YANMAR OPERATION MANUAL MARINE AUXILIARY ENGINE 6EY22LW a e748 TR aa|H.F.. specification Contents 118 00 Engine information 01 Introduction 02 General wamings and cautions and related safety data 03 Technical data 04 General data 05 Schematic diagrams 06 Preparation setting values 07 Design dataftolerances check 08 Scheduled inspection 00 Engine operation 09 Pre-operation procedure 10 Normal operation procedures 11. Post-operation procedures 12 Emergency stop procedures 14 Operation test 15 Normal operation data sheet 16 General fault description 00 Fuel oil, lubricating oil, and cooling water 17 Fluids 01 Cylinder block and cylinder liner 01 Cylinder block. 01 Description of function 02 Inspection and maintenance 02 Cylinder liner 01 Description of function 02 Inspection and maintenance = Parts List Cylinder block & liner Cylinder side cover Cylinder side cover (relief valve) Gear case Oil sealing (SFW) Breather pipe Pump case cover 11 Cylinder head 01 Cylinder head 01 Description of function 02 Inspection and maintenance 02 Intake/exhaust valve 01 Description of function 02 Inspection and maintenance 03 Valve seat 02 Inspection and maintenance 04 Valve guide 05 Replacement 08 Valve bridge guide 02 Inspection and maintenance 06 Valve rotator 02 Inspection and maintenance 07 Nozzle sleeve 02 Inspection and maintenance = Parts List cylinder head Valve arm ass'y & bonnet Indicator valve (0000-000-01-00 (0000-001-02-00, (0000-001-03-00, (000-000-0400 (0000-001-05-00, (0000-001-08-00, (0000-000-07-00 (0000-001-08-00 (0000-001-08-00 (000-001-1000, (000-001-1100 (0000-001-12-00 (0000-001-14-00 (0000-001-15-00, (0000-000-16-00 (0000-001-17-00 0101-000-01-00 (0101-000-02-00 (0102-000-01-00 (0102-000-02-00 (0101-000-50-00 (0102-000-50-00 (0103-000-50-00 (0104-000-50-00, (0105-000-50-00 10106-000-50-00, 0107-000-50-00 1101-000-01-00 1101-001-02-00 11102-000-01-00 11102-000-02-00 1103-000-02-00 1104-000-05-00 1108-000-02-00 1108-000-02-00 1107-000-02-00 1101-001-50-00 1102-000-50-00 11103-000-50-00 YANMAR|H.F.. specification Contents 28 14 Timing gear, camshaft, and intake/exhaust swing arm 01 Timing gear 01 Description of function 1401-000-01-00 02 Inspection and maintenance +1401-000-02-00 02 Camshaft 01 Description of function 1402-000-01-00 02 Inspection and maintenance +1402-000-02-00 03 Intake/exhaust swing arm 01 Description of function 1403-000-01-00 02 Inspection and maintenance 1403-000-02-00 = Pars List Idle gear 1401-000-50-00 Camshaft 1402-000-50-00 418 Air cooler, exhaust manifold, and turbocharger 01 Air cooler 01 Description of function 1801-000-01-00 02 Inspection and maintenance 1801-000-02-00 02 Exhaust manifold 01. Description of function 1802-000-01-00 02 Inspection and maintenance 1802-001-02-00 03 Turbocharger 01 Description of function 1803-000-01-00 04 Cleaning 1803-000-04.00 04 Cleaning 1803-001-04.00 = Parts List Air cooler 1801-000-50-00 Exhaust gas manifold 11802-000-50-00 Exhaust gas manifold cover 11803-000-50-00 Turbine 1804-001-50-00 Turbine mount 41805-000-50-00 Air duct (TPS48) 1806-000-50-00 Air duct (TPS52) 1807-000-50-00 Exhaust gas outlet pipe 11808-000-50-00 Boost air pressure pipe 11809-000-50-00 Blower washing pipe 1810-000-50-00 Blower washing too! (TPS) 181 1-000-50-00 Insulation covering 1812-001-50-00 Turbine water filing pipe 1813-000-50-00 Blower & turbine washer 1814-000-50-00 24 Main bearing, crankshaft, and oil sealing cover 01 Main bearing 01 Description of function 2101-000-01-00 02 Inspection and maintenance 2101-000-02-00 02 Crankshaft 01 Description of function 2102-000-01-00 02 Inspection and maintenance 2102-000-02-00 03 Flywheel 01 Description of function 2103-000-01-00 03 Adjust 2103-000-03-00 = Parts List Main metal 2101-000-50-00 Crankshaft & flywheel 2102-000-50-00 Fiywheel pointer & tuming device 2103-000-50-00, YANMAR|H.F.. specification Contents 3/8 22 Piston and connecting rod 01 Piston 01 Description of function 02 Inspection and maintenance 02 Connecting rod 01 Description of function 02 Inspection and maintenance = Pars List Piston Connecting rod 30 Lubricating oil system 00 Lubricating oil system 01 Description of function 1 Lubricating oil pump 01 Description of function 02 Inspection and maintenance 02 Lubricating oil pressure control valve 01 Description of function 02 Inspection and maintenance 03 Lubricating oil thermostat 01 Description of function 02 Inspection and maintenance 04 Lubricating oil strainer 01. Description of function 02 Inspection and maintenance 08 Lubricating oil cooler 02 Inspection and maintenance 06 Lubricating oil bypass filter FM200DS. 01 Disassemble procedure 04 Cleaning Pats List Lubricating oil pump Lubricating oll priming pump Lubricating oil cooler Lubricating oll pressure regulating valve Dipstick Lubricating oi strainer Lubricating oil by-pass strainer (FM200DS) Lubricating oi! thermostat Lubricating oll pipe (pump to cooler) Lubricating oll pipe (strainer to by-pass strainer) (FM200DS) Lubricating oil pipe (strainer OUT) Lubricating oil pipe (turbine) Lubricating oll pipe (priming) Lubricating oll pipe (governor) Lubricating oll pipe (generator) Lubricating oil pressure gauge pipe Lubricating oll pipe (pinion lubrication) 2201-000-01-00 2201-000-02-00 2202-000-01-00 '2202-000-02-00 2201-000-50-00 2202-000-50-00 3000-000-01-00 3001-000-01-00 3001-000-02-00 3002-000-01-00 3002-000-02-00 3003-000-01-00 3003-000-02-00 3004-000-01-00 3004-000-02-00 3005-000-02-00 '3006-000-01-00, 3006-000-04-00 3001-000-50-00 3002-000-50-00, '3003-000-50-00 3004-000-50-00 3005-000-50-00 3008-000-50-00 307-000-5000 3008-000-50-00 3009-000-50-00 3010-000-50-00 3011-000-50-00 3012-000-50-00, 3013-000-50-00, 3014-000-50-00 3015-000-50-00, 3016-000-50-00 '3017-000-50-00 YANMAR|H.F.. specification Contents 48 40 Cooling devices (00 Cooling water system (ireshwater-treshwater dual system) 01 Description of function 4000-000-01-00 1 Cooling water pump 02 Inspection and maintenance 4001-000-02-00 02 Cooling water thermostat (high-temperature water) 01. Description of function 4002-000-01-00 02 Inspection and maintenance -4002-000-02-00 03 Cooling water selecting valve (low-temperature water) (option) 01. Description of function 4003-000-01-00 02 Inspection and maintenance -4003-000-02-00 = Parts List Cooling water pump (high-temperature water) 4001-000-50-00 Cooling water pump (low-temperature water) -4002-000-50-00 Thermostat (high-temperature water) 4003-000-50-00, Cooling water outlevinlet pipe (one-pump mixing specification) 4004-000-50-00 Cooling water outleviniet pipe '4005-000-50-00 Cooling water pipe (high-temperature water) (pump to IC) 4006-000-50-00, Cooling water pipe (low-temperature water) (pump to /C) 4007-000-50-00 Cooling water pipe (low-temperature water) (without svitch valve) -4008-000-50-00 ‘Switch valve (low-temperature water) (option) ‘4009-000-50-00, Cooling water pipe (L.O. cooler OUT) 4010-000-50-00, Cooling water collecting pipe 4011-000-50-00 Cooling water drain pipe 4012-000-50-00 Air vent pipe (a cooler) & water drain pipe (boost air chamber) 4018-000-50-00, Pressure gauge pipe 4014-000-50-00 Cooling water pipe (warm up) 4015-001-50-00 Orifice 4016-000-50-00 YANMAR|H.F.. specification Contents 5/8 50 Fuel oil system 00 Fuel oil system 01 Description of function 01 Fuel injection valve 01. Description of function 02 Inspection and maintenance 02 Fuel feed pump (M.D.0)) (option) 01 Description of function 02 Inspection and maintenance (03 Fuel injection pump 01 Description of function 02 Inspection and maintenance 04 Fuel injection pump drive unit 01 Description of function 02 Inspection and maintenance 06 Fuel strainer 01. Description of function 04 Cleaning 07 Fuel oil pressure control valve 01. Description of function 02 Inspection and maintenance 08 Seal pot 01 Description of function 02 Inspection and maintenance 09 Float switch 01. Description of function Pats List Fuel injection valve Fuel injection pipe Fuel feed pump (M.0.0,) (option) Fuel injection pump Fuel injection pump drive unit Fuel oll strainer Fuel pressure regulating valve & overflow fuel tank Fuel oil pipe (feed pump inlet / outlet) (option) Fuel oll pipe (strainer to main pipe) Fuel oil main pipe Fuel oll pipe (main pipe to pressure regulating valve) Overflow fuel ol pipe (cylinder) Fuel oll leak defection pipe Drain pipe & overflow fuel oll pipe (engine outlet) Fuel valve overflow fuel oll pipe (head OUT) Fuel valve overflow fuel oll pipe Drain pipe & blowoff pipe (fuel ol strainer) '5000-001.01-00 '5001-000-01-00 001-001-02-00 '5002-000-01-00 5002-000-02-00 '5003-001-01-00 003-001-02-00 '5004-000-01-00 5004-000-02-00 '5006-001-01-00 '5006-001-04-00 '5007-001-01-00 5007-001-02-00 '5008-000-01-00 '5008-000-02-00 '5009-000-01-00 '5001-000-50-00 '5002-000-50-00, '5003-001-50-00 '5004-000-50-00 '5005-000-50-00 '5006-001-50-00, '5007-001-50-00 '5008-001-50-00 '5009-001-50-00 '5010-001-50-00 '5011-000-50-00, '5012-001-50-00, '5013-000-50-00, '5014-000-50-00, 5015-000-50-00 '5016-001-50-00 '5017-001-50-00, YANMAR|H.F.. specification Contents ae 60 Governor and governor drive unit 01 Govemor 01 Description of function (NZ) 6001-000-01.00 01 Description of function (UGB) 001-002-0100 01 Description of function (UG-25*) 6001-003-01-00 02 Govemor dive unit 01 Description of function 002-000-0100 02 Inspection and maintenance 6002-000-02-00 03 Speed control device 01 Description of function 003-000-0100 03 Adjust (NZ) 6003-000-02-00 03 Adjust (UGB, UG-25") 6003-002-02-00 04 Star’stop handle 01 Description of function 004-000-0100 02 Inspection and maintenance 6004-000-02-00 = Pats List Hydraulic governor (NZ61) 6001-000-50-00 Hydraulie govemor driving device (NZ) 6002-000-50-00 Hydraulic governor driving device (UG8) 6002-002-50-00 Hydraulic governor driving device (UG-25*) 6002-003-50-00 Speed relay 6003-000-50-00 Speed control device 6004-000:50-00 Starstop handle 6008-000-50-00 Link assy (NZ) 6006-000-50-00 Link a'ssy (UGB) 6006-002-50-00 Link a'ssy (UG-25") 6006-003-50-00 3R YANMAR|H.F.. specification Contents 78 65 Special attachments 01 Stop solenoid valve 01 Description of function 501-000-0100 02 Inspection and maintenance 6501-000-02-00 02 Operating station selector 01 Description of function 502-000-0100 03 Pressure gauge 03 Adjust 503-000-03-00 04 Digital thermometer 02 Inspection and maintenance 6504-000-02-00 (05 Fuel injection volume control ar piston & stopping ar piston 01 Description of function 66506-000-01-00 02 Inspection and maintenance 6506-000-02-00 05 Stopping air piston 01 Description of function 508-003-0100 02 Inspection and maintenance 6506-100-02-00 = Parts List Control air pipe (fuel cut) (3 connects) 6501-000-50-00 Control air pipe (stopping air piston) 6501-003-50-00 Control ar joint 502-000-5000 Control air joint (low-temperature water) (with switch valve) 6503-000-50-00 Magnetic pick-up 504-000-50-00 Gauge pane! 508-000-5000 Pressure switch (controlar) 16506-000-50-00 Pressure switch & transmitter (6 connects) 6507-000-50-00 Pressure switch & needle valve (starting ait £6508-000-50-00 Pressure transmitier & needle valve (fuel oi) 6509-000-50-00 Temperature switch 510-000-50-00 Resistor CMP 511-000-5000 Junction box 6512-000-50-00 Thermometer 8513-000-50-00 Float switch (lubricating oil sump tank) 6514-000-50-00 Fuel injection volume contol air piston & stopping ar piston __6515-000-50-00 Stopping ar piston 6515-003-50-00 3R YANMAR|H.F.. specification Contents 8/8 70 Starting device 00 Air stating pipe device 01 Description of function 01 Airfiter 04 Cleaning Parts List Air starter Starting air pipe (arstrter inlet) Starting air pipe (pressure switch valve) Control air pipe (inlet) 92 Disassembly tools, other tools 01 Hydraulic jack 04 Description of function 02 other tools 08 Measurement = Parts List Hydraulic pump & hydraulic jack (cylinder head) Hydraulic pump & hydraulic jack (main bearing cap) Hydraule pump & hydraulic jack (connecting rod) Slandard tools Oil drain pan Special tools Cylinder head support APPENDIX ‘YANMAR Worldwide Service Network List TURBOTWIN engine & ar starter TS0-P service manual Integral relay valve installation and operation manual ‘7000-000-01-00 7001-000-04-00 7001-000-50-00 7002-000-50-00 7003-000-50-00 "704-000-5000, 9201-000-01-00 19202-000-08-00 '9201-000-50-00 '9202-000-50-00, '9203-000-50-00, 19204-001-50-00 19205-000-50-00, 19206-000-50-00, '9207-000-50-00 YANMAReee Coe [Engine information Introduction 6 1. Introduction ‘Thank you for purchasing a YANMAR diesel engine. ‘This Operation Manual has been prepared for your safe and effective use of this product. Before you use this product, carefully read and fully understand the instructions about operation, inspection and maintenance. Keep this manual in a safe location. Make sure that the operator can always read it, Because the inspection and maintenance instructions are for professional technicians, necessary but basic knowledge has been omitted. 1.1 Using this manual + The text and illustrations of this operation manual can partly disagree with products of some specifications. In that case, refer to the separate Engine Specification and Final Drawing, + The contents of this operation manual can change without prior notification to improve the quality and performance of the product and to improve safety. + For disassembly and maintenance of special specifications (e.g. the turbocharger and govemon, refer to the separate operation manuals + Ifyou lose or damage this operation manual, please contact YANMAR or your sales or service agent. Ifyou transfer this engine, also transfer this Operation Manual, Final Document and Records of Shop ‘Trial with the engine to the next owner. + The numerical values in this manual are based on the SI system (Intemational System of Units) 1.2 Inquiries + Only use genuine YANMAR replacement parts or other specified parts. Order parts from your nearest YANMAR sales or service agent. When you order a part, clearly specify = Engine name (model) - Engine serial number - Part name - Part number. + Ifyou: use the engine differently from the intended usage purpose or conditions OR + operate the engine differently from the contents ofthis operation manual, you can cause accidents and malfunctions. Before you make a modification to the engine, contact, YANMAR or your sales or service agent. Do not make a modification that is not approved by YANMAR. + If you have questions or comments about this manual, please contact YANMAR or your sales or service agent YANMAReee Coe [Engine information Introduction 26 2. About this operation manual ‘The major terms used in this operation manual are defined as follows: The front of the engine: opposite side of the flywheel The back of the engine: the flywheel side Operation side: on the left side as viewed from the flywheel side (fuel injection pump side) Non-operation side: on the right side as viewed from the flywheel side (exhaust manifold side) Turn right: clockwise rotation as viewed from the fywheel side Turn left: counterclockwise rotation as viewed from the flywheel side Cylinder number: counted from the flywheel side (1, 2,3, ..) Flywheel oll! TED [Joriven mecrine Turn right (Close rotation) Turn left (Counter ockise rotation) Fig. List of terms YANMARHae 0000-000.01-00 Introduction 35, [Engine information 3. About this operation manual ‘See the index for an overview of related contents, ‘The contents ofthe titles are as follows, Inspection and maintenance 10 somes 1" Fig.2 List of titles Engine series Topic-specific codes Function parts Tasks Number of pages “Task conditions: shows the required preconditions for each part to perform the task Personnel: required standard man hours Tools required for the task ©. Supplies: consumable products (e.g. lubricating cil, grease, wire) (May not be included in the standard delivery) 10. Spare parts: consumable parts (e.g. O-rings, gaskets, toothed washers) (May not be included in the standard delivery.) 11. Safety precautions: shows safety precautions that apply to the whole chapter YANMAReee Coe [Engine information Introduction a6 4. About the parts list A parts list is attached to this manual. It is sorted by part categories. {A figure withthe integrated parts and their reference numbers is on the first page. ‘The parts are listed with their part names and part numbers on the pages that follow. ‘The list is sorted as follows. Cae COREE Cylinder Block & Liner ustrated parts data 3 4 5 6 ik ie oe 2 itesearn BOLT CYUROER HEAD mow 2 mest NUT CaP oa Fig.3 List of parts 1. Part category In this operation manual, all parts are sorted in categories. Parts are listed together with related pars. ‘Therefore, some parts are possibly listed in more than one category 2. Reference number The number in the figure. 3. Level Nominal parent-child relationship of the parts 1: Parent parts (assembly parts) 2: Child parts included in “1" 3: Child parts included in “2", grandchild parts in terms of “t 4. Part number The individual number ofthe part. Please use this number when you order a part, 5. Part name ‘The official part name. Please use this name when you order a part. 6. Number of parts (sorted by mode!) How many of the part are used per engine, ‘Abbreviation: Engine model Lw: 6ey22L-W ALW: 6EY22AL-W YANMARGEY22W eed [Engine information Introduction 86 5. Symbols for piping and instruments ‘This operation manual uses these symbols for the piping system. Instruments Valves. Piping parts Pump BE] Giote vaive J Fiange sitting Plunger pump Ded | Needie vaive | Reducer Differential pressure gauge Pq | AWomatepmessue TA | Avent pipe I@E| or signa De | Atorste terme. “| Safety plate |_| Grazed level gauge Lea | Safety valve © | Accumulator @)| Pressure switch 1&1 | solensid vaive | Capillary tube (| Temperature swtcn | P<] | Pressure reducing vane | cut | Cupper pipe Float switch TO Diniex check vane | stra | EaeOn Steet PRS Diferental pressure Sw | [TBI] velocity reguating vaive | stam | Caton See! pie, @| Pressure rarsmiter | Op | Fomvelume regulating | gre | Machine structural aaisance trp. eens 08, | Pipe outside diameter [(@)| Temecaune 1B. | Pipe ier meter Fa e 3 iB a Valves that are always closed (globe valve, angle valve and needle valve) are shown in black. pla : Always open plq : Always closed Fig.4 Symbols YANMAReee Coe [Engine information General warnings and cautions and related safety data Ww 4.For your safety ‘This manual and the engine have safely indications. They are important symbols and warnings that are necessary to operate this product safely. ‘The safety indications tell you this: This safety symbol is used with most safety precautions. Itis @ precaution and a warning. It tells you: Be careful! This is about your safety! Carefully read and obey the instruction that comes with this symbol. DANGER indicates a hazardous situation which, if not avoided, STEER wi cosutn death orserous nur. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates @ hazardous situation which, If not avoided ACAUTION could cosuit in minor or moderate injury NOTICE indicates a situation which can cause damage to the Nees ‘machine, personal property and /or the environment or cause the equipment to operate improperly. Fig. Signal word YANMAReee Coe [Engine information General warnings and cautions and related safety data a7 2. Basic precautions 2.1 Obey the safety instructions When you operate or do maintenance on the engine, obey all safety instructions, precautions and work procedures. + When you do work in a team, use signals (e.g. commands, hand signs). All personnel must know the signals, Put on the correct work clothes. Do not put on work clothes with oll stains. They burn easily. Put on protective equipment that is applicable for your task. E.g. helmet, safely goggles, safety shoes, protective mask, protective gloves, lifeline. Use the applicable tools for the task, Use the correct special tools of the engine. Do not jump on or off the engine. Prepare a workbench that has the applicable dimensions for the engine. Safety the footing of the workbench. Do not do work from a dangerous body position. 2.2 Inappropriate modifications YANMAR is not responsible for injury or damage that is the result of not approved modification. If a modification is necessary, speak to a representative of the service network (see the append + Your engine and its safety devices are sealed for safety. Do nat remove the safety seals. + Ifa safety seal is removed, immediately speak to a representative of the service network (see the appendix). Obey their instructions. 2.3 About airflow Make sure that the engine room has good airflow and sufficient air (oxygen). + Itis very dangerous to breathe exhaust gas. If you find an exhaust gas leak, repair it immediately + Alot of air (oxygen) is necessary for the turbocharger... Make sure that the room has sufficient air. + The battery makes hydrogen gas when it charges, The gas is very flammable, Make sure that the hydrogen gas does not stay in the room, 2.4 Install a fire extinguisher and first-aid kit Know where the fire extinguisher is. Know how to operate it. Make a decision about the safety procedures for fres or accidents, The safety procedures must include a contact person and a telephone number. Fist A Kit Fie Eineusher eneriney Prone PTY N 3 Fig.2. Symbols 2.8 Safety device check This engine has safety devices, e.g. the covers of the rotating parts, the heat shielding covers of the exhaust pipe, and the protective covers of hot engine parts, Make sure that these safety devices are correctly installed. If they are damaged, repair them immediately + Never remove the covers of the rotating parts when the engine operates. If your clothing, hands or ‘other body parts are caught, injury can occur. 2.6 Working with flammable material (e.g. fuel oil, lubricating Alfie is strictly prohibited in the engine room, Fuel oll and lubricating oll bum easily. Especially the fuel oil is very flammable and dangerous. + Cigarettes, matches and lighters are not permitted near flammable material + When you do welding or grinding, be careful of sparks and keep flammable material away. + Keep the fuel oil and lubricating oil in the specified location. Make sure that only approved persons use them, + Do not keep flammable material in the room that is not necessary. YANMAReee Coe [Engine information General warnings and cautions and related safety data 37 2.7 Working on hot portions or portions under high pressure During operation and immediately after the engine stops, all of the engine is very hot. Be careful that you do not get bumed. + Replace cooling water, lubricating oil and fiers when the engine is cool Do not touch hot engine parts (e.9. the exhaust pipe or pressure indicator cock) with bare hands. Put on gloves. Do not touch the heater and heated sections of the fuel oil system with bare hands. When you open a plug or cap, steam or hot water can come out and burn you. Stop the engine and wait until it is cool, Then slowly turn the cap and release the pressure, Then remove the cap. 2.8 Inspection of the electrical system Obey the instructions that follow when you do maintenance of the electrical system, + Before you start your task, disconnect the power source. It can cause an electric shock or fire. + Before you do an inspection of the battery system, make sure that you disconnect the grounding ‘cable (-) terminal. If you make an incorrect connection and cause a short circuit, a fire can occur. + Battery Mui is a strong acid. It causes inflammation to the skin and eyes, If you get it on your skin or in your eyes, immediately flush the area with a lot of clean water. Get medical aid 2.9 Using organic solvents Obey the instructions that follow when you use organic solvents. + Organic solvent turns into gas and can be breathed by personnel. This is dangerous. Make sure that the room has sufficient airflow. ‘+ Organic solvent in high concentration can dissolve fats and is absorbed by the skin. This is dangerous. Put on protective gear when you use organic solvents. YANMAReee Coe [Engine information General warnings and cautions and related safety data 47 3. How to lift the engine Do not let the engine or driven machine fall when you lift or move it It is very dangerous. To prevent an accident, obey the instructions that follow when you lift the engine. + Use a wire rope and shackles that are applicable to the engine weight. + Use a wire rope with the correct Ienath. The engine or common bed must not tt to one side. + Put a padding (e.g. a wooden block) between the wire rope and the engine or a driven machine. + Attach the padding to prevent damage to the engine or driven machine. Use a padding that does not break or fall during iting, + Do not go into the area below the lifted item, 3.1 Installation location for lifting tools = Generator set When you lift the engine, use the lifting metal piece that is on the bottom of the common bed. IMiN.1300 Less than 60 de, Mn.2400 Fig.3 How to lif the generator set YANMARCe Hae General warnings and cautions and related safety data [Engine information SIT 4. Location of safety labels (warning labels) ‘To make sure that you use the engine safely, the engine has safety labels (waming labels). Carefully read all safety labels to prevent accidents. Ifa safety label is dirty or missing: Find the part number and send an order for a new safety label to your ‘YANMAR sales agent, (Refer to the service network list "YANMAR Worldwide Service" in the appendix of this manual.) When you get the new safety label, attach it to the specified location 4 2 2 A_CAUTION a Sao a8. diam. 922 rene. eronnenucran eese i ale oe a an No. CODE No. CODE 1] _ap208.028700 [5 | _42621-070480 2[satese.07240 [6 | sasexe.07200 3_|“sa1ereo7230 [7 | ratte o7z10 4 [“1are1607270 Fig.4 Location of safety labels (warning labels) YANMARHae gs and cautions and related safety data 67 [Engine information General wart 1 2 RRERA= ARRLORE A 2 4 caution | SSS Sea: Sen | (eee Sowenin| Pee: No. CODE No. Cope 1] 14673-07290 4] 14161607250. 2 [1s1616.07220 5 | 14161607240 ai Ne CODE Seine Fig.5 Location of safety labels (warning labels) aR YANMAReee Coe [Engine information General warnings and cautions and related safety data WW 5. Precautions before maintenance 5.1 Putting a warning notice Put a warning notice board when you do an inspection or servicing of the engine. + Tell all related personnel about your work. + Tell all unrelated personne! to not go in the engine room. 5.2 Maintenance immediately after engine stop Do not open the cylinder side cover for 10 minutes after engine stop. Ifnew air comes into the engine immediately after engine stop, an explosion can occur. Immediately after the engine stops, all of the engine is very hot. Obey the instructions that follow to prevent bum injures. + Make sure that you (e.g. your hands, body and clothing) do not touch the turbocharger, exhaust ‘manifold, exhaust pipes or engine body. + When you drain lubricating oil, be careful that you do not get burned by the oil (including small drops of oi. + When you disassemble the cooling water system, steam or hot water can come out and burn you, ‘Wait until the engine is cool. Then put the plug or tightening nut in a waste cloth. Slowly loosen it. 5.3 Preparation before work Before you start work, make the engine room clean, Make sure that all spare parts and tools are at their specified locations. Prepare the following objects as necessary for the task + Tools and accessories + Lubricating oil, genuine parts, waste cloths, wire and others. + Workbench suitable to the engine height + Wire rope (Do not use wire rope that has broken strands, wear, twists, deformations or defective ends.) 6. Maintenance precautions 6.1 Precautions during work When you do work in a team, carefully examine the area around you to prevent any dangers. Obey the instructions that follow during engine inspection and maintenance. + Keep all removed parts safely and make sure that they do not fall + When you do work at a height, put on the safety belt or ife-line. + Put on the protective equipment that is applicable for your task. + Be careful when you hold items with dity gloves. The items can fall and cause damage or injuty. + Iffuel or lubricating oil spills, clean the area immediately. You can slip and fall 6.2 Use the applicable tools Make sure that you understand how to operate the special tools before you use them. + When you lit heavy objects, obey the instructions of the slinger (the person who puts the object on the crane), + Carefully examine the rubber hose and the joints of the hydraulic jack for damage. + Use the applicable liting gear and be very careful when you do work with heavy objects, + When you weld or grind, put on protective equipment. 7. Precautions after servicing 7.1 Precautions after work Obey the instructions that fllow ater you do engine inspections and maintenance. + Put back all tools (e.g. liting gear and wires) to their correct location. + Remove all lubricating oil that is not necessary from the engine room, + Remove the warning notice board. Tell all related personnel that your work is complete, YANMARGEY22W ered [Engine information Technical data 4 4. Engine specification Engine model Eva Type : Vertical, water-cooled, 4-oycle diesel engine Number of ovinders 7 3 Cylinder bore = stroke mam B20 x 320 Total displacement z 7298 ‘Combustion method 7 Direct injection ‘Compression ratio. 7 1524 ups |_2W [880 [748 [ato [00 [a7 [i080 Continuous rated wwe | 600 | 680 | 740 | 800 | 900 | 1020 output Rota: + ree mi 7201750 fee) Ceres - Left (viewed from the flywheel side) Firing order 7 T4263-541 ‘Operation side + Right (viewed from the opposite side of the flywheel) ‘Type of turbocharger - Exhaust gas turbine turbocharger (with air cooler) Forced lubrication by intemal pump Lubricating system 7 (The system oilis also used as turbocharger lubricating oi) (The system ols also used as rocker arm lubricating oil), Type of hubriating oitsump | = ‘Sump incorporated in the common bed Type af cooling : Freshwater freshwater mix cooling system Type of starting : Air starter eet om Spare mers Tove] a (engine body) | wet Refer tothe Final Drawing Overall | am height Engine dry weight : (engine body) YANMARCe [Engine information GEY22W Technical data aa Engine model GEYI2ALW Type 5 Vertical, water-cooled, 4oycle diesel engine Number of eyinders és 6 Gylinder bore x stroke Tam B20 ¥ 320 Total displacement z 72.98 ‘Combustion method 5 Direct injection ‘Compression ratio 5 75.21 up |_RW [880 [970 | i020 | vio | vi80 | i900 | 1370 Continuous rated wwe | 800 [900 | 950 | 1000 | i300 | 4200 | Ta00 Diecionel cesianet ; Left vewed from the feet side) Firing order 7 TAROT ‘Operation side 5 Right (viewed from the opposite side ofthe wheel) ‘Type of turbocharger : Exhaust gas turbine turbocharger (with air cooler) Forced lubrication by internal pump Lubricating system ' Che system ols also used as turbocharger lubricating il) (The system oil also used as rocker arm Lbricating oi) Type of beating of ; ‘Sump incorporated in the common bed Type of cooling 5 Freshwater freshwater mix Cooling system Type of starting 5 ir starter Overall | length Epanecimen- Tore) — (engine body) Refer tothe Final Drawing, Overall | am height Engine dry weight : (engine body) YANMARCoE [Engine information GEY22W Technical data a4 2. Accessories & attachments Aasessories & devices Tipe Remarks Turbocharger Exhaust gas turbine = ‘Charge air cooler Plate-fnned, mull-tubular E Governor Hydraulic : Fuel injection pump Bosch E Fuel injection valve Mulichole Without cooling Fuel feed pump Gear Option with insulator and differential Fuel strainer Changeover, mesh type "a typ pressure gauge Lubricating oil pump Gear 7 Lubricating olf cooler Tow finned tube, multctubutar With thermostat Lubricating oil strainer ‘Selt-backwashing Lubricating oll bypass fiter Centrifugal : Cooling water pump (freshwater) Centrifugal Air starter Turbine : YANMARHae 0000-004-03-00 Technical data 44 [Engine information 3. Weight of major parts ‘When you lif a part, use a rope, lifting gear and hook that is appropriate to the weight of the part Part name Unit] 6EV22LW | 6EV22ALW Remarks Cylinder head * | 179 : Piston & connecting rod assembly " 7 - Cylinder liner” 68 e Charge air cooler” 150 = Lubricating oll cooler 185 a Turbocharger 175 220 = Fuel feed pump 25 a Fuel strainer 7 7 Lubricating oil pump 5 = Cooling water pump 38 = Air starter kg 195 : ‘Camshaft (Split in 2 paris) 96,75 a ‘Camshaft drive gear 28 . Idle gear assembly 7 2 eae oe : Main bearing cap * 40 s Gear fosing on he opps sie of ae 2 Cylinder block "2800 . ‘Crankshaft 1308 1101 _| including balance weights Flywheel 1420 828 Including the ring gear *: Use the special tool to disassemble. YANMAReee Coe [Engine information General data 1 4. Conversion table for the International System of Units (SI) and other units ‘The conversion values in this table are based on the SI and metric system. Force N Tat 7 0701972 9.80665 i Force momentum, torque Nm kgfm i | 0.101972 380865 i Pressure Pa ration? mag Tami 1 1.0197 x 10° 41,0197 * 10 7.501 «10% 9.80665 = 104 1 1.0000 « 10 7.356 x 107 9.80665 x 10° 1.0000 « 107 7 7.356 «10 4.3332 « 107 1.3595 « 10% 1.3595 « 107 : Work, eneray RW 7 Kear rar 1 3.6 x 10° 8.600 x 107 3.671 x 10° 2.778 x 107 ul 2.389 « 104 1.0197 « 107 1.163 «102 4.106 « 10° T 4.269 « 107 2724x108 9.80685 2.343 «109 1 Power RW PS 7 : 1.3596 07385 7 YANMARGEY22W eed formati Schematic diagrams U3 4. Engine view Coating water tm regtiating vale Tuocharge Engine panel Fate! Hyerauic governor Fal prossure contol valve Lubricating of strainer (auiomate baclewasher type) — Lubricating of tmp Fegulating valve Ai cooler Coating water pump Lube ot pss requ vale Lube ol cooler: FFig.2 Non-operation side (exhaust manifold side) YANMARGEY22W eed Schematic 2s I view of the engine exhaust vabe Intake vaio. ner need ston pn yin lack ear case ae Tost bearing ie gor a yao Crankshat gear Main bosrig. Cranks Spina goer Fig.3. Vertical view of the engine YANMARGEY22W eed [Engine information Schematic diagrams 33 3. Horizontal view of the engine Valve beige Exhaust mani Rocker am ~F Boost chamber Fustinjecton vate 7 Cong water Pretec i Luang Piston cng © Cynder bok Fu injection pare aera ) comecing ok. seat nite an rar ap Euloce wo an tig bat oO | Oommen o Oris Fig.4 Horizontal view of the engine YANMARae CREED Preparat [Engine information in setting values 2 1. Protective device setting values Tem Unit] Alarm setting value | Emergency stop setting value Engine inlet lubricating oll pressure MPa os T O45 Engine cooling freshwater temperature | °C 95 100 fl TI2% to 115 % ofthe rated Rotational overspeed mi : speed 2. Holding volumes of lubricating oil and cooling water Tem Unit_| Holding vorume Engine (incl, cooler, fiter & piping) 30 Lubricating oll tank (common bed) 1200" Lubricating oil Type NZBT 13 Governor Type UGB a 15 ‘Type UG-25* 24 ‘Cooling water [Engine (incl. piping) 150 (freshwater) __[ Cooler (ubricating oi, air) 40 *:The values may be different depending on the specification, Refer to the Final Drawing 3R YANMARHae Corr [Engine information Preparation setting values 22 3. Pressure and temperature settings ltems shown in the table below for which monitoring are required vary depending on the regulation and specifications. Tem Unit | Setting value Remarks 0000-001-17 Fuel supply pressure Recommended pressure in MPa : Refer to the Records of g:l¥omaimaximum combustion pressure (Pax) ereanel & [Labrcating of pressure Mpa |——o551006 & [Cooling water pressure Gacket cooling line) 01810050 ‘Cooling water pressure (cooler cooling ine) 0.1810050 Stara pressure [Stig airreservoir 294 Lower limit 7.16 ls [After decompression 0.85 to 1.0 At the air starter inlet ‘Cooling water engine outlet temperature ‘24 ‘Cooling water lubricating lf cooler niet <38 g | temperature = | Lubricating oil engine inlet temperature 2 § | (cooter outlet c ke é 5 Refer to the Records of © | Exhaust temperature (at each cylinder outlet) ‘Shop Trial . Refer to the Records of Exhaust gas turbocharger inlet temperature eae *: Refer to the Records of Shop Trial and records the values on this page. The values are different depending (on the engine specification and output YANMARce GEY22W [Engine information Design data/tolerances check 13 4. Assembly adjustment values item Unit] Adjustment value Remarks Piston top clearance (A) ran 22440.18 g | Open (before TD.C) 50 > £ aa 5 [Closed (ater B.C) ° = & | B | vatve nead clearance ©) mm 04 When engine is cold & | | Open (before BD.) 49 = 3/2 eo 5 |S | Closed (atter7.0.C) 34 5 E | | valve head clearance (8) mm 08 When engine is cold Refer tothe Fuel injection pump begins injections eed deg, Records of Shop Trial, ‘Opening pressure (Tel injection valve) MPa 45.005 5 *: Refer to the Records of Shop Trial and records the values on this page. The values are different depending ‘on the engine specification and output. noe ae Fig. Assembly adjustment values Adit 8 ator ‘oting ito 2070 YANMARCore [Engine information GEY22W Design data/tolerances check 2n3 2. Clearance & wear limits of major parts skitt Nominal Standard] Wax alowable | Usage imitot os dimension | T*¢° | Gearance | “clearance |. pas Tnner diameter ofthe top part of 70088 aan the cylinder block (top) 2304 40.056 | A1=0.126 ‘Outer diameter ofthe top part of “0070 | 100.193 rr the eylinder finer (top) “0.105 inner diameter of the fop part of +0032 sone the cylinder block (bottom) re 0 |a2=0020] py 95 ‘Outer diameter ofthe top part oF 0020} 100.087 aa the cylinder liner (bottom) 0.055 = |rinner diameter ofthe cylinder 0.032 ais 5 | bottom) a 0 | 0015, & | Outer diameter of the oylinder “0015 | 100.091 ae & | ner (bottom “0.059 2 c=2.06 § | Top clearance 224 | sore | C7208 | nner diameter of the protection | 5 >154 | 40.08 oe S |ing #155 7 ‘Outer diameter ofthe piston | > 573 | ayqp | 10188 ' head Inner diameter of the cylinder 40.040 ates frre 2220 oa. Uneven wear 00.192 o2 ‘Outer diameter ofthe piston 15 >+5 966] anon oo *:20 mm from the piston head Fig.2 Cylinder and cylinder ner YANMAReee Core [Engine information Design data/tolerances check 313 Nominal Siandard | Max alowable | Usage imi ee dimension | T°? | clearance clearance of parts: FE Thickness ofthe ison ngs | Wo 77 | aos ’ : ay No. 1 to No. 2 Nee Thickness ofthe oilrings | F580 025 5° ~~~ . a7 5 “0070 ‘Width ofthe piston ring (No. 1) Boao | Not Not 015 6 G=0.110 ‘Waa ofe piston ring groove F015] feo qss | | G=04 7085 g | No. 1) +0.100 £ a] -0.030 T FE | wth of the piston ring (No. 2)"* “050 | No.2 rae) 0.22 | wath of the piston ring groove : +0050 | C085 | G=04 v0.28 & | (Wo.2) +0,028 | wath of the it ring“! poole 02 S : $008] tooo7s | HO4 § | wath of he ol ring groove Saco +03 ‘2 Tinner diameter of piston pin 0.115 a bearing 40.095 | J=0.095 Cuter diameter ofthe piston pin pve eat “008 Tmnerdameteronmepstonsin | «7° —¥9.050 ay hole +0.030 | K=0.030 to 0,065 ‘Outer diameter ofthe piston pin aoe 0.08 “1: Replace the rings after 8000 to 12000 hours (2 to 3 years) atthe time of a scheduled inspection. Replace all rings with new ones even iftheir dimensions agree with the wear limits, “2: Replace the ‘st ring with a new one when its plated layer is wom out and the base metal begins to be ‘exposed. Replace the 2nd ring when the taper face is gone. Fig.3 Piston, piston pin and rings YANMAReee Core [Engine information Design data/tolerances check ans Nominal Sandard] Max allowable [Usage mitot ee dimension | T!F@°® | clearance clearance parts inner diameter ofthe oankpin +0208 ae bearing reo | 20-140 _| L=0:140 7 | too.234 | Uneven wear] ‘Outer diameter ofthe erankpin oo a Inner diameter ofthe main +0239 oa J | bearing +0.170_| M=0.170 is cha T—] 100.268 [Uneven wear] | Outer diameter ofthe main shaft ay a 5 | wa ortie base part man oir 1a, bearing °° 0273 | n=0.177 Width of the base part main 0.035} 10 0.308 aoe shat ° cs 2102-00-02 cieererel According to crankshaft inspection 8 Fig.4 Crankshaft YANMARGEY22W eed [Engine information Design data/tolerances check sins Nominal Sandard] Max allowable [Usage mitot ee dimension | T° | clearance clearance parts ‘Our diameter ofthe niake O70 a valve shat are | 2090 | R1=0.070] pag ae Tnner diameter of the intake 7002 | 100.116 : eiaE valve guide o ‘Outer diameter ofthe exhaust 0.080 088 valve shat ore |2:100_| Ra-0.080 inner diameter ofthe exhaust F002] 10 0.128 one valve guide 0 inner diameter ofthe valve 0,080 vote bridge ore |20080_| s-o018 § | Outer diameter of the vane 70046 | 10 0.052 as = | bridge guide +0.028 5 | Thickness of the iniakerexhaust | —— : 3 ake t54 | 202 50 g | Wid of the intakerexhaust a 3 [vane seat uses | 02 - - 79 Diameter of te contact part of | tee veo | 20.41 - : 273 ‘Outer diameter of he rocker 2.008 i arm shaft 0.034 | w=o.029 4 innerdiameteroftnerockeram | °*° |[—so085—] tote | W025 oa bush +0.020 Inner diameter of the swing arm ol +02 50 x=0.010 ‘Outer diameter ofthe swing arm D010] 100.055 a shaft 0.030 : Fig. Valve mechanism YANMAReee Core [Engine information Design data/tolerances check ans Nominal Sandard] Max allowable [Usage mitot ee dimension | T° | clearance clearance parts ‘Our diameter of he standard 085 a camshat iss |_2-148 | y=0085 | Jy 29 inner diameter ofthe camshat 0.080} 100.238 40.17 base part bearing ° | Thickness of the camshat 010 : | thrust bearing " -012_| z=0.15 2 70AT—] 10023 | Wath ofthe camshan thrust oe : ‘Outer diameter of he camshat “0.085 oo middie portion 0.148 a=0,085 = - inner diameter ofthe camsnat] °' |—so090~] woo2se | #93 middle portion bearing ° Fig.6 Camshaft SAR YANMARCore [Engine information GEY22W Design data/tolerances check 73 Nominal ‘Siandard | Wax allowable | Usage imitor ee dimension | T° | cearance clearance parts ‘Outer diameter of the pump +0005 a shat gay |0008 | v0.05 | oy 9. | Inner diameter ofthe pump 0.076 | 10 0.084 ay E | shan bush +0.060 Pump case one - 2 os : ou 2 easranern DZ] 100.304 § | Outer iametr othe gear ao : | Wath of te pump case #0063 | : 130 ° covey d=0.22 Wat ofthe pump gear TaRo) to 0188 : be La Fig.7 Lubricating ol pump Nominal ‘Slandard ] Max allowable | Usage imitot ee dimension | TFA | clearance clearance parts: = | Outer diameter of the impeier 0720 a | nub boss) 0.174 5 0.770 = 2110 €=1.60 bl +0690 to 0.864 7 @ | Inner diameter ofthe casing +0650 1.0 8 Fig.8 Cooling water pump aR YANMARCore GEY22W [Engine information Design data/tolerances check 813 Nominal ‘Sandard] Max allowable [Usagetmitot ee dimension | T° | clearance clearance parts ‘Our diameter of the pump 0a ma shan aos |2041_| b=0.020 inner diameter ofthe pump 0.021} 10 0.062 ay shaft bush o E | Pump case are ’ a o48 oo . ail aeraseerern DOB] 100.130 | Outer diameter of he gear oe : 5 +0018 | d=0.026 & | wath of te pump case oe . (Ciguid 165 : 0.016 | packing Width of the pump gear oe | aaa . less) Fig.9 Fuel feed pump Nominal ‘Slandard ] Max allowable | Usage mitot oo cee dimension Tolerance | cearance clearance parts Cining gearand ppump-driving 0.19 , gear) - 100.29 i : Gear backlash ga 5 (Bevel gear) 0.12 S M=3_ 7 100.2 ou : $ [Camshan dive F | Outer diameter ofthe idle 4 | a 017 ear shat e107 gro.se Inner diameter of the bush al) 40.14 ) J | Fig.10 tle gear YANMARCore [Engine information GEY22W Design data/tolerances check 913 Nominal Sandard] Max allowable [Usage mitot ee dimension | T° | clearance clearance parts 3 0 3 | Outer diameter of he crankshat oe : z oso ‘5 | inner diameter of the oll 228 | 4060 | 00852 . S| detector +0.50 : 6 Fig.11 Oil deflector flywheel side YANMARCore Hae Design data/tolerances check [Engine information 10/13 3. Table of Tightening Torques for Major Bolts and Nuts ‘There are three tightening methods for the major bolts and nuts ofthis engine: hydraulic tightening, angle tightening and torque tightening. Obey the instructions in the manual and tighten major bolts correctly Unless otherwise specified, apply lubricating oil on the thread and bearing surface 3.1 Hydraulic tightening This is a tightening method with a hydraulic jack. Obey the instructions in this manual for the hydraulic jack when you operate it. All specified pressure values are in the table that follows. cuwaiarater | © specrwayarauc Pan name 5 oressie Faces wth och = ‘wea Cylinder head tightening nut ~ M39%2.0. Round 58.8205 ‘Main bearing cap tightening nut" M39%2.0 Round 368205 Connecting rod tightening nut ~ M33 x 2.0 Round 5540.5 *: When you tighten any of these parts, refer to the match mark and tighten the part with the specified oil pressure. 3.2 Angle tightening For this tightening method, first tighten the bolt unti itis seated, then tum it to the specified turning angle. The seating torque and the tuning angle are in the table that follows, Screw diameter] Bot orm] Sea" 1 Spaced Part name : Facetosace | TOM=N*0 | sgnoningange pen | wis (rm) | rue o Balance weight tightening bolt " M24 x 2.0 32 50 80 (0 to +3) *: When you tighten any of these parts, refer to the match mark and tighten the part to the specified tightening angle. YANMARGEY22W eed [Engine information Design data/tolerances check 1113 3.3 Torque tightening Tighten all major bolts with the torque method, if hydraulic tightening and angle tightening are not applicable. The specified tightening torque for major bolts isin table that follows. Sere Bolt or nut Part name diameter | Face-to-tace |, HIMENING | Remarks - wit (mm | fraue Nm) piten Indicator cock tightening nut Mia 75 2 301070 : Rocker arm shaft support tightening nut M20* 15 30] 33010370 | Fuel injection vaive nozzle sleeve © M33x1.5 | 2grooves | 30010320 - Fuel injection nozzle retainer tightening nut WIOXTS iT wa Fuel injection valve case nut * M28 * 1.5 27 166 to 176 = Fuel injection vaive pressure-regulating locknut "| M33 x 1.5 a ‘97 to 103 7 Fuel injection pipe joint bolt ~ 7 6 - (cylinder head side) MB*4-25 | hoxsockey) | 921035 5 3 Fuel injection pipe joint bott (pump side) M10%15 | mercnarey | 701075 : Fuel injection pump tightening nut * M14 «1.5 22 120 to 130 - Fuel injection pump delivery vaive Body : 70 . 7 Tightening bolt eee (hex-socket) oem si 70 Fuel injection pump barrel retaining bot M1201.75 | jextocaen | 851080 . Fast injection pump protector WAKE 30 301060 5 Fuel injection timing adjust bolt locknut * M22 «1.5 32 196 to 245 a Camshaft coupling nut ia xis 79] Woot 0-| —U-nat Cam gear tightening bolt wide 79 | 14010 160) ide gear shaft tightening bok Migxis 24 [24s 10255 | Coating water pump impel waaxis | 06 | s2010340 | ethan Cooling water pump driving geartighiening nut | Maa x20 36 23816255] Main bearing cap side bolt M27 x20 36 ToT t0 765 | Flywheel tightening bow M2IxTS | 64010670 | Lubricating oi pump driving gear tightening nut | ~M30* 2.0 46 | 480%0 520 | ‘Swing arm shaf tightening Bolt Mex 15 24] 15010 180 [ Fuel injection pipe cap nul M2O*TS 32 Dios 7 Fuel branch pipe cap nut M25 *2.0 3 3010 80 5 “The parts have a special tool YANMAReee Core [Engine information Design data/tolerances check 1213 3.4 General bolts Tighten any bolts other than the major ones according to the table that follows, + For parts with a tightening section made of aluminum: tighten to 80 % of the torque shown in the table that follows. + For general bolts, do not apply lubricating oil to the thread and the bearing surface. + This table is applicable only to the bolts whose part No. (an 11- YANMARGEY22W eed [Engine information Scheduled inspection 5/5 Tnspedtion and servicing frequency (in hours) = seize] 2l53| 8 z Part Maintenance 828/58 28/58 Remarks. 8 ele 2|§2|So|se eglég|tslealog = [Airstaier [Cleaning the ar fiter o 5 & | Fuel cutot air |ision Replacing the Oxing ° ‘Turbocharger | Disassembling and cleaning ro Charge air Disassembly, inspection, a | cooler cleaning and hydraulic test & | Engine Engine ar | Gauge inspection ° ‘Alarm switch | etalon est o YANMARGEY22W eed [Engine operation Pre-operation procedure 16 CONDITION ‘Wake sure thatthe engine room is clean and Gdy. Make sure fat nathing preveris engine operation Before you stat the engine, make sure tha all parts are in a good condition. For the adjustment values (e.g the clearance on the valve head ofthe intake/exhaust valves, and the beginning ofthe discharge from the {uel injection pump), refer to the "Assembly adjustment values” table in "Design datatolerances check Make sure that all bolts and nuts ae tight PERSONNEL perso EQUIPMENT [RSRSSRSRROREEE Raichet hande "TaT67S-82651 Tpe Socket (24) 47673-92841 1 pe SUPPLIES RSRBRSSUSTEST IDEMITSU KOSAN Daphne Mechanic 220 SPARES NGipenelatureiiny SAFETY 1. Turning the flywheel ‘When you adjust the clearance on the valve head of the intake/exhaust valves or the beginning of the discharge from the fuel injection pump, use the turning device. Obey the instructions for the turing device that follow. Be careful that your body does not touch any moving parts when you turn the flywheel. Do not put your hand into the cylinder block. After you finish tuming, disengage the turning gear and put the stopper into the groove. Tighten the lock bolt If you do not disengage the turning gear, the engagementidisengagement switch activates and you ‘cannot start the engine. Fig.1_ Installation locations for the tuning mechanism YANMAReee CoE [Engine operation Pre-operation procedure 216 | Prepare the special turning tools. 2. Remove the lock bar Loosen the 2 lock bots of the stopper. 1. Remove the stopper from the groove A of the turing shaft. 5. Push in the shaft until it engages with the gear. Install the stopper in the groove B on the turning shaft. Tighten the 2 lock bolts. Install the turning socket and the ratchet handle to the shaft, Turn Make sure that the crankshaft does not turn suddenly when you disassemble or inspect the moving parts. To do so, engage the turning gear and lock it with a lock bar. Use the the lock bar, because it prevents the crankshaft from turning suddenly during disassembly and inspection. Engage the turning gear and lock the turning shaft with the stopper. Tighten the lock bar. 8. After you finish turning, disengage the turning gear. 8. Put the stopper into groove A. Tighten the lock botts. Keep the lock bar in a safe place (e.g. a tool case) to prevent loss. (ee gear) Tuming gear Lint ste Stopper Lockbae Gear disenaoaed Geer engaged Turing shat Fig.2. Maintenance ofthe turning mechanism 2. Lubricating oil system (yellow coating) 4. Draining the lubricating oil system 11 Before you fil new lubricating oil, drain the fluids in the devices or parts that follow. Open the drain valve or plug to drain + The common bed of the lubricating oil sump tank + Lubricating oil cooler + Lubricating oil strainer + Governor oil sump YANMAReee CoE [Engine operation Pre-operation procedure 36 2. Filling the lubricating oil 1 - Fill all devices with lubricating oil Fill tothe top limit ofthe oil level gauge or the dipstick 2- Remove the top cover of the governor. 3 Fillthe lubricating oil up to 2 mm to 3 mm higher than the center of the ol level gauge. 4.~ Manually lubricate the area around the govemor link, Make sure that it moves easily. ‘Speed contollever Cannector —StarVStop hana Not Lever rain pug AA Fig.3 Lubrication points (governor link) 5 - Do a lubricating oll inspection Change itifitis very contaminated or deteriorated. Control ofthe lubricating oi! 0000-001-17 3. Priming of the lubricating oil When the engine stops, lubricating ol priming operates NOTICE + Switch the control power supply for the motor-operated priming pump to ALWAYS ON. No. Lever shat, + Tum the power supply off if: + The ship stops for a long term. + The power installation is inactive. = You do maintenance on the power installation. If priming stops for2 hours or more, do a new priming for approximately 20 minutes or more. Priming pressure: 0.02 MPa to 0.20 MPa 4, Releasing air from the lubricating oil strainer Before you start the engine, release the air from the lubricating oil strainer if: + = The lubricating oil priming pump has stopped for 2 hours or more. + = You disassemble and clean the lubricating il strainer + = You change the lubricating oil = You disassemble and do maintenance on the lubricating oil system, 41 - Operate the lubricating ol priming pump. 2 Loosen the lubricating oll air vent plug 3 Release the air. 4 Tighten the air vent plug YANMAReee CoE [Engine operation Pre-operation procedure 416 5 - Ifyou cannot operate the lubricating ol priming pump, obey these instructions 1- Do an air running (5 times for approximately 3 seconds). 2+ Release the air, 3 Release the air again after engine start 3. Cooling water system (the freshwater system has blue coating and the seawater system has green coating) 41. Examine the cooling water tank and look for contamination of the cooling water. If the cooling water is very dirty, replace it 2, Fillthe cooling water tank with cooling water. Filltto the top limit ofthe water level gauge. Add corrosion inhibitor. Selecting and controlling the corrosion inhibitor 0000-001-17 3. Open and close each valve of the cooling water pipe system according to the operation conditions. 4. Open the air vent cock on the top of the air cooler and release the air. If you replaced the cylinder liner or removed it for servicing: Remove the cylinder side cover and make sure that there are no water leaks inside the cylinder, 4. Fuel oil system (red coating) 4. Drain the fue oll strainer andthe fuel il tank 2. Fill the fuel ol tank with fuel oi 3. Measure the fuel level 4. Open oF close each valve according to the operation conditions + For heavy fuel ol engines with marine diesel ol starUstop specifications: Turn on the heater forthe heavy fuel ol pipeline. Heat the heavy fuel oil until it has the correct viscosity. Then switch from ‘marine diesel oil to heavy fuel oll M.0.0. Change-over 0000-00110 For engine specifications that use heavy fuel ol forthe engine start and stop, make sure thatthe fuel ailtemperaure (vScosiy) at the engine Inet is correc. HF.O. Direct start 0000-001-10 Properties of the fuel ol at engine inlet 0000-00-17 + The seal pots a the fuel ol pressure gauge inet. At the frst star, fil ethylene glycol before you start the engine Servicing the fue! ol seal pot §008-000-02 8. Release the air from the fuel system. 6. After engine installation, servicing or a long engine stop, drain air from the fuel system. Obey these instructions. 11 Fully tum the handle of the bypass valve ofthe fuel feed pump counterclockwise to open the bypass valve. 2 Open the air vent cock of the fuel oll strainer and release the air 3 Loosen the air vent plug of the fue! injection pump to release the air. aR YANMARGEY22W Ceres [Engine operation Pre-operation procedure 516 Fig.4 Releasing the air 4. Turn the bypass valve handle clockwise to close it. Tur it until it stops. Fuel feed pump - Inspection 5002-000-02 Fuel oll pressure control valve - Assemble procedure 5007-001-02 5. Air system 4. Open these drain cocks and drain Fig.5 Draining the air system 6. Start air system (white coating) 41. Drain the start air reservoir. 2. Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine (2.16 MPa or higher). 3. After pressure reduction, check that the pressure is between 0.85 MPa and 1.0 MPa, Ifthe pressure is diferent, adjust the reducing valve at the air starter inlet. 7. Protection and speed control devices 41, Make sure the turning gear is in the GEAR OUT position, 2, Set the power switch of the protective devices and the alarm devices to the ON position. YANMAReee CoE [Engine operation Pre-operation procedure 6/6 NOTICE The protective devices and the alarm devices do not operate if the power switch is not set to ON. 3. Check that the devices operate. 4, Move the start/stop handle from STOP to START and back. 5. Make sure that the rack of the fuel injection pump, the first lever shaft of the governor link and the connector move easily 6. Make sure that the pointer of that speed control shaft of the govemor points between 1 and 2 on the scale, NOTICE ‘After you replace or service the govemor or the fuel injection pump, make sure that the link mechanism is comectly connected. ‘Speed control device (NZ) - Adjustment 6003-00-02 ‘Speed control device (UGB) - Adjustment 6003-02-02 CONDITION YANMARGEY22W eed [Engine operation Normal operation procedures 14 CONDITION Pre-operation procedures 0000-00708 PERSONNEL Rasp EQUIPMENT IRSRSSRESTSRET SUPPLIES SPARES SAFETY Moving part hazard: DO NOT touch or come close to moving parts with your hands, body or cloth- ing. NEVER touch a moving part. Noise hazard: Put on ear protection (ear plugs) inthe engine room to prevent hearing loss. ACAUTION High temperature hazard: DO NOT touch the parts that follow with your bare hands when the engine operates or immediately after engine stop. There isa risk of burn injury Turbocharger, exhaust piping, intake air piping “Indicator cock Flue, funnel! Make sure that the room has good airflow. A lot of air (oxygen) is necessary for the turbocharger. Keep the control air valve open during engine operation. f you close it, the protective devices do not operate, 4. Engine start This engine is started by an airstarter. Press the START switch, The battery-powered pilot-air solenoid valve on the air starter will open and start the engine. ACAUTION Keep your face away from the air starter when you start the engine. Dirt on the exhaust port of the air starter can come into your eye and cause injury. NOTICE a + If someone is present, give a signal and make sure that the person is safe before you start the engine, + Measure the amount of fuel ol, lubricating oil and air + Turn on the power supply of the engine protection device before you start the engine. + After a long engine stop or servicing, make sure that you start the engine on the engine side. + In case of an unusual increase of engine rotation, unusual sounds or smoke, immediately move the startistop handle to STOP and stop the engine. How to do an air running Before the first stat after installation, servicing or a long engine stop, do an air running and obey the procedures that follow. Make sure that there are no defects. Then start the engine on the engine side. A large quantity of fuel ol, cooling water or lubricating olin the cylinders can cause water hammering, 1 Make sure that the turning gear is disengaged (GEAR OUT position). YANMARGEY22W eed [Engine operation Normal operation procedures 214 2 Set the control position switch on the engine or the operation mode switch on the remote panel to the ENGINE position, 3 Open the pressure indicator cocks on all cylinders. 4 - Set the start/stop handle to STOP. 5 - Press the START switch for 2 to 3 seconds to start the air running 2. How to start the engine 11 Make sure that the tuning gear is disengaged (GEAR OUT position). 2. Make sure that the pressure indicator cocks on all cylinders are closed. 3~ Set the control position switch on the engine or the operation mode switch on the remote panel to ENGINE or REMOTE, depending on the control position 4- Set the startistop handle to RUN. 5 - Make sure that the needle of the governor speed control shat shows the correct (specified) speed 6 7-- Press the start switch for 2 to 3 seconds. Release the switch after ignition. Open the startup air reservoir and control air valve. ‘Start ste Operating Speed contol shat. Statitop handle 6a: ya os ‘Tonminal hat Fig.1 How to start the engine 3. In case of start failure o not restart the engine immediately after a failed start. Unburned combustion gas in the flue can ignite and cause an explosion. If you try to start the engine without a cooling period, the starter can become too hot and malfunction, 1 Do an air running and discharge the gas from the exhaust gas system. Then restart the engine. 2 Ifthe engine does not start in 30 seconds or less, stop the starter. Let the starter rest and cool for, 2.5 minutes or more. Then try again. 4, Starting without control power ‘At manual start, the control module is notin operation. This can cause overspeed of the air starter. Use the manual start only in emergencies. 11- Ifthe battery for the START switch is emply (in case of emergency), push the manual button of the air starter to start the engine. 2 Retum the button to its original position immediately after the engine stars. YANMAR