenly (without tilting), put a
circular board against it and hit it in.
Make sure that you do not hit the seal directly with a hammer.

Figure 7-33 Replacing the Oil Seal on the Opposite Side of the Flywheel

Grease Filling

Crankshaft End of
Anti-flywheel Side

014781-00E

7-25
MAINTENANCE YANMAR 6NY16L-W

Disassembling and Assembling the Crankshaft Oil Seal on the Flywheel Side
During crankshaft overhaul or when oil leaks from the oil seal, disassemble and assemble the oil seal
according to these instructions.

•How to Remove the Oil Seal

The oil seal is a swinger-type seal. Make sure that you use the drawing-out tools and obey the below
instructions.

• Stop the engine and wait for the engine temperature to drop.
• When you remove the oil seal, make sure that you do not cause damage to the crankshaft and the
inner surface of the oil seal case.
• The slinger-type oil seal is only on the flywheel side. There is no slinger-type oil seal on the oppo-
site side of the flywheel.
• Do not use the removed oil seal again.

Figure 7-34 Removing the Oil Seal

Oil Seal Case

Figernail
Fingernail Position
Inner Ring

Fablic

rn-- Lip
Slinger
Central Bolt
Enlarged drawing

014842-00E

1. Remove the fabric with a screwdriver.

2. Remove the lip and the inner ring with pliers. Only the slinger stays.
3. Remove the oil seal case.
4. Attach the drawing-out tool (130605-92530), the center bolt (130605-92550) and the pawl
(130605-92540).
5. Fix the pawl to the drawing-out tool. Attach the pawl in three locations as shown in the figure. The
end of the pawl must touch the return part in front of the slinger
6. Slowly tighten the center bolt and remove the slinger. If the return part of the slinger turns upside
down, change the position of the pawls and do the task again.

7-26
MAINTENANCE YANMAR &NYl&L·W

•Important Considerations for Installing

The oil seal is a swinger-type seal. Make sure that you use the insertion tools and obey the below
instructions.

• Replace the oil seals with new ones. Do not use the removed oil seal again.
• There are different oil seals depending on the direction of engine rotation. Use the correct oil seal.
• Refer to the figure and make sure that the oil seal faces in the right direction. Insert it.
• When you install the oil seal, make sure that you do not cause damage to the crankshaft and the
inner surface of the oil seal case.
• If you change from a radial-type oil seal to a slinger-type oil seal, it is necessary to change the oil
seal case.

Figure 7-35 Installing the Oil Seal

Oil Seal Case Oil Seal

Lip
Plate
Q)

Insertion Tool ~

Central Bolt

Washer

Detail A

014843-00E

1. Apply lubricating oil to the oil seal lip.

2. Temporarily install the bolt (130605-92520) to the plate (130605-92510) at 3 locations.
3. Insert the insertion tool (130605-92500) up to the crankshaft. Align the center of the crankshaft
and the plate. Tighten the bolt through the window of the insertion tool with a hexagonal wrench.
4. Insert the oil seal (148620-01880) in the plate. Attach the insertion tool.
5.Tighten the center bolt (26153-200652) to the insertion tool. Press-fit the oil seal.
6. Tighten the center bolt until the insertion tool touches the plate.
7. After insertion, check that the installation location (size B) of the oil seal end and the slinger is
within 0.3 mm. If it is larger than 0.3 mm, sealing can not be maintained. Repeat the task and
install a new oil seal.

7-27
MAINTENANCE YANMAR 6NY16L·W

Timing Gear, Camshaft & Intake/Exhaust Tappet

Figure 7-36 Timing Gear Match Marks

Idle Gear A Idle Gear B

Cam Shaft Gear

Driving Gear
(for Fuel injection pump)

Crank Gear 014790-00E

Timing Gear
Normal operation also causes backlash and wear on the gear teeth. Even when operating at normal
speeds (for a long time), torsional movement can cause hair cracks and pitching wear of the gear. Check
the gears for backlash. Check the condition of the teeth surface.

•Important Considerations for Disassembly_ and Assembly

1. Be careful. All these parts have match marks on their alignment tooth: the cam·gear, the cam driv-
ing idle gear, the crank gear, the fuel cam driving gear A and B.
2. When you loosen the cam gear tightening nut, put a wood piece into the gear alignment.
Do not put a screwdriver or a metal piece.
3. When you remove the crank gear: Drill a hole into the bottom land of the gear. Put a chisel into
the hole. Lightly hit the chisel to loosen the gear alignment.
4. When you insert the crank gear, put it into an oil pan .and increase the temperature to between _)
150 °C and 180 °C. Let the gear become warm for approximately 30 minutes. Take the crank gear
out of the oil bath. Quickly insert it into the crankshaft and shrink-fit it.
Do not heat the crank gear with a gas burner. Too much temperature weakens its material and
strength. Use an oil bath.
The mating interference of the crank gear is 0.068 mm to 0.133 mm.

Figure 7-37 Removing the Crank Gear

Crank Gear (Customer's provision)

Drilled Hole Pit
Drilled Hole

Crank Shaft
014791-00E

7-28
 MAINTENANCE YANMAR &NYl&L·W

Intake/Exhaust Camshaft
Obey the below steps if:
• The wear on the cam, camshaft bearings and bush is more than the wear limit.
• These parts are damaged.

Figure 7-38

Distributing Valve Body

Centering Tool (Optional)

014792-00E

Figure 7-39
(~)
Thrust Collar
Cam Shaft Bush Suction & Exhaust Tappets cam Shaft Gear
Distributing Valve

Cam Shaft Bush 014793-00E

•Important Considerations for Disassembly and Assembly

1. The intake/exhaust cam and the shaft are integrated, but the outer diameter of the bearings is
made large. You can remove the shaft, if you remove:
• The flywheel
• The cam gear on the flywheel side
• The thrust collar
• The gear on the opposite side of the flywheel.
2. When you replace the camshaft bush:
• Press-fit the bush.
• Check the roundness.
• Check the joint of the bush for defects.
Before you press-fit, correctly align the oil holes of the bush and the cylinder block.
3.After you replace the camshaft and attach it to the engine, turn the flywheel until cylinder no. 1 is
at 4 ° before top dead center of the compression stroke. Make sure that the air hole for the
cylinder no. 1 of the distributor valve starts to open. At that time, lightly tap the knock pin into the
body of the distributor valve.
4. When you replace the distributor valve: Remove the core from the with the core drawing-out tool.
Do processing on the knock pin oil hole of the inner diameter of the distributor valve body and the
end of the camshaft.
5. Tum the engine and check that the slit on the camshaft end and the alignment part on the
distributor valve end have a clearance.

7-29
MAINTENANCE YANMAR GNY1'GL·W

Intake/Exhaust Tappet
Check the mating surfaces of the cam and the push rod. Check the sliding parts.

Fuel injection Pump and Governor

The fu~I injection pump is a precision device. Defects of this pump have a large influence on the
performance of combustion and the speed regulation.
J

Be very careful when you disassemble and assemble the fuel injection pump.

Do a new adjustment of the fuel injection pump after re-assembly. Do a new adjustment of the fuel
injection pump when you replace a major part (e.g. the plunger assembly, roller guide assembly or fuel
camshaft). Use a special pump tester. A pump tester is shown in the figure.

Figure 7-40

Replacing the Plunger and Plunger Barrel

Replace the plunger and the barrel with the fuel injection pump installed to the engine.

• Disassembling
1. Loosen the delivery valve cap until you can turn it by hand.
2. Loosen the barrel support tightening nut. Remove the barrel support washer.
3. Remove the plunger block assembly. At that time, carefully obey these instructions:

• Align the match mark 5 of the rack to the end and fix it. Fix the rack with the rack fixing screw.
• If you do not align the rack scale as described above and remove the plunger block, the inside pin-
ion catches. Also, if you pull with too much force, you can cause damage to the pinion teeth and
break the end of the setscrew on the top spring retainer. Also obey these instructions when you
assemble.

4. When you remove the plunger block assembly, multiple shims will come out from between the
barrel support and the pump body. Make sure that you know which shim belongs to which
cylinder. Keep the shims in good order.

7-30
MAINTENANCE YAN MAR &NYl&L-W

Figure 7-41

5th Graduation

I
I

!\ ____ _ *

5. Disassembling the plunger block assembly

Disassemble the plunger block according to the sequence in the figure.

Figure 7-42 Structure of the Plunger Block Assembly (Disassemble in the Numbered Sequence)

~"-... ~
6
7
Delivery Valve Packing
Delivery Valve Spring --I l ~Delivery Valve Holder
9 Delivery Valve -----t i 9 Check Valve Retainer
4
10 Delivery Valve Guide ~ I Check Valve Spring
12 Deflector --9 I Check Valve
0 j ~Stopper
I a

e .
11 Plunger Barrel
i;:;; i - - Piece 8
0
15 0-ring --0 j 0-- 0-ring 5

1s
17
p;,w,
Circlip
----fJ
--0
I
I o Barrel Support 13

3 P1"""" __fl !
~ I @3-- 0-rings 14
16 Top Spri"g Rotal""~ ~
2 Plunger Spring --I
1 Bottom Spring Retainer~ 014796-0lEOO

7-31
MAINTENANCE YAN MAR 6NY16L-W

• The pinion is locked with a circlip to prevent the plunger from coming out. But if you apply pressure
to the plunger spring part and shake it a little bit, the plunger comes out.
• Be careful that you do not cause damage to the plunger.
• If it is necessary to remove the pinion, remove the pin that holds the barrel support and top spring
retainer. Use radio pliers.

•Assembling

Figure 7-43 Figure 7-44

0 Agree set mark

Pinion Plunger ,!'" '\

' I
\._ __, /

014197-00X

1. Set the rack sale to 5 and fix the rack.

2. Check that the end of the setscrew on the top spring retainer protrudes approximately 2 mm to
the inside, as seen from the top of the pump body.
3. Assemble the plunger block.
1- Put 3 new 0-rings on the barrel support.
Replace the 0-rings with new ones every time you do a disassembly.
2-lnsert the plunger barrel into the.barrel support.
When you insert it, align the pin that reaches into the inner diameter of the barrel support to
the key groove of the barrel.
3- Insert the pinion in the plunger barrel.
4- Put the top spring retainer on the plunger barrel. Fix the long hole of the barrel support and
top spring retainer with a pin.
5- Insert the circlip of the .pinion. (
6-lnsert the plunger spring.
7- Install the plunger collar to the bottom spring retainer. Align the match marks of the plunger
collar and the pinion. Insert until the plunger collar catches on the pinion circlip.
4. Make sure that you install a 1 mm shim to the top of the pump body.
If you do not replace the plunger, use the same shim thickness as before.
If you do not replace the plunger, use the same shim thickness as before.
5. Align the notch of the pinion in the plunger block assembly with the groove on the top spring
retainer.

7-32
MAINTENANCE YANMAR &NYl&L·W

Figure 7-45

In overlap with the Can not be reassembled

notch part of pinion because a tooth of
pinion in protruding

014799-00E

Figure 7-46

Pinion

014000-00E

6. Carefully push it in from the top of the pump body. Make sure that the plunger block assembly
(the notch as described above) passes the end of the setscrew on the top spring retainer.

• Apply oil to the 0-ring of the barrel support and the hole of the pump body. Make sure that
you do not cause damage to the 0-ring.
• When the barrel support is difficult to insert, do not drive it in by force.
• The spring resists the barrel support, if you do not turn the camshaft and move the roller
guide to the lowest position.

Figure 7-47

Align them

014801-00E

7. Insert the horseshoe-shaped shim (that you removed before disassembly)_ between the pump
body of the removed cylinders and the barrel support.

7-33
MAINTENANCE YANMAR 6NYl6L-W

8. Check that the notch of the plunger faces in the same direction on all cylinders, as seen from the
top of the pump body. If one faces in a different direction, check the alignment of the rack and
pinion and align it again, if necessary.
9. Insert the barrel and match the bumps on its outer circumference with the dents on the inside of
the deflector.
1O. Insert the delivery valve, delivery packing, delivery spring and stopper. Screw in the delivery
retainer by hand until it is tight.

If you cannot screw it in until it is tight, the delivery or the packing is not correctly aligned. Check and
move it into the right position.

11. Install the washer for the barrel support and tighten the nut. Align the match marks of the barrel
support and pump body.
Barrel support tightening torque: 53.8 N·m to 63.8 N·m
(-------\
12. Tighten the delivery retainer.
\__j
Delivery retainer tightening torque: 186 N·m to 206 N·m

Figure 7-48

Set Mark

014002-00B

\ i
"-._/

7-34
MAINTENANCE
YANMAR &NY1&L·W

Fuel Camshaft
Disassemble the fuel camshaft when you inspect the governor or if there is a defect. Disassemble the
governor first, then obey the instruction in Figure 7-49.

Figure 7-49 Removing the Fuel Camshaft (in Numerical Order)

~-
' '-
~I
~ ct:l> 2

'
el
~- ,, '8"' ~
I

• Disassembly and Cleaning

1. After you finish .the disassembly of the governor, lift all tappets of the fuel pump.
2. Remove the camshafts to the governor side. Obey the order in Figure 7-49.

Remove the shaft, oil seals on the governor side, bearing caps and ball bearings together.

3. Replace the ball bearing with a new one every 8,000 to 10,000 hours (approximately 2 years) or
when you find unusual wear.
4. Check the cams and tappets for unusual wear.
5. Replace the oil seals, 0-rings and all packings with new ones.
Make sure that the oil seal faces in the direction of the seal lip.
6. When you finish the camshaft installation, check that the thrust clearance of the camshaft is less
than 0.1 mm.
If necessary, adjust the clearance with shims.

Disassembly and Inspection of the Mechanical Governor

Disassemble the governor every 4,000 to 5,000 hours (approximately 1 year) of op~ration or when a
defect occurs.

•Important Considerations for Disassembly and Assembly

1. Remove the fuel injection pump and the governor assembly from the engine.
2. Remove the governor case cover.

7-35
MAINTENANCE YANMAR &NY1&L·W

Figure 7-50

!
!
!
. l
r::'-::rii
I:
: !r>t'.1
Tighten uniformly

Fuel Cam Shaft Governor Weight

Drawing-out Tool 014804-00E

Figure 7-51 Disassembling the Governor (in Numerical Order)

Note: The arrows in the figure show the direction of removal.

3. Disassemble in the order shown in Figure 7-51.

4. Remove the governor weight with a special tool (optional). (See Figure 7-50.)
5. The average service life of the ball bearing is 8,000 hours to 10,000 hours (approximately 2
years).
But replace it with a new one if there is unusual wear.
6. Replace it with a new one.if there is unusual wear on the mating surface of the governor weight
contact metal and the ball valve washer.
7. Conduct the assembly in the opposite order, but replace the cotter pin, 0-rings and all packings
with new ones.

7-36
 MAINTENANCE YANMAR 6NY16L·W

Disassembly and Inspection of the SG Governor

See the separate "Hydraulic Governor Service Manual".

SG Governor Drive Unit

•Important Considerations for Disassembly and Assembly
1. Replace the ball bearing of the governor drive unit with a new one every 8,000 to 10,000 hours
(approximately 2 years) of operation or when you find unusual wear.
· 2. Measure the backlash of the driving gear.
Put a piece of lead wire (thickness of 0.3 mm to 0.4 mm) between the driving gear and the pinion
gear. Turn the gears. Remove the lead wire and measure the thickness (a+ b). This value is the
backlash.
Figure 7-52 Gear backlash

Pinion

(
Backlash
\.
Standard 0.08 mm to 0.16 mm
Usage limit 0.4 mm

Driving Gear
014806-00E

If the backlash is equal or higher than the usage limit, replace the driving gear or the pinion with a
new one.

Make sure that the driving gear tightening nut is tight.

Tightening torque for the driving gear tightening nut: 79 N·m

Figure 7.53

Control Lever Shaft

(_)
Ball Bearing

Governor Mounting Seat

Connection Pin

A-A Section

014.807-00B

7-37
MAINTENANCE vANM.A'A. &NY1&L-w·

3. Check the wear on the spline coupling.

Figure 7-54 Gear Backlash

Backlash
Standard 0.03 mm to 0.08 mm
Usage limit 0.2mm
Governor Shaft

Spline Coupling

4. Replace the oil seal of the control ·lever shaft with a new one every 2 to 3 years.
5. Check the return spring of the control rack for breakage. Check the connecting pin for wear. If you
find a defect, replace the parts with new ones.
6. When you install the governor, check that the mating surfaces of the governor shaft and spine
coupling make good contact and are free from stress.
7. Set the control rack to "O" (zero). Screw the stopper bolt in or out until its end and the hub (boss)
of the control lever make contact.

Connecting the SG govern~r

1. Temporarily adjust the length A of the coupling rod to approximately 144 mm.
2. Completely move the stop lever to STOP.
3. Put a slot screwdriver into terminal shaft. Completely turn it to FUEL DECREASE.
4. The speed control lever has 3 holes .. Insert it into the governor terminal shaft until the coupling rod
connects to the middle hole. After insertion,· tighten the small screws.
The terminal shaft is serrated. If the speed control lever is difficult to insert, adjust the length of
the coupling rod.
5. Move the stop lever in a horizontal position. Make sure that the angle between lever no. 2 and the
coupling rod (angle a) is a right angle. Make sure that the angle between the coupling rod and the
speed control lever (angle ~)is also a right angle.

Figure 7-55

Control Rack
Return Spring

Control Lever

Stopper Bolt

Connecting Pin

7-38
 MAINTENANCE YANMAR 6NY16L·W

•Connecting the Speed Control Lever and Coupling Rod

Usually, the coupling rod is connected to the middle hole of the speed control lever (position b ). But it
can be different, because the length of the coupling rod depends on the load, mass and performance
of the governor. Therefore, the length is set for each engine.
It is recommended to make a record of the coupling rod position before disassembly.

Setting Variation
(a)> (b) > (c)

Lubricating Oil Pump and Lubricating Oil Cooler

Lubricating Oil Pump (Gear-type)

•Inspection and Servicing
1. Check for seizure and unusual wear on the pump shaft bush.
2. Check the clearance of the gear and the pump body (housing).
3. Check the clearance of the gear and the cover.
4. Check the tooth contact of gear no.1 and gear no. 2. Check for unusual wear.
5 .. Check the spring of the relief valve for breakage. The opening pressure of the relief valve is 1.08
MPa to 1.28 MPa.
6. Check the seat of the relief valve for damage. Grind it if necessary.
7. During installation, check the teeth contact and backlash of the driving gear.

· Figure 7-56 Lubricating Oil Pump (Gear-type)

No.1Gear
0

0
0 0

Q)
c~i 0
0
0

Safety Valve
Driving Gear

~
Body

014810-00B

7-39
MAINTENANCE 'YANMAR &NYl&L-W

Lubricating Oil Cooler

Disassemble and clean if the cooling effect decreases or during regular inspections.

Figure 7-57

Cooler Body

Brush (Option)

Set Mark

Tube Nest plate

•Cleaning an_d Inspection

1 . Remove the cooling tube assembly from the cooler barrel. Remove scale from the cooling tube
surface.
2. Clean the pipes of cooling pipe assembly with a cleaning brush.
3. Carefully check for unwanted material and buildup on the cover of the cooling water inlet. If you
find any, remove it.
When you assemble, make sure that the rubber packing is in the correct position.
4. Remove the cooling tube (assembly) from the cooler barrel. When you assemble again, align the
match marks of the barrel and the tube sheet.

Lubricating Oil Pump of the-Fuel Injection Pump

Figure 7-58

Piston Oil Seal 020409-00E

•Handling
1. At initial operation or after a lubricating oil change, push the manual lubricating oil priming pump
several times. When the suction pipe is filled with lubricating oil, start the engine and check that
the oil signal operates. If the lubricating oil circulates during operation, the oil signal is green.
2. If the circulation of the lubricating oil is not good, check the intake valve, delivery valve and spring
for damage. Replace any damaged part.
3. Do an overhaul approximately once every year.

7-40
MAINTENANCE YANMAR &NYl&L·W

Cooling Water Pump

If there is an oil or water leak from the shaft, check the pump and replace it with a new one, if necessary.

• Important Considerations for Disassembly and Assembly

1. If the clearance between the impeller and pump cover is too large, replace the part that is more
worn.
The cooling water pump impeller and the impeller tightening nut are integrated.
If turning tightens the screws, turn in the other direction to remove the impeller.

Figure 7-59 How to Remove the Impeller

Casing

Pump Cover

Impeller

Oil Seal

014812-00E

7-41
MAINTENANCE YANlilfAR &NYIGL·W

2. When you replace the mechanical seal, make sure that you do not cause damage to the sealing
and that no dirt collects.

Do not apply oil to the ceramic and carbon face of the sealing. Do not apply lubricating oil or
grease. Do not touch with oily fingers.
Oil on the seal prevents water from coming in. This causes heat and unusual wear, and the
sealing effect is lost.

3. When you replace the oil seal, be careful of the direction of the seal lip.
4.Apply grease to the oil seal lip.
5. Replace the ball bearing of the cooling water pump after 6,000 to 10,000 hours.
6. Disassemble the cooling water pump in the order shown in Figure 7-60.
Remove the shaft and the ball bearing together from the casing bracket to the driving gear.

Figure 7-60 Disassembling the Cooling Water Pump (in Numerical Order)
(_)

7-42
MAINTENANCE YANMAR &NYl&L·W

Intake/Exhaust System
Exhaust Manifold
1. This engine has water-cooled exhaust manifold. When you disassemble, check for cracks.
Also, when you re-assemble, replace the gasket packings with new ones to prevent water and gas leaks.
2. Install and remove the exhaust manifold with the special mounting bolt wrench.
Figure 7-61

330mm
014814-00X

Turbocharger
1. Clean the air filter (sponge material) approximately once every week (40 to 50 hours).
2. Remove the air filter on the compressor side approximately every 2,000 hours. Turn the oil shaft
with your finger. Check that that it moves smoothly and without rattling. If it does not move
smoothly, overhaul the part.
3. For the overhaul procedure, see the separate service manual for the TD13 turbocharger.

Charge Air Cooler

The air cooler quickly becomes dirty on the cooling water side and the air side. Clean it at regular
intervals depending on the engine's usage conditions and properties.

•Inspection and Servicing

1. On the air side, do a steam cleaning. If the parts are very dirty, soak them in detergent (5 % to 10
% solution of Neos CM 305 D and Gamlen CW solvent distributed by Exeno Yamamizu). Blow
with compressed air. Clean again with water.
2. On the water side, clean the inside of the tube with a brush.
3. The cover of the water chamber in the air cooler has an anti-corrosive c;oating. If the coating is
damaged, clean and degrease it sufficiently. Then apply epoxy paint.

Freshwater Cooler
1. Remove the cooling tube (assembly) from the cooler barrel. When you assemble again, align the
match marks of the barrel and the tube sheet. Remove it on the non-operation side.
2. Remove the cooling tube assembly from the cooler barrel. Remove scale from the cooling tube surface.
3. Clean the pipes of cooling pipe assembly with a cleaning brush. The brush is an optional part.
Figure 7-62

Freshwater Cooler

Match Mark

.. ..
..
Brush

Removal
Direction

014815-00201

7-43
MAINTENANCE YANMAR 6NY16L-W

[Memo]

7-44
 PRINCIPAL DIMENSIONS & MASS FOR DISASSEMBLY & SERV YANMAR &NYl&L-W

PRINCIPAL DIMENSIONS & MASS FOR DISASSEMBLY & SERVICING

Principal Dimensions for Disassembly & Servicing

The drawing-out height is indicated as the lowest height from the crankshaft center when drawing-out
from the operation side.

Cylinder Liner Cylinder Head Piston Cam Shaft

0
---1628----i

( \
;::
N
~

Turning Bar

Center of Crankshaft Center of No.6 Cylinder

014816-00E

- - - 945 -----=--t

8-1' (2 pages)
PRINCIPAL DIMENSIONS & MASS FOR DISASSEMBLY & SERV YANMAR &NYl&L·W

Mass of Major Parts

When you lift a part, use a rope, lifting gear and hook that is appropriate to the weight of the part.
* Remove parts that are marked with this symbol with the attached special tool.

Part Name Mass (in kg) Remarks

Cylinder head * 57
Piston & connecting rod assembly * 21
Cylinder liner * 17
Camshaft 38
Camshaft gear 10
Camshaft drive idle gear assembly 21.5
Pump drive idle gear assembly 7
Main bearing cap (standard) * 9
Main bearing cap (intermediate)* 8
Turbocharger assembly 29 TD13M \
Air cooler assembly 87 YPC23 )
Lubricating oil cooler assembly 50
Freshwater cooler assembly 67
Lubricating oil pump assembly 22
Cooling water pump assembly 18.5 includes drive gear
Fuel injection pump assembly 28.5 includes mechanical governor
Lubricating oil filter assembly 21 Notch wire
Lubricating oil bypass filter assembly 2.5 Centrifugal GF-1
Fuel oil filter assembly 12
Cylinder block * 750
Crankshaft assembly 265 includes crankshaft gear
Flywheel 171
Exhaust manifold 58.5 Water-cooled
oil pan 90
Flywheel housing 92
Gear housing 51

8-2
TIGHTENING TORQUES FOR BOLTS AND NUTS YANMAR 6NYl6L·W

TIGHTENING TORQUES FOR BOLTS AND NUTS .

Obey the instructions of this manual when you tighten bolts and nuts.
Be careful. If you tighten incorrectly, loose bolts or nuts can cause personal injury or device
damage.

• Unless otherwise specified, apply lubricating oil on the thread and bearing surface (the part under the
head). Then tighten the bolt or nut.
· * Parts that are marked with this symbol in the table have a match mark. When you tighten these
parts, refer to the match mark and tighten with the specified torque and tightening angle.

Angle Clamping Bolt

When you tighten the bolt to the seating tightening torque:

• Check the position of the match mark.
• If necessary, make a match mark on the part.
• Tighten the bolt to the specified angle.

Screw Face-to-face Seating Specified

Diameter Width of Tightening Tightening
Part Name Remarks
)( Bolt or Nut Torque Angle
Pitch (mm) N·m (deg)
Apply Protec grease to the
Connecting rod bolt ~· M20 x 1.5 30 49 95 to 105
thread and seating surface.
Main bearing cap bolt I
M27 x 2.0 41 49 100 to 110
tightening nut ~ •

Other Major Bolts and Nuts

• * When you disassemble a part with this symbol, use the attached special tool.
• Make sure that you tighten the bolts and nuts in the following table to the specified torque with a torque
wrench.

9-1 (6 pages)
TIGHTENING TORQUES FOR SOLTS AND NUTS YANMAii GNYIGL-W

Face-to-face Tightening
Screw
Width Torque
Diameter
Part Name of Remarks
)(

Bolt or Nut N·m

Pitch
(mm)
M22 x 1.5 30 See "How to Tighten the Cylinder Head
Head bolt tightening nut *
Tightening Nuts" on page 9-4 for the
Head bolt auxiliary bolt M12 x 1.75 19 tightening method and torque.
Apply seizure inhibitor
(Moly dry spray by
Cylinder head bolt (studded side) M22 x 1.5 - 373 ± 20
Sumico or equivalent)
to the thread.
Rocker-arm shaft support clamping bolt M10 x 1.5 17 39 ± 5

Fuel injection nozzle retainer tightening nut M14 x 1.5 22 157 + 10

0

Air starting valve retainer nut M10 x 1.5 17 39 ± 5

Nozzle sleeve * M28 x 1.5 - 235±10

Main bearing cap tightening bolt (studded
side)
M27 x 2.0 - 490 ± 29

Main bearing cap side bolt M16 x 2.0 24 245 ± 10

.Apply Protec grease to
Flywheel tightening bolt M20 x 1.5 24 490 ± 29 the thread and seating
surface.
Camshaft gear clamping bolt M36 x 3.0 55 932 ± 49
Camshaft idle gear mounting base clamp-
M16x1.5 24 177 ± 10
ing bolt
Lubricating oil pump driving gear tightening
M24 x 2.0 36 167 ± 10 Left-hand screw
nut
Pump idle gear mounting base clamping M12 x 1.75 19 78 ±5
bolt & nut M14x1.5 19 118 ± 5
Cooling water pump driving gear tightening .
M20 x 1.5 30 137 ± 10
nut
Cooling water pump impeller M20 x 1.5 19 137 ± 10 Left-hand screw
Piston cooling nozzle tightening bolt M20 x 1.5 22 54 ±5
Piston cooling oil passage cover tightening Apply screw lock agent
M6 x 1.0 10 11 +1
0 to the thread
bolt
Fuel injection pump camshaft tightening nut M27 x 2.0 41 350 ± 25
Fuel injection pump driving gear tightening
M27 x 2.0 41 270 ± 25
nut
Fuel injection pump PTO shaft coupling
M14 x 1.5 19 127 +10
0
side bolt
Fuel injection pump PTO shaft coupling 98 +10
M12 x 1.25 17 0
clamping bolt
Fuel injection pipe nut (pump side) M18 x 1.5 27 59 ± 10
Fuel injection pipe nut (head side) M16 x 1.5 27 59 ±5

9-2
 TIGHTENING TORQUES FOR BOLTS AND NUTS YANMAR &NYl&L·W

• How to Install the Connecting Rod Bolt

When you install the connecting rod bolt, use its match mark as guidance, but install it to the specified
angle with an angle gauge. Make a new match mark.

Be sure to stamp a new match mark each time you disassemble a connecting rod. Each bolt is stamped
with a match mark when it leaves the factory. But the tightening torque of the bolt varies depending on
break-in between the bolt thread, the bearing surface and the large end serration of the connecting rod. If
you replace the connecting rod bolts or the connecting rod, tighten and loosen the bolts 3 or 4 times by
approximately 90° to break them in.

How to Make a Match Mark

Stamp a match mark on each bolt with the crank pin bearings not installed. Obey these instructions.
1. Apply lubricating oil to the bolt thread. Apply Protec grease to the bearing surface. Tighten it by
hand until it is seated.
2. Tighten the bolt to the seating torque with a torque wrench.
Seating torque: 49 N·m
3. Align the 0° position of the angle gauge with the A mark of the connecting rod. Make a match
mark at the 100° position on the side of the bolt guard.

Figure 9-1

(
\ R:::: Matoh Ma~ 014484-00E

How to Tighten
Tighten the top and bottom bolts alternatively in 3 turns. Align the match marks of the connecting rod and
the bolt.

Table 9-1 Tightening Order and Angle

1st Turn 2nd Turn 3rd Turn

Top bolt 20° 60° 100°
Bottom bolt 40° so· 100°

9-3
TIGHTENING TORQUES FOR BOLTS AND NUTS YANMAR &NY1&L-W

• How to Tighten the Cylinder Head Tightening Nuts

1. Apply lubricating oil to the thread and seating face of the nut and the bolt.
2. Tighten the cylinder head clamping nut in 3 turns. Obey the order in the figure.
3. Next, tighten the auxiliary bolt in 2 turns.

Figure 9-2 Cylinder Head Tightening Order

014485-00EOl

Table 9-2 Head Bolt Tightening Nut Tightening Torque Table (when Replacing)

Unit: N·m
Tightening Nut (CD-®) Auxiliary Bolt (®, ®)
1st tum 147 ± 20 Do not tighten
2nd turn 294 ± 20 49 ±4.9
Without \,
3rd 637 ± 29 )
washer 88 ± 4.9
turn
With washer 520 to 549

Note: When you replace the cylinder head, head clamping bolt and tightening nut with new ones. ·
Because the head seating surface, the tightening nut seating surface and the head bolt thread
are not broken-in yet, it is necessary to tighten them with more torque the first time only.

Table 9-3 Head Bolt Tightening Nut Tightening Torque Table (for Regular Maintenance)

Unit: N·m
Tightening Nut (CD-®) Auxiliary Bolt(®,®)
1st tum 147 ± 20 Do not tighten
2nd turn 294 ± 20 49 ± 4.9
Without
3rd 588 ± 29
washer 88 ± 4.9
turn
With washer 490 to 519

Note: The torque in this table applies also when only a washer is installed.

9-4
TIGHTENING TORQUES FOR BOLTS AND NUTS YAHMAR 6NY16L·W

Regular Bolts and Nuts

• Tighten regular steel bolts (7T) and nuts (6T) according to the following table.
• If the clamping section is made of aluminum, tighten the part to 80 % of the torque shown in the table.
• Be careful. The table does not apply to brass or stainless bolts.

Screw Diameter Face-to-face

Tightening Torque
Part Name )(
Width of Remarks
Pitch Bolt or Nut (mm) N·m
Hex bolt M6 x 1.0 10 10 to 12
and MB x 1.25 13 24 to 27
hex nut M10x1.5 17 44 to 54
M12x1.75 19 78 to 98
M14x1.5 22 123 to 152
M16 x 1.5 24 206 to 245
M16 x 2.0 24 206 to 245

Pipe Joint Bolt

• Tighten the pipe joint bolt without applying lubricating oil to the thread.
• If the clamping section is made of aluminum, tighten the part to 80 % of the torque shown in the table.

Screw Diameter
x MS x 1.25 M12 IC 1.25 M141C1.5 M16><1.5 M18><1.5 M20 x 1.5 M22 IC 1.5
Pitch
Face-to-face Width
12 17 19 22 24 27 30
mm
Tightening Carbon
12 to 17 25 to 34 39 to 49 49 to 59 69 to 79 88 to 98 147 to 196
torque steel
N·m Brass 8 to 12 18 to 25 27 to 34 34 to 41 48 to 55 62 to 69 98 to 137

9-5
TIGHTENING TORQUES FOR BOLTS AND NUTS YANMAR 6NY16L·W

[Memo]

9-6
CLEARANCE AND WEAR LIMITS OF MAJOR PARTS YANMAA 6NY16L·W

CLEARANCE AND WEAR LIMITS OF MAJOR PARTS

Unit: mm
Dimension Standard Max. Usage
Part Name Drawing Nominal Clearance at allowable Limit of
Tolerance
Dimension Installation clearance Parts
Inner diameter of the top part +0.115
+0.18
of the cylinder block (top) A 0 A= 0.220
0197 A= 0.45
Outer diameter of the top B -0.220 to 0.395
""' -0.35
part of the cylinder liner (top) -0.280
Inner diameter of the top part +0.046

~
I +0.13
c: of the cylinder block (bottom) 0 B = 0.040
0188 B = 0.20
.8 Outer diameter of the top part
en -0.040 to 0.116
·a. of the cylinder liner (bottom)
cc -0.070
-0.13
ii3
:§
.._
Q)
Inner diameter of the bottom
part of the cylinder block
] tr 0183
+0.046
0 B = 0.015
c = 0.20
+0.13

'O Outer diameter of the bottom -0.015 to 0.091

.= part of the cylinder liner
014486-00X
-0.045
-0.13
">.
(..)
See "TABLE OF ENGINE STANDARD
~-
(..)
0
Top clearance D -i--E - - ADJUSTMENTS" on page 3-1.
-1 I n1
:0
.._ -
~

+0.5**
Q) Inner diameter of the ~

I +0.115
'O 0160 One-sided
.s: cylinder liner I 4 f()' ~
ll= 0 E=0.98to
- wear 0.25
">.
(.)
Outer diameter of the -
-
"\:
r
._F 0159 ±0.02
1.05

piston head -

~
Inner diameter of the +0.03
cylinder liner
Outer diameter of the
J /,
014487-00X
0160

0159.9
0

±0.02
F=0.08to
0.15
F = 0.21
-0.27
piston skirt
Thickness of the piston
G =6.4 ±0.12 - - G = 6.05*
ring (No. 1 to No. 3) - G -
Thickness of the oil rings
/
-- .... J1 H =4.5
+0.25
-0.15 - - H = 4.25

Width of the piston ring

(No. 1)
c: -iJ2 -0.020
-0.035 J1=0.070
-0.15

Width of the piston ring c -iJ3 4

+0.070 to 0.105
J1 = 0.3
+0.27

en
Cl
c:
·c:
'O
groove (No. 1)
Width of piston ring (No.
2)
Width of the piston ring
groove (No. 2)
J:: 014488-00X
4
+0.050
-0.020
-0.035
+0.045
+0.025
J2 = 0.045
to 0.080
J2 = 0.3
-0.15

+0.27

[[)~
c:
ro
c:
·a.
Width of the piston ring
(No. 3)
t] -0.020
-0.035 J3 = 0.045
-0.15
c: Width of the piston ring II II 4 J3 = 0.3
.8 Ill Ill +0.045 to 0.080
en +0.27
·a. groove (No. 3) II 11
+0.025

~ r/
c Width of the oil ring El] -0.010
.8 -0.15
en -0.025 K = 0.035
a: 6 K= 0.3
Width of the oil ring +0.045 to 0.070 ·
L M +0.27
groove 014489-00X +0.025
Outer diameter of the 0
+0.09
piston pin -0.013 L=0.087to
062 L = 0.25
Inner diameter of piston 0.120

m
+0.107
+0.18
pin bearing +0.087
Outer diameter of the 0
piston pin -0.09
-0.013 M = 0.025
062 M = 0.15
Inner diameter of the +0.040 to 0.053
+0.09
.
014855-0X
piston pin hole +0.025
. .
. Replace nng No. 1 when its plated layer 1s worn and the base metal becomes v1s1ble. Replace nng No. 2 and No. 3 when the taper face is gone .
** This is the limit for ring No. 1 when the piston is at top dead center.

10-1 (4 pages)
CLEARANCE AND WEAR LIMITS OF MAJOR PARTS YANMAR GNYl&L·W

Unit: mm
Dimension Standard Max. Usage
Part Name Drawing Nominal Clearance at Allowable Limit of
Tolerance
Dimension Installation Clearance Parts
Outer diameter of the 0 Uneven wear
crank pin -0.022 N = 0.064 0.1
0115 N = 0.2
Inner diameter of the _,_p +0.129 to 0.151
. +0.18
crank pin bearing +0.064
Width of the large end of
the connecting rod f~///~~= ¢/
// 68
-0.30
-0.40 P = 0.35to
p = 0.7
/ / +0.15 0.55
Width of the crank pin ,/
Q
¢:: ~ +0.05
ro
..c:
en Outer diameter of the lL_j 0 0 Uneven wear
..ii::
c main shaft -0.025 Q = 0.072 0.1
ro
._ 0135 Q =0.2
(,) Inner diameter of the - - +0.137 to 0.162
+0.18
main bearing ~
~ I ::: +0.072
Width of the main shaft
(standard part)
\
R
---
i.----'--'
._
+0.030
0 Thrust clearance
11
' 65 R = 0.141 R =0.35
Width of the main bearing
(standard part)
- \-Deflection
014490-00E
-0.141
. -0.260
to 0.290

See "Permitted Value of the

Deflection - - Deflection" on page 6-26.
Intake
Valve head valve
- - See "TABLE OF ENGINE
STANDARD ADJUSTMENTS" on
clearance Exhaust
valve ~"
el ~
r
I
- - page 3-1.

Outer diameter of the -0:05

intake valve stem Rl v -0.07 U1=0.060
-0.18

Inner diameter of the 1 H~ 012

+0.026 to 0.096
U1 =0.2
+0.12
intake valve guide
-~ u +0.010
Outer diameter of the
exhaust valve stem
Inner diameter of the
exhaust valve guide
l~ ~
...... ·.1..

a•
.LC 012
-0.05
-0.07
+0.026
+0.010
U2= 0.060
to 0.096
U2 = 0.2
-0.18

+0.12

Outer diameter of the a·{SUC. =120° +0.046 i

E valve bridge guide exh. = 90" -0.07
en
'2
014491-00E
014
+0.028 v = 0.014 V= 0.2
__..../

ro to 0.052
..c: Inner diameter of the +0.08
+0.18
CJ
Q) valve bridge +0.06
E
Intake
Q)
> Thickness of valve
W 1 =3.8 - - 3.4
~ the intake/ ±0.2
Exhaust
exhaust valve
valve
W2= 2.9 - - 2.5

~
Intake
Width of intake/ valve
X1=5.4 - - 6.0
exhaust valve ±0.2
Exhaust
seat
valve w X 2 = 5.8 - - 6.3
014492-00X

· Diallleter of the contact

part on the intake/exhaust y '= 051 ±0.1 - - 52.2
valve seat
Outer diameter of the -0.009
z -0.12
-0.034 z = 0.019 z = 0.15
~
rocker arm shaft
032
Inner diameter of the +0.065 to 0.099
+0.12
rocker arm bush 014493-00X +0.010

10-2
 CLEARANCE AND WEAR LIMITS OF MAJOR PARTS YANMAR GNYIGL-W

Unit: mm
Dimension Standard Max. Usage
Part Name Drawing Nominal Clearance at Allowable Limit of
Tolerance
Dimension Installation Clearance Parts
Outer diameter of the -0.06
-0.18
'~\LJ
camshaft -0.09 a =0.040to
080 a= 0.2
Inner diameter of the +0.075 0.165
+0.10
;:!
~~~a
camshaft bearing +0.020
¢:::
ro
..c Thickness of the thrust -0.2
I/)
-
E
ro
bearing Olh -0.25

: : : : lt1 :ii ~ ;:ID

1r
()
b = 0.20 to
8 b = 0.5
Width of the thrust +0.1 0.35
bearing
--b
0
-
:1 014494·00X

~-
Gear backlash (timing M =4.5 c=0.15to
( ' gear) (module)
- 0.25
c = 0.4 -
\_)
014495-00X

L..
ro Outer diameter of the idle
-0.03

Ii
Ql
Cl gear shaft (camshaft -0.17
c: -0.06
0 driving) d = 0.03 to
'iii 080 d = 0.2
I/)
.E 0.09
Inner diameter of the idle +0.03
I/)
c:
+0.14
gear bush 0
~ 014496-00X
I-

,.
Outer diameter of the idle -0.03
-0.17
gear shaft (pump driving) -0.06
e = 0.03 to
070 e =0.2
Inner diameter of the idle +0.03 0.09
+0.14
gear bush 0
014491-00X

Outer diameter of the -0.040

-0.10
pump shaft -0.053 f = 0.040 to
030 f = 0.15
Inner diameter of the +0.021 0.074
f g +0.10
0.

!]
bush I 0
E
:J
0. Outer diameter of the
I -0.20
·5 gear
II --r -
I - -0.25 g =0.200to
Cl a: ~ 072 g = 0.50
.5 Inner diameter of the ] +0.046 0.296
'lii -
u
·c::
.c
pump case
~~ f]- 0
:J
...J Width of the gear
-ts11 014498-00X
66
-0.06
-0.09 c=0.060to
h = 0.18
-
+0.046 0.136
Width of case gear
0
-
Outer diameter of the
0.
E
:J
0.
L..

.l!l
impeller hub (boss)

:m.
.~iii'
IJ: '-
j = 0.390 to
ro I I
j 080 - j = 0.8
3:: Inner diameter of the I~ 0.435

0
Cl
.5 casing 5 u~n
I

0
(_) Iii;;!;
014499-00X

10-3
CLEARANCE AND WEAR LIMITS OF MAJOR PARTS YANMAR &NYl&L·W

[Memo]

10-4
 TROUBLESHOOTING & COUNTERMEASURES YAHMAR 6NY16L·W

TROUBLESHOOTING & COUNTERMEASURES

Defects and malfunctions have many different causes. Sometimes there is more than one cause.
Consider the changes in running performance, time and content of maintenance and servicing, and the
history of part replacements. Quickly find the cause and
take the correct countermeasures.

Problems with Engine Start ............................................................................................ 11-2 Page

The Flywheel Does Not Turn .................................................................................... 11-2 Page
The Flywheel Turns, But No Ignition ........................................................................ 11-2 Page
Rotation Speed Suddenly Decreases ............................................................................. 11-3 Page
The Output of the Cylinders Is Irregular (the Difference in Maximum Combustion Pressure and
Exhaust Temperature Between Cylinders Is High) ......................................................... 11-3 Page
The Exhaust Gas Has a Bad Color ................................................................................ 11-3 Page
The Pressure of the Lubricating Oil Decreases Below the Specified Pressure .............. 11-4 Page
Irregular Sounds During Engine Operation .................................................................... 11-4 Page
The Cooling Water Temperature Is Too High ................................................................. 11-4 Page
The Exhaust Temperatures of All Cylinders Are Too High .............................................. 11-5 Page
Engine Suddenly Stops .................................................................................................. 11-5 Page

/\
'-~- ....-

11-1 (6 pages)
TROUBLESHOOTING & COUNTERMEASURES YANMAR 6NY16L-W

• Problems with Engine Start

The Flywheel Does Not Turn

Cause Countermeasure
1. The starting air pressure is too low. Fill the starting air tank with air.
2. The air starting valve is stuck or the valve seat is no Disassemble and do servicing on the air
airtight. starting valve.
3. Incorrect installation of the starting air distributor valve Check the match mark of the distributor
valve.
4. The intake/exhaust valve is not airtight. Grind the intake/exhaust valve seat.
5. The viscosity of the lubricating oil is too high. Warm up the engine or change to a
lubricating oil with lower viscosity.
6. Seizure of a moving part
1- Seizure of the piston and cylinder liner Check and repair the part or replace it.
2- Seizure of the main bearing and camshaft bearing Check and repair the part or replace it.

The Flywheel Turns, But No Ignition

Cause Countermeasure
1. The fuel oil is not pressure-fed to the fuel injection
pump.
1- The fuel tank is empty. Fill the fuel tank with fuel oil.
2- The fuel pipe is clogged (valves do not open and Check that all valves open and close
close correctly). correctly.
3- Fuel oil filter is clogged. Clean the filter.
4- Malfunctions of the fuel feed pump Check and repair.
Ch~ck and repair, then bleed the air.
5-Air enters at the joints.
2. Malfunction of the fuel cut-off air piston Check and repair.
3. Malfunction of the fuel injection pump
1- The plunger or plunger guide is stuck. Check and repair the part or replace it.
2-Wear or seizure of the plunger guide Replace.
3- The part is incorrectly assembled (match marks Disassemble and inspect.
are not aligned).
4. Malfunction of the fuel injection valve
1-The needle is stuck or burned. Check and repair the part or replace it.
2- The nozzle spring is broken. Replace.
3- The fuel injection pressure decreases. Adjust the pressure.
4- The nozzle has too much oil leakage. Check and clean the mating surfaces of
the nozzle and body, or replace the
nozzle.
5- The high-pressure fuel pipe is broken or incorrectly Replace the high-pressure fuel pipe, or
tightened. correct the tightening.

5. Malfunction of the governor Check and repair the part or replace it.
(The governor link is loose or the spline has wear.)
6. The intake/exhaust valve is not airtight.
1- The head of the intake/exhaust valve has no clear- Adjust the valve head clearance.
ance.
2- The intake/exhaust valve is stuck. Grind or replace the valve seat.
3- The intake/exhaust valve has damage. Grind or replace the valve seat.

7. The cetane number of the fuel is too low. Use a fuel oil with higher quality (cetane
number 45 or higher).

11-2
TROUBLESHOOTING & COUNTERMEASURES YANMAR 6NY16L·W

•Rotation Speed Suddenly Decreases

Cause Countermeasure
1. Fuel oil filter is clogged. Clean the filter.
2. Seizure of a moving part (piston, main bearing or turbo- Check and repair the part or replace it.
charger)
3. There is air in the fuel pipe system. Check and repair the fuel pipe system,
then bleed the air.
4. There is water in the fuel oil. Drain the part (e.g. filter, tank).
5. Malfunction of the fuel injection pump Check and repair the part or replace it.
6. Malfunction of the fuel injection valve Check and adjust the governor, or replace it.
7. Malfunction of the governor Check and adjust the governor, or replace it.

• The Output of the Cylinders Is Irregular (the Difference in Maximum

Combustion Pressure and Exhaust Temperature Between Cylinders Is High)
Cause Countermeasure
1. There is air in the fuel pipe system. Check and repair the fuel pipe system,
then bleed the air.
2. There is water in the fuel oil. Drain the part (e.g. filter, tank).
3. The fuel injection volume of the cylinders is irregular.
1- The position of the fuel injection pump racks is Check and adjust.
incorrect.
2- The fuel injection pump plunger is stuck or has Check and repair the part or replace it.
wear.
3- Malfunction of the fuel injection valve Check and repair the part or replace it.
4- The fuel injection pipe is loose or has damage. Inspect or replace.
5- The fuel cam has damage. The intake/exhaust Check and repair or replace the part.
cam has damage.
4. The intake/exhaust valve is stuck or the seat of the Check and repair or replace the part.
intake/exhaust valve has damage.

• The Exhaust Gas Has a Bad Color

Cause Countermeasure
1. The injection timing is incorrect. Check and adjust the timing. Refer to the
Records of
Shop Trial. ·
2. Malfunction of the fuel injection valve (Fuel injection Check the valve, adjust the pressure, or
pressure decreases or nozzle is stuck.) .replace.
3. Malfunction of the fuel injection pump Check and repair or replace the part.
4. The clearance of the intake/exhaust valve head is Adjust the clearance, or repair or replace
incorrect or the seat of the intake/exhaust valve has the valve seat.
damage.
5. The intake/exhaust valve is stuck. Disassemble the valve and repair.
6. The intake/exhaust cam has damage. Replace the camshaft.
7. Malfunction of the turbocharger
1- Intake filter is clogged. Clean.
2- The blower side or turbine side is dirty. Disassemble and clean.
8. The charge air cooler is dirty. (The charge air tempera- Disassemble and clean.
ture is too high.)
9. The fuel oil is bad. Use a fuel oil with higher quality.
10. Overload Reduce the load.

11-3
TROUBLESHOOTING & COUNTERMEASURES YANMAR 6NY16L·W

• The Pressure of the Lubricating Oil Decreases Below the Specified Pressure
Cause Countermeasure
1. The lubricating oil pipe or cylinder block oil hole plug is Check and repair the lubricating oil pipe
loose. and all oil hole plugs.
2. The lubricating oil filter is clogged. Disassemble and clean.
3. The clearance of the crankshaft bearing is too large. Check the clearance, then replace the
bearing.
4. The oil pressure control valve is stuck or the adjusting Check the part. Repair or adjust it.
bolt is loose.
5. The lubricating oil relief valve is stuck. Check the part. Repair it.
6. The temperature of the lubricating oil is too high.
1- The cooling water level is low. Check the low-temperature water pump.
2- The oil cooler is dirty. Check the part, then disassemble and clean.
3- There is a lot of blow-by (gas leakage) into the Check the piston rings and cylinder liner.
crankcase.
4- The piston of the lubricating oil thermostat is stuck Check the part, repair or replace it.
or the element has a defect.
7. There is air in the lubricating oil pump. (The lubricating Fill lubricating oil.
oil level is low.)

• Irregular Sounds During Engine Operation

Cause Countermeasure
1. The bearings of the crankshaft or camshaft have too Check the clearance, then replace the
much clearance. bearing.
2. A bolt is loose.
1- Connecting rod bolt Replace the connecting rod and the
bolts, then re-tighten.
2- Flywheel tightening bolt Check the bolts, then re-tighten or
replace.
3. The clearance of the intake/exhaust valve head is Check, then adjust the clearance.
incorrect or a bolt is loose.
4. The fuel injection timing is incorrectly adjusted. Check, then adjust.
5. The fuel injection volume is too large.
1- Malfunction of the fuel injection pump Check the part, repair or replace.
2- Malfunction of the fuel injection valve Check the part, repair and adjust.
6. The gear backlash or gear bearing wear increases. Check the part, adjust or replace.

• The Cooling Water Temperature Is Too High

Cause Countermeasure
1. The cooling water level is too low. Check and repair the cooling water
pump.
2. The cooling water thermostat is stuck or has a malfunc- Check or replace the thermostat.
tion.
3. The freshwater cooler is dirty. Disassemble and clean the cooler.

11-4
TROUBLESHOOTING & COUNTERMEASURES YANMAR 6NY1&L·W

• The Exhaust Temperatures of All Cylinders Are Too High

Cause Countermeasure
1. The charge air temperature is too high.
1- The cooling water level in the charge air cooler is Check and repair the low-temperature
too low. water pump.
2- The charge air cooler is dirty (on the cooling water Disassemble and clean.
side and air side).
3- The temperature in the engine room is too high. Check and do servicing of the ventilation
equipment in the engine room.
2. The charge air pressure is too high.
1- The turbocharger filter is clogged. Clean the filter.
2- The charge air cooler (on the air side) is clogged. Disassemble and clean.
3- The turbocharger is dirty (on the turbine side or Clean the blower side or disassemble
blower side) or has damage. and clean.
4- The back pressure at the exhaust port increases. Check and clean the exhaust manifold
and exhaust pipe.
5- The engine room has negative pressure. Check and do servicing of the ventilation
equipment in the engine room.
3. The fuel oil has incorrect properties. Examine the property analysis results
and change the fuel oil if necessary.
4. Overload Reduce the load.

• Engine Suddenly Stops

Cause Countermeasure
1. The protective device operates. Check the switch, then repair the defect.
1- Overspeed Replace if necessary.
2- The lubricating oil pressure decreases.
3- The temperature of the cooling water increases
unusually.
2. Malfunction of the governor or governor gear Check the part and repair or replace.
3. The fuel tank is empty. Fill fuel oil.
4. There is air in the fuel oil system. Bleed the air from the filter and fuel pipe.
5. The fuel filter is clogged. Disassemble and clean.
6. Seizure of a moving part Check and repair the part, or replace it.
(e.g. piston, main bearing, crank pin bearing, timing
gear)

11-5
TROUBLESHOOTING & COUNTERMEASURES YANMAR &NYl&L·W

[Memo]

11-6
 PARTS LIST
t:)jj\,\ Requesf
Though this Parts List has been edited to serve also
.:. 0)$~*1iI&:J'.&ifO)#~ t*b. -r~• L -r.@ as the appended figures of the pertinent Operation
~~i"#.~5~L~B~•%t•~-t~.:t# Manual, any Part No. thereof is subject to a change
without notice. Consequently, when you are in need
~~ii"~~·~~-~-~-~-~i"#.fi~ of a particular Part, Kindly place your order of that
g~. B~•%t~~~~g~(B~).~~-% Part with your nearest Yanmar Parts Selling Agent,
writing clearly Model and Mfg. No. of your engine
t~~L-rftfi0)~~~-•£•~m~m~~<
together with Part Name and Part No. of the Part in
t!. ~ l,\o demand.

$ifA~X~~·~ tllll'I ti fir. Of~~)

Exampe of items & indication necessary at the time
of ordering Yanmer engine parts.
~lji E! .&Vt;~ ~llll~m•~
911 $~~~ Engine Model
Engine Mfg. No.
$ ~ I' ~
Part Name
J..~~tt:E: 1 set Part No.
Q' ty Peq' d 1 set
":4--~"
i:J:.,~
Note
.:: 0)$£*9='8~1=%""-(X R)~%~~ 1b O)li The parts number with mark "(XR)" is for clock-
wise rotating engine and with mark "(XL)" is for
:ti@l*'~~ffl ( x L) ic%0) 1b O)li:ti@l*';ji~ffl
counterclockwise rotating engine.
t~i"o

ft ~ El ~ INDEX FIGURES

(
-

\ #~l. $1 IJ ::.-- ~"' '/ r.· fr.U Fig. 1. Cylinderhead Ass' y ·

\ '-- !
#~2. 1J Afl!IJs J: tffl!I~ · IJJ1r~11 Fig. 2. Cam Shaft & Bearing · Valve Mechanism
1t~3. ll•U~fl Fig.3. Gear Trains, valve timing & pump driving
#~4. 3:.:flll~fr*Il . Fig.4. Main Bearing Ass' y
#~5. i:: J.. r / .Js .1: tfllii*' . ~ 1J / r:; 1 tttu Fig. 5. Piston & Connecting Rod · Cylinder Liner Ass'y

1t~6. 3:.J:lllbfitt~ Fig. 6. Main Moving Pam Ass' y. crankshaft etc

#~7. 7 7 : .-- 7 *Hi~ :t 1 Jll $1- Jllft*-li Fig. 7. Oil Seal Ass' y, crankshaft end
#~8. ~~~~fffr*'Ii Fig. 8. Air Cooler Ass' y
#~9. *~~F~1f~li Fig.9. Suction & Exhaust Pipe System
#1§10. 7 J --lfft~
1 Fig.IO. Breather Alls' y, crank case

#~11. iM iitiffi ;f- / 7' ft*,[ Fig.11. Lub. Oil Pump Ass' y
#1§12. iM iitiffi ~~ffft kl[ Fig.12. Lub. Oil Cooler Ass' y
#~13. iril iit 7111 waJ J±1rft*Ji Fig.13. Lub. Oil Pressure Regulation Valve Ass' y

6NY16L
f..t!Bl14 -1. 7Mnt7!!!.:. L fHt*1i ( / -;; 7 7 1-'n!::.) Fig.14 -1. Lub. Oil Filter Ass' y, notch wire type
ff!Bl14 -2. J,ntiffi.:. LiHt*1l (~-l.,J:t GF- 1 ~) Fig.14 -2. Lub. Oil Filter Ass' y, centrifugal type GF-1
1t~1s. irntrm~~~ Fig.15. Lub. Oil Pipe System
1t~16. ~;i;p7j(;f- / 7'frt;H. Fig.16. Cooling Water Pump Ass' y
#~17. Fig.17. Fresh Water Cooler & The~ostat Ass' y

#~18. {-f;;W*I~ 11~ 7- ~ii Fig.18. Cooling Water By-pass Line

#0019. <-f;:W*~~tl Fig.19. Cooling Water Pipe System
ff~20. ~;fStl!Jt M :r- ;;. 7'tf:;fili Fig.20. Fuel Injection Pump Ass' y
ff !Bl21. ~:fEl.Pltt:F / 7'.mtb~ii Fig.21. Fuel Injection Pump Driving Device
#~22. ~f..J.llltt:#-1±& Fig.22. Fuel Injection Valve Ass' y
ff !Bl23-l. ~:fEl.llltt:T- / 7' ttlltl?::..--7 Fig.23-1. Fuel Injection Pump Lub. Oil Tank
#~23-2. ~f-1.llltt:F / 7' i±lltliE'if Fig.23-2. Lub. Oil Pipe for Fuel Injection Pump
ff ~24. ~:fEl.7!!!.:: L ff1±*1l Fig.24. Fuel Oil Filter Ass' y
#~25. ~:fEl.lll~t~1±*1l (itll~ff) Fig.25. Fuel Injection Pipe Ass' y, with covered pipe
#~26. ~:fEl.illl~~ift Fig.26. Fuel Oil Pipe System
#~27. ff 1~-Ttt*JI. (tl~J:\) Fig.27. Governor Ass' y, mechanical type
#~28. ;alb:#-1±*1! Fig.28. Starting Air Valve Ass' y

#~29. ~lb~~ll:#tt*1l Fig.29. Starting Air Check Valve Ass' y

1t~30. 1*~#tt *1l (.f-lb) Fig.30. Control Valve Ass' y, manual
#~31. ~tb~7t~#fr*1l Fig.31. Starting Air Distributing Valve Ass' y
1t~32. tziltb~~~~il Fig.32. Starting Air Pipe System
1t~33. afff:f&:fr*1l Fig.33. Gauge Board Ass' y

./'---- ........ '\

\ •.. ~

2007.08.24R
6NY16L
Fig. 1. Cylinderhead Ass'y

CD A-Afi1iilil
Section A - A

43 ®

0-Dmiilil
Section D - D

B- B fi1i ilii
r· ->
@ (f~ c - c Wi\___) Qj) §) 6 NY I 6 l.
Section 8 ·· B Sec lion C - C
 Fig. 1. Cylinderhead Ass'y

H ~ £ ~ 15-
Item c
ca Part Name
Quantity Part No.

v ~ 1J /9" ~ -:1 t:ttm 6set 730605-11060 CYLINDER HEAD ASS'Y

1 ~ ') /)l~ "} i-· 6 130605-11011 CYLINDER HEAD
2 7'7 7' M33 30 152623-11960 PLUG M33
3 '"·:1.::f-/ 30 127610-11760 GASKET
4 7'77' 20Xl.5 24 152633-11690 PLUG 20Xl. 5
5 jfiij1 {' ·:1 .::f- / 20 x 1 24 23414-200000 GASKET. copper 20x1

6 7'7 7' PTl/8 6 23875-010000 PLUG PTl/8

7 7'7 7' PTl/4 6 23875-020000 PLUG PTl/4
8 -;t 7 7'PT3/8 12 23875-030000 PLUG PT3/8
9 1<1i.;/~- 1- <~> 12 130605-11080 VALVE SHEET.suction
10 1<1v/~- t- <~~> 12 130605-11090 VALVE SHEET.exhaust

11 I#~~ (~~) 12 130605-11160 VALVE GUIDE.suction

12 #~~ <1M~O 12 130605-11170 VALVE GUIDE.exhaust
13 / ') ·:1 :; ti -1 I'" 12 152623-11530 BRIDGE GUIDE
14 !Qk~ 12 130605-11101 SUCTION VALVE
15 m~ 12 130605-11111 EXHAUST VALVE

16 1<1v/.Ar.L..~-1v 24 133654-11150 VALVE STEM SEAL

17 #'fQ 24 145647-11120 VALVE SPRING
18 1<1v/o--r-;r 24s 27320-130450 VALVE ROTATOR
19 lfil';fQ (24) 27323-130450 CONED DISK SPRING
20 ";J -11v,f ti. (144) 27325-130450 COIL SPRING
21 ll:6"Jf\1B (24) 27324-130450 CIRCLIP
(144} 27326-130450 STEEL BALL
22 -~

23 48 27310-120000 COTIER
24 6 152623-11852 NOZZLE SLEEVE
25 '" ·:1.::f- :;_,, (J ;:(1v.A J -/)
1 6 152673-11860 GASKET.nozzle sleeve
26 0 ') /7' P39 12 152633-11750 0-RING P39

27 ~PlM#1fl3~ 6 130605-11900 HOLDER.fuel injection valve

28 ~~ 6 540623-53360 WASHER
29 ~;f- 1v t- M14x125 6 159646-11730 STUD BOLT Ml 4 x 125
30 7 ·:1 r M14 6 26602-140002 NUT Ml4
31 '"':1.::f-/ (F.0.J.A'Jv) 6 133688-11940 GASKET.F.O. nozzle

32 f®b;f-1v t- MlOx3o 12 26212-100302 STUD BOLT MlO x 30

33 7-·:1 r MlO 12 .26706-100002 NUT MlO
6NY1 6 L
2011. 03. 02R
 1'1°~ 1 . ~ 1) / 9·/'\ ·:; F1±t§. ®
Fig. 1. Cylinderhead Ass'y

H $£~~
Item CJ
ca Part Name
Quantity Part No.

34 ;f-'Jv r Ml2X 180 12 26206-121802 BOLT Ml2Xl80

35 ;f-'1v r Ml2Xll0 12 26206-121102 BOLT Ml2Xll0

'\l #!Def±*il 6set 730605-11200 ROCKER ARM ASS'Y

\1 #IJIM:Hll (IJ&~) 6s 130605-11380 ROCKER ARM ASS'Y,suction
36 #JJIB (I!&~) (6) 130605-11200 ROCKER.suction
37 7 '1 ~ .1 (#J»B) (6) 148616-11220 BUSH.rocker arm
38 ~~.tJt (#T~i) (6) 148616-11230 ADJUSTING SCREW.valve clearance
39 .tl::.~7 "J r Ml4 (6) 26692-140002 LOCK NUT Ml4

6s 130605-11390 ROCKER ARM ASS'Y,exhaust

(6) 130605-11210 ROCKER ARM.exhaust
7 "J ~ .1 (#Jl9B) (6) 152623-11221 BUSH.rocker arm
42 ~~.tJt (#T~i) (6) 148616-11230 ADJUSTING SCREW.valve clearance
43 .tl::.~-t- ·y r Ml4 (6) 26692-140002 LOCK NUT Ml4
44 -f}";f--,.. (#Jl9Bfill) 6 130605-11260 SUPPORT.rocker arm shaft

"V #JJW.filltUil 6s 130605-11240 SHAFT ASS'Y, rocker arm

45 #JJW.fill (6) 130605-11250 SHAFT.rocker arm
46 '1'7 7• PT 1/8 (6) 23871-010000 PLUG PTl/8
47 fdlffl Cff3.tl::.~"9 (6) 22242-000320 RETAINER.C type

'\l r~.Jv77 •J '1 :Yfr*.ll 12s 152623-11500 VALVE BRIDGE ASS'Y

48 ,,~,v77 •J ·y :Y (6) 152623-11510 VALVE BRIDGE
49 §~ (#IJW.$) (6) 140623-11740 CONTACT PIECE. rocker arm part
50 §1fl (#f$$) (6) 152623-11540 CONTACT PIECE. valve stem part
51 ~~.fJ t 12 140623-11521 ADJUSTING SCREW
52 11:.~-t- ·y r M12 12 26696-120002 LOCK NUT Ml2
53 ;f-'Jv r MlO x 115 18 26206-101152 BOLT M10Xll5

'\l ii{ /* f±*'l 6set 730605-11300 ~ ASS'Y

*' / *
':I "

\1 •y ,.. frfJl 6s 130605-11310 .BONNET ASS' Y

54 ;f,':.;;t. •y ,.. (6) 130605-11320 BONNET
55 , , '1 .::f / ( ;f. / •y .r ) * (6) 130605-11330
26206-100752
GASKET.bonnet
BOLT MlOX75
56 ;f. Jv 1- MIO x 75 18
57 ~~ 10 18 22137-100000 WASHER 10

6NY16L
 Fig. 1. Cylindgrhead Ass'y

H $A'1i1'~
Item $ c
1111
:g ~ Part Name
Quantity Part No.

7-:::J //~ 1' 7 t-frll 6set 730605-03111 DECOHP SHAFT ASS'Y

"58 f :J :,-/fdl 6 130605-03600 SHAFT.decomp
59 -e ·:1 t- # Jvr 6 133670-03620 SET BOLT
60 ~IJ.tl:~ (f:J//fdl) 6 133670-03641 STOPPER.decomp shaft
61 ifiij1~ ·:t .::f / 8Xl 6 23414-080000 GASKET.copper 8Xl
62 Q IJ /~· (lA) Pl2 6 24311-000120 0-RING (lA) Pl2

63 ~ttPJtM:#-f:U.ll 6set #~ 22 ~~ FU8... INJECTICW VALVE ASS'Y

Refer to Fig.22
-
64 taJJJ:#ri±M 6set #~ 27 ~~ STARTIMJ VALVE ASS'Y
Refer to Fig.27

6NY16L

2011. 03. 02R

Fig. 2. Cam Shaft & Bearing· Valve Mechanism

~~ m1tl
Sue. Exh.

~__,r-.i-.., [_~.b-· ~

l~.l........Jut-.\-l_lri·~-jiliiii.

'-------------

~6;..•J::.-Y
~6Cyl.

(fJ)

/
6 NY 161.
''--- . ../
 M~2. nA~S~~~~·~#~~@
Fig. 2. Cam Shaft & Bearing· Valve Mechanism

H $ ~ :Jf ~
Item c
DD Part Name
Quantity Part No.

\l tJ A.flbtU.ll 1 set 730605-14100 CAM SHAFT ASS'Y

l 71 Afl!I 1 130605-14020 CAM SHAFT
2 .:¥-\" ( tJ Afl!J) 1 130605-14101 GEAR.cam shaft
3 ~~~ ('fJA.:f!-\7) 1 152623-14320 RETAINING PLATE.cam gear
4 1-·:1 I- ('fJA-¥1") 1 152623-14351 NUT.cam gear
5 tfflHHf l~lhi: 1 152623-14330 LOCK WASHER

6 ;f.Jv 1- MB x 20 2 26206-080202 BOLT MB x 20

7 7 .x. .ff-.:f- 12X45 1 22512-120450 FEATHER KEY 12 x 45

\l ih#illtil .6set 730605-14050 VALVE r.EruANISM

8 ~ /'{ •:; 1- 6 152623-14201 TAPPET
9 AAf$tlJll <19k3n) 6s 130605-14451 PUSH ROD ASS'Y,suction
AA~f±U (19k3n> (6) 130605-14401 PUSH ROD.suction
y- I- <AA•...t> (6) 140623-14410 SEAT.push rod upper
y- I- <AA•r> (6) 140623-14420 SEAT, push rod lower

lo AA•f±a rn~~> 6s 130605-14461 PUSH ROD ASS'Y,exhaust

AAtlf±*ll <11~3n> {6) 130605-14411 PUSH ROD.exhaust
y-" (MlJ~...t) (6) 140623-14410 SEAT.push rod upper
SEAT.push rod lower
y- 1- <AA•r> (6) 140623-14420

\l tJ A.flb.flb~frll 1set 730605-02050 CAM SHAFT BEARING ASS'Y

11 fl!I§t 7 152623-02420 BEARING
12 A7 A r ;( 57 Jv ('f] Afl!I) 1 152623-02580 THRUST BEARING, cam shaft
13 ;f.Jv r Ml2X28 2 26206-120282 BOLT M12X28
14 ~;rti.m~ 12 2 22212-120000 SPRING WASHER 12
15 m~ 12 2 22137-120000 WASHERR 12

\l ..),f;:frilft 1set 730605-01470 COVER ASS'Y

16 l,f:. (ffiJf:KttlllztiHfD ls 130605-01640 COVER, taking out tachometer
17 re ·;1 .:f / ( l.filEttl&l±lffl) 1 130605-01990 GASKET, cover
18 ;f.Jv r Ml2X22 4 26206-120222 BOLT Ml2X22
19 ~~ <ffi1Ettlll{:±lffl) 1 152679-14180 SCREW, taking out tachometer

6NY16L
2011. 03. 02R
''.t~ 3 . ~ !II ~I& !ltlJ ~ lJl
I
Fig. 3.
~
G ear Trains, valve timing
& pump driving

? 7 /? <f'.(..
Crark Cenler

A-Allfiilii 8-Bl'tiiilii
. A- A 0 0 Section B - 8
Sectmn
---l
A, B, C, D

Q) CD

/-". D-D
I •
1.
'- ...
/ , .
Section 0- D 6NYJ61.
 Fig. 3. Gear Trains, valve timing & pump driving

$ ~ 1li -5-
Item Cl
ca ~­
Quantity Part No.
Part Name

1 f.ti;g) 6 ~!!Ji{ <DR, crank shaft

Refer to Fig. 6
'V 7-< I" Jlt:f vf±*-l! <tJ kfdntrll! lset 730605-14200 IDLE GEAR ASS'Y,cam shaft gear &
t.>J: tf PiMiF /:tmJJJiJll!) injection punp driving gear
71 i-:·11A~i'tt*1l ls 130605-14591 IDLE GEAR ASS' Y
2 71 l-'1v¥i' A (1) 130605-14601 IDLE GEAR A
3 71 i-:· 1v.:¥i' B (1) 130605-14611 IDLE GEAR B
4 -j.y:.,t:i (1) 130605-14620 BUSH
s -W-rr i:· / (1) 22312-060060 PARALLEL PIN
/
I
\...__
s iJ-r--r (71 i-:·1v.:¥i') 1 130605-14631 RETAINER. idle gear
1 "':1v- r 1 130605-14750 PLATE
8 ;f-1t.-r Mlsx10 4 26152-161102 BOLT M6Xl0

1 f.ti;g) 2 ~m <DR. cam shaft

Refer to Fig. 2
Mf81 21 ~m G:AR. injection Pllll1l driving
Refer to Fig. 21

'V iF /:fmlh7-< I" J!t:f-VfUll lset 730605-14210 IDLE GEAR ASS' Y, lub. oi I purrp & C. W.
pump driving
71 i-:·1v.:¥i'f±U ls 130605-14641 IDLE GEAR ASS'Y
11 7-1 i-:·1v.:¥i' (1) 130605-14651 IDLE GEAR
12 -f·y :.,t:i (1) 141616-14620 BUSH

13 1J -r-;- (7 -1 i-:·1i....:¥i') 1 130605-14671 RETAINER. id I e gear

14 iJ 7 - 1 130605-14680 COLLAR
1s "':1v- r 1 130605-14761 PLATE
16 ;f-f;i... r MI4x8o 2 26292-140802 BOLT M14 x 80

11 ~;- ·"} r 2 138613-39390 CAP NUT

18 1!1.1~ '"/ =\'- / 14x1 2 23414-140000 GASKET. copper 14x1
19 ~;f-f;i... r M12x9o 2 26212-120902 STUD BOLT M12 x 90
20 -;- ·y r M12 2 26706-120002 NUT M12

Mf81 11 ~m <DR. tub. oi I pump driving

Refer to Fig.11
M~ 16 ~m <CAR. cooling water purrp driving
Refer to Fig. 16

6NY16L
Fig. 4. Main Bearing Ass'y

3 3

,-··-1
k..J
L 1,·
r,...- ..·....

t1
~l,d-;c~

•. -J· °'--···-

.fl
"'llll llll 7?1'm1'-J~llf
Anti-flyweel Side Intermediate Parts Flywheel Side

4 4

'·
)
 Fig. 4. Main Bearing Ass'y

H $ ift:i :fl i5-

Item $ Cl
aa ~ :f1F Part Name
Quantity Part No.

1 :/ •J /:9'/a., 7 1 130605-01034 CYLINDER BLOCK

2 ;. 7 Jv4'-"" ") 7' <~~> 1 130605-02030 MAIN BEARING CAP, fly-wheel side
3 ;. --r /;. 7 Jv 7 1v ~ Ct> 7 130605-02130 MAIN BEARING.AL upper
4 ;. -1 / /. :9 Jv 71v ~· Cfl 7 130605-02140 MAIN BEARING.AL lower
5 /. :9 Jl;4'--\' 'Y '1' ( crrai) 6 130605-02050 MAIN BEARING.middle &anti-flywheel
side

6 5¥-rr I:"/ 6X12 2 22312-060120 PARALLEL PIN 6Xl2

7 7.. 7 7.. t- /. :9 Jv 4 152623-02151 THRUST BEARING
8 J. 7 11;4'- "" 7 '1' :f.Jv t- 14 152623-02072 BEARING CAP BOLT
I 9 -}- ") ,.. 14 146613-01221 NUT
·(
' 10 -it.{ i-:- ;f{ JI; ,.. 10 130605-02080 SIDE BOLT
11 ~ 4 130618-02080 ~

6 NY 1 6 L
2011. 03. 02R
 Fig. 5. Pston & Connecting Rod · Cylinder Liner Ass'y.

24

~ iliiil'J
Operating side
12
7 71' ;J<-1' - JI-ill!
Flywheel side

-(j])

n n

(
-~
i
l·ll==l!-1I
I~
I

I~ ~\
A ;X ~Ji
?: ''·' ·Arrow See A
\ ___ ) &7 71 >!<-(-Ml!!
2005. 5. 23R 6 NY J6L
Anti-flvwheel siclP.
 {"tj-[@5. t:A!---:.tcSJ:L}~~~· ~ 1)/5.. 71-J-f±*-H ®
Fig.S. PISTON & CONNECTING ROD· Cylinder Liner ASS'Y

~ :it
Item Quantity Part Name

V l::"?. J-. ;:,.;{tlll 6set 730605-22012 PISTON ASS'Y

1 1:: ?.}-;:..;(FCD)
0
6 130605-22053 PISTON, FCD
2 l:: ?. J-. ;:,.; !J ;:..; ::1No.1
0
6 133624-22150 PISTON RING, No.1
3 t"?. J-. ;:,.; !) ;:..; P"No.2 6 133624-2216.0 PISTON RING, No.2
4 l::"?.}-/!J/:1No.3 6 152694-22131 PISTON RING, No.3
5 ;t ..{ Jv !J / :1 f:Ull 6s 133624-22180 OIL RING ASS'Y
;t..{ Jv !) /:1 (6) 133624-22190 OIL RING
::i. ..{ Jv.:I:.""" ,;;%..r~ /?I' (6) 133624-22200 COIL EXPANDER

6 1::
0
?. 65Xl35
}-/!::";:..; 6 130605-22300 PISTON PIN 65X135
7 /\fflC~.tl:~~ 62 12 22252-000620 RETAINING RING, C type 62
8 . "}Jr'{- (;t ..{ 1v=¥ 1'" 7 !) - ) 12 130605-22450 COVER, oil gallery
9 ;f-1v J-. M6x10 24 26116-060102 BOLT M6Xl0.
10 l:f b.Jllb~: 24 22212-060000 SPRING WASHER

"V Jmfl•{tlll 6set 730605-23010 CONNECTING ROD ASS'Y

11 lmtii*' 6 130605-23010 CONNECTING ROD
12 l:: ?.J-.;:..;t'/;L7'1v
0
(6) 130605-23100 PISUTON PIN BEARING
13 mi:·:.-- (12) 137673-23251 PARALLEL PIN
14 0:;1!-";:f-1v!- (12) 130605-23200 ROD BOLTE
15 .p7;:,.;7c:•:,,-;l?1Jv 12 130605-23350 CRANK PIN METAL

'\l t" -A r. ;:..;~$;1J / ;;('1i.-tta 6set 730605-39400 PISTON COOLING NOZZLE ASS'Y
16 .J;;(1v{tl.ll(l:: ?.l-/~%ql)
0
6s 130605-39300 NOZZLE ASS'Y,piston cooling
/;;(1v (t ?.l-/~%ql)
0
(6) 130605-39310 NOZZLE,pistion cooling
~;t.tl:~tl.t:. M6X6 (6) 26911-060062 SLOTTED SET SCREW M6 x 6
17 .11E~ 6 133670-39340 WASHER
1s trm.:f:;:f-;vJ- 10 6 23857-100000 BOLT FOR PIPE JOINT
19 ¥fit";:..; ax 12 6 22312-080120 PARALLEL PIN 8 x 12

'\l ~ !.1 ;:..; 1' 7-1 -Ttta 6set 730605-01070 CYLINDER LINER ASS' Y
20 ~l)/~7-17 6 130605-0ll40 CYLINDER LINER
21 ~tr/':;1~/(J:) 6 130605-01280 RUBBER PACKING, upper
22 ~tr/'/I-' 6 130605-01290 RUBBER BAND
23 ~tr/':;1~/ Cf) 12 152623-01300 RUBBER PACKING, lower

24 JJ';.7,-1-,,·:1t/(A,:1r 2.0 6 130605-01260 GASKET 2.0 cylinder head

JJ';.7,-1-1,':tt:--(A,::il-' 1.8 (6) 130605-01250 GASKET 1.8 cylinder head
:1J';i,7,-1-,,·:1t:--CA,:1r 2.2 (6) 130605-01270 GASKET 2.2 cylinder head

2011. 03. 02R 6NY16L

Fig. 6. Main Moving Parts Ass'y, crankshaft etc.

6 NY 161.
 Fig. 6. Main Moving Parts Ass'y, crankshaft etc.

H ~ £ iii {j-
Part Name
Item $ Cl
aa ~ ~
Quantity Part No.

'V ? 5 ;/? '1bf±il lset 730605-21010 CRANK SHAFT ASS'Y

l :77/'l'fib l 130605-21010 CRANK SHAFT
2 1.1: -VJ tl l; Ml 2 6 141616-21050 SLOTTED SET SCREW M12
3 -¥-\7- (77:.-7fdl) l 130605-21221 GEAR.crank shaft
4 ffil::"/ 6X6 1 22312-060060 PARALLEL PIN 6X6

'V 7 7-< *-< -

'"f±m lset 730605-21110 FL'MER ASS'Y
5 7 7.;f' *-1-Jv 1 130605-21400 FLYWHEEL
6 .r- Jv 1- <7 7 -{ *-{ - Jv) 12 152673-21500 BOLT.flywheel
7 ffil::"/ 10X50 l 22312-100500 PARALLEL PIN 10X50
8 -:>-?l'.)£lll 1. 2 1 22451-121000 WIRE 1. 2

6NY16L
 Fig. 7. Oil Seal Ass'y, crankshaft end

J
0

.&7 71 *1-Jt,il!I 7 71 * 1 - Jt,il!I

Anti-flywheel Side Flywheel Side

2011. 03. 02R 6NY16L

 1t~ 7. ? 7 / ?~~::t1 Jv~-Jv1±*11. ®
Fig. 7. Oil seal Ass'y, crankshaft end

H $~~~
Item $ Cl
aa g ff]\ Part Name
Quantity Part No.

v 1set 730605-01252 OIL SEAL ASS'Y, flywheel side

~ ..f '" ~ - '"f±*1l
( 7 7-f *-f JldRD.
1 '7-.A{±*-Ii ls 130605-01802 CASE ASS'Y
2 ,~";I .:t- / 1 130605-01811 GASKET
3 ~-111.ty-Jv (L 7J 1 7 /) 1 148620-01880 OIL SEAL
4 8X22 11 26206-080222 BOL T M8X22
;y. '"' "
5 Y - '"' '7 ·:1 Y -Y 8 11 22190-080003 SEAL WASHER 8

v :fv-T-:Af±m 1set 730605-01202 GEAR CASE ASS'Y

\ 6 ~-\77"-.A 1 130605-01505 GEAR CASE
I
/

v 77--< *--< -}""":; /~f±m 1set 730605-01302 R..YWlEEL H(J.JSING ASS'Y

7 7 7-1 *-1 - Jv 1 " / : ; / 7' 1 130605-01603 FLYWHEEL HOUSING
8 M1':77 /:./ 1 130605-01620 FLANGE,coveing
I~ ':I .:t- / 1 130605-49150 GASKET

v ~ ..f '"'" /f±f;H,. 1set 730605-01401 OIL PAN ASS'Y

9 ~.{ Jvr\'/ 1 130605-01753 OIL PAN

v ,5,f=f±ll (&7 71 *-1 - J1'iftg 1set 730605-01350 COVER ASS'Y,crank case of

?7/?'T-:A) anti-flywheel side
10 J,f: 1 130605-01460 COVER
11 l~';l.:t-/ 1 130605-01490 GASKET

v jJ/(-f±il (&771 *-f-Jj, 1set 730605-01360 COVER JSS'Y,crank shaft of

fRg?7 /?tdl) anti-flywheel side
12 nr~- 1 130605-01881 COVER
13 ;f-11.t " M8X25 8 26206-080252 BOLT M8X25
14 y-Jv'7 ·:1 Y"'\' 8 8 22190-080003 SEAL WASHER 8

6NY16L
2011. 03. 02R
Fig· 8. Air Cooler Ass'y

Arrow See A

' ~~llli:J
AirOullcl

6 NY I 6 I.
 Fig. 8. Air Cooler Ass'y

I ~:ii $ g :fli -5-

Item c
aa Part Name
Quantity Part No.

\J ~~ftWiRtf±*ll lset 730605-18301 AIR COCl.ER ASS'Y

1 'r-~/7' 1 130605-18602 CASING
2 ~~ A 1 130605-18520 END PLATE A
3 ~~ B 1 130605-18530 END PLATE B
4 r... "I(!' (C. W. iliAD) 1 130605-18661 HEADER.C.W in/outlet
5 1{ ·:1 .::f / (C. W. iliAD) 1 130605-18760 GASKET,C.W. in/outlet

6 r... ·:1 (!' (C. W. ~ L) 1 130605-18690 COVER.C.W. return

7 I { ':I .::f / ( c. w. ~ L) 3 130605-18770 GASKET. C. W. in/outlet
8 ":11/- l'-7-1' / 298 133970-18610 PLATE FIN
9 tft!fl~ 54 141616-18720 COOLING PIPE
10 ti 7 -:f.Jv t- 29 136606-18720 COLLAR BOLT

11 ti 7 - :f. 1v t- 3 130605-18720 COLLAR BOLT

12 -J- "/ t- M12 32 26706-120002 NUT M12
13 it~ 1 139654-18971 NAME PLATE
14 ff:AW"jg~ 1 137603-18981 CAUTION PLATE
15 IJ r.( ':I r 8 137900-91451 RIVET

16 ~l&ft7 7 /:.; 4 137800-33370 FLANGE.fitting Zn.

17 /{•:,o.::f/ 4 137800-33380 GASKET
18 1{·.>'.::f/ 4 132310-09330 GASKET
19 :f.Jv t- Ml0X22 8 26206-100222 BOLT M10X22
20 -J- ·:1 t- Ml 0 ·4 26706-100002 NUT MlO

21 Wi~ 40X40 4 27200-400400 ANTI -CORROS IvE l INC 40 x 40

22 7A~·:1":1=1".I'/ B 1/4 4 23634-040022 ASTAP COCK B 1/4
23 ~/{ ·:1.::f / 13x1 4 23414-130000 GASKET. copper 13x1

6NY16L
Fig. 9. Suction & Exhaust Pipe System

A-Afffiim
SectionA- A

Ql)
 Fig. 9. Suction & Exhaust Pipe System

ttii ~ {ff,3 {}
Item c
00
Part Name
Quantity Part No.

\J fl~~"';('.=.* - Jj, tt {±*-ft 1set 730605-13011 EXHAUST MANIFOLD ASS'Y

1 VF~ 7.::. * - Jv i-:·ft*ll ls 130605-13103 EXHAUST MANIFOLD ASS'Y
2 7'71/' (5) 146673-11950 PLUG
3 ,,,·y4°"/ (5) 146673-11960 PACKING
4 s..
iJl~ ... t.: <VF~?.::.*- Jv I'"> 2 130605-13160 SIDE COVER.exhaust manifold
5 ,,,74°"/ 2 130605-13170 PACKING
6 ;f. Jv I- MlO x 25 8 26206-100252 BOLT Ml0X25

7 ~ .. t.: <VF~7=-*-1v I''> 1 152623-13300 COVER.exhaust manifold

...
\ 8 ,,,·y4°"/ 1 152623-13311 PACKING
9 ;f.Jvl- M10Xl8 4 26206-100182 BOLT Ml0X18
10 77 /:J 1 139653-49210 FLANGE
11 ,,,·y4°"/ 1 43400-003170. PACKING

12 ;f-'Jv I- M12X30 4 26206-120302 BOLT Ml2X30

13 7'71/' PT 3/8 1 23875-030000 PLUG PT 3/8
14 7J<~~ :i ·:11 PT 3/8 1 43600-500311 COCK PT 3/8
15 ~;f-11.- I- c~ - l:'"/ffl) 4 152623:...13401 STUD BOLT. turbine
16 -J- ·:1 I- MlO 4 26703-100002 NUT MlO
17 '!tl~~ 10 4 22212-100000 SPRING WASHER 10

18 .1'°·:14-/ (A..·y l''t.tlD) 6 130605-13200 PACKING.head outlet

19 -f-Jv I- Ml2 x 30 24 26203-120302 BOLT Ml2X30
20 /\.f!:J 7' 7 1/' G 1/2 4 23894-040002 HEXAGON PLUD G 1/2
21 iiJ.1' ')'.:to-/ 21x1 4 23414-210000 COPPER PACKING 21x1

\J i.t~- t-{±ID. 1set 730605-13060 SlFPffiT ASS' Y, exhaust nani fold .

<*~"?=*-}" tt)
22 -tj-;p. - " 1 130605-13302 SUPPORT
23 -it ;p. - " 1 130605-13310 SUPPORT
24 ;f-Jv 1- MlO x 20 8 26206-100202 BOLT Ml 0x 20

\l ~*fi~frlD. (ID13M!rl)
25 ~ti (TD13M~) ls 130605-18110 TURBO-CHARGER. TD13M type
26 7/:7.Jr..., I- (:i@~tlAD) 1 148816-18404 GASKET. turbo-charger inlet

\l m~At; / tt frm 1set 730618-18160 EXHAUST BEtl> ASS'Y

27 VF~~/ t: ls 130618-18340 EXHAUST BEND
W:i~~ (1) 130618-1834A HEAT INSULATING MATERIALS

6 NY 1 6 L
2011. 03. 02R
 Fig. 9. Suction & Exhaust Pipe System

Mi $ .fa ~ ~
Item c
ca Part Name
Quantity Part No.

28 1\1Ir:t 7 1f G 1/2 2 23893-040002 PLUG G1/2

iij1{·y~/ 21Xl 2 23414-210000 GASKET. copper 21x1
29 -if ;f, - 1- 1 130618-18350 SUPPORT
;f- Jv I- Ml2X22 4 26206-120222 BOLT Ml2 x 22
;f-'Jv I- Ml2X20 1 26203-120202 BOLT M12 x 20

30 ~~f?;:li!Jfifr*-R (YPS-23~) lset #181 8 ~.Im AIR COCliR ASS' Y. YPC-23 type
Refer to Fig. 8

I.7~'.l H±ll lset 730605-18211 AIR DUCT ASS'Y,air cooler inlet

(~~f?;:li!Jfi/\.[J)

31 *~~~~ (~~fftfjD) 1 130618-18150 AIR DUCT, turbo-charger outlet

32 ;f-Jlt I- Ml0X30 1 26206-100302 BOLT Ml0X30
~~ 10 1 22137-100000 WASHER 10

33 .:'";t·m.:f. 1 126635-18201 RUBBER HOSE

34 *-A7 1) ·:1-f 115 1 23000-115000 HOSE CLIP 115
35 :r.. 7 ~;' 7 I- (~~~:tOff AD) ·1 130605..::.18212 AIR DUCT.air cooler inlet
36 1{·:1~:.t (~~~:tO~AD) 1 130605-18221 GASKET;air cooler inlet
37 ;f-Jv I- MIO x 28 10 26206-100282 BOLT M10X28
;f-Jv I- MlOX 170 4 26206-101702 B.OLT ·M10Xl70
~~ 10 14 22137-100000 WASHER 10

'1 I.7~'.l H±ll lset 730605-18380 AIR OOCT ASS'Y,air cooler outlet
( ~ ~f?;:li!Jfi l:li [J )
38 :r.. 7 ~7 I- (~~~:tO~tfjD) 1 130605-18161 AIR DUCT.air cooler outlet
39 1{ ·:1 ~/A (~~~:tO~tfjD) 1 130605-18250 GASKET A.air cooler outlet
40 1{·:1~:.tB <~m~:tn~teo> 1 130605~18261 GASKET B,air cooler outlet
41 1{·:1~/C (~m~:tp~tfjD) 1 130605-18270 GASKET C,air cooler outlet

42 ;f-Jv I- Ml0X25 25 26206..;.100252 BOLT MlOX25

43 ;ff Jlt I- MIO x 75 5 26206-100752 BOLT Ml0X75
44 1\~ -f 7 7' G 3/8 I 23897-030002 PLUG G 3/8
li]1{.y,::\=-/ 17Xl 1 23414-170000 GASKET. copper 17x1

45 -if;f,- I- A C~mt%1ZD~) 1 130605-18171 SUPPORT A.air ·cooler

;f- Jv I- M12 x 35 4 26206-120352 BOLT M12 x 35
46 -if ;f,- I- B (~mt%1ZPff} 1 130605-18180 SUPPORT B.air cooler
;f-11'1- M12 x 65 2 26206-120652 BOLT Ml2X65
;ff Jlt I- Ml2 x 45 2 26206-120452 BOLT M12 x 45
6NY16L
2011. 03. 02R
 ft~ 9 . mft ~F ~ ~ ~ iii ®
Fig. 9. Suction & Exhaust Pipe System

H $£~-5"
Item $ CJ
aa :g f1I> Part Name
Quantity Part No.

\I ..),f~(±it (I7~? f-) . lset 746613-12150 COVER ASS'Y,air duct

47 J,,f:. 1 146613-12150 COVER
48 1{ "J 4=-/ 1 140623-12190 GASKET
49 ;f- Jv I- M10X20 4 26206-100202 BOLT · Ml0X20

6NY16L
 f1~10. "i ') - -if 1± *1l ®
Fig. 10. Breather Ass'y, crank case

/ .------,----,---
. '
~ '
~ ____ _J__ __ _J_ __ _
. '

I~l --- , , --o

-- -- ~ ' 0 0
:.
1
-=~~==r- -- -- : \: l ~---=--
•. ------=-:__
···-- --1
4

.
.
·h --~
__ :__ I I ..-,
y-~ ..J • ' • ,_,
Lr
. : ~=~--1 i j _. .\.._
. :url
•
. . I t I

,. ~--1 l ---

- - -----
6LY16L
 1t~ 10. j' 1) - -tf 1± *H ®
Fig. 10. Breather Ass'y, crank case

g
~ji $ ~ :m: 15- Part Name
Item $ Cl
aa ft]\
Quantity Part No.

\1 -j' v--fff±il 1set 730605-03011 BREArnER ASS'Y

1 /1) _.., ls 130605-03351 BREATHER

2 ''')!.::\=-/ 1 130605-03380 GASKET
3 :¥11.t ~ Ml0X75 2 26206-100752 BOLT Ml0X75
4 77..7-;7'-:::1·1~ ls 23637-040032 ASTAP COCK

\1 ~v/t!~i±W 1set 730605-03150 DRAIN PIPE ASS'Y

5 ~· v /f!~ ls 130605-03450 DRAIN PIPE
6 77..7·1'1'-:::1·1~ 1 23637-040031 ASTAP COCK
7 i1J1' •y .::\=- / 17X 1 1 23414-170000 GASKET, copper 17X 1
fii11' •y .::\=- / 17X0. 5 1 23414-170500 GASKET.copper 17X0. 5
i!]1'.::f / 17XQ. 25 1 23414-170250 GASKET.copper 17XQ. 25

6 NY 1 6 L
2011. 03. 02R
 Fig. 11. Lub. Oil Pump Ass'y

A-Ami mi
Section A - A

(\J)

0 ® 0

Al 0 0

0
CD (:)
il\'liltii!JIUD
Luh. Oil Outlet

r
ill'lilfiill.A.i:J
Lub. Oil lnler

(j~

I~
6 NY I 6 I.
 it[g] 11. ~~~~m ;F :/ 7°f±1Jl @
Fig. 11. Lub. Oil Pump Ass'y

Item CJ ttii: 00 ~ ~ ~
$ DD ~ f'fJ\ Part Name
Quantity Part No.
\J 1J!Jm-;e ~ "./ 7 ttm lset 730605-32106 LUB. OIL PlltlP ASS'Y
~!:t!±m ls 130605-32013 BODY ASS'Y
1 ~{:it (1) 130605-32023 BODY
2 / ..1:/.:i. (2) 152623-32131 BUSH
.cS,f;.f±*-H ls 130605-32075 COVER ASS' Y
3 ,s,t;_ ( 1) 130605-32085 COVER
4 7' '"/ :/ .:t. (2) 152623-32131 BUSH

mJ.r~•tt*.D. ls 130605-32100 DRIVING GEAR ASS'Y

5 ®!1! <U> (1) 133814-32110 GEAR.driving
6 fill (~) (1) 130605-32110 SHAFT.driving

~lh®!f!f.ttll ls 133814-32150 DRIVEN GEAR ASS"Y

7 . Ji§!f! (tnb) (1) 133814-32110 GEAR.driven
8 fill (tHIJ) (1) 133814-32160 SHAFT.driven

9 imilti!B ;f. / 7'~@!1! 1 130605-33201 l.UB. OIL PUMP DRIVING GEAR

10 -r .., !- M24 1 130605-32250 NUT M24
ll
12
*' '"' t-
sµ..fj-1:"/
Ml2X35
6X20
6
2
26206-120352
22312-060200
BOLT Ml2X35
PARALLEL PIN 6X20

13 # 1 130605-32652 VALVE
14 #lih 1 130605-32141 VALVE SPRING
15 .11:~ :r. Jv I- M36 1 138613-32440 BOLT M36
16 *11BB 1 138613-32450 LOCK WASHER
17 0 ') "./.,. 1 130605-32700 0-RING

18 ''74"-/ 1 130605-32030 GASKET

19 7'"17'7 ~ Gl/2 1 23897-040002 PLUG Gl/2
20 i\]1 ' ., 4"- "./ 21 Xl 1. 23414-210000 GASKET.copper 21x1

2003. 7.23R 6NY1 6L

l ~---
 Fig. 12. Lub. Oil Cooler Ass'y

I-;-

A-Amiim
Section A - A

8-B!Jfiim
Section B - B ·

- ....

( ~--) ti I.YI ti I.

\
 Fig. 12. Lub. Oil Cooler Ass'y

H $~*~
Item $ CJ
DD ~ ft]\ Part Name
Quantity Part No.

\l ;r;))i;dl it!lliitt*ti. 1set 730605-33010 WB. OIL COOLER ASS'Y

1 *1* 1 130605-33011 BODY, cooler
2 fJ,, _ ({J!ljjjj) 2 130605-33160 COVER.side
3 :g~ 2 146673-33200 END PLATE
4 t- i;-tt-~ 9 146673-33320 BAFFLE PLATE
5 ti!IJ~ 95 130605-33230 COOLING PIPE

6 ( t- i?-t!"~)
l!iiA~ 20 130605-33290 DISTANCE PLATE.baffle plate
7 0 •J './ -1' (lA) Pl80 2 24311-001800 0-RING OA) Pl80
8 1'1IJ -j' 7 -1' G 3/8 2 23897-030002 PLUG G 3/8
9 li]1' .., .:f- / 17Xl 2 23414-170000 GASKET.copper 17Xl
10 ¥ 1v I- Ml2X35 12 26206-120352 BOLT Ml2X35

11 fJ,, - Ltiii> 1 130605-33170 COVER, upper

12 I ' •y .:f- './ 1 130605-33180 GASKET
13 ¥1v I- Ml0X30 6 26206-100302 BOLT M10X30
14 ¥1v I- Ml0X80 3 26206-100802 BOLT Ml0X80
15 8£~ 10 9 22137-100000 WASHER 10

16 1'1IJ -j' 7 -1' G 3/8 1 23897-030002 PLUG G 3/8

17 ji]1.: •y .:\=- './ 17Xl . 1 23414-170000 GASKET.copper 17X 1
18 AA7'7 -1' M30 5 23887-300002 HEXAGON HEAD PLUG M30
19 ~''·:1.:\=-/ 30Xl 5 23414-300000 GASKET.copper 30Xl

20 L.O.H~ 1 130605-33500 L.O.CONNECTING PIPE

21 0 1) / ~ (lA) G55 2 24321-000550 0-RING (lA) G55

2008. 1. 17R 6NY16L

 -------------------

Fig. 13. Lub. Oil Pressure Regulating Valve Ass'y

rut $~ili-5"
Item ~
CJ
op :g :ff!\ Part Name
Quantity Part No.
\1 il'1J;it;w~ff*f±m lset 730605-34010 LUB. OIL PRESS!ff REQJLATING VALXSs, y

1
2
*<*
~!£#
1
1
130605-34010 BODY
141'616-34030 · PRESSURE REGULATING VALVE
3 'itJ 1 146613-34040 SPRING
4 i!J~;f.Jv r 1 138613-34100 ADJUST! NG BOLT

5 'itJ~ 1 537678-34130 RETAINER.spring

6 'it.J.til!;t 1 537678-34080 HOLDER, spring
7 'it.J.til!;tr~ •y 4=- / 1 137600-34090 GASKET.spring holder
8 ;f.Jv r M8Xl6 4 26206-080162 BOLT M8Xl6

9 ~-j- ":I " 1 139964-34120 CAP NUT

10 11: t.> 7- '7 I- M16 1 26772-160002 LOCK NUT M16
11 li]1~ -:14=- / 2 23414-160000 GASKET, copper
12 J~·y-4=-/ 1 130605-34550 GASKET
13 :f-Jv r Ml2X65 4 26206-120652 BOLT Ml2X65
. 6NY1 6 L
Fig. 14-1. Lub. Oil Filter Ass'y, notch wire type

(3~

1)
<~--
------

t -i ®

6 NY 161.
 ft~14-1. j/3~)~5ffi ;:_ l.,~f±i-J3. (./ ·:; 7-? 1-VJ:\) ®
Fig. 14-1. Lub. Oil Filter Ass'y, notch wire type

M $ci?i:#-i5"
Item $ CJ
CCI ~ f1J\ Part Name
Quantity Part No.

lset 730605-35013 LO.STRAINER ASS'Y,notch wire type

\J ;rl);*;!B;: l.,~~~7? 4 -Vrt )
1 ;<$:ft 1 130605-35101 BODY
2 'flJ~:J ':I 7 1 130605-35200 SWITCHING COCK
3 Q IJ /7' (lA) P53 1 24311-000530 0-RING (lA) P53
4 1'\·:14'-/ 1 148616-35130 PACKING
5 0 1 148616-35140 WASHER

6 1-\ ':I4'- /MJ;t 1 146673-35440 GLAND

7 :f- Jv I- Ml0X35 2 26206-100352 BOLT Ml0X35
8 0 10 2 22137-100000 WASHER 10
9 Ji;~ 1 146673-35280 NAME PLATE
10 11:6":> :f- Jv I- MlO 1 12560.0-02451 SET SCREW MlO

11 i!j.1-\' "/ .q:. / 1ox·1 l 23414-100000 GASKET, copper lOXl

\J .:i:.. v ;l / H±*.ll 2s 146673-35181 ELEMENT ASS'Y
12 .I. I/ ;l / I- (J ':I 7- '7 4 -17 ) (2) 146673-35191 ELEMENT.notch wire
13 1-\'':14°":..- (.:r..v;C :..- t-) (2) 146673-35160 GASKET, element
14 ~~tU171 2 146673-35790 Air vent plug
15 )~1 ;f- / 2 153672-59900 Packing (for Air vent plug)

\J ;: L~"r- 7.tl:m 2s 148616-35600 CASE ASS'Y.filter

6 7"-7. (1) 148616-35530 CASE
7 7~7'9 (1) 148616-35550 ADAPTER
18 i-:· v :..-7'7 7· MlO (1) 148616-35580 DRAIN PLUG MIO
\ 19 QI} /7' (1) 148616-35590 0-RING

20 QI} /7' 2 148616-35220 0-RING

21 -e / 9 :f-Jv 1- 2 130605-35250 CENTER BOLT
22 Q 1) /7' 4 148616-35570 0-RING
23 ';l'.t.l 2 137600-71030 SPRING
24 ~~ 16 2 130605-35350 WASHER 16

25 ¥!J;t (.I. I/ ;l / I-) 2 146673-35170 GLAND.element

26 .:\=-.y ·:17'-t- ':I I- 2 130605-35260 SLEEVE NUl'
27 1<11.- 7 .r-1v 1- 2 130605-35270. VALVE BOLT
28 0 /7' PS 1) 2 24311-000080 0-RING PB
29 i-:· v :..-1'\..f 7' ls 130605-35291 DRAIN PIPE

30 i-:· I/ ;n {' .{ 7' ls 130605-35301 DRAIN PIPE

31 ~.1'\·:14°"/ 16X 1 4 23414-160000 GASKET.copper 16Xl
6NY1 6 L
2011. 03. 02R
 Fig. 14-1. Lub. Oil Filter Ass'y, notch wire type

ttl!.: $ £ ii ~
Item $ Cl
aa ~ ~ Part Name
Quantity Part No.

32 1\flr:t? 7' M20 2 23887-200002 PLUG M20

33 ii]1 \' ')' .:\=- / 20Xl 2 23414-200000 GASKET.copper 20Xl

34 ~t.l{lAN:Ull 1 148688-35301 RELIEF VALVE ASS'Y

35 1'~·:14'-/ 1 130605-35110 GASKET

36 i2!ll:#tU11 ls 152623-34170 CHECK VALVE ASS'Y

#~ (1) 144626-34370 VALVE SEAT
M~ (1) 24190-120001 STEEL BALL
iit2 (1) 152623-34380 SPRING \
\ __ j
'i t.l ¥11 ;{_ (1) 144626-34390 HOLDER.spring
ii]1\' ':I.:\=-/ 16X 1 (1) 23414-160000 GASKET.copper 16Xl

37 iJl1Ji:.tf£fitf* ls 46150-050820 RESISTANCE BULB

38 ~:!Xt:.Lttt 10o·c ls 28551-030300 THERMOMETER l00°C
-

6NY16L
2011. 03. 02R
 Fig. 14-2. Lub. Oil Filter Ass'y, centrifugal type GF-1.

@----..11.
------13
~...u-+----@
w--.+---i J J

1-?t----®

A- A ·IT ii
Section A-A

6NY16L
 1'1"~14-2. J11)~5w~ ~H1±~Gi 1L.'i\) @
Fig. 14-2. Lub. O ii Filter Ass'y, centrifugal type

fdi $~*~
Item $ CJ
Oil g f1J\ Part Name
Quantity Part ·No.

v 11Jm;m c. 1..,~<±m 1set 730605-35400 WB. OIL FILTER. centr i fuga I type
(ij1C.,it) GF-1~ GF-1
;$:{;$:{±*ii ls BODY ASS' Y
2 ;$:/;;$: (1) BODY
3 A.7A.r'7·:1:/1' (1) THRUST WASHER
4 A. I:°/!-"' Jv (1) SPINDLE
5 # (1) VALVE

6 ,;r~ (1) SPRING

7 0 •) /.Y (1) 0-RING
8 7'7~ (1) PLUG
9 I {' •y ;t. / 7• 1 135410-35970 GASKET

o-7'ttM ls ROTOR ASS' Y

11 o-7$ttfJl (ls) ROTOR BODY ASS'Y
12 '1 /:/.:z. v-7 (1) INSULATOR
13 '1 /:/.:z. v-7'tUJI (ls) INSULATOR ASS' Y
14 0 •) /~ (1) 135410-35960 0-RING

15 ,;r~ (1) SPRING

16 0 ') /.Y (1) 135410-35950 0-RING
17 . o-7'tJr~- (1) ROTOR COVER
18 tl:. N'.> 7- •y I- (1) LOCK NUT
19 JXJL- (2) NOZZLE

20 A.7A.r'7...,:/-\' 1 THRUST WASHER

21 -j- .., I- 1 NUT
22 ;$:{;;$:tJ1<- 1 BODY COVER
23 1{'·:14=-/'l'. 1 135410-35990. GASKET
24 !d-r ·:1 ". l 135410-35980 CAP NUT

25 ,{' •:; .:t- / 1 135410-35320 GASKET

26 <f.Jv r Ml0X25 4 26206-100252 BOLT Ml0X25

6 NY 1 6 L
 1-t~1s. ~ll jft 5m iW ~ti: ®
Fig. 15. Lub. Oil Pipe System.

'---

"'
.... 12x2.o s s
"'"?
"
IO
•40A ~ 7- ~ 1:110

Mist Gas Outlet

iril Tit 71111:11 D

Lub. Oil Outlet
115*

I ~
f(J n:Jr1tr111.::. L-ff
()t.(.,j:\)
Lu~. Oil Filte~ (Centrifugal Type)
0
IO

9 CD

6NY16L
 Fig. 15. Lub. Oil Pipe System.

$~~~
Item Cl
ca ~­
Quantity Part No.
Part Name

1 '°'/ ~· (;it-1 Jv1'°/lliD) 1 130605-39100 BEND.oil pan outlet

iMitfifilg ls 130605-39113 LUB. OIL PIPE.
(;it-{ ;t,..i{/-iMfiti'IE;f- /-j') oi I pan - lub. oi I pump
'"·y;\=-/ (j!J) 1 138673-01990 GASKET,quadrate
I { •y ;\=- / (.=_fij) 2 152673-39160 GASKET. triangle

2 iMitfitf3g 1 130605-39401 LUB. OIL PIPE. lub. oi 1 pump - cooler

<iMiififil;f- :--7'-MHnn)
3 I { ·y ;\=- / ( ;f- / -j'{!l!J) 1 43400-004350 GASKET.pump side
( 4 ,{ ·y 4=- :-- <~:tn~mlJ) fiJ 1 130605-39420 GASKET.cooler side quadrate

5 =-:n~1t/~Jj,7" ls 740623-39342 CHANGE-OVER VALVE. 3 ways

(9-1' :--?";f-/-j'Jij)
6 1{·y;\=-/ (1j,!{!1J) AD 1 43400-003021 GASKET.oval
7 I{' •y ;\=- / ( lj\!flj) tfj D 2 43400-002901 GASKET.oval

s iMfititf3g ( 71 ~- ;1.t-¥-17) 1 130605-39551 LUB. OIL PIPE. idle gear

jf.)1{ •y ;\=- / 12x1 4 . 23414-120000 GASKET. copper 12X 1
'i!fm¥¥;i- r 2 23857-060000 PIPE JOINT BOLT

9 iMmitl311f <~nPJtt-t;f. / 7') ls 130605-39270 LUB. OIL·. PIPE. fuel injection pump
J.ilr·: •y ;\=- / 12 X 1 4 23414-120000 GASKET. copper 12 x 1
'i!fm¥¥;i- r 2 23857-060000 PIPE JOINT BOLT

10 iMmitl31!f ls 130605-39284 LUB. OIL PIPE. rack of fuel injection

(~*4PIM;f-;; 7'7 ·:1 7) pump
~I{' •)I ;\=- / 12 X 1 4 23414-120000 GASKET. copper 12X 1
1!fm¥¥;i- r 2 23857-060000 PIPE JOINT BOLT

11 imjfitifil~ t) 'i!f ( fl I {-j-) ls 130605-39232 LUB. OIL RETURN PIPE, governor

J.ij1{' •y ;\=- / 22X 1 4 23414-220000 GASKET, copper 22X 1
wm¥¥;v r 2 23857-180000 PIPE JOINT BOLT

12 iMmiEBw (jj,c.,c. Ln) ls 130605-39265 LUB. OIL PIPE. centrifugal type f i 1ter
wm¥:¥Jv r 1 23857-060000 PIPE JOINT BOLT
J.i.11 {' •y ;\=- / 12 x 1 2 23414-120000 GASKET. copper 12x1

6NY16L
2011. 03. 02R
 ft~15. ~~5m~~ti ®
Fig. 15. Lub. Oil Pipe System.

~ii $ aEi ~ -l5'

Item c
ca Part Name
Quantity Part No.

13 i!'llfflilil.EE1J~t1f ls 130605-39853 LUB. OIL PIPE.pressure gauge

14 .::..- I-' )(;.1\')(;/ ls 43600-030773 · NEEDLE VALVE
jf.ij.1 ~ -:i 4- / 12 x 1 2 23414-120000 GASKET, copper 12x1
:/a-1/I- 1 43530-001760 JOINT
~-;- ""J I- 1 23821-060001 CAP NUT

ls 130618-39561 LUB. OIL PIPE.filter - turbo-charger

130618-39520
1r.Ll:~~¥1 1 23297-120121 PIPE SUPPORTER
I~ ""J 4- / {tM!lj) 1 43400-002971 GASKET.oval
;f- Jv rMlO x 25 2 26116--100252 BOLT Ml0X25
16
li#fH.ll ls 152623-34170 CHECK VALVE ASS' Y
#& (1) 144626-34370 BODY.valve seat
M (1) 24190-120001 STEEL BALL
l;!Q (1) 152623-34380 SPRING
I;!t.21f!l .:t (1) 144626-34390 HOLDER.spring
ifa].1 ~ ""J 4- ;,..- 16Xl (1) 23414-160000 GASKET. copper 16 x 1
ifa]1 ~ '"/ 4- / 18Xl 2 '23414-180000 GASKET. copper 18 x l
17
imffli!Bir rnt~7'v~ r A, B) 130605-39570 LUB. OIL PIPE. turbo-charger -
(l&J~:ta-V!lff#) pressure regulating valve
/~·:t+ ;,. - (11"J!fj) 1 23428-260000 GASKET. oval
;f-Jv !- Ml0X25 2 26206-100252 BOLT Ml0X25
1-:•"J.:f-/ 1 144626-39562 GASKET
;f-Jv r Ml0X30 2 26206-100302 BOLT MlO X30
A.--::-~ 1 130618-39600 SPACER
s.Ll:.~~¥1: 1 23297-250121 PIPE SUPPORTER
18
1'Jmntr1'7-1' ~ :'./P-~~:1' LUBRICATING OIL PRIMING PUMP
(Parts for exchange) BEARING FOR MOTOR
~~?' Jfl~7 !J /~

ABBW!'!~-::$7 }fl 1 24107~062030 at Motor maker by ABB company

k 1 24107-062020 fl

~-~;/,A~~~-?' ffl 1 24105-062020 at Motor maker by SIEMENS company

k 1 24107-062020 II

6 NY l 6 L

2011. 03. 02R

Fig. 16. Cooling Water Pump Ass'y.

Q.2
t ii;!IJ.ij(IJllJ
Cooling Wa1erOu1lel

11

6 I. y l 6 I.
 Fig. 16. Cooling Water Pump Ass'y

I
rut ~ ifa i1f -5
Item $ c
ca :g fj]\ Part Name
Quantity Part No.

"\/ i'1iil17.lc~ ;_,/fUll lset 730605-42010 OJCl.ING WATER.FUP ASS'Y

~!IJ7l<~/7' ls 730605-42020 COOLING WATER PUMP
1 >r-://7' (1) 130605-42011 CASING
2 "/]I'{- (1) 130605-42021 COVER
3 :/.y 7 I- (1) 130605-42031 SHAFT
4 .{ /-"' 7 (1) 130605-42040 IMPELLER
5 ;. tJ .:::.. tJ 1v :/ - 1v · (1) 136600-42502 MECHANICAL SEAL

6 ~fdl~ (1) 24102-062064 BALL BEARING

7 ~fdl~ (1) 24101-063064 BALL BEARING
8 Q IJ ;,i 7' (lA) P25 (1) 24311-000250 0-RING (lA) P25
9 CJf~.tl:.~~ (1) 22252-000720 RETAINING RING,C type
10 :;t .{ JV :/ - Jv (1) 136600-42480 OIL SEAL

11 Q IJ / j ' (lA) Gl65 (1) 24321-001650 0-RING (lA) Gl65

12 M20 (1) 26736-200002 NUT M20
-r ") "
13 ? •y :/ i" (1) 22137-200000 WASHER
14 7 .x.off-.+- (1) 22512-070200 FEATHER KEY
15 -=>'ift;f. 1v I- Ml0X20 (6) 26106-100202 FLANGE BOLT MlOX20

16 1'11Hilift"1' 7 7' Gl/4 (1) 23897-020002 HEXAGON PLUG Gl/4

17 ii!J.1 {' •y .+ / 13Xl (1) 23414-130000 GASKET, copper 13Xl
18 "fJ7- (1) 130605-42050 COLLAR

19 ~!IJ7J<;f- / "1'ml.ni1Uf! 1 130605-42401 GEAR.cooling water pump driving

20 ,1{'.y .+ / 1 130605-42140 GASKET
21 :f. Jv I- Ml0X25 6 26206-100252 BOLT Ml0X25

6.NY 1 6 L
Fig. 17. Fresh Water Cooler & Thermostat Ass'y

A-AWiilii 8-· BWiim

Section A-A
Section B- B

CD

Sea Water Inlet

l~ 6 NY t61.
 Fig. 17. Fresh Water Cooler & Thermostat Ass'y

~ii $£~~
Item CJ
ca Part Name
Quantity Part No.

v m7l<it!llnttm lset 730605-44150 FRESH WATER COil.ER ASS'Y

1 *f* cm7f<f.ft!lln> 1 130605-44021 BODY.frsh water cooler
:i 7 f.Hll <ffl7f<Xt!lln) ls 126683-44210 CORE ASS'Y,fresh wate cooler
3 1J 7-7 A (1) 126683-44220 RETAINER A
4 1J 7-7 B (1) 126683-44230 RETAINER B

5 7'v-I- A (2) 126683-44240 PLATE A

6 7'v- 1- B (2) 126683-44250 PLATE B
1 1{.{ -:t <m7f<f.ft!lln> (66) 148633-44260 PIPE.fresh water cooler
( \, 8 ;(.;o{--if A (12) 148633-44270 SPACER A
\'--. . /

9 ;(.;o{--if B (4) 126683-44280 SPACER B

10 O•J;.;1' 2 24321-002100 0-RING

11 1J1{- A (ffl7f<fli!ll~AD) 1 130605-44051 COVER A.fresh water cooler inlet
ttW "J f±*ll Ul!i*Xt!ll~) ls 126683-44530 PARTITION ASS'Y,fresh water cooler
13 f±W tJ (ffl7J<fli!IJ~) (1) 126683-44540 PARTITION. fresh water cooler
14 lllHt~ (1) 126683-44550 PLATE

15 ;f.Jv I- M6X 10 2 26113-060102 BOLT M6Xl0

16 1
1J {- B (ffl*Xt!Pn:±iD) 1 130605-44060 COVER B.freshwater cooler outlet
17 ;f.Jvl- Ml0X40 12 26206-100402 BOLT Ml0X40
18 ~;f{Jv I- Ml0X30 2 26226-100302 STUD BOLT MlO x 30
19 r •y I- Ml'O 24 26706-100002 NUT MlO
20 t.l l; 7'71' 1 127610-11750 PLUG
21 1{ ')' .:t- / 1 127610-11760 GASKET

1 126683-44400 COVER.fresh water cooler

23 1{ •y .:t- / 1 148218-33061 GASKET
24 ;f.JvI- Ml0X22 4 26206-100222 BOLT MlOX22 .
25 --/7 7' M36 1 41649-000130 PLUG M36.
26 1{ •y .:t- / (}L) 1 43416-000060 GASKET.round

21 11toott ls 146613-44900 GAUGE.water level

28 .~.iEH~#7 7 ;.; :Y 4 137800-33370 FLANGE, fitting zinc
29 ~~.tia 40X40 4 27200-400400 ANTI-CORROSIVE ZINC 40X40
30 1{ •y .:t- / (}L) 4 132310-09330 GASKET.round
31 I { ')' .:t- / (1J'-*'D 4 137800-33380 GASKET.oval
32 r ·y I- MlO 4 26706-100002 NUT MlO
33 ;f-Jv I- Ml0X22 8 26206-100222 BOLT MlOX22

6 NY 1 6 L
2011. 03. 02R
 1'.f"~ 17. j~7J<~i!J15is J: LJ\'-ij- - -t: .A 9 ·:; I-- @
Fig. 17. Fresh Water Cooler & Thermostat Ass'y

Cl
rut $ iib ~ ~
Part Name ·
Item DD
Quantity Part No.

34 7 -{ 7 ls 120445-44600 FILLER
7" v ·1 ~ 1' 4=- 1' ·1 7" (1) 123682-44210 PRESSURE CAP
35 /{ ·1 .:f / ( 7 -{ 7) 1 120445-44611 GASKET;filler
36 ;f-Jv 1- MB x 16 4 26206-080162 BOLT M8Xl6
37 /{-{ / (;;f'-/{- 7 D - ) 1 123482-44570 PIPE.over flow

38 B::'@:it;t& 1 152623-44620 CAUTION PLATE

39 jg;t& 1 146613-44361 NAME PLATE
40 /-\ - tJ - .A 7 1) ..:i. r/ 1) .r-( ·1 I- 4 137900-91451 RIVET

41 /\~ 7" 7 7· G 3/8 1 23894-030002 HEXAGON PLUG G3/8

42 ~/'~ ·1 4=- / 17 x 1 1 23414-170000 GASKET.copper 17Xl

43 '"/ 7 Jr "I 1- 1 130605-44311 . BRACKET

44 ;f-JL- I- M14 x 40 5 26292-140402 BOLT M14X40

\l =E A 9 ':I H±*Al
-fj" - lset 730605-48010 THERrtllSTAT ASS'Y
45 Jr - A (-it-· ·~".A ~ ·1 I- ) 1 130605-48100 CASE. thermostat
46 -tt-~.A~ ·1 I- 71° 4 140623-48250 THERMOSTAT 71°
47 fJ/{- (-7-.A) 1 130605-48120 COVER.case
48 /'·1.:f/ (-tt-~.A~ ".1 I-AD) 2 130605-48140 GASKET. thermostat inlet
49 /' -;I 4=- / ( tJ / { - ) 1 130605-48130 GASKET.cover
50 r~·14=-/ <rrr*~!ll~.i\D) 1 130605-49300 GASKET.fresh water cooler inlet

51 /\~7"7 7' G3/4 1 23897--060002 HEXAGON PLUG G3/4

52 ~/-- -:.r .:f / 27Xl 1 23414-270000 GASKET.copper 27Xl
53 /\~ 7" 7 7' Gl/2 2 23897-040002 HEXAGON PLUG Gl/2
54 aq/' ·14=- / 21x1 2 23414-210000 GASKET.copper 21Xl
55 /\~ 7" 7 7' G3/8 1 23897-030002 HEXAGON PLUG G3/8
56 1i3/{ -:.r .:f / 17Xl 1 23414-170000 GASKET.copper 17X.l

57 :f-Jv t- Ml2Xl05 4 26206-121052 BOLT M12x105

58 :f-Jv 1- M10X65 6 26206-100652 BOLT Ml0X65
59 :f-Jv t- M10X30 4 26206-100302 BOLT Ml0X30
60 :f- Jlt 1- M12 x 30 2 . 26206-120302 BOLT Ml2 x 30
61 ~~i (~30) 1 130605-4901 o Orifice (; 30)

6NY16L
2011. 03. 02R
Fig. 18. Cooling Water By-pass Line

6NY16L
 Fig. 18. Cooling Water By-pass Line

tt:ii $ £ ~ -5-
Item $ CJ
DD :g ~ Part Name
Quantity Part No.

\I it'WJJ<1~11~A.!tll! lset 730605-48160 COCl.ING WATER BY-PASS Lit£ ASS' Y

1 *l* 1 130605-48200 BODY
2 ~ . . t: 1 141616-49270 COVER
3 ~!117)< ... {4 ....~A.# 1 146603-49281 BY-PASS VALVE.cooling water
4 "':,; J-:'1v 1 153623-48270 HANDLE

5 ~~ 1 146613-49330 NAME PLATE

6 ') "' ·;.r "
2 137900-91451 RIVET
7 ....~ ·;.r .:f- / 1 43400-000880 GASKET
8 ¥1v " Ml2X30 4 26206-120302 BOLT Ml2X30
9 -f-4 D /.f~ "I .:f- / 1 23418-330000 GASKET.nylon

10 O•J :,_,~ (lA) P24 1 24311-000240 0-RING (lA) P24

11 m~ 22 1 22137-220000 WASHER 22
12 m~ 14 1 22137-140000 WASHER 14
13 $~ .:f-- 5Xl6 1 22522-050160 WOODRUFF KEY 5Xl6
14 l.l:VJ-T 'Y " <"':.; t:· Jv > .1 136610-66410 LOCK Nllf.handle
15 !JJ t:" / 3. 2x20 1 22417-320200 SPLIT PIN 3. 2x20

16 ~t><tl 7 7 / :,/ 2 130605-49390 FLANGE.spectacle type

17 Jf:J ... " 'Y .:f- / 4 159616-49390 GASKET.quadrate
18 ¥1v " Ml2X35 8 23887-300002 BOLT .Ml2X35
19 fr..flJ "f 7 ~ G3/8 1 23894-030002 PLUG G3/8
20 i;}.f " 'Y .:f- / 17Xl 1 23414-170000 GASKET.copper 17Xl
( "1.
\__

6NY16L
 Fig. 19. Cooling Water Pipe System.

60.5x3.9 ST

~$~~~~ llU-i~~n~.....~
Lub. Oil Cooler
1
, . i:CUTT
i..- =--tt~
. <
r
lftlJ(l:liD
Sea Water Outle
ljjlJ(;f- :--7 &
0
Fresh Water Pump 10~ ram ~,

....::> ....:::>
--~
· 7f<.?-fi"~F~7.::.;t--Jv i:
-...-
u u
Water Cooled Exh. Manifold : ~~?-fi"!fl~ :
CO ID

. I Aff~ler
- -·

~7}(.AD
Sea Water Inlet

2011. 03. 02R 6NY16L

 Fig. 19. Cooling Water Pipe System.

g ~:m $ £ tti ~
Part Name
Item $ CI
ac f,j;
Quantity Part No.

1 ff;!07J<:gtUll <~7f<;f- '/""/- 1 130605-49101 COOLING WATER PIPE.

y 1J / :$7'/o ·:1 7) fresh water pump - cylinder block
f:L77/~ 1 23211-050000 FLANGE.round type
''·:1.:f-/ (j:L) 1 23438-050000 GASKET.round
¥;Lt I- Ml2 x 30 4 26206-120302 BOLT Ml2 x 30

2 V)7'J<.tJ 7 -7 / ~ 1 130605-49290 FLANGE.spectacles type

, , ':I .:f- / (!J\.flj) 2 130605-49150 GASKET.oval
3 ''·:1.:f-/ 1 130605-49500 GASKET

4 ff;!O*:g 1 130605-49140 COOLING WATER PIPE.

(iB!JMiEEff;W~A. o) tub. oil cooler inlet
:r-· ;Lt I- Ml2X30 4 26206-120302 BOLT Ml2X30
5 I' ':I .:f- / (1J'*'D 1 130605-49150 GASKET.oval
6 , , .,, .:f- / ( iJ '*'D 1 130605-49180 GASKET.oval

7 "" / i-:· ( y 1) / :$7'"" ':I i-· - 6 130605-49350 BEND. cylinder head -

~F~<=-*-11.t !-=') exhaust manifold
I,, ., .:f- / ("" ·:; i-:·m,D 6 13367G-49331 GASKET.cylinder head side
, , ':I .:f- / ( 7 =-*- lv HJllJ) 6 130605-49360 GASKET.manifold side

¥11.t I- MlO X30 12 26116-100302 BOLT MlO X30

¥11.t I- M10X25 6 26116-100252 BOLT MlO X25
¥11.t I- Ml0X60 6 26116-100602 BOLT M10X60

8 (f;W71<W (jg_~#ttlD) 1 130605-49121 COOLING WATER PIPE. thermostat outlet

9 i'{tt;n71<:g 1 130605-49131 COOLING WATER PIPE.
( Y ') /;r/o ·:1 7 A.D) cylinder block inlet
10 ~ti'M'!-¥ 1 148816-49710 RUBBER HOSE
*-7.. 7 1) ·:1 -:/' 4 23000-102000 HOSE CLIP

11 , , ·:; .:f- / ( 1J~J) 1 130605-49150 GASKET.oval

12 , , ·:; .:f- / <-=-~) 1 130605-49310 GASKET. triangle
13 ''·:14'-/ 1 130605-49500. GASKET
14 ,, ·:; .+ / (lj\.!f!.JJ) 1 130605-49510 GASKET.oval

15 -ij--~7..7 .,, t-7"-7..:171<- 1 ft~ 17 t5~ COVER. thernnstat case

Refer to Fig. 17

6NY16L
2011. 03. 02R
 ft~19. ~!11*~~~ ®
Fig. 19. Cooling Water Pipe System.

$ ab ~ -i5-
I tern ca
Cl
~·
Quantity Par t No.
Part Name

16 7 7 :,; ; {!MfJJ) . 1 130605-49160 FLANGE.oval

0 ') / j ' 2 24321-000750 0-RING
I' •;I .:f / ( tj\tJj) 1 130605-49180 GASKET.oval

1 130605-49171 COOLING WATER PIPE. fresh water pump

inlet
;f. Jv t- Ml2 x 45 2 26206-120452 BOLT Ml2 x 45
''·:.i.:f/ (~) 1 43400-003170 GASKET,quadrate
;f.Jv I- Ml2X30 8 26206-120302 BOLT M12 x 30
A,77/) 1 23211-050000 FLANGE.round
''·:.i.:f / (jl,) l 23438-050000 GASKET.round

18 ~ / F (mlf<~tPntf:lD) l 130605-49201 BEND.fresh water cooler outlet

,, ·:.i .:f;.; (m7f<~tontl:lo> 1 130605-49260 GASKET. fresh water cooler outlet

~1it~i'JI&ft7 7 /:; l 137800-33370 FLANGE.anti-corrosion zinc

, , ·:.i .:f ;,.- (1M~-1J) 1 137800-33380 GASKET.oval
''·:.i.:f / (jl,) 1 132310-09330 GASKET.round
~jj~ft 40X40 1 27200-400400 ANTI-CORROSION ZINC 40 x 40
;f. Jv t- MlO x 22 2 26206-100222 BOLT MlO x 22
-J- ·:.i I- MlO 1 26706-100002 NUT MlO

19 tf;!Plf<:g ls 130605-49212 COOLING WATER PIPE.fresh water cooler

(mlf<~tnn-~m~inH> - air cooler
1-\ ·;.i .:f / (~) 1 ·43400-003170 GASKET,quadrate
;f. Jv 1- Ml2 x 30 4 26206-120302 BOLT M12X30
1-\-;1.;f / (;€fj) 1 138673-01990 GASKET,quadrate
;f. Jv t- Ml2 x 30 4 26206-120302 BOLT M12X30

20 ~:,; ~- (~m~!PHAD) l 130605-49370 BEND.air cooler inlet

1-\·;1.::f/ (;€fj) 1 132500-49250 GASKET.quadrate
;f. Jv t- Ml2 x 30 4 26206-120302 BOLT Ml2 x 30

ls 752623-49200 DRAIN aJCK ASS'Y,cvlinder block

21 *~~ :::J ';/ ?t±til.
( :.- IJ "/~70 ';/?)
(1) 152623-49930 BODY
*f*
:If-•
l.l:.~-J- ·:.i t- Ml4
(1)
(1)
152623-49920
26694-140002
VALVE
LOCK NUT M14
lf<ti~:g ls 152623-49981 DRAIN PIPE
j;J1-\ ·:.i .:f / 18x1 1 23414-180000 GASKET. copper 18x1
fiil1-\ ·;.i .:f / 20 x 1 1 23414-200000 GASKET. copper 20x1
6 NY 1 6 L
2011. 03. 02R
 ft~19. i~~*~~& ®
Fig. 19. Cooling Water Pipe System.

H $ ll~ ~ -i5-
Item $ c
l:Ul
~· ff]; Part Name
Quant i tY Part No.

22 jJJ'\- (mJJ<it!ll~V.. tJ) 1 f";t~17 ~~ COVER, fresh water cooler inlet

Refer to Fig. 17

'
6t'JY16L
fig. 20. Fuel Injection Pump Ass'y

(,....--,\i
\...__./ 6 I. Y I 6 I.
 Fig. 20. Fuel Injection Pump Ass'y

H ~~~~
Item Cl
cc Part Name
Quantity Part No.

V ~*411JtM~ :.r/f±*1l lset 730605-51781 FUEL INJECTI 00 PlW ASS' Y

1 ;:t -1 11.t:;., - 11.t 1 137610-42480 OIL SEAL
2 /.$:~ (PJUt-f- '/1') 1 130605-51010 BODY.fuel injection pump
3 fJ J.,.. :/ .y 7 " (llJU>t.f- / 7') 1 152623-51041 CAM SHAFT. injection pump
4 0 - 7 "( 7 1) / ~ 2 152623-51050 ROLLER BEARING
5 1J -T - -1- ( r<. 7 1) / 7·) 1 152623-51060 RETAINER.bearing
O iJ / 7' (lA} sgo 2 24341-000900 0-RING (lA) sgo
6 1J 7 - (" 7 1) / 7') 1 152623-51070 COLLAR, bearing

( 7' 7 / ~ "i' {±*1! 6s 130605-51100 PLUNGER ASS'Y

\
7 1{1./)l,.t (6) 130605-51110 BARREL
8 7'7/~.y (6) 130605-51130 PLUNGER

g 77 v '7 7 6 152623-51150 DEFLECTOR

10 ,;rt;l (7'7 / ~-?) 6 152679-51160 SPRING, plunger
11 'itl§l: A 6 . 152623-51170 SPRING RETAINER A
12 'itl§l: B 6 152623-51181 SPRING RETAINER B
13 tl t; ('itl§l:~ll:~) 6 152623-51190 SET SCREW. locking retainer

7r::..."J HHJl 6s 152673-51200 TAPPET ASS' Y

14 7•"J:/.:i. (D-7) (6) 152623-51212 BUSH.roller
15 0 - 7 ( 7" "") ") (6) 152623-51222 ROLLER, tappet
16 c/ (o-7) (6) 152623-51232 PIN. roller
17 7r::..'"J t- (o-7) (6) 152673-51240 TAPPET, roller
18 11:~~ (D-7 l:
0
/). (6) 152673-51250 .RETAINING RING

1g tl t; (7r::..'"J t-~ll:~) 6 152623-51270 SCREW

20 Q IJ /~ pg 7 144626-51281 0-RING pg
21 0 1J /~ P6 8 144626-51290 0-RING P6

r 1) "( 1) 1{Jl,.t7{±*1J. 6s 152673-51300 DELIVERY

22 -=r 1) "( 1) I { J(l 7 (6) 152673-51310 DELIVERY VALVE
23 :/ - " (r 1) ~ 1) I { )V 7) (6) 152693-51321 SEAT.delivery valve

6 137600-51332 SPRING.delivery valve

6NY16L
2011. 03. 02R
 Fig. 20. Fuel Injection Pump Ass'y

H $ i?a ~ ~
Item $ CJ
aa ii ff!\ Part Name
Quantity Part No.

~~4Ht*'l 6s 130618-51352 DAMPJNG VALVE ASS' Y

25 7 1; ,r.;: 1; * Jv ?" (6) 130618-51360 HODER. delivery valve
26 Ar /I I\ (6) 130618-51380 STOPPER. delivery valve
~-.A (6) 130618-51370 PIECE, delivery valve
.A -;1'1) './~ (6) 148691-51370 SPRING, check valve
:t -it .:i:. (6) 148691-51380 RETAJNER
7- .:i:. /I 7 1~1v7' (6) 148218-51370 CHECK VALVE
'27 o 1; / ~
(71; ,r.;: 1; Jv ?") * 6 152673-51360 0-RING, delivery holder
28 1'\ /I :t- './ (71; ,r.;: 1; 1~ 1v 7) 6 152673-51390 PACKING, delivery valve

r\1,.11v~ if- - H±*ll 6s 152679-51390 BARREL SUPPORT ASS'Y

29 ,,{ v Jl.t~if- - I- (6) 152679-51400 BARREL SUPPORT
30 1:0
/ (r{ v Jl.ttiNJ) (6) 144626-51410 PIN

31 O•J /~ (r'vJv"if;f-- 1-) 18 152673-51420 0-RING,barrel support

32 c/ OitJ§ttiJ.1:.V.,) 6 144626-51430 PIN
33 QI}/~ (.f{l/Jv~if-- f-) 6 152673-51430 0-RING, barrel support

34 :.--.L..tUll. ls 152623-51450 SHIM ASS' Y

Yk T=O. 5 (2) 152623-51430 SHIM T=O. 5
:.-- .L.. T=0.12 (2) 152623-51440 SHIM T=0.12
Yk T=O. 3 (4) 152623-51460 SHIM T=O. 3
y.L.. T=0.15 (4) 152623-51470 SHIM T=0.15
y.L.. T=O. l (4) . 152623-51480 SHIM T=O. l

35 5-:;7 .1 152623-51500 RACK

36 C'..::..;t/ 6 152623-51510 PINION
37 t2 l; ( 5 •y 7 J!mJ.l:.V.,) l l44626-51521 SCREW
38 '!t2 (~§flk) l 140623-51530 SPRING
39 ~~ (iW§flk) 1 140623-51540 WASHER
40 ll:VJ~ (7'7 / :Y .y) 6 152623-51540 RETAING RING, plunger

41 5 -:; 7 {¥aifai 1 152623-51551 COVER, rock

42 ~7- ·y I- (f!flffii/IW) 1 152623-51560 CAP NUT.fuel limit
43 7-:; 7 J,,f;:_ 1 152623-51570 COVER
44 '1'"'.IY:L (7·Y7) 2 140623-51580 BUSH
45 1 152623-51580 GASKE1
"" •y .:\=-/

46 ' " •y -t- / ( 7 •y 7 ti~fiii) l 152623-51591 GASKET

47 ;f-J[.. I- (.:i:. 7ti~) 2 138613-51660 BOLT.air vent
48 QI}/~ (/07-7 ~) 2 152673-51660 0-RING,protector
49 7'7 7"(F. 0. ttlD) l 144626-51670 PLUG, F. 0. outlet
7'7 7"(F. 0. AD) 1 148616-51671 PLUG. F. 0. inlet
6NY16L
2011. 03. 02R
 . 11~20. !it&*4Pl it*' / 7°1±11. ®
Fig. 20. Fuel Injection Pump Ass'y

H $£~~
Item $ CJ
DD ~ ~ Part Name
Quantity Part No.

50 0 1)/ l/(F. 0. l:tlAD) 3 144626-51680 0-RING. F. 0. inlet/outlet

51 7'7 ~l(L. 0. ~7!BO) l 136603-51690 PLUG. L. 0. filler
52 .y - 1v '7 ·:1 .y 1' 6 2 144626-51700 SEAL WASHER 6
53 ~ 10 144626-51730 SET SCREW
54 .Y L. T=l. O (PJfM~WD 12 152623-51750 SHIM T=L 0, injection timing

55 .y L. <±*.!! <PJtt-t~J.JD 6s 152623-51760 SHIM ASS' Y

.Y L. T=O. 5 (24) 152623-51770 SHIM T=0.5
.Y L. T=O. 3 (24) 152623-51780 SHIM T=0.3
( ~ "· Y L. T=0.1 (24) 152623-51790 SHIM T=O. l
\ !

56 ~;y.,i,. 1- (1{!.11v-tt;f- - 1- > 12 152623-51800 STUD BOLT,burrel support

57 '7 ",/ Y '\' <" <v Jv-tf ;f- - r > 12 152623-51810 WASHER,burrel support
58 7'07-77 2 130605-51830 PROTECTOR
59 fill~ ( "f1 L. .Y '\' 7 r i:t:irai> 1 152623-51850 BEARING.cam shaft mediate
60 I { •;,r .of- / ( 7 -{ - . i..:· ;f- / "/) 2 124410-51861 GASKET.feed pump

61 1) "-·:1 " 6 124220-51890 RIVET

62 it~ 1 130~05-51910 NAME PLATE
63 it~ 1 144626-51930 LABEL
64 7·:1Y/I/ 3 144626-51940 BUSHING
65 0 1) /!/ 5 144626-51950 0-RING
66 ttEPffli"f 1 151695-61090 TIN SEAL
"'?--:$ '? *Jit 1 22453-060000 WIRE
,
/ - "'.
67 .Y-Jv'7 ·:1-Y"" 6 2 22190-060002 SEAL WASHER 6
68 y-Jv'7 ",/ :/'\' 16 1 22190-160002 SEAL WASHER 16
69 t!t.l.~~ 5 2 22217-050000 SPRING WASHER 5
70 ,;rt.i.~~ 6 6 22217-060000 SPRING WASHER 6

71 'itl.~~ 12 12 22217-120000 SPRING WASHER 12

72 "'?--:$ '? • 3 22454-1>80000 WIRE
73 7 ;r. ~-4'-- 7X22 1 22512-070222 FEATHER KEY 7X22
74 7 ;r. ~-.of-- 10X34 1 22512-100340 FEATHER KEY 10X34
75 ,{.y,of-/ 2 23414-080012 PACKING

76 /-;fl!. 7' 7 I/ 2 23887-120002 PLUG

77 /\.fll "1' 7 I/ 1 23887-160002 PLUG
78 .r-1v r 8X30 4 26013-080302 BOLT 8X30
79 "'? 'i .Y. 1v t- 8X50 1 26106-080502 BOLT 8X50
80 .r-1v" 8X22 1 26116-080226 BOLT 8X22
·6NY16L
 Fig. 20. Fuel Injection Pump Ass'y

Mi $ ifa 1li ~
Item $ CJ
DD :g ~ Part Name
Quantity Part No.
81 :f®6 :¥ Jv t- 6 26226-060162 STUD BOLT
82 1\~ /t :¥ ,i., t- 6X25 2 26450-060252 BOLT 6X25
83 t-'-"01'tJ t 2 26557-050122 SCREW
84 -j- -:; I- 6 6 26716-060002 NUT 6
85 -r ·y " 12 26736-120002 NUT

86 1.1::~-r ·y 1- s 1 26757-080002 LOCK NUT 8

87 ll:~tJt 8X32 1 26911-080322 LOCK SCREW 8X32
88 :/-Jv'7 •y :/.y 12 1 22190-120002 SEAL WASHER 12

6NY16L
Fig. 21. Fuel Injection Pump Driving Device

:...•J;, Vf1.1 ·, .~fll!itri

ISide !'nee of Cylimh:rhruck
I

A- A lf1i ii'ii
Section A··· A

-~----i .,.r::~

.~--.:.: ..
! !:

l>irc..:rtion 11f 111msl

?7 :<?fdl'l'·t·
Center of Crunkshafl
 1"1~21. !tt&*:flljiij ;F / 7°~1&IJJ~~f±*!l ®
Fig. 21. Fuel Injection Pump Driving Gear

H $~~~
Item w CJ
DD g ft
Quantity Part No.
Part Name

\J ~'*PlMif- :rJ'mJJJ~~ lset 730605-54011 RJE1... INJECTICll P\W OOIVING <EAR

1 !Mb Jr - .A ( P1Ut ;f. '/1') 1 130605-54361 CASE. injection pump driving
2 ,{";~/ (!!JlKi/JT-.A) l 130605-54370 GASKET.case
3 Ufdl (DJUt:F /:1) 1 130605-54410 SHAFT. injection pump driving
4 ]ifdl~ 6309 1 24101-063094 BALL BEARING 6309
5 ~fdl~ 6209 1 24101-062094 BALL BEARING 6209

6 .A~--tt 1 152623-54420 ' SPACER·

7 7-·:1 r M45X 1. 5 (]ifdl§t) 1 24211-045002 NUT M45Xl. 5, ball bearing
( \, 8 '*~ 45 1 24231-045000 LOCK WASHER 45
\, i
9 -¥-\7 <PlM-r- ::..-:tU> 1 130605-54381 GEAR. injection pump driving
10 7 ~-tf~- 10X30 1 22512-100300 FEATHER KEY 10X30

11 mI? 1.1:~'*~ 1 140623-54420 LOCK WASHER

12 7·:1rM27 1 26732-270002 NUT M27
13 ;t-11v:/-1v 1 120220-02460 OIL SEAL
14 f!lr¥M-~(.3ifl!l§t) l 140623-54710 RETAINER.ball hearing
15 :f-1v r Ml0X20 2 26206-100202 BOLT Ml0X20
16 ittJm~ 10 2 22212-100000 SPRING WASHER 10
17 7 ~-tf~- 10X36 1 22512-100360 FEATHER KEY 10X36

'\/ ff!~P.lMif- :rJ'Jlllt-t-8 1set 730605-54052 r,nm, fuel injection Pl.ml

18 llirftii' <f'!flPJlM ir- / -;t > ls 130605-54022 MOUNT.fuel injection pump
19 Ykf±*-!l ls 130605-54100 SHIM ASS'Y
(
I
\
'
y k (T=O. 5) (1) 130605-54110 SHIM. T=O. 5
\ )
'
:/k (T=O. 3) (1) 130605-54120 SHIM. T=O. 3
Yk (T=O. 2) (2) 130605-54130 SHIM.T=0.2
Yk (T=O. D (1) 130605-54140 SHIM.T=0.1

20 Yk{:t*-ll ls 130605-54150 SHIM ASS' Y·.

:/k (T=O. 5) (l) 130605-54160 SHIM.T=0.5
:/ k (T=O. 3) (1) 130605-54170 SHIM. T=O. 3
:/ k (T=O. 2) (2) 130605-54180 SHIM.T=0.2
:/ k (T=O. D (1) 130605-54190 SHIM. T=0.1

21 :f-1v r Ml6X40 2 26156-160402 BOLT Ml6X40

22 sµ..fft"/ 12X35 2 22312-120350 PARALLEL PIN 12X35
23 ;f- Jl,,J• Ml2Xl20 4 2611&-121202 BOLT Ml2Xl20
,, Ml2X 115 2 2611 &-121152 " M12X 115
24 '*~ 12 6 22137-120000 WASHER 12

2011. 03. 02R 6NY16L

 Fig. 21. Fuel Injection Pump Driving Gear

CJ
rut $£~{}
Part Name
Item DD
Quantity Part No.

25 -ff :f- - I- A 1 130605-54452 SUPPORT A

26 -ff :f- - I- B 1 130605-54463 SUPPORT B
27 ;f{ Jv 1- MlO x 22 2 26206-100222 BOLT MlO x 22
28 ;f{ Jv 1- MlO x 30 2 26206--100302 BOLT Ml0X30

1set 730605-54031 INJECTION PU1tf> DRIVING SHAFT COVER

ASS'Y
29 'fJJ{- <P.RM:f- :.t7'0fdl) 1 130605-54262 COVER. injection pump driving shaft
30 ;f{ Jv I- MlO x 14 4 26206-100142 BOLT Ml0Xl4
(
\

31 fij6;f-Jv I- M16x100 2 26232-161002 STUD BOLT M16Xl00

32 -r ':I I- 16 2 26732-160002 NUT 16
33 7 ;J:.. -tf .:t- - 10 x 340 1 22512-100340 FEATHER KEY 10X340

v t:. p~fd!M!=Httll ls 148688-54990 FLEXBLE COUPLING ASS'Y

34 r:firaiM!-=F 1 148688-54490 COUPLING. intermediate
35 rmlJfdlM!.:f. 1 148688-54510 COUPLING.driving shaft
36 Wl~ti 16 148688-54520 ADJUSTING PLATE
. 37 ~h?i 8 148688-54540 WASHER
38 .m~ 8 148688-54550 WASHER
39 sv..m~ 2 148688-54580 WASHER

40 't~.m~ 14 1 22217-140000 SPRING WASHER 14

41 -:>';!ft~:APJ;f-Jlt I- Ml2X25 6 26138-120252 HEXAGON FLANGE BOLT Ml2X25
42 -:>';!ft~:APJ;f{Jlt f- Ml2X40 2 26138-120402 HEXAGON FLANGE BOLT Ml2X40
43 ;f."Jv 1- M14 x 60 1 26156-140602 BOLT M14 X60
44 -:>';!ft~ -J- ·:1 I- Ml2 2 26376-120002 NUT M12

\l 11.RM:f-;.; 7'M!-=Fl±*.ll ls 130605-54500 COUPLING ASS'Y, injection pump

45 PJtM;f- / 7'M!.:f. (1) 130605-54550 COUPLING, injection pump
46
47
Ill"-r
':I
11:~.m~
I- M27
(1)
(1)
140623-54420 · WASHER
26736-270002 NUT M27

6NYI6L
2011. 03. 02R
 ItRzz. ffif+Hg,l#{tfrfl @
Fig.22. Fuel Injecton Valve A ss'y

-tr---T!il __4
-+

L___-ft__:fiJ \\
I E3---lll I Fq I

_@

I
I
I

6 N Yr6L
 Fig. 22. Fuel Injection Valve Ass'y

H $£~~
Item $ t:I
aa :g fj]\ Part Name
Quantity Part No.

'V :lt!~Piti:#H±*ll (1200 @l~ffl) 6set 730605-53140 AJEL INJECTIOO VALVE ASS'Y
1 J :X1vttU 6s 133670-53020 NOZZLE ASS'Y
J ;(11.t*U: (6) 133670-53050 NOZZLE BODY
J ;(11.t.1'1v7 (6) 140677-53010 NOZZLE VALVE
2 J:X1vr-yr 6 152623-53080 NOZZLE NUT
3 J :X1v*1v7" 6 130605-53100 NOZZLE HOLDER
4 ; x11.t7.:1' •J / 7' 6 139684-53120 NOZZLE SPRING
5 7 "J I- (t!f~tJ t;) 6 139684-53170 NUT.adjusting screw

6 Sf.IT l::" / 12 138613-53200 PARALLEL PIN

7 J ;(Jv A :1 •J / -7° ~ - I- 6 139684-53210 NOZZLE SPRING SHEET
8 1.{Jv7'A I- ·;1 :1A~--tj- 6 139684-53240 VALVE STOP SPACER
9 'i.1d¥M.. 6 139684-53340 SPRING RETAINER
10 0 •) /7' 6 152623-533~0 0-RING

11 &W~.Q t; <ll.IMEE:1J) 6 152623-53440 .ADJUST SCREW. injection pressure

12 4'--V ") :1 <f.W~t.2 t.;) 6 139684-53450 CAP.adjusting screw
13 ... ~.,,4'-/ 12 23414-120000 PACKING
14 0 •) /7. (lA) P40 6 24311-000400 0-RING (lA) P40
15 ... ~"J4'-/ (J ;(Jv7"J 1-) 6 133688-11940 GASKET.nozzle nut

6 NY 1 6 L
2011. 03. 02R
 fqigj 23-1. ~*4PJi~;j'~ :_., :f;1~ffi ~ :_., 'J
Fig. 23-1. Fue I Injection Pump Lub. 0 i I Tank

FOPi-tL071-l-:'P"-

11

(
,........_ __,,

•
020410-00J

~tfj filh§Mi~ ii~

No. Part No. $~;:g~ Part Name Quantity
1 130604-39600 9 /? (FO ;f-/:17-.:i.r).:i.. TANK(FOP LUB OIL 1
2 43210-005990 79 COVER 1
3 26116-060102 ;f-JI,, t- 6 x 1 0 BOLT, 6 X 10 4
4 41632-004950 'r / .1 ;f- rJ DIPSTICK, LUB.OIL 1
5 23897-040002 6tJ?:17Jf G 1/2 PLUG, G 1/2 1
6 23414-210000 t-:'71~·;;~:,, 2 1x 1 GASKET, 21 X 1. 0 1
7 26206-120402 ;f-JI,, t- 1 2 x 4 0 BOLT, · 12 X40 4
8 41670-004190 .A~--+.t SPACER 4
9 144626-51930 -=E ~1\/ LABEL, OIL FEED 1
10 152694-39460 ::i:,,7~ (LO ~.:i..'7=.:i..'7 SCREEN, INLET 1
11 135200-52213 :¥-\7? :,,~:,, (FD P VALVE.FEED PUMP 1
12 23414-300000 t-:'71~·;;;:\:-:,, 3 0 x 1 GASKET, 30 X 1. 0 1
13 152694-39470 */91' (L0:171'~/Jj BODY, OIL PRIMING 1
14 135200-52320 1~·y~:,, PACKING 1
15 152623-52300 :171' ~ :,,Jj t-·;;7 CMP KNOB ASSY, PLYMING 1
16 138613-39490 L 0 ::i :,,;:\:- STRAINER, LUB. OIL 1
17 26206-080252 ;f-JI,, t- 8 x 2 5 BOLT, .8 X25 2

6NY16L
 {'1"~ 23-2. ~*~Pl~t~~j'5:£5mW~~ 112\
Fig.23-2. Lub. Oi I Pipe for Fuel Injection Pump®

6NY16L
 f-t~ 23-2. ~*4nl~'1"~ ~ :7';t;mw2~
Fig. 23-2. Lub. Oi I Pipe for Fuel Injection Pump
Jit±:I fill~·~ ii~
fill~:g~ Part Name Quantity
No. Part No.
1 130604-39612 LO j]/ (FO 9 /'J-':J:!f-7" PIPE(LUB OIL 1
2 23414-200000 1'\·:J~/ (-;>' )(... 2 0 GASKET, 20 X 1.0 2
3 130604-39631 LO j]/ (':J:!f-7"-7-r-t-: P PIPE(LUB OIL 1
4 23857-080000 1l /':J:!f-T"if-Jv t- a BOLT, JOINT 8 1
5 23414-140000 t-:'r)1'\·:J~/ 1 4 x 1 GASKET, 14 X 1. O 2
6 130604-39651 LO j]/ (7-r-t-: P -•:J:!f-7" PIPE(LUB OIL 1
7 23857-080000 1J /':J:!f-T"if-Jv t- a BOLT, JOINT 8 1
8 23414-140000 i-:'r)1'\·:J~/ 1 4 x 1 GASKET, 14 X 1. 0 2
9 130604-39780 j]/ t->"JJ"T'J. BRACKET 1
10 26116-060102 if-Jv t- 6 x 1 o BOLT, 6 X 10 1
i 11 130604-39672 L 0 j] './ (':J:!f-7"-::J ~ PIPE(LUB OIL 1
\ ......___ ,,
12 23857-150000 1l /':J:!f-T"if-Jv t- 1 5 BOLT, JOINT 15 2
13 23414-200000 1'\':J~/ (-;>' )(... 2 0 GASKET, 20 X 1.0 4
14 130604-39780 j] './ t-> j]-j-lj' BRACKET 1
15 26116-060102 if-Jv t- 6 x 1 o BOLT, 6 X 10 1
16 26716-060002 "T':J t- 6 NUT, 6 1
17 130604-39730 -lj-;f-- t- A ( L 0 j] ~ BRACKET A (LUB PIPE 1
18 130604-39750 j] './ t-> j]-j-lj' A BRACKET A (LUB PIPE 1
19 26206-120352 if-Jv t- 1 2 x 3 5 BOLT, 12 X 35 1
20 26206-080162 if-Jv t- a x 1 6 BOLT, 8 X 16 1
21 26706-080002 "T':J t- a NUT, 8 1
22 130604-39740 -!j-;f-- t- B ( L 0 j] './ BRACKET B (LUB PIPE 1
23 130604-39760 j]/ t->"JJ"Tlj' B BRACKET B (LUB PIPE 1
24 26206-120352 if-Jv t- 1 2 x 3 5 BOLT, 12 X 35 1
25 130604-39691 LO"JJ/ (:::i:_,.- FOP PIPE(LUB OIL 1
26 152623-39910 1J /':J:!f-T"if-Jv t- BOLT, PIPE JOINT 1
27 23414-120000 1'\':J~/ (~ )(... 1 2 GASKET, 12 X 1.0 2
28 23297-060081 "JJ/t-;("JJ-j-lj'A 6X8 CLAMP, 6 X 8 1
29 26206-080142 if-Jv t- ax 1 4 BOLT, 8 X 14 1
30 130604-39711 L 0 j] './ (jji~"T-9 /'J PIPE(LUB OIL 1
31 23857-180000 1l /':J~T"if-Jv t- 1 8 BOLT, JOINT 18 1
32 23414-220000 1-!'r-)1'\':J~/ 2 2 x 1 GASKET, 22 X 1.0 4
33 43510-001780 1l /':J:!f-7-iFJv t- BOLT, PIPE JOINT 1
34 130605-39284 LO j]/ (?':J'J MGOV PIPE, LUB.OIL 1
35 23857-060000 1l /':J:!f-T"if-Jv t- 6 BOLT, JOINT 6 2
36 23414-120000 1'\·:J~/ (~ )(., 1 2 GASKET, 12 X 1. 0 4
37 23297-060081 "JJ/t-;("JJ-j-lj'A 6X8 CLAMP, 6 X 8 1
38 26206-080142 if-Jv t- ax 1 4 BOLT, 8 X 14 1
39 123482-39660 9·/1'\ CM P ( llJRWJltlJ.tl:) DUMPER ASSY 1
40 105582-34100 ;;t -1' Jv :_,. lj' 7 Jv SIGNAL, OIL 1
6NY16L
 Fig. 24. Fuel Oil Filter Ass'y
i'UitJJMm 71 Jv~
:<$:1ilif.t~Jlit L. "Ctt~~:tt. °'C"''° {>O)
a-000)~1:filiJ... ;- .o···!F13oo-soo~r.i
ff!'ll~l:J&jl,t, <0

Procedure of flushing filter

Attach this fllter outside
the element of fuel oil
filter and after 300- 500
--"-.,.-n
operational hours, remove
and throw away this flush-
I\/ !'" J!,,{U:ift ing filter.
Handle Position
(ll.iE 1it jlfi
Normal Operation

(2)1-i:il!ij"/o-;t 7
Left Side Blow-off
@

.AD1ll!J
Inret Side

c rut $£~-5-
Item $ QQ ~- ~ Part Name
Quantity Part No.
\J QM!~ LfifHll ls 137600-55250 FUEL OIL FILTER ASS'Y
1 ~Lfi*{t (1) BODY.filter
2 'r-7.. (2) case
3 ·" / 1''11.t (1) HANDLE
(_)
4 fdl (2) SHAFT
5 J ·:17-'7-1'-\".:r.vit / r (2) 137600-55260 ELEMENT.notch wire
6 .1'~"14'-/ (1) 137600-55900 GASKET
7 .1'~"14=-/ (2) 137600-55910 GASKET
8 /~·y.:\=-/ (2) 137600-55930 GASKET

9 ~lt~tt (2) AIR VENTING PLUG

10 ~7-"' r (2) SLEEVE NIIT
11 )'~•)!.:\"-/ (2) 137600-55920 GASKET
12 /~•y.:\=-/ (4) GASKET
13 *'it-tr "I 1- (2) CLAMPING NUT

14 Q IJ /7° (2) 0-RING

15 L!td (2) SPRING
16 ::i ·:1 ~tl:lll (7'a-;it7) (1) COCK ASS'Y,for blow off
17 7'7 7' (1) PLUG
I
6NY16L
 Fie. 25. Fuel Injection Pipe Ass'y, with covered pipe

® ®

~~PiM;F /7°ill1J
Fuel Injection Pump Side

-~~PIM#irul
Fuel Injection Valve Side

6LY16L
 Fig. 25. Fuel Injection Pipe Ass'y, with covered pipe

g
ttii ~~~~
Part Name
Item ~
Cl
aa flF Part No.
Quantity

\] ~~PlM~f±tfi 1set 730605-59161 FUa INJECTIOO PIPE ~·y

1 PlM~ (NO. 1 CYL. ) ls 130604-59341 INJECTION PIPE. No.1 CYL.

2 llJtM~ (NO. 2 CYL.) ls 130604-59351 INJECTION PIPE, NO. 2 CYL.
3 PlM~ (NO. 3 CYL.) ls 130604-59361 INJECTION PIPE. NO. 3 CYL.

4 PJtM~ (NO. 4 CYL.) ls 130604-59371 INJECTION PIPE. NO. 4 CYL.

5 llJtM~ (No. 5 CYL.) ls 130604-59381 INJECTION PIPE. NO. 5 CYL.
6 PjtM~ (No. 6 cyl.) ls 130604-59391 INJECTION PIPE. NO. 6 CYL.

( 7 i.tfiilB#!:€i~~ 2s 152673-59670 LEAKED OIL COLLECTION BLOCK

\
8 Q IJ '"./'/ (lA) P24 12 24311-000240 0-RING (lA) P24
9 ~· 7 '"./ f-:'r: •y ;f '"./ 24 151623-59681 PACKING
10 ,.: ')' ;f / 6 130604-59860 GASKET
11 0 •J /'/ (lA) Pl4 6 24311-000140 0-RING (lA) Pl4

6NY16L
2011. 03. 02R
 Fig. 26. Fuel Oil Pipe System.

5 ®

~#l!Jt~•Hr
Fuel Injection Valve

!'~\
:,___ j
~#7' / 7r.... u1
to Fuel Oil Tank I
I
~#illtiilllt!N') \ I
Fuel Oil Drain Sump. I
8ir2.9
*15A STS41D
6x1.5 STS3 0
~#i.iilli
Fuel Oil Drain
"f{Jf.-j-
~#PJttt;Y- / 7"
Govemor Fuel Injection Pump
trl"...----,<r.
~f4rm.:. L-*
Fuel Oil Filter

~*'1-7 1 -)-';f- / 7"

Ct)
Fuel Feed Pump Cl>
t-
en

2ox2.s STS37D
-"?
N
x
CJ
N

t25A
~#7' /7 J: ~
from Fuel Oil Taruc

@ 7 3

6NY16L
 Fig. 26. Fuel Oil Pipe System.

ttS: $ £ ii ~
I tern Cl
ca Part Name
Quantity Part No.
1 ~Nim~ (71-1-·z,:.--:tAD) ls 152623-59250 FUEL OIL PIPE. feed pump inlet
~Mf.f.;t-· ,i., 1- 1 135310-59920 PIPE JOINT BOLT
jf.J/"' •y .:f / 20x1 2 23414-200000 GASKET. copper 20x1

2 ~f4im~ ls 130605-59401 FUEL OIL PIPE. feed pump - filter

(71 - F;f- :.--7°-.: l~)
~Mf.f.;f- ,i., r 1 43521-000231 PIPE JOINT BOLT
im1 {' •y .:f / 20 x 1 2 23414-200000 GASKET. copper 20x1
/ {' •y .:f / ( tl\.:flJ) 1 23428-230000 GASKET.oval
;f-' Jv r MlO x 25 1 26206-100252 BOLT MlO x 25
;f·f Jv 1- MlO x 40 1 26206-100402 BOLT Ml0X40

3 ~Nim~ ls 130605-59411 FUEL OIL PIPE.

(.: L~-lllM;f- /7°) filter - injection pump
,{' ·y .:f / (tj\!j~IJ) 1 23428-230000 GASKET.oval
;f-Jv r M10X25 1 26206-100252 BDLT Ml 0 x 25
;f-'Jv r Ml0X40 1 26206-100402 BOLT M10X40
~m-¥*' ,i., r 1 43510-001380 PIPE JOINT BOLT
jii)1{' •y .:f / 20X 1. 2 23414-200000 . GASKET. copper 20x1

lset ft[@ 25 ~~ FUEL INJECT ION P1PE

Refer to Fig.25

5 ~Mimim~ <lllM#) ls 130605-59907 FUEL LEAKED OIL PIPE. injection valve

/ ~~.f.;t-'Jv 1- 6 23857-060000 PIPE JOINT BOLT
j!PJ/' ·y .:f / 12X 1 12 23414-120000 GASKET. copper 12 x 1
~r·;r r 1 23821-100001 CAP NUT
:J3.{/r 1 43530-001800 JOINT

6 1tl.lf4im~ I? ~ ls 152623-59320 FUEL OIL. RETURN PIPE.

(lljf.t;f, :.--7°--71 - F;f- :.--7°) injection pump - feed pump
~l# 1 135310-59910 RETURN VALVE
'"'·:t.:f/ 2 135310-59930 GASKET
~Mf.f.;f-11; r 1 23857-080000 PIPE JOINT BOLT
j!PJ1{'.:t.:f / 14Xl 2 23414-140000 GASKET. copper 14x1

1 irtl~i:t <~f.:t.: t...n> 1 130605-59430 DRAIN PAN. fuel oil filter

I{' •;t .:f / ( /1\*-lj) 2 23428-230000 GASKET.oval

6NY16L
2011. 03. 02R
 1t~2s. t& *~ 5m ~~iii ®
Fig. 26. Fuel Oil Pipe System.

- ~ii $£~~
Item $ CJ
aa g f,j\ Part Name
Quantity Part No.

8 ~Mimiffi:g ls 130605-59540 FUEL LEAKED OIL PIPE.

(;:: L~i1B§t:1t-imiffit.:·~) filter drain pan - drain sump.
iim-f.¥Jt.- 1- 1 23857-100000 PIPE JOINT BOLT
~/~·:14'-/ 16X 1 2 23414-160000 GASKET. copper 16x1

9 ~f4i~iffi:g (Djtt-f T- / 7°) ls 130605-59931 FUEL LEAKED OIL PIPE. injection pump
:gm-f.¥Jt.- 1- 1 23857-060000 PIPE JOINT BOLT
i!Dj1{ ·:; .:t:- / 12X 1 2 23414-120000 GASKET.copper 12X 1

10 ~ttiRfiiffit:• ~ 1 41659-000250 DRAIN SUMP '.v-\

BOLT M10X25 ii'-_)
2 26206-100252
;ff'"' "
:gm-f.
Ml0X25
1 43590-001540 PIPE JOINT

(_)

6NY16L
2011. 03. 02R
Fig. 27. Governor Ass'y, mechanical type

6 LY I 6 I.
 Fig. 27. Governor Ass'y, mechcnical type

c :g
~ii $ ~ ~ -5
Item $ 00 #); Part Name
Quantity Part No.

1 7f""--< 11.t :/ - 11.t 1 135210-51080 OIL SEAL

2 Q IJ /:7' 1 122710-51360 0-RING
3 1) "( ':/ r 2 124220-51890 RIVET
4 7' '') ://:7'" 1. . 144626-51940 BUSHING
5 Q IJ /:7' 1 144626-51950 0-RING

6 tl/<-r'r-7-.. 1 152623-61010 GOVERNOR CASE

7 /{•'J.::t-/ (tfF\-j-Jr-7-,.) 1 152623-61051 GASKET.governor case
8 / '° ''J .::t- / ( ti/ '7- 'r - A. ,.5, t::. ) 1 144626-61071 GASKET.governor case cover

9 ,.5,f::. (ti/ <-j-Jr- A.) 1 152623-61080 COVER, governor case

11 /{ '') .::t- / (,.5,f::.) 1 140623-61110 GASKET.cover

12 Ip<- C~t3 'J ._,, :7) 1 140673-61160 LEVER.connecting link

\J ti/ <-r r'J :r..-1 H±~Jl ls 130605-61300 GOVERNOR WEIGHT·ASS'Y

13 tf/ <-r r'J :r.. 1 r (2) 140673-61212 GOVERNOR WEIGHT
14 t:·._,, (t1/<-rr'J:r..1 r> (2) 140623-61223 PIN.governor weight
15 / '') : / .:L ( r'J :r..-{ I- t:" /) (4) 140623-61232 BUSH.weight pin
16 ~ii ( r'J :r..-{ I-) (2) 135210-61240 CONTACT PIECE.weight
17 mii (r/ :r..-1' r t:" ::,.- > (4) 140623-61251 WASHER.weight pin
18 tJ'/<-r?:r...1 rst;t (1) 140623-61290 GOVERNOR WEIGHT SUPPORT
19 if:Q)ijB c (4) 22242-000120 CIRCLIP. C type

20 :tv- t- 1 136603-61270 PLATE

21 A.7A.t-m~ 1 140623-61310 THRUST WASHER
22 /'\. 7 IJ / :7' ( A. 7 A. r ) 1 135210-61320 BEARING. thrust
23 lf:Q)j- '') I- 1 144606-61320 LOCK NUT

\J tftJ.~tUll ls 136603-61330 SPRING SHOE.ASS'Y

24 'ft;).~ (1) 136603-61340 SPRING SHOE
25 / '') : / .:L ('it;).~) (1) 140673-61350 BUSH.spring shoe

26 :.;"" 7 r ( :::J / r D - Jv v / <- ) 1 144626-61510 SHAFT. control lever

27 / '') : / .:L <~ l v1<-) 2 144626-61431 BUSH.first lever
28 -;- ·') r (@lfiilifllllU 2 136603-61440 NUT.revolution limit
29 raim ( :/] L... fill) 1 136603-61500 SPACER.cam shaft
30 ll:O'.>-r ·1 r 1 136603-61510 LOCK NUT

6NY16L
2011. 03. 02R
 Fig. 27. Governor Ass'y, mcehanical type

Itern $ CJ
ca :g ft ~-
Quantity
15Bfili~-1:5"
Part No.
Part Name

31 ~l [.,1.1'- 1 136603-61530 FIRST LEVER

32 ~~(~l[..11{-) 2 135210-61540 CONTACT PIECE.first lever
33 :/1'71- (~2 [..11{-) 1 136603-61560 SHAFT. second lever
34 f!ll5tA (~ 2 I..11 ' - ) 1 148616-61570 BEARING A, second lever
35 [..11'\'- (~ 2 [..11{-) 1 136603-61590 LEVER.second lever

BOLT. lever stopper

36 ;ff'"'I-
( [..11 { - A I- ':I I-\') 1
1
152623-61590
136603-61600 NEEDLE BEARING
37 .:::...- f-:';!,-A(? ') ::,_,7·
38 A IJ - 7' A ( ~ 2 v I { - ) 1 144626-61620 SLEEVE A.second lever
39 f!ll5t B (~2 L//'-) 1 148616-61640 BEARING 8,second lever I
/ -
\
l j
40 7 ':I 7 ;@~ ') / 7 1 140673-61650 RACK CONNECTING LINK '~ --

41 ;t-1' 11.t :/ - '"' <fm5t> 2 148616~61650 OIL SEAL.bearing

42 ~=¥- (:(jt>. l:) 1 140673-61660 JOINT.clockwise screw
43 mlff~ (~ Ltf t>.) 1 144626-61790 PLATE.return spring
44 0 ') /7' 2 144626-61800 0-RIN
45 [.//{- (~2 [.//'\'-fEll) 1 144626-61820 LEVER.second lever shaft

46 .A I- ·:17'" / f-:';l.t 1 135210-,61830 STOP HANDLE

47 )(~~ (~.I!:) 1 144626-61840 NAME PLATE.stop
48 t
0
Uft>.JU<'.ff)
:;_., 1 135210-61850 PIN.
49 IJ /7 (7 ·:1.7~~) 1 152623-61850 LINK.rack connecting
50 tl-1 F ( IJ / 7 ) 1 136603-61860 GUIDE. Iink

-
51 ~=f.B 1 136603-61870 JOINT B
52 lit>. (flfi!IJ) 1 136603-61890 SPRING. ----

55 7' ·;; :/ ::,_,7• {L. 0. tf:lD) 1 152623-61910 BUSHING, lob. oi 1 outlet

56 .I!:~ -}- ':I I- 1 125310-66270 LOCK NUT

57 "'~ 11: ~-}- ·:; I- 1 125310-66280 HEXAGON LOCK NUT
58 C / ( 1) / 7) 4 180110-66410 PIN. 1ink
59 ~~ 4 131110-66420 WASHER
60 ~~ 1 22117-080000 WASHER

61 :/ - ;1.t '7 ·:1 :/ "" 1 22190-120002 SEAL WASHER

62 li't>.~~ 14 1 22217-140000 SPRING WASHER
63 11:~"9 c 2 22242-000110 CIRCLIP.C type
64 11:~"9 E 1 22272-000070 CIRCLIP. E type
6NY16L
 Fig. 27. Governor Ass'y, ·mechanical type

tt:i!: $ a=ti ~ i5-

Item $ CJ
oa :g f1j\ Part Name
Quantity Part No .
65 .;izn: t"/ 6X 14 3 22312-060140 PARALLEL PIN 6Xl4
66 j'--1-\t"/ 3Xl8 1 22322-030180 TAPER PIN 3X 18
67 i1J\::"/ 1. 6x12 4 22417-160120 SPLIT PIN 1. 6x12
68 --:::>-:>".)~ 0.6 1 22453-060000 WIRE 0.6
69 .$Fl.::\'-- 3X 10 1 22522-030100 WOODRUFF KEY 3Xl0
70 ,, ·:14'- / 12 2 23414-120000 GASKET 12

71 "fr.Jirf 7 'f 12 1 23887-120002 HEXAGON PLUG Ml2

72 Q IJ /7' 1 24312-000050 0-RING
73 Q IJ /7' 1 24312-000080 0-RING
74 Q IJ / 7' I)
t... 24312-000200 0-RING
75 --:>tift*" ;i,. t- M6Xl6 2 26106-060162 FLANGE BOLT M6Xl6
76 --:>tr ft*" ;i,. t- M6Xl8 4 26106-060182 FLANGE BOLT M6X 18

77 --::>ttt-t;f.1v t- M8X22 1 26106-080222 FLANGE BOLT M8X22

78 --:>ttt-J";f. Jv t- M8X32 7 26106-080322 FLANGE BOLT M8X32
79 M:i6;f.1v t- M8X 16 4 26216-080162 STUD BOLT M8X16
80 M:i6 ;t-. 11-- t- M8X25 4 26216-080252 STUD BOLT M8X25
81 --:>tift7-·:1 I- M8 6 26366-080002 FLANGE NUT M8

6NY16L
 1'1"~28. ~~ JjJ ft 1± .*1! ®
Fig. 28. Starting Air Valve Ass'y.

(-.

I
g H '$ .g ~ ~
Item ~
CJ
a.a ff]\ Part Name
Quantity Part No.

'\/ ~11im±m &set 730605-71101 STARTINJ VALVE ASS'Y

1 130605-71111 BODY
2 *"*
~iJJ#
6
6 130605-71121 STARTING VAL VE
3 l:".A I-/ 6 130605-71150 PISTON
4 ittJ 6 135410-71130 SPRING
5 .UIH!tJ 12 138613-23290 CONED DISK SPRING
6 Uf-':I I- MB 6 26346-080002 U-NUT. MB

7 1!1.1~ '!I~/ 17Xl 6 . 23414-170000 GASKET.copper 17Xl

8 Q IJ /~ (lA) G25 6 24321-000250 0-RING (lA) G25
9 ;t;:"*11!1.;t 6 130605-71160 · RETAINER.body
10 1!11~';1~ / 20Xl 6 130605-71250 GASKET, copper 20Xl

2011. 03. 02R 6NY16L

 11~29 -a). ~iJJ~~.11:#1±*1! @
Fig. 29 -a). Starting Air Check Valve Ass'y.

Mi itJ&'~.:E .g"
to Starting Air Main Pipe
---,-'

/.'!
./
h1~1t-"
to Control Valve

rl-------h
CD u__I 1
--W
~-'A.nrJ: tJ
· : · ~ ·from Air Reservoir

l t!kiif # J: t)
I from Control Valve

6NY16L

2Q03. 7.23R
 11~.29 -a). M:JjjJ~ ~.tl:#f±~~ ®
Fig. 29 -a). Starting Air Check Valve Ass'y.

Item c :g H ~g~~
~ 00 f,)\ Part Name
Quantity Part No. I
"V ~ll:.#1±*11 1set 730605-72010 AIR a-IECK VALVE ASS'Y
1 ~ll:.#*f* 1 130605-7201 o. BODY.air check valve
2 #t$ 1 180110-72020 VALVE ROD.air check valve
3 t:fb 1 180110-72030 SPRING,
4 l:fb¥!J-t.b t; 1 135410-72040 HOLDER. springve
5 f,ij1' ·~ .:f / 22Xl 1 23414-220000 GASKET. copper· 22X 1

6 lfflM# 11 .{ r 1 135410-72050 PISTON GUIDE

7 ffflM# I 180110-72060 PISTON
() 8 ''7.:f / .1 180110-72070 GASKET
9 :f-;i., t- MlO x 75 2 26206-100752 BOLT MlOX 75
'T::.r I- MlO 2 26706-100002 NUT MlO
10 JtRt-tt5' 1 130605-72050 BRACKET
-r- ,i., I- Ml0X20 2 26206-100202 BOLT M10X20

()

6NY16L
2003. 7.23R
 1-.flg) 29-b). y~llJ~~~.it.#1±M U~ill.JY~l'.i1.JFf:D @
Fig.29-b). Starting Air Check Valve Ass'y
(Automatic start)

@ @ 3
\\

11#31)
from Control Valve

i/
/

2003. 7.23R 6NY1 6L

 fq[@ 29-b). ~Etlb~~.tl:#f±*~ ( §itJ~ilitJFFl) ®
Fig. 29-b). Starting Air Check Valve Ass'y.
(Automatic start)
Cl
~
ttm: ~g~~
Item Hi3 ~
cc
Quantity Part No. I Part Name

\l ~.tl:.#fr*ll 1set 730605-72022 AIR CHECK VALVE ASS'Y

1 ~l.1::.#*1* 1 130605-72020 BODY.air check valve
2 #~ 1 130605-72080 VALVE ROD.air check valve
3 t±'tl 1 180110-72030 SPRING
4 It tJ. ¥f3 ;l t.l t; 1 44100-552180 HOLDER. springve
5 f,;]1' ·~ .:f- ::..- 28X I I 23414-280000 GASKET.copper 28x1

6 lfflM#tf 4 r I 135410-72050 PISTON GUI DE

i 7 lfflM# 1 44100-555700 PISTON
\
8 I-\•/ .:f- / 1 180110-72070 GASKET
9 :f-JL'.1- MIO x 75 2 26206-100752 BOLT MIO x 75
T-Y I- MIO 2 26706-100002 NUT MIO
10 I&t-t-Ei' 1 130605-72050 BRACKET
*' Jv I- Ml0X20 2 26206-100202 BOLT Ml0X20

---.....,,,

. 6 NY 1 6 L
2003. 7.23R
 Fig. 30. Control Valve Ass'y, manual

~11:.
Stopping

I
/

®@®@@(ij)QJ)

to Air Check Valve \

6LY16L
 Fig. 30. Control Valve Ass'y, manual

tt:I: $ £ ilf ~
Item ~
Cl
DD ~ f,J\ Part Name
Quantity Part No.

\I tif6t1rf±*1! 1set 752623-72200 CONTROL VALVE ASS'Y,rnanual

1 ;$'.f* 1 135410-72200 BODY
2 if;~ 1 42222-550740 NAME PLATE
3 7.. '/ 1) .:z. t/ IJ r{, '1 f- 2 137900-91451 ' SCREW RIVET

4 Utt- 1 180110-72210 CONTROL VALVE

5 iiti 1 141616-72320 . SPRING
6 ';ftJ tilJ ;{_ 1 135410-72230 HOLDER.spring
7 llJ1 ~ '1 .:t- / 14X 1 1 23414-140000 GASKET, copper 14X l
/
8 1, / i..:·1i.,~~ 1 180110-72240 SUPPORTER.handle
\,
9 j{li}1~ .., .:t- / 1 180110-77250 GASKET.copper

10 ~7- ·1 I- 1 135410-72260 SLEEVE NUT

11 " / !-=" Jv 1 180110-72270 HANDLE
12 .11:.~t"/ 1 180110-72280 LOCK PIN
13 .m~ 1 180110-72290 WASHER
14 ~Jt"/ 1X8 1 22417-100080 SPLIT PIN 1X8

6NY16L
2011. 03. 02R
Fig. 31. Starting Air Distributing Valve Ass'y.

t-l>S;, •J > Y"

lo No. 5 Cyl.

lo No. 2Cyl. t-ll 3 ,. '} ;- y ·'·

lo No. 3 Cyl.

\. ) 6 NY I fi I.
 Fig. 31. Starting Air Distributing Valve Ass'y.

:g Mi: $ ~ ~ -5
Item $ Cl
ao fefj\ Part Name
Quantity Part No.

\l ~Dl#fr*-'l lset 730605-72300 DISTRIBUTING VALVE ASS'Y

1 :<$:1* (7tlf#) ls 130605-72400 BODY.distributing valve
2 7 ..,~.:J. (1) 136600-72450 BUSH
3 SJZfit"/ 6X32 2 22312-060320 PARALLEL PIN 6X32
4 ,-:: ·1 .::\=- / (7t~#:<$:l:*) 1 130605-72460 GASKET.distributing valve body

5 ,b,f: (7tl:f#:<$:l*) 1 130605-72420 COVER.distributing valve

6 /{•y.::f/ (l~t:) 1 137600-72430 GASKET.cover
7 7t~# 1 137600-72410 DISTRIBUTING VALVE
8 .:t -{ Jld1 "Y 7' 18X 1/8 1 24714-180010 OIL CUP 18Xl/8
9 ;f- Jv I- Ml0X70 4 26206-100702 BOLT Ml0X70

6NY16L
Fig. 32. Starting Air Pipe System

\, ___ . / 6NY16L
 1t~32. i~IJJ~3K~~~f±*1l ®
Fig. 32. Starting Air Pipe System Ass'y

Item ~
CJ
ca g ff]\
u $ J6 ~ {}
Part Name
Quantity Part No.

1 7 7 /:; (1J\*1J) 1 43321-000830 FLANGE

2 ii).1 { •y .:f / 25Xl 1 23414-250000 COPPER PACKING 25Xl
3 ;y. Jv t- Ml2X50 1 26206-120502 BOLT Ml2X50
4 -j- '-;/ I- Ml2 1 26706-120002 NUT Ml2
5 1i~ff. (~.I.l:#AD) 1 43590-006700 PIPE JOINT.check valve inlet
6 iij.1{ 7 .:f / 22Xl 1 23414-220000 GASKET.copper 22Xl

'1 MJJ.b~~iH±*1l lset 730605-73100 STARTING AIR PIPE ASS' Y,

(~.Ll:.#-tif1m) check valve ~ control valve
7 ~!IJ~~'i[ ls 130605-73102 STARTING AIR PIPE.
(~.I.1:#--f**it#) check valve - control valve
8 ~!IJ~~ig ls 130605-73112 STARTING AIR PIPE,
(W{t#-~.I.1:#) control valve - check valve
W~.:f.;f- 1v I- 3 23857-080000 PIPE JOINT BOLT
ii).1 { '':/ .:f / 14Xl 6 23414-140000 GASKET.copper 14Xl

'1 MJJ.b~~~ttm lset 730605-73110 STARTING AIR MAIN PIPE ASS'Y

9 ~ilJ~filW ls 130605-73201 STARTING AIR MAIN PIPE
1{•':f.:f / (}L) 6 140623-73261 GASKET.round type
;f-Jv t- M8X45 12 26206-080452 BOLT M8X45
iiJ1 { '':/ .:f / 25Xl · 1 23414-250000 GASKET.copper 25Xl
;f-'Jv t- Ml2X30 1 26206-120302 BOLT Ml2X30

10 ~~ff 1 137600-73500 SAFETY PLATE

( 11 ~~fitf!J~ 1 139653-73490 HOLDER.safety plate

'1 MJJ.b~~~f±M lset 730605-73171 STARTIOO .AIR PIPE ASS' Y,

(~1£#-M:ilh#) distributing valve starting valve
12 ~IJJ~if ls 130605-73430 STARTING AIR PIPE,
(j:1[-cf:iat{~~) main pipe _;,, junction plate
13 ~111~~1[ ls 130605-73901 STARTING AIR PIPE.
<cf:im~~-~l'f#> junction plate - distributing valve
1ilf:f.;f-11.- t- 3 23857-080000 PIPE JOINT BOLT
i!).1 { '':/ .:f / 16Xl 7 23414-140000 GASKET, copper 16Xl
.:i.~;;t / 1 23831-080000 UNION

14 cf:ilf~J!l: 1 130605-73581 JUNCTION PLATE

;f-11.- t- M10X25 2 26206-100252 BOLT M10X25

6NY16L
2011. 03. 02R
 Fig. 32. Starting Air Pipe System Ass'y

H $ ~ ~ -5
Item CJ
aa
Part Name
Quantity Part No.

15 M:iiJJ~~g NO. 1 CYL. ls 130605-73910 STARTING AIR PIPE,NO.l CYL.

()}fi}jp·--cpi£~~) distributing valve ,...., junction plate
16 M:iiJJ~~g NO. 2 CYL. ls 130605-73920 STARTING AIR PIPE,N0.2 CYL.
()1£#-r:flM!~~) distributing valve - junction plate
17 M:iiJJ~~g NO. 3 CYL. ls 130605-73930 STARTING AIR PIPE.N0.3 CYL.
<71re#-ct:im~~> distributing valve - junction plate
18 MiiJJ~~lff NO. 4 CYL. ls 130605-73940 STARTING AIR PIPE.N0.4 CYL.
<71re#-r:flif~~> distributing valve ,...., junction plate

19 MiiJJ~~~ NO. 5 CYL. ls 130605-73950 STARTING AIR PIPE,N0.5 CYL. (

/

()}~#-i:fli£~JU distributing valve - junction platt;'~ /

20 M:iiJJ~3ng NO. 6 CYL. ls 130605-73960 STARTING AIR PIPE,N0.6 CYL.
<'1~#-r:flm~~>
wm-=F ;t; 1i.. 1- 10 23857-080000 PIPE JOINT BOLT
r.ve ·:1.:f-::,,, 14x1 22 23414-140000 GASKET, copper 14Xl
..:i..::.;t / 2 23831-080000 UNION

21 MiiJJ~~g NO. 1 CYL. ls 130605-73710 STARTING AIR PIPE NO.I CYL,

( cpi{~~-Mrlb#) junction plate ,...., starting valve
22 M:iiJJ~3ng NO. 2 CYL. ls 130605~73720 STARTING AIR PIPE No:2 CYL,
(cpk{!~~-M:iiJJ#} junction plate ,...., starting valve
23 ~i/J~~W NO. 3 CYL. ls 130605-73730 STARTING.AJR PIPE N0.3 CYL,
(cpk{!~~'"'-~iJJ#) junction plate ,...., starting valve
24 M:iiJJ~3ng NO. 4 CYL. ls 130605-73740 STARTING AIR PIPE N0.4 CYL,
(cpM!~~-M:iiJJ#) junction plate ,..... starting valve

25 Milb~3ng NO. 5 CYL. ls 130605-73750 STARTING AIR PIPE N0.5 CYL,

( cpi{~~-~iJJ#) junction plate ,..... starting valve
26 M:iiJJ~~ft NO. 6 CYL. ls 130605-73760 STARTING AIR PIPE N0.6 CYL.
( cpjt!~~-~iJJ#) junction plate ,...., starting valve
..:i..::.;;t / 12 23831-080000 UNION
14Xl 12 23414-140000 GASKET.copper 14Xl

27 gtfll;t~~ 2 138987-73450 PIPE SUPPORT

28 gtfll;t (A) 1 152623-73310 PIPE SUPPORT (A)
29 gtfll.:t (8) 1 152623-73320 PIPE SUPPORT (B)
30 gtfll;t (C) 1 152623-73330 PIPE SUPPORT (C)
i

31 fttfll;t (D) 1 152623-73340 PIPE SUPPORT (D)

32 Wtfll;t <E> "1 152623-73350 PIPE SUPPORT (E)
33 ;f-Jvl- M10Xl5 12 26206-100152 BOLT M10Xl5
6NY1 6 L
·2011. 03. 02R
Fig. 33. Gauge Board Ass'y

I
C[J>

--
. ------®
 Fig. 33. Gauge Board Ass'y

H $ ~ ~ -;
Item CJ
aa Part Name
Quantity Part No.

\1 ttiitif±il 1set 730605-91020 GAUGE BOARD ASS'Y

1 tt~JflZfti& 1 130605-91010 GAUGE BOARD
2 EE:fJtt (0.4MPa) 4 28886-040000 PRESSURE GAUGE. 0.4MPa
3 EE:fJ~t (lMPa) 1 28886-105060 PRESSURE GAUGE. lMPa
4 ,b,f;:. 1 150623-91300 COVER

5 1NJ t; M4 x 12 18 26557-040122 CROSS RECESSED HEAD SCREW M4x12

-t-·:1 I- M4 18 26717-040002 NUT M4
,;rt.im~ 4 18 22212-040000 SPRING WASHER 4
6 1{ ';I .:f / (ji.) 4 122117-39150. GASKET.round type

7 ,,r'J:_}/~ 1 130605-91091 HOUSING

8 .Y.1v 1- M6Xl0 4 26116-060102 BOLT M6Xl0
m~ 6 4 22117-060000 WASHER 6

9 ~C:ti' 4 137600-91023 DAMP ING RUBBER

10 lj\Q I.; M6Xl6 8 26557-060162 CROSS RECESSED HEAD SCREW M6x16
7- ·:1 1- M6 8 26716-060002 NUT M6
tft.im~ 6 8 22212-060000 SPRING WASHER 6
11 · IW~ C:ti' 4 41411-000290 DAMP ING RUBBER

12 ;f. Jv I- MlO x 40 4 26206-100402 BOLT MlO x 40

13 7- ·:1 1- MlO 4 26706-100002 NUT MlO
.tl:~-t- ·:1 I- MIO 4 26796-100002 LOCK NUT MlO

14 ff1Jtt1lf (~~) ls 130605-91210 PRESSURE GAUGE PIPE.boost air

15 .lf:1JttW (imffti!il) ls 130605-91220 PRESSURE GAUGE PIPE. lubricating oil
16 ff:1Jtt1lf (i@itg7k) ls 130605-91230 PRESSURE GAUGE PIPE.hot temp. water
17 .lf1Jtt1lf (flttg7k) ls 130605-91240 PRESSURE GAUGE PIPE.cold temp. water
18 EEt.JlttW (~fl.rm) ls 130605-91250 PRESSURE GAUGE PIPE, fuel oil
19 Jl:~-j- "/ 1- 4 45511-005210 LOCK NUT
20 .:t..=.;t / 4 43550-002730 UNION
21 -=-- i-: 1v# 4s 43600-006951 NEEDLE VALVE
l!J1{·;1.:f/ 10Xl 4 23414-100000 GASKET. copper 10x1

22 ft~ ( ~ 1) / ~(fj!{J7J<.) 1 42221-007830 NAME PLATE. cyl"inder C. W.

1) .I'( •;J I- 2 137900-91451 RIVET

23 jg~ (MJiltid:I) 1 42221-007740 NAME PLATE, lubricating oil

•) .I'( ';/ I- 2 137900-91451 RIVET
6NY16L
2011. 03. 02R
 Fig. 33. Gauge Board Ass'y

H $ ~ ~ -5 Part Name
Item $ CJ
cc ::g ff]\
Quantity Part No.

24 it~ (~~) 1 42221-007870 NAME PLATE.boost air

•J "·:1 r 2 137900-91451 RIVET
25 it~ (~ -7~!1171<) 1 42221-007840 NAME PLATE.cooler C.W.
•J" ·:1 r 2 137900-91451 RIVET
26 jg~ (~fl-) I 42221-007780 NAME PLATE, fuel oil
lJ ""'.)' r 2 137900-91451 RIVET

27 ffilfitt 1 130605-91770 TACHOMETER

28 rill~ (IHl~U) I 130605-91780 SPACER, tachometer
130605-91400 CABLE. tachometer , -·
29 ftb~fib 1
/

30 J\ '.)' :f / ( t.: p Jj.flll) I 130605-39030 GASKET, cable

31 Jj\Q t M4Xl4 4 26557-040162 CROSS RECESSED HEAD SCREW M4Xl4
-j- ';/ t- M4 4 26717-040002 NUT M14
tt'td~~ 4 4 22212-040000 SPRING WASHER

32 it~ (ffiIEtt) 1 42221-021240 NAME PLATE. tachometer

') "';/ t- 2 137900-91451 RIVET
33 fc?:~ffiIEttitt& 1 42221-021220 NAME PLATE.critical revolution
') " ';I t- 2 137900-91451 RIVET

34 IflHtt:i' <tt~fi) 1 130605-91101 BRACKET.gauge board

35 ;f.1v t- M10X20 3 26206:-100202 BOLT Ml0X20
36 ~:r- - r 1 130605-91152 SUPPORT
37 ;f{ Jv r Ml0X20 2 26206-100202 BOST Ml0X20
-J- •;I t- MIO 2 26706-100002 NUT MIO
". )
\

6NYI6L
2011. 03. 02R
 SllllllllllllllllllllllllllllllllllllHlllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllUlllllllllllllllllllllllllllllllllllllllllllllllllllllit:

I Yanmar's Worldwide Service Network I

'5111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111~

f Domestic Office I I Overseas Office I

YANMAR CO.,LTO. [61 Yanmar Europe B.V. (YEU)
Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
• Yanmar (Head office) Country Code: 31
1-32, Chayamachi, Kita-ku, Osaka, Japan 530-8311 Phone: 36-5493200 Fax:36-5493209
• Yanmar (Tokyo) !ID Yanmar Asia (Singapore) Corp. Pte. Ltd. (YASC)
1-1, 2-Chome, Yaesu, Chuo-ku, Tokyo, Japan 4 Tuas Lane, Singapore 638613
104-8486 Country Code: 65
• Export Dept. Marine Phone: 6595-4200 Fax: 6862-5189
Country Code: 81
Phone: 3-3275-4909 Fax: 3-3275-4969
[Q] Yanmar America Corp. (YA)
101 lntermational Parkway, Adairsville, GA 30103, U.S.A.
• Large Power Products Operations Division Country Code: 1
1-1, 1-Chome, Nagasu Higashi-dori, Amagasaki, Phone: 1-770-877-9894 Fax: 1-770-877-9009
Hyogo, Japan 660-8585 [Q] Yanmar Engine (Shanghai). Co., Ltd .
.• Quality Assurance Dept. 18F, North Tower, Shanghai Stock Exchange Building
Country Code: 81 528 South Pudong Road, Pu Dong Shanghai, China 200120
Phone: 6-6489-8017 Fax: 6-6488-4009 Country Code: 86
Phone: 21-6880-5090 FAX: 21-6880-8090
[f] Yanmar Co., Ltd. India liaison Office
603, Maithili Signet Sector 30A, Opp Vashi Railway Starion
Vashi, Navi Mumbai 400703
Country Code: 91
Phone: (022)2781-0975, 2781-0976
FAX: +91-22-4155-5310

YANMAR ENGINEERING CO.,LTD. + Hong Kong Office

Room 1208, C.C. Wu Building, 302-308 Hennessy Road,
• Tokyo Office Wanchai, Hong Kong, China
1-1, 2-Chome, Yaesu, Chuo-ku, Tokyo, Japan 104-8486 Country Code: 852
Country Code: 81 Phone: 2833-9032 Fax: 2904-7783
Phone: 3-3242-6954 Fax: 3-3242-6960
Web: www.yanmar.eo.jp/ye/ E-mail: endo@yanmarhk.com.hk

• Osaka Office (Head Office)

+ Greece Liaision Office
5th Floor, 130, Sygrou Avenue, Athens, Greece
1-1, 1-Chome, Nagasu Higashi-dori, Amagasaki, Country Code: 30 .
Hyogo, Japan 660-8585 Phone: 210-922-2481 Fax: 210-922-2484
Country Code: 81 E-mail: yanmargr@tee.gr I yanmar@weboffice.gr
Phone: 6-6489-8048 Fax: 6-6481-6101
Web: www.yanmar.co.jp/ye/ + Philippines Liaision Office
Bldg 3, Berthaphil South, Bayanihan St.,
Jose Abad Santos Avenue, Clark Freeport Zone 2023
Pampanga Philippines.
Country Code: 63
Phone: 45-499-154111542

(Edition 15, December 2010) 1/4

I Overseas Office I @ Cistar Tech HK Ltd.
+ Taiwan Branch 3/F., 81 Hing Wah Street West Lai Chi Kok, Kowloon
Hong Kong, China
No.56, Yugangjung 2 Rd., Chienchen Dist, Kaohsiung, Taiwan Phone:+85227750161 Fax: +85227726054
Country Code: 886 E-mail: info@cistarhk.com
Phone: 7-815-4198 Fax: 7-815-3280 Web: www.cistarhk.com

+ Dubai Liaison Office 0 Charter Technical Services Ltd.

Gold & Diamond Park, Manufacturing office 3006, Room 1207-8, C.C.Wu Building 302-308,
Ground Floor Building-3, Sheikh Zayed Road P.O Hennessy Road, Wanchai, Hong Kong, China
.Box 214831 Dubai, U.A.E Phone: 2803-5649 FAX : 2803-5701
Country Code: 971
Phone: 4-341-8787 Fax: 4-341-8778
PHILIPPNES (Country Code: 63)

I Overseas Service Agents I @ YANMAR ENGINEERING CO., LTD. PHILIPPINES LIAISON OFFICE
Bldg 3, Berthaphil South, Bayanihan St.,
Jose Abad Santos Avenue, Clark Freeport Zone 2023
ASIA Pampanga Philippines.
Phone: 45-499-1541/1542 Fax: 45-499-1543
SRILANKA (Country Code: 94) mSeapowers Trading & Industrial services
O Colombo Dockyard (Pte) Ltd. 316-A Mamatid Cabuyao, Laguna, Philippines
Phone: 917-500-3017 Fax: 49-502-0765
Graving Docks Port of Colombo, P.0.Box 906, E-mail: seapowers@pldtdsl.net
Colombo 15, Srilanka
Phone: 11-2522461-5 Fax: 11-2446441
MALAYSIA (Country Code: 60)
CHINA (Country Code: 86) @ Pan Sarawak Co., Sdn. Bhd.
f} Yanmar Engine (Shanghai) Co., Ltd. Wisma Pansar 23-27, Workshop Road 96007 Sibu
18F, North Tower, Shanghai Stock Exchange · Sarawak, Malaysia
Building 528 South Pudong Road, Pu Dong Phone:84-333366 Fax:84-314555
Shanghai, China 200120
Q) Chong Lee Leong Seng Enterprise Sdn. Bhd.
Phone: 21-6880-5090 FAX: 21-6880-8090
Lot 530, Persiaran Subang Permai Sg. Penaga
@ GOLTENS SHANGHAI CO., l TD Industrial Park, USJ 1 47500 Subang Jaya Selangor
Darul Ehsan, Malaysia
Block No.5, No.533 Yuanzhong Road, Nanhui Phone: 3-5632-1577 Fax: 3-5632-3126
Industrial Zone, Nanhui District, Shanghai, China
Phone: 21-58186628 FAX: 21-58186633
E-mail: shanghai@goltens.com INDONESIA (Country Code: 62)
G) TIANJIN PORT TUG·BOAT & LIGHTER COMPANY ~ Yan mar Jakarta Service Center C/O P. T. Pioneer
/YANMAR ENGINE SERVICE CENTER Jalan Ir. H. Juanda, No.40-42, Jakarta 10120, Indonesia
(P.O. Box 2502-Jakarta 10025)
No.383 Yongtai Road, Tanggu District, Tianjin, China Phone: 21-385-8526 Fax: 21-384-8995
Phone: 22-2570-7510 FAX: 22-2570-7510
0 DALIAN WANFANG MARINE TECHNOLOGY CO.; LTD ~ P. T. Pioneer
No.40 Aixian Street, Qixianling, Dalian High-Tech Jalan Ir. H. Juanda, No.40-42, Jakarta 10120, Indonesia
Industrial Zone, China (P.O. Box 2502-Jakarta 10025)
Phone: 411-84799000 FAX: 411-84795678 Phone: 21-344-8486 Fax: 21-384-8995
E-mail: wf@china-wf.com

0 Charter Technical Services Ltd. - INDIA (Country Code: 91)

Dongguan Representative Office (i) Yanmar Co., Ltd. India liaison Office
No.33 Jiaoyu Road Banshi Changping Town, 603, Maithili Signet Sector 30A, Opp Vashi Railway Station
Dongguan, Guangdong, China. Vashi, Navi Mumbai 400703
Phone: 769-8339-4935 FAX: 769-8339-7937 Phone: (022)2781-0975, 2781-0976
FAX: +91-22-4155-5310
HONG KONG (Country Code: 852) «I IND-AUST Maritime Pvt. Ltd.
715, J.K. Chambers Sector 17, Vashi,
@ Yanmar Engineering (HK) Co., Ltd. New Bombay-400 703. India
Room 1208, C.C. Wu Building, 302-308, Phone: 22-55912233127892524
Hennessy Road, Wanchai, Hong Kong, China Fax: 22-55912234 I 27892529
Phone: 2833-9032 Fax: 2904-7783 E-mail: INFO@INDAUST.COM
E-mail: endo@yanmarhk.com.hk

214
 SINGAPORE (Country Code: 65) EUROPE
@ Yanmar Asia (Singapore) Corp. Pte. Ltd. (YASC) NETHERLANDS (Country Code: 31)
4 Tuas Lane, Singapore 638613
Phone: 6861-3855 Fax: 6862-5189 @ Yanmar Europe B.V. (YEU)
Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
mChong Lee Leong Seng Co., (Pte) Ltd. Phone: 36-5493200 Fax: 36-5493209
23 Tuas Avenue 2, Singapore 639454
Phone: 6264-2922 Fax: 6861-8785 W Nicciverken Holland B.V.
Algerastraat 20, 3125 BS Schiedam, The Netherlands
Phone: 10-2380999 Fax: 10-2380988
KOREA (Country Code: 82) E-mail: shiprepair@nicoverken.nl
Web: http://www.nicoverken.nl
~ Hwa 111 Trading Co., Ltd.
#93, 2-GA, Namhang Dong, Young Do-ku, Busan, Korea ~ Fuji Trading (Marine) B.V.
Phone: 51-412-6385 Fax: 51-414-8752 Kortenoord 2-8 3087 AR Rotterdam, The Netherlands
E-mail: hwaill@hwaill.co.kr Phone: 10-429-8833 Fax: 10-429-5227

PLUS Service Co.

U.K. (Country Code:.44)
Room 3806, Centum Leaders Mark B/D, 1514 U-Dong,
Haeundae-gu, Busan, 612-889, Korea
~ Shipaid Diesel Services Ltd.
Phone: 51-745-8201"-'2/4 Fax: 51-745-8203
E-mail: plusbusan@hanafos.com Units, 1&2, Plot 10, Westminster Trading Estate,
,r-·~\ Westminster Road, North Hykeham Lincoln, LN6 3QY
1
\.
1 CHIBA MARINE KOREA Co., Ltd. Phone: 1522-696642 FAX: 1522-695153
E-mail: shipaid.diesel@globaluk.net
1-90, Chunghak-Dong, Yeongdo-gu, Busan, Korea
Phone: 51-418-8998 Fax: 51-418-5880
E-mail: chibako@korea.com GREECE (Country Code: 30)
mYANMAR ENGINEERING CO., LTD.
THAILAND (Country Code:.66) Greece Liaison Office
5th Floor, 130, Sygrou Avenue, Athens, Greece
tJ) Siam Consotium Service Co., Ltd. Phone: 210-922-2481 Fax: 210-922-2484
103-107. Damronglatpipat Road, Klongtoey, Prakanong, E-mail: yanmargr@tee.gr I yanmar@weboffice.gr
Bangkok, Thailand 10110
Phone: 2-249-8023 Fax: 2-249-7985 GERMANY (Country Code: 49)
@) Star Marine Engineering Co., Ltd ~ Nippon Diesel Service
215 M11 Tumbol Bangphueng Phrapradaeng , Herniann-Blohm-Str. 1 D-20457, Hamburg, Germany
Samutprakarn, Thailand 10130 Phone: 40-317710 Fax: 40-311598
Phone: 2-816-8001 FAX: 2-463-2616
E-mail: info@starmarineeng.com
ICELAND (Country Code: 354)

TAIWAN (Country Code: 886) @MARAS E.H.F

() @} Yanmar Engineering Co., Ltd Taiwan Branch

No.56, Yugangjung 2 Rd., Chienchen Dist, Kaohsiung, Taiwan
Akralind 2 201 K-pavogur Iceland
Phone: 555-6444 Fax: 565-7230
E-mail: maras@maras.is
Phone: 7-815-4198 Fax: 7-815-3280
E-mail: yanmar-tw@umail.hinet.net
SPAIN (Country Code: 34)
fD Yee Foo Marine Industrial Co., Ltd.
~ Skandiaverken, S.A.
6F-3, No.369 Fusing North Road, Taipei,
Taiwan ROC. 105 Po. Ind. Torrelarragoiti Parcela P7M, Pab. 1y2 48170
Phone: 2-8712-0848 Fax: 2-8712-0797 Zamunio Bizkaia SPAIN
Phone: +34 94 6880200 Fax: +34 94 6880216
~ Seikoh Co., Ltd. E-mail: skv@skvbermeo.com
No.56 Yugang Jung 2 Rd., Chien Chen Dist. Kaohsiung, Taiwan
Phone: 7-831-2303 Fax: 7-882-3911 TURKEY (Country Code: 90)

~ARASMAK SANAYI. MUM. DAN. VE TIC.LTD.ST!.

Uphill Towers Residence, A1-A No.67,Bati Atasehir,
Istanbul, Turkey
Phone: +90 216 688 5385 Fax: +90 216 688 5386
E-mail: aras@arasmak.com

3/4
MIDDLE EAST PAPUA NEW GUINEA (Country Code: 675)

ARAB REPUBLIC OF EGYPT (Country Code: 20) @ Lutheran Shipping

P.O. Box 1459, Lae, Papua New Guinea
~Mapso Phone: 42-6190 FAX: 42-5806 Telex: NE 44172
P.O. Box 2643, 44 Industrial Area, Cairo/lsmailia
Desert Road, Cairo, Egypt
Phone: 2-2962777 (8 lines) Fax: 2-2962780 NORTH AMERICA
E-mail: mapso@soficom.cor
U.S.A (Country Code: 1)
'-fl Mapso-Alexandria Office
5 Orabi Street, Alexandria, Egypt © Yanmar America Corp. (YA) Georgia Office
Phone: 3-483-3453 Fax: 3-483-3486 101 International Parkway, Adairsville, GA 30103,U.S.A.
Phone: 1-770-877-9894 Fax: 1-770-877-9009
U.A.E (Country Code: 971) © YANMAR AMERICA CORPORATION. NEW YORK BRANCH
Parker Plaza 16F, 400 Kelby Street, Fort Lee, NJ
@) YANMAR ENGINEERING CO., LTD. DUBAI LIAISON OFFICE
07024 U.S.A.
Gold & Diamond Park, Manufacturing office 3006, Phone: 201-592-8500 FAX: 201-592-8503
Ground Floor Building-3, Sheikh Zayed Road P.O E-mail: HWatanabe@yanmar.com
Box 214831 Dubai, U.A.E
Phone: 4-341-8787 Fax: 4-341-8778 @) Marine Turbo & Diesel Inc.
E-mail: ymrdubai@eim.ae
1090 7th Street, Richmond, Ca, 94801, U.S.A.
e> Albwardy Marine Engineering (L.L.C) Phone: 510-236-3525 Fax: 519-236-3576
Dubai Shipdocking Yard P.O. Box 6515 Dubai, U.A.E @ GOLTENS New York Corp.
Phone: 4-324-1001, 4-324-1561 Fax: 4-324-1005
160 Van Brunt Street, Brooklyn, NY 11231 U.S.A.
@ Goltens Co. Ltd. Dubai Branch Phone: 718-855-7200 ·Fax: 718-802-1147
Al Jadaf Ship Docking Yard P.O. Box 2811, Dubai, U.A.E
Phone: 4-324-1642 Fax:4-324-1963 @ GOLTENS Miami Co. Inc.
Web: http://www.goltens.com 2323 N.E. Miami Court· Miami, Florida 33137 U.S.A.
Phone: 305-576-4410 Fax: 305-576-3827
E-mail: morten. lindkvist@goltens.com
AFRICA ~ UNITED WORLD ENTERPRISE, INC
SOUTH AFRICA (Country Code: 27) 6310 Winfree Houston, Texas 77087 U.S.A.
Phone: 1-713-641-1915 Fax: 1-713-641-2717
@ IMS CAPE, A Division of ZEST ELECTRIC MOTORS (PTY) LTD.
124 Marine Drive Service Road, Parden Eiland, 7420,
South Africa, P.O. Box 63 Parden Eiland 7420
SOUTH AMERICA
Phone: 511-8201 Fax: 511-8238
BRASIL (Country Code: 55)

OCEANIA @ Metalock do Brasil Ltda

Rua Visconde do Rio Branco 20/26, 11013-030,
AUSTRALIA (Country Code: 61) Santos, SP, Brasil \"-_./
Phone: 13-3222-4686 ·Fax: 13-3222-4088
Q) Forgacs Cairncross Dockyard Pty. Ltd. E-mail: santos@metalock.com.br
Web: http://www.metalock.com.br
Thynne Road Morningside, Brisbane, Queensland 4170,
Australia
Phone: 7-322-70856 Fax: 7-3399-6164

~ Waterside Engineering Pty. Ltd.

48-50 Export Drive Brooklyn 3025, Victoria, Australia
Phone: 3-931:4-3722 Fax: 3-9314-3799
E-mail: waterside-eng.com

© Jaitco
10199 Kurraba Road, Neutral Bay, N.S.W. 2089, Australia
Phone: 2-99098545 Fax: 2-99531728

~ Japan Marine Engineering Co.,ltd

475 Warrigal Road Moorabbin Victoria Australia 3189
Phone: +61-3-9555-5277 FAX: +61-3-9555-5344
E-mail: sales@jmeaust.com.au

4/4
()

OPERATION MANUAL

6NY16L-W

Apr 2011: 1st edition

Issued by : Yanmar Co.,Ltd.

Large Power Products Operations Division
Quality Assurance Dept.,
Edited by : YANMAR TECHNICAL SERVICE CO.,LTD.
 '\

: ~ . :.
. . .~

. : .. .

·1 SERVICE MANUAL
~ . .' ' -~
,,

,' .
'- . ·"

' .
.· •
. .... ,
I
'·
• '

MITSUBISHI
r ..
TURBOCHARGERS
-TD09
" .'

l
'c___~;:.
•\

t'. -~ --!.
f" .._.:-:·
. '
I
I.
'·
. TD--10
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1.
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.
J

.TD13
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. ~ '··.~,.

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' I ~•
 INTRODUCTION

This Service Manual is written to familiarize you with the construction of the Mitsubishi
TD09, TDlO and TD13 Turbochargers and to outline basic recommended procedures.
Long life and efficient performance are the essential qualities required of the turbochargers
if they are to fulfil their function of turbocharging the engines. These qualities depend to a
great extent on the care exercised in repairs of the products.
We hope you read this manual carefully, preferably referring to the separate pans catalogue,
to get to know new turbochargers and learn how to service them before starting disassembly,
inspection, cleaning, repair and reassembly.
The description, illustrations and specifications contained iii this manual were of the tur-
bochargers manufactured at the time this manual was approved for printing .
.0 Mitsubishi reserves the right to change specifications or design without notice and without
incurring obligation.

HOW TO READ THIS MANUAL

1. The parts read in the texts or shown in the illustrations are numbered in disassembling
sequence prescribed for each system or assembly.
2. The items to be inspected during disassembly are indicated in C:=J in the disassem-
bled view.
3. The maintenance standards to be referred to for inspection and reassembly are indicated
in easy-to-refer passages of the texts and also iii the "MAINTENANCE STANDARDS"
chart.
4. Each assembling sequence is shown· in the form of, for example, ~--+ ~ --+ ©--+ ®--+
() CD,"below the assembled view. · ·
5. The_ following marks are used in this manual:
 NOTES, CAUTIONS and WARNINGS

These symbols are used to emphasize important and critical instructions. They are used for
the following conditions:

(NOTE) ............ ~ . . . . . . . . . . . Operating procedures, conditions, etc., which

are essential to highlight.

(&CAUTION) · · · · · · · · · · · · · · · · Operating procedures, practices, etc., which,

if not stric~y observed, will result in damage
to or destruction of the product. ·

AwARNING . . . . . . . . . . . . . . . . Operating proced'ures, practices, etc., which,

if not correctly followed, will result in per-
sonal injury or loss of life.

J)EFINITION OF TERMS

. In this manual, the following terms are used in the dimensional and other specifications:

NOMINAL SIZE . . . . . . . . . . . . . . . Indicates the standard dimension of a part.

.. ASSEMBLY STANDARD . . . . . . . . Indicate the dimension of a part- that is, the
dimension to be attained at the time of
reassembly, or the standard performance. Its
value is rounded to the nearest whole number
needed for inspection and is different from the
design vah.~e.
STANDARD CLEARANCE Indicates the clearance to be obtained between
mating pafl.s at the time of reassembly.
REPAIR LIMIT . . . . . . . . . . . . . . . . . A part which has reached this limit must be
repaired.
SERVICE LIMIT . . . . . . . . . . . . . . . . A part which has reached this limit must be
replaced.
i

TABLE OF CONTENTS

Description 1

Disassembly 3
Cleaning and inspection
1. Cleaning ................................................... 8
2. Inspection . . . ·. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Maintenance standards
1. Maintenance standard~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
 DESCRIPTION
TD09

Compressor wheel Thrust bearing Turbine back plate

Exhaust
Air inlet Q . . gas outlet

Bearings t
Compressor cover Bearing housing Exhanst gas inlet Turbine housing

TDlO and TD13

Compressor wheel Thrust bearing Shaft & turbine wheel

Air outlet

. . Exhaust
Airinlet ¢ gas outlet

...
Exhanst gas inlet
Compressor cover
Bearings

1
 DESCRIPTION

The turbocharger consists of a mixed-flow turbine, There are some applications requiring more power
driven by the exhaust gases coming from the en- from a given size of engine. For such applications,
gine, a centrifugal air compressor for pumping air turbocharging meets the requirement by enabling
toward the inlet manifold of the engine, and a shaft the engine to convert more fuel into a large power
common to the turbine and compressor. output.
The turbocharger supplies a larger amount of air The high turbocharger technology of Mitsubishi is
to the engine than the amount it can draw in natu- reflected in these turbochargers in terms of per-
rally aspirated condition. formance, reliability and durability. In each model,
separated type bearings are used to support close
For those diesel engine applications needing not so
to the ends of the shaft on which a greater part of
high "boost" (manifold) pressures, the larger
rotary mass is concentrated.
amount of inlet air that turbocharging makes
available eliminates sooty exhaust smoke, reduces In each model, the shaft is made slender in order
the chances of engine overheating (by keeping to reduce the loss due to high-speed rotary friction.
down the cylinder temperature), improves fuel A separate type turbine back plate is used to block
economy and does away with the need of engine more effectively the flow of heat from turbine side
derating at higher altitudes. to bearing housing.

()

2
 DISASSEMBLY
TD09

Thrust face wear

10

Rubbing contact with

Rubbing contact with
compressor wheel turbine wheel, cracks
and distortion

Rubbing contact with

turbine wheel and damage

Vane distortion, damage. rubbing

contact on back face, gas erosion and
damage to ring grooves
Damage to bearing bore, gas
erosion and distortion of
turbine side flange

CD V-clamp ®>0-ring @ Piston ring

® Compressor cover ® Oil deflector @ Turbine back plate
©Locknut @ Thrust ring (compressor side) ®Bearing
@ Compressor wheel @ Thrust bearing ®Snap ring
@Snap ring· @ Thrust ring (turbine side) @Snap ring
(J) Insert @ V-clamp @Bearing
® Piston ring @ Turbine housing ® Bearing housing
® Finger sleeve @Shaft & turbine wheel

-------1[& CAUTION Ji------,

The vanes of compressor wheel and turbine
wheel are not quite strong and can easily be
distorted. When handling these wheels, be
careful not to drop or shock them.
'"

3
DISASSEMBLY

TDlO and TD13

Vane distortion, damage,

~bbing contact on back
face and gas erosion

Rubbing contact with

compressor wheel

Vane distortion, damage, rubbing

contact on back face, gas erosion and
damage to ring grooves

Damage to bearing bore, gas

erosion and distortion of
turbine side flange

©Snap ring @) 0-ring @ Piston ring

® Compressor cover @ Oil deflector @ Turbine back plate
@ 0-ring @ Thrust ring (compressor side) @Bearing
©Locknut @ Thrust bearing ®Snap ring
@ Compressor wheel @ Thrust ring (turbine side) @Snap ring
®Snap ring @ V-clamp @Bearing
(j) Insert @ Turbine housing ® Snapring
@ Piston ring @ Shaft & turbine wheel ® Bearing housing
® Finger sleeve

r-------i~ &CAUTION ~1--------..

The vanes of compressor wheel and turbine
wheel are not quite strong and can easily be
distorted. When handling these wheels, be
careful not to drop or shock them.
~ ~

4
 MITSUBISHI TC TD13 Parts List 49182-06700 RECEIVED FROM MAKER

Part No. Part Name QTY

49162-23200 RING,SNAP 1
49181-21100 BEARING 2
49181-21600 BEARING,THRUST 1
49181-22200 DEFLECTOR,OIL 1
49181-22300 RING SNAP 3
49181-22500 INSERT 1
49181-22600 O-RING (INSERT) 1
49181-23100 RING,PISTON(T-SIDE) 2
49181-42100 SLEEVE FLINGER 1
49181-42240 NUT 1
49181-42300 RING THRUST (C) 1
49181-42400 RING THRUST (T) 1
49182-09030 CARTRIDGE ASSY 1
49182-19300 PLATE,BACK TURBINE 1
49182-25210 HOUSING ASSY,BEARING 1
49182-30231 SHAFT & T/W ASSY 1
49182-45010 WHEEL,COMPRESSOR 1
49182-20210 HOUSING,BEARING 1
49183-22800 PIN SPRING 1
00665-02048 RIVET,SCREW 2
49169-54200 PLATE,NAME 1
49181-22700 O-RING (C/C) 1
49181-23501 PLATE 4
49181-23701 BOLT 8
49182-19500 BOLT,HEXAGON M4 2
49182-56030 COVER,COMPRESSOR 1
49182-58130 COVER,RCC 1
F3156-14500 O-RING 1
49181-14004 V-CLAMP ASSY.(T SIDE 1
49182-11350 HOUSING,TURBINE 1
49182-14305 LAGGING 1
35A30-00100 O-RING 2
49181-14004 V-CLAMP ASSY.(T SIDE 1
49182-54330 SILENCER ASSY. 1
 DISASSEMBLY

1. Preparation for disassembly

Hold the flange of turbine housing ( 16) in
a vise.

Hold the turbine housing securely to prevent it

from.moving during disassembling work.
~ )

2. Removal of compressor cover

/ ~NOTE ~1--------. .
Before separating compressor cover (2), bear-
ing housing (25) and turbine housing (16), be
®
sure to give a match mark across each joint with
a punch or quick-drying ink pen to aid in reas-
sembling them correctly.
' ~

[TD09]
(1) Using a box wrench, loosen V-clamp (1).
(2) Remove compressor cover (2).
[TDIO and TD13]
(1) Using a box wrench, loosen snap ring (1).
(2) Using a plastic hammer, lightly tap around on
compressor cover (2) to remove the cover.
Also, remove 0-ring (3) from the bearing
housing.

3. Removal of compressor wheel

----.&CAUTION i - - - - - . . . . .
Be careful not to bump the compressor wheel
against the compressor cover.

(1) Hold the boss of shaft & turbine wheel (17),

and remove lock nut (4) securing compressor
wheel (5).

5
DISASSEMBLY

(2) While holding the turbine wheel by one hand,

tum compressor wheel (5) back and forth by
the other hand to lift it off the shaft.

4. Removal of snap ring

AwARNING
Hold down the snap ring by hand while
pinching the ring ends with a snap ring pli·
ers, so that the ring will not fly off just in case
the ring ends slip off the pliers.

Using snap ring pliers (A) (49160-90100),

remove snap ring (6).

5. Removal of insert, oil deflector and related

parts
(1) Using two screwdrivers, gently lift insert (7)
off bearing housing (25).
(2) Separate finger sleeve (9) complete with pis-
ton ring (8) from insert (7).
(3) Remove the following parts from bearing
housing (25):

@) 0-ring
® Oil deflector
@ Thrust ring (compressor side)
@ Thrust bearing
@ Thrust ring (turbine side)

6. Removal of V-clamp
Using a box wrench, loosen the bolt of V-
clamp (15), and displace its installation
position.

6
 DISASSEMBLY

7. Removal of shaft & turbine wheel

(1) Lift bearing housing (25) complete with shaft
& turbine wheel (17) off turbine housing (16)
by one hand holding the shaft and by the other
hand holding the bearing housing.

(2) Tum bearing housing (25) upside down (with

the turbine wheel up) and lay it on the com-
pressor cover. Remove the following parts:

@ Shaft & twbine wheel

@ Piston ring
@ Turbine back plate
®Bearing (compressor side)

8. Removal of snap rings and bearing

------.&CAUTION,____ __
a) Use the snap ring pliers (49160-90200) to
remove the snap rings.
b) When removing the snap rings, be careful
not to damage the inside surface of bearing
housing and sealing face (turbine side) of
(j piston ring.

Lay bearing housing (25) on the bench with

the compressor side up, and remove the
following parts:

® Snap ring (compressor side)

@ Snapring }
® Bearing (tu.rbine side)
® Snap ring (IDIO and TD13)

7
 CLEANING AND INSPECTION

1. Cleaning
Blasting equipment is used in the factory to
clean turbochargers. At the dealer level, the
following cleaning method, based on the use
of a non-flammable solvent (for which Die
Cleaner T-30 of Daido Chemical-make is
recommended), may be applied.
r-------1~ NOTEJ1-------~,
Non-sudsing household detergent may be used
instead of the solvent. In such a case, be sure
to select one that is chemically neutral and does
not attack metals.

(1). Visually inspect the parts to detect signs of·

burning and other malconditions in order to
obtain as much informatipn as possible be-
fore washing them. '
(2) Immerse the parts in the washing pan filled
with the solvent, and wash each clean, making
it completely free of oily matter.
(3) Take out the washed parts and dry them by
directing pressure air: blow off the solvent
from every nook and comer of each part.
(4) Scale-like deposits, if any, must be removed
by using a plastic scraper or bristle brush.
After removing the deposits off, wash the part
and dry it again as before.

r------1[& CAUTION Ji------,

When washing and drying the parts, handle
them carefully and avoid denting or nicking
them.

(5) Protect the sliding surfaces of the cleanea

. parts against rusting by applying clean engine
oil to them.

8
 CLEANING AND INSPECTION

2. Inspection
(1) Bearing housing
Measure the inside diameter of bearing bores
in the housing. If it is more than the service
limit, replace the housing.
Unit: mm (in.}
Item Service limit
Inside diameter of TD09 22.268 (0.876 69}
bearing bores in TDlO
housing TD13 · 30.006 (1.18134}

(2) Bearings
(a) Measure the outside diameter of the bear-
ing. If it is less than the serVice limit, re-
place the bearing.

Unit: mm (in.}
Item Service limit
TD09 22.144 (0.871 81}
·Outside diameter
of bearing TDlO 29.876 (1.176 22}
TD13

(b) Measure the inside diameter of the bearing.

If it is more than the service limit, replace
the bearing.
Unit: mm (in.)
Item Service limit
TD09 13.542 (0.533 15}
Inside diameter of
bearing TDlO 18.050 (0.710 63}
TD13

(c) Measure the length of the bearing. If it is.

less than the service limit, replace the bear-
ing.
Unit: mm (in.)
Item Service limit
TD09 14.440 (0.568 50}
Length of bearing TDlO
TD13
17.440 (0.686 61}

9
CLEANING AND INSPECTION

(3) Shaft & turbine wheel

(a) Measure the diameter of the shaft journals.
If it is less than the service limit, replace the
shaft & turbine wheel and piston ring.
Unit: mm (in.)
Item Service limit
1D09 13.496 (0.53134)
Diameter of shaft
journals 1D10
1Dl3 17 .996 (0. 708 50)

(b) Using a dial indicator and V-block, meas-

ure the runout of the shaft. If it is more than
the service limit, replace the shaft & turbine
wheel.

Do not attempt to straighten a disto~ed shaft.

Be sure to replace the shaft & turbine wheel
with a new one when the shaft is badly distorted.

Unit: mm (in.)
Item Service limit
Runout of shaft 0.015 (0.000 59)

(c) Check the journal surfaces for condition. If

they are roughened, hold the shaft on a lathe
by tightening it in the chucks at its center,
and tum it at 300 to 600 rpm to lightly
polish the journals with #400 sandpaper and
engine oil.

(4) Insert
Insert
Put a new piston ring in the groove in the
insert, and measure the end gap of the ring. Piston ring
If it is not correct, replace the ipsert.
Unit: mm (in.)
Item Service limit

1D09 0.05 to 0.15

End gap of piston (0.002 0 to 0.005 9)
ring 1Dl0 0.05 to 0.25
1D13 (0.002 0 to 0.009 8)

10
 ASSEMBLY
TD09

cj

Assembling sequence

C)
r------~f NOTE11--------..., r-----~f &CAUTION 11------
a) Replace the following parts when reas- Replace the compressor wheel or the shaft &
sembling the turbocharger: turbine wheel if its vanes are distorted or
@ Piston ring cracked. A single vane having minor distortion
® Piston ring or scratching is not the cause for replacement;
@) 0-ring in such a case, never attempt to re-shape the
b) After installing the overhauled turbocharger distorted vane.
on the engine, crank the engine with the
starter to allow the engine oil to flow to the
turbocharger.

11
ASSEMBLY

TDlO and TD13

Assembling sequence

- - - - - 1 &cAUTIONi------
a) Replace the following parts when reas- Replace the compressor wheel or the shaft &
sembling the turbocharger: turbine wheel if its vanes are distorted or
@ Piston ring cracked. A single vane having ininor distortion
@ Piston ring . or scratching is not the cause for replacement;
@ 0-ring in such a case, never attempt to re-shape the
@) 0-ring distorted vane.
b) After installing the ovelhauled turbocharger
on the engine, crank the engine with the.
starter to allow the engine oil to flow to the
turbocharger.

12
 ASSEMBLY.

1. Installation of shaft & turbine wheel and

bearing
(1) Reassemble the following parts:
® Bearing housing
@ Snap ring (TDIO and TD13)}
@ Bearing (turbine side)
@Snap ring
® Snap ring (compressor side)
-------i[ & CAUTION]1------
a) Use the snap ring pliers (49160:-90200) to
install the snap rings. After installing the
snap rings in place, make sure they rotate
freely when turned by fingers
b) Apply engine oil to the inside and outside
surfaces of the bearing.

(2) Lay bearing housing (25) on compressor cover

(2), and put turbine back plate (19) in place. roLarge
(3) Put piston ring (18) in the groove formed of
shaft & turbine wheel (17).
(4) When installing shaft & turbine wheel (17)
)24•=ll
End gap
complete with the piston ring to bearing
housing (25), position the piston ring as
shown, and put the shaft & turbine wheel in
the housing while rotating it back and forth.

,,.-------1{ & CAUTION }1------,.,

a) When insUuling thepiston ring, be careful
neither to expand the ring more than is
necessary nor to twist its ends.
b) After installing the piston ring in its groove,
apply MOLYKOTE to it
c) The piston rings are common to the turbine
and compressor sides.
d) Never force the shaft & turbine wheel un-
less it is in line with the. turbine back plate
and bearing housing.
\.

13
ASSEMBLY

(5) After installing shaft & turbine wheel (17),

hold the end of the shaft by hand, and tum it
upside down so that its compressor side is up.
Put compressor-side bearing (20) in place.
Then, put bearing housiilg (25) on turbine
housing (16) and tighten V-clamp (15) tem-
porarily.·

2. Installation of thrust bearing

Apply engine oil to the inside and outside
surfaces of thrust ring (14) and thrust
bearing (13), and put the thrust ring and
bearing in place. Position the thrust bearing
by entering the groove pin in fu.e locating
hole.

3. Installation of 0-ring
Apply grease to 0-ring (10), and put the 0-
ring in place.

4. Installation of oil deflector

Apply engine oil to both sides of thrust ring
(12) and put the thrust ring in place. Put
oil deflector (11) with its baffle side down.

14
 ASSEMBLY .

5. Reassembly of insert subassembly

(1) Put the insert parts in the following sequence:
® Finger sleeve
@ Pis.fun ring
(j) Insert

,,--------1[ & CAUTION Ji--------.,

a) When putting the piston ring on the finger
sleeve, be careful neither to expand the ring
more than is necessary nor to twist its ends.
b) Apply MOLYK.OTE to the piston ring fit-
ted to the finger sleeve, and put the sleeve
on the insert, taldng care not to damage the
ring.

(2) Install the insert subassembly on bearing

housing (25).

6. Installation of snap ring

r [&CAUTION] ....
a) Be sure to position the snap ring correctly.
b) Give light hammer blows to the ends of the
snap ring through a screwdriver to fit the
ring. in the groove in the bearing housing.
c) When giving hammer blows to the snap
ring, be careful not to damage the bearing
housing.
..... ~

Using the snap ring pliers (49160-90100),

put snap ring (6) on bearing housing (25),
C! with its tapered side up.

15
 -- -~- -- -----~---------

ASSEMBLY

7. Measurement of clearance between shaft &

turbine wheel and turbine housing
Set up a dial indicator on shaft & turbine
wheel (17) as shown. Move the shaft in the
axial direction to measure the clearance. If
the clearance is incorrect, disassemble and
investigate for the cause.
Unit: mm (in.)
Item Standard clearance
Clearance between TD09 0.29 to 0.93
shaft & turbine (0.011 4 to 0.036 6)
wheel and turbine TDlO 0.29 to 0.91
housing TD13 (0.011 4 to 0.035 8)

8. Installation of compressor wheel

Put compressor wheel (5) in place. Apply
MOLYKOTE to the threads of lock nut (4)
@
and tighten the lock nut to the specified
torque.
Unit: N·m [kgf·m] (lbf.ft)
Item Tightening torque ~w
25.5 to 27.5
TD09 [2.6 to 2.8] Compressor
(18.8 to 20.3) wheel side
50 to 54
Metric unified [5.1 to 5.5)
thread - (37 to 40)
TDlO
TD13 86.3 to 90.2
Spiral lock [8.8 to 9.2)
thread (63.7 to 66.5)

9. Measurement of axial play of shaft & tur-

0 bine wheel
Set up a dial indicator on shaft & turbine
wheel (17) as shown. Move compressor
wheel (5) in the axial direction to measure
the axial play. If the axial play is incorrect,
disassemble and investigate for the cause.
Unit: mm (in.)
Item Assembly standard
Axial play of shaft & 0.075 to 0.135
turbine wheel (0.002 95 to 0.005 31)

·1s
 ASSEMBLY

10. Measurement of clearance between

turbine back plate and turbine wheel
Remove the turbine housing from bearing
housing (25), and put compressor cover (2).
Using feeler gauges, measure the clearance
between the turbine back plate and turbine
wheel. If the clearance is incorrect, disas-
semble and investigate for the cause.
--------1 NOTE 1--------
Be sure to measure the clearance at the tips of
the vanes with two feeler gauges as shown.

Unit mm (in.)
Item Standard clearance

TD09 0.6 to 1.2

(0.024 to 0.047)
Clearance between 0.65 to 1.25
turbine back plate TDlO (0.025 6 to 0.049 2)
and turbine wheel
0.55'.to 1.15
TD13 (0.021 7 to 0.045 3)

11. Installation of turbine housing

(1) Put turbine housing (16) on baring housing
(25), making sure it is correctly positioned
with respect to the housing.

(2) Apply MOLYKOTE to the threads of V-

clamp (15), and tighten the clamp to the
specified torque.

17
 ASSEMBLY

12. Installation of compressor cover

Put compressor cover (2) on the turbine
housing, making sure it is correctly positioned
with respect to the turbine housing. Apply
grease to 0-ring (3) when installing it (TDlO
and TDl 3 only).

13. Installation of V-clamp or snap ring

[TD09]
Apply MOLYKOTE to the threads of V-clamp (1)
,,
and tighten the V-clamp to the specified torque.

7.8 to 9.8 N:m

Tightening torque [0.8 to 1.0 kgf·m]
for V-clamp (5.8 to 7.2 lbf·ft)

[TDlO and TD13]

Install snap ring (1) to compressor cover (2).

()

18
 TROUBLESHOOTING

Problem Correction

Abnormal noise or vibration. (1) Bearing could be in faulty condition, or rotating parts,
particularly wheels, could be rubbing surrounding parts.
This type of trouble is often caused by keeping a deterio-
rated lube oil in service, by inadequate oil supply due to a
clogged oil pipe or broken or clogged oil filter, or by
habitual quick cold starting or abrupt shutting down of a
hot engine.
(2) Evidence of rubbing contact on rotating parts indicates
loss of balance in rotating mass or a distorted shaft, c~used
by a worn bearing or by an airborne object impinging
upon the compressor or turbine wheel to disturb its mass
distribution.
In either case, the turbocharger must be taken down and
inspected. Usually repair service is required. ·

Turbocharger appears to be in (1) Exhaust gases could be leaking. Check exhaust gas line
good condition but engine lacks from engine manifold to turbocharger gas inlet.
power. ,'(2) Abnormally high back pressure to turbocharger exhaust gas
outlet could be the cause. Check muffler for clogging with
carbon.
(3) Boost air could be leaking, or air cleaner could be clogged.
If clogged, clean or replace air cleaner element.
(4) Compressor interior could be dirty with excessive dust
build-up. If this happens to be the cause, remove compres-
sor cover and clean.
(5) After shutting down engine, try to spin rotor by hand. If
rotor will not spin, disassemble turbocharger and clean.

Oil leaks from exhaust gas outlet (1) Clogged air cleaner is liable to create a negative pressure
pipe or from inlet air pipe. condition or suction side to draw in lube oil. Clean or
Exhaust smoke tends to be replace air cleaner element
whitish. (2) Check lube oil return pipe for damage. A dented. or dis-

0 torted pipe must be repaired or replaced.

(3) See if piston ring is worn or, because of its groove being
worn, loose in groove: if so, replace worn parts.
(4) Keeping turbocharger in service with its bearing in faulty
condition will damage piston ring in time, resulting in
leakage of oil into both ends, that is, gas outlet pipe and
inlet air pipe.

19
 MAINTENANCE STANDARDS
1. Maintenance standards Unit: mm (in.)

Item Nominal Assembly standard Repair limit Service limit

value [Standard clearance] [Clearance] [Clearance] Remarks
22.26 22.268
Inside diameter of TD09 (0.876 4) (0.876 69)
bearing bores in
bearing housing TDlO 30 30.006
TD13 (1.18) (1.181 34)
22.144
TD09 (0.871 81)
Outside
diameter TDlO '29.876
TD13 (l.176 22)
TD09 13.542
Inside (0.533 15)
Bearing diameter TDlO 18.050
TD13 (0.710 63)
14.440
TD09 (0.568 50)
Length
TDlO 17.440
TD13 (0.686 61)
13.5 13.496
TD09 (0.531) (0.531 34)
Diameter of
Shaft & journals
turbine TDlO 18 17.996.
wheel TD13 (0.71) (0.708 50)
. 0.015
Runout of shaft (0.000 59)
0.05 to0.15
TD09 (0.002 0 to 0.005 9) With piston
End gap of piston ring fitted
ring TDlO 0.05 to0.25 in insert
TD13 (0.002 0 to 0.009 8)
0.29 to0.93
Clearance between TD09 lco.0114to0.036 6)1
shaft & turbine wheel
and turbine housing TDlO [ 0.29 to 0.91 ]
TD13 (0.011 4 to 0.035 8)
Axial play of shaft & 0.075 to 0.135
turbine wheel (0.002 95 to 0.005 31)

TD09 [ 0.6 to 1.2 ]

(0.024 to 0.047)
Clearance between
turbine back plate and TDlO [ 0.65 to 1.25 ]
turbine wheel (0.025 6 to 0.049 2)

TD13 [ 0.55 to 1.15 ]

(0.021 7 to 0.045 3)

20
 2. Tightening torques
TD09
Thread Width Tightening torque
Fastener Diam. - pitch, across flats, Remarks
mm mm N-m kgf·m lbf·ft

Compressor wh~l lock nut ApplyMOLY-

9- 1.0 17.0 25.5 to 27.5 2.6 to 2.8 18.8 to 20.3 KOI'E to threads.
Apply MOLY-
V-Clamp nut 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2 KOI'E to threads,

TDlO and TD13

Thread Width Tightening torque
Fastener Diam. - pitch, across flats, Remarks
mm mm N·m kgf·m lbf·ft
Metric unified
Compressor thread 11-1.0 19.0 50 to 54 5.1 to 5.5 37 to40
ApplyMOLY-
wheel lock KOI'E to threads.
nut Spiral lock 11 -1.0 19.0 86.3 to 90.2 8.8 to 9.2 63.7 to 66.5
thread
Apply MOLY-
V-clamp nut 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2 KOI'E to threads.

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21
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Jun. "96
Printed in Japan Pub. No. 99629-91151