YANMAR OPERATION MANUAL MARINE PROPULSION ENGINE 6EY26W Eng. No. 1115, 1116 RAB07001All Rights Reserved, Copyright WANMAR CQ. LTD.EY2G OPERATION MANUAL Work No.RA-B07001 Engine No.1115 (Clockwise Rotation Engine) No.1116 (Counterclockwise Rotation Engine) CONTENTS Page No. 00 Basic Descriptions 01 Preface MB1690-00-01a-02 30 Engine Specification M81695-00-309-01 M51695-00-30a-00 03 Direction of Rotation M8 1690-00-03r-00 M51690-00-03b-00 04 External and Sectional View M51695-00-04d-02 06 Term & Symbol Marks M51690-00-05a-01 06 Precautions on Maintenance M81695-00-06b-03 07 Precautions prior to Maintenance & Servicing M61695-00-07a-02 18 Protective Device Setting Values Holding Volumes of Lubricating Oil & Cooling Water Pressure & Temperature Setting Values M51695-00-186-05 (09 Assembly Adjustment Values Clearances & Wear Limits of Major Parts M51695-00-09b-03 40 Table of Tightening Torques of Major Bolts & Nuts M81690-00-10b-04 11 Principal Dimensions & Mass for Disassembly & Servicing M51695-00-11b-03 48. SI Unit Conversion Tabie MS1690-00-13a-00 414 Symbol Marks on Piping Layout & Instruments M51690-00-14a-01 00 Operation 21 Operational Preparation M51695-00-21b-01 22 Starting M51695-00-220-00 23 Running MB1695-00-23b-01 24 Stopping M51695-00-24a-01 25 Special Running Method M51695-00-25a-01 33 Data Sheet MB1695-00-332-00 00 Trouble shooting & Countermeasures M81695-00-41a-02 00 Fuel Oil, Lubricating Oil & Cooling Water 51 Quantity Criteria of Fuel Oil M81695-00-51a-00 58 Choosing of Lubricating Oil M51695-00-58a-01 59 Control on Lubricating Oil M51695-00-59a-02 60 List of Lubricating Oil Brands MB1695-00-80a-01 62 Criteria on Cooling Fresh Water MB1690-00-62a-01 63 Selection and Control of Corrosion Inhibitor M51690-00-63a-01 00 Measurement of Running Performance 91 Precaution on Measuring Performance & Measure Items M51690-00-91-01 92 Measurement of Running Performance M51690-00-92b-00 93. Measurement of Max. Combustion Pressure M81690-00-930-00 YANMARLy et ee FN mre) Work No.RA-807001 Engine No.1115 (Clockwise Rotation Engine) No. 1116 (Counterclockwise Rotation Engine) CONTENTS Page No. 01 Cylinder Block & Cylinder Liner 01 Outline M51890-01-042-00 02 Overhauling the Cylinder Block M51690-01-022-00 03 Overhauling the Cylinder Liner M51690-01-03a-01 1 Parts List of Cylinder Block Cylinder Block M51695-01-51b-04 Cylinder Side Cover M51695-01-52d-01 Cylinder Side Cover (Relief Valve) M51695-01-53c-02 Gear Case M51695-01-54d-05 Oil Pan. M51695-01-55a-02 Oil Sealing (SFW) M51695-01-56b-02 Oil Sealing (OF W) M51695-01-62a-02 Breather Pipe M51695-01-60a-02 Pump Case Cover ‘M51695-01-58e-00 € 08 Turning Device 01 Outline (Manual Cranking) M51690-08-01a-02 02 Operation of the Manual Cranking Device M51690-08-022-01 1 Parts List of Turing Device M51695-08-512-00 M51695-08-510-00 41 Cylinder Head & Its Accessories 01 Outline MS1690-11-018-00 02 Overhauling the Cylinder Head M51690-11-022-01 03 Overhauling the Intake / Exhaust Valves 1M51890-11-032-02 04 Overhauling the Intake / Exhaust Valve Seat M51690-11-042-01 05 Overhauling the Intake / Exhaust Valve Guide M51690-11-05a-01 06 Overhauling the Intake / Exhaust Valve Bridge & Guide M51690-11-06a-00 07 Overhauling the Valve Rotator M51690-11-078-00 08 Adjusting the Intake / Exhaust Valve Head Clearance M51690-11-08a-03 ‘Parts List of Cylinder Head Cylinder Head MS1695-11-513-04 Valve Arm Ass'y & Bonnet M51695-11-522-05 Indicator Valve M51695-11-532-02 14 Timing Gear, Camshaft & Intake / Exhaust Swing Arm 01 Outline MB51690-14-012-00 02. Overhauling the Timing Gear M51690-14-022-02 03 Servicing the Camshaft M51690-14-032-01 04. Servicing the Intake / Exhaust Swing Arm M51690-14-048-01 '™ Parts List of Timing Gear M51695-14-519-00 M51695-14-512-00 '™ Parts List of Camshaft & Suction / Exhaust Swing Arm M51695-14-52s-00 MB1695-14-52c-00 YANMAREY26G OPERATION MANU. 18 Air Cooler, Exhaust Manifold & Turbocharger 01 Outline 02 Servicing the Air Cooler (03. Overhauling the Exhaust Manifold Turbocharaing Operation Manual (STS) 05 Turbocharger Blower Washing Procedure ™ Parts List of Air Cooler (FW Side TIC) & Parts List of Boost Ali (FW Side TIC) Air Duct Boost Air Gauge Pipe Parts List of Exhaust Ges (FW Side T/C) Exhaust Gas Manifold Exhaust Gas Manifold Cover Exhaust Gas Outlet Pipe for Turbocharger Exhaust Gas Pipe Insulation Covering ™ Parts List of Turbocharger (FW Side T/C) = Parts List of Turbocharger Blower Washer (FW Side T/C) 21 Main Bearing & Crankshaft 01 Outing 02 Overhauling the Main Bearing 03 Overhauling the Crankshaft 04 Measurement of Crankshaft Deflection RATO-S Coupling instruction Manual ™ Parts List of Main Bearing ™ Parts List of Crankshaft & Flywheel ™ Parts List of RATO Coupling 22 Pistons & Connecting Rod 01 Outline 02 Overhauling the Pistons & Piston Pins 03 Overhauling the Connecting Rods m Parts List of Piston & Connecting Rod Work No.RA-B07001 Engine No.1175 (Clockwise Rotation Engine) Page ‘No.1116 (Counterclockwise Rotation Engine) pee CONTENTS Page No. MS1695-18-01b-00 M51690-18-02b-01 M51695-18-03b-01 7596002en-3 M51690-18-05b-02 M51695-18-520-04 MB51695-18-540-03 M51695-18-55-01 M51695-18-58b-00 M51695-18-60a-02 M51695-18-61b-02 M51695-18-63b-00 M51695-18-65b-00 M51695-18-67b-02 M51695-18-69a-01 M51690-21-01a-00 M51690-21-02a-01 M51690-21-032-01 MS1695-21-04k-04 MA_1G291104AC_EN M51695-21-512-01 M51695-21-62t -02 M51695-21-62s-02 M51695-21-530-00 M51690-22-01b-01 M51690-22-02b-01 M51690-22-036-02 M51695-22-51b-03 YANMAREY26G OPERATION MANUAL Work No.RA-B07001 Engine No.1115 (Clockwise Rotation Engine) Page No. 1116 (Counterclockwise Rotation Engine) ir CONTENTS Page No. 30 Lubricating Oil System 01 Outline (Turbocharger is equipped to the flywheel side) M51696-30-01a-02 02 Overhauling the Lubricating Oil Purp 1M51690-30-02a-01 03 Adjusting & Overhauling the Pressure Regulating Valve 04. Adjusting & Checking the Thermostats 08 Overhauling the Lubricating Oil Strainer 08 Overhauling the Lubricating Oil Cooler 09 Overhauling the Lubricating Oil Bypass Filter (Centrifugal Type) = Parts List of Lubricating Oil Pump ™ Parts List of Lubricating Oil Pressure Regulating Valve 1™ Parts List of Lubricating Oil Strainer 1 Parts List of Lubricating Oil Cooler ™ Parts List of Oil By-pass Filter (Centrifugal Type) '™ Parts List of Lubricating Oil Pipe System (Pump ~ Cooter) (Cooler ~ Strainer) (for Pressure Gauge) (FW Side T/C) (for Turbocharger) 40 Cooling Water System 01 Outline {Turbocharger is equipped on the flywheel side, and two cooling water ‘pump is equipped on the cylinder block.) 02 Overhauling the Cooling Water Pump Overhauling the See Water Pump 03. Overhauling the Cylinder Jacket Cooling Water Thermostats 04 Servicing of Bypass Valve in the Air Cooler (Turbocharger is equipped on the fiywheel side) '™ Parts List of Cooling Water Pump (Fresh Water Side) ™ Parts List of Cooling Water Pump (Sea Water Side) '™ Parts List of Cooling Water Thermostat Valve ™ Cooling Water Pipe System (Pump ~ Cylinder) Collecting Pipe Drain Pipe (Cylinder) (FW Side T/C) (Pump ~ Air Cooler) (FW Side TIC) {LOIC ~ IC) (FW Side TIC) {F-W,) (FW Side TIC) By-Pass Valve (VC) (FW Side TIC) UC Drain Pipe (FW Side TIC) (Pressure Gauge) (FW Side TIC) Parts List of Zinc Ass'y M51690-30-03a-01 M51690-30-04a-01 M51690-30-062-06 M51690-30-082-00 M51690-30-09b-01 M51695-30-519-02 M51695-30-512-02 MB1695-30-620-01 MB51695-30-532-03 M51695-30-55a-02 M51695-30-56¢-02 M51695-30-579-03 M51695-30-572-02 M51695-30-58c-00 M51695-30-602-02 M51695-30-62b-00 M51695-40-01¢-00 M51690-40-022-01 M51690-40-02b-01 M51690-40-032-00 M51690-40-04b-01 M51695-40-519-01 M51695-40-512-02 M51695-40-529-00 M51695-40-52a-02 M51695-40-532-00 M51695-40-542-01 M51695-40-550-03 M51695-40-58b-02 M51690-40-58b-01 M51690-40-62a-02 M51695-40-64c-01 M51695-40-70c-00 M51690-40-66a-01 M51695-40-670.02 M51695-40-69a-01 M51695-40-69b-01 YANMAREY26 OPERATION MANUA! Work No.RA-B07001 Engine No.1115 (Clockwise Rotation Engine) No.1116 (Counterclockwise Rotation Engine) CONTENTS Page No. 50 Fuel Oil System 01 Outline M51695-50-01a-02 (02 Overhauling the Fuel Oil Feed Pump & Adjusting the Pressure M51690-50-02c-01 03. Overhauling the Fue! Injection Pump ‘M51690-50-032-03, (05 Regulation of the Fuel Injector Volume (Exhaust Gas Temperature) M51690-50-05a-01 (06 Adjusting the Fuel Injection Timing M51690-60-06a-01 07 Overhauling the Fue! Injection Pump Drive M51690-50-072-00 08 Overhauling the Fuel Injector & Adjusting the Injection Pressure M51690-50-08a-02 09 Overhauling the Fuel Oil Sirainer M51680-50-08a-01 410 Overhauling the Fuel Oil Pipe M51690-50-10a-02, m Parts List of Fuel Injection Valve M51695-50-51¢-01 Parls List of Fuel Feed Pump & Driving Device M51695-50-529-02 ¢ M51695-50-528-02 . = Parts List of Fuel Injection Pump M51695-50-53a-05 Parts List of Fuel Injection Pump Driving Device M51695-50-54a-01 1 Parts List of Fuel Injection Pipe M51695-50-55a-00 = Parts List of Fuel Oil Strainer (KANAGAWA) M51695-50-57b-00 Parts List of Fuel Oil Pressure Regulating Valve MB1695-50-59b-01 m Parts List of Overflow Fuel Tank & Float Switch M51695-50-620-00 1 Parts List of Overfiow Fuel Sump 1M51695-0-72a-00 Parts List of Accumulator M61695-50-73a-02 ™ Parts List of Fuel Oil Pipe System (Inlet ~ Strainer) 1M61695-50-64a-03 (Strainer ~ Main Pipe) M51695-50-862-05 (Main Pipe) M51695-50-67a-03 (Main Pipe ~ Regulating Valve) MB1695-60-7 12-03 (Overflow for Injection Valve) M51695-50-682-02 (Overfiow for Feed Pump & Cylinder) M51695-50-694-00 (Overfiow for injection Pipe) M51695-50-70a-00 \ 60 Governor & Governor Gear 01 Outline M51690-60-012-00 ZEXEL Service Manual (Governor RHD10) PubNo.BE74E-11040 02. Overhauling the Governor Link M51690-60-02a-00 03 Overhauling the Governor Gear M51690-60-03a-00 1 Paris List of RHD Govemor & Driving Device M51695-60-51d-00 ™ Paris List of RHD Governor Linkage M51695-60-52a-02 ™ Parts List of Start / Stop Lever M51695-60-53a-00 'm Parts List of Link Ass'y (RHD Type) M51695-80-54a-02 63 Control & Protective Devices 01 Outline M51695-63-01a-01 04 Adjusting the Pressure Transmitter M6 1690-63-04a-00 06 Maintenance of the Pressure Gauge M51690-63-062-00 YANMARWork No.RA-B07001 Engine No.1115 (Clockwise Rotation Engine) EY26G OPERATION MANUAI No. 1116 (Counterclockwise Rotation Engine) CONTENTS 65 70 92 95 Special Attachments 03 Maintenance of the Electromagnetic Pick-up 05 Maintenance of the Turning Switch 06 Maintenance of the Start / Stop Lever Interlock Switch 08 Maintenance of the Electromagnetic Stop Valve 09 Maintenance of the Air Strainer 1. Maintenance of the Speed Relay 12 Maintenance of the Startup Fue! Control Air Piston & Shutdown Air Piston 13 Maintenance of the Speed Regulating Valve 14 Maintenance of the Pressure Switch 15 Maintenance of the Temperature Switch 17 Maintenance of the Fuel Oil Float Switch 18 Maintenance of the Fuel Pump Rack Potentiometer_ 20 Boost Compensator Adjustment Procedure 1m Parts List of Magnetic Pick-up (FW Side T/C) ™ Parts List of Gauge Panel (Electric Tachometer) (FW Side TIC) ™ Parts List of Gauge Panel (Pressure Gauge) (FW Side T/C) ™ Parts List of Air Piston for Fuel Limit & Engine Stop ™ Parts List of Pressure Switch (5 Connects) ™ Parts List of Pressure Switch (3 Connects) & Parts List of Temperature Switch ‘® Parts List of Fuel Oil Rack Transmitter ™ Parts List of Boost Compensator ‘Start up/Control Air System & Air Starter 01 Outline of the Main Components Installation and Operating manual Operating & Service Manual for Integral relay Valve wm Parts List of Air Starter ™ Parts List of Starting Air Devices Starting Air Pipe Control Air Pipe HD Governor Control Air Pipe Hydraulic Jack 01 Outline of the Main Components 02. How to Use the Hydraulic Tools 03 Location Used & Installation Method. = Parts List of Hydraulic Jack (Cylinder Head) (Main Bearing Cap) (Rod Bott) (Pantograph) Installation Notes Yanmar's Worldwide Service Network Page No. 151690-65-032-01 1151690-65-052-00 M51690-65-082-00 M51690-65-082-02 M51690-65-092-01 M61690-65-1 12-00 M51690-65-122-01 M51690-65-132-00 M51690-65-142-00 1M51690-65-152-00 M151690-65-172-00 M51690-65-182-01 M51695-65-208-00 M5 1695-65-52d-00 1i51695-65-54c-00 151695-65-630-03 M5 1695-65-56e-01 151695-65-58! -00 §M51695-65-59h-00 1M51695-65-600-02 M51695-65-642-02 1M51695-65-660-00 M51690-70-01m-01 T7241 11-737 M51695-70-51r -00 M51695-70-524-06 M51695-70-632-00 M51695-70-54c-01 M51690-92-012-03 M51690-92-028-00 M51680-92-032-00 M51695-92-512-01 M51695-92-522-01 M51695-92-53a-02 M51695-92-54a-00 M51695-95-12c-00 YANMAREY26G OPERATION MANUAL CET Basic Descriptions No. Page 00 Preface 00-01a-02 | 14 C Thank you for purchasing a YANMAR Diesel Engine. 1. Foreword This Operation Manual has been prepared for your safe and effective use of the engine. Read thorough this Operation Manual and fully understand the safety precautions and precautions regarding the operation, checking and servicing before using this engine. (1) Keep this Operation Manual at a clearly identified place accessible for the operator to refer to it at any time. (2) The text and illustrations of this Operation Manual may partly disagree with engines of some specifice- tions, For such engines, refer to the Engine Specification and Final Document we have submitted you sepa- rately. Also rote that this Operation Manuals subject to change for improving the quay and performances of engine or for safety. (3) For the following devices, refer to the corresponding operation manuals separately attached, Attachments of special specifications (4) In this manual, the numerical values are based on the Si system (Intemational System of Units). However, the numerical values based on the conventional unit system are also given in brackets. (5) Replacement parts should be our genuine parts or specified parts. Order a part to your nearest sales or service agent of Yanmar's parts. When ordering a part, clearly specify page number to which parts have been described, the Part Name (part description) and Part No., and the Model and manufacture’s Serial No. of the engine. (6) If you should have lost or damaged this Operation Manual, or if you have any questions and advice, please contact us or your nearest sales or service agent (shown in the service network list "YANMAR Worldwide Service" appended fo this manual) (7) IF you transfer this engine, also transfer this Operation Manual, Final Document and Records of Shop ‘Trial with the engine to the next owner. (8) tf you use this engine for an application or under service condition other than those specified, or if you handle itnot in accordance with this Operation Manual, an accident or a failure may be caused. Please contact us or your nearest sales or service agent before changing any technical data of the engine or modifying the engine after it has been delivered. Never modify the engine without consulting us. (8) When exporting or providing yanmar products to non-residents, please comply with the security trade control laws. YANMAREY26G OPERATION MANUAL Es Basic Descriptions C For safe use of your engine. ) SAFETY STATEMENTS ‘Yanmar is concemed for your safety and your machine's condition. Safety statements are one of the primary ways to call your attention to the potential hazards associated with Yanmar LV Series engine operation. Follow the precautions listed throughout the manual before operation, during ‘operation and during periodic maintenance procedures for your safety, the safety of others and to protect the performance of your engine. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a label attached to it, make sure you order the new part and label at the same time. This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol DANGER indicates a hazardous situation which, if not DANGER avoided, will result in death or serious 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 AXCAUTION avoided, could result 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. YANMAREY26 OPERATION MANUA UE Basic Descriptions No. 00 Preface 2. How to read the Manual Read this manual referring to the following descriptions. (1) This manual is composed according to the list of the "CONTENTS" page. (2) Each chapter has each page number and is arranged to match each user's specifications. 2-4, Title [Clockwise Rotation Engine PALL LO msi Piston & Connecting Rod Overhaul of Piston & Piston Pin é ‘es The remarked items are the following explanations. @® Model name of engine © Model No. of engine © Group code © Group name © Title of the chapter ® index of specification This index is added when distinction is necessary for different specifications. © Document No. Peculiar No. of each document for each specifications © Serial pane No. of the chapter YANMAREY26 OPERATION MANUAI fe Basic Descriptions No, Preface 0018-02 2-2. How to read the Parts List Read the parts list in this manual referring to the following items. (1) lustration and referring number of the parts are shown at the first page. (2) The name and part number of the parts corresponding to the number in the first page are written in the table, (3) Explanations on the each item in the table are as follows, he te Ce Od LY SEMBIEE YU veo y ote Parts List of Cylinder Block a 2 al | Lh ARES No, Pege 01 orste0o | 24 No | Level | Order | Part to, cnet sdstuaed t[t 751695-01560 | 7y2%Fa77 Assy | BLOCK ASSY, OMLINDER | 1 2 | 2 | x | tsress-oi011 | ey>e7ay9 BLOCK, CYLINDER 1 | 3 [3 |x | tstes5-o7091 | xenaryFR—x | CAP, NETAL BASE 1 4 [3 |x | 15169502051 | aa ey CAP, NETAL 6 5] 3 151605-02070 | RU KCX SRT | BOLT, METAL CAP i 6 | 3 151695-02080 | 44 FRI BOLT, SIDE 4 OTitle Tite is the name of the group that has most close relation with each chapter. Several parts belong to other chapter are also in the lst as they could not be separated from main group. ®No. Number attached to the illustration in the first page @Lovel Nominal parent-child relationship of the parts 1: Parent parts (Assembly parts) 2 : Child paris included in "1" 3 : Child parts included in "2", Grand child parts in terms of "1* @ Order The parts marked "x in this item cannot be supplied by itself as they cannot be treated separate from upper component. © Part No. Order the part by this number. OnRaH Japanese name @Part Name English name ®ay Number of the parts per one engine YANMARCounterclockwise Rotation Engine EY2G OPERATION MANUAL aT ‘Basic Descriptions i No. Page 00 Engine Specification 00-30q-00 12 1.Engine Specification Model Unit BEY26W Type = Vertical, water-cooled, 4-cycle diesel engine Combustion chamber _ Direct injection type No. of cylinders cast 6 Cylinder bore mm 260 Stroke mm 385 Total cylinder displacement L 122.64 Compression ratio = 14.0 Rated output KW 1920 Rated speed mint 750 Direction of rotation of crankshaft cat Counterclockwise as viewed from the flywheel side ‘Operating side f: On the left as viewed from the flywheel side ‘Order of firing Soe 1-3-5-6-4-2-41 Supercharging system er Exhaust gas (turbocharger) with air cooler Cooling system cant Freshwater & Seawater dual system cooling Forced lubrication Lubricating system ~ (system oil also used as turbocharger lub oil) (System oll also used as rocker arm lub.ol) Lubricating oil sump system = Dry Sump ‘Starting system _ Air motor starting ‘Overall length mm Dimensions Overall width mm | Refer to the Final Drawing ‘Overall height | mm Mass (of engine singly) kg 2012.10.18R YANMARCounterclockwise Rotation Engine EY26 OPERATION MANUAL Deed Basic Descriptions Engine Specification Page 212 00 2.Types of Accessories & Attachments ‘Acoessory/Atiachment Type Remarks Supercharger Air-cooled exhaust gas turbine Boost ar cooler Plate finned mutttubular Governor Hydraulic Fuel injection pump Boaeh Independent per cylinder Fuel vale on Non-cooled, with nozzle sleeve (Long-stem, multiple jet nozzle) Fual feed pump Gear For marine diesel oll Fuel oil fiter ae oe For engine inlet Lub ol pump Gear Lub.il cooler Low finned tube multitubular wlautomatic temperature control valve aera Polyester mash element ‘Automatic backdiushing I Centrifugal For bypass fier ‘Lub oll tank Bottom tank Dry sump Cooling water pump Centrifugal Cylinder jacket side and Cooler side Fresh water coolers Plate or mutttubular Equipped to the hull Air starter Turbine Compressed air 2012.10.18R YANMARClockwise Rotation Engine EY26G OPERATION MANUAL ened Basic Descriptions No. 00 Engine Specification Page 00-30a-01 | 1/2 41. Engine Specification Model Unit 6EY26W Type _ Vertical, water-cooled, 4-cycle diesel engine Combustion chamber _ Direct injection type No. of eylinders = 6 Cylinder bore mm 260 Stroke mm 385 ‘Total cylinder displacement L 122.64 ‘Compression ratio - 14.0 Rated output kW 1920) Rated speed min* 750 Direction of rotation of crankshaft] — Clockwise as viewed from the flywheel side Operating side - On the left as viewed from the fiywheel side Order of fring 7 1-28-6-5-3-1 Supercharging system = Exhaust gas (turbocharger) with eir cooler Costing system - Freshwater & Seawater dual system cooling Forced lubrication Lubricating system - (system oll also used as turbocharger lub.il) (system oil also used as rocker arm lub.oll) Lubricating oil sump system = Dry Sump Starting system = Air starter starting Overall length | mm Dimensions | Overall width mm — | [ Refer to the Final Drawing Overall height ma | Mass (of engine singly) ‘9 YANMAREY26 Basic Descriptions 00 Engine Specification e Rotation Engine OPERATION MANUAL rd No, Page 00-30a-01 | 212 2. Types of Accessories & Attachments Fuel valve Accessory/Attachment Type Remarks Supercharger Air-cooled exhaust gas turbine Boost air cooler Plate finned multitubular ‘Governor Hydraulic Fuel injection pump Bosch Independent per cylinder Bosch {Long-stem, multiple jet nozzle) Non-cooled, with nozzle sleeve Fuel feed pump Gear For marine diesel oil Fuel oil strainer Manual back-washing, duplex, For engine inlet change over notch wire Lub.oil pump Gear Lub.oil cooler Low finned tube multitubular wiautomatic temperature control valve Lub.oil strainer Polyester mesh element ‘Automatic backflushing I Centrifugal For bypass filter Lub.oil tank Bottom tank Dry sump Cooling water pump Centrifugal Air starter Turbine Compressed air YANMARCounterclockwise Rotation Engine EY26 OPERATION MANUAL Ura Basic Descriptions No. Page 00 Direction of Rotation 00-03-00 | 4/1 Direction of rotation is counterclockwise as viewed from the flywheel side. Direction of Rotation Flyweot YANMARClockwise Rotation Engine EY26 OPERATION MANUAL a Basic Descriptions Direction of Rotation No. 00-03-00 Page wn Direction of rotation is clockwise as viewed from the flywheel side. Direction of Rotation Flywheel YANMAREY2G OPERATION MANUAL Ey Basic Descriptions Wo. az 00 External and Sectional View 1. External View 41-1. Operation Side View Fig. 00-04-1 Operation Side View Gauge pane! Governor Cooting water pump Fuol of srainor Fig. 00-04-2 Non-Operation Side View ‘Sea water pump (Optional pars} Lubricating of strainer utomate back washing type ‘Cooling water pump Lubsicatng ol by-pass fiter Fue ot feed pump centritugal ype YANMAREY26 OPERATION MANUAL eed Basic Descriptions External and Sectional View 2. Sectional View 2-4. Sectional View of Longitudinal Fig. 00-04-3 Sectional View of Longitudinal a 2 4 ae) Nos Not 0° 5 i 7 gi q 6 18. Fed t¢-—, 19. i] 7 nm n 43 fi i ea 5 i A 16-4 ako $ erp iaert B 14 * r\ t i l 15 T t m1 0 2 9 8 a No. Part Name No. Part Name 1_| Cylinder block 11_| Bott of main bearing 2 | Cylinder head 12. | Main bearing 3 | Suction valve 13 | Thrust bearing 4 | Exhaust valve 14 | Flywheel 8__| Protection ring 15 | Ring gear 6 | Cylinder ner 16 | Crank gear 7 | Piston pin 17 | idle gear 8 | Crank shaft 18 | Cam gear 9-_| Balance weight 19. | Gear case 10 | Cap of main bearing 20_| Fuel il injection valve = 21 | FW. auto temp. control valve YANMAREY26 OPERATION MANU Ur Basic Descriptions No. Page 00 External and Sectional View 00-046-02 | 3/3 2-2. Cross Sectional View Fig, 00-04-4 Cross Sectional View 23 22 24. 33, 25. 26. 27. 34 28 29 30 35 37 36 34 38 32 39 No. Part Name No. Part Name 22_| Valve bridge 31 | Rod bolt 23. | Rocker arm 32_| Side bolt 24 [Push rod 33 | Exhaust manifold 25 | Fuel ol injection pump 34 | Suction room 26 [piston 35_| Cooling water passage 277 [piston ring 36 | Lubricant passage 28 | Swing arm 37_ | Lubrication oil cooler [29 | cam shaft 38_|L.O. auto temp, control valve 30 | Connecting rod | 3¢ [ow pan YANMAREY26G OPERATION MANUAL 51690 Basic Descriptions No. Page 00 Term & Symbol Marks aaaneaye ee 4. The major terms used in this Operation Manual are defined as follows’ Front part of engine: Part opposite to the flywheel end Rear part of engine: Part on the flywheel end Operation side Left side as viewed form the flywheel end (fuel injection pump side) Non-operation side _: Right side as viewed from the flywheel end (exhaust manifold side) OW rotation : Clockwise rotation as viewed from the flywheel end CCW rotation Counterclockwise rotation as viewed from the flywheel end Cylinder No Assigned in the ascending order from the cylinder nearest to the flywheel end Non-operation side Flywives| ‘Mactir hat Hisdrvon Fuel injection puma Operation side 2. The following symbol marks are used in the safety labels shown in this Operation Manual and posted on the engine. Caution marks and signal words DANGER indicates a hazardous situation which, if not Caos avoided, will result in death or serious 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, could result in minor or moderate injury. ACAUTION NOTICE indicates a situation which can cause damage to the eel. machine, personal property and / or the environment or cause the equipment to operate improperly. Symbol marks Caution marks Others Refer to another page, or chapter of this Operation Manual or other document. Rotating part Explosion hazard [4 oad hazard hi é Fiat High temperature Hazardous noise High pressure alr hazard Zl hazard YANMAR00 Basic Descriptions No. EY26G OPERATION MANUAL Page Precautions on Maintenance 00-06b-03 | 4/5 1. Basic Precautions Be cautious of handling of fuel and lubricating oil. y «if fie is brought close to fuel andior lubricating ol, there is the possi- [ MAmAsies bility of catching fire. (Particularly the fuel is highly flammable and dangerous.) «Fire should be strictly prohibited in the engine installed place (engine room). *Check for leak of fuel oil and lubricating oil. f you find a defective point, repair it and wipe out leaked fuel or lubricating oil. *Store the fuel oil and lubricating oil at the specified place and do not allow persons other than those con- cerned to handle them. *Unnecessary flammables in the engine installed place (engine room) may cause fire. Therefore, store these flammables in another specified pla + Ventilate Well. Ventilate well. Ventlate well 1o prevent gas intoxication. “Exhaust gas emitted from an engine is dangerous. if Exhaust gas is leading, promptly repair such a leaking point at the exhaust pipe. “Ventilate well the indoor engine installed place (andlor the engine room.) sTake care that the room does not fall short of the air (oxygen) because the turbocharger takes in a great + Inhaling exhaust gas is very dangerous. volume of air. When working indoors, sufficiently + While charging the battery, there is danger of catching fire because ventiaie the room. serie Observe the precautions for ensuring safety. *Check of Safety Devices “Check the all the safety devices of your engine have been set normally. +if a safety device is wrongly used, it leads to a serious accident resulting in injury or death. -Promptly repair a cover a rotating part, a heat shielding cover for exhaust pipe, a pro- tective cover of the heating region or the like, if found damaged. -Never run the engine while the cover of a rotating part is removed, Otherwise during operation, your hand, body or clothing may be caught in the rotating part, resulting in your injury, YANMAREY26 OPERATION MANUAL ead ‘Basic Descriptions No. Page 00 Precautions on Maintenance 00-06b-03 | 2/5 ACAUTION No Modification, Please. + When you want to modify your engine, consult us or your nearest sales or service agent in advance. Yanmar can not be responsible for an acci- dent resulting in injury or death or an engine trouble resulted from unauthorized modification. + Your engine and its safety devices have been sealed for the sake of safety. Don't break or tamper with a seal indiscreetly. ‘easeraeaneee + Ifa sealing is missing, take a proper step of promptly contacting us or your nearest sales or service agent for ensuring the proper initial set- ting. Be Cautious of Handling of a High-temperature or High-pressure Spot. Take care not to get burt. -During running and immediately after the engine has stopped, the whole engine is heated. Take care not to get burnt. ‘When changing cooling water, lubricating oil or filter immediately after the engine has. stopped, proceed to work only after the temperature has lowered. ‘Do not touch a high-temperature region such as the exhaust pipe or pressure indicator cock of engine with bare hands. *Do not touch the heater and heated sections of fuel oil system with bare hands. “Since the pressure indicator becomes hot, be sure to wear gloves when taking reading. +f you uncap the radiator or fresh water tank, vapor or hot water may blow up, causing you to get burnt. *Stop the engine and wait until the temperature has dropped. Then, wrap the cap with cloth and slowly loosen it to release the internal pressure. After that, remove the cap. YANMAREY26G OPERATION MANUA| eed pa ‘Basic Descriptions No. Page Precautions on Maintenance 00-06003 | 35 NOTICE Strict Observance of the Safety Rules ‘+ When running the engine or servicing it for its maintenance, observe the safely rules, precautions on safety and work procedures. * When carrying out a joint work, work according to the predetermined signs. + When carrying out a joint work, work according to the predetermined signs, Way of pre-work arrangement + According to kind of work required + Everyone to contemplate and consider + Everyone to understand well + Fix the most suitable way to work + Wear the proper protective garment. Don't wear oil smudged work clothes because they are prone to catch fire. + Wear protectors such as helmet, safety goggles, safety shoes, protective mask, protective glove, life- line, etc., depending on the nature of work required. + 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. Installing of a Fire Extinguisher and First-aid Kit + Install a fire extinguisher against a possible fire, and check how to use it. + Fix a safekeeping place for a first-aid kit, and install it there. + Fix the actions to be taken when fire or an accident has occurred. + Establish a means of reporting to emergency medical institution such as an ‘emergency hospital, and have its telephone number written down, ap evens 4. Safety has prioty ver ll the works. 2, Safety is more important than any other duties. 8. Its naadless to say tat ‘Safely First" means that safely has priority over working efficiency. 4, Safety is tne founction for working efciency. ety ic naver contradictory toworkng efciency Before starting © nsra x YANMAREY26G OPERATION MAN Basic Descriptions Precautions on Maintenance 1151695 2. Engine Lifting Procedures In order to prevent accident, be sure to observe the following instructions when lifting the engine. + Select the wire and shackle with the sufficient capacities to lift the engine. + Adjust the wire length correctly so that the engine will not tilt when lifted. + Place wooden blocks, etc. to the positions where the wire contacts the engine or driven equipment. + Do not enter under the lifted engine Nos Cynder No oyinder {he ibid an he oxh mani side {he outlcw an te exh. mani so Nos ofincer Not oye the certo on he opsrting sie the este onthe operating side 19 Sling attaching points Engine (singly) + Install the special Iiting fixture to the head tightening bolts of the No.2 and 3 cylinders and No.6 and 6 cylinders + Check that the cylinder heads have been tightened with the specified hydraulic pressure before lifting. + Keep the iting angle ofthe wire within 60 degrees. Reduction - reversing gear (Marine gear) + For the wire rope attaching points, refer to the respective Operation Manuals. YANMAREY26G OPERATION MANU. CETL Basic Descriptions: 1 No. 00 | Precautions on Maintenance 00-06-03 List of Safety Labels This page shows where safety labels are posted for safety use of this engine. Carefully read the cautions shown on the safety labels to prevent accidents. if any safety label is stained, damaged or lost, order it to your nearest Yanmar seles or service agent (shown in the service network list "YANMAR Worldwide Service” appended to this manual) by clearly specifying its Part No., and post it 9 [_@ cauTION SSCA eee We Part Ng, Ne; Part Ni 1 | agp71-020460_[ 6 | 141616.07200 Z| 146673.07230 [7 141616-07230 '3|-4223-028700 [8 | “t1a1616-o7220 4—|141616-07210_ [9 141616-07240 ‘5 | -148674-73510 [40 | 146673-02740 YANMAREY26 OPERATION MANU. Basic Descriptions Precautions prior to Maintenance & Servicing 1. Precautions Prior to Maintenance Servicing Indication of Warnings in Checking and Servicing + While checking and/or maintenance servicing the engine, post a notice on a wating indicating board for danger prevention. + Strive for safety, maintaining a close contact with the respective parties concerned ties concemed to enter the engine installed place (and/or the engine room), for instance Immediately After an Engine Stop ADANGER Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine. Otherwise, entry of external air may result in explosion. ACAUTION ‘Take care not to get burnt. sImmediately after the engine has stopped, the whole engine is heated. Therefore, take care not to get burnt. Take care not to allow your hands, body and clothing to make contact with the turbo- charger, exhaust manifold, exhaust pipe and engine as a whole. +If you attempt to drain oil while the engine is still hot, take care not to get burnt with splash of ol. «If you disassemble the cooling water system while the engine is still hot, vapor or hot water may blow out, causing you to get burnt. Wait until the engine becomes cool, then wrap the disassembling part with cloth or the like and slowly loosen it. YANMARLcd 6A UO LE Ceo Basic Descriptions Precautions prior to Maintenance & Servicing Preparation Prior to Working + Since 2 working area will be stained/smudged, put it in good order. + Prepare engine jigs and tools ready to use. + Prepare oil, genuine parts, waste cloth, wire, etc. according to the nature of work to be done. + Secure a work bench fitted to the height of the engine, Use prohibition standard of wire rope Check the wire rope well before using it. Do not use the wire rope in the following cases. More than 10% of Broakago | the wire is broken within 1 twist. ee, ‘nese EER x Tersion Torsion | The wire is twisted, mid ee The wire has a lot of Deformation Corrosion DDeformaton| deformation oF corrosion, Damaged |The loop end is faite end unraveled or worn by the stopper. YANMAREY26 OPERATION MANU. ed ‘Basic Descriptions No, Page 00 | Precautions prior to Maintenance & Servi 00-07a-02 | 3/9 2. Precautions During Maintenance Servi ADANGER Precautions in Use of, In such works with welder, electrical tools and grinder, 1, be careful of sparking. Since there is the possibility of catching fire, try not to leave combustibles such as fuel, lubricating oil and used waste cloth in a working area. Fes poison] Precautions in Checking the Electrical System “Shut off the power supply before starting the work. Otherwise, a fire may occur or you , may receive electric shock. Y ‘When checking the battery system, be sure to disconnect the earth cable () terminal. Otherwise, the negative terminal may be short-circuited by mistake, resulting in fire. The strong acid battery electrolyte put on your skin or eyes will cause inflammation. If the battery electrolyte should be put on your skin or eyes, immediately flush it with fresh water, then consult a phy: Precautions for Using Organic Solvent + Since an organic solvent is highly volatile, liable to be gasified and absorbed by worker through his breathing as it vaporized, pay close atten- Seer ere tion to ventilation when handling it. + Since a highly concentrated organic solvent has the property of dissolving fats and oils and is absorbed by worker through his skins, be careful of han- dling it. + When working with such a solvent, be sure to wear rubber gloves YANMAREY26G OPERATION MANUAL Basic Descriptions Precautions prior to Maintenance & Servicing 00 NOTICE Check in Course of Work + For a joint work strive for elimination of a possible danger by keeping alert to the surroundings. + Tie such an accessory detached in work to a stable post or spot so that it will not fall down, + For a work ata height, put on the safety belt or life-ine. + According to the condition of working, wear protectors. + Be careful of oll stained or smudged protective glove because working with such a glove might lead to @ damage of parts or a personal injury as your hands are apt to slip. + Wipe off or mop up spilled fuel or oll at once because, ifeft alone, itis dan- gerous as it causes a sii + Prepare a box to accommodate removed parts in advance so that they will not be lost nor damaged. + If necessary, provide setting marks before disassembling the engine so that you can reassemble it in the proper reassembling sequence, + Reassemble the setting marked portions with reference to the setting marks. + Tighten the bolts and nuts to the specified torque or hydraulic pressure. Use of the Proper Tools + Use the specified engine tools to prevent the damage of the respective bolts and nuts of the engine. + When handling a heavy thing, follow the slinger’s instructions. + In advance of using exclusive tools, check the function of these tools, + Carefully check for any damages to rubber hose and joints of hydraulic jacks. + Use the specified iting gear, hook, rope, etc.; and pay attention to safety when handling a heavy thing particularly. No. Page o0-07a-02 | 4/9 lorenarion| anual YANMARLhe a UO | Basic Descriptions 00 | Precautions prior to Maintenance & Servicing | 45.974. 3. Precautions at Completion of Maintenance Servicing NOTICE Check of Work Finish + Check if detached parts have been efited at the specified spots in the total number, + Check if the damaged parts have been replaced with the good ones. + Retum tools, ting gear, hook, rope, etc. used to the former safekeeping place. + Remove fuel and oil from the engine installed place (andlor the engine room). + Keep the engine installed place (and/or the engine room) in order and tidy so that it will not interfere with daily operation, + Before starting the engine, check various parts to see if there is no abnormality Refer back to 3-2. Precautions on Operation, (1) Prior to Starting of the Engine. + Proceed t a load run, and check that the performance does not differ from that e prior to the maintenance servicing. Refer back to 3-2, Precautions on Operation, (2) During a Run * As soon as a load run is completed, enter records of performance as well as the nature of maintenance servicing in your Engine Log. (Keeping of records and then reporting of work completion) KEEP TIDY YANMAREY26G OPERATION MANUAL DE Basic Descriptions Precautions prior to Maintenance & Servicing 4, Precautions in Maintenance Checking To use an engine always in good order, checking is necessary for trouble prevention. The period of checking ‘can not be fixed indiscriminately itis influenced by application of the engine, conditions of use, quality of fuel oil and lub. oil used, and daily handling circumstance NOTICE + The following tables of checking show the standard checking frequency. Perform the initial overhaul servic- ing to these checking tables. Then, based on the obtained checking (on wear corrosion, accumulation of carbon, accumulation of sludge and others), make the most economical checking schedule suitable for your engine, and conform to the specified schedule from the second checking, + As for the items whose checking frequency is shown by the accumulated operation hours and number of days, schedule the checking at the earlier timing. Table-t Tae a a cecking Area Tay bal eo an sant (or 300~500hrs) Saga a ek ane Govemer devi Gow volume chek Srasng TC areaon a inka stem Fueled a ecko bak Fa ea Fuel al sar rang Sain rH) | Oat carn ask on ak ae Foe etn pum “Cheok oF pion aTEaE ingvote Wen ringer het on ose Tow J [otpene noire [oivatne oc Lub. of propery ara 3 | tas. otbypassevaner Overhaul deorng eR Saami wate fnoea ; Blower wasting Tubocare —— Pi er washing Sask at ase ‘Starting air starter is fastened firmly = ‘Check that no air leaks from those and tet. J [emma [Sao nan | Each thermometer ‘Check on defective indication haa oases of Engine appeerence bate ete, check cache ae teak ek00 Basic Descriptions Precautions prior to Maintenance & Servicing EY26 OPERATION MANU. No, 00-078-02 51695 719 Table 2, Checking Table for Engine Using Marine Diesel Oil (1/3) Part to Be Checked Div. Nature of Service ‘Chacking& Serving Frequency (hs) ‘ra or2000~ 2800 Tyeeraeno 5000 2~ Sy er G00 ~ tonto Byer B00 ~ 20000 Ful injabon valve Drawing-out check & agjusiment : ‘sttmes500~ e00hs Cylinder head Cylinder head ‘Check & adjustment of the valve head dearance 0] [Sem orto~io ‘Check of valve spring ‘Check disassembly & check of valve rotator Disassembly, check & cleaning (Grinding of sue-Jexh. valve seat Scale cleaning & hydraulic test of water chamber Replacement of stem seal (SucJExh. Valve) Check of cyl. head bolt tightening force Piston Drawing-out, cleaning, checking & measurement of piston Check & measurement of piston rings Check & measurement of piston pin Connecting rod Check & measurement of piston pin metal Check & measurement of crank-pin metal (Chiack of connecting rod bolt tightening force (Change of connecting roa bats [20,000 hes. yl. tiner Inner dia. chacking, cleaning & measurement of fofofofololojojojolo[ojojo Drawing-out, check & cleaning of water jacket part Crankshaft ‘Measurement of crank pin outer dia, & journal ) Measurement & adjustment of deflection ‘Major Moving Paris Main bearing Disassembly, metal checking & measurement (Gheck on tightening force of main bearing clamping bolls oo (Check on lightening force of side bolt O| Camshant Check of cam & roller bearing Disassembly & check of fuel pump tappet Disassembly check & measurement of swing arn o|o Drawing-out of camshaft & bearing check & measurement 3° Timing gear (Check of tooth bearing & backlash Disassembly of dle gear & check & measurement of bearing ° (Check of idle gear mounied shaft tightening force ) Note: An asterisk (*) given in the following tables refers to the timing of initial check after the initial start ‘or part replacement. Perform the check from the second time and onward at the ordinary frequency. YANMAR‘Basic Descriptions EY26 0 Pe UE ed No. 00 A Aan Precautions prior to Maintenance & Servicing | go.o7a.02 | aie ‘Table 2. Checking Table for Engine Using Marine Diesel il (2/3) Chaskng & Seriang Froquncy ee.) g gle eau Nature of Service SR/a|E) © Checked Pal 3 8/8 ]8/3| B/ Sls] 28] = S/E] 5 e/E)= 2) & |Fuelfocd pump, [Check of tooth bearing & backlash ° & | lu. ol pump, & $ |coldwater pump | Disassembly, check & measurement of bearing ° & | eiving interme 3 | stogear Check of gear mounted shaft dghlening force ° | Governor driving Bloven Disassembly & check of Linkage system ° (Check of injection timing ° Tet time: 300-500 é eae (Check of deflector & replacement ° 3 Disassembly cleaning & check ° 3 lrorece Disassembly & check ° 3 Pure [Replacement of oilseal ° * TFO.control & ‘stop air piston Replacement of o-ring oO ite [change eee (depended on results of property analysis) ° Tub cl cooier _[Disessembly, check, cleaning & hydraulie test, o Thewmostate | Disassembly, check & cleaning ° [valve 3 Disasserbiy check & measurement oC @ | Lub. oil pump Disassembly & check of pres. reg. valve & safety 5 valve e 3 (Check of strainer canalo (0) every aye Replacement of strainer candle (O)| every 6yr. Lab, ol strainer To rotation Won gear, turbine, ° flushing arm Replacement of Oxing [At overhaul YANMAR ~EY2G OPERATION MANUA Basic Descriptions No. Page 00 | Precautions prior to Maintenance & Servicing | go.o72.02 | 99 Table 2. Checking Table for Engine Using Marine Diesel Oil 3/3) ‘Cheating & Sewing Frequerey (hs) alala|élg Z| Partto Be Checked Nature of Service Fs elale glglelsis Se eles s/s 2/28 Thermostatic vive | Disassembly, check & cleaning 3] Disassembly, check & measurement | & Replacement of mechanical seal To E [Fresh waercooler | Disassembly, check cleaning & hycraulo test To & | Cooling water Change ° 2 | resh water) (@epended on results of property analysis) 8 Check of anliconesive zine & replacement (Air Seawater cooling parts cooler & Lub. oil cooler) ° é é = | Starting aie starter —_| Disassemble and clean the air strainer ° 2 = = & Turbocharger Disassembly & cleaning oO 3 [ Boost air cooter Disassembly, check, clearing & hydraulic test ° & [Engine tachometer | Galloration of indication 3 ‘Alarm switch ‘Actuation test ° YANMAREY26G OPERATION MANU Basic Descriptions 00 Protective Device Setting Values Holding Volumes of Lubricating Oll & Cooling Water Pressure & Temperature Setting Values a No. Page 00-18-05 | 41 1. Protective Device Setting Values item Unit | Alarm Setting Value | Emer.Stop Setting Value Engine lub.il pressure MPa 0.20 018 Turbocharger lub. ol pressure MPa 0.20 - Cooling water (Iresh water) temperaiure | * 95 - 1 = 118 ~ 120% of the rated Rotational overspeed ir oad 2, Holding Volumes of Lubricating Oil and Cooling Water [Unit te Item Holding Volume Remarks Engine a & | finchinside the cooler, strainer & piping) 2 | Lup. tank 2600 2 Type RHD 13 5 8 | covemor Type UG-8 15 3 | Cylinder jacket (resh water) 250 5 | Cooler 50 3, Pressure & Temperature Setting Values Tem [__Seting valve Remarks Fuel feed pressure [___050~ 055 Maximum cornbustion pressure(Pmax) * Refer to Records of Shop Tal Lub cll pressure 040 ~ 050 | Cooling water pressure(acket cooling ine) | MPa 0.20~ 025 @ | Cooling water pressure(cooler cooling line) 0.20 ~ 0.25 2 |sarng ar — [Sara artmk Te Tavern 78 pressure [After decompression or~10 [At the airstarter niet (Gociing water engine outlet tomparature | BO=8 [Cooling water ar cooteriniet temperaiure_| Beiow3s 3 |Laboit engine net temperate mite § | (cooler outlet) a 2 [Exist tempers : Roars RIES Sap ® |(ateach cyinder outet) ri Exh.gas turbocharger inlet temp. * Peete Note: (1) The numerical value is a standard value, There is a remark different depending on the specification. {2} Fora star (+ ) given above, refer to the Records of Shop Trial and enter the obiained value here because it varies according to the engine specification and output. YANMAR00 Basie Descriptions EY2G OPERATION MANUAL Assembly Adjustment Values ‘51695, No. Clearance & Wear Limits of Major Parts 0-09-03 | 45 1.Assembly Adjustment Values item Adjustment Value Remarks Piston top clearance (A) mm 74x03 Z| Open (before 0.6.) 60 s deg | _ Close (after 8D.C) a § | Vaive nead clearance B) mm oa in the cold state 3 | Open (before 8.0.C) 66 s deg. % | _ Close (ater 10.0) 45 g | & | _ Valve head clearance @) [me o7 In the celd state : 8 : 2 ni e 4.) i FF eee iy en agust 8, it ee t a uel njecton pump begins t delver] a Refer to Records of Shop (before TD.C) 09 raat Injection pressure, (vel rjector wpa 400208 YANMAREY2G OPERATION MANUAL M51695 Basic Descriptions No. Page 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts 00-09b-03, 25 2. CLEARANCES & WEAR LIMITS OF MAJOR PARTS: (Utin nm Daren] wax, | ge Clearance tem sieteh atonabe | Uintet Nomat [Taeance|Aszrin| Qlawabe | Ue Inner aa ofeyinderupprpan| > ay BR |oe-o082 | acon [22 ‘Outer dia, of eyinder finer T $354 [p62] to0.176) A 1 coperoat 3% Inner aa. Faye ie “a2 TT part AZ |A2=0.030, =f ‘Outer dia. of cylinder Ter $310 Fogg | to 0-02] A208 fewsr sat au8 8 | er dia. ofeynder ewer par i sgonz wor = | Oaeraa, otayinderiner aN® | 308 barar B02 - $ lower part 0.140 # | op caarance wa [aoa | - | os | 2 5 [ner cia of ner upper pan ez | vot 3 i $272 Foes] toose7| [ower a proteton ra 2 218 Inner da of prtecton ng 20 [204 ovo ant 08 ‘Outer dia. of piston head 26657 | +0.02 eae a Imer di. ofoyinder ner e200 | GOH oa e03 ‘Outer dia. of piston skit part 6259.86 | +0.02 0.2 Radial thick. of piston rings, ale aa a Nereus ==9 Fs90 | +015 - * Rael hick, fing wera [aos | - | - | o7 With ison fing Ho Ba Ne | 2 2] wiath of ae +0.100 G04 3 | wom of pton ing groove, Nos Bie 708 + Jah olson rine No.2 } G50 war 2? z eo NM a armen : 2a er 2 3010 E [With o i ing joo [22940_|r0005 | oy |? 2 ¥0.060 to 0.100 ‘tad E |i of ing groove aee a8 Taner i of pon mata 220 | 0.100 7038 eee J=0.30 Outer. opin pin Sev [Boe | Ber “D8 Inner dia, epson pr hoe ome Feceo vans Outer dia. of| 2 Ae of pion pin ar “205 2: The ‘strings to be replaced with the new one when is plated layer is worn out and base metal begins to be exposed; the 2nd ring, when the taper face is gone. YANMARLet) Basic Descriptions OPERATION MANUAL No, 51695 Page 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts 0-09-03 | 3/5 Uritin am) Toinension r tem steteh mene gesance Ugo int Normal | Tolerance ‘Assembling Clearance "arts 7 Inner da, of rank pin bearing Na 13388 03 6220 2M o54| 10.30 7 detection ‘Outer dia. of crank pin I Saxo wear Taner da, of main bearing aS 703 7 6260 [S——|NR238.,,| te0.98. | atoame & | outer dia. ofjoural Sox0 weer & | width of detum part main beaire 338 0.46 48 vat Ne05 With of datum part joural xpos | twos2 4035 cs | Refer to No. 21-04 Measurement of Deflection e z — | = |srankshaft detection, 3) Allowable value of the deflection. Outer da. of suction valve oie [ate lesa, | manna 2 1 = Inner dia, of suction vane 026] 100.126 guide: 3 40.28 cura canal SH leaw,_| oom 2 Inner dia, of exhaust valve O19 Fyp026-] t00.140) Ro a guide 3 Inner da, of valve bridge 1000 2078 $+0,020 7 2 s-02 Outer dia. of valve brid 0920 |” 100.054 - § | guide rt -0.033 a & [Marin fickpessor [Suc “oa suclexh. - - - 5 | poppet part Ba “05 3 [Wath ot sucrexn, |_ Sue ee Ee = +09 valve seat Exh, U2=9.8 +10 ia, ofsucexh,vaive |_ Suc. Wee87 | a4 a ef +4.0 Seal contact pat Eh vegas | = Outer dia. of rocker arm shaft 3010 O04 Suter dia, 201040 | ye 680 og | to daso| WH0.25 Inner dia. of rocker arm bush 33,20 40.22 985 Toor] todo} X02 Outer dia. of swing arm shaft Ne RRB oA YANMAREY26G OPERATION MANUAL Oe Basic Descriptions No, Page 00 Assembly Adjustment Values Clearance & Wear Limits of Major Parts 00-09b-03 45 (Unit in mm) Dimension Ea Mex. | Us tem Sketch 7 earance | papwable | Uimtor Normal. [Tolerance | Assembla | Qeatsnue | ‘Pars | "ine Oiier Gia, of camshat datum 2.088 am pan = 173 a Maer es Y=0.33, |} Inner dia. of camshaft datum +0150 | 10233) TT" [oe part beating 3040 | Thickness of camshaft datum “0.100 a [ose : ta [220_|z-0200 | p05 E | wa of camshat trust cotar | =i” : +a309 | 10500 a 8 [rousing @ 20300 (Quer cia. of camshat intone: “0.083 can slate part gira |-2983__} 0.083 Inner da. of earch orm sos | 190299 var slo part bearng 040 Outer cia. oft. ot pump shat 212 : — gay RO lomo | teats inner dia. oflub. ol pump shat soo7e | 100.084 a (bh 20.080 2 +9.058 § nner dia of pump case - 0 | ex0.200 oe 705 8 Jouter dia, of gear azo | 9804 - HH +0.035, Wiath of pump case 7 Maa 105 ° heaven d=0.18 Toda] Wath of pump gear meno “0.072 = 2107 gga pipwe| _ [teoz0 | aos | ot 10 0.32 : jp | Seer backlash 8.0 g (Governor TF e a - fos | : a0 ‘e025 4 meng non ‘Outer dia. of cam driving inter- a" 0.036 2 | mediate gear shaft 0071 ERE é orto erocae | gro Inner ca, ofthe above's bush 9035 ota YANMAREY2G OPERATION MANUAL Basic Descriptions No. Page 00 Assembly Adjustment Values Clearance & Wear of Major Parts 00-09b-03 | 5/5 (Unit in mm) Dimension a Max. | Usage ctearance | Me _ aaa Normal | Tolerance | Assembling | Cigaranee | “pons! ‘Time g Oi defector cover ° 8) ower dle ofcranksnat ; 3.16 - 3 fiw j=0.050 5 $230 00 Sa] : +060 B| nner dia. of ol shioks O80 - YANMARLh 4 oe te) M51690 Basic Descriptions Table of Tightening Torques of Major Bolts & Nuts No. 00-10b-04 If tightened improperly, a personal injury or damage of device may be caused. Be cautious. NOTICE Unless otherwise specified, apply lub.oil on the thread and bearing surface, and then tightening a bolt or nut + On the parts prefixed with a star (3) in the following tables, a match mark is stemped. However, when tight- ening any of these parts, do not refer to the match mark but tighten it to the specified torque, specified tight- ening angle or specified hydraulic pressure. 1. Hydraulic Pressure Clamping Bolts FacetoFace Speciic Hydraulic Part Description Sorew Diax Pitch | Wiath of BolyNut Pressure Remarks (om) MPa 3 Cylinder head tightening nut MasxS0 Round 38005 3 Main bearing cap tightening nut MASxS0 Round 1.005 % Connecting rod tightening nut Hy in " (Lower side) 332.0 Round 51.0205 Balance weight clamping nut Ma2x3.0 Round 50005 2. Angle Clamping Bolts NOTICE * When tightening the following boit, apply the Protec grease on its bearing surface and lub.cil on its thread. + Tighten such a bol with the seating tightening torque, check the position of set marks or stamp set marks if required and tighten the bolt to the specified angle. Face-to-Face Seating ‘Specified Pandesciton — | S0¥0I6. | ator | mahtenngTorqve| Tehering | Remarks Bolt/Nut (rnm) (Nem) Angle (deg.) TY Fas Comecteg od tghenig at | wots | 30 0% eo) |htbuteeaton ci 7 3 step tigt tening Fig, 00-101 Tigherng the connecting rbot) o” Si Gono seaing er 90% iteep ——— ANS ON 802 tn step so" Fa (esta) YANMARLhe 4: Res MU eer Basic Descriptions Table of Tightening Torques of Major Bolts & Nuts 3. Other Major Bolts (Torque Tightening) NOTICE + Be‘ore tightening a flywheel clamping bolt or fuel injection valve nozzle sleeve, apply Protec grease on its thread and bearing surface. + When tightening a camshaft coupling U-nut or camshaft gear mounting nut, apply seizure inhibitor (Three Bond 1910 orits equivalent) on its thread and bearing surface. + In the case of bolts and nuts other than aforementioned, apply lubricating oil their thread and bearing sur- face when tightening them, + The parts prefixed with an asterisk (*) in the following table are provided with an exclusive tool, respectivery. + Tighten the bolts & nuts mentioned in the following table with sure use of a torque wrench to the respec- tively specified torques. Factores | Tranny omar Part Description Seew Dia. | ava forque™ | Remarks Bolt (nm) Nem Indicator cock tightening ut Mia 175 13 ~~ 5 Rocker arm shaft stand clamping bolt M20%1.5 30) 295 ~ 335 Fuel injection valve nozzie sieeve MEBx1.5 Zerooves [360 ~ 400 Fue! injection valve guard tightening nut wa xi.75 73 30~ 40 Fuel injection valve case nut MADKT.S 3% 360 ~ 420 Fue nection vae econ BessuTe TGV | yaa 7.25 7 aaiaten ing tock nut Fuel injection pipe JOmTESEE (on Fjecion valve 7 € Voy. head side) MBx425 | (hex. socket) 30 Fuel injection pipe joint bolt (on pump side) m10%4.5 | (hex Socket) 69 Fuel injection pump tantening nut METS 2 105 = 216 Fuel injection pump equalizing valve Body z 0 i clamping bolt Mr2x175 | (hex socket) | 84 ~ 89 Fuol injection pump barrel retaining bok miax175 | (rox Socket) | 84~ 89 Fuel injection pump protector M2axT5 30 4559 Fuel injection timing adjust bolt lock nut 24x20 32 M3~ 302 [Fuel injection pump rack guide bolt MBx1.25 13 o~8 Fuel injection pump barrel locking bolt MBx1.25 | (nox. Socket) 7~9 [Camshaft coupling nat (nut) waiaxts 18 96 ~ 108 [Applying seiz- [Cam gear clamping bot MIBxTS 24 304 = 343 _|u'e inhibitor Intermediate gear shaft mounting Bok MZ0x1.5 30 245 ~ 265 Infermediate gear set plate bolt Mi2x 175 8 60~70 [Sea water pump Impeller ightering nut 20x15 30 18 ~ 128 [Sea water pump impeller M30%8.5 6 245 ~ 265, * Fresh water pump impeler M30%3.5 6 400 ~ 440 [Cocting water pump driving gear tghtering nut | —M33%2.0 30 290 ~ 538 Main bearing cap side bot M33x2.0 cy 080 ~ 1130 Flywheel clamping boltinut M36 «3.0 set) 1000 ~ 1080 [Exhaust manifold camping bol WIEXTS 24 Tar S167 [Exhaust expansion joint clamping bot M2015 30 245 ~ 265 Lub. olf pump driving gear tightening nut 33x20 50) 620 ~ 680 _|Latand heed [Swing arm shat clamping bolt 20x15 30) 245 ~ 276 Turbocharger mounting boit M20%1.5 30 455 ~ 475 ntercooier mount ightening Bat M20%.5 30 | 283 ~ 306 “3 Clockwise rotation engine = Right-hand thread Counterclockwise rotation engine = Left-hand thread YANMARLA ULL Peed Basic Descriptions No, Table of Tightening Torques of Major Bolts & Nuts 00-10-04 4, General Bolts + Tighten any bolts other than the major ones according to the following tabie. + Tighten @ part which clamping section is made of aluminum, tighten it to 80% of the torque shown in the fol lowing table. + The following table is applicable only to the bolts which Pert No. (an 11-digit numeral} shown in the attached Parts List consists of 2 at its first place and 2, 5 or 6 atts fifth place, 1) Standard Torque Values ‘Screw Dia. Face-to-Face Tightening Torque x Width of BolNut Pitch (mm) (mm) Nm Mex 1.0 10 to~ 12 MBx 1.25 43 24~ 27 Mi10x15 7 44~ 64 M12 x 1.75 19 78 ~ 98 Mi4x15 2 123 ~ 182 MI8x15 24 208 ~ 245 M18x2.0 24 206 ~ 245 2) Standard Torque Values Seew De yiseeiaFace Tightening Torque Gea Pitch (mm) (mm) Nem (mm) MBx1.25 14 17 ~20 3 M12 1.25 17 25 ~ 34 8 M14x15 19 30 ~ 49 8 Mi8x1.5 2 49~ 59 10 Miax15 24 69 ~ 78 12 M20x1.5 aT 88 ~ 98 18 M22x1.5 30 147 ~ 196 18 YANMAREY26G OPERATION MANUAL Ue Basic Desoriptions No. Principal Dimensions & Mass for Disassembly & Servicing 1, Disassembly and Mai Disassembly Drawing 00-11-03 intenance Space To tuocharger sis “To the opposite sie of turbocharger rel (Turbocharger) aes 3 [' tosonerco element [When camshaft was disassembled) J-crankshatt conter _Vigwed from fywhea! Viewed from fywhest Drawing of disassembing al eyiners (When all cylinders disassembled) Paris & Assemblies | Code | GEY26 Parts & Assemblies | Code | 6EY26 Piston extraction height | A | 1900 [LO strainer element G | 480 [Cylinder finer | 2480 IFO feed pump H_[ 830 [Cylinder head c_ | 2030 [LO pump | 200) [Camshaft (when spit) D_ | i2a0 [CW pump a i100 [Air cooler core E | 1610 | [Turning length «_ | Ra70 LO cooler core F_| 430 | (When disassembling specific cylinder) (Only the differences from above are shown.) (mm) Paris & Assemblies Code | 6EY26 Carrying out to the opposite side of [Piston extraction height P| 2460 Tic. Cylinder finer ao _ | 2780 (exceeding the cyl. head) Cylinder head R_ | 2230 a rea Piston extraction height L 2860 arrying out to TIC side ode | Oylinderiiner mM) 3180 (Cylinder head N__| 2620 YANMAREY26 Basic Descriptions 00 OPERATION MANUAL DT Principal Dimensions & Mass for Disassembly & Servicing No. 00-41b-03, 2. Mass of Major Parts Name of Part & Assembly Mass (ka) Remarks Cylinder head (assembly) 280 Per toyl Piston and con. rod 144 Piston + Con. rod + Piston pin Cylinder finer 109 Per toyl Main bearing cap 62 Per 1 cap Ar cooler (core) 340 Exhaust manifold cover 18 Per 1 cover Exhaust manifold 26 Per 4 po. Turbocharger 495 Including main outlet pipe ‘Camshaft 6 ‘split type, per one pe. ‘Camshaft gear 475 Timing gear assembly 61 LO cooler (assembly) 380 LO pump (assembly) 90 LO strainer (assembly) 160 ‘CW pump (assembly) 60 ‘CW collecting pipe 10.5 Per‘ pe. FO feed pump 25 FO strainer 13 FO injection pump (assembly) 25 Per pe Pump case cover 94 Pert pe Air starter (assembly) 30 Gear case cover (assembly) 168 1 assembly Crankshaft (assembly) 2108 620 For RATO27 series Fiywheel assembly 617 For RATO29 series, 412 For RATOS1 series YANMAR|. ete y Basic Descriptions SI Unit Conversion Table OPERATION MANU. Conversion values between the international unit system (SI) and the metric unit system are shown below: 41) Power w iat ieee 1 0.101972, ‘1kgf=9.80865N 9.80665 1 2) Moment of Power, Torque Nem kgf m 1 o.101972 9.80665 1 3) Pressure Pa katfcm? mAq mmHg 1 1.0197 x 10 | 4.0197 x 10% | 7.501 x 10% 9.80865 x 104 1 1.0000 x 10 | 7.356 x 10? 9.80865 x 10? | 1,0000 x 104 1 7.386 X 10 1.3332 X 10? | 1.3595 x 10° | 1.3595 x 10? 1 4) Work, Energy KWeh J kcal kgm 1 3.6 x 108 8.600 x 107 | 3.671 x 10° 2.778 x 07 1 2.389 x 10% | 1.0197 x 107 1.163 x 103 | 4.186 x 103 1 4.269 x 10? 2.724 x 10% 9.80665 2.943 x 103 1 5) Work efficiency, Power kW PS 1 1.3596 0.7365 1 YANMAREY26 Basic Descriptions OPERATION MANUAL ry) Symbol Marks on Piping Layout & Instruments ‘Symbol Marks on Piping Layout & instruments Instruments Valves Piping Parts QD] pane DEI stove vane a] Fienge fing | @B | Punser pump DSA] Neate vaive a1 | Shutot vaive Vand pnp | mre vane Ty] srectace tage GI meter De | tert vane oY soit Strainer DK | stuice vaive B | Boss Centrifugal strainer Dhq | Screwed check valve IH] orifice Automatic bactwash stner | [Sq | Swing check vaive L| Expansion joint [3] | Porous plate strainer cyinder | FFE | Piston valve LUX] Flexible pipe coupling MeteraSensors Bed | treenay piston vane | O] | seatpot @ | thermometer pad | cock | boop seat | Pressure gave DL | toee-way cock & | Roser Dirental pressure gauge | SKI | Rgoaing eee (7 | Airvent pipe @E| ov sianat De | an te EL | satety pate |__| races evel souge Safty viva © | Accumulator Pressure such Solnol ave | cept ube © [ temperate ston ><] | Pressure reducing vane | oot | Ouppersine © | oat ston Ea] Capi cnc vane se | gamer seep Differential pressure SW Veloty regulating vane | STH | Ee ue Pressure trensmitter © | Bay volume regulating” | re | Machine sructiral Resttance temp. censor 30. | Pipe cus la | Temocoue va. | Pe mer aa Remarks: The black valve (glove valve, ange valve and needle valve) snow the valve closed constantly ply : Opened constantly plg : Ciosed constantly 2010.10.20R YANMAREY26G OPERATION MANU. aT Operation Wo. Operational Preparation 00-21b-01 Before the initial start of the engine after its installation or before its restart after its overhaul servicing or a long term stoppage, sufficiently perform the following inspection and operation preparation in addition to daily inspection and operational preparation, and make sure there is no abnormality and the operational preparation has completed 1. Make sure no part nor tool has been left in the crankcase. 2. Check for a part not tightened yet. 2. If you have disassembled the valve mechanism, check the suction/exhaust valve head clearance. } 00-09 Adjustment of Suc./Exh. Valve Head Clearance 4, Operate the lubricating oil priming pump, and open the pressure indicator cocks of all the cylinders, While turing the flywheel, make sure the lubricating oil is dropping from each part of the valve rocker arm shafts, piston pins, crankpins, main bearings and swing arms. 5.Bleed the air from the lubricating cil strainer. 6 Bleed the air from the fuel oil filter and inlet pipe of fuel injection pump. 7. Manually lubricate the governor link, and make sure it moves smoothly. 4. Turning Be careful not to allow your {Never put your hand into the crankcase.) Refer to the following section as to the procedures of turning. (CD) 08 Turning Device NOTICE Set back the turning gear to the GEAR OUT position and set the stopper in the groove. Fasten the set bolt and set the lock bar. Unless the turning gear is the GEAR OUT position, the tuming gear engagementidisengagement switch actuates to disable starting. (optional spec) 2. Lubricating Oil System The piping parts of lubricating oil system are banded with yellow coating. Inspection and Oil Supply of Lubricating Oil Sump 1.Open the drain valve, cock or plug of the following oil sumps and devices; and discharge the drain. 4- Engine oil pan or lubricating system oil sump 2- Lubricating oil cooler and oil strainer 3-Governor oll sump ‘Supply the lubricating oil to the upper limit of oil level gauge or dipstick in each oil sump; Manually lubricate the necessary parts, YANMARLhe A LU Ue eee No. Operation Operational Preparation 00-21b-01 Fig. 00-21-1 Draining & Air Bleeding Point (Lub. Oi System) Fig. 00-21-2 Hand Lubricating Points LO, strainer Air Bleed Plug Hand Lubricating Points Drain Pag LO, Cooler 1st Lover Shaft 2. Check the properties of lubricating of and iftis considerably contaminated or deteriorated, change it. 00-59 Control on Lub. Oil Priming of Lubricating Oi ‘While turing the flywheel, operate the lub. oil stand-by pump about 5 minutes. 3. Fuel Oil System ‘The piping parts of fuel oil systern are banded with red coating, 4.Drain the fuel oil tank and fuel oil fier. 2.Supply the fuel oll into the fuel oil tank, and check the fue! oil amount. Then, open or close each valve according to the operation conditions. 3.Bleed air from the fuel oil system. After engine installation, long-term stoppage or overhaul of the engine, bleed air from the fuel oil system by the following procedures. 1.Open the bypass valve of the fuel feed pump. Fig, 00-21-3 Fuel Injection Pump (Fully turn the bypass handle counterclockwise.) 2.Open the air bleed cock of fuel ol fiter to blaed air. 3.Loosen the air bleed plugs on the fuel injection pump. 4.Loosen the air plug of the fuel piping to bleed. 5.Close the bypass valve. (Fully turn the bypass handle clockwise.) Air Bleed Plug 50-02 Fuel Oil Feed Pump YANMAREY2G OPERATION MANUAL Od Operation No. Page 00 | Operational Preparation 00-21b-01 | 3/4 4. Cooling Water System ‘The piping parts of fresh water system are banded with blue coating and that of sea water system are banded with green coating, ‘.nspect the cooling water tank, and check whether the cooling water is not contaminated. if the cooling water is contaminated considerably, change it 2.Supply the cooling water to the upper limit of water level gauge, and add a proper amount of rust inhibi- tor. 00-63 Brands of Rust Inhibitor & Adding Quantity 3.Open and close each valve of the cooling water pipe system according to the operation conditions. NOTICE ‘When you have replaced the cylinder liner or drawn it out for servicing, remove the cylinder side cover and make sure no water leaks inside oylinder. }. Boost Air System Open the drain cock of the following point to drain the air drain, Fig. 00-21-4 Boost Air Drain Cock 6. Starting Air System ‘The piping parts of starting air system are banded with white coating. 4.Drain the starting air reservoir, 2.Make sure that the pneumatic pressure in the air reservoir is high enough to start the engine (2.2MPa or higher). 3.Check that the pressure after decompression is within the range of 0.7 ~ 1.0MPa. (If found outside the range, regulate the pressure by means of a reducing valve provided at the air motor inlet.) YANMAR1) 61d Ne ee Dd No. 00-21b-04 Operation Operational Preparation 7. Control and Protective Devices Remote control device 1. Changing over the control position selector switch to the REMOTE (wheel house) setting, confirm the fol- lowings: 1-Shift the control lever from the AHEAD position to the NEUTRAL position and then to the ASTERN position and vice versa, and make sure that the changeover valve handle of reduction-reversing gear correctly agrees with the respective settings of the control lever and actuates smoothly. 2-Shit the governor handle from the ACCELERATION side to the DECELERATION side and vice versa, and make sure the governor lever actuates smoothly. 2. Be sure to set the control lever in the NEUTRAL position. 3. Change over the control position selector switch to the ENGINE (engine room) side setting when starting the engine, 4, Cheok that the changeover valve of reduction-reversing gear is set in the NEUTRAL position. Governor gear 1. Shift the start stop lever from the RUN position to the STOP position and vice versa, and make sure the rack of fuel injection pump, 1st lever shafft of govemor link and connector move smoothly. 2. Check that the pointer of speed control shaft of the governor Is indicating the graduation 1 to 2 NOTICE After replacing or servicing the governor and/or fuel injection pump, check that coupling of the linkage is not wrong, 60-02 Overhaul of Governor Link Protective devices 1. Check that the turning gear is in the GEAR OUT setting. 2. Set the power switches of protective and alarm devices to the ON position Unless the power switches are set in the ON position, the protective and alarm devices do not actuate. 3. Check that the main valve of the air source panel is opened, 4.Press the emergency stop switch, and check that the light is lighting up and that the stopping air piston is. actuating YANMAREY26 OPERATION MANUA eed Operation 00 Starting This engine is started by an air starter. Press the START switch. Then, the pilot air solenoid valve directly attached to the air starter will open on the battery power to start the engine. ACAUTION During start operation, do not bring your face close to the air starter, Dust adhered at the exhaust port of air starter may enter your eye, resulting in injury. Start the Engine after Signaling * Check if no one is around the engine. + If someone is found near the engine, give him a sign that the engine will be started. Only then start it * Check the holding capacities of fuel, cil, ar, ete + Tum on the power supply of the engine protection device before starting up the engine. + After the engine has been stopped fora long time or after the engine has been serviced, be sure to start up the engine at the engine side, + Ifthe rotational speed rises extremely rapidly or if you find an usual sound or fume, immediately set the start'stop lever in the STOP position to stop the engine, Check After the Engine Is Started + Check if pressure values of each instrument/gauge board are normal. + Check if there are no unusual sound and abnormal heat buildup. + Check for any leakages of fuel, oil, air, etc, and ifa leakage is found, prompty repair. + Except in case of emergency, apply the load afier a warming-up. 1. Running Procedures NOTICE {fa large amount of fuel oil, cooling water or lubricating oll should be entrapped in cylinders, * water hammering * may occur. Perform air running by the following procedures, and make sure there is no abnormality. Then, start the engine by the alatm panel on the engine side. + Make sure the turning gear is it the GEAR OUT position. + Set the ENGINE/REMOTE operation selector switch in the ENGINE position, + Open the pressure indicator cooks of all the oylinders. + Set the start/stop lever in the STOP positon. + Hold the START switch pressing for 2 to 3 seconds to effect air running, YANMAREY26 OPERATION MANUAL 51695 Operation No 00-220-00 2. Starting operation procedures Start the engine by the following procedures. 1. Make sure the turing gear is it the GEAR OUT position. 2. Make sute the pressure indicator cock is closed. 3. Set the operation selector switch to the ENGINE or REMOTE position corresponding to the control panel to be selected. 4, Set the start / stop lever in the RUN position. ‘5. Make sure the speed control shaft (pointer) of governor indicates the position of ordinary operation. 6, Open the starting air reservoir valve and control air valve. 7. Hold the START switch pressing for 2 to 3 seconds, and make sure of ignition. Only then release the switch, Fig. 00-22-1 Start Operating Procedures ‘Sian Switch StartiStop Lever, YANMARPas eae M51695 ‘Operation No. 00-20-00 3. Corrective actions to be taken in starting failure ACAUTION If the engine cannot be properly started, unburnt combustion gas in the flue may be ignited, resulting in explosion. Therefore, perform air running to discharge the gas from the exhaust gas system before attempting to restart the en: Make sure the flywheel has completely stopped, and then press the START switch. 4. Engine start when there is no controlled source. Ifthe battery power for the START switch has been exhausted (in case of emergency), push the manual button of solenoid valve for air starter relay valve to start the engine. Refer to "70 Starting Air Sysytem & Air Starter". Return the button to origin direction immedietely after engine has started. NOTICE Use starting manual switch only in emergency, because the air starter may rotate excessively as the control ‘module is not in operation in this case. YANMAREY26 OPERATION MANUAL 51695 Operation No, Page 00 Running 00-23b-01 | 12 During a Run + Keep watching the pressure and temperature or check for unusual sound and abnormal heat buildup. + Check whether the engine fully shows its proper performances and record the check resulls. (Refer to the Records of Shop Trial, then record the check results on the Engine Log.) Take care not to be caught in a rotating part. “Never allow your hands, body and clothing to make contact or bring close to any e rotating part. Take care not to get hearing loss. Q *Put an ear protection in engine-room during running, because can cause hearing loss. ACAUTION Take care not to get burnt. -During running and immediately after the engine has stopped, the whole engine is heated. Therefore, take care not to get burnt. “Take care not to allow your hands, body and clothing to make contact turbocharger, exhaust manifold, exhaust pipe andlor engine as whole. “if any abnormality is detected, immediately stop the engine and repair it. the ‘When changing over the control position changeover cock to the wheel house side after the engine is, started, be sure to set the control lever of the wheel house in the NEUTRAL position. This is to prevent the ship from starting to move as the clutch engages simultaneously with the control position changeover cock operation. ACAUTION During a run and immediately after the engine stop, never touch the following parts with bare hands. Otherwise, you may get burnt. + Turbocharger, Exhaust pipe system, Boost air pipe system, Indicator cock + Flue and funnel During a run, never touch any moving part. Otherwise, you may be caught in, resulting in injury. Keep the control air valve opened during a run. IF you close it, the protective devices cannot actuate, ‘Take care that the room does not fall short of the air (oxygen) because the turbocharger takes in a great volume of air, 2010.10.20R YANMAREY26 OPERATION MANUAI Od No, 00-23b-01 Operation Running NOTICE The critical speed that may cause torsional vibration is within the normal rotation speed range, quickly avoid it. (1) Run the engine for about 10 minutes at 300 ~ 500 min without load to warm it up. (2) Increase the speed gradually. (2) If you continue running the engine with a low load for longer than three hours, observe the following load factors, otherwise combustion worsens and fouling of the combustion chamber, exhaust pipe, turbo- charger, etc. becomes heavy. NOTICE ‘Adjustment of Boost air temperature (In the case of sea water cooling) @ Run the engine at 25% or higher load factor. @ Adjust the boost air temperature 40 to 60°C , operating the cooling water bypass valve handle of the boost air cooler. As the bypass valve handle is set in the Bypass side, the cooling water bypassed, and the boost air temperature rises. Fig. 00-23-1 Sea Water Bypass Valve (Boost Air Cooler) Cooler Bypass (4) In the case of a high humidity, this is not ebnormal although much drain may be produced as the moisture in the air is condensed, In this case, run the engine as the drain cock of the boost air cooler kept opened. (6) Measure the running performance once a day and record the measurement data (CL) 00-02 measurement of Running Performance 2010.10.20R, YANMAREY26G OPERATION MANUAL ard Operation No. 00 Page Stopping a 00-24a-01 When Stopping the Engine + Do not stop the engine simultaneousiy with load shutoff. + Except in case of emergency, keep running the engine without load after load shutoff + Keep the engine ready for being started up. + Promptly repair the points that have been troubling during a run. TOS ‘Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine. Otherwise, the entry of external air may result in explosion. ACAUTION Take care not to get burnt. sImmediately after the engine has stopped, the whole engine is heated, Therefore, take care not to get burnt. Take care not to allow your hands, body and clothing to make contact with the turbocharger, exhaust manifold, exhaust pipe and engine as a whole. sIfyou attempt to drain oil while the engine is still hot, take care not to get burnt with splash of oil. «if you disassemble the cooling water system while the engine is still hot, vapor or hot water may blow out, causing you to get burnt. Wait until the engine becomes cool, then wrap the disassembling part with cloth or the like and slowly loosen it. 1.Stopping in Normal Running Except in case of emergency, stop the engine by the following procedures: 1) Preparation of stopping (1) Slowdown the rotation gradually prior to entry into port, and make sure the ahead and astem operations of the reduction-reversing gear work smoothly. (2) Perform a low-speed run without load at 300 to 500 min for about 10 minutes. 2) Stopping operation (1) Set the startistop lever in the STOP position. (2) Run the lubricating oil priming pump for 15 minutes or more to cool piston and tarbocharger. (3) Open the pressure indicator cock, and perform air running to discharge the as from the combustion chambers. (4) Open or close the valves of each system according to the stopping conditions. When the cooling water may be frozen under cold weather, or before a long term stoppage, drain the cooling water from the cylinder jacket side and cooler side, 2010.10.20R YANMAREY26 OPERATION MANUAL Ud ‘Operation No, Stopping 00-24a-01 2. Emergency Stop ACAUTION If any of the following problems arises, immediately set the start/stop lever in the STOP position to stop the engine, NOTICE If the engine is not stopped by setting the start/stop lever in the STOP position or pressing the STOP switch, close the fuel oll inlet vaive, (1) Any of the following alarms has been issued. ¢ ‘© Expressive pressure drop of lub. oil : # Expressive temperature rise of lub.oil ‘© Expressive tempera rise of cooling water ¢ Overspeed (2) An unusual sound has been made. (3) Heat has generated unusually from a part (4) Smoke is issued from a bearing or any other moving part. (5) A pipe of fuel oil, lub. oll or cooling water system has been broken, (6) The supply of cooling water has stopped, and itis impossible to supply it immediately. (7) A setscrew o bolt of a moving part is loose or broken. (8) Moisture is mixed in the lubricating oil. (9) The boost air pressure has dropped, and the exhaust temperature has excessively risen (10) The rack of fuel injection pump has stuck. (11) The exhaust gas temperature at individual cylinder outlet has dropped 40°C less than the mean exhaust gas temperature at each cylinder outlet, misfiring is often the cause of wrong influence on the torsional vibration. 3. Disposal After an Emergency Stop \When repairing the engine or investigating the cause of problem, observe the following items: Do not open the side cover of crankcase for at least 10 minutes after having stopped the engine. Entry of fresh air into the engine may cause ignition of oil mist, resulting in explosion 2010.10.20R YANMAREY2G OPERATION MANUAL UE Operation Special Running Method As for non-supercharged running and decreased number of cylinders running, the method of running to be performed as emergency disposal is set forth. Since a secondary trouble is likely to occur if such method of running Is applied for iong time, operate the engine as short as possible and perform the service and restore the engine as quickly as possible. 4.Grinding running After repair or renewal of pistons, piston rings or cylinder liners, perform the grinding running in order to pre- vent the seizure and abnormal wear. ‘© Do not run the engine inside the torsional vibration critical speed range. ¢ Perform the no-load running for 10 minutes at each ofthe following speed and then the load running for 20 minutes. ® 300 ~ 500 min @ Rated Speed x 0.6 min’ @ Rated Speed x 0.9 min’ @ Rated Speed 2, Non-supercharged operation In case where the turbocharger is in trouble and cannot be repaired through replacement of spare parts, fit the iplements to the turbocharger, and perform non-supercharged operation at low load. (© Operaie the engine at the following speed. Possible speed at non-supercharged operation : 320 min? €@ In the case where the exhaust gas temperature at cylinder head outlet exceeds that of the 100% load in the Records of ‘Shop Trial, lower the speed further. ‘© Avoid running inside the torsional vibration critical speed range. Fig. 00-25-1 Fitting Procedures of Implements for Non-supercharged Operation Turbine housing ‘Sealing Device Tle at Operation Manual of Turbocharger 2010.10.20REY26 OPERATION MANUAL OTT Operation Special Running Method Disassembly of Turbocharger @ Remove the silencer. @ Remove the compressor housing. ® Remove the turbine housing from bearing housing. Fitting of the Implements @ Attach the sealing device to the turbine housing and tight it with nuts and washers. @ install the sealing device with turbine housing to the engine @ install the exhaust gas piping parts on the turbine housing, @ Fit wire netting to the intake port of the air duct for not to suck foreign matters, @ Seal the inlet and outlet holes of the turbine lubricating oil pipes of its mount. ACAUTION Check during a run that there is no leakage of exhaust gas and lul 3, Decreased Number of Cylinders Running In the case where the engine cannot be repaired as the parts are damagad or restored through replacement of spare parts, stop the fuel feeding to cylinders in trouble, and perform decreased number of cylinders run- ning with the load lowered. (© Perform a running with the load of less than 50% ofthe rated load (The speed should be the rated speed * 0.8 mir or fess) €@ It there is the torsional vibration ertical speed range, run the engine in the range 20 min® lower than the low limit. © Run the engine under the condition that the exhaust gas temperature at the cylinder head outlet is below that ofthe 100% load in the Records of Shop Tal ‘© Do not perform the decreased number of cylinders running in the case where vibration becomes severe. Fuel Feeding Stopping Procedures ACAUTION Be sure to execute this work after stopping the engine. If it is done during a run, the implement is sent flying, and you are in danger of being injured 2010.10.20R YANMARhe eau Lue ed Operation No. Special Running Method 00-258-01 Fig. 00-25-2 Fuel Injection Pump Actuation Stopping Procedures = Ol Shielding Ubrola o “Tappet Supporting Block Pump Tappet Disposal of the trouble Section (1) In the case where the suction and exhaust system parts (suction and exhaust valves, swing arms, suc- tion and exhaust cam push rods, etc.) are in trouble, detach the push rods and prevent the swing arms from actuating (2) In the case where the pistons, crank-pin metals, etc. are in trouble, remove the pistons and connecting rods, stop up the oil hole of crank-pins, and prevent the lubricating oll pressure from dropping (3) The vibration grows end drive in the low rotation. 2010.10.20R, YANMAREY26 OPERATION MANU. Ud Operation No, |Page o Data Sheet oo-ssa-00 | 12 MN) Engine Model Eng. No. El Fuel Oil Glutch Model ‘Glutch No. Git Kinematics Type of TIC Turbo. Sit Viscosity Lab Oil Brand Viscosity(SEA) Specific Gravity Load 14 12 34 aa] 40 Room Temp. S Date Time Total Running Hours H Note | No2eyi_ | Cylinder | Nos eyl | Oanet No.4 cyl | °C nen NoSoyl | No.6 oy! | a iniet 172 | °C Outlet | Engine iniet| c Engine Outlet © Notoy | % & No2eyl | 6 a Gait) icant No3cyl | °c 5 | water utiet No.4 cyl | %c NoSeyl | % No6oyl | % Lub. ilCooleriniet_| © Air Cooler Inlet °c ‘Air Cooler Outlet © Lup. on [LO S00t6r Inlet % Engine Inlet % Boost Air | Cylinder Inlet © Fuel Oi|__| Engine Iniet ca ‘Clutch Lub, | Cooler inlet cy oll Cooler Outlet °C YANMAROperation Ly 64 eel ase V ae ey Va No, Cd i Pareneer 0033000 | 212 Toad w|i | 34] 44] MO Not oy! _| MPa No2oyl_| MPa a Nodeyl_| MPa Nod ey | MPa | NoSeyl_| MPa | No6eyl_| MPa § [Engine tub. o1 MPa é Turbo. Lub. Oil MPa Boost hi MPa Jacket Cooling Water MPa Cooter Cooling Water MPa Fuel Of MPa Giutsh Lub. OF MPa Clutch Operation Oit MPa YANMAR00 | EY26 OPERATION MANUA Trouble shooting & Countermeasures aed No. oo-sta-o2 | 14 1.Starting Failure 41) Flywheel not turned 2.Malfunction of air starter pilot solenoid valve (4) Engagement / disengagement switch actuated. {Start / stop lever set in the STOP position) (8) Too high viscosity of lubricating oil (6) Seizure of moving part 4 Seizure of piston and cylinder liner 2.Seizure of main bearing and / or camshaft bearing Cause Countermeasure 19 air pressure insufficient Fil the starting air tank with ai. (2) Engagement / disengagement switch actuated Disengage the turning gear. {(Turming gear set at the intermeshing position) (3) Malfunction of air starter 41.Voltage drop of air starter battery Charge the battery. Press the manual starting push button to start the engine, Sot the start/stop lever at the RUN positon. Warm up the engine. (Check and repair the piston and cylinder liner, or replace them. Check and repair the pertinent main bearing or camshaft or camshalt bearing, oF replace it 2) Flywheel tured, but ignition not taken place. Cause Countermeasure (i) Fuel oil not sent under pressure to fuel injection pump 1.Fuel tank empty 2.Clogging of fuel oil pipe (improper opening and closing of each valve) 3.Clogging of fuel oil strainer 4.Fallure of fuel feed pump 5.Air entry through each joint (2) Maifunction of stopping air piston (3) Defect of fuel injection pump 1.Sticking of plunger and plunger guide 2.Wear or seizure of plunger guide 3.Improper assembling (deviation of match marks) (4) Defect of fuel injection valve 1.Sticking or seizure of needle. 2.Breakage of nozzle spring 3.Fuel injection pressure dropped 4.0il leakage from nozzle excessive 5.Breakage or improper clamping of high-preseure fuel pipe (6) Malfunction of governor (loose governor link and worn spline (6) Poor aitighiness of suction / exhaust valve 4.No clearance at head of suction / exhaust valve 2.Sticking of suction / exhaust valve 3.Damage of seat of suction / exhaust valve (7) Too low cetane number of fuel ‘Supply the fuel to the fuel tank, Check the opening and closing status of each valve. Clean the strainer. Check and repair the pump. Check and repair each joint, then bieed air. ‘Check and repair the air piston. ‘Check and repair the plunger or plunger guide, or replace it. Replace the plunger. ‘Overhaul and check the pump. ‘Check and repair the needle, or replace it Replace the nozzle soring. Regulate the pressure. ‘Check and clean the mating surfaces of noz~ zie and body, or replace the nozzle. Replaoe the high-pressure fuel pipe, or cor rect clamping, Check and repair the governor, or replace it Adjust the vaive head clearance. Grind or replace the valve. Grind or replace the valve seat Use a high- quality fuel ol YANMAR€or er Ua ry 00 . No, Page Trouble shooting & Countermeasures oostec2 | 24 2, Rotational Speed Dropped Spontaneously Cause Countermeasure (1) Clogging of fuel ol strainer {2) Seizure of moving part (piston, main bearing or turbo- charger) (3) Air mixed in fuel oi pipe system (4) Moisture content in fuel oil (6) Defect of fuel injection pump (6) Defect of fuel injection vaive (7) Malfunction of governor Clean the strainer. Check and repair the pertinent moving part, of replace it ‘Check and repair the fue! oil pipe system, then, bleed air. Drain the strainer, tank, etc. ‘Check and repair the pump, or replace it. Check and adjust the valve, or replace it. Check and adjust the governor, or replace it. temperature is lerge among cylinders.) 3, Output of Each Cylinder not in Uniformity. (Dispersion of the maximum combustion pressure and exhaust Cause Countermeasure (1) Air mixed In fuel ol pipe system (2) Moisture content in fuel cil (2) Fuel injection volume not in uniformity among cylinders ‘.Nonuniform position of fue! injection pump racks 2.Sticking or wear of fuel injection pump plunger 3,Defect of fuel injection vaive 4.Looseness or damage of fuel injection pipe 8.Sticking of suction / exhaust valve or damage of suction / ‘exhaust valve seat 6.Damage of fuel cam, or damage of suction / exhaust cam ‘Check and repair the Tuel oli pipe system, then bleed air Drain the strainer, tank, etc ‘Check the position of fuel injection pump. racks, then adjust it Check and repair the plunger, or replace it Check and repair the valve, or replace it. Check and repair the pipe, or replace it. Check and repair the pertinent valve or valve seat, or replace it Check the fuel cam or suction / exhaust cam, then repair it, of replace it 4. Bad Color of Exhaust Gas Cause CaUnTerneaSUTe (i) Improper injection timing (2) Defect of fuel injection vaive (fuel injection pressure drop, sticking of nozzle) (8) Defect of fuel injaction pump (4) improper adjustment of suction / exhaust valve head clear- ance or damage of suction / exhaust valve seal (5) Sticking of suction / exhaust valve (6) Damage of suction / exhaust cam (7) Defect of turbocharger 4 .Clogging of strainer 2.Fouling of the blower side or turbine side (6) Fouling of boost air cooler (too high temperature of boost air) (8) Shortage of fuel oi! (10) Overtoad Check and adjust the ting. Check the vaive, then regulate the pressure, or replace it Check the pump, then repair it, or replace the pertinent valve sect. Adjust or correct the clearance, or replace the pertinent valve sect ‘Overhaul the suction / exhaust valve, and then correct it Replace the camshaft ‘Wash the strainer. Overhaul and wash the turbocharger / blower. Overhaul and clean the air cooler. Use a high-quality fuel oil. Reduce the load. YANMAREY26 OPERATION MANUAI Ce 00 Trouble shooting & Countermeasures No, Page 00-41a-02 | 3/4 5. Lub. Oil Pressure Dropped below the Specified Pressure. Cause Countermeasure (i) Looseness of lub. oll pipe and cylinder block oi! hole plug (2) Clogging of iub. oil strainer (3) Excessive clearance of crankshaft bearing (4) Sticking of lub. oil pressure regulating valve or loose adjusting bolt (5) Sticking of lub. oil safety valve (6) Too high temperature of lub. oll 1.Shortage of cooling water volume 2.Fouling of lub, oil cooler 3.Excessive blow-bye (gas leak) into the crankcase 4.Sticking of piston of lub. oil thermostatic valve or defect of its element (7) Air sucked in tub. oil pump (shortage of lub. oll volume) ‘Check and repair the lub. oll pipe and each cil hole plug, Ovethaul and clean the strainer. ‘Check the clearance, then replace the metal Check the valve and bolt, then repair or adjust the pertinent part. Check the valve and bolt, then repair it Check the cooling water pump. ‘Check the cooler, then over haul and clean it ‘Check the piston rings and cylinder liner. ‘Check the piston and element, then repair ‘or replace the pertinent part. Replenish the lub. oil 6. Unusual Sounds Heads (Knocking Occurred) During Operation 1.Connecting rod bolts 2.Flywheel clamping bolts (3) Improper adjustment of suction / exhaust valve head clearance or loose bolt (4) Improper adjustment of fuel injection timing (5) Fuel injection volume excessive ‘.Malfunction of fuel injection pump 2.Detect of fuel injection valve (6) Increase of gear backiash or wear of gear bearing Cause Countermeasure (i) Excessive clearance of bearing of crankshalt of cam- | Cheok the clearance, then replace the pert shaft nent bearing. (2) Loose botts ‘Check the connecting rod and bolts, then retighton the bolts or replace them. ‘Chek the bolts, then retighten them, or replace them, ‘Check the clearance and bolt, then adjust the clearance. Check the timing, then adjust it. Check and repair the pump, or replace it Check and repair the valve, then adjust it Check and adjust the gear or its bearing, or replace it. 7. Cooling Water Temperature Too High Cause Countermeasure (1) Shortage of cooling water volume (2) Sticking or defect of cooling water thermostatic valve Check and repair the cooling water pump. Check or replace the thermostatic valve. YANMAREY26G OPERATION MANUAL ed ae i No, Page Trouble shooting & Countermeasures costenn | 44 8, Exhaust Temperatures of All the Cylinders Too High Cause Countermeasure (i) Boost air temperature too high ‘Boost air cooler cooling water temperature too high 2.Shortage of boost air cooler cooling water volume 3.Fouling of boost air cooler (cooling water side & air side) 4.Engine room internal temperature too high (2) Boost air pressure too high 4.Clogging of turbocharger strainer 2.Clogging of boost air cooler (air side) 3.Fouling of turbocharger (turbine side & blower side) or its damage 4,Rise of back pressure at exhaust port 5.Engine room put under a negative pressure (3) Unsuitable properties of fuel oil (4) Overload Check the cooling water system, and lower the cooling water temperature to the speci- fied range. Check and repair the cooling water pump. Overhaul and wash the cooler. Check and service the engine room ventila- tion equipment. Wash the strainer. Overhaul and wash the cooler. ‘Wash the blower side or overhaul and wash the turbocharger, or replace it Check and clean the exhaust manifold and exhaust pipe. Check and service the engine room ventila- tion equipment. Judging from the property analysis results, change the fuel oil if necessary. Reduce the load. 9. Engine Stopped Suddenly ‘Cause Countermeasure (i) Protective device switched on 1.Overspeed 2.Lub. oil pressure drop 3.Temperature rise of cooling water excessive {2) Governor or governor gear (3) Fuel tank empty (4) Air mixed in fuel oil system (6) Clogging of fuel ol strainer (6) Seizure of interlocking part (piston, main bearing, crank-pin bearing, timing gear, etc.) tive part. If necessary, replace the perti- nent part Check the governor and governor gear, then repair or replace the pertinent part. Replenish the fuel oil Bleed air from the strainer and oil pipe. Overhaul and clean the strainer. Check and repair the pertinent part, or 7] Check the switch, then repair the defec- replace it YANMAREY2G OPERATION MANU. Fuel Oil, Lubricating Oil & Cooling Water Quality Criteria of Fuel Oil ae No. 00-51-00 Page wn 00 ‘The properties of fuel oil applicable to this engine are shown in the following table. ‘The properties of fuel oit are uncertain and broadly ranged; thus they affect such factors as a smooth run of the engine, maintenance interval and service life of parts. Consequently, it might be necessary to change the specifications of engine or add attachment in accordance with the applied fue! oil 4. Quantity Criteria of Fuel Oil tem Quality Criteria Viscosity at40°C mms | 2t0 11 Density15 °C kglin’ < 900 Flash point [ % > 60 Residual carbon mass.% <03 Sulfur content mass % <1.0 property ena! vatue | AS eentent mass.% < 0.01 Water content vol% <04 Vanadium ppm = atrium pm = ‘Aluminum + silica ppm = Cetane index 345 Iso DMB: cIMAG ~ Quality criteria equivalent fuel oil BSI ws M.DO. 2011.9.20R YANMAREY26 OPERATION MANU. CTL Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 Choosing of Lubricating Oil aoeaor el eant Depending on properties of fuel oil and conditions of usage of the engine, lub. oil to be selected varies. Choose lub. oll API Service Grade CE or CD Class. 1. Viscosity Use an oil shown in the below table. Viscosity | Spectc | "#82, P!"t | Pour Point | Knomate Veo0sIy (5) viscosity (SAE) | Gravity | open typey} (°C) | 40% | 100% | Index 40 | 0893 | >240 | <—7.5 |140~ 155] 14 ~ 15.5] 96 ~ 110 2. Total Base Number (T.B.N.) Select @ lub. oil based on the values given in the following table for the base number against the sulfur con- tent including in the fuel used. Fuel Oil Used Total Base Redwood No.1 {Sulfur Content] Number Viscosity (wt %) (BN) s(100F) | (mgkOHia) M.D.O. equivalent [<1 9~ 15 Lib. oil to be applied: NOTICE (1) Avoid blended use of different brands, {ln the unavoidable case of blended use of different brands of lub, consult your lub. oil supplier.) (2) IF lub. oil of 2 high total base number (T.B.N.) is used when Using fuel oil of a low sulfur content, addi- tive (calcium catbonate) of lub. oil sticks to the high-temperature area together with carbon residue and causes adverse effects as mentioned below: For that reason, use the proper lub. oil ‘® Accumulation of the aforementioned deposits on the combustion chamber hinders sliding of piston rings, and may cause scuffing to the rings, cylinder iners, etc. Besides, they may cause bite-in and blow-bye if intruded into exhaust valves. }) 00-60 List of Lub. Oi! Brands 2010.10.20R YANMAREY2G OPERATION MANUA ETL Fuel Oil, Lubricating Oil & Cooling Water No. Page 00 Control on Lubricating Oil oo-s9e02 | 1 ACAUTION @in case of handling the lubricating oil inside the engine immediately after an engine stop, be careful not to get burnt @ Should there be a possibility of lubricating oil to get in your eyes or to stick to your skin during handling of lubricating oil, wear protectors such as safety goggles and rubber gloves. © If lubricating oil get in your eyes or stick to your skin, it might cause inflammation. In such case, flush an affected region with clean water, and then consult a physician, if necessary. @ Method of disposing waste oll has been provided for in the law. Dispose of waste oil properly accord- ing to the pertinent law. In case you don't know what to do, inquire of your supplier of lubricating oil about this matter, and dispose of waste oil accordingly. 4. Control Criteria Conduct the property analysis of lub. oil used every 500 hours of engine run, and change or make up the lub. oil as guided by control criteria set forth in the following table. tem Unit Control Criteria Citcel Value of Usage Flash point (PM method) | °C > 180 740 ‘Change in viscosity — | mm/sj40°C) Within new oil £15 % New oll +25 % Moisture content voi% (1 /G-FOyy | GASKET 2 24 2 11694-01920 | 7% (CWATYY COVER, JACKET t 25 2 22137-20000 | #4 (34% 20 WASHER, 20 24 26 2 23211-01500 | YA75Y9 (5K 16 A4% | FLANGE, 15 1 27 2 23414-120000 | yy (WW 12 GASKET, 12 39 28 2 23414-16000 | FLY (WL 16 GASKET, 16 1 29 2 23414-20000 | YY (ZL 20 GASKET, 20 1 30 2 23414-210000 | uty (WL 21 GASKET, 21 3 at 2 23414-270000 | YY (WM 27 GASKET, 27 10 YANMAREY26 MERI LU LTERDBRR SLL ey Poe No, Page 01 Ly yesos Parte Lieecainene Dison Hos | Lot | trae | Pert ho Baer Part None | Oty | sams 32 2 23414-00000 | styY (VIL 30 GASKET, 30 6 33 2 23438-015000 | ivy 5K 15x 1. 5 | GASKET, 15 X 1.5 t 34 2 23887-120002 | 69 FFF 12 PLUG, 12 39 35 2 23887-160002 | 67 TSF 16 PLUG, 16 1 36 2 23887-200002 | 649757 20 PLUG, 20 1 37 2 23887-30002 | 647757 30 PLUG, 30 6 38 2 23897-040002 | 649757 G 1/2 PLUG, G 1/2 3 39 2 23897-060002 | 6AI FFF G 374 PLUG, G 3/4 10: 40 2 23961-050000 | AVIFYY 50 A1y FLANGE, 50 2 82 2 24311-00160 | O47 1A P16. O | PACKING, P 16.0 1 4 24 24311-000210 | OF 1A P 21. O | PACKING, P 21.0 1 42 2 24311-00420 | OF 1A P 42. 0 | PACKING. P 42.0 24 43 i 24316-000120 | OF 4D P 12. O | PACKING, P 12.0 6 44 Pet 24316-00210 | OF 4D P 21. 0 | PACKING, P 21.0 48 45 iG 24316-000240 | OF 4D P 24. O | PACKING, P 24.0 48 46 2 26152-160352 | HL GkY 16x 35 BOLT, 16 X 35 4 47 2 26152-160352 | HL GRY 16x 35 BOLT, 16 X 35 4 48 2 26152-160352 | HL b GRY 16x 35 BOLT, 16 X 35 3 49 2 26152-20402 | Lb GY 20 x 40 BOLT, 20 X 40 4 50 2 26152-200402 | Hb GRY 20x 40 BOLT, 20 X 40 4 51 2 26206-100202 | Lb 10 x 20 BOLT, 10 X 20 4 52 2 26206-120302 | Ab 12 x 30 BOLT, 12 X 30 8 53 2 151605-01281 | AbD COVER 24 54 2 26232-200502 | PIIERMb ChYY20 x50 | STUD, BOLT 20 X 50 24 5 He 26232-201602 | drasiwb (AYKYZ20%x160 | STUD, BOLT 20 X 160 | 24 56 2 26732-200002 | +Yb Gky 20 NUT. 20 24 57 He 26742-20002 | aHFt+Yb GhY 20 NUT, 20 24 58 ret 43400-003170 | siyey GASKET 2 59 2 43400-04080 | siyaey GASKET 1 1 x 751695-02210 | DAVIDTUAS BUSH ASS'Y, CAMSHAFT | Iset 60 2 151695-02420 | Pyva (ALYVIb BUSH, CAMSHAFT 7 YANMARPe Le Be ed SY LSE BR No. Page 01 yyy » Parts ice orien hae Cn ae to: | Lot | trae | Part he maar Part ame | By | ters 1 x 151695-01300 | DULY YIRLIS COVER, AIR CHAMBER | Ssets | 61 2 151695-01310 | AN— (QOAYY, Ay% | COVER, AIR CHAMBER 5 62 2 1§1695-01270 | stwe> (GOs LYAN— | PACKING, AIR COVER 5 65 2 26152-200302 | HuLb (RY 20x 30 BOLT, 20 X 30 20 | iH x 751695-01380 | P9eLYTSLYYS, AVI | COVER, AIR CHAMBER: set 1 2 151695-01060 | a\- (99499, A¥FGAI | COVER, AIR CHAMBER 1 62 2 181695-01270 | swt (QOFLIAK PACKING, AIR COVER 1 65 2 26152-200302 | LE (RY 20% 30 BOLT. 20 K 30 4 18 2 23414-120000 | YF (WL 12 GASKET, 12 X 1.0 1 80. 2 23884-120002 | 6hHYTFSFM12 PLUG, N12 1 1 x T336A-0018A0 | 44.975: = 965A | FLANG ASS'Y. BLANK | fisets 63 2 23961-065000 | A425 465 A | FLANG. BLANK W 64 2 138673-01990 | wy (7 VPA) GASKET, (NON-ASB. } W 66 2 26206-120302 | HiLb 12x 30 BOLT, 12 X 30 44 it x 751695-02200 | AZAMVTYDE (ALUVTb | METAL ASS'Y, CAM THRUST | Iset | oT 2 151695-02581 | ADAKOT (HAYYTb | METAL, CAM THRUST [ 1 68 2 26152-200552 | Abb Ghy 20x55 BOLT, 20 x 55 3 69 1 x TS1G9S-ONIZI | DY LHFAF YOR LINER ASS'Y, CYLINDER | Ssets 2 151695-01190 | SUL FS4t LINER, CYLINDER 6 Wn 2 151623-01321 | TArtyy PACKING, RUBBER 12 2 2 181605-01351 | TA PK (Leo Fy PACKING, RUBBER 12 1B 2 151605-01441 | FA PK (CYL S44 PACKING, CYL. LINER 6 4 2 181695-01121 | FaFovayuyy RING, PROTECTION 6 5 2 151695-01320 | wy KB PK (T 0 PACKING, HEAD T=1.0 | 6 76 1 181695-12210 | stu (AY RA USF PACKING, CYL. OUTLET 6 YANMARCi eae PU YIM BRE Parts List of Cylinder Side Cover et eg SUL TERB DRE YANMAREY2G #3ikSiB1# Operation Manual fo LV TERI No Page 01 PY DFM BRE Parts List of Cylinder Side Cover Shee ae ai | U | FLANNGE, 80 1 w | 2 153605-84100 [892 PACKING 1 2 | 2 26152-160252 [Rk GkY 16 x 25 | BOLT, 16 X 25 4 INMARis ¢- 1 e Ee es me) tL irra LVL TERBBEE No. Page 7 parte List of tat tie orsieas | 30 Hor | toet |e | Fart. saan Part tome [85 | ate 1 |x _| 751695-01250 | nx-v98 (7IS4yN9an | COVER ASS'Y leet EE torea5-o1401 | as— (7 I5eYOMAIA | COVER 1 a] 2 2asat-ooriod [0 y7 1k Gti PACKING, 110 1 a [2 26162-160252 | ALE GRY 16 x 25 [BOLT, 16 X25 4 3 [2 23887-16002 | 649757 M16 PLUG, NI6 1 aa | 2 23414-17000 | yer (Ze 17 GASKET, 17 1 | | { 1 [x | t51695-o1290 [Ary 75298 (Fy— | SHUT FLANGE (BREATHER | tset | (a7 [2 151695-09010 [Ado 75 (FU SHUT FLANGE (BREATHER | 1 | 2 t81695-08100 [tye (Fy—F PACKING BREATHER i 0 [2 26206-120202 | Rb 12 x 20 BOLT, 12 X 20 4 YANMAR6 ee ee ee LY LEGPEEE AA WAND RR Parts List of Oi! Pan No. 01-554-02 2008.9.10R YANMAREY26 ##/ikRH Operation Manual eared LY LLEABHAR No, Page 01 FA WAU BRE Parts List of Oi! Pan Shae gu [usn [a3] RES ae] mas No, | Level | Order | Part No, BRe% Part Name Oty | Rerarks tft 1695-01211 | FA MAYY DS (R54 | OIL SINP CORY SINP | Iset 2/2 35410-01780 | 759 _w 30 PLUS, GO 2 3] 2 za4i4-aocoo | (f7* (2 SOT. | acres, 90 x 1.0 2 4] 2 26152-200682 | ARLE GRY 20x 65 | BOLT, 20x 65 6 | FA SIDE s| 2 26132-200002 | FYE ChY 20 wT, 20 6_| AN SIDE 6 | 2 26152-200862 | aI GY 20x 65 | BOLT, 20 X 55 6 7/2 22212-20000 | i FAT 20 WASHER, 20 2 3] 2 26152-160502 | ab GkY 16x 50 | BOLT, 16 X 60 0 9] 2 22212-160000 | Re HH 16 WASHER, 16 0 wld 182654-99190 | M72 aASKET 2 nit 23211-18016 | SASKET 1 7] 2 26162-200882 | aL GRY 20% 48 | BOLT, 20x 45 8 ia | 2 22212-20000 | i FAR 20 WASHER, 20 8 2008.8.40R YANMARLeh td het 2k a) eee LY LTEABB BE Parts List of Oil Sealing (SF¥) BODY (D4 4 I) BR YANMARLh kee) Uc ae LY SERDAR No. Page 01 MOY (D544 IA) BAR | Parts List of Oil Sealing (SFW) oreo tee aa fo: | loet | ar naan Part tame | Ot [aah 1 X | 751695-01192 | 74 (JS4ARI HT COVER ASS'Y, SFW Iset 1 2 151695-01542 | 24995 (SFW COVER ASS'Y, SFW Is 4 3 22333-100250 | F—NEY (RY 10% 25 | PIN, 10. X 25 2 5 3 23414-22000 | yy (WL 22 GASKET, 22 1 6 3 23887-220002 | 69 75H 22 PLUG, 22 1 it 3 26206-120302 | #Lb 12x 30 BOLT, 12 X 30 5 8 3 26706-100002 | +b 10 ‘NUT, 10 2 9 3 26911-120122 | KARY (EF12%x 12 | SCREW, 12 X 12 2 10 2 138613-01590 | RYYAATAVED PIN, PARALLEL M12 X 28.) 2 an 2 26152-200452 | Lb GRY 20% 45 BOLT, 20 X 45 12 12 2 26706-120002 | +b 12 NUT, 12 2 fit X | 751695-01461 | PISHUYIS (SEW ‘SEALING, OIL SF set 13 2 151695-01571 | FIZAY (SFW ‘SEALING, OIL SFH Is 16 3 22137-100000 | #H% (SH¥ 10 WASHER, 10 2 7 3 22137-120000 | #H* (SH* 11 WASHER, 11 2 18 3 26182-100451 | Y—vatb 10x 45 BOLT, REAMER 10 X 45 2 19 3 26606-10002 |b CRY 10 NUT, 10 2 20 3 26911-100102 | KART (EF10x 10 ‘SCREM, 10 X 10 1 a 3 26911-120122 | hARY (EF12%12 ‘SOREH, 12 X 12 1 22 2 26206-10252 | Lb 10x 25 BOLT, 10 X 25 8 1 B 2 22137-100000 | #A% (SHE x 10 WASHER, 10, 8 4 2 22340-100202 | A4I9EY (4Y 10% 20 |PIN, 10 X 20 2 25 2 26706-100002 | +r 10 NUT, 10 2 29 vs 151695-01730 | Avy (PISAY PACKING, OIL THROWER 1LY LEED EE DY (RIDA ART —IVG) BB Parts List of Oil Sealing (OFW) RIP Oppose side of fywmest tec YANMAREe LET me fo LU LTERMBH BE No. Page 01 MOY (RIDA A — IVA) BR Parts List of Oi! Sealing (OFW) Oe HAA fo | tenet | oaer | Part he, saan vert nono | OR | parts 1 x 751895-01400 | FIS#ULIS (OFW SEALING ASS'Y, OIL SFW| Iset 1 2 151695-01600 | PI544 (OFW ‘SEALING, OIL SFW 1s 4 3 26182-080401 | J—ZAVLR 8 x 40 BOLT, REAMER 8 X 40 2 5 3 26706-080002 | FY B NUT, 8 2 6 3 22137-100000 | #4 (SH 10 WASHER, 10 2 7 2 26206-100252 | Hb 10x 25 BOLT, 10 X 25 8 8 2 22137-100000 | ¥H* (SH¥ 10 WASHER, 10. 8 9 2 22340-10202 | RYYAATADEY PIN, PARALLEL M10K20 | 2 10 2 26706-100002 | #YF 10 ‘NUT, 10 2 16 2 151695-01770 | sky (FISHY PACKING, OIL THROWER 1 1 x 781695-01420 | o92H»Y (YFF+!) OFW | PIPE ASS'Y, SEALING OFH | Iset nf 2 23834-100000 | a=4#Y 10 UNION 10 1 12 2 23414-16000 | yy (WL 16x 1 GASKET, 16 X 1 1 | 73 2 151695-01681 | O9AAYYZES PIPE, OVER FLOW Is 14 2 23854-100000 | ALIFE 10 BOLT, PIPE JOINT 1 15 2 23414-160000 | sty¥> (WL 16x 1 GASKET, 16 X 1 2 YANMARDY LFE ABDI No. Page 01 52 hike SR MR Parts List of Breather Pipe ot 608-02 YANMARLh eS ee Ce LY LEMDBR SARE SMA Parts List of Breather Pipe No, Cd Page 01-60-02 | 2/2 Part Name fam | ae Oty | Remarks EARAYIDE (SEW BREATHER PIPE ASS’ Y set | RY#Y (LOFAITIV PACKING, VALVE RLh CRY 16 x 36 BOLT, 16 X 35 EARREAY A (TRAY BREATHER ERBREAY B (Tad IL BREATHER RIVE GRY 16 x 50 BOLT, 16 X 50 ib GhY 16 x 55 BOLT, 16 X 56 FUR CRY 16 NUT, 16 Rb CO (SABRE SUPPORT (BREATHER Rb 12 x 25 BOLT, 12 X 25 12 1 x 751695-09041 | FOP ite COVER, FUEL OIL PUMP | Iset 14 2 146673-07400 | A4 vive LABEL, YANWAR 1 15 2 151695-09110 | Avi— ASI(FOP Sy | COVER, CASE UPPER A 1 16 2 151695-09120 | ANN AYS(FOPR YY | COVER, CASE LOWER A 1 17 2 151695-09130 | AN- AFA(FO COVER, CASE INNER A 1 18 2 151695-09140 | AVi-— BOE(FOPY COVER, CASE UPPER B 1 19 2 14673-09150 | YAS (FOP AN KNOB 6 20 2 161695-09150 | #it- BYS(FOP Sy | COVER, CASE LOWER B i 2 2 151695-09160 | at-B+A(FO COVER, CASE INNER B 1 22 2 151695-09170 | AN-CUS(FOP YY | COVER, CASE LONER C 1 23 2 181695-09180 | Avt— C OX(FOP YY | COVER, CASE UPPER C 1 24 2 151695-09190 | AWW CH+AC(FOP YY | COVER, CASE INNER C 1 25 2 181695-09450 | aF4-45(F OP Avi— | PLATE, FIXED 12 26 2 151695-09251 | AN— C(FOP YyOr COVER, PUMP CASE UP 1 2 2 151695-09271 | AVX— D(FOP v9 | COVER, PUMP CASE UP 1EY26 DARE it a Se CCU ed LY LTERBB BR No, Page 01 MARKY TBA N—MBR Parts List of Pump Case Cover pierce (Eren fe | Lovet | ora | Pert ha, asm Pert Nene | Tey | sorte 2B 2 151695-09300 | ##K— (FOP 2 yAv\— | SUPPORT, PUMP CHANBER | 5 29 2 151695-09310 | #7K— (FOP Sy avi— | SUPPORT, PUMP CHANBER | 1 30. 2 22272-000070 | KATE 7 RING, 7 6 3 2 26206-100142 | AL 10% 14 BOLT, 10 X 14 12 32 2 26206-100182 | Ab 10% 18 BOLT, 10 X 18 1 33 2 26206-100202 | ALb 10% 20 BOLT, 10 X 20 12 34 2 26553-040202 | +Aa4V(+FH 4 x 20 | SCREW, 4 X 20 24 36 2 26573-040252 | #5IRV(+FH 4 x 25 | SCREW, 4 X 25 4 36 2 26716-040002 | +#Yb 4 NUT, 4 41) 65 da ea Cd Turning Device No. 08 Outline (Manual Cranking) Page o8-01a-02 | 4/1 The manual cranking device is a gear that interlocks with the flywheel, It is installed below the air starter on the operating side, When the manual cranking device is interlocked with the flywheel, the engagementidisen- gagement switch is actuatad, which disables starting the engine. 08.01-1 Manual Cranking Device Instal Fryweo! Airsianter Manual cranking device part of your body to contact moving parts while turning the flywheel. (e.g. never put your hand into the crankcase) YANMAREY26G OPERATION MANUA| Ug Turning Device No Page 08 Operation of the Manual Cranking Device os-oza01 | 44 Handle the manuat cranking device as follows: @ Prepare the special tools for turning, ‘Special Tool Description | Part No. Raichet handle 147673 - 92851 Socket (M24) | 42111 - 001850 @ Detach the lock bar, loosen the two stopper bolts and then remove the stopper from slot A in the manual crankshaft ® Push the shaft in to the GEAR IN position. @ Place the stopper in sheff slot B and tighten the two lock bolts. © ANtach the socket and ratchet handle to the manuel cranking shaft and then turn the flywheel Before disassembling or checking any moving part engage the manual cranking shaft gear with the flywheel and lock it with the lock bar to prevent the crankshaft from being rotated. The lock bar is used to prevent the crankshaft from turning while service or overhauling the engine. Interlock the gear, lock the manual cranking shaft with the stopper, and then tighten the lock bar. © When through rotating the engine, move the gear back to the GEAR OUT position, put the stopper in slot A, and then tighten the lock bolts and lock bar. Keep the look bar in the tool box so as not to lose it. Fig. 08-02-1 Manual Cranking Device Handiing Procedures GEAR Pos ERE? stoner SEAR OUTER Micro Switch / 2010.10.20R YANMAREbRRHA het eee a) CME EL Sa D7 RRR i Parts List of Turning Device Dee Page 08-61a-00 | 12 23-4 et 1 FLYWHEEL SIDE YANMAR 2007.9.20RHEAR | [Counterclockwise Rotation Engine’ ey et tea) ee eur ed Poe a = 7 “ vane Parts List of Turning Device 08-812-00 212 Wo | leet | oder | Part her anes Pare Wome | Oy | pore it x 751695-07180 | boy (IS4hkI—W POINTER, FLYWHEEL Aset it 2 11695-07332 | Yiy (7544 IL YA* | POINTER, FLYWHEEL 1 2 2 26206-100162 | HLF 10x16 BOLT, 10 X 16 2 1 x 751695-08100 | 5 YIIDFUDE TURNING DEVICE Iset 3 2 146673-08300 | S¥WIb (FW4—=y4 | SHAFT, F/W TURNING 1 4 2 146673-08310 | 4+" (FW 4—: io GEAR, TURNING 1 5 2 146673-08320 | Abs (FW? Y | STOPPER, F/W TURNING 1 6 2 151695-08330 | Qy4/i— (FWYFYTP x | BAR, LOCK 1 7 2 22512-050120 | DL¥-#- 5 x12 KEY, 5 X 12 1 8 2 26206-100122 | Abb 10x 12 BOLT, 10 X 12 2 9 2 26356-160002 | Ut'Yb (KY 16 U-NUT, 16 1 1 x 747673-74110 | 2 F9IH9=Y SW | TURNING SW. ASS'Y Iset 10 2 147673-73600 | bY Y7¥4 (YS SW | MOUNT, LIMIT SWITCH 1 W 2 22312-060120 | Af4aney 6x12 PIN, 6 X 12 2 12 2 26206-100162 | AF 10x 16 BOLT, 10 X 16 2 13 2 46150-000960 | YEYb SW (XE-Q 22-2 | SWITCH, LIMIT 1 “4 2 26557-040352 | +AaAY (+ 7H ‘SCREW M 4 X 35 ty ery 2008.6.23R YANMARB—=LIRERBR Parts List of Turning Device 23-4 kd FLYWHEEL SIDE 2007.9.20R YANMAR onGEER | [Clockwise Rotation Engine 6 te Uc M51695 oa F—= YF RERRR it i Parts List of Turning Device os-stc00 | 22 fs | Lot | trae | Pert he saan Parte | Ot | names i x 751695-07170 | Dey (I34a4—W POINTER, FLYWHEEL Aset_ i 2 151695-07351 | Yer (2344 YA | POINTER, FLYWHEEL 1 2 2 26206-10162 | AIL 10K16 BOLT, 10 X 16 2 i x 751695-08100 | % FIDELIS TURNING DEVICE Iset 3 2 146673-08300 | LD b (FWS—=Y4 | SHAFT, F/W TURNING 1 4 2 146673-08310 | ¥¥" (FW9—-=YF GEAR, TURNING 1 5 2 146673-08320 | AbYA— (FW? J | STOPPER, F/W TURNING 1 6 2 151695-08330 | Qy4ii- (FWYFy TP A | BAR, LOCK 1 7 2 22512-050120 | JE¥-¥#- 5K 12 KEY, 5 X 12 1 8 2 26206-100122 | Lb 10x12 BOLT, 10 X 12 2 9 2 26356-160002 | UY GRY 16 UNUT, 16 1 1 X | 747673-74110 | 3 GIID ‘SW | TURNING S.. ASS’ Y Iset 10 2 147673-73600 | KUYTH4 ( ‘yb SW | MOUNT, LIMIT SWITCH 1 W 2 22312-060120 | A¢avey 6x12 PIN, 6 X 12 2 12 2 26206-100162 | Lb 10x16 BOLT, 10 X 16 2 13 2 46150-00960 29h SW (XE-@ 22-2 | SWITCH, LIMIT 1 14 2 26557-040352 | FAAAY (+ 7H 4X35 | SCREW M4 X 35 2 2008.6.23R YANMAREY26 OPERATION MANU DL Cylinder Head & Its Accessories No. Page Outline 11-01a-00 qa 41, Cylinder head Each water-cooled cylinder head is installed over four cylinder head studs screwed into the cylinder block A special hydraulic jack is used to tighten and to loosen the nut on the cylinder head stud. Fig. 11-01-1 Cylinder Head 2. Exhaust and Intake valves There are a total of four intake and exhaust valves for each cylinder. The exhaust valve seats are water- ‘cooled. The intake and exhaust valves are laid out in pairs, with the boost and exhaust air systems on the ‘same operation side, thus making maintenance and inspection access from the camshaft and fuel injection pump easy. Fig. 11-01-2 Cutaway view of the cylinder head 2007.3.28R* YANMAREY26 OPERATION MANUAL OT Cylinder Head & Its Accessories No. Page "1 Overhauling the Cylinder Head 41-02a-01 44 If carbon has accumulated on the surface of cylinder head exposed to the combustion gas, it hinders combus- tion. Or, if scale has formed on the cooling water line it wil impede the cooling effect. Also, a crack might occur on the combustion surface of cylinder head if there is an uneven thermal load while the engine is running, Consequently, the cylinder head is overhauled periodically (and the accessories are removed and checked at the same time.) 1) Disassembly sequence (1) Detach the cylinder head cover, and remove the fuel and lubrication oil ines near the cylinder head. (Be careful not to lose the copper gaskets and other small parts.) (2) Disconnect the fuel injection line and injector. (Ci chapter 50-08 overhauling the Fuel injector (3) Remove the intake & exhaust valve rocker arms and rocker arm shaft as a set. Fig. 11-02-1 Cross Section of the Cylinder Head Rocker Arn Bonnet Rocker Arm ylinder Head Bot Cylinder Hees Sightoning Nut Push Rod Push Rod Cover (4) Remove the exhaust manifold (6) Disconnect the indicator. (6) Remove the push rod and cover at the same time, (7) Detach the exhaust temperature sensors. (Be very careful not to damage them.) 2010.10.20R YANMAREY26 OPERATION MANUAL ead ‘Cylinder Head & Its Accessories ho, Overhauling the Cylinder Head 11-02a-01 Fig. 11-02-2 Overhead view of the Cylinder Head Cylinder Head Bolt Cylinder Head Clamping Nut Ful Injection Valve Inceator (Sampling) Valve Such Valve Rocker fem Recker Arm Shaft Pedestal AL — Fel nection Pipe iB Bonnet eee (8) Unscrew the cylinder head clamping Nuts with the aid of a hydraulic jack. Chapter 92-01 ~ 03 Hydraulic Jack [Cylinder head tightening sequence} [Loosen or tighten the four cylinder head clamping nuts on one oylinder simultaneously. ] @ Clean the area around the cylinder head nuts. (Tighten each nut with the handle until itis seated. ) @ Attach the installation bolt to the cylinder head stud for the hydraulic jack. @ Attach the spacer. (Attach the spacer so that the notched part of the spacer faces the adjacent head. ) @ Attach the hydraulic jack to the installation bolt and tighten the hydraulic jack clamping nut NOTICE ‘Make sure that the piston on hydraulic jack is flush with the end of the main hydraulic jack body. © Connect a hydraulic pump to the hydraulic jack with a rubber hose. 2010.10.20R YANMAREY26 OPERATION MANUAL eae Cylinder Head & Its Accessories No. Page 1 Overhauling the Cylinder Head 41-02-01 34 Fig. 1-02-8 Hydraulic Jack Connection Points sack piston must be fish ‘with jack main body. Laser eee From Hydraulic Pump Pig (uae, D) ‘Space’ _ Notch Part ana. © Then, one of the rubber hoses from the hydraulic jack connects A to B, and the other connects C to D. (Loosen the plug on hydraulic jack B & C to bieed air from each hydraulic jack. ) @ Loosen the hydraulic jack clamping nuts 1/4 turn each. NOTICE ifthe notched part of spacer mounting surface makes contact with the adjacent cylinder head, the spacer or cylinder head may be damaged. Therefore, make sure the notched part is not in contact with the cylinder head. Then raise the hydraulic pressure. @Close the relief valve on the hydraulic pump and pump the lever to boost the hydraulic pressure to the spec- ified pressure. (Specified hydraulic pressure : 58.0 + 0.5 MPa © Insert the handle into the hole in a nut through the hole in a spacer. Then turn the nut 2010.10.20R YANMAREY26 OPERATION MANUAI 51690 Cylinder Head & Its Accessories No. Overhauling the Cylinder Head 41-028-01 ‘© When disassembling the cylinder head, loosen the nut by turning it past seven or eight holes. © When tightening the nut, keep turing the nut until itis seated. If you cannot remove a nut with the handle, slowly raise the hydraulic pressure and then try to turn it again. Do not raise the hydraulic pressure above 58.5 MPa. @ Open the escape valve on the hydraulic pump slowly, to lower the hydraulic pressure to 0. @ Tighten the hydraulic jack clamping nut unti itis flush with the hydraulic jack. Then drain the oil from the hydraulic jack. @ Disconnect the rubber hoses from the hydraulic jack. @ Remove the hydraulic jack, spacer, and spacer bolt. ‘© When disassembling, confirm that loosening is notin the cylinder head stud bolt after removing the tightening nuts. ‘© Before disassembling, make sure the alignment marks on the nuts and bolts are actually aligned. (8) Remove the oylinder head with the special tool designed to lift the cylinder head. (When lifting the cylin- der head, pay full attention not to catch anything on threads of the cylinder head clamping bolts. They must not be damaged.) 2) Cautions when making overhaul checks & reassembling (1) Check on the level of carbon build up on the combustion surface of the cylinder head, especially near the intake & exhaust valve holes (to help you determine an appropriate service interval.) Moreover, after cleaning the cylinder head, check carefully for any cracks. (2) Check the degree of scale in the waterjacket part of cylinder head. Clean away scale with a scale remov- ing agent. Even if the engine is fresh water cooled, it should be cleaned once every two years because scale may stil build up depending on water quality. Use a chemical cleaner to remove scale (such as Unicon 146 available from YANMAR) while the engine is not in use. You don't have to wait for an over- haul (8) Carefully check the socket and spigot part of the cylinder head parts will cause blow-by during operation. (4) No particular adjustments will be necessary for the oylinder head packing because the standard top clear- ance will be correct if @ packing the same size as the previous one is used. (6) After cleaning the surface of various parts, the holes and other small areas in the parts should also be cleaned carefully. However, do not plug holes with anything. Instead cover the parts involved with a cloth ot plastic sheet to prevent drt from getting into them. (6) When fitting a cylinder head onto the block, apply lubricating compound to the threaded parts. ing surface, because flaws on these 2010.10.20R YANMAREY2G OPERATION MANUAI Ty Cylinder Head & Its Accessories Overhauling the Intake / Exhaust Valves " No. Page 11-03-02 | 113 1) Disassembly procedure (1) Remove the fuel injectors. Chapter 50-08 Overhauling the Fuel Injectors (2) Attach the valve spring compression too! to a fuel injector clamping stud ‘Special Too! Description Patt No, Valve spring compression tool 51695-92290 valve spring compression plate 75 7605-02320 valve spring compression bolt 26162-181704 Fig, 11-03-1 Intake / Exhaust Valve Removal and Reinstallation Procedure Ketter Ke f f Vat Spring Compression Bott Inakoeshaust Valve W fA Valve Spring Compression Tool \ave Spring Compression Plate Fuel Injection Valve. i raust Val ing ale IntakotExhavet Valve Spring STH | : ! | aj Turn the bolt on the valve spring compression tool to hold down the vaive rotator, and take out the valve key. Incidentally, when disassembling the valve spring and valve rotator without removing the cylinder heed, perform steps (1) & (2) above with the piston at T.D.C. Take care not to mix up the intake and exhaust valves, since they look similar but are made of diferent materials. Fig. 11-03-2 Markings on the Intake and Exhaust Valve | taarking Tul Infake Vave:7SUHS CO Exhaust Vale 7 B0AC DI 2010.10.20R YANMAREY26 OPERATION MANUAL Ud Cylinder Head & Its Accessories No, Overhauling the Intake / Exhaust Valves 11-032-02 2) tems to check (1) Check for sulfuric acid corrosion and bent stems on the intake and exhaust valves. Measure the dimen- sions. If the clearance between the valve stem and the corresponding valve guide exceeds the wear limit, replace either the valve or valve guide, whichever is most worn. (2) Check for high-temperature corrosion on the valve head NOTICE Correct the valve poppet tip part upon careful checking it because ifit becomes too thin, it may be chiped and the pieces may enter the combustion chamber and turbocharger, causing @ serious secondary damage. (However, do not grind the combustion surface side of the valve poppet part for this correction.) (3) Check for blow-by and carbon being compressed into the valve seat. According to what is found, you may need to grind the face of the seat. (4) Measure the dimensions of the valve seat, I the seat has reached the wear limit, replace it. (5) Check for cracks and corrosion in the valve springs. (6) Two valve keys are used to lock each intakelexhaust valve. Store and use them as pairs. In time of reas sembly, use them by a pair and for the same valve. (Unless they are handled by a pair, the valve stem might be damaged due to an inferior contact of the valve key part.) 3) Intakefexhaust valve grinding (1) Perform initial valve grinding earlier than usual, as indicated in Chapter 00-07, in the Table of Periodic Checks. Evaluate the situation and then determine an appropriate interval for subsequent servicing, (2) Check the clearance between the valve guide and stem, replace the pertinent part, and then grind the valve. ]} Chapter 00-09 Clearances & Wear Limits of Major Parts (8) Apply the proper quantity of grinding compound to the vaive to be ground and grind the valve carefully with the proper tool ‘The final grinding should be done with oil. No, Exclusive Tool Description Part No. 1 _| Grinding tool 138613-92340 Spring 159666-92250 Grinding compound 28210-000070 Fig, 11-03-3 Intake and Exhaust Valve Grinding Procedures 2010.10.20R YANMAREY26 OPERATION MANU a Cylinder Head & Its Accessories No. Page 1 Overhauling the Intake / Exhaust Valves 11-0302 | 33 (4) Ifa flaw on the face of an intake or exhaust valve is so deep that it must be corrected by grinding, grind the vaive at the angle shown in the figure on the right. Grind unt the outer edge of the valve seat makes contact with the valve. ‘damm a Intake valve E 120 Exhaust valve a7 90 Fig. 11-03-4 Angle of the Valves and Intake and Exhaust Valve Seat Exhaust Valve Seat Intake Valve Seat 8 90° By 2010.10.20R YANMAREY2G OPERATION MANUA Cylinder Head & Its Accessories No, Page 11 | Overhauling the Intake / Exhaust Valve Seat | joao | 1 ‘The intake/exhaust valve seat has been shrink fitted to the cylinder head, and the exhaust vaive seat is a cooled shrink-fit type. 41) Checking & servicing NOTICE Do not use a gas burner to eliminate carbon stuck to the combustion surface or the exhaust port. Otherwise, the exhaust valve seat may become loose or the O-rings may dateriorate, resulting in a water leak. (1) Check the amount of blow-by and carbon ground ig, 14.04-1 Valve Seat Correcting Procedures into the valve seat. Based on what you see, grind (Rough Finishing) the seat. Since the satellite hes been built on the valve seat face, ifa flaw on itis so deep, correct it with use of a rough correcting seat cutter (with grinder), and then grind the valve seat. (A seat cutter is available as an option.) (2) Check for water leaks in the exhaust vaive seat area. (Ifa water leak is found, replace the valve seat.) (3) Measure the contact diameter of the valve seat, If the measurement exceeds the wear limit, replace the valve seat with a new one. Chapter 00-09 Clearances & Wear Limits of Major Parts 2) Replacing a vaive seat, Replace the valve seat as follows: (1) Removing a valve seat Fig, 11-04-2 Valve Seat Correction Procedures Build up the circumference of the vaive seat face with welding rod applied by are welding. This material is used to remove the valve seat, If the exhaust valve seat is difficult to remove because of the O-rings installed in it, weld an iron plate to the valve seat. Then hammer out the valve seat using a round rod passed through the valve guide. Valve Seat (2) Installing a valve seat © Check for flaws, hit marks and burrs on the hole where the valve seat will be inserted into the oylinder head. Also inspect the outer edge of the valve seat. if any problems are found, correct thern. @ Measure the diameter of the new valve seat and the valve seat hole. Confirm that there will be an inter- ference fit. 2010.10.20R YANMAREY26 Cylinder Head & Its Accessories au OPERATION MANUAL Overhauling the Intake / Exhaust Valve Seat Ce No. 11-04a-01 [Interference values for the Valve Seat] (Unit: mm) Intake valve seat 0.055 ~ 0.105 Exhaust valve seat 0.063 ~ 0.100 (87 ¢ part) 0.100 ~ 0.137 (1004 part) © Heat the whole cylinder head to 40 ‘C to 60°C . Heating should be done with a steam cleaner. @ Then chill the valve seat with liquid carbon dioxide. Ifiquié carbon dioxide is not available, soak the valve seat in a mixture consisting of a small ump (10 kg) of dry ice and alcohol (1.5 lit.) for 1 hour or more. iSlen ee = Chill the exhaust valve seat with the O-rings installed in it, Do not use liquid nitrogen. If you did, the O- rings would harden and break when inserting the valve seat in the cylinder head. NOTICE Just before inserting the exhaust valve seat into its hole in the cylinder head, apply anti-seize liquid (spray) and silicone-based liquid packing (Three- Bond 1211 or equivalent) to the hole in the head. © Using the intake valve (or exhaust valva) as a guide, rapidly insert the valve seat into its hole in the cylinder head. = yee Take care not to tlt the valve seat. Apply a load to the valve seat for one to two minutes, to avoid insufficient insertion into the hole. NOTICE Fig, 11-04-3 Exhaust Valve Seat Inserting Procedures 2 sSeteure inhibitor (spray) Liquis Packing Fig. 11-04-4 Valve Seat insertion Procedures INSERT vy Vive Seat nC After replacing the exhaust valve seat, be sure to conduct a hydraulic test to make sure no water leaks between the mated parts TTest pressure: 0.7 MPa (7 kaffem) 2040.10.20R YANMAREY26G OPERATION MANU. re Cylinder Head & Its Accessories 11 | Overhauling the Intake / Exhaust Valves Guide No, Page 11-05a-01 | 14 The intake and exhaust valve guides have been shrink fitted, inserted and installed, along with the stem seal 1) Checking & servicing (1) Measure the clearance between the valve guide and the valve stem. If the measurement exceeds the wear limit, replace the valve guide or valve. (2) Replace the stem seal each time the valves are serviced. 2) Removing a valve guide Remove the valve guide by hammering on it from the valve side using a stepped bar of two steps. 3) Installing a valve guide Chill the valve guide in liquid nitrogen or liquid carbon dioxide, and then press fit. Interference: 0.001 ~ 0.037 mm NOTICE Fig, 11-05-1 Valve Guide Removing Procedures =H i i i 32 | Doubling Rod te Hanver, When press fitting the valve guide, hold it by the flanged part 4) Installing a stem seal Install the stem seal using a jig so as not to damage the stem seal lip. 2010.10.20R YANMAREY26 OPERATION MANU. Card Cylinder Head & Its Accessories No, Page 11 | Overhauling the Intake / Exhaust Valve Bridge & Guide tt-06e-00 | 4/1 The valve bridge guide has been shrink fited into the cylinder head. Ifthe engine is used with excessive clear- ance between the valve bridge and the valve bridge guide, the valve bridge may drop while the valves are working, causing a malfunction in the valves, uneven weer in the valve guide. 4) Checking & servicing If the clearance between the vaive bridge and valve bridge guide exceeds the wear limit, replace either the valve bridge or valve guide, whichever is more worn. 2) Replacement of the valve bridge guide Chill the valve bridge guide with liquid nitrogen or liquid carbon dioxide. Then press fitit into the cylinder head Fig. 11-08-1 Cross Section View of Cylinder Head (Exhaust Valve Side) Vale Bridge Valve Bridge Guide {Cyllnder Head 2007.4.10R*aEY26 OPERATION MANUAL Uta Cylinder Head & its Accessories No. Overhauling the Valve Rotator 11-07a-00 Improper rotation of the vaive rotator will cause carbon to be ground into the valve seat, causing blow-by in the seat and affecting the service life of the valve and valve seat. Therefore, check and check the valve rotator overhaul periodically. ‘To remove the valve rotator without disassembling the cylinder head, set the piston to T.D.C. on the com- pression stroke, and then remove the valve rotator. (EQ) Chapter 1-03. Overhauling the Intake / Exhaust Valves. 1) Checking & servicing Remove the circlip, and check each part. If any of the following parts is found to be defective, replace it. Fig. 11-07-4 Valve Rotator ball ace LOE Bovevite Spring [I soring shoe cielip Coll Spring = ‘@ Wear (in the body groove) or corrosion in the Belleville spring @ Wear (deformation) or corrosion in the ball @Wom or broken coll spring @ Wear of the body groove 2} Installation ‘© Install the coil springs, balls and Belleville spring in the proper direction @® After installing them, check clearance A. 2007.4.10R"EY2G OPERATION MANUAI CT Cylinder Head & Its Accessories No. Page 11 | Adjasting the Intake / Exhaust Valves Head Clearance | ii.oga03 | 4/4 Adjust the intake/exhaust valve head clearance, as follows, because the valve mechanism of this engine is designed to use two intake (or exhaust) valves by means of a T-shaped valve bridge. This bridge will be dis- torted and cause abnormal wear on the valve bridge guide and/or valve quide unless it adjusted for the oper- ation of two valves simultaneously (1) Prepare the following special tools: ‘Special Tool Deseription Part No. Feeler gauge 0.4mm thick (intake) & 0.7mm thick (exhaust) | 28312 - 000750 Fig. 11-08-1 Valve Head Clearance Adjusting Procedure: 1 2 (Valve Head Clearance) iF (2) Turn the flywheel to bring the relevant cylinder to T.D.C. on the compression stroke. oles Do not mistake this position for the top of valve overlap, {3) Loosen the lock nuts @ & ® , and then loosen the rocker arm adjusting screw D and valve guard adjust- ing screw @ (4) Press down the center of the valve guard from above so that clearance(@)becomes zero, Gradually tighten the valve guard adjusting screw @ so that clearance(® becomes zero. After making the adjust- ‘ment, lock the adjusting screw @ so that it can't turn, and tighten the lock nut @ securely. (6) Puta feeler gauge into clearance(©)between the rocker arm adjusting screw @ and the valve guard, and gradually tighten the rocker arm adjusting screw @ until the clearance is narrow enough to just allow the feeler gauge to be inserted smoothly. Then, lock the adjusting screw (D , and tighten the lock nut @ (6) After having securely tightened the lock nut @, make sure that the feeler gauge can still be inserted and drawn out smoothly. Valve head clearance: Chapter 00-09 Table of Standard Engine Adjustments YANMARLS et ed me eel Peed LYDIA Y KBE No. DU LeTAY FRBR Parts List of Cylinder Head | 11-51-04 DoH Flywheel side =o = YANMARLeith Et ch Rd stenkaL cad cout ead LY LIA Y KBE No. Page 1 VU VIN y RRR Parts List of Cylinder Head a ete ieee fh. |Lowt | tear | Part saan Part Hone | TE | sons 1 x 751695-11104 | YY YHAYE ASSY HEAD ASSY, CYLINDER | Gets 1 2 7S1695-11113 | PU YSEAYE HEAD ASSY, CYLINDER 6s 3 3 151695-11950 | ShA2Y—b (SUC. F—/< | SEAT, INTAKE VALVE 12 4 3 151695-11090 | sLFY—b (EXHAY VALVE SEAT, EXHAUST 12 5 3 151695-11890 | OY (EXHY—b Ye | O-RING, SEAT LOWER 12 6 3 151695-11880 | OF (EXH Y—b I | O-RING, SAET UPPER 12 7 3 152623-11960 | F5FM33 PLUG, M33 30 at a 127610-11760 | vay ‘GASKET. 30 8 3 139653-11641 | Avi— COVER, BLIND 48. 42 3 138613-11660 | toy GASKET 48 9 3 23876-010000 | #Y7F5FRO1 PLUG, ROI 18 10 3 23876-030000 | AY F57TROS PLUG, ROS 30, iW 3 23876-020000 | 42 757RO2 PLUG, RO2 48 12 3 151695-11760 | PK (/XMAY-F PACKING, SLEEVE 6 13, 3 151695-11790 | XWAY-FU9S NOZZLE SLEEV ASSY 6s 15, 4 151695-11780 | ALD aL FLAME SHOUTER 6 16 3 24326-000600 | 0 J) »7 G=60 O-RING 12 7 2 151695-11181 | | COTTER, SUC/EXH. VALVE | 48. 23 2 151695-11500 | PUY Ydi4 F GUIDE, BRIDGE 12 24 2 151694-11501 | WIAFLY—I (YoFV* | SEAL, VALVE STEM 12 | SUC. ey 2 11607-11580 | SWIAFAY—I 19 SEAL, VALVE STEM 12 | EXH. 26 2 146673-11750 | ky YoEDY PIN, CONNECTING 6 an 2 26232-202402 | SIAsKLb (hymRY 20x 240 | STUD, BOLT 20 X 240 6 28 2 151695-11370 | SEI SALE ‘STUD, BOLT 6 29 2 26732-20002 | +b (RY 20 NUT, 20 12 wo 2 26212-120652 | YAS 12x 65 | STUD, BOLT 12 X 90 12Le ee me) CUCU el tae LYLINY KOBE No. Page “1 DU vstay KBR pace uicciat Smee M51a04 | 93 Wo: | towt | tr | Port te amen Part Wane | Cy | nowt 31 He 26212-120902 | SEAS b 12x 90 | STUD, BOLT 12 X 90 12 32 2 26212-120502 | JEASHRILb 12 x 50 | STUD, BOLT 12 X 50 12 33 2 26706-12002 | +b 12 NUT, 12 36 34 He 23893-040002 | 6A7 FFF G 172 PLUG, G 1/2 12 35 2 23414-21000 | YY (WN 21 GASKET, 21 12 36 He 26206-100102 | AL 10% 10 BOLT, 10 X 10 6 7 2 153672-59910 | Y-VIYS— 10 WASHER, SEAL 10 6 38 2 23887-120002 | 6AV FSF 12 PLUG, 12 6 | 30 Ey 13672-89920 | Y-ADYS¥— 12% 1. 2 | WASHER, SEAL 12X 1.2] 6 40 2 181695-11800 | sty> (FOV PACKING, VALVE 6 YANMARLe A eos a) eee M51695 LYLEA Y KBE FMRS + RUA Y b BRR Parts List of Valve Arm Ass’ y & Bonnet No. 11-62a-08 25-4 t4 — 1) FLYWHEEL SIDEi) et be est mee) i EEL eed LY LIA Y FRB No. Page 1 FMRBS RUA Y b BRR Parts List of Valve Arm Ass’ y & Bonnet tee ieae tb: | Uoet | trae | Pet he Pork awe | Oty | Roe 1 |x | r51695-11150 SUPPORT ASSY, SHAFT | fete 1/[2 T51605-11140 | (Ve 12 GASKET, 12 6 5 2 26706-120002 | FYk 12 NUT, 12 12 1 x 751695-15052 | Put@yAyvygs VALVE ASS'Y. SAFTY sets 6 2 151895-15202 | Futiuny VALVE, SAFETY 6 8 3 151695-15221 | Futuny VALVE 6 9 3 151695-15231 | 4% (Potivay ‘SPRING (SAFETY VALE 6 10 3 151695-15241 | ROT (Pot LAY | RETAINER 6 W 3 161695-15251 | tAAI (PUY 9¥4" 9s TIMING GEAR ASSY Iset 1 2 151695-14280 | FHL4 (FT EW PLATE, IDLE 1 2 2 181695-14290 | KU Ya 4 (74 EI BRACKET. IDLE 1 3 2 151695-14590 | 44729 5 (AAP 1 KIL | GEAR ASSY, CAN IDLE Is 6 3 151695-14620 | Pyva(yr4 FLey BUSH, IDLE GEAR 1 7 3 22312-060060 | Af A9EY 6X6 PIN, 6X6 1 8 2 22137-120000 | F¥AR(SHY 12 WASHER, 12 4 9 2 26152-200602 | Ab (hY 20 X 6O | BOLT, 20 X 60 6 10 2 26208-120252 | Rb 12X25 BOLT, 12 X 25 4 2008.9.10R YANMARERAS | (Cc Ti Lath + BRERA LY IP — LB RR Parts List of Camshaft & Suction / Exhaust Swing Arm BIS 74 — 1) OPPOSITE SIDE OF FLYWHEEL aa se 2012.12.03R YANMARLk het MO) oak hi Ube ed Hi Lait BARA VIF — LBB Parts List of Camshaft & Suction / Exhaust Swing Arm | 14-52s-00 | 2/2 [Counterclockwise Rotation Engine| No. Page eo MRE Port Hane Pela 1 x 751695-14220 | ALOT ASSY | CANSHAFT ASS'Y Iset 2 2 181695-14041 | AALVTRCKL Av | CAMSHAFT, XL GEAR 1 3 2 181695-14800 | AAL7hCXL NOG.5 | CAMSHAFT, XL NO6.5 1 4 2 181695-14810 | AALS 7 hCXL _NO43 | CAMSHAFT, XL NO4. 3 1 5 2 151695-14820 | AASV DhCXL NOZ1 | CAMSHAFT, XL NO2.1 1 6 2 153605-14730 | U—aARIL BOLT, REAMER 36. 7 2 26356-140002 | UFYKGRY 14 UANUT, 14 36 8 2 151695-14500 | FR ALIVIb GEAR, CAMSHAFT 1 9 2 151695-14170 | 49 ED GEAR, GOV. DRIVE 1 10 2 153605-14810 | AIL ba BOLT, CAM GEAR 12 1 | 2 |__| 2esre-t20a00 | 2x¥—4—12 x G0 | KEY, 12 X 20 1 2 | 2 26206-120802 | rRILF 12 XK 80 BOLT, 12 X 90 4 a 2 151695-91080 | 7 FOS>Ch4F>7 | WASHER, DRIVE SHAFT | 1 | 1 |X | tot606-14251 | EDAD OFS 7S | SHING ARH ASS'Y vets ia | 2 15605-14240 | RLF ACATY 77 —Le | BOLT, SWING ARMA | 6 4 | 2 151696-14270 | SVD RAL YF F—A | SHAFT, SHING ARH 66 16 2 151695-14301 | A4 YY P—L CMP. ARM ASS'Y, SWING 12s 7 3 163605-14221 | 2-5 (SUCEXH 9 Ay b ROLLER, TAPPET 42 | 8 151605-14290 | E>(@XY KE—S | PIN, TAPPET ROLLER | 12 22 2 151695-14421 | AN-(FySanye COVER, PUSH ROD 12 23 2 151695-14550 | PyyanyeYos ROD ASSY, PUSH 128 2 2 22242-00550 | KAD C(YD 55 RING, 55 24 2B 2 24321-000350 | 0 ')»4 1A G 36.0 | PACKING, G 35.0 24 29 2 24550-022150 | E54 7YYaA 22X15 | BEARING, 22 X 15 12 30, 2 26152-200602 | ALR (RY 20X60 BOLT, 20 X 60 6 2012.12.03R[GES BA | [ Clockwise Rotation Engine LoD ch Jia bh 4212 Ay eek Malbec Dead Db BURA YIP — LAB RR i Parts List of Camshaft & Suction / Exhaust Swing Arm 14-520-04 2a— 2e—s 4 RIS 4 A — OppoSiTe SIDE OF FLYWHEEL YANMAR[ZB RRHHBEAA | | Clockwise Rotation Engine | et) ERIKA Operation Manual Ord Pi ALtd- MERA T7— hee |" ie Parts List of Camshaft & Suction / Exhaust Swing Arm | 14-52c-01 22 fo | ot | ower | Pert tor naan Part name | | Rare 1 x 751695-14210 | ALOT ASSY CAMSHAFT ASSY. Iset 2 2 151695-14041 | ALAS IKCXR A¥4r | CAMSHAFT, XR GEAR: 1 3 2 151695-14650 | A127 7 b(XR NO6.5 | CAMSHAFT, XR NO6. 5. 1 4 2 151695-14660 | ALS VIE(XR NOS.3 | CAMSHAFT, XR NO4.3 1 5 2 151695-14670 | HASVDE(XR NO2.1 | CAMSHAFT, XR NO2.1 1 6 2 153605-14730 —wRILb BOLT, REAMER: 36 7 2 26356-140002 | UFYEGRY 14 UANUT, 14 36 8 2 151695-14100 | #4 (ALoOVIb GEAR, GAMSHAFT 1 9 2 151695-14170 | #¥GHAFS ED GEAR, GOV. DRIVE 1 10 2 153605-14810 | AIL bp Lear BOLT, GAM GEAR 12 WW 2 22512-120300 | PL4F-¥— 12X30 | KEY, 12 X 30 12 2 26206-120302 | RL 12X30 BOLT, 12 X 30 4 31 2 151695-91060 | 2 EGLO (A4 F247 | WASHER, DRIVE SHAFT 1 1 x 751695-14251 | EYAL YO FLOS ‘SWING ARM ASSY Gsets, 13, 2 153605-14240 | ALF A(A4Y97—L | BOLT, SWING ARN A 6 4 2 151695-14270 | SY DR(ATYAP—+ | SHAFT, SWING ARM 6s 16 2 151695-14301 | A4 YF P—L CMP. ARM ASS’ Y, SHING 12s 7 3 15605-14221 | A—> (SUCEXH 4 ~y b ROLLER, TAPPET 12 | 18: 3 161695-14230 | Ev(anybho-> PIN, TAPPET ROLLER 12 22 Zz 191695-14421 | AAN—(Fyvaaye COVER, PUSH ROD 12 | 23 2 161695-14550 | Pyyvaayesgs ROD ASS’, PUSH 12s 27 2 22242-000550 | KAD C(YD 55 RING, 55 24 28 2 24321-000350 | OJ 1 A G 35,0 | PACKING, G 35.0 24 29 2 24550-022150 | F514 DySa 22x15 BEARING, 22 X 15 12 30, 2 26152-200602 | ARLE (RY 2060 BOLT, 20 X 60 6EY26G OPERATION MANUAI Air Cooler, Exhaust Manifold & Turbocharger No. Page 18 Outline 18-0tb-00 | 1 The air cooler is box shaped and is designed to function as a turbocharger mount. Therefore, the turbo- charger and air cooler are fitted compactly on the side of the unit of the flywheel. ‘The air cooler tubes are installed with a finned plate in two-pass for good cooling performance. The core of the air cooler can be extracted from the casing without removing the turbocharger. Turbocharger is a high performance air-cooled radial model. The exhaust manifold consists of two passages to make good use of the pulse energy from the exhaust gas. Fig. 18-01-1 Air cooler & Turbocharger Exhouet Manifold He CUT tt Air Cooler 4 + a a Ny, LIN Ve 2007.4.10R* YANMAREY26G OPERATION MANUAL Ol Ai Cooler, Exhaust Manifold & Turbocharger No, Page 18 Sel ig the Air Cooler 48-02b-01 42 ‘The air cooler body is designed to serve as a support for mounting the turbocharger. The core of the cooler ‘can be removed without removing the turbocharger or cooler body from engine. Cooking Water OUT Fig, 18-0244 Air cooler 4. DISASSEMBLY Disassemble the air cooler according as follows. 4.Prepare the following special tools ‘Special Tool Description Part No, Note Tool A 151692-92450 Tool B 15169292460 Tool C 151695-92670 Tool D 151695-92680 Tool E 15695-92690 Eyebolt (M16) 26610-16002 2 pieces 2, Remove the cooling water tube, by-pass valve and air vent pipe. 3, Remove the frame, o-ring and thin plate on the operating side (the water return cover side) 4, Remove the frame securing the core to the non-operating side and attach the tools A and B. Tool D Eyepot 1 Tool Tool B secon Fig. 18-02-2 Drawing the Core 2012.2.10R YANMAREY26 OPERATION MAN 51690 Air Cooler, Exhaust Manifold & Turbocharger No. Servicing the Air Cooler 18-02b-01 5, Push the core from the operating side toward the non-operating side. 6. When core has been drawn out about 120mm, insert a pipe under the air cooler (between the cooler and tool) and pull the core out more from the non-operating side. Insert another pipe when core is drawn out further. oes It should be expected that the core will moves more than you might think when a pipe is placed under the ‘core, Never stand in front of the core. 7.When the core has been drawn out about 500mm, screw the eyebolts into the thread holes in the core and suspend it NOTICE Never suspend the core with a single eyebolt. The core mass is 340 kg. 2. CHECKING AND SERVICING 1. Clean the air side (finned plata) with steam or soak finally wash it in water. MOtes ‘The appropriate cleaning fluid is the following product or equivalents. Neos Co.,Ltd. : Neos One-4 Kurita Water Industries Ltd. : Emocon 1E-55 in cleaning fluid. Blow compressed air across it and 2, Remove the water covers on the core and clean the interior of the tubes. Brush them with a long-handied brush. 3. Check the coating on the inner surface of the duct and cooler body. If the coating has peeled off, repair it 4, Check for clogged drain holes. 5,Repiace the o-rings and gaskets with new ones. 3. ASSEMBLY Assemble the air cooler by reversing the sequence used to disassemble it NOTICE + Apply clean engine ol lightly to the rail on the air cooler body before installing the core in the body. But do not use grease for this purpose. + Use liquid seal forthe thin plate on the water return cover side. 2011,7.19R YANMAREY26 OPERATION MANUAL De Air Cooler, Exhaust Manifold & Turbocharger No. Page 18 Overhauling the Exhaust Manifold Getsoant aes The exhaust manifold consists of a 1,4,6 cylinder group end a 2,36 cylinder group. The manifold is covered with glass cloth and is surrounded by a steel cover to insulate it and make it fireproof. 1. Disassembly Disassemble the exhaust manifold as follows. 1, Remove the cover on the exhaust manifold. 2, Remove the electrical wiring and its supports 3.Remove the fireproof cover. 4. Remove the bolts from the manifold and expansion joint flange and remove the expansion joint. 5.Remove the supports. 6.Attach an eyebolt fo each manifold and suspend them to move them away after removing the bolts on the cylinder head side. NOTICE 1-Check the tightness of the bolts before you loosen them. 2-Pay attention to keep the gasket from falling when you remove the manifold. 3-The nuts and bolts on the exhaust manifold, and the related parts are made of stainless steel. Do not mix them with the bolts on the other parts. Fig. 18-03-1 Exhaust manifold Insulation Covering Expansion Joint Support Exhaust ManifoldLs 64 -e) e e M51695 Air Cooler, Exhaust Manifold & Turbocharger No, Overhauling the Exhaust Manifold vacant 2. Assembly ‘Assemble the exhaust manifold by reversing the sequence used to disassemble it. 1. Apply anti-seize to each bolt and nut, and then tighten it 2. Check the mark stamped on the expansion joint flange and put it on in the proper direction, according to the mark. ewes on NOTICE + If the expansion joint is fitted backward, carbon will be trapped in the gap causing the expansion joint to break quickly, 4-Glass cloth covered by aluminum foil is used for lagging 2-Lag the exhaust manifold with glass cloth, and stitch up the loose edges of the cloth. 3-Coat the stitched-up part with sealant. 4-In case the fireproof covering (lagging) comes off the exhaust manifold, there will be @ possibilty of a fire breaking out from oil spray or other combustibles coming in contact with the manifold. 5-Use of asbestos as lagging material is prohibited. YANMAROperating Instructions KBB 9 ST5 Exhaust Gas Turbocharger OPERATING and MOUNTING INSTRUCTIONS for EXHAUST GAS TURBOCHARGER ST5 For information only! Kompressorenbau Bannewitz GmbH Windbergstrate 45 01728 Bannewitz Federal Republic of Germany Phone: +49 (351) 40 85 603 (Sales) +49 (351) 40 85 633 (Service) +49 (172) 35 16 045 (24-hour phone) Fax: +49 (351) 40 85 840 +49 (351) 40 85 648 (Service) STSENO3.doc 3" Edition (01/2011) Page 1 of 44 Issued: 122010 Ro Checked: Released 7596002enOperating Instructions ST5 Exhaust Gas Turbocharger KBB ® Name plate Kompressorenbau

125 kPa (1.25 bar) Ifalarm values are adapted accordingly to the engine data, the values specified above are not to be exceeded andlor be fallen below in the case The maximum speed and the maxit um exhaust gas temperature before turbine are indicated on the name plate and the test certificate! 1.3 Dimensions ee All dimensions are specified in mm! Length *) 1225 ... 1320 Width **) max. 610 Height **) max. 690 *) Exhaust gas turbocharger with silencer or intake housing and exhaust-gas elbow **) Dimensions depend on the housing position Exhaust gas Inlet single-nozzle housing 4x 163 mm Inlet double-nozzle housing 2x @ 100 mm Inlet three-nozzle housing 3x@ 85 mm Outlet @ 300 mm Charge air Outlet @ 175 mm Cooling compressor | Inlet 2xM18x 1.5 Lubricating oil Inlet at bearing housing 914.5 mm Outlet at bearing housing 945mm Compressor washing | Air piping M18 x 1.5 Water piping M16x 1.5, Turbine washing —_| Water piping M18 x 1.6 Drainage 75mm Further connection dimensions can be taken from the assembly drawing Page 6 of 44 3" Edition (01/2011) STSEN03.docOperating Instructions KBB 9 ST5 Exhaust Gas Turbocharger Chapter 1 The piping for the pipe connections listed is not included in the scope of CH supply of Kompressorenbau Bannewitz GmbH. ( Pipes have always to be laid free of stress. 1.4 Test connections ‘The TC is equipped with the following test connections which can be used as required. ‘+ There are two threads each (M18x1.5) provided at the air intake housing, compressor housing and turbine-inlet housing and at the exhaust-gas elbow for measuring the temperature and pressure, ‘+ For measuring the speed, the bearing housing can be equipped with a speed sensor. 1.5 Weight of important subassemblies Exhaust gas turbocharger, compl. *) 352 kg Exhaust gas turbocharger, basic unit 269 kg Silencer 42 kg Air-intake bend 17g Compressor housing, compl. akg Insert, compressor housing 19 kg Turbine housing, comp 82kg Insert, turbine housing 15g Containment shield 26 kg Exhaust-gas elbow 47 kg Cartridge (Bearing housing with rotor) 88 kg Bearing housing ST kg Rotor 20 kg Shaft 14kg Compressor impeller kg *) Basic unit including silencer and exhaust-gas elbow (see neme plate) without insulation STS5ENO3.doc 3" Edition (01/2011) Page 7 of 441.6 Vibrations Operating Instructions KBB® Chapter 1 ST5 Exhaust Gas Turbocharger Maximum admissible vibration load at engine for 2... 250 Hz: Admissible value atTC at silencer (atplace LG) _ | (at place SD) Velocity Vans (mm/s) | max. 45 mms _| max. 74 mm/s Amplitude Sans mm max.0,7mm_| max. 1,1 mm Acceleration ens (mis?) | max. 70 mis*_| max. 111 mis? Page 8 of 44 3" Edition (01/2011) ST5EN03.docKBB Operating Instructions ST5 Exhaust Gas Turbocharger Chapter 2 241 2.2 SAFETY The exhaust gas turbocharger is an incomplete machines and has been designed on the basis of the following standards and regulations: 1. Machinery directive 2006/42/EC 2. Risk assessment and evaluation for ISO 14121-1 Built-in safety systems + Asafety system for the turbocharger is not necessary as its design and connection with the engine to which itis attached require an inherent safety. + For general speed monitoring, Le. without a tum-off function being included, the ‘turbocharger can be equipped with a tachometer. Assembly and disassembly work must not be done during operation. See chapters 7.3.1 and 7.3.2 for maintenance and cleaning jobs which may be done while the engine is running. Safety measures (to be taken by user) + These operating instructions are part of the exhaust gas turbocharger and shall be always accessible for the operators and maintenance personnel. ‘+ The operating instructions should be read before commissioning the turbocharger. Particular attention should be paid to directions and information relating to dangers. The user is required ‘+ to make his operators and maintenance personnel familiar with safe working methods ‘+ to supervise the observance of the safety regulations. ‘The individual jobs in these instructions are described such that they can be understood by skilled workers, The necessary tools and testing/inspection means must be made available to these workers. ‘The user must obtain permission to operate the unit from the local authorities and observe the following: 1. labour safety 2. cleaning and maintenance of the machines 3. product disposal 4, environmental protection ST5EN03.doce 3" Edition (01/2011) Page 9 of 44Operating Instructions KBB Chapter 2 ST5 Exhaust Gas Turbocharger 5 2.3 Declaration of incorporation In accordance with Directive 2006/42/EC, Annex II, part 1, section B Manufacturer: Kompressorenbau Bannewitz GmbH Windbergstrafie 45 01728 Bannewitz, Federal Republic of Germany Product : Exhaust turbocharger ‘Type, specification , serial no. see name plate ‘The head of the engineering department, Klaus Buchmann, Windbergstraite 45, 01728 Bannewitz, is authorized to compile all the special documents in accordance with Annex Vil B. ‘The exhaust turbocharger is defined as @ partly completed machinery in accordance with article 2g and intended to be assembled to a combustion engine only. The special technical documents in accordance with Annex Il B were compiled and in response to @ reasonable request of a national authority transmitted on an electronic base. ‘The exhaust turbocharger must not put into service until the final machinery into which is it to be incorporated has been deciarad in conformity with the provisions of this Directive. Ingotf Ulbricht Corporate Quality Page 10 of 44 3 Edition (01/2011) STSEN03.docOperating Instructions KBBO ST5 Exhaust Gas Turbocharger Chapter 3 3 GENERAL INFORMATION ABOUT DANGER 3.1 Danger zone ‘The danger zone is defined by the engine as the turbocharger is an integral part of the engine. During turbocharger operation, the user must keep the danger zone free CEH of any objects s0 to ensure unhindered access to tho unit. Ear muffs should be worn as the sound level is high. Care should also be taken when approaching the hot housings. «The exhaust gas turbocharger is mounted on the engine. It may not be interfered with when the engine is running '* Make sure the exhaust gas pipes at the turbine side cannot come loose during operation since exhaust gas might escape at this point, ‘+ As the exhaust gas turbocharger is an integral part of the engine, its operation is described in connection with the engine. However, its maintenance is described separately in the operating instructions. 3.2 Operators and maintenance personnel Operators and maintenance personnel are persons who are responsible for transport, assembly, installation, operation, setting, maintenance, cleaning and troubleshooting. Make sure to observe the following accident prevention regulations: + winches, hoisting and drawing gear (BGV D 8) + load take-up devices for hoisting operations (BGR 500 chapter 2.8) If these regulations are not observed, your life and limb may be endangered! 4. The turbocharger may only be maintained by duly qualified and authorised persons. 2. In maintaining the turbocharger, the responsibilities shall be clearly defined and must be adhered to so as to prevent confusing competences with respect to the safety aspect. 3. The operating instructions shall be followed irrespective of what kind of work (operation, maintenance, repair etc.) is concerned. 4, The cleaning, maintenance and repair work described in these instructions are easy to understand by persons skilled in mechanical, cleaning and maintenance work. The necessary tools and testing/inspection means must be available to these persons. 5. Operators are not allowed to interfere with the unit in a way that would affect machine safety. 6. Itis also within the responsibilty of the operator to see to it that no unauthorized person ‘works on the turbocharger. STSEN03.doc 3" Edition (01/2011) Page 11 of 44Operating Instructions KBBé Chapter 3 ST5 Exhaust Gas Turbocharger 3 7, The operator must inform the user without delay of any safety-affecting changes to the turbocharger. 8. In order to ensure a long service life, the exhaust gas turbocharger has to be operated in accordance with the technical specification. 3.3 Installation of spare and wear parts It is emphasised that spare parts and accessories not supplied by us are not tested/inspected and approved by us. The installation and use of such products may negatively affect the performance of your turbocharger. We assume no liabllty for damage caused by the use of components and accessories not made by us. For ordering spare parts and tools, please refer to the + spare parts list + tools list. The spare parts lists attached (see chapter 8.2) contain all spare parts for the turbocharger. DIN (standard) parts may be bought from specialised dealers. For the assembly, disassembly and commissioning of the turbocharger, refer to the respective chapters in these operating instructions, Before doing any maintenance, cleaning or repair work, the engine must have come to a standstill. Therefore turn the engine off and secure it against unintentional re-starting. ‘See chapters 7.3.1 and 7.3.2 for maintenance jobs which can be done during engine operation. Make sure to observe the following accident prevention regulations: ‘winches, hoisting and drawing gear (BGV D 8) + load take-up devices for hoisting operations (BGR 500 chapter 2.8). If these regulations are not observed, your life and limb may be ‘endangered! See the inspection schedule (see chapter 6.4) for the maintenance CZ inorvais Page 12 of 44 3" Edition (01/2011) STSENO3.docOperating Instructions KBB 8 ST5 Exhaust Gas Turbocharger Chapter 4 4 DESIGN 41 Brief description Exhaust gas turbocharger (TC): Type STS Specification number: 750% Mass 366 kg 4.2 Construction 43 44 ‘The exhaust gas turbocharger (TC) STS is equipped with a single-stage radial flow turbine and a single-stage radial flow compressor. The turbine wheel and the shaft consist of one part, the compressor Impeller is mounted on the shaft. The rotor has a bearing consisting of two plain bearings in a bearing housing. The compressor housing and the turbine housing ere flanged to the bearing housing. You can use @ silencer or alternatively an intake housing (intake elbow) at the entrance of the ‘compressor housing. ‘The plain bearings are lubricated by the lubricating oil system of the engine. The lubricating oll flow depends on the oil temperature, oll pressure and TC speed. Function ‘The rotor is driven by the exhaust-gas energy of the diesel engine. The exhaust gases reach the turbine wheel via the turbine housing and the turbine nozzle ring, ‘The compressor impeller mounted on the same shaft takes in the required combustion air via a silencer, compresses the air to a higher pressure and transports the compressed air to the engine via a charge air cooler. ‘The TC is not equipped with a special control device. The TC speed is adjusted depending ‘on the operating conditions of the engine. Usage to the intended purpose ‘The exhaust gas turbocharger is intended for supercharging combustion engines. Any other Usage is not permitted and has to be cleared up with Kompressorenbau Bannewitz GmbH (KBB) in advance. Modifications and additional attachments to the TC are subject to a written consent of Kompressorenbau Bannewitz GmbH, non-observance of the aforementioned invalidates any rights of warranty claim, The usage to the intended purpose also includes that the specified maintenance and inspection work is carried out regularly and to the full extent (see Chapter 6.4) ‘The TC specification attached to the engine is thermodynamically adjusted and is binding for this engine variant, Le. if the TC has to be replaced, use the same TC specification again. ST5EN03.doc 3" Edition (01/2011) Page 13 of 44Operating Instructions KBB Chapter 5 ST5 Exhaust Gas Turbocharger 9 5 OPERATION 5.1 Commissioning 5.2 Prior to commissioning, itis imperative to make sure that the plain bearings of the TC are ‘supplied with oil. The plain bearings are lubricated by the lubricating oil system of the ‘engine. The lubricating oil fw depends on the oll temperature, oil pressure and TC speed, The lubricating oil pressures required for special operating conditions are listed in chapter 14 Ensure and check the free retum flow of the lubricating oil The following has to be checked ‘+ lubricating oil pressure upstream of TC, ‘+ lubricating oil temperature upstream of TC. ‘+ Ensure the lubricating oll supply of the plain bearings (see chapter 1.1). ‘+ Lubrication has to be started prior to start-up processes. + Pay special attention to prevent leakages in the oil supply and return pipes to prevent oil from flowing onto the hot, gas-carrying housings in order to prevent the formation of hazardous oil vapours (and fire risk). Starting-up The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started together with the engine. The TC speed is adjusted depending on the operating conditions of the engine. The charge air pressure required for the engine is fixed by adjusting the turbine nozzle ring and the compressor diffuser during the TC tuning, If the corresponding meters are available, enter the following measured values into the engine log during engine operation (at least once every 24 operating hours}: «| Speed of exhaust gas turbocharger + Exhaust gas temperature upstream of turbine or downstream of cylinder ‘+ Charge air temperature downstream of compressor or downstream of charge air cooler ‘+ Charge air pressure downstream of compressor ‘+ Lubricating oll temperature upstream of TC ‘+ Lubricating oil pressure upstream of TC + The engine has to be stopped immediately when the oil pressure falls below the minimum value. + Pay special attention to prevent leakages in the oil supply and return pipes to prevent oil from flowing onto the hot, gas-carrying housings in order to prevent the formation of hazardous oil vapours (and fire risk). ‘Additfonaily perform the following checks at regular intervals : Page 14 of 44 3" Edition (01/2011) STS5EN03.docKBBS Operating Instructions ST5 Exhaust Gas Turbocharger Chapter 5 5.3 5.4 5.5 ‘+ Tightness of the exhaust gas, charge air and oil piping ‘+ Smooth running of the exhaust gas turbocharger ‘The charge air pressure is utilised as a parameter for the exhaust gas turbocharger speed. Unsteady operation (vibration of TC) indicates an increased unbalance of rotating parts, possibly resulting in the rotor or bearing being damaged (see chapter 6.5). Stopping After the engine has been stopped, the exhaust gas turbocharger continues to run for some time. The run out period depends on the installation. If the rotor comes to an immediate standstill, this can be caused by one of the following reasons: © damaged bearings ‘+ compressor impelier or turbine blades come in contact with the housing as the clearance is compensated due to extensive forces caused by thermal distortion + clamped foreign matters, ‘The turbocharger must lubricated 15 minutes after the engine is turned eo. ‘The lubricating time is to be extended in case of engines with a turbine iniet temperature >580°C (at full load) or oll inlet temperature >B0°C. Pay attention to the operating instructions of the engine manufacturer. Failures Failures can be detected by abnormal measured values (exhaust gas temperature, charge air pressure, speed), heavy noise or leakages of lubricating oll pipes. In case of irregularities on the TC, reduce the engine load or stop the engine. Since even minor failures may cause heavy consequential damage, determine and immediately eliminate the cause of failure (see chapter 6.5) Emergency operation of the exhaust gas turbocharger If the exhaust gas turbocharger has to be shut down due to a defect and the engine has to run in emergency operating mode, perform the work according to chapter 7.3.3. ‘After shutting down the exhaust gas turbocharger, limit the engine output in order to prevent the exhaust gas temperature from exceeding admissible values downstream of the outlet cylinders. Pay attention to the operating instru fons of the engine manufacturer. ST5EN03.doc 3" Edition (01/2011) Page 15 of 44Chapter 5 5.6 Operating Instructions KBB ST5 Exhaust Gas Turbocharger 9 Measures for extended period without operation When shutting down an exhaust gas turbocharger, which was operated with an engine before, for more than twelve month, it has to be dismounted from the engine. ‘An inspection should be carried out in accordance with the maintenance schedule in chapter 64. Itis necessary to completely dismantle the exhaust gas turbocharger. All components are to be oleaned and slightly rubbed with oll. Then the exhaust gas turbocharger can be reassembled. All machined surfaces and flanges are to be evenly coated with an anticorrosive agent (such as Tecty!). All openings should be sealed. Additionally, a hygroscopic drying agent can be put into the interior spaces of the compressor housing and the turbine inlet ‘The preserved exhaust gas turbochargers and spare parts should be kept in a dry room (humidity of 60 % max.) and protected from moisture, aggressive gases and vapours. At rest, the exhaust gas turbocharger should be protected against steady vibration which may damage the bearings r ‘The state of the preserved parts and exhaust gas turbochargers should be checked every twelve months. Before re-operating the exhaust gas turbocharger, itis necessary to clean off the anticorrosive agent. Page 16 of 44 3" Edition (01/2011) STSEN03.docOperating Instructions KBB 9 ST5 Exhaust Gas Turbocharger Chapter 6 6 MAINTENANCE 6.1 General 6.2 6.3 Meintenence and monitoring work is summarised in the maintenance schedule in chapter 64. Proper maintenance work enables failures to be detected in time. Maintenance work also indicates necessary overhauls as well as work to be scheduled during yard or harbour times 6 on interruptions. ‘The operating hours specified in the maintenance schedule are to be considered as average values. They can be extended or shortened according to existing operating conditions as well as adjusted to the maintenance intervals of the engine. It is important to eliminate even minor, apparently insignificant defects immediately and to determine and eliminate their causes in order to prevent consequential damage at the engine or exhaust gas turbocharger. If the engine is not equipped with an automatic monitoring system with data recording, entries into the engine log are required at least once every 24 operating hours. Thereby, deviations can be detected in time, Maintenance work In order to keep the exhaust gas turbocharger in a safe condition, perform the inspection ‘and check of various subassemblies and components according to the maintenance schedule in chapter 6.4. The chapter 7.3 includes detailed instructions on the work sequence for assembly and disassembly work, Make sure to observe the following accident prevention regulations: + winches, hoisting and drawing gear (BGV D 8) + load take-up devices for hoisting operations (BGR 500 chapter 2.8). For a basic overhaul or repairs affecting essential parts of the exhaust CHP gas turbocharger, itis recommended to document their condition. Cleaning Cleaning the silencer + see chapter 7.3.3 Cleaning the compressor ‘+ Cleaning during operation: see chapter 7.3.1 ‘+ Mechanical cleaning: see chapters 7.3.7 and 7.3.8 ST5ENO3.doc 3" Edition (01/2011) Page 17 of 44Operating Instructions KBB Chapter 6 ST5 Exhaust Gas Turbocharger 5 Remove the compressor housing and silencer. (The compressor impeller remains on the shaft.) Remove all deposits with diesel fuel or another admissible liquid cleansing agent. Make sure to observe the accident prevention regulations! While washing, make sure to prevent the cleansing agent from entering the charge air piping or the interior of the turbocharger. Cleaning the turbine ‘* Cleaning during operation: see chapter 7.3.2 (for heavy fuel cil operation only) Page 18 of 44 3" Edition (01/2011) ‘STSENO3.docOperating Instructions KBB 9 ST5 Exhaust Gas Turbocharger Chapter 6 6.4 Maintenance schedule 6.4.1 Maintenance for operation with Marine Diesel Oil (MDO) ‘The operating hours given in the table are guidelines, which can be CH reduced for adjustment to the maintenance intervals of the engine. The Inspections (I to Ill) must be performed only by authorized service centers. tem Chapter Maintenance work Required Maintenance interval parts (operating hours) 7 ‘Check for abnormal noise 24 27.8.4 Compressor washing during 24-48 operation, actuate compressor washing system 37.33 Replace filter mat at silencer approx. 500 ‘or on demand 4 ‘Check fastening bolts at the feet, ‘once after tighten all housing bolts and commissioning, then piping joints every 1,000 hours, B Inspection | (9910) max. 12,500 + disassembly (9920) + cleaning (9930) + checking of rotor & bearings ‘+ checking of housings + assembly & inspection 1 2000) max. 25,000 + like inspection | (9910) + replacement of the bearings (9920) (9930) 7. inspection i (2000) max. 60,000 + like inspection | (4000) : + replacement of the rotor (g910) ¢ (e920) (9930) (2000) Rotor (0910) Set “Gaskets and shims” (4000) Bearings (4010) and (4020) (9920) Set “Connection elements 1° (8930) Set "Connection elements 2° 6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO) ‘The operating hours given in the table are guidelines, which can be [GP _"eeucwd for acjustment tothe maintenance intervals ofthe engine. The interval of the inspection “0” are to be shortened dependent on the fuel quality. The Inspections (I to Ill) must be performed only by authorized service centers. STS5EN03.doc 3" Edition (01/2011) Page 19 of 44Operating Instructions KBBO Chapter 6 ST5 Exhaust Gas Turbocharger Item Chapter Maintenance work Required Maintenance interval parts (operating hours) 1 Check for abnormal noise 28 2. 7.3.1. Compressor washing during 24-48 operation, actuate compressor washing system 3 Turbine washing during ‘Approx. 300 operation, actuate turbine depending on HFO 7.32 washing system quality Cleaning with water 4. 73.3 Replaced filter mat at silencer ‘Approx, 500 oron demand 5. Check fastening bolts at the. once after feet, tighten all housing bolts commissioning, then and piping joints every 1,000 hours 6. Inspection 0 (9910) depending on HFO + disassembly cartridge (9920) + checking turbine (2930) + assembly 7. Inspection | (9910) max. 12,500 «disassembly (9920) * cleaning (9930) * checking rotor and bearings + checking housing + _assembl 8. Inspection Il (4000) max. 25,000 «like inspection | (9910) ‘* replacement of bearings (9920) (9930) 9. Inspection III (2000) max. 50,000 like inspection | (4000) + replacement of the rotor (8910) + assembly (9920) (9930) (2000) Rotor (9910) Set “Gaskets and shims" (4000) Bearings (4010) and (4020) (9920) Set "Connection elements 1" (930) Set "Connection elements 2" The nozzle ring is subject to an increased wear for heavy fuel oil operation. Therefore it is a wear part. The lifetime of the nozzle ring is approximately 12,500 hours, but depends on HFO quality and operating conditions. After exceeding the lifetime the nozzle ring should be replaced in case of fundamental change of performance data as charge air pressure and exhaust temperature. Page 20 of 44 3" Edition (01/2011) ST5EN03.docOperating Instructions KBBS® ST5 Exhaust Gas Turbocharger Chapter 6 6.5 Trouble-shooting table 8) 2| Blsle ==) 3/8 2\ 8) 2/8! || [2 “J elsisl |2) |8 S]5 8) | sel 8) |e Slele] jes ase 3) 515 S]e| 8} e| & | 3/3) | 3/8) 8) ale 8) §] &) 9| 3] 3) 5) 5 5 ayaa iaaa 2] a] al =| 3] 3) 8) 318 | 2) B 3] 2) $) 8) 8) 8 Causes €) | 8| §| £/ 3) 5| 2) 8 Chapter | 2) 55/2] 8] 3/3] 2] 2 Silencer or air filter contaminated 7.3.3 Compressor contaminated 7.3.8 ‘Charge air cooler contaminated Engine Leaking exhaust gas piping Engine Exhaust gas counter pressure too high | Engine downstream of turbine “Turbine wheel or compressor impeler | Service damaged (unbalanced) center, Defective bearing Servies center Rotor in contact with housing Service conter Foreign matter in turbine or compressor | Service (unbalanced) center “Turbine contaminated 732 Turbine nozzle ring contaminated 7.3.2 Failure of fuel injection at engine Engine ‘Leaking charge air piping Engine High air intake temperature Engine Inlet or outet valves of the engine Engine contaminated Low air intake temperature Engine Lubricating oil iter contaminated Engine Lubricating oil pressure gauge defective | Engine Lubricating oil inlet temperature too high | Engine Excessive pressure in oil retum Engine Sealing air ineffective Service center Gaskets damaged, connections leaking | Engine Plain compression rings damaged Service center STS5EN03.doc 3" Edition (01/2011) Page 21 of 44Chapter 7 Operating Instructions ST5 Exhaust Gas Turbocharger Keno 7 71 7.2 DISASSEMBLY AND ASSEMBLY Introduction ‘The chapter 7.3 shall enable the user to perform simple repair and maintenance work by himsett. Work sheets are sorted acoording to the sequence required to disassemble the exhaust gas turbocharger. It is assumed that the staff is familiar with the work and that the tools required are ready at hang. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding hoists have to be available. Make sure to observe the following accident prevention regulations: + winches, hoisting and drawing gear (BGV D 8) * load take-up devices for hoisting operations (BGR 500 chapter 2.8). Checking the components ‘The check list shown below can be used as instruction for checking the condition of the exhaust gas turbocharger and its major components. AS a tule, the user is able to eliminate minor damage. Major damage effecting rigidity, balance and smooth running of rotating components should be eliminated by the manufacturer or an authorized workshop. If damaged parts ate returned for repair, ensure an appropriate protection against transportation damage, After having disassembled the exhaust gas turbocharger, perform the following checks at the cleaned parts, Rotor, compl. - Are the turbine blades damaged or did they contact the housing? ~ Are contact traces visible at the housing? ~ Are contact traces visible at the rotor? If re-working is performed or if rotor parts are replaced, rebalancing has to be executed! ‘Compressor impeller = Can you detect any sliding traces or cracks at the compressor impeller? ~ Are the bore and the axial surface OK? Turbine nozzle ring ~ Are the guide vanes twisted or worn out? = Is foreign matter clamped into the ducts? = Can you detect traces of foreign matter? Housing - Are the housings heavily contaminated by oil, dust or soot? - Is there any leakage at the housing? (Main items: connection flanges, charge air, exhaust gas and oil connections) ~ Are all bolts and nuts tight? Page 22 of 44 3" Edition (01/2011) ST5EN03.docKBB® Operating Instructions ST5 Exhaust Gas Turbocharger Chapter 7 73 7.3.1 Work sheets Compressor washing (Every 25- Legend 1 Ball valve 2 Water tank 3 Water piping 4 Air piping Work sequ 50 operating hours) jence: 5. Operate the engine close to full load. 6. Open the water tank (2), fill with clean water (no sea water) (approx. 0,5 ), close the water tank 7. Open the ball valve (1), wait for approx. 20 sec., close valve (1). The compressed air piping via the ball valve (1) into the water tank. The water is through the water piping into the injection pipe, atomised by the air taken in is the compressor blades at high speed. flows through the presse and hit LN ee + Perform cleaning with warm engine close to full load operation only. ‘+ Continue to operate the engine for at least 10 to 15 min. after cleaning. ‘+ Donot wash before a pause of operation. Corrosion risk! + Washing is ineffective in case of hardened deposits, thus perform washing at regular intervals. + Donot use any chemical additives! If the negative pressure upstream of the compressor is too high, water Is already taken in when the water is filled into the water tank and the cleaning effect is reduced. in order to avoid this, you can: ‘+ install the water tank at a lower level or + include a second stop valve, which Is opened after the water tank has. been closed, into the water piping. ST5EN03.doc 3" Edition (01/2011) Page 23 of 44