Yammar 6ey26 - Me Manual

6EY26
Eng. No. 0500
Thank you for purchasing

YANMAR product.
Be sure to read this Operation Manual for
you to use this product safety and correctly.
Even after reading it, carefully keep it, making clear
to all personnel concerned where it’ s kept so that
the operator, mechanic or supervisor will have an Order No. R7-BB3301
access to it whenever he wants to read or refer to it. 2009.11.20
OPERATION MANUAL
Work No.R7-BB3301 (Engine No.0500) (Clockwise Rotation Engine) Page
CONTENTS 1/6
Page No.
00 Basic Descriptions
01 Preface M51690-00-01a-00
12 Engine Specifications M51695-00-12k-00
03 Direction of Rotation M51690-00-03b-00
04 External and Sectional View M51695-00-04f-00
05 Term & Symbol Marks M51690-00-05a-00
06 Precautions on Maintenance M51695-00-06b-00
07 Precautions prior to Maintenance & Servicing M51695-00-07c-00
18 Protective Device Setting Values M51695-00-18b-00
Holding Volumes of Lubricating Oil & Cooling Water
Pressure & Temperature Setting Values
09 Assembly Adjustment Values M51695-00-09a-02
Clearances & Wear Limits of Major Parts
10 Table of Tightening Torques of Major Bolts & Nuts M51690-00-10a-00
11 Principal Dimensions & Mass for Disassembly & Servicing M51695-00-11h-00
13 SI Unit Conversion Table M51690-00-13a-00
14 Symbol Marks on Piping Layout & Instruments M51690-00-14a-00
00 Operation
21 Operational Preparation M51695-00-21f-00
22 Starting M51695-00-22j-00
23 Running M51695-00-23h-00
24 Stopping M51695-00-24b-00
25 Special Running Method M51695-00-25a-00
33 Data Sheet M51695-00-33a-00
00 Trouble shooting & Countermeasures M51695-00-41a-00
00 Fuel Oil, Lubricating Oil & Cooling Water

51 Quantity Criteria of Fuel Oil M51692-00-51a-00
52 Calculation of CCAI M51692-00-52a-00
53 Quality Criteria of Blended Fuel Oil M51692-00-53a-00
54 Properties of Fuel Oil at Engine Inlet M51692-00-54a-00
55 How to Find out Heavy Fuel Oil Heating Temperature M51692-00-55a-00
56 How to Find out Viscocity of Blended Oil M51692-00-56a-00
57 Changeover to Heavy Fuel Operation and Heavy Fuel Operation M51692-00-57b-00
58 Choosing of Lubricating Oil M51692-00-58a-00
59 Control on Lubricating Oil M51692-00-59a-00
60 List of Lub. Oil Brands M51692-00-60a-01
62 Criteria on Cooling Fresh Water M51690-00-62a-00
63 Selection and Control of Corrosion Inhibitor M51690-00-63a-00
00 Measurement of Running Performance
91 Precautions on Measuring Performance & Measure Items M51690-00-91a-00
92 Measurement of Running Performance M51690-00-92b-00
93 Measurement of Max. Combustion Pressure M51690-00-93a-00
OPERATION MANUAL
CONTENTS 2/6
Page No.
01 Cylinder Block & Cylinder Liner
01 Outline M51690-01-01a-00
02 Overhauling the Cylinder Block M51690-01-02a-00
03 Overhauling the Cylinder Liner M51690-01-03a-00
Parts List of Cylinder Block
Cylinder Block M51695-01-51b-02
Cylinder Side Cover M51695-01-52d-00
Cylinder Side Cover (Relief Valve) M51695-01-53c-01
Gear Case M51695-01-54b-03
Oil Pan M51695-01-55a-02
Oil Sealing (SFW) M51695-01-56b-01
Oil Sealing (OFW) M51695-01-62a-00
Breather Pipe M51695-01-60a-01
Pump Case Cover M51695-01-58a-00
08 Turning Device
01 Outline (Manual Cranking) M51690-08-01a-00
02 Operation of the Manual Cranking Device M51690-08-02a-00
Parts List of Turning Device M51695-08-51c-00
11 Cylinder Head & Its Accessories
01 Outline M51690-11-01a-00
02 Overhauling the Cylinder Head M51690-11-02a-00
03 Overhauling the Intake / Exhaust Valves M51690-11-03a-01
04 Overhauling the Intake / Exhaust Valve Seat M51690-11-04a-00
05 Overhaul\ling the Intake / Exhaust Valve Guide M51690-11-05a-00
06 Overhauling the Intake / Exhaust Valve Bridge & Guide M51690-11-06a-00
07 Overhauling the Valve Rotator M51690-11-07a-00
08 Adjusting the Intake / Exhaust Valve Head Clearance M51690-11-08a-01
Parts List of Cylinder Head
Cylinder Head M51695-11-51a-02
Valve Arm Ass’y & Bonnet M51695-11-52a-01
Indicator Valve M51695-11-53a-02
14 Timing Gear, Camshaft & Suction / Exhaust Swing Arm
01 Outline M51690-14-01a-00
02 Overhauling the Timing Gear M51690-14-02a-01
03 Servicing the Camshaft M51690-14-03a-00
04 Servicing the Intake / Exhaust Swing Arm M51690-14-04a-00
Parts List of Timing Gear M51695-14-51a-00
Parts List of Camshaft & Suction / Exhaust Swing Arm M51695-14-52a-02
OPERATION MANUAL
CONTENTS 3/6
Page No.
18 Air Cooler, Exhaust Manifold & Turbocharger
01 Outline M51695-18-01b-00
02 Servicing the Air Cooler M51690-18-02b-00
03 Overhauling the Exhaust Manifold M51695-18-03b-00
Operating and Mounting Instruction for Exhaust Gas Turbocharger 4588903en-8
05 Turbocharger Blower Washing Procedure M51690-18-05b-00
06 Turbocharger Turbine Washing Procedure M51690-18-06b-00
Parts List of Air Cooler M51695-18-52b-00
Parts List of Boost Air
Air Duct M51695-18-54a-01
Boost Air Gauge Pipe M51695-18-55b-01
Parts List of Exhaust Gas
Exhaust Gas Manifold M51695-18-58a-00
Exhaust Gas Manifold Cover M51695-18-60a-01
Exhaust Gas Outlet Pipe for Turbocharger M51695-18-61d-00
Exhaust Gas Pipe M51695-18-63a-01
Insulation Covering M51695-18-65a-01
Parts List of Turbocharger M51695-18-67d-00
Parts List of Turbocharger Blower Washer M51695-18-69a-00
Parts List of Turbocharger Turbine Washer M51695-18-71a-00
21 Main Bearing & Crankshaft
01 Outline M51690-21-01a-00
02 Overhauling the Main Bearing M51690-21-02a-00
03 Overhauling the Crankshaft M51690-21-03a-00
04 Measurement of Crankshaft Deflection M51695-21-04b-02
Parts List of Main Bearing M51695-21-51a-00
Parts List of Crankshaft & Flywheel M51695-21-52a-02
Parts List of RATO Coupling M51695-21-53d-00
22 Piston & Connecting Rod
01 Outline M51690-22-01a-00
02 Overhauling the Pistons & Piston Pins M51690-22-02a-01
03 Overhauling the Connecting Rods M51690-22-03a-01
Parts List of Piston & Connecting Rod M51695-22-51a-01
OPERATION MANUAL
CONTENTS 4/6
Page No.
30 Lubricating Oil System
01 Outline (Turbocharger is equipped to the flywheel side) M51695-30-01a-00
02 Overhauling the Lubricating Oil Pump M51690-30-02a-00
03 Adjusting & Overhauling the Pressure Regulating Valve M51690-30-03a-00
04 Adjusting & Checking the Thermostats M51690-30-04a-00
06 Overhauling the Lubricating Oil Filter M51690-30-06a-02
08 Overhauling the Lubricating Oil Cooler M51690-30-08a-00
09 Overhauling the Lubricating Oil By-pass Strainer (Centrifugal Type) M51690-30-09b-00
Parts List of Lubricating Oil Pump M51695-30-51a-01
Parts List of Lubricating Oil Pressure Regulating Valve M51695-30-52a-01
Parts List of Lubricating Oil Strainer M51695-30-53a-02
Parts List of Lubricating Oil Cooler M51690-30-55a-01
Parts List of Lubricating Oil By-pass Strainer (Centrifugal Type) M51695-30-56c-01
Parts List of Lubricating Oil Pipe System
(Pump ～ Cooler) M51695-30-57a-02
(Cooler ～ Strainer) M51695-30-58a-02
(for Pressure Gauge) M51695-30-60a-02
(for Turbocharger) M51695-30-62a-00
40 Cooling Water System
01 Outline (OFW Side T/C - Engine side P × 1) M51695-40-01f-00
02 Overhauling the Cooling Water Pump M51690-40-02a-01
03 Overhauling the Cylinder Jacket Cooling Water Thermostats M51690-40-03a-00
04 Servicing of Bypass Valve in the Air Cooler M51690-40-04b-00
(Turbocharger is equipped on the flywheel side)
Parts List of Cooling Water Pump (Fresh Water Side) M51695-40-51a-01
Parts List of Cooling Water Thermostat Valve M51695-40-53a-00
Parts List of Cooling Water Pipe System
(Pump ～ Cylinder) M51695-40-54a-01
(Collecting Pipe) M51695-40-55c-01
(Cylinder Drain Pipe) M51695-40-56b-01
(Air Cooler Inlet) M51695-40-74a-00
(Air Cooler ～ LO Cooler) M51695-40-76a-00
(F.W.) M51695-40-64c-00
(By-Pass Valve of Air Cooler) M51695-40-70c-00
Parts List of I/C Drain Pipe M51690-40-66a-00
Parts List of Cooling Water Pipe (Pressure Gauge) M51695-40-67b-01
OPERATION MANUAL
CONTENTS 5/6
Page No.
50 Fuel Oil System
01 Outline M51695-50-01b-00
02 Adjusting the Fuel Oil Pressure M51690-50-02b-00
03 Overhauling the Fuel Injection Pump M51690-50-03a-00
05 Regulation of the Fuel Injection Volume (Exhaust Gas Temperature) M51690-50-05a-00
06 Adjusting the Fuel Injection Timing M51690-50-06a-00
07 Overhauling the Fuel Injection Pump Drive M51690-50-07a-00
08 Overhauling the Fuel Injector & Adjusting the Injection Pressure M51690-50-08a-01
10 Overhauling the Fuel Oil Pipe M51690-50-10a-01
11 Overhauling the Fuel Oil Seal Pot M51690-50-11a-00
Parts List of Fuel Injection Valve M51695-50-51a-00
Parts List of Fuel Injection Pump M51692-50-53a-01
Parts List of Fuel Injection Pump Driving Device M51695-50-54a-01
Parts List of Fuel Injection Pipe M51695-50-55a-00
Parts List of Fuel Oil Pressure Regulating Valve M51695-50-59a-01
Parts List of Overflow Fuel Tank & Float Switch M51695-50-62a-00
Parts List of Overflow Fuel Sump M51695-50-72a-00
Parts List of Accumulator M51695-50-73a-00
Parts List of Fuel Oil Pipe System
(Inlet ～ Main Pipe) M51695-50-66b-01
(Main Pipe) M51695-50-67a-03
(Main Pipe ～ Pressure Regulating Valve) M51695-50-71b-01
(Overflow for Injection Valve) M51695-50-68a-01
(Overflow for Cylinder) M51695-50-69b-00
(Overflow for Injection Pipe) M51695-50-70a-00
60 Governor & Governor Gear
60 Outline M51690-60-01a-00
ZEXEL Service Manual (Governor RHD10) PubNo.EE74E-11017
02 Overhauling the Governor Link M51690-60-02a-00
03 Overhauling the Governor Gear M51690-60-03a-00
Parts List of Governor & Driving Device M51695-60-51d-00
Parts List of Governor Linkage M51695-60-52a-01
Parts List of Start / Stop Lever M51695-60-53a-00
Parts List of Link Ass'y (RHD Type) M51695-60-54a-01
63 Control & Protective Devices
01 Outline M51695-63-01a-00
04 Adjusting the Pressure Transmitter M51690-63-04a-00
05 Maintenance of the Thermo-Resistance Bulb M51690-63-05a-00
06 Maintenance of the Presure Gauge M51690-63-06a-00
OPERATION MANUAL
CONTENTS 6/6
Page No.
65 Special Attachments
03 Maintenance of the Electromagnetic Pick-up M51690-65-03a-00
05 Maintenance of the Turning Switch M51690-65-05a-00
06 Maintenance of the Start / Stop Lever Interlock Switch M51690-65-06a-00
07 Maintenance of the Electromagnetic Start Valve M51690-65-07a-00
08 Maintenance of the Electromagnetic Stop Valve M51690-65-08a-00
09 Maintenance of the Air Filter M51690-65-09a-00
11 Maintenance of the Speed Relay M51690-65-11a-00
12 Maintenance of the Startup Fuel Control Air Piston & Shutdown Air Piston M51690-65-12a-00
13 Maintenance of the Speed Regulating Valve M51690-65-13a-00
14 Maintenance of the Pressure Switch M51690-65-14a-00
15 Maintenance of the Temperature Switch M51690-65-15a-00
17 Maintenance of the Fuel Oil Float Switch M51690-65-17a-00
18 Maintenance of the Fuel Pump Rack Potentionmeter M51690-65-18a-00
Parts List of Magnetic Pick-up M51695-65-52d-00
Parts List of Gauge Panel (Electric Tachometer) M51695-65-54c-00
Parts List of Gauge Panel (Pressure Gauge) M51695-65-63b-02
Parts List of Air Piston for Fuel Limit & Engine Stop M51695-65-56e-00
Parts List of Pressure Switch (5 Connects) M51695-65-58j-00
Parts List of Pressure Switch (4 Connects) M51695-65-59f-00
Parts List of Temperature Switch M51695-65-60a-01
Parts List of Fuel Oil Rack Transmitter M51695-65-64a-01
70 Starting Air System & Air Motor
01 Outline of the Main Components M51690-70-01c-00
02 Overhauling the Air Motor M51690-70-02a-00
Installation and Maintenance Manual 3540598
Parts List of Air Motor M51695-70-51a-00
Parts List of Starting Air Devices
(Starting Air Pipe) M51695-70-52a-01
(Control Air Pipe) M51695-70-53a-00
(Governor Air Pipe) M51695-70-54a-01
92 Hydraulic Jack
01 Outline of the Main Components M51690-92-01a-01
02 How to Use the Hydraulic Tools M51690-92-02a-00
03 Location Used & Installation Method M51690-92-03a-00
Parts List of Hydraulic Jack
(Cylinder Head) M51695-92-51a-01
(Main Bearing Cap) M51695-92-52a-01
(Rod Bolt) M51695-92-53a-02
(Pantograph) M51695-92-54a-00
95 Installation Notes M51695-95-12a-00
Yanmar's Worldwide Service Network

OPERATION MANUAL M51690
Basic Descriptions No. Page
00 Preface 00-01a-00 1/4
Thank you for purchasing a YANMAR Diesel Engine.
1. Foreword
This Operation Manual has been prepared for your safe and effective use of the engine. Read thorough this
Operation Manual and fully understand the safety precautions and precautions regarding the operation,
checking and servicing before using this engine.
(1) Keep this Operation Manual at a clearly identified place accessible for the operator to refer to it at any
time.
(2) The text and illustrations of this Operation Manual may partly disagree with engines of some specifica-
tions.
For such engines, refer to the Engine Specification and Final Document we have submitted you sepa-
rately.
Also note that this Operation Manual is subject to change for improving the quality and performances
of engine or for safety.
(3) For the following devices, refer to the corresponding operation manuals separately attached.
Attachments of special specifications
(4) In this manual, the numerical values are based on the SI system (International System of Units).
However, the numerical values based on the conventional unit system are also given in brackets.
(5) Replacement parts should be our genuine parts or specified parts. Order a part to your nearest sales
or service agent of Yanmar’s parts. When ordering a part, clearly specify page number to which parts
have been described, the Part Name (part description) and Part No., and the Model and manufacture’s
Serial No. of the engine.
(6) If you should have lost or damaged this Operation Manual, or if you have any questions and advice,
please contact us or your nearest sales or service agent (shown in the service network list "YANMAR
Worldwide Service" appended to this manual).
(7) If you transfer this engine, also transfer this Operation Manual, Final Document and Records of Shop
Trial with the engine to the next owner.
(8) If you use this engine for an application or under service condition other than those specified, or if you
handle it not in accordance with this Operation Manual, an accident or a failure may be caused. Please
contact us or your nearest sales or service agent before changing any technical data of the engine or
modifying the engine after it has been delivered. Never modify the engine without consulting us.
2005.3.10R
00 Preface 00-01a-00 2/4
For safe use of your engine.
Be sure to abide by -marked DANGERs, WARNINGs and CAUTIONs described in this Manual. As
far as safety is concerned, they are particularly important parts of instructions.
● The following shows the safety marks used for caution indications in this Operation Manual and
safety labels attached to this product and explains their meaning.
It indicates that a danger of possible death or serious injury is very great when
the proper precautions is not followed.
It indicates that there is a danger of resulting in death or serious injury

when the proper precautions is not followed.
It indicates that there is the possibility of resulting in injury or serious

damage to the engine when an advice on safety handling or the proper
precautions is not followed.
● Where the safety labels are posted is shown in page 00-06.
The cautions prefixed with the mark in this Operation Manual are especially important for safe handing
of this product. A failure to observe this caution may incur a deterioration of performances or trouble/accident
of this product. Therefore, be sure to observe the items.
2005.3.10R
00 Preface 00-01a-00 3/4
2. How to read the Manual

Read this manual referring to the following descriptions.
(1) This manual is composed according to the list of the "CONTENTS" page.
(2) Each chapter has each page number and is arranged to match each user’s specifications.
2-1. Title
C D A
F
Clockwise Rotation Engine
OPERATION MANUAL M51690 B
Piston & Connecting Rod 0Q 2CIG
22 Overhaul of Piston & Piston Pin 22-02-00 1/4
E G H 023864-00E
The remarked items are the following explanations.

A Model name of engine
B Model No. of engine
C Group code
D Group name
E Title of the chapter
F Index of specification
This index is added when distinction is necessary for different specifications.
G Document No.
Peculiar No. of each document for each specifications
H Serial pane No. of the chapter
2005.3.10R
00 Preface 00-01a-00 4/4
2-2. How to read the Parts List

Read the parts list in this manual referring to the following items.
(1) Illustration and referring number of the parts are shown at the first page.
(2) The name and part number of the parts corresponding to the number in the first page are written in the
table.
(3) Explanations on the each item in the table are as follows.
Operation Manual M51695

ࠪ࡝ࡦ࠳ਥ૕ㇱㇱຠ⴫ 0Q 2CIG
01 ࠪ࡝ࡦ࠳ࡉࡠ࠶ࠢ઀⚵
01-51b-00 2/4
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ࠪ࡝ࡦ࠳ࡉࡠ࠷ࠢ‫ޓ‬㧭㧿㧿㨅 $.1%-#55;%;.+0&'4
: ࠪ࡝ࡦ࠳ࡉࡠ࠷ࠢ $.1%-%;.+0&'4
: ࡔ࠲࡞ࠠࡗ࠷ࡊ㧔ࡌ㧙ࠬ %#2/'6#.$#5'
: ࡔ࠲࡞ࠠࡗ࠷ࡊ %#2/'6#.
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ࠨࠗ࠼ࡏ࡞࠻ $1.65+&'
023865-00X
① Title
Title is the name of the group that has most close relation with each chapter. Several parts belong to other
chapter are also in the list as they could not be separated from main group.
② No.
Number attached to the illustration in the first page
③ Level
Nominal parent-child relationship of the parts
1 : Parent parts(Assembly parts)
2 : Child parts included in "1"
3 : Child parts included in "2", Grand child parts in terms of "1"
④ Order
The parts marked " × " in this item cannot be supplied by itself as they cannot be treated separate from
upper component.
⑤ Part No.
Order the part by this number.
⑥部品名称
Japanese name
⑦ Part Name
English name
⑧ Q'ty
Number of the parts per one engine
2005.3.10R
00 Engine Specification 00-12k-00 1/2
1.Engine Specification
Model Unit 6EY26
Type --- Vertical, water-cooled, 4-cycle diesel engine
Combustion chamber --- Direct injection type
No. of cylinders --- 6
Cylinder bore mm 260
Stroke mm 385
Total cylinder displacement L 122.64
Compression ratio --- 14.0
Rated output kW 1800
Rated speed min-1 750
Direction of rotation of crankshaft --- Clockwise as viewed from the flywheel side
Operating side --- On the left as viewed from the flywheel side
Order of firing --- 1-2-4-6-5-3-1
Supercharging system --- Exhaust gas (turbocharger) with air cooler
Cooling system --- Freshwater & Freshwater dual system cooling
Forced lubrication
Lubricating system --- (system oil also used as turbocharger lub.oil)
(system oil also used as rocker arm lub.oil)
Lubricating oil sump system --- Dry Sump
Starting system --- Air motor starting
Overall length mm
Dimensions Overall width mm Refer to the Final Drawing
Overall height mm
Mass (of engine singly) kg

00 Engine Specification 00-12k-00 2/2
2.Types of Accessories & Attachments

Accessory/Attachment Type Remarks
Supercharger Air-cooled exhaust gas turbine
Boost air cooler Plate finned multitubular
Governor Hydraulic
Fuel injection pump Bosch Independent per cylinder
Lub.oil pump Gear
Lub.oil cooler Low finned tube multitubular w/automatic temperature control valve
Ⅰ Polyester mesh element Automatic backflushing

Lub.oil strainer
Ⅱ Centrifugal For bypass strainer
Lub.oil tank Bottom tank Dry sump
Cooling water pump Centrifugal Cylinder jacket side
Air motor Turbine Compressed air

00 Direction of Rotation 00-03b-00 1/1
Direction of rotation is clockwise as viewed from the flywheel side.
Direction of Rotation
023868-00E
00 External and Sectional View 00-04f-00 1/3
1. External View
1-1. Operation Side View
Fig. 00-04-1 Operation Side View
Gauge Panel
Turbocharger
Governor
Air Cooler
Cooling Water Pump
Relife Valve
Air Motor Flywheel 019399-00E
1-2. Non-Operation Side View

Fig. 00-04-2 Non-Operation Side View
Sea Water Pump

(Optional Parts)
Lubricating Oil Filter

Automatic Back Washing Type
Lubricating Oil Cooler Cooling Water Pump
Lubricating Oil By-Pass Filter

Centrifugal Type
Lubricating Oil Pump 019400-00E

2. Sectional View
2-1. Sectional View of Longitudinal
Fig. 00-04-3 Sectional View of Longitudinal

㧺㧻㧚㧢㧺㧻㧚㧝

019451-00X
No. Part Name No. Part Name

1 Cylinder Block 11 Bolt of Main Bearing
2 Cylinder Head 12 Main Bearing
3 Suction Valve 13 Thrust Bearing
4 Exhaust Valve 14 Flywheel
5 Protection Ring 15 Ring Gear
6 Cylinder Liner 16 Crank Gear
7 Piston Pin 17 Idle Gear
8 Crank Shaft 18 Cam Gear
9 Balance Weight 19 Gear Case
10 Cap of Main Bearing 20 Fuel Oil Injection Valve
－ 21 F.W. Auto Temp. Control Valve
2008.05.20R
2-2. Cross Sectional View
Fig. 00-04-4 Cross Sectional View

㧢㧜㧡㧜㧠㧜㧟㧜

019452-01X
No. Part Name No. Part Name

22 Valve Bridge 31 Rod Bolt
23 Rocker Arm 32 Side Bolt
24 Push Rod 33 Exhaust Manifold
25 Fuel Oil Injection Pump 34 Suction Room
26 Piston 35 Cooling Water Passage
27 Piston Ring 36 Lubricant Passage
28 Swing Arm 37 Lubrication Oil Cooler
L.O. Auto Temp. Control
29 Cam Shaft 38
Valve
30 Connecting Rod 39 Oil Pan
2008.05.20R
00 Term & Symbol Marks 00-05a-00 1/1
1) The major terms used in this Operation Manual are defined as follows:
Front part of engine: Part opposite to the flywheel end
Rear part of engine: Part on the flywheel end
Operation side: Left side as viewed form the flywheel end (fuel injection pump side)
Non-operation side: Right side as viewed from the flywheel end (exhaust manifold side)
CW rotation: Clockwise rotation as viewed from the flywheel end
CCW rotation: Counterclockwise rotation as viewed from the flywheel end
Cylinder No: Assigned in the ascending order from the cylinder nearest to the flywheel end
Non-operation Side
Flywheel
6 5 4 3 21 Machine that
is driven
Fuel Injection Pump

Operation Side 023872-00E
2) The following symbol marks are used in the safety labels shown in this Operation Manual and
posted on the engine.
(1) Caution marks and signal words
It indicates that a danger of possible death or serious injury is very great when
the proper precautions is not followed.
It indicates that there is a danger of resulting in death or serious injury

when the proper precautions is not followed.
It indicates that there is the possibility of resulting in injury or serious

damage to the engine when an advice on safety handling or the proper
precautions is not followed.
It indicates a handing caution which, if not observed, may incur a deterioration

of performance or a trouble/accident of this product.
(2) Symbol marks

(a)Caution marks (b)Others
Caution Caution on ・・Refer to another page,

on explosion rotating part section or chapter of this
Operation Manual or other
document.
Caution on
Caution on fire
high temperature
Caution on Caution on
hazardous high pressure air
noise
00 Precautions on Maintenance 00-06b-00 1/5
1.Basic Precautions
Strict Observance of the Safety Rules
• When running the engine or servicing it for its maintenance, observe the safety rules, precautions on
safety and work procedures.
• When carrying out a joint work, work according to the predeter-
mined signs.
Way of pre-work arrangement

(1) According to kind of work required
(2) Everyone to contemplate and consider
(3) Everyone to understand well
(4) Fix the most suitable way to work
Before starting a work
• Wear the proper protective garment. Don't wear oil

smudged work clothes because they are prone to catch
fire.
• Wear protectors such as helmet, safety goggles, safety
shoes, protective mask, protective glove, life-line, etc.,
depending on the nature of work required. (1) Safety has priority over
all the works.
Safety helmet
(2) Safety is more impor-
Life-line
tant than any other
duties.
(3) It is needless to say
Protective glove that "Safety First"
means that safety has
Safety shoes priority over working
Be propely clothed
efficiency.
(4) Safety is the foundation
• When working on the engine, use the specified engine for working efficiency.
tools. Use jigs or tools suitable for particular work because Safety is never contra-
use of a wrong tool causes an injury. dictory to working effi-
ciency.
Be properly tools
• While at work, do not jump on and off the engine.

• For working, install a work bench fitted to the size of your engine to secure a good footing. Don't work
in a dangerous position.
019672-10E
2008.10.27R
No Modification, Please.
• When you want to modify your engine, consult us or your nearest sales
or service agent in advance. Yanmar can not be responsible for an acci-
dent resulting in injury or death or an engine trouble resulted from unau-
thorized modification.
• Your engine and its safety devices have been sealed for the sake of
safety. Don't break or tamper with a seal indiscreetly.
• If a sealing is missing, take a proper step of promptly contacting us or
Sealed
your nearest sales or service agent for ensuring the proper initial set-
ting.
019673-10E
Observe the precautions for ensuring safety.
Check of Safety Devices
• Check the all the safety devices of your engine have been set normally.
• If a safety device is wrongly used, it leads to a serious accident resulting in injury or death.
• Promptly repair a cover a rotating part, a heat shielding cover for exhaust pipe, a protective cover of
the heating region or the like, if found damaged.
• Never run the engine while the cover of a rotating part is removed. Otherwise dur-
ing operation, your hand, body or clothing may be caught in the rotating part, result-
ing in your injury.
019674-00E
Be Cautious of Handling of a High-temperature or High-pressure Spot.
— Take care not to get burnt. —

• During running and immediately after the engine has stopped, the whole engine is heated. Take care
not to get burnt.
• When changing cooling water, lubricating oil or filter immediately after the engine has
stopped, proceed to work only after the temperature has lowered.
• Do not touch a high-temperature region such as the exhaust pipe or pressure indicator
cock of engine with bare hands.
• Do not touch the heater and heated sections of fuel oil system with bare hands.
• Since the pressure indicator becomes hot, be sure to wear gloves when taking read-
ing.
• If you uncap the radiator or fresh water tank, vapor or hot water may blow up, causing
you to get burnt.
• Stop the engine and wait until the temperature has dropped. Then, wrap the cap with
cloth and slowly loosen it to release the internal pressure. After that, remove the cap.
019676-00E
2008.10.27R
Be Cautious of Handling of Fuel & Lubricating Oil.
• If fire is brought close to fuel and/or lubricating oil, there is the possibility of catching
fire.
(Particularly the fuel is highly flammable and dangerous.)
• Fire should be strictly prohibited in the engine installed place (engine room).
• Check for leak of fuel oil and lubricating oil. If you find a defective point, repair it and
wipe out leaked fuel or lubricating oil.
• Store the fuel oil and lubricating oil at the specified place and do not allow persons
other than those concerned to handle them.
• Unnecessary flammables in the engine installed place (engine room) may cause fire.
Therefore, store these flammables in another specified place.
NO SMOKING CAUTION:
FLAMMABLES
019675-00E
Ventilate Well.
• Exhaust gas emitted from an engine is dangerous. Ventilate well to prevent gas intoxication.
• If Exhaust gas is leading, promptly repair such a leaking
point at the exhaust pipe.
• Ventilate well the indoor engine installed place (and/or the
engine room.)
• Take care that the room does not fall short of the air (oxy-
gen) because the turbocharger takes in a great volume of
air.
• While charging the battery, there is danger of
catching fire because hydrogen gas is gen- s Inhaling exhaust gas is very dangerous.
When working indoors, sufficiently
erated
ventilate the room.
019677-10E
Installing of a Fire Extinguisher and First-aid Kit

FIRE
• Install a fire extinguisher against a possible fire, and check how to use EXTINGUISHER
it.
• Fix a safekeeping place for a first-aid kit, and install it there.
• Fix the actions to be taken when fire or an accident has occurred.
• Establish a means of reporting to emergency medical institution such
as an emergency hospital, and have its telephone number written
down.
019678-00E
2008.10.27R
2. Engine Lifting Procedures
In order to prevent accident, be sure to observe the following instructions when lifting the engine.
• Select the wire and shackle with the sufficient capacities to lift the engine.
• Adjust the wire length correctly so that the engine will not tilt when lifted.
• Place wooden blocks, etc. to the positions where the wire contacts the engine or driven equipment.
• Do not enter under the lifted engine
No.4 Cylinder No.2 Cylinder

the outside on the exh. manifold side the outside on the exh. manifold side
No.5 Cylinder No.1 Cylinder

the center on the operating side the center on the operating side
023876-00E
Less than 60 deg.
023877-00E
1) Lifting sling attaching points Engine (singly)

• Install the special lifting fixture to the head tightening bolts of the No.2 and 3 cylinders and No.5 and 6 cyl-
inders.
• Check that the cylinder heads have been tightened with the specified hydraulic pressure before lifting.
• Keep the lifting angle of the wire within 60 degrees.
2) Reduction - reversing gear (Marine gear)
• For the wire rope attaching points, refer to the respective Operation Manuals.
2008.10.15
3. List of Safety Labels

This page shows where safety labels are posted for safety use of this engine.
Carefully read the cautions shown on the safety labels to prevent accidents.
If any safety label is stained, damaged or lost, order it to your nearest Yanmar sales or service agent (shown
in the service network list "YANMAR Worldwide Service” appended to this manual) by clearly specifying its
Part No., and post it.
023878-00X
No. Part No. Part Description Q’ty

① 141616-07200 Safety Label, warning on blow-by explosion 1
② 141616-07210 Safety Label, warning on rotating part 1
③ 141616-07220 Safety Label, high temp. caution 2
④ 141616-07230 Safety Label, handling caution 2
⑤ 141616-07240 Safety Label, handling caution 2
⑥ 146673-07230 Safety Label, high press. air caution 1
00 Precautions prior to Maintenance & Servicing 00-07c-00 1/9
(1) Precautions Prior to Maintenance Servicing
Indication of Warnings in Checking and Servicing
• While checking and/or maintenance servicing the engine, post a notice on

a warning indicating board for danger prevention.
• Strive for safety, maintaining a close contact with the respective parties
concerned.
• Strive to prevent a danger from emerging, forbidding other than the parties
concerned to enter the engine installed place (and/or the engine room), for
instance.
Immediately After an Engine Stop
• Do not open the side cover of crankcase for at least 10 minutes after having stopped the
engine. Otherwise, entry of external air may result in explosion.
Take care not to get burnt.

• Immediately after the engine has stopped, the whole engine is heated. Therefore, take
care not to get burnt.
Take care not to allow your hands, body and clothing to make contact with the turbo-
charger, exhaust manifold, exhaust pipe and engine as a whole.
• If you attempt to drain oil while the engine is still hot, take care not to get burnt with splash
of oil.
• If you disassemble the cooling water system while the engine is still hot, vapor or hot
water may blow out, causing you to get burnt.
• Wait until the engine becomes cool, then wrap the disassembling part with cloth or the like
and slowly loosen it.
Preparation Prior to Working
• Since a working area will be stained/smudged, put it in good order.

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

Check the wire rope well before using it. Do not use the wire rope in the following cases.
1 twist cutting off wire

Disconnection
of wire

nominal
Wear diameter 7% or more
decrease
Kink
kink

remarkable shap crumble remakable corrosion
Transfornation
crack opening has gotten untied

root part of compression stop is damaged

End piece is
abnormal
019687-00E
An accident may occur if the safety rules are not followed.
(2) Precautions During Maintenance Servicing
Check in Course of Work
• For a joint work strive for elimination of a possible danger by keeping alert
to the surroundings.
• Tie such an accessory detached in work to a stable post or spot so that it
will not fall down. OPERATION
MANUAL
• For a work at a height, put on the safety belt or life-line.
• According to the condition of working, wear protectors.
• Be careful of oil stained or smudged protective glove because working with
such a glove might lead to a damage of parts or a personal injury as your
hands are apt to slip.
• Wipe off or mop up spilled fuel or oil at once because, if left alone, it is dangerous as it causes a slip.
• Prepare a box to accommodate removed parts in advance so that they will not be lost nor damaged.
• If necessary, provide setting marks before disassembling the engine so that you can reassemble it in the
proper reassembling sequence.
• Reassemble the setting marked portions with reference to the setting marks.
• Tighten the bolts and nuts to the specified torque or hydraulic pressure.
Use of the Proper Tools
• Use the specified engine tools to prevent the damage of the respective bolts and nuts of the engine.
• When handling a heavy thing, follow the slinger's instructions.
• In advance of using exclusive tools, check the function of these tools.
• Carefully check for any damages to rubber hose and joints of hydraulic jacks.
• Use the specified lifting gear, hook, rope, etc.; and pay attention to safety when handling a heavy thing
particularly.
Precautions in Use of Fire
• In such works with welder, electrical tools and

grinder, be careful of sparking.
Since there is the possibility of catching fire,
try not to leave combustibles such as fuel,
lubricating oil and used waste cloth in a work-
ing area.
Fire strict prohibition
019626-00E
2008.11.11R
Observe the precautions for ensuring safety.
Precautions in Checking the Electrical System
• Shut off the power supply before starting the work. Otherwise, a fire may occur or you
may receive electric shock.
• When checking the battery system, be sure to disconnect the earth cable
(–) terminal. Otherwise, the negative terminal may be short-circuited by mistake, resulting
in fire.
• The strong acid battery electrolyte put on your skin or eyes will cause inflammation. If the
battery electrolyte should be put on your skin or eyes, immediately flush it with fresh
water, then consult a physician.
Precautions for Using Organic Solvent
• Since an organic solvent is highly volatile, liable to be gasified and absorbed by worker through his
breathing as it vaporized, pay close attention to ventilation when handling it.
• Since a highly concentrated organic solvent has the property of dissolving fats and oils and is absorbed
by worker through his skins, be careful of handling it.
• When working with such a solvent, be sure to wear rubber gloves.
(3) Precautions at Completion of Maintenance Servicing
Check of Work Finish
• Check if detached parts have been refitted at the specified spots in the total num-
ber.
• Check if the damaged parts have been replaced with the good ones.
• Return tools, lifting gear, hook, rope, etc. used to the former safekeeping place. ENG
• Remove fuel and oil from the engine installed place (and/or the engine room). LOG INE
• Keep the engine installed place (and/or the engine room) in order and tidy so that
it will not interfere with daily operation.
• Before starting the engine, check various parts to see if there is no abnormality.
Refer back to 3-2. Precautions on Operation, (1) Prior to Starting of the Engine.
• Proceed t a load run, and check that the performance does not differ from that
existed prior to the maintenance servicing. KEEP TIDY
Refer back to 3-2. Precautions on Operation, (2) During a Run.
• As soon as a load run is completed, enter records of performance as well as the
nature of maintenance servicing in your Engine Log. (Keeping of records and then
reporting of work completion)
(4) Precautions in Maintenance Checking

To use an engine always in good order, checking is necessary for trouble prevention. The period of checking
can not be fixed indiscriminately it is influenced by application of the engine, conditions of use, quality of fuel
oil and lub. oil used, and daily handling circumstance.
• The following tables of checking show the standard checking frequency. Perform the initial overhaul ser-
vicing to these checking tables. Then, based on the obtained checking (on wear corrosion, accumulation
of carbon, accumulation of sludge and others), make the most economical checking schedule suitable
for your engine, and conform to the specified schedule from the second checking.
• As for the items whose checking frequency is shown by the accumulated operation hours and number of
days, schedule the checking at the earlier timing.
Table-1
Nature of Work
Checking Area
Monthly
Daily Weekly
(or 300~500hrs)
Starting air tank Pressure check Draining
Checking & lubrication

Governor gear Gov. oil volume check
of linkage system
Check on rack scale
Fuel Oil System
position
Fuel injection pump
*Check on pinion lubri-
cating volume
Injection timing adjust Check on looseness of
bolt lock nuts
Lub. oil property
Lub. Oil System
Oil pan & Auxiliary tank Oil volume check

analysis
Lub. oil bypass strainer Overhaul cleaning
Check on leak from

Cooling water pump
mechanical seal
2008.2.26R
Nature of Work
Checking Area
Monthly
Daily Weekly
(or 300~500hrs)
Pre-filter washing
Turbocharger
Blower washing
Check that electrical

wiring is fastened firmly
Starting air motor Check that no air leaks
from the air pipe and
the joint.
Check on defective
Instrument
Each pressure gauge

indication
Check on defective
Each thermometer
indication
Check on the loose-
Engine appearance ness of bolts & nuts
Check
Each pipe system Leak check

Table 2. Checking Table for Engine Using Heavy Fuel Oil (1/3)
An asterisk (*) given in the following tables refers to the timing of initial check after the initial start or part
replacement. Perform the check from the second time and onward at the ordinary frequency.
Checking & Servic-

ing Frequency (hrs.)
2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
6 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div.
Nature of Service
Checked
1,500 ～
Fuel injction valve Drawing-out check & adjustment 2,000
1st time:500～800hrs
Check & adjustment of the valve head clearance ○

Check of valve spring ○
Cylinder head
Check disassembly & check of valve rotator ○

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

Measurement of crank pin outer dia. & journal ○
Crankshaft
Measurement & adjustment of deflection ○
Disassembly, metal checking & measurement ○
Main bearing Check on tightening force of main bearing clamping bolts ○
Check on tightening force of side bolt ○
Check of cam & roller bearing ○
Disassembly & check of fuel pump tappet ○
Camshaft
Disassembly, check & measurement of swing arm ○
Drawing-out of camshaft & bearing check & measurement ○
Check of tooth bearing & backlash ○
Timing gear Disassembly of idle gear & check & measurement of bearing ○
Check of idle gear mounted shaft tightening force ○
2009.3.20R
Checking Servicing
Cycle (hrs.)
2 ～ 3 yr. or 8,000 ～ 10,000
5 yr. or 16,000 ～ 20,000

3 mo. or 1,000 ～ 1,500
3 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Part to Be
Div.
Nature of Service
Checked
Major Moving Parts
Check of tooth bearing & backlash ○

Lub. oil pump,
& cold water
Disassembly, check & measurement of bear-
pump driving
ing ○
intermediate
gear.
Check of gear mounted shaft tightening force ○
Change of hydraulic fluid ＊ ○

Gov. Gear
Governor
Disassembly & check ○
Governor driv- Disassembly & check of tooth bearing &
ing gear bearing ○
Check of injection timing ○ 1st time: 300 - 500

Fuel injection
Fuel Oil System
pump
Check of deflector & replacement ○
Disassembly, cleaning & check ○
Pressure Check on filling of ethylene glycol ○
gauge seal pot Change of ethylene glycol ○
F.O.control &
stop air piston
Replacement of o-ring ○
Change
Lub. oil
(depended on results of property analysis) ○
Lub. oil cooler Disassembly, check, cleaning & hydraulic test ○

Thermostatic
valve
Disassembly, check & cleaning ○
Lub. Oil System
Disassembly, check & measurement ○

Lub. oil pump Disassembly & check of pres. reg. valve &
safety valve ○
Check of filter candle ○ every 2yr.

Replacement of filter candle (○) every 4yr.
Lub. oil filter Worm gear, turbine,
Check of rotation ○ flushing arm
Replacement of O-ring At overhaul
2008.6.25R
Checking Servicing
Cycle (hrs.)
2 ～ 3 yr. or 8,000 ～ 10,000

5 yr. or 16,000 ～ 20,000
3 mo. or 1,000 ～ 1,500
3 mo. or 2,000 ～ 2,500
1 yr. or 4,000 ～ 5,000
Div.
Part to Be Checked Nature of Service
Thermostatic valve Disassembly, check & cleaning ○

Starting Air System Cooling Water System
Disassembly, check & measurement ○

Cooling water pump
Replacement of mechanical seal ○
Fresh water cooler Disassembly, check, cleaning & hydraulic test ○
Change (depended on results of property
Cooling water
analysis) ○
Starting air motor Disassemble and clean the air filter ○
Turbocharger Disassembly & cleaning ○

Disassembly, check, cleaning & hydraulic
○
Other
Boost air cooler

test
Engine tachometer Calibration of indication ○
Alarm switch Actuation test ○
2008.6.25R
Protective Device Setting Values
00 Holding Volumes of Lubricating Oil & Cooling Water
Pressure & Temperature Setting Values 00-18b-00 1/1
1. Protective Device Setting Values

Item Unit Alarm Setting Value Emer.Stop Setting Value
Engine lub.oil pressure MPa 0.20 0.15
Turbocharger lub. oil pressure MPa 0.06 －
Cooling water (fresh water) temperature ℃ 95 －

118 ～ 120% of the rated
Rotational overspeed min-1 － speed
2. Holding Volumes of Lubricating Oil and Cooling Water

[Unit: Itr.]
Item Holding Volume Remarks
Engine
60
(incl.inside the cooler, strainer & piping)
Lubricating Oil
Lub.oil tank ≧ 2600
Type RHD 1.3

Governor
Type UG-8 1.5
Cylinder jacket (fresh water) 250

Cooling water
Cooler 50
3. Pressure & Temperature Setting Values

Item Setting Value Remarks
0.50 ～ 0.55 Marine diesel oil (M.D.O.)
Fuel feed pressure
0.55 ～ 0.65 Heavy fuel oil (H.F.O.)
Maximum combustion pressure(Pmax) ★ Refer to Records of Shop Trial.
Pressure
Lub. oil pressure 0.40 ～ 0.50

MPa
Cooling water pressure(jacket cooling line) 0.20 ～ 0.25
Cooling water pressure(cooler cooling line) 0.20 ～ 0.25
Starting air Starting air tank 2.94 Lower limit:1.18
pressure After decompression 0.7 ～ 1.0 At the air motor inlet
Cooling water engine outlet temperature 90 ± 5
Cooling water air cooler inlet temperature Below38
Temperature
Lub.oil engine inlet temperature

65 ～ 75
(cooler outlet)
℃
Exhaust temperature Refer to Records of Shop
(at each cylinder outlet) ★ Trial.
Refer to Records of Shop
Exh.gas turbocharger inlet temp. ★ Trial.
Note: (1) The numerical value is a standard value. There is a remark different depending on the specification.
(2) For a star ( ★ ) given above, refer to the Records of Shop Trial and enter the obtained value here
because it varies according to the engine specification and output.
00 Assembly Adjustment Values
Clearance & Wear Limits of Major Parts 00-09a-02 1/5
1.Assembly Adjustment Values
Item Adjustment Value Remarks
Piston top clearance(A) mm 17.0 ± 0.25

Exhaust Valve Suction Valve
Open(before T.D.C.) 50
deg.
Close(after B.D.C) 82
Valve head clearance(B) mm 0.4 In the cold state
Open(before B.D.C) 66
deg.
Close(after T.D.C) 64.5
Valve head clearance(B) mm 0.7 In the cold state

Timing/Clearance
# B
Adjust B after
setting it to zero
015417-00X 016156-00E
Fuel injection pump begins to Refer to Records of Shop

deliver(before T.D.C)
deg. ★ Traial.
Injection pressure, fuel injector MPa 34.0 ± 0.5
2005.3.10R
2. CLEARANCES & WEAR LIMITS OF MAJOR PARTS

(Unit in mm)
Dimension St’d Max. Usage
Item Sketch Clearance Allowable Limit of
Normal Tolerance Assembling Clearance Parts
Time
Inner dia. of cylinder upper part +0.057 +0.1
A1 - 0.000 A1=0.062
φ354 A1=0.20
Outer dia. of cylinder liner -0.062 ～ 0.176
-0.15
upper part -0.119
Inner dia. of cylinder middle +0.032 +0.10
part A2 0 A2=0.030
φ310 A2=0.15
Outer dia. of cylinder liner -0.030 ～ 0.102
-0.10
lower part -0.070
+0.052
Cylinder & cylinder liner
Inner dia. of cylinder lower part B +0.13

0 B=0.100
φ306 ～ 0.192
B=0.2
Outer dia. of cylinder liner -0.100
016157-00X -0.17
lower part -0.140
C=16.75
Top clearance 17.0 ± 0.25 C=17.5 －
～ 17.25
+0.032
Inner dia. of cyl. liner upper part +0.1
㧯 0 0.050
φ272 ～ 0.167 －
-0.050
Outer dia. protection ring 㧰 -0.15
-0.135
Inner dia. of protection ring φ258 ± 0.1 +0.8
D=0.131
～ 1.55 －
Outer dia. of piston head φ256.57 ± 0.02 －
㧱
+0.040 E=0.125
Inner dia. of cylinder liner φ260 0 ～ 0.195
+0.4
016295-00X E=0.3
E=0.12
Outer dia. of piston skirt part φ259.86 ± 0.02 -0.2
～ 0.20
Radial thick. of piston rings, (
F=9.0 ± 0.15 －－ ★
No.1 ～ No.2
(
Radial thick. of oil ring F=7.0 ± 0.15 －－ 6.7
016158-00X
-0.035
Width of piston ring, No.1 No.1 -0.2
-0.065 No.1
7.0 G=0.110
G=0.4
Piston piston pin & rings
+0.100 ～ 0.165
Width of piston ring groove, No.1 +0.3
+0.075
J -0.030
Width of piston ring No.2 No.2 -0.2
G -0.060 No.2
6.0 G=0.090
+0.085 G=0.4
Width of piston ring groove. No.2 ～ 0.145 +0.3
H +0.060
-0.010
Width of oil ring -0.2
-0.040 H=0.045
10.0 H=0.4
+0.060 ～ 0.100
Width of oil ring groove +0.3
+0.035
Inner dia. of piston pin metal +0.120 +0.33
+0.100 J=0.100
K J=0.30
0 ～ 0.135
Outer dia. of piston pin 016296-00X -0.05
-0.015
φ110
Inner dia. of piston pin hole +0.060 +0.15
+0.040 K=0.040
K=0.15
0 ～ 0.075
Outer dia. of piston pin -0.05
-0.015
★ : The 1st ring is to be replaced with the new one when its plated layer is worn out and base metal begins to be exposed;
the 2nd ring, when the taper face is gone.
2007.9.25R
(Unit in mm)
Dimension St’d Max.
Item Sketch Clearance Allowable Usage Limit
Normal Tolerance Assembling Clearance of Parts
Time
Inner dia. of crank pin bearing +0.249 +0.3

L 0.180
L=0.180
φ220 ～ 0.279
L=0.30
deflection
Outer dia. of crank pin 0 wear of
-0.030 0.1
016159-00X
Inner dia. of main bearing M +0.269 +0.3

N +0.200
M=0.200
φ250 ～ 0.299
M=0.35 deflection
Crankshaft
Outer dia. of journal 0 wear of

-0.030 0.1
Width of datum part main bearing -0.190 -0.46
-0.324
N=0.127
121 N=0.5
+0.040 ～ 0.208
Width of datum part journal 0 +0.35
016160-00X
Refer to No. 21-04 Measurement of

Deflection －－ crankshaft deflection,
3) Allowable value of the deflection.
016161-00X
Outer dia. of suction valve -0.080 -0.32

-0.100 R1=0.060
φ19 ～ 0.104
R1=0.32
Inner dia. of suction valve +0.026 +0.26
guide 0
Outer dia. of exhaust valve -0.100 -0.35
S -0.120 R=0.068
φ19 ～ 0.112
R=0.35
Inner dia. of exhaust valve +0.026 +0.28
guide 0
R +0.021
Inner dia. of valve bridge +0.000 +0.18
S=0.020
φ24 ～ 0.054
S=0.2
Outer dia. of valve bridge -0.020 -0.18
guide -0.033
Valve Mechanism
016162-00X
Margin thickness of Suc. T1=7.5 -0.4

suc./exh. valve
7
－－－
poppet part Exh. T2=4.5 -0.5
Width of suc./exh. Suc. 8 U1=6.1 +0.9
valve seat －－－
Exh. U2=9.9 +1.0
6
Dia. of suc./exh. valve Suc. V=φ87
seat contact part
016163-00X
± 0.1 －－ +1.0
Exh. V=φ85
Outer dia. of rocker arm shaft -0.010 -0.1
-0.040 W=0.030
φ60 ～ 0.150
W=0.25
Inner dia. of rocker arm bush +0.110 +0.22
+0.020
016164-00X 9
Inner dia. of swing arm +0.030 +0.2
0 X=0.010
φ55 ～ 0.060
X=0.2
Outer dia. of swing arm shaft -0.010 -0.1
: 016165-00X -0.030
2008.2.26R
(Unit in mm)
Clearance Allowable
Item Sketch Assembling Limit of
Normal Tolerance Clearance Parts
Time
Outer dia. of camshaft datum -0.043 -0.20
part ;C -0.08. Y=0.083
φ173 Y=0.33
Inner dia. of camshaft datum +0.150 ～ 0.233
< +0.17
part bearing 0.040
Thickness of camshaft datum -0.100
Camshaft
part -0.200 Z=0.300

－
13 Z=0.5
Width of camshaft thrust collar +0.300 ～ 0.500
housing +0.200 －
Outer dia. of camshaft interme- -0.043 -0.20
diate part -0.083 a=0.083
φ173 a=0.3
Inner dia. of camshaft intermedi- 016166-00X +0.150 ～ 0.233
+0.17
ate part bearing 0.040
Outer dia. of lub. oil pump shaft ± 0.008 -0.12
b=0.052
b c d φ40 b=0.15
Inner dia. of lub. oil pump shaft +0.076 ～ 0.084
+0.10
bush +0.060
Lub. oil pump
+0.054
Inner dia. of pump case
0 c=0.200
－
φ84 c=0.5
-0.200 ～ 0.304
Outer dia. of gear b -0.250 －
+0.035
Width of pump case 0 －
d=0.072
105 d=0.18
c 016167-00X -0.072 ～ 0.142
Width of pump gear -0.107 －
(Tuning gear &
pump drive f=0.20
H gear) －～ 0.32
f=0.5 －
Gear backlash M=6.0
Transmission gear
(Governor f=0.15
016168-00X gear) －～ 0.25
f=0.3 －
M=4.5
Intermedat gear (timing gear)
Outer dia. of cam driving inter- -0.036 -0.17
mediate gear shaft -0.071
g
g=0.036
φ110 g=0.2
～ 0.106
+0.035
Inner dia. of the above’s bush +0.14
0
016169-00E
2005.3.10R
(Unit in mm)
Clearance
Item Sketch Assembling Allowable Limit of
Normal Tolerance Clearance Parts
Time
Oil Shield Cover 0

Oil shield, flywheel side
Outer dia. of crankshaft -0.15 －
L
j=0.050
φ250 －
～ 0.75
+0.60
Inner dia. of oil shield +0.50 －
016170-00E
2005.3.10R
00 Table of Tightening Torques of Major Bolts & Nuts 00-10a-00 1/3
Tighten the major bolts by the specified procedures.

If tightened improperly, a personal injury or damage of device may be caused. Be cautious.
(1) Unless otherwise specified, apply lub.oil on the thread and bearing surface, and then tightening a bolt
or nut.
(2) On the parts prefixed with a star ( ★ ) in the following tables, a match mark is stamped. However, when
tightening any of these parts, do not refer to the match mark but tighten it to the specified torque,
specified tightening angle or specified hydraulic pressure.
1. Hydraulic Pressure Clamping Bolts
Face-to-Face
Screw Specific Hydraulic
Width of
Part Description Dia × Pressure Remarks
Bolt/Nut
Pitch MPa (kgf/cm2)
(mm)
★ Cylinder head tightening nut M48×3.0 Round 58.0 ± 0.5
★ Main bearing cap tightening nut M48×3.0 Round 61.0 ± 0.5
★ Connecting rod tightening nut

M33×2.0 Round 51.0 ± 0.5
(Lower side)
Balance weight clamping nut M42×3.0 Round 50.0 ± 0.5
2. Angle Clamping Bolts
(1) When tightening the following bolt, apply the Protec grease on its bearing surface and lub.oil on its
thread.
(2) Tighten such a bolt with the seating tightening torque, check the position of set marks or stamp set
marks if required and tighten the bolt to the specified angle.
Face-to-Face Seating Specified

Screw Dia. Width of Tightening Tightening
Part Description Remarks
× Pitch Bolt/Nut Torque Angle
(mm) N-m (deg.)
Applying
Connecting rod tightening bolt
M22 × 1.5 30 50+5
-0 90+3
-0 grease &
(upper side)
lub.oil
2007.10.10R
3.Other Major Bolts (Torque Tightening)
(1) Before tightening a flywheel clamping bolt or fuel injection valve nozzle sleeve, apply Protec grease on
its thread and bearing surface.
(2) When tightening a camshaft coupling U-nut or camshaft gear mounting nut, apply seizure inhibitor
(Three-Bond 1910 or its equivalent) on its thread and bearing surface.
(3) In the case of bolts and nuts other than aforementioned, apply lubricating oil their thread and bearing
surface when tightening them.
(4) The parts prefixed with an asterisk (*) in the following table are provided with an exclusive tool, respec-
tivery.
(5) Tighten the bolts & nuts mentioned in the following table with sure use of a torque wrench to the
respectively specified torques.
Screw Dia.Face-to-Face Tightening Torque Remarks

Part Description Width of
× Pitch Bolt/Nut (mm) N・m (Kgf・m)
Indicator cock tightening nut M12 × 1.75 19 52 ～ 56 5.3 ～ 5.7
Rocker arm shaft stand clamping bolt M20 × 1.5 30 295 ～ 335 30 ～ 34
*Fuel injection valve nozzle sleeve M68 × 1.5 2 grooves 350 ～ 400 36 ～ 41
Fuel injection valve guard tightening nut M12 × 1.75 19 30 ～ 40 3～4
*Fuel injection valve case nut M40 × 1.5 46 380 ～ 420 39 ～ 43
*Fuel injection valve injection pressure regulat-
ing lock nut M12 × 1.25 19 40 ～ 50 4～5
Fuel injection pipe joint bolt (on injection valve / 6
cyl. head side) M8 × 1.25 (hex. socket) 30 3
8
Fuel injection pipe joint bolt (on pump side) M10 × 1.5 (hex. socket) 69 7
*Fuel injection pump tightening nut M20 × 1.5 27 196 ～ 216 20 ～ 22
Fuel injection pump equalizing valve body 10
clamping bolt M12 × 1.75 (hex. socket) 84 ～ 89 8.5 ～ 9.0
10
Fuel injection pump barrel retaining bolt M12 × 1.75 (hex. socket) 84 ～ 89 8.5 ～ 9.0
Fuel injection pump protector M24 × 1.5 30 49 ～ 59 5～6
Fuel injection timing adjust bolt lock nut M24 × 2.0 32 343 ～ 392 35 ～ 40
Fuel injection pump rack guide bolt M8 × 1.25 13 6～8 0.6 ～ 0.8
6
Fuel injection pump barrel locking bolt M8 × 1.25 (hex. socket) 7～9 0.7 ～ 0.9
Applying seiz-
Camshaft coupling nut (U-nut) M14 × 1.5 19 98 ～ 108 10 ～ 11 ure inhibitor
Applying seiz-
Cam gear clamping bolt M18 × 1.5 24 304 ～ 343 31 ～ 35 ure inhibitor
Intermediate gear shaft mounting bolt M20 × 1.5 30 245 ～ 265 25 ～ 27
Intermediate gear set plate bolt M12 × 1.75 19 60 ～ 70 6～7
Sea water pump impeller tightening nut M20 × 1.5 30 118 ～ 128 12 ～ 13 Left-hand thread
Sea water pump impeller M30 × 3.5 46 245 ～ 265 25 ～ 27 Left-hand thread
Fresh water pump impeller M30 × 3.5 46 400 ～ 440 41 ～ 45 Left-hand thread
Cooling water pump driving gear tightening nut M33 × 2.0 50 490 ～ 539 50 ～ 55
Main bearing cap side bolt M33 × 2.0 46 1080 ～ 1130 110 ～ 115
60
Flywheel clamping bolt/nut M36 × 3.0 55(nut) 1000 ～ 1060 102 ～ 108
Exhaust manifold clamping bolt M16 × 1.5 24 147 ～ 167 15 ～ 17
Exhaust expansion joint clamping bolt M20 × 1.5 30 245 ～ 265 25 ～ 27
Lub. oil pump driving gear tightening nut M33 × 2.0 50 620 ～ 680 63 ～ 69 Left-hand thread
Swing arm shaft clamping bolt M20 × 1.5 30 245 ～ 275 25 ～ 28
Turbocharger tightening bolt M20 × 1.5 30 455 ～ 475 46 ～ 48
Intercooler mount tightening bolt M20 × 1.5 30 283 ～ 306 29 ～ 31
2005.4.10R
4.General Bolts
(1) Tighten any bolts other than the major ones according to the following table.
(2) Tighten a part which clamping section is made of aluminum, tighten it to 80% of the torque shown in
the following table.
(3) The following table is applicable only to the bolts which Part No. (an 11-digit numeral) shown in the
attached Parts List consists of 2 at its first place and 2, 5 or 6 at its fifth place.
1) Standard Torque Values
Screw Dia. Face-to-Face Tightening Torque

× Width of Bolt/Nut
Pitch (mm) (mm) N-m (kgf-m)
M6 × 1.0 10 10 ～ 12 (1.0 ～ 1.2)
M8 × 1.25 13 24 ～ 27 (2.4 ～ 2.8)
M10 × 1.5 17 44 ～ 54 (4.5 ～ 5.5)
M12 × 1.75 19 78 ～ 98 (8 ～ 10)
M14 × 1.5 22 123 ～ 152 (12.5 ～ 15.5)
M16 × 1.5 24 206 ～ 245 (21 ～ 25)
M16 × 2.0 24 206 ～ 245 (21 ～ 25)
2) Standard Torque Values
Screw Dia. Face-to-Face Tightening Torque

Outer dia. of pipe
× Width of Bolt/Nut
(mm)
Pitch (mm) (mm) N-m
M8 × 1.25 14 17 ～ 20 3
M12 × 1.25 17 25 ～ 34 6
M14 × 1.5 19 39 ～ 49 8
M16 × 1.5 22 49 ～ 59 10
M18 × 1.5 24 69 ～ 78 12
M20 × 1.5 27 88 ～ 98 15
M22 × 1.5 30 147 ～ 196 18
2005.4.10R
00 Principal Dimensions & Mass for Disassembly & Servicing
00-11h-00 1/2
1.Disassembly and Maintenance Space
Disassembly Drawing
To turbocharger side To the opposite side of turbocharger
802 E
(Turbocharger)
M
L
Q
N
P
R
(Inter cooler core)
Crankshaft center
Crankshaft center
No.1 cylinder center
No.6 cylinder center

Viewed from flywheel
430 I LO pump
J CW pump
F LO cooler core
B G LO filter element D
A Turning bar C
(When camshaft was disassembled)
Crankshaft center Crankshaft center
K
649
Viewed from flywheel Viewed from flywheel
Drawing of disassembling all cylinders

023899-00E
(When all cylinders disassembled)

(Unit: mm)
Parts & Assemblies Code 6EY26 Parts & Assemblies Code 6EY26
Piston extraction height A 1900 LO filter element G 430
Cylinder liner B 2480 LO pump I 900
Cylinder head C 2030 CW pump J 1100
Camshaft (when split) D 1240 Turning length K R 470
Air cooler core E 1610
LO cooler core F 430
(When disassembling specific cylinder) (Only the differences from above are shown.)
(mm)
Parts & Assemblies Code 6EY26
Carrying out to the opposite side of Piston extraction height P 2460
T/C. Cylinder liner Q 2790
(exceeding the cyl. head) Cylinder head R 2230
Piston extraction height L 2860
Carrying out to T/C side
Cylinder liner M 3180
(exceeding T/C)
Cylinder head N 2620
00 Principal Dimensions & Mass for Disassembly & Servicing
00-11h-00 2/2
2. Mass of Major Parts
Name of Part & Assembly Mass (kg) Remarks
Cylinder head (assembly) 260 Per 1cyl.
Piston and con. rod 144 Piston + Con. rod + Piston pin
Cylinder liner 109 Per 1cyl.
Main bearing cap 62 Per 1 cap
Air cooler (core) 340
Exhaust manifold cover 18 Per 1 cover
Exhaust manifold 26 Per 1 pc.
Turbocharger 495 Including main outlet pipe
Camshaft 75 3-split type, per one pc.
Camshaft gear 47.5
Timing gear assembly 61
LO cooler (assembly) 380
LO pump (assembly) 90
LO filter (assembly) 160
CW pump (assembly) 60
CW collecting pipe 10.5 Per 1 pc.
FO injection pump (assembly) 25 Per 1 pc.
Pump case cover 9.1 Per 1 pc.
Air motor (assembly) 30
Gear case cover (assembly) 168 1 assembly
Crankshaft (assembly) 2108
Flywheel assembly 609 For RATO2911

00 SI Unit Conversion Table 00-13a-00 1/1
Conversion values between the international unit system (SI) and the metric unit system are shown below:
1) Power
Conversion Example
N kgf
1N=0.101972kgf
1 0.101972 1kgf=9.80665N
9.80665 1
2) Moment of Power, Torque
N・m kgf・m
1 0.101972
9.80665 1
3) Pressure
Pa kgf/cm2 mAq mmHg
1 1.0197 × 10-5 1.0197 × 10-4 7.501 × 10-3

9.80665 × 104 1 1.0000 × 10 7.356 × 102
9.80665 × 103 1.0000 × 10-1 1 7.356 × 10
1.3332 × 102 1.3595 × 10-3 1.3595 × 10-2 1
4) Work, Energy
kW•h J kcal kgf•m
1 3.6 × 106 8.600 × 102 3.671 × 105

2.778 × 0-7 1 2.389 × 10-4 1.0197 × 10-1
1.163 × 10-3 4.186 × 103 1 4.269 × 102

2.724 × 10-6 9.80665 2.343 × 10-3 1
5) Work efficiency, Power
kW PS
1 1.3596
0.7355 1
00 Symbol Marks on Piping Layout & Instruments 00-14a-00 1/1
Symbol Marks on Piping Layout & Instruments
Instruments Valves Piping Parts

Pump Glove valve Flange fitting
Plunger pump Needle valve Shut-off valve
Hand pump Angle valve Spectacle flange
M Motor Bufferfly valve Joint
Filter Sluice valve Boss
Centrifugal filter Screwed check valve Orifice

AUTO
Automatic backwash filter Swing check valve Expansion joint
Porous plate filter cylinder Piston valve Flexible pipe coupling
Meter&Sensors Three-way piston valve Seal pot
T Thermometer Cock Loop seal
P Pressure gauge Three-way cock Reducer

Automatic pressure
PD Differential pressure gauge regulating valve Air vent pipe
Automatic temp.
P Oil signal regulating valve Safety plate
Grazed level gauge Safety valve Accumulator

S
PS Pressure switch Solenoid valve Capillary tube
TS Temperature switch Pressure reducing valve CUT Cupper pipe

Carbon steel pipe
FS Float switch Duplex check valve STPG for pressure tube
Carbon steel pipe
DPS Differential pressure SW Velocity regulating valve STKM for high pressure tube
Flow volume regulating STS Machine structural
PT Pressure transmitter valve carbon steel pipe
RB Resistance temp. sensor O.D. Pipe outside dia.
TC Thermocouple I.D. Pipe inner dia.
Remarks:
The black valve (glove valve, angle valve and needle valve) show the valve closed constantly.
: Opened constantly
: Closed constantly
023900-00E
Operation No. Page
00 Operational Preparation 00-21f-00 1/4
Before the initial start of the engine after its installation or before its restart after its overhaul servicing or
a long term stoppage, sufficiently perform the following inspection and operation preparation in addition
to daily inspection and operational preparation, and make sure there is no abnormality and the opera-
tional preparation has completed.
(1) Make sure no part nor tool has been left in the crankcase.
(2) Check for a part not tightened yet.
(3) If you have disassembled the valve mechanism, check the suction/exhaust valve head clearance.
00-09 Adjustment of Suc./Exh. Valve Head Clearance
(4) Operate the lubricating oil priming pump, and open the pressure indicator cocks of all the cylinders.
While turning the flywheel, make sure the lubricating oil is dropping from each part of the valve
rocker arm shafts, piston pins, crankpins, main bearings and swing arms.
(5) Bleed the air from the lubricating oil strainer.
(6) Bleed the air from the fuel oil filter and inlet pipe of fuel injection pump.
(7) Manually lubricate the governor link, and make sure it moves smoothly.
1. Turning
Be careful not to allow your body to make contact with a moving part while turning the flywheel. (Never
put your hand into the crankcase.)
Refer to the following section as to the procedures of turning.
08 Turning Device
Set back the turning gear to the GEAR OUT position and set the stopper in the groove. Fasten the set
bolt and set the lock bar.
Unless the turning gear is the GEAR OUT position, the turning gear engagement/disengagement switch
actuates to disable starting. (optional spec)
2. Lubricating Oil System
The piping parts of lubricating oil system are banded with yellow coating.
1) Inspection and Oil Supply of Lubricating Oil Sump

(1) Open the drain valve, cock or plug of the following oil sumps and devices; and discharge the drain.
① Engine oil pan or lubricating system oil sump
② Lubricating oil cooler and oil strainer
③ Governor oil sump
Supply the lubricating oil to the upper limit of oil level gauge or dipstick in each oil sump;
Manually lubricate the necessary parts.
Operation No. Page
Fig. 00-21-1 Draining & Air Bleeding Point (Lub. Oil System) Fig. 00-21-2 Hand Lubricating Points
L.O. Strainer Air Bleed Plug
Hand Lubricating Points
Drain Plug L.O. Cooler

1st Lever Shaft
023901-00E
023902-00E
(2)Check the properties of lubricating oil; and if it is considerably contaminated or deteriorated, change it.
00-59 Control on Lub. Oil
2) Priming of Lubricating Oil

While turning the flywheel, operate the lub. oil stand-by pump about 5 minutes.
3. Fuel Oil System

The piping parts of fuel oil system are banded with red coating.
(1) Drain the fuel oil tank and fuel oil filter.
(2) Supply the fuel oil into the fuel oil tank, and check the fuel oil amount. Then, open or close each valve
according to the operation conditions.
(3) Bleed air from the fuel oil system.
(4) You use an engine of marine diesel oil (M.D.O.) start/stop specifications, turn on the heater for the heavy
fuel oil (H.F.O.) pipe line, and continue heating the H.F.O. until its viscosity becomes proper.
If you use an engine of heavy fuel oil (H.F.O.) start/stop specifications, make sure the fuel oil temperature
(viscosity) at the engine inlet is proper.
00-54 Properties of Fuel Oil at the Engine Inlet
After engine installation, long-term stoppage or overhaul of the engine, bleed air from the fuel oil system
by the following procedures.
(1) Open the bypass valve of the fuel feed pump. Fig. 00-21-3 Fuel Injection Pump
(Fully turn the bypass handle counterclockwise.)
(2) Open the air bleed cock of fuel oil filter to bleed air. Air Bleed Plug
(3) Loosen the air bleed plugs on the fuel injection pump.
(4) Loosen the air plug of the fuel piping to bleed.
(5) Close the bypass valve.
(Fully turn the bypass handle clockwise.)
50-02 Fuel Oil Feed Pump

016155-00E
2008.10.27R
Operation No. Page
4. Cooling Water System

The piping parts of fresh water system are banded with blue coating and that of sea water system are
banded with green coating.
(1) Inspect the cooling water tank, and check whether the cooling water is not contaminated. If the cooling
water is contaminated considerably, change it.
(2) Supply the cooling water to the upper limit of water level gauge, and add a proper amount of rust inhibitor.
00-63 Brands of Rust Inhibitor & Adding Quantity

(3) Open and close each valve of the cooling water pipe system according to the operation conditions.
When you have replaced the cylinder liner or drawn it out for servicing, remove the cylinder side cover
and make sure no water leaks inside cylinder.
5. Boost Air System

Open the drain cock of the following point to drain the air drain.
Fig. 00-21-2 Boost Air Drain Cock

‫ޓ‬
‫ޓ‬
‫ޓ‬
Drain Cock
Open
023905-00E
6. Starting Air System

The piping parts of starting air system are banded with white coating.
(1) Drain the starting air reservoir.

(2) Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine (2.2MPa or
higher).
(3) Check that the pressure after decompression is within the range of 0.7 ～ 1.0MPa. (If found outside the
range, regulate the pressure by means of a reducing valve provided at the air motor inlet.)
Operation No. Page
7. Control and Protective Devices

1) Remote control device
(1) Changing over the control position selector switch to the REMOTE (wheel house) setting, confirm the fol-
lowings:
① Shift the control lever from the AHEAD position to the NEUTRAL position and then to the ASTERN
position and vice versa, and make sure that the changeover valve handle of reduction-reversing gear
correctly agrees with the respective settings of the control lever and actuates smoothly.
② Shift the governor handle from the ACCELERATION side to the DECELERATION side and vice versa,
and make sure the governor lever actuates smoothly.
(2) Be sure to set the control lever in the NEUTRAL position.
(3) Change over the control position selector switch to the ENGINE (engine room) side setting when starting
the engine.
(4) Check that the changeover valve of reduction-reversing gear is set in the NEUTRAL position.
2) Governor gear
(1) Shift the start stop lever from the RUN position to the STOP position and vice versa, and make sure the
rack of fuel injection pump, 1st lever shaft of governor link and connector move smoothly.
(2) Check that the pointer of speed control shaft of the governor is indicating the graduation 1 to 2.
After replacing or servicing the governor and/or fuel injection pump, check that coupling of the linkage is
not wrong.
60-02 Overhaul of Governor Link
3) Protective devices
(1) Check that the turning gear is in the GEAR OUT setting.
(2) Set the power switches of protective and alarm devices to the ON position
Unless the power switches are set in the ON position, the protective and alarm devices do not actuate.
(3) Check that the main valve of the air source panel is opened.
(4) Press the emergency stop switch, and check that the light is lighting up and that the stopping air piston is
actuating.
Operation No. Page
00 Starting 00-22j-00 1/3
This engine is started by an air motor.

Press the START switch. Then, the pilot air solenoid valve directly attached to the air motor will open on the
battery power to start the engine.
Start the Engine after Signaling
• Check if no one is around the engine.

• If someone is found near the engine, give him a sign that the engine will be
started. Only then start it.
• Check the holding capacities of fuel, oil, air, etc.
• Turn on the power supply of the engine protection device before starting up
the engine.
• After the engine has been stopped for a long time or after the engine has been serviced, be sure to start
up the engine at the engine side.
• If the rotational speed rises extremely rapidly or if you find an usual sound or fume, immediately set the
start/stop lever in the STOP position to stop the engine.
Check After the Engine Is Started
• Check if pressure values of each instrument/gauge board are normal.

• Check if there are no unusual sound and abnormal heat buildup.
• Check for any leakages of fuel, oil, air, etc., and if a leakage is found, promptly repair.
• Except in case of emergency, apply the load after a warming-up.
During start operation, do not bring your face close to the air motor. Dust adhered at the exhaust port of
air motor may enter your eye, resulting in injury.
1.Air Running Procedures
If a large amount of fuel oil, cooling water or lubricating oil should be entrapped in cylinders, " water ham-
mering " may occur.
Perform air running by the following procedures, and make sure there is no abnormality. Then, start the
engine by the alarm panel on the engine side.
● Set the ENGINE/REMOTE operation selector switch in the ENGINE position.
● Open the pressure indicator cocks of all the cylinders.
● Set the start/stop lever in the STOP position.
● Hold the START switch pressing for 2 to 3 seconds to effect air running.
Operation No. Page
00 Starting 00-22j-00 2/3
2. Starting operation procedures

Start the engine by the following procedures.
(1) Make sure the turning gear is it the GEAR OUT position.
(2) Make sure the pressure indicator cock is closed.
(3) Set the operation selector switch to the ENGINE or REMOTE position corresponding to the control panel
to be selected.
(4) Set the start / stop lever in the RUN position.
(5) Make sure the pointer of speed control shaft of governor indicates the position of ordinary operation
(rated speed).
(6) Open the starting air reservoir valve and control air valve.
(7) Hold the START switch pressing for 2 to 3 seconds, and make sure of ignition. Only then release the
switch.
● Keep the control air valve opened during a run.
Fig. 00-22-1 Start Operating Procedures
Start Switch Start/Stop Lever
㧾㨁㧺
㧠㧜
㧟㧜
㧞㧜
㧝㧜
㧜
㧿㨀㧻㧼
023911-00E
(8) Starting the engine on M.D.O. and continue M.D.O. operation for more than 15 minutes.
Operation No. Page
00 Starting 00-22j-00 3/3
3. Corrective actions to be taken in starting failure
If the engine cannot be properly started, unburnt combustion gas in the flue may be ignited, resulting in
explosion. Therefore, perform air running to discharge the gas from the exhaust gas system before
attempting to restart the engine.
(1) Make sure the flywheel has completely stopped, and then press the START switch.
(2) If the battery power for the START switch has been exhausted (in case of emergency), turn the manual
switch of air motor to the direction from 0 to 1 with a minus screwdriver to start the engine.
Return the switch to 0 direction immediately after engine has started
Fig. 00-22-2 Air Motor Manual Switch
(N[YJGGN
#KT/QVQT
'OGTIGPE[/CPWCN$WVVQP
016930-00E
Use starting manual switch only in emergency, because the air motor may rotate excessively as the con-
trol module is not in operation in this case.
2007.3.15R
Operation No. Page
00 Running 00-23h-00 1/2
During a Run
• Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup.
• Check whether the engine fully shows its proper performances and record the check results. (Refer to
the Records of Shop Trial, then record the check results on the Engine Log.)
Take care not to be caught in a rotating part.

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

• During running and immediately after the engine has stopped, the whole engine is
heated. Therefore, take care not to get burnt.
• Take care not to allow your hands, body and clothing to make contact with the turbo-
charger, exhaust manifold, exhaust pipe and/or engine as whole.
• If any abnormality is detected, immediately stop the engine and repair it.
Take care not to get hearing loss.

• Put an ear protection in engine-room during running, because can cause hearing loss.
When changing over the control position changeover cock to the wheel house side after the engine is
started, be sure to set the control lever of the wheel house in the NEUTRAL position. This is to prevent
the ship from starting to move as the clutch engages simultaneously with the control position changeover
cock operation.
○ During a run and immediately after the engine stop, never touch the following parts with bare hands.
Otherwise, you may get burnt.
•Turbocharger, Exhaust pipe system, Boost air pipe system, Indicator cock
•Flue and funnel
○ During a run, never touch any moving part. Otherwise, you may be caught in, resulting in injury.
Keep the control air valve opened during a run.

If you close it, the protective devices cannot actuate.
Take care that the room does not fall short of the air (oxygen) because the turbocharger takes in a great
volume of air.
Operation No. Page
00 Running 00-23h-00 2/2
The critical speed that may cause torsional vibration is within the normal rotation speed range, quickly
avoid it.
(1) Run the engine for about 10 minutes at 300 ～ 500 min-1 without load to warm it up.
(2) Increase the speed gradually.
(3) Changeover to heavy Fuel Operation
● Heat the heavy fuel oil and check that the fuel in the circulating line has the specified viscosity (11 ～
14cSt at Eng. inlet) and pressure. (This is necessary to prevent clogging of the fuel filter and exces-
sive pressure rise in the fuel injection pipe.)
● After checking that the temperature and pressure of each engine part is within the specified range,
change over to heavy fuel operation with a load of 30% or higher. (When the engine runs at 60% of the
rated engine speed or faster.)
(4) Heavy Fuel Operation
● During heavy fuel operation, check that the fuel viscosity (or temperature) pressure are within the
specified range.
(5) If you continue running the engine with a low load for longer than three hours, observe the following load
factors, otherwise combustion worsens and fouling of the combustion chamber, exhaust pipe, turbo-
charger, etc. becomes heavy.
As the bypass valve handle is set in the Bypass side, the cooling water bypassed, and the boost air
temperature rises.
Fig. 00-23-1 Sea Water Bypass Valve (Boost Air Cooler)

‫ޓ‬
‫ޓ‬
‫ޓ‬
Bypass
Cooler 023917-00E
(6) In the case of a high humidity, this is not abnormal although much drain may be produced as the moisture
in the air is condensed.
In this case, run the engine as the drain cock of the boost air cooler kept opened.
(7) Measure the running performance once a day and record the measurement data.
00-92 Measurement of Running Performance

Operation No. Page
00 Stopping 00-24b-00 1/3
When Stopping the Engine
• Do not stop the engine simultaneously with load shutoff.

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

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

Except in case of emergency, stop the engine by the following procedures:
1) Preparation of stopping
(1) Slowdown the rotation gradually prior to entry into port, and make sure the ahead and astern operations
of the reduction-reversing gear work smoothly.
(2) Perform a low-speed run without load at 300 to 500 min-1 for about 10 minutes.
(3) If you use an engine of marine diesel oil (M.D.O.) start/stop specifications, switch over the fuel oil from
the heavy fuel oil (H.D.O.) to the M.D.O. to prevent the H.F.O. from being stagnant inside the fuel oil
pipes, fuel injection pumps when stopping the engine.
As the reference, continue running the engine on the marine diesel oil (M.D.O.) for more than 15 minutes
before stopping the engine. However, since the required time depends upon the load applied when the
fuel oil is switched over and the capacity of pipes in the vessel, consult the dockyard where the engine
has been installed.
2) Stopping operation
(1) Set the start/stop lever in the STOP position.
(2) Run the lubricating oil priming pump for 15 minutes or more to cool piston and tarbocharger.
(3) Open the pressure indicator cock, and perform air running to discharge the as from the combustion
chambers.
(4) Open or close the valves of each system according to the stopping conditions.
When the cooling water may be frozen under cold weather, or before a long term stoppage, drain the
cooling water from the cylinder jacket side and cooler side.
2007.3.15R
Operation No. Page
00 Stopping 00-24b-00 2/3
2. Emergency Stop
If any of the following problems arises, immediately set the start/stop lever in the STOP position to stop
the engine.
If the engine is not stopped by setting the start/stop lever in the STOP position or pressing the STOP
switch, close the fuel oil inlet valve.
(1) Any of the following alarms has been issued.

● Expressive pressure drop of lub. oil
● Expressive temperature rise of lub.oil
● Expressive tempera rise of cooling water
● Overspeed
(2) An unusual sound has been made.

(3) Heat has generated unusually from a part
(4) Smoke is issued from a bearing or any other moving part.
(5) A pipe of fuel oil, lub. oil or cooling water system has been broken.
(6) The supply of cooling water has stopped, and it is impossible to supply it immediately.
(7) A setscrew or bolt of a moving part is loose or broken.
(8) Moisture is mixed in the lubricating oil.
(9) The boost air pressure has dropped, and the exhaust temperature has excessively risen.
(10) The rack of fuel injection pump has stuck.
(11) The exhaust gas temperature at individual cylinder outlet has dropped 40℃ less than the mean exhaust
gas temperature at each cylinder outlet, misfiring is often the cause of wrong influence on the torsional
vibration.
3. Disposal After an Emergency Stop

When repairing the engine or investigating the cause of problem, observe the following items:
Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine. Entry of
fresh air into the engine may cause ignition of oil mist, resulting in explosion.
2009.3.31R
Operation No. Page
00 Stopping 00-24b-00 3/3
If you have stopped the engine while it is running on the heavy fuel oil (H.F.O.), immediately discharger
the H.F.O. from the fuel oil pipes, and fuel injection pumps, and displace them with marine diesel oil
(M.D.O.).
If the residual H.F.O. is cooled and its viscosity rises, it becomes impossible to restart the engine.
(1) Set the fuel oil changeover valves at the engine inlet and outlet to the marine diesel oil (M.D.O.) posi-
tion.
(2) Open the return valve of fuel oil main pipe.
(3) Turn the flywheel to discharge the H.F.O. from the fuel injection pipes and fuel injection valves. (Set
the start/stop lever in the RUN position, and turn the flywheel under the fuel injection status.)
Fig. 00-24-1 H.F.O. Discharging Points
RETURN VALVE
F.O.PRESS.
REGULATING VALVE
023931-00E
Operation No. Page
00 Special Running Method 00-25a-00 1/3
As for non-supercharged running and decreased number of cylinders running, the method of running to be
performed as emergency disposal is set forth. Since a secondary trouble is likely to occur if such method of
running is applied for long time, operate the engine as short as possible and perform the service and restore
the engine as quickly as possible.
1.Grinding running
After repair or renewal of pistons, piston rings or cylinder liners, perform the grinding running in order to pre-
vent the seizure and abnormal wear.
● Do not run the engine inside the torsional vibration critical speed range.
● Perform the no-load running for 10 minutes at each of the following speed and then the load running for 20 minutes.
① 300 ～ 500 min-1 ② Rated Speed × 0.6 min-1 ③ Rated Speed × 0.9 min-1
④ Rated Speed
2. Non-supercharged operation
In case where the turbocharger is in trouble and cannot be repaired through replacement of spare parts, fit the
implements to the turbocharger, and perform non-supercharged operation at low load.
● Operate the engine at the following speed.
Possible speed at non-supercharged operation : 320 min-1
● In the case where the exhaust gas temperature at cylinder head outlet exceeds that of the 100% load in the Records of
Shop Trial, lower the speed further.
● Avoid running inside the torsional vibration critical speed range.
Fig. 00-25-1 Fitting Procedures of Implements for Non-supercharged Operation
Turbine housing
Sealing Device
023934-00E
Operation Manual of Turbocharger

Operation No. Page
Disassembly of Turbocharger
① Remove the silencer.
② Remove the compressor housing.
③ Remove the turbine housing from bearing housing.
Fitting of the Implements

① Attach the sealing device to the turbine housing and tight it with nuts and washers.
② Install the sealing device with turbine housing to the engine.
③ Install the exhaust gas piping parts on the turbine housing.
④ Fit a wire netting to the intake port of the air duct for not to suck foreign matters.
⑤ Seal the inlet and outlet holes of the turbine lubricating oil pipes of its mount.
Check during a run that there is no leakage of exhaust gas and lubricating oil.
3. Decreased Number of Cylinders Running

In the case where the engine cannot be repaired as the parts are damaged or restored through replacement
of spare parts, stop the fuel feeding to cylinders in trouble, and perform decreased number of cylinders run-
ning with the load lowered.
● Perform a running with the load of less than 50% of the rated load.
(The speed should be the rated speed × 0.8 min-1 or less)
● If there is the torsional vibration critical speed range, run the engine in the range 20 min-1 lower than the low limit.
● Run the engine under the condition that the exhaust gas temperature at the cylinder head outlet is below that of the
100% load in the Records of Shop Trial.
● Do not perform the decreased number of cylinders running in the case where vibration becomes severe.
Fuel Feeding Stopping Procedures
Be sure to execute this work after stopping the engine. If it is done during a run, the implement is sent fly-
ing, and you are in danger of being injured
Operation No. Page
Fig. 00-25-2 Fuel Injection Pump Actuation Stopping Procedures
Oil Shielding Umbrella
Tappet Supporting Block
Pump Tappet
023935-00E
Disposal of the trouble Section

(1) In the case where the suction and exhaust system parts (suction and exhaust valves, swing arms, suc-
tion and exhaust cam push rods, etc.) are in trouble, detach the push rods and prevent the swing arms
from actuating.
(2) In the case where the pistons, crank-pin metals, etc. are in trouble, remove the pistons and connecting
rods, stop up the oil hole of crank-pins, and prevent the lubricating oil pressure from dropping.
(3) The vibration grows and drive in the low rotation.
Operation No. Page
00 Data Sheet 00-33a-00 1/2
M/V
Engine Model Eng. No. E/# Fuel Oil
Clutch Model Clutch No. C/# Kinematics
Type of T/C Turbo. S/# Viscosity
Lub.Oil Brand Viscosity(SEA) Specific Gravity
Load 1/4 1/2 3/4 4/4 11/10

Room Temp. ℃
Date
Time
Total Running Hours H
No.1 cyl ℃
No.2 cyl ℃
Cylinder No.3 cyl ℃
Head
Outlet No.4 cyl ℃
Exh. Gas
No.5 cyl ℃
No.6 cyl ℃
Inlet 1/2 ℃
T/c
Outlet ℃
Engine Inlet ℃
Engine Outlet ℃
No.1 cyl ℃
Temperature
No.2 cyl ℃
Cylinder No.3 cyl ℃
Cooling Outlet
Water
No.4 cyl ℃
No.5 cyl ℃
No.6 cyl ℃
Lub. Oil Cooler Inlet ℃
Air Cooler Inlet ℃
Air Cooler Outlet ℃
LO Cooler Inlet ℃
Lub. Oil
Engine Inlet ℃
Boost Air Cylinder Inlet ℃
Fuel Oil Engine Inlet ℃
Clutch Lub. Cooler Inlet ℃
Oil Cooler Outlet ℃
Operation No. Page
00 Data Sheet 00-33a-00 2/2
Load 1/4 1/2 3/4 4/4 11/10

No.1 cyl MPa
No.2 cyl MPa
No.3 cyl MPa
Pmax
No.4 cyl MPa
No.5 cyl MPa
No.6 cyl MPa
Pressure
Engine Lub. Oil MPa

Turbo. Lub. Oil MPa
Boost Air MPa
Jacket Cooling Water MPa
Cooler Cooling Water MPa
Fuel Oil MPa
Clutch Lub. Oil MPa
Clutch Operation Oil MPa
No. Page
00 Trouble shooting & Countermeasures 00-41a-00 1/4
1. Starting Failure
1) Flywheel not turned
Cause Countermeasure
(1) Starting air pressure insufficient Fill the starting air tank with air.
(2) Engagement / disengagement switch actuated Disengage the turning gear.
(Turning gear set at the intermeshing position)
(3) Malfunction of air motor
1.Voltage drop of air motor battery Charge the battery.
2.Malfunction of air motor pilot solenoid valve Press the manual starting push button to start
the engine.
(4) Engagement / disengagement switch actuated. Set the start / stop lever at the RUN positon.
(Start / stop lever set in the STOP position)
(5) Too high viscosity of lubricating oil Warm up the engine.
(6) Seizure of moving part
1.Seizure of piston and cylinder liner Check and repair the piston and cylinder liner,
or replace them.
2.Seizure of main bearing and / or camshaft bearing Check and repair the pertinent main bearing or
camshaft or camshaft bearing, or replace it.
2) Flywheel turned, but ignition not taken place

(1) Fuel oil not sent under pressure to fuel injection pump
1.Fuel tank empty Supply the fuel to the fuel tank.
2.Clogging of fuel oil pipe (improper opening and closing of Check the opening and closing status of each
each valve) valve.
3.Clogging of fuel oil filter Clean the filter.
4.Failure of fuel feed pump Check and repair the pump.
5.Air entry through each joint Check and repair each joint, then bleed air.
(2) Malfunction of stopping air piston Check and repair the air piston.
(3) Defect of fuel injection pump
1.Sticking of plunger and plunger guide Check and repair the plunger or plunger guide,
or replace it.
2.Wear or seizure of plunger guide Replace the plunger.
3.Improper assembling (deviation of match marks) Overhaul and check the pump.
(4) Defect of fuel injection valve
1.Sticking or seizure of needle. Check and repair the needle, or replace it.
2.Breakage of nozzle spring Replace the nozzle spring.
3.Fuel injection pressure dropped Regulate the pressure.
4.Oil leakage from nozzle excessive Check and clean the mating surfaces of nozzle
and body, or replace the nozzle.
5.Breakage or improper clamping of high-pressure fuel pipe Replace the high-pressure fuel pipe, or correct
clamping.
(5) Malfunction of governor (loose governor link and worn
Check and repair the governor, or replace it.
spline
(6) Poor airtightness of suction / exhaust valve
1.No clearance at head of suction / exhaust valve Adjust the valve head clearance.
2.Sticking of suction / exhaust valve Grind or replace the valve.
3.Damage of seat of suction / exhaust valve Grind or replace the valve seat.
(7) Too low cetane number of fuel Use a high- quality fuel oil.
No. Page
2. Rotational Speed Dropped Spontaneously

(1) Clogging of fuel oil filter Clean the filter.
(2) Seizure of moving part (piston, main bearing or turbo- Check and repair the pertinent moving part, of
charger) replace it.
(3) Air mixed in fuel oil pipe system Check and repair the fuel oil pipe system, then
bleed air.
(4) Moisture content in fuel oil Drain the filter, tank, etc.
(5) Defect of fuel injection pump Check and repair the pump, or replace it.
(6) Defect of fuel injection valve Check and adjust the valve, or replace it.
(7) Malfunction of governor Check and adjust the governor, or replace it.
3. Output of Each Cylinder not in Uniformity. (Dispersion of the maximum combustion pressure and exhaust
temperature is large among cylinders.)
(1) Air mixed in fuel oil pipe system Check and repair the fuel oil pipe system, then
bleed air.
(2) Moisture content in fuel oil Drain the filter, tank, etc.
(3) Fuel injection volume not in uniformity among
cylinders
1.Nonuniform position of fuel injection pump racks Check the position of fuel injection pump racks,
then adjust it.
2.Sticking or wear of fuel injection pump plunger Check and repair the plunger, or replace it.
3.Defect of fuel injection valve Check and repair the valve, or replace it.
4.Looseness or damage of fuel injection pipe Check and repair the pipe, or replace it.
5.Sticking of suction / exhaust valve or damage of suction / Check and repair the pertinent valve or valve
exhaust valve seat seat, or replace it.
6.Damage of fuel cam, or damage of suction / exhaust cam Check the fuel cam or suction / exhaust cam,
then repair it, of replace it.
4. Bad Color of Exhaust Gas

(1) Improper injection timing Check and adjust the timing.
(2) Defect of fuel injection valve (fuel injection pressure drop, Check the valve, then regulate the pressure, or
sticking of nozzle) replace it.
(3) Defect of fuel injection pump Check the pump, then repair it, or replace the
pertinent valve sect.
(4) Improper adjustment of suction / exhaust valve head clear- Adjust or correct the clearance, or replace the
ance or damage of suction / exhaust valve seat pertinent valve sect.
(5) Sticking of suction / exhaust valve Overhaul the suction / exhaust valve, and then
correct it.
(6) Damage of suction / exhaust cam Replace the camshaft.
(7) Defect of turbocharger
1.Clogging of filter Wash the filter.
2.Fouling of the blower side or turbine side Overhaul and wash the turbocharger / blower.
(8) Fouling of boost air cooler (too high temperature of boost Overhaul and clean the air cooler.
air)
(9) Shortage of fuel oil Use a high-quality fuel oil.
(10) Overload Reduce the load.
No. Page
5. Lub. Oil Pressure Dropped below the Specified Pressure.

(1) Looseness of lub. oil pipe and cylinder block oil hole plug Check and repair the lub. oil pipe and each
oil hole plug.
(2) Clogging of lub. oil strainer Overhaul and clean the strainer.
(3) Excessive clearance of crankshaft bearing Check the clearance, then replace the metal.
(4) Sticking of lub. oil pressure regulating valve or loose Check the valve and bolt, then repair or
adjusting bolt adjust the pertinent part.
(5) Sticking of lub. oil safety valve Check the valve and bolt, then repair it.
(6) Too high temperature of lub. oil
1.Shortage of cooling water volume Check the cooling water pump.
2.Fouling of lub. oil cooler Check the cooler, then over haul and clean it.
3.Excessive blow-bye (gas leak) into the crankcase Check the piston rings and cylinder liner.
4.Sticking of piston of lub. oil thermostatic valve or defect Check the piston and element, then repair or
of its element replace the pertinent part.
(7) Air sucked in lub. oil pump (shortage of lub. oil volume) Replenish the lub. oil.
6. Unusual Sounds Heads (Knocking Occurred) During Operation

(1) Excessive clearance of bearing of crankshaft of camshaft Check the clearance, then replace the perti-
nent bearing.
(2) Loose bolts
1.Connecting rod bolts Check the connecting rod and bolts, then
retighten the bolts or replace them.
2.Flywheel clamping bolts Check the bolts, then retighten them, or
replace them.
(3) Improper adjustment of suction / exhaust valve head Check the clearance and bolt, then adjust the
clearance or loose bolt clearance.
(4) Improper adjustment of fuel injection timing Check the timing, then adjust it.
(5) Fuel injection volume excessive
1.Malfunction of fuel injection pump Check and repair the pump, or replace it.
2.Defect of fuel injection valve Check and repair the valve, then adjust it.
(6) Increase of gear backlash or wear of gear bearing Check and adjust the gear or its bearing, or
replace it.
7. Cooling Water Temperature Too High

(1) Shortage of cooling water volume Check and repair the cooling water pump.
(2) Sticking or defect of cooling water thermostatic valve Check or replace the thermostatic valve.
No. Page
8. Exhaust Temperatures of All the Cylinders Too High

(1) Boost air temperature too high
1.Boost air cooler cooling water temperature too high Check the cooling water system, and lower
the cooling water temperature to the speci-
fied range.
2.Shortage of boost air cooler cooling water volume Check and repair the cooling water pump.
3.Fouling of boost air cooler (cooling water side & air side) Overhaul and wash the cooler.
4.Engine room internal temperature too high Check and service the engine room ventila-
tion equipment.
(2) Boost air pressure too high
1.Clogging of turbocharger filter Wash the filter.
2.Clogging of boost air cooler (air side) Overhaul and wash the cooler.
3.Fouling of turbocharger (turbine side & blower side) or Wash the blower side or overhaul and wash
its damage the turbocharger, or replace it.
4.Rise of back pressure at exhaust port Check and clean the exhaust manifold and
exhaust pipe.
5.Engine room put under a negative pressure Check and service the engine room ventila-
tion equipment.
(3) Unsuitable properties of fuel oil Judging from the property analysis results,
change the fuel oil if necessary.
(4) Overload Reduce the load.
9. Engine Stopped Suddenly

(1) Protective device switched on
1.Overspeed Check the switch, then repair the defec-
2.Lub. oil pressure drop tive part. If necessary, replace the perti-
3.Temperature rise of cooling water excessive nent part.
(2) Governor or governor gear Check the governor and governor gear, then
repair or replace the pertinent part.
(3) Fuel tank empty Replenish the fuel oil.
(4) Air mixed in fuel oil system Bleed air from the filter and oil pipe.
(5) Clogging of fuel oil filter Overhaul and clean the filter.
(6) Seizure of interlocking part (piston, main bearing, crank- Check and repair the pertinent part, or
pin bearing, timing gear, etc.) replace it.
Fuel Oil, Lubricating Oil & Cooling Water No. Page
00 Quality Criteria of Fuel Oil and Influence on Engine 00-51a-00 1/2
The properties of fuel oil applicable to this engine are shown in the following table.
The properties of fuel oil are uncertain and broadly ranged; thus they affect such factors as a smooth run of
the engine, maintenance interval and service life of parts. Consequently, it might be necessary to change the
specifications of engine or add attachment in accordance with the applied fuel oil.
1.Quantity Criteria of Fuel Oil

Direct burning fuel oil --- 200sec.Oil 1,500sec.Oil 3,500sec.Oil 7,000sec.Oil
Quality Criteria
at 50 ℃ mm2/s 3～8 < 30 < 180 < 380 < 700

Viscosity
R.W.No.1 at 100°
F sec. 37 ～ 58 < 200 < 1500 < 3500 < 7000
Specific gravity at
< 0.86 < 0.991 < 0.991 < 0.991 < 0.991
15/4 ℃
Flash point ℃ > 60 > 60 > 60 > 60 > 60
mass.
Residual carbon < 0.7 < 10 < 15 < 18 < 22
%
mass.
Sulfur content < 1.0 < 3.5 <5 <5 <5
%
Property
critical mass.
Ash content --- < 0.10 < 0.10 < 0.15 < 0.20
value %
Moisture content vol.% < 0.1 < 0.5 < 1.0 < 1.0 < 1.0
Vanadium ppm --- < 150 < 300 < 500 < 600
Sodium ppm --- < 30 < 40 < 100 < 200
Aluminum ppm --- < 30 < 30 < 30 < 30
(Cetane no. of
Diesel index > 30 > 25 > 20 > 15
> 45)
ISO DMBorDMA RMB10 RME25 RMG35 RMH55
Quality criteria equivalent CIMAC --- CIMAC B10 CIMAC E25 CIMAC G35 CIMAC H55
fuel oil BSI --- (M4) (M6) (M7) M9
JIS M.D.O I.F.O H.F.O.(heavy fuel oil)
Note: M.D.O. = marine diesel oil; I.F.O. = intermediate fuel oil
" Use HFO with the CCAI, (an ignitability index), below 850 as an standard. (However, please note that the
said value was estimated from the past operation data and that the value can vary depending on the future
fuel oil quality.) The use of HFO with CCAI exceeding 850 will cause faulty combustion and aggravate
exhaust color. If such use is inevitable, raise the intake air temperature. This will improve combustion to an
extent. However, raise the intake air temperature carefully in relation with the exhaust temperature, since this
will affect the exhaust temperature and other engine performance."
What is CCAI?
CCAI stands for Calculation Carbon Aromaticity Index, which shows an ignitability index.
The index, in consideration of the relation between aromatic compound content in fuel oil and the ignit-
ability is used to obtain the aromaticity degree in relation with the fuel oil properties. The larger the CCAI
value, the larger the firing delay for inferior ignitability. In this case, the HFO direct starting is not possible
or exhaust color is aggravated due to faulty combustion.
2009.2.26R
00 Quality Criteria of Fuel Oil and Influence on Engine 00-51a-00 2/2
2.Characteristics of Heavy Fuel Oil and Influence on Engines
1) VISCOSITY
Viscosity and the viscosity index fluctuate widely in case of heavy fuel oil. Accordingly, it is important to control
and maintain the proper viscosity level the engine requires to run normally.
2) SPECIFIC GRAVITY, ASPHALTENE qAND DIESEL INDEX

The higher the specific gravity of the fuel oil, the higher its asphaltene content. High asphaltene content of the
fuel oil lowers the diesel index because of the higher level of high molecular aromatic hydrocarbon. This low-
ers the ignition performance of the engine, and causes abnormal combustion.
To enhance the ignition performance, a higher compression-ratio, optimal-combustion chamber shape and
structure must be used in the engine. It is also necessary to heat the engine to the proper temperature.
The quality of fuel oil pre-treatment gives large effect to the specific gravity. Accordingly, it is important to
make appropriate arrangement for the pre-treatment equipment and method.
3) VANADIUM
In general, high vanadium content fuel oil causes high temperature corrosion of the exhaust valve. To prevent
this, cooling of the exhaust valve face and the use of corrosion-resistant material are necessary.
4) ALUMINA AND SILICA

Fine particles of alumina or silica catalyzers in the fluid catalytic cracking (FCC) fuel oil will cause abnormal
wear of the engine's sliding parts. The installation and handling of proper pre-treatment equipment for the fuel
oil is therefore extremely important. When using FCC fuel oil, it is necessary to remove all particles which
exceed 3 ~ 5μm in size.
5) CARBON RESIDUE
Excessive carbon residue will usually accelerate the accumulation of combustion products in the combustion
chamber especially under low load operation, and such residue on the sliding parts of the engine will result in
excessive wear and excessive lubricating oil consumption.
To cope with this problem, the engine design must minimize the adverse effects of the combustion products.
Regarding wear, consideration of effective lubrication of the sliding parts and employment of durable materials
are necessary.
6) SULFUR
High sulfur content of the fuel oil causes low temperature corrosion of the combustion chamber. To prevent
this, the temperature of the combustion chamber must be kept at an appropriate level.
2009.2.26R
00 Calculation of CCAI 00-52a-00 1/1
CCAI = D - 81 - 141࡮ loglog (V + 0.85)

D : Density kg/m3 @ 15͠‚ V : Viscosity mm2 /S @ 50͠
V D CCAI
1 800 800
820 810
860
820
2 860
830
The smaller CCAI,
880 the better firing
3 and combustion
840
performance.
4 900
5 850
920 The larger CCAI,
the inferior firing
940 860 performance.
This will cause
10 normal operation
870 to be hard.
960
20
980 880
30
50 1000
890
100 1020
900
200
1040
400 910
1000
920
5000
930
40000
50000
[ Example ]
Obtaining CCAI of HFO with the viscosity of 380cSt @ 50͠ and the density of 985 kg/m3
@ 15͠ from the table above:
Draw a line from the viscosity (V) 380cSt to the density (D) 985 and extend the line to
CCAI column. The fuel oil CCAI in the present example is 846.
00 Quality Criteria of Blended Fuel Oil 00-53a-00 1/1
In the case of using a highly viscose fuel oil by blending with marine diesel oil to lower the viscosity of fuel oil,
in addition to the case of direct burning of fuel oil set forth above for its pretreatment, apply the blending ratio
shown in the following table based on the quality criteria on the blended fuel oil, not based on the viscosity cri-
teria.
When blending fuel oil of different production origins, sludge may be separated out, resulting in clogging
of fuel oil filters and sticking of fuel injection pumps and fuel injection valves. Pay your attention to this
regard.
Blended fuel oil 200-sec. oil equivalent 1,500-sec. oil equivalent 3,500-sec. oil equivalent
ISO RMB10 RME25 RMG35
Quality criteria on
direct burning CIMAC CIMAC B10 CIMAC E25 CIMAC G35
equivalent fuel oil
BSI (M4) (M6) (M7)
M.D.O.: H.F.O.(1,500-sec.oil)
60 : 40
M.D.O.: H.F.O.(3,500-sec.oil) M.D.O.: H.F.O.(3,500-sec.oil)
Blending ratio(%) 70 : 30 40 : 60
M.D.O.: H.F.O.(7,000-sec.oil) M.D.O.: H.F.O.(7,000-sec.oil)
60 : 40 30 : 70
Note: M.D.O. = marine diesel oil; H.F.O. = heavy fuel oil

Viscosity after blending: 00-56 How to Find out the Viscosity of Blended Oil
00 Properties of Fuel Oil at the Engine Inlet 00-54a-00 1/1
Impurities contained in the heavy fuel oil (H.F.O.) may cause fuel injection pumps and fuel injection valves to
be damaged, cylinder liners to be excessively worn and exhaust valves and valve seats to be deteriorated.
Therefore, raise the cleaning effect of pretreatment system to the maximum extent, and also supply the fuel oil
heated to have the proper pressure and viscosity.
Residual oil of a catalytic cracking refining device is sometimes used for industrial low-cost, high-viscos-
ity fuel oil. In this residual oil, there remain fine particles of silica and alumina that are catalysts for this
device.
A low-cost, high-viscosity fuel oil which uses there bases will cause abnormal wear of piston rings, cylin-
der lines, fuel injection pumps, fuel injection valves, etc.
Therefore, use a low-cost, high-viscosity fuel oil treated of content less than 0.03 wt. % of ash, minimum
of silicon and aluminum and removed of all particles which exceed 3 ～ 5 μmin size, utilizing the F.O.
treating apparatus.
Incidentally, the moisture content should be kept at less than 0.2 vol. %.
(1) Recommend properties of heavy fuel oil (H.F.O.) at engine inlet
Moisture content Less than 0.2 vol.%

Content of solid particles Less than 20 ppm
Size of FFC catalytic particle Less than 5μm
(2) Recommended viscosity and pressure of heavy fuel oil (H.F.O.) at engine inlet
Recommended Viscosity Recommended Pressure

Fuel oil
at the Engine Inlet MPa
200-sec. oil 0.20 ～ 0.25
1,500-sec. oil 11 ～ 14 mm2/s 0.40 ～ 0.45
3,500-sec. oil (R.W. No.1 55 ～ 65 sec.) 0.45 ～ 0.50
7,000-sec. oil 0.65 ～ 0.70
M.D.O. 3 ～ 8 mm2/s 0.50 ～ 0.55
Heating temperature: 00-55 How to Find out the Heavy Fuel Oil Heating Temperature
00 How to Find out the Heavy Fuel Oil Heating Temperature 00-55a-00 1/1
Example: In the case of finding out the heating temperature of 700 mm2/s (at 50 ℃ ) fuel oil
Find the intersecting point ① corresponding to viscosity of 700 mm2/s and temperature of 50 ℃ on a
line ② standing for viscosity-temperature relation of 700 mm2/s (at 50 ℃ ) fuel oil.
On this line ②, locate a point corresponding to the recommend viscosity at the engine inlet, and then
draw a perpendicular ③ from this point to the axis of abscissa (x-axis).
The intersection of this perpendicular with the x-axis indicates the heating temperature required. (In
this case, the temperature is 150 ℃ .)
mm2/s
mm2/s
mm2/s
mm
2
/s
mm
2
/s
mm
2
mm /s
2
/s
mm2/s
(1) Prepare a correct viscosity-temperature relation chart according to the properties of fuel oil existing at
the time of its delivery to you.
If the viscosity - temperature line corresponding to your applied fuel oil is not shown, enter the viscos-
ity and temperature of the applied fuel oil on the above chart, item from the intersecting point of the
entered data draw a line in parallel to the nearest drawn viscosity-temperature line, and find out the
heating temperature accordingly.
(2) Set the fuel heating temperature so that the fuel oil viscosity becomes 11 to 14 cSt (55 to 65 sec.) at
the engine inlet to allow some temperature drop in the piping system.
00 How to Find out the Viscosity of Blended Oil 00-56a-00 1/1
Example: In the case of finding out the viscosity of blending (R.W. No.1 at 100° F) 7,000-sec. heavy fuel oil
(H.F.O.) with (R.W. No.1 at 100° F) 40-sec. marine oil (M.D.O.) at the blending ratio of 70:30.
On the left y-axis (axis of ordinate) corresponding to 100 % H.F.O., locate the point Ａ corresponding
to the viscosity (7,000 sec.) of H.F.O.; on the right y-axis corresponding to 100 % M.D.O., the point
Ｂ corresponding to the viscosity (40 sec.) of M.D.O. Now draw a straight line Ｋ to link both located
points.
Then, locate the point Ｙ corresponding to the blending ratio of 70 % H.F.O. and 30 % M.D.O. on the
axis of abscissa (x-axis), and draw a perpendicular ① from the point Ｙ to the drawn straight line Ｋ,
intersecting at the point Ｃ. Finally, draw a horizontal line ② from thus found intersecting point Ｃ to
the left y-axis to find out the viscosity of the blended oil. (In the case, the viscosity at 100°
F is about
550 sec.
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00 Changeover to Heavy Fuel Operation and Heavy Fuel Operation (Appendices) 00-57b-00 1/2
Pre-treatment
Thoroughly clean the heavy fuel in the pre-treatment stage.
1.M.D.O. CHANGE OVER
(1) Starting
• Start the engine on M.D.O. and continue M.D.O. operation for more than 15 minutes.
(2) Changeover to heavy fuel operation

• Heat the heavy fuel oil and check that the fuel oil in the circulating line has the specified viscosity (11 ~ 14
mm2/s at eng. inlet) and pressure (this is necessary to prevent clogging of the fuel strainer and excessive
pressure rise in the fuel injection pipe).
• After checking that the temperature and pressure of each engine part is within the specified range,
changeover to heavy fuel operation with the load more than 30%.
Open H.F.O. outlet valve
Close M.D.O. outlet valve
Open H.F.O. inlet valve
Close M.D.O. inlet valve
H.F.O. changeover complete

019124-01E
(3) Heavy fuel operation

• During heavy fuel operation, check that the fuel oil viscosity (or temperature) and pressure are within the
specified range.
(4) Stopping
• Change from heavy fuel operation to M.D.O. operation.
Air vent from the strainer
Open M.D.O. inlet valve
Close H.F.O. inlet valve
Leave in this stage for 2 to 3 minutes, and return the

H.F.O. remaining in the main pipe to the H.F.O. tank.
Depending on the length of the inboard piping,
the waiting time may be longer.
Open M.D.O. outlet valve
Close H.F.O. outlet valuve
Run with M.D.O. for 20 minutes (flushing) (Note)
Stop the engine

019125-01E
(Note) Time depends on the load at switching (more than 30%) and onboard piping capacity.
2009.2.26R
00 Changeover to Heavy Fuel Operation and Heavy Fuel Operation (Appendices) 00-57b-00 2/2
2.H.F.O. DIRECT START
(1) Starting and heavy fuel operation

• During engine standby period
① Heat and circulate the heavy fuel oil to obtain the viscosity of 11 ~ 14 mm2/s at the engine inlet.
② Heat the engine, circulating the jacket cooling water at a temperature of 65 ~ 70 ℃ .
• After checking the above conditions, start the engine.
(2) Stopping
• Even after stopping the engine, keep heating the fuel oil to the specified viscosity and circulating it (when
re-starting the engine, make sure that the above engine standby conditions concerning heavy fuel oil and
jacket cooling fresh water are satisfied at least two hours in advance of re-starting).
• When stopping the engine at long term period, change to M.D.O. operation before shutting down, and be
sure to completely replace all the heavy fuel oil in the fuel oil piping with M.D.O.
That if the temperature of the fuel oil drops below the pour point while the engine is stopped, it will not be
able to re-circulate heated fuel oil.
(3) Others
• When the engine is stopped in emergencies or for other reasons, remove the heavy fuel oil which remains
in the fuel piping, and prepare the engine for re-starting on M.D.O.
• For routine maintenance, inspection and servicing, please refer to the engine's operation manual.
2009.2.26R
00 Choosing of Lubricating Oil 00-58a-00 1/1
Depending on properties of fuel oil and conditions of usage of the engine, lub. oil to be selected varies.
Choose lub. oil API Service Grade CE or CD Class.
1.Viscosity
Use an oil shown in the below table.
Frash point Kinematic Viscosity(cSt)

Viscosity Specific Pour Point Viscosity
Application ℃
(SAE) Gravity (℃) 40 ℃ 100 ℃ Index
(Open Type)
● Marine auxiliary
engine
40 0.893 > 240 < － 7.5 140 ～ 155 14 ～ 15.5 96 ～ 110
● Marine propulsion
engine
2.Total Base Number (T.B.N.)

Select a lub. oil based on the values given in the following table for the base number against the sulfur con-
tent including in the fuel used.
Fuel Oil Used Total Base

Redwood No.1 Sulfur Content Number
Viscosity (wt. %) (T.B.N.)
s(100°F) (mgKOH/g)
M.D.O. equivalent <1 9 ～ 15
I.F.O. eq. 200-sec. < 3.5 16 ～ 26
1,500-sec
H.F.O. eq. 3,500-sec. <5 30 ～ 42
7,000-sec
Lub. oil to be applied: 00-60 List of Lub. Oil Brands
(1) Avoid blended use of different brands.

(In the unavoidable case of blended use of different brands of lub, consult your lub. oil supplier.)
(2) If lub. oil of a high total base number (T.B.N.) is used when using fuel oil of a low sulfur content,
additive (calcium carbonate) of lub. oil sticks to the high-temperature area together with carbon res-
idue and causes adverse effects as mentioned below: For that reason, use the proper lub. oil.
● Accumulation of the aforementioned deposits on the combustion chamber hinders sliding of piston
rings and may cause scuffing to the rings, cylinder liners, etc. Besides, they may cause bite-in and
blow-bye if intruded into exhaust valves.
2007.6.4R
00 Control on Lubricating Oil 00-59a-00 1/1
①In case of handling the lubricating oil inside the engine immediately after an engine stop, be careful not
to get burnt.
② Should there be a possibility of lubricating oil to get in your eyes or to stick to your skin during handling
of lubricating oil, wear protectors such as safety goggles and rubber gloves.
③ If lubricating oil get in your eyes or stick to your skin, it might cause inflammation. In such case, flush
an affected region with clean water, and then consult a physician, if necessary.
④ Method of disposing waste oil has been provided for in the law. Dispose of waste oil properly accord-
ing to the pertinent law. In case you don’t know what to do, inquire of your supplier of lubricating oil
about this matter, and dispose of waste oil accordingly.
1. Control Criteria
Conduct the property analysis of lub. oil used every 500 hours of engine run, and change or make up the lub.
oil as guided by control criteria set forth in the following table.
Item Unit Control Criteria Critical Value of Usage
Flash point (PM method) ℃ > 180 140
Change in viscosity mm2/s(40℃) Within new oil ± 15 % New oil ± 25 %
Moisture content vol.% < 0.1 0.2
n-pentane insoluble matter
mass.% < 1.5 2.0
(A method)
Toluene insoluble matter
mass.% < 1.5 2.0
(A method)
Difference between
n-pentane and toluene mass.% － < 0.5
insoluble matters
Meas. method HCl HClO4 HCl HClO4
Fuel oil used method method method method
M.D.O. 3.0 6.0 1.0 4.0
Total base number mgKOH/g 200-sec.oil 5.0 10.0 3.0 7.0
1,500-sec.oil
12.0 18.0 10.0 15.0
3,500-sec.oil
7,000-sec.oil 12.0 18.0 10.0 15.0
2. Oil Change Criteria

Since oil change criteria vary as depended on conditions of use of the engine, an instance of the criteria may
be set forth as follows although they could not fixed uniformly on base of the time used alone.
(1) Ask your lub. oil supplier to analyze the lub. oil being used and thus to determine whether the oil can be
further used continually or not.
Sample 500 cc of lub. oil at least from the drain plug of lub. oil strainer immediately after stopping the
engine for asking the analysis of lub. oil.
(2) Procuring a spot test kit to learn the remaining total base number, degree of contamination, cleanness
dispersing qualities of lub. oil used, etc. as a simple way of criteria, make the most of using such a spot
test kit.
(3) Should either of the aforementioned criteria be not possible, change the entire volume of lub. oil with the
new one at about 1,500 running hours in the case of constantly holding the oil volume of 1 ltr. /kW by
replenishing with the new oil.
00 List of Lubricating Oil Brands 00-60a-01 1/1
API Service Grade CE or CD/SAE 40 Equivalent.

Intermediate fuel oil Heavy fuel oil
Fuel Oil Spec. Marine diesel oil
I. F.O.=(R.W. No.1 at 100°
F) H.F.O.=(R.W. No.1 at 100° F)
Division M.D.O.
200sec. Oil 1,500sec./3,500sec./7,000sec.Oil
Total Base
Number(T.B.N)
9 ～ 15 16 ～ 25 30 ～ 42
Supplier
YANMAR MARINE
YANMAR --- ---
SUPER OIL 40
IDEMITSU DAPHNE MARINE OIL SW 40 DAPHNE MARINE OIL SA 40
DAPHNE MARINE OIL SX 40
KOSAN DAPHNE MARINE OIL MV 40 DAPHNE MARINE OIL SH 40
MCL 40
Castrol TLX Plus 204 Castrol TLX Plus 304
CASTROL CASTROL MHP 154
Castrol TLX Plus 304 Castrol TLX Plus 404
SEAMAX EXTRA 40
BRITISH BP Energol IC-HFX 204 BP Energol IC-HFX 304

BP ENERGOL DS3-154
PETROLEUM BP Energol IC-HFX 304 BP Energol IC-HFX 404
Delo 3000 Marine 40

Chevron Delo 1000 Marine OIL 40 Delo 2000 MARINE SAE 40 Delo 3400 Marine 40
(CALTEX, TEXACO) Taro 12XD 40 Taro 20 DP 40 Taro 30 DP 40
Taro 40 XL 40
COSMO OIL COSMO MARINE SUPER 40 COSMO MARINE 4025 COSMO MARINE 4040
FUJI KOSAN FUKKOL MARINE 412 FUKKOL MARINE 420 FUKKOL MARINE 430
MOBIL GARD 412 MOBIL GARD M430

EXXON MOBIL MOBIL GARD 412
MOBIL GARD M430 MOBIL GARD M440
KYGNUS OIL KYGNUS MARINE DX 40 KYGNUS MARINE DX 340 ---

JAPAN
JOMO MARINE D-14 JOMO MARINE D-24 JOMO MARINE D-34
ENERGY
TOTAL AURELIA XL 4030 AURELIA XL 4040

DISOLA M 4015
Lubmarine AURELIA TI 4030 AURELIA TI 4040
NIPPON OIL MARINE T104 MARINE T204 MARINE T304
ARGINA S OIL 40 ARGINA T OIL 40

SHELL GADINIA OIL 40
RIMURA FB OIL 40 ARGINA X OIL 40
2008.12.25R
00 Criteria on Cooling Fresh Water 00-62a-00 1/1
(1) Use pure water (distilled water) or tap water.

(2) Use the water having the properties shown in the following table.
Recommended Water Quality

Do not use hard water.
pH 298K (25 ℃ ) 6.3 ～ 8.0 If hard water is used, scale adheres to
water chambers such as cylinder head and
Total hardness (CaCO3) < 100 ppm cylinder water jackets and may cause an
overheat. Pay your particular attention to
Chlorine ion (Cl-) concentration < 100 ppm this regard.
M alkalinity 30 ～ 100 ppm
Ammonium ion (NH4+) conc. < 0.05 ppm
Sulfate ion (SO4- -) concentration < 100 ppm
Evaporated residue < 400 ppm

00 Selection and Control of Corrosion Inhibitor 00-63a-00 1/1
(1) Add a corrosion inhibitor to cooling fresh water because use of fresh water causes a drop in strength of
parts and the cooling effect through corrosion of water chamber and adhering of scale.
(2) Select a corrosion inhibitor which does not have an adverse effect on parts of the cooling water system
because parts made of cast iron, carbon steel, brass and bronze, are used in the cooling water system of
an engine.
• In the case where aluminum materials are used in the cooling water system, consult the supplier of cor-
rosion inhibitor because a kind of corrosion inhibitor to be used differs in this case.
• As to the adding quantity of and concentration control on corrosion inhibitor and addition and handling of
supplementary adjuster, obey the criteria set by the supplier of corrosion inhibitor.
• In the case where the concentration of corrosion inhibitor could not be controlled, annually change the
cooling water by the total volume.
① Do not dump cooling water to which the corrosion inhibitor was added directly to the ocean or river.
Since the method of treating the waste liquor has been provided for in the law, such liquid has to be
treated according to instructions given by the supplier of corrosion inhibitor.
② Do not mix different brands of corrosion inhibitor. (In the case where mixing of different brands of cor-
rosion inhibitor is unavoidable, consult the suppliers of corrosion inhibitor.
③ A corrosion inhibitor is chemical for industrial water treatment use; do not use it in the drinking water line.
④ When handling, wear rubber gloves and gauze mask to avoid direct contact with hands or other parts
of the body.
⑤ If the chemical accidentally comes in contact with skin, eyes or mouth, wash out thoroughly with fresh
water. If the problem persists, consult a doctor.
(3) Recommended brands of corrosion inhibitor

Brands of corrosion inhibitor applicable to the enclosed circuit specification of the cooling water system are
shown in the following table.
Brand Supplier Brand Supplier
Royal Caviruston Antirust
Yanmar Sangyo Co., Ltd
* Royal Freeze Diesel Guard NB UNITOR & Taiho
Polycrin I - 109 Rocor NB Liquid Industries Co., Ltd.
Polycrin I - 175 Kurita Water Industries Ltd. Nalcool 2000
* Kurilex L - 501 * Nalfleet 9 - 111 NALCO Japan Co., Ltd.
Neos PN - 106S Nalfleet 9 - 108
Neos Co., Ltd.
Neos PN - 106 Uniprot PC - 200
Nippon Yuka Kogyo Co., Ltd.
Hi-mol L - 10 Uniprot PC - 300
Taiho Industries Co., Ltd.
Hi-mol AM - 5 Shadan K Otsuka Chemical Co., Ltd.
* Olgard C-601 Organo Co., Ltd. Liquide WT ASHLAND JAPAN Co., Ltd.
• In the case where the cooling water system is of the enclosed circuit specification, consult the supplier of
corrosion inhibitor because some brands drop in the concentration of corrosion inhibitor early.
• Notice a corrosion inhibitor which doubles as an anti-freeze has a low thermal conductivity and may be
overheated during a load running.
• In the case where aluminum materials are in the cooling water system, use a brand of corrosion inhibitor
asterisked above.
2006.10.16R
Measurement of Running Performance No. Page
00 Precaution on Measuring Performance & Measure Items 00-91a-00 1/2
1.Precautions on Measuring Performance

1) Precautions During a Running
Take care of the following matters during a running.
☆ Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup.
☆ Check whether the engine fully shows its proper performance and record the check results.
(Refer to the Records of Shop Trial, then record the results on the Engine Log.)
Take care not to be caught in a rotating part.

● Never allow your hands, body and clothing to make contact or bring close to any rotat-
ing part.
Take care not to get hearing close.

● Put an ear protection in engine room during running, because can cause hearing loss.
Take care not to burnt.

● During running and immediately after the engine has stopped, the whole engine is
heated. Therefore, take care not to get burnt.
2009.3.31R
00 Precaution on Measuring Performance & Measure Items 00-91a-00 2/2
2) Precautions on Measuring Performance

On measuring performance, compare reading with corresponding values given in the Records of Shop Trial
or the Records of Transfer Trial, and if found to be abnormal, carry out an adjustment or servicing required.
Refer to the following items since the engine performance vary according to the room temperature, water
temperature, conditions of load, etc.
(1) The dispersion of the maximum combustion pressure (Pmax) among cylinders is normal if it is within
0.5MPa.
● Pmax may rise considerably as depended on properties of fuel oil. However, in any case, run the engine
to keep Pmax below 19MPa.
● Relation between the Pmax and the boost air temperature.
If the room temperature rises, Pmax falls; conversely, if the room temperature drops, Pmax rises.
There is a tendency of Pmax 0.1MPa against the room temperature change 3 ℃ .
(2) Exhaust gas temperature refers to the corresponding temperature recorded in the Transfer Trial.
● The dispersion of the exhaust gas temperature among the respective cylinder outlet is normal if it is
within 40 ℃ .
Even if this temperature is found not uniform among cylinders, it is unnecessary to force revising this
non-uniformity if the fuel injection volume and Pmax are found uniform among cylinders.
● If the dispersion of the exhaust gas temperature among individual cylinder outlet is more than 40 ℃ and
the exhaust gas temperature at individual cylinder outlet has dropped more than 40 ℃ of the mean
exhaust gas temperature at each cylinder outlet, immediately stop the engine, investigate the cause of
problem and repair the engine avoid misfiring which is often the cause of wrong influence on the tor-
sional vibration.
Even if above mentioned dispersion is more than 40 ℃ and the mean exhaust gas temperature at each
cylinder outlet is within the limits of ±40 ℃ , would you stop and repair the engine suitably because of
unbalance for the engine combustion performance.
● Relation between the room temperature and the exhaust gas temperature
The exhaust gas temperature varies at the rate of about twice the room temperature change. Neverthe-
less, use the engine within the limit values, maintaining the good servicing of the engine, etc. and reduc-
ing the load because fouling of turbocharger and suction/exhaust passage, exhaust pressure, properties
of fuel oil, etc. may influence this relation.
2009.3.31R
00 Measurement of Running Performance 00-92b-00 1/1
1. Measurement of Runnning Performance

Check and record the following engine performance once a day while the load is stable.
① Internal max. combustion pressure (Pmax)(Each cylinder)
② Exhaust gas temperature (Each cylinder outlet)
③ Exhaust gas temperature (Turbocharger inlet)
④ Exhaust gas temperature (Turbocharger outlet)
⑤ Lub. oil temperature (Cooler inlet)
⑥ Lub. oil temperature (Engine inlet)
⑦ Cooling water temperature (Engine inlet)
⑧ Cooling water temperature (Engine outlet)
⑨ Cooling water temperature (Air cooler outlet)
⑩ Cooling water temperature (Air cooler inlet)
⑪ Cooling water temperature (Lub. oil cooler outlet)
⑫ Air temperature (Air cooler inlet)
⑬ Air temperature (Engine inlet)
⑭ Each pressure indicated on the gauge panel
⑮ Room temperature
2. Measurement of Running Performance

Fig. 00-92-1 Running Performance Confirming Points
Operating Side
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2006.11.30R
00 Measurement of Max. Combustion Pressure 00-93a-00 1/1
1.Measurement of Max. Combustion Pressure
● Wear gloves when taking a measurement because the pressure indicator bocomes hot.
● Take care not to burnt, as indicator cocks become hot when opened.
(1) Prepare the following exclusive tools.
No. Exclusive Tool Description Part No.
① Pressure indicator cock turning handle 151695-92361
② Pressure indicator 147673-93753
Fig. 00-93-1 Pmax. Measurement Procedures
Ԙ
Ԛ
Turning Handle Inserting Hole
Max. Pressure Indicator Cock
Valve
023955-00E
(2) Open the valve of pressure indicator cock with use of pressure indicator cock turning handle ① , and
lightly race/rev up the engine for two to three times.(For prevention of dust and foreign matter from
intruding into pressure indicator)
(3) Attach the pressure indicator ② , and close its exhaust valve ③ .
(4) Be sure to fully open (do not open halfway) the valve of pressure indicator cock with the use of turning
handle, and close the indicator cock when the pressure becomes the highest.
(5) After reading out the Pmax, open the exhaust valve of pressure indicator.
(6) Detach the pressure indicator when its needle shows 0 MPa.
(When the pressure indicator cock is found hard to loosen, use the turning handle.)
(1) Should the dispersion in Pmax among cylinders exceed 0.5Mpa, adjust it with the injection timing of
within 1°
(2) Should the Pmax exceed its limiting value, adjust the injection timing upon examining the engine per-
formances
2008.6.25R
Cylinder Block & Cylinder Liner No. Page
01 Outline 01-01a-00 1/1
1.Cylinder block
The cylinder block is made of a cast iron, and main bearing cap is a suspended type. It has a dual wall con-
struction that can handle very high combustion pressures effectively. The cylinder block houses the cam
case, boost air chamber, cooling water and lubricating oil passages. This is effective in not only minimizing
the external plumbing (for a simpler external appearance), but also in making the maintenance, inspection
and handling of the engine easier.
Fig. 01-01-1 Cylinder block
018718-00E
2.Cylinder liner Fig. 01-01-2 Cylinder liner

The cylinder liner is a wet liner, and three kinds of O-rings
are installed in the skirt of the liner. The liner is made of a
special cast iron that has superior wear-resistant charac-
teristics. The flange of the liner is a high strength design
with thick walls able to withstand the high combustion
pressures developed in this engine. The wall of the liner
skirt is also very thick, to prevent wear from piston slap-
ping. The inner surface of the liner has a honed finish.
The flange of the liner is compulsorily cooled, and water
jacket around the liner is cooled uniformly with spinning
water flow. This enables optimum control of the tempera-
ture in the interior wall of the combustion chamber. To
eliminate the risk of bore polishing, the liner is provided
with an antipolishing ring . It is installed at the upper end of
the liner.
An antipolishing ring is installed at the upper end of the
liner to prevent carbon buildup and thus preventing wear-
ing of the liner.
Cooling water path
018719-00E
2007.3.28R*
01 Overhauling the Cylinder Block 01-02a-00 1/1
Servicing
Excluding some special cases, such as a burned out crankshaft, the cylinder block does not normally need to
be removed. When the cylinder head, piston, cylinder liner, etc., are removed, perform the following checks
and services:
1) Checking and servicing

(1) Check for loose cylinder head bolts and main bearing cap clamp bolts.
● When replacing a bolt with damaged threads

Apply a anti-seize compound (Sumitomo Metal Mining's Low Call Spray, or equivalent) to the threaded
part of the stud, and install the new bolt.
Stud torque: 200+500 N ･ m
● Install the O-ring on the stud and then apply white paint.
Fig. 01-02-1 Cylinder Block Check Points
018720-00X
(2) Clean the boost air chamber. If the rust preventive paint applied on the inner surface has worn away,
repaint it. (Epoxy resin paint: Nippon Paint's Hi-Pon 50, or equivalent)
(3) Clean the water jacket and cylinder liner holes in cylinder block, and check for corrosion.
If any of the main bearings has been burned, measure the size of the main bearing cap hole.
Straightness : 0.03 mm or less deviation in 1 mm of length
Roundness : 0.02 mm or less
2007.3.28R*
01 Overhauling the Cylinder Liner 01-03a-00 1/2
● Periodically measure the inner diameter of the cylinder liner because the amount of wear on the inner sur-
face of the cylinder liner varies, according to the level of control of the lubricating oil used, the cooling water
temperature and the normal working load.
Measure the inner diameter of the cylinder liner while it is still in the cylinder block.
● Remove the cylinder liner periodically and check for corrosion because the cooling water may cause corro-
sion in the cylinder liner water jacket and corrode the outer surface of the cylinder liner.
1) Disassembly preparation
(1) Prepare the following special tools: Fig. 01-03-1Cylinder Liner Drawing-out Procedures
No. in the 11
drawing Special Tool Description Part No.
6
1 Spacer 151695-92040 5
2 Liner upper removal device 151695-92011 2

3 Parallel Pin 22312-100200 3
4 Bolt 142613-92030 1
5 Washer 22137-270000
6 Nut 26732-270002 4
7 Liner Lower removal device 151623-92020
8 Parallel Pin 22312-100250
9 Nut 26732-270002
10 Lock Nut 26772-270002 8
11 Eyebolt 26610-160002
7
(2) When removing the cylinder liner, cover the crankshaft Approximately 45mm
with a sheet or protective cloth to prevent water or for- 9
eign material from sticking to it. 10
018721-00E
2) Disassembly
Remove the cylinder liner as follows:
(1) Attach the special tools in the ascending order of the number in the drawing, shown in Fig.01-03-1.
(2) Adjust the bolt ④ so that it protrudes below the bottom of the lower removal device ⑦ about 45mm. Lock
the bolt ④ with the lock nut ⑨ .
(3) While supporting the cylinder liner to prevent it from making contact with the cylinder, tighten the nut ⑥ .
(4) Then tighten the nut ⑥ until the O-ring comes off.
(5) Place the liner on the parallel pins ( ③ ⑧ ) on the upper and lower removal devices ( ② ⑦ ), and secure
the liner removal tool.
(6) Attach a wire rope to the eyebolt ⑪ , and lift out the cylinder liner.
2007.11.20R
01 Overhauling the Cylinder Liner 01-03a-00 2/2
3) Checking & servicing
Do not use sandpaper, a wire brush, or anything scratchy when cleaning the outer surface of the cylinder
liner. Otherwise, the heat-treated layer on the surface will be removed, leading to rust and corrosion.
(1) If the measurement of the inner diameter of the cylinder liner exceeds the wear limit or if the measured
value is likely to reach the wear limit before the next service cycle, replace the cylinder liner.
(2) Check for signs of seizures, streaks or corrosion on the sliding surface of the cylinder liner.
(3) Perform a dye check on the rounded part of collar of the cylinder liner to look for cracks.
(4) Check for corrosion and wear in the part of the cylinder liner that mates with the cylinder block.
4) Reassembly
(1) Replace the O-rings for the cylinder liner. Apply lubricating oil or silicone oil to the new O-rings and install
them. Then, eliminate any torsion from the O-rings.
Before installing the O-rings, stretch them to check whether any cracks have developed on their surface
due to changes in temperature or humidity which might have occurred while they were stored.
Fig. 01-03-2 Liquid Packing & Lubrication Points
Lubrication Oil
Liquid Packing
Lubrication Oil
018722-00E
(2) JJust before installing the cylinder liner, apply silicone-based liquid packing (Three-Bond 1107, or equiv-
alent) to the upper section of cylinder block. Also apply lubricating oil to the mating surfaces of the cylin-
der liner and block.
(3) Attach special tools ② thru ⑪ to the cylinder liner. Then, align the zero mark on the cylinder liner with the
punch mark on the cylinder block. Install the cylinder liner into the cylinder block. (Do not use the spacer
① when installing the liner.)
After overhauling or servicing the cylinder liner, check for water leaks around the O-rings when filling the
water tank with cooling water and while test running the engine.
2007.3.28R*
ೞ᧙ӕৢᛟଢ୿ Operation Manual M51695
シリンダ主体部部品表 No. Page
01 シリンダブロック仕組
01-51b-02 1/4
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㧻㧲‫ޓ‬㧲㧸㨅㨃㧴㧱㧱㧸
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㧣 020412-02X-1
2008.9.10R
01-51b-02 2/4
見出レベルオーダ部品番号個数備考

部品名称 Part Name
No. Level 0rder Part No. Q'ty Remarks
1 1 X 751695-01012 シリンダブロツクＡＳＳＹ BLOCK ASS'Y, CYLINDER 1set
2 151695-01012 シリンダブロツク BLOCK, CYLINDER 1s 　
3 X 151695-02031 メタルキヤツプ（ベ－ス CAP, METAL BASE 1 　
3 X 151695-02051 メタルキヤツプ CAP, METAL 6 　
5 3 151695-02070 ボルト（メタルキヤツプ BOLT, METAL CAP 14 　
6 3 151695-02080 サイドボルト BOLT, SIDE 14 　
7 3 151605-02091 ナツト（メタルキヤツプＢＴ NUT, METAL CAP BOLT 14 　
8 2 151695-01201 ボルト（ＣＹＬヘツド BOLT, CYLINDER HEAD 24 　
9 2 151605-01211 ナツト（ＣＹＬヘツドボルト NUT, CYLINDER HEAD 24 　
10 2 146674-01440 ＣＷレンラクカン（７ . ５ CONNECT PIPE 24 　
11 2 151695-01700 カバ－（カムジクタン COVER, CAM SHAFT 1 　
12 2 151695-01710 ＰＫ（カムジクタンカバ－ PACKING, SHAFT COVER 1 　
13 2 151695-01722 ＲＬＯレンラクカナグ PIECE, RLO CONNECT. 6 　
14 2 151695-01781 カバ－（クウキシツタンメン COVER, AIR CHAMBER 1 　
15 2 151695-01801 ヘイシフランジＡ FLANGE, CLOSE A 2 　
16 2 152633-01810 Ｏリング O-RING 6 　
17 2 151695-01820 パツキン（ヘイシフランジＡ PACKING, FLANGE A 2 　
18 2 151695-01831 ヘイシフランジＢ FLANGE, CLOSE B 1 　
19 2 151695-01840 パツキン（ヘイシフランジＢ PACKING, FLANGE B 1 　
20 2 151695-01850 ＣＷレンラクカンＡ PIPE, CONNECT. A 12 　
21 2 151695-01860 ＣＷレンラクカンＢ PIPE, CONNECT. B 12 　
22 2 151695-01870 ＬＯレンラクカン（ＧＣ PIPE, L/O CONNECTING 1 　
23 2 151695-18220 パツキン（Ｉ／Ｃ－ブロツク GASKET 1 　
24 2 151694-01920 フタ（ＣＷスイシツ COVER, JACKET 1 　
25 2 22137-200000 ザガネ（ミガキ２０ WASHER, 20 24 　
26 2 23211-015000 マルフランジ（５Ｋ１５ヘイシ FLANGE, 15 1 　
27 2 23414-120000 パツキン（マル１２ GASKET, 12 39 　
28 2 23414-160000 パツキン（マル１６ GASKET, 16 1 　
29 2 23414-200000 パツキン（マル２０ GASKET, 20 1 　
30 2 23414-210000 パツキン（マル２１ GASKET, 21 3 　
31 2 23414-270000 パツキン（マル２７ GASKET, 27 10 　
2008.10.15R
01-51b-02 3/4

32 2 23414-300000 パツキン（マル３０ GASKET, 30 6 　
33 2 23438-015000 パツキン５Ｋ１５×１．５ GASKET, 15 X 1.5 1 　
34 2 23887-120002 ６カクプラグ１２ PLUG, 12 39 　
35 2 23887-160002 ６カクプラグ１６ PLUG, 16 1 　
36 2 23887-200002 ６カクプラグ２０ PLUG, 20 1 　
37 2 23887-300002 ６カクプラグ３０ PLUG, 30 6 　
38 2 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 3 　
39 2 23897-060002 ６カクプラグＧ３／４ PLUG, G 3/4 10 　
40 2 23961-050000 カクフランジ５０ヘイシ FLANGE, 50 2 　
41 2 24311-000210 Ｏリング１ＡＰ２１．０ PACKING, P 21.0 2 　
42 2 24311-000420 Ｏリング１ＡＰ４２．０ PACKING, P 42.0 24 　
43 2 24316-000120 Ｏリング４ＤＰ１２．０ PACKING, P 12.0 6 　
44 2 24316-000210 Ｏリング４ＤＰ２１．０ PACKING, P 21.0 48 　
45 2 24316-000240 Ｏリング４ＤＰ２４．０ PACKING, P 24.0 48 　
46 2 26152-160352 ボルト（ホソ１６×３５ BOLT, 16 X 35 8
47 2 26152-160352 ボルト（ホソ１６×３５ BOLT, 16 X 35 4
48 2 26152-160352 ボルト（ホソ１６×３５ BOLT, 16 X 35 3
49 2 26152-200402 ボルト（ホソ２０×４０ BOLT, 20 X 40 4
50 2 26152-200402 ボルト（ホソ２０×４０ BOLT, 20 X 40 4
51 2 26206-100202 ボルト１０×２０ BOLT, 10 X 20 4
52 2 26206-120302 ボルト１２×３０ BOLT, 12 X 30 8
53 2 151605-01281 ホゴトウ COVER 24
54 2 26232-200502 ウエコミボルト（ホソホソ２０×５０ STUD, BOLT 20 X 50 24
55 2 26232-201602 ウエコミボルト（ホソホソ２０×１６０ STUD, BOLT 20 X 160 24
56 2 26732-200002 ナツト（ホソ２０ NUT, 20 24
57 2 26742-200002 コガタナツト（ホソ２０ NUT, 20 24
58 2 43400-003170 パツキン GASKET 2
59 2 43400-004080 パツキン GASKET 2
1 X 751695-02210 カムジクウケシクミ BUSH ASS'Y, CAMSHAFT 1set

60 2 151695-02420 ブツシユ（カムシヤフト BUSH, CAMSHAFT 7
2008.9.10R
01-51b-02 4/4

1 X 751695-01300 クウキシツフタシクミ COVER, AIR CHAMBER 5sets 　
61 2 151695-01310 カバ－（クウキシツ，メッキ COVER, AIR CHAMBER 5 　
62 2 151695-01270 パツキン（クウキシツカバ－ PACKING, AIR COVER 5 　
65 2 26152-200302 ボルト（ホソ２０×３０ BOLT, 20 X 30 20 　
　
1 X 751695-01311 クウキシツフタシクミ、ネジツキ COVER, AIR CHAMBER 1set 　
77 2 151695-01391 カバ－（クウキシツ，メッキＧネジ COVER, AIR CHAMBER 1 ※1
62 2 151695-01270 パツキン（クウキシツカバ－ PACKING, AIR COVER 1 ※1
65 2 26152-200302 ボルト（ホソ２０×３０ BOLT, 20 X 30 4
78 2 23414-170000 パツキン（マル１７ GASKET, 17 X 1.0 1
79 2 23414-210000 パツキン（マル２１ GASKET, 21 X 1.0 1
80 2 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 1
81 2 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 1
1 X T336A-0018A0 ヘイシフランジシクミカク６５Ａ FLANG ASS'Y, BLANK 11sets

63 2 23961-065000 ヘイシフランシカク６５Ａ FLANG, BLANK 11
64 2 138673-01990 パツキン（ノンアス） GASKET, (NON-ASB.) 11
66 2 26206-120302 ボルト１２×３０ BOLT, 12 X 30 44
1 X 751695-02200 スラストウケシクミ（カムシヤフト METAL ASS'Y, CAM THRUST 1set

67 2 151695-02581 スラストウケ（カムシヤフト METAL, CAM THRUST 1
68 2 26152-200552 ボルト（ホソ２０×５５ BOLT, 20 X 55 3
69 1 X 751695-01121 シリンダライナシクミ LINER ASS'Y, CYLINDER 6sets

2 151695-01190 シリンダライナ LINER, CYLINDER 6
71 2 151623-01320 ゴムパツキン PACKING, RUBBER 12
72 2 151605-01351 ゴムＰＫ（レイキヤクドウ PACKING, RUBBER 12
73 2 151605-01441 ゴムＰＫ（ＣＹＬライナ PACKING, CYL.LINER 6
74 2 151695-01121 プロテクシヨンリング RING, PROTECTION 6
75 2 151695-01320 ヘツドＰＫ（Ｔ＝１．０ PACKING, HEAD T=1.0 6
76 1 151695-12310 パツキン（ヘツドイリグチ PACKING, CYL.OUTLET 6
2008.10.15R
01 シリンダ側ふた部品表
01-52d-00 1/2
Parts List of Cylinder Side Cover
㧝㧝㧢
㧤㧥
㧝㧞
㧥
㧝㧜
㧺㧻㧝
㧺㧻㧞
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㧺㧻㧠
㧺㧻㧡
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㧝㧠
㧡
෻ࡈ࡜ࠗࡎࠗ࡯࡞஥
㧻㧼㧼㧻㧿㧵㨀㧱‫ޓ‬㧿㧵㧰㧱‫ޓ‬㧻㧲‫ޓ‬㧲㧸㨅㨃㧴㧱㧱㧸
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ࡈ࡜ࠗࡎࠗ࡯࡞஥ 㧠
㧲㧸㨅㨃㧴㧱㧱㧸‫ޓ‬㧿㧵㧰㧱㧝䋵 020414-02X
2008.9.10R
01 シリンダ側ふた部品表
01-52d-00 2/2
Parts List of Cylinder Side Cover

1 X 751695-01152 ソクフタＡＳＳＹ COVER ASSY 8sets
1 2 151695-01432 ソクフタＡＳＳＹ COVER ASSY 8
3 3 151695-01421 Ｏリング（シリンダソクフタ O-RING, SIDE COVER 8
4 2 22137-200000 ザガネ（ミガキ２０ WASHER, 20 16
5 2 26152-200452 ボルト（ホソ２０×４５ BOLT, 20 X 45 16
1 X 751695-01341 カムシツフタＡＳＳＹ COVER ASSY, CAM BOX 6sets

6 2 151695-01741 カムシツフタＡＳＳＹ COVER ASSY, CAM BOX 6
8 3 151695-01761 パツキン（カムシツフタ GASKET, CAMBOX COVER 6
9 2 22137-200000 ザガネ（ミガキ２０ WASHER, 20 24
10 2 26156-200452 ボルト（ホソ２０×４５ BOLT, 20 X 45 12
11 2 26232-200652 ウエコミボルト（ホソ２０×６５ STUD BOLT, 20 X 65 12
12 2 26732-200002 ナット（ホソ２０ NUT 20 12
2008.10.30R
01 シリンダ側ふた（リリーフバルブ）部品表
01-53c-01 1/2
Parts List of Cylinder Side Cover(Relief Valve)
㧺㧻㧝
㧝㧜
㧺㧻㧞㧥㧝㧝
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㧺㧻㧟
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ࡈ࡜ࠗࡎࠗ࡯࡞஥
㧲㧸㨅㨃㧴㧱㧱㧸‫ޓ‬㧿㧵㧰㧱 020415-01X
2008.9.10R
01 シリンダ側ふた（リリーフバルブ）部品表
01-53c-01 2/2
Parts List of Cylinder Side Cover(Relief Valve)

1 X 751694-03120 ソクフタ（カエンボウシ V COVER ASS'Y 4sets
1 2 151694-01442 ソクフタＡＳＳＹ（リリーフＶ COVER ASS'Y RELIEF 4
3 3 151695-01421 Ｏリング（シリンダソクフタ O-RING, SIDE COVER 4
4 2 146673-03760 パツキン（リリ－フＶ GASKET, VALVE 4
5 2 146673-03870 リリ－フバルブＣＭＰ VALVE ASS'Y, RELIFE 4
6 2 22190-080003 シールワッシャー（マル８ GASKET, 8 16
7 2 26206-080602 ボルト８×６０ BOLT, 8 X 60 16
8 2 22217-080000 バネザガネ８ WASHER, 8 16
9 2 26706-080002 ナット８ NUT, 8 16
10 2 22137-200000 ザガネ（ミガキ２０ WASHER, 20 8
11 2 26152-200452 ボルト（ホソ２０×４５ BOLT, 20 X 45 8
2008.9.10R
01 ギヤケース部品表
01-54b-03 1/3
Parts List of Gear Case
㧞㧤
㧞㧣
㧞㧥
㧝㧢
㧞㧜
㧝㧠
㧟㧥
㧟㧣
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㧝㧣
㧝㧤

㧟㧢㧥
㧝㧝㧤
㧝㧜㧥
㧟㧡㧝㧥㧙㧣㧣
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㧝㧣
㧞㧣
㧝㧡㧜㧝
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㧞㧝
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㧞㧟
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㧞㧢㧝㧤
㧻㧼㧼㧻㧿㧵㨀㧱‫ޓ‬㧿㧵㧰㧱‫ޓ‬㧻㧲‫ޓ‬㧲㧸㨅㨃㧴㧱㧱㧸 020419-01X
2008.9.10R
01-54b-03 2/3

1 X 751695-01062 ギヤケ－スカバ－シクミ COVER ASS'Y, GEAR CASE 1set
1 2 151695-01502 カバ－（ギヤケ－スＣＭＰ COVER, GEAR CASE 1s
5 3 22333-100350 テ－パピン（ネジ１０×３５ PIN, 10 X 23 3
6 3 26206-120452 ボルト１２×４５ BOLT, 12 X 45 11
7 3 26706-100002 ナツト１０ NUT, 10 3
8 2 133970-01670 ６カクプラグ５１８ＵＮＦ PLUG, 5/8UNF 2
9 2 23414-160000 パツキン（マル１６ GASKET, 16 2
10 2 23887-300002 ６カクプラグ３０ PLUG, 30 1
11 2 23414-300000 パツキン（マル３０ GASKET, 30 1
12 2 133970-01590 ネジツキヘイコウピン PIN, PARALLEL 2
13 2 26706-120002 ナツト１２ NUT, 12 2
14 2 24316-001150 Ｏリング４ＤＰ１１５ PACKING, P115 2
15 2 26152-202102 ボルト（ホソ２０×２１０ BOLT, 20 X 210 2
16 2 26152-201802 ボルト（ホソ２０×１８０ BOLT, 20 X 180 2
17 2 26152-201402 ボルト（ホソ２０×１４０ BOLT, 20 X 140 1
18 2 26152-200802 ボルト（ホソ２０×８０ BOLT, 20 X 80 15
19 2 151695-39780 ボルト（ホソ２０×８０ BOLT, 20 X 80 2
20 2 26152-161702 ボルト（ホソ１６×１７０ BOLT, 16 X 170 3
21 2 26232-160402 ウエコミボルト（ホソホソ１６×４０ STUD, BOLT 16 X 40 9
22 2 26732-160002 ナツト（ホソ１６ NUT, 16 9
23 2 26212-120402 ウエコミボルト１２×４０ STUD, BOLT 12 X 40 10
24 2 26706-120002 ナツト１２ NUT, 12 10
25 2 26212-120302 ウエコミボルト１２×３０ STUD, BOLT 12 X 30 8
26 2 26706-120002 ナツト１２ NUT, 12 8
27 2 151695-01470 カクフランジ８０ヘイシ FLANNGE, 80 1
28 2 153605-34100 パツキン PACKING 1
29 2 26152-160252 ボルト（ホソ１６×２５ BOLT, 16 X 25 4
2008.9.10R
01-54b-03 3/3

1 X 751695-01250 カバ－シクミ（アブラキリロウユカ COVER ASS'Y 1set
30 2 151695-01490 カバ－（アブラキリロウユカ COVER 1
31 2 153605-34100 パツキン PACKING 1
32 2 26152-160252 ボルト（ホソ１６×２５ BOLT, 16 X 25 4
33 2 23887-160002 ６カクプラグＭ１６ PLUG, M16 1
34 2 23414-170000 パツキン（マル１７ GASKET, 17 1
1 X 751695-01350 ヘイシフランジシクミ（ＳＷＰ FLANGE, ASS'Y, CLOSE 1set

35 2 151695-01911 ヘイシフランジ（ＳＷＰ FLANGE, CLOSE 1
36 2 26206-120302 ボルト（１２×３０ BOLT, 12 X 30 6
1 X 751695-01230 ヘイシフタシクミ（ブリーザ SHUT FLANGE (BREATHER 1set

37 2 151695-03010 ヘイシフタ（ブリーザ SHUT FLANGE (BREATHER 1
38 2 151695-03130 パツキン（ブリーザ PACKING BREATHER 1
39 2 26206-120202 ボルト１２×２０ BOLT, 12 X 20 4
2008.9.10R
01 オイルパン部品表
01-55a-02 1/2
Parts List of Oil Pan
㧥
㧙㧣㧣
㧝㧣
㧞㧣
㧜㧝
㧣
㧯
㧝㧠
㧝㧟
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㧝㧜
㧝㧞
㧞
㧟
㧣
㧠
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㧢

㧝
㧝㧤
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2008.9.10R
01 オイルパン部品表
01-55a-02 2/2
Parts List of Oil Pan

1 1 751695-01211 オイルパンシクミ（ドライ OIL SUMP (DRY SUMP 1set
2 2 135410-01780 プラグ　Ｍ３０ PLUG, M30 2
3 2 23414-300000 パツキン（マル３０×１．０ GASKET, 30 X 1.0 2
4 2 26152-200652 ボルト（ホソ２０×６５ BOLT, 20 X 65 6 FW SIDE
5 2 26732-200002 ナツト（ホソ２０ NUT, 20 6 FW SIDE
6 2 26152-200552 ボルト（ホソ２０×５５ BOLT, 20 X 55 6
7 2 22212-200000 バネザガネ２０ WASHER, 20 12
8 2 26152-160502 ボルト（ホソ１６×５０ BOLT, 16 X 50 40
9 2 22212-160000 バネザガネ１６ WASHER, 16 40
10 1 132654-39190 パツキン GASKET 2

11 1 23211-150166 マルフランジ（５Ｋ１５０ FLANGE, 150 2
12 1 26233-160452 ウエコミボルト（ホソホソ１６×４５ STUD,BOLT 16 X 45 16
13 1 26733-160002 ナツト（ホソ１６ NUT, 16 16
14 1 26773-160002 トメナツト（ホソ１６ NUT, 16 16
1 X 751695-01090 ヘイシフランジ（オイルパン FLANGE ASS'Y, OIL PAN 1set

15 2 23211-200000 マルフランジ（５Ｋ２００ヘイシ FLANGE 200 1
16 2 43400-004230 パツキン GASKET 1
17 2 26152-200452 ボルト（ホソ２０×４５ BOLT, 20 X 45 8
18 2 22212-200000 バネザガネ２０ WASHER, 20 8
2008.9.10R
01 油切り ( フライホイール側 ) 部品表
01-56b-01 1/2
Parts List of Oil Sealing (SFW)
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2007.9.20R
01 油切り ( フライホイール側 ) 部品表
01-56b-01 2/2
Parts List of Oil Sealing (SFW)

1 X 751695-01191 フタ（フライホイルガワ COVER ASS'Y, SFW 1set
1 2 151695-01541 フタシクミ（ＳＦＷ COVER ASS'Y, SFW 1s
4 3 22333-100250 テ－パピン（ネジ１０×２５ PIN, 10 X 25 2
5 3 23414-220000 パツキン（マル２２ GASKET, 22 1
6 3 23887-220002 ６カクプラグ２２ PLUG, 22 1
7 3 26206-120302 ボルト１２×３０ BOLT, 12 X 30 5
8 3 26706-100002 ナツト１０ NUT, 10 2
9 3 26911-120122 トメネジ（ヒラ１２×１２ SCREW, 12 X 12 2
10 2 138613-01590 ネジツキヘイコウピン PIN, PARALLEL M12 X 28 2
11 2 26152-200452 ボルト（ホソ２０×４５ BOLT, 20 X 45 12
12 2 26706-120002 ナツト１２ NUT, 12 2
1 X 751695-01461 アブラキリシクミ（ＳＦＷ SEALING, OIL SFW 1set

13 2 151695-01571 アブラキリ（ＳＦＷ SEALING, OIL SFW 1s
16 3 22137-100000 ザガネ（ミガキ１０ WASHER, 10 2
17 3 22137-120000 ザガネ（ミガキ１１ WASHER, 11 2
18 3 26182-100451 リ－マボルト１０×４５ BOLT,REAMER 10 X 45 2
19 3 26606-100002 ナツト（ホソ１０ NUT, 10 2
20 3 26911-100102 トメネジ（ヒラ１０×１０ SCREW, 10 X 10 1
21 3 26911-120122 トメネジ（ヒラ１２×１２ SCREW, 12 X 12 1
22 2 26206-100252 ボルト１０×２５ BOLT, 10 X 25 8 1
23 2 22137-100000 ザガネ（ミガキ×１０ WASHER, 10 8
24 2 22340-100202 ヘイコウピン（ネジ１０×２０ PIN, 10 X 20 2
25 2 26706-100002 ナツト１０ NUT, 10 2
2008.9.10R
01 油切り（反フライホイール側）部品表
01-62a-00 1/2
Parts List of Oil Sealing (OFW)
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㧣㧞
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2008.9.10R
01 油切り（反フライホイール側）部品表
01-62a-00 2/2
Parts List of Oil Sealing (OFW)

1 X 751695-014000 アブラキリシクミ（ＯＦＷ SEALING ASS'Y, OIL SFW 1set
1 2 151695-01600 アブラキリ（ＯＦＷ SEALING, OIL SFW 1s
4 3 26182-080401 リ－マボルト８×４０ BOLT, REAMER 8 X 40 2
5 3 26706-080002 ナツト８ NUT, 8 2
6 3 22137-100000 ザガネ（ミガキ１０ WASHER, 10 2
7 2 26206-100252 ボルト１０×２５ BOLT, 10 X 25 8
8 2 22137-100000 ザガネ（ミガキ１０ WASHER, 10 8
9 2 22340-100202 ネジツキヘイコウピン PIN, PARALLEL M10X20 2
10 2 26706-100002 ナツト１０ NUT, 10 2
1 X 751695-01420 ロウユカン（アブラキリＯＦＷ PIPE ASS'Y, SEALING OFW 1set

11 2 23834-100000 ユニオン１０ UNION 10 1
12 2 23414-160000 パッキン（マル１６×１ GASKET, 16 X 1 1
13 2 151695-01680 ロウユカンシクミ PIPE, OVER FLOW 1s
14 2 23854-100000 カンツギテボルト１０ BOLT, PIPE JOINT 1
15 2 23414-160000 パッキン（マル１６×１ GASKET, 16 X 1 2
2008.9.10R
01 ミスト抜き管部品表
01-60a-01 1/2
Parts List of Breather Pipe
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2007.9.20R
01 ミスト抜き管部品表
01-60a-01 2/2
Parts List of Breather Pipe

1 X 751695-03212 ミストカンシクミ（ＳＦＷ BREATHER PIPE ASS'Y 1set
1 2 153605-34100 パツキン（ＬＯチヨウアツＶ PACKING, VALVE 2
2 2 26152-160352 ボルト（ホソ１６×３５ BOLT, 16 X 35 4
3 2 151695-03052 ミストヌキカンＡ（Ｔホイル BREATHER 1
4 2 151695-03061 ミストヌキカンＢ（Ｔホイル BREATHER 1
5 2 26152-160502 ボルト（ホソ１６×５０ BOLT, 16 X 50 3
6 2 26152-160552 ボルト（ホソ１６×５５ BOLT, 16 X 55 1
7 2 26732-160002 ナツト（ホソ１６ NUT, 16 4
8 2 151695-03290 サポ－トＣ（ミストヌキ SUPPORT(BREATHER 1
9 2 26206-120252 ボルト１２×２５ BOLT, 12 X 25 4
10 2 151695-03070 サポ－トＡ（ミストヌキ SUPPORT(BREATHER 1
11 2 26206-120252 ボルト１２×２５ BOLT, 12 X 25 2
12 2 26464-080000 Ｕボルト（Ｅ８０ U-BOLT, 80 1
13 2 26706-100002 ナツト１０ NUT, 10 2
14 2 23414-170000 パツキン（マル１７ GASKET, 17 1
15 2 23637-040032 アスタツプホンタイＢ３／８ COCK, 3/8 1
16 2 151695-03300 ドレンヌキ（ＳＦＷミストカン PIPE, DRAIN 1s
17 2 152672-59560 サポ－ト（１０ SUPPORT (10 1
18 2 26206-080352 ボルト８×３５ BOLT, 8 X 35 1
19 2 26706-080002 ナツト８ NUT, 8 1
20 2 22212-080000 バネザガネ８ SPRING WASHER 8 1
2008.6.30R
01 燃料ポンプ室カバー部品表
01-58a-00 1/3
Parts List of Pump Case Cover
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2005.4.10R
01-58a-00 2/3

1 X 751695-09020 ソクブオオイシクミ SIDE COVER ASS'Y 1set
1 2 151695-09050 サポ－ト（ソクブオオイ SUPPORT, SIDE COVER 1
2 2 151695-09060 ソクブオオイ（ＳＦＷ．シタ COVER, SIDE LOWER 1
3 2 151695-09071 ソクブオオイ（ＯＦＷ COVER, SIDE 1
4 2 151695-09081 ソクブオオイ（ＳＦＷ．ウエ COVER, SIDE UPPER 1
5 2 151695-09351 ソクブオオイ（ＯＦＷ．ウエ COVER, SIDE UPPER 1
6 2 26206-100202 ボルト１０×２０ BOLT, 10 X 20 6
7 2 26206-120252 ボルト１２２５ BOLT, 12 X 25 11
1 X 751695-09030 サポ－ト（ＦＯＰシツカバ－ SUPPORT, FOP COVER 1set

8 2 151695-09092 サポ－ト（ＦＯＰカバ－ SUPPORT, PUMP COVER 1
11 2 146673-09170 カンツギテボルトＭ１６ BOLT, PIPE JOINT M16 8
12 2 23883-160002 ６カクプラグ１６ PLUG 16 4
13 2 153672-59980 シ－ルワツシヤ－（フツソＳＰＣコマル１６ SEAL WASHER 16S.<F> 12
1 X 751695-09040 ＦＯＰシツカバ－ COVER, FUEL OIL PUMP 1set

14 2 146673-07400 メイバン（ヤンマ－ LABEL, YANMAR 1
15 2 151695-09110 カバ－Ａウエ（ＦＯＰシツ COVER, CASE UPPER A 1
16 2 151695-09120 カバ－Ａシタ（ＦＯＰシツ COVER, CASE LOWER A 1
17 2 151695-09130 カバ－Ａナカ（ＦＯＰシツ COVER, CASE INNER A 1
18 2 151695-09140 カバ－Ｂウエ（ＦＯＰシツ COVER, CASE UPPER B 1
19 2 146673-09150 ツカミ（ＦＯＰカバ－ KNOB 6
20 2 151695-09150 カバ－Ｂシタ（ＦＯＰシツ COVER, CASE LOWER B 1
21 2 151695-09160 カバ－Ｂナカ（ＦＯＰシツ COVER, CASE INNER B 1
22 2 151695-09170 カバ－Ｃシタ（ＦＯＰシツ COVER, CASE LOWER C 1
23 2 151695-09180 カバ－Ｃウエ（ＦＯＰシツ COVER, CASE UPPER C 1
24 2 151695-09190 カバ－Ｃナカ（ＦＯＰシツ COVER, CASE INNER C 1
25 2 151695-09450 コテイイタ（Ｆ０Ｐカバ－ PLATE, FIXED 12
26 2 151695-09250 カバ－Ｃ（ＦＯＰシツウエ COVER, PUMP CASE UP 1
2008.9.10R
01-58a-00 3/3

27 2 151695-09270 カバ－Ｄ（ＦＯＰシツウエ COVER, PUMP CASE UP 1
28 2 151695-09300 サポ－ト（ＦＯＰシツカバ－ SUPPORT, PUMP CHAMBER 5
29 2 151695-09310 サポ－ト（ＦＯＰシツカバ－ SUPPORT, PUMP CHAMBER 1
30 2 22272-000070 トメワＥ７ RING, 7 6
31 2 26206-100142 ボルト１０×１４ BOLT, 10 X 14 12
32 2 26206-100182 ボルト１０×１８ BOLT, 10 X 18 1
33 2 26206-100202 ボルト１０×２０ BOLT, 10 X 20 12
34 2 26553-040202 ナベコネジ（＋アナ４×２０ SCREW, 4 X 20 24
35 2 26573-040252 サラコネジ（＋アナ４×２５ SCREW, 4 X 25 4
36 2 26716-040002 ナツト４ NUT, 4 4
2007.9.20R
Turning Device No. Page
08 Outline (Manual Cracking) 08-01a-00 1/1
The manual cranking device is a gear that interlocks with the flywheel. It is installed below the air motor on the
operating side. When the manual cranking device is interlocked with the flywheel, the engagement/disen-
gagement switch is actuated, which disables starting the engine.
Fig. 08-01-1 Manual Cranking Device Installation Point
Flywheel
Air Motor
Manual Cranking Device
018723-00E
Be careful not to allow any part of your body to contact moving parts while turning the flywheel.
(e.g. never put your hand into the crankcase)
2007.3.28R*
Turning Device No. Page
08 Operation of the Manual Cranking Device 08-02a-00 1/1
Handle the manual cranking device as follows:

① Prepare the special tools for turning.
Special Tool Description Part No.
Ratchet handle 147673 - 92851
Socket (M24) 42111 - 001850
② Detach the lock bar, loosen the two stopper bolts and then remove the stopper from slot A in the manual
crankshaft.
③ Push the shaft in to the GEAR IN position.
④ Place the stopper in shaft slot B and tighten the two lock bolts.
⑤ Attach the socket and ratchet handle to the manual cranking shaft and then turn the flywheel.
Before disassembling or checking any moving part engage the manual cranking shaft gear with the fly-
wheel and lock it with the lock bar to prevent the crankshaft from being rotated. The lock bar is used to
prevent the crankshaft from turning while service or overhauling the engine. Interlock the gear, lock the
manual cranking shaft with the stopper, and then tighten the lock bar.
⑥ When through rotating the engine, move the gear back to the GEAR OUT position, put the stopper in slot A,
and then tighten the lock bolts and lock bar.
Keep the lock bar in the tool box so as not to lose it.
Fig. 08-02-1 Manual Cranking Device Handling Procedures
Manual Cranking Shaft Flywheel

(Ring Gear)
GEAR IN Pos.
Stopper GEAR OUT Pos.
Micro
Switch
Look Bar B A Turning Gear

018724-00E
2007.3.28R*
右回転機関用 Clockwise Rotation Engine
No. Page
08 ターニング装置部品表
Parts List of Turning Device 08-51c-00 1/2
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020429-00X
2007.9.20R
No. Page
08 ターニング装置部品表
Parts List of Turning Device 08-51c-00 2/2

1 Ｘ 751695-07170 シシン（フライホイール POINTER, FLYWHEEL 1set
1 2 151695-07351 シシン（フライホイルシユキ POINTER, FLYWHEEL 1
2 2 26206-100162 ボルト１０×１６ BOLT, 10 X 16 2
1 Ｘ 751695-08100 ターニングソウチシクミ TURNING DEVICE 1set

3 2 146673-08300 シヤフト（ＦＷターニング SHAFT, F/W TURNING 1
4 2 146673-08310 ギヤ（ＦＷターニング GEAR, TURNING 1
5 2 146673-08320 ストツパー（ＦＷターニング STOPPER, F/W TURNING 1
6 2 151695-08330 ロツクバ－（ＦＷジテンＴＰメ BAR, LOCK 1
7 2 22512-050120 フエザ－キ－５×１２ KEY, 5 X 12 1
8 2 26206-100122 ボルト１０×１２ BOLT, 10 X 12 2
9 2 26356-160002 Ｕナツト（ホソ１６ U-NUT, 16 1
1 Ｘ 747673-74110 ターニングダツカクニンＳＷ TURNING S.W. ASS'Y 1set

10 2 147673-73600 トリツケダイ（リミツトＳＷ MOUNT, LIMIT SWITCH 1
11 2 22312-060120 ヘイコウピン６×１２ PIN, 6 X 12 2
12 2 26206-100162 ボルト１０×１６ BOLT, 10 X 16 2
13 2 46150-000960 リミツトＳＷ（ＸＥ－Ｑ２２－２ SWITCH, LIMIT 1
14 2 26557-040352 ナベコネジ（＋アナ４×３５ SCREW M 4 X 35 2
2008.6.23R
Cylinder Head & Its Accessories No. Page
11 Outline 11-01a-00 1/1
1. Cylinder head
Each water-cooled cylinder head is installed over four cylinder head studs screwed into the cylinder block.
A special hydraulic jack is used to tighten and to loosen the nut on the cylinder head stud.
Fig. 11-01-1 Cylinder Head
018725-00X
2. Exhaust and Intake valves

There are a total of four intake and exhaust valves for each cylinder. The exhaust valve seats are water-
cooled. The intake and exhaust valves are laid out in pairs, with the boost and exhaust air systems on the
same operation side, thus making maintenance and inspection access from the camshaft and fuel injection
pump easy.
Fig. 11-01-2 Cut-away view of the cylinder head
2007.3.28R*
11 Overhauling the Cylinder Head 11-02a-00 1/4
If carbon has accumulated on the surface of cylinder head exposed to the combustion gas, it hinders combus-
tion. Or, if scale has formed on the cooling water line it will impede the cooling effect. Also, a crack might occur
on the combustion surface of cylinder head if there is an uneven thermal load while the engine is running.
Consequently, the cylinder head is overhauled periodically (and the accessories are removed and checked at
the same time.)
1) Disassembly sequence
(1) Detach the cylinder head cover, and remove the fuel and lubrication oil lines near the cylinder head. (Be
careful not to lose the copper gaskets and other small parts.)
(2) Disconnect the fuel injection line and injector.
Chapter 50-08 Overhauling the Fuel Injector
(3) Remove the intake & exhaust valve rocker arms and rocker arm shaft as a set.
Fig. 11-02-1 Cross Section of the Cylinder Head Rocker Arm
Bonnet
Rocker Arm
Cylinder Head Bolt
Cylinder Head
Tightening Nut
Push Rod
Push Rod Cover
018726-00E
(4) Remove the exhaust manifold.

(5) Disconnect the indicator.
(6) Remove the push rod and cover at the same time.
(7) Detach the exhaust temperature sensors. (Be very careful not to damage them.)
2007.3.28R*
Fig. 11-02-2 Overhead view of the Cylinder Head
Cylinder Head Bolt
Cylinder Head Clamping Nut
Fuel Injection Valve

Indicator (Sampling) Valve
Suc/Exh. Valve
Rocker Arm
Rocker Arm Shaft Pedestal
Fuel Injection Pipe
Bonnet 018727-00E
(8) Unscrew the cylinder head clamping Nuts with the aid of a hydraulic jack.
<A hydraulic pump, a set of hydraulic jacks>
Chapter 92-01 ～ 03 Hydraulic Jack
[Cylinder head tightening sequence]

Loosen or tighten the four cylinder head clamping nuts on one cylinder simultaneously.
① Clean the area around the cylinder head nuts.

Tighten each nut with the handle until it is seated.
② Attach the installation bolt to the cylinder head stud for the hydraulic jack.
③ Attach the spacer.
Attach the spacer so that the notched part of the spacer faces the adjacent head.
④ Attach the hydraulic jack to the installation bolt and tighten the hydraulic jack clamping nut.
Make sure that the piston on hydraulic jack is flush with the end of the main hydraulic jack body.
⑤ Connect a hydraulic pump to the hydraulic jack with a rubber hose.
2007.3.28R*
Fig. 11-02-3 Hydraulic Jack Connection Points
D B
A C
Jack piston must be flush

with jack main body.
From Hydraulic Pump

Hydraulic Jack Assy.
Plug.
(Jack B, D)
Spacer
Notch Part 018728-00E
⑥ Then, one of the rubber hoses from the hydraulic jack connects A to B, and the other connects C to D.
Loosen the plug on hydraulic jack B & C to bleed air from each hydraulic jack.
⑦ Loosen the hydraulic jack clamping nuts 1/4 turn each.
If the notched part of spacer mounting surface makes contact with the adjacent cylinder head, the spacer
or cylinder head may be damaged. Therefore, make sure the notched part is not in contact with the cylin-
der head. Then raise the hydraulic pressure.
⑧Close the relief valve on the hydraulic pump and pump the lever to boost the hydraulic pressure to the spec-
ified pressure.
Specified hydraulic pressure : 58.0 ± 0.5 MPa
⑨ Insert the handle into the hole in a nut through the hole in a spacer. Then turn the nut.
2007.3.28R*
● When disassembling the cylinder head, loosen the nut by turning it past seven or eight holes.
● When tightening the nut, keep turning the nut until it is seated.
If you cannot remove a nut with the handle, slowly raise the hydraulic pressure and then try to turn it
again.
Do not raise the hydraulic pressure above 58.5 MPa.
⑩ Open the escape valve on the hydraulic pump slowly, to lower the hydraulic pressure to 0.
⑪ Tighten the hydraulic jack clamping nut until it is flush with the hydraulic jack. Then drain the oil from the
hydraulic jack.
⑫ Disconnect the rubber hoses from the hydraulic jack.
⑬ Remove the hydraulic jack, spacer, and spacer bolt.
● When disassembling, confirm that loosening is not in the cylinder head stud bolt after removing the tight-
ening nuts.
● Before disassembling, make sure the alignment marks on the nuts and bolts are actually aligned.
(9) Remove the cylinder head with the special tool designed to lift the cylinder head. (When lifting the cylin-
der head, pay full attention not to catch anything on threads of the cylinder head clamping bolts. They
must not be damaged.)
2) Cautions when making overhaul checks & reassembling

(1) Check on the level of carbon build up on the combustion surface of the cylinder head, especially near the
intake & exhaust valve holes (to help you determine an appropriate service interval.).
Moreover, after cleaning the cylinder head, check carefully for any cracks.
(2) Check the degree of scale in the waterjacket part of cylinder head. Clean away scale with a scale remov-
ing agent. Even if the engine is fresh water cooled, it should be cleaned once every two years because
scale may still build up depending on water quality. Use a chemical cleaner to remove scale (such as
Unicon 146 available from YANMAR) while the engine is not in use. You don't have to wait for an over-
haul.
(3) Carefully check the socket and spigot part of the cylinder head fitting surface, because flaws on these
parts will cause blow-by during operation.
(4) No particular adjustments will be necessary for the cylinder head packing because the standard top clear-
ance will be correct if a packing the same size as the previous one is used.
(5) After cleaning the surface of various parts, the holes and other small areas in the parts should also be
cleaned carefully. However, do not plug holes with anything. Instead cover the parts involved with a cloth
or plastic sheet to prevent dirt from getting into them.
(6) When fitting a cylinder head onto the block, apply lubricating compound to the threaded parts.
2007.3.28R*
11 Overhauling the Intake / Exhaust Valves 11-03a-01 1/3
1) Disassembly procedure
(1) Remove the fuel injectors.
Chapter 50-08 Overhauling the Fuel Injectors
(2) Attach the valve spring compression tool to a fuel injector clamping stud.
valve spring compression tool 151695-92290
valve spring compression plate 151695-92320
valve spring compression bolt 26152-161704
Fig. 11-03-1 Intake / Exhaust Valve Removal and Reinstallation Procedure
Valve Spring Compression Bolt Intake/Exhaust Valve

Valve Spring Compression Tool Valve Spring Compression Plate
Fuel Injector Clamping Stud Intake/Exhaust Valve Spring
018729-00E
Turn the bolt on the valve spring compression tool to hold down the valve rotator, and take out the valve
key. Incidentally, when disassembling the valve spring and valve rotator without removing the cylinder
head, perform steps (1) & (2) above with the piston at T.D.C.
Take care not to mix up the intake and exhaust valves, since they look similar but are made of different
materials.
Fig. 11-03-2 Markings on the Intake and Exhaust Valve
Marking
Date
Intake Valve : 7 SUH3

Exhaust Valve : 7 80AC
018730-00E
2007.3.28R*
2) Items to check
(1) Check for sulfuric acid corrosion and bent stems on the intake and exhaust valves. Measure the dimen-
sions. If the clearance between the valve stem and the corresponding valve guide exceeds the wear
limit, replace either the valve or valve guide, whichever is most worn.
(2) Check for high-temperature corrosion on the valve head.
Correct the valve poppet tip part upon careful checking it because if it becomes too thin, it may be chipped
and the pieces may enter the combustion chamber and turbocharger, causing a serious secondary dam-
age. (However, do not grind the combustion surface side of the valve poppet part for this correction.)
(3) Check for blow-by and carbon being compressed into the valve seat. According to what is found, you
may need to grind the face of the seat.
(4) Measure the dimensions of the valve seat. If the seat has reached the wear limit, replace it.
(5) Check for cracks and corrosion in the valve springs.
(6) Two valve keys are used to lock each intake/exhaust valve. Store and use them as pairs. In time of reas-
sembly, use them by a pair and for the same valve. (Unless they are handled by a pair, the valve stem
might be damaged due to an inferior contact of the valve key part.)
3) Intake/exhaust valve grinding
(1) Perform initial valve grinding earlier than usual, as indicated in Chapter 00-07, in the Table of Periodic
Checks. Evaluate the situation and then determine an appropriate interval for subsequent servicing.
(2) Check the clearance between the valve guide and stem, replace the pertinent part, and then grind the
valve.
Chapter 00-09 Clearances & Wear Limits of Major Parts
(3) Apply the proper quantity of grinding compound to the valve to be ground and grind the valve carefully
with the proper tool.
The final grinding should be done with oil.
No. Exclusive Tool Description Part No.
1 Grinding tool 138613-92340
2 Spring 159666-92250
3 Grinding compound 28210-000070
Fig. 11-03-3 Intake and Exhaust Valve Grinding Procedures
018731-00X
2007.3.28R*
(4) If a flaw on the face of an intake or exhaust valve is so deep that it must be corrected by grinding, grind
the valve at the angle shown in the figure on the right. Grind until the outer edge of the valve seat makes
contact with the valve.
d mm α°
Intake valve 89 120
Exhaust valve 87 90
Fig. 11-03-4 Angle of the Valves and Intake and Exhaust Valve Seat
Exhaust Valve Seat

Intake Valve Seat
Φd
0
120q-30’ 0
90q
-30’
α +30’
0 018732-00E
2007.3.28R*
11 Overhauling the Intake / Exhaust Valve Seat 11-04a-00 1/2
The intake/exhaust valve seat has been shrink fitted to the cylinder head, and the exhaust valve seat is a
cooled shrink-fit type.
Do not use a gas burner to eliminate carbon stuck to the combustion surface or the exhaust port.
Otherwise, the exhaust valve seat may become loose or the O-rings may deteriorate, resulting in a water
leak.
(1) Check the amount of blow-by and carbon ground Fig. 11-04-1 Valve Seat Correcting Procedures
into the valve seat. Based on what you see, grind (Rough Finishing)
the seat. Since the satellite has been built on the
valve seat face, if a flaw on it is so deep, correct it
with use of a rough correcting seat cutter (with
grinder), and then grind the valve seat. (A seat
YANMAR
cutter is available as an option.)
018733-00X
(2) Check for water leaks in the exhaust valve seat area. (If a water leak is found, replace the valve seat.)
(3) Measure the contact diameter of the valve seat. If the measurement exceeds the wear limit, replace the
valve seat with a new one.
2) Replacing a valve seat

Replace the valve seat as follows:
(1) Removing a valve seat Fig. 11-04-2 Valve Seat Correction Procedures
Build up the circumference of the valve seat face
with welding rod applied by arc welding. This
Iron Plate
material is used to remove the valve seat. If the
exhaust valve seat is difficult to remove because Arc Welding
of the O-rings installed in it, weld an iron plate to Valve Seat
the valve seat. Then hammer out the valve seat
using a round rod passed through the valve guide.
018734-00E
(2) Installing a valve seat

① Check for flaws, hit marks and burrs on the hole where the valve seat will be inserted into the cylinder
head. Also inspect the outer edge of the valve seat. If any problems are found, correct them.
2007.4.10R*
11 Overhauling the Intake / Exhaust Valve Seat 11-04a-00 2/2
② Measure the diameter of the new valve seat and the valve seat hole. Confirm that there will be an inter-
ference fit.
[Interference values for the Valve Seat] (Unit: mm)

Intake valve seat 0.055 ～ 0.105
0.063 ～ 0.100 (87φpart)

Exhaust valve seat
0.100 ～ 0.137 (100φpart)
③ Heat the whole cylinder head to 40 ℃ to 60 ℃ . Heating should be done with a steam cleaner.
④ Then chill the valve seat with liquid carbon dioxide. If liquid carbon dioxide is not available, soak the valve
seat in a mixture consisting of a small lump (10 kg) of dry ice and alcohol (1.5 lit.) for 1 hour or more.
Chill the exhaust valve seat with the O-rings installed in it. Do not use liquid nitrogen. If you did, the O-
rings would harden and break when inserting the valve seat in the cylinder head.
Fig. 11-04-3 Exhaust Valve Seat Inserting Procedures
Just before inserting the exhaust valve seat

into its hole in the cylinder head, apply anti-
seize liquid (spray) and silicone-based liquid
Seizure Inhibitor
packing (Three-Bond 1211 or equivalent) to (spray)
the hole in the head.
Liquid Packing 018735-00E
⑤ Using the intake valve (or exhaust valve) Fig. 11-04-4 Valve Seat Insertion Procedures
as a guide, rapidly insert the valve seat
into its hole in the cylinder head. INSERT
Valve Seat
Take care not to tilt the valve seat. Apply a

load to the valve seat for one to two minutes,
to avoid insufficient insertion into the hole.
018736-00E
After replacing the exhaust valve seat, be sure to conduct a hydraulic test to make sure no water leaks
between the mated parts.
Test pressure: 0.7 MPa (7 kgf/cm2)
2007.4.10R*
11 Overhauling the Intake / Exhaust Valve Guide 11-05a-00 1/1
The intake and exhaust valve guides have been shrink fitted, inserted and installed, along with the stem seal.
(1) Measure the clearance between the valve guide Fig. 11-05-1 Valve Guide Removing Procedures
and the valve stem. If the measurement exceeds
the wear limit, replace the valve guide or valve.
(2) Replace the stem seal each time the valves are
serviced.
Doubling Rod
2) Removing a valve guide Ǿ32
Remove the valve guide by hammering on it from the
valve side using a stepped bar of two steps.
HANMER
3) Installing a valve guide
Chill the valve guide in liquid nitrogen or liquid carbon
dioxide, and then press fit it.
Interference: 0.001 ～ 0.037 mm
018737-00E
When press fitting the valve guide, hold it by the flanged part.
4) Installing a stem seal

Install the stem seal using a jig so as not to damage the stem seal lip.
2007.4.10R*
11 Overhauling the Intake / Exhaust Valve Bridge & Guide 11-06a-00 1/1
The valve bridge guide has been shrink fitted into the cylinder head. If the engine is used with excessive clear-
ance between the valve bridge and the valve bridge guide, the valve bridge may drop while the valves are
working, causing a malfunction in the valves, uneven wear in the valve guide.

If the clearance between the valve bridge and valve bridge guide exceeds the wear limit, replace either the
valve bridge or valve guide, whichever is more worn.
2) Replacement of the valve bridge guide

Chill the valve bridge guide with liquid nitrogen or liquid carbon dioxide. Then press fit it into the cylinder head.
Fig. 11-06-1 Cross Section View of Cylinder Head (Exhaust Valve Side)
Valve Bridge
Valve Bridge Guide
Cylinder Head
018738-00E
2007.4.10R*
11 Overhauling the Valve Rotator 11-07a-00 1/1
Improper rotation of the valve rotator will cause carbon to be ground into the valve seat, causing blow-by in
the seat and affecting the service life of the valve and valve seat. Therefore, check and check the valve rotator
overhaul periodically.
To remove the valve rotator without disassembling the cylinder head, set the piston to T.D.C. on the com-
pression stroke, and then remove the valve rotator.
Chapter 11-03. Overhauling the Intake / Exhaust Valves.

Remove the circlip, and check each part. If any of the following parts is found to be defective, replace it.
Fig. 11-07-1 Valve Rotator
I Body
ball race
Belleville Spring
I Spring Shoe
Circlip
Coil Spring
Ball
Section I-I A
018739-00E
① Wear (in the body groove) or corrosion in the Belleville spring

② Wear (deformation) or corrosion in the ball
③ Worn or broken coil spring
④ Wear of the body groove
2) Installation
① Install the coil springs, balls and Belleville spring in the proper direction.
② After installing them, check clearance A.
2007.4.10R*
11 Adjusting the Intake / Exhaust Valve Head Clearance 11-08a-01 1/1
Adjust the intake/exhaust valve head clearance, as follows, because the valve mechanism of this engine is
designed to use two intake (or exhaust) valves by means of a T-shaped valve bridge. This bridge will be dis-
torted and cause abnormal wear on the valve bridge guide and/or valve guide unless it adjusted for the oper-
ation of two valves simultaneously:
(1) Prepare the following special tools:
Feeler gauge 0.4mm thick (intake) & 0.7mm thick (exhaust) 28312 - 000750 ･･ S
Fig. 11-08-1 Valve Head Clearance Adjusting Procedure
1 2
C (Valve Head Clearance)
A B
Valve Bridge
018740-00E
(2) Turn the flywheel to bring the relevant cylinder to T.D.C. on the compression stroke.
Do not mistake this position for the top of valve overlap.
(3) Loosen the lock nuts ② & ④ , and then loosen the rocker arm adjusting screw ① and valve guard adjust-
ing screw ③ .
(4) Press down the center of the valve guard from above so that clearance A becomes zero. Gradually
tighten the valve guard adjusting screw ③ so that clearance B becomes zero. After making the adjust-
ment, lock the adjusting screw ③ so that it can't turn, and tighten the lock nut ④ securely.
(5) Put a feeler gauge into clearance C between the rocker arm adjusting screw ① and the valve guard, and
gradually tighten the rocker arm adjusting screw ① until the clearance is narrow enough to just allow the
feeler gauge to be inserted smoothly. Then, lock the adjusting screw ① , and tighten the lock nut ② .
(6) After having securely tightened the lock nut ② , make sure that the feeler gauge can still be inserted and
drawn out smoothly.
Valve head clearance: Chapter 00-09 Table of Standard Engine Adjustments
2007.4.10R*
シリンダヘッド部品表 No. Page
11 シリンダヘッド部品表
11-51a-02 1/3
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020431-01X
2008.9.10R
11-51a-02 2/3

1 X 751695-11102 シリンダヘツドＡＳＳＹ HEAD ASSY, CYLINDER 6sets
1 2 751695-11112 シリンダヘツド HEAD ASSY, CYLINDER 6s
3 3 151695-11950 バルブシ－ト（ＳＵＣ．テーパ SEAT, INTAKE VALVE 12
4 3 151695-11090 バルブシ－ト（ＥＸＨベン VALVE SEAT, EXHAUST 12
5 3 151695-11890 Ｏリング（ＥＸＨシ－トシタ O-RING, SEAT LOWER 12
6 3 151695-11880 Ｏリング（ＥＸＨシ－トウエ O-RING, SAET UPPER 12
7 3 27241-400000 ワンガタプラグ４０ PLUG 40 30
8 3 27241-500000 ワンガタプラグ５０ PLUG 50 48
9 3 23876-010000 ネジプラグＰＴ１／８ PLUG PT1/8, SCREW 18
10 3 23876-030000 ネジプラグＰＴ３／８ PLUG PT3/8, SCREW 54
11 3 23876-020000 ネジプラグＰＴ１／４ PLUG PT1/4, SCREW 24
12 3 151695-11760 ＰＫ（ノズルスリ－ブ PACKING, SLEEVE 6
13 3 151695-11790 ノズルスリ－ブシクミ NOZZLE SLEEV ASSY 6s
15 4 151695-11780 カエンシンニュウボウシワ FLAME SHOUTER 6
16 3 24326-000600 ＯリングＧ＝６０ O-RING 12
17 2 151695-11181 バルブガイド GUIDE, VALVE 24
18 2 151695-11120 キユウキベン（ＳＵＨ３７ VALVE, INTAKE 12
19 2 151695-11110 ハイキベン（ナイモニツク VALVE, EXHAUST 12
20 2 151695-11480 ベンバネ SPRING, VALVE 24
21 2 151695-11601 バルブロ－テ－タ ROTATOR, VALVE 24
22 2 151605-11970 コツタ（キユウハイキベン COTTER, SUC/EXH.VALVE 48
23 2 151695-11500 ブリツジガイド GUIDE, BRIDGE 12
24 2 151694-11591 バルブステムシ－ル（リップツキ SEAL, VALVE STEM 12 SUC.
25 2 151607-11580 バルブステムシ－ル１９ SEAL, VALVE STEM 12 EXH.
26 2 146673-11750 セツゾクピン PIN, CONNECTING 6
27 2 26232-202402 ウエコミボルト（ホソホソ２０×２４０ STUD, BOLT 20 X 240 6
28 2 151695-11370 ウエコミボルト STUD, BOLT 6
29 2 26732-200002 ナツト（ホソ２０ NUT, 20 12
30 2 26212-120902 ウエコミボルト１２×９０ STUD, BOLT 12 X 90 12
31 2 26212-120652 ウエコミボルト１２×６５ STUD, BOLT 12 X 65 12
32 2 26212-120502 ウエコミボルト１２×５０ STUD, BOLT 12 X 50 12
2008.9.10R
11-51a-02 3/3

33 2 26706-120002 ナツト１２ NUT, 12 36
34 2 23893-040002 ６カクプラグＧ１／２ PLUG, G 1/2 12
35 2 23414-210000 パツキン（マル２１ GASKET, 21 12
36 2 26206-100102 ボルト１０×１０ BOLT, 10 X 10 6
37 2 153672-59910 シ－ルワツシヤ－１０ WASHER, SEAL 10 6
38 2 23887-120002 ６カクプラグ１２ PLUG, 12 6
39 2 153672-59920 シ－ルワツシヤ－１２×１．２ WASHER, SEAL 12 X 1.2 6
40 2 151695-11800 パツキン（ＦＯＶ PACKING, VALVE 6
2008.9.10R
11 弁腕支持台・ボンネット部品表
11-52a-01 1/2
Parts List of Valve Arm Ass'y & Bonnet
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020430-01X
2008.9.10R
11 弁腕支持台・ボンネット部品表
11-52a-01 2/2
Parts List of Valve Arm Ass'y & Bonnet

1 X 751695-11150 ベンワンジクダイシクミ SUPPORT ASSY, SHAFT 6sets
1 2 751695-11140 ベンワンジクダイシクミ SUPPORT ASSY, SHAFT 6s
2 3 151695-11261 ベンワンジクダイ SUPPORT, ARM SHAFT 6
3 3 151695-11251 シヤフト（ベンワン SHAFT, ROCKER ARM 6
4 3 27225-060080 ウチコミプラグ６×８ PLUG, 6 X 8 6
5 4 151695-11210 ハイキベンワン ARM, EXHAUST ROCKER 6s
6 4 151695-11241 ブツシユ（ベンワン BUSH, ROCKER ARM 6
7 4 151695-11220 キユウキベンワン ARM, INTAKE VALVE 6s
8 4 151695-11241 ブツシユ（ベンワン BUSH, ROCKER ARM 6
9 3 27225-050060 ウチコミプラグ５×６ PLUG, 5 X 6 24
10 3 142613-11231 チヨウセイネジ（ベンワン） SCREW, ADJUST 12
11 3 26772-180002 トメナツト（ホソ１８ NUT, 18 12
12 3 142613-11351 ベンワンアテガネ RETAINER 12
13 3 138613-11390 ベンワンアテガネ RETAINER, ROCKER ARM 12
14 3 22242-000600 トメワＣ（ジク６０ RING, 60 12
15 2 151695-11520 バルブブリツジＣＭＰ BRIDGE ASSY, VALVE 12sets
18 3 134673-11530 シ－ト（バルブブリツジ SEAT, VALVE BRIDGE 12
19 3 151636-11540 シ－ト（キユウハイキベン SEAT, VALVE 12
20 3 151695-11580 チヨウセイネジ SCREW, ADJUSTING 12
21 3 26772-160002 トメナツト（ホソ１６ NUT, 16 12
1 X 751695-11300 ボンネツトシクミ BONNET ASSY, CYL. 6sets

22 2 151695-11301 ボンネツトシクミ BONNET ASSY, CYL. 6s
23 3 151695-11281 パツキン PACKING 6
25 2 151695-11340 ボンネットフタシクミ PLUG BONNNET ASSY 6
27 3 151695-11330 パッキン（ボンネットフタ PACKING, PLUG BONNET 6
28 2 151695-11380 カンザボルトＭ１２ SPACER BOLT M12 6
29 2 153605-11431 ツカミ（ベンワンジクフタ KNOB 12
30 2 22137-200000 ザガネ（ミガキ２０ WASHER, 20 12
31 2 22242-000200 トメワＣ（ジク２０ CIRCLIP 20 12
32 2 153672-59970 シールワッシャー２０×１．２ WASHER, SEAL 20 X 1.2 12
2008.9.10R
11 指圧採取弁部品表
11-53a-02 1/2
Parts List of Indicator Valve
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2006.9.20R
11 指圧採取弁部品表
11-53a-02 2/2
Parts List of Indicator Valve

1 X 751695-15101 インジケータダイシクミ MOUNT ASS'Y, INDICATOR 6sets
1 2 151695-15350 ソケツト（Ｍ２２Ｘ２ SOCKET, M22 X 2 6
2 2 151695-15361 インジケ－タダイ MOUNT, INDICATOR 6
3 2 23414-080000 パツキン（マル　８ GASKET, 8 6
4 2 23414-120000 パツキン（マル　１２ GASKET, 12 6
5 2 26706-120002 ナツト　１２ NUT, 12 12
1 X 751695-15052 アンゼンベンシクミ VALVE ASS'Y, SAFTY 6sets

6 2 151695-15202 アンゼンベン VALVE, SAFETY 6
8 3 151695-15221 アンゼンベン VALVE 6
9 3 151695-15231 バネ（アンゼンベン SPRING(SAFETY VALE 6
10 3 151695-15241 バネウケ（アンゼンベン RETAINER 6
11 3 151695-15251 バネオサエ（アンゼンベン CAP SPRING SAFETY V 6
12 3 151695-15260 トメナットＭ２０Ｘ１ CHECK NUT M20 X 1 6
13 2 151695-15270 パツキン（アンゼンベン GASKET, VALVE 6
14 2 151695-15110 インジケ－タコツク INDICATOR COCK 6
2008.9.10R
Timing Gear, Camshaft & Intake / Exhaust Swing Arm No. Page
14 Outline 14-01a-00 1/1
1) Timing gear Fig. 14-01-1 Timing Gear

The gear train is inside the gear case opposite to
the flywheel side. The gear on the crankshaft Cam gear
drives the lubricating oil pump and the fuel feed
pump drive gear directly, and it drives the cam
Idle gear A Gov. Drive
gear through idle gears A and B. The governor Bevel Gear
drive gear is also equipped with a cam gear. Idle
gear A drives the gears for two kinds of cooling Idle gear B
water pumps (high temperature and low tempera-
Cooling Water Pump Gear
ture side). Please refer to Figure 14-02-1 for (High Temp. Side)
details about the arrangement of each gear train. (Low. Temp. Side)
Crank Gear
Fuel Oil
Lub. Oil pump gear Feed Pump Gear
018741-00E
2) Camshaft
The camshaft has three cam shape lobes: the Fig. 14-01-2 Camshaft
intake cam, the exhaust cam and the fuel pump
cam. The cams and bearing faces are induction
hardened for higher wear resistance. The cam-
shaft is divided into three parts with the breaks
being between the No.2 and No.3 cylinders and
between the No.4 and No.5 cylinders. High-preci-
sion bolts secure each part. This reduces the dis-
tance required to extract the parts and makes
disassembly and assembly easy.
018742-00X
3) Valve operating mechanism Fig. 14-01-3 Valve Train

The valve operating mechanism uses the swing
arm system.
The valve operating mechanism uses a swing
arm system. The design of the swing arm system
is simple with no moving part in the tappet
guides. This is instrumental in reducing the iner-
tial mass of the valve train and in rendering supe-
rior dynamic characteristics.
018743-00X
2007.4.10R*
14 Overhauling the Timing Gear 14-02a-01 1/3
Even under the condition of normal operation, there is a wear of gears. This may cause a pitching wear, pluck-
ing and hair cracks on the tooth surface.
Besides, since the wear is related to noise and vibration periodically check the backlash of gears and contact
of tooth surface.
When disassembling the timing gears, measure the backlash of gears, If the measurement exceeds the allow-
able value, replace the pertinent gear of bearing with the new one.
(1) Remove the cooling water pump, fuel oil feed pump, lub. oil pump and fuel oil filter (together with its
mount).
(2) Remove the gear case.
Lift the gear case up with rope. If the gear case falls, an accident may occur.
Since the gear case is positioned with two knock pins, jack it up with M12 bolts to remove it.
A set mark is stamped on the side of crank gear, idle gear A, idle gear B and cam gear. When assembling
the timing gears, set the No.1 (or No.6) cylinder at the B.D.C., and align the set marks.
Fig. 14-02-1 Timing Gear Alignment Marks
Cam Gear
Gov. Drive Bevel Gear

Idle Gear A
Idle Gear B
Set Mark

(High Temp. Side)
(Low Temp. Side)
Lub. Oil Pump Gear

Fuel Oil Feed Pump Gear
Crank Gear 018744-00E
2007.4.10R*
1) Cam gear
The governor drive bevel gear is incorporated to the cam gear, and they are incorporated to the
camshaft together with the tachometer drive coupling.
Disassemble (or reassemble) the cam gear according to the following sequence with the cover of timing gear
case removed:
(1) Remove the governor and governor driver.
(2) Remove the cam gear clamping bolt and tachometer drive coupling.
(3) Draw out the cam gear toward the flywheel side, and remove the gear through the window of timing gear
case.
(4) Cam gear clamping procedures
○ Mating the number stamped on the head of cam gear clamping bolt with the number stamped on the
side of cam gear, incorporate the bolt into the gear. (Number of the bolt holes are counted in clock-
wise direction from 1, 2 mark on the cam gear.)
○ When tightening the cam gear clamping bolt, apply the seizure inhibitor (Three-Bond 1910 or its
equivalent) on the bearing surface and threaded part of the bolt, and then tighten the bolt to the spec-
ified torque.
Fig. 14-02-2 Cam Gear Disassembling Procedures
Governor
Governor Drive
Gov. Drive Bevel Gear
Cam Gear Clamping Bolt

Cam Gear
Idle Gear B
Idle Gear A
Crank Gear
018745-00E
2007.4.10R*
2) Idle Gear Disassembling Procedures

Remove the idle gears according to the following procedures.
(1) Remove the cam gear.
For their removing procedures, refer to the following.
Chapter ; Preceding chapter, 1) Cam Gear
(2) After the keep plate is removed, idol gear A ･ B is detached by the set.
(3) Checking and servicing
Check for seizure and uneven wear of idle gear bearing and mounting shaft, and measure the dimensions.
If the bearing clearance exceeds the allowable valve, replace the bearing or mounting shaft.
Fig. 14-02-3 Idle Gear Disassembling Procedures
Idle Gear A
Idle Gear B
Idle Gear
Mounting shaft
Keeper Plate
018746-00E
3) Crank gear
(1) To facilitate removal of crank gear, drill a hole below the bottom land of the gear, and drive a chisel into
this hole. This will loosen fitting, and thus the gear can be easily removed.
Take care not to damage the positioning knock pin.
(2) The detached crank gear cannot be used again.

(3) Before incorporating the crank gear, put it in the oil bath, and hear the bath to about 150 to 190 ℃ , leave the
gear in the bath for about 60 minutes, and then take it out of the bath.
After that, quickly insert the crank gear to the crankshaft.
Refrain from heating the crank gear with a burner or the like, otherwise the temperature will rise excessively
to change the structure of the material and to decrease its strength. Instead, use of an oil bath is recom-
mended for this purpose.
2007.4.10R*
14 Servicing the Camshaft 14-03a-00 1/2
The camshaft has three cam shape lobes: the intake cam, the exhaust cam and the fuel pump cam. The cams
and bearing faces are induction hardened for higher wear resistance. The camshaft is divided into three parts
with the breaks being between the No.2 and No.3 cylinders and between the No.4 and No.5 cylinders. High-
precision bolts secure each part. If the engine installation site does not have enough space to extract the cam-
shaft in one piece, split it at the connectors and then pull two parts out from the engine. Pull the camshaft out
toward the front side (the side opposite the flywheel)
1) Disassembly
Disassemble the camshaft as follows:
(1) Remove the cover, then the rocker arms, shaft pedestals and push rods.
(2) Disconnect the fuel injection pipe joint. Then remove the fuel injection pump and fuel injection pump
drive.
(3) Remove the intake and exhaust swing arms.
For details about removing them, refer to the following:
Chapter 14-04, Intake and Exhaust Swing Arms
(4) Remove the cam gears.

For details about removing them, refer to the following:
Chapter 14-02, Cam gear
(5) Remove the cam gear clamping bolt and tachometer drive coupling.
(6) Pull out the camshaft.

(1) Check for flaws and excessive wear on the fuel pump cam, intake and exhaust cams and bearings.
(2) Measure the dimensions of camshaft bearing parts and bearings, and check the clearance between each
bearing and the shaft.
Fig. 14-03-1 Cam Shaft Coupling Part
Driled Hole Notch
018747-00E
2007.4.10R*
14 Servicing the Camshaft 14-03a-00 2/2
(3) A press fitting jig is necessary to replace a camshaft bearing.
When installing a bearing on the camshaft, place the bearing so that its joint faces up and its oil hole is
mated with oil hole in the camshaft. Then press it into position.
Fig. 14-03-2 Camshaft Bearing Press-fitting Procedure
Oil Hole
45q
Joint
018748-00E
3) Reassembly
Reassemble the camshaft in the reverse sequence used for disassembly, paying attention to the following
points:
(1) Make sure the camshaft coupling surfaces are free from any foreign matter or lubricating oil. Then, align
the notch with the drilled hole to reassemble the camshaft.
(2) Tighten the U-nuts of the coupling only after applying anti-seize (Three-Bond 1910 or equivalent) to the
threaded parts and bearing surfaces.
2007.4.10R*
14 Servicing the Intake / Exhaust Swing Arm 14-04a-00 1/1
The valve mechanism forcibly lubricates the roller pins using the swing arm system.
1) Disassembly
Remove the rocker arm shaft pedestal and push rods, and disassemble the swing arm assembly as follows:
(1) Remove the cam case cover. Loosen the swing arm shaft clamping bolts, and remove the arm shaft and
arm together as a set.
(2) Remove the circlips form the arm shaft using circlip pliers (P/#28190-000020). Then remove the swing
arms and spacers.
Fig. 14-04-1 Swing Arm Disassembly Procedures
Exh. Suc.
Push Rod
Set Mark Push Rod Bracket
㧱㧿
㧱
Circlip
Roller
Swing Arm
Swing Arm Shaft

018749-00E

(1) See if the roller rotates smoothly or catches look for flaws on the outer edge and for lopsided contact with
the roller. (If any defect is detected, replace the swing arm with the new one by assembly.)
(2) Check shaking of the tappet seat of swing arm shaft. Measure the dimensions of the swing arm shaft and
swing arm shaft bearing. If any of the measurements exceeds the wear limit, replace the swing arm shaft
or the swing arm.
3) Reassembly
Reassemble the intake/exhaust swing arm assembly by reversing the sequence used to disassemble it.
(1) Check for any deformed or missing collars in the swing arm shaft clamping bolt holes.
(2) Install the swing arm shaft so that the "E" alignment mark is positioned on the left side.
Screw on the clamping bolts with the "E" alignment mark on the left side and the "S" alignment mark on
the right side.
Do not make a mistake during this installation. If it is not installed properly, the lubricating oil passage will
be blocked and the arm shaft and roller pins will be burned out.
(3) After installing the rocker arm shaft pedestal, adjust the intake/exhaust valve head clearance. For details
about the adjustment procedures, refer to the following:
Chapter 11-08, Adjusting the Intake/Exhaust Valve Head Clearance
2007.4.10R*
No. Page
14 タイミングギヤ部品表
Parts List of Timing Gear 14-51a-00 1/2
㧝
㧤
㧝㧜
2005.4.10R
No. Page
14 タイミングギヤ部品表
Parts List of Timing Gear 14-51a-00 2/2

1 X 751695-14300 タイミングギヤシクミ TIMING GEAR ASSY 1set
1 2 　 151695-14280 オサエイタ（アイドル PLATE, IDLE 1
2 2 　 151695-14290 トリツケダイ（アイドル BRACKET, IDLE 1
3 2 151695-14590 ギヤシクミ（カムアイドル GEAR ASSY, CAM IDLE 1s
6 3 151695-14620 ブツシユ
（アイドルギヤ BUSH, IDLE GEAR 1
7 3 22312-060060 ヘイコウピン　６Ｘ６ PIN, 6 X 6 1
8 2 22137-120000 ザガネ（ミガキ１２ WASHER, 12 4
9 2 　 26152-200602 ボルト（ホソ２０Ｘ６０ BOLT, 20 X 60 6
10 2 　 26206-120252 ボルト１２Ｘ２５ BOLT, 12 X 25 4
2008.9.10R
No. Page
14 カム軸・吸排気スイングアーム部品表
Parts List of Camshaft & Suction / Exhaust Swing Arm 14-52a-02 1/2
㧞㧟
㧞㧟㧞㧤
㧞㧞
㧞㧤
㧞㧤
㧝㧤
㧞㧞
㧝㧠㧝㧢
㧞㧣
㧞㧤㧞㧣
㧝㧣
㧞㧥㧡
㧝㧢㧝㧤㧟㧜㧢㧣
㧝㧣㧞㧥
㧝㧟
㧞㧣
㧠
㧢㧣
㧝㧝
㧟
㧢㧣
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㧤
㧝㧜
㧥
㧝㧞
2007.9.20R
No. Page
14 カム軸・吸排気スイングアーム部品表
Parts List of Camshaft & Suction / Exhaust Swing Arm 14-52a-02 2/2

1 X 751695-14111 カムシヤフトＡＳＳＹ CAMSHAFT ASSY 1set
2 2 151695-14041 カムシヤフト
（ＸＲギヤ CAMSHAFT, XR GEAR 1
3 2 151695-14450 カムシヤフト（ＸＲ NO6.5 CAMSHAFT, XR NO6.5 1
6 2 153605-14730 リ－マボルト BOLT, REAMER 36
7 2 26356-140002 Ｕナツト（ホソ１４ U-NUT, 14 36
8 2 151695-14100 ギヤ（カムシヤフト GEAR, CAMSHAFT 1
9 2 151695-14170 ギヤ（ガバナクドウ GEAR, GOV.DRIVE 1
10 2 153605-14810 ボルト（カムギヤ BOLT, CAM GEAR 12
11 2 22512-120300 フエザ－キ－１２Ｘ３０ KEY, 12 X 30 1
12 2 26206-120302 ボルト１２Ｘ３０ BOLT, 12 X 30 4
31 2 151695-91060 クドウジクザ（カイテンケ WASHER, DRIVE SHAFT 1
1 X 751695-14251 ドウベンソウチシクミ SWING ARM ASSY 6sets

13 2 153605-14240 ボルトＡ（スイングア－ム BOLT, SWING ARM A 6
14 2 151695-14270 シヤフト
（スイングアーム SHAFT, SWING ARM 6s
16 2 151695-14301 スイングアームＣＭＰ ARM ASS'Y, SWING 12s
17 3 153605-14221 ロ－ラ（SUCEXH タペツト ROLLER, TAPPET 12
18 3 151695-14230 ピン（タペツトロ－ラ PIN, TAPPET ROLLER 12
22 2 151695-14421 カバ－（プツシユロツド COVER, PUSH ROD 12
23 2 151695-14550 プツシユロツドシクミ ROD ASS'Y, PUSH 12s
27 2 22242-000550 トメワＣ（ジク５５ RING, 55 24
28 2 24321-000350 Ｏリング１ＡＧ 35.0 PACKING, G 35.0 24
29 2 24550-022150 ドライブツシユ 22Ｘ15 BEARING, 22 X 15 12
30 2 26152-200602 ボルト（ホソ　20Ｘ60 BOLT, 20 X 60 6
2008.10.15R
Air Cooler, Exhaust Manifold & Turbocharger No. Page
18 Outline 18-01b-00 1/1
The air cooler is box shaped and is designed to function as a turbocharger mount. Therefore, the turbo-
charger and air cooler are fitted compactly on the side of the unit of the flywheel.
The air cooler tubes are installed with a finned plate in two-pass for good cooling performance. The core of the
air cooler can be extracted from the casing without removing the turbocharger.
Turbocharger is a high performance air-cooled radial KBB model.
The exhaust manifold consists of two passages to make good use of the pulse energy from the exhaust gas.
Fig. 18-01-1 Air cooler & Turbocharger
Exhaust Manifold
Turbocharger
‫ޓ‬
㧭㧙㧭
Air Cooler
018751-00E
2007.4.10R*
18 Servicing the Air Cooler 18-02b-00 1/2
The air cooler body is designed to serve as a support for mounting the turbocharger. The core of the cooler
can be removed without removing the turbocharger or cooler body from engine.
Fig. 18-02-1 Air cooler
Air IN
Air OUT
Body
Cooling Water IN
Core
Cooling Water OUT 018754-00E
1) Disassembly
Disassemble the air cooler according as follows.
(1) Prepare the following special tools
Special Tool Description Part No. Note

Tool A 151695-92650
Tool B 151695-92660
Eyebolt(M16) 26610-160002 2 pieces
Pipe -- φ60.5 × 800L × 2 pieces
(2) Remove the cooling water tube, by-pass valve and air vent pipe.
(3) Remove the frame, o-ring and thin plate on the operating side (the water return cover side).
(4) Remove the frame securing the core to the non-operating side and attach the tools A and B.
Fig. 18-02-2 Drawing the Core

Eybolt
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬
‫ޓ‬ ‫ޓ‬
Pipe Pipe
Tool 018755-00E
2007.4.10R*
18 Servicing the Air Cooler 18-02b-00 2/2
(5) Push the core from the operating side toward the non-operating side.
(6) When core has been drawn out about 120mm, insert a pipe under the air cooler (between the cooler and
tool) and pull the core out more from the non-operating side. Insert another pipe when core is drawn out
further.
It should be expected that the core will moves more than you might think when a pipe is placed under the
core. Never stand in front of the core.
(7) When the core has been drawn out about 500mm, screw the eyebolts into the thread holes in the core
and suspend it.
Never suspend the core with a single eyebolt. The core mass is 340 kg.
2) Checking and Servicing

(1) Clean the air side (finned plate) with steam or soak it in cleaning fluid. Blow compressed air across it and
finally wash it in water.
The appropriate cleaning fluid is the following product or equivalents.

Neos Co.,Ltd. : Neos One-1
Kurita Water Industries Ltd. : Emocon 1E-55
(2) Remove the water covers on the core and clean the interior of the tubes. Brush them with a long-handled
brush.
(3) Check the coating on the inner surface of the duct and cooler body. If the coating has peeled off, repair it.
(4) Check for clogged drain holes.
(5) Replace the o-rings and gaskets with new ones.
3) Assembly
Assemble the air cooler by reversing the sequence used to disassemble it.
• Apply clean engine oil lightly to the rail on the air cooler body before installing the core in the body. But
do not use grease for this purpose.
• Use liquid seal for the thin plate on the water return cover side.
2007.4.10R*
18 Overhauling the Exhaust Manifold 18-03b-00 1/2
The exhaust manifold consists of a 1,4,5 cylinder group and a 2,3,6 cylinder group. The manifold is covered
with glass cloth and is surrounded by a steel cover to insulate it and make it fireproof.
1) Disassembly
Disassemble the exhaust manifold as follows.
(1) Remove the cover on the exhaust manifold.
(2) Remove the electrical wiring and its supports.
(3) Remove the fireproof cover.
(4) Remove the bolts from the manifold and expansion joint flange and remove the expansion joint.
(5) Remove the supports.
(6) Attach an eyebolt to each manifold and suspend them to move them away after removing the bolts on the
cylinder head side.
① Check the tightness of the bolts before you loosen them.

② Pay attention to keep the gasket from falling when you remove the manifold.
③ The nuts and bolts on the exhaust manifold, and the related parts are made of stainless steel. Do not
mix them with the bolts on the other parts.
Fig. 18-03-1 Exhaust manifold
Insulation Covering Expansion Joint
Support Exhaust Manifold
2) Assembly
Assemble the exhaust manifold by reversing the sequence used to disassemble it.
(1) Apply anti-seize to each bolt and nut, and then tighten it
(2) Check the mark stamped on the expansion joint flange and put it on in the proper direction, according to
the mark.
2007.4.16R*
18 Overhauling the Exhaust Manifold 18-03b-00 2/2
Fig. 18-03-2 Expansion Joint Mark
Expansion Joint Mark
Gas Flow
If the expansion joint is fitted backward, carbon will be trapped in the gap causing the expansion joint to
break quickly.
① Glass cloth covered by aluminum foil is used for lagging.

② Lag the exhaust manifold with glass cloth, and stitch up the loose edges of the cloth.
③ Coat the stitched-up part with sealant.
④ In case the fireproof covering (lagging) comes off the exhaust manifold, there will be a possibility of a
fire breaking out from oil spray or other combustibles coming in contact with the manifold.
⑤ Use of asbestos as lagging material is prohibited.
2007.4.16R*
Operating Instructions
HPR5000 Exhaust Gas Turbocharger
OPERATING
and
MOUNTING INSTRUCTIONS
for
EXHAUST GAS
TURBOCHARGER
HPR5000
For information only!
Kompressorenbau Bannewitz GmbH

Windbergstraße 45
01728 Bannewitz
Federal Republic of Germany
Phone: +49 (351) 40 85 603 (Sales)

+49 (351) 40 85 633 (Service)
+49 (172) 35 16 045 (24-hour phone)
Fax: +49 (351) 40 85 840
HPR5000EN08.doc 8th Edition (07/2008) Page 1 of 54

Issued: 08/2008 Ro Checked: Released:
4588903en
HPR5000 Exhaust Gas Turbocharger
Name-plate
The data given in the operating instructions only apply to the exhaust gas turbocharger with the serial
number mentioned above. The name-plate is affixed at the side of the bearing housing of the exhaust
gas turbocharger.
In case you have questions regarding the exhaust gas turbocharger, it is important to give the correct
• TC type (Type)
• Serial No. (Serial)
• Specification No. (Spec.)
Only if these data are known, the request can be handled properly and promptly.
Direct your inquiries to the following address:
Kompressorenbau Bannewitz GmbH

Windbergstr. 45
01728 Bannewitz
Federal Republic of Germany
Fax: +49 (351) 40 85 840

Phone: +49 (351) 40 85 603 (Sales)
+49 (351) 40 85 633 (Service)
+49 (172) 35 16 045 (24-hour phone)
E-mail: [email protected]
Page 2 of 54 8th Edition (07/2008) HPR5000EN08.doc

HPR5000 Exhaust Gas Turbocharger Contents
Table of Contents
Chapter Title Page
1 TECHNICAL DATA ....................................................................... 5

1.1 Operating data ...............................................................................................5
1.2 Alarm values ..................................................................................................6
1.3 Dimensions ....................................................................................................6
1.4 Test connections ...........................................................................................7
1.5 Weight of important subassemblies ............................................................7
1.6 Vibrations .......................................................................................................8
2 SAFETY......................................................................................... 9
2.1 Built-in safety systems..................................................................................9
2.2 Safety measures (to be taken by user) ........................................................9
3 GENERAL INFORMATION ABOUT DANGER........................... 10
3.1 Danger zone .................................................................................................10
3.2 Operators and maintenance personnel .....................................................10
3.3 Installation of spare and wear parts...........................................................11
4 DESIGN ....................................................................................... 12
4.1 Brief description ..........................................................................................12
4.2 Construction ................................................................................................12
4.3 Function........................................................................................................12
4.4 Usage to the intended purpose ..................................................................12
5 OPERATION ............................................................................... 13
5.1 Commissioning............................................................................................13
5.2 Starting-up....................................................................................................13
5.3 Stopping .......................................................................................................14
5.4 Failures .........................................................................................................14
5.5 Emergency operation of the exhaust gas turbocharger...........................14
5.6 Measures for extended period without operation.....................................15
6 MAINTENANCE .......................................................................... 16
6.1 General .........................................................................................................16
6.2 Maintenance work........................................................................................16
6.3 Cleaning........................................................................................................17
6.4 Maintenance schedule.................................................................................18
6.4.1 Maintenance for operation with Marine Diesel Oil (MDO) ..............................18
6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO) ..................................19
6.5 Trouble-shooting table ................................................................................20

Contents HPR5000 Exhaust Gas Turbocharger
Chapter Title Page
7 DISASSEMBLY AND ASSEMBLY ............................................. 21

7.1 Introduction ................................................................................................. 21
7.2 Checking the components ......................................................................... 21
7.3 Test results.................................................................................................. 23
7.4 Clearance sheet .......................................................................................... 25
7.5 Work sheets................................................................................................. 26
7.5.1 Compressor washing .................................................................................... 26
7.5.2 Turbine washing............................................................................................ 27
7.5.3 Shutting down the exhaust gas turbocharger................................................ 29
7.5.4 Bearing check ............................................................................................... 30
7.5.5 Disassembly of the complete turbocharger ................................................... 31
7.5.6 Assembly of the complete turbocharger........................................................ 32
7.5.7 Assembly and disassembly of the silencer or air-intake housing .................. 33
7.5.8 Cleaning the silencer .................................................................................... 34
7.5.9 Assembly and disassembly of the compressor housing................................ 35
7.5.10 Disassembly and assembly of the cartridge.................................................. 36
7.5.11 Disassembly of the rotor, complete............................................................... 37
7.5.12 Assembly of the rotor, compl......................................................................... 39
7.5.13 Disassembly of the exhaust-gas elbow ......................................................... 42
8 SPARE PARTS AND TOOLS ..................................................... 43
8.1 General......................................................................................................... 43
8.2 Spare parts .................................................................................................. 44
8.2.1 Exhaust gas turbocharger, complete (1000) ................................................. 44
8.2.2 Exhaust gas turbocharger, basic unit (1100)................................................. 45
8.2.3 Cartridge (1200)............................................................................................ 46
8.2.4 Rotor (2000).................................................................................................. 47
8.2.5 Bearings (4000) ............................................................................................ 47
8.2.6 Turbine housing (5000) ................................................................................. 48
8.2.7 Compressor housing (6000).......................................................................... 49
8.2.8 Gasket set (9910) ......................................................................................... 50
8.2.9 Standard parts 1 (9920) ................................................................................ 51
8.2.10 Standard parts 2 (9930) ................................................................................ 52
8.2.11 Standard parts 2.1 (9931) ............................................................................. 52
8.3 Tools ............................................................................................................ 53
8.3.1 Tool Set (9800) ............................................................................................. 53
8.3.2 Optional tools ................................................................................................ 54

HPR5000 Exhaust Gas Turbocharger Chapter 1
1 TECHNICAL DATA
1.1 Operating data
Specification 458xxxx
Max. speed 41,500 rpm
Max. exhaust gas temperature upstream of turbine 650 °C
Lubricating oil
Types of lubricating oil: engine oil with a kinematic viscosity of 60 ... 115 mm²/s
at 50 °C, e.g. SAE30, SAE40
Nominal oil filter fineness upstream of TC max. 25 µm
Lubricating oil pressure upstream of TC 300 + 150 kPa
Admissible lubricating oil pressures for special operating states
at start-up min. 50 kPa
from start-up to idle running min. 50 kPa
at standstill (pre-lubrication or re-lubrication/standby mode) see diagram below
Lubricating oil temperature upstream of TC 40 ... 105 °C
Lubricating oil temperature downstream of TC max. 120 °C
Lubricating oil flow 20 ... 30 l/min
Sound power level (measured on silencer at 108 dB(A)
100 mm distance from compressor housing at 37,000 rpm
Counter-pressure downstream of turbine max. 2.5 kPa(g)
Vacuum upstream of compressor max. 1.5 kPa(g)
poil
(kPa)
toil (oC)
Admissible lubricating oil pressure for continuous pre- and re-lubrication
(standby operation)

Chapter 1 HPR5000 Exhaust Gas Turbocharger
1.2 Alarm values
Measurement Alarm value

TC speed 0.97 * n max
Exhaust gas temperature before turbine t max – 15K
Lubricating oil outlet temperature of TC < 120 °C
Lubricating oil pressure before TC > 125 kPa (1.25 bar)
If alarm values are adapted accordingly to the engine data, the values
specified above are not to be exceeded and/or be fallen below in the case
of lubricating oil pressure!
The maximum speed and the maximum exhaust gas temperature before
turbine are indicated on the name-plate and the test certificate!
1.3 Dimensions
All dimensions are specified in mm!
Length *) 1225 ... 1320

Width **) max. 610
Height **) max. 690
*) Exhaust gas turbocharger with silencer or intake housing and exhaust-gas elbow
**) Dimensions depend on the housing position
Exhaust gas Inlet single-nozzle housing 1x Ø 153 mm

Inlet double-nozzle housing 2x Ø 100 mm
Inlet three-nozzle housing 3x Ø 85 mm
Outlet Ø 300 mm
Charge air Outlet Ø 175 mm
Lubricating oil Inlet at bearing housing Ø 14.5 mm
Outlet at bearing housing Ø 45 mm
Compressor washing Air piping M18 x 1.5
Water piping M16 x 1.5
Turbine washing Water piping M18 x 1.5
Drainage Ø 75 mm
Further connection dimensions can be taken from the assembly drawing.

The piping for the pipe connections listed is not included in the scope of
supply of Kompressorenbau Bannewitz GmbH.
Pipes have always to be laid free of stress.
1.4 Test connections

The TC is equipped with the following test connections which can be used as required.
• There are two threads each (M18x1.5) provided at the air intake housing, compressor
housing and turbine-inlet housing and at the exhaust-gas elbow for measuring the
temperature and pressure.
• For measuring the speed, the bearing housing can be equipped with a speed sensor.
1.5 Weight of important subassemblies
Exhaust gas turbocharger, compl. *) 354 kg

Exhaust gas turbocharger, basic unit 265 kg
Insulation 16 kg
Silencer 40 kg
Air-intake bend 18 kg
Compressor housing 86 kg
Turbine housing 87 kg
Exhaust-gas elbow 46 kg
Cartridge (Bearing housing with rotor) 88 kg
Bearing housing 49 kg
Rotor 18 kg
Shaft 14 kg
Compressor impeller 4 kg
*) Basic unit including silencer and exhaust-gas elbow (see name-plate) without insulation
1.6

Vibrations
Maximum admissible vibration load at engine for 2 ... 250 Hz :
Admissible value at TC at silencer

(at place LG) (at place SD)
Velocity VRMS (mm/s) max. 45 mm/s max. 71 mm/s
Amplitude SRMS mm max. 0,7 mm max. 1,1 mm
Acceleration aRMS (m/s²) max. 70 m/s² max. 111 m/s²

2 SAFETY
The exhaust gas turbocharger has been designed on the basis of the following standards
and regulations:
1. EC machinery directive (89/392/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC)
2. EN 292 Parts 1 and 2: Safety of machines (fundamentals)
3. EN 294 Safety of machines; Safety distances to be kept to prevent the upper limbs
from reaching dangerous zones
2.1 Built-in safety systems

• A safety system for the turbocharger is not necessary as its design and connection with
the engine to which it is attached require an inherent safety.
• For general speed monitoring, i.e. without a turn-off function being included, the
turbocharger can be equipped with a tachometer.
Assembly and disassembly work must not be done during operation.

See chapters 7.5.1 and 7.5.2 for maintenance and cleaning jobs which
may be done while the engine is running.
2.2 Safety measures (to be taken by user)

• These operating instructions are part of the exhaust gas turbocharger and shall be
always accessible for the operators and maintenance personnel.
• The operating instructions should be read before commissioning the turbocharger.
Particular attention should be paid to directions and information relating to dangers.
The user is required
• to make his operators and maintenance personnel familiar with safe working methods
• to supervise the observance of the safety regulations.
The individual jobs in these instructions are described such that they can be understood by
skilled workers.
The necessary tools and testing/inspection means must be made available to these
workers.
The user must obtain permission to operate the unit from the local authorities and observe
the following:
1. labour safety
2. cleaning and maintenance of the machines
3. product disposal
4. environmental protection

3 GENERAL INFORMATION ABOUT DANGER
3.1 Danger zone

The danger zone is defined by the engine as the turbocharger is an integral part of the
engine.
During turbocharger operation, the user must keep the danger zone free
of any objects so to ensure unhindered access to the unit.
Ear muffs should be worn as the sound level is high. Care should also be
taken when approaching the hot housings.
• The exhaust gas turbocharger is mounted on the engine. It may not be interfered with
when the engine is running.
• Make sure the exhaust gas pipes at the turbine side cannot come loose during operation
since exhaust gas might escape at this point.
• As the exhaust gas turbocharger is an integral part of the engine, its operation is
described in connection with the engine. However, its maintenance is described
separately in the operating instructions.
3.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport,
assembly, installation, operation, setting, maintenance, cleaning and troubleshooting.
Make sure to observe the following accident prevention regulations:

• winches, hoisting and drawing gear (VBG 8)
• load take-up devices for hoisting operations (VBG 9a)
If these regulations are not observed, your life and limb may be endangered!
1. The turbocharger may only be maintained by duly qualified and authorised persons.
2. In maintaining the turbocharger, the responsibilities shall be clearly defined and must be
adhered to so as to prevent confusing competences with respect to the safety aspect.
3. The operating instructions shall be followed irrespective of what kind of work (operation,
maintenance, repair etc.) is concerned.
4. The cleaning, maintenance and repair work described in these instructions are easy to
understand by persons skilled in mechanical, cleaning and maintenance work.
The necessary tools and testing/inspection means must be available to these persons.
5. Operators are not allowed to interfere with the unit in a way that would affect machine
safety.
6. It is also within the responsibility of the operator to see to it that no unauthorized person
works on the turbocharger.

7. The operator must inform the user without delay of any safety-affecting changes to the
turbocharger.
8. In order to ensure a long service life, the exhaust gas turbocharger has to be operated in
accordance with the technical specification.
3.3 Installation of spare and wear parts

It is emphasised that spare parts and accessories not supplied by us are not
tested/inspected and approved by us. The installation and use of such products may
negatively affect the performance of your turbocharger. We assume no liability for damage
caused by the use of components and accessories not made by us.
For ordering spare parts and tools, please refer to the
• spare parts list
• tools list.
The spare parts lists attached (see chapter 8.2) contain all spare parts for the turbocharger.
DIN (standard) parts may be bought from specialised dealers.
For the assembly, disassembly and commissioning of the turbocharger, refer to the
respective chapters in these operating instructions.
Before doing any maintenance, cleaning or repair work, the engine must
have come to a standstill. Therefore turn the engine off and secure it
against unintentional re-starting.
See chapters 7.5.1 and 7.5.2 for maintenance jobs which can be done
during engine operation.
• load take-up devices for hoisting operations (VBG 9a).
If these regulations are not observed, your life and limb may be
endangered!
See the inspection schedule (see chapter 6.4) for the maintenance
intervals.

4 DESIGN
4.1 Brief description

Exhaust gas turbocharger (TC): Type HPR5000
Specification number: 458xxxx
Mass : 354 kg
4.2 Construction
The exhaust gas turbocharger (TC) HPR5000 is equipped with a single-stage radial flow
turbine and a single-stage radial flow compressor.
The turbine wheel and the shaft consist of one part, the compressor impeller is mounted on
the shaft. The rotor has a bearing consisting of two plain bearings in a bearing housing. The
compressor housing and the turbine housing are flanged to the bearing housing. You can
use a silencer or alternatively an intake housing (intake elbow) at the entrance of the
compressor housing.
The plain bearings are lubricated by the lubricating oil system of the engine. The lubricating
oil flow depends on the oil temperature, oil pressure and TC speed.
4.3 Function
The rotor is driven by the exhaust-gas energy of the diesel engine. The exhaust gases
reach the turbine wheel via the turbine housing and the turbine nozzle ring.
The compressor impeller mounted on the same shaft takes in the required combustion air
via a silencer, compresses the air to a higher pressure and transports the compressed air to
the engine via a charge air cooler.
The TC is not equipped with a special control device. The TC speed is adjusted depending
on the operating conditions of the engine.
4.4 Usage to the intended purpose

The exhaust gas turbocharger is intended for supercharging combustion engines. Any other
usage is not permitted and has to be cleared up with Kompressorenbau Bannewitz GmbH
(KBB) in advance.
Modifications and additional attachments to the TC are subject to a written consent of
Kompressorenbau Bannewitz GmbH, non-observance of the aforementioned invalidates
any rights of warranty claim.
The usage to the intended purpose also includes that the specified maintenance and
inspection work is carried out regularly and to the full extent (see Chapter 6.4).
The TC specification attached to the engine is thermodynamically adjusted and is binding
for this engine variant, i.e. if the TC has to be replaced, use the same TC specification
again.

5 OPERATION
5.1 Commissioning
Prior to commissioning, it is imperative to make sure that the plain bearings of the TC are
supplied with oil. The plain bearings are lubricated by the lubricating oil system of the
engine. The lubricating oil flow depends on the oil temperature, oil pressure and TC speed.
The lubricating oil pressures required for special operating conditions are listed in chapter
1.1.
Ensure and check the free return flow of the lubricating oil.
The following has to be checked :
• lubricating oil pressure upstream of TC,
• lubricating oil temperature upstream of TC.
• Ensure the lubricating oil supply of the plain bearings

(see chapter 1.1).
• Lubrication has to be started prior to start-up processes.
• Pay special attention to prevent leakages in the oil supply and return
pipes to prevent oil from flowing onto the hot, gas-carrying housings
in order to prevent the formation of hazardous oil vapours (and fire
risk).
5.2 Starting-up
The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started
together with the engine.
The TC speed is adjusted depending on the operating conditions of the engine. The charge
air pressure required for the engine is fixed by adjusting the turbine nozzle ring and the
compressor diffuser during the TC tuning.
If the corresponding meters are available, enter the following measured values into the
engine log during engine operation (at least once every 24 operating hours):
• Speed of exhaust gas turbocharger
• Exhaust gas temperature upstream of turbine or downstream of cylinder
• Charge air temperature downstream of compressor or downstream of charge air cooler
• Charge air pressure downstream of compressor
• Lubricating oil temperature upstream of TC
• Lubricating oil pressure upstream of TC
• The engine has to be stopped immediately when the oil pressure falls
below the minimum value.
• Pay special attention to prevent leakages in the oil supply and return
pipes to prevent oil from flowing onto the hot, gas-carrying housings
in order to prevent the formation of hazardous oil vapours (and fire
risk).
Additionally perform the following checks at regular intervals :

• Tightness of the exhaust gas, charge air and oil piping
• Smooth running of the exhaust gas turbocharger
The charge air pressure is utilised as a parameter for the exhaust gas turbocharger speed.
Unsteady operation (vibration of TC) indicates an increased unbalance of rotating parts
possibly resulting in the rotor or bearing being damaged (see chapter 6.5).
5.3 Stopping
After the engine has been stopped, the exhaust gas turbocharger continues to run for some
time.
The run out period depends on the installation.
If the rotor comes to an immediate standstill, this can be caused by one of the following
reasons:
• damaged bearings
• compressor impeller or turbine blades come in contact with the housing as the clearance
is compensated due to extensive forces caused by thermal distortion
• clamped foreign matters
The turbocharger must lubricated 15 minutes after the engine is turned

off.
The lubricating time is to be extended in case of engines with a turbine

inlet temperature >580°C (at full load) or oil inlet temperature >80°C.
Pay attention to the operating instructions of the engine manufacturer.
5.4 Failures
Failures can be detected by abnormal measured values (exhaust gas temperature, charge
air pressure, speed), heavy noise or leakages of lubricating oil pipes.
In case of irregularities on the TC, reduce the engine load or stop the engine.
Since even minor failures may cause heavy consequential damage, determine and
immediately eliminate the cause of failure (see chapter 6.5)
5.5 Emergency operation of the exhaust gas turbocharger

If the exhaust gas turbocharger has to be shut down due to a defect and the engine has to
run in emergency operating mode, perform the work according to chapter 7.5.3.
After shutting down the exhaust gas turbocharger, limit the engine output
in order to prevent the exhaust gas temperature from exceeding
admissible values downstream of the outlet valves.

5.6 Measures for extended period without operation

When shutting down an exhaust gas turbocharger, which was operated with an engine
before, for more than twelve month, it has to be dismounted from the engine.
An inspection should be carried out in accordance with the maintenance schedule in chapter
6.4.
It is necessary to completely dismantle the exhaust gas turbocharger. All components are to
be cleaned and slightly rubbed with oil. Then the exhaust gas turbocharger can be
reassembled. All machined surfaces and flanges are to be evenly coated with an
anticorrosive agent (such as Tectyl). All openings should be sealed. Additionally, a
hygroscopic drying agent can be put into the interior spaces of the compressor housing and
the turbine inlet.
The preserved exhaust gas turbochargers and spare parts should be kept in a dry room
(humidity of 60 % max.) and protected from moisture, aggressive gases and vapours. At
rest, the exhaust gas turbocharger should be protected against steady vibration which may
damage the bearings.
The state of the preserved parts and exhaust gas turbochargers should be checked every
twelve months.
Before re-operating the exhaust gas turbocharger, it is necessary to clean off the
anticorrosive agent.

6 MAINTENANCE
6.1 General
Maintenance and monitoring work is summarised in the maintenance schedule in chapter
6.4.
Proper maintenance work enables failures to be detected in time. Maintenance work also
indicates necessary overhauls as well as work to be scheduled during yard or harbour times
or on interruptions.
The operating hours specified in the maintenance schedule are to be considered as average
values. They can be extended or shortened according to existing operating conditions as
well as adjusted to the maintenance intervals of the engine.
It is important to eliminate even minor, apparently insignificant defects immediately and to
determine and eliminate their causes in order to prevent consequential damage at the
engine or exhaust gas turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording,
entries into the engine log are required at least once every 24 operating hours. Thereby,
deviations can be detected in time.
6.2 Maintenance work

In order to keep the exhaust gas turbocharger in a safe condition, perform the inspection
and check of various subassemblies and components according to the maintenance
schedule in chapter 6.4.
The chapter 7.5 includes detailed instructions on the work sequence for assembly and
disassembly work.

If bolts and nuts cannot be loosened immediately, do not apply excessive force in order to
avoid damage of threads causing subsequent machining. Apply diesel fuel and wait for half
an hour. In this way, "seizing" of threads can be avoided in most cases.
For bolted connections under heavy thermal load, bolts and nuts are made of high-
temperature material. Make sure that you do not confuse these bolts and nuts with
conventional ones during assembly work. In order to prevent burning and to facilitate
subsequent disassembly, apply a suitable bolt paste (e.g. molybdenum sulphide paste,
graphite) to those bolted connections prior to assembly. Contaminations have to be
previously removed from the threads.

During assembly, all bolted connections equipped with locking elements (lock nut, locking
plate, spring washer) have to be properly locked.
For a basic overhaul or repairs affecting essential parts of the exhaust

gas turbocharger, it is recommended to document their condition. The
"Test results" form can be used as a sample (see chapter 7.3).
6.3 Cleaning
Cleaning the silencer
• see chapter 7.5.8
Cleaning the compressor

• Cleaning during operation: see chapter 7.5.1
• Mechanical cleaning: see chapters 7.5.7 and 7.5.8
Remove the compressor housing and silencer. (The compressor impeller remains on the
shaft.) Remove all deposits with diesel fuel or another admissible liquid cleansing agent.
Make sure to observe the accident prevention regulations!

While washing, make sure to prevent the cleansing agent from entering
the charge air piping or the interior of the turbocharger.
Cleaning the turbine

• Cleaning during operation: see chapter 7.5.2
(for heavy fuel oil operation only)

6.4 Maintenance schedule
6.4.1 Maintenance for operation with Marine Diesel Oil (MDO)
The operating hours given in the table are guidelines, which can be
reduced for adjustment to the maintenance intervals of the engine.
Item Chapter Maintenance work Required Maintenance interval

parts (operating hours)
1. Check for abnormal noise 24
2. 7.5.1 Compressor washing during 24 - 48

operation, actuate compressor
washing system
3. 7.5.8 Clean air filter at silencer approx. 250
or on demand
4. Check fastening bolts at the feet, once after
tighten all housing bolts and commissioning, then
piping joints every 1,000 hours
5. 7.5.4 - Inspection I (9910) max. 12,500
7.5.12 • disassembly (9920)
• cleaning (9930)
• checking of rotor & bearings
• checking of housings
• assembly
6. 7.5.4 - Inspection II (4000) max. 25,000
7.5.12 • like inspection I (9910)
• replacement of the bearings (9920)
(9930)
7. 7.5.4 - Inspection III (2000) max. 50,000
• replacement of the rotor (9910)
(9920)
(9930)
(2000) Rotor (9910) Set “Gaskets”

(4000) Bearings (4010) and (4020) (9920) Set “Standard parts 1”
(9930) Set “Standard parts 2”

6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO)
The operating hours given in the table are guidlines, which can be
reduced for adjustement to the maintenance intervals of the engine.
The interval of the inspection “I” are to be shortened dependent on the
fuel quality.
Item Chapter Maintenance work Required Maintenance

parts interval
(operating hours)
1. Check for abnormal noise 24

2. 7.5.1 Compressor washing during 24 - 48
operation, actuate compressor
washing system
3. Turbine washing during operation, Approx. 300
actuate turbine washing system depending on HFO
7.5.2 Cleaning with water quality
4. 7.5.8 Clean air filter at silencer Approx. 250
or on demand
5. Check fastening bolts at the feet, once after
tighten all housing bolts and piping commissioning, then
joints every 1,000 hours
6. 7.5.4 - Inspection I (9910) max. 12,500
7.5.12 • disassembly (9920)
• cleaning (9930)
• checking rotor and bearings
• checking housing
• assembly
7. 7.5.4 - Inspection II (4000) max. 25,000
• replacement of bearings (9920)
(9930)
8. 7.5.4 - Inspection III (2000) max. 50,000
• replacement of the rotor (9910)
• assembly (9920)
(9930)
(2000) Rotor (9910) Set “Gaskets”

(4000) Bearings (4010) and (4020) (9920) Set “Standard parts 1”
(9930) Set “Standard parts 2”
The nozzle ring is subject to an increased wear for heavy fuel oil
operation. Therefore it is a wear part.
The lifetime of the nozzle ring is approximately 12,500 hours, but it
depends on HFO quality and operating conditions.
After exceeding the lifetime the nozzle ring should be replaced in case of
fundamental change of performance data as charge air pressure and
exhaust temperature.

6.5 Trouble-shooting table
Charge air pressure and/or speed too high

Charge air pressure and/or speed too low
Temp. upstream of turbine too high
Fault
Lubricating oil pressure too low

Delayed start, short coasting
Lubricating oil leakage
Turbocharger vibrates
Turbocharger pumps
Heavy noise
Causes Chapter
Silencer or air filter contaminated 7.5.8
Compressor contaminated 7.5.8
Charge air cooler contaminated Engine
Leaking exhaust gas piping Engine
Exhaust gas counter pressure too high Engine
downstream of turbine
Turbine wheel or compressor impeller 7.5.10 -
damaged (unbalanced) 7.5.12
Defective bearing 7.5.4
Rotor in contact with housing 7.5.11
Foreign matter in turbine or compressor 7.5.8,
(unbalanced) 7.5.10
Turbine contaminated 7.5.2
Turbine nozzle ring contaminated 7.5.2
Failure of fuel injection at engine Engine
Leaking charge air piping Engine
High air intake temperature Engine
Inlet or outlet valves of the engine Engine
contaminated
Low air intake temperature Engine
Lubricating oil filter contaminated Engine
Lubricating oil pressure gauge defective Engine
Lubricating oil inlet temperature too high Engine
Excessive pressure in oil return Engine
Sealing air ineffective
Gaskets damaged, connections leaking
Plain compression rings damaged 7.5.11

7 DISASSEMBLY AND ASSEMBLY
7.1 Introduction
The chapter 7.5 shall enable the user to perform certain repair and maintenance work by
himself.
Work sheets are sorted according to the sequence required to disassemble the exhaust gas
turbocharger.
It is assumed that the staff is familiar with the work and that the tools required are ready at
hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding
hoists have to be available.

7.2 Checking the components

The check list shown below can be used as instruction for checking the condition of the
exhaust gas turbocharger and its major components. As a rule, the user is able to eliminate
minor damage. Major damage effecting rigidity, balance and smooth running of rotating
components should be eliminated by the manufacturer or an authorized workshop. If
damaged parts are returned for repair, ensure an appropriate protection against
transportation damage.
After having disassembled the exhaust gas turbocharger, perform the following checks at
the cleaned parts. The condition is to be recorded in the "Test results" form, chapter 7.3.
Rotor, compl. - Are the turbine blades damaged or did they contact the housing?
- Are contact traces visible at the housing?
- Are contact traces visible at the rotor?
- Does the shaft run smoothly?
- How is the condition of the bearings?
- Are the plain compression rings heavily worn?
If re-working is performed or if rotor parts are replaced, rebalancing has

to be executed! For admissible residual unbalance, refer to clearance
sheet, chapter 7.4)
Wear occurs at the plain compression rings at the turbine and

compressor sides in axial direction during running-in, which is intended
and could be max. 0.5 mm.
Compressor impeller
- Can you detect any sliding traces or cracks at the compressor impeller?
- Are the bore and the axial surface OK?

Bearing - Is the axial clearance of the rotor impeller inadmissible high?
- Are the running surfaces of the compressor and/or turbine bearings heavily
worn?
For evaluation of bearings, refer to chapter 7.5.4 .
Turbine nozzle ring

- Are the guide vanes twisted or worn out?
- Is foreign matter clamped into the ducts?
- Can you detect traces of foreign matter?
Housing - Are the housings heavily contaminated by oil, dust or soot?

- Is there any leakage at the housing? (Main items: connection flanges, charge
air, exhaust gas and oil connections)
- Are all bolts and nuts tight?

7.3 Test results
Exhaust gas turbocharger: Serial No. :

Specification No. :
Type of engine : Engine No. :
Customer name :
Address :
(Location, ship's name)
Latest inspection/overhaul on : by :
Inspected/overhauled on : by :
Number of operating hours - since commissioning:

- since latest inspection/overhaul:
Results of the inspection of components

Rotor/ Shaft
Turbine blades O no
damaged O yes
O blade parts missing
O traces of foreign matter
Contamination / deposit O no
on rotor blades O slight Plain compression O no
O heavy ring damaged O yes
O unilateral
O uniform Radial deviation of rotor
(acc. to Clearance sheet) ........
mm
Blades tarnished O no Blade cracks O no
O yes O yes
Location : ..............
Gap: turbine wheel/housing Gap: compressor impeller/housing
(acc. to clear. sheet) (acc. to clear. sheet)
Clear.S12 : .......mm Clear.S1 : .......mm
Clear.S14 : .......mm Clear.S2 : .......mm
Sliding traces O no Rotor rebalanced O no
at shaft O yes O yes
Bearing seats O no Condition prior to O good
damaged O yes rebalancing O poor
Compressor impeller
Sliding traces O no Blade cracks O no
O yes O yes
Location: ............... Location : .............
Contamination O clean Quality of O good
O contaminated bore O average
O oily O poor

Turbine nozzle ring

Guide vanes O good O Part torn out
O twisted O Traces of foreign matter
O scaled O worn out
Bearing housing
O clean Sealing air bores O clean
O coked O narrowed
O corroded O clogged
Compressor diffuser
Guide vanes O little Damage O no
contamination O heavy O yes
Location : ...............
Compressor bearing
O used
O replaced Reason ................
Load-carrying surface of radial bearing Load-carrying surface of thrust bearing
B(rad) : ................ mm B(ax) : ................. mm
Marks O no Marks O no
O yes O yes
Location: ............Depth : ................. mm Location: ................Depth: ................... mm
Turbine bearing
O used Load-carrying surface
O replaced B(rad) : ................ mm
Reason................
Marks O no
O yes Location: ...............Depth: ................. mm
Silencer
Contamination O oil Condition of felt layer O good
O dust O poor
O soot
Filter mat O yes
cleaned O no
Other defects/ component/ type :

7.4 Clearance sheet
V a l u e s (in mm)
New condition Limit
clear.
Clear. Parts designation min max
max *)
1 Compressor impeller - compressor housing (radial) 0.55 0.65 0.9
2 Compressor impeller - compressor housing (axial) 0.6 0.7 1.1
5 Tilting clearance (rotor – bearing) <0.6 0.8
(measured at location E)
12 Turbine wheel - turbine housing (radial) 0.55 0.65 0.9
14 Turbine wheel - turbine housing (axial) 0.4 0.7 1.0
15 Rotor - compressor bearing (axial) 0.12 0.2 0.23
18 Compression ring - turbine bearing cover 0.2 0.5 -
19 Compression ring - compressor bearing cover 0.1 0.3 -
*) re-working or replacement required if exceeded
**) measured at location E
Admissible unbalance of rotor: 13.25 gmm bearing compressor
and 13 gmm bearing turbine
Admissible radial deviation of rotor: 0.020 mm (location E)
Tightening torque of rotor nut: 105 (+ 5) Nm
Clear. 19 (S19 = L2 – L3) Clear. 18
a) compressor b) compressor
X – reference edge bearing housing bearing fixed bearing loosened

7.5 Work sheets

7.5.1 Compressor washing
(Every 25 - 50 operating hours)

Legend
1 Ball valve
2 Water tank
3 Water piping
4 Air piping
Work sequence:
1. Operate the engine close to full load.
2. Open the water tank (2), fill with clean water (no sea water) (approx. 0,5 l), close the
water tank.
3. Open the ball valve (1), wait for approx. 20 sec., close valve (1). The compressed air
flows through the air piping via the ball valve (1) into the water tank. The water is
pressed through the water piping into the injection pipe, atomised by the air taken in
and hits the compressor blades at high speed.
• Perform cleaning with warm engine close to full load operation only.
• Continue to operate the engine for at least 10 to 15 min. after cleaning.
• Do not wash before a pause of operation. Corrosion risk!
• Washing is ineffective in case of hardened deposits, thus perform
washing at regular intervals.
• Do not use any chemical additives!
If the negative pressure upstream of the compressor is too high, water is
already taken in when the water is filled into the water tank and the
cleaning effect is reduced. In order to avoid this, you can:
• install the water tank at a lower level or
• include a second stop valve, which is opened after the water tank has
been closed, into the water piping.

7.5.2 Turbine washing
(For heavy fuel oil operation only, every 300 operating hours respective depending on HFO
quality)
Heavy fuel oil operation results in contamination and deposits on nozzle
ring and turbine wheel reducing the efficiency. Due to these deposits the
charge air pressure will be increased.
The washing intervals depend on the fuel quality and operating
conditions. That's why they must be adjusted based on the experience
gained during engine operation if necessary later on.
The increase of charge air pressure by for e.g. more than 0.1 bar (at same
engine power) could be used for adjusting the washing interval, which
could be adjusted within 25 to 600 hours.
Read and take down the charge air pressure and exhaust gas
temperatures at a reference point (at 75 % or 100 % of the output) before
and after washing to check the washing effect.
Legend (Example, could vary depending on engine installation)

1 Sanitary fresh water 6 Wash-water piping 10 Escape funnel or sight glass
2 Regulating valve 7 Injector (optional)
3 Fresh-water piping 8 Connection for drain 5000 Turbine housing
4 Removable flexible tube (optional) 9100 Exhaust gas elbow
5 Stop valve 9 Valve (optional)
Work sequence:
1. Check injection nozzle/ valve (7) for free passage!
2. Connect the flexible tube (4) to fresh-water piping (3).
3. Reduce the engine output so that the temperature before turbine has come down
to its specified value. (see table)
If the temperature before turbine is not available, the temperature after

turbine can be used as reference point!
4. Wait for approx. 10 minutes!

5. Open the valve (9) of the drain (8) (if present).
6. Open valve (2) and adjust the water pressure (see table).
7. Open stop valve (5) for approx. 30 seconds and close again.
8. Wait for approx. 3 minutes so that the injected water can evaporate.
9. Repeat steps 7. and 8. twice or three times.
10. Close the stop valve (5), valve (2) and the valve (9) of the drain.
11. Run dry the exhaust gas turbocharger at constant load for approx. 30 minutes,
increase engine load slowly!
12. Repeat the washing process if the exhaust gas turbocharger is affected by vibrations
which did not occur before.
13. Remove the flexible tube (4).
The effect of the turbine washing could be controlled by changing of

charge air pressure and exhaust temperature!
Water pressure and washing period could be increased for improvement
of washing effect, if necessary!
Operating values for turbine washing
Exhaust gas Exhaust gas Exhaust gas Water Total

temperature temperature temperature pressure washing
before turbine after turbine after cylinder (gauge) period
400 – 420 °C <330 °C 300 – 330 °C 2.5 – 4.5 bar 3-4x 30 sec
• Hot exhaust gas can escape from the drain - Risk of burning!
• Continue to operate the engine for at least 30 minutes after cleaning.
• Do not wash before a stop of operation. Corrosion risk!
• Washing is ineffective in case of hardened deposits, thus perform
washing at regular intervals from the beginning.
• In the case of ineffective washing the turbine is to be cleaned
mechanically. For this purpose the turbine housings are to be
dismantled.
• Pay attention also to instruction of the engine’s operating manual!

7.5.3 Shutting down the exhaust gas turbocharger
In case of a TC damage especially at the rotor or bearing, it is

recommended to shut down the TC in order to avoid any further damage.
When the engine is operated with a defective exhaust gas turbocharger,

limit the engine output in order to prevent the exhaust gas temperature
from exceeding admissible values downstream of the cylinder.
Related chapters
7.5.7, 7.5.9, 7.5.10
Initial condition: The turbocharger is mounted on the engine.

Mass of the silencer approx. 40 kg
Mass of the air intake housing approx. 18 kg
Mass of the compressor housing approx. 86 kg
Mass of the cartridge (bearing housing with rotor) approx. 88 kg
Mass of the sealing device (9804) approx. 26 kg
Work sequence:
1. Disassemble the silencer (9010) / air intake housing (9020) (see chapter 7.5.7).
2. Loosen all piping at the compressor housing (6010).
3. Disassemble the compressor housing (6010) (see chapter 7.5.8).
4. Remove the cartridge (1200) (bearing housing with rotor) and turbine nozzle ring
(7010) from the turbine housing (5010) (see chapter 7.5.10).
Use a hoist!
Caution in removing the cartridge in order to avoid damage to the turbine

blades.
5. Attach the sealing device (9804) to the turbine housing (5010) and tight with washers
(5100) and hexagon nuts (5090).
6. Screw the sealing device (9804) to the engine console.

7.5.4 Bearing check
Related chapters 7.5.7 to 7.5.11

New bearing
Thrust bearing (4020)
Sliding surface
Radial bearing (4010/4020)
Wedge-
shaped
Load- sector
carrying
surface
Legend
D Bearing diameter
R Radius of wedge surface
B(ax) Load-carrying surface width of
thrust bearing Bearing after
B(rad) Load-carrying surface width longer
of radial bearing operation
Tools required Sliding surface
1 Micrometer screw
1 Caliper gauge
Initial condition: Compressor bearing (4020) and turbine bearing (4010) are disassembled.
Work sequence 1 : Load-carrying surface of radial bearings
1. Carefully clean the bearing!
2. Determine the width of the load-carrying surface B(rad)!
3. Visual inspection!
Replace bearing if :
• the width of the load-carrying surface B(rad) at the compressor and
turbine has reached 16 mm,
• heavy dirt marks can be seen.
Determine the causes!
Work sequence 2 : Load-carrying surface of thrust bearings

1. Carefully clean the bearing.
2. Determine the width of the load-carrying surface B(ax).
3. Determine the axial clearance S15.
4. Visual inspection!
Replace bearings if :
• B(ax) is larger than 2/3 of the sliding surface,
• the sliding surfaces reveal heavy dirt marks.
If bearing material is deposited on the bearing surfaces of the shaft, a

repair is required in an authorized workshop.

7.5.5 Disassembly of the complete turbocharger
a)
b)
Mass of complete TC is approx. 354 kg

Pay attention to piping and sheathings!
Work sequence :
1. Remove the sheathings from the turbine housing and loosen the exhaust gas piping if
necessary.
2. Loosen the exhaust gas piping from the turbine housings. Pay attention to gaskets!
3. Loosen the piping at the compressor housing (6010), remove them if necessary.
4. Attach the exhaust gas turbocharger to a hoist. For this purpose
a) Screw the eye screw into the bearing housing (3010) or
b) Put two ropes around the flange between the silencer and the compressor housing
and between the turbine housing and the exhaust-gas elbow.
5. Loosen and remove the fastening screws at the sides of the bearing housing (3010).
6. Lift and carefully place the exhaust-gas turbocharger on a wooden base, secure
against tilting.
7. Cover the openings of the lubricating oil pipes in the engine console in order to prevent
dirt from entering the lubricating oil system.

7.5.6 Assembly of the complete turbocharger
a)
b)
Mass of complete TC is approx. 354 kg

Pay attention to piping and sheathings!
Work sequence :
1. Attach the complete TC to a hoist (see chapter 7.5.5) and put it onto the engine
console. Pay attention to the pipe connections!
2. Screw in and tighten the fastening screws at the sides of the bearing housing (3010).
3. Connect the exhaust gas piping to the turbine housings.
4. Attach the sheathing.
5. Connect the charge air piping.
6. Connect the water and air piping for compressor washing.
7. Tighten the bolts at the connecting pipes.
8. Supply lubricating oil to TC and check all flanged connections for leakages.
After having installed the TC, check that the assembly is free of stresses
and forces. Rework piping, if necessary.
Only use perfect gaskets for the pipe joints. Apply molybdenum sulphide
lubricant to the connecting bolts of the exhaust gas piping prior to
installation.

7.5.7 Assembly and disassembly of the silencer or air-intake housing
Mass of the silencer approx. 40 kg

Mass of the air-intake housing approx. 18 kg
Tightening moment of V-band 35 Nm !
Work sequence 1 : Disassembly of silencer / air-intake housing
1. Put a rope around the silencer (9010) or intake housing (9020) and attach it to a hoist.
2. Slightly loosen the V-band (6020) at both screws (6190).
3. Remove the V-band (6020) from the flange.
4. Pull off the silencer/air-intake housing in axial direction from the compressor housing
(6010).
Work sequence 2 : Assembly of silencer / air-intake housing
1. Put a rope around the silencer (9010) or intake housing (9020) and attach it to a hoist.
2. Slide silencer / air-intake housing in axial direction onto the compressor housing
(6010).
3. Install the V-band (6020) and tighten at both screws (6190).

7.5.8 Cleaning the silencer
(Every 250 or 12,500

operating hours)
Related chapter 7.5.7
General
In most cases merely the filter mat has to be cleaned. For this purpose the silencer may
stay at the exhaust gas turbocharger.
The given maintenance interval of 250 operating hours is just a mean guide value, since the
accumulation of dirt in the filter mat and the pressure drop resulting therefrom are largely
dependent on the environment. For operation under extreme conditions, it is recommended
to add a maintenance indicator (water gauge) signalling the right moment for cleaning.
This indicator shall be adjusted so as to give the cleaning signal when a vacuum of
app. 100 mm w.g. is reached at point A intended for mounting (e.g. a MANN maintenance
indicator for air filters, max. 200 mm w.g. = 20 mbar).
Work sequence: Cleaning the filter mat
1. Open and remove the tension tapes (9014)
2. Pull the filter mat (9012) from the silencer (9010) .
3. Put the filter mat (9012) into a cleansing liquid for approx. 10 hours. Subsequently
rinse in the liquid and externally clean with a soft brush, stub out and let dry the filter
mat.
4. Install the filter mat (9012) and tension tapes (9014).
Work sequence: Cleaning the silencer
If the silencer is heavily contaminated or if an inspection is carried out,
the silencer has to be cleaned completely..
1. Dismount the silencer (9010) (see chapter 7.5.7).

2. Put the silencer for approx. 10 hours into a cleansing liquid. Subsequently, externally
clean with a soft brush and let dry.
3. Install the silencer (9010).
To operate the exhaust gas turbocharger without a filter mat is not
permitted!
Pay attention to applicable accident prevention regulations (handling of
hazardous, volatile, combustible solvents) and fire protection regulations
(DIN 14096). Cleaning by P3-solution or trichlorethylene is prohibited. If
other solvents are used, check the compatibility with the filter material. In
case of ship operation pay attention to the regulations of the
classification societies with regard to washing liquids.

7.5.9 Assembly and disassembly of the compressor housing
Mass of cartridge (bearing housing with rotor) approx. 88 kg.

Mass of compressor housing approx. 86 kg.
Make sure not to damage the compressor impeller during assembly and
disassembly of the compressor housing.
Work sequence 1 : Disassembly of the compressor housing
1. Slightly loosen the hexagon nuts (6160) at the clamping flanges (6140).
2. Turn the compressor housing (6010) until the eye bolt can be attached to the hoist.
3. Completely loosen and remove the clamping flanges (6140).
4. Remove the compressor housing (6010) and put it on a wooden base.
5. Loosen and remove the screws (6070) and washers (6080).
6. Remove the compressor housing (6010) from the insert (6040), pay attention to the
shims (6131 – 6135).
7. Loosen and remove the screws (8040) together with stop bushings (8020).
8. Remove the compressor diffuser (8010).
9. Remove O-rings (6030, 6090 and 8030) and check for damage.
Work sequence 2 : Assembly of the compressor housing
1. Install and, if necessary, replace the O-rings (6030, 6090 and 8030).
2. Lay the insert (6040) with shim (6131 – 6135) according to clearance S2 on a wooden
base. And then lay the compressor housing (6010) on the insert (6040).
3. Tighten the insert (6040) with screws (6070) and washers (6080).
4. Slide the compressor diffuser (8010) onto the bearing housing centring (3010) and
fasten with the stop bushings (8020) and screws (8040).
5. Attach the compressor housing (6010) to a hoist and slide it onto the bearing housing
(3010).
6. Install the clamping flanges (6140) and slightly fasten with washers (6170) and
hexagon nuts (6160).
7. Turn the compressor housing (6010) into the required housing position.
8. Tighten the hexagon nuts (6160) at the clamping flanges (6140).
• Mark the position of the compressor housing (6010)!

7.5.10 Disassembly and assembly of the cartridge
Mass of cartridge (bearing housing and rotor) approx. 88 kg.

Mass of the turbine housing approx. 87 kg.
Caution in disassembling and assembling in order to avoid damage to the
turbine blades.
Caution in disassembling the turbine housing in order to prevent the
turbine nozzle ring from falling out!
Work sequence 1 : Disassembly of the cartridge
1. Loosen and remove the hexagon nuts (5090) and washers (5100).
2. Screw eye bolt into the bearing housing (3010) and attach it to a hoist.
3. Loosen and remove both screws on the side of bearing housing (3010).
4. Forcing-off uniformly the bearing housing (3010) with forcing screws. Are the
connection with carbon glued, net with diesel fuel and wait a minute.
5. Move careful the bearing housing (3010) out of the turbine housing (5010) in axial
direction. Put it on a wooden base.
6. Remove the turbine nozzle ring (7010) from the turbine housing (5010).
Work sequence 2 : Assembly of the cartridge
1. Clean the connecting flange between the bearing housing and turbine housing from
combustion residues using fine abrasive cloth. Subsequently, apply a molybdenum
sulphide lubricant to the flange.
2. Insert the turbine nozzle ring (7010) into the turbine housing (5010), pay attention to
the position of the locating bolts (7020)!
3. Fasten the bearing housing (3010) by means of a rope at the hoist and move it towards
the turbine housing (5010)
4. Carefully slide the bearing housing (3010) into the turbine housing. Screw fast the
hexagon nuts (5090) with washers (5100).
5. Tighten the screws for the feet on the engine console.
6. Check the rotor for contact by slightly rotating it.

7.5.11 Disassembly of the rotor, complete
For disassembling the rotor, mount the cartridge on a rack (9822) (see
chapter 8.3.2).
Mass of the cartridge (bearing housing and rotor) approx. 88 kg

Mass of the complete rotor 18 kg
Work sequence :
1. Disassemble the speed sensor (9110) - if provided – and remove it.
2. Put the locking device (9801) on the turbine wheel and attach the device to the flange
of bearing housing (3010).
3. Loosen the rotor nut (2060) with a torque spanner.
4. Remove the rotor nut (2060) and coupling disk (2050).
5. Carefully remove the compressor impeller (2040) from the shaft (2010).
The installation position of the compressor impeller in relation to the

shaft is marked or has to be remarked with a scriber.
6. Loosen the screws (3090).

7. Remove the bearing cover of the compressor (3040); if necessary force off the cover
with screws (3090). The plain compression ring (2090) is located in the bearing cover.
Pay attention to the gaskets (3081/3/5) under the bearing cover (3040)!
8. Remove the spacer (2030) from the shaft.

10. Remove the compressor bearing (4020), force off if necessary.

11. Put the extractor (9803) on the shaft (2010) and screw it into the threads of the thrust
ring (2020).
12. Remove the thrust ring (2020) from the shaft.
13. Carefully pull the shaft (2010) out of the bearing housing (3010).
14. Remove the plain compression ring (2070) from the shaft.
15. Remove the feather key (2080) from the shaft.
16. Remove the heat shield (3030).

17. Pull the bearing guide sleeve (3020) out of the bearing housing (3010) by using forcing
screws, do not cant.
Pay attention to the gaskets (3081/3/5) under the bearing guide sleeve
(3020)!
18. Loosen the screw plugs (3120), remove the separating plate (3060).
19. Loosen the screw plug (3200) with spring washer (3210).
20. Pull the turbine bearing (4010) out of the bearing guide sleeve (3020).
Now the turbocharger is disassembled. Check, evaluate and clean the
parts according to chapters 7.2 and 7.3.

7.5.12 Assembly of the rotor, compl.
Related chapters 7.5.5 - 7.5.11
Mass of the cartridge (bearing housing and rotor) approx. 88 kg

Mass of the complete rotor 18 kg
• For assembling the rotor, mount the bearing housing on an

assembling trestle.
• Prior to the assembly, check the cleanliness of the bearing housing,

oil-conducting ducts and sealing air piping.
• If all components and gaskets are to be reused, it is not necessary to

check the clearances, otherwise pay attention to the specification
given in the clearance sheet, chapter 7.4.
Work sequence :
1. Insert the turbine bearing (4010) into the bearing guide sleeve (3020) and tighten with
the screw plug (3200) and washer (3210).
2. Check that the thread plug (3110) is screwed into the bearing guide sleeve (3020)!
Always install the turbine bearing (4010) with 3 cylindrical pins (4050)
(protection against torsion)!
Always insert the thread plug (3110) in the bearing guide sleeve (3020). Do
not forget the thread plug when components are replaced!
3. Insert the separating plate (3060), fasten with screw plugs (3120).
4. Insert the bearing guide sleeve (3020) with the original gasket (3081/3083/3085) or a
gasket of the same thickness into the bearing housing (3010), do not cant.
5. Fasten the bearing guide sleeve (3020) with two screws.
6. Attach the heat shield (3030) to the centring on the bearing housing.

7. Insert the plain compression ring of the turbine (2070) into the shaft groove.
8. Insert the feather key (2080) into the groove.
9. Use the guide sleeve (9805) to move in the shaft.
10. Apply clean oil to the turbine bearing. Carefully insert the shaft (2010) into the bearing
housing (3010).
11. Apply oil to the thrust ring (2020) and put the ring onto the shaft.
12. Apply oil to the compressor bearing (4020). Put the bearing onto the shaft with its flat
flange side pointing downward and fasten with screws (3100) and washers(3130).
13. Check clearance S18: (only if components are replaced)
a) b)
a) Fasten the compressor bearing (4020) with the screws (3100). Press the
shaft (2010) against the bearing housing. Apply a dial gauge to the shaft end
and adjust it to zero.
b) Loosen the screws (3100) and again force-off the compressor bearing
(4020) by approx. 1 mm. The shaft is displaced by the clearance S18; correct by
changing the thickness of the gasket (3081-3085) under the bearing guide sleeve if
necessary.
14. Attach the locking device (9801) for the rotor to the turbine wheel and fasten it to the
flange of the bearing housing.

15. Slide the spacer (2030) onto the shaft up to the shoulder; pay attention to the assembly
position.
16. Check clearance S19: (S19 = L2 – L3)
(X – reference edge at bearing housing)
• Determine the dimension L3.

• Again remove the spacer (2030).
• Install the compressor bearing cover (3040).
• Determine the dimension L2 and calculate S19 (S19 = L2 – L3).
• Correct S19 by changing the thickness of the gasket under the compressor
bearing cover (3040).
17. Install and fasten the compressor bearing cover (3040) with screws (3090) and
washers (3130).
18. Insert the plain compression ring (2090) into the bearing cover (3040).
19. Slide the compressor impeller (2040) onto the shaft (2010); pay attention to the
assembly position.
20. Grease the threads with a lubricant containing MoS2. Install the coupling disk (2050)
and rotor nut (2060).
The mounting marks at the shaft and the compressor impeller must
match.
Lock the rotor by means of the locking device (9801). It is imperative to

use a universal joint with the torque spanner!
21. Tighten the rotor nut (2060) with 105 Nm.

22. Check the rotor for smooth running: Slowly rotate the rotor. It must be possible to
rotate the rotor easily without sensible resistance.
23. Check the rotor for truth of rotation: Apply a dial gauge to the end of the compressor
impeller and measure the radial run-out of the rotor while slowly rotating the rotor. For
the radial run-out refer to the Clearance sheet in chapter 7.4.
Now the bearing housing with rotor is assembled. The exhaust gas turbocharger can be
completed according to chapters 7.5.5 to 7.5.10.

7.5.13 Disassembly of the exhaust-gas elbow
Mass of the exhaust-gas elbow 46 kg
Initial condition: Exhaust gas piping is disassembled.
Work sequence:
1. Attach the exhaust-gas elbow (9100) by means of a rope to a hoist.
2. Loosen and remove the hexagon nuts (5090) together with the washers (5100).
3. Remove the exhaust-gas elbow (9100) in axial direction from the turbine housing
(5010) and put it on a wooden base.
5. Force the turbine housing insert (5020) with forcing screws off the turbine housing
(5010).

8 SPARE PARTS AND TOOLS
8.1 General
The following details are required for an order:
1. Address of orderer
2. Type of turbocharger
3. Serial number of turbocharger (see name-plate on page 2)
4. Specification number of turbocharger (see name-plate on page 2)
5. Part number, designation and quantity
6. Shipment address
The spare parts box supplied by order contains a selection of the most important wear parts
and a relevant listing.
The parts contained in the spare parts box are preserved for a storage
period of two years.
A certain selection of tools is also supplied if ordered. These tools are necessary to maintain
and repair the exhaust gas turbocharger and are not included in the basic equipment of
every workshop.

8.2 Spare parts
8.2.1 Exhaust gas turbocharger, complete (1000)
Part No. Quantity Designation Remarks

1200 1 Cartridge
3140 1 Screw plug only available within the 'Standard parts 1' (9920) set
3150 1 Gasket only available within the 'Standard parts 1' (9920) set
5000 1 Turbine housing
6000 1 Compressor housing
6020 1 V-band
6190 2 Hexagon socket screw only available within the 'Standard parts 1' (9920) set
9010 1 Silencer
9012 1 Filter mat
9014 2 Tension tape
9020 1 Intake housing
9040 1 Gasket only available within the gasket set (9910)
9050 2 Screw plug only available within the 'Standard parts 2 ' (9930) set
9055 1 Screw plug only available within the 'Standard parts 2 ' (9930) set
9100 1 Exhaust gas elbow
9101 3 Flange
9102 12 Hexagon screw only available within the 'Standard parts 2 ' (9930) set
9103 12 Ripped washer only available within the 'Standard parts 2 ' (9930) set
9110 1 Speed sensor or screw plug (3140) with gasket (3150)

8.2.2 Exhaust gas turbocharger, basic unit (1100)

1200 1 Cartridge
5090 36 Hexagon nut only available within the 'Standard parts 2' (9930) set
5100 36 Ripped washer only available within the 'Standard parts 2' (9930) set
6030 1 O-Ring, compressor only available within the gasket set (9910)
housing
6140 8 Clamping flange
6150 24 Stud bolt only available within the 'Standard parts 1' (9920) set
7010 1 Turbine nozzle ring
7020 3 Locating bolt only available within the 'Standard parts 2' (9930) set
8010 1 Compressor diffuser
8020 2 Stop bushing only available within the 'Standard parts 1' (9920) set
8030 1 O-Ring, compressor only available within the gasket set (9910)
diffuser

8.2.3 Cartridge (1200)

2000 1 Rotor
3010 1 Bearing housing
3020 1 Bearing guide sleeve
3030 1 Heat shield
3040 1 Bearing cover, compressor
3060 1 Separator plate
3081 *) Gasket, bearing cover (0.1) only available within the gasket set (9910)
3110 1 Thread plug only available within the 'Standard parts 1' (9920) set
3210 1 Spring washer only available within the 'Standard parts 1' (9920) set
4010 1 Turbine bearing complete
4020 1 Compressor bearing
4050 3 Cylindrical pin also available within the 'Bearings' (4000) set
*) according clearance setting

8.2.4 Rotor (2000)

2010 1 Shaft
2020 1 Thrust ring
2030 1 Spacer
2040 1 Compressor impeller
2050 1 Thrust disc/Driving plate
2060 1 Rotor nut
2070 1 Compression ring also available within the gasket set (9910)
2080 2 Feather key only available within the 'Standard parts ' (9920) set
2090 1 Compression ring also available within the gasket set (9910)
8.2.5 Bearings (4000)

4010 1 Turbine bearing (inclusive 3x4050 assembled)
4020 1 Compressor bearing

8.2.6 Turbine housing (5000)

5020 1 Insert, turbine housing
7020 3 Locating bolt only available within the 'Standard parts 2.1' (9931) set

8.2.7 Compressor housing (6000)

6030 1 O-Ring, compressor housing only available within the gasket set (9910)
6040 1 Insert, compressor housing
6050 1 Screw plug only available within the 'Standard parts '
(9920) set
6060 1 Gasket only available within the 'Standard parts '
(9920) set
6070 6 Hexagon socket screw only available within the 'Standard parts '
(9920) set
6080 6 Ripped washer only available within the 'Standard parts '
(9920) set
insert
6110 2 Screw plug optional connection for jetassist
6120 2 Gasket optional connection for jetassist
6131 *) Shim (0.1) only available within the gasket set (9910)
6140 8 Clamping flange
6150 24 Stud bolt only available within the 'Standard parts '
(9920) set
6160 24 Hexagon nut only available within the 'Standard parts '
(9920) set
6170 24 Ripped washer only available within the 'Standard parts '
(9920) set
*) according clearance setting

8.2.8 Gasket set (9910)

2070 1 Compression ring only available within the gasket set (9910)
2090 1 Compression ring only available within the gasket set (9910)
3081 2 Gasket, bearing cover (0.1) only available within the gasket set (9910)
insert
6131 2 Shim (0.1) only available within the gasket set (9910)
8030 1 O-Ring, compressor diffuser only available within the gasket set (9910)

8.2.9 Standard parts 1 (9920)

2080 2 Feather key only available within the 'Standard parts 1' (9920) set
3110 1 Thread plug only available within the 'Standard parts 1' (9920) set
3140 1 Screw plug also available within the 'Standard parts 2' (9930) set
3150 1 Gasket also available within the 'Standard parts 2' (9930) set
4050 3 Cylindrical pin also available within the 'Bearings' (4000) set
5140 4 Hexagon-head bolt only available within the 'Standard parts 1' (9920) set
8020 2 Stop bushing only available within the 'Standard parts 1' (9920) set

8.2.10 Standard parts 2 (9930)
Part Quantity Designation Remarks

No.
9102 12 Hexagon head screw only available within the 'Standard parts 2' (9930) set
9220 4 Hexagonal screw optional for insulation
9221 4 Washer optional for insulation
9222 4 Hexagonal head screw optional for insulation
9931 1 Standard parts 2.1
8.2.11 Standard parts 2.1 (9931)
Part Quantity Designation Remarks

No.
5090 36 Hexagon nut also available within the 'Standard parts 2' (9930) set
5100 36 Ripped washer also available within the 'Standard parts 2' (9930) set
5130 24 Stud bolt also available within the 'Standard parts 2' (9930) set
7020 3 Locating bolt
9230 24 Hexagonal head screw optional for insulation

8.3 Tools
8.3.1 Tool Set (9800)

9801 1 Locking device for rotor
9803 1 Extractor, thrust ring
9805 1 Guide sleeve
9806 2 Hexagon head screw for (9801)
9807 4 Forcing screw for insert turbine housing
9808 1 Eye bolt
9809 2 Eye bolt
9810 1 Eye bolt
9807

8.3.2 Optional tools

9822 1 Rack, complete only for cartridge HPR5000/6000

9804 1 Sealing device stoppage of the exhaust gas turbocharger

18 Turbocharger Blower Washing Procedure 18-05b-00 1/1
If the turbocharger blower becomes fouled, the exhaust gas temperature may rise and the service life of fuel
injectors and exhaust valves may be shortened. Washing the blower too late has less effect than washing it in
a timely fashion. Therefore, wash the blower periodically and check the boost air pressure before and after
washing it.
(1) Wash the blower during a run at about 75% or more of full load. Continue the run under load for at
least 10 ～ 15 min after washing the blower.
(2) If the boost air pressure is not restored even after washing the blower, overhaul the turbocharger and
clean it.
(3) Fresh water alone is not effective in cleaning the blower. Use cleaning fluid (P/#137616-18400) to
wash the blower.
(4) Do not wash it just before halting operation. Corrosion may form.
Fig. 18-5-1 Turbocharger Blower Washing Procedure
Hand Pump
Water Filler Plug
Cap
018759-00E
(1) Operate the engine close to full load.

(2) Open the drain cock on the boost air passage.
(3) Suck a measured amount of cleaning fluid into a hand pump. (about 0.5l)
(4) Connect the hand pump to the water filler plug, and pump the cleaning fluid in over 10 to 20 sec.
(5) Add the same amount of fresh water the same as just described.
(6) Repeat steps (3) to (5) three or four times.
(7) If the boost air pressure is not restored, repeat the washing procedure again after waiting 10 minutes or more.
(8) After washing the blower, close the drain cock and attach the cap on the filler plug.
(9) When through washing, continue the run under load for at least 10 to 15 min.
2007.4.10R*
18 Turbocharger Turbine Washing Procedure 18-06b-00 1/2
Turbine washing
Heavy fuel oil operation results in contamination and deposits on nozzle ring and turbine wheel reducing the
efficiency. Due to these deposits the charge air pressure will be increased.
The washing intervals depend on the fuel quality and operating conditions. That’s why they must be adjusted
based on the experience gained during engine operation if necessary later on. The washing interval could be
adjusted from 50 to 600 hours.
The increase of charge air pressure could be used for adjusting the washing interval, which could adjusted
within 50 to 600 hours.
Read and take down the charge air pressure and exhaust gas temperatures at a reference point (at 75% or
100% of the output) before and after washing to check the washing effect.
Fig. 18-06-1 Turbine Washing
Exhaust gas elbow
Turbine houging
6 5 4 3 2
10
023922-00E
Legend
1 Sanitary fresh water 6 Wash-water piping
2 Regulating valve 7 Injector
3 Fresh-water piping 8 Connection for drain (optional)
4 Removable flexible tube 9 Valve (optional)
5 Stop valve 10 Escape funnel or sight glass (optional)
Work sequence
1. Connect the flexible tube (4) to fresh-water piping (3).
2. Reduce the engine output to approx. 15% of its rating until the temperature after cylinder has come down
to its specified value. (see table)
3. Wait for approx. 10 minutes!
4. Open the valve (9) of the drain (8) (if present).
5. Open valve (2) and adjust the water pressure (see table).
18 Turbocharger Turbine Washing Procedure 18-06b-00 2/2
6. Open stop valve (5) for approx. 30 seconds and close again.
7. Wait for approx. 3 minutes so that the injected water can evaporate.
8. Repeat steps 6. and 7. twice or three times.
9. Close the stop valve (5), valve (2) and the valve (9) of the drain.
10.Run dry the exhaust gas turbocharger at constant load for approx. 30 minutes, increase engine load
slowly!
11. Repeat the washing process if the exhaust gas turbocharger is affected by vibrations which did not occur
before.
12.Remove the flexible tube (4).
Operating values for turbine washing

Exhaust gas
Exhaust gas
temperature after Water pressure Total washing
Engine output temperature before
cylinder (gauge) period
the turbine
(for reference)
max. 15% 300 - 330 ℃ 400 - 420 ℃ 2.5 - 4.5 bar 3 - 4 × 30 sec
● Hotexhaust gas can escape from the drain - Risk of burning!

● Continue to operate the engine for at least 30 minutes after cleaning.
● Do not wash before a stop of operation. Corrosion risk!
● Washing is ineffective in case of hardened deposits, thus perform washing at regular intervals.
● Pay attention also to instruction of the engine’s operating manual!
No. Page
空気冷却器（T/FW 側装備）部品表
18
Parts List of Air Cooler（FW Side T/C） 18-52b-00 1/2
冷却水：清水用
Water Spec.：Fresh Water
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㧟㧝㧜
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No. Page
空気冷却器（T/FW 側装備）部品表
18
Parts List of Air Cooler（FW Side T/C） 18-52b-00 2/2
冷却水：清水用
Water Spec.：Fresh Water

No Level 0rder Part No. Q’ty Remarks
751695-18170 エアクーラシクミ AIR COOLER ASS'Y 1set
1 1 151695-18281 エアク－ラ（ケ－シングシクミ CASE ASSY, COOLER 1 　
2 2 151695-18061 エアク－ラ　コア（９２．４Ｍ２ COOLER, AIR 92.4M2 1 　
3 2 151695-18300 トリツケダイ（Ｉ／Ｃ，Ｔ／Ｃ，Ｔホ MOUNT(I/C,T/C 1 　
10 1 22212-200000 バネ　ザガネ　　２０ WASHER, 20 11 　
11 1 26152-200902 ボルト（ホソ　２０Ｘ　９０ BOLT, 20 X 90 5 　
12 1 26232-200902 ウエコミボルト（ホソホソ２０Ｘ　９０ STUD,BOLT 20 X 90 6 　
13 1 26732-200002 ナツト（ホソ　２０ NUT, 20 6
14 1 24316-000320 Ｏリング　４Ｄ　Ｐ　３２．０ PACKING, P 32.0 1
15 1 24316-000600 Ｏリング　４Ｄ　Ｐ　６０．０ PACKING, P 60.0 1 　
4 2 151695-18700 パツキン
（カバ－ GASKET, C/COVER 1
5 2 151695-18710 パツキン（カバ－ GASKET, R/COVER 1
6 2 151695-18730 Ｏリング O-RING 1
7 2 151695-18750 パツキン（ケ－シング GASKET, CASING 1
8 2 151695-92630 プラグ PLUG 10 ※
9 2 151695-92640 ナイロンブラシ NYLON BRUSH 1 ※
※イラスト表現していません。
※ There is not illustration chart..
給気管系部品表 No. Page
18 エアダクト（T/FW 側）部品表
18-54a-01 1/2
Parts List of Air Duct（FW Side T/C）
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2007.9.20R
18 エアダクト（T/FW 側）部品表
18-54a-01 2/2
Parts List of Air Duct（FW Side T/C）

1 X 751695-18270 エアダクト　シクミ AIR DUCT ASS'Y 1set
1 2 151695-18310 エアダクト（Ｔ／ＣＯＵＴ AIR DUCT(T/C OUT 1
2 2 132853-18410 フランジ（キウキレンラクカン FLANGE, INTAKE PIPE 1
3 2 151695-18950 ガスケツト（ＴＣ．ＳＵＣ GASKET, T/C INLET 1
4 2 151695-18960 ガスケツト（エアダクト GASKET, AIR DUCT 1
5 2 22137-160000 ザガネ（ミガキ１６ WASHER, 16 6
6 2 24324-002200 Ｏリング４ＣＧ２２０．０ PACKING, G220.0 1
7 2 26153-160652 ボルト（ホソ１６×６５ BOLT, 16 X 65 6
8 2 26206-120352 ボルト１２×３５ BOLT, 12 X 35 8
9 2 26733-160002 ナツト（ホソ１６ NUT, 16 6
10 2 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 1
11 2 23414-210000 パツキン（マル２１ GASKET, 21 1
12 2 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 1
13 2 23414-170000 パツキン（マル１７ GASKET, 17 1
14 2 23887-120002 ６カクプラグ１２ PLUG, 12 1
15 2 23414-120000 パツキン（マル１２ GASKET, 12 1
2007.10.10R
18 給気圧力計管（T/FW 側）部品表
18-55b-01 1/1
Parts List of Boost Air Gauge Pipe（FW Side T/C）
《当部品表のイラスト図はありません。》
《There is no illustration chart of this part table.》

1 X 751695-12430 アツケイカン（キユウキ PIPE, PRESS.GAUGE 1set
1 2 43714-030290 アツケイカンＡ（キユウキ PIPE, PRESS.GAUGE A 1
2 2 43714-030301 アツケイカンＢ（キユウキ PIPE, PRESS.GAUGE B 1
3 2 152623-91200 サポ－トＡ（アツケイカン SUPPORT, PIPE A 4
4 2 152623-91210 サポ－トＢ（アツケイカン SUPPORT, PIPE B 2
5 2 23414-120000 パツキン（マル１２ GASKET, 12 2
6 2 26116-060252 ボルト６×２５ BOLT, 6 X 25 4
7 2 26716-060002 ナット６ NUT, 6 1
8 2 43600-030772 ニ－ドルバルブ VALVE, NEEDLE 1
2008.10.15R
排気マニホールド・排気管系部品表 No. Page
18 排気マニホールド（T/FW 側）部品表
18-58a-00 1/2
Parts List of Exhaust Gas Manifold（FW Side T/C）
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18 排気マニホールド（T/FW 側）部品表
18-58a-00 2/2
Parts List of Exhaust Gas Manifold（FW Side T/C）

1 X 751695-13210 ハイキマニホールド（Ｔホイル EXH.GAS MANIFOLD ASS'Y 1set
1 2 151695-13200 パツキン（ヘツドＯＵＴ GASKET, HEAD OUT 6
2 2 153836-13290 ヘイシフランジ FLANGE, BLIND 2
3 2 153633-13321 パツキン（ＥＸＨ GASKET, EXHAUST 17
4 2 151695-13530 レンラクカンＡ（ＨＰＲ５０００ PIPE A(EXHAUST 2
5 2 151695-13540 レンラクカンＢ（ＨＰＲ５０００ PIPE B(EXHAUST 1
6 2 151695-13550 ＥＸＨマニホルド（１，４，５ EXH MANIFORD 1,4,5 3
7 2 151695-13560 ＥＸＨマニホルド（２，３，６ EXH MANIFORD 2,3,6 3
8 2 151695-13570 サポ－トＡ（ハイキマニホルド SUPPORT A(EXH.MANI 5
9 2 151695-13640 サポ－トＢ（ハイキマニホルド SUPPORT B(EXH.MANI 3
10 2 151694-13650 シンシユクツギテ（１２５Ａ BELLOWS (125A 6
11 2 22133-160000 ザガネ（ミガキ１６ WASHER, 16 12
12 2 26153-160302 ボルト（ホソ１６×３０ BOLT, 16 X 30 10
13 2 26153-160452 ボルト（ホソ１６×４５ BOLT, 16 X 45 24
14 2 45511-005500 ナツトＭ１６ NUT, M16 68
15 2 45521-013680 ボルトＭ１６×６０ BOLT, M16 X 60 56
16 2 45521-017350 ボルト（Ｍ１６×７０ BOLT, M16 X 70 12
2008.9.10R
18 排気マニホールドカバー（T/FW 側）部品表
18-60a-01 1/2
Parts List of Exhaust Gas Manifold Cover（FW Side T/C）
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㧥
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2007.9.20R
18 排気マニホールドカバー（T/FW 側）部品表
18-60a-01 2/2
Parts List of Exhaust Gas Manifold Cover（FW Side T/C）

1 X 751695-13310 ハイキマニホ－ルドカバ－ COVER, EXH.MANIFOLD 1set
1 2 151695-13400 カバ－Ａ（ハイキマニホルド COVER, EXH.MANIFOLD A 1
2 2 151695-13422 カバ－Ｂ（ハイキマニホルド COVER, EXH.MANIFOLD B 5
3 2 151695-13510 サポ－トＤ（ハイキカバ－ SUPPORT, EXH.COVER D 1
4 2 151695-13472 サポ－トＡ（ハイキカバ－ SUPPORT, EXH.COVER A 5
5 2 151695-13482 サポ－トＢ（ハイキカバ－ SUPPORT, EXH.COVER B 12
6 2 151695-13450 サポ－トＣ（ハイキカバ－ SUPPORT, EXH.COVER C 3
7 2 26206-120252 ボルト１２×２５ BOLT, 12 X 25 84
8 2 22217-120000 バネザガネ１２ WASHER, 12 36
9 2 26206-100202 ボルト１０×２０ BOLT, 10 X 20 6
10 2 22217-100000 バネザガネ１０ WASHER, 10 6
2008.9.10R
排気管系部品表 Parts List of Exhaust Gas No. Page
18 排気ガス過給機出口管部品表
18-61d-00 1/2
Parts List of Exhaust Gas Outlet Pipe for Turbocharger
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018353-00X
排気管系部品表 Parts List of Exhaust Gas No. Page
18 排気ガス過給機出口管部品表
18-61d-00 2/2
Parts List of Exhaust Gas Outlet Pipe for Turbocharger

1 X 751695-18120 ハイキデグチカンシクミ EXH.OUTLET PIPE ASSY 1
1 1 151695-18840 ハイキレンラクカン（450A PIPE, EXHAUST 450A 1
2 1 153606-18860 ガスケツト（Ｔ／Ｃデグチ GASKET, T/C OUTLET 1
3 1 23414-140000 パツキン（マル　１４ GASKET, 14 1
4 1 23414-210000 パツキン（マル　２１ GASKET, 21 4
5 1 23883-140002 ６カクプラグ　１４ PLUG, 14 1
6 1 23893-040002 ６カクプラグ　Ｇ　１／２ PLUG, G 1/2 4
7 1 26703-120002 ナット１２ NUT, 12 12
8 1 23414-270000 パツキン（マル　２７ GASKET, 27 1
9 1 23893-060002 ６カクプラグ　Ｇ　３／４ PLUG, G 3/4 1

排気管系部品表 No. Page
18 排気連絡管（T/FW 側）部品表
18-63a-01 1/2
Parts List of Exhaust Gas Pipe（FW Side T/C）
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2007.9.20R
18 排気連絡管（T/FW 側）部品表
18-63a-01 2/2
Parts List of Exhaust Gas Pipe（FW Side T/C）

1 X 751695-13260 ハイキレンラクカン（Ｔホイル PIPE, EXH.T/C IN 1set
1 2 153606-13200 ガスケツト（Ｔ／Ｃイリグチ GASKET, T/C IN 2
2 1 151695-13580 レンラクカンＡ（Ｔ／ＣＩＮ PIPE A(EXH.T/C IN 1
3 2 151695-13590 レンラクカンＢ（Ｔ／ＣＩＮ PIPE B(EXH.T/C IN 1
4 2 23414-210000 パツキン（マル２１×１．０ GASKET, 21 X 1.0 4
5 2 23414-270000 パツキン（マル２７×１．０ GASKET, 27 X 1.0 2
6 2 23893-040002 ６カクプラグＧ１／２ PLUG, G 1/2 4
7 2 23893-060002 ６カクプラグＧ３／４ PULG, G 3/4 2
8 2 45511-005490 ナツト　Ｍ１２ NUT, M12 10
9 2 151695-13690 ボルトＭ１２×６５アルテ BOLT, M12 X 65 6
10 2 151695-13340 ボルトＴ／ＣＩＮ BOLT, T/C IN 2
2007.9.20R
18 防火被覆（T/FW 側）部品表
18-65a-01 1/2
Parts List of Insulation Covering（FW Side T/C）
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2005.6.30R
18 防火被覆（T/FW 側）部品表
18-65a-01 2/2
Parts List of Insulation Covering（FW Side T/C）

1 X 751695-13450 ボウカヒフク（Ｔホイル INSULATER, ASS'Y. HEAT 1set
1 2 151695-13750 ボウカヒフク（ヘツドＯＵＴ INSULATER, HEAT 6
2 2 151695-13760 ボウカヒフク（フランジ INSULATER, HEAT 3
3 2 151695-13770 ボウカヒフク（ベロ－ズ INSULATER, HEAT 6
4 2 151695-13780 ボウカヒフク（タンブ INSULATER, HEAT 2
5 2 151695-13800 ボウカヒフク（Ｔ／Ｃ　ＯＵＴ INSULATER, HEAT 1
6 2 151695-13790 ボウカヒフク（Ｔ／Ｃ　ＩＮ INSULATER, HEAT 2
7 2 151695-13900 ボウカヒフク（Ｔ／Ｃサポート INSULATER ,HEAT 1
8 2 151695-13920 ボウカヒフク（エアダクト，Ｔホ INSULATER, HEAT 1
9 2 151695-13940 ボウカヒフク（インジケータ INSULATER, HEAT 6
2008.9.10R
No. Page
18 過給機（T/FW 側）部品表
Parts List of Turbocharger（FW Side T/C） 18-67d-00 1/2
㧠㧞
No. Page
18 過給機（T/FW 側）部品表
Parts List of Turbocharger（FW Side T/C） 18-67d-00 2/2

1 1 151694-18060 カキユウキ（ＨＰＲ５０００ TURBINE, HPR5000 1
1 X 751695-18210 Ｔ／Ｃサポートシクミ T/C SUPPORT ASS'Y 1set

2 2 151695-18320 サポ－ト（Ｔ／Ｃ SUPPORT, T/C 1
3 2 151695-18130 ボルト（Ｍ２０ホ．ＴＰＳ５７ BOLT, M20 TPS57 2
4 2 26152-200452 ボルトＭ２０×４５ BOLT M20 X 45 4
2007.9.20R
18 ブロワ洗浄装置（T/FW 側）部品表
18-69a-00 1/1
Parts List of Turbocharger Blower Washer（FW Side T/C）

1 X 751695-18450 ブロワセンジヨウパイプ PIPE, BLOWER WASHING 1set
1 2 151695-18450 ブロワセンジヨウパイプ PIPE, BLOWER WASHING 1
2 2 152696-59550 サポ－ト　１０Ｘ１ SUPPORT 10 X 1 2
3 2 153602-92950 プラグ PLUG 1
4 2 23010-018000 ホ－スバンド１８ CLAMP, HOSE 18 1
5 2 23414-160000 パツキン（マル　１６Ｘ１．０ GASKET, 16 X 1.0 1
6 2 23834-100000 ユニオン　１０ UNION, 10 1
7 2 26206-120352 ボルト１２×３５ BOLT, 12 X 35 1
2007.9.20R
18 タービン洗浄装置（T/FW 側）部品表
18-71a-00 1/1
Parts List of T/C Turbine Washer（FW Side T/C）

1 X 751694-18350 タービンセンジョウソウチシクミ T/C WASHING ASS'Y 1set
1 2 146674-18460 ソケット　Ｇ３／４ SOKET G3/4 2
2 2 151694-18500 Ｔ／Ｃセンジョウカン（Ａ PIPE A(TURBINE CLEAN 1
3 2 151694-18510 Ｔ／Ｃセンジョウカン（Ｂ PIPE B(TURBINE CLEAN 1
4 2 151694-18520 サポート SUPPORT 1
5 2 151694-18550 ボウカヒフク（タービンセンジョウ INSULATERHEAT 1
6 2 23297-120121 カンドメカナクＡ１２Ｘ１２゛ CLAMP, 12 X 1.2 1
7 2 23414-270000 パッキン（マル２７Ｘ１．０ GASKET, 27 X 1.0 6
8 2 26152-200502 ボルト（ホソ２０Ｘ５０ BOLT, 20 X 50 2
9 2 26206-120122 ボルト　１２Ｘ１２ BOLT, 12 X 12 1
10 2 26773-160002 トメナット（ホソ　１６ NUT, 16 2
11 2 43510-001310 カタクチカンツギテ JOINT, PIPE 2
12 2 43590-004120 スナップジョイント（オス） JOINT, SNAP 1
13 2 43600-015850 ニードルバルブシクミ VALVE ASS'Y 2s
2008.9.10R
Main Bearing & Crankshaft No. Page
21 Outline 21-01a-00 1/1
The crankshaft is made of the forged carbon steel. The pin and journal diameters are both designed to be
quite large, are induction hardened and then polish-finished.
The engine vibration is controlled by placing balance weights in the ideal position.
The main bearing cap is firmly fastened to the cylinder block with two main bearing bolts and two side bolts.
The main bearing bolt is tightened using hydraulic pressure applied to a special tool.
The main bearing and the crankpin bearing are made of aluminum.
Fig. 21-01-1 Main bearing and crankshaft outline chart
008233-00X
2007.4.10R*
21 Overhauling the Main Bearing 21-02a-00 1/7
Balance weights are added to the crankshaft in the six places shown in the figure below.
Thrust bearings are installed before and after the No.1 main bearing. The metal main bearing cap is sus-
pended under cylinder block and secured with two clamping bolts. The tightening nuts are set to the specified
hydraulic pressure and two side bolts are tightened to the specified torque.
Side bolts
The main bearing caps 1-7 are equipped with side bolts.
The bearing numbers are marked on the main bearing caps, the tightening nuts, and the side bolts.
Fig. 21-02-1 Main Bearing Numbers

Cylinder No. No.6 No.5 No.4 No.3 No.2 No.1
* * * * * *
Crankshaft arm with which
balance weight is equipped
Main Bearing Cap No. No.7 No.6 No.5 No.4 No.3 No.2 No.1
On the opration side
Stamped Mark of On the No.7 No.6 No.5 No.4 No.3 No.2 No.1
Tightening Nut & Side Bolt non-opration side No.14 No.13 No.12 No.11 No.10 No.9 No.8 018761-00E
Main Bearing
None of the main bearing caps can be taken out through the cylinder side cover
1) Preparation for disassembly
(1) Prepare the following special tools.
<For the hydraulic Pump & hydraulic jack type>
Chapter 92-01 ～ 03) Hydraulic Jack Handling Procedures
<Main bearing retaining tools>
No. Exclusive Tool Part No.
1 Jack (Scissors Type) 153603-92750
2 Clamping Tool 151605-92860
<Upper bearing installation and removal device>
No. Exclusive Tool Part No.
3 Upper metal detaching/ attaching pin 153604-92970
4 Upper metal inserting implement 151695-92710
(2) Remove the crankcase side covers near the main bearing to be disassembled and those covering the
adjacent bearings.
(3) Unscrew the side bolts of the main bearing to be disassembled. Unscrew them on both sides.
Note: At this point, also loosen the side bolts on the adjacent bearings.
(4) Turn the crankshaft up so that the crankpin is close to working side. (Balance weight and connecting rod
are in a place that doesn't interfere with the job.)
(5) Do the self-rotation prevention processing (See chapter 08-02) of crankshaft, except for turning.
2007.4.10R*
2) Disassembly
(1) Main bearing nut disassembly/reassembly procedures
Tighten and loosen the two main bearing cap clamping nuts simultaneously.
① Attach a spacer bolt to each main bearing clamping bolt.

② Attach the spacer, and temporarily secure it to the main bearing nut with the spacer lock bolt .
Fig. 21-02-2 Hydraulic jack installation chart
(Operation Side) (Non-Operation Side)
From Hydraulic Pump
Crank Shaft Center

Balance weight
Main Bearing Cap

Side Bolt
Rubber Hose
Main Bearing
Cap Bolt
Turning Handle
Copupler
Main Bearing Cap Nut
Spacer Locking Bolt Spacer Hydraulic Jack Assy' 018762-00E
③ Attach a hydraulic jack to the spacer bolt, and tighten the hydraulic jack clamping nut.
Make sure that the hydraulic jack piston is flush with the end surface of the hydraulic jack main body.
④ Connect the hydraulic pump to the hydraulic jack with a rubber hose.
⑤ Loosen the hydraulic jack clamping nut by 1/4 turns.
⑥ Remove the spacer lock bolt.
⑦ Close the escape valve on the hydraulic pump, and pump the lever to boost the hydraulic pressure to the
specified level.
Specified hydraulic pressure: 61.0 ± 0.5MPa
⑧ Insert the handle into a hole in a nut through the hole in the spacer. Then turn the nut.
• When disassembling loosen the nut by turning it past seven or eight holes in the nut.
• When assembling it, turn the nut until it is seated.
2007.4.10R*
When disassembling the main bearing, if the nut cannot be removed with the handle, slowly raise the
hydraulic pressure and then try turning it.
Do not raise the hydraulic pressure above 61.5MPa
⑨ Gradually open the hydraulic pump escape valve until the hydraulic pressure is reduced to 0.
⑩ Tighten the hydraulic jack clamping nut until it is flush with the hydraulic jack, then drain the oil from the
jack.
⑪ Disconnect the rubber hose from each hydraulic jack.
⑫ Remove each hydraulic jack, spacer and spacer bolt.
(2) Main bearing cap assembly / reassembly procedures

① Loosen the main bearing cap clamping nut two to three turns and attach the retaining tools (scissors type jack).
• Fix the tools to the supporting rail in the oil pan with the clamping tools immediately below the main bearing
Do not remove both of the tightening nuts simultaneously. Otherwise, the main bearing cap may fall and
injure you.
Fig. 21-02-3 Main bearing cap support tools installation procedures
Jack
Scissors type
Clamping Tool
Supporting Rail
018763-00E
② Remove the main bearing cap clamping nut, and manipulate the jack to lower the main bearing cap.
③ Remove the lower main bearing.
The main bearing cap cannot be removed from the engine through the crankcase-side cover.
Therefore, remove the lower bearing and place it in the oil pan.
2007.4.10R*
(3) Upper main bearing removal procedures
Insert the bearing installation/removal pin"3" into the crankshaft oil hole from the operation side (so that
the head of the pin lies along the edge of crankshaft). Then, slowly turn the flywheel in the normal rota-
tion direction and pull the upper bearing out on the non-operation side.
Fig. 21-02-4 Removing the upper bearing

(Operation Side)
Upper bearing installation/

removal pin
018764-00E
(4) Thrust bearing removal procedures
Thrust bearings are provided so that the main bearing cap at the reference position (main bearing cap
No.1) is placed between then. Attach and remove the main bearing cap No.1 and thrust bearings the
same way the main bearing cap Nos. 2 through 7 were handled.
Fig. 21-02-5 Removing the thrust bearing
Upper Bearing
Lower Bearing
018765-00E
2007.4.10R*
3) Inspecting and servicing the main bearing and thrust bearings
If the clearance between the main bearing and crankshaft gets larger, the lubrication oil pressure will
drop, resulting in a burned bearing and increased deflection, which may cause the crankshaft to break or
some other serious accident. Therefore, make very sure to inspect and service the main bearing and
thrust bearings.
(1) Check for flaws and fretting corrosion on the surfaces of the main bearing caps that are in contact with
the cylinder block.
(2) Check for fretting corrosion on the mating surface and back-side of the main bearing. Also check for
flaws, burned areas or foreign matter pressed into its sliding surface.
Do not repair the back-side surface or sliding surface of the main bearings. If you try to, the bearing
clearance may change.
(3) Make sure the main bearing cap clamping bolt is not excessively loose.
Stud torque: 200+500 N • m
(4) Measure the clearance between the crankshaft and the bearing.
① To measure the clearance accurately, remove the crankshaft and measure the outer diameter of the
crankshaft and the inner diameter of the main bearing cap.
② To determine the clearance without removing the crankshaft, place a lead wire about 0.5mm in diam-
eter on the sliding surface of the lower main bearing (position it along the edge of crankshaft and fix it
with grease or the like to prevent it from moving). Tighten the main bearing cap to the specified
hydraulic pressure, then take out the lead wire and measure its thickness.
(5) If the clearance is too large, beyond the wear limit, replace the bearing with a new one.
Be sure to replace both the upper and lower bearings with new ones at the same time.
If the crankshaft is excessively worn (unevenly worn), replace the upper and lower bearings with smaller
ones. In this case, the crankshaft must be polished to match the dimensions of the smaller bearings that
will be used.
[Thrust metal]
(1) Check for wear and burnout.
(2) If the clearance between the bearings and crankshaft is too great, replace both the upper and lower bear-
ings at the same time.
2007.4.10R*
Fig. 21-02-6 Measurement of thrust bearing
①Secure the dial gauge stand to the cyl-

inder block and place the dial gauge
in contact with the crankshaft. Then,
move the crankshaft forward to reset
the indicator to 0.
② Move the crankshaft backward. Then,
take a reading from the dial gauge.
This reading indicates the thrust
clearance.
Thrust Bearing
018766-00E
(3) When attaching a thrust bearing, position it so that its groove faces forward.
4) Installation procedure
Reassemble the main bearing as follows.
(1) Main bearing installation procedure
① Turn the flywheel. Stop turning when the crankshaft oil hole is visible from the operation side.
② Temporarily remove the lower bearing, then attach the upper bearing insertion tool "4" to the main bear-
ing cap.
③ Wipe off any dirt or oil on the back of the housing and the bearing when you are ready to install the main
bearing.(Make sure there is no oil on the back of the bearing. Then, install it.)
④ Spread the lubricating oil by bare-handed in the main bearing metal inner surface, when you attach the
main bearing.
Fig. 21-02-7 Installing the main bearing
(Operation side)
Upper bearing installation/

removal pin Upper bearing inserting device
018767-00E
2007.4.10R*
Position the upper bearing correctly in the forward/backward direction so that the projection on upper
bearing engages the hole in the cylinder block.
⑤ Attach the upper bearing by aligning the guide groove in the insertion tool with the projection on the bearing.
At this time, set the projection of the upper bearing on the operation side.
Because the hole of the cylinder block is processed on the non-operation side of it, the projection of the
upper bearing engages with the hole of cylinder block if the upper bearing is inserted by being rotated as
shown in Fig.21-02-7.
⑥ Insert the alignment pin "3" into the crankshaft oil hole on the operation side.
Position the alignment pin so that the head of the pin is along the edge of crankshaft.
Then, hold the pin in close contact with the edge using some grease, to prevent it from falling out during
the turning operation.
⑦ Operate the jack to raise the main bearing cap until the bearing makes contact with the crankshaft.
Note that pressing the insertion tool too hard will damage the bearing
⑧ Slowly turn the flywheel counterclockwise.
☆ Make sure that the projection on the bearing is engaged in the hole on the cylinder block.
☆ Continue turning the flywheel until the end surface of bearing is flush with the end surface of cylinder
block.
⑨ Lower the main bearing cap, remove the alignment pin and insertion tool, then attach the lower bearing.
⑩ Raise the main bearing cap, and tighten the main bearing cap nut until the main bearing cap makes close
contact with the cylinder block.
⑪ Remove the jack and clamping tool.
(2) Main bearing cap side bolt tightening procedures
If you have loosened the side bolts of the adjacent main bearing during disassembly, first tighten the side
bolt on the operation side to the specified torque. Then tighten the bolt on the other side.
⑫ Tighten the side bolt on the operation side to half the specified torque.
(Do not screws in the side bolt on the non operation side.)
Specified torque: 1080N • m
⑬ Attach the hydraulic jack and tighten the main bearing cap nut using the specified hydraulic pressure.
After tightening the nut, make sure the alignment mark on the nut is aligned with the alignment mark on
the bolt.
⑭ Tighten the side bolts on the operation side to the specified torque.
⑮ Screw in the side bolts on the other side and tighten them to the specified torque.
2007.4.10R*
21 Overhauling the Crankshaft 21-03a-00 1/6
It is necessary to check the crankshaft periodically, as described in Section 00-07, because the following may
occur in the crankshaft:
(1) Uneven crankshaft wear.
(2) Excessive gap between the main bearing and the crankshaft due to wear.
(3) Cracking from operation if the crankshaft deflection exceeds the allowable value.
(4) Development of a hairline crack when the crankshaft burns out, for instance, due to a lack of oil.
(5) Cracking due to operation at critical engine speeds accompanied by torsional vibration.
If the crankshaft and main bearing should burn out, do not replace the bearing. Also measure the surface
hardness of the crankshaft and inspect for hairline cracks with a magnaflux device.
Criterion
Crankshaft surface hardness Criterion Should be 65-85HS
Hairline crack Should not be seen
Crankshaft Disassembly & Reassembly

Since this section primarily discusses the details of shop disassembly & reassembly, begin work only after
careful reading of this sectione.
(1) Precautions before starting work

① Since all the parts belonging to cylinders must be removed in the first place, pay close attention not to
lose any of the parts that are removed (small parts in particular) such as the packing and O-rings.
Also, it is essential to set about the job with arrangement for keeping dissembled parts in order, having a
place to put them in, and parts cans, etc. at the ready so that there will never be surplus or missing parts
when reassembly is complete.
② While working, always pay attention to the alignment marks on some of the parts and their installation
locations.
③ If there are no alignment marks in a complicated section, you can stamp alignment marks prior to dis-
assembling, in order to make the reassembly easier.
④ Please note that there is a possibility of the parts seizing unless all rust, flaws, dirt, etc. are removed
from the threaded parts.
⑤ Before disconnecting the heavy lift, the distribution of the weight in the part must be examined. Always
perform correct sling work using a suitable steel wire rope for the weight.
⑥ A complete overhaul takes into account a total check of the various engine parts, most of which is
described here.
(2) Major tools and implements for working

① Cylinder block inverter bases
② Cylinder block lifting tools
③ Wire (for lifting cylinders), nylon slings, etc.
④ Hydraulic jack (special tool)
⑤ Wooden block to place under the cylinder block after inverting the cylinders
⑥ Wooden block used in lifting of a cylinder
2007.4.10R*
(3) Parts to be removed from the engine

① Separate the areas directly coupled at the front and rear of the engine
② Remove the anchor bolts
③ Turbocharger
④ Air cooler (intercooler)
⑤ Exhaust pipe
⑥ Cylinder head & push rods
⑦ Piston, connecting rod & push rods
* ⑧ Fuel pump & tappets
* ⑨ Camshaft & intake /exhaust swing arm
⑩ Associated pump parts (lubrication oil, fuel feed & cooling water)
⑪ Governor, gauge panel & *governor gear
⑫ Front & rear covers, gear related parts & flywheel
⑬ Various tubes (for lubrication oil, cooling water, fuel & air)
⑭ Oil pan
Note: The asterisks (*) above refer to parts that do not necessarily need to be removed for disassembly, but
may make the work more convenient.
The covers on the front and rear areas, and the gear related parts have to be removed because the front
and rear couplings of the cylinder must be placed on the rollers built into the inverters.
(4) Lifting and inverting a cylinder

After making sure you have all the necessary cylinder lifting tools, inverters, wire, etc., do the following:
① Place the cylinder lifting tools inside cylinder head bolt No.3 in the No.4 cylinder.
Fig. 21-03-1 Cylinder Lifting
Sling
018768-00E
Pay attention to the center of gravity of the cylinder block.
2008.10.15R*
② Determine the length of wire necessary, after considering the height the cylinder must be lifted to.
③ Lock the bases of cylinder inverters to prevention them turning sideways while inverting the cylinder.
Fig. 21-03-2 Securing the Cylinder
Inverter
Wooden Block
Locking Piece
018769-00E
④ Install the inverters to match the measured length from the outer face of crankshaft flange to the outer
face of the front coupling.
Length L: L = about 3,200 mm
Fig. 21-03-3 Reversing
L
018770-00X
⑤ Using properly sized wire to handle the weight of the cylinder block, lift, shift, and move the cylinder block
only under the supervision of a person in charge of sling operations.
Crankshaft + cylinder mass Approx. 9,000 kg
2008.10.15R*
⑥ After resting the cylinder block temporarily on the inverters, and before inverting it, lead the auxiliary wire
under the cylinder block in the direction opposite to the direction you will be turning in.
Preventing rolling and shock while inverting.
⑦ After slackening the main lifting wire and auxiliary wire fully, move the main wire in the direction that the
cylinder will be inverted, pull up on the auxiliary wire according to the condition of the cylinders as they
are tilted, and actuate the main and auxiliary wires alternately to invert the cylinder block.
Be careful not to allow slack in the wires.
⑧ Install four cylinder lifting blocks on the lower surface of the cylinder.
Fig. 21-03-4 Lifting Hook
Lifting Hook4
018771-00E
⑨ Prepare wooden blocks to be inserted under the cylinder block for it to rest on.
⑩ Lift the cylinder block off the inverters and rest it on the wooden blocks.
Be careful to support the cylinder block so that it won't topple.
Fig. 21-03-5 Preventing of Falls Fig. 21-03-6
Wooden Block
Wooden Block
018772-00E
018773-00E
2008.10.15R*
(5) Removal and reassembly of the main bearing cap and crankshaft
① Using a sponge or paper towel, remove all the grease or oil on the top of the bearing cap
② Use the special hydraulic jack to remove the cap nut.
Hydraulic jack procedure for disassembly
Chapter 21-02 Main Bearing
③ Gradually raise the two M16 eyebolts to remove the bearing cap.
☆ Make sure that nothing gets caught on the cylinder, the cap, the bolts, etc.
☆ Be careful not to damage the crank bearing.
Fig. 21-03-7 Lifting a Bearing Cap Using Eyebolts

Eyebolt
Bearing Cap
018774-00E
④Pay special attention to the crankshaft's center of gravity when lifting it horizontally. Use nylon slings in the
No.1 & No.6 crankshaft areas, lift the crankshaft gradually, and remove it from the cylinder block.
Fig. 21-03-8 Lifting the Crankshaft
Nylon Sling
Lifting the Crankshaft
Crankshaft mass: Approx. 2,100 kg
018775-00E
2007.4.10R*
⑤ When disassembling the crankshaft, clean the various parts and remove any dirt, flaws, rust, or corro-
sion.
⑥ Insert the (upper) crank bearings and thrust bearing (on the flywheel side) into the bearing areas, and
apply fresh oil to them.
• Pay attention to the notches on the bearing areas and the fit of the notches on the bearings.
• This crank bearing has nine holes.
⑦Attach eyebolts to the bearing cap, insert the lower crank bearings, and place a bearing cap on the crank-
shaft so that the bearing will not fall out.
• Pay attention to the notches on the bearing areas and the fit of the notches on the bearings.
⑧ At this time, set the thrust-bearing metals to the both sides of bearing cap, and also insert the φ6 × 12
straight pins into it.
⑨ Torque the cap nuts and side bolts with the hydraulic jack in the reverse sequence used for disassembly.
⑩ Finally, check the thrust clearance of the crankshaft.
Standard thrust clearance: 0.13 - 0.21 mm
⑪ Make sure the crankshaft can be turned smoothly and easily.
If the crankshaft cannot be turned, it is necessary to check and adjust the various parts until it can be
turned smoothly and easily.
⑫ During reassembly, be sure to match the alignment mark on the flange of the crankshaft with the align-
ment mark on the flywheel.
Fig. 21-03-9 Alignment mark

Alignment Mark "0"
0
High-precision Bolt
Crankshaft
Flywheel markings
(Front) (Back)
018776-00E
2008.10.15R*
21 Measurement of Crankshaft Deflection 21-04b-02 1/4
The crankshaft deflection means the gap between open and close of the crank arms, it is useful to check the
installing alignment and judge the influence on main metal damages.
If the crankshaft deflection becomes too large, the crankshaft may be broken, resulting in an accident. Conse-
quently, you should measure the crankshaft deflection periodically.
(1) Measure the crankshaft defection when the engine is cold.

(2) Whenever you have removed or tightened the engine installation (anchor) bolts, the common bed clamp
bolts or the driven machine (such as a generator) clamp bolts, measure the crankshaft deflection.
(3) Move the tip of the deflection gauge, and make sure the dial gauge needle returns to the original position.
1) Procedure for measuring deflection

(1) Gather the following special tools.
Deflection gauge 42111-002520
Deflection gauge mirror 42111-001420
Ratchet handle for turning 147673-92851
Socket (M24) for turning 42111-001850
(2) Open the pressure indicator cocks on all cylinders.
(3) Turn the flywheel to bring it to the PB position, Fig. 21-04-1 Position for Attaching the Deflection Gauge
which is 30 degrees past B.D.C.
(4) Attach the deflection gauge and set the dial
gauge needle to read zero.
(5) Slowly turn the flywheel in the normal rotational
direction of the engine. Take and record readings
of the dial gauge at the P, T, E, and EB positions. D
D/2 L
Deflection Gauge
D = Crank journal diameter of 250mm

L = Crank arms width of 120 mm 018777-01E
Fig. 21-04-2 Positions for Measuring Deflection

T
Deflection Gauge Position
(When the Crank Pin is at PB)
(measuring reference)
PB : 30qafter B.D.C. (fuel injection pump side) P E
Calculation for deflection;
P : 90qbefore T.D.C. (fuel injection pump side)
30q30q • Vertical deflection = T-PB
T : Top Dead Center (T.D.C.) PB EB and T-EB as well
E : 90qafter T.D.C. (exhaust manifold side) B
EB : 30qbefore B.D.C. (exhaust manifold side) • Horizontal deflection = P-E
Crank Pin Position
018778-01E
2009.3.31R
2) Criteria on results of the deflection measurement

Deflection readings are recorded of dial gauge at each crank pin position with the reference to the position EB
or PB.
Vertical deflection is calculated by the difference in readings of the position between T and EB, T and PB.
Horizontal deflection is calculated by the difference in readings of the position between P and E.
The relation between deflection readings of dial gauge at each crank pin position and the figure with open and
close of crank arms are defined seeing on Fig.21-04-3.
Fig. 21-04-3
Dial Gauge Reading ＋－
Crankshaft
(lower spread) (lower shrink)
(1) If the deflection increases every time it is periodically measured, this is probably caused by wear in the
crankshaft and/or the main bearings. If the deflection increases suddenly in just one cylinder, you should
suspect that the corresponding main bearing is worn abnormally. In these cases, check the relevant parts.
(2) Since the measured deflection when the engine is hot will depending largely on the engine temperature
at the time the measurement is taken, it cannot be relied on.
3) Allowable deflection (at RATO Coupling)
Reduction-Reversing Gear Side [Unit: 1/100mm] Note: "S" stands for stroke
Cylinder No. Calculation for deflection Deflection
－ 11.55 ～＋ 3.85
〔　　　　　〕
－ 3S ～＋ 1S
(T-PB), (T-EB)
10,000
1
± 5.775
〔　　　　　〕
± 1.5S
(P-E)
10,000
± 3.85
(T-PB), (T-EB)
〔　　　　　〕
± 1S
Other
(P-E)
10,000
4) Correction of the deflection

In the case where the deflection exceed the allowable value, correct the deflection by redistributing the instal-
lation shim and shaft centers of the engine and driven machine (or outer bearings).
● It is unnecessary to forcibly correct the deflection at measured position T (crank-pin T.D.C.) to upper
spread even if the deflection is found to be lower contract because the mass of the flywheel and cou-
pling causes a deflection.
● Since a poor centering precision of the coupling may cause an excessive deflection and the damage
of coupling, correct the shaft center of the engine according to the pertinent coupling type.
2009.3.31R
(1) As for center deflection C, lower the engine side by 0.05 to 0.1 mm, counter on a deflection caused by the
mass of the flywheel and coupling.
(2) Fit the dial gauge according to the following procedures as depended on the coupling type, and measure
the facial deflection and center deflection.
① Make sure that the crank deflection values for cylinders No.2 ～ 6 are within the specifications.
② Remove the intermediate plate from the flexible coupling area.
③ Measure the distance across the faces (L) of the direct coupling.
④ Fit a dial gauge on the flexible coupling and measure the deflection on the face and outer circumfer-
ence while turning the flywheel.
Fig. 21-04-4 Centering Points
Dial Gauge
Flywheel B
Engine Side Driven Machine Side

C (Clutch, Pump, Gen. etc)
A
Flexble Coupling
(Spacer)
L 018780-00E
Specifications
Facial deflection : Less than 0.2 mm (dial gauge at point A)
Outer circumferential deflection : Less than 0.10 mm (dial gauge at point B), assuming that the reverse
and reduction gear is raised 0.2 mm above the engine, in view of the sag caused by the flywheel.
(1/2 x C= 0.2)
Fig. 21-04-5 Centering Procedures
Flywheel
F
018781-00E
2007.4.10R*
RATO coupling
Remove the rubber element from the RATO coupling, fit the dial gauge on the reduction-reversing gear side,
and measure the facial deflection of the flywheel side fitting face.
Criteria [Unit: mm]

Center Deflection Facial Deflection Facing Gap
Coupling
C F D L
RATO-G2711 790 152

± 0.2 ± 0.2 ± 0.2
RATO-G2911 860 160.3
Fig. 21-04-6 RATO Coupling
Flywheel
Dial Gauge
Shaft of Operation Machine
L
ǾD
RATO Coupling
018783-00E
2007.4.10R*
No. Page
21 主軸受メタル部品表
Parts List of Main Bearing 21-51a-00 1/2
㧠
㧠㧣
෻ࡈ࡜ࠗࡎࠗ࡯࡞஥ 㧝
㧝㧣
020449-00X
No. Page
21 主軸受メタル部品表
Parts List of Main Bearing 21-51a-00 2/2

1 X 751695-02010 シュジクウケメタルシクミ METAL ASS'Y 1set
1 2 151695-02350 メインメタル　ＣＭＰ METAL ASS'Y, MAIN 7s
4 2 153605-02372 スラストメタル　ＣＭＰ METAL ASS'Y, THRUST 2s
7 1 22312-060120 ヘイコウピン６Ｘ１２ PIN, 6 X 12 4
2008.9.10R
主軸受・クランク軸部品表 No. Page
21 クランク軸・フライホイール部品表
21-52a-02 1/2
Parts List of Crankshaft ＆ Flywheel
㧝㧡
㧝㧞
㧝㧟
㧝㧠
㧝㧜
㧔㧝㧕
㧝㧝
㧥
㧔㧝㧕
㧤㧢
2007.9.20R
21 クランク軸・フライホイール部品表
21-52a-02 2/2
Parts List of Crankshaft ＆ Flywheel

1 1 751695-21010 クランクシヤフトＡＳＳ’Ｙ CRANKSHAFT ASS'Y 1set
3 2 153605-21050 トメネジ（Ｍ１８Ｘ２．０ SETSCREW 6
5 2 151695-21131 バランスウエイトボルト BOLT, BALANCE WEIGHT 6
6 2 151695-21141 ナツト（バランスウエイト NUT, BALANCE WEIGHT 6
7 2 151695-21200 ギヤ（クランク　ＸＲ　Ｚ＝６８ GEAR, CRANKSHAFT XR 1
8 2 22312-060060 ヘイコウピン６Ｘ６ PIN 6 X 6, STRAIGHT 1
9 2 22312-160300 ヘイコウピン　１６Ｘ３０ PARALLEL PIN 16 X 30 12
1 742103-21090 リ－マボルトシクミ BOLT ASS'Y, REAMER 8sets

10 2 142103-21510 リ－マボルト BOLT, REAMER 8
11 2 153623-21560 ＵナツトＭ３６（フライホイル NUT, FLYWHEEL M36 8
1 751695-21400 ＦＷシクミ（ＲＡＴＯ２９１１ F.W. ASS'Y(RATO 2911 1set

12 2 151695-21400 フライホイル（ＲＡＴＯ２９１１ FLYWHEEL(RATO2911 1
13 2 151695-21601 リングギヤ GEAR, RING 1
14 2 26206-120452 ボルト　１２Ｘ４５ BOLT M12 X 45 16
1 42326-013791 フライホイ－ルオオイ COVER, FLYWHEEL 1 ※1

15
1 42326-013841 フライホイ－ルオオイ COVER, FLYWHEEL 1 ※2
※ 1 In the case of OFW side T/C.

※ 2 In the case of FW side T/C.
2008.9.10R
21 ブルカン RATO 軸継手部品表
21-53d-00 1/2
Parts List of RATO Coupling
㧟㧝㧞 024641-00X
21 ブルカン RATO 軸継手部品表 2/2
21-53d-00
Parts List of RATO Coupling

TOOOH-0013M1 RATO-SG2911 シクミ RATO-SG2911 ASS'Y
1 1 22451-200000 ツヅリセン　２．０ WIRE, 2.0 16
2 1 45423-019481 ブルカン RATO
（SG2911 COUPLING, RATO SG2911 1
3 1 45521-014530 ボルト　Ｍ１８（ホ）Ｘ４５ BOLT, M18X45 32
Pistons & Connecting Rod No. Page
22 Outline 22-01a-00 1/1
1. Pistons & Piston rings
The piston is a thin solid self-contained object made of ductile cast iron. The grooves in the piston for rings are
laser hardened/quenched. The cocktail shaker system is used to cool the upper part. The piston is cooled by
the lubricating oil supplied through the hole in the connecting rod. A set of piston rings consist of three rings.
There are two compression rings and one oil ring. Each ring has been chrome plated on the sliding surface.
Fig. 22-01-1 Piston Design & Piston Ring Types (Clockwise)
Cooling Chamber
Barrel Face
Tapered Face
Beveled with
Coil Expander
018786-00E
2. Connecting Rods & Bearings

The connecting rod is made of three parts from forged carbon steel. The piston can be removed by removing
the upper rod bolts on the big end.
The big end bearing is a split bearing consisting of an aluminum alloy with a steel backing plate. The small
end bearing is a lead bronze bushing with a steel backing plate.
2007.4.10R*
22 Overhauling the Pistons & Piston Pins 22-02a-01 1/4
The frequency for removing and checking the pistons varies according to the results of the daily maintenance,
especially the lubricating oil control and engine loading (overloading and excessively low loading). Therefore,
the supervisor must set the proper frequency. However, the initial overhaul and checks should be performed
at the times mentioned in Chapter 00-07.
From then on, the subsequent maintenance schedule should set according to the results of the overhaul
check, any increase in blow-by and any increase in lubricating oil consumption. When the lubricating oil con-
sumption has become twice the initial value, it will be necessary to overhaul and clean the piston, and replace
the piston rings.
1. Disassembly
1) Preparation for Disassembly
Prepare the following special tools.
No. Special Tool Description Note

① Extraction plate for the anti-polishing ring
② Liner retaining device
③ Spacer
④ Upper liner extraction device
⑤ Eyebolt Lifting out the piston
2) Removing the anti-polishing ring.

(1) Set the piston at a position about 60 to 70°before T.D.C.
(2) Place the anti-polishing ring extraction plate ① on top of the piston.
Place the plate so that its outer tapered part faces toward the piston, but do not allow it to make contact
with the cylinder liner.
(3) Install the liner retaining device ② and spacer ③ and lock them with the cylinder head tightening nut.
(4) Turn the flywheel, and remove the anti-polishing ring.
Fig. 22-02-1 Removal of the Anti-polishing Ring

Cyl. Head
Tightening Nut
Ԛ
ԛ Ԙ
Anti-polishing Ring
Tapered Part
018788-00E
2007.4.10R*
(5) Remove the disassembling tools the anti-polishing ring.

(6) Clean out the carbon in the upper part of the cylinder liner.
3) Pulling out the Piston

Sine the connecting rod is a three-part design, the piston can be pulled out from above by removing the con-
necting rod bolts on the upper part of the big end.
Disassemble the piston and connecting rod as follows.
(1) Remove the cylinder side covers for cylinder being worked on from both the operating side and the non-
operating side.
(2) Turn the flywheel until the crankshaft is at B.D.C., so that the upper connecting rod bolts can be removed.
(Select a position such that the socket wrench will not come into contact with the cylinder block.)
(3) Check the alignment marks on the connecting rod bolts prior to disassembly.
(4) Loosen and remove the connecting rod bolts.
(5) Screw the eyebolt into the middle of the piston to be able to lift it.
(6) Lift the piston slowly and pay attention to the straight pins in the connecting rod and the big end housing.
(7) When the connecting rod comes off the straight pins in the big end housing, lift the piston completely to
remove it from the cylinder.
(8) Check for damage on the mating surface of the big end housing and the straight pins.
Fig. 22-02-2 Removing a Piston (Clockwise)
Eyebolt
Straight Pin
018789-00E
2007.4.10R*
4) Removing the Piston Pin & Piston Rings

(1) Remove the piston pin circlips with pliers.
Note that the circlip will spring out and injure you if it slides off the tip of the pliers in the course of remov-
ing the circlip.
(2) Pull out the piston pin while holding the connecting rod.
(3) Remove the piston rings with a special tool.
Wear gloves because the corners of rings will be sharp and can injure you, even after the engine has run
a long time.
Be careful not to force the gap in the ring open to more than 80mm. The ring may break.
2. Checking & servicing

Check the amount and condition of the carbon stuck on the piston and the state of wear in the various parts.
Refer to these results in deciding when to make the next check.
Do not use sandpaper on the surface of the piston skirt. It has a special coating. (A carbon cleaning
agent such as Unicon 146 or Neos is recommended for washing the piston.)
(1) Check the contact surface of piston skirt.

(2) Check the contact surface of the wrist pin holes.
(3) Check the piston for cracks on the top surface, ring grooves and inside using the Penetration Test.
Fig. 22-02-3
Penetration Test on a Piston
018790-00E
2007.4.10R*
(4) Remove the piston cooling chamber cover, and check for scale buildup.
(5) Measure the dimensions of the piston and wrist pin.
(6) It is recommended that you replace the piston rings with new ones after considering the time until the
next engine service.
(7) When replacing a piston, create the same alignment mark on the new one as on the previous one.
3. Installing a Piston
Install the piston in the reverse sequence used to remove it. Pay attention to the following points.
(1) Install the perforated piston cooling chamber cover on the non-operation side. Apply the proper screw
lock agent (Tokyo Three Bond Screw-Lock No.1 or equivalent) on the bolts before screwing them in.
(2) Install the wrist pin circlip with its opening facing straight down.
(3) Install the piston rings with their marked sides facing upward and their cuts rotated 120°away from the
adjacent rings.
(4) Install the oil ring with its coil joint position rotated 180°away from its cut.
(5) Install the piston and connecting rod, aligning their marks with each other.
Fig. 22-02-4 Installing a Piston (Clockwise) Fig. 22-02-5 Insert the Piston (Clockwise)
Piston Alignment Mark Marking
Piston Insertion Guide

1 RN
2R
Circlip
Opening
Cover
(Perforated)
Cut
Coil Joint
Rod Alignment mark
018791-00E 018792-00E
(6) Turn the crankshaft to the B.D.C. position.

(7) Apply clean engine oil to the sides of the piston, the rings and cylinder liner.
(8) Place the insertion guide on the cylinder liner, and install the piston. (Tap the top of the piston with a resin
hammer to drive the piston down.)
2007.4.10R*
22 Overhauling the Connecting Rods 22-03a-01 1/9
The connecting rod is three-divided structure. Remove the upper rod bolts, and draw out the piston and con-
necting rod first. After removing the piston and connecting rod, disassemble the big end housing by using the
hydraulic jack.
1. Removal of upper Rod Bolts

Concerning the removal of upper rod bolts, it is written at the pages of "Drawing out of Piston". Please refer to
the following section.
22-02-1-3) Drawing out of Piston
2. Disassembly of Connecting Rod Big End Housing

Disassemble the connecting rod big end housing as follows.
1) Preparation for Disassembly
(1) Prepare the following special tools.
No. Tool Name Note
1 Tool A 151695-92510
2 Tool B 151695-92520
3 Tool C 151695-92530
4 Bolt M20 × 1.5 L=30
5 Eyebolt 26610-080002
6 Hydraulic Jack Refer to the Section 92
(2) Remove the cylinder side covers of the affected cylinder from both sides.
(3) Turn the flywheel to bring the big end housing to the non-operation side for disassembly.
Turning the flywheel is described in "Manual cranking device".

Please refer to the following section.
(4) Install Tool B in the opening on the operation side, where the cylinder side cover has been removed.
(5) Insert Tool A in the opening on the non-operation side and push it toward the operation side.
(6) Fasten the set bolt to fix the tool A.
(7) Install tool C and the eyebolt on the big end housing.
2007.4.10R*
(8) Turn the crankshaft so that big end housing is placed on Tool A.
Fig. 22-03-1 Installation of the Tools (Clockwise)
Operation Side Non-Operation Side
Tool㧮 Eyebolt Tool㧯 Tool㧭 018795-00E
2) Disassembly of Rod Bolt Nut

Hydraulic jacks are used to assemble and disassemble the rod bolt nuts.
Loosen and tighten all the nuts on one cylinder at the same time.
The operation of the hydraulic jack is described in "Hydraulic Jack".

Please refer to the following section.
Fig. 22-03-2 Hydraulic Jack
Coupler
Piston
Body
Back-up Ring
O-ring Hydraulic Jack
Back-up Ring
Spacer
Turning Handle
018796-00E
2007.4.10R*
(1) Make sure there are no flaws or dirt on the threaded parts of the connecting rod.
Fig. 22-03-3 Connecting the Hydraulic Jack (Clockwise)
Hydraulic Jack
Joint
Coupler
018797-00E
(2) Insert spacers in the outer edge of the connecting rod bolt (at two places).
(3) Put the hydraulic jack on the rod bolt and screw in it until the spacer makes contact with the big end and
the hydraulic jack. (two bolts)
(4) Loosen the hydraulic jack about 180°away from the point where contact is made.
(5) Connect a hydraulic pump to each hydraulic jack with rubber hoses.
• Make sure the hydraulic hoses are completely inserted into the couplers.
• Make sure that the hydraulic jack piston is flush with the end surface of the hydraulic jack body.
(6) Operate the hydraulic pump to boost the hydraulic pressure to the specified pressure.
Specified hydraulic pressure : 51 MPa
• Make sure that the surface of the hydraulic piston comes up 1 ～ 1.5mm above the body.
(7) Insert the turning handle into a hole in the nut through a hole in the spacer. Then turn the nut counter-
clockwise.
If you cannot turn the nut with the turning handle, slowly raise the hydraulic pressure and try turning it
again.
Do not raise the hydraulic pressure above 60 MPa.
2007.4.10R*
(8) Gradually open the relief valve on the hydraulic pump to lower the hydraulic pressure to 0 MPa.
Make sure that the surface of the hydraulic piston is flush with the end surface of the hydraulic jack body.
(The oil pressure will be 0.)
(9) Disconnect the rubber hoses from the hydraulic jacks.

(10) Remove the hydraulic jacks and spacers.
(11) Remove the connecting rod bolt nuts.
3) Disassembly of the Big end Housing

After removing the connecting rod bolt nut, remove the big end housing.
Tool A and B are used for disassembly.
(1) Place the big end housing on tool A.
(2) Remove and take out the half from each side opening.
Do not allow the crankshaft bearing to fall.

Do not damage the straight pin.
(3) After the big end housing has been safely removed, remove the tools.
(4) Reinstall the cylinder side covers immediately after removing the big end housing to keep the area inside
the cylinder block clean.
3. Checking
1) Wrist pin bearing
(1) Check for cracks or flaws in the wrist pin bearing.
(2) Check the contact and look for a loose fit in wrist pin bearing.
(3) Measure the inner diameter of wrist pin bearing. If the bearing has reached the wear limit or it is expected
that it will reach the limit before next overhaul, replace the bearing with a new one. Since the wrist pin
bearing has been shrink fitted, remove it by hammering it out using an appropriate cushion piece or by
pressing it out.
2) Connecting Rod
(1) Check for cracks and wear on the serrated mating surfaces between the connecting rod and the big end
housing.
If water hammering happened or abnormal combustion was seen in the engine, check the connecting
rods for bend inclination and then check them for cracks using a penetration test.
2007.4.10R*
3) Big end Housing of the Connecting Rod

(1) Check for cracks and wear on the serrated mating surfaces.
(2) Check for any damage in the mating surfaces and straight pins on the top.
4) Rod Bolt, Nut

(1) Check for flaws and scoring on the bearing surface and threads of the bolt and nut.
(2) If flaws or scoring are found, correct it or replace the parts.
To prevent the rod bolts from being broken due to fatigue, replace them about every 20000 operating
hours, even if their appearance is normal.
5) Crankpin Metal
(1) Check for cracks, seizures and imbedded foreign objects on the sliding surface of each bearing.
(2) Check the contact on the rear and mating surface of each bearing.
(3) Install the crankshaft bearings in the big end housing of the connecting rod, and tighten the rod bolt nuts
with the hydraulic jack to the specified value.
(4) Measure the inner diameter of the bearings. If the bearing has reached the wear limit or it is expected that
it will reach the limit before the next overhaul, replace the bearings.
(5) Measure the thickness of the upper and lower bearings. If the difference between the dimensions A & C
and the dimensions A & B is 0.04 mm or more, replace the bearings.
Fig. 22-03-4 Bearing thickness measurement points
Approx. 40mm A
Approx. 40mm
C
018806-00E
2008.12.3R*
6) Procedure for Checking the Crankshaft Bearing While the Engine is at Rest
To check the crankshaft bearing without overhauling the cylinder head and piston while the engine is at rest,
suspend the piston halfway up the cylinder, as shown in the figure, and proceed with the check.
Fig. 22-03-5 Suspending the Piston
Fuel Injector Extracting Tool
Suspending Bolt
(Screw in Approximately 15 mm)
Piston
018807-00E
Before proceeding with this job, make sure that the crankshaft has been locked so that it cannot rotate.
Bring the manual cranking gear into contact with the flywheel and secure the lock bar in the manual
cranking device. If you don't, the crankshaft will rotate and you will be injured. For details about the oper-
ation of the lock bar, refer to "Operation of the Manual Cranking Device".
08-02 Operation of the Manual Cranking Device
2007.4.10R*
4. Assembly of the Connecting Rod Big end Housing

1) Installation of the Crankshaft Bearings
(1) When replacing the bearings, replace them as a pair of upper and lower bearings.
(2) Note that the lower bearing has oil holes in it, while the upper bearing does not. Do not reverse them.
2) Installation of the Connecting Rod Big end Housing

Install the connecting rod big end housing in essentially the reverse of the disassembly procedure.
(1) Install the special tools on the cylinder block as described section 2-1) "Preparations for Disassembly".
(2) Clean the crankshaft bearing and the big end housing.
(3) Turn the flywheel and rotate the crankshaft to a position on the side opposite the operating side.
(4) Install the bearing in the big end housing without applying the oil to the back of the bearing.
(5) Apply clean oil on the sliding surface of the crankshaft bearing and set the big end housing on Tool B.
(6) Adjust the crankshaft position so that its center matches the center of the housing.
(7) Install the upper and lower parts of the big end housing on the crankshaft and screw the connecting rod
nuts onto the rod bolts.
• Do not allow the crankshaft bearing to fall.

• Before installing the big end housing, make sure the straight pins on top are normal.
(8) Set the hydraulic jack on the connecting rod bolts and connect the pump using the same procedure as
described in section 2-2), "Disassembly of the Rod Nuts".
• Make sure that the hydraulic hoses are completely attached to the coupler.
(9) Operate the hydraulic pump to boost the hydraulic pressure to the specified pressure.
(10) Turn the nut clockwise with the turning handle until the bearing surface contacts the connecting rod.
(11) Gradually open the relief valve of the hydraulic pump to lower the pressure to 0MPa.
(12) Remove the hydraulic jack and hoses after making sure that pressure is 0MPa.
(13) Remove Tools A and B.
5. Assembly of the Connecting Rod

Before installing the connecting rod, it is necessary to install the piston on the small end of the connecting rod.
Therefore, refer to the following section.
22-02-3 Installing the Piston
2007.4.10R*
1) Installation of a Connecting Rod

(1) Turn the crankshaft position to the B.D.C. (Bottom Dead Center) position.
(2) Put the mating surface of the big end on the upper side of the journal. (This position will be held by its
own weight.)
(3) Install the piston according to the procedure described in section 22-02-3 "Installation of a Piston".
(4) Push the piston down until it contacts the mating surface of the connecting rod and the big end housing.
(5) Make sure that straight pins are correctly placed.
2) Fastening the upper Rod bolts (angular method)

The connecting rod bolts are tightened using the angular method. In order to tighten the bolts correctly, marks
indicating the specified clamping angle are stamped on the connecting rod (at two points, A & B).
When disassembling the connecting rod bolts or replacing them with new ones, be sure to stamp an
alignment mark just like it was stamped on each connecting rod bolt before being shipped from our shop.
This is because the tightening torque of the bolt will vary, depending on the accommodation of the
threaded bolt and the bearing surface.
Fig. 22-03-6 Rod Bolt Fig. 22-03-7 Tightening the Rod Bolt (Angular method)
Connecting Rod
Rod Bolt
(Upper)
A
90q
018809-00X
Big End Housing
Rod Bolt
(Lower)
018808-00E
2007.4.10R*
When loosening the connecting rod bolts or replacing them with new ones, it is necessary to stamp a new
alignment mark on the bolt to maintain the correct angular adjustment.
Stamp a new alignment mark on the connecting rod as follows.
(1) Cut or grind off the old alignment marks on the side of the bolt collar.
(2) Make sure there is no dirt or flaws on the threaded part of the connecting rod bolts and on the connecting
rod. Clean them if necessary.
(3) Apply lubricating oil to the threaded part and protective grease on the bearing seat of the respective con-
necting rod bolts.
When replacing the connecting rod bolts or the connecting rod, tighten the bolts to the specified clamping
angle (90 °) and loosen them again three of four times, to allow the bolts and the connecting rod to
accommodate to each other.
(4) Using a torque wrench, tighten the bolts to the specified torque.
Seating torque : 50 N ･ m
(5) Stamp an alignment mark on the side of the bolt collar, aligned with the mark at point A on the connecting
rod.
Fig. 22-03-8 Stamping an alignment mark
0q
30q
A
60q
90q
B
Alignment mark
018810-00E
(6) Tighten the bolts in 3 steps, dividing the specified tightening angle into 3 steps. First, tighten the 4 bolts to
30°. Then to 60°. Finally, tighten the 4 bolts to 90°.
• The deviation between the alignment mark on the bolt and alignment mark B on the connecting rod
should be less than 2mm in the direction that the bolts are tightened.
After replacing the connecting rod bolts or the connecting rod, stamp the Cylinder No., Bolt No., and so
forth as were stamped on the originals.
2007.4.10R*
No. Page
22 ピストン・連接棒部品表
Parts List of Piston & Connecting Rod 22-51a-01 1/2
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2008.9.10R
No. Page
22 ピストン・連接棒部品表
Parts List of Piston & Connecting Rod 22-51a-01 2/2

1 751694-22011 ピストンシクミ PISTON ASS'Y 6sets
1 2 151694-22011 ピストン（Ｄ２１２ PISTON, D212 6
3 2 151695-22330 フタ（ピストン、アナナシ COVER, PISTON 6
4 2 151695-22340 フタ（ピストン、アナアリ COVER, PISTON 6
5 2 133970-01780 サラバネザガネＤ２４ SPRING WASHER 24
6 2 26206-120202 ボルト１２×２０ BOLT, 12 X 20 24
7 2 26911-120122 トメネジ（ヒラ１２×１２ SCREW M10X12 12
8 1 751692-22500 ピストンリングＳＥＴ RING, PISTON 6
9 2 151692-22140 ピストンリング（ＮＯ．１ RING, PISTON 6
10 2 151605-22150 ピストンリング（ＮＯ．２ RING, PISTON 6
11 2 151695-22230 オイルリング（コイル RING, OIL 6s
14 2 151695-22300 ピストンピンシクミ PISTON PIN ASS'Y 6s
17 2 22252-001100 トメワＣ（アナ１１０ CIRCLIP 110 12
1 X 751695-23011 コネクテイングロツドシクミ CONNECTING ROD ASS'Y 6sets

18 2 151695-23031 コネクテイングロツド ROD, CONNECTING 6
19 3 151695-23071 ハウジング HOUSING 6
20 3 151695-23080 ロツド（ロングストロ－ク ROD, LONG STROKE 6
22 3 151695-23200 ロツドボルト BOLT, CONNECTING ROD 12
23 3 151605-23210 ナツト（ロツドボルト NUT, CONNECTING ROD 12
24 3 151695-23221 ロツドボルト（ウエ BOLT, CONN.ROD UPPER 24
25 3 151695-23250 ヘイコウピン１２×２０ PIN, PARALLEL 12 X 20 12
26 2 151695-23380 クランクピンメタルＣＭＰ BEARING, ASS'Y 6sets
29 2 132654-23861 ノズル（Ｐレイキヤク VALVE ASSY, INJECTION 6
30 2 153623-23950 トメネジＭ２０ SCREW, M20 6
31 2 151695-23111 メタル（ピストンピン METAL, PISTON PIN 6
2008.9.10R
Lubricating Oil System No. Page
30 Outline
(Turbocharger is equipped to the flywheel side) 30-01a-00 1/1
1. Lubricating Oil System

The lubricating oil system consists of an oil pump, oil cooler, thermostats, a main oil filter, an oil pressure reg-
ulator and a bypass oil filter. A dry sump system is standard. The lubricating oil delivered from the oil pump
flows through the oil cooler, oil strainer and main gallery to the sliding parts in the engine and turbocharger to
lubricate them, and then to the pistons to cool them.
Fig. 30-01-1 Lubricating Oil System

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2. Outline of Main Components

The lubrication oil pump is gear driven. A safety valve (pressure relief valve) is installed in the lubrication oil
pump. The lubrication oil cooler is a multi-tubular type equipped with thermostats and a bypass passage. The
main lubrication oil filter is continuously self cleaning and automatic. It does not require an external power
source. The lubrication oil strainer for the bypass is a centrifugal strainer. The lubrication oil pressure regulator
is a piston type and is located on the outlet of the main oil filter.
2007.4.18R*
30 Overhauling the Lubricating Oil Pump 30-02a-00 1/1
1. Disassembly
(1) Disconnect the pickup pipe and delivery pipe from the lubrication oil pump.
(2) Remove the lubrication oil pump.
(3) Remove the pump drive gear and disassemble the pump.
Note that the drive gear shaft has a left handed thread. Also, pay attention to the direction in which to
tighten and loosen the nut. Since the pump gear and shaft have been shrink fitted, secure the drive gear
when you loosen the nut.
Fig. 30-02-1 Disassembly of the Lubrication Oil Pump
Body Bushing Cover Ball Bearing
Drive Gear
Gear (Driven) Gear (Drive) Safety Valve 018822-00E
2. Checking
(1) Check for damage or abnormal wear on the pump gear teeth.
(2) Check for damage or burned side surfaces on the pump gears and housing.
(3) Check for burned areas or abnormal wear on the pump shafts and bushings.
(4) Measure the radial clearance between the pump gear and the housing.
(5) Measure the side clearance between the pump gear and the housing.
(6) Check the safety valve spring to see if it is broken.
(7) Check the seat of the safety valve for damage.
(8) Check for damage and backlash in the drive gear teeth and mounting.
(9) Since the life of the ball bearings for the driving shaft is expected to be 8000-12000 hours of operation,
replace them with the new ones when near this cumulative operating time.
Please note that the spring can pop out of the safety valve while disassembling it and injure you.
2007.4.18R*
30 Adjusting & Overhauling the Pressure Regulating Valve 30-03a-00 1/1
1. Adjusting the Lubricating Oil Pressure

If the lubricating oil pressure is outside the specified range, adjust it as follows.
(1) Before adjusting the lubricating oil pressure, first clean the lubrication oil strainers.
(2) Run the engine, and then adjust the oil pressure to the specified value only after the oil temperature
is steady.
Do not loosen the adjusting bolt to the extent that it can come out of the cover.
Hot oil will spurt out and may scald you.
(1) Remove the cover and loosen the lock nut.

(2) Adjust the pressure by screwing the adjusting bolt in or out.
• Clockwise : The pressure increases.
• Counterclockwise : The pressure is reduced.
(3) Tighten the lock nut and install the cover securely after making the adjustment.
Fig. 30-03-1 Pressure Regulating Valve
Valve Valve Spring Retainer,Spring Adjusting Bolt
Gasket Nut Cover 018823-00E
2. Disassembly
(1) Loosen the adjusting bolt after removing the cover and loosening the lock nut.
(2) Remove the cover of the valve body and take out the spring and valve.
3. Checking and servicing

(1) Check the damage of the valve and valve seat.
(2) Check the smooth movement of the valve.
(3) Check the breakage and elasticity of the spring and replace it with new one if it has not kept enough elas-
ticity to regulate the oil pressure.
Be careful of the spring that springs out from the body in disassembly to inflict you an injury.
2008.10.15R*
30 Adjusting & Checking the Thermostats 30-04a-00 1/1
1. Adjusting the Lubrication Oil Temperature

The automatic thermostat has been set so that the lubrication oil temperature at the engine inlet is kept at 60 ～ 75℃.
If the temperature of the lubrication oil exceeds this range, check and adjust it as follows.
Fig. 30-04-1 Lubrication Oil Adjustment Procedures
Conical Spring Adjusting Bolt

Indicator Plate
Lock Nut
A
E C O NT R
OL TUR
VA RA
L PE
M
℃ P.
V
E
T
E
EN
L
T
OI
REW
SC
TO
G
ET
N
G
TI
温 LO
W ER T EM P.
S
度 JU
を AD
下げ
る
Element Piston Gasket Plug 018824-00E
(1) Remove the plug and measure the dimension "A". ("A" is a depth from the end of the lock nut to the top of
the adjusting bolt.)
(2) Loosen the lock nut slightly.
(3) Screw the adjusting bolt in the direction shown by the arrow on the indicator plate.
• Clockwise : The temperature will decrease.
• Counterclockwis : The temperature will increase.
(4) Tighten the lock nut and install the plug securely after the adjustment is complete.
If the temperature does not drop even after making the adjustment above, suspect that the lubrication oil
cooler is fouled, a piston is sticking, there is a malfunctioning element or some other cause. Find the
cause and repair the problem.

(1) Remove the cover and make sure the piston moves smoothly. (If the piston catches or sticks, repair it.)
(2) Remove the element (installed with the piston).
(3) Soak the element in cold water and then warm water for 3 to 5 minutes, respectively, and measure lift B
on the element spindle.
Lift on the element spindle (normal part)
Fig. 30-04-2
Checking Water Temperature Lift(B)
Element
Cold Water that is 30 ℃ or less 5 ± 0.1 mm
Piston
㧮 Warm Water that is 65 ℃ or more Greater than 35 mm
018825-00E Element Spindle
(4) If the element spindle lift does not equal the values shown above, replace the element with a new one.
(5) When reassembling, adjust dimension "A" to the value measured in the procedure above.
2007.4.18R*
30 Overhauling the Lubricating Oil Filter 30-06a-02 1/6
1.Outline of the oil filter design

This filter is a back-flushing type 6.46.The element is made from polyester resin yarn woven in a hollow cylin-
drical shape. A lot of these elements are installed in columns in the filter housing. The lubricating oil passes
from the inside to the outside of the element, and is filtered by the yarn. Any dirt which builds up on the inside
of an element is pushed down into the oil pan through the hole in the Flushing Canal which corresponds to the
hole in the element. The elements are flushed once every ten seconds. The Flushing Canal rotates, and so
the backwashing filtration operation is done continuously while the engine is running.
The Flushing arm is driven by a turbine wheel which gets its energy from the lubricating oil flowing into the fil-
ter. The high speed of the turbine wheel is reduced by a worm gear to reduce it to the speed required to turn
the Flushing Canal.
The Flushing Canal speed is greatly reduced from the rotation of the turbine wheel, to 1/200 or less, by a
worm gear. It makes one complete rotation every ten seconds. As can be understood from the description
above, maintaining this filter is very easy.
Fig. 30-06-1 Filter
Pressure Different Contact Indicator
Filter Element Flushing Canal

Cover Plate
Pinion Gear
Gear Unit
Flushing Canal Shaft
Cover
O-Ring
Turbine Wing
from L.O. Pump

to Maine Gallery
Gear
Plug for Drain
018826-01E
࡮Cock A and B must be in lever position seeing on

below drawing under normal operating conditions.
Cock A Cock B
Direction of lever Direction of lever
Shut or Test Open
(normal operation)
3Way Open
Shut
Open
(normal operation)
029475-00E
2009.3.31R
2.Routine maintenance checking

The filter is an automatic, back-flushing type, so it is normally not necessary to replace the filter element.
However, please check the following items when you run the engine daily.
(1) Check the Pressure Difference Contact Indicator Fig. 30-06-2
The red segment of the disc indicates the amount of differential Pressure Diffrnce Contact Indicator
pressure. The red part is variable by the amount of differential
no matter within approx. 5mm
pressure. If the red part is over approx. 50%, a signal is emitted
via the differential pressure indicator basically. When a differen-
tial pressure warning raises an alarm, please clean the filter ele-
ment.
Otherwise, it must be ensured that the filter element is cleaned
even before emitting a signal.
Note: If the red part is indicated due to the initial differential pres-
sure, it’s no matter within 5mm approximately.
(2) Check the rotation of the Flushing Canal
Please confirm that the Flushing Canal shaft is turning by looking
through the inspection glass in the center of the cover.
(3) Check the filter and connections for leaks
029305-00E
Please make sure that none of the joints or sealed parts of the fil-
ter are leaking.
3.Inspecting and cleaning the filter elements

When a differential pressure warning is issued, or the red part becomes visible, please check and clean the
filter element as follows.
Fig. 30-06-5 Cross section
① Open the bypass line
② Close the shut-off valves at the filter inlet and outlet.
③ Now drain the oil from the filter at the drain screw.
④ Remove the cover (2).
⑤ Pull the entire filter element, including the Flushing Canal (3) and gear (15), out of the housing. Make sure
that the exposed gear (15) is not damaged.
⑥ Remove the upper cover plate (9).
⑦ The filter elements (7) can now be pushed out from below or pulled out from above.
⑧ Place the filter elements (7) in a BOLL CLEAN 2000 cold cleaner solution for a maximum of 24 hours.
⑨ After immersing the filter elements (7), use a high pressure compressed air sprayer to clean them from
the outside toward the inside.
A maximum pressure of 6.0MPa can be used at a cleaning nozzle distance not closer than 20cm from the
filter elements. Otherwise, the mesh may be damaged. Hot water at high pressure is more effective in
cleaning the elements than compressed air.
⑩ Before reinstalling the entire filter element, you must check the ease of motion of the flushing facility.
Defective filter elements (7) must not be reused.
⑪ Now push the entire filter element into the housing. By turning the flushing shaft (10) slightly, the gear (15)
is forced into the drive pinion of the gear unit (13).
⑫ It is advisable to replace all static seals during an overhaul.
⑬ Re-assemble the cover. Replace the O-ring (66) also.
2009.3.31R
4. Inspection the Pressure Difference Contact Indicator

Please check the Pressure Difference Contact Indicator as follows.
Fig. 30-06-1 Filter
Fig. 30-06-3 Pressure Difference Contact Indicator Inspection Procedures
Difference Contact Indicator
Plug
Filter Outlet Cock A Filter Inlet Cock B
029476-00E
① Close the filter inlet cock B. Fig. 30-06-4

② Turn off the filter outlet cock A to the Test position. Pressure Diffrnce Contact Indicator
③ Loosen the plug.
④ There is the differential pressure condition due to dropping down
red part is
pressure of the filter outlet side. on the middle
⑤ Please make sure that a signal is emitting when the red part is on
the middle of Indicator.
red part is
on the middle 029308-00E
2009.3.31R
5.Sources of faults and remedy

Problem Cause Reasons and corrective action.
Viscosity too high Wait for normal the engine to heat up and check again.
High volume of dirt Make sure the bypass treatment unit is functional.
Filter elements clogged Clean the elements.
Check the flow control devices in the outlet and sludge discharge
Flushing volume too low
lines for clogging.
Turbine jammed. Remove any material jammed between the turbine

and the wall.
Differential
pressure Gear unit defective.
increase Check for ease of movement.
Replace the gear unit if necessary.
Shaft end does not turn Flushing Canal jammed.

Remove any foreign matter.
Operating pressure < 0.2Mpa.

Run for prolonged period at a higher pressure (0.5~0.6MPa) to elim-
inate the blockage.
Oil quantity too low / Add oil
6.FILTER INNER PARTS LIST

The filter inner parts list is on the next page.
Please refer to it when exchanging parts.
2009.3.31R
30
2009.3.31R

$

Lubricating Oil System

$
Fig. 30-06-5 Cross section

Overhauling the Lubricating Oil Filter
OPERATION MANUAL

No.
## #
30-06a-02

018828-00X
Page
5/6
M51690
Fig. 30-06-6 Parts List

TYPE:6.46 DN80
No. PART NAME Q’ TY PART No. No. PART NAME Q’ TY PART No.
1 HOUSING 1 6530037 53 BOLT 2 2000122
2 COVER 1 6430015 55 SCREWING 4 2500024
3 FLUSHING CANAL 1 6552680 57 TUBE 1 7300002
SCREW PLUG 1 2007222
4 JOINING TUBE 1 5151253
5 SIEVE PLATE (UNDER) 1 5150509 60 㧻- RING 1 3040133
6 SIEVE PLATE (UPPER) 1 5150510 61 㧻- RING 1 3040017
7 FILTER ELEMENT 48 1365425 62 㧻- RING 1 3040652
8 SIEVE 1 5701800 63 㧻- RING 96 3049400
PERFORATED PLATE 1 7108804
9 COVER PLATE 1 5107504 65 㧻- RING 1 3031743
10 FLUSHING CANAL SHAFT 1 5309685 66 㧻- RING 1 3040115
11 TURBINE HOUSING 1 6858809 68 GASKET 1 3290012
12 FLANGE FASTENING 1 5301346 69 GASKET 3 3270002
13 GEAR 1 2709131 70 GASKET 1 3332814
14 TURBINE WING WITH WH 1 2784401 71 GASKET 1 3048235
15 TOORHED WHEEL 1 2705519 75 SPRING RING 3 2209799
16 BUSH 1 5300723 76 BOLT 3 2000122
17 BUSH 1 5060722 77 NUT 1 2100047
18 VALVE 6 0209130 79 BOLT 1 2000115
22 PRESSURE SPRING 1 2310058 80 NAME PLATE 1 9402913
23 DEEP GROOVE BALL BEARING 1 2703599
24 PRESSURE DIFFERENT 1 0550001
CONTACT INDICATOR 81 INDICATION BUSH 1 3529686
25 SCREW 1 2000257 82 TENSION RING 1 5209684
26 PIN 1 2301130 83 INSPECTION GLAS 1 4707080
27 SPRING TYPE STRAIGHT 3 2300010 85 SPRING 1 2311117
28 ANGLE NALL COCK 2 2560063
100 PLUG 1 2000191
30 STUD BOLT 8 2000239 101 GASKET 1 3270006
31 NUT 8 2100011 102 SCREWING 2 2508115
103 TUBE 1 7303640
104 NIPPLE 2 2510987
34 PLUG 1 2000194
35 PLUG 3 2000187
37 BOLT 6 2000142
38 BOLT 3 2000130
39 BOLT 3 2000130
40 BOLT 1 2000197
41 BOLT 1 2000658
42 BOLT 2 2000122
43 BOLT 6 2000133
45 BOLT 3 2000121
46 SPRING RING 3 2200235
47 DISC 1 5008712
48 WASHER 1 2200007
018829-00E
2009.3.31R
30 Overhauling the Lubricating Oil Cooler 30-08a-00 1/1
1. Disassembly
(1) Drain the lubrication oil from the lubrication oil cooler.
(2) The oil strainer is detached.
(3) Remove the side covers from the cooling water inlet and outlet.
(4) Remove the cooling water pipe assembly.
Fig. 30-08-1 Disassembly of the Lubrication Oil Cooler
O-Ring
Cover (Outlet Side)
0 Mark
Cooling Water Outlet
Lubrication Oil Inlet
Cooling Pipe
018830-00E

(1) Clean the pipes on the cooling water side and on the lubrication oil side of the cooling water pipe assembly.
• Descale the pipe on the cooling water side with a long-handled brush.
• Clean the pipe on the lubrication oil side with a sludge cleaning agent such as "Neos". Steam cleaning
is also appropriate.
Fig. 30-08-2 Cleaning the cooling pipe
Brush
(Option)
018831-00E
(2) Replace the o-rings on the cooling water inlet and outlet side covers with new ones.
3. Assembly
Assemble the lubrication oil cooler by reversing the sequence used to disassemble it, paying special attention
to the following points.
• Align the "0" mark on the cooling pipe assembly with the one on the cooler body when installing the
pipe assembly and body.
2007.4.18R*
30 Overhauling the Lubricating Oil Bypass Filter (Centrifugal Type) 30-09b-00 1/3
FM200 type Bypass Filter
Stop the engine before cleaning the bypass strainer. If you disassemble the bypass strainer while the
engine is running, oil mist may be blown out and you may be burned by hot oil.
This FM200 centrifugal bypass filter should be cleaned at regular intervals ensuring that the thickness of the
dirt deposit inside the rotor does not exceed approximately 35 mm.
The filter assembly is fitted with a cut off valve, which is located in the filter body. This valve is designed to pro-
tect the engine by stopping the supply of lube oil to the filter at start-up and during periods when the oil pres-
sure is below the valve rating.
1) Disassembly & cleaning

Disassemble and clean the lube oil bypass filter according to the following procedures:
(1) Ensure the engine stopped, and the filter has come to a complete stop before proceeding.
(2) Remove the band clamp ④ ,unscrew the cover nut ⑥ and remove the centrifuge cover assembly ⑤ .
(3) Allow the oil to drain out of the rotor assembly ⑨ . Withdraw the rotor assembly vertically upwards from
the spindle.
・At this time, it is noted not to damage an upper and lower rotor bearing.
(4) Secure the rotor assembly ⑨ on the rotor disassembly tool. Unscrew the rotor cover nut ⑩ and separate
the rotor cover from the rotor body ⑱ .
(5) Remove the stand-tube ⑬ .
(6) Remove sludge deposits from the inside of the rotor cover ⑭ using a spatula, and remove the paper
insert from the rotor cover. Clean the rotor components using a suitable cleaning fluid.
2007.4.18R*
Fig. 30-09-1 FM200 type Bypass Filter

TQVQTDGCTKPI

roter cver
slot

pin

LUB.OIL
INLET

LUB. OIL
OUTLET

ͳ NAME ͳ NAME
BODY ASSEMBLY BEARING TUBE
BODY STAND TUBE
SPINDLE ROTOR COVER
COVER CLAMP PAPER INSERT
COVER ASSEMBLY CIRCLIP
COVER NUT O-RING (ROTOR ASSEMBLY)
O-RING ROTOR BODY
COVER NOZZLE
ROTOR ASSEMBLY O-RING (FILTER BODY)
ROTOR COVER NUT CUT OFF VALVE KIT
STIFFNENER PLATE FLANGE GASKET
015477-00E
2007.4.18R*
2) Reassembly
(1) Ensure that all rotor components (including the two nozzles located in the rotor body) are thoroughly
cleaned and free from debris before reassembly.
Completely remove the sludge. Otherwise, the residual may cause an unbalance in rotation, resulting in
damage to the bearing.
(2) Fit a new paper insert into the rotor cover, and attach the whole rotor assembly component. And then
tighten with the rotor cover nut ⑩ .
・ Examine the centrifuge body O ring ⑰ for damage and renew if necessary.
・ Inspect rotor bearings for wear and replace bearing tube ⑫ if necessary.
・ Reassemble the rotor assembly ⑨ ensuring that the rotor cover slot and rotor body pin are aligned.
This prevents the unbalance during operation.
(3) Replace the rotor assembly ⑨ on the spindle.
・ Inspect spindle ② for wear and replace filter body assembly ① if necessary.
After replacing the rotor assembly, check the rotor spins freely.
(4) Replace the filter cover assembly ⑮ and fasten the centrifuge cover nut ⑥ hand tight. (Tightening torque
=5 ～ 7 Nm)
・ Examine the filter body O ring for damage and renew if necessary.
(5) Replace the cover clamp ④ and tighten hand tight. (Tightening torque =5 ～ 7 Nm)
The band clamp must be securely fitted during operation of the centrifuge.
(6) With the centrifuge running, check all joints for leaks.
2007.4.18R*
No. Page
30 潤滑油ポンプ部品表
Parts List of Lubricating Oil Pump 30-51a-01 1/2
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2008.9.10R
No. Page
30 潤滑油ポンプ部品表
Parts List of Lubricating Oil Pump 30-51a-01 2/2

X 751695-32050 ＬＯポンプシクミ（ＸＲ PUMP ASS'Y, LUB.OIL 1s
1 1 751695-32150 ＬＯポンプ（ＸＲ PUMP ASS'Y, LUB.OIL 1
14 2 26206-120352 ボルト１２Ｘ３５ BOLT, 12 X 35 8
15 2 751895-32300 アンゼンベン VALVE, SAFETY 2s
17 3 151895-32410 ベン（アンゼンベン VALVE, SAFETY 2
18 3 151895-32320 バネ SPRING, SAFETY VALVE 2
19 3 151895-32330 チヨウセイシム PLATE, ADJUSTING 2
23 3 151895-32370 バネオサエ RETAINER, SPRING 2
24 3 23414-280000 パツキン（マル２８ GASKET, 28 2
26 1 151695-32750 ギヤ（ＬＯポンプ GEAR, LUB.OIL PUMP 1
27 1 151695-32700 ナツトＭ３３Ｘ２（ヒダリ NUT, M33 X 2 LH 1
28 1 22512-100320 フエザ－キ－１０Ｘ３２ KEY, 10 X 32 1
29 1 26206-120402 ボルト　１２Ｘ４０ BOLT, 12 X 40 10
2008.10.31R
No. Page
30 潤滑油圧力調整弁部品表
Parts List of Lubricating Oil Pressure Regulating Valve 30-52a-01 1/2
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2007.9.20R
No. Page
30 潤滑油圧力調整弁部品表
Parts List of Lubricating Oil Pressure Regulating Valve 30-52a-01 2/2

1 1 751695-34012 バルブ（ＬＯチヨウアツ VALVE, OIL PRESS 1set
2 2 151695-34011 ボデイ（ＬＯＰＣＶ BODY 1
3 2 142613-34030 ベン VALVE 1
4 2 138613-34100 チヨウセイボルト BOLT, ADJUSTING 1
5 2 26772-160002 トメナツト（ホソ１６ NUT, 16 1
6 2 139964-34120 フクロナット COVER, ADJUST BOLT 1
7 2 23414-160000 パツキン（マル１６ GASKET, 16 2
8 2 26206-120302 ボルト１２×３０ BOLT, 12 X 30 2
9 2 142613-34070 カバ－（チヨアツベン COVER, CONTROL VALVE 1
10 2 142613-34080 フタパツキン PACKING, COVER 1
11 2 142613-34060 バネウケ RETAINER, SPRING 1
12 2 142613-34040 バネ SPRING, PRESS.R.V. 1
13 2 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 2
14 2 23414-170000 パツキン（マル１７ GASKET, 17 2
15 2 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 2
16 2 23414-210000 パツキン（マル２１ GASKET, 21 2
17 2 23887-280002 ６カクプラグ２８ PLUG, 28 1
18 2 23414-280000 パツキン（マル２８ GASKET, 28 1
19 1 　 24321-000750 Ｏリング１ＡＧ７５．０ PACKING, G 75.0 1
20 1 　 151695-34300 パツキン（ＬＯチヨウアツ PACKING, VALVE 1
21 1 　 26152-160402 ボルト（ホソ１×４０ BOLT, 16 X 40 8
22 1 　 26152-161302 ボルト（ホソ１６×１３０ BOLT, 16 X 130 2
2008.9.10R
No. Page
30 潤滑油こし部品表
Parts List of Lubricating Oil Strainer 30-53a-02 1/2
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020466-01X
2007.10.10R
No. Page
30 潤滑油こし部品表
Parts List of Lubricating Oil Strainer 30-53a-02 2/2

1 X 751695-35012 ＬＯコシキシクミ STRAINER ASS'Y 1set
1 2 151695-35053 ストレーナ（ＡＵＴＯ．Ｂ＆Ｋ STRAINER, AUTO 1
2 2 151695-35070 ウエコミＢＴＭ３０ホ×１９０ STUD, M30 X 190 2
3 2 151695-35350 レンラクカン（ＰＣＶモドシ PIPE, CONNECTING 1
4 2 24321-000850 Ｏリング１ＡＧ８５．０ PACKING, G 85.0 2
5 2 26152-302402 ボルト（ホソ３０×２４０ BOLT, 30 X 240 1
6 2 26736-300002 ナット（ホソ３０ NUT, 30 2
2009.3.31R
No. Page
30 潤滑油冷却器部品表
Parts List of Lubricating Oil Cooler 30-55a-01 1/3
冷却水　:　清水用
Water Spec. : Fresh Water
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2007.9.20R
No. Page
冷却水　:　清水用
Water Spec. : Fresh Water

X 751692-33210 ＬＯク－ラシクミ COOLER ASSY, LUB.OIL 1set
1 1 751692-33220 ＬＯク－ラ COOLER ASSY, LUB.OIL 1s
2 2 151692-33010 ボデイ－（ＬＯク－ラ BODY, COOLER 1
3 2 151695-33110 カバ－（ＬＯク－ラ COVER, OIL COOLER 2
4 2 26152-160452 ボルト（ホソ１６×４５ BOLT, 16 X 45 16
5 2 151695-33410 カバー（ＬＯツウロ COVER, PASSAGE 2
6 2 151695-33420 パツキン（ＬＯク－ラフタ GASKET, COOLER COVER 2
7 2 26206-120252 ボルト１２×２５ BOLT, 12 X 25 8
8 2 151695-33040 ＬＯク－ラカンＣＭＰ PIPE, L/O COOLER 1
9 2 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 5
10 2 23414-170000 パツキン（マル１７ GASKET, 17 9
11 2 23894-030002 ６カクプラグＧ３／８ PLUG, G 3/8 4
12 2 151695-33150 Ｏリング１ＡＧ２５０．０ PACKING, G250.0 2
13 2 151695-33160 ホンタイ（ＬＯサ－モスタツト BODY, THERMOSTAT A 1
14 2 151695-33570 ピストン（ＬＯサ－モスタツト PISTON, THERMOSTAT 1
15 2 151695-33520 エレメント ELEMENT 1
16 2 151692-33530 チヨウセイボルト BOLT, ADJUSTING 1
17 2 151605-33150 エンスイバネ（サ－モスタツト SPRING, CONICAL COIL 1
18 2 151692-33550 カバ－Ａ（ＬＯサ－モスタツト COVER, THERMOSTAT A 1
19 2 24316-000850 Ｏリング４ＤＰ８５．０ PACKING, P 85.0 1
20 2 26111-160352 ボルト１６×３５ BOLT, 16 X 35 4
21 2 151695-33580 トメナツト（サ－モスタツト NUT, THERMOSTAT 1
22 2 23414-160000 パツキン（マル１６ GASKET, 16 2
23 2 23887-160002 ６カクプラグ１６ PLUG, 16 1
24 2 151695-38250 メイバン（ＬＯサ－モスタツト LABEL, THERMOSTAT 1
25 2 137900-91451 パ－カ－スクリユ－リベツト RIVET, PARKERIZED 3
26 2 151692-33370 パツキン（Ａ GASKET, (A 1
27 2 151692-33380 パツキン（Ｂ GASKET, (B 1
28 2 26206-121552 ボルト１２×１５５ BOLT, 12 X 155 2
2008.9.10R
No. Page

29 2 151692-33390 ボルト１６×１５５ BOLT, 16 X 155 4
30 2 151692-33320 ＬＯバイパスカン BY-PASS PIPE(L.O. 1
31 2 24326-001100 Ｏリング４ＤＧ１１０．０ O RING 4D G110 2
32 2 24326-000850 Ｏリング４ＤＧ８５．０ O RING 4D G85 1
33 2 24375-000850 バックアップリング８５ BACK UP RING 85 2
34 2 26152-160352 ボルト（ホソ１６×３５ BOLT, 16 X 35 4
35 2 151692-33350 カクフランジ８０Ａ FLANG 80 1
36 2 26152-161102 ボルト（ホソ１６×１１０ BOLT, 16 X 110 2
37 2 26152-161302 ボルト（ホソ１６×１３０ BOLT, 16 X 130 4
38 1 151962-33600 ボルト（ホソ３０×２５０ BOLT, 30 X 250 2
39 1 151962-33610 ボルト（ホソ３０×２９０ BOLT, 30 X 290 2
40 1 151695-33620 ウエコミボルトＭ３０×３３０ STUD, M30 X 330 1
41 1 151695-33630 ウエコミボルトＭ３０×４４５ STUD, M30 X 445 1
42 1 26736-300002 ナツト（ホソ３０ NUT, 30 2
2008.9.10R
No. Page
30 潤滑油バイパス遠心こし部品表
Parts List of Lubricating Oil By-pass Strainer (Centrifugal Type) 30-56c-01 1/2
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ẢṖᴤ౉ญ
LUB.OIL
INLET
LUB. OIL
OUTLET
ẢṖᴤ಴ญ
㧢
020467-01X
2008.9.10R
No. Page
30 潤滑油バイパス遠心こし部品表
Parts List of Lubricating Oil By-pass Strainer (Centrifugal Type) 30-56c-01 2/2

X 753605-35201 バイパスＬＯコシキシクミ BY-PASS STRAINER ASS'Y 1set
1 1 42430-006072 ＦＭ２００　ＬＯコシキ STRAINER, FM-200 1s
2 2 753605-35451 ペーパーインサート PAPER INSERT 1
3 2 75605-35410 ０リング（ロータＡＳＳＹ） O-RING, ROTOR ASSEMBLY 1
4 2 753605-35430 ０リング ( フルターボディー） O-RING, FILTER BODY 1
5 2 753605-35420 ０リング O-RING, COVER NUT 2
6 2 753605-35440 パッキン（フランジ ) GASKET, FLANGE 1
7 1 26206-120352 ボルト１２Ｘ３５ BOLT, 12 X 35 4
X 751695-35210 サポートシクミ SUPPORT ASS'Y 1set

8 1 151695-35303 サポ－ト（ＬＯエンシンコシキ SUPPORT, LUB.OIL 1
9 1 26152-160402 ボルト（ホソ１６Ｘ４０ BOLT, 16 X 40 4
10 1 153605-34100 パッキン（ＬＯチヨウアツベン PACKING 1
2008.9.10R
潤滑油系統配管部品表 No. Page
30 潤滑油管（ポンプ～クーラ）部品表
30-57a-02 1/2
Parts List of Lubricating Oil Pipe（Pump ～ Cooler）
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ᯏ㑐౉ญ 㧻㧼㧼㧻㧿㧵㨀㧱‫ޓ‬㧿㧵㧰㧱‫ޓ‬㧻㧲‫ޓ‬㧲㧸㨅㨃㧴㧱㧱㧸
㧱㧺㧳㧵㧺㧱‫ޓ‬㧵㧺㧸㧱㨀 018434-00E
2007.3.23R
30 潤滑油管（ポンプ～クーラ）部品表
30-57a-02 2/2
Parts List of Lubricating Oil Pipe（Pump ～ Cooler）

Ｘ 751695-39111 ＬＯカンシクミ（ポンプＯＵＴ PIPE, ASS'Y, LUB. OIL 1set
1 1 151695-39020 ＬＯカン（ポンプＯＵＴ PIPE, LUB.OIL 1
2 1 24321-001250 Ｏリング　１Ａ　Ｇ１２５．０ PACKING, G125 1
3 1 26152-160352 ボルト（ホソ１６Ｘ３５ BOLT, 16 X 35 1
4 1 26152-160652 ボルト（ホソ１６Ｘ６５ BOLT, 16 X 65 3
5 1 26732-160002 ナツト（ホソ１６ NUT. 16 3
6 1 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 1
7 1 23414-210000 パツキン（マル２１ GASKET, 21 1
8 1 151695-39300 ギヤクシベン（１０Ｋ８０Ａ VALVE, REVERSE 1
9 1 26152-161152 ボルト（ホソ１６Ｘ１１５ BOLT, 16 X 115 4
10 1 26732-160002 ナット（ホソ１６ NUT. 16 4
11 1 23458-080000 パツキン１０Ｋ８０Ｘ１．５ GASKET, 80 X 1.5 2
12 1 151694-39031 ＬＯカン（ポンプ－ク－ラ PIPE, LUB.OIL 1
13 1 26152-160352 ボルト（ホソ１６Ｘ３５ BOLT, 16 X 35 4
14 1 24321-001100 Ｏリング１ＡＧ１１０．０ PACKING, G110.0 1
15 1 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 2
16 1 23414-210000 パツキン（マル２１ GASKET, 21 2
17 1 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 1
18 1 23414-170000 パツキン（マル１７ GASKET, 17 1
19 1 151694-39651 サポート（ＬＯヒジョウＩＮ SUPPORT（LO PIPE 1
20 1 26464-080000 Ｕボルト（Ｅ－８０ U-BOLT（E-80 1
21 1 26706-100002 ナット１０ NUT. 10 2
2007.3.23R
30 潤滑油管 ( クーラ～こし ) 部品表
30-58a-02 1/2
Parts List of Lubricating Oil Pipe (Cooler ～ Strainer)
㧥
㧝㧜
㧝㧡
㧤
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㧝
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020468-00X
2007.9.20R
30 潤滑油管 ( クーラ～こし ) 部品表
30-58a-02 2/2
Parts List of Lubricating Oil Pipe (Cooler ～ Strainer)

1 X 751695-39150 ＬＯカンシクミ（クーラコシキ PIPE ASS'Y, LUB.OIL 1set
1 1 151695-39061 ＬＯカン（ク－ラ－コシキ PIPE, LUB.OIL 1
2 1 151695-39070 カクフランジ FLANGE, SQUARE 1
3 1 24311-000900 Ｏリング１ＡＰ９０．０ PACKING, P 90.0 1
4 1 24321-001100 Ｏリング１ＡＧ１１０．０ PACKING, G110.0 2
5 1 26152-160352 ボルト（ホソ１６×３５ BOLT, 16 X 35 8
X 751695-39370 ＬＯカン（エンシンコシキ PIPE ASS'Y, LUB.OIL 1set

6 1 151695-39521 ＬＯカン（エンシンコシキ１Ｎ PIPE, LUB.OIL 1
7 1 151695-39530 ユニオン（Ｇ１／２－Ｒ１／２ UNION, G1/2-R1/2 1
8 1 23414-210000 パツキン（マル２１ GASKET, 21 1
9 1 23414-210000 パツキン（マル２１ GASKET, 21 2
10 1 43510-000350 カンツギテボルト（Ｇ１／２ BOLT, PIPE JOINT 1
11 1 43551-000241 ユニオンＰＴ１／２×１５ UNION,PT1/2X15 1
12 1 43600-023230 ボ－ルバルブ（１／２ VALVE, BALL 1
13 1 146673-39211 サポ－ト１５×１ＣＭＰ SUPPORT 1s
15 1 151695-39511 サポート（ＬＯカン，エンシンコシキ SUPPORT(LO,ROC-5 1
16 1 26206-120202 ボルト１２×２０ BOLT, 12 X 20 1
17 1 26206-120502 ボルト１２×５０ BOLT, 12 X 50 1
18 1 26706-120002 ナツト１２ NUT, 12 1
2008.9.10R
30 潤滑油圧力計管（T/FW 側）部品表
30-60a-02 1/1
Parts List of Lubricating Oil Pipe （for Pressure Gauge)（FW Side T/C）

X 751695-39420 アツケイカン（ＬＯ PIPE ASS'Y, PRESS. GAUGE 1set
1 1 138988-01680 プラグ　Ｍ３０ＸＭ１２ PLUG, M30 X 12 1
2 1 43711-097431 アツケイカンＢ（ＬＯ PIPE, PRESS.GAUGE B 1
3 1 151695-39753 アツケイカンＡ（ＬＯ PIPE, PRESS.GAUGE A 1
4 1 153605-49920 サポ－ト　６Ｘ１ SUPPORT,INJECT.PP.2 6
5 1 23414-120000 パツキン
（マル　１２ GASKET 12, ROUND 2
6 1 23414-300000 パツキン
（マル　３０ GASKET 30,ROUND 1
7 1 26206-120302 ボルト　１２Ｘ３０ BOLT M12 X 30 3
8 1 43600-030772 ニ－ドルバルブ NEEDLE 1
2007.9.20R
潤滑油系統配管部品表 Parts List of Lubricating Oil Pipe System No. Page
30 過給機用潤滑油管（T/FW 側）部品表
30-62a-00 1/2
Parts List of Lubricating Oil Pipe (for Turbocharger)
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潤滑油系統配管部品表 Parts List of Lubricating Oil Pipe System No. Page
30 過給機用潤滑油管（T/FW 側）部品表
30-62a-00 2/2
Parts List of Lubricating Oil Pipe (for Turbocharger)

1 1 151695-39360 ＬＯカンＡ（Ｔ／Ｃ　デグチ，Ｔホ PIPE(T/C OUT)A 1
2 1 151695-39370 ＬＯカンＢ（Ｔ／Ｃデグチ，Ｔホ PIPE(T/C OUT)B 1
3 1 23428-510000 コバンパツキン５１Ｘ１．５ GASKET, 51 X 1.5 1
4 1 23428-510000 コバンパツキン５１Ｘ１．５ GASKET, 51 X 1.5 1
5 1 23438-040000 パツキン　５Ｋ　４０Ｘ１．５ GASKET, 40 X 1.5 1
6 1 26152-160352 ボルト（ホソ　１６Ｘ　３５ BOLT, 16 X 35 2
7 1 26152-160352 ボルト（ホソ　１６Ｘ　３５ BOLT, 16 X 35 2
8 1 26152-160552 ボルト（ホソ　１６Ｘ　５５ BOLT, 16 X 55 2
9 1 26732-160002 ナツト（ホソ　１６ NUT, 16 2
10 1 146683-39281 サポ－トセツト SUPPORT SET 1
11 2 X 146683-39271 サポ－ト　２０Ｘ１ SUPPORT 2
12 1 151695-39330 ＬＯカン（Ｔ／Ｃ　ＩＮ，Ｔホ PIPE(T/C IN 1
13 1 151695-39470 サポ－ト（ＬＯ　Ｔ／Ｃ　ＩＮ SUPPORT, L/O PIPE IN 1
14 1 23414-250000 パツキン（マル　２５　Ｘ　１．０ GASKET, 25 X 1.0 2
15 1 23414-250000 パツキン（マル　２５　Ｘ　１．０ GASKET, 25 X 1.0 2
16 1 23857-200000 カンツギテボルト　２０ BOLT, JOINT 20 1
17 1 23857-200000 カンツギテボルト　２０ BOLT, JOINT 20 1
18 1 26206-120202 ボルト　１２Ｘ　２０ BOLT, 12 X 20 1
19 1 26206-120552 ボルト　１２Ｘ　５５ BOLT, 12 X 55 1
20 1 26796-120002 トメナツト　１２ NUT, 12 2
Cooling Water System No. Page
40 Outline (FW Side T/C - Engine side P×1) 40-01f-00 1/2
1.Outline
The engine cooling water system is divided into two circuits, one the high temperature side circuit to cooling
the cylinder liner and cylinder head and the other low temperature side circuit to cool air cooler, LO cooler
and other auxiliary equipment
Fig. 40-01-1 Cooling water system
# (9':2#05+106#0-
'/'4)'0%;(9+0.'6
*7..(+66+0)
2 2
&4#+0
(927/2
#
#
01 %;. 01 %;.
#
#+4%11.'4 6
6
#
.7$1+.%11.'4
#
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#
#
/ (927/2

*7..(+66+0)
#
#
# (9%11.'4 #

59176.'6
*7..(+66+0) 59+0.'6
(Remarks)
This is a standard system diagram.
Details at each construction have been described to the final drawing. 018284-00E
2.Low Temperature Side Cooling Water System

The low temperature side cooling water system is cooled by freshwater in the broken line route shown with
the above-mentioned system chart. The cooling water fed forcefully with the motor pump cools in order of the
air cooler, and the lubricating oil cooler.
3.High Temperature Side Cooling Water System
The high temperature side cooling water system is cooled by freshwater in the solid line route shown with the
above-mentioned system chart. In the high temperature side cooling water system, cooling water pressure-
40 Outline (FW Side T/C - Engine side P×1) 40-01f-00 2/2
fed by the engine mounted cooling water pump, cools the cylinder liner, cylinder head and branches into two
flows; one returns to the CW pump through the temperature regulating valve and the other returns.
4.Cooling Water Pump
Both the freshwater cooling water pumps are the centrifugal volute pumps.
The high temperature side cooling water pump is driven by the engine.
5.Cooling Water Temperature Regulating Valve
The cooling water temperature regulating valve uses the direct acting type. The valve keeps the temperature
at engine outlet at a constant level.
Temperature Setting : 90 ± 5 ℃
2008.11.10R
40 Overhauling the Cooling Water Pump 40-02a-01 1/2
1.Disassembly
Disassemble the cooling water pump in the numbered sequence shown in Fig 40-02-1.
Fig. 40-02-1 Cooling Water Pump

%CUKPI

#

018835-00E
Remove the ball bearings 15 & 16 together with the shaft as they are press-fitted onto the shaft.
2.Checking & servicing

(1) Measure the clearance A between the impeller 7 and the case. If the measurement exceeds the allow-
able value, replace whichever part is worn more.
( A : 0.4 ～ 1.0 mm)
(2) If necessary, replace the mechanical seal 8 and oil seal 17.
Do not reverse the direction of the parts when installing them.
Fig. 40-02-2 Oil Seal Installation Direction
018836-00X
(3) Replace the ball bearings every 8,000 to 10,000 hours, even if their appearance is good.
When press-fitting a bearing onto the shaft, apply the load on the inner race of the bearing.
(4) Replace the wavy washer 10 with a new one every time the pump is disassembled.
2007.4.18R*
40 Overhauling the Cooling Water Pump 40-02a-01 2/2
3.Assembly
Assemble the cooling water pump by reversing the sequence used to disassemble it, paying attention to the
following points.
(1) When installing the shaft, be careful not to create a flaw on the lip of the oil seal.
(2) Tighten the impeller 7 and driving gear nut 9 to the specified torque.
Part Torque (N-m)
Impeller 400 +400
Driving Gear Nut 490 +490
2007.4.18R*
40 Overhauling the Cylinder Jacket
Cooling Water Thermostats 40-03a-00 1/2
1.Outline
These thermostats are installed at the outlet of the cylinder jacket in order to raise the temperature of the
jacket water quickly and control its temperature when running. The thermostat is set to keep the water tem-
perature at the engine outlet between 85 ～ 95 ℃ .
Fig. 40-03-1 Cooling Water Thermostat
from the Cylinder Head Element Seal

from the Cylinder Head
Stem
Lock Nut
Housing Seal
Element Nut
Pin
to the Cooler Body
to the Cooling Water Pump

018837-00E 018838-00E
2.Disassembly & Assembly (Replacing the Element)

(1) Remove the bolts and nuts to disassemble the body.
(2) Remove the lock nut and pull the pin out of the stem.
(3) Turn the nut on the stem and remove the element.
(4) Remove the pin which connects the element to the stem.
(5) Connect the new element to the stem with a new pin.
(6) Remove the pins in the manual controller and replace the stem seal with a new one.
(7) Install new element seals in the body after coating them with silicon grease.
(8) Insert the stem into the body and adjust its hole to face the hole in the manual controller.
(9) Turn the nut until that the pin hole in the stem is at the "AUTO" position on the manual controller. Set the
pin at that position.
(10) Secure the stem with a lock nut.
(11) Install the housing seals in the body after coating them with silicon grease.
(12) Tighten the bolts and nuts on the body.
2007.4.18R*
40 Overhauling the Cylinder Jacket
Cooling Water Thermostats 40-03a-00 2/2
Fig. 40-03-2 Pin position on the manual controller
MANUAL
COLD
AUTO
018839-00E
3.Checking and servicing

Check the element as follows.
(1) Check the element for a broken spring or foreign matter on the valve seat surface.
(2) Dip the sensing part of the element into cold/hot water and measure the valve lift.
The normal lift from cold to hot is 9.5 mm.
Fig. 40-03-3 Valve lift of the Element

Lift 9.5mm
Sensing Part
018840-00E
(3) If the lift of the valve is unsatisfactory, replace the element.
2007.4.18R*
40 Servicing the Bypass Valve in the Air Cooler
(Turbocharger is equipped on the flywheel side) 40-04b-00 1/1
1. Operation
If the temperature of the intake air is low, sulfuric acid corrosion is considerable. The bypass valve is installed
at the inlet/exit of the air cooler cooling water pipe line in order to keep the temperature of the intake air prop-
erly.
Turn the handle of the bypass valve and adjust the temperature of the intake air from 40 to 60 ℃ at the load of
15% or more.
Fig. 40-04-1 Bypass Valve of Air Cooler Cooling Water
Full flow Bypass
to Air Cooler CW IN CW IN
from Air Cooler to LO Cooler to LO Cooler
018842-00E
(1) Turn the handle and adjust the amount of the flowing water (temperature of the intake air).
• Handle is directly upper : Full flow to air cooler. (at high load)
• Handle is 45 degree upper left : Water is being bypassed. (at low load)
Turn the handle 1～2 times a week to remove the scale from the valve, as the scale brings the stick of valve.
2007.4.18R*
No. Page
40 冷却水ポンプ（清水側）部品表
Parts List of Cooling Water Pump (Fresh Water Side) 40-51a-01 1/2
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㧣
㧢
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㧝㧥㧝㧝
㧝㧥㧝㧤㧝㧠
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㧠
㧝㧣㧡
㧝㧞
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㧥
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㧞㧡㧞㧝
㧞㧢㧞㧠
020469-00X
2005.4.10R
No. Page
40 冷却水ポンプ（清水側）部品表
Parts List of Cooling Water Pump (Fresh Water Side) 40-51a-01 2/2

X 751695-42011 ＣＷポンプ（ＸＲ PUMP ASS'Y, XR 1set
1 1 751695-42102 ＣＷポンプ（ＨＴＸＲ PUMP ASS'Y, WATER XR 1s
2 2 151695-42011 トリツケダイ BRACKET 1
4 2 151695-42030 カバ－ COVER 1
5 2 151695-42041 シヤフト（ＸＲ SHAFT, XR 1
6 2 151695-42050 インペラＢ（ＸＲ IMPELER 1
7 2 151695-42060 Ｏリング O-RING 2
8 2 151695-42490 メカニカルシ－ル MECHANICAL SEAL 1
9 2 24311-000380 Ｏリング１ＡＰ３８．０ O-RING 1A P-38.0 1
10 2 142613-42130 オイルシ－ル（ＴＣ４５６８１２） SEAL TC45 X 68 X 12,OIL 1
11 2 24101-063094 ベアリング（６３０９） BALL BEARING 1
12 2 24101-062094 ベアリング（６２０９） BALL BEARING 1
13 2 22252-001000 トメワ（アナ１００ CIRCLIP 100(H) 1
14 2 22512-100400 フエザ－キ－１０×４０ KEY 10 X 40 1
15 2 26732-330002 ナツト（ホソ３３ NUT M33 1
16 2 153623-42430 オリマゲザガネ WASHER 1
17 2 26116-100252 ボルト１０×２５ BOLT M10 X 25 PLATED 12
18 2 23897-020002 ６カクプラグＰＦ１／４ PLUG PF1/4, HEX. 6
19 2 23414-130000 パツキン（マル１３ GASKET 13, ROUND 6
20 1 151695-42450 ギヤ（ＣＷＰＸＲ GEAR, WATER PUMP XR 1
21 1 146673-42481 モレケンシユツカン（ＣＷ－Ｐ PIPE, LEAK DETECT. 1
23 2 23341-080000 カンツギテ８－１４ JOINT, 8-14 1
24 1 23297-080121 カントメカナグＡ８×１２ CLAMP, 8 X 12 1
25 1 23414-140000 パツキン（マル１４ GASKET, 14 2
26 1 23854-080000 カンツギテボルト８ BOLT, JOINT 8 1
27 1 24321-001600 Ｏリング１ＡＧ１６０．０ PACKING, G160.0 1
2008.9.10R
No. Page
40 冷却水温度調節弁部品表
Parts List of Cooling Water Thermostat Valve 40-53a-00 1/2
㧢㧠㧟㧡
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No. Page
40 冷却水温度調節弁部品表
Parts List of Cooling Water Thermostat Valve 40-53a-00 2/2

X 751695-48110 オンチョウベンシクミ THERMOSTAT ASS'Y 1set
1 1 151695-48020 オンチョウベン（ＨＴＷ THERMOSTAT(HTW 1
2 2 151695-48050 Ｏリング（ホンタイ　ＡＭＯＴ O-RING(BODY AMOT 1
3 2 40000-015380 エレメント（ＡＭＯＴ　９１ド ELEMENT(AMOT TEMP.91 3
4 2 40000-016060 Ｏリング（スカート　ＡＭＯＴ O-RING(SKIRT AMOT 3
5 2 40000-016070 Ｏリング（ツバ　ＡＭＯＴ O-RING(COLLAR AMOT 3
6 2 40000-016110 Ｏリング（レバー　ＡＭＯＴ O-RING(LEVER AMOT 3
7 1 151695-49480 パツキン PACKING 1
8 1 26152-160452 ボルト（ホソ　１６Ｘ４５ BOLT M16 X 45 4
2009.10.5R
冷却水系統配管部品表 No. Page
40 冷却水管 ( 清水ポンプ～シリンダ ) 部品表
40-54a-01 1/2
Parts List of Cooling Water Pipe (Pump ～ Cylinder)
㧝㧜
㧝㧟
㧝㧞
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㧡
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㧡
018264-00X
2008.9.10R
40 冷却水管 ( 清水ポンプ～シリンダ ) 部品表
40-54a-01 2/2
Parts List of Cooling Water Pipe (Pump ～ Cylinder)

Ｘ 751695-49012 ＣＷレンラクカン（Ｐ-ＣＹＬ PIPE, C/W CONNECTING 1set
1 1 151695-49252 ＣＷレンラクカン（Ｐ－ＣＹＬ PIPE, C/W CONNECTING 1
2 1 23414-120000 パツキン（マル１２ GASKET, 12 2
3 1 23414-170000 パツキン（マル１７ GASKET, 17 1
4 1 23414-210000 パツキン（マル２１ GASKET, 21 1
5 1 23438-100000 パツキン５Ｋ１００Ｘ１．５ GASKET, 100 X 1.5 2
6 1 23887-120002 ６カクプラグ　１２ PLUG, 12 2
7 1 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 1
8 1 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 1
9 1 26152-160452 ボルト（ホソ１６Ｘ４５ BOLT, 16 X 45 4
ウエコミボルト
10 1 26232-161102 STUD, BOLT 16 X 110 4
（ホソホソ１６Ｘ１１０
11 1 26732-160002 ナツト（ホソ１６ NUT, 16 4
12 1 43400-004080 パツキン GASKET 2
13 1 43600-022590 ギヤクシベン１００Ａ CHECK VALVE 100A 1
14 1 151695-49270 ＣＷレンラクカンＢ PIPE, C/W CONNECTING 1
15 1 26152-160502 ボルト（ホソ１６Ｘ５０ BOLT, 16 X 50 4
2007.9.20R
40 冷却水集合管部品表
40-55c-01 1/2
Parts List of Cooling Water Collecting Pipe
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㧞㧞 020475-00X
2007.9.20R
40 冷却水集合管部品表
40-55c-01 2/2
Parts List of Cooling Water Collecting Pipe

X 751695-49113 ＣＷシュウゴウカンシクミ PIPE ASS'Y, COLLECTING 1set
1 1 151623-49380 メガネフランジ FLANGE, SPECTACLE 6
2 1 151694-49580 ＣＷレンラクカン（ヘツドＯＵＴ PIPE, C/W HEAD OUT 6
3 1 151695-49330 ＣＷシユウゴウカン PIPE ASSY, COLLECTING 4
4 1 151695-49340 ＣＷシユウゴウカン（１，６ PIPE ASSY, COLLECTING 2
5 1 151695-49460 フランジ（ＣＷシユウゴウ FLANGE 6
6 1 151694-49450 エアヌキ（フランジ AIR VENT(FLANGE 1
7 1 23414-170000 パツキン（マル　１７ GASKET, 17 8
8 1 23414-210000 パツキン
（マル　２１ GASKET, 21 6
9 1 23428-440000 コバンパツキン４４Ｘ１．５ GASKET, 44 X 1.5 12
10 1 23897-030002 ６カクプラグ　Ｇ　３／８ PLUG, G 3/8 8
11 1 23897-040002 ６カクプラグＧ１／２ PLUG G1/2, HEX. 6
12 1 24326-000500 Ｏリング　４Ｄ　Ｇ　５０．０ O-RING 4D G 50 6
13 1 24326-001100 Ｏリング　４Ｄ　Ｇ１１０．０ PACKING, G110.0 12
14 1 24326-001200 Ｏリング　４Ｄ　Ｇ１２０．０ PACKING, G120.0 7
15 1 24375-001100 バツクアツプリング　１１０ BACK UP RING 110 12
16 1 26152-160652 ボルト　Ｍ１６Ｘ６５ BOLT M16 X 65 21
17 1 26206-120302 ボルト　１２Ｘ３０ BOLT M12 X 30 18
18 1 26206-120652 ボルト　１２Ｘ６５ BOLT M12 X 65 PLATED 12
19 1 26706-120002 ナツト　１２ NUT, 12 12
20 1 26732-160002 ナツト（ホソ　１６ NUT, 16 21
21 1 151694-49300 サポ－ト（ＣＷシユウゴウカン SUPPORT(CW COLLECT 6
22 1 22133-120000 ザガネ（ミガキ　１２ WASHER 12, POLISHED 12
23 1 26206-120252 ボルト　Ｍ１２Ｘ２５ BOLT M12 X 25 12
X 751694-49490 オリフイス（エアヌキ ORIFICE ASS'Y 1set

24 1 43330-005620 オリフイス ( ５Ｋ－２５、ＩＤ６ ORIFICE 1
25 1 23438-025000 パツキン ( マル２５ GASKTE 25 2
2009.3.31R
40 冷却水ドレン抜き管（シリンダ）（T/FW 側）部品表
1/3
Parts List of Cooling Water Drain Pipe（Cylinder）（FW Side T/C） 40-56b-01
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020490-01X
2008.9.10R
2/3

X 751694-49440 ドレンヌキ（クウキシツＳＦＷ PIPE ASS'Y., DRAIN 1set
1 1 23414-210000 パツキン（マル２１ GASKET, 21 1
2 1 23637-040041 アスタツプホンタイＡ１／２ COCK, 1/2 1
3 1 151695-49990 ドレン（クウキシツＳＦＷ PIPE, DRAIN 1s
4 1 23297-120121 カントメカナグＡ１２×１２ CLAMP, 12 X 12 1
5 1 132654-59960 サポ－トセツト SUPPORT SET 2s
7 1 26206-120452 ボルト１２×４５ BOLT, 12 X 45 2
8 1 26706-120002 ナツト１２ NUT, 12 2
9 1 22212-120000 バネザガネ１２ WASHER, 12 2
10 1 151694-49500 サポ－トＡ SUPPORT A 1
X 751694-49461 シリンダミズヌキ（ＯＦＷ PIPE, WATER VENT 1set

11 1 23414-210000 パツキン（マル２１ GASKET, 21 1
12 1 23637-040041 アスタツプホンタイＡ１／２ COCK, 1/2 1
13 1 151695-49980 ミズヌキ（シリンダＳＦＷ PIPE, WATER VENT 1s
14 1 23414-160000 パツキン（マル１６ GASKET 16, ROUND 1
15 1 23834-100000 ユニオン１０ UNION 10 1
16 1 151694-49930 シリンダミズヌキＡ PIPE, WATER VENT A 1s
17 1 151695-49840 サポ－ト（コツク SUPPORT, COCK 1
18 1 43550-000500 ユニオン（アツリヨクトリダシ UNION 1
19 1 26732-180002 ナツト（ホソ１８ NUT, 18 1
20 1 26152-160252 ボルト（ホソ１６×２５ BOLT, 16 X 25 1
21 1 23414-170000 パツキン（マル１７ GASKET, 17 1
22 1 23637-040032 アスタツプホンタイＡ３／８ COCK, 3/8 1
23 1 151692-49720 シリンダミズヌキＢ（ＯＦＷ PIPE, WATER VENT B 1
26 1 26206-080352 ボルト８×３５ BOLT M8 X 35 2
28 1 26706-080002 ナツト８ NUT M 8 2
2008.9.10R
3/3

X 751694-49431 ドレンヌキ（クウキシツＯＦＷ PIPE ASS'Y., DRAIN 1set
29 1 23414-210000 パツキン（マル２１ GASKET, 21 1
30 1 23637-040041 アスタツプホンタイＡ１／２ COCK, 1/2 1
31 1 151695-49970 ドレンヌキＡ（クウキシツＯＦＷ PIPE, DRAIN 1s
32 1 151692-49730 ドレンヌキＢ（クウキシツＯＦＷ PIPE, DRAIN 1s
33 1 151695-39780 ６カクボルトＭ２０×８０ BOLT, 20 X 80 1
34 1 151692-49750 サポ－トＢ SUPPORT B 1
35 1 26206-120202 ボルト１２×２０ BOLT, 12 X 20 1
37 1 26206-080352 ボルト８×３５ BOLT M8 X 35 2
2008.9.10R
冷却水配管部品表 No. Page
40 冷却水管（～ I/C）（T/FW 側）部品表
40-74a-00 1/2
Parts List of Cooling Water Pipe（～ Air Cooler）（FW Side T/C）
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ฝ࿁ォᯏ㑐↪ Clockwise Rotation Engine
40 冷却水管（～ I/C）（T/FW 側）部品表
40-74a-00 2/2
Parts List of Cooling Water Pipe（～ Air Cooler）（FW Side T/C）

× 751694-49040 ＣＷカンＡ（～Ｉ／Ｃシクミ CW PIPE( ～ I/C ASS'Y 1set
1 1 151694-49070 ＣＷカンＡ（～Ｉ／Ｃ CW PIPE( ～ I/C 1
2 1 151694-49050 ＣＷカンＢ（～Ｉ／Ｃ CW PIPE( ～ I/C 1
3 1 151694-49060 ＣＷカンＣ（～Ｉ／Ｃ CW PIPE( ～ I/C 1
4 1 151694-49220 ベンドＢ（ボウシヨク BEND(CORROSION PROOF 1
6 1 151695-49480 パツキン PACKING 3
7 1 151694-49750 サポ－ト（ＳＷＰ～Ｉ／Ｃ SUPPORT(SWP-I/C 3
8 1 23414-120000 パツキン（マル　１２　Ｘ　１．０ GASKET, 12 X 1.0 4
9 1 23414-170000 パツキン（マル　１７　Ｘ　１．０ GASKET, 17 X 1.0 1
10 1 23884-120002 ６カクプラグ　１２ PLUG, 12 4
11 1 23894-040002 ６カクプラグ　Ｇ　１／２ PLUG, G 1/2 1
12 1 26152-160302 ボルト（ホソ　１６Ｘ　３０ BOLT, 16 X 30 6
13 1 26152-160402 ボルト（ホソ　１６Ｘ　４０ BOLT, 16 X 40 4
14 1 26152-160602 ボルト（ホソ　１６Ｘ　６０ BOLT, 16 X 60 8
15 1 26206-120302 ボルト　１２Ｘ　３０ BOLT, 12 X 30 4
16 1 26463-100000 Ｕボルト（Ｄ　１００ U-BOLT, 100 3
17 1 26706-120002 ナツト　１２ NUT, 12 6
18 1 26732-160002 ナツト（ホソ　１６ NUT, 16 8
19 1 151694-49910 パツキン PACKING 1
2009.10.5R
40 冷却水管（I/C ～ LO/C）（T/FW 側）部品表
40-76a-00 1/2
Parts List of Cooling Water Pipe（I/C ～ LO/C）（FW Side T/C）
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40 冷却水管（I/C ～ LO/C）（T/FW 側）部品表
40-76a-00 2/2
Parts List of Cooling Water Pipe（I/C ～ LO/C）（FW Side T/C）

× 751694-49010 ＣＷカン（Ｉ／ＣＩＮ，ＯＵＴシクミ CW PIPE(I/C IN, OUT ASS'Y 1set
1 1 151694-49010 ＣＷカン（Ｉ／ＣＩＮ，ＯＵＴ CW PIPE(I/C IN, OUT 2
2 1 151694-49210 ベンドＡ（ボウシヨク BEND(CORROSION PROOF 1
3 1 151695-49480 パツキン PACKING 2
4 1 151694-49910 パツキン PACKING 3
5 1 23414-170000 パツキン（マル　１７Ｘ１．０ GASKET, 17 X 1.0 2
6 1 23894-030002 ６カクプラグ　Ｇ　３／８ PLUG, G 3/8 2
7 1 26152-160402 ボルト（ホソ　１６Ｘ　４０ BOLT, 16 X 40 8
8 1 26206-120302 ボルト　１２Ｘ　３０ BOLT, 12 X 30 8
9 1 26206-120452 ボルト　１２Ｘ　４５ BOLT, 12 X 45 4
10 1 26706-120002 ナツト　１２ NUT, 12 4
× 751694-49020 ＣＷカン（Ｉ／Ｃ～ＬＯＣシクミ CW PIPE(I/C ～ LOC ASS'Y 1set

11 1 151694-49020 ＣＷパイプ（Ｉ／Ｃ～ＬＯク－ラ CW PIPE(I/C ～ LO/C 1
12 1 151695-49480 パツキン PACKING 1
13 1 151694-49910 パツキン PACKING 1
14 1 23414-210000 パツキン（マル　２１Ｘ１．０ GASKET, 21 X 1.0 1
15 1 23894-040002 ６カクプラグ　Ｇ　　１／２ PLUG, G 1/2 1
16 1 26152-160402 ボルト（ホソ　１６Ｘ４０ BOLT, 16 X 40 4
17 1 26206-120302 ボルト　１２Ｘ　３０ BOLT, 12 X 30 4
27 1 23414-170000 パツキン（マル　１７Ｘ１．０ GASKET, 17 X 1.0 1
28 1 23894-030002 ６カクプラグ　Ｇ　３／８ PLUG, G 3/8 1
× 751694-49050 ＣＷカン（ＬＯＣＯＵＴシクミ CW PIPE(LOC OUT ASS'Y 1set

18 1 151694-49030 ＣＷカン（ＬＯク－ラＯＵＴ CW PIPE(LO/C OUT 1
19 1 151695-49480 パツキン PACKING 1
20 1 151694-49720 サポ－ト（ＬＯク－ラＯＵＴ SUPPORT(CW PIPE 1
21 1 23414-210000 パツキン（マル　２１Ｘ１．０ GASKET, 21 X 1.0 1
22 1 23894-040002 ６カクプラグ　Ｇ　１／２ PLUG, G 1/2 1
23 1 26152-160302 ボルト（ホソ　１６Ｘ　３０ BOLT, 16 X 30 2
24 1 26152-160402 ボルト（ホソ　１６Ｘ　４０ BOLT, 16 X 40 4
25 1 26463-100000 Ｕボルト（Ｄ　１００ U-BOLT, 100 1
26 1 26706-120002 ナツト　１２ NUT, 12 4
2009.10.5R
40 冷却水管（清水側）（T/FW 側）部品表
40-64c-00 1/3
Parts List of Cooling Water Pipe（F.W.）（FW Side T/C）
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㧱㧺㧳㧵㧺㧱‫ޓ‬㧻㨁㨀㧸㧱㨀 020481-01X
2009.3.31R
40-64c-00 2/3

X 751694-49180 ＣＷカン（ＨＴＷキカンＩＮ CW PIPE(HTW IN 1set
1 1 151694-49140 ＣＷカン（キカンイリグチ CW PIPE(ENG. IN 1
2 1 151695-49480 パツキン PACKING 1
3 1 151694-49730 サポ－ト（ＨＴＷキカンＩＮ SUPPORT(HTW ENG. IN 1
4 1 26152-160402 ボルト（ホソ　１６Ｘ４０ BOLT, 16 X 40 4
X 751694-49210 ＣＷカン（ＨＴＷヒジョウＩＮ CW PIPE(HTW IN 1set

5 1 151694-49181 ＣＷカン（ＨＴＷヒジヨウＩＮ CW PIPE(EMERGENCY IN 1
6 1 151695-49480 パツキン PACKING 1
7 1 151694-49771 サポ－ト（ＣＷヒジヨウＩＮ SUPPORT(CW EMERGENCY 1
8 1 26152-160402 ボルト（ホソ　１６Ｘ４０ BOLT, 16 X 40 2
9 1 26152-161302 ボルト（ホソ　１６Ｘ１３０ BOLT, 16 X 130 2
× 751694-49100 ＣＷカン（ＨＴＷキカンＯＵＴ CW PIPE(HTW OUT 1set

10 1 151695-49100 ＣＷカン（エンジン　ＯＵＴ PIPE COOLING WATER 1
11 1 147683-49260 フタ（ＣＷツウロデグチ COVER, WATER INLET 1
12 1 151695-49480 パツキン PACKING 2
13 1 151694-49700 サポ－ト（ＨＴＷ　ＯＵＴ SUPPORT(HTW OUT 1
14 1 26152-160302 ボルト（ホソ１６Ｘ３０ BOLT, 16 X 30 6
15 1 26152-160652 ボルト（ホソ１６Ｘ６５ BOLT, 16 X 65 4
16 1 26152-161402 ボルト（ホソ１６Ｘ１４０ BOLT, 16 X 140 4
17 1 26732-160002 ナツト（ホソ１６ NUT, 16 8
X 751695-49150 ＣＷカン（オンチョウシクミ CW PIPE (THERMOSTAT 1set

18 1 151695-49480 パツキン PACKING 2
19 1 151695-49730 ＣＷカン（オンチヨウ　ＩＮ PIPE, COOLING WATER 1
20 1 151695-49762 ＣＷカン（オンチヨウベン PIPE, COOLING WATER 1
22 1 23414-170000 パツキン（マル　１７ GASKET 17, ROUND 2
23 1 23414-210000 パツキン（マル　２１ GASKET 21, ROUND 3
25 1 23894-030002 ６カクプラグ　Ｇ３／８ PLUG G3/8, HEX. 2
26 1 23894-040002 ６カクプラグ　ＰＦ１／２ PLUG G1/2, HEX. 3
2009.10.5R
40-64c-00 3/3

27 1 26152-160402 ボルト　１６Ｘ４０ BOLT M16 X 40 4
28 1 26152-160452 ボルト（ホソ　１６Ｘ　４５ BOLT M16 X 45 2
29 1 26152-160652 ボルト　Ｍ１６Ｘ６５ BOLT M16 X 65 3
30 1 26152-160752 ボルト（ホソ　１６Ｘ７５ BOLT M16 X 75 PLATED 2
31 1 26152-161702 ボルト　Ｍ１６ホＸ１７０ BOLT M16 X 170 2
32 1 26732-160002 ナツト（ホソ　１６ NUT M16 3
2009.3.31R
40 冷却水バイパス弁（空気冷却器）（T/FW 側）部品表
40-70c-00 1/2
Parts List of Cooling Water By-Pass Valve（I/C）（FW Side T/C）
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㧝 020477-00X
40 冷却水バイパス弁（空気冷却器）（T/FW 側）部品表
40-70c-00 2/2
Parts List of Cooling Water By-Pass Valve（I/C）（FW Side T/C）

X 751694-48010 バイパスバルブ（Ｉ／Ｃ VALVE ASS'Y, BY-PASS 1set
1 1 151694-48400 リュウリョウチョウセイベン VALVE(BY-PASS 1
2 1 151694-48410 サポ－ト（バイパスベン SUPPORT(BY-PASS I/C 1
3 1 26152-160302 ボルト（ホソ　１６Ｘ３０ BOLT, 16 X 30 3
4 1 26206-120402 ボルト　１２Ｘ４０ BOLT, 12 X 40 4
2007.9.20R
40 I/C ドレン抜き管（T/FW 側）部品表
40-66a-00 1/2
Parts List of I/C Drain Pipe（FW Side T/C）
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40 I/C ドレン抜き管（T/FW 側）部品表
40-66a-00 2/2
Parts List of I/C Drain Pipe（FW Side T/C）

X 751694-49410 ミズヌキカンシクミ（Ｉ／ＣＴホ PIPE ASS'Y, WATER VENT 1set
1 1 23414-170000 パツキン（マル１７ GASKET 17, ROUND 2
2 1 23637-040031 アスタツプコツク ASTAP COCK 2
3 1 151694-49950 ミズヌキＡ（Ｉ／Ｃ　Ｔホイル PIPE, WATER VENT 1
4 1 23297-100121 カントメカナグ　Ａ１０Ｘ１２ RETAINER 10 X 12 2
5 1 151694-49960 ミズヌキＢ（Ｉ／Ｃ　Ｔホイル PIPE, WATER VENT 1
6 1 151694-49990 サポ－ト（ドレンパイプ SUPPORT 1
7 1 152672-59580 サポ－トセツト SUPPORT SET 1
9 1 26206-080402 ボルト８Ｘ４０ BOLT 8 X 40 1
10 1 22212-080000 バネザガネ８ SPRING WAHER 8 1
11 1 26706-080002 ナツト８ NUT M 8 1
X 751694-49420 ドレンカンシクミ（Ｉ／Ｃケース PIPE ASS'Y, DRAIN 1set

12 1 23414-170000 パツキン（マル　１７ GASKET 17, ROUND 1
13 1 23637-040032 アスタツプコツクホンタイ BODY, ASTAP COCK 1
14 1 151694-49810 ドレンヌキ（Ｉ／Ｃケ－ス PIPE, DRAIN 1
2008.9.10R
40 冷却水圧力計管（T/FW 側）部品表
1/1
Parts List of Cooling Water Pipe (Pressure Gauge)（FW Side T/C） 40-67b-01

X 751695-49360 アツリョクケイカンシクミ（H.T.FW CW PIPE ASS'Y(H.T.FW 1set
1 1 43600-030772 ニ－ドルバルブ VALVE, NEEDLE 1 　
2 1 23414-120000 ドウパッハン（マル１２ GASKET 12 2 　
3 1 43714-030311 オツケイカンＡ（H.T.FW CW PIPE A(H.T.FW 1
4 1 153605-91700 サポートＡ（アツケイカン SUPPORT A 2
5 1 153605-91710 ボルト６Ｘ３０ BOLT 6 X 30B 2
6 1 26116-060252 ボルト６Ｘ２５ BOLT 6 X 25 1 　
7 1 26176-060002 ナット M ６ NUT M6 1 　
751695-49370 アツリョクケイカンシクミ（L.T.CW CW PIPE ASS'Y(L.T.CW 1set

9 1 23414-120000 ドウパッハン（マル　１２ GASKET 12 2
10 1 43714-030320 オツケイカンＡ
（L.T.CW CW PIPE A (L.T.CW 1
11 1 43714-030331 オツケイカンＢ
（L.T.CW CW PIPE B (L.T.CW 1
12 1 151695-91810 サポート（アツケイカン SUPPORT 1
14 1 26206-120222 ボルト　１２Ｘ２２ BOLT 12 X 22 2
16 1 152623-91210 サポートＢ（アツケイカン SUPPORT 3B 1
17 1 26111-060302 ボルト　６Ｘ３０ BOLT 6 X 30 1
2007.11.05R
Fuel Oil System No. Page
50 Outline 50-01b-00 1/1
1.Fuel oil system

Two specifications on fuel oil(marine diesel oil and low-quality heavy fuel oil) are available for this engine.
Please refer to Fuel System Diagram drawn by your builder for details of the supply section in the low-quality
fuel system. The fuel circuit on the engine side is described here.
The fuel system of engine is composed of the part where the fuel is supplied, the part where the high pressure
fuel oil is jetted, the part where the oil return, and the piping part, and they are connected.
Fig. 50-01-1 Fuel Oil System

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4GOCTMU
6JKUKUCUVCPFCTFU[UVGOFKCITCO
&GVCKNUCVGCEJEQPUVTWEVKQPJCXGDGGPFGUETKDGFVQVJGHKPCNFTCYKPI 018285-00E
2.Outline
The pump has a discharge valve equipped with a delivery valve at the top and is a 147MPa high-pressure
type. The plunger barrel is the top closed type.
The injector passes through the cylinder head, and the joints are flared fittings at all points. The injector has
multiple staggered holes in the nozzle and has a low inertia design due to the low mass of the moving parts.
2007.4.18R*
50 Adjusting the Fuel Oil Pressure 50-02b-00 1/1
Adjusting the fuel oil pressure

The edge of the fuel oil return tube is equipped with a fuel oil pressure adjustment valve.
To absorb pulses in the pressure of the fuel being returned, it is equipped with an accumulator.
Fig. 50-02b Pressure Adjustment Valve
Accumlator
Fuel Oil Pressure Gauge

㧻
㧿
Valve Control the Oil Pressure
018850-00E
Pressure adjustment
The fuel oil pressure valve is supposed to adjust the engine fuel oil supply to the pressure in the specifications.
(Refer to the description in Section 00-09 of this manual.)
1. Adjust the pressure after cleaning the fuel filter.

2. Adjust the pressure while applying tank head pressure.
2007.4.18R*
50 Overhauling the Fuel Injection Pump 50-03a-00 1/2
The fuel injection pump is made very precisely because if it malfunctions it has an adverse effect on combus-
tion and governor performance. Therefore pay full attention to handling, disassembling & reassembling it.
1) Disassembly sequence
(1) The following disassembly tool is needed.
Fuel Injection Pump Disassembly Tool

(Refer to Fig. 50-03-2 Procedure for Removing the Plunger)
No. Description Part No.T Q’ty
1 Handle 132654-92050 1
2 Retainer Plate 151695-92060 1
3 Distance Piece 132654-92070 2
4 Barrel Retainer 153605-92080 1
5 Bolt M8 × 16 26206-080162 2
6 Bolt M18 × 50 26152-180502 2
(2) Disassemble the pump according in the numbered sequence shown in Fig 50-03-1.
Fig. 50-03-1 Fuel Injection Pump Disassembly Procedures
15 Bolt
19 Derivery Valve Spring
17 Steel Ball
18 Derivery Valve
20 Return Spring
21 Gasket
9 Bolt
16 Isobaric Valve body
10 Barrel
11 Barrel Set Bolt
12 㧻㧙Ring
8 Protactor
14 Damper Ring
23 Control Rack
7 Pinion Ring
13 㧻㧙Ring
22 Rack Guide Bolt
6 Spring Seat A
3 Plunger
4 Spring
5 Spring Seat B
2 Plunger Guide
1 Circlip
018851-00E
2007.4.18R*
50 Overhauling the Fuel Injection Pump 50-03a-00 2/2
(3) When disassembling the fuel injection pump, loosen the delivery valve holder retainer with a socket
wrench.
Fig. 50-03-2 Procedure for Removing the Plunger
018852-00E
(4) Be sure to handle the plunger and barrel as a pair.
Fig. 50-03-3 Procedure for Removing the Plunger Guide
Plunger Guide
Ԛ
Circlip
ԝ
018853-00E
2) Cautions when checking & reassembling

(1) Be sure to match the alignment marks on the plunger and control ring (pinion) as well as those on the pin-
ion and control rack.
(2) When inserting the plunger barrel into the pump body, make it face the mounting bolt hole on the outer
circumference and secure it with a mounting bolt.
(3) Periodically check the protector fitted to the pump body and replaces it with a new one if erosion is seen
at the tip. After clamping, be sure to confirm that the control rack can be moved with light pressure.
(4) Refer to Page 50-06 for details about adjusting the fuel injection timing.
2007.4.18R*
50 Regulation of the Fuel Injector Volume
(Exhaust Gas Temperature) 50-05a-00 1/1
Regulation of the Fuel Injector Volume (Rack Scale)
(1) If the difference in exhaust temperatures between the cylinders exceeds 40 ℃ with a recently ser-
viced fuel injector, adjust the rack for the corresponding fuel injection pump.
(2) Keep the difference between the rack adjustments for all the cylinders within one graduated mark on
the index.
Fig. 50-05-1 Fuel Injection Volume Regulating Procedures
Fuel Injection Pump

Fuel Injection Volume
Decrease Increease
Ԙ ԙ Rack
018854-00E
(1) Loosen the lock nut ② .

(2) Turn the rack adjusting bolt ① as follows:
Clockwise : To increase the injection volume (exhaust temperature increases)
Counterclockwise : To decrease the injection volume (exhaust temperature drops)
(3) Tighten the lock nut.
2007.4.18R*
50 Adjusting the Fuel Injection Timing 50-06a-00 1/2
If it is necessary to adjust the fuel injection timing, base the adjustments on the data recorded during a run
under load. After gathering the data, stop the engine and adjust the timing as follows:
1) Procedures for checking the fuel injection timing
(1) Turn the flywheel to align the mark on the body of fuel injection pump with that on the plunger guide.
(2) The graduation on the index pointed at by the flywheel pointer shows the current fuel injection timing.
(The flywheel index, from -10° to +30° around T.D.C. has 2° graduations and outside of this range,
the marks are every 5°.)
2) Adjusting the injection timing
Do not let your fingers come close to the lock nut or oil shield plate while turning the flywheel. Otherwise,
your fingers may be caught and you may be injured.
(1) Prepare the following exclusive tools:
Single-ended wrench (M24) for the adjusting bolt 138603 - 92510
Double-ended wrench 28110 - 220240
Ratchet handle for turning 147673 -92851
Socket (M24) for turning 42111 - 001850
Fig. 50-06-1 Fuel Injection Timing Adjustment Procedures
Fuel Injection Pump
Maked Line
1
2
Oil Shield Plate

018855-00E
(2) Turn the flywheel so that the adjusting bolt 1 is at the lowermost position.
(3) Loosen the lock nut 2.
(4) Turn the flywheel in the direction that the engine rotates so as to align the flywheel pointer with the injec-
tion timing mark (on the flywheel index) for the cylinder being adjusted.
Advance the injection timing: Pmax rises.

Retard the injection timing: Pmax drops.
2007.4.18R*
50 Adjusting the Fuel Injection Timing 50-06a-00 2/2
(5) Turn the adjusting bolt to align the line marked on the pump body with the line on the plunger guide.
(6) Turn the flywheel to position the adjusting bolt at the lowest possible point..
(7) Tighten the lock nut. (Hold the adjusting bolt with a wrench so as not to allow the bolt to turn when the
lock nut is tightened)
After adjusting the injection timing, turn the flywheel in the engine rotation direction. When the adjusting
bolt is at the uppermost position, push the oil shield plate up further to make sure there is still allowance
for the pump stroke. (Use the fuel pump priming too.)
2007.4.18R*
50 Overhauling the Fuel Injection Pump Drive 50-07a-00 1/1
Cautions to observe when disassembling & reassembling the tappet for fuel pump are as follows:
(1) Clean out anything fouling the oil hole.
(2) Check the roller rotation (to see if it rotates smoothly or drags).
(3) Use only a genuine part for the oil shield disc O-ring on the pump mount.
Fig. 50-07-1 Tappet for the Fuel Pump
O-Ring
Oil Shieid Disc
O-Ring
Tappet
Packing
Roller
Roller Pin
018944-00E
2007.4.18R*
50 Overhauling the Fuel injector & Adjusting the Injection Pressure 50-08a-01 1/4
When injectors do not receive regular qualified service, it has a great influence on the combustion perfor-
mance and the engine over all. Since it is difficult to give a single service interval for the fuel injectors, deter-
mine the period for checking & servicing by various events such as a change in the exhaust temperature,
color of the exhaust, etc.
1) Removing a fuel injector

(1) Prepare the following special tools
No. Special Tool Description Part No.
1 Body of fuel injector removal tool 151695-92340
2 Removal bolt 159666-92160
3 Nut 26706-120002
Fig. 50-08-1 (1/2) Procedure for Removing the Fuel Injector
Fuel injector Removal Tool
Extraction Bolt
Fuel injector
018945-00E
(2) Remove the clamping bolts on the joint in the fuel injection pipe using a wrench. (Also remove the bolts
on the fuel injection pump side.)
(3) Loosen the cap nut on the fuel injection pipe and remove it with the pipe.
Handle the injection pipe with care because oil will leak later if the spherical surface on either end of fuel
injection pipe is damaged, even a little.
(4) Remove the fuel injector tightening nut.
2007.4.18R*
Fig. 50-08-1 (2/2) Fuel Injector Removal Procedure
Nut
Turn
Fuel Injector Removal Tool
Turn
Extraction Bolt
Cap Nut
Flange
Injection Pipe Fuel Injectior
Bolt
Packing
Nozzle
Injection Joint Pipe 018946-00E
(5) Screw the extraction bolt into the fuel injector guard.
(6) Attach the body of the removal tool.
(7) Tighten the nut to pull out the fuel injector.
2) Installing the injector

After cleaning the fuel injector and adjusting the fuel injection pressure, reinstall the fuel injector while observ-
ing the following:
(1) Take care not to damage the tip of the nozzle sleeve when it passes the fuel injector mounting hole.
(2) Replace the case nut packing with a new one.
(3) First, tighten the cap nut on fuel injection pipe and then tighten the fuel injector nut.
(4) Do not change the installation direction because spherical washers are used in the injection pipe joint
clamping bolts on the fuel injection pump side.
(5) Tighten the clamping bolts on the fuel injection pipe joint on the cylinder head side and then tighten the
fuel injection pump side alternately. Go back and forth two or three times, tightening gradually.
(6) Oil should not leak from the overflow oil pipes after installing a fuel injector or during operation.
2007.4.18R*
3) Disassembly of a fuel injector

(1) Clean off any carbon stuck to the outside of the nozzle and then disassemble the fuel injector. (The car-
bon can be more easily removed by soaking the nozzle in carbon remover or a stock solution of cresol.)
(2) First remove the fuel injector guard and then disassemble the valve in the sequential numbered order
shown in the drawing below.
Fig. 50-08-2 Fuel injector Disassembly Procedure
12 14
11
10
1
9 2
8
3
4
7
6 13
5
018947-00X
4) Injection test & injection pressure regulation
When operating the nozzle tester, be careful not to expose any part of your body to spray from the injec-
tor. If you spray your body with fuel, you will be seriously injured because the injection pressure is very
high, 34 MPa.
(1) Attach the injector to the nozzle tester.

(2) Detach the cap on the nozzle adjustment screw (pressure) and adjust the injection pressure to the value
given on Page 00-09 by tightening or loosening the adjustment screw.
(3) Check the injection condition by rapidly operating the hand lever on the nozzle tester. If the hand lever on
the tester is operated too slowly at this time, fuel will run down, causing you to mistakenly believe that
the nozzle is out of order. Thus, pay strict attention to this requirement.
(4) Maintain an oil pressure 2.0 MPa lower than the pressure at the start of the injection to conduct an oil-
tight test. If no fuel oil oozes out of the nozzle at this pressure, the nozzle can be used as before.
(5) If the nozzle is found to be defective, when replacing it with a new one first loosen the nozzle adjustment
screw (pressure) and then fit the new nozzle. Finally, tighten the nozzle lock nut to the specified torque.
Clamping torque for nozzle lock nut: 30 ～ 40 N・m
2007.4.18R*
The nozzle lock nut should be torqued to such an extent that it is advanced by about 45Åãbeyond the point
where it becomes tightened with full force of your hand. After torquing it down, conduct a continuous injection
test at the specified injection pressure and confirm that there are no oil leaks. Pay special attention to the fact
that excessive clamping on the nozzle lock nut will distort the nozzle and might cause it to stick or damage the
straight pin.
Fig. 50-08-3 Injection Test Procedure
Fuel injector
Test Oil
Handle Lever
Nozzle Tester
018948-00E
Fig. 50-08-4 Injection Pressure Adjustment Procedure
Pressure increase Pressure drop
Pressure Adjust Screw
Lock Nut
Flat Blade Screwdriver
Fuel injector
018949-00E
2007.4.18R*
50 Overhauling the Fuel Oil Pipe 50-10a-01 1/1
Fuel oil pipes are connected by pipe plates installed per fuel injection pump in each cylinder. It is possible to
disassemble a fuel injection pump in each cylinder by moving the ring of the fuel pipe coupling at the pipe cen-
ter and moving the pipe coupling to one side.
Fig. 50-10-1 Fuel Oil Pipe
Fuel Injection Pump

O-Ring
Bushing
Fuel Oil Pipe B
Fuel Oil Pipe Joint
Fuel Oil Pipe B 018952-01E

Fuel Oil Pipe A
Pipe Plate
Fig. 50-10-2 Detail of Fuel Oil Pipe
The Condition in which the Ring is Ring

Placed in the Flange Side O-Ring
O-Ring
018953-01E
(1) Assembly
Assemble the fuel oil pipes as follows.
① Attach rings and O-rings to the fuel oil pipes A and B. Do not put the rings in the grooves yet.
Place them in the flange side.
② Apply lube oil or grease to the pipe insertion part (O-ring part).
③ Insert the pipes A and B to the fuel pipe coupling and shorten the distance between the surface of flange.
④ While the guide portion of the pipe A flange is inserted to the pipe plate, extend the pipe B flange until it
reaches the pipe plate.
⑤ Tack each flange of the pipes A and B to the pipe plate with a hexagon socket head bolt and adjust the
position of the fuel pipe coupling.
⑥ Tighten the bolt of the pipe flange.
*When the fuel pipe coupling is hard to move, do not move forcibly.
Move the fuel pipe coupling after loosening the bolt of the pipe flange.
⑦ Put the snap ring into the groove.
(2) Disassembly
Disassemble the fuel oil pipes in the reverse order of assembly.
2009.1.30R
50 Overhauling the Fuel Oil Seal Pot 50-11a-00 1/1
1. Fuel Oil Seal Pot Servicing Procedures (for Engine Using H.F.O.)
Seal pots are equipped to the mount for fuel oil pressure gauge of an engine using the heavy fuel oil (equiva-
lent to 1500-sec. or higher fuel oil).
Fig. 50-11-1 Seal Pot Servicing Procedures
Fuel Pressure Gauge
Seal Pot
1) Remove the filler plug (1) and the air vent plug (2).
2) Pour ethylene glycol from the filler until it overflow from the air vent plug.
3) When the seal pot is filled with ethylene glycol, securely tighten the plug (1) & (2).
2. Maintenance of Fuel Oil Seal Pot
As the temperature drops, the viscosity of heavy fuel oil rises. If the heavy fuel oil has entered the bourdon
tube of pressure gauge such is gauge does not work properly when the temperature has dropped. For that
reason always keep the seal pot and the piping leading to the gauge filled with ethylene glycol.
1) Periodically (about every two months) loosen the plug (2), and check if the fuel oil does not overflow.
2) Exchange of ethylene glycol. (about every 1 years)
2006.10.28R
No. Page
50 燃料噴射弁部品表
Parts List of Fuel Injection Valve 50-51a-00 1/2
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020491-00X
No. Page
50 燃料噴射弁部品表
Parts List of Fuel Injection Valve 50-51a-00 2/2

1 1 751695-53100 ＦＯフンシヤベンＡＳＳＹ VALVE ASS'Y, FUEL 6sets
2 2 151695-53000 ノズル（１６０３０４Ｕ１３０４９８Ｇ NOZZLE ASS'Y 6s
5 2 151695-53080 ナツト（ノズルトリツケ NUT, NOZZLE 6
6 2 151695-53100 ノズルホルダ HOLDER, NOZZLE 6
7 2 151695-53160 ボルト（ノズルＳＰチョウセイ BOLT 6
8 2 139684-53170 チヨウセイネジナツト NUT 6
9 2 142613-53200 Ｆ０．Ｖヨウヘイコウピン（５Ｘ１０） PARALLEL PIN 5X10 24
10 2 153605-53212 シ－ト（ノズルＳＰ SEAT, NOZZLE SPRING 6
11 2 153623-53221 ノズルスプリング SPRING, NOZZLE 6
12 2 153605-53230 スペ－サ（ムレイ SPACER 6
13 2 151695-53330 オサエ（ノズルＳＰ RETAINER, SPRING 6
14 2 153605-53450 キヤツプナツト CAP NUT 6
15 2 23414-120000 パツキン（マル　１２ GASKET 12, ROUND 12
16 2 24316-000650 Ｏリング４ＤＰ６５．０ O-RING 4D P 65.0 6
17 2 24326-000700 Ｏリング４ＤＧ７０．０ O-RING 4D G 70.0 6
2008.9.10R
No. Page
50 燃料噴射ポンプ部品表
Parts List of Fuel Injection Pump 50-53a-01 1/3
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016230-00X
2007.2.10R
No. Page

1 1 751695-51204 ＦＩＥ　ＡＳＳＹ（ＥＹ２６ FIE ASS'Y(EY26 6sets

3 2 151695-51402 プランジヤＣＭＰ PLUNGER ASS'Y 6s
7 2 151695-51171 プランジヤスプリング SPRING, PLUNGER 6
8 2 151695-51180 バネウケ（Ａ RETAINER, SPRING 6
9 2 151695-51190 バネウケ（Ｂ RETAINER, SPRING 6
10 2 151695-51200 プランジヤガイド GUIDE, PLUNGER 6
11 2 151695-51210 トメワ CIRCLIP 6
12 2 153605-51223 Ｏリング（イチブシロ），ＦＰ３３ O-RING(WHITE PAINT) 12
13 2 153605-51242 Ｏリング O-RING 6
14 2 151673-51250 バレルマワリドメボルト BOLT 6
15 2 153605-51250 パツキン（ＦＩＣ GASKET 6
16 2 151695-51300 トウアツベンＣＭＰ VALVE ASS'Y, DELIVERY 6s
19 4 22312-040120 ヘイコウピン４Ｘ１２ PIN 4 X 12 12
20 3 151695-51330 デリベリバルブＣＭＰ VALVE ASS'Y, DELIVERY 6
21 4 151695-51350 デリベリバルブ VALVE, DELIVERY 6
22 4 151695-51360 ストツパ（デリベリ STOPPER, DELIVERY 6
23 4 151695-51370 リタ－ンバルブＳＰウケ RETAINER, SPRING 6
24 4 151695-51380 スプリング（デリベリバルブ SPRING, DELIVERY 6
25 4 151695-51390 スプリング（リタ－ンバルブ SPRING, RETURN VALVE 6
26 4 24190-070003 コウキユ７／３２ BALL, 7/32 6
27 3 153604-51381 カクリング（ＣＰＶ RING 6
28 2 153604-51401 Ｏリング（ホンタイウエ O-RING 6
29 2 153604-51410 ダンパリング RING, DAMPER 6
30 2 153604-51450 プロテクタＣＭＰ PROTECTOR ASS'Y 12s
32 3 148633-53600 Ｏリング GASKET, JOINT 12
33 2 151695-51501 ラツク RACK 6
34 2 153605-51511 ピニオン RACK PINION 6
35 2 153605-51550 ボルト（ラツクマワリドメ） BOLT 6
36 2 138688-51570 シムセツト SHIM SET 6
43 2 138613-51730 ラツクポインタ－ POINTER 6
44 2 151695-51851 Ｏリング O-RING 18
2008.9.10R
No. Page
45 2 151695-51861 Ｏリング O-RING 6

48 2 153605-51901 クウキヌキボルト BOLT, AIR VENT 6
49 2 129100-52200 カバー COVER 6
50 2 158805-85900 プラグ（Ｇ１／４ PLUG G1/4 6
51 2 158805-85910 プラグ（Ｇ３／８ PLUG G3/8 18
52 2 22190-100006 シ－ルワツシヤ（コマル．フツソ）１０ SEAL WASHER 10S <F> 6
53 2 23414-080012 パツキン（コマル８ GASKET 8 6
54 2 23414-120016 パツキン（コマル１２ GASKET 12 12
55 2 23887-120002 ６カクプラグ１２ PLUG 12, HEX. 12
56 2 26450-080122 ６カクアナボルト８Ｘ１２ BOLT 8 X 12 6
57 2 26450-120652 ６カクアナボルト１２Ｘ６５ BOLT 12 X 65 72
58 2 26557-060102 ナベコネジ（＋アナ６Ｘ１０ SCREW 6 X 10 12
59 2 26577-060142 サラコネジ（＋アナ６Ｘ１４ SCREW M 6 X 14 6
2008.9.10R
No. Page
50 燃料噴射ポンプ駆動装置部品表
Parts List of Fuel Injection Pump Driving Device 50-54a-01 1/2
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020495-01X
2008.9.10R
No. Page
50 燃料噴射ポンプ駆動装置部品表
Parts List of Fuel Injection Pump Driving Device 50-54a-01 2/2

X 751695-54110 ＦＯポンプクドウソウチシクミ DRIVING DEVICE, FO-P 6sets
1 1 751695-54100 ＦＯポンプクドウソウチ DRIVING DEVICE, FO-P 6sets
2 2 151695-54010 トリツケダイ（ＦＯＰ BRACKET, F/O PUMP 6
TAPPET ASS’Y,
3 2 151695-54090 タペツトＣＭＰ（ＦＯＰ 6
F/O PUMP
6 2 151695-54200 チヨウセイネジ（タペツト SCREW, TAPPET ADJUST 6
8 2 153605-54231 アブラキリ SEALING, OIL 6
9 2 151695-54030 フタ（ＦＯＰトリツケダイ COVER, PUMP MOUNT 6
10 2 26557-080102 ナベコネジ（＋アナ８Ｘ１０ SCREW, 8 X 10 12
12 2 26742-240002 コガタナツト（ホソ２４ NUT, 24 6
13 2 24321-000450 Ｏリング１ＡＧ４５．０ PACKING, G 45.0 6
14 2 27225-050060 ウチコミプラグ５Ｘ６ PLUG, 5 X 6 12
15 2 22351-040010 スプリングピン４ＡＷ１０ PIN, SPRING 6
16 1 151695-54020 ＬＯレンラクカン PIPE, L/O CONNECTING 6
17 1 146673-54040 ヘイコウピン（ＦＯＰダイ PIN, PUMP MOUNT 6
18 1 151695-54050 パツキン（トリツケダイ PACKING, MTG.BRACKET 6
19 1 24311-000160 Ｏリング１ＡＰ１６．０ PACKING, P 16.0 6
2008.9.10R
No. Page
50 燃料噴射管部品表
Parts List of Fuel Injection Pipe 50-55a-00 1/2
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No. Page
50 燃料噴射管部品表
Parts List of Fuel Injection Pipe 50-55a-00 2/2

X 751695-59200 ＦＯフンシヤカン PRESSURE PIPE, FO 6sets
1 1 146673-59020 パツキン PACKING 6
2 1 151695-59061 コウアツカンツギテ JOINT, PRESSURE PIPE 6s
6 1 151695-59180 フクロナツト（ＦＯフンシヤカン NUT, INJECTION PIPE 6
7 1 151694-59200 コバンフランジ FLANGE, OVAL 6
8 1 151695-59220 パツキン PACKING 6
9 1 151695-59230 ＦＯフンシヤカン PIPE, FUEL INJECTION 6
10 1 146673-59240 キユウメンザガネ（Ｍ１０ WASHER, M10 12
11 1 151695-59240 キユウメンザガネ（ウケ WASHER 12
12 1 146673-59250 パツキン PACKING 6
13 1 26450-080402 ６カクアナボルト８Ｘ４０ BOLT, 8 X 40 12
14 1 26450-100652 ６カクアナボルト１０Ｘ６５ BOLT, 10 X 65 12
2008.9.10R
No. Page
50 燃料調圧弁部品表
Parts List of Fuel Oil Pressure Regulating Valve 50-59a-01 1/2
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2007.9.20R
No. Page
50 燃料調圧弁部品表
Parts List of Fuel Oil Pressure Regulating Valve 50-59a-01 2/2

1 1 732653-59303 ＦＯチヨウアツベンクミタテ CONTROL VALVE, FUEL 1set
2 2 139653-34090 フクロナツト CAP NUT 1
3 2 132654-59281 ホンタイ（チヨウアツベン BODY, CONTROL VALVE 1
4 2 151673-59320 ベン（ＦＯチヨウアツＶ．，Ｌ４０ VALVE L40 1
5 2 153672-59870 シ－ルワツシヤ－３３ WASHER, SEAL 33 1
6 2 153672-59980 シ－ルワツシヤ－１６Ｘ１．６ WASHER, SEAL 16 X 1.2 2
8 2 135610-84310 チヨウセイネジササエ SUPPORT, SCREW 1
9 2 26772-160002 トメナツト（ホソ１６ NUT, 16 1
10 2 44100-004850 バネ SPRING 1
11 2 153672-59930 シ－ルワツシヤ－１４ WASHER, SEAL 14 2
12 2 153672-59960 シ－ルワツシヤＤ＝１８ WASHER, SEAL D=18 1
13 2 23458-025000 パツキン１０Ｋ２５Ｘ１．５ GASKET, 25 X 1.5 1
14 2 23887-140002 ６カクプラグ１４ PLUG, 14 2
15 2 23897-030002 ６カクプラグＧ３／８ PLUG, G 3/8 1
16 2 26152-160502 ボルト（ホソ１６Ｘ５０ BOLT 16 X 50 2
17 2 26152-160552 ボルト（ホソ１６Ｘ５５ BOLT 16 X 55 2
18 2 26732-160002 ナット（ホソ１６ NUT 16 4
2009.3.31R
No. Page
50 漏油タンク・フロートスイッチ部品表
Parts List of Overflow Fuel Tank ＆ Float Switch 50-62a-00 1/2
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No. Page
50 漏油タンク・フロートスイッチ部品表
Parts List of Overflow Fuel Tank ＆ Float Switch 50-62a-00 2/2

X 751695-59350 フロートスイッチシクミ FLOAT SWITCH ASS'Y 1set
1 1 151695-59600 ロウユタンク（フロ－トＳＷ TANK, OVER FLOW 1
2 1 151695-59610 ＦＯロウユカン（フロ－トＳＷ PIPE, F/O OVER FLOW 1
3 1 151695-59620 ＦＯモドリカン（フロ－トＳＷ PIPE, FUEL RETURN 1
4 1 151695-59630 ツギテ（ＦＯフロ－トＳＷ JOINT, FLOAT SWITCH 1
5 1 151695-59640 ＦＯドレンカン（フロ－トＳＷ PIPE, FUEL DRAIN 1
6 1 133670-59710 カンツギテボルト（Ｍ１８ BOLT, PIPE JOINT M18 1
7 1 151695-59890 サポ－ト（フロ－トＳＷモドリカン SUPPORT, SWITCH 1
9 1 153672-59960 シ－ルワツシヤＤ＝１８ WASHER, SEAL D=18 2
10 1 23297-080121 カントメカナグＡ８Ｘ１２ CLAMP, 8 X 12 1
11 1 23637-040042 アスタツプホンタイＢ１／２ COCK, 1/2 1
12 1 23831-080000 ユニオン８ UNION, 8 3
13 1 26206-080252 ボルト８Ｘ２５ BOLT, 8 X 25 4
14 1 26206-100102 ボルト１０Ｘ１０ BOLT M10 X 10 PLATED 1
15 1 43230-014360 パツキン（フロ－トＳＷ GASKET, FLOAT SWITCH 1
16 1 43230-014440 ザガネＴ＝３（フロ－トトテ WASHER, FLOAT SWITCH 1
17 1 46111-018771 フロ－トスイツチ（ＦＯロウユ SWITCH, FLOAT 1
2008.9.10R
No. Page
50 漏油溜め部品表
Parts List of Overflow Fuel Sump 50-72a-00 1/2
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No. Page
50 漏油溜め部品表
Parts List of Overflow Fuel Sump 50-72a-00 2/2

X 751695-59400 ロウユダメシクミ SUMP ASS'Y 1set
1 1 151695-59781 サポ－ト（ロウユダメ SUPPORT, SUMP 1
2 1 23414-210000 パツキン（マル２１Ｘ１．０ GASKET, 21 X 1.0 1
3 1 23897-040002 ６カクプラグＧ１／２ PLUG, G 1/2 1
4 1 26206-100252 ボルト１０Ｘ２５ BOLT M10 X 25 4
5 1 41650-001110 ＦＯロウユダメ（０．６Ｌ SUMP, FUEL OVERFLOW 1
6 1 43570-000920 フランジツギテ JOINT, FLANGE 1
2007.9.20R
No. Page
50 アキュムレータ部品表
Parts List of Accumulator 50-73a-00 1/1
0205001-00X

1 1 151695-59760 アキユムレ－タ（０．３２ ACCUMLATOR(0.32 2
2005.4.10R
燃料配管系統部品表 No. Page
50 燃料油管 ( 入口～主管 ) 部品表
50-66b-01 1/3
Parts List of Fuel Oil Pipe (Inlet ～ Main Pipe)
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0205006-00X
2007.9.20R
50-66b-01 2/3

X 751695-59181 ＦＯカン（コシキ－シュカン PIPE,FUEL IN 1set
1 1 151695-59542 サポ－トＢ（ＦＯＶモドリ SUPPORT, RETURN B 2
2 1 26206-120202 ボルト１２Ｘ２０ BOLT, 12 X 20 4
3 1 151695-59561 サポ－ト２７．２Ｘ２ SUPPORT, 27.2 X 2 2
4 1 26206-120502 ボルト１２Ｘ５０ BOLT, 12 X 50 2
5 1 138613-59282 プラグ（エア－ヌキ PLUG, AIR VENT 1
6 1 153672-59900 シ－ルワツシヤ８Ｘ１．２ WASHER, SEAL 8 X 1.2 1
7 1 151692-59900 サポ－ト（ＦＯシユカンツギ SUPPORT, PIPE JOINT 1
8 1 26206-120252 ボルト１２Ｘ２５ BOLT, 12 X 25 2
9 1 151692-59930 ネンリヨウカンツギテ JOINT, FUEL PIPE 1
10 1 24326-000250 Ｏリング４ＤＧ　２５．０ PACKING, G 25.0 1
11 1 26450-080652 ６カクアナボルト８Ｘ６５ BOLT, 8 X 65 3
12 1 151692-59890 サポート（ＦＯシュカン SUPPORT(FO MAIN PIPE 1
13 1 26206-100202 ボルト１０Ｘ２０ BOLT, 10 X 20 2
14 1 151674-59980 フレドメ（ＦＯモドリ CLAMP, RETURN PIPE 2
15 1 26206-080602 ボルト８Ｘ６０ BOLT, 8 X 60 2
16 1 26706-080002 ナツト８ NUT, 8 2
17 1 151694-59181 ＦＯカン（コシキ－ツギテ PIPE,FO(FILTER OUT 1
18 1 151694-59170 ＦＯカン（ツギテ－シュカン PIPE,FUEL IN 1
19 1 24326-000450 Ｏリング４ＤＧ４５．０ PACKING, G 45.0 2
20 1 26206-120802 ボルト１２Ｘ８０ BOLT, 12 X 80 2
21 1 26206-120852 ボルト１２Ｘ８５ BOLT, 12 X 85 2
22 1 26706-120002 ナツト１２ NUT, 12 4
23 1 151694-59651 サポート（ＦＯカン SUPPORT(FO PIPE 1
24 1 26116-200802 ボルト２０Ｘ８０ BOLT, 20 X 80 1
25 1 153605-59400 フレドメ SUPPORT 1
26 1 26206-120352 ボルト１２Ｘ３５ BOLT, 12 X 35 1
27 1 151695-59270 アツリョグケイトリダシザ MOUNT(FO PRES GAUGE 1
28 1 23897-040002 ６カクプラグＧ１／２ PLUG G1/2 1
29 1 23414-210000 パッキン（マル２１ GASKET 21 1
30 1 23897-030002 ６カクプラグＧ３／８ PLUG G3/8 1
2007.9.20R
50-66b-01 3/3

31 1 23414-170000 パッキン（マル１７ GASKET 17 1
33 1 26206-120182 ボルト１２Ｘ１８ BOLT, 12 X 18 2
35 1 26206-120182 ボルト１２Ｘ１８ BOLT, 12 X 18 1
36 1 151694-91250 サポート（ＦＯアツリョクケイ SUPPORT(FO PRESS. GA 1
37 1 26116-060102 ボルト６Ｘ１０ BOLT, 6 X 10 2
38 1 146673-59890 パッキン（シールポット PACKING 1
39 1 146673-59881 ホンタイ（シールポット BODY (SEAL POT 1
40 1 146673-59980 カイカン（シールポット PIPE (SEAL POT 1
41 1 26206-080502 ボルト８Ｘ５０ BOLT, 8 X 50 4
42 1 23897-060002 ６カクプラグＧ３／４ PLUG G3/4 1
43 1 153672-59850 シールワッシャー２７ WASHER, SEAL 27 1
44 1 23887-120002 ６カクプラグＭ１２ PLUG M12 2
45 1 23414-170000 パッキン（マル１２ GASKET 12 2
46 1 23875-010000 ネジプラグＲ０１ PLUG R01 2
47 1 146673-59940 カンアツバルブ VALVE, PRESSURE CAUG 1
48 1 43400-005640 パツキンＴ＝１．０（Ｇ１／４ GASKET, T=1.0 G1/4 2
49 1 139653-91170 セツゾクカナグ CONNECTOR 1
50 1 132658-91270 カンショウゴム RUBBER 2
51 1 132658-91260 オサエガネ RETAINER 1
52 1 26116-050402 ボルト５Ｘ４０ BOLT, 5 X 40 4
53 1 26716-050002 ナツト５ NUT, 5 4
2007.9.20R
50 燃料油主管部品表
50-67a-03 1/2
Parts List of Fuel Oil Pipe (Main Pipe)
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020503-02X
2009.1.30R
50 燃料油主管部品表
50-67a-03 2/2
Parts List of Fuel Oil Pipe (Main Pipe)

X 751694-59050 ネンリヨウシュカンシクミ MAIN PIPE ASS'Y 1set
1 1 151692-59150 ネンリヨウハイカンバンＡ BASE A, F.O.PIPE 5
2 1 151692-59160 ネンリヨウハイカンバンＢ BASE B, F.O.PIPE 1
3 1 151895-59291 ネンリヨウシユカンＡ MAIN PIPE A(F.O. 10
4 1 151895-59221 ネンリヨウシユカンＢ MAIN PIPE B(F.O. 12
5 1 151895-59270 ネンリヨウシユカンＣ MAIN PIPE C(F.O. 2
6 1 151895-59230 ネンリヨウカンツギテ PIPE JOINT 12
7 1 151695-59210 Ｏリング（ＦＰ６３）Ｐ２６ O-RING(FP63)P26 48
8 1 22242-000320 トメワＣ（ジク　３２ RING, 32 22
9 1 151895-59251 サポート（ＦＯシユカン） SUPPORT(F.O. MAIN 1
10 1 151895-59280 コテイカナグ（ＦＯカン PIPE SUPPORT 2
11 1 24316-000220 Ｏリング４ＤＰ２２．０ PACKING, P 22.0 12
12 1 24326-000250 Ｏリング４ＤＧ２５．０ PACKING, G 25.0 2
13 1 24326-000300 Ｏリング４ＤＧ３０．０ PACKING, G 30.0 22
14 1 24550-012120 ドライブツシユ１２Ｘ１２ BEARING, 12 X 12 12
15 1 23887-120002 ６カクプラグ１２ PLUG, 12 1
16 1 23887-200002 ６カクプラグ２０ PLUG, 20 2
17 1 23414-120000 パツキン（マル１２×１．０ GASKET, 12 X 1.0 1
18 1 153672-59970 シールワッシャー２０×１．２ WASHER, SEAL 20 X 1.2 2
19 1 26206-100552 ボルト１０Ｘ０５５ BOLT, 10 X 55 36
20 1 26206-121952 ボルト１２Ｘ１９５ BOLT, 12 X 195 2
21 1 26450-080222 ６カクアナボルト　８×２２ BOLT, 8 X 22 66
22 1 26450-080222 ６カクアナボルト　８×２２ BOLT, 8 X 22 6
2009.1.30R
50 燃料油管（主管～調圧弁）部品表
50-71b-01 1/2
Parts List of Fuel Oil Pipe (Main Pipe ～ Regulating Valve)
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020508-01X
2009.3.31R
50 燃料油管（主管～調圧弁）部品表
50-71b-01 2/2
Parts List of Fuel Oil Pipe (Main Pipe ～ Regulating Valve)

X 751695-59081 ＦＯモドリカンシクミ PIPE ASS'Y.(FO RETURN 1set
1 1 151694-59191 ＦＯモドリカン（シュカン－Ｖ PIPE.(FO RETURN 1
2 1 24326-000550 Ｏリング４ＤＧ５５．０ PACKING, G 55.0 1
3 1 26152-160452 ボルト（ホソ１６Ｘ４５ BOLT, 16 X 45 2
4 1 26152-160552 ボルト（ホソ１６Ｘ５５ BOLT, 16 X 55 2
5 1 26732-160002 ナツト（ホソ１６ NUT, 16 4
6 1 24326-000250 Ｏリング４ＤＧ２５．０ PACKING, G 25.0 1
7 1 153672-59870 シールワッシャー　３３ WASHER, SEAL 33 1
8 1 26450-080652 ６カクアナボルト８Ｘ６５ BOLT, 8 X 65 3
9 1 151695-59072 サポート（ネンリョウシュカン SUPPORT(FO MAIN PIPE 1
11 1 26206-120202 ボルト１２Ｘ２０ BOLT, 12 X 20 4
12 1 26206-120602 ボルト１２Ｘ６０ BOLT, 12 X 60 4
X 751695-59482 ＦＯローユカンシクミ PIPE ASS'Y.(OVERFLOW 1set

13 1 151692-59650 ホンタイ（ドレンコック BODY, RETURN VALVE 1
14 1 141646-59660 ベンボウ（ドレンコック SHAFT, RETURN VALVE 1
15 1 24316-000100 Ｏリング４ＤＰ１０ PACKING, P10 11
16 1 141646-59670 フクロナット NUT, CAP 1
17 1 42221-012780 メイバン（ジョウジヘイ NAME PLATE 1
18 1 22451-106000 ツヅリセン０．６ WIRE 1
19 1 153672-59970 シールワッシヤー２０Ｘ１．２ WASHER, SEAL 20 X 1.2 3
20 1 151694-59793 ネンリョウパージカン PIPE, FUEL RETURN 1
21 1 151694-59640 サポ－ト（ＦＯローユカン SUPPORT, OVERFLOW 1
22 1 26206-120182 ボルト１２Ｘ１８ BOLT, 12 X 18 1
23 1 146673-39201 サポ－ト１５Ｘ１ SUPPORT, 15 X 1 2
24 1 26206-120452 ボルト１２Ｘ４５ BOLT, 12 X 45 1
25 1 26706-120002 ナツト（ホソ１２ NUT, 12 1
2009.3.31R
50 燃料漏油管（FO 噴射弁）部品表
50-68a-01 1/2
Parts List of Fuel Oil Pipe (Overflow for Injection Valve)
㧡㧭
㧞
㧠㧠㧞
㧝㧜
㧝㧥
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㧝㧢 020509-00X
2008.9.10R
50 燃料漏油管（FO 噴射弁）部品表
50-68a-01 2/2
Parts List of Fuel Oil Pipe (Overflow for Injection Valve)

X 751692-59250 ＦＯＶロウユカン（ヘツド－レ OVERFLOW PIPE, FO.V 1set
1 1 151692-59800 ＦＯＶロウユカン（ヘツド－レ OVERFLOW PIPE, FO.V 6s
2 1 153672-59920 シ－ルワツシヤ－１２Ｘ１．２ WASHER, SEAL 12 X 1.2 24
3 1 23831-060000 ユニオン６ UNION, 6 6
4 1 23851-060000 カンツギテボルト６ BOLT, JOINT 6 12
5 1 151695-39920 パツキン（マル１２　 GASKET, 12 6
X 751695-59251 ＦＯＶロウユカン（レ－ル－ツキ PIPE, OVER FLOW 1set

6 1 153602-59150 ギヤクシベンＡＳＹ VALVE ASS'Y, REVERSE 1S
7 1 151695-59821 ＦＯＶロウユカン（レ－ル－ツキ PIPE, OVER FLOW 1S
8 1 151695-59832 ＦＯＶロウユカン（ツギテ－Ｆ PIPE, OVER FLOW 1S
9 1 23857-100000 カンツギテボルト１０ JOINT BOLT 10 1
10 1 153672-59980 シ－ルワツシヤ－１６Ｘ１．６ WASHER, SEAL 16 X 1.2 2
12 1 151695-59420 サポート（ＦＯフランジ SUPPORT(FO FLANGE 1
13 1 26152-200902 ボルトＭ２０ホＸ９０ BOLT M20 X 90 1
14 1 43310-006910 トクシユフランジ（Ｍ１４） FLANGE M14, SPECIAL 1
15 1 26206-100452 ボルト１０Ｘ４５ BOLT M10 X 45 2
16 1 26706-100002 ナツト１０ NUT M10 2
2008.9.10R
50 燃料漏油管（シリンダ）部品表
50-69b-00 1/2
Parts List of Fuel Oil Pipe (Overflow for Cylinder)
㧣
㧣
㧥
㧤
㧠

016231-00X
2006.9.1R
50 燃料漏油管（シリンダ）部品表
50-69b-00 2/2
Parts List of Fuel Oil Pipe (Overflow for Cylinder)

X 751695-59291 シリンダロウユカンシクミ PIPE ASS'Y, OVER FLOW 1set
1 1 151694-59640 サポート（ＦＯロウユカン SUPPORT 1
2 1 26206-120182 ボルト１２×１８ BOLT, 12 X 18 1
3 1 26706-120002 ナット１２ NUT, 12 1
4 1 146673-39211 サポ－ト１５Ｘ１ＣＭＰ SUPPORT 3
6 1 151694-59771 ＦＯロウユカン（ＣＹＬ．Ｂ PIPE, F/O OVER FLOW 1
8 1 26206-120352 ボルト１２Ｘ３５ BOLT, 12 X 35 2
9 1 43510-000340 カンツギテボルト BOLT, PIPE JOINT 1
10 1 26206-120452 ボルト１２Ｘ４５ BOLT, 12 X 45 1
2008.9.10R
50 燃料漏油管（噴射管）部品表
50-70a-00 1/2
Parts List of Fuel Oil Pipe (Overflow for Injection Pipe)
㧞
෻ࡈ࡜ࠗࡎࠗ࡯࡞஥ 㧠
㧟
㧞
020501-00X
50 燃料漏油管（噴射管）部品表
50-70a-00 2/2
Parts List of Fuel Oil Pipe (Overflow for Injection Pipe)

X 751695-59280 ＦＯロウユカン（コウアツカン PIPE, F/O OVER FLOW 1set
1 1 151695-59810 ＦＯロウユカン（コウアツカン PIPE, F/O OVER FLOW 6
3 1 23831-060000 ユニオン６ UNION, 6 6
4 1 23857-060000 カンツギテボルト６ BOLT, JOINT 6 6
2008.9.10R
Governor & Governor Gear No. Page
60 Outline 60-01a-00 1/1
An RHD hydraulic governor made by "Bosch Automotive Systems Corporation" is used for this engine.
This governor is a high performance variable speed governor. Since the hydraulic fluid is totally contained
within the governor, plumbing and sub-tank installation are unnecessary when installing the governor on the
engine. It is a very compact design. The governor is driven by a bevel gear that is installed on the cam gear on
the engine.
Three kinds of remote controllers can be supplied and they are shown in the table below.
Controller Type Outline of operation
When the motor is running, the speed setting screw moves vertically and
this movement changes the load on the speed control spring to vary
Governor Motor Controller
engine speed. The engine speed can also be changed manually in the
same way, by turning the synchronizer knob.
When air is supplied to the pneumatic controller at a specified pressure,

the air pressure acts on the diaphragm and plate. It compresses the spring
which depresses the pushrod. The pushrod acts on the speed-adjustment
Pneumatic Controller
link in the governor to change the load on the speed control spring. The
engine speed can also be freely changed manually in the same way, by
turning the knob on the top of the controller.
A lever is installed on the governor speed control shaft and the engine
Wire Controller speed is adjusted by the remote control cable. The engine speed can also
be freely changed manually by turning the knob on the top of the controller.
Please refer to the separate "SERVICE MANUAL GOVERNOR MODEL RHD (RHD 6 & RHD 10)" for details
about the design, operation, maintenance, repair and adjustment of the RHD series hydraulic governors and
controllers.
2007.3.28R*
60 Overhauling the Governor Link 60-02a-00 1/1
Adjusting the linkage of the governor gear.

When the engine is equipped with an RHD governor.
1) Rotate the start/stop handle to the STOP setting, and adjust the rack adjustment screws for the fuel injec-
tion pumps of all the cylinders so that the rack graduation is "8" to "9" on the scale in each case. (At this
time, also make sure that the No.1 lever can be moved with a light touch.)
Fig. 60-02-1 Governor Link (Type RHD Governor)

Start/Stop Handle
Governor No.1 Lever Shaft Fuel Pump
Connector
RUN
40
30
20
10
0
FUEL
NOTCH
STOP
016232-00E
2) Adjust the coupling bolt on the No.2 lever so that the distance between the center of the No.1 lever shaft
and the center of the connector is about 85 mm. Then connect the connector to the governor lever.
Fig. 60-02-2 Set Point of Link
223mm
About
About 55mm
Connector
About 85mm
No.1 Lever Shaft Center 016233-00E
3) Insert a flat blade screwdriver into the end of output shaft, and turn this shaft all the way toward the fuel
DECREASE side, to bring the pointer to graduation "0".
Next, turn the output shaft toward the fuel INCREASE side by one graduation, to set the pointer to "1".
Secure the governor lever to the output shaft by clamping the mounting bolt.
4) Confirm that there is no twist in the governor gear.
5) Move the start/stop handle to the RUN position and then to the STOP position. Confirm the graduated rack
reading for each fuel injection pump.
STOP position: This start/stop handle position corresponds to the injection pump position where nothing is
heard from the injectors as the flywheel is turned.
2008.10.15R*
60 Overhauling the Governor Gear 60-03a-00 1/1
1) Governor
Refer to the separate Hydraulic Governor Service Manual.
2) Governor driving gear
[Cautions for disassembly & reassembly]
(1) Replace the ball bearings in governor drive gear with new ones after 8,000-10,000 hours of operation
(about two years), or when they show abnormal wear.
(2) When fitting the drive gear, check the backlash in the bevel gear, and adjust the backlash by regulating
the number of shims in the bevel gear boss part. For details about bevel gear backlash, refer to Section
00-09.
(3) When installing the governor, make sure there is no forcing fitting of governor shaft and spline coupling.
Fig. 60-03-1 Type RHD Governor Driver
Governor
Spline Coupling
Driving Shaft
Ball Bearing
Spacer
Circlip Adjusting Shim
Bevel Gear
018692-00E
2007.3.28R*
No. Page
60 RHD 油圧ガバナおよび駆動装置部品表
Parts List of RHD Governor ＆ Driving Device 60-51d-00 1/2
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㧝㧥
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෻ࡈ࡜ࠗࡎࠗ࡯࡞஥ 㧣
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㧝㧤
㧝㧞 0205012-00X
2007.9.20R
No. Page
60 RHD 油圧ガバナおよび駆動装置部品表
Parts List of RHD Governor ＆ Driving Device 60-51d-00 2/2

1 1 41100-005310 ユアツガバナ（RHD10 GOVERNOR, RHD10 1
X 751695-61110 ガバナクドウソウチシクミ DRIVING DEVICE, GOV. 1set

2 1 151695-61100 トリツケダイ（ガバナ BRACKET, GOVERNOR 1
3 1 151695-61110 クドウジク（ガバナ SHAFT,GOVERNOR DRIVE 1
4 1 151695-61120 カンザ（ＲＨＤガバナ SPACER, RHD GOVERNOR 1
5 1 151695-61140 パツキン（ガバナダイ PACKING, GOV.MOUNTING 1
6 1 142613-61150 チヨウセイシム（Ｔ=0.5） SHIM T=0.5 1
7 1 151695-61150 ベベルギヤ（ＲＨＤ GEAR, BEVEL RHD 1
8 1 142613-61160 チヨウセイシム（Ｔ=0.2） SHIM T=0.2 1
9 1 22137-140000 ザガネ（ミカ゛キ　１４ WASHER, 14 1
10 1 22252-000520 トメワＣ（アナ　　５２ RING, 52 1
11 1 22340-100202 ヘイコウピン（ネジ　10 x 20 PIN, 10 X 20 2
12 1 22417-320320 ワリピン　３．２Ｘ３２ PIN, 3.2 X 32 1
13 1 22512-070220 フエザ－キ－　7 x 22 KEY, 7 X 22 1
14 1 24101-060054 ベアリング　６００５ BEARING, 6005 NTN 1
15 1 24101-062054 ベアリング　６２０５ BEARING, 6205 NTN 1
16 1 26212-100602 ウエコミボルト 10 x 60 STUD,BOLT 10 X 60 4
17 1 26706-100002 ナツト　１０ NUT, 10 2
18 1 26871-140002 ミゾツキナツト（ホソヒク１４ NUT, 14 1
19 1 43400-004020 ガバナトリツケパツキン GASKET, GOVERNOR 1
20 1 26716-100002 コガタナット１０ NUT, 10 4
21 1 22117-100000 ザガネ（コマル１０ WASHER, 10 4
2007.9.20R
No. Page
60 調速装置（RHD ガバナ）部品表
Parts List of RHD Governor Linkage 60-52a-01 1/3
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016242-00X
㧞㧡
2007.9.20R
No. Page

X 751695-66010 チョウソクソウチシクミ（ＲＨＤ GOV.LINKAGE, RHD 1set
1 1 137600-51540 バネ（チヨウセイジク SPRING, SHAFT 6
2 1 137600-51560 ツギテ（チヨウセイジク JOINT 6
3 1 114780-61090 フウインヨウスズ TIN 1
4 1 151695-66090 レバ－（テイシピストン LEVER, STOP PISTON 1
5 1 139964-66480 ＮＯ．３レバ－（Ｂ LEVER, 3RD B 1
6 1 151695-66600 ＮＯ．
２レバ－ LEVER, 2ND 1
7 1 151695-66701 シヤフト（１ＳＴレバ－ SHAFT, 1ST LEVER 1
8 1 153604-66760 ブツシユ（１ＳＴシヤフト BUSH, 1ST LEVER SHAFT 4
9 1 138613-66802 ＮＯ．１レバ－ LEVER, 1ST 6
10 1 139653-66810 レバ－アテガネ RETAINER, LEVER 6
11 1 142613-66820 コテイカナグ PIECE, FIXING 6
12 1 142822-66830 バネ SPRING 6
13 1 151695-66830 ボルト（ラツクアジヤスタ BOLT, RACK ADJUST 6
15 1 142613-66841 スラストカラ－ COLLAR, THRUST 8
16 1 151695-66850 デイスタンスピ－ス PIECE, DISTANCE 6
17 1 151604-66860 ジクウケバコ（１ＳＴレバ HOUSING, BEARING 1
18 1 151695-66880 ジクウケダイ（１ＳＴレバ STAND, LEVER BEARING 3
19 1 138613-66920 バネ SPRING 1
22 1 22137-220000 ザガネ（ミガキ２２ WASHER, 22 6
23 1 22212-060000 バネザガネ６ WASHER, 6 6
24 1 22312-060300 ヘイコウピン６Ｘ３０ PIN, 6 X 30 6
25 1 22322-050350 テ－パピン５Ｘ３５ PIN, 5 X 35 2
26 1 22351-050035 スプリングピン５ . ０ＡＸ３５ PIN, 5.0A X 35 15
27 1 22451-100100 ツヅリセン１．０Ｘ１００ WIRE, 1.0 X 100 1
28 1 26206-080202 ボルト８Ｘ２０ BOLT, 8 X 20 2
29 1 26206-120252 ボルト１２Ｘ２５ BOLT, 12 X 25 6
30 1 26557-060122 ナベコネジ（＋アナ６Ｘ１２ SCREW, 6 X 12 6
31 1 26577-040082 サラコネジ（＋アナ４Ｘ８ SCREW, 4 X 8 1
2008.9.10R
No. Page

32 1 26706-080002 ナツト８ NUT, 8 1
33 1 26756-060002 トメナツト６ NUT, 6 6
34 1 26796-100002 トメナツト１０ NUT, 10 1
35 1 138987-66820 スラストカナモノ RETAINER, THRUST 1
2009.3.31R
No. Page
60 発停ハンドル部品表
Parts List of Start/Stop Lever 60-53a-00 1/2
㧡
㧤
㧝㧥
㧠
㧝㧢
㧞㧜
㧔㧞㧕㧔㧞㧕
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㧝㧣㧞㧝
㧝
㧞㧝㧜
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㧝㧝
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㧞㧠
㧞㧡
㧞㧞
㧝㧡
㧝㧤
No. Page
60 発停ハンドル部品表
Parts List of Start/Stop Lever 60-53a-00 2/2

X 751695-66020 ハッテイハンドルシクミ HANDLE, START/STOP 1set
1 1 151695-66010 ハツテイハンドルダイ BRACKET, HANDLE 1
2 1 139653-66050 ハツテイハンドルＡＣＭＰ HANDLE, START/STOP A 1s
4 2 139653-66261 ハツテイハンドルジク SHAFT, START/STOP 1
5 2 138613-66270 ハツテイハンドルトツテ KNOB, HANDLE 1
6 2 139653-66280 ハツテイハンドルツメ CLAW, HANDLE 1
8 2 130140-66540 バネ SPRING 1
9 1 151604-66170 レバ－ダイブシユ BUSH, LEVER MOUNT 1
10 1 147673-66200 レバ－トリツケダイ MOUNT, LEVER 1
11 1 151695-66210 メイバントリツケイタ PLATE, LABEL SETTING 1
12 1 141616-66220 ハツテイハンドルトメイタ PLATE, STOPPER 1
13 1 137600-66230 トメボルト BOLT, STOPPING 2
14 1 153604-66760 ブツシユ（１ＳＴシヤフト BUSH,1ST LEVER SHAFT 1
15 1 22137-060000 ザガネ（ミガキ６ WASHER, 6 3
16 1 22137-100000 ザガネ（ミガキ１０ WASHER, 10 2
17 1 22242-000360 トメワＣ（ジク３６ RING, 36 1
18 1 26116-060302 ボルト６Ｘ３０ BOLT, 6 X 30 3
19 1 26206-100402 ボルト１０Ｘ４０ BOLT, 10 X 40 2
20 1 26206-120252 ボルト１２Ｘ２５ BOLT, 12 X 25 2
21 1 26716-060002 ナツト６ NUT, 6 3
22 1 46130-000110 マイクロスイツチ SWITCH, MICRO 1
X 751695-66150 ロードインジケータ LOAD INDICATOR 1set

23 1 151695-66930 シシン（ロ－ドインジケ－タ POINTER,LOAD INDICA. 1
24 1 22212-080000 バネザガネ８ WASHER, 8 1
25 1 26206-080102 ボルト８Ｘ１０ BOLT, 8 X 10 1
X 751695-66300 メイバン（ハンドル LABEL, HANDLE 1set

26 1 151695-66920 メイバン（ハツテイハンドル LABEL, HANDLE 1
27 1 137900-91451 パ－カ－スクリユ－リベツト RIVET, PARKERIZED 4
2008.9.10R
No. Page
60 連結桿（RHD ガバナ）部品表
Parts List of Link A'ssy (RHD Type) 60-54a-01 1/2
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㧝㧠
㧝㧡㧥
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㧣
2008.9.10R
No. Page
60 連結桿（RHD ガバナ）部品表
Parts List of Link A'ssy (RHD Type) 60-54a-01 2/2

X 751695-66140 レンケツカンシクミ PIPE ASSY, CONNECT
1set
（ＲＨＤ (RHD
1 1 147673-61650 チヨウソクレバ－ LEVER, GOVERNOR 1
2 1 151695-66390 レンケツカンジク SHAFT, CONNECTOR 1
3 1 151695-66470 レンケツカン CONNECTOR 1
4 1 151695-66420 レンケツカンカラ－ COLLAR, CONNECTOR 1
5 1 151695-66430 バネ SPRING, CONNECTOR 1
6 1 151695-66440 レンケツカンナツト NUT, CONNECTOR 1
7 1 142615-66460 レンケツカンピン PIN, CONNECTOR 1
8 1 132310-66590 レンケツカンピン PIN, CONNECTOR 1
9 1 22137-080000 ザガネ（ミガキ８ WASHER, 8 1
10 1 22137-120000 ザガネ（ミガキ１２ WASHER, 12 1
11 1 22212-080000 バネ　ザガネ８ WASHER, 8 1
12 1 22351-040020 スプリングピン４．０ＡＸ２０ PIN, 4.0A X 20 1
13 1 22417-250250 ワリピン２．５Ｘ２５ PIN, 2.0 X 25 1
14 1 22417-320200 ワリピン３．２Ｘ２０ PIN, 3.2 X 20 1
15 1 26206-080202 ボルト８Ｘ２０ BOLT, 8 X 20 1
2008.10.15R
Control & Protective Devices No. Page
63 Outline 63-01a-00 1/1
Fig. 63-01-1 Concept Chart
Handle for Remote control
Hydraulic Govemor Rack Shaft
Electric-Pneumatic
Converter
Flywheel
Engine
018694-00E
Outline
1.The electric signal for the speed command determined by the position of the electric remote control handle
in the wheelhouse room is sent to the electro-pneumatic converter installed in the converter panel.
2.Compressed air (0.7 MPa) is supplied to the electro-pneumatic converter from the air reservoir via the pres-
sure reducing valve. The electro-pneumatic converter supplies compressed air to the actuator in the gover-
nor. The pressure of the air corresponds to the electric signal from the handle.
3.The actuator gives a speed setting command to the governor by the movement of the diaphragm. The
actual engine speed is controlled via a gear train.
4.Comparing the air pressure signal and the actual engine speed data, the governor sets the control lever to
match the command from the wheelhouse.
5.Engine speed is controlled by the movement of the governor control lever, since the control lever is linked to
the fuel control rack in the fuel injection pump.
2007.3.28R*
63 Adjusting the Pressure Transmitter 63-04a-00 1/1
1) Adjusting the Main Pressure Take-off Valve

Check and adjust the operation of the needle valve provided the pressure gauge or pressure transmitter
plumbing in order to prevent damage or malfunctions due to pulsation.
● Main Fuel Pressure valve: Open 1/4 turn from the completely closed position.
● Other pressure valves: Open one turn from the completely closed position.
2) Adjusting the Remote Pressure Indicator

A pressure transmitter has been installed to indicate the pressure remotely. If the indicated pressure on the
remote side has to be adjusted, do the following.
● Remove the top cover from the pressure transmitter.

● Lightly press the head of the ZERO or SPAN screw with a small screwdriver (2mm in diameter), and turn
the screw in the desired adjusting direction.
Fig. 63-04-1 Adjusting the Pressure Transmitter
Connector
Top Cover
Press. Transmitter
52#0
<'41
Test Valve
Adusting Screw
Screwdriver
018696-00E
● As the screw is turned clockwise, the value shown will change as shown by the arrow in the following
graphs.
O# ZERO ADJUSTMENT O# SPAN ADJUSTMENT

Current
Current

2Q 2 2 /2C 2 2 /2C
Pressure Pressure 018697-00E
2007.3.28R*
63 Maintenance of the Thermo-Resistance Bulb 63-05a-00 1/5
CONSTRUCTION
The thermal resistance bulb is composed of a
resistor element, internal wires, a protection tube
and a terminal box.
Fig. 63-05-1
1. There are two types of resistor elements; one

Terminal box
for low temperature use and the other for high
temperature use. The element spools for both Gland
types are made of oxidized alumina. Around
the spool a platinum wire and inner wires are
wound and welded for security. The element Terminal
spool for low temperature use has an insula-
tion tube over the inner wires, which are
welded to the terminals through the terminal
board.
The insulation tube and the terminal board are
made of high quality ceramic insulating mate-
rial, while the terminals use selected material
that is very stability in oxidizing and reducing
atmospheres. The element spool for high tem-
peratures is enclosed in a sleeve type insula- Terminal board
tion tube (super-ceramic), thus it is fully Set screw
protected against vibration and shocks which Insulating tube
may occur while in use
Insulating powder Bolt
2. The inner wires are nickel and welded to the
resistor element. Plag
3. The material used in the protective tube is

based on SUS 304.
4. The terminal box is made from an aluminum

die-cast casing. The wire pass-through fittings
comply with JIS F8801, 20a/15c.
Cupper packing
Sleeve Protective tube

(for high temperature use)
Sleeve Insulating powder

(insulated tube for
high temperature use)
Element
Constrution for Constrution for

High Temrerature Use Low Temrerature Use
018698-00E
2007.3.28R*
1. Items concerning Safety

Before starting inspection or servicing, always pay attention to the following points to prevent accidents from
occurring due to electric shocks or short circuits:
(1) Be sure to turn off the power.
(2) Before starting work, make sure no voltage is present by using a tester.
(3) Except in an emergency, do not perform live-line operations. Pay special attention to high-temperature
systems where exhaust gases are present.
General information about electric shocks

How electric shocks occur:
(1) When a human body comes into contact with something that is charged and makes a current path to
ground.
(2) When a human body comes into contact with two lines at voltage and creates a short circuit between the
lines.
(3) When a human body comes into contact with a path used by electricity, such as an electric wire or a
switch, and the person becomes part of the load current path.
Electric shock prevention measures

(1) Eliminate poor insulation in wiring and electrical equipment.
(2) Complete all grounding work on electrical equipment.
(3) Provide electric leakage prevention devices for cables running to electrical equipment that is operated in
wet places.
(4) Be sure to turn off the power before starting any inspection or repair work.
2. Outline
The thermo-resistance bulb is a detector used to measure the temperature of water, oil, air, gas, etc. by uti-
lizing the property of metal in which its resistance varies, depending on temperature.
Our thermo-resistance bulbs, mainly made of platinum wires, are so designed that they will function well in
harsh environmental conditions.
3. Configuration
Usually, the interior of our resistance bulbs consists of the following items (1), (2) and (3), and the exterior is
composed of the following items (4), (5), (6) and (7):
(1) Resistance element :This consists of a high-density ceramic bobbin and platinum wire used as a resistor.
(2) Internal conductor : Wires that connect the resistor element to the terminals of the thermo-resistance
bulb.
(3) Insulating powder : Powder that insulates the wire resistor and prevents degradation. It also improves
resistance to vibration.
(4) Protecting tube : Tube used to prevent the resistor element and inner wires from coming into direct
contact with the object to be measured.
(5) Bolts : Hardware to secure the protective tube.
(6) Plug and Well : Hardware used to install the resistance bulb at the point to be measured.
(7) Terminal box : Used to connect the wires leading from the metal element (the resistor) to external
electric wires.
2007.3.28R*
4.Principle of Operation
Generally, the electric resistance of metal changes in proportion to changes in temperature. Therefore, the
current temperature can be determined from the relationship between the electric resistance of a metal and
the local temperature by measuring the resistance of the metal.
5.Installation and Wiring

Observe the following precautions when installing the resistance bulb:
(1) Select a place and method by which the temperature of the object to be measured and any variations in
temperature may be rapidly conducted to the bulb with high fidelity. Handle the bulb with care to prevent
the protective tube from being bent and to avoid dropping or otherwise giving a mechanical shock to the
bulb.
(2) Install the bulb in a place that is convenient for maintenance and inspection and which is subject to little
or no vibration, dust and moisture.
(3) Before starting to connect the bulb, check the symbols and markings on the bulb to avoid making incor-
rect connections. Use crimped terminals for the termination of electric wires, and connect them firmly to
prevent accidents such as disconnections and short circuits.
6.Maintenance and Inspection

6.1 Items and intervals
Item Initial Inspection Interval
* Mechanical inspection After one month Six months
* Electrical inspection After one month One year
* Cleaning After one month One year
*See Section 6.6.
6.2 Opening Conditions

(1) Turn off the switch to the power supply circuit.
(2) Mark the terminals of the disconnected external conductors to prevent errors when reconnecting.
(3) The internal resistor element cannot and must not be opened in the field.
6.3 Opening Procedure

Remove the lid of the terminal box. → Loosen the terminal screws on the cables. →
Loosen the cable gland
6.4 Tools Required

(1) Philips screwdriver
(2) Wrench
(3) Locking wrench (for the cable gland)
(4) Nipper
(5) Tester
6.5 Maintenance Condition

Spare parts must be on hand.
2007.3.28R*
6.6 Maintenance Procedure

(1) Mechanical Inspection
Items Method Remarks
a. Tightened parts such as * Check to see that there are no loose parts.
bolts, plugs and well.
b. Terminals * Check to see that all the terminals are firmly

tightened.
c. Cable gland * Check the cable gland for looseness and the
packing for damage.
d. Problems with the electric * Check the electric wires for scorched insulation
wires due to excessively high temperatures, and for
disconnections due to vibration.
(2) Electrical Inspection
a. Continuity of conductive * Check the continuity between A and B and Check for the pres-
wires between B and B using a tester. ence or absence of a
connection.
b. Resistance * Remove the external conductive wires, and

measure the resistance between A and B to
make sure that it is appropriate.
c. Insulation resistance * Check to see that the resistance of the insula- Look for fluctuations in
tion between the terminals and the protective the tester.
tube is 5MΩ or more at 500VDC.
(3) Cleaning
Remove extraneous matter * Dismount the thermo-resistance bulb, and Prevent any increase
from the high-temperature remove extraneous matter from the area where in errors or sintering.
protective tube. it is inserted.
2007.3.28R*
6.7 Probable cause, investigation and action to resolve the problem
State of accident Cause of presumption Investigation and treatment
Disconnection or Heat, vibration, and mechanical shock * Replace them with spare
Insulation failure a. Low temperature type: Contamination such as parts.
with sea water, fresh water, or oil due to defective (The tester indication should
equipment be infinite when discon-
b. High temperature type: Chemical changes in the nected, if the insulation resis-
insulator due to high temperatures tance is 1Ω or less.)
Short-circuit Insufficient space between the lines leading to the
bulb
Phased increase in a. Faulty indicator * Use a standard resistor

the margin of error b. Faulty thermo-resistance bulb instead of the thermo-resis-
1) Increase in element resistance tance bulb and inspect again.
2) Decrease in element resistance * Replace them with spare
3) Increase in extraneous matter in the protective parts.
tube. * Remove the thermo-resis-
tance bulb, and remove any
extraneous matter.
Rapid change in a. Abnormal measuring device * Replace it with a new spare.

the margin of error b. Poor connection due to loose screws
c. Internal defect in the thermo-resistance bulb
6.8 Reassembly method

(1) Reverse the procedure used to open the unit.
(2) High temperature type: Apply anti-seize to the engine-side mounting screw.
6.9 Items to check

(1) Check if the external conductor is connected properly.
(2) Check if the cap is tightened properly.
(3) Check the tightened sections, such as bolts and plugs, for looseness.
(4) Turn on the switch to the power supply circuit.
2007.3.28R*
63 Maintenance of the Pressure Gauge 63-06a-00 1/1
Glycerin-filled pressure gaug

A sealed glycerin solution pressure gauge is used for its reliability and durability.
1) If the liquid level is such that the internal gear and link mechanism are submerged in liquid, the durability
will be improved.
2) Vent hole
(1) A vent hole is provided on pressure gauges with a maximum graduation of less than 1.5 MPa. Cut off the
tip of the rubber cap with scissors (when fitting such a pressure gauge to the engine). If the cap is used
as a blind (with the tip intact), the gauge will not give a correct reading.
(2) A blind plug is fitted on the back of pressure gauges with a maximum graduation of 1.5 MPa or higher.
3) Handling
(1) When detaching the gauge panel during routine engine maintenance, be sure to lay the gauge with the
rubber cap side up.
(2) If the liquid becomes contaminated while using such a pressure gauge, take off the rubber cap to drain
the internal solution. Then, refill it with new solution. [The solution to use for refilling (P/#42111-002800)
is available separately.]
(3) When liquid needs to be added to the pressure gauge, remove the rubber cap and add the special solu-
tion.
Fig. 63-06-1 Glycerin-filled Pressure Gauge
A B
Cut off the top of

the rubber cap
ll
id Leve
m Liqu
Minimu
018699-00E
Min. liquid level A-18 mm

(It this liquid level is maintained, there is no problem about durability.)
2007.3.28R*
Special Attachments No. Page
65 Maintenance of the Electromagnetic Pick-up 65-03a-00 1/1
This pick up is a sensor used to detect the rotational speed of the engine. It is mounted near the outer
edge of the flywheel ring gear.
1) Adjusting the mounting dimensions

When the pickup is installed or replaced, be sure to adjust the clearance.
If the clearance is badly adjusted, the actual engine speed may not be detected, and the protective
device (for over-speeding) may not be activated.
• Adjust the screw in the pickup so that the clearance between the pickup tip and the outer edge of the ring
gear is 1.4 to 2.1mm. (Screw in the pickup tip so that it touches the outer edge of the ring gear, and then turn
it back by 1 ～ 1.5 turns.)
• Tighten the lock nut securely.
Fig. 65-03-1 Electromagnetic Pickup Mounting Procedures
Electromagnetic Pickup
Lock Nut
1.4㨪2.1mm
Flywheel Ring gear 018700-00E
2007.3.28R*
65 Maintenance of the Turning Switch 65-05a-00 1/1
This switch is incorporated near the cranking device on the engine. It is designed so as to prevent an auto-
matic or remote start from taking place while the engine is running.
The ON/OFF signal from this switch is incorporated as one of the starting conditions in the automatic and
remote starting circuits of the engine. Therefore, when the manual crank gear is in contact with the ring gear
on the flywheel, the circuit is off and the engine cannot be started either automatically or remotely.
When the manual crank gear ① is placed in the position that does not engage the flywheel ring gear ② , the
roller part of the microswitch ④ is pushed in by the tapered part of the turning shaft ③ , and the contacts in the
microswitch are "ON".
On the other hand, when the manual crank gear ① moves to the position where it engages with the flywheel
ring gear ② , the tapered part of the turning shaft ③ also moves. Then, the roller part of the microswitch ④ is
pushed out and the contacts in the microswitch are "OFF".
Since this switch is turned on when the roller part pushed in, only the COM and NO terminals are used. The
NC terminal is not used.
Conduct a performance test on this switch once every three months.
Fig. 65-05-1 Turning Switch
ԛ ԙ
Ԛ Ԙ 018595-00X
2007.3.28R*
65 Maintenance of the Start/Stop Lever Interlock Switch 65-06a-00 1/1
[Start/Stop Handle Interlock Switch]

This switch is installed under the start/stop handle. The start/stop handle interlock switch ② detects whether
the engine is stopped by means of the start/stop handle ① (no fuel is being injected), and if the handle is in
the remote control start (automatic start) position or in the engine starting stage. It sends an electric signal
(ON/OFF signal) to the remote monitoring room which indicates whether the engine condition will allow fuel
injection.
This electric signal is included as one of the starting conditions in the starting circuit for the automatic start
sequence. Therefore, if the start/stop handle ① is in the engine stop position, no starting command can be
sent to the engine, preventing unnecessary consumption of starting air as well as serving as a preventive
measure against an accidental automatic start while performing maintenance or making checks.
For the engine to be ready to start, the start/stop handle ① must be in the remote start position.
The start/stop handle interlock switch ② is a microswitch. When the start/stop handle ① is in the engine stop
position, the actuator ③ is pushed in, the COM-NO contacts are closed (ON), and the COM-NC contacts are
open (OFF). When the start/stop handle ① is in the remote start position (not in the engine stop position), the
actuator ③ returns to the original condition, the COM-NO contacts are opened and the COM-NC contacts are
closed.
● Only the COM and NC terminals are used.
● The NO terminal is not used.
● Conduct a performance test once every three months.
● The contacts in this switch are rated for 5A at 24VDC.
Also, even if an engine is stopped, a false alarm will not be sent because of the function of this switch.
NOTES: 1. If the microswitch needs to be reinstalled for any reason, secure it so that distance A (over which
the actuator ③ is depressed by moving the start/stop handle ① ) is between 2mm and 5mm.
If this dimension is not set correctly, this switch will not work or may be damaged. Thus, care
should be taken.
2. Both during operation and while in the start stand-by mode, the actuator ③ on this microswitch
should never be touched.
Fig. 65-06-1 Illustration of the Start/Stop Handle Interlock Switch
Start/Stop Handle
Ԙ (RUN)
RUN
40
(STOP) 30
20
10
0
FUEL
NOTCH
STOP
Actuator
Ԛ
Micro switch
ԙ 018596-00E
2007.3.28R*
65 Maintenance of the Electromagnetic Start Valve 65-07a-00 1/4
This system is composed of a three-way electromagnetic valve and a relay valve. The electromagnetic valve
supplies or discharges starting air to the air motor by opening or closing the valve as the electricity is turned
on and off. The relay valve supplies the starting air to the main air motor.
1. Construction
Fig. 65-07-1 External View of the Electromagnetic Start Valve (Relay Valve)
Operation air inlet (From the air motor)
Starting Air Inlet Starting Air Outlet
Operation Air Outlet Safety Valve

(To the air motor)
Electromagnetic Valve Relay Valve 018701-00E
Specification for each part

1. Working conditions ••• Outside air temperature : -20 ～ 80 ℃ , Humidity : 95% or less,
Fluid : Compress air,
Inlet pressure : 30bar or less, Outlet pressure : 0 ～ 10bar
2. Electromagnetic valve ••• Voltage : DC24V(Working range : 9 ～ 24V),
Current consumption : 5.5W
Valve type : Normally closed (Opens when current is applied.)
3. Safety valve ••• Setting : 10bar
2007.3.28R*
2. Test and Inspection Procedures
■ Solenoid Valve
Supply 9VDC to 24VDC to the solenoid from a DC power source. The solenoid should activate the armature
at 9VDC or more. When the solenoid is functioning properly, the armature will click.
■ Trouble shouting guide
Problem Cause Solution
System doesn't No electric signal Check the electrical connections.

operate.
Insufficient battery charge Check the battery charge.
Abnormal voltage Check the plunger for damage.
No air pressure Check the air pressure and air lines.
Blow-by Check the drive pinion for damage.

Make sure the correct drive pinion is installed on the air
motor.
The air motor is not present
Check the ring gear for damage.
or is damaged.
Check for backlash.
See if the internal housing port in the air motor is
blocked.
Bad valve Inspect the plunger for damage.
Low power No air pressure Check the air pressure and air lines.
Check the plunger for damage.

Check the master pinion for damage and proper lubri-
Bad valve
cation.
Lubricate or replace the O-ring if necessary.
☆ Be sure to wear safety glasses when performing any maintenance on this valve.
☆Always shut off the air supply and electricity and disconnect the air supply before installing or removing
any component on this valve, before making any adjustments to this valve or before performing any
maintenance on this valve.
☆ Never attempt to remove the cap and/or the housing cover until the air pressure is completely equal-
ized (at ambient pressure).
If disassembly, adjustment or repair is attempted while there is pressure in the lines, a strong force
may be applied to the internal components of the valve, and they may be blown out.
2007.3.28R*
Fig. 65-07-2 Relay Valve Cross Section
10.Cover Plug Gasket 6.Cover Pulg 5.Houging Cover 15.Naster Piston Pin
9.㧻-Ring
14.Cover Bolt
11.㧻-Ring
12.㧻-Ring
4.Master Piston
8.㧻-Ring
INLET OUTLET 3.Grommet
16.Pistn Ass'y
2.Housing
7.Gasket
1.Cap 13.Cap Screw 018597-00E
3. DISASSEMBLY
■ General information :
1. Do not disassemble this valve any further than necessary to replace worn or damaged parts.
2. When clamping a part in a vise, always use copper-covered vise jaws to protect the surface of the part
and help prevent distortion. This is particularly true of threaded parts.
3. Do not remove any press-fitted part unless the removal of that part is necessary for replacement or
repairs.
4. Always have a complete set of seals and O-rings on hand before starting any overhaul of a valve. Never
reuse old seals or gaskets.
■ Disassembling the valve :

1. Use a 5-mm Allen wrench to loosen the cap bolt (13) and remove it.
Lift the cap (1) off the valve housing. Pull the return spring and the piston assembly (16) out of the valve
housing.
2. Turn the valve housing upside down.
3. Use a 6-mm Allen wrench to loosen the cover bolt (14) and remove it.
Pull the housing cover (5) away from the valve housing. Grab the master piston (4) and pull it out of the
valve housing.
Pull the cap from the valve housing.
4. Remove all the O-rings and gaskets and replace them.
2007.3.28R*
4. Reassembly
■ General information :
1. When clamping a part in a vise, always use copper-covered jaws to protect the surface of the part and
help prevent distortion. This is particularly true of threaded parts or housings.
2. Except for bearing, always clean every part and then wipe it with a thin film of oil before installation.
3. Apply O-ring grease to all the O-rings before final reassembly.
■ Reassembling the valve :

1. Put the O-ring (8) on the grommet (3).
2. Apply O-ring grease to the piston shaft. Slide the piston assembly into the valve housing. Slide the piston
spring into the bottom of the piston.
3. Apply grease to the gasket (7) in the valve cap groove.
4. Attach the cap (1) to the valve housing. Screw in the cap bolt (13) and tighten it to a torque of 25N-m using
a 5-mm Allen wrench.
5. Secure the valve housing in the vise.
6. Reinstall the O-ring (11) in the piston groove. Apply O-ring grease to it. Then, push the piston into the
valve housing.
7. Apply grease to the O-ring (11) and reinstall it in the valve housing groove.
8. Attach the housing cover (5) to the valve housing. Screw in the cover bolt (14) and tighten it to a torque of
25N-m using a 5-mm Allen wrench.
2007.3.28R*
65 Maintenance of the Electromagnetic Stop Valve 65-08a-00 1/2
1) Outline of the construction

This valve is opened and closed electrically, in order to supply and discharge the operation air. When electric-
ity is supplied, the solenoid ① pulls up the plunger ② , opening port "A" and closing port "B" at same time.
Thus, the control air supplied from part "2" is stopped at port "A" and supplied to the engine shutdown air pis-
ton through part "1". When the electricity is cutoff, the solenoid ① is released and the plunger ② is pushed
down by the force of the spring ③ , closing port "A" port and opening port "B". Thus, the operation air that was
being supplied from part "1" to the air piston for stopping the engine is shut off. At the same time, the opera-
tion air from port "A" is discharged through part "0" into the atmosphere through port "B".
Fig. 65-08-1 Electromagnetic Stop Valve
Ԛ
B port
A port 018598-00E
● This electromagnetic valve requires 24V DC and 0.38A of current (continuous rating).
● If the voltage is changed, make sure to keep the voltage within -10 to +15% of the rated voltage.
2) Servicing
This electromagnetic valve does not need any special maintenance or inspection. However, in order to keep
the magnetic valve in good condition and working a long time, it is best to perform a periodic inspection, once
or twice a year.
When removing the electromagnetic valve from the system or performing maintenance, be sure to turn
off the power, discharge the fluid, and relieve any air pressure.
(1) Disassembly
Disassemble the valve as follows.
① Remove the nut on the coil housing and detach the solenoid from the main housing.
② When the core tube assembly (4) is removed, the inner parts of the valve body can be disassembled
easily, in order.
③ Be very careful not to damage the parts when disassembling the valve.
2007.3.28R*
65 Maintenance of the Electromagnetic Stop Valve 65-08a-00 2/2
(2) Checking
Check the following items.
① Make sure the actual voltage is the same as the voltage specified for the coil.
② Check the coil for damage.
If the following DC resistance is measured, the coil is normal.
24V DC coil: 45 Ω
③ See if any sealing tape or other material has entered or clogged the valve or orifice.
④ Check for any oil mist or oil in the valve.
⑤ Check for flaws and excessive wear on the seat of the movable piece (plunger: ② ).
⑥ Check for a broken spring or permanent fatigue in the spring.
(3) Reassembly
① Carefully clean the parts that will be reused.
② Tighten the core tube to a torque of 30 N-m.
③ Fasten the nut on the coil housing tightly.
④ After reassembly, check the following items.
● Does the valve operate normally at the minimum and maximum working pressure?
● Are there any internal leaks when the solenoid is not pulling the plunger up?
2007.3.28R*
65 Maintenance of the Air Filter 65-09a-00 1/1
The air filter for the starting air is attached to the air inlet on the engine.
1. Clean the air filter once every three months

2. When disassembling and cleaning the air filter, observe the following items
(1)Before disassembling and cleaning the air filter, close the main valve on the starting air pipe.
(2)Loosen the air relief plug slowly, to release the remaining pressure.
(3)Do not loosen the main cap to release the pressure.
Fig. 65-09-1 Detail View of the Air Filter
Cap
Element
Air Relief Plug
Main Body
018599-00E
2007.3.28R*
65 Maintenance of the Speed Relay 65-11a-00 1/2
1. Specifications
1) Construction: All of the parts are installed on the printed circuit board, which is stored in a steel case.
The printed circuit board is composed of electronic parts etc., which improve reliability.
2) Contact Output: Contact configuration ( 14L : Starting detection [to protect the air motor],
14 : Starting detection, 13: Detects specified speed,
12 : Overspeed detection, SC: Detector disconnection)
Contact capacity (100VAC/24V DC, 0.5A)
3) Power source: 24V DC, 2.2W (Operating range: 18 ～ 32V)
4) Measurement accuracy: ± 1.0% at F.S.
5) Working temperature: -15 ～ 70 ℃
6) External packaging: BC Plating
Fig. 65-11-1 External View of the Speed Relay
Test pushbutton
P S P E E D R E L AY
TYPE SPR-P06 Sensor Fault (LED)
N SENSOR
T0 (B) TEST FAULT

12
T2 (A) Operation (LED)
L H
4La min-1
13
Rev. Set Volume
4Lc
L H
4a -1
min
14
4c
L H
3a
min-1
3c
SPAN
2a
L H
2c
L H
Sb ZARO
SOURCE
Sc DC V
OUTPUT SIGNAL
VP DC
NO.
VN Meiyo 2006
018702-00E
2. Operation manual
1) Outline:The speed relay detects 3 positions during revolution. It can also detect a disconnection of the
detector and a tachometer receiver can be connected.
2) Configuration
(a) Speed detection: The pulses from the electromagnetic revolution detector attached to the engine are
counted and used as an input signal.
(b) Signal conversion and amplification: The frequency is in proportion to the revolution speed and the
engine speed is converted to a DC voltage by means of a frequency-voltage converter. This signal is
smoothed and it outputs as a voltage that represents the engine speed.
(c) Comparison with the reference value: A DC voltage from the constant-voltage power supply is compared
with the engine speed voltage described in item (b). When the detected speed is larger than the speed
represented by the constant voltage device, the output relay is activated. In this case, the LED lights.
2007.3.28R*
65 Maintenance of the Speed Relay 65-11a-00 2/2
3) Operating point adjustments

(a) When the speed adjustment knob is turned counterclockwise, the specified operating speed will decrease
(turned to the left), and when it is turned clockwise, the specified speed will increase (turned to the right).
(b) Bring the engine to the desired speed and hold it there. Then, turn the adjustment knob clockwise until
the LED goes out. Next, turn it counterclockwise and secure it where the LED is lit.
Fig. 65-11-2 Connection Diagram for the Speed Relay
REGULATOR SENSOR AIR MOTOR START RATED OVER

DISCONNECTION REV. DETECT DETECT SPEED SPEED
LED LED LED LED LED(RED)

SF 14L 14 13 12
SENSOR ABNORMAL
DETECTOR SC RELAY 14L RELAY 14 RELAY 13 RELAY 12 RELAY
SET.VR
FREQUENCY-VOLT 1L 1 2 TEST 3
CONVERTOR PB
F/V
VOLT-CURRENT 14L 14 13 12 SC
ZERO SPAN
T2 T0
P N (A) (B) VP VN 4La 4Lc 4a 4c 3a 3c 2a 2c Sb Sc
SEALED OUTPUT SIG.

(Don’t ground a shield) DRY CONTACT
POWER SOURCE OUTPUT SIGNAL
DC24V DC0㨪10V AT (AC100V DC24V 0.5A)
MAGNETIC
PICK-UP FULL SCALE 018703-00E
3. Precautions
1) Mount this device in a panel. After confirming the polarity, connect the power source.
2) Only use a DC power source that has been smoothed (ripple: 2V/P-P or less).
3) Short all the external connection terminals to conduct an insulation resistance test,. Do not apply a voltage
that exceeds 500VDC.
4) Do not perform a withstand voltage test.
5) Perform an operation check at the specified engine speed using the test pushbutton.
6) Leave unused terminals open.
7) Use a shielded wire to connect the revolution detector to this device. Also use a shielded cable as an output
signal line. Be sure to connect the shield wire on this device to the T0 (B) and VN terminals. If this shielded
wire is not connected or connected incorrectly, it may cause a malfunction.
8) The shield wires at the revolution detector end should not be grounded to all the trunk connection boxes,
panels, devices, and through hulls.
The wires in the terminal areas should be isolated with electricians tape. Otherwise, it may destroy this
device or cause a fire.
9) Do not move the zero and span adjustment knobs because they were adjusted before shipment.
2007.3.28R*
65 Maintenance of the Startup Fuel Control Air Piston & Shutdown Air Piston 65-12a-00 1/6
In the following drawing, item ③ is the startup fuel control air piston, and item ④ is the shutdown air piston.
Fig. 65-12-1 Startup Fuel Control Air Piston & Shutdown Air Piston
Ԛ ԛ ԟ Ԝ
ԙ
a
Fuel Fuel
Increased Reduced
Ԡ
Ԟ
018704-00E
1.Startup Fuel Control Air Piston

The startup fuel control air piston is designed to limit the fuel injection volume in order to increase the engine
speed gradually when the engine is started automatically or by remote control.
Fig.65-12-1 shows the engine while at rest, and Fig. 65-12-2 shows the fuel control components when the
engine is starting.
The function of this air piston is as follows: When the starting air electromagnetic valve is activated due to a
start command, the operation air (0.6 ~ 1.0MPa) passes through the speed regulating valve and flows into the
air cylinder cover ② from the air cylinder inlet ① , in order to move the air piston ③ and the shutdown air pis-
ton ④ . It also moves the rod ⑤ which is linked to the shutdown piston to the right, which moves the lever ⑥
and consequently the fuel rod attached to the first lever shaft ⑦ . Thus the fuel injection volume is reduced.
2007.3.28R*
Fig. 65-12-2 Startup Fuel Control Air Piston
Ԛ ԛ
018705-00X
Since the operation air is discharged into the atmosphere from the starting air electromagnetic valve when a
startup is complete, the spring ⑧ pushes the air pistons ③ and ④ to the left, following the discharge of the
operation air. As a result, the fuel limit control is removed and the engine returns to normal operation.
Turning the adjusting screw ⑨ regulates the fuel injection volume. However, because this screw was properly
set prior to shipment from our factory, do not adjust it except in a special case where this adjustment is vitally
necessary.
If this adjustment is vitally necessary, as the gap "a" between the adjusting screw ⑨ and the shutdown air pis-
ton ④ is increased by turning this screw, the fuel injection amount will increase when starting. If the gap "a" is
reduced, the injection amount will decrease.
If the gap "a" is too large, control of the fuel when starting will not be possible. If the gap "a" is too small, the
engine will not start. Therefore, pay very careful attention to this adjustment.
2.Shutdown Air Piston

The shutdown air piston is designed to stop the supply of fuel, in order to stop the engine automatically or
remotely.
Fig. 65-12-3 shows the conditions when the engine is being stopped. The function of this air piston is as fol-
lows: The operation air (0.6 ~ 1.0 MPa) supplied through the shutdown electromagnetic valve flows into the air
cylinder ⑪ from the air cylinder inlet ⑩ and moves the shutdown air piston ④ to the right.
The rod ⑤ which is linked to the air piston moves the lever ⑥ which in turn moves the fuel rod connected to
the first lever's shaft ⑦ . Consequently, fuel injection is halted, and the engine is brought to a stop.
If the operation air is shut off, 40 ~ 60 seconds later the air remaining inside the air cylinder ⑪ will be dis-
charged into the atmosphere through the shutdown electromagnetic valve and the spring ⑧ pushes the air
piston ④ to the left. Then the engine returns to its normal state.
The appropriate fuel pump rack spacing (4 ~ 5 mm) in which no fuel is injected is adjustable by means of the
cap nut ⑫ and lock nut ⑬ on the tip of the rod ⑤ . However, since this rack spacing was properly adjusted
prior to shipment from our factory, do not adjust it unless vitally necessary.
If this adjustment becomes necessary, pay attention to the following:
When the rack setting limiting the amount of fuel injected approaches zero, the plunger guide will bottom out
and problems occur. When the rack spacing is too large, the stroke from the shutdown air piston to the lever
⑥ is less, and consequently, the engine cannot be stopped by this air piston. Therefore, pay careful attention
to the adjustment.
2007.3.28R*
Fig. 65-12-3 Shutdown Air Piston
ԡ Ԣ Ԝ Ԥ ԣ
018706-00X
To check the startup fuel control air piston and the shutdown air piston, supply operation air, and check the
movement of the lever ⑥ .
Conduct a performance test once every three months
2. Fuel Injection Limiting, Stopping & Safety System Stopping Air Piston
In the attached figures, A is the air piston for the fuel oil injection limiting, B is the air piston for the stop, and
C is the air piston for the safety system stop.
A) Fuel Injection Limiting Air Piston

The fuel injection limiting air piston is supposed to throttle fuel injection (volume) for the purpose of moderat-
ing a rise in rotational speed of the engine when it is started up automatically or remote controlled.
Fig. 65-12-4 Air Piston For Fuel Injection Limiting, Stopping & Saftey System Stopping
1 2 7 8 12 6 3 4 5
F.O. F.O.
Increased Diminished
"a"
㧭㧮㧯 016266-00E
2007.3.28R*
Fig. 65-12-5 Fuel Injection Limiting Air Positon
6 3 4 5
Air
1 2 7 㧭㧮㧯
016267-00E
Fig.65-12-4 shows the state when the engine is in rest whiles Fig.65-12-5 shows the state of limiting fuel injec-
tion (volume) at engine starting time.
The operation of this air piston is as follows: As the starting air solenoid valve actuates upon the starting com-
mand, the control air (of 0.6 ~1.0 MPa) passed through the speed regulating valve and flows into the air cylin-
der cover ② from the air cylinder inlet part ① to move the fuel injection limiting air piston A as well as the
stopping air piston B and the safety system stopping air piston C and thus to shift a rod ③ which is linked to
the latter air piston to the right to move a lever ④ which in turn moves the fuel rod fixed to the first lever shaft
⑤ to limit fuel injection (volume).
Since the control air is discharged into the atmosphere from the starting air solenoid valve simultaneously with
a starting completion, a spring ⑥ pushes back the air pistons A , B & C to the left, following the outflow of
control air. Consequently, fuel limiting is lifted, and the state prior to operation is restored.
Adjustment of an adjust screw '/~) enables a regulation of fuel injection (volume). However, because this
screw has been properly set prior to shipment from our factory, do not adjust it unless this adjustment is partic-
ularly required.
Note: When the adjustment is needed particularly, as the gap "a" between the adjust screw ⑦ and the stop-
ping air piston B is widened by turning the screw, the fuel injection (volume) at engine starting time
increases; as the gap "a" is narrowed conversely, the injection (volume) decreases.
If the gap "a" Is widened too much, the fuel injection (volume) at engine starting time could not be lim-
ited. If the gap "a" is narrowed extremely, the engine does not start up at all. Thus, pay close attention to
this regard.
2007.3.28R*
B) Stopping Air Piston

The stopping air piston is supposed to stop supply of fuel oil In order to stop the engine in its automatic or
remote stopping.
Fig. 65-12-6 Stopping Air Piston
Air 6 3 11 10 4 5
8 9 㧭㧮㧯 016268-00E
Fig. 65-12-6 shows the state when the engine is in rest. The operation of this air piston Is as follows: The con-
trol air (of 0.6 ~1.0 MPa) supplied through the stopping solenoid valve flows into the air cylinder ⑨ from the air
cylinder inlet part ⑧ and shifts the stopping air piston B and the safety system stopping air piston C to the
right.
A rod ③ that is linked to the latter air piston moves a lever ④ , which in turn moves the fuel rod fixed to the first
lever shaft ⑤ to halt fuel injection. Consequently, the engine is brought to a stop.
If the control air is shut off in 40 ~ 60 seconds later, the air remaining Inside the air cylinder ⑨ is discharged
into the atmosphere through the stopping solenoid valve, and a spring ⑥ pushes back the air pistons B & C to
the left. Consequently, the state prior to stopping, / operation is restored.
The proper rack scale (4 ~ 5 mm) of no fuel injection is adjustable by means of a cap nut ⑩ and a lock nut ⑪
provided at the tip of the rod ③ . However, because the rack scale has been properly adjusted prior to ship-
ment from our factory, do not readjust it.
Note: When the readjustment is needed particularly, do so with attention paid to the following.
As the rack scale of no fuel injection approaches the zero, the plunger guide absorbs shock to cause a
poor working. If the rack scale becomes too large on the other hand, the stroke of the stopping air piston
becomes lacking and it cannot move a lever ④ , sufficiently, and thus the engine can not be stopped by
this air piston. Thus, pay close attention to this regard.
2007.3.28R*
C) Safety System Stopping Air Piston

The safety system stopping air piston is supposed to stop supply of fuel in order to stop the engine when stop-
ping the engine by means of a safety system required by the NK (MO) rules.
Fig. 65-12-7 Safty System Stopping Pistion
12 13 6 3 4 5
Air
㧭㧮㧯
016269-00E
Fig. 65-12-7 shows the when the engine is in rest by the safety system.
The operation of this air piston is as follows:
As the engine stopping solenoid valve actuates, the control air (of 0.6~1.0 MPa) supplied through the stopping
solenoid valve flows into the air cylinder ⑬ from the air cylinder inlet part ⑫ and shifts the safety system stop-
ping air piston C to the right.
A rod ③ , which is linked to the said air piston, moves a lever ④ , which in turn moves the fuel rod fixed to the
first lever shaft ⑤ to halt fuel injection. Consequently, the engine is brought to a stop. If the control air is shut
off in 40~60 seconds later, the air remaining inside the air cylinder ⑬ is discharged into the atmosphere
through the stopping solenoid valve, and a spring ⑥ pushes back the air piston C to the left. Consequently,
the state prior to stopping/operation is restored.
Procedure for adjusting this air piston is the same as for the stopping air piston set forth in B).
However, because the adjustment has been done properly prior to shipment from our factory, do not readjust
it.
To check the fuel injection limiting, stopping and safety system stopping air pistons, send the control air into
the air piston assembly, and confirm the movement of a lever ④ . Conduct such a performance test once in
every three months.
2007.3.28R*
65 Maintenance of the Speed Regulating Valve 65-13a-00 1/1
Speed Regulating Valve

This speed regulating valve is installed at an intermediate point between the startup fuel control air piston and
the starting air electromagnetic valve. It determines the number of seconds that the fuel injection amount is
limited during starting, and it gradually eliminates the limit.
When starting the engine automatically or by remote control, the operation air (0.5 ~ 0.7 or 0.7 ~ 1.0MPa) sup-
plied from the starting air electromagnetic valve, after a start command is received, enters this valve in section
A. This valve then pushes the check valve ① open and finally air flows from section B into the startup fuel con-
trol air piston.
When a self-sustaining engine speed is detected by the tacho-dynamo and the speed relay, and the startup air
electromagnetic valve is closed, the check valve ① closes in the operation air between the speed regulating
valve and the startup fuel control air piston. Thus, the operation air is gradually discharged into the atmo-
sphere from the opening between the throttle valve ② and the main body ③ and then through the electromag-
netic valve.
If this throttle valve ② is turned counterclockwise, the amount of air discharge increases, and the discharge
will be completed in a short time. On the other hand, if the throttle valve is turned clockwise, the amount of air
discharge decreases, and the discharge will require a longer time. However, if turned all the way clockwise,
this throttle valve is closes and restriction on starting time fuel control continues into normal operating stage of
engine. Therefore, never shut down this throttle valve at any time.
Fig. 65-13-1 Drawing Showing the Operation of the Speed Regulating Valve
㧮㧭
Ԙ
018707-00X
2007.3.28R*
65 Maintenance of the Pressure Switch 65-14a-00 1/2
The pressure switch is used to detect a pressure drop in the lubricating oil or cooling water. Then it sends a
signal to the alarm panel or monitoring panel which sounds an alarm or stops the engine automatically.
If fluid pressure in the connecting tube exceeds the specified value, the bellows and spindle are pushed up
and the working plate on the tip of the spindle is pushed up. This activates the microswitch and the contacts
(between terminals 1 and 2) are opened.
If the pressure drop takes place due to a specific cause while the engine is running, the force pushing the bel-
lows for the lubricating oil or cooling water will decrease, and the working plate is forced back to its original
position by the force of the spring. This closes the contacts in the microswitch.
Since the specified detection pressure was adjusted at the factory prior to shipment, according to the engine
specifications, the setting should not be readjusted arbitrarily.
Fig. 65-14-1 Pressure Switch and Contact Configuration
Pressure Switch Body

Terminal
In
3(N.O.) 1
1
2(N.C.) 3
2
Terminal 1: Supply 㧗 Out N.O.
Terminal 2: Supply 㧙 Out N.C.
Terminal 3: Functional test
Pressure : Connects with the case
intake Contact composition: Single Pole Double Terminal(SPDT)
Contact load: 0.1A,250V(AC11)
12W,125V(DC11)
018708-00E
Fig. 65-14-2 Cross Section of the Pressure Switch
Screw for
pressure adjustment
Terminal
Spring
Maicro-switch
Pressure intake
Bellows
018709-00E
2007.3.28R*
65 Maintenance of the Pressure Switch 65-14a-00 2/2
However, if the pressure setting must be changed according to a change in the specifications, refer to the fol-
lowing method for adjustment.
Adjustment method
※ The pressure setting will increase when the pressure setting knob is turned clockwise. There is a differen-
tial in the operation pressure at which the switch flips when the pressure is rising or descending.
Fig. 65-14-3 Pressure Adjustment and Differential
P
3 3 3
1 1 1
2 2 2
Pressure Increase Pressure Decrease
ԙ Ԙ ԙ
t
Pressure Setting
Differential
Pressure Adjusting Knob 018710-00E
Check the pressure switch for leaks from the joint (the switch installation metal fittings, the test cock, etc.) with
the connecting tube. Check the open range of the needle valve, and check for abnormal wiring. Conduct a
performance test once every three months.
Note:
The pressure switch for the fuel is a double-diaphragm design and its construction is different from other
switches. Since the pressure switch might be damaged if a single diaphragm design were used for the fuel,
pay special attention when ordering a replacement.
2007.3.28R*
65 Maintenance of the Temperature Switch 65-15a-00 1/2
Temperature Switch
The temperature switch is used to detect a temperature increase in the lubricating oil or cooling water and to
transmit an electric signal to the alarm panel or monitoring panel. A warning can be issued or the engine can
be stopped automatically.
The temperature sensor is installed in a pipe of the engine. If the fluid temperature is below the specified
value, the expansion of the gas inside this sensor tube is relatively small and the microswitch is not activated.
The contacts (between terminals 1 - 3) in the microswitch remain open.
When the engine is operating, if the temperature of the lubricating oil or cooling water exceeds the specified
value, the bellows and spindle are pushed up and the working plate on the tip of the spindle is pushed up.
This activates the microswitch and the microswitch contacts are closed.
Since the temperature setting was adjusted at the factory prior to shipment (to match the engine's specifica-
tions), it should not be readjusted arbitrarily.
Fig. 65-15-1 Temperature Switch and Contact Configuration
Terminal
In
3(N.O.) 1
1
2(N.C.) 3
2
Body of Pressure Switch Terminal 1: Input Out N.O.
Terminal 2: Normal close Out N.C.
Terminal 3: Normal open
: Connects with the case
Contact composition: Single Pole Double Terminal (SPDT)
Contact load: 0.5A,250V(AC15)
12W,125V(DC13)
Temperature senser
018711-00E
2007.3.28R*
65 Maintenance of the Temperature Switch 65-15a-00 2/2
However, if the temperature setting must be changed according to a change in the specifications, refer to the
following method for adjustment.
Adjustment method
※ The temperature setting will increase when the temperature setting knob is turned clockwise.
There is a differential in the operation temperature at which the switch flips when the temperature is rising
or descending.
Fig. 65-15-2 Temperature Adjustment and Differential
T
3 3 3
1 1 1
2 2 2
Temperature Increase Temperature Decrease
ԙ Ԙ ԙ
t
Setting Temperature
Differential
Temperature Adjusting Knob 018712-00E
Check the temperature switch for a leak of the gas inside it.
2007.3.28R*
65 Maintenance of the Fuel Oil Float Switch 65-17a-00 1/1
The float switch will open the normally closed contacts (B contact) when the level in the fuel oil tank rises.
Since the position of this float switch was set when it was shipped from the factory, it is not necessary to dis-
assemble, adjust, or maintain it. The float will fall if the stopper under the float is removed. Therefore, do not
remove it.
1.Principle of Operation
When the magnet that is built into the float passes through the detection range of the reed switch, the float
switch is activated.
Fig. 65-17-1 Float Switch Principle of Operation
Magnet
Float
Reed Switch
018713-00E
2.Operation Oil Level

Fig. 65-17-2 Float Switch Operating Oil Level
㧻㧲㧲
Operation Type of Contact㧦OFF when the float is high

Oil Level
About 36mm
Float ̪: The operation reverses when
㧻㧺
the float descends.
Stopper
018714-00E
3.Notes on Handling
Do not hit or bang the float switch, or handle it carelessly. It may cause a malfunction.
1) Notes and points for long-term storage of a spare
a. Store it indoors so that it is not exposed to direct sunlight, rain, or wind. (Seal it in plastic or a similar con-
tainer.)
b. Do not lay it directly on the floor. Put it on a palette to store it.
c. Do not detach the cover over the switch case until the float switch is installed on the device and the wires
are connected.
d. Perform a visual inspection regularly (about every six months).
2) Notes on initial operation
When using the float switch after it has been stored for a long time:
a. Check the bolts and screws for looseness.
b. Measure the insulation resistance of the microswitch and make sure it is 10 MΩ or more.
2007.3.28R*
65 Maintenance of the Fuel Pump Rack Potentiometer 65-18a-00 1/3
1.Outline
This device is designed to detect the rack position of the fuel injection pump by means of a non-sliding mag-
netic potentiometer and to perform a comparative calculation using built in circuitry to produce a 4 ~ 20mA
current signal output. When compared with a sliding type device, this has a long life and is considerably more
resistant to vibration.
2.Specification
2-1 Position detection section : Magnetic potentiometer CP-2UN-05
Input voltage: 10VDC or less, Effective electrical angle: 60°
Mechanical angle: 360°(endless)
2-2 Computing circuitry
① Input Signal :The position detection section correctly detects 20 ~ 60°of change in the angle of the input shaft
② Output :DC4 ～ 20mA, Load resistance: 500Ω or less
2-3 Supply Power :24VDC(20 ～ 32V) Ripple : 2V P-P or less
3.Operation
A block diagram and a system connection diagram are shown in Fig.65-18-1.
Fig. 65-18-1 Block Diagram & System Chart
Constant Voltage Section

Can also be installed on this side.
㧝㧗
Input Shaft Power

DC24V
4㨪20mA
SPAN
㧞㧙
Indicator Indicator Other load

ZERO
Position Detector
018715-00E
3-1 The output at the zero position is set using the ZERO adjustment in the computing circuit. …………………
(ZERO adjustment)
3-2 The output current at the 100% position is set using the SPAN adjustment in the computing circuit. …
(SPAN adjustment)
3-3 A constant voltage of 6.4VDC is obtained from the constant-voltage power supply section and it is added
to the magnetic potentiometer.
4. System Connections
4-1 Refer to Fig.65-18-1 for system connection details.
4-2 Use a shielded wire when connecting the system to the position detector, and connect one end of the
shielded wire to ground.
5.Installation and Adjustment

5-1 Mechanical positioning of the position detector
① Install the position detector so that the angle of the connecting rod against the lever on the rack shaft
side and the angle of the connecting rod against the lever on the detector side are about 90°each at the
point which is in the middle of the detection range.
2007.3.28R*
Fig. 65-18-2 Installation of the Detector

Working angle (20㨪60q)
Input Shaft on the Detector

Detection Point
Right angle
(at the mid-point position)
018669-00E
② Set the detection point at about the mid-point in the detection range. Remove the rear cover of the posi-
tion detector.
③ Loosen the three screws inside the detector, and turn the potentiometer. Then, adjust it so that the keyed
groove in the input shaft on the detector faces the same direction as the exit of the lead wire from the
potentiometer. Tighten the three screws as they were before.
Fig. 65-18-3 Positioning (angle) the Potentiometer
ԘThe lead wire from the

potentiometer shoud exit in the
same direction as the keyed
groove at about the mid-point
position.
ԙLoosen the three screws.
ԚTurn the potentiometer used for

position detection.
ԛTighten the three screws as

they were defore. 018600-00E
5-2 Adjusting the computing circuit

① As shown in Fig. 65-18-4, set the dip switches on the printed circuit board in the terminal box according
to the direction that the input shaft rotates.
Fig. 65-18-4 Setting the dip switches
Printed Circuit Board

Clockwise rotation
(when viewed from the input shaft)
Switch setting when (CW) is 100%
ZERO SPAN
CW
Counterclockwise rotation 㧗㧙
(when viewed from the input shaft)
Switch setting when (CCW) is 100% CCW
1 2
018670-00E
2007.3.28R*
② Adjust the ZERO and SPAN trimmers on the printed circuit board in the terminal box, within the range of
4 ~ 20mA.
Changes in the characteristics caused by each trimmer are shown in Fig. 65-18-5 & -6. Refer to these
figures.
Fig. 65-18-5 Change of special character Fig. 65-18-6 Change in the characteristics from
istics for ZERO adjustment adjusting the SPAN trimmer
(mA) (mA)
20 20
16 CW 16 CW
Output Output
12 CCW 12 CCW
8 Standard Characteristics 8 Standard Characteristics
4 4
(Parallel translation in a transverse direction) (The slope changes at fulcrum point P)
P
0 20 40 60 80 100 (%) 0 20 40 60 80 100 (%)
Fuel Pump Rack Position 018716-00E Fuel Pump Rack Position 018717-00E
[Description of the adjustment in the computing circuit]

③ Move the rack to the 0% detection point position, and adjust the ZERO trimmer so that the output current is 4mA.
④ Move the rack to the 100% detection point position, and adjust the SPAN trimmer so that the output cur-
rent is 20mA.
⑤ When the SPAN has been adjusted, there is a possibility that the current output at the 0% point may
change. Therefore, check item ③ again. If necessary, adjust items ③ and ④ repeatedly.
6. Maintenance
6-1 If the mechanical relationship between the detection position and the input shaft is in good condition, it is
not necessary to readjust this device.
6-2 If the mechanical relationship between the detection position and the input shaft is incorrect, adjust item 5.
6-3 This device uses an electronic circuit. Therefore, moisture, dust, etc. may cause a malfunction. Pay atten-
tion to avoid contamination.
7. Precautions
7-1 When wiring the transmitter, use a shielded wire to prevent electrical noise from interfering. Although a
protective circuit is installed, it may not absorb large electrical impulses.
7-2 Do not perform any insulation resistance or withstand voltage tests on these parts. (The semiconductors
may be damaged.).
2007.3.28R*
No. Page
65 電磁ピックアップ（T/FW 側）部品表
Parts List of Magnetic Pick-up (FW Side T/C) 65-52d-00 1/2
㧝
㧞
㧠
㧟
020642-00X
2007.9.20R
No. Page
65 電磁ピックアップ（T/FW 側）部品表
Parts List of Magnetic Pick-up (FW Side T/C) 65-52d-00 2/2

X T000G-0004D0 ピックアップシクミ PICK UP ASS'Y 1set 機関用
1 1 46150-026100 マグネチツクピックアップ PICK UP 1
2 1 45511-006890 ナツト（５／８－１８ＵＮＦ NUT 1
1 X 751695-86050 サポート（ピックアップ SUPPORT，PICK UP 1set

3 1 41704-001850 トリツケイタ（ピックアップ BRACKET, PICK UP 1
4 1 26152-160302 ボルトＭ１６ホＸ３０ BOLT M16 × 30 2
2007.9.20R
No. Page
65 機関計器板（電気式回転計）
（T/FW 側）部品表
Parts List of Gauge Panel (Electric Tachometer)(FW Side T/C) 65-54c-00 1/2
㧟
㧠
㧔㧝㧕
㧡
㧢
㧔㧝㧕
㧣
㧢
㧡
㧞 020643-00X
2007.9.20R
No. Page
65 機関計器板（電気式回転計）
Parts List of Gauge Panel (Electric Tachometer)(FW Side T/C) 65-54c-00 2/2

X T516A-0039B0 ケイキバン（キリカエＳＷナシ INSTURUMENT PANEL 1set
1 1 46150-068540 ケイキバン INSTURUMENT PANEL 1s
2 2 X 46150-042481 デンキシキカイテンケイ TACHOMETER, ELECTRIC 1
3 2 X 46150-050290 コネクタプラグ CONECTOR PLUG 2
4 2 X 46150-050300 ガスケツト（コネクタ GASKET, CONNECTOR 2
5 1 26116-060142 ボルト６Ｘ１４ BOLT M 6 X 14 8
6 1 22117-060000 ザガネ（コマル６ WASHER 6 8
7 1 42221-021240 カイテンＭＩＮメイバン LABEL 1
8 1 137900-91451 パーカースクリューリベット RIVET 2
2007.9.20R
No. Page
65 機関計器板（圧力計）
Parts List of Gauge Panel (Pressure Gauge)(FW Side T/C） 65-63b-02 1/2
㧞㧟
㧞㧝
㧞㧟
㧝㧝
㧟
㧝㧡
㧝㧢
㧝㧠
㧝㧞㧣
㧝㧜
㧞㧜
㧠
㧞㧟
㧞㧤
㧞㧥
㧝㧥
㧢
㧡㧝㧣
㧞㧞㧞
㧝㧤㧝㧝
㧞㧠
㧝㧟㧞㧟
2007.9.20R
No. Page
65 機関計器板（圧力計）
Parts List of Gauge Panel (Pressure Gauge)(FW Side T/C） 65-63b-02 2/2

X 751695-91250 ケイキバン（Ｔホイル GAUGE PANEL ASS'Y 1set
1 1 153633-01370 ボウシンゴム ABSORBER, SHOCK 4
2 1 122117-39150 パツキン（マル PACKING 4
3 1 41690-005181 ケイキバンサポ－ト SUPPORT, PANEL 1
4 1 151695-91851 アツケイカン（ＬＯ PIPE, PRESS.GAUGE 1
5 1 151695-91861 アツケイカン（Ｈ／ＴＣＷ PIPE, PRESS.GAUGE 1
6 1 151695-91871 アツケイカン（Ｌ／ＴＣＷ PIPE, PRESS.GAUGE 1
7 1 151695-91881 アツケイカン（キユウキ PIPE, PRESS.GAUGE 1
8 1 22117-060000 ザガネ（コマル６ WASHER, 6 4
9 1 26116-060142 ボルト６Ｘ１４ BOLT M 6 X 14 4
10 1 22212-040000 バネザガネ４ WASHER, 4 15
ナベコネジ（＋アナ
11 1 26557-040122 SCREW, 4 X 12 15
４Ｘ１２
12 1 26717-040002 ナツト４ NUT, 4 15
13 1 26206-120182 ボルト１２Ｘ１８ BOLT M12 X 18 4
14 1 26232-200502 ウエコミボルト（ホソ２０Ｘ５０ STUD,BOLT 20 X 50 5
15 1 22212-200000 バネザガネ２０ WASHER, 20 5
16 1 26732-200002 ナツト（ホソＭ２０ NUT M20 5
17 1 28886-040000 アツケイ（Ｇ０．４ＭＰＡ PRESSUREGA, 0.4MP 1
18 1 28886-060000 アツケイ（Ｇ０．６ＭＰＡ PRESSUREGA, 0.6MP 2
19 1 28886-104550 アツケイ（Ｇ１．０ＭＰＡ PRESSUREGA, 1.0MP 1
20 1 150623-91300 メクラフタ COVER
（GAUGE 1
21 1 41690-005170 ケイキバンボツクス BOX, PANEL 1
22 1 41690-004970 ケイキトリツケイタ BRACKET, PANEL 1
23 1 26706-080002 ナツト８ NUT, 8 8
24 1 42130-017221 FO アツリョクケイ（２ . ０ＭＰＡ GAUGE,PRESS.2.0MPA 1
2007.9.20R
No. Page
65 燃料制限・停止エアピストン部品表
Parts List of Air Piston for Fuel Limit & Engine Stop 65-56e-00 1/2
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020646-00X
2007.9.20R
No. Page
65 燃料制限・停止エアピストン部品表
Parts List of Air Piston for Fuel Limit & Engine Stop 65-56e-00 2/2

X T000G-0001C2 ＦＯカット（セイゲン , テイシ FO.CUT(LIMIT, STOP 1set
1 1 T000G-0005C0 エアピストンシクミ AIR PISTON ASS'Y 1s
2 2 44100-004231 エア－シリンダ（テイシヨウ） AIR CYL.(FOR STOP) 1
3 2 44100-004240 エアシリンダ－フタ（マエ） COVER, FRONT 1
4 2 44100-004250 エアシリンダフタ（ウシロ COVER, REAR 1
5 2 44100-002380 サドウボウ ROD 1
6 2 44100-004280 エア－ピストンヨウスプリング SPRING 1
7 2 44112-000170 サドウボウヨウカラ－ COLLAR 1
8 2 22322-040220 テ－パ－ピン４Ｘ２２ TAPER PIN 4 X 22 1
9 2 44100-004270 エヤ－ピストン（シヤダン PISTON, AIR 1
10 2 44100-004260 エヤ－ピストン（セイゲン PISTON, AIR 1
11 2 24316-000400 Ｏリング４ＤＰ４０．０ O-RING 4D P-40.0 2
12 2 44100-002370 チヨウセイボルト BOLT 1
13 2 22190-100001 シ－ルワツシヤ－（ナツトヨウ）１０ SEAL WASHER 10(NUT) 1
14 2 26696-100002 トメナツト（ホソ１０ LOCK NUT M10 1
15 2 44100-018310 パツキン GASKET 1
16 2 26116-060202 ボルト６Ｘ２０ BOLT M6 X 20 4
17 2 22212-060000 バネザガネ６ SPRING WASHER 6 4
18 2 23887-140002 ６カクプラグ１４ PLUG 14, HEX. 1
19 2 23414-140000 パツキン（マル１４ GASKET 14, ROUND 1
20 1 44112-000440 レバ－ヨウカナモノ FITTINGS 1
21 1 26796-100002 トメナツト１０ NUT M10, LOCK 1
22 1 26206-100252 ボルト１０Ｘ２５ BOLT M10 X 25 2
23 1 159616-23570 サラバネ SPRING WASHER 1
2008.9.10R
No. Page
65 圧力スイッチ（テストバルブ 5 連）部品表
Parts List of Pressure Switch（5 Connects） 65-58j-00 1/2
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#PCVVCEJGFUGPUQTQHCRGTVKPGPVQTICPK\CVKQPOWUVNQQMCVVJGHKPCNFTCYKPI 017470-00X
No. Page
65 圧力スイッチ（テストバルブ 5 連）部品表
Parts List of Press. Switch（5 Connect) 65-58j-00 2/2

1 1 23414-120000 パツキン
（マル　１２ GASKET, 12 25
2 1 23414-130000 パツキン
（マル　１３ GASKET, 13 5
3 1 23831-060000 ユニオン　　６ UNION, 6 1
4 1 23834-060000 ユニオン　　６ UNION, 6 3
5 1 23897-020002 ６カクプラグ　Ｇ　　１／４ PLUG, G 1/4 5
6 1 24311-000090 Ｏリング　１Ａ　Ｐ　　９．０ O-RING 1A P-9.0 10
7 1 43530-002310 キヤツプ
（Ｍ１２ CAP(M12 6
8 1 43550-003920 ユニオン（Ｍ１２／Ｍ１４ UNION(M12/M14 4
10 1 46150-067390 テストバルブ（５レン TEST VALVE(5 CONNECT 1
11 1 23887-120002 ６カクプラグＭ１２ PLUG, M12 1
12 1 43310-007770 ヘイシフランジ（テストＶ BLIND FLANGE 2
13 1 24311-000070 Ｏリング　１Ａ　Ｐ　７．０ O-RING 1A P-7.0 2
14 1 26116-050122 ボルト　５Ｘ　１２ BOLT M 5X 12 PLATED 4
15 1 46111-027481 アツリヨクＳＷ（０．１３ＭＰa SWITCH, PRESSURE 1 ※1
16 1 46150-050121 アツリヨクハッシンキ TRANSMITTER, PRESSURE 1 ※2
※ 1　低温水側、警報用
　　 Alarm to L.T.FW pressure
※ 2　高温水側、圧力発信器
　　 Transmitter to H.T.FW pressure
《参考資料 Reference》
センサーリスト List of Sensor
圧力スイッチ Pressure Switch 圧力発信器 Pressure Transmitter
部品番号設定値 Setting Pressure (MPa) 部品番号計測範囲 (MPa)

Part No. 1-2 : ON 1-2 : OFF Part No. Range of Measurement
46111-027381 0.03 0.05 46150-050111 0 ～ 0.4

46111-027411 0.06 0.08 46150-050121 0 ～ 0.6
46111-027481 0.13 0.15 46150-050131 0 ～ 1.0
46111-027501 0.15 0.17
46111-027551 0.20 0.22
46111-027561 0.25 0.28
46111-044190 0.40 0.43
No. Page
圧力スイッチ ( テストバルブ 4 連 ) 部品表
65 Parts List of Pressure Switch (4 Connects) 65-59f-00 1/2
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#PCVVCEJGFUGPUQTQHCRGTVKPGPVQTICPK\CVKQPOWUVNQQMCVVJGHKPCNFTCYKPI 017471-00X
No. Page
圧力スイッチ ( テストバルブ 4 連 ) 部品表
65 Parts List of Pressure Switch (4 Connects) 65-59f-00 2/2

No Level 0rder Part No. Qﾕty Remarks
1 1 23414-120000 パツキン（マル　１２ GASKET, 12 3
2 1 23414-130000 パツキン（マル　１３ GASKET, 13 4
3 1 23897-020002 ６カクプラグ　Ｇ　　１／４ PLUG, G 1/4 4
4 1 24314-000160 Ｏリング　４Ｃ　Ｐ　１６．０ PACKING, P 16.0 3
6 1 46150-067380 テストバルブ（４レン TEST VALVE(4 CONNECT 1
7 1 46111-027501 アツリヨクＳＷ（１．５Ｋ SWITCH,PRESSURE 1 （1）
8 1 46111-027551 アツリヨクＳＷ（２．０Ｋ SWITCH, PRESSURE 1 （2）
9 1 46150-050131 アツリヨクハツシンキ（１０Ｋ TRANSMITTER 10K,PRES 1 （3）
10 1 43310-007770 ヘイシフランジ（テストＶ BLIND FLANGE 1
11 1 24311-000070 Ｏリング　１ＡＰ　　７．０ O-RING 1A P-7.0 1
12 1 26116-050122 ボルト　５Ｘ　１２ BOLT M 5X 12 PLATED 2
（1）潤滑油圧力停止用　Trip of lubricating oil

（2）潤滑油圧力警報用 Alarm of lubricating oil
（3）潤滑油圧力用 For lubricating oil
《参考資料 Reference》
センサーリスト List of Sensor
圧力スイッチ Pressure Switch 圧力発信器 Pressure Transmitter
部品番号設定値 Setting Pressure (MPa) 部品番号計測範囲 (MPa)

Part No. 1-2 : ON 1-2 : OFF Part No. Range of Measurement
46111-027381 0.03 0.05 46150-050111 0 ～ 0.4

46111-027411 0.06 0.08 46150-050121 0 ～ 0.6
46111-027481 0.13 0.15 46150-050131 0 ～ 1.0
46111-027501 0.15 0.17
46111-027551 0.20 0.22
46111-027561 0.25 0.28
46111-044190 0.40 0.43
No. Page
温度スイッチ部品表
65
Parts List of Tamperature Switch 65-60a-01 1/1
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1 1 46111-042300 オンドスイツチ（９５Ｃ RELAY.THERMO.95C 1
2 1 46150-065920 ソクオンテイコウタイ RESISTANCE BULB 1
2005.5.10R
No. Page
65 燃料ラックポテンショメータ部品表
Parts List of Fuel Oil Rack Transmitter 65-64a-01 1/2
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020647-00X
2007.9.20R
No. Page
65 燃料ラックポテンショメータ部品表
Parts List of Fuel Oil Rack Transmitter 65-64a-01 2/2

X 751695-65200 ポテンシヨメ－タ－ソウチ POTENTIOMETER ASS'Y. 1set
1 1 41704-001240 ポテンシヨメ－タ－ POTENTIOMETER 1
3 1 26116-060202 ボルトＭ６Ｘ２０ BOLT M 6X 20 4
4 1 41704-001220 レバ－ LEVER 1
5 1 26116-060302 ボルトＭ６Ｘ３０ BOLT M 6X 30 1
7 1 41704-000370 レバ－ LEVER 1
9 1 26116-060202 ボルトＭ６Ｘ２０ BOLT M X 20 1
10 1 22532-040160 アタマツキキ－４Ｘ１６ KEY 1
11 1 41704-000140 ジヨイントボ－ル JOINT BALL 1
12 1 41704-000150 ジヨイントボ－ル BALL, JOINT 1
13 1 41711-004010 レンケツボウ ROD, CONNECTING 1
14 1 45523-000890 ナツトＭ５ WING NUT M 5 1
15 1 26756-050002 トメナツトＭ５ LOCK NUT M 5 1
16 1 41704-000420 セレ－シヨンツキザガネ WASHER 1
17 1 26116-050202 ボルトＭ５Ｘ２０ BOLT M5 X 20 1
18 1 26116-050252 ボルトＭ５Ｘ２５ BOLT M5 X 25 1
19 1 22212-050000 バネザガネ５ SPRING WASHER 5 2
20 1 22137-050000 ザガネ（ミガキ５ WASHER 5, POLISHED 2
21 1 26716-050002 ナツトＭ５ NUT M 5 2
X 751695-65110 トリツケダイ（ポテンショメータ MOUNT ASS'Y 1set

22 1 151695-65150 トリツケダイ（テイシＰ MOUNT 1
23 1 26206-100202 ボルトＭ１０Ｘ２０ BOLT M10 X 20 6
24 1 151695-65160 サポート（ポテンショメータ SUPPORT 1
25 1 26203-120502 ボルトＭ１２Ｘ５０ BOLT M12 X 50 2
2007.9.20R
Starting Air System & Air Motor No. Page
70 Outline of the Main Components 70-01c-00 1/2
1. Outline
The air system in the engine is composed of a startup air system that starts the engine, an air system that
controls the amount of fuel injected when the engine starts (it also stops the engine), and a safety/control air
system that controls engine speed using the governor. An air motor is used to start the engine. The com-
pressed air pressure (maximum pressure: 2.9MPa) used to start the engine is reduced to 1.0MPa with a
pressure regulator, and then sent to the air motor.
The compressed air is sent through the safety/control air system from the compressed air tank to drive the air
piston, at a pressure of 0.7 ~ 1.0MPa.
Fig. 70-01-1 Diagram of the Start up/Control Air System

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2. Starting device
The starting device is a turbine type air motor, which drives the ring gear through a pinion gear to turn the
engine. A relay valve, starting valve and pressure regulator are integrated into the air motor.
2007.4.18R*
70 Outline of the Main Components 70-01c-00 2/2
3. Safety/control device
The safety/control system consists of a governor, a start/stop handle, a fuel injection pump, an air piston, and
associated linkage. The linkage interlocks these parts with the lever shaft and other moving parts.
When the engine is started, the air piston acts on the interlock lever connected to the fuel injection control
shaft (1st lever shaft), which controls the fuel injection volume. It also huts off the fuel injection when the
engine must make an emergency stop. Normally, the start/stop handle is used to stops the engine.
4. Process for starting the engine with an air motor

When the start up electromagnetic valve opens, air flows to the drive housing in the air motor.
As a result, the pinion gear is extended and it engages the ring gear. When the pinion gear is completely engaged
with the ring gear, air flows into the main circuit, the turbine rotates, and the pinion gear rotates the engine.
When the specified engine speed (125 revolutions per minute) is reached, the valve is shut off and the pinion
gear is disengaged from the ring gear.
Fig. 70-01-2 Air Motor
018956-00X
Fig. 70-01-3 Air Motor Operation Chart
Solenoid Valve
Maine Circuit
Air port(pilot outlet)
Air port(pilot inlet)

Main port
Relay valve
Pinion
023924-00E
2007.4.18R*
70 Overhauling the Air Motor 70-02a-00 1/1
This engine uses a turbine-powered air motor and its drive housing is pre-engaged type.
The model number is ST950CP03L26S-3A.
This air motor generates a torque up to 386N-m at a starting air pressure of 1.0MPa.
Refer to the explanation in this manual (in section 00-22b-00) for details about how the engine starts routinely.
For a description of the air motor overhaul procedure, refer to the air motor manufacturer's manual
『INSTALLATION AND MAINTENANCE MANUAL FOR ST900 SERIES TURBINE-POWERED STARTERS』
included with this engine.
Manual included:
『INSTALLATION AND MAINTENANCE MANUAL FOR ST900 SERIES TURBINE-POWERED STARTERS』
2007.4.18R*
No. Page
70 エアモータ部品表
Parts List of Air Motor 70-51a-00 1/2
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ဳ ᑼ ࠦ ࡯ ࠼ 㧦ST950 CP03 L-26S-3A

MODEL CODE㧦ST950 CP03 L-26S-3A 020654-00X
2005.4.10R
No. Page
70 エアモータ部品表
Parts List of Air Motor 70-51a-00 2/2

X 751695-77100 スタータ（エア STARTER(AIR 1set
1 1 151695-77010 スタ－タ（ＳＴ９５０ STARTER 1
2 1 22217-140000 バネザガネ１４ WASHER, 14 3
3 1 26292-140402 ボルト（ホソ１４Ｘ４０ BOLT, 14 X 40 3
X 751695-77130 エアスタータトリツケダイ MOUNT, AIR STARTER 1set

4 1 151695-77050 トリツケダイ（エアスタ－タ MOUNT, AIR STARTER 1
5 1 22312-160450 ヘイコウピン１６Ｘ４５ PIN, 16 X 45 1
6 1 24550-040400 ドライブツシユ４０Ｘ４０ BEARING, 40 X 40 1
7 1 26152-200502 ボルト（ホソ２０Ｘ５０ BOLT, 20 X 50 2
8 1 26152-200902 ボルト（ホソ２０Ｘ９０ BOLT, 20 X 90 4
2007.9.20R
始動空気配管系統付属機器部品表 No. Page
70 始動空気配管部品表
70-52a-01 1/3
Parts List of Starting Air Pipe
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020634-01X
2009.3.31R
70-52a-01 2/3

X 751695-73162 エアカンシクミ（シドウクウキＩＮ PIPE ASS'Y, AIR 1set
1 1 151695-73140 エアカン（シドウクウキＩＮ PIPE, AIR 1s
2 1 151695-73700 サポ－ト（ＡＩＲＩＮＬＥＴ SUPPORT, AIR INLET 1
3 1 26206-120252 ボルト１２Ｘ２５ BOLT, 12 X 25 2
4 1 151695-73091 ストレ－ナ４０Ａ（スタ－タ STRAINER, STARTER 1
5 1 151695-73830 フランジ（バルブＩＮ FLANGE, VALVE IN 1
6 1 151695-73011 リレーバルブ（ＲＲ１５０ VALVE, RELAY RR150 1
7 1 151695-73052 ベンド（エアモ－タＩＮ BEND, AIR MOTOR IN 1
8 1 151695-73100 ウエコミボルト（エアイリグチ STUD BOLT (AIR IN 4
9 1 26706-100002 ナツト１０ NUT, 10 4
10 1 151695-73930 ボルト（１／２－１３ＵＮＣ BOLT, 1/2-13UNC 4
11 1 24321-000500 Ｏリング１ＡＧ５０．０ PACKING, G 50.0 3
12 1 146673-91430 アツリヨクケイ GAUGE, PRESSURE 1
13 1 43400-005640 パツキンＴ＝１．０（Ｇ１／４ GASKET, T=1.0 G1/4 1
14 1 139653-91170 セツゾクカナグ CONNECTOR 1
15 1 151695-73320 ユニオン（Ｍ１４－Ｒ１／４ UNION, M14-R1/4 1
16 1 26152-160302 ボルト（ホソ１６Ｘ３０ BOLT, 16 X 30 2
17 1 151695-77910 サポート（エアモータ SUPPORT(AIR MOTOR 1
18 1 26206-120302 ボルト１２Ｘ３０ BOLT, 12 X 30 2
19 1 26152-200402 ボルト（ホソ２０Ｘ４０ BOLT, 20 X 40 2
X 751695-73171 パイロツトエアカンシクミ PIPE ASS'Y., PILOT AIR 1set

20 1 151695-73330 ユニオン（ＮＰＴ１／４－Ｍ１６ UNION, NPT1/4-M16 2
21 1 151695-73220 パイロツトエアカンＡ PIPE, PILOT AIR A 1
22 1 151695-73300 ソケツトＧ１／８－Ｍ１４ SOCKET, G1/8 X M14 1
24 1 23414-140000 パツキン（マル１４Ｘ１．０ GASKET, 14 X 1.0 2
25 1 151695-73210 パイロツトエアカンＢ PIPE, PILOT AIR B 1
26 1 151695-73310 ソケツトＧ１／８－Ｍ１４ SOCKET, G1/4 X M14 1
28 1 23414-140000 パツキン（マル１４Ｘ１．０ GASKET, 14 X 1.0 2
2009.3.31R
70-52a-01 3/3

29 1 152623-59680 サポート（２ケセット RUBBER SUPPORT 1s
31 1 26206-080302 ボルト８Ｘ３０ BOLT, 8 X 30 1
32 1 26706-080002 ナツト８ NUT, 8 1
33 1 23414-130000 パツキン（マル１３Ｘ１．０ GASKET, 13 X 1.0 1
2009.3.31R
70 空気配管（操作空気）部品表
70-53a-00 1/2
Parts List of Control Air Pipe
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㧝㧡
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㧟
㧝㧢㧞㧞
㧥
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㧝㧣㧝㧜㧞㧠
㧝㧞
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㧥㧝㧜
㧝㧤
㧝㧥
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㧝
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ᠲ૞ⓨ᳇౉ญ
70 空気配管（操作空気）部品表
70-53a-00 2/2
Parts List of Control Air Pipe

X 751694-73311 ソウサクウキカンシクミ PIPE ASS'Y (CONTROL 1set
1 1 153605-59920 ユニオンＭ１６－ＰＴ３／８ UNION, M16-PT3/8 1
2 1 151694-73511 ソウサクウキカン（セイギョ PIPE(AIR, CONTROL 1
3 1 151695-73531 ソウサクウキカン（テイシ PIPE, AIR INLET 1
4 1 151694-73590 ユニオン（Ｍ１４－Ｒ１／４ UNION (M14-R1/4 1
5 1 151695-73602 サポ－ト（ソウサクウキ SUPPORT, AIR 1
6 1 151694-73651 トリツケイタ（デンジベン PLATE, VALVE 1
7 1 22212-040000 バネザガネ４ WASHER, 4 8
8 1 23102-100034 クイコミ（Ｒネジ１０－Ｒ３／８ FITTING, 10-R 3/8 1
9 1 23414-120000 パツキン（マル１２Ｘ１．０ GASKET, 12 X 1.0 3
10 1 23414-140000 パツキン（マル１４Ｘ１．０ GASKET, 14 X 1.0 2
11 1 23414-140000 パツキン（マル１４Ｘ１．０ GASKET, 14 X 1.0 4
12 1 23414-160000 パツキン（マル１６Ｘ１．０ GASKET, 16 X 1.0 1
13 1 23414-160000 パツキン（マル１６Ｘ１．０ GASKET, 16 X 1.0 1
14 1 23834-080000 ユニオン８ UNION, 8 1
16 1 23884-120002 ６カクプラグ１２ PLUG, 12 3
17 1 23884-160002 ６カクプラグ１６ PLUG, 16 1
18 1 26152-200402 ボルト（ホソ２０Ｘ４０ BOLT, 20 X 40 2
19 1 26206-120502 ボルト１２Ｘ５０ BOLT, 12 X 50 4
20 1 26557-040142 ナベコネジ（＋アナ４Ｘ１４ SCREW, 4 X 14 8
21 1 26706-120002 ナツト１２ NUT M12 4
22 1 43554-001581 ユニオンＭ１６ホＸＰＴ１／４ UNION, M16 X PT1/4 1
23 1 43600-016270 ネジコミタマガタベン VALVE, BALL CHECK 1
24 1 44100-015570 スピ－ドコントロ－ラ CONTROLLER, SPEED 1
25 1 46116-011340 ３ポウデンジベン 3WAY MAGNETIC VALVE 2
2008.6.25R
70 空気配管（RHD ガバナ空気）部品表
70-54a-01 1/1
Parts List of RHD Governor Air Pipe
≪当部品表のイラスト図はありません。≫
≪ There is no illustration chart of this part table. ≫

X T516Z-0007A1 ＧＯＶ. ソウサクウキカン PIPE ASS'Y. (GOV.AIR 1set
1 1 43714-030351 ガバナソウサクウキカン PIPE(GOV.,CONTROL AIR 1s
2 1 43730-026820 サポート（ガバナクウキ SUPPORT 1
3 1 41722-000340 ユニオン UNION, 1
4 1 26772-180002 トメナットＭ１８ホ NUT M18 1
5 1 44100-015570 スピ－ドコントロ－ラ CONTROLLER, SPEED 2
6 1 23163-020000 ニップル　ＰＴ１／４ NIPPLE PT1/4 1
7 1 23102-100024 クイコミ（Ｒネジ　１０－Ｒ１／４ FITTING, 10-R 1/4 1
2008.6.25R
Hydraulic Jack No. Page
92 Outline of the Main Components 92-01a-01 1/3
The hydraulic jack is used to loosen or tighten the cylinder head nuts, the main bearing cap nuts and the con-
necting rod nuts.
It loosens or tightens the four nuts on each cylinder head simultaneously, or the two nuts on each main bear-
ing or connecting rod.
If the hydraulic fluid leaks while the hydraulic jack is being used, the fluid may spurt out under high pres-
sure, resulting in serious injury. Therefore, be sure to observe the following precautions:
• Do not use the hydraulic jack with a rubber hose that has defects or is leaking.
• Do not put nor drop a heavy object on any rubber hose.
• Do not pull on any rubber hose. Do not bring your face close to the jack or branch tee while the jack is
under pressure.
1) Special tools
The special tools relating to the hydraulic jack and the number of tools used while working are as shown in the
following table.
Number of tools used while working
No. Special Tool Description Part No. For the For the For
cylinder main the connecting
headd bearing rod
① Hydraulic pump 146673-92200 1
② Pressure gauge fixture 146673-92210 1
③ Gauge damper 153605-92481 1
④ Pressure gauge 153625-92801 1
⑤ Rubber hose (3m) 153625-92760 1
⑥ Branch Tee 146673-92240 1
⑦ Rubber hose (1m) 153625-92750 4 2 2
⑧ 90°elbow 151605-92740 2 2 --
⑨ Coupler (male) 153625-92770 4 2 2
⑩ Coupler (female) 153625-92780 4 2 2
151605-92370 4 2 --
⑪ Hydraulic jack assembly
151695-92443 -- -- 2
151605-92721 4 -- --
⑫ Spacer 151605-92691 -- 2 --
151695-92481 -- -- 2
⑬ Hydraulic jack mounting bolt 151605-92700 4 2 --
⑭ Hydraulic jack tightening nut 26732-390002 4 2 --
⑮ Spacer bolt 26206-080202 -- 2 --
⑯ Plug (Allen head) 23875-030000 2 2 --
28230-090150 1 1 --
⑰ Turning handle
132654-92510 -- -- 1
2007.10.10R*
2) Relationship of the parts
Fig. 92-01-1 Hydraulic Pump Assembly Drawing
Ԙ Ԛ ԛ
Air Vent Plug Relief Valve ԙ Ԝ 018964-00E
Fig. 92-01-2 Hydraulic Rubber Hose Fig.92-01-3 Hydraulic Rubber Hose

(Cylinder Head, Main Bearing Cap) (Connecting Rod)
ԡ ԡ
Ԡ Ԡ
Ԟ Ԟ
ԝ ԝ
From the From the

Hydraulic Pump Hydraulic Pump
018965-00E
018966-00E
Fig. 92-01-4 Hydraulic Jack Assembly Drawing(for the Cylinder Head)
Ԝ Ԥ ԥ Ԝ
Piston
Back-up Ring
Main Body
Ԣ
O-Ring Ԡ
Back-up Ring ԡ
ԧ ԟ
ԣ
Ԩ 018967-00E
2007.4.18R*
Fig. 92-01-5 Hydraulic Jack Assembly Drawing (for the Main Bearing Cap)
Ԧ
Ԩ
ԣ
ԧ ԟ
ԡ
Back-up Ring
Ԡ
Main Body
O-Ring
Ԣ
Back-up Ring Ԝ
ԥ
Piston
Ԥ 018968-00E
Fig. 92-01-6 Hydraulic Jack Assembly Drawing (for Connecting Rod)
Coupler ԡ
Piston
Main Body
Back-up ring Ԣ
Hydraulic jack
O-ring
Back-up ring
Spacer
Turning handle Ԩ
018969-00E
2007.4.18R*
92 How to Use the Hydraulic Tools 92-02a-00 1/1
1) Function of hydraulic tools

The hydraulic pump, the hydraulic jack and related hydraulic tools are special tools used to loosen the cylinder
head nuts, the main bearing cap nuts and the connecting rod nuts, in order to disassemble these items. These
tools are also used to tighten the nuts to the specified torque when reassembling them.
2) How to use the hydraulic tools

(1) When reassembling the hydraulic tools, be sure to use Teflon tape on the threads so that there will be no
leaks.
(2) Connect the hydraulic pump to the first hydraulic jack with a 3-m rubber hose. Connect the first hydraulic
jack to the next one using a 1-m rubber hose.
(3) Cover any couplers not connected to the hydraulic jack with dust caps.
(4) The hydraulic pump uses ISO VG32 hydraulic fluid.
Table of Hydraulic Fluids by Brand (Viscosity: ISO VG32)
[ Wear resistant hydraulic fluid ]

General hydraulic fluid
SUPPLIER Brand
Tellus Oil C32

SHOWA SHELL
Tellus Oil 32
Super Hiland 32
NIPPON OIL
Super Hiland V32
Cosmo Epoch ES32

COSMO OIL
Cosmo Hydro AW32
JOMO Hydrax 32
JAPAN ENERGY ELF
JOMO Hydrax ES32
Daphne Hydraulic Fluid 32

IDEMITSU KOSAN
Daphne Super Hydro 32A
DTE Oil Light, Unipower 32

EXXON MOBIL
DTE 24 Oil, Unipower SQ32
(5) Rest the hydraulic pump horizontally to use it.

(6) Open the air valve to operate the hydraulic pump.
(7) When a hydraulic jack is used for the first time, the rubber hose will fill with hydraulic fluid. Therefore,
when the hydraulic pressure begins to rise, check the oil level in the hydraulic pump, and then add
hydraulic fluid as necessary.
(8) If the hydraulic jack does not work even though the hydraulic pressure has risen to the specified value, it
will be because of loose couplers. Open the relief valve on the hydraulic pump to release the hydraulic
pressure. Then check the connection on all of the couplers.
3) Storing the hydraulic jack

(1) To prevent rust, apply a light coat of lubricating oil to the hydraulic jack and store it in a protected place.
(2) Put a cap on each coupler when storing them.
2007.4.18R*
92 Location Used & Installation Method 92-03a-00 1/1
1) Location used
The hydraulic pump, the hydraulic jack and related hydraulic tools are special tools used to loosen the nuts
on the following three parts when disassembling the engine. These tools are also used to tighten the nuts to
the specified torque when reassembling the engine.
(1) Cylinder head nuts.
(2) Main bearing cap nuts.
(3) Connecting rod nuts.
2) Installation method and operating procedure

The method for installing the hydraulic pump, hydraulic jack and related hydraulic tools was described in the
previous section (Chapter 92-01). Since the details about handling each item are described in the relevant
chapter, refer to these chapters.
The chapter in which these items are described is shown below.
(1) Cylinder head nuts
Refer to the chapter "11-02 Overhauling the Cylinder Heads"
(2) Main bearing cap nut.
Refer to the chapter "21-02 Overhauling the Main Bearings"
(3) Connecting rod bolt nut.
Refer to the chapter "22-03 Overhauling the Connecting Rods"
2007.4.18R*
油圧ジャッキ部品表 No. Page
92 油圧ジャッキ（シリンダヘッド）部品表
92-51a-01 1/2
Parts List of Hydraulic Jack (Cylinder Head)
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㧞㧡
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020636-01X
2008.9.10R
92 油圧ジャッキ（シリンダヘッド）部品表
92-51a-01 2/2
Parts List of Hydraulic Jack (Cylinder Head)

X 746683-92111 ユアツポンプシクミ PUMP ASS'Y 1set
1 1 146673-92200 ユアツポンプ PUMP ASS'Y 1
2 1 146673-92210 トリツケカナグ（アツリヨク BRACKET, MOUNTING 1
3 1 146673-92240 ブランチ BRANCH 1
4 1 153605-92481 ゲ－ジダンパ DAMPER, GAUGE 1
5 2 153605-92460 パッキン GASKET 2
6 1 153625-92750 ゴムホ－ス（７００ＫＧ１Ｍ HOSE, RUBBER 700KG 2
7 1 153625-92760 ゴムホ－ス（７００ＫＧ３Ｍ HOSE, RUBBER 700KG 1
8 1 153625-92801 アツリヨクケイ（１００ＭＰＡ GAUGE, PRESSURE 1
19 1 151605-92740 カクエルボ（ＦＭＬ－３／８ ELBOW, FML-3/8 2
20 1 153625-92770 オスカツプラ－（Ｓ－１Ｈ COUPLER, S-1H 2
X 751695-92170 ユアツジャッキ（ヘッドＢＴ HYDRAULIC JACK ASS'Y 1set

9 1 151605-92640 スパナ（ユアツジヤツキ WRENCH, HYD.JACK 1
10 1 151695-92370 ユアツジヤツキ HYDRAULIC JACK ASSY 4s
13 2 24321-000600 Ｏリング１ＡＧ６０．０ PACKING, G 60.0 4
14 2 24321-001300 Ｏリング１ＡＧ１３０．０ O-RING 1A G-130.0 4
15 2 24375-000600 バツクアツプリングＴ２Ｇ６０ RING,BACKUP T2 G 60 4
16 2 24375-001300 バツクアツプリングＴ２Ｇ１３０ RING,BACKUP T2 G 130 4
26 2 151695-92410 カバー COVER 1
27 2 26116-040062 ボルト４Ｘ６ BOLT 4 X 6 4
17 1 151605-92700 カンザＢＴ（ユアツジヤツキ BOLT, HYD.JACK 4
18 1 151605-92721 カンザ（ユアツジヤツキ SPACER, HYD.JACK 4
19 1 151605-92740 カクエルボ（ＦＭＬ－３／８ ELBOW, FML-3/8 2
20 1 153625-92770 オスカツプラ－（Ｓ－１Ｈ COUPLER, S-1H 2
21 1 153625-92780 メスカツプラ－（Ｓ－１Ｒ COUPLER R 4
22 1 23875-030000 ネジプラグＲ０３ PLUG, R03 2
23 1 26732-390002 ナツト（ホソ３９ NUT, 39 4
24 1 28230-090150 タ－ニングハンドル９Ｘ１５０ HANDLE, 9 X 150 1
25 1 153625-92750 ゴムホ－ス（７００ＫＧ１Ｍ HOSE, RUBBER 700KG 2 　
2008.9.10R
92 油圧ジャッキ（主軸受押え）部品表
92-52a-01 1/2
Parts List of Hydraulic Jack (Main Bearing Cap)
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㧡
㧝㧤㧞㧝㧞㧟㧝㧣㧞㧠
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㧞㧜㧝㧥㧡㧞㧞㧝㧢

020637-00X
2008.9.10R
92 油圧ジャッキ（主軸受押え）部品表
92-52a-01 2/2
Parts List of Hydraulic Jack (Main Bearing Cap)

1 1 146673-92200 ユアツポンプ PUMP ASS'Y 1 ※
2 1 146673-92210 トリツケカナグ（アツリヨク BRACKET, MOUNTING 1 ※
3 1 146673-92240 ブランチ BRANCH 1 ※
4 1 153605-92481 ゲ－ジダンパ DAMPER, GAUGE 1 ※
5 1 153625-92750 ゴムホ－ス（７００ＫＧ１Ｍ HOSE, RUBBER 700KG 2 ※
6 1 153625-92760 ゴムホ－ス（７００ＫＧ３Ｍ HOSE, RUBBER 700KG 1 ※
7 1 153625-92801 アツリヨクケイ（１００ＭＰＡ GAUGE, PRESSURE 1 ※
8 1 151605-92640 スパナ（ユアツジヤツキ WRENCH, HYD.JACK 1 ※
9 1 151695-92370 ユアツジヤツキ HYDRAULIC JACK ASS'Y 2s ※
10 2 151695-92380 ピストン（ユアツジヤツキ PISTON, HYD.JACK 2 ※
12 2 24321-000600 Ｏリング１ＡＧ６０．０ PACKING, G 60.0 2 ※
13 2 24321-001300 Ｏリング１ＡＧ１３０．０ O-RING 1A G-130.0 2 ※
14 2 24375-000600 バツクアツプリングＴ２Ｇ６０ RING, BACKUP T2 G 60 2 ※
15 2 24375-001300 バツクアツプリングＴ２Ｇ１３０ RING, BACKUP T2 G 130 2 ※
25 2 151695-92410 カバー COVER 1 ※
26 2 26116-040062 ボルト４Ｘ６ BOLT 4 X 6 4 ※
16 1 151605-92700 カンザＢＴ（ユアツジヤツキ BOLT, HYD.JACK 2 ※
18 1 151605-92740 カクエルボ（ＦＭＬ－３／８ ELBOW, FML-3/8 2 ※
19 1 153625-92770 オスカツプラ－（Ｓ－１Ｈ COUPLER, S-1H 2 ※
20 1 153625-92780 メスカツプラ－（Ｓ－１Ｒ COUPLER R 2 ※
21 1 23875-030000 ネジプラグＲ０３ PLUG, R03 2 ※
22 1 26732-390002 ナツト（ホソ３９ NUT, 39 2 ※
23 1 28230-090150 タ－ニングハンドル９Ｘ１５０ HANDLE, 9 X 150 1 ※
X 751605-92141 カンザシクミ（メタルＣＡＰ SPACER ASS'Y 1set

17 1 151605-92691 カンザ（ユアツジヤツキ SPACER, HYD.JACK 2 　
24 1 26206-080202 ボルト８Ｘ２０ BOLT, 8 X 20 2 　
※ヘッドボルト用と同一工具です。共通で使用下さい｡
※ The tool is the same for the cylinder-head bolt, please use it together.
2008.9.10R
92 油圧ジャッキ（ロッドボルト）部品表
92-53a-02 1/2
Parts List of Hydraulic Jack (Rod Bolt)
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㧠
㧟
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㧡
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㧝㧡㧝㧜
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㧝㧞
㧝㧠

㧝㧣
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92 油圧ジャッキ（ロッドボルト）部品表
92-53a-02 2/2
Parts List of Hydraulic Jack (Rod Bolt)

1 1 146673-92200 ユアツポンプ PUMP ASS'Y 1 ※
2 1 146673-92210 トリツケカナグ（アツリヨク BRACKET, MOUNTING 1 ※
3 1 146673-92240 ブランチ BRANCH 1 ※
4 1 153605-92481 ゲ－ジダンパ DAMPER, GAUGE 1 ※
5 1 153625-92750 ゴムホ－ス（７００ＫＧ１Ｍ HOSE, RUBBER 700KG 2 ※
6 1 153625-92760 ゴムホ－ス（７００ＫＧ３Ｍ HOSE, RUBBER 700KG 1 ※
7 1 153625-92801 アツリヨクケイ（１００ＭＰＡ PRESS.GAUGE 1 ※
18 1 153625-92770 オスカツプラ－（Ｓ－１Ｈ COUPLER H 2 ※
X 751695-92153 ユアツジヤツキ（ロツドＢＴ HYDRAULIC JACK ASS'Y 1set 　

8 1 151695-92443 ユアツジヤツキ（ロツドＢＴ JACK, HYDRAULIC 2s 　
10 2 151695-92493 ピストン（ユアツジヤツキ PISTON, HYD.JACK 2 　
11 2 24321-000550 Ｏリング１ＡＧ５５．０ PACKING, G 55.0 2 　
12 2 24321-001150 Ｏリング１ＡＧ１１５．０ PACKING, G115.0 2 　
13 2 24375-000550 バツクアツプリングＴ２Ｇ５５ RING, BACKUP T2 G 55 2 　
14 2 24375-001150 バツクアツプリングＴ２Ｇ１１５ RING, BACKUP T2 G115 2 　
19 2 151695-92420 カバー COVER 1 　
20 2 26116-040062 ボルト４Ｘ６ BOLT 4 X 6 4 　
15 1 151695-92481 カンザ（ユアツジヤツキ SPACER, HYD.JACK 2 　
16 1 132654-92510 タ－ニングハンドル HANDLE, TURNING 1 　
17 1 153625-92780 メスカツプラ－（Ｓ－１Ｒ COUPLER, R 2
※ヘッドボルト用と同一工具です。共通で使用ください。
※ The tool is the same for the cylinder-head bolt, please use it together.
2008.9.10R
92 油圧ジャッキ（パンタグラフ）部品表
92-54a-00 1/2
Parts List of Hydraulic Jack (Pantograph)
㧝㧠
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㧥
㧝㧡
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㧠
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㧤㧘㧣
㧝㧝㧝㧟
㧝㧠 020640-00X
2008.9.10R
92 油圧ジャッキ（パンタグラフ）部品表
92-54a-00 2/2
Parts List of Hydraulic Jack (Pantograph)

X 753603-92361 ジャッキ（パンタグラフ JACK, PANTOGRAPH 1set
1 1 146674-92120 ソケツト（１９ SOCKET, 19 1
2 1 153603-92750 ジヤツキ（パンタグラフ JACK, PANTOGRAPH 1
3 2 153603-92530 カナグＡ FITTING, A 1
4 2 151605-92770 カナグＢ FITTING, B 1
6 2 151605-92880 カナグＣ FITTING, C 1
7 2 151605-92890 ナツト NUT 1
8 2 26206-120302 ボルトＭ１２Ｘ３０ BOLT M12X 30 1
9 2 26292-140352 ボルト（ホソ１４Ｘ３５ BOLT, 14 X 35 1
10 1 138613-92850 ラチエツトハンドル HANDLE, RATCHET 1
11 1 151605-92860 クランプＡＳＹ CLAMP ASS'Y 2
13 2 151605-92850 クランプ（シユジクＣヨウＪ CLAMP 2
14 2 22272-000070 トメワＥ７ RING, 7 4
15 1 26111-160302 ボルトＭ１６Ｘ３０ BOLT M16 X 30 2
2008.9.10R
No. Page
95 Installation Notes 95-12a-00 1/2
1. Preparations for installation

● The engine bed on which the engine and the reverse reduction gear are mounted must be sufficiently
strong and rigid. Place reinforcing ribs near each installation bolt.
● Clean the surface of the engine bed, and check the installation position. (See the completion drawing.)
● Install the reverse reduction gear and then the engine. Then center them with the propeller shaft (or
the intermediate shaft).
● If you use CHOCKFAST and there is a jack-up bolt hole in the area in which the resin will flow, fill in
the screw hole first using soft filler such as putty.
2. Resin Chock
The shipping classification organizations regulate the resin allowable face pressure.
To be followed as recommendation of a resin chock manufacturer about the face pressure and volume.
Fig. 95-12-1
CUT-OUT OF TOP PLATE 93 311.5 400 400 400 400 310 90 FRONT P.T.O
FOR FLY-WHEEL
165 215 185.5 200 185
204.5 ̪ 200
No.1 CYL
960
No.6 CYL
1400
1050
RESIN CHOCKS
725.5 677
̪
P.T.O. FLANGE OF ̪2-Ǿ37 HOLES FOR 16-Ǿ37 HOLES 6-POSITION OF

RATO COUPLING Ǿ38 REAMER JACK BOLT
CENTER OF CRANK SHAFT SIDE BOLT
1140 HOLDING DOWN BOLT

(M33)
1050
400
SIDE ADJUSTER
30 EEL
12
Ǿ YWH
MAX
156
FL abt.106
90
28
(24㨪30)
22
862
RESIN CHOCKS
NOTE
THE REQUIREMENT OF
CLASS, SOCIETIES
TO BE FULFILLED.
(888)
(16) (915) (16) DUM(SPONGE)
(1450)
018988-00E
2007.4.18R*
No. Page
95 Installation Notes 95-12a-00 2/2
3. Installing the engine

① When a resin liner is used for the installation, the responsible agency limits the allowable pressure on
the resin face. Therefore, the shipyard is requested to check the face pressure.
Using resin liner the allowable face pressure of each responsible agency is as shown in the following table.
Responsible agency Allowable face pressure (MPa) Temperature ( ℃ )
NK, LR, NW, CR, KR 4.41 80
USCG 4.41 80
ABS, BV, GL, CCS 3.43 80
jg 3.43 80
**The face pressure is calculated by the value of the supported weight + the bolt tightening force.
② The thickness of the resin must follow the recommended value from the resin liner manufacturer.
③ Installation Bolts
Stud bolts are used for installation and the recommended method for tightening them is from both sides
using double nuts.
The standard torque is shown in the following table. (Bolt material: S45C)
Bolt size Tightening torque (N-m)
M27 590
M30 790
M33 1080
M36 1390
M39 1810
4. Centering of the engine and reduction (reversing) gear coupling

Refer to page "21-04" in this manual for details about centering the engine and reverse and reduction gear
coupling.
2007.4.18R*
Yanmar's Worldwide Service Network
Domestic Office Overseas Office
A Yanmar Europe B.V. (YEU)
Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Yanmar (Head office) Country Code: 31
1-32, Chayamachi, Kita-ku, Osaka, Japan 530-8311 Phone: 36-5493200 Fax: 36-5493209
Yanmar (Tokyo) B Yanmar Asia (Singapore) Corp. Pte. Ltd. (YASC)
1-1, 2-Chome, Yaesu, Chuo-ku, Tokyo, Japan 4 Tuas Lane, Singapore 638613
104-8486 Country Code: 65
Export Dept. Marine Phone: 6595-4200 Fax: 6862-5189
Country Code: 81
C Yanmar America Corp. (YA)
Phone: 3-3275-4909 Fax: 3-3275-4969
951 Corporate Grove Drive, Buffalo Grove, IL 60089-4508, U.S.A.
Large Power Products Operations Devision Country Code: 1
1-1, 1-Chome, Nagasu Higashi-dori, Amagasaki, Phone: 847-541-1900 Fax: 847-541-2161
Hyogo, Japan 660-8585 D Yanmar Engine (Shanghai). Co., Ltd.
Quality Assurance Dept. Room 2002, China Insurance Building, 166
Country Code: 81 Pudong Lujiazui East Road, Shanghai, China
Phone: 6-6489-8017 Fax: 6-6488-4009 Country Code: 86
Phone: 21-5879-5090 Fax: 21-5879-8090
E Yanmar Co., Ltd. India liaison Office
603, Maithili Signet Sector 30A, Opp Vashi Railway Starion
Vashi, Navi Mumbai 400703
Country Code: 91
Phone: (022)2781-0972, 2781-0975, 2781-0976
FAX: +91-22-2781-0977
Hong Kong Office

Room 1208, C.C. Wu Building, 302-308 Hennessy Road,
Tokyo Office (Head Office)
Wanchai, Hong Kong, China
1-1-1, Shinbashi, Minato-ku, Tokyo, Japan 105-0004
Country Code: 81 Country Code: 852
Phone: 3-3508-1112 Fax: 3-3508-1123 Phone: 2833-9032 Fax: 2904-7783
Web: www.yanmar.co.jp/ye/ Greece Liaision Office
Osaka Office 5th Floor, 130, Sygrou Avenue, Athens, Greece
1-1, 1-Chome, Nagasu Higashi-dori, Amagasaki, Country Code: 30
Hyogo, Japan 660-8585 Phone: 210-922-2481 Fax: 210-922-2484
Country Code: 81 Philippines Office
Phone: 6-6489-8048 Fax: 6-6481-6101
Web: www.yanmar.co.jp/ye/ 6th Floor, YL Holdings Building, 115 V.A. Rufino Street
Corner Salcedo Street, Legaspi Village 1229, Makati City,
Philippines.
Country Code: 63
Phone: 2-893-2880 / 4262 Fax: 2-893-4339
23
21
A
19 22
20 53
24 Greece 18 C 42
25 5 14
26 4 Tokyo
28 27 China D3 39
32 Osaka 41 40 43
29 Hong Kong 16
U.A.E 17 Taiwan
30 31 12 15 6 7
E Philippinnes
1 B 44
13 8
9
10 11 38
50
37 34 48 45
33 49 46 47
36 51
(Edition 12, April 2009) 1/4

Overseas Office MALAYSIA
8 Pan Sarawak Co., Sdn. Bhd.
Liaison Office (Dongguan) Wisma Pansar 23-27, Workshop Road 96007 Sibu
No.33, Jiaoyu Road, Banshi, Changping Town, Sarawak, Malaysia
Dongguan, Guangdong, China Country Code: 60
Country Code: 86 Phone: 84-333366 Fax: 84-314555
Phone: 769-8339-4935 Fax: 769-8339-7937
9 Chong Lee Leong Seng Enterprise Sdn. Bhd.
Taiwan Branch Lot 530, Persiaran Subang Permai Sg. Penaga
No.56, Yugangjung 2 Rd., Chienchen Dist, Kaohsiung, Taiwan Industrial Park, USJ 1 47500 Subang Jaya Selangor
Country Code: 886 Darul Ehsan, Malaysia
E-mail: [email protected] Phone: 3-5632-1577 Fax: 3-5632-3126
Dubai Liaison Office INDONESIA
Gold & Diamond Park, Manufacturing office 3006,
10 Yanmar Jakarta Service Center C/O P.T.
Ground Floor Building-3, Sheikh Zayed Road P.O
Box 214831 Dubai, U.A.E Pioneer
Country Code: 971 Jalan Ir. H. Juanda, No.40-41-42, Jakarta, Indonesia
Phone: 4-341-8787 Fax: 4-341-8778 (P.O. Box 2502-Jakarta 10025)
Country Code: 62
Phone: 21-385-8526 Fax: 21-384-8995
Overseas Service Agents 11 P.T. Pioneer
Jalan Ir. H. Juanda, No.40-41-42, Jakarta 10120, Indonesia
ASIA (P.O. Box 2502-Jakarta 10025)
SRILANKA Country Code: 62
Phone: 21-344-8486 Fax: 21-344-8995
1 Colombo Dockyard (Pte) Ltd.
Graving Docks Port of Colombo, P.O.Box 906, INDIA
Colombo 15, Srilanka 12 IND-AUST Maritime Pvt. Ltd.
Country Code: 94
Phone: 11-2522461～5 Fax: 11-2446441 715, J.K. Chambers Sector 17, Vashi,
New Bombay-400 703. India
CHINA Country Code: 91
Phone: 22-55912233 / 27892524
3 GOLTENS SHANGHAI CO., LTD Fax: 22-55912234 / 27892529
Block No.5, No.533 Yuanzhong Road, Nanhui SINGAPORE
Industrial Zone, Nanhui District, Shanghai, China 13 Chong Lee Leong Seng Co., (Pte) Ltd.
Country Code: 86
23 Tuas Avenue 2, Singapore 639454
Phone: 21-58186628 FAX: 21-58186633 Country Code: 65
4 TIANJIN PORT TUG-BOAT & LIGHTER COMPANY Phone: 6264-2922 Fax: 6861-8785
/YANMAR ENGINE SERVICE CENTER KOREA
No.383 Yongtai Road, Tanggu District, Tianjin, China
Country Code: 86 14 Hwa Trading Co., Ltd.
Phone: 22-2570-7510 FAX: 22-2570-7510 #136. 1-Ka, Dae kyo-Dong, Young Do-Ku, Busan, Korea
Country Code: 82
5 DALIAN WANFANG MARINE TECHNOLOGY CO., LTD Phone: 51-412-6385 Fax: 51-414-8752
No.40 Aixian Street, Qixianling, Dalian High-Tech THAILAND
Industrial Zone, China
15 Siam Consotium Service Co., Ltd.
Country Code: 86
Phone: 411-84799000 FAX: 411-84795678 103-107. Damronglatpipat Road, Klongtoey, Prakanong,
Bangkok, Thailand 10110
HONG KONG Country Code: 66
Phone: 2-249-8023 Fax: 2-249-7985
6 Cistar Tech HK Ltd.
Y.T.M.L. No.44, Cha Kwo Ling Road, Yau Tong Bay, TAIWAN
Kowloon, Hong Kong, China 16 Yee Foo Marine Industrial Co., Ltd.
Country Code: 852 6F-3, No.369 Fusing North Road, Taipei,
Phone: +85227750161 Fax: +85227726054 Taiwan ROC. 105
Country Code: 886
PHILIPPNES Phone: 2-8712-0848 Fax: 2-8712-0797
7 Seapowers Trading & Industrial services 17 Seikoh Co., Ltd.
316-A Mamatid Cabuyao, Laguna, Philippines No.56 Yugang Jung 2 Rd., Chien Chen Dist. Kaohsiung, Taiwan
Phone: 917-500-3017 Fax: 49-502-0765 Phone: 7-831-2303 Fax: 7-882-3911
E-mail: [email protected]
2/4
EUROPE MIDDLE EAST
RUSSIA ARAB REPUBLIC OF EGYPT
18 Nakhodka Ships Service Ltd. 27 Mapso
59, Nakhodka Avenue Nakhodka, Russia 692900 P.O. Box 2643, 44 Industrial Area, Cairo/Ismailia
Country Code: 7 Desert Road, Cairo, Egypt
Phone: 423-66-2-38-12 Fax: 423-66-2-10-71 Country Code: 20
Phone: 2-2962777 (8 lines) Fax: 2-2962780
NETHERLANDS
28 Mapso-Alexandria Office
19 Nicoverken Holland B.V. 5 Orabi Street, Alexandria, Egypt
Algerastraat 20, 3125 BS Schiedam, The Netherlands Country Code: 20
Country Code: 31 Phone: 3-483-3453 Fax: 3-483-3486
Phone: 10-2380999 Fax: 10-2380988
SAUDI ARABIA
20 Fuji Trading (Marine) B.V.
29 Saudi Diesel Generators Company Ltd.
Kortenoord 2-8 3087 AR Rotterdam, The Netherlands
Country Code: 31 P.O.Box 87, Dhahran Airport 31932, Saudi Arabia
Phone: 857-6769 / 8028/8036 Fax: 857-4681
U.K.
24 U.A.E
21 Shipaid Diesel Services Ltd.
00 Units, 1&2, Plot 10, Westminster Trading Estate, 30 Albwardy Marine Engineering (L.L.C)
Westminster Road, North Hykeham Lincoln, LN6 3QY Dubai Shipdocking Yard P.O. Box 6515 Dubai, U.A.E
Phone: 1522-533990 FAX: 1522-695153 Phone: 4-324-1001, 4-324-1561 Fax: 4-324-1005
31 Goltens Co. Ltd. Dubai Branch
GERMANY
Al Jadaf Ship Docking Yard P.O. Box 2811, Dubai, U.A.E
22 Nippon Diesel Service Coutry Code: 971
Hermann-Blohm-Str. 1 D-20457, Hamburg, Germany Phone: 4-324-1642 Fax:4-324-1963
Country Code: 49
Phone: 40-317710 Fax: 40-311598
AFRICA
ICELAND
MOROCCO
23 MARAS E.H.F
32 Aalborg International S.A.
Akralind 2 201 K-pavogur Iceland
Country Code: 354 Port De Peche, Agadir, Morocco
Phone: 555-6444 Fax: 565-7230 Country Code: 212
Phone: 844234 / 841346 Fax: 845273
ITALY
24 NDI SRL SOUTH AFRICA
Via G.B. Guarini, 33, 157121 Livorno-Italy 33 IMS Engineering (Prz) Ltd.
Country Code: 39 124 Marine Drive Parden Eiland, 7420, South Africa
Phone: 0586-429053 Fax: 0586-443606 P.O. Box 63 Parden Eiland 7420
Country Code: 27
SPAIN Phone: 21-511-8201 Fax: 21-511-6698
25 Skandiaverken, S.A.
Po. Ind. Torrelarragoiti Parcela P7M, Pab. 1y2 48170
Zamunio Bizkaia SPAIN
Country Code: 34
Phone: +34 94 6880200 Fax: +34 94 6880216
TURKEY
26 Aras Makina Sanayi Mumessillik ve Ticaret Ltd Sirketi
Aydintepe Mh.Sahilyolu Cd. Denizciler Ticaret Merkezi
No.51. 34947 Tuzla-Istanbul, Turkey
Country Code: 90
Phone: 216-392-9211　Fax: 216-392-8827
3/4
OCEANIA SOUTH AMERICA
AUSTRALIA TRINIDAD AND TOBAGO
34 Forgacs Cairncross Dockyard Pty. Ltd. 44 Caribbean Dockyard Ltd.
Thynne Road Morningside, Brisbane, Queensland 4170, P.O. Box 1147, Port Chaguaramas, Trinidad, W.I.
Australia Country Code: 1
Country Code: 61 Phone: 809-634-4239 / 4229 / 4378
Phone: 7-322-70856 Fax: 7-3399-6164 Fax: 809-625-1215 / 809-674-1743
URUGUAY
36 Waterside Engineering Pty. Ltd.
45 Tsakos Industries Navales S.A.
48-50 Export Drive Brooklyn 3025, Victoria, Australia
Country Code: 61 Avda. Gral Rondeau 2023 Montevideo Uruguay
Phone: 94-83-36 Fax: 94-70-95
37 Jaitco
10199 Kurraba Road, Neutral Bay, N.S.W. 2089, Australia ARGENTINA
Country Code: 61 46 Cromwell S.A.
Phone: 2-99098545 Fax: 2-99531728
Carifornia 733 1168-Buenos Aires, Argentina
51 Japan Marine Engineering Co.,ltd Country Code: 54
475 Warrigal Road Moorabbin Victoria Australia 3189 Phone: 1-301-4124 Fax: 1-302-7407
Country Code: 61 47 Arzen Corpopation S.A.
Phone: +61-3-9555-5277 FAX: +61-3-9555-5344 Av. De Mayo 1370 Piso 2 Of 15 1362 Buenos Aires, Argentina
Country Code: 54
PAPUA NEW GUINEA Phone: 1-325-9585 Fax: 1-325-9586
38 Lutheran Shipping CHILE
P.O. Box 1459, Lae, Papua New Guinea 48 Sociedad Maestaranga Yungay Ltda
Country Code: 675
Jose Tomas Ramos 184 Casilla 906 Vaiparaiso, Chile
Phone: 42-6190 FAX: 42-5806 Telex: NE 44172
Country Code: 56
Phone: 214476 Fax: 211898
NORTH AMERICA 49 Diesel Motors Thno
U.S.A Vevtas-Servicios 56-41 Colon n 2090 Casillia
206-Talcanuano, Chile
52 YANMAR AMERICA CORPORATION. NEW YORK BRANCH Country Code: 56
Parker Plaza 16F, 400 Kelby Street, Fort Lee, NJ Phone: 544208 Fax: 542942
07024 U.S.A. BRASIL
Country Code: 61
Phone: 201-592-8500 FAX: 201-592-8503 50 Metalock do Brasil Ltda
Rua Visconde do Rio Branco 20/26, 11013-030,
39 Marine Turbo & Diesel Inc. Santos, SP, Brasil
1090 7th Street, Richmond, Ca, 94801, U.S.A. Country Code: 55
Country Code: 1 Phone: 13-3222-4686 Fax: 13-3222-4088
Phone: 510-236-3525 Fax: 519-236-3576
40 North Florida Ship Yards Inc.
P.O. Box 3255 Jacksonville, Florida 32206, U.S.A.
Coutry Code: 1
Phone: 904-354-3278 Fax:904-353-2665
41 International Five Star Marine Service Inc.
905 Willow Creek Drive La Porte, Texas 77571, U.S.A.
Country Code: 1
Phone: 713-473-8660 Fax: 713-473-8667
42 GOLTENS New York Corp.
160 Van Brunt Street, Brooklyn, NY 11231 U.S.A.
Coutry Code: 1
Phone: 718-855-7200 Fax: 718-802-1147
43 GOLTENS Miami Co. Inc.
2323 N.E. Miami Court・Miami, Florida 33137 U.S.A.
Coutry Code: 1
Phone: 305-576-4410 Fax: 305-576-3827
4/4
Marine Propulsion Engine
Model
OPERATION MANUAL
1st edition : November, 2009
Issued by : Quality Assurance Dept.,

Large Power Products Operations Division
Yanmar Co.,Ltd.
Edited by : Yanmar Technical Service Co.,Ltd.
Order No. R7-BB3301

Yammar 6ey26 - Me Manual

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6EY26

Eng. No. 0500

Thank you for purchasing

00 Fuel Oil, Lubricating Oil & Cooling Water

Yanmar's Worldwide Service Network

Thank you for purchasing a YANMAR Diesel Engine.

For safe use of your engine.

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

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

● Where the safety labels are posted is shown in page 00-06.

2. How to read the Manual

The remarked items are the following explanations.

2-2. How to read the Parts List

Operation Manual M51695

⷗಴ ࡟ࡌ࡞ ࠝ࡯࠳ ㇱຠ⇟ภ ୘ᢙ ஻⠨

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

Combustion chamber --- Direct injection type

No. of cylinders --- 6

Cylinder bore mm 260

Total cylinder displacement L 122.64

Compression ratio --- 14.0

Rated output kW 1800

Rated speed min-1 750

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

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

Cooling system --- Freshwater & Freshwater dual system cooling

Lubricating oil sump system --- Dry Sump

Starting system --- Air motor starting

Dimensions Overall width mm Refer to the Final Drawing

Mass (of engine singly) kg

2.Types of Accessories & Attachments

Supercharger Air-cooled exhaust gas turbine

Boost air cooler Plate finned multitubular

Fuel injection pump Bosch Independent per cylinder

Lub.oil pump Gear

Ⅰ Polyester mesh element Automatic backflushing

Lub.oil tank Bottom tank Dry sump

Cooling water pump Centrifugal Cylinder jacket side

Air motor Turbine Compressed air

Direction of rotation is clockwise as viewed from the flywheel side.

Air Motor Flywheel 019399-00E

1-2. Non-Operation Side View

Sea Water Pump

Lubricating Oil Filter

Lubricating Oil Cooler Cooling Water Pump

Lubricating Oil By-Pass Filter

Lubricating Oil Pump 019400-00E

No. Part Name No. Part Name

－ 21 F.W. Auto Temp. Control Valve

2-2. Cross Sectional View

Fig. 00-04-4 Cross Sectional View

No. Part Name No. Part Name

Fuel Injection Pump

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

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