Service manual
Table Of Contents
- Cover
- History of Revision
- FOREWORD
- CONTENTS
- FOR SAFETY
- 1. General
- 2. Inspection and adjustment
- 2.1 Periodic maintenance schedule
- 2.2 Periodic inspection and maintenance procedure
- 2.2.1 Check before starting
- 2.2.2 inspection after initial 50 hours or one month operation
- 2.2.3 Inspection every 50 hours or monthly
- 2.2.4 Inspection every 100 hours six months
- 2.2.5 Inspection every 150 hours or one year
- 2.2.6 Inspection every 250 hours or one year
- 2.2.7 Inspection every 1,000 hours or four years
- 2.3 Adjusting the no-load maximum or minimum speed
- 2.4 Sensor Inspection
- 2.5 Thermostat inspection
- 2.6 Adjusting operation
- 2.7 Long storage
- 3. Troubleshooting
- 4. Disassembly and reassembly
- 5. Inspection and servicing of basic engine parts
- 6. Fuel injection equipment
- 6.1 Fuel Injection pump/governor
- 6.1.1 Fuel system diagram
- 6.1.2 Fuel injection pump service data and adjustment
- 6.1.3 Fuel injection pump structure
- 6.1.4 Removing a fuel injection pump
- 6.1.5 Installing a fuel injection pump
- 6.1.6 Adjusting fuel injection timing
- 6.1.7 Troubleshooting of fuel injection pump
- 6.1.8 Major faults and troubleshooting
- 6.2 Fuel feed pump
- 6.3 Fuel filter
- 6.4 Fuel tank
- 6.1 Fuel Injection pump/governor
- 7. Intake and exhaust system
- 8. Lubrication system
- 9. Cooling water system
- 9.1 Cooling water system
- 9.2 Seawater pump
- 9.3 Fresh water pump
- 9.4 Heat exchanger
- 9.5 Pressure cap and coolant recovery tank
- 9.5.1 Pressure cap construction
- 9.5.2 Pressure cap pressure control
- 9.5.3 Pressure cap inspection
- 9.5.4 Replacing filler neck
- 9.5.5 Function of the coolant recovery tank
- 9.5.6 Specifications of coolant recovery tank
- 9.5.7 Mounting the coolant recovery tank
- 9.5.8 Precautions on usage of the coolant recovery tank
- 9.6 Thermostat
- 9.7 Bilge pump and bilge strainer (Optional)
- 10. Reduction and reversing gear
- 11. Remote control (Optional)
- 12. Electrical system
- 13. Service standards
- 14. Tightening torque for bolts and nuts
- Colophon
- Back cover
CONTENTS
1. General ............................................................................................................................ 1
1.1 Exterior views ...........................................................................................................................1
1.2 Specifications ...........................................................................................................................2
1.3 Fuel oil, lubricating oil and cooling water .................................................................................4
1.3.1 Fuel oil .............................................................................................................................................. 4
1.3.2 Lubricating oil.................................................................................................................................... 4
1.3.3 Cooling water .................................................................................................................................... 5
1.4 Engine outline ..........................................................................................................................6
1.5 Piping diagrams .....................................................................................................................10
1.6 Exhaust gas emission regulation ...........................................................................................12
1.6.1 Engine identification (EPA/ARB)..................................................................................................... 12
1.6.2 Exhaust gas emission standard (EPA/ARB) ................................................................................... 13
1.6.3 Guarantee conditions for emission standard (EPA/ARB) ............................................................... 13
2. Inspection and adjustment ............................................................................................. 15
2.1 Periodic maintenance schedule .............................................................................................15
2.2 Periodic inspection and maintenance procedure ...................................................................17
2.2.1 Check before starting...................................................................................................................... 17
2.2.2 inspection after initial 50 hours or one month operation ................................................................. 20
2.2.3 Inspection every 50 hours or monthly ............................................................................................. 25
2.2.4 Inspection every 100 hours six months........................................................................................... 30
2.2.5 Inspection every 150 hours or one year.......................................................................................... 30
2.2.6 Inspection every 250 hours or one year.......................................................................................... 31
2.2.7 Inspection every 1,000 hours or four years..................................................................................... 37
2.3 Adjusting the no-load maximum or minimum speed ..............................................................44
2.4 Sensor Inspection ..................................................................................................................44
2.4.1 Oil pressure switch.......................................................................................................................... 44
2.4.2 Thermo switch................................................................................................................................. 44
2.5 Thermostat inspection ............................................................................................................45
2.6 Adjusting operation ................................................................................................................46
2.6.1 Preliminary precautions .................................................................................................................. 46
2.6.2 Adjusting operation procedure ........................................................................................................ 46
2.6.3 Check points and precautions during running................................................................................. 47
2.7 Long storage ..........................................................................................................................48
3. Troubleshooting .............................................................................................................49
3.1 Preparation before troubleshooting ........................................................................................49
3.2 Quick reference chart for troubleshooting ..............................................................................50
3.3 Troubleshooting (Concerning engine and fuel injection equipment) ......................................59