Yanmar 6CXM-GTE Service Manual Download

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SERVICE MANUAL

MARINE DIESEL ENGINE

M9961-H1302

6CXM-GTE/GTE2

Summary of Contents for 6CXM-GTE

Page 1: ...SERVICE MANUAL MARINE DIESEL ENGINE M9961 H13021 6CXM GTE GTE2 ...

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Page 3: ...R MARINE DIESEL ENGINE Product name 6CXM GTE GTE2 Revision No Revision date Reason for revision Revision outline Revised item page Revised by Rev 1 November 05 To add more details of fuel injection pump 3 11 Fuel Oil System was increased From page 3 29 to page 3 43 24 Marine Business Development Dept ...

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Page 75: ...l Injection Pump The Yanmar YPES PS fuel injection pump is an integrated type and the engine revolutions are transmitted to the cam shaft of the pump through the driving gear and advance timer 1 Specifications Unit 6CXM GTE 6CXM GTE2 Plunger dia mm 13 Plunger pre stroke mm 3 5 Delivery valve suck back q ty mm3 st 70 Delivery valve dia mm 7 Cam lift mm 12 Thrust clearance mm 0 01 0 05 Plunger sprin...

Page 76: ...port as the plunger rises and the pressure in the fuel injection pipe drops A fuel leak return hole is provided in the plunger barrel This returns fuel which leaks through the gap between the plunger and the barrel to the fuel drain sump through the drain pipe preventing dilution of the lubricant in the cam chamber 3 Injection volume control The fuel control mechanism is shown in following fig The...

Page 77: ...njection pressure drops and the deliv ery valve is brought down by the delivery valve spring At the same time the suck back collar 1 blocks off the fuel injection pipe and the delivery chamber and the valve continues descending until the seat 2 comes in contact with the barrel The fuel oil pressure in the fuel injection pipe decreases proportionately with the lowering of the valve due to increased...

Page 78: ... by the centrifugal force and push the control rack to reduce the fuel The weight force is balanced with the spring force to maintain the idling speed 3 Condition during maximum speed When the engine reaches its maximum speed the weight force is balanced with the governor spring force and the rack is kept at the appropriate injection position If the engine load is reduced the engine speed increase...

Page 79: ...ition tends to decrease according to the rise of engine speed Accordingly a larger capacity pump is used The use of a large capacity pump however gives over torque and adverse exhaust color due to excessive fuel injection dur ing medium speed high load operation To prevent this and to control fuel injection volume at the medium high load opera tion to the proper level the reversed angleich mechani...

Page 80: ...ch spring is completely com pressed This is the max injection position To explain the function more concretely during the medium to high load operation even if the tension lever contacts the fuel limiter and the rack is at the max position the reversed angleich spring overcomes the thrust force of the governor since the revolution is below the max speed and caused the governor level to move to the...

Page 81: ...e and the exhaust turns black 3 The boost compensator limits the advancing of the rack and keeps it at R3 position The rack starts to move at pressure of PA and reaches to R2 position when pressure rises up to PB or more 4 In engines with the boost compensator injection quantity in the range of rack positions R2 R3 shadowed area is lim ited and thus black exhaust is controlled 2 Equipment When the...

Page 82: ... up the engine speed and the boost pressure is raised the diaphragm is pressed by the charg ing pressure causing the boost compensator s lever to move to turn the control rack to the fuel increase side max injection quantity is obtained ...

Page 83: ...spacer by moving only the moving parts of the governor cover 4 Remove the connecting spring by inserting needle nosed pliers between the governor case and spacer 5 Slide the governor case and pull out the link pin of the fuel control rack 6 Remove the snap rings on both ends of the governor lever shaft 7 Put a rod 10 mm 0 3937 in or less diameter on one end of the governor lever shaft and tap it u...

Page 84: ...wance Repair 1 Wear excessive clearance of governor weight pin pin hole Within the standard clearance of 0 2mm and should move smoothly Replace the governor weight cmp 2 Contact surface of governor sleeve with weight roller No excessive wear Replace the sleeve 3 Thrust bearing No seizure discoloration or breakage Replace the thrust bearing 4 Free length fall of governor spring Free length Within 6...

Page 85: ...te plate 4 Mount the governor link to the governor lever assembly 5 Put the governor lever shaft assembly in the governor case insert the governor lever shaft until the O ring groove come out from the opposite side of the governor case and fit the O ring 6 After mounting the O ring tap the governor lever in the opposite direction and mount the E shaped stop rings on the grooves at both ends Govern...

Page 86: ... the rack link 9 Fit the link connecting spring to the spring pin at the rack link with the spring set bar by pushing the rack link into the governor link 10 Mount the governor case to the fuel pump unit lightly tapping it with a wooden hammer and tighten the bolts 11 Mount the governor case cover 12 Insert the control lever to the control lever shaft and tighten the nut Note Move the control leve...

Page 87: ...and put them back in the same cylinder 1 Preparation 1 Wash off the dirt and grease on the outside of the pump with cleaning oil kerosene or diesel oil before disassembly 2 Perform the work in a clean area 3 Take off the drain plugs and drain the lubrication oil 2 Disassembly 1 Fix the outside of the automatic timer and remove the nut 2 Screw the puller into the nut hole Remove the automatic timer...

Page 88: ...l by turning it to and fro 7 Remove and mark the shims to recall the original assembly 8 Remove the plunger and plunger barrel together with the plunger spring and lower spring retainer 9 Remove the delivery valve holder delivery valve valve spring valve stopper and O ring from the plunger barrel 10 Remove the straight pins securing the spring shoe to the barrel support then remove the pinion Note...

Page 89: ...pside down and remove the hex hollow set bolts that secure the middle bearing 15 Remove the cam support and the shims by prying open the slots in the support with screw drivers 16 Remove the camshaft together with the middle bear ing from the drive side Note Be careful not to damage the governor case oil seal when removing the camshaft ...

Page 90: ...ding surface against the roller pin are not a problem 2 If there are burrs or discoloration repair or replace the body as this will lead to dilution of the lubricant 4 Inspection of fuel camshaft and bearings 1 Fuel camshaft Inspect for scratches or wear of cam surface deforma tion of key grooves and screw on both ends Replace it if necessary 2 Replace the bearings if the outer race surface are fl...

Page 91: ...en the camshaft support with four screws 6 Tap both ends of the camshaft with a mallet to seat the bearings Turn the camshaft by hand and feel its rotating resis tance preload If it is too heavy adjust it by adding shims Remove the shim if it is too light Note Always replace gaskets packing and O rings with new ones Note Apply grease to the middle bearing to prevent it from falling out before inst...

Page 92: ...gn the groove in the tappet with the setting bolt and insert the tappet 12 Screw in the spring shoe setting bolts 13 Insert the rack in the pump housing and align its ninth division of the scale with the end surface of the pump housing thread 14 Lock the rack position with a special setting bolts as shown below 15 Install new O ring in the plunger barrel Note Be careful not to damage the O rings N...

Page 93: ...and install the spring shoe on the barrel collar Secure the spring shoe with the straight pins 18 Insert the clip ring into the groove in the pinion 19 Install the plunger spring 20 Hook the neck of the plunger to the spring retainer align the plunger flange with the slots in the pinion and push the plunger until it is locked by the clip ring on the pinion 21 Place a shim around each stud bolt 22 ...

Page 94: ...e delivery valve holder 26 Align the marks on the barrel support and the pump housing then tighten the nuts to the specified torque 27 Tighten the delivery valve holders to the specified torque Note Apply clean lube oil to the O rings and pump housing bore in order not to damage the O ring Do not try to drive in the barrel Before inserting the plunger barrel assembly turn the camshaft and set the ...

Page 95: ...at the sliding section of the plunger assembly Excessive tightening of the delivery valve holder distor tion of the plunger barrel Damage or particles at the tooth of the control rack or pin ion Damage at the outer periphery of the control rack Damage at the control rack hole in the pump housing In each case disassemble and repair 31 Assemble the governor 32 Fill the pump and governor with clean l...

Page 96: ...rnor 300 cc 5 Connect the fuel oil pipes and operate the pump tester to purge the air in the line 6 Set the oil feed pressure from the pump tester to the injection pump at the pressure specified in the separate service data sheet 2 Adjustment of pre stroke 1 Remove the delivery valve holder of No 6 cylinder Remove the delivery valve spring and delivery valve 2 Screw the pre stroke measuring device...

Page 97: ...the pressure gauge to the delivery valve holder of the cylinder to be tested 2 Set the governor control lever in the stop position operate the injection pump at about 200 rpm and make sure that the pressure gauge reading is 49 MPa 500 kgf cm2 or more All the time lightly move the control rack towards fuel increase side Replace the plunger if the pressure does not reach this value 3 Check to see th...

Page 98: ...compensator at R 9 0 mm air pressure in the boost air pipe is 0 MPa 0 kgf cm2 Fuel limiter released regulator at FULL position 2 Check the limit rack position of the boost compensator R 15 The pressure in the boost compensator piping line increased 0 ψ 0 2 MPa 0 ψ 2 kgf cm2 3 Make the following adjustment and air leakage check of the boost compensator piping under the air pressure of 0 2 MPa 2 kgf...

Page 99: ...E 6CXM GTE2 6CXM GTE 6CXM GTE2 6CXM GTE 6CXM GTE2 Ԙ 13 5 1425 1450 197 r 3 195 r 3 r 3 at 2850rpm at 2900rpm 5 350 10 㨪 20 r 15 㧙 11 7 1000 194 r 5 199 r 5 㧙 Reversed angleich 11 0 750 191 196 㧙㧙 12 4 1175 198 measure 㧙㧙 4 1600 1625 10 㨪 20 㧙 High idle 9 500 110 r 5 㧙㧙 10 200 190 r 10 㧙 Start Test condition Engine spec 6CXM GTE 6CXM GTE2 Nozzle holder ass y D27672 53100 D27672 53200 Model 6CXM ...

Page 100: ... 3 43 12 8 Adjusting points 1 11 9 4 Setting of injection q ty at start Setting of reduced injection q ty of boost compensator Adjusting of rated injection q ty Adjusting of stroke of reversed Angleich ...

Page 101: ...ure in the lower cham ber becomes negative As to the check valve in the upper chamber right vale is closed and left valve is opened Thus the fuel is delivered to the outlet As the pressure in the lower chamber is negative left valve in the lower chamber is closed and right valve is opened and then fuel flows into the lower chamber When piston moves downward the pressure in the lower chamber rises ...

Page 102: ...feed pump body the whole fuel pump body must be replaced 6 Clean the filter screen in cleaning solvent and check it for damage or clogging Replace it if damaged 3 11 14 Assembly of fuel feed pump Assemble in the reverse order of disassembly 3 11 15 Inspection after assembly 1 Air leak test Inspect the air tightness of each pipe and packing etc Especially check the inlet side because air is likely ...

Page 103: ...e B is tightened completely Tighten the valve A so that the pressure gauge indicator does not move when the pres sure is applied Replace the piston spring if it is defective 4 Delivery volume test Operate the fuel injection pump at the specified rpm open valve B until the pressure gauge indicator shows 0 098 MPa 1kgf cm2 and measure the delivery rate for one minute Suction head 1 m Within 25 strok...

Page 104: ...auto matically as follows When the speed is increased the fly weight expands outward from the fly weight holder under centrifugal force The roller installed on the fly weight moves outward along the guide cam while compressing the timer spring Because the guide cam is connected directly to the camshaft the camshaft rotates only as far as the timer spring has been compressed and injection timing is...

Page 105: ...ws and degeneration 4 Assembly 1 Clean all parts in cleaning solvent 2 Install the weights and rollers in the timer case 3 Install the spacers and timer case cover and tighten the cover with two bolts 5 Installation 1 Install the timer on the camshaft of the injection pump by aligning the key groove with the key 2 Tighten the timer with the cap nut through the spring washer and packing 3 Fill the ...

Page 106: ...ed down by the nozzle spring and closed after fuel is injected Oil that leaks from between the nozzle valve and nozzle body goes from the hole on top of the nozzle spring through the oil leakage fitting and back into the fuel tank Adjustment of injection starting pressure is effected with the adjustment bolt 2 Nozzle specifications Engine model 6CXM GTE 6CXM GTE2 Type Semi long type hole nozzle No...

Page 107: ...t 6 Fit the fuel injection valve puller tool Place the foot of the support bolt on the plane making an right angle to the fuel injection valve 7 Adjust the foot length so that the puller tool body makes a right angle to the fuel injection valve and a distance of about 20 mm is ensured for the injection valve 8 Apply lube oil to the puller bolt and screw it to the return oil joint bolt hole of the ...

Page 108: ...he body and released Rotate the nozzle a little and try again Replace the nozzle as a set if there are some places where it does not slide smoothly 7 Reassembly of fuel injection nozzle 1 Install the fuel injection nozzle B 2 Install the fuel injection pipe joint to the fuel injection nozzle B together with the rubber packing E 3 Tighten the nozzle tightening nut C 4 Tighten the fuel injection pip...

Page 109: ...m the fuel tank are removed 2 Replacement of filter element Replace the element every 250 hours of use Replace the element even before the provided time if the filter interior is contaminated or damaged If there is water or sediment inside the filter wash it in clean oil and remove dust and rust completely Draining of filter Every 50 hours of use Filter element Every 250 hours of use Part No of el...

Page 110: ...t is clogged 5 Air is sucked into the fuel due to defective connections in the pip ing from the fuel tank to fuel feed pump 6 Defective valve contact of feed pump 7 Piston spring of feed pump is broken 8 Inter spindle or tappet of feed pump is stuck Supply Open Clean Replace element Repair Repair or replace Replace Repair or replace Nozzle does not work 1 Nozzle valve does not open or close normal...

Page 111: ...t 2 Uneven injection volume 3 Injection timing is defective 4 Plunger is worn and fuel injection adjustment is difficult 5 Governor spring is too weak 6 Feed pump can t feed oil at low speed 7 Fuel supply is insufficient at low speed due to clogging of fuel filter Repair or replace Repair Repair Inspect and adjust Adjust Adjust Replace Replace Repair or replace Disassemble and clean or replace ele...

Page 112: ...1 21 Tools Name of tool Shape Apprication Governor weight support extractor 721820 92580 Timer extractor 158591 54200 Spring set bar 121978 51610 Prestroke measuring device 155900 51350 Pressure gauge 155900 51500 ...

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