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CHAPTER- 01

INTRODUCTION TO YANMAR 6LY2A-STP ENGINE

Picture 01-I

1. Introduction to Model Number 6LY2A-STP

There are three types of similar category 6LY Yanmar Engine Models.

a. 6LYA-STP
b. 6LYA-STE
c. 6LY2A-STP

6 L Y 2 A ST P

No. of Cylinders
Inline
Yanmar
2nd Version
Assembled in America
Standard Turbocharger
Pleasure

Note: 6LY 2A-STP Engines are used by Sri Lanka Navy

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2. General Specifications of 6LY2A-STP Engine

a. Type : Vertical Water Cooled 4- Cycle diesel

engine
b. No of cylinders : 06
c. Bore × Stroke : 105.9 × 110 mm
d. Displacement : 5.813 Ltr
e. Max RPM : 3300(440 hp/324 kW)
f. Continoues RPM : 3100(350 hp/257 kW)
g. High idling RPM : 3670 ± 25
h. Low Idling RPM : 700 ± 25
i. Combustion System : Direct Injection
j. Starting System : Electric starting
k. Cooling System : Fresh water cooling
l. Direction of rotation : Counter clockwise (viewed from flywheel
side)
m. Lub Oil capacity : 20 Ltrs
n. Cooling water capacity : Engine 20 Ltrs, Sub tank 1.5 Ltrs
o. Dry mass (Gear Less) : 535 kg
p. Injector Nozzle
Opening pressure : 290- 300 Kg/cm2

3. Constructional features of block and other components

a. Cylinder block

The cylinder block is made with a thin-skinned, (low- weight), short skirt type
with rationally placed ribs. The side walls are waver shape to maximize rigidity for
strength and low noise.

b. Cylinder head

The cylinder head is made with 6-cylinder integral construction, mounted with 26
bolts. Special alloy satellite with superior resistance to heat and wear is fitted on the seat,
and the area between the valves is cooled by a water jet.

c. Piston and piston pins

Piston is made of a special light alloy with superior thermal expansion

characteristics, and the top of the piston forms a swirl type combustion chamber. The
opposite face of the piston combustion surface is oil jet cooled.

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d. Connecting rod
The connecting rod is made of high- strength forged carbon steel. The large end
with the aluminum metal can be separated in two and small end has a 2 layer copper alloy
coil bushing.

e. Crank shaft and main bearing

The crank pins and crank journal have been induction hardened for superior
durability, and the crank shaft is provided with four balance weights for optional balance.
The crank shaft main bearing is of the hanger type. The upper metal (cylinder block side)
is provided with an oil groove. There is no oil groove on the lower metal (bearing cap
side). The bearing cap (location cap) of the flywheel side has a thrust metal which
supports the thrust load.

f. Camshaft and tappets

The camshaft is normalized and the cam and bearing surface hardened and
ground. The cams have a curve that minimizes the repeated shock on the valve seats and
maximizes valve seat life.

g. Timing gear

The timing gear is helical type for minimum noise and special treated for
durability.

h. Fly wheel

The function of the flywheel is through inertia, to rotate the crank shaft in a
uniform and smooth manner by absorbing the turning force created during the
combustion stroke of the engine, and by compensating for the decrease in turning force
during the other strokes. Fly wheel is mounted and secured by 6 bolts on the crank shaft
end at the opposite end to the gear case.

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4. Performance curves

CHAPTER-02

SYSTEMS RELATED TO ENGINE

Picture 01-II

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CHAPTER- 02

SYSTEMS RELATED TO THE ENGINE

5 Fresh Water System

The fresh cooling system is indirect sea water cooled, fresh water circulation type system.
Fresh water is pumped by the engine driven fresh water pump from the fresh water tank to the
cylinder jacket for cooling of cylinder, turbocharger and the cylinder head.

Fresh water tank

Heat Exchanger

Fresh water
pump
Thermostat

Turbocharger

Fresh Water
Manifold

Cylinder
Head
Cylinder Block

Picture 02-I: Layout of fresh water system

a. Thermostat: The thermostat is fitted between the cylinder head outlet and heat
exchanger. The thermostat is closed when the fresh water temperature is below 71oC.
Therefore just after the engine is started and low load operation, the temperature of the
fresh water is kept within a constant range by the thermostat.

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Opening temperature 71 oC
Full open temperature 85 oC
Valve lift at full open 8 mm
Diameter 50 mm

Table 02-I: Characteristics of thermostat

b. Heat Exchanger: The main function of heat exchanger is cooling of fresh water
by the sea water. When the temperature of the fresh water rises, the thermostat opens,
fresh water flows to the heat exchanger and it is then cooled by the sea water in the tubes
as it flows through cooling pipe.

Bundle length 499 mm

No of tubes 201
Small tube diameter 6.35 mm
Tube material Copper nickel
Body length 585 mm
Body diameter 130.2 mm
Body material Std. dwv
No. of baffles 4
Cut off row 9
Baffle spacing 97.6 mm
No of passes 3
Separator type Standard 3 pass

Table 02-II: Specification of Heat Exchanger

c. Fresh Water Pump: The fresh water is a centrifugal (volute) type pump and
circulates water from the fresh water tank to the cylinder head.

Crank shaft speed(max) 3500 rpm

Pump shaft speed 2590-3030 rpm
Delivery capacity 350 ltr/min
Total head 6.6 mAq

Table 02-III: Specifications of Fresh Water Pump

6. Fuel System

Fuel oil take suction from store tank through fuel oil separator filter, water and fuel
separated, after filter it goes to suction for fuel feed pump. The fuel filter is installed between the

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fuel feed pump and fuel injection pump. It removes dirt/foreign matter from the fuel pumped
from the fuel tank. The filtered fuel is fed to the reservoir in the pump housing, where the
plunger raises its pressure. The fuel then passes through the injection pipe for injection in to each
cylinder via the fuel injection nozzle

Fuel water
Fuel tank separator

Over flow line

Over flow
line

Fuel peed
pump
Fuel
injector

High Fuel filter

pressure
line

Injection
pump

Picture 02-II: Layout of Fuel System

a. Fuel feed pump: As the delivery pressure of the fuel pump climbs, the pressure at the
back of the piston also rises, overcoming the piston spring force, and hindering the
lowering of the piston thus, the fuel flow automatically stops, and the fuel pressure is
maintained within a fixed range.

b. Fuel Injection Pump: YPES-6AL2 type inline fuel injection pump is installed in this
engine. The engine gears drive the cam shaft via the timing gears.

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c. Fuel injection nozzle: Thesa are Hole type fuel injection nozzles.

Engine model 6LY2A-STP

Nozzle i.d. mark Y DLL A-145 S 345LZ1
Spray angle 1450
No of injection hole x dia 5x 0.34 5x Ø 0.34 mm
Nozzle opening pressure 290~300 kgf/cm
Nozzle Tightening 68.6~73.5 Nm
Tightening nut
Torque High pressure pipe 5.3~58.8 Nm
joint
Adjusted screw cap 49.0~53.9 Nm
Nozzle lift 0.31~0.33 mm
Body mark CK

Table 02-IV

Nozzle body identification number the type of nozzle can be determined from the number
inscribed on the outside of the nozzle body.

Y DLL A- 145 S 355LZ1

Design code

Nozzle size

Spray angle

Mounting angle of nozzle

on cylinder head
code A: at angle
no code: not at angle

Type (DLL: semi-long type)

Yanmar

Picture 02-III

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7 Lubrication system

The main function of lubrication system is supply required lub oil to reduce friction of
the engine moving component such as piston, crank shaft bearings, cam shaft bearing etc…

Lube oil in the oil pan is pump up through the intake filter and intake piping by the lube
oil pump through the hole in the cylinder body anon to the discharge filter. The lube oil which
flows from the holes in the cylinder body through the bracket to the oil element is filtered and
send to the oil cooler. It returns from the oil cooler to the bracket. Then pressure is regulated, and
it is fed back to main gallery in the cylinder body.

The lube oil which flows in the main gallery goes to the crank shaft journal, lubricate the
crank pin from the crank shaft journal, and portion of the oil is fed to the cam shaft bearing. Lube
oil is sent from the gear case cam bearings through the holes in the cylinder body and cylinder
head to the rocker arm shaft to lubricate the rocker arms and valves. Lube oil is also sent from
the main gallery to the piston cooling nozzle to cool the piston surface, and it sent through the
intermediate bearing and respective gears. Lube for fuel injection pump is sent by pipe from the
main gallery to the fuel injection pump. Part of lube oil is sent from the oil cooler discharge to
the turbocharger, then pump back from the turbocharger to the oil pan.

a. Lub oil pump: fuh gear type lub oil fmdusmhla jk w;r Lub oil
fmdusmh crank shaft gear tl u.ska l%shdlrjhs' fuu fmdusmhg pressure regulating
valve tlla ijslr we;s w;r th 3'5~4'5kg/cm3 msvkhla moaO;sh ;=, mj;ajd
.ks'

b. Lub oil Filter: fuu hka;% j, Lub oil Filter folla Ndjs;d jk w;r
tajd Full flow type iy bypass type f,i yeoskafjs'

c. Lub oil cooler: fuu jrA.fha hka;%j, we;s Lub oil cooler tl Sea water
u.ska isis,a lrkq ,nhs Lub oil iy Sea water tlska tlg jsreoaO osYdj,g .uka
lsrsug ie,eiajsu u.ska Lub oil cooler tflys ldrAHlaIu;dj jevs lr we;'

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Timer Assy Bypass Full flow

Filter
FIP Oil cooler

Lube oil
pressure TO SUMP
regulating
valve

L/O gallery

Main
metal

Lube oil Intake

pump/Safety filter
Rocker arm shaft
valve

Turbocharger

Cam metal

Picture 02-IV: Layout of lubrication oil system

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8. Charge Air system

Exhaust gas coming out of the engine is accelerated it is flowing speed through the
nozzle of the turbine. The blower impeller mounted on the turbine shaft receives torque force of
the turbine shaft, suck in the air and compresses. Air goes to the charge air cooler and cool high
density air is flowing to the air inlet manifold. One air pipe connects to the governor for boost air
pressure.

To Combusion

Inlet manifold

Inlet air Turbocharger

To lube oil
sensor unit

Boost air to injection pump

Sea water from

Charge air cooler
Fresh water cooler

Sea water to lube oil cooler

Picture 02-V: Layout of charge air system

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9. Sea Water System

Takes sea water from jet through valve and pressure to sea water pump. the sea water
pump cooled the lube oil in the lube oil cooler- inter air cooler and goes to the heat exchanger,
where it cools the fresh water. Then it is sent to the mixing elbow and is discharge from the ship
with the exhaust.

Out board
Mixing
Elbow

Charge air
cooler

L/O cooler
Cooling sea
water pump

Heat exchanger

Picture 02-VI: Layout of sea water system

10. Electrical system

a. Stop Solenoid

fuys m%Odk ldrAh jkqfha hka;%h keje;ajsug wjYH ls%hdj,sh is¥lsrsuhs'

tkuz hka;%h lsh
% d;aul js we;s jsgos kej;ajSfuz h;=frka fyda l+uk fyda fodaIhlska

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fyda Stop Solenoid tlg wjYH iemhqu ,enqkq jsg Stop Solenoid tl ls%hd;aul js
Engine tfla oykhg wjYH f;,a ,nd osu is¥fkdlsrsu ksid hka;%h kj;S.

b. Alternator output
fuys m%Odk ldrAh jkqfha negrs wdfrdamKh lsrsug wjYH iemhqu
,nd.eksuhs. frdagrh, Stator Ml ;+, lerljsu;a iu. Stator ys js¥,sOdrdjla
ksIamdokh fjs' tu Odrj AC Odrdjls. tu AC Odrdj vfhdavs 06 lska hq;a
Rectifier tlg ,ensu;a iu.u tu AC Odrj Trio Diode j,g ,ndfokq ,nhs'
tu.ska th md,khlska hq;+j kej; frdagrhg ,ndosula is¥krkq ,nhs' fuu
ls%hdj,sh os.ska os.gu is¥jsu ksid negrs wdfrdamkh jkq ,nhs' Alternator output
;sfnzoehS oek.eksu ioyd Working Lamp tlla mek,a fndavh ;+, olajd we;. tu
n,anh os.gu oe,afjskus Alternator output tl negrshg ,efnkafka ke;.

c. Battery Connection
negrs jhrA hka;%hg iusnkao lsrsfusos m,uqfjkau is¥l, hq;af;a iagdgrA
fudagrhg wjYH (+) iemhqu fid,khsvs tlg ,ndosu yd bka wk;rej (-) iemhqu
Engine tfla fyda ke;skus Stator Motor Body tlg ,ndosuhs. bka miq tu jhrA fol
tk fid,khsvs tfla (+) iemhqu ,nd¥ka jhrh negrsh w.%hg yd Engine tfla
Body tlg ,nd¥ka (-) Odrdj negrsfha(-) w.%hg ,ndosu is¥lrekq ,nhs' negrs
jhrA .e,jsfuos m,uqfjkau negrshg iusnkao lr we;s jhrA .e,jsug j.n,d .;
hq;+ w;r miqj Engine tl yd Starter Motor fhka negrs iemhqu bj;a lrkq ,nhs.

;jo negrs kv;a;+ lsrsuo is¥l, hq;+h tkuz

(1) kssis mrsos negrs j;+r ne,su
(2) negrsh ieujsgu jsh<s ia:dkhl ;snsu
(3) negrsh iu;,d N+ushl ;snsu
(4) negrsh kv;a;+ lsrsfuos ud, uq¥ jeks ikakdhl WmlrK ms<snoj
ie,ls,su;a jsu'

d. Removing of wire harness prior to dismantling of engine

jhrA ykiai .e,jsug fmr negrs iemhqu bj;a lsrsu is¥l, hq;+ w;r bka
miqj jhrA ykiai .e,jsu is¥lrkq ,nhs' m,uqfjkau Exhaust fmdaf,dagrA j,
iemhqu .e,jsu;a bka miqj ue.akgsla mslma .e,jsu issoq lrhs. miqj stop solenoid
fha iemhqu .e,jsu yd Lub Oil Alarm yd Lub Oil Shut Down .e,jsu is¥lrkq
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,nhs' High Temperature Alarm yd Shut Down Switch j,g ,nd fok jhrA bj;a
lsrsfuka wk;+rej ish,q jhrA iusnkaO jk Terminal Box tl .e,jsh hq;=h' miqj
Starter Motor hg iusnkaOjk jhrA .e,jsula is¥lrk w;r .,jk ,o ish,a,gu
ksis Marking oud .eksu wksjdrAfhkau lsrsug j.n,d .; hq;+h.

Picture 02-VII: Electrical system

Picture 02-VII: Electrical system

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CHAPTER- 03

ROUTINE MAINTENANCE

11. Following periodical inspections, imperative to conduct to keep the engine in its best
condition.

1. Daily
2. First 50 hrs
3. Every 250 hrs (or 1 year)
4. Every 500 hrs (or 2 years)
5. Every 1000 hrs (or 4 years)
6. Every 2500 hrs (Top Overhaul)
7. Every 7500 hrs (Major Overhaul)

12. Daily Routine

a. Check fuel level.

b. Check lub oil level.
c. Check cooling water (sea water) discharge.
d. Check Coolant level and add if any required
e. Check and adjustment of Remote Control Cable.
f. Check alarm devices.
g. Check for any leakages (Lube oil, Coolant, Sea water, Exhaust).

13. First 50 Hours Routine

a. Drain off Fuel Tank.

b. Drain off Fuel Filters and Water Separators.
c. Check and clean Lube Oil inlet filter net.
d. Check battery electrolyte volume.
e. Change Lub Oil and check Lub Oil sample for any metal particles.
(Only after initial 50 hrs)
f. Change Lub Oil Filters (Only after initial 50 hrs)
g. Adjustment of injector pressure and atomizing condition (1st time)
h. Adjustment of clearances of Intake and Exhaust Valves (1st time).
i. Renew coolant of the cooling system.

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14. Every 250 Hours routine (or after one year)

a. Replace Fuel Filter Element

b. Replace Lube Oil Filter Element.
c. Adjustment of injector pressure and atomizing condition (1st time)
d. Adjustment of clearances of Intake and Exhaust Valves (1st time).
e. Check and adjustment of Remote Control Cable.
f. Check and cleaning of Lube Oil inlet filter net.
g. Replacement of Lube Oil.
h. Adjustment tension of alternator drive belt.
i. Visual inspection of Turbo Charger and Waste Gate.

15. Every 500 Hours routine (or after Two years)

a. 250 Hours routine.

b. Clean Turbocharger and Waste Gate.

16. Every 1000 Hours routine (or after four years)

a. 250 and 500 Hours routine

b. Adjustment of clearance of Intake and Exhaust valve.
c. Adjustment of injection pressure and atomizing condition.

17. Every 2500 Hours routine (Top overhaul)

a. 250, 500 and 1000 Hours routine.

b. Cleaning of Lube Oil cooler.
c. Check and replacement of Impeller.
d. Cleaning of seawater system (including Fresh Water and Lube Oil Cooler)
e. Cleaning of Fresh Water system ( Including Heat exchanger and tank)
f. Adjustment of injection timing.
g. Overhaul and check of Fuel Feed Pump.
h. Adjustment injection pressure and atomizing condition.
i. Adjustment of clearance of Intake and Exhaust Valve.
j. Lapping Intake and Exhaust Valve.
k. Check and cleaning of Lube Oil Cooler.
l. Check and replacement of Cooling Water Pump Impeller.
m. Cleaning of Fresh Water system.
n. Check and cleaning of Lube Oil Cooler.
o. Check of bearings, Friction plate and seal.
p. Crank Shaft end play to be checked.
(Standard – 0.132-0.223 mm, Wear limit – 0.29 mm )

18. 7500 Hours routine (Major Overhaul)

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CHAPTER- 04

TROUBLE SHOOTING

19 High Fresh Water temperature

a. Check sea water circulation system, suction strainer, sea water pump, sea water
passage in fresh water cooler
b. Check fresh water circulation system, fresh water pump, thermostat, fresh water
passage of lube oil cooler.
c. Check insufficient amount of cooling water in system
d. Check air in cooling water system
e. Check any leakage from cooling system

20. Low lubrication oil pressure

a. Check clogging of lube oil filter

b. Check lube oil temperature is high
c. Check any faulty of pressure gauge
d. Check insufficient amount of lube oil in oil pan
e. Check viscosity of lube oil
f. Check oil leakage from pump safety valve
g. Check loosen of pressure adjustment valve
h. Check condition of lube oil pump

21. Engine does not shut down

a. Check stop solenoid function correctly

b. Check injection pump level sticking

22. Rough idle

a. Inaccurate length of RPM cable

b. Inaccurate governor setting
c. Seizure of moving part

23. Breather emission

a. Worn upper part of cylinder liner

b. Worn piston ring
c. Sticking of piston ring
d. Check lube oil temperature too high

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24. Lubrication oil dilution/ contamination

a. Check lube oil pump seal/ fresh water pump seal/ sea water pump seal damage
b. Check lube oil cooler/ fresh water cooler/ charge air cooler, O ring, and gasket
damage
c. Check cylinder block and cylinder head crack

25. Black/ white/ blue smoke

a. Check engine over load condition

b. Check dirty in charge air cooler
c. Check quality of fuel oil
d. Check clogged in air filter
e. Check turbocharger impeller
f. Check fuel injector
g. Check and service fuel injection pump
h. Check lube oil level and condition

26. Faulty fuel injection pump

Sr No Defect/ Fault/ Observation Repair action

i Faulty of Plunger operation Check, repair or replace Plungers
ii Worn Plungers Replace Plungers
iii Faulty Injection Valve Check, repair or replace Injection
valve
iv Uneven quantity of fuel Adjust fuel injection
injection
v Irregular fuel injection Adjust fuel injection
timing

Table 04-I

27. Faulty Injection Valve

Sr No Defect/ Fault/ Observation Repair action

i Injection opening is clogged Clean fuel injectors
ii Sticking of valve needle Check, Repair or replace
injectors Nozzle
iii Low injection pressure Adjust injector’s pressure
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iv Faulty injection spray condition Check, Repair or replace

injectors
v Carbon deposit Clean injectors

Table 04-II

28. Faulty Turbocharger

Sr No Defect/ Fault/ Observation Repair action

i Air filter clogged Clean Air filter
ii Dirty impeller Clean impeller
iii Turbine nozzle clogged Clean Turbine nozzle
iv Bearing damaged Replace Bearing

Table 04-III

29. Faulty Fuel Injection Valve

Sr No Defect/ Fault/ Observation Repair action

i Low injection pressure Increase injection pressure
ii Damage fuel valve spring Replace valve spring
iii Sticking of Valve Needle Disassemble and lap
iv Faulty of injection spray Disassemble and repair

Table 04-IV

30 Faulty fuel injection system

Sr No Defect/ Fault/ Observation Repair action

i Early fuel injection Delay injection timing
ii Fuel pressure is too high Adjust standard injection
pressure

Table 04-V
31 Excessive quantity of fuel injected each time

Sr No Defect/ Fault/ Observation Repair action

i Excessive quantity of fuel is Adjust pump Adjustment fuel
injected from fuel pump rack

Table 04-VI
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32 Other reasons for Black/ white/ blue smoke

Sr No Defect/ Fault/ Observation Repair action

i Insufficient cooling water Check Cooling Water Pump
ii Excess Piston clearance Replace/overhaul engine
iii Excess Bearing clearance Replace/ overhaul engine
iv Poor quality fuel oil Replace with good fuel oil
v Water mixed in fuel oil Replace with good fuel oil
vi Incorrect fuel pressure Check and repair injectors

Table 04-VII

33 Miscellaneous defect

(a) The engine suddenly stops

Sr No Defect/ Fault/ Observation Repair action

i Insufficient oil in fuel tank Add fuel oil and prime
ii Air in fuel oil system and fuel Bleed air
Injection pump
iii Water in fuel oil tank Remove water from drain and
fuel oil System and prime
iv Fuel oil Cock close Check and make necessary
repairs
v Clogging of Fuel Oil Filters Clean Fuel Oil Filters
vi Damage in fuel oil system Replaced pipe line
vii Problem with Fuel Feed Pump Repair Fuel Feed Pump

Table 04-VIII

(b) Emergency stoppage device in operation

Sr No Defect/ Fault/ Observation Repair action

i Loose Lube oil pressure adjustment Tighten adjustment valve
valve
ii Clogging of lube oil filter Clean lube oil filter
iii Leakage from Lube oil safety valve Tighten safety valve
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iv Trouble with Lube oil pump Remove and repair/replace

lube oil pump
v Relay operation triggered by low Return to original condition
Lube oil pressure

Table 04-IX

(c) Governor malfunctioning

Sr No Defect/ Fault/ Observation Repair action

i Damage to Governor Spring Replace to Governor spring
ii Sticking of Governor Sleeve Clean carefully to ensure good
working order

Table 04-X

34 Trouble with the Exhaust Gas Turbocharger

(a) Low suction pressure

Sr No Defect/ Fault/ Observation Repair action

i Dirty suction filter and silencer Clean suction filter
ii Dirty blower and exit side of blades Clean blades
iii Leakage in the suction system Repair suction lines
iv Leakage of exhaust gas Repair exhaust system
v Rise in temperature of suction air Admit fresh air to engine
room
vi Low air pressure in engine room Open door or install blowers
ventilation duct
vii Damaged packing Replace packing
viii Damaged turbine blades Replace turbine wheel
ix Damaged nozzle ring Replace nozzle ring
x Dirty turbine blades Clean turbine blades
xi Clogged nozzle Clean nozzle
xii Clogged exhaust pipe Clean exhaust pipe
xiii Back pressure too Clean or replace piping
xiv Inaccurate pressure gauge Replace pressure gauge

Table 04-XI

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(b) Abnormal vibration

Sr No Defect/ Fault/ Observation Repair action

i Gas leakage from exhaust valve Lap exhaust vales
ii Defective fuel injection system Check and adjust injection timing/
disassemble and check Injection
Pump. Repair or replace faulty
parts. Disassemble and check
Injection Valve. Repair / replace
faulty parts
iii Misshapen Turbine Nozzle Replaced Turbine Nozzle
iv Dirty Turbine Nozzle Clean Turbine Nozzle
v Over loading Reduce load
vi Inaccurate pressure gauge Replace

Table 04-XII

(c) High suction pressure

Sr No Defect/ Fault/ Observation Repair action

i Damage Turbine Blades Replace Turbine Blades
ii Damage Blower Blades Replace
iii Oxidation on Turbine Blades Clean and repair or replace
iv Damage bearing Replace Blower Blades
v Bent turbine shaft Replace turbine shaft
vi Loose assembly Tight as defined

Table 04-XIII

(d) Other defect related to turbine

Sr No Defect/ Fault/ Observation Repair action

i Abnormal noise elastic spring Re assemble elastic spring
ii Bearing damage Replace Bearing
iii Obstruction of retaining parts Repair or replaced parts
iv Dirty turbine and Blower Clean turbine and Blower
v Foreign material in Turbine entrance Repair or replaced Turbine

vi Sudden load change (surging) Stabilize load, or replace

Turbine Nozzle

Table 04-XIV
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35. Lub oil becomes dirty quickly

Sr No Defect/ Fault/ Observation Repair action

i Gas in bearing room Repair bearing
ii Clogging of seal air passage Clean seal air passage
iii Damaged pacing Replace pacing
iv Clogging of balanced air passage Clean balanced air passage
v Poor quality lube oil Replace lube oil
vi Temperature of lube oil too high Replenish lube oil when
insufficient / increase amount
of cooling water

Table 04-XV

36. Suction pressure pulsation

Sr No Defect/ Fault/ Observation Repair action

i Irregular cylinder combustion Adjust combustion
ii Sudden load change Insure proper portion
iii Blower side excessively dirty Clean Blower side

Table 04-XVI

37. High air temperature - Increase cooling water in air cooler,

Clean cooler core.
38. Starting Problem

(a) Pinion gears do not mesh

Sr No Defect/ Fault/ Observation Repair action

i Loose battery engage magnet terminal Tighten terminal
ii Faulty connection in starting switch Repair starting switch
iii Faulty positioning of positioningof pinion and Adjust
ring gears
iv Seizure of starter metal Replace starter metal

Table 04-XVII

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(b) Fuel oil not injected

Sr No Defect/ Fault/ Observation Repair action

i Imperfect priming of Prime well fuel oil
fuel oil system system
ii Injection cut off due to faulty governor Adjust Injection
iii Clogging of fuel inlet filter Clean fuel inlet filter
iv Insufficient fuel oil in tank Add fuel to fuel tank
v Fuel oil tank cock closed Open cock
vi Clogging in fuel oil pipe Clean fuel oil pipe
vii Damage fuel oil supply pump Disassemble and
repair or replace
viii Water in fuel oil tank Drain water

Table 04-XVIII

(c) Faulty fuel injection valve

Sr No Defect/ Fault/ Observation Repair action

i Faulty valve seat Lap valve seat
ii Sticking of valve needle Lap valve needle
iii Worn valve needle Replace valve needle
iv Clogged outlet Clean or replace
outlet

Table 04-XIX

(d) Leakage of pressurized air

Sr No Defect/ Fault/ Observation Repair action

i Air leakage from suction/exhaust valves Lap valves
ii No tappet clearance Adjust tappet clearance
iii Faulty Gasket packing Replace Gasket packing
iv Upper part of cylinder liner worn Replace cylinder block
v Worn piston ring Replace piston ring
vi Piston ring sticks Disassemble and repair or
Replace Piston ring
vii Damage valve spring Replace valve spring

Table 04-XX

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CHAPTER- 05

REFERRING MANUALS/CATALOGUES

39 Operation manual

This operation manual describes the operation, inspection and maintenance details of the
6LY2A-STP Yanmar marine diesel engine. Following of the precautions described in this
manual will enable us to use this engine with complete satisfaction. This manual indicates the
intervals at which maintenance on engine is to be performed. The maintenance table describes
the required interval and the checks to be made in respective locations. We have to follow the
steps given in that section for all the procedures to be performed. The details of all the checks
and dates that inspections have made are to be recorded for future reference.

In addition, a guide to trouble shooting, directions for locating and correcting engine
problems, specifications and torque valves of engine system are also given in the operator’s
manual.

40 Work shop/Service manual

The procedure in this manual was developed for a shop environment with engine
disassembly and assembly being performed. Almost all the important details of disassembly and
reassembly of the engine components are described in details for the convenience of the user.
The information is presented in very basic terms to make sure the instructions are easily
understood. Wrench sizes and shop tooling are identified in the procedure when needed.

Special technical circulars bulleting

 M/E (P&W) is standing orders for “Work shop instructions”

41 Part catalog

This Spare part catalog consist all of the Drawings, Part numbers, figure numbers, part
names of relevant items of the Yanmar 6LY2A-STP marine diesel engine.

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CHAPTER- 06

SAFETY AND HEALTHY MONITORING

42. Alarm devices and Functions

i. Low lub oil presuure alarm

Yanmar 6LY2A STP jrA.fha hka;% j, Low lub oil presuure alarm tl
0'5^±0.1) bar switch hla yryd main panel tlg iuznkaO jk w;r th
yryd alarm indication tlla iy buzzer alarm tlla jYfhka osia fjz' idudkH
wjia:dfjzoS hka;%h mK .ekajSug fmr LOP switch tl ixjD; wjia:dfjz
mj;sk w;r hka;%h mK .ekajSfuka miq th jsjD; fjz' hka;%h l%shdldrS
wjia:djloS LOP tl 0'5 bar g jvd wvq jQ jsgl LOP switch tl active fjz'
tfia jSfuka switch yryd negative supply tlla .uka lsrSfuka main panel
tfla LOP bulb iy alarm tl l%shd lsrSug mgka .kS'

ii. Fresh water high temperature alarm

Yanmar 6LY2A STP jrA.fha hka;% j, Fresh water high temperature
alarm tl 95^±2) Co switch hla yryd main panel tlg iuznkaO jk w;r
th yryd alarm indication tlla iy buzzer alarm tlla jYfhka osia fjz'
idudkH wjia:dfjzoS hka;%h mK .ekajSug fmr FWT switch tl jsjD;
wjia:dfjz mj;sk w;r hka;%h l%shdldrS wjia:djloS FWT tl 97 Co g jvd
jevs jQ jsgl FWHT switch tl active fjz' tfia jSfuka switch yryd negative
supply tlla .uka lsrSfuka main panel tfla FWHT bulb iy alarm tl l%shd
lsrSug mgka .kS'

iii. Battery charge alarm

Yanmar 6LY2A STP jrA.fha hka;% j, Alternator tflka Battery
charge fkdjkafkakuz th Battery charge f,i main pannel tfla bulb tlla
oe,ajSfuka iy buzzer alarm tlla jYfhka osia fjz' hka;%h mK .ekajSug
fmr pannel tfla battery charge f,i oelafjk bulb h oe,afjk w;r hka;%h
mK .ekajSfuka miq Altrenator tl u.ska Battery wdfrdamKh jSug mgka .;a
miq battery charge bulb tl ksjShhs'

iv. Cooling water level alarm

Yanmar 6LY2A STP jrA.fha hka;% j, Cooling water tank tfla
Cooling water level tl fmkakquz lsrSu i|yd Flotter switch tlla Ndjs;d lr
we;' huz fyhlska Cooling water level tl wvqjqjfyd;a main pannel tfla bulb
tlla Cooling water level f,i osiajSfuka iy buzzer alarm tlla u.ska
fmkakquz lrhs'
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v. Exhaust flow alarm

Yanmar 6LY2A STP jrA.fha hka;% j, Exhaust flow alarm tl oelajSu
i|yd Exhaust flower switch hla tkuz Flotter switch tlla Ndjs;d lr we;'
hka;%h mK .ekajSug fmr main pannel tfla Exhaust f,i bulb hla
oe,afjuska Alarm tllao ksl=;ajk w;r hka;%h mK .ekajSfuka miq Sea
water iu. Exhaust msgjSug mgka.;a miq Exhaust bulb tl ksjShhs' huz
fyhlska Sea water suction tl wvq jqjfyd;a Discharge tl wvqjk w;r th
Exhaust bulb tl oe,ajSfuka fmkakquz lrhs'

43. Shutdown devices and Functions

i. Low lub oil presuure Shutdown

Yanmar 6LY2A STP jrA.fha hka;% j, Low lub oil presuure Shutdown
tl 0'2^±0.1) bar switch hla yryd Engine tl Wv ijs lr we;s Juction box
tfla Turminal Bar tlg ijsfjz' bkamiq tu jhrh md,k ueosrsfha Alarm
control panel tfla Turminal Bar tlg ijsfjz'
huz fyhlska hka;%h mK.kajd we;s jsgloS LOP tl 0'2 bar olajd
wvqjqjfyd;a LOPS tl ixjD; fjz' tu ksid Electronic speed switch tfla
wod, switch h yryd Relay tl Power jSu i|yd wjYH Negative supply tl
wod, Relay w.%hg iuznkaO fjz' bkamiq tu Relay tl Energize jS Stop
solenoid tfla Relay tl Power jSu i|yd ,ndfoa' tfia jSfuka Low lub oil
presuure Shutdown tl l%shd;aul jS hka;%h iajhxl%Shj kj;d oukq ,nhs'

ii. Fresh water high temperature Shutdown

Yanmar 6LY2A STP jrA.fha hka;% j, Fresh water high temperature
Shutdown tl 100^±3) Co switch hla yryd Engine tl Wv ijslr we;s
Junction box tfla Turminal Bar tlg ijsfjz' bkamiq tu jhrh md,k
ueosrsfha Alarm control panel tfla Turminal Bar tlg ijsfjz'
huz fyhlska hka;%h mK.kajd we;s jsgloS FWT tl 100^±3) Co
olajd jevsjqjfyd;a FWTS tl ixjD; jS Negative supply tl wod, Relay
w.%hg iuznkaO fjz' bkamiq tu Relay tl Energize jS Stop solenoid tfla
Relay tl Power jSu i|yd ,ndfoa' tfia jSfuka Fresh water high temperature
Shutdown tl l%shd;aul jS hka;%h iajhxl%Shj kj;d oukq ,nhs'

iii. Overspeed shutdown

Yanmar 6LY2A STP jrA.fha hka;% j, Overspeed shutdown tl 3200
RPM g ilid we;s w;r th Speed sensor tl yryd Engine tl Wv ijslr
we;s Junction box tfla Turminal Bar tlg ijsfjz' bkamiq th md,k ueosrsfha
Alarm control panel tfla Turminal Bar tlg ijsfjz' bkamiq th Electronic
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speed switch tlg iuznkaO jSfuka Speed signal tl Electronic speed switch
hg ,nd.kakd w;r ilid we;s RPM tflaoS tkuz 3200 RPM oS
Potentiometer g iuznkaO Relay tl ixjD; fjz' Relay tfla w.%hg Positive
jhrh iuznkaO jS we;s nejska wod, Relay tl Power jk w;r fuu
l%shdj,sfhka miq Alarm control box tlg iuznkaO jS Junction box tfla
Terminal bar tl yryd Stop solenoid tfla Relay tl Power jSu i|yd wjYH
Positive tl ,ndfohs'tfia jSfuka Over speed shutdown tl l%shd;aul jS
hka;%h iajhxl%shj kj;d oukq ,nhs'

44. Waste-gate Valve

fuys uq,sl ldrAH jkafka msvkh md,kh lsrsuhs' huzlsis wjia:djl hka;%fha
fjz.h wvqrlrk wjia:dfjzos Turbocharger tfla Turbine wheel tlg hk oejqk
jd;h fjk;a udrA.hlska Exhaust moaO;shg hejsuhs' tjsg Turbocharger fha fjz.h
wvqjk w;r iemhquz jd; msvkh wvqfjz' fuh hka;%fha ls%hdldrs;ajhg n,mdk
w;r Harmful damage j,lajd,hs'

fuys l%shdldrs;ajh isoq jkqfha hka;%h ,nd .kakd l%shdldrs jdhq m%udkh
0.5 bar j,g jvd jevs jq wjia:dfjz isg tys we;s l=vd ngh u.ska Activator tl
jsjD;js tys we;s Shaft tlla u.ska Waste-gate tl jsjD; fjs. tu.ska hka;%fha
oejqkq jd;h Turbine Wheel tl yryd fkdf.dia By Pass Housing tl u.ska
Exhaust Manifold tflka msgfjs. tu ksid Turbine Wheel tfla fjs.h tl wvq jk
nejska tu.ska Compression Wheel tflao fjs.h wvqjs ,nd .kakd Suction Air
m%udKh wvq fjs. tjsg hka;%fha RPM tl md,kh fjhs'

45. Limitations

a. hka;%h oSrA> ld,hla wvq RPM j, l%shd;aul lsrSfuzoS iEu meh 02 lg

jrlau tys RPM tl Wmrsu w.fha uo fjz,djla l%shd;aul l< hq;=h'
b. Fresh Water Temperature tl 93oC my, w.hlos hka;%h Operate l, hq;= fjz
c. Lub oil Pressure tl 1.5 bar jevs w.hlos hka;%h Operate l, hq;= fjz'
d. hka;%h RPM tl 3100 g jevs w.hlos Operate fkdl, hq;= fjz'

46. Blow by Measurement and Identification

Breather line tflka jevsmqr jdhqj msgjSu u.ska fuh yoqkd .; yels w;r
fuysos Engine tflka ,nd .kakd Odrs;dj wvqfjs’ fuh Engine tflys tla tla
Cylinder hkays iusmsvk Odrs;dj uek ne,su ^Compresion test & u.ska jsksYaph lr
.; yels fjs’ fuu w.h 23-28 bar mrdifha ;snsh hq;= w;r tu wju w.hg jvd
wvq jQ jsg by; fodaIh we;s njg ks.ukh l<yel'

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47. Healthy Operating Parameters

SR.NO Operating Parameters Min Max

01 Tachometer 675 rpm 3100 rpm
02 Lub oil Pressure 1.5 bar 6 bar
03 Fresh Water Temperature 65 oC 88 oC
meter
04 SeaWater Flow (Exhaust) - Fresh Water Temperature
93oC jevs jq jsg

Table 06-I

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CHAPTER- 07

m%dfhda.sl mqyqKqj (Practical Training)

48' hka;%fha fldgia .e,jsu my; wdldrhg isoql, hq;=h

a. hka;%fha we;s c,h ,sysis f;,a bj;a l, hq;=h'

b. hka;%fha jsoHq;a moaO;sh bj;a l, hq;=h'

c. Turbocharger tl .e,jsh hq;=h'

d. hka;%fha Exhaust manifold , Fresh water cooler .e,jsh hq;=h'

e. Lub oil filter, bracket iy pipe line .e,jsh hq;=h'
f. Charge air cooler iy Lub oil cooler .e,jsh hq;=h'
g. Injection pump , High pressure line iy Injectors .,jd bj;a l, hq;=h'
h. Fresh water pump tl iy Sea water pump tl .e,jsh hq;=h'
i. Fly wheel tl iy Vibration damper tl .e, jsh hq;=h'
j. bka miq Gear wheel housing , Oil pan lub oil pan , Lub oil pump, intermediate
sump .e, jsh hq;=h'
k. bka miq Rocker arms iy Push rods .e, jsh hq;=h'
l. inlet manifold tl iy cylinder heads .e, jsh hq;=h
m. bka miq Piston iy connecting rods .e,jsh hq;=h'
n. hka;%h block tl wfkla mi yrjd Idle gear, cam shaft iy gear case .e,
jsh hq;=h'
o. bka miq Fly wheel housing tl .e,jsfuka wk;=rej main bearing cap .,jd
crank shaft tl bj;a l, hq;=h'
p. Piston cooling nozzle iy tappet .,jd bj;a l, hq;=h'

hka;%fha fldgia .e,jsfuzos jsfYaIfhka ie,ls,su;a jsh hq;af;a .,jk ,o

fldgia fjka fjka jYfhka kdu mqjre fhdod tu fldgia j,g ydks fkdjk mrsos
wkq ms,sfj,g wiqrd ;ensh hq;=h' tu fldgia wiqrd ia:dkh oqjs,s j,ska f;dr
msrsisoq ia:dkhla jsh hq;=h' fjk;a NdKav mrsyrKh fkdjk ia:dkhla jsh hq;=h'

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49. msrsisoq lsrsfuzos wkq.ukh l, hq;= lreKq

a. .,jk ,o fldgia msrsisoq lsrsfuzos tu fldgia j,g ydks fkdjk o%jH

Ndjs;d l, hq;=h'

b. msrsisoq lsrsu ioyd ridhdksl oshr Ndjs;fha os kshus; idkao%kh ;sfnzoehs

mrsCId lsrsfuka miq Ndjs;hg .; hq;=h'

c. Charge air cooler N=usf;,a j,ska msrsisoq lsrsfuka wk;=rej kej; c,fhka
fidaod fjs,d .; hq;=h'

d. ,sysis f;,a .uka lrk k, moaO;sh ksishdldrj msrsisoq lr iuzmSvk jd;h

hjd wm o%jH fkdue;s njg ;yjqre lr .; hq;=h'

50. .,jk ,o fldgia mrsCId lsrsu iy usKquz .; lsrSu

a. fydoska msrsisoq lssrsfuka wk;=rej mshjs weig fmfkk brs ;e,suz, isrsuz,
;e,suz weoaoehs mrsCId l, hq;=h'
b. weig fkdfmfkk brs;e,suz ;sfnzoehs mrsCid lsrsu ioyd DPT l, hq;=h'
jsfYaIfhka Crank shaft, cam shaft , valve head, cylinder block hk fldgia
DPT l, hq;=h'

c. Ndjs;d l, fldgia kej; Ndjs;hg fmr ksIamdo;hd jsiska os we;s isudj,

usKquz ;sfnsoehs usksuz lr ne,sh hq;=h'uskqus o;a; igyka lrk fmdaru my;
mrsos fjs'

(i) Cylinder Block Cylinder block test lsrsu ioyd ksIamdolhd jsiska ioyka
lr we;af;a DPT l%uh muKs' tys huz lsis brs ;e,sula ;snqk fyd;a is,skavrA Block
tl bj; oeush hq;=h' my; wdldrhg DPT l, hq;=h'

(a) mrsCId l, hq;= m%foaY fydoska msrsisoq l, hq;=h'

(b) m<uqj Cleaner tl Ndjs;d lr msi oeush hq;=h'
(c) bka miq penetrant tl spray lr usks;a;= 05-10 l muK ld,hla
;ensh hq;=h'

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(d) bka miq Developer spray l, hq;= w;r usks;a;= 10 lg miq m%foaYh
mrsCId l, hq;= w;r tys r;= mdg brs ;e,suz fyd ;s;a ;sfnzoehs mrsCId l, hq;=h'

(ii) Cylinder Head Cylinder head tflys ksIamdolhd jsiska oykhg yiqjk
m%foaYh ;=, brs ;e,suz ;sfnzoehs mrsCId l, hq;= wdldrh ioyka lr we;' tu ls%hd
j,sh cylinder block tl DPT lrk wdldrhgu l, hq;=h'

(iii) Fresh Water Cooler Fresh water cooler fhys ldkaoq jsus weoaoehs mrsCId
lr ne,sh hq;=h' th iuzmsvk jd;h fyd iuzmsvk c,h Wmfhda.s lrf.k lr
.; yel'

Test pressure : 2 Kg /cm2

(iv) Lub Oil Cooler Lub oil cooler msrsisoq lsrsfuka wk;=rej tys tubes j,
ldkaoq jsuz we;aoehs iuzmsvk jd;h fyda iuz msvk c,h Wmfhda.s lrf.k ,sysis
f;,a moaO;sh iy uqyqoq c,h moaO;sh fjk fjku mrslaId l, hq;=h'

Test pressure : 3 Kg /cm2

(v) Reconditioning of Crank Shaft Crank shaft msrsisoq lsrsfuka wk;=rj DPT
mrsCIdj lr tys m,oq jsuz we;soehs mrsCId l, hq;=h'bka wk;=rej bending of crank
shaft mrsCId l, hq;=h' tu mrsCIdj ioyd V block folla foflf,jr ys Dial
gauge iy magnetic base wdOdrfhka crank shaft ys bend mrsCId l, yel'

tyS isudj 0.03mm jsh hq;=h' fldyq ,Kq wdOdrfhka fmd,sIa lsrsfuka
wk;=rej crank shaft kej; ijs lsrsug fmr tys we;s main journal , crank pin wdosh
uskquz lr th ksIamdolhd jsiska os we;s limit j, ;sfnz oehs .Kkh l, hq;=h' th
jrA. 03lg fnod we;' tkuz STD, 0'25 mm, 0'50 mm.

STD tlg jvd wvq js ;sfnz kuz B,. ;;ajhg tkuz 0'25mm Grinding l, hq;=h'
;jo Oil hole kshu mrsos msrsisoq lr wm o%jH fkdue;s njg ;yjqre l, hq;=h'

(vi) Reconditioning Turbocharger m%Odk wM;ajevshd j,os fyda yosis kv;a;=

jlos turbocharger iusmqrAK w,q;a jevshd l, hq;=h'

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(vii) Reconditioning Sea Water Pump m%Odk w,q;ajevshdjlos Sea water

pump tl ys m%Odk jYfhka my; ioyka oE msnsoj ie,ls,su;a jsh hq;=h'

(a) Rubber impeller levs fyd f.js ;sfnz kuz w,q;ska impellor oeush hq;=h'
(b) Wear plate tl f.js f.dia ;sfnz kuz th udre l, hq;=h'
(c) Pump housing tl f.js f.dia we;akuz w,q;ska housing tl oeush
hq;=h'
(d) mechanical seal tflka j;=r ldkaoq fjz kuz th wM;a seal tlla oeush
hq;=h'
(e) bearing mrsCId lr n,d levs f.dia fyd f.js we;akuz w,q;ska oeush
hq;=h

(viii) Fresh Water Pump Fresh water pump fldgia j,g .e,jsu fkdl,
hq;= nj ksIamdolhd jsiska ioyka lr we;' thg fya;=j .e,jsu b;d wisre ksidh'
.e,jsu isoq l,o th ijs lsrsu wmyiq njh' huz fodaIhla ;snqK fyd;a iuzmqrAK
fmduzmh udre l, hq;=h' tfia kuqoq my; ioyka oE mrsCId l, hq;=h'

(a) Bearing unit mrsCId l, hq;=h

(b) Impeller blade mrsCId l, hq;=h

(c) Mechanical seal

(xi) Recondition of Engine Block Engine block mrsCId lsrsfuka wk;=rej

tys Bore tl .Kkh lsrsfuka wk;=rej ksIamdolhd jsiska os jrA. 03 wod,j
fudk jrA.hg wh;ao hkak ;srKh l, hq;=h' tkuz L, M fyda S bka miq cam
bush iy main bearing uskquz lr oil clearance kshus; mrsos we;soehs mrsCId l,
hq;=h' jsfYaIfhka tys we;s oil hole j, wmo%jH fkdue;s njg ;yjqre lr .;
hq;=h'

(x) Selection of Main and Connecting Rod Bearing fuh f;dard .eksfuka
m%Odk jYfhka fldgia 03la bearing we;'

(a) STD

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(b) 0.25 mm under size

(c) 0.50 mm under size

m%:ufhka Main journal iy crank pin uskquz lr o;a; ,ndf.k bearing o;a;
j,ska wvq lsrsfuka miq oil clearance wkqj jrA.h ;srKh l, yel' tk STD
;;ajfha bearing ijs lsrsfuzos isudj blaujd oil clearance ;sfns kuz bearing 0.25mm
f;dard .; hq;=h'

(xi) Selection of Piston Ring Piston ring f;dard .eksfuzos Ndjs;d lrk ,o
piston ring gap iy groove width uskquz lr isudjka ;=, fkdue;s kuz w,q;ska oeush
hq;=h'

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51. Data sheet for major overhauling on Yanmar 6LY2A-STP engine.

YANMAR/WORK PROCEDURE/01

MAJOR OVERHAUL DATA SHEET

CENTRAL YANMAR WORKSHOP – NCNA

ENGINE SR. NO.

CRAFT
LOCATION PORT/ STBD
SFC RH
RECEIPT FROM
DATE OF RECEIPT
DATE OF MOH/BDR COMMENCED
DATE OF MOH/BDR COMPLETION
DATE OF TRANSFERRED
INSTALLED ON

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01. CYLINDER BLOCK

20(T)

90(M)

188(B)

Nominal dimension (mm) Limit dimension (mm)

L 105.920 - 105.930
Inner diameter of
M 105.910 - 105.919 106.050
cylinder
S 105.900 - 105.909
Circularity of cylinder bore Less than 0.03 -
Cylindricity of cylinder bore Less than 0.02 -

Cylinder bore Cylinder

Cylinder Cylinder Circularity Cylindricity
Dia bore Dia Remarks
unit position (mm) (mm)
A - A (mm) B - B (mm)
T
1 M
B
T
2 M
B
T
3 M
B
T
4 M
B
T
5 M
B
T
6 M
B

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02. CRANKSHAFT AND MAIN BEARING

a. Main journal

Standard (mm) Wear limit(mm)

Journal outer dia 74.952-74.964 74.90
Bushing inner dia 75.000-74.045 75.10
Oil clearance 0.036-0.093 0.15

Journal Journal outer Main bearing Oil clearance (By

Remarks
No. Dia (mm) Inner dia (mm) plastic gauge) (mm)
A-A
1
B-B
A-A
2
B-B
A-A
3
B-B
A-A
4
B-B
A-A
5
B-B
A-A
6
B-B
A-A
7
B-B

b. Crank pin
Standard (mm) Wear limit (mm)
Pin outer dia 64.952-64.964 64.90
Bushing inner dia 65.000-65.042 65.10
Oil clearance 0.036-0.093 0.16

Crank Crank pin outer dia Oil clearance (By

Remarks
Pin no. (mm) plastic gauge) (mm)
A-A
1
B-B
A-A
2
B-B
A-A
3
B-B
A-A
4
B-B
A-A
5
B-B
A-A
6
B-B
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c. Crank shaft bending

Limit (mm) value (mm) Remarks

Crankshaft bending Less than 0.03

03. CAMSHAFT AND TAPPETS

a. Cam shaft journal

Standard (mm) Wear limit (mm)

journal outer dia 56.910 – 56.940 56.80
Oil clearance 0.040-0.140 0.20

Journal Bushing inner Oil

Journal
outer dia dia clearance remarks
No.
(mm) (mm) (mm)
A-A
01
B-B
A-A
02
B-B
A-A
03
B-B
A-A
04
B-B

b. Camshaft height

Standard (mm) Limit (mm)

Lift Intake/ exhaust 6.5 6.1

Cam profile No. 01 02 03 04 05 06

Cam height(mm)
Intake Cam dia (mm)
Lift (mm)
Cam height(mm)
Exhaust Cam dia (mm)
Lift (mm)
Remarks

c. Cam shaft deflection

Limit (mm) value (mm) Remarks
Camshaft deflection 0.02

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d. Camshaft side gap

Standard (mm) Limit (mm) value(mm) remarks

Side Before repair
0.05-0.20 0.29
gap After repair

e. Outer diameter of tappet

Standard (mm) Wear Limit (mm)

Tappet stem outside dia 14.218 – 14.233 14.17

Cylinder
Tappet Stem outer dia (mm) Remarks
unit
Intake
1
Exhaust
Intake
2
Exhaust
Intake
3
Exhaust
Intake
4
Exhaust
Intake
5
Exhaust
Intake
6
Exhaust

f. Push rod
Standard (mm) Wear Limit (mm)
Push rod bend Less than 0.03 0.3
Push rod dia 8.5 -

Cylinder Push rod bend

Push rod Push rod dia (mm) Remarks
unit (mm)
Intake
1
Exhaust
Intake
2
Exhaust
Intake
3
Exhaust
Intake
4
Exhaust
Intake
5
Exhaust
Intake
6
Exhaust

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04. CYLINDER HEAD

a. Intake and Exhaust valve

Standard (mm) Wear Limit (mm)

Intake 1.731 2.32
Seat width
Exhaust 2.121 2.73
Valve stem Intake 8.960 – 8.975 8.9
outer dia Exhaust 8.940 – 8.955 8.9

Cylinder Valve stem outer dia (mm)

Valve Seat width Remarks
unit A-A B-B
Intake
1
Exhaust
Intake
2
Exhaust
Intake
3
Exhaust
Intake
4
Exhaust
Intake
5
Exhaust
Intake
6
Exhaust

b. Valve sinking

Standard (mm) Wear Limit (mm)

Valve sink and Intake 0.6 – 0.8 (Protrusion) 0.6 (Sink)
project Exhaust 0.2 – 0.4 (Sink) 1.8 (Sink)

Cylinder
Valve sinking Remarks
unit
Intake
1
Exhaust
Intake
2
Exhaust
Intake
3
Exhaust
Intake
4
Exhaust
Intake
5
Exhaust
Intake
6
Exhaust
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c. Valve spring

Free length Standard (mm) Wear Limit (mm)

Inside 44.75 43.50
Outside 45.15 43.7

Cylinder
Valve spring Free length Remarks
unit
Inside
1
Outside
Inside
2
Outside
Inside
3
Outside
Inside
4
Outside
Inside
5
Outside
Inside
6
Outside

05. PISTON

a. Piston diameter

Mark Specified (mm) Wear Limit (mm)

L 105.799 or more – 105.809 or less
Piston outer ML 105.794 or more – 105.799 or less
105.770
dia MS 105.789 or more – 105.794 or less
S 105.779 or more – 105.789 or less

Piston No. Outer dia (mm) Remarks

1
2
3
4
5
6

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b. Piston pin

Standard (mm) Wear Limit (mm)

Piston pin insert hole dia 37.000 37.020
Piston pin outer dia 36.989 – 37.000 36.964
clearance 0 – 0.022 0.045

Piston Insert hole dia (mm) Pin outer dia (mm)

clearance(mm) Remarks
No. A-A B-B A-A B-B
1
2
3
4
5
6

c. Piston ring groove clearance

Piston
Standard (mm) Limit (mm)
ring
Groove width 2.570-2.585 -
2nd
Rings width 2.470-2.490 -
ring
clearance 0.080-0.115 0.15
Groove width 4.010-4.025 -
Oil
ring Rings width 3.970-3.990 -
clearance 0.020-0.055 0.15

Piston ring 01 02 03 04 05 06
nd
2 ring clearance
Oil ring clearance
Remarks

d. Piston ring gap

Standard (mm) Wear Limit (mm)
First piston ring gap 0.25 – 0.40 1.5
Second piston ring gap 0.25 – 0.40 1.5
Oil ring gap 0.25 – 0.40 1.5

Piston ring 01 02 03 04 05 06
Top ring gap
Second ring gap
Oil ring gap
Remarks
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06. CONNECTING ROD

a. Twist and Parallelism

Standard (mm) Wear Limit (mm)

Con rod twist and parallelism 0.05 0.07
Con rod side clearance 0.20 – 0.40 0.45

Con rod Twist Parallelity Side clearance

Remarks
No. (mm) (mm) (mm)
1
2
3
4
5
6

b. Piston pin bearing

Standard (mm) Wear Limit (mm)

Piston pin bearing inner dia 37.025 – 37.040 37.100
Piston pin and bearing oil
0.030 – 0.061 0.11
clearance

Con rod Bearing inner dia Piston Pin outer dia Piston pin and
No. (mm) (mm) bearing oil clearance Remarks
A-A B-B A-A B-B (mm)
1
2
3
4
5
6

07. MEASUREMENT AND ADJUSTMENT

a. Valve clearance

Valve Standard (mm) Remarks

Inlet 0.1
Exhaust 0.5

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b. Gear wheel inspection

Inspection Remarks
Gear teeth
A-A
Gear timing marks B-B
C-C

c. Lub oil pump

Service limit(mm) Value(mm) Remarks

Gear to pump clearance 0.098
Gear to cover clearance 0.093

d. Crankshaft side gap

Limit
Standard (mm) value(mm) remarks
(mm)
Before
repair
Side gap 0.132-0.223 0.29
After
repair

e. Turbocharger axial and radial play

Standard Limit (mm)

Value (mm) remarks
(mm)
Before repair
Axial 0.06-0.09 0.11
After repair
Before repair
Redial 0.11-0.18 0.215
After repair

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f. Fuel injectors

Nozzle opening
No Of Back Seat Spray
pressure Remarks
Injector leakage tightness pattern
(290- 300 bar)
Before repair
01
02
03
04
05
06
After repair
01
02
03
04
05
06

08. CONCLUSION

Sr No Description Remarks
01
02
03

Measured by :

Checked by :

……………………………
ME (W/S)

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52. Assembling the Engine

i. hka;%h kej; ijs lsrsfuzos my; ioyka oE ms,snoj wjOdkh fhduq l,

hq;=h'

Cylinder Block

(a) Oil hole msrsisoq l, hq;=h

(b) Tappet inlet iy exhaust jYfhka ksj/osj ijs l, hq;=h'

(c) Piston cooling nozzle ijs lr kshus; mrsos ;o l, hq;=h'

(d) Cam bearing ijs l, hq;=h' Oil hole wvqu ;ruska 2$3 jsjD; jsh
hq;=h'

(e) iqM jYfhka oil wdf,am lr crank shaft tl oeush hq;=h'

(f) Main bearing iy crank bearing oil iqM jYfhka wf,am l, hq;=h'
(g) Main bearing cap ijs l, hq;=h'
(h) kshus; m%us;shg main bearing cap bolt ;o l, hq;=h'

ii. ijs lsrsug we;s ish,qu fldgia fydoska msrsisoq js we;aoehs mrsCId l, hq;=h'

ii. Moving part ijs lsrsfuzos iqM jYfhka wM;a ,sysis f;,a wdf,am l, hq;=h'

iv. ishMu gasket iy O rings w,q;ska oeush hq;=h'

v. Gasket fkdue;s ia:dk ioyd wkqu; RTV Silicon Ndjs;d l, hq;=h'

vi Oil Clearance and Thrust clearance ms,snoj ie,ls,su;a jsh hq;=h'
vii fydo ;;ajfha bolt iy washer Ndjs;hg .; hq;=h'
viii Bolt ;o lsrsfusos wod, kshuhka ms,smeosh hq;=h'
ix ksIamdolhd ioyka lr we;s kshu wdldrhg .e,fmk mrsos hka;%h ijsl,
hq;=h'

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53. Checking and adjusting the fuel injection timing

fuu hka;%hg Fuel injection Pump tl iusnkaO lsrsu ioyd hka;%h iqodkus
lsrsfusos hka;%hg ksIamdolhd jsiska oS we;s wdldrhg Gear timing mark j,g hka;%h
ilid .; hq;= w;r my; rEm igyfka oelafjk wdldrhg th is\q lr .; yel'

Cam Shaft Gear

B
C Sea Water Pump Gear

B C

Timer wheel A

Idle Gear A Crank shaft Gear

Idle Gear

Lubricating pump Gear

Picture 07-I

fuu wdldrhg hka;%h ilid .eksfuka wk;=rej Timer wheel tfla we;s key
way tl fuel injection Pump tflys we;s Key tl yd iumd; lr hka;%h yd Fuel
injection Pump tl iusnkaO l< hq;=fjs' wk;=rej hka;%fha flywheel housing tflys
i|yka ^Align Mark Line) ia:dkh yd Fuel injection Pump tflys we;s Align Mark j,
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we;s uOHia: ia:dkh yd iumd; lr hka;%hg fuel injection pump iusnkaO lrkak
tjsg hka;%h kshus; Fuel Timing (before TDC 15o ± 1o ) j,g ilia fjs'

54. Adjustment of Valve Clearance

hka;%fha Valve adjust lsrsu i|yd uq,skau hka;%fha wxl tl Piston h Cylinder
tflys Compression TDC j,g .eksu i|yd hka;%h lrljd .;hq;=^m,uq jgh&
w;r ^counterclockwise when viewed from flywheel side) tu wjia:dfjsos flywheel
housing tflys we;s Timing mark tl yd flywheel tflys wxl tl i|yka ia:dkfha
we;s mark tl yd iumd; lr.; hq;=fjs' 01 Piston tl Compression TDC tk jsg
wxl 06 jk piston tl over lap ia:dkhg meusfkk w;r tu wjia:dfjsos hka;%fha
;ensh yels Valve Clearance Adjust l< hq;= fjs' bka wk;=rej kej; ^fojk jgh&
hka;%h lrljd 06 jk Piston tl Compression TDC j,g .; hq;=fjs' tu
wjia:dfjsos wxl 01 Over Lap wjia:djg meusfka' fusysos hka;%fha b;srs Valve
Clearance adjust lsrsu l< yel'

fuu hka;%fha Inlet 0.10mm yd Exhaust 0.50mm jk w;r fuu w.hka j,g
Valve Clearance Adjust l< hq;=fjs' my; wdldrhg tla tla jghka j,os valve
adjust lsrsu i|yd hka;%fha Valve ilia jSu is\qfjs'

m,uq jgh fojk jgh

No Inlet Exh No Inlet Exh
01 √ √ 01 - -
02 - √ 02 √ -
03 √ - 03 - √
04 - √ 04 √ -
05 √ - 05 - √
06 - - 06 √ √

 by; l%uhg wu;rj hka;%fha Firing order tfla ms<sfj< wkqj Valve
Clearance ieliSu ksje/os l%uhls'

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55' bkaOk jsosk j, lrkq ,nk mrsCIdjka

Picture 07- II

i. Opening Pressure Test

fuf,i y¥kajkq ,nkafka ksIamdolhd jsiska oS we;s Pressure tlg wkqj Injector
tfla bkaOk jssosk mSvkh fjhs’ tu Pressure tl Injector tflka tlg fjkia jk
w;r injector tll Opening pressure tl f,i i,lkafka Needle valve by<g tijSu
i|yd Spring tl yels,Sug fhdok mSvkhhs’ tu Injector tfla Opening Pressure tl
f,i ye|skafjz’ Opening pressure tl wvq jevs l, yelafla Spring tfla Tension wvq jevs
lsrSfuks’

Pressure Adjust lsrSu

Screw tl u.ska Spring tfla Tension tl wvq jevs lsrSu ;+<ska Pressure tl
Adjust lr .; yel’

ii. Spray Pattern Test

fuysoS Injector tflka jsoskq ,nk Fuel taldldr rgdjlg jsh hq;+h’ fyd| ;;ajfha
we;s Injector tll kuz Fuel spray lsrSfuzoS lg lg yvla we;sfjz’ fodaI iys; injector
tllska Nozzle tfla Hole Clean lsrSfuka tu fodaIh ksjeros lr .; yel’ Spray angle
tl ksIamdolhd os we;s fldaKhg is¥jkjdoehs mrsCId lsrsu l< hq;=h’

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iii. Back Leakage Test

´kEu Injector tll Back leakage tlla ;snSu w;HjYH fjz’ ta ukao Injector tl
;+< we;s fldgia Cooling jkqfha wdmiq .uka .kakd Fuel j,sk’s Back leakage tl hkq
Nozzle body tl;a Needle valve tlla w;r we;s Clearance tflka miq mig .,k bkaOk
m%udKh fjhs’

Injector tll Back leakage tl mrSlaId lrkq ,nkafka Opening Pressure tflka
2$3la mSvkh wvq jSug .;jk ld,h ;;amr 6-30 w;r jsh hq;+h’ ;;amr 6 lg fmr
wvqfï kuz Back leakage tl jevs w;r ;;amr 30 g jvd ld,h .;fjzkuz Back leakage
tl wvq jk w;r fuu wjia:dj,os wksjdrAHfhkau Nozzle tl udre l< hq;+h’ Injector
s hq;+h’
tester tflys bkaOk ldka¥jSuz fkd;snh

iv Tip Leak Test

fuu mrSlaIdj lsrSfuzoS Nozzle tl jsh<s ;;ajhl ;snh s hq;+h’ Opening pressure
tflka 20 bar wvqfjka ;;amr 10 la muK ;ndf.k isgSfuzoS Nozzle Hole ;+,ska f;,a
nska¥ jYfhka ldka¥ jkafka oehs mrSCId l< hq;+h’ f;,a nska¥q jYfhka ldka¥ jkafka kuz
thg fya;=j bkaOk jssoskhl Needle tfla Sheet tl Nozzle Body tfla Sheet tl iu.
fyd|ska iumd; (Sheet) fkdjSuhs’ th u.yrjd .; yelafla bkaOk ldka¥ jSu we;s
Nozzle body tl iy Needle valve tl Lap lr .eksfuks’ th ksjeros lr.eksug
fkdyels jqjfyd;a w,q;ska Nozzle tlla oeuSu is¥l< hq;=h’

56. Quality control points

tkacsu kej; assemble lsrsfusos my; ioyka Specifications yd tightening torque

ms<snoj b;d ie,ls,su;a jsh hq;=h'

i. Specifications

No Description Standard value

01 Top clearance 0.8 ± 0.10
Combustion

02 Injection timing 15° ± 1° bTDC (FID)

03 Injection pressure 28.4 +1.0 MPa

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04 Valve timing Intake Open bTDC 59° ± 5 °

Close aBDC 63° ± 5 °
Exhaust Open bBDC 58° ± 5 °
Close aTDC 46° ± 5 °

05 Valve clearance Intake 0.1 ± 0.05 (in cold state)

Exhaust 0.5 ± 0.05 (in cold state)

06 Valve sinking Intake 0.7 ± 0.1 (Protrusion)

Head gasket

Exhaust 0.3 ± 0.1(Sinking)

07 Head gasket thickness(at tightening) 1.30 ± 0.05

08 Cylinder liner Roundness 0.015

Cylindercity 0.025

Table 07-I

ii. Tightening torque

No Name Screw dia. x Pitch Tightening torque (Nm)

01 Head bolt M 14 x 1.5 (118 177 226 ± 10)
02 Rod bolt M 12 x 1.25 137 ± 4.9
03 Flywheel bolt M 16 x 1.5 294 ± 10
04 Metal cap bolt M 15 x 1.5 255 ± 10
05 Crank V- pulley bolt M 16 x 1.5 226 ± 10
06 Timer nut (fuel injection M 18 x 1.5 127 ± 10
pump)
07 Exhaust manifold installing M 8 x 1.25 25 ± 2
bolt

Table 07-II

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