0ae22-G00103-20171110 6ey22 (A) LW Hfo 4-2R

Les OPERATION MANUAL MARINE AUXILIARY ENGINE 6EY22(A)LW H.F.O. SPEC. 6EY22LW 6EY22ALW YANMARAll Rights Reserved, Copyright YANMAR CO.,LTD.H.F.O. specification Contents ae 00 Engine information 01 Introduction 0000-000-01-00 02. General warnings and cautions and related safety data 0000-001-02-00 03 Technical data 0000-001-02-00 04 General data 0000-000-04-00 05 Schematic diagrams (0000-001-05-00 06. Preparation setting values 0000-001-06-00 07 Design datanolerances check 0000-000-07-00 08 Scheduled inspection 0000-001-08-00 00 Engine operation 09 Pre-operation procedure 0000-001-09-00 10 Normal operation procedures (0000-001-10-00 11 Post-operation procedure 0000-001-11-00 12 Emergency stop procedure 0000-001-12-00 14 Operation test 0000-001-14-00 15. Normal operation data sheet 0000-001-15-00 16 General fault description 0000-000-16-00 00 Fuel oil, lubricating oil, and cooling water 17 Fluids 0000-001-17-00 01 Cylinder block and cylinder liner 01 Cylinder block 01 Description of function 0101-000-01-00 02 Inspection and maintenance 0101-000-02-00 02 Cylinder liner 01 Description of function 0102-000-01-00 02 Inspection and maintenance 0102-000-02-00 1 Parts List Cylinder block and liner 0101-000-50-00 Cylinder side cover 0102-000-50-00 Cylinder side cover (relief valve) 0103-000-50-00 Gear case 0104-000-50-00 Gil sealing (SEW) 0105-000-50-00 Breather pipe 0108-000-50-00 Pump case cover 0107-000-50-00 41 Cylinder head 01 Cylinder head 01 Description of function 1101-000-01-00 02 Inspection and maintenance 1101-001-02-00 02 Intake/exhaust valve 01 Description of function 1102-000-01-00 02 Inspection and maintenance 1102-000-02-00 03 Valve seat 02 Inspection and maintenance 41103-000-02-00 04 Valve guide 05 Replacement 1104-000-05-00 05 Valve bridge guide 02 Inspection and maintenance 1108-000-02-00 06 Valve rotator 02 Inspection and maintenance 41108-000-02-00 07 Nozzle sleeve 02 Inspection and maintenance 1107-000-02-00 = Parts List Cylinder head 1101-001-50-00 ‘Valve arm ass'y and bonnet 1102-000-50-00 Indicator valve 4103-000-50-00 aR YANMARH.F.O. specification Contents 28 14 Timing gear, camshaft, and intake/exhaust swing arm 01 Timing gear 01 Description of function 02 Inspection and maintenance 02. Camshaft 01 Description of function 02 Inspection and maintenance 03 Intake/exhaust swing arm 01 Description of function 02 Inspection and maintenance = Parts List Idle gear Camshaft 18 Air cooler, exhaust manifold, and turbocharger 01 Air cooler 01 Description of function 02 Inspection and maintenance 02 Exhaust manifold 01 Description of function 02 Inspection and maintenance 03 Turbocharger 01 Description of function 04 Cleaning 04 Cleaning = Parts List Air cooler Exhaust gas manifold Exhaust gas manifold cover Turbine Turbine mount Air duct (TPS48) Air duot (TPS52) Exhaust gas outlet pipe Boost air pressure pipe Blower washing pipe Blower washing tool (TPS) Insulation covering Turbine water filing pipe Turbine washer (TPS) Turbine washer (A130, A135) Turbine washer drain pipe (A130, A135) 21 Main bearing, crankshaft, and oil sealing cover 01 Main bearing 01 Description of function 02 Inspection and maintenance 02 Crankshaft 01 Description of function 02 Inspection and maintenance 03 Flywheel 01 Description of function 03 Adjust = Parts List Main metal Crankshaft and flywheel Flywheel pointer and tuming device 1401-000-01-00 1401-000-02-00 1402-000-01-00 1402-000-02-00 1403-000-01-00 1403-000-02-00 1401-000-50-00 1402-000-50-00 1801-000-01-00 1801-000-02-00 1802-000-01-00 1802-001-02-00 1803-000-01-00 1803-000-04-00 1803-001-04-00 1801-000-50-00 1802-000-50-00 1803-000-50-00 1804-001-50-00 1805-000-50-00 1806-000-50-00 1807-000-50-00 4808-000-50-00 1809-000-50-00 1810-000-50-00 1811-000-50-00 1812-001-50-00 1813-000-50-00 1814-000-50-00 1814-000-50-10 1814-001-50-10 2101-000-01-00 2101-000-02-00 2102-000-01-00 2102-000-02-00 2103-000-01-00 2103-000-03-00, 2101-000-50-00, 2102-000-50-00 2103-000-50-00 3-9R YANMARH.F.O. specification Contents 38 22 Piston and connecting rod 04 Piston 01. Description of function 02 Inspection and maintenance 02 Connecting rod 01 Description of function 02 Inspection and maintenance = Parts List Piston Connecting rod 30 Lubricating oil system 00 Lubricating oil system 01 Description of function 04 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 05 Lubricating oil cooler 02 Inspection and maintenance 06 Lubricating oil bypass filter FM200DS 01. Description of function 04 Cleaning = Parts List Lubricating oil pump Lubricating oil priming pump Lubricating oil cooler Lubricating oil pressure control valve Dipstick Lubricating oil strainer Lubricating oil bypass filter (FM200DS) Lubricating oil thermostat Lubricating oil pipe (pump to cooler) Lubricating oll pipe (strainer to bypass filter) (FM200DS) Lubricating oil pipe (strainer OUT) Lubricating oil pipe (turbine) Lubricating oil pipe (priming) Lubricating oil pipe (governor) Lubricating oil pipe (generator) Lubricating oil pressure gauge pipe Lubricating oil 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 '3007-000-50-00 3008-000-50-00 '3009-000-50-00 '3010-000-50-00 3011-000-50-00, '3012-000-50-00 3013-000-0-00 3014-000-50-00 '3015-000-50-00 3016-000-50-00 3017-000-50-00 YANMARH.F.O. specification Contents ae 40 Cooling devices 00 Cooling water system (freshwater-freshwater dual system) 01 Description of function 4000-000-01-00 01 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) 1. 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 outletinlet pipe (one-pump mixing specification) 4004-000-50-00 Cooling water outlet/Inlet pipe 4005-000-50-00 Cooling water pipe (high-temperature water) (pump to VC) 4006-000-50-00 Cooling water pipe (low-temperature water) (pump to VC) 4007-000-50-00 Cooling water pipe (low-temperature water) (without switch 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 (air cooler) and water drain pipe (boost air chamber) 4013-000-50-00 Pressure gauge pipe 4014-000-50-00 Cooling water pipe (warm up) 4015-001-50-00 Orifice 4018-000-50-00 YANMARH.F.O. specification Contents 5/8 50 Fuel oil system (00 Fue! oil system 01 Description of function 01 Fuel injection valve 1. Description of function 02 Inspection and maintenance 02 Fuel feed pump (M.D.0.) (option) 01 Description of function (02 Inspection and maintenance 03 Fue injection pump 01 Description of function 02 Inspection and maintenance (04 Fue! injection pump drive unit 1. Description of function (02 Inspection and maintenance 06 Fue! 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 = Parts List Fuel injection valve Fuel injection pipe Fuel feed pump (M.0.0.) (option) Fuel injection pump Fuel injection pump drive unit Fuel strainer Fuel oil pressure control valve and overflow fuel tank Fuel pipe (feed pump inlet/outlet) (option) Fuel pipe (strainer to main pipe) Fuel main pipe Fuel pipe (main pipe to pressure control valve) Overflow fuel oil pipe (cylinder) Fuel oil leak defection pipe Drain pipe and overfiow fuel oll pipe (engine outlet) Fuel valve overflow fuel oil (head OUT) Fuel valve overflow fuel oil Drain pipe and blowoff pipe (uel strainer) '5000-001-01-00 '5001-000-01-00 001-001-02-00 '5002-001-01-00 002-001-02-00 '5003-001-01-00 5003-001-02-00 '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 5002-000-50-00 003-001-50-00 '5004-001-50-00, 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 3-4R YANMARH.F.O. specification Contents oe 60 Governor and governor drive unit 01 Governor 01 Description of function (NZ) 6001-000-01-00 01. Description of function (UG-8) 6001-002-01-00 01 Deseription of function (UG-25*) 6001-003-01-00 02 Governor drive unit 01 Description of function 6002-000-01-00 02 Inspection and maintenance 6002-000-02-00 03 Speed control device: 01. Description of function 6002-000-01-00 03 Adjust (NZ) 6003-000-03-00 03 Adjust (UG-8, UG-25*) 6003-002-03-00 04 Start/stop handle 01 Description of function 6004-000-01-00 02 Inspection and maintenance 6004-000-02-00 = Parts List Hydraulic governor (NZ61) 6001-000-50-00 Hydraulic governor driving device (NZ) 6002-000-50-00 Hydraulic governor driving device (UG-8) 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 Startistop handle 6005-000-50-00 Link a'ssy (NZ) 6008-000-50-00 Link a'ssy (UG-8) 6006-002-50-00 Link a'ssy (UG-25*) 6006-003-50-00 aR YANMARHA F.0. specification Contents 718 65 Special attachments 04 Stop solenoid valve 01. Description of function 02 Inspection and maintenance 02 Operating station selector 01 Description of function 03 Pressure gauge 03 Adjust 04 Digital thermometer 02 Inspection and maintenance 05 Fue! injection volume control air piston and stopping air piston 01 Description of function 02 Inspection and maintenance 05 Stopping air piston 01 Description of function 02 Inspection and maintenance = Parts List Control air pipe (uel cut) (3 connects) Control air pipe (stopping air piston) Control air joint Control air joint (low-temperature water) (with switch valve) Magnetic pick-up Gauge panel Pressure switch (control air) Pressure switch and transmitter (6 connects) Pressure switch and needle vaive (starting ait) Pressure transmitter and needle valve (fuel oil) Temperature switch Resistor CMP Junction box ‘Thermometer Float switch (lubricating oil sump tank) Fuel injection volume control air piston and stopping air piston ‘Stopping air piston 6501-000-01-00 6501-000-02-00 6502-000-01-00 6503-000-03-00, 6504-000-02-00 6505-000-01-00 6505-000-02-00 6505-003-01-00, 6505-100-02-00 6501-000-50-00, 6501-003-50-00 6502-000-50-00 6503-000-50-00 6504-000-50-00, 6505-000-50-00 6506-000-50-00 6507-000-50-00 6508-000-50-00 6509-000-50-00 6510-000-50-00 651 1-000-50-00, 6512-000-50-00 6513-000-50-00 6514-000-50-00 6515-000-50-00 6515-003-50-00 aR YANMARH.F.O. specification Contents 8/8 70 Starting device 00 Air starting pipe device 01 Description of function 01 Air fiter 04 Cleaning = Parts List Air starter Starting air pipe (air starter inlet) Starting air pipe (pressure switch valve) Control air pipe (inlet) 92 Disassembly tools, other tools 01 Hydraulic jack 01 Description of function 02 Other tools, 06 Measurement = Paris List Hydraulic pump and hydraulic jack (cylinder head) Hydraulic pump and hydraulic jack (main bearing cap) Hydraulic pump and hydraulic jack (connecting rod) ‘Standard tools il drain pan Special tools Cylinder head support APPENDIX YANMAR Worldwide Service Network List TURBOTWIN engine and air starter T50-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 7004-000-50-00 9201-000-01-00 '9202-000-06-00 '9201-000-50-00 19202-000-50-00 9203-000-50-00 19204-001-50-00 19205-000-50-00 '9206-000-50-00, 19207-000-50-00, YANMARCera Ceres) Introduction 5 [Engine information 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 governor), 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 (International 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 of this 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. + Ifyou have questions or comments about this manual, please contact YANMAR or your sales or service agent. YANMARCera Ceres) Engine information Introduction ae 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 flywheel side Tum left: counterclockwise rotation as viewed from the flywheel side Cylinder number: counted from the flywheel side (1, 2,3, ..) ytinder number — AX yuheet loanonoaarR Z Turn right (Clockwise rotaton) Turn left (Counter clockwise rotation) Fig.1 List of terms YANMARCera Ceres) Engine information Introduction oe 3. About this operation manual ‘See the index for an overview of related contents, The contents of the titles are as follows. Inspection ae maintenance 4 5 6 cenasnos 7 one TE 8 00m ot SRE RT ET 9 9s EEE a EE 10 —— owes 1——_ Fig.2 List of titles 1. Engine series Topic-specitic codes Function parts Tasks 2 3 4 5, Number of pages 6, Task conditions: shows the required preconditions for each part to perform the task 7. Personnel: required standard man hours 8, Tools required for the task 9. Supplies: consumable products (e.g. lubricating oil, 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 YANMARCera Ceres) Engine information Introduction ae 4. About the parts list A paits list is attached to this manual. Itis sorted by part categories. ‘A figure with the 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. Gaza SORE (Cylinder Block & Liner Illustrated parts data a 3 4 5 72 FB063S-07070 BLOCK, CYLINDER 74 2 2 10633-01200 BOLT, CYLINDER HEAD ao 32 180633-01210 NUT, HEAD a 42 150698-01210 NUT, CAP ae Fig.3 List of parts 1, Part category In this operation manual, all parts are sorted in categories. Parts are listed together with related parts. 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 "1 4, Part number The individual number of the par. 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 YANMARGEY22W eee) [Engine information Introduction 5/5 5. Symbols for piping and instruments This operation manual uses these symbols for the piping system. Instruments Valves Piping parts Pump DEL | Globe valve | Flange fitting Plunger pump DX | Needle vaive =i | Shutoff vaive Hand pump Ri Anaie valve AIH] Spectacte fange Motor De | Butfertly valve =H) Joint Filter DK | Sluice valve B | Boss Centrifugal filter Dlq | Screwed check valve | H+} Orifice Automatic backwash titer | Raq | Swing check valve $L| Expansion joint 3] | Porous piate fiter cylinder] fq | Piston valve nn Flexible pipe coupling Meters & sensors _| Bel | Tiree-way piston vatve | [] | Seal pot |@ |_Termometer DOd | Cock | Loop seal @)| Pressure gauge DRI | Three-way cock > | Reducer Diferental pressure gauag Dkq | Amomate pEssue 7 | Arvent pipe @E| oi signat ‘Automatic emp “| Satety plate [| orazed level gauge Safety valve © | Accumulator Pressure switch Solenoid valve a! Capillary tube | Temperature switch P<] | Pressure reducing valve | cur | Copper pipe (| Feat outer EQ Ouwiexcheckvave | seo | Camonslear phe Diferental pressure SW | fTS]| Velocity equating vaive | sro | Capon SteeLpIpE Presse vanamitor | Gp | Fane oumeoouarE | ae | Mee sur Resistance temp. sensor 00. | Pipe outside diameter. |G) | Thermocouple 1p. | Pipe inner diameter. a ie 3 3 ie pik : Always open plq : Always closed Valves that are always closed (globe valve, angle valve and needle valve) are shown in black. Fig.4 Symbols YANMARCera eres) Engine information 5 5 General warnings and cautions and related safety data 7 1. For your safety This manual and the engine have safety 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 a 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, PETEISREEN wit resut in death or serous injury WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided. ALCAUTION oui suit in minor or moderate injury. NOTICE indicates a situation which can cause damage to the NOTICE machine, personal property and / or the environment or cause the equipment to operate improperly. Fig.1 Signal word YANMARCera eres) Engine information 5 5 General warnings and cautions and related safety data 27 2. Basic precautions 2.4 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 oil stains. They bum easily. + Put on protective equipment that is applicable for your task. E.g. helmet, safety goggles, safety shoes, protective mask, protective gloves, life-ine. + 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 appendix) + Your engine and its safety devices are sealed for safety, Do not 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 fires or accidents. The safety procedures must include a contact person and a telephone number. + First Aid Kit + Fite Extinguisher + Eimerzency Phone PPT » Fig.2. Symbols a 2.5 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 safely 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 oil) All fire is strictly prohibited in the engine room. Fuel oil and lubricating oil 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, YANMARCera eres) Engine information 5 5 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 fiters when the engine is cool + Do not touch hot engine parts (e.g. the exhaust pipe or pressure indicator cock) with bare hands. Put ‘on gloves. + Do not touch the heater and heated sections of the fuel ol 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 fluid is a strong acid It causes inflammation to the skin and eyes. If you getit 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 ‘When you use organic solvents, obey the instructions that follow. + Organic solvent turns into gas and can be breathed by personnel. This is dangerous. Make sure that the room has sufficient airfow. + 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. 2.40Exporting or providing this product to non-residents ‘When exporting or providing yanmar products to non-residents, please comply with the security trade control laws. OR YANMARCera eres) Engine information 5 5 General warnings and cautions and related safety data av 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 he engine + Use a wire rope and shackles that are applicable to the engine weight. + Use a wire rope with the correct length. The engine or common bed must not ti 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 lifting + Do not go into the area below the lied 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. N.1300 Less than 60 deg MIN.3400 98s Fig.3. How to lift the generator set YANMARCera eres) Engine information 5 5 General warnings and cautions and related safety data ST 4. Location of safety labels (warning labels) To make sure that you use the engine safely, the engine has safety labels (warning 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. 1 2 A ESA ng Tans cevice ron rome 4 _CAUTION At Bhewe s-cyunt.uenasimccres| | "ESSER SEES || |paengeeemson rome 4 5 : [a CAUTION AOE & | lyse pte | SaRG mmresten, rr lo. CODE No. CODE 1 42223.028700 5] 42221.020450 2 [141616.07240. a 141616-07200 3__[1ste16.07230 Z 141616.07210 aT orarer6.07270 [I Fig.4 Location of safety labels (warning labels) YANMARSel CEE Engine information 5 5 General warnings and cautions and related safety data 67 No. CODE No. CODE _1 J] 1a673.07280 [4 —[_141616.07250_ 2 [ta161607220 5 141616.07240 3.) 14867473910 No. CODE 6] iaesrs-92740 Fig.5 Location of safety labels (warning labels) aR YANMARCera eres) Engine information 5 5 General warnings and cautions and related safety data ite 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 personnel 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. If new 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 burn injuries. + 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 oil. + When you disassemble the cooling water system, steam or hot water can come out and bum 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 fal. + When you do work at a height, put on the safety belt or life-ine. + Put on the protective equipment that is applicable for your task. + Be careful when you hold items with dirty gloves. The items can fall and cause damage or injury. + 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 lift heavy objects, obey the instructions of the slinger (the person who puts the abject on the crane). + Carefully examine the rubber hose and the joints of the hydraulic jack for damage. + Use the applicable lifting 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 follow after you do engine inspections and maintenance. + Put back all tools (e.g. lifting 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. YANMARCera Coenen) [Engine information Technical data uh 1. Engine specification Engine model EY22LW Type a Vertical, water-cooled, 4-cycle diesel engine Number of cylinders - 6 Cylinder bore * stroke mm 220 « 320 Total displacement 2 72.98 ‘Combustion method - Direct injection ‘Compression ratio : 1521 KW 60 | 745 | 600 | 680 | 970 | 1080 Output Continuous rated Kive | 600 | 680 | 740 | 800 | 900 | 1020 output Rola a Hee mir 720/780 prection es - Left (viewed from the flywheel side) Firing order : 142-6354 ‘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 - (The system oil is also used as turbocharger lubricating oil.) (The system ois also used as rocker arm lubricating oil) Type of lubricating ofl sump | __— ‘Sump incorporated in the common bed ‘Type of cooling a Freshwater-freshwater mix cooling system ‘Type of starting - Air starter Overall length oan Engine dimen- ray sions San mm (engine body) Refer to the Final Drawing. Overall |, height Engine dry weight gi ry weigl kg (engine body) YANMARCera Coenen) [Engine information Technical data ae Engine model EY22ALW Type a" Vertical, water-cooled, 4-cycle diesel engine Number of cylinders - 6 Cylinder Bore x stroke mm 3220» 320 Total displacement 7 72.99 ‘Combustion method : Direct injection ‘Compression ratio - 15.21 KW | 880 | 970 | 1020 | 1100 | 1180 ] 1800 | 1870 Continuous rated ea kWe ‘800 900 950 1000 1100 1200 1300 one Foti 9200/1000 Prrection eee - Left (viewed from the flywheel side) Firing order : 4 7 Operation side : Right (viewed from the opposite side of the flywheel) ‘Type of turbocharger - Exhaust gas turbine turbocharger (with air cooler) Forced lubrication by internal pump Lubricating system a" (The system oil is also used as turbocharger lubricating oil.) (The system oil is also used as rocker arm lubricating oil.) {pe of lubricating ol! - ‘Sump incorporated in the common bed sump Type oT cooing : Freshwater Reshwater mix cooing aytem Type ofstaring : Tisiaer Overall length tu Engin dimensions Over | {engine body) Refer to the Final Drawing. Overall a hevght Engine dy weight : (engine body) 9 YANMAR[Engine information GEY22W Technical data Ce ere) 314 2. Accessories & attachments Fuel strainer Lubricating oil pump Changeover, mesh type Gear ‘Accessories & devices Type Remarks Turbocharger Exhaust gas turbine : ‘Charge air cooler Plate-finned, multitubular : ‘Governor Hydraulic 5 Fuel injection pump Bosch - Fuel injection valve Multc-hole ‘Without cooling Fuel feed pump Gear ‘Option with insulator and differential pressure gauge Lubricating oil cooler Low finned tube, multi-tubular With thermostat Lubricating oil strainer Self-backwashing Lubricating oll bypass filter Centrifugal : Cooling water pump (freshwater) Centrifugal : Airstarter Turbine - YANMARGEY22W Ce ere) [Engine information Technical data 414 3. Weight of major parts ‘When you lift a part, use a rope, lifting gear and hook that is appropriate to the weight of the part. Part name Unit | 6EY22UW | 6EY22ALW Remarks Cylinder head * 179 : Piston and connecting rod assembly * 7 : Cylinder liner” 68 - Charge air cooler (core) 150 : Lubricating oil cooler 185 : Turbocharger 175 220 : Fuel feed pump 25 : Fuel strainer 7 : Lubricating oll pump ro : Cooling water pump 35 : Air starter ko 195 : ‘Camshaft (Split in 2 parts) 96, 75 : ‘Camshaft drive gear 28 : Idle gear assembly 7 : pean ma cover 41,33,9 . Main bearing cap” 40 - Gear housing on the opposite side of ran . the flywheel Cylinder block 2800 : Crankshaft 1308 1101 | including balance weights Flywheel 1420 928 Including the ring gear *: Use the special tool to disassemble YANMAR[Engine information units GEY22W General data ‘The conversion values in this table are based on the SI and metric system. eee) 4 1. Conversion table for the International System of Units (SI) and other Force N Kat 7 O101972 80665 1 Force momentum, torque im Torm 7 0.101972 3180665 1 Pressure Pa katiom? mag mmHg 7 1.0197 x 10° 4.0197 x 104 7.501 «109 9.80665 = 10" 1 7.0000 x 10 7.356 « 102 9.80665 x 10° 1.0000 x 107 7 7.356 * 10 1.3382 x 107 1.3595 x 107 1.3595 x 107 1 Work, energy RW T Keal Farm 1 3.6 x10 {8.600 x 107 3.671 x 10° 2.778 « 107 1 2.389 « 107 1.0197 x 107 1.163 x 10 4.186 x 10° 1 4.269 x 107 2.724 x 105 9.80865 2.343 x 103 7 Power RW PS 1 13596 07355 T YANMARSel Cee Schematic diagrams 113 1. Engine view Cooling wator temp regulating valve Engine contol panel Flywhoe! Fuel strainer Fuel pressure ‘contl valve Lubricating of strainer (automatic backewasher Sp) poeta Lubricating of| temp. regulating valve Air cooler Cooling water pump Lube ol pressure regulating vale Fuel feed pump Lube oi pump Lube oi cooler. Fig.2Non-operation side (exhaust manifold side) YANMARCera Cre) Engine information Schematic diagrams 23 2. Vertical view of the engine Exhaust valve Intake valve finder hea Crankshaft Main boaring cap Ring gear Fig.3 Vertical view of the engineCera Cre) Schematic diagrams 3/3 3. Horizontal view of the engine Valve bridge: Exhaust mand Boost chamber Rocker arm————__™~ Cooling water Piston sng. Cylinder block Fol intion pum. Swing arm shaft (intake & exhaust) Piston: Cylinder tine Connecting rod ee oe Connecting rd bo. Crane ain bearing cap Balance weight Fig.4 Horizontal view of the engine YANMARCera Roe) Engine information i i Preparation setting values 12 4. Protective device setting values Item’ Unit Alarm setting value | Emergency stop setting value Engine inlet lubricating oil pressure MPa 0.5 0.45 Engine cooling freshwater temperature | °C % 700 a i 112% to 115 % ofthe vated otational overspee: mi : speed 2. Holding volumes of lubricating oil and cooling water Item’ ‘Unit Holding volume Engine (incl. cooler, filter & piping) 50 Lubricating oil tank (common bed) 1200 Lubricating oil Type NZBi 13 Govemor Type UGE a 15 Type UG-25" 2A Cooling water | Engine (incl. piping) 0) (freshwater) Cooler (lubricating oil, air) ad *: The values may be different depending on the specification. Refer to the Final Drawing, aR YANMARCee) GEY22W [Engine information Preparation setting values 22 3. Pressure and temperature settings Items shown in the table below for which monitoring are required vary depending on the regulation and specifications, Trem a SR Remarks 10000-001-17 Fuel supply pressure Recommended pressure in MPa @ | Intemal maximum combustion pressure (Pmax) ; Referto the Records of g Shop Trial § [Capreang orpressure MPa 55106 & Cooling water pressure (jacket cooling line) 0.1510 0.50 Cooling water pressure (cooler cooling line) 0.1510 0.60 Starting ait reservoir 2.94 Lower limit: 1.18 Start-air pressure ‘Afler decompression 0800074 ‘At the air starter inlet Cooling water engine outlet temperature 524 ‘Cooling water lubricating oil cooler inlet as o {temperature | Lubricating olf engine iniet temperature § | (cooler outlet) °c ose & : Referto the Records of © | Exhaust temperature (at each cylinder outlet) cao : Refer to the Records of Exhaust gas turbocharger iniet temperature Ca *: 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 3-7R YANMARCera rere) Engine information . Design data/tolerances check 13 1. Assembly adjustment values Item Unit Adjustment value Remarks Piston top clearance (A) mm 2.24+0.18 - @ | Open (before T.0.C.) 50 - 3 deg, a Closed (after B.D.C.) 0 - & | & | valve head clearance (B) mm 04 ‘When engine is cold 8 |g | Open (before B.C) 0 > gle deg 8 | 5 | Closed (atert0.c) 31 - E | 2 | vatve head clearance (8) mm 09 When engine is cold a Refer to the Fuel injection pump begins injections . (before T.D.C.) a eee Opening pressure (fuel injection valve) MPa 45.0405 - * 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. )Q Tee a Adjust B after Selig io zor0 Ee Bae Fig.1 Assembly adjustment values YANMARGEY22W eee) [Engine information Design data/tolerances check 213 2. Clearance & wear its of major parts Pan name NOTA | Tolerange | Standard] Max allowable | Usage imnitor dimension clearance | clearance parts Inner diameter of he top par of 0.088 aaa the cylinder block (top) +0.056 | A1=0.126 a Outerdiameterofthe ppator| °° |—oo7o | too.1es | AI=075 the cylinder liner (top) 0.105 inner diameter of the top pari of 0.032 aa the cylinder block (bottom) oor 0 |a2=0020| 4595 ‘Outer diameter of the top part of 0.020} 10 0.087 ln | 5 | the cylinder liner (bottom) 0.055 & inner diameter ofthe oyinder 70.032 von & | (bottom) o | B+0.015 2 2 | outer diameter ofthe oyinder | °76? | —o.078~} 100.091 ae a1 & | iner (bottom) -0.059 z C206 = § |Top clearance 224 | sors | 2208 | copaa - [Inner diameter othe protection | 3154 | s0.05 s08 8 | fing D=1.55 . ‘Outer diameter ofthe pis er diameter ofthe piston | 31575 | agp | 10189 - head Inner diameter of the eylind +0.040 04 Inner diameter oftecxinder | 99 9 we Uneven vear to0.192 foe ‘Outer diameter ofthe PION 1 29 968 | ao.oa op skirt * 20 mm from the piston head Fig.2 Cylinder and cylinder liner YANMAReee) GEY22W [Engine information Design data/tolerances check 313 a NOmINa | Tojerance | Sandard Max alowable ] Usage Tit dimension clearance | clearance | of parts F Thickness ofthe pist ness ofthe piston rings | No. 4:7.5 | 40.15 5 : +2 No. 1 toNo. 2 stoi ‘Thickness of the oil rings “ 0 +£0.25 - - 47 5 0.070 Width of the piston ring (No. 1)“ To030 | No.1 0.15 Taare parma GeE | «© jwosas—] SOMO — g,| (v0.1) +0.100 = | wath of the piston ring (No. 2)" Bee8 | No.2 No.2 0.22 & | Wait of he piston ring groove 5 70050] Foto, | G=04 as & | (No.2) +0.025 5 5 “0.070 & 1 F | Wath ofthe ol ring ° “0.030 | H+0.030 0.4 0.2 € +0.045, to 0.075 4 § | ath of ne ong groove aaa 0.3 ‘a. |inner diameter of piston pin ¥0.115 yi bearing 40.095 | J=0.095 2 0 to 0.130 vase Cuter diameter of the piston pin on 0.08 inner diameter ofthe pitonpin °° | 0.050 x01 hole +0.030_| K=0.030 ei 0 to 0.065 Pee Outer diameter of the piston pin ia 0.08 “1; Replace the rings after 8000 to 12000 hours (2 to 3 years) at the time of a scheduled inspection. Replace 2: all ings with new ones even if their dimensions agree with the wear limits. Replace the ‘st ring with a new one when its plated layer is worn 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 YANMARCera rere) [Engine information Design data/tolerances check 43 — NomInaT | Tolerance | Slandard | Max alowable | Usage imitor dimension clearance | clearance parts Inner diameter of the crank pin +0208 AX bearing +0140 L=0.140 Outer diameterorthewanmpn | | O | woz) 8 Uneven wear] er diameter of the crank pin a i Inner diameter of the main 0.230 | leaeeoan | bearing 220 {20170 | M=0.170 | yepap & | outer diameter of the main shat fo, | foe el 2 -0.029 ot 6 | Width of the base part main 0.177 ral bearing a 0.273 47 ag With of the base part main 70.035 | 100.308 leecassem shaft ° mene 5 - 2102-000-02 According to crankshaft inspection Fig.4 Crankshaft YANMARCera rere) Engine information . Design data/tolerances check 513 ra Nominal, Slandard | Max allowable | Usage imitar an dimension | ''*@NC® | clearance | clearance parts ‘Outer diameter ofthe talake 0.070 ns valve shaft ote | :2.090 | R1=0.070| 49.59 Inner diameter of the intake 70.026 | 100.116 aoe valve guide o ‘Outer diameter ofthe exhaust 0.080 aa valve shaft ore |_-2:100_| 2=0.080 | ponga5 é Inner diameter of the exhaust 0.025] 100.126 ar valve guide 0 Inner diameter of the valve +0.080 40.18 bridge ore [20.080 | s-o.014 a & | Outer diameter of the vaive 70.046 | to 0.052 7 é | bridge guide +0.028 & | Thickness ofthe inlakelexhaust | 2 | valve T=5.4 20.2 a - 5.0 g | Wath of the intakerexhaust same - - a & | valve seat Diameter of the contact part of p= the valve sheet ee on . ~ he ‘Outer diameter ofthe rocker 0.008 ry arm shaft -0.034 | We0.029 - inner diameteroftherookerarm| °*° [+0085] toate | WH025 Pe bush +0.020 Inner diameter of the swing arm ¥0.025 40.2 oa 0 X=0,010 ceo ‘Outer diameter of the swing arm 0.010 to 0.055 04 shaft -0.030 7 @=0 w. Fig. Valve mechanism YANMAReee) [Engine information GEY22W Design data/tolerances check 613 ra Nominal, Slandard | Max allowable | Usage imitar an dimension | ''*@NC® | clearance | clearance parts ‘Outer diameter ofthe standard “0.085 is camshaft 0.148 Y=0.085 rel inner diameter ofthe camshat | °'°° 0080] too2ss | YS? vr base part bearing ° « | Thickness ofthe camshaft 0.10 & | thrust bearing 012 | z=0.15 . 3 1" 2-05 5 +017 10 0.23, & | wath of the camshat thrust aes - ‘Outer diameter of the camshaft 0.085 02 middle portion o1ss | -2148 | a0085 | so 35 Inner diameter of the camshaft 70.090 | 100.238 aT mille portion bearing ° Fig.6 Camshaft IR YANMAReee) [Engine information GEY22W Design data/tolerances check 73 — NomInaT | Tolerance | Slandard | Max alowable | Usage imitor dimension clearance | clearance parts ‘Outer diameter ofthe pump $0,008 aia shaft ono -0.008 | p=0.052 Dons | inner diameter of the pump 70076 | 100.084 a E | shaft bush +0.060 | Pump case eee - Se oO e=0.200 7 2 wea c=05 & | Outer diameter of the gear 0.200 | 10 0.304 - 8 0.250 5 | \watn or tne pump case *0.088 : 130 ° ee d=0.22 0.080 to 0.193 \Wiath of the pump gear a : Le =a wt La lb Fig.7_ Lubricating oil pump Part name Nominal] To ierance ‘Standard | Max. allowable | Usage limit of dimension clearance | clearance parts @ | Outer diameter of the impeller “0120 aa § | hub (boss) 0.174 . 5 e=0.770 E : i di ter of th ee +0.690 to 0.864 eens +10 & | Inner diameter of the casing Oee 8 ew Fig.8 Cooling water pump 3-7R YANMARCera rere) Engine information . Design data/tolerances check 813 — NomInaT | Tolerance | Standard] Max alowable | Usage imitor dimension clearance | clearance parts ‘Outer diameter ofthe pump 0.020 ry shaft 0.041 b=0.020 =( inner diameter of he pump ae pags 0 ee leer shaft bush o E | Pump case cee : 2 one 0.080 . Si (Gusraeneeean 0.087] 100.130 | Outer diameter ofthe gear panes - 3 +0.018 d=0.026 & | wiath of the pump case nee toon . (Liquid 165 0.016 packing Width of the pump gear Paoettlt ondin : less) L b e Te } T GfSteS dl Fig.9 Fuel feed pump Nominal ‘Slandard | Max allowable | Usage limitor Part name Tolerance dimension clearance | clearance parts Giming gear and pump-driving . 19 a - Gear backlash gear) to 0.29 tld ear backlast hae & (Bevel gear) 10.12 8 M=3 i to0.2 oe . $ | Camshaft drive * | Outer diameter of the idle eyes 0.17 gear shaft 107 as 9-02 Inner diameter of the bush ea +014 c vale gear Fig.10 Idle gear YANMAReee) [Engine information GEY22W Design data/tolerances check 913 ra Nominal, Slandard | Max allowable | Usage imitar an dimension | ''*@NC® | clearance | clearance parts 8 o | Outer diameter ofthe crankshaft ee 5 7 205 peed 5 | Inner diameter of the oil +060 | to0.652 . 8 | deflector +0.50 6 12 Detects Fig.11 Oil deflector flywheel side YANMARGEY22W eee) [Engine information Design data/tolerances check 3. Table of Tightening Torques for Major Bolts and Nuts ‘There are three tightening methods for the major bolts and nuts of this 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 10/13} 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, ‘Sorew diameter Specified hydraulic Part name x Shape of nut pressure pitch (MPa) Cylinder head tightening nut” M39*2.0 Round 588205 Main bearing cap tightening nut” M39*2.0 Round 588205 ‘Connecting rod tightening nut ™ M33 «2.0 Round 55205 * 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 until it is seated, then tum it to the specified turning angle. The seating torque and the turning angle are in the table that follows. Screw diameter Bolt ae Specified Part name x face-to-face Soraue. | tightening angle teh width (mm) aa o p (Nm) Balance weight tightening bot” | M24 2.0 32 50 80 (010 +3) *: When you tighten any of these parts, refer to the match mark and tighten the part to the specified tightening angle. YANMAReee) GEY22W [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 is in table that follows. ‘Screw Bolt or nut ; Part name diameter | face-to-ace | ,Tattening | Remarks F facet orque (Nm) pitch Tndieator cock tightening nut Max 75 78 804070 5 Rocker ani Sha support tightening nat M2015 30] 33010370] = Fuel injection valve nozzle sleeve” 33x15 | Zorooves | 30010320 | - Fuel injection nozzle retainer Ughtening nat MIOXTS 17 201025 > Ful injection valve case nut™ M28x 15 a | 16610176 | Fuel injection valve pressure-regulating locknut”| M33 1.5 a 9710103 |= Fuel injection pipe joint bot Me x 125 6 ao t03 7 (cylinder head side) hex-socket) : 3 Fuel injection pipe joint bot (pump side) MI0*15 | mex erexen | 701078 : Fuel injection pump tightening nut” Max 45 2 | 200130 | Fuel injection pump delivery valve Body . 70 - Tightening bolt seaatnanel en cock0 | Rectacaa 70 Fuel injection pump barrel retaining bolt MI2175 | rox tener | 851080 : Fuel injection pump protector Maa* 20 30 501060 = Fuel injection timing adjust bolt locknut™ M22 * 1.5 30 | 196t0245 | Camshaft coupling nut Max TI] Toot 11] —U-wat Cam gear tightening bot Mia 79 | 14010760 | Tale gear shaft tightening bolt MiB*4S 24] 245 t0 255 | : Round-hole Tet-hand Cooling water pump impeller waaxis | REneR | 420 t04s0 | eRRaN Coalng water pump driving gear tightening nut | ~W2Ax20 36 | 23510255] Main bearing cap sie bolt M27 x20 36 | 70710765 | Flywheel tightening Bott 22x45 2] 6i0t0 670 | Lubricating oi pump driving gear tightening nut_| ~W30%2.0 46 | 460%0820 | Swing arm sha tightening Bok MiB x45 24] 180%0 180 | - Fuel injection pipe cap nut M20*75 32 401045 5 Fuel branch pipe cap nut M25 *2.0 32 80t0 90 : “The parts have a special tool. YANMARCera rere) Engine information . Design data/tolerances check 12/13) 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-digit numeral) shown in the attached parts list consists of 2 at its first place and 2, 5 or 6 at its fifth place. (Example: 2XXX2-XXXXXX, BXXXS-XXXXKX, 2XXKE-XKXXKX) oan oat Bol or nut Tightening torque pitch face-to-face width (mm) (Nm) ME x1.0 0 Tt 12 Max 125 3 2810 27 MiIOx1S 7 4410 64 Miz *4.75 19 7B i0 98 Mid x15 22 72310 152 Migx1.S 24 206 0 245 Mig x20 2 2061 245 3.5 Tightening torque for pipe joint bolts (material: S25C) eee Bolt or nut Tightening torque | Outer diameter of pipe face-to-face width (mm) (Nm) (mm) pitch Bx 1.25 1 i710 20 3 Mi2*1.25 17 251034 6 M14x75 19 | 39 to 49. 8 Miex4.5 2 491059 70 Mi8 x75 24 | 69 to 78 12 M20%4.5 27 8810 98 15 M22 «7.5 30 147 to 196 18 YANMARCera rere) Design data/tolerances check [Engine information 4. Principal dimensions for disassembly & servicing ‘These are the dimensions necessary for disassembly and servicing of the engine. Make sure that you have enough space for your work before you start the disassembly and servicing, 2006. amir EF 1922 3) y ra utoganer |_| d é 85] sg g|§| als Crankshaft center, ‘ ie i PUL ‘Cama (etn 3 z Cooking water pump 3 5 Ful feed pump a Sta Walon Remarks 3 3| LW specification “2: MET22 turoocharger specication Fig.12 Principal dimensions for disassembly & servicing 3-4RCera ee) Engine information 7 . Scheduled inspection 15 Do the engine inspections at regular intervals. This makes sure that the engine operates in a good condition and prevents defects, The inspection intervals depend on the operating conditions and the quality of the fuel oil and lubrication oil. Thus it is difficult to recommend a fixed inspection schedule, This inspection table shows the standard intervals. Do the first overhaul according to this table. Schedule the next inspection according to the results of your first overhaul (e.g. the wear, corrosion and contamination with carbon and sludge). Ian engine part has two inspection periods (operating hours and number of days), schedule the inspection at the earlier time. 1. Table of routine maintenance inspections T month Part Daily ‘Weekly a coniisee [Starting air reservoir Pressure inspection Draining i Governor oil level Linkage system eee inspection inspection and lubrication Rack scale position Fuel injection pum inspection Ee oa Taspection of the pinton Fy lubrication volume $ Disassemble and clean (depending on the 5 |Fucl strainer Draining ditorontal eressure & ‘gauge display) Tajecion-timing adjusting Taspection Tor Toose bolt looknuts = [Lubrication ortank 5 | (common bed) il level inspection 2 Disassembly and 5 [Bypass fiter ceasing [cooing water pump Mechanical seal Teak inspection ‘Cleaning of the pre-fiter Teaning of the blower [Turbocharger Teaning of the turbine (60h to 200h) BE Jeeans wing Inspection for loose 2 wiring z Tnspection for eaking & [Air Piping connections = Tanpescure gauges | MSPSGION Tor TareaINe 2 ae ame gauges 2 la menometes Inspection for defective 2 gauges Bolt and nut inspection (looseness), leak inspection on all portions (cooling water, fuel oi lubricating oil, intake air & exhaust gas) I pipings Leak inspection aR YANMAR Engine appearanceCera ee) Engine information 7 . Scheduled inspection 28 2. Table of scheduled maintenance inspections * This is the first inspection after the first engine start or after you replace a part. Do the inspection at the normal frequency from the second time on. Inspection and servicing frequency (in hours) Part Maintenance Remarks Category 3 months or 1000 to 1500 months oF 2000 to 2500 T year or 4000 to 5000 Zio 3 years or 8000 to 12000 % year or 16000 to 20000 Fuel injection | Removal, inspection and valve adjustment 8 tsttime: 500 h to 800 Inspection and adjustment ofthe valve head clearance Inspection of the valve spring o Disassembly and inspection oF the valve rotator Disassembly, inspection and | eS cleaning Valve seat grinding i o As necessary cylinder head Cylinder head ‘Scale cleaning and hydraulic test of the water chamber ‘Stem seal (intake/exhaust valves) replacement Hydraulic test of the cylinder E ° head bolt tightening Removal, cleaning, inspection and measurement of the ° ° piston Piston Inspection and measurement of iS the piston rings Inspection and measurement of iB the piston pin Tnspection and measurement of the piston pin bearing Crank pin bearing inspection and measurement Connecting rod | Po Tnspection of the tightening force iS of the connecting rod bolt Replacing the connecting rod ae 20000 h Major moving pars Tnspection, cleaning and measurement of the inner ° Cylindertiner | diameter Removal, inspection and cleaning of the water jacket Measurement of the journal and the outer diameter of the ° Crankshaft | crank pin Deflection measurement and 6 adjustment YANMARCera ee) Engine information 7 . Scheduled inspection 38 Inspection and servicing frequency (in hours) Part Maintenance Remarks Category 3 months or 1000 to 1500 @ months or 2000 to 2500 Tyear or 4000 to 5000 210 3 years or 8000 to 12000 % year or 16000 to 20000 Disassembly, bearing inspection and measurement Inspection of the tightening force | of the main bearing bolts ° Main bearing ° Tnspection of the tightening force of the side bolt Tnspection of the cam and roller contact, Disassembly and inspection of | 5 the fuel pump tappet Camshaft Disassembly, inspection and measurement of ° the swing arm ‘Crankshaft removal, bearing inspection and ° measurement Inspection of tooth contact and iS backlash Major moving parts Disassembly of the idle gear, inspection and ° Timing gear | measurement of the bearing Inspection of the idle gear mounted shaft ° tightening force Fuel feed pump | Inspection of tooth contact and Lubricating of! | eth pump driving gear Replace hydraulic om aalnO) Governor Disassembly and inspection ° Governor drive | Disassembly and inspection of unit the tooth contact and bearing ‘Speed control mechanism YANMARCera ee) Engine information Scheduled inspection 4s Taspection and servicing frequency (in hours) = selsg|.2lss|. 8 2 Part Maintenance 28 [28/58/2858 Remarks 8 BSE S (Se lo2 (88 ESlES | 8 los los Taspection of te injection timing o Tsttime: 30H 16 SOOh Fuclinjecion | eetecing Ponto and ° pump | Disassembly, cleaning and 5 inspection Disassembly and inspection o Fuel feed pump [Replacing the oi seal o Replacing the ball bearing | 000 A to 10000 Pressure gauge | Ethylene glycol level inspection | ©) Every 2 months seal pot Replace the ethylene glycol | o ‘Accumulator (on the fuel oil primary piping | Replacing the accumulator Oo erceaee and pressure control valve) Lubricating on | C2PeNdInG On he properties (> analysis) Lubricating oi | Disassembly, inspection, cooler cleaning and hydraulic test ¢ Thermostat | DSassembly, inspection and a Eg cleaning % Disassembly, inspection and a | Lubricating oi! | measurement & | Pump Disassembly and inspection of 2 the relief valve ¢ & [Pressure Disassembly, inspection and a | control valve | cleaning 7 | Filter candle inspection I ° Every 2 years Lubricating on Replace the iter candi © [Eve a eas strainer Rotation check ° minnie Replace the O-ring Maintenance time _ [eos Dssssomby, Inspector and a § Disassembly, inspection and 5 3 | cooling water | measurement 5 | pump Replacing the mechanical seal o g Replacing the ball bearing 8000 h to 10000 h @ [Freshwater | Disassembly, inspection 5 *§ | cooler and hydraulic test S | Cooling water | Replacing (depended on results a (reshwater) _| of property analysis) * VANMARCera ee) Engine information 7 . Scheduled inspection 5/5 Inspection and servicing frequency (in hours) g sg|sg/3|58|.8 & Part Maintenance 22 [28/58 /28\58 Remarks 5 poles [be (52 22 egies sleses é | Airstarter Cleaning the air fiter o & | Fuel cut-off air 8 pon Replacing the O-ring ° Turbocharger __| Disassembling and cleaning o Charge air | Disassembly, inspection, T a 5 cooler cleaning and hydraulic test & [EngRe | Gauge inspection ° ‘Alarm switch | Actuation test ° YANMARCera ener Engine operation. . Pre-operation procedure 16 CONDITION “ake Sure Bat the engine rooms clean and bay, Make Sure at nothing prevents engine operation Before you startthe engine, make sure that al parts are in a good condtion. Forth adjustment values (e.g the clearance on the valve head ofthe intake/exhaust valves, and the beginning ofthe discharge from the {uelinjecton pump), refer tothe “Assembly adjustment values’ table in "Design datatolerances check Make sure that all bolts and nuts ae tight PERSONNE! [BBE RE SE Trade o estiiated time" EQUIPMENT (RGiieneae oe : Teenieaton pee Ratchet handle 47673-92651 ‘Socket (24) 42111-001850 SUPPLIES SanRRRREE a IDEMITSU KOSAN Daphne Mechanic 220 SPARES JRORRSASERIE! a SAFETY Be careful that your body does net touch any moving parts when you turn the flywheel Do not put your hand into the cylinder block. + 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. 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 tuming device that follow. ohio After you finish turning, disengage the turning gear and put the stopper into the groove. Tighten the lock bott If you do not disengage the turning gear, the engagementidisengagement switch activates and you cannot start the engine. sar YANMARCera ener Engine operation Pre-operation procedure 216 Ring gear Tuning goar mechanism Flywtoo! Prepare the special tuming tools Remove the lock bar. Loosen the 2 lock bolts of the stopper. Remove the stopper from the groove A of the turing shaft. Push in the shaft until it engages with the gear. Install the stopper in the groove B on the tuning shaft. Tighten the 2 lock bolts. Install the tuming socket and the ratchet handle to the shaf.. Turn Afler you finish tuning, disengage the tuming gear. Put the stopper into groove A. Tighten the lock bolts. Keep the lock bar in a safe place (e.g. a tool case) to prevent loss. Flywheot (rosea) g ‘Tuming gear, a 3 BA Limit site ‘Stopper Lockbar (Goar disengaged Tuming shaft Fig.2 Maintenance of the tuning mechanism YANMARCera ener Engine operation. . Pre-operation procedure 316 2. Lubricating oil system (yellow coating) 1, Draining the lubricating oil system 1. Before you fill 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 2. Filling the lubricating oi 1 - Fill all devices with lubricating oil. Fill to the top limit of the oil level gauge or the dipstick 2. Remove the top cover of the governor. 3- Fill the lubricating oil up to 2 mm to 3 mm higher than the center of the oil level gauge. 4~ Manually lubricate the area around the governor link, Make sure that it moves easily, ‘Spesq conttollever Connector _Start’Stop handle No.t Lever Govemor oe Drain pug No.1 Lever shat Fig.3. Lubrication points (governor link) 5 - Do a lubricating oil inspection 6 - Change it if itis very contaminated or deteriorated Control of the lubricating oll 0000-01-17 3. Priming of the lubricating oil ‘When the engine stops, lubricating oil priming operates. NOTICE + Switch the control power supply for the motor-operated priming pump to ALWAYS ON. + 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. 1 If priming stops for 2 hours or more, do a new priming for approximately 20 minutes or more. Priming pressure: 0.02 MPa to 0.20 MPa YANMARCera ener Engine operation. . Pre-operation procedure 416 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 oil strainer. = You change the lubricating oil - You disassemble and do maintenance on the lubricating oil system. 4 - Operate the lubricating oil priming pump. 2- Loosen the lubricating oil ar vent plug. 3- Release the air 4 Tighten the air vent plug ‘5 Ifyou cannot operate the lubricating oil priming pump, obey these instructions: 1- Doan 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. Fill he cooling water tank with cooling water. Fillit to the top limit of the 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. Ifyou 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) 41. Drain the fuel oil strainer and the fuel oll tank 2, Fill the fuel oll tank with fuel ol 3. Measure the fuel level 4. Open or close each valve according to the operation conditions. + For heavy fuel oll engines with marine diesel oil starVstop specifications: Tum on the heater for the heavy fuel oil pipeline. Heat the heavy fuel oil until it has the correct viscosity. Then switch from marine diesel oil to heavy fuel oll. M.D.0, Change-over 0000-01-10 + For engine specifications that use heavy fuel oil for the engine start and stop, make sure that the fuel oil temperature (viscosity) at the engine inlet is correct. H.F.©, Direct start 0000-01-10 Properties of the fuel oil at engine inlet 0000-01-17 + The seal pot is at the fuel oil pressure gauge inlet. At the first start, fil ethylene glycol before you start the engine. Servicing the fuel oil seal pot 5008-00-02 5. Release the air from the fuel system. YANMARCera ener Pre-operation procedure 516 Engine operation 6. After engine installation, servicing or a long engine stop, drain air from the fuel system. Obey these instructions. 1- Fully tum the handle of the bypass valve of the fuel feed pump counterclockwise to open the bypass valve, 2. Open the air vent cock of the fuel oil strainer and release the air 3 Loosen the air vent plug of the fue! injection pump to release the air, Fig.4 Releasing the air 4- Tur the bypass valve handle clockwise to close it. Turn it until it stops. Fuel feed pump - Inspection 5002-00-02 Fuel oil pressure control valve - Assemble procedure 5007-001-02 5. Air system 1, Open these drain cocks and drain Fig.5. Draining the air system 6. Start air system (white coating) 4. 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) After pressure reduction, check that the pressure is between 0.90 MPa and 1.1 MPa Ifthe pressure is different, adjust the reducing valve at the air starter inlet. 3-7R YANMARCera ener Engine operation Pre-operation procedure 6/6 7.Protection and speed control devices 1. 2 CONDITION Make sure the turning gear is in the GEAR OUT position. Set the power switch of the protective devices and the alarm devices to the ON position. NOTICE ‘The protective devices and the alarm devices do not operate if the power switch is not set to ON. Check that the devices operate. Move the start/stop handle from STOP to START and back Make sure that the rack of the fuel injection pump, the first lever shaft of the governor link and the connector move easily 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) - Adjust 6003-00-03 Speed control device (UG-8) - Adjust 6003-02-03 YANMARCera Cree) Engine operation. i Normal operation procedures 14 CONDITION “Pe-eparation procedures 0000-07-00 PERSONNEL jBaRgRr “Caegrmraae= Shifievel Trade EQUIPMENT [RSRRSRIR SUPPLIES |RSRSHSERISEE SPARES RGHSRGaMIER Ese SAFETY /AWARNIN Moving part hazard: DO NOT touch or come close to moving parts with your hands, body or clothing, NEVER touch a moving part. Noise hazard: Put on ear protection (ear plugs) in the engine room to prevent hearing loss. 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. + High temperature hazard: DO NOT touch the parts that follow with your bare hands when the engine operates or immediately after engine stop. There is a 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 ait (oxygen) is necessary for the turbocharger. + Keep the control air valve open during engine operation. if you close it, the protective devices do not operate. 1. Engine start This engine is started by an air-starter. Press the START switch, The battery-powered pilot-air solenoid valve on the air starter will open and start the engine. NOTICE + 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 oil, lubricating oll and air. + Tum on the power supply of the engine protection device before you start the engine. + Afler 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 start/stop handle to STOP and stop the engine. 1, How to do an air running Before the first start 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 oll, cooling water or lubricating oil in the cylinders can cause water hammering 11- Make sure that the tuning gear is disengaged (GEAR OUT position). YANMARGEY22W CEE Engine operation. : Normal operation procedures 24 2- Set the control positi 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 turing gear is disengaged (GEAR OUT position). In switch on the engine or the operation mode switch on the remote panel to 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 start/stop handle to RUN. 5 - Make sure that the needle of the governor speed control shaft shows the correct (specified) speed 6 - Open the startup air reservoir and control air valve, 7 - Press the start switch for 2 to 3 seconds, Release the switch after ignition. Start sich Operating select sich ‘Speed control shaft. Stattistop handle Tera shat 3. In case of start failure Do 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. 11 Do an air running and discharge the gas from the exhaust gas system. Then restart the engine. 2. If the 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 not in operation. This can cause overspeed of the air starter. Use the manual start only in emergencies. 1- Ifthe battery for the START switch is empty (in case of emergency), push the manual button of the air starter to start the engine. 2. Return the button to its original position immediately after the engine starts. YANMARCera Cree) Engine operation. i Normal operation procedures 3/4 5. Checks after engine start Do these checks, If you find any problems, stop the engine and do the necessary repairs. + Make sure that the pressure values on the instrument panel are correct. + Examine all pipes for leaks. + Listen for unusual sounds and look for unusual heat. 6. Automatic and remote starts Refer to the respective sections. 2. Switching to heavy fuel oil 1. M.D.O. change-over 1 Start the engine on marine diesel oll and operate it for 15 minules or more in the M.D.O. setting 2 Increase the temperature of the heavy fuel oi, Make sure thatthe fuel olin the circulating line has the specified viscosity (11 mm/s to 14 mm?is at engine inlet) and pressure. This prevents clogging of the fuel strainer and an unusual increase of pressure in the fuel injection pipe: 3.- Make sure that the temperature and pressure of all engine parts agrees with the specified range. Open HFO auat valve Close MID 0. out valve Open FO. natvave Close WD O. lat valve TIE. changeover complete Fig.2 Change-over switch 4 - Switch to heavy fuel operation when the engine reaches a load factor of 20 % or more. 5 - When you operate the engine with heavy fuel oil, make sure that the fuel oil viscosity and pressure are in the specified range. 2. H.F.O. DIRECT START 1 = Increase the temperature of the heavy fue! oil and send it through the system until ithas a viscosity at engine inlet of 11 mms to 14 mms. 2. Send the jacket cooling water (65 °C to 70 °C) through the system to increase the temperature of the engine. 3 Make sure that the above conditions are met. Then start the engine. 3. Checks during operation 1. Initial running-in operation Initial operation can cause very much wear to the piston rings and cylinder liner. To prevent this, operate the engine on marine diesel oil for this length of time: + After installation: for 10 to 20 hours. + After replacement of piston rings, a piston or cylinder liner: for 20 to 30 hours. 2, Regular (routine) operation Frequently examine the pressure and temperature. Make sure that there are no unusual sounds or unusual heat. If you find a defect, immediately stop the engine and make the necessary repairs. When the engine starts and increases rotation speed, it can momentarily rotate at a very high speed, This is caused by torsional vibration of the camshaft. In that case, let the engine quickly increase speed to the ‘specified rotation setting. When it rotates at the specified speed, the torsional vibration will go away. 1. Operate the engine without load for approximately 10 minutes to warm it up. YANMARCera Cree) Engine operation. i Normal operation procedures 44 2. Ifyou run the engine at low load for more than 3 hours, the combustion becomes bad and fouling of the combustion chamber, exhaust pipe and turbocharger increases. Obey these instructions: Ifyou use marine diesel oil, operate the engine at a load factor of 15% or more. Ifyou use heavy fuel oil, operate the engine at a load factor of 20% or more. + Operate the engine at a load factor of 15 % or more, ifthe engine has an air temperature control device (option) that increases the temperature of the intake air. ‘When the engine operates at a lower load factor, switch to M.D.O. operation, 3- If humidity is high, the air moisture can condense and cause a lot of drain water. This is normal. In this case, run the engine with an open drain cock of the charge air cooler. 4- Measure the engine performance at intervals of 1 day or shorter. Record the results. Refer to the Records of Shop Trial and record the results in the engine log Engine performance measurement and measurement locations 0000-001-14 CONDITION YANMARCera '0000-001-11-00 Engine operation Post-operation procedure 12 CONDITION PERSONNEL [BERGHE ae Se ae EQUIPMENT (NSRRSRSaEIS SRERCSTGRSoee SUPPLIES RERRSRSERE? SPARES Sie oR a SAFETY Carefully read and understand "General warnings and cautions and related safety data (0000-100- 02)". When the engine is hot, fresh air that enters the engine can ignite oil mist and result in an explosion. Do not open the side cover of the cylinder block for 10 minutes or more after engine stop. ACAUTION High temperature hazard Immediately after the engine stops, all of the engine is very hot. Be careful that you do not get, burned. 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 from the hot engine, be careful that you do not get burned by the oil {including small drops of oil. When you disassemble the cooling water system while the engine is hot, steam or hot water can ‘come out and burn you. Wait until the engine is cool. Then put the part that you want to remove in waste cloth. Slowly loosen it. 1. Checks at engine stop 41. Do not stop the engine at the same time as the load shutoff. Only do so in emergencies. 2. After load shutoff, operate the engine without load, then stop it 3. Make sure that the engine is always ready to star. 4. Immediately repair any defects of the operating engine. YANMARCera '0000-001-11-00 Engine operation. Post-operation procedure 22 2. How to perform the H.F.O. change-over = M.D.O. change-over For the start/stop specifications for marine diesel oil on heavy fuel oil engines, switch from heavy fuel oll to marine diesel oil. This makes sure that no heavy fuel oil collects inside the fuel pipes, filters and pumps when the engines stops. Run the engine with marine diesel oil for about 20 to 30 minutes. The time can change depending on the load at the time of the switch and the capacity of the ship pipes. Confirm with the dockyard where the engine was installed. Tarvent fom he strainer Open MO. it vane Close HFO. met valve eaves stage fo 2 103 milena eur te HES raainngn te man ape ina HO tan Deporsing or the ng of he ard ping, Tse FO salon TRNAS ono Fig.1 Change-over switch m= H.F.O. direct start ‘When you stop the engine on heavy fuel cil: Increase the temperature of the fuel to the specified viscosity and send it through the engine. Make sure that the heavy fuel oil and jacket cooling water meet the standby conditions 2 hours or more before engine start Before you stop the engine for a long time, switch to marine diesel oil operation. Make sure that no heavy fuel oil is in the piping and that all the heavy fuel oil is replaced by marine diesel oil 3. Stopping the engine 1. Operate the engine without load for approximately 10 minutes. 2. Set the start/stop handle to STOP. 3. Operate the standby lubricating oil pump or the electric lubricating oil priming pump for 15 minutes or more. This decreases the temperature of the piston and the turbocharger. 4. Open the pressure indicator cock. Do an air running to release gas from the combustion chambers. 5. Open or close the valves of all circuits as itis specified for engine stops. 6. Drain the cooling water on the cylinder block side and the cooler side if: - The weather is cold and the cooling water can freeze. - You stop the engine for a long period CONDITION aR YANMARCera Cerner) Engine operation. Emergency stop procedure 12 1. Emergency stop ITany of the following problems occurs, immediately set the start/stop handle to STOP and stop the engine. ‘The lubricating oil pressure decrease alarm operates, The lubricating oil temperature increase alarm operates. ‘The cooling water temperature increase alarm operates. ‘The overspeed alarm operates. Unusual noise Unusual heat ‘Smoke from a bearing or other moving part A broken pipe of the fuel oil system, lubricating oil system or cooling water system ‘The supply of cooling water has stopped, and it is impossible to supply it immediately. ‘A loose or broken bolt or setscrew of a moving part Water in the lubricating oil The intake air pressure decreases and the exhaust temperature increases unusually. The rack of the fuel injection pump is stuck. ‘The exhaust temperature of one cylinder is 40 °C higher or lower than the average temperature of all cylinders, (There is risk of misfiring and torsional vibration.) NOTICE Ifyou set the start/stop handle to STOP or press the STOP switch and the engine does not stop, close the fuel oil inlet valve 2. Precautions after an emergency stop + When the engine is hot, fresh air that enters the engine can ignite oil mist and result in an explosion. Do not open the side cover of the cylinder block for 10 minutes or more after engine stop. Ifthe engine stops during operation on heavy fuel oil: immediately drain all heavy fuel oil in the fuel oil pipes, fuel oil strainer and fuel injection pumps. Replace it with marine diesel oil. Obey the instructions below. Ifthe temperature of the fuel oll decreases and the viscosity increases. The engine becomes difficult to start, 1 Set the fuel oil changeover valves at the engine inlet and outlet to marine diese! oil 2 Open the bypass valve of the fuel feed pump. 3. Open the drain cock of the fuel oil strainer and the drain valve of the fuel oil main pipe, 4 Turn the flywheel to drain the heavy fuel oil from the fuel injection pipes and fuel injection valves. ((f you set the start/stop handle to RUN and turn the flywheel, fuel spray comes out of the nozzles.) YANMAReee) GEY22W Emergency stop procedure Engine operation Fig.1 After an emergency stop YANMARCera errcer ed Engine operation. ; Operation test 413 Measure the temperature and pressure of all parts during operation. This makes sure that the engine properties are in the correct ranges, Record the values in the engine log, 1. Precautions during operation Refer to "Normal operation procedures 0000-001-10 " 2. Measuring the operating performance Measure and record these engine properties when the load is stable. Do it at intervals of 1 day or shorter. Use the "Normal operation data sheet 0000-01-15 " 7 Maximum combustion pressure qo Cooling water Temperature (Pmax) (all cylinders) (low-temp air cooler inlet) 2 Exhaust temperature (at each cylinder outlet) | 11 Cling water temperature (high-temp air cooler inlet) Cooling water temperature 3 Exhaust temperature (turbocharger inlet) 12 (lubricating oil cooler outlet) @ Exhaust temperature 79 Intake air temperature (total outlet) (for reference) (air cooler inlet) (or reference) Lubricating oil temperature (cooler inlet) 14 _Intake air temperature (engine inlet) All pressure values on the gauge panel 6 Lubricating oil temperature (engine inlet) 15 (lubricating oil, intake air, high-temperature cooling water, low-temperature cooling water) 7 Cooling water temperature (engine inlet) 16 Fuel oilpressure Cooling water temperature 8 (engine common outlet) 17 Fuel oil temperature (engine inlet) 9 Cooling water temperature 18 Room temperature (low-temp air cooler outlet) 3. Measuring total maximum combustion pressure Refer to "Pressure indicator 9202-00-06 * YANMARCera errcer ed Engine operation. ; Operation test 23 4. Precautions when measuring operation performance Refer to the items that follow because the engine performance varies according to the room temperature, water temperature and load conditions. + A difference in maximum combustion pressure (Pmax) within 0.6 MPa between cylinders is normal, Pmax can increase very much depending on the properties of the fuel oil. Keep the Pmax below 20.0 MPa, Ifthe room temperature increases, the Pmax decreases. If the room temperature decreases, the Pmax increases. If the room temperature changes by 2.5 °C, the Pmax changes by 0.1 MPa. Make sure that the exhaust temperatures are the same as in the Records of Transfer Trial or Records of Shop Trial, A difference of exhaust temperature between the cylinder outlets is normal fit is less than 40 °C. Itis not necessary to adjust this difference if the fuel injection volume and Pmax are equal among all cylinders. Ifthe difference of the exhaust temperature between the cylinder outlets is more than 40 °C, but less than +40 °C of the average exhaust temperature, the combustion is unbalanced. Stop the engine and do the appropriate maintenance. Ifthe difference of the exhaust temperature at the cylinder outlet of one cylinder is more than 40 °C higher or lower than the average exhaust temperature at cylinder outlet, misfiring can occur and cause torsional vibrations. Immediately stop the engine. Find the cause and repair it. ‘The exhaust temperature changes at about twice the rate as the room temperature. But contamination of the turbocharger and the intake/exhaust passage, exhaust pressure and properties of fuel oll can have an effect on this relation. Do maintenance, decrease the load and use the engine within its limits, aOR YANMAR[Engine operation Operation test 3/3 Fig.1 Operating performance check locations VYANMARCera Cee) Engine operation. ~ Normal operation data sheet Ww 1, Data recording paper Ship name Engine type Engine number (I #) Fuel oi Turbocharger type Turbocharger (Si #) cooae Lubricating ot Specific Hydraulic oi viscosity (SAE) ravty Load Room temperature coe Date of measurement Hime of measurement [Total operating hours A Engine speed min No.7 eylinder No. Zeyinder cylinder [No.3 cylinder loutiets. [No.4 oylinder Beer No. S cylinder No. 6 cylinder Tnlet Wo. 1103) | "C Turbo- [inlet (No. 4106) | °C 7 icharger [Outlet a g (or reference) ie Engine niet o e Engine outlet Le IS |cooting [Lubricating oil cooTer outlet °c lwater [Air cooler iniet (ow-lemp side) | °C [Air cooler inlet (high-temp side) | °C [Air cooler outlet (ow-temp side) | "°C Lubricating [Cooler infet °C il Engine inlet °C [Air cooler inlet (or reference) | °C Intake air Engine inlet °C Fueroi! [Engine iniet T No.7 eylinder MPa No. Zeylinder MPa bos No. Scylinder | MPa No.4 oylinder MPa 8 No. Scyinder | MPa 3 No.6 cylinder | MPa | (carcatag on [Capa intake air MPa (Cylinder side cooling water MPa (Cooler side cooling water MPa Fuel oll MPa aR YANMARCera oer) Engine operation. — General fault description 121 This chapter shows the cause and recommended action for general malfunctions. Find the malfunction in the list that follows and take the applicable action, Ifthe action is difficult, consult YANMAR or your sales or service agent. No: Malfunction Page T_| Starting faiure rat 2 [Unstable engine rotation 624 [Insufficient output eat 1 | Inoorrect exhaust temperature (6) or maximum combustion aa pressure (Pmax) [Bad color of exhaust gas Tah [Unusual noise and vibration ial 7__[Sudden engine stop Tet [Engine does not stop Tat @ [Overspeed 172A 70__|Low pressure of the lubricating of Tea T1_[High temperature of the lubricating olf T9721 12 _|Low pressure of the cooling water Gackel system) [ 2072t 73 [High temperature of he cooling water Gacket system) Barat aR YANMAReee) Engine operation GEY22W General fault description 2121 1. Starting failure Starting failure Flywheel id not tm Fiywhee! ted, but no ignition suddenly decreased Insaticint sian a Botoive ar sate Ew (Reojindortres) (Sore ofindors do rotiro Insufficient starting air Fig.1 Starting failure Malfunction etion Insufficient starting air pressure Insufficient air in the air reservoir Fillair Teak of the main valve ofthe alr reservoir Do maintenance, repair or replace Leak of the relief valve Do maintenance, repair or replace Defective air filer Repair Defective automatic air filer starter Repair Malfunction of the pressure gauge display Repair or replace Defective start air piping Piping stop valve: closed Clogged piping ‘Open the valve Clean Defective control system Low voltage of the battery for the control solenoid valve Defective automatic control panel Defective control contact Charge the battery Repair or replace Repair or replace Disconnected control wire Repair Defective control solenoid valve Do maintenance, repair or replace Turing gear engagementidisengagement switch operates Put the turing gear to the disengage position The stop switch engages Putthe stop handle to the operation position aR YANMAReee) Engine operation GEY22W General fault description 3/21 Defective air starter Mal ination Reto Defective starter Tneorrect pressure of the pressure reduction valve Do maintenance or repair Relay valve is stuck Do maintenance or repair Bearing is stuck Do maintenance or repair Defect of the air starter Teeth of the pinion gear engage badly Low voltage of the batiery for the control solenoid valve Tum the gear Charge the battery Defective automatic control panel Repair or replace Defective control contact Disconnected control wire Repair or replace Repair Defective control system Defective control solenoid valve Turing gear engagementidisengagement ‘switch operates Do maintenance, repair or replace Put the turning gear to the disengage position Stop switch operates Move the stop handle in the operation position Integrated pump Bad tuning Malfunction Aalion Piston and cylinder tiner Do maintenance, repair or replace High resistance of the moving | Crankshaft Do maintenance, repair or replace parts Camshaft Do maintenance, repair or replace (e.g. seizure) Gear shaft bearing Do maintenance, repair or replace Do maintenance, repair or replace High viscosity of the lubricating oil Make sure that all valves of the pipes for engine warming open and close well Replace with a lubricating ol oF lower viscosity aR YANMAReee) Engine operation GEY22W General fault description 4121 Starting failure Flywheel natn Flywheel turned, suddenly decreased tt ro igniton Insufficient stan ar ) Cate arsarer) (Beeuming) (Gham) Gea No cylinder fires Fig.2 Starting failure Low chamber temperature Malfunction Raion Increase the chamber temperature Cooling water temperature 1s Too low Increase the water temperature Defective fuel control system Defective governor Do maintenance or repair Insufficient lubricating oi! on the govemor Fil oll ‘Stuck control (rattling sound) Do maintenance or repair Malfunction of the fuel cut-off air piston Problems with engine operation Inspect and repair control Problems with engine operation Malfunction ofthe air piston for fuel Inspect and repair Low speed of the flywheel High viscosity of the lubricating oil Make sure that all valves ofthe pipes for engine warming open and close well Replace with a lubricating oll of lower viscosity High resistance of the moving parts = Seizure on piston or cylinder liner ~ Crankshaft Do maintenance, repair or replace Fuel oll is not send with pressure to the fuel injection pump Empty fuel tank Fill the fuel tank with fuel of Clogged fuel pipe (valves do not open and close correctly) Examine the opening/closing of all valves Clogged fuel strainer Defective fuel feed pump Clean the strainer Do maintenance or repair Air ingress at the joints Examine and repair the part, then bleed the air Poor quality of fuel oil Incorrect properties (lash point) Use a fuel oll with higher quality (cetane number 45 or higher) ‘Water in the fuel oi! Remove the water Air in the fuel pipe system Examine and repair the part, then bleed the air aR YANMAReee) Engine operation GEY22W General fault description 5/21 Some cylinders do not fire Defective fuel injection valve Malfunction Defective nozzle Raton Do maintenance or replace Tneorrect open-vaive pressure ‘Agjust the open-vaive pressure Excessive oil leakage from the fuel Examine and clean the mating surfaces of the nozzle, spacer and injection valve body Replace if necessary Damaged fuel injection pipe Replace Loose fuel injection pipe Tighten it Defective fuel injection pump ‘Stuck rack Examine, do maintenance ‘Stuck plunger Examine, do maintenance ‘Worn plunger, barrel Replace Defective delivery valve Examine, repair or replace Tneorrect assembly Checking the match mark Tnstall again and obey the match mark (rack and pinion) Tneorrect fuel injection timing Agust to the specified value Insufficient compression pressure Air leak of the piston ring (Stuck, worn, broken) Do maintenance or replace Intake/exhaust valve is not airtight (The valve stem is stuck or the valve spring is broken) Do maintenance or replace Thoorrect adjustment of the intake exhaust valve head clearance Do maintenance aR YANMAReee) Engine operation GEY22W General fault description 6/21 2. Unstable engine rotation Unstable engine rotation Batealve fuel conial and supply sya Thais canbe among Sando ~ Exhaust lemperalire and explosion pressure vary Fig.3. Unstable engine rotation Defective fuel control and supply system Malfunction Raion Defective fuel control system Defective governor Do maintenance or repair Insufficient lubricating oi! on the govemor ‘Stuck controt ink (rattling sound) Fill oi Do maintenance or repair Defective fuel feed system Insufficient feed pressure (defective adjusting valve and pump) Clogged fuel oi strainer Do maintenance or repair Clean ‘Water in the fuel oil Remove the water Defective water separator Do maintenance or repair Air in the fuel pipe system Incorrect viscosity of fuel oil Examine and repair the part, then bleed the air ‘Change fo an appropriate fuel oil YANMAReee) Engine operation General fault description GEY22W 7/21 Uneven combustion among cylinders Malfunction Reto Defective fuel injection valve Defective nozzle Do maintenance or replace Broken nozzle spring Replace Theorrect open-valve pressure Aguust the pressure Excessive oil leakage from the fuel Examine and clean the mating surfaces of the nozzle, spacer and injection valve body Replace if necessary Damaged fuel injection pipe Replace Fust injection pipe is Toose Tighten Defective fuel injection pump Rack is uneven ‘Stuck rack Examine, adjust Examine, do maintenance Stuck plunger Examine, do maintenance or replace ‘Worn plunger, barrel Defective delivery valve Replace Examine, do maintenance or replace Bad installation (match mark does not match) Tnstall again and obey the match mark (rack and pinion) Tneorrect fuel injection timing ‘Agjust to the specified value Insufficient compression pressure Air eak of the piston ring (Stuck, worn, broken) Do maintenance or replace Intakefexhaust valve is not aitight (The valve stem is stuck or the valve spring is broken) Incorrect adjustment of the intake exhaust valve head clearance Do maintenance or replace Adjust YANMARCera oer) Engine operation. - General fault description 8/21 3. Insufficient output Insufficient output fone eee eee aaa (Ciierecthesteteo coy) ANT aa High emperatre Tow lenpemure ‘ofthe exnaustale atthe exhaust a Fig.4 Insufficient output Rack not engaged Malfunction Ration Defective governor Do maintenance or repair Defective fuel control system | Stuck control link can cca Do maintenance or repair High temperature of the exhaust air Marunction ation Overload (lorque rich) 5 Decrease the load High resistance of the moving | Piston and cylinder ner Do maintenance or repair parts Crankshat Do maintenance or repair (9. seizure) Camshaft Do maintenance or repair Low temperature of the exhaust air Malfunction Ration Defective fuel pressure adjui Do maint Insufficient fuel feed pressure _| valve aera Defective fuel feed pump Do maintenance or repair Clogged fuel ol strainer 5 Clean Water in the fuel oi 5 Remove the water Examine and repair the par, then Air in the fuel pipe system Reareer Uneven combustion among cylinders ‘See "2, Unstable engine rotation’ aR YANMAReee) Engine operation General fault description GEY22W 9/21 4. Incorrect exhaust temperature (te) or maximum combustion pressure (Pmax) Incorrect te or Pmax (he cylinders fected Te high Tehigh, te high) twhigh Te low, Pmas high Pmaxiow Pmaxigh} | _Pmaxtow } | Pmaxlow Punprack Fis a Toute | (Hanienpeame) — [Pomprack maxim propertios aicpressure_ |_olthe intake ar reaxinum Fig.5 Incorrect exhaust temperature (te) or maximum combustion pressure (Pmax) Pump rack maximum Malfunction ation Overload (lorque richy High resistance of the moving Piston and oylinder liner Decrease the load Do maintenance or repair parts Crankshaft Do maintenance or repair (e49, seizure) Camshaft Do maintenance or repair Fuel oil properties Waianation Ration Incorrect fuel oil properties = Use high-quality fuel Low intake air pressure Wraianation Ralion Clogged pre-tter Clean Ditty turbocharger Dirty compressor side Clean Dirty turbine side Clean Clogged air cooler fn : Clean Tiogged (high resistance) exhaust Clean port (exhaust pipe) Negative pressure in the engine chamber Make the airflow better High temperature of the intake air Malfunction Ration Dirty oF clogged fin Clean Bae cr ancese High Temperature oF he cooling | iuey water Tnsufficient cooling water Aqjust High temperature of he intake air Make the airflow better YANMAR

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