Yanmar Marine Diesel Engine 6GH-UTE Service Repair Manual

MllAINE DIESEi. ENGINE MODEL &GH-UTE

------------------------------------------------------------6GH-UTE Foreword This Service Manual describes the construction and functions of the major parts of the 6GH-UTE engine and illustrates the disassembly and assembly procedures (standard servicing procedures) necessary for maintaining and servicing the engine. Please read this manual carefully so that you are completely familias with the construction and func- tion of each part before you start actual servicing work. The construction and servicing procedures described in this manual may be slightly modified for the improvement of quality and performance without prior notice. Please do not hesitate to contact tis if you have any queries or suggestions. Prepare before you work ! For accurate and efficient service work, check and prepare the following: 1. Check the customers' service ledger 1) When was the machine last serviced? 2) How many months or hours has the machine been used since the previous servicing? 31 What was the previous trouble, and what parts were replaced? 4) Which parts should you replace this·time? 2. Prepare parts Check the stock of parts which are needed for servicing. 3. Prepare recording forms Check sheets, Parts measurement record sheet. Operation test record sheet 4. Prepare servicing measurement tools, containers~ etc. Printed in Japan AOA!959-8807

Contents 1. Specifications •.••••••.•••••••••••••••••••••••••••••••••••••••••••••••• 2 1·1 Majorspecifications ..••••.•••••..••••. • · • • • • • • · • • ••• • • • • • · • · • • • • • • • · · 2 1·2 Dimensions •••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 2. Disassembly and Assembly • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5 2· 1 Preparations for disassembly and assembly. • • • • • • • • • • • • • • • • • • • • • • • • • • • • . . • • 5 2·2 Toots, measuring instrumenu and other servicing equipment. . . . . . . . . . . . . . . . . . . . . 6 2·3 Assembly procedures •••••••••••••••••••• • • • • • • • • • • • • • • • • • • • • • • • • • • • 9 3. Checking and servicing major engine parts •••.••••••••••••••••••••••••••••.•••• 26 3·1 Cylinder head •••.••••.••••••••••.••••••• • • • · • • • •. • • • •••• • •••• • • •• 26 3·2 Piston and piston pin •••••••••••••••••• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 29 3·3 Connecting rod •••.••••••••••.••••••••••••••••••••••••• • • • • • • . • • • • 32 3-4 Cylinder liner .•••. : • . • • • • • • • • • • • • • • • • • • . • • • • . • • • • • • • . • • • • • • • • • • • • 33 3.5 Crankshaft and main bearing ••••••••••••.•••••••.••.•.•.•••• • • • • • .• • • · 35 3·6 Camshaft and tappet .••••••••.••••••• • • • • · • • • • • • • • • • • • • • • • • • • • · • • • • 36 3.7 nming gears .••••••••••••••••••••••••••••••••••••••••••..••.••••• 37 3·8 Cylinder block ••.•.•..•.••.•••.•••••••••.•.••••••••••.••••••••••• 38 3.9 Lub. oil system • • • • • . • . . • • • . • . . • • . • • • • • • • • • • • • • . . • . . • • • . • • • • . • • • • • 41 3·10 Cooling watersystem ••••••••.•.•••••.••••••••..•••••••.•••••••••••• 44 3· 11 Fuel system • • • . • • • • • • • • • • • • • • • • • . • • . • • • • • • • • • . . • • . • • • • • • • • • • . • • • 48 3· 12 Governor. • • • • • • • • • • • . • . • • . • • • • • . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 51 3· 13 Electrical system. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . • • • • • • . 53 3·14 Supercharger ••.•.•••••.•...•...•••..••••••••••••••••••••• · ••••• • 59 3· 15 Reduction gear • . • • • • • . • . • . • • • • . • • • • • • • • • • • . . • . • . • • . • • • • . • • • • • • • • • 60 4. Service standard tabla ••••.••••••••••••••••••••••••••••••••••••• • • • • • • • • 69 5. Tightening torque for major bolts and nuts. . • . • . • • • • • • • • • • • . . • • • • • • • • • • • • • • • • • • 72 5-1 Tightening torque for major bolts and nuts. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 72 5·2 Tightening torque forstandard bolts and nuts .•••••••••••••••••••••••••••••• 73 6. Periodical checking • • . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . • • • • • • • • • 74 Printed in Japan AOA1959-8807

I. Specifications ;._.:.... ............................................................................................................ ~6GH-UTE 1 . Specifications 1·1 Major Specification Model Type Combustion system Aspiration No. of cyl. - Bore x Stroke Displacement Output/Crankshaft speed Continuous Brake mean effective pressure rating Piston speed Specifications Output/Crankshaft speed Max. rating Brake mean effective pressure Piston speed Non-load rotation speed (Max./Min.) Starting system Firing order Direction of Crankshaft rotation (viewed Propeller shaft from stern) Lub. oil Max. capacity Effect Model Type Reduction ratio (forward) Propeller shaft speed (at cont. rating) Marine gear Direction of rotation (propeller shaft) Dry weight Lubricating oil I Max. capacity I Effective Hydraulic oil pressure Fuel injection pump Injection timing Fuel system Type of injection nozzle degree Injection pressure Applicable fuel Fuel filter Labrication Engine lub. Lub. oil discharge volume oil system Lub. oil pressure Lub. oil filter Printed in Japan AOA1959·8807 mm (in.) 2 HP/rpm kg/cm 2 m/sec. (in./sec.) HP/rpm kg/cm 2 m/sec. (in./sec.) rpm 2 2 rpm kg (lbs) 2 2 kg/cm 2 kg/cm 2 2/hr./rpm kg/cm 2 2 6GH-UTE Vertical, water-cooling, 4·cycle diesel engine 0 irect injection Turbocharger with air cooler 6-117.9 x 140 (6-4.642 x 5.512) 9.17 330/2250 14.39 10.50 (0.4134) Light duty rating Work boat rating 360/2300 330/2250 15.36 14.39 10.73 10.50 (0.4224) (0.4134) 2500-2550/400-450 2400-2450/400-450 Electric starting, 24V-5.5kw 1-4-2-6-3-5-1 Counter-clockwise Bi·rotation 32 14 YX-120 YX·120L Hydraulic wet multi-disk type 2.03 2.57 3.04 3.55 4.00 4.59 1108 875 740 634 563 490 Clockwise or counterclockwise viewed from stem 275 (606) 350 (772) 11 10 20 22 In-line type, D.K.K.C AD b.T.D.C 13 6-0.33 x 145, Hole type 240 Diesel oil or light oil Paper element Forced lubrication by geared pump 6600/2300-6300/2200 4-5 (suction side) (Discharge side) perforated steel plat.e Paper element

Model 6GH-UTE Sea water pump Rubber impeller type, gear driving type Freshwater pump Centre type, gear driving type Cooling Cooling Fresh water cooling water 2/hr./rpm Seawater: 10500/2300-10000/2200 system Pump discharge volume Fresh water: 15000/2300-14300/2200 Fresh water capacity inside engine 2 30 Fresh water capacity in sub-tank 2 1.7 Type Garrette T51AK Turbo- Cooling Air cooling charger Lubrication Common with engine Air cooler Type and capacity Fin tube type Cooling Seawater cooling Engine dimension: mm (in.) 1762 x 861 x 1237 (49.69 x 33.90 x 48.70) Overall length x overall width x overall height Piston stroke height (from installation floor) mm(in.) 840 (33.07) Engine dry weight (inc. clutch) kg (lb) 1200 (2640) A NOTE light duty rating: Continuous operation hours at max. below 2 hours. 3 Printed in Japan AOA1959-8807

/. Specifications --------------------------------------------------------------------------------------------------------------------------------------------6GH-UTE 1-2 Dimensions Unit: mm Printed in Japan. AOA1959-8807 P.C.D. 333.4 Crank shaft center 384 443 SECTION A Crank shaft center Ptopeller shaft .. nter 300 Cooling ,.. woter 21 O 2 90 outlet pli>o 1-""=..i--="'--' •44.5/55.8 rubber - SECTION B 4 "' N ., 6-M12 Screws S.M10 Screws depth 19/26 DetaU of Front Coupling 660 7 1'3 0 0 " "' 8 fresh ttW11ter tank 0 ... oo .. ~ ... ... ·- 0 .. Rotation of Cfankshaft 1661 124 1071 466 50 180 911 er 138 120 150 4 ill - - . ~ ) ' .. I \. Cooling sea water inlet 30 I 220 J ...._ \ ,_,- l n 133 - Air fiher for turt>c- 36 117 \ 1430 - 12-•18.5 Holes M16 bolt - View from Upper 1859 1342 447.5 fuel return pipe ~/16 Rubbw hos• I· ,, .. 436 --je 51 6-M12 Jack bolts W20 Re•nar bolts / I/ on N 140 23 H -=iii gi 0 0 ... N .. N on N 2-MlOx 1.5 Screwo Detail of Propeller Shaft Coupling Mist outlat pipe p.JS/46 .,ny1 ho .. COOiing see water inlet pipe ~.5/55.5 Rubber hosa Aot.tion of propeller shaft Exh.pspipe 125A Starting motor Lub. oll filter

2. Disassembly and Assembly --------..;.---------------------------------------------------6GH-UTE 2. Disassembly and Assembly 2-1 Preparations for Disassembly and Assembly (1 l Symbol• for disassembly and assembly Symbol Explanation Symbol Explanation ~ Note C2: I Use tool ~ Measure l •1 }D Apply liquid packing ~ Feed oil or grease & Warning •1: Liquid packing {Three Bond TB1212) {21 Disassembly • Prepare disassembly tools, measuring instruments and recording paper. • Prepare washing machine and cans. • Provide a space and cases for assembled parts. • Drain cooling water and lube oil completely out of the engine. • Always place parts in order of disassembly. • Replace bolts and nuts temporarily in their original locations to prevent confusion. • If trouble is located, first determine the cause of the trouble to prevent removal or disassembly of un· related parts. (3) Assembly • Wash and check the parts to be assembled with due care. • Apply fresh engine oil or the designated lubricant to sliding and moving parts before assembly. • Replace gasket packings, copper packings and other packings with new ones. Printed in Japan ADA!959·8807 5 YANMAR part code: 977770--01212 • Use liquid packing, if necessary, to prevent water and oil leakage. • Align all marked parts carefully during assembly. When fitting replacement parts, pay attention to their combination. • Do not confuse the bolU, nuts and washers. and tighten the major nuts and bolts to the designated torques. Use particular care when tightening the parts made of aluminium alloy. • Apply engine oil to the thread and contacting face of major bolts before tightening them to the designated torque. A NOTE Use a spanner wrench during disassembly and a torqu11 wrench during assembly.

1. Disassembly and Assembly. ------------------..;..--------------------------------------~6GH-UTE 2-2 Tools, Measuring Instruments and Other Servicing Equipment The disassembly and reassembly of the major parts is possible with the standard tools attached to the engine, but for more efficient and exact disassembly and reassemtr ly with better measurement and diagnosis, we recommend you to provide the following tools and equipment. 2·2·1 Exclusive tools for 6GH-UTE No. Kind of tool Valve guide tool Application Valve guide press-fitting Materiel S45C Sinter here ~o --i ....,1~'"'t,... t"'8"'t"'1 -1 I 6 13.7 t 5• 10.5391 3 too 13.9371 21.5 I0.8461 10. t 181 mm (in.) 6GH002 50 It .9691 Knurling 21.5 I0.8461 Illustration ~30 1~1.1811 13.7 10.5391 too 13.9371 mm (in.) 6GH003 Printed in Japan AOA1959·8807

2·2·2 General disassembly and assembly tools Please refer to the separate "Handling Manual for Measuring Instruments" (YANMAR Business Dept. Technical Material No. 57-017). 2·2·3 Other equipment Item Liquid Three·Bond gasket No. 1 Three·Bond No. 2 Three· Bond No. 3 Three· Bond No. 4 Three·Bond No. 10 Thre .. Bond TB1212 Metal Neji Lock adhesive Neji Lock Super Three·Bond Seal Type O·ring kit (in pouch) Extreme· Local paste pressure- lubricant (Molyb- Paste Spray den um disulfide) Molly Paste H Printed in Japan AOA1959·8807 Volume YANMAR Code No. 100g (0.22 lb) 977771 [Also available in 200g -00100 (0.44 lb) and 1 kg (2.2 lb)) 100g (0.22 lb) 977772 [Also available in 200g -00100 (0.44 lb) and 1 kg (2.2 lb)) 150g (0.33 lb) 977773 -00100 100g (0.22 lb) 977774 [Also available in 200g -00100 (0.44 lb) and 1 kg (2.2 lb)] 100g (0.22 lb) 977770 -00100 1009 (0.22 lb) 977770 (0.22 lb) -01212 200g (0.44 lb) 977777 -00200 50g (0.11 lb) 977778 -00050 Sm/reel (196.85 in.) 977779 -00500 ~1.9/2m 1 pc. 977770 (~0.075nB.74 in.) -57000 ¢2.4/2m 1 pc. l~.o94nB.4 in.) ~.1/2m 1 pc. (~.122ns. 74 in.) ~.5/2m 1 pc. (~.13BnB.74 in.) ¢5.7/2m 1 pc. l~.224nB.74 in.) 50g (0.11 lb) 977754 -00050 330g (0.726 lb) 977753 -00330 50g (0.11 lb) 977755 -00050 7 Property and Application Non-drying solventless liquid packing. easy-to-remove, excellent seawater resistance, for use on every jointing face. Non·drying liquid packing, easy·to-apply, excellent against water and oil, especially gasoline. Drying and film.forming type, low viscosity, thin film, suitable for jointing faces of precision parts. Semi-drying, viscous and elastic, for application to irregular faces, excellent heat, water and oil resistance. Solventless sealant of silicone group, for sealing of high·temperature parts [-so•c - 2so 0 cJ. Non-fluid, silicone group, good for padding. For prevention of loosening of screws, gas leakage and rusting. Unscrewable by 10 to 20% of tightening torque. Locks bolts semi·permanently with strong adhesiv .. ness For sealing screw joints in piping. Applicable temp. range [-150°C -200°C] Any size of 0-ring required in emergencies can be made by this kit. [Kit includes adhesives, releasant, cuttsr and jig.) For assembly of cylinder, piston, bearing, shaft etc. of engine. Spray type for greater convenience. For prevention of seizure at threaded paru subject to high temperature. To be used for suc./exh. valve (stem, guide, face).

2. Disassembly and Assembly ----------------------------------------------------------~6GH-UTE Item Volume YANMAR Code No. Descaling Unicon 146 1 case [4 kg (8.8 lb) 97410 agent x 4] -01460 Test paper: 1 pc. Neutralizer 1 case 974100 (Caustic soda) [2 kg (4.4 lb) x 4] -02000 PH Test paper 974100 -03000 Anticorrosives 22 974100 -04200 YANMAR Super·Freeze 22x1can (Antifreeze mixture) 182x 1 can 2002x 1 can Dealt by YANMAR SANG YO Temp. -5°c -10°c -15°c -20°c Valumic ratio 15% 25% 30% 35% Metal Clean Y 1 kg (2.2 lb) x 20 975600 (Detergent) -2000 Blower Clean 42x4 919200 -10000 18 2 x 1 919200 -30000 [1500ccx6] x 15seu 919200 -20000 B Property and Application 0 Removes scale quickly. (1 - 10 hrs.) 0 Dilute one unit of unicon in ten units of sea water, and stir well. 0 Disassembled parts can only be descaled by immersion in the solution, but descaling time can be shortened by circulating the solution through the various parts. o Allow the detergent to weaken and neutralize it before throwing it away. (Dip the PH test paper in the solution. It is effective as long as the color of the paper is red.) Mix into the fresh cooling water system at a ratio of 1: 10 and conduct engine idling for around 5 min. Anticorrosive power lasu for 6 months. Can be used as antifreeze in winter and coolant in summer. Prolonged use for 2 years is guaranteed. It may also be mixed with anticorrosives. -25°c -30°c -35°c -40°C 40% 45% 50% 55% o Strong enough to remove even persistent carbon deposiu. 0 Double the cleansing power when heated, with equal safety. 0 Does not corrode iron or most other metals (Anti-corrosive effect.) 0 Dilute 1 kg (2.2 lb) in 40 2 of water before use. o When using a washing machine, dilute to 4 - 6% solution and heat [at 60 - 80°C] Special detergent for cleaning blower or supercharger and air cooler. (which do not require flushing with water). Printed in Japan AOA1959-8807

Yanmar Marine Diesel Engine 6GH-UTE Service Repair Manual

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