INDUSTRIAL. DIESEL.

EllBlllE
MARINE DIESEL. EllBlllE

MODEL HA (L) series

 SERVICE MANUAL
MODELHAseries

~ Y6111M61A DIESEL EllBlllE CD.§LTD.

Printed in Japan
OOOOAOA1014-9110
 Contents

Sec. 1. GENERAL INFORMATION (GI) 9. Removing Scales

.••.....••... Page M - 1·22 (during disassembly) .............. 6-14
1. External View .................. 1-1 10. Anti-Corrosion Agent ............. 6-14
2. Specifications . . . . . . . . . . . . . . . . . . . 1-6
3. Performance Curves . . . . . . . . . . . . . . 1-8 Sec. 7. FUEL SYSTEM (FS) ....•.•.• Page 7-1 - 7-42
4. Sectional Views ...•............. 1-10 1. Service Information • . . . • . • . . . . • . . 7 · 1
5. Accessories ..................... 1-12 2. Injection Nozzle . . . . • . . . . • . . . . . . . 7-5
6. Model Identification .............. 1-16 3. Injection Pump.. . . . . • . . . . . . . . . . . 7-8
7. Fuel, Lubricant and Coolant ....... 1-17 4. Feed Pump ....................• 7-32
8. Service Rules ................... 1-18 5. Governor ...................... 7-36
9. Standard Tightening Specifications .. 1-18 6. Automatic Timer
10. Special Tools ................... 1-19 (Marine Engine Only) ............. 7-41

Sec. 2. MAINTENANCE (Ml) .•.•..•• Page 2-1 -2-16 Sec. 8. INTAKE ANO EXHAUST SYSTEM (IE)
1. Maintenance Schedule ............ 2·1 ••.••••••••.• Page8-1-8·10
2. Maintenance Procedure . . . . . . . . . . . 2-3 1. Service Information . . . . . . . . . . . . . • 8· 1
2. Intake System . . . . .. . . .. .. .. . .. . 8-1
Sec. 3. CYLINDER HEAD ANO VALVE (CH) 3. Exhaust System . . . . .. .. . . . . .. . . . 8-1
.... , .......• Page3-1-3-13 4. Turbocharger (6HAL-TE, and
1. Service Information . . . . . . . . . . . . . . 3-1 6HA(M)-HTE ................... 8-3
2. Removal . . . . . . . . . . . . . . . . . . . . . . . 3-3
3. Disassembly . . . . . . . . . . . . . . . . . . . . 3-4 Sec. 9. ELECTRICAL SYSTEM (ES) •.• Page 9-1 - 9-33
4. Inspection and Repair . . . . . . . . . . . . 3-5 1. Battery and Charging System . . . . . . . 9-1
5. Assembly ...................... 3-11 2. Starting System . . . . . . . . . • . . . . . . . 9· 15
6. Instaflation ..................... 3-12 3. Instruments .................... 9-25
4. Warning System
Sec. 4. ENGINE PROPER (EP) .......Page 4-1 -4-28 (Marine Engine Only) ........•.... 9-28
1. Service Information . . . . . . . . . . . . . . 4-1
2. Piston and Connecting Rod . . . . . . . . 4-3 Sec. 10. ENGINE EMERGENCY STOP SYSTEM (EE)
3. Cylinder Liner .................. 4-11 ... , ...• , .•• Page 10-1 -10·5
4. Gear Train ..................... 4-13 1. Service Information .............. 10-1
5. Camshaft and Valve Train ......... 4-18 2. Electrical Stop System ....•....... 10·1
6. Crankshaft ..................•.. 4-20 3. Mechanical System .......•....... 10-3
7. Cylinder Block .................. 4-27
Sec.11. ENGINE INSTALLATION (El)
Sec. 5. LUBRICATION SYSTEM (LS) ... Page 5-1 - 5·7 .•.•••.•••• Page 11·1 -11·26
1. Service Information .............. 5-1 1. Industrial Engine ................ 11-1
2. Oil Pump . . . . . . . . . . . . . . . . . . . . . . 5-4 2. Marine Engine ...•............. 11·14
3. Oil Filter . . . . . . . . . . . . . . . . . . . . . . 5-5
4. Oil Cooler . . . . . . . . . . . . . . . . . . . . . . 5·5 Sec. 12. TROUBLE SHOOTING (TS) •. Page 12-1 -12-3
5. Pressure Regulator Valve . . . . . . . . . . 5-7 1. Troubleshooting ................. 12-1

Sec. 6. COOLING SYSTEM (CS) ...... Page 6-1 - 6·14 Sec. 13. MARINE GEAR (MG) ••.•.• Page 13·1 -13·19
1. Service Information . . . . . . . . . . . . . . 6· 1 1. Service Information ...........•.. 13-1
2. Cooling Water Pump 2. Oil Pump/Selector Valve .......... 13-8
(Industrial Engine) . . . . . . . . . . . . . . . 6-4 3. Input Shaft/Gear Shaft ........... 13·10
3. Sea Water Pump (Marine Engine) . . . . 6-6 4. Output Shaft ...........•...... 13-14
4. Fresh Water Pump (Marine Engine) ... 6-8 5. Input Shaft Flange .............. 13-16
5. Fresh Water Cooler ............... 6-10 6. Oil Strainer Cleaning ............ 13-17
6. Pressure Cap and Reserve Tank ..... 6-11 7. Shim Adjustment ............... 13-17
7. Thermostat . . . . . . . . . . . . . . . . . . . . . 6-12 8. Troubleshooting .............•.. 13-19
8. Cap and System Leak Test ......... 6-12 Printed in Japan
Sec.1. GENERAL INFORMATION (GI)

Contents of this section

Page
1. External View ..................................... 1-1
11·1.] 4HAL Industrial Engine........................... 1·1
11·2.] 6HAL Industrial Engine........................... 1·2
11·3.] 6HAL·T Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1·3
11-4.] 6HAE Marine Engine..... . . . . . . . . . . . . . . . . . . . . . . . . 1-4
11-5.] 6HA-HTE Marine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
12-1.] Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
[2-2.] Marine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3. Performance Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

[3-1.] 4HAL Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
13-2.] 6HAL Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
13-3.] 6HAL-T Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
13-4.] 6HAL-HT Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . 1-8
13-5.] 6HAE and 6HAME Marine Engine.. . . . . . . . . . . . . . . . . . . 1-9
[a 6.] 611/z I ITE a::e:I SI l:':M 1ITE Pv1u: i::c E::gi::c . . . . . . . . . . . . . . . 19

4. Sectional Views .................................... 1-10

14-1.] 6HAL-T Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
14-2.] 6HA-HTE Marine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5. Accessories ........................................ 1-12

15-1.] Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
15-2.] Marine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

6. Model Identification ................................. 1-16

7. Fuel, Lubricant and Coolant .......................... 1-17

17-1.] Recommended Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
17-2.] Recommended Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . 1-17
17-3.] Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

8. Service Rules ...................................... 1·18

9. Standard Tightening Specifications ..................... 1-18

10. Special Tools ...................................... 1-19

GI
1. External View [-1.]

1. General Information
1. External View
[1-1.) 4HAL Industrial Engine
Fig. Gl-1. 4HAL External view

Starting motor

Lube oil filter

Alternator

Fuel filter Fuel injection pump

Timing mark cover

Fuel feed pump

Dipstick
Drain plug
Printed in Japan
1-1.
GI
1. External View [ 2.]

[1-2.] &HAL Industrial Engine

Fig. Gl-2. 6HAL External view

Radiator cap

Air cleaner

Alternator
Lube oil filter

Fuel filter

Drain plug
Fuel feed pump Oil filler cap
Dipstick

Printed in Japan
1-2.
GI
1. External View [-3.]

[1-3.] 6HAL-T Industrial Engine

Fig. Gl-3. 6HAL·T External view
Turbocharger Radiator cap

Lube oil filter

Fuel filter Alternator
Injection nozzle

Air cleaner

Instruments

Timing mark cover

Fuel feed pump

Fuel injection pump Drain plug

Printed in Japan
1-3.
GI
1. External View [--4.]

[1-4.] &HAE Marine Engines

Fig. Gl-4. 6HAE External view Pressure cap
Fresh water tank
(Heat exchanger)

Fuel filter Lube oil filters Sea water pump

Fuel injection pump Fresh water pump

Decompression handle

Injection nozzle

Stop knob

Timing mark cover

Oil filler cap

Lube oil evacuation port

Fuel feed pump Dipstick

Alternator

Printed in Japan
1-4.
GI
1. External View(-5.)

[ 1-5. ]6H A-HTE and 6HA-DTE Marine Engine

Fig. Gl-5. 6HA-HTE and 6HA-DTE External view

Turbocharger
Prefilter

Turbocharger oil filter

Starting motor

Lube oil filters Sea water pump

Fuel filter
Fresh water pump

Fuel injection pump

lntercooler
'
Stop knob

Timing mark cover

Oil filler cap

Fuel feed pump

Lube oil evacuation port

Alternator Dipstick

Printed in Japan
F032G0223 1-5.
GI
2. Specifications [-1.]

2. Specifications
[2-1.] Industrial Engine
Model 4HAL 6HAL 6HAL-T GHAL-HT

Type Vertical 4.cycle, water-cooled diesel engine

Combustion type Direct injection
Number of cylinders 4 6
Bore x Stroke mm (in) 130 x 150 (5.12 x 5.91)
Displacement .Lieu.in.) 7.964 (485.91 11.946 1728.94)
Continuous rated output HP 86 100 125 150 160 190 200 240
At 1-hr. rated output HP 95 110 138 165 176 209 220 264
Engine speed r.p.m. 1,500 1,800 1,500 1,800 1,500 1,800 ' 1,500 1,800
Average piston speed m/s (ft/s) 7.5 (24.61 9.0 129.5) 7.5 (24.61 9.0 129.5) 7.5 (24.61 9.0 129.5) 7.5 (24.6) 9.0 (29.5)
Applicable generator capacity KVA 70 BO 100 125 130 150 170 200
Frequency Hz 50 60 50 60 50 60 50 60
Compression ratio 15.6' 1 14.7 ' 1 14.5: 1
··-- -----
Firing order (Viewed from radiator side) 1 ·2-4-3 1-4-2-6-3-5
-------
Starting system Electrical
Type Forced circulating type
Wat&r pump centrifugal type
Cooling Radiator Colgate fin type
system Thermostat Wax pellet type
24-ll6·3/B U.S. gal, 4.2,t'.,(11 U.S. gal,
Cooling water capacity 32 .l(B-1/2 U.S. gal, 7 Imp. gal)
5-1/4 Imp. gal) 9-1/4 Imp. gal)
Type Forced lubrication type
Oil pump Gear pump
Oil filter Paper filter type
Lubrication -
Oil cooler Water-coated multiple fin type
system
Oil pressure regulating valve Cylindrical, with exterior adjusting screw
19.5.f.15-1/B U.S. gal,
Oil capacity 291,,(7-5/8 U.S. gal, 6-3/8 Imp. gal)
4-1/4 Imp. gall
Injection pump Bosch integral pump, model PES-A Bosch integral pump, model PES-P
Governor Centrifugal all-speed control type, model RSV
Injection valve Semi-long hole nozzle
Fuel system Injection I Rated speed r.p.m. 1,500 1,800 1,500 1,800 1,500 1,800 1,500 1,800
timing I BTDC 26° 26° 29° 23° 23°
Injection pressure kg/cm 2 {psi) 220 (3129)
Feed pump Plunger type
Fuel filter Paper element
Exhaust gas I, Exhaust gas turbo·
Turbocharger -
turbocharger charger with intercooler
Starter motor V-Kw 24-5.2 24---<l
Electrical
Alternator V·W 24 - 400 (3-phased, AC generator)
system
Battery 12V-120AHx2 12V-150AHx2
Power takeoff position Flywheel side
P.T.0. Direction of rotation Counterclockwise (Viewed from flywheel side)
Flywheel housing SAE No. 1
Engine weight (dry)• kg (lb) 810 (1,7861 1,110 (2,447) 1,190 (2,623) 1,236 (2,725)
Overall length mm (in) 1,933.9 (76.11 2,339.9 (91.9) 2.397.4 (94.4) 2,393.4 194.2)
Dimensions Overall width mm (in) 962 (37.1) 967 (38.11 858.5 (33.8) 893.5 (35.2)
Overall height mm (in) 1,386 (54.6) 1,386 (54.6) 1,473 (58.01 1,473 (58.0)

* Without engine bed (Channel bed, or with vibration proof bed for generator is available as standard equipment.I

Printed in Japan
1-6.
GI
2. Specifications (-2.)

[2-2.]Marine Engine
6HA(M)-E
a) Engine

Item Unit Specifications

Model - 6HAE(With marine gear) 6HAM-E(With marine gear)
Type - 4-cycle,6-cycle water cooled diesel engine with turbocharger
Combustion chamber type - Direct injection
Turbocharging system - Exhaust gas turbocharger with intercooler
Cylinder bore X Stroke mm( in) 130x150(5. 118x 5.906)
Displacement f(cu in) 11.946
Output HP/rpm 165/2000 173/2000
Continuous
Net mean effective pressure kg/om(psi) 6.22(88.45) 6.52(92.71)
rating
Mean piston speed m(ft)/sec. 10.00(32.81)
- I
Practical Output HP/rpm 200/2100 208/2100
maximum Net mean effective pressure : kg/cnf(psi) 7. 18(102. 10) 7.46(106.08)
Mean piston speed m(ft)/sec. 10.50(34.45)
Starting method,capacity kW Electric,24V 6kW
Maximum explosion pressure/Compression ratio kg(psi)/cm 85( 1208.7)/15.6
Piston top clearance/Valve clearance mm( in) 1.2(0.047) 0.4(0.016)
Injection pump type - I PEP Bosch in-line collective type(plunger dia·: +
Injection timing(FIO) 0
BTDC I 21
I
Injection valve type - Holes nozzle 4-+ 0.36x150°
Fuel system Injection pressure kg/cm'( psi) 220(3128.4)
Applicable fuel oil - Diesel fuel oil
Fuel filter - Paper element
Firing order - 1-4-2-6-3-5-1
I
Lubricating method - I Forced lubrication with gear pump
Oil delivery capacity I/hr 7300min. (27830US gal,241001mp gal)at 2000rpm
Oil pressure kg/c.l(psi)
Lubricating
Oil filter - Paper element( double)
system
Applicable lubricating oil - API grade CD
I Total f 38
Oil capacity
I Effective I 20
Cooling method - Constant-high-temperature fresh water cooling
Coo Ii ng system Cooling water delivery volume I/hr Sea water pump:12000min.,Fresh water pump:14000mln.(at2000rpm)
Fresh water capacity f 45(170US gal,2041mp gal)
Type - --
Cooling method - --
Turbocharger
Lubricating method - --
Lubricating oil pressure kg/c.l(psi) --
Type,capacity rri' (ft 2 ) --
lntercooler
Cooling method - --
Type - Electric bilge pump
Bilge pump
Delivery volume I /hr

Printed in Japan 1- 7.
F032G0223
GI
2. Specifications(-2.)

Item Unit Specifications

Power take-off position - Flywheel side
Operation side - Port side
Direction of rotation(viewed from stern side) - Counterclockwise
Dimensions
mm( in) 2008 x 885 x 1097(79.055 x 34.843 x 43.189)
Overall lenath Xwidth x heiaht
Height for piston removal(from mounting surface) mm(in) 920(36.220)
Dry weigth{except marine gear) kg( lb) 1145(2524. 725)

b) Marine gear

Item Unit Specifications

Model - YP-60LE MGN46BL MGN47BL
--------·
Type - Hydraulic,wet.multi-disc clutch
Forward - 1.77 2.07 2.58 2.91 3.53 3.90 4.42 5.00 5.55 6.00
Reduction ratio
Reverse -

Revolution speed of propeller shaft( forward) rpm 966 774 688 567 512 452 400 360 333
Direction of rotation(viewed from stern side) - Clockwise or counterclockwise
Lubrication method - Forced lubrication with gear pump
Lubrication oil Total £ 8 7 8
capacity Effective £ ,1
Cooling method -
Dry weight kg( lb) 205(452.025) 265(584.325) 247(544.635)

Printed in Japan
1-7-1- F032G0223
GI
2. Specifications (-2.)

6HA(M)-HTE
a) Engine

Item Unit Specifications

Model - 6HA-HTE(With marine gear) \6HAM-HTE(With marine gear)
Type - 4-cycle,6-cycle water cooled diesel engine with turbocharger
Combustion chamber type - Direct injection
Turbocharging system - Exhaust gas turbocharger with intercooler
Cylinder bore x Stroke mm(in) 130x 150(5.118x 5.906)
Displacement f (cu in) 11.946
Output HP/rpm 240/2000 I 25212000
Continuous
rating
Net mean effective pressure kg(psi)/ool 9.04(128.5) I 9.49(134.9)
Mean piston speed m(ft)/sec. 10.00(32.81)
-
Practical Output HP/rpm 300/2100 I 312/2100
maximum Net mean effective pressure kg/crti(psi) 10.76(153.0) 11.19(159.1)
I
Mean piston speed m(fl)/sec. 10.50(34.45)
Starting method,capacity kW Electric,24V 6kW
Maximum explosion pressure/Compression ratio kg(psi)/ari 110(1564.2)/14.6
Piston top clearance/Valve clearance mm( in) 1.2±0.1(0.047±0.004 )/0.4(0.016)
Injection pump type - PEP Bosch in-line collective type(pluger dia·= +
0
Injection timing(FID) BTDC 17±1
Injection valve type - Hole nozzle(4-+0.38X150°}
Fuel system Injection pressure kg/crrl(psi) 220±5(3128.4±71.1)
Applicable fuel oil - Diesel fuel oil
1 Fuel filter - Paper element
Firing order - 1-4-2-6-3-5-1
L ub ricati ng method - Forced lubrication with gear pump
Oil delivery capacity f /hr 7300min(27630US gal,241001mp gal)at2000rpm
Oil pressure kg/crrl(psi)
Lubricating
Oil filter - Paper element( double)
system
Applicable lubricating oil - API grade CD
Total f 38
Oi I capacity
Effective f 20
Cooling method - Constant-high-temperature fresh water cooling
Cooling system Cooling water delivery volume I/hr Sea water pump:12300min.,Fresh water pump:16000min.(at2000rpm}
F rash water capacity f 50(189US gal,2271mp gal}
Type - MITSUBISHI 4LF
Cooling method - Air cooling
Turbocharger
Lubricating method - Forced lubrication with gear pump( together with engine lubrication)
Lubricating oil pressure kg/crrl(psi)
Type.capacity nl(ft') 7.lT
lntercooler
Cooling method - Sea water cooling
Type - Electric bilge pump
Bilge pump
Delivery volume I/hr

Printed in Japan
F032G0223 1-7-2.
GI
2. Specifications(-2.)

Item Unit Specifications

Power take-off position - Flywheel side
Operation side - Port side
Direction of rotation(vlewed from stern side) - Counterclockwise
Dimensions
••(In} 2007x945x1233(79.016 x 37.205 x 48.543)
Overall length Xwidth x height
Height for piston removal{from mounting surface) 11111(in) 920(36.220)
Dry weigth(except marine gear) kg( lb} 1230(2712.15)

b) Marine gear

Item Unit Specifications

Model - YP-120E YP-120LE YP-120NE
Type - Hydraulic,wet,multi-disc clutch
I Forward - 2.12 2.68 3.05 3.55 4.05 4.66 4.99 5.54 5.96
Reduction ratio
I Reverse -
Revolution speed of propeller shaft(forward) rpm 945 746 666 564 494 429 401 361 336
Direction of rotation(viewed from stern side) - Clockwise or counterclockwise
Lubrication method - Forced lubrication with gear pump
Lubrication oil I Total I 11
capacity I Effective I 12
Cooling method -
Ory weight kg( lb} 300(661.5) 380(837.9) 480(1068.4)

Printed in Japan
1-7-3. F032G0223
GI
2. Specifications (-2.)

6HA(M )-DTE
a) Engine

Item Unit Specifications

Model - 6HA-DTE(With marine gear) 6HAM·DTE(With marine gear)
Type - 4-cycle,6-cycle water cooled diesel engine with turbocharger
Combustion chamber type - Direct injection
Turbocharging system - Exhaust gas turbocharger with intercooler
Cylinder bore x Stroke m11(in) 130x 150(5.118x5.906)
Displacement R(cu in) 11.946
Output HP/rpm 300/2000 314/2000
Continuous
Net mean effective pressure kg/ori(psi) 11.30(160.7) 11.74(166.9)
rating
Mean piston speed m(ft)/sec. 10.00(32.81)
-
Practical Output HP/rpm 350/2100 364/2100
maximum Net mean effective pressure kg/ori(psi) 12.56(178.6) 13.06(185.7)
Mean piston speed m(ft)/sec. 10.50(34.45)
Starting method.capacity kW Electric. 24V 6kW
Maximum explosion pressure/Compression ratio kg(psi)/ori 115(1635.3)/14.8
Piston top clearance/Valve clearance mm( in) 1.2(0.047)/0.40(0.016)
Injection pump type - PEP Bosch in-line collective type( plunger dia·: +
Injection timing(FID) 'BTDC
Injection valve type - Hole nozzle(5-0.35x 150)
Fuel system Injection pressure kg/cril(psi) 220±5(3128.4±71.1)
Applicable fuel oil - Diesel fuel oil
Fuel filter - Paper element
Firing order - 1-4-2-6-3-5-1
Lubricating method - Forced lubrication with gear pump
Oil delivery capacity I/hr 7300min.(27630US gal,241001mp gal)at2000rpm
Oil pressure kg/ool(psi)
Lubricating
Oil filter - Paper element( double)
system
Applicable lubricating oil - API grade CD

Oil capacity
I Total R 38
I Effective R 20
Cooling method - Constant-high-temperature fresh water cooling
Cooling system Cooling water delivery volume I/hr Sea water pump:13000mln.,Fresh water pump:17000min.{2000rpm)
Fresh water capacity R 53(200US gal,2411mp gal)
Type - MITSUBISHI 4LF
Cooling method - Air cooling
Turbocharger
Lubricating method - Forced lubrication with gear pump( together with engine lubrication)
Lubricating oil pressure kg/crri(psi)
Type.capacity ..!(ft') 7.11
Intercooler
Cooling method - Sea water cooling
Type - Electric bilge pump
Bilge pump
Delivery volume R /hr

Printed in Japan
F032G0223
1-7 -4.
GI
2. Specifications (-2.)

Item Unit Specifications

Power take-off position - Flywheel side
Operation side - Port side
Direction of rotation(viewed from stern side) - Counterclockwise
Dimensions
mm( in) 2021X939 X 1259(79.882 X36.969 X49.667)
Overall lenath Xwidth x heiaht
Height for piston removal(from mounting surface) mm( in) 920(36.220)
Dry weigth(except marine gear) kg(lb) 1250(2756.25)

b) Marine gear

Item Unit Specifications

Model - YP-120E YP-120LE YP-120NE
Type - Hydraulic,wet,multi-disc clutch
Forward - 2.12 2.68 3.05 3.55 4.05 4.66 4.99 5.64 5.96
Reduction ratio
Reverse -

Revolution speed of propeller shaft(forward) rpm 945 746 656 564 494 429 401 361 336
Direction of rotation(viewed from stern side) - Clockwise or counterclockwise
Lubrication method - Forced lubrication with gear pump
Lubrication oil Total I 11
capacity Effective I 12
Cooling method -
Dry weight kg(lb) 300(661.5) 380(837.9) 480( 1058.4)

P rinled in Japan
1- 7-5. F032G0223
GI
3. Performance Curve (-1./-2./-3./-4.]

3. Performance Curve
[3-1.] 4HAL Industrial Engine [3-3.] 6HAL-T Industrial Engine
Fig. GI-&. 4HALE Pertormence curve Fig. Gl-8. &HAL-TE Pertormance curve
E 80 §,
60 ~
Torque 70 ""Qj
v
Torque
50

40
~
~ 60 t
~
22_0
30 _,
200
~.,,.,,.,.
.... /
140 180
~"~,.. __.V
120
-- .c 160
"<
y;, <F'S!' ' .c

100

80
,..... ,a\\\\<;\
-
~~
·-r -:....---
,,,.... -

!Ill oll'lll"~
I
-
0.:

Cl>
c0
140

120
J'

/ "/<;Jfo"
-~~
,~"" -
0.:
I

.Q
Cl>
c
60
.... -::.. :::..-::-:::;:
Ca"
\. 1a\\ aE 100
//" c.
E
v iilc /
""'c
40 80
8 ·o
0

Specific fuel consumption 180 ~.\I a.

I 180 -
~
Specific fuel consumption .\I
160 ~
(/)
c. J 160 i
(/)
1000 1200 1400 1600 1800 1000 1200 1400 1600 1800
Speed of crankshaft: rpm Speed of crankshaft: rpm

[3-2.] &HALE Industrial Engine [3-4.] 6HAL·HT Industrial Engine

Fig. Gl-7. &HALE Pertormance curve Fig. Gl·9. 6HAL·HT Pertormance curve

I I
--+-+--- 100
iOf(\Ue I
90
L---

t
Torque ' _(__
....
--· r 80
' I I

50
260 -~J __ I
~-

,
I
, .c
l~
240 0.:
I
I <l' / ,/
180 220
I
' . ,.f>
"'aE
- ----- I-
.c ! <!>~ ,,.''
v
~
0.:
"'~
160 200
I
y"""

,K.·1
""<fo'I#- - Cl> E
.....
,,_
140 180
c
"'c"
120

100

60
----
.........
\·""'.;.:1". "IS/"\
:..--::-;;; IC .....~<; (jl
C°" ' 190

180 CJ
iE
5
a.
I

~
160

140
120
'/
,
,,
/
I
I
I
.
-·
8
Qi
.2
_g
u
a.
I 60
Specific fuel consumptioo
- 170
Qi
2 "5
Specific fuel consumption
' - 180
"'c.
(/)

·1 I I
' '

~ 0
i
160
160 ~
0 (/) 1000 1200 1400 1600 1800
1000 1200 1400 1600 1800
Speed of crankshaft: rpm Speed of crankshaft: rpm

Printed in Japan
1-8.
GI
3. Perfomance Curve(-5)

[3-5.] Marine Engine

SHAME
&HAE
200
Outp l(M ~imu
'""' rCu
,., -
200
, -, ~,
, h
, ~
~, ...~
, l1 ,..J, ~ ,. -1'1 I
.,.i<1

.:;,- ·-
!
.;,if ,.~ .c . ..
150 I
0.. /
150
~-
I ll.:, //I
1v
/
/

~ .,.i<1 I :/ c, I
a.
.c
100 , r.o # 1) .§ A I

~ 'f ~ ~ /
'5
0
,j ~ tput ("ubic !curve ) c"
~

8
~
7
Outp I (Cu ~c Cu "')

0 ' o; 50 '

~~ ' "'
- "
u. 2
·c Fu Con umn n
2 20~
• ""' ""''
2
0
v
" ·~ he Fi I Co
(Cu bi Cun
sum~
,,,
·ion
200
so&
u 0
""'- (Cubi Cun S)
2

--
~

"""
-
1
_,. __ 1
1
160
s >ecific Fuel ons lnptio (Fue Stop Brake Powe) ( uel S o Br ke"
1000 1200 1400 1600 1600 2000 2200
Speed of Crankshaft rpm
1000 1200 1400 1800 1800 200Q 2200
Speed of Crankshaft rpm
'"'

-
6HA-HTE
I tort Maxi
'"' I
urve
300
/
/ ....~ ' .c .c
250 a: ci_

200
"',,. "/ ~ "''t
~/
,~/ "
c,
§
I
c,

/, ,./,'. ~ I
I II
'
~
~ 150 , ~
c
/ '#'
8 I
'/ /,t Out• (Cu .., c -1
2soU
o;
0

100
240~
"- y

. 2 2og

*
u
50 - ...... 200~

0
. - -~
"'
~fie
.
uol ~
180"'

1'0
pecifi Fuel Cons mpt (M dmui I
1000 1200 1400 1600 1800 2000 2200
Speed of Crankshaft rpm

&HA-DTE &HAM· DTE

' m• ""c rvel

--/t
Ou put ( axln .c .c
cC ci_
7,
" "s
~ /'.
3 00
c, c,
:? -:-,
:1 -?:
~
;.$\ I 5
~
2~
~ I
00

~ ,
/,/
"
00
/,,. ~ 81oot---k--t--7f--t---+--1f--+--4too§
200'di ~
lluh•d( u~c UM I u.
""' 0
u.
0
... .. ""' uol ..... ptlon 1so-=
u

.... ~~
·- '-., MS
1 60~
(F,. Sloi>Bra: I
1000 1200 1400 1600 1800 2000 2200
Speed of Crankshaft: rpm

Printed in Japan
F032G0223
1-9.
GI
4. Sectional Views [-1.]

4. Sectional Views
[4-1.) &HAL-T Industrial Engine
Fig. 61·12. 6HAL·T Sectional view

No. Name of parts No. Name of parts No. Name of parts

1 Radiator 9 Camshaft 17 Instrument panel

2 Fan 10 Intake valve 18 Flywheel

3 Thermostat 11 Exhaust valve 19 Alternator

4 Cooling water pump 12 Fuel filter 20 Lubricating oil pump

5 Turbochager 13 Fuel feed pump 21 Dip stick

6 Air intake manifold 14 Fuel injection pump 22 Drain cock

7 Air cleaner 15 Governor 23 Drain plug

8 Rocker arm 16 Piston 24 Bracket

Printed in Japan
1-10.
GI
4. Sectional Viows(-2.)

[4-2.]GHA-HTE and 6HA-DTE Marine Engine

Fig. Gl-13. 6HA-HTE and 6HA-DTE Sectional view

Nn Name of parts Nn Name of parts Nn Name of parts

1 Cooling water pump(sea water} 9 Intake valve 17 Piston

2 Fresh water tank(heat excharger) 10 anti corrosion zinc 18 Lube oil evacuation port
3 Turbocharger 11 automatic timer 19 Flywheel
4 Exhaust manifold 12 Fuel injection pump 20 Marine gear
5 Inter coler 13 Fuel filter 21 Alternator
6 Decamp lever 14 Governor 22 Lubricating oil pump
7 Fuel injection nozzle 15 Crankshaft 23 Coupling

B Exhaust valve 16 Dip stick 24 Bracket

Printed in Japan
F032G0223 1-11.
GI
5. Accessories [-1. I

5. Accessories
[5-1.) Industrial Engine
o: Standard .& : Optional

Generator Industrial
Application
4HAL 6HAL 6HAL-T 6HAL-HT 4HAL 6HAL 6HAL-T 6HAL-HT

Fuel system F.O. tank 100.2 (mounted on engine) 0 0 0 0 - - - -

F.O. tank 100 ...... 10002 ... ... ... ... ... ... ... ...
Water separator (Fixed on engine) ... ... ... ... ... ... ... ...
F .0. filter paper element
(additional, not fixed on engine)
... ... ... ... ... ... ... ...
F.O. filter, paper element
0 0 0 0 0 0 0 0
(fixed on engine)
F.O. feed pump (mecanical)
0 0 0 0 0 0 0 0
Fixed on fuel injection pump
Lubrication L.O. filter (paper element) 0 0 0 0 0 0 0 0
system L.0. cooler 0 0 0 0 0 0 0 0
Sender unit (pressure) 0 0 0 0 0 0 0 0
'
L.0. priming device (manual) ... ... ... ... ... ... ... ...
L.0. rotary hand pump with rubber
nose (supply & evercation)
... ... ... ... ... ... ... ...
Cooling Radiator & fan with safety net 0 0 0 0 0 0 0 0
system Water pump 0 0 0 0 0 0 0 0
Thermostat for cooling water 0 0 0 0 0 0 0 0
Heater for cooling water, single
AC200V 1KW
... ... ... ... ... ... ... ...
Sender unit (temp) 0 0 0 0 0 0 0 0
Stating Stater motor 24V 5.2 kW 0 - - - 0 - - -
system Stater motor 24V 6 kW 0 0 0 0 0 0
Alternator & regurator 24V 400W 0 0 0 0 0 0 0 0
Equipment P.T.O. clutch SAE No. 1
(Anderton or Yanmarl - - - - 0 0 0 0

Engine bed - - - - 0 0 0 0
Engine bed with antivibration 0 0 0 0 - - - -
Bonnet ... ... ... ... - - - -
Control Instrument panel 0 0 0 0 0 0 0 0
(Instrument panel) Tachometer (mechanical) 0 0 0 0 0 0 0 0
L.0. pressure gauge {electric) 0 0 0 0 0 0 0 0
C.W. temperature gauge {electric) 0 0 0 0 0 0 0 0
Charge lamp 0 0 0 0 0 0 0 0
Starter switch 0 0 0 0 0 0 0 0
Engine stop device with solenoids
(electric)
... ... ... ... ... ... ... ...
Control Engine stop device (manual) 0 0 0 0 0 0 0 0
Safety stop device (Low L.O. IMecanical ... ... ... ... ... ... ... ...
pressure High C.W. temp.) I Electric ... ... ... ... ... ... ... ...
Over speed control device (electric) ... ... ... ... ... ... ... ...
Battery switch 0 0 0 0 0 0 0 0

i'.'.~
• u
4HAL 24V, 120 AH (12V,
120AHX 2)
... - - - ... - - -
:: !!.
••
"' u
6HAL-(T) .24V, 150AM
(HT) (12V, 150AHX 21
- ... ... ... - ... ... ...
Wire with terminal for battery ... ... ... ... ... ... ... ...
Exhaust gas temperature gauge ... ... ... ... ... ... ... ...
Air pressure gauge for turbocharger - - ... ... - - ... ...

Printed in Japan
1-12.
GI
5. Accessories [-1.]

Generator Industrial
Application
4HAL 6HAL 6HAL·T 6HAL·H1 4HAL 6HAL 6HAL·T 6HAL-HT

Intake & Air cleaner (Donaldson) 0 0 0 0 0 0 0 0

exhaust system
Exhaust pipe
(outdoor) - - - - OBOA 0100A 0125A 0125A
(indoor) - - - - - - - -
Flexible joint
(outdoor) - - - - - - - -
(indoor) OBOA 0100A 0125A 0125A .. BOA .. lOOA .. 125A .. 125A

Expansion joint
(outdoor) - - - - - - - -
{indoor) .. BOA .. 100A 0126A 0125A .. BOA A100A O 125A 0125A

Exhaust silencer
(outdoor) - - - - .. BOA .. 100A .. 125A .. 125A
(indoor) OBOA 0100A 0125A 0125A OBOA 0100A O 125A 0125A
Piping material for joint .. BOA .. 100A .. 125A .. 125A .. BOA .. 100A .. 125A .. 125A

Others
Turbocharger
Installation bolt .
-
..- 0
. ..
0
.
-
.- 0
. . 0

Standard tool
Special tool ..
0 0
. 0
. .
0
.
0
.
0
.
0
.
0

Operation manual
Parts catalog
Service manual
..
0

..
0
..
0
..
0
....
0
..
0

...
0
...
0

Anti·rust agent
Spare parts kit
0
. 0
. 0
. ..
0
.
0
..
0
.
0
.
0

Printed in Japan
1-13.
GI
5. Accessories(-2.)

[5-2. ]Marine Engine 0 : Standard A: Optional

Name of accessories Quantity 6HA(M)E 6HA(M)-HTE 6HA(M)-DTE
2
Installation plate
4 sets
"' "' "'
Adjusting shim
2 sets
"' "' "'
Installation Adjusting shim( reverse gear)·
4 "' "' "'
Jack bolt
Bolt & nut
"' "' "'
BOAX1.6m
B or 12
1
"' "'
-
"'
-
Exhaust pipe
125AX 1.6m 1
"'
-
1
"'
- -
"'
Air Exhaust silencer
BOA
125A 1
"'
-
1
"'
- "'
-
Exhaust flexible joint
BOA
125A 1
"'
-
Breather hose 1 sets 0
"'0 "'0
Drain separator 1 sets 0 0 0
Additional fuel filters(fixed on hull)
Fuel system 1 sets
for heavy oil BS class 81
Additional fuel filters( fixed on hull) 1 sets
"' "' "'
"' "' "'
Lubrication system
Fuel feed vinyl pipe with band
Oil evacuation pump(rotary type)
1 sets
1 sets
"'
0
"'
0 0
"'
Heat exchanger 1 sets 0 0 0

Cooling system
Kingston cock for wooden ship 1 sets
"' "' . "'
Rubber hose with band
Reserve tank for fresh water
3m
1 sets
"'
0
"'0 "'
0

Bilge pump
Electric type
Jabsco type.engine driven
1 sets
"' "' "'
1 sets
"' "' "'
Control head
Single lever
Twin lever
1 sets
"' "' "'
1 sets
2
"' "' "'"'
Remote control
3m
5m 2
"' "'
Cable
2
"' "' "'
7m
2
"' "' "'
10m
Instrument panel(includes alarm buzzer,
1 sets
"'
0
"'
0
"'0
warning lamp,swich:electric type)

Operation
3m
4m
1
1 "'
0 "'
0
"'0
Wireharness 6m(3+3)
7m(3+3)
1 sets
"' "' "'
1 sets
"' "' "'
10m(3+3+4)
Housing & mounting(Yanmer original)
1 sets

1 sets
"'0 "'
0
"'
0
Housing & mounting(SAE No.3)
Front PTO device
V-pulley(for SAE No3)BX3,10'(without belt)
1 sets
"' "' "'
Housing mounting(for SAE No.3)
1 sets
"' "' "'
1 sets
"' "' "'
Printed in Japan
1-14. F032G0223
GI
5. Accessories(-2.)

0 : Standerd .&.:Optional
Name of accessories Quantity 6HA(M)E 6HA(M)·HTE 6HA(M)-DTE
Battery switch 1 sets ... ... ...
Battery and terminal 1 sets ... ... ...
Electrical system 400W 1 sets 0 0 0
Alternator 600W 1 sets ... ... ...
980W 1 sets ... ... ...
Oil strainer 2 ... ... ...
Filter element Fuel strainer 1 ... ... ...
Spare parts
Oil strainer for turbocharger 1 ... ... ...
6 ... ... ...
Anti-corrosion zinc Revers gear
.
Heart exchanger and oil cooler

2 ... ... ...

Inter cooler 2 - ... ...
Ventilator 30rrl/min·' 6HA(M)E.
50rrl/min·' 6HA(M)·HTE
6HA(M)·DTE
1 sets ... ... ...
Standard tool 1 sets 0 0 0
Special tool 1 sets ... ... ...
Others Caution plate 1 sets 0 0 0
Operation manual 1 0 0 0
Service manual 1 ... ... ...
Parts book
For engine 1 ... ... ...
For turbocharger 1 - ... ...
Remark:(•)lndicates 6HAE.6HA-HTE SHA-DTE only.

Printed in Japan
F032G0223 1·15.
GI
2. Marine Engine( 4.)

(Unit mm)
'"'----885<-----<
SHAME --1----449 '---------1527---------1
Fuel ofl Inlet pipe
] .pano Rubber pipe r759
Exhaust Gas pipe 0
80A Gas pipe ·a
: I:

Coollng sea water

Inlet pipe, ,;45156
Rubber pipe

Im
.
~

"
~
~
-
~

7 8
-;.!
I
176 A B
PC,t,138
e Holes Tapped M 10, 17 Deep
110 4
8~22 holes M 18 Founda tion bolts ,_
i-...
14-25.4
12 Hol es Tapped M10, 14 Deep
- 8 Holes Tap ped M12,
17 Deep

'-5
~.

"'. -.
"'"' \" :il..,
- ~~ .," ' 0
~
- . --2-:5---- - j~ E
~ ~
40 - ~ 1 ~
..
M

"''!
<O
~ "'"'
'Y
.I
~ ~
.§><t'"
:
~1 ~
1ll1 ,p '\'
¢"'"'
i.:9:::i0'~----1040 Isoi 20 SAE NO. 1 FOi' heat exchanger cooling
(attached to engine) system

&HAM·HTE '----939---~-i
8HAM·DTE
459~480
Exhaust Gu pipe
125A Gas pipe 330 I '-------15275--------i
Fuel oil Inlet pipe 1/18110 r--511
Rubber pipe

"'
i:;,.t-~~:-t-----~1 ·a~
'2

Cooling sea wati-r

Inlet pipe 045158 "'
Rubber pipe ·~
e
.eE N

"'
:ii"' "' M
M

!" i>
:;:
~

0
12
a;
M "'
8 Holes Tapped M10, 17 Deep
7
l'C0138 8 ~
176 A B
a Holes Tapped M12, 13 Deep
Printed in Japan
1-15-1. F032G0223
GI
2. Marine Engine(-5.)

"'
N
-t~-
',j
"' 0

"'
,
--- ·--8-· ~
~ -<·--
4

30 360
SECTION A
40
430
572
SECTION B
1:f 1040
90
.lk,
&HAE 6HA-HTE &HA-DTE
Model YP-60 YP-120L MGN57BL
MGN46BL MGN47B YP-120 MGN568 MGN56BL MGN57BL
A 700 700 790 700 700 890 700 750 890
B 218 400. 3 106 220 185 117 130 118 117
c 214. 5 90 90 90 150 90 90 90 90
D 199 243 191. 6 141 270 217 269 270

r
.----B----< 1------H----.j
c .-----A----~
i------J------;
i--------0-----...i

6HAE 6HA-HTE 6HA-DTE

Model YP-60 MGN46BL MGN478 YP-120 YP-120L MGN57BL MGN56B MGN56BL MGN57BL
A 629.5 517 607 654 628 645 555 645 645
B 480. 5 377 417 480 454 455 415 455 455
c 25.4 25.4 25.4 25. 4 25.4 25.4 25.4 25.4 25.4
D 552. 5 552.5 552. 5 552.5 552.5 552.5 552.5 552.5 552.5
E 511.175 511. 175 511. 175 511. 175 511. 175 511. 175 511. 175 511. 175 511.175
F 40 40 50 50 50 50 46 50 50
G 132 144 170 145 145 180 144 180 180
H 382 568 664 478 510 752 600 616 752
I 66 84 145 79 128 197. 5 81 • 128 197. 5
J 700 700 790 700 700 890 700 750 890
K 196 214 275 209 258 327. 5 211 258 327. 5
L 184 226 283 198 255 326. 5 209 257 326. 5
M 190 180 240 205 205 240 180 240 240
N 235 222 287 250 250 287 222 287 287
0 750 750 840 750 750 940 750 800 940

Printed in Japan
F032G0223 1-15·2.
GI
6. Model Identification

6. Model Identification
Fig. Gl·14. Identification and serial number location

Printed in Jo.pan
1-16.
GI
7. Fuel, Lubricant and Coolant(-1./-2.)

7. Fuel, Lubricant and Coolant

[7-1.]Recommended Fuel [7-2.]Recommended Lubrication Oil
Use diesel fuel oil corresponding to JIS K2204 Selection of lubricating oil is very important for
Nn2(the fuel used for diesel trucks).!! a precision a diesel engine. If improper lubricating oil is
filter is attached, heavy oil BS class Bl maya used or change of lubricating oil is neglected,
lso be used. it causes sticking of piston ring, sezure or early
a.)Recommended brands wear of pistons and cylinder liners and the
Supplier Brand rapid wear of bearings and various other work-
SHELL Shell Oiesoline(or local equivalent} ing parts to reduce durability ofthe engine.
CAL TEX Caltex Diesel Oil a.)Recommended SAE viscosity number
MOBIL Mobil Diesel Oil SAE 10W I SAE ~~~r I SAE 30W I SAE 40W
ESSO Esso Diesel Oil
15° 30°
B.P.
B.P. Diesel Oil
(British Petroleum) Engine room (atmospheric) temperature ("'C)

b.)Recommended brands

API SAE Brand

Engine Model
Grade Number SHELL ESSO MOBIL

Melina Multigrede 10-30

Melina Multigrade 15-40
Rotella SX 10-30 Delvac 1110
10 HDX 10W
Rotella SX 15-40 Delvac 1210
Gadinia 10-30
Gadinie 15-40

4HAL Melina 20
Delvac 1120
6HAL cc 20 Gadinia 20 Essolube HDX 20
6HA(M)E Delvec 1220
Rotella sx 20
Melina 30
Delvac 1130
30 Gedinia 30 Essolube HDX 30
Delvac 1230
Rotella SX 30
Melina 40
Delvac 1140
40 Gadinia 40 Essa lube HDX40
Delvac 1240
Rotella SX 40

10 Rimula Xoil 10W Essolube D-3 !OW Delvac 1310

Rimula 20
Essolube D-3 20W
20 Rimula X20 Delvec 1320
Essolube D-3 20
Rimule CT20
6HAL-T
6HA(M)-HTE cc Rimula 30
6HA(M)-DTE 30 Rimula X30 Essolube D-3 30 Oelvac 1330
Rimula CT30
Rimula 40
40 Rimula X40 Essotube D-3 40 Delvac 1340
Rimula CT40

Prinll!d in Japan
F032G0223 1-17.
GI
7. Fuel, Lubricant and Coolant [-3.] 8. Service Rules 9. Standard Tightening Specifications

£7-3.J Coolant 9. Standard Tightening

a.) Anti-rust agent Specifications
Use Yanmar anti-corrosive agent to prevent incru-
To tighten bolts and nuts whose tightening torques
station and rust in the cooling water system of
are not specified, follow the Iist below:
industrial engines and the fresh water system of
marine engines. ,A Note:
*Mixing ratio If the tightening part is made of aluminum, tighten
Soft water: Yanmar anti-corrosive agent to 80 % of the specified torque.
10: 1
Torque values
Diameter x Pitch
b.) Anti-freeze solution Kg-m ft-lb
Use Yanmar anti-freeze solution in climates in M6 x 1.0 1.1 8
which cooling water freezes. MS x 1.25 2.6 19
MIO x 1.5 5.0 36
Minimum --5°C: -10°C -15°C -20°C -25°C M12 x 1.75 9.0 65
temperature (23°F) (14°F) (5°F) (-4°F) (-13°F)
M14x 1.5 14.0 101
Percentage or
anti-freeze to 12% 22 % 29% 35% 44% M16 x 1.5 23.0 166
fresh water

8- Service Rules
1. Use only Yanmar parts. Use recomended lubri-
cants or their equivalent. Parts and lubricants
that do not meet Yanmar's design specifications
may damage the engine.
2. Use the correct special tools designed for this
product.
3. Install new gaskets, 0-rings, cotter pins, lock
plates, lock wires etc. when reassembling.
4. When torquing bolts or nuts, begin with larger-
diameter or inner bolt first, and tighten to the
specified torque diagonally, unless a particular
sequence is specified.
5. Clean parts in cleaning solvent after disassembly.
Lubricate any sliding surface before reassembly.
6. When installing a new oil seal, make sure that
the seal Iip is coated with grease (however, coat
the front oil seal with engine oil). After clean-
ing the oil seal or related parts, coat the seal lip
with grease.
7. After reassembly, check all parts for proper in-
stallation and operation.

Printed in Jo.pan
1-18.
GI
10. Special Tools

10. Special Tools

Name Tool Number Description Remarks (page)

Open end wrench 28110·320360 32x 36 mm

Open end wrench 28110-410460 41 x46mm

Box wrench 28227-130170 13x 17mm

Box wrench 126650-92720 for cylinder head bolts (3-3)

Box wrench 126650-92710 for connecting rod bolts (4-4)

Hexagonal bolt 26116-100162 for tightening connecting rod bolt wrench (4-4)

Cranking handle 28230-090150 for cranking the flywheel

Box wrench 126650-92700 for injection pump

Piston slider 126650-92140 (4-10)

~
\LY M20

204 ®·
144626-92010 (4-12)

Cylinder liner puller

M20-
-
144626-92030 0
(4-12)
iil

M20- -CI!
Printed in Japan
1-19.
GI
10. Special Tools

Name Tool Number Description Remarks (page)

129.5 $

(4·12)
Cylinder liner puller 126650-92020

@M20

M12

Cooling water pump impeller

wrench
126650-92400
1: · · (6·5)

5¢

145610-92900 -.--
(Body) i
I

0
Cam gear puller 126650-92650
(M12)
~1 (4-14)

126650·92660
(M14) 105

M32 x 1.5

Automatic timer puller 126630-92770

180
• Marine engine only
(7· 11)

126650·926 70

Flywheel straight pin puller (4·21 I

126650·92680
(MB)

Printed in Japan
1-20.
GI
10. Special Tools

Name Tool Number Description Remarks (page)

14·21)
Flywheel hanger 144626-92850

Piston ring expander 135410·92140 14·5)

6HAL-HT with large adaptor only

Cap tester 126650-927 50 16-13)

Printed in Japan
1-21.
GI
10. Special Tools

Name Tool Number Description Remarks (page)

Stem seal driver

126650-92580
(Driver)

126650-92590
~IY~
I 50
)
I
RM~
100
I
(3-11)

(Guide) S45C

Valve spring compressor 126650-92600 (3-4)

(Sugino Machine MB-19)

Injection nozzle sleeve expander 126650-92630 (3-11)

~===="'[§>

9.5~

Nozzle sleeve holder 126650-92640

125
am II
10
(3-10)

Nozzle puller 126650-92620

(M10)

26116-080182 (7-5)
(MS) (
(

126650-92610
I
28210-00070
Valve lapping tool
(3-8)
2821 0-00030 Compound

for rocker arm

28190-00020

Circlip pliers
for piston pin

28190-000120

Printed in Japan
1-22.
Sec. 2. MAINTENANCE {Ml)

Contents of this section

Page
1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2·1
[1-1.] Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2·1
[ 1·2.] Marine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2·2

2. Maintenance Procedure .. .. 2·3

[2·1.J Fuel System 2·3
[2·2.J Lubrication System . 2·5
[2·3.J V·belt. 2·8
[2·4.J Cooling System (Industrial Engine) 2·8
[2-5.] Sea Water System (Marine Engine) 2·10
[2·6.J Fresh Water System (Marine Engine) 2·12
[2-7.J Valve Clarance 2·14
[2-8.J Air Cleaner (Industrial Engine) 2·15
[2-9.J Turbocharger 2·15
 Ml
1. Maintenance Schedule [-1.]

2. Maintenance
1. Maintenance Schedule
[1-1.] Industrial Engine
1. Periodic inspection and servicing is necessary to 2. Parts disassembled for inspection and servicing
keep the engine in top operating condition at all shou Id be correctly assembled, make sure that
times. Perform inspection promptly according to they are in good condition before using.
the following list and quickly correct any defects
found.

o : Replace
Periodic inspection (Industrial engine) o : Check and refill, clean, adjust, lubricate, repair or replace if necessary.
Service period
Items Remarks
Daily
Every Every Every Every (Reference page)
50·hr. 250-hr. 500-hr. 1,000-hr.
Check fuel level and refill 0

Fuel Drain deposit and water in fuel tank 0 (2-3)

system Drain deposit and water in fuel filter 0 (2-3)
Replace fuel filter element 0 (2-3)
Check oil level and refill 0 (2-5)
Drain deposit in oil filter 0 (2-5)
Lubrication Replace oil filter element 0 (2-6)
system Replace engine oil
0
Every 150 hours (2-6)
(first time)
Check oil pressure 0

Check coolant level 0

Check V-belt tension 0 (2-8)

Clean radiator fin Every 6,000 hours, or 1 year (2-8)
Cooling Clean cooling system Every 6,000 hours, or 1 year (2-9)
system
Change coolant Every 6,000 hours, or 1 year (2-8)
Replace rubber hose Every 2 years
Grease cooling water pump Every 1,500 hours (2-9)
Check cooling water temperature 0

Electrical Check warning lamp 0

system Check battery electrolyte level 0 (9-4)
Air Check dust indicator 0
cleaner Replace every
Clean/Replace element Clean 2,000 hours (2-15)

Clean Blower cleaning 0 6HAL-T only {2-15)

~

Turbocharger Check air/9as leakage 0 6HAL-T only

and prefilter Disassemble and check major parts Every 5,000 hours 6HAL-T only {8-4)
Replace injection nozzle Every 5,000 hours (7-5,-7)
Check valve clearance First time 0 (2-14)
Check bolts, nuts and fasteners 0

Check water/oil leakage 0

Engine with
Grease clutch parts 0
clutch

Printed in Japan
2-1.
Ml
1. Maintenance Schedule [-2.]

[1-2.] Marine Engine

1. Periodic inspection and servicing is necessary to 2. Parts disassembled for inspection and servicing
keep the engine in top condition at all times. should be correctly assembled, make sure that
Perform inspection promptly according to the they are in good condition before using.
following list and quickly correct any defects found.

o : Replace.
Marine engine o: Check and refill, clean, adjust, lubricate, repair or replace if necessary.
Service period (whichever comes first)
Remarks
Items Every Every Every Every Every
Daily (Reference page
50 hr. 250 hr. 500 hr. 1000 hr. 2500 hr.
Check fuel level and refill 0
0
Drain deposit and water in fuel tank (2-3)
{When replenislJmentl
Fuel
system
Drain deposit and water in fuel filter
and fuel-water separator
a
(first time)
I (2-3,-4)

·Replace fuel filter element 0 (2-3)

Check oil pressure 0
Check oil level and refill
0 (2-5,-7)
(oil pan and reverse gear)
Drain deposit in oil tilter 0 (2-5)
0 D
Replace oil filter element (2-6)
Lubrica- (first time)
ti on 6HA(M)-HTE
Replace turbocharger oil filter element 0
system only (2-7)
Clean oil cooler 0 (5-5)
0
Engine 0 12-6)
(first time)
Change oil
Clutch o I 0 (2-7)
(first time)
Check cooling water discharge condition 0
Cooling
Check/Replace sea water pump impeller 0 D (2-11)
sea water
system Check anti-corrosion zinc 0 (2-10)
Clean sea water system 0 (2-12)
Check cooling water temperature 0
Cooling
Check coolant level 0
fresh water
system Change coolant 0 (2-12)
Clean fresh water system 0 (2-14)
Fuel Check injection timing 15000 hr.I
injection Disassemble and check fuel feed pump 0 (7-33,-34)
pump and Check injection pressure and spray form 0 (7-6)
nozzle
Replace injection nozzle 0 (7-5.- 7)
Cylinder Check valve clearance firs.Ptime 0 (2-14)
head Lap valve and seat 15000 hr.)
0
Check remote control wire (first time)
0

Check warning lamps 0

Electrical
Check battery electrolyte level 0 (9-4)
system
Check alternator drive belt tension 0
6HA(M)-HTE
Clean prefilter and turbocharger 0
only (2-15)
Turbo- 6HA(M)-HTE
Check air/gas leakage 0
charger only
6HA(M)-HTE
Disassemble and check major parts (5000 hr.
only (8-4)

Printed in Japan
2-2.
Ml
2. Maintenance Procedure [-1.]

o : Replace.
o: Check and refill, clean, adjust, lubricate, repair or replace if necessary.
Service period (whichever comes first)
Remarks
Items Every Every Every Every Every
Daily (Reference page
50 hr. 250 hr. 500 hr. 1000 hr. 2500 hr.
0
6HA(M)-HTE
Inter Check anti-corrosion zinc
only (2·10)
cooler 6HA(M)-HTE
Drain deposit in intercooler 0
only (2·10)
Check oil cooler 5000 hr.
Reverse
gear Check oil filter screen 0 (2-7)
Check anti-corrosion zinc I 0 I (2·0)

2. Maintenance Procedure c.) Fuel filter element replacement

1. Remove the filter center bolt, then remove
[2-1.] Fuel System the filter case.
a.) Fuel tank draining 2. Replace the element.
3. If the rubber packing is damaged as well replace it
Loosen the drain cock at the bottom of the tank 4. Securely install the filter case, spring, washers,
and drain foreign matter and water accumulated element and center bolt.
at the bottom. 5. Bleed air from the fuel system (see page 2-4)
b.) Fuel filter draining
A Note:
1. Detach the drain plug and drain foreign matter • After installation, make sure there are no fuel
and water accumulated at the bottom of the leaks.
filter. • If there is a pre-filter also replace the element as
2. Make sure that the sealing washer on the drain indicated above.
plug is in good condition, then install the drain Fig. Ml-2. Fuel filter exploded view
plug.

A Note: ~
~""'~---
If there is a pre-filter, drain it as indicated above.
Providing a pre-filter lengthens the life of the fuel
injection pump and injection nozzles.

Draining the fuel filter

·"-"'
Fuel filter
0~Drain plug

0-ring

r4----,Center bolt

Printed in Japan
2-3.
Ml
2. Maintenance Procedure [-1.]

d.) Fuel-water separator draining (marine engine) f.) Fuel system air bleeding
1. Remove the drain plug and drain water and for- 1. For engines with the model PES-A injection
eign matter accumulated in the water separator. pump, rotate the governor handle counterclock-
2. Make sure that the washer is in good condition wise to tighten it fully, and then rotate it clock-
and install the drain plug. wise about 2 turns. For engines with the model
Fig. Ml-3. Draining the fuel-water separator PES-P injection pump, set the regulator handle
in the "normal" position.
2. Turn the priming pump knob on the fuEll feed
pump counterclockwise (when it is rotated coun-
terclockwise the pump can be operated vertically).
Fig. Ml-5. Priming pump

/I Fuel-water separntor

:------'---'-r#.7/

Drain plug

e.) Fuel-water separator cleaning (marine engine)

1. Remove the center bolt and remove the water
separator case and element.
2. Clean the case and element with cleaning solvent
and dry with compressed air.
3. Inspect the element and replace it if it is dam- Fuel feed pump
aged.
4. Replace the rubber packing if it is damaged. 3. Loosen the air vent plug on the fuel filter and
5. Securely install the case, spring, washers, element operate the priming pump until air is completely
and center bolt. bled and fuel flows from the air vent. Then
6. Bleed air from the fuel system. tighten the vent plug.
A Note: Fig. Ml-6. Air vent plug
After cleaning, make sure that there are no fuel leaks.
Fig. Ml-4. Fuel-water separator exploded view
~

~Rubber packing

u--
~- Element

~VIJasher
.~Spring

Air vent plug

H - s e p a r a t o r case

/V-o.ring I
Ora in plug ~ Center bolt

Printed in Japan
2-4.
Ml
2. Maintenance Procedure [-1./-2.]

4. Loosen the air vent bolt at the left of the injec· [2-2.] Lubrication System
tion pump and operate the priming pump. After
making sure that fuel flows from the air vent a.) Engine .oil level check
and that air is completely bled, tighten the 1. Check the oil level with the dipstick.
vent bolt (see Fig. Ml·5).
5. Push and rotate the priming pump knob clock·
Fig. Ml-8. Inspecting the oil level
wise and tighten it.

A Caution:
If the knob is not securely tightened, it may loosen
and suck in air. Also, always place a cover over it to ..._ Upper limit

prevent water from entering the pump, which

may cause rust and adhesion.

Lower limit

6. Loosen the injection pipe cap nuts at the injec-

tion pump (all cylinders). and crank the engine
with the starting motor. After making sure that
fuel flows from the cap nut and that air is com-
pletely bled, tighten the cap nuts. its.
2. If the oil level is nearing the lower limit, remove
A Note: the filler cap and add the recommended oil (see
For marine engines, set the decompression handles page 1-16) to the upper limit.
to the "non-compression" position during this op-
eration. Fig. Ml·9. Oil filler cap

Fig. Ml-7. Loosening the cap nuts

Oil filler cap

b.) Engine oil filter draining

7. Set the decompression handles to the "run" posi- 1. Remove the drain plug(s) installed in the oil filter
tion (marine engines only). center bolt(s) and drain the water and foreign
8. Crank the engine with the starting motor. Injec- matter accumulated in the filter(s) ..
tion will start in 3 - 5 seconds and the engine
will start.
Printed in Japan
2-5.
Ml
2. Maintenance Procedure [-2.]

2. Make sure that the sealing washer(s) are in good d.) Engine oil change (marine engine)
condition and then install the drain plug(s).
1. Wait for 1-2 hours after stopping the engine and
remove the oil filler cap.
Fig. Ml-10. Draining the oil filter (marine engine)
2. Remove the oil evacuation port cap from the
(Industrial engines are provided with a single filter)
engine and connect the vinyl hose of the evacua-
tion pump. Then drain the oil with the evacua-
tion pump.

':. .·
Fig. Ml-12. Draining the oil

~ 1"""''lJ.:.1U<.41'~ ..~ ~,,·~ ~ 0

J 0
l:J\..
jllj . . . I

0 0
'IJl.-_!

Drain plugs ••
•
c.) Engine oil filter element replacement Evacuation pump (rotary type)

1. Remove the oil filter drain plug(s) and drain the

oil inside the filter(s). 3. Remove the drain plug(s) on the oil filter(s) and
2. Remove the center bolt(s) and then remove the remove the oil insidethefilter(s) (see Fig. Ml-10).
filter case(s) and element(s). 4. Pour in the prescribed amount of recommended
3. Replace the element(s). Then make sure that the oil (see page 1-16) through the oil filler opening.
0-ring(s) are in good condition and install the
Oil capacity: 38 Q (10 U.S. gal, 8'/, Imp. gal)
filter case(s) and center bolt(s).
4. Install the drain plug(s).
e.) Engine oil change (industrial engine)
Fig. Ml·11. Replacing the oil filter element 1. Wait for 1-2 hours after stopping the engine and
remove the oil filler cap.
2. Remove the drain plug and drain the oil.

Fig. Ml-13. Oil drain plug

~

Drain plug

Printed in Japan
2-6.
Ml
2. Maintenance Procedure [-2.]

3. Remove the drain plug on the oil filter and drain g.) Marine gear oil change (marine engine)
oil from the filter.
1. Wait for 1-2 hours after stopping the engine and
4. Install the drain plug.
remove the oil filler cap.
5. Pour in the prescribed amount of recommended 2. Remove the dipstick, connect the vinyl hose of
oil (see page 1-16) through the oil filler opening.
the rotary pump to the opening and drain the oil.
Oil capacity - 4HAL: 19.5 £ (5'/, U.S. gal, 4% Imp. gal)
3. Pour in the prescribed amount of the recommend-
6HAL·T: 29 £ (7'/, U.S. gal, 6'/, Imp. gal)
ed oil (see page 1-16) through the oil filler
opening.

f.) Marine gear oil level check (marine engine)

h.) Marine gear oil filter screen cleaning
1. Inspect the oil level with an oil level gauge. (marine engine)

Fig. Ml-14. Checking the oil level (typical) 1. Drain oil from the marine gear.
2. Remove the oil filter screen and clean it with
Dipstick
cleaning solvent.
3. Inspect the screen and replace it if damaged.
4. Install the screen and pour in oil.

Upper limit

i.) Turbocharger oil filter element replacement

(6HA(M)-HTE)
1. Remove the cartridge type filter element.
.__ Lower limit 2. Install a new element .

Fig. Ml-16. Replacing the turbocharger oil filter

2. If the oil level is lower than the lower limit or

is nearing it, remove the filler cap and add the
recommended engine oil (see page 1-16) up to
the upper limit.

Fig. Ml-15. Adding oil (typical)

Printl.'d in Japan
2-7.
Ml
2. Maintenance Procedure [-3./-4.]

[2-3.] V-beh Fig. Ml·19. Adjusting the belt tension

a.) Tension adjustment
1. Inspect the V-belt and replace it if there are
cracks or deterioration.
2. Push the center between the pulleys with your
finger and measure the amount of deflection.
Standard deflection: 10 - 15 mm (0.4 - 0.6 in)

Fig. Ml· 17. Inspecting the belt tension (industrial engine)

Pivot bolts

[2-4.] Cooling System (Industrial engine)

a.) Radiator fin cleaning
1. Inspect for foreign matter or dirt between the
radiator core fins.
2. If there is any dirt, blow it out with compressed
air or wash it off with water.
Fig. Ml·18. Inspecting the belt tension (marine engine)
b.) Coolant change
1. Remove the radiator cap, loosen the radiator
drain plug and drain the coolant.

A warning:
System is under high pressure when the engine is hot. To
avoid danger of releasing scalding coolant. remove cap only
when engine is cool (below 60°C).

Fig. Ml-20. Radiator drain plug

3. If the measured value is not within the limit,

loosen the generator pivot and adjusting bolts and
pry the generator away from the engine to adjust
belt tension. After adjusting, securely tighten
the bolts.

Printed in Japan
2-8.
Ml
2. Maintenance Procedure [-4.]

2. Loosen the drain plug at the cylinder block and c.) Cooling system cleaning
drain the coolant inside. 1. Dissolve the following amount of Yanmar scale
solvent (manufactured by JAPAN ORGANO)
Fig. Ml-21. Cylinder block coolant drain plug
in a small quantity of water.
Amount of Yanmar scale solvent to be used:
4HAL: 2,500 gr (5.5 lb)
SHAL,T: 3,500 gr (7.7 lb)

A warning:
If the powder or solution of scale solvent accidentally gets
in your eyes, wash immediately with clean water.

_j 2. Remove the radiator cap, loosen the radiator

drain plug and drain the same amount of coolant
as the amount of Yanmar scale solvent solution
to be put in.
,& Warning:
Do not remove the radiator cap when the engine is hot.
3. Tighten the radiator and cylinder block drain The coolant is under pressure and severe scalding could
result.
plugs.
4. Pour in coolant which is a mixture of soft water
3. Pour in the solution gradually from the filling
and Yanmar anti-corrosion agent (ratio of 10 : 1 opening, being careful not to let it foam.
respectively) up to the filler neck of the radiator. 4. Start the engine with the radiator cap removed.
Coolant mixture capacity:
Operate it for about 2 hours until the color of
4HAL: 25 Q (6'/, U.S. gal, 5% Imp. gal)
the coolant turns from purple to yellow.
SHALE,·T: 35 Q (914 U.S. gal, 7l4 Imp. gal)
5. After making sure that the cooling water has
A caution: become yellow, stop the engine and drain the
Always use clean soft water. If hard water is used coolant.
scale will quickly accumulate and cooling efficiency 6. Fill the cooling system with clean ~oft water,
will decline. and drain the cooling water after an hour of rat-
ing operation. Conduct this operation twice.
Fig. Ml-22. Filling the cooling system 7. Fill the cooling system with coolant.

d.) Water pump greasing

Insert water resistant grease, from the grease nipple
at the water pump, with a grease pump.

Fig. Ml-23. Cooling water pump

5. Install the radiato.r cap.

A warning: Water pump

Securely tighten the cap. Insufficient tightening is danger-
ous because hot water will spurt out during operation.

Prin/('d in Japan
2-9.
Ml
2. Maintenance Procedure [-5.]

[2-5.] Sea Water System (marine engine) Oil cooler - 2

lntercooler - 2 (6HA(M)-HTE only)
a.) Sea water draining Reverse gear cooler -1 (YP100)
1. Fully open the water drain cock at the reverse 2 (NICO)
the vessel. Fig. Ml-26. Anti-corrosion zincs
2. Fully open the water draining cock at the ma-
rine gear oil cooler and drain the sea water. Anti-corrosion zinc
3. Loosen the sea water pump cover bolts to drain
sea water.

Fig. Ml-24. Water drain cock at the marine gear oil cooler
(typical)

Anti-corrosion zincs

On model 6HA(M)-HTE, drain the sea water by

fully opening the drain cock at the intercooler.

Fig. Ml-25. lntercooler drain cock

Clutch oil cooler (typical)
Anti-corrosion zincs

Anti-corrosion zinc

4. Close the water drain cocks.

b.) Anti-corrosion zinc inspection and replacement

Engine oil cooler
1. Drain the sea water.
2. Remove each anti-corrosion zinc attaching flange.
Number of anti·corrosion zinc:
Fresh water cooler - 4

Printed in Japan
2-10.
Ml
2. Maintenance Procedure [-5.]

3. Remove the corrosion on the surface of the anti- Fig. Ml-27. New piece of anti-corrosion zinc
corrosion zinc and compare with a new piece of
zinc (see Fig. Ml-27). If the amount of zinc is 1/2
or less, remove the lock nut and replace the zinc
with a new one.

4. Use a new gasket and install the anti-corrosion

zinc/flange assembly.

Anti-corrosion zinc

c.) Sea water pump impeller inspection

and replacement
1. Drain the sea water (see page 2-10). 4. Inspect for wear and damage of the impeller,
2. Loosen the bolts securing the sea water pump wear plate, cover and mechanical seal, and re-
cover and drain remaining sea water. place the part if necessary.
3. Remove the cover and impeller.

Fig. Ml-28. Sea water pump exploded view

Pump housing

Impeller Cover
0-ring

Printrd in Japan
2-11.
Ml
2. Maintenance Procedure [-5./-6.]

5. Coat the pump shaft, 1.D. of impeller and blade 7. Start the engine and operate it without a load for
surface of the impeller and its tips with water about 2 hours until the color of the cooling
resistant grease. Then install the impeller. water turns from purple to yellow.

A Note: Fig. Ml-30. Cleaning the sea water system

Set the direction of the impeller blades as shown
in Fig. Ml-29.

Fig. Ml-29. Direction of the impeller blades

Water pump

55 Gallon tank

YAN MAR Scale solvent solution

Direction of rotation
8. After making sure that the cooling water has
6. Install the pump cover. become yellow, stop the engine and drain the
cooling water.
9. Connect the hoses at the cooling water inlet and
d.) Sea water system cleaning outlet, circulate sea water and clean the sea water
system.
1. Stop the engine and fully open the Kingston cock.
2. Being carefu I not to let the sea water leak,discon- [2-6.] Fresh water System (marine engine)
nect the sea water inlet hose from the engine
and connect a hose of 2 - 3 m (6.5 - 10 ft). a.) Coolant change
3. Disconnect the cooling water outlet hose from 1. Remove the caps of the fresh water tank and re-
the marine gear oil cooler and connect a hose of serve tank.
2 - 3 m (6.5 - 10 ft).
4. Prepare a 55 gallon tank and place the hose ends A warning:
on the cooling water inlet and outlet sides into Do not remove the fresh water tank cap when the engine is
the tank. hot. The coolant is under pressure and severe scalding could
5. Fill the 55 gallon tank with about 100 2 (26 U.S. result.
gal, 22 Imp. gal) of sea or fresh water.
2. Loosen the plugs of the fresh water tank, exhaust
6. Put the following amount of Yanmar scale sol- manifold, fresh water pump, cylinder block and
vent (manufactured by JAPAN ORGANO) into cooling water passage cover B and drain the
the 55 gallon tank and dissolve it. fresh water. Then tighten all plugs.
Amount of Yanmar scale solvent to be used:
6HA(M)E:
6HA(M)-HTE:

A Warning:
If the powder or solution of the scale solvent accidentally
gets in your eyes wash immediately with clean water.

Printed in Japan
2-12.
Ml
2. Maintenance Procedure [-6.]

Fig. Ml-31. Position of the drain plugs

Exhaust manifold

Fresh water tank

~~-f---

SHAE only

3. Pour in a coolant which is a mixture of soft water 4. Pour in the coolant up to the upper limit of the
and Yanmar anti-corrosion agent (ratio of 10 : 1 reserve tank.
respectively) up to the upper surface of the fresh Reserve tank capacity: 1.7 Q (1% U.S. qt, 1% Imp. qt)
water tank.
Fresh water capacity: Fig. Ml·33. Reserve tank
SHAE: 45 Q (11'1,U.S. gal, 9'1, Imp. gal) Filler cap

6HA·HTE: 50 Q (13% U.S. gal, 11 Imp. gal)

A caution:
Always use soft water. If hard water is used, scale
will quickly accumulate in the cooling system and
cooling efficiency will decrease.

Fig. Ml-32. Filling opening in the water tank

Filler cap

Printed in Japan
2· 13.
Ml
2. Maintenance Procedure [-6./-7.]

5. Install the reserve tank and fresh water tank filler [2-7.] Valve Clearance
caps.
1. Remove the cylinder head covers.
A warning:
Securely tighten the fresh water tank cap. Insufficient
2. Remove the timing mark cover.
3. Rotate the flywheel in the normal rotating direc-
tightening is dangerous because hot water will spurt out tion with a crankin~ handle, and align the T mark
during operation. of the cylinder to be inspected with the index
mark("9'). Make sure that the piston is at TDC
(Top Dead Center) on the compression stroke.
b.) Fresh water system cleaning
1. Dissolve the amount of Yanmar scale solvent
A Note:
If it is at TDC on compression stroke, the intake
(manufactured by JAPAN ORGANO) shown be- and exhaust valves are both closed (same level) and
low in a small amount of water. the rocker arms are loose.
Amount of Yanmar scale solvent to be used:
6HA(M)E: 4,500 gr (9.9 lb) Fig. Ml-34. "T" mark and index mark
6HA(M)-HTE: 5,000 gr (11.0 lb)

A Warning:
Cranking handle

If the powder or solution of the scale solvent accidentally

gets in your eyes wash immediately with clean water.

2. Remove the fresh water tank cap, loosen the

drain plugs of the fresh water tank and the cylin-
der block and drain the same amount of fresh
water as the amount of solution to be pour in.
Then close the drain plugs.

A warning:
Do not remove the fresh water tank cap when the engine is
Index mark('"')
hot. The coolant is under pressure and severe scalding could
result.
4. Inspect the valve clearance with a feeler gauge.
3. Pour the solution gradually into the fresh water
Valve clearance: IN, EX ... 0.4 mm (0.016 in)
tank, being careful not to let it foam.
5. Make adjustments by loosening the lock nut and
4. Start the engine with the fresh water tank cap turning the adjusting screw.
removed, and operate with no load for about 2
hours until the color of the fresh water turns
from purple to yellow.
A Note:
Securely tighten the lock nut after adjustment.
5. After making sure that the fresh water has be-
come yellow, stop the engine and drain the fresh
water (see page 2-12).
6. Fill the fresh water system with fresh water, op-
erate with no load for one hour and drain the
fresh water. Conduct th is operation twice.
7. Pour in the coolant (see page 2-13).

Printed in Japan
2-14.
Ml
2. Maintenance Procedure [-7./-8./-9.]

Fig. Ml-35. Inspecting and adjusting the valve clearance Fig. Ml-37. Removing the element

Feeler
gauge -i--.c.-7'1

6. Re-inspect the valve clearance. 3. Clean by either of the two methods listed below:
7. Perform steps 3 - 6 for each cylinder, and install • Clean by blowing in compressed air of 7 kg/cm 2
the cylinder head covers and timing mark cover. ( 100 psi) or less from the inside of the element.
• Immerse the element in a solution of cleaning
agent (Donaldson ND-1500 or equivalent) for
[2-8.] Air Cleaner (Industrial engine) about 30 minutes, then wash with clean water
and dry it in a well ventilated place.
1. Loosen the air cleaner cover band screw and re- 4. Instal I the element and cover.
move the cover.

Fig. Ml-36. Removing the air cleaner cover

[2-9.] Turbocharger C&HAL-T, &HACMJ-HTEl
a.) Prefilter cleaning
1. Remove the prefilter from the silencer, and
wash it in a mild soap solution.
2. After washing, air dry the prefilter thoroughly
in a well-ventilated place.

Fig. Ml-38. Removing the prefilter

Prefilter

2. Remove the wing nut and then remove the ele-

ment.

Printed in Japan
2-15.
Ml
2. Maintenance Procedure [-9.]

b.) Blower cleaning 4. Wait 3-5 minutes after filling with the washing
1. Remove the prefilter from the silencer, and agent, fill with another 150 cc of fresh water in
remove the plug from the water filler hole. the same manner as step 3.
2. Partially open the drain cock at the bottom of 5. Operate the engine for at least 15 minutes
the intake manifold. under load, after filling with fresh water.
6. Tighten the water filler hole plug and drain
cock securely.
Fig. Ml-39. Drain cock
7. Compare air pressure prior to and after clean-
I ing. If no pressure change is found, repeat the
cleaning 10 minutes later.
\

Drain cock

3. Operate the engine at approximately 1,800

rpm (cruising). Fill with about 150 cc of
Yanmar turbocharger washing agent through
the water filler hole for about ten seconds.
A Note:
If Yanmar turbocharger washing agent is not
available, prepare a small bottle and a crown
cap of cola. Pour a crown full of mild soap
in the bottle, fill it 70% with soft water and
shake them, then use as washing agent.
Fig. Ml-40. Wassing agent filling

Washing
agent

Printed in Japan
2-16.
Sec. 3. CYLINDER HEAD AND VALVE (CH)

Contents of this section

Page
1 . Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3· 1
[1·1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·1
[1·2.] Tools and Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·2
[1·3.] Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·2
[ 1-4.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·2

2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
[2·1.1 Industrial Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
[2-2.] Marine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
[3-1.] Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
[3-2.] Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4. Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

[4-1.] Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
[4-2.] Rocker Arm and Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·5
[4-3.] Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·6
[44.] Valve, Valve Guide and Valve Seat . . . . . . . . . . . . . . . . . . . . 3-6
[4-5.] Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
[4-6.] Nozzle Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·9

5. Assembly ......................................... 3-11

[5-1.] Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
[5-2.] Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

6. Installation ........................................ 3· 12
CH
1. Service Information (-1.]

3. Cylinder Head & Valve

1. Service Information
[1-1.] Description.
The cylinder head, made of special cast iron, is an swirl type intake ports and large diameter intake
integral 4 cylinder type for the 4-cylinder engine valves, and is designed for superior combustion
and an integral 3 cylinder type for the 6-cylinder performance.
engine. It is equipped with the unique Yanmar

Fig. CH-1. Cylinder head ~

·
~ocknut
~ Rocker arm
exploded view
\ ~ Valve adjusting screw

~~~erarmshaft

-~ "9

Shaft sprin

~- ~~J 9 /Valvecotter
' "~/Outer valve spdng
0

"> -'---:'.!
Spring reta~::~·=================~----"'.""'~-_-
1
-
---------C!>~d--41---1-1-~~li§J.@~
Nozzle sleeve---------~:-\ ~ vlnner valve spring

Stem seal ' 9 : Valve guide

Cylinder h e a d ' - - - - - - - - - - ' ·

Printed in Japan
3-1.
CH
1. Service Information [-2./-3./-4.]

[1-2.] Tools and Materials

Valve spring compressor (126650-92600) Vernier calipers
Valve guide remover (126650-92570) Impact wrench
Valve guide driver (126650-92560) Cylinder gauge
Injection nozzle sleeve expander (126650-92630) Micrometer
Nozzle sleeve holder (126650-92640) Depth gauge
Stem seal driver (126650-92580 and 126650-92590) Square
Valve seat grinder Torque wrench ( 0 - 55 kg-m)
Straight edge Color check
Feeler gauge set Thread locking" agent

[1-3.] Torque values

Diameter x Pitch width across flats Torque values
Item Remarks
(mm) (mm) kg-m ft- lb
M16x2.0 24 24 92 See page 3-13
Cylinder head bolt
M12 x 1.75 19 5.5 40 See page 3-13
Rocker arm shaft holder nut M10 x 1.5 17 3.5 25 See page 3-13

Fasteners not listed above should be tightened to the standard torques listed on page 1-17.

[1-4.] Specifications
a.) Service data
Item Standard Service limit
Rocker arm shaft outside diameter mm (in) 24.967 - 24.980 (0.9830 - 0.9835) 24.85 (0.978)
Rocker arm bushing-to-shaft clearance mm (in) 0.020 - 0.094 (0.0008 - 0.0037) 0.20 (0.008)
Para! lel with
0.05 (0.002) Max.
crankshaft
Cylinder head warpage mm(in) 0.15 (0.006)
Right angle
0.02 (0.001) Max.
with crankshaft
IN. 3.0-3.4 2.7 (0.106)
Valve thickness mm (in)
EX. 1.85-2.15 1.5 (0.059)
IN. 11.965-11.980 (0.4711 -0.4716)
Valve stem outside diameter mm (in) 11.85 (0.467)
EX. 11.920 - 11.935 (0.4692 - 0.4699)
IN. 12.010 - 12.025 (0.4728 - 0.4734)
Valve guide inside diameter mm (in) 12.10 (0.476)
EX. 11.985 - 12.003 (0.4718 - 0.4726)
IN. 0.03 - 0.06 (0.001 - 0.002)
Valve guide-to-stem clearance mm (in) 0.20 (0.008)
EX. 0.05 - 0.083 (0.002 - 0.003)
Valve guide installation height mm (in) IN., EX. 15 (0.591) .......
IN. 2.8 (0.110) 3.3 (0.130)
Valve seat width mm (in)
EX. 2.0 (0.079) 2.5 (0.098)
Valve depression mm (in) IN., EX. 0.2 - 0. 7 (0.008 - 0.028) 1.0 (0.039)
Valve spring squareness mm (in) ....... 1.0 (0.039)
7.1 - 7.9/46.0
Inner 6.2/46.0 (13.7/1.811)
(15.65 - 17.42/1.811)
Valve spring tension kg/mm (lb/in)
14.8 - 16.4/50.0 12.0/50.0 (26.5/1.968)
Outer
(32.63 - 36.16/1.968)
Inner 52.9 (2.083) 51.0 (2.008)
Valve spring free length mm (in)
Outer 55.7 (2.193) 55.5 (2.185)

Printed in Japan
3-2.
 CH
2. Removal [-1.]

2. Removal Fig. CH-J. Cylinder head bolt removal sequence

[2-1.] Industrial Engine

1. Drain the coolant (see page 6-4).
2. Disconnect the electrical connectors around the e0 e® c~J3' 3

cylinder head.
3. Remove the intake manifold (see page 8-1 ). © e @l ©
4. Remove the fuel injection nozzle (see page 7-5).
5. Remove the exhaust manifold (see page 8-2). 0 CG e 0
6. Remove the cooling water passage (cylinder
head to thermostat housig), and the thermostat 0 e ®
housing. 3~ylinder (3 +3 = 6 cylinder)

7. Remove the cylinder head cover(s).

8. Loosen the valve adjusting screw lock nuts and
screws.
9. Remove the nuts securing the valve rocker arm 0@ ®© ® 0
@j @j
holders and remove the rocker arm shaft assem-
bly. © ® @I e ©
A Note: 0 ® @) e 0
On 6-cylinder, mark rocker arm shaft assembly to
insure original assembly. e e 4~yllnder
® ®
Fig. CH-2. Removing the rocker arm shaft assembly

12. Remove the cylinder head(s).

Rocker arm shaft assv A Note:

• Cylinder head weight: 3-cylinder 60 kg (132 lb),
approx. 4-cylinder 75 kg (165 lb) approx.
• On 6-cylinder, mark cylinder heads to insure
original assembly.

Fig. CH-4. Removing the cylinder head

Cylinder hea

10. Remove the push rods.

A Note:
Mark all push rods to insure original assembly.
11. Remove the cylinder head bolts.

Aeaution:
• Perform this operation while the engine is cold
to prevent warpage.
• Loosen the cylinder head hold-down bolts in
the sequence in Fig. CH-3 in three to four steps. 13. Remove the cylinder head gasket(s).
Printed in Japan
3-3.
 CH
2. Removal [-2.] 3. Disassembly [-1./-2]

[2-2.] Marine Engine 3. Disassembly

1.Drain the sea water (see page 2-10).
2.Drain the fresh water (see page 2-12). [J-1.] Rocker Arm Shaft
3.Remove the intake manifold (see page 8-1 ). 1. Remove the snap ring from the rocker arm shaft
4.On model 6HA(M)-HTE, remove the injection end.
pipes. 2. Remove the rocker arms, springs, thrust washers
5. Remove the fuel injection nozzle (see page 7-5). and shaft holders from the shaft.
6. Disconnect the electrical connectors around
the cylinder heads. A Note:
Mark each part to insure original assembly.
7. On model 6HA(M)-HTE, perform the following
operations: [3-2.] Cylinder Head
a. Remove the turbocharger lubricating oil pipes.
b. Loosen the V-clamp on the compressor side 1. Compress the valve spring with a valve spring
of the turbocharger. (see page 8-3). compressor ( 126650-92600) and remove the
8. Remove the cooling water passage (cylinder head valve cotters. Then remove the valve spring re-
to exhaust manifold). tainer, inner spring, outer spring and valve.
9. Remove the bolts securing the exhaust manifold
ANote:
to the cylinder heads. Loosen the bolts securing
the exhaust manifold stays, and move the ex- Be careful not to damage the gasket surface of the
haust manifold outward so that the cylinder head cylinder head.
can be removed. Fig. CH-6. Removing the valve cotters
Fig. CH-5. Shifting the exhaust manifold

2. Remove the valve stem seal and spring guide.

A Note:
The valve stem seal cannot be reused so remove it
only when necessary.
Fig. CH-7. Removing the valve stem seal

10. Follow the steps 7 - 13 of "Cylinder Head Re-

moval" for Industrial Engine (see page 3-3).

Printed in Japan
3-4.
CH
4. Inspection and Repair [-1./-2.]

4. Inspection and Repair Fig. CH-9. Measuring the rocker arm shaft D.D.

[4-1.] Cylinder Head Cover

a.) Cylinder head cover
Inspect the seal rubber on the cylinder head cover.
If it is damaged or deteriorated, replace cylinder
head cover.

b.) Decompression cam (marine engine)

Inspect the decompression cam for ware or damage.
If it is excessively worn or damaged, replace the
decompression lever assembly.
When replacing it, remove the screws and set pins b.) Rocker arm inspection
and then remove the decompression lever assembly.
Install new decompression lever and align the set Inspect the rocker arm for wear or damage. Replace
pin holes of the decompression cam and cylinder rocker arm if it is damaged or excessively worn.
head cover. Instal I the set pins and screws.
A Note:
Fig. CH·B. Decompression lever exploded view Grooved wear on the contact area of the rocker
(marine engine) arm to the valve stem can be repaired by using an
oil stone.
Cylinder head cover

c.) Rocker arm-to-shaft clearance

1. Measure and record the inside diameter of the
rocker arm bushing.

Fig. CH-10. Measuring the inside diameter of the rocker arm

Decompression
handle

DecompressorCam

[4-2.] Rocker Arm and Shaft

a.) Rocker arm shaft inspection
1. Blow the oil hole of the shaft with compressed
air and check that it is not clogged.
2. Measure and record the rocker arm shaft outside
2. Calculate the clearance between the rocker arm
diameter.
and shaft. The clearance is the difference between
Service limit: 24.85 mm (0.978 inl
the bushing inside diameter and the shaft out-
side diameter.
Service limit: 0.20 mm (0.008 inl
If the clearance exceeds the service limit, replace
the rocker arm assembly.
Printed in Japan
3-5.
CH
4. Inspection and Repair [-3./-4.]

[4-3.] Cylinder Head 2. Measure the thickness of the valve.

Service limit - Intake: 2.7 mm (0.106 in)
a.) Combustion surface inspection
Exhaust: 1.5 mm (0.059 in)
1. Inspect the cylinder head combustion surface
for abnormal discoloration and deformation. Fig. CH-13. Valve thickness
2. Inspect the cylinder head combustion surface Exhaust valve Intake valve

for cracks with a color check.

Fig. CH-11. Color checking of the combustion surface

3. Measure and record the outside diameter of the

valve stem.
Service limit - Intake: 11.85 mm (0.467 in)
Exhaust: 11.85 mm (0.467 in)

Fig. CH-14. Measuring the valve stem 0.0.

b.) Warpage inspection

1. Clean the cylinder head surface.
2. Measure the warpage of the cylinder head sur-
face with a straight edge and feeler gauge.
If the warpage exceeds the service limit, replace
the head or repair it with a surface grinder.
Service limit: 0.15 mm (0.006 in)

Fig. CH-12. Measuring the cylinder head warpage b.) Valve guide inspection
Measure and record the inside diameter of the valve
guide.
Service limit - Intake: 12.10 mm (0.476 in)
Exhaust: 12.10 mm (0.476 in)

Fig. CH-15. Measuring the valve guide 1.0.

[4-4.] Valve, Valve Guide and Valve Seat

a.) Valve inspection
1. Inspect each valve for bending, burning, scratch-
es or abnormal stem wear.

Printed in Jo.pan
3-6.
CH
4. Inspection and Repair [-4.]

c.) Valve guide-to-valve stem clearance • The inside diameter of a new valve guide is de-
Calculate the clearance between the valve guide and signed so that it will be within the standard value
valve stem. The clearance is the difference between after installation. Therefore, there is no need for
the outer diameter of the stem and the inner dia- reamer finish.
meter of the guide.
Fig. CH-17. Installing the valve guide
Service limit - Intake: 0.20 mm (0.008 in)
Valve guide driver
Exhaust: 0.20 mm (0.008 in) ( 126650·92560)

If the clearance exceeds the service limit, replace

the valve and guide.

d.) Valve guide replacement

A Note:
Be careful not to damage the gasket surface of the e.) Valve seat inspection
cylinder head.
Inspect the valve seat. If the seat is too wide, too
narrow, rough or uneven, the seat must be ground.
1. Using a valve guide remover (126650·92570), Valve seat width
drive out the valve guide from the bottom of the Service limit
Standard
cylinder head (combustion surface side).
Intake: 2.8 mm (0.110 in) 3.3 mm (0.130 in)
Exhaust: 2.0 mm (0.079 in) 2.5 mm (0.098 in)
Fig. CH-16. Removing the valve guide

Fig. CH-18. Measuring the valve seat width

Valve guide remover
11 26650·92570)

Fig. CH-19. Valve seat width

2. Using a valve guide driver (126650-92560), Seat width 2.0mm

(0.079 in) /'
drive the valve guide from the top of the cylin-
der head.
7
A Note:
• Install the valve guide until its shoulder is flush
with the head surface.
• Projection amount of the valve guide (IN., EX.):
15 mm (0.591 in).
Printed in Japan
3-7.
CH
4. Inspection and Repair [-4.]

f.) Valve seat refacing 2. Grind the valve seat with a 70° cutting stone.
3. Install a 15° finish cutting stone and cut the valve
A Note: seat to the proper width.
• Before refacing the valve seat, always inspect the
valve guide-to·stem clearance, and replace the Fig. CH·22. Valve seat refacing sequence
valve and valve guide if necessary.
• Remember the contact position of the valve and
seat while refacing. If the contact area on the
face of the valve is too high, grind the seat only
with 1!) and 30" cutting stones for the intake,
and 1S' and 4S' cutting stones for the exhaust.
If the contact area on the valve face is too low,
grind the seat with 10° and 30° cutting stones
for the intake, and 10° and 4S' cutting stones
for the exhaust.
• Be careful not to over-grind.

Fig. CH-20. Contact area of the valve

Contact too high

Contact too low

4. Knead the valve compound with oil, and lap the

valve and seat with the mixture.
5. Use oil only and lap the valve and seat.
6. After lapping, wash any residual compound off
the cylinder head and valve.

g.) Valve depression inspection

1. Remove the roughness of the valve seat with a
Measure the valve depression (the depth from the
30° cutting stone for intake, and 45° cutting
head to the valve), and if it exceeds the service limit
stone for exhaust.
replace the valves and cylinder head.
Service limit: 1.0 mm (0.039 in)
Fig. CH·21. Refacing the valve seat
Fig. CH·23. Measuring the valve depression
Valve seat grinder

Depth gauge

Cutter

PrintPd in Japan
3-8.
CH
4. Inspection and Repair [-5./-6.]

[4-5.] Valve Spring c.) Tension inspection

a.) Squareness inspection Measure the tension of each spring with a spring
tester.
Check the valve springs for squareness with a square
Service limit -Inner: 6.2 kgl46.0 mm (13.7 lbl1.811 in)
on a surface plate. Replace the spring if it exceeds
Outer: 12-0 kgl50.0 mm (26.5 lb/1.968 in)
the service limit.
Service limit: 1.0 mm (0.039 in)
Fig. CH-26. Measuring the valve spring tension

Fig. CH-24. Measuring the valve spring squareness

[4-6.] Nozzle Sleeve

Surface plate
a.) Nozzle sleeve inspection
Inspect the inside of the nozzle sleeve. If there are
carbon deposits or foreign particles, remove them.
b.) Free length inspection
Measure the free length of the spring. A Note:
Service limit -Inner: 51 mm (2.008 in) If there are carbon deposits, foreign particles or
Outer: 55.5 mm (2.185 in) grooves on the packing surface, gas leakage will oc-
cur and the injection valve and nozzle sleeve will
Fig. CH-25. Measuring the valve spring free length stick because of the carbon. The sleeve expanded
area will loosen when removing the injection valve,
causing water leakage.

Fig. CH-27. Installed nozzle sleeve

Nozzle sleeve

Expanded area

Printed in Japan
3-9.
CH
4. Inspection and Repair [-6.]

b.) Nozzle sleeve re-expanding 4. Remove the fragments of the sleeve remaining in
the expanding area of the cylinder head and the
The nozzle sleeve expands in the cylinder head
carbon on the seat surface.
groove as shown in Fig. CH-27. If water leakage oc-
5. Thoroughly clean the expanding area, seat sur-
curs, re-expand the sleeve following the steps for
face and 0-ring surface of the cylinder head.
expanding the sleeve under "Nozzle sleeve replace-
6. Install a new 0-ring on a new nozzle sleeve and
ment".
insert the nozzle sleeve into the cylinder head.
A Note:
A Note:
• Re-expand the sleeve after completely removing
Install the nozzle sleeve so that the combustion sur-
the carbon deposit around the expanded area of
face of the cylinder head and the end of the nozzle
the nozzle sleeve.
sleeve will be parallel (see Fig. CH-29).
• The sleeve can be re-expanded only once. The
amount to be installed (L measurement) of the
mandrel is approximately 7 mm (0.28 in). 7. Install the copper packing for the injection valve
into the nozzle sleeve. Secure the nozzle sleeve
by using a nozzle sleeve holder ( 126650-92640)
c.) Nozzle sleeve replacement and injection nozzle attaching nuts.
Torque: 1 kg-m (7.2 ft/lb) or less
If water leakage is not prevented even after re-
expanding the sleeve, replace the nozzle sleeve in
the following order:
A caution:
Use only packing in good condition to prevent the
1. Tap a M12 thread in the expanded area of the packing surface in the nozzle sleeve from damage,
sleeve from the combustion surface side. which will cause gas leakage.
2. Screw a 50 mm (2 in) M12 bolt through the
plain washer into the thread. Fig. CH-29. Installing the nozzle sleeve holder
3. Tap the bolt head with a hammer from the com- Nozzle sleeve holder Injection nozzle nuts, 1 kg-m
(126650-926401 (7.2ft-lb) Max,
bustion surface side, and drive the nozzle sleeve
out to the opposite side.

A Note:
Take care not to damage the nozzle sleeve opening
in the head.

Fig. CH-28. Removing the nozzle sleeve

Bolt M12 x SOmm

Plain washer

Incorrect

8. Place the cylinder head on the working bench

--Cylinder head with the intake manifold side down.
9. Coat the expander roller, the expanding area of
the sleeve and the protective washer (M 10 plain
Expanded area
washer) at the combstion side with molybdenum
disu Ifide grease.
10. Completely insert the expander roller into the
nozzle sleeve through the plain washer.
Prmted in Japan
3-10.
CH
4. Inspection and Repair [-6.] 5. Assembly [-1.]

Acaution: A Note:
• Always use a plain washer to save the com- Because the roller is equipped with an automatic
bustion surface from damage. advancing angle, rotate the impact wrench intermit-
• Completely insert the roller. Insufficient inser- tently to prevent the sleeve from over-expanding.
tion of the roller will result in insufficient ex-
Fig. CH-31. Expanding the sleeve
panding length of the sleeve, causing water leak- Impact wrench
age. Also, insertion of the fuel injection nozzle
will not be possible.

Fig. CH-30. Condition before expanding the sleeve

Cylinder head

Expander mandrel

Fig. CH-32. Condition after completing sleeve expansion

Expanded area

Copper packing Thrust collar

L::o4Qmm (1.57 in) approx.

11. Install an impact wrench on the mandrel and ro-

tate the mandrel clockwise viewed from the com-
bustion surface side. The sleeve will be expanded
automatically by the advance angle of the roller.
As shown in Fig. CH-32, complete expanding
when the L measurement is reached is as follows: 12. Rotate the impact wrench counterclockwise and
L measurement after expanding the pipe - remove the expander from the sleeve.
New sleeve: 12 mm (0.47 in) 13. After expanding the sleeve, thoroughly remove
Re-expanded sleeve: 7 mm (0.28;n.) molybdenum disulfide grease from the sleeve.

5. Assembly
[5-t] Cylinder Head Fig. CH-33. Installing the stem seal

Assemble in the reverse order of disassembly, but 0

note the following points:
When the stud bolt and screw plug are removed,
install them after coating the threads with locking
agent. Stem seal driver

a.) Stem seal installation Valve stem seal

1. Install the valve spring guide on the valve guide. Valve spring guide

2. Install a new stem seal on the stem seal driver

(126650-92580 and 126650-92590).
3. Gently, drive the stem seal until driver tool seats
the cylinder head surface.
4. Remove the stem seal driver.
Printed in Japan
3-11.
CH
5. Assembly [-2.] 6. Installation

[5-2.] Rocker Arm 4. On the 6-cylinder, check with a straight edge

that both cylinder heads are flush and correct
Asseml'.>le in the reverse order of disassembly, but
the position if necessary.
note the following point:
Make sure that the oil passages in the shaft holder
Fig. CH-36. Checking the cylinder head position
and shaft are not plugged.

Fig. CH-34. Oil passages in the shaft and holder

~ . t:l!iV Oil passage I

Straight edge

6. Installation
Install in the reverse order of removal, but note the
following points: 5. Tighten the cylinder head bolts in the following
1. Clean the gasket surfaces of the cylinder block order:
and cylinder head. a. Coat the bolt threads and the seat surfaces
2. lnstal I new cylinder head gasket(s). 0-rings on the with engine oil. Then screw in the bolts by hand.
cylinder block. b. Tighten the M16 bolts in three steps in these-
quence shown in Fig. CH-37, to the following
A Note: torques:
First: 6 kg·m (43 ft-lb)
• For the gasket and 0-ring do not use liquid
sealant. Second: 12 kg-m (46 ft-lb)
• Install the gasket(s) and 0-rings in the correct Third: 24 kg-m (92 ft-lb)
position.
Fig. CH-37. Cylinder head bolt (M16) tightening sequence
3. Install the cylinder head (s) on the cylinder block.

Fig. CH-35. Installing the cylinder head

6-cylinder

Cylinder
head

4-cylinder

Cylinder head gaskets

Printed in Japan
3-12.
CH
6. Installation

c. Tighten M12 bolts in two steps in the sequence

shown in Fig. CH-38, to the following torques:
Fir.;t: 3.5 kg-m (27 ft-lb)
Second: 5.5 kg-m (40 ft-lb)

Fig. CH-38. Cylinder head bolt (Ml 2) tightening sequence

o® o()) o(JJ
0 0 0 0 6-cylinder
0 0 0 0
0 0 0

o® o()) o® o®
0 0 0 0 0 4-cylinder

0 0 0 0 0
0 0 0 0

6. Tighten the nuts securing the rocker arm holder

to the torque of 3.5 kg-m (25 ft-lb).
7. After installing therockerarmshaftassembly,ad-
just the valve clearance (see page 2-14)J).
8. For models equipped with a turbocharger, refer
to page 8-2 when installing the intake and ex-
haust system.
9. After installation, fill the cooling system (see
page 2-9 for industrial engine, page 2-13 for
marine engine).

Printed in Japan
3-13.
Sec. 4. ENGINE PROPER (EP)

Contents of this section

Page
1. Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
(1-1.] Tools and Materials...... . . . . . . . . . . . . . . . . . . . . . . . . 4-1
(1-2.] Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
[ 1·3.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

2. Piston and Connecting Rod ... ____ .... _. - ... _. _. _.... _ 4-3
[2· 1.] Description . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 4·3
[2·2.] Removal . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 4·4
[2·3.l Inspection . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 4-5
(2-4.] Installation . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 4-9

3. Cylinder Liner ..................................... 4-11

(3-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
(3-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
(3-3.] Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4. Gear Train ........................................ 4-13

[4· 1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
[4·2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
(4-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
(4-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

5. Camshaft and Valve Train ....... __ - .... - - __ .. _. _. __ .. 4-18

(5-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
(5-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
(5-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
(5-4.] Installation . . . . . . . . . . . . . . . __ . . . . . . . . . . . _ ...... 4-20

6. Crankshaft . _____ ... __ •. ___ . _. __ ...... - __ .......... 4-20

(6-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
(6-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
(6-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
(6-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

7. Cylinder Block . __ . _. _.............................. 4-27

[7·1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4·27
(7-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
(7-3.] Oil Passage Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
EP
1. Service Information [-1./-2.]

4. Engine Proper
1. Service Information
[1-1.] Tools and Materials
Piston pin bushing driver (126650·92550)
Piston ring expander (135410-92140)
Piston slider (126650-92140)
Cylinder liner puller (144626-92010, 144626-92030, 126650-92020)
Cam gear puller (126650-92650, 145610-92900, 126650-92660)
Automatic timer puller (126630-92770)
Flywheel straight pin puller (126650-92670, 126650-92680)
Flywheel hanger (144626-92850)
Torque wrench
Vernier calipers
Micrometer
Cylinder gauge
Connecting rod aligner
Feeler gauge
Depth gauge
Dial indicator
V-blocks
Straight edge
Fuse - 1.5 x 10 mm (0.06 x 0.4 in)
Plastigage
Anti~rust agent

Lithium grease
Color check

[1-2.] Torque Values

Torque values
Item Diameter x Pitch (mm) Across flat (mm) Remarks
kg-m ft· lb
Connecting rod M14 x 1.5 22 18.5 134 See page 4-10
Oil pump idle gear M12x1.75 19 6 43 See page 4-16
Timing idle gear M16x 1.5 24 12 87 See page 4-17
Camshaft drive gear M30 x 1.5 46 20 145 See page 4-19
Injection pump drive gear M14 x 1.5 22 8 58 See page 4-17
Automatic timer M18x 1.5 27 14 101 See page 4-18
Silicon rubber damper M16x 1.5 24 20 145 See page 4-18
··---
Generator drive gear M20 x 1.5 30 13 94 --
Metal cap M20 x 2.5 30 35 253 See page 4-25
Flywheel M18 x 1.5 27 20 145 See page 4-26

Printed in Japan
4-1.
EP
1. Service Information [-3.]

[1-3.] Specifications
Service data

Item Standard Service limit

Inside diameter of cylinder liner mm (in) 130 -130.03 (5.1181 - 5.1193) 130.2 (5.1260)
s 130-130.010 (5.1181 -5.1185)
Cylinder Cylinder liner identification MS 130.010 - 130.015 (5.1185 - 5.1187)
mm (in)
block and inside diameter ML 130.015 - 130.020 (5.1187 - 5.1189)
M 130.020 -130.030 (5.1189 - 5.1193)
Cylinder liner projection mm (in) 0.03 - 0.11 (0.0012 - 0.0043) -
Cylinder liner out-of-round mm (in) O.ol 5 (0.0006) Max. 0.1 (0.0039)
Top clearance mm (in) 1.1 -1.3 (0.0433-0.0512) -
Piston outside diameter mm (in) 129.843 - 129.873 (5.1119 - 5.1131) 129.65 (5.1043)
s 129.843 - 129.853 (5.1119 - 5.1124)
Piston identification MS 129.853 - 129.858 (5.1124 - 5.1126)
Piston mm (in)
and outside diameter ML 129.858 - 129.863 (5.1126-5.1128)
L 129.863 - 129.873 (5.1128 - 5.1131)
Piston-to-piston pin clearance mm (in) 0 - 0.027 (0 - 0.0011) -

Piston pin outside diameter mm (in) 47.989 -48.00 (1.8893 -1.8898) 47.95 (1.8778)
No. 1 0.4 - 0.55 (0.016 - 0.022) 1.5 (0.06)
No. 2 0.4 - 0.55 I0.016 - 0.022) 1.5 (0.06)
Piston ring end gap mm (in)
No. 3 0.4 - 0.6 (0.016 - 0.024) 1.5 (0.06)
Oil 0.3 - 0.5 (0.012 - 0.020) 1.5 (0.06)
Piston ring
No. 1 0.065 - 0.090 (0.0027 - 0.0035) 0.15 (0.006)
Piston ring-to-ring groove No. 2 0.030 -0.060 (0.0012 - 0.0024) 0.15 (0.006)
mm (in)
clearance No. 3 0.050 - 0.085 (0.0020 - 0.0033) 0.15 (0.006)
Oil 0.035 - 0.065 (0.0014 - 0.0026) 0.15 (0.006)
Parallelism and distortion mm (in) 0.02 (0.0008) for 100 (3.937) 0.07 (0.0028)
Side clearance mm (in) 0.150 - 0.324 (0.0059 -0.0128) 0.4 (0.0158)
Piston pin bushing inside diameter mm (in) 48.025 -48.040 (1.8908- 1.8913) 48.1 (1.894)
Small end oil clearance mm (in) 0.025 - 0.051 (0.0010 - 0.0020) 0.07 (0.0028)
Connecting
Large end oil clearance mm (in) 0.04 -0.108 (0.0016 -0.0043) 0.13 (0.0051)
rod
Crankpin metal Standard 82.0 - 82.048 (3.2283 - 3.2302) --
inside diameter 0.25 (0.0098) undersize 81.500 - 81.548 (3.2087 - 3.2120) -
mm (in) 0.5 (0.0197) undersize 81.0 - 81.048 (3.1890 - 3.1909) --
Backlash 0.12 - 0.20 (0.0047 - 0.0079) 0.35 (0.0138)
Shaft outside diameter mm (in) 41.95 -41.97 (1.6516 -1.6524) -
Timing Bushing inside diameter mm (in) 42.00 - 42.025 (1.6535 - 1.6545) -
idle gear Oil clearance mm (in) 0.03 - 0.075 (0.0012 - 0.0030) 0.15 (0.0059)
Timing Side clearance mm (in) 0.15 - 0.30 (0.0059 - 0.0118) 0.4 (0.016)
gear Shaft outside diameter mm (in) 29.959 - 29.98 ( 1. 1795 - 1.1803) -
Oil pump Bushing inside diameter mm (in) 30.00 - 30.021 (1.1811 - 1.1819) -
idle gear Oil clearance mm (in) 0.020 - 0.062 (0.0008 - 0.0024) 0.15 (0.0059)
Side clearance mm (in) 0.10 - 0.20 (0.0039 - 0.0079) 0.4 (0.016)

Printed in Japan
4-2.
EP
1. Service Information [-3.] 2. Piston & Connecting Rod [-1.]

Item Standard Service limit

Bend mm (in) 0.02 (0.0008) 0.15 (0.0059)

Cam height mm (in) 53.87 - 53.95 (2.1208 - 2.1240) 53.4 (2.102)
Journal outside diameter mm (in) 62.94 - 62.97 (2.4780 - 2.4791) 62.8 (2.4 72)
Camshaft
Camshaft bushing inside diameter mm (in) 63.02 - 63.05 (2.4811 - 2.4823) 63. 15 (2.4862)
Journal_,,_oil clearance mm (in) 0.05 - 0.15 (0.0020 - 0.0059) 0.23 (0.0091)
Side clearance mm (in) 0.10 -0.35 (0.0039 -0.0138) 0.42 (0.0165)
Bend mm (in) O.Q15 (0.0006) Max. 0.15 (0.006)
Outer diameter mm (in) 81.94 - 81.96 (3.2260 - 3.2268) 81.37 (3.2035)
1 Crank pin Out-of-round mm (in) 0.015 (0.0006) -
Qi I clearance mm (in) 0.040 - 0.108 (0.0016 - 0.0043) 0.13 (0.0051)
Outer diameter mm (in) 99.94 - 99.96 (3.9346 - 3.9354) 99.37 (3.9124)
Journal Out-of-round mm (in) O.Q15 (0.0061 -

Oil clearance mm (in) 0.050 - 0.118 (0.0020 - 0.0047) 0.14 (0.0055)

Crankshaft Side clearance n1m (in) 0.07 - 0.219 (0.0028 - 0.0086) 0.33 (0.013)

Main metal Standard 100.010 - 100.058 (3.9374 - 3.9393) -

inside diameter 0.25 (0.0098) undersize 99.510 - 99.558 -3.9177 - 9.9160) -
mm (in) 0.5 (0.0197) undersize 99.010 - 99.058 (3.8980 - 3.8999) -
-
Thrust metal Standard 3.0(0.1181) -
thickness 0.25 (0.0098) undersize 3.125 (0.1230) -
mm (in) 0.5 (0.0197) undersize 3.25 (0.1279) -
·---·.
Deflection mm (in) - 0.015 (0.0006)
' Outer diameter mm (in) 35.950-35.975 (1.4154-1.4163) 35.9 (1.4134)
Tappet
Tappet guide inside diameter mm (in) 36.00 -36.025 (1.4173 -1.4183) 36.06 (1.4197)
Qi I clearance mm (in) 0.025 - 0.075 (0.0010 - 0.0030) 0.12 (0.0047)
Push rod bend mm (in) 0.03 (0.0012) Max. 0.3 (0.012)

2. Piston & Connecting Rod

[2-1.] Description
The pistons are made of aluminum alloy cast (LO- in the piston. Because the piston skirt is not equipp-
EX) which has the characteristics of minimum ed with an oil control ring, the amount of oil main-
thermal expansion and excellent cooling capacity. tained at the thrust surface is large, allowing opti-
During operation, the oval shape of the piston main- mum lubrication. Also, because the hardness of the
tains optimum contact with the cylinder liner skirt section increases, distortion of the piston is
and reduces oil consumption. Also, toroidal type kept at a minimum and it always maintains stable
combustion chamber, which has excellent starting contact. A ring trigger is cast into the top ring
capacity and minimum fuel consumption, is equipp- groove, designed to increase durability. Further-
ed on top of the piston. Furthermore, three com- more, the piston and liner are selectively matched
pression rings and one oil control ring are installed for a perfect fit.

Prinll'd in Japan
4-3.
EP
2. Piston & Connecting Rod [ -1./-2.]

Fig. EP-1. Piston and piston rings 8. Remove the connecting rod cap bolts and remove
the caps.

A Note:
Mark each part to insure original assembly.
Fig. EP-3. Removing the connecting rod bolts

The connecting rod, made of forged carbon steel,

has increased strength. The large end of the rod is
split horizontally and is equipped with special alloy
crankpin metals, and a double layered copper alloy 9. Remove the carbon deposit from the cylinder
bushing is installed in the small end. liner.
10. Screw piston pulling bolts (MB x 1.25) in the
[2-2.] Removal holes on top of the piston, and pull up and re-
1. On industrial engine, drain the cooling system move the piston/connecting rod assembly.
(see pages 2-8, 10 and 12).
2. On industrial engine, remove the drain plug on A Caution:
the oil pan and drain the engine oil. On engines with turbochargers, be careful not to
3. Drain the fuel system (see page 7-10).). damage the L-shaped nozzle when removing the
4. Remove the two fuel pipes between the injection piston/connecting rod assembly.
pump and fuel filter, and remove the fuel filter.
5. Remove the cylinder head(s) (see page 3-3).JO). A Note:
6. Remove the oil dipstick from the oil pan (Indus- Mark each part to insure original assembly.
trial engine only).
7. Remove the cylinder block side covers.
Fig. EP-4. Removing the piston/connecting rod assembly
Fig. EP·2. Removing the cylinder block side covers

Piston pulling bolts

r
Printed in Japan
4-4.
EP
2. Piston & Connecting Rod [-3.]

11. Remove the piston rings with a piston ring ex- 2. Install the cylinder head gasket(s) and cylinder
pander ( 135410-92140). head(s). and tighten in the specified sequence
12. Remove the snap ring, remove the piston pin and and torque (see page 3-12).
separate the piston and connecting rod. 3. Rotate the crankshaft by using a cranking handle
and crush the fuses.
A Note: 4. Remove the cylinder head and crushed fuses.
5. Measure the thickness of fuses with vernier cali-
When removing the pin, note the direction of the
h'Yanmar" mark. pers or micrometer. The top clearance is the av-
erage value of the thickness of the three fuses.
Top clearance: 1. 1 - 1.3 mm
(0.0433 - 0.0512 in)
Fuse diameter: 1.5 mm (0.059 in)
6. If the top clearance exceeds the indicated value,
[2-3.] Inspection inspect for wear of the crankpin, journal piston
pin and other metal parts, and bend of the con-
a.) Top clearance
necting rod.
1. Place high quality fuses of 1.5 mm (0.059 in)
diameter and 10 mm (0.39 in) long in three
places on top of the piston as shown in Fig. EP-6.
b.) Piston
Fig. EP-5. Top clearance Inspect the pistons for damage and cracks and ring
grooves for wear or damage. If such abnormalities
are found replace the piston.

c.) Piston outside diameter measurement

Measure the outside diameter of the piston at the
skirt.

A Note:
Measurements should be taken 2 mm (0.079 in)
from the bottom and at right angle to the piston
pin.
Standard: 129.843 - 129.873 mm
(5.1119-5.1131 in)
Service limit: 129.65 mm (5.1043 in)

Fig. EP-6. Position of fuse for the measuring

Fig. EP-7. Measuring the outer diameter of the piston 0.0.

Prinled in Japan
4-5.
EP
2. Piston & Connecting Rod [-3.]

A Note:
Fig. EP-8. Measuring the piston ring-to-ring groove
clearance
• When· replacing the piston, check the piston pin
hole-to-piston pin clearance.

Piston pin hole inside diameter 48.0 -48.016 mm

(Standard): ( 1.8898 - 1.89014 in)
Piston pin outside diameter 47.989 - 48.0 mm
(Standard): (1.8893 -1.8898 in)
Piston pin hole-to-pin clearance 0 -0.027 mm
(Standard): (0 - 0011 in)

Feeler gauge

• Select correct size of piston to obtain specified

piston-to-cylinder liner clearance (see page 4-12).

Size Code Piston 0.D. e.) Piston ring end gap

As shown in Fig. EP-9, Insert each piston ring into
-0.157 mm ( -0.0062 in)
s 130
-0.147 mm
51181
· -0.0057 in
the liner with the top of the piston. Measure the
end gap at 50 mm (2 in) from the bottom of the
-0.147 mm ( _1
MS 130 5 181 -0.0057 in ) liner using a feeler gauge.
-0.142 mm -0.0055 Jn
-0.142 mm ( . -0.0055 in)
ML 130 5 1181 Service limit
-0.137 mm -0.0053 Jn
-0.137 mm ( .
Top 1.5 mm (0.06 in)
L 130 5 1181 -0.0053 in)
-0.127 mm -0.0050 Jn 2nd 1.5 mm (0.06 in)
3rd 1.5 mm (0.06 in)
Oil 1.5 mm (0.06 in)

Fig. EP-g. Measuring the piston ring end gap

d.) Piston ring groove-to-piston ring clearance
Measure the piston ring-to-ring groove clearance. If
it exceeds the service limit, replace the piston ring.

Ring-to-groove clearance
Service limit Cylinder liner
Top 0.15 mm (0.006 in)
2nd 0.15 mm (0.006 in)
Piston
3rd 0.15 mm (0.006 in)
Oil 0.15 mm (0.006 in) 0

End gap

Printed in Japan
4-6.
EP
2. Piston & Connecting Rod [-3.]

f.) Piston pin outside diameter h.) Connecting rod side clearance
Measure the outside diameter of the piston pin. Re- Assemble the connecting rod on the crankshaft and
place the piston pin if it is worn beyond the service measure the side clearance. Replace the connecting
limit or if there is excessive stepped wear. rod if the measured value exceeds the service limit.
Standard: 47.989 -48.000 mm (1.8893 -1.8898 in) Standard: 0.15 -0.324 mm (0.0059 -0.0128 in)
Service limit: 47.95 mm (1.8778 in) Service limit: 0.4 mm (0.0158 in)

Fig. EP-10. Measuring the piston pin 0. 0. Fig. EP-12. Measuring the connecting rod side clearance

i.) Piston pin bushing

g.) Connecting rod parallelism and distortion Measure the inside diameter of the piston pin bush-
ing at the connecting rod small end. Calculate the
Inspect the connecting rod for bend or distortion oil clearance by subtracting the measurement of the
using a connecting rod aligner. outside diameter of the piston pin from the meas-
Standard: For every 100 mm (3.937), ured value.
0.02 mm (0.0008 in)
Piston pin bushing l.D.:
Service limit: 0.07 mm (0.0028 in) Standard: 48'.025 -48.040 mm (1.8908 -1.8913 in)
Service limit: 48.1 mm (1.894 in)
Fig. EP-11. Connecting rod alignment Oil clearance:
Standard: 0.025 - 0.051 mm (0.0010 - 0.0020 in)
Distortion Service limit: 0.07 mm (0.0028 in)

Fig. EP-13. Measuring the piston pin bushing 1.0.

Parallelism

Printed in Japan
4-7.
EP
2. Piston & Connecting Rod [-3.]

If the inside diameter of the bushing or the oil clear- j.) Crankpin metal
ance exceed the service limit, or if the bushing is
1. Inspect all metals for separation, melts, scores,
damaged, replace the piston pin bushing in the fol-
burns and for the condition of the contact sur-
lowing order:
face. If any defects are detected replace the crank-
1. Remove the piston pin bushing with a piston pin pin metals.
bushing driver ( 126650-92550).
2. Measure the oil clearance with a Plastigage. If the
Fig. EP-14. Removing the piston pin bushing measurement exceeds the service limit, replace
the crankpin metals.

A Note:
• Wipe any oil from the crankpin and crankpin
Piston pin bushing driver
1126650·92550)
metal before using Plastigage.
• Place the Plastigage in the crankshaft direction
• Tighten the connecting rod bolts to the specified
toque.
Torque: 18.5 k!l'm (134 ft-lb)
Standard: 0.040 - 0.108 mm
(0.0016 - 0.0043 in)
Service limit: 0.13 mm (0.0051 in)

Fig. EP· 16. Measuring the crankpin metal oil clearance

2. Drive in the new piston pin bushing with the

same tool so that the oil holes in the bushing and
connecting rod are aligned.

Fig. EP-15. Pressing in the piston pin bushing

Flattened plastigage

Replacement crankpin metals

Classifi- Inside diameter Thickness

l.D. code mm (in)
cation mm (in)
82.0 - 82.048 2.5
Standard STD (0.0984)
(3.2283 - 3.2302)
0.25 mm
81.75 -81.798 2.625
A Note:
(0.0098 in)
undersize (3.2185 - 3.2204)
U-025 (0.1033)
The inside diameter of the new piston pin bushing 0.5mm
is adjusted so that it will be the standard value after 81.5 - 81.548 2.75
(0.0197 in) U-05
(3.2087 - 3.2106) (0.1083)
installation. Therefore reamer finish is unnecessary undersize
but make sure it is installed correctly with a cylin-
der gauge.
Standard: 48.025 - 48.040 mm
(1.8908 - 1.8913 in)

Printed in Japan
4-8.
EP
2. Piston & Connecting Rod [-4.]

[2-4.] Installation Fig. EP-18. Piston and piston rings

1. Coat the piston pin with engine oil. Insert it in
the piston and connecting rod, then install the
snap ring.

A Note:
• Assemble the piston and connecting rod so that
the large diameters of the valve recess on the pis-
ton head is the right side when the incised mark
on the connecting rod large end is on your side,
as shown in Fig. EP-17. (The large diameter side
is intake and is incised with an "S" mark, and the
small diameter side is exhaust and is incised with
an "E" mark.}
• Make sure the connecting rod rotates freely with-
out binding.

Fig. EP-19. Piston ring end gap position

Fig. EP-17. Assembling the piston and connecting rod
Small valve recess {Exhaust) Large valve recess (Intake)

3. Coat the cran kpins, upper cran kpin metals, pis-

tons and cylinder liners with engine oil. Insert
Mark
the piston/connecting rod assembly with a pis-
ton slider (126650-92140) from the top of the
cylinder.

2. Install the piston rings with a piston ring expand-

er (135410-92140).
A Note:
• Insert with the incised mark on the connecting
rod large end on the cylinder block side cover
A Note: side.
• Keep the ring in a horizontal direction (do not • Install the piston/connecting rod assemblies in
twist it} when expanding it. their original locations.
• End gap should not exceed eight times the ring
width.
• All rings should be installed with markings
facing up.
• Space the piston ring end gaps 120 degrees apart
as shown in Fig. EP-19.
Prinl<'d in Japan
4-9.
EP
2. Piston & Connecting Rod [-4.]

Fig. EP-20. Installing the piston/connecting rod assembly Fig. EP-22. Tightening the rod cap

Piston slider
I 126650·92140)

4. Coat the lower crankpin metals with engine oil,

and install the connecting rod cap, aligning the
marks. 6. Check the connecting rod side clearance.
Standard: 0.15 - 0.324 mm
A.Note: (0.0059 - 0.0128 in)
• Install the rod caps in their original locations. 7. Install the cylinder block side covers.

Fig. EP-21. Connecting rod and cap marks

A.Note:
Tighten the side cover bolts in two or more steps
and in a criss-cross pattern.

Fig. EP-23. Installing the cylinder block side cover

5. Coat the nut seat surfaces and the connecting rod

bolts with engine oil. Install the rod bolts on the
rod and tighten the nuts to torque 18.5 kg·m
(134 ft·lb).
8. Insert the oil dipstick (industrial engine only).
A Note: 9. Install the cylinder head(s) (see page 3· 12).
• Install the rod bolts and nuts in their original lo· 10. On industrial engine, install the fuel filter and
cations. fuel lines.
• Make sure that the bolt head is not on the shoul· 11. Fill the cooling system (fresh water) and lubrica·
der of the rod. ti on system (see pages 2· 7, 9 and 13).
• Replace all rod bolts every 10,000 operation 12. Check the cooling water system for leaks with a
hours or whenever disassembled three times. cap tester (see page 6-12).
13. On industrial engine, bleed air from the fuel
system (see page 2-4).
Printed in Japan
4·10.
EP
3. Cylinder Liner [-1./-2.]

3. Cylinder Liner Fig. EP-25. Measuring the cylinder liner bore

[J-1.] Description
Cylinder gauge
Because the cylinder liner is cooled to a constant
temperature by fresh water, wear from excessive
cooling during low load is prevented. The liner is
made of non-plated special cast iron which has high
resistance to wear and damage, and the outside is
entirely processed. It is machined to a uniform thick-
ness to prevent local heat expansion and to improve
durability. Two 0-rings (rubber packings) are install-
ed at the cylinder liner skirt to prevent the cylinder
liner from deformation and distortion, and also to
prevent the cooling water from leaking into the
crankcase. b.) Projection
Measure the projection amount from the cylinder
block surface to the cylinder liner flange.
[J-2.] Inspection Standard: 0.03-0.11 mm (0.0012-0.0043 in)
Remove the piston/connecting rod assembly (see An excessive amount of projection is due mainly to
page 4-4) and inspect as follows.IVS. rust on section A of the cylinder.

a.) Inside Diameter Fig. EP-26. Measuring the projection amount of the
Measure the cylinder liner inside diameter as shown clylinder liner
in Fig. EP-24 with a cylinder gauge.
Inside diameter:
Standard: 130.00 -130.03 mm (5.1181 -5.1193 in)
Service limit: 130.2 mm (5:1260 in)
Out-of-round:
Standard: 0.015 mm (0.0006 in) max.
Service limit: 0.1 mm (0.0039 in)

Fig. EP-24. Measuring points the cylinder liner bore

Cylinder liner

:s
!!! ·=
E
E "'ci
0 ~
~ E
E
0
~

------ ,'
Printed in Japan
4-11.
EP
3. Cylinder Liner [-3.]

[3-3.] Replacement Fig. EP-28. Installing the cylinder liner puller

When replacing the cylinder liner, cross reference
144626-92010
the cylinder liner and piston codes to determine
the replacement cylinder liner.
144626·92030

Cylinder liner l.D. Inside diameter

+O +a
s 130
+o.010 mm
5 181
·1 +0.0004 in
+o.010 mm +o.0004 in
MS 130 5 1181
+0.015 mm · +0.0006 in
+O.Q15 mm +o.0006 in
ML 130 5 1181
+0.020 mm · +0.0008 in
+0.020 mm _ +0.0008 in
L 130 5 1181
+0.030 mm +0.0012 In

o : Can be used
• : Cannot be used
12665().92020
Piston O.D. code
------"
"O
s MS ML L
0 2. Screw in the puller nut and remove the cylinder
u
----------
s 0 & & &
liner.
ci
-~
MS & 0 0 &

"c: ML & 0 0 & Fig. EP·29. Removing the cylinder liner

::::;
L & & & 0 Cylinder liner puller

Fig. EP-27. Code on the cylinder liner

Model
Yanmar mark

Manufacturing
\ date

Water pressure
test mark

1" Manufacturer's
code

b.) Installation
1. Remove the rust on the liner contact surface in
the cylinder block with sandpaper.

a.) Removal A Note:

1. Install the cylinder liner puller (144626-92010, Make sure that the liner can be inserted smoothly
144626-92030 and 126650-92020) as shown in without the cylinder liner rubber 0-rings.
Fig. EP-28. 2. Place new 0-rings in the groove of the liner.
Printed in Japan
4-12.
EP
3. Cylinder Liner [-3.] 4. Gear Train [-1.]

Fig. EP-32. Inserting the cylinder liner

A Note:
Be careful not to twist it.

Material Identification

CR55
Upper groove with lip in l.D.
(neo-prene rubber)
NBR70 blue dot mark
Lower groove
(nitrile rubber)

Fig. EP-30. Rubber 0-rings for the cylinder liner

4. Measure the liner projection (see page 4-11 ).

5. Inspect for out-of-round with a cylinder gauge.

4. Gear Train
[4-1.] Description
The gear train is arranged as shown in Figs. EP-33
and 34. Helical gears with tempered and ground
gear surfaces are used, which reduce noise as well
as improve durability.

Fig. EP-33. Gear train (industrial engine)

Camshaft gear
,,,;::;=R,....
3. Coat the liner rubber 0-rings with oil white
paint for rust prevention and lubrication.
Insert the liner in the cylinder block with both
hands.

Fig. EP·31. Appling oil white paint

L.0. pump drive gear

l'rintl'd in Japan
4-13.
EP
4. Gear Train [-1./-2.]

Fig. EP-34. Gear train (marine engine) Fig. EP-36. Removing the gear housing
Camshaft gear

F .0. injection pump

drive gear

Fresh water pump

drive gear

L.O. pump gear

7. Remove the injection pump drive gear by screw-

ing the puller bolts in the threaded holes in the
gear.
[4-2.] Removal
a.) Industrial engine A Note:
1. Drain the coolant (see page 6-4). When removing only the drive gear, put an align-
2. Drain the lubricating oil. ment mark on the drive gear and idle gear to insure
3. Remove the alternator (see page 9·7). getting original alignment.
4. Remove the radiator and cooling water pump 8. Bend up the lock washer and remove the cam
(see page 6-5). gear nut. Remove the cam gear with a cam gear
5. Remove the crankshaft V-pulley and damper puller (126650-92650, 145610-92900, and
(except for 4HAL). 126650-92660).

Fig. EP-35. Removing the crankshaft V-pulley A Note:

When removing only the cam gear, put an align-
•ment mark on the cam gear and idle gear to insure
original alignment.
Fig. EP-37. Removing the cam gear
126650-92650

6. Remove the gear housing by screwing puller

bolts in the threaded holes in the gear housing.
Printed in Japan
4-14.
EP
4. Gear Train [-2.l-3.l

9. Bend up the lock washer and remove the bolt. fig. EP·39. Removing the gear housing cover
Remove the timing idle gear.

A Note:
Be careful not to lose the straight pin.
10. Remove the lock wire and remove the timing idle
gear base.
11. Bend up the lock washer and remove the bolt.
Remove the oil pump idle gear and base.

A Note:
Be careful not to lose the straight pins.

b.) Marine engine

1. Drain the coolant (see page 6-9).
2. Drain the engine oil (see page 2-6). Gear housing

3. Remove the alternator (see page 9-8.)

4. Remove the fresh water cooler, fresh water pump
10. Remove the automatic timer cap and cap nut.
and sea water pump (see page 6-7, 9).
5. Remove the si Iicon damper cover.
6. Remove the silicon damper. A Note:
Prepare an oil pan since the engine oil will leak out
7. Remove the oil seal housing by screwing the case
when the cap is removed.
mounting bolts in the threaded holes in the oil
11. Remove the automatic timer with an automatic
seal housing.
timer puller (126630·92770).
A Note: A Note:
The bearing outer race can be removed at the same
time. When removing the automatic timer only, put an
alignment mark on the timer gear and idle gear.
Fig. EP-38. Removing the oil seal housing 12. Follow the steps 8 to 11 of the industrial engine.
Oil seal housing

[4-3.] Inspection
a.) Gears
1. Check each gear for excessive or abnormal wear.
Replace if necessary.

Housing mounting bolts

8. Remove the alternator drive V-pulley together

with the drive gear.
9. Remove the gear housing cover by screwing puller
bolts in the thread holes in the cover.
Prinled in Japan
4· 15.
EP
4. Gear Train [-3./-4.]

2. Inspect each gear for backlash. If it exceeds the Fig. EP.111. Measuring the idle gear l.D.
service limit, replace the engaged gears as a set.
Standard: 0.12 -0.20 mm (0.0047 -0.0079 in)
Service limit: 0.35 mm (0.0138 in)

Fig. EP-40. Measuring the backlash

A caution: c.) Idle gear side clearance

Unsuitable backlash will cause abnormal noise, ex· Measure the idle gear side clearance. If it exceeds
cessive wear or damage at the tooth. Moreover, the the service limit, replace the idle gear or base.
valve and fuel injection timings will be incorrect Idle gear:
and the engine will not run smoothly. Standard: 0.15 - 0.30 mm (0.0059 - 0.0118 in)
Service limit: 0.4 mm (0.016 in)
A Note: Oil pump idle gear:
• When replacing the oil pump drive gear on the Standard: 0.10 -0.20 mm (0.0039 -0.0079 in)
industrial engine, remove the oil pan. Service limit: 0.4 mm (0.016 in)
• When crankshaft gear replacement is necessary,
replace it with the crankshaft assembly.

b.) Idle gear oil clearance

[ 4-4.] Installation
Measure the inside diameter of the idle gear bushing
a.) Industrial engine
and the outside diameter of the base shaft, and cal·
culate the oil clearance. If it exceeds the service 1. Coat the shaft on the oil pump idle gear base
limit, replace the idle gear or the base. with engine oil. Install the idle gear on the shaft.
Timing idle gear: Tighten the metal cap to torque 6 kg-m (43 ft-
• Shaft 0.0.: lb).
Standard: • 41.95 -41.97 mm (1.6516 -1.6524 in)
• Bushing 1.0.: A Note:
Standard: 42.00 - 42.025 mm (1.6535 -1.6545in) • Do not forget to attach the straight pins.
• Oil clearance: • Securely bend the lock washer against the bolt
Standard: 0.03 - 0.075 mm (0.0012 -0.0030 in) head.
Service limit: 0.15 mm (0.0059 in) • Check the backlash and side clearance.
Oil pump idle gear:
Backlash: 0.12 - 0.20 mm (0.0047 - 0.0079 in)
• Shaft 0. 0.: Side clearance: 0.10 - 0.20 mm (0.0039 - 0.0079 in)
Standard: 29.959 - 29.98 mm (1.1795 -1.1803 in)
2. Install the timing idle gear base with its oil hole
• Bushing 1.0.:
Standard: 30.00 -30.021 mm (1.1811-1.1819 in) facing up.
• Oil clearance:
Standard: 0.020 - 0.0062 mm (0.0008-0.0024 in) A Note:
Service limit: 0.15 mm (0.0059 in) Secure the bolts with new lock wires.
Printed in Japan
4-16.
EP
4. Gear Train [-4.]

Fig. EP-42. Installing the timing idle gear base aligning the timing marks "O" on the pump
drive gear and idle gear with the timing marks on
the idle and crankshaft gears aligned, and torque
the nut to 8 kg-m (58 ft-lb).

A Note:
Check the backlash:
t g Align 3 8 - Backlash: 0.12 -0.20 mm (0.0047-0.0079 in)

• 7. Use a new gasket and install the gear housing.

~g a
~ A Note:
• Be careful not to turn over the oil pan gasket.
g 3 • Coat the coupling with lithium grease.
• Coat the three face mating surface with liquid
I\ sealant.
Fig. EP-44. Installing the gear housing
3. Coat the idle gear shaft with engine oil and in-
stall the idle gear while aligning the timing marks
"O" on the idle and crankshaft gears.
Fig. EP-43. Timing marks

8. Install the crankshaft V-pulley and damper (ex-

4. Torque the bolt to 12 kg-m (87 ft-lb). Check the cept for 4HALE).
idle gear for backlash and side clearance.
Backlash: 0.12 -0.20 mm (0.0047 -0.0079 in) Fig. EP-45. Installing the crankshaft V-pulley
Side clearance: 0.15 - 0.30 mm (0.0059 - 0.0118 in)
5. Install the cam gear while aligning the timing
marks "O" on the cam gear and idle gear with
the timing marks on the idle and crankshaft
gears aligned, and torque the nut to 20 kg-m
(145 ft-lb).

A Note:
Check the backlash and side clearance.
Backlash: 0.12 -0.20 mm (0.0047 - 0.0079 in)
Side clearance: 0.1 - 0.35 mm (0.0039 - 0.0138 in)

6. Install the injection pump drive gear while

Printed in Japan
4-17.
 EP
4. Gear Train [-4.] 5. Camshaft and Valve Train [-1./-2.]

9. Install the cooling water pump and radiator (see 5. Camshaft and Valve Train
page 6-6).
10. Install the alternator. [5-t] Description
11. Fill the cooling system and lubrication system.
12. Perform the water leakage test (see page 6-12). The camshaft is made of normalized steel and the
cam lobes and journals are surface-tempered and
b.) Marine engine ground. The cams are the polynomial type with a
buffering curve which lessens the cyclical shock on
Procedures 1 to 5 are the same as those for the in- the valve seats and improves their durability.
dustrial engine. seats.
6. Install the automatic timer and torque the nut
to 14 kg-m (101 ft-lb).
[5-2.] Removal
A Note:
1. On the industrial engine, remove the gear housing
Align the timing marks on the timer and idle gear
(see Fig. EP-43). and cam gear (see page 4-14). On the marine
7. Install the automatic timer cap. Position the oil engine, remove the gear housing cover and cam
filler opening of the timer up and pour in engine gear (see page 4-15).
oil up to the opening.
8- Use a new gasket and install the gear housing
A Note:
cover. Before removing the cam gear, put an alignment
9. Install the alternator drive V-pulley. mark to the cam gear and idle gear.
10. Install the oil seal case, oil seal and outer race as 2. Remove the cylinder head (see page 3-3).
an assembly. 3. Remove the tappets.

A Note: A Nate:

Coat the oil seal lip, crankshaft and outer race with Mark all tappets to insure getting original assembly.
engine oil.
Fig. EP-47. Removing the tappets.
Fig. EP-46. Installing the oil seal case assembly

~o C)
~-lli~
11. Install the silicon damper and torque bolts to 20
kg-m (145 ft-lb). 4. Remove the camshaft thrust metal.
12. Install the damper cover. 5. Remove the camshaft.
13. Install the sea water pump, fresh water pump and
fresh water cooler. A Note:
14. Install the alternator. • Before removing the camshaft, make sure that
15. Fill the cooling system and oil pan. all tappets are removed.
16. Perform the water leakage test on the fresh water • Be careful not to damage the camshaft metals
system (see page 6-12). and camshaft.
Printed in Japan
4-18.
EP
5. Camshaft and Valve Train [-2./-3.]

Fig. EP48. Removing the camshaft c.) Camshaft journal and metal
Measure the camshaft journal diameters and metal
inside diameters and calculate the oil clearance. If
it is worn beyond the service limit, replace the met-
als and/or camshaft.
Camshaft journal outside diameter:
Standard: 62.94 - 62.97 mm (2.4780 - 2.4791 in)
Service limit: 62.8 mm (2.472 in)
Metal inside diameter:
Standard: 63.02 -63.05 mm (2.4811 - 2.4823 in)
Service limit: 63.15 mm (2.4862 in)
Oil clearance:
[5-3.] Inspection Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
a.) Camshaft inspection Service limit: 0.23 mm (0.0091 in)
Check the camshaft for damage and bend, and re-
pair or replace it if necessary. Support both ends of
the camshaft with V-blocks and measure the runout d.) Camshaft side clearance
with a dial indicator by rotating the shaft one turn
Install the camshaft gear, torque the nut to20 kg-m
and reading 1/2 of the maximum runout of the in-
(145 ft-lb) and measure the side clearance. If the
dicated difference of the gauge.
value exceeds the service limit, replace the thrust
Service limit: 0.15 mm (0.0059 in)
metal at the gear end.
Fig. EP49. Measuring the camshaft bend Standard: 0.10 - 0.35 mm (0.0039 - 0.0138 in)
Service limit: 0.42 mm (0.0165 in)

Fig. EP-51. Camshaft side clearance

Gear end thrust metal
'

b.) Cam height

Measure each cam height with a micrometer, and
if it is worn beyond the service limit, replace the
camshaft.
Standard: 53.87 -53.95 mm (2.1208 - 2.1240 in)
6HA-HTE: 53.96-54.04mm (2.1244-2.1276 in)
Service limit: 53.4 mm (2.102 in)
6HA-HTE: 53.5 mm (2.106 in) Fig. EP-52. Measuring camshaft side clearance

Fig. EP·50. Cam height

..-----....._

Cam height

Printed in Japan
4-19.
EP
5. Camshaft and Valve Train [-3./-4.] 6. Crankshaft [-1.]

Replacement thrust metal Fig. EP-54. Measuring the tappet 0.0.

Clas'Sification Size code Thickness
Standard STD 8.0 mm (0.3150 in)
0.25 mm (0.0098 in)
0025 8.25 mm (0.3248 in)
oversize
0.5 mm (0.0197 .in)
005 8.5 mm (0.3347 in)
oversize

e.) Tappet inspection

As shown in Fig. EP-53, the tappets are off-set, ro-
tate during operation and prevent local wear. Inspect g.) Push rod inspection
the amount of contact. If there is excessive local Measure each push rod bend, and replace it if the
wear or uneven contact, replace the tappet and re- value exceeds the service limit.
pair the cam. Standard: 0.03 mm (0.0012 in) max.
Service limit: 0.3 mm (0.012 in)
A Note:
If the tappet friction surface with cam is damaged,
inspect the camshaft too.
[5-4.] Installation
Fig. EP-53. Camshaft and tappet 1. Insert the camshaft.
Tappets 2. Install the camshaft thrust metal.
3. Coat the tappets with engine oil and insert them
into the cylinder block guide holes.

A Note:
• Install each tappet in original location.
• Make sure the tappets move freely without bind-
ing.
Camshaft 4. Install the cylinder head (see page 3-12).
5. Install the cam gear. On the industrial engine, in-
stall the gear housing and related parts. On the
marine engine, install the gear housing cover and
related parts. (Industrial engine: see page 4-17,
Marine engine: see page 4-18).

f.) Tappet oil clearance

Measure the outside diameter of the tappet and the 6. Crankshaft
inside diameter of the tappet guide hole in the cyl-
inder block and calculate the oil clearance. If it is [6-t] Description
not within the service limit, replace the tappet and/
or cylinder block. The crankshaft is a special steel-stamped forging
with balance weights and is designed to minimize
Tappet outside diameter:
Standard: 35.950 -35.975 mm (1.4154 - 1.4163 in)
vibration by improving balance. The crankpins
Service limit: 35.9 mm (1.4134 in) and journals are induction-hardened for minimum
Tappet guide hole inside diameter: wear. The crankpin and main journal bearings are
Standard: 36.00 -36.025 mm (1.4173 -1.4183 in) made of special metal to improve durability. The
Service limit: 36.06 mm (1.4197 in) front and rear seal contact surfaces are perfectly
Oil clearance: finished for the oil seal. Also, special seals are used
Standard: 0.025 - 0.075 mm (0.0010 - 0.0030 in) which improve durability against wear of the shaft
Service limit: 0.12 mm (0.0047 in) and seal, and prevent oil leakage.
Printed in Japan
4-20
EP
6. Crankshaft [-2.]

[6-2.] Removal 10. Remove the flywheel with a Flywheel Hanger

(144626-92850).
a.) Industrial engine
1. Remove the starter motor (see page 9-18).
2. Remove the oil filter and oil cooler (see page
A Note:
Flywheel weight: approx. 70 kg (154 lb)
5-5).
3. Remove the piston/connecting rod assemblies Fig. EP-57. Removing the flywheel
(see page 4-4 ). Flywheel hanger
I 144626-928501
4. Remove the gear housing, cam gear, injection
pump drive gear and timing idle gear (see page
4-14).
5. Remove the injection pump (see page 7-10).
6. Remove the camshaft (see page 4-18).
7. Remove the gear housing flange.

Fig. EP-55. Removing the gear housing flange

..
·IA . =· ... 11. Remove the bolts securing the rear oil seal housing

·~ ~ 0
and remove the oil seal housing by screwing
' draw bolts in the threaded holes .
• 12. Turn the cylinder block upside down.
• •

A Note:
Turning over weight:
4-cylinder: approx. 190 kg (419 lb)
6-cylinder: approx. 240 kg (529 lb)
13. Remove the oil pan bolts and remove the oil pan
by screwing draw bolts in the threaded holes
in the oil pan.
8. Remove the flywheel tightening bolt lock wire.
9. Remove the flywheel straight pins with a Fly- Fig. EP-58. Removing the oil pan
wheel Straight Pin Puller ( 126650-92670 and Oil n
126650-92680).

Fig. EP-56. Removing the flywheel straight pin

Puller bolt
(126650-92680)

Puller
(126650-92670)·
14. Remove the lubricating oil inlet and outlet pas-
sages.
Flywheel 15. Remove the oil pump.
Printed in Japan
4-21.
 EP
6. Crankshaft (-2./-3.]

16. Remove the flywheel housing. 5. Remove the gear housing cover, cam gear, auto-
matic timer and timing idle gear (see page 4-_15).
A Note: 6. Remove the injection pump (see page 7-11 ).
Flywheel housing weight: approx. 40 kg (88 lb) 7. Remove the camshaft (see page 4-18).
8. Remove the gear housing.
Fig. EP-59. Removing the flywheel housing
Fig. EP-61. Removing the gear housing

( '\

9. Remove the marine gear.

17. Remove the main journal metal caps. 10. Remove the flexible coupling at the engine side.
11. Follow the removal procedures 8 to 19 for the
A Note: industrial engine.
Mark each cap to insure getting original assembly.
18. Remove the thrust metals.
[6-3.] Inspection
19. Remove the crankshaft by using a hoist or chain c.) Crankshaft color check
block.
After washing the crankshaft, inspect it with a color
A Note: check or magnetic crank detector. If there are cracks
or excessive wear, replace it. If the damage is light,
Crankshaft weight:
4-cylinder: approx. 80 kg (176 lb) re-grind it.
6-cylinder: approx. 135 kg (297 lb)
Fig. EP-62. Color-checking the crankshaft
Fig. EP-60. Removing the metal

b.) Crankshaft bend

b.) Marine engine
Support both ends of the crankshaft on V-blocks.
1. Remove the starter motor (see page 9-18). Rotate the crankshaft, measure the central journal
2. Remove the oil filter and oil cooler (see page runout with a dial indicator, and calculate the bend
5-5). (1/2 of the runout). If it exceeds the service limit,
3. Remove the piston/connecting rod assemblies replace the crankshaft.
(see page 4-4}. Standard: 0.015 mm (0.0006 in)
4. Remove the exhaust manifold. Service limit: 0.15 mm (0.006 in)
Printed in Japan
4-22.
EP
6. Crankshaft [-3.]

Fig. EP-63. Measuring the crankshaft bend Fig. EP-65. Measuring points of O.D.

Out-of-round
A Note:
When the crankshaft is re-ground, use undersize
crankpin metals and main metals and adjust the oil
clearance to the standard value.

d.) Main metal

c.) Crankpin and journal Inspect all metals for melting, scratches, score or
Inspect each crankpin and journal for wear, out-of- wear. Replace the metals, if any defect is found.
round and oil clearance. If the out-of-round exceeds
e.) Main metal oil clearance
the service limit but the outside diameter is within
the service limit, regrind the crankshaft. If the out- Measure the inside diameter of the main metal and
side diameter exceeds the service limit, replace the the outside diameter of the main journal, and cal-
crankshaft. culate the oil clearance. If it exceeds the service
limit, replace the main metal with an appropriate
A Note: undersize metal.
Standard: 0.050 - 0.118 mm (0.0020 - 0.0047 in)
For out-of-round condition, measure A and B of
crankpin and journal and calculate difference (see Service limit: 0.14 mm (0.0055 in)
Fig. EP-65).
Fig. EP-66. Measuring the main metal l.D.
Crankpin
• Outside diameter
Standard: 81.94 - 81.96 mm (3.2260 - 3.2268 in)
Service limit: 81.37 mm (3.2035 in)
• Out-of-round
Service limit: 0.015 mm (0.0006 in)
• Oil clearance
Standard: 0.040 - 0.108 mm (0.0016 - 0.0043 in)
Service limit: 0.13 mm (0.0051 in) Replacement main metal
Journal
• Outside diameter Classifi- Inside diameter Size code
Thickness
Standard: 99.94 - 99.96 mm (3.9346 - 3.9354 in) cation mm (in) mm (in)
Service limit: 99.37 mm (3.9124 in) Standard 100.010 - 100.058 STD 3.0
• Out-of-round (3.9374 - 3.9393) (0.1181)
Service limit: 0.015 mm (0.0006 in) 0.25 mm 3.125
(0.0098 in) 99.760 - 99.808 U-025
• Oil clearance (3.9275 - 3.9294) (0.1230)
undersize
Standard: 0.050 - 0.118 mm (0.0020 -0.0047 in)
Service limit: 0.14 mm (0.0055 in) 0.5mm 3.25
99.510 - 99.558 U·05
(0.0197 in) (3.9177 - 3.9196) (0.1279)
undersize
Fig. EP-64. Measuring the O.D. and out-of-round
Fig. EP-67. Main metal

Printed in Japan
4-23.
EP
6. Crankshaft [-3.]

f.) Crankshaft side clearance 2. Using a flat plate, and install a new oil seal, being
Move the crankshaft to one side, install a dial indi- careful not to tilt it.
cator on the end surface of the crankshaft and meas-
ure the side clearance. The side clearance can also A Note:
be gained by directly measuring the thrust surface • Make sure that there are no score in the oil seal
clearance between the thrust metal and crankshaft housing bore. Note the installation direction.
with a feeler gauge. If the value exceeds the service
g. EP-70. Oil seal installation direction
limit, replace the thrust metals with appropriate ones.
Front (Gear side) oil seal Rear (Flywheel side) oil seal
Standard: 0.07 -0.219 mm (0.0028 - 0.0086 in)
Service limit: 0.33 mm (0.013 in)
Fresh water
Fig. EP-68. Measuring the crankshaft side clearance tank or radiator Engine side Flywheel side
side

Right hand
thread

• Install the oil seal using a press. However, if a

press is not available, place the oil seal horizon-
tally on the case bore and a block as shown in
Fig. EP-71. Then drive in the entire outer periph·
ery evenly and install the oil seal, being careful
not to tilt it.
EP-71. Installing the oil seal
Replacement thrust metal
Classification Size code Thickness

Standard STD 3.0 mm (0.1181 in)

0.25 mm (0.0098 in)

0025 3.125 mm (0.1230 in)
oversize
0.5 mm (0.0197 in)

1r .
005 3.25 mm (0.1279 in)
oversize

Fig. EP-69. Thrust metal

-0.05 mm (0.0020 in)
Th,ckness -0.10 mm 10.0039 in)
• Coat the outer periphery of the oil seal lightly
with oil to prevent the rubber from damage.
• Silicon rubber is used for the oil seal on the fly-
wheel side, so avoid touching it with gasoline or
solvents. When installing the oil seal, coat the
seal lip with lithium grease. Do not use silicon
grease.
• Because a spiral oil seal is used on the gear side,
coat the seal lip with engine oil. Do not coat it
Oil grooves
with grease since the spiral will be clogged and
viscous pump action will be lost, causing oil
leakage.
g.) Crankshaft oil seal replacement
• Use engine oil to clean the oil seal. Do not use
1. Drive the oil seal out. gasoline or solvents.
Prin/('d in Japan
4-24.
EP
6. Crankshaft [-4.]

[6-4.] Installation 4. Coat the threads and seat surface of the metal cap
bolts with engine oil. Torque the bolts to 35
a.) Industrial engine
kg-m (253 ft-lb).
1. Install the main metal (upper metal) and thrust
metal on the cylinder block. A Note:
Install the bolts in their original location.
A Note: 5. After tightening the metal caps, make sure that
• Turn the cylinder block upside down. the crankshaft rotates freely. Also check the side
• The upper main metal has an oil groove. Also, clearance.
align the oil holes when installing the upper Side clearance: 0.007 - 0.219 mm (0.0028 - 0.0086 in)
main metal. 6. Instal I the oil pump.
• Install the main metal in its original position.
• Install the thrust metal with the oil groove facing
outwards (thrust surface of the crankshaft).
A Note:
Get the end surface of the pump drive gear and the
end surface of the idle gear flush, and loosely tighten
Fig. EP-72. Installing the main metal
the bolts. After rotating the crankshaft and making
the teeth contact horizontal, tighten the pump bolts.

Fig. EP-74. Installing the oil pump

2. Coat the crankshaft journals with engine oil and

install the crankshaft.
3. Instal I the lower main metals on the metal caps
and install the metal caps on the cylinder block. 7. Check the oil pump drive gear for backlash.
Backlash: 0.12 - 0.20 mm (0.0047 - 0.0079 in)
Install the thrust metal at the flywheel side cap.
8. Use new gaskets and install the engine oil inlet
A Note: and outlet passages.
9. Use a new gasket, align the knock hole with the
• Position the "F" mark on the metal cap on the
knock pin and instal I the flywheel housing.
flywheel side.
• Be sure all parts are installed in their original posi- A Note:
tions. • Coat the three faced matching corner with liquid
• Coat each metal with engine oil before installa- sealant.
tion. • Make sure that the housing and cylinder block
surfaces are flush.
Fig. EP-73. Installing the metal cap
Fig. EP-75. Installing the flywheel housing

Flywheel side

"F" Marks

Printed in Japan
4-25.
 EP
6. Crankshaft [-4.]

10. Use a new gasket and install the oil pan. 13. Using the Flywheel Hanger (144626-92850).
install the flywheel.
A Note:
Tighten after aligning it to the matching surface of Fig. EP-78. Installing the flywheel
the cylinder block (Marine engine only).

Fig. EP-76. Installing the oil pan

Oil pan

[f

14. Coat the straight pin with engine oil and drive it
in the crankshaft hole until it stops.
15. Torque the flywheel attaching bolts to 20 kg-m
11. Turn the cylinder block to its upright position. (145 ft-lb). Secure the boltswithanewlockwire.
12. Install the rear oil seal housing assembly.
A Note:
A Note: Install the lock wire in the direction which will not
loosen the bolts, as shown in Fig. EP-79.
• Place the engine oil supply cut-away upward
inside the housing.
Fig. EP-79. Installing the lock wire
• Fill the oil seal lip gap and crankshaft with lithi-
um grease. Do not use silicon grease.
• Be careful not to damage the seal lip.

Fig. EP-77. Installing the rear oil seal housing assembly

···-::·.·.. .
.··. ·: .· . ·.:: . ,.

16. Use a new gasket, align the knock hole with the
knock pin and install the gear housing flange.

A Note:
• Cut off the projecting portion of the flange gasket.
• Coat the three faced matching corner with liquid
sealant.

Printed in Japan
4-26.
 EP
6. Crankshaft [-4.] 7. Cylinder Block [-1./-2.]

Fig. EP-80. Installing the gear case flange 18. Instal I the camshaft and thrust metal, and insert
the tappets.
19. Install the piston/connecting rod assemblies, and
then install the cylinder heads (see page 4-9).
20. Install the injection pump (see page 7-31).
21. Install the timing idle gear, automatic timer and
cam gear. Install the gear housing cover and its
related parts (see page 4-18).

7. Cylinder Block
[7-1.] Description
17. Install the camshaft and thrust metal, and insert
The cylinder block is constructed with minimum
the tappets. thickness to reduce its weight. It is a deep skirt
18. Instal I the piston/connecting rod assemblies and type, special ribs are employed in the inside and
the cylinder head(s) (see page 4-9).
the side wal Is are undulating. These features increase
19. Install the injection pump (see page 7-30). the strength and rigidity as well as reduce noise.
20. Install the timing idle gear, injection pump drive
gear and cam gear. Then install the gear housing Fig. EP-82. Cylinder block
and its related parts (see page 4-16).

b.) Marine engine

Follow the steps 1 thru 15 of the industrial engine
installation procedure.
16. Install the flexible coupling. Then install the re-
duction reverse gear.
17. Use a new gasket and instal I the gear housing.

A Note:
• Cut off the projecting portion of the gasket.
• Coat the three faced matching corner with liquid
sealant.

Fig. EP-81. Installing the gear housing

Gear housing

[7-2.] Inspection
a.) Visual inspection
If the engine has been frozen or dropped, visually
inspect it for cracks and damage, make a color
check and repair if necessary.
Printed in Japan
4-27.
EP
6. Crankshaft [-2./-3.]

A Note:
A color check uses an aerosol-type crack detecting
liquid. It can detect cracks not visual in various
metals. Read the manufacturer's instruction before
using it.

b.) Cylinder block warpage

Measure the cylinder head attaching surface for
warpage with a straight edge and feeler gauge. If it
exceeds the service limit, reface or replace the cylin-
der block.
Service limit: 0.15 mm (0.0059 in)

A Note:
Use a surface grinder after removing the cylinder
liners and knock pins to reface the cylinder block.

c.) Gasket surface

Inspect the gasket and 0-ring attaching surfaces for
scoring or damage.

[7-3.] Oil passage cleaning

When replacing the cylinder block, overhauling or
reassemblying the engine, clean all oil passages
thoroughly and make sure that they are not clogged.

A Note:
• Completely remove the gasket materials from the
gasket surfaces and make sure that it does not go
into the 01'l passage.
• Do not remove the blind plug from the cylinder
block.

Printed in Japan
4-28.
Sec. 5. LUBRICATION SYSTEM (LS)

Contents of this section

Page
1. Service Information ................................. 5-1
[1-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
[1·2.] Tools and Materials.............................. 5-3
[ 1-3.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5·3

2. Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

[2-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
[2·2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
[2-3.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

3. Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

[3-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5·5
[3-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

4. Oil Coller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

[4-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
[ 4-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
[4-3.] Inspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
[4-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . ___ ... . . . 5-7

5. Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

[5-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
[5-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
[5-3.] Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
LS
1. Service Information [-1.]

5. Lubrication System
1. Service Information
[1-1.] Description
The pressure lubrication of the engine is accom- is sent from the cylinder head to lubricate the rocker
plished by a gear type oil pump. arm shaft and intermittently lubricates the valve
stem from the rocker arm. A part of the oil from
Oil in the oil pan is drawn up by the oil pump
the oil gallery is sent through the injection pump
through the strainer and transported by pressure.
to lubricate the pump camshaft.
Then the oil is thoroughly strained by the oil filter
and cooled by the oil cooler. Next it is adjusted Pistons of the 4HAL, 6HAL and 6HA(M)E
to the prescribed pressure by the oil pressure regu- engines are cooled by the oil from the jet
lator valve and is sent to the oil gallery from which at the connecting rod small end. The 6HAL-T, and
if flows in two paths. Oil in the first path is sent 6HA-HTE engines are equipped with a fixed jet, by
to the main metal to lubricate it, and is then sent which the back side of the pistons is cooled.
through the oil hole in the crankshaft to lubricate
the crankpin metal. Next, it is sent to the connect- Furthermore, a pressure sender unit is provided in
ing rod small end through the hole drilled in the the system, so that normal pressure can be confirm-
connecting rod to lubricate the piston pin metal. ed by the pressure gauge on the instrument panel.
Oil on the other path lubricates the camshaft metal,

Fig. LS-1. Engine lubrication system (Industrial engine)

4, 6HAL
I

r Rocker arm shaft ..

-·
Fixed jet
(6 HA L -T, f..Ll""'=".,J
Fuel injection pump

Oi I gallery I
•
6HAL-
HT only
I

Oil cooler

Oil pressure
regulator valve
L.O.
filter

Lubricating oil

Printrd in Japan
5-1.
Fig. LS-2. Engine lubrication system (Marine engine)

6HA(M)E

Oil pressure switch

Turbocharger
(6HA1Ml-HTE only)

Camshaft

Fuel injection pump

'------~~:_____::::'.''.__~Q~;~;~('~'~(6~H~A~l~M~(-=::_.J=:".:::;;~~~2Jl[t;~=lt1: Timing gear

HTE only)
Filter clogg1ng
warning switch
(By pass valve)
(1.5 kg/cm 1 ) r
Turbochargerf~ lfi4c::~1
oil filter
Lube oil pump
(6HA(M)·
HTE only)

Oil pressure
regulator valve
(4.5-5.0 kg/cm 1 l
Oil safety
valve !10 kg/cm 1 )

Qi! pan

Printed in Japan
5-2.
LS
1. Service Information [-2./-3.]

[1-2.] Tools and Materials

Feeler gauge
Dial indicator
Straight edge
Liquid sealant

[1-3.] Specifications
a.} Torque value

Th read diameter x pitch Width across flats Torque values

Item Remarks
(mm) (mm) kg·m ft·lb

Oil pump drive gear M22 x 1.5 32 17.5 127 See page 5-4

b.) Specifications

Item Specifications
Industrial engine
Model Marine engine
4HAL l6HAL. 6HAL·T, HT
Engine speed rpm 1800
Pump speed rpm 1430
Oil pump Delivery Q/h (U.S. gal/h, Imp. gal/h) 3100 (019. 682'1, i I 5670 (1498, 1248}1)
Oil temperature oC (oF) 80(176)
Delivery pressure kg/cm 2 (psi) 5 (71)
2
Safety valve opening pressure kg/cm (psi) 10 (142)
Type Paper filter type full flow
Filtering area cm 2 (in 2 ) 5200 (806) 5200 (806) x 2
U.S. gal/min,
Rated volume of flow £/min 105 127%, 21 '/,) 105 (27%, 21-1/8) x 2
Imp. gal/min
Oil filter

Bypass valve opening pressure kg/cm 2 (psi) 1.5 ± 0.3 (21 ± 4)

Oil capacity Q(U.S.gal.lmp.gal) Full 19.5 (5'/,. 414) I 29 (7'1,. 6'1,) 38 ( 10, 8'/, )

c.} Service data

Item Standard Service limit

Oil pump gear-to-body clearance mm (in) 0.06 -0.12 (0.0024 - 0.0047) 0.17 (0.0067)

Oil pump gear-to-cover clearance mm (in) 0.06 - 0.12 (0.0024 - 0.0047) 0.17 (0.0067)

Industrial engine 3.5 -4.5 (50 - 64)

Regulator valve pressure (at 1800 rpm) kg/cm 2 (psi)
Marine engine 4.0 - 4.5 (57 - 64)

Printed in Japan
5-3.
LS
2. Oil Pump [-1./-2./....J.]

2. Oil Pump Fig. LS-3. Measuring the oil pump gear-to-pump cover
clearance
[2-1.] Removal Straight edge

1. Drain the engine oil.

2. For the marine engine, install the gear housing
cover (see page 4-14).
3. Remove the oil pan by screwing draw bolts in the
thread holes in the oil pan.
4. Remove the oil pump drive gear.
5. Remove the oil inlet and outlet pipes.
6. Remove the oil pump.

[2-2.] Inspection Feeler gauge

Remove the oil pump cover and measure the oil

pump gear-to-oil pump body and the gear-to-cover
clearances. If the measured value exceeds the serv- A Note:
ice limit or if there is local wear, replace the oil • The oil pump should be disassembled only when
pump assembly. oil pressure does not rise sufficiently even after
Gear-to--pump clearance
adjusting with the pressure regulator valve.
Standard: 0.06 - 0.12 mm (0.0024 - 0.0047 inl • When assemblying, make sure that the drive shaft
Service limit: 0.17 mm (0.0067 in) (gear) rotates smoothly.
Gear-to-cover clearance
Standard: 0.06 - 0.12 mm (0.0024 - 0.0047 in)
Service limit: 0.17 mm (0.0067 in) [2-3.] Installation
Fig. LS-2. Measuring the oil pump gear-to-pump body 1. Install the oil pump drive gear on the oil pump.
clearance 2. Use a new gasket and install the oil pump on the
cylinder block.

A Note:
• Get the surface of the oil pump drive year and
the surface of the idle gear flush and tighten
temporarily. Rotate the crankshaft so that the
engagement of the teeth is parallel. Then tighten
the pump bolts.

• Check the backlash of the drive gear.

Backlash: 0.12 - 0.20 mm (0.0047 - 0.0079 in)

3. Torque the oil pump drive gear to 17.5 kg-m ( 127

ft-lb).
4. Use new gaskets and attach the oil inlet and out-
let pipes.
5. Use a new gasket and install the oil pan.

A Note:
• Coat the three faced matching corner with liquid
sealant.
• Tighten after securely matching with the surface
of the cylinder block.

Printed in Japan
5-4.
LS
2. Oil Pump [-3.] 3. Oil Filter [-1./-2.] 4. Oil Cooler [-1.]

4. For the marine engine, remove the gear housing 4. Oil Cooler
cover (see page 4-17).
5. Install all drain plugs and pour in the recommend· [ 4-1.] Description
ed oil up to the upper level.
A multi-plate type oil cooler is used for the indus-
trial engine. It cools the lubricating oil inside the
plate by passing cooling water outside it, which
3. Oil Filter prevents oil temperature from increasing and length-
ens the life of the lubricating oil.
[3-1.] Description
Filter paper with superior filtering capacity is used
for the oil filter. Lubricating oil is passed into the
outer periphery of the element, is filtered and sent Fig. LS-5. Construction of the oil cooler on the industrial
to the oil cooler from the central section. engine
Should case the filter element be clogged, the oil
filter proper is equipped with a bypass valve to pre·
vent lubricating oil shortage in the lubrication sys-
tem.
A double filter is used for marine engines, and it is
designed so that a warning lamp lights when the fil-
ter is clogged during operation.

Fig. LS-4. Construction of oil filter

0
-,
-- I ~Cooling water
-~ I Lubrication oil

I~+---__,
ir 00
0
A tubular type oil cooler is used for the marine en-
1-'-----"'ll oo
Filter
element
gine, which cools the lubricating oil outside the
tubes with sea water preventing oil temperature
I from increasing.

Fig. LS-6. Construction of the oil cooler on the marine

engine

Drain plug

[3-2J Inspection ~Cooling water

Check that the bypass valve operates smoothly. C Lubrication oil

Printed in Japan
5-5.
LS
4. Oil Cooler [-2./-3.]

[ 4-2.] Removal [ 4-3.] Inspection

a.) Industrial engine a.) Industrial engine
1. Loosen the drain plug on the oil filter and drain 1. Inspect the interior and plates of the oil cooler,
the lubricating oil. and if there are scales or rust, remove them (see
2. Drain the cooling water (see page 6-4). page 6·14).
3. Remove the oil filter.
4. Remove the cooling water passages. Fig. LS-9. Oil cooler (industrial engine)
5. For engines with a turbocharger, remove the
turbocharger oil pipe.
6. Remove the oil cooler.

A Note:
If the gasket is stuck and it is difficult to remove
the oil cooler, do not tap it but slightly pry the 2. Check that the bypass valve operates smoothly.
pressure regulator valve portion.
b.) Marine engine
Fig. LS-7. Removing the oil cooler (industrial engine)
1. Remove the oil cooler side covers and pull out
the oil cooler pipe assembly.
2. Inspect the interior of the covers and pipes, and
if there are scales or corrosion, remove them (see
page 6·14).
3. Check that the pipes are not clogged. Use new
0-rings and install the covers.

Fig. LS· 10. Oil cooler {marine engine)

6HAIMl·HTE

Oil cooler housing

b.) Marine engine
1. Close the kingston cock.
2. Remove the drain plug on the oil filter and drain
the lubricating oil.
Cooler core
3. Drain the sea water from the drain cock at the
marine gear oil cooler.
4. Remove the sea water pump cover to drain sea
water.
5. Remove all wires and hoses from the oil cooler.
6. Remove the oil cooler.
6HA(M)E
Fig. LS-8. Removing the oil cooler (marine engine)

Printed in Japan
5-6.
LS
4. Oil Cooler [-4.] 5. Pressure Regulator Valve [-1./-2./-3.]

[4-4.] Installation [5-JJAdjustment

1. Instal I in the reverse order of removal. 1. Make sure that there is no oil leakage in any part.
2. Remove the cap nut and loosen the lock nut.
A Note: 3. Operate the engine at 1800 rpm, and set to the
Apply new gaskets and 0-rings. Coat the gasket sur- specified oil pressure by rotating the adjusting
face with liquid sealant. screw while looking at the pressure gauge.
2. Pour in the prescribed amount of lubricating oil. Adjusting the oil pressure
3. With the industrial engine, pour in cooling water
(see page 6-6). Industrial engine Marine engine
4. Inspect for water leakage and oil leakage.
Specified oil pressure
3.5 -4.5 4 -4.5
(at 1800 rpm I
2 (50 -64) (57 -64)
kg/cm (psi I
5. Pressure Regulator Valve
Fig. LS·12. Adjusting the oil pressure
[5-1.] Description
The pressure regulator valve regulates the oil pres-
sure so that lubricating oil is sent to all parts of the
lubricating oil circuit at the specified pressure. It is
installed on the oil cooler on industrial engines and
the lower left side of the cooling water passage cham-
ber cover A on marine engines.

Fig. LS-11. Construction of the pressure regulator valve

Adjusting screw

Valve

Spring
I I 4. After adjusting, securely tighten the lock nut and
instal I the cap nut.

Lock nut

Cap nut Adjusting screw

[5-2.] Inspection
If the pressure indicated on the pressure gauge on
the instrument panel is lower than the specified oil
pressure during operation, clearance of lubricated
bearings in the lubricating oil circuit may be too
large due to wear of the shaft or bearing, or the
spring of the pressure regulator valve may have
deteriorated. In these cases, adjust the valve to the
specified pressure. If the pressure increases but in
stages (stick-slip) the pressure regulator may be
faulty, inspect and repair it.
l'rinted in Japan
5-7.
Sec. 6. COOLING SYSTEM (CS)

Contents of this section

Page
1. Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
[1-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
I 1-2.] Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
I 1-3.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

2.Cooling Water Pump (Industrial Engine) ................. 6-4

[2-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·4
[2-2.] Mechanical Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-5
12-3.l Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·5
[2-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

3. Sea Water Pump (Marine Engine) . . . . . . . . . . . . . . . . . . . . . . . 6-6

[3-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·7
[3-2.] Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
[3-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
13-4.] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
13-5.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

4. Fresh Water Pump (Marine Engine) . . . . . . . . . . . . . . . . . . . . . 6-8

[4-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·9
14-2.] Mechanical Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-10
14-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
[4-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . 6-10

5. Heat Exchanger .................................... 6-10

[5-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·10
15-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·11
[5-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·11
[5-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·11

6. Pressure Cap and Reserve Tank ........................ 6-11

[6·1.l Description . . . . . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . 6·11
16-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·12

7. Thermostat ........................................ 6-12

17-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
[7-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
[7-3.l Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

8. Cap and System Leak Test ............................ 6-12

[8-1.] Pressure Cap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6·12
18·2.] Water Leak Test (Fresh Water) . . . . . . . . . . . . . . . . . . . . . . 6·13

9. Removing Scales (During Disassembly) .................. 6-14

10. Anti-Corrosion Agent ................................ 6-14

[10-1.] Effects of Yanmar Anti-Corrosion Agent . . . . . . . . . . . . . . . . 6·14
[10-2.] How to use Yanmar Anti-Corrosion Agent . . . . . . . . . . . . . . . 6-14

11. Antifreeze ........................................ 6-14

cs
1. Service Information [-1.)

6. Cooling System
1. Service lnfonnation
[1-1.] Description
The cylinder and cylinder head are cooled by
cooling water which is cooled in the radiator on
industrial engine, and by fresh water which is cool-
ed by sea water in the water cooler on marine engine.
The cooling water circuit of each engine is as fol-
lows:

a.) Industrial engine When the temperature of the cooling water exceeds
The cooling water sent out of the cooling water a fixed maximum temperature, the thermostat
pump cools the oil in the engine oil cooler. It is sends a part of it to the radiator to be cooled.
then sent through the cooling water jacket in the Then the cooling water is re-circulated by the
cylinder block and cools the cylinder liners. Then cooling water pump.
it cools the cylinder head and is passed over its top.

Fig. CS-1. Cooling water circuit (industrial engine)

Cylinder liner
Lubricating oil cooler

Prin/Pd in Japan
6-1.
cs
1. Service Information (-1.]

b.) Marine engine Fresh water sent out from the fresh water pump
Sea water sucked up by the sea water pump is sent enters the water jacket of the engine and cools the
to the fresh water cooler where it cools the fresh cylinders and cylinder liners, then the cylinder
water. Then it cools the oil in the engine oil cooler heads. Next it enters the water passage of the ex-
and marine gear oil cooler and is discharged from haust manifold, and the part of the fresh water
the vessel. In the 6HA-HTE model, sea water which exceeded the fixed maximum temperature
emerging from the fresh water cooler is sent to the is sent to the fresh water cooler. After the fresh
intercooler where it cools the intake air. Then it is water is cooled the fresh water pump re-circulates it.
returned to the fresh water cooler and is sent to the Also, anti-corrosion zincs are installed in the sea
oil cooler. water circuit to prevent corrosion.
Reserve tank
Fig. CS-2. Cooling water circuit of the marine engine
Thermostat
1ntercooler
Exhaust manifold

Fresh water tank

(Heat exchanger)

Cool'lng water pump

(Sea waterl

~Seawater
Fresh water

Sea water filter {optional)

It is recommended to use a sea water filter between the kingston cock and the sea water pump to prolong
the sea water pump service life and maintain the cooling effect by preventing the float from entering into
the cooling system.
NOTE: Clean the sea water filter periodically (every 150 to 250 hours). The filter condition can be seen
from outside.
Printed in Japan
6-2.
cs
1. Service Information [-2./-3.]

[1-2.] Tools and Materials

1. Heater 2. Cooling water pump impeller wrench (126650.92400) 3. Thermometer 4. Cap tester (126650.92750)
5. Silicon oil 6. Liquid sealant 7. Yanmar scale solvent 8. Anti·corrosion agent

[1-3.] Specifications
a.) Torque value
• Left-hand thread
Thread diameter x pitch Width across Torque values
Item Remarks
mm flats mm Kg-m ft-lb
Cooling-water pump drive pulley M20 x 1.5* 13 94 see page 6-6
Sea water pump drive gear M22 x 1.5 32 17.5 127 see page 6-7
Fresh water pump drive gear M20 x 1.5 30 13 94 see page 6-10
---- ----·----- -
Cooling water pump impeller M16x 1.5 - 7 51 see page 6-5
Fresh water pump impeller M16x 1.5 - 7 51 see page 6-10
For the tightening of bolts and nuts other than those listed above, tighten to the standard torque (see page
1-17).
b.) Specifications (Industrial engine)
1 Item Specifications
Model 4HAL I 6HAL I 6HAL-T
--- I 3
Delivery
--
m /h (Cu. ft/h) 11.5 (406) I 17.0 (75) I 20.6 (727)
Cooling-water pump Pump rotation speed
'----------------- - ·--------
rpm 2556
Entire lift
.. ----
m (ft) 7 (23.0)
-----·
0 0
Opening temperature C ( F) 69.5-72.5 (157.1-162.5)
Thermostat --------'-----
Fu 11 y open temperature °C (°F) 85 (185)
Pressure cap Opening pressure Kg/cm 2 (psi) 0.9 ± 0.15 (13 ± 2)

c.) Specifications (Marine engine)

Item Specifications
Model 6HA(M)E 6HA(M)-HTE
Engine speed rpm 1goo 2100 1900 2100
Pump rotation speed rpm 2560 2830 2560 2830
Fresh water 3
Delivery m /h (cu. ft/h) 13 (459) 15 (530) 14.5 (512) 17 (600)
capacity
Entire lift m (ft) 6 (19.7) 7 (23.0) 6 (19.7) 7 (23.0)
Pump rotation speed rpm 1636 1808 1636 1808
Sea water 3
Delivery m /h (cu. ft/h) 11.5 (406) 13 (459) 11.5 (406) 13 (459)
pump
Entire lift m(ft) 8.5 (27.9) 10 (32.8) 8.5 (27.9) 10 (32.8)

Fresh water Engine £(U.S. gal, Imp. gal) 45 (12, 10) 50 (131', 11)
capacity Reserve tank £(U.S. gal, Imp. gal) 1.7 (%, '/,)
Pressure cap Opening pressure 2
kg/cm (psi) 0.9±0.15 (13±2)
Opening temperature oC (o F) 63.5 - 66.5 (146.3 -151.7)
Fixed
temperature (65°C) Fully open temperature oC (oF) 80 (176)
Thermostat
Opening temperature oC (oF) 69.5 -72.5 (157.1 -162.5)
Fixed
temperature (71°C) Fully open temperature OC(OF) 85 (185)

Printed in Japan
6-3.
cs
2. Cooling Water Pump (-1.]

2. Cooling Water Pump (Industrial Engine)

Fig. CS-3. Cooling water pump exploded view

Gasket

Pump housing

[2-1.] Removal
1. Loosen all drain plugs and drain the coolant.

Fig. CS-4. Drain plugs

,• •-

0 .-,,.
~

Printed in Japan
6-4.
 cs
2. Cooling Water Pump [-1./-2./-3.]

2. Remove the V-belt cover. [2-2.] Mechanical Seal Replacement

3. Remove the protective net of the radiator fan.
If there is a large amount of water leakage, replace
4. Remove the cooling water outlet and inlet and
the mechanical seal.
bypass outlet rubber hoses.
1. Remove the impeller with an impeller holder
5. Remove the radiator supports (upper).
( 126650-92400).
6. Remove the nut attaching the radiator rubber
mounts.
Fig. CS-7. Removing the impeller
7. Remove the radiator.
Impeller wrench

Fig. CS-5. Removing the radiator (126650-92400) 1-...;;;;r----LU..ot..l.t:a..ctl

2. Replace the mechanical seal.

Fig. CS-8. Mechanical seal

8. Remove the cooling fan.

9. Loosen the nut tightening the cooling water pump
drive pulley (left-hand thread).
10. Loosen the generator pivot and adjusting bolts
and remove the V-belt.
11. Remove the cooling water pump drive pulley.
A Note:
Impeller

Be careful not to lose the key.

3. Torque the impeller to 7 kg-m (51 ft-lb) with the
12. Remove the cooling water pump.
impeller wrench (126650-92400).
Fig. CS-6. Removing the cooling water pump
[2-3.] Inspection
a.) Bearing
Inspect the bearing for wear or damage. If it should
be replaced, replace according to the following pro-
cedures:
1. Remove the impeller and mechanical seal (see
"mechanical seal replacement").
2. Remove the snap ring and remove the shaft.
3. Replace the bearing.
4. Replace the oil seal and coat the sealing lip with
grease.
5. Insert the shaft and install the snap ring.
6. Install the mechanical seal and impeller.
Printed in Japan
6-5.
cs
2. Cooling Water Pump [-3./-4.] 3. Sea Water Pump

b.) Pump housing and impeller 8. Install the radiator supports (upper).
Inspect. the inner surface of the pump housing and 9. Install the cooling fan protection net.
impeller. Remove scales and rust if there are any, 10. Adjust the V-belt tension (see page 2-8).
and replace any part if there are cracks etc. 11. Install the V-belt cover.
12. Tighten the drain plugs and pour in coolant.

[2-4.] Installation Model Capacity

1. Use a new gasket and install the cooling water 4HAL 25 Q (6-5/8 U.S.gal, 5-1/2 Imp.gal)
pump.
6HAL 35 Q (9·1/4 U.S.gal, 7·3/4 Imp.gal)
2. Connect the rubber hoses.
3. Install the drive pulley. 6HAL·T 33 Q (8·3/4 U.S.gal, 7-1/4 Imp.gal)
4. Stretch the V-belt and torque the pulley nut to
6HAL-HT 42 Q(11·1 /8 U .S.gal, 9-1 /4 I mp.gal)
13 kg·m (94 ft-lb).
5. Install the cooling fan.
6. Install the radiator. 13. Check for water leakage in the cooling system
7. Install the cooling water rubber hoses. with a cap tester (see page 6-12).).

3. Sea Water Pump

(Marine Engine)
Fig. CS-9. Sea water pump
exploded view

l___

Pump housing

Impeller Cover
0-ring

Printed in Japan
6-6.
cs
3. Sea Water Pump [-1./-2./--3./-4.]

[3-1.] Removal d.) Mechanical seal

1. Drain the sea water (see page 2-10). If there is a large amount of water leakage from the
2. Remove the side cover from the sea water pump. drain pipe, replace the mechanical seal.
3. Remove the rubber hoses from the sea water
Fig. CS-11. Mechanical seal
pump.
4. Remove the sea water pump together with the
attaching base.
Fig. CS· 10. Removing the sea water pump

•
•
Mechanical seal

~/
.I
I
I Remove the mechanical seal by removing the snap

~I(
ring (see Fig. CS-9).

A caution:
• Be careful not to damage each sliding surface
while replacing.
[3-2.] Disassembly • Coat the sliding surface of the mechanical seal
with a small amount of high quality silicon oil to
1. Remove the rubber impeller.
prevent early leakage due to insufficient fit.
2. Remove the pump housing from the attaching
base and remove the wear plate.
e.) Bearing
Inspect the bearing for wear or damage. Replace
[3-3.] Inspection faulty bearings in the following order (see Fig. CS-9):
a.) Rubber impeller 1. Remove the mechanical seal.
2. Remove the pump drive gear.
If there is damage or wear on the impeller, replace it. 3. Remove the snap ring and pull out the shaft.
4. Replace the bearing.
b.) Wear plate 5. Replace the oil seal with a new one and coat the
Inspect the wear plate, and if the side surface is sealing lip with grease.
worn or if it is deformed, replace it. 6. Insert the shaft and secure it with a snap ring.
7. Install the drive gear and torque the nut to 17.5
C.) Pump housing kg-m (127 ft-lb).
8. Install the mechanical seal.
If there is excessive wear on the inner surface of the
housing or on the sliding surface of the impeller,
replace it. [3-4.] Assembly
Assemble in the reverse order of disassembly, but
note the following points:
1. Coat the pump shaft and the inside diameter and
outer periphery of the impeller with grease.
Printed in Japan
6-7.
cs
3. Sea Water Pump [-4./-5.] 4. Fresh Water Pump

2. When assemblying the impeller on the housing, 3. Use a new 0-ring and gasket.
note the rotation direction. 4. Coat the gasket surface with liquid sealant.

Fig. CS-12. Assemblying direction of the impeller

[3-5.) Installation
Install in the reverse order of removal.

4. Fresh Water Pump

(Marine Engine) Pump cover

Fig. CS-13. Fresh water pump

exploded view Gasket

Impeller

Gasket

Mechanical seal

);!/.._
Pump housing

l
'

~J

Printed in Japan
6-8.
cs
4. Fresh Water Pump [-1.]

[4-1.] Removal
1. Loosen all drain plugs and drain the fresh water.
Fig. CS-14. Position of the drain plugs

Exhaust manifold

Water passage cover

I •

Fresh water tank

,,..,,~_.,...\.._--~eat exchanger)

6HA(M)E only

2. Disconnect the fresh water pump from the cool- Fig. CS-15. Removing the fresh water pump
ing water connecting chamber cover A.
3. Loosen the connection of the water passage to
the cooling water inlet.
4. Remove the fresh water pump together with the.
drive gear.

IiI·
.'

Printed in Japan
6-9.
cs
4. Fresh Water Pump (-2./-3./-4.] 5. Heat Exchanger (-1.]

[4-2.] Mechanical Seal Replacement b.) Pump housing and impeller

If there is a large amount of water leakage from the Inspect the inner surface of the pump housing and
drain pipe, replace the mechanical seal. the outer surface of the impeller. If there are scales
1. Remove the fresh water pump cover. or rust remove them and replace the parts if there
2. Remove the impeller with an impeller wrench are cracks etc.
( 126650-92400). [4-4.J Installation
Install in the reverse order of removal. After install-
Fig. CS-16. Removing the impeller ing, tighten the drain plugs, pour in coolant and in-
Impeller wrench spect for water leakage in the fresh water system
(126650-92400) 1-...;;;;r----===~ with a cap tester (see page 6-12).
6HA(M)E: 45 £ (11'/, U.S. gal, 9'/, Imp. gal)
6HA(M)-HTE: 50 £ (1314 U.S. gal, 11 Imp. gal)

5. Heat Exchanger
[5-1.] Description
A tubular type heat exchanger is used, which
3. Replace the mechanical seal. cools the fresh water outside tubes by sending
sea water through the tubes. Thermostats, equipped
Fig. CS-17. Mechanical seal in the fresh water circuit, maintain appropriate
temperature when the engine is in operation.
The heat exchanger is also used as the fresh water
tank. A reserve tank is attached to the upper sec-
tion so that the engine can be operated for a long
time without a .resupply of fresh water. If the
amount of fresh water should decrease, the water
level warning device on the upper section of the
Mechanical seal
heat exchanger will detect it and signal danger
with a lamp and buzzer.
4. Install the impeller and torque it to 7.0 kg-m (51
ft-lb) with the impeller wrench (126650-92400). Fig. CS-18. Heat exchanger
Water level warning switch
5. Install the fresh water pump cover.
Water fillter cap

[4-3.] Inspection
a.) Bearing
Inspect the bearing for wear or damage. If it has to
be replaced, replace in the following order:
1. Remove the pump drive gear (see Fig. CS-13). Water cooler core

2. Remove the pump cover, impeller and mechanical

Cover A
seal (see "mechanical seal replacement").
3. Remove the snap ring and pull out the shaft.
4. Replace the oil seal with a new one and coat the
sea Ii ng Ii p with grease.
5. Insert the shaft in the housing and install the
snap ring.
6. Install the mechanical seal, impeller and pump
cover.
7. Install the drive gear and torque the nut to 13
kg-m (94 ft-lb).
Printed in Japan
6-10_
cs
5. Heat Exchanger [-2./-3./-4.l 6. Pressure Cap and Reserve Tank [-1.]

[5-2.l Removal Fig. CS-20. Installing the core

1. Loosen the drain plug of the heat exchanger
and drain the fresh water.
2. Drain the sea water (see page 2-10).
3. Remove the cooling water connecting pipes from
the heat exchanger.

Fig. CS-19. Removing the heat exchanger

[5-3.] Inspection
0
1. Remove the heat exchanger covers and re-
move the core.
2. Inspect the inside surface of the cover and inside
of the tube of the core. If there are scales, re-
move them with a YAN MAR scale solvent.
3. Install the heat exchanger core and covers.
[5-4.] Installation
Install in the reverse order of removal. After install-
A Note: ing, pour in the specified amount of fresh water
Align the "O" mark on the core with the "O"mark (see page 2-13) and check for water Leakage with
on the housing. a cap tester.

6. Pressure Cap and Reserve Tank

[6-1.] Description
When the temperature of the cooling water (fresh cooling system (the fresh water cooling system in
water) increases, it is lowered by the radiator in in- marine engines) rise. When the steam pressure ex-
dustrial engines and by the sea water inside the ceeds 0.9 kg/cm' (13 psi) the pressure cap opens as
heat exchanger in marine engines. However, during shown in Fig. CS-21 to blow out steam, which con-
over-load and prolonged continuous operation, the sumes cooling water (fresh water). This consump-
water temperature and steam pressure inside the tion is refilled by the reserve tank.

Fig. CS-21. Function of the pressure cap

From reserve tank

- (or atmospheric)

When reducing pressure

(Below 0.05 kg/cm')

Printed in Japan
6-11.
cs
6. Pressure Cap and Reserve Tank [-2.] 7. Thermostat [-1./-2.] 8. CAP and System Leak Test [-1.]

[6-2.] Inspection [7-2.] Inspection

If there are foreign particles on the pressure cap, Place the thermostat in a container of water. In·
the cap will not close completely, causing a reduc· sert a thermometer and heat the container. Check
tion of cooling water. Therefore, inspect and re· that the valve starts to open at opening temperature
move foreign particles and scales. and that it opens completely at fully open temper·
ature. Replace the thermostat if the difference be-
A warning: tween the operating temperature and specified tem-
Do not remove the cap when the engine is hot. The coolant perature is too great or if it is damaged.
is under pressure and severe scalding could result.
Fig. CS-23. Inspecting the thermostat

Thermometer
7. Thermostat
[7-1.] Description Heater
The thermostat always maintains the temperature
of the cooling water (fresh water) at a specified
range and prevents the engine from excessive cool-
ing, etc.
The industrial engine is equipped with thermostats
for 71°C ( 160° F) at the cooling water outlet. The
marine engine is equipped with thermostats of
65°C (149°F) and 71°C(160°F) at the fresh water
cooler inlet (between the cooling water outlet
side of the cylinder head and exhaust manifold
on model HTE).
[7-3.] Thermostat Installation

Opening temperature
63.5 - 66.5°C
(146.3 -151.7°FI
A Note:
65°C • Check the temperature identification mark.
(149°F) Fully open temperature
80°C • Make sure there are no foreign particles or scales.
(176°F)
69.5 - 72.5°C
Opening temperature
(157.1 - 162.5°F)
71°C 8. Cap and System Leak Test
(160°F) 85°C
Fully open temperature
(185°F) A Note:
When using the cap tester, follow the manufacturer's
Fig. CS·22. Characteristics of the thermostat instructions.

[8-1.] Pressure Cap Test

j.s 8 (0.321
1. Install the attachment adaptor (6HAL·HT only
and cap on the cap tester .
2. Operate the cap tester pump and apply pressure.
E
E The pressure cap is operating collectly if the gauge
indicates the pressure range 0.9 ± 0.15 kg/cm'
~ (13 ± 2 psi) after 6 seconds. If the pressure does
~ o'--~~~-+-~-;-~~~~~~~
not rise or if it drops after rising the causes may
Full open temperature be corrosion, cracks, damaged packing or cor·
rosion of the spring. In such cases replace the
Opening temperature cap assembly.
Printed in Japan
6-12.
cs
8. Cap and System Leak Test [-1./-2.)

A Note: 4. If pressure rises over 0.1 kg/cm' ( 1.4 psi) after

standing for 5 minutes, inspect the following
If there are foreign particles or scales on the seal
places for water leakage.
section, an abnormal value may be obtained. There-
fore, clean the seal section properly before testing. Places for inspection (while applying pressure): radi-
ator, connections of various hoses, cooling water
Fig. CS-24. Inspecting the pressure cap pump, each packing area.
If the gauge needle drops even when water leakage
is not found in these places, water may be leaking
from the cylinder head, head gasket or inside the
block.
b.) Marine engine
1. Fill with fresh water up to the upper surface of
the water tank.
2. Install the cap tester on the filler neck.
3. Operate the pump and set the pressure at 0.9 ±
0.15 kg/cm' (13 ± 2 psi), and inspect for water
leakage.

A Caution:
Be careful when applying pressure because exces-
sive pressure will damage the matching surface pack-
[8-2.] Water Leak Test
(Fresh Water) ings of the cooling water system as well as the hoses.

a.) Industrial engine Places for inspection (while applying pressure): vari-
ous hose connections, cooling water pump, each
1. Fill the radiator with cooling water up to the packing section.
filler neck. If the gauge needle drops even when water leakage
2. Install the attachment adaptor on the filler neck is not found in these places, water may be leaking
(6HAL-HT only), and install the cap tester on th from the cylinder head, head gasket or inside the
the adaptor. block.
3. Operate the pump and set the pressure at 1.2 kg/
cm' ( 17 psi) and let it stand for 5 minutes. Fig. CS-26. Water leak test
A Caution:
Be careful when applying pressure because excessive
pressure will damage the matching surface packings
Cap tester
of the cooling system as well as the hoses. (126650-92750)

Fig. CS-25. Water leak test

Attachment adaptor
(For 6HAL-HT)

Printed in Japan
6-13.
cs
9. Removing Scales 10. Anti-Corrosion Agent(-1./-2.)

9.Removing Scales the anti-corrosion agent dissolved in the fresh

(During Disassembly) water form a protective film over the metal
surface to prevent rust from forming by cutting
1.Dilute Yanmar scale solvent with approxima- out oxygen.
tely 10 times its weight of water (sea water
may be used for the sea water circuit.) Stir it [10-2,]How to Use Yanmar Anti-Corrosion Agent
and dissolve the agent to make cleaning solu- After cleaning the fresh water system with
tion. clean fresh water,pour in Yanmar anti-corrosion
2. Immerse the disassembled parts in this clean- agent and fill with the prescribed amount of
ing solution for 5-15 hours. Then take the parts fresh water.
out and thoroughly wash with water. It is re- Yan mar anti-corrosion agent: fresh water= 1:10
commended to prepare a solution with appro-
ximately 1% of this scale solvent neutralization If soft water is used, replace the coolant when
agent to wash the parts in before washing specified by periodical maintence schedule.If the
with water. water used contains any amount of salt, replace
coolant more frequently.

10. Anti-Corrosion Agent

11. Antifreeze
In fresh water cooled diesel engines, anti-corro-
sion maintenance of the fresh water cooling On cold days (of less than 5 °C), use antifreeze
system is very important. Conduct anti-corro- (antifreezing solution). Since freezing of cooling
sion maintenance with the following points in water can be prevented by use of antifreeze, a
mind: trouble to drain out cooling water everyday can
•Prevent solid matter from getting into the be omitted if antifreeze is used. After water
fresh water cooling system and clean the washing the cylinder interior, feed in cooling
system periodically with Yanmar scale solvent water mixed with antifreeze.
solution.
•Always use clean soft water. The salt in sea Min. air temp. (°C) -5 -10 -15 -20 -25 -30
water will accelerate corrosion. Ratio of antifreeze ( %) 12 22 29 35 40 44
•Use Yan mar anti-corrosion agent mixed with
4HAL 3 5.5 7.2 8.7 10 11
soft water as coolant.
6HAL 4.2 7.7 10 12.2 14 15.4
Volume of 6HAL-T 4 7.3 9.6 11.6 13.2 14.5
[10-1.]Effects of Yanmar Anti-Corrosion Agent antifrezze
6HAL-HT 5 9.2 12.2 14.7 16.8 18.5
If the anti-corrosion agent is dissolved in the required
(R) 6HA(M)E 5.4 9.9 13.1 15.8 18 19.8
cooling water, formation of rust in the circula-ti
6HA(M)-HTE 6 11 14.5 17.5 20 22
on circuit will be prevented. However, there are
6HA(M)-DTE 6.4 11.7 15.4 18.6 21.2 23.4
various types of anti-corrosion agents with diffe-
4HAL 25
rent functions, having different effects on various
6HAL 35
metals.
Cooling 6HAL-T 33
Therefore, the most suitable materials must be system
6HAL-HT 42
combined while considering the various metals capacity
(R) 6HA(M)E 45
used for the fresh water circuit and their condi-
6HA(M)-HTE 50
tion.
6HA(M)-DTE 53
Yanmar anti-corrosion agent is a combination
of materials that suits the metals used for
Yan mar diesel engines. Its main function is the
truncated type, in which the constituent parts of

Printed in Japan
6-14. F032G-0223
Sec. 7. FUEL SYSTEM (FS)

Contents of this section

Page
1. Service Information ................................. 7·1
[ 1-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
[1-2.] Tools and Materials.............................. 7-2
[ 1-3.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

2. Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7·5

[2-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
[2-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
[2-3.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
[2-4.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

3. Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

[3-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
[3-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
[3-3.] Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
[3-4.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
[3-5.] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
[3-6.] Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
[3-7.] Installation . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
[3-8.] Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

4. Feed Pump ........................................ 7-32

[4-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
[4-2.] Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
[4-3.] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
[4-4.l Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
[4-5.] Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

5. Governor ......................................... 7-35

[5-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
[5-2.] Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
[5-3.] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

6. Automatic Timer (Marine Engine Only) .................. 7-41

[6-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
FS
1. Service Information [-1.]

7. Fuel System
1. Service Information
[1-1.] Description
Fuel in the fuel tank is sent to the injection pump and is then ignited.
through the fuel filter by the feed pump.
The injection pump is equipped with a governor,
The fuel is pressurized in the injection pump to the
pressure of approximately 220 kg/cm 2 (3129 psi), and is designed to provide output and torque capaci-
ty suitable for the type of operation.
and the pressurized fuel is sent to the injection noz-
zles through the fuel injection pipes. It is injected Also, fuel leaking at the injection nozzle returns to
into the combustion chamber at the upper section the fuel tank through the fuel return pipe.
of the piston where it is mixed with the whirl of air

Fig. FS-1. Fuel system

Fuel return pipe Fuel injection pipe

Fuel injection pump

Governor

Additional fuel tilter

(optional) for heavy oil
Fuel filter
(BS class 81)
Filtrating area: 10,000 cm 1
/

'"
Additional fuel filter (optional)
NOTE:To prolong engine !ife, it is
recommended to use an
aditional fuel filter {fixed
on hull). Parallel type

Fuel tank
Fuel-water
separator

Printed in Japan
7-1.
FS
1. Service lnformation(-1.)

[1-2. ]Tools and Materials

Injection nozzle puller Anti-rust agent

(126650-92620.26116-080182. 126650-92610) Liquid sealant
Torqu wrench Overhaul tool kit for the model P ES-A pump
Nozzle tester 126650-92760(Diesel kiki No. 5790-101)
Nozzle cleaning pin Overhaul tool kit for the model PES-P pump
Dial indicator 00000-00000(Diesel kiki No. 5790-700)
Micrometer Nozzle tester(735400-93101)
Vernier calipers Pump tester
Spring scale

[1-3. ]Specifications
a.)Torque valve

Thread diameter x pitch Width across flats Torque valve

Item (mm) (mm)
Remarks
kg-m ft-lb
Injection nozzle assembly M8X 1.25 13 1.0 7.2 See page 7-7
PES-A 2.5
Injection pipe M14X1.5 19 31 See page 7-7
PES-P 4
Injection nozzle l{"-16U NF ......... 7.3 53 See page 7-7
Flange sleeve( model PES-P) 17 4.3 31 See page 7-24

Delivery valve holder( model PES-P) ......... 22

12-0- a1-o- See page 7-24
12-0-11 81-0-80
Delivery valve holder(model PES-A) ......... 22 4.3 31 See page 7-20
Fly weight( model PES-A) ......... ......... 8 58 See page 7-40
Injection pump shaft M14X 1.5 22 8 58 See page 7-30
Automatic timer MBxl.5 27 14 101 See page 7-31
Fly weight(model PES-P) ......... ......... 6 43 See page 7-40

For the tightening of bolts and nuts other than those listed above. refer to the standard tightening torque(see page 1-17).

b. )$pacifications
Item Specififications

Type Semi-long type whole nozzle

Injection pressure kg/OTl(psi) 220(3128)

4HAL.6HAL:0.34(0.0134) X4
Nozzle
Diameter 11m(in) x
number of holes
6HA(M )E:0.36(0.0142) X4

6H A ( M )-H TE.SH A ( M )-DTE,6H A L-T:0.38(0.0150) x 4

Injection
nozzle
Injection pattern 150°

Freel length ram( in) 30.5(1.2007)

Nozzle
spring
Installed length mm( in) 29.24(1.1512)

Length during lift mm(in) 28.44(1.1197)

Nozzle spring adjustment Screw type

Printed in Japan
7-2. F032G-0223
FS
1. Service lnformation(-2./3.)

Item Specifications

Pump model PES-A PES-P

Rotation direction(seen from driving side) Right

4-cylinder: 1-2-4-3
Injection order(seen from driving side) 1-4-2-6-3-5
6-cylinder:l-4-2-6-3-5

Diameter m11(in) 9.5(0.3740) 11 (0.4331)

Plunger
Lead 11m(in) 15(0.6905)clockwise lead 22(0.8661 )clockwise lead

6H A (M) E :59(0.0036)
4HAL:51(0.0031) 6H AL-T ,6HAL-HT,
Delivery volune m~(cu-in)
6HAL:43(0.0026) 6H A(M)-HTE,6HA(M)-DTE,
:70(0.0043)
Delivery
valve Diameter mm( in) 6(0.2362)

4-cylinder: 1.5(0.0591)
Lift mm( in) 1.6(0.0708)
6-cyl inder: 1.8(0.0708)
Injection Cam lift mm( in) 8(0.3150) 10(0.3937)
pump
Thrust clearance mm( in) 0 .03-0.05( 0.0012-0.0020) 0. 02-0. 06 (0. 0008-0 .0024)

0.10(0.0039)

0.12(0.0047)

Camshaft 0.14(0.0055)

Shim thickness mm( in) 0.16(0.0063)

0.18(0.0071)

0.30(0.0118)

0.50(0.0197)

Plunger Free length mm( in) 55.4(2.18)

spring
Spring tension kg/mm 2.68(150)

Delivery Free length mm( in) 23.3(0.9173)

valve spring
Spring tension kg/mm 1.61 1.7

Pump rotation speed rpm 550±50 800 1050

Engine speed rpm 1100 1600 2100

Automatic timer Advancing degree o• 1.9±0.5° 4.5±0.5°

6HA(M)E 21· 24.8±1° 30±1°

Injection timing
6HA(M)-HTE 17° 20.8± 1° 30±1°

Printed in Japan
F032G0223 7-3.
FS
1. Service Information (-2.13.)

c. )Service data

Item Service data

Model 4HAL 6HAL 6HAL-HT 6HA(M)E HA( M)-HTEl6H A( M)-DTE

Pump model PES-A PES-P

At pump stand still 150(0.33)Max. 130(0.29)Max.

Control rack(control rod) 600 rpm 100(0.22)Max. 50(0.ll)Max.
sliding resistance gr(ib)
1000 rpm ......... 70(0.15)Max .

Pre-stroke 111m( in) 2.7(0.106) 3.3(0.130) 3.0(0.118)

Injection interval 90° ± 30' 60° ± 30'

Oil-tightness of delivery valve: 100-90kg-cni

(1422-1280 psi)descending time
Limit of use:5 sec Max. .........
Rack( rod )position mm( in) 12.7(0.500) 8.7(0.343) 9.0(0.354) 10.3(0.406)

Pump rotation speed rpm 900 1050

a<(cu-in)/min 109±2.2(6.65±0.13) 133.2±2.7 123±2.5 170±3.4

Injection volume (8.13±0.16) (7.51±0.15) (10.37±0.21)
Inequality volume % ±2
injection
volume
Rack(rod)position 111111(in) 7.5(0.295) 5.2(0.205) 5.6(0.220) 5.1(0.201)

Pu mp rotation speed rpm 250 200

Injection volume cnf(cu-in)/min 3. 75 ± 0.38( 0.229±0.0023) 2.4±0.24 3.0±0.3

(0.146±0.016) (0.183±0.018)
Inequality volume % ±10

Reted rpm

0
Injection timing BTDC 2e· 1500 2e 23° 21° 17°

1800 29°

Lift capacity(at pump speed 1000 Lifting height: 1 m

Lilting height:0.6 m(2.0 ft)within 40 sec.
stroke/min. (3.3 ft)within 40 sec.

Feed pump Delivery capacity(at pumfi speed 405 .,,!(24.7 cu-in)min. 530.,,!(32.3 cu-in)min.
1000 stroke/min.with 1 kg ad
within 15 sec. within 15 sec.
pressure applied outlet side)

Air tightness 30.,,!(1.83 cu-in)/min. Max

Printed in Japan
7-4. F032G0223
FS
2. Injection Nozzle [-1./-2.]

2. Injection Nozzle Fig. FS-3. Nozzle body

(2-1.] Description
The injection pump forces open the nozzle at high
Nozzle body
pressure sending atomized fuel into the combustion Fuel passage
chamber. The fuel delivered from the injection
pump passes through the fuel hole in the nozzle
holder, and is collected in the fuel retaining
chamber at the lower section of the nozzle valve.
When the fuel pressure reaches 220 kg/cm 2 (3129 Nozzle valve
psi) the fuel pushes to the nozzle valve and is in-
jected into the combustion chamber. When delivery
from the injection pump ends, the nozzle valve is
closed by the force of the nozzle spring.

Fuel which leaked from the fitting section of the ---Injection hole

nozzle valve and nozzle body returns to the fuel

tank through the return pipe at the top of the cap
nut.
(2-2.] Removal
Fig. FS-2. Construction of the injection nozzle
1. Remove the fuel return pipe.
2. Disconnect the fuel injection pipe.
Adjusting screw
3. Remove the injection nozzle attaching nuts and
Cap nut install the nozzle puller ( 126650-92620, 26116-
080182 and 126650-92610).

A Note:
Adjust the puller plate so that it is at a right angle
to the nozzle and clearance between the top of the
nozzle and the plate is 5 mm (0.2 in).
Nozzle holder Fig. FS-4. Installing the nozzle puller
Support bolt
( 126650-92620)
Push rod

Nozzle valve

Nozzle nut
Puller plate
1126650-92610)

Nozzle body

4. Coat the draw bolt of the tool with lubricating

oil. Screw it in the return pipe connecting bolt
hole at the top of the nozzle and pull out the
Printed in Japan
7-5.
FS
2. Injection Nozzle [-2./-3.]

nozzle. When the top of the nozzle is in contact [2-3.] Inspection

with the lower face of the plate, loosen the draw
a.) Nozzle injection hole
bolt and readjust the support bolts. Continue this
operation until the valve is completely pulled out Inspect the injection holes in the nozzle for carbon
(about 4 times). deposits, and clean holes if necessary.

Fig. FS-5. Removing the injection nozzle

b.) Nozzle function

Inspect as fol lows with a nozzle tester (735400-
93101) and diesel fuel oil.
• Spray form
Operate the lever of the tester at a speed of about
1 - 2 times per second. If the spray is streamed or
if the atomized particles are large and drip, replace
the nozzle assembly.

Fig. FS-6. Normal spray form

~
I I

+
I

~
~ ~

A Good
•
/'i, ~

NO Good

• Air-tightness of the valve seat section Fig. ES-7. Inspecting the overflow volume
Apply pressure less than the injection starting pres-
sure of 20 kg/cm 2 (284 psi). If drops of fuel collect
at the injection holes, replace the nozzle assembly.

• Spray degree
Compare the width of the 4 sprays. If there are ex-
treme differences in degrees of each spray replace
the nozzle assembly.

• Overflow
If the volume of overflow fuel from the fuel return
pipe at the top of the nozzle is extreme, replace the
nozzle assembly. However, the cause may be else-
where so inspect the nozzle attaching parts, etc.

Printed in Japan
7-6.
FS
2. Injection Nozzle (-3./-4.]

c.) Disassembly inspection [2-4.] Installation

Remove the nozzle nut, remove the nozzle body 1. Completely remove rust and carbon from the
from the injection nozzle holder and make the fol- nozzle holder and sleeve. Then coat the nozzle
lowing inspections; holder with anti-rust agent.
• Inspect for damages at the attaching surface to 2. Insert the copper packing in the inside of the
the nozzle holder, sliding surface of the nozzle sleeve and the dust seal on the nozzle holder.
valve and valve seat. If there is damage, replace
the assembly. Clean the nozzle with fuel oil and A Note:
hold the body upright, then I ift the nozzle valve Use new copper packing, and after installing make
about 2/3 of its length. It is in good condition if sure that it seats properly.
the nozzle valve drops smoothly when released. 3. Install the nozzle.

A Note: A Note:
A new nozzle is immersed in anti-rust oil and com- Be sure not to bind the copper packing.
pletely cut off from outside air by a seal. 4. Install the nozzle attaching nuts and tighten them
After removing the seal, clean the inside and outside alternately.
of the nozzle with fuel oil and wash the anti-rust Torque: 1.0 kg-m (7.2 ft-lb)
oil completely off.

Fig. FS-8. Nozzle body and valve sliding test

A Note:
If a torque wrench is not available, use a 100 mm
length open end wrench and tighten the nuts with
your thumb and index fingers as shown in Fig. FS-
10.

Fig. FS-10. Tightening the nozzle nuts

• Inspect the injection nozzle body and valve, and

replace them if there is grooved wear of over
0.3 mm (0.012 in) at the sliding surface.
Fig. FS-9. Nozzle body and valve

j
Seat surface
~·
Nozzle body
I [P
Aeaution:
If the tightening is not even combustion efficiency
Sliding surface
at low speed will worsen and gas leakage in the
sleeve may occur. Also, inspect the attaching stud
Nozzle valve
bolts for rust, if there is rust remove it, then coat
the bolts with paint. If the rust is heavily formed
replace the stud bolts.
5. Connect the fuel injection pipe.
When assembling the nozzle, clean it with fuel oil Torque: 4.3 kg-m (31 ft-lb)
and be careful not to let foreign matter enter. Then 6. Connect the fuel return pipe.
tighten the nut to the torque of 7.3 kg-m (53 ft-lb). 7. Bleed air from the fuel system (see page 2-4).

Printed in Japan
7-7.
FS
3. Injection Pump [-1.]

3. Injection Pump
[3-1.] Description
Fig. FS-11. Injection pump (PES-A)

Pump cover

Camshaft
bearing

~---Control sleeve

:::::: ...,
Cover----~

0-ring----'
Spring seat

Tappet
Screw plug

Fig. FS-12. Injection pump (PES-P)

Cover
Control rod

Plunger block

Pump housing

Camshaft
Bearing
Shim
Cover

Plug

Center bearing

Cover

Tappet

Printed in Japan
7-8.
FS
3. Injection Pump [-1.]

a.) Construction and operation The plunger rises further and when the plunger
The injection pump used is the type in which fuel lead reaches the inlet/outlet port of the barrel, pres-
is sent by the plunger constant stroke. Because the surizing of the fuel and injection from the nozzle
plunger is integrated to the inside of the plunger ends. Further elevation of the plunger will not send
barrel in a super-precise fit, these should be replaced fuel.
as a set. Fig. FS-14. Plunger
The fuel sent through the filter by the feed pump is
repleted in the fuel chamber in the pump housing.
The inlet/outlet port of the plunger barrel are con-
Right hand lead
nected to the fuel chamber. When the top of the
plunger descends to the inlet/outlet port of the
plunger barrel, fuel starts to be sucked inside the
barrel; suction ends when the plunger reaches
its lowest position. The camshaft rotates, the plung-
er rises while compressing the plunger spring and
when the top of the plunger closes the inlet/outlet
port of the barrel the fuel starts to be pressurized.
When this pressure becomes higher than the delive-
ry valve spring force and/or fuel pressure in the
injection pipe, it forces the delivery valve upward
and sends the fuel to the nozzle holder. When the
plunger rises further and the pressure at the nozzle
becomes higher than the injection starting pressure b.) Fuel control mechanism
of 220 kg/cm' (3129 psi), the nozzle valve is forced The fuel control mechanism of the model PES-A
up and injection begins. pump is shown in Fig. FS-16. The T-shaped flange
at the bottom of the plunger is fixed in the lead of
Fig. FS-13. Construction of the injection pump (PES-P)
the control sleeve, and the pinion attached to the
Delivery valve holder
control sleeve with a clamp screw is engaged to
the control rack. Therefore, when the-control rack
Shim is moved the plunger rotates at the same time, thus
changing the effective stroke and controlling the
injection amount.

Fig. FS-15. Fuel control mechanism (PES-A)

Plunger barrel

Decrease

Increase

Control sleeve
Cover
"T" Shaped flange

Printed in Japan
7-9.
FS
3. Injection Pump [-1./-2.]

In the model PES-P pump, an L-shaped control rod [3-2.] Removal

is used instead of the control rack. The control
a.) Industrial engine
rod is provided with the same number of grooves as
the number of cylinders on the pump, balls welded 1. Remove the drain plug at the fuel filter and drain
to the control sleeve are in these grooves. There- the fuel.
fore, when the control rod is moved, the plunger is
rotated by the control sleeve, thus changing the in- A Note:
jection volume. The draining can be done rapidly if the spherical
pipe joint is loosened.
Fig. FS-16. Fuel control mechanism (PES-P) 2. Disconnect the fuel injection pipes.
Plunger barrel 3. Remove the fuel pipes between the pump and
fuel filter, and then remove the fuel filter.

Control rod
A Note:
Be sure the 0-ring does not fall.

Fig. FS-18. Removing the fuel filter

Control sleeve "T" Shaped flange

c.) The delivery valve operation

The delivery valve at the top of the plunger prevents
the fuel inside the injection pipe from flowing back
to the plunger side as well as sucks back the fuel to 4. Disconnect the stop wire and the ball joint of
prevent dripping. When the valve is forced back by the regulator handle from the injection pump.
the delivery valve spring, it cuts off the fuel to the 5. Remove the cooling water inlet pipe.
injection pipe then descends until it reaches the 6. Remove the injection pump drive gear access
valve seat sucking back fuel. Fuel pressure in the cover.
injection valve is lowered by this descent, which
Fig. FS-19. Removing the access cover
causes the nozzle valve to close as well as sucking
back the fuel which is about to drip.

Fig. FS-17. Delivery valve operation

Delivery valve spring 0

Delivery valve holder

a: Suck back stroke

Printed in Japan
7-10.
 FS
3. Injection Pump [-2./-3.l

7. Disconnect the lubricating oil pipe from the in- Fig. FS-21. Removing the automatic timer
jection pump.
8. Remove the vibration stopper from the injec-
tion pump.
9. Remove the injection pump drive gear together
with the pump coupler from the pump camshaft.
10. Remove the injection pump.

A Note:
When removing the injection pump, do not move
the drive gear unnecessarily.
Automatic timer

b.) Marine engine

1. Procedures 1 - 3 are the same as for the industrial 10. Remove the injection pump.
engine.
4. Disconnect the stop wire and control cable from
the pump.
A Note:
• Do not lose the semi-circular key of the pump
5. Remove the alternator (see page 9-8). camshaft.
6. Remove the automatic timer access cover. • After removing the pump, do not move the auto·
ma tic timer unnecessarily.
Fig. FS-20. Removing the access cover

[3-3.] Disassembly
a.) Model PES-A pump
1. Remove the nuts and remove the feed pump.

Fig. FS-22. Removing the feed pump

7. Disconnect the oil pipe from the pump.

8. Remove the cap from the automatic timer and
drain the lubricating oil.
9. Remove the cap nut. Screw the automatic timer
puller ( 126630-92770) into the cap nut hole.
Remove the automatic timer by tightening the 2. Remove the pump cover.
puller tool with 24mm open end wrench. 3. Rotate the camshaft, and when each cam is at
the top dead center insert tappet holders be-
tween the tappet adjusting bolts and nuts, and
disengage the tappet from the shaft.

Printed in Japan
7-11.
FS
3. Injection Pump [-3.]

Fig. FS-23. Inserting the tappet holders Fig. FS-25. Disconnecting the control rack and link

Tappet holders

4. Recline the pump and remove the screw plugs

with an L-shaped wrench.
7. Remove the link and start spring from the spring
Fig. FS-24. Removing the screw plugs
eye.

A Note:
Be careful not to deform the spring.
8. Remove the round nut attaching the fly weight
with a socket wrench.

Fig. FS-26. Removing the round nut

5. Remove the bolts attaching the governor cover.

A Note:
Mark the length of the bolts to insure original as-
sembly.
6. Slightly shift the governor cover to the governor
side, depress the link arm with a screwdriver and
disconnect the link from the control rack.

A Note:
Be careful not to damage the start spring by shift-
ing the governor cover too much.

Printed in Japan
7-12.
 FS
3. Injection Pump [-3.)

9. Screw an extractor into the fly weight holder Fig. FS-29. Removing the camshaft
and remove the fly weight assembly.

Fig. FS·27. Removing the fly weight

15. Remove the tappet holders.

Fig. FS-30. Removing the tappet holders

10. Remove the key.

11. Remove the bolts attaching the governor housing
and the bolt attaching the spring eye.
12. Remove the governor housing.

A Caution:
Be careful not to damage the oil seal.

Fig. FS-28. Removing the governor housing

16. Insert a roller contracting tool through the screw

plug hole at the bottom of the pump, remove
the tappet to the cam chamber and take out it
from the camshaft hole. Remove the lower spring
seats.

A Note:
Mark each part to insure original assembly.

Fig. FS-31. Removing the tappets

13. Insert a screwdriver in the groove of the bearing
cover, and pry the bearing cover out.

A Note:
Be careful not to damage the oil seal.
14. Remove the camshaft from the pump gear side.

Printed in Japan
7-13.
FS
3. Injection Pump [-3.]

17. Insert a plunger contracting tool through the 19. Place the injection pump upright and remove the
plug hole and remove the plungers. Remove the valve holder lock plate.
plunger springs from the screw plug holes. 20. Loosen the delivery valve holders with a socket
wrench and remove the delivery valve holders to·
A Note: gether with the delivery valve springs.
• Take care not to damage the plungers.
• Mark each plunger to insure original assembly. Fig. FS-34. Removing the delivery valve holders
• Immerse the plungers in clean fuel oil.

Fig. FS-32. Removing the plungm

18. Remove the upper spring seats and control sleeves 21. Remove the delivery valves and delivery valve
together with the control pinion from the cover seats.
plate opening.
A Note:
A Note: Always immerse the delivery valve assembly to·
Mark each part to insure original assembly. gether with the plungers in clean fuel.

Fig. FS-33. Removing the control sleeve Fig. FS-35. Removing the delivery valve

Printed in Japan
7-14.
 FS
3. Injection Pump [-3.]

22. Push the plunger barrels up from the cover plate 24. Align bearing extracting tool hooks to the cam·
opening with your fingers and remove them. shaft ring. Match the bolt to the center hole of
the camshaft and remove the inner race.
A.Note:
Immerse in clean fuel oil. Fig. FS-38. Removing the inner race

A.caution:
Never change the combination of the plunger barrel
and plunger.

Fig. FS-36. Removing the plunger barrel

Bearing extracting tool

25. By using an outer race extracting tool, place the

tapered section in the clearance between the
bearing cover and outer race and screw in the
nut. Then remove the outer race by driving it
out from the roller side of the bolt.

Fig. FS-39. Removing the outer race

23. Remove the rack guide screw at the reverse side

of the pump body and pull the control rack out
to the governor side.

Fig. FS-37. Removing the control rack

b.) Model PES·P pump

1. Remove the nuts and remove the feed pump.

Printed in Japan
7-15.
FS
3. Injection Pump [-3.]

2. Remove the bottom cover by removing the screws. 4. Remove the bearing cover setting screws. Remove
the bearing cover using a bracket extractor.
Fig. FS-40. Removing the bottom cover

A Note:
Do not lose the camshaft end play adjusting shim
between the pump housing and bearing cover.
5. Remove two hexagonal socket bolts securing the
center bearing at the pump bottom with a alien
wrench.

Fig. FS-42. Removing the hexagonal socket bolts

Allen wrench

3. Remove the screw plug at the front side of the

pump. Rotate the camshaft and when each cam
is at the top dead center position, insert tappet
holders in the plug screw holes and disconnect
the cam and tappets.

Fig. FS-41. Inserting the tappet holders

6. Remove the governor (see page 7-37).

7. Lightly tap the end of the camshaft with a wood-
en hammer from the governor side, and remove
the camshaft together with the center bearing.

Fig. FS-43. Removing the camshaft

Printed in Japan
7-16.
 FS
3. Injection Pump [-3.]

8. Install the setting screws of a tappet mounting 11. Remove the plunger springs.
device on both ends of the pump housing. Then 12. Remove the control sleeves and upper spring
operate the lever to push the tappet up, remove seats with a plunger clamp device.
the tappet holders and then remove the tappet Align the ball attached to the sleeve flange with
assembly. the tappet guide groove in the pump housing so
as to remove.
Fig. FS44. Removing the tappet assembly
Fig. FS46. Removing the control sleeve

Tappet holder

9. Remove the tappet mounting device. Hook a

wire into the hole in the lower spring seat and 13. Place the pump upright and remove the closing
remove it. The plunger may also be extracted at cover.
the same time. 14. Remove two flange sleeve fixing nuts.
10. Gently remove the plunger using a plunger insert.
A caution:

A Note:
If the flange sleeve is turned horizontally the fuel
injection volume will change. Therefore, put a
• Be careful not to damage the plunger.
mark on the flange sleeve and pump body.
• Mark each part to insure original assembly.
• Immerse the removed plunger in clean fuel oil. Fig. FS47. Removing the flange sleeve nut
Fig. FS-45. Removing the plunger

Printed m Japan
7-17.
 FS
3. Injection Pump [-3.]

15. Tighten a delivery valve holder assembly extrac- 16. Remove the screw bushing at the opposite side
tor to the delivery valve holder. Rotate the handle of the drive side with a special wrench, and re-
and move the plunger block assembly upward. move the pin and bushing. Then remove the bush-
ing and control rod.
A Note:
• Be careful not to lose the adjusting shim at the A Note:
contact surface of the flange sleeve and pump Be careful not to lose the pin.
housing and the 0-rings at the outer periphery of
the plunger barrel. Fig. FS-49. Removing the control rod
• Mark each part to insure original assembly. Then
immerse in clean fuel oil.

Fig. FS-48. Removing the delivery valve holder

17. Disassemble the plunger block assembly as fol-

lows:
1) Install a fitting plate in a vice, and install the
plunger block assembly on it. Loosen the de-
livery valve holder with a socket wrench.

Fig. FS-50. Loosening the delivery valve holder

1°1I
I

Printed in Japan
7-18.
FS
3. Injection Pump [-3./-4.)

2) Remove two 0-rings from the plunger. Remove [3-4.] Inspection

the snap ring securing the barrel with snap ring
a.) Pump housing
pliers.
Inspect the housing for cracks and thread damages.
Fig. FS-51. Removing the snap ring Replace the housing if necessary.
b.) Camshaft
Inspect for damage or wear at the tapered section,
cam surface and thread, as well as for deformation
of the key groove. Replace the camshaft if necessary.
c.) Bearing
If the bearing surface is peeling off or damaged, or
if the reverse side is dull, replace the bearing.
d.) Tappet
If the bearing surface is peeling of the damaged, or
tappet are worn or damaged, replace the tappet.
e.) Plunger
1. Thoroughly clean the plunger. If the plunger
lead section is damaged or discolored, or if
movement is not smooth, replace the plunger.
2. Tilt it approximately 60°, partly extract the
plunger. It is in good condition if it slides down
slowly under its own weight. Repeat this several
3) Remove the delivery valve holder with your times while rotating the plunger. If it slides too
hand, and then remove the delivery valve gasket quickly or binds along the way, repair or replace
and delivery valve. it.

Fig. FS-52. Removing the delivery valve holder Fig. FS-53. Sliding resistance test of the plunger

Slides down

4) Push the plunger barrel out from the flange

sleeve and remove it.
Printed in Japan
7-19.
FS
3. Injection Pump [-4./-5.]

a.) Model PES-A pump

A Note: Assemble in the reverse order as disassembly, but
In the model PES-P pump, replacing should be done
as an assembly of the plunger block. note the following points:

f.) Delivery valve

1. Inspect the piston and valve seat for damage, dents 1. When assembling the plunger barrel, make sure
and wear and replace it if necessary. that the barrel and pump body are free of dust.
2. After cleaning the delivery valve, block the bot- Then insert the barrel so that the barrel stop pin
tom part of the delivery valve seat with your is in the key groove at the outer periphery of the
finger and push the delivery valve lightly. It is in barrel. Remove the plug, match the barrel so that
good condition if it springs back. If it does not, its port can be seen and place the pin in the
the piston is heavily worn and must be replaced. groove. Rotate the barrel from the cover plate
opening. If it rotates, the pin is not in the key
A Note: groove, so put the pin in securely.
In the model PES-P pump, replacing should be done
as an assembly of the plunger block. Fig. FS-55. Installing the plunger barrel

Fig. FS-54. Testing the delivery valve

2. Assemble a new gasket at the delivery valve and

insert it into the upper surface of the plunger
barrel. Tighten the valve with a delivery valve
holder and seat the valve seat and upper surface
of the plunger barrel. Remove the delivery valve
g.) Plunger spring and delivery valve spring holder and attach the delivery valve spring to the
Inspect the spring for damages, rust and local wear. delivery valve. Then tighten the delivery valve
Replace the spring if not in good condition. holder to the torque of 4.3 kg-m (31 ft-lb).

A caution:
[3-5.] Assembly If the tightening torque of the delivery valve holder
exceeds the specified torque, the plunger will be
A Note: distorted, the sliding resistance of the control rack
Always replace gasket packing, oil seals and 0-rings will increase, and proper performance will not be
with new ones. obtained. Furthermore, it will damage the pump
housing and delivery valve gasket.

Printed in Japan
7-20.
FS
3. Injection Pump [-5.]

Fig. FS-56. Tightening the delivery valve holder Fig. FS-58. Matching position of the control rack and
pinion

Control pinion

Pinch section

4. After engaging the control pinion with the rack,

measure the stroke where the rack is completely
shifted to the governor side. The stroke should be
18 mm (0.71 in). If the stroke is not correct, re-
engage.

Fig. FS-59. Measuring the control rack stroke

3. Align the mark on the control rack to the end

surface of the pump housing and point the pinch
section of the pinion to your side and engage it
with the rack.

Fig. FS-57. Position of the rack when assembling the

control pinion

Scale

5. When assembling the plunger, place the arrow

mark upward. Insert it together with the lower
spring seat into the plunger barrel with plunger
pincers.

Printed in Japan
7-21.
FS
3. Injection Pump [-5.]

Fig. FS-60. Plunger 7. When tightening the bearing cover onto the pump
housing, be careful not to damage the matching
surface gasket and oil seal lip.
II ii 8. After assembling the bearing cover, measure the
shaft end play and adjust it to the standard value
II with a shim.
Standard: 0.03 - 0.05 mm (0.0012 - 0.0020 in)
9. After assembling the injection pump, hook a
spring scale to the control rack and measure the
sliding resistance. Make sure that the entire stroke
slides smoothly and that it moves smoothly at
the load shown below.
Arrow mark Sliding resistance: 150 g (0.33 lb) max.
If the sliding resistance is large it may be caused by
the following. Therefore, disassemble the pump
and wash or repair it.
• Resistance at the sliding section of the plunger
assembly is large.
Fig. FS-61. Installing the plunger • Excessive tightening of the delivery valve holder
(distortion of the plunger barrel).
• Damage or foreign particles at the tooth of the
control rack or pinion, or at the outer periphery
of the control rack.
• Damage to the control rack hole in the pump
housing.

Fig. FS-63. Measuring the sliding resistance of the

control rack

6. When assembling the camshaft, assemble so that

the cam for the feed pump is at the attaching
hole of the feed pump.
Fig. FS-62. Assembling the camshaft

b.) Model PES-P pump

Assemble in the reverse order of disassembly, but
note the following points:
1. When assembling the plunger barrel on the flange
sleeve, align the guide groove in the barrel with
the knock pin of the sleeve.
Printed in Japan
7-22.
FS
3. Injection Pump [-5.]

Fig. FS-64. Assembling the plunger barrel 4. When installing the 0-rings on the plunger barrel,
Guide groove install the upper 0-ring on the plunger barrel
and the lower 0-ring inside the pump housing
I I with an insert.

Fig. FS-66. Attaching the 0-rings

[)

Knock pin

2. Assemble in the order; delivery valve, gasket,

spring delivery valve holder.
5. When attaching the plunger block assembly to
A Note: the pump housing, coat the 0-ring and plunger
barrel skirt with grease. Attach so that the knock
Always assemble after coating the 0-ring on the
delivery valve holder with grease to prevent it from pin on the flange sleeve is at the front side (op-
damage during assembly. posite side as the control rod).
3. Assemble in the order: shim, distance ring and
0-ring from the bottom of the flange sleeve.
Fig. FS-67. Installing the plunger block assembly
Then attach the washer and deflector and secure
them with the snap pin.

A Caution:
As shown in Fig. FS-66, attach the deflector so that
the shorter side measured from the top and bottom
end surfaces to the hole is at the lower side. If this
is reversed, the inlet/outlet port in the plunger bar-
rel and the hole in the deflector will meet, causing
erosion of the pump housing by cutting off fuel
during injection completion.

Fig. FS-65. Installing direction of the deflector

Deflector

Printed in Japan
7-23.
FS
3. Injection Pump [-5.]

6. When tightening the flange sleeve nut, align the 8. Insert the control rod from the driving side. After
scribe lines on the flange sleeve and pump hous- inserting it assemble in the order: bushing, pin
ing made during disassembly. Then equally tight- and screw.
en them alternately with a torque wrench. 9. Assemble the control sleeve from the cam cham-
Torque: 4.3 kg-m (31 ft-lb) ber side, and completely place the ball on the
sleeve in the groove in the control rod.
Fig. FS-68. Tightening the flange sleeve
A Note:
Assembly is made easier if the groove in the control
rod and the tappet guide groove in the pump hous-
ing are aligned.

Aeaution:
If the ball on the control sleeve is not in the control
rod groove, the ball will be deflected when assem-
bling related parts, causing improper sliding of the
control rod after assembly is completed.
Fig. FS-70. Assembling the control rod and sleeve
Ball
Control rod
7. Tighten the delivery valve holder to the specified
torque with a torque wrench or a socket wrench.
Torque: 12 -> 0-> 12-> 0-> 11 kg-m
(87 .... 0 .... 87 .... 0 .... 80 ft-lb)

Aeaution:
If the tightening torque is less than the specified
torque, it will cause oil leakage or damage of the
related parts. If it is too large, it will cause malfunc-
tion of the plunger or damage the related parts.
Fig. FS-69. Tightening the delivery valve holder
10. After installing the control sleeve, assemble in the
order: upper spring seat, plunger spring and
plunger.

A Note:
Install the plunger so that the mark on the flange
is pointing to the front of the pump.

11. While compressing the tappet together with the

plunger spring, insert the flange on the plunger
into the guide groove in the control sleeve with a
tappet mounting device.

Printed in Japan
7-24.
 FS
3. Injection Pump (-5.]

Fig. FS·71. Compressing the tappet If the measured value differs from the specified
measurement, adjust the shim thickness of the gover-
nor housing at the side opposite to the driving side.

Thickness of applicable shims

1.2 mm (0.047 in)
1.5 mm (0.059 in)
1.8 mm (0.071 in)
2.0 mm (0.079 in)

Fig. FS-73. Adjusting the shim (governor side)

Bearing cover
or Governor
housing

12. Note the incised line on the end of the camshaft

and insert the camshaft from the driving side.
Attach a measuring plate to the tapered section
of the driving side, and press in and fix the posi·
ti on of the bearing outer race at the opposite side
of the driving side into the ring so that the dis-
tance from the pump housing end surface to the
measuring plate end surface is L = 13.8 ± 0.5 mm
(0.543 ± 0.020 in).
Fig. FS-72. Measuring the L-measurement

13. After installing the bearing cover, measure the

side clearance of the camshaft with a camshaft
measuring device. If it is not within the standaf'd
limit, adjust with a shim.
Side clearance: 0.02 -0.06 mm (0.0008 - 0.0024 in)

Thickness of applicable shims

0.10 mm (0.0039 in)
0.12 mm (0.0047 in)
0.14 mm (0.0055 in)
0.16 mm (0.0063 in)
-------
0.18 mm (0.0071 in)
0.30 mm (0.0118 in)
0.50 mm (0.0197 in)

Printed in Japan
7-25.
 FS
3. Injection Pump [-5./-6.]

Fig. FS-74. Measuring the camshaft side clearance If the sliding resistance is too large, it may be caused
by the following:
• Resistance of the sliding section of the plunger
assembly is too large.
• Excessive tightening of the delivery valve holder
(distortion of the plunger barrel).
• The ball of the sleeve is not completely in the
groove of the control rod.
• There are foreign particles in the control rod
groove.
• The control rod hole of the pump housing is
damaged.

[3-6.] Adjustment
a.) Model PES-A pump
After assembling the injection pump, adjust as
follows with an injection pump tester.
Pump tester: Yanmar III type marine engine tester or Diesel
Ki ki pump tester.

A.Note:
A pump attaching board is necessary when using
testers other than the Yanmar tester.
• Preparation
Bearing cover 1. Install the pump on the pump tester.
2. Operate the control lever and make sure that the
entire stroke of the control rack is 18 ~~mm
(0. 71 ~8· 1 in). Also make sure that the control
2
14. After completing the assembly of the injection rack moves smoothly to the increased injection
pump, measure the sliding resistance of the cori- volume direction by the force of the start spring.
trol rod. Attach a spring scale to the control rod volume direction through the force of the start
and make sure that the entire strokeslidessmooth· spring.
ly and that it moves smoothly at the load shown
3. Rotate the pump at low speed, loosen the air
below:
bleeder screw and bleed the air from the pump.
Sliding resistance: 130 g (0.29 lb) max.
• Pre-stroke adjustment
Fig. FS-76. Measuring the sliding resistance of the control rod
1. Set the control rack in the position of 12.7 mm
(0.5 in), place the No. 1 cylinder plunger at bot-
tom dead center. Operate the control valve (high
pressure control valve) of the pump tester and
send high pressure fuel into the injection pump.

Printed in Japan
7-26.
FS
3. Injection Pump [-6.]

2. Attach a plunger stroke measuring device to the Fig. FS-78. Aligning the rack mark
cover plate on the injection pump. Touch the
measuring device (dial indicator) to the top of the
No. 1 cylinder tappet, and set the pointer to zero.
3. Rotate the flywheel on the pump tester in the
normal rotation direction of the injection pump.
When the plunger rises and covers the inlet/
outlet port in the plunger barrel, and when the
flow of fuel stops, injection starts. Measure
the plunger stroke (pre-stroke) from bottom
dead center to the start of injection. Mark
Pre-stroke: 2.7 mm (0.106 in)

Fig. FS-77. Measuring the pre-stroke

2. Rotate the pump by hand and check the No. 1

cylinder injection start timing.
3. Rotate the pump in the normal rotating direction
(clockwise when seen from the driving side) and
measure the No. 4 (No. 2 on model 4HAL) cyl-
inder injection start timing. Adjust the interval
to 60° (90° on model 4HAL) by the interval
adjusting bolt.

Fig. FS-79. Measuring the injection interval

4. If the stroke is not the standard value, position

the plunger at top dead center and adjust the
stroke by turning the tappet adjusting screw as
necessary.

• Injection start interval adjustment

1. Align the mark on the control rack with the bush-
ing end surface.

4. Repeat the above-mentioned operation in the fol-

lowing oder and adjust the injection start interval
if necessary.
6HAL: 1 -4 -2 -6 -3 -5
Interval 60° ± 30' each
4HAL: 1-2-4-3
Interval 90° ± 30' each

Printed in Japan
7-27.
FS
3. Injection Pump [-6.]

• Delivery valve fuel leak test Fig. FS-80. Delivery valve fuel leak test
1. Connect an approximately 1000 kg/cm' (14220
psi) pressure gauge to the delivery valve holder.

Pressure gauge
2. Drive the pump, apply pressure of approximate-
ly 120 kg/cm 2 (1707 psi) and measure the time
required for the pressure to drop from 100 kg/
cm 2 ( 1422 psi) to 90 kg/cm2 ( 1280 psi).
Pump speed: 200 rpm
Pressure drop limit: 5 seconds or less

• Injection amount adjustment

1. Measure the fuel injection amount under the
following conditions:
Fuel delivery pressure: 1.6 kg/cm 2 (23 psi)
Fuel injection pressure: 220 kg/cm 2 (3129 psi)

2. Make sure that correct injection nozzles and

pipes are used.
3. Measure the fuel injection amount.
Fuel injection amount

Fuel injection amount Inequality amount

Model Control rack position mm (in) Pump speed rpm
cm 3 (cu-in)/min. %

4HAL 12.7 (0.500) 900 109 ± 2.2 (6.65 ± 0.13) ±2

6HAL
7.5 (0.2951 250 3.75 ± 0.38 (0.229 ± 0.023) ±10

• Pre-stroke adjustment
Inequality amount=
Maximum injection amount Average injection 1. Remove the No. 1 cylinder delivery valve holder,
~-o_f_e_ac_h_c_y_li_n_de_r~~~~~-•-m_o_u_nt~~ xioo delivery valve spring, delivery valve and gasket
Average injection amount from the driving side. Screw a plunger stroke
measuring device to the flange sleeve. Put the
control rod in the full throttle position, rotate
4. If the fuel injection amount is not the specified the pump by hand, put the plunger bottom dead
amount, adjust by moving the pinion and con- center by the plunger stroke and set the dial indi-
trol sleeve position. cator to zero. Slowly rotate the pump in the nor-
mal rotating direction (clockwise when seen from
the driving side) and measure the plunger lift un-
b.) Model PES-P pump til fuel flow from the overflow pipe stops.
After assembling the pump, perform tt>e following
Specified pre-stroke:
tests with a pump tester:
6HAL-T, 6HA(M)E: 3.3 mm (0.130 in)
Pump tester: Diesel Kiki 5760-051
6HA(M)-HTE: 3.0 mm (0.118 in)

Printed in Japan
7-28.
FS
3. Injection Pump [-6.]

Fig. FS·Bl. Measuring the No. 1 cylinder pre-stroke Fig. FS-82. Adjusting the No. 1 cylinder pre-stroke
Plunger stroke
measuring device

A Note:
2. If the measured value is not standard pre-stroke, When replacing the shim, remove the plunger block
adjust by changing the shim thickness between assembly. When assembling the shim on the pump
the flange sleeve and pump. housing, coat each 0-ring with grease, insert the
plunger barrel 0-ring into the housing bore and coat
Thickness of applicable shims the plunger barrel skirt with grease.
0.50 mm (0.0197 in)
0.60 mm (0.0236 in) • Injection start timing interval adjustment
0. 70 mm (0.0276 in) 1. Inspect the angle of injection timing accord-
0.80 mm (0.0315 in) ing to the fuel injection order by using the No. 1
0.90 mm (0.0354 in) cylinder pre-stroke as the base.
0.40 mm (0.0157 in)
0.15 mm (0.0059 in) 2. If the injection start angle is not within the speci-
fied range, adjust in the same manner as adjust-
ing the pre-stroke.

Injection order (cylinder No.) 1 4 2 6 3 5

Injection start angle 0 60° ± 30' 120° ± 30' 180° ± 30' 240° ± 30' 300° ± 30'

Printed in Japan
7-29.
FS
3. Injection Pump [-6./-7.]

• Injection amount adjustment

1. Measure the fuel injection volume under the fol-
lowing condition:
Fuel delivery pressure: 1.6 kg/cm 2 (23 psi)
Fuel injection pressure: 220 kg/cm 2 (3129 psi)
2. Make sure that correct injection valve and pump
are used.
3. Measure the fuel injection amount.

Injection amount

Control rod position Pump speed Injection amount Inequality amount

Model
mm (inl (rpm) cm 3 (cu·in)/min. %

9.0 (0.354) 1050 123 ± 2.5 (7.51±0.15) ±2

6HA(M)E
5.6 (0.220) 200 2.4 ± 0.24 (0.146±0.015) ±10

6HAL·T 8.7 (0.343) 900 133.2±2. 7 (8.13±0.16) ±2

6HAL·HT 5.2 (0.205) 250 3. 75±0.38 (0.229±0.023) ±10

10.3 (0.406) 1050 170±3.4 (10.37±0.21) ±2

6HA(M)-HTE
5.1 (0.201) 200 3.0±0.3 (0.183±0.018) ±10

Inequality amount=
[3-7.] Installation
Maximum injection amount Average injecton a.) Industrial engine
~~of_e_a_c_h_cy_l_in_d_e_r~~~~~•-m_o_u_nt~_x 100
Average injection amount
1. Loosely tighten the injection pump to the attach-
ing base.

A Note:
To adjust the injection amount, loosen two nuts Align the pump camshaft key with the pump cou-
securing the flange sleeve and rotate the flange pling key groove.
sleeve. The adjusting range of the flange sleeve is
approximately 10°.
2. Tighten the injection pump shaft nut to the tor-
Fig. FS-83. Adjusting the injection amount que of 8 kg-m (58 ft-lb).
3. Install the access cover.
4. Install the cooling water inlet pipe.
5. Install the fuel filter and connect the fuel pipes.
6. Connect the fuel injection pipes and torque to
4.3 kg-m (31 ft-lb).
7. Connect the oil pipe.
8. Bleed air from the fuel system (see page 2-4).
9. Adjust the fuel injection timing.

I \...
,I J 7,q !PC,

Printl'd in Japan
7-30.
FS
3. Injection Pump [-7./-8.]

b.) Marine engine 3. Install the automatic timer cap.

1. Loosely tighten the injection pump to the attach- 4. Position the oil supply hole in the automatic
ing base. timer upward and fill with engine oil up to the
oil supply hole (approx. 250 cc).
A Note:
5. Instal I the access cover.
6. Instal I the alternator.
Align the pump camshaft key to the key groove in
the automatic timer. 7. Follow steps 6 to 10 of procedure "Industrial
engine installation" (page 7-30).
2. Install the automatic timer cap nut and torque it
to 14 kg-m (101 ft-lb).

[3-8.] Adjustment
a.) Fuel injection timing adjustment 2. Rotate the flywheel slowly until the No. 1 cylin-
1. Disconnect the No. 1 cylinder injection pipe at der piston is about 35° before top dead center on
the injection pump. the compression stroke.
This position is the injection start timing. Check 3. Observe the delivery valve holder while rotating
that the "1 ·6T" mark on the flywheel is aligned the flywheel, and stop the flywheel when fuel
with the following crank angle of the index plate just begins flowing from delivery valve.
on the housing.

Injection timing

Model 4HAL, 6HAL 6HAL

6HAL·HT 6HA(M)E 6HA(M)·HTE
(rated rpm) (1500) (1800)
Injection timing
26° 29° 23° 21° 17°
(B.T.D.C.)

Fig. FS-84. Inspecting the injection timing

4. Adjustment is made by loosening the injection
pump securing nuts and inclining the pump to-
wards the outside if the injection is too quick
and inclining it towards the engine side if the
timing is too slow .

. ,, .
' I
1 I'

Printed in Japan
7-31.
FS
4. Feed Pump [-1.]

4. Feed Pump
[ 4-1.] Description
The fuel feed pump is installed on the side of the sends it to the injection pump through a fuel filter.
injection pump and is a piston pump which is driven Its construction is shown in Figs. FS-85 and 86. It
by the injection pump cam. also automatically adjusts the fuel delivery pressure.
The feed pump sucks up fuel from the fuel tank and

Fig. FS-85. Construction of the feed pump Fig. FS-86. Construction of the feed pump
(Model PES·A pump) (Model PES-P pump)

Priming pum1-
Piston spring
Priming pump ,
Check valve
Check valve

Check valve

Piston
Piston
Oil seal
Oil seal

Fig. FS-87. Feed pump exploded view (Model PES-A pump)

Printed in Japan
7-32.
FS
4. Feed Pump [-1./-2./-3.]

Fig. FS-88. Feed pump exploded view (Model PES-P pump)

Priming pump
,-- -1

/ Snap ring

.~
Hou,;n~ Ga•k•~ Pipe joint bolt

Fig. FS-89. Operation of the feed pump

Outlet Inlet

Inside chamber Inlet

l
Outside chamber
. I
Inside chamber
Outside chamber
I
Outlet

At rated pressure rise

When the outside chamber pressure

overcomes the piston spring force,
the piston is pushed up and separated
from the push rod

[ 4-2.] Disassembly [ 4-3.] Assembly

1. Remove the plug and then remove the piston Assemble in the reverse order of disassembly.
spring.
2. Remove the piston. A Note:
3. Push the tappet from the opposite side of the When assembling, check each part for wear or dam-
plug and remove the snap ring. age and replace if necessary. Always use new gaskets.
4. Remove the tappet and push rod.
5. Loosen the nut at the bottom of the priming
pump and remove the priming pump assembly.
6. Remove the inlet and outlet check valve springs
and check valves.
Printed in Japan
7-33.
FS
4. Feed Pump [-4./-5.]

[4-4.] Inspection
a.) Air leak test Fig. FS-90. Inspecting leakage from the push rod seal
Inspect the air-tightness of each pipe and packing
etc. Especially check the inlet side because air is Graduated glass
container
likely to enter due to the negative pressure of the Compressed air
suction action during piston movement. 2kg/cm 2 (28 psi)

b.) Push rod seal leakage inspection

Plug the outlet, apply compressed air of 2 kg/cm 2
(28 psi) through the inlet port, place it in an fuel
Plug outlet
tank and inspect for leakage from the push rod seal.
If there are air bubbles over 30 cm' (1.83 cu-in)
per minute, replace the oil seal, push rod or the
feed pump housing.
Leakage volume (new part): 30 cm 3 (1.83 cu-in)/min. max.

[4-5.] Test
a.) Lift capacity test
Under the following condition, check the ability
to suck up fuel by using the priming pump.

Lift capacity

for model PES-A for model PES-P

Pump speed 100 strokes/min. 60 - 100 strokes/min.

-·-
Pipe inside diameter x length 8 x 200 mm (0.315 x 7.9 in)

Lifting height 1 m (3.3 ft) 0.6 m J2.0 ft)

Required time within 40 sec.

b.) Output capacity test (Model PES-A)

Run the pump at 1000 rpm and measure the out-
put capacity while applying pressure of 1 kg/cm 2
to the outlet side of the pump.

for model PES-A for model PES-P

Output capacity 405 cm 3 (24.7 cu-in) min. 530 cm 3 (32.3 cu-in) min.
Required time within 15 sec.

Printed in Japan
7-34.
FS
5. Governor [-1.]

5. Governor
[5-1.) Description
Fig. FS-91. Construction of the governor

Swivel lever

_.-Tension lever

Governor spring

Camshaft

Fly weight

Sleeve
Shifter Full load stop bolt

Floating lever

a.) Condition during engine start Fig. FS-92. Condition of the governor during engine start
When the control lever is operated until it touches
the maximum speed stop, the swivel lever, which
moves integrally with the control lever, pulls the
Control rack
tension lever by the governor spring until it touches
the full load stop bolt. Because the fly weight is not Floating lever
moved during this time, the control rack (rod), Tension lever
which moves with the floating lever through the
force of the start spring provided at the end of the
floating lever, is pushed in the direction of fuel in- Swivel lever

crease. \l\lhen the engine is started, centrifugal force

works on the fly weight. The starter spring is over-
come by this centrifugal force and the shifter is
pushed back until it touches the tension lever.

Fly weight \:;J-Control lever

Printed in Japan
7-35.
FS
5. Governor [-1.]

b.) Condition during idling Fig. FS-94. Condition of the governor during
maximum speed
When the engine is started and the control lever is
returned to the idling position, the governor spring
is free. The fly weight can expand outward even Governor spring
at slow speed, and the tension lever is pushed {Increased tension)
back until it touches the idling sub spring. In this
position the idling lever maintains smooth idling
with the aid of the idling sub spring. This is because
when rotation drops the centrifugal force decreases,
the idling spring pushes the tension lever to the left
and contracts the fly weight to the inside, pushes
the control rack (rod) to the direction of fuel in-
crease to maintain constant idling.

Fig. FS-93. Condition of the governor during idling

Governor spring {free)
J-

d.) Condition during engine stop

By pulling the stop lever to the stop position, the
control rack is moved to the stop position regardless
of the position of the control lever, thus stopping
Tension
lever the engine.

Fig. FS-95. Condition during engine stop

c.) Condition during maximum speed

When the control lever is moved to maximum
output (until it touches the maximum speed
stop) from the idling position, the tension in the
governor sleeve increases which pulls the tension
lever until it touches the full load stop bolt and
moves the shifter and sleeve to the left.
Movement of the guide lever and floating lever is Stop lever
transmitted to the control rack by the link and
maintains the full load position of the rack. Then,
rotation rises to the position where the centrifugal
force of the fly weight and tension of the governor
spring are proportionate, and reaches full load maxi-
mum rotation.

Printed in Japan
7-36.
 FS
5. Governor [-2.]

e.) Performance curve

A Note:
Fig. FS-96. Model PES-A pump • Clean the work bench and operation site before
disassembling.
• Record the performance of the governor prior to
disassembly as well as the tightening amounts of
e900 ± 5 -""""=--=i=::::::::::::==-, the adjusting screws.
• During disassembly, put each part in order.
~750 ± 5 1 - - - - + - - - - - - - 1

! 1. Remove the injection pump (see page 7-10).

,~
. 2. Remove the closing cover attaching bolts at the
governor end surface, and remove the closing
cover.
3. Remove the idling spring lock nut and remove
the idling spring.
0 6 7.5 12.7 18+ 3
Advance angle (Degree) 0
Fig. FS-98. Removing the idling spring lock nut
Fig. FS-97. Model PES-P pump

4.55.1 10.3 13+1.5 18+3

Advance angle (Degree) 0 0

[5-2.] Disassembly 4. Loosen the tension lever shaft plugs tightened

onto both end surfaces of the governor cover.
A caution: 5. Remove the idling sub spring nut and remove the
The governor is sealed to maintain its performance. idling sub spring.
If the seal is removed and adjustment is changed, 6. Remove the governor cover attaching bolts, and
the performance of the engine will change and the separate the governor cover and governor housing.
indicated engine performance will not be obtained.
Therefore, if disassembly is required, be especially
careful and follow these points.

Printed in Japan
7-37.
FS
5. Governor [-1./-2.]

Fig. FS-100. Removing the tension lever

A Note:.
The link is connected to the control rod and the
starting spring to the spring eye. Therefore, depress
the plate spring with a screwdriver from the top,
shift the governor cover to the left (or right) to dis-
connect these and remove the starting spring from
the spring eye with pointed pliers.

Fig. FS-99. Removing the governor cover

···.· -

- Governor
housing

,.;

9. Remove the bottom of the floating lever from the

fork, extract the sleeve from the bottom and re-
move the guide lever together with the floating
Plate spring lever.
10. See Fig. FS-101 to remove the shifter from the
sleeve. Also, see Fig. FS-102to separate the shifter
and bearing.

A Note:
Do not damage the chrome plating at the end of
Aeaution:
the shifter.
When removing the governor cover, take care not
to bend it to the right or left against the governor Fig. FS-101. Disassembling the shifter and sleeve
housing. If the governor cover is bent when the link Extractor tool
is connected, the link will be bent, and after com- Support plate
pleting the assembly of the governor, the sliding
resistance of the control rod will be increased and '
the governor will not move smoothly.
7. Remove the loosened tension lever shaft plugs
and remove the tension lever shaft.
8. Remove the tension lever with your fingers from
the top of the governor cover. Tilt the tension
lever to the side and remove the governor spring
from the swivel lever. "' '

Printed in Japan
7-38.
 FS
5. Governor (-2.]

Fig. FS-102. Disassembling the bearing and shifter 13. Remove the camshaft nut and spring washer with
a special tool. Screw an extractor tool into the
the fly weight holder and remove the fly weight
assembly.

Fig. FS-104. Removing the fly weight

Support plate

11. Remove the control lever, and then remove the

lever shaft collar and shim.
12. Remove two snap rings and remove the bushing
by tapping the swivel lever lightly from the con-
trol lever attaching side. Remove the other bush-
ing and remove the swivel lever. 14. Disengage the tappets and camshaft (see page
7-11 for the PES-A pump and page 7-16 for the
A Note: PES-P pump).
The swivel lever is removed only when the parts 15. Remove the governor housing attaching bolts,
must be replaced or when movement is not smooth, and drive the governor housing out with a wood-
etc. If it is removed, always replace the 0-ring and en or plastic hammer.
oil seal with new ones.
Fig. FS-105. Removing the governor housing
Fig. FS-103. Removing the swivel lever

Printed in Japan
7-39.
FS
5. Governor [-2./~.]

3. The measurement from the end surface of the

A Note: governor housing to the shifter (L measurement)
Thoroughly clean the disassembled parts with clean
is 19 mm (0. 748 in) for the PES-A pump and
fuel oil and inspect for abnormalities. Replace parts
21 mm (0.827 in) for the PES-P pump.
which are excessively worn or are rusty.
Fig. FS-107. "L" measurement

[5-3.] Assembly
Assemble in the reverse order of disassembly, but
note the following points:
1. The tightening torque of the fly weight nut is
8 kg-m (58 ft-lb) for the industrial engine and
6 kg-m (43 ft-lb) for the marine engine.
2. When assembling the shifter and sleeve, install a
bearing on the sleeve and then insert the shifter
as shown in Fig. FS-107.
Governor housing

A caution:
• The assembled measurement of the shifter is ad-
justed according to the shim at the factory, so
do not change the combination of the shim.
• Be careful not to damage the chrome plating sur-
face at the end of the shifter.
4. Install the idling spring on the spring guide, then
A Note: connect them to the tension lever. Adjust so that
After assembly, install the shifter and make sure the measurement from the tension lever end sur-
that the sleeve rotates smoothly. face to the rod end surface is 1.5 ± 0.1 mm (0.59 ±
0.004 in), and lock with a nut.
Fig. FS-106. Assembling the shifter and sleeve
Fig. FS-108. Assembling the idling spring

Q Shifter

Pressing bearing Pressing shifter

Printed in Japan
7-40.
FS
5. Governor [-2.] 6. Automatic Timer (Marine engine only) [-1.]

5. Coat the pump housing-to-governor housing sur- Fig. FS-109. Construction and operation of the automatic
faces and the governor housing-to-governor timer
cover surfaces with liquid sealant (Three Bond Flange
No. 4 or equivalent) to prevent lubricating oil
leakage.

6. Automatic Timer
(Marine engine only)
Fly weight
[6-1.] Description Fly weight holder pin
At low speed
The automatic timer is equipment that controls (Pump speed 550rpm or less)
fuel injection automatically through centrifugal
force by rotation.
The automatic timer adjusts the advancing angle
automatically as follows: - When the speed is in-
creased the fly weight expands outward centering on
the fly weight holder through the centrifugal force.
The roller installed on the fly weight moves outward
along the flange curve while compressing the timer
spring. Because the flange is connected directly to
Centrifugal force
the camshaft, the camshaft rotates only the com-
At maximum speed
pressed amount of the timer spring and injection (Full advance)
timing is advanced.

Fig. FS-110. Automatic timer exploded view

Gasket

~-Cop
Oil seal
\Plug
Gasket

Roller
0-ring
Iv weight holder

Flange assembly
Cover

Printed in Japan
7-41.
FS
6. Automatic Timer (Marine engine only) [-1.]

Advancing angle of the automatic timer

Pump speed rpm 550 ± 50 800 1050

Engine speed rpm 1100± 100 1600 2100
Advancing angle 00 1.9 ± 0.5° 4.5 ± 0.5°
6HA(M)E 21° 24.8 ± 1° 30 ± 1°
Injection timing
6HA(M)-HTE 17° 20.8 ± 1° 26 ± 1°

Fig. FS-111. Advancing angle of the automatic timer

~ 4.5 ± 0.51------------~
~

~
•
°'g• 1.9 ± 0 . 5 t - - - - - - - - 7 ( '
0

~
"C

"'
0 550 ± 50 800 1050

Pump speed (rpm)

Printed in Japan
7-42.
Sec. 8. INTAKE & EXHAUST SYSTEM (IE)

Contents of this section

Page
1. Service Information ................................. 8·1
[1-1.] Tools and Materials.............................. 8·1
[1·2.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8·1

2. Intake System ..................................... 8-1

[2·1.) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8·1
[2-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8·2
[2·3.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8·2

3. Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8·2

[3· 1.l Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8·2
[3·2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
[3-3.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

4. Turbocharger (6HAL·T, 6HAL·HT and 6HA(M)-HTE) ....... 8·3

[4-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
[4-2.l Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
[ 4-3.] Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
[4-4.l Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
[4-5.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
[4-6.l Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
[4-7.] Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
[4-8.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
IE
1. Service Information [-1./-2.] 2. Intake System [-1.]

8. Intake & Exhaust System

1. Service Information
(1-1.] Tools and Materials [1-2.] Specifications
3/8" socket wrench a.) Torque value
5/8" socket wrench
Torque values
Pliers 49160-90100 Item
kg-m ft-lb
Pliers 49160-90200
Compressor lock nut 2.8 20
Pliers 49160-90300
Feeler gauge V-clamp lock nut 1.1 8
Micrometer To tighten the bolts and nuts other than those men-
Dial indicator tioned above, follow the standard tightening torque
Blast equipment (page 1-17).

b.) Service data

Item Standard mm (in)

Bearing housing inside diameter 22.27 (0.8768) Max.
Shaft journal outside diameter 14.25 (0.5610) Min.
Shaft runout 0.015 (0.0006) Max.
Turbocharger
Insert inside diameter (Piston ring end gap) 0.026 -0.102 (0.0010 -0.0040)
Turbine wheel-to-turbine housing clearance (at assembly) 0-44 - 0.85 (0.0173 - 0.0335)
Shaft end play (at assembly) 0.08 - 0.152 (0.0031 - 0.0060)

2. Intake System
[2-1.] Removal
a.) 4HAL and 6HAL 3. Remove the intake manifold.
1. Remove the intake connecting rubber hose (air
cleaner-to-intake manifold).
2. Remove the air cleaner bands and remove the
air cleaner.
c.) 6HA(M)-HTE
3. Remove the fuel injection pipes together with
the stay. 1. Close the kingston cock. Drain the sea water.
4. Remove the intake manifold. 2. Remove the air duct B.
3. Remove the cooling water connecting pipes.
4. Remove the intercooler support and remove the
b.) 6HAL-T and 6HA(M)E
intercooler.
1. On 6HAL-T model, remove air duct C. 5. Remove the injection pipe stay and remove the
2. Remove the fuel injection pipes together with injection pipes.
the stay. 6. Remove the intake manifold.
Printed in Japan
8-1.
IE
2. Intake System [-2./-3.] 3. Exhaust System [-1.]

[2-2.] Inspection Fig. IE-2. lntercooler

a.) Air cleaner (Industrial engine)
The air cleaner swirls the air current with the fin at
the filter paper end and collects the dirt in the air Cover
in the dust cup, as well as filtering the air with
the filter paper. When the element is soiled the red
signal of the dust indicator will appear (635 mm
(25 in) Hq or more). In such cases inspect the
element (see page 2-15).

b.) Intake silencer (6HA (M) El

lntercooler
Remove the cover from the intake manifold and
remove the intake silencer. Inspect for damages.
Fig. IE-1. Intake silencer
w
i·rm' Packings

Support bracket

[2-3.] Installation
Install in the reverse order of removal, but note the
following points:
1. Use new gaskets.
2. After installing, bleed air from the fuel system
(see page 2-4).
3. On the 6HA(M)-HTE model, close the drain
cocks.

c.) Intake manifold

Inspect the inner surface of the intake manifold.
3. Exhaust System
Remove the soil and rust if necessary.
[3-1.] Removal
a.) Industrial engine
d.) lntercooler (6HA(M)-HTE)
1. On 6HAL-T model, remove the turbocharger
Inspect the water passage in the intercooler. Re- (see page 8-3).
move the scales and rust if necessary (see page 2. Remove the exhaust manifold.
6-14).

b.) Marine engine

1. Drain fresh water from the drain cocks at the
fresh water cooler and exhaust manifold.
2. Remove the cables from the thermometer sen-
sor and thermo switch.
3. On 6HA(M)-HTE model, remove the turbo-
charger (see page 8-3).
Printed in Jo.pan
8-2.
 IE
3. Exhaust System(-2./-3.) 4. Turbocharger(-1./-2.)

4.Remove the cooling water pipes (cylinder head fresh water passage in exhaust manifold and
to exhaust manifold). clean if necessary.
5.0n 6HA(M)-HTE model,remove the thermotat 2.0n industrial engine, inspect the seal ring for
case and bypass pipes. damege and replace if necessary.
6.Remove the exhaust manifold.
7.Remove the two exhaust manifold support
brackets. [3-3. ]Installation
Install in the reverse order of removal, but notet
[3-2. ]Inspection he following points:
1.lnspect for cabbon deposits inside the exhaust 1. Use new gaskets.
manifold and clean if necessary. For marine 2.Close the drain cocks.
engines, inspect for scale and rust inside the 3.For marine engine, pour in coolant.

4. Turbocharger
(6HAL-T, 6HA(M)-HTE, and 6HA(M)-DTE)
[ 4-1,] Description
The turbocharger consists of a centrifugal comp- smoke density, cylinder temperature and fuel
ressor installed on the same shaft as the double consumption, and decreases declension of perfor-
current turbine which is driven by the exhaust mance at high altitude during low boost presure.
gas from the engine. By supplying a largea Moreover, the high boost pressure increases
mount of intake air this mechanism reduces engine output.
Model Turbin nozzle area Caril Blower type Engine model
4LF302 24.9 302 6HAL-T
4LF402 29.7 402 6HAL-HT
4LF602 29.7 602 6HA(M)-HTE
4LF602 29.7 602 6HA(M)-DTE

Fig. IE-3. Construction of the turbocharger Bearing housing

Turbine Housing

Compressor cover

Compressor wheel
Shaft/Turbine wheel assembly

Flinger sl-·..--

Bearings
[4-2. ]Removal.
1.Disconnect the lubricationg oil pipes at the 3.Remove the exhaust vent together with the at-
turbocharger. taching base.
2.Disconnect air duct A and the rubber hose. 4.Remove the turbocharger.

Printed in Japan
F032G0223 8-3.
IE
4. Turbocharger [-3.]

[ 4-3.] Disassembly Snap rings

Fig. IE-4. Turbocharger exploded view Oil deflector

O;i cont,ol sl->

Bearings
Thrust rings
Thrust bearing

Lock nuts for

"V" clamp

\"O" ring

1. Loosen the clamp and remove the compressor 4. Remove the compressor wheel.
housing. 5. Remove the shaft/turbine assembly from the
2. Loosen the clamp and remove the turbine hous- bearing housing/pin assembly.
ing. 6. Remove the snap pin securing the insert with
3. Hold the boss of the turbine wheel with a 3/8" pliers (49160-90100).
or 5/8" socket wrench. Loosen the compressor 7. Slowly extract the insert with two screwdrivers.
wheel lock nut with a 5/8" socket wrench and
remove it. Fig. IE·6. Removing the insert

Fig. IE·S. Removing the lock nut Bearing housing

Flinger sleeve
Insert

Printed in Japan
8-4.
 IE
4. Turbocharger [-3./-4.]

8. Remove the flinger sleeve, oil deflector, thrust

rings, thrust bearing and spacer sleeve.
A Note:
Be careful not to erode the bearing hole and sealing
A caution:
hole.
5. Clean by blowing in compressed air. Completely
Do not remove the groove pin since it is press-fit.
remove sol id matter from oil passages.
9. Remove the snap rings with pliers (49160-90200)
6. Immerse it again in inflammable cleaning solu-
and remove the bearings and oil control sleeve.
tion.
Fig. IE-7. Bearings and control sleeve 7. Use compressed air to dry it.
8. Coat the inner and outer surfaces with oil, and
keep it in a clean vinyl bag etc. until inspection
Snap rings and assembly.

le~
Snap rings

A
co. c
b.) Compressor wheel
1. Immerse it in inflammable cleaning solution and

I
Oil control sleeve
remove the oily dirt.
2. Use compressed air to dry it.
3. Apply vapor blast or dry honing to the entire
surface.

Bearings A Note:
Try as much as possible not to touch the inside
10. Remove the sealing rings from the flinger sleeve. diameter.
Remove the sealing rings from the shaft/turbine 4. Perform the after-blast cleaning by blowing com-
wheel assembly. pressed air.
A caution:
5. Keep it in a clean vinyl bag etc. until inspection
and assembly.
Do not expand the sealing rings too much to avoid
damage.
11. Remove the snap ring with pliers (49160-90300)
c.) Shaft/turbine wheel assembly
and remove the turbine back plate.
1. Immerse it in inflammable cleaning solution and
remove the oily dirt.
[ 4-4.] Cleaning 2. Use compressed air to dry it.
3. Cover the shaft with a suitable rubber hose etc.
A Note: and apply vapor blast or dry honing to the en-
• Use mild soap for cleaning. Do not use corrosive tire turbine wheel.
detergents.
• Use a plastic scraper or hard bristled brush for A caution:
the aluminum parts. Be careful not to concentrate the application on the
• If blast equipment is not prepared, effective seal ring groove.
alternatives may be used. 4. Remove the cover from the shaft. If the journal
is rough, polish it lightly with No. 400 sandpaper.
5. Immerse it again in inflammable cleaning solu-
a.) Bearing housing/pin assembly tion.
1. Clean deposits and accumulations on the surface. 6. Use compressed air to dry it.
2. Immerse it in inflammable solution and remove 7. Coat the shaft with oil and keep the assembly in
the oily dirt. a clean vinyl bag etc. until inspection and assem-
3. Use compressed air to dry it. bly.
4. Apply vapor blast or dry honing to the entire in-
ner and outer surfaces.
Printed in Japan
8-5.
IE
4. Turbocharger [-4./-5.]

d.) Compressor housing a.) Bearing housing/pin assembly

1. Remove the deposits on the outer surface with a 1. Inspect for cracks, damage, pitching at the gas-
plastic scraper or hard bristled brush. ket surface and machine processed surface, and
2. Immerse it in inflammable cleaning solution and deformation of the flange at the turbine side.
remove the oily dirt. Replace the parts if necessary.
3. Use compressed air to dry it. 2. Inspect the bearing hole and piston hole and re-
4. Apply vapor blast or dry honing to the entire place the parts if they are heavily damaged or
cover. worn. Also replace parts if the bearing hole
5. Perform the after-blast cleaning by blowing com- inside diameter exceeds the standard value.
pressed air. Bearing hole inside diameter
6. Keep it in a clean vinyl bag etc. until inspection Standard: 22.27 mm (0.8768 in) max.
and assembly.

b .) Compressor wheel
e.) Turbine housing and turbine back plate 1. Inspect blades for distortion, damage, corrosion
1. Immerse them in inflammable cleaning solution and signs of interfering and replace if necessary.
and remove oily dirt.
2. Blow compressed air to dry them. A caution:
3. Clean the inner and outer surfaces by a sand blast Do not straighten the blade deflection.
or steel grit blast. 2. Inspect for signs of interfering with the bearing
4. Perform the after-blast cleaning by applying com- housing and the piston ring groove. Replace the
pressed air. part if it is heavily damaged or worn.
5. Coat the inner and outer surfaces with oil and 3. Inspect the journal for damage and wear. Replace
keep them in a clean vinyl bag etc. until inspec- the part if it is heavily damaged or if the outside
tion and assembly. diameter is less than the standard value.
Journal outside diameter
Standard: 14.25 mm (0.5610 in) min.
f.) Small parts 4. Measure shaft runout by using a dial indicator
and V-block. Replace the part if it exceeds the
1. Immerse them in inflammable cleaning solution
service limit.
and remove oily dirt.
Service limit (total indicator reading): 0.015 mm (0.0006 in)
2. Wipe dry with a clean cloth.
3. Coat them with oil and store them until inspec-
tion and assembly. A caution:
Do not straighten the shaft runout.
Fig. IE-8. Measuring the shaft runout
g.) Pipe connecting parts
1. Immerse them in inflammable cleaning solution
and remove oily dirt and deposits.
2. Brush them carefully at the screw section.
3. Immerse them in inflammable cleaning solution
and blow compressed air to dry them.
4. Keep them in a vinyl bag etc. until assembly.

[4-5.] Inspection
A Note:
Inspect each part after cleaning.
Printed in Japan
8-6.
IE
4. Turbocharger [-5./--{;.]

c.) Compressor housing

A Note:
Inspect for signs of interfering with the compres- Install the snap ring with the flat side facing the
sor wheel. Replace the part if it is heavily damaged. back plate.
Remove small score with sandpaper etc. 2. Install the snap ring in the groove in the inside
with pliers (49160-90200).

d.) Turbine housing and turbine back plate A Note:

Inspect for signs of interfering with the turbine Install the snap ring with the flat side facing the
wheel, and cracks, pitching and deformation due to compressor side (the rounded surface to the tur-
overheating and replace or polish the part if neces- bine side).
sary. 3. Coat the bearing with clean lubricating oil and
fit it until it touches the snap ring.
4. Install the control sleeve with the flat surface
e.) Insert side facing the bearing side, and install the snap
Insert a new sealing ring into the insert bore, make ring in the groove at the outside.
sure that the outer periphery is securely fitted and Fig. IE-9. Installing the bearing
measure the ring end gap with a feeler gauge. If the
measured value is not within the standard value, re-
place the insert. Snap rings

A le~
Ring end gap
Standard: 0.026 - 0.102 mm (0.0010 - 0.0040 in)

f.) Flinger sleeve co. c

Inspect the flinger sleeve surface, sealing ring groove
and flinger. Replace the part if it is excessively dam-
aged or worn.
I
Oil control sleeve

Bearings

[ 4-6.] Assembly 5. Turn the bearing housing assembly so that the

turbine side points down. Install the snap ring
A Note: in the inner groove so that the rounded surface
Replace the following parts with new ones during points to the bearing side. Coat the bearing with
reassembly. lubricating oil and install it, then install the snap
Assembly ring in the outer groove so that its rounded sur-
face points to the bearing side.
Part name Number
6 Coat the sealing ring with lubricating oil and in-
Lock nut 1 stall it in the groove in the shaft/turbine wheel
Sealing ring (compressor side) 2 assembly, being careful not to expand it too
0-ring (small diameter side) 1 much. After installing the sealing ring in the
Thrust bearing 1 groove center.
Bearing 2 7. Carefully insert the shaft/turbine wheel assembly
0-ring (large diameter side) 1 into the bearing housing until the wheel seats
Sealing ring (Turbine side) 1 the turbine back plate.

1. Place the bearing housing assembly with the com- A caution:

pressor side down on a work bench. Install the • Be careful not to damage the turbine blades.
turbine back plate and install the snap ring with • Do not force the sealing ring into the hole with-
pliers (49160-90300). out centering.
Printed in Japan
8-7.
 IE
4. Turbocharger [-6.]

Fig. IE-10. Installing the shaft/turbine wheel assembly

A Note:
Be careful that the turbine wheel assembly does
not slip off the bearing housing assembly.
Bearing housing 15. Pass the insert through the shaft, insert it in the
bearing housing and press it down until the
snap ring groove appears. (Tap it lightly with a
0 plastic hammer if necessary.)

ll~
16. Attach the snap ring to the housing groove with
pliers (49160-90100) so that the inclined surface
of the snap ring points outward.

~
17. Install a dial indicator on the bearing housing as-
sembly and aim the pointer to the end of the
shaft. Move the shaft up and down and measure
the turbine wheel-to-housing clearance. If the
measured value is not within the standard value,
Shaft/Turbine wheel
assembly disassemble and check the cause (for example
Sealing ring scratches, deposits, mis-matchings, etc.)
Turbin wheel-to-housing clearance
Standard: 0.44 - 0.85 mm (0.0173 - 0.0335 in)
8. Install the thrust ring on the shaft.
9. Coat the thrust surface of the thrust bearing with
clean lubricating oil. Align the thrust bearing with Fig. IE-12. Measuring the turbine wheel-to-housing
the groove pin and install the thrust bearing. clearance
10. Insert the spacer sleeve in the shaft and pass it
through into the thrust bearing.
11. Install the thrust ring, then install the oil deflec-
tor with the buffle down and aligned with the
groove pin.
12. Coat the sealing ring with lubricating oil. Install
it in the groove center in the flinger sleeve.
13. Install the 0-ring in the insert and insert the
flinger sleeve.

Fig. IE-11.

Thrust
ring

14. Place the bearing housing assembly with the com-

pressor side down and support the turbine wheel
with a wooden or plastic block.
Printed in Japan
8-8.
IE
4. Turbocharger [-6./-7./-8.]

18. Install the compressor wheel on the shaft. 21. Install the 0-ring in the groove in the flange on
the bearing housing.
Fig. IE-13. Attaching the compressor wheel 22. Install the V-clamp on the compressor side flange
on the bearing housing.
23. Lightly coat the flange surface on the bearing
housing with grease, attach the compressor cover
and then attach the V-clamp to the housing and
cover.
24. Coat the screw on the clamp and seat of the lock
nut with graphite grease. Tighten the lock nut to
the torque of 1.1 kg-m (8.0 ft-lb).
25. Measure the turbine back plate-to-turbine wheel
clearance with two feeler gauges. If the measured
value is not within the standard value, check for
the cause as in procedure 17.
Back plate-to-turbine wheel clearance
Standard: 0.43 - 0.97 mm (0.0169 - 0.0389 in)
26. Install the turbine housing on the bearing housing
19. Coat the threads and seat of the lock nut with assembly as in procedures 22 to 24.
graphite grease and install it on the shaft. Torque
it to 2.8 kg·m (20 ft·lb) with a 3/8" or 5/8" sock·
et wrench. Rotate the wheel with your hand and [4-7.] Storage
make sure that the wheel rotates freely without
binding. If necessary, disassemble and perform
procedures 1 to 19 above.
A Note:
When storing the turbocharger, it is very important
20. Install a dial indicator on the bearing housing,
to prevent foreign matter from entering it.
place it at the end of the shaft and measure the
1. Cover all openings of the turbocharger.
end play. If the measured value is not within the
standard value, check for the cause as in proce- 2. If it is not installed on an engine immediately,
spray oil over the whole body, put it in a clean
dure 17.
vinyl bag etc. and have the container sealed dur-
End play
Standard: 0.08 -0.152 mm (0.0031 - 0.0060 in)
ing storage.
3. Store it in a place where temperature change is
Fig. IE-14. Measuring the end play minimum, with low humidity and no dust.

[4-8.] Installation
1. Check the air duct pipe for damage and replace
it if the lining is peeling off.
2. Check that there is no foreign matter in the
intake system and exhaust manifold.

A caution:
Even small particles will cause great damage in the
rotor if sucked in at high speed.
3. Use a new gasket between the turbocharger and
manifold, and install the turbocharger.

A Note:
Make sure that the old gasket materials are com-
pletely removed. Coat the bolt threads with oil.
Printed in Japan
8-9.
IE
4. Turbocharger [-8.]

4. Connect air duct A to the rubber hose.

A Note:
If the V-clamp is loosened to change the direction
of the compressor cover or turbine housing, reinstall
it properly on the flange and torque the V-clamp
nut to 1.1 kg-m (8.0 ft-lb).
5. Install the outlet vent.
6. Fill the bearing housing with clean lubricating oil.
7. Connect the oil supply pipe.
8. Crank the engine until lubricating oil flows from
the oil outlet evenly. Connect the oil output pipe.
9. Start the engine, run it at idling speed for 3 min·
utes or more and inspect the oil supply pipe for
oil leakage. Also this prevents oil cut-off and gets
rid of smal I particles.
10. Inspect the engine oil level.

Printed in Japan
8-10.
Sec. 9. ELECTRICAL SYSTEM (ES)

Contents of this section

Page
1. Battery and Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
[1-1.] Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
[ 1·2.] Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9·5
[1-3.] Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
[1-4.] Regulator (Industrial Engine Only) . . . . . . . . . . . . . . . . . . . 9-14

2. Starting System .................................... 9-15

[2-1.l Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
(2-2.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . 9-19
[2-3.] Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9· 19
[2-4.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . 9-20
[2-5.] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9·24
[2-6.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
[2-7.] Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

3. Instruments ....................................... 9-25

(3-1.l Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
(3-2.] Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
[3-3.] Cooling Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . 9-26
(3-4.] Lub. Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

4. Warning System (Marine Engine Only) ................... 9-28

[ 4-1.] Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
[ 4-2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . 9-29
ES
1. Battery and Charging System (-1.)

9. Electrical System
1.Battery and Charging System
[ 1-1. ]Service Information

a.)Tools and materials

Bearing puller
Service tester
Verner calipers

b. )Specifications
Specifications

Industrial engine Marine engine

Item
6HAL 6HA(M)-HTE
4HAL 6HAL-T 6HA(M)E
6HA(M)-OTE
&HAL-HT

Capacity x number 12V /120A H x 2 12V/150AH X2 12V/150AHx2 12V /200A H x 2

Battery
Specific gravity 1.260/20'C --
Sawafuji type PB-2123 0.213-401-0311

Nominal voltage DC-24V -

Output 400W -
Alternator
(Generator)
Charge starting
Reted output
27V/min.(Less than 900 rpm)
15A (at 5000rpm/28V)
-
14.5A(at 3000rpm/28V)

Rotation direction Clockwise{viewed from driving side)

Pulley B-68 belts x 2 A beltsx 1

Built-in regulator ········· Silicon transistor type

Regulator Sawafuji type PB-5058(Tirrill type) .........

c. )Service data

Item Standard Service limit

Slip ring diameter 111m(in) 37.5(1.476) 35(1.38)

Rotor coil resistance Approximately 16-200(at 20'C, 68'F)

Stator coil resistance 1-1.30 (at 20'C, 68° F )2-plTase resistance

Brush length mrn(in) 19(0.75) 10(0.4)

V-belt deflection 111111( in) 10-15(0.4-0.6)

Printed in Japan
F032G0223 9-1.
co ... :"' en
m
-::E
Q.
~ ,p·
m
Cf'
..ii
ID

s:
:"'
::i <..
.....
:=.-:::: n
..,<> " ::r "'Q.iii"
~ c: a
::0
Q.

Instrument panel
CD
=- =· "'iil3
:=. i;·
3 - .!2
CQ ...9
.
~

;;;·
1.25W 1.25Y -=
s·
=-
.., CD
3 ~
Tachometer Lube oil pressure gauge Wire color code
lE ..3
w

0 JIT3W:F5
CD ~
B: Black W/B: White/Black
:e:::+" ::!.
-·
~·
Cooling water G Green WIG: White/Green
~
temp. switch R: Red W/l: White/Blue ::r cii! I
1J·~-~
W:White W/R: White/Red !!.. ... ~
nCD .,

.
Y:Yellow W/Y· White/Yellow -·
ct~
Starter
L/W: B~~e/White
-·
1_3
w~ ~·m
switch CD
3

Charge warning Engine stop Warning lamp

5W

5R WIG W/L B W/l WIG L/W W W/L

...
~
CD
lamp switch Viewed from A-A Viewed from B·B "
-!!
r1 Engine bed

-,I ~l~I"'"I>
l '
I t' ;I I Starter
Motor
I
~l"'I""
in1ninininin

::::::
- I

'"..: ltjfiif.. "-~

II Battery switch ...-- - - -- .
I r-
-~,. ~--!'l.:~l- ---J:
$
1'71( I

M 12V
~"·" """ 'F3 1.25 y I I ~
1.25Y ==
Battery f-A t.25Y LO. pressure
switch Emergem;y
1.258 Caurions:
Relay
Regulator (1) L.0. pre$$Ure 1. Alwaysusa24Vbattery.
5B 2. Tum off the battery switch when connecting
1.258 ~ (2) C.W.
temperature <1nd disconnecting the wires.
3. ConntJCtall wires properly.
1.25W/L
4. Do not tum off the battery switch while
~ running the engine.
1.25 W/G 5. Before charging a battery, tum off the bat-
NOTE:
1.25W/Y
Alternator 1. Dotted line (- · - -j indicates local purchase tery switch and remove the cap from each
..-:-2sw1e parts. cell.
2. The wires in the instrument panel are A V0.5 6. Keep flame' and sparks away from charging
unless otherwilitl indkated. battery.

~
~-
~

••
~
~
 '.\'
~-
......,
m
~

. "'
CD
m

••
~ Wire color code
..."' ~
<m
..."s; re.-.
§ -n ~
B : Black - ::r Q.

....-"
Instrument panel
L/W: Blue/White n
::r
Lube oil· pressure- g~uge Water temp W : White m

."'s·
0
~.CCI
gauge Cooling water ~
.;;
W/8: White/Black -<

. f-- 8 1.25W
=
temp. sender unit W/G: White/Green
W/L: White/Blue
"'" -
~

-·3 .
ill :!
<
~

~
W/Y: White/Yellow :;
rt= I DD Y : Yellow
:e
;: :;.· =·
~· 3

....
::r ..
1.25L/W 6PM 6PF I
3 !:!-:
Starter Charge warning r 8
W/8 W/Y y B
....
n..,
~

~ ~
switch ::r-
lamp (JW)
" 3
5W

5R W/G W/L B L/W W W/L

.
[
3

Vliwed from A-A Viewed from 8-B

=
'lii
sterter motor "
~
r, Engine bed ~
..."
d-!- l' I -, :.:!
I ~
- I I 1.25Y ~
II

~
--1rt--ti,-~-
Battery switch NOTE:
1. Dotted line (- · - ·} indicates local purchase
__so mm' :
- - - - - -· parts.
2. The wires in the instrument panel are A V0.5
L.O. pressure unless otherwise indicated.
~ f--A sender unit
Battery Cautions:
6PF 1. Alwaysuse24Vbattery.
1.25W/L 5R 1.258 2. Turn off the battery switch when connecting
and disconnecting the wires.
Regulator
1.258 3. Connect all wires properly.
4. Do not wrn off the battery switch while
running the ngine.
1.25W/L 58 5. Before charging a battery, turn off the
1.258 battery switch and remove the cap from
1.25W/G each cell.
6. Keep flames and sparks away from charging
1.25W/Y Alternator
battery.
1.25W/8

"'?>
ES
1. Battery and Charging System [-2.]

[1-2.] Battery • Elec1rolyte specific gravity

Measure the electrolyte specific gravity with a hy-
Awarning: drometer.
• Because the electrolyte is poisonous, be careful when
handling or storing it.
• Avoid the electrolyte touching skin, eyes or clothing.
A Notes:
• Take the specific gravity reading at the highest
Antidote: EXTERNAL-Flush with water.
level as shown in Fig. ES-5.
EYES: Flush with water and get prompt medical
• Be careful not to spill the electrolyte outside the
attention.
battery.

Fig. ES-5. Measuring the specific gravity

a.) Inspection
• Visual inspection
1. Inspect the case for cracks, damage and electro-
1yte Iea kage.
2. Inspect the battery holder for looseness corro-
sion and damage.
3. Inspect the terminals for rust and corrosion, and Hydrometer

the cables for damage.

4. Inspect the caps for cracks, electrolyte leakage
Electrolyte
and clogged vent holes.

• Electrolyte level •
Inspect the electrolyte level every 7 - 10 days. The
electrolyte must always be 10- 20 mm (0.39 - 0. 79
in) above the plates. If it is lower, add distilled water
up to the prescribed level.
Battery capacity measured by the hydrometer
(at electrolyte temperature 20°C, 68°f)
Fig. ES-4. Inspecting the electrolyte level
Specific gravity Capacity Charging

1.230 or more 75% or more Unnecessary

Necessary
1.200 50% (quick-charge allowed)
Necessary
1.170 25% (bench charge)
Proper level

Too high
WliIiToo
Ill/low///11/1

Prinled in Japan
9-5.
ES
1. Battery and Charging System [-2.l

Fig. ES-6. Relationship between electrolyte temperature

A Not~: and specific gravity
Measure the temperature oftheelectrolyteandcon-
vert the specific gravity at 20° C. 1:-
·~
1.29 - -- r...
--....
- Conversion formula -
~ 1.28 - .... ...... ....
S20 = St+ 0.0007 (t - 20)
S20 = Specific gravity at 20° C "'·~ 1.27
....
-
,_ ..... - ---- --
-
~

en
St Electrolyte specific gravity {actual measured value) 1.26
-- .... -- .... r...
-
~

t Electrolyte temperature .... ,_

1.25 .... --- -- ~

1.24 -- ....
r-.
,_ -
1.23 --
b.) Battery charging -10 0 10 20 30 40 50
Electrolyte temperature (°C)
1. Inspect the electrolyte level and specific gravity.
2. Connect the <±l of the charger to the <±l terminal
of the battery and the 8 to the 8 terminal. Fig. ES-7. Amount of self-discharge
3. When performing the quick-charge, set the cur- ~ 6
rent to 1/2 or less of the battery capacity, and E
for the bench-charge set it at 1/10 or less. "0
E
5
'
4. Measure the specific gravity during charging and
check that gas is being generated to confirm that
••
.c
~
• 4 ""- --........
the battery is being charged properly. ~

..
~ 3 " r-.....
en
"" ""--- -
Awarning: 2

-
-
"
• Battery produces explosive gases. Keep sparks, flames
I'....
and cigarettes away.
• The electrolyte temperature should not exceed 45°C. "-
• The ON and OFF for charging should be done with the 0 2 3 4 5 6
charger switch. If it is done at the battery terminal, it Period after charging !Days)
will give off sparks and may lead to explosion.

A caution:
• Remove the battery caps during charging.
• When charging with the charger, remove the bat- c.) Battery cable
tery cables since it will affect other equipment.
If the battery cable is too long, loss of voltage (re-
sistance) along the way will increase and full capaci-
ty will not be obtained. Therefore, select the bat-
The life of the battery differs greatly according to tery length and the cross section area as shown in
how it is used, but generally if it is used for over 2 Fig. ES-8.
years the capacity will decline and it will be diffi-
cult to start the engine. If capacity is not fully
recovered even after re-charging, replace the bat- Fig. ES-8. Relationship between cable length and resistance
tery with new one. Also, since the battery will 60mm2

v
self-discharge even when it is stored, re-charge about
once a month in summer and once every two
months during winter.
~

0"
z ......
.....
I./
..... ~
..... ----100mm 2
120mm 2
80mm 2

~ - -- - -2 4 ~
:.--- - -
150mm2
~-o.oo 2(0hme)

~
:::>
'
2 4 6 8 10 12 13 14 16 18 m
Battery cable length (Total of+ and - )

Printed in Japan
9-6.
ES
1. Battery and Charging System [-3.]

Example:
If the (±J cable is 3.5 m, the 8 cable is 3.5 m and
the sum is 7 m, then loss resistance is 0.002 n or
less according to the graph in Fig. ES-8. Therefore,
a cable with cross section of 60 mm' is allowable.

[1-3.] Alternator
a.) Description
The alternator for marine engines is equipped with
a built-in full transistor type regulator, which does
not produce electric waves to obstruct the radio or
fish detector. The regulator and the alternator for
industrial engines are separate.

Fig. ES-9. Alternator sectional view (industrial engine)

Stator coil~
Stator
Brush cover---~ ~---Bearing holder

~---Ball bearing
Brush spring---~

Brush holder---~

Brush---~
~---Key

Rear cover---~
'------IPulley

+ Side diode---~

- Side diode---~

'----'Fan
Rotor

' - - - - F r o n t cover

Printed in Japan
9-7.
ES
1. Battery and Charging System [-3.]

fig. ES-10. Alternator sectional view (marine engine)

Stator coil
Brush cover---,
Stator

Brush spring---,
~-----Bearing holder
Brush holder---,
Brush,---, ~-----Ball bearing

,,------Key

Regulator cover-----111
Regulator------<11111-
Ball bearing------111--

~-----Pulley
Rear cover---'

+ Side diode, _ _ _,

- Side diode, _ _ _J ~-----Fan

Rotor
~-----Front cover

b.) Removal fig. ES-11. Removing the alternator (industrial engine)

• Industrial engine
1. Remove the V-belt cover.
2. Remove the V-belt adjustor.
3. Disconnect the wire leads at the alternator.
4. Remove the alternator.

Pivot bolts

Printed in Japan
9-8.
ES
1. Battery and Charging System [-3.]

• Marine engine 3. Remove the regulator (marine engines only).

1. Remove the V-belt cover.
2. Loosen the V-belt adjusting bolt and remove the Fig. ES-13. Removing the regulator (marine engines)
V-belt.
3. Remove the generator cover.
4. Disconnect the wire leads at the generator.
5. Remove the generator.

Fig. ES-12. Removing the alternator (marine engine)

Regulator

4. Remove the brush holder cover.

5. Disconnect the wires from the brushes.

A Note:
Mark the connecting positions of the wires.
Pivot bolt

Fig. ES-14. Connection of the brush wires

c.) Disassembly k..--------.~

~
1. Remove the transistor regulator cover (marine
engine). Marine engine Industrial engine
2. Remove the solder and disconnect the wire leads
at the regulator (marine engine).
6. Remove the brush holder attaching bolts, and re-
A Note: move the brush holder together with the brushes.
Mark the wire colors and regulator terminal codes
to insure original connection. Fig. ES-15. Removing the brushes

Terminal code Cable color

Industrial engine E Black (AV5)
B Red (AV5), White/Blue (AVl.25) Brush holder
F White/Black (AVl.25)
N White/Green (AVl.25)
Marine engine B Red (AV5)

(]
E Black (AV5)
L Blue (AV-.85)

Printed in Japan
9-9.
ES
1. Battery and Charging System [-3.l

7. Remove the 3 through bolts securing the rear and 11. Remove the solder at the middle section of the
front covers. When separating the rear and front, lead wire coming from the stator coil and diode,
place the pulley downward and lift up the rear and separate the stator coil from the rear cover.
cover.
Remove the stator and rear cover together. Fig. ES-19. Separating the rear cover and stator

Fig. ES-16. The front and rear when separated

12. Remove the nuts at each terminal and then re-

move each bushing.

8. Hold the rotor with a vise on the copper plates

A Note:
Mark the assembling order of bushings on each
and remove the pulley nut. terminal to insure original assembly.
Fig. ES· 17. Removing the pulley nut 13. Remove the rear cover and diode holder attach-
ing screw (also attaching the condenser holder).
14. Remove the diode holder from the rear cover.
15. Remove the solder of the lead cable and diode.

A Note:
When melting the solder grip the diode side with
long nosed pliers and be careful that heat is not
transmitted directly to the diode.
Fig. ES-20. Removing the solder at the diode

9. Remove the V-pulley/fan with a puller. Remove

the semi-circular key.
10. Remove the bearing protector tightening bolts
and separate the front cover and rotor.
Fig. ES-18. Separating the front cover and rotor

Pulley/Fan Rotor

Front cover

Printed in Japan
9-10
ES
1. Battery and Charging System [-3.l

Fig. ES-21. Stator and rear cover exploded view

Rear cover
Diode holder

f)o<ll. {

~~4fe-o
a{;
d.) Inspection Fig. ES-23. Continuity test for the rotor coil
• Slip ring
Wipe clean slip rings with cloth immersed in alcohol.
Inspect the slip rings for roughness. If the surfaces
are rough polish with No. 500 - 600 sandpaper.
Measure the diameter of the slip rings.
Standard: 37.5 mm (1.476 in)
Service limit: 35 mm (1.38 in)

Fig. ES-22. Measuring the slip ring diameter

• Rotor coil ground test

Inspect for continuity between one slip ring and the
rotor core or shaft. If there is continuity the coil or
slip ring is grounded and the rotor should be replaced.
Fig. ES-24. Ground test of the rotor coil
Slip rings

• Rotor coil continuity test

Inspect the continuity between the slip rings. It is
in good condition if the resistance is within or close
to the specified value. If the resistance is extremely
low, there is a layer short at the rotor coil; and if
there is no continuity, the coil is an open circuit.
In either case replace the rotor.
Rotor coil resistance: Approx. 16 - 20 n (at 20°C, 68°F)

Printed in Japan
9-11.
ES
1. Battery and Charging System (-3.]

• Stator coil continuity test Fig. ES-27. Measuring the brush length
Inspect the continuity of each output terminal. The
stator is in good condition if the resistance is near
the specified value. If there is no continuity, the
coil is open, so replace the stator.
Prescribed resistance value of the stator coil:
Approx.1-1.3S"! (at 20°C, 68°F)

Fig. ES-25. Continuity test of the stator coil

• Brush operation
Make sure that the brushes move smoothly in the
brush holder.
• Diode

• Stator coil ground test 6 rectification diodes are used. The continuity direc-
tions of the<±>side diode (red) and theGside diode
It is in good condition if there is no continuity be- (blue) are opposite.
tween each stator coil lead wire and the stator core. Inspect the continuity of each diode. Replace the
If there is continuity, the stator coil is grounded, diode if there is continuity in both directions or
so replace the part. if there is no continuity in either direction.

Fig. ES-26. Ground test for the stator coil

A Caution:
Never use a high voltage insulation resistance meter
such as a meggar for the inspection, since high volt·
age will damage the diode.

Fig. ES-28. Diodes

• Brush wear
Measure the length of the brush.
Standard: 19 mm (0.75 in)
Service limit: 10 mm (0.4 in)

Printed in Japan
9-12.
ES
1. Battery and Charging System [-3.]

Fig. ES-29. Continuity test for the diode f.) Installation

Install in the reverse order of removal. After install-
ing adjust the V-belt tension (see page 2-9).

g.) Test
• Output rpm test
Set the variable resistance (VR) at any point, turn
on the switch (SW1 ), increase the rotation of the
generator gradually and set the output to the stand-
ard value (industrial engine: 15A 28V, marine en-
gine: 14.5A 28V). Measure the rpm at this point.
The generator is in good condition if it is 5,000 rpm
for industrial engines and 3,000 rpm or less for ma-
rine engines.
• Built-in regulator (marine engine)
Fig. ES-31. Testing output rpm (industrial engine)
Measure the resistance between the F and E term i-
SW1
n a ls of the regulator. Reverse the polarity of the
tester and measure again.
(Tester used: Rx 1 at internal battery voltage 3V.)
T" VR
(Variable
Polarity of the tester
v ...L
resistance)
Resistance 24V
+ (red lead) - (black lead) (Ohm)
F E Approx. 60
E F Approx. 30 Regulator

Fig. ES-30. Measuring the resistance of the regulator

(marine engine) Fig. ES-32. Testing output rpm (marine engine)
SW1

Lamp
3W _I_ VR
v 24V
(Variable
resistance)

• High speed rotation test (marine engine)

While measuring the output rpm, set the rpm
at 5,000 rpm with the SW1 opened. Operate for
e.) Assembly about 1 minute and make sure that the terminal
Assemble in the reverse order of disassembly. voltage does not exceed 30V. Also make sure that
there are no abnormalities (noise, etc.).
A Note:
When assembling, pack high quality grease (heat
resistant) at each bearing.
Printed in Japan
9-13.
ES
1. Battery and Charging System [-4.]

[1-4.] Regulator (Industrial Engine Only) Fig. ES-34. Inspecting the field relay
a.) Description
The regulator is a tirrill type with a charge warning r----~~·
lamp relay. It regulates the voltage and inspects
• 42
whether the alternator is operating with an inspec- 1300 n
tion circuit.
F •
2oon 9110
/
' I.
l___
b.) Performance test
1. Insert the starter key into the starter switch and ,__j' ____ _ j E
turn it to "ON". The charge warning lamp should Voltage regulator Field relay
go on.
2. Start the engine and check the warning lamp. The
warning lamp should go off.
3. Connect a voltmeter and ammeter as shown in
Fig. ES-33.
4. Increase the alternator speed to 3,000 - 5,000
F(W~ ~(BJ i
L(WRI

rpm. Make sure that the ammeter reading is less N(WGJ lg(WLJ

than 5A and check the regulated voltage.

Regulated voltage: 28 - 30 V/5 A max.

d.) Adjustment
Fig. ES-33. Performance test
Remove the screws and solder, then remove the
Alternator
regulator cover.

N • Voltage regulator
Battery
Regulator Connect the alternator and regulator as shown in
Fig. ES-35. Rotate the alternator at 5,000 rpm by
using a motor.
Check the voltmeter when the ammeter indicates
c.) Inspection 5A. If the voltage is not within 28 - 29V, loosen
the lock nut and turn the coil spring adjusting nut
Apply voltage between the regulator N(white/green)
(Fig. ES-36). Turn the nut clockwise to increase
and E(Black) terminals and increase voltage to check
voltage and counterclockwise to decrease it.
the field relay on.

Field relay on voltage: 5 V max. Fig. ES-35. Bench test connection

Decrease the voltage and check the field relay off. Tachometer
Field relay off voltage: 3 V max. ---1A1------

Printed in Japan
9-14.
ES
1. Battery and Charging System (-4.] 2. Starting System (-1.]

Fig. ES-36. Regulator Fig. ES-38. Adjusting the Yoke gap

Point (armature)
Armature
Point (point holder)
Screw
Point holder

m.--Spring hook
l;£!;B-..__Lock nut
=~~~~~~~~~:;; Adjusting nut

• Field relay armature gap

1. Loosen the point holder screw.
2. Hold the an;nature so that a 1 mm (0.039 in)
feeler gauge can be inserted between the arma-
ture and core, move the point holder until the
lower points touch then tighten the screw.
3. Loosen the armature screw and align the points.
Tighten the screw and remove the feeler gauge.
2. Starting System
Fig. ES-37. Adjusting the armature gap
[2-1.] Service Information
Armature c..J a.) Description
Feeler gauge
Instead of the conventional multi-disc type pinion
Core clutch, the starting system is equipped with a dentil
Screw
Point holder
type pinion clutch, which is a completely new
mechanism. It is small, light-weight and strong, with
reliable performance and having the following char·
acteristics:
• Because the clutch is the dentil type (saw·
toothed), engagement is reliable and if disengages
well during over-run.
• Conventional mechanisms engage when the pin·
ion advances and touches the ring gear, it is
rotated by the subsidiary electrical current. In
• Yoke gap the dentil clutch, the pinion rotates and engages
due to the function of the clutch itself, with the
1. Loosen the screw and insert a 0.2 mm (0.008 in)
advancing force of the pinion clutch moved by
feeler gauge between the armature and yoke.
the force of the magnetic switch. The electrical
2. Push the armature in the direction of the arrow
current flowing through the magnetic switch
(Fig. ES-38) to seat the armature to the yoke,
during engagement is less than 1/2 of conven-
then tighten the screw. Remove the feeler gauge.
tional mechanisms. Also, the magnetic switch is
made smaller and is resistant to scorching.
• When the number of rotations of the pinion
reaches about 10,000 rpm, the clutch is com-
pletely disengaged by a built-in iron piece.

Printed in Japan
9-15.
ES
2. Starting System [-1.]

• Because the clutch is small, light-weight and with containing oil, to which oil had to be supplied
a small outer diameter, it was possible to use alu- from the oil supply opening. In this new mecha-
minum for the pinion case, and the weight of the nism wrapped bushings are used, and since a
starter motor itself was decreased by more than grease dam is provided, grease has to be replenish-
2 kg. ed only once a year during maintenance servicing.
• Metals for the front, center and rear pinions in
conventional mechanisms were sintered metals • Construction and operation of the starter motor

Fig. ES-39. Sectional view of the starter motor

Magnetic switch

Shift lever

Pinion case

Pinion clutch Brush cover

Armature

A pinion shift type with main switch is used for Fig. ES-40. Starting circuit
the starter motor. It is composed of the motor sec-
tion (yoke and field armature), pinion clutch sec-
tion (dentil type) and magnetic switch section. Also,
a main contact is installed in the magnetic switch.
When the starter switch is depressed, voltage is ap- ,,,...--
plied 10 the S terminal, and when the pinion and
gear engage, the main contact at the plunger rear l'----U-<~F.C.
Battery {24V)
section closes and the engine starts.
Printed in Japan
9-16.
ES
2. Starting System [-1.]

When the starter switch is pushed, electricity flows main contact, electrical current does not flow, and
to the pull in coil (p) and holding coil (h) of the during engine start the moving core is maintained
engage switch, the moving core is imbibed, the by the holding coil.
pinion clutch is pushed by the lever and engages When the starter switch is disengaged, the main con-
the ring gear. tact opens and the pinion clutch is returned to the
When the pinion engages the ring gear, the main stop position by the return spring.
contact closes and the main electrical current
flows. Because the pull coil is disengaged by the • Construction and operation of the pinion clutch

Fig. ES-41. Construction and operation of 1he pinion clutch

Weight

Retaining ring--~ ,------Holder

,-----,Clutch
Pin--,
,----Spring Clutch disengages
Pinion ,---D-plate

Retaining ring

'
Indexing 1'
distance •
Cushion Shifter

a) At clutch engagement bl At clutch disengagement

(At over-run, 10,000 rpm.)

The pinion clutch is composed of the advance sleeve slides. At about 10,000 rpm, the weight moves to
(a straight spline is cut into the inner diameter and the outer periphery direction along the pin through
a helical spline is cut into the outer diameter). pin- centrifugal force as shown in Fig. ES-41 (b), and
ion and clutch engage like a saw-tooth a cushion the pinion and clutch are completely disengaged.
which absorbs shock and a centrifugal piece The shock when the main contact closes and during
(weight) spring which separates the engagement of starting is absorbed by the cushion (rubber).
the clutch and pinion during over-run.
The pinion clutch advances and touches the ring
gear through the advancing force (by the imbibing b.) Tools and materials
force of the engage switch) of the lever. The spring
inside the case is compressed, the pinion is rotated Service tester
in the direction of the motor by the helical spline Micrometer
of the advance sleeve and clutch, and engages the Vernier calipen
ring gear. (This movement is called indexing, and Spring scale
the maximum indexing distance is 10.5 mm.)
When the engine starts and the rotation of the pin-
ion becomes faster than that of the armature, the
dentil clutch (the section engaged like a saw-tooth)
Printed in Japan
9-17.
 ES
2. Starting System [-1.]

c.) Specifications

Industrial ·engine
Item ~HALF 6HAL, 6HAL-T, Marine engine
4HAL 6HAL-HT
Sawafuji type 0300-552-0910 0330-602-0120 +-

Nominal output 5.2 kW 6 kW +-

Nominal voltage 24 v +-

Rotation direction (viewed from pinion side) Clockwise +-

Clutch type Dentil type +-

Engaging system Pinion shift type +-

Module 3.5 +-
Pinion
Number of teeth 11 +-

d.) Service data

Item Standard Service limit

Spring tension kg (lb) 2.0 (4.4) 1.6 (3.6)

Brush
Brush length mm (in) 22 (0.87) 15 (0.59)

Outside diameter mm (in) 53.5 (2.106) 50.5 (1.988)

Commutator Runout mm (in) 0.03 (0.0012) max. 0.2 (0.008)

Mica depth mm (in) 0.5 - 0.8 (0.02 - 0.03) 0.2 (0.008)

Armature Thrust gap mm (in) 0.2 - 0.3 (0.008 - 0.012) .......
Inside diameter mm (in) 19 +o.033 (0. 7480 +0.0013 ) 19.3 (0.760)
Front metal
-0 -0
Shaft outside diameter mm (in) 19-0.040 (0 7480 -0.0016) .......
-0.073 . -0.0029
Inside diameter mm (in) 22.5:'.g· 033 (0.8858~g- 0013 l 22.8 (0.898)
Center metal
Shaft outside diameter mm (in) 22.5:g:g~ (0.8858:g:gg1~> .......
Inside diameter mm (in) 18 +o.027 (0. 7087 +o.0011 ) 18.3 (0.720)
Rear metal
-0 -0
Shaft outside diameter mm (in) -0.032 (O -0.0013) .......
18 -0.059 .7087 -0.0023
Inside diameter mm (in) 19. 1:'.g· 052 (o. 1s2o~g.oo20 l 19.4 (0.764)
Pinion metal
Shaft outside diameter mm (in) 19-0.040 (0 7480 -0.0016) .......
-0.073 . -0.0029
Deflection of magnetic switch contact spring mm (in) 1.5 (0.06) .......
Timing gap mm (in) 1.0 - 2.0 (0.04 - 0.08) .......
Insulation capacity (coil-to-terminal) 1Mr! min. .......
Printed in Japan
9-18.
ES
2. Starting System [-2./-3.]

(2-2.] Removal A Note:

1. Remove bolt at the lower left of the cooling Check how the brushes are attached (assemble
water connecting chamber cover B. with the cable crossed).
2. Disconnect the cable at the starter motor.
3. Remove the starter motor. Fig. ES44. Removing the brushes

Fig. ES42. Removing the starter motor

-@

] \!
(~\
Starter motor

5. Remove the four through bolts from the rear

bracket side.
6. Remove the pinion case.
7. Remove the center bracket.
(2-3] Disassembly
1. Disconnect the wire at the magnetic switch. A Note:
2. Remove the four magnetic switch attaching Check how many adjusting shims there are between
bolts and remove the magnetic switch. the center bracket and armature, and be careful not
to lose them.
Fig. ES43. Removing the magnetic switch 8. Remove the pinion clutch from the center brack-
et.

Fig. ES45. Removing the pinion clutch

-~--=

3. Remove the brush cover. ©Gcg)

4. Remove the four brushes by hooking a string to Pinion clutch
the end of the brush spring and pulling the spring.
Printed in Japan
9-19.
ES
2. Starting System (-3./-4.]

9. Remove the armature from the yoke. Fig. ES-47. Mica depth
Commutator
Fig. ES-46. Removing the armature

-c:::=>-
Good Bad

Yoke

c.) Armature coil insulation test

It is in good condition if there is no continuity be-
tween the commutator and shaft or armature coil.
10. Remove the rear bracket assembly. If there is continuity, there is a grounded circuit, so
replace the armature.
A Note:
Do not lose the shaft bearing thrust washer at the Fig. ES-48. Armature insulation test
rear bracket interior.

[2-4.] Inspection
a.) Commutator
If the commutator surface is corroded or rough,
repair with No. 500 - 600 sandpaper. If the rough-
ness is extreme or if the surface runout is beyond
the service limit, replace the commutator.

Commutator runout d.) Armature shaft and bearing inspection

Standard: 0.03 mm (0.0012) max.
Service limit: 0.2 mm (0.008 in) Measure the outside diameter of the armature shaft
and if it is heavily worn, replace it. Measure the in-
Commutator outside diameter side diameter of the shaft bearing and if it is worn
Standard: 53.5 mm (2.106 in) beyond the service limit, replace it.
Service limit: 50.5 mm (1.988 in)
Armature shaft outside diameter
[Front]
b.) Commutator mica depth Standard: 18.927 - 18.960 mm (0.7451 - 0.7464 in)
Inspect the mica depth, and if it is shallow, repair [Center]
it by scraping with a metal saw blade. Standard: 22.427 - 22.460 mm (0.8829 - 0.8842 in)
[Rear)
Mica depth Standard: 17.941 -17.968 mm (0.7064 - 0.7074 in)
Standard: 0.5 - 0.8 mm (0.02 - 0.03 in) [Pinion)
Allowable: 0.2 mm (0.008 in) Standard: 18.927 -18.960 mm (0.7451 -0.7464 in)
Printed in Japan
9-20.
ES
2. Starting System [-4.]

Shaft bearing inside diameter f.) Brush surface and operation

[Front] If the brush surface is heavily damaged, replace it.
Standard: 19.0 - 19.033 mm (0.7480 - 0.7493 in)
Inspect the brush operation inside the holder, and
Service limit: 19.3 mm (0.760 in)
[Centerl
if it is faulty, repair or replace it.
Standard: 22.5 - 22.533 mm (0.8858 - 0.8871 in) g.) Brush spring tension
Service limit: 22.8 mm (0.898 in)
Measure the brush spring tension with a spring scale.
[Rear]
Standard: 18.0 -18.027 mm (0.7087 - 0.7098 in) Standard: 2.0 kg (4.4 lbl
Service limit: 18.3 mm (0.720 in) Service limit: 1.6 kg (3.6 lbl
[Pinion]
Standard: 19.1 -19.152 mm (0.7520 - 0.7540 in) Fig. ES-51. Measuring the brush spring tension
Service limit: 19.4 mm (0.764 in)
Spring scale

Fig. ES-49. Measuring the armature shaft 0.0.

Cloth

Spring

e.) Brush length h.) Brush holder insulation test

Measure the brush length with vernier calipers. Inspect for continuity between the brush holder
Standard: 22 mm (0.87 in) and brush holder base. If there is continuity, there
Service limit: 15 mm (0.59 in) is a grounded circuit, so replace the brush holder.

Fig. ES-50. Measuring the brush length Fig. ES-52. Brush holder insulation test

Printed in Japan
9-21.
ES
2. Starting System [-4.]

i.) Field coil continuity I.) Indexing amount

Inspect for continuity between both terminals Depress the gear and measure the contraction
to which filed coil brushes are connected, and be- amount. It is in good condition if the contraction
tween the yoke and each terminal. If there is no is about 10 mm (0.39 in).
continuity the coil is open, so replace the part.
Fig. ES-55. Measuring the indexing amount
Fig. ES-53. Field coil continuity test

m.) Clutch operation

j.) Field coil insulation test Hold the shaft and rotate the gear clockwise and
Remove the field coil earth screw and inspect for counterclockwise. It is in good condition if it ro-
continuity between the coil terminal and the yoke. tates smoothly in only one direction.
If there is continuity, the field coil is grounded, so
replace. Fig. ES-56. Inspecting the clutch operation

k.) Yoke
If the inside of the yoke has carbon deposits or rust,
clean it with compressed air etc., being careful not
to damage the field coil.

A Note:
When cleaning, do not remove the field coil from
the yoke.

Fig. ES-54. Cleaning the inside of the yoke

If the number of faulty engagements increases, the

cause may be insufficient grease within the clutch.
In such cases, immerse the pinion clutch in engine
oil SAE No. 20-30, or fill the case up with engine
oil while the case is attached to the starter.
Printed in Japan
9-22.
ES
2. Starting System [-4.]

n.) Pinion q.) Condition of the contact (contact points)

Inspect the pin ion teeth for wear or damage. Also Place the plunger side down, depress the magnetic
inspect that the pinion slides smoothly. switch and inspect for continuity between the M
o.) Pinion inside diameter and B terminals. If there is no continuity, repair or
replace the contacts.
Measure the pinion inside diameter and replace the
pinion if it is worn beyond the service limit. Fig. ES-59. Inspecting for contact
Standard: 19.1 -19.152 mm (0.7520 -0.7540 in)
Service limit: 19.4 mm (0.764 in)

Fig. ES-57. Measuring the pinion metal 1.0.

r.) Holding (h) coil continuity test

It is in good condition ifthere is continuity between
the S terminal and magnetic switch body (metal).
If there is no continuity, the coil is open so replace.
p.) Magnetic switch contact
Because the contact points inside the magnetic
switch become rough due to the high electrical cur- Fig. ES-60. "h" coil continuity test
rent during every starting operation, always inspect
them during disassembly. If they are rough remove
the terminal bolt and repair or replace. Repair by
placing No. 500-600 sandpaper on a working board
and polishing the contact points. When installing
the repaired contact points, assemble adjustment
packing with the thickness needed to supply the
ground amount and adjust the installation height
to the specified value.
Installation height: 28 mm (1.1 in)

Fig. ES-58. Adjusting the contact point height

Contact points

s.) Pull in (p) coil continuity test

It is in good condition if there is continuity between
~~~=t\Adjustment
the S and M terminals. Replace the coil if there is
packing no continuity.
Printed in Japan
9-23.
ES
2. Starting System [-4./-5./-6./-7.]

Fig. ES-61. "p" coil continuity test Fig. ES-63. Measuring the timing gap
Push lightly

[2-5.] Assembly
Assemble in the reverse order of disassembly.
A Note:
Push back the pinion very lightly when measuring.
A Note: If it is pressed back forcefully, the pinion clutch
When assembling, coat each bearing with high quali- spring will be compressed.
ty grease (Albania No. 2, No. 3 or equivalent).
Adjust the magnetic clutch connector until speci-
fied timing gap is obtained.
[2-6.] Installation
Install in the reverse order of removal.
Fig. ES-64. Adjusting the timing gap

[2-7.] Adjustment
a.) Timing gap
When the moving core of the magnetic switch is
completely pulled in and the main contacts are com-
pletely closed, or when the pinion is pushed back
lightly by hand (force of 2 kg, 4 lb or less), measure
the clearance (timing gap) between the pinion end
and pinion case ..
Timing gap: 1.0 - 2.0 mm (0.04 - 0.08 in)

Fig. ES-62. Wiring at timing gap measurement

Magnetic switch
Switch (1)

Printed in Jo.pan
9-24.
ES
3. Instruments (-1.]

3. Instruments [3-1.] Tachometer

Checking the engine speed is important when
Fig. ES-65. Instrument panel (industrial engine)
inspecting engine performance (on marine engines,
Water temperature gauge Oil pressure gauge Tachometer also the vessel speed etc.).

a.) Industrial engine

The mechanical tachometer is driven by the engine
camshaft through the cable.

Fig. ES-67. Mechanical tachometer (Industrial engine)

Engine stop button Charge warning lamp Starter switch

4HAL and 6HAL

(The instrument panel on 6HAL-HT has an intake x 1650rpm

air pressure gauge.)

Fig. ES-66. Instrument panel (marine engine)

Engine oil pressure gauge Tachometer b.) Marine engine

Water temperature gauge Hour meter The electrical tachometer indicates rpm by pulse
0
signal which is generated by the tachometer
sensor.
The tachometer sensor is installed at the end of
the engine camshaft. It identifies the actual posi-
tion of the camshaft and produces a corresponding
electrical voltage signal to the tachometer by
0
variation of magnetic field.

Clock
Buzzer switch
Fig. ES-68. Tachometer sensor
lamp panel Fuse

Prin!ed in Japan
9-25.
ES
3. Instruments [-2./-3.]

[3-2.] Hour Meter [3-3.] Cooling Water Temperature Gauge

a.) Industrial engine The water temperature gauge is the movable mag-
The accumulated number of engine operation netic type. The thermistor system is employed for
hours is indicated by the 5 digit number within the thermo unit. Temperature is detected by the
the tachometer. If the engine is operated at 1,650 thermo unit at the cooling water pipe (4HAL)
rpm for one hour, the meter indicates 1 hour (the and thermostat ca~e (6HAL-T) in industrial engines,
first digit is 1/10 of an hour). Therefore, for and at cooling water pipe 8 between the cylinder
engines rated 1,500 rpm the actual operating hours head and exhaust manifold on marine engine, and
are the hours indicated on the meter x 1.10, and is indicated on the meter.
for engine rated 1,800 rpm it will be the hours The thermistor inside the unit has the character-
indicated on the meter x 0.92. istic of high resistance during low temperature and
low resistance during high temperature. This
Engine speed Actual operating hour characteristic is used to detect cooling water
1,500 rpm Indicated hour x 1.10 temperature change as a change of electrical
1,800 rpm Indicated hour x 0.92 current, which is converted to magnetic field
change by the coil at the meter so that it will be
indicated on the meter.
Fig. ES-69. Hour meter (Industrial engine) The thermo unit for the marine engine also has a
thyristor for the warning system. If the engine
temperature raises up to the specified value, the
thyristor closes the electric circuit until the electric
xlOOOhr.--~
source is OFF.
x 100 hr.

x 10hr.- Fig. ES-71. Thermo unit (Marine engine)

Hr.--~

x 1/10hr. (6min.l--~
Terminals

b.) Marine engine

Terminal base
The hour meter operates electrically while the
starter and battery switchies are ON.

Fig. ES-70. Hour meter (Marine engine)

0 0 1 0 3
x 1000 hr. __J I Spring
x 100hr.__J
Wire
x10hr--~

1/10 hr. (6 min.l--~ One count

for 3.6 sec.

Thermister

Printed in Japan
9-26.
ES
3. Instruments [-3.l

a.) Water temperature gauge inspection fig. ES-72. Inspecting the water temperature gauge
1. Remove the thermo unit and connect it to the
water temperature gauge.
2. Place the unit in a container with water of 80° C
(176°F) and measure the water temperature
gauge. If difference between the thermometer
and the temperature gauge on the instrument
panel exceeds the service limit, inspect the unit.

3. Measure the resistance of the unit, and if the

measured value differs excessively from the re-
sistance value shown below, replace the unit.

Water temperature gauge

Temperature °C (°F) 30 (86) 40 (104) 50 (122) 70 (158) 80 (176)

---· ·--. -·---·-· --
Temperature indicated on thermometer oc ....... ....... .. ..... ....... 75.5 - 84.5
--~----· ..
Thermo sensor unit resistance value f;l 730 - 810 ....... 330 -370 160-180 .......

Fig. ES-73. Measuring the resistance of the sender unit [3-4.] Lubrication Oil Pressure Gauge
The lubricating oil pressure gauge is the movable
magnetic type, and the unit employed is the re-
sistance type. Oil pressure is detected by the sender
unit at the cylinder block (injection pump side) on
the industrial engine and at the oil cooler outlet
side on the marine engine, and is indicated on the
meter.

4. On marine engine: a.) Pressure gauge inspection

Place the thermo sensor in the container with On the industrial engine, remove the plug at the
water. Check the thyristor for continuity while pressure detecting connector or the oil pressure
heating. If there is continuity at 40° - 45° C switch, and on the marine engine remove the oil
(104° - 113°F) or above, the thyristor is pressure switch. Attach a standard pressure gauge
normal. (Bourdon tube type) through this attaching opne-
5. If there are no abnormalities in the unit, inspect ing, operate the engine and measure the difference
the meter. If the indicator on the temperature between the standard pressure gauge and the in-
gauge indicates on low temperature side when strument. Also measure the resistance of the sender
the main switch is set to OFF, or if it does not unit at every pressure level. If the difference is
indicate low temperature even when the switch great, replace the instrument of the unit.
is set to ON, replace the water temperature
gauge.

Printed in Japan
9-27.
ES
3. Instruments [-3.] 4. Warning System [-1.]

Fig. ES-77. Measuring the resistance of the sender unit

A Note: (marine engine)
Perform the test by decreasing the engine speed to
change the pressure in the order of 4 to kg/cm' a
(57 to a psi)

Pressure gauge

Pressure kg/cm 2 (psi) 0 4 (57)

Indicated pressure kg/cm 2 -0.2 -0.2 3.6 -4.4

Unit resistance !1 78 -88 39 -46

Fig. ES-74. Inspecting the lubricating oil pressure gauge

(industrial engine)

4. Warning System
(Marine Engine Only)
[4-1.] Service Information
a.) Description
The warning circuit inspects the engine condition
during engine operation, and is a piece of equip·
ment that warns the operator promptly when there
Fig. ES·75. Inspecting the lubricating oil pressure gauge are abnormalities. It is equipped with the follow-
(marine engine) ing warning circuits.

• Cooling water (fresh water) temperature warning

system
The tip of the thermo switch is provided with
high thermal expansion material, and when
the temperature rises to the operating tempera-
ture, the contact point operates the ON and OFF.

Fig. ES·78. Construction of the thermo switch

Fig. ES-76. Measuring the resistance of the sender unit

(industrial engine)

• Cooling water (fresh water) level warning system

The contact point installed in the water level
switch operates the ON and OFF by the vertical
movement of the float.
Prinled in Japan
9-28.
ES
4. Warning System [-1./-2.]

Fig. ES-79. Construction of the water level switch Besides these, the following equipments are also
provided. These indicate only by the lamp on the
instrumerit panel and the buzzer does not sound.
• Charge warning lamp
• Oil filter clogging warning lamp
• "Wait" lamp
When the filter element is clogged and the differ-
Air heather hole ence of pressure inside and outside the element be-
comes 1.5 ± 0.3 kg/cm' (21 ± 4 psi) or more, the
bypass valve opens, oil is sent into each lubricating
part, the warning switch is turned ON, the warning
Flat
lamp on the instrument panel illuminates and indi-
Snap ring
cates that the filter element must be replaced.
Fig. ES-80. Construction of the bypass valve

• Lubricating oil pressure warning system

The lubricating oil switch is attached to the out· Insulation
let of the oil cooler, and when oil pressure drops packing

the spring force closes the contact point.

• Marine gear oil pressure warning system
The lubricating oil switch is also installed to the
marine gear lubrication system, and when oil
pressure drops, the spring force closes the con-
tact point. Contact points Torque: 3.5kg-m (25ft-lb)

If any of the three above mentioned should occur, b .) Tools and materials
the corresponding lamp (red) on the warning panel Service tester
illuminates and the buzzer sounds to notify the Heater
operator of the abnormality. Thermometer

c.) Specifications
ON 103 - 109 (217 - 228)
Thermo switch operating temperature °C (°F)
OFF 100 -103 (212 - 217)

95 - 103 (3.740 -4.06) from filter surface

Water level switch operating level mm (in)
74 - 82 (2.913 - 3.228) from switch attaching surface

Oil pressure switch operating pressure kg/cm 2 (psi) 0.8 - 1.2 (11 -17)

[4-2.] Inspection Fig. ES-81. Thermo switch Thermo switch

a.) Thermo switch

1. Remove the thermo switch from the engine and
connect it to the tester or warning panel.

Printed in Japan
9-29.
ES
4. Warning System [-2.]

Fig. ES-82. Inspecting the thermo switch Fig. ES-83. Water level switch

Thermometer

Approx. 600W heater

No continuity

2. Place the thermo switch in a container with anti· t

freezing solution or oil. Then while measuring
the temperature, increase the temperature by
1°C (1.8°F) per minute until it reaches about
95"C (203°F).
If the operating temperature of the switch differs
greatly from the specified operating temperature,
•
Continuity
Water level
Float

replace the switch.

c.) Oil pressure switch
Turn the buzzer switch and starter switch to "ON".
ON 103 - 109°C 1217 - 228°F) The contact is good if the pilot lamp illuminates
Operating
temperature and the buzzer sounds for about 3 seconds and
OFF 100 -103°C (212 -217°F) then goes off.

Fig. ES-84. Oil pressure switch

b.) Water level switch

1. Connect the tester to the lead wire and ground
with the water level switch attached to the fresh
water tank (there is continuity in this condition).
2. Pour water into the fresh water tank and stop
when the continuity is OFF. Then measure the
water level from the filler upper surface or from
the water level switch attaching surface. Replace
the switch if the measured value differs greatly
from the specified level.

From filler 93 -101 mm

Operating upper surface (3.66 - 3.98 in)
water level From switch 72-BOmm
attaching surface (2.83-3.15in)
Inspect the lamp and pressure switch if the lamp
does not illuminate when the starter and buzzer
switches are turned ON.
Operating oil pressure: 0.8 -1.2 kg/cm 2 (11 -17 psi)

Printed in Japan
9-30.
ES
4. Warning System(-2.)

d.)Oil filter clogging warning switch. Fig. ES-86. Inspecting the clutch oil pressure
switch (typical)
Make sure that the pilot lamp is not burnt out.
Set the starter switch to ON, ground the terminal
of the switch attached to the filter by using a
screwdriver or a piece of wire of and check that
the lamp illuminates.

A Note:
When disassembling the warning switch, comp-
letely insulate the switch terminal.

Fig. ES-85. Inspecting the filter clogging warning switch.

Clutch oil pressure switch

!.)Warning system
Tern the buzzer and starter switch to ON. If all
six lamps illuminate at the same time and the
'~,, buzzer sounds for about three seconds and then
"'"'\. ~~-:: Oil filter warning goes off, the system is operating properly. If
----... switch three are lamps which do not illuminate, inspect
the lamp and its wire lead.

Fig. ES-87. Instrument panel

e.)Clutch oil pressure warning switch
Make sure that the pilot lamp is not burnt. Set r::======::--.,~
~It€> (t,;:I; !;"f;!H'
the starter switch to ON and check that the clutch
WAIT
oil pressure warning lamp illuminates.
Disconnect the wire from the oil pressure switch ;t1ll1l<Jl<i1 !Ill I l::: illli!Uo ~II
C.W.TEMP OIL ~:= L.0.Fll TER
and operrate the engine. If there is continuity
;tlllil:il:lli l! • '7 , 7;.a:
between the switch terminal and ground, the C.W.LEVEL CHARGE G.0.PRESS
switch is faulty so replace it.

""WAIT" lamp Goes on and off temperature is below 42. 5"C. Operate the engine after it goes off.

"C.W.TEMP" lamp Lights when cooling water temperature is excessively high.

"C.W.LEVEL"' lamp Lights when th~ cooling water level is below specified level.

"'LO.PRESS"" lamp Lights when the engine lube oil pressure is below normal operating range.

"'L.0.TEMP"" lamp Flashing when the lub oil temperature is exessively high.

"CHARGE" lamp goes off when the alternator is charging.

"'LO.FILTER"" lamp Lights when the lube oil filter is clogged.

"G.O.PRESS" lamp Lights when the marine gear lub oil pressure is below normal operating range.

Printed in Japan
F032G0223
9-31.
ES
4. Warning System (-2.)
; ALARM BUZZER ~WARNING LAMP GOES ON AND
WARNING LAMP ON (WITH TIMER)SOUNDS ..........,.,OF

~
SWITCH POSITION I II Ill IV

WARNING LAMP
ALARM BUZZER
AN~ Battery
switch ON ON
Starter key switch

START-ON ON

Battery switch .
I
OFF-ON
Alternator(CHARGE)
I
.
Water temperature (C.W.TEMP) I
'

Lube oil pressure

(LO.PRESS) '
Starter key switch
(LO.TEMP)
......."
II Wait about
OFF-ON Water level (C.W.LEVEL) ~
5 minutes.
STAND BY
Marine gear oil pressure (C.0.PRESS) "WAIT"" lamp
' aces on and off.

.....I_...
Lube oil filter colgging (LO.FILTER)
.
Ill
Starter key switch C.W.temperature low,
(WAIT)
-
START-ON wait while warning up • '
IV STAND BY

temperature reaches 42.5°C

I. BATTERY SWITCH(OFF-ON)
When the battery switch is put "ON", the A Caution:
"CHARGE" warning lamp comes on. • When the engine is running, do not cut off
the battery switch.
11. STARTING KEY SWITCH(OFF-+ON) • If the battery switch is cut off, the altrnator
When the starter key switch is tyrned "ON", will be damaged.
the buzzer will sound and all warning lamps • If the buzzer and/or warning lamp stays on
go on for 3 seconds. after 3 seconds, it is abnormal.
Lube oil quantity, water level and othe func-
A Caution: tions should be checked.
The buzzer will not sound if the buzzer switch CAUTIONS AFTER STARTING
is off. With the clutch control handle in neutral,perform
INSTRUMENT CHECK the following.
Check that the instruments on the instrument 1.After starting the engine, warm up at 700-800
panel are in the following conditions. rpm for 5 minutes.
• Oil pressure gauge needle is in operation. 2.Make sure that sea water is coming out of the
• Water temperature gauge is in operation. cooling water (sea water) outlet.
• Hour mater is in operation. 3.Check that the charge warning lamp(CHARGE)
• Oi I pressure gauge, water temperature gauge goes off.
and tachometer light on when you tern illumi- 4.When the water temperature gauge indicates
nation switch on. 42.5°C, check that te "Wait" lamp comes on.
Ill. STARTER KEY SWITCH(ON-+START-ON) IV. STAND BY
When the starter key switch is turned" START", Warm the engine up until the "WAIT" lamp
the engine will start. goes off, operate the engine under load.
The" WAIT" lamp will go on and off until the

Printed in Japan
9-32. F032G0223
Sec.10. ENGINE EMERGENCY
STOP SYSTEM (EE)
Contents of this section
Page
1. Service Information ................................. 10·1
[1·1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10·1
[1·2.] Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10·1
[1·3.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10·1

2. Electrical Stop System ............................... 10·1

[2·1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10·1
[2·2.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10·2

3. Mechanical System .................................. 10-3

[3-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10·3
[3-2.] Temperature Detecting Valve Inspection . . . . . . . . . . . . . . . . 10-4
[3-3.] Controller Operating Pressure Inspection ..... . . . . . . . . . . . 10-5
EE
1. Service Information [-1./-2./-3.] 2. Electrical Stop System [-1.]

10. Engine Emergency Stop System

1. Service Information

[1-1.] Description [1-2.] Tools and Materials

Optional protective equipment can be installed Heater

to stop the engine automatically when the cool- Alcohol thermometer
ing water temperature rises abnormally or when Electric bulb
oil pressure drops for some reason during operation. Bourdon tube type pressure gauge
This protective equipment is available in electri-
cal or mechanical systems.

[1-3.] Specifications

Item Specifications
Hitachi system ER2-01
Emergency relay
Rated voltage DC24V
Electrical
ON 98 - 102 1208 - 216)
stop system Thermo switch Operating temperature oC (oF)
OFF 93 - 97 (199 - 207)
Oil pressure switch Operating pressure kg/cm 2 (psi) 0.8 - 1.2 ( 11 - 17)
AMOTO system 2800 D
2
Specified pressure kg/cm (psi) 1.0 (14)
2
Range of operating pressure kg/cm (psi) 0.35 - 3.1 (5 - 441 variable
Controller
Mechanical when
6.3 (14) 1 in. at radius position
stop system operating
Operating force of lever kg (lb)
when
3. 7 ( 8) 1 in. at radius position
stopped

Temperature AMOTO system 2230C-0-2

detecting valve Specified temperature oC (oF) 96 (205)

2. Electrical Stop System

[2-1.] Description

This equipment stops the engine by the thermo the fuel pump. The solenoid pulls the stop lever of
switch and pressure switch if the cooling water tem- the governor and stops the engine. Also, the engine
perature rises abnormally or if the oil pressure drops can be stopped by pushing the stop button on the
during operation. When these switches are turned instrument panel.
on, the emergency relay detects these conditions
and operates the solenoid attached to the rear of
Printed in Japan
10-1.
EE
2. Electrical Stop System [-1./-2.]

a.) Thermo switch [2-2.] Inspection

A substance with a high rate of thermal expansion
is used at the end of the thermo switch. When the
cooling water temperature reaches the prescribed a.) Thermo switch
operating temperature, the switch contact point 1. Remove the thermo switch from the engine and
closes or opens the electrical circuit. connect it as shown in Fig. EE-4.

Fig. EE-1. Construction of the thermo switch Fig. EE-3. Thermo switch

I
Thermo unit
1

,_,___~~~~I
Thermo switch

b.) Oil pressure switch

The oil pressure switch is attached to the cylinder
Fig. EE-4. Inspecting the thermo switch
block (oil pressure extracting connector). It closes
the contact point with a spring forca when oil pres-
sure drops.

Test bulb (3W)

Fig. EE-2. Construction of the oil pressure switch

12V battery
Approx. 600W heater

Specified pressure
is indicated
2. Raise the liquid temperature to about 95°C
(203°F) then increase the temperature by 1°C
( 1.8° F) per minute. If the current flows at a
temperature other than the prescribed operating
temperature, replace the thermo switch.
Operating temperature:
ON: 98 -102°C (208 - 216°F)
OFF: 93 - 97°C (199 - 207°F)

Printed in Japan
10-2.
EE
2. Electrical Stop System [-2.] 3. Mechanical System [-1.]

b.) Oil pressure switch 3. Mechanical System

1. Stop the engine, remove the pressure sender unit
from the cylinder block (oil pressure extracting
connector) and install a Bourdon tube pressure [3-1.] Description
gauge (0 - 6 kg/cm', 0 - 85 psi) on the extract-
ing connector. (Thread diameter of the connec- In this equipment the engine can be stopped by the
tor is PT 1/8). temperature detecting valve and by the oil pressure
inducing section inside the controller attached to
Fig. EE-5. Oil pressure switch and pressure sender unit the cylinder block. When the cooling water tem-
perature rises abnormally or when oil pressure
drops during operation the engine is stopped. These
two parts detect abnorma I conditions, operate the
controller which pulls the stop lever to stop the
Pressure sender unit engine. The engine can also be stopped by pulling
the manual stop lever at the rear of the controller.

Fig. EE-6. Construction of the mechanical emergency stop

equipment
Oil pressure switch

Temperature detecting valve

2. Start the engine and allow to reach operating

temperature of 80° -90° C ( 176° -194 ° F). Manual
3. Run the engine at idle.speed (approx. 500 rpm). stop lever

4. While observing the Bourdon tube pressure

gauge, gradually lower the oil pressure by Fuel injection pump
adjusting the oil pressure regulator valve. Take
care not to screw off the adjusting screw (30 ¢ Oil releasing flow when water
pitches). Oil pan temperature rises abnormally
5. Check the pressure when the emergency seal
relay operates and the engine stops.
6. If the measured value differs excessively from
the oil pressure switch specified pressure, replace
Fig. EE-7. Controller
the oil pressure switch.
Specified pressure: 0.8 -1.2 kg/cm 2 (11 -17 psi) Controller

c.) Handling
When the engine is stopped by the emergency
system or by the engine stop button, turn the
stop button to "OFF" and then to "ON" again
before re-starting the engine.
• The lamp which is switched on during an abnor-
mal stop can be switched off by turning the bat-
tery switch to "OFF".
• When stopping the engine manually by pushing
the stop button, maintain pressure on the but-
ton until the engine stops.
Printed in Japan
10-3.
EE
3. Mechanical System [-1./-2.]

When the cooling water temperature rises abnormal- b.) Handling

ly (96°C, 205° F), the temperature detecting valve When starting, set the reset latch in the "START"
opens, and operates the controller, lowering the position. The reset latch is automatically released
oil pressure (1 kg/cm', 14 psi or less) by releasing (it returns to the "RUN" position) so that the con-
oil to the oil pan. troller can operate when the engine oil pressure
When oil pressure decreases ( 1 kg/cm', 14 psi or rises to 1.9 - 2.0 kg/cm' (27 - 28 psi).
less) the controller detects it directly and operates.

a.) Construction of the temperature detecting valve [3-2.) Temperature Detecting Valve Inspection
The oil is always at the (*) mark at the top of the
oil detecting valve. When cooling water tempera- Remove the temperature detecting valve and set it
ture rises to 96°C, (205° F)of more, the valve rises as shown in Fig. EE-9. Raise oil temperature to
and oil is returned to the oil pan. about 90°C (194°F) and then gradually increase
oil temperature by 1°C (l.8°F) per minute. Read
the temperature when bubbles emerge from the
Fig. EE-8. Construction of the temperature detecting valve
valve release hole. Replace the valve if there is a
difference of 2°C (3.6° F) or more from the speci-
fied temperature of 96°C (205° F).

A Note:

&
t::=====::::::-:~===~To controller2 • Place the tip of the alcohol thermometer as near
as possible to the temperature sensor on the de-
(Operates 1 kg/cm ,
14psi or less) tecting valve during the test.
Nut
• Conduct the test while stirring the oil.
+
Engine oil pressure
Spring Fig. EE-9. Inspecting the temperature detecting valve

Pin

Adjusting screw
Washer Valve
Sealing washer
• Temperature detecting valve Compressed
~:;::====l:'....:J== +- air
Body

Oil is released into oil pan

at 96°C (205°F) Oil release hole

Alcohol
thermometer

Sensor

Hf
Water temperature Sensor
Heater

Printed in Japan
10-4.
EE
3. Mechanical System [-3.l

[3-3.] Controller Operating Pressure Inspection -2. Start the engine and allow it to idle (approx.
500 rpm).
1. Stop the engine, remove the pressure sender unit -3. Adjust the oil pressure to 1 kg/cm' (14 psi)
from the cylinder block (oil pressure extracting by turning the oil pressure regulating valve
connector) and install a Bourdon tube pressure adjusting screw.
gauge (0-6 kg/cm', 0-85 pis) on the extract- -4. Turn the operating pressure adjusting screw
ing connector (Connector thread: PT 1/8). crockwise until the engine stops.
2. Start the engine and allow to reach operating -5. Screw in the oil pressure regulating valve
temperature of 80° -90° C ( 176° -194° C). adjusting screw 2 - 3 turns. Start the engine
3. Run the engine at idle (approx. 500 rpm). and recheck the operating pressure by fol-
4. While observing the pressure gauge, gradually lowing the steps 1 thru 5.
lower the oil pressure by adjusting the oil If operating pressure is too low
pressure regulator valve. Take care not to screw -1. Start the engine and allow it to idle (500
off the adjusting screw (30 pitches). rpm). Adjust the oil pressure to 1 kg/cm'
5. Check the pressure when the controller operates (14 psi) by turning the oil pressure regulat-
and the engine stops. ing valve screw.
6. If the measured value differs excessively from -2. Turn the controller adjusting screw clock-
the specified pressure, adjust the controller as wise until the engine stops.
described below. -3. Screw in the oil pressure regulating valve
• If operating pressure is too high screw 2 - 3 turns. Start the engine and
-1. Loosen the pressure adjusting screw lock nut recheck the operating pressure by following
and turn the adjusting screw counterclock- the steps 1 thru 5.
wise 2 - 3 turns.

Fig. EE-10. Controller operating pressure adjustment

Controller
Lock nut

0
Adjusting screw

Printed in Japan
10-5.
Sec.11. ENGINE INSTALLATION (El)

Contents of this section

Page
1. Industrial Engine ................................... 11-1
[1-1.J Output Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
[1-2.J Clutch Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ·2
[ 1-3.J Side Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·2
[ 1-4.J Engine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
[1-5.J Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
[ 1-6.J Mounting Foundation of the Stationary Engine . . . . . . . . . . . 11-7
[ 1-7.J Carrying in the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
[ 1-8.J Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
[1-9.J Anchor Bolts and Support Washers . . . . . . . . . . . . . . . . . . . 11-9
[1-10.J Concreting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
[1-11.l Final Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
[ 1-12.J FuelSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·11
[ 1-13.] Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
[ 1-14.J Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

2. Marine Engine ......................... _ .......... 11-14

[2-1.l Engine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·14
[2-2.J Engine Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
[2-3.J Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
[2-4.J Garring the Engine into the Engine Room . . . . . . . . . . . . . . . 11-16
[2-5.J Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
[2·6.] Engine Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·18
[2·7.J Final Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·19
[2-8.J Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
[2·9.] Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
[2-10.] Sea Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
[2-11.l Fresh Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 11-22
[2-12.] Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23
[2-13.J Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
[2-14.] Bilge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
[2-15.J Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·25
[2-16.J Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
El
1. Industrial Engine [-1.1

11. Engine Installation

1. Industrial Engine
[1-1.] Output Correction
The indicated engine output is the output obtained b.) Altitude correction
under the fol lowing conditions:
Correct 1% for every 100 m (328 ft) above sea level.
Engine intake temperature: 5° -30°C (41° -86°F)
Atmospheric pressure: 760 mm Hg (30 in Hg),
altitude 150 m (492 ft)
Relative humidity: 65% or less
c.) Humidity correction
When operating the engine in an environment with Table for revising the humidity is indicated below.
conditions other than the standard condition, per·
form the output correction as shown below:

a.) Engine intake temperature correction A Note:

To 30°C: continous rated output When revising the humidity, refer to the atmos-
To 40°C: 96% of the continuous rated output pheric temperature instead of the engine intake
To 50°C: 92% of the continuous rated output temperature.

Relative temperature and humidity correction (%)

Atmospheric
Relative humidity (%)
temperature
oc OF 10 20 30 40 50 60 70 80 90 100
30 86 ....... ....... ....... ....... 0.1 0.6 1.2 1. 7 2.2 2.7
32 90 ....... ....... ....... ....... 0.4 1.0 1.1 2.1 2.7 3.3
34 93 ....... ....... ....... 0.1 0.8 1.4 2.1 2.7 3.3 4.0
36 97 ....... ....... ······· 0.4 1.2 1.9 2.6 3.3 4.0 4.7
38 100 ....... ······· ....... 0.8 1.6 2.4 3.1 3.9 4.7 5.5
40 104 ....... ....... 0.2 1.1 2.0 2.9 3.8 4.7 5.5 6.4
42 108 ....... ....... 0.5 1.5 2.5 3.5 4.5 5.4 6.4 7.4
44 111 ....... ....... 0.9 2.0 3.0 4.1 5.2 6.3 7.4 8.5
46 115 ....... ....... 1.2 2.4 3.6 4.8 6.0 7.3 8.5 9.7
48 118 ....... 0.3 1.6 2.9 4.3 5.6 7.0 8.3 9.6 11.0
50 122 ....... 0.6 2.0 3.5 5.0 6.5 7.9 9.4 10.9 12.4
52 124 ....... 0.9 2.5 4.1 5.8 7.4 9.0 10.6 12.3 13.9

Printed in Japan
11-1 .
El
1. Industrial Engine [-2./-3.]

U-2.] Clutch Capacity As an example, the capacity value at side load of

the Anderton R704 type over center clutch (op-
The relation of the clutch capacity and work equip- tional) is shown in the table on next page:
ment driving torque is as follows:

Clutch capacity > Work equipment

X Factor
(torque) driving torque

Clutch capacity
Work equipment Factor
Compressor (1-cylinder type) 4.0 - 5.0
Compressor (2-cylinder type) 3.0
Compressor (4-cylinder type) 1.9
Centrifugal pump 1.0 - 1.5
Conveyor 1.25-2.0
Cement making 3.0
Deep well-fire pump 1.25
Fan and blower 1.25- 2.0
Paper mill machinery 2.5

Example:

Average torque of 6HAL of 150 HP/1,800 rpm=

59.7 kg-m (432 ft-lb)
59. 7 kg-m (432 ft·lb) x 1.5 =
89.55 kg·m (648 ft-lb)< 96.8 kg-m (700 ft-lb)
R704 over center clutch

Therefore, the Anderton R704 type over center

clutch is usable.

U-3.] Side Load

The capacity value when operating at side load is:

L= 126.000 x HP X FL= lb
NxD
L = side load, lbs
N = Shaft speed (rpm)
HP= horse power
D = pulley pitch diameter, inch
FL= load factor Chain 1.25
V-be\t 1.5
2-ply flat belt 2.50

Printed iri Japan

11-2.
El
1. Industrial Engine [-3./-4.]

Allowable side load table for Anderton R704 type over center clutch (reference)

Allowable side load

Maximum
at distance 'X'
torque .In put speed -

- ....
10,000 Hr. rating
(rpm) ~
Mean
x ---;o
torque

X= 3 in X = 4 in X = 5 in X= 6 in X = 7 in X = 8 in

1000 4980 4480 3880 3430 3070 2770

1500 4390 4170 3880 3430 3070 2770
1: 1
2000 4040 3830 3650 3430 3070 2770
2500 3800 3600 3430 3270 3070 2770
1000 3320 3150 2990 2850 2730 2610
1500 2930 2780 2640 2520 2410 2310
1.5 : 1
2000 2690 2560 2430 2320 2220 2120
2500 2530 2400 2280 2180 2080 1990
1000 2490 2360 2250 2140 2050 1960
1500 2200 2080 1980 1890 1810 1730
2: 1
2000 2020 1920 1820 1740 1660 1590
2500 1900 1800 1710 1630 1560 1490
1000 1990 1890 1800 1710 1640 1570
1500 1760 1670 1590 1510 1440 1380
2.5: 1
2000 1620 1530 1460 1390 1330 1270
2500 1520 1440 1370 1310 1250 1190

[1-4.] Engine Room

When planning the lay-out of the engine room, give Amount of air necessary for combustion
full consideration to the engine, inspection of the
driving mechanism, maintenance and operation. 86 PS/1500 rpm 377 m3 (13.310 cu-ft)/Hr
4HAL
Also give full consideration to the fuel tank, bat- 100 PS/1800 rpm 452 m3 (15.960 cu-ft)/Hr
tery, related piping and wiring, and all equipment 125 PS/1500 rpm 563 m 3 (19.950 CU·ft)/Hr
and fixtures for assembly, and design the most ap- 6HAL
150 PS/1800 rpm 700 m3 (24.710 cu-ft)/Hr
propriate engine room. The following items indicate
the necessary engine room conditions. 150 PS/ 1500 rpm 680 m~ (24.000 cu-ft)/Hr
6HAL-T
170 PS/1800 rpm 790 m3 (27.890 cu-ft)/Hr

a.) Engine room ventilation

When the temperature of the engine room rises,
the intake air volume decreases and causes the en-
gine output to decline. Therefore, the engine room
should be thoroughly ventilated.
Printed in Japan
11-3.
El
1. Industrial Engine [-4./-5.]

b.) Exhaust disposal Fig. El-1. Disposing the radiator exhaust air
1. Since the temperature of the radiator exhaust
air rises (70° - 75°C, 158° - 167°F) during full
load operation, completely dispose of the ex-
haust air. The exhaust of the indoor installation,
with the bonnet and sound insulating set, should
be disposed of outdoors via a duct, so that they
do not blow into the radiator fan.

A Note:
The capacity of the radiator is affected by the
temperature of the cooling air.
2. The exhaust duct resistance must be 5 mm (0.2
in) Aq. or less.
If the duct reistance reaches 10 mm (0.4 in) Aq.
or more, output correction is required.

[1-5.] Dimensional Drawing

Fig. El-2. Dimensional drawing (4HAL)

408 '" 5&4

1933.9

'" "'

J W.R. ANDERTON
Model R704
Air!te>"'
~

' /

"' ""'

Printed in Japan
11-4.
El
1. Industrial Engine [-5.]

Fig. El-3. Dimensional drawing (6HAL)

"'
'" ... '2333.9

rL ... F--"
:_,;
' '

::·~:',
W_A_ ANDERJON
'-J , __ Model; R704
>--_j - -
,' ' I ',

':,/-)':' ~/'',,) ~
' '

-
!::::'
•
~\11 1~
i
""

Fig. El4. Dimensional drawing (6HAL-T)

856 5

483 5 375

5969

WR_ ANOERION
Model. R705

203.2

Printed in Japan
11-5.
El
1. Industrial Engine [-5.]

Fig. El-5. Dimensional drawing (6HAL-HT)

2393.4
483.5 410

"' "" "'"

r~
' ~.

W.A.ANOERTON
Mo<1e1. A705

Flywheel hou,.og
"' !SAE No 1 I

'" '" '"

Printed in Japan
11-6.
El
1. Industrial Engine [-6./-7./-8.]

[1-6.] Mounting Foundation of the Stationary Engine Fig. El-7. Carrying in the engine with a wooden float and
rollers
The foundation should be strong enough to bear
the load of the equipment and inertia and vibration
during engine operation. Consult civil engineers or
architects to make a correct foundation.

[1-7.] Carrying in the Engine

To carry in the independent engine, hook wires to
the 2 lifting hooks at the top of the engine and sus- ~g.:;den-r=TI11:=r11~~===J
pend it from a hoist of 1.5 tons or more.

A warning:
Ro\1ers~~:l;~~~;::;~~~~~n;:;;;::7~~
I
I
I
I '' I
I 'II 'II
Weight of the independent engine I I
'I 'I I

..
I I
I I
'I I I
!- - ~' '·-~' '~--' '
I
' -I'
' L-
4HAL: 820 kg (1,808 lb) -~' ~-~ ~._""

6HAL: 1,110 kg (2.447 lb)

6HAL-T: 1, 150 kg (2,535 lb)

Fig. El-6. Carrying in the engine with a hoist

[1-8.] Centering
a.) Centering of the engine and equipment
When installing the engine and equipment on an in-
tegral base, first fix the equipment and then center
the engine by the following procedure:
1. Attach jack bolts to the screw holes in the engine
mounting brackets and align the drive shaft cen-
ter line of the engine to the shaft center line of
the equipment.

Fig. El-8. Jack bolts

If the engine and generator are attached to a base,

the engine can be carried in by placing a wooden
float under the base and by rolling it with rollers
and winch or with a chain block etc. Remove the
rollers and wooden float after the engine is carried
in.

Printed in Japan
11-7.
El
1. Industrial Engine [-8.]

2. Attach a dial indicator to the coupling of the 5. Tighten the engine mounting brackets to the base
equipment, rotate the drive shaft and measure with engine mounting bolts (M18 bolts) and re-
the runout of the drive shaft coupling. check for misalignment.
Allowable coupling (A): 0.05 mm (0.0020 in) or less 6. Connect both couplings.
3. Insert a feeler gauge between both couplings and
measure the surface inclination.
'.'l'll~a~le coupling surface : 0.05 mm (0.0020 in) b.) Stationary engine centering
mchnat1on (B)
Perform the following if the engine and equipment
are attached to an integral base.
Fig. El-9. Measuring coupling misalignment 1. Attach jack bolts to the jack bolt holes in the
base and set the base at the attaching height.

Fig. El-11. Jack bolts

Jack bolt

\l Iron plate

A~ ---.
-fil----

4. Make adjustments by adjusting temporarily with : : '

:: ' '
jack bolts at the engine mounting brackets, and '·"
'._ J u '.,
' .~
' '
'.'
then by increasing or decreasing shims. Loosen
the jack bolts.

Shim thickness x number (6 sets):

1.6 mm (0.0630 in) x 1
0.3 mm (0.0118 in) x 2
0.1 mm (0.0039 in) x 2 2. By using a level gauge adjust with the jack bolts
so that the right, left, front and rear directions
Fig. El-10. Adjusting with shims of the base upper surface are horizontal.

A caution:
Set the jack bolts so that at least one screw head
projects from the bottom of the base.

Printed in Japan
11-8.
El
1. Industrial Engine [-8./-9./-10./-11.]

c.) Centering when the bases of the stationary en- [1-10.] Concreting
gine and equipment are different
1. Make concrete with the ratio of cement, sand and
When mounting the engine first, follow procedures
gravel 1 : 2 : 4.
1 - 2 mentioned on previous page. If the equipment 2. Pour in and pack the concrete.
is installed first, the final centering is facilitated if
the level is adjusted so that the clutch shaft center
is about 1 mm lower than that of the equipment. A Note:
Remove water from the anchor bolt hole before
concreting.
Fig. El-12. Level adjustment for different bases

3. 12 - 24 hours after concreting, loosen the jack

bolts one turn and eliminate the clearance be-
tween the concrete and support washer. Tighten
all jack bolts by 1/4 turn and maintain the unit
level.

Aeaution:
Let the concrete stand for at least 2 weeks so that
it dries completely. During the rainy season or when
humidity is high, let is stand for several more days.

Fig. El-14. Concreting

Support washers Jack bolt

L
[1-9.] Anchor Bolts and Support Washers
1. Fabricate anchor bolts and support washers. Ma-
chine the base side surface of the support washers. Foundation
Iron braces
2. Install the anchor bolts, flat washers and support
washers on the base, and tighten with nuts until
4 - 5 bolt threads project.
3. Spot-weld the flat washers to the anchor bolts.

Fig. El-13. Installing the anchor bolts

[1-11.] Final Centering

a.) When the same base is used for the engine and
equipment
Flat washe 1. Loosen all jack bolts, and use a level gauge to
make sure that the left, right, front and rear di-
rections of the upper surface of the base are ho-
rizontal. If the base is not horizontal, make ad-
Anchor bolt
justments with the jack bolts and insert a shim.
2. Remove the cylinder block rear side cover and
timing mark cover of the flywheel housing.
Printed in Japan
11 ·9.
El
1. Industrial Engine (-11.]

3. Attach a deflection gauge to the No. 6 crank (on Fig. El-17. Adjusting the shims
4HAL, No. 4) of the crankshaft and place its
pointer to point at the main journal outer di-
ameter.

Fig. El-15. Attaching the deflection gauge

Deflection gauge

6. Tighten the engine mounting bolts and re-check

4. Rotate the crankshaft with a turning handle, and the deflection.
measure the deflection at the position shown in
Fig. El-15.
Allowable deflection limit: 0.015 mm (0.0006 in) max. b.) When different bases are used for the stationary
engine and equipment
Fig. El·16. Position to measure the deflection
TDC If the engine is mounted first, center in the same
order as for the integral base.
If the engine is mounted last, center as follows
since the drive shaft is adjusted to about 1 mm be-
low the shaft center of the equipment:
1. Loosen the tightening nuts of the engine mount-
ing base.
2. Lift the engine base with jack bolts by about
1 mm to the position of the shaft center.
3. Follow procedures 2 - 6 of "Centering of the
Engine and Equipment" (see page 11-7).
BOC
Fig. El-18. Centering the engine

5. If the deflection exceeds the allowable limit,

loosen the engine mounting bolts, eliminate the
deflection with jack bolts and make adjustments
by increasing or decreasing the shims at the en-
gine mounting brackets. Then loosen the jack
bolts.

Printed in Japan
11-10.
El
1. Industrial Engine [-11./-12.]

4. Follow procedures 2 - 6 on the final centering Fig. El-20. Fuel line connection
of "When the Same Base is Used for the Engine
and Equipment" (see page 11-9).

[1-12.] Fuel System

1. Since the fuel tank affects the combustion of
the engine, wear of the fuel system parts, etc.,
use one which meets the following requirements:
• Provide a cover for interior inspection and clean-
ing, a drain cock, breather pipe, fuel filler open-
ing and cap at the top of the tank, a fuel level
gauge and a drain tank.
• The position of the fuel feed pipe opening must
be 50 mm (2 in) above the bottom of the tank.
Also attach a fuel cock.
• Install the fuel return pipe connecting opening.
• There shou Id be no fuel leakage. Also, the in-
terior shou Id be treated with anti-rust agents.

Fig. El-19. Representative example of the fuel tank

Fuel return pipe
connection
Level gauge
Fuel supply __....-----~{
cock
SOmm Fuel feed pump
(2i,n_>~,._,'i"

Access cover

Drain tank Fuel supply cock

Fuel tank
Fuel filter 1m (39 in) max

2. The feed pipe extracting opening of the fuel tank

must not be 1 m (3.28 ft) lower than the fuel
feed pump. Also, install the tank as close as
possible to the engine.

Printed in Japan
11-11.
El
1. Industrial Engine [-12./-13.]

3. It is recommended that an extra filter be install- b.) Expansion coupling

ed between the fuel tank and fuel feed pump. 1. Note the attaching direction of the expansion
coupling.
A Note:
Installing an extra filter lengthens the life of the Fig. El-22. Expansion coupling
fuel injection pump and injection valve.
4. Install all equipment in positions where drain-
ing and cleaning can be performed easily.
5. Use hoses for the piping, and straighten the pip-
ing as much as possible. If it must be bent, the
bend must be 50 mm (2 in) R or more. Direction of exhaust gas
6. The fuel hose must be routed so that it is away
from heated parts such as the exhaust system, etc.

[1-13.] Exhaust System 2. Set the exhaust pipe so that the clearance be-
a.) Order of connecting the exhaust pipe tween the exhaust pipe and expansion coupling
is 1O - 15 mm (0.4 - 0.6 in) to absorb the ex-
4HAL, 6HAL: exhaust pipe - (exhaust expansion pansion of the exhaust pipe caused by thermal
coupling) - silencer - funnel or out-
expansion. Then connect the expansion coupling
doors.
and exhaust pipe.
6HAL-T: exhaust pipe - (exhaust expansion
coupling) - silencer - funnel or out-
Fig. El-23. Attaching the expansion coupling
doors

Fig. El-21. Exhaust system (typical)

' ' Expansion coupling

'
' '
'
'T '
I
' '
0-_)

A Caution:
Suspend the exhaust pipe with a stay etc. so that
its weight does not fall on the exhaust manifold.

Printed in Japan
11-12.
El
1. Industrial Engine [-13./-14.]

c.) Heat-resistance treatment 3. Use battery cables with a cross-sectional area

1. Since the temperature of the exhaust becomes of 80 mm' (0.14 sq-in).
very high, wrap the expansion coupling and ex-
haust pipe with an insulator (see Fig. E 1-24) for Fig. El-26. Connecting the batteries
safety and to prevent the temperature rising in Starter motor Batteries
the engine room.

Fig. El-24. Heat insulator

Asbestos Molding

Asbestos cloth or
asbestos tape

4. Connect the + cable of the battery to the B

terminal of the starter motor via the battery
switch, and the - cable to the engine with a
Thin galvanized iron sheet or heat resistant backing finished iron sheet
ground bolt.

Fig. El-27. B terminal of the starter motor

2. When the exhaust pipe penetrates the wall of the "B" Terminal
building, use an eye block or sleeve (steel pipe)
and place asbestos 50 mm (2 in) thick between
the wal I and exhaust pipe.

Fig. El-25. Wall of the building and the exhaust pipe

Starter motor Battery positive cable

[1-14.] Electrical System

a.) Battery
1- Connect in series two 12V-120AH batteries for
the 4HAL and two 12V-150AH batteries for
other models.
2. Install the batteries in a position where the length
of the battery cable wil I be 4 m ( 13 ft) or less.
Printed in Japan
11-13.
El
2. Marine Engine [-1./-2.]

2. Marine Engine Fig. El-29. Height of the engine room

[2-1.] Engine Room

The engine room must be laid out after carefully
considering the engine, front power take-off and in-
spection, maintenance and operation of the driving
mechanism. Also, maintain the installing position
and space of the fuel tank, battery, kingston cock,
related piping and wiring, remote control cabling,
etc.

Fully examine all attached equipment and fittings, c.) Propeller shaft coupler
and design the most suitable engine room by con-
Space must be sufficient to move the propeller shaft
sulting the dockyard.
flange surface toward the stern so that the reverse
The following are requirements necessary for en-
gear can be moved during servicing, etc.
gine operation.

[2-2.] Engine Bed

a.) Engine room ventilation
An increase in the engine room temperature 1. Although the installation angle of the engine dif-
causes a reduction in the intake air volume and thus fers with the hull shape and engine installation
0

a drop in engine output. Therefore, ventilation of position, it must be g or less when the vessel is
the engine room must be as prescribed or more. cruising. If the tilt exceeds go, the output will
Area of the ventilating window: decrease, the parts will wear abnormally and oil
4,000 cm 2 (620 sq-inl consumption will increase.
Ventilator capacity:
6HA(M)E: 30 m 3 (1,060 cu-ft) or more/min. Fig. El-30. Installing angle of the engine
6HA(M)-HTE: 50 m 3 (1,766 cu-ft) or more/min.

Fig. El-28. Ventilation of the engine room

2. Fix the height of the engine installation surface

so that there is no contact at the bottom of the
engine.
3. Sufficient space must be available for easy appli-
cation of a wrench to the bolt on the propeller
shaft joint.
4. The bed must be constructed so that a wrench
can be set at the bottom of the engine base to
b.) Height of the engine room re-tighten the engine mounting bolts.
The height must be more than the piston extracting 5. The bed must be constructed so that the propeller
height from the engine mounting surface. shaft and the engine drive shaft are in a straight
Piston extraction height: 920 mm (36.3 in) or more line.
Printed in Japan
11-14.
El
2. Marine Engine(
. 3.)

[ 2-3.]Di'men s1onal
· Drawing 100.1 Unit>= mm

6HA(M)E

npipe

/1145/56 Rub':!•; 1 ~n~•t pip•

Cooling-

8·3/8·16 VN q,(.J
hole1, 14 de:;, t•PP•d

8·3/8·16 VNC olft, 14 dffp

tePP9d holH, 14 d-.,P

, 10.4
Unit= mm
6HA(M)-HTE
6HA(M )-DTE

Exheutt _.pip• 125A G

Cooling... "PIP•
Rub~~t••. lnl9' pipe
I
otHl!!i/56
_.....
":,.4~·---.--~ ..

B-3/8-18 VNC
holft, 1 4 deep tappld

Printed in Japan
F032G0223 11 -15.
El
2. Marine Engine [-4.]

[2-4.] Carrying the Engine into the Engine Room • 6HAE

When carrying in the engine with the clutch side
a.) Horizontal suspending method downward (see Fig. E 1-34), hook a wire to the lift·
It is recommended that the engine be carried in by ing bracket (A) and branching pipe of the exhaust
suspending it horizontally from the two I ifting manifold (third one from the fresh watertankside).
brackets attached to the engine. and after suspending it horizontally by hooking
the lifting bracket (B) to the chain block, loosen
the chain block and suspend the engine at an angle
Fig. El-33. Carrying in the engine by suspending it
horizontally of 50°.
If the engine must be suspended at an angle of more
than 50°, hook the wire to two engine mounting
brackets at the fresh water cooler side instead of
hooking it to the branching pipe of the exhaust
manifold.

Fig. El-34. Diagonal suspending with the clutch side down

Lifting bracket (A) Chain block

Exhaust manifold
Fresh water tank

Awarning:
The weight of the engine (6HA·HTE) is approximately 1.5
tons.
If the engine must be carried in by suspending it
diagonally, perform as follows:
b.) Diagonal suspending method Filting bracket (8)

A Warning;
• Use a crane of 2 tons or more and a chain block.
• Be careful not to apply shock to the wires or chain dur-
ing the suspending operation.

Approx. 50°
Aeaution:
• To prevent damage, place a wood block or wrap
a cloth to all portion of the engine which touch
the cable or chain.
• To prevent the oil pan (aluminum) from damage,
first suspend the engine horizontally with a crane
and chain block, and then loosen the chain block
to suspend it diagonally.

Printed in Japan
11-16.
 El
2. Marine Engine [-4.]

When carrying in the engine with the clutch side Fig. El-36. Diagonal suspending with the clutch side down
upward (see Fig. El-35), after hitching the chain (6HA·HTE)
block to the lifting bracket (A) and cable to the
two clutch mounting brackets, loosen the chain Wire (2) (2-2.Sm
length)
block to make it diagonal.

Fig. El-35. Diagonal suspending with the clutch side up Chain block
Wire (1) (2.6m
length)

Place 200mm length

wood block

Approx. 60° Lifting bracket B

Within 80°

Lifting bracket (A)

When suspending the engine with the clutch side
" up (see Fig. El-37), remove the four bolts (1) from
the cooling water inlet at the clutch oil cooler and
disconnect the cooling water pipe.
Remove the clutch lubricating oil pressure detec-
tor sensor (2) and seal the attached opening with
• 6HA·HTE tape etc. to prevent dirt from entering.
When suspending the engine with the clutch side Loosen the remote control cable clamp bracket (3)
down (see Fig. El-36), pass wire (1) through the and rotate it by 90° to direct it backwards.
engine mounting brackets at the fresh water tank Pass the cable (4) through the inside of the cooling
side and hook wire (2) to wire ( 1) by placing a water pipe and hook it to the two clutch mounting
wood block about 200 mm (8 in) long. After sus- brackets. Hook a chain block to the wire (5) passing
pending the engine horizontally by hooking a chain through lifting brackets A and Band the branching
block to the lifting bracket B, loosen the chain pipe of the exhaust manifold (third one from the
block and lower the clutch side. fresh water tank side), and then loosen the chain
block to make the suspension diagonal.
A Note:
Since cable (2) touches the fresh water tank when
the suspending angle is small, place a cloth or some-
thing on the tank.

Printed in Japan
11-17.
El
2. Marine Engine [-4./-5./-6.)

Fig. El-37. Diagonal suspending with the clutch side 3. Center the propeller shaft and drive shaft by
(6HA-HTE) using shims.
Shim thickness x number (6 sets):
1.6 mm (0.0630 in) x 1
0.3 mm (0.0118 in) x 2
0.1 mm (0.0039 in) x 2

Wire (4) 4. Tighten the mounting bolts in a criss-cross pat-

tern.
151

a;;;.>J;fl~lutch mounting [2-6.] Engine Centering

bracket
Before installing the intermediate shaft (or the pro-
peller shaft) to the engine drive shaft, make sure
that the couplings of both shafts are centered.
1. Install a dial gauge on the intermediate shaft (or
the propeller shaft) and check the drive shaft
coupling for runout by rotating the drive shaft
with the clutch in "Neutral" position.
[2-5.] Engine Installation 2. Lock the drive shaft, rotate the intermediate
shaft (or the propeller shaft) and measure the
1. If the engine bed is made of wood, use a steel runout.
engine plate. Make sure that the engine plate and Allowable coupling runout (A): 0.05 mm (0.0020 in) max.
the wooden bed touch completely and machine
the bed if necessary. 3. Insert a feeler gauge between both couplings and
measure the surface inclination.
Fig. El-38. Installing the engine plate Allowable coupling inclination (B):
0.05 mm (0.0020 in) max.

Fig. El-39. Measuring the misalignment of the couplings

Dial indicator A

Propeller shaft
side

Feeler gauge

2. Use square washers and hexagonal nuts for the

bottom of the engine mounting bolts (hull side),
and use flat washers, hexagonal nuts and lock
nuts for the engine mounting brackets side.
Bolt diameter: 18 mm
Printed in Japan
11-18.
El
2. Marine Engine (-6./-7.]

4. Adjust temporarily with the jack bolts at the en- 3. Rotate the crankshaft with a turning handle and
gine mounting bracket and then by increasing or measure the deflections at the positions shown
decreasing the shims. Then loosen the jack bolts. in Fig. El-42.
Allowable deflection limit: 0.015 mm (0.0006 in) max.
Fig. El-40. Adjusting the shim
Fig. El-42. Deflection measuring position
TDC

BOC

4. If the deflection exceeds the allowable limit,

5. After tightening the engine mounting bolts, re-
loosen the engine mounting bolts, eliminate the
check the misalignment.
deflection with jack bolts and adjust by increas-
6. Connect both couplings.
ing or decreasing the shims. Then loosen the jack
A Note: bolts.
After launching the vessel, re-check the misalign-
Fig. El-43. Adjusting the shim
ment of the drive shaft and the intermediate shaft
(or the propeller shaft).

[ 2-7.] Final Centering

After centering the engine and installing the front
drive equipment, perform final centering of the en-
gine with clutch ON.
1. Remove the cylinder block side covers and the
timing mark cover on the flywheel housing.
2. Attach deflection gauges to the No. 1 and No. 6
cranks of the crankshaft at a point on the main
outside diameter.

Fig. El-41. Attaching the deflection gauge

0 5. Tighten the engine mounting bolts and re-check

the deflection.

Deflection gauge
Printed in Japan
11-19.
El
2. Marine Engine 8.J

[2-8.] Piping o·1agram

Fig. El-44. Piping diagram (6HA(M)E)

:i
L n" Hose clip

i[ffi A

~[ti_: mr 11 '---,
Kingston cock
/ ~BOA~
fi==" Ll.lbe oil filters (38)
Dia. ¢89.9

Rubber hose c
4>55.5 II 5.Smm Lube oil cooler

Exhaust manifold 0

Manne gear oil cooler

Reserve tank

Lube Oil filter scre1rn

Lube oi1 pump ln1ect1on nozzle

Intake manifold

'c

---------':l x
A__ for
Add1t1onal fuel f1I
heavy ool ms ter (opt1onall

~-­
Fuel filter , F1ltratuig a class 81 !
- ~ rea 10,000 cm'
~iltrating area·
Additional fuel f'I1
,000 cm' · NOTE: T ter (opt1onalf
(Fi11ed on engine! o prolong engine rt
1 .
recommended e, 1t is Fuel- water separator
tional fuel filt to ~se
an adi·
hull) p er (fixed on
· arallel type .....__From fuel tank

Printed in J apan
11-20.
El
2. Marine Engine(-8.)

Fig. El-45. Piping diagram (6HA(M)-HTE and 6HA(M)-DTE)

40 8""19
"' ~ ,._..
24
M16B~,,.
~·
~
! c14;ea
. N ::::Jg
$
~ PFS"
"'
. HOM clip A

Turboch1rger lube
:~
Kingston cock
oil filter

Turbocharger
' ~~~~-A~ -
f5BI
/
r·,.-..
c
---1 Oii.~139.8

Se1 water
/
filter (optiOl'llU
I
: M1rin1gnr
oil cooter

pump
Oil pump

Hut 1xci,.n;.r
8
Lube oil pump

~~ . J lntercooter

• '
\
Addition11 fuel filter

\
Fu11 t i l t e r - - - - - - - ' - > '
Filtralin; 1ru: Additional fuel filter (optional I
Q
,
,
(optional) for heavy oil
(BS cl111 81 I
Filtrating arH: 10,000 cm 1

5,000 cm 1 NOTE: To prolong engine 1ife, it is

(Fixed on engine) r1comm.nded to use an 1di-
tion1l fuel filter (fixed on Fu1l-w1t1r sepmrator
hulll. Parallel type
+---From fuel tank

Printed in Japan
F032G0223 11-21.
El
2. Marine Engine [-9./-10./-11.)

[2-9.] Fuel System d.) Cooling water outlet

See the corresponding item of the industrial engine • For the wet-type exhaust, refer to the exhaust
(see page 11-11 ). system (see page 11-23).
• For the dry-type exhaust, connect the reverse
gear oil cooler and the outlet of the vessel with a
[2-10.] Sea Water Cooling System rubber hose, and securely tighten the hose with a
hose clamp.
a.) Kingston cock
• Determine the position of the kingston cock by
the direction of the sea water inlet pipe and inlet
joint of the sea water pump.
• Finish the packing surface of the attaching sec- [2-11] Fresh Water Cooling System
tion with a grinder.
• Install the cock using canvas packing on the out- Install the reserve tank 50 - 100 mm (2 - 4 in) be-
side of the hull and canvas or rubber packing on low the fresh water tank filler cap, and connect it
the inside. to the connector at the fresh water tank filler neck
with vinyl hose.
Fig. El-46. Installing the kingston cock
Fig. El-47. Installing the reserve tank
Filler neck
Water tank

Vinyl hose

b.) Sea water strainer

It is recommended a sea water strainer be installed
between the kingston cock and sea water pump.
Always install it in areas where there is a lot of
dirt in the sea water.
c.) Piping
• Use rubber hose which must be as straight as
possible. If it must be bent, bend it at 400 mm.
(16 in) R or more.
• Secure the connecting ends with hose clamps.
Printed in Japan
11-22.
El
2. Marine Engine [-12.]

[2-12.] Exhaust System Fig. El-50. Horizontal exhaust

1. Support the exhaust pipe with a turn buckle so

that its weight does not fall on the exhaust mani-
fold.
Fig. El-48. Vertical exhaust

Fig. El-51. Wet-type exhaust

Fig. El-49. Diagonal exhaust

10-5Dmm (0.4-2.0 in)

2. If the central exhaust outlet of the exhaust mani-

fold on the 6HA(M)E is used, remove the cover
and install the pipe on the exhaust outlet at the
flywheel side. Connect the central exhaust out·
let connector to the central exhaust outlet.
Fig. El-52. Central exhaust outlet connector (6HA(M)E)

Exhaust manifold

Outlet connector

Printed in Japan
11-23.
El
2. Marine Engine [-12./-13.]

3. Since a turbocharger is equipped on the6HA(M)- Fig. El-55. Wet-type exhaust

HTE, install the expansion coupling between
the exhaust elbow and exhaust pipe. After ad-
justing the clearance between the exhaust pipe
and expansion coupling to 10 - 15 mm (0.4 -
0.6 in) with turn buckles, tighten the flanges
with bolts.

A Note:
Note the direction of the coupling.

Fig. El·53. Expansion coupling (6HA(M)-HTE only)

Direction of exhaust gas

Fig. El-54. Installing the exhaust pipe (6HA-HTE only)

5. Position the exhaust outlet so that the exhaust
pipe will be as short as possible.
6. Attach a water-proof cover to prevent rain from
entering the exhaust pipe.
7. Since the exhaust temperature will be very high,
insulate by wrapping the exhaust pipe with
high quality asbestos after piping. Also wrap the
¢====:::;r--Expansion coupling expansion coupling section with asbestos.

[ 2-1 J .] Crankcase Breather

1. Install the breather pipe from outside the engine
room (outside the vessel).

Awarning:
4. For the wet-type exhaust, position the exhaust Always keep it outside the vessel and separate it from the
outlet 10 - 50 mm (0.5 - 2 in) above the water ventilator by at least 500 mm (20 in).
level at full load. Also, install the sea water vol- 2. Connect the breather pipe and the engine side
ume adjusting valve (see Fig. E 1-55). breather with hose so that there is no bend or
slack, and secure both ends with hose clamps.

Printed in Japan
11-24.
El
2. Marine Engine [-13./-14./-15.]

Fig. El-56. Crankcase breather Fig. El-58. Installing seat of the remote control stand

• Breather pipe
+ 4-7mm
(0.28 in) dia.

Rubber hose

44mm (1.73 in)

75mm (2.95 in)

Breather

2. Temporarily connect the governor remote con-

[2-14.] Bilge Pump trol cable to the governor regulator handle, and
secure the cable to the support with a clamp.
1. Install the bilge pump strainer with the metal
holder in the position at the bottom of the vessel
where water is most collected. The outlet pipe
A Note:
The remote control cable must be as straight as
must be positioned above the water level (at full possible. Sharp bends will increase the operating
load). load and shorten the life of the cable.

Fig. El·57. Installing the bilge pump 3. Loosen the lock nut and adjust by rotating the
ball joint so that when the throttle handle of the
remote control stand is moved completely, the
governor regulator lever will be completely open-
ed and closed. Attach the ball joint to the regu-
lator lever with a nut, and tighten the lock nut.

Fig. El-59. Connecting and adjusting the governor cable

2. Connect the red switch wire to the + side of

the battery and the black wire to the negative
- side of the battery.

Support

Control cable
[2-15.] Remote Control
1. Install the remote control stand. The installing
screw hole must be aligned to the stand. Ball joint

Printed in Japan
11-25.
El
2. Marine Engine (-15./-16.]

4. Temporarily connect the clutch remote control 4. Connect the battery positive + cable to the
cable to the operating lever at the clutch, and starter motor B terminal via the battery switch
secure the cable to the support with a clamp. and the negative - cable to the engine with a
5. Loosen the lock nut and adjust by rotating the ground bolt.
ball joint so that when the remote control stand
clutch lever is set in the positions of forward, Fig. El·62. B terminal of the starter motor
neutral and reverse, the operating lever at the
clutch is securely moved to the corresponding "B" Terminal
positions. After adjusting, attach the cable to the -- =-:/=---===
-E~==-
operating lever with a nut and tighten the lock
nut
' ,> .• -. ... -··,-,,-,_ ..
Fig. El·60. Connecting and adjusting the clutch cable

Battery positive cable

b.) Instrument panel and warning system

Connect the instrument panel and warning system
[2-16.] Electrical System to the wiring harness of the engine with junction
cables.
a.) Battery
1. Connect two 12V-200AH batteries in series.
2. Install the battery in a position where the length
of the battery cable will be 4 m (13 ft) or less.
3. Use battery cables with cross-sectional area
of 80 mm 2 (0.14 sq-in).

Fig. El-61. Connecting the batteries

Starter motor

Printed in Japan
11-26.
Sec.12. TROUBLESHOOTING (TS)

Contents of this section

Page
1. Troubleshooting .................................... 12·1
TS
1. Troubleshooting

12. Troubleshooting
Trouble Probable cause Remarks

1. Engine does not start

A. Pinion does not come out when 1.) Discharged battery
starter switch is operated 2.) Poor wire harness, battery or switch terminal connection
3.) Seized starter pinion
4.) Malfunction of magnetic switch plunger, or coil open or short circuit
5.) Faulty starter switch

B. Pinion engages ring gear 1.) Discharged battery

but starter does not turn 2.) Open circuit cable between battery and magnetic switch, or
poor cable contact between magnetic switch and motor
3.) Battery cable too long or too thin
4.) Faulty pinion and ring gear engagement
5.) Worn brushes, faulty brush spring contact
6.) Damaged or soiled commutator
7.) Faulty, armature or field coil
8.) Poor field coil and brush contact
9.) Faulty magnetic switch and contactor contact

C. Starter runs at ful I rpm 1.) Incorrectly attached starter

before pinion engages 2.) Faulty timing gap adjustment
ring gear 3.) Weak pinion clutch spring

D. Starter rotates but engine 1.) Faulty pinion clutch

does not start 2.) Faulty engine

E. Engine rotates but does not 1.) Empty fuel tank

start 2.) Air sucked into fuel system
3.) Clogged fuel strainer element
4.) Air mixed into injection pump
5.) Malfunction of plunger and delivery valve
6.) Seized injection pump roller guide, or worn cam
7.) Loose injection pipe connection
8.) Seized or faulty nozzle valve
9.) Faulty nozzle spray
10.) Incorrect injection pressure
11.) Faulty feed pump valve
12.) Low compression - faulty intake or exhaust valve seat,
damaged exhaust valve spring, blown cylinder head
gasket, worn piston, piston ring and cylinder

F. Engine starts but stops 1.) Clogged fuel pipe and filter
immediately 2.) Air mixed into fuel
3.) Clogged vent port of fuel tank cap
4.) Faulty feed pump valve

2. Engine idling is not stable 1.) Incorrect control lever adjustment

2.) Air mixed into injection pump
3.) Malfunction of nozzle

Printed in Japan
12-1.
TS
1. Troubleshooting

Trouble Probable cause Remarks

2. Engine idling is not stable 4.) Unbalanced compression of each cylinder

5.) Malfunction of injection pump or governor

3. Loss of power 1.) Incorrect valve clearance

2.) Faulty valve seat
3.) Blown cylinder head gasket
4.) Worn, seized or damaged piston ring
5.) Worn cylinder liner
6.) Incorrect injection timing
7.) Insufficient fuel injection volume
8.) Incorrect nozzle injection pressure, or seized nozzle valve
9.) Clogged fuel pipe
10.) Air mixed with fuel
11.) Water mixed with fuel
12.) Contaminated turbocharger blower
13.) Clogged turbocharger prefilter

4. Overheating 1.)Insufficient or bad engine oil

2.) Insufficient water or corrosion in water system
3.) Loose, worn or damaged cooling water pump drive belt
(industrial engines)
4.) Faulty cooling water (fresh water, sea water) pump
5.) Incorrect valve clearance
6.) Increased resistance inside exhaust system
7.) Incorrect injection timing
5. Noisy engine
A. Crankshaft metal 1.) Oil clearance too large due to metal or crankshaft wear
2.) Local wear of crankshaft
3.) Seized metal

B. Connecting rod metal 1.) Worn crankpin metal

2.) Worn crankpin
3.) Distorted connecting rod
4.) Seized crankpin metal
5.) Insufficient oil

C. Piston, piston pin and 1.) Piston clearance too large due to piston and piston ring wear
piston ring 2.) Worn piston and piston ring
3.) Seized piston
4.) Faulty piston contact
5.) Damaged piston ring

D. Others 1.) Worn crankshaft thrust metal

2.) Timing gear backlash too large
3.) Valve clearance too large
4.) Worn rocker arm
5.) Faulty cooling water pump bearing
6.) Faulty cooling water pump drive belt (industrial engines)
6. Excessive fuel consumption 1.) Incorrect injection timing
2.) Low compression

Printed in Japan
12-2.
TS
1. Troubleshooting

Trouble Probable cause Remarks

6. Excessive fuel consumption 3.) Engine mounted improperly

7. Excessive lube oil consumption

A. Oil up 1.) Too large cylinder-to-piston clearance
2.) Worn, damaged or seized piston ring
3.) Incorrect piston ring gap position
4.) Clogged oil ring hole
5.) Misassembled piston ring
6.) Clogged air breather
7.) Oil level too high

B. Oil down 1.) Worn valve stem and valve guide

2.) Blown cylinder head gasket
3.) Faulty valve stem seal

C. Oil leakage 1.) Tightening insufficient

2.) Faulty packing
3.) Faulty oil seal
4.) Too high lubricating oil.pressure regulator valve pressure

8. Lubricating oil pressure is low 1.) Inappropriate oil quality

2.) Faulty oil pressure adjusting valve
3.) Worn oil pump
4.) Cracked or damaged oil pump, or leakage from connection
5.) Worn crank metal or crankpin metal

9. Engine knocks 1.) Incorrect injection timing

2.) Incorrect nozzle injection pressure
3.) Faulty nozzle injection mechanism
4.) Engine oil entering combustion chamber - oil up, oil down,
oil viscosity too low

10. Exhaust gas is smoky

A. Exhaust gas is white 1.) Injection timing is late
2.) Low compression
3.) Water mixed with fuel
4.) Engine oil entering combustion chamber

B. Exhaust gas is black 1.) Injection timing is too late

2.) Excessive load
3.) Excessive injection volume
4.) Unbalanced injection
5.) Faulty nozzle spraying
6.) Contaminated turbocharger blower
7.) Clogged turbocharger prefilter

Printed in Japan
12-3.
Sec. 1 3. MARINE GEAR (MG)

Contents of this section

Page
1. Service Information ................................. 13·1
[ 1-1.] Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13· 1
[ 1·2.] Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
[ 1-3.] Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13·6
[ 1-4.] Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13·6
(1-5.] General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7

2. Oil Pump/Selector Valve •............................ 13-8

(2-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
(2-2.] Disassembly of Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 13·8
(2-3.] Disassembly of Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . 13-8
(2-4.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
(2-5.J Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
(2-6.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

3. Input Shaft/Gear Shaft .............................. 13-10

[3·1.l Removal . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . 13-10
(3-2.] Disassembly of Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
(3-3.] Disassembly of Gearshaft . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
(3-4.] Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13·13
(3-5.] Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . 13-13
(3-6.] Installation . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . 13-14

4. Output Shaft ..................................... 13-14

(4-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
(4-2.J Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . 13-16
(4-3.] Installation . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . 13-16

5. Input Shaft Flange ................................. 13-16

(5-1.] Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . 13·16
(5-2.] Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13·16

6. Oil Strainer Cleaning ............................... 13-17

7. Shim Adjustment .................................. 13-17

(7-1.] Adjustment of Input Shaft and Gear Shaft Shims .........• 13-17
(7-2.] Adjustment of Output Shaft Shim . . . . . . . . . . . . . . . . . • • . 13-18

8. Troubleshooting ................................... 13-19

MG
1. Service Information (-1.]

1 3. Marine Gear
1 . Service Information
[1-1.) Description
a.) Construction forward clutch outer and is in constant mesh
The marine gear consists of the housing, input with the reverse driven gear. The reverse driven
shaft, gear shaft, output shaft, selector valve and gear is shrinked on the reverse clutch outer which
gear pump. is integral with the gear shaft. The sintered plates
The input shaft, gear shaft and output shaft are are splined onto the internal spline of the clutch
installed in the housing and are power transmission outer.. T_he s_te~I plates are splined to the pinion.
device. The pinion 1s in constant mesh with the output
The selector valve is mounted externally on the shaft gear.
housing end cover and is control device that When the high pressure oil delivered by the selector
hydraulically engages the desired clutch. valve exerts on the clutch piston, the sintered
The gear pump, which is contained in the end plates and steel plates are squeezed together and
cover and driven by the stern side end of the gear the pinion is locked to the shaft.
shaft on MGN46B-1, MGN46BL-8 and MGN47BL- Forward: The engine drives the input shaft
8 models; and is contained in the selector valve and co~nterclockwise. As the forward clutch is applied
driven by the stern side end of the input shaft in forward, the foward pinion rotates counter-
on MGN56B-8, MGN56BL-8 and MGN57BL-8 clockwise at the engine speed. The forward pinion
models, supplies the pressure oil to the selector drives the output shaft clockwise at a reduced
valve for the clutch engagement, clutch cooling, speed.
and bearing and gear lubrication.
The marine gear is bolted directly to the engine Reverse: The engine drives the input shaft
flywheel housing. counterclockwise. The reverse drive gear drives the
reverse driven gear clockwise at the engine speed.
b.) Power flow As the reverse clutch is applied in reverse the
reverse pinion rotates clockwise at the e~gine
Power from the engine is transmitted to the speed. The reverse pinion drives output shaft
input coupling (flange) via the drive ring and rub- counterclockwise at a reduced speed. ·
ber block mounted on the spider.
The input coupling is splined with the input A Note:
shaft which is integral with the forward clutch The direction of rotation is viewed from the
outer. The reverse drive gear is shrinked on the stern side.
Fig. MG-1. Power flow of the marina gear
Rubber block

Forward pinion

Reverse drive gear

~--Forward clutch outer

fT?.~--- Input shaft

~----Gear shaft

Output shaft g e a r - - - - - '

Reverse driven g e a r - - - - - - '

Printed in Japan
13-1.
MG
1. Service Information [-1.)

c.) Hydraulic system d.) Selector valve

The hydraulic system is as shown in Fig. 2. The Flow of the pressure oil changed by selector
oil contained in the oil sump that is located in the valve is as shown in Fig. 3. High pressure oil
bottom of the main housing is sucked through discharged from the gear pump comes in A and
the oil strainer by the gear pump assembly. The is directed to two passages through the valve
oil that is given high pressure at the pump will stem grooves. One passage supplies the actuating
then be led to the selector valve body via the pressure to the forward or reverse clutch, and
oil cooler. It further flows to the rotary-shaped another passage supplies the back pressure to the
valve stem after being regulated or a specified regulating valve through the small hole of the
pressure at the regulating valve. By changing the orifice piston.
oil passages in the valve stem, the oil could be
delivered either to the forward clutch or the As shown in Fig. 2, the pressurized oil coming
reverse clutch to actuate. from the gear pump forces the piston A of the

Fig. MG-2. Oil flow of the marine gear

Forward clutch Reverse clutch

Lubricating
oil Clutch
actuating
oil

Orifice piston

\1:--------;.-:.~:-
Lubricating oil
pressure regulating
-9'
LT..!
* ,........,....,~+-i-+'T"",.-.-~

valve
L______ _
Piston B

r---
' I I
L.!..J I
Piston A I
I : I I
L---.J L---l
Clutch oil preuure
regulating valve
Oil cooler

Gear pump

Oil strainer

Oil sump
I
Printed in Japan
13-2.
MG
1. Service Information [ -1.]

regulating valve upward, while the back pressure Fig. MG-4. Mechanical sefety clutch
from the selector valve passes slowly through
the small hole of the orifice piston and pushes Sintered plate
the piston B of the regulating valve downward. Steel plate
The spring being pushed by both pistons allows oil
pressure to rise gradually so that the clutch engage-
ment is accomplished smoothly.
When selector lever is put back to the neutral
position, pressurized oil that has been pushing the
piston B moves the orifice piston so as to release
the pressure at once.

Fig. MG-3. Sectional view of the selector valve

Reverse Neutral -0- Clutch spring

Shaft Emergency bol

1
Piston

Forward

- - To forward clutch

The oil remained at the clutch oil pressure regulat-

ing valve is led to the lubricating oil pressure
regulating valve through the oil passage. Then, the
oil is regulated there and distributed to every part
that requires lubrication. Emergency
clutch bolt

e.) Mechanical safety clutch

The marine gear is equipped with a device that
enable to lock up the clutch mechanically in case
of emergency that the clutch slips or fails to be
engaged.

There are two bolts on MGN46B-1, MGN46BL-8

and MGN47BL-8 models; and four bolts on
MGN56B-8, MGN56BL-8 and MGN57BL-8 models
called "emergency bolts" in the forward clutch.
By screwing these bolts with a hexagonal wrench,
the forward clutch is mechanically engaged.
Reverse clutch is not equipped with emergency
bolts.
Printed in Japan
13-3.
MG
1. Service Information (-2.J

(1-2.] Sectional View

Fig. MG-5. Sectional view of MGN468-1

Reverse pinion Gear shaft

Gear pump

Forward pinion

Input shaft
Oil strainer

Output shaft '---Output flange

ii seal carrier

Printed in Japan
13-4.
MG
1. Service Information [-2.]

Fig. MG-6. Sectional view of MGN568-8

Reverse pinion Gear shaft

Selector valve

Forward pinion

Forward clutch

Oil strainer

Gear pump

Output shaft

Oil seal carrier

Printrd in Japan
13-5.
MG
1. Service Information [-3/-4.]

[1-3.) Tools and Materials

Hydraulic puller Liquid sealant
Bearing puller Torque wrench
Plastic hammer

[1-4.) Specifications
a.) Torque valves

It~I 46B-1 46BL·8 47BL-8

Spider 2 .0 kg-m ( 15 lb-ft) 2.0 kg-m ( 15 lb-ft) 2.0 kg·m ( 15 lb-ft)

Outer shaft 18.5 kg-m (134 lb·ft) 46.0 kg-m (333 lb-ft) 65.0 kg-m (470 lb-ft)
Output coupling 36.2 kg-m (262 lb-ft) 25.6 kg-m (185 lb-ft) 29.0 kg-m (210 lb-ft)
Oil seal carrier 4.3 kg-m ( 31 lb-ft) 7.5 kg-m ( 54 lb-ft) 4.3 kg-m ( 31 lb-ft)
Oil strainer 4.3 kg-m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft)
Oil pump 4.3 kg-m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft)

I~el 56B-8 56BL-8 57BL-8

Spider 3.5 kg-m ( 25 lb-ft) 3.5 kg-m ( 25 lb-ft) 3.5 kg-m ( 25 lb-ft)
Output shaft 46.0 kg-m (333 lb-ft) 65.0 kg-m (470 lb-ft) 88.6 kg-m (641 lb-ft)
Output coupling 26.0 kg·m (188 lb-ft) 29.0 kg·m (210 lb-ft) 29.0 kg-m (210 lb-ft)
Oil seal carrier 7.9 kg-m ( 57 lb-ft) 4.3 kg-m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft)
Oil strainer 4.3 kg-m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft)
Selector valve 4.3 kg-m ( 31 lb-ft) 4.3 kg·m ( 31 lb-ft) 4.3 kg-m ( 31 lb-ft)

For tightening torques which are not listed above, follow the standards given below.

Item Torque Item Torque

8 mm bolts, nuts 1.2 kg-m ( 9 lb-ft) 5 mm socket bolts 0. 7 kg-m ( 5 lb-ft)
10 mm bolts, nuts 2.4 kg-m (18 lb-ft) 6 mm socket bolts 1.2 kg-m ( 9 lb-ft)
12 mm bolts, nuts 4.2 kg-m (30 lb-ft) 8 mm socket bolts 2.8 kg-m (20 lb-ft)
14 mm bolts, nuts 7.2 kg-m (52 lb-ft) 10 mm socket bolts 5.6 kg-m (40 lb-ft)

b.) Specifications

Model MGN46B-1 MGN46BL-8 MGN47BL-8

Type Hydraulic, multi-disc clutch, wet type (flange SAE No. 1)
Reduction ratio (forward) 1.53 1.97 2.58 3.05 3.53 3.90 4.42 5.00 5.55 6.00
Propeller shaft rpm
1,307 1,018 775 656 567 512 452 400 360 333
(continuous rated)
Direction of rotation
Clockwise, viewed from stern side
(propeller shaft)
Dry weight 220 kg (485 lbs) 275 kg (606 lbs) 350 kg (772 lbs)

Printed in Japan
13-6.
MG
1. Service Information [-4/-5.J

Model MGN56B-8 MGN56BL·8 MGN57BL·8

Type Hydraulic, multi-disc clutch, wet type (flange SAE No. 1)
Reduction ratio (forward) 1.65 2.00 2.48 2.92 3.43 4.04 4.48 5.08 5.50 5.91
Propeller shaft rpm 1,000 806 684 584 495 446 394 364 338
1,212
(continuous rated)
Direction of rotation
Clockwise. viewed from stern side
(propeller shaft)
Dry weight 340 kg (750 lbs) 465kg(1,025 lbs) 520kg (1,1461bs)

c.) Service data

Item Standard Service limit

Backlash of input flange and shaft 0.030 -0.100 mm (0.0012-0.0039 in) 0.3 mm (0.012 in)
Backlash of forward (reverse)
pinion and output shaft gear 0.13 -0.25 mm (0.0051-0.0098 in) 0.6 mm (0.024 in)

Backlash of reverse drive and driven gears 0.11 - 0.23 mm (0.0043-0.0091 in) 0.6 mm (0.024 in)
Backlash of sintered plate and forward (reverse)
clutch outer 0.155 - 0.355 mm (0.0061--0.0140 in) 0.5 mm (0.020 in)

Backlash of steel plate and forward (reverse)

pinion
0.10 - 0.23 mm (0.0039-0.0091 in) 0.6 mm (0.024 in)

Sintered plate thickness 2.35 - 2.45 mm (0.0925-0.0965 in) 2.2 mm (0.087 in)
Thickness 2.98 - 3.02 mm (0.1173--0.1189 in) 2.5 mm (0.098 in)
Oil seal ring
End gap 0.15 -0.35 mm (0.0059--0.0138 in)
MGN46B·1, 46BL-8, 47BL-8 MGN56B-8, 56BL·8, 57BL-8
Clutch oil regulating valve Inner 44.0 mm (1.73 in)
spring free length 45.5 mm (1.79 in)
Outer 70.0 mm (2.76 in) 61.0 mm (2.40 in)
Shaft end play 0 - 0.1 mm (0-0.004 in)

[1-5.) General Instructions

1. The service procedures and photographs contained in this manual are based on MGN46BL-8 Model.
Those for the other models are similar.

Printed in Japan
13-7.
MG
2. Oil Pump/Selector Valve (-1/-2/-3.]

2. Oil Pump/Selector Valve Fig. MG-9. Disassembling the gear pump

[2-1.] Removal
1. Remove the four joint bolts and remove the
oil pipes.

Fig. MG-7. Removing the oil pipes

Fig. MG-10. Exploded view of the gear pump

Pump cover Pump case Driven gear Pump base

2. Remove the gear pump assembly and selector

valve assembly from the end cover.

A Note:
On MGN568-8, MGN56BL-8 and MGN57BL-8
models, as the gear pump is mounted on the
selector valve, remove as a unit.
Fig. MG-8. Removing the gear pump assembly and selector
valve
., J r
Drive gear
'
""'"'
·~. '
_...,
~
, r:·
/""~
,,
,~·

.
...~..... -• [2-3.] Disassembly of Selector Valve
:r 1. Loosen the four socket bolts retaining the
-
,. base plate with a hexagonal wrench.

'
·~
.•.
""""'··· ...._ Fig. MG-11. Loosening the socket bolts
• •·
,,·:;,
~---·,

.,., Socket bolts

'
[2-2.] Disassembly of Gear Pump
1. On MGN56B-B, MGN56B L-8 and MGN57B L-8,
remove the gear pump assembly from the
selector valve.
2. Hold the pump cover and lightly tapping the
pump base with a copper or plastic hammer
disassemble the gear pump.

A Caution:
Take care not to damage the mating surface
corners of the cover, case and base.
Printed in Japan
13-8.
MG
2. Oil Pump/Selector Valve [-3.]

2. Remove the selector valve stem with the lever. 5. Remove the regulating valve cover.
Be careful I not to lose the detent ball and spring
as they jump out at this time. Fig. MG-15. Removing the cover
Regulating valve cover
Fig. MG-12. Removing the valve stem

6. Remove the large piston, inner and outer springs,

spacer and small piston.
3. Screw the base plate retaining bolt in the
threaded hole in the sealing plug and pull the Fig. MG-16. Removing the clutch oil regulating valve
plug with the bolt out of the valve body.
Fig. MG-13. Removing the sealing bolt •
_ _.,...ease plate retaining
bolt

Outer spring

7. Pull out the spring pin and disassemble the

selector valve lever and stem.
4. Remove the spring and orifice piston.
A Note:
Fig. MG-14. Removing the orifice piston Make sure that there are aligning marks on the
valve lever and stem. If there are no marks, punch
the marks before disassembling.

0-ring
Printed in Japan
13-9.
MG
2. Oil Pump/Selector Valve [-3/-4/-5/--6.) 3. Input Shaft/Gear Shaft [-1.)

Fig. MG-17. Aligning marks of the valve lever and stem 3. After installation, inspect the oil level with the
dipstick. If the oil level is lower than the lower
limit or is nearing it, remove the filler cap and
add the recommended engine oil up to the
upper limit. Run the engine for a few minites
at idle and recheck the oil level.

Fig. MG-18. Checking the oil level

-- Upper limit

(2-4.] Inspection
- Lower limit
1. Check the sliding surfaces of the pump gears,
case, base and cover for wear, scratches or
scoring.
2. Check the regulating valve pistons, orifice piston 3. Input Shaft/Gear Shaft
and selector valve stem for wear, scratches or
scoring. (3-1.] Removal
3. Check the valve springs for damage.
Measure the clutch oil regulating valve spring 1. Remove the drain plug and drain the oil thor·
free length. oughly.
MGN46B·1, MGN46BL·B, MGN47BL-8 2. Remove the gear pump and selector valve (see
Standard: Inner: 44.0 mm (1.73 in) page 13-8).
Outer: 70.0 mm (2.76 in) Remove the oil strainer (see page 13-17).
MGN56B·B, MGN56BL-8, MGN57BL-8
Standard: Inner: 45.5 mm (1.79 in)
Fig. MG-19. Drain plug
Outer: 61.0 mm (2.40 in)

[2·5.] Assembly
Assemble the gear pump and selector valve in the
reverse order of disassembly. Note the followings.
1. Clean all parts in cleaning solvent.
2. Blow out all passages of the selector valve body.
3. Coat all parts with clean engine oil.
4. When installing the selector valve lever on
the stem, align the punch marks (Fig. MG-17).

3. Remove the shims and oil pump drive block.

(2-6.] Installation
1. Install the gear pump and selector valve on A Note:
the end cover and tighten the bolts to 4.3 The drive block is installed on the rear end of the
kg·m (31 lb-ft). input shaft with the knock pin on MGN568-8,
2. Install the oil pipes and joint bolts. MGN56BL-8 and MGN57BL-8 models.
Printed in Japan
13-10.
MG
3. Input Shaft/Gear Shaft [-1/-2.]

Fig. MG-20. Removing the shims and drive block 6. Pull out the drive shaft assembly and gear
shaft assembly.

Fig. MG-23. Pulling out the drive shaft and gear shaft

4. Remove the bolts tightening the end cover to

the housing.
Fig. MG-21. Removing the bolts
(3-2.) Disassembly of Input Shaft
1. Remove the section ring and thrust washer
from the bow side.

Fig. MG·24. Removing the section ring

Section ring

Thrust washer

5. Remove the end cover by screwing puller bolts

into the threaded holes in the cover.

A Note:
The taper roller bearing outer races are removed
together with the end cover. 2. Remove the pinion, thrust washer and collar.

Fig. MG-22. Removing the end cover Fig. MG-25. Removing the pinion

Pinion

Thrust washer

Thrust collar

PrintPd in Japan
13-11.
MG
3. Input Shaft/Gear Shaft (-2.]

3. Using a screwdriver, remove the snap ring 6. Remove the clutch spring and wahser.
retaining the clutch pack.
Fig. MG-29. Removing the clutch spring and washer
Fig. MG-26. Removing the snap ring

7. Screw puller bolts in the threaded holes in the

4. Remove the back plate and clutch plates (sint· clutch piston and pull the piston out of the
ered plates, steel plates). clutch outer with bolts.

Fig. MG-27. Removing the clutch plates Fig. MG-30. Removing the clutch piston
Back plate Sintered plate

5. Remove the center snap ring from the shaft. 8. Remove the square ring from the shaft.
Fig. MG-28. Fig. MG-31. Removing the square ring

'.
;:

•
p1£' .
.'<#r ;0. £;: r·

Center snap ring

Printed in Japan
13-12.
MG
3. Input Shaft/Gear Shaft [-2/-3/-4/-5.]

9. Remove the square ring from the piston. 2. Disassemble the gear shaft in the same manner
of the input shaft disassembly described earlier.
Fig. MG-32. Removing the piston square ring

[3-4.] Inspection
1. Check the reverse drive (driven) gear for wear
or damage. Replace the input (gear) shaft if
necessary.
2. Check the pinion for wear or damage.
Replace if necessary.
3. Check the clutch spring for damage.
4. Check the sintered plates for discoloration and
measure the thickness.
Standard: 1.35-2.45 mm
(0.0925-0.0965 in)
Service limit: 2.2 mm (0.087 in)
10. Remove the four oil seal rings from the stern 5. Check the steel plates for warpage.
side end of the shaft. 6. Check the taper roller bearings for wear, dis·
coloration or damage. If the replacement is
Fig. MG-33. Removing the oil seal rings necessary, remove the inner race with a bearing
puller.
7. Measure the oil seal ring thickness and end
gap.
Oit seal rings
Standard: Thickness: 2.98-3.02 mm
(0.1173-0.1189 in)
End gap: 0.15-0.35 mm
(0.0059-0.0138 in)
Service limit: Thickness: 2.5 mm (0.089 in)

8. Check the thrust washers for wear.

[3·5.] Assembly

[J.J.] Disassembly of Gear Shaft Assemble the input shaft and gear shaft in the
reverse order of disassembly. Note the followings;
1. Using a bearing puller, remove the bearing inner 1. When installing the square ring, apply grease
race from the bow side end of the shaft. and be careful I not to bind.
Fig. MG-34. Removing the inner race 2. Install the sintered plates and steel plates alter·
nately one after the other so that the piston
and back plate are adjacent to the sintered
Bearing puller
plates. (Sintered plates: 6 on MGN468·1,
Inner race MGN46BL·8 and MGN47BL·8 models; 9 on
MGN568·8, MGN56BL·8 and MGN57BL·8
models. Steel plates: 5 on MGN468·1,
MGN46BL·B and MGN47BL·8; 8 on MGN56B·8
MGN56BL·8 and MGN57BL·8).

l'rm/f'd in Japan
13· 13.
MG
3. Input Shaft/Gear Shaft [-51--6.I 4. Output Shaft [-1.I

3. To install the clutch spring retaining snap ring, 4. Output Shaft

force down it into the shaft groove with pinions.
After installation, make sure that the snap [4-1.] Removal
ring is seated in the groove securely and inspect
the shaft surface for scratches or scoring. Repair 1. Remove the input shaft and gear shaft (see
with oil stone if necessary. page 13-10).
2. Straighten the lock washer tabs and loosen
Fig. MG-35. Installing the clutch spring retaining snap ring the output shaft flange lock bolts.
Remove the bolts and lock washer.

Fig. MG-37. Lock washer and bolts

Pinions

4. After assembling the clutch, check the clutch

operation by applying air into oil passage.
Fig. MG-36. Checking the clutch operation 3. Using a hydraulic puller, remove the output
shaft flange.

A Note:
If the puller cylinder has not enough stroke, add
metal piece smaller than the output shaft diameter
between the shaft and puller ends.

Fig. MG-38. Removing the output shaft flange

Hydraulic puller

[J-6.] Installation
Install the input shaft and gear shaft in the reverse
order of removal. Note the followings.
1. Tighten the end cover in a criss-cross pattern
in 2-3 steps. 4. Remove the key by removing the socket bolt.
2. If the bearing is replaced, adjust the shim (see
page 13-17). A Note:
3. After installation, fill the recommended oil On MGN468·1 model, the flange is splined to
up to the upper limit (see Fig. MG-18). the shaft therefor key is not used.
Printed in Jo.po.n
13-14.
MG
4. Output Shaft (-1.]

5. Remove the oil seal carrier mounting bolts. 8. Place the reverse gear unit on firm wood blocks
with the input side facing down so that the
Fig. MG-39. Removing the carrier mounting bolts spider turns freely.

Fig. MG-42. Placing the reverse gear unit

6. Remove the oil seal carrier together with oil

seal by screwing two puller bolts (M12 x 1.75)
evenly in the threaded holes in the carrier. 9. Remove all the rear cover tightening bolts,
then remove the rear cover by screwing two
Fig. MG-40. Removing the oil seal carrier puller bolts (MlO x 1.5) evenly in the threaded
holes in the rear cover.

Fig. MG-43. Removing the rear cover

7. Remove the taper roller bearing adjusting shims.

Fig. MG-41. Removing the adjusting shims

10. Remove the two bolts tightening the shroud
to the housing then remove the output shaft
together with the shroud from the housing.

Printed in Japan
13-15.
MG
4. Output Shaft [-21-3.] 5. Input Shaft Flange [-11-2.]

Fig. MG-44. Removing the output shaft 3. Remove the spacer.

Fig. MG-46. Removing the spacer

(4-2.) Inspection
1. Check the output shaft gear teeth for wear or
damage.
2. Check the taper roller bearing for wear, dis- 4. Lightly tapping the input shaft flange, drive
coloration or damage. If the replacement is it out of the housing.
necessary, remove the inner race with a bearing A Note:
puller. Do not remove the input shaft flange unless the
replacement is necessary.
(4-3.) Installation
Install the output shaft in the reverse order of Fig. MG-47. Removing the input shaft flange
removal. Note the followings;
1. As the stainless bolts are used for the lower
bolts of the rear cover, do not mix them with
the other bolts.
2. Tighten the rear cover, oil seal carrier and
output shaft flange in a criss-cross pattern in
2-3 steps to specified torque (see page 13-6).

5. Input Shaft Flange

(5-1.] Removal
1. Remove the output shaft (see page 13-14).
2. Remove the snap ring retaining the bow side A Note:
bearing of the input sheft. If the spider requires replacement, remove the
cotter pins and loosen the nuts. Replace the
Fig. MG-45. Removing the snap ring spider with a new one, tighten the nuts to 2.0
kg-m (15 lb-ft) on MGN468-1, MGN468L-8
and MGN47BL-8 models, and 3.5 kg-m (25 lb-ft)
on MGN56BL-8, MGN56BL-8 and MGN578L-8
models, then secure the nuts with new cotter pins.

(5-2.) Installation
Install the input shaft flange in the reverse order
of removal.
A Note:
Replace the oil seal with a new one.
PrinlPd in Japan
13-16.
MG
6. Oil Strainer Cleaning 7. Shim Adjustment (-1.]

6. Oil Strainer Cleaning 7. Shim Adjustment

1. Remove the strainer cover and gasket. Whenever the taper roller bearing has been re-
placed, shim thickness must be adjusted.
Fig. MG-48. Removing the strainer cover
[7-1.] Adjustment of Input Shaft and
Gear Shaft Shims
1. After installing the end cover, drive the outer
race in the end cover lightly and evenly.
2. Measure the distance from the end cover sur-
face to the outer race side surface (dimension
A).
Fig. MG-50. Measuring the dimension A

2. Remove the spring and strainer screen.

Fig. MG-49. Removing the strainer screen

3. Measure the projection height of the selector

valve or concavity depth of the pump base
(dimension B).
Fig. MG-51. Measuring the dimension B
.,.11
• ft_,.

3. Wash the screen in cleaning solvent and air dry.

A Note:
Inspect the screen and if it is damaged replace
with a new one.
4. Measure the gasket thickness.
4. Install the strainer and spring.
5. Install the cover and tighten to 4.3 kg-m (31 A Note:
lb-ft). Genuine NICO's part is 0.3 mm (0.012 in) of
6. Check the oil level. thickness.
/'rinled in Jupan
13-17.
MG
7. Shim Adjustment (-1/-2.]

Fig. MG-52. Measuring the gasket thickness 3. Measure the projection height of the oil seal
carrier (dimension B).

Fig. MG-54. Measuring the dimension B

5. Determine the shim thickness so that the end

play of the shaft becomes 0-0.1 mm (0-0.04
in). 4. Determine the shim thickness so that the end
MGN46B·1, MGN46BL·B, MGN47BL-B play of the shaft becomes 0-0.1 mm (0-
Input shaft side: 0.004 in).
Shim thickness= A+ 0.3 - B - (0 to 0.1) Shim thickness= A - B - (0 to 0.1)
Gear shaft side: Unit: mm
Shim thickness= A - 0.3 - B + (0 to 0.1)
MGN56B-B, MGN56BL-8, MGN57BL·8
Shim thickness= A + 0.3 - B - (0 to 0.1) THICKNESS OF AVAILABLE SHIM
Unit: mm 0. 1 mm (0.004 in)
0.2 mm (0.008 in)
0.5 mm (0.020 in)
[7-2.] Adjustment of Output Shaft Shim 1.0 mm (0.039 in)
1. After installing the rear cover, drive the outer
race in the rear cover lightly and evenly.
2. Measure the distance from the rear cover surface
to the outer race side surface (dimension A).

Fig. MG-53. Measuring the dimension A

Printed in Japan
13-18.
MG
8. Troubleshooting

8. Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY REFERENCE PAGE

Low oil pressure Partially clogged oil strainer Clean 13-17

Sticking piston in clutch oil Clean or replace 13-9
pressure regulating valve
Damaged or worn oil seal ring Replace 13-13
Worn gear pump Replace 13-8
Deviation of remote control Adjust -
system
Clogged orifice piston Clean 13-9
Damaged or weakened spring in Replace 13-9
the clutch oil regulating valve

No oil pressure Low oil level or empty sump Check for oil leakage -
and replace defective
parts. Fill sump.
Damaged gear pump Replace 13-B

High oil pressure Sticking piston in clutch oil Clean or replace

pressure regulating valve

Low lubrication oil pressure Clogged orifice in selector valve Clean 13-9
Sticking piston in clutch oil Clean or replace 13-9
regulating valve

Overheat Slipping clutch Inspect clutch and 13-13

replace defective parts
Oil level too high Correct oil level 13-10
Damaged bearing Replace -
Turning in company Refer to next -
Turning in company Sticking clutch plates Replace 13-11
Sticking pinion bushing Replace 13-11
Sticking thrust washers on Replace 13-11
pinion ends
Damaged or weakened clutch Replace 13-11
spring

Improper shifting Seized clutch Replace clutch plates 13-11

Failure of remote control Adjust or replace -
system
Damaged or weakened clutch Replace 13-11
spring

Excessive noise Worn or damaged gear teeth or Repair or replace -

spline
Damaged bearing Replace -
Damaged or worn rubber block Replace -
Loose bolts or nuts Tighten 13-6

Printed m Japan
13-19.
VANMAR DIESEi. EllBlllE CD.,I. TD.
1-32, CHAYA MACHI. KITA-KU, OSAKA 530 JAPAN TEL.106)376-6211 TELEX 63436 YANMARJ FAX.(06)372-2455

Printed in Japan
OOOOAOA1014-9110