YANMAR DIESEL ENGINE woo. GNIGS UN OPERATION MANUAL © — YANMAR DIESEL ENGINE CO.,LTD. I.B.C.No, 96-6N165-0E 96.3.30YANMAR WORLDWIDE SERVICE YANMAR DIESEL ENGINE CO.,LTD. Domestic Offices (Heed Offices) S Quality Administration Division 352," chayamsens Kitasku Osaka 590, Jeoeh ‘Tel: 06-97-6259, Fax 06378-1124 [Tokyo ottiees:| Athome, Yee, Chuck, Tokyo 108, pan + Export Dept, Marine Fer 03.3278-4908 Fax: 08927-4969 ‘e Export Deot, Inoustrel Fok 039278-4018, ex 0902781977 {Large Engine Operations Division] rnagaseki Works] “cchome, Nagas, Higesi-dori,Amegosaki- = Quality Control Deas. el: 08-289:2017 Fx: 06-488-4003 (Yanmar Engineering Co., Lee 4-8, 8 Chome, Higashiveno, Daito-Ku, 1 Yanmar Europe 8.V. (YEU! Brogplein 11, 1292 BS Almerede Vaart Netherlands, Fol; 09240-25460, Fax: 03240-26916 Felen: 707927MA NL 2Yanmar Asia (Singapore) Corp, Pte, Ltd, (vase) Noe Tuer Lane, Jurong Town. Singepore 763 Far 961-5077 Fex: 861-1608 ‘3Yanmar Diets! America Corp. (YA) 1301 Comorate Grove Drve, Buffalo Grove, Te 60088. US.A. ‘Tals 708-541-1960 Fox: 705-841-2161 ‘TWxi 910-686-0025, 4 Yanmar Jakarts Series Conter BT. Pionner Treding Co,, Lic. 42 jk eH. Juande, Jokare, indones Ter: 376308, Fax: 0062219-62946 Gables COPITRA JAKARTA Ow NORWAY 1. Universal Diesel A/S. P.O. Bex 2002 Toyen, N-0608, Oslo 6 ‘Tels 2193200 Few: 687038 ‘Telex: 76855 UNIDI 2 Sewvice GERMANY 2.Nippon Diesel Service, GMBH. ermantBlobmstr 10-2000, Ham ura Tels 40-311323~8 Foxe 50311508 ‘Telex! 2165460 NDSD ‘,Bottener & Groning ‘theses 16, 2 Hamburg 11 Fels 040-788150 Telex: 2163364 8UGD 1994.00 BD, ® 1 Service Agents O-YANMAR Office NETHERLANDS 4, Nieoverken Holland 8.V. ‘logouttraat 1, Schiedam ‘Toit 010.8370877 Telex: 24531 (Nicos NL) usa 5.Golten Marine Co. Ine. ‘160. Van Brune Sireet, Brookiyn, NYC, NV 11253 Fels 212-855:7200 Tolox: 22.2918 6. Asiborg Cisory Houston Ine HSW Bronce Bend Angleton, 1% 77315 Felt d0g-843-2010 ‘Telex: 792 720 AB BOS AGLT 7.A-M, Marine System Service Corp. 100 Manhatten Ave, Suite 608 Union ity, NS 07087, Satzovoae-4011 Telex: 299812 FHNUR PORTUGAL B.Lisneve .0.B0x 2138, Lisbos 3 Fars 606 17IN. Yara} 2784121. ard) Telex: 12049/16370/18172 AB ILISNAP) eayeT 9. $uee Canal Author ort Said Shipyard Iameitio ‘Tel: 2201 Ismailia ‘Tolow: 92153 SUCANA UN INDIA 10.Mazagon Dock Lid, Dockyard Road, Tngie 400300 ‘Tel: 860863 Telex: 01 7-2560/4014 UK. 11,Shipald Diesel Services Lt ‘B Marjorie Avenue, Linedia LNG 750 els 0522-33090 ‘Telex: 86361 SHIPADG. AUSTRALIA 12.6 & H Engine Service Py, Lid S.OBox 207, Townsuile, Queensland, ‘Mazagon, Bomboy, ‘810 Fels 07-71-2824 19.Macitime Engineering Pry. Lt. 28 Byron Sureet, Bul Guesneland, 4174 Ta bs, Brisbane, "309-5899 x1 145104 TEKMAR, s4.ttarine & Diesel Service Pry. Led 'BS'Hothem Parade Artarmon 2064 New ‘South Wales Fels 430-4986 Telex: AA 23992 16.Buchanan & Brock Ship Repair Pry, Lig. $80 Kensington Roa, Footscray, Vicworle, 3011 ‘Yat: 03-8807786 Telex: AA 152316 wae. 16.Arab Heavy tndustces Ltd. PoO.Box 528, Aman ‘Tet 422001/4225021422194~7 olen: 69811 (AHILEM) Fans 007871-6822137 ‘SAUDI ARABIA 17.Saudl Shipping & Maritime Serviees Co, Lis. eta Office: Jason Proton 7822, Jeddah, Soudiarebie “Tel: 6440577/6442008/6447299/ baa0854 ‘Tolan: 403845 Tean 5 Dammem Branch BibBox 2587, Denman, Seudiarabis Tave27a010 ‘elon: 602184 Tran Si SINGAPORE 1B.chong Lee Leong Seng Co. (Pte) Lid. ‘800 House, 387 delsn Ahmad Irehim, ‘Shingapove 2202 ‘ots 2642822, Fax: 65.2640202, bie: GOODENGINE Telex: CLUS AS28221 VENEZUELA 10. Inversiones Indies CA ‘62008 Ccheeso CarseatPreface oc vaxman GNIGS CONTENTS 7 1. Precautions on Safety 1-1, Basic Precautions .. 2. Precautions on Operation .. 2 Prior to Starting of the Engine ....... 2-2. When Starting the Engine 2-3, When Stopping the Engine Precaution on Maintenance . 341. Precautions Prior to Maintenance Servicing, sum 3-2, Precautions during Maintenance Servicing wns O12 3-3. Precautions at Completion of Maintenance Servicing. ..munamien O13 List of Safety Labels .. 5. Name of Various Parts sane Major Engine Specifications ‘Table of Engine Standard Adjustments .. Operation Handling Prior to Operation... 1 Run (Starting from the Engine Side) sno ae 37 Daily Run nee a 3-10 (Check of Various Parts, Starting, Warming-up Run, Load Run and Stopping) Fuel Oil, Lub. Oil & Cooling Water 41. Fuel 41 42, Lub. Oil .. sen sane de J 43. Cooling Water 44 Periodical Checking ... re So Inspection, Adjustment and Servicing 6-1. Inspection, Adjustment and Servicing While Running smn 1 6-2. Inspection, Adjustment and Servicing in Stopping ....~ 1 Table of Tightening Torques of Major Bolts... — 71 Clearances & Wear Limits of Major Parts sen &1 94 ‘Troubleshooting & Countermeasures ....Preface ‘ ‘Thank you for your kind purchase of a YANMAR engine. Outline ‘This Operation engine, we ask you (o be surs orcad this Manual carefully to acquire ull owledge on its operation, checking, Manval purports for you to use the engine in safety and effectively. Before your usc of the maintenance, etc. DANGERS, WARNINGS & CAUTIONS Be sure to abide by/1\ marked DANGERs, WARNINGs and CAUTIONS described in this Manual, As far as safety is concerned, they arc particularly important parts of instructions, ZX DANGER: indicates that a danger of posible death or serious injury is wery great when the proper precaution is not followed, ZX, WARNING: itindicatesthat here is a danger of resulting death or serious injury when the proper precaution is not followed. injury or serious damage to the AX, CAUTION: indicates that there is the possibility of resulting i engine when an advice on safety handling or the proper precaution is not followed. (2) Keep this Manual in good custody, Make clear where itis kept, and make sure itis accessible for the ‘operator to refer toit at any time. (2) Refrain from using the engine until you have fully understood descriptions of this Manual, (3) When this Manualis lost or mutilated, promptly contact us or your nearest sales or service agent to procure the replacement Operation Manual,@ &) © Mm For replacement parts, be sure to use our genuine parts or specified parts. When transferring your engine to the next owner, be sure to attach this Manual, Drawings of Completion, Records of Shop Trial, etc. to the engine, and hand them over to that transferee, “There might be a case that the contents (text, illustration, etc.) ofthis manual partly disagrees with the actual product as depended on its specification In this case, please refer tothe Engine Specifications and/or Finished & Approved Drawings we have submitted you separately. ‘Also, parts used in the engine may be changed in course of production over years for purpose of quality or performance improvements and or for the sake of safety. Consequently, your understanding is asked that the ‘contents of this Manval--text or illustrations--may not correspond with your engine perfectly. If you find any obscure passages or have any doubis, feel free to make your inquiries at us or your nearest sales or service agent about your points of question. 02,ZX WARNING: An accident may occur if the safety ries are not followed |. PRECAUTIONS ON SAFETY 7 Strict Observance of the Safety Rules «© When running the engine or servicing it for its maintenance, observe the safety rules, precautions on safety and work procedures. ‘* When carrying out a joint work, work according to the predetermined signs. ‘¢ When using oil and grease, pay your attention to fie in particular, and be careful to prevent an accident from occurring. Wey of reer Dersagenent chee inh 33 rege ma! Poa ORs he Re Geta BO SAFETY FIRST [—— Check of Safety Devices ‘© Check the all the safety devices of your engine have been sct normally, # Ifa safety device is wrongly used, it leads to a serious accident resulting in injury or death. ‘© Promptly repair a cover of a rotating part, a heat shielding cover for exhaust pipe, a protective cover of the heating region or the like, if found damaged. HANDS OFFI [Wearing of Protective Garment and Protectors ‘# Wear the proper protective garment. Don't wear oil smudged work clothes because they are pronc to.cateh fire. © Don't forget tawear the helmet, safety goggles, safety shoes, protective mask, protective glove, lifeline, ctc., depending on the nature of work required, ZA wean pnorecrons 03ZX WARNING: Follow precautions [or the sake of safety Check of Specttied Jigs or Tools ‘® When working on the engine, use the specified engine tools. ‘© Use jigs or tools suitable for particular work because use of a wrong tool causes an injury. E ZB A modification not recommended by Yanmar may present a problem about safety. ify your engine, consult us or your nearest sales or service agent in advance. Yanmar No Modification, Please. © When you want to m can not be responsible for un accident resulting in injury or death or an engine trouble resulted from unauthorized modification, ‘# Your engine and its safety devices bave been sealed for the sake of safely, Don’t break or tamper with a seal indiscrectly. © Ifa sealing is missing, take # proper step of prompily contacting us or your nearest sales or service. agent for ensuring the proper initial setting. pool Te, ETE EF P ty) Me Nf, HANDS OFFI uy ro Getting on and off Your Engine ‘© While at work, do not jump on and off the engine. © For working, installa work bench fitted to the size of your engine to secure a good footing, Don’t work in ‘a dangerous position. ‘9 Inthe case of a work at a height, put a life-line on, and moreover wear protectors. ese) O4ZX. wannine: An accident may ocou ifthe salty rules ae nt followed. Keep Fire away feom Fuel and i, $< $$ <_< $a If fire is brought close to fuel and/or oil, there is the possibility of catching fire. (Particularly the fuel is very flammable and dangerous.) «Keep fire such asa lighted cigaretic or a struck match away (rom combustibles. 4 Keep fuel and ol in custody at an appointed place, and do nol allow the others than persons concerned (0 come near the storage. [—— Be Cautious of Handling of a High-temperature or High-pressure Spot. ‘8 It is dangerous to change the cooling water, oil or filter immediately after the engine comes to a stop. Proceed to work according to the specilied procedure only after the temperature falls 8 To uncap the radiator for feeding water to it, stop the engine, slowly unscrew the cap after the temperature falls to release the internal pressure, and only then detach the cap. ‘6 When repairing or adjusting a heater or heating part in the fuel system, be careful not to touch such a part with bare hands as there is a danger of getting burnt, © Do not touch such z high-temperature region as the exhaust pipe or pressure indicator cock of engine with bare hands. T—— Be Cautious of Asbestos Dust, ‘Asbestos materials are not used to make accessories of a Yanmar engine. ‘Asbestos dust, for example, if regularly inhaled, has a danger of suffering such e physical handicap as (3) Lung cancer, (2) Bronchogenic cancer or (3) Submedial skin cancer. ‘When handling a material containing asbestos, psy attention to the following: # When cleaning, do not use the compressed air. ‘© Sprinkle water during cleaning so as to prevent asbestos dust from scattering in the air. © Wear a dust mask, if required.ZY, WARNING: Follow precautions forthe sake of safety. —— installing ofa Fire Extinguisher and a Flesteaid Kit “6 Install a fire extinguisher against a possible fire, and have its attached label read thoroughly (0 learn how to use it Fix a salokee Establish a means of reporting to emergen its telephone number written down, ing place for a first-aid kit, and install it there. .ey medical institution such as an emergency hospital, and have # Since an organic solvent is highly volatile, liable to be gasified and absorbed by worker through his breathing asit vaporized, pay close altention to ventilation when handlin centrated organic solvent has the property of dissolving fats and oils and is absorbed by ‘© Since a highly eon ‘worker through his skins, be careful of handling it. # When working with such a solvent, be sure to wear protectors. : ae WEAR PI 2a SlekD /EAR PROTECTORSZX WARNING: An accident may occur ifthe safety rales are not followed. 2. PRECAUTIONS ON OPERATION 2-1, Prior to Starting of the Engine Securing the Sefety of the Working Area '® Proceed o setting about your work only after checking in advance whether there is a danger or not, © Check whether there are any unnecessary things in the engine installed place (and/or the engine room) or not. ‘© Checkif there arc any leakages of fue, ol, air, battery uid, ete. ‘© Check if working jigs and tools are kept in order and ready to use, '¢ Refer to Section 6, Periodical Checking. (See page 6-1.) a Fire Prevention ‘© Customarily remove combustibles from the engine installed place (and/or the engine room) because they might cause the fire if accursulated there. and if there is such a trouble, wipe offoil stain upon repairing the leaking, ‘* Check for leakages of fucl, oil, ete. point, ‘¢ Have the place where the fire extinguishe nstalled and its usage confirmed.ZX WARNING: Follow precautions for the sake of salty. Ventilate Well. ‘® Exhaust gas emitted (rom an engine is dangerous. ‘# exhaust gas is leaking, promptly repair such a leaking point as the exhaust pipe. ‘¢- Ventilate weil the indoor engine installed place (and/or the engine room.) 2-2. When Starting the Engine J—— Start the Engine after Signaling ‘© Check iffno one is around the engine. ‘+ ifsomeone is found near the engine, give him a sign that the engine will be started, Only then start ‘© Cheek the holding capacities of fuel, oil, air, ete. ‘¢ Be suro to detach the turning bar once the engine is started, and keop it at its fixed housing spot. SAFETY FIRST [—— Check after the Engine Is Started ‘© Check if pressure values of each instrument/gauge board are normal. Check if there are unusual sound and abnormal heat buildup. ‘© Check for eny leakages of fucl, oil, air, cto, and if'a leakage is found, promptly repair. After a warming-up, apply the load gradually. '» Except in case of emergency, avoid applying the load without werming-up. 0-8ZQ\ WARNING: An accident may occur ifthe safety rules are not followed. Check during a Run ‘© Check if the engine is displaying normal performance, ‘© Constantly pay attention to pressures and temperatures or unusual sound and abnormal heat buildup, etc. ‘» Record the engine performance for maintaining it at satisfactory performance. (Gee Records of Shop Trial, and then proceed to entering in your Engine Log.) © If an abnormality is found of engine, repair it at once. ‘© Don't bring your hands close to a rotating part of eagine carelessly 2.3. When Stopping the Engine ‘Check in Stopping of the Engine Except in case of emergency, do not stop the engine simultaneously with load shutoff, After a load shutoff, run the engine without load, Repair at once a spot troubling during a run. See to it that the engine is ready to start at any time.SANG: Wann Poles tere net ee ors 3. PRECAUTIONS ON MAINTENANCE, 3-1. Precuutions prior to Maintenance Servicing (——— Indication of Warnings in Checking and Servicing, ‘® While checking and/or maintenance servicing the engine, post a notice on a warning in ting board for danger prevention, ‘© Strive for safety, maintaining a close contact with the respective parties concerned. ‘Strive to prevent a danger from emerging, forbidding other than the parties concerned to enter the engine installed place (and/or the engine room), for instance. A Hetorrtk # Since a working arca will be stained/smudged, provide the engine installed place (and/or the engine room) with covering. ‘Prepare engine jigs and tools ready to use. ‘Prepare oils, genuine parts, waste cloth, wire, cic. according to the nature of work to be done. © Secure a work bench fitted to the height of the engine. S = GENUINE PARTS QS 0-10ZY WARNING: An accidont may occur ifthe safety rules are not followed, f-— Use of the Proper Toots - ‘© Use the specified engine (ools to prevent the damage of the respective bolts and nuts of the engine, © When handling a heavy thing, pay attention not to damage parts, and follow the slinger's instructions. ‘* Inadvance of using hydraulic jacks, check the function of these tools. ‘© Carefully check for any damages to rubber hose and joints of hydra in other than their specific use will damage paris, lo nol practice such usage. © Since working with tools ‘¢ Use the specified lifting gear, hook, rope, ete.; and pay attention to safety when handling @ hcavy thing particularly. SS oe aS aes, ZY Toots Precautions in Use of Fire In such works with welder, electrical tools and grinder, wear safety goggles, and be curcful of sparking. ‘© Try not to leave combustibles in a working arcs. ‘© Pay attention to fucl, oil, used waste cloth, ete, eo aE Baicuisnea ouZA WARNING: An accident may ocour if he safety rules ate not followed, Use of the Proper Taakg ——_$— '* Use the specified engine tools to prevent the damage of the respective bolts and nus of the engine, ‘¢ When handling a heavy thing, pay attention not to damage parts, and follow the slinger’s instructions. ¢ Inadvance of using hydraulic jacks, check the function of these (ools. © Carefully check for any damages 10 rubber hose and joints of hydraulic jacks. damage patts, dv not practice such usage. 8 10 sufety when handling @ heavy thing @ Since working with tools in other than their specific use * Use the specified lifting gear, hook, rope, ete; and pay atten particularly, Precautions in Use of Fire # Insuch works with welder, electrical tools and grinder, wear safety goggles, and be careful of sparking, '» Trynot to leave combustibles in 8 working area, * Pay attention to fuel, oil, used waste cloth, ete.AX wane: Foti pecans forthe ak of sey 3-2, Precautions during Muintenance Servicing Check in Course of Work ‘© For a joint work, strive for elimination of a possible danger by keeping alert to the surroundings. Tie such an accessory detached in work (o a stable post or spot so that it will not fall down, For a work at height, put on the safety belt or lifeline, For the sake of safety in general, workers are held responsible to wear protectors. glove because working with such a glove might lead to a damage of parts or a personal injury as your hands are apt to slip. Be careful of oil stained or smudged prote Wipe off or mop up spilled fucl or oil at once because, if left alone, itis dangerous as it causes a slip. Prepare a box to accommodate removed parts in advance so that they will not be lost nar damaged. Disnsscible the engine or its part with a thought given to how to reassemble. Pay attontion to where setting marks have been given, clamp whatever parts to the specified torque with these setting marks taken as the reference in reassembly, and then stamp new setting marks. (Refer to Section 9, Table of Major Bolt Clamping Torques. (See page 9-1.)] forenanion| pANUAL. —<—lZY WARNING: An accident may occur ifthe safety rules are not followed. 3.3. Precautions nt Completion of Maintenance Servicing Check of Work Finish, Check if detached parts have been refitted at the specified spats in the (otal number. the good ones, Check if the damaged parts have been replaced Return engine tools, lifting gear, hook, rope, etc. uscd to the former safekeeping place, Remove the covering against fuel and oil and/or from the engine installed place (andor the engine room). Keep tho engine installed place (and/or the engine room) in order and tidy so that i will not interfer with daily operation, Before starting the engine, check various parts to sec if there is no abnormality ‘© Start the engine, and check if there is any leakage of fucl, oil, cooling water, air, ete. * Procecd to a load run, and check that the performance docs not differ from that existed prior to the maintenance servicing, ‘ Ithereis a substantial difference in performance between before and after the servicing, make the necessary adjustment, and check that the expected performanes is being displayed. ‘+ As soon as a load run is completed, enter records of performance as well as the nature of maintenance servicing in your Engine Log. (Keeping of records and then reporting of work completion) ‘# Remove such as a standing signboard, and contact the respective parties concerned For reporting the completion of work. (Keeping of Records and then Reporting of Work Completion) KEEP TIDY! 013ac CAUTION pasiitg ReEE sapseryesya suasnas. 4, List of Safety Labels Yanmar GN1IGS: “AmB, UO CUR EP HE ABNCUS vy TERN GUC CERN ney sonneee -maumasveyeeasaeud + |. Baie sapsevyeags Exvosad moving parts Sndbdsd. Sod F Hat suri Ph we eign scorns J ONRORRLY, RECTAN Yor viderstand The HIER AY DAUD TCC AU, ONMENR ts AUTRE OBCEAL. elore startite operation. fe to (oltow the Insirecttons ta MOERMALW. AD RAW NRMNC FBR. eration nanval can lead Lo “ARNE 23d. RAMNL COST eMCEAN, “RARAERURSRMMARLE BSE, SACL troind (he enciay for safer and property batore start] th OWRACH. ABADOAPURDRS emLT ‘i yguvesed noving parts daria 141616-07250| Safety Plate (Danger) Part No. Part Name Quantity @] 141616-07200| Satety Plate (Warning) 1 @| 14616-07210] Safety Plate (Warning) 1 @| 141616-07220] Safety Plate (Caution) 2 @| 141616-07230] Safety Plate (Caution) 1 @| 141616-07240] Safety Plate (Caution) 1 ® OFDHENHY. HHO, HuAACMNGLS CLT sorbet laspectiag dering or edlately after eperatton A safety plate indicated on this page has been stuck to a dotted part of an engine illustrated here, When such a safety plate vas stained or dropped out, place your order for its replacement vith your nearest Yannar office or agent, specifying the Part Number; and in due time st- ick the replacenent. safety plate. o-14 opt Eodendy. AKORUARALORL. BERR ABAGENNAREI BAY, FREBMUTCEAL, OxKOALNHY. BUM. ENEBGEHSOENANY Uns 2amL TcEAD, OF MODUAMALNEC. 2 LEOANADG IBBU. MELA OARORMIREL. PH EDDENUHIIT. Dame 757 ORD, ENtiM ORT GORY. BLED =: Woo H ONBCRUT CURL. YIRECI- ITN RRR, 1OAMURIBUTREL, WARACE DE ROSNAENES,NAME OF VARIOUS PARTS Tee fat te Tea Tai ome Te faa Name Tes Tut Name Tg a Name 1 | Feeliniection pump 10 | Lub. oil feeding port 19 | Oilpan 28 | Turbocharger 37. | Ae duct Gntercooter inter) 2. | inspection cove, fuel isjection | 41 | Cylinder Drain Valve 20 | Decompression handle 29 | Exhaust manifold 38 | Mist pipe 3. | Gm fase cover 12 | Puet oit er 21 | Bonnet 30 | Lube oll strainer (for turbo-eharger) 4. | Flywhest housing 13 | covernor Motor 22 | Cytndor head 21 | subs oll posure regulating abe 5 | air cooler 14 | Buel feed pump 23 | Oil pan drain plug Soil htacven sear 6 | Fresh water cooter 15. | Stopping handle 24 | Cooling water pump 33 | Exhaust outlet expansion joint 7 | Crankease cover 16 | Governor 25 | Ineregor soning water votome | 34 | 146 ol one 8 | Lub. oit wing pump 17 | Water fier eap 26 | Sea water pump 35, | Starter (cell motor) 9 | Dipsuck 18 | Governor handle 27 | Air ter (for turbocharges) 246 | Fuel ot pressure regulating valve 0-15 onsvaxman GNIGS MAJOR ENGINE SPECIFICATIONS Mosel Unit 6NI65-EN Type Vertical, water-cooled, cycle diesel engine ‘Combustion chamber Direct injection type No. of cylinders 6 Cylinder bore mm 165 Stroke mm 232 Total cylinder displacement £ 29.76 Compression ratio 14 Rated speed of revolution 1,400 Direction of rotation of crankshaft Counterclockwise as viewed from the flywheel side Operating side (On the left as viewed from the flywheel side Order of firing 1-4-2-6-3-5- ‘Supercharging system Exhaust gas turbine supercharger (turbocharger) with air cooler Cooling system Constandy high temperature cooling system (equipped with fresh water cooler) Lubricating system Lubrication: Fully automatic lubrication by pump equipped in engine (08 sump: Wet sump Starting system Electric starting motor or air starting motor Overaenath ma 2,208 Dimensions [Overall width Tam 1,338 Overal height ram 1,810 Mass , dry(ceduction-teversing gear incl} kg. 3,200 (4,150) {Configuration of Cylinders} ©OOOOD Fy] rmyanmar GNIGS 2. TABLE OF ENGINE STANDARD ADJUSTMENTS Depending upon the individual unit of engine, there is some dispersion in performance; thus, refer to the Record of Factory Run Test. ‘Adjustment Value Item Remarks 6NI65 £ | Begins to open (before 7.0.0.) 50° s § | Begins to close (efter B.0.0.) 40° & | Valve head clearance (B) 0.3 on engine isin the & | Besins 10 open (before B.0.0.) 51° = % | Begins to close (afer T.0.C.) aie i | Valve head clearance (B) 04 mo engine si the Fuel injection pump begins to r~19 deliver (before T.D.C.) Injection pressure ket/ed 280210 Fuel presse ket /ad 2. 0~3. 0 g i Lub. oil pressure kgt/cd 6. 0~6. 0 Cooling water pressure at/ad | Fresh Water (Cylinder) Sea Water (Cooler) “Turbocharger ub. of i Maen ket/od 3. 5~5. 0 Cooling water engine at flesh water 2 | outlet temperature es TOE @ |b. off temperature a 2 |_ (atoll cooler inlet) a Pie & LSS er a saraso © | inlet temperature limityanmar GNIGS 3, OPERATION 3-1, Handling Prior to Operation ‘At the time of initial starting of your engine or at the time of reoperation following the overhaul servicing or a long-time rest of engine, put the following into effect. Z\ WARNING Observe the following ccaution for turning in starting preparation: Do not touch; Front power take off equipment and the part of revolution with your hand. (For prevention of an accident of your handle being causht in) 3-1-1, Confirmation on Lub, Oil System and Oil Supply 1) Confirm staying of drain and mixing-in of water and fuel oil at the following ofl staying parts, and clean these paris, if they ere fouled, The oil staying parts are (1) engine oil pan, (2) lub. ofl strainer, (3) lub. ofl cooler, (4) sump of governors, (5) sump of reduction-reversing gear. 2) Supply of lub. ol After checking of the aforementioned item 1, supply cach oil staying part with-the specified quantity of lub, ofl, Furthermore, feed off to around the governor link, For oil feeding volume, refer to Chapter 4, (3-1) (3-2) \ Feeding port \ portDecomp, Handle 3) Priming of lub, of (1) Detach bonnets and crankease side covers, and tum decompression handles of all cylinders Pri to the “DECOMP.” position, respectively. yaumar GNIGS (2) While turning the flywheel, operate the lub. oil wing pump, or Auxiliary pump and check that oil drips from suction/exhaust vaive arm parts, piston cooling nozzle and crank pins, respectively. (3) After priming of lub, oil, return and fasten bonnets and crankcase side covers to their former positions, respectively. (4) Confirm for the absence of oil leakage at various parts during priming. ump (3-6) Piston cooling hole {ON JP Piston cooling nore!yauman GNIGS 3-1-2, Confirmation on Cooling Water System and Water Supply 1) Open each valve of cooling water pipe system in agreement with operating conditions, 2) Fill the cooling water system with water, and check that there is no water leakage at various parts, 3) Supply the fresh water (Total fresh water amount is 127.) to the full water level. with taking out the cap of the fresh water cooler. After complete the water supply, should be close the pressure cap to the fresh water cooler. (3-7) Filler cap Feeding port 3-1-3. Confirmation on Fuel Oil System and Oil Supply 1) Open the drain cock (or plug) of fuel tank and fuel oil filter, respectively, to discharge drain, filteryanman GNIGS (3-9 2/2) Gap nut (inject I Plug(air vent) © jajectoin pump ws outlet valve of the tank. ipe system according to the following procedure: clock wise Direction 2) Refuel the fuel tank, and open th 3) Carry out air venting of fuel ofl pi (J) Operate the handle after turned the handle of F.O. feed pump to anti-c Please continue the priming until finish the air purge of all cylinders. (2) Loosen the air venting plug provided at the main fuel pipe end of fuel off filter and then the air venting plug of fuel injection pump, and check that overflowing out, (3) Loosen the (injection pump side) cap nut of fuel injection pipe, turn the flywheel, and check that fuel oil comes out from ail the cylinders. (At this time, have the stopping handle and decompression handles set in the “RUN” and “DECOMP.” positions, respectively.) If there, js a cylinder from which fuel oil does not come out at this time, air has not been vented from it, Consequently, change the position of flywheel a little, loosen tht air venting plug of the injection pump again, and check thet air bubble no longer appears in overflowing fue! ofl. {7X caution } ZN CAUTION Wipe off fuel oil overflowed from the air venting plug part in fuel oil priming completely with such as a rag, for instance. bubble disappears from fuel oil pipe, end nem the Dy " Desition, turn the flywheel five to six 7 (4) Tighten the cap nut of fuel injec: (S) Set the stopping handle in the “STOP! confirm that there is not fuel injection sound. (6) Fully turn the priming handle of Fuel oil feed p wump with pushing that, Run position Stop handieyaxman GNIGS 3-14, Starting Electric System 1) Check that terminals of each electric wiring are adequately clamped, 2) Cheek for the charged state of battery, (Abide by the instruction manual for battery.) If found ischarged, charge the battery, 3-1-5, Starting Air Systen 1) Open the charging valve of the starting air reservoir and run the compressor to char= ge the air into the starting air reservoir unti| its air pressure becomes 22 to 30kaf Jck. (In the case of automatic charging specification, keep the compressor in the autonatic running state with the charging valve not closed.) 2) Discharge the drain from the starting air reservoir and drain separator. 3) Taken the air pressure of the starting air reservoir is 22 to 30kgt/c#, check that. the set pressure for reducing valve for air motor starting has been regulated to the pressure renge of 7 to 10kaf/ci. 4) Check the upper and lower limit oil levels of the oiler for starting air notor. (312) Solenoid valve or quick valve / reducing valve Air reservoir n Starting air motor © compressoryvanman GNIGS: 3-1-6. Drain Discharging fros the Suction and Exhaust Valve Syste Open the drain cock of the supply air connecting pipe as well as the drain valve of the exhaust pipe flue to renove the drain. (3-13) drain cock Z\ WARNING Procedure of checking on water hammer prevention in a decompression shaft type engine Prior to initial starting following the installation of the engine or its long-time rest, check if water, fuel, ete, are staying inside cylinders by any possibility according to the following procedure: 1) Tilt decompression shaft of all cylinders to the non-compression side, and turn the flywheel to bring the No. | cylinder to 2 position of 25° before the compression top, 2) Set only the decompression shaft of the No. 1 cylinder in the run position, and turn the fly- wheel slowly. If turning could passed the compression top without feeling 2 shock at your hand, that (No. 1) eylinder is normal 3) Check all other cylinders one after another in order of firing according to the same procedure as above. 4) If these is e cylinder for which turning to the compression top could not be done as your hand felt a shock, consider that cylinder to be abnormal, If this is the case, clear up the cause thereof by setting the cylinder head free, and take a proper siep, Z\ DANGER Be sure to detach the tuming bar. (Uf the engine is started with ruming bar kept inserted, it will come off flying when the engine starts up to cause an accident resulting in injury or death)yarman GNIGS 3-2, Run (Starting from the Engine Side) Gn daily operation, star-marked (marked) items mentioned in this Section need not be put into effect.) At the time of initial starting of your engine or at the time of reoperation following the overhaul servicing or a longetime rest of engine, start your engine from the engine side whether it is an “automatic starting” or “remote starting” engine, That the engine is to be started upon confirmed of engine stopping possibility (fuel shut-off) with (3~14) Sterter switch key J R (3-16 2/2) Quick valve oy @.) A = = a Open (Stare) U f Close ZA WARNING ) Never touch the following parts during a ran: Contact Prohibited (1) Turbocharger boost air duct (2) Smokestack (Aue) ) wa get bumed 1 3) Front take i ' (2) Front powe Jake fF equipmenteané the) wa be wounded as caught in! * Runningin: (1) Execute @ munning-in at the time of servicing of engine, Run in the engine without load for about ten minutes each for 100 rpm intervals from approximately 600 rpm to the rated number of revolutios (2) After nodoad running, perform’load runnings with 25 %, 50 %, 75 % end 100 % loads in that order, jal starting end efter overhaulyaxman GNIGS. 3-2-1, Method of Starting from the Engine Side Az In the case of cell motor starting a) Turn on the battery switch, B: In the case of air notor starting a) Open every valve of the starting air reservoir and air line. b) Adjust the lubrication from the oiler to the air notor that the oi! dropping from the oiler will be ebout one drop per second. In the case of not starting over a long per- iod of time of longer than one week, adjust the dropping oi! to two to three drove pe: second. (3-17) Bareery Switen ora. S Oil dropping dlinspection port 1) Tum decompression handles to the “RUN” position. 2) Check that the stopping handle is in the “RUN" position, 3) Turn the governor handle so that the pointer of governor speed control shaft indicates graduation 2 (3 ~19 1/2) Govenor handie (3-19 7/2)yanmar GNIGS 4) Operate the starter switch key. Then, the engine starts rotating. Furthermore, when the firing takes place (rotation increases), release the starter switch key, (3-21) ZX CAUTION Release the starter switch key below the engine revolution of $00 rpm. Besides, to restart the engine in case of a starting failure, operate the starter switch key in about ten seconds after the engine comes to a stop. (A measure to prevent a damage of starting motor) 5) Tum the governor handle clockwise to rise the engine rotational speed gradually to the rated revolution, (about 600rpx) (At this time, check that both the lub, oil pressure and the cooling water pressure are risen to the respectively specified values.) Lub. oil pressure + 5.0~6. Okgt/cat Fuel feed pressure =: 2,0~3, Okg tf /cat Cooling water pressure: 1.5~2. Skgt/edt( forhisnaemp.) 0, 5~1, Ske /caf (for ww-semp)) Wontrol air pressure: 7.0~10, Okgf/cat 7\ WARNING Quickly pass over the normally critical region of revolution which imparts torsional vibration, (3-24) Boost air pressure guage CM. pressure guage | anni pressure gunae OO (estinder) c Depending on conditions of specification, the arrangenent for the pressure gauge may differ fron the standard layout or the pressure gau- ge nay not be attached in sone cases, Critical revolution plate 3-9yasman GNIGS (3-25) 5) Should be purge the air from sea water circulating line by opening the air purge cock whitch installed on the cover of air cooler (Installed upper pert of the opere- tion side) SEPT ee ° BO 18 sje 7) Should be check the fresh water level on the site glass of the fresh water cooler. If in case so low water level, it can not confirm the water level on site glass that time, please stop ‘the engine then supply fresh water to full level again with taking out the pressure cap. then resoving the pressure cap from the fresh water cooler, be careful of steam uhich nay blow off to cause you a possible burn, (3 ~26) ‘ar level senseor___ Filler cap Water level se coe (C.. Feeding port) 8) Turn off the battery switch after starting, Besides, close valves of the air reservoir and air pipe line, (except in the case of using the compressed air of the air reservoir for such as a protective circuit, for instance. ) 9) After the engine is started, be sure to turn “ON" the power switch for protective devices, 3-10varman GNIGS 3:3, Daily Run : Camry out strictly instructions of the following Subsections 3-3+] & 3-3-2 prior to starting for daily nun, 33-1, Oil Volume Check of Oi] Staying Parts and Priming Lub, oil volume check points are'(1) oil pan, (2) governor (3) sump of reduction-reversing gear. Priming of lub, ofl Set decompression handles in the “DECOMP.” position, switch over the priming pump change-over cock to the “PRIMING" position, operate the lub. oil wing pump while tuming the flywheel, and continue priming until the engine lub, oil pressure becomes about 0, Skef/al - (After this priming, remove the tuming bar, change the priming (3-27) pump -change-over cock to the “RUN” position, and tum de- compression handles of all cylinders to the “DECOMP." position.) Lub. oil pressure about 0,5kef/at 3-3-2. Confirmation on Fuel Oil and Cooling Water Systems 1) Check that each valve of these systems is opened or closed in agreement with operating condi- tions, 2) Check that the required volume of fuel oil and cooling water is available 3-11yvauman GNIGS 3-3-3. Starting 7 Start the engine according to foregoing Subsection 3-2-1, Z\ cauTION Starting on an extremely cold day Starting procedure is the same as the aforementioned, However, pay attention to the following points: (1) Restric the operating time of starter switch button to less than 15 seconds at any one time, (2) When operating the starter switch again as the engine does not start by one try, do so after waiting 10 seconds at least to elapse. 3-3-4, Warming-up Run 1) For warming-up run, perform a no-load running at the Rated speed of revolution (about 600rpa) for about 5 to 10 minutes, 2) Open the air venting plug of delivery side lub, oi strainer to vent the air out, 3) Confirm that the indication of each pressure gauge is the specified value. 4) Check for abnormal heat generation, gas leakage, etc. at the engine exterior, turbo-charger and 5) Check the fresh water level of fresh water cooler, 1f the water level is found dropped, stop the engine, and replenish fresh water. /\ DANGER When uncapping the fresh water cooler water filler, be careful of steam blowoff to give a danger of possible bum. Besides, do not touch the filler cap with bare hands, And, be sure to tighten the cap fully, because cooling water pressure becomes the state of no increase for standard value, if operate as want of tightening the cap, fresh water will be leaked from the over Slow pipe of the pressure cap when fresh Normally, ‘abnormal,’ The leakage water temperature will be rised up on the load operation, That is not will be stopped when the fresh water temperature rise will be stabilized, (3-30) Filler cap \Corvertlow pipe 3-12yanmar GNIGS Never touch the following parts during « run: Contact Prohibited (1) Turbocharger boost air duct (2) Smokestack (flue) (3) Front power take off equipmentsand the part of revolution, } Wit ect umes ! } Will be wounded 2s cavgh: in | 1) Confirm of lub. oil temperature at the lub. oil cooler outier, Note Limit temperature of lub. oil cooler is 70°C (3-32) Thernoneter“

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