Sea NL Ve MARINE PROPULSION ENGINE 6AYM-WGT a NEForeword: This Service Manual has been developed for the exclusive use of service and repair professionals such as YANMAR authorized distributors and YANMAR authorized dealers. itis written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and/or safely. All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing, The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. YANMAR and WAINMIAR are registered trademarks of YANMAR CO., LTD. in Japan, the United States andlor other countries. All Rights Reserved: No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or informa- tion storage and retrieval systems - without the written permission of YANMAR CO,, LTD. MODEL GAYM-WGT, 6AYM-WET, 6AYM-WST SERVICE MANUAL CODE OB6AY-ENO010 All Rights Reserved, Copyright YANMAR GO, LTD.CONTENTS FOR YOUR SAFETY 41 Safety Precautions 2 6 8 Location of Safety Decals (Waring Labels). Safety Precautions when Lifting the Engine ENGINE SPECIFICATIONS Location of Components Piping Diagram Fuel Oil, Lubricating Oil and Coolant 13 SI Unit Conversions 16 DISASSEMBLY AND ASSEMBLY Precautions for Disassembly and Reassembly 7 Disassembly and Reassembly Tools. 18 Disassembly Procedures 29 Reassembly 50 INSPECTING AND SERVICING OF ENGINE'S MAJOR PARTS Preliminaries Standard for Parts Replacement (Including Correction) Cylinder Head Cylinder Block Cylinder Liner. Pistons Connecting Rods Crankshaft and Main Bearing 100 Oil Seal of the Crankshaft 103 Camshaft and Tappets 104 Timing Gear 107 Flywheel 109 Viscous Damper coor oe 109 Fuel Injection Equipment 110 Governor, 112 Disassembly, Reassembly and Inspection of the Fuel Injection Pump 125 Fuel Feed Pump 141 Adjustment of the Injection Timing 145 Fuel injector 146 Boost Compensator 149 Fuel Filter 151 Lubricating Oil System 153 Cooling Water System co Eo oe 159 Turbocharger 166 Electrical System 185 Starting Air Motor (Special Order) 194MAINTENANCE INSPECTIONS. - 195 Precautions for Maintenance and Inspections 195 Periodic Maintenance Schedule 195 STORAGE STANDARD 198 TROUBLESHOOTING AND COUNTERMEASURES . 199 Starting Failure 199 REFERENCE ADJUSTMENT VALUE ..... . 204 SERVICE REFERENCE TABLE TIGHTENING TORQUES FOR MAJOR BOLTS AND NUTS ... 208 TEST RUNNING 214FOR YOUR SAFETY — 1 FOR YOUR SAFETY The main causes for accidents is that basic safety rules and precautions were not obeyed. It is important to prevent accidents before they happen by avoiding their causes. Before you start any repair or maintenance work: Read this manual carefully and make sure that you understand the applicable inspection or maintenance procedures and the safety precautions. If you do repair or maintenance work without the necessary knowledge, you can cause unforeseen accidents. Itis not possible to predict all dangers that can occur during repair or maintenance and indicate them in a manual. Therefor it is necessary to carefully consider workspace safety beyond what is expressed in this manual and on the safety decals Especially during repair or maintenance work that is not described in the manual, obey the instructions by qualified mechanics. About safety decals (warning labels) Safety decals (warning labels) are attached to the engine. Please consider them for your safely. Make sure that you replace safety decals that are lost or difficult to read. Obey the handling instructions for used engines as you do with new engines. The symbols on the safety decals have the following meanings. DANGER indicates a hazardous situation which, if not avoided, will result PCa in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. AWARNING | CAUTION indicates a hazardous situation which, if not avoided, could ACAUTION result in minor or moderate injury. NOTICE indicates a situation which can cause damage to the machine, NOTICE personal property andlor the environment or cause the equipment to operate improperly.2 — FOR YOUR SAFETY Safety Precautions Make sure that you obey these precautions for safe maintenance. 1 Precautions for the maintenance facility (room) ANAS Do your work in a room that has good airflow Make sure that the airflow is sufficient when: + The engine operates. + You weld parts. + You remove paint with sandpaper. If you do not obey this: You can breathe in poisonous gas or dust. This is very dangerous to the body. ACAUTION Make the room bright Make sure that your workspace has sufficient lighting. f your workspace is dark and visfon is Poor, use a portable safety lamp. Use lamps with light bulbs that are covered with a wire cage. If you do not obey this: The light bulb can accidentally break and ignite leaked oil Do your work in a room that is sufficiently wide and flat The floor area in the maintenance facility (room) must be sufficiently large and flat with no holes. If you do not obey this: You can fall or other unforeseen accidents can occur. Do your work in a room that is clean and tidy Make sure that no dust, oil or parts are on the floor. If you do not obey this: Unforeseen accidents can occur. Fully equip the facility with fire-extinguishing equipment Place a fire extinguisher in your vicinity in case a fire breaks out. Also, do an appropriate inspection of the fire-e:FOR YOUR SAFETY — 3 1 Precautions for your work ad | AWARNING Do all holding and lifting in an appropriate manner Do not hold or lift when supported only by a block, wooden piece or a jack. Do all holding and lifting from the specified lifting points and fixtures, and use equipment that easily handles the weight. If you do not obey this: Serious accidents can occur. ACAUTION Put on safe work clothes Worker must put on a helmet, work jacket, boiler suit, safety shoes and safety equipment that matches their task. The work clothes must fit well If you do not obey this: You can get caught in the engine and serious accidents can occur. Use the applicable tools + Use the correct tools for your work. Use tools of the correct size when you loosen or tighten the engine. If you do not obey this: You can get seriously hurt or damage the engine. + Make sure that you tighten all spaces that are indicated in the manual to the specified torque. If you do not obey this: Parts may become loose and fall, causing parts damage or personal injury. * Do not work in an uncomfortable position. If you do not obey this: Unforeseen injuries can occur. 1 Precautions for handling parts Peas e & Be careful when filling fuel Keep away all fire such as cigarettes and matches when fi If you do not obey this: Fire and explosions can occur. 9 fuel. Be careful when opening the coolant filler cap Do not open the coolant filler cap when it is hot. If you do not obey this: Hot water blows out and burn injury can occur.4 — FOR YOUR SAFETY Be careful with rotating parts Keep away your hands and tools from rotating parts during engine operation. Hf you do not obey this: You can get caught and injury can occur. Be careful with short-circuits of the harness Remove the (-) terminal of the battery during maintenance. If you do not obey this: You may get an electric shock, and a short-circuit of the harness can cause a fire. Be careful when charging the battery The battery makes flammable gas when it charges. Keep away all fire. Make sure that there is good airflow. Ifyou do not obey this: An explosion can occur. Be careful when opening the side cover Do not open the side cover when the engine is hot. If you do not obey this: The new air intrusion may lead to an explosion. Be careful when starting the engine Make sure that nobody is near the engine. If somebody is near the engine, give a signal and make sure that they are safe. Then start the engine. Remove the turning handle, and store it in the specified location. IF you do not obey this: Injury can occur. ACAUTION Be careful hot parts Do not touch the engine's hot parts during or ater operation. If you do not obey this: The high temperature can cause burn injury. Be careful with the battery fluid Battery fluid is diluted sulfuric acid, so make sure that you do not get it on your clothes or skin. If you do not obey this: You can make a hole in your clothes and burn injury can occur.FOR YOUR SAFETY — 5 About the use of genuine parts NOTICE Use genuine parts Ifyou do not obey this: You can shorten the operating life of the engine and unforeseen accidents can occur. Use NOx-compliant parts ‘According to the laws preventing environmental pollution and sea hazards, itis necessary to make a record signed by a supervisor when certain parts are replaced, The parts in question are listed in the engine service manual. About disposing waste NOTICE Be careful when disposing waste Fil all waste oll and waste fluids into containers and do not spill Never dumb them outdoors or into sewage, rivers or the sea. Appropriately dispose of waste materials in accordance with laws and regulations, e.g. commission a professional collector to dispose of the waste materials.6 — FOR YOUR SAFETY Location of Safety Decals (Warning Labels) To ensure your safety, the locations of the safety decals are indicated Protect the safety decals from dirt and damage. If they are damaged or lost, replace them with new ones. 1 Operation side Peay ORS TERT SURED, oases BLOM EEySBhEY. ‘hlever renove the cap while the Gngine (¢ etill hot. eft water ay spurt out and brn you TReen, eam ARRUEC HEU. fares sanEU ES, cay enue ini iis, vo ARUN EUTRAL RAC EORO RNa es Don't open 10min. ater stop FTE1GO7210-~ |frcon cause injry vy explosionFOR YOUR SAFETY — 7 1 Non-operation side8 — FOR YOUR SAFETY Safety Precautions when Lifting the Engine ‘The engine can cause serious injury when it falls during lifting. Obey the below instructions to prevent accidents during fiting, + Make sure that the engine is lifted by qualified persons. * Before lifting, make sure that the engine lifting bracket and mounting bolt have no damage and are in good shape. If you find a fault, stop immediately and contact your YANMAR dealer or distributor. * Select lifting tools (e.g. wire rope and shackle) that are appropriate for heavy loads. + Select the wire rope length so that the engine does not tilt during lifting. + Before lifting, examine the lifting tools and make sure that they have no damage and are in good shape. * Protect the parts of the engine or driven equipment that touch the wire rope with protective material. * The tension of the wire rope changes depending on the lifting angle. Make sure that the angle is within 60". + Ifyou use a marine gear that is not listed in this operation manual, separate the marine gear from the ‘engine, and lift the marine gear and engine separately. + During lifting and moving the engine, do not go under the engine or near the engine. For the mass, refer to Specifications in the Operation Manual.ENGINE SPECIFICATIONS — 9 ENGINE SPECIFICATIONS ae Tak [San [SAREE aN ee eral watercoled, yee dae engine onbuatoncharber : ec nection be ee 7 6-168 160 Total cylinder displacement a 20.38 ee — c alma a Rated output (at whee eo en vez | 55) Fas cea rt wean | 1000 | too | 1000 ranks ion deen : Curate awed othe Bee) 1-4-2-8-3-5-1 Fidog order: 7 (No. 4 cylinder; flywheel side) |[Fuet injection pump: 7 YANMAR 6 in-line 2 eee dea 95105 ]1s05| 1208] 16205 Fup ofmecin noes | ram degen | lope 0030 160° 4-002 07" [injection pressure MPa 31205 jisbeatg : Forced beating wih gear pump teteaing (Oz = Freshwater col eeong Lables stg ol pa We oe [ring of coase ‘ Eolas | Seawater pump = Rubber impeller, gear driving type cooing | eclant pump = Cartfigal gear ving ype ctr (Cosing = Fohvatr coor colng wih heat xharge a |, Coolant tank: 65, gsc eee . Reservoir tank: 3 Fuk [pe : Tora Or errger__Cocng E Rrwoing eee = Fin and tube j eating 7 ‘Seawater cooling a : Ele serng ora stra Engi yas foul rare ges rm 728 Note+ The rating shown represents net brake power at the flywheel. + Cylinder numbers are counted from flywheel side (No. 1).10 —— ENGINE SPECIFICATIONS Location of Components ™ Operation side Intake manifold Flor cap) ‘Coolant tank (eat exchange) Seawater ‘Atornator cae Govemor Fue injoction pump Fuel pring pump Ful food pump Dipstck 1 Non-operation side _— haus maniol nan ot sere ff Ge \ ste {eootent)"® star Engineer engines bypass fiterENGINE SPECIFICATIONS — 11 Piping Diagram Cooling water system Seawater oul pipe @r- Liang - ‘cole | = xtinder 3 1 2 Exhaust gos Filler cap g manifold Coolant ' RS 5 z | 8 Sha 2 gee Seawater ine Seawater pump jp O ‘Seawatorinlet pipe eh Coolant ine — Lubricating oil system Taare at y A Taba san palo ] Clpremure cont ave P99 |~— Piston Camshatt Main bearing Lubricating Te ; 1 é ae Gil pan = Fuclinjecion pume-—e—— << Turbocharger safely valve << si12 —— ENGINE SPECIFICATIONS Fuel oil system To each valve LL Fuel injection pump _———_I Pressure contol valve Ful fitor Fo drain pipe Ful foed pump! Fool over flow pipe Water soparator ‘ul ft)ENGINE SPECIFICATIONS — 13 Fuel Oil, Lubricating Oil and Coolant Fuel ‘The following table shows the fuel oil specifications for this engine model Fuel oil properties affect the smooth running of the engine, its maintenance intervals and the service life of its parts, They come in a broad range and can be uncertain. Thus, depending on the applied fuel ol, it might be necessary to add attachments or change the specifications of the engine. @ Quality criteria of fuel oil Viecosty at 60°C mile 3-8 Specific gravity at 15°C gfom® = 086 Flash point °c 560 Residual carbon mass <07 Sullur content mass 10 [Ash content mass 008 Moisture content vol% =O. Vanadium ppm - Sodium ppm = Aluminum ppm = Diesel index (Cetane no. of = 45) AST DST 20 Quality criteria equivalent fuel oil 55-2068 Glass At or AP 150 8217 DMX EN 500 NOTICE The fuel injection system consists of precision parts. For that reason, only use fuel that is free of water and dust, Contaminated fuel causes malfunctions. Thus, pay attention to the following when supplying fuel. ‘Also, drain and do maintenance servicing of the fuel filter as described in P195 [Maintenance Inspections] during daily maintenance. When supplying fuel + When supplying fuel stored in a drum, let the drum rest for one day or longer so that impurities can settle, and fil the top layer of oll to the engine. + If supplying fuel from a storage tank to the service tank, wait one day or more after the fuel was filled to the stor- age tank before you supply the fuel to the service tank.14 —— ENGINE SPECIFICATIONS Lubricating oil Selection of lubricating oil is very important for a diesel engine. If improper lubricating oil is used or change of lubri- cating oil is neglected, it causes sticking of piston rings, seizure or early wear of pistons and cylinder liners and faster wear of bearings and various other moving parts that reduce the durability of the engine. Choosing the lubricating oil Service categories Use an engine oil that meets or exceeds the following guidelines and classifications: + APL Classification: Grade CD, CF + SAE Viscosity grade: 40, 15W-40 (Only if the sulfur content of the used fuel is less than 0.5 %) + TB.N. [MgKOHIg}: 9- 15 Viscosity | Specific | Flash point °C) , Kinetic viscosity (mm/s) Viscosity Pour point (°C) (SAE) gravity {open type) 40°C 700"¢ index 0 0898 3240 =75 740-155 74-185 96-110 TEwa40 088 5230) =30 > 700 74-185 > a0 NOTICE + Do not blend. (If you cannot avoid blending diferent brands of lubricating cil, consult your lubricating oil supplier) + Ifyou use a lubricating oll with a high total base number (TB.N.) and a fuel oll with low sulfur content, the additive (calcium carbonate) of the lubricating ol sticks to high-temperature areas and deposits with carbon residue. This causes the adverse effects mentioned below. Thus, use the proper lubricating cil ‘Accumulation of these deposits in the combustion chamber hinders the sliding of the piston rings and may cause scuffing on the rings, cylinder ners and other parts. Also, the deposits may cause bite-in and blow-by ithey enter the exhaust valves. Selecting the oiler lubricating oil for the air starter (option) For engines with an air starter, select a lubricating oil for the oiler based on the ambient temperature. Temperature range Lubricating oil type Eg, Turbine oil #00 (spindle oil not applicable) Eg, #00 refiigerating machine of (spindle oil not applicable) 5°C-60°C E.g. Turbine ol, category 1, ISO VG 32 “18 °C-8°C For reftigerating machines, category 1, ISO VG 15 Selecting the marine gear oil Refer to the Operation Manual of the marine gear.