ContentsGEY1IS(AL OPERATION MANUAL CONTENTS | 16 Page No. 00 Basic Descriptions 01 Preface. 1M46623-00-012-00 02 Engine Specification M46623-00-022-00 M46623-00-02-00 08 Direction of Rotation M46623-00-032-00 04 Extemal and Sectional M46623-00-04a-00 05 Term & Symbol Marks 1M46623-00-05a-00 06 Precautions on Maintenance 1M46623-00-06a-00 07 Precautions prior to Maintenance & Servicing M46623-00-07a-00 08 Protective Device Setting Values M46623-00-08a-00 Holding Volumes of Lubricating Oil & Cooling Water Pressure & Temperature Setting Values 09 Assembly Adjustment Values M46623-00-09a-00 Clearance & Wear Limits of Major Parts 10 Table of Tightening Torques of Major Bolts & Nuts M46623-00-10a-00 11 Principal Dimensions & Mass for Disassembly & Servicing M46623-00-11a-00 1 SI Unit Conversion Table M46623-00-13a-00 14 Symbol Marks on Piping Layout & Instruments. M46623-00-14a-00 00 Operation 21 Operational Preparation M46623-00-21a-00 22 Starting M46623-00-22a-00 23 Running M46623-00-23a-00 24 Stopping M46623-00-24a-00 33 Data Sheet M46623-00-33a-00 00 Trouble shooting & Countermeasures 1M46623-00-41a-00 00 Fuel Oil, Lubricating Oil & Cooling Water 51 Quantiy Criteria of Fuel Oil 1M46623-00-51a-00 52 Calculation of CCAI M46623-00-52a-00 53 Quality Criteria of Blended Fuel Oil M46623-00-53a-00 54 Properties of Fuel Oil at the Engine Inlet M46623-00-54a-00 55 How to Find out the Heavy Fuel Oil Heating Temperature M46623-00-55a-00 oO 56 How to Find out the Viscosity of Blended Oil M46623-00-56a-00 58 Choosing of Lubricating Oil M46623-00-58a-00 59 Choosing of Lubricating Oil M46623-00-59a-00 60 List of Lubricating Oil Brands M46623-00-60a-00 62 Criteria on Cooling Fresh Water 1M48623-00-62a-00 63 Selection and Control of Corrosion Inhibitor M46623-00-63a-00 00 Measurement of Running Performance 91 Precat 1s on Measuring Performance & Measure Items M46623-00-91a-00 92 Measurement of Running Performance M46623-00-92a-00 93 Measurement of Max. Combustion Pressure M46623-00-93a-00 YANMARGEYIS\A)L OPERATION MANUAL CONTENTS Page No. 01 Cylinder Block & Cylinder Liner 01 Outline M46623-01-01-00 02 Overhauling the Cylinder Block M46623-01-02a-00 03 Overhauling the Cylinder Liner M46623-01-03a-00 1 Parts List of Cylinder Block Cylinder Block & Liner M46623-01-51-00 Cylinder Side Cover 1M46623-01-52a-00 Cylinder Side Cover (Relief Valve) M46623-01-53a-00 Cylinder Side Cover (Relief Valve) M46623-01-53b-00 Gear Case M46623-01-54a-00 Oil Sealing (SFW) M46623-01-56a-00 Breather Pipe M46623-01-57a-00 Pump Case Cover M46623-01-582-00 11 Cylinder Head & Its Accessories (01 Outline 46623-11-012-00 02 Overhauling the Cylinder Head 1M46623-11-022-00 03 Overhauling the Intake / Exhaust Valves 1M46623-11-032-00 (04 Overhauling the Intake / Exhaust Valve Seat 1M146623-11-042-00 (05 Overhauling the Intake / Exhaust Valve Guide M46623-11-052-00 06 Overhauling the Intake / Exhaust Valve Bridge & Guide M46623-11-062-00 07 Overhauling the Valve Rotator M46623-11-072-00 08 Adjusting the Intake / Exhaust Valve Head Clearance M46623-11-082-00 09 Overhauling the Nozzle Sleeve M46623-11-092-00 = Parts List of Cylinder Head Cylinder Head M46623-11-51a-00 Valve Arm Ass'y & Bonnet M46623-11-52a-00 Indicator Valve M46623-11-53a-00 44 Timing Gear, Camshaft & Intake / Exhaust Swing Arm 04 Outline 46623-14-012-00 02 Overhauling the Timing Gear M46623-14-024-00 03 Servicing the Camshaft 1M46623-14-032-00 (04 Servicing the Intake / Exhaust Swing Arm M46623-08-04a-00 m Parts List of Idle Gear M46623-14-512-00 Parts List of Camshaft M46623-14-522-00 48 Air Cooler, Exhaust Manifold & Turbocharger 01 Outline of Exhaust Manifold M46623-18-012-00 02 Outline of Air Cooler 46623-18-02-00 03 Charge-Air Heating Device (Option) M46623-18-03a-00 03 Adjusting of boost air temperature (Fresh water & sea water dual cooling system) M46623-18-03b-00 04 Overhauling the Exhaust Manifold M46623-18-042-00 Mitsubishi Exhaust Gas Turbocharger Model MET18SRC Instruction Manual Tz-EM18-0004 05 Turbocharger Blower Washing Procedure 46623-18-05a-00 ‘™ Parts List of Intercooler §M46623-18-51a-00 1 Parts List of Intercooler (Fresh water sea water dual cooling system) M46623-18-51b-00 m Parts List of Boost Air Pressure Switch Pipe & Pressure Gauge M46623-18-55a-00 2008.8.20R YANMARGEY1IS(AL OPERATION MANUA CONTENTS. Page No. = Parts List of Exhaust Gas Pipe Exhaust Gas Manifold M46623-18-57a-00 Exhaust Gas Manifold Cover 1M46623-18-59a-00 Exhaust Gas Outlet Pipe M46623-18-61a-00 Insulation Covering M46623-18-642-00 Turbine Inner Parts (MET18) M46623-18-66a-00 Blower & Turbine Washer M46623-18-68a-00 Air Duct (MET18) M46623-18-692-00 Blower & Turbine Washer Tools M46623-18-70a-00 21 Main Bearing & Crankshaft 01 Outline M46623-21-01a-00 02 Overhauling the Main Bearing M46623-21-02a-00 03 Overhauling the Crankshaft M46623-21-03a-00, 04 Measurement of Crankshaft Deflection M46623-21-04a-00 = Parts List of Main Metal M46623-21-51a-00 = Parts List of Crankshaft & Flywheel M46623-21-52a-00 = Paris List of Flywheel M46623-21-53a-00 22 Piston & Connecting Rods 01 Outline M46623-22-01a-00 02 Overhauling the Pistons, Pistons & Connecting Rods M46623-22-02a-00 = Parts List of Piston & Connecting Rod M46623-22-51a-00 30 Lubricating Oil System 01 Outline M46623-30-01a-00 02 Overhauling the Lubricating Oil Pump 1M46623-30-022-00 03 Adjusting & Overhauling the Pressure Regulating Valve M46623-30-03a-00 04 Adjusting & Checking the Thermostats. M46623-30-04a-00 06 Overhauling the Lubricating Oil Fiker M46623-30-06a-00 08 Overhauling the Lubricating Oil Cooler M46623-30-08a-00 (09 Cleaning of Lube Oil Bypass Strainer M46623-30-09a-00 09 Overhauling the Lubricating Oil Bypass Strainer (FM200DS Type) M46623-30-09b-00 @Q = Parts List of Lubricating Oil Pump: M46623-30-51a-00 1 Pars List of Lubricating Oil Priming Pump 1M46623-30-52a-00 = Parts List of Lubricating Oil Cooler M46623-30-532-00 = Parts List of Lubricating Oil Cooler(Fresh water sea water dual cooling system) M46623-30-53b-00 = Parts List of Lubricating Oil Pressure Regulating Valve M46623-30-54a-00 = Parts List of Lubricating Oil Strainer M46623-30-56a-00 m Parts List of Lubricating Oil By-pass Strainer (FM200DS Type) M46623-30-56b-00 = Parts List of Lubricating Oil Thermostat M46623-30-572-00 = Parts List of Lubricating Oil Pipe System (Pump ~ Cooler) M46623-30-58a-00 (Strainer OUT) M46623-30-59a-00 (Pressure regulating valve ~ Turbine) M46623-30-60a-00 (Priming) M46623-30-61a-00 L.O. Pressure Switch Pipe & Pressure Gauge M46623-30-62a-00 = Parts List of Dipstick M46623-30-70a-00 = Parts List of Lubricating Oil Pipe (Lubricate Pinion of Fuel Injection Pump) M46623-30-80a-00 = Parts List of Lubricating Oil Pipe (Generator) M46623-30-90a-00 2008.8.20R YANMARGEYISi\AL OPERATION MAN CONTENTS, 40 Cooling Water System ‘01 Outline (Two cooling water pumps are equipped on the cylinder block) 01 Outline (Fresh water & sea water dual cooling system) 02 Overhauling the Cooling Water (Fresh water) Pump 03 Overhauling the Cylinder Jacket Cooling Water Thermostatic Valve 04 Jacket Cooling Water Two-step Temperature Control Device 05 Check & Replacement of Anticorrosive Zinc (Fresh water & sea water dual cooling system) 06 Chemical cleaning procedure (Fresh water & sea water dual cooling system) 1 Parts List of Cooling Water Pipe System Cooling Water Pump (High Temp. Water) Cooling Water Pump (Low Temp. Water) Thermostat (High Temp. Water) Thermostat (High Temp. Water) Cooling Water Collecting Pipe Switch Valve (High Temp. Water) ‘Switch Valve (Low Temp. Water) By-Pass Valve (Low Temp. Water:sea water)(Manual operation) (Fresh water sea water dual cooling system) Cooling Water Pipe (High Temp. Water) (Pump ~ VC ~ Brock) Cooling Water Pipe (Low Temp. Water) (Pump ~ VC ~ L.O. Cooler) Cooling Water Pipe (Low Temp. Water : sea water) (Engine inlet ~ U/C ~ L.O. Cooler) (Fresh water sea water dual cooling system) Cooling Water Pipe (L.O. Cooler OUT) Cooling Water Pipe (Low Temp. Water : sea water) (Lubricating Oil Cooler OUT) (Fresh water sea water dual cooling system) Cooling Water Outlet / Inlet Pipe Cooling Water Outlet/inlet Pipe (Fresh water sea water dual cooling system) Cooling Water Drain Pipe (Cylinder) Air Vent Pipe (Air Cooler) & Water Drain Pipe (Boost Air Chamber) Pressure Switch & Pressure Gauge Cooling Water Pipe (By-pass & Warm Air) 50 Fuel Oil System 01 Outline 02 Overhauling the Fuel Oil Feed Pump 03 Adjusting the Fuel Oil Pressure 04 Overhauling the Fuel Injection pump 05 Regulation of the Fuel Injector Volume (Exhaust Gas Temperature) 06 Adjusting the Fuel Injection Timing 07 Agjustment of Fuel Injection Pump Pinion Lubricating Oil Flow Volume (for Engine Using H.F.O.) 08 Overhauling the Fuel Injection Pump Drive (09 Overhauling the Fuel Injector & Adjusting the injection Pressure 10 Overhauling the Fuel Oil Fiter 11 Maintenance and Inspection of the Fuel Oil Seal Pot Parts List of Fuel Injector 1 Paris List of Fue! Feed Pump (M.D.0.) m Parts List of Fuel Feed Pump (H.F.O.) = Parts List of Fue! Injection Pump (M.D.0.) = Parts List of Fuel Injection Pump (H.F.O.) = Parts List of Fuel Injection Pump Bracket | 46 Page No. 1M46623-40-01a-00 M46623-40-01b-00 M46623-40-02a-00 M46623-40-03a-00 M46623-40-04a-00 M46623-40-05a-00 M46623-40-06a-00 M46623-40-51a-00 M46623-40-52a-00 M46623-40-53a-00 M46623-40-54a-00 1M46623-40-55a-00 M46623-40-56a-00 M46623-40-57a-00 M46623-40-57b-00 M46623-40-592-00 M46623-40-612-00 M46623-40-61b-00 M46623-40-62a-00 M46623-40-62b-00 M46623-40-63a-00 M46623-40-63b-00 M46623-40-64a-00 M46623-40-652-00 M46623-40-66a-00 M46623-40-70a-00 M46623-50-012-00 M46623-50-02a-00 M46623-50-03a-00 M46623-50-04a-00 M46623-50-05a-00 M46623-50-06a-00 M46623-50-07a-00 M46623-50-08a-00 M46623-50-09a-00 M46623-50-10a-00 M46623-50-1112-00 M46623-50-51a-00 M46623-50-52a-00 M46623-50-53a-00 M46623-50-54a-00 M46623-50-55a-00 M46623-50-56a-00 2008.8,20R YANMAROY ea eae UC Lea Page CONTENTS 516 Page No 1 Parts List of Fuel injection Pipe M46623-50-57a-00 1m Parts List of Fuel Filter (M.D.0.) M46623-50-58a-00 1m Parts List of Fuel Filtor (H.F.O.) 1M46623-50-59a-00 1 Parts List of Fuel Pressure Regulating Valve & Overflow Fuel Tank M46623-50-602-00 m Parts List of Accumulator M46623-50-61a-00 1 Parts List of Fuel Oil Main Pipe Ma6623-50-702-00 = Parts List of Fuel Oil Pipe (M.D.0.) (Feed Pump Inlet / Outlet) M46623-50-71-00 = Parts List of Fuel Oil Pipe (H.F.O.) (Feed Pump Inlet/Outlet) M46623-50-722-00 ™ Pars List of Fuel Oil Pipe (M.D.O.) (Filter ~ Main Pipe) M46623-50-73a-00 1 Parts List of Fuel Oil Pipe (H.F.O.) (Filter ~ Main Pipe) M46623-50-742-00 1 Parts List of Fuel Oil Pipe (Main Pipe ~ Pressure Regulating Valve Retum) M46623-50-75a-00 = Parts List of Overflow Fuel Oil Pipe (Fuel Pump Case) M46623-50-762-00 1 Parts List of Fuel Oil leak defection Pipe M46623-50-72-00 1m Parts List of Drain Pipe & Overflow Fuel Oil Pipe (Engine Outlet) M46623-50-78a-00 1 Parts List of Overflow Fuel Oil Pipe from Fuel Injector (H.F.O.) M46623-50-792-00 = Parts List of Overflow Fuel Oil Pipe from Fuel Injector (M.D.O.) (Engine Outlet) M46623-50-802-00 1 Parts List of Fuel Filter Drain Pipe (M.D.0.) M46623-50-812-00 1m Parts List of Fuel Filter Drain Pipe (H.F.O.) M46623-50-822-00 60 Governor & Governor Gear 01 Outline M46623-60-012-00 NZ SERIES HYDRAULIC GOVERNOR (MODEL NZ61/NZ115) SERVICE MANUAL 0BNZ6-G00100 02 Overhauling the Governor Link (NZ Governor) M46623-60-02a-00 02 Overhauling the Governor Link (PSG Governor) M46623-60-02b-00 03 Overhauling the Governor Drive Unit M46623-60-03a-00 = Parts List of Hydraulic Governor M46623-60-51a-00 1 Parts List of Hydraulic Governor Driving Device (NZ) M46623-60-52a-00 1 Parts List of Hydraulic Governor Driving Device (PSG -1) M46623-60-52b-00 1 Parts List of Hydraulic Governor Driving Device (PSG -2) M46623-60-52c-00 1 Parts List of Governor Motor (With Limit Switch) M46623-60-53a-00 = Parts List of Governor Motor (Without Limit Switch) 1146623-60-54a-00 1 Parts List of Speed Relay M46623-60-55a-00 1 Parts List of Fuel Cut (Fuel Limit & Engine Stop) M46623-60-56a-00 1m Parts List of Governor Linkage M46623-60-57a-00 m Parts List of Start/Stop Handle M46623-60-58a-00 m= Parts List of Link A’ssy (NZ Governor) M46623-60-59a-00 1 Parts List of Link A’ssy (PSG Governor) 1M46623-60-59b-00 63 Control & Protective Devices 06 Maintenance of the Pressure Gauge M46623-63-06a-00 65 Special Attachments 03 Maintenance of the Electromagnetic Pickup M46623-65-03a-00 04 Maintenance of the Control Position Select Switch M46623-65-04a-00 05 Maintenance of the Turning Switch M46623-65-05a-00 06 Maintenance of the Start / Stop Lever interlock Switch 1M46623-65-06a-00 08 Maintenance of the Electromagnetic Stop Valve M46623-65-08a-00 09 Maintenance of the Air Filter 1M46623-65-09a-00 12 Servicing of Starting Time Fuel Control Air Piston & Stopping Al Piston M46623-65-12a-00 17 Maintenance of the Fuel Oil Float Switch M46623-65-17a-00 1 Parts List of Control Air Pipe (Cooling Water Switch Valve) 1M46623-65-51a-00 1 Paris List of Control Air Pipe (Fuel Cut) M46623-65-52a-00 2008.11.27R YANMARGEY1S\A)L_ OPERATION MAN CONTENTS Page No. = Parts List of Control Air Joint M46623-65-53a-00 m Parts List of Control Air Joint (High Temp. Water) M46623-65-542-00 Parts List of Control Air Joint (Low Temp. Water) 1M46623-65-55a-00 = Parts List of Control Air Joint (2 connect) (High / Low Temp. Water) M46623-65-56a-00 1 Parts List of Operation Place Change-over Switch M46623-65-61a-00 = Parts List of Start Switch M46623-65-62a-00 m Pars List of Magnetic Pick-up 1M46623-65-63a-00 = Parts List of Gauge Panel M46623-65-64a-00 Parts List of Bracket (Pressure Switch) M46623-65-71a-00 = Parts List of Pressure Switch & Test Valve (3 Connects) (L.O.) M46623-65-72a-00 = Parts List of Pressure Switch & Test Valve (Boost Air & Cooling Water) M46623-65-73a-00 = Parts List of Pressure Switch & Test Valve (Starting Air M46623-65-74a-00 = Parts List of Pressure Switch & Test Valve (Control Air) 1M46623-65-75a-00 = Parts List of Pressure Switch & Test Valve (Fuel Oil) M46623-65-76a-00 = Parts List of Temperature Switch M46623-65-77a-00 Parts List of Resistor CMP M46623-65-78a-00 m Parts List of Junction Box M46623-65-79a-00 1 Parts List of Thermometer M46623-65-80a-00 70 Starting Air System & Air Motor (01 Outline of the Main Components M46623-70-01a-00 02 Overhauling the Air Motor M46623-70-02a-00 INSTALLATION AND MAINTENANCE MANUAL 04578001 for SERIES 150T()P TURBINE-POWERED STARTERS Operation and Maintenance Manual for Series SRV125F Starter Relay Valve CCN 04579728 m Parts List of Air Starter 1M46623-70-51a-00 = Parts List of Starting Air Pipe M46623-70-52a-00 92 Hydraulic Jack 01 Outline of the Main Components M46623-92-01a-00 02 How to Use the Hydraulic Tools M46623-92-02a-00 03 Location Used & installation Method 1M46623-82-03a-00 = Parts List of Hydraulic Pump & Hydraulic Jack (Cylinder Head) M46623-92-51a-00 = Parts List of Hydraulic Pump & Hydraulic Jack (Main Bearing Cap) M46623-92-52a-00 = Parts List of Standard Tools M46623-92-61a-00 1 Parts List of Oil Drain Pan 1M46623-82-62a-00 m= Parts List of Special Tools: M46623-92-63a-00 Yanmar’s Worldwide Service Network 2008.11.27R YANMARete OPERATION MANUAL 46623 Basic Descriptions No. Page 00 pretece) o0-01a00 | 14 Thank you for purchasing a YANMAR Diesel Engine. ) 1, Foreword ‘This Operation Manual has been prepared for your safe and effective use of the engine. Read thorough this Operation Manual and fully understand the safety precautions and precautions regarding the operation, checking and servicing before using this engine. | (1) Keep this Operation Manual at a clearly identified place accessible for the operator to refer to it at any time (2) The text and illustrations of this Operation Manual may partly disagree with engines of some specifi- cations, For such engines, refer to the Engine Specifications and Final Drawings we have submitted you sep- arately. Also note that used parts and the contents of this Operation Manual description of this engine are changed without notifying the user before hand for improving the quality and performances of engine ot for safety. (3) For the following devices, refer to the corresponding operation manuals separately attached, ‘Attachments of special specifications. (4) In this manual, the numerical values are based on the SI system (International System of Units). (6) Replacement parts should be our genuine parts or specified parts. Order a part to your nearest sales cr service agent of Yanmar's parts. When ordering a part, clearly specify page number to which parts have been described, the Part Name (part description) and Part No, and the Model and manufac- ture’s Serial No, of the engine. (©) If you should have lost or damaged this Operation Manual, or if you have any questions and advice, please contact us or your nearest sales or service agent (shown in the service network list "YANMAR Worldwide Service Network" appended to this manual. (7) Ifyou transfer this engine, also transfer this Operation Manual, Final Drawings and Records of Shop Trial with the engine to the next owner, (8) If you use this engine for an application or under service condition other than those specified, or if you handle it not in accordance with this Operation Manual, an accident or a failure may be caused. Please contact us or your nearest sales or service agent before changing any technical data of the engine or modifying the engine after it has been delivered. Never modify the engine without consulting us. (8) If you find any obscure passages or have any doubts, feel free to make your inquiries to us or your nearest sales or service agent (shown in the service network list YANMAR Worldwide Service Net- work" appended to this manual) YANMARGEYIS\A\L OPERATION MANU. Ura) Basic Descriptions No. 00-012-00 C For safe use of your engine. Be sure to abide by as -marked DANGERs, WARNINGs and CAUTIONS described in this Manual. As far as safety is concerned, they are particularly important parts of instructions. ‘© The following shows the safety marks used for caution indications in this Operation Manual and © safety labels attached to this product and explains their meaning, the proper precautions is not followed. It indicates that there is a danger of resulting in death or serious injury when the proper precautions is not followed. It indicates that there is the possibility of resulting in injury or serious damage to the engine when an advice on safety handling or the proper precautions is not followed. ‘© Where the safety labels are posted is shown in page 00-06. 1 Tne cautions prafied wih the /'\, makin this Operation Menu are especialy npotant for safe handing of this product. A failure fo observe this caution may incur a deterioration of performances or trouble/accident of this product. Therefore, be sure to observe the items. YANMARar Vee ds ied Basic Descriptions No. [Page Preface oo-o1a-00 | 3/4 2. How to read the Manual Read this manual referring to the following descriptions. (10)This manual is composed according to the list of the "CONTENTS" page. (11)Each chapter has each page number and is arranged to match each user's specifications. 241. Title ‘Cylinder Block & Cylinder Liner No. 01 Outline oroteo0 | 11 © © ° The remarked items are the following explanations. Model name of engine ® Model No. of engine © Group code © Group name © Tile of the chapter © Chapter No. Peculiar No. of each chapter for each specifications @ Serial page No. of the chapter YANMARCee Vlas tea Meare Basic Descriptions No. rad 00-01-00 2-2. How to read the Parts List Read the parts list in this manual referring to the following items. (1) Illustration and referring number of the parts are shown at the first page. (2) The name and part number of the parts corresponding to the number in the first page are written in the table. (8) Explanations on the each item in the table are as follows. oY de edd ee he condo Ce LY LSE RRB EIE No. Page Ny EI o9 tha Parts List of Cylinder Blook ore ot ee PPP fF F Bh | UAW | 4-9 BABS Bh | me | No | Level | Order Part No. RE era Q'ty | Remarks 1 1 746623-0101 | YYy¥Joy7 ASSY BLOCK ASSY, CYLINDER | 1 2 | 2 |X | v46020-o1010 | ye IRYD BLOCK, CYLINDER 1 a | 3 | x | 146603-02090 | x3ue¥YICR—A___| CAP, WETAL BASE 5 © [3 |X | tassea-o2060 [250097 (AP, ETAL 6 5 | 3 46673-02070 | AL RAS RIT —_ | BOLT, NETAL CAP 14 é[3 146679-02000 | 94 FARE BOLT, SIDE 4 | OTitle Title is the name of the group that has most close relation with each chapter. Several parts belong to other chapter are also in the list as they could not be separated from main group. QNo. Number attached to the illustration in the first page @ Level Nominal parent-child relationship of the parts 1 : Parent parts (Assembly parts) 2: Child parts included in * 3: Child parts included in @ Order The parts marked" x "in this item cannot be supplied by itself as they cannot be treated separate from upper component. © Part No. Order the part by this number. OnaeK Japanese name Part Name English name ®aty Number of the parts per one engine Grand child paris in terms of "1" YANMARGEYIS\ALL OPERATION MANUAL Orr) Basic Descriptions 00 Engine Specification No. Page 00-02-00 | 1/2 4. Engine Specification Model Unit Gey aL Type = Vertical, water-cooled, 4-cycle diesel engine | ‘Combustion system = "Direct injection No. of cylinders = 6 7 Cylinder bore | mm 6180 _ Stroke mm | 280 Total cylinder displacement 275 [Compression ratio 157 a KW 400 | 450 500 550 615 kWe 360 | 400 450 500 560 Rated speed min! 7201750 Direction of rotation of crankshaft Counterclockwise as viewed from the flywheel side Operating side = On the left as viewed from the flywheel side (Order of fring = 1426351 Supercharging system - Exhaust gas (turbocharger) with air cooler ep i Freshwater & Freshwater mixing dual cooling system / Freshwater & Seawater dual cooling system (Option) Lubricating system Forced lubrication (system oil also used as turbocharger lub.cil) (system oil also used as rocker arm lub.oil) Lubricating oil sump system ‘Common Bed Incorporated Sump Starting system _ Air motor starting Overall fenath | mm Dimensions | Overallwidth | mm Refer to the Final Drawing Overall height | mm Mass (of engine singly) kg 2008.8.20R YANMAR00 GEY1S\A)L OPERATION MANU, Basic Descriptions Engine Specification LL} No, 00-02a-00 | 2/2 2, Types of Accessories & Attachments ‘Accessory/Attachment Type Remarks ‘Supercharger Air-cooled exhaust gas turbine Boost air cooler Plate finned multitubular Governor Hydraulic Fuel injection pump Bosch Independent per cylinder Fuel injector Non-cooled perforated Lub. oil pump Gear Pressure regulating valve integrated Lub. oil cooler Low finned tube multitubular wlautomatic temperature control valve | Lub. oil fter Polyester mesh element ‘Automatic backflushing Lub. oll bypass filter Centrifugal Option Spec. Cooling water pump Centrifugal Cylinder jacket side Starting air motor Turbine Compressed air “| YANMARt=) gti Basic Descriptions 00 Engine Specification OPERATION MANUAL CLE [00-02-00 | 12 1. Engine Specification Model Unit 6EYIGAL Type = Vertical, water-cooled, 4-cycle diesel engine ‘Combustion system = - Direct injection No. of ylinders 7 6 Cylinder bore mm #180 | Stroke mm ~ 280 Total cylinder displacement 5 42.75 a : ‘Compression rato aaa 157 xw | 455 | 500 | 550 | 615 | 660 | 680 | 745 | 800 Rated output kwe | 400 | 450 | 500 | 80 | 600 | 620 | 680 | 750 Rated speed rin! ~ 900/ 1000 Direction of rotation of erankshatt | _- Counterclockwise as viewed from the flywheel side Operating side = (On the left as viewed from the flywheel side ‘| (Order of firing _ 1-4-2636 7 Is r al Exhaust gas (turbocharger) with air cooler Cooting system ~ | “Frecmvatora Seawator dua song sate (Option) ~__Foroed lubrication Lubricating system ~ (system oil also used as turbocharger lub.il) (system cil also used as rocker arm lub.oil) Lubricating oil sump system = ‘Common Bed Incorporated Sump Starting system — Air motor starting Overalliengh | mm |) Dimensions [Overall width | _ mm Refer to the Final Drawing Overall height | mm Mass (of engine singly) kg 2008.8.20R YANMAR00 GEYISi\ALL OPERATION MANUA Basic Descriptions Engine Specification Cora No. Page 00-02b-00 2. Types of Accessories & Attachments ‘Accessory/Attachment Type Remarks. Supercharger Air-cooled exhaust gas turbine Boost air cooler Plate finned muttitubular Governor Hydraulic Fuel injection pump Bosch Independent per cylinder Fuel injector Non-cooled perforated Lub. oll pump Gear Pressure regulating valve integrated | Lub. oil cooler Low finned tube multitubular ‘wiautomatic temperature control valve Lub. oil iter 7 Polyester mesh element Automatic backflushing Lub. oil bypass fiter Centrifugal Option Spec Cooling water pump Centrifugal Cylinder jacket side Starting air motor Turbine Compressed air YANMARAD tI Sodas talise Miia cal Cred Basic Descriptions No. Page 00 Direction of Rotation 00-03a-00 4 Direction of rotation is counterclockwise as viewed from the flywheel side. ww Viewed from this side YANMARGEYIS/A\L OPERATION MANUAL Ud Basic Descriptions No, External and Sectional View ae 1, External View 1-1. Operation Side (Fuel Injection Pump Side) Fuel fer Fuel pressure control valve 4-2. Non-Operation Side (Exhaust Manifold Side) Lube oil tr (automatic back-washer typo) Lube ol temp. regulating valve Junetion box, Cooling wator pump Fuel feed pump Lube ol pressure regulating valve Lube ol cooler YANMARGEYIS‘\AL OPERATION MANU Urs Basic Descriptions No. External and Sectional View 00-04a-00 2. Sectional View 2-4. Sectional View of Longitudinal Fig, 0-04-1 Sectional View 9 M10 sass No. Part Name No. Part Name 1_ | Cylinder Block 11_| Bolt of Main Bearing 2 | Cylinder Head 12_ | Main Bearing a 3 | Suction Valve 13. | Thrust Bearing 4 _| Exhaust Valve 14 | Flywheel 8 _| Protection Ring 15 | Ring Gear 6 | Cylinder Liner 16 | Crank Gear 7_| Piston Pin 17_ | idle Gear ~ 8 | Crank Shaft 18 | Cam Gear 9_| Balance Weight 19 | Gear Case 10_| Cap of Main Bearing 20. [Fuel Ol! Injection Valve YANMARGEYIS\AL OPERATION MAN Basic Descriptions No. rx} External and Sectional View 00-04a-00 3. Cross Sectional View Rocker arm>——__ Valve bridge > ‘Exhaust manifold Fuel Injection Valve > Fuel injection pump Exhaust valve > eed _-——4 Boost chamber Cylinder liner isto ‘Swing arm shaft a {intake & exhaust) Cooling water passage Camshaft Lube oll passage Cylinder block ? 4 Connecting rod Crankshaft Pps} is Hwan bearing cap rf} _-—4 Balance weight | oO Side bolt 4 Main bearing bolt O O ‘Common Bed i= 4 ose ne YANMARGEYIS\A)L OPERATION MAN Basic Descriptions ered No. Term & Symbol Marks ae 1)The major terms used in this Operation Manual are defined as follows: Front part of engine: Part opposite to the flywheel end Rear part of engine: Part on the flywheel end Operation side: Left side as viewed form the flywheel end (fuel injection pump side) Non-operation side: Right side as viewed from the flywheel end (exhaust manifold side) (CW rotation: Clockwise rotation as viewed from the flywheel end CCW rotation: Counterclockwise rotation as viewed from the flywheel end Cylinder No: Assigned in the ascending order from the cylinder nearest to the flywheel end [Non-operation Side EEREEH O0000@ Fiywneet Q, eel L ue Injection Pump ai Operation Side ose 2) The following symbol marks are used in the safety labels shown in this Operation Manual and posted on the engine. (1) Caution marks and signal words It indicates that a danger of possible death or serious injury great when the proper precautions is not followed. very It indicates that there is a danger of resulting in death or serious \jury when the proper precautions is not followed. It indicates that there is the possibility of resulting in injury or ser ‘ous damage to the engine when an advice on safety handling or the proper precautions is not followed. CAUTION iil > It indicates a handing caution which, if not observed, may incur a deterioration of performance or a trouble/accident of this product. (2) Symbol marks (@) Caution marks Caution Caution on Ké Caution on on explosion rotating part -4| high pressure oi “di , Caution on Ml) 2800 entre high trnperatre (0) oth- Caution on Refer to another page, or hazardous 2 ae chapter of this Operation noise Z igh pr [=] Manual or other document YANMARGEYISIAL OPERATION MANUAL eo oo | ese Daceretons : No. Page Precautions on Maintenance eae 1. Basic Precautions Strict Observance of the Safety Rules + When running the engine or servicing it for its maintenance, observe the safety rules, precautions on safety and work procedures. + When carrying out a joint work, work according to the predeter- mined signs, Way of pre-work arrangement (1) According to kind of work required (2) Everyone to contemplate and consider (3) Everyone to understand well (4) Fix the most suitable way to work + Wear the proper protective garment. Don't wear oil smudged work clothes because they are prone to catch fire. + Wear protectors such as helmet, safety goggles, safety shoes, protective mask, protective glove, life-iine, etc., depending on the nature of work required (1) Safety has priority over all the works. (2) Safety is more impor tant than any other duties. (3) It is needless to say that "Safety First” means that safety has priority over working efficiency. (4) Safety is the foundation + When working on the engine, use the specified engine for working efficiency. tools. Use jigs or tools suitable for particular work because Safety is never contra- Use of a wrong tool causes an injury. dictory to working eff ciency. + While at work, do not jump on and off the engine. + For working, install a work bench fitted to the size of your engine to secure a good footing. Don't work In a dangerous position YANMARGEY18\AL OPERATION MANUAL Basic Descriptions Precautions on Maintenance 00 ~— AXcarmon ification, Please. + When you want fo modify your engine, consult us or your nearest sales or service agent in advance. Yanmar can not be responsible for an acci- dent resulting in injury or death or an engine trouble resulted from unau- thorized modification. + Your engine and its safety devices have been sealed for the sake of safety. Don't break or tamper with a seal indiscreetly. + If a sealing is missing, take a proper step of promptly contacting us or your nearest sales or service agent for ensuring the proper initial set- ting, Z|\ WARNING | Observe the precautions for ensuring safety. Check of Safety Devices + Check the all the safety devices of your engine have been set normalh + Ifa safety device is wrongly used, it leads to a serious accident resulting in injury or death. + Promptly repair a cover a rotating part, a heat shielding cover for exhaust pipe, a protective cover of the heating region or the like, if found damaged. "+ Never run the engine while the cover of a rotating partis removed. Otherwise dur- (ZQwmmme) ing operation, your hand, body or clothing may be caught in the rotating part, result- ing in your injury. ° ¥ (A\cauron)} ‘Be Cautious of Handling of a High-temperature or High-pressure Spot. —Take care not to get burnt. — + During running and immediately after the engine has stopped, the whole engine is heated. Take care not to get bumt. ‘cumen’) * When changing cooling water, lubricating oil or iter immediately after the engine has (Gewnor) stopped, proceed to work only after the temperature has lowered. / + Do not touch a high-temperature region such as the exhaust pipe or pressure indicator cock of engine with bare hands. WEG} - Do not touch the heater and heated sections of fuel cl system with bare hands. * Since the pressure indicator becomes hot, be sure to wear gloves when taking read- ing + you uncap the radiator or fresh water tank, vapor or hot water may blow up, causing you to get burt, + Stop the engine and wait until the temperature has dropped. Then, wrap the cap with lth and slowly loosen itt release the internal pressure. After thal, remove the cap YANMARGEYIS\A\L OPERATION MAN Basic Descriptions No. Page 00 Precautions on M 00-06a-00 | 3/6 Z{\DANGER | Be Cautious of Handling of Fuel & Lubri 19 Oil. ; + If fire is brought close to fuel andlor lubricating oll, there is the possibility of catching fire. (Particularly the fuel is highly flammable and dangerous.) GL,| Fire should be strictly prohibited in the engine installed place (engine room). + Check for leak of fuel oil and lubricating oil If you find a defective point, repair it and ipe out leaked fuel or lubricating oil. + Store the fuel oil and lubricating oil at the specified place and do not allow persons other than those concerned to handle them. + Unnecessary flammables in the engine installed place (engine room) may cause fire. Therefore, store these flammables in another specified place. TATION; ALANABLES Ventilate Well. + Exhaust gas emitted from an engine is dangerous. Venta well to prevent gas intxication. + If Exhaust gas is leading, prompily repair such a leaking [<>] point atthe exhaust pipe | > aa = Ventilate well the indoor engine installed place (and/or the a ro =p engine room.) me + Take care that the room does not fall short of the air (oxy- ag (t= a gen) because the turbocharger takes in a great volume of | & ¢ ) tt air. fi uP + While charging the battery, there is danger of S catching fire because hydrogen gas is gen- _* Inhaling exhaust gas is very dangerous. When working indoors, suficiently ae ventilate the room, Installing of a Fire Extinguisher and First-aid Kit FIRE + Install a fire extinguisher against a possible fire, and check how to use BTINGLISHER it + Fix a safekeeping place for a first-aid kit, and install it there, + Fix the actions to be taken when fire or an accident has occurred. + Establish a means of reporting to emergency medical institution such ‘as an emergency hospital, and have its telephone number written down. YANMARGEY1IS\A)\L OPERATION MANU. Ura) Basic Descriptions Precautions on Maintenance 2. Engine Lifting Procedures + Select the wire and shackle with the sufficient capacities to lift the gen.set. + Adjust the wire length correctly so that the gen.set will not tilt when lifted. + Place wooden blocks, etc. to the positions where the wire contacts the gen.set or driven equipment. + Choose such a cushioning material as will not be damaged not removed during lifting, then attach it not be allow its contacts with the engine or driven machine to be damaged. * Do not enter under the lifted gen.set. Common bed set 1) When lifting the engine and generator, ft by the iting fixtures installed to the common bed floar, (see fig. below). 2) In order not to cause the wire to contact the engine, use the lifting balance as shown below. MIN. 1050, ‘more than 8.5m MIN-2800 15 Generator set masses ~ 750 kWe : 11400 kg ~ 615 kWe : 10800 kg YANMARGEYIS\A\L OPERATION MANU ES Basic Descriptions No. Precautions on Maintenance Page 00-06a-00 | 5/6 00 3. Putting position of Safety Labels This page shows where safety labels are posted for safety use of this engine. Carefully read the cautions shown on the safety labels to prevent accidents. If any safety label is stained, damaged or lost, order it to your nearest Yanmar sales or service agent (shown in the service network list "YANMAR Worldwide Service” appended to this manual) by clearly specifying its Part No., and post it. No. Part No. Part Description ay ® 71616-07200 Safety Labal, waming on blow-by explosion | 4 @ 41616-07210 | Safety Label, waming on rotating part 1 ® 41616-07220 Safety Label, high temp. caution 2 ® | 141616-07230 ‘Safety Label, handling caution | © 141616-07240 | Safety Label, handling caution _ 2 © 46673-07230 Safely Label, high press. air caution 1 | 46673-92740 Safely Label, high press. oll caution 1 YANMARGEYIS\AJL OPERATION MANU Basic Descriptions No. Precautions on Maintenance ered 00-06a-00 4, Safety Labels ® Az zB CAUTION a YANMAl poem (VANMAR essen) —— [Axe corres AE caution a ace [are aanenn ih pressure ol | esis stres acne. | cn esse am mane tea score am YANMARGEYISiIA\L OPERATION MAN LAs Basic Descriptions No. Page 00 Precautions prior to Maintenance & Servicing 00-072-00 aa 1. Precautions Prior to Maintenance Servicing Indication of Warnings in Checking and Servicing * While checking and/or maintenance servicing the engine, post a notice on ‘a waming indicating board for danger prevention. + Strive for safety, maintaining a close contact with the respective parties concerned. + Strive to prevent a danger from emerging, forbidding other than the parties concerned to enter the engine installed place (and/or the engine room), for instance. Immediately After an Engine Stop + Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine. Otherwise, entry of external air may result in explosion. Take care not to get burnt. + Immediately after the engine has stopped, the whole engine is heated. Therefore, take care not to get burnt. ‘Take care not to allow your hands, body and clothing to make contact with the turbo- charger, exhaust manifold, exhaust pipe and engine as a whole. + If you attempt to drain oil while the engine is still hot, take care not to get burnt with splash of ol. + If you disassemble the cooling water system while the engine is still hot, vapor or hot water may blow out, causing you to get bumt. + Wait until the engine becomes cool, then wrap the disassembling part with cloth or the like and slowly loosen it. YANMARGEY1IS\AL OPERATION MANU LTA Basic Descriptions Precautions prior to Maintenance & Servicing No. 00 00-07a-00 Preparation Prior to Working + Since a working area will be stained/smudged, put it in good order. + Prepare engine jigs and tools ready to use + Prepare oil, genuine parts, waste cloth, wire, etc, according to the nature of work to be done. + Secure a work bench fited to the height of the engine. Use prohibition standard of wire rope Check the wire rope well before using it. Do not use the wire rope in the following cases. Disconnection of wire Wear Kink Transformation End pies is abnormal YANMARGEYIS\A OPERATION MANUAL CT xE Basic Descriptions No. Page 00 | Precautions prior to Maintenance & Servicing |. oo-cre-00 | aitz lent may occur if the safety rules are not followed. 2. Precautions During Maintenance Ser ing Check in Course of Work + For a joint work strive for elimination of a possible danger by keeping alert to the surroundings. + Tie such an accessory detached in work to a stable post or spot so that it will not fall down: operation + For a work at a height, put on the safety belt or lifeine. + According to the condition of working, wear protectors. + Be careful of oil stained or smudged protective glove because working with such a glove might lead to a damage of parts or a personal injury as your hands are apt to slip. + Wipe off or mop up spilled fuel or oil at once because, if eft alone, itis dangerous as it causes a slip. + Prepare a box to accommodate removed parts in advance so that they will not be lost nor damaged. + Ifnecessary, provide setting marks before disassembling the engine so that you can reassemble it in the proper reassembling sequence. + Reassemble the setting marked portions with reference to the setting marks. + Tighten the bolts and nuts to the specified torque or hydraulic pressure. Use of the Proper Tools + Use the specified engine tools to prevent the damage of the respective bolts and nuts of the engine. + When handling a heavy thing, follow the slingers instructions. + In advance of using exclusive tools, check the function of these tools. + Carefully check for any damages to rubber hose and joints of hydraulic jacks. + Use the specified ling gear, hook, rope, ete.; and pay attention to safety when handling a heavy thing particulanly Precautions in Use of Fire (immaar) *1" Such works with welder, electical tools and ve and Flam grinder, be careful of sparking. rou Mabie, Since there is the possibilty of catching fre, OO GLj,| 77 not to leave combustibles such as fuel, lubricating oil and used waste cloth in a work ing area. 33) AX) YANMARGEYISIA\L OPERATION MANU. Basic Descriptions Precautions prior to Maintenance & Servicing Errore} No. 00-07-00 JARNING | Observe the precautions for ensuring safety. DANGER il Precautions in Checking the Electrical System ; + Shut off the power supply before starting the work. Otherwise, a fire may occur or you 7Kownasn ] ower supply ) . y ye (Ayana may receive electric shock. + When checking the battery system, be sure to disconnect the earth cable HLj,| — Oterminal. Otherwise, the negative terminal may be short-circuited by mistake, resulting i in fire + The strong acid battery electrolyte put on your skin or eyes will cause inflammation. If the battery electrolyte should be put on your skin or eyes, immediately flush it with fresh water, then consult a physician. Precautions for Using Organic Solvent + Since an organic solvent is highly volatile, liable to be gasified and absorbed by worker through breathing as it vaporized, pay close attention to ventilation when handling it + Since a highly concentrated organic solvent has the property of dissolving fats and oils and is absorbed is + When working with such a solvent, be sure to wear rubber gloves. 3, Precautions at Completion of Maintenance Servicing Check of Work Finish’ + Check if detached parts have been refitted at the specified spots in the total num- ber. + Check if the damaged parts have been replaced with the good ones. + Retum tools, lifting gear, hook, rope, etc. used to the former safekeeping place. + Remove fuel and oil from the engine installed place (and/or the engine room). + Keep the engine installed place (and/or the engine room) in order and tidy so that it wll not interfere with daily operation. + Before starting the engine, check various parts to see if there is no abnormality Refer back to 3-2. Precautions on Operation, (1) Prior to Starting of the Engine. + Proceed t a load run, and check that the performance does not differ from that existed prior to the maintenance servicing, Refer back to 3-2. Precautions on Operation, (2) During a Run + As soon as a load run is completed, enter records of performance as well as the nature of maintenance servicing in your Engine Log. (Keeping of records and then reporting of work completion) YANMARrs qo £3 gti Basic Descriptions Precautions prior to Maintenance & Servicing OPERATION MANUAL OT xe No, Page 00 512 00-07-00 4, Precautions in Maintenance Checking To use an engine always in good order, checking is necessary for trouble prevention. The period of checking can not be fixed indiscriminately it is influenced by application of the engine, conditions of use, quality of fuel oil and lub. oll used, and daily handling circumstance. LS + The following tables of checking show the standard checking frequency. Perform the initial overhaul servicing to these checking tables. Then, based on the obtained checking (on wear corrosion, accumu- lation of carbon, accumulation of sludge and others), make the most economical checking schedule suitable for your engine, and conform to the specified schedule from the second checking, + As for the items whose checking frequency is shown by the accumulated operation hours and number of days, schedule the checking at the earler timing, Table 1. Table of Routine Maintenance Checking Nature of Work’ Checking Area Monthi Daily Weekly (or 300 ~ s00hrs) ‘Starting air tank Pressure check Draining Checking & lubrication Governor Goy. oil volume check of linkage system Check on rack scale position Fuel injection pump 1 Check on pinion lubricating volume Fuel ol filter Back-washing (blow off) | Overhaul cleaning Injection timing ‘Check on looseness of adjusting bolt lock nuts Lub. oil Tank (Common Bod) Oil volume check * 2 Lub. oil bypass strainer Overhaul cleaning Lub. Oil System Check on leak from Cooling water pump mechanical seal 1 For Heavy Fuel Oil Spec * 2 Option 2008.3.12R YANMARBasic Descriptions 00 GEYIS\AL OPERATION MANUA Precautions prior to Maintenance & Servi Mee No, Page 00-07a-00 | 6/12 Nature of Work Checking Area Monthly cae ee (0r 300 ~ 500hrs) Precfter washing Turbocharger Blower washing Electric Check that electrical Wiring wiring is fastened firmly Starting air motor Check that no air leaks Air pipes from the air pipe and the joint. ‘| Each pressure Check on defective 2 | gauge indication E 5 5 & | Each thermometer | Check on defective z indication ‘Check on the loose- Engine appearance ness of bolts & nuts Each pipe system Check on leakage YANMARGEYIS\A\L OPERATION MANUAL CE Basic Descriptions No. Page 00 ii Precautions prior to Maintenance & Servicing | go.o73.00 | 712 Table 2. Checking Table for Engine Using Marine Diesel Oil (M.D.O.) (1/3) ‘An asterisk (") given in the following tables refers to the timing of intial check after the initial start or part replacement. Perform the check from the second time and onward at the ordinary frequency. Checking & Sani tng Froquoncy (ie) alglsiEls ys |ParttoBe i T(s{elr 8 2 epee Nature of Service blaltlale BSS] EE ele| Ziel zl2/s/2 5/s]=|7/ S| Fuel injector | Drawing-out check & adjustment 100 “e:500~ 200m Check & adjustment ofthe valve head Gearance o 3 Check of valve spring £ Check disassembly & check of valve rolaior ifnecessary 8 Disassembly, check & cleanit 2 | cylinder head a a) S 5 Grinding of suc Jehx. valve seat oO ‘Seale cleaning & hydraulic test of water chamber ° Replacement of stem seal (SucJEhx. Valve) © heck of Gy. head bolt ightening force =| lo Drawing-out, cleaning, checking & meas ° 7 | Piston ‘Check & measurement of piston rings ° | ‘Check & measurement of piston pin oO ‘Check & measurement of piston pin metal © connecting rog [oReek measurement of erenkcpin metal © necting Od |r eck of connecting rod bolt tightening angie Oly [change of connecting rod bats 20000 fre i Taner dia. checking, cleaning & measurement ° Ale Drawing-out, check & cleaning of wator Jacket part © o [Measurement of crank pin outer dia. & journal ° § [Crankshaft [Measurement & adjustment of deflection “| Jol- - 2 ‘assombly, metal checking & measurement © B |Main bearing [Check on ightening force of main bearing clamping bots ° (Check on lightening torque of side bolt ° (Check of cam & roller bearing © Disassombly & check of fuel pump tappet Camshat y a 2 Disassembly, check & measurement of swing arm ° Drawing-outoferankshat & bearing check & measurement ° = (Gheck of tooth bearing & backlash ° ‘Timing gear | Disassombiy fico goar & check & measuremant of bearing °o (Chock of dle gear mounted shaft tightening torque ° YANMAR00 GEY1S(\A\L OPERATION MANUAL Basic Descriptions Precautions prior to Maintenance & Servicing No, 00-072-00 ra) Page ent2 Table 2. Checking Table for Engine Using Marine Diesel Oil (M.D.0.) (2/3) (Checking Servicing yee (hrs) _| a)8]s) 2/8 Part to Be patos 2 22 Forney Nature of Service alglglalé ala|| 7/5) £ Check of tooth bearing & backlash °. E |Lub. oil pump, P| & cold water 3 |pump driving Disassembly, check & measurement of bearing ° 3 | intermediate — 5 gear. s Check of gear mounted shaft tightening torque ° E ‘Change of hydraulic uid *|o $ | Governor 2 Disassembly & check 3 & Governor driv- 8 \ino gear Disassembly & check of tooth bearing & bearing ° E ‘Check of injection timing ° ‘st time: 300 - 500 iweten ‘Check of deflector & replacement ° 2 Disassembly, cleaning & check ° 5 2 Disassembly & Check 3 | Fuel feed pump uv 7 | & Replacement of oll seal ° a Change (depended on results of property 5 analysis) Lub. oll cooler | Disassembly, check, cleaning & hydraulic test ° Thermostatic |, ee Disassembly, check & cleaning ° g Disassembly, check & measurement ° 3 |Lub. oil pump [Disassembly & check of pres. reg. valve & a @ safety valve 5 | Press. regutation : 7 4 |tere Disassembly, check & cleaning ° ‘Check of fter candle Olevery 4 yr. Replacement of fiter candle io every 6 yr Lub. ol iter - worm gear, turbine, Check of rotation ° Tania Replacement of O-ring ‘At overhaul 2008.2.20R YANMAR1 gt OPERATION MANUAL Tee Basic Descriptions No. Page 00 | Precautions prior to Maintenance & Servicing | oy.g74.09 | 9/12 Table 2. Checking Table for Engine Using Marine Diesel Oil (M.D.0.) (3/3) Ghecking Servicing Gyete ta) 8/8)/8/e/= B | Part to Be Checked Nature of Service Ryze ale Beles eye Ble] slo]2 ola|=|2/5 Thermostatic valve _ | Disassembly, check & cleaning ° 5 | cool Disassembly, check & measurement ° ©) |B | ccoting water pump = & Replacement of mechanical seal ° B | Fresh water cooler | Disassembly, check, cleaning & hydraulic test ° eee Change 2 | Fresh water) (depended on results of property analysis) ell 6 | Sea water | ame Check of anticorrosive zine & replacement | © § | starting airmotor | Disassemble and clean the ar fiter ° & | FO.conirol & siop air 3 [fison Replacement of O-ring Turbocharger Disassembly & cleaning c | Disassembly, check, cleaning & hydraulic ° z test 7 Engine tachometer _ | Calibration of indication ° ‘Aiarm switch ‘Actuation test _[o YANMAR00 GEY18\AL OPERATION MANUA Basic Descriptions Precautions prior to Mi Wea] Page 10/12 Table 3. Checking Table for Engine Using Heavy Fuel Oil (1/3) Ls ‘An asterisk (*) given in the following tables refers to the timing of intial check after the initial start or part replacement. Perform the check from the second time and onward at the ordinary frequency. Div. Part to Be Checked Nature of Service Checking & Servic: ing Frequency (hs.) ‘3m, oF 1,000 ~ 1500 ‘mo 2,000 ~ 2.500 Tyror4000 ~ 000, 2~ 8 yor 8000 ~ 10,000 5 yor 16000 ~ 20000 Fuel injector Drawing-out check & adjustment v 38 ‘et tine:S00~a00hr ‘Cylinder head ‘Check & adjustment of the valve head clearance ° ‘Check of valve spring lo (Check disassembly & check of valve rotator necessary Disassembly, check & cleaning (Grinding of suc fohx. valve seat Soale cleaning & hydraulic test of water chamber Replacement of stem seal (Suc /Ehx. Valve) Check of cyl. head bolt tightening force Major Moving Parts Piston Drawing-out, cleaning, checking & measurement of piston (Ghack & measurement of piston rings Check & measurement of piston pin Connecting rod Chack & measurement of piston pin metal ‘Check & measurement of crank-pin metal Check of connecting rod bolt tightening angie ‘o[o[ofo[o[o[o[ojofofo ‘Change of connecting rod bolts [20,000 hrs. yh liner inner dia, checking, cleaning & measurement 9! ‘Drawing-out, check & cleaning of water jacket part (Crankshaft Measurement of crank pin outer dia. & journal ° Measurement & adjustment of deflection Main bearing Disassembly, metal checking & measurement Ghack on lightening force of main bearing clamping bolts ‘Check on tightening torque of side bolt ololo Camshaft (Ghack of cam & roller Bearing Disassembly & check of fuel pump tappet Disassembly, check & measurement of swing arm Drawing-ut of crankshaf & bearing check & measurement Timing gear ‘Check of tooth bearing & backlash Disassembly of de gear & check & measurement of bearing (Check of idle gear mounted shaft tightening torqueC=) at ry OPERATION MANUAL ee Basic Descriptions No. Page 00 i i i ici Precautions prior to Maintenance & Servicing | ooraan | «tz Table 3. Checking Table for Engine Using Heavy Fuel Oil (2/3) T ‘Checking Servicing | yde (ts) 8)/8/g|2\8 3 [Part to Be Tie lei2|s Sees Nature of Service alalgials | Bele ele | g/ 2] s|2 5] slsl=|7|s g| Check of tooth bearing & backlash ° & |Lub. oil pump, 2 |& cold water 3 |pump driving | Disassembly, check & measurement of bearing ° & |intermediate a 5 | gear. s Check of gear mounted shaft tightening torque ° Change of hydraulic uid + § |covemor ‘ange of hydraulic ful ° a Disassembly & check oO @ (Govemor driv- & |ing gear Disassembly & check of tooth bearing & bearing ° : Check of injection timing ° ‘st time: 800 - 500 . fueeston heck of deflector & replacement ° 5 Disassembly, cleaning & check ° a Disassembly & Check ° é & [Fuel feed Pump Replacement of oll seal ° 'B | Pressure gause | Check on filling of ethylene glycot oO | * | seal pot Change of ethylene glycol ° ‘Accumulator [Change of accumulator (© [Option Change (depended on results of property oe analysis) e Lub. oil cooler _[Disassembly, check, cleaning & hydraulic test ° Thermostatic |, a Disassembly, check & cleaning ° 5 Disassembly, check & measurement ° & |Lub. oil pump [Disassembly & check of pres. reg. valve & @ safety valve ° 6 > Press. regutation |, ean § [rane Disassembly, check & cleaning jo Check of fiter candle [_[O]eveny2yr. Replacement of fier candi (0) [every 4 yr. Lub. oil fitter —_ ~ |worm gear, turbine, Check of rotation oO} flushing arm Replacement of O-ring | [At overhaul 2008.2.20R YANMAR00 GEY1S\A\L OPERATION MANU. Basic Descriptions Precautions prior to Maintenance & Servicing rad Page 12/12 Table 3. Checking Table for Engine Using Heavy Fuel Oil (3/3) Checking Servicing Oyete (rs) #)8)/8/2/8 & | Part to Be Checked Nature of Service rjeyrjale glgls|/gle fls/2le/s elel Zale g}e|s|e]e els[-|T/e Thermostatic valve __| Disassembly, check & cleaning ° 5 - Disassembly, check & measurement O° | Cooling water pump & Replacement of mechanical seal ° 3 | Fresh water cooler _| Disassembly, check, cleaning & hydraulic test ° = | Cooling water ‘Change | fresh water) (depended on results of property analysis) 2 § | Starting air motor Disassemble and clean the air filter ° | FO control & stop air 3 | Giston Replacement of O-ring ° Turbocharger Disassembly & cleaning ° = eee eeee Disassembly, check, cleaning & hyraul 5 6 Engine tachometer _| Calibration of indication ° ‘Alarm switch ‘Actuation test ° YANMARGEYISIAIL OPERATION MANUAL rsd Basic Descriptions 00 ng te en ie (Holsieg ccoure & Tamperature Setting Vanes) 00-08-00 | 1 1. Protective Device Setting Values Tem Unit Alarm Setting Value | EmerStop Setting Value Engine lub.oil pressure MPa 0.34 | 0.29 Cooling water (fresh water) temperature *c 8 100 Rotatk oy 112 ~ 115% of the rated Rotational overspeed min = eed 2. Holding Volumes of Lubricating Oil and Cooling Water (Unit: item Holding Volume Remarks 3 | linclinside the cooler, iter & piping) B | Luboil tank (common bed) 1000 $ Type NZ61 13 $ | coveror a Type PSG 20 = | Cylinder jacket (fresh water) 90 2 | Oilcooler (included air cooler) & 6 (fresh water) 3. Pressure & Temperature Setting Values Tem Sattng Va Remar Fuel feed pressure 0.55 ~ 0.65 Heavy fuel oll (H.F.0.) | Maximum combustion pressure (Pmax) * net DD 2 [Lub ol pressure 040 = 085 4 | Cooing water pressure Gacket cooing ney] MPA 0150.40 & |Cooling water pressure (cooler cooling line) 0. 0.40 Staring air [Starting airtank 294 Lower mitt. 18 ressure [After decompression _oF=18 IA the air moior inet ooling water engine oulet temperature | [Cooling water air cooler inlet temperature Boiowsa | 8 lupo engine inattomporaturo —- & |{cooleroutet) lee 50788 _ 8 Jpnastiomperaure | Roterto Records af Stop |(ateach cylinder outlet) | ee Trial, Exh gas turbocharger inlet temp * a eee Note: (1) The numerical value is a standard value. There is a remark different depending on the specification. (2) Fora star (+ ) given above, refer to the Records of Shop Trial and enter the obtained value here because it varies according to the engine specification and output. YANMARGEYIS\A\L OPERATION MAN' eed Basic Descriptions Page 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts 116 1. Assembly Adjustment Values item ‘Agjustmont Value Remarks Piston top clearance (A) om 20202 Z| Open (before 7.0.6.) 50 = sje) og, - § | _ Close (atter 8.0.6) 50 & | Vaive head clearance (8) mm 03 Inthe cold state 2] Open (before B.0.C) - 8 S dog. 3 | Close (ter t0.0) 30 g | | Yeve ead carance @) mm 08 in the cold state 3 th 8 p 8 2 e ty & eat | Ct ii t | = | Adjust 8 ater | H / tating tf 20 Fuel injection pump begins to deliver % Refer to Records of Shop (before T.0.C) a a Trial Injection pressure, fuel injector MPa 34005 YANMARGEYIS\A)L OPERATION MANUAL Basic Descriptions errs) Page 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts 216 2. CLEARANCES & WEAR LIMITS OF MAJOR PART (Unit : mm) Dimension wa Max Usage Cresrance | Allowable La Sketch Normal | Tolerance | Assenbing | “Clear | fais! inner dia. of cylinder *p.029 aleeon parts = : a 0246 AN=DO7S 4 | A1=0.25 ‘Outer dia. of cylinder “0.075 a liner upper part 0.110 : Inner dia. of cylinder 40.029 middle part 0 |A2=0.020 = “018 $222 =O ba 4] A202 ‘Outer dia. of cylinder “0.020 aa liner middle part 0.065 3 [Inner dia. of cylinder 0.029 Pa | lower part 2a Lo B=0.015 B | Outer dia. of cylinder 0.015 ~ 0.088, an § {liner lower part 0.058 $ | Top clearance 20 |+0.20 |0=18~22 - E Jinner dia. of cyl. liner 5 + +08 & |upper part 6178 | £005 | 9 oo5 = 1.045] — Inner dof protection ras eons _ Inner dia. of cylinder +0.030 liner lower part $180 | “9 = 0.153 Outer i of pston ak er7esee| + 0015 oo & B | Radial thick. of piston 7 - & |rings, No.1 ~ No.2 Ge |e - * § | Radial thick. of ol ing F=50 | + 0.25 - = 4 & | YANMARGEY1S\A) OPERATION MANUAL TL Basic Descriptions No. Page 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts o0-09a-00 | 3/6 (Unit: mm) Dimension 3a] Wax Usage crarace | Algwable ci a Normal ] Tteranco | Arsaning |"Cleae | Umit Width of piston ring, 02 No.4 No.1 45 . = Width of piston ring eater eas groove, No.1 Width of piston Ang 2 No.2 No.2 TanEIE J 40 Gabe , | Width of piston ring = woe E | groove, No.2 § _ . ° § | Width of oil ring 0.2 § 6.0 He0.4 | width of oi ring groove 403 5 Jinner dia. of piston pin »\ fF i \{ soa7 metal | ‘o17648-00% ‘J=0.25 Outer aia. of piston pin “0.05 O75 (era oon ale Ee K=0.15, Outer dia. of piston pin 0.15 YANMARBasic Descriptions GEY1IS\AL OPERATION MANUAL No. 46623 Page trion, 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts 00-09-00 | 4/6 Inner dia. of crank pin 40.145 Bae bearing 0.080 L=0.080 ~0.170 A deflection Outer dia. of crank pin a weer of nner dia, of main bear- +0.189 ae ing +0.120 g 120 defiection| & | Outer dia. of erank jour- 0 o2t4 wear of & |nal 0.025 ot 5 - ot §|______ Width of datum part 0.140 yh main bearing -0:200 Width of datum part 0.030 a FP journal 0 ied Refer to 21-04 Measurement of Deflection — | Deffection, 3) Allowable defiec- YANMARGEYIS\A\L OPERATION MANUAL xd Basic Descriptions \ fae 00 ‘Assembly Adjustment Values Clearance & Wear Limits of Major Parts 00-092-00 | 56 (Unit: mm) Dimension Gees atic] us fearance | Alowable tem Sketen Normal | Tolerance | Assembing | "Clear ) ‘Pats’ ; — - + 7 | Outer dia. of intake nae | val =0.060 | pene __| on R1=0.060 | 24=9.32 |Thner dia. of intake valve = 0.104 ry | guide | ‘Chrome (Chrome-lted Outer ea. oF| pating aso0ss |R2sose | 0% oO exhaust 1250 58 [Re valve Nimonic ou a 0.35 inner dia. of exhaust R9°0.088 }R3=0.35 [Oe valve guide ~ 0.412 Inner dia. of valve +018 | bridge o14 2 S02 § [Outer dia. of valve ee ~ 0.052 aa | bridge guide ‘= | Margin thickness of in/ 7 'S |ex. valve poppet part \ eee 7 7 a g 7 va | Width of nex. valve u r leas = = aa seat 1 | Dia. ofinvex vaiveseat | Pt (oo | contact part ee - ie toes Qugr ds foto | [2.009 on shaft 7 Ff 40.034 | ya . 36 | _—__,W"0.028 || W=0.25 Inner dia. of rocker arm Ww [0.085 von bush +0.020 Inner dia, of swing arm |. __sgp 402 6) $40 |} 1. x=0.2 Outer dia. of swing arm x ee yy shaft nso YANMAR00 GEYIS\AIL OPERATION MANU Basic Descriptions Assembly Adjustment Values Dera} Page Clearance & Wear Limits of Major Parts 616 (Unit: me) Usage tom Limit Parts (Outer dia. of camshaft “0.17 datum part Inner dia. of camshaft 40.17 datum part bearing ™ 4 | Thickness of camshaft - & | datum part 2 | aot canchat rst = & | collar housing Outer dia. of camshaft “0.47 intermediate part Inner dia. of camshaft 40.17 intermediate part bearing ‘Outer dia. of lub. oil - ump shaft Inner dia, of ub. oll 40.18 q. [pump shaft bush B nner i of pump case = & | Outer dia. of pump gear = Width of pump case = Width of pump gear = Outer dia. of mpelier ry g [boss 5 é $ 5 | inner dia. of pump oa 2 |casing 6 Cuter dia. of pump shaft OA Inner dia. of pump shaft bush +04 Inner dia. of pump case Fuel Feed Pump Outer dia. of pump gear Width of pump case Width of pump gearGEY1IS(A\L OPERATION MANUAL CE Basic Descriptions No, Page 00 | Table of Tightening Torques of Major Bolt & Nuts 00-103-00 | 1/3 {ee} $$ Tighten the major bolts by the specified procedures. If tightened improperly, a personal injury or damage of device may be caused, Be cautious. (1) Unless otherwise specified, apply lub.oil on the thread and bearing surface, and then tightening a bolt or nut. (2) On the parts prefixed with a star ( + ) in the following tables, a match mark is stamped. However, when tightening any of these parts, do not refer to the match mark but tighten it to the specified torque, specified tightening angle or specified hydraulic pressure. 1. Hydraulic Pressure Clamping Bolt | Face-to-Face at Desrt | screwoin| “ramon | Seese vere | Sr Desctitin j Somme | wae of esse | Remats 2 (mm) +* Cylinder head tightening nut | M33 x 2.0 Round 58.8 0.5 1& Main bearing cap tightening nut | M33 x 2.0 Round 58.8 + 0.5 2. Angle Clamping Bolts Ls (1) Before tightening a connecting rod bolt, apply the Protec grease on its bearing surface and lub.oil on its thread. (2) Tighten a bolt to the seating tightening torque, then tighten it to the specified angle. | Face-to-Face | _Se2tng | Specified Part Deserpion Screw Dia. | T"waath of | Tihtening | Teahiening | emacs ich | Bolt/Nut (mm) na (don) + Connection rod bolt M25 x 15 | 32 49 120'8 Balance weight clamping bott | m24 x 2.0 | 32 49 20'9 YANMARGEYIS\AL OPERATION MANU. Basic Descriptions Table of Tightening Torques of Major Bolt & Nuts ora) No, 00-102-00 00 213 3, Other Major Bolts (Torque Tightening) Ls (1) Before tightening a flywheel clamping bolt or fuel injection valve nozzle sleeve, apply Protec grease on its thread and bearing surface. (2) Before tightening a camshaft coupling nut, apply seizure inhibitor (Three-Bond 1910 or its equivalent) on its thread and bearing surface. (3) The paris prefixed with an asterisk (*) in the following table are provided with an exclusive tool, respectively. (4) Be sure to tighten a part with @ torque wrench to the specified torque. Face-to-Face | "ahtening Pat Desorption serow ia] FARR | Terme | Remarks % Piteh | Bott (mm) | — Nem indicator cock lightening nut Miax 475] ‘19 59-69 Rocker arm shaft stand clamping bolt Migx15| 24 | 186-206 ‘ M22 x15; 187 = 167 [Engine Using MO. }+ Fuel inject ee aeientomee ao 15] 7 9°S [2a5~265][Engine Using HEO. Fuel injection valve guard tightening nut Miox45| 17 30-44 [Fuel injection valve case nut wzex15| 27 ‘(167176 | Fuel injection valve injection pressure regulating = oan was x15] 41 47-51 F Fu! injection pipe joint bolt e (on cyl. head side) MBX 1.25) (hex. socket) |_2° F Fuel injection pipe joint Bott 3 (on pump side) __|M10.x 45} (hex. socket) | 9% ad Fel injocon pump ightening nut Maxie] 19 74~ 88 FusT injection pump equalizing valve body clamp- 3 = ing bot M10 X 1.5] (hex. socket) | 547 5° Ful injection pump barrel retaining bolt M10 X 1.5] (hex, socket) | 54752 Fuel injection pump protector woxts| 27 ‘| 40-89 Fuel injection timing adjust bolt Tock nut waa x15 30 106~ 245 [Camshaft coupling rut M2425) 17 38~98 [Usut Tar | Tightening together with [Cam gear clamping bolt maxis] 19 [137~157| emerge idle gear shaft clamping bolt uisx15| 24 [170-180 [Cooling water pump impeller tightening nut Mig x15] 24 _| 93~ 103 [Lefthand screw + Cootng water pump impair (Bronze) waz x 25| PUSS Tao -720| Len hand screw * Cooling water pump impeller (Cast iron) 2a x 2.5] ‘urd Se%*t | 290 ~ 310 Letthand screw [Cooling water pump driving gearlighieringnut [M2420] 96 _[235~255 | Main bearing cap side bolt z M22 x 1.5 32 343 ~ 382 Fiywheal clamping bok Y[w2oxas| 24 [520-580 Exhaust manifold camping bok m2xi75[ 79 30=69 [Exhaust expansion joint clamping bok Mi2x1.75| 19 59-69 Lub.oi pump ariving gear tightening nut Med 2.0, 86 _*(187~ 177 [Swing arm shaft clamping bolt Misx15) 4 [8-137 2008.12.04R YANMARGEYIS\A)L OPERATION MANUAL rd Basic Descriptions No. Page 00 | Table of Tightening Torques of Major Bolt & Nuts | o193.00 | 30 4. General Bolts Ls (1) Tighten any bolts other than the major ones according to the following table. (2) Tighten a part whose clamping section is made of aluminum, tighten it to 80% of the torque shown in the following table. (3) The following table is applicable only to the bolts whose Part No. (an 11-digit numeral) shown in the attached Parts List consists of 2 at its frst place and 2, 5 or 6 at its fifth place. 4)Standard Torque Values ‘Screw Dia, Face-to-Face Tightening Torque x Width of BolvNut > Pitch (mm) (mm) Nm MB x 1.0 10 10-12 Me x 1.25 13 | 24~27 M10 x 15 17 44 ~ 54 M12 x 1.75 19 78 ~98 M14 x 15 2 123 ~ 182 M16 x 15 28 ~ 206~ 245 M16 x 2.0 24 206 ~ 245 2) Standard Torque Values Soon Bi fmnofam [Terni To@ | ove aa tape Pitch (mm) en) Nan (mm) Ma x 1.25 “| 17~20 3 M12 x 1.25 17 25~34 6 Mia x 15 19 39~49 8 Mi6 x 1.5 2 49 ~59 ~ 10 Miexis | 24 69~78 12 M20 x 1.5 ar 38-98 15 "M22 x 41.8 eee 147 ~ 196 18 YANMARGEY1IS(A)L OPERATION MAN Basic Descriptions Cex} No, 00 Principal Dimensions & Mass for Disassembly & Servicing 00-114-00 1. Disassembly and Maintenance Space [Unit : mm] Dismantling to the Operation Side Cooling Water Outlet Piston Oyiner oy Hea Collecting Pipe oyinder Center Exh, Manifold S| i Turing Bar Dismantling to the Rear End 2012 Camshaft (Split in Two)’ Cooling Water Pump Fuel Feed Pump oan No Cyt. Center errno 1 | YANMARGEYIS\AL OPERATION MANUAL Od Basic Descriptions No. Page 00 | Principal Dimensions & Mass for Disassembly & Servicing o0-11a-00 | 212 2. Mass of Major Parts | /A\caAUTION Serer eee Tec (1) When hoisting a part, use rope and lifting gear and hook that can withstand the can withstand the weight of the part (2) When disassembling any of the parts prefixed with an asterisk (*) in the following table, use the attached exclusive tool. (Unit: kg} Part Description Mass Remarks * Cylinder head 105 = Piston & connecting rod assy. a2 * Cylinder iner 40 * Air cooler 300 Include the casing Lub. oil cooler 106 Turbocharger 140 Fuel feed pump 16 - Lub. oil pump 2 25 Cooling water pump 35 | Air motor 18 ‘Camshaft (spit in two) 1X2 : | Camshaft driving gear 7 | intermediate gear assy. | 20 * Exhaust manifold cover 45 * Main bearing cap 22 “Antilywheel end gear case 3 Cylinder block 7,604 Crankshatt 352 include the balance weight Flywheel 738 | Include ring gear 2008.4.17R YANMARc=) Sate Y OPERATION MANUAL Basic Descriptions No. Page 00 SI Unit Conversion Table | co-1se00 | wn Conversion values between the international unit system (SI) and the metric unit system are shown below: 1)Power Conversion Example N kat 101972kaf 1 0.101972 80865N 9.80665 1 2)Moment of Power, Torque Nem kgf +m 1 0.101972 9.80665 1 3) Pressure Pa katiom? mag mmHg 1 1.0197 x 10° | 1.0197 x 104 | 7.501 x 10% 9.80665 x 10* 1 1.0000 x 10 | 7.366 x 10? “e.80665 10° | 1.0000 x 104 1 7.366 X 10 1.3332 10? | 1.3595 x 10% | 1.3595 x 10% 1 4) Work, Energy kWeh J kcal kgf 1 36x 10® | e600 x 10? | g671 x 10° 2.778 x 07 1 2.389 x 104 | 1.0197 x 107 1463 x 10° | ates x10? | 1 4.260 % 10? 2.724 x 108 9.80665 2.343 x 10% 1 5) Work efficiency, Power kW. PS 1 1.9596 0.7355 1 YANMARGEYIS\A\L OPERATION MANUAL rd | Basic Descriptions No. Pege 00 | Symbol Marks on Piping Layout & Instruments ‘Symbol Marks on Piping Layout & Instruments Instruments Valves Piping Parts Pump 7 Glove valve |=] range sting Plunger pump Needle valve aa | Shutoff valve Hand pump ‘Angle valve =H | Spectacte tange - Motor Bufferfly valve - Joint Filter 2 Sluice valve Boss Centrifugal fiter ‘Automatic backwash filter ‘Swing check valve Expansion joint s+] Screwed check valve | —I-| Orifice am mw Porous plate filter cylinder Piston valve Flexible pipe coupling Meter&Sensors Three-way piston valve Seal pot (| Thermometer Cook |G | Loop seat (P)| Pressure gauge Three-way cock c& | Reducer Differential pressure gauge renulaing oe (> | Airvent pipe IE] oil signal seat ee _B_| Safety plate [| crazedievel gauge | Safety valve © | Accumulator Pressure switch |” Solenoid valve +++] Capiiary tube (48) | Temperature switch | Pressure reducing valve | cut | Cupper pipe epg | Carbon steel pipe Float switch for pressure tube Duplex check valve Velocy regulating valve | sau | eppon steel pipe Flow volume regulating | srg | Machine structural Differential pressure SW Pressure transmitter fai] x Keto ig aay x ol RR valve carbon steel pipe Resistance temp. sensor 0D. | Pipe outside dia, ‘Thermocouple to. | Pipe inner dia. O@@ee@ a ie 3 a The black valve (glove valve, angle valve and needle valve) show the valve closed constantly. Bia { Opened constantly pla : Closed constantly YANMARGEYISIA\L OPERATION MANUAL rg Operation No. Page 00. Operational Preparation o0-21a-00 | 1/5 Before the initial start of the engine after its installation or before its restart after its overhaul servicing or a long term stoppage, sufficiently perform the following inspection and operation preparation in addition to daily inspection and operational preparation, and make sure there is no abnormality and the opera- tional preparation has completed. (1) Make sure no part nor too! has been left in the crankcase. (2) Check for a part not tightened yet. (3) If you have disassembled the valve mechanism, check the suction/exhaust valve head clearance. (Cy 00-09 Adjustment of Suc/Exh. Valve Clearance (4) Operate the lubricating oll priming pump, and open the pressure indicator cocks of all the cylinders, ‘While turning the flywheel, make sure the lubricating oil is dropping from each part of the valve rocker arm shafts, piston pins, crankpins, main bearings and swing arms. (6) Bleed the air from the lubricating oil strainer. (6) Bleed the air from the fuel oi fier and inlet pipe of fuel injection pump. (7) Manually lubricate the governor link, and make sure it moves smoothly. 1, Turing {em Be careful not to allow your body to make contact with a moving part while turing the flywheel. (Never put your hand into the crankcase.) Refer to the following section as to the procedures of tuning, T)} 00-08 Turing Device Set back the turning gear to the GEAR OUT position and set the stopper in the groove. Fasten the set bolt and set the lock bar. Unless the turning gear is the GEAR OUT position, the turning gear engagementidisengagement switch actuates to disable starting. (optional spec) 2. Lubricating Oil System The piping paris of lubricating oll system are banded with yellow coating 41)Inspection and Oil Supply of Lubricating Oil Sump (1) Open the drain valve, cock or plug of the following oil sumps and device: © Lubricating oil cooler and oil fiter @ Governor oil sump ‘Supply the lubricating oll to the upper limit of oil level gauge or dipstick in each oil sump; Manually lubricate the necessary parts. ; and discharge the drain. YANMARGEYIS\A\L OPERATION MANU. Lx) Operation Operational Preparation Fig. 00-21-4 Hand Lubricating Points ‘Manually lubricate the governor tink ‘and control device (circled points) Connector ‘Control Lever for Gov. output Ast Lever shat Oil Level Gauge Remove the top cover and Supply ollto 2 to 8 mm above the center of ol level gauge —\onin Pi (2) Check the properties of lubricating oil; and ift is considerably contaminated or deteriorated, change it. {Cj 00-59 contrat on Lub. oi 2) Priming of lubricating oil This engine employs the continuous priming system using a motor-operated pump, a ‘© Keep the control power supply for the motor-operated priming pump of this engine switched ON always. ‘@ Switch OFF the said power supply in a long-term stoppage of the ship and in a rest and maintenance servicing of the power installation. After priming has stopped for two hours or longer, perform priming for about 20 minutes or longer. Priming pressure: 0.02 ~ 0.20MPa 3) Air Bleeding of Lub. Oil Cooler Ly © If any of the following items arises, start the engine after bleeding air from the lub. oll cooler, operate the priming pump. © After priming has stopped for two hours or longer. © After disassembling & cleaning the lub. oil strainer. @ After changing the lub. oil or disassembling the piping parts of lubricating oil system, Air Bleeding Procedures (1) Operate the priming pump. (2) Open the air bleed valve of the lub. oil cooler. (@) Discharge the air, and then close the air bleed valve. ‘e If you cannot operate the motor-operated priming pump, perform air running for about 3 seconds repeatedly five times, ‘After starting the engine should be executed the air venting again. YANMARGEYISIA\L OPERATION MANUAL ed Operation Ne Page 00 Operational Preparation ooztaco | as 3. Fuel Oil System ‘The piping parts of fuel oil system are banded with red coating. (1) Drain the fuel oil tank and fuel ol filter. (2) Supply the fuel oil into the fuel oil tank, and check the fuel oil amount. Then, open or close each valve according to the operation conditions. (8) Bleed air from the fuel oil system. (4) You use an engine of marine diesel oil (IV.F.0.) start/stop specifications, tum on the heater for the heavy fuel oll (H.F.0.) pipe line, and continue heating the H.F.O. unti its viscosity becomes proper. Ls Ifyou use an engine of heavy fuel oil (H.F.O.) start’stop specifications, make sure the fuel oil tempera- ture (viscosity) at the engine inlet is proper. (CL) 00-54 Properties of Fuel Ol atthe Engine inet ‘After engine installation, long-term stoppage or overhaul of the engine, bleed air from the fuel oil system by the following procedures. (1) Open the bypass vaive of the fuel feed pump. (Fully tun the bypass handle counterclockwise.) (2) Open the air bleed cock of fuel cil fier to bleed air. (3) Loosen the air bleed plugs on the fuel injection pump. (Two places) (4) Loosen the air plug of the fuel piping to bleed. (5) Close the bypass valve. (Fully tun the bypass handle clockwise.) Fig, 00-21-2 Fuel Injection Pump ‘Al Bleed Plug (CQ) 90.02 overhauting he Fuel Oi Feed Pump & Adjustment of Pressure YANMARGEY1IS\AL OPERATION MANUAL Operation rx] No, 00-21-00 Page 415 00 Operational Preparation 4, Cooling Water System The piping paris of fresh water system are banded with blue coating and that of sea water system are banded with green coating. (1) Inspect the cooling water tank, and check whether the cooling water is not contaminated. If the cooling water is contaminated considerably, change it. (2) Supply the cooling water to the upper limit of water level gauge, and add a proper amount of rust inhibitor. (LZ) 00-63 Brands of Rust Inhibitor & Adding Quantity (3) Open and close each valve of the cooling water pipe system according to the operation conditions. ‘When you have replaced the cylinder liner or drawn it out for servicing, remove the oylinder side cover and make sure no water leaks inside cylinder. 5. Boost Air System ‘Open the drain cock of the following point to drain the air drain. Fig. 00-21-3 Boost Air Drain Cock YANMARGEYIS\IA)L OPERATION MANUAL Te | Operation No. Page 00 Operational Preparation 00-21a-00 | 5/5 6. Starting Air System The piping parts of starting air system are banded with white coating (1) Drain the starting air reservoir. (2) Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine (2.16MPa or higher). (3) Check that the pressure after decompression is within the range of 0.7 ~ 4.0MPa. (If found outside the range, regulate the pressure by means of a reducing valve provided at the air motor inlet.) 7. Control and Protective Devices 1)Governor (1) Shift the start stop lever from the RUN position to the STOP position and vice versa, and make sure the rack of fuel injection pump, 1st lever shaft of governor link and connector move smoothly. (2) Check that the pointer of speed control shaft of the govemnor is indicating the graduation 1 to 2. Ly ‘After replacing or servicing the governor and/or fuel injection pump, check that coupling of the linkage is | not wrong. | (CL) 60-02 overhauling the Governor Link | 2) Protective devices (1) Check that the turning gear is in the GEAR OUT setting. (2) Set the power switches of protective and alarm devices to the ON position LS . : | Unless the power switches are set in the ON position, the protective and alarm devices do not actuate, MO (8) Confirm operation YANMARt=) > gt: iy OPERATION MANUAL ee Operation No. Page 00 Starting 00-20-00 | 1/3 This engine is started by an air motor. Press the START switch. Then, the pilot air solenoid valve directly attached to the air motor will open on the battery power to start the engine. rt the Engine after Signaling * Check if no one is around the engine. | + If someone is found near the engine, give him a sign that the engine will be started. Only then start it ‘SAFETY FIRST * Check the holding capacities of fuel, oll, air, etc. + Be sure to detach the turning device once the engine is started, and keep it at it's fixed housing spot. + Tum on the power supply of the engine protection device before starting up the engine. + After the engine has been stopped for a long time or after the engine has been serviced, be sure to start | up the engine at the engine side, + Ifthe rotational speed rises extremely rapidly or if you find an usual sound or fume, immediately set the start/stop lever in the STOP position to stop the engine. ‘Check After the Engine Is Started * Check if pressure values of each instrumentigauge board are normal * Check if there are no unusual sound and abnormal heat buildup. * Check for any leakages of fuel, oil, air, etc., and if a leakage is found, promptly repair. + Except in case of emergency, apply the load after a warming-up. During start operation, do not bring your face close to the air motor. Dust adhered at the exhaust port of air motor may enter your eye, resulting in injury. ie = 1) Air Running Procedures Ly Ifa large amount of fuel oil, cooling water or lubricating oil should be entrapped in cylinders, * water ham- meting" may occur. Perform air running by the following procedures, and make sure there is no abnormality. Then, start the engine by the alarm panel on the engine side. @ Set the ENGINE/REMOTE operation selector switch in the ENGINE position. ‘© Open the pressure indicator cocks of all the cylinders. ‘ Set the start/stop lever in the STOP position. @ Hold the START switch pressing for 2 to 3 seconds to effect air running. YANMARCa olds mua pre ‘Operation No. 00-22-00 2) Starling operation procedures Start the engine by the following procedures. (1)Make sure the turning gear is it the GEAR OUT position. (2)Make sure the pressure indicator cock is closed. (3)Set the operation selector switch to the ENGINE or REMOTE position corresponding to the control panel to be selected (4) Set the start / stop lever in the RUN position. (6) Make sure the pointer of speed control shaft of governor indicates the position of ordinary operation (rated speed). (6) Open the starting air reservoir valve and control air valve. (7)Hold the START switch pressing for 2 to 3 seconds, and make sure of ignition. Only then release the switch Fig. 00-22-1 Start Operating Procedure ‘Start Switon ‘StarvStop Lever — Operating Select Switch YANMARGEYIS\ALL OPERATION MANUAL xs Operation No. Page i Starting 00-22-00 | 30 3) Corrective actions to be taken in starting failure | + If the engine cannot be properly started, unburnt combustion gas in the flue may be ignited, resulting in explosion, Therefore, perform air running to discharge the gas from the exhaust gas system before attempting to restart the engine, + When the engine can not be started in 30 seconds, you have to start again after stopping the starter to cool more than 2 minutes and half. In case lack of cooling time when you drive continuously, the starter might become unavailable because of overheating and soon Make sure the flywheel has completely stopped, and then press the START switch. 4) Engine start when there is no controlled source. If the battery power for the START switch has been exhausted (in case of emergency), push the manual bution of air motor to start the engine. Retum the button to origin direction immediately after engine has started. Fig. 00-222 Air Motor Manual Switch a 4 Emergoncy Manual Buten Use starting manual switch only in emergency, because the air motor may rotate excessively as the con- trol module is not in operation i this case. 5) Checks to be made immediately after starting Check the following items. If any abnormality is found, stop the engine and repair it (1) Value indicated by the pressure indicator on the gauge panel. (2) Leak from each piping. (3) Unusual sound and abnormal heat generation of each part. 2008.10.24R YANMARGEYISAL 0 Operation ERATION MANUAL LAE No. ao Page Running 00-23-00 412 During a Run + Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup. + Check whether the engine fully shows its proper performances and record the check results. (Refer to the Records of Shop Trial, then record the check results on the Engine Log.) + If any abnormality is detected, immediately stop the engine and repair it. Take care not to be caught in a rotating part. + Never allow your hands, body and clothing to make contact or bring close to any rotating part + Never touch any movement pars. Take care not to get burt. + During running and immediately after the engine has stopped, the whole engine is heated. Therefore, take care not to get burnt. + Take care not to allow your hands, body and clothing to make contact with the turbo- charger, exhaust manifold, exhaust pipe and/or engine as whole, Take care not to get hearing loss. + Put an ear protection in engine-room during running, because can cause hearing loss. © During a run and immediately after the engine stop, never touch the following parts with bare hands. Otherwise, you may get burnt. | + Turbocharger, Exhaust pipe system, Boost air pipe system, Indicator cock + Flue and funnel © During a run, never touch any moving part. Otherwise, you may be caught in, resutting in injury. © Take care that the room does not fall short of the air (oxygen) because the turbocharger takes in a great volume of air Keep the control air valve opened during a run. If you close i, the protective devices cannot actuate. YANMARGEY1S\AL OPERATION MANU. io ‘Operation Ls _ The critical speed that may cause torsional vibration is within the normal rotation speed range, quickly avoid it. (1)Run the engine for about 10 minutes at low load fo warm it up. (2)Ifyou continue running the engine with a low load for longer than three hours, observe the following load factors, otherwise combustion worsens and fouling of the combustion chamber, exhaust pipe, turbo- charger, etc. becomes heavy. IF fuel oil used the marine diese! oil (M.0.0.), run the engine at 15% or higher load factor. (3) In the case of a high humidity, this is not abnormal although much drain may be produced as the mois- ture in the air is condensed. In this case, run the engine as the drain cock of the boost air cooler kept opened. (4) Measure the running performance once a day and record the measurement data. (LL) 00-92 Measurement of Running Performance YANMARGEY1IS\AL OPERATION MANUAL Operation Stopping When Stopping the Engine + Do not stop the engine simultaneously with load shutoff. + Except in case of emergency, keep running the engine without load after load shutoff. + Keep the engine ready for being started up. + Promptly repair the points that have been troubling during a run. + Do not open the side cover of crankcase for at least 10 minutes after having stopped the (Gomes } engine. Otherwise, the entry of external air may result in explosion. we Take care not to get burnt. + Immediately after the engine has stopped, the whole engine is heated. Therefore, take care not to get bumt. Take care not to allow your hands, body and clothing to make contact with the turbo- charger, exhaust manifold, exhaust pipe and engine as a whole. + Ifyou attempt to drain oil while the engine is still hot, take care not to get bumt with splash of + If you disassemble the cooling water system while the engine is still hot, vapor or hot water may blow out, causing you to get burnt. Wait until the engine becomes cool, then wrap the disassembling part with cloth or the like and slowly loosen it. 1. Stopping in Normal Running Except in case of emergency, stop the engine by the following procedures: 1) Preparation of stopping (1) Perform the without load for about 10 minutes. (2)If you use an engine of marine diesel oil (M.D.0.) start/stop specifications, switch over the fuel oil from the heavy fuel oll (H.D.0.) to the M.D.O. to prevent the H.F.O. from being stagnant inside the fuel oil pipes, fuel injection pumps when stopping the engine. As the reference, continue running the engine on the marine diesel oll (M.D.O.} for more than 15 minutes before stopping the engine. However, since the required time depends upon the load applied when the fuel oil is switched over and the capacity of pipes in the vessel, consult the dockyard where the engine has been installed. 2) Stopping operation (1) Set the start/stop lever in the STOP position. (2) Run the lubricating oil priming pump for 15 minutes or more to piston and turbocharger. (3) Open the pressure indicator cack, and perform air running to discharge the as from the combustion chambers. (4) Open or close the valves of each system according to the stopping conditions, When the cooling water may be frozen under cold weather, or before a long term stoppage, drain the cooling water from the cylinder jacket side and cooler side. YANMARGEYISiIA\L OPERATION MANUAL CEL xe ‘Operation No. Stopping 00-24a-00 2. Emergency Stop If any of the following problems arises, immediately set the starstop lever in the STOP position to stop the engine. Ls Ifthe engine is not stopped by setting the startstop lever in the STOP position or pressing the STOP switch, close the fuel ol inlet valve. (1) Any of the following alarms has been issued. @ Expressive pressure drop of lub. oil © Expressive temperature rise of lub.oil @ Expressive tempera rise of cooling water @Overspeed (2) An unusual sound has been made. (3) Heat has generated unusually from a part (4) Smoke is issued from a bearing or any other moving part. (6)A pipe of fuel oil, lub. oil or cooling water system has been broken. (6) The supply of cooling water has stopped, and it is impossible to supply it immediately. (7)A setscrew or bolt of a moving part is loose or broken. (8) Moisture is mixed in the lubricating oil (8) The boost air pressure has dropped, and the exhaust temperature has excessively risen. (10)The rack of fuel injection pump has stuck 3. Disposal After an Emergency Stop ‘When repairing the engine or investigating the cause of problem, observe the following items. /\ WARNING Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine. Entry of fresh air into the engine may cause ignition of oil mist, resulting in explosion. YANMARGEYISi\A\L OPERATION MANUAL aed Operation ao ea 00 Stopping 00-24a-00 | 3/3 Ls If you have stopped the engine while it is running on the heavy fuel oil (H.F.0.), immediately discharger the H.-F. from the fuel oll pipes, and fuel injection pumps, and displace them with marine diesel cil (M.D.O.). Ifthe residual H.F.O. is cooled and its viscosity rises, it becomes impossible to restart the engine. (1) Set the fuel oil changeover valves at the engine inlet and outiet to the marine diesel oll (M.D.0.) position. (2) Open the bypass valve of fuel feed pump. (3) Open the drain cock of fuel oil fitter and drain valve of fuel oil main pipe. (4) Tur the flywheel to discharge the H.F.O. from the fue! injection pipes and fuel injection valves. (Set the start/stop lever in the RUN position, and turn the flywheel under the fuel injection status.) Fig, 00-24-1 H.R. Discharging Points =u AGIA ° Fuel Oi Fiter— Drain Cock — Normal “CLOSE” Discharge “OPEN” YANMAR7) 6 Sedat Mad Engine Performance Cra} 00 Data Sheet is MN Engine Model Eng. No. E/it Fuel Olt Kinematics ‘Type of TIC Turbo. Sit Viscosity Lub.Oil Brand Viscosity (SEA) Specific Gravity Load 14 112 3/4 aia] 110 Room Temp. c Data Time Total Running Hours H Noto | No2ew | = ome No.3eyt | °C exh. Ges | Outlet Nosoyl | NoSoyl | No6oyl | c al _ inlet | c _ Outlet [8 | ~ | Engine intet °c _ [ Engine Out °c “| § “| 5 c E © | coatng | gfe : Water = o — - *c Lub, OllGooleriniet__| °C Air Gooler inlet | Air Cooler Outlet [ ae LO Cooler Inlet | °c Engine Inlet [* Boost Air | Cylinder Inlet * FuelO | Engine inlet *c YANMAR00 Engine Performance f= gtr Data Sheet JL. OPERATION MANU. 46623 Page 212 Load 4 [12 | 34 | 44 | 10 No.teyl_| MPa No2oyl_| MPa pmax NoSeyl_| MPa Nodoyt_| MPa No.Soy!_| MPa g No.6 oy | MPa E [Engine Luo MPa Turbo. Lub, Oil MPa Boost Air | MPa | Jacket Cooling Water MPa Cooler Cooling Water MPa Fuel Oil MPa YANMARGEYIS\A\L OPERATION MANUAL 00 Trouble shooting & Countermeasures ery No. Page o0-41a-00 | 14 The causes of abnormalities and troubles are diverse, and they break out from compsite factors. Catching a change in running performance and referring to the record of maintenance and servicing date and the history of part replacement, locate the cause early and take the proper countermeasures. 1. Starting Failure 41) Flywheel not turned Cause Countermeasure (1) Slariing air pressure insufficient (2) Malfunction of air motor 41.Voltage drop of air motor battery 2.Malfunction of air motor pilot solenoid valve (3) Engagement / disengagement switch actuated, (Start / stop lever set in the STOP position) (4) Too high viscosity of lubricating oil (6) Seizure of moving part 4.Seizure of piston and cylinder liner 2.Selzure of main bearing and / or camshaft bearing Fill he starting air tank with air. Charge the battery. Press the manual starting push button to stat the engin. ‘Set the start/stop lever at the RUN positon. Warm up the engine. Check and repair the piston and cylinder liner, or replace them, Check and repair the pertinent main bearing or camshaft or camshaft bearing, or replace it 2) Flywheel tumed, but ignition not taken place Cause Countermeasure | (1) Fuel oil not sent under pressure to fuel injection pump 1.Fuel tank empty 2.Clogging of fuel cil pipe (Improper opening and closing of each valve) 3.Clogging of fuel ol fiter 4Failure of fuel feed pump 5.A\r entry through each joint (2) Malfunction of stopping air piston (3) Defect of fuel injection pump 1.Sticking of plunger and plunger guide 2.Wear or seizure of plunger guide 3.lmproper assembling (deviation of match marks) (4) Defect of fuel injection valve 1 Sticking or seizure of needle. 2.Breakage of nozzle spring 3.Fuel injection pressure dropped 4.0! leakage from nozzle excessive 5,Breakage or improper clamping of high-pressure fuel pipe (6) Malfunction of governor (loose governor link and worn spline) (6) Poor airtightness of intake / exhaust valve 4,.No clearance at head of intake / exhaust valve 2.Sticking of intake / exhaust valve 3,Damage of seat of intake / exhaust valve (7) Too low cetane number of fuel Supply the fuel to the fuel tank. Check the opening and closing status of each valve. Clean the fiter, Check and repair the pump. Check and repair each joint, then bleed air. Check and repair the air piston, Check and repair the plunger or plunger guide, or replace it Replace the plunger. Overhaul and check the pump. Check and repair the needle, or replace it Replace the nozzle spring, Regulate the pressure, Check and clean the mating surfaces of nozzle /and body, or replace the nozzle. Replace the high-pressure fuel pipe, or correct clamping, Check and repair the governor, or replace it ‘Adjust the valve head clearance. Grind or replace the valve. Grind or replace the valve seat Use a high- quality fuel oil. YANMAR00 GEYIS\A\L OPERATION MANU. Trouble shooting & Countermeasures rex} No. Page 214 00-41a-00 2. Rotational Speed Dropped Spontaneously Cause Countermeasure (1) Clogging of fuel of fiter (2) Seizure of moving part (piston, main bearing or turbocharger) (3) Air mixed in fuel oil pipe system (4) Moisture content in fuel oil (6) Defect of fuel injection pump (6) Defect of fuel injection valve (7) Malfunction of governor Clean the fiter. ‘Check and repair the pertinent moving part, of replace it. ‘Check and repair the fuel oil pipe system, then bleed air. Drain the fter, tank, etc. Check and repair the pump, or replace it. Check and adjust the valve, or replace it. Check and adjust the governor, of replace it. 3. Output of Each Cylinder not in Uniformity. (Dispersion exhaust temperature is large among cylinders.) of the maximum combustion pressure and Cause Countermeasure (i) Air mixed in fuel oil pipe system (2) Moisture content in fuel oil (3) Fuel injection volume not in uniformity among cylinders ‘1.Nonuniform position of fuel injection pump racks 2.Sticking or wear of fuel injection pump plunger 3.Defect of fuel injection valve 4,Looseness or damage of fuel injection pipe '5.Sticking of intake / exhaust valve or damage of intake / ‘exhaust valve seat 6.Damage of fuel cam, or damage of intake / exhaust cam (Check and repair the fuel oll pipe system, then bleed air. Drain the filter, tank, etc. Check the position of fuel injection pump racks, then adjust it. Check and repair the plunger, or replace it. Check and repair the valve, or replace it. Check and repair the pipe, or replace it Check and repair the pertinent valve or valve seat, or replace it. Check the fuel cam or intake / exhaust cam, then repair it, of replace it 4, Bad Color of Exhaust Gas Cause Countermeasure (i) Improper injection timing (2) Defect of fuel injection valve (fuel injection pressure drop, sticking of nozzle) (8) Defect of fuel injection pump (4) Improper adjustment of intake / exhaust valve head clear- lance or damage of intake / exhaust valve seat (8) Sticking of intake / exhaust valve (6) Damage of intake / exhaust cam (7) Defect of turbocharger 1.Fouling of the blower side or turbine side (8) Fouling of boost air cooler (too high temperature of boost air) (9) Shortage of fuel oi! (10)0verioad Check and adjust the timing. ‘Check the valve, then regulate the pressure, or replace it Check the pump, then repair it, or replace the pertinent valve sect. [Adjust or correct the clearance, or replace the pertinent valve sect. Overhaul the intake / exhaust valve, and then correct it Replace the camshaft ‘Overhaul and wash the turbocharger / blower. Overhaul and clean the air cooler. Use a high-quality fuel oil Reduce the load. YANMARGEYIS‘A\L OPERATION MANUAL Ud no No. Page Trouble shooting & Countermeasures co-41e-00 34 5. Lube Oil Pressure Dropped below the Specified Pressure. Cause Countermeasure TI) Looseness of ibe oll pipe and cylinder BIOGK oll hale plug | Check and repair the lube oll pipo and each oll (2) Clogging of lube ol strainer (3) Excessive clearance of crankshaft bearing (4) Sticking of ube oil pressure regulating valve or loose adjust- ing bott (6) Sticking of lube oil safety valve (6) Too high temperature of lube oi 1.Shortage of cooling water volume 2.Fouling of lube oil cooler 3.Excessive blow-bye (gas leak) into the crankcase 4.Stioking of piston of lube oil thermostatic valve or defect of its element (7) Air sucked in lube oil pump (shortage of lube oil volume) hole plug, ‘Overhaul and clean the strainer. Check the clearance, then replace the metal ‘Check the valve and bolt, then repair or adjust the pertinent part. Check the valve and bolt, then repair it. ‘Check the cooling water pump. Check the cooler, then over haul and clean it. Check the piston rings and cylinder liner. Check the piston and element, then repair or replace the pertinent part. Replenish the lube oil 6. Unusual Sounds Heads (Knocking Occurred) During Operation Cause Countermeasure (i) Excessive clearance of bearing of crankshaft of camshaft (2) Loose bolts 41.Connecting rod bolts 2.Flywheel clamping bolts (3) Improper adjustment of intake / exhaust valve head clear- ance or loose bolt (4) Improper adjustment of fuel injection timing (5) Fue! injection volume excessive ‘Malfunction of fuel injection pump 2.Defect of fuel injector (6) Increase of gear backiash or wear of gear bearing Check the clearance, then replace the pertinent bearing, Check the connecting rod and bolts, then retighten the bolts or replace them, Check the bolts, then retighten them, or replace them, Check the clearance and bolt, then adjust the (clearance. Check the timing, then adjust it. Cheok and repair the pump, or replace it Check and repair the injector, then adjust it. Check and adjust the gear or its bearing, or replace it 7. Cooling Water Temperature Too High Cause Countermeasure (i) Shorlage of cooling water volume (2) Sticking or defect of cooling water thermostatic valve ‘Check and repair the cooling water pump. Check o replace the thermostatic valve. YANMARGEY1IS\ALL OPERATION MANU. 46623 No. | Page 00 i Trouble shooting & Countermeasures 00-41a-00 44 8. Exhaust Temperatures of All the Cylinders Too High Cause Countermeasure (i) Boost air temperature too high 1.Boost air cooler cooling water temperature too high 2.Shortage of boost air cooler cooling water volume 3.Fouling of boost air cooler (cooling water side & air side) 4,Engine room internal temperature too high (2) Boost air pressure too low 1.Clogging of turbocharger fiter 2.Clogging of boost air cooler (air side) 3,Fouling of turbocharger (turbine side & blower side) or its ‘damage 4.Rise of back pressure at exhaust port 6.Engine room put under a negative pressure (3) Unsuitable properties of fuel oi! (4) Overload Check the cooling water system, and lower the cooling water temperature to the specified range. Check and repair the cooling water pump. ‘Overhaul and wash the cooler. Check and service the engine room ventilation ‘equipment, Wash the filter. Overhaul and wash the cooler. ‘Wash the blower side or overhaul and wash the turbocharger, or replace it Check and clean the exhaust manifold and jexhaust pipe. Check and service the engine room ventilation ‘equipment, Judging from the property analysis results, change the fuel oll if necessary. Reduce the load 9. Engine Stopped Suddenly Case Countermeasure: (1) Protective device switched on 1.Overspeed 2.Lube oil pressure drop 3.Temperature rise of cooling water excessive (2) Governor or governor gear (@) Fuel tank empty (4) Air mixed in fuel oil system (6) Clogging of fuel ol fiter (6) Setzure of interlocking part (piston, main bearing, crank-pin bearing, timing gear, etc.) ‘| Check the switch, then repair the defective part. If necessary, replace the pertinent part. Check the governor and governor gear, then repair or replace the pertinent part. Replenish the fuel ol. Bleed air from the fter and oil pipe. Overhaul and clean the filter. Check and repair the pertinent part, or replace it. YANMARGEYIS\A\L OPERATION MAN Ud Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 | Quality Criteria of Fuel Oil o0-sta-00 | 41 The properties of fue! cil applicable to this engine are shown in the following table. The properties of fuel oil are uncertain and broadly ranged; thus they affect such factors as a smooth run of the engine, maintenance interval and service life of parts. Consequently, it might be necessary to change the specifications of engine or add attachment in accordance with the applied fuel cil Quantity Criteria of Fuel Oil Quality Criteria Direct buming fuel oi 200sec.0i | 1,500sec.01 | 3,500sec.01 | 7,000see. 01 = at 50°C mms | 3~8 <30 <180 | <380 | <700 Viscosity - = RW.No.1 at 100 | sec. | 37~58 | <200 | <1500 | <3500 | <7000 ~~ [Specific gravity at . = : : fae oss | 60 > 60 > 60 > 60 > 60 Resiaa'caton | ™* | 25 | 20 | > 16 1SO___| DMBorDMA | RMBIO_| RMEZ5 | RMG35 | RMHSS Quality criteria equivalent | _CIMAG == __ | CIMAG 610 | CIMAG E25 | GIMAG G36 | CIMAC Hs5 fuel ol BSI = (Mia) (wey (7) mo as MD.O LEO H.F.O (heavy fue! oll) Note: IM.D.0. = marine diesel oil; .F.0. = intermediate fuel oil " Use HFO with the CCAl, (an ignitabilty index), below 850 as an standard. (However, please note that the said value was estimated from the past operation data and that the value can vary depending on the future fuel oil quality.) The use of HFO with CAI exceeding 850 will cause faulty combustion and aggravate exhaust color. If such use is inevitable, raise the intake air temperature. This will improve combustion to an extent. However, raise the intake air temperature carefully in relation with the exhaust temperature, since this will affect the exhaust temperature and other engine performance.” What is CCAI? GCAI stands for Calculation Carbon Aromaticty Index, which shows an ignitabllty index. The index, in consideration of the relation between aromatic compound content in fuel oll and the ignit- ability is used to obtain the aromaticty degree in relation with the fuel oll properties. The larger the CCA value, the larger the fring delay for inferior ignitabilty. In this case, the HFO direct starting is not possible or exhaust color is aggravated due to faulty combustion. YANMARReh Ot Solids tUod Mulan x Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 it Calculation of CCAI eee ee CCAI = D - 81 - 141 + loglog (V + 0.85) D:: Density kgim3 @ 15°C, V:: Viscosity mm? /S @ 50°C [v D cCAI ) 1 800 800 810 820 830 The smaller CCA, the better fring and combustion performance, 840 850 ‘The larger CCA, ‘the inferior fring performance, This wil cause normal operation 10 be hard. 860 870 880 890 900 910 920 930 [Example } Obtaining CCAI of HFO with the viscosity of 380cSt @ 60°C and the density of 985 kg/m? 16°C from the table above: Draw a line from the viscosity (V) 380cSt to the density (0) 985 and extend the line to CAI column, The fuel ol CCAI in the present example is 846.OPERATION MANUAL TT xe Fuel Oil, Lubricating Oil & Cooling Water 00 Quality Criteria of Blended Fuel Oil No, Page 00-53a-00 | 4/1 In the case of using a highly viscose fuel oil by blending with marine diesel oil to lower the viscosity of fue! oil in addition to the case of direct buming of fuel oil set forth above for its pretreatment, apply the blending ratio. shown in the following table based on the quality criteria on the blended fuel oil, not based on the viscosity cri- teria When blending fuel oil of different production origins, sludge may be separated out, resulting in clogging Of fuel oil filters and sticking of fuel injection pumps and fuel injection valves. Pay your attention to this regard, Blended uel oi | _200-sec. oll equivalent | 1,500-seo. oll equivalent | 3,500-sec. oil equivalent Iso RMB10 | RME25 RMG35_ sas IMAC CIMACBI0 | _—_-CIMAC E25 CIMAG G35 BSI (way (we) (wry M.D.0: HFO(1,500-se00%) - 60:40 atoning ratiogs) |MO-O=HFO(GS00seca! | .D0: HF 0,8500-sec 180 140 Change in viscosity _ [mm*ls(40°C)| “Within new oll = 15% New oll = 25% Moisture content vol% <0. repenane eciie mate Tags. 218 20 Tene sae Maas eas a Difference between pentane and toluene | mass.% = <05 insoluble matters Meas. method | HCI HGIO, | HCI HGIO, Fuel ol used [method | method | method | method MD.O. 3.0 a Total base number | mgKOH/g |__200-sec.0i 50 30 70) 7,500-sec 3500-sec.0r | ‘7° ay aan 7,000-sec.cil 720 | 10.0 15.0 2. Oil Change Criteria Since oil change criteria vary as depended on conditions of use of the engine, an instance of the criteria may be set forth as follows although they could not fixed uniformly on base of the time used alone. (1) Ask your lub. oil supplier to analyze the lub. oil being used and thus to determine whether the oll can be further used continually or not. Ls ‘Sample 500 cc of lub. oil at least from the drain plug of lub. oil strainer immediately after stopping the engine for asking the analysis of lub. oil (2) Procuring a spot test kit to leam the remaining total base number, degree of contamination, cleanness dis- persing qualities of lub. oil used, etc. as a simple way of criteria, make the most of using such a spot test kit (3) Should either of the aforementioned criteria be not possible, change the entire volume of lub. il with the ‘new one at about 1,500 running hours in the case of constantly holding the oil volume of 4 itr. kW by replenishing with the new oil YANMARate OPERATION MAN’ Cre} Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 i icati List of Lubricating Oil Brands 00-60a-00 1" API Service Grade CE of CD Equivalent / SAE #30, 40. ‘ Intermediate fuel oil Heavy fuel oi! roo boa I FO.=(RW.No.1 at 100°F) | H.F.O.=(RW.No.t at 100°F) 2008ec. Oil 1,500s06/3 500sec:/7,000see. (Sultur Content 5) (<1.0) eael cea Total Base Nene) 9~15 16~ 25 30 ~ 42 YANMAR MARINE eee SUPER OIL 30, 40 an a IDEMITSU DAPHNE MARINE OL SW30, 40 | DAPHNE MARINE OIL SA30, 40] KOSAN DAPHNE MARINE OIL. SX20, 40 yapHNE MARINE OIL MV30, 40 | DAPHNE MARINE OIL SH40 ML 30, 40 ; CASTROL TLX Pius 203, 204 | CASTROL TLX Plus 303, 304 CASTROL —_| CASTROL MHP 183, 154 ; : SERA ERA antaa CASTROL TLX Plus 303, 304 | CASTROL TLX Plus 403, 404 BRITISH BP ENERGOL IG-HFX308, 304 PETROLEUM {BP ENERGOL 053-153, 164 | BP ENERGOL IC-HFX 203, 204 |EP ENERCOY icupeaus, ao DELO 3000 MARINE 30, 40 [Chevron DELO 1000 MARINE 90, 40 DELO 2000 MARINE 90, 40 DELO 3400 MARINE 30, 40 (CALTEX, TEXACO} | TARO 12XD 30, 40 TARO 20 DP30, 40 TARO 30 DP30, 40 TARO 40 XL30, 40 [COSMO OL [COSMO MARINE SUPER 30, 40 [COSMO MARINE 3025, 4025 [COSMO MARINE 3040, 4040 FUJIKOSAN | FUKKOL MARINE 312,412 |FUKKOL MARINE 820, 420 | FUKKOL MARINE 330, 430 ee [MOBIL GARD 312, 412 MOBIL GARD M330, M430 Se ieseaeeeaaee | eeeumenerameateesene MOBIL GARD M330,M430 | MOBIL GARD M340, M440 KYGNUS OIL |KYGNUS MARINE X30, 40 | KYGNUS MARINE DX 330, 340 = JAPAN | ~ eNeny [YOMO MARINE D-13, 14 | JOMO MARINE D-23, 24 JOMO MARINE 0-33, 34 TOTAL 5 To ine _ [DISOLA M3015, M4ots AURELIA XL3030, XL4030 | AURELIA XL8040, XL4040 NIPPON OIL [MARINE T103, T104 MARINE 203, T204 MARINE 7303, T304 = onoene ARGINA S OIL 30, 40 JARGINA T OIL 90, 40 RIMULA FB OIL 30, 40 | ARGINA x OIL 30, 40 2008.5.1R YANMARGEYIS\A\L OPERATION MANUAL M46623 Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 iteri i Criteria on Cooling Fresh Water ooszaoo | 41 (1)Use pure water (distilled water) or tap water. (2) Use the water having the properties shown in the following table. LN Recommended Water Quality pH 208K @5°C) 63~80 Do not use hard water. = If hard water is used, scale adheres to Total hardness (CaCO) < 100 ppm water chambers such as cylinder head and cylinder water jackets and may cause an Chlorine jon (Cr) concentration | < 100 ppm overheat. Pay your particular attention to Malkalinity 30100 ppm | | Ms reser ‘Ammonium ion (NH,*) cone. <0.05 ppm Sulfate fon (SO,"“) concentration |< 100 ppm Evaporated residue < 400 ppm YANMARGEYIS\A\L OPERATION MANUAL CAE Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 | Selection and Control of Corrosion Inhibitor | oog3a09 | 114 (1) Add a corrosion inhibitor to cooling fresh water because use of fresh water causes a drop in strength of parts and the cooling effect through corrosion of water chamber and adhering of scale (2)Select a corrosion inhibitor which does not have an adverse effect on parts of the cooling water system because parts made of cast iron, carbon steel, brass and bronze, are used in the cooling water system of an engine. Ly + In the case where aluminum materials are used in the cooling water system, consult the supplier of cor- rosion inhibitor because a kind of corrosion inhibitor to be used differs in this case, + As to the adding quantity of and concentration control on corrosion inhibitor and addition and handling of supplementary adjuster, obey the criteria set by the supplier of corrosion inhibitor. “In the case where the concentration of corrosion inhibitor could not be controlled, annually change the water by the total volume. @Do not dump cooling water to which the corrosion inhibitor was added directly to the ocean or river. Since the method of treating the waste liquor has been provided for in the law, such liquid has to be treated according to instructions given by the supplier of corrosion inhibitor. ®Do not mix different brands of corrosion inhibitor. (In the case where mixing of different brands of cor- rosion inhibitor is unavoidable, consult the suppliers of corrosion inhibitor. @A corrosion inhibitor is chemical for industrial water treatment use: do not use it in the drinking water line. @When handling, wear rubber gloves and gauze mask to avoid direct contact with hands or other parts of the body. @ If the chemical accidentally comes in contact with skin, eyes or mouth, wash out thoroughly with fresh water. Ifthe problem persists, consult a doctor. (3) Recommended brands of corrosion inhibitor Brands of corrosion inhibitor applicable to the enclosed circuit specification of the cooling water system are shown in the following table. Brand Supplier Brand Supplier Royal Caviruston Antirust Yanmar Sangyo Co.,Ltd * Royal Freeze eeaieere eee Diesel Guard NB | UNITOR & Taiho Polyerin 1-108 NB Liquid _| Industries Co., Lid, Polycrin |- 175 Kurita Weter Industries Ltd ;o1 2000 Kuritex = 501 *Nalfeet9-771___|NALCO Japan Co., Ltd Neos PN - 1065, Naifleet 9- 108 Neos PN - 106 pecmteeane Uniprot PC = 200 Ti vuka Kogyo Co, Li Himot - 10 Taino industries Co, uta ||_UniPret PC = 300 ° " Himol AM - 5 7 Shadan K (Otsuka Chemical Co, Ltd Oigard C-601 Organo Co.,Ltd Liquide WT [ASHLAND JAPAN Co,, Li A — + In the case where the cooling water system is of the enclosed circuit specification, consult the supplier of Corrosion inhibitor because some brands drop in the concentration of corrosion inhibitor early. + Notice a corrosion inhibitor which doubles as an antifreeze has a low thermal conductivity and may be overheated during a load running + In the case where aluminum materials are in the cooling water system, use a brand of corrosion inhibitor asterisked above. YANMARC=) ati y OPERATION MANUAL Lexy Measurement of Running Performance 00 | Precaution on Measuring Performance & Measure Items No. Page 00-12-00 | 11 1. Precautions on Measuring Performance 1) Precautions During a Running Take care of the following matters during a running +e Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup. + Check whether the engine fully shows its proper performance and record the check results. (Refer to the Records of Shop Trial, then record the results on the Engine Log.) | Take care not to be caught in a rotating part. @ Never allow your hands, body and clothing to make contact or bring close to any rotat- ing part. Take care not to get hearing close. Put an ear protection in engine room during running, because can cause hearing loss. von) Take care not to burt. @ During running and immediately after the engine has stopped, the whole engine is. heated. Therefore, take care not to get burnt. Ki ell ell 2) Precautions on Measuring Performance On measuring performance, compare reading with corresponding values given in the Records of Shop Trial or the Records of Transfer Trial, and if found to be abnormal, carry out an adjustment or servicing required. LS = Refer to the following items since the engine performance vary according to the room temperature, water temperature, conditions of load, etc. (1) The dispersion of the maximum combustion pressure (Pmax) among cylinders is normal if tis within O.5MPa. ‘© Pmax may rise considerably as depended on properties of fuel oi to keep Pmax below 19MPa. ‘© Relation between the Pmax and the boost air temperature, Ifthe room temperature rises, Pmax falls; conversely, if the room temperature drops, Pmax rises. There is a tendency of Pmax 0.1MPa against the room temperature change 3°C (2) Exhaust gas temperature refers to the corresponding temperature recorded in the Transfer Trial. ‘© The dispersion of the exhaust gas temperature among the respective cylinder outlet is normal ifit is within 40°C . Even if this temperature is found not uniform among cylinders, itis unnecessary to force revising this non-uniformity if the fuel injection volume and Pmax are found uniform among cylinders. ‘# Relation between the room temperature and the exhaust gas temperature The exhaust gas temperature varies at the rate of about twice the room temperature change. Neverthe- less, use the engine within the limit values, maintaining the good servicing of the engine, etc. and reduc, ing the load because fouling of turbocharger and suction/exhaust passage, exhaust pressure, properties of fuel oil, etc. may influence this relation, |. However, in any case, run the engine YANMARGEYISIA)L OPERATION MANUAL rx) ‘Measurement of Running Performance No. Page 00 i Measurement of Running Performance 00-22-00 aa] 1, Measurement of Running Performance Check and record the following engine performance once a day while the load is stable. @ Intemal max. combustion pressure (Pmax) (Each cylinder) @ Exhaust gas temperature (Each cylinder outlet) @ Exhaust gas temperature (Turbocharger inlet) @ Exhaust gas temperature (Turbocharger outiet) ® Lub. oil temperature (Cooler inlet) © Lub. oil temperature (Engine inlet) ® Cooling water temperature (Engine inlet) ® Cooling water temperature (Engine outlet) © Cooling water temperature (Air cooler outlet) @® Cooling water temperature (Air cooler inlet) 4 Cooling water temperature (Air cooler inlet : High temperature C.W.) ® Cooling water temperature (Lub. cil cooler oullet) @ Air temperature (Air cooler inlet) @ Air temperature (Engine inlet) ® Each pressure indicated on the gauge panel ® Room temperature YANMARGEYISi\A\L OPERATION MANUAL Ora ‘Measurement of Running Performance Ne. Measurement of Running Performance 00-928-00 2, Measurement of Running Performance Fig, 00-92-1 Running Performance Confirming Points Operation Side (Fuel injection pump side) Non-Operation Side (Exh, manifold side) YANMARGEYIS\A\LL OPERATION MANUAL rd ‘Measurement of Running Performance No. Page 00 | Measurement of Max. Combustion Pressure Measurement of Max. Combustion Pressure ‘¢ Wear gloves when taking a measurement because the pressure indicator becomes hot. @ Take care not to burnt, as indicator cocks become hot when opened (1) Prepare the following exclusive tools. No. Exclusive Tool Description Part No. @ | Pressure indicator cock turing handle 13605-92360 @ | Pressure indicator 13760-93751 Fig, 00-93-1 Pmax. Measurement Procedures “Turning Handle Inserting Hole Valve Max, Pressure Indicator Cock (2)Open the vaive of pressure indicator cock with use of pressure indicator cock turning handle @ , and lightly racelrev up the engine for two to three times.(For prevention of dust and foreign matter from intruding into pressure indicator) (2) Attach the pressure indicator @), and close its exhaust valve @ (4)Be sure to fully open (do not open halfway) the valve of pressure indicator cock with the use of turning handle, and close the indicator cock when the pressure becomes the highest. (6) After reading out the Pmax, open the exhaust valve of pressure indicator. (6)Detach the pressure indicator when its needle shows 0 MPa. (When the pressure indicator cock is found hard to loosen, use the turning handle.) Ly (1) Should the dispersion in Pmax among cylinders exceed 0.5Mpa, adjust it with the injection timing of within 1° (2) Should the Pmax exceed its limiting value, adjust the injection timing upon examining the engine per- formances YANMAR| | YUYIFOYI-Ss4tt— | Cylinder Block & Cylinder Liner \l 0GEYISIA\L OPERATION MANUAL ites Cylinder Block & Cylinder Liner No. Outline 01-012-00 1, Cylinder block The cylinder block is made of a cast iron, and main bearing cap is suspended type, Ithas a dual wall construction that can handle very high combustion pressures effectively. The cylinder block houses the cam case, boost air chamber, cooling water and lubricating oil passages. This is effective not only in minimizing the external plumbing (for a simpler external appearance), but also in making the maintenance, inspection and handling of the engine easier. Fig, 01-01-1 Cylinder block 2. Cylinder liner The cylinder liner is a wet liner, and is made of a special cast iron that has superior wear-resistant character- istics. The flange of liner is a high strength design with thick walls able to withstand the high combustion pres- sures and the inner surface of liner has a honed finish ‘An anti-polishing ring is installed at the upper end of the liner to prevent carbon buildup and thus preventing wearing of the liner. Fig, 01-01-2 Cylinder liner ‘Ant-polishing ing ylindor tine: Piston YANMARGEYIS\A\L OPERATION MANUAL Trad Cylinder Block & Cylinder Liner an No. Page Overhauling the Cylinder Block orozeco | an Servicing Excluding some special cases, such as a burned out crankshaft, the cylinder block does not normally need to be removed. When the cylinder head, piston, cylinder liner, etc., are removed, perform the following checks and services: 1) Checking and servicing (1) Check for loose cylinder head bolts and main bearing cap clamp bolts. ‘© When replacing a bolt with damaged threads. Apply an anti-seize compound (Sumitomo Metal Mining's Low Call Spray, or equivalent) to the threaded part of the stud, and install the new bolt ‘Stud torque: 196 “#4 @ install the O-ring on the stud and then apply white paint Fig. 01-02-1 Cylinder Block Check Points ‘O Ring (2) Clean the boost air chamber. If the rust preventive paint applied on the inner surface has worn away, repaint it. (Epoxy resin paint: Nippon Paint’s Hi-Pon 50, or equivalent) (3) Clean the water jacket and cylinder liner holes in cylinder block, and check for corrosion. If any of the main bearings has been burned, measure the size of the main bearing cap hole. Straightness: 0.03 mm or less deviation in 11mm of length Roundness: 0.02 mm or less YANMARtj gt OPERATION MANUAL Ts Cylinder Block & Cylinder Liner No. Page 01 Overhauling the Cylinder Liner \atosecoulee Cylinder liner ‘© Periodically measure the inner diameter of the cylinder liner because the amount of wear on the inner surface of the cylinder liner varies, according to the level of control of the lubricating oil used, the cooling water temperature and the normal working load. Measure the inner diameter of the cylinder liner while itis still in the cylinder block, and with use of the inner diameter position measuring implement (Pi : 4211-02930) ‘® Remove the cylinder liner periodically and check for corrosion because the cooling water may cause corrosion in the cylinder liner water jacket and corrode the outer surface of the cylinder liner. 1) Disassembly preparation (1) Prepare the following special tools: No. | _ Special Tool Description Part No. ® | Spacer 199653-82040 | @ | Liner upper removal device | 14673-92010 @ | Bott | 137655-92030 | @ | 22137-240000 © | Nut 26732-240002 © | Liner lower removal device | 146663-92020 @ | Nut (26732-240002 ® | Lock Nut 26772-24002 (2)When removing the cylinder liner, cover the crankshaft with a sheet or protective cloth to prevent water oF foreign material from sticking to it, YANMARGEYISIAIL OPERATION MANU Ord Cylinder Block & Cylinder Liner No. Overhauling the Cylinder Liner 01-03a-00 2) Disassembly Remove the cylinder liner as follows: (1) Attach the special tools in the ascending order of the number in the drawing, shown in Fig. 01-03-1 ‘Attach the aforementioned liner upper removal device @) and the lower removal device ©) so that their respective stepped parts face the inner diameter side of the cylinder liner, and the lower removal device ® in the direction of crankshaft. Fig, 01-03-1 Cylinder Liner Drawing-out Procedures. ® [ Aut Oo Jae (2) Adjust the bolt 3 so that it protrudes below the bottom of the lower removal device 6 about 60 mm. Lock the bolt @ with the lock nut @ (3) While supporting the cylinder liner to prevent it from making contact with the cylinder, tighten the nut ©). (4) Fit the cylinder liner in stepped part on the lower side of the upper removal device @ , and lock the cylin- der liner with the drawing-out tools. (6) Attach a wire rope to the upper removal de @®, and tit the cylinder tiner. YANMAR8 GEYIS‘A OPERATION MANUAL CTL Cylinder Block & Cylinder Liner No. Page 01 Overhauling the Cylinder 01-03-00 | 3/4 3) Checking & servicing Do not use sandpaper, a wire brush, or anything scratchy when cleaning the outer surface of the cylinder liner. Otherwise, the heat-treated layer on the surface will be removed, leading to rust and corrosion. (1) f the measurement of the inner diameter of the cylinder liner exceeds the wear limit or if the measured value is likely to reach the wear limit before the next service cycle, replace the oylinder liner. (2) Check for signs of seizures, streaks or corrosion on the sliding surface of the cylinder liner. (3) Perform a dye check on the rounded part of collar of the cylinder liner to look for cracks. (4) Check for corrosion and wear in the part of the cylinder liner that mates with the cylinder block. 4)Reassembly (1)Replace the O-rings for the cylinder liner. Apply lubricating cil or silicone cil to the new O-rings and install them. Then, eliminate any torsion from the O-rings, Ly Before installing the O-rings, stretch them to check whether any cracks have developed on their surface due to changes in temperature or humidity, which might have occurred while they were stored (2) Just before installing the cylinder liner, apply silicone-based liquid packing (Three-Bond 1211, or equiv- alent) to the upper section of cylinder block. Also apply lubricating oil to the mating surfaces of the cylin- der liner and block, Fig. 01-03-2 Liquid Packing & Lubrication Points guid Packing \ Lubrication Oi Lubrication Oi eno YANMARgt oe ML ie Cylinder Block & Cylinder Liner No. Overhauling the Cylinder Liner 01-086-00 (a) Attach special tools Q ~ @ to the cylinder liner. Then, align the zero mark on the cylinder liner with the punch mark on the cylinder block. Install the cylinder liner into the cylinder block. (Do not use the spacer @ when installing the liner.) Fig, 1-03-3 Cylinder Block & Liner Set Mark -& ‘After overhauling or servicing the cylinder liner, check for water leaks around the O-rings when filing the water tank with cooling water and while test running the engine, YANMARCo eg PY bce ce me) UL rex) LY LTEAMBER No, YYYFIOYIRIAF Parts List of Cylinder Block & Liner 01-51-00 co 7 BI34 74 — I oppasite OF FLYWHEEL YANMARPE eed LU LRERBA BE No. Page 01 LYLEI AyD att Parts List of Cylinder Block & Liner al eae A: 6EYIGL B: GEYIBAL 2 aes or fo | loet | tar | Part to saat Par tame FRO [1 746623-01560 | YY FIND BLOGK, GYLINDER t[a4 [2 | 2 | x | 14662-01010 | pupa Faye BLocK, cvuinper | 1 | 1 3 [2 146673-01200 | HL (CYLAYE | BOLT, CYLINDER HEAD | 24 | 24 ale 146673-01212 | FR (AYR. 497 | NUT, HEAD CAP 4 [14 5 | 2 146673-01212 | FY (AYE. 4477 | NUT, HEAD GAP 2 | 24 6 | 2 146673-01280 | ah PROTECTOR 24 | m4 @ 7 | 2 |_| 146623-o1400 | 04399 (Lo#esy— | cover, 1/0 Gallery | 1 | 1 em aete|| 147676-01410 | CWLYS2 A> (14 | PIPE, CONNECT. 14 12 | 12 | 9 | 2 |__| 46674-01440 | cwLy5aay (7. 5 | PIPE, connect. 7.5 | 18 | 18 HOH a2 139653-01590 | =aSb | STUD 24 | 24 nf 2 | 14673-01720 | RLO Le >7.A+7 | PIECE, RLO CONNECT. | 6 | 6 “zl? | 15263-01810 | 047 O-RING 6|s ipo! 147673-01850 | A475 (cw y%70 | FLANGE, CLOSE 2/2 4 [2 138673-01990 | AyD GASKET, OIL SUMP 2/2 15 | 2 | x | 14662302030 | x20 (<—A | CAP, WETAL BASE tifa 16 | 2 | x | 146623-02050 | x3 VeryF ‘CAP, METAL 6/6 7 7{ 2 146673-02070 | Rab (50a | BOLT, WETAL CAP 14 | 14 wl 2 | 49673-02080 | #4 FRYE A | BOLT, SIDE A 14 [14 THea| 146673-11950 | 57 (YYSAyE | PLuG crLinoeR HEAD | 7 | 7 20 | 2 |_| 46673-11960 | yey (57 PACKING, PLUG fa 2 | 2 |_| 29221-40001 | aviv75y9 400% | FLANGE, 40 t{4 2|2 | 23414-12000 | yy (RW 12x41. 0 | GASKET, 12 X 1.0 fa al 2 23414-170000 | 17D (Wb 17*1. 0 | GASKET, 17 X 1.0 rita m2 2414-20000 | i> (Wh 20x71, 0 | GASKET, 201.0 | 7 | 7 % | 2 2aa14-210000 | VF (ib 21x41. 0 | GASKET, 21 X 1.0 tfa 2 | 2 23414-21000 | rivy (Rb 21%1, 0 | GASKET, 21 X 1.0 2/2 2 | 2 73426-440000 | atviiyy 44x 1. 6 | GASKET, 44 X 1.5 tf | 2 23875-01000 | AYISF RO1 PLUG, ROT [el 2 | 2 23875-03000 | AVIF7 ROS PLUG, ROS ela a0 | 2 ~ | 2a84-120002 | 60275 PLUG 2 t/a YANMAReS Dee ge wy CLC RLU ora) LY LIERHB AR No. Page 01 Yr By ] Parts tae a inder Block Liner enced 2 a r Mo | loet | tar | Fart to. aaen perce OR al 2 23887-20002 | 649957 20 PLUG, 20 7[2 a] 2 23804-090002 | 67 ITY G 3/8 | PLUG, 63/8 2/2 a3 | 2 73804-040002 | 67757 G 1/2 | PLUG, 61/2 t[a uf 2 29¢04-040002 | AI IST @ 172 | PLUG, G 1/2 2/2 | 2 24311-00090 [0427 1A P 9. 0 | PACKING, P 9.0 6 | 6 36 | 2 24311-00280 | 07 1A P28. 0 | PACKING, P 28.0 24 | 2 amie 24316-00210 | 044 4D P21. 0 | PACKING P 21.0 30 | 30 38 | 2 24316-00240 | 07 4D P 24. 0 | PACKING, P 24.0 30 | 30 | 2 24316-000350 | 09 4D P 36. 0 | PACKING, P 35.0 12 | 12 af 2 24321-00650 | 07 1A G 66. 0 | PACKING, 6 65.0 2 [2 a [2 24550-081150 | F547 yva 31x16 | BEARING, 31 X 15 12 | 12 al 2 26206-120282 | VE 12%26 BOLT, 12 X 26 3 | 8 “| 2 26206-120302 | aVE 12x90 BOLT, 12 X 80 2/2 “| 2 26232-160402 | 92akit (RAY 16x40 | STUD, BOLT 16x40 | 2 | 2 “| 2 26282-160852 | Ozaetie AY 16x45 | STUD, BOLT 16X45 | 12 | 12 a | 2 26232-160602 | 9za8Aus cavaY 16x60 | STUD, BOLT 16x60 | 1 | 1 a] 2 26732-162002 | 9238RMb (hVAYI6»200 | STUD, BOLT 16 x 200 | 1 | 1 «| 2 26732-162102 | azasans hvAYI6x210 | STUD, BOLT 16x 210 | 1 | 1 “49 | 2 26706-12002 | FY b 12 MT, 12 24 | 24 0 | 2 26732-16002 | Fb GRY 16 NT, 16 5|5 51 | 2 26732160002 | Fy k GRY 16 NUT, 16 12 | 12 s2 | 2 146673-02420 | FYDA CALS b | BUSH, GAISHAFT Tha] 33 | 1 | | 146623-01900 | Su>¥544 ASSY | LINER ASSY, OYLINDER | 6 | 6 wt | 2 | x | r46629-01160 | oye 547 LINER, CYLINDER 6 fs 85 | 2 146673-01291 | 3h PK (YYFS4F | PACKING, CYL.LINER | 6 | 6 se | 2 14619-01301 | 544.0072 | PACKING, RUBBER 6 | 6 57 | 1 140623-01120 | FaF9yayYy7 | PROTECTION RING 6 | 6 se | 1 146644-01940 | SYR PK T=1. 0 | PACKING HEAD T=1.0 | 6 | 6 soft 14644-01330 [ Ay F PK T=0. 8 | GASKET, T-0.8 6/6] 60 | 1 |_| 16644-01350 | avevey eT=1. 2 Sus | GASKET 6[s| a] 14623-02410 | 5Ab9% CHAS | METAL, CAM THRUST | 1 | 1 YANMAR4S LY LTERBBBR Seek Md eka icalbriclt rad No. Page o1 YUYVETFOIDRITF maemo Parts List of Cylinder Block & Liner in sulin las] oeme | ge ex oy | ea No | Level | Order | Part No eee ee » |e] toms 62 | 1 | | 22212-08000 | a HHA 8 WASHER, 8 6|6 ef 26206-080282 | RU 8x25 BOLT, 8X 25 66]. 0) ae YANMARCET AT a ches ch i heuieohidMidcolda ia Cae LY LTERDB BR No, YY LFW T= Parts List of Cylinder Side Cover 01-82a-00 > IR BIST } S/F “he N i) J SEAR L Wo OILLING 29 30° \ ye 258 a Ne vis? e 23-44 JSP PUWWNEEL SIDE ae YANMAROe ge bs LUSTER YUL SMart. Parts List of Cylinder Side Cover Cee No. Pree} Page 01 01-52-00 | 2/2 A: OEYI8L B: GEYI8AL -! ‘aia O'ty | Mo | let | tar | Part te saan Part Wane FS 1 14673-01381 | 7) >¥7775 (ASY | COVER ASSY, CYL SIDE | 10 | 10 ole 14673-01401 | BUDE YI IS Cover, cyLinper side | 10 | 10| a[2 145673-o14Tt | 674 (CYL 975 | GASKET, SIDE covER | 10 | 10 4fa 22137-16000 | Fax (SH 16 | WASHER, 16 40 | 40 5 26152-160352 | Rnb GhY 16x95 | BOLT, 16 X35 “| 20 | 20 6 26282-160952 | 9u28Aik (Ryty 16x96 | STUD.BOLT 16X95 | 20 | 20 7 26732-16002 | + F GRY 16 NT, 16 20 | 20 8 14623-01820 | AyD (ahevIS | PACKING GEAR cOVER | 1 | 1 9 14623-01840 | 73 CALEY COVER, CAN GEAR t/a 10 22137-12000 | FH (SA 12 | WASHER, 12 66 11 26206-120502 | #iUK 12% 50 BOLT, 12 X 60 Pee 12 26206-21002 | #UK 12x100 | BOLT, 12 X 100 a[4 13 146673-01610 | 98 (oeyY COVER, AIR cHaWBER | 3 | 3 4 | 146673-01620 | Avey (oRLYTE | PACKING, AIR COVER | 3 | 3 15 | 26206-120252 | Rk 12x25 BOLT, 12 X 26 te | | 16 [146673-01750 | mavy>s COVER, GAN BOK 3 [3 17 146673-01760 | N9%> ChASy75 | GASKET, cANBOX coveR | 3 | 3 18 22137-160000 | *Fi% (SA 16 | WASHER, 16 18 | 18 19 26152-160652 | RLF GRY 16x66 | BOLT, 16 X 65 2 | 12 20 26282-160652 | #xazns thyky 16x66 | STUD, BOLT 16X65 | 6 | 6 21 26732-16002 | FY GY 16 NUT, 16 “6/6 2 146623-01600 | 73 COVER 1/4 2B | zasti-000600 | 0VY% 1A P 60.0 | PACKING, P 60.0 1/4 24 | 26206-120282 | Rk 12x25 BOLT, 12 X 2 «[al 25 | 146623-39680 | 6275 FLANGE, OVAL [1] 26 | 23428-510000 | axvtyey 51x41. 8 | GASKET, 1X 1.5 it ea 27 26162-160502 | HULK GY 16x60 | BOLT, 16 x 60 2/2] 28 29221-490001 | aiv75¥9 49 4% | FLANGE, 49 {1 | 29 20428-610000 | aKvityey 61x1. 5 | GASKET, 51 X 1.8 tio 30 26152-160402 | HULK GY 16x40 | BOLT, 16 x 40 2[2| YANMARSoe ae eek Md Lee oh ee nlea ed LY LFERMDEE No, YU LSB STE (YY—DIILF ) Parts List of Cylinder Side Cover (Relief Valve) 01-838-00 SIDE OF FLYWHEEL o/ yp YANMAROe oe eect Ea Cl un Leb cold reed LY LTERBARE No, Page 01 YU LSM (YY—DALT) Parts List of Cylinder Side Cover (Relief Valve) | °'S9-00 | 9? As GEYI8L B: SEYIBAL e or fo | tt | har | Port nem Parc tame FEO (cial 46579-01991 | 298277 79 cover assy, cyt. sive | 2 | 2 [2 [2 [x | tass7s-o14s1 | sysy9>9 1 y-2 | cover, orLinper sive | 2 | 2 fa[2 | 1assrs-o14it | vay (oye 77 75 | GASKET, SIDE coveR | 2 | 2 oa ea 142613-08541 | KV (YT V_| GASKET, VALVE mike 5 [1 153623-08750 | Y'J—I/WF CMP | VALVE ASSY, RELIEF | 2 | 2 6 | 2 153623-08500 | AIL FYE | SEAT, VALVE | 2 | 2 7 | 3 | x | 153623-09510 | sw Fy—baRD a4 | BODY, VALVE SEAT 2/2 a | 3 153623-03520 | si FY—hty-> | PACKING, VALVE SEAT | 2 | 2 9] 2 59623-03590 | 9 y—2iWF VALVE, RELIEF 2 [2 wo] 2 153623-03640 | a/8— (Y)—DAWF | COVER, RELIEF VALVE | 2 | 2 n| 2 138613-09550 | <>K& SPRING, RELIEF VALVE | 2 | 2 | wl 2 15962-03650 | AX—+ (D/L | SPACER, RELIEF VALVE | 12 | 12 3] 2 22212-08000 | Nx FHA 8 WASHER, 8 2/12 uf 2 26206-080302 | UF 8x30 BOLT, 8 X 30 12 | 12 5] 1 22137-16000 | Faia (SH 16 | WASHER, 16 3 | 16 | 1 |__| 2s414-o80000 [ Aveey Cen axt. o | GASKET, 8 X 1.0 2] 2 7 | 1 |_| 2srs2-te0ss2 | ak chy 16x95 | BOLT, 16 x 95 em aca 18 | 1 | | 26292-160952 | axasav chvity 16xss | STUD BOLT 16x35 | 4 | 4 wl] 1 26450-80282 | BAD 7HRILE 8x26 | BOLT, 8 X 26 2/2 20 [1 26732-16002 | FYb GRY 16 NUT, 16 aa ca YANMAR